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RETURN
Introduction General Information Backhoe Loaders
Service Data Book 1992 on
Loadalls RTFL Excavators Wheeled Loaders
SEPTEMBER 2003
Fastrac Skidsteer Range
Robot 1CX
Teletruk PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © ROCESTER, STAFFORDSHIRE, ST14 5LS, ENGLAND Tel. ROCESTER (01889) 590312 PRINTED IN ENGLAND
Publication No. 9804/1103
Articulated Dump Trucks
INDEX
Introduction
1992 Data Book The JCB Service Data Book is compiled in sections as listed on the main title page at the front of the book. The section names on the title page register with the tabs of the section divider cards to promote rapid reference to the relevant machine ranges. The General Section is applicable to all machine ranges, covering such subjects as conversion tables, torque settings etc. The various machine range sections contain information on current or recent machines as detailed in their respective contents pages. Information on earlier machines is contained in the previous Data Book, publication no. 9804/1102. The page numbering in each section is not continuous. This is to allow for additional pages to be inserted as they are issued. A basic explanation of the page number system is given below to enable correct location of pages.
Page number example:
20 - 05 - 02/1
A Machine Range e.g. Backhoe Loader, Loadall etc.
B Subject classification Data, Fault Finding, etc
C Number to suit detail variation within subject
When locating pages, refer to the page number in the sequence A, followed by B, followed by C. The service data book is not intended as a substitute for service manuals which should be consulted for all further details.
9804/1103
70 - XX - XX/X
Issue 1
CONTENTS INDEX
General
Contents
Metric Units Conversion Factors Conversion Tables - Capacity - Length - Pressure - Temperature Hydraulic Formulae Torque Settings Antifreeze Protection Hydraulic Circuit Symbols
9804/1103
1-1 1-2 1-3 1-4 1-5 1-6 1-7 2-1 3-1 4-1
General Section Contents
Issue 1
CONTENTS CONTENTS
General
1-1
Metrication - S.I.Units The following list gives the units and symbols to be found in technical publications. Quantity
Name of Unit
Unit Symbol
Angle
second minute degree
" ' 0
Area
square millimetre
mm2
Capacity
litre
l
Ampere ohm Volt
A V
Flow
litre per minute
l/m
Force
Newton
N
Length
millimetre metre kilometre
mm m km
Mass
kilogram
kg
Moment of force
Newton metre
Nm
Pressure
bar
bar
Speed
kilometre per hour
km/h
Temperature
degree Celsius
°C
Time
second minute hour day
s min h d
Volume
cubic millimetre cubic centimetre
mm3 cm3
cubic metre
m3
Electric
9804/1103
— Current — Resistance — Tension
1-1
Issue 1
CONTENTS CONTENTS
General
1-2
Conversion Factors Imperial to S.l. Units To convert imperial units to Sl multiply by the conversion factor. To convert Sl units to imperial divide by the conversion factor.
9804/1103
Quantity
Imperial
Metric
Conversion Factor
Area
in2 ft2
mm2 m2
645.2
yd2
m2
0.8361
Capacity
pints—UK pints—US gallon—UK gallon—US
I I I l
0.5683 0.4731 4.5461 3.785
Flow
gal/min—UK gal/min—US
l/min I/min
4.5461 3.785
Force
Ibf
N
4.45
Length
in mile
mm km
25.4 1.6093
Mass
Ib
kg
0.4536
Moment of force
Ibf in Ibf ft Ibf ft
Nm Nm kgf m
0.112 985 1.3558 0.1383
Pressure
Ibf/in2 Ibf/in2
bar
0.068 95
kgf/cm2
0.070 31
Speed
ft/s mile/h
m/s km/h
0.3048 1.6093
Volume
in3 yd3
cm3 m3
16.387
0.0929
0.7646
1-2
Issue 1
CONTENTS CONTENTS
1-3
General
Conversion Tables - Capacity UK gallons to US gallons and litres Select the known capacity from the centre column and read off the required conversion. US gallon 1.201 2.402 3.603 4.804 6.005 7.206 8.407 9.608 10.809 12.010 18.014 24.019 30.024 36.029 42.033 48.038 54.043 60.047 66.052 72.057 78.062 84.067 90.071 96.076 102.081 108.086 114.090 120.095
9804/1103
1 2 3 4 5 6 7 8 9 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
UK gallon
Litres
0.833 1.665 2.498 3.331 4.163 4.996 5.829 6.661 7.494 8.327 12.490 16.653 20.815 24.980 29.143 33.307 37.470 41.634 45.797 49.960 54.124 58.287 62.450 66.614 70.777 74.940 79.104 83.267
4.546 9.092 13.638 18.184 22.730 27.276 31.822 36.368 40.914 45.461 68.191 90.922 113.652 136.383 159.113 181.844 204.574 227.305 250.035 272.766 295.496 318.227 340.957 363.688 386.418 409.149 431.879 454.610
UK gallon 1 2 3 4 5 6 7 8 9 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
1-3
0.219 0.440 0.659 0.879 1.099 1.319 1.539 1.759 1.979 2.199 3.299 4.399 5.499 6.599 7.699 8.799 9.898 10.998 12.098 13.198 14.298 15.398 16.498 17.598 18.697 19.797 20.897 21.997
Issue 1
CONTENTS CONTENTS
1-4
General
Conversion Tables - Length Fractions of an inch to decimals of an inch and millimetres. Inch 1/64 1/32 1/16 1/8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1
Millimetre
0.015 625 0.031 250 0.062 500 0.125 000 0.187 500 0.250 000 0.312 500 0.375 000 0.437 500 0.500 000 0.562 500 0.625 000 0.687 500 0.750 000 0.812 500 0.875 000 0.937 500 1.000 000
0.396 875 0.793 750 1.587 500 3.175 000 4.762 500 6.350 000 7.937 500 9.525 000 11.112 500 12.700 000 14.287 500 15.875 000 17.462 500 19.050 000 20.637 500 22.225 000 23.812 500 25.400 000
Inches to millimetres and feet to metres Select the known length from the centre column and read off the required conversion. Inch 0.039 0.078 0.118 0.157 0.197 0.236 0.275 0.315 0.354 0.394 0.590 0.787 0.984 1.181 1.378 1.574 1.772 1.968 2.165 2.362 2.559 2.756 2.953 3.149 3.346 3.543 3.740 3.937
9804/1103
1 2 3 4 5 6 7 8 9 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Millimetres
Feet
25.4 50.8 76.2 101.6 127.0 152.4 177.8 203.2 228.6 254.0 381.0 508.0 635.0 762.0 889.0 1016.0 1143.0 1270.0 1397.0 1524.0 1651.0 1778.0 1905.0 2032.0 2159.0 2286.0 2413.0 2540.0
3.281 6.562 9.843 13.124 16.405 19.686 22.967 26.248 29.529 32.810 49.215 65.620 82.025 98.430 114.835 131.240 147.645 164.050 180.455 196.860 213.265 229.670 246.075 262.480 278.885 295.290 311.695 328.100
1-4
Metres 1 2 3 4 5 6 7 8 9 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
0.3048 0.6096 0.9144 1.2192 1.5240 1.8288 2.1336 2.4384 2.7432 3.0480 4.5720 6.0960 7.6200 9.1440 10.668 12.192 13.716 15.240 16.764 18.288 19.812 21.336 22.860 24.384 25.908 27.432 28.956 30.480
Issue 1
CONTENTS CONTENTS
1-5
General
Conversion Tables - Pressure Ibf/in2 to kgf/cm2 and Bar Select the known pressure from the centre column and read off the required conversion. Ibf/in2 142.233 284.466 426.699 568.932 711.165 853.398 995.631 1137.864 1280.097 1422.330 2844.660 4266.990 5689.320 7111.650 8533.980 9956.310 11378.640 12800.970 14223.300 28446.600 42669.900
9804/1103
kgf/cm2 10 20 30 40 50 60 70 80 90 100 200 300 400 500 600 700 800 900 1000 2000 3000
0.703 1.406 2.109 2.812 3.516 4.219 4.922 5.625 6.328 7.031 14.062 21.093 28.124 35.155 42.186 49.217 56.248 63.279 70.310 140.620 210.930
Ibf/in2 145.038 290.076 435.114 580.152 725.190 870.228 1015.266 1160.304 1305.342 1450.380 2900.760 4351.140 5801.520 7251.900 8702.280 10152.660 11603.040 13053.420 14503.800 29007.600 43511.400
1-5
Bar 10 20 30 40 50 60 70 80 90 100 200 300 400 500 600 700 800 900 1000 2000 3000
0.690 1.379 2.069 2.758 3.448 4.137 4.827 5.516 6.206 6.895 13.790 20.685 27.580 34.475 41.370 48.265 55.160 62.055 68.950 137.900 206.850
Issue 1
CONTENTS CONTENTS
1-6
General
Conversion Tables - Temperature Select the known temperature from the centre column and read off: To the right for equivalent in deg F To the left for equivalent in deg C.
Deg C
- 31.7 - 28.9 - 26.1 - 23.3 - 20.6 - 17.8 - 15.0 - 12.2 - 9.4 - 6.7 - 3.9 - 1.1 1.7 4.4 7.2 10.0 12.8 15.6 18.3 21.1 23.9 26.7 29.4 32.2 35.0 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.8 65.6 68.3 71.1 73.9 76.7 79.4 82.2 85.0
9804/1103
- 25 - 20 - 15 - 10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185
Deg F
Deg C
- 13.0 - 4.0 5.0 14.0 23.0 32.0 41.0 50.0 59.0 68.0 77.0 85.0 95.0 104.0 113.0 122.0 131.0 140.0 149.0 158.0 167.0 176.0 185.0 194.0 203.0 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0 356.0 365.0
87.8 90.6 93.3 96.1 98.9 101.7 104.4 107.2 110.0 112.8 115.6 118.3 121.1 123.9 126.7 129.4 132.2 135.0 137.8 140.6 143.3 146.1 148.9
1-6
Deg F
190 195 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300
374 383 392 401 410 419 428 437 446 455 464 473 482 491 500 509 518 527 536 545 554 563 572
Issue 1
CONTENTS CONTENTS
General
1-7
Hydraulic Formulae
Pump flow (litres/min) = Displacement (cm3/rev) x Speed (rev/min) 1000 Pump flow (UK gal/min) = Displacement (in3/rev) x Speed (rev/min) 277.4
Power output of Hydraulic Pump (kw) = Flow (litres/min) x Pressure (bar) 600 Power output of Hydraulic Pump (hp) = Flow (UK gal/min) x Pressure (Ibf/in2) 1430
Power output of Hydraulic Motor (kw) = Torque (Nm) x Speed (rev/min) 9550 Power output of Hydraulic Motor (hp) = Torque (Ibf ft) x Speed (rev/min) 5250
Cylinder Thrust (kgf) = pressure (bar) x piston area (mm2) 98 Cylinder Thrust (Ibf) = pressure (Ibf/in2) x piston area (in2)
9804/1103
1-7
Issue 1
CONTENTS
General
Torque Settings (for all machines except JS Range) Use only where no torque setting is specified in the text. Values are for dry threads and may be within three percent of the figures stated. For lubricated threads the values should be REDUCED by one third. Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
UNF Grade 'S' Bolts Bolt Size in.
Hexagon (A/F) (mm.) in.
1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1.1/4 1.1/2
(6.3) (7.9) (9.5) (11.1) (12.7) (14.3) (15.9) (19.0) (22.2) (25.4) (31.7) (38.1)
7/16 1/2 9/16 5/8 3/4 13/16 15/16 1.1/8 1.5/16 1.1/2 1.7/8 2.1/4
Nm 14 28 49 78 117 170 238 407 650 970 1940 3390
Torque Settings kgf m 1.4 2.8 5.0 8.0 12.0 17.3 24.3 41.5 66.3 99.0 198.0 345.0
lbf ft 10 20 36 58 87 125 175 300 480 715 1430 2500
Metric Grade 8.8 Bolts Bolt Size No.
Hexagon (mm.)
mm.
M5 M6 M8 M10 M12 M16 M20 M24 M30 M36
(5) (6) (8) (10) (12) (16) (20) (24) (30) (36)
8 10 13 17 19 24 30 36 46 55
Nm 7 12 28 56 98 244 476 822 1633 2854
Torque Settings kgf m 0.7 1.2 3.0 5.7 10 25 48 84 166 291
lbf ft 5 9 21 42 72 180 352 607 1205 2105
Metric Socket-head Capscrews
Bolt Size No.
(mm)
M5 M6 M8 M10 M12 M16 M20 M24
(5) (6) (8) (10) (12) (16) (20) (24)
9804/1103
Nm 11 19 46 91 159 395 770 1332
2-1
Torque Settings kgfm 1.1 2.0 4.8 9.5 16 40 79 135
lbf ft 8 12 34 67 120 290 570 980
Issue 1
CONTENTS
General
Torque Settings - continued (for all machines except JS Range) RIVET NUT BOLTS/SCREWS Bolt Size
Torque Settings (for steel rivet nuts) Nm kgf m lbf ft
(mm) M3 M4 M5 M6 M8 M10 M12
(3) (4) (5) (6) (8) (10) (12)
1.2 3.0 6.0 10 24 48 82
0.12 0.3 0.6 1.0 2.5 4.9 8.4
0.9 2.0 4.5 7.5 18.0 35.5 60.5
HOSE & PIPEWORK CONNECTIONS USING 'O' RING FACE SEALS (ORFS)
Note: Adapters A always have a UNF thread for the ORFS hose connection B but the thread A on the opposite end of the adapter may be either UNF or metric. Measure the thread diameter carefully before choosing the relevant torque setting table. 'O' Ring Boss Adapters (Item A above) Nominal Diameter of UNF Thread (inches) 7/16 9/16 3/4 7/8 11/16 15/16 15/8 17/8
Nominal Diameter of Metric ThreadTorque Settings (mm) Nm kgf m lbf ft
Torque Settings Nm kgf m lbf ft 20 35 81 108 183 298 380 488
2.1 3.6 8.3 11.1 18.7 30.5 38.8 50
15 26 60 80 135 220 280 360
8 10 12 14 16 18 20 22 27 33 42 48 60
10 20 35 45 55 70 80 100 170 310 330 420 500
1.1 2.1 3.6 4.7 5.8 7.1 8.2 10 17 32 34 43 51
7 15 26 33 41 52 59 74 125 229 243 310 369
ORFS Hydraulic Hose Connections (Item B above) Nominal Thread Diameter (inches) 9/16 11/16 13/16 1 13/16 1 7/16 111/16 2 9804/1103
Torque Settings Nm kgf m lbf ft 24 33 44 58 84 115 189 244
2.5 3.3 4.8 6.0 8.6 11.8 19.4 24.9
18 24 35 43 62 85 140 180
2-2
Issue 1
CONTENTS
General
Antifreeze Protection The protection provided by JCB Universal Anti-freeze is shown below. If any other anti-freeze is used, refer to the manufacturers' instructions and ensure that a corrosion inhibitor is included. DO NOT use solutions of more than 60% or less than 50% or damage to the cooling system will occur. Solution
55%
Maintains circulation down to deg C deg F -36 -33
Protects against damage down to deg C deg F -41 -42
The strength of the anti-freeze solution must be checked at least once a year, preferably at the beginning of the cold period. It is an advantage to leave the anti-freeze in all the year round as it gives continued protection against corrosion. Always renew the anti-freeze every two years. A 50% anti-freeze mixture must be used even if frost protection is not needed. This gives protection against corrosion and raises the coolant's boiling point.
! WARNING Antifreeze can be harmful. Obey the manufacturer's instructions when handling neat or diluted antifreeze. 7-3-4-4
9804/1103
3-1
Issue 1
CONTENTS
General
Introduction to Hydraulic Schematic Symbols Complex hydraulic components and circuits can be described to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used. There are many symbols in use and it would be impossible to include them all here. However it should be noted that most are only variations or refinements on the basic principles explained here. If more detailed information is required you are recommended to obtain a copy of BS2917 or IS01219. Once familiar with the symbols, the engineer can use hydraulic circuit diagrams as an aid to fault finding. It will be possible to see the complete hydraulic circuit and decipher the relationship between hydraulic components.
Pumps & Motors
Fixed capacity pump one direction of flow
Fixed capacity pump two directions of flow
Variable capacity pump one direction of flow
General (Basic & Functional Symbols)
Spring Variable capacity pump two directions of flow
Flow restriction affected by viscosity Direction of flow
Fixed capacity motor one direction of flow Indication of rotation
Fixed capacity motor two directions of flow
Indication of direction and paths of flow Variable control
Variable capacity motor one direction of flow Rams
Variable capacity motor two directions of flow
Single acting
Double acting
Double ended
Double acting with damping at rod area end
9804/1103
4-1
Issue 1
CONTENTS
General
Introduction to Hydraulic Schematic Symbols (continued) Control Valves
Used to enclose several valves indicating that they are supplied as one unit
One way restrictor
3-Position, 4-Port spring centred pilot operated valve
High pressure selector (shuttle valve)
3-Position, 6-Port spring centred hand operated valve
Throttling orifice normally closed
3-Position, 4-Port spring centred solenoid & pilot pressure operated valve
Throttling orifice normally open
3-Position, 4-Port spring centred detent hand operated valve
Relief valve Non - return valve
Non - return valve with back pressure spring Variable restrictor
Pilot operated non - return valve
9804/1103
4-2
Issue 1
CONTENTS
General
Introduction to Hydraulic Schematic Symbols (continued) Energy Transmissions and Conditioning Working line, return or feed
Reservoir - return line above fluid level
Pilot control
Drain lines
Reservoir - return line below fluid level
Flexible pipe
Header tank
Pressure sealed tank
Line junction
Accumulator Crossing lines
Filter or strainer
Air bleed
Water trap
Line plugged, also pressure test point
Cooler - with no indication of coolant flow
Line plugged with take off line
Cooler - indicating direction of coolant flow
Quick release couplings - connected
Heater
Quick release couplings - disconnected
9804/1103
4-3
Issue 1
CONTENTS
General
Introduction to Hydraulic Schematic Symbols (continued) Control Mechanisms Rotating shaft-one direction
Solenoid one winding
Rotating shaft-two directions Solenoid two winding Detent M
Electric motor operated
Locking device Internal pressure pilot operated Over centre device External pressure pilot operated Simple linkage Pressure operated spring release General control Pilot operated by solenoid pilot valve Push button operated Pilot operated by a solenoid or separate pilot valve
Lever operated
Pressure gauge
Pedal operated
Stem operated
Pressure switch
Spring operated
Roller operated
Roller trip operated (one directional)
9804/1103
4-4
Issue 1
CONTENTS
General
Introduction to Hydraulic Schematic Symbols (continued) Control Valves FIG 1 Control valves are usually represented by one or more square boxes. Position 1
Position 2 Position 3
Fig. 1 shows a control valve represented by three boxes. The number of boxes indicates the number of possible valve operating positions, (4 boxes - 4 positions etc). Fig. 2 - In circuit diagrams the pipework is usually shown connected to the box which represents the unoperated condition. (Hydraulic circuit diagrams are usually shown in the unoperated condition).
FIG 2
Fig. 3 shows a valve described as a 3- position, 4-port control valve. Port describes the openings to and from the valve by which the hydraulic fluid enters or leaves. In the fig shown, Position 2 indicates that in an unoperated condition all 4 ports are blocked. If the valve spool was moved to Position 1, movement of the spool would connect Port 1 to Port 2, and Port 3 to Port 4. If the valve spool was moved to Position 3, movement of the spool would connect Port 1 to Port 4, and Port 3 to Port 2.
Port 1
Port 3
FIG 3 It must be noted that not all spools are of the same type. Their operating designs can be seen by following the path the flow arrows take in their respective operating squares. Three typical JCB style spools are known as 'D' spools, 'F' spools and 'N' spools. The 'D' spools generally control rams because when in the neutral position the outlet ports are blocked, preventing ram movement. Fig 3 shows a 'D' type spool. Fig 4 - 'F' spools are often shown as four position spools with the three normal positions for neutral and service control; and the forth position, which has a detent, connects both sides of the ram together to allow the service to 'float'.
Port 2
Port 4
FIG 4
Fig 5 - 'N' spools are sometimes used to control hydraulic motors, and it can be seen from the flow arrows, that in neutral position both service ports are connected to the exhaust oil port
FIG 5
9804/1103
4-5
Issue 1
CONTENTS
General
Introduction to Hydraulic Schematic Symbols (continued) Example of Schematic Circuit Some of the symbols described on the preceding pages have been arranged into a simple schematic circuit shown below. Hydraulic tank A is a pressurised tank with an internally mounted strainer B on the suction line to the fixed displacement pump C. System pressure is limited to the setting of relief valve D. Valve spool E is an open-centre spool that is in neutral position; flow from the pump passes through the spool and returns to the hydraulic tank.
Example Circuit Key A B C D E F G
Hydraulic Tank Strainer Fixed Displacement Pump Relief Valve Spool One Way Valve Double Acting Hydraulic Ram
If the lever operated spool is moved away from neutral position hydraulic fluid is directed to either head side or rod side of hydraulic ram G. Notice that the fluid must first open one way valve F before flowing to the ram.
A B
C
G D E F
9804/1103
4-6
Issue 1
CONTENTS
Backhoe Loaders
Contents i
2CX, 2DX, 210S, 212S and Variants Contents Page No. * General Information -Lubricants and Capacities - 2CX from m/c no 655000 to 656500 - 210S from m/c no 655000 to 656500 - 2CX, 2CXL, 210S, 210SL from m/c no. 657001 - 2DX from m/c no. 659249 - 2CX from m/c no. 659598 - 2CX, 2DX from m/c no. 659599 (N. America to m/c no 659599) - 210S, 212S from m/c no. 762080 * -Statics Dimensions and Weight - 2CX, 210S from m/c no 655000 to 656500 - 2CX, 210S from m/c no. 657001 - 2CX, 210S with Extending Dipper from m/c no. 657001 - 2CX, 210SL from m/c no. 657001 - 2CX Airmaster from m/c no. 657001 - 2CX Farm Master from m/c no. 657001 - 2CXU, 210SU from m/c no. 657001 - 2DX, 212SU from m/c no. 659249 - 2DX, 212S with Extending Dipper from m/c no. 659249 * Data - Electrical - 2CX, 210S from m/c no. 655000 to 656500 - 2CX, 2CXL, 210S, 210SL from m/c no. 657001 - 2DX from m/c no. 659249 - 2CX, 2DX, 210S and Variants from m/c no. 657001 - 2CX from m/c no. 655030 to 656999 - 2DX from m/c no. 657001 - 2CX from m/c no. 659600 to 761891 - 2CX, 2DX, 210S, 212S from m/c no. 760841 - 212SU (N. Am) from m/c no. 657001
10 - 00 - 01/1 10 - 00 - 01/2 10 - 00 - 01/3 10 - 00 - 01/4 10 - 00 - 01/5 10 - 00 - 01/6 10 - 00 - 01/7
10 - 00 - 02/1 10 - 00 - 02/2 10 - 00 - 02/3 10 - 00 - 02/4 10 - 00 - 02/5 10 - 00 - 02/6 10 - 00 - 02/7 10 - 00 - 03/1 10 - 00 - 03/2 10 - 05 - 01/1 10 - 05 - 01/2 10 - 05 - 01/3 10 - 05 - 01/4 10 - 05 - 01/5 10 - 05 - 01/6 10 - 05 - 01/6 10 - 05 - 01/7 10 - 05 - 01/8
* Data - Hydraulics -Machine Hydraulics - 2CX, 210S from m/c no. 655000 to 656500 - 2CX, 2CXL, 210S, 210SL from m/c no. 657001 to 658960 - 2CX, 2DX from m/c no. 658961 -Steer Hydraulics - 2CX, 210S from m/c no. 655000 to 656500 - 2CX, 2CXL, 210S, 210SL from m/c no. 657001 to 658960 - 2CX, 2CXL, 2DX, 210S, 210SL from m/c 658961 * Data - Transmission - Front and Rear Axles - 2CX, 210S from m/c no. 655000 to 656500 - 2CX, 210S from m/c no. 657001 - 2CXAM, 2CXL, 210FM, 210SL, 2DX from m/c no. 657001 - Syncro Shuttle - 2CX, 210S from m/c no. 655000 to 656500 - 2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL from m/c no. 657001 - 2CXAM from m/c no. 657001 - Tyre Sizes and Pressures - 2CX, 210S from m/c no. 655000 to 656500 - 2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL from m/c no. 657001 Data - Brakes - 2CX, 210S from m/c no. 655000 to 656500 - 2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL from m/c no. 657001
* Data Engine - 2CX, 210S from m/c no. 655000 to 656500 - 2DX Range from m/c no. 659249 (including 212S to m/c no. 762079) 9804/1103
Backhoe Loader Contents - 1
10 - 05 - 02/1 10 - 05 - 02/2 10 - 05 - 02/3 10 - 05 - 03/1 10 - 05 - 03/1 10 - 05 - 03/1
10 - 05 - 04/1 10 - 05 - 04/1 10 - 05 - 04/1 10 - 05 - 05/1 10 - 05 - 05/2,3 10 - 05 - 05/4 10 - 05 - 06/1 10 - 05 - 06/2
10 - 05 - 07/1 10 - 05 - 07/1
10 - 05 - 08/1 10 - 05 - 08/2 Issue 6*
CONTENTS
Backhoe Loaders
Contents ii
2CX, 2DX, 210S, 212S and Variants Contents (continued) Page No. Data - Pneumatics - 2CXAM from m/c no. 657001
10 - 05 - 09/1
Fault Finding - Syncro Shuttle - Mechanical - 2CX, 2DX, 210S, 212S from m/c no. 655000 - Syncro Shuttle - Hydraulics - 2CX, 210S from m/c no. 655000 - Parking Brake - 2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL from m/c no. 657001 - Pneumatics - 2CXAM from m/c no. 657001 - Air Conditioning - 2CX, 2DX, 210S, 212S Circuit Diagrams - Electrical - 2CX, 210S from m/c no. 655000 to 656500 - 2CX, 2CXL, 2CXFM, 210S, 210SL from m/c no. 657001 - 2DX from m/c no. 659249 to760840 - 2CX from m/c no. 659599 to 760840 - 2CXAM to m/c no. 658332 - 2CXAM from m/c no. 658333 to 659598 - 2CXAM from m/c no. 659599 - 2CX, 2DX, 210S, 212S from m/c no. 760841 - 2CXU, 212SU (N,America only) from m/c no. 657001 * - 2CX, 2DX, 212SU from m/c no. 489724 - Electrical Circuit Options and Variations - Electrical Pick-up Hitch - 2CX, 2DX, 212SU - Worklights Circuit, German/Italian Builds * - 2CX, 2DX, 212SU - Heater Circuit, Heater/Air Conditioning Circuit * - Later Machines - Compressor Circuit, Radio Circuit * - Later Machines - Hammer Circuit, Hand Held Hydraulic Tools Circuit, Hydraclamp Circuit * Circuit Diagrams - Hydraulics - 2CX, 210S from m/c no. 655000 to 656500 - 2CX, 210S from m/c no. 657001 to 658960 - 2CX, 2CXL, 210S, 210SL - Auxiliary Hand Held Tools - 2CX, 2DX from m/c no. 658961 - 2CXL, 210SL, 2CXFM from m/c no. 657001 - 2CX, 212SU (N.America only) from m/c no. 657001 - Steering - 2CX, 210S from m/c no. 655000 to 656500 - 2CX, 2CXL, 210S, 210SL from m/c no. - Pneumatics - 2CXAM from m/c no. 657001
9804/1103
Backhoe Loader Contents - 2
10 - 10 - 01/1,2,3 10 - 10 - 01/4,5 10 - 10 - 02/1 10 - 10 - 03/1 10 - 10 - 04/1,2
10 - 15 - 01/1,2 10 - 15 - 01/3,4 10 - 15 - 01/5,6,7,8 10 - 15 - 01/5,6,7,8, 10 - 15 - 01/9,10 10 - 15 - 01/11,12 10 - 15 - 01/13 10 - 15 - 01/14,15,16,17 10 - 15 - 01/18,19,20,21 10 - 15 - 01/22 to 27 10 - 15 - 02/1 10 - 15 - 02/2 10 - 15 - 02/3 10 - 15 - 02/4 10 - 15 - 02/5
10 - 20 - 01/1,2 10 - 20 - 01/3,4 10 - 20 - 01/5 10 - 20 - 02/1,2 10 - 20 - 02/3 10 - 20 - 02/4,5 10 - 20 - 03/1 10 - 20 - 03/2 10 - 20 - 03/3
Issue 7*
CONTENTS
Backhoe Loaders
Contents iii
3CX, 4CX (200 Series) Contents (continued) General Information Fluids, Lubricants and Capacities * - 3CX, 4CX & variants from m/c no. 930000 Static Dimensions - from m/c no. 400001 - 3CX (214) 4x4 (Sideshift) - 3CX (214) 4x4 (Centremount) - 4C (215) 4x4 - 4CN (216) 4x4 - 3CX (214) 4x4 Sitemaster (Sideshift) - 3CX (214) 4x4 Sitemaster (Centremount) - Hammermaster 4x4 - 217 - 4CX (214S) 4x4x4 (Sideshift) - 4CX (214S) 4x4x4 (Centremount) - 4C (215S) 4x4x4 - 4CN 4x4x4 - 4CX (214S) 4x4x4 Sitemaster (Sideshift) - 4CX (214S) 4x4x4 Sitemaster (Centremount) - 217S - 3CX Super 4x4x4 (from m/c. no. 430001) - 4CX Super 4x4x4 (from m/c. no. 430001) - 3CXE (214E) Static Dimensions - from m/c no. 460001 - 3CX Sideshift - 4CX Sideshift - 3CX Super - 3CX Centremount - 4CX Centremount - 4C, 4CN Data -Electrical (3CX, 4CX - 200 Series) - General (from m/c no. 400001) - Circuit Protection (from m/c no. 400001 to 430000) - Circuit Protection (from m/c. no. 430001) - Relay Identification - Syncro Shuttle m/c's (from m/c. no. 400001 to 430000) - Relay Identification - Powershift m/c's (from m/c. no. 400001 to 430000) - Relay Identification - All Machine Models (from m/c. no. 430001) -Electrical (2DX, 212 Servo Machines and Variants (except 2CX) from m/c no. 400001 - General - Fuses - Bulbs - Relay Identification - Pin Identification - Logic Box - RH Joystick - LH Joystick - Harness Identification -Electrical (3CX, 4CX and Variants from m/c no. 460001) - General - Fuse Identification - Link Box Fuses - Bulbs - Relay Identification - Harness Identification -Hydraulic (3CX, 4CX Standard Machines) - Machine Hydraulics (from m/c no. 400001) - Steer Hydraulics (AWS) (from m/c no. 400001) - Steer Hydraulics (2WS) (from m/c no. 400001) -Hydraulic (3CXE (214E) Machines) - Machine Hydraulics -Hydraulic 2DX, 212 Servo Machines and Variants (except 2CX) from m/c no. 400001) - Machine Hydraulics -Hydraulic Pumps (3CX, 4CX and Variants from m/c no. 460001) -Loader Valve (3CX, 4CX and Variants from m/c no. 460001) -Backhoe Valve (3CX, 4CX and Variants from m/c no. 460001) 9804/1103
Backhoe Loader Contents - 3
15 - 00 - 01/1-8 15 - 00 - 01/9 - 10
15 - 00 - 02/1 15 - 00 - 02/2 15 - 00 - 02/3 15 - 00 - 02/4 15 - 00 - 02/5 15 - 00 - 02/6 15 - 00 - 02/7 15 - 00 - 02/8 15 - 00 - 02/9 15 - 00 - 02/10 15 - 00 - 02/11 15 - 00 - 02/12 15 - 00 - 02/13 15 - 00 - 02/14 15 - 00 - 02/15 15 - 00 - 02/16 15 - 00 - 02/17 15 - 00 - 02/18 15 - 00 - 03/1 15 - 00 - 03/1 15 - 00 - 03/3 15 - 00 - 03/4 15 - 00 - 03/5 15 - 00 - 03/6
15 - 05 - 01/1 15 - 05 - 01/2 15 - 05 - 01/3 15 - 05 - 01/4 15 - 05 - 01/5 15 - 05 - 01/6 15 - 05 - 01/10 15 - 05 - 01/11 15 - 05 - 01/11 15 - 05 - 01/12,13 15 - 05 - 01/14 15 - 05 - 01/15 15 - 05 - 01/15 15 - 05 - 01/16,17 15 - 05 - 01/19 15 - 05 - 01/20,20A,23,24,25 15 - 05 - 01/21 15 - 15 - 01/21 15 - 05 - 01/22,23,24,25,26 15 - 05 - 01/27,28,29 15 - 05 - 02/1,2,3,4,5 15 - 05 - 02/6 15 - 05 - 02/6 15 - 05 - 02/7 15 - 05 - 02/8,9,10 15 - 05 - 02/11,11A,12 15 - 05 - 02/13,14,15,16 15 - 05 - 02/17,18 Issue 8*
CONTENTS
Backhoe Loaders
Contents iv
Contents (continued) Data (continued) -Transmission - Front Axle (2DX, 212 and Variants (except 2CX ) from m/c no. 400001) - Rear Axle (3CX, 4CX and Variants from m/c no. 460001) - Tyre Sizes and Pressures (3CX, 4CX from m/c no. 400001) - Tyre Sizes and Pressures (3CX, 4CX and Variants from m/c no. 460001) - Syncro Shuttle (3CX, 4CX from m/c no. 400001) - Powershift (3CX, 4CX from m/c no. 400001) - Syncro Shuttle (3CX, 4CX and Variants from m/c no. 460001) - Stall Figures - 3CX, 4CX AWS Machines from m/c no. 400001 - Stall Figures - 3CX, 4CX 2WS Machines from m/c no. 400001 - Stall Figures (3CX, 4CX and Variants from m/c no. 460001) -Brakes - Standard Machines (All Models (except 2CX) from m/c no. 400001) - Servo Machines (All Models (except 2CX) from m/c no 400001) - 3CX, 4CX and Variants from m/c no. 460001 -Engine - All Models (except 2CX) from m/c no. 400001 - 3CX, 4CX and Variants from m/c no. 460001 Fault Finding -Electrical (3CX, 4CX and Variants from m/c no. 460001) -Hydraulic (Standard Machines) (All Models (except 2CX) from m/c no. 400001) - Introduction - Diagnosis -Hydraulic (Servo Machines) (All Models (except 2CX) from m/c no. 400001) -Variable Flow Hydraulics (All Models (except 2CX) from m/c no. 460001) -Syncro Shuttle (All Models (except 2CX) from m/c no. 400001) - Gearbox - 2/4 Wheel Drive Clutch - 'Spring-on to 4WD' (3CX, 4CX from m/c. no. 400077 to 415011) - 2/4 Wheel Drive Clutch - 'Pressure-on to 4WD' (3CX, 4CX from m/c. no. 415012) - 2/4 Wheel Drive Clutch (3CX, 4CX and Variants from m/c no. 460001) -Powershift Gearbox (All Models (except 2CX) from m/c no. 400001 - Introduction and Index - Diagnosis - Powershift Transmission (3CX, 4CX and Variants from m/c no. 460001) - Introduction and Index - Diagnosis -Brakes All Models (except 2CX) from m/c no. 400001) -Steering (3CX, 4CX and Variarts from m/c no. 460001) Circuit Diagrams - Electrical -Machines from 400001 to 430000 - Basic Machines (3CX 2WS with Syncro Shuttle) - Steer Circuit (AWS Machines Only) - Powershift Transmission - 2/4 Wheel Drive (to m/c. no. 409434) - Transmission Dump (to m/c. no. 413772) - Instrument Lights Test Button (to m/c. no. 404502) - Hydraulic Speed Control (to m/c. no. 406613) -Machines from 430001 - Basic Machines (3CX 2WS with Syncro Shuttle) - Powershift & Steer Circuit (AWS Machines Only) - Powershift Transmission (2WS Machines Only) and Steer Circuit for 3CX 4x4x4x Machines - 3CX, 4CX and Variants from m/c no. 460001 - Basic Machines (3CX 2WS with Syncro Shuttle) - Powershift Transmission (PS700) and Steer Circuit-AWS - Powershift Transmission (PS700) - 2WS - Steer Circuit - 3CX 4x4x4 Machines only - 3CXE (214 Series 3) only
9804/1103
Backhoe Loader Contents - 4
Page No. 15 - 05 - 03/1 15 - 05 - 04/1 15 - 05 - 05/1 15 - 05 - 05/2,3 15 - 05 - 06/1,2 15 - 05 - 07/1,2 15 - 05 - 07/2A,2B 15 - 05 - 07/3 15 - 05 - 07/4 15 - 05 - 07/5,6,7,8,9 15 - 05 - 08/1 15 - 05 - 08/1 15 - 05 - 08/2
15 - 05 - 09/1 15 - 05 - 09/2 15 - 10 - 01/1,2 15 - 10 - 02/1 15 - 10 - 02/1,2,3,4 15 - 10 - 03/1 15 - 10 - 03/2,3 15 - 10 - 06/1,2,3 15 - 10 - 06/4 15 - 10 - 06/5,6 15 - 10 - 6/7,8 15 - 10 - 07/1 15 - 10 - 07/2,3 15 - 10 - 07/4 15 - 10 - 07/5,6,7,8 15 - 10 - 08/1,2,3,4 15 - 10 - 09/1,2,3
15 - 15 - 01/1,2 15 - 15 - 01/3 15 - 15 - 01/4 15 - 15 - 01/5 15 - 15 - 01/5 15 - 15 - 01/6 15 - 15 - 01/6 15 - 15 - 01/7,8,9,10 15 - 15 - 01/11,12 15 - 15 - 01/13,14 15 - 15 - 01/15,16,17,18 15 - 15 - 01/19,20 15 - 15 - 01/21,22 15 - 15 - 01/21,22 15 - 15 - 01/23,24,25
Issue 1
CONTENTS
Backhoe Loaders
Contents v
2CX, 2DX, 210S, 212S and Variants Contents (continued) Circuit Diagrams - Electrical (continued) - 3CX, 4CX, and Variants from m/c no.460001 (cont’d) - 214e Series 4 only - Autoshift Transmission - 2WS only - Autoshift Transmission - AWS only - Powershift Transmission (PS750) and Steer Circuit - AWS - Powershift Transmission (PS750) - 2WS - Steer Circuit - 3CX 4x4x4 only - Auxiliary Options - Servo Machines * - 3CX, 4CX and Variants from m/c no. 495455 * - Basic Machine * - Transmission and Steering * - Options * - Autoshift Transmission * - Servo Command Pilot Circuit Circuit Diagrams - Hydraulic -Standard Machine - 3CX, 4CX Basic Machine from m/c no. 402174 - Circuit Variations from m/c no. 400001 - Steer Hydraulics (AWS from m/c no 400001) - Steer Hydraulics (2WS from m/c no. 400001) - Steer Hydraulics (4WS from m/c no. 460001) - Steer Hydraulics (4WS from m/c no. 460001)
*
*
15 - 15 - 01/26,27,28 15 - 15 - 01/29,30 15 - 15 - 01/31,32 15 - 15 - 01/33,34 15 - 15 - 01/35,36 15 - 15 - 01/35,36 15 - 15 - 01/37,38,39 15 - 15 - 02/5,6 15 - 15 - 03/1/,2,3,4 15 - 15 - 03/5,6 15 - 15 - 03/7,8,9,10 15 - 15 - 03/11,12 15 - 15 - 03/13,14
15 - 20 - 02/1,2 15 - 20 - 02/3,4 15 - 20 - 02/5 15 - 20 - 02/6 15 - 20 - 02/7 15 - 20 - 02/8
-Servo Machines (All Models except 2CX) - from machine no. 400001 to 420485 - from machine no. 420486 3CX, 4CX, 214, 215, 217 & ‘S’ Series Machines from m/c no. 460001 3CX, (214E Series 3) Machines only 214e (Series 4) only (from m/c no. 460001) 214Se (Series 4) Only 3CX ‘S’ Series Options (from m/c no. 460001) 4CX Gear Pump Option (from m/c no. 460001) Variable Flow Hydraulics (from m/c no. 460001) - 7-Spool with High Flow Options - 6-Spool with High/Low Flow Options - 4CXE, 4CX Super-Hand Held Tools Option
15 - 20 - 04/7,8 15 - 20 - 04/9,10 15 - 20 - 04/11
- Brakes (All Models (except 2CX) from m/c no. 400001) - Standard Machines - Servo Machines
15 - 25 - 01/1 15 - 25 - 02/1
9804/1103
Backhoe Loaders Contents - 5
15 - 20 - 03/1,2 15 - 20 - 03/3,4 15 - 20 - 04/1,2 15 - 20 - 04/3 15 - 20 - 04/4 15 - 20 - 04/4A 15 - 20 - 04/5,6 15 - 20 - 04/5
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
2CX
10 - 00 - 01/1
From m/c no. 655000 to 656500
Lubricants & Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below.
ITEM
CAPACITY Litres (UK Gal)
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
64 (14)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
7.2 (1.6)
JCB 15W/40 Multigrade -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104D
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30, MIL-L-2105, API CD/SE, MIL-L-2104C MIL-L-46152
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W, MIL-L-46152, API CD/SE, MIL-L-2104D
Engine (Coolant)
12.5 (2.75)
JCB Universal Antifreeze/water (See Coolant Mixtures)
ASTM D3306-74
Syncro Shuttle
19 (4.2)
JCB Special Transmission Fluid
ESP-M2C 33G
Front Axle Housing Hubs (x2)
4 (0.88) 1 (0.22)
JCB HD90 Gear Oil JCB HD90 Gear Oil
API-GL-5 MIL-L-2105
Rear Axle Housing Hubs (x2)
4 (0.88) 1 (0.22)
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B
JCB Light Hydraulic Fluid ††
ISO VG15
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) †
ISO VG46
JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)
ISO VG32
JCB MPL Grease
Lithium based, No. 2 consistency.
Brake System Hydraulic System
Grease Points
70 (15.4) (including tank)
---
† Note:
The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level indicator on hydraulic tank.
††
DO NOT USE ORDINARY BRAKE FLUID.
9804/1103
10 - 00 - 01/1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
210S
10 - 00 - 01/2
From m/c no. 655000 to 656500
Lubricants & Capacities (210S) Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below.
ITEM
CAPACITY US Gal (litres)
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
16.81 (64)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
1.92 (7.2)
JCB 15W/40 Multigrade 14° F to 122° F (-10° C to 50° C)
SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104D
JCB Super Universal Agricultural 5° F to 86° F (-15° C to 30° C)
SAE10W/30, MIL-L-2105, API CD/SE, MIL-L-2104C MIL-L-46152
JCB Torque Converter Fluid 0° F to 32° F (-18° C to 0° C)
SAE10W, MIL-L-46152, API CD/SE, MIL-L-2104D
Engine (Coolant)
3.30 (12.5)
JCB Universal Antifreeze/water (See Coolant Mixtures)
ASTM D3306-74
Syncro Shuttle
5.04 (19.0)
JCB Special Transmission Fluid
ESP-M2C 33G
Front Axle Housing Hubs (x2)
1.05 (4.0) 0.26 (1.0)
JCB HD90 Gear Oil JCB HD90 Gear Oil
API-GL-5 MIL-L-2105
Rear Axle Housing Hubs (x2)
1.05 (4.0) 0.26 (1.0)
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B
JCB Light Hydraulic Fluid ††
ISO VG15
JCB High Performance Hydraulic Oil (Above 100° F, 38° C) †
ISO VG46
JCB Special Hydraulic Fluid (Below 100° F, 38° C)
ISO VG32
JCB MPL Grease
Lithium based, No. 2 consistency.
Brake System Hydraulic System
Grease Points
18.49 (70.0) (including tank)
---
† Note:
The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level indicator on hydraulic tank.
††
DO NOT USE ORDINARY BRAKE FLUID.
9804/1103
10 - 00 - 01/2
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
2CX, 2CXL, 210S, 210SL
10 - 00 - 01/3
From m/c no. 657001
Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently runin. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below.
ITEM
CAPACITY
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
22.0
Diesel Oil
ASTM D975-66T Nos. 1D, 2D
2.9
JCB 15W/40 Multigrade -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40, MIL-L-46152B, API CE/SF, MIL-L-2104D
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30, MIL-L-2105, API CD/SE, MIL-L-2104C MIL-L-46152
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W, MIL-L-46152, API CD/SE, MIL-L-2104D
Litres
UK Gal USA Gal
Fuel Tank
83.2
18.3
Engine (Oil)
10.7
2.4
Engine (Coolant)
11
2.4
2.9
JCB Universal Antifreeze/water (See Coolant Mixtures)
ASTM D3306-74
Syncro Shuttle
17.5
3.8
4.6
JCB Special Transmission Fluid
ESP-M2C 33G
Axles (2CX, 210S) Housing Hubs (x4)
4 1
0.88 0.22
1.1 0.26
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B
Axles (2CXL, 2CX Farm Master, 210SL) Housing 8.8 1.94 2.33 Hubs (x4) 1.8 0.4 0.48
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F)
ISO VG46
JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)
ISO VG32
---
JCB MPL Grease
Lithium based, No. 2 consistency.
---
JCB HP Grease (High Performance)
Lithium based, No. 2 consistency.
Hydraulic System †
Grease Points
77 17 20.4 (including tank)
† Note:The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level indicator on hydraulic tank.
9804/1103
10 - 00 - 01/3
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
2DX
10 - 00 - 01/4
From m/c no. 659249
Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently runin. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY Litres UK Gal
USA Gal
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
83.2
18.3
22
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
11.1
2.5
2.9
JCB 15W/40 Multigrade -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104D
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30, MIL-L-2105, API CD/SE, MIL-L-2104C MIL-L-46152
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W, MIL-L-46152, API CD/SE, MIL-L-2104D
Engine (Coolant)
12.0
2.6
3.2
JCB Universal Antifreeze/water (See Coolant Mixtures)
ASTM D3306-74
Syncro Shuttle
17.5
3.8
4.6
JCB Special Transmission Fluid
ESP-M2C 33G
Axles (SD55) Housing
8.8
1.94
2.3
JCB Special Gear Oil
ESEN-M2C 86A/B
1.8
0.4
0.5
Hubs (x4) Hydraulic System*
Grease Points
82 18.04 (including tank)
21.7
JCB Special Gear Oil JCB High Performance Hydraulic Oil
ISO VG46 (Above 38 °C, 100 °F)
JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)
ISO VG32
---
JCB MPL Grease
Lithium based, No. 2 consistency.
---
JCB HP Grease (High Performance)
Lithium based, No. 2 consistency.
* Note:The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level indicator on hydraulic tank.
9804/1103
10 - 00 - 01/4
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
2CX
10 - 00 - 01/5
From m/c no. 659598
Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently runin. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below.
ITEM
CAPACITY
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
22.0
Diesel Oil
ASTM D975-66T Nos. 1D, 2D
2.9
JCB 15W/40 Multigrade -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40, MIL-L-46152B, API CE/SF, MIL-L-2104D
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30, MIL-L-2105, API CD/SE, MIL-L-2104C MIL-L-46152
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W, MIL-L-46152, API CD/SE, MIL-L-2104D
Litres
UK Gal USA Gal
Fuel Tank
83.2
18.3
Engine (Oil)
10.7
2.4
Engine (Coolant)
11
2.4
2.9
JCB Universal Antifreeze/water (See Coolant Mixtures)
ASTM D3306-74
Syncro Shuttle
17.5
3.8
4.6
JCB Special Transmission Fluid
ESP-M2C 33G
Axles (2CX, 210S) Housing Hubs (x4)
4 1
0.88 0.22
1.1 0.26
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B
Axles (2CXL, 2CX Farm Master, 210SL) Housing 8.8 1.94 2.33 Hubs (x4) 1.8 0.4 0.48
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F)
ISO VG46
JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)
ISO VG32
---
JCB MPL Grease
Lithium based, No. 2 consistency.
---
JCB HP Grease (High Performance)
Lithium based, No. 2 consistency.
Hydraulic System †
Grease Points
77 17 20.4 (including tank)
† Note:The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level indicator on hydraulic tank.
9804/1103
10 - 00 - 01/5
7110-3/1-1.5
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
2CX, 2DX North American Machines to m/c no. 762079 Lubricants and Capacities
15 - 00 - 01/6
From m/c no. 659599
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently runin. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY Litres UK Gal
USA Gal
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
83.2
18.3
22
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
11.1
2.5
2.9
JCB 15W/40 Multigrade -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104D
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30, MIL-L-2105, API CD/SE, MIL-L-2104C MIL-L-46152
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W, MIL-L-46152, API CD/SE, MIL-L-2104D
Engine (Coolant)
12.0
2.6
3.2
JCB Universal Antifreeze/water (See Coolant Mixtures)
ASTM D3306-74
Syncro Shuttle
17.5
3.8
4.6
JCB Special Transmission Fluid
ESP-M2C 33G
Axles Housing (SD55) 8.8 Housing (SD40) 4.0
1.94 0.88
2.3 1.0
JCB Special Gear Oil JCB Special Gear Oil
API-GL4 API-GL4
Hubs (x4 - SD55) 1.8 Hubs (x4 - SD40) 1.0
0.4 0.22
0.5 0.25
JCB Special Gear Oil JCB Special Gear Oil
API-GL4 API-GL4
18.04
21.7
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F)
ISO VG46
JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)
ISO VG32
---
JCB MPL Grease
Lithium based, No. 2 consistency.
---
JCB HP Grease (High Performance)
Lithium based, No. 2 consistency.
Hydraulic System† (including tank)
Grease Points
82
† Note:The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level indicator on hydraulic tank.
9804/1103
15 - 00 - 01/6
7110 - 3/1-2.3
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
210S, 212S
10 - 00 - 01/7
From m/c no. 762080
Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently runin. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY USA Gal
Litres
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
22
83.2
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
2.9
11.1
JCB 15W/40 Engine Oil -10 °C to 50 °C (14 °F to 122 °F)
CF-4/SG, SAE15W/40
JCB Engine Oil 10W -20 °C to 10 °C (-4 °F to 50 °F)
CF-4/SG, SAE10W
Engine (Coolant)
3.2
12.0
JCB Universal Antifreeze/water (See Coolant Mixtures)
ASTM D3306-74
Syncro Shuttle
4.6
17.5
JCB Special Transmission Fluid
ESP-M2C 33G
Axles Housing (SD55)
2.3
8.8
JCB Special Gear Oil
API-GL4
0.5
1.8
JCB Special Gear Oil
API-GL4
21.7
82
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F)
ISO VG46
JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)
ISO VG32
JCB Moly EP#2 Grease
Lithium based, No. 2
Hubs (x4 - SD55) Hydraulic System† (including tank)
Grease Points
---
† Note:The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level indicator on hydraulic tank.
9804/1103
15 - 00 - 01/7
3270 - 3/1-3.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
214e (N. America)
15 - 00 - 01/8
From m/c no. 460001
Fluids, Lubricants and Capacities (cont’d) ➄
!WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area. GEN-1-3
➅
Note: AWS axles with limited slip differential must use JCB Special Gear Oil.
9804/1103
15 - 00 - 01/8
3270 - 3/1-5.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX, 210S
10 - 00 - 02/1
From m/c no. 655000 to 656500
Static Dimensions
S136710
9804/1103
10 - 00 - 02/1
Issue 1
Backhoe Loaders
CONTENTS
2CX, 210S
10 - 00 - 02/2
From m/c no. 657001
Static Dimensions and Weight
Item
Description
Dimensions
A
Overall length
4.88m (16ft 0in)
B
Overall height
2.67m (8ft 9in)
C
Height to top of cab
2.63m (8ft 6in)
D
Wheelbase
1.92m (6ft 3in)
E
Minimum ground clearance
0.35m (1ft 2in)
F
Slew ground clearance
0.46m (1ft 6in)
G
Width
1.85m (6ft 1in)
Machine weight - Fully operational with 6-in-1 shovel, 450mm (18in.) excavator bucket, full fuel tank and 80kg operator.
5230kg (11532lb)
Note: Dimensions based on standard tyres fitted (12.5 x 18, 10 PR traction). For Backhoe and Loader dimensions contact your JCB Distributor.
B
C
F
E D G A
A182671
9804/1103
10 - 00 - 02/2
3060/179
Issue 2*
Backhoe Loaders
CONTENTS CONTENTS
2CX, 210S with Extending Dipper
10 - 00 - 02/3
From m/c no. 657001
Static Dimensions and Weight 2CX (with Extending Dipper) Item
Description
Dimensions
A
Overall length
4.88m (16ft 0in)
B
Overall height
2.67m (8ft 9in)
C
Height to top of cab
2.63m (8ft 6in)
D
Wheelbase
1.92m (6ft 3in)
E
Minimum ground clearance
0.35m (1ft 2in)
F
Slew ground clearance
0.46m (1ft 6in)
G
Width
1.85m (6ft 1in)
Machine weight - Fully operational with 6-in-1 shovel, 450mm (18in.) excavator bucket, full fuel tank and 80kg operator.
5310kg (11708lb)
Note: Dimensions based on standard tyres fitted (12.5 x 18, 10 PR traction). For Backhoe and Loader dimensions contact your JCB Distributor.
B
C
F
E D
G A
A208661
9804/1103
10 - 00 - 02/3
3060/180
Issue 2*
Backhoe Loaders
CONTENTS CONTENTS
2CXL, 210SL * Static
10 - 00 - 02/4
From m/c no. 657001
Dimensions and Weight
Item
Description
Dimensions
A
Overall length
4.43m (14ft 6in)
B
Overall height
2.63m (8ft 6in)
C
Wheelbase
1.92m (6ft 3in)
D
Width
1.85m (6ft 1in)
Machine weight - Fully operational with Quickhitch and 6-in-1 shovel, full fuel tank and 80kg operator.
5574kg (12290lb)
Note: Dimensions based on standard tyres fitted (12.5 x 18, 10 PR traction). For Loader dimensions contact your JCB Distributor.
B
C
D A
A198341
9804/1103
10 - 00 - 02/4
3060/181
Issue 2*
Backhoe Loaders
CONTENTS CONTENTS
*
2CX Airmaster
10 - 00 - 02/5
From m/c no. 657001
Static Dimensions
1.92m (6ft 3in) 4.90m (16ft 1in)
2.49m (8ft 2in)
1.80m (5ft 11in)
9804/1103
1.37m (4ft 6in) 10 - 00 - 02/5
3060/179
Issue 2*
Backhoe Loaders
CONTENTS CONTENTS
2CX Farm Master
10 - 00 - 02/6
From m/c no. 657001
Static Dimensions and Weight Item
Description
Dimensions
A
Overall length
4.44m (14ft 7in)
B
Overall height
2.68m (8ft 8in)
C
Wheelbase
1.92m (6ft 3in)
D
Width
1.95m (6ft 5in)
Machine weight - Fully operational with Quickhitch and standard shovel, full fuel tank and 80kg operator.
5670kg (12502lb)
Note: Dimensions based on standard tyres fitted (405/70 R 20, XM27). For Loader dimensions contact your JCB Distributor.
B
C
D A
A220291
9804/1103
10 - 00 - 02/6
3060/182
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
2CXU, 210SU
10 - 00 - 02/7
From m/c no. 657001
Static Dimensions and Weight Item
Description
Dimensions
A
Overall length
4.47 m (14 ft 8 in)
C
Height to top of cab
2.68 m (8 ft 7 in)
D
Wheelbase
1.92 m (6 ft 3 in)
E
Minimum ground clearance
0.33 m (1 ft 1 in)
G
Width
1.95 m (6 ft 5 in)
Machine weight - Base unit
4907 Kg (10814 lbs)
With cab
5088 Kg (11214 lbs)
The machine weight includes, standard shovel, three point hitch, full fuel tank and 80 kg (176 lbs) operator. The 2CXU machine must have either an implement or counterweight attached to the three point hitch before the machine is used to its full loader capabilities. Maximum rated operating load with a 0.07 m3 (2.50 ft3) general purpose shovel - with counterweight without counterweight Lift capacity, bottom hitch links at ball end H when fully lowered
3000 Kg (3 tonne)
Maximum load on each axle
5500 Kg (5.5 tonne)
2150 Kg (4740 lbs) 1400 Kg (3087 lbs)
When an implement is attached, the weight on the front axle should be greater than or equal to 0.2 the gross weight of the machine. However do no exceed the maximum load of the rear axle. Note: Dimensions based on standard tyres fitted (12.5 x 18, 10 PR traction). For Backhoe and Loader dimensions contact your JCB Distributor.
C
E D G A
9804/1103
A182672
10 - 00 - 02/7
3060/183
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
2DX, 212S
10 - 00 - 03/1
From m/c no. 659249
Static Dimensions and Weight Item
Description
Dimensions
A
Overall length
5.10m (16ft 9in)
B
Width over tyres
1.95m (6ft 5in)
C
Overall height
3.41m (11ft 2in)
D
Standard shovel width
2.10m (6ft 10in)
Operating weight with 1.37m shovel
6500kg (14326lbs)
Note: Dimensions based on standard tyres fitted (12.5 x 20, 10 PR traction). For Backhoe and Loader dimensions contact your JCB Distributor.
C
D
A
B A227680
9804/1103
10 - 00 - 03/1
3270 - F/1-3.1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
2DX, 212S with Extending Dipper
10 - 00 - 03/2
From m/c no. 659249
Static Dimensions and Weight Item
Description
Dimensions
A
Overall length
5.40m (17ft 8in)
B
Width over tyres
1.95m (6ft 5in)
C
Overall height
3.39m (11ft 3in)
D
Standard shovel width
2.10m (6ft 10in)
Machine weight - Fully operational with 6-in-1 shovel, 610mm (24in.) excavator bucket, and full fuel tank.
6840 kg (15082 lbs)
Note: Dimensions based on standard tyres fitted (12.5x20 industrial traction). For Backhoe and Loader dimensions contact your JCB Distributor.
C
D
A
B
A279700
9804/1103
10 - 00 - 03/2
3060/178
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX, 210S
10 - 05 - 01/1
From m/c no. 655000 to 656500
Data - Electrical System Battery Cranking Performance at -18 °C (0 °F) Reserve Capacity (minutes) for 25 amp load Alternator Starter Motor Light Bulbs Side/Tail Stop Direction Indicators Head Number Plate Interior Work Instrument Beacon Inspection Lamp (where fitted)
12 Volt, negative earth 410 Amps to 1.4 V.P.C. 180 A127, 55 Amp max. output S12-85 (2M113) 5 W (front & rear) 21 W (rear) 21 W (front & rear) 55 W dip, 60 W main 2x5W 10 W 55 W (front & rear) 1.2 W 70 W Halogen 55 W (floodlight pattern)
Circuit Protection Circuits Brake Lights Instruments Left hand side/tail lights; number plate lights Right hand side/tail lights; panel lights Spare Hazard warning lights Interior (cab) light; radio (if fitted); beacon Spare (Option: Stabiliser relay) Horn (front); headlight flash; front wiper and wash Rear wiper and wash Horn (rear) Headlight - dipped beam Headlight - main beam; warning lights Front working lights Direction indicators Dump relay; forward/reverse relay; reverse alarm Heater Buzzer; hand dump Rear working lights Spare (Option: Rear window heater) Spare (Option: Engine/Transmission oil pressure warning lights) Spare (Option:Engine coolant/Transmission oil temperature warning lights) Spare Spare (Option: Breaker)
Rating (Amps) 5 5 5 5 10 10 - (10) 10 5 5 10 10 10 5 5 10 5 10 - (20) - ( 5)
Fuse No. A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3
- (5) - (5)
C4 C5 to C8 C9
S136670
9804/1103
10 - 05 - 01/1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX, 2CXL, 210S, 210SL
From m/c no. 657001
Data - Electrical System Battery Cranking Performance at -18 °C (0 °F) Reserve Capacity (minutes) for 25 amp load Alternator Starter Motor
12 Volt, negative earth 410 Amps to 1.4 V.P.C. 180 A127, 55 Amp max. output S12-85 (2M113)
Fuses
Bulbs
The electrical circuits are protected by fuses. The fuses are located in a fuse box on the switch console. If a fuse ruptures, find out why and rectify the fault before fitting a new one. Fuse No. A1 A2 A3 A4 A5 A6 A7 A8 A9
Fuse Rating (Amps) Brake lights 5 Instruments 10 LH side/tail lights; number plate lights 5 RH side/tail lights 5 Thermostart 15 Hazard warning lights 10 Interior (cab) light; beacon 20 Stabiliser leg interlock 5 Horn (front); windscreen wiper; headlight flash 15
B1 B2 B3 B4 B5 B6 B7
Rear wiper and wash Horn (rear) Dipped beam; rear fog light Main beam; warning lights Front work lights Direction indicators Dump relay; forward/reverse solenoid; reverse alarm Heater motor Buzzer; hand dump
10 10 10 10 10 10 5
Rear work lights Engine shut off system Parking brake solenoid Radio; wiper park Road lights relay Attachments socket Blank 2/4WS steering circuit (where fitted) Air conditioning unit (where fitted)/ High output heater (where fitted)
10 5 5 15 15 15
B8 B9
C1 C2 C3 C4 C5 C6 C7 C8 C9
Circuit
15 5
Headlights - main Headlights - dip Indicators Instruments Work lights Number plate light Side/tail lights Interior lights Stop lights Beacon Inspection lamp (where fitted) Rear fog Warning lights
Rating (Watts) 45 W 37.5 W 21 W (front & rear) 1.2 W 55 W Halogen (front & rear) 2x5W 5W (front & rear) 10 W 21 W (rear) 70 W Halogen 55 W (floodlight pattern) 21 W 3W
Relay Identification 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Parking brake Road lights Reverse Forward Transmission dump Flashers Neutral start Stabiliser leg lock Parking brake solenoid Buzzer Parking brake start 4 Spool option 4 Spool option Trailer flasher buzzer
5 20
A201931
9804/1103
10 - 05 - 01/2
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
2DX
From m/c no. 659249
Data - Electrics Fuses The electrical circuits are protected by fuses. The fuses are located in the front console, underneath cover A. If a fuse ruptures, find out why and rectify the fault before fitting a new one. Fuse No. A1 A2 A3 A4 A5 A6 A7 A8 A9
Circuit
Fuse Rating (Amps) Brake lights 5 Instruments 5 LH side/tail lights/number plate light 5 RH side/tail lights/number plate light 5 Rear wiper and wash 5 Hazard warning lights 10 Interior (cab) light; beacon; face level fan 10 Radio 5 Horn (front); windscreen wiper; headlight flash 10 Attachments socket 15 Engine shut off system 5 Dipped beam 10 Main beam; warning lights 10 Front work lights 10 Direction indicators 5 Parking brake solenoid 5 Heater motor 20 Horn (rear) 10 Rear work lights 10 Where fitted - 2/4WS steering circuit; compressor; Stabiliser leg interlock 5 Dump relay; forward/reverse solenoid; 10 reverse alarm Rear fog light 5 Thermostart 15
B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5
R1
R2
R7
R8
R3
R4
R9
R10
R5
R6
R11 R12
Bulbs
Rating (Watts)
Headlights - main Headlights - dip Indicators Instruments Work lights Number plate light Side/tail lights Interior lights Stop lights Beacon Inspection lamp (where fitted) Rear fog Warning lights
45 W 37.5 W 21 W (front & rear) 1.2 W 55 W Halogen (front & rear) 2x5W 5W (front & rear) 10 W 21 W (rear) 70 W Halogen 55 W (floodlight pattern) 21 W 3W
Relays R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20
Transmission Dump Neutral Start Parking Brake Buzzer Parking Brake Light Indicators Forward ‘Ignition’ 1 Reverse ‘Ignition’ 2 Stabiliser Leg Lock;Compressor Road Lights Hammer Neutral Lock 4 Spool Option (if fitted) Quick Hitch (if fitted) 4 Spool Option (if fitted) Quick Hitch Buzzer (if fitted) Trailer Warning Buzzer (if fitted) Shutdown Relay (if fitted)
S227260
R13 R14 10
10
8
5
20
7
10
5
6
10
5
5
5
10
15
4
5
10
5
3
5
10
10
2
5
5
5
1
5
15
10
A
9804/1103
A
15
9
R15 R16
B
5
10
R17 R18 R19 R20
A230370
C
10 - 05 - 01/3
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX, 2DX, 210S, 212S and Variants
10 - 05 - 01/4
From m/c no. 657001
Data - Electrical System Battery Cranking Performance at -18 °C (0 °F) Reserve Capacity (minutes) for 25 amp load Alternator Starter Motor
12 Volt, negative earth 410 Amps to 1.4 V.P.C. 180 A127, 55 Amp max. output S12-85 (2M113)
The electrical circuits are protected by fuses. The fuses are located in the front console, underneath cover A. If a fuse ruptures, find out why and rectify the fault before fitting a new one. The fuses are identified using column letters (A, B and C) and row numbers (1 to 9). Note that all the fuses are shown (including optional equipment fuses). Your machine may not be equipped with all the fuses shown on these pages.
Bulbs
Rating (Watts)
Headlights - main Headlights - dip Indicators Instruments Work lights Number plate light Side/tail lights Interior lights Stop lights Beacon Inspection lamp (where fitted) Rear fog Warning lights
45 W 37.5 W 21 W (front & rear) 1.2 W 55 W Halogen (front & rear) 2x5W 5W (front & rear) 10 W 21 W (rear) 70 W Halogen 55 W (floodlight pattern) 21 W 3W
9804/1103
10 - 05 - 01/4
3270 - C/1-1.5
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX
10 - 05 - 01/5
From m/c no. 655030 to 656999
Data - Electrics Fuses
Relay Identification
Fuse No. A1 A2 A3 A4 A5 A6 A7 A8 A9
Circuit
Fuse Rating (Amps) Brake lights 5 Instruments 10 LH side/tail lights; number plate lights 5 RH side/tail lights 5 Thermostart 15 Hazard warning lights 10 Interior (cab) light; beacon 20 Stabiliser leg interlock 5 Horn (front); windscreen wiper; headlight flash 15
B1 B2 B3 B4 B5 B6 B7
10 10 10 10 10 10 5
B8 B9
Rear wiper and wash Horn (rear) Dipped beam; rear fog light Main beam; warning lights Front work lights Direction indicators Dump relay; forward/reverse solenoid; reverse alarm Heater motor Buzzer; hand dump
C1 C2 C3 C4 C5 C6 C7 C8 C9
Rear work lights Engine shut off system Parking brake solenoid Radio; wiper park Road lights relay Attachments socket Blank 2/4WS steering circuit Air conditioning unit, high output heater
10 5 5 15 15 15
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Parking brake Road lights Reverse Forward Transmission dump Flashers Neutral start Stabiliser leg lock Parking brake solenoid Buzzer Parking brake start 4 Spool option 4 Spool option Trailer flasher buzzer
15 5
5 20
A
A
A201931 S181851
9804/1103
10 - 05 - 01/5
7110 - C/1-2.3
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
10 - 05 - 01/6
2DX from m/c no. 657001 2CX from m/c no. 659600 to 761891 Data-Electrics Fuses
Relays
Fuse Circuit Fuse Rating No. (Amps) A1 Brake lights 5 A2 Instruments 5 A3 LH side/tail lights/number plate light 5 A4 RH side/tail lights/number plate light 5 A5 Rear wiper and wash 5 A6 Hazard warning lights 10 A7 Interior (cab) light; beacon; face level fan 10 A8 Radio 5 A9 Horn (front); windscreen wiper; headlight flash 10
R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20
B1 B2 B3 B4 B5 B6 B7 B8 B9
Attachments socket Engine shut off system Dipped beam Main beam; warning lights Front work lights Direction indicators Parking brake solenoid Heater motor Horn (rear)
15 5 10 10 10 5 5 20 10
C1 C2
Rear work lights 2/4WS steering circuit; compressor; stabiliser leg interlock Dump relay; forward/reverse solenoid; reverse alarm Rear fog light Thermostart
10
C3 C4 C5
A
5 10 5 15
R1
R2
R7
R8
R3
R4
R9
R10
R5
R6
R11 R12
A
R13 R14 10
10
8
5
20
7
10
5
6
10
5
5
10
10
15
4
5
10
5
3
5
10
10
2
5
5
5
1
5
15
10
A
15
9
Transmission Dump Neutral Start Parking Brake Buzzer Parking Brake Light Indicators Forward ‘Ignition’ 1 Revers ‘Ignition’ 2 Stabiliser Leg Lock;Compressor Road Lights Hammer Neutral Lock 4 Spool Option Quick Hitch 4 Spool Option Quick Hitch Buzzer Trailer Warning Buzzer Shutdown Relay
R15 R16
B
R19 R20
5
10
R17 R18
C A230371
9804/1103
10 - 05 - 01/6
S227260
7110 - C/1-3.2
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
2CX, 2DX, 210S, 212S
10 - 05 - 01/7
From m/c no. 760841
Data - Electrics Fuses
Relays
Fuse Circuit Fuse Rating No. (Amps) A1 Brake lights 5 A2 Instruments 5 A3 LH side/tail lights/number plate light 5 A4 RH side/tail lights/number plate light 5 A5 Rear wiper and wash 5 A6 Hazard warning lights 10 A7 Interior (cab) light; beacon; face level fan 10 A8 Radio 5 A9 Horn (front); windscreen wiper; headlight flash 10 B1 B2 B3 B4 B5 B6 B7 B8 B9
Attachments socket Engine shut off system Dipped beam Main beam Front work lights Direction indicators Parking brake Heater motor; air conditioning Horn (rear)
C1 C2 C3 C4 C5
Rear work lights 15 Where fitted - compressor; Stabiliser leg interlock 5 Transmission Dump 7.5 Rear fog light 5 Thermostart 15
A
10 5 15 15 10 5 5 15 10
R1
R2 R7
R8
R3
R4 R9
R10
R5
R6 R11
R12
9 8
R13
R14
7
R15
R16
R17
R18
R19
R20
R21
R22
R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 R22
Transmission Dump Neutral Start Parking Brake Buzzer Brake Light Indicators Forward ‘Ignition’ 1 Reverse ‘Ignition’ 2 Stabiliser Leg Lock;Compressor Road Lights Hammer Compressor Neutral Start Engine Shut Off Solenoid Front Work Lights Front Auxiliary Front Auxiliary Air Conditioning Rear Quickhitch Front Quickhitch Trailer Indicator Buzzer
A
6 5 4 3 2 1 A
B
C A300850
9804/1103
10 - 05 - 01/7
S227260
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
10 - 05 - 01/8
212SU (N.Am)
From m/c no. 657001
Data - Electrics Fuses
Relays
Fuse Circuit No. A1 Brake lights A2 Instruments A3 LH side/tail lights/number plate light A4 RH side/tail lights/number plate light A5 Rear wiper and wash A6 Hazard warning lights A7 Beacon A8 Radio A9 Horn (front); windscreen wiper; headlight flash
Fuse Rating (Amps) 5 5 5 5 7.5 10 15 5
R1 R2 R3 R4 R5 R6 R7 R8 R9 R10
Neutral Start ‘Ignition’ 1 Transmission Dump ‘Ignition’ 2 Front Work Lights Parking Brake Warning Buzzer Forward Indicators Reverse
20
B1 B2 B3 B4 B5 B6 B7 B8 B9
Attachments socket Engine shut off system Dipped beam Main beam Front work lights Direction indicators Parking brake Heater motor; air conditioning Blank
10 5 15 15 10 5 5 15 15
C1 C2 C3 C4 C5
Rear work lights Power Take off Transmission Dump Rear fog light Thermostart
15 5 7.5 5 15
A 9 8 7
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
6 5 4 3
A
2 1 A
B
C A300870
9804/1103
10 - 05 - 01/8
S227260
7110 - C/1-5.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX, 210S
10 - 05 - 02/1
From m/c no. 655000 to 656500
Data - Machine Hydraulics Pump Type Flow at 2250 rev/min and system pressure
550 56.25 litres/min
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.)
220
225
3200
Auxiliary Relief Valves (A.R.V.) Loader Shovel Ram Head Side (pilot-operated) Shovel Ram Rod Side (pilot-operated) Auxiliary Ram Head Side (direct acting) Auxiliary Ram Rod Side (direct acting)
207 207 241 241
211 211 246 246
3000 3000 3500 3500
Excavator Slew Ram Head Side (pilot-operated) Slew Ram Rod Side (pilot-operated) Boom Ram Head Side (pilot-operated) Boom Ram Rod Side (direct acting) Dipper Ram Head Side (pilot-operated) Dipper Ram Rod Side (direct acting) Bucket Ram Head Side (direct acting)
241 241 241 262 241 241 241
246 246 246 267 246 246 246
3500 3500 3500 3800 3500 3500 3500
bar
kgf/cm2
lbf/in2
1.72
1.76
25
Nm
kgf m
lbf ft
Piston Head Lift Ram Shovel Ram Slew Ram Boom Ram Stabiliser Ram Dipper Ram Bucket Ram Hydraclamp Ram
405 405 405 405 405 405 405 405
41.5 41.5 41.5 41.5 41.5 41.5 41.5 41.5
300 300 300 300 300 300 300 300
End Cap Lift Ram Shovel Ram Slew Ram Boom Ram Stabiliser Ram Dipper Ram Bucket Ram Hydraclamp Ram
450 450 450 450 450 450 450 450
45.9 45.9 45.9 45.9 45.9 45.9 45.9 45.9
332 332 332 332 332 332 332 332
Return Line Filter By-pass pressure Ram Torque Settings
9804/1103
10 - 05 - 02/1
12.38 UK gal/min (14.87 US gal/min)
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX, 2CXL, 210S, 210SL
10 - 05 - 02/2
From m/c no. 657001 to 658960
Data - Machine Hydraulics Hydraulic Pump (to machine serial number 657447) Model/Reference Rotation Mounting Flow at 2000 rev/min and system pressure
Single-Priority/3939 Clockwise Engine Timing Case (with adapter) litres/min UK gal/min US gal/min 58 12.76 15.32
Hydraulic Pump (from machine serial number 657448) Model/Reference Rotation Mounting Flow at 2000 rev/min and system pressure
Single-Priority/4506 Clockwise Engine Timing Case (direct - no adapter required) litres/min UK gal/min US gal/min 58 12.76 15.32
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.)
220
225
3200
Auxiliary Relief Valves (A.R.V.) Loader Shovel Ram Head Side (pilot-operated) Shovel Ram Rod Side (pilot-operated) Auxiliary Ram Head Side (direct acting) Auxiliary Ram Rod Side (direct acting) Excavator Slew Ram (pilot-operated) Boom Ram Head Side (pilot-operated) Boom Ram Rod Side (direct acting) Dipper Ram Head Side (pilot-operated) Dipper Ram Rod Side (direct acting) Bucket Ram Head Side (direct acting) Hammer Hydraulic Tool Circuit (HTC)
241 277.7 241 241
246 281 246 246
3500 4000 3500 3500
241 241 262 241 241 241 241 138
246 246 267 246 246 246 246 141
3500 3500 3800 3500 3500 3500 3500 2000
Return Line Filter
bar
kgf/cm2
lbf/in2
1.72
1.76
25
Nm
kgf m
lbf ft
405 405 405 405 405 405 405 405
41.5 41.5 41.5 41.5 41.5 41.5 41.5 41.5
300 300 300 300 300 300 300 300
678 678 678 678 678 678 678 450
69.2 69.2 69.2 69.2 69.2 69.2 69.2 45.9
500 500 500 500 500 500 500 332
By-pass pressure Ram Torque Settings Piston Head Lift Rams Shovel Rams Slew Rams Boom Ram Stabiliser Rams Dipper Ram Bucket Ram Clam Shovel Ram End Cap Lift Rams Shovel Rams Slew Rams Boom Ram Stabiliser Rams Dipper Ram Bucket Ram Clam Shovel Ram
9804/1103
10 - 05 - 02/2
Issue 2
CONTENTS CONTENTS
Backhoe Loaders
10 - 05 - 02/3
2CX, 2DX
From m/c no. 658961
Data - Machine Hydraulics Main Hydraulic Pump Model/Reference Rotation Mounting Flow at 2000 rev/min and system pressure
Single/5910P Clockwise Engine Timing Case (with adapter) litres/min UK gal/min US gal/min 58 12.76 15.32
Auxiliary Hydraulic Pump (2DX only) Model/Reference Rotation Mounting Flow at 2000 rev/min and system pressure
Single/4240J Anti-Clockwise Auxiliary Take-Off litres/min UK gal/min 28 6.16
US gal/min 7.39
Relief Valve Operating Pressures (2DX) Note: Relief valve settings for the 2CX range of machines remain as shown on page 10 - 05 - 02/2.
Main Relief Valve (M.R.V.)
bar
kgf/cm2
lbf/in2
240
246
3500
Auxiliary Relief Valves (A.R.V.) Loader Shovel Ram Head Side (pilot-operated) Shovel Ram Rod Side (pilot-operated) Auxiliary Ram Head Side (direct acting) Auxiliary Ram Rod Side (direct acting) Excavator Slew Ram (Head Side) Slew Ram (Rod Side) Boom Ram Head Side Boom Ram Rod Side Dipper Ram Head Side Dipper Ram Rod Side Bucket Ram Head Side Hydraulic Tool Circuit (HTC) (When Fitted)
241 277.7 241 241
246 281 246 246
3500 4000 3500 3500
262 262 248 316 248 248 248 138
267 267 253 267 253 253 253 141
3800 3800 3600 4495 3600 3600 3600 2000
Return Line Filter
bar
kgf/cm2
lbf/in2
1.72
1.76
25
Nm
kgf m
lbf ft
405 405 405 405 405 405 405 405
41.5 41.5 41.5 41.5 41.5 41.5 41.5 41.5
300 300 300 300 300 300 300 300
678 678 678 678 678 678 678 450
69.2 69.2 69.2 69.2 69.2 69.2 69.2 45.9
500 500 500 500 500 500 500 332
By-pass pressure Ram Torque Settings Piston Head Lift Rams Shovel Rams Slew Rams Boom Ram Stabiliser Rams Dipper Ram Bucket Ram Clam Shovel Ram End Cap Lift Rams Shovel Rams Slew Rams Boom Ram Stabiliser Rams Dipper Ram Bucket Ram Clam Shovel Ram
9804/1103
10 - 05 - 02/3
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX, 210S
10 - 05 - 03/1
From m/c no. 655000 to 656500
Data - Steer Hydraulics System Type Pump Steering Unit Type Priority Valve Type
Full power hydrostatic (See Page 10 - 05 - 02/1) OSPC 100LS OLS 80
Operation Pressures Relief Valve Operating Pressure (up to Machine No. 655603) Relief Valve Operating Pressure (from Machine No. 655604) Shock Valve Operating Pressure (up to Machine No. 655493) Shock Valve Operating Pressure (from Machine No. 655494)
bar 125 138 250 192
kgf/cm2 128 141 255 197
lbf/in2 1800 2000 3625 2800
Steer Ram Torque Settings Piston Head End Cap
Nm 405 678
kgf m 41.5 69.2
lbf ft 300 500
2CX, 2CXL, 210S, 210SL
From m/c no. 657001 to 658960
Data - Steer Hydraulics System Type Pump Steering Unit Priority Valve
Full power hydrostatic (See Page 10 - 05 - 02/2) OSPCLS Integral with pump
Operation Pressures Relief Valve Operating Pressure Shock Valve Operating Pressure Anti-cavitation Valve - 2CX Farm Master m/c’s only (optional on 2CXL, 210SL m/c’s)
bar 139 193 20
kgf/cm2 142 197 20.4
lbf/in2 2000 2800 290
Steer Ram Torque Settings Piston Head End Cap
Nm 300 450
kgf m 30.6 45.9
lbf ft 221 332
2CX, 2CXL, 2DX, 210S, 210SL
From m/c no. 658961
Data - Steer Hydraulics System Type Pump Steering Unit Priority Valve
Full power hydrostatic (See Page 10 - 05 - 02/3) OSPCLS Integral with brakes charge valve
Operation Pressures Relief Valve Operating Pressure Shock Valve Operating Pressure Anti-cavitation Valve
bar 139 193 20
kgf/cm2 142 197 20.4
lbf/in2 2000 2800 290
Steer Ram Torque Settings Piston Head End Cap
Nm 300 450
kgf m 30.6 45.9
lbf ft 221 332
Brakes Charge/Steering/Priority Valve Brake Circuit Operating Pressures Cut-in Cut-out
90 bar (1305 lbf/in2) 110 bar (1595 lbf/in2)
9804/1103
10 - 05 - 03/1
Issue 3
CONTENTS CONTENTS
Backhoe Loaders
2CX, 210S
10 - 05 - 04/1
From m/c no. 655000 to 656500
Data - Front & Rear Axles Type Weight (dry, less wheels; approx.) Overall Gear Ratio Crownwheel & Pinion Ratio Number of Steer Rams Type of Mounting Type of Brakes
Front Axle SD40 245 kg (540 lb) 16.154:1 13:35 1 Pivot —
21.818:1 (TUV) 11:40 (TUV)
Rear Axle SD40 (with brakes) 245 kg (540 lb) 16.154:1 21.818:1 (TUV) 13:35 11:40 (TUV 1 Pad 3 Plate
2CX, 210S
From m/c no. 657001
Data - Front & Rear Axles Type Designation Type of Brakes Installation Front Rear Weight (dry, less wheels; approx.) Overall Gear Ratio Crownwheel & Pinion Ratio Number of Teeth Crownwheel Pinion Hub reduction Toe-in Castor angle Camber angle Kingpin inclination Number of steer rams Input type
JCB spiral bevel input with epicyclic hub reduction SD40 (with brakes) Oil immersed multi-plate disc located in hubs Centre pivot Rigid pad mount 245 kg (540 lb) 16.154:1 2.692:1 35 13 6:1 0° 0° 1° 0° 1 Yoke coupling
2CXAM, 2CXL, 210FM, 210SL, 2DX
From m/c no. 657001
Data - Front & Rear Axles Type Designation Type of Brakes Installation Front Rear Weight (dry, with no steer rams and without wheels) Overall Gear Ratio Crownwheel & Pinion Ratio Number of Teeth Crownwheel Pinion Hub reduction Toe-in Castor angle Camber angle Kingpin inclination Number of steer rams
9804/1103
JCB spiral bevel input with epicyclic hub reduction SD55 (with brakes) Oil immersed multi-plate disc located in hubs Centre pivot Rigid pad mount 330 kg (728 lb) approx 16.2:1 3:1 33 11 5.4:1 0° 0° 1° 0° 1
10 - 05 - 04/1
Issue 3
CONTENTS CONTENTS
Backhoe Loaders
2CX 210S 2CX,
10 - 05 - 05/1
From m/c no. 655000 to 656500
Data - Syncro Shuttle Syncro Shuttle Type Drive Output Weight (dry) Torque Converter Dia. Torque Multiplication at Stall Gear Ratios
1st 2nd 3rd 4th
Combined torque converter, reverser, and gearbox unit with integral parking brake. SS600 4 wheel-drive, double yoke 150 kg (330 lb) 280 mm (11 in) 2.45:1 5.55:1 3.44:1 1.83:1 1.00:1
Minimum Engine Rev/Min at Converter Stall
2100 rev/min
Converter Pressures (in neutral)
bar
kgf/cm2
lbf/in2
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
2.4 - 3.4 5.2 - 6.5 1.3 - 2.0 5.2 - 5.9
2.5 - 3.5 5.3 - 6.7 1.4 - 2.1 5.3 - 6.0
35 - 50 75 - 95 20 - 30 75 - 85
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
1.0 - 1.7 2.0 max 0.3 - 0.6 1.0 - 1.7
1.1 - 1.8 2.0 max 0.3 - 0.6 1.1 - 1.8
15 - 25 29 max 4.0 - 8.0 15 - 25
6.5
6.7
95
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
0.2 - 0.3 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6
0.2 - 0.4 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6
3.0 - 5.0 6.0 - 10.0 2.0 - 3.0 4.0 - 8.0
At 50 deg. C
1000 rev/min 2000 rev/min
9.3 - 10.3 10.7 - 11.7
9.5 - 10.5 10.9 - 12.0
135 - 150 155 - 170
At 100 deg.C
1000 rev/min 2000 rev/min
9.3 - 10.3 9.3 - 10.3
9.5 - 10.5 9.5 - 10.5
135 - 150 135 - 150
Converter In at 50 deg.C Converter In at 100 deg.C
Converter Out at 50 deg.C Converter Out at 100 deg.C
Converter Inlet Relief Valve Pressure (max.)
Lubrication Pressures (in neutral) At 50 deg.C At 100 deg.C
Main Line Pressure (in neutral)
Clutch Pressure (forward and reverse) At 50 deg. C
1000 rev/min 2000 rev/min
5.5 - 6.2 6.9 - 7.6
5.6 - 6.3 7.0 - 7.7
80 - 125 100 - 145
At 100 deg.C
1000 rev/min 2000 rev/min
5.5 - 6.2 6.2 - 6.9
5.6 - 6.3 6.3 - 7.0
80 - 125 90 - 140
litres/min
US gal/min
UK gal/min
Flow Rates (in neutral) Cooler at 50 deg.C
1000 rev/min 2000 rev/min
10.4 - 13.6 14.5 - 20.0
2.8 - 3.6 3.8 - 5.3
2.3 - 3.0 3.2 - 4.4
Cooler at 100 deg.C
1000 rev/min 2000 rev/min
10.2 - 12.5 22.7 - 26.1
2.7 - 3.3 6.0 - 6.9
2.3 - 2.8 5.0 - 5.7
Pump at 50 deg.C
1000 rev/min 2000 rev/min
11.0 - 15.0 22.5 - 29.5
2.9 - 4.0 6.0 - 7.8
2.5 - 3.3 5.0 - 6.5
9804/1103
10 - 05 - 05/1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
10 - 05 - 05/2
2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL
From m/c no. 657001
Data - Synchro Shuttle Syncro Shuttle
Combined torque converter, reverser, and gearbox unit with integral parking brake. SS400 4 wheel-drive, double yoke 150 kg (330 lb) 30 kph (18 mph) 20 kph (12 mph) 4.27:1 6.31:1 2.50:1 3.70:1 1.18:1 1.75:1 0.70:1 1.03:1
Type Drive Output Weight (dry) Gear Ratios 1st 2nd 3rd 4th Torque Converters Ratio Colour Coded Dots Designation
2.8:1 3 Brown SSL11
2.78:1 1 Pink & 1 Yellow SSS11
2.4:1 2 Orange & 1 Green WH11
Stall Figures 2CX 2CXL
Airmaster
Farm Master
2CX - 20 kph
210SU
2DX
max r.p.m. min. r.p.m.
2127 2027
2127 2027
1790 1700
2170 2070
2127 2027
N/A N/A
max. r.p.m. min. r.p.m.
1825 1725
1825 1725
1490 1400
1848 1748
1825 1725
N/A N/A
65 bhp 74 bhp
●
●
●
●
SSL11 (2.8:1) SSS11 (2.78:1) WH11 (2.4:1)
●
Pump Size
58 l/min (12.7 gal/min) (15.3 USA gal/min)
●
●
Fan Ratio
1 to 1 1 to 1.25
●
●
Engine Stall Speed 1 Converter only
2
Converter + MRV
Build Specification Engine Size
Converter Type
●
●
●
●
●
●
●
●
●
● ●
●
●
● ●
bar
kgf/cm2
lbf/in2
2.4 - 3.4 5.2 - 6.5 1.3 - 2.0 5.2 - 5.9
2.5 - 3.5 5.3 - 6.7 1.4 - 2.1 5.3 - 6.0
35 - 50 75 - 95 20 - 30 75 - 85
Converter Out (measure at 50 deg.C and 2000 rev/min)
3.4
3.5
50 max
Converter Relief (Safety) Valve Pressure
6.5
6.7
95 max
Converter Pressures (in neutral) Converter In at 50 deg.C Converter In at 100 deg.C
9804/1103
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
10 - 05 - 05/2
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL
10 - 05 - 05/3
From m/c no. 657001
Data - Synchro Shuttle (cont'd) Lubrication Pressures (in neutral) At 50 deg.C
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
0.2 - 0.3 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6
0.2 - 0.4 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6
3.0 - 5.0 6.0 - 10.0 2.0 - 3.0 4.0 - 8.0
At 50 deg. C
1000 rev/min 2000 rev/min
9.3 - 10.3 10.7 - 11.7
9.5 - 10.5 10.9 - 12.0
135 - 150 155 - 170
At 100 deg.C
1000 rev/min 2000 rev/min
9.3 - 10.3 9.3 - 10.3
9.5 - 10.5 9.5 - 10.5
135 - 150 135 - 150
At 100 deg.C
Main Line Pressure (in neutral)
Clutch Pressure (forward and reverse) † At 50 deg. C
1000 rev/min 2000 rev/min
7.6 - 9.7 9 - 11
7.7 - 9.8 9.1 - 11.25
110 - 140 130 - 160
At 100 deg.C
1000 rev/min 2000 rev/min
7.6 - 9.7 7.6 - 9.7
7.7 - 9.8 7.7 - 9.8
110 - 140 110 - 140
† Note: The forward and reverse clutch pressures should always be the same as the mainline pressure less (a maximum of) 1.7bar (25lbf/in2; 1.8kgf/cm2). If the mainline pressure is in the lower part of the tolerance band, then the forward and reverse clutch pressures should also be in the lower part of the tolerance band and vice versa.
Flow Rates (in neutral) Cooler at 50 deg.C
Cooler at 100 deg.C
Pump at 50 deg.C
9804/1103
1000 rev/min
1000 rev/min
1000 rev/min
litres/min
UK gal/min
US gal/min
10.4 - 13.6 2000 rev/min
2.3 - 3.0 14.5 - 20.0
2.8 - 3.6 3.2 - 4.4
3.8 - 5.3
10.2 - 12.5 2000 rev/min
2.3 - 2.8 22.7 - 26.1
2.7 - 3.3 5.0 - 5.7
6.0 - 6.9
11.0 - 15.0 2000 rev/min
2.5 - 3.3 22.5 - 29.5
2.9 - 4.0 5.0 - 6.5
6.0 - 7.8
10 - 05 - 05/3
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
10 - 05 - 05/4
2CXAM
From m/c no. 657001
Data - Synchro Shuttle Syncro Shuttle with PTO (Power Take Off) Description
PTO Weight (dry without converter) Gear Ratios 1st 2nd 3rd 4th
Combined torque converter, reverser, and gearbox unit with integral parking brake. SS400 4 wheel-drive, double yoke with additional PTO for compressor drive Solenoid operated, multi-plate friction drive in constant mesh 190kg (418.95 lbs) 30 kph (18 mph) 4.27:1 2.50:1 1.18:1 0.70:1
Torque Converter Ratio Colour Coded Dots Engine Rev/Min at Converter Stall Engine Rev/Min at Converter Stall + MRV Operating
2.83:1 2 Yellow, 1 Orange 2027 - 2127 1725 - 1825
Converter Pressures (in neutral) Converter In at 50 deg.C 1000 rev/min 2000 rev/min Converter In at 100 deg.C 1000 rev/min 2000 rev/min Converter Out (measure at 50 deg.C and 2000 rev/min)
bar 2.4 - 3.4 5.2 - 6.5 1.3 - 2.0 5.2 - 5.9 3.4
kgf/cm2 2.5 - 3.5 5.3 - 6.7 1.4 - 2.1 5.3 - 6.0 3.5
lbf/in2 35 - 50 75 - 95 20 - 30 75 - 85 50 max
Converter Relief (Safety) Valve Pressure
6.5
6.7
95 max
Lubrication Pressures (in neutral) At 50 deg.C 1000 rev/min 2000 rev/min At 100 deg.C 1000 rev/min 2000 rev/min
0.2 - 0.3 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6
0.2 - 0.4 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6
3.0 - 5.0 6.0 - 10.0 2.0 - 3.0 4.0 - 8.0
9.3 - 10.3 10.7 - 11.7 9.3 - 10.3 9.3 - 10.3
9.5 - 10.5 10.9 - 12.0 9.5 - 10.5 9.5 - 10.5
135 - 150 155 - 170 135 - 150 135 - 150
7.6 - 9.7 9 - 11 7.6 - 9.7 7.6 - 9.7
7.7 - 9.8 9.1 - 11.25 7.7 - 9.8 7.7 - 9.8
110 - 140 130 - 160 110 - 140 110 - 140
litres/min 10.4 - 13.6 14.5 - 20.0 10.2 - 12.5 22.7 - 26.1 11.0 - 15.0 22.5 - 29.5
UK gal/min 2.3 - 3.0 3.2 - 4.4 2.3 - 2.8 5.0 - 5.7 2.5 - 3.3 5.0 - 6.5
US gal/min 2.8 - 3.6 3.8 - 5.3 2.7 - 3.3 6.0 - 6.9 2.9 - 4.0 6.0 - 7.8
Type Drive Output
Main Line Pressure (in neutral) At 50 deg. C At 100 deg.C
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
Clutch Pressure (forward and reverse) † At 50 deg. C 1000 rev/min 2000 rev/min At 100 deg.C 1000 rev/min 2000 rev/min Flow Rates (in neutral) Cooler at 50 deg.C Cooler at 100 deg.C Pump at 50 deg.C
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
† Note: The forward and reverse clutch pressures should always be the same as the mainline pressure less (a maximum of) 1.7bar (25lbf/in2; 1.8kgf/cm2). If the mainline pressure is in the lower part of the tolerance band, then the forward and reverse clutch pressures should also be in the lower part of the tolerance band and vice versa.
9804/1103
10 - 05 - 05/4
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX, 210S
10 - 05 - 06/1
From m/c no. 655000 to 656500
Data - Tyre Sizes & Pressures Cross Ply Front Type
Size
Ply
Pressure (Normal Duty) † bar lbf/in2
Pressure (Heavy Duty) †† bar lbf/in2
Industrial Traction
10.5 - 18
10
3.3
Industrial Traction
12.5 - 18
10
2.3
Type
Size
Ply
Industrial Traction
10.5 - 18
10
2.3
34
2.75
40
Industrial Traction
12.5 - 18
10
1.8
26
2.5
36
48
34
3.75
54
3.4
49
Not 210S
Rear Pressure (Normal Duty) † bar lbf/in2
Pressure (Heavy Duty) ††† bar lbf/in2 Not 210S
† These tyre pressures are recommended for road travel and normal working conditions. †† These tyre pressures are recommended when handling heavy or palletised loads. ††† These tyre pressures are recommended when using a rock breaker or patch planer.
Radial Ply Front Type
Size
XM27
335/80R18
Type
Size
Pressure bar
lbf/in2
1.8
26
Rear
XM27
9804/1103
Pressure
335/80R18
10 - 05 - 06/1
bar
lbf/in2
1.8
26
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
10 - 05 - 06/2
2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL
From m/c no. 657001
Data - Tyre Sizes & Pressures Note: Wheel fixing on SD40 axle was changed from 8 stud to 4 stud at machine serial number 657150. Wheel fixing on SD40 Limited Slip Differential axle was changed from 8 stud to 4 stud at machine serial number 657159. The first machine fitted with SD55 axles (5 stud fixing) was serial number 657628.
FRONT Type
Size
Ply
Pressure (Normal Duty) † bar lbf/in2
Pressure (Heavy Duty) †† bar lbf/in2
Firestone Super Traction Lug
12.5 x 18
10
1.5
22
2.1
30
Goodyear Sure Grip Lug
12.5/80 x 18 10
2.5
36
3.5
51
Continental AS Farmer
12.5 x 18
10
1.75
26
2.55
37
Michelin X M27
335/80 R18
-
1.8
26
2.7
39
Dunlop SP PG7
385/55 R18
-
2.5
36
3.8
55
Goodyear SG Implement
12.5/80 x 18 10
2.5
36
3.5
51
Michelin X M27
405/70 R 20 -
1.4
20
2.4
34
Type
Size
Ply
Pressure (Normal Duty) † bar lbf/in2
Pressure (Heavy Duty) ††† bar lbf/in2
Firestone Super Traction Lug
12.5 x 18
10
1.7
25
1.9
28
Traction S.G. Goodyear
12.5/80 x 18 10
2.25
33
2.5
36
Continental AS Farmer
12.5 x 18
10
1.75
26
2.0
29
Michelin X M27
335/80 R18
-
1.8
26
2.2
32
Dunlop SP PG7
385/55 R18
-
2.25
33
3.0
44
Goodyear SG Implement
12.5/80 x 18 10
2.25
33
2.5
36
Michelin X M27
405/70 R 20 -
1.4
20
1.8
26
REAR
† These tyre pressures are recommended for road travel and normal working conditions. †† These tyre pressures are recommended when handling heavy or palletised loads. ††† These tyre pressures are recommended when using a rock breaker or patch planer. Note: If the tyres fitted to your machine are not listed, then contact your JCB Distributor for advice, DO NOT guess tyre pressures.
9804/1103
10 - 05 - 06/2
Issue 2
CONTENTS CONTENTS
Backhoe Loaders
2CX, 210S
10 - 05 - 07/1
From m/c no. 655000 to 656500
Data - Brakes Service Brakes Type Actuation Location Friction Plates (3 per brake pack, i.e. 6 per axle) Outside Diameter Inside Diameter Nominal Facing Area per Plate Hydraulic Piston Diameter
JCB Oil-Immersed Multi-Plate Disc Hydraulic Rear axle hubs 166 mm (6.54 in) 120 mm (4.72 in) 20660 mm2 (32 in2) 128.5 mm (5.06 in) inside diameter, 150.1 mm (5.91 in) outside diameter
Master Cylinder Type Piston Diameter (each) Piston Area (each)
Lucas Girling CV 25.4 mm (1 in) 507 mm2 (0.79 in2)
Parking Brake Type Disc Diameter
Manually Adjusted Caliper, cable operated, mounted on transmission output 279.4 mm (11 in)
2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL
From m/c no. 657001
Data - Brakes Service Brakes Type Actuation Location Friction Plates Counter Plates Accumulator Pressure Brake Circuit Operating Pressure Cut-in Cut-out
JCB oil-immersed multi-plate disc high pressure brakes with hydraulic accumulators for emergency application. Hydraulic ON, spring OFF. Front and rear axle hubs. 2 per brake pack, i.e., 8 per machine. 3 per brake pack, i.e., 12 per machine. 25 bar (363 lbf/in2). 90 bar (1305 lbf/in2). 110 bar (1595 lbf/in2).
Parking Brake Type Actuation Location Friction Plates 30 k.p.h. Gearbox 20 k.p.h. Gearbox Counter Plates 30 k.p.h. Gearbox 20 k.p.h. Gearbox
9804/1103
Oil-immersed multi-plate disc. Spring ON, hydraulic OFF. Within the gearbox. 9 off 6 off 10 off 7 off
10 - 05 - 07/1
Issue 3
Backhoe Loaders
CONTENTS CONTENTS
2CX, 210S Data Engine
From m/c no. 655000 to 656500
Type Number of cylinders Bore and Stroke Swept Volume Compression Compression
Perkins D3.152 naturally aspirated 3 91.44 mm (3.60 in) x 127.0 mm (5.00 in) 2500 cm3 (152.7 in3) Ratio 18.5:1 Pressure 17-31 bar (250-450 lbf/in2) [maximum variation between cylinders; 3.5 bar (50 lbf/in2)] 1,2,3 0.30 mm (0.012 in) 2.1-4.1 bar (30-60 lbf/in2)
Injection Sequence Valve Clearance - Cold Oil Pressure (Hot) at maximum speed Fuel System Injection Pump Type Injection Pump Setting Code Maximum Governed Speed Maximum No-load Speed Idling Speed 750 rev/min Injection Timing Static
Injectors
C.A.V., D.P.A., mechanically governed Perkins/ISO 36960TW/2/2470 2250 rev/min 2470 rev/min 20° BTDC (equivalent to 0.192 in displacement)
Engine Angle 27° (checked at TDC compression) Fuel Pump Angle 37° - Working Pressure 170 atm - Setting Pressure 185 atm
Cooling System Coolant Pressure Coolant Temperature Temperature Warning Light operates at
9804/1103
10 - 05 - 08/1
0.48 bar (7 lbf/in2) (normal) 80-85 deg C 98 deg C
15 - 05 - 08/1
7110 - C/1-.5
Issue 4*
CONTENTS
Backhoe Loaders
2CX, 210S
10 - 05 - 08/1A
From m/c no. 657001
Data Engine 2CX Range Including 210S, 212SU to m/c no. 762079 Type Build Number Number of cylinders Bore and Stroke Swept Volume Compression Ratio Compression Pressure
Perkins 1004-4LR2 naturally aspirated AA50429 (65BHP) 4 100 mm (3.937 in) x 127.0 mm (5.00 in) 3990 cm 3 (243.5 in 3 ) 16.5:1 20-34 bar (240-493 lbf/in 2 ) [maximum variation between cylinders - 3.5 bar (50 lbf/in 2 )]
Injection Sequence Valve Clearance - Hot or Cold
1, 3, 4, 2
- inlet 0.20 mm (0.008 in) - exhaust 0.45 mm (0.018 in) Maximum Speed (no load) Governed Speed Idling Speed
2160 rev/min 2000 rev/min 820 rev/min
Fuel System Injection Pump Type Injection Pump Setting Code Injection Timing Injection Setting Lift Pump Type
C.A.V., D.P.A., mechanically governed 2643C621/HM46L/850/7/2160 16° ± 2° BTDC Pressure 250 atm AC Diaphragm
Induction System Air Cleaner Typ Max. Restriction (at which warning light operates)
635 mm (25 in) H 2 0
Lubrication System Oil Pump Type Oil Pressure (hot) at maximum speed
Eccentric rotor 2.0 bar (30 lbf/in 2 ) (minimum)
Cooling System Coolant Pressure Coolant Temperature (normal) Temperature Warning Light operates at
0.48 bar (7 lbf/in 2 ) 80-85 °C (176 - 185 °F) 98 °C (209 °F)
2 stage, dry element
* Note: For further details of the engine refer to Engine Service Manual 9806/0100
9804/1103
10 - 05 - 08/1A
7110 - C/1-.5
Issue 1*
CONTENTS
Backhoe Loaders
2DX Range (including 212S to m/c no. 762079)
10 - 05 - 08/2
From m/c no. 659249
Data Engine Type Build Number Number of cylinders Bore and Stroke Swept Volume Compression Ratio Compression Pressure
Perkins 1000 Series, naturally aspirated AA50525 (75HP) 4 100 mm (3.937 in) x 127.0 mm (5.00 in) 4 litres (243 in 3 ) 16.5:1 28 bar (400 lbf/in 2 ) [maximum variation between cylinders - 3.5 bar (50 lbf/in 2 )]
Injection Sequence Valve Clearance - Hot or Cold - inlet 0.20 mm (0.008 in) - exhaust 0.45 mm (0.018 in) Maximum Speed (no load) Governed Speed Idling Speed
1, 3, 4, 2
2320 - 2420 rev/min 2200 rev/min 750 rev/min
Fuel System Injection Pump Type Injection Pump Setting Code Injection Timing Injection Setting Pressure Lift Pump Type
C.A.V., D.P.A., mechanically governed DM55L/1000/1/2420 16.5° BTDC 220 atm AC Diaphragm
Induction System Air Cleaner Type Max. Restriction (at which warning light operates)
2 stage, dry element 559mm (22 in) H 2 0
Lubrication System Oil Pump Type Oil Pressure (hot) at maximum speed
Eccentric rotor 2.0 bar (30 lbf/in 2 ) (minimum)
Cooling System Coolant Pressure Coolant Temperature (normal) Temperature Warning Light operates at
0.48 bar (7 lbf/in 2 ) 80-85 °C (176 - 185 °F) 98 °C (209 °F)
Note: For further details of the engine refer to Engine Service Manual 9806/0100
9804/1103
15 - 05 - 08/2
7110 - C/1-1.5
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
2CXAM
10 - 05 - 09/1
From m/c no. 657001
Data - Pneumatics Performance Maximum working pressure
6.9 bar (100 Ibf/in2)
Rated F.A.D. at full output to ISO 1217
73.2 Itr/sec (4.4 m3/min, 155 ft3/min)
Maximum air delivery temperature at full output - at compressor unit discharge
120°C (248°F)
- at delivery manifold Maximum permissible ambient temperature (continuous full load)
110°C (230°F)
50°C (122°F)
Compressor Air delivery
Two 3/4” BSP Cocks
Air filter
dry paper element
Load control method
speed control and inlet throttling
Oil filter
single bowl, spin-on cartridge type
Method of lubrication
pressure feed to bearings and rotors
Oil cooler
air blast
Oil reclamation
combined kinetic/filtration
Oil system capacity (approx.)
19.5 litre (41/4 imp. gal)
9804/1103
10 - 05 - 09/1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
10 - 10 - 01/1
2CX, 2DX, 210S, 212S
From m/c no. 655000
Fault Finding - Syncro Shuttle - Mechanical Before carrying out the checks listed the machine should, if possible, be operated to determine the fault area(s), and bring the systems to their normal working temperatures. Ensure that the correct quantity and grade of oil is used and that there are no obvious leaks. A
If the transmission is noisy, start at check 1.
B
If the transmission is overheating, start at check 4.
C
If the transmission will not pull, start at check 12.
D
If there is no drive in one or both directions, start at check 17.
E
If the transmission is jumping out of gear, start at check 29.
F
If the transmission is sticking in gear, start at check 39.
G
If ratios are 'crash changing', start at check 41.
CHECK
ACTION
1
Is there noise when selecting direction?
YES: NO:
Check 3 Check 2
2
Is there noise when running with direction selector in neutral and ratio selector in a gear?
YES: NO:
Check 9 Check 19
3
Is there air in the hydraulic system?
YES: NO:
Continue running to expel air. Check 4
4
Is the fluid level correct?
YES: NO:
Check 5 Check level only when machine is cold and top-up as required.
5
Are the oil passages restricted?
YES: NO:
Clear the restriction. Check 6
6
Is the suction strainer restricted?
YES: NO:
Remove and clean strainer. Check 7
7
Is pump pressure as specified?
YES: NO:
Check 9 Check clutch pressure maintenance valve is free to operate.
8
When flow testing pump, is output low?
YES: NO:
Renew pump. Check converter sprag clutch for wear or slip.
9
Does the noise continue when direction selector is in forward or reverse?
YES: NO:
Check 10 Check 11
10
Is transmission misaligned?
YES:
Renew mountings and check position. Check 'converter out' pressure and flow.
NO:
11
Are the pump bushes worn?
YES: NO:
Renew Check converter for wear or cooler for restriction to flow.
12
Is the transmission not pulling in one direction only?
YES: NO:
Check 16 Check 13
13
Is the transmission not pulling in both Forward and Reverse?
YES: NO:
Stall test machine, Check 14. Check 16
9804/1103
10 - 10 - 01/1
3270 - F/1-3.1
Issue 3*
CONTENTS
Backhoe Loaders
10 - 10 - 01/2
2CX, 2DX, 210S, 212S
From m/c no. 655000
Fault Finding - Syncro Shuttle - Mechanical CHECK
ACTION
14
Is 'converter in' pressure as specified?
YES: NO:
Check 15 Inspect converter relief valve for damage. Check the relief valve pressure setting.
15
Is pump being driven by converter?
YES: NO:
Check pump pressure. Renew damaged parts.
16
Are clutch sealing rings damaged?
YES:
Tap pressure gauge into clutch feed lines to monitor pressure.
17
Is there drive in one direction only?
NO: YES: NO:
Check clutch plates for damage. Check 19 Check 18
18
Is the start switch in the run position and supplying current to the neutral start relay?
YES: NO:
Check 19 Rectify.
19
Is the fault only when the transmission is hot?
YES:
Dismantle solenoid and check components. Check microswitches, relay and wiring loom.
NO:
20
Is the noise a growl, hum or grinding?
YES: NO:
Check gears for damage or wear. Check 21
21
Is the noise a hiss, thump or bumping?
YES: NO:
Check bearings for damage or wear. Check 22
22
Is the noise a squeal?
YES: NO:
Check free running gears for seizure. Check 23
23
Is the noise present when in neutral or when in gear?
NEUTRAL: IN GEAR:
24
Is the countershaft or its bearings worn or damaged?
YES: NO:
Renew damaged parts. Check 25
25
Is there excessive backlash in the gears?
YES: NO:
Adjust by checking shaft end float. Check 26
26
Is the mainshaft pilot bearing worn?
YES: NO:
Renew. Check gear teeth for scuffing.
27
Is the mainshaft rear bearing worn?
YES: NO:
Renew. Check 28
28
Are the sliding gear teeth worn or damaged?
YES: NO:
Renew gears. Check 29
29
Are the selector forks loose?
YES: NO:
Tighten screws. Check 30
30
Are the selector fork pads or grooves in gears worn?
YES: NO:
Renew worn parts. Check 31
31
Are the dog gear teeth worn?
YES: NO:
Renew. Check 32
32
Are the selector rod detent springs broken?
YES: NO:
Renew. Check 33
9804/1103
10 - 10 - 01/2
Check 24 Check 27
3270 - F/1-2.2
Issue 3*
CONTENTS
Backhoe Loaders
10 - 10 - 01/3
2CX, 2DX, 210S, 212S
From m/c no. 655000
Fault Finding - Syncro Shuttle - Mechanical CHECK
ACTION
33
Are the selector rods worn or damaged?
YES: NO:
Renew. Check 34
34
Are the selector fork pads out of position?
YES: NO:
Reposition or renew (check interlock). Check 35
35
Is there excessive end float in gears or shafts?
YES: NO:
Adjust. Check thrust washers and mating faces.
36
Is the synchroniser bronze worn?
YES: NO:
Renew synchro pack. Check 37
37
Are steel chips embedded in the bronze?
YES:
Continue using, chips will either embed below bronze or be rejected. Check 38
NO: 38
Are the synchroniser components damaged?
YES: NO:
Renew. Check free running gears for seizure or damage.
39
Are the sliding gears tight on the splines?
YES: NO:
Free or renew. Check 40
40
Are chips wedged between splines of shaft or gear?
YES: NO:
Remove chips. Ensure that clutch is disengaged when dump pedal is pressed.
41
Are steel chips embedded in the bronze?
YES:
Continue using, chips will either embed below bronze or be rejected. Check 42
NO: 42
Are the synchroniser spring pins damaged?
YES: NO:
Renew synchro. Check 43
43
Is the synchroniser bronze worn?
YES: NO:
Renew synchro. Check blocker pins.
9804/1103
10 - 10 - 01/3
3270 - F/1-2.2
Issue 3*
CONTENTS CONTENTS
Backhoe Loaders
2CX, 210S
10 - 10 - 01/4
From m/c no. 655000
Fault Finding - Syncro Shuttle - Hydraulic Before commencing with the fault finding procedure make sure that the correct type of transmission fluid has been used. LACK OF POWER Possible Cause 1 Poor engine condition. 2 Low oil level. 3 Worn pump. 4 Torque converter damage. 5 Low mainline pressure. 6 Clutches slipping. 7 Internal leakage. 8 9 10
Remedy 1 Check and if necessary repair engine. 2 Top up system. 3 Check flow and if necessary repair or renew pump. 4 Check and if necessary repair or renew torque converter. 5 See fault 'Low Mainline Pressure'. 6 See fault 'Low Clutch Pressure'. 7 a) Check internal cored galleries and casting for porosity. b) Check condition of seals. 8 See fault 'High Stall Speeds'. 9 See fault 'Low Stall Speeds'. 10 See fault 'Overheating'.
High stall speeds. Low stall speeds. Overheating.
LOW MAINLINE PRESSURE (in neutral) Possible Cause 1 Worn pump. 2 Blocked suction strainer. 3 Pressure maintaining valve sticking/leaking. 4 Oil aerated (foaming).
5
Remedy 1 Check flow and if necessary repair or renew pump. 2 Clean suction strainer. 3 Free off or renew valve. 4 a) Internal leakage (cored galleries) - inspect/repair transmission. b) Dirty suction strainer - clean strainer. c) High oil level - drain to proper level. d) Incorrect grade of oil - drain then refill with correct oil. 5 a) Check external pipework for parking brake circuit. b) Check parking brake (pressure) circuit - refer to parking brake fault finding procedure on page 10-10-01/9. c) Disconnect parking brake and re-check.
Oil leak through parking brake on/off circuit.
HIGH STALL SPEEDS (Forward & Reverse Clutches) Possible Cause 1 Damaged converter blades. 2 Clutches slipping. 3 Internal leakage.
Remedy 1 Check and if necessary renew converter. 2 See fault 'Low Clutch Pressure'. 3 a) Check internal cored galleries and casting for porosity. b) Check condition of seals.
LOW STALL SPEEDS (Forward & Reverse Clutches) Possible Cause 1 Poor engine condition. 2 Torque converter reaction member clutch slipping.
Remedy 1 Check and if necessary repair engine. 2 Check and if necessary renew torque converter.
LOW CONVERTER OUT PRESSURE Possible Cause 1 Low mainline pressure. 2 Converter internal leakage. 3 Converter relief valve faulty. 4 Restriction in converter feed.
Remedy 1 See fault heading 'Low Mainline Pressure'. 2 Check and if necessary renew converter. 3 Check and if necessary repair relief valve. 4 See item 10 in fault 'Overheating'
LOW PUMP FLOW Possible Cause 1 Low oil level. 2 Blocked suction strainer. 3 Worn pump.
Remedy 1 Top up system. 2 Clean suction strainer. 3 Repair or renew pump.
9804/1103
10 - 10 - 01/4
Issue 2
CONTENTS CONTENTS
Backhoe Loaders
2CX, 210S
10 - 10 - 01/5
From m/c no. 655000
Fault Finding - Syncro Shuttle - Hydraulic (cont’d) HIGH CONVERTER OUT PRESSURE Possible Cause 1 Oil cooler/lines blocked. 2 Converter in pressure incorrect 3 Converter relief valve faulty.
Remedy 1 Clean cooler, free blockage. 2 Check converter in pressure correct 3 Check and if necessary repair relief valve.
LOW LUBRICATION PRESSURE Possible Cause 1 Low mainline pressure. 2 Oil cooler/lines blocked. 3 Ruptured lubrication line. 4 Converter internal leakage. 5 Converter relief valve faulty. 6 Leak at pump to case joint (indicated by low cooler flow) 7 Restriction in converter feed
Remedy 1 See fault heading 'Low Mainline Pressure'. 2 Clean cooler, free blockage. 3 Repair line. 4 Check and if necessary renew converter. 5 Check and if necessary repair or renew relief valve. 6 Check and if necessary repair or replace as necessary. 7 See item10 in fault 'Overheating'
LOW CLUTCH PRESSURE AND/OR CLUTCH SLIPPING Possible Cause 1 Low mainline pressure. 2 Worn pump. 3 Blocked restrictor orifice in F/R solenoid valve block. (Both F/R clutches will indicate low pressure). 4 Clutch seals worn. 5 6
Clutch piston rings worn. Mechanical failure.
LOW COOLER FLOW Possible Cause 1 Converter relief valve faulty. 2 Leak at pump to case joint . 3 Worn pump. 4 Internal leakage. 5
Remedy 1 Check and if necessary repair or renew relief valve. 2 Check and if necessary repair or replace as necessary. 3 Check flow and if necessary repair or renew pump. 4 a) Check internal cored galleries and casting for porosity. b) Check condition of seals. 5 See item 10 in fault 'Overheating'.
Restriction in converter feed.
OVERHEATING Possible Cause 1 Low oil level. 2 High oil level. 3 Trapped or kinked hoses in cooler system. 4 Low converter out pressure and flow rate. 5 Oil cooler blocked. 6 Operating in wrong gear range. 7 Water system overheating. low water level etc. 8 Oil aerated (foaming). 9 Clutch piston(s) sticking on return stroke. 10 Cored galleries on front housing pump mounting face wrong depth (indicated by excessively low pressure and flow on converter out cooling line). 11 Leakage across pump mounting face and front case. loose
9804/1103
Remedy 1 See fault heading 'Low Mainline Pressure'. 2 Check flow and if necessary repair or renew pump. 3 Remove F/R solenoid and clear restriction in solenoid valve block. 4 Confirm with a clutch leak test, if required renew clutch seals 5 Confirm with a clutch leak test, renew piston rings. 6 Strip and rebuild clutch, renew parts as required.
Remedy 1 Top up system. 2 Drain oil to correct level. 3 Renew or repair hoses. 4 Repair or renew the converter relief valve. 5 Clean cooler. 6 Select correct gears to suit working conditions. 7 Rectify water system problems, eg radiator, cooler lines, 8 9 10
See fault 'Low Mainline Pressure', item 4. Check and repair clutch piston(s) and seal(s). Replace front housing (or rectify existing housing).
11
Check for damaged surface on both components and pump mounting bolts.
10 - 10 - 01/5
Issue 2
CONTENTS CONTENTS
Backhoe Loaders
2CX 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL 2CX,
10 - 10 - 02/1
From m/c no. 657001
Fault Finding - Parking Brake PARKING BRAKE INOPERATIVE BUT TRANSMISSION FUNCTIONS IN FORWARD AND REVERSE Check
Action
1
Is distance spacer fitted to centre bolt?
YES: Check 2. NO: Fit spacer.
2
Is the parking brake solenoid spool sticking?
YES: Free off or renew valve. NO: Check 3.
3
Put the starter switch in 'IGN' position. Disengage the parking brake, is there a voltage reading at the parking brake feed wire?
YES: Dismantle parking brake and check condition. NO: Check 4.
4
Put the starter switch in 'IGN' position. Is there a voltage reading at the parking brake solenoid feed wire?
YES: Renew parking brake relay. NO: Check switch and wiring.
PARKING BRAKE PERMANENTLY ENGAGED Check
Action
1
Is the parking brake solenoid spool sticking?
YES: Free off or renew valve. NO: Check 2.
2
Put the starter switch in 'IGN' position. Disengage the parking brake, is there a voltage reading at the parking brake feed wire?
YES: Check 4. NO: Check 3.
3
Put the starter switch in 'IGN' position. Is there a voltage reading at the parking brake solenoid feed wire?
YES: Check 4. NO: Check switch and wiring.
4
Has the parking brake been dismantled recently?
YES: Dismantle and check for correct build. NO: Check 5.
5
Is the transmission main line pressure correct?
YES: Check 6. NO: See Transmission Fault Finding.
6
Is the main line pressure correct with the parking brake circuit isolated?
YES: Dismantle parking brake and check condition. NO: See Transmission Fault Finding.
9804/1103
10 - 10 - 02/1
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
10 - 10 - 03/1
2CXAM
From m/c no. 657001
Fault Finding - Pneumatics FAULT Compressor fails to build up to working pressure
POSSIBLE CAUSE
REMEDY
a
Choked air intake filter
a
Change air intake filter element
b
Suction unloader valve stuck on seat
b
Inspect and release valve through unloader air intake
c
Faulty blow down valve
c
Overhaul or change blow down valve
d
Faulty gauge
d
Overhaul or change gauge
a
Suction unloader valve stuck open
a
Inspect and release valve through unloader air intake
b
Suction unloader/compressor joint leak
b
Tighten or renew joint
c
Punctured diaphragm on pressure regulator or unloader piston
c
Inspect and renew
d
Safety valve faulty
d
Inspect and rectify
e
Air/oil separator faulty
e
Clean or change element
Plant not operating at correct minimum or maximum speed
a
Speed control faulty
a
Reset speed control
b
Engine fault
b
Refer to engine Service Manual
Excessive compressor oil consumption
a
Receiver scavenge oil restrictor choked
a
Clean oil restrictor
b
Air/oil separator faulty
b
Clean or change element
c
Incorrect grade of oil
c
Drain and refill with correct grade of oil
a
Machine not standing level or sited badly
a
Level machine or resite for maximum air flow
b
Air receiver level low
b
Top up air receiver oil
c
Incorrect grade of compressor oil
c
Drain and refill with correct grade of oil
d
Air/oil separator choked
d
Clean or change element
e
External surface of oil cooler clogged
e
Clean external surface of oil cooler
f
Clogging of compressor oil circulating system
f
Drain, flush and refill oil circulating system
g
Faulty temperature switch or circuit
g
Check circuit and/or change faulty switch(es)
a
Parking brake not applied, transmission not in neutral
a
Engage parking brake, put transmission in neutral
b
Power take-off solenoid fuse (A8) blown
b
Change fuse
c
Power take-off solenoid faulty
c
Check circuit and change solenoid if necessary
Compressor fails to off-load (safety valve blowing)
Shut down due to high air delivery temperature
Compressor drive will not engage
9804/1103
10 - 10 - 03/1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
10 - 10 - 04/1
2CX, 2DX, 210S, 212S Fault Finding - Air Conditioning Harness Wires Use the harness illustration below to complete continuity checks on the air conditioning harness wires.The harness connects to the mainframe harness via connector A, located behind the side console panel.
ITEM
DESCRIPTION
A B C D E F
Air Conditioning Power (from fuse C9) Controls Pressure Switch Pressure Switch Compressor Splice
WIRE
DESCRIPTION
20 21 685 686 687 688 689
Controls to Power Controls to Compressor Power to Splice Controls to Pressure Switch Pressure Switch to Splice Pressure Switch to Pressure Switch Controls to Splice
B
F
A
E
D
C A201500
9804/1103
10 - 10 - 04/1
7110 - B/3-2.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX, 2DX, 210S, 212S
10 - 10 - 04/2
From m/c no. 657001
Fault Finding - Air Conditioning (cont’d) No Air Conditioning CHECK
ACTION
1
Are the controls set correctly, i.e. air conditioning selected, thermostat switch set to coldest position and blower switched on?
YES: NO:
Check 2 Reset controls and retest.
2
Is the air conditioning (evaporator) blower working?
YES: NO:
Check 3. Check 4.
3
Is the compressor running (visual check of pulley/clutch)?
YES: NO:
Check11. Check 7.
4
Is the air conditioning fuse (B8) blown?
YES: NO:
Renew fuse and retest. Check 5.
5
Is there a 12V supply to the pressure switch harness? (See Pressure Switch Testing)
YES: NO:
Check 6. Check 9.
6
Does the compressor clutch engage with both pressure switches bypassed? (See Pressure Switch Testing)
YES: NO:
Check 7. Renew the compressor clutch and retest.
7
Does the compressor clutch engage with HP switch bypassed? (See Pressure Switch Testing)
YES: NO:
Renew high pressure switch and retest. Check 8.
8
Does the compressor clutch engage with LP switch bypassed? (See Pressure Switch Testing)
YES: NO:
Renew low pressure switch and retest. Charge check required by refrigeration engineer.
9
Does the clutch engage with thermostat switch bypassed?
YES: NO:
Renew thermostat switch and retest. Check all electrical connections.
10 Are blower switch and wiring OK?
YES: NO:
Renew blower motor. Renew switch or wiring.
11 Is sight glass indication OK?
YES: NO:
Check 12. Charge check required by refrigeration engineer.
12 Is condensor air flow blocked?
YES: NO:
Clean condensor and radiator. Check 13.
13 Is evaporator air flow blocked?
YES: NO:
Clean filter and, if necessary the evaporator. Call in refrigeration engineer.
9804/1103
10 - 10 - 04/2
7110 - B/3-3.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX, 210S
10 - 15 - 01/1
From m/c no. 655000 to 656500
Circuit Diagrams - Electrical Main Components & Switches
Fuses
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
A1 - A9 B1 - B9 C1 - C9
Battery Starter Switch Thermostart Neutral Start Relay Starter Solenoid Starter Motor Loader Dump Switch Gear Lever Dump Switch Dump Relay Parking Brake Relay Forward/Reverse Switch Forward Relay Reverse Relay Forward Solenoid Reverse Solenoid Reverse Alarm (Option) Parking Brake Switch Water Temperature Gauge Fuel Gauge Water Temperature Gauge Sender Fuel Gauge Sender Diodes Buzzer Transmission Oil Temperature Switch Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Switch Warning Lights Test Switch Diodes Speedo/Tachometer Alternator Rear Wash/Wipe Switch Rear Washer Rear Wiper Hazard Switch Flash Unit Diode Direction Indicator Switch Heater Switch Resistor Heater Beacon Interior Light Switch Radio (Option) Front Wash/Wipe Switch Front Washer Front Wiper Horn Horn Push Rear Horn (Option) Rear Horn Push (Option) Brake Lights Switch Headlight Flash Switch Dip Switch Road Light Switch Road Light Relay Front Work Lights Switch Rear Work Lights Switch Stabiliser Leg/Neutral Start Interlock Relay Stabiliser Leg/Neutral Start Interlock Solenoid
9804/1103
See page 10 - 05 - 01/1 for fuse details
Lights 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109
Parking Brake Engine Oil Temperature Warning (Option) Engine Coolant Temperature Warning (Option) Transmission Oil Temperature Warning Engine Oil Pressure Warning Transmission Oil Pressure Warning Blocked Air Filter Warning No Charge Warning Hazard Warning Hazard Warning Switch Repeater Direction Indicator Switch Right Hand Indicator Right Hand Indicator Left Hand Indicator Left Hand Indicator Beacon Interior Brake Brake Main Beam Main Beam Main Beam Warning Dip Beam Dip Beam Front Work Front Work Front Work Warning Left Hand Tail Left Hand Side Water Temperature Gauge Fuel Gauge Speedo/Tachometer Gauge Number Plate Number Plate Right Hand Tail Right Hand Side Dipper Rear Work Rear Work Rear Work Warning
Cable Colour Code B G K LG N O P R S U W Y
10 - 15 - 01/1
Black Green Pink Light Green Brown Orange Purple Red Slate Blue White Yellow
Issue 2
CONTENTS CONTENTS
Backhoe Loaders
Backhoe Loaders
2CX, 210S
10 - 15 - 01/2
From m/c no. 655000 to 656500
Circuit Diagrams - Electrical
153201
9804/1103
10 - 15 - 01/2
10 - 15 - 01/2
Issue 2
CONTENTS CONTENTS CONTENTS
Backhoe Loaders
Backhoe Loaders
10 - 15 - 01/3
2CX, 2CXL, 2CXFM, 210S, 210SL
From m/c no. 657001
Circuit Diagrams - Electrical
22
202
201
204 200
17
10 - 15 - 01/3
205 11
209 1/2 207 246
242
400
20
12
241
809
11 4
668
607 605 630
621 617
620 682
631
622
636
602 612
637
637
618
603
664
801
802
811
24
5
10
631
402
406
407
860
14
404
408
401
637
657
627 644
1
3
13 633
+ -
A5
38
25
637
649 638
648
639
249
9
53 51
656 653 643
654
642 669
604
614
804
249
244
A183041
9804/1103
4
258 245
681
58 54 52
69 648 649
638
637
73
254
806
224
219
803
807
8
31 30 29 28 27 26
639
646/647 639 638
633
652
637 637 637
76
85 83
655
88
639 648 623
90 661 659
638 649
660 658
651 624
680
619
684
92
15
212
857
859
44 43
18
102
77 94
6
247
853
59
257
248
37 36 35 34 33
39
47
851
866 252
409
814
60
816 815
835 834
414
412
827 238
410
236
250
50
55
222
832 831
413
40
46
849
842 844/845
836
61
75 74 72
95
32
253
89 87 86 84
19
640
91
65 64
818 886 839 837
820
214 822 821
216
B5
213
68
812
42 255
2
7 865
411
218
862
863
800
808
833
234 231
93
215 819
235 847 846
848
416
78
C3
17 16
805
239
49
B9
101
48
56
B7
23
41
243
221
70 67 66 63 62
82
A3
237
825
228
A4
45
855
861
B4
227
810
230
B3
80
96
21
853
98
856
884
A8
225
826 229
841
100
A2
223 217
57
71
233
232
99
A6 B1
7
403
79
81
B6
838
830
211
880 883
16
18
97
A7 B8
B2
405
A9 A1
882
256
6 226
10 203
C4
850
C5
10
9
4
C1
251
415
3
C2 C6
8
817
C7
10 - 15 - 01/3
A183040-1
Issue 2
CONTENTS CONTENTS
Backhoe Loaders
2CX, 2CXL, 2CXFM, 210S, 210SL
10 - 15 - 01/4
From m/c no. 657001
Circuit Diagrams - Electrical Main Components, Lights and Switches 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Battery Starter Switch Thermostart Starter Motor Starter Solenoid Neutral Start Relay Parking Brake Switch Parking Brake Interlock Relay Forward/Reverse Switch Forward Relay Forward Solenoid Reverse Solenoid Reverse Alarm (optional) Reverse Relay Parking Brake Warning Relay Gear Lever Dump Switch Loader Lever Dump Switch Dump Relay Parking Brake Relay Parking Brake Solenoid Stabiliser Leg/Neutral Start Interlock Relay Stabiliser Leg/Neutral Start Interlock Solenoid (optional) Instrument Console Water Temperature Sender Fuel Gauge Engine Coolant Temperature Switch Transmission Oil Temperature Switch Engine Oil Low Pressure Warning Light Switch Transmission Oil Low Pressure Warning Light Switch Air Filter Blocked Switch Warning Lights Test Button (if fitted) Instrument Console Light Engine Coolant Temperature Warning Light Transmission Oil Temperature Warning Light Engine Oil Low Pressure Warning Light Transmission Oil Low Pressure Warning Light Air Filter Blocked Warning Light Speedo/Tachometer Alternator Alternator No Charge Light Buzzer Rear Windscreen Wash/Wipe Switch Rear Windscreen Wiper Motor Rear Windscreen Wiper Wash Motor Hazard Warning Light Switch Flasher Unit Hazard Warning Light Diode Direction Indicator Switch Direction Indicator Light Right Hand Indicator Light - Front Right Hand Indicator Light - Rear Left Hand Indicator Light - Front Left Hand Indicator Light - Rear Heater Motor Heater Resistor Heater Switch Beacon Cab Interior Light Cab Interior Light Switch
9804/1103
61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102
Front Windscreen Wiper Motor Front Windscreen Wiper Switch Front Windscreen Washer Pump Switch Front Windscreen Washer Pump Front Horn Front Horn Button Rear Horn Button (optional) Rear Horn (optional) Rear Brake Lights Rear Brake Light Switch Headlamp Flasher Switch Right Hand Main Beam Lamp Left Hand Main Beam Lamp Main Beam Warning Light Right Hand Dipped Beam Light Left Hand Dipped Beam Light Rear Fog Light (optional) Rear Fog Light Switch (optional) Headlight Dip Switch Road Lights Relay Road Lights Switch Front Working Lights Switch Front Working Lights Front Working Lights Warning Light Left Hand Tail Light Left Hand Side Light Water Temperature Gauge Light Fuel Gauge Light Speedo/Tachometer Light Number Plate Lights Right Hand Tail Light Right Hand Side Light Rear Working Lights Rear Working Lights Warning Light Low Brake Pressure Warning Light Engine Shut Off System Radio Carrier Rear Work Light Switch Attachments Power Socket Low Brake Pressure Warning Switch Diodes Diodes
Fuses A1 - A9 B1 - B9 - See Technical Data pages for fuse details C1 - C9
10 - 15 - 01/4
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
10 - 15 - 01/5
2DX from m/c no. 659249 to 760840 2CX from m/c no. 659599 to 760840 Circuit Diagram - Electrical
3
64 5
63
2
111
15
10
114
117
7
81
27 80
118
116
6
26
77
71 8
112
9 110
17
115
119
74
76 75
20
113
29
177
4
11
82
12 78 79
174
175
171 ➁
21
179 19 13 176
69
73
14
66
28 121 123 125 127 129
16
120 122
1
131
124 126 128 130
133 132
25
170
18
22
23 24
62 65
A1 67 178
173
68
72 70
C5
C3
B7
C2
B1
B6
A6
61 172
10 - 15 - 01/5
3270 - C/18-1.3
CONTENTS
9804/1103
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
10 - 15 - 01/6
2DX from m/c no. 659249 to 760840 2CX from m/c no. 659599 to 760840 Circuit Diagrams - Electrical Main Components 1 Battery 2 Thermostart 3 Starter Motor 4 Starter Solenoid 5 Forward Solenoid 6 Reverse Solenoid 7 Reverse Alarm 8 Parking Brake Solenoid 9 PTO Solenoid ➀ 10 Compressor Temperature Sender ➀ 11 Compressor Temperature Gauge ➀ 12 Compressor Hourmeter ➀ 13 Stabiliser Leg Solenoids ➀ 14 Steer Mode Solenoids ➀ 15 Steer Mode Unit ➀ 16 Junction Box 17 Hammer Solenoid ➀ 18 Flasher Unit 19 Diode 20 Trailer Indicator Warning Buzzer ➀ 21 Side Instrument Console 22 Tachometer 23 Water Temperature Gauge 24 Fuel Gauge 25 Hourmeter 26 Water Temperature Sender 27 Fuel Sender 2 Buzzer 29 Shut Down System (Compressor) ➀ 30 Engine Shut Off System 31 Front Instrument Console 32 Alternator 33 Rear Horn ➀ 34 Rear Windscreen Washer Pump 35 Rear Windscreen Wiper Motor 36 Front Windscreen Washer Pump 37 Front Windscreen Wiper Motor 38 Front Horn 39 Dipper Socket 40 Face Level Fan ➀ 41 Beacon Motor 42 Tracker ➀ 4 Radio ➀ 44 RH Speaker ➀ 4 LH Speaker ➀ 4 Heater Resistor ➀ 47 Heater Motor ➀ 48 Air Conditioning Motor ➀ 4 Heater Resistor 50 Heater Motor
9804/1103
Switches 61 Starter Switch 62 Forward/Reverse Switch 63 Gear Lever Dump Switch 64 Loader Lever Dump Switch 65 Parking Brake Switch 66 Compressor Switch ➀ 67 Front Proximity Switch ➀ 68 Rear Proximity Switch ➀ 69 Steer Mode Selector Switch ➀ 70 Brake Lights Switch ➀ 71 Hammer Switch 72 Hazard Warning Light Switch 73 Direction Indicator Switch 74 Engine Coolant Temperature Switch 75 Transmission Oil Temperature Switch 76 Engine Oil Low Pressure Warning Light Switch 77 Transmission Oil Low Pressure Warning Light Switch 78 Air Filter Blocked Switch 79 Low Brake Pressure Warning Switch 80 Compressor Air Filter Switch ➀ 81 Air Receiver Temperature Switch ➀ 82 Air/Oil Delivery Temperature Switch ➀ 83 Rear Horn Button 84 Rear Windscreen Wash/Wipe Switch 85 Front Windscreen Wash/Wipe Switch 86 Front Horn Button 87 Road Lights Switch 88 Headlamp Flasher Switch 89 Headlight Dip Switch 90 Front Working Lights Switch 91 Rear Work Light Switch 92 Beacon Switch 93 Cab Interior Light Switch 94 Heater Switch ➀ 95 Air Conditioning Switch ➀ 96 Freeze Valve ➀ 97 Low Pressure Switch ➀ 98 High Pressure Switch ➀ 99 Heater Switch 100 Rear Fog Light Switch ➀
15 - 15 - 01/6
Issue 2*
CONTENTS
Backhoe Loaders
10 - 15 - 01/7
2DX from m/c no. 659249 to 760840 2CX from m/c no. 659599 to 760840 Circuit Diagrams - Electrical Lights 110 Left Hand Brake Light 111 Left Hand Trailer Brake Light ➀ 112 Right Hand Trailer Brake Light ➀ 113 Right Hand Brake Light 114 Left Hand Trailer Indicator Light ➀ 115 Left Hand Indicator Light - Front 116 Left Hand Indicator Light - Rear 117 Right Hand Trailer Indicator Light ➀ 118 Right Hand Indicator Light - Front 119 Right Hand Indicator Light - Rear 120 Alternator No Charge Light 121 Parking Brake Warning Light 122 Engine Coolant Temperature Warning Light 123 Transmission Oil Temperature Warning Light 124 Engine Oil Low Pressure Warning Light 125 Transmission Oil Low Pressure Warning Light 126 Air Filter Blocked Warning Light 127 Low Brake Pressure Warning Light 128 2 Wheel Steer Selected Warning Light 129 4 Wheel Steer Selected Warning Light 130 Hazard Warning Light 131 Main Beam Warning Light 132 Side Instrument Console Light 133 Direction Indicator Light 134 Front Instrument Console Warning Lights 135 Side Lights Warning Light 136 Rear Working Lights Warning Light 137 Front Working Lights Warning Light 138 Rear Fog Light Warning Light ➀ 139 Left Hand Main Beam Light 140 Right Hand Main Beam Light 141 Left Hand Dipped Beam Light 142 Right Hand Dipped Beam Light 143 Left Hand Trailer Light ➀ 144 Left Hand Number Plate Light 145 Left Hand Tail Light 146 Left Hand Side Light 147 Right Hand Trailer Light ➀ 148 Right Hand Number Plate Light 149 Right Hand Tail Light 150 Right Hand Side Light 151 Front Working Lights 152 Rear Working Lights 153 Rear Fog Light ➀
9804/1103
Relays 170 Neutral Start Relay 171 Neutral Lock Relay 172 ‘Ignition’ Relay 1 173 Transmission Dump Relay 174 Forward Relay 175 Reverse Relay 176 Parking Brake Light Relay 177 Parking Brake Relay 178 Compressor Neutral or Stabiliser Leg Lock Relay 179 Hammer Relay ➀ 180 Shutdown Relay ➀ 181 ‘Ignition’ Relay 2 182 Road Lights Relay 183 Air Conditioning Relay ➀
Fuses A1 - A9 B1 - B9 - See Technical Data pages for fuse details C1 - C9 Note ➀ : Indicates non standard equipment Note ➁ : Link wire to be fitted to neutral lock relay on non Airmaster machines. Note ➂ : On standard build when no optional shutdown system is fitted, a link wire is fitted on wire 105.
10 - 15 - 01/7
7110 - C/1-1.5
Issue 2*
Backhoe Loaders
CONTENTS CONTENTS
10 - 15 - 01/8
2DX from m/c no. 659249 to 760840 2CX from m/c no. 659599 to 760840 Circuit Diagram - Electrical
30
139
180 ➂
142 144 141 143
140
153
145
38
36
148 147
146
34
43
149
98
45
39 151
93
152
48 41
40
150
50
47 97
37 35
33
44
32 B4
183
42
B3
100 88 89
A3 A4
31
46
96
49
85 128 135 130 137 134
83
84
86
133 131 136 138
92 C4 90 91
87
95
94
B5 B2
A2
B9
A5
C1
A9
A7 181
9804/1103
10 - 15 - 01/8
99
A8 B8
182
3270 - C/18-1.3
Issue 2*
CONTENTS
Backhoe Loaders
2CX AM
To m/c no. 658332
Electrical Schematic Circuit Component Key
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Neutral Start Relay Parkbrake Switch Parkbrake Interlock Relay Parkbrake Warning Relay Parkbrake Relay Compressor Switch Temperature Sender Parkbrake Solenoid Temperature Gauge Hourmeter Power Take Off (PTO) Solenoid Neutral Start Interlock Parkbrake Interlock Air Receiver Temperature Switch Air Filter Blocked Switch Air/Oil Delivery Temperature Switch Engine Shut Off Solenoid (ESOS) Relay Engine Shut Off Solenoid (ESOS)
>
From Starter Switch (IGN ON)
9804/1103
10 - 15 - 01/9
Issue 1
Backhoe Loaders
CONTENTS
2CX AM
to m/c no. 658332
Electrical Schematic Circuit (continued) 1
C3
2
3 4 8
5
7 A8
9
6 10
11
12
13 14 15 16
17 C2 18 9804/1103
10 - 15 - 01/10
A212850
Issue 1
Backhoe Loaders
CONTENTS
2CX AM
From m/c no. 658333 to 659598
Electrical Schematic Circuit
1
2 3
4 5
8
7 9 10 11
12
13
6
14 15 16
17
18
A252070
9804/1103
10 - 15 - 01/11
Issue 1
CONTENTS
Backhoe Loaders
2CX AM
From m/c no. 658333 to 659598
Electrical Schematic Circuit (continued) Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Neutral Start Relay Parkbrake Switch Parkbrake Interlock Relay Parkbrake Warning Relay Parkbrake Relay Compressor Switch Temperature Sender Parkbrake Solenoid Temperature Gauge Hourmeter Power Take Off (PTO) Solenoid Neutral Start Interlock Parkbrake Interlock Air Receiver Temperature Switch Air Filter Blocked Switch Air/Oil Delivery Temperature Switch Engine Shut Off Solenoid (ESOS) Relay Engine Shut Off Solenoid (ESOS)
>
From Starter Switch (IGN ON)
9804/1103
10 - 15 - 01/12
Issue 1
CONTENTS
Backhoe Loaders
2CX AM
from m/c no. 659599
Electrical Schematic Circuit With the introduction of the revised cab (2CX machines from serial number 659599), the compressor electrical circuit is shown as an option on the main 2DX machine electrical circuit. Refer to Service Manual, publication number 9803/7110.
9804/1103
10 - 15 - 01/13
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
10 - 15 - 01/14
2CX, 2DX, 210S, 212S
From m/c no. 760841
Circuit Diagram - Electrical
3
5
63
2
6
118
75 74
71 17
9
115
81
79
26 27
117 116
14
7 154 8
114
111 112
10
77
78
79
82 29
76
119 20
64 113
110 4
11 174
175
12
177
185 179
171 184 2
28 19
13 176
25
73
22
130 132 121 123 125 127 120 122 124 126 128129 131 133
16
69 66
1
23 24 18
170
21
62
173 65
178
72 67
68 70
61 172
9804/1103
10 - 15 - 01/14
7110 - C/7-8.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX, 2DX, 210S, 212S
10 - 15 - 01/15
From m/c no. 760841
Circuit Diagrams - Electrical Note: Circuits shown with dashed lines indicate nonstandard equipment. For instance, compressor components are only fitted on the JCB Airmaster machine. Main Components 1 Battery 2 Thermostart 3 Starter Motor 4 Starter Solenoid 5 Forward Solenoid 6 Reverse Solenoid 7 Reverse Alarm 8 Parking Brake Solenoid 9 PTO Solenoid ➀ 10 Compressor Temperature Sender ➀ 11 Compressor Temperature Gauge ➀ 12 Compressor Hourmeter ➀ 13 Stabiliser Leg Solenoids ➀ 14 Steer Mode Solenoids ➀ 15 Steer Mode Unit ➀ 16 Junction Box 17 Hammer Solenoid ➀ 18 Flasher Unit 19 Diode 20 Trailer Indicator Warning Buzzer ➀ 21 Side Instrument Console 22 Tachometer 23 Water Temperature Gauge 24 Fuel Gauge 25 Hourmeter 26 Water Temperature Sender 27 Fuel Sender 28 Buzzer 29 Shut Down System (Compressor) ➀ 30 Engine Shut Off System 31 Front Instrument Console 32 Alternator 33 Rear Horn ➀ 34 Rear Windscreen Washer Pump 35 Rear Windscreen Wiper Motor 36 Front Windscreen Washer Pump 37 Front Windscreen Wiper Motor 38 Front Horn 39 Dipper Socket 40 Face Level Fan ➀ 41 Beacon Motor 42 Tracker ➀ 43 Radio ➀ 44 RH Speaker ➀ 45 LH Speaker ➀ 46 Heater Resistor ➀ 47 Heater Motor ➀ 48 Air Conditioning Motor ➀ 49 Heater Resistor 50 Heater Motor
9804/1103
Switches 61 Starter Switch 62 Forward/Reverse Switch 63 Gear Lever Dump Switch 64 Loader Lever Dump Switch 65 Parking Brake Switch 66 Compressor Switch ➀ 67 Front Proximity Switch ➀ 68 Rear Proximity Switch ➀ 69 Steer Mode Selector Switch ➀ 70 Brake Lights Switch ➀ 71 Hammer Switch 72 Hazard Warning Light Switch 73 Direction Indicator Switch 74 Engine Coolant Temperature Switch 75 Transmission Oil Temperature Switch 76 Engine Oil Low Pressure Warning Light Switch 77 Transmission Oil Low Pressure Warning Light Switch 78 Air Filter Blocked Switch 79 Low Brake Pressure Warning Switch 80 Compressor Air Filter Switch ➀ 81 Air Receiver Temperature Switch ➀ 82 Air/Oil Delivery Temperature Switch ➀ 83 Rear Horn Button 84 Rear Windscreen Wash/Wipe Switch 85 Front Windscreen Wash/Wipe Switch 86 Front Horn Button 87 Road Lights Switch 88 Headlamp Flasher Switch 89 Headlight Dip Switch 90 Front Working Lights Switch 91 Rear Work Light Switch 92 Beacon Switch 93 Cab Interior Light Switch 94 Heater Switch ➀ 95 Air Conditioning Switch ➀ 96 Freeze Valve ➀ 97 Low Pressure Switch ➀ 98 High Pressure Switch ➀ 99 Heater Switch 100 Rear Fog Light Switch ➀
10 - 15 - 01/15
7110 - C/7-9.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX, 2DX, 210S, 212S
10 - 15 - 01/16
From m/c no. 760841
Circuit Diagrams - Electrical Lights 110 Left Hand Brake Light 111 Left Hand Trailer Brake Light ➀ 112 Right Hand Trailer Brake Light ➀ 113 Right Hand Brake Light 114 Left Hand Trailer Indicator Light ➀ 115 Left Hand Indicator Light - Front 116 Left Hand Indicator Light - Rear 117 Right Hand Trailer Indicator Light ➀ 118 Right Hand Indicator Light - Front 119 Right Hand Indicator Light - Rear 120 Alternator No Charge Light 121 Parking Brake Warning Light 122 Engine Coolant Temperature Warning Light 123 Transmission Oil Temperature Warning Light 124 Engine Oil Low Pressure Warning Light 125 Transmission Oil Low Pressure Warning Light 126 Air Filter Blocked Warning Light 127 Low Brake Pressure Warning Light 128 2 Wheel Steer Selected Warning Light 129 4 Wheel Steer Selected Warning Light 130 Hazard Warning Light 131 Main Beam Warning Light 132 Side Instrument Console Light 133 Direction Indicator Light 134 Front Instrument Console Warning Lights 135 Side Lights Warning Light 136 Rear Working Lights Warning Light 137 Front Working Lights Warning Light 138 Rear Fog Light Warning Light ➀ 139 Left Hand Main Beam Light 140 Right Hand Main Beam Light 141 Left Hand Dipped Beam Light 142 Right Hand Dipped Beam Light 143 Left Hand Trailer Light ➀ 144 Left Hand Number Plate Light 145 Left Hand Tail Light 146 Left Hand Side Light 147 Right Hand Trailer Light ➀ 148 Right Hand Number Plate Light 149 Right Hand Tail Light 150 Right Hand Side Light 151 Front Working Lights 152 Rear Working Lights 153 Rear Fog Light ➀ 154 Reverse light
9804/1103
Relays 170 Neutral Start Relay 171 Neutral Lock Relay ➁ 172 ‘Ignition’ Relay 1 173 Transmission Dump Relay 174 Forward Relay 175 Reverse Relay 176 Parking Brake Light Relay 177 Parking Brake Relay 178 Compressor Neutral or Stabiliser Leg Lock Relay 179 Hammer Relay ➀ 180 Shutdown Relay ➀ ➂ 181 ‘Ignition’ Relay 2 182 Road Lights Relay 183 Air Conditioning Relay ➀ 184 2 Wheel steer Relay 185 4 Wheel Steer relay Fuses A1 - A9 B1 - B9 - See Technical Data pages for fuse details C1 - C9 Wire Number Identification See Wire Number Identification on Page 8 -10 for wire and harness number details. Note ➀: Indicates non standard equipment Note ➁: Link wire to be fitted to neutral lock relay on non Airmaster machines. Note ➂ : On standard build when no optional shutdown system is fitted, a link wire is fitted on wire 105.
10 - 15 - 01/16
7110 - C/7-10.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX, 2DX, 210, 212
10 - 15 - 01/17
From m/c no. 760841
Circuit Diagram - Electrical
9804/1103
10 - 15 - 01/17
7110 - C/7-11.1
Issue 1
CONTENTS CONTENTS
10 - 15 - 01/18
Backhoe Loaders
2CXU, 212SU (N. America only)
From m/c no. 657001
Circuit Diagram - Electrical
600
119
7 2
3
5
6
9
114
8
30
75
32 79
78 76
74
77
26
27
23
24
115
64 63
4
117 118 116
16 174
175 19
73 22
18 176 28
1 62
121 133
127 122 124 125 130 120 123 126 131 25
65 31 72
173 66 176
61 172
001 830Y 837C 200 160AH 9804/1103
10 - 15 - 01/18
7110 - C/7-12.2
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CXU, 210SU (N. America)
10 - 15 - 01/19
From m/c no. 657001
Circuit Diagrams - Electrical Main Components 1 Battery 2 Thermostart 3 Starter Motor 4 Starter Solenoid 5 Forward Solenoid 6 Reverse Solenoid 7 Reverse Alarm 8 Parking Brake Solenoid 9 Power Take Off Solenoid 16 Junction Box 18 Flasher Unit 19 Diode 22 Tachometer 23 Water Temperature Gauge 24 Fuel Gauge 25 Hourmeter 26 Water Temperature Sender 27 Fuel Sender 28 Buzzer 30 Engine Shut Off System 31 Front Instrument Console 32 Alternator 34 Rear Windscreen Washer Pump 35 Rear Windscreen Wiper Motor 36 Front Windscreen Washer Pump 37 Front Windscreen Wiper Motor 38 Front Horn 41 Beacon Motor 43 Radio ➀ 44 RH Speaker ➀ 45 LH Speaker ➀ 49 Heater Resistor 50 Heater Motor
9804/1103
Switches 61 Starter Switch 62 Forward/Reverse Switch 63 Gear Lever Dump Switch 64 Loader Lever Dump Switch 65 Parking Brake Switch 66 Power Take Off Switch 70 Brake Lights Switch ➀ 72 Hazard Warning Light Switch 73 Direction Indicator Switch 74 Engine Coolant Temperature Switch 75 Transmission Oil Temperature Switch 76 Engine Oil Low Pressure Warning Light Switch 77 Transmission Oil Low Pressure Warning Light Switch 78 Air Filter Blocked Switch 79 Low Brake Pressure Warning Switch 84 Rear Windscreen Wash/Wipe Switch 85 Front Windscreen Wash/Wipe Switch 86 Front Horn Button 87 Road Lights Switch 88 Headlamp Flasher Switch 89 Headlight Dip Switch 90 Front Working Lights Switch 91 Rear Work Light Switch 92 Beacon Switch 93 Cab Interior Light Switch 99 Heater Switch 100 Rear Fog Light Switch ➀
10 - 15 - 01/19
7110 - C/7-13.2
Issue 1
CONTENTS
Backhoe Loaders
2CXU, 210SU (N. America only)
10 - 15 - 01/20
From m/c no. 657001
Circuit Diagrams - Electrical Lights 110 Left Hand Brake Light 111 Left Hand Trailer Brake Light ➀ 112 Right Hand Trailer Brake Light ➀ 113 Right Hand Brake Light 114 Left Hand Trailer Indicator Light ➀ 115 Left Hand Indicator Light - Front 116 Left Hand Indicator Light - Rear 117 Right Hand Trailer Indicator Light ➀ 118 Right Hand Indicator Light - Front 119 Right Hand Indicator Light - Rear 120 Alternator No Charge Light 121 Parking Brake Warning Light 122 Engine Coolant Temperature Warning Light 123 Transmission Oil Temperature Warning Light 124 Engine Oil Low Pressure Warning Light 125 Transmission Oil Low Pressure Warning Light 126 Air Filter Blocked Warning Light 127 Low Brake Pressure Warning Light 128 Reverse Lights 130 Hazard Warning Light 131 Main Beam Warning Light 133 Not Fitted In This Application 134 Not Fitted In This Application 135 Not Fitted In This Application 139 Left Hand Main Beam Light 140 Right Hand Main Beam Light 141 Left Hand Dipped Beam Light 142 Right Hand Dipped Beam Light 143 Left Hand Trailer Light ➀ 144 Left Hand Number Plate Light 145 Left Hand Tail Light 146 Left Hand Side Light 147 Right Hand Trailer Light ➀ 148 Right Hand Number Plate Light 149 Right Hand Tail Light 150 Right Hand Side Light 151 Front Working Lights 152 Rear Working Lights 153 Rear Fog Light ➀
9804/1103
Relays 170 Neutral Start Relay 172 ‘Ignition’ Relay 1 173 Transmission Dump Relay 174 Forward Relay 175 Reverse Relay 176 Parking Brake Light Relay 178 Working Lights Relay 181 ‘Ignition’ Relay 2 Fuses A1 - A9 B1 - B9 - See Technical Data pages for fuse details C1 - C9 Note ➀: Indicates non standard equipment
10 - 15 - 01/20
7110 - C/7-14.2
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
10 - 15 - 01/21
2CXU, 212SU (N. America only)
From m/c no. 657001
Circuit Diagrams - Electrical
600
143 145
110
147 149
151
111
34 35
112
36 50
113
45
153 139 141 140 142
38
144 146
43
152
148 150
41
49 93
89
44
100
88 70
90 85 178 86
84
87
91
92
99
181 001 830Y 837C 200 160AH
9804/1103
10 - 15 - 01/21
7110 - C/7-15.2
Issue 1
9804/1103 1
6 4
2 6
9 8 7 3 4 5 6 2
8
FUSE P2 200D/200M
FUSE P1 200G/200L
FUSE P4 200E/200R
10 - 15 - 01/22 35
8
10
5
42 18
4
17
1
43 9
9
9
9
9
41 HOURMETER
TACHOMETER
FUEL SENDER
Backhoe Loaders
2
3
011
FUSE P3
7110 - C/7-16.1
ILLUMINATION
-
408
WATER TEMP SENDER
2CX, 2DX and Variants
9
47
U
409
46
TACHOMETER
45 -
FUEL GAUGE
401
FLASHER UNIT
RH REAR INDICATOR
RH FRONT INDICATOR
LH REAR INDICATOR
LH FRONT INDICATOR
HAZARD SWITCH
JUNCTION BOX
FRONT HORN
FRONT WIPER
FRONT WASHER PUMP
FACE LEVEL FAN
INTERIOR LIGHT
HEATER/AIR CON CONNECTOR
REAR WIPER
REAR WASHER PUMP
E.S.O.S.
RH BRAKE LIGHT
LH BRAKE LIGHT
COMPRESSOR SOLIENOID
COMPRESSOR CONNECTOR
PARKBRAKE
DUMP SWITCH (LOADER)
DUMP SWITCH (GEAR)
REVERSE ALARM
REVERSE SOLENOID
REVERSE RELAY
FORWARD SOLENOID
FORWARD RELAY
IGNITION RELAY 1
NEUTRAL START RELAY
STARTER SOLENOID
STARTER MOTOR
BATTERY
THERMOSTART
44
+
C2
6 WATER TEMP GAUGE
U
49
31
12 13
+
2 49a
9
802
806
806
37
804
7
FLASHER RELAY
32 805
31
300
33
36 INDICATOR SWITCH
30
FUSE C4
FRONT W/W SWITCH
104
27 805
303
34 38
FUSE A3
23 HAZARD SWITCH
8
JUNCTION BOX
M
803
3
814
26
841
M
FUSE A1
1
840
839
9
FRONT HORN SWITCH
864
24 25
101
6
HEATER/AIR CON CONNECTOR
862
10
FUSE B2
2
110
110
5
303
863
10
FUSE C5
6
28
829
816
952
22
FUSE C8
102
14 105
19
REAR WASH/ WIPE SWITCH
9 COMPRESSOR CONNECTOR
18
829
103
3 7
936
17
FUSE B5
1 5 8 8
21
FUSE A2
15 2
FUSE A8
6
967
20
FUSE B6
2 10 7
933
4
11 934
1
126
BRAKE LIGHTS SWITCH
810 953
4
REVERSE RELAY
811
812
2
121
8 6
934
8 9
TRANS DUMP RELAY
1 7
PARKBRAKE RELAY
10
912
808
809
4
401
R
N
FORWARD RELAY
BATTERY
16
FUSE A6
FUSE A4
107
842
3
122
FUSE A5
8 2
IGNITION RELAY 1
002
2 5
200
FOR / REV SWITCH F
NEUTRAL START RELAY
4
FUSE C9
004
5 5
200C
200B
IGNITION SWITCH
003
3 6
M
FUSE C7
1 5
M
010
CONTENTS
10 - 15 - 01/22
From m/c no. 489724
Circuit Diagram - Electrical
40
29 39
412 407
805
401
49
829
7 007
50
48
828
828
106
806
804
830
5
001 011
110
BATTERY FEED
Issue 1
BATTERY FEED
10 - 15 - 01/23 70
51
5
73 2
8 4
007 6
828 2
4 2
6
5
8
6
4
1
5
6
3
74 2
76 2 8
7
8
2 8
83 2
84 5
3
79
77
6
5
2
837 837
834
87
3
2
830
829
837
834
835
89 90
830
829
834 836
1
833
FUSE C10
FUSE C2
3
FOG LT SWITCH
894
402
405
403
404
406
458
BRAKE PRESS SWITCH
92
93
7110 - C/7-18.1
RH SIDE LIGHT
RH TAIL LIGHT
DIPPER SOCKET
LH SIDE LIGHT
LH TAIL LIGHT
RH MAIN BEAM
LH MAIN BEAM
LH DIP BEAM
RH DIP BEAM
LIGHTS RELAY
FOG LIGHT
BEACON
REAR WORKING LIGHTS
FRONT WORKING LIGHTS
IGNITION RELAY 2
POWER SOCKET
REAR HORN
RADIO SOCKET
ALTERNATOR
AIR FILTER VAC. SWITCH
TRANS OIL PRESS SWITCH
ENGINE OIL PRESS SWITCH
TRANS OIL TEMP SWITCH
WATER TEMP SWITCH
2CX, 2DX and Variants
FUSE A10
81
FUSE A9
17
862
7
DIP/MAIN BEAM SWITCH
FUSE C1
BEACON SWITCH
861
861
8
1
828
4
832
5 3
R/W/L SWITCH
401 3
ROAD LIGHTS SWITCH
2
117
1
855
68
311
8
855
805 7
127
106 3
78 88
FUSE C3
011 312
59 7
116
67 F/W/L SWITCH
871
72 82
ROAD LIGHTS RELAY
66
REAR HORN SWITCH
BUZZER
57 6
H/LIGHT FLASH
AIR FILTER
TRANS OIL PRES
2
80
FUSE B8
829 ENGINE OIL PRES
6
314
60 61 62 63 64 65
TRANS OIL TEMP
WATER TEMP
71
FUSE B10
SIDE CONSOLE INSTRUMENTS 10
75
FUSE B7
7 11
011
9 9
309
7 12
310
8
58
HAND BRAKE
W
FUSE B9
6 ALTERNATOR
56 18
011
2 FRONT W/L
55
REAR FOG
407
LINK REQUIRED FOR UK BUILD
54
REAR W/L
53 3
IGNITION RELAY 2
3 16
114
MAIN BEAM
52
HAZARD WARNING
411
FUSE B4
5 1
118
TURN SIGNAL
4
FUSE B3
12 SIDE LIGHRS
407
304
LIGHTS
412
FUSE C6
106
FRONT CONSOLE INSTRUMENTS 2 W STEER
11
FUSE B1
MASTER
69 M
9804/1103 WARNING
CONTENTS
Backhoe Loaders 10 - 15 - 01/23
From m/c no. 489724
Circuit Diagram - Electrical (cont’d)
91 95
94
7
5
7
806
86
804
830
4
85
1
110
200D/200M
200G/200L
200E/200R
Issue 1
CONTENTS
Backhoe Loaders
2CX, 2DX and Variants
10 - 15 - 01/24
From m/c no. 489724
Circuit Diagrams - Electrical (Cont’d) Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Thermostart Battery Starter motor Starter relay Neutral start relay Ignition switch Ignition relay 1 Forward/Reverse switch Forward relay Forward solenoid Reverse relay Reverse solenoid Reverse alarm Transmission dump relay Parking brake relay Gear lever dump switch Loader lever dump switch Parking brake switch Compressor connector Compressor solenoid LH brake light RH brake light Brake lights switch Engine shut off solenoid (E.S.O.S.) Rear washer pump Rear wiper motor Rear wash/wipe switch Heater/air con. connector Interior light switch Face level fan Front washer pump Front wiper motor Front wash/wipe switch Front horn Front horn switch Junction box LH front indicator LH rear indicator RH front indicator RH rear indicator Indicator switch Hazard switch Flasher relay Water temperature sender Water temperature gauge Fuel level sender Fuel gauge Tachometer Hourmeter Panel illumination Front instrument console Turn signals lamp Side lights lamp Main beam lamp Hazard warning lamp Rear work lights lamp Front work lights lamp Rear fog lights lamp Side instrument console Alternator ‘no charge’ lamp
9804/1103
61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95
Parking brake warning lamp Engine coolant temperature warning lamp Transmission oil temperature warning lamp Engine oil low pressure warning lamp Transmission oil low pressure warning lamp Air filter blocked warning lamp Buzzer Alternator Radio socket Rear horn switch Rear horn Auxiliary power connector Ignition relay 2 Front worklights switch Front worklights Front worklights relay Rear worklights switch Rear worklights Rear worklights relay Beacon Beacon switch Fog light Fog light switch Headlight flash switch Road lights relay Road lights switch Dip/main beam switch RH dipped beam LH dipped beam LH main beam RH main beam LH tail light LH side light RH tail light RH side light
10 - 15 - 01/24
7110 - C/7-17.1
Issue 1
FUSE P2
FUSE P1
FUSE P4
9804/1103 4
1 2
6 6 2
9 8 7 3 4 5 6
8 5
10 - 15 - 01/25 31
14 3 4
2 6
5 8
7
39 2
8
10
5
41 18
4
17
1
C2
31
6
411
FLASHER RELAY
49
49a
806
806
805
44
802
38 INDICATOR SWITCH
303
40
300
8
FRONT HORN SWITCH
814
45
FUSE C4
1
HEATER FAN MOTOR
18
804
4
805
7
841
839
M
104
3
840
864
FLASHER UNIT
RH REAR INDICATOR
RH FRONT INDICATOR
LH REAR INDICATOR
LH FRONT INDICATOR
HAZARD SWITCH
FRONT HORN
FRONT WIPER
FRONT WASHER PUMP
FACE LEVEL FAN
INTERIOR LIGHT
HEATER
AIR CON CONNECTOR
REAR WIPER
REAR WASHER PUMP
E.S.O.S.
RH BRAKE LIGHT
LH BRAKE LIGHT
JUNCTION BOX
PARKBRAKE
DUMP SWITCH (LOADER)
DUMP SWITCH (GEAR)
REVERSE ALARM
REVERSE SOLENOID
REVERSE RELAY
FORWARD SOLENOID
FORWARD RELAY
IGNITION RELAY 1
NEUTRAL START RELAY
STARTER SOLENOID
STARTER MOTOR
BATTERY
THERMOSTART
212SU
FUSE A3
23
HAZARD SWITCH
1
36
803
6
34
FUSE B2
27
32 FRONT W/W SWITCH
20
30 HEATER RESISTOR
862
891
29
110
8 2
800B
863
PARKBRAKE SWITCH
M
M
110
5
303
800
7
33
FUSE C5
2
102
892 3
HEATER SWITCH
5 1
26 28
FUSE C8
810 6
829
6
19
829
4
103
6
25
REAR WASH/ WIPE SWITCH
22
105
15 10
816
6
FUSE A8
5 8
FUSE B5
3 8 9 2
FUSE A2
1 5 7
933
10 7
24
FUSE B6
BRAKE LIGHTS SWITCH
2 1
126
4
21
FUSE A1
11 936
13
PTO SWITCH
6
815
8 9
17
101
122
1 7
REVERSE RELAY
16
936
10
934
4
TRANS DUMP RELAY
967 PARKBRAKE RELAY
811
812
2
912
808
809
FORWARD RELAY
3
FUSE A4
8 824
R
8
N
F
2 3
411
107
5 2
IGNITION RELAY 1
FUSE A5
842
9 5
200
002
FOR / REV SWITCH
5 NEUTRAL START RELAY
4
FUSE C9
004
BATTERY
1
200C
200B
IGNITION SWITCH
003
10
M
FUSE C7
1
M
010
CONTENTS
Backhoe Loaders 10 - 15 - 01/25
From m/c no. 489724
Circuit Diagram - Electrical
12 47
35 46
37
805
411
42
43
828
2
828
3
806
804
7 829
007
011
001 011
FUSE P3 110
200D/200M BATTERY FEED
200G
200E/200R
7110 - C/7-19.1
Issue 1
BATTERY FEED
10 - 15 - 01/26 2
8 4
007 6
6 8 6
5 4
70 6
71 2
2
8
74 8
73
69
7 2
80 81
5
3
2
837
87
3
5 2
830
829
834 836
86 830
829
85
FUSE A10
2
833
1
FUSE C10
3
FUSE A9
8
DIP/MAIN BEAM SWITCH
1
828
5 3 8
ROAD LIGHTS SWITCH
1 7
84
311
2 6
832
4 3
FUSE C2
76 FOG LT SWITCH
835
7
127
6
862
894
402
405
403
FUEL SENDER
FOG LIGHT
89
88 90
7110 - C/7-21.1
RH SIDE LIGHT
Backhoe Loaders
RH TAIL LIGHT
DIPPER SOCKET
LH SIDE LIGHT
LH TAIL LIGHT
RH MAIN BEAM
LH MAIN BEAM
LH DIP BEAM
RH DIP BEAM
LIGHTS RELAY
BEACON
REAR WORKING LIGHTS
FRONT WORKING LIGHTS
IGNITION RELAY 2
RADIO SOCKET
ALTERNATOR
AIR FILTER VAC. SWITCH
TRANS OIL PRESS SWITCH
ENGINE OIL PRESS SWITCH
TRANS OIL TEMP SWITCH
WATER TEMP SWITCH
BRAKE PRESS SWITCH
TACHOMETER
WATER TEMP SENDER
212SU
FUSE C3
011 312
828 2
FUSE C1
411
BEACON SWITCH
805 7
79
FUSE B8
5 5
861
W
77
ROAD LIGHTS RELAY
4
3
H/LIGHT FLASH
FRONT CONSOLE INSTRUMENTS 6
861
407
R/W/L SWITCH
66 855
855
67
314
116
59 60 61 62 63 64 65
F/W/L SWITCH
14
BUZZER
17
AIR FILTER
8
TRANS OIL PRES
404
68
FUSE B10
117
TRANS OIL TEMP
9
ENGINE OIL PRES
406
458
408
72
FUSE B7
829 12 13
011
54 11
WATER TEMP
55 56 57 58
HAND BRAKE
10
309
2 ALTERNATOR
411
FUSE B9
011
3 MASTER WARNING LIGHTS
9
1
310
5 MAIN BEAM
9
412
IGNITION RELAY 2
52 53 HAZARD WARNING
9
HOURMETER
407
304
51 TURN SIGNAL
9
4 8
FUSE C6
106
9
411
FUSE B1
49 TACHOMETER
FUEL GAUGE
409
50
ILLUMINATION
-
U
WATER TEMP GAUGE
48
9
+
-
U
CONTENTS
M
9804/1103 +
CONTENTS CONTENTS
10 - 15 - 01/26
From m/c no. 489724
Circuit Diagram - Electrical (cont’d)
92
75
91
78
7
83
5
7
806
82
804
4
1
110
200D/200M
200G
200E/200R
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
212SU
10 - 15 - 01/27
From m/c no. 489724
Circuit Diagrams - Electrical (cont’d) Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Thermostart Battery Starter motor Starter relay Neutral start relay Ignition switch Ignition relay 1 Forward/reverse switch Forward relay Forward solenoid Reverse relay Reverse solenoid Reverse alarm Transmission dump relay Parking brake relay Gear lever dump switch Loader lever dump switch Parking brake solenoid Parking brake switch Power take-off switch P.T.O. solenoid Junction box Brake light switch LH brake light RH brake light Engine shut off solenoid (E.S.O.S.) Rear wash/wipe switch Rear washer pump Rear wiper motor Air conditioning connector Heater switch Heater resistor Heater fan motor Interior light Face level fan Front washer pump Front wiper motor Front wash/wipe switch Front horn switch Front horn Hazard switch Indicator switch Flasher relay LH front indicator LH rear indicator RH front indicator RH rear indicator Water temperature sender Water temperature gauge Fuel level sender Fuel gauge Tachometer Hourmeter Front instrument console Turn signals lamp Hazard warning lamp Main beam lamp Master warning lamps Alternator ‘no charge’ lamp Parking brake warning lamp
9804/1103
61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92
Engine coolant temperature warning lamp Transmission oil temperature warning lamp Engine oil low pressure warning lamp Transmission oil low pressure warning lamp Air filter blocked warning lamp Buzzer Alternator Radio socket Ignition relay 2 Front worklights relay Front worklights switch Front worklights Rear worklights relay Rear worklights switch Rear worklights Beacon switch Beacon Fog light switch Fog light Headlight flash switch Road lights relay Road lights switch Dip/main beam switch RH dip beam LH dip beam LH main beam RH main beam LH tail light LH side light Dipper socket RH tail light RH side light
10 - 15 - 01/27
7110 - C/7-20.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
10 - 15 - 02/1
Electrical Circuit Options and Variations Electrical Pick-up Hitch
+ -
Battery Starter Switch Flasher Unit Hazard Warning Light Diode Direction Indicator Switch Direction Indicator Light Right Hand Indicator Light - Front Right Hand Indicator Light - Rear Left Hand Indicator Light - Front Left Hand Indicator Light - Rear Rear Brake Lights Rear Brake Light Switch Trailer Brake Lights Trailer Indicator Warning Buzzer Right Hand Trailer Indicator Light Left Hand Trailer Indicator Light Diverter Switch † Diverter Solenoid Valve †
1 2
10 203
101AL
C6
B6
A1
A6
107
211
223 217
922
101AM
45
600GC
243
239
238
946
236
70
† The auxiliary hydraulic control lever operates either the auxiliary loader service (e.g. 6-in-1 clamshovel) or the trailer hitch ram. Diverter switch 107 must be in the ON position to operate the hitch ram.
237
1 2 46 47 48 49 50 51 52 53 54 69 70 103 104 105 106 107 108
48 46
49
255
410
455
50 253
815
816
816J
806L
849 853
47
853
851
805K
600GD
850
108
104
53 51
69
9804/1103
10 - 15 - 02/1
633 637
649
7110 - C/7-7.1
649
648
105
638
648
639
54 52
600GE
106
103
Issue 1
Backhoe Loaders
CONTENTS
10 - 15 - 02/2
2CX, 2DX, 212SU Electrical Circuit Options and Variants
From m/c no. 489724
Worklights Circuit - German/Italian Builds Main Components
RH SIDE LIGHT
RH TAIL LIGHT
DIPPER SOCKET
LH SIDE LIGHT
LH TAIL LIGHT
14 13
12
11
RH MAIN BEAM
RH DIP BEAM
LIGHTS RELAY
REAR WORKING LIGHTS
Right hand dip beam Left hand dip beam Left hand main beam Right hand main beam Left hand rear light Left hand side light Dipper socket Right hand tail light Right hand side light
LH MAIN BEAM
11 12 13 14 15 16 17 18 19
LH DIP BEAM
Front worklights relay Front worklights switch Front worklights Rear worklights relay Rear worklights switch Rear worklights Headlights flash switch Road lights relay Road lights switch Dip/main beam switch
FRONT WORKING LIGHTS
1 2 3 4 5 6 7 8 9 10
19
16
830
829 837
18
829
830
837
15
FUSE C10
834
TO INST PANEL
836
834
FUSE C2
861
861
855
855
6
833
3
837
834
17
3
7
2
5
5
8
10
5
2
4
832
117 4
5
2
4
4
6
3
7
8
011
6
011
8
ROAD LIGHTS SWITCH
1 6
FUSE A9
1
FUSE A10
6
2
828
4
5
DIP/MAIN BEAM SWITCH
TO INST PANEL
7
R/W/L SWITCH
3
116
2
F/W/L SWITCH
TO FOG LT SW 6
5
TO HAZARD SW
9
2
TO INST PANEL
SW ILUMINATION
311
127 ROAD LIGHTS RELAY
H/LIGHT FLASH
FUSE B7
309
310
FUSE B9
7
5
4
2
3
1
8 FUSE B8
110 FEED
FUSE P4
FUSE C3
312
011 IGN FEED
LINK NOT REQUIRED ON GERMAN/ITALIAN BUILDS
TO INST PANEL
FUSE P1
A363450
9804/1103
10 - 15 - 02/2
7110 - C/7-22.1
Issue 1
Backhoe Loaders
CONTENTS
10 - 15 - 02/3
2CX, 2DX, 212SU Electrical Circuit Options and Variants
From m/c no. 489724
Heater Circuit
Heater/Air Conditioning Circuit
Main Components
Main Components
1 2 3
1 2 3 4 5 6 7 8 9
HEATER
AIR CON.
Heater switch Air conditioning switch Heater resistor Heater fan motor Freeze valve switch Air conditioning relay Low pressure switch High pressure switch Compressor clutch
HEATER
Heater switch Heater resistor Heater fan motor
HIGH PRESS SWITCH
965
M
9
7
4
M
M
964
961
3
LOW PRESS SWITCH
HEATER FAN MOTOR
8
2
6
HEATER RESISTOR
962
5
6
3
8
800
2
2
800E
5
800A
8
2
1
7
AIR CON SWITCH
4
800B
HEATER SWITCH
1
3
AIR CON RELAY
FREEZE VALVE
HEATER RESISTOR
800
3
7
1
5
963
800B
4
800B
2
3
1
B4
B3
A4
C1
FUSE C8
A363460
9804/1103
600
B1
829
1
102
600
FUSE C8
829
102
HEATER SWITCH
B5
10 - 15 - 02/3
A363470
7110 - C/7-23.1
Issue 1
CONTENTS
Backhoe Loaders
10 - 15 - 02/4
2CX, 2DX, 212SU Electrical Circuit Options & Variations
Later Machines
Compressor Circuit - 2CX, 2DX
Radio Circuit
Main Components
Main Components
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3
Radio unit Loudspeaker Loudspeaker
RADIO
AIR DELIVERY TEMP SW
AIR RECIEVER TEMP SW
AIR FILTER SW
COMPRESSOR HOURMETER
COMPRESSOR TEMP GAUGE
COMPRESSOR SOLENOID
COMPRESSOR TEMP SENDER
Stop/Start button Start button Compressor start relay Compressor shut-down relay Compressor interlock relay Compressor hourmeter Compressor temperature sender Compressor temperature gauge Air filter blocked switch Air receiver temperature cut-out switch Air delivery temperature cut-out switch Compressor solenoid (already fitted)
12 7
602
2
-
860
+
952
8
U
1
6
3
4
511
2
952
9 10 11
7
9
601
3 2
4
3
9804/1103
FUSE A6
PARKBRAKE LIGHTS RELAY
A363480
10 - 15 - 02/4
304
121
STOP/START SWITCH
953
1
1
157
2
START BUTTON
3
959
FUSE C6
5
600
3
600
4 2 1
COMPRESSOR START RELAY
5
2
4
COMPRESSOR SHUTDOWN RELAY
951
859
459
459
6
955
8
1 459
5
COMPRESSOR INTERLOCK RELAY
10
A363490
7110 - C/7-24.1
Issue 1
CONTENTS
Backhoe Loaders
10 - 15 - 02/5
2CX, 2DX, 212SU Electrical Circuit Options & Variations Hand Held Hydraulic Tools Circuit
Hydraclamp Circuit
Main Components
Main Components
Main Components 1 2
Selector switch Actuating solenoid
HAND HELD TOOLS SOLENOID
Hammer relay Hammer solenoid Hammer ON/OFF switch
HAMMER SOLENOID
1 2 3
1 2
Selector switch Actuating solenoid
HYDROCLAMP SOLENOID
Hammer Circuit
Later Machines
8
2
2
801
2
966
801
3
3
7
899
1
1
3
1
7
1
8
8
A364130
9804/1103
600
829
AUXILIARY FEED SKT
600
829
101
FUSE A1
FUSE A1
FUSE A1
101
600
AUXILIARY FEED SKT
1
101
HAMMER RELAY
2
2
A364140
10 - 15 - 02/5
A364150
711 0 - C/7-25.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX, 210S
10 - 20 - 01/1
From m/c no. 655000 to 656500
Circuit Diagrams - Hydraulic Component Key T S P 1A
Tank Suction Line Pump
23 24 25 30 31 32 33 34 35 36 37 38 39 50 51 52 53
Neutral Circuit Lines 1B 2 X 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 3K 3L 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4R 4S 4T 4U 4V 4W 4X 4Y 4Z 4AA 4AB 4AD 5 6 6A 7 8 8A 20 21 22
Priority Valve To Steering Circuit Loader Valve Block Loader Shovel Ram Spool Loader Lift Ram Spool Auxiliary Ram Spool Main Relief Valve Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Load Hold Check Valves Auxiliary Ram Head Side A.R.V. Auxiliary Ram Rod Side A.R.V. Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Hydraclamp Valve Slew A.R.V. Slew A.R.V. Boom Ram Head Side A.R.V. Boom Ram Rod Side A.R.V. Dipper Ram Rod Side A.R.V. Dipper Ram Head Side A.R.V. Bucket Ram Head Side A.R.V.
Shovel Ram L.H. Lift Ram R.H. Lift Ram L.H. Hydraclamp Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram Dipper Ram Bucket Ram Breaker Ram Bi-Restrictor Bi-Restrictor Bi-Restrictor Bi-Restrictor
Note: Excavator services shown here are to the JCB 'X' control pattern.
Load Hold Check Valves
Bucket Ram Rod Side A.R.V. Breaker Spool Breaker Ram Head Side A.R.V. Auxiliary Ram A.R.V. (Not used with Rock Breaker) Load Hold Check Valve Blanking Plug Suction Strainer Filter Filter By-pass Valve Cooler Pressure Test Connector (prior to Machine No. 655604 Pressure Test Connector (from Machine No. 655604 Auxiliary Ram R.H. Auxiliary Ram L.H. Shovel Ram R.H.
9804/1103
10 - 20 - 01/1
Issue 3
CONTENTS CONTENTS
Backhoe Loaders
10 - 20 - 01/2
2CX, 210S
From m/c no. 655000 to 656500
Circuit Diagrams - Hydraulic
S9808/9047-1
9804/1103
10 - 20 - 01/2
10 - 20 - 01/2
Issue 3
Backhoe Loaders
CONTENTS CONTENTS
10 - 20 - 01/3
2CX, 210S
From m/c no. 657001 to 658960
Circuit Diagram - Hydraulic
20
26 27
11
21 4
1 5
4A
4W 4H
10 L
R
2
19
3
9B
4W 4B
7
4J 4L
3A 24
8
3E
19
3F
4W 3J
LS
6
28
19
22
4K
4C
9
6A
9A T
P
3B
4D
30
4W
31
29 3J
13 15
17
4E
3C
25 3G 3D
14
3J 4W
23
8
19 4M 4R
4F
3H
4N
4W
18
16
4W
27
4P 4T
4S
14 8
12
32
12
4V 4U
1
4G 12
33
A210610 9804/1103
10 - 20 - 01/3
7110 - E/2-2.6
Issue 4*
CONTENTS CONTENTS
Backhoe Loaders
2CX, 210S
10 - 20 - 01/4
From m/c no. 657001 to 658960
Circuit Diagrams - Hydraulic Component Key
Rams
1 2 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4R 4S 4T 4U 4V 4W 5 6 6A 7 8 9 9A 9B 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32 33
Tank Pump and Priority Valve Loader Valve block (2 or 3 Spool) Loader Shovel Ram Spool Loader Lift Ram Spool with Float Auxiliary /Quick Hitch Ram Spool Main Relief Valve Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Auxiliary /Quick Hitch Ram Head Side A.R.V. Auxiliary /Quick Hitch Ram Rod Side A.R.V. Load Hold Check Valves Excavator Valve Block (6 or 7 Spool) Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Hydraclamp Valve Slew A.R.V. Slew A.R.V. Boom Ram Head Side A.R.V. Boom Ram Rod Side A.R.V. Dipper Ram Rod Side A.R.V. Dipper Ram Head Side A.R.V. Bucket Ram Head Side A.R.V. Bucket Ram Rod Side A.R.V. Auxiliary /Breaker Spool Auxiliary/ Breaker Ram Head Side A.R.V. Auxiliary Ram A.R.V. (Not used with Rockbreaker) Blanking Plug (see note 2) Load Hold Check Valves Suction Strainer Filter Filter By-pass Valve Cooler Pressure Test Connectors Steer Valve Steer Relief Valve Steer Shock Valves Steering Alignment Valve Auxiliary Attachment Quick Release Couplings Rockbreaker Quick Release Couplings Brakes Charge Valve Accumulators Brake Valve Pressure Warning Switch Front Brakes Rear Brakes Bi-restrictor Hydraulic Quickhitch Quickhitch Locking Tap
9804/1103
Shovel Ram R.H. Shovel Ram L.H. Lift Ram R.H. Lift Ram L.H. Hydraclamps Stabiliser Rams Slew Rams Boom Ram Dipper Ram Bucket Ram Rockbreaker Extending Dipper
Note 1: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 4B, 4L and 4K swap positions with items 4E, 4M and 4N respectively. Note 2: Blanking plug 4V is used when only the hammer circuit is installed (the hammer return line goes straight back to the hydraulic tank).
10 - 20 - 01/4
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
10 - 20 - 01/5
2CX, 2CXL, 210S, 210SL Circuit Diagrams - Auxiliary Hand Held Tools Component Key 1 2 3 4 5 6 7 8 9
Hydraulic Tank Pump Loader Valve Block Filter Excavator Valve Block B.H.T.M.A. Class 'C' Quick Release Couplings Auxiliary Tool Switch Priority Flow Divider Hi-flow Return Line
4 1 5 9
2 6 8 3
7
A173420 A173420
9804/1103
10 - 20 - 01/5
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX, 2DX
10 - 20 - 02/1
From m/c no. 658961
Circuit Diagram - Hydraulic Component Key 1 2 2A 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4W 5 6 6A 7 8 9 9A 9B 10 11 12 13 14 15 16 17 18 19 20 21
Tank Main Pump Auxiliary Pump Loader Valve block (2 or 3 Spool) Loader Shovel Ram Spool Loader Lift Ram Spool with Float Auxiliary /Quick Hitch Ram Spool Main Relief Valve Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Auxiliary /Quick Hitch Ram Head Side A.R.V. Auxiliary /Quick Hitch Ram Rod Side A.R.V. Load Hold Check Valves Excavator Valve Block (6 or 7 Spool) Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Hydraclamp Valve Slew A.R.V. Slew A.R.V. Boom Ram Head Side A.R.V. Boom Ram Rod Side A.R.V. Dipper Ram Rod Side A.R.V. Dipper Ram Head Side A.R.V. Bucket Ram Head Side A.R.V. Load Hold Check Valves Suction Strainer Filter Filter By-pass Valve Cooler Pressure Test Connectors Steer Valve Steer Relief Valve Steer Shock Valves Steering Alignment Valve Auxiliary Attachment Quick Release Couplings Rockbreaker Quick Release Couplings Brakes Charge/Priority Valve Accumulators Brake Valve Pressure Warning Switch Front Brakes Rear Brakes Bi-restrictor Hydraulic Quickhitch Quickhitch Locking Tap
9804/1103
Rams 22 23 24 25 26 27 28 29 30 31 32 33 33A 33B * 34 * 35 * 36
Shovel Ram R.H. Shovel Ram L.H. Lift Ram R.H. Lift Ram L.H. Hydraclamps Stabiliser Rams Slew Rams Boom Ram Dipper Ram Bucket Ram Rockbreaker Breaker Valve Solenoid Check Valve Check Valve Front Steer Ram Rear Steer Ram
Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 4B, 4L and 4K swap positions with items 4E, 4M and 4N respectively.
10 - 20 - 02/1
3270 - F/1-3.1
Issue 4*
Backhoe Loaders
CONTENTS CONTENTS
10 - 20 - 02/2
2CX, 2DX, 210S, 212S
From m/c no. 658961
Circuit Diagram - Hydraulic
26 27 10 L
R
9B
1 5
4
8 20
2A 36
4A
4W 4H
35 22
21
11 19
3
LS
4W
4J 4L
4B
9 7 2
3A
9A
8
24
3E
3F
13
S
19
T
P
G1
4W 3J
6A 4D
3B G2
T
LS
A1
30
4W
31
29
16 3J
P
4K
4C
6
EF
28
19
4E
4W
4N
A2
3C
25 15 8
3G 17
3D
14
19
4W 4M
4F
3H 3J
18 8
27
4P
23
14
4G
34
33A 33 33B
9804/1103
10 - 20 - 02/2
32
7110 - E/2-2.6
CONTENTS
12
Issue 4*
Backhoe Loaders
CONTENTS CONTENTS
10 - 20 - 02/3
2CXL, 210SL, 2CXFM
From m/c no. 657001
Circuit Diagrams - Basic Machine Component Key 1 2 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 5 6 6A 7
8 9 9A 9B 10 11 13 14 15 16 17 18 20 21 22 23 24 25 40
Tank Pump and Priority Valve Loader Valve block (2 or 3 Spool) Loader Shovel Ram Spool Loader Lift Ram Spool with Float Auxiliary /Quick Hitch Ram Spool Main Relief Valve Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Auxiliary /Quick Hitch Ram Head Side A.R.V. Auxiliary /Quick Hitch Ram Rod Side A.R.V. Load Hold Check Valves Suction Strainer Filter Filter By-pass Valve Cooler
Pressure Test Connectors Steer Valve Steer Relief Valve Steer Shock Valves Steering Alignment Valve Auxiliary Attachment Quick Release Couplings Brakes Charge Valve Accumulators Brake Valve Pressure Warning Switch Front Brakes Rear Brakes Hydraulic Quickhitch Quickhitch Locking Tap Shovel Ram R.H. Shovel Ram L.H. Lift Ram R.H. Lift Ram L.H. Anti-cavitation Valve
40 C
V
20 21
P
5
10
11
1 22 L
R
3
9B
2 7
3A 24
8
3E
3F 3J
LS
6
9
6A
9A T
P
3B
3J
13 17
15
3C
25 3G
3H 3J
3D 18
16 14
23
8 14 8
A221000 A221000
9804/1103
10 - 20 - 02/3
Issue 3
Backhoe Loaders
CONTENTS CONTENTS
10 - 20 - 02/4
2CX, 212SU 9N. America only)
From m/c no. 657001
Circuit Diagram - Hydraulic 4 29 4A
4E
4G 28
4B
4G
27
4C
4F
40
4G 26
C
V
4D P
4G
10 31
32
5
30
1 22 R
L
3
9B
2 7
3A 3E
24
8
3F 3J
LS
6
9
6A
9A T
P
3B
3J
13 15
17
3C
25 3G
3H
3D
3J
18
16 14
23
8 14 8
11
20
9804/1103
10 - 20 - 02/4
21
7110 - E/2-6.2
Issue 1
CONTENTS CONTENTS CONTENTS
Backhoe Loaders
2CX, 212SU (N. America only)
10 - 20 - 02/5
From m/c no. 657001
Circuit Diagram - Hydraulic Component Key 1 Tank 2 Pump and Priority Valve 3 Loader Valve block (2 or 3 Spool) 3A Loader Shovel Ram Spool 3B Loader Lift Ram Spool with Float 3C Auxiliary /Quick Hitch Ram Spool 3D Main Relief Valve 3E Shovel Ram Head Side A.R.V. 3F Shovel Ram Rod Side A.R.V. 3G Auxiliary /Quick Hitch Ram Head Side A.R.V. 3H Auxiliary /Quick Hitch Ram Rod Side A.R.V. 3J Load Hold Check Valves 4 3 Point Hitch Valve Block 4A Lift/Lower/Float Spool 4B Pitch Spool 4C Tilt Spool 4D Auxiliary Spool 4E Lift ARV 4F Tilt ARV 4G Load Hold Check Valves 5 Suction Strainer 6 Filter 6A Filter By-pass Valve 7 Cooler 8 Pressure Test Connectors 9 Steer Valve 9A Steer Relief Valve 9B Steer Shock Valves 10 Steering Alignment Valve 11 Auxiliary Attachment Quick Release Couplings 13 Brakes Charge Valve 14 Accumulators 15 Brake Valve 16 Pressure Warning Switch 17 Front Brakes 18 Rear Brakes 20 Hydraulic Quickhitch 21 Quickhitch Locking Tap 22 Shovel Ram R.H. 23 Shovel Ram L.H. 24 Lift Ram R.H. 25 Lift Ram L.H. 26 Auxiliary Cylinder 27 Tilt Cylinder 28 Pitch Cylinder 29 Lift Cylinder 30 2/4 Wheel Steer Selector Valve 31 Front Steer Cylinder 32 Rear Steer Cylinder 40 Anti-cavitation Valve
9804/1103
10 - 20 - 02/5
7110 - E/2-7.2
Issue 1
CONTENTS CONTENTS CONTENTS
Backhoe Loaders
2CX, 210S
10 - 20 - 03/1
From m/c no. 655000 to 656500
Circuit Diagrams - Steering Component Key T S P 2 5 6 6A 7 8 8A 40 41 42 43 43A 43B 43C
Tank Suction Line Pump Priority Valve Suction Strainer Filter Filter By-pass Valve Cooler Pressure Test Connector (prior to Machine No. 655604) Pressure Test Connector (from Machine No. 655604) Front Steer Ram Rear Steer Ram Counterbalance Valve Steering Control Valve Shock Valve Relief Valve Non-return Valve
Note: Components T, S, P, 2, 5, 6, 6A, 7 and 8 are common to both the hydraulic circuit and the steering circuit.
S9808/9002-2
9804/1103
10 - 20 - 03/1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2CX, 2CXL, 210S, 210SL
10 - 20 - 03/2
From m/c no. 657001
Circuit Diagrams - Steering Component Key P S T X 5 8 40 41 42 43 43A 43B 43C 58
Pump and Priority Valve Suction Line Tank To Loader Valve Block Suction Strainer Pressure Test Connector Front Steer Ram Rear Steer Ram Steer Alignment Tap Steering Control Valve Shock Valve Relief Valve Non-return Valve Steer Load Sense Line
Note: Components P, S, T, 5 and 8 are common to both the hydraulic circuit and the steering circuit.
9804/1103
10 - 20 - 03/2
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
10 - 20 - 03/3
2CXAM
From m/c no. 657001
Circuit Diagram - Pneumatics Component Key 1 2 3 4 5 6 7 8
Air Reciever Hose Oil Cooler Hose Oil Filter Hose Compressor Hose
8 1
7
2
6
5
4
3
A213330
9804/1103
10 - 20 - 03/3
3270 - F/1-3.1
Issue 2*
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX, (200 Series)
15 - 00 - 01/1
From m/c no. 400001
General Information - Fluids, Lubricants and Capacities ITEM
CAPACITY Litres UK Gal
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
100
Diesel Oil
ASTM D975-66T Nos. 1D, 2D
JCB 15W/40 Multigrade -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104D
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30, MIL-L-2105, MIL-L-46152, API CD/SE, MIL-L-2104C
22
Engine (Oil) ➀ 2 Wheel Steer Machines - Build AA 9.7 - Build AA (Hot Climate) 11.0 - Build AB 10.0
2.1 2.4 2.2
4 Wheel Steer Machines - Build AB 10.0
2.2
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W, MIL-L-46152, MIL-L-2104D, API CD/SE
Engine (Coolant)
20.0
4.4
JCB Universal Antifreeze/water
ASTM D3306-74
Syncro Shuttle (2WD) ➁
15.75
3.5
JCB Special Transmission Fluid
ESP-M2C 33G
JCB Special Transmission Fluid
ESP-M2C 33G
Syncro Shuttle (4WD) ➁ 16.25 3.6 (machines up to serial number 431230) Syncro Shuttle (2WD) ➁
13.0
2.9
Syncro Shuttle (4WD) ➁ 14.0 3.1 (machines from serial number 431230) Powershift ➁
14.75
3.25
JCB Special Transmission Fluid
ESP-M2C 33G
13 18 2.0
2.86 3.96 0.44
JCB HD90 Gear Oil
API-GL-5 MIL-L-2105C
Rear Axle (AWS) Housing Hubs (x2)
18 2.0
3.96 0.44
JCB Special Gear Oil
ESEN-M2C 86A/B
Rear Axle (2WS)
23
5.0
JCB Special Gear Oil
ESEN-M2C 86A/B
Slew Gearbox
4.3
0.9
JCB HD90 Gear Oil
API-GL-5, MIL-L-2105C
Brake System - Standard
1.2
0.26
JCB Light Hydraulic Fluid
ISO VG15
- Servo
1.4
0.31
! CAUTION: DO NOT USE ORDINARY BRAKE FLUID
135
29.7
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F)
ISO VG46
JCB Hydraulic Fluid HP32 (Below 38 °C, 100 °F)
ISO VG32
Front Axle (4WD) Housing (2WS) Housing (AWS) Hubs (x2)
➅
Hydraulic System ➂
Air Conditioning System
1544 g
3.4 lb
Refrigerant
R134a
Boom Lock
1.0
0.22
JCB Light Hydraulic Fluid
ISO VG15
.
.............continued 9804/1103
15 - 00 - 01/1
Issue 3
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX, (200 Series)
15 - 00 - 01/2
From m/c no. 400001
General Information - Fluids, Lubricants and Capacities (cont’d) ITEM
CAPACITY Litres UK Gal
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Grease Points
---
JCB MPL Grease or JCB HP Grease ➃
Lithium based, No. 2 consistency.
Extending Dipper
---
Waxoyl ➄
Electrical connections
---
As a corrosion and moisture inhibitor all exposed connections should be coated liberally with petroleum jelly.
➀
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended. The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system. Figures quoted within ±0.5 litre (0.11 U.K. gal).
➁
Note: The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system. Figures quoted within ±1.0 litre (0.22 U.K. gal).
➂
Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level indicator on hydraulic tank.
➃
Note: JCB HP Grease is a high specification grease, in certain applications this grease must be used, for instance transmission bearings during an overhaul.
➄
! WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area. GEN-1-3
➅
Note: AWS axles with limited slip differential must use JCB Special Gear Oil.
9804/1103
15 - 00 - 01/2
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX and Variants
15 - 00 - 01/3
From m/c no. 460001
Lubricants and Capacities ITEM
CAPACITY FLUID/LUBRICANT Litres UK Gal
INTERNATIONAL SPECIFICATION
†Fuel Tank (with toolbox) 110 24.2 Diesel Oil ASTM D975-66T Nos. 1D, 2D †Fuel Tank (without toolbox) 150 33 Diesel Oil ASTM D975-66T Nos. 1D, 2D Fuel Tank (All later m/c’s) 130 28.6 Diesel Oil ASTM D975-66T Nos. 1D, 2D †Initial build machines only, all machines built after Feb. 1997 have a 130 litre (28.6 gal.) capacity tank.
*
Engine (Oil) ➀ 2 Wheel Steer Machines - Build AA - Build AA (Hot Climate) - Build AB
9.7 11.0 10
4 Wheel Steer Machines - Build AB
JCB 15W/40 Multigrade -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40 API CF4/SG
2.1 2.4 2.2
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30 API CE/SF
10.0
2.2
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W API CD/SF
2 Wheel Steer Machines - Build AR - Build AK
11.0 10
2.4 2.2
JCB Super Multigrade 15W/40 -10°C to +50°C (14°F to 122°F)
SAE15W/40 CF-4/SG
4 Wheel Steer Machines - Build AK
10.0
2.2
JCB Super Multigrade 10W/30 -15°C to +40°C (5°F to 104°F)
SAE10W/30 CF-4/SG
Engine (Coolant)
23.0
5.1
JCB Four Seasons Antifreeze & Summer Coolant/Water (see Coolant Mixtures)
ASTM D3306, BS6580
Syncro Shuttle (2WD) ➁
14.4
3.2
JCB Special Transmission Fluid
ESP-M2C 33G
Syncro Shuttle (4WD) ➁
15.4
3.4
Friction modified oils MUST NOT be used (eg. Dexron ATF type)
Powershift ➁
14.75 15.4
3.25 3.4
JCB Special Transmission Fluid ESP-M2C 33G Friction modified oils MUST NOT be used (eg. Dexron ATF type).
Front Axle (4WD) Housing (2WS) Housing (4WS) ➅ Hubs (x2)
13 18 2.0
2.86 3.96 0.44
Rear Axle (4WS) Housing Hubs (x2) Rear Axle (2WS)
18 2.0 23
3.96 0.44 5.0
Brake System - Standard
1.2
0.26
JCB Light Hydraulic Fluid
- Servo
1.4
0.31
! CAUTION: DO NOT USE ORDINARY BRAKE FLUID
130
28.6
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F)
ISO VG46
JCB Hydraulic Fluid HP32 (Below 38 °C, 100 °F)
ISO VG32
Hydraulic System ➂
9804/1103
JCB HD90 Gear Oil (without LSD) API-GL-5 JCB Special Gear Oil Plus (with LSD) API-GL-4 Must be suitable for use with limited slip differentials (LSD).
JCB Special Gear Oil Plus API-GL-4 Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
15 - 00 - 01/3
ISO VG15
3270 - 3/1-2.2
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 00 - 01/4
3CX, 4CX and Variants
From m/c no. 460001
Fluids, Lubricants and Capacities (Cont’d)
ITEM
CAPACITY FLUID/LUBRICANT Litres UK Gal
INTERNATIONAL SPECIFICATION
Grease Points consistency
---
Lithium
JCB HP Grease
complex
NLGI
No.2
including extreme pressure additives or JCB Special MPL-EP Grease ➃ Lithium based NLGI No.2 consistency including extreme pressure additives Extending Dipper
---
Waxoyl ➄
Electrical connections
---
As a corrosion and moisture inhibitor all exposed connections should be coated liberally with petroleum jelly.
Power Sideshift Chains
---
JCB Chain Lubricant
➀
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended. The figure quoted is TOTAL system capacity. Use the MIN and MAX marks onthe dipstick when filling the system. Figures quoted within ±0.5 litre (0.11 U.K. gal).
➁
Note: The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system. Figures quoted within ±1.0 litre (0.22 U.K. gal).
➂
Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level indicator on hydraulic tank.
➃
Note: JCB HP Grease is a high specification grease, in certain applications this grease must be used, for instance transmission bearings during an overhaul.
➄
!WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area. GEN-1-3
➅
Note: AWS axles with limited slip differential must use JCB Special Gear Oil.
9804/1103
15 - 00 - 01/4
3270 - 3/1-3.2
Issue 1
Backhoe Loaders
CONTENTS
214, 214E, 215, 215E, 217 (N. America)
15 - 00 - 01/5
From m/c no. 460001
Fluids, Lubricants and Capacities
ITEM
CAPACITY US Gal Liters
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
†Fuel Tank (with toolbox) †Fuel Tank (without toolbox) Fuel Tank (All later m/c’s)
29 39.6 34.3
110 150 130
Diesel Oil Diesel Oil Diesel Oil
ASTM D975-66T Nos. 1D, 2D ASTM D975-66T Nos. 1D, 2D ASTM D975-66T Nos. 1D, 2D
Engine (Oil) ➀ 2 Wheel Steer Machines - Build AA - Build AA (Hot Climate) - Build AB
2.6 2.9 2.7
9.7 11.0 10
JCB 10W or JCB 15W/40 Below 32 °F (0°C)
† API CF4/SG, † MIL-L-2104F
JCB 30W or JCB 15W/40 Above 32 °F (0°C)
† Note: spec given for 15W/40
4 Wheel Steer Machines - Build AB
2.7
10.0
2 Wheel Steer Machines - Build AR - Build AK
13.2 12.0
2.4 2.2
JCB 15W/40 Engine Oil -10°C to +50°C (14°F to 122°F)
SAE15W/40 CF-4/SG
4 Wheel Steer Machines - Build AK
12.0
2.2
JCB 10W Engine Oil -20°C to +10°C (-4°F to 50°F)
SAE10W CF-4/SG
Engine (Coolant)
6.07
23
Anti-freeze/Water
ASTM D3306-74
JCB Special Transmission Fluid
ESP-M2C 33G
Syncro Shuttle (2WD) ➁
3.2
14.4
Syncro Shuttle (4WD) ➁
3.4
15.4
Powershift ➁
3.9
14.75
JCB Special Transmission Fluid
ESP-M2C 33G
3.4 4.8 0.5
13 18 2.0
JCB GL-5 80W/90 JCB GL-5 85W/140
API-GL-5
Rear Axle (4WS) Housing Hubs (x2)
4.8 0.5
18 2.0
JCB Special Gear Oil Plus
API-GL-4
Rear Axle (2WS)
6.1
23
JCB Special Gear Oil Plus
API-GL-4
Brake System - Standard
0.32
1.2
Light Hydraulic Fluid
ISO VG15
- Servo
0.37
1.4
! CAUTION: DO NOT USE ORDINARY BRAKE FLUID
Hydraulic System ➂ Grease Points
34.3 ---
130
JCB Hydraulic Fluid JCB Moly EP # 2 Grease
Extending Dipper
---
Front Axle (4WD) Housing (2WS) Housing (4WS) Hubs (x2)
Electrical connections
---
➅
ISO VG46 Lithium based, No. 2
Waxoyl ➄ As a corrosion and moisture inhibitor all exposed connections should be coated liberally with petroleum jelly.
†Initial build machines only, all machines built after Feb. 1997 have a 34.3 gal. (130 liter) capacity tank.
Continued....... 9804/1103
15 - 00 - 01/5
3270 - 3/1-4.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
214, 214E, 215, 215E, 217 (N. America)
15 - 00 - 01/6
From m/c no. 460001
Fluids, Lubricants and Capacities (Cont’d) ➀
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended. The figure quoted is TOTAL system capacity. Use the MIN and MAX marks onthe dipstick when filling the system. Figures quoted within ±0.5 litre (0.11 U.K. gal).
➁
Note: The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system. Figures quoted within ±1.0 litre (0.22 U.K. gal).
➂
Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level indicator on hydraulic tank.
➃
Note: JCB HP Grease is a high specification grease, in certain applications this grease must be used, for instance transmission bearings during an overhaul.
➄
!WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area. GEN-1-3
➅
Note: AWS axles with limited slip differential must use JCB Special Gear Oil.
9804/1103
15 - 00 - 01/6
3270 - 3/1-2.2
Issue 1
Backhoe Loaders
CONTENTS
214e (N. America)
15 - 00 - 01/7
From m/c no. 460001
Fluids, Lubricants and Capacities NORTH AMERICAN MACHINES - 214e & 214Se ITEM
CAPACITY US Gal Liters
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
34.3
130
Diesel Oil
ASTM D975-66T Nos. 1D, 2D
Engine (Oil) ! 2 Wheel Steer Machines - Build AR
2.6
9.7
JCB 15W/40 -10°C to + 50°C (14°F to 122°F) JCB 10W -20°C to + 10°C (-4°F to 50°F)
CF 4/SG, SAE 15W/40 CF 4/SG, SAE 10W
Engine (Coolant)
6.07
23
Anti-freeze/Water
ASTM D3306-74
Syncro Shuttle (2WD) "
3.8
14.4
JCB Special Transmission Fluid
ESP-M2C 33G
Syncro Shuttle (4WD) "
4.0
15.4
Front Axle Housing (2WS) Hubs (x2)
3.4 0.5
13 2.0
JCB GL-5 80W/90
API-GL-5
Rear Axle
6.1
23
JCB Special Gear Oil Plus
API-GL-4
Brake System - Standard - Servo
0.32 0.37
1.2 1.4
Light Hydraulic Fluid ISO VG15 ! CAUTION: DO NOT USE ORDINARY BRAKE FLUID
Hydraulic System #
34.3
130
JCB Hydraulic Fluid
ISO VG46
Grease Points
---
JCB Moly EP # 2 Grease
Lithium based, No. 2
Extending Dipper
---
Waxoyl $
Electrical connections
---
As a corrosion and moisture inhibitor all exposed connections should be coated liberally with petroleum jelly.
!
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended. The figure quoted is TOTAL system capacity. Use the MIN and MAX marks onthe dipstick when filling the system. Figures quoted within ±0.5 litre (0.11 U.K. gal).
"
Note: The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system. Figures quoted within ±1.0 litre (0.22 U.K. gal).
#
Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level indicator on hydraulic tank.
*%
Note: JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing must be carried out more frequently. Continued.......
9804/1103
15 - 00 - 01/7
3270 - 3/1-6.2
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
214e (N. America)
15 - 00 - 01/8
From m/c no. 460001
Fluids, Lubricants and Capacities (cont’d) ➄
!WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area. GEN-1-3
➅
Note: AWS axles with limited slip differential must use JCB Special Gear Oil.
9804/1103
15 - 00 - 01/8
3270 - 3/1-5.1
Issue 1
Backhoe Loaders
CONTENTS * 3CX,
4CX and Variants
15 - 00 - 01/9
From m/c no. 930000
General Information - Service Capacities and Lubricants ITEM
CAPACITY FLUID/LUBRICANT Litres UK Gal
INTERNATIONAL SPECIFICATION
Fuel Tank
150
33
Diesel Oil
ASTM D975-66T Nos. 1D, 2D
2 Wheel Steer Machines - Build AR - Build AK
11.0 10
2.4 2.2
JCB Super Multigrade 15W/40 -10°C to +50°C (14°F to 122°F)
SAE15W/40 CF-4/SG
4 Wheel Steer Machines - Build AK
10.0
2.2
JCB Super Universal Agricultural -15°C to +40°C (5°F to 122°F)
SAE10W/30 CF-4/SG
Engine (Coolant)
23.0
5.1
JCB Four Seasons Antifreeze & Summer Coolant/Water (see Coolant Mixtures)
ASTM D3306, BS6580
Syncro Shuttle (2WD) ➁
14.4
3.2
JCB Extreme Performance
SAE10W
Syncro Shuttle (4WD) ➁
15.5
3.4
(Below 40°C, 104°F) JCB Extreme Performance
SAE10W
Engine (Oil) ➀
(Below 40°C, 104°F) Powershift 6 speed ➁
16
3.5
JCB Extreme Performance
SAE10W
Powershift 4 speed ➁
15.5
3.4
(Below 40°C, 104°F) JCB Extreme Performance
SAE10W
(Below 40°C, 104°F) Front Axle (4WD) Housing (2WS) Housing (4WS) ➅
JCB HD90 Gear Oil (without LSD) API-GL-5 JCB Special Gear Oil Plus (with LSD) API-GL-4 Must be suitable for use with limited slip differentials (LSD).
13 18
2.86 3.96
Hubs (x2)
2.0
0.44
Rear Axle (4WS) Housing Hubs (x2) Rear Axle (2WS)
18 2.0 23
3.96 0.44 5.0
Brake System
1.4
0.3
JCB Light Hydraulic Fluid ISO VG15 ! CAUTION: DO NOT USE ORDINARY BRAKE FLUID
Hydraulic System ➂
130
28.6
JCB High Performance Hydraulic Oil
JCB Special Gear Oil Plus API-GL-4 Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
ISO VG46
(Above 38 °C, 100 °F) JCB Hydraulic Fluid HP32 (Below 38 °C, 100 °F)
9804/1103
15 - 00 - 01/9
ISO VG32
3280 - 3/28-1.1
Issue 1*
Backhoe Loader
CONTENTS
15 - 00 - 01/10
3CX, 4CX and Variants
From m/c no. 930000
General Information - Service Capacities and Lubricants
ITEM
CAPACITY FLUID/LUBRICANT Litres UK Gal
INTERNATIONAL SPECIFICATION
Grease Points
---
Lithium based NLGI No.2 consistency including extreme pressure additives Lithium based NLGI No.2 consistency
JCB HP Grease or JCB Special MPL-EP Grease ➃
including extreme pressure additives Waxoyl ➄
Extending Dipper
---
Electrical connections
---
As a corrosion and moisture inhibitor all exposed connections should be coated liberally with petroleum jelly.
Power Sideshift Chains
---
JCB Chain Lubricant
➀
➁ ➂ ➃ ➄
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended. The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system. Figures quoted within +0.5 litre (0.11 UK gal). Note: The figure quoted us TOTAL system capacity. Use the MIN and MAX amrks on the dipstick when filling the system. Figures quoted within +1.0 litre (0.22 UK gal) Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level indicator on hydraulic tank. Note: JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing must be carried out more frequently !WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area. GEN-1-3
➅
Note: 4WS alxes with liited slup differential must use JCB Special Gear Oil Plus
Coolant Mixtures ! WARNING Antifreeze can be harmful. Obey the manufacturer’s instructions when handling neat or diluted antifreeze. 7-3-4-4
The protection provided by JCB Four Seasons Antifreeze and Summer Coolant is shown below. If any other antifreeze is used refer to the manufacturer’s instructions and ensure that a corrosion inhibitor is included. DO NOT use solutions of more than 60% or less than 50% or damage to the cooling system will occur. 55% Solution - Maintains circulation down to -36°C (-33°F), protects agains damage down to -41°C (-42°F) The strength of the antifreeze solution must be checked at least once a year, preferably at the beginning of the cold period. It is an advantage to leave the antifreeze in all year round as it gives continued protection against corrosion. Always renew the antifreeze every two years. A 50% antifreeze mixture must be used even if frost protection is not needed. This gives protection against corrosion and raises the coolant’s boiling point. It should be noted that serious damage to the cooling system can occur if corrosion inhibitors are not used.
9804/1103
15 - 00 - 01/10
3270 - 3/28-2.2
Issue 1*
Backhoe Loaders
CONTENTS CONTENTS
3CX (214) 4X4 SIDESHIFT
15 - 00 - 02/1
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
6.00m(19ft 8in)
B
Overall height
3.54m(11ft 7in)
C
Height to top of cab
2.84m(9ft 4in)
D
Wheelbase - 2WD
2.11m(6ft 11in)
- 4WD
2.17m(7ft 1in)
E
Minimum ground clearance
0.36m(1ft 2in)
F
Slew ground clearance
0.5m(1ft 8in)
G
Width
2.35m(7ft 8in)
J
Centreline of rear axle/centreline of kingpost
1.32m(4ft 4in)
H
Cabless build, Maximum fixed height
2.06m(6ft 9in)
C H F
E J
G
D A A163130
B A163130
G 9804/1103
15 - 00 - 02/1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
3CX (214) 4X4 CENTREMOUNT
15 - 00 - 02/2
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
7.08m(23ft 3in)
B
Overall height
3.54m(11ft 7in)
C
Height to top of cab
2.84m(9ft 4in)
D
Wheelbase - 2WD
2.21m(7ft 3in)
- 4WD
2.27m(7ft 5in)
E
Minimum ground clearance
0.36m(1ft 2in)
F
Slew ground clearance
0.50m(1ft 8in)
G
Width
2.35m(7ft 8in)
J
Centreline of rear axle/centreline of kingpost
1.22m(4ft 0in)
H
Cabless build, Maximum fixed height
2.06m(6ft 9in)
C H F
E J
D A
G
B A163140
G
9804/1103
15 - 00 - 02/2
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
4C (215) 4X4
15 - 00 - 02/3
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
7.47m(24ft 6in)
B
Overall height
3.89m(12ft 9in)
- with Extra-Dig
3.96m(13ft 1in)
C
Height to top of cab
2.84m(9ft 4in)
D
Wheelbase - 2WD
2.21m(7ft 3in)
- 4WD
2.27m(7ft 5in)
E
Minimum ground clearance
0.36m(1ft 2in)
F
Slew ground clearance
0.50m(1ft 8in)
G
Width
2.35m(7ft 8in)
J
Centreline of rear axle/centreline of kingpost
1.20m(3ft 11in)
H
Cabless build, Maximum fixed height
2.06m(6ft 9in)
C H F
E J
D A
G
B A163140
G
9804/1103
15 - 00 - 02/3
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
4CN (216) 4X4
15 - 00 - 02/4
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
7.44m(24ft 5in)
B
Overall height
3.73m(12ft 3in)
C
Height to top of cab
2.84m(9ft 4in)
D
Wheelbase - 2WD
2.21m(7ft 3in)
- 4WD
2.27m(7ft 5in)
E
Minimum ground clearance
0.36m(1ft 2in)
F
Slew ground clearance
0.50m(1ft 8in)
G
Width
2.24m(7ft 4in)
J
Centreline of rear axle/centreline of kingpost
1.20m(3ft 11in)
H
Cabless build, Maximum fixed height
2.06m(6ft 9in)
C H F
E J
D A
G
B A163150
G
9804/1103
15 - 00 - 02/4
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
3CX (214) 4X4 SITEMASTER (SIDESHIFT)
15 - 00 - 02/5
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
6.00m(19ft 8in)
B
Overall height
3.58m(11ft 9in)
C
Height to top of cab
2.84m(9ft 4in)
D
Wheelbase - 2WD
2.11m(6ft 11in)
- 4WD
2.17m(7ft 1in)
E
Minimum ground clearance
0.36m(1ft 2in)
F
Slew ground clearance
0.50m(1ft 8in)
G
Width
2.35m(7ft 8in)
J
Centreline of rear axle/centreline of kingpost
1.32m(4ft 4in)
H
Cabless build, Maximum fixed height
2.06m(6ft 9in)
C H F
G
E
J
D A
B A163160
G
9804/1103
15 - 00 - 02/5
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
3CX (214) 4X4 SITEMASTER (CENTREMOUNT)
15 - 00 - 02/6
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
7.59m(24ft 11in)
B
Overall height
3.58m(11ft 9in)
C
Height to top of cab
2.84m(9ft 4in)
D
Wheelbase - 2WD
2.21m(7ft 3in)
- 4WD
2.27m(7ft 5in)
E
Minimum ground clearance
0.36m(1ft 2in)
F
Slew ground clearance
0.50m(1ft 8in)
G
Width
2.35m(7ft 8in)
J
Centreline of rear axle/centreline of kingpost
1.32m(4ft 4in)
H
Cabless build, Maximum fixed height
2.06m(6ft 9in)
C H F
E J
D A
G
B A166290
G
9804/1103
15 - 00 - 02/6
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
HAMMERMASTER 4X4
15 - 00 - 02/7
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
6.00m(19ft 8in)
B
Overall height
3.54m(11ft 7in)
C
Height to top of cab
2.84m(9ft 4in)
D
Wheelbase - 2WD
2.11m(6ft 11in)
- 4WD
2.17m(7ft 1in)
E
Minimum ground clearance
0.36m(1ft 2in)
F
Slew ground clearance
0.50m(1ft 8in)
G
Width
2.35m(7ft 8in)
J
Centreline of rear axle/centreline of kingpost
1.32m(4ft 4in)
H
Cabless build, Maximum fixed height
2.06m(6ft 9in)
C H F
E J
G
D A A163130
B A163130
G 9804/1103
15 - 00 - 02/7
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
217
15 - 00 - 02/8
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
7.48m(24ft 6in)
B
Overall height
4.14m(13ft 7in)
- with Extra-Dig C
Height to top of cab
D
Wheelbase
4.22m(13ft 10in) 2.84m(9ft 4in)
- 2WD
2.26m(7ft 5in)
- 4WD E
Minimum ground clearance
0.36m(1ft 2in)
F
Slew ground clearance
0.50m(1ft 8in)
G
Width
2.44m(8ft 0in)
J
Centreline of rear axle/centreline of kingpost
Not available at print
H
Cabless build, Maximum fixed height
Not available at print
C H F
E J
D A
G
B A163140
G
9804/1103
15 - 00 - 02/8
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
4CX (214S) 4x4x4 (SIDESHIFT)
15 - 00 - 02/9
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
6.07m (19ft 11in)
B
Overall height
3.49m (11ft 5in)
C
Height to top of cab
2.78m (9ft 2in)
D
Wheelbase
2.22m (7ft 3in)
E
Minimum ground clearance
0.31m (1ft 0in)
F
Slew ground clearance
0.45m (1ft 6in)
G
Width
2.35m (7ft 8in)
H
Cabless build, Maximum fixed height
2.01m (6ft 7in)
J
Centreline of rear axle/centreline of kingpost
1.32m (4ft 4in)
C H F
E J
G
D A
B A162830
G 9804/1103
15 - 00 - 02/9
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
4CX (214S) 4x4x4 (CENTREMOUNT)
15 - 00 - 02/10
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
6.07m (19ft 11in)
B
Overall height
3.49m (11ft 5in)
C
Height to top of cab
2.83m (9ft 3in)
D
Wheelbase
2.32m (7ft 7in)
E
Minimum ground clearance
0.40m (1ft 4in)
F
Slew ground clearance
0.48m (1ft 7in)
G
Width
2.35m (7ft 8in)
H
Cabless build, Maximum fixed height
2.06m (6ft 9in)
C H F
E D A
G
B
A170890
9804/1103
15 - 00 - 02/10
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
4C (215S) 4x4x4
15 - 00 - 02/11
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
8.53m (28ft 0in)
B
Overall height
3.89m (12 ft 9in)
- with Extra-Dig
3.96 (13ft 1in)
C
Height to top of cab
2.82m (9ft 3in)
D
Wheelbase
2.32m (7ft 8in)
E
Minimum ground clearance
0.40m (1ft 4in)
F
Slew ground clearance
0.48m (1ft 7in)
G
Width
2.35m (7ft 8in)
H
Cabless build, Maximum fixed height
2.06m (6ft 9in)
C H F
E D A
G
B
A170890
9804/1103
15 - 00 - 02/11
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
4CN 4x4x4
15 - 00 - 02/12
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
8.53m (28ft 0in)
B
Overall height
3.89m (12 ft 9in)
C
Height to top of cab
2.82m (9ft 3in)
D
Wheelbase
2.32m (7ft 8in)
E
Minimum ground clearance
0.40m (1ft 4in)
F
Slew ground clearance
0.48m (1ft 7in)
G
Width
2.35m (7ft 8in)
H
Cabless build, Maximum fixed height
2.06m (6ft 9in)
C H F
E D A
G
B A171020
G
9804/1103
15 - 00 - 02/12
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
4CX (214S) 4x4x4 SITEMASTER (SIDESHIFT)
15 - 00 - 02/13
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
6.07m (19ft 11in)
B
Overall height
3.53m (11ft 7in)
C
Height to top of cab
2.78m (9ft 2in)
D
Wheelbase
2.22m (7ft 3in)
E
Minimum ground clearance
0.31m (1ft 0in)
F
Slew ground clearance
0.45m (1ft 6in)
G
Width
2.35m (7ft 8in)
H
Cabless build, Maximum fixed height
2.01m (6ft 7in)
J
Centreline of rear axle/centreline of kingpost
1.32m (4ft 4in)
C H F
G
E
J
D A
B A162850
G
9804/1103
15 - 00 - 02/13
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
4CX (214S) 4x4x4 SITEMASTER (CENTREMOUNT)
15 - 00 - 02/14
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
8.53m (28ft 0in)
B
Overall height
3.53m (11ft 7in)
C
Height to top of cab
2.78m (9ft 2in)
D
Wheelbase
2.32m (7ft 8in)
E
Minimum ground clearance
0.31m (1ft 0in)
F
Slew ground clearance
0.45m (1ft 6in)
G
Width
2.35m (7ft 8in)
H
Cabless build, Maximum fixed height
2.01m (6ft 7in)
J
Centreline of rear axle/centreline of kingpost
1.32m (4ft 4in)
C H F
E J
D A
G
B A170771
G
9804/1103
15 - 00 - 02/14
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
217S
15 - 00 - 02/15
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
9.14m(30ft 0in)
B
Overall height
4.19m(13ft 9in)
- with Extra-Dig
4.27m(14ft 0in)
C
Height to top of cab
2.87m(9ft 5in)
D
Wheelbase
2.32m(7ft 8in)
E
Minimum ground clearance
Not available at print
F
Slew ground clearance
0.43m(1ft 5in)
G
Width
2.44m(8ft 0in)
J
Centreline of rear axle/centreline of kingpost
Not available at print
H
Cabless build, Maximum fixed height
Not available at print
C H F
E J
D A
G
B A165850
G 9804/1103
15 - 00 - 02/15
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 00 - 02/16
3CX Super 4x4x4
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
6.00m (19ft 8in)
B
Overall height
3.53m (11ft 7in)
C
Height to top of cab
2.78m (9ft 2in)
D
Wheelbase
2.22m (7ft 3in)
E
Minimum ground clearance
0.31m (1ft 0in)
F
Slew ground clearance
0.45m (1ft 6in)
G
Width
2.24m (7ft 4in)
H
Cabless build, Maximum fixed height
2.01m (6ft 7in)
J
Centreline of rear axle/centreline of kingpost
1.32m (4ft 4in)
Machine weight - 4WD with 610mm (24in) excavator bucket, General Purpose shovel and full fuel
7650kg (16865lb)
* Note: Dimensions based on standard tyres fitted (16.9/14 x 24 -12PR).
B C H F
E J
D A
A229150
G 9804/1103
15 - 00 - 02/16
Issue 2*
Backhoe Loaders
CONTENTS CONTENTS
4CX Super 4x4x4
15 - 00 - 02/17
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
6.07m (19ft 11in
B
Overall height
3.93 m ( 12ft 10in)
C
Height to top of cab
2.78m (9ft 2in)
D
Wheelbase
2.22m (7ft 3in)
E
Minimum ground clearance
0.31m (1ft 0in)
F
Slew ground clearance
0.45m (1ft 6in)
G
Width
2.35m (7ft 8in)
H
Cabless build, Maximum fixed height
2.01m (6ft 7in)
J
Centreline of rear axle/centreline of kingpost
1.32m (4ft 4in)
Machine weight - 4WD with 610mm (24in) excavator bucket, 6-in-1 shovel, bucket mounted forks and full fuel
8460kg (18654lb)
* Note: Dimensions based on standard tyres fitted (16.9/14 x 24 -12PR).
C H F
G
E
J
D A
B A162850
G
9804/1103
15 - 00 - 02/17
Issue 2*
Backhoe Loaders
CONTENTS CONTENTS
3CXE (214E)
15 - 00 - 02/18
From m/c no. 400001
General Information - Static Dimensions Item
Description
Dimensions
A
Overall length
7.11m (23ft 4in)
B
Overall height
3.43 m ( 11ft 3in)
C
Height to top of cab
2.83m (9ft 3in)
D
Wheelbase - 2WD
2.21m (7ft 3in)
- 4WD
2.26m (7ft 5in)
E
Minimum ground clearance
0.33m (1ft 1in)
F
Slew ground clearance
0.43m (1ft 5in)
G
Width
2.24m (7ft 4in)
Machine weight - 4WD with 610mm (24in) excavator bucket, 0.95m3 loader bucket
6641kg (14870lbs)
Note: Dimensions based on following tyres fitted -rear: 18.4 x 26 industrial; front: 10.5/80 x 18PR.
C
F
E D A
G
B A257120
G
9804/1103
15 - 00 - 02/18
Issue 1
Backhoe Loaders
CONTENTS
15 - 00 - 03/1
3CX Sideshift
From m/c no. 460001
General Information - Static Dimensions
B C
F
E G D
G
A
A
Overall length
3CX 5.62
3CX Sitemaster 5.62
3CX Sitemaster Plus 5.62
3CX Powermaster 5.62
B
Overall height - standard backhoe fitted - extending dipper fitted
3.52 3.60
3.60
3.60
3.60
C
Height to top of cab
2.87
2.87
2.87
2.87
D
Wheelbase
2.17
2.17
2.17
2.17
E
Ground clearance - stabiliser
0.37
0.37
0.37
0.37
F
Ground clearance - kingpost
0.52
0.52
0.52
0.52
G
Width
2.23
2.23
2.23
2.23
Dimensions in metres and are based on standard tyres fitted. For Backhoe and Loader dimensions contact your JCB Distributor.
9804/1103
15 - 00 - 03/1
5380/205
Issue 1
Backhoe Loaders
CONTENTS
15 - 00 - 03/2
4CX Sideshift
From m/c no. 460001
General Information - Static Dimensions
B C
F
E G D
G
A
A
Overall length
4CX 5.91
4CX Sitemaster 5.91
4CX Super 5.91
4CX Super Sitemaster 5.91
B
Overall height - standard backhoe fitted - extending dipper fitted
3.59 3.67
3.67
3.92
3.96
C
Height to top of cab
2.84
2.84
2.84
2.84
D
Wheelbase
2.22
2.22
2.22
2.22
E
Ground clearance - stabiliser
0.34
0.34
0.34
0.34
F
Ground clearance - kingpost
0.50
0.50
0.50
0.50
G
Width
2.33
2.33
2.33
2.33
Dimensions in metres and are based on standard tyres fitted. For Backhoe and Loader dimensions contact your JCB Distributor.
9804/1103
15 - 00 - 03/2
5380/206
Issue 1
Backhoe Loaders
CONTENTS
15 - 00 - 03/3
3CX Super
From m/c no. 460001
General Information - Static Dimensions
B C
F
E G D
G
A A270000
A
Overall length
3CX Super 5.91
3CX Super Sitemaster 5.91
B
Overall height
3.49
3.57
C
Height to top of cab
2.82
2.82
D
Wheelbase
2.22
2.22
E
Ground clearance - stabiliser
0.33
0.33
F
Ground clearance - kingpost
0.48
0.48
G
Width
2.23
2.23
Dimensions in metres and are based on standard tyres fitted. For Backhoe and Loader dimensions contact your JCB Distributor.
9804/1103
15 - 00 - 03/3
5380/207
Issue 1
Backhoe Loaders
CONTENTS
15 - 00 - 03/4
3CX Centremount
From m/c no. 460001
General Information - Static Dimensions
B C
F
E G D
G
A
A
Overall length
3CX 7.19
3CX Sitemaster 7.19
3CXE 7.19
B
Overall height - standard backhoe fitted - extending dipper fitted
3.43 3.53
3.53
3.43 -
C
Height to top of cab
2.84
2.84
2.84
D
Wheelbase - 2WD - 4WD
2.21 2.28
2.21 2.26
2.21 2.26
E
Ground clearance - mainframe
0.33
0.33
0.33
F
Ground clearance - front axle
0.28
0.28
0.28
G
Width
2.23
2.23
2.23
Dimensions in metres and are based on standard tyres fitted. For Backhoe and Loader dimensions contact your JCB Distributor.
9804/1103
15 - 00 - 03/4
5380/208
Issue 1
Backhoe Loaders
CONTENTS
15 - 00 - 03/5
4CX Centremount
From m/c no. 460001
General Information - Static Dimensions
B C
F
E D A
G
Sitemaster machine shown. A260730
A
Overall length
4CX 7.37
4CX Sitemaster 7.37
B
Overall height - standard backhoe fitted - extending dipper fitted
3.43 3.53
3.53
C
Height to top of cab
2.84
2.84
D
Wheelbase
2.31
2.31
E
Ground clearance - mainframe
0.34
0.34
F
Ground clearance - front axle
0.45
0.45
G
Width
2.33
2.33
Dimensions in metres and are based on standard tyres fitted. For Backhoe and Loader dimensions contact your JCB Distributor.
9804/1103
15 - 00 - 03/5
5380/209
Issue 1
Backhoe Loaders
CONTENTS
15 - 00 - 03/6
4C, 4CN
From m/c no. 460001
General Information - Static Dimensions
B C
F
E D
G
A
G
A260770
4C 4X4 7.49
4C 4X4X4 7.47
4CN 4X4X4 TBA
Overall height - standard backhoe fitted - extending dipper fitted
3.89 3.91
3.89 3.91
3.89 3.91
C
Height to top of cab
2.84
2.84
2.84
D
Wheelbase
2.31
2.31
2.31
E
Ground clearance - mainframe
0.34
0.34
0.34
F
Ground clearance - front axle
0.28
0.45
0.45
G
Width
2.33
2.33
2.35
A
Overall length
B
Dimensions in metres and are based on standard tyres fitted. For Backhoe and Loader dimensions contact your JCB Distributor.
9804/1103
15 - 00 - 03/6
5380/210
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX, (200 Series)
15 - 05 - 01/1
From m/c no. 400001
Data - Electrical System Type
12 Volt, negative earth
Battery (Heavy Duty) - Cold crank amps for 1 minute to 1.4 volts per cell at -18 deg C (0 deg F)
550
- Reserve capacity (minutes) for 25 amp load
220
Battery (Temperate) - Cold crank amps for 1 minute to 1.4 volts per cell at -18 deg C (0 deg F)
410
- Reserve capacity (minutes) for 25 amp load
170
Alternator 2WS
Lucas - 65 Amp maximum output
4WS
Magnetti Marelli - 72 Amp maximum output
4WS (air conditioning or ServoPlus builds)
Magneti Marelli - 85 Amp maximum output
Starter Motor
Lucas
Light Bulbs Head lights - main/dip
45/37.5W
Work lights
55W Halogen (front & rear)
Front side lights
5W
Tail/stop lights
5/21W
Fog light
21W
Direction turn indicators
21W (front & rear)
Instruments
1.2W
Warning lights
3W
† Number plate light
2 x 5W
Interior light
10W
† Beacon
70W Halogen
† Note: These items are not apllicable to U.S.A.
9804/1103
15 - 05 - 01/1
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX, (200 Series)
15 - 05 - 01/2
From m/c no. 400001 to 430000
Data - Electrical ?@
Circuit Protection
O2@@@@@@@@@@@@@6?2@@@@6KO2@@6?2@@@6K?O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6Kf?O@K O2@@6K @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@ @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6KO@?@K??O2@@@@@@6K? ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6?26K?fO@K? 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The electrical circuits are protected by fuses. The fuses are located in a fuse box to the right of the steering pedestal. If a fuse melts, find out why and rectify the fault before fitting a new one. The fuses are identified using column letters (A, B and C) and row numbers (1 to 9).
! CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5
COLUMN 'A' 1
Reverse alarm, brake lights, 2/4WD solenoid †††.
Fuse Rating 10 Amp
2
Gauges, stabiliser lock relay.
5 Amp
3
Left hand sidelights, dipper light.
5 Amp
4
Gauge illumination, right hand sidelights.
5 Amp
5
Rear wiper.
5 Amp
6
Hazard warning lights.
10 Amp
7
Beacon, Interior light.
10 Amp
8
Radio.
9
Horn, headlight flash, front wiper/washer.
5 Amp
S143211
†
Note: Machines prior to serial number 400077 have the fog light circuit protected by fuse B3, not C4 as indicated.
††
Note: Steering solenoids and proximity switches are fitted to AWS machines only.
10 Amp
COLUMN 'B' 1
Junction box, remote unload solenoid (HSC).
10 Amp
2
Fuel pump solenoid (engine stop).
3
Dip beam†.
10 Amp
4
Main beam.
10 Amp
5
Front work lights.
10 Amp
6
Direction turn indicators.
5 Amp
7
Dump relay.
5 Amp
8
Heater.
9
Hand dump, buzzer.
5 Amp
††† Note: Machines up to serial number 403024 have the brake lights protected by fuse A1. Machines from serial number 403025 to 404851 have the brake lights protected by fuse C3. Machines from serial number 404852 have the brake lights, and 2/4WD solenoid protected by fuse A1 (as indicated in the fuse identification chart).
15 Amp 5 Amp
COLUMN 'C' 1
Rear work lights.
2
Steering solenoids, proximity switches ††.
3
2/4 WD switch & relay, forward relay and solenoid, reverse relay and solenoid.
10 Amp 5 Amp
Powershift only - forward high/low relay & solenoid, reverse high/low relay & solenoid, drive (mainshaft/layshaft) relay & solenoid, neutral relay.
10 Amp
4
Fog light †.
10 Amp
5
When applicable - heated seat, clock & cigar lighter.
15 Amp
9804/1103
15 - 05 - 01/2
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
15 - 05 - 01/3
3CX, 4CX, (200 Series)
From m/c no. 430001
Data - Electrical
Circuit Protection The relays and fuses are located in the side console underneath cover A.
! CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5
Fuse Identification
* If a fuse melts, find out why and rectify the fault before fitting a new one. The fuses are identified using column letters (A, B and C) and row numbers (1 to 9). Note that all the fuses are shown (including optional equipment fuses). Your machine may not be equipped with all the fuses shown on this page.
*
COLUMN 'A' Fuse Rating 1 Brake lights. 5 Amp 2 Warning lights, buzzer, gauges. 5 Amp 3 Left hand sidelights. 5 Amp 4 Right hand sidelights. 5 Amp 5 Rear wiper/washer. 5 Amp 6 Hazard warning lights. 10 Amp 7 Beacon, Interior light. 10 Amp 8 Radio. 5 Amp 9 Horn, headlight flash, front wiper/washer. 15 Amp COLUMN 'B' 1 Junction box 2 Fuel pump solenoid (engine stop). 3 Dip beam. 4 Main beam. 5 Front work lights. 6 Indicators. 7 4WD (automatic brake). 8 Heater. 9 Rear horn.
*
COLUMN 'C' 1 Rear work lights. 10 Amp 2 Steer mode, hydraulic speed control (HSC) 5 Amp 3 Gearbox control, reverse alarm. 10 Amp 4 Fog light. 5 Amp 5 Heated seat, clock & cigar lighter 15 Amp 6 Forward and reverse controls, reverse alarm 3 Amp
* Note: Fuse C6 is only fitted on machines from serial number: 3CX (214) - 438636; 4CX (214S) - 437866. Prior to this, the gear controls were protected by fuse C3.
10 Amp 5 Amp 10 Amp 10 Amp 10 Amp 5 Amp 5 Amp 30 Amp 10 Amp
A S247030
9804/1103
15 - 05 - 01/3
Issue 3*
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX, (200 Series)
15 - 05 - 01/4
From m/c no. 400001 to 430000
Data - Electrical
Relay Identification - Syncro Shuttle M/c's Relays are used in electrical circuits for a variety of reasons. However, the more usual application is to protect components like switches etc. from being overloaded. A relatively small current (from the switch) energises the relay coil, this coil causes internal contacts to open (or close) and therefore controls a (larger) current in another circuit. Although relays look similar, internally they can be different, for example, they can be single contact or double contact; normally closed or normally open. Make sure you fit the correct type of relay, otherwise the machine electrical circuits will not function properly. All the relays on your machine (except items T & U) are housed in the front console as shown. Items T & U are secured to the parking brake mounting bracket, as shown in the inset. Relay B C D E F G H J K L R S T U V
Description (to serial no. 409434) Neutral Start Stabiliser Leg Lock (if fitted) Reverse Alarm (if fitted) Buzzer Road Lights Parking Brake Forward Drive Reverse Drive Flasher Transmission Dump 2/4WD Brake 2WD Select Hydraulic Speed Control † Hydraulic Speed Control † -
Description (from 409435 to 430000) Neutral Start Stabiliser Leg Lock (if fitted) Reverse Alarm (if fitted) Buzzer Road Lights Parking Brake Brake Lights 2WD Select Flasher Transmission Dump Forward Drive Reverse Drive Hydraulic Speed Control † Hydraulic Speed Control † Parkbrake Dump ††
Note † : From machine serial number 406613 the hydraulic speed control circuit is operated with a single relay, not two relays as shown. Note ††: The parkbrake dump relay is only applicable on machines from serial number 413772.
E
DC
B
F
G
H
J
K
L
T R
U
9804/1103
15 - 05 - 01/4
S V
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX, (200 Series)
15 - 05 - 01/5
From m/c no. 400001 to 430000
Relay Identification - Powershift M/c's Relay A B C D E F G H J K L M N P Q R S T U V
Description (to serial no. 409434) Ignition Neutral Start Stabiliser Leg Lock (if fitted) Reverse Alarm (if fitted) Buzzer Road Lights Parking Brake Forward Drive Reverse Drive Flasher Transmission Dump Forward High/Low Ratio Reverse High/Low Ratio Drive (Layshaft/Mainshaft) Neutral (Powershift) 2/4WD Brake 2WD Select Hydraulic Speed Control † Hydraulic Speed Control † -
Description (from 409435 to 430000) Ignition Neutral Start Stabiliser Leg Lock (if fitted) Reverse Alarm (if fitted) Buzzer Road Lights Parking Brake Forward High/Low Ratio Reverse High/Low Ratio Flasher Transmission Dump Forward Drive Reverse Drive Drive (Layshaft/Mainshaft) Neutral (Powershift) Brake Lights 2WD Select Hydraulic Speed Control † Hydraulic Speed Control † Parkbrake Dump ††
Note †: From machine serial number 406613 the hydraulic speed control circuit is operated with a single relay, not two relays as shown. Note ††: The parkbrake dump relay is only applicable on machines from serial number 413772.
E
A
D C B F
G
R
S
K
L
T H
U
J
9804/1103
15 - 05 - 01/5
M N
P
Q V
S215400
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 05 - 01/6
3CX, 4CX, (200 Series)
From m/c no. 430001
Data - Electrical * Note 1: On 3CXE (214E) machines the lights relay (item 15)
Relay Identification - All Machine Models * The
* *
* *
will be fitted at position 7 (in place of the hydraulic speed control relay). Items 13 to 24 will not be fitted.
relays and fuses are located in the side console underneath cover A. Note that all the relays are shown (including optional equipment relays). Your machine may not be equipped with all the relays shown on this page.
* Note
Relay Identification
* Note 3: On 3CX 4x4x4 machines, the neutral relay (item 24)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
➀ ➁
2: Earlier Powershift machines had the neutral relay (item 24) located in position 5.
is moved to a single relay base located on the left hand side of the fuse base. Positions 23 and 24 then house 2 wheel steer and 4 wheel steer select relays respectively (see inset X).
Ignition Neutral Start Indicators Ignition 5-Speed Transmission Dump Hydraulic Speed Control (HSC) - see Note 1 Forward Drive Buzzer Parking Brake Reverse Drive Reverse Horn Auxiliary Attachment (Jaw) Heater Lights - see Note 1 Worklights (Italian Requirement Only) Hammer Circuit All Wheel Braking Forward High/Low Ratio ➀ 2 Wheel Drive ➁ Reverse High/Low Ratio ➀ Drive (Layshaft/Mainshaft) ➀ Neutral ➀ - see Notes 2 & 3
A
Powershift Machines Only S247030
All Wheel Steer Machines Only
S247490
X 23
24
1
4
7
10
13
16
19
21
2
5
8
11
14
17
20
22
3
6
9
12
15
18
23
24
S247020
9804/1103
15 - 05 - 01/6
Issue 2*
Backhoe Loaders
CONTENTS CONTENTS
ALL MODELS (EXCEPT 2CX)
15 - 05 - 01/10
From m/c no. 400001
Data - Electrical (Servo Machines)
General System Type
12V, negative earth
Alternator
85amp maximum output
Logic Control Box
supply input 12V d.c. range 11V - 15V current consumption (no load) 25mA (max) electromagnetic compatibility - test procedure to ISO WD11452 - test frequency 1MHz to 1GHz field strength - 25V/m, control box should function to functional specification - 50V/m, control box should exhibit no hazardous effects or permanent damage to the
*
system signal inputs - joystick X and Y axis, range 3V to 9V full axis travel† - joystick Z axis, LH wiper range, 6V to 3V† - joystick Z axis, RH wiper range 6V to 9V† signal outputs - hydraulic control valves, neutral position, 6V ± 0.6V†
*
Note: Logic control boxes from February 1994 are designed to isolate the excavator and loader control relays when the joysticks are in the neutral position. This neutral position switch will activate almost immediately the joystick is left in neutral. - control limits, loader valve, 4.2V to 7.8V normal operation† - control limits, loader valve, 9V with float enabled† - control limits, backhoe valve, 3V to 9V† See relevant pages for logic box description of operation.
Joysticks
operating range 11V to 15V axis output (refer to signal inputs - logic box) † These are nominal values proportional to the supply input voltage, i.e. 25 to 75% of the battery voltage See relevant pages for joystick (and axis) descriptions of operation.
9804/1103
15 - 05 - 01/10
Issue 2*
Backhoe Loaders
CONTENTS CONTENTS
ALL MODELS (EXCEPT 2CX)
15 - 05 - 01/11
From m/c no. 400001
Data - Electrical (Servo Machines)
Fuses
Bulbs
The electrical circuits are protected by fuses. The fuses are located in a fuse box to the right of the steering pedestal. If a fuse melts, find out why and rectify the fault before fitting a new one. The fuses are identified using column letters (A, B and C) and row numbers (1 to 9).
Bulbs
! CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5
COLUMN 'A' A1 4WD/Brakes, Stop Lights
Fuse Rating 10 Amp
A2 Instruments, Reverse Alarm†
5 Amp
A3 Left Hand Sidelights
5 Amp
A4 Right Hand Sidelights
5 Amp
A5 Rear Wiper, Rear Wash†
10 Amp
A7 Beacon, Interior Light
10 Amp
A9 Horn, Front Wash/Wiper
Headlights - main/dip
45/37.5 W
Work lights
55 W Halogen (front & rear)
Front Side lights
5W
Tail/stop lights
5/21 W
Fog light
21 W
Indicators
21 W (front & rear)
Instruments
1.2 W
Warning lights
3W
Number plate light
2x5W
Interior light
10 W
Beacon
70 W Halogen
5 Amp
A6 Hazard Warning Lights A8 Radio†
Bulb Rating
5 Amp 10 Amp
COLUMN 'B' B1 Hydraulic Options B2 Fuel Pump solenoid (Engine Stop) B3 Dipped Beam
10 Amp 5 Amp 10 Amp
B4 Main Beam
10 Amp
B5 Front Work Lights
10 Amp
B6 Indicators
5 Amp
B7 Dump Relay Feed
10 Amp
B8 Heater
15 Amp
B9 Hand Dump, Buzzer
5 Amp
COLUMN 'C' C1 Rear Work Lights. C2 Steering solenoids, proximity switches. C3 Gearbox Control, 2 Wheel Drive C4 Fog light†
10 Amp 5 Amp 10 Amp 5 Amp
C5 Heated seat, clock & cigar lighter†
15 Amp
C6 Servo Controls
20 Amp
Note: Items marked with a '†' are available as optional extras.
S190050
9804/1103
15 - 05 - 01/11
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 05 - 01/12
ALL MODELS (EXCEPT 2CX)
From m/c no. 400001
Data - Electrical (Servo Machines)
4 3
2 1
5
6
7
8
9
10
16 15 14 13 12 11
22 21 23 25 24
20
S193280
17 9804/1103
15 - 05 - 01/12
18
19 Issue 1
Backhoe Loaders
CONTENTS CONTENTS
ALL MODELS (EXCEPT 2CX)
15 - 05 - 01/13
From m/c no. 400001
Data - Electrical (Servo Machines)
Relay Identification Relays 1 to 16 are housed in the front console, at the side of the steering pedestal. Relays 17 to 25 are housed behind the side console panel. The relays are identified as follows: Relay
Description
1
Ignition
2
Neutral Start
3
Reverse Alarm
4
Buzzer
5
Road Lights
6
Parking Brake
7
2/4WD Brake
8
2WD Select
9
Flasher
10
Transmission Dump
11
Neutral (Powershift)
12
Drive (Layshaft/Mainshaft)
13
Reverse Drive
14
Forward Drive
15
Reverse High/Low Ratio
16
Forward High/Low Ratio
17
Hydraulic Speed Control
18
Steering
19
Loader
20
Backhoe
21
Hammer
22
Hydraclamp
23
Horn
24
Horn Change Over
25
Jaw (aux)
9804/1103
15 - 05 - 01/13
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 05 - 01/14
ALL MODELS (EXCEPT 2CX)
From m/c no. 400001
Data - Electrical (Servo Machines)
Logic Box - Pin Identification Connector A PIN * A B C D E F G H J K L M N P R * S * T * U V
DESTINATION * WIRE Connector C Boom Signal 418 Bucket Signal 417 Slew Signal 416 Steering Signal 451 12V Switch Supply 421 Steering On/Off 444 12V Input (Direct) 112H Reverse Gear Switch 888 Forward Gear Switch 887 Forward Gear Relay 809 Reverse Gear Relay 808 Shovel Signal 415 Clam Signal 414 Dipper Signal 419 RH Mode Switch (LH Joystick) 446 LH Mode Switch (LH Joystick) 445 Loader Signal 413
Connector B PIN A B C D E F G H J K L M N P R S T U V
DESTINATION * WIRE +ve Input (via reset) 882H Loader Valve Relay 440 12V Common Earth 605N Backhoe Valve Relay 450 Seat Forward Switch 895A Seat Rearward Switch 896 Safety Solenoid 422 Reset Required Indicator 439 Float Available Indicator 437 RTD Available Indicator 438 Shovel Position Switch (Arms) 844 RTD Enable Switch 443 Fault Reset Switch 882G Float Enable Switch - Input 1 441 Float Enable Switch - Input 2 442 Joystick Isolator Switch 449
DESTINATION * WIRE LH Joystick (+ve Out ) 423 LH Joystick (-ve Out) 424 LH Joystick (Common) 428 RH Joystick (+ve Out) 430 RH Joystick (-ve Out) 431 RH Joystick (Common) 435 LH Joystick (Z Axis Left Signal) 429 LH Joystick (Z Axis Right Signal) 427 LH Joystick (X Axis Signal ) 425 LH Joystick (Y Axis Signal) 426 RH Joystick (Y Axis Signal) 433 RH Joystick (Z Axis Right Signal) 434 RH Joystick (X Axis Signal ) 432 RH Joystick (Z Axis Left Signal) 436
PIN A B C D E F G H J K L M N P R S T U V
A244360
M L
A
K T H
C P
V S
J
M
B N
U
R
D E
G F
Harness Connector 'A' 9804/1103
15 - 05 - 01/14
L
A
K T H
C P
V S
J
M
B N
U
R
D E
G F
Harness Connector 'B'
L
A
K T H
C P
V S
J
B N
U
R
D E
G F
Harness Connector 'C' Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
15 - 05 - 01/15
ALL MODELS (EXCEPT 2CX)
From m/c no. 400001
Data - Electrical (Servo Machines)
RH Joystick - Pin Identification PIN A B C D E F G H J K L M N P R S T U V
DESTINATION Logic Box (+ve Out) Logic Box (Z Axis Right Signal) Logic Box (X Axis Signal ) Seat Harness Splice (Aux Switch) Auxiliary Relay Logic Box (Y Axis Signal) Logic Box (Z Axis Left Signal) Logic Box (-ve Out) Seat Harness Splice (Transmission Dump Switch) Transmission Dump Relay Cab Harness Splice (HSC Switch) HSC Relay Logic Box (Common) -
WIRE 430 434 432 110F 898 433 436 431 107J 838B 101T 889 435 -
B C D
A
M
N P R
E
U V S
F
L K
T
J
G H A244100
Harness Connector
LH Joystick - Pin Identification PIN A B C D E F G H J K L M N P R S T U V
DESTINATION Hydraclamp Relay Seat Harness Splice (Hydraclamp Switch) Logic Box (Supply Input) Logic Box (Z Axis Right Signal) Logic Box (X Axis Signal ) Horn Relay Seat Harness Splice (Horn Switch) Logic Box (Y Axis Signal) Logic Box (Z Axis Left Signal) Logic Box (-ve Out) Logic Box (LH Mode Switch) Seat Harness Splice (LH Mode Switch) Seat Harness Splice (RH Mode Switch) Logic Box (RH Mode Switch) Logic Box (Common) -
9804/1103
WIRE 885 112K 423 427 425 890 110G 426 429 424 445 421E 421F 446 428 -
15 - 05 - 01/15
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
15 - 05 - 01/16
ALL MODELS (EXCEPT 2CX)
From m/c no. 400001
Data - Electrical (Servo Machines)
4
H
G
L 6
K
5
8 J
2
7
F
D
3
7
C
B
E
A
1 S193310
9804/1103
15 - 05 - 01/16
Issue 2
CONTENTS CONTENTS
Backhoe Loaders
ALL MODELS (EXCEPT 2CX)
15 - 05 - 01/17
From m/c no. 400001
Data - Electrical (Servo Machines)
Harness Identification Key 1
Mainframe Harness A B C D E
2
Cab Harness C F G H J
3
Panel to Mainframe Connector 1 Panel to Mainframe Connector 2 Panel to Cab Connector
Seat Harness H K L
5
Cab to Mainframe Connector Cab to Panel Connector Cab to Logic Box Connectors Cab to Seat Connectors Cab to Roof Harness (2 off)
Panel Harness A B F
4
Mainframe to Panel Connector 1 Mainframe to Panel Connector 2 Mainframe to Cab Connector Backhoe Valve Block Solenoid Connectors Loader Valve Block Solenoid Connectors
Seat to Cab Connectors Left Hand Joystick Connectors Right Hand Joystick Connectors
Cab Roof Harness J
Roof to Cab Harness (2 off)
6
Seat Proximity Switch Harness
7
Rear Lights Extension Harness
Note: The routing of the rear light extension harnesses will vary depending on whether the machine is a sideshift or centremount type. The centremount routing is shown in dotted line form, the sideshift routing shown in solid line form. 8
Logic Box
9804/1103
15 - 05 - 01/17
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
15 - 05 - 01/19
3CX, 4CX and Variants Data - Electrical
From m/c no. 460001
General System Type
12 Volt, negative earth
Battery (Heavy Duty) - Cold crank amps for 1 minute to 1.4 volts per cell at -18 deg C (0 deg F)
550
- Reserve capacity (minutes) for 25 amp load
220
Battery (Temperate) - Cold crank amps for 1 minute to 1.4 volts per cell at -18 deg C (0 deg F)
410
- Reserve capacity (minutes) for 25 amp load
170
Electronic Control Unit Shift points Hz
449/05401
2nd to 3rd
3rd to 4th
693
1467
4th to 3rd 1304
3rd to 2nd
2nd to 1st
570
326
Note: The part number and ECU settings can be verified and checked on the Psion Workabout. Alternator 2WS
65 Amp nominal output
4WS
72 Amp nominal output
4WS (air conditioning or ServoPlus builds)
85 Amp nominal output
9804/1103
15 - 05 - 01/19
3270 - C/1-1.3
Issue 1
Backhoe Loaders
CONTENTS
15 - 05 - 01/20
3CX, 4CX and Variants Data - Electrical Fuse Identification
From m/c no. 460001
! CAUTION Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5
The relays and fuses are located in the side console underneath cover A. If a fuse melts, find out why and rectify the fault before fitting a new one. The fuses are identified using column letters (A, B and C) and row numbers (1 to 9). Note that all the fuses are shown (including optional equipment fuses). Your machine may not be equipped with all the fuses shown on this page.
ALL MODELS (Except 3CXE, 214E) COLUMN 'A' Fuse Rating 1 Hydraulic Auxiliary, Smooth Ride System 10 Amp 2
Fuel pump solenoid (engine stop)
3
Indicators
7.5 Amp
4
Steer mode, proximity switches
7.5 Amp
5
Gearbox Control, Transmission
10 Amp
6
Powered rear window
20 Amp
7
Brake lights
5 Amp
8
4WD (automatic brake)
3 Amp
9
Left hand sidelights
3 Amp
10
Right hand sidelights
3 Amp
COLUMN 'B' 1 Instruments, buzzer
5 Amp
Fuse Rating 5 Amp
2
Front Horn, front wiper/washer
15 Amp
3
Rear horn
7.5 Amp
4
Heated seat, cigar lighter, face level fan
5
Rear wiper/washer
6
Brake switch
10 Amp
7
Rear work lights
25 Amp
8
Headlights
20 Amp
9
Front work lights
25 Amp
10
Spare
COLUMN 'C' 1 Fog light
15 Amp
10
9
8
7
6
5
3
2
1
5A
10A
4W
3A
3A
3A
A 5A
20A 10A 7.5A 7.5A
5 Amp
-
4
R B 25A 20A 25A 10A
5A
15A 7.5A 15A
5A
0
15A 15A
C 3A
30A 20A
5A 10A 15A 7.5A 3A
A276790
Fuse Rating 3 Amp
2
Main lights
7.5 Amp
3
Hazard lights
15 Amp
4
Beacon, interior light
10 Amp
5
Radio
6
Thermostart
20 Amp
7
Heater
30 Amp
8
Ignition relay coils
9
Main Beam
15 Amp
10
Dip Beam
15 Amp
5 Amp
A
3 Amp
S252511
9804/1103
15 - 05 - 01/20
3270 - 3/1-2.3
Issue 2*
CONTENTS
Backhoe Loaders
3CX, 4CX and Variants Data - Electrical Fuse Identification
15 - 05 - 01/20A
From m/c no. 460001 Relay Identification
The relays and fuses are located in the side console underneath cover A. COLUMN 'A' Fuse Rating 1 Hydraulic Auxiliary, Smooth Ride System 10 Amp 2 Fuel pump solenoid (engine stop) 5 Amp 3 Indicators 7.5 Amp 4 Steer mode, proximity switches 7.5 Amp 5 Gearbox Control, Transmission 10 Amp 6 Powered rear window 20 Amp 7 Brake lights 5 Amp 8 4WD (automatic brake) 3 Amp 9 Left hand sidelights 3 Amp 10 Right hand sidelights 3 Amp
1 2 3 4 5 6 7 8 9 10 11 12
Ignition Neutral Start Indicators Ignition Front Work Lights Transmission Dump Rear Work Lights Forward Drive Buzzer Parking Brake Reverse Drive Reverse Horn
COLUMN 'B' Fuse Rating 1 Instruments, buzzer 5 Amp 2 Front horn, front wiper/washer 15 Amp 3 Rear horn 7.5 Amp 4 Heated seat, cigar lighter, face level fan 15 Amp 5 Rear wiper/washer 5 Amp 6 Brake switch 10 Amp 7 Rear work lights 25 Amp 8 Headlights 20 Amp 9 Front work lights 12 Amp 10 Spare COLUMN 'C' 1 Fog light 2 Main lights 3 Hazard lights 4 Beacon, interior light
10
9
8
7
6
Fuse Rating 3 Amp 7.5 Amp 15 Amp 10 Amp
5
4
3
2
1
5A
10A
4W
3A
3A
3A
A 5A
20A 10A 7.5A 7.5A
A
R B 25A 20A 25A 10A
5A
15A 7.5A 15A
5A
0
15A 15A
C 3A
30A 20A
A333470
5A 10A 15A 7.5A 3A A276790
7
0
8
!
9
@
0 1
0 4
0 2
5
F R
3
6
P
R A265070
9804/1103
15 - 05 - 01/20A
3270 - 3/1-4.3
Issue 1
Backhoe Loaders
CONTENTS
3CX, 4CX and Variants
15 - 05 - 01/21
From m/c no. 460001
Data - Electrical Link Box Fuses
Bulbs
To further protect the machine wiring harnesses and electrical circuits, a fuse link box is fitted to the battery, as shown at B. Remember to check the main circuit fuses as well as the link box fuses shown on this page. 1
Hazard warning lights, Beacon, Lights
30 Amp
2
Wash/Wipe, Transmission, Indicators
50 Amp
3
Work lights, Fog Lights, Brake lights
50 Amp
4
Ignition, Heater, Thermostart
50 Amp
Head lights - main/dip †
45/37.5W
Front Lights ††
55W Halogen
Work lights
55 Halogen (front & rear)
Front side lights †
5W
Tail/stop lights
5/21W
Fog light †
21W
Direction turn indicators
21W (front & rear)
Instruments
1.2W
Warning lights
3W
Number plate light †
1 x 5W
Interior light
10W
Beacon †
70W Halogen
Note: These items are not applicable to North America Note: These items are applicable to North America only
B
S254320
9804/1103
1
2
3
4
A254310
15 - 05 - 01/21
3270 - C/1-3.1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 05 - 01/22
3CX, 4CX and Variants
From m/c no. 460001
Data - Electrical 3CXE, 214E only
The relays and fuses are located in the side console underneath cover A. Note that all the relays are shown (including optional equipment relays). Your machine may not be equipped with all the relays shown on this page.
B C D E F G H J K L M N
All Models (Except 3CXE, 214E) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 19 20 21 22 23 24 25 26 27 28 29 30 !
Ignition Neutral Start Indicators Ignition Heater Transmission Dump Hydraulic Speed Control (HSC) Forward Drive Buzzer Parking Brake Reverse Drive Reverse Horn Front Work Lights Worklights (Italian, German requirement only) Lights Rear Work Lights Intermittent Wash/Wipe All Wheel Braking (standard machines) Reverse alarm (autoshift machines) Forward High/Low Ratio ! 2 Wheel Drive " Neutral Reverse High/Low Ratio ! Drive (Layshaft/Mainshaft) ! Auto Hydraulic Speed Control (HSC) 4 Wheel Steer # 2 Wheel Steer # Hammer Circuit Steer Relay 1 # Steer Relay 2 # Auxiliary Attachment (Jaw) Powershift Machines Only "$ All Wheel Steer Machines Only # 3CX 4x4x4 Machines Only - not applicable to N.Am.
Ignition Neutral Start Indicators Ignition Front Work Lights Transmission Dump Rear Work Lights Forward Drive Buzzer Parking Brake Reverse Drive Reverse Horn
0
0
P L
B
E
H
C
F
J
M
D
G
K
N
F R
0
R A265070
A
S252511
25
26
27
1
0 28
29
30
2
0
3
4
7
0
5
6
10
13
19
16
F
P 8
14
11
17
20
F R 9
12
R 23
D 15
R
22
18
21
4W
N
R
24
AUTO
A260440
9804/1103
15 - 05 - 01/22
3270 - C/1-3.3
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
15 - 05 - 01/23
3CX, 4CX and Variants
From m/c no. 460001
Data - Electrical Fuse Identification - Servo Command
Relay Identification - Servo Command
The relays and fuses are located in the side console underneath cover A.
5 6 7 8 9 10
Right hand pilot valve Left hand pilot valve Return to dig Main feed Servo isolation switch Change over solenoids
A
Fuse Rating 5 Amp 5 Amp 1 amp 10 Amp 3 Amp 15 Amp
R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 R22 R23 R24 R25
Ignition Front seat Front mode changeover Rear seat Rear mode changeover Right hand joystick proportional switch supply Right hand amplifier supply Front auxiliary supply Hammer interlink Stabiliser isolate Left hand amplifier supply Sweeper/Clam changeover Pilot valves changeover Auxiliary/Clam 2 changeover Auxiliary/Clam 1 changeover Stabiliser/Clam 2 changeover Stabiliser/Clam 1 changeover Stabiliser/Auxiliary 1 changeover Stabiliser/Auxiliary 2 changeover Stabiliser lower changeover Stabiliser raise changeover Stabiliser lower/mode changeover Stabiliser raise/mode changeover Dump interlink (autoshift only) Spare
R11
R10
R8
R9
R13
R12
R6
R7
R15
R14
R4
R5
R17
R16
R2
R3
BUZZER
R1
10 9 8 7 6 5 4 3 2 1
R18
R20
R22
R24
R19
R21
R23
R25
A334090
9804/1103
15 - 05 - 01/23
3270 - C/1-5.2
Issue 1
CONTENTS
Backhoe Loaders
15 - 05 - 01/24
3CX, 4CX and Variants
From m/c no. 460001
Data Electrical Fuse Identification - 214Se
Relay Identification 214Se
COLUMN 'A' 1 Hydraulic auxiliary 2 Fuel pump solenoid (engine stop) 3 Turn signals 4 Spare 5 Gearbox control, Transmission 6 Spare 7 4WD (automatic brake) 8 Brake lights 9 Right hand sidelights 10 Left hand sidelights
Fuse Rating 5 Amp 5 Amp 7.5 Amp
COLUMN 'B' 1 Instruments, buzzer 2 Front horn, front wiper/washer 3 Spare 4 Auxiliary power socket 5 Rear wiper/washer 6 Brake switch 7 Rear work lights 8 Headlights 9 Front work lights 10 Beacon
Fuse Rating 5 Amp 15 Amp
COLUMN 'C' 1 Spare 2 Dip beam 3 Lights 4 Hazard 5 Face level fan 6 Radio 7 Thermostart 8 Heater 9 Ignition relay coils 10 Main beam
Fuse Rating
A B C D E F G H J K L M N
10 Amp 3 Amp 5 Amp 3 Amp 3 Amp
4 Wheel brake Lights Turn signals Reverse drive Forward drive Front work lights Parking brake Transmission dump Rear work lights Neutral start Ignition 1 Buzzer Ignition 2
20 Amp 15 Amp 10 Amp 25 Amp 20 Amp 25 Amp 10 Amp
15 Amp 7.5 Amp 15 Amp 10 Amp 1 Amp 20 Amp 30 Amp 3 Amp 15 Amp
A
B
C
D
E
F
G
H
J
4W
4W
10
9
8
7
6
5
4
3
2
1
4W
A A 3A 3A 3A
5A 5A 3A
10A 10A
7.5A 7.5A
5A 5A 5A 5A
K
B B 10A 15A 20A 10A 25A 25A 20A 20A 25A 10A 15A
L
15 5A 5A 15A 1
M
1
N
C 15A 3A 3A 30A 20A 1A 10A 15A 15A 7.5A 7.5A 15A 15A 15A
2
345740
9804/1103
2
345741
817/16774
15 - 05 - 01/24
3270 - C/1-6.2
Issue 1
CONTENTS
Backhoe Loaders
15 - 05 - 01/25
3CX, 4CX and Variants
From m/c no. 495455
Data - Electrical Relay Identification
Fuse Identification Fuse Rating Dip beam 15 Amp Fog light 3 Amp Main beam 15 Amp Ignition relay coils 3 Amp Heater 30 Amp Thermostart 20 Amp Radio 5 Amp Beacon, Interior light 10 Amp Hazard light 15 Amp Lights 7.5 Amp Front working lights 25 Amp Headlights 20 Amp Rear working lights 25 Amp Return to dig enable 5 Amp Brake switch 10 Amp Rear wiper/wash 10 Amp Heated seat, Cigar lighter, Face level fan 15 Amp Rear horn 7.5 Amp Front horn, Front washer/wiper 15 Amp Instruments, Buzzer 5 Amp Right hand side lights 5 Amp Left hand side lights 5 Amp 4 wheel drive (automatic brakes) 3 Amp Brake lights 5 Amp Spare Gearbox control, Transmission 10 Amp Steer mode proximity switch 7.5 Amp Direction indicators 7.5 amp Fuel pump solenoid (engine stop) 5 amp Hydraulic auxiliary 10 Amp
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
A B C D E F G H J K L M N P Q R S T U
Heater Direction indicator Ignition Ignition Neutral start Buzzer Intermittent wash/wipe switch Rear working lights Front working lights Rear horn 2/4 wheel braking Engine run Auxiliary (jaw bucket) Reverse alarm Hydraulic speed control Hammer Main lights 2 wheel drive Parking brake
P
Q
M
N
S
R
G
F
K
L
U
T
E
H
J
C
D
A
B
A356072
A357830 A356071
21
22
23
25
26
14 15
16
24
27
28
29
30
4WD
1
2
9804/1103
3
4
5
6
7
8
9
10
11
12
15 - 05 - 01/25
13
17
18
3270 - C/1-7.2
19
20 Issue 1
CONTENTS CONTENTS
Backhoe Loaders
15 - 05 - 01/26
3CX, 4CX and Variants
From m/c no. 460001
Data - Electrical Relay Identification - Autoshift Only
Relay Identification - Powershift Transmission From Serial No. 495455
The relays and fuses are located in the side console underneath cover A. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Ignition Neutral Start Indicators Ignition Heater Parking Brake Hydraulic Speed Control Auxiliary Attachment (Jaw) Buzzer Auto Hydraulic Speed Control Hammer Reverse Horn Front Working Lights Working Lights (Italian, German requirement only) Lights Rear Working Lights Intermittent Wash/Wipe Reverse Alarm
1 2 3 4 5 6 7 8
Spare Reverse drive Reverse (High/Low ratio) Forward (High/Low ratio) Transmission dump Forward drive Driveshaft interlock Drive (Layshaft/Mainshaft)
2 6
1 5
3 7
4 8
A359330
Relay Identification - Syncro Shuttle Transmission From Serial No. 495455 1 2 3 4
A
Transmission dump Forward drive Spare Reverse drive
A333470
1
4
7
0
£
^
2
5
8
!
$
&
3
6
9
@
%
1 3
*
2 4
A357840
A334100
9804/1103
15 - 05 - 01/26
3270 - C/1-8.2
Issue 1
CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 05 - 01/27
From m/c no. 460001
Data Electrical Harness Identification
3
4
2
6
5
7
ITEM
DESCRIPTION
1 2 3 4 5 6 7
Mainframe Harness Panel Harness Cab Harness Cab Roof Harness Solenoid Harness Rear Light Harnesses Engine Shut Off Harness
1
Note: The illustration shows a typical machine.
9804/1103
15 - 05 - 01/27
3270 - C/40-1.2
Issue 1
CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 05 - 01/28
From m/c no. 460001
Data - Electrical Harness Identification
Item 1 2 3 4 5
Description Seat Loader Valve Block Auxiliary Valve Block Excavator Valve Block Manifold Block
9804/1103
15 - 05 - 01/28
3270 - C/40-2.1
Issue 1
CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 05 - 01/29
From m/c no. 495455
Data Electrical Harness Identification
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16
Description Chassis Harness Cab Panel Harness Cab Roof Harness Powershift Transmission Harness (not shown) Rear Cab (Sideshift) Harness Rear Lights (Sideshift) Harness Auxiliary Harness Head Lights Harness (not shown) Powershift Relay Harness Steer Mode Harness Air Conditioning Harness (not shown) Power Tool Extension Harness Servo Auxiliary Chassis Harness 3CX Link Connector (not shown) Strap Earth
9804/1103
15 - 05 - 01/29
3270 - C/40-3.1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 05 - 02/1
3CX, 4CX
From m/c no. 400001
Data - Hydraulic (Standard Machines)
Machine Hydraulics Hydraulic Pumps ('Hamworthy' type) - UK and Rest of World, except North America Hydraulic Pump - Option 1 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure
Double pump/190906 Clockwise (AWS), Anti-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart litres/min UK gal/min 82.2 18.0 58.4 12.8 See - Relief Valve Operating Pressures
Hydraulic Pump - Option 2 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure
Double pump/190706 Clockwise (AWS), Anti-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart litres/min UK gal/min 66.2 14.6 58.4 12.8 See - Relief Valve Operating Pressures
Hydraulic Pump - Option 3 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure
Double pump/190705 Clockwise (AWS), Anti-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart litres/min UK gal/min 66.2 14.6 43.6 9.6 See - Relief Valve Operating Pressures
Hydraulic Pump - Option 4 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure
Double pump/190606 Clockwise (AWS), Anti-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart litres/min UK gal/min 58.4 12.8 58.4 12.8 See - Relief Valve Operating Pressures
Hydraulic Pump Applicability Chart Pump Type
2-Wheel Steer Machines 3CX
S/Master
H/Master
All Wheel Steer Machines 4CX 4C
4CN
S/Master
190906
* 190706 190705
√
√
√
√
√
√
√
√
√
√
190606 Note: The applicability chart is intended as a guide only, make sure that you check the pump data plate (mounted on the pump) to determine exactly which type of pump is fitted to your machine. 9804/1103
15 - 05 - 02/1
Issue 4*
Backhoe Loaders
CONTENTS CONTENTS
15 - 05 - 02/2
3CX, 4CX
From m/c no. 400001
Data - Hydraulic (Standard Machines)
Machine Hydraulics Hydraulic Pumps ('Ultra' type) - UK and Rest of World, except North America Hydraulic Pump - Option 1 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure
Double pump/4071 (2WS), 4075 (AWS) Clockwise (AWS), Anti-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart litres/min UK gal/min 81.2 17.9 57.4 12.6 See - Relief Valve Operating Pressures
Hydraulic Pump - Option 2 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure
Double pump/4072 (2WS), 4074 (AWS) Clockwise (AWS), Anti-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart litres/min UK gal/min 65.3 14.4 57.4 12.6 See - Relief Valve Operating Pressures
Hydraulic Pump - Option 3 Model/Reference Rotation Mounting: 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure
Double pump/4070 (2WS) Anti-clockwise Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart litres/min UK gal/min 65.3 14.4 45.5 10.0 See - Relief Valve Operating Pressures
Hydraulic Pump - Option 4 Model/Reference Rotation Mounting: 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure
Double pump/4073 (2WS) Anti-clockwise Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart litres/min UK gal/min 57.4 12.6 57.4 12.6 see - Relief Valve Operating Pressures
Hydraulic Pump Applicability Chart Pump Type
2-Wheel Steer Machines 3CX
S/Master
H/Master
√
√
√
√
√
√
All Wheel Steer Machines 4CX 4C
4CN
S/Master
√
√
√
4071 4075 4072
* 4074 4070
√
4073 Note: The applicability chart is intended as a guide only, make sure that you check the pump data plate (mounted on the pump) to determine exactly which type of pump is fitted to your machine. 9804/1103
15 - 05 - 02/2
Issue 4*
CONTENTS CONTENTS
Backhoe Loaders
ALL MODELS (EXCEPT 2CX)
15 - 05 - 02/3
From m/c no. 400001
Data - Hydraulic (Standard Machines) (continued) *
Machine Hydraulics Hydraulic Pumps ('Hamworthy' type) - NORTH AMERICA ONLY Hydraulic Pump - Option 1 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure Pump section 1 (mounting bracket end) Pump section 2 Maximum working pressure Hydraulic Pump - Option 2 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure Pump section 1 (mounting bracket end) Pump section 2 Maximum working pressure Hydraulic Pump - Option 3 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure Pump section 1 (mounting bracket end) Pump section 2 Maximum working pressure Hydraulic Pump - Option 4 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure Pump section 1 (mounting bracket end) Pump section 2 Maximum working pressure
Double pump/190906 Clockwise (AWS), Anit-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart 21.6 US gal/min 15.4 US gal/min See - Relief Valve Operating Pressures Double pump/190706 Clockwise (AWS), Anit-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart 17.5 US gal/min 15.4 US gal/min See - Relief Valve Operating Pressures Double pump/190705 Clockwise (AWS), Anit-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart 17.5 US gal/min 11.5 US gal/min See - Relief Valve Operating Pressures Double pump/190606 Clockwise (AWS), Anit-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart 15.4 US gal/min 15.4 US gal/min see - Relief Valve Operating Pressures
Hydraulic Pump Applicability Chart Pump Type
2-Wheel Steer Machines 214
215
216
217
All Wheel Steer Machines 214S 215S 216S 217S S/Master
S/Master
190906 190706 190705 190606 Note: The applicability chart is intended as a guide only, make sure that you check the pump data plate (mounted on the pump) to determine exactly which type of pump is fitted to your machine.
9804/1103
15 - 05 - 02/3
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
ALL MODELS (EXCEPT 2CX)
15 - 05 - 02/4
From m/c no. 400001
Data - Hydraulic (Standard Machines) (continued) *
Machine Hydraulics Hydraulic Pumps ('Ultra' type) - NORTH AMERICA ONLY Hydraulic Pump - Option 1 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure Hydraulic Pump - Option 2 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure Hydraulic Pump - Option 3 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure Hydraulic Pump - Option 4 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure
Double pump/4071 (2WS), 4075 (AWS) Clockwise (AWS), Anti-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart 21.48 US gal/min 15.12 US gal/min See - Relief Valve Operating Pressures Double pump/4072 (2WS), 4074 (AWS) Clockwise (AWS), Anti-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart 17.28 US gal/min 15.12 US gal/min See - Relief Valve Operating Pressures Double pump/4070 (2WS) Clockwise (AWS), Anti-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart 17.28 US gal/min 12.0 US gal/min See - Relief Valve Operating Pressures Double pump/4073 (2WS) Clockwise (AWS), Anti-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart 15.12 US gal/min 15.12 US gal/min see - Relief Valve Operating Pressures
Hydraulic Pump Applicability Chart Pump Type
2-Wheel Steer Machines 214
215
216
217
All Wheel Steer Machines S/Master
214S 215S 216S 217S S/Master
4071 4075 4072 4074 4070 4073 Note: The applicability chart is intended as a guide only, make sure that you check the pump data plate (mounted on the pump) to determine exactly which type of pump is fitted to your machine. 9804/1103
15 - 05 - 02/4
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
15 - 05 - 02/5
3CX, 4CX, (200 Series)
From m/c no. 400001
Data - Hydraulic (Standard Machines)
Machine Hydraulics Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) @ 1500 RPM
228 - 240
233 - 245
3300 - 3500
Unloader Valve
207 - 220
211 - 225
3000 - 3200
165 - 200 303 - 317
168 - 204 309 - 323
2400 - 2900 4400 - 4600
241 - 255
246 - 260
3500 - 3700
303 - 317 338 - 352
309 - 323 344 - 358
4400 - 4600 4900 - 5100
303 - 317 241 - 255 241 - 255
309 - 323 246 - 260 246 - 260
4400 - 4600 3500 - 3700 3500 - 3700
303 - 317 241 - 255 241 - 255 241 - 255 241 - 255 255 - 269 bar 138 - 150 207 - 220 138 - 145 207 - 214 138 - 145 207 - 214 207 - 214 138 - 150 21 bar
309 - 323 246 - 260 246 - 260 246 - 260 246 - 260 260 - 274 kgf/cm2 141 - 153 211 - 225 141 - 148 211 - 218 141 - 148 211 - 218 211 - 218 141 - 153 21 kgf/cm2
4400 - 4600 3500 - 3700 3500 - 3700 3500 - 3700 3500 - 3700 3700 - 3900 lbf/in2 2000 - 2200 3000 - 3200 2000 - 2100 3000 - 3100 2000 - 2100 3000 - 3100 3000 - 3100 2000 - 2200 300 lbf/in2
303 - 317 303 - 317 303 - 317
309 - 323 309 - 323 309 - 323
4400 - 4600 4400 - 4600 4400 - 4600
250 250 250 303 - 317
255 255 255 309 - 323
3625 3625 3625 4400 - 4600
bar
kgf/cm2
lbf/in2
1.4
1.4
20
Auxiliary Relief Valves (A.R.V.) † Loader Shovel Ram Head Side Shovel Ram Rod side Backhoe Boom Ram Head Side Boom Ram Rod Side * to m/c 435209 (Sideshift ), 434984 (C/mount) * from m/c 435210 (Sideshift ), 434985 (C/mount) Bucket Ram Head Side Centremount (17' backhoe - 217 models only) Centremount (14' backhoe) Centremount (15' 6" backhoe up to M/C 413521) Centremount (15' 6" backhoe from M/C 413522 except knuckle boom) Sideshift Bucket Ram Rod Side (Machines with Powerbreaker only) Dipper Ram Head Side Dipper Ram Rod Side Slew Left and Right Attachments Extradig Ram Head Side Extradig Ram Rod Side Jaw Bucket Ram Head Side Jaw Bucket Ram Rod Side Knuckle Ram Head Side Knuckle Ram Rod Side Hammermaster Roadbreaker Sequence Valve Hose Burst Protection Valves (optional) Machine Serial Numbers - up to 402173 Boom Ram Rod Side Dipper Ram Rod Side Loader Lift Rams Head Side Machine Serial Numbers - from 402174 Boom Ram Rod Side Dipper Ram Rod Side Loader Lift Rams Head Side Stabiliser Check Valve Relief Valve (Centremount M/c's) Return Line Filter By-pass pressure
† When setting 'Hamworthy' Loader Valve A.R.V.'s using a hand pump, set 15 bar (220 lbf/in2) below nominal figure shown. † When setting 'Husco' Loader Valve A.R.V.'s using a hand pump, set to the figure shown above. Note: Later type loader valves are produced by a different manufacturer (Husco). When appropriate, the loader valve will be identified using the manufacturer's name, (Hamworthy - earlier type, or Husco - later type). In some instances, there will be no need to differentiate (e.g., descriptions of operation - the valves operate in the same manner).
9804/1103
15 - 05 - 02/5
Issue 3*
CONTENTS CONTENTS
Backhoe Loaders
15 - 05 - 02/6
3CX, 4CX, (200 Series)
From m/c no. 400001
Data - Hydraulic (Standard Machines)
Steer Hydraulics (AWS Machines) System Type Hydraulic Supply Control Unit Type Control Unit Relief Valve Operating Pressure (at 1500 revs/min) Control Unit Shock Valve Operating Pressure lbf/in2
Full Power Hydrostatic From Main Hydraulic Pump Via Priority Valve Load Sensing With Integral Relief Valve 120 ± 3.5 bar 175 - 190 bar
122 ± 3.5 kgf/cm2 178 - 199 kgf/cm2
Front Steer Ram(s) Dimensions Bore Rod Diameter Stroke End Cap Assembly A/F Piston Head Assembly A/F
60 mm (2.362 in) 30 mm (1.181 in) 210.6 mm (8.290 in) 55 mm (2.165 in) 41 mm (1.614 in)
Rear Steer Ram(s) Dimensions Bore Rod Diameter Stroke End Cap Assembly A/F Piston Head Assembly A/F
60 mm (2.362 in) 30 mm (1.181 in) 210.6 mm (8.290 in) 55 mm (2.165 in) 41 mm (1.614 in)
Steer Ram Torque Settings Piston Head End Cap
Nm 405 678
kgf m 41 69
1740 ± 50 lbf/in2 2538 - 2756
lbf ft 300 500
Steer Hydraulics (2WS Machines) System Type Hydraulic Supply Control Unit Type Control Unit Relief Valve Operating Pressure (at 1500 revs/min) Control Unit Shock Valve Operating Pressure lbf/in2
Full Power Hydrostatic From Main Hydraulic Pump Via Priority Valve Load Sensing With Integral Relief Valve 120 ± 3.5 bar 175 - 190 bar
Steer Ram(s) Dimensions 2 Wheel Drive Machines Location Bore Rod Diameter Stroke End Cap Assembly A/F Piston Head Assembly A/F
1 Ram - Front Axle (Right Hand Side) 70 mm (2.756 in) 30 mm (1.181 in) 290 mm (11.417 in) 65 mm (2.559 in) 55 mm (2.165 in)
4 Wheel Drive Machines Location Bore Rod Diameter Stroke End Cap Assembly A/F Piston Head Assembly A/F
1 Ram - Front Axle (Left Hand Side) 70 mm (2.756 in) 30 mm (1.181 in) 290 mm (11.417 in) 65 mm (2.559 in) 55 mm (2.165 in)
Steer Ram Torque Settings Piston Head End Cap
9804/1103
122 ± 3.5 kgf/cm2 1740 ± 50 lbf/in2 178 - 199 kgf/cm2 2538 - 2756
Nm 405 678
15 - 05 - 02/6
kgf m 41 69
lbf ft 300 500
Issue 3
CONTENTS CONTENTS
Backhoe Loaders
15 - 05 - 02/7
3CX, 4CX, (200 Series)
From m/c no. 400001
Data - Hydraulic (3CXE (214E) Machines)
Machine Hydraulics Hydraulic Pump Model/Reference: Rotation: Mounting: Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Maximum working pressure
Single pump/6197 Anti-clockwise Chassis (driveshaft driven) 3CXE machines only 99.0 litres/min; 21.9 UK gal/min; 26.3 US gal/min 230 bar; 234.5 kg/cm2; 3335 lbf/in2
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) @ 1500 RPM
228 - 240
233 - 245
3300 - 3500
172 - 176 308 - 312
175 - 179 314 - 318
2500 - 2550 4475 - 4525
245 - 252 308 - 312
249 - 257 314 - 318
3550 - 3650 4475 - 4525
245 - 252 245 - 252
249 - 257 249 - 257
3550 - 3650 3550 - 3650
245 - 252 245 - 252
249 - 257 249 - 257
3550 - 3650 3550 - 3650
258 - 266
263 - 271
3750 - 3850
303 - 317 120 - 125
309 - 323 122 - 127
4400 - 4600 1740 - 1813
Auxiliary Relief Valves (A.R.V.) Loader Shovel Ram Head Side Rod side Backhoe Boom Ram Head Side Rod Side Bucket Ram Head Side Rod Side Dipper Ram Head Side Rod Side Slew Ram Left and Right Stabiliser Ram Left and Right Steering Attachments Hammermaster 170 173 2465 Loader Valve Identification (Fig 1) 1 Loader Arm Spool 2 Shovel Spool 2A Rod Side 2B Head Side 3 Auxiliary Relief Valve 4 Inlet Port 5 Outlet Port 6 High Pressure Carry Over Port
3 1 2
5
2A 6
2B
4
3 A248220
Fig 1 9804/1103
15 - 05 - 02/7
Issue 3
CONTENTS CONTENTS
Backhoe Loaders
15 - 05 - 02/8
ALL MODELS (EXCEPT 2CX)
From m/c no. 400001
Data - Hydraulic (Servo Machines)
Machine Hydraulics Hydraulic Pumps Loader Valve Electric Supply Metering Characteristics Section Designation - Loader, Shovel, Clam Auxilary Relief Valve Pressures - Shovel Ram Head Side - Shovel Ram Rod Side Main Relief Valve Pressure - see Note 1 * - machines up to serial no. 419307 * - machines from serial no. 419308 Valve Block Identification - Spool 1 - Spool 2 -A -B -C -D -E -F - Spool 3 (Optional) -A -B Output Descriptions - Loader Arm
- Shovel
- Clam
See Page E/1-2, in Service Manual 9803/3260
Logic Box Closed Centre Load Sensed PVG 32 Bar 165 - 179 303 - 317
kgf/cm2 168 - 183 309 - 323
lbf/in2 2400 - 2600 4400 - 4600
260 265 3770 230 235 3335 Refer to Fig 1 (view shown as fitted on machine) Loader Arms Service Shovel Service Head Side Rod Side Load Sense Line Connection Port Pump Tank Pressure Test Point (plugged - use test point on backhoe valve) Clam Service Rod Side Head Side Operation Port Neutral Full Deflection - see Note 2 Lift A 6V 4.2V Lower B 6V 7.8V * Float 6V 9V (with ‘Float Enable’ selected) Dump A 6V 3V Crowd B 6V 9V * Return-to Dig B 6V 9V (with ‘RTD Enable’ selected) Open A 6V 3V Close B 6V 9V
Note 1: On machines up to serial number 419307 both the loader and the backhoe valves house main relief valves. However, the main relief in the loader valve is factory set at 260 bar and would therefore never reach 'cracking' pressure. The MRV in the backhoe valve is set at 230 bar and therefore controls the hydraulic system pressure. On machines from serial number 419308 only the loader valve houses a main relief valve (a blanking plug is fitted in the backhoe valve). The MRV in the loader valve is set at 230 bar and controls the hydraulic system pressure. Note 2: Figures assume 12V battery voltage - output is proportional to battery voltage.
D
E C
F A
A
A
B
1
B
2
B
3
A193570
9804/1103
15 - 05 - 02/8
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
15 - 05 - 02/9
ALL MODELS (EXCEPT 2CX)
From m/c no. 400001
Data - Hydraulic (Servo Machines) (continued)
Machine Hydraulics Backhoe Valve Electric Supply Metering Characteristics Section Designation - Bucket, Slew, Steering - Boom, Dipper Auxilary Relief Valve Pressures * - Boom Ram Head Side * - Boom Ram Rod Side * - Bucket Ram Head Side * - Bucket Ram Rod Side - Dipper Ram Head Side - Dipper Ram Rod Side * - Slew Left and Right Main Relief Valve Pressure - see Note 1 * - machines up to serial no. 419307 * - machines from serial no. 419308 Valve Block Identification - Spool 1 * A * B - Spool 2 - Spool 3 * A * B - Spool 4 * A&B - Spool 5 * A * B * - Port C * - Port D * - Port E * - Item F * - Item G
Logic Box Open Centre Load Sensed PVG 32 PVG 120 Bar 266 - 280 341 - 355 303 - 317 241 - 255 241 - 255 241 - 255 241 - 255
kgf/cm2 271 - 285 348 - 362 309 - 323 246 - 260 246 - 260 246 - 260 246 - 260
lbf/in2 3850 - 4060 4945 - 5148 4400 - 4600 3500 - 3700 3500 - 3700 3500 - 3700 3500 - 3700
260 265 3770 230 235 3335 Refer to FIG 2, (view shown as fitted on machine) Boom Rod Side Head Side Dipper Bucket Head Side Rod Side Slew Slew Cylinders Steering Port ‘P’ Steer Mode Valve, Port ‘L’ Orbitrol Unit Front Steer Rams - LH rod side & RH head side, Port ‘R’ Orbitrol Unit Load Sense Line Connection Port Pump Tank Pressure Test Point Valve Sections Interface
* Note
1: On machines up to serial number 419307 both the loader and the backhoe valves house main relief valves. However, the main relief in the loader valve is factory set at 260 bar and would therefore never reach 'cracking' pressure. The MRV in the backhoe valve is set at 230 bar and therefore controls the hydraulic system pressure.
1
3
5
C
B
B
E
D A
A
B A
B A
A
F
FIG 2
9804/1103
4
G
B
On machines from serial number 419308 only the loader valve houses a main relief valve (a blanking plug is fitted in the backhoe valve). The MRV in the loader valve is set at 230 bar and controls the hydraulic system pressure.
2
15 - 05 - 02/9
A193580
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
ALL MODELS (EXCEPT 2CX)
15 - 05 - 02/10
From m/c no. 400001
Data - Hydraulic (Servo Machines) (continued)
Machine Hydraulics Backhoe Valve (continued) Output Descriptions (ISO + Pattern) - Boom - Dipper - Bucket - Slew Auxiliary Valve Relief Valve Pressures - Main - Auxiliary Head Rod Side
Operation Lift Lower Lift Lower Dump Crowd Left Right
Port A B B A B A B A
Neutral 6V 6V 6V 6V 6V 6V 6V 6V
Bar 227
kgf/cm2 231.5
lbf/in2 3300
138 - 145 207 - 214
141-148 211 - 218
2000-2100 3000 - 3100
Slew Motion Control Valve - see Note 1 Relief Valve Pressures - Slew Left and Right
Bar 235
kgf/cm2 238.5
lbf/in2 3408
Unloader Valve Relief Valve Pressures - Unloader
Bar 207
kgf/cm2 211
lbf/in2 3000
Bar 200
kgf/cm2 204
lbf/in2 2900
Hose Burst Protection Valves Relief Valve Pressures High Pressure Filter By-pass pressure Filter 'Clogged' Indicator - see Note 2
Full Deflection 3V 9V 9V 3V 9V 3V 3V 9V
3.5 3.5 50 'Pop-up Button' Differential Pressure Indicator Mounted on Top of Filter
Note 1: ServoPlus machines from serial number 420485 are not fitted with a slew motion control valve. Instead, new type spools are fitted on the slew service of the excavator valve block; these spools are also able to fine control the slewing motion of the backhoe. In addition to the spools, new relief valves are fitted on the slew services. Technical Bulletin 2/148 also refers. Note 2: On later machines the ‘pop-up’ visual indicator is deleted from the specification of the hydraulic filter. Make sure that the filters are changed at the recommended interval.
9804/1103
15 - 05 - 02/10
Issue 1
CONTENTS CONTENTS
*
Backhoe Loaders
3CX, 4CX and Variants
15 - 05 - 02/11
From m/c no. 460001
Data - Hydraulic Hydraulic Pumps Model/Reference Rotation (viewed on end of driveshaft) Mounting Theoretical displacement: Pump section 1 (mounting flange end) Pump section 2 Flow at 2200 rev/min and system pressure (95% displacement): Pump section 1 (mounting flange end) Pump section 2 Maximum continuous pressure (P1) 230 bar (3335 lbf/in 2 ) Maximum speed @ pressure P1 Minimum speed @ pressure P1 Approximate Weight Model/Reference Rotation (viewed on end of driveshaft) Mounting Theoretical displacement: Pump section 1 (mounting flange end) Pump section 2 Flow at 2200 rev/min and system pressure (95% displacement): Pump section 1 (mounting flange end) Pump section 2 Maximum continuous pressure (P1) Maximum speed @ pressure P1 Minimum speed @ pressure P1 Approximate Weight Model/Reference Rotation (viewed on end of driveshaft) Mounting Theoretical displacement: Pump section 1 (mounting flange end) Pump section 2 Flow at 2200 rev/min and system pressure (95% displacement): Pump section 1 (mounting flange end) Pump section 2 Maximum continuous pressure (P1) Maximum speed @ pressure P1 Minimum speed @ pressure P1 Approximate Weight Model/Reference Rotation (viewed on end of driveshaft) Mounting Theoretical displacement: cc/rev cu in/rev Pump section 1 (mounting flange end) Pump section 2 Flow at 2200 rev/min and system pressure (95% displacement): Pump section 1 (mounting flange end) Pump section 2 Maximum continuous pressure (P1) Maximum speed @ pressure P1 Minimum speed @ pressure P1 Approximate Weight
Double pump/4070H Anti-clockwise Chassis (driveshaft driven) cc/rev 33 23 litres/min 68.9 48.0 3000 rev/min 500 rev/min 20.7kg (45.6 lbs) Double pump/8282B Anti-clockwise Chassis (driveshaft driven) cc/rev 36 26 litres/min 75.2 54.3 230 bar (3335 lbf/in 2 ) 3000 rev/min 500 rev/min 23.8kg (52 lbs) Double pump/7441N Anti-clockwise Chassis (driveshaft driven) cc/rev 41 26 litres/min 85.6 54.3 230 bar (3335 lbf/in 2 ) 3000 rev/min 500 rev/min 22kg (48.5 lbs) Double pump/4071F Anti-clockwise Chassis (driveshaft driven) 41 29 litres/min 85.6 60.6 230 bar (3335 lbf/in 2 ) 3000 rev/min 500 rev/min 22.1kg (48.7 lbs)
cu in/rev 2.01 1.40 UK gal/min 15.1 10.5
cu in/rev 2.19 1.59 UK gal/min 16.5 11.9
cu in/rev 2.50 1.59 UK gal/min 18.8 11.9
2.50 1.77 UK gal/min 18.8 13.3
S273090
9804/1103
15 - 05 - 02/11
3270 - E/1-10.2
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 05 - 02/11A
From m/c no. 460001
Data - Hydraulics (cont’d) Hydraulic Pumps (continued) Machine models applicable to Type Reference Rotation (viewed on end of driveshaft) Mounting Load Sense Pressure (in neutral position) Load sense pressure relief Valve (if fitted) Stand-by Pressure Maximum Hydraulic Stall Pressure 460001 to 472554 without relief valve 460001 to 472554 with relief valve and all from 472555 Maximum Displacement Flow at 2200 rev/min and 2500 lb/in2 pressure † - minimumum acceptable flow rate (new or rebuilt pump) - minimumum acceptable flow rate (used pump) Flow in the Load Sense Line at 2200 rev/min (no pressure) Weight
4CX, 4CX Super Variable Displacement A10VO - 978753 Anti-clockwise Chassis (driveshaft driven) Maximum permitted - 5 bar; 72.5 lbf/in2 230 bar; 3335 lbf/in2 20 bar; 290 lbf/in2 232 bar; 3364 lbf/in2 270 bar; 3915 lbf/in2 74cc/rev; 4.5 in3/rev 75 -80 litres/min; 16.5 - 17.6 UK gal/min 70 - 75 litres/min; 15.4 - 16.5 UK gal/min 1 - 5 litres/min; 0.22 - 1.1 UK gal/min TBAkg (TBA lbs)
† Note: It is not possible to test full pump flow at system pressure, figures quoted give a ‘snapshot’ indication of pump performance.
S273090
9804/1103
15 - 05 - 02/11A
3270 - E/1-10.2
Issue 1
CONTENTS
Backhoe Loaders
15 - 05 - 02/12
3CX, 4CX and Variants
From m/c no. 460001
Data Hydraulic (cont’d) Hydraulic Pumps (continued) Model/Reference Rotation (viewed on end of driveshaft) Mounting Theoretical displacement Flow at 2200 rev/min and system pressure (95% displacement): Maximum continous pressure (P1) Maximum speed @ pressure P1 Minimum speed @ pressure P1 Approximate Weight
Single pump/6197C Anti-clockwise Chassis (driveshaft driven) 51 cc/rev; 3.11 cu in/rev 104.5 litres/min; 22.9 UK gal/min 330 bar (4785 lbf/in2) 3000 rev/min 500 rev/min 11.75kg (25.9 lbs)
Model/Reference Rotation (viewed on end of driveshaft) Mounting Theoretical displacement Flow at 2200 rev/min and system pressure (95% displacement): Maximum continous pressure (P1) Maximum speed @ pressure P1 Minimum speed @ pressure P1 Approximate Weight
Single pump/J101702 Anti-clockwise Chassis (driveshaft driven) 51 cc/rev; 3.05 cu in/rev 105 litres/min; 23.1 UK gal/min 265 bar (3842 lbf/in2) 3000 rev/min 500 rev/min 13 kg (28.6 lbs)
Relief Valve Operating Pressures: Extradig Ram Head Side Extradig Ram Rod Side Jaw Bucket Ram Head Side Jaw Bucket Ram Rod Side Knuckle Ram Head Side Knuckle Ram Rod Side Hammermaster Power Sideshift (both) Roadbreaker
bar 138 - 145 207 - 214 138 - 145 207 - 214 138 - 145 207 - 214 207 - 214 207 - 214 138 - 150
kgf/cm2 141 - 148 211 - 218 141 - 148 211 - 218 141 - 148 211 - 218 211 - 218 211 - 218 141 - 153
lbf/in2 2000 - 2100 3000 - 3100 2000 - 2100 3000 - 3100 2000 - 2100 3000 - 3100 3000 - 3100 3000 - 3100 2000 - 2200
bar 303 - 317
kgf/cm2 309 - 323
lbf/in2 4400 - 4600
bar 3.0 - 3.5
kgf/cm2 3.0 - 3.6
lbf/in2 43.5
Weight: TBA kg (TBA lbs)
Stabiliser Check Valve Relief Valve (Centremount M/c's) Relief Valve Operating Pressures: Check Valve Weight: TBA kg (TBA lbs)
Hydraulic Filter Element Relief Valve Operating Pressures: By-pass pressure
9804/1103
15 - 05 - 02/12
3270 - E/1-2.2
Issue 2*
Backhoe Loaders
CONTENTS CONTENTS
*
15 - 05 - 02/13
3CX, 4CX and Variants
From m/c no. 460001
Data - Hydraulic (cont’d) Loader Valve Machine Models applicable to: 3CX, 4CX, 214, 215, 217, ‘S’ Series Valve Block Identification: ITEM DESCRIPTION 1 Arms lift service 2 Shovel service 3 Auxiliary (optional) 4 Pump section 1 - inlet 5 Pump section 2 - inlet 6 Pressure test port 7 Unloader Assembly
ITEM 8 9 10 11 12 13 14
Relief Valve Operating Pressures: Main Relief Valve (M.R.V.) @ 1500 RPM Unloader Valve Auxiliary Relief Valves (A.R.V.) Loader Shovel Ram Head Side Shovel Ram Rod side
DESCRIPTION Unloader solenoid Auxiliary relief valve Tank port High pressure carry-over (HPCO) port Service ports Load hold check valve assemblies Data plate
bar 228 - 230 203 - 207
kgf/cm2 233 - 235 207 - 211
lbf/in2 3300 - 3335 2950 - 3000
165 - 179 303 - 317
168 - 183 309 - 323
2400 - 2600 4400 - 4600
Weight 25kg (55lbs)
1
2
3
7 9
@
@
8 @
6 $
5
£ !
0 4
@
@
@
9
A262160
9804/1103
15 - 05 - 02/13
3270 - E/1-3.2
Issue 2*
CONTENTS *
Backhoe Loaders
15 - 05 - 02/14
3CX, 4CX and Variants
From m/c no. 460001
Data - Hydraulic (cont’d) Loader Valve Machine Models Applicable to: 3CXE, 214E Series 3 Valve Block Identification: ITEM DESCRIPTION 1 Arms lift service 2 Shovel service 3 Pump inlet 4 Tank port 5 Auxiliary relief valve 6 High pressure carry-over (HPCO) port 7 Service ports
Relief Valve Operating Pressures: Main Relief Valve (M.R.V.) @ 1500 RPM Auxiliary Relief Valves (A.R.V.) Loader Shovel Ram Head Side Shovel Ram Rod side
bar 228 - 230
kgf/cm2 233 - 235
lbf/in2 3300 - 3335
170 - 174 308 - 312
173 - 177 314 - 318
2465 - 2520 4475 - 4525
Weight: 8kg (17.6lbs)
A262420
9804/1103
15 - 05 - 02/14
3270 - E/1-4.2
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
15 - 05 - 02/15
3CX, 4CX and Variants
From m/c no. 460001
Data Hydraulic (cont’d) Loader Valve Machine Models Applicable to: 214e Series 4 Valve Block Identification: ITEM DESCRIPTION 1 Auxiliary service 2 Arms lift service 3 Shovel service 4 Pump inlet 5 Tank port 6 Auxiliary relief valve 7 High pressure carry-over (HPCO) port 8 Service ports
Relief Valve Operating Pressures: Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) Loader Shovel Ram Head Side Shovel Ram Rod side
bar 228 - 235
kgf/cm2 233 - 239
lbf/in2 3300 - 3400
172 - 179 310 - 317
175 - 183 316 - 323
2500 - 2600 4500 - 4600
Note: The pressure testing and adjustment MUST be carried out as detailed on pages E/13-1 to E/13-8. Weight: 10 kg (22 lbs)
A313430
9804/1103
15 - 05 - 02/15
3270 - E/1-5.3
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
15 - 05 - 02/16
3CX, 4CX and Variants
From m/c no. 460001
Data - Hydraulic (cont’d) Loader Valve Machine Models Applicable to: 4CX, 4CX Super
Valve Block Identification: ITEM DESCRIPTION 1 Auxiliary (optional) service 2 Shovel service 3 Arms lift service 4 Pump inlet 5 Tank port 6 Load sense port (to pump) 7 Priority load sense port (from steer unit)
ITEM 8 9 10 11 12 13
Relief Valve Operating Pressures: Priority Relief Valve† Auxiliary Relief Valves (A.R.V.) @ 0.5gal/min (1.9 litres/min) Shovel Ram Head Side Shovel Ram Rod side
DESCRIPTION Priority work port (to steer until) Load sense carry over port (to backhoe valve) Service ports Auxiliary relief valve (rod side) Auxiliary relief valve (head side) Priority relief valve†
bar 170 - 176
kgf/cm2 173 - 179
lbf/in2 2450 - 2550
170 - 174 306 - 314
173 - 177 312 - 320
2465 - 2520 4450 - 4550
† Note: Steer circuit pressure is controlled by a relief valve housed in the orbitrol unit (see section H). The priority relief valve housed in the loader valve must be set at 2500 lb/in2, this will ensure it does not interfere with the operation of the relief valve housed in the orbitrol unit.
Weight: 2 Spool - TBA kg (TBA lbs) 3 Spool - TBA kg (TBA lbs)
A273670
9804/1103
15 - 05 - 02/16
3270 - E/1-11.1
Issue 1
Backhoe Loaders
CONTENTS
15 - 05 - 02/17
3CX, 4CX and Variants
From m/c no. 460001
Data - Hydraulic (cont’d) Backhoe Valve Machine Models Applicable to: 3CX, 3CXE, 4CX, 214, 214E, 215, ‘S’ Series Valve Block Identification: ITEM DESCRIPTION 1 Bucket crowd 2 Dipper † 3 Stabiliser 4 Stabiliser 5 Boom † 6 Slew 7 Auxiliary relief valve
ITEM 8 9 10 11 12
DESCRIPTION Tank port High pressure carry-over (HPCO) port Service ports Load hold check valve assemblies Make-up check valve assembly
Relief Valve Operating Pressures: Boom Ram Head Side Boom Ram Rod Side Bucket Ram Head Side Centremount (17' , 15’ 6” backhoe - except knuckle) Centremount (14' backhoe, 15’ 6” backhoe with a knuckle fitted) Sideshift Bucket Ram Rod Side (Machines with Powerbreaker only) Dipper Ram Head Side Dipper Ram Rod Side Slew Left and Right
bar 241 - 255 338 - 352
kgf/cm2 246 - 260 344 - 358
lbf/in2 3500 - 3700 4900 - 5100
303 - 317 241 - 255 241 - 255 241 - 255 241 - 255 241 - 255 255 - 269
309 - 323 246 - 260 246 - 260 246 - 260 246 - 260 246 - 260 260 - 274
4400 - 4600 3500 - 3700 3500 - 3700 3500 - 3700 3500 - 3700 3500 - 3700 3700 - 3900
Weight: 44 kg (97 lbs) - Centremount 46 kg (101 lbs) - Sideshift † System shown is for JCB plus pattern and JCB diagonal pattern. For ISO system, the boom and dipper spools change position, i.e. boom is position 2 and dipper is position 5. The bottom ARV from spool 5 will also be swapped with the bottom ARV from spool 2.
1
2
3
4
7
8
FIG SHOWS A CENTREMOUNT VALVE 9804/1103
5
6
7
7
0
0
0
0
0
0
!
!
!
!
!
!
0
0
0
0
0
0
7
7
7
7
9 @
A262520
15 - 05 - 02/17
3270 - 3/1-2.2
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
2DX, 212 and Variants (except 2CX)
15 - 05 - 03/1
From m/c no. 460001
Data Transmission
Front Axle Note: It is essential that the correct ratio axle in relation to the gearbox ratio is fitted to the machine. Do not fit a new axle with a different ratio to the axle being replaced. ALL WHEEL STEER MACHINES Type JCB spiral bevel input with epicyclic hub reduction Designation Installation Number of steer rams Weight (dry, with no steer rams and without wheels) Overall Gear Ratio Crownwheel and Pinion Ratio Number of Teeth Crownwheel Pinion Hub Reduction Input Type Yoke Oscillation Toe - in Castor Angle Camber Angle King - pin inclination
SD70 Centre pivot 2 385 kg (850 lbs) approximately 24.975:1 4.625:1 37 8 5.4:1 ± 5° 0° 0° 1° 0°
2 WHEEL STEER MACHINES (4 Wheel Drive) Type JCB spiral bevel input with epicyclic hub reduction Designation Installation Number of steer rams Weight (dry, with no steer rams and without wheels) Hub Reduction Input Type Oscillation Toe - in Castor Angle Camber Angle King - pin inclination Ratios Overall Crownwheel and Pinion Number of Teeth Crownwheel Pinion
SD55 Centre pivot 1 330 kg (728 lbs) approximately 5.4:1 Yoke ± 5° 0° 0° 1° 0° OPTION 1 OPTION 2 16.2:1 19.2:1 3:1 3.556:1 33 32 11 9
2 WHEEL STEER MACHINES (2 Wheel Drive) Type JCB centre oscillation, non-driven Installation Weight (dry, with steer ram and without wheels) Oscillation Toe - in Castor Angle Camber Angle
9804/1103
Centre pivot 239 kg (525 lbs) ± 5° 0° 0° 3 ° positive
15 - 05 - 03/1
3270 - F/1-2.2
Issue 2*
CONTENTS CONTENTS
*
Backhoe Loaders
3CX, 4CX and Variants
15 - 05 - 04/1
From m/c no. 460001
Data Hydraulic (cont’d) Rear Axle Note: It is essential that the correct ratio axle in relationship to the gearbox ratio is fitted to the machine. Do not fit a new axle with a different ratio to the axle being replaced. ALL WHEEL STEER MACHINES Type Designation Installation Number of steer rams Weight (dry, with no steer rams and without wheels) Half (Axle) Shaft Braking/Type Input Type Oscillation Toe - in Castor Angle Camber Angle King - pin inclination Hub Reduction Ratios Overall Crownwheel and Pinion Number of Teeth Crownwheel Pinion
3 piece, JCB spiral bevel input with epicyclic hub reduction and inboard braking SD70 Rigid pad mount 1 (Double rod) 410 kg (904 lbs) approx. 5 friction plate, 6 counter plate (each half shaft) Yoke ± 5° 0° 0° 1° 0° 5.4:1 OPTION 1 OPTION 2 15.78:1 18.16:1 2.923:1 3.363:1
OPTION 3 13.7:1 2.538:1
38 13
33 13
37 11
* Note: From 1st April 1999 the hub is splined and not doweled. Machine serial number TBA. 2 WHEEL STEER MACHINES Type Designation Installation Weight (dry and without wheels) Half (Axle) Shaft Braking/Type Input Type Hub Reduction Ratios Overall Crownwheel and Pinion Number of Teeth Crownwheel Pinion
9804/1103
3 piece, JCB spiral bevel input with epicyclic hub reduction and inboard braking PD70 Rigid pad mount 386 kg (851 lbs) approx. 5 friction plate, 6 counter plate (each half shaft) Yoke 5.4:1 OPTION 1 OPTION 2 OPTION 3 15.78:1 18.16:1 13.7:1 2.923:1 3.363:1 2.538:1 38 13
37 11
15 - 05 - 04/1
33 13
3270 - F/1-2.2
Issue 3*
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX, (200 Series)
15 - 05 - 05/1
From m/c no. 400001
Data - Transmission (continued)
Tyre Sizes and Pressures TWO WHEEL STEER MACHINES Type
Size
Ply bar
Pressure lbf/in2
Front - 2WD Ribbed (Armstrong) Ribbed (Goodyear) Industrial Industrial Industrial
11L x 16 11.0 x 16 11L x 16 10.5 x 18 12.0 x 18
12 12 12 10 12
4.4 4.2 4.4 3.8 3.5
64 60 64 55 50
Front - 4WD † Industrial Traction Industrial (Firestone) Industrial (Olympic) Radial Industrial † Radial † Radial Industrial
14 x 17.5 10.5 x 18 12.0 x 18 12.0 x 18 335/80 x R18 12.5/80 x 18 335/80 - R20 12.5 - R20 12.5/12.0 x 18
10 10 12 12 XM27 10 XM27 XM27 12
3.8 3.8 3.5 4.5 3.5 4.25 3.0 3.0 3.5
55 55 50 65 50 61 * (see WARNING below) 43.5 43.5 50
Rear - 2WD & 4WD Industrial Industrial Industrial Industrial Traction (Goodyear) Traction (Olympic) Industrial Traction Industrial Radial Industrial
16.9 x 24 19.5L x 24 19.5L x 24 21L x 24 18.4 x 26 18.4 x 26 18.4 x 26 16.9 x 28 16.9 x 28 16.9 - R28 18.4 x 30
10 10 12 12 12 12 12 12 12 XM27 14
2.2 1.9 2.3 2.2 2.5 2.0 2.0 2.4 2.2 3.1 2.0
32 27.5 33 32 36 * (see WARNING below) 29 29 35 32 45 29
10 12 14 12 XM27 XTLA
2.2 2.6 2.6 2.6 3.1 2.5
32 * (see WARNING below) 38 38 38 45 36 * (see WARNING below)
ALL WHEEL STEER MACHINES Front and Rear - 4WD † Industrial † Industrial † Industrial Industrial † Radial Radial
16.9 x 28 16.9 x 28 16.9 x 28 16.9 x 24 16.9 x R28 15.5 x 25
Note: 12 ply tyres must be fitted on rear wheels when any backhoe attachment is used. For the correct pressure see the table above. The front wheels from machine serial number 400001 are made from a stronger construction than front wheels fitted prior to 400001. Wheels fitted to Backhoe Loaders prior to 400001 must not be used on the new Backhoe Loaders. †
Steering lock restriction stops must be fitted to 4 wheel drive machines that have this type of tyre fitted, consult your JCB Distributor for advice.
WARNING: Tyres indicated above with an asterix (*) are not recommended or approved for use on 5-speed machines. DO NOT use these tyres on 5-speed machines.
9804/1103
15 - 05 - 05/1
Issue 3
Backhoe Loaders
CONTENTS CONTENTS
15 - 05 - 05/2
3CX, 4CX and Variants
From m/c no. 460001
Data - Transmission (continued) Tyre Sizes and Pressures Front Wheels Note: If the tyres fitted to your machine are not listed, then contact JCB for advice, DO NOT guess tyre pressures.
Front Wheels AWS/4WD MACHINES Item
Size x Ply
Type
Make
Remarks
Pressure bar
lbf/in2
1
16.9x24x12
IND
ARMSTRONG
TUBELESS
2.6
38
2
16.9x24x12
IND
GOODYEAR
TUBELESS
2.6
38
3
15.5x25
XTLA
MICHELIN
TUBELESS
2.5
36
4
16.9x28x12
IND
ARMSTRONG
TUBELESS
2.6
38
5
16.9x28x12
IND
GOODYEAR
TUBELESS
2.6
38
6
16.9x28x10
IND
GOODYEAR
TUBELESS
2.2
32
7
16.9x28
XM27
MICHELIN
TUBELESS
2.7
39
8
16.9x28x14
IND
NOKIA
TUBE
2.6
38
9
16.9x24x12
IND
GOODYEAR
TUBELESS
2.6
38
10
16.9x28x12
TRAC
OLYMPIC
TUBELESS
2.6
38
11
16.9x28x12
IND
OLYMPIC
TUBE
2.6
38
12
14.9x24x12
IND
GOODYEAR
TUBELESS
2.75
40
13
16.9x28
IND
GOODYEAR
TUBELESS
2.5
36
2WS/2WD MACHINES 21
11.0x16x12
RIB
ARMSTRONG
TUBELESS
4.4
64
22
11.0x16x12
RIB
GOODYEAR
TUBELESS
4.2
61
23
11Lx16x12
IND
ARMSTRONG
TUBELESS
4.4
64
24
10.5x18x10
IND
FIRESTONE
TUBELESS
3.8
55
25
12.0x18x12
IND
FIRESTONE
TUBELESS
3.5
51
2WS/4WD MACHINES 31
14x17.5x10
IND
ARMSTRONG
TUBELESS
3.8
55
32
14x17.5x10
IND
GOODYEAR
TUBELESS
3.8
55
34
12.0x18x12
IND
FIRESTONE
TUBELESS
3.5
51
35
12.0x18x12
IND
OLYMPIC
TUBELESS
4.25
62
36
335 x18
XM27
MICHELIN
TUBELESS
3.5
51
37
12.5x18x10
IND
GOODYEAR
TUBELESS
4.25
62
38
335 x20
XM27
MICHELIN
TUBE
3.0
43.5
39
340 x18
IND
GOODYEAR
TUBELESS
3.2
46
Items 4, 5, 6, 7,8, 9, 10, 11, 13, 38 must have steering lock restriction stops fitted.
9804/1103
15 - 05 - 05/2
3270 - F/1-3.1
Issue 1
Backhoe Loaders
CONTENTS
15 - 05 - 05/3
3CX, 4CX and Variants
From m/c no. 460001
Data - Transmission (continued) Tyre Sizes and Pressures Rear Wheels Note: If the tyres fitted to your machine are not listed, then contact JCB for advice, DO NOT guess tyre pressures.
AWS MACHINES Item
Size x Ply
Type
Make
Remarks
Pressure bar
lbf/in2
1
16.9x24x12
IND
ARMSTRONG
TUBELESS
2.6
38
2
16.9x24x12
IND
GOODYEAR
TUBELESS
2.6
38
3
15.5x25
XTLA
MICHELIN
TUBELESS
2.5
36
4
16.9x28x12
IND
ARMSTRONG
TUBELESS
2.6
38
5
16.9x28x12
IND
GOODYEAR
TUBELESS
2.6
38
6
16.9x28x10
IND
GOODYEAR
TUBELESS
2.2
32
7
16.9x28
XM27
MICHELIN
TUBELESS
2.7
39
8
16.9x28x14
IND
NOKIA
TUBE
2.6
38
9
16.9x24x12
IND
GOODYEAR
TUBELESS
2.6
38
10
16.9x28x12
TRAC
OLYMPIC
TUBELESS
2.6
38
11
16.9x28x12
IND
OLYMPIC
TUBE
2.6
38
12
14.9x24x12
IND
GOODYEAR
TUBELESS
2.75
40
13
16.9x28
IND
GOODYEAR
TUBELESS
2.5
36
2WS MACHINES 21
16.9x24x10
IND
ARMSTR0NG
TUBELESS
2.2
32
22
16.9x24x12
IND
GOOOYEAR
TUBELESS
2.2
32
23
19.5x24x10
IND
ARMSTRONG
TUBELESS
1.9
28
24
19.5x24x12
IND
ARMSTRONG
TUBELESS
2.3
33
25
21L x24x12
IND
GOODYEAR
TUBELESS
2.2
32
26
18.4x26x12
TRAC
GOODYEAR
TUBELESS
2.5
36
27
18.4x26x12
TRAC
OLYMPIC
TUBELESS
2.4
35
28
18.4x26x12
IND
GOODYEAR
TUBELESS
2.0
29
29
16.9x28x12
TRAC
OLYMPIC
TUBELESS
2.2
32
30
16.9x28x12
TRAC
FIRESTONE
TUBE
2.2
32
31
16.9x28x12
IND
GOODYEAR
TUBELESS
2.2
32
32
16.9x28
XM27
MICHELIN
TUBELESS
2.5
36
33
18.4x30x14
IND
GOODYEAR
TUBE
2.0
29
34
16.9x28
IND
GOODYEAR
TUBELESS
2.5
36
Note: 12 ply tyres must be fitted on rear wheels when any backhoe attachment is used. For the correct pressure see the table above. Items 4, 5, 6, 7,8, 9, 10, 11, 13 must have steering lock restriction stops fitted.
9804/1103
15 - 05 - 05/3
3270 - F/1-4.1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 05 - 06/1
3CX, 4CX, (200 Series)
From m/c no. 400001
Data - Transmission (cont’d)
Syncro Shuttle Description
Combined torque converter, reverser, and gearbox unit with integral parking brake. SS640 (4 wheel drive) 176 kg (388 lb) Std Ratio Low Ratio 36 38 19 17
Designation Weight (dry) Number of Teeth Transfer Gear Layshaft Input Gear (4WD) - 2WS - AWS Output Gear (4WD) - 2WS - AWS Gear Ratios 1st 2nd 3rd 4th Torque Converter Dia. Torque Multiplication at Stall
24 24
26 24
34 34 Std Ratio 5.56:1 3.45:1 1.83:1 1.00:1 279mm (11in.) 2.20:1 or 2.40:1 or 2.80:1
32 or 33 34 Low Ratio 6.56:1 4.06:1 1.90:1 1.00:1
Torque Converter Colour Code Identification Colour Coded Dots
2.20:1 Ratio 2 purple 1 White
2.40:1 Ratio 2 Orange 1 Green
Minimum Engine Rev/Min at Converter Stall
See pages 15 - 05 - 07/3 and 07/4
Converter Pressures (in neutral) Converter In at 50 deg.C 1000 rev/min 2000 rev/min
bar 2.4 - 3.4 5.2 - 6.5
kgf/cm2 2.5 - 3.5 5.3 - 6.7
lbf/in2 35 - 50 75 - 95
Converter In at 100 deg.C
1000 rev/min 2000 rev/min
1.3 - 2.0 5.2 - 5.9
1.4 - 2.1 5.3 - 6.0
20 - 30 75 - 85
Converter Out at 50 deg.C
1000 rev/min 2000 rev/min
1.0 - 1.7 2.0 max
1.1 - 1.8 2.0 max
15 - 25 29 max
Converter Out at 100 deg.C
1000 rev/min 2000 rev/min
0.3 - 0.6 1.0 - 1.7
0.3 - 0.6 1.1 - 1.8
4.0 - 8.0 15 - 25
Converter Inlet Relief Valve Pressure (max.)
6.5
6.7
95
Lubrication Pressures (in neutral) At 50 deg.C 1000 rev/min 2000 rev/min
bar 0.2 - 0.3 0.4 - 0.7
kgf/cm2 0.2 - 0.4 0.4 - 0.7
lbf/in2 3.0 - 5.0 6.0 - 10.0
At 100 deg.C
0.1 - 0.2 0.3 - 0.6
0.1 - 0.2 0.3 - 0.6
2.0 - 3.0 4.0 - 8.0
1000 rev/min 2000 rev/min
2.80:1 Ratio 3 Brown
.....cont'd
9804/1103
15 - 05 - 06/1
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
15 - 05 - 06/2
3CX, 4CX, (200 Series)
From m/c no. 400001
Data - Transmission (cont’d)
Syncro Shuttle (cont'd) Main Line Pressure (in neutral) At 50 deg. C
1000 rev/min 2000 rev/min
bar 9.3 - 10.3 10.7 - 11.7
kgf/cm2 9.5 - 10.5 10.9 - 12.0
lbf/in2 135 - 150 155 - 170
1000 rev/min 2000 rev/min
9.3 - 10.3 9.3 - 10.3
9.5 - 10.5 9.5 - 10.5
135 - 150 135 - 150
Clutch Pressure (forward and reverse) At 50 deg. C 1000 rev/min 2000 rev/min
bar 8.3 - 9.0 9.0 - 10.0
kgf/cm2 8.4 - 9.1 9.1 - 10.2
lbf/in2 120 - 130 130 - 145
At 100 deg.C
8.3 - 9.0 8.3 - 9.0
8.4 - 9.1 8.4 - 9.1
120 - 130 120 - 130
1000 rev/min 2000 rev/min
8.6 - 9.3 8.6 - 9.3
8.8 - 9.5 8.8 - 9.5
125 - 135 125 - 135
1000 rev/min 2000 rev/min
L/min 10.4 - 13.6 14.5 - 20.0
US gal/min 2.8 - 3.6 3.8 - 5.3
UK gal/min 2.3 - 3.0 3.2 - 4.4
Cooler at 100 deg.C
1000 rev/min 2000 rev/min
10.2 - 12.5 22.7 - 26.1
2.7 - 3.3 6.0 - 6.9
2.3 - 2.8 5.0 - 5.7
Pump at 50 deg.C
1000 rev/min 2000 rev/min
11.0 - 15.0 22.5 - 29.5
2.9 - 4.0 6.0 - 7.8
2.5 - 3.3
At 100 deg.C
1000 rev/min 2000 rev/min
Clutch Pressure (to disconnect 4 wheel drive) At 50 deg. C
Flow Rates (in neutral) Cooler at 50 deg.C
9804/1103
15 - 05 - 06/2
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX, (200 Series)
15 - 05 - 07/1
From m/c no. 400001
Data - Transmission (cont’d)
Powershift Description
Full electro-hydraulic transmission unit with input, reverse, layshaft, mainshaft and 4 wheel drive clutch packs. Torque converter and parking brake integral . PS740 (4 wheel drive) 236 kg (520 lb) 265 kg (585 lb) Std Ratio Low Ratio 45 46 18 16
Designation Weight (dry) - 4-Speed Gearbox Weight (dry) - 5-Speed Gearbox Number of Teeth Transfer Gear Layshaft Input Gear (4WD) - 2WS - AWS Output Gear (4WD) - 2WS - AWS Gear Ratios 1st 2nd 3rd 4th 5th (if fitted) Torque Converter Dia. Torque Multiplication at Stall
26 24
26 or 25 24
41 41 44 44 Std Ratio Low Ratio 5.72:1 6.58:1 3.23:1 3.71:1 1.77:1 1.77:1 1.00:1 1.00:1 0.788:1 0.788:1 279mm (11in.) 2.20:1 or 2.40:1 or 2.80:1
Torque Converter Colour Code Identification Colour Coded Dots
2.20:1 Ratio 2 Purple 1 White
2.40:1 Ratio 2 Orange 1 Green
2.80:1 Ratio 3 Brown
5-Speed Gearboxes Only -
1 Black 1 Orange
2 Black 1 Green
N/A
Minimum Engine Rev/Min at Converter Stall
See pages 15-05-07/3 & 15-05-07/4
Converter Pressures (in neutral) Converter In at 50 deg.C 1000 rev/min
bar 2.8 - 4.1
kgf/cm2 2.8 - 4.2
lbf/in2 40 - 60
2000 rev/min
4.8 - 6.2
4.9 - 6.3
70 - 90
1000 rev/min
1.9 - 2.3
1.9 - 2.3
27 - 33
2000 rev/min
2.3 - 2.7
2.3 - 2.7
33 - 39
Converter Inlet Relief Valve Pressure (max.)
6.5
6.7
95
Lubrication Pressures (in neutral) At 50 deg.C 1000 rev/min
bar 0.14 - 0.28
kgf/cm2 0.14 - 0.28
lbf/in2 2.0 - 4.0
2000 rev/min
0.28 - 0.55
0.28 - 0.56
4.0 - 8.0
Converter Out at 50 deg.C
9804/1103
15 - 05 - 07/1
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
15 - 05 - 07/2
3CX, 4CX, (200 Series)
From m/c no. 400001
Data - Transmission (cont’d)
Powershift (cont'd) Mainline Pressure (in neutral) At 50 deg. C
Flow Rates (in neutral) Cooler at 50 deg.C
Pump at 50 deg.C
1000 rev/min
bar 9.0 - 10.0
kgf/cm2 9.1 - 10.2
lbf/in2 130 - 145
2000 rev/min
9.7 - 11.0
9.8 - 11.3
140 - 160
1000 rev/min
litres/min 10.4 - 13.6
US gal/min 2.8 - 3.6
UK gal/min 2.3 - 3.0
2000 rev/min
14.5 - 20.0
3.8 - 5.3
3.2 - 4.4
1000 rev/min
11.0 - 15.0
2.9 - 4.0
2.5 - 3.3
2000 rev/min
22.5 - 29.5
6.0 - 7.8
5.0 - 6.5
The following clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2): Input Clutch Pressure (high and low ratio) Reverse Clutch Pressure (high and low ratio) Layshaft Clutch Pressure Mainshaft Clutch Pressure 2/4 Wheel Drive Clutch Pressure
9804/1103
15 - 05 - 07/2
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX and Variants
15 - 05 - 07/2A
From m/c no. 460001
Data - Transmission (continued) Syncro Shuttle Description Designation Weight (dry) 2WD 4WD Gear Ratios 1st 2nd 3rd 4th Torque Convertor Torque Converter Dia. Torque Converter Identification Torque Multiplication at Stall Torque Convertor Colour Coded Dots
Combined torque converter, reverser, and gearbox unit with integral parking brake. SS640 (4 wheel drive) 157 kg (346 lb) 176 kg (388 lb) Std Ratio Low Ratio 5.56:1 6.56:1 3.45:1 4.06:1 1.83:1 1.90:1 1.00:1 1.00:1 310 mm (12.2 in.) 12.2 - D 12.2 - P 2.82:1 2.54:1 2 Purple 2 Orange 1 Yellow 1 Yellow lbf/in2 35 - 50 75 - 95 20 - 30 75 - 85 15 - 25 29 max 4.0 - 8.0 15 - 25 95
Converter Pressures (in neutral) Converter In at 50 deg.C 1000 rev/min 2000 rev/min Converter In at 100 deg.C 1000 rev/min 2000 rev/min Converter Out at 50 deg.C 1000 rev/min 2000 rev/min Converter Out at 100 deg.C 1000 rev/min 2000 rev/min Converter Inlet Relief Valve Pressure (max.)
bar 2.4 - 3.4 5.2 - 6.5 1.3 - 2.0 5.2 - 5.9 1.0 - 1.7 2.0 max 0.3 - 0.6 1.0 - 1.7 6.5
kgf/cm2 2.5 - 3.5 5.3 - 6.7 1.4 - 2.1 5.3 - 6.0 1.1 - 1.8 2.0 max 0.3 - 0.6 1.1 - 1.8 6.7
Lubrication Pressures (in neutral) At 50 deg.C 1000 rev/min 2000 rev/min At 100 deg.C 1000 rev/min 2000 rev/min
bar 0.2 - 0.3 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6
kgf/cm2 0.2 - 0.4 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6
lbf/in2 3.0 - 5.0 6.0 - 10.0 2.0 - 3.0 4.0 - 8.0
Main Line Pressure (in neutral) † At 50 deg. C 1000 rev/min 2000 rev/min At 100 deg.C 1000 rev/min 2000 rev/min
bar 9.7 - 12.8 11.4 - 14.1 11.4 - 12.8 11.4 - 13.4
kgf/cm2 9.8 - 13.0 11.6 - 14.4 11.6 - 13.0 11.6 - 13.7
lbf/in2 140 - 185 165 - 205 165 - 185 165 - 195
Clutch Pressures † Flow Rates (in neutral) Cooler at 50 deg.C Cooler at 100 deg.C Pump at 50 deg.C
All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2)
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
L/min 10.4 - 13.6 14.5 - 20.0 10.2 - 12.5 22.7 - 26.1 11.0 - 15.0 22.5 - 29.5
US gal/min 2.8 - 3.6 3.8 - 5.3 2.7 - 3.3 6.0 - 6.9 2.9 - 4.0 6.0 - 7.8
UK gal/min 2.3 - 3.0 3.2 - 4.4 2.3 - 2.8 5.0 - 5.7 2.5 - 3.3 5.0 - 6.5
† Note: For gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2 ).
9804/1103
15 - 05 - 07/2A
3270 - F/1-5.1
Issue 1
Backhoe Loaders
CONTENTS
3CX, 4CX and Variants
15 - 05 - 07/2B
From m/c no. 460001
Data - Transmission (continued) Powershift Description
Designation Weight (dry) 2WD 4WD Gear Ratios 1st 2nd 3rd 4th Torque Convertor Torque Converter Dia. Torque Converter Identification Torque Multiplication at Stall Torque Convertor Colour Coded Dots
Full electro-hydraulic transmission unit with input, reverse, layshaft, mainshaft and 4 wheel drive clutch packs. Torque converter and parking brake integral . PS740 (4 wheel drive) and PS750 220 kg (484 lb) 236 kg (519 lb) Std Ratio 5.72:1 3.23:1 1.77:1 1.00:1
Low Ratio 6.58:1 3.71:1 1.77:1 1.00:1
310 mm (12.2 in.) 12.2 - D 12.2 - P 2.82:1 2.54:1 2 Purple 2 Orange 1 Yellow 1 Yellow bar kgf/cm2 2.8 - 4.1 2.8 - 4.2 4.8 - 6.2 4.9 - 6.3
lbf/in2 40 - 60 70 - 90
Converter Out at 50 deg.C
1000 rev/min 2000 rev/min Converter Inlet Relief Valve Pressure (max.)
1.9 - 2.3 2.3 - 2.7 6.5
1.9 - 2.3 2.3 - 2.7 6.7
27 - 33 33 - 39 95
Lubrication Pressures (in neutral) At 50 deg.C 1000 rev/min 2000 rev/min
bar 0.14 - 0.28 0.28 - 0.55
kgf/cm2 0.14 - 0.28 0.28 - 0.56
lbf/in2 2.0 - 4.0 4.0 - 8.0
Main Line Pressure (in neutral) † At 50 deg. C 1000 rev/min 2000 rev/min At 100 deg.C 1000 rev/min 2000 rev/min
bar 9.7 - 12.8 11.4 - 14.1 11.4 - 12.8 11.4 - 13.4
kgf/cm2 9.8 - 13.0 11.6 - 14.4 11.6 - 13.0 11.6 - 13.7
lbf/in2 140 - 185 165 - 205 165 - 185 165 - 195
Converter Pressures (in neutral) Converter In at 50 deg.C 1000 rev/min 2000 rev/min
Clutch Pressures † Flow Rates (in neutral) Cooler at 50 deg.C Pump at 50 deg.C
All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2)
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
litres/min 10.4 - 13.6 14.5 - 20.0 11.0 - 15.0 22.5 - 29.5
US gal/min 2.8 - 3.6 3.8 - 5.3 2.9 - 4.0 6.0 - 7.8
UK gal/min 2.3 - 3.0 3.2 - 4.4 2.5 - 3.3 5.0 - 6.5
† Note: For new gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2 ).
9804/1103
15 - 05 - 07/2B
3270 - F/1-6.2
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 05 - 07/3
3CX, 4CX, (200 Series)
From m/c no. 400001
Data - Transmission (cont’d)
Stall Figures The figures given below and on the following page apply to 'bedded-in' engines, i.e. engines that have done a minimum of 250 working hours, therefore they should not be used for PDI checks. They are intended to be used as guideline figures only and should not be considered as servicing parameters. ALL WHEEL STEER MACHINES 4CX
4CX 214S 215S N.Am. ServoPlus
4CX option Nordic Iceland
4CX option Malasia
217S N.Am.
max r.p.m. min. r.p.m.
2170 2100
2130 2065
2160 2085
2120 2055
2100 2030
max. r.p.m. min. r.p.m.
1795 1700
1770 1670
1685 1575
1660 1550
1640 1530
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Engine Stall Speed 1 Converter only
2
Converter + MRV
Build Specification Engine Size
N.A. (74 bhp) T2 (90 bhp) T3 (96 bhp)
Converter Type
SSL 11 (2.8:1) WH 11 (2.4:1) W11 (2.2:1)
Pump Size (UK gals)
26 gal 28 gal 30 gal 34 gal
Fan Ratio
1 to 1 1 to 1.25
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1 to 1.36
9804/1103
● ●
15 - 05 - 07/3
Issue 1
CONTENTS
3CX
3CX
214 N.Am.
3CXT
3CXT
3CXT+ 3CXT+ 3CXT option Nordic Iceland
3CXT option South Africa
214T N.Am.
215 N.Am.
217 N.Am.
CONTENTS
Note: All tests conducted with single pump option selected unless specified thus #, then tests to be conducted with double pump option selected.
3CX, 4CX, (200 Series)
TWO WHEEL STEER MACHINES
Data - Transmission (cont’d)
9804/1103
Stall Figures
Engine Stall Speed Convertor Only
max r.p.m. min r.p.m.
1755 1695
1735 1670
2215# 2145#
1900 1830
1875 1810
1890 1820
1870 1800
1880 1810
1860 1790
2070 2000
2065 1995
1915 1840
2
Convertor + MRV
max r.p.m. min r.p.m.
1360 1260
1340 1245
1830# 1730#
1525 1420
1510 1405
1515 1410
1495 1390
1380 1220
1365 1200
1730 1630
1675 1570
1465 1345
Backhoe Loaders
15 - 05 - 07/4
1
Build Specification Engine Size
Convertor Type
Pump Size (U.K. gals)
SSL 11 (2.8:1) WH 11 (2.4:1) W11 (2.2:1)
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26 UK gal. 28 UK gal. 30 UK gal. 34 UK gal.
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1 to 1 1 to 1.25 1 to 1.36
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Issue 1
15 - 05 - 07/4
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From m/c no. 400001
Fan Ratio
N.A. (74 bhp) T2 (90 bhp) T3 (96 bhp)
CONTENTS
3CXT
3CXT
3CXT
3CXT
3CXT
3CXT
214E N. Am.
214 N. Am.
214T/215E N. Am.
214T/215E N. Am.
Engine Speed @ Stall Combination 1.Convertor only. Max.r.p.m. 1880 1905 Min.r.p.m. 1790 1800
2040 1935
2015 1910
2040 1935
2015 1910
2100 2000
2070 1980
2160 2050
2200 2095
2230 2170
2220 2160
2070 1975
2060 1960
2.Convertor + M.R.V. Max.r.p.m. Min.r.p.m.
1575 1430
1550 1405
1475 1310
1445 1270
1655 1560
1635 1545
1345 1140
1650 1575
1745 1620
1720 1580
1630 1540
1620 1540
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15 - 05 - 07/5
Build specification. Engine size. N.A. (75hp) (56kw) T2 (91hp) (68kw) T3 (96hp) (72kw) Convertor type. 12.2D (2.82) 12.2P (2.54) Pump size. 50cc 33/23cc 36/26cc 41/26cc 41/29cc
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15 - 05 - 07/5
Isssue 1
Air Conditioning None (Europe) None (R.O.W.) Europe Europe (Hot) R.O.W.
1465 1365
From m/c no. 460001
3270 - F/1-7.1
Fan Ratio. 1 to 0.85 1 to 1.06 1 to 1.16
1100 stall
215/217 215/217 N. Am. N. Am.
Backhoe Loaders
3CX
CONTENTS
3CXE
3CX, 4CX and Variants
Note. On all double pump options the test is to be carried out with single pump option selected.
Data - Transmission (continued)
9804/1103
Pump/Transmission Stall Speed Combinations 2WS Machines, 12.2 Convertor, Gear Pump, 1000 Series Engine
CONTENTS
4CX
4CX
4C/4CN
4C/4CN
4C/4CN
214S N. Am.
214S N. Am.
215S/217S N. Am.
Engine Speed @ Stall Combination 1.Convertor only. Max.r.p.m. 2040 Min.r.p.m. 1935
2015 1910
2100 2000
2070 1980
2095 2000
2070 1975
2060 1960
2100 2000
2075 1980
2070 1975
2060 1960
2.Convertor + M.R.V. Max.r.p.m. Min.r.p.m.
1575 1430
1550 1405
1655 1560
1635 1545
1650 1560
1630 1540
1620 1530
1655 1560
1635 1545
1630 1540
1620 1530
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Build specification. Engine size. N.A. (75hp) (56kw) T2 (91hp) (68kw) T3 (96hp) (72kw) Convertor type 12.2D (2.82) 12.2P (2.54) Pump size. 50cc 33/23cc 36/26cc 41/26cc 41/29cc
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15 - 05 - 07/6
Issue 1
Air Conditioning None (Europe) None (R.O.W.) Europe Europe (Hot) R.O.W.
●
From m/c no. 460001
3270 - F/1-8.1
Fan Ratio. 1 to 0.85 1 to 1.06 1 to 1.16
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215S/217S N. Am.
Backhoe Loaders
15 - 05 - 07/6
3CXSuper
CONTENTS
3CXSuper
3CX, 4CX and Variants
Note. On all double pump options the test is to be carried out with single pump option selected.
Data - Transmission (continued)
9804/1103
Pump/Transmission Stall Speed Combinations - AWS Machines, 12.2 Convertor, Gear Pump, 1000 Series Engine
CONTENTS
4CXSuper 4CXSuper 4CXSuper
2130 2035
2155 2055
2130 2035
2155 2020
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Convertor type 12.2D (2.82) 12.2P (2.54)
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Pump size. 74 Variable
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Fan Ratio. 1 to 0.85 1 to 1.06 1 to 1.16
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15 - 05 - 07/7
Issue 1
From m/c no. 460001
3270 - F/1-9.2
Air Conditioning None (Europe) None (R.O.W.) Europe Europe (Hot) R.O.W.
●
Backhoe Loaders
15 - 05 - 07/7
Build specification. Engine size. N.A. (75hp) (56kw) T2 (91hp) (68kw) T3 (96hp) (72kw)
CONTENTS
Engine Speed @ Stall Combination 1.Convertor only. Max.r.p.m. 2155 Min.r.p.m. 2055
4CX
3CX, 4CX and Variants
4CX
Data Transmission (cont’d)
9804/1103
Pump/Transmission Stall Speed Combinations - AWS Machines, 12.2 Convertor, Variable Pump, 1000 Series Engine
CONTENTS
3CXT
3CXT
3CXT
3CX
3CX
214E
214e
214
214e.T
Std lift
Std lift Hi. lift
Hi. lift
Contractor
Contractor
N. Am.
N. Am.
N. Am.
Engine Speed @ Stall Combination 1.Convertor only. Max.r.p.m. 1965 2080 Min.r.p.m. 1850 1975
2070 1960
2080 1980
2070 1965
2135 2030
2125 2020
2170 2075
2240 2170
2.Convertor + M.R.V. Max.r.p.m. Min.r.p.m.
1720 1600
1675 1545
1660 1530
1770 1660
1760 1650
1415 stall
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15 - 05 - 07/8
Build specification. Engine size. N.A. (75hp) (56kw) T1 (80hp (60kw) T2 (91hp) (68kw) T3 (100hp) (74kw) Convertor type. SSL11(2.83) 12.2D (2.82) 12.2P (2.54) Pump size. 50cc 33/23cc 36/26cc 41/26cc 41/29cc
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215 217 N. Am.
2220 2110
2240 2170
2240 2165
2230 2160
2120 2015
1555 1280
1770 1625
1745 1580
1890 1760
1875 1745
1760 1645
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15 - 05 - 07/8
Issue 1
Air Conditioning None Europe ROW
1735 1615
215E 214T N. Am.
From m/c no. 460001
3270 - F/1-10.2
Fan Ratio. 1 to 0.85 1 to 1.06 1 to 1.16
1520 1380
N. Am.
215E 214T N. Am.
Backhoe Loaders
3CXT
CONTENTS
3CX
3CX, 4CX and Variants
Note. On all double pump options the test is to be carried out with single pump option selected.
Data Transmission (cont’d)
9804/1103
Low Emission Engine Stall Speed Combinations - 2WS Machines
CONTENTS
3CXS Hi. lift
3CXS Hi. lift
4CX
4CX
Engine Speed @ Stall Combination 1.Convertor only. Max.r.p.m. 2080 Min.r.p.m. 1975
2070 1965
2080 1980
2070 1965
2135 2030
2125 2020
2135 2030
2120 2015
2.Convertor + M.R.V. Max.r.p.m. Min.r.p.m.
1735 1615
1720 1600
1675 1545
1660 1530
1770 1660
1760 1650
1770 1660
1760 1645
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Build specification. Engine size. N.A. (75hp) (56kw) T2 (91hp) (68kw) T3 (100hp) (74kw) Convertor type 12.2D (2.82) 12.2P (2.54)
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Pump size. 50cc 33/23cc 36/26cc 41/26cc 41/29cc 74 Variable
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Fan Ratio. 1 to 0.85 1 to 1.06 1 to 1.16
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4CXS 4CX
214S N. Am.
215S/217S N. Am.
2180 2080
2170 2065
2125 2020
2120 2015
1760 1650
1760 1645
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15 - 05 - 07/9
Issue 1
Air Conditioning None (Europe) None Europe Europe (Hot) R.O.W.
●
4CXS 4CX
From m/c no. 460001
3270 - F/1-11.1
●
4CXS/4C 4CXS/4C
Backhoe Loaders
15 - 05 - 07/9
3CXS Std lift
CONTENTS
3CXS Std lift
3CX, 4CX and Variants
Note. On all double pump options the test is to be carried out with single pump option selected.
Data Transmission (cont’d)
9804/1103
Low Emission Engine Stall Speed Combinations - AWS Machines
CONTENTS CONTENTS
Backhoe Loaders
ALL MODELS (EXCEPT 2CX)
15 - 05 - 08/1
From m/c no. 400001
Data - Brakes STANDARD MACHINES Service Brake Type Actuation Location
JCB Oil-Immersed Multi-Plate Disc Hydraulic - vacuum servo assisted for machines powered by model AB turbocharged engine Rear Axle Centre Casing (2 brake packs)
Friction Plates (5 per brake pack) Outside Diameter Inside Diameter Nominal Facing Area per Plate Hydraulic Piston Diameter
220 mm (7.992 in) 180 mm (6.811 in) 12616 mm2 (19.3 in2) 216 mm (8.5 in)
Master Cylinder (combined servo assistance) Number of Cylinders Type Piston Diameter (each)
2 Frenos compensated master cylinder 22.22 mm (0.875 in)
Exhauster Type
Frenos Iruna
Parking Brake Type output Disc Diameter
Manually Adjusted Caliper, cable operated, mounted on transmission 279.4 mm (11 in)
SERVO MACHINES Service Brake Type Actuation Location
As 'Standard Machines' As 'Standard Machines' As 'Standard Machines'
Friction Plates (5 per brake pack) Outside Diameter Inside Diameter Nominal Facing Area per Plate Hydraulic Piston Diameter
As 'Standard Machines' As 'Standard Machines' As 'Standard Machines' As 'Standard Machines'
Master Cylinder Number of Cylinders Type Front Rear Piston Diameter Front (each) Rear
3 (two front and one rear) Frenos compensated master cylinder with integral servo unit Frenos master cylinder with remote mounted servo unit 22.22 mm (0.875 in) 28.575mm (1.125 in)
Brake Changeover Valve Number of Changeover Valves Purpose
2 Isolate front brake system from rear brake system
Exhauster Type
As 'Standard Machines'
Parking Brake Type Disc Diameter
As 'Standard Machines' As 'Standard Machines'
9804/1103
15 - 05 - 08/1
Issue 2
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 05 - 08/2
From m/c no. 460001
Data - Brakes Service Brake Type
JCB Oil-Immersed Multi-Plate Disc
Actuation
Hydraulic - vacuum servo assisted for machines powered by model AB turbocharged engine
Location
Rear Axle Centre Casing (2 brake packs)
Friction Plates (5 per brake pack) Outside Diameter Inside Diameter Nominal Facing Area per Plate Hydraulic Piston Diameter
220 mm (7.992 in) 160 mm (6.299 in) 18603 mm2 (28.8 in2) 216 mm (8.5 in)
Master Cylinder (combined servo assistance) Number of Cylinders 2 Type
Compensated master cylinder
Piston Diameter (each)
22.22 mm (0.875 in)
Parking Brake Type Disc Diameter
Manually Adjusted Caliper, cable operated, mounted on transmission output 279.4 mm (11 in)
Note: Because the service brakes are located in the rear axle, instructions for dismantling and assembly are shown in the Transmission Section (Rear Axle Brakes).
9804/1103
15 - 05 - 08/2
3270 - G/1-1.2
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
15 - 05 - 09/1
ALL MODELS (EXCEPT 2CX)
From m/c no. 400001
Data - Engine Type Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance - Cold
- Inlet - Exhaust Oil Pressure (hot) at maximum speed - AA - AB Maximum Air Cleaner Restriction
Perkins 1000 Series 4 cylinder Engines AB - turbocharged, AA - Naturally Aspirated 100mm (3.937 in) 127mm (5.000 in) 4 litres (243 in3) Turbocharged 16.0:1, Naturally Aspirated 16.5:1 28 bar (400 lbf/in2) [maximum variation between cylinders 3.5 bar (50 lbf/in2)] 1,3,4,2 0.20mm (0.008 in) 0.45mm (0.018 in) 2.1 bar (30 lbf/in2) 2.6 bar (40 lbf/in2) 559mm (22 in H2O)
Fuel System Injection System Details Engine Model
Type
Injection Pump
Injectors
BHP
Code
Static Timing
Code
Working/Setting Pressures
All Wheel Steer Machines AB50364 Turbocharged
96
CM78L/1100/1/2420
15.5° BTDC
JG
230 atm
2 Wheel Steer Machines AA50386 Naturally Aspirated AB50388 Turbocharged AB50389 Turbocharged
76 90 96
DM55L/1000/1/2420 GM64L/1000/2/2420 CM78L/1100/1/2420
16.5° BTDC 23.0° BTDC 15.5° BTDC
HZ JK JG
220 atm 220 atm 230 atm
Idling Speed - All builds Maximum Governed Speed - All builds Maximum No-load Speed (High Idle) - All builds
750 rev/min 2200 rev/min 2320 - 2420 rev/min
Cooling System Coolant Pressure Coolant Temperature (Normal) Temperature Warning Light operates at:
0.48 bar (7 lbf/in2) 80-85 °C (176-185 °F) 98 °C (208 °F)
Note: When removing the engine from the machine the following points must be noted: i
Engine removal is possible 'through the top'.
ii The front crankshaft pulley must be removed prior to engine removal. iii Special lifting wires must be used to lift the engine see 'General Information', Section 1, in the Service Manual (publication number 9803/3260). iii The torque convertor can be left on the transmission (flexi plate removed from flywheel). iv The alternator, starter motor and hydraulic pump can be left on the engine. For further details see Engine Manual Publication No. 9806/0100
9804/1103
15 - 05 - 09/1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX and Variants
15 - 05 - 09/2
From m/c no. 460001
Data - Engine Type
1000 Series 4 cylinder Engines AB - Turbocharged AA - Naturally Aspirated AK - Turbocharged AM - Turbocharged and Intercooled AR - Naturally Aspirated
Engine Build List Number
AA50608 - AR50656, AR50654, AR50678 - 56kw (75bhp), AK50745 60kw (80bhp) AA50606 - 56kw (75bhp) AB50607 - 67.5 kw (90.5bhp), AK50628 - 68.5 kw (92bhp) AB50609 - 71.5kw (96bhp), AK50640 - 74.6 kw (100bhp) AM50647 85.5 kw (115bhp)
Bore AA, AB, AK, AM AR Stroke Swept Volume
100mm (3.937 in) 103mm (4.055 in) 127mm (5.000 in) AB, AA, AK, AM 4 litres (243 in3) AR 4.23 litres (258 in3) Compression Ratio AB 16.0:1 AA 16.5:1 AK, AM 17.25:1 AR 18.5:1 Compression Pressure 28 bar (400 lbf/in2) [maximum variation between cylinders 3.5 bar (50 lbf/in2)] Injection Sequence 1,3,4,2 Valve Clearance - Cold - Inlet 0.20mm (0.008 in) - Exhaust 0.45mm (0.018 in) Oil Pressure (hot) at maximum speed - AA 2.1 bar (30 lbf/in2) - AB, AK, AM 2.6 bar (40 lbf/in2) - AR 2.0 bar (30 lbf/in2) Maximum Air Cleaner Restriction 559mm (22 in H2O) Injection System Details - Refer to appropriate Engine Service Manual. Idling Speed Maximum Governed Speed Maximum No-load Speed (High Idle)
- All builds - All builds - All builds
880 - 930 rev/min 2200 rev/min 2400 - 2440 rev/min
Cooling System Coolant Pressure Coolant Temperature (Normal) Temperature Warning Light operates at:
0.48 bar (7 lbf/in2) 80-85 °C (176-185 °F) 98 °C (208 °F)
For further engine details see Engine Service Manual: AA, AB - 9806/0100 AK, AM, AR - 9806/2140
9804/1103
15 - 05 - 09/2
3270 - K/1-1.2
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX and Variants
15 - 10 - 01/1
From m/c no. 460001
Fault Finding - Electrical Contents
Introduction Page No.
Introduction No drive on power up No drive and continuous warning buzzer No drive Missing gears No 4th gear (4 speed machines only) Downshift protection not operating No dump No 4 wheel drive Intermittent 4 wheel drive Transmission will not downshift Lower gear than switch selected engaged Kickdown not operating Reverse will not select Psion unit will not operate
Fault No drive on power-up.
15-10-01/1 15-10-01/1 15-10-01/1 15-10-01/1 15-10-01/1 15-10-01/1 15-10-01/2 15-10-01/2 15-10-01/2 15-10-01/2 15-10-01/2 15-10-01/2 15-10-01/2 15-10-01/2 15-10-01/2
The purpose of this section is to help you trace electrical faults to a faulty unit. Once you have traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given in the Service Manual. To help identify circuits, refer to the electrical schematic diagrams. Refer to Section F, Fault Finding also as this section will deal with the mechanical aspect. 1
Before you begin fault finding, read the Safety information at the beginning of this manual.
2
Make simple checks before say, stripping a major component.
3
Make any relevant electrical checks before commencing work.
Probable Cause
Action
Blown ECU fuse.
Check ECU fuse A5
ECU mainframe connector loose.
Check connector is mating correctly with ECU.
Gear twist switch not in neutral.
Gear switch must be in neutral on power up before a gear can be selected.
No drive and continuous warning buzzer.
Attempting to select drive with the handbrake engaged.
Release handbrake.
No drive.
Faulty gear switch.
Check switches and wiring.
Handbrake sticking.
Check handbrake assembly.
Faulty gearbox harness.
Check gearbox harness and connector for continuity.
Faulty dump input.
Check dump switch and wiring.
Faulty solenoid(s)
Check solenoid(s) and wiring.
Fault gear switch
Check switch and wiring
Low oil pressures
Check clutch pack pressures, see Section F. Check mainline pressure, see Section F.
Mechanical failure
See Section F.
Faulty speed signal
Check speed sensor and wiring. Check speed sensor installation.
Missing gears
No 4th gear (4 speed machine only)
..... continued
9804/1103
15 - 10 - 01/1
3270 - C/6-1.1
Issue 1
CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 10 - 01/2
From m/c no. 460001
Fault Finding - Electrical Fault
Probable Cause
Action
Downshift protection not operating
Faulty speed signal
Check speed sensor and wiring. Check speed sensor installation.
No dump selection
Faulty dump input
Check dump switch and wiring.
No 4 wheel drive (if fitted)
Faulty 4 wheel drive input
Check 4 wheel drive switch and wiring.
Faulty 4 wheel drive solenoid
Check solenoid and wiring.
Faulty 4 wheel drive input
Check 4 wheel drive switch and wiring.
2/4 wheel drive brake switch operating
Check brake switch and wiring.
Transmission will not downshift
Speed too fast for selected downshift
Slow the machine.
Lower gear engaged than selected
Kickdown engaged
Check kickdown switch and wiring.
Kickdown not operating
Speed too fast to engage lower gear
Slow the machine.
Faulty kickdown input
Check kickdown switch and wiring.
Reverse will not operate
Speed too fast to reverse direction
Slow machine.
Psion will not communicate
Faulty connecting lead.
Check lead connection.
No power to ECU
Turn ignition ON. Check fuse A5. Check power supply to ECU.
Intermittent 4 wheel drive
9804/1103
15 - 10 - 01/2
3270 - C/6-2.1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 10 - 02/1
From m/c no. 400001
ALL MODELS (EXCEPT 2CX) Fault Finding - Hydraulic (Standard Machines)
Fault Finding Contents
Introduction Page No.
Introduction
15 - 10 - 02/1
Lack of power in all hydraulic functions
15 - 10 - 02/1
All hydraulic rams slow to operate
15 - 10 - 02/2
One hydraulic service fails to operate or is slow to operate
15 - 10 - 02/2
The engine tends to stall when the hydraulics are under load
15 - 10 - 02/2
A spool is sticking
15 - 10 - 02/3
Leaking Oil Seal (Control Valves)
15 - 10 - 02/3
Ram creep
15 - 10 - 02/3
Hydraulic oil becomes too hot
15 - 10 - 02/4
Steering fails to operate or is stiff to operate Steering fails to respond to selected mode
Fault 1
Lack of power in all hydraulic functions.
The purpose of this section is to help you trace hydraulic faults to a faulty unit (valve, actuator, ram etc). Once you have traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given in the Service Manual. To help identify circuits, valves, rams etc mentioned in the fault finding procedures, refer to the hydraulic schematic diagrams. 1
Before you begin fault finding, read the Safety information at the beginning of the Service Manual.
2
Make simple checks before say, stripping a major component.
3
Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F).
4
What ever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.
5
Make any relevant electrical checks before moving on to the hydraulics.
6
Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit.
7
Replace any seals such as 'O' rings before reassembling hydraulic components.
15 - 10 - 02/4
15 - 10 - 02/4
Probable Cause
Action
Insufficient hydraulic fluid.
Check for leaks and top up as required.
Hydraulic leaks in system.
Check hoses, replace as required.
Engine performance.
Check engine performance, see transmission section for stall speed test procedures.
Main relief valve (MRV) setting incorrect.
Check and adjust as required.
Low pump flow.
Check pump flow, if required service or replace pump.
Hydraulic tank breather
Clean or replace the breather
Tank filter by-pass valve
Check condition of hydraulic filter
Unloader valve pressure setting too high
Check pressure setting of the unloader valve.
..... continued 9804/1103
15 - 10 - 02/1
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
15 - 10 - 02/3
From m/c no. 400001
ALL MODELS (EXCEPT 2CX) Fault Finding - Hydraulic (Standard Machines) (continued) Fault 5
6
7
A spool is sticking.
Leaking Oil Seal (Control Valves)
Ram creep.
Probable Cause
Action
Oil temperature abnormally high.
Check for correct fluid, see Lubricants and Capacities. Check oil cooler and grille for blockage.
The hydraulic fluid is dirty.
Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system Fill with clean hydraulic fluid.
The service pipe connection is over tightened.
Check tightening torque.
The valve housing was twisted during installation.
Loosen retaining bolts and tighten to correct torque figures.
Pressure too high.
Check system pressure.
A control linkage is bent
Disconnect the linkage. Repair the linkage if possible, or fit a new one
A spool is bent
Dismantle the control valve. Renew spool as necessary.
A return spring is broken.
Renew as necessary.
A return spring or cap is out of alignment.
Remove the cap, check that the spring is in the correct position. Refit cap and torque tighten bolts
Temperature distribution within control valve not uniform.
Warm the entire system up before using service.
Paint or dirt on the seal face.
Remove the seal and clean.
The back pressure in the valve circuit is excessively high.
Check circuit pressures. Adjust if possible. Otherwise investigate thoroughly.
Spool damaged.
Dismantle. Inspect all parts. Renovate or renew as necessary.
The seal is not secured.
Clean the seal and tighten the retaining bolts to the correct torque.
The seal is cut or damaged.
Fit a new seal.
Associated ram or pipe lines from ram leaking.
Check and rectify as required.
Check valve malfunctioning (if fitted, e.g. stabiliser circuit)
Test check valve, rectify as required.
Associated valve section spools leaking.
Rectify, check for contamination.
Associated ARV leaking
Rectify, check for contamination.
..... continued
9804/1103
15 - 10 - 02/3
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
15 - 10 - 02/4
From m/c no. 400001
ALL MODELS (EXCEPT 2CX) Fault Finding - Hydraulic (Standard Machines) (continued) Fault 8
9
Hydraulic oil becomes too hot
Steering fails to operate or is stiff to operate
Probable Cause
Action
Oil cooler obstructed
Remove debris from cooler fins
Restriction in neutral circuit lines
Check hoses, replace as necessary
Hydraulic filter clogged and by-pass valve not working
Change hydraulic filter
Tyres not inflated to correct pressure
Inflate tyres to correct pressure
Insufficient hydraulic fluid.
Check for leaks and top up as required.
Low pump flow.
Check pump flow, if required service or replace pump.
Leaks in the relevant hoses or component connections
Check hoses and connections for leaks
Steer relief valve set incorrectly
Check pressure setting of steer unit relief valve, adjust as required.
Priority valve not operating correctly
Check if the priority valve is sticking, rectify as required. Check the load sense line from the steer unit to the priority valve for signs of leaking or poor connection.
Steer mode valve not operating correctly
Check if spools sticking, rectify as required Check if solenoids operating, replace solenoids as required
Mechanical failure
Check for damaged axle components, such as rams, trackrods, linkages etc. Check for damaged steer unit components. Steering column and associated components not set correctly.
10 Steering fails to respond to selected mode
Selector switch faulty
Check selector switch, replace as required
Proximity switches not operating correctly
Check setting of proximity switches, reset or replace switches as required.
Steer mode valve not operating correctly
Check if spools sticking, rectify as required Check if solenoids operating, replace solenoids as required.
9804/1103
Leaks in the relevant hoses or component connections
Check hoses and connections for leaks
Electrical failure
Check relevant electrical connectors, if problem still persists, do a wiring continuity check on relevant circuits.
15 - 10 - 02/4
Issue 2
CONTENTS CONTENTS
Backhoe Loaders
15 - 10 - 03/1
From m/c no. 400001
ALL MODELS (EXCEPT 2CX) Fault Finding - Hydraulic (Servo Machines)
If there appears to be a fault with the machine, eliminate the obvious and easiest tasks first before doing any detailed fault finding: 1 2 3 4 5 6 7 8 9
Check that the hydraulic oil level is correct. Check that the joystick isolator switch has not been pressed. Check that the system reset switch is not illuminated, (if so, press the switch to reset the system). Check that the seat is in its detent position (forward or rearward), remember the system will not work unless the seat is correctly positioned. Check that the relevant fuses and relays are intact. If a service is not operating (e.g. dipper), check the L.E.D. on the solenoid, if showing green then the problem is not associated with the valve, if showing red, the problem will be valve related. Check if any 'unofficial' electrical modifications have been made, for instance all relays should be diode protected, etc. If the engine will not start, check that the gear select switch is not in the 'padlock' position (turned fully anti-clockwise). Determine if the fault is electrical or hydraulic.
The following descriptions identify briefly some possible problems that may occur, and the associated remedial checks. 1
System Continually Resets
11
Check seat alignment. Check proximity switch adjustment. Check that stop switch is not depressed 2
Seat Rear and Seat Forward Functions Mixed Up.
Check wiring to switch. Check relay and wiring. Check wiring to solenoid. Check fuse B1 12
Check that proximity switches are connected correctly 3
Aux. Solenoid (e.g. Jaw) Inoperative
Float Inoperative Check wiring to switch. Check that hose burst check valves are not fitted on the loader arm circuit
System Is Completely Dead 13
Check that fuse C6 has not blown
RTD Inoperative Check shovel reset switch. Check wiring to switch
4
5
LH Joystick is Inoperative Check feed from control box at wire 423. Remember when seat is forwards that LH joystick is inoperative
14
RH Joystick is Inoperative
15
Check relay and wiring. Check wire 440 to control box
Check feed from control box at wire 430 6
RH Mode Switch Inoperative
16
17
Joystick Steering Inoperative Check wiring to switch. Check relay and wiring. Check logic box output at wire 444
Horn Inoperative Check wiring to switch. Check relay and wiring. Check that seat forward proximity switch is switching change over relay
9
Hydraulics Inoperative Check backhoe 'fault' solenoid. Check safety solenoid. Check unloader valve. Check joystick isolator switch not pressed. Check if air has entered load sense line (purge as required)
LH Mode Switch Inoperative Check that RH mode works correctly. Check that wire 445 is connected to control box
8
Excavator Valve Block Inoperative Check relay and wiring. Check wire 450 to control box
Check feed from control box at wire 421. Check that wire 446 is connected to control box 7
Loader Valve Block Inoperative
Hydraclamp Inoperative
18
Hydraulic Services Inoperative Check output from logic box at relevant valve block solenoid. Check relevant valve block. Check input to logic box from joysticks
Check wiring to switch. Check wiring to relay. Check wiring to solenoid 10
Machine Will Not Start Not in neutral. Gear select switch in lock position (turned fully anti-clockwise). Check that transmission dump switch is not stuck. Check relay and wiring
9804/1103
15 - 10 - 03/1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
ALL MODELS (EXCEPT 2CX)
15 - 10 - 03/2
From m/c no. 460001
Fault Finding - Variable Flow Hydraulics Fault Finding Contents
Introduction Page No.
Introduction
15 - 10 - 03/3
High or low system pressure
15 - 10 - 03/3
Pump stays at high pressure
15 - 10 - 03/3
Pressure or flow obtained at one port only
15 - 10 - 03/3
No pressure or flow at either port
15 - 10 - 03/3
High work port leakage
15 - 10 - 03/3
Leaks between sections
15 - 10 - 03/4
Sticking spool
15 - 10 - 03/4
Detent will not hold
15 - 10 - 03/4
Electrical detent will not hold
15 - 10 - 03/4
This section details the possible faults that may be found with the loader and backhoe valve blocks. The faults listed only appertain to valve blocks fitted on variable flow hydraulic machine systems (Rexroth valves). 1
Before you begin fault finding, read the Safety information at the beginning of this manual.
2
Make simple checks before say, stripping a major component.
3
Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F).
4
What ever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.
5
Make any relevant electrical checks before moving on to the hydraulics.
6
Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit.
7
Replace any seals such as 'O' rings before reassembling hydraulic components.
Poor performance, slow operating speed and/or low maximum stall speed 15 - 10 - 03/4
PROBLEM: POSSIBLE CAUSE: CORRECTIVE ACTION:
High or Low system pressure. 1) Wrong pressure and/or flow regulator valve settings. 2) Loss of pilot signal due to shuttle failure. 1) Readjust regulator valves. 2) Operate individual services to determine which shuttle is at fault, (see page E/16-2).
PROBLEM: POSSIBLE CAUSE: CORRECTIVE ACTION:
Pump stays at high pressure. 1) Sticking main spool. 2) Sticking compensator spool. 1) See ‘Sticking Spool’ guide. 2) Remove & clean compensator spool.
PROBLEM: POSSIBLE CAUSE: CORRECTIVE ACTION:
Can only obtain pressure or flow at one port. 1) Dirt in primary shuttle or damaged o-ring. 1) Remove & clean shuttle, inspect o-ring and replace if required.
PROBLEM: POSSIBLE CAUSE: CORRECTIVE ACTION:
No pressure or flow at either port. 1) Dirt in secondary shuttle. 1) Shift one spool at a time with blocked ports until faulty section found, remove shuttle and clean, inspect o-ring and replace if required.
PROBLEM: POSSIBLE CAUSE: CORRECTIVE ACTION:
High work port leakage. 1) Spool not centred. 2) Dirt in port relief valve. 1) Check centring springs. 2) Remove & clean relief valve.
....continued 9804/1103
15 - 10 - 03/2
3270 - E/4-10.2
Issue 1
Backhoe Loaders
CONTENTS
ALL MODELS (EXCEPT 2CX)
15 - 10 - 03/3
From m/c no. 460001
Fault Finding - Variable Flow Hydraulics (cont’d) PROBLEM: POSSIBLE CAUSE: CORRECTIVE ACTION:
Leaks between sections. 1) Missing or cut seals. 1) Disassemble valve stack and check for missing or cut o-rings.
PROBLEM: POSSIBLE CAUSE:
Sticking spool. 1) Linkage binding. 2) Damaged spool. 3) Uneven torque of tie-rod. 4) Incorrect number of shims on tie-rods. 1) Check linkage. 2) Remove and inspect spool. 3) Loosen tie-rod bolts, check and re-torque. 4) Disassemble and check that each tie-rod has one shim.
CORRECTIVE ACTION:
PROBLEM: POSSIBLE CAUSE: CORRECTIVE ACTION:
Mechanical detent will not hold. 1) Broken detent shaft. 1) Remove detent & inspect.
PROBLEM: POSSIBLE CAUSE: CORRECTIVE ACTION:
Electrical detent will not hold. 1) Current broken. 1) Check current going into detent.
PROBLEM: POSSIBLE CAUSE: CORRECTIVE ACTION:
Poor performance, slow operating speed and/or low maximum stall speed. 1) Blocked flow regulator spool. 1) Flow check, remove and clean flow regulator valve, see page E/10-36.
9804/1103
15 - 10 - 03/3
3270 - E/4-11.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
ALL MODELS (EXCEPT 2CX)
15 - 10 - 06/1
From m/c no. 400001
Fault Finding - Syncro Shuttle Gearbox Before carrying out the checks listed the machine should, if possible, be operated to determine the fault area(s), and bring the systems to their normal working temperatures. Ensure that the correct quantity and grade of oil is used and that there are no obvious leaks. A
If the transmission is noisy, start at check 1.
B
If the transmission is overheating, start at check 4.
C
If the transmission will not pull, start at check 12.
D
If there is no drive in one or both directions, start at check 17.
E
If the transmission is jumping out of gear, start at check 29.
F
If the transmission is sticking in gear, start at check 39.
G
If ratios are 'crash changing', start at check 41.
CHECK
ACTION
1
Is there noise when selecting direction?
YES: Check 3 NO: Check 2
2
Is there noise when running with direction selector in neutral and ratio selector in 1st?
YES: Check 9 NO: Check 19
3
Is there air in the hydraulic system?
YES: Continue running to expel air. NO: Check 4
4
Is the fluid level correct?
YES: Check 5 NO: Check level only when machine is cold and top-up as required.
5
Are the oil passages restricted?
YES: Clear the restriction. NO: Check 6
6
Is the suction strainer restricted?
YES: Remove and clean strainer. NO: Check 7
7
Is pump pressure as specified?
YES: Check 9 NO: Check clutch pressure maintenance valve is free to operate.
8
When flow testing pump, is output low?
YES: Renew pump. NO: Check converter sprag clutch for wear or slip.
9
Does the noise continue when direction selector is in forward or reverse?
YES: Check 10 NO: Check 11
10
Is transmission misaligned?
YES: Renew mountings and check position. NO: Check 'converter out' pressure and flow.
11
Are the pump bushes worn?
YES: Renew NO: Check converter for wear or cooler for restriction to flow.
12
Is the transmission not pulling in one direction only?
YES: Check 16 NO: Check 13
13
Is the transmission not pulling in both Forward and Reverse?
YES: Stall test machine, Check 14. NO: Check 16
9804/1103
15 - 10 - 06/1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
ALL MODELS (EXCEPT 2CX)
15 - 10 - 06/2
From m/c no. 400001
Fault Finding - Syncro Shuttle Gearbox (continued) CHECK
ACTION
14
Is 'converter in' pressure as specified?
YES: Check 15 NO: Inspect converter relief valve for damage. Check cooler bypass valve pressure setting.
15
Is pump being driven by converter?
YES: Check pump pressure. NO: Renew damaged parts.
16
Are clutch sealing rings damaged?
YES: Tap pressure gauge into clutch feed lines to monitor pressure. NO: Check clutch plates for damage.
17
Is there drive in one direction only?
YES: Check 19 NO: Check 18
18
Is the start switch in the run position and supplying current to the neutral start relay?
YES: Check 19 NO: Rectify.
19
Is the fault only when the transmission is hot?
YES: Dismantle solenoid and check components. NO: Check microswitches, relay and wiring loom.
20
Is the noise a growl, hum or grinding?
YES: Check gears for damage or wear. NO: Check 21
21
Is the noise a hiss, thump or bumping?
YES: Check bearings for damage or wear. NO: Check 22
22
Is the noise a squeal?
YES: Check free running gears for seizure. NO: Check 23
23
Is the noise present when in neutral or when in gear? NEUTRAL: Check 24 IN GEAR: Check 27
24
Is the countershaft or its bearings worn or damaged?
YES: Renew damaged parts. NO: Check 25
25
Is there excessive backlash in the gears?
YES: Adjust by checking shaft end float. NO: Check 26
26
Is the mainshaft pilot bearing worn?
YES: Renew. NO: Check gear teeth for scuffing.
27
Is the mainshaft rear bearing worn?
YES: Renew. NO: Check 28
28
Are the sliding gear teeth worn or damaged?
YES: Renew gears. NO: Check 29
29
Are the selector forks loose?
YES: Tighten screws. NO: Check 30
30
Are the selector fork pads or grooves in gears worn?
YES: Renew worn parts. NO: Check 31
31
Are the dog gear teeth worn?
YES: Renew. NO: Check 32
32
Are the selector rod detent springs broken?
YES: Renew. NO: Check 33
9804/1103
15 - 10 - 06/2
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
ALL MODELS (EXCEPT 2CX)
15 - 10 - 06/3
From m/c no. 400001
Fault Finding - Syncro Shuttle Gearbox (continued) CHECK
ACTION
33
Are the selector rods worn or damaged?
YES: Renew. NO: Check 34
34
Are the selector fork pads out of position?
YES: Reposition or renew (check interlock). NO: Check 35
35
Is there excessive end float in gears or shafts?
YES: Adjust. NO: Check thrust washers and mating faces.
36
Is the synchroniser bronze worn?
YES: Renew synchro pack. NO: Check 37
37
Are steel chips embedded in the bronze?
YES: Continue using, chips will either embed below bronze or be rejected. NO: Check 38
38
Are the synchroniser components damaged?
YES: Renew. NO: Check free running gears for seizure or damage.
39
Are the sliding gears tight on the splines?
YES: Free or renew. NO: Check 40
40
Are chips wedged between splines of shaft or gear?
YES: Remove chips. NO: Ensure that clutch is disengaged when dump pedal is pressed.
41
Are steel chips embedded in the bronze?
YES: Continue using, chips will either embed below bronze or be rejected. NO: Check 42
42
Are the synchroniser spring pins damaged?
YES: Renew synchro. NO: Check 43
43
Is the synchroniser bronze worn?
YES: Renew synchro. NO: Check blocker pins.
9804/1103
15 - 10 - 06/3
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX, (200 Series)
15 - 10 - 06/4
From m/c no. 400077 to 415011
Fault Finding - 2/4 Wheel Drive Clutch
‘Spring-On’ to 4WD Type Clutch 2WD Cannot be Engaged In normal operation the 2/4 wheel drive clutch is spring loaded and therefore engaged to give 4 wheel drive. The clutch must be pressurised to give 2 wheel drive. Before starting the more detailed fault finding procedures - eliminate the obvious: 1 2 3 4 5 6
Check that the transmission oil level is correct. Check that the fuse for the 2/4WD circuit is intact. Check that the 4-wheel drive external pipework is not damaged. Check that all the electrical connections are clean and secure. Check that the mainline pressure is correct (see 'Low Mainline Pressure'). Check that the pump flow rate is correct.
If the fault is not rectified after eliminating the obvious, check the following: Possible Cause
Remedy
7
7
Low mainline pressure
Identify if the fault is related to the 2/4WD disconnect: 7.1 Disconnect the external pipework to the 2/4WD clutch. Cap and plug open orifices.
(Minimum pressure required to disengage 2/4WD clutch is 8.6 bar; 125 lb/in2).
7.2 Check the mainline pressure - if the pressure is correct, the fault must be within the 2/4WD (see step 8). If the reading is still low check the transmission in the normal manner. 8
9
Low mainline pressure (due to 2/4WD clutch):
8
Rectify fault:
8.1 2/4WD solenoid spool sticking.
8.1 Strip, clean and re-assemble solenoid valve, renew valve if required.
8.2 2/4WD solenoid permanently energised.
8.2 Check the 2/4WD relay and select switch, replace as necessary.
8.3 2/4WD solenoid spool O-ring failed.
8.3 Renew O-ring.
8.4 Clutch shaft sealing rings leaking.
8.4 Renew clutch shaft sealing rings.
8.5 Excessive clutch shaft end float.
8.5 Rectify fault, renew parts as required, reset end float (should not exceed 0.03 mm; 0.001 in)
8.6 Wrong type clutch piston fitted.
8.6 Fit correct type clutch piston (ie, without bleed hole).
8.7 Clutch piston O-ring failed.
8.7 Replace clutch piston O-ring.
Defective 2/4WD clutch:
9
Rectify fault:
9.1 Worn pressure plate
9.1 Inspect pressure plate, renew as required.
9.2 Worn actuating sleeve.
9.2 Measure length of actuating sleeve and renew as required, sleeve length should be 60.70 mm; 2.390 inches
9.3 Incorrect clutch pack end float.
9.3 Measure clutch pack end float (should be 0.75 - 1.5 mm; 0.030 - 0.059 inches). Correct as required.
4WD Cannot be Engaged No pressure is required to engage 4WD (spring loaded). Check that the front wheel drive train is intact (ie propshaft and axle). Also check that the solenoid spool is not sticking (in the 2WD position). Finally check the 2/4 wheel drive switch and relays.
9804/1103
15 - 10 - 06/4
Issue 2
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX, (200 Series)
15 - 10 - 06/5
From m/c no. 415012
Fault Finding - 2/4 Wheel Drive Clutch
‘Pressure-On’ to 4WD Type Clutch 4WD CANNOT BE ENGAGED In normal operation the 2/4 wheel drive clutch is spring loaded off and therefore disengaged to give 2 wheel drive. The clutch must be pressurised to give 4 wheel drive. Before starting the more detailed fault finding procedures - eliminate the obvious: 1 2 3 4 5 6
Check that the transmission oil level is correct. Check that the fuse (C3) for the 2/4WD circuit is intact. Check that the 4-wheel drive external pipework is not damaged and that the drive train is intact. Check that all the electrical connections are clean and secure. Also check that the solenoid spool is not sticking (in the 2WD position). Check that the mainline pressure is correct (see 'Low Mainline Pressure'). Check that the pump flow rate is correct.
If the fault is not rectified after eliminating the obvious, check the following: Possible Cause
Remedy
7
7
Low mainline pressure
Identify if the fault is related to the 2/4WD disconnect: 7.1 Disconnect the external pipework to the 2/4WD clutch. Cap and plug open orifices. 7.2 Check the mainline pressure - if the pressure is correct, the fault must be within the 2/4WD (see step 8). If the reading is still low check the transmission in the normal manner.
8
9
Low mainline pressure (due to 2/4WD clutch):
8
Rectify fault:
8.1 2/4WD solenoid spool sticking.
8.1 Strip, clean and re-assemble solenoid valve, renew valve if required.
8.2 2/4WD solenoid spool O-ring failed.
8.2 Renew O-ring.
8.3 Clutch shaft sealing rings leaking.
8.3 Renew clutch shaft sealing rings.
8.4 Excessive clutch shaft end float.
8.4 Rectify fault, renew parts as required, reset end float (should not exceed 0.03 mm; 0.001 in)
8.5 Wrong type clutch piston fitted.
8.5 Fit correct type clutch piston (ie, without bleed hole).
8.6 Clutch piston O-ring failed.
8.6 Replace clutch piston O-ring.
Defective 2/4WD clutch:
9
Rectify fault:
9.1 Worn friction/counter plates
9.1 Inspect friction/counter plates, renew as required.
9.2 Mechanical failure of 4WD unit
9.2 Strip and inspect 4WD unit. Check that the electrical and hydraulic circuits are functioning correctly.
9.3 Incorrect clutch pack end float.
9.3 Measure clutch pack end float (should be 1.0 to 2.3 mm). Correct as required.
9804/1103
15 - 10 - 06/5
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX, (200 Series)
15 - 10 - 06/6
From m/c no. 415012
Fault Finding - 2/4 Wheel Drive Clutch (cont’d)
‘Pressure-On’ to 4WD Type Clutch 2WD CANNOT BE ENGAGED (CONT’D) No pressure is required to engage 2WD(spring loaded). Check that the solenoid spool is not sticking (in the 4WD position), then see below.
Possible Cause
Remedy
10
10
Incorrect type of solenoid valve fitted.
Check solenoid. Note: Powershift and Syncro Shuttle machines have different types of solenoid - check parts list.
11
Non-return valve faulty (noticeable because 2WD cannot be engaged).
11
Check the non-return valve. Note: NOT fitted on Powershift machines.
12
2/4WD solenoid permanently energised.
9804/1103
12
15 - 10 - 06/6
Check the 2/4WD relay and select switch, replace as necessary.
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX and Variants Fault Finding - Syncro Shuttle Transmission 2/4 Wheel Drive Clutch
15 - 10 - 06/7
From m/c no. 460001
4WD CANNOT BE ENGAGED In normal operation the 2/4 wheel drive clutch is spring loaded off and therefore disengaged to give 2 wheel drive. The clutch must be pressurised to give 4 wheel drive. Before starting the more detailed fault finding procedures - eliminate the obvious: 1 2 3 4 5 6
Check that the transmission oil level is correct. Check that the fuse for the 2/4WD circuit is intact. Check that the 4-wheel drive external pipework is not damaged and that the drive train is intact. Check that all the electrical connections are clean and secure. Also check that the solenoid spool is not sticking (in the 2WD position). Check that the mainline pressure is correct (see 'Low Mainline Pressure'). Check that the pump flow rate is correct.
If the fault is not rectified after eliminating the obvious, check the following:
Possible Cause
Remedy
7
7
Low mainline pressure
Identify if the fault is related to the 2/4WD disconnect: 7.1 Disconnect the external pipework to the 2/4WD clutch. Cap and plug open orifices. 7.2 Check the mainline pressure - if the pressure is correct, the fault must be within the 2/4WD (see step 8). If the reading is still low check the transmission in the normal manner.
8
Low mainline pressure (due to 2/4WD clutch):
8
Rectify fault:
8.1 2/4WD solenoid spool sticking.
8.1 Strip, clean and re-assemble solenoid valve, renew valve if required.
8.2 2/4WD solenoid spool O-ring failed.
8.2 Renew O-ring.
8.3 Clutch shaft sealing rings leaking.
8.3 Renew clutch shaft sealing rings.
8.4 Excessive clutch shaft end float.
8.4 Rectify fault, renew parts as required, reset end float (should not exceed 0.03 mm; 0.001
in)
9
8.5 Wrong type clutch piston fitted.
8.5 Fit correct type clutch piston (ie, without bleed hole).
8.6 Clutch piston O-ring failed.
8.6 Replace clutch piston O-ring.
Defective 2/4WD clutch:
9
Rectify fault:
9.1 Worn friction/counter plates
9.1 Inspect friction/counter plates, renew as required.
9.2 Mechanical failure of 4WD unit
9.2 Strip and inspect 4WD unit. Check that the electrical and hydraulic circuits are functioning correctly.
9.3 Incorrect clutch pack end float. to
9.3 Measure clutch pack end float (should be 1.0 2.3 mm). Correct as required.
9804/1103
15 - 10 - 06/7
3270 - F/61-4.1
Issue 1
CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 10 - 06/8
From m/c no. 460001
Fault Finding - Syncro Shuttle Transmission 2/4 Wheel Drive Clutch (cont'd) 2WD CANNOT BE ENGAGED No pressure is required to engage 2WD(spring loaded). Check that the solenoid spool is not sticking (in the 4WD position), then see below. Possible Cause
Remedy
10
10
Incorrect type of solenoid valve fitted.
Check solenoid. Note: Powershift and Syncro Shuttle machines have different types of solenoid - check parts list.
11
Non-return valve faulty (noticeable because 2WD cannot be engaged).
11
Check the non-return valve. Note: NOT fitted on Powershift machines.
12
2/4WD solenoid permanently energised.
9804/1103
12
15 - 10 - 06/8
Check the 2/4WD relay and select switch, replace as necessary.
3270 - F/61-5.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
ALL MODELS (EXCEPT 2CX)
15 - 10 - 07/1
From m/c no. 400001
Fault Finding - Powershift Gearbox
Introduction The Powershift fault finding procedures concern themselves with general problems normally associated with this type of transmission system, and so the layout is a 'Possible Cause and Remedy' type. Full flow, pressure and stall testing procedures for the Powershift transmission start on page F/91-1 in the service manual (publication number 9803/3260). Before commencing with the fault finding procedure make sure that the correct type of transmission fluid has been used (JCB Special Transmission Fluid).
Powershift Fault Finding - Index Page No. Lack of Power
15 - 10 - 07/2
Low Mainline Pressure
15 - 10 - 07/2
High Stall Speeds (On All Clutches)
15 - 10 - 07/2
Low Stall Speeds (On All Clutches)
15 - 10 - 07/2
Low Converter Out Pressure
15 - 10 - 07/2
Low Pump Flow
15 - 10 - 07/2
High Converter Out Pressure
15 - 10 - 07/3
Low Lubrication Pressure
15 - 10 - 07/3
* Low Clutch Pressure and/or Clutch Slipping 15 - 10 - 07/3 Overheating
9804/1103
15 - 10 - 07/3
15 - 10 - 07/1
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
ALL MODELS (EXCEPT 2CX)
15 - 10 - 07/2
From m/c no. 400001
Fault Finding - Powershift Gearbox (continued) LACK OF POWER Possible Cause 1 Poor engine condition. 2 Low oil level. 3 Worn pump. 4 Torque converter damage. 5 Low mainline pressure. 6 Clutches slipping. 7 Internal leakage. 8 High stall speeds. 9 Low stall speeds. 10 Overheating
Remedy 1 Check and if necessary repair engine. 2 Top up system. 3 Check and if necessary repair or renew pump. 4 Check and if necessary repair or renew torque converter. 5 See fault 'Low Mainline Pressure'. 6 Check clutch pressures, check clutch piston rings. 7 Check internal cored galleries and the casting for porosity. 8 See fault 'High Stall Speeds (on ALL clutches)'. 9 See fault 'Low Stall Speeds (on ALL clutches)'. 10 See fault 'Overheating'.
LOW MAINLINE PRESSURE Possible Cause 1 Worn pump. 2 Blocked suction strainer. 3 Pressure maintaining valve sticking/leaking. 4 Oil aerated (foaming).
5
Oil leak thru' 2/4WD circuit.
Remedy 1 Check and if necessary repair or renew pump. 2 Clean suction strainer. 3 Free off or renew valve. 4 a) Internal leakage (cored galleries) - inspect/repair transmission. b) Dirty suction strainer - clean strainer. c) High oil level - drain to proper level. d) Incorrect grade of oil - drain then refill with correct oil. 5 a) Check external pipework for 2/4WD circuit. b) Check 2/4WD (pressure) circuit - refer to 2/4 wheel drive clutch fault finding procedure on pages 15-1006/4 or 15-10-06/5.
HIGH STALL SPEEDS (ON ALL CLUTCHES) Possible Cause 1 Damaged converter blades. 2 Clutches slipping. 3 Internal leakage.
Remedy 1 Check and if necessary repair or renew converter. 2 Strip, inspect and fit new clutch friction/counter plates. 3 Check internal cored galleries and the casting for porosity.
LOW STALL SPEEDS (ON ALL CLUTCHES) Possible Cause 1 Poor engine condition. 2 Torque converter reaction member clutch slipping.
Remedy 1 Check and if necessary repair engine. 2 Check and if necessary repair torque converter.
LOW CONVERTER OUT PRESSURE
*
Possible Cause 1 Low mainline pressure. 2 Converter internal leakage. 3 Converter relief valve faulty. 4 Restriction in converter feed.
Remedy 1 See fault heading 'Low Mainline Pressure'. 2 Check and if necessary renew converter. 3 Check and if necessary repair relief valve. 4 See item 10 in fault 'Overheating'.
LOW PUMP FLOW Possible Cause 1 Low oil level 2 Blocked suction strainer. 3 Worn Pump.
Remedy 1 Top up system. 2 Clean suction strainer. 3 Repair or renew pump
HIGH CONVERTER OUT PRESSURE
* *
Possible Cause 1 Oil cooler/lines blockage. 2 Converter in pressure incorrect. 3 Converter relief valve faulty. 9804/1103
Remedy 1 Clean cooler, free blockage. 2 Check converter in pressure correct. 3 Check and if necessary repair relief valve.
15 - 10 - 07/2
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
ALL MODELS (EXCEPT 2CX)
15 - 10 - 07/3
From m/c no. 400001
Fault Finding - Powershift Gearbox (continued) LOW LUBRICATION PRESSURE
* *
Possible Cause 1 Low mainline pressure 2 Oil cooler/lines blockage. 3 Ruptured lubrication line. 4 Converter internal leakage. 5 Converter relief valve faulty. 6 Leak at pump to case joint (indicated by low cooler flow) 7 Restriction in converter feed
Remedy 1 See fault 'Low Mainline Pressure'. 2 Clean cooler, free blockage. 3 Repair line. 4 Check and if necessary renew converter. 5 Check and if necessary repair or renew relief valve. 6 Check and if necessary repair or replace as necessary. 7 See item 10 in fault 'Overheating'
LOW CLUTCH PRESSURE AND/OR CLUTCH SLIPPING Possible Cause Low mainline pressure. Worn pump. Blocked restrictor orifice in solenoid valve block.
Remedy 1 See fault heading 'Low Mainline Pressure'. 2 Check flow and if necessary repair or renew pump. 3 Remove solenoid(s) and clear restriction in solenoid valve block. 4 Confirm with a clutch leak test, if required renew clutch seals. 5 Confirm with a clutch leak test, renew piston rings. 6 Strip and rebuild clutch, renew parts as required.
*1 *2 *3 *4 *
5 6
Clutch seals worn. Clutch piston rings worn. Mechanical failure.
OVERHEATING Possible Cause 1 Low oil level. 2 High oil level. 3 Trapped or kinked hoses in cooler system. 4 Low converter out pressure and flow rate. 5 Oil cooler blockage. 6 Operating in wrong gear range usage. 7 Water system overheating. 8 Oil aerated (foaming). 9 Clutch piston(s) sticking on return stroke. 10 Cored galleries on front housing pump mounting face wrong depth (indicated with an excessively low pressure and flow on the converter out cooling line). See illustration below. 11 Leakage across pump mounting face and front case.
Remedy 1 Top up system. 2 Drain oil to correct level. 3 Renew or repair hoses. 4 Repair or renew the converter relief valve. 5 Clean cooler. 6 Select correct gears to suit working conditions. 7 Rectify water system problems, eg radiator, cooler lines, low water level etc. 8 See fault 'Low Mainline Pressure', item 4. 9 Check and repair clutch piston(s) and seal(s).
10 Replace front housing (or rectify existing housing). 11 Check for damaged surface on both components and loose pump mounting bolts.
S154080
9804/1103
15 - 10 - 07/3
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 10 - 07/4
From m/c no. 460001
Fault Finding - Powershift Transmission Introduction The Powershift fault finding procedures concern themselves with general problems normally associated with this type of transmission system, and so the layout is a 'Possible Cause and Remedy' type. Full flow, pressure and stall testing procedures for the Powershift transmission start on page F/111-1. Before commencing with the fault finding procedure check the condition of the transmission oil. The type and condition of the oil is vital to the long term integrity of the gearbox. Check for the following transmission oil faults: Incorrect oil type (must be JCB Special Transmission Fluid). Incorrect oil level (stop the engine before checking the gearbox oil level). Oil overheating. Oil contaminated with water. Many types of faults can be caused by the above. In particular see the fault finding section on oil contaminated with water.
Powershift Fault Finding - Index Page No. Lack of Power
15 - 10 - 07/5
Low Mainline Pressure
15 - 10 - 07/5
High Stall Speeds (On All Clutches)
15 - 10 - 07/5
Low Stall Speeds (On All Clutches)
15 - 10 - 07/5
Low Converter Out Pressure
15 - 10 - 07/5
Low Pump Flow
15 - 10 - 07/5
High Converter Out Pressure
15 - 10 - 07/5
Low Lubrication Pressure
15 - 10 - 07/6
Low Clutch Pressure and/or Clutch Slipping
15 - 10 - 07/6
Overheating
15 - 10 - 07/6
4WD Cannot Be Engaged
15 - 10 - 07/7
2WD Cannot Be Engaged
15 - 10 - 07/7
Transmission Oil Contaminated with Water
15 - 10 - 07/8
9804/1103
15 - 10 - 07/4
3270 - F/101-1.2
Issue 1
CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 10 - 07/5
From m/c no. 460001
Fault Finding - Powershift Transmision (cont’d) LACK OF POWER Possible Cause 1 Poor engine condition. 2 Low oil level. 3 Worn pump. 4 Torque converter damage. 5 Low mainline pressure. 6 Clutches slipping. 7 Internal leakage. 8 High stall speeds. 9 Low stall speeds. 10 Overheating 11 Converter safety relief valve faulty. LOW MAINLINE PRESSURE Possible Cause 1 Worn pump. 2 Blocked suction strainer. 3 Pressure maintaining valve sticking/leaking. 4 Oil aerated (foaming).
5
Oil leak thru' 2/4WD circuit.
Remedy 1 Check and if necessary repair engine. 2 Top up system. 3 Check and if necessary repair or renew pump. 4 Check and if necessary repair or renew torque converter. 5 See fault 'Low Mainline Pressure'. 6 Check clutch pressures, check clutch piston rings. 7 Check internal cored galleries and the casting for porosity. 8 See fault 'High Stall Speeds (on ALL clutches)'. 9 See fault 'Low Stall Speeds (on ALL clutches)'. 10 See fault 'Overheating'. 11 Check and if necessary repair safety relief valve.
Remedy 1 Check and if necessary repair or renew pump. 2 Clean suction strainer. 3 Free off or renew valve. 4 a) Internal leakage (cored galleries) - inspect/repair transmission. b) Dirty suction strainer - clean strainer. c) High oil level - drain to proper level. d) Incorrect grade of oil - drain then refill with correct oil. 5 a) Check external pipework for 2/4WD circuit. b) Check 2/4WD (pressure) circuit - refer to 2/4 wheel drive clutch fault finding procedure on page 15 - 10 07/7
HIGH STALL SPEEDS (ON ALL CLUTCHES) Possible Cause 1 Damaged converter blades. 2 Clutches slipping. 3 Internal leakage. 4 Converter safety relief valve faulty.
Remedy 1 Check and if necessary repair or renew converter. 2 Strip, inspect and fit new clutch friction/counter plates. 3 Check internal cored galleries and the casting for porosity. 4 Check and if necessary repair safety relief valve.
LOW STALL SPEEDS (ON ALL CLUTCHES) Possible Cause 1 Poor engine condition. 2 Torque converter reaction member clutch slipping.
Remedy 1 Check and if necessary repair engine. 2 Check and if necessary repair torque converter.
LOW CONVERTER OUT PRESSURE Possible Cause 1 Low mainline pressure. 2 Converter internal leakage. 3 Converter relief valve faulty. 4 Restriction in converter feed.
Remedy 1 See fault heading 'Low Mainline Pressure'. 2 Check and if necessary renew converter. 3 Check and if necessary repair relief valve. 4 See item 10 in fault 'Overheating'.
LOW PUMP FLOW Possible Cause 1 Low oil level 2 Blocked suction strainer. 3 Worn Pump.
Remedy 1 Top up system. 2 Clean suction strainer. 3 Repair or renew pump
HIGH CONVERTER OUT PRESSURE Possible Cause 1 Oil cooler/lines blockage. 2 Converter in pressure incorrect. 3 Converter relief valve faulty.
Remedy 1 Clean cooler, free blockage. 2 Check converter in pressure correct. 3 Check and if necessary repair relief valve.
9804/1103
15 - 10 - 07/5
3270 - F/101-2.2
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 10 - 07/6
From m/c no. 460001
Fault Finding - Powershift Transmission (cont’d) LOW LUBRICATION PRESSURE Possible Cause 1 Low mainline pressure 2 Oil cooler/lines blockage. 3 Ruptured lubrication line. 4 Converter internal leakage. 5 Converter relief valve faulty. 6 Leak at pump to case joint (indicated by low cooler flow) 7 Restriction in converter feed LOW CLUTCH PRESSURE AND/OR CLUTCH SLIPPING Possible Cause 1 Low mainline pressure. 2 Worn pump. 3 Blocked restrictor orifice in solenoid valve block. 4
Clutch seals worn.
5 6
Clutch piston rings worn. Mechanical failure.
OVERHEATING Possible Cause 1 Low oil level. 2 High oil level. 3 Trapped or kinked hoses in cooler system. 4 Low converter out pressure and flow rate. 5 Oil cooler blockage. 6 Operating in wrong gear range usage. 7 Water system overheating.
Remedy 1 See fault 'Low Mainline Pressure'. 2 Clean cooler, free blockage. 3 Repair line. 4 Check and if necessary renew converter. 5 Check and if necessary repair or renew relief valve. 6 Check and if necessary repair or replace as necessary. 7 See item 10 in fault 'Overheating'
Remedy 1 See fault heading 'Low Mainline Pressure'. 2 Check flow and if necessary repair or renew pump. 3 Remove solenoid(s) and clear restriction in solenoid valve block. 4 Confirm with a clutch leak test, if required renew clutch seals. 5 Confirm with a clutch leak test, renew piston rings. 6 Strip and rebuild clutch, renew parts as required.
Remedy 1 Top up system. 2 Drain oil to correct level. 3 Renew or repair hoses. 4 Repair or renew the converter relief valve. 5 Clean cooler. 6 Select correct gears to suit working conditions. 7 Rectify water system problems, eg radiator, cooler lines, low water level etc. 8 See fault 'Low Mainline Pressure', item 4. 9 Check and repair clutch piston(s) and seal(s). 10 Replace front housing (or rectify existing housing).
8 Oil aerated (foaming). 9 Clutch piston(s) sticking on return stroke. 10 Cored galleries on front housing pump mounting face wrong depth (indicated by an excessively low pressure and flow on the converter out cooling line). 11 Leakage across pump mounting face and front case. 11 Check for damaged surface on both components and loose pump mounting bolts.
9804/1103
15 - 10 - 07/6
3270 - F/101-3.1
Issue 1
CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 10 - 07/7
From m/c no. 460001
Fault Finding - Powershift Transmission (cont’d) 2/4 Wheel Drive Clutch 4WD CANNOT BE ENGAGED In normal operation the 2/4 wheel drive clutch is spring loaded off and therefore disengaged to give 2 wheel drive. The clutch must be pressurised to give 4 wheel drive. Before starting the more detailed fault finding procedures - eliminate the obvious: 1 2 3 4 5 6
Check that the transmission oil level is correct. Check that the fuse for the 2/4WD circuit is intact. Check that the 4-wheel drive external pipework is not damaged and that the drive train is intact. Check that all the electrical connections are clean and secure. Also check that the solenoid spool is not sticking (in the 2WD position). Check that the mainline pressure is correct (see 'Low Mainline Pressure'). Check that the pump flow rate is correct.
If the fault is not rectified after eliminating the obvious, check the following: Possible Cause 7 Low mainline pressure
Remedy 7 Identify if the fault is related to the 2/4WD disconnect: 7.1 Disconnect the external pipework to the 2/4WD clutch. Cap and plug open orifices. 7.2 Check the mainline pressure - if the pressure is correct, the fault must be within the 2/4WD (see step 8). If the reading is still low check the transmission in the normal manner.
8
8
Low mainline pressure (due to 2/4WD clutch): 8.1 2/4WD solenoid spool sticking. 8.2 2/4WD solenoid spool O-ring failed. 8.3 Clutch shaft sealing rings leaking. 8.4 Excessive clutch shaft end float. in) 8.5 Leakage through piston ball valve, due to contamination or valve not seating correctly. 8.6 Clutch piston O-ring failed.
9
Defective 2/4WD clutch: 9.1 Worn friction/counter plates
Rectify fault: 8.1 Strip, clean and re-assemble solenoid valve, renew valve if required. 8.2 Renew O-ring. 8.3 Renew clutch shaft sealing rings. 8.4 Rectify fault, renew parts as required, reset end float (should not exceed 0.03 mm; 0.001 8.5 Replace piston or rectify as required. 8.6 Replace clutch piston O-ring.
9
9.2 Mechanical failure of 4WD unit
9.3 Incorrect clutch pack end float. to
Rectify fault: 9.1 Inspect friction/counter plates, renew as required. 9.2 Strip and inspect 4WD unit. Check that the electrical and hydraulic circuits are functioning correctly. 9.3 Measure clutch pack end float (should be 1.0 2.3 mm). Correct as required.
2WD CANNOT BE ENGAGED No pressure is required to engage 2WD(spring loaded). Check that the solenoid spool is not sticking (in the 4WD position), then see below. Possible Cause 10 Incorrect type of solenoid valve fitted.
Remedy 10 Check solenoid. Note: Powershift and Syncro Shuttle machines have different types of solenoid - check parts list.
11
2/4WD solenoid permanently energised.
11
12
Piston ball valve blocked.
12
9804/1103
15 - 10 - 07/7
Check the 2/4WD relay and select switch, replace as necessary. Replace piston or rectify as required.
3270 - F/101-4.2
Issue 1
CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 10 - 07/8
From m/c no. 460001
Fault Finding - Powershift Transmission (cont’d) Transmission Oil Contaminated with Water Carefully inspect the transmission oil for signs of water contamination. Contaminated oil will contain water droplets or be visibly emulsified. Water droplets may be visible on the dipstick or inside the filler tube. For oil analysis purposes, the maximum permissible water content of the oil is 0.10%. If the transmission oil has been contaminated with water, faults or damage to the gearbox may be apparent as a result. Before remedying, thoroughly investigate and rectify the cause of the water contamination. Possible Cause
Remedy
1
Water ingress during filling/topping up.
Carry out flushing procedure. Refill with JCB Special Transmission Fluid.
2
Missing/incorrect dipstick, damaged filler tube.
Renew missing/incorrect/damaged components. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.
3
Machine operated in deep water.
Carry out flushing procedure. Refill with JCB Special Transmission Fluid.
4
Oil cooler failure.
Remove, inspect, test oil cooler. Renew if applicable. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.
5
Gearbox or bevel gearbox casings damaged.
Inspect, renew damaged components. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.
6
Gearbox oil circuit pipes/hoses damaged.
Inspect, renew damaged components. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.
Gearbox faults caused typically by water contamination and other factors related to the transmission oil:
1
Fault
Possible Cause
Remedy
Pressurisation of transmission casing - Dipstick blows out/oil leaking from dipstick tube.
Water in oil combined with heat from torque converter causes steam.
Replace/renew dipstick. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.
Gearbox over filled with oil.
Drain the oil level to the correct level, see Routine Maintenance - Checking Transmission Oil Level.
2
Clutch Failure - Friction Lining Separation.
Water ingress.
Renew friction plates. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.
3
Clutch Failure - Clutch Piston Seizing.
Water ingress causing nylon components to swell and stick when hot.
Carry out flushing procedure. Refill with JCB Special Transmission Fluid. Note: If after a period of service without water contamination seizing still occurs, renew piston.
Overheating transmission oil.
See Fault Finding - Overheating.
Water ingress.
Fit new bearings. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.
4
Badly worn/noisy bearings.
Insufficient lubrication.
9804/1103
15 - 10 - 07/8
3270 - F/101-5.1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 10 - 08/1
ALL MODELS (EXCEPT 2CX)
From m/c no. 460001
Fault Finding - Brakes Note: The brakes generate a high temperature when operating, this means that the casing will be hot to touch, this condition is normal. Note: 4WS machines do not have dual pedal braking. FAULT
POSSIBLE CAUSE
POSSIBLE CAUSE
A
1
Check master fault
1
Check master cylinder in
2
Friction/counter plate distortion.
2
Check friction/counterplates.
1
Air in Hydrualic system.
1
Check fluid reservoir level. Check for fluid/air leaks,rectify as required.
2
Leak in hydraulic system.
2
Check for fluid loss at master cylinder and brake piston, all pipes and fittings for loose connections. Rectify as required.
3
Friction/counter plate distortion.
3
Renew friction/counter plates BOTH sides.
B
One or both brakes do not apply. (Brake travel not excessive, brakes not pulling to one side)
Pedal travel excessive (but not touching floor).
C
Applying one brake (pedals unlocked) also partially engages the other brake.
1
Valve stem seal inside (non-active) 1 master cylinder piston not sealing.
Renew master cylinder position.
D
Pedal hard to operate.
1
Tightness at pedal pivot.
1
Inspect pedal pivot. Free-off/lubricate.
2
Fluid contamination seal damage.
2
Flush system and renew all hydraulic seals.
3
Misaligned push rod/pedal.
3
Check and rectify as required.
4
Kinked or crushed brake pipes.
4
Check/renew brake pipwork.
Items 5 to 7 are for machines fitted with servo assisted brakes only:
E
F
Pedals touch floor under constant pressure - no fluid loss
Pedals touch floor under constant pressure - and fluid loss
9804/1103
5
Vacum failure due to low vacim at source.
5
Inspect/service engine mounted exhauster unit as required.
6
Blocked/leaking vacum pipe.
6
Check/renew vacum pipe.
7
Servo defect.
7
Renew servo unit.
1
Master cylinder fault.
1
Check master cylinder in single and coupled pedal modes to identify fault area, service as required.
2
Friction/counter plate distortion.
2
Renw friction/counter [plates BOTH sides.
3
Air in hydraulic system.
3
See item B. 1.
1
External fluid leaks.
1
Visually Check brake circuit for fluid loss, service as required.
2
I nternal fluid leaks.
2
See ‘Brake Piston Seal Leakage Test’ on page 15-10-08/04.
15 - 10 - 08/1
3270 - F/101-1.2
Issue 2*
Backhoe Loaders
CONTENTS
15 - 10 - 08/2
ALL MODELS (EXCEPT 2CX) Fault Finding - Brakes (cont’d)
From m/c no. 460001
FAULT
POSSIBLE CAUSE
POSSIBLE CAUSE
G
1
Compensating feature not working.
1
Inspect master cylinder compensating. Check if blockage in bridging pipe. Service as required.
2
Braking system inoperative on one side.
2
Unlatch pedals to test circuits individually.
3
Friction plates worn beyond limits or distortion on one side.
3
Renew friction counter plates BOTH sides.
4
Badley adjusted push rods.
4
Adjust push rod (1mm minimum).
5
Servo operating rod out of adjustment.
5
Adjust servo operating rod.
6
Annular piston fault (see item J6)
6
See item J6.
1
Friction plates worn beyond limits or distorted on one side.
1
Renew friction/counter plates BOTH sides.
2
Master cylinder fault.
2
Check master cylinder in single and coupled pedal modes to identify fault area, service as required.
3
Annular piston fault (see item J6)
3
See itemJ6.
4
Incorrect/low axle oil.
4
Fill axle with correct type of oil.
5
Vacum failure (machines fitted with 5 servo assisted brakes only).
1
Brake pedal spring fault.
2
Master cylinder fault (plunger stuck 2 in bore).
3
Blocked hole in master cylinder resvoir cap.
4
Brake pedal free travel incorrect.
5
Fluid contamination/seal damage.
6
Annular brake piston(s) binding in axle.
H
J
Pulling to one side when pedals locked together.
Poor braking (not pulling to one side).
One or both brakes not releasing.
1
Inspect vacum source/pipes, service as required. Fit a new spring Service as required.
3
Fit a new resvoir cap
4
Adjust pedal free travel.
5
Flush system and renew hydraulic seals.
6.1 Check that the correct brake fluid has been used (incorrect fluid could swell the annular brake piston seals). 6.2 Check if annular brake piston seals in good condition. 6.3 Check that the annular brake piston rotates freely in its own housing with no seals fitted. 6.4 Check that the annular brake piston seal retracts the piston approximately 0.5mm (0.020 in).
7
Kinked or crushed brake pipes.
7
8 Friction/counter plates not free on 8 splines and/or dowels. 9804/1103
15 - 10 - 08/2
Check and renew pipes as required. Check friction/counter plates for free movement, replace if required - BOTH sides. 3270 - F/101-2.2
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
15 - 10 - 08/3
ALL MODELS (EXCEPT 2CX)
From m/c no. 400001
Fault Finding - Brakes (continued) FAULT
POSSIBLE CAUSE
ACTION
K Poor braking when hot.
1
Moisture in system vapourizing when axle is hot.
1
Strip axle and clean annular piston to remove moisture. Remove master cylinders and check for corrosion, service as required. Flush hydraulic brake system.
L Excessive brake noise in operation.
1
Deterioration of axle oil or wrong type of axle oil.
1
Change axle oil.
2
Axle oil loss.
2
Refill axle with correct oil and check for leaks.
3
Friction plates worn beyond limits.
3
Renew friction/counter plates.
4
Friction/counter plates in poor condition.
4
Check for distortion or surface pitting and/or roughness of friction/counter plates (annular grooving of counter plates is acceptable).
1
Slight cut or nick in the brake piston 1 seal, see 'Brake Piston Seal Leakage Test' page 15-10-08/4.
Note: Due to the metal to metal contact of oil immersed brakes, limited noise can be heard which is consistent with this type of design - this is normal.
M Fluid loss when machine standing, for instance - overnight (see note).
Strip axle, replace seal.
Note: Confirm fault is as indicated by checking that the pedals DO NOT touch floor under constant pressure.
9804/1103
15 - 10 - 08/3
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
ALL MODELS (EXCEPT 2CX)
15 - 10 - 08/4
From m/c no. 400001
Fault Finding - Brakes (continued)
Brake Piston Seal Leakage Test The following procedure explains how to check if a brake piston seal is severely damaged/perished or if the seal has a small cut or nick. The test must only be done when the axle is COLD.
5
Repeat steps 1 to 4 for the opposite brake piston seal.
6
Reconnect all brake pipes and bleed the brake system as recommended in the service manual (publication no. 9803/3260).
!WARNING
Before working on the brake system make sure the machine is on level ground and chock all four wheels. BRAK 1-4
!WARNING
Do not drive the machine with any part of its brake system disconnected. When the following test has been completed reconnect all brake pipes and bleed the brake system using the recommended procedure. BRAK 2-1
1
Remove and cap brake piston feed pipe A.
2
Fill the brake piston housing with JCB Light Hydraulic Fluid.
3
Check for severe piston seal damage:
Use illustration 107710 and amend to show clear tube fitted, also show level indicator mark on tube.
3.1 Install a hand pump (see note 1) fitted with a 0 - 40 bar (0 - 600lbf/in2) pressure gauge to port B, as shown at X. Note 1: The hand pump MUST be filled with JCB Light Hydraulic Fluid. DO NOT exceed 69bar (1000lbf/in2). 3.2 Use the hand pump to generate a pressure in the brake piston housing. 3.3 If the pressure falls off rapidly, or if no pressure reading can be obtained, the seal is severely damaged and needs replacing with a new one. 4
Check for small cuts or nicks in the piston seal: 4.1 Install an adapter fitted with a piece of clear tube (approximately 122mm [48in.] long) to the brake piston port B, as shown at Y (see note 2).
Note 2: The tube must be kept vertical during the test, use tape to attach the tube to the side of the machine. 4.2 Fill the tube until approximately three quarters full with JCB Light Hydraulic Fluid 4.3 Using a suitable pen, mark the level line of the brake fluid on the tube, as shown at C. 4.4 After approximately 1/2 hour, check if the level has dropped below the original marked line, if it has then check the brake piston seal for slight nicks, cuts or generally for wear.
9804/1103
15 - 10 - 08/4
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX and Variants
15 - 10 - 09/1
From m/c no. 460001
Fault Finding - Steering Contents
Introduction Page No.
Introduction
15 - 10 - 09/1
Steering wheel difficult to turn
15 - 10 - 09/1
Steering wheel turns on its own
15 - 10 - 09/2
Machine will not turn when the steering wheel turned.
15 - 10 - 09/2
Steering fails to respond to selected mode (4WS Machines only)
15 - 10 - 09/3
Fault
1
Steering wheel difficult to turn.
The purpose of this section is to help you trace hydraulic faults to a faulty unit (valve, actuator, ram etc). Once you have traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the steering section. To help identify circuits, valves, rams etc mentioned in the fault finding procedures, refer to the hydraulic schematic diagrams (near the beginning of the Hydraulics Section). 1
Before you begin fault finding, read the Safety information at the beginning of this manual.
2
Make simple checks before say, stripping a major component.
3
Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F).
4
What ever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.
5
Make any relevant electrical checks before moving on to the hydraulics.
6
Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit.
7
Replace any seals such as 'O' rings before reassembling hydraulic components.
Probable Cause
Action
Tyres not inflated to correct pressure
Inflate tyres to correct pressure
Insufficient hydraulic fluid.
Check for leaks and top up as required.
Leaks in the relevant hoses or component connections
Check hoses and connections for leaks
Air in the hydraulic system.
Bleed system - bleed the load sense line.
Low pump flow.
Check pump flow, if required service or replace pump.
Steer relief valve set incorrectly
Check pressure setting of steer unit relief valve, adjustas required.
Worn or damaged parts in the steer control valve.
Remove and inspect.
....... continued
9804/1103
15 - 10 - 09/1
3270 - H/4-1.1
Issue 1*
Backhoe Loaders
CONTENTS
3CX, 4CX and Variants
15 - 10 - 09/2
From m/c no. 460001
Fault Finding - Steering (cont’d) Fault 1
Steering wheel difficult to turn. (continued)
Probable Cause Priority valve not operating correctly
Action Check if the priority valve is sticking, rectify as required. Check the load sense line from the steer unit to the priority valve for signs of leaking or poor connection.
Steer mode valve not operating correctly (4WS Machines only)
Check if spools sticking, rectify as required Check if solenoids operating, replace solenoids as required
Mechanical failure
2
3
Steering wheel turns on its own.
Machine will not turn when the steering wheel turned.
Check for damaged axle components, such as rams, trackrods, linkages etc.
Dirt in the steer control unit (causing sleeves to stick open)
Clean and inspect unit.
Steer control valve centring springs damaged, broken or missing.
Check unit.
Steer control valve - position of rotor to shaft slot incorrect.
See page H/16-4, step 9. Correct as required.
Insufficient hydraulic fluid.
Check for leaks and top up as required.
Leaks in the relevant hoses or component connections
Check hoses and connections for leaks
Air in the hydraulic system.
Bleed system - bleed the load sense line.
Low pump flow.
Check pump flow, if required service or replace pump.
Steer relief valve set incorrectly
Check pressure setting of steer unit relief valve, adjust as required.
Worn or damaged parts in the steer control valve.
Remove and inspect.
Priority valve not operating correctly
Check if the priority valve is sticking, rectify as required. Check the load sense line from the steer unit to the priority valve for signs of leaking or poor connection.
9804/1103
15 - 10 - 09/2
3270 - H/4-2.1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX and Variants
15 - 10 - 09/3
From m/c no. 460001
Fault Finding - Steering (cont’d) Fault 3
Machine will not turn when the steering wheel turned (continued).
Probable Cause Steer mode valve not operating correctly (4WS Machines only)
Action Check if spools sticking, rectify as required Check if solenoids operating, replace solenoids as required
4
Steering fails to respond to selected mode (4WS Machines only)
Mechanical failure
Check for damaged axle components, such as rams, trackrods, linkages etc.
Steer column splined shaft not fully engaged in steer valve.
Check shaft engagement.
Power track rod failure
Check power track rod for signs of damge, leaks etc.
Selector switch faulty
Check selector switch, replace as required
Proximity switches not operating correctly
Check setting of proximity switches, reset or replace switches as required.
Steer mode valve not operating correctly
Check if spools sticking, rectify as required Check if solenoids operating, replace solenoids as required.
9804/1103
Leaks in the relevant hoses or component connections
Check hoses and connections for leaks
Electrical failure
Check relevant electrical connectors, if problem still persists, do a wiring continuity check on relevant circuits.
15 - 10 - 09/3
3270 - H/4-3.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX, (200 Series)
15 - 15 - 01/1
From m/c no. 400001 to 430000
Circuit Diagrams - Electrical
Basic Machine Component List The basic circuit shows a standard 3CX (214) machine fitted with syncro shuttle transmission and 2 wheel steer. Refer to pages 15-15-01/3 to 15-15-01/6 for circuit differences, e.g. AWS circuit, Powershift circuit etc. Note that ONLY the differences are shown. 1 2 3 4 5 6 7 8 9 9A 10 11 11A 12 13 14 15 16 17 18 19 20 21 22 23 24 26 27 28 29 30 31 32 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55
Battery Starter Switch Thermostart Starter Solenoid Starter Motor Neutral Start Relay Transmission Dump Relay Forward Relay Transmission Foot Dump Switch Transmission Hand Dump Switch Forward Solenoid Park Brake Relay Park Brake Dump Relay Reverse Relay Reverse Solenoid Park Brake Switch Coolant Temperature Gauge Coolant Temperature Sender Fuel Gauge Fuel Gauge Sender Diode Bank Engine Coolant Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Restriction Switch Speedometer / Tachometer Alternator Alternator Warning Warning Buzzer Park Brake Indicator Light Brake Light Switch ➁ Brake Lights ➁ 2/4 Wheel Drive Solenoid ➂ 2/4 Wheel Drive Relay ➂ 2/4 Wheel Drive Brake Relay ➂ 2/4 Wheel Drive Select Switch ➂ Rear Wiper Motor Rear Wiper Switch Fuel Pump Solenoid Indicator Flasher Relay Hazard Warning Switch Hazard Warning Lamp RH Direction Indicators LH Direction Indicators Direction Indicator Switch Diode Heater Motor Heater Switch Beacon Beacon Switch Interior Lamp Interior Light Switch Radio Washer Motor
9804/1103
56 57 58 59 60 61 62 63 64 65 67 69 70 71 72 75 76 77 78 79 80 81 82 83 84 85 87 88 89 90 119 120 125 126
Front Washer/Wiper Switch Front Wiper Motor Horn (Front) Horn Push (Front) Head Light Flasher Switch Head Light Main Beam Lamps Main Beam Warning Dipped Head Light Lamps Head Light Dip Switch Head and Side Lights Switch Front Working Lights Front Working Lights Switch Lighting Relay Rear Working Lights Rear Working Lights Switch Gauge Illumination (Tacho, Water, Fuel) Reverse Alarm Relay Reverse Alarm Side Light Left Hand Tail Light Left Hand Socket (Dipper Light) LH Number Plate Light (Cab) Number Plate (Chassis) Side Light Right Hand Tail Light Right Hand Hydraulic Speed Control Switch Hydraulic Speed Control Switch Hydraulic Speed Control Relay Hydraulic Speed Control Solenoid Socket (Junction Box Feed) Rear Fog Light ➀ Rear Fog Light Switch ➀ Rear Washer Motor Rear Washer Switch
➀
Note: Machines prior to serial number 400077 have the fog light circuit protected by fuse B3, not C4 as indicated.
➁
Note: Machines up to serial number 403024 have the brake lights protected by fuse A1. Machines from serial number 403025 to 404851 have the brake lights protected by fuse C3. Machines from serial number 404852 have the brake lights and 2/4WD solenoid protected by fuse A1 (as indicated in the fuse identification chart).
➂
Applicable to 2WS machines only (from serial number 409435). For 2WS machines prior to 409434 and all 4WS machines, refer to page C/15-5.
Fuses A1 - A9 B1 - B9 C1 - C4 Refer to page 15-05-01/2 for fuse details and ratings.
15 - 15 - 01/1
Issue 2
CONTENTS CONTENTS CONTENTS
Backhoe Loaders
15 - 15 - 01/2
3CX, 4CX (200 Series)
From m/c no. 400001 to 430000
Circuit Diagrams - Electrical
Basic Machine (2WS with Syncro Shuttle)
600G 600BN
600AD 600AC 600Y
600BT
600BS
10
600C
600CE 600BF
600V
16
13
21
18
14
912
600AA
809
40
44
807
67
82
47
855A 867B
837B 855B 603
80 834
56
829
840
855
F
852
1
26
912
31
27
41
862
909 103A
853B
800A
815
+ 7
810C
11
107M 107N
004
405
404
401
406
403
412
51
9
28
30
9A
868 110B
59
110A
907
64
303
87
70
105 104A 300 102
C4
908
110C
104B
37
19
110
832B
861 101P
828B
111A
B7 B9
A2
29
107 411
000D
A1
107D 002K
000E 002L
001D
C3
002B 111
B6
001E
001F
001C
002D
002C 002A
001B
A5
103C
832
A6 200J
B8
A7
000B
200H
002H
101
A9 000A
72 65
B1
002G
000C 002J
90
600BE
104C
B2
865
120
868A
108
106
101A
828A
303F
39
100
828
866
103E
103
835
A4
60
42
200
A3
836
833
102A
402
B3
814
49
407
200A
100A
830D
B4
58
126
11A
810A 838
56
600EB
800B
802 815A
6
48
803
108B
600N
69
863
N R
88
831
804A
-
119
B5
830
837
600BH
864
808
842
861B 861A
841
877 108
84
79
839 805
806
38
125
71 85
834B
57
55
M 877A
83
837A
894
46
600DF
89
600BJ
600AY
600AR
75
600AV
61 M
76
600AS
78 81
834A
M
604 600P
600T
62
M
M
35
17
63
604A
600AX
600H
600AU
600DW
600BC
804
303A
808A
600G 600BM
600BC
50
45
853
24
912A
15
600DY
600AZ
600AB
36
003
52
600AK
600BK
M
5
43
600
816
22
600AP
53 77
20
4
600BC
600AZ
600BG
600AJ
600B
816E
12
8
600G
600BD 816D
23
815
3
600H
600CD
811
600AZ
32
600CF
600CK
600BL
34
600BU
600S 812
600CB
600H
000F
302 200E
C2
103B 002F
104C
2 601 602
C1 200G
859
A8 200K
304
860
54
600R
A214640
A214640
9804/1103
15 - 15 - 01/2
15 - 15 - 01/2
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX, (200 Series)
15 - 15 - 01/3
From m/c no. 400001 to 430000
Circuit Diagrams - Electrical (continued)
Circuit Diagram Component List Steer Circuit (AWS Machines Only) 2 110 111 112 113 114 115 116 117
Starter Switch Front Proximity Switch Rear Proximity Switch Steer Mode Select Switch Steer Mode Printed Circuit Board Crab/4 Wheel Steer Solenoid 4 Wheel Steer Solenoid Crab Steer Solenoid 2 Wheel steer Solenoid
600L
113
822
823
821
112
824A
826A
845
825A
826B
824B
825B
115
116
117
109C
109D
109F
819 820 600BW
600BV
110
114
111 109A
109E
109B
2 109
002E
C2 002B
A2
A216990
9804/1103
15 - 15 - 01/3
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX, (200 Series)
15 - 15 - 01/4
From m/c no. 400001 to 430000
Circuit Diagrams - Electrical (continued)
Circuit Diagram Component List Powershift Transmission 1 2 6 7 9A 11 14 29 30 140 141 142 143 144 145 146 147 148 149 150 151 152 153
Battery Starter Switch Neutral Start Relay Transmission Dump Relay Transmission Hand Dump Switch Park Brake Relay Park Brake Switch Warning Buzzer Park Brake Indicator Light Drive Relay (Layshaft & Mainshaft) Layshaft Solenoid Mainshaft Solenoid Forward High/Low Relay Forward Low Solenoid Forward High Solenoid Neutral Relay Reverse High/Low Relay Reverse Low Solenoid Reverse High Solenoid Powershift Column Switch 'Ignition' Relay Forward Relay Reverse Relay
>>
Indicates feed to the 2WD circuit, only applicable on machines up to serial number 409435.
600AF
600BS
600BY
144
142 600AG
600BT
600BX
600BZ
149
600AC
600CA
141
148
145 600AE
600BF
600AD
600AH
812
811 X
848
849
810
14
851 600Y
850
600V
143
846
6
146
817
147
140
107F
152
815 600BN
813
810C
847
153
107B
107E
808A
11 401
30
883B 884B
810A
884C
809
A2
7
R
F
1
2 4 3
N
29
838A
9A
-
852
111A
1 +
150
600W
2 107 100
C3
001A
151 B9 200C 200D
B7
002
A216980
9804/1103
15 - 15 - 01/4
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX, (200 Series)
15 - 15 - 01/5
From m/c no. 400001 to 430000
Circuit Diagrams - Electrical (continued)
Circuit Diagram Component Lists 2/4 Wheel Drive (all machines up to serial number 409434) 2 31 32 34 35 36 37
Transmission Dump Circuit (machines up to serial number 413772) 2 6 7 8 9 9A 10 11 12 13 14 19 29 30
Starter Switch Brake Light Switch Brake Lights 2/4 Wheel Drive Solenoid 2/4 Wheel Drive Relay 2/4 Wheel Drive Brake Relay 2/4 Wheel Drive Select Switch
600CB
Starter Switch Neutral Start Relay Transmission Dump Relay Forward Relay Transmission Foot Dump Switch Transmission Hand Dump Switch Forward Solenoid Park Brake Relay Reverse Relay Reverse Solenoid Park Brake Switch Diode Bank Warning Buzzer Park Brake Indicator Light
34
600BR
600AB
32
600Y
A216960
600BN
600AD 600AC
600BT
600BS
600BF 600V
13
10
853
811
812
14
600AA
815
12
8 816
107B
809
107E
808A
35 853A 854
818
36
F
N R 852
108B 877
815
37
6
7
810C
11 810A
838
401
107D
31 108
100A
9
30
9A 100
A1
106
19
111A
B7 B9
A2
107 411
000D
29
C3 000E
2
9804/1103
A216950
15 - 15 - 01/5
2
C3 111
001B
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
3CX, 4CX, (200 Series)
15 - 15 - 01/6
From m/c no. 400001 to 430000
Circuit Diagrams - Electrical (continued)
Circuit Diagram Component Lists Instrument Lights Test Button (machines up to serial number 404502) 2 19 20 21 22 23 24 25 29
Starter Switch Diode Bank Engine Coolant Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Restriction Switch Warning Lights Test Button Warning Buzzer
600C
600BU
Hydraulic Speed Control - 2 Relays (machines up to serial number 406613) 2 85 86 87 88 89
Starter Switch Hydraulic Speed Control Switch Hydraulic Speed Control Warning Hydraulic Speed Control Switch Hydraulic Speed Control Relay Hydraulic Speed Control Solenoid
600BP
600CF
21
23
25
85
600CK
20
22
24
89 867A
410
101A
86 88
867B
867
88 866A 101C
866
404 406
405 403
402
87 101A
A2
19 29 101
2
2
B1
B9 A216970
9804/1103
15 - 15 - 01/6
A216940
Issue 2
CONTENTS CONTENTS CONTENTS
Backhoe Loaders
15 - 15 - 01/7
3CX, 4CX (200 Series)
From m/c no. 430001
Circuit Diagrams - Electrical
Basic Machine (2WS with Syncro Shuttle)
19 143 7
60 61
5
3
8 9
6
140 141 10
11
13
12
14
15
142
20
73 74 75 76 77
145 144
1
68
63
113
4
114
116 16 54
118
117
24
72 21
69 110
115
22
23 146
65
147 149 151 153 155 156 148 150 152 154 155
17
62 18
67 112
66
70
71
64
111 2
A228951 (CAD 852/35036 - 1/4)
9804/1103
15 - 15 - 01/7
15 - 15 - 01/7
Issue 3
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX, (200 Series)
15 - 15 - 01/8
From m/c no. 430001
Circuit Diagrams - Electrical (continued)
Basic Machine Component List The basic circuit shows a standard 3CX (214) machine fitted with syncro shuttle transmission and 2 wheel steer. Refer to pages 15-15-01/11 to 15-15-01/14 for circuit differences, e.g. AWS circuit, Powershift circuit etc. Note that ONLY the differences are shown. Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 6 Forward Solenoid 7 Reverse Solenoid 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 10 Fuel Pump Solenoid 11 Hydraclamp Solenoid 12 Hydraulic Speed Control Solenoid 13 Socket (Junction Box Feed) 14 Shovel Reset Solenoid 15 Rear Horn 16 Diode 17 Indicator Flasher Unit 18 Side Instrument Console 19 Coolant Temperature Sender 20 Fuel Gauge Sender 21 Tachometer 22 Coolant Temperature Gauge 23 Fuel Gauge 24 Hourmeter 25 Front Instrument Console 26 Alternator 27 Cigar Lighter 28 Clock 29 Face Level Fan 30 Heated Seat 31 Rear Washer Motor 32 Rear Wiper Motor 33 Washer Motor 34 Front Wiper Motor 35 Horn (Front) 36 Socket (Dipper Light) 37 Beacon 38 Tracker 39 Radio 40 Heater Motor 41 Heater Resistor 42 Air Conditioning Compressor 54 Warning Buzzer
Switches 60 Transmission Dump Switch (Gear) 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 65 Brake/Drive Select Switch 66 Hydraclamp Switch 67 Hydraulic Speed Control Switch 68 Hydraulic Speed Control Switch 69 Shovel Reset Switch 70 Rear Horn 71 Hazard Warning Switch 72 Direction Indicator Switch 73 Engine Coolant Temperature Switch 74 Transmission Oil Temperature Switch 75 Engine Oil Pressure Switch 76 Transmission Oil Pressure Switch 77 Air Filter Restriction Switch 78 Face Level Fan Switch 79 Heated Seat Switch 80 Rear Washer/Wiper Switch 81 Head Light Flasher Switch 82 Front Washer/Wiper Switch 83 Horn Push (Front) 84 Rear Fog Light Switch 85 Head and Side Lights Switch 86 Head Light Dip Switch 87 Front Working Lights Switch 88 Rear Working Lights Switch 89 Interior Light Switch 90 Interior Light Switch 91 Beacon Switch 92 Heater Switch 93 Air Conditioning Switch 94 Air Conditioning Pressure Switch 95 Air Conditioning Pressure Switch Fuses A1 - A9 B1 - B9 C1 - C6 Note: Fuse C6 is only fitted on machines from serial number: 3CX (214) - 438636; 4CX (214S) - 437866. Prior to this, the gear controls were protected by fuse C3. Refer to page 15-05-01/3 for fuse details and ratings.
9804/1103
15 - 15 - 01/8
Issue 2
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX, (200 Series)
15 - 15 - 01/9
From m/c no. 430001
Circuit Diagrams - Electrical (continued)
Basic Machine Component List (continued) Relays 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 117 Hydraulic Speed Control Relay 118 Rear Horn Relay 119 Ignition Relay ‘2’ 120 Road Lights Relay 121 Italian Worklight Relay 122 Heater Relay
Lights 140 LH Brake Light 141 RH Brake Light 142 LH Front Indicator 143 LH Rear Indicator 144 RH Front Indicator 145 RH Rear Indicator 146 Alternator Warning Indicator Light 147 Park Brake Indicator Light 148 Water Temperature Indicator Light 149 Transmission Temperature Indicator Light 150 Engine Oil Pressure Indicator Light 151 Transmission Oil Pressure Indicator Light 152 Air Filter Blocked Indicator Light 153 Hazard Warning Indicator Light 154 Main Beam Warning Indicator Light 155 Gauge Illumination 156 Turn Signal Indicator Light 157 Master Warning Lights 158 Side Lights Indicator Light 159 Rear Work Lights Indicator Light 160 Front Work Lights Indicator Light 161 Rear Fog Light Indicator Light 162 Rear Fog Light 163 LH Main Beam Light 164 RH Main Beam Light 165 LH Dip Beam Light 166 RH Dip Beam Light 167 LH Number Plate Light 168 LH Tail Light 169 LH Side Light 170 RH Number Plate Light 171 RH Tail Light 172 RH Side Light 173 Front Working Lights 174 Rear Working Lights
9804/1103
15 - 15 - 01/9
Issue 1
CONTENTS CONTENTS CONTENTS
Backhoe Loaders
15 - 15 - 01/10
3CX, 4CX (200 Series)
From m/c no. 430001
Circuit Diagrams - Electrical
Basic Machine (2WS with Syncro Shuttle)
162
164 165 163
33 27
29
167 169 170 172
166
168
171
173
89
174
37
35
31
36
26
41
34 28
90
32
30
42
39
40 84
95
25 86
82 157
158 156
153 154
159
94
78 79
160
87
88
161 80
91 83 93
121 92
81 119
120 85
A2289611 A228960 (CAD 852/35036 - 2/4)
9804/1103
15 - 15 - 01/10
15 - 15 - 01/10
Issue 2
CONTENTS
45
48
3
61 63
46
44
47 102
1
16
123
126
15 - 15 - 01/11
Backhoe Loaders
4
16
16 101
16
116
53
115 127
125
16 113
114
16
124
110
16 16 16 100
16
49 175
50
176
51
177
CONTENTS
43 9
5
3CX, 4CX, (200 Series)
8
Circuit Diagrams - Electrical (cont’d)
9804/1103
Powershift Transmission & Steer Circuit - AWS Machines Only
178
52
112 96
64
97
98
99
FUSE C6
111
119
Issue 2
A228972
A228972
15 - 15 - 01/11
2
From m/c no. 430001
FUSE C3
62
CONTENTS
Backhoe Loaders
Issue 2*
From m/c no. 430001
Note: Fuse C6 is only fitted on machines from serial number: 3CX (214) - 438636; 4CX (214S) - 437866 Prior to this, the gear controls were protected by fuse C3.
CONTENTS
Lights 175 4 Wheel Steer Indicator Light 176 Crab Steer Indicator Light 177 2 Wheel Steer Indicator Light 178 Front Instrument Console Illumination
*
Switches 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 96 4 Wheel Drive Switch 97 Powershift Column Switch 98 Front Proximity Switch 99 Rear Proximity Switch 100 Steer Mode Select Switch 101 4 WS/Crab Selector (part of PCB - item 53) 102 2 WS/4 WS Selector (part of PCB - item 53)
Relay 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 119 Ignition Relay ‘2’ 123 Neutral Relay 124 Auto 2 Wheel Drive Relay 125 Drive Relay (Layshaft & Mainshaft) 126 Forward High/Low Relay 127 Reverse High/Low Realy
From m/c no.
15 - 15 - 01/12
Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 16 Diode 43 Mainshaft Solenoid 44 Layshaft Solenoid 45 Forward Low Solenoid 46 Forward High Solenoid 47 Reverse High Solenoid 48 Reverse Low Solenoid 49 Crab/4 Wheel Steer Solenoid 50 4 Wheel Steer Solenoid 51 Crab Solenoid 52 2 Wheel Steer Solenoid 53 Steer Mode Printed Circuit Board
3CX, 4CX, (200 Series)
Note: Except for the transmission and steer circuits (shown above), the AWS electrical circuit is the same as shown on Page15-15-01/7 to 15-15-01/10.
Circuit Diagrams - Electrical (cont’d)
9804/1103
Powershift Transmission & Steer Circuit - AWS Machines Only
CONTENTS
43
45
48
141
61 63
44
46
47
1
130
129 116
Backhoe Loaders
123 126
15 - 15 - 01/13
4 115 127
125 113
114
16 110
65
147
16
CONTENTS
140 9
3
3CX, 4CX, (200 Series)
8 5
Circuit Diagrams - Electrical (cont’d)
9804/1103
Powershift Transmission - 2WS Machines Only and Steer Circuit for 3CX 4x4x4 Machines
16
16
100 50 112 62
52
64
177 178
97
2
111 FUSE C6
119
A228981
Issue 2
15 - 15 - 01/13
FUSE C2
99
From m/c no. 430001
98
CONTENTS
Backhoe Loaders
* *
Lights 140 LH Brake Light 141 RH Brake Light 147 Park Brake Indicator Light 177 2 Wheel Steer Indicator Light 178 Front Instrument Console Illumination
Wire Number Identification Refer to pages C/42-1 on for full wire number identification and descriptions.
Issue 2
15 - 15 - 01/14
Note: Fuse C6 is only fitted on machines from serial number: 3CX (214) - 438636; 4CX (214S) - 437866 Prior to this, the gear controls were protected by fuse C3.
From m/c no. 430001
* * *
Switches 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 65 Brake/Drive Select Switch 97 Powershift Column Switch 98 Front Proximity Switch 99 Rear Proximity Switch 100 Steer Mode Select Switch
* *
Relay 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 119 Ignition Relay ‘2’ 123 Neutral Relay 125 Drive Relay (Layshaft & Mainshaft) 126 Forward High/Low Relay 127 Reverse High/Low Relay 129 4 Wheel Steer Relay 130 2 Wheel Steer Relay
CONTENTS
15 - 15 - 01/14
* *
Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 16 Diode 43 Mainshaft Solenoid 44 Layshaft Solenoid 45 Forward Low Solenoid 46 Forward High Solenoid 47 Reverse High Solenoid 48 Reverse Low Solenoid 50 4 Wheel Steer Solenoid 52 2 Wheel Steer Solenoid
3CX, 4CX, (200 Series)
Note: Except for the transmission circuit (shown above), the 2WS electrical circuit is the same as shown on Pages 15-15-01/7 to 15-15-01/10.
Circuit Diagrams - Electrical (cont’d)
9804/1103
Powershift Transmission - 2WS Machines Only - and Steer Circuit for 3CX 4x4x4 Machines
CONTENTS CONTENTS
Backhoe Loaders
15 - 15 - 01/15
3CX, 4CX and Variants
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) Basic Machine
19
61
60
143 63 5
3
9
8
1 112
140
10
116 141 6
11
57
12
13 14
15
73
20
74
145
B
B
142
144
B/N
B/O
75
76
77 106
68
56
7
4 114
113
54 16
118 105
117
69
72 146
65
17
110
66
23
21
155
24 18
67
115
22
147 149 151 175 148 150 152
70
62 71 64
111 2
9804/1103
15 - 15 - 01/15
3270 - C/18-1.3
Issue1
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX and Variants Circuit Diagram - Electrical (cont’d) Basic Machine Component List 1
15 - 15 - 01/16
From m/c no. 460001
Refer to pages 15 - 15 - 01/15 and 15 - 15 - 01/18 The basic circuit shows a standard 3CX (214) machine fitted with syncro shuttle transmission and 2 wheel steer.Pages 15 - 15 - 01/19 to 15 - 15 - 01/31 show machine circuits that differ from the ‘basic’. Note that ONLY the differences are shown.
Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 6 Forward Solenoid 7 Reverse Solenoid 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 10 Fuel Pump Solenoid 11 Hydraclamp Solenoid 12 Hydraulic Speed Control Solenoid 13 Socket (Junction Box Feed) 14 Shovel Reset Solenoid 15 Rear Horn 16 Diode 17 Indicator Flasher Unit 18 Side Instrument Console 19 Coolant Temperature Sender 20 Fuel Gauge Sender 21 Tachometer 22 Coolant Temperature Gauge 23 Fuel Gauge 24 Hourmeter 25 Front Instrument Console 26 Alternator 27 Cigar Lighter 28 Clock 29 Face Level Fan 30 Heated Seat 31 Rear Washer Motor 32 Rear Wiper Motor 33 Washer Motor 34 Front Wiper Motor 35 Horn (Front) 36 Socket (Dipper Light) 37 Beacon 38 Tracker 39 Radio 40 Heater Motor 41 Heater Resistor 42 Air Conditioning Compressor 54 Warning Buzzer 56 Electric Rear Window ECU 57 Electric Rear Window Motor
Switches 60 Transmission Dump Switch (Gear) 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 65 Brake/Drive Select Switch 66 Hydraclamp Switch 67 Hydraulic Speed Control Switch 68 Hydraulic Speed Control Switch 69 Shovel Reset Switch 70 Rear Horn 71 Hazard Warning Switch 72 Direction Indicator Switch 73 Engine Coolant Temperature Switch 74 Transmission Oil Temperature Switch 75 Engine Oil Pressure Switch 76 Transmission Oil Pressure Switch 77 Air Filter Restriction Switch 78 Face Level Fan Switch 79 Heated Seat Switch 80 Rear Washer/Wiper Switch 81 Head Light Flasher Switch 82 Front Washer/Wiper Switch 83 Horn Push (Front) 84 Rear Fog Light Switch 85 Head and Side Lights Switch 86 Head Light Dip Switch 87 Front Working Lights Switch 88 Rear Working Lights Switch 89 Interior Light Switch 90 Interior Light Switch 91 Beacon Switch 92 Heater Switch 93 Air Conditioning Switch 94 Air Conditioning Pressure Switch 95 Air Conditioning Pressure Switch 105 Electric Rear Window Switch 106 Brake Fluid Low Level Warning Switch Fuses A1 - A10 B1 - B10 C1 - C10 Refer to page 15 - 05 - 01/20 for further fuse details and ratings. ..... continued
9804/1103
15 - 15 - 01/16
3270 - C/18-2.2
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 15 - 01/17
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) Basic Machine Component List 2 Refer to pages 15 - 15 - 01/15 and 15 - 15 - 01/18 Relays 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 117 Hydraulic Speed Control Relay 118 Rear Horn Relay 119 Ignition Relay ‘2’ 120 Road Lights Relay 121 Italian Worklight Relay 122 Heater Relay 132 Front Working lights Relay 133 Rear Working lights Relay Refer to page 15 - 05 - 01/22 for relay identification
173 Front Working Lights 174 Rear Working Lights 175 Brake Fluid Low Level Warning Light Cable Colour Code B Black N Brown S Slate G Green O Orange U Blue K Pink P Purple W White LG Light Green R Red Y Yellow
Lights 140 LH Brake Light 141 RH Brake Light 142 LH Front Indicator 143 LH Rear Indicator 144 RH Front Indicator 145 RH Rear Indicator 146 Alternator Warning Indicator Light 147 Park Brake Indicator Light 148 Water Temperature Indicator Light 149 Transmission Temperature Indicator Light 150 Engine Oil Pressure Indicator Light 151 Transmission Oil Pressure Indicator Light 152 Air Filter Blocked Indicator Light 153 Hazard Warning Indicator Light 154 Main Beam Warning Indicator Light 155 Gauge Illumination 156 Turn Signal Indicator Light 157 Master Warning Lights 158 Side Lights Indicator Light 159 Rear Work Lights Indicator Light 160 Front Work Lights Indicator Light 161 Rear Fog Light Indicator Light 162 Rear Fog Light 163 LH Main Beam Light 164 RH Main Beam Light 165 LH Dip Beam Light 166 RH Dip Beam Light 167 LH Number Plate Light 168 LH Tail Light 169 LH Side Light 170 RH Number Plate Light 171 RH Tail Light 172 RH Side Light
9804/1103
15 - 15 - 01/17
3270 - C/18-3.3
Issue 1
CONTENTS CONTENTS CONTENTS
Backhoe Loaders
15 - 15 - 01/18
3CX, 4CX and Variants
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) Basic Machine
35
34
162
164 165 163
27
29
168
173
171
174
42
89
33
31
30
166
167 169 170 172 37 36
39
41
90
32
95
26
40 84
25 78 79 157
158 156
94
86
86
87
80
160 154 159 161 153
83 82
88 85
121
132
81
93
91
133
92
120
119
9804/1103
15 - 15 - 01/18
15 - 15 - 01/18
3270 - C/18-4.3
Issue 1
CONTENTS CONTENTS CONTENTS
Backhoe Loaders
15 - 15 - 01/19
3CX, 4CX and Variants
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) Powershift (PS700) Transmission and Steer Circuit - AWS Machines only
63
16
61
3
12 68
43 44
5
8
1
140
9
102
16
136 141
134
112 46
114
47
48
45
117
102 4
135
115
53
101
116 124
127
67 100
113
110
114 64 96
176
175
49
97
50
51
177 178 52
62
98
2
99
111 119
9804/1103
15 - 15 - 01/19
15 - 15 - 01/19
3270 - C/18-5.?
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 15 - 01/20
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) Powershift Transmission (PS700) and Steer Circuit - AWS Machines only Component List Refer to page 15 - 15 - 01/19 Note: Except for the transmission and steer circuits (shown opposite), the AWS electrical circuit is the same as shown on Pages 15 - 15 - 01/15 to 15 - 15 - 01/18. It should be noted that some of the options shown may not be fitted on all machine models. Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 12 Hydraulic Speed Control Solenoid 16 Diode 43 Mainshaft solenoid 44 Layshaft Solenoid 45 Forward Low Solenoid 46 Forward High Solenoid 47 Reverse High Solenoid 48 Reverse Low Solenoid 49 Crab/4 Wheel Steer Solenoid 50 4 Wheel Steer Solenoid 51 Crab Solenoid 52 2 Wheel Steer Solenoid 53 Steer Mode Printed Circuit Board
Switches 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 67 Hydraulic Speed Control Switch 68 Hydraulic Speed Control Switch 96 4 Wheel Drive Switch 97 Powershift Column Switch 98 Front Proximity Switch 99 Rear Proximity Switch 100 Steer Mode Select Switch 101 4 WS/Crab Selector (part of PCB - item 53) 102 2 WS/4 WS Selector (part of PCB - item 53)
9804/1103
Relay 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 117 Hydraulic Speed Control Relay 119 Ignition Relay ‘2’ 123 Neutral Relay 124 Auto 2 Wheel Drive Relay 126 Forward High/Low Relay 127 Reverse High/Low Relay 134 Auto Hydraulic Speed Control Relay 135 Driveshaft interlock Relay 136 Driveshaft Relay Lights 140 LH Brake Light 141 RH Brake Light 175 4 Wheel Steer Indicator Light 176 Crab Steer Indicator Light 177 2 Wheel Steer Indicator Light 178 Front Instrument Console Illumination
15 - 15 - 01/20
3270 - C/18-6.3
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 15 - 01/21
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) Powershift Transmission(PS700) - 2WS Machines only Steer Circuit 3CX 4X4X4 Machines Component List Refer to page 15 - 15 - 01/22 Note: Except for the transmission and steer circuits (shown opposite), the 2WS and the 3CX 4x4x4 electrical circuit is the same as shown on Page 15 - 15 - 01/15 to 15 - 15 - 01/18. It should be noted that some of the options shown may not be fitted on all machine models. Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 8 Reverse Alarm 12 Hydraulic Speed Control Solenoid 16 Diode 44 Layshaft Solenoid 45 Forward Low Solenoid 46 Forward High Solenoid 47 Reverse High Solenoid 48 Reverse Low Solenoid 50 4 Wheel Steer Solenoid 52 2 Wheel Steer Solenoid 67 Hydraulic Speed Control Switch 68 Hydraulic Speed Control Switch Switches 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 65 Brake/Drive Select Switch 97 Powershift Column Switch 98 Front Proximity Switch 99 Rear Proximity Switch 100 Steer Mode Select Switch
9804/1103
Relay 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 117 Hydraulic Speed Control Relay 119 Ignition Relay ‘2’ 125 Driveshaft Relay 126 Forward High/Low Relay 127 Reverse High/Low Relay 129 4 Wheel Steer Relay 130 2 Wheel Steer Relay 131 Steer Relay 134 Auto Hydraulic Speed Control Relay 135 Steer Relay 136 Drive Relay (Layshaft & Mainshaft) Lights 140 LH Brake Light 141 RH Brake Light 147 Park Brake Indicator Light 177 2 Wheel Steer Indicator Light 178 Front Instrument Console Illumination
15 - 15 - 01/21
3270 - C/18-7.3
Issue 1
CONTENTS CONTENTS CONTENTS
Backhoe Loaders
15 - 15 - 01/22
3CX, 4CX and Variants
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) Powershift (PS700) - AWS Machines only Steer Circuit 2CX 4X4X4 Machines
63 43 44
5
3
140
1
112
68
141
136
8
117
45 135
4
130
48
46 47
116
126
124 113
134 129
65
115
147
12
61
49
114
127
67
110 135 100
175 50
62
64 52 177
178
131 97
99
98
2 111 119
9804/1103
15 - 15 - 01/22
15 - 15 - 01/22
3270 - C/18-8.3
Issue 1
CONTENTS CONTENTS CONTENTS
Backhoe Loaders
15 - 15 - 01/23
3CX, 4CX and Variants
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) 3CXE (214E Series 3) only
TO PAGE C/18 - 11 19 143 60
5
3
6
7
140
9
1
15
10
142
73
20
74
75
76
77
145 144
8
61
141 63 114
113
4
118
16
72
62
147 149 151 146
96 110
54
16
37
17
115
22
23
21
148 150 152
155
24 18
70 112
71 64 A274310 (CAD 852/30213)
2
9804/1103
111
15 - 15 - 01/23
15 - 15 - 01/23
3270 - C/18-9.?
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 15 - 01/24
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) 3CXE (214E Series 3) only Component List Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 6 Forward Solenoid 7 Reverse Solenoid 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 10 Fuel Pump Solenoid 15 Rear Horn 16 Diode 17 Indicator Flasher Unit 18 Side Instrument Console 19 Coolant Temperature Sender 20 Fuel Gauge Sender 21 Tachometer 22 Coolant Temperature Gauge 23 Fuel Gauge 24 Hourmeter 25 Front Instrument Console 26 Alternator 35 Horn (Front) 37 Strobe Light Socket 54 Warning Buzzer Switches 60 Transmission Dump Switch (Gear) 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 70 Rear Horn 71 Hazard Warning Switch 72 Direction Indicator Switch 73 Engine Coolant Temperature Switch 74 Transmission Oil Temperature Switch 75 Engine Oil Pressure Switch 76 Transmission Oil Pressure Switch 77 Air Filter Restriction Switch 83 Horn Push (Front) 87 Front Working Lights Switch 88 Rear Working Lights Switch 96 4 Wheel Drive Switch
9804/1103
Relays 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 118 Rear Horn Relay 119 Ignition Relay ‘2’ 132 Front Working lights Relay 133 Rear Working lights Relay Lights 140 LH Brake Light 141 RH Brake Light 142 LH Front Indicator 143 LH Rear Indicator 144 RH Front Indicator 145 RH Rear Indicator 146 Alternator Warning Indicator Light 147 Park Brake Indicator Light 148 Water Temperature Indicator Light 149 Transmission Temperature Indicator Light 150 Engine Oil Pressure Indicator Light 151 Transmission Oil Pressure Indicator Light 152 Air Filter Blocked Indicator Light 153 Hazard Warning Indicator Light 155 Gauge Illumination 156 Turn Signal Indicator Light 159 Rear Work Lights Indicator Light 160 Front Work Lights Indicator Light 173 Front Working Lights 174 Rear Working Lights Fuses A1 - A10 B1 - B10 C1 - C10 Refer to page 15 - 05 - 01/2 for further fuse details and ratings.
15 - 15 - 01/24
3270 - C/18-10.2
Issue 1
CONTENTS
Backhoe Loaders
CONTENTS CONTENTS
15 - 15 - 01/25
3CX, 4CX and Variants
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) 3CXE (214 E Series) only
FROM PAGE C/18 - 9
173
174
35 26
25
87 156
153
159 160
88
83
132
133
119
A274320 (CAD 852/30213)
9804/1103
15 - 15 - 01/25
15 - 15 - 01/25
3270 - C/18-11.2
Issue 1
CONTENTS CONTENTS
Backhoe Loader
15 - 15 - 01/26
3CX, 4CX and Variants
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) 214E Series 4 only
19 35 5
3
7 8
60 6
140
9
1
143
20
145
40 37
10
13
58
31
142
144
33
61 141
32
34
113 41
4
97 72
116
114
17 80
82 96
115 110
92
25
83
22
23
21
62 112
64 71
111 2
9804/1103
15 - 15 - 01/26
3270 - C/18-12.12
Issue1
CONTENTS CONTENTS
Backhoe Loader
3CX, 4CX and Variant
15 - 15 - 01/27
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) 214e Series 4 only Component List Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 6 Forward Solenoid 7 Reverse Solenoid 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 10 Fuel Pump Solenoid 15 Rear Horn 16 Diode 17 Indicator Flasher Unit 18 Side Instrument Console 19 Coolant Temperature Sender 20 Fuel Gauge Sender 21 Tachometer 22 Coolant Temperature Gauge 23 Fuel Gauge 24 Hourmeter 25 Front Instrument Console 26 Alternator 35 Horn (Front) 37 Strobe Light Socket 54 Warning Buzzer Switches 60 Transmission Dump Switch (Gear) 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 70 Rear Horn 71 Hazard Warning Switch 72 Direction Indicator Switch 73 Engine Coolant Temperature Switch 74 Transmission Oil Temperature Switch 75 Engine Oil Pressure Switch 76 Transmission Oil Pressure Switch 77 Air Filter Restriction Switch 83 Horn Push (Front) 87 Front Working Lights Switch 88 Rear Working Lights Switch 96 4 Wheel Drive Switch
9804/1103
Relays 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 118 Rear Horn Relay 119 Ignition Relay ‘2’ 132 Front Working lights Relay 133 Rear Working lights Relay Lights 140 LH Brake Light 141 RH Brake Light 142 LH Front Indicator 143 LH Rear Indicator 144 RH Front Indicator 145 RH Rear Indicator 146 Alternator Warning Indicator Light 147 Park Brake Indicator Light 148 Water Temperature Indicator Light 149 Transmission Temperature Indicator Light 150 Engine Oil Pressure Indicator Light 151 Transmission Oil Pressure Indicator Light 152 Air Filter Blocked Indicator Light 153 Hazard Warning Indicator Light 155 Gauge Illumination 156 Turn Signal Indicator Light 159 Rear Work Lights Indicator Light 160 Front Work Lights Indicator Light 173 Front Working Lights 174 Rear Working Lights Fuses A1 - A10 B1 - B10 C1 - C10 Refer to page 15-15-01/2 for further fuse details and ratings.
15 - 15 - 01/27
3270 - C/18-13.2
Issue 1
Backhoe Loader
CONTENTS CONTENTS
15 - 15 - 01/28
3CX, 4CX and Variants
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) 214 E Series 4 only
74
76
59 73
75
77
174
173 39 26
60 29
54
87 78 88
24
147 149 151 146 148 150 152
28
18 132
133
119
9804/1103
15 - 15 - 01/28
3270 - C/18-14.2
Issue1
Backhoe Loader
CONTENTS CONTENTS
15 - 15 - 01/29
3CX, 4CX and Variants
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) Autoshift Transmission - 2WS Machines Only 1 2 5
4 3 70 71
90
50 72 6 73
7
8 51 9 52 53 54
10 11 12
16
13 55
14 77
15
180D
74
17
18
56
19
75 57 76
9804/1103
15 - 15- 01/29
3270 - C/18-15.2
Issue 1
CONTENTS CONTENTS
Backhoe Loader
3CX, 4CX and Variants
15 - 15 - 01/30
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) Autoshift Transmission - 2WS Machines Only Component List Refer to page 15-15-01/29 Except for the circuits shown opposite the 2WS Autoshift electrical circuit is the same as shown on pages 15-15-01/15 to 15-15-01/18. Main Components 1 Thermostart 2 Battery 3 Starter Switch 4 Starter Solenoid 5 Starter Motor 6 Reverse Alarm 7 Speed Sensor 8 Autoshift Electronic Control Unit (ECU) 9 Forward Low Solenoid 10 Forward High Solenoid 11 Mainshaft Solenoid 12 Layshaft Solenoid 13 Reverse Low Solenoid 14 Reverse High Solenoid 15 Autoshift Gear Selector 16 Autoshift Gear Selector 17 Warning Buzzer 18 Psion Tester Connection 19 Hydraulic Speed Control Solenoid Switches 50 Park Brake Switch 51 Forward/Reverse Switch 52 Transmission Dump Switch 53 Autoshift Kickdown Switch 54 Autoshift Throttle Switch 55 Brake Mode Selector 56 Hydraulic Speed Control Switch 57 Hydraulic Speed Control Switch Relays 70 Neutral Start Relay 71 Parking Brake Relay 72 Ignition 1 Relay 73 Reverse Alarm Relay 74 Ignition 2 Relay 75 Hydraulic Speed Control Relay 76 Auto Hydraulic Speed Control Relay 77 2 Wheel Brake Relay Lights 90 Parking Brake Indicator Fuses A1 - A10 B1 - B10 C1 - C10 Refer to page 15 - 05 - 01/2 for further fuse details and ratings.
9804/1103
15 - 15 - 01/30
3270 - C/18-16.2
Issue 1
Backhoe Loader
CONTENTS CONTENTS
15 - 15 - 01/31
3CX, 4CX and Variants
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) Autoshift Transmission - AWS Machines Only 1 2 4
5
3 70 71
90
50 72 6
73
7
8 51 9 52 53
10
54 11 12
16
13 14 55
15
17 74
18
75
56
76
9804/1103
15 - 15 - 01/31
19 57
3270 - C/18-17.1
Issue 1
CONTENTS CONTENTS
Backhoe Loader
3CX, 4CX and Variants
15 - 15 - 01/32
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) Autoshift Transmission - AWS Machines only Component List Refer to page 15 - 15 - 01/31 Except for the circuits shown opposite the AWS Autoshift electrical circuit is the same as shown on pages 15 - 15 01/15 to 15 - 15 - 01/18 Main Components 1 Thermostart 2 Battery 3 Starter Switch 4 Starter Solenoid 5 Starter Motor 6 Reverse Alarm 7 Speed Sensor 8 Autoshift Electronic Control Unit (ECU) 9 Forward Low Solenoid 10 Forward High Solenoid 11 Mainshaft Solenoid 12 Layshaft Solenoid 13 Reverse Low Solenoid 14 Reverse High Solenoid 15 4 Wheel Drive Solenoid 16 Autoshift Gear Selector 17 Warning Buzzer 18 Psion Tester Connection 19 Hydraulic Speed Control Solenoid Switches 50 Park Brake Switch 51 Forward/Reverse Switch 52 Transmission Dump Switch 53 Autoshift Kickdown Switch 54 Autoshift Throttle Switch 55 4 Wheel Drive Switch 56 Hydraulic Speed Control Switch 57 Hydraulic Speed Control Switch Relays 70 Neutral Start Relay 71 Parking Brake Relay 72 Ignition 1 Relay 73 Reverse Alarm Relay 74 Ignition 2 Relay 75 Hydraulic Speed Control Relay 76 Auto Hydraulic Speed Control Relay Lights 90 Parking Brake Indicator Fuses A1 - A10 B1 - B10 C1 - C10 Refer to page 15 - 05 - 01/2 for further fuse details and ratings.
9804/1103
15 - 15 - 01/32
3270 - C/18-18.1
Issue 1
CONTENTS CONTENTS
Backhoe Loader
3CX, 4CX and Variants
15 - 15 - 01/33
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) Powershift Transmission (PS750) and Steer Circuit - AWS Machines only Refer to pages 15-15-01/34 Note: Except for the transmission and steer circuits (shown opposite), the AWS electrical circuit is the same as shown on 15-15-01/15 to 15-15-01/18 It should be noted that some of the options shown may not be fitted on all machine models. Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 12 Hydraulic Speed Control Solenoid 16 Diode 43 Mainshaft solenoid 44 Layshaft Solenoid 45 Forward Low Solenoid 46 Forward High Solenoid 47 Reverse High Solenoid 48 Reverse Low Solenoid 49 Crab/4 Wheel Steer Solenoid 50 4 Wheel Steer Solenoid 51 Crab Solenoid 52 2 Wheel Steer Solenoid 53 Steer Mode Printed Circuit Board
Switches 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 67 Hydraulic Speed Control Switch 68 Hydraulic Speed Control Switch 96 4 Wheel Drive Switch 97 Powershift Column Switch 98 Front Proximity Switch 99 Rear Proximity Switch 100 Steer Mode Select Switch 101 4 WS/Crab Selector (part of PCB - item 53) 102 2 WS/4 WS Selector (part of PCB - item 53)
9804/1103
Relay 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 117 Hydraulic Speed Control Relay 119 Ignition Relay ‘2’ 124 Auto 2 Wheel Drive Relay 126 Forward High/Low Relay 127 Reverse High/Low Relay 134 Auto Hydraulic Speed Control Relay 135 Driveshaft Interlock Relay 136 Driveshaft Relay Lights 140 LH Brake Light 141 RH Brake Light 142 Parking Brake Indicator Light 175 4 Wheel Steer Indicator Light 176 Crab Steer Indicator Light 177 2 Wheel Steer Indicator Light 178 Front Instrument Console Illumination
15 - 15 - 01/33
3270 - C/18-19.2
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 15 - 01/34
3CX, 4CX and Variants Circuit Diagram (cont’d) Powershift (PS750) Transmision and Steer Circuit - AWS Machines only
63
16
61
12 68
43 44
5
3
From m/c no. 460001
8
9
1
140 112
53
141
48
136 46
45
102 47
117
134
116
4
135 115
124
126
101
127 110
142
113
114
67 100
16 16 64 97
96
50
62
176
175
49
51
177 178 52
16
98
99
2 111
9804/1103
119
15 - 15 - 01/34
3270 - C/18-20.1
Issue1
Backhoe Loaders
CONTENTS CONTENTS
15 - 15 - 01/35
3CX, 4CX and Variants
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) Powershift (PS750) Transmission - 2WS Machines Steer Circuit - 3CX 4X4X4 Machines only
12
63 3
49
43 44
16
5
61 112
140
1
68
141
125
8
65
117 46
45
48
132
131
47 134
4
135
115
116 63 126
124
110
114
113
147
67
127
130 16
50
100
178
16 62
52 64 16
177
129 97
99
98
2 111
9804/1103
119
15 - 15 - 01/35
3270 - C/18-21.?
Issue1
CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 15 - 01/36
From m/c no. 460001
Circuit Diagram - Electrical (cont’d) Powershift Transmission (PS750) - 2WS Machines Steer Circuit - 3CX 4X4X4 Machines only Component List Refer to page 15-15-01/35 Note: Except for the transmission and steer circuits (shown opposite), the 2WS and the 3CX 4x4x4 electrical circuit is the same as shown on Pages 15-15-01/15 to 15-15-01/18. It should be noted that some of the options shown may not be fitted on all machine models. Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 8 Reverse Alarm 12 Hydraulic Speed Control Solenoid 16 Diode 43 Mainshaft Solenoid 44 Layshaft Solenoid 45 Forward Low Solenoid 46 Forward High Solenoid 47 Reverse High Solenoid 48 Reverse Low Solenoid 49 Drive/Brake Solenoid 50 4 Wheel Steer Solenoid 52 2 Wheel Steer Solenoid
Switches 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 65 Brake/Drive Select Switch 67 Hydraulic Speed Control Switch 68 Hydraulic Speed Control Switch 97 Powershift Column Switch 98 Front Proximity Switch 99 Rear Proximity Switch 100 Steer Mode Select Switch
9804/1103
Relay 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 117 Hydraulic Speed Control Relay 119 Ignition Relay ‘2’ 124 Auto 2 Wheel Drive Relay 125 Driveshaft Relay 126 Forward High/Low Relay 127 Reverse High/Low Relay 129 4 Wheel Steer Relay 130 2 Wheel Steer Relay 131 2 Wheel Steer Solenoid Relay 132 4 Wheel Steer Solenoid Relay 134 Auto Hydraulic Speed Control Relay 135 Driveshaft Interlock Relay Lights 140 LH Brake Light 141 RH Brake Light 147 Park Brake Indicator Light 177 2 Wheel Steer Indicator Light 178 4 Wheel steer Indicator Light
15 - 15 - 01/36
3270 - F/18-22.1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 15 - 01/37
From m/c no. 460001
3CX, 4CX and Variants Circuit Diagram - Electrical (cont’d) Auxiliary Options
Hand Held Tools (Gear Pump) 1 2 3
Switch Indicator Lamp Solenoid
9804/1103
Dedicated Quick Hitch 1 2 3 4 5 6
Hydraulic Enable Switch Indicator Lamp Warning Buzzer Operator Switches Relay Solenoid
Pole Planter
Smooth Ride System (SRS)
1 2 3
1 Selector Switch/LED 2 Accumulator Solenoids
Selector Switch Grab Solenoid Rotation Solenoid
15 - 15 - 01/37
3270 - C/18-23.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 15 - 01/38
From m/c no. 460001
Circuit Diagrams - Electrical (cont’d) Auxiliary Options (cont’d)
Hammer
Hand Held Tools (Variable Flow Pump)
1 2 3 4
1 2 3 4
Micro Switch Relay Panel Switch Hammer Solenoid
9804/1103
Switch Indicator Lamp Solenoid (normally open) Solenoid
15 - 15 - 01/38
3270 - C/18-24.1
Issue 1
CONTENTS
Backhoe Loaders
3CX, 4CX and Variants Circuit Diagram - Electrical (cont’d) Auxiliary Options (cont’d)
15 - 15 - 01/39
From m/c no. 460001
Powershift (PS750) 2/4WD Powered On 2WD (Germany)
Power Sideshift with Hammer Circuit
1 2 3 4 5
1 2 3 4 5 6 7 8
Brake Light Switch Brake Mode Switch Auto 2WD Relay 4 Wheel Brake Relay 4WD/4WB Relay
9804/1103
Micro Switch Hammer Relay Hammer Switch Hydraclamp Switch Hammer Solenoid Hydraclamp Solenoid Power Sideshift Solenoid Buzzer
15 - 15 - 01/39
3270 - C/18-25.1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 15 - 02/5
From m/c no. 400001
ALL MODELS (EXCEPT 2CX)
446
446
Circuit Diagrams - Electrical (Servo Machines)
9804/1103
15 - 15 - 02/5
Issue 2
CONTENTS CONTENTS
Backhoe Loaders
15 - 15 - 02/6
From m/c no. 400001
ALL MODELS (EXCEPT 2CX) Circuit Diagrams - Electrical (Servo Machines) (continued)
Servo Controls Component Key 28 29 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 181
Transmission Dump Relay Gear Select Switch Safety Solenoid Steer Relay Steer Solenoid Clam Solenoid Shovel Solenoid Loader Solenoid Dipper Solenoid Slew Solenoid Bucket Solenoid Boom Solenoid Backhoe Relay Loader Relay Joystick Steer Enable Switch Forward/Reverse Select Switch Joystick Isolator Switch Right Hand Joystick Left Hand Joystick Shovel Position Switch Return to Dig (RTD) Enable Switch Float Enable Switch Fault Reset Switch Seat Rear Switch Seat Forward Switch Hydraclamp Relay Hydraclamp Solenoid Auxiliary Service Relay (e.g. Jaw Bucket) Auxiliary Service Solenoid (e.g. Jaw Bucket) Horn Relay Horn Change Over Relay Front Horn Rear Horn Logic Control Box Backhoe Valve Solenoid Hydraulic Speed Control Relay
9804/1103
15 - 15 - 02/6
Issue 1
9804/1103 200
001 8
PRIMARY FUSE 1
6 2
6 8
15 - 15 - 03/1 10
15
002
16 18 1 3
30
13 31 32
830 2
3
35 36 37 38 39 40 41
BUZZER
45 45 45
33
830
45 46
43
47 48 49
53 54 55 56 57 RH SPEAKER
412
50 51
806
200
3270 - C/19_1.1
304A
LH SPEAKER
REAR FOG
402
405
403
404
406
DIRECT EARTH
FUEL SENDER
RADIO
WARNING CLUSTER
INSTRUMENT PANEL
AIR FILTER VAC. SW
TRANS OIL PRESS SWITCH
ENGINE OIL PRESS SWITCH
TRANS OIL TEMP SWITCH
WATER TEMP SWITCH
HOURMETER
TACHOMETER
CLOCK
WATER TEMP SENDER
3CX, 4CX and Variants
FRONT W/L
REAR W/L
MAIN BEAM
411
HAZARD WARNING
SIDE LIGHTS
TURN SIGNAL
LIGHTS
WARNING
MASTER
ILLUMINATION
AIR FILTER
TRANS OIL PRES
ENGINE OIL PRES
TRANS OIL TEMP
WATER TEMP
HAND BRAKE
ALTERNATOR
HOURMETER
0
3 617
7
TACHOMETER
CLOCK
408
26
4
-
FUEL GAUGE
409
25
804
17 4
29 U
4 WATER TEMP GAUGE
18 -
FLASHER UNIT
28
304
U
FLASHER UNIT
RH FRONT INDICATOR ROOF-USA RH REAR INDICATOR ROOF-USA
RH REAR INDICATOR
RH FRONT INDICATOR
LH FRONT INDICATOR ROOF-USA
LH REAR INDICATOR ROOF-USA
LH FRONT INDICATOR
LH REAR INDICATOR
HAZARD SWITCH
IGNITION RELAY 2
E.S.O.S.
COLD START ADVANCE
IGNITION RELAY 1
ALTERNATOR
NEUTRAL START RELAY
STARTER SOLENOID
STARTER MOTOR
BATTERY
THERMOSTART
27
FUSE C4
17 C2
2
+
+
9
FUSE B1
5 49
31
B/O
24
106
8
806
805
23
300
49a
6 806
B/N
22
802
804
INDICATOR SWITCH
21
FUSE C2
4
20
104
803
19
HAZARD SWITCH
007
12
FUSE A3
14
IGNITION RELAY 2
105
5
200
4 2
133
4
WAXSTAT
BATTERY ISOLATOR
10
FUSE A2
810 TO GEARBOX CONTROL FEED
6
107
FUSE A5 11
IGNITION RELAY 1
002
8
W
200
2
FROM NEUTRAL SELECT
200
842
8
133
004
BATTERY
3
FUSE C7
KEY SWITCH
003
NEUTRAL START RELAY
FUSE C5 1
PRIMARY FUSE 3
PRIMARY FUSE 4
200
010
CONTENTS CONTENTS
Backhoe Loaders 15 - 15 - 03/1
From m/c no. 495455
Circuit Diagrams - Electrical Basic Machine
859 EARTH
601
60
860
59
602
58
407 805 407
44 401
FRONT CONSOLE INSTRUMENTS
42 52
INSTRUMENTS
34 SIDE CONSOLE 835
855
861
837
830
200
007
002
133
001
Issue1
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 15 - 03/2
From m/c no. 495455
Circuit Diagrams - Electrical Basic Machine (cont’d) The basic circuit shows a standard mahine. Pages 15 - 15 - 03/5 to 15 - 15 - 03/14 show machine circuits that differ from the ‘basic’. Note that ONLY the differences are shown.
Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Thermostart Battery Isolator Battery Starter Switch Neutral Start Relay Starter Solenoid Starter Motor Alternator From Neutral Selector Cold Start Advance Cold advance start Engine Shut Off Switch (ESOS) To Gearbox Control Feed Ignition Relay ‘1’ Ignition Relay ‘2’ Hazard Warning Switch Indicator Flasher Unit Direction Indicator Switch LH Rear Indicator LH Front Indicator LH Rear Roof Indicator (N. Am) LH Front Roof Indicator (N. Am) RH Front Indicator RH Rear Indicator RH Front Roof Indicator (N. Am) RH Rear Roof Indicator (N. Am) Coolant Temperature Sender Fuel Gauge Sender Coolant Temperature Gauge Fuel Gauge Clock Tachometer Hourmeter Side Instrument Console Alternator Warning Indicator Light Park Brake Indicator Light Water Temperature Indicator Light Transmission Temperature Indicator Light Engine Oil Pressure Indicator Light Transmission Oil Pressure Indicator Light Air Filter Blocked Indicator Light Panel Illumination Warning Buzzer Front Instrument Console Master Warning Lights Turn Signal Indicator Side Lights Indicator Hazard Warning Indicator
9804/1103
49 50 51 52 53 54 55 56 57 58 59 60
Main Beam Warning Indicator Light Rear Working Light Indicator Front Working Light Indicator Rear Fog Light Indicator Engine Coolant Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Restriction Switch Radio (if fitted) RH Speaker LH Speaker
15 - 15 - 03/2
3270 - C/19-2.1
Issue 1
200
9804/1103
73
007
133
15 - 15 - 03/3 10
80 8 7
6 7
835
855 4
861 6
830
78 93 5
3 1
2
8 2
4
6
97
94 8
110
8
95
837 800
828
BEACON SWITCH
2 7
7 3
8
105 106 904
HEATER FAN MOTOR 935
B/P
B/Y
B/Y
B/U
B/G
M
102
1042 8
86
4
7
101 2 8
2
3270 - C/19-4.1
AIR-CON COMPRESSOR
903
HEATER RESISTOR
91
902
861
861
855
855
100
HEATER RELAY
7
894
830
FUSE C9
834
837
RH DIP BEAM
B
AIR-CONDITIONING
HEATER RELAY
HEATER
BEACON
INTERIOR LIGHT
REAR WORKING LIGHTS
FRONT WORKING LIGHTS
LIGHT SWITCH
RH SIDE LIGHT
RH TAIL LIGHT
No PLATE LIGHT
DIPPER SOCKET
LH SIDE LIGHT
LH TAIL LIGHT
LH DIP BEAM B
B
RH MAIN BEAM B
LH MAIN BEAM
LIGHTS RELAY
B
B
FOG LIGHT
FRONT HORN
Backhoe Loaders
AIR-CON SWITCH
81
3
HEATER SWITCH
5 1
102
4 6
R/W/L SWITCH
FUSE A10
829
833
B/U
835
FOG LIGHT SWITCH
814
FRONT WIPER
FRONT WASHER PUMP
REAR WIPER
REAR WASHER PUMP
HEATED SEAT
FACE LEVEL FAN
CIGAR LIGHTER
3CX, 4CX and Variants
FUSE C7
ROAD LIGHTS SWITCH
4
FUSE C3
2
99
303
5
5
FUSE B8
3
117
6
98
309
79
3
FUSE B10
116
74
6
310
82
89
F/W/L SWITCH
2
87
1133
8
836
INTERMITTENT ECU
FUSE C10
76
FUSE A9
832
67 3
DIP SWITCH
7
FUSE C1
868
71
TERRITORIAL OPTION ITALY, GERMAN ONLY
64 88
407
829
69 FRONT HORN SWITCH
840
84 85
ENGINE RUNING RELAY
8
841
M
83
FUSE C1
3
984
68
311
1
982
983
77
FUSE B9
66 M
127
1133
6 7
FRONT W/W SWITCH
M
75
ROAD LIGHTS RELAY
2
839
72
REMOVED FOR TERRITORIES ITALY, GERMAN ONLY
5
864
862
70
H/LIGHT FLASH
65 863
M
110
63 HEATED SEAT SWITCH
407
FUSE B2
REAR WASH/ WIPE SWITCH
830
62
FUSE B5
114
61
103
FUSE B4
CONTENTS CONTENTS
15 - 15 - 03/3
From m/c no. 495455
Circuit Diagrams - Electrical Basic Machine (cont’d)
90 92 110
M
109
96 108
6 3
107 2
103
829
2
1853
001
PRIMARY FUSE 2
Issue1
9804/1103
13 TO FUSE A5 TO FUSE A5 14
15 - 15 - 03/5 7
1
4
810
6
2
TO NEUTRAL START RELAY
1 2 2WS WRNG LIGHTS
3
4
11
12
13
9
14
3270 - C/19-5.1
15 16 17
(FRONT CONSOLE)
825
5
2WS SOLENOID (SIDE CONSOLE)
812
848
811
849
STEER MODE P.C.B.
PROXIMITY SWITCHES
FORWARD HIGH SOLENOID
FORWARD LOW SOLENOID
REVERSE HIGH SOLENOID
REVERSE LOW SOLENOID
REVERSE ALARM
Backhoe Loaders
CRAB WRNG LGHT
2WS/4WS MODE SELECTOR
5
4WS/CRAB MODE SELECTOR
4
CRAB SOLENOID
824
826
4WS RELAY
2WS RELAY
847
TRANSMISSION EARTH
LAYSHAFT SOLENOID
MAINSHAFT SOLENOID
DUMP SWITCH (LOADER)
P/BRAKE SWITCH
REVERSE ALARM
REVERSE SOLENOID
FORWARD/REVERSE RELAY
FORWARD SOLENOID
DUMP SWITCH (LOADER) DUMP SWITCH (GEARLEVER)
P/BRAKE SWITCH
3CX, 4CX and Variants
4WS WRNG LGHT
4WS SOLENOID
6
8
845
20
CRAB/4WS SOLENOID
8
7
823
6
CRAB RELAY
6
STR MODE SW
17 7
822
9
CRAB/4WS RELAY
10
820
821
883
106
852
8
FORWARD H/L RELAY
3
REAR PROX SW
2 819
8
FRONT PROX SW
3
10
858
12 6
4
5
856
REVERSE H/L RELAY
3
7
3
5
9
2
852 5
21
FUSE B1
9 3
1
2
19
007
TO NEUTRAL START RELAY 1
18
109
4 16
FUSE A4
810
8
850
851
3
107
1
1
6
11
883
2
POWER SHIFT GEAR SELECTOR
4
808
7 1
REVERSE RELAY
10 2
FOR / REV SWITCH
9 4
R
1
N
F
8
809
11
DRIVE RELAY
12 15
002
7 10
5
INTERLOCK RELAY
14
FORWARD RELAY
1 815
13
107
4
TRANS DUMP RELAY
847
815
3
934
811
811
10
815
3
REVERSE RELAY
812
934
815
401
5 6
401
808
809 5
107
810
5
FOR / REV SWITCH
9 3 1
R
6
FORWARD RELAY
8
N
F
8
TRANS DUMP RELAY
10
934
815
401
2
107
107
810
CONTENTS CONTENTS
15 - 15 - 03/5
From m/c no. 495455
Circuit Diagrams - Electrical Transmission and Steering
22 STEER MODE P.C.B.
10
10
7
18
Issue1
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 15 - 03/6
From m/c no. 495455
Circuit Diagrams - Electrical Transmission And Steering Manual Transmission
Steer Mode - 4CX and 3CX Super (4x4x4)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
To wire 401 on page C/19-1 Parking Brake Relay Parking Brake Switch Transmission Dump Relay Dump Switch on Loader Lever Dump switch on Gear lever Forward/Reverse Selector Lever Forward Relay To Neutral Start Relay on page C/19-1 Forward Solenoid Reverse Relay Reverse Solenoid To Fuse A5 on page C/19-1 Reverse Alarm
Powershift Transmission 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
To wire 401 on page C/19-1 Parking Brake Relay Parking Brake Switch Transmission Dump Relay Dump Switch on Loader Lever Gear Selector Switch Forward/Reverse Selector Lever Forward Relay To Neutral Start Relay on page C/19-1 Interlock Relay Drive Relay Reverse Relay Mainshaft Solenoid To Fuse A5 on page C/19-1 Layshaft Solenoid Reverse Alarm Reverse High/Low Relay Reverse Low Solenoid Reverse High Solenoid Forward High/Low Relay Forward Low Solenoid Forward High Solenoid
9804/1103
Front Proximity Switch Rear Proximity Switch Steer Mode Selector Switch Steer Mode Printed Circuit Board Crab/4WS Relay Crab Relay 2WS Relay 4WS Relay 4WS/Crab Selector (part of 4) 2WS/4WS Selector (part of 4) Crab/4WS Solenoid 4WS Solenoid 4WS Indicator Light Crab Solenoid Crab Indicator Light 2WS Solenoid 2WS Indicator Light Side Console 2WS Indicator Light Front Console
15 - 15 - 03/6
3270 - C/19-6.1
Issue 1
9804/1103 TH
15 - 15 - 03/7 1 2
2 6
1 5
3
101
7
4 2 830
4
107
3
304
8
SPEED SENSOR
974
853
SPEEDO
SPEED SENSOR
HYDRACLAMP SOLENOID
HAMMER SOLENOID
JAW SOLENOID
RH BRAKE LIGHT
LH BRAKE LIGHT
4WB RELAY
4WD SOLENOID
AUTO 2WD RELAY
RH BRAKE LIGHT
LH BRAKE LIGHT
4 WB RELAY
2WD/2WB 2WD/4WB 4WD/4WB SOLENOID
AUTO 2WD RELAY
3CX, 4CX and Variants
FUSE A10
7 3
8
FUSE A5
1 10
109
6
920
870
874
8
FUSE C4
8
7
HAMMER RELAY
4
HYDRACLAMP SWITCH
6
899
898
2
AUX HYD SWITCH
3
872
873
JAW RELAY
816
7
FUSE A4
2
3 5
101
8
5
FUSE A1
2
829
3
FUSE A7
8
ILLUMINATION
7
875
8
858
10 3
4WB RELAY
5
FROM 4 GEAR SELECTOR
6
933
1
126
5
877
2
FUSE A8
853
BR MODE SW
6
FUSE B6
4 AUTO 2WD RELAY
922
854
7
BRAKE LIGHTS SWITCH
9
922
4WD SWITCH
4WB RELAY
3
107
6 816
877
1
FUSE A5
8
3
830
6
AUTO 2WD RELAY
2 2
FUSE A7
FUSE A8
818
10
ILLUNINATION
933
107
858
9
126
BRAKE LIGHTS SWITCH
TH
4
FUSE B6
FUSE A5
1 FROM 4 GEAR SELECTOR
CONTENTS CONTENTS
Backhoe Loaders 15 - 15 - 03/7
From m/c no. 495455
Circuit Diagrams - Electrical Options
5 7 8 9
5
1
2 3
1
5
818
1830
3270 - C/19-8.1
Issue1
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 15 - 03/8
From m/c no. 495455
Circuit Diagrams - Electrical Options (cont’d) 2 Wheel Steer/Brake Mode
Auxiliary and Hydraclamp Hydraulics
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9
From 4th Gear Selector Auto 2 Wheel Drive Relay 4 Wheel Braking Relay Brake mode Selector Switch 4 Wheel Drive/4 Wheel Brake Solenoid Brake Light Switch LH Brake Light RH Brake Light
All Wheel Steer/Brake Mode 1 2 3 4 5 6 7 8
From 4th Gear Selector 4 Wheel Drive Selector Switch Brake Light Switch Auto 2 Wheel Drive Relay 4 Wheel Braking Relay 4 Wheel Drive Solenoid LH Brake Light RH Brake Light
9804/1103
Excavator Lever Push Button Selector Switch Auxiliary Selector Switch Floor Push Button Selector Switch Hydraclamp Selector Switch Jaw Relay Hammer Relay Jaw Solenoid Hammer Solenoid Hydraclamp Solenoid
Speedometer Option 1 2 3
Speed Sensor Speedometer Illumination
15 - 15 - 03/8
3270 - C/19-7.1
Issue 1
CONTENTS
Backhoe Loaders
15 - 15 - 03/9
3CX, 4CX and variants Circuit Diagrams - Electrical
From m/c no. 495455
2
ROADBREAKER SWITCH
854
1
3
9804/1103
801
929 101
FUSE A1
126
Powershift 4WD Auto 2WD In 4th Powered on 2WD German 1 Brake Light Switch 2 4 Wheel Brake Relay 3 Brake Mode Selector 4 Auto 2WD Relay 5 4WD/AWB Solenoid
1
QUICK-HITCH FEED SWITCH
858
114
FUSE B4
BRAKE LIGHTS SWITCH
1 1
4
2
933
FUSE A5
FUSE A8
3
BR MODE SW
107
877
801
4
5
Hand Held Tools 1 Rockbreaker Switch 2 Indicator Lamp 3 Rockbreaker Solenoid
Dedicated Quick Hitch 1 Hitch Enable Switch 2 Indicator Lamp 3 Alarm 4 Push Button 5 Push Button 6 Quick Hitch Relay 7 Quick Hitch Solenoid
15 - 15 - 03/9
FUSE B4
8
972
6
3
114
1
2
930
1855
7
10
OPERATOR HOLD-IN SWITCHES
4
AUTO 2WD RELAY
2
6
931
853
QUICK-HITCH RELAY
ROADBREAKER SOLENOID
932
7
3
ROTATION SOLENOID
GRAB SOLENOID
5
QUICK-HITCH SOLENOID
QUICK HITCH
HAND HELD TOOLS
AUTO 2WD RELAY
4WD/4WB
2WD/4WB
2WD/2WB
4 WB RELAY
4WD/AWB SOLENOID
Options (cont’d) Auxiliary
A370070
Pole Planter 1 Selector Switch 2 Grab Solenoid 3 Rotation Solenoid
3270 - C/19-11.1
Issue 1
CONTENTS
Backhoe Loaders
15 - 15 - 03/10
3CX, 4CX and Variants Circuit Diagrams - Electrical
From m/c no. 495455
H.S.C. RELAY
H.S.C. SOLENOID
LEVER 'HOLD' SOLENOID
ACCUMULATOR SOLENOIDS
Options (cont’d) Auxiliary (cont’d)
867
5
3 4 H.S.C. RELAY
10
6
865 2
4
5
H.S.C. BUTTON
2
8
1 6
3
1856
8
2
8
3
132
132
TH
FROM 4 GEAR SELECTOR
818
FUSE A9
829
2
830
8
1
H.S.C. SWITCH
1
3
7
829
SRS SWITCH
7
SHOVEL RESET SWITCH
3
7
866
CROWD RAM PROXIMITY SWITCH
1851
1801
2
7
9
1857
844
2
1
FUSE B7
FUSE A1
101
Smooth Ride System (SRS) 1 Selector Switch 2 Accumulator Solenoids
9804/1103
Return To Dig (Shovel Reset) 1 Selector Switch 2 Ram Proximity Switch 3 Lever ‘hold in’ Solenoid
Hydraulic Speed Control 1 Supply from 4th Gear Selector 2 Selector Switch 3 Control Lever Push Button 4 Relay 5 HSC Solenoid
15 - 15 - 03/10
3270 - C/19-12.1
Issue 1
CONTENTS
Backhoe Loaders
3CX, 4CX and Variants Circuit Diagrams - Electrical Autoshift Transmission
15 - 15 - 03/11
From m/c no. 495455
A378770
9804/1103
15 - 15 - 03/11
3270 - C/19-9.1
Issue 1
CONTENTS
Backhoe Loaders
3CX, 4CX and Variants Circuit Diagrams - Electrical Autoshift Transmission (cont’d) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
15 - 15 - 03/12
From m/c no. 495455
From Ignition Relay 2, see item 15 page 15 - 15 - 03/1 From Ignition Relay 1, see item 14 page 15 - 15 - 03/1 From Parking Brake Relay, see item 36 page 15 - 15 - 03/1 To Neutral Start Relay, see item 5 page 15 - 15 - 03/1 Parking Brake Relay Parking Brake Switch Reverse Alarm Relay Reverse Alarm Speed Sensor Forward/Reverse Selector Switch Dump Switch Kickdown Switch Throttle Switch Autoshift Gear Selector Autoshift Electronic Controller All Wheel Steer Machines Only From Brake Switch, see item 3 page 15 - 15 - 03/7 4 Wheel Drive Selector Switch 2 Wheel Steer machines Only Brake Mode Selector Switch From Brake Switch, see item 3 page 15 - 15 -03/7 2 Wheel Braking Relay Alarm To Hydraulic Speed Control Switch, see item 2 page 15 - 15 - 03/10 Forward Low Solenoid Forward High Solenoid Mainshaft Solenoid Layshaft Solenoid Reverse Low Solenoid Reverse High Solenoid 4 Wheel Drive Solenoid Psion Diagnostic Connector
9804/1103
15 - 15 - 03/2
3270 - C/19-10.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
15 - 15 - 03/13
3CX, 4CX and Variants
From m/c no. 495455
Circuit Diagrams - Electrical Servo Command Pilot Circuit 1 IGN SW
5
FUSE 3A
1826
14
3
2
1
PROPORTIONAL SWITCH. LH STAB, AUX.OPT.
16 18 4k
930
0.5k 0V
16
1V
D8 6
D5 D11
R5
5
FUSE 3A
1843
1807
1807
HAMMER SOLENOID FEED
19
RH AMPLIFIER 3
2
7 4
1
PROPORTIONAL SWITCH. CLAM, AUX, RH STAB.
1841
R4
1850
1842
1833
R3
R2
10V
9V
D9
1812 D2
0.5k
15
13
1810
4
1823
1825
1827
921 875
D7
1824
REAR HORN
FROM TACHO ILLUMINATION
D1
TRANS DUMP
1806
1811
TO HSC RELAY
11 RTD
1805
QUICK HITCH SWITCHES
934
AUX FEED
D6
1851
17 LH AMPLIFIER
929
AUTO DUMP RELAY
TO AUTO ECU
FUSE 1A
1814
EXISTING +VE FEED TO HORN
AUX
1813
934
PUMP DUMP
10 FLOAT
2
1805
S3
RTD
STAB
R
MODE
F
12
4 7
9
1857
1839
1840
L3
6
7
8
1809
SWITCH
112
3
2
1846
SERVO
7
SWEEPER BLOWER SWITCH
3 ENABLE
S1 8
5
6
1804
6
1824
L1
2
S2
131
3
8
L2 8
1821
R7 5
7
6
D10
1822
844
830 2
FROM TRANS DUMP RELAY
101
37 1808
2
012
7
D4
931
D3
SERVO BUZZER
FUSE 15A
R1
FUSE 3A
FUSE 10A
101AB
12V +VE FEED
1816
107
200V
1808
870
20
870
R8
R10
R9
R13
R12
R14
R15
4k
0.5k
1844
R16
0V
R19
R18
R17
1V
0.5k 9V
10V
1845
1838 1834
1832
1849
1847 1807 947
1848
R23
1
2 22
ARMS/BOOM CHANGEOVER VALVE
9804/1103
23
T
24
SHOVEL/BUCKET CHANGEOVER VALVE
B
25 LOADER VALVE
15 - 15 - 03/13
27 AUX VALVE
R.STAB
H
28
H
T
29
R
B
30 EXCAVATOR VALVE
H
T
31
AUX OPTION
1802
1803
R.STAB
955
L.STAB
956
953
954
957
L.STAB
AUX OPTION
5
6
R
R
26
AUX EXT DIP
958
AUX EXT DIP
4
3
H
21
CLAM
959
CLAM
960
1836
1831
R22
1828
R21
FUSE 5A
R20
FUSE 5A
1837
1829
R
B
32
33
LH PILOT PRESSURE VALVE
34 LH/RH PILOT PRESSURE VALVE
36
35
GROUND
AUX VALVE
3270 - C/19-14.1
Issue1
CONTENTS CONTENTS
Backhoe Loaders
3CX, 4CX and Variants
15 - 15 - 03/14
From m/c no. 495455
Circuit Diagrams - Electrical Servo Command Pilot Circuit (cont’d) The circuit shown refers to the Servo option only, for the remainder of the circuit see the appropriate additional circuit. Main Components 1 Starter Switch 2 Return To Dig Switch 3 Servo Enable Switch 4 Sweeper Blower Switch 5 Shovel Limit Switch 6 Forward Seat Proximity Switch 7 Rearward Seat Proximity Switch 8 Mode Changeover Switch 9 Stabiliser Switch 10 Float Electro Magnetic Latch Coil 11 Return To Dig Electro Magnetic Latch Coil 12 Hydraulic Speed Control Switch 13 Transmission Dump Switch 14 Auxiliary Switch 15 Rear Horn 16 Quick Hitch Switch 17 Left Hand Amplifier 18 Left Hand Proportional Rocker Switch 19 Right Hand Amplifier 20 Right Hand Proportional Rocker Switch 21/22 Manifold Arms/Boom Changeover Solenoid 23/24 Manifold Shovel/Bucket Changeover Solenoid 25/26 Loader Solenoid 27/28 Auxiliary Solenoid 29/30 Excavator Left Hand Stabiliser Solenoid 31/32 Excavator Right Hand Stabiliser Solenoid 33 Manifold Left Hand Pilot Pressure Valve 34 Manifold Left/Right Hand Pilot Pressure Valve 35/36 Auxiliary Option Solenoid 37 Alarm
R20 R21 R22 R23
Stabiliser Lower Changeover Stabiliser Raise Changeover Stabiliser Lower Mode Changeover Stabiliser Raise Mode Changeover
On the illustration: B = Bottom T = Top H = Head R = Rod
Relays R1 Ignition R2 Front Seat R3 Front Mode Changeover R4 Rear Seat R5 Rear Mode Changeover R6 Spare R7 Dump Interlink (autoshift only) R8 Front Auxiliary Supply R9 Hammer Interlink R10 Stabiliser Isolator R11 Spare R12 Sweeper/Clam Changeover R13 Pilot Valve Changeover R14 Auxiliary/Clam 2 Changeover R15 Auxiliary/Clam 1 Changeover R16 Stabiliser/Clam 2 Changeover R17 Stabiliser/Clam 1 Changeover R18 Stabiliser/Auxiliary 1 Changeover R19 Stabiliser/Auxiliary 2 Changeover 9804/1103
15 - 15 - 03/14
3270 - C/19-13.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
15 - 20 - 02/1
From m/c no. 402174
3CX, 4CX (200 Series) Circuit Diagrams - Hydraulic (Standard Machines)
Basic Machine (2WS & AWS Machines) Component Key P1 P2 P2A S T 1A 1B 2A 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 3K 3L 3M 3N 3P 3Q 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4R 4S 4T 4U 4V 4W 4X 6 6A 7 7B 13 25 26 31 32 33
Pump, Main Section Pump, Secondary Section Pressure Test Point (auxiliary attachments) Suction Line Tank Neutral Circuit Line Neutral Circuit Line Neutral Circuit Line Loader Valve Block Pressure Test Point (M.R.V.) Main Relief Valve Loader Lift Ram Spool Loader Shovel Ram Spool Clamshovel Spool Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Load Hold Check Valve Load Hold Check Valve Load Hold Check Valve Unloader Valve Spool Unloader Pilot Valve Unloader Check Valve Pressure Test Point (Unloader) Hydraulic Speed Control Solenoid Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Hydraclamp Valve Slew A.R.V. Slew A.R.V. Boom Ram Rod Side A.R.V. Boom Ram Head Side A.R.V. Dipper Ram Head Side A.R.V. Dipper Ram Rod Side A.R.V. Bucket Ram Head Side A.R.V. Load Hold Check Valve Load Hold Check Valve Load Hold Check Valve Load Hold Check Valve Load Hold Check Valve Load Hold Check Valve Make-up Check Valve In-tank Filter Filter By-pass Valve Priority Valve Connection to Steer Circuit Anti-cavitation Check Valve Sequence Valve Hydraulic Oil Cooler Shovel Ram R.H. Shovel Ram L.H. Lift Ram R.H.
9804/1103
34 35 36 52 53 54 55 56 57 58 59 61 62 62A 64 65 66
Lift Ram L.H. Clam Shovel Ram R.H. Clam Shovel Ram L.H.51 Bucket Ram Boom Ram Stabiliser Ram Stabiliser Ram Dipper Ram Left Hand Slew Ram(Centremount Machines Only) Right Hand Slew Ram(Centremount Machines Only) One Way Restrictor Stabiliser Check Valve (Standard on Centremount, Optional on Sideshift Machines) Hose Burst Protection Valve (optional) Hydraclamps (Sideshift Machines Only) Hydra-clamp Exhaust Line Slew Cylinders (Sideshift Machines Only) One Way Restrictor (Centremount Machines Only) Hose Burst Protection Valve (optional)
Note: Excavator services shown here are to the JCB control pattern. If ISO, Case or Ford control pattern is used, the excavator spools and relief valves will apply to different services. Note: The policy of JCB is one of continuous improvement, therefore as products develop, there may be variations to the circuits. Page 15-20-02/3 titled 'Circuit Variations' will identify these differences.
15 - 20 - 02/1
Issue 3
CONTENTS CONTENTS
Backhoe Loaders
15 - 20 - 02/2
3CX, 4CX (200 Series)
From m/c no. 402174
Circuit Diagrams - Hydraulic
54
62A 4
62
35
4G T 4X
31
33
6
4R
6A
61 C2
4H
58
E P
4A
C2
1B
E
T
P
4S
4J 59
3
S
66
T
V2
4K
V2
65
65
4B P2
3E
P1
4T C
25
52
4L
51
55
3K
3G
64
56
4C 3D
V2 V1
V
61
4U
3F
3J
C2 E
4D T
V2
P
3C 4V
26
P E
C2
1A
57
T
V2
4E 3M
66 13
64 4M
3H
3Q
1A
4W
3L
4N
59
4P
2A
4F
34
32
3N
3B
3P
3A 36
EF
7B
P
53 P2A
CF
PP
9808/9555-2
7
9808/9555-2
9804/1103
15 - 20 - 02/2
15 - 20 - 02/2
Issue 3
Backhoe Loaders
CONTENTS CONTENTS
15 - 20 - 02/3
From m/c no. 400001
ALL MODELS (EXCEPT 2CX) Circuit Diagrams - Hydraulic (Standard Machines)
Circuit Variations The hydraulic schematic diagram shown on page 15 - 20 - 02/2 shows the latest machine hydraulic circuit. The purpose of this page is to identify 'older' circuit variations, where possible the machine serial numbers will be given to help identify the machine range(s). Hose Burst Protection Valves (to Serial Number 402173) The illustration shows the HBPV when fitted to the boom circuit. This valve is also fitted on the dipper ram and the loader arms. 4 61 4S
4B 4K
Component Key
C2 V2
4 4S 4K 4L 4B 52 61
V1 C1
4L
52
A196780
Excavator Valve Block Load Hold Check Valve Boom Ram Rod Side A.R.V. Boom Ram Head Side A.R.V. Boom Spool Boom Ram Hose burst Protection Valve (Optional)
'Hamworthy' Type Loader Valve The illustration shows the 'Hamworthy' type loader valve, the latest type loader valve (Husco) has the pilot valve solenoid (used to control the unloader spool) as an integral part of the valve block, not a separate item as shown at 3Q.
1A 3M
3 Component Key 3L
3N 3P 3Q T
P2
P1 P2 T 1A 3 3L 3M 3N 3P 3Q
Pump, main Section Pump, Secondary Section Tank Neutral Circuit Line Loader Valve Block Unloader Valve Spool Unloader Pilot Valve Unloader Check Valve Pressure Test Point (Unloader) Hydraulic Speed Control Solenoid
P1 A197090
9804/1103
15 - 20 - 02/3
Issue 2
CONTENTS CONTENTS
Backhoe Loaders
15 - 20 - 02/4
From m/c no. 400001
ALL MODELS (EXCEPT 2CX) Circuit Diagrams - Hydraulic (Standard Machines)
Circuit Variations (cont'd) Hydraclamp Control Valve (to Serial Number 430000) The illustration shows the manual type hydraclamp control valve. Machines from serial number 430001 have the hydraclamp valve operated by a switch (and solenoid).
Component Key T 1B 4 4A 4G 4H 4R 4X 62
Tank Neutral Circuit Line Excavator Valve Block Slew Spool Hydraclamp Valve Slew A.R.V. Load Hold Check Valve Make-up Check Valve Hydraclamps (Sideshift Machines Only)
1B
T
4 62 4G 4X
4R
4H
4A
A217690
9804/1103
15 - 20 - 02/4
Issue 3
Backhoe Loaders
CONTENTS CONTENTS
15 - 20 - 02/5
From m/c no. 400001
ALL MODELS (EXCEPT 2CX) Circuit Diagrams - Hydraulic (Standard Machines)
Steer Hydraulics (All Wheel Steer Machines) Component Key P1 P2 P2A S T 6 7 8 9 10 11 12 42 43 44
Pump, Main Section Pump, Secondary Section Pressure Test Point Suction Line Tank In-tank Filter Priority Valve Steer Mode Valves Assembly Front Steer Ram - Left Hand Front Steer Ram - Right Hand Rear Steer Ram - Right Hand Rear Steer Ram - Left Hand Steer Control Unit Shock Valve Steer Control Unit Relief Valve
Note: Hydraulic component port identification letters are shown in parenthesis, e.g. (LS). The same letters will be stamped on the actual component.
T 6
43
(L)
10
9
(R)
S
42
(T)
(P)
(A)
(B)
(LS)
P2 P1 8 44 (T)
(P)
(CF) (LS)
(P)
7 P2A 12
11
9808/9510-3
9804/1103
15 - 20 - 02/5
Issue 2
Backhoe Loaders
CONTENTS CONTENTS
15 - 20 - 02/6
From m/c no. 400001
ALL MODELS (EXCEPT 2CX) Circuit Diagrams - Hydraulic (Standard Machines)
Steer Hydraulics (2-Wheel Steer Machines) Component Key P1 P2 P2A S T 6 7 9 10 42 43 44
Pump, Main Section Pump, Secondary Section Pressure Test Point Suction Line Tank In-tank Filter Priority Valve Front Steer Ram - Left Hand (4 wheel drive only) Front Steer Ram - Right Hand (2 wheel drive only) Steer Control Unit Shock Valve Steer Control Unit Relief Valve
Note: Hydraulic component port identification letters are shown in parenthesis, e.g. (LS). The same letters will be stamped on the actual component.
T 6 43
(L)
(R)
10 9
S 42 (LS)
P2 P1 (P)
44
(T)
(CF) (LS)
(P)
7 P2A
9808/9545-1
9804/1103
15 - 20 - 02/6
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 20 - 02/7
3CX, 4CX
From m/c no. 460001
Steer Hydraulics (4WS Machines) System Type Hydraulic Supply Control Unit Type
Full Power Hydrostatic From Main Hydraulic Pump Via Priority Valve Load Sensing With Integral Relief Valve
ORBITROL VALVE - FIG 1 Model - Volumetric Displacement - Relief Valve - Check Valve - Shock Valve - Relief Valve Operating Pressure (at 1500 revs/min) - Shock Valve Operating Pressure
160 OSPC 160 cc/rev Fitted Fitted Fitted 120 ± 3 bar 175 - 190bar
122 ± 3.5 kgf/cm2 178 - 199 kgf/cm2
PRIORITY VALVE - FIG 2 Stand by Pressure
7 bar
7.1 kgf/cm2
1740 ± 50 lbf/in2 2538 - 2756 lbf/in2
102 lbf/in2
LS
EF
P LS
LS
FIG 2
FIG 1
9804/1103
15 - 20 - 02/7
3270 - H/1-1.1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 20 - 02/8
3CX, 4CX
From m/c no. 460001
Steer Hydraulics (2WS Machines) System Type Hydraulic Supply Control Unit Type
Full Power Hydrostatic From Main Hydraulic Pump Via Priority Valve Load Sensing With Integral Relief Valve
ORBITROL VALVE - FIG 1 Model - Volumetric Displacement - Relief Valve - Check Valve - Shock Valve - Relief Valve Operating Pressure (at 1500 revs/min) - Shock Valve Operating Pressure Model - Volumetric Displacement - Relief Valve - Check Valve - Shock Valve - Relief Valve Operating Pressure (at 1500 revs/min)
200 OSPC 200 cc/rev Fitted Fitted Fitted 120 ± 3 bar 175 - 190bar 250 OSPC 250 cc/rev Fitted Fitted Not Fitted 120 ± 3 bar
PRIORITY VALVE - FIG 2 Stand by Pressure
7 bar
122 ± 3.5 kgf/cm2 178 - 199 kgf/cm2
1740 ± 50 lbf/in2 2538 - 2756 lbf/in2
122 ± 3.5 kgf/cm2
1740 ± 50 lbf/in2
7.1 kgf/cm2
102 lbf/in2
LS
EF
P LS
LS
FIG 2
FIG 1
9804/1103
15 - 20 - 02/8
3270 - H/1-2.1
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
15 - 20 - 03/1
From m/c no. 400001 to 420484
ALL MODELS (EXCEPT 2CX) Circuit Diagrams - Hydraulic (Servo Machines) Pumps, Valves, Filters & Tank P1 P2 P1A P2A S T TA 1 1A 2 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 3K 3L 3M 4 4A 4B 4C 4D 4E 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 4W 4X 4Z 5 5A 5B 5C 6 7 8 8A 8B 9 9A 9B 10
Pump, Main Section Pump, Secondary Section Pressure Test Point (Loader & Backhoe MRV & ARV) Pressure Test Point (Unloader Valve, Auxiliary Attachments & Steer Circuit) Suction Line Tank In-tank Filter Hydraulic Oil Cooler Twin Check Valve (Cooler & Make Up) High Pressure Filters Loader Valve Block Pressure Relief Valve (& Filter) Pressure Adjustment Spool Pressure Reduction Valve (Pilot Pressure) Pressure Relief Valve (Pilot Pressure) Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Anti-cavitation Valves Shuttle Valves Load Hold Check Valves Loader Lift Ram Spool Loader Shovel Ram Spool Clamshovel Spool Backhoe Valve Block Pressure Relief Valve Pressure Adjustment Spool Pressure Compensator Shuttle Valves Load Hold Check Valves (LHCV) Pressure Compensator Valve (with integral LHCV) Pressure Relief Valve (Pilot Pressure) Pressure Reducing Valve (Pilot Pressure) Boom Spool Boom Ram Head Side A.R.V. Boom Ram Rod Side A.R.V. Dipper Spool Dipper Ram Head Side A.R.V. Dipper Ram Rod Side A.R.V. Bucket Spool Bucket Ram Head Side A.R.V. Slew Spool Steer Spool Backhoe Valve Fault Solenoid Filter Unloader Valve Unloader Valve Spool Unloader Pilot Valve Unloader Check Valve Hydraulic Speed Control Valve Priority Valve Steer Control Unit Shock Valves Steer Unit Relief Valve Steer Mode Valve 2WS/AWS Solenoid Valve Crab/AWS Solenoid Valve Hydraclamp Valve
9804/1103
11 12 12A 12B 12C 12D 12E 12F 13 14 15 16 17 18
Safety Solenoid Valve Auxiliary Valve (Stabilisers) Extending Dipper/Knuckle Spool Relief Valve Auxiliary Relief Valve (Head Side) Auxiliary Relief Valve (Rod Side) Stabiliser Spool Stabiliser Spool Check Valve (Fitted with Knuckle Option) Stabiliser Check & Relief Valve Stabiliser Check & Relief Valve Slew Motion Control Valve One Way Restrictor Hose Burst Protection Valve (see page E/2-3, service manual 9803/3260, item 61 for details)
Rams 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
15 - 20 - 03/1
Clam Shovel Ram L.H. Clam Shovel Ram R.H. Lift Ram L.H. Lift Ram R.H. Shovel Ram L.H. Shovel Ram R.H. Front Steer Ram LH Front Steer Ram RH Rear Steer Ram RH Rear Steer Ram LH Hydraclamps (Sideshift Machines Only) Boom Ram Dipper Ram Bucket Ram Left Hand Slew Ram(Centremount Machines Only) Right Hand Slew Ram(Centremount Machines Only) Slew Cylinders (Sideshift Machines Only) Stabiliser Ram Stabiliser Ram Extending Dipper Ram Knuckle Boom Ram
Issue 2
CONTENTS CONTENTS
Backhoe Loaders
15 - 20 - 03/2
ALL MODELS (EXCEPT 2CX)
From m/c no. 400001 to 420485
Circuit Diagrams - Hydraulic (Servo Machines) 31 10
16 40 LS
33
15
4D 37 3
36
35
48
4W 4C
3H 39 38
3M
4D 17
9B 9
3H
4T
4C
44
9A 3F
3L 46
4D 3J
3E
8
L
R
8A
4R
3H 3G
4E
3K 4H
LS
3G
3J P
3C
4Z LS
EF
P2A
3B
P
CF
3D 3A
18
4D 4P
4N
4Q
4G
T
18 47 14
7
LS
30
43
4J
T
P
32
42
41 8B
34
45
4S
T HPCO
4D
TA
4L
4K
T
4M
4G 5
P
5C
12F
C
4X 6
S P2
5A
4A 4B P1A
5B
P1
12E
T
4
MA
P
12D
1
2
12C
11 49
12A 1A 12B P
13 50
12
A193291
9804/1103
15 - 20 - 03/2
15 - 20 - 03/2
Issue 2
CONTENTS CONTENTS
Backhoe Loaders
15 - 20 - 03/3
ALL MODELS (EXCEPT 2CX)
From m/c no. 420486
Circuit Diagrams - Hydraulic (Servo Machines) 31 10 40 B
LS
33
15
A
4D 37 3
36
35
3H
B
48
4X 4C B
39
A
38
3M
4W 4D
9
3H
B
3F
4V
4U
4C
44
9A
A
B
3L
4T
4D 3J
3E
17
A
9B
8
L
46 A
R
8A 4R
3H
B
3G
A
4E
3K 4H
LS
3G
3J P
3C
4Z
B
LS
A
EF
P2A
3B
P
CF
3D 3A
18
4D 4P
4N
4Q
18
4G
T
47 14
7
LS
30
43
4J
T
P
32
42
41 8B
34
45
4S
B A
T
HPCO
4D
TA
4L
4K
T
4M
4G 5
P
5C
12F
C
4Y 6
S P2
5A
4B P1A
5B
P1
12E
T
4
MA
P
12D
1
2
12C
11 49
12A 1A 12B P
12
13 50
A245980
9804/1103
15 - 20 - 03/3
15 - 20 - 03/3
Issue 1
CONTENTS CONTENTS
Backhoe Loaders
15 - 20 - 03/4
From m/c no. 420486
ALL MODELS (EXCEPT 2CX) Circuit Diagrams - Hydraulic (Servo Machines) Pumps, Valves, Filters & Tank P1 P2 P1A P2A S T TA 1 1A 2 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 3K 3L 3M 4 4A 4B 4C 4D 4E 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 4U 4V 4W 4X 4Y 4Z 5 5A 5B 5C 6 7
Pump, Main Section Pump, Secondary Section Pressure Test Point (Loader & Backhoe MRV & ARV) Pressure Test Point (Unloader Valve, Auxiliary Attachments & Steer Circuit) Suction Line Tank In-tank Filter Hydraulic Oil Cooler Twin Check Valve (Cooler & Make Up) High Pressure Filters Loader Valve Block Pressure Relief Valve (& Filter) Pressure Adjustment Spool Pressure Reduction Valve (Pilot Pressure) Pressure Relief Valve (Pilot Pressure) Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Anti-cavitation Valves Shuttle Valves Load Hold Check Valves Loader Lift Ram Spool Loader Shovel Ram Spool Clamshovel Spool Backhoe Valve Block Pressure Relief Valve Pressure Adjustment Spool Pressure Compensator Shuttle Valves Load Hold Check Valves (LHCV) Pressure Compensator Valve (with integral LHCV) Pressure Relief Valve (Pilot Pressure) Pressure Reducing Valve (Pilot Pressure) Boom Spool Boom Ram Head Side A.R.V. Boom Ram Rod Side A.R.V. Dipper Spool Dipper Ram Rod Side A.R.V. Dipper Ram Head Side A.R.V. Bucket Spool Bucket Ram Head Side A.R.V. Bucket Ram Rod Side A.R.V. 1 Slew Spool Slew A.R.V. Slew A.R.V. Steer Spool Backhoe Valve Fault Solenoid Filter Unloader Valve Unloader Valve Spool Unloader Pilot Valve Unloader Check Valve Hydraulic Speed Control Valve Priority Valve
9804/1103
8 8A 8B 9 9A 9B 10 11 12 12A 12B 12C 12D 12E 12F 13 14 15 17 18
Rams 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
Steer Control Unit Shock Valves Steer Unit Relief Valve Steer Mode Valve 2WS/AWS Solenoid Valve Crab/AWS Solenoid Valve Hydraclamp Valve Safety Solenoid Valve Auxiliary Valve (Stabilisers) Extending Dipper/Knuckle Spool Relief Valve Auxiliary Relief Valve (Head Side) Auxiliary Relief Valve (Rod Side) Stabiliser Spool Stabiliser Spool Check Valve (Fitted with Knuckle Option) Stabiliser Check & Relief Valve Stabiliser Check & Relief Valve One Way Restrictor Hose Burst Protection Valve (see page E/2-3, service manual 9803/3260, item 61 for details)
Clam Shovel Ram L.H. Clam Shovel Ram R.H. Lift Ram L.H. Lift Ram R.H. Shovel Ram L.H. Shovel Ram R.H. Front Steer Ram LH Front Steer Ram RH Rear Steer Ram RH Rear Steer Ram LH Hydraclamps (Sideshift Machines Only) Boom Ram Dipper Ram Bucket Ram Left Hand Slew Ram(Centremount Machines Only) Right Hand Slew Ram(Centremount Machines Only) Slew Cylinders (Sideshift Machines Only) Stabiliser Ram Stabiliser Ram Extending Dipper Ram Knuckle Boom Ram
Note 1: The auxiliary relief valve on the bucket ram rod side service is only installed when a hammermaster is fitted.
15 - 20 - 03/4
Issue 1
CONTENTS CONTENTS
*
Backhoe Loaders
15 - 20 - 04/1
3CX, 4CX, 214, 215, 217 & ‘S’ Series Machines Circuit Diagrams - Hydraulics The policy of JCB is one of continuous improvement, therefore as products develop, there may be variations to the circuits. Component Key C Tank Cap JJ Connections (as applicable) P1 Pump, Main Section P2 Pump, Secondary Section P2A Pressure Test Point (auxiliary & unloader) S Suction Line T Tank M Connections (as applicable) MM Quick Release Couplings 1A Neutral Circuit Line 1B Neutral Circuit Line 2A Neutral Circuit Line 3 Loader Valve Block 3A Pressure Test Point (M.R.V.) 3B Unloader Pilot Valve 3C Loader Lift Ram Spool 3D Loader Shovel Ram Spool 3E Clamshovel Spool 3F Shovel Ram Head Side A.R.V. 3G Shovel Ram Rod Side A.R.V. 3J Load Hold Check Valve 3L Unloader Valve Spool 3M Main Relief Valve 3N Unloader Check Valve 3Q Hydraulic Speed Control Solenoid 4 Excavator Valve Block Excavator services shown here are to the JCB control pattern. If ISO, Case or Ford control pattern is used, the excavator spools and relief valves will apply to different services. 4A Slew Spool 4B Boom Spool 4C Stabiliser Spool 4D Stabiliser Spool 4E Dipper Spool 4F Bucket Spool 4G Hydraclamp Valve (Sideshift Machines Only) 4H Slew A.R.V. 4J Slew A.R.V. 4K Boom Ram Rod Side A.R.V. 4L Boom Ram Head Side A.R.V. 4M Dipper Ram Head Side A.R.V. 4N Dipper Ram Rod Side A.R.V. 4P Bucket Ram Head Side A.R.V. 5 Auxiliary Valve Block (foot operated) 5A Auxiliary Spool 5B A.R.V. 5C A.R.V. 6 In-tank Filter 6A Filter By-pass Valve 6B Suction Strainer 7 Priority Valve 8 Filter Fitted from machine s/no. 475518 or see bulletin 2/218. 9 Filter Fitted from machine s/no. (twin pump) 473385 and (single pump) 473444 or see bulletin 2/218. 10 Diverter Valve (hammer only) 11 Sequence Valve (hammer only) 12 Flow Regulator Valve 9804/1103
From m/c no. 460001 13 14 15 16 26 31 32 33 34 35 36 38 39 40 41 42 43 44 51 52 53 54 55 56 57 59 62 65 66 67 68 69 70 71
15 - 20 - 04/1
Anti-cavitation Check Valve Check Valve (optional) Smooth Ride System Selector Valve Assembly Smooth Ride System Accumulator Hydraulic Oil Cooler Shovel Ram R.H. Shovel Ram L.H. Lift Ram R.H. Lift Ram L.H. Clam Shovel Ram R.H. Clam Shovel Ram L.H. 2 Wheel Steer Power Track Rod AWS Rear Axle Power Track Rod AWS Front Axle Power Track Rod AWS Valve Assembly Steer Control Valve Shock Valves Steer Control Valve Relief Valve Bucket Ram Boom Ram Stabiliser Ram Stabiliser Ram Dipper Ram Left Hand Slew Ram Right Hand Slew Ram Stabiliser Check Valve Hydraclamps (Sideshift Machines Only) Restrictor Dipper Restrictor with By-Pass Manual Isolation Valve Manual Change Over Valve Extending Dipper Ram High Flow Options Low Flow options
HIGH FLOW OPTIONS
LOW FLOW OPTIONS
JJ MM
Hammer
69 M
MM
M
68
67 11
EXTENDING DIPPER
MM
3270 - E/6-1.4
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
15 - 20 - 04/2
3CX, 4CX, 214, 215, 217, “S” Series
From m/c no. 460001
Circuit Diagrams - Hydraulic (cont’d)
35
C
1B 31 4 T
62
54
4G 6
33
4H
6B
6A
4A
40 S
4J
3 4B
39
3E
65
59 4K 4L
3F P2
41
3D
P1 3J
P1
P2
3B
15
2A 26 T
ACC
3Q
3J
43 3A
3M
4E
42
51
4F JJ
4P
JJ
T
7
53
8
10
32
12 36
57
59
44
3N
13
66
4M 4N
3L 16
55
4D
3C
52
4C
3G
34
56
38
11
14
P2A 9
1A M
5A
5B
M
5C
15 - 20 - 04/2
3270 - E/6-2.6
CONTENTS
9804/1103
Issue 3*
CONTENTS CONTENTS
*
Backhoe Loaders
15 - 20 - 04/3
3CXE (214E Series 3)
From m/c no. 460001
Circuit Diagram - Hydraulic (cont’d)
Component Key Hydraulic Tank In Tank Filter Hydraulic Oil Cooler Single Stage Hydraulic Pump One Way Restrictor Shovel Rams Quick Release Couplings Lift Rams Loader Valve Block
9804/1103
K L N Q S W Y Z AA
Flow Regulator Valve Pressure Test Point Steer Valve Priority Valve Excavator Valve Block Stabiliser Rams One Way Restrictor Slew Rams Boom Ram
15 - 20 - 04/3
BB Dipper Ram CC Bucket Ram DD Suction Strainer EE Stabilizer Check Valve FF Filter Fitted from m/c no. 475518 or see bulletin 2/218 GG Tank Cap
3270 - E/7-1.2
CONTENTS
A B C D E F G H J
Issue 3*
CONTENTS CONTENTS
*
Backhoe Loaders
15 - 20 - 04/4
214e Series 4 only Circuit Diagram - Hydraulic
From m/c no. 460001
GG
P
NEUTRAL CIRCUIT H.P.C.O.
S
F
W
A EE SLEW
DD
B
H
SHOVEL
2WS FRONT POWER TRACK ROD
J4
BOOM
F
ENGINE
Y
Y
D LOADER
Z
J3 L
STABILISER
R
BB N AUX
J2
CC
AA
STABILISER
Z
C
Y P
LS
T
DIPPER
MRV
J1
J
LS EF
P
CF
Q
BUCKET
PP
H
EE
FF
H.P.C.O.
E W F
HAMMERMASTER 260L
HAMMERMASTER 280
HAMMERMASTER 360
P B
L
A
NEUTRAL CIRCUIT / TANK RETURN
K
G
M
G
HAMMER RETURN HAMMER FEED
Component Key
9804/1103
Hydraulic Tank In-tank Filter Hydraulic Oil Cooler Single Stage Hydraulic Pump Twin Check Valve Shovel Rams Quick Release Couplings Lift Rams Loader Valve Block Main Relief Valve
J2 Auxiliary Spool J3 Lift Spool J4 Shovel Spool K Flow Regulator Valve (Option) L Pressure Test Point M Auxiliary Valve Block (Option) Either option K or M can be fitted but not both. N Steer Valve P Auxiliary Rams
15 - 20 - 04/4
Q S W Y Z AA BB CC DD EE
Priority Valve Excavator Valve Block Stabiliser Rams One Way Restrictor Slew Rams Boom Ram Dipper Ram Bucket Ram Suction Strainer Stabiliser Check Valve
FF Filter Fitted from machine serial number 475518 or see bulletin 2/218. GG Tank Cap
3270 - E/7-2.2
CONTENTS
A B C D E F G H J J1
Issue 2*
CONTENTS CONTENTS
Backhoe Loaders
15 - 20 - 04/4A
214 Se Series 4 Only
From m/c no. 460001
Circuit Diagrams - Hydraulic NEUTRAL CIRCUIT H.P.C.O.
GG
1
P S
F
W
2
A
EE
S1
DD
B
SLEW
H 4 J4
SHOVEL
S2
ENGINE
BOOM
R
L
Y
3
D J3
LOADER
Y Z
S3
STABILISER
BB N S4
J2
AUX
CC
HH
AA
STABILISER
Z
C
Y P
LS
T
S5
DIPPER
J4
BUCKET
MRV
J1
J
LS EF
P
CF
L
Q PP
H
EE
FF
H.P.C.O.
E W F
HAMMERMASTER 260L
HAMMERMASTER 280
HAMMERMASTER 360
P B
L
A
NEUTRAL CIRCUIT / TANK RETURN
G
M
K
G
HAMMER RETURN HAMMER FEED
Component Key A B C D E F G H J J1 9804/1103
Hydraulic Tank Return filter Hydraulic Oil Cooler Single Stage Hydraulic Pump Twin Check Valve Shovel Rams Quick Release Couplings Lift Rams Loader Valve Block Main Relief Valve
J2 Auxiliary Spool J3 Lift Spool J4 Shovel Spool K Flow Regulator Valve (Option) L Pressure Test Point M Auxiliary Valve Block (Option) Either option K or M can be fitted but not both. N Steer Valve P Auxiliary Rams
15 - 20 - 04/4A
Q S S1 S2 S3 S4 S5 S6
Priority Valve Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool
W Y Z AA BB CC DD EE
Stabiliser Rams One Way Restrictor Slew Rams Boom Ram Dipper Ram Bucket Ram Suction Strainer Stabiliser Check Valve
FF GG HH 1 2 3 4
Last Chance Filter Tank Cap Extending Dipper Front Power Track Rod Rear Power Track Rod Steer Control Valve Steer Selector Valve
A356640
3270 - E/6-9.1
Issue 1
Backhoe Loaders
CONTENTS
15 - 20 - 04/5
3CX, 4CX
From m/c no. 460001
Circuit Diagrams - Hydraulic 3CX ‘S’ Series & 4CX Gear Pump Options
3CX ‘S’ Series Options
This circuit shows the Extending Dipper and Power Sideshift, for the main hydraulic circuit see pages 15-20-04/1 and 1520-04/2.
This circuit shows the Low Flow Hammer, Extending Dipper and Power Sideshift, for the main hydraulic circuit see pages 15-20-04/1 and 15-20-04/2
Component Key
Component Key
HPCO
HPCO
M MM T 10 11 69 72 73 74 75 76
High Pressure Carry Over (From Excavator Valve Block 4) Hydraulic Connections Quick Release Couplings Hydraulic Tank Return Diverter valve Sequence valve Extending Dipper Ram Change Over Valve Power Sideshift Cylinder Relief Valve Manual Change Over Valve Isolation Valve
M MM T 11 69 72 73 74 76 77
High Pressure Carry Over (From Excavator Valve Block 4) Hydraulic Connections Quick Release Couplings Hydraulic Tank Return Sequence valve Extending Dipper Ram Change Over Valve Power Sideshift Cylinder Relief Valve Isolation Valve Hammer
69
69
75
77
11
11
10 HPCO 76
76
HPCO
72 M
72
74 T
73
74
M
T
M
73
9804/1103
15 - 20 - 04/5
3270 - E/6-3.1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
3CX ‘S’ Series
15 - 20 - 04/6
From m/c no. 460001
Circuit Diagrams - Hydraulic Options This circuit shows the Low Flow Hammer and Extending Dipper, for the main hydraulic circuit see pages 15 - 20 - 04/1 and 15 - 20 - 04/2 Component Key HPCO M T 11 69 76 77
High Pressure Carry Over (From Excavator Valve Block 4) Hydraulic Connections Hydraulic Tank Return Sequence valve Extending Dipper Ram Isolation Valve Hammer
69
77 11
76
HPCO
T M M
9804/1103
15 - 20 - 04/6
3270 - E/6-4.1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 20 - 04/7
4CXE, 4CX Super-Variable Flow Hydraulics (7 Spool with High Flow Options) Circuit Diagrams - Hydraulic
From m/c no. 460001
49 T
7 P
LS
25
8 P
50
54
26 L
3
P
R
T
45
49
18
17
B 15
48
S 5
6
T
B
P
A
27
B
4
53
A 15A
46
51
LS
52
28
L
18
17
L1 47
16 P
29
B 36
T
A 16
43 28
T 17 P PRLS
LS
T
1 17
10
2
11
9
15
37 30
B A
15
PR
20
17 21
18
44
17
19
22
18
31
18 12
B A
B
17
38
18
A 32
17
19 18
15
B
17
16
17
19 18
P2
21
17
9804/1103
B A
20
B A
ACC
14 P1
40 33
15 23
22
18
15
A T
39
A
13
24
B
18
16
41 34
LS
B A
16A
15 - 20 - 04/7
3270 - E/7-10.3
Issue1
CONTENTS CONTENTS
Backhoe Loaders
4CXE, 4CX Super - Variable Flow Hydraulics (7 - Spool with High Flow Options) Circuit Diagrams - Hydraulic Component Key
15 - 20 - 04/8
From m/c no. 460001
Small letters on the schematic indicate port markings. Refer to Technical Data pages at the beginning of this section for more information. Ports A and B are always identified as service ports (feed and return from respective ram). T 1 2 P 3 4 5 6 7 8 9 10 11 12 13 14 15 15A 16 16A 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
Hydraulic Tank By-pass Filter Suction Line Pump Variable Flow Stroking Piston Control Piston System Pressure Spool Stand-by Pressure Spool Hydraclamp Valve Hydraclamps Loader Valve Block Priority Inlet Section Relief Valve † Auxiliary Service Spool Shovel Service Spool Lift Service Spool Auxiliary Relief Valves (anti-cavitation) ARV item 16 if Rockerbreaker Application Auxiliary Relief Valves (direct acting) ARV Only Fitted For Rockbreaker Application Secondary Shuttle Valve Primary Shuttle Valve Load Hold Check Valve Auxiliary Rams Shovel Rams Lift Rams Smooth Ride Selector Valve Smooth Ride Accumulator Backhoe Loader Valve Block Extradig Priority Valve Extradig Service Spool Compensator Valves Slew Service Spool Boom Service Spool Stabiliser Service Spool Stabiliser Service Spool Dipper Service Spool Bucket Service Spool Extradig Ram Slew Rams Boom Ram
9804/1103
38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
Stabiliser Ram Stabiliser Ram Dipper Ram Bucket Ram Accumulator Oil Cooler Load Sense Relief Valve Steer Unit Assembly Steer Valve Relief Valve Shock Valves Quick release Couplings Isolation Valve Extending Dipper Isolation Valve Foot Valve Extending Dipper Ram Hammer
† Note: Steer circuit pressure is controlled by a relief valve housed in the orbitrol unit (see section H). The priority relief valve housed in the loader valve must be set at 2500 lb/in2 (173 bar, 176 kgf/cm2) this will ensure it does not interfere with the operation of the relief valve housed in the orbitrol unit.
15 - 20 - 04/8
3270 - E/7-11.3
Issue 1
CONTENTS
Backhoe Loaders
4CXE, 4CX Super - Variable Flow Hydraulics (6 - Spool with High/Low Flow Options) Circuit Diagrams - Hydraulic
15 - 20 - 04/9
From m/c no. 460001
Component Key Small letters on the schematic indicate port markings. Refer to Technical Data pages at the beginning of this section for more information. Ports A and B are always identified as service ports (feed and return from respective ram). T 1 2 P 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16A 17 18 19 20 21 22 23 24 25 28 29 30 31 32 33 34 36 37
Hydraulic Tank By-pass Filter Suction Line Pump Variable Flow Stroking Piston Control Piston System Pressure Spool Stand-by Pressure Spool Hydraclamp Valve Hydraclamps Loader Valve Block Priority Inlet Section Relief Valve † Auxiliary Service Spool Shovel Service Spool Lift Service Spool Auxiliary Relief Valves (anti-cavitation) Auxiliary Relief Valves (direct acting) ARV Only Fitted For Rockbreaker Application Secondary Shuttle Valve Primary Shuttle Valve Load Hold Check Valve Auxiliary Rams Shovel Rams Lift Rams Smooth Ride Selector Valve Smooth Ride Accumulator Backhoe Loader Valve Block Compensator Valves Slew Service Spool Boom Service Spool Stabiliser Service Spool Stabiliser Service Spool Dipper Service Spool Bucket Service Spool Slew Rams Boom Ram
9804/1103
38 39 40 41 42 43 44 45 46 47 48 49 50 54 55
Stabiliser Ram Stabiliser Ram Dipper Ram Bucket Ram Accumulator Oil Cooler Load Sense Relief Valve Steer Unit Assembly Steer Valve Relief Valve Shock Valves Quick release Couplings Isolation Valve Hammer Load Sense Isolation Valve
† Note: Steer circuit pressure is controlled by a relief valve housed in the orbitrol unit (see section H). The priority relief valve housed in the loader valve must be set at 2500 lb/in2 (173 bar, 176 kgf/cm2) this will ensure it does not interfere with the operation of the relief valve housed in the orbitrol unit.
15 - 20 - 04/9
3270 - E/7-12.1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 20 - 04/10
4CXE, 4CX Super - Variable Flow Hydraulics (6 - Spool with High/Low Flow Options) Circuit Diagrams - Hydraulics
From m/c no. 460001
49 7
50 54
P
8 L
3
P
49
R
T
55
45
B 48
S 5
6
T
B
P
A
T
LS
P
46
4
25
LS
L
28
X
18
17
L1 47
16 P
29
B 36
T
A 16
43 28
T 17 P PRLS
LS
T
1 17
10
2
11
9
15
37 30
B A
15
PR
20
17 21
18
44
17
19
22
18
31
18 12
B A
B
17
38
18
A 32
17
19 18
15
B
17
16
17
19 18
21
17
B A
20
9804/1103
P2
B A
ACC
14 P1
40 33
15 23
22
18
15
A T
39
A
13
24
B
18
16
41 34
LS
B A
16A
15 - 20 - 04/10
3270 - E/7-13.1
Issue1
Backhoe Loaders
CONTENTS
4CXE, 4CX Super - Variable Flow Hydraulics Circuit Diagrams - Hydraulic
15 - 20 - 04/11
From m/c no. 460001
Hand Held Tools Option
X 1
2
3
LS
9
4
25 LS
LS
5
T P 6
A322650
Component Key P T X 1 2 3 4 5 6 9 25
Pump Variable Flow Hydraulic Tank Main Circuit Connection Pressure Flow Regulator High Pressure Flow Spool Relief Valve (2000 lb/in2 - 138 bar - 146 kgf/cm2) Load Sense Solenoid Hand Held Tool Shuttle Valve Excavator Valve Block Loader Valve Block
9804/1103
15 - 20 - 04/11
3270 - E/7-14.1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 25 - 01/1
From m/c no. 400001
ALL MODELS (EXCEPT 2CX) Circuit Diagrams - Brakes (Standard Machines) 1 2 3 4 5 6 7 8
Engine mounted exhauster unit Brake system reservoir Front RH servo unit and master cylinder Front RH brake pedal Front LH servo unit and master cylinder Front LH brake pedal Axle (RH) brake pack Axle (LH) brake pack
7
1 4 3
2
6 5
8 A198310
9804/1103
15 - 25 - 01/1
Issue 1
Backhoe Loaders
CONTENTS CONTENTS
15 - 25 - 02/1
From m/c no. 400001
ALL MODELS (EXCEPT 2CX) Circuit Diagrams - Brakes (Servo Machine) 1 2 3 4 5 6 7 8 9 10 11 12
Engine mounted exhauster unit Brake system reservoir Front RH servo unit and master cylinder Front RH brake pedal Front LH servo unit and master cylinder Front LH brake pedal Brake changeover valve Brake changeover valve Axle (RH) brake pack Axle (LH) brake pack Rear master cylinder Rear servo unit
9
7
1
12 4 3
2
11 6 5
8
10
A194220
9804/1103
15 - 25 - 02/1
Issue 1
INDEX
Loadalls
Contents i
ALL MODELS Contents Page No. General Information Fluids, Lubricants and Capacities - 525-58, 525-67, 527-58, 527-67, 530-95 - 530-110 - 530-10 (AK/AR Builds) - 530-120, 537-120, 537-130 - 505-19, 505-22 - 506-36 - 508-40 & 510-40 - 525-58 FS Plus, 530-67, 535-67 - 520-55 RS - 520-55 AWS (AA/AB Builds) - 520-55 AWS (AK/AR Builds) - 526-55, 526, 526S (AA/AB Builds) - 526-55, 526, 526S (AK/AR Builds) - 520-50 (N. America) - 528-70, 528S - 506B, 506C, 506C (HL), 508C - 520-50, 525-50 (AA Build) - 520-50, 525-50, 525-52 (AK/AR Builds) - 526 (N.America) - 530, 535, 540 - 530, 533, 535, 540 * - 532, 537, 550
20 - 00 - 01/1 20 - 00 - 01/2 20 - 00 - 01/2A 20 - 00 - 01/3 20 - 00 - 01/4 20 - 00 - 01/5 20 - 00 - 01/6 20 - 00 - 01/7 20 - 00 - 01/8 20 - 00 - 01/9 20 - 00 - 01/9A 20 - 00 - 01/10 20 - 00 - 01/10A 20 - 00 - 01/11 20 - 00 - 01/12 20 - 00 - 01/13 20 - 00 - 01/14 20 - 00 - 01/15 20 - 00 - 01/16 20 - 00 - 01/17 20 - 00 - 01/17A & 17B 20 - 00 - 01/18.
Static Dimensions & Weights - 525-58, 525-67, 527-58,527-67 - 530-95 - 530-110 - 530-120, 537-130 - 505-19 & 505-22 - 506-36 - 508-40 - 510-40 - 520-55, 520S - 526-55, 526, 526S - 537-120 - 530-67, 535-67 - 520-50, 525-50, 525-52 - 530, 540 - 535 - 530, 535, 540 Performance Dimensions - 532, 537, 550 - 506, 506 (HC), 508 (N. America) - 526 (N. America) - 528-70, 528S
20 - 00 - 02/1 20 - 00 - 02/2 20 - 00 - 02/3, 3A 20 - 00 - 02/4 20 - 00 - 02/5 20 - 00 - 02/6 20 - 00 - 02/7 20 - 00 - 02/8 20 - 00 - 02/9 20 - 00 - 02/10 20 - 00 - 02/11 20 - 00 - 02/12 20 - 00 - 02/13 20 - 00 - 02/14 20 - 00 - 02/14A 20 - 00 - 02/15 20 - 00 - 02/16, 17 20 - 00 - 02/18, 19 20 - 00 -02/20 20 - 00 - 02/21, 22
Data - Electrical - From m/c no. 567362 General Fuses Relay Indentification - 520-55, 520S, 520-55 RS (504B N. Am), 526-55, 526, 526S (526N.Am) from m/c no. 277001 General & Fuses Relay Indentification Fuses - 520-50, 525-50, 525-52 from m/c no. 754000 General Relay Identification Fuses
9804/1103
Loadall Contents - 1
20 - 05 - 01/1 20 - 05 - 01/2 20 - 05 - 01/3
20 - 05 - 01/6 20 - 05 - 01/6 20 - 05 - 01/7 20 - 05 - 01/8 20 - 05 - 01/8 20 - 05 - 01/9
Issue 6*
INDEX
Loadalls
Contents ii
ALL MODELS Contents (continued) Page No. Data - Electrical (cont’d) 520-55, 526-55, 526, 526S (526 N.Am) From m/c no. 279000 to 280299 Relay Identification Fuse Identification
*
20 - 05 - 01/10 20 - 05 - 01/12
526, 526S (526N. Am) Relay Identification Fuse Identification
20 - 05 - 01/11 20 - 05 - 01/13
530, 535, 540 From m/c no 767001 Relay Identification Fuse Identification
20 - 05 - 01/14 ,14A, 14B,15, 15A 20 - 05 - 01/16
532, 537, 540-170, 550, 5508 From m/c no. 767001 Relay Identification Fuse Identification Fuse Links
20 - 05 - 01/17, 18, 18A, 18B, 20 - 05 - 01/19 20 - 05 - 01/19
528-70 Syncro Shuttle Transmission From m/c no. 796000 Fuse and Relay Identification
20 - 05 - 01/20, 23
528S From m/c 796102 Relay Identification Fuse Identification
20 - 05 - 01/21 20 - 05 - 01/22
528-70, 528S From m/c no. 796000 Fuse Links
20-05-01/23
506B, 506C, 506C(HL), 508C Relay Identification Fuse Identification
20 - 05 - 01/24 20 - 05 - 01/25
Data Hydraulics - 525-58, 525-67, 527-58, 527-67, 535-67 From m/c no. 567362 - 530-95 From m/c no. 567362 - 530-110 From m/c no. 567362 - 530-120 From m/c no. 567362 - 505-19 & 505-22 From m/c no. 567362 - 506-36 From m/c no. 567362 - 508-40 From m/c no. 567362 - 510-40 From m/c no. 567362 - 520-55, 526-55, 520S, 526, 526S from m/c no. 567362 - 537-120 From m/c no. 567362 - 537-130 From m/c no. 567362 - 520-50, 525-50, 525-52 From m/c no. 754000 - 530 Agricultural - 530 Construction - 540 Agricultural From m/c no. 767001 - 540 Construction From m/c no. 767001 - 535 From m/c no. 767001 - 532 from m/c no. 567362 - 537, 550 From m/c no. 767001 - 528-70, 528S From m/c no. 796000 - 506B, 506C - 506C (HL), 508C - 540-170, 5508 with Servo Controls from m/c no. 780925 Data Engine - All models from m/c no. 567362 - 520-55, 526-55, 526, 526S From m/c no.277001 - 520-50, 525-50, 525-52 From m/c no. 754000 - 530, 535, 540 and 532, 537, 550 From m/c no. 767001 9804/1103
Loadall Contents - 2
20 - 05 - 02/1 20 - 05 - 02/2 20 - 05 - 02/3 20 - 05 - 02/4 20 - 05 - 02/5 20 - 05 - 02/6 20 - 05 - 02/7 20 - 05 - 02/8 20 - 05 - 02/9 20 - 05 - 02/10 20 - 05 - 02/11 20 - 05 - 02/12 20 - 05 - 01/13 20 - 05 - 02/14 20 - 05 - 02/14A 20 - 05 - 02/14B 20 - 05 - 02/14C 20 - 05 - 02/15 20 - 05 - 02/16 20 - 05 - 02/17 20 - 05 - 02/18 20 - 05 - 02/19 20 - 05 - 02/20
20 - 05 - 03/1 20 - 05 - 03/2 20 - 05 - 03/3 20 - 05 - 03/4 Issue 8*
INDEX
Loadalls
Contents iii
ALL MODELS Contents (continued)
- 506B, 506C, 506C (HL), 508C
20 - 05 - 03/5 Page No.
* Axles - 525-58, 67, 527-58, 67, 530-67, 95, 535-67, 505-19 & 22 From m/c no. 567362 - 530-120, 537-120, 130, 508-40 & 510-40 From m/c no. 567362 - 530-110 & 506-36 From m/c no. 567362 - 520-55 RS From m/c 277001 - 520-55 4 Wheel Steer to m/c no. 2768610 - 520-55 4 Wheeled Steer from m/c no. 2768611 - 526-55, 526, 526S to m/c no. 280999 - 526-55, 526, 526S to m/c no. 280299 - 520-50, 525-50 from m/c no. 754000, - 526, 526S from m/c no. 280300 - 528-70 from m/c no. 796000 - 528S from m/c no. 796102 - 506B, 506C, 506C (HL),508C
20 - 05 - 04/1 20 - 05 - 04/1 20 - 05 - 04/1 20 - 05 - 04/2 20 - 05 - 04/2 20 - 05 - 04/2 20 - 05 - 04/2 20 - 05 - 04/3 20 - 05 - 04/3 20 - 05 - 04/3 20 - 05 - 04/4 20 - 05 - 04/4 20 - 05 - 04/5
Data-Tyres - All models, except 530, 532, 535, 537, 540, 550 - 530, 532, 535, 537, 550, 540
20 - 05 - 04A/1 20 - 05 - 04A/4
Data Transmission - Syncro Shuttle, All models from m/c no. 567362 - 520-55 Syncro Shuttle from m/c no. 277001 - 520-50, 525-50, 525-52 from m/c no. 754000 - 520, 526 Powershift from m/c no. 277001 - 528 Powershift from m/c no. 796000 - 506, 508 Powershift - 520, 526 Syncro Shuttle from m/c no. 277001 - 528 Syncro Shuttle from m/c no. 796000 - 506, 508 Syncro Shuttle - 530, 532, 535, 537, 540, 550 Powershift - 532, 537, 550, Axles and Stall Speeds from m/c no. 767001 - 530, 535, 540 Axles and Stall Speeds from m/c no. 767001
20 - 05 - 05/1, 2 20 - 05 - 05/2 20 - 05 - 05/2 20 - 05 - 05/3 20 - 05 - 05/3 20 - 05 - 05/3 20 - 05 - 05/3A 20 - 05 - 05/3A 20 - 05 - 05/3A 20 - 05 - 05/4 20 - 05 - 05/5 20 - 05 - 05/6
Data-Brakes - 525-58/67, 527-58/67, 530-67, 535-67, 505-19/22 From m/c no. 567362 - 530-95/110, 506-36 from m/c no. 567362 - 530-120, 537-120/130, 508-40, 510-40 from m/c no. 567362 - 520-55 RS from m/c no. 277001 to 279119 - 520-55 AWS from m/c no. 277001 to 279119 - 526-55, 526, 526S from m/c no. 277467 to 280299 - 520-55 AWS from m/c no. 279120 - 520-50, 525-50, 525-52 - 526-55, 526, 526S, 520-55 4WS, from m/c no. 2768611 - 532, 537 from m/c no. 2768611 - 528-70 from m/c no. 796000 - 528S from m/c no. 796102 - 530, 535, 540 from m/c no. 767001 - 532, 537, 550 fromm/c no. 767001 - 506B, 506C, 506C(HL), 508C
20 - 05 - 07/1 20 - 05 - 07/1 20 - 05 - 07/2 20 - 05 - 07/2 20 - 05 - 07/3 20 - 05 - 07/3 20 - 05 - 07/3 20 - 05 - 07/3 20 - 05 - 07/4 20 - 05 - 07/4 20 - 05 - 07/5 20 - 05 - 07/5 20 - 05 - 07/6 20 - 05 - 07/6 20 - 05 - 07/7
9804/1103
Loadall Contents - 3
Issue 3*
INDEX
Loadalls
Contents iv
ALL MODELS Contents (contunued)
Page No. Data-Steering - All models from m/c no. 567362 - 520-55, 526-55, 526, 526S from m/c no. 277001 * -All models from m/c no. 773135 - 520-50, 525-50, 525-52 from m/c no. 754000 - 530, 532, 537 from m/c no 754000 - 528-70 from m/c no. 796000 - 528S from m/c no. 796102 - 530, 535, 540 from m/c no. 767001 - 532, 537, 550 from m/c no. 767001 - 506B, 506C, 506C (HL), 508C
20 - 05 - 08/1 20 - 05 - 08/1 20 - 05 - 08/1A 20 - 05 - 08/2 20 - 05 - 08/2 20 - 05 - 08/3 20 - 05 - 08/3 20 - 05 - 08/4 20 - 05 - 08/4 20 - 05 - 08/5
Circuit Diagrams-Electrical - All models from m/c no. 567362 - 520-55 (504B N. Am), 520-55 RS from m/c no. 277001 to 277535 - 520-55 from m/c no. 277536 - 526-55 to m/c no. 278965 - All models from 567362 (Powershift option) - Safe Load Indicator Circuit from m/c no. 576404 - 520-55, 520S from m/c no. 278966 - 526-55, 526S (526 N.Am) from m/c no. 278966 to 280299 - 526-55, 526, 526S (526 N.Am)(Powershift ECU) from m/c no. 280300 to 280576 - 526-55, 526, 526S (526 N. Am) (Syncroshuttle) from m/c no. 280300 - 520-55 (Syncro Shuttle) from m/c no. 281847 - 526, 526S (526 N. Am) (Powershift) from m/c no. 280577 - 528-70 (Syncro Shuttle) from m/c no. 796000 - 528S (Powershift) from m/c no. 796102 - 528S (Syncro Shuttle) from m/c no. 796102 - 530 Without Neutral Start Relay from m/c no. 767001 to768836 - 530 With Nuetral Start Relay/ECU from m/c no. 768837 to 770053 - 530 With Relay Controlled Transmission (ECU not fitted) from m/c no. 770054 to 770958 - 530, 540 Sway Machines from m/c no. 770959 - 530, 540 Non-Sway Machines from m/c no. 770959 - 530, 540 With Manual Auxiliary Controls from m/c no. 775402 - 535 With Manual Auxiliary Controls from m/c no. 777362 - 530, 540 With Single Lever Controls from m/c no. 775402 - 535 With Single Lever Controls from m/c no. 777362 - 530, 535, 540 from m/c no. 7670001/530 FS Super, 540 FS Super, 530SXL, 540 SXL - 532, 537 Without Neutral Start Relay from m/c no. 767001 to 768956 - 532, 537 With Neutral Start Relay/ECU from m/c no. 768957 to 770063 - 532, 537 With Relay Controlled Transmission (ECU not fitted) from m/c no. 770064 to 770958 - 532, 537, 550 from m/c no. 770959 - 532, 537, 550 With Manual Auxiliary Controls from m/c no. 775402 - 540-170, 5508 with Servo Controls to m/c no. 1004130 * - 540-170, 5508 with Servo Controls from m/c no. 1004131 * - 506B (Syncro Shuttle) to m/c no. 578676 - 506B (Syncro Shuttle) from m/c no. 578677 - 506C, 508C (Syncro Shuttle) to m/c no. 585396 - 506C, 508C (Syncro Shuttle) from m/c no. 585397 - 506C, 508C (Powershift with 6 Transmission Relays) to m/c no. 585396 - 506C, 508C (Powershift with 7 Transmission Relays) to m/c no. 585396 - 506C, 508C(Powershift) from m/c no. 585397 - 533-105 Machines *
20 - 15 - 01/1 to 3 20 - 15 - 01/4 to 6 20 - 15 - 01/7 to 9 20 - 15 - 01/7 to 9 20 - 15 - 01/10 20 - 15 - 01/11 20 - 15 - 01/12 to 14 20 - 15 - 01/12 to 14 20 - 15 - 01/15 to 21 20 - 15 - 01/22 to 27 20 - 15 - 01/22 to 27 20 - 15 - 01/29 to 34 20 - 15 - 01/37 to 40 20 - 15 - 01/41 to 46 20 - 15 - 01/47 to 52 20 - 15 - 02/1 to 4 20 - 15 - 02/5 to 8 20 - 15 - 02/9 to 12 20 - 15 - 02/13 to 16 20 - 15 - 02/17 to 20 20 - 15 - 02/21 to 26 20 - 15 - 02/21 to 26 20 - 15 - 02/27 to 32 20 - 15 - 02/27 to 32 20 - 15 - 02/33 to 38 20 - 15 - 03/1 to 4 20 - 15 - 03/5 to 8 20 - 15 - 03/9 to 12 20 - 15 - 03/13 to 16 20 - 15 - 03/17 to 22 20 - 15 - 03/17 to 24 20 - 15 - 03/25 to 32 20 - 15 - 04/1 to 3 20 - 15 - 04/4 to 6 20 - 15 - 04/7 & 8 20 - 15 - 04/9 & 10 20 - 15 - 04/11 & 12 20 - 15 - 04/13 & 14 20 - 15 - 04/15 & 16 20 - 15 - 05/1 to 6
9804/1103
Loadall Contents - 4
Issue 3*
INDEX
Loadalls
Contents v
ALL MODELS Contents (continued)
Page No. Circuit Diagrams - Hydraulics - 525-58/67, 527-58/67, 530-95 from m/c no. 567362 to 574295 - 527-58/67, 535-67 from m/c no. 574296 - 530-120 from m/c no. 567362 - 530-110 from m/c no. 567362 - 505-19 & 505-22 from m/c no 567362 to 574295 - 505-19 & 505-22 from m/c no. 574296 - 506-36 from m/c no. 567362 - 508-40 from m/c no. 567362 - 510-40 from m/c no. 567362 - 520-55 RS, 520-55 4 Wheel Steer from m/c no. 277001 to 278610 - 520-50 4 Wheel Steer from m/c no. 278611 - 526-55, 526, 526S from m/c no 277001 to 280299 - 537-120, 537-130 from m/c no. 572900 - 520-50, 525-50, 525-52 from m/c no. 754000 - 520-55 RS, 520-55 4WS from 278610 - 520-55 4WS from m/c no. 278611 - 526-55, 526, 526S to m/c no. 280299 - 526, 526S with Dual Lever Control from m/c no. 280300 - 526, 526S with Single Lever Control Option from m/c no.280300 - 528-70 from m/c. 796000 - 528S from m/c no. 796102 - 528S with Single Lever Controls from m/c no. 796102 - 530, 540 Agricultural from m/c no. 767001 - 530 Construction from m/c no. 767001 to 770616 - 530, 540 Construction with Single Lever Control from m/c no. 767001 to 770617 - 530 Construction with Manual Auxiliary Controls from m/c no. 775402 - 530 Construction with Manual Auxiliary Controls from m/c no. TBA * (fitted with 2-stage pump) - 530 Construction with Manual Auxiliary Controls from m/c no. 775402 * (fitted with 3-stage pump) - 540 Construction with Manual Auxiliary Controls from m/c no 775402 - 540 Construction with Manual Auxiliary Controls from m/c no. 775402 * (fitted with 3-stage pump) - 535-95 from m/c no. 777362 - 535-95 Machines (fitted with a 3-stage pump) from m/c no. 777362 * - 535-95 Machines (fitted with a 2-stage pump) from m/c no. TBA * - 532 to m/c no. 770638 - 537, 550 to m/c no. 770613 - 532 from m/c no 770639 to 775401 - 537, 550 from m/c no. 770614 to 775401 - 532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402 - 506B - 506C - 506C (HL), 508C - 540-170 with Servo Controls from m/c no. 780925 - 533-105 Machines from serial no. 786756 *
9804/1103
Loadall Contents - 5
20 - 20 - 02/1, 2 20 - 20 - 02/2A, 2B 20 - 20 - 02/3, 4 20 - 20 - 02/5, 6 20 - 20 - 02/7, 8 20 - 20 - 02/8A, 8B 20 - 20 - 02/9, 10 20 - 20 - 02/11,12 20 - 20 - 02/13, 14 20 - 20 - 02/15, 16 20 - 20 - 02/17, 18 20 - 20 - 02/17, 18 20 - 20 - 02/19, 20 20 - 20 - 02/21, 22 20 - 20 - 02/23, 24 20 - 20 - 02/25, 26 20 - 20 - 02/25, 26 20 - 20 - 02/27, 28 20 - 20 - 02/29, 30 20 - 20 - 02/31, 32 20 - 20 - 02/31, 32 20 - 20 - 02/33, 34 20 - 20 - 02/35, 36 20 - 20 - 02/37, 38 20 - 20 - 02/39, 40 20 - 20 - 02/41, 42 20 - 20 - 02/41A, 42A 20 - 20 - 02/41B, 42B 20 - 20 - 02/43, 44 20 - 20 - 02/43A, 44A 20 - 20 - 02/45, 46 20 - 20 - 02/45A, 46A 20 - 20 - 02/45B, 46B 20 - 20 - 02/47, 48 20 - 20 - 02/47, 48 20 - 20 - 02/49, 50 20 - 20 - 02/49, 50 20 - 20 - 02/51, 52 20 - 20 - 02/53, 54 20 - 20 - 02/55, 56 20 - 20 - 02/57, 58 20 - 20 - 02/59, 60 20 - 20 - 02/61, 62
Issue 3*
Loadalls
CONTENTS
* 525-58,
525-67, 527-58, 527-67, 530-95
20 - 00 - 01/1
From m/c no. 567362
Fluids, Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY Litres (Gal)
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
90 (20)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
10 (2.2)
JCB 15W/40 Multigrade -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE
JCB Universal Antifreeze/water ( See Coolant Mixtures)
ASTM D3306-74
JCB Special Transmission Fluid ††JCB Special Transmission Fluid
ESP-M2C 33G ESP-M2C 33G
Engine (Coolant)
Gearbox Syncro Shuttle * Powershift
17 (3.7)
18.25 (4.0) ††15.0 (3.3)
Front Axle Housing Hubs (x2)
18 (3.9) 2.0 (0.4)
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B ESEN-M2C 86A/B
Rear Axle Housing Hubs (x2)
13 (2.8) 2.0 (0.4)
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B ESEN-M2C 86A/B
JCB Light Hydraulic Fluid
ISO VG15
Brake System
DO NOT USE ORDINARY BRAKE FLUID * Hydraulic System
†152 (33.5)
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)
ISO VG46
Grease Points
JCB Special MPL Grease
Lithium based, No. 2 consistency
Wear Pad Runways
JCB Waxoyl
Boom Hoses
JCB Special Slide Lubricant
ISO VG32
* † Note: : This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. * †† Note: This is a system capacity. Use the 'MIN' and 'MAX' marks on the dipstick when refilling the system. Coolant Mixtures
9804/1103
%
Antifreeze
Starts to Freeze
55
9.35 litres (2.04 gal)
-36° C (-33 °F)
20 - 00 - 01/1
Issue 3*
Loadalls
CONTENTS
20 - 00 - 01/2
530-110
From m/c no. 567362
Fluids, Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently runin. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY Litres (Gal)
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
90 (20)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
10 (2.2)
JCB 15W/40 Multigrade -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE
Engine (Coolant)
18 (3.9)
JCB Universal Antifreeze/water ( See Coolant Mixtures)
ASTM D3306-74
Syncro Shuttle
18.25 (4.0)
JCB Special Transmission Fluid
ESP-M2C 33G
Front Axle Housing Hubs (x2)
18 (3.9) 2.0 (0.4)
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B ESEN-M2C 86A/B
Rear Axle Housing Hubs (x2)
13 (2.8) 2.0 (0.4)
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B ESEN-M2C 86A/B
JCB Light Hydraulic Fluid
ISO VG15
Brake System
DO NOT USE ORDINARY BRAKE FLUID Hydraulic System
†190 (41.8)
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB HP32 (Below 38 °C, 100 °F) JCB Light Hydraulic Fluid (For Iceland, Norway, Sweden and Finland ONLY)
ISO VG46
Grease Points
JCB Special MPL Grease
Lithium based, No. 2 consistency
Wear Pad Runways
JCB Waxoyl
Boom Hoses
JCB Special Slide Lubricant
ISO 32 ISO VG15
† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. Coolant Mixtures
9804/1103
%
Antifreeze
Starts to Freeze
55
10 litres (2.2 gal)
-36° C (-33 °F)
20 - 00 - 01/2
Issue 2
Loadalls
CONTENTS
20 - 00 - 01/2A
530-110 AK and AR Engine Builds Fluids, Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY Litres (Gal)
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
90 (20)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
10 (2.2)
JCB High Performance Engine oil -10°C to 50°C (14°F to 122°F)
SAE15W/40 API CF4/SG (ACEA E2:B2:A2)
JCB High Performance Engine oil -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30 API CF4/SG (ACEA E2:B2:A2)
Engine (Coolant) 55% Concentration
18 (3.9) 10 (2.2)
JCB Four Seasons Antifreeze/water And Summer Coolant (See Coolant Mixtures)
ASTM D3306-74
Syncro Shuttle
18.25 (4.0)
JCB High Performance Transmission Fluid
JCB 4000/0900 Friction modified oils MUST NOT be used (eg. Dexron ATF type).
Front Axle Housing Hubs (x2)
18 (3.9) 2.0 (0.4)
JCB High Performance Gear Oil Plus
Rear Axle Housing Hubs (x2)
JCB 4000/2200 Must be suitable for use with oil immersed brakes and limited slip Differentials (LSD).
13 (2.8) 2.0 (0.4) JCB Light Hydraulic Fluid
ISO VG15
Brake System
DO NOT USE ORDINARY BRAKE FLUID Hydraulic Tank †
Grease Points ††
190 (41.8)
JCB High Performance Hydraulic Fluid 46 (Above 38 °C, 100 °F) JCB High Performance Hydraulic Fluid 32 (Below 38 °C, 100 °F)
ISO VG46
JCB HP Grease
Lithium complex NLGI No. 2 consistency including extreme pressure additives. Lithium based NLGI No. 2 consistency including extreme pressure additives.
JCB Special MPL-EP Grease
Wear Pad Runways
JCB Waxoyl
Boom Hoses
JCB Special Slide Lubricant
ISO VG32
† Note 1: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Watch level sight glass when filling. †† Note 2: If JCB MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals; all 500 hour greasing operations must be carried out at 50 HOUR intervals.
9804/1103
20 - 00 - 01/2A
2055/127
Issue 1
Loadalls
CONTENTS
* 530-120,
20 - 00 - 01/3
537-120 & 537-130
From m/c no. 567362
Fluids, Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY Litres (Gal)
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
90 (20)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
10 (2.2)
JCB 15W/40 Multigrade -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE
Engine (Coolant)
23.5 (5.2)
JCB Universal Antifreeze/water ( See Coolant Mixtures)
ASTM D3306-74
Syncro Shuttle
18.25 (4.0)
JCB Special Transmission Fluid
ESP-M2C 33G
Front Axle Housing Hubs (x2)
17 (3.7) 2.0 (0.4)
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B ESEN-M2C 86A/B
Rear Axle Housing Hubs (x2)
18 (3.9) 0.75 (0.16)
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B ESEN-M2C 86A/B
JCB Light Hydraulic Fluid
ISO VG15
Brake System
DO NOT USE ORDINARY BRAKE FLUID Hydraulic System
†292 (64.3)
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB HP32 (Below 38 °C, 100 °F)
ISO VG46
Grease Points
JCB Special MPL Grease
Lithium based, No. 2 consistency
Wear Pad Runways
JCB Waxoyl
Boom Hoses
JCB Special Slide Lubricant
ISO 32
† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. Coolant Mixtures
9804/1103
%
Antifreeze
Starts to Freeze
55
12.92 litres (2.84 gal)
-36° C (-33 °F)
20 - 00 - 01/3
Issue 3*
Loadalls
CONTENTS
20 - 00 - 01/4
505-19, 505-22
From m/c no. 567362
Fluids, Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY Gal (Liters)
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
24.8 (93)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
2.6 (10)
JCB 15W/40 Multigrade -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE
Engine (Coolant)
4.4 (17)
JCB Universal Antifreeze/water (See Coolant Mixtures)
ASTM D3306-74
Syncro Shuttle
5.7 (22)
JCB Special Transmission Fluid
ESP-M2C 33G
Front Axle Housing Hubs (x2)
4.7 (18) 0.6 (2.0)
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B ESEN-M2C 86A/B
Rear Axle Housing Hubs (x2)
3.4 (13) 0.5 (2.0)
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B ESEN-M2C 86A/B
JCB Light Hydraulic Fluid
ISO VG15
Brake System
DO NOT USE ORDINARY BRAKE FLUID Hydraulic System
†28.8 (110)
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB HP32 (Below 38 °C, 100 °F)
ISO VG46
Grease Points
JCB Special MPL Grease
Lithium based, No. 2 consistency
Wear Pad Runways
JCB Waxoyl
Boom Hoses
JCB Special Slide Lubricant
ISO 32
† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. Coolant Mixtures
9804/1103
%
Antifreeze
Starts to Freeze
55
2.45 gal (9.35 liters)
-22 °F (-36° C)
20 - 00 - 01/4
Issue 2
Loadalls
CONTENTS
20 - 00 - 01/5
506-36
From m/c no. 567362
Fluids, Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY Gal (Liters)
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
23.7 (90)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
2.6 (10)
JCB 15W/40 Multigrade -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE
Engine (Coolant)
4.7 (18)
JCB Universal Antifreeze/water (See Coolant Mixtures)
ASTM D3306-74
Syncro Shuttle
4.8 (18.25)
JCB Special Transmission Fluid
ESP-M2C 33G
Front Axle Housing Hubs (x2)
4.7 (18) 0.5 (2.0)
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B ESEN-M2C 86A/B
Rear Axle Housing Hubs (x2)
3.4 (13) 0.5 (2.0)
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B ESEN-M2C 86A/B
JCB Light Hydraulic Fluid
ISO VG15
Brake System
DO NOT USE ORDINARY BRAKE FLUID Hydraulic System
†50.2 (190)
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB HP32 (Below 38 °C, 100 °F)
ISO VG46
Grease Points
JCB Special MPL Grease
Lithium based, No. 2 consistency
Wear Pad Runways
JCB Waxoyl
Boom Hoses
JCB Special Slide Lubricant
ISO 32
† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. Coolant Mixtures
9804/1103
%
Antifreeze
Starts to Freeze
55
2.6 gal (10 liters)
-22 °F (-36° C)
20 - 00 - 01/5
Issue 2
Loadalls
CONTENTS
20 - 00 - 01/6
508-40, 510-40
From m/c no. 567362
Fluids, Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY Gal (Liters)
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
23.7 (90)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
2.6 (10)
JCB 15W/40 Multigrade -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE
Engine (Coolant)
6.2 (23.5)
JCB Universal Antifreeze/water (See Coolant Mixtures)
ASTM D3306-74
Syncro Shuttle
4.8 (18.25)
JCB Special Transmission Fluid
ESP-M2C 33G
Front Axle Housing Hubs (x2)
4.5 (17) 0.5 (2.0)
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B ESEN-M2C 86A/B
Rear Axle Housing Hubs (x2)
4.7 (18) 0.2 (0.75)
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B ESEN-M2C 86A/B
JCB Light Hydraulic Fluid
ISO VG15
Brake System
DO NOT USE ORDINARY BRAKE FLUID Hydraulic System
†77.0 (292)
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB HP32 (Below 38 °C, 100 °F)
ISO VG46
Grease Points
JCB Special MPL Grease
Lithium based, No. 2 consistency
Wear Pad Runways
JCB Waxoyl
Boom Hoses
JCB Special Slide Lubricant
ISO 32
† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. Coolant Mixtures
9804/1103
%
Antifreeze
Starts to Freeze
55
3.4 gal (12.92 liters)
-22 °F (-36° C)
20 - 00 - 01/6
Issue 2
Loadalls
CONTENTS
525-58 FS Plus, 530-67, 535-67
20 - 00 - 01/7
From m/c no. 567362
Fluids, Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently runin. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY Litres (Gal)
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
90 (20)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
10 (2.2)
JCB 15W/40 Multigrade -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE
JCB Universal Antifreeze/water ( See Coolant Mixtures)
ASTM D3306-74
JCB Special Transmission Fluid JCB Special Transmission Fluid
ESP-M2C 33G ESP-M2C 33G
Engine (Coolant)
Gearbox Syncro Shuttle Powershift
17 (3.7)
18.25 (4.0) †15.0 (3.3)
Front Axle Housing Hubs (x2)
18 (3.9) 2.0 (0.4)
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B ESEN-M2C 86A/B
Rear Axle Housing Hubs (x2)
13 (2.8) 2.0 (0.4)
JCB Special Gear Oil JCB Special Gear Oil
ESEN-M2C 86A/B ESEN-M2C 86A/B
JCB Light Hydraulic Fluid
ISO VG15
Brake System
DO NOT USE ORDINARY BRAKE FLUID Hydraulic Tank
††152 (34.5)
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)
ISO VG46
Grease Points
JCB Special MPL Grease
Lithium based, No. 2 consistency
Wear Pad Runways
JCB Waxoyl
Boom Hoses
JCB Special Slide Lubricant
ISO VG32
†† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. † Note: This is a system capacity. Use the 'MIN' and 'MAX' marks on the dipstick when refilling the system. Coolant Mixtures
9804/1103
%
Antifreeze
Starts to Freeze
55
9.35 litres (2.04 gal)
-36° C (-33 °F)
20 - 00 - 01/7
Issue 2
CONTENTS
Loadalls
20 - 00 - 01/8
520-55 RS
From m/c no. 277001
Fluids, Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal
* Fuel Tank Up to serial No. 279000 From serial No. 279001
120 160
26.4 35.2
* Engine (Oil)
10
2.2
31.7 42.2
2.6
* Engine (Coolant) 55% Antifreeze
20 11
4.4 2.4
ASTM D975-66T Nos. 1D, 2D
JCB High Performance Engine Oil -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40 API CF4/SG (ACEA E2:B2:A2)
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30 API CD/SF
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W API CD/SF
NORTH AMERICA JCB 15W/40 Engine Oil 14°F to 122°F (-10°C to 50°C)
SAE 15W/40 API CF4/SG
JCB 10W Engine Oil -4°F to 50° F (-20°C to 10°C)
SAE 10W API CF4/SG
JCB Four Seasons Antifreeze And Summer Coolant Starts to freeze -36 °C (-33 °F)
ASTM D3306-74
NORTH AMERICA Permanent Antifreeze Starts to freeze -33 °F (-36 °C)
ASTM D3306-74
JCB High Performance Transmission Fluid
JCB: 4000/0900 Friction modified oils MUST NOT be used (eg Dexron ATF type).
JCB High performance Gear Oil Plus
JCB: 4000/2200 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).
JCB High Performance Hydraulic Fluid 46 (Above 38 °C, 100 °F) JCB High Performance Hydraulic Fluid 32 (Below 38 °C, 100 °F) JCB Light Hydraulic Fluid
ISO VG46
17
3.7
4.5
* Front Axle Housing Hubs (x2)
9.7 0.6
2.1 0.1
2.5 0.16
* Rear Axle Housing Hubs (x2)
5.0 1.5
1.1 0.3
1.3 0.4
* Hydraulic Tank (1) Up to serial No. 279000 From serial No. 279001
100 110
22.0 24.2
* Grease Points (2)
Diesel Oil (See Types of Fuel)
5.3 2.9 * Syncro Shuttle Transmission
Up to serial No. 279000 From serial No. 279001
INTERNATIONAL SPECIFICATION
26.4 29.0
ISO VG32 ISO VG15
NORTH AMERICA (All Machines) JCB Hydraulic Fluid JCB HP Grease JCB Special MPL-EP Grease
* Wear Pad Runways
JCB Waxoyl
* Boom Hoses
JCB Special Slide Lubricant
ISO VG46 Lithium complex NLGI No. 2 constsituency including extreme pressure additives. Lithium based NLGI No. 2 constsituency including extreme pressure additives.
* Note 1:
This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling.
* Note 2:
If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All 500 hour greasing operations must be carried out at 50 HOUR intervals.
9804/1103
20 - 00 - 01/8
3610 - 3/1-2.4
Issue 4*
CONTENTS
Loadalls
20 - 00 - 01/9
* 520-55
*
AWS AA and AB Engine Builds Fluids, Lubricants and Capacities
From m/c no. 277001
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal
* Fuel Tank Up to serial No. 279000 From serial No. 279001
120 160
26.4 35.2
* Engine (Oil)
10
2.2
31.7 42.2
INTERNATIONAL SPECIFICATION
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
JCB High Performance Engine Oil -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40 API CF4/SG (ACEA E2:B2:A2)
JCB Super Universal
SAE10W/30 Agricultural
API CD/SF
-15 °C to 30 °C (5 °F to 86 °F)
2.6
* Engine (Coolant) 55% Antifreeze
20 11
4.4 2.4
NORTH AMERICA JCB 15W/40 Engine Oil 14°F to 122°F (-10°C to 50°C)
SAE 15W/40 API CF4/SG
JCB 10W Engine Oil -4°F to 50° F (-20°C to 10°C)
SAE 10W API CF4/SG
JCB Four Seasons Antifreeze And Summer Coolant Starts to freeze -36 °C (-33 °F)
ASTM D3306-74
NORTH AMERICA Permanent Antifreeze Starts to freeze -33 °F (-36 °C)
ASTM D3306-74
JCB High Performance Transmission Fluid
JCB: 4000/0900 Friction modified oils MUST NOT be used (eg Dexron ATF type).
JCB High performance Gear Oil Plus
JCB: 4000/2200 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).
JCB High Performance Hydraulic Fluid 46 (Above 38 °C, 100 °F) JCB High Performance Hydraulic Fluid 32 (Below 38 °C, 100 °F) JCB Light Hydraulic Fluid
ISO VG46
17
3.7
4.5
* Front Axle Housing Hubs (x2)
5.5 1.5
1.2 0.3
1.4 0.4
* Rear Axle Housing Hubs (x2)
5.0 1.5
1.1 0.3
1.3 0.4
* Hydraulic Tank (1) Up to serial No. 279000 From serial No. 279001
100 110
22.0 24.2
* Grease Points (2)
SAE10W API CD/SF
5.3 2.9 * Syncro Shuttle Transmission
Up to serial No. 279000 From serial No. 279001
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
26.4 29.0
ISO VG32 ISO VG15
NORTH AMERICA (All Machines) JCB Hydraulic Fluid JCB HP Grease JCB Special MPL-EP Grease
* Wear Pad Runways
JCB Waxoyl
* Boom Hoses
JCB Special Slide Lubricant
* Note 1: * Note 2:
9804/1103
ISO VG46 Lithium complex NLGI No. 2 constsituency including extreme pressure additives. Lithium based NLGI No. 2 constsituency including extreme pressure additives.
This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals; all 500 hour greasing operations must be carried out at 50 HOUR intervals. All 500 hour greasing operations must be carried out at 50 HOUR intervals.
20 - 00 - 01/9
3610 - 3/1-3.4
Issue 5*
CONTENTS
Loadalls
20 - 00 - 01/9A
520-55 AWS AK and AR Engine Builds Fluids, Lubricants and Capacities
From m/c no. 277001
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. * ITEM
CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal
INTERNATIONAL SPECIFICATION
Fuel Tank
Engine (Oil)
160
35.2
10
2.2
42.2
2.6
Engine (Coolant) 55% Antifreeze
20 11
4.4 2.4
ASTM D975-66T Nos. 1D, 2D
JCB High Performance Engine Oil -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40 API CF4/SG (ACEA E2:B2:A2)
JCB High Performance Engine Oil
SAE10W/30 -15 °C to 40 °C (5 °F to 104 °F) API CF4/SG (ACEA E2:B2:A2)
NORTH AMERICA JCB 15W/40 Engine Oil 14°F to 122°F (-10°C to 50°C)
SAE 15W/40 API CF4/SG
JCB 10W Engine Oil -4°F to 50° F (-20°C to 10°C)
SAE 10W API CF4/SG
JCB Four Seasons Antifreeze And Summer Coolant Starts to freeze -36 °C (-33 °F)
ASTM D3306-74
5.3 2.9
NORTH AMERICA Permanent Antifreeze Starts to freeze -33 °F (-36 °C)
ASTM D3306-74
JCB High Performance Transmission Fluid
JCB 4000/0900 Friction modified oils MUST NOT be used (eg Dexron ATF type).
JCB High Performance Gear Oil Plus
JCB 4000/2200 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).
JCB High Performance Hydraulic Fluid 46 (Above 38 °C, 100 °F) JCB High Performance Hydraulic Fluid 32 (Below 38 °C, 100 °F) JCB Light Hydraulic Fluid
ISO VG46
Syncro Shuttle Transmission
17
3.7
4.5
Front Axle Housing Hubs (x2)
5.5 1.5
1.2 0.3
1.4 0.4
Rear Axle Housing Hubs (x2)
5.0 1.5
1.1 0.3
1.3 0.4
Hydraulic Tank (1)
110
24.2
29.0 Grease Points (2)
Diesel Oil (See Types of Fuel)
ISO VG32 ISO VG15
NORTH AMERICA (All Machines) JCB Hydraulic Fluid JCB HP Grease JCB Special MPL-EP Grease
Wear Pad Runways
JCB Waxoyl
Boom Hoses
JCB Special Slide Lubrican
ISO VG46 Lithium complex NLGI No. 2 constsituency including extreme pressure additives. Lithium based NLGI No. 2 constsituency including extreme pressure additives.
* Note 1:
This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed.
* Note 2:
If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals; all 500 hour greasing operations must be carried out at 50 HOUR intervals. All 500 hour greasing operations must be carried out at 50 HOUR intervals.
9804/1103
20 - 00 - 01/9A
3610 - 3/1-5.2
Issue 2*
CONTENTS
Loadalls
20 - 00 - 01/10
526-55, 526, 526S AA and AB Engine Builds Fluids, Lubricants and Capacities
From m/c no. 277001
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. * ITEM
CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal
Fuel Tank Up to serial No. 279000 From serial No. 279001
120 160
26.4 35.2
Engine (Oil)
10
2.2
31.7 42.2
INTERNATIONAL SPECIFICATION
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
JCB High Performance Engine Oil -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40 API CF4/SG (ACEA E2:B2:A2)
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W API CD/SF
NORTH AMERICA JCB 15W/40 Engine Oil 14°F to 122°F (-10°C to 50°C)
SAE 15W/40 API CF4/SG
JCB 10W Engine Oil -4°F to 50° F (-20°C to 10°C)
SAE 10W API CF4/SG
JCB Four Seasons Antifreeze And Summer Coolant Starts to freeze -36 °C (-33 °F)
ASTM D3306-74
NORTH AMERICA Permanent Antifreeze Starts to freeze -33 °F (-36 °C)
ASTM D3306-74
5.3 2.9
JCB High Performance Transmission Fluid
JCB 4000/0900 Friction modified oils MUST NOT be used (eg Dexron ATF type).
JCB High performance Gear Oil Plus
JCB 4000/2200 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).
JCB Light Hydraulic Fluid Do not use ordinary brake fluid
ISO VG15
JCB High Performance Hydraulic Fluid 46 (Above 38 °C, 100 °F) JCB High Performance Hydraulic Fluid 32 (Below 38 °C, 100 °F) JCB Light Hydraulic Fluid
ISO VG46
API CD/SF
2.6
Engine (Coolant) 55% Antifreeze
20 11
4.4 2.4
Syncro Shuttle Transmission
17
3.7
4.5
Front Axle Housing Hubs (x2)
9 2
1.98 0.44
2.4 0.5
Rear Axle Housing Hubs (x2)
8.4 2
1.85 0.44
2.2 0.5
Brake System From serial No. 280300 Hydraulic Tank (1) Up to serial No. 279000 From serial No. 279001
Up to serial No. 279000 From serial No. 279001 Grease Points (2)
100 110
22.0 24.2
26.1 29.0
NORTH AMERICA (All Machines) JCB Hydraulic Fluid JCB HP Grease JCB Special MPL-EP Grease
Wear Pad Runways
JCB Waxoyl
Boom Hoses
JCB Special Slide Lubricant
* Note 1: * Note 2: 9804/1103
Fr us
ISO VG32 ISO VG15 ISO VG46 Lithium complex NLGI No. 2 constsituency including extreme pressure additives. Lithium based NLGI No. 2 constsituency including extreme pressure additives.
This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All 500 hour greasing operations must be carried out at 50 HOUR intervals.
20 - 00 - 01/10
3610 - 3/1-4.3
Issue 4*
CONTENTS
Loadalls
20 - 00 - 01/10A
526-55, 526, 526S AR and AK Engine Builds Fluids, Lubricants and Capacities
From m/c no. 277001
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. * ITEM
CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal
INTERNATIONAL SPECIFICATION
Fuel Tank
Engine (Oil)
160
35.2
10
2.2
42.2
2.6
Engine (Coolant) 55% Antifreeze
20 11
4.4 2.4
ASTM D975-66T Nos. 1D, 2D
JCB High Performance Engine Oil -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40 API CF4/SG (ACEA E2:B2:A2)
JCB High Performance Engine Oil
SAE10W/30 -15 °C to 40 °C (5 °F to 104 °F) API CF4/SG (ACEA E2:B2:A2)
NORTH AMERICA JCB 15W/40 Engine Oil 14°F to 122°F (-10°C to 50°C)
SAE 15W/40 API CF4/SG
JCB 10W Engine Oil -4°F to 50° F (-20°C to 10°C)
SAE 10W API CF4/SG
JCB Four Seasons Antifreeze And Summer Coolant Starts to freeze -36 °C (-33 °F)
ASTM D3306-74
5.3 2.9
NORTH AMERICA Permanent Antifreeze Starts to freeze -33 °F (-36 °C)
ASTM D3306-74
JCB High Performance Transmission Fluid
JCB 4000/0900 Friction modified oils MUST NOT be used (eg Dexron ATF type).
JCB High Performance Gear Oil Plus
JCB 4000/2200 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).
JCB High Performance Hydraulic Fluid 46 (Above 38 °C, 100 °F) JCB High Performance Hydraulic Fluid 32 (Below 38 °C, 100 °F) JCB Light Hydraulic Fluid
ISO VG46
Syncro Shuttle Transmission
17
3.7
4.5
Front Axle Housing Hubs (x2)
9.0 2.0
1.98 0.44
2.4 0.5
Rear Axle Housing Hubs (x2)
8.4 2.0
1.85 0.44
2.2 0.5
Hydraulic Tank (1)
110
24.2
29.0 Grease Points (2)
Diesel Oil (See Types of Fuel)
ISO VG32 ISO VG15
NORTH AMERICA (All Machines) JCB Hydraulic Fluid JCB HP Grease JCB Special MPL-EP Grease
Wear Pad Runways
JCB Waxoyl
Boom Hoses
JCB Special Slide Lubricant
ISO VG46 Lithium complex NLGI No. 2 constsituency including extreme pressure additives. Lithium based NLGI No. 2 constsituency including extreme pressure additives.
* Note 1:
This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed.
* Note 2:
If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All 500 hour greasing operations must be carried out at 50 HOUR intervals.
9804/1103
20 - 00 - 01/10A
3610 - 3/1-6.2
Issue 2*
Loadalls
CONTENTS
* 520-50
20 - 00 - 01/11 *
(N. America)
From m/c no. 754000
Fluids, Lubricants and Capacities Notice: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below.
*
ITEM
CAPACITY FLUID/LUBRICANT US Gal (Liters)
INTERNATIONAL SPECIFICATION
* Fuel Tank
23.8 (90)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
* Engine (Oil)
2.6 (10)
JCB 15W/40 Engine Oil - 14 °F to 122 °F (10 °C to 50 °C)
SAE15W/40, API CF4/SG
JCB 10W Engine Oil - 5 °F to 86 °F(15 °C to 30 °C)
SAE10W/30, API CF4/SG
* Engine (Coolant) 55% Antifreeze
5.3 (20) 2.9 (11)
JCB Universal Antifreeze/water Starts to freeze -33 °F (-36 °C)
ASTM D3306-74
* Gearbox
4.6 (17.5)
JCB Special Transmission Fluid
ESP-M2C 33G Friction modified oils MUST NOT be used (eg. Dexron ATF type).
* Axles Housing Hubs (x4)
2.3 (8.8) 0.47 (1.8)
JCB Special Gear Oil Plus
API GL4 Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
* Hydraulic Tank
†18.5 (70)
JCB High Performance Hydraulic Oil (Above 100 °F, 38 °C) JCB Special Hydraulic Fluid (Below 100 °F, 38 °C)
ISO VG46
* Grease Points
†† JCB HP Grease
Lithium based, No. 2 consistency
* Wear Pad Runways
JCB Waxoyl
ISO VG32
* † Notice: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. * †† Notice: If JCB MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All 500 hour greasing operations must be carried out at 50 HOUR intervals.
9804/1103
20 - 00 - 01/11
8185/109
Issue 2*
Loadalls
CONTENTS
528-70, 528S Fluids, Lubricants and Capacities ITEM
20 - 00 - 01/12
From m/c no. 796000
CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal
INTERNATIONAL SPECIFICATION
Fuel Tank
Engine (Oil)
160
35.2
10
2.2
42.2
Engine (Coolant) 55% Antifreeze
20 11
4.4 2.4
Transmission Syncro Shuttle & Powershift
17
3.7
4.5
Front Axle Housing Hubs (x2)
9 2
1.98 0.44
2.4 0.5
Rear Axle Housing Hubs (x2)
8.4 2
1.85 0.44
2.2 0.5
Hydraulic Tank †
110
24.2
Grease Points ††
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
JCB Super 15W/40 Multigrade -10°C to 50°C (14°F to 122°F)
SAE15W/40 API CF4/SG
JCB Super 10W/30 Multigrade -15°C to 40°C (5°F to 104°F)
SAE10W/30 API CF4/SG
JCB Four Seasons Antifreeze & Summer Coolant Starts to freeze -36 °C (-33 °F)
ASTM D3306-74
JCB Special Transmission Fluid
JCB 4000/0900 Friction modified oils MUST NOT be used (eg Dexron ATF type).
JCB High Performance Gear Oil Plus
JCB 4000/2200 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).
JCB Special Performance Gear Oil Plus
JCB High Performance Hydraulic Fluid 46 (Above 38 °C, 100 °F) JCB High Performance Hydraulic Fluid 32 (Below 38 °C, 100 °F)
ISO VG46
JCB HP Grease
Lithium complex NLGI No. 2 consistency including extreme pressure additives. Lithium based NGLI No. 2
JCB Special MPL-EP Grease
ISO VG32
consistency including extreme pressure additives. Wear Pad Runways
JCB Waxoyl
Boom Hoses
JCB Special Slide Lubricant
† Note:
This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed.
†† Note:
If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals
9804/1103
20 - 00 - 01/12
8450/147
Issue 1
Loadalls
CONTENTS
20 - 00 - 01/13
506B, 506C, 506C (HL), 508C (N. America) Fluids, Lubricants and Capacities Notice: Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY FLUID/LUBRICANT US Gal (Liters)
INTERNATIONAL SPECIFICATION
Fuel Tank
23.7 (90)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
2.6 (10)
JCB 15W/40 Engine Oil 14°F to 122°F (-10°C to 50°C)
SAE 15W/40 API CF4/SG
JCB 10W Engine Oil -4°F to 50°F (-20°C to 10°C)
SAE 10W API CF4/SG ASTM D3306-74
Engine (Coolant)
6.2 (23.5)
Permanent Antifreeze (See Coolant Mixtures)
Transmission Syncro Shuttle Powershift
4.8 (18.25) 3.9 (15.0)
JCB Special Transmission Fluid
Front Axle Housing Hubs (x2)
4.7 (18) 0.5 (2.0)
JCB Special High performance Gear Oil
Rear Axle Housing Hubs (x2)
API GL4 MUST be suitable for use with oil immersed brakes and limited-slip differentials (LSD)
3.4 (13) 0.5 (2.0) JCB Hydraulic Fluid
ISO VG15
Brake System
ESP-M2C 33G Friction modified oils must not be used (eg. Dexron ATF type)
DO NOT USE ORDINARY BRAKE FLUID Hydraulic Tank 506C, 506C 506C, 508C
†32.0 (121) †48.0 (181)
JCB High Performance Hydraulic Oil (Above 100 °F, 38 °C)
ISO VG46
Grease Points
JCB Moly EP #2 Grease
Lithium based, No. 2 consistency
Wear Pad Runways
JCB Waxoyl
Boom Hoses
JCB Special Slide Lubricant
Boom Chains
JCB Chain Lubricant
†Notice: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all cylinders closed. Watch level sight glass when filling. IF JCB MPL-EP or MPL-Moly grease is used all 50 hour greasing operations must be carried out at 10 HOUR intervals, All 500 hour greasing operations must be carried out at 50 HOUR intervals. Coolant Mixtures
9804/1103
%
Antifreeze
Starts to Freeze
55
3.4 gal (12.92 litres)
-36° C (-33 °F)
20 - 00 - 01/13
3640U - 3/1-1.3 & 3/1-2.3
Issue 1
Loadalls
CONTENTS
20 - 00 - 01/14
520-50, 525-50 AA Engine Build Fluids, Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY Litres (Gal)
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
90 (20)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
10 (2.2)
JCB High Performance Engine Oil -10°C to 50°C (14°F to 122°F)
SAE15W/40 API CF4/SG (ACEA E2:B2:A2)
JCB Super Universal Agricultural -15°C to 30°C (5°F to 86°F)
SAE10W/30 API CD/SE
JCB Torque Converter Fluid -18°C to 0°C (0°F to 32°F)
SAE10W API CD/SE
Coolant Capacity 55% Concentration
20 (4.4) 9.4 (2.0)
JCB Four Seasons Antifreeze And Summer Coolant ( See Coolant Mixtures)
ASTM D3306-74
Gearbox
17.5 (3.8)
JCB High Performance Transmission Fluid
JCB 4000/0900 Friction modified oils MUST NOT be used (eg. Dexron ATF type).
Axles Housing (520-50) Housing (525-50) Housing (525-52) Hubs (x4 - 520-50) Hubs (x4 - 525-50) Hubs (x4 - 525-52)
4.0 (0.88) 8.8 (1.94) 8.8 (1.94) 1.0 (0.22) 1.8 (0.4) 1.8 (0.4)
JCB High Performance Gear Oil Plus
JCB 4000/2200
Hydraulic Tank (†)
70 (15.4)
JCB High Performance Hydraulic Fluid 46 ISO VG46 (Above 38°C, 100°F) JCB High Performance Hydraulic Fluid 32 ISO VG32 (Below 38°C, 100°F)
Grease Points (††)
Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
JCB HP Grease
JCB Special MPL-EP Grease
Lithium complex NLGI No. 2 consistency including extreme pressure additives. Lithium based NLGI No. 2 consistency including extreme pressure
additives Wear Pad Runways
JCB Waxoyl
†Note: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Watch level sight glass when filling. ††Note: If JCB MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals; all 500 hour greasing operations must be carried out at 50 HOUR intervals.
9804/1103
20 - 00 - 01/14
8170/109
Issue 1
Loadalls
CONTENTS
20 - 00 - 01/15
520-50, 525-50, 525-52 AK and AR Engine Builds Fluids, Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY Litres (Gal)
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
90 (20)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
10 (2.2)
JCB High Performance Engine Oil -10°C to 50°C (14°F to 122°F)
SAE15W/40 API CF4/SG (ACEA E2:B2:A2)
JCB High Performance Engine Oil -15°C to 40°C (5°F to 104°F)
SAE10W/30 API CF4/SG (ACEA E2:B2:A2)
Coolant Capacity 55% Concentration
20 (4.4) 9.4 (2.0)
JCB Four Seasons Antifreeze And Summer Coolant ( See Coolant Mixtures)
ASTM D3306-74
Gearbox
17.5 (3.8)
JCB High Performance Transmission Fluid
JCB 4000/0900 Friction modified oils MUST NOT be used (eg. Dexron ATF type).
Axles Housing (520-50) Housing (525-50) Housing (525-52) Hubs (x4 - 520-50) Hubs (x4 - 525-50) Hubs (x4 - 525-52)
4.0 (0.88) 8.8 (1.94) 8.8 (1.94) 1.0 (0.22) 1.8 (0.4) 1.8 (0.4)
JCB High Performance Gear Oil Plus
JCB 4000/2200
Hydraulic Tank (†)
70 (15.4)
JCB High Performance Hydraulic Fluid 46 ISO VG46 (Above 38°C, 100°F) JCB High Performance Hydraulic Fluid 32 ISO VG32 (Below 38°C, 100°F)
Grease Points (††)
Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
JCB HP Grease
JCB Special MPL-EP Grease
Lithium complex NLGI No. 2 consistency including extreme pressure additives. Lithium based NLGI No. 2 consistency including extreme pressure
additives Wear Pad Runways
JCB Waxoyl
†Note: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Watch level sight glass when filling. ††Note: If JCB MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals; all 500 hour greasing operations must be carried out at 50 HOUR intervals.
9804/1103
20 - 00 - 01/15
8170/110
Issue 1
Loadalls
CONTENTS
20 - 00 - 01/16
526 (N. America) Fluids, Lubricants and Capacities Notice: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below.
ITEM
CAPACITY US Gal (Liters)
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
31.7 (120)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine Oil
12 (2.2)
JCB 15W/40 Engine Oil 14°F to 122°F (-10°C to 50°C)
SAE 15W/40 API CF4/SG
JCB 10W Engine Oil -4°F to 50°F (-20°C to 10°C)
SAE 10W API CF4/SG
Engine (Coolant)
5.2 (20)
Permanent Antifreeze (See Coolant Mixtures)
ASTM D3306-74
Transmission Syncro Shuttle Powershift
4.4 (17) 4.0 (15.5)
JCB Special Transmission Fluid
ESP-M2C 33G
Front Axle Housing Hubs (x2)
2.3 (9) 0.5 (2)
JCB Special Gear Oil Plus
Rear Axle Housing Hubs (x2)
API GL4 Must be suitable for oil immersed brakes and Limited Slip Differentials (LSD).
2.2 (8.4) 0.5 (2) JCB Light Hydraulic Fluid Do Not Use Ordinary Brake Fluid
ISO VG15
JCB Hydraulic Fluid (Above 100 °F (38 °C)
ISO VG46
Grease Points
††JCB HP Grease
Lithium based, No. 2 consistency
Wear Pad Runways
JCB Waxoyl
Boom Hoses
JCB Special Slide Lubricant
Brake System From Serial No. 280300 Hydraulic Tank
†29.0 (110)
† Notice: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all cylinders closed. †† Notice: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals; all 500 hour greasing operations must be carried out at 50 HOUR intervals.
9804/1103
20 - 00 - 01/16
8037/121
Issue 1
Loadalls
CONTENTS
20 - 00 - 01/17
530, 535, 540 Fluids, Lubricants and Capacities
ITEM Litres
CAPACITY UK Gal US gal
Fuel Tank
125
27.5
Engine (Oil)
10
(2.2)
30
23 23.5
5.0 5.2
INTERNATIONAL SPECIFICATION
Diesel Oil
ASTM D975-66T Nos. 1D, 2D
JCB Super Multigrade 15W/40 CF4/SG, SAE15W/40 -10 °C to +50 °C (14 °F to 122 °F) JCB Super Multigrade 10W/30 CF4/SG, SAE10W/30 -15 °C to +40 °C (5 °F to 104 °F)
2.6
* Engine (Coolant) Except AM Engine AM Engine only
FLUID/LUBRICANT
6.0 6.2
NORTH AMERICA JCB 15W/40 Engine Oil CF4/SG, SAE15W/40 14 °F to 122 °F (-10 °C to +50 °C) JCB Engine Oil 10W CF4/SG, SAE10W -4 °F to +50 °F (-20 °C to +10 °C) JCB Four Seasons Antifreeze and Summer Coolant NORTH AMERICA Permanent Antifreeze
Transmission (See Note 1)
21 23
4.6 5.0
Axles Housing Hubs (x4)
18 2.0
3.9 0.4
Housing Hubs (x4)
5.5 6.0
4.6 0.48
112 121
Braking System
Grease Points (See Note 3)
Wear Pad Runways
3
0.7
JCB Special Transmission Fluid ESP-M2C 33G
NORTH AMERICA JCB Special Gear Oil
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)
24.6 26.6
530, 540 535
ASTM D3306-74
JCB High Performance Gear Oil API GL4
Hydraulic Tank (See Note 2) 530, 540 535
ASTM D3306-74
ESEN-M2C 86A/B
ISO VG46
ISO VG32
29.5 32.0
NORTH AMERICA JCB Hydraulic oil
0.8
JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID
ISO VG15
JCB HP Grease
Lithium based
NORTH AMERICA JCB Moly EP 2 Grease
Lithium based No. 2 constituency
ISO VG46
JCB Waxoyl
Note 1: Wet fill capacity, eg. at fluid change 21 litres, dry fill capacity eg. after rebuild 23 litres. Note 2: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Note 3: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals.
9804/1103
20 - 00 - 01/17
3630 - 3/1-3.5
Issue 2*
Loadalls
CONTENTS
20 - 00 - 01/17A
530, 533, 535, 540 Fluids, Lubricants and Capacities Type AA and AB Engines ITEM Litres
CAPACITY UK Gal US gal
Fuel Tank
125
27.5
Engine (Oil)
10
(2.2)
30
2.6
Engine (Coolant)
23
5.0
21 23
4.6 5.0
Axles Housing Hubs (x4)
18 2.0
3.9 0.4
Housing Hubs (x4)
5.5 6.0
4.6 0.48
112 121
Braking System
Grease Points (See Note 3)
Wear Pad Runways
3
0.7
Diesel Oil
ASTM D975-66T Nos. 1D, 2D
JCB Super Multigrade 15W/40 -10 °C to +50 °C (14 °F to 122 °F) JCB Super Universal Agricultural -15 °C to +40 °C (5 °F to 104 °F) JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE15W/40 API CF4/SG
NORTH AMERICA JCB 15W/40 Multigrade 14 °F to 122 °F (-10 °C to +50 °C) 10W/30 Multigrade -4 °F to +50 °F (-20 °C to +10 °C) JCB 10W -18 °C to 0 °C (0 °F to 32 °F)
NORTH AMERICA Permanent Antifreeze
JCB Extreme Performance Transmission Oil
NORTH AMERICA JCB Special Gear Oil
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)
24.6 26.6
530, 540 535, 533
INTERNATIONAL SPECIFICATION
SAE10W/30, API CD/SE, SAE 10W, API CD/SE
SAE15W/40 API CF4/SG SAE10W/30 API CD/SE SAE10W API CD/SE ASTM D3306-74
ASTM D3306-74
JCB: 4000/2501
JCB High Performance Gear Oil API GL4
Hydraulic Tank (See Note 2) 530, 540 535, 533
FLUID/LUBRICANT
JCB Four Seasons Antifreeze and Summer Coolant 6.0
Transmission (See Note 1)
From m/c no. 767001
ESEN-M2C 86A/B
ISO VG46
ISO VG32
29.5 32.0
NORTH AMERICA JCB Hydraulic oil
0.8
JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID
ISO VG15
JCB HP Grease
Lithium based
NORTH AMERICA JCB Moly EP 2 Grease
Lithium based No. 2 constituency
ISO VG46
JCB Waxoyl
Note 1: Wet fill capacity, eg. at fluid change 21 litres, dry fill capacity eg. after rebuild 23 litres. Note 2: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Note 3: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals. 9804/1103
20 - 00 - 01/17A
3630 - 3/1-2.6
Issue 1*
Loadalls
CONTENTS
20 - 00 - 01/17B
530, 533, 535, 540 Fluids, Lubricants and Capacities Type AR, AK and AB Engines ITEM Litres
CAPACITY UK Gal US gal
Fuel Tank
125
27.5
Engine (Oil)
10
(2.2)
30
2.6
Engine (Coolant)
23
5.0
21 23
4.6 5.0
Axles Housing Hubs (x4)
18 2.0
3.9 0.4
Housing Hubs (x4)
5.5 6.0
4.6 0.48
112 121
Braking System
Grease Points (See Note 3)
Wear Pad Runways
3
0.7
Diesel Oil
ASTM D975-66T Nos. 1D, 2D
JCB Super Multigrade 15W/40 -10 °C to +50 °C (14 °F to 122 °F) JCB Super Universal Agricultural -15 °C to +40 °C (5 °F to 104 °F) JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE15W/40 API CF4/SG
NORTH AMERICA JCB 15W/40 Multigrade 14 °F to 122 °F (-10 °C to +50 °C) 10W/30 Multigrade -4 °F to +50 °F (-20 °C to +10 °C) JCB 10W -18 °C to 0 °C (0 °F to 32 °F)
NORTH AMERICA Permanent Antifreeze
JCB Extreme Performance Transmission Oil
NORTH AMERICA JCB Special Gear Oil
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)
24.6 26.6
530, 540 535, 533
INTERNATIONAL SPECIFICATION
SAE10W/30, API CD/SE, SAE 10W, API CD/SE
SAE15W/40 API CF4/SG SAE10W/30 API CD/SE SAE10W API CD/SE ASTM D3306-74
ASTM D3306-74
JCB: 4000/2501
JCB High Performance Gear Oil API GL4
Hydraulic Tank (See Note 2) 530, 540 535, 533
FLUID/LUBRICANT
JCB Four Seasons Antifreeze and Summer Coolant 6.0
Transmission (See Note 1)
From m/c no. 767001
ESEN-M2C 86A/B
ISO VG46
ISO VG32
29.5 32.0
NORTH AMERICA JCB Hydraulic oil
0.8
JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID
ISO VG15
JCB HP Grease
Lithium based
NORTH AMERICA JCB Moly EP 2 Grease
Lithium based No. 2 constituency
ISO VG46
JCB Waxoyl
Note 1: Wet fill capacity, eg. at fluid change 21 litres, dry fill capacity eg. after rebuild 23 litres. Note 2: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Note 3: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals. 9804/1103
20 - 00 - 01/17B
3630 - 3/1-3.6
Issue 1*
Loadalls
CONTENTS
20 - 00 - 01/18
532, 537, 550 Fluids, Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
Fuel Tank Engine (Oil) Engine Type: AA, AB, AR & AK Builds
CAPACITY Litres (Gal) 125 (27.5)
10 (2.2)
Engine Type: AA & AB Builds Only
Engine (Coolant)
23 (5.0)
Gearbox Wet fill Dry fill
21 (4.6) 23 (5.0)
Axles Housing Hubs (x4)
18 (3.9) 2.0 (0.4)
Brake System
Hydraulic Tank (†)
Grease Points (††)
131 (28.8)
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
JCB Super Multigrade 15W/40 -10 °C to 50 °C (14 °F to 122 °F) JCB Super Multigrade 10W/30 -15 °C to 40 °C (5 °F to 104 °F)
SAE15W/40 API CF4/SG SAE10W/30 API CF4/SG
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F) JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W/30 API CD/SE SAE10W API CD/SE
JCB Four Seasons Antifreeze And Summer Coolant (See Coolant Mixtures)
ASTM D3306-74
JCB Special Transmission Fluid
ESP-M2C 33G Friction modified oils MUST NOT be used (eg. Dexron ATF type).
JCB High Performance Gear Oil
API GL4 Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID
ISO VG15
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)
ISO VG46
JCB HP Grease
Lithium complex NLGI No. 2 consistency including extreme pressure additives. Lithium based NLGI No. 2 consistency including extreme pressure additives
JCB Special MPL-EP Grease
Wear Pad Runways
ISO VG32
JCB Waxoyl
†Note: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. ††Note: If JCB MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals; all 500 hour greasing operations must be carried out at 50 HOUR intervals.
9804/1103
20 - 00 - 01/18
8130/120
Issue 1
Loadalls
CONTENTS CONTENTS
*
20 - 00 - 02/1
525-58, 525-67, 527-58, 527-67
From m/c no. 567362
Static Dimensions and Weights
C
A
H K E F G
D B
A122340
DESCRIPTION
DIMENSION 525-58, 527-58
525-58FS, 527-58FS
525-67, 527-67
525-67FS, 527-67FS
A
Overall height
2.59 m (8 ft 6 in)
2.57 m (8 ft 5 in)
2.59 m (8 ft 6 in)
2.57 m (8 ft 5 in)
B
Overall width
2.34 m (7 ft 8 in)
2.35 m (7 ft 8 in)
2.34 m (7 ft 8 in)
2.35 m (7 ft 8 in)
C
Inside width of cab (between windows)
0.93 m (3 ft 0 in)
0.93 m (3 ft 0 in)
0.93 m (3 ft 0 in)
0.93 m (3 ft 0 in)
D
Track
1.90 m (6 ft 3 in)
1.90 m (6 ft 3 in)
1.90 m (6 ft 3 in)
1.90 m (6 ft 3 in)
E
Wheelbase
2.38 m (7 ft 10 in)
2.38 m (7 ft 10 in)
2.49 m (8 ft 2 in)
2.49 m (8 ft 2 in)
F
Overall length to front tyres
3.87 m (12 ft 8 in)
3.87 m (12 ft 8 in)
4.05 m (13 ft 3 in)
4.05 m (13 ft 3 in)
G
Overall length to front of Q-Fit carriage
4.46 m (14 ft 7 in)
4.46 m (14 ft 7 in)
4.79 m (15 ft 8 in)
4.79 m (15 ft 8 in)
H
Ground clearance
0.42 m (1 ft 5 in)
0.40 m (1 ft 4 in)
0.42 m (1 ft 5 in)
0.40 m (1 ft 4 in)
K
Centre of gravity (unladen)
1.21 m (3 ft 11 in)
1.21 m (3 ft 11 in)
1.34 m (4 ft 3 in)
1.34 m (4 ft 3 in)
6300 kg (13,860 lb)
6300 kg (13,860 lb)
6422 kg (14,128 lb)
6422 kg (14,128 lb)
Weight (unladen)
9804/1103
20 - 00 - 02/1
Issue 3*
Loadalls
CONTENTS
20 - 00 - 02/2
530-95
From m/c no. 567362
Static Dimensions and Weights
C
A H K D
E
B
F G
DESCRIPTION
DIMENSION
A
Overall height
2.59 m (8 ft 6 in)
B
Overall width
2.35 m (7 ft 8 in)
C
Inside width of cab (between windows)
0.94 m (3 ft 1 in)
D
Track
1.90 m (6 ft 3 in)
E
Wheelbase
2.49 m (8 ft 2 in)
F
Overall length to front tyres
4.78 m (15 ft 8 in)
G
Overall length to front of Q-Fit carriage
5.60 m (18 ft 4 in)
H
Ground clearance
0.4 m (1 ft 4 in)
J
Boom overhang
0.54 m (1 ft 8 in)
Weight (unladen)
9804/1103
J
A198790
7960 kg (17,550 lbs) Approximately
20 - 00 - 02/2
Issue 1
Loadalls
CONTENTS
20 - 00 - 02/3
530-110
From m/c no. 567362
Static Dimensions and Weights
C
A
H K E F G
D B
*A122430 DESCRIPTION
DIMENSION
* A
Overall height
2.59 m (8 ft 6 in)
* B
Overall width
2.35 m (7 ft 8 in)
Inside width of cab (between windows)
0.94 m ( 3 ft 1 in)
D
Track
1.90 m (6 ft 3 in)
E
Wheelbase
2.49 m (8 ft 2 in)
* F
Overall length to front tyres
4.78 m (15 ft 8 in)
* G
Overall length to front of Q-Fit carriage
5.60 m (18 ft 4 in)
* H
Ground clearance
0.4 m ( 1 ft 4 in)
* K
Centre of gravity (unladen, stabilisers raised)
1.36 m (4 ft 6 in)
C
Weight (unladen)
9804/1103
7960 kg (17,550 lbs) Approximately
20 - 00 - 02/3
8190/151
Issue 2*
CONTENTS
Loadalls
20 - 00 - 02/3A
530-110
From m/c no. 567362
Performance Data Forklift Performance † Lift capacity to full height
3000 kg (6,614 lb)
Lift capacity at full reach
950 kg (2,095 lb)
Lift height
10.95 m (36 ft 1 in)
Reach at maximum lift height
1.55 m (5 ft 5 in)
Maximum forward reach
6.85 m (23 ft 0 in)
Placing height
10.3 m (33 ft 9 1/2 in)
† Based on 500 mm (20 in) Load Centre. See Load Charts.
Loader Performance (Standard GP Bucket) Bucket rated capacity
1.0 m3 (35 cu ft)
Maximum dump height at 45 degrees
TBA
Maximum dump height
10.65 m (35 ft 1 in)
Maximum loadover height
10.80 m (35 ft 5 in)
Placing height
TBA
9804/1103
20 - 00 - 02/3A
8190/152
Issue 1
Loadalls
CONTENTS
20 - 00 - 02/4
530-120, 537-130
From m/c no. 567362
Static Dimensions and Weights
C
A
H K D
E F
B
G S140100
DESCRIPTION
DIMENSION
A
Overall height
2.56 m (8 ft 5 in)
B
Overall width
2.364 m (7 ft 9 in)
C
Inside width of cab (between windows)
0.94 m ( 3 ft 1 in)
D
Track
1.90 m (6 ft 3 in)
E
Wheelbase
2.49 m (8 ft 2 in)
F
Overall length to front tyres
4.44 m (14 ft 6 in)
G
Overall length to front of Q-Fit carriage Ground clearance
5.30 m (17 ft 5 in) 0.38 m ( 1 ft 3 in)
H
Weight (unladen)
9804/1103
8730 kg (19,250 lbs) Approximately
20 - 00 - 02/4
Issue 1
Loadalls
CONTENTS
20 - 00 - 02/5
505-19, 505-22
From m/c no. 567362
Static Dimensions and Weights
C
A
H K E F
D B
G A122340
DESCRIPTION
DIMENSION 505-19
505-22
A B
Overall height Overall width
8 ft 6 in (2.59 m) 7 ft 6 in (2.29 m)
8 ft 6 in (2.59 m) 7 ft 6 in (2.29 m)
C
Inside width of cab (between windows)
3 ft 2.5 in (0.92 m)
3 ft 2.5 in (0.92 m)
D
Track
6 ft 3 in (1.90 m)
6 ft 3 in (1.90 m)
E
Wheelbase
7 ft 10 in (2.38 m)
8 ft 2 in (2.49 m)
F
Overall length to front tires
12 ft 8 in (3.86 m)
13 ft 3 in (4.04 m)
G
Overall length to front of Q-Fit carriage
14 ft 7 in (4.45 m)
15 ft 8 in (4.77 m)
Ground clearance
1 ft 4.5 in (0.42 m)
1 ft 41/2 in (0.42 m)
13,960 lbs (6300 kg)
15,345 lbs (6960 kg)
H
Weight (unladen)
Notice: Dimensions are based on a machine with 15.5-25 tires fitted.
9804/1103
20 - 00 - 02/5
Issue 1
Loadalls
CONTENTS
20 - 00 - 02/6
506-36
From m/c no. 567362
Static Dimensions and Weights
C
A
H D
E
B
F G S157670
DESCRIPTION
DIMENSION
A Overall height
8 ft 6 in (2.59 m)
B Overall width
7 ft 6 in (2.29 m)
C Inside width of cab (between windows)
3 ft 21/2 in (0.92 m)
D Track
6 ft 3 in (1.90 m)
E Wheelbase
7 ft 10 in (2.38 m)
F Overall length to front tires
12 ft 8 in (3.86 m)
G Overall length to front of Q-Fit carriage
14 ft 7 in (4.45 m)
H Ground clearance
1 ft 41/2 in (0.42 m)
Weight (unladen)
20,616 lbs (9350 kg) Approximately
Notice: Dimensions are based on a machine with 15.5-25 tires fitted.
9804/1103
20 - 00 - 02/6
Issue 1
Loadalls
CONTENTS
20 - 00 - 02/7
508-40
From m/c no. 567362
Static Dimensions and Weights
C
A H
D
E F
B
G S141370
DESCRIPTION
DIMENSION
A Overall height
8 ft 6 in (2.59 m)
B Overall width
8 ft 1 in (2.46 m)
C Inside width of cab (between windows)
3 ft 1 in (0.94 m)
D Track
6 ft 8 in (2.03 m)
E Wheelbase
9 ft 2 in (2.80 m)
F Overall length to front tires
16 ft 1 in (4.90 m)
G Overall length to front of Q-Fit carriage
19 ft 2 in (5.86 m)
H Ground clearance
1 ft 31/2 in (0.39 m)
Weight (unladen)
9804/1103
24,458 lbs (11,094 kg) Approximately
20 - 00 - 02/7
Issue 1
Loadalls
CONTENTS
20 - 00 - 02/8
510-40
From m/c no. 567362
Static Dimensions and Weights
C
A
H
D
E F
B
G S140100
DESCRIPTION
DIMENSION
A Overall height
8 ft 6 in (2.59 m)
B Overall width
8 ft 0 in (2.44 m)
C Inside width of cab (between windows)
3 ft 1 in (0.94 m)
D Track
6 ft 3 in (1.90 m)
E Wheelbase
9 ft 2 in (2.80 m)
F Overall length to front tires
16 ft 1 in (4.91 m)
G Overall length to front of Q-Fit carriage
19 ft 1 in (5.81 m)
H Ground clearance
1 ft 4 in (0.4 m)
Weight (unladen)
9804/1103
26,808 lbs (12,160 kg)
20 - 00 - 02/8
Issue 1
Loadalls
CONTENTS
20 - 00 - 02/9
520-55, 520S
From m/c no. 567362
Static Dimensions and Weights
C
A H E
D B
F G
DESCRIPTION
DIMENSION
A
Overall height
7 ft 5 in (2.26 m)
B
Overall width
7 ft 11/2 in (2.17 m)
C
Inside width of cab
2 ft 11 in (0.88 m)
D
Front track
6 ft 2 in (1.87 m)
E
Wheelbase
7 ft 5 in (2.25 m)
F
Overall length to front tyres
12 ft 4 in (3.76 m)
G
Overall length to front of Q-Fit carriage
14 ft 6 in (4.42 m)
H
Ground clearance
1 ft 1 in (0.32 m)
Weight (unladen)
10745 lb (4875 kg)
Note: The above figures are based on a machine fitted with 12.5/80 X 18" tyres.
* Performance
A245130
8020/191
Dimensions †
Forklift Performance Lift capacity to full height
4500 lb (2041 kg)
Lift capacity at full reach
2000 lb (907 kg )
Lift height
18 ft 0 in (5.50 m)
Maximum forward reach
10 ft 6 in (3.20 m)
Placing height
15 ft 61/2 in (4.74 m) 8020/193
* † Based on 24 in (610 mm) Load Centre. See Load Charts.
9804/1103
20 - 00 - 02/9
Issue 3*
Loadalls
CONTENTS
20 - 00 - 02/10
526-55, 526, 526S
From m/c no. 277001
Static Dimensions and Weights
C
A
H E
D B
F G A195450
ø
*
DESCRIPTION
DIMENSION 526-55
DIMENSION 526
DIMENSION 526S
A
Overall height
7 ft 61/2 in (2.30 m)
7 ft 61/2 in (2.30 m)
7 ft 81/2 in (2.38 m)
B
Overall width
7 ft 31/4 in (2.23 m)
7 ft 31/4 in (2.23 m)
7 ft 31/4 in (2.23 m)
C
Inside width of cab
2 ft 11 in (0.88 m)
2 ft 11 in (0.88 m)
2 ft 11 in (0.88 m)
D
Front track
6 ft 0 in (1.85 m)
5 ft 11 in (1.81 m)
5 ft 11 in (1.81 m)
E
Wheelbase
7 ft 5 in (2.26 m)
7 ft 7 in (2.33 m)
7 ft 7 in (2.33 m)
F
Overall length to front tyres
12 ft 51/2 in (3.80 m)
12 ft 91/2 in (3.90 m)
12 ft 91/2 in (3.90 m)
G
Overall length to front of Q-Fit carriage
14 ft 6 in (4.42 m)
14 ft 10 in (4.52 m)
14 ft 10 in (4.52 m)
H
Ground clearance
1 ft 2 in (0.36 m)
1 ft 51/2 in (0.45 m)
1 ft 51/2 in (0.45 m)
Weight (unladen)
12122 lb (5500 kg)
12171 lb (5520 kg)
12877 lb (5840 kg) 8020/192
Performance Dimentional Forklift Performance† Lift capacity to full height
5730 lb (2600 kg)
Lift capacity at full reach
2204 lb (1000 kg)
Lift height
18 ft 2 in (5.54 m)
Maximum forward reach
10 ft 0 in (3.05 m)
Placing height
15 ft 8 in (4.78 m)
†Based on 24 in (610 mm) Load Centre. See Load Charts.
9804/1103
20 - 00 - 02/10
8020/193
Issue 3*
Loadalls
CONTENTS
20 - 00 - 02/11
537-120
From m/c no. 567362
Static Dimensions and Weights
C
A H K D
E F
B
G S141370
DESCRIPTION
DIMENSION
A Overall height
2.59 m (8 ft 6 in)
B Overall width
2.46 m (8 ft 1 in)
C Inside width of cab (between windows)
0.94 m (3 ft 1 in)
D Track
1.98 m (6 ft 6 in)
E Wheelbase
2.80 m (9 ft 2 in)
F Overall length to front tyres
4.91 m (16 ft 1 in)
G Overall length to front of Q-Fit carriage
5.87 m (19 ft 3 in
H Ground clearance
0.4 m (1 ft 4 in)
K Centre of gravity (unladen, stabilisers raised)
1.28 m (4 ft 2 in)
Weight (unladen)
9804/1103
11,100 kg (24,458 lbs) Approximately
20 - 00 - 02/11
Issue 1
Loadalls
CONTENTS
20 - 00 - 02/12
530-67, 535-67
From m/c no. 567362
Static Dimensions and Weights
C
A
H K E F
D B
G A214860
DESCRIPTION
DIMENSION
A
Overall height
2.57 m (8 ft 5 in)
B
Overall width
2.36 m (7 ft 9 in)
C
Inside width of cab (between windows)
0.94 m (3 ft 1 in)
D
Track
1.90 m (6 ft 3 in)
E
Wheelbase
2.49 m (8 ft 2 in)
F
Overall length to front tyres
4.23 m (13 ft 11 in)
G
Overall length to front of Q-Fit carriage
4.96 m (16 ft 3 in)
H
Ground clearance
0.40 m (1 ft 4 in)
K
Centre of gravity (unladen)
1.44 m (4 ft 9 in)
Weight (unladen)
9804/1103
7170 kg (15,770 lb)
20 - 00 - 02/12
Issue 1
Loadalls
CONTENTS
* 520-50, * Static
20 - 00 - 02/13
525-50, 525-52
From m/c no. 754000
Dimensions and Weight
C
A
H K
D
E
B
F G A234930
DESCRIPTION
DIMENSION 520-50
DIMENSION 525-50
DIMENSION 525-52
A
Standard overall height Low cab option
2120 mm (6ft 11in) 1985 mm (6ft 6in)
2190 mm (7ft 2in) 2055 mm (6ft 9in)
2250 mm (7ft 5in) 2115 mm (6ft 11in)
B
Overall width
1800 mm (5ft 11in)
1820 mm (6ft 0in)
1880 mm (6ft 2in)
C
Inside width of cab (between windows)
830 mm (2ft 7in)
830 mm (2ft 7in)
830 mm (2ft 7in)
D
Track
1530 mm (5ft 0in)
1490 mm (4ft 11in)
1490 mm (4ft 11in)
E
Wheelbase
2000 mm (6ft 7in)
2000 mm (6ft 7in)
2000 mm (6ft 7in)
F
Overall length to front tyres
3080 mm (10ft 1 in)
3130 mm (10ft 3in)
3130 mm (10ft 3in)
G
Overall length to front of carriage
3590 mm (11ft 9in)
3620 mm (11ft 11in)
3620 mm (11ft 11in)
H
Ground clearance
300 mm (1ft 0in)
360 mm (1ft 2in)
420 mm (1ft 4in)
K
Centre of gravity (unladen)
1020 mm (3ft 9in)
1020 mm (3ft 9in)
1020 mm (3ft 9in)
4700 Kg (10,362lb)
5400 Kg (11,905lb)
5400 Kg (11,905lb)
*
Weight (unladen)
* Note: Only 520-50 machines are available in N. America.
9804/1103
20 - 00 - 02/13
8170/151
Issue 2*
Loadalls
CONTENTS
20 - 00 - 02/13A
From m/c no. 754000
520-50, 525-50, 525-52 Performance Dimensions
Forklift Performance † (except N. America) 520-50
525-50
525-52
Lift capacity to full height
2000 Kg (4,410 lb)
2500 Kg (5,511 lb)
2500 Kg (5,511 lb)
Lift capacity at maximum reach
700 Kg (1,543 lb)
1000 Kg (2,205 lb)
1000 Kg (2,205 lb)
Maximum lift height
5000 mm (16ft 4in)
5000 mm (16ft 4in)
5200 mm (17ft 1in)
Reach at maximum lift height
500 mm (1ft 6in)
500 mm (1ft 6in)
500 mm (1ft 6in)
Maximum forward reach
2820 mm (9ft 2 in)
2820 mm (9ft 2in)
2820 mm (9ft 2in)
Reach with 1 tonne load
2255 mm (7ft 3in)
2820 mm (9ft 2in)
2820 mm (9ft 2in)
Placing height, 2 tonne load
4600 mm (15ft 0in)
4600 mm (15ft 0in)
4600 mm (15ft 0in) 8170/152
† Based on 500 mm (20 in) Load Centre.
Forklift Performance ††(N. America) Lift capacity to full height
4,400 lb. (1998 kg)
Lift capacity at maximum reach
1,650 lb. (749 kg)
Maximum lift height
16 ft 4 in (5000 mm)
Reach at maximum lift height
1 ft 10 in (559 mm)
Maximum forward reach
9 ft 6 in (2896 mm)
Reach with 2,200 lb load
8 ft 5 in (2565 mm)
Placing height, 4,400 lb load
15 ft 0 in (4572 mm)
†† Based on 24 in (609 mm) Load Center.
8185/152
Loader Performance (Standard GP Bucket) 520-50
525-50
525-52
Bucket rated capacity
0.7 m3 (24 cu ft)
0.9 m3 (32 cu ft)
0.95 m3 (33 cu ft)
Maximum dump height at 45° bucket angle
4.07 m (13ft 3in)
4.11 m (13ft 6in)
4.17 m (13ft 8in)
8170/152
9804/1103
20 - 00 - 02/13A
Issue 1
Loadalls
CONTENTS
20 - 00 - 02/14 *
530, 540
From m/c no. 767001
Static Dimensions and Weights
C
A
K
D B
H E F G
A264240
DESCRIPTION
DIMENSION
DIMENSION
530
540
A
Overall height
2480 mm (8ft 1 in)
2490 mm (8ft 2in)
B
Overall width
2230 mm (7ft 1 in)
2290 mm (7ft 6in)
C
Inside width of cab (between windows)
940 mm (3ft 1in)
940 mm (3ft 1in)
D
Track
1794 mm (5ft 10in)
1870 mm (6ft 2in)
E
Wheelbase
2750 mm (9ft 0in)
2750 mm (9ft 0in)
F
Overall length to front tyres
4380 mm (14ft 4in)
4380 mm (14ft 4in)
G
Overall length to front of carriage
4940 mm (16ft 2in)
4990 mm (16ft 4in)
H
Ground clearance
390 mm (1ft 2in)
400 mm (1ft 4in)
K
Centre of gravity (unladen)
1420 mm (4ft 8in)
-
Weight (unladen)
6475 kg (14,277 lb)
7400 kg (16,314 lb)
9804/1103
20 - 00 - 02/14
8130/151
Issue 2*
Loadalls
CONTENTS
20 - 00 - 02/14A
535
From m/c no. 767001
Static Dimensions and Weights C
A2
A1 N W 15
H1
H2
K
115 L
D
E
B
P
F M
T
H3
X
G
A345760
M
R1/R2
S
R3 U1/U2
R4 V
DIMENSION A1 A2 B C D E F
2465 mm (8ft 1in) 2630 mm (8ft 8in) 2290 mm (7ft 6in) 960 mm (3ft 2in) 1870 mm (6ft 2in) 2750 mm (9ft 0in) 4410 mm (14ft 6in) - without hitch 4520 mm (14ft 10in) with hitch G 4980 mm (16ft 4in) H1 410 mm (1ft 5in) H2 380 mm (1ft 4in) H3 411 mm (1ft 5in) K 1415 mm (4ft 8in) - Unladen L 1200 mm (3ft 11in) M 1067 mm (3ft 6in) 1200 mm (3ft 11in) N 1830 mm (6ft)
9804/1103
DIMENSION P R1 R2 R3 R4 S T U1 U2 V W X
1030 mm (3ft 5in) 4277 mm (14 ft) - 1067mm forks (T) 4392 mm (14ft 5in) - 1200mm forks (T) 3176 mm (10ft 5in) (T) 559 mm (1ft 10in) (T) 1226 mm (4ft) 103 mm (4 in) 3718 mm (12ft 3in) - 1067mm forks (T) 3833 mm (12 ft 7in) - 1200mm forks (T) 6817 mm (22ft 5in) - 1067mm forks (T) 30° with hitch 40° without hitch 16.3°
Weight (unladen) 7910 kg (17,438 lb) Entries marked (T) are theoretical not measured values. Machine tested with 445/70 R24 XM47 tyres.
20 - 05 - 02/14A
8130/152
Issue 1
CONTENTS
Loadalls
20 - 00 - 02/15
530, 540
From m/c no. 767001
Performance Dimensions * Forklift
Performance †
530
*
535
540
Maximum lift capacity
3000 kg (6,615 lb)
3500 kg (7,716 lb)
4000 kg (8,818 lb)
Lift capacity to full height
2500 kg (5,512 lb)
1750 kg (3,858 lb)
3000 kg (6,614 lb)
Lift capacity at maximum reach
1250 kg (2,756 lb)
600 kg (1,323 lb)
1500 kg (3,307 lb)
Maximum lift height
7000 mm (22ft 9in)
9500 mm (31 ft 2 in)
7000 mm (22ft 8in)
Reach at maximum lift height
480 mm (1ft 6in)
2430 mm (7 ft 11 in)
480 mm (1ft 7in)
Maximum forward reach
3700mm (12ft 2in)
6520 mm (12 ft 2 in)
3700 mm (12ft 2in)
Reach with 1 tonne load
3700mm (12ft 2in)
5290 mm (17 ft 4 in)
3700 mm (12ft 2in)
* † Based on 500 mm (20 in) Load Centre.
9804/1103
20 - 00 - 02/15
Issue 2*
CONTENTS
Loadalls
20 - 00 - 02/16 *
532, 537, 550
From m/c no. 767001
Static Dimensions and Weights
C
A H K
D B
E F G A264250
DESCRIPTION
DIMENSION
DIMENSION
DIMENSION
532
537
550
A
Overall height
2580 mm (8ft 5in)
2580 mm (8ft 5in)
2590 mm (8ft 6in)
B
Overall width
2350 mm (7ft 8in)
2350 mm (7ft 8in)
2350 mm (7ft 8in)
C
Inside width of cab (between windows)
940 mm (3ft 1in)
940 mm (3ft 1in)
940 mm (3ft 1in)
D
Track
1900 mm (6ft 2in)
1900 mm (6ft 2in)
1900 mm (6ft 2in)
E
Wheelbase
2750 mm (9ft 0in)
2900 mm (9ft 5in)
2900 mm (9ft 5in)
F
Overall length to front tyres
4830 mm (15ft 10in)
5180 mm (17ft 0in)
5180 mm (17ft 0in)
G
Overall length to front of carriage
5800mm (19ft 0in)
6190 mm (20ft 3in)
6230 mm (20ft 5in)
H
Ground clearance
390 mm (1ft 2in)
390 mm (1ft 2in)
400 mm (1ft 4in)
K
Centre of gravity (unladen)
1380 mm (4ft 6in)
1660 mm (5ft 5in)
-
Weight (unladen)
9430 kg (20,793 lbs)
10,600 kg (23,373 lbs)
11,300 kg (24,912 lbs)
9804/1103
20 - 00 - 02/16
Issue 2*
CONTENTS
Loadalls
20 - 00 - 02/17 *
532, 537, 550
From m/c no. 767001
Performance Dimensions Forklift Performance*
532
537
550
Maximum lift capacity
3200 kg (7,056 lb)
3700 kg (8158 lb)
4536 kg (10,00 0 lb)
Lift capacity to full height
3200 kg (7,056 lb)
3700 kg (8158 lb)
4536 kg (10,000 lb)
Lift capacity at maximum reach
1250 kg (2,756 lb)
1500 kg (3,307 lb)
1134 kg (2,500 lb )
Maximum lift height
12000 mm (39ft 4 in)
13500 mm (44ft 3in)
13500 mm (44ft 3in)
Reach at maximum lift height
1450 mm (4ft 9 in)
1680 mm (5ft 5in)
1680 mm (5ft 6in)
Maximum forward reach
8010 mm (26ft 3in)
9250 mm (30ft 3in)
9250 mm (30ft 4in)
Reach with 1 tonne load
8010 mm (26ft 3in)
9250 mm (30ft 3in)
-
Placing height, 2 tonne load
-
-
-
* Based on 500 mm (20 in) Load Centre.
9804/1103
20 - 00 - 02/17
Issue 2*
Loadalls
CONTENTS
20 - 00 - 02/18
506, 506 (HL), 508 (N. America) Static Dimensions and Weights
C
A
H D
E
B
G A196390
DESCRIPTION
DIMENSION 506
506 (HL)
508
A
Overall height
8 ft 8 in (2.67 m)
8 ft 8 in (2.67 m)
8 ft 8 in (2.67 m)
B
Overall width
7 ft 8 in (2.13 m)
8 ft 1 in (2.46 m)
8 ft 1 in (2.46 m)
C
Inside width of cab (between windows)
3 ft 0 in (0.93 m)
3 ft 0 in (0.93 m)
3 ft 0 in (0.93 m)
D
Track
6 ft 3 in (1.92 m)
6 ft 7 in (2.01 m)
6 ft 7 in (2.01 m)
E
Wheelbase
9 ft 1 in (2.78 m)
9 ft 10 in (3.00 m)
9 ft 10 in (3.00 m)
G
Overall length to front of Q-Fit carriage
17 ft 6 in (5.34 m)
20 ft 1 in (6.12 m)
20 ft 1 in (6.12 m)
Ground clearance
1 ft 3 in (0.38 m)
1 ft 4 in (0.41 m)
1 ft 4 in (0.41 m)
Weight (unladen)
21,040 lbs (9,540 kg)
22,150 lbs (10,069 kg)
25,225 lbs (11,440 kg)
H
Notice: Dimensions are based on a machine with 15.5-25 tires fitted.
9804/1103
20 - 00 - 02/18
8205/171
Issue 1
Loadalls
CONTENTS
20 - 00 - 02/19
506, 506 (HL), 508 (N. America) Performance Data Forklift Performance † 506
506 (HL)
508
Lift capacity to full height
6,000 lb (3000 kg)
6,000 lb (3000 kg)
8,000 lb (3628 kg)
Lift capacity at full reach
2,000 lb (900 kg)
1,500 lb (681 kg)
1,800 lb (816 kg)
Lift height
36 ft 1 in (11.0 m)
42 ft 0 in (12.8 m)
42 ft 0 in (12.8 m)
Reach at maximum lift height
5 ft 5 in (1.65 m)
5 ft 11 in (1.80 m)
5 ft 11 in (1.80 m)
Maximum forward reach
23 ft 5 in (7.1 m)
27 ft 4 in (8.33 m)
27 ft 4 in (8.33 m)
33 ft 10 in (10.31 m)
-
-
Placing height
† Based on 24 in (610 mm) Load Center. See Load Charts.
9804/1103
20 - 00 - 02/19
8205/172
Issue 1
Loadalls
CONTENTS
20 - 00 - 02/20
526 (N. America) Static Dimensions and Weights
A H E F
D B
G A245130
DESCRIPTION
DIMENSION
A
Overall height
7 ft 81/2 in (2.38 m)
B
Overall width
7 ft 31/4 in (2.23 m)
C
Inside width of cab
2 ft 11 in (0.88 m)
D
Front track
5 ft 11 in (1.81 m)
E
Wheelbase
7 ft 7 in (2.33 m)
F
Overall length to front tires
12 ft 91/2 in (3.90 m)
G
Overall length to front of Q-Fit carriage
14 ft 10 in (4.52 m)
H
Ground clearance
1 ft 51/2 in (0.45 m)
Weight (unladen)
12877 lb (5840 kg)
Performance Dimensions Forklift Performance † Lift capacity to full height
5730 lb (2600 kg)
Lift capacity at full reach
2204 lb (1000 kg)
Lift height
18 ft 2 in (5.54 m)
Maximum forward reach
10 ft 0 in (3.05 m)
Placing height
15 ft 8 in (4.78 m)
† Based on 24 in (610 mm) Load Center.
9804/1103
20 - 00 - 02/20
8037/191 and 192
Issue 1
Loadalls
CONTENTS
20 - 00 - 02/21
528-70, 528S Static Dimensions and Weights
C
A H D B
E F G
A314940
DESCRIPTION
DIMENSION 528-70
DIMENSION 528S
A
Overall height
8 ft 11 in (2.46 m)
8 ft 11 in (2.46 m)
B
Overall width
7 ft 6 in (2.29 m)
7ft 7 in (2.31 m)
C
Inside width of cab
2 ft 11 in (0.88 m)
2 ft 11 in (0.88 m)
D
Front track
6 ft 2 in (1.88 m)
6 ft 2 in (1.88 m)
E
Wheelbase
8 ft 10 in (2.70 m)
8 ft 10 in (2.70 m)
F
Overall length to front tyres
14 ft 7 in (4.45 m)
14 ft 7 in (4.45 m)
G
Overall length to front of Q-Fit carriage
16 ft 11 in (5.15 m)
16 ft 11 in (5.15 m)
H
Ground clearance
1 ft 7 in (0.48 m)
1 ft 7 in (0.48 m)
Weight (unladen)
13800 lb (6260 kg)
14575 lb (6610 kg)
Turn radius over tyres (4WS)
11 ft 9 in (3.58 m)
TBA
9804/1103
20 - 00 - 02/21
8450/191
Issue 1
CONTENTS
Loadalls
20 - 00 - 02/22
528-70, 528S Performance Dimensions Forklift Performance †
528-70
528S
Lift capacity to full height
5292 lb (2400 kg)
5071 lb (2300 kg)
Lift capacity at full reach
2756 lb (1250 kg)
2756 lb (1250 kg)
Lift height
22 ft 2 in (6.75 m)
22 ft 2 in (6.75 m)
Maximum forward reach
12 ft 3 in (3.73 m)
12 ft 3 in (3.73 m)
Placing height
20 ft 0 in (6.1 m)
20 ft 0 in (6.1 m)
Note: Lift capacity to full height is reduced to 5071 lb (2300 kg) for 528S machines fitted with 17.5LR24 tyres.
† Based on 20 in (500 mm) Load Centre.
9804/1103
20 - 00 - 02/22
8450/192
Issue 1
CONTENTS
Loadalls
ALL MODELS
20 - 05 - 01/1
From m/c no. 567362
Data - Electrical System Type Battery Cold Crank amps for 1 minute to * 1.4 VPC at -18°C (0°F) * Reserve capacity (minutes) for 25 amp load * Alternator Starter Motor
12 volts, negative earth
410 to 585 170 to 230 Lucas A127-65, 65 amp maximum output Lucas M127/2.8
Light Bulbs Headlights main/dip Working lamps Front side lamps * Stop/tail lamps/reverse (if fitted) Indicator lamps Number plate lamp Fog lamp Interior lamp Panel/warning lamps Beacon
9804/1103
45W/40W or 60/55W (halogen) 55W (Halogen) 5W 21W/5W/21W 21W 10W 21W 18W 1.2W 55W (Halogen)
20 - 05 - 01/1
Issue 2*
Loadalls
CONTENTS
20 - 05 - 01/2
ALL MODELS
From m/c no. 567362
Data - Electrical The electrical circuits are protected by fuses. The fuses are located in a fuse box near the steering pedestal. They are in three rows, labelled A, B, and C. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one. Row A
Row B
Row C
Fuse Rating
Circuit
Rating
Fuse
Circuit
Rating
1
Starter relay
1
1
Reversing lights, panel warning light
5
2
Safe load indicator
1 2
3
Brake lock (USA)
5
4
Heater
15
5
Seat/parking brake warning (if fitted)
10
6
Horn
20
7
Indicators
7.5
8
Hazard warning lights 15
9
Engine shut-off solenoid (ESOS)
Forward/reverse switch, transmission dump switch (if fitted), manual gearbox 7.5 powershift gearbox 15
Fuse
Circuit
1
L.H. Main beam
7.5
2
R.H. main beam, main beam warning light
7.5
Cooling fan solenoid (if fitted)
15
Radio (if fitted)
1
3
4 3
Interior lights, roof wiper (if fitted) beacon (if fitted) or as above plus rear wiper
15
4
Brake lights
7.5
5
Steer circuit (without IP67) (with IP67)
5 7.5
Panel illumination, L.H. sidelights
7.5
5
6
7
10
R.H. sidelights, number plate light, one working light, or above but with two working lights
10
8
L.H. dipped beam
7.5
9
R.H. dipped beam
7.5
Note: The radio fuse may need to be replaced by one of a higher rating as specified in radio fitting instructions. 5
Servo control
10
6
Headlamp flasher (if fitted)
15
*9
Reverse alarm (powershift) 5
15
Note: Machines not fitted with road lights should not have fuses fitted at positions A7, A8, B8, B9, C1 and C2.
S112251
9804/1103
20 - 05 - 01/2
Issue 3*
Loadalls
CONTENTS
20 - 05 - 01/3
ALL MODELS
From m/c no. 567362
Data - Electrical Location The relays are located in front of the steering wheel, to gain access remove the panel. Non servo machines
Basic servo machines (525-58, 525- 67, 505-19 & 505-22)
A F
A F E
B
E
C
J
D
G
D
B C
S167142
S167140
A B C D E F
Steer mode PCB relay Reverse alarm relay Buzzer relay Flasher relay Sidelights relay Hand brake warning relay
A B C D E F G
Steer mode PCB relay Reverse alarm relay Buzzer relay Flasher relay Sidelights relay Hand brake warning relay Servo controls relay
Servo/Remote machines (530-110, 530-120)
A E J
H D
B
FC G A B C D E F G H J
S167142
Steer mode PCB relay Reverse alarm relay Flasher relay Sidelights relay Hand brake warning relay Stop relay Servo remote controls relay Buzzer isolation relay Buzzer relay
9804/1103
20 - 05 - 01/3
Issue 1
Loadalls
CONTENTS
20 - 05 - 01/4
ALL MODELS
From m/c no. 567362
Data - Electrical Machines with IP67 electrics
Machines with transmission dump relay
(All except 530-120 up to serial No. 572168, 530-120 up to serial No. 572242)
(All except 530-120 from serial No. 572169, 530-120 from serial No. 572243)
L
K L
N
M E H D
D
F
C
F
C
H
E
J
J
K
G
B
B G
A
A
S172170
A B C D E F G H J K L
Steer mode printed circuit board Reverse alarm relay Buzzer relay Forward relay Flasher relay Sidelights relay Hand brake warning relay Ignition relay Parking brake relay Neutral start relay Reverse relay
9804/1103
S215940
A B C D E F G H J K L M N
20 - 05 - 01/4
Steer mode printed circuit board Reverse alarm relay Buzzer relay Forward relay Flasher relay Sidelights relay Hand brake warning relay Ignition relay 4 Wheel drive/brake relay Neutral start relay Reverse relay Transmission dump relay Diode gate
Issue 2
Loadalls
CONTENTS
ALL MODELS
20 - 05 - 01/5
From m/c no. 567362
Data - Electrical Machines with Powershift option
P N M J
D C
K
H
E
R
F G
Q S
B
A
S215930
A B C D E F G H J K M N P Q R S
Steer mode printed circuit board Reverse alarm relay Buzzer relay Forward relay Flasher relay Sidelights relay Hand brake warning relay Ignition relay 4 Wheel drive/brake relay Neutral start relay Transmission dump relay Diode gate Reverse high/low relay Forward high/low relay Drvieshaft relay Neutral drive relay
9804/1103
20 - 05 - 01/5
Issue 2
Loadalls
CONTENTS
* 520-55,
20 - 05 - 01/6
520S, 520-55 RS (504B N. Am), 526-55, 526, 526S (526 N. Am)
From m/c no. 277001
Data - Electrical * Fuse Identification
The electrical circuits are protected by fuses. The fuses are located in a fuse box inside the door. They are in three rows, labelled A, B and C. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one. Note: The radio fuse may need to be replaced by one of a higher rating as specified in radio fitting instructions.
520-55, 526-55, 520-55RS (504B N.Am) From Machine Serial Number 277001 to 278965 (279014 504B) Row A Fuse 1 2 3 4 5 6 7 8 9
Row B
Circuit Rating Starter relay 1 Safe load indicator 1 Diverter valve relay 5 Heater 15 Spare Horn, Front wiper, Washer pump 15 Indicators 7.5 Hazard warning lights 10 Engine shut-off solenoid (ESOS) 5
Fuse 1 2 3 4 5 6 7
8 9
Row C
Circuit Rating Reversing lights, panel warning light 7.5 Forward/reverse switch, transmission dump relay 5 Interior lights, beacon (if fitted) 10 Brake lights 7.5 Spare Panel illumination, L.H. sidelights 7.5 R.H. sidelights, number plate light, working light 15 L.H. dipped beam 7.5 R.H. dipped beam 7.5
Fuse 1 2 3 4 5
Circuit L.H. Main beam R.H. main beam, main beam warning light Headlamp flash Radio (if fitted) Face level fan or air conditioning
Rating 7.5 7.5 15 1 10 15
526, 526S (526 N.Am) With Powershift Transmission From Machine Serial Number 278966 to 280576 526, 526S (526 N.Am) With Syncro Shuttle Transmission From Machine Serial Number 278966 to 280573 520-55, 520S From Machine Serial Number 278966 Onwards Fuse 1 2 3 4 5 6 7 8 9 +
Row A Circuit
Rating
Fuse
Starter relay 1 Engine shut off solenoid (ESOS) 5 Spare Forward/reverse switch 15 (10)+ Transmission ECU (if fitted) 7.5 Reverse alarm 10 Spare Spare Diverter valve 10
1 2 3 4 5 6 7 8 9
Row B Circuit Safe load indicator (SLI) Horn, Headlamp flasher Heater/Air conditioning fan (if fitted) Face fan, Air conditioning compressor (if fitted) Wipers, Washers Beacon, Interior light Radio Instrument panel Spare
Rating
Fuse
1 10
1
15 15 15 7.5 5 5
2 3 4 5 6 7 8 9
Row C Circuit R.H. Side lights, Working lights L.H. Side lights Dip beam Main beam Brake lights Hazard warning lights Indicators Spare Spare
Rating 15 7.5 10 10 10 15 10
Machines with syncro shuttle transmission.
Fuse links
1 2 3 4 5
Circuit Rating Horn, Hazard warning lights, Beacon, Interior light 40 Road lights, Working lights 40 Not used ESOS, Forward/reverse switch, Brake lights 40 Diverter valve, SLI, Heater, Wipers, Radio, Instruments 80
4 5
2
1
3 S245110
9804/1103
20 - 05 - 01/6
S192451 3610-C/1-4.2
Issue 4*
Loadalls
CONTENTS
* 520-55,
20 - 05 - 01/7
520-55 RS (504B N. Am), 526-55, 526, 526S (526 N. Am)
From m/c no. 277001
Data - Electrical * Relay Identification
520-55, 526-55, 520-55RS (504B N.Am) From Machine Serial Number 277001 to 278965 (279014 504B) 1 2 3
Indicator relay Forward relay Reverse relay
4 5 6
Side lights relay Parking brake relay Dump switch relay
7 8 9
Buzzer relay Reverse alarm relay Auxiliary solenoid relay
10 Brake light relay 12/13 Starter relay 11/14 Neutral start relay
Note: Relays 13 and 14 can be fitted either way round, to identify them the Neutral Relay has an ‘I’ on it. On later machines relay 13 is on the main board 12 and diode 15 is fitted in its place. Diode 15 links the handbrake warning light and transmission dump to disconnect the drive when the handbrake is applied. Also, relay 14 is on the main board 12.
520-55, 520S, 526-55 From Machine Serial Number 278966 (279015 504B) onwards 1 2 3
Indicator relay Forward relay Reverse alarm relay
4 5 6
Side lights relay Parking brake relay Dump switch relay
7 8 9
Buzzer relay Spare Spare
10 Air conditioning relay 11 Neutral start relay 12 Starter relay
526, 526S (526 N.Am) From Machine Serial Number 280300 to 280576 (Powershift Transmission) 1 2 3
Indicator relay Spare Reverse relay
4 5 6
Side lights relay Spare Spare
7 8 9
Buzzer relay Spare Auxiliary solenoid relay
10 Air conditioning relay 11 Neutral start relay 12 Starter relay
526, 526S (526 N.Am) From Machine Serial Number 280300 to 280573 (Syncro Shuttle Transmission) 1 2 3
Indicator relay Forward relay Reverse alarm relay
4 5 6
Side lights relay Parking brake relay Dump switch relay
7 8 9
Buzzer relay Spare Auxiliary solenoid relays
10 Air conditioning relay 11 Neutral start relay 12 Starter relay
% 3
2
1
6
5
4
7 0
8 !
9
£
$
@
S192450
9804/1103
20 - 05 - 01/7
3610 - C/1-2.6
Issue 3*
Loadalls
CONTENTS
* 520-50,
20 - 05 - 01/8
525-50, 525-52
From m/c no. 754000
Data - Electrical Battery Cold Crank amps for 1 minute to 1.4 VPC at -18°C (0°F) Reserve capacity (minutes) for 25 amp load
12 volts, negative earth
Alternator Starter Motor Light Bulbs Headlights main/dip Working lamps Front side lamps Stop/tail lamps/reverse Indicator lamps Number plate lamp Fog lamp Interior lamp Panel/warning lamps Beacon
Lucas A127-65, 65 amp maximum output Lucas M127/2.8
410 to 58 170 to 230
45W/40W or 60/55W (halogen) 55W (Halogen) 5W 21W/5W/21W 21W 10W 21W 18W 1.2W 55W (Halogen)
Relay Identification Relays are used in the electrical circuits for a variety of reasons. The most usual application is to protect components like switches etc. from being overloaded. A relatively small current (from the switch) energises the relay coil, this causes internal contacts to open or close which controls a larger current in another circuit. Although relays look similar, internally they can be different, for example, they can be single or double contact; normally closed or open. Make sure you fit the correct type of relay, otherwise the machine electrical circuits will not function correctly. The relays are identified as follows: 1 2 3 4
Work light Parking brake light Park brake Transmission dump
5 6 7 8
Buzzer Neutral start Reverse Forward
9 10 11 12
Flasher Ignition 1 Ignition 2 Lights
1
2
3
4
5
6
7
8
9
0
!
@
S239200
9804/1103
20 - 05 - 01/8
3620-C/1-1.1
Issue 2*
Loadalls
CONTENTS
* 520-50,
20 - 05 - 01/9
525-50, 525-52
From m/c no. 754000
Data - Electrical Fuse Identification The electrical circuits are protected by fuses. The fuses are located in a fuse box inside the door. They are in three rows, labelled A, B and C. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one. Row A Fuse Circuit Rating Rating 1 Brake lights 5 2 Panel warning lights, Warning buzzer, Instrument lights 5 3 L.H. sidelights L.H. number plate light, L.H. trailer light (if fitted) 5 4 R.H. sidelights, R.H. number plate light, R.H. trailer light (if fitted) 5 5 Roof wiper, rear wash/wipe switch 5 6 Hazard warning lights 10 7 Face level fan (if fitted), beacon switch 10 8 Radio (if fitted) 5 9 Front wash/wipe switch, horn switch, headlight flasher 10
Row B Fuse
Circuit
1
Junction box (if fitted) Engine shut-off solenoid (ESOS) L.H. dipped beam R.H. dipped beam L.H. main beam R.H. main beam Working lights - Opt Working lights - Std Indicators Parking brake circuit Heater Spare
2 3 4 5 6 7 8 9
Row C Rating
Fuse Circuit
15
1 2 3
5 10 10 15 10 5 5 15
4 5 6 7 8 9
Spare Safe load indicator Forward/reverse switch, transmission dump relay Spare Thermostart Spare Spare Spare Spare
5 5 10 15
Note: The radio fuse may need to be replaced by one of a higher rating as specified in radio fitting instructions. Fuse links
1 2 3 4 5
Circuit
Rating
Starter relay Tracker, Radio, Hazard lights, Wipers Lights relay Starter switch Not used
60 30 40 30 80
3 5
1 2 4 S245110
S239200
9804/1103
20 - 05 - 01/9
3620-C/1-2.2
Issue 2*
Loadalls
CONTENTS
* 520-55,
20 - 05 - 01/10
526-55, 526, 526S (526N.Am)
* From m/c no. 279000 to 280299
Data - Electrical Relay Identification Relays are used in the electrical circuits for a variety of reasons. The most usual application is to protect components like switches etc. from being overloaded. A relatively small current (from the switch) energises the relay coil, this causes internal contacts to open or close which controls a larger current in another circuit. Although relays look similar, internally they can be different, for example, they can be single or double contact; normally closed or open. Make sure you fit the correct type of relay, otherwise the machine electrical circuits will not function correctly. The relays are identified as follows:
From Machine Serial Number 279000 to 280299 (Powershift Transmission) 1 2 3
Indicator relay Spare Reverse relay
4 5 6
Side lights relay Spare Spare
7 8 9
Buzzer relay Spare Auxiliary solenoid relay
10 Air conditioning relay 11 Neutral start relay 12 Starter relay
From Machine Serial Number 279000 to 280299 (Syncro Shuttle Transmission) 1 2 3
Indicator relay Forward relay Reverse alarm relay
4 5 6
Side lights relay Parking brake relay Dump switch relay
7 8 9
Buzzer relay Spare Auxiliary solenoid relays
10 Air conditioning relay 11 Neutral start relay 12 Starter relay
% 3
2
1
6
5
4
7 0
8 !
9
£
$
@
S192450
9804/1103
20 - 05 - 01/10
Issue 2*
Loadalls
CONTENTS
* 526,
20 - 05 - 01/11
526S (526 N.Am)
Data - Electrical (cont’d) Relay Identification (cont’d) * 526, 526S (526 N.Am) - Powershift Transmission * From M/c Serial No 280577 Onwards
* 526, 526S (526 N.Am) - Syncro Shuttle Transmission * From M/c Serial No 280574 Onwards
The relay configuration for machines with powershift transmission is shown at A.
The relay configuration for machines with syncro shuttle transmission is shown at B.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12
Buzzer relay Neutral start relay Starter relay Side lights relay Parking brake relay Auxiliary solenoid relay Air conditioning relay Reverse alarm/light relay Dump switch relay Reverse high/low relay Forward high/low relay Drive shaft relay Reverse relay Forward relay Drive relay Hazard warning light relay
Buzzer relay Neutral start relay Starter relay Side lights relay Parking brake relay Auxiliary solenoid relay Air conditioning relay Spare Dump switch relay Hazard warning light relay Reverse relay Forward relay
B 1
4 7
2
58
3
6 9 ! @
0
A 1
4 7 0 £
2
5 8 ! $
3
6 9 @ %
^
A282130
9804/1103
20 - 05 - 01/11
*
3610-C/1-3.3
Issue 2*
Loadalls
CONTENTS
* 520-55,
20 - 05 - 01/12
526-55, 526, 526S (526 N.Am)
From m/c no. 279000 to 280299
Data - Electrical (cont’d) Fuse Identification The electrical circuits are protected by fuses. The fuses are located in a fuse box inside the door. They are in three rows, labelled A, B and C. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one. Note: The radio fuse may need to be replaced by one of a higher rating as specified in radio fitting instructions.
Fuse 1 2 3 4 5 6 7 8 9 +
Row A Circuit
Rating
Fuse
Starter relay 1 Engine shut off solenoid (ESOS) 5 Spare Forward/reverse switch 15 (10)+ Transmission ECU (if fitted) 7.5 Reverse alarm 10 Spare Spare Diverter valve 10
1 2 3 4 5 6 7 8 9
Row B Circuit Safe load indicator (SLI) Horn, Headlamp flasher Heater/Air conditioning fan (if fitted) Face fan, Air conditioning compressor (if fitted) Wipers, Washers Beacon, Interior light Radio Instrument panel Spare
Rating
Fuse
1 10
1
15 15 15 7.5 5 5
2 3 4 5 6 7 8 9
Row C Circuit R.H. Side lights, Working lights L.H. Side lights Dip beam Main beam Brake lights Hazard warning lights Indicators Spare Spare
Rating 15 7.5 10 10 10 15 10
Machines with syncro shuttle transmission.
Fuse links 1 2 3 4 5
Circuit Rating Horn, Hazard warning lights, Beacon, Interior light 40 Road lights, Working lights 40 Not used ESOS, Forward/reverse switch, Brake lights 40 Diverter valve, SLI, Heater, Wipers, Radio, Instruments 80
4 5
2
1
3 S245110 S192451
9804/1103
20 - 05 - 01/1
Issue 2*
Loadalls
CONTENTS
*
20 - 05 - 01/13
526, 526S (526 N.Am) Data - Electrical Fuse Identification The electrical circuits are protected by fuses. The fuses are located in a fuse box, as shown. If a fuse blows, find out why before fitting a new one. Additional fuse links are fitted at the battery positive terminal. Note: The radio fuse may have a higher rating, depending on the type of radio fitted. Check radio fitting instructions.
*
From M/c Serial No 280577 (Powershift), 280574 (Syncro Shuttle). Fuse 1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Circuit Rating Flasher Relay 7.5 Face fan, air conditioning compressor (if fitted) 10 Diverter valve 10 Heater/air conditioning fan (if fitted) 15 Wipers, Washers 15 Safe load indicator (SLI) 1 Instrument panel 5 Spare Spare Spare Starter Relay 1 Engine shut off solenoid (ESOS) 5 Forward/reverse Switch (Powershift transmission) 15 (Syncro Shuttle transmission) 10 Joystick control (if fitted) 7.5 Spare Brake lights 10 Reverse alarm/light 5 Spare Spare Spare Right hand side lights/work lights 15 Left hand side lights 5 Dip beam 10 Main beam 10 Spare Spare Head lamp flash or horn 15 Beacon, interior light 7.5 Radio 5 Hazard warning lights 15
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 A282120
Fuse Links Fuse Circuit 1 Headlight flash, horn, beacon, interior light, hazards, radio 2 Roadlights, worklights 3 Indicators, face fan, Air conditioning compressor clutch (if fitted), hydraulic hitch, changeover valve, heater/Air conditioning fan, wash/wipers, safe load indicator, instruments 4 Starter, ESOS, transmission, brake lights, safe load indicator, reverse alarm/lights, thermostart 5 Not used 9804/1103
4
Rating 40 40
5
2
1 3
40
40 80
20 - 05 - 01/1
*
3610-C/1-5.2
Issue 2*
CONTENTS
* 530,
535, 540
* Data
- Electrical
Loadalls
20 - 05 - 01/14
*From m/c no. 767001
Relay Identification Relays are used in the electrical circuits for a variety of reasons. The most usual application is to protect components like switches etc. from being overloaded. A relatively small current (from the switch) energises the relay coil, this causes internal contacts to open or close which controls a larger current in another circuit. Although relays look similar, internally they can be different, for example, they can be single or double contact; normally closed or open. Make sure you fit the correct type of relay, otherwise the machine electrical circuits will not function correctly. The relays are identified as follows
1
530 only (from S/N 767001 to S/N 768836) (Without Neutral Start) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Audible alarm Reverse lights Starter Hazard warning lights Side lights Air conditioning Sway isolation Auxiliary change-over Auxiliary A Auxiliary B Retract Extend 2 Wheel drive brake -
4
90
2
56 !@ %^
3
78 £$ &*
530 only (from S/N 768837 to S/N 770053) (With Neutral Start) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Audible alarm Neutral start Starter Hazard warning lights Side lights Air conditioning Sway isolation Auxiliary change-over Auxiliary A Auxiliary B Retract Extend Reverse 2 Wheel drive brake -
9804/1103
A335670
NOTE: ECU deletion cut-in numbers are transmission dependant. Transmission Part Number
Serial Number of cut-in
449/06100 449/06200 449/06300 449/06400 449/06500 449/06600
770055 770065 770053 770069 770063 770093
20 - 05 - 01/14
3630 - C/1-2.4
Issue 2*
CONTENTS
Loadalls
530, 535, 540 Data - Electrical Relay Identification (cont’d) 530, 540 Fitted with smooth Ride System (SRS)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1
7
18 19
3
10 11
20 21
4
12 13
22 23
5
14 15
24 25
8
6
From m/c no. 767001
Audible alarm Neutral start IGN Feed 1 IGN Feed 2 Dump Parkbrake Hazard warning lights Sidelights Air conditioning Forward relay Reverse 1 Reverse 2 2 wheel drive brake Auxiliary change-over Sway isolation Forward HI/LO Reverse HI/LO Drive Driveshaft Neutral Dump SRS relay
16 17
9
2
20 - 05 - 01/14A
A335680
9804/1103
20 - 05 - 01/14A
3630 - 3/1-5.2
Issue 1
CONTENTS
Loadalls
20 - 05 - 01/14B
530, 535, 540 From m/c no. 767001 Data - Electrical Relay Identification (cont’d) 530 FS Super, 540 FS Super Machines with Five Speed Powershift Transmission 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Audible alarm Neutral start IGN Feed 1 IGN Feed 2 Hazard warning lights Sidelights Air conditioning Auxiliary change-over Sway isolation Reverse 2 Two wheel drive brake relay Neutral relay Dump relay Smooth Ride System SRS relay -
1
5
2
6
7
12 13
3
8
9
14 15
4
10 11
16 17 A372461
9804/1103
20 - 05 - 01/14B
3630 - 3/1-6.2
Issue 1
Loadalls
CONTENTS
20 - 05 - 01/15
530, 535, 540
From m/c no. 767001
Data - Electrical (cont’d) * Relay
Identification (continued) * 530 only (from S/N 770054 to S/N 770958) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1 1
7 7
Audible alarm Neutral start IGN Feed 1 IGN Feed 2 Dump Parkbrake Hazard warning lights Sidelights Air conditioning Auxiliary change-over 2 Auxiliary change-over Forward relay Reverse 1 Reverse 2 2 wheel drive brake Auxiliary A Auxiliary B Retract Extend Forward HI/LO Reverse HI/LO Drive Driveshaft
16 & 17 ^
2 2
18 ( 19 8 9 9 8 *
3 3
21 10 ! 11 ) 20 21 0
4 4
23 22 23 12 £ 13 22 @
5 6 6 14 % 15 24 24 25 5 $ A335680
9804/1103
20 - 05 - 01/15
3630 - C/1-3.4
Issue 3*
CONTENTS
Loadalls
20 - 05 - 01/15A
530, 535, 540
From m/c no. 767001
Data - Electrical (cont’d) Relay Identification (continued) 530/540 (from S/N 770959 onwards) 535 (from S/N 777362 onwards) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Audible alarm Neutral start IGN Feed 1 IGN Feed 2 Dump Parkbrake Hazard warning lights Sidelights Air conditioning Forward relay Reverse 1 Reverse 2 Two wheel drive brake relay Auxiliary change-over Sway isolation Forward HI/LO Reverse HI/LO Drive Driveshaft
1
7
2
4
5
9
14 15
10 11
16 17
12 13
18 19
8
3
6
360940
9804/1103
20 - 05 - 01/15A
3630 - C/1-4.4
Issue 1
CONTENTS
Loadalls
20 - 05 - 01/16
530, 535, 540
From m/c no. 767001
Data - Electrical (cont’d) Fuse Identification This illustration shows a typical fuse installation. The electrical circuits are protected by fuses. The fuses are located in a fuse box, as shown. If a fuse blows, find out why before fitting a new one. Additional fuse links are fitted at the battery positive terminal. 1 2 3 4 5 6 7 8 9 10
Note: The radio fuse may have a higher rating, depending on the type of radio fitted. Check radio fitting instructions.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Circuit Boom isolator Joystick controls Safe Load Indicator (SLI)/Load Moment Indicator (LMI) Heater Air conditioning, face fan Wipers Clock, radio, heater seat Instrument panel Direction Indicators Auxiliary hydraulics
Rating 7.5 10 5 15 15 15 5 7.5 10 7.5
16 17 18 19 20
Starter relay 5 Engine shut-off solenoid (ESOS) 5 Steer mode selector 7.5 Powershift 15 2/4 Wheel drive selector 5 2/4 Wheel drive selector with trailer electrics (530) 10 Auxiliary socket 10 Brake lights 10 Rear work light 7.5 Reverse lights, reverse alarm 7.5 BLANK
21 22 23 24 25 26 27 28 29 30
Right hand side lights Left hand side lights Dip beam lights Main beam lights Front working light Rear fog light BLANK Horn, Headlight flash Warning beacon, Interior light, Radio Hazard lights
31 32 33 34 35 36 37 38 39 40
Smooth Ride System (if fitted) SPARE SPARE Air suspension seat (if fitted) SPARE BLANK BLANK BLANK BLANK BLANK
9804/1103
10 10 10 10 10 5 10 5 15 5
15
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
A348080
B A D E
C S245111
Fuse Links S/N 767000 to 770053
A B C D E
Circuit Horn, Hazard warning lights, Beacon, Interior light Road lights, Working lights Not used ESOS, Forward/reverse switch, Brake lights SLI, Heater, Wipers, Radio, Instruments
Rating 30 30 40 80
Fuse Links S/N 770054 onwards
B C D
Circuit Horn, Hazard warning lights, Beacon, Interior light Road lights, Working lights SLI, Heater, Wipers, Radio, Instruments ESOS, Forward/reverse switch, Brake lights
E
Not used
A
20 - 05 - 01/16
Rating 40 40 40 40 80
3630 - C/1-5.1 3630 - C/1-6.1
Issue 3*
CONTENTS
*
532, 537, 550 Data - Electrical (cont’d)
*
Relay Identification
Loadalls
20 - 05 - 01/17
*From m/c no. 767001
Relays are used in the electrical circuits for a variety of reasons. The most usual application is to protect components like switches etc. from being overloaded. A relatively small current (from the switch) energises the relay coil, this causes internal contacts to open or close which controls a larger current in another circuit. Although relays look similar, internally they can be different, for example, they can be single or double contact; normally closed or open. Make sure you fit the correct type of relay, otherwise the machine electrical circuits will not function correctly. The relays are identified as follows
532/537 (from S/N 767001 to S/N 768956) (Without Neutral Start) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Audible alarm Reverse lights and alarm Starter Hazard warning lights Side lights Air conditioning Sway isolation Stabiliser isolation Auxiliary A Auxiliary B 2 Wheel drive brake -
532/537 (from S/N 768957 to S/N 770063) (With Neutral Start) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Audible alarm Neutral start Starter Hazard warning lights Side lights Air conditioning Sway isolation Stabiliser isolation Auxiliary A Auxiliary B Reverse 2 Wheel drive brake -
9804/1103
Note: ECU deletion cut-in numbers are transmission dependant.
20 - 05 - 01/17
Transmission Part Number
Serial Number of cut-in
449/06100 449/06200 449/06300 449/06400 449/06500 449/06600
770055 770065 770053 770069 770063 770093
3660 - C/1-2.1
Issue 2*
Loadalls
CONTENTS
*
532, 537, 550, 5508 Data - Electrical (cont’d)
20 - 05 - 01/18
From m/c no. 767001
Relay Identification (cont’d) 532/537 (from S/N 770064 to S/N 770958) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1 1
7 7
Audible alarm Neutral start IGN Feed 1 IGN Feed 2 Dump Parkbrake Hazard warning lights Sidelights Air conditioning Sway isolation Stabilizer isolation Forward relay Reverse 1 Reverse 2 2 wheel drive brake Auxiliary A Auxiliary B Auxiliary change-over 2 Forward HI/LO Reverse HI/LO Drive Driveshaft -
16 & 17 ^
2 2
18 ( 19 8 9 9 8 *
3 3
10 ! 11 ) 20 ( 21 0
4 4
22 23 23 22 12 £ 13 @
Note: ECU cut-in numbers are transmission dependent (see page 20 - 05 - 01/17 for transmission details).
25 5 6 6 14 % 15 24 25 5 $ A343330
9804/1103
20 - 05 - 01/18
3660 - C/1-3.2
Issue 3*
CONTENTS
Loadalls
20 - 05 - 01/18A
532, 537, 540-170, 550, 5508 Data - Electrical (cont’d)
From m/c no. 767001
Relay Identification (cont’d) 532/537/550 (from S/N 770959 onwards) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
1
7
2
4
5
9
14 15
10 11
16 17
12 13
18 19
8
3
6
Audible alarm Neutral start IGN Feed 1 IGN Feed 2 Dump Parkbrake Hazard warning lights Sidelights Air conditioning Sway isolation Stabilizer isolation Forward relay Reverse 1 Reverse 2 2 wheel drive brake Forward HI/LO Drive Reverse HI/LO EMPTY
A361560
* 532/537/550 (from S/N 770959 onwards)
5
1
7
2
8 9
3
10 11
16 17
4
12 13
18 19
14 15
20 21
6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Audible alarm Neutral start IGN Feed 1 IGN Feed 2 Dump Parkbrake Hazard warning lights Sidelights Air conditioning Sway isolation Stabilizer isolation Forward Reverse Reverse alarm/light 2 wheel drive/brakelights EMPTY Pump dump Forward HI/LO Reverse HI/LO Drive Driveshaft
A361561
9804/1103
20 - 05 - 01/18A
3660 - C/1-4.3
Issue 2*
Loadalls
CONTENTS
20 - 05 - 01/18B
532, 537, 540-170, 550, 5508 Data - Electrical (cont’d)
From m/c no. 767001
Relay Identification (cont’d) 532/537/550 (from S/N 770959 onwards) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1
5
7
16 17
2
8 9
18 19
3
10 11
20 21
4
12 13
22 23
14 15
24 25
6
* 540-170/5508 Machines from S/N 1004131
A361140
9804/1103
Audible alarm Neutral start IGN Feed 1 IGN Feed 2 Dump Parkbrake Hazard warning lights Sidelights Air conditioning Sway isolation Stabilizer isolation Forward relay Reverse 1 Reverse Alarm/light 2 wheel drive/brake lights Forward HI/LO Reverse HI/LO Drive relay Driveshaft relay EMPTY EMPTY Inner boom extend interlock (if fitted) Lift isolation Stabiliser lift unloader Inner boom extend
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
20 - 05 - 01/18B
Audible alarm Neutral start IGN Feed 1 IGN Feed 2 Dump Parkbrake Hazard warning lights Sidelights Air conditioning Sway isolation Stabiliser isolation Forward relay Reverse 1 Reverse alarm/light 2 wheel drive/brake lights Left stabiliser Right stabiliser Forward HI/LO Reverse HI/LO Drive relay Driveshaft relay Extension boost Lift isolation Stabiliser lift unloader Inner boom extend
3660 - C/1-5.4
Issue 2*
CONTENTS
* 532,
Loadalls
20 - 05 - 01/19
537, 540-170, 550, 5508
From m/c no. 767001
Data - Electrical (cont’d) Fuse Identification This illustration shows a typical fuse installation. The electrical circuits are protected by fuses. The fuses are located in a fuse box, as shown. If a fuse blows, find out why before fitting a new one. Additional fuse links are fitted at the battery positive terminal. Note: The radio fuse may have a higher rating, depending on the type of radio fitted. Check radio fitting instructions.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Circuit Boom isolator BLANK Auxiliary controls (up to 775402 only) Load Moment Indicator (LMI) Heater Air conditioning, face fan Wipers Radio, clock & heated seat Instrument panel Direction Indicators EMPTY
Rating 7.5 10 5 15 15 15 5 7.5 10
5 5 7.5 15
18 19 20
Starter relay & road light switch illumination Engine shut-off solenoid (ESOS) Steer mode selector Powershift 2/4 Wheel drive selector, or Brake lights (540-170/5508 only) 2/4 Wheel drive with trailer electrics (if fitted) Auxiliary socket Brake lights 2-Wheel drive relay coil (540-170/5508 only) Rear work light Reverse lights & Reverse Alarm EMPTY
21 22 23 24 25 26 27 28 29 30
Right hand side light Left hand side light Dip beam lights Main beam lights Front working light Rear fog light EMPTY Horn, Headlight flash Warning beacon, Interior light Hazard lights
10 10 10 10 10 5
16 17
31 32 33 34 35 36 37 38 39 40
Hydraulics (540-170/5508 only) Boom work light (540-170/5508 only) SPARE Air Suspension Seat (if fitted) SPARE EMPTY EMPTY EMPTY EMPTY EMPTY
9804/1103
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
5 10 10 10 10 7.5 7.5
31 32 33 34 35 36 37 38 39 40
B A D E
C S245111
Fuse Links S/N 768700 to 770053
10 5 15
A
15 5
B C D E
Circuit Horn, Hazard warning lights, Beacon, Interior light Road lights, Working lights Not used ESOS, Forward/reverse switch, Brake lights SLI, Heater, Wipers, Radio, Instruments
Rating 30 30 40 80
15 Fuse Links S/N 770054 onwards
A B C D E
Circuit Horn, Hazard warning lights, Beacon, Interior light Road lights, Working lights SLI, Heater, Wipers, Radio, Instruments ESOS, Forward/reverse switch, Brake lights Not used
20 - 05 - 01/19
3660 - C/1-6.2 3660 - C/1-7.1
Rating 40 40 40 40 80 Issue 3*
*
Loadalls
CONTENTS
20 - 05 - 01/20
528-70 Data - Electrical (cont’d) Syncro Shuttle Transmission
From m/c no. 796000
Fuse Identification Circuit
Relay Identification Rating
1 2 3 4 5 6 7 8 9 10
Indicators 7.5 Face level fan 7.5 Auxiliary 2 5 Heater 15 Blank Windscreen washer & wipers 15 Safe Load Indicator/Load Moment Indicator 1 Instrument panel 5 Blank Thermo-start 20
11 12 13 14 15 16 17 18 19 20
Ignition relays & road lights switch illumination 1 Engine shut-off solenoid (ESOS) 5 Transmission 10 Brake lights 7.5 Blank Blank Reverse alarm & reverse lights 5 Main lights 15 Front worklight relay 15 Rear worklight relay 10
21 22 23 24 25 26 27 28 29 30
Right hand side lights & illumination Left hand side lights Dip beam Main beam Rear fog light Side lights (all) Headlight flash & horn Warning beacon & interior light Radio Hazard warning lights
A B C D E F G H J K L M
5 5 10 10 5 7.5 15 7.5 5 15
Buzzer Neutral start Ignition Sidelights Park brake Rear work light Spare Front work light Transmission dump Flasher Forward Reverse
A
D G
B
E H
K
C
F J
L M
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 321000
9804/1103
20 - 05 - 01/20
3650 - C/1-2.2
Issue 1
Loadalls
CONTENTS
20 - 05 - 01/21
528S Data - Electrical (cont’d) Fuse Identification Circuit 1 2 3 4 5 6 7 8 9 10 11 12 13
From m/c no. 796102
Rating
Indicators 7.5 Face level fan Air conditioning compressor (if fitted) 10 Auxiliary 2 Hitch hydraulics (if fitted) 10 Heater 15 Windscreen washers & wipers 15 Safe Load Indicator/Load Moment Indicator 1 Instrument panel 5 Spare Spare Spare
14 15 16 17 18 19 20
Ignition relays & road lights switch illumination 1 Engine shut-off solenoid (ESOS) 5 Transmission (Syncro Shuttle) 10 Transmission (Powershift) 15 Single lever control (if fitted) 7.5 Rear worklight 15 Brake lights 10 Reverse alarm & reverse lights 5 Spare Spare Spare
21 22 23 24 25 26 27 28 29 30
Right hand side lights & illumination Left hand side lights Dip beam Main beam Rear fog light Spare Headlight flash & horn Warning beacon & interior light Radio Hazard warning lights
15 5 10 10 5
A
D G
B
E H
K
C
F J
L M
1 2 3 4 5 6 7 8 9 10
15 7.5 5 15
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 321000
9804/1103
20 - 05 - 01/21
3650 - C/1-3.2
Issue 1
Loadalls
CONTENTS
20 - 05 - 01/22
528S Data - Electrical (cont’d) Relay Identification Power Shift Transmision
From m/c no. 796102
Syncro Shuttle Transmission
The relay configuration for machines with Powershift Transmission is shown at A.
The relay configuration for machines with Syncroshuttle Transmission is shown at B.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12
Buzzer Neutral star Ignition Side lights Parking brake Auxiliary 2 change over Air conditioning Reverse alarm & light Dump switch Reverse high/low Forward high/low Drive Reverse Forward Driveshaft Flasher
Buzzer Neutral start Ignition Side lights Parking brake Auxiliary 2 change over Air conditioning Spare Transmission dump Flasher Forward Reverse
B 1
4 7
2
5 8
3
6 9 ! @
0
A
9804/1103
1
4 7 0 £
2
5 8 ! $
3
6 9 @ %
^
A282130
20 - 15 - 01/22
3650 - C/1-4.1
Issue 1
Loadalls
CONTENTS
528-70, 528S Data - Electrical (cont’d) Fuse Links Circuit 1 2 3 4 5
20 - 05 - 01/23
From m/c no. 796000
Rating
Horn, Hazard warning lights, Beacon, Interior light, Radio, Headlight flash Road lights, Working lights Direction indicators, Face fan, SLI, Instruments, Wipers, Air conditioning compressor Starter, ESOS, Transmission, Brake lights, Reverse Alarm and lights, Thermostart Not Used
40 40 40 40
4 5
2
1
3
S245110
A308110
9804/1103
20 - 15 - 01/23
3650 - C/1-5.1
Issue 1
*
Loadalls
CONTENTS
20 - 05 - 01/24
506B, 506C, 506C(HL), 508C Data - Electrical Relay Identification All Machines with Syncro Shuttle Transmission Location The relays are located in front of the steering wheel, remove the panel to gain access. A B C D E F G H
A
Steer mode PCB relay Forward relay Reverse relay Transmission dump relay Parkbrake warning Neutral start relay Buzzer Ignition Relay (506C & 508C only - not shown)
B G
H C D
F
E
S167142
506C And 508C Machines with Powershift Transmission A B C D E F G H J K M N P Q R S
Steer mode printed circuit board Reverse alarm relay Buzzer relay Forward relay Flasher relay Sidelights relay Hand brake warning relay Ignition relay 4 Wheel drive/brake relay Neutral start relay Transmission dump relay Diode gate Reverse high/low relay Forward high/low relay Driveshaft relay Neutral drive relay
Early Machines
R
Q
Later Machines
P
P
R
D
B
H
Q
X
C
M
B
M
G
K
G
D
C
K 328820
THE FOLLOWING RELAYS ARE NOT LOCATED: FLASHER SIDELIGHTS 4 WHEEL DRIVE/BRAKE NEUTRAL DRIVE DIODE GATE
9804/1103
20 - 05 - 01/24
3640U - C/1-1.2
Issue 1
CONTENTS
Loadalls
20 - 05 - 01/25
506B, 506C, 506(HL), 508C Data - Electrical Fuse Identification This illustration shows a typical fuse installation. The electrical circuits are protected by fuses. The fuses are located in a fuse box near the steering pedestal. They are in three rows labelled A, B and C. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one. Additional fuse links are fitted at the battery positive terminal. ROW A
1 2 3 4 5 6 7 8 9
Circuit Engine shut-off solenoid (ESOS) Transmission Spare (Max. 10A) Heater Washers, wipers & horn Face fan Instrument panel Reverse alarm Work lights
Rating 5 7.5 7.5 15 10 5 5 10
ROW B
1 2
Circuit Rating Interior light, roof wiper, rear wiper & beacon 10 Ignition relay 1 3-9 Not used S269270
ROW C Circuit
Rating
Not used
9804/1103
20 - 05 - 01/25
3640U - C/1-2.3
Issue 1
CONTENTS
Loadalls
20 - 05 - 02/1
525-58, 525-67, 527-67, 527-58, 530-67 & 535-67
From m/c no. 567362
Data - Hydraulics Pump Type Flow at max. engine rev/min — at zero pressure — at system pressure
Sundstrand SP/230/40, gear type 88.0 litres/min 84.0 litres/min
19.4 UK gal/min 18.5 UK gal/min
Supplementary Pump (Farm Special Plus & 530-67, 535-67) Type Ultra IPR/009/CT/DT/BE/8451 Flow at max. engine rev/min — at zero pressure 19.8 litres/min 4.4 UK gal/min — at system pressure 17.8 litres/min 4.0 UK gal/min Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 — Spool 5 — Spool 6 Relief Valve Operating Pressures Main Relief Valve (MRV) Auxiliary Relief Valves (ARV) — Attachments — Carriage Tilt, head side — Carriage Tilt, rod side — Hydraulic Tow Hitch lower (head side) — Hydraulic Tow Hitch raise (rod side) — Sway, head side — Sway, rod side Note: On later machines the sway ARVs are not fitted
Boom Raise & Lower Boom Extend & Retract Auxiliary (see note) Carriage Tilt Auxiliary (see note) Auxiliary (see note) bar 220
kgf/cm2 224
lbf/in2 3200
138 138 275 96 172 131 165
140 140 281 98 176 133 168
2000 2000 4000 1400 2500 1900 2400
Bore
Boom Lift - 525-58, 527-58 Boom Lift - 525-67, 527-58, 530-67, 535-67 Boom Extension - 525-58, 527-58 Boom Extension - 525-67, 527-58, 530-67, 535-67 Tilt Ram Displacement Tow Hitch Sway Ram Sway Ram (later machines)
mm 110 110 70 70 110 110 70 110 110
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 25 microns (0.001 in) 0.17 bar 125 microns (0.005 in)
NAT ASP engine TURBO engine
5.3 US gal/min 4.8 US gal/min
Kontak, parallel service, double acting spools.
Rams
Fan Motor Type Max fan speed at Max engine rev/min
23.2 US gal/min 22.2 US gal/min
in 4.3 4.3 2.8 2.8 4.3 4.3 2.8 4.3 4.3
Rod Dia. mm in 60 2.4 60 2.4 50 1.9 50 1.9 50 1.9 50 1.9 30 1.2 50 1.9 50 1.9
Stroke mm 615 807 1700 1968 620 355 220 196 178
in 24.2 31.8 66.9 77.5 24.4 13.9 8.7 7.7 7.0
Sundstrand TFU 200/8, gear type / Ultra 1MR 084C 8784 18 inch fan 20 inch fan 40° C ambient 46° C ambient 40° C ambient 46° C ambient temp. zone temp. zone temp. zone temp. zone 2100 2500 2100 2100 2300 2600
Note: The function of spools 3, 5 & 6 (where fitted) will vary from machine to machine but may include the following: Hydraulic Tow Hitch, Sway Control and Auxiliary Attachment Control.
9804/1103
20 - 05 - 02/1
Issue 3*
CONTENTS
Loadalls
20 - 05 - 02/2
530-95
From m/c no. 567362
Data - Hydraulics Pump Type Flow at max. engine rev/min — at zero pressure — at system pressure
Sundstrand SP/230/40, gear type 88.0 litres/min 84.0 litres/min
19.4 UK gal/min 18.5 UK gal/min
23.2 US gal/min 22.2 US gal/min
Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 — Spool 5 — Spool 6
Kontak, parallel service, double acting spools.
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Attachments — Carriage Tilt, head side — Carriage Tilt, rod side — Sway, head side — Sway, rod side Note: On later machines the sway ARVs are not fitted
220
225
3200
138 138 275 131 165
140 140 281 133 168
2000 2000 4000 1900 2400
Boom Raise & Lower Boom Extend & Retract Auxiliary (see note) Carriage Tilt Auxiliary (see note) Sway
Rams Boom Lift Boom Extension Tilt Ram Displacement Sway * Sway Ram (later machines)
Bore mm 110 100 120 120 110 110
in 4.3 3.9 4.7 4.7 4.3 4.3
Rod Dia. mm in 60 2.3 60 2.3 65 2.5 65 2.5 60 1.9 50 1.9
Stroke mm 1020 3860 495 495 196 178
in 40.1 151.9 19.4 19.4 7.7 7.0
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)
Fan Motor * Type
Sundstrand TFU 200/8, gear type / Ultra 1MR 084C 8784
Max fan speed at Max engine rev/min
40° C ambient temp. zone 1800 1800
NAT ASP engine TURBO engine
46° C ambient temp. zone 2100 2100
Note: The function of spools 3, 5 (where fitted) will vary from machine to machine but may include the following: Hydraulic Tow Hitch, and Auxiliary Attachment Control.
9804/1103
20 - 05 - 02/2
Issue 2*
CONTENTS
Loadalls
20 - 05 - 02/3
530-110
From m/c no. 567362
Data - Hydraulics Pump Type Flow at max. engine rev/min — at zero pressure — at system pressure
Sundstrand SP/230/40, gear type 88.0 litres/min 84.0 litres/min
19.4 UK gal/min 18.5 UK gal/min
23.2 US gal/min 22.2 US gal/min
Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 — Spool 5 — Spool 6
Kontak, parallel service, double acting spools.
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Attachments — Carriage Tilt, head side — Carriage Tilt, rod side
241
245
3500
138 138 275
140 140 281
2000 2000 4000
Boom Raise & Lower Boom Extend & Retract Auxiliary Carriage Tilt Stabiliser Stabiliser
Rams Boom Lift Boom Outer Extension Boom Inner Extension Tilt Ram Displacement Stabiliser
Bore mm 110 110 90 120 120 100
in 4.3 4.3 3.5 4.7 4.7 3.9
Rod Dia mm in 60 2.3 60 2.3 60 2.3 65 2.5 65 2.5 60 2.3
Stroke mm 1020 2560 2690 495 495 380
in 40.1 100.7 105.9 19.4 19.4 15
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)
Fan Motor * Type Max fan speed at Max engine rev/min NAT ASP engine TURBO engine
9804/1103
Sundstrand TFU 200/8, gear type / Ultra 1MR 084C 8784 40° C ambient temp. zone 1800 1800
20 - 05 - 02/3
46° C ambient temp. zone 2100 2100
Issue 2*
CONTENTS
Loadalls
20 - 05 - 02/4
530-120
From m/c no. 567362
Data - Hydraulics Pump * Type Flow at max. engine rev/min — at zero pressure — at system pressure
Sundstrand SP/230/50 or Ultra 2PR050, gear type 110.0 litres/min 105.0 litres/min
24.2 UK gal/min 23.0 UK gal/min
29.0 US gal/min 27.6 US gal/min
Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 — Spool 5 — Spool 6 — Spool 7
Kontak, parallel service, double acting spools.
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
241
245
3500
138 138 275 131 165
140 140 281 133 168
2000 2000 4000 1900 2400
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Attachments — Carriage Tilt, head side — Carriage Tilt, rod side — Sway, head side — Sway, rod side * Note: On later machines the sway ARVs are not fitted
Boom Raise & Lower Boom Extend & Retract Auxiliary Carriage Tilt Stabiliser Stabiliser Sway
Rams Boom Lift Boom Outer Extension Boom Inner Extension Tilt Ram Displacement Stabiliser Sway Sway Ram (later machines)
mm 120 120 100 130 130 110 110 110
Bore in 4.7 4.7 3.9 5.1 5.1 4.3 4.3 4.3
Rod Dia. mm in 65 2.5 65 2.5 60 2.3 50 1.9 50 1.9 60 2.3 50 1.9 50 1.9
Stroke mm 1040 3053 3107 695 500 527 196 178
in 40.9 120.1 122.3 27.3 19.6 20.7 7.7 7.0
On machines from serial number 567736 Tilt Ram Displacement
130 130
5.1 5.1
65 65
695 500
27.3 19.6
2.5 2.5
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)
Fan Motor * Type Max fan speed at Max engine rev/min NAT ASP engine TURBO engine
9804/1103
Sundstrand TFU 200/8, gear type or Ultra 1MR 084C 8784 40° C ambient temp. zone 1800 1800
20 - 05 - 02/4
46° C ambient temp. zone 2500 2500
Issue 2*
Loadalls
CONTENTS
20 - 05 - 02/5
505-19, 505-22
From m/c no. 567362
Data - Hydraulics Pump Type Flow at max. engine rev/min — at zero pressure — at system pressure
Sundstrand SP/230/40, gear type 88.0 litres/min 19.4 UK gal/min 84.0 litres/min 18.5 UK gal/min
23.2 US gal/min 22.2 US gal/min
Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 — Spool 5 — Spool 6
Kontak, parallel service, double acting spools.
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Attachments — Carriage Tilt, head side — Carriage Tilt, rod side — Hydraulic Tow Hitch lower (head side) — Hydraulic Tow Hitch raise (rod side) — Sway, head side — Sway, rod side Note: On later machines the sway ARVs are not fitted
220
224
3200
138 138 275 96 172 131 165
140 140 281 98 176 133 168
2000 2000 4000 1400 2500 1900 2400
in 4.3 4.3 2.8 2.8 4.3 4.3 2.8 4.3 4.3
mm 60 60 50 50 50 50 30 50 50
Boom Raise & Lower Boom Extend & Retract Auxiliary (see note) Carriage Tilt Auxiliary (see note) Auxiliary (see note)
Rams Boom Lift - 505-19 (19 ft) Boom Lift - 505-22 (22 ft) Boom Extension - 505-19 (19 ft) Boom Extension - 505-22 (22 ft) Tilt Ram Displacement Tow Hitch Sway Ram * Sway Ram (later machines)
Bore mm 110 110 70 70 110 110 70 110 110
Rod Dia. in 2.4 2.4 1.9 1.9 1.9 1.9 1.2 1.9 1.9
Stroke mm 615 807 1700 1968 620 355 220 196 178
in 24.2 31.8 66.9 77.5 24.4 13.9 8.7 7.7 7.0
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 25 microns (0.001 in) 0.17 bar 125 microns (0.005 in)
Fan Motor Type Max fan speed at Max engine rev/min
NAT ASP engine TURBO engine
Sundstrand TFU 200/8, gear type 18 inch fan 40° C ambient temp. zone 2100 2100
46° C ambient temp. zone 2500 2100
505-19 ONLY 20 inch fan 40° C ambient 46° C ambient temp. zone temp. zone 2300
2600
Note: The function of spools 3, 5 & 6 (where fitted) will vary from machine to machine but may include the following: Hydraulic Tow Hitch, Sway Control and Auxiliary Attachment Control.
9804/1103
20 - 05 - 02/5
Issue 2*
CONTENTS
Loadalls
20 - 05 - 02/6
506-36
From m/c no. 567362
Data - Hydraulics Pump Type Flow at max. engine rev/min — at zero pressure — at system pressure
Sundstrand SP/230/40, gear type 88.0 litres/min 84.0 litres/min
19.4 UK gal/min 18.5 UK gal/min
23.2 US gal/min 22.2 US gal/min
Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 — Spool 5 — Spool 6
Kontak, parallel service, double acting spools.
Relief Valve Operating Pressures Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Attachments — Carriage Tilt, head side — Carriage Tilt, rod side
bar 241
kgf/cm2 245
lbf/in2 3500
138 138 275
140 140 281
2000 2000 4000
Rams
Bore mm 110 110 90 120 120 100
in 4.3 4.3 3.5 4.7 4.7 3.9
Rod Dia. mm 60 60 60 65 65 60
Boom Lift Boom Outer Extension Boom Inner Extension Tilt Ram Displacement Stabilizer
Boom Raise & Lower Boom Extend & Retract Auxiliary Carriage Tilt Stabiliser Stabiliser
in 2.3 2.3 2.3 2.5 2.5 2.3
Stroke mm 1020 2560 2690 495 495 380
in 40.1 100.7 105.9 19.4 19.4 15
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)
Fan Motor Type
Sundstrand TFU 200/8, gear type
Max fan speed at Max engine rev/min
40° C ambient temp. zone 1800 1800
NAT ASP engine TURBO engine
9804/1103
20 - 05 - 02/6
46° C ambient temp. zone 2100 2100
Issue 1
CONTENTS
Loadalls
20 - 05 - 02/7
508-40
From m/c no. 567362
Data - Hydraulics Pump Type Flow at max. engine rev/min — at zero pressure — at system pressure
Sundstrand SP/230/50, gear type 110.0 litres/min 105.0 litres/min
24.2 UK gal/min 23.0 UK gal/min
29.0 US gal/min 27.6 US gal/min
Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 — Spool 5 — Spool 6 — Spool 7
Kontak, parallel service, double acting spools.
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Attachments — Carriage Tilt, head side — Carriage Tilt, rod side — Sway, head side — Sway, rod side
241
245
3500
138 138 275 131 165
140 140 281 133 168
2000 2000 4000 1900 2400
Boom Lift Boom Outer Extension Boom Inner Extension Tilt Ram Displacement Sway
Bore mm 110 120 100 130 130 110
Rod Dia. in 4.3 4.7 3.9 5.1 5.1 4.3
Stroke mm 60 65 60 50 50 50
in 2.3 2.5 2.3 1.9 1.9 1.9
mm 1050 3053 3107 695 500 196
in 41.3 120.1 122.3 27.3 19.6 7.7
On machines from serial number 567736 Tilt Ram Displacement
130 130
5.1 5.1
65 65
2.5 2.5
695 500
27.3 19.6
Rams
Boom Raise & Lower Boom Extend & Retract Auxiliary Carriage Tilt Stabiliser Stabiliser Sway
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)
Fan Motor Type
Sundstrand TFU 200/8, gear type
Max fan speed at Max engine rev/min
40° C ambient temp. zone 2300
TURBO engine
9804/1103
20 - 05 - 02/7
46° C ambient temp. zone 2900
Issue 1
CONTENTS
Loadalls
20 - 05 - 02/8
510-40
From m/c no. 567362
Data - Hydraulics TECHNICAL DATA (510-40 Only) Pump * Type Flow at max. engine rev/min — at zero pressure — at system pressure
Sundstrand SP/230/50, or Ultra 2PR050 gear type 110.0 litres/min 105.0 litres/min
24.2 UK gal/min 23.0 UK gal/min
29.0 US gal/min 27.6 US gal/min
Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 — Spool 5 — Spool 6 — Spool 7
Kontak, parallel service, double acting spools.
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Attachments — Carriage Tilt, head side — Carriage Tilt, rod side — Sway, head side — Sway, rod side Note: On later machines the sway ARVs are not fitted
241
245
3500
138 138 275 131 165
140 140 281 133 168
2000 2000 4000 1900 2400
Boom Raise & Lower Boom Extend & Retract Auxiliary Carriage Tilt Stabilizer Stabilizer Sway
Rams Boom Lift Boom Outer Extension Boom Inner Extension Tilt Ram Displacement Stabilizer Sway * Sway Ram (later machines) On machines from serial number 567736 Tilt Ram Displacement
mm 120 120 100 130 130 110 110 110
Bore in 4.7 4.7 3.9 5.1 5.1 4.3 4.3 4.3
Rod Dia. mm in 65 2.5 65 2.5 60 2.3 50 1.9 50 1.9 60 2.3 50 1.9 50 1.9
Stroke mm 1040 3053 3107 695 500 527 196 178
in 40.9 120.1 122.3 27.3 19.6 20.7 7.7 7.0
130 130
5.1 5.1
65 65
695 500
27.3 19.6
2.5 2.5
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)
Fan Motor Type
Sundstrand TFU 200/8, gear type
Max fan speed at Max engine rev/min
40° C ambient temp. zone 2600
TURBO engine
9804/1103
20 - 05 - 02/8
46° C ambient temp. zone 2900
Issue 2*
CONTENTS
Loadalls
20 - 05 - 02/9
520-55, 526-55, 520S, 526, 526S
From m/c no. 567362
Data - Hydraulics Pump Type Flow at 2200 engine rev/min — at zero pressure — at system pressure
Powermaster 2PR 036, gear type 79.0 litres/min 75.0 litres/min
17.4 UK gal/min 16.5 UK gal/min
21.0 US gal/min 20.0 US gal/min
Control Valves Type
— Spool 1 — Spool 2 — Spool 3 — Spool 4
Kontak, parallel service, double acting spools. Services Operated Mode of Operation All Machines 526, 526S Machines with except as column right Single Lever Control Option
Auxiliary Boom Raise & Lower Carriage Tilt Boom Extend & Retract
Mechanical Mechanical Mechanical Mechanical
Pilot Mechanical Mechanical Pilot
* Relief Valve Operating Pressures
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Auxiliary, rod side — Auxiliary, head side — Carriage Tilt Crowd, head side — Carriage Tilt Dump, rod side
Rams
bar
kgf/cm2
lbf/in2
241
245
3500
193 144 250 276
196 144 255 281
2798 2080 3625 4002
Bore mm in Boom Lift 100 3.9 Boom Extension 70 2.7 Tilt Ram (520-55) 120 4.7 Tilt Ram (526-55, 526, 526S) 130 5.1 Displacement 70 2.7 Hitch (earlier type) 50 1.9 Hitch (later type) 50 1.9 Hitch (526S with 24 inch (600mm) wheels) 50 1.9
Rod Dia. mm in 60 2.3 50 1.9 70 2.7 75 2.9 40 1.5 25 1.0 25 1.0 25 1.0
Stroke mm in 1101 43.3 1700 66.0 333 13.1 333 13.1 700 27.5 254 10.0 305 12.0 340 13.4
Open centre mm in 2542 100.0 3685 145 1023 40.3 1023 40.3 1645 64.75 698 27.5 -
Closed centre mm in 1440 56.6 1985 78.1 690 27.1 690 27.1 945 37.2 444 17.5 475 18.7 510 20.0
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
9804/1103
Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)
20 - 05 - 02/9
3610 - E/1-1.5
Issue 5*
CONTENTS
Loadalls
20 - 05 - 02/10
537-120
From m/c no. 567362
Data - Hydraulics Pump * Type Flow at max. engine rev/min — at zero pressure — at system pressure
Sundstrand SP/230/50 or Ultra 2PR050, gear type 110.0 litres/min 105.0 litres/min
24.2 UK gal/min 23.0 UK gal/min
29.0 US gal/min 27.6 US gal/min
Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 — Spool 5
Kontak, parallel service, double acting spools.
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Attachments — Carriage Tilt, head side — Carriage Tilt, rod side
241
245
3500
138 138 275
140 140 281
2000 2000 4000
Boom Raise & Lower Boom Extend & Retract Auxiliary Carriage Tilt Sway
Rams Boom Lift Boom Outer Extension Boom Inner Extension Tilt Ram Displacement Stabiliser Sway Ram
Bore mm 120 120 100 130 130 110 110
in 4.7 4.7 3.9 5.1 5.1 4.3 4.3
Rod Dia. mm in 65 2.5 65 2.5 60 2.3 65 2.5 65 2.5 60 2.3 50 1.9
Stroke mm 1040 3053 3107 695 500 527 178
in 40.9 120.1 122.3 27.3 19.6 20.7 7.0
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)
Fan Motor Type
Ultra 1MR 084C 8784
Max fan speed at Max engine rev/min
40° C ambient temp. zone 1800 1800
NAT ASP engine TURBO engine
9804/1103
20 - 05 - 02/10
46° C ambient temp. zone 2500 2500
Issue 2*
CONTENTS
Loadalls
20 - 05 - 02/11
537-130
From m/c no. 567362
Data - Hydraulics * Pump Type Flow at max. engine rev/min — at zero pressure — at system pressure
Sundstrand SP/230/50 or Ultra 2PR050, gear type 110.0 litres/min 105.0 litres/min
24.2 UK gal/min 23.0 UK gal/min
29.0 US gal/min 27.6 US gal/min
Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 — Spool 5 — Spool 6 — Spool 7
Kontak, parallel service, double acting spools.
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Attachments — Carriage Tilt, head side — Carriage Tilt, rod side
241
245
3500
138 138 275
140 140 281
2000 2000 4000
Boom Raise & Lower Boom Extend & Retract Auxiliary Carriage Tilt Stabiliser Stabiliser Sway
Rams Boom Lift Boom Outer Extension Boom Inner Extension Tilt Ram Displacement Stabiliser Sway Ram
Bore mm 120 120 100 130 130 110 110
in 4.7 4.7 3.9 5.1 5.1 4.3 4.3
Rod Dia. mm in 65 2.5 65 2.5 60 2.3 65 2.5 65 2.5 60 2.3 50 1.9
Stroke mm 1040 3584 3648 695 500 527 178
in 40.9 141.1 143.6 27.3 19.6 20.7 7.0
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)
Fan Motor Type
Ultra 1MR 084C 8784
Max fan speed at Max engine rev/min
40° C ambient temp. zone 1800 1800
NAT ASP engine TURBO engine
9804/1103
20 - 05 - 02/11
46° C ambient temp. zone 2500 2500
Issue 2*
CONTENTS
Loadalls
20 - 05 - 02/12
520-50, 525-50, 525-52
From m/c no. 754000
Data - Hydraulics Pump Type Flow at 2200 engine rev/min — at zero pressure — at system pressure
Powermaster 2PR 036, gear type 79.0 litres/min 75.0 litres/min
17.4 UK gal/min 16.5 UK gal/min
21.0 US gal/min 20.0 US gal/min
Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4
Auxiliary Boom Raise & Lower Carriage Tilt Boom Extend & Retract
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
241
245
3500
185 185 250 275
188 188 255 280
2683 2683 3625 3987
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) * — Auxiliary, rod side * — Auxiliary, head side — Carriage Tilt Crowd, head side — Carriage Tilt Dump, rod side Rams Boom Lift Boom Extension Tilt Displacement Hitch
Kontak, parallel service, double acting spools.
Bore mm in 110 4.3 70 2.7 120 4.7 70 2.7 50 1.9
Rod Dia. mm in 60 2.3 50 1.9 70 2.75 40 1.5 25 0.9
Stroke mm in 1020 40.1 1700 66.0 334 13.1 503 19.8 254 9.8
Open centre mm in 2390 94.0
698
27.5
Closed centre mm in 1370 53.9 2545 100.2 651 25.6 744 29.3 444 17.5
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)
Hydraulic Tank Capacity
9804/1103
70 litres (15.4 gals)
20 - 05 - 02/12
3620-E/1-1.2
Issue 3*
Loadalls
CONTENTS
20 - 05 - 02/13
530 Agricultural Data - Hydraulics * Triple Pump Type
Main pump 2PR036 Fan pump 2PR016 (Machines to S/N 771429) Fan pump 1PX160 (Machines from S/N 771430) Steer pump 2PR019 Priority valve 2VP-EAF-JIJ2V1-00-00-56
82.0 litres/min (18.0 UK gal/min) 35.0 litres/min (7.7 UK gal/min) 36.5 litres/min (8.0 UK gal/min) 43.3 litres/min (9.5 UK gal/min)
* Control Valves Type
Parallel service, double acting spools.
Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4
Boom Raise & Lower Carriage Tilt Boom Extend & Retract (electro/servo operated) Auxiliary (electro/servo operated)
Servo Pressure Range
bar
kgf/cm2
lbf/in2
Machines to S/N 771429; Machines from S/N 771430;
10 - 20 10 - 30
10.2 - 20.4 10.2 - 30.6
145 - 290 145 - 435
bar
kgf/cm2
lbf/in2
241
245
3500
138 (220†) 138 138 275
140 (223†) 140 140 280
2000 (3190†) 2000 2000 3987
Bore mm in 130 5.1 70 2.7 110 4.3 120 4.7 50 1.9 110 4.3
Rod Dia. mm in 70 2.7 50 1.9 50 1.9 60 2.3 25 0.9 50 1.9
Stroke mm in 753 29.6 2470 97.2 474 18.6 294 11.5 429 16.8 136 5.4
* Relief Valve Operating Pressures Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Auxiliary, rod side — Auxiliary, head side — Carriage Tilt Dump, head side (A port) — Carriage Tilt Crowd, rod side (B port) Rams Boom Lift Boom Extension Tilt Displacement Hitch Sway
Open centre mm in 1894 74.5 5225 205.7 1306 51.4 946 37.2 1028 40.4 629 24.8
Closed centre mm in 1141 44.9 2755 108.4 832 32.7 652 25.6 599 23.5 493 19.4
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 10 microns (0.0004 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in)
Hydraulic Tank Capacity
112 litres (24.6 UK gals)
Fan Motor Oil Flow Max fan speed at Max engine rev/min
30.0 litres/min (6.6 UK gal/min) at 190 bar (2760 lbf/in2) 2200
† Machines with pick-up hitch. Since this ARV also controls the pressure to the boom auxiliary service, ensure that this pressure will not cause damage to attachments used with the machine.
9804/1103
20 - 05 - 02/13
3630 - E/1-1.4
Issue 2*
Loadalls
CONTENTS
20 - 05 - 02/14
530 Construction Data - Hydraulics * Triple Pump Type
Main pump 2PR036 Fan pump 2PR016 (Machines to S/N 771429) Fan pump 1PX160 (Machines from S/N 771430) Steer pump 2PR019 Priority valve 2VP-EAF-JIJ2V1-00-00-56
82.0 litres/min (18.0 UK gal/min) 35.0 litres/min (7.7 UK gal/min) 36.5 litres/min (8.0 UK gal/min) 43.3 litres/min (9.5 UK gal/min)
* Control Valves Type
Parallel service, 4 double acting spools.
Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4
Boom Raise & Lower Boom Extend & Retract Carriage Tilt Auxiliary/Sway (electro/servo operated)
* Servo Pressure Range Machines to S/N 771429; Machines from S/N 771430; * Relief Valve Operating Pressures Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Auxiliary, rod side — Auxiliary, head side — Carriage Tilt Dump, head side (A port) — Carriage Tilt Crowd, rod side (B port) — Boom Extend head side (A port) — Boom Extend rod side (B port) * Rams Boom Lift Boom Extension Tilt Displacement Hitch
bar
kgf/cm2
lbf/in2
10 - 20 10 - 30
10.2 - 20.4 10.2 - 30.6
145 - 290 145 - 435
bar
kgf/cm2
lbf/in2
260
263
3770
138(220†) 138 138 275 241 241
140(223†) 140 140 280 245 245
2000(3190†) 2000 2000 3987 3500 3500
Bore mm in 140 5.5 70 2.7 110 4.3 120 4.7 50 1.9
Rod Dia. mm in 75 2.9 50 1.9 50 1.9 60 2.3 25 0.9
Stroke mm in 753 29.6 2470 97.2 474 18.6 294 11.5 429 16.8
Open centre mm in 1894 74.5 5225 205.7 1306 51.4 946 37.2 1028 40.4
Closed centre mm in 1141 44.9 2755 108.4 832 32.7 652 25.6 599 23.5
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 10 microns (0.0004 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in)
Hydraulic Tank Capacity
112 litres (24.6 UK gals)
Fan Motor Oil Flow Max fan speed at Max engine rev/min
30.0 litres/min (6.6 UK gal/min) at 190 bar (2760 lbf/in2) 2200
† Machines with pick-up hitch. Since this ARV also controls the pressure to the boom auxiliary service, ensure that this pressure will not cause damage to attachments used with the machine.
9804/1103
20 - 05 - 02/14
3630 - E/1-2.4
Issue 2*
Loadalls
CONTENTS
20 - 05 - 02/14A
540 Agricultural
From m/c no. 767001
Data - Hydraulics Triple Pump Type
Main pump 2PR036 Fan pump 2PR016 (Machines to S/N 771429) Fan pump 1PX160 (Machines from S/N 771430) Steer pump 2PR019 Priority valve 2VP-EAF-JIJ2V1-00-00-56
82.0 litres/min (18.0 UK gal/min) 35.0 litres/min (7.7 UK gal/min) 36.5 litres/min (8.0 UK gal/min) 43.3 litres/min (9.5 UK gal/min)
Control Valves Type
Parallel service, 4 double acting spools.
Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4
Boom Raise & Lower Carriage Tilt Boom Extend & Retract (electro/servo operated) Auxiliary (electro/servo operated)
Servo Pressure Range
bar
kgf/cm2
lbf/in2
Machines to S/N 771429; Machines from S/N 771430;
10 - 20 10 - 30
10.2 - 20.4 10.2 - 30.6
145 - 290 145 - 435
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Auxiliary, rod side — Auxiliary, head side — Carriage Tilt Dump, head side (A port) — Carriage Tilt Crowd, rod side (B port) — Boom Extend head side (A port) — Boom Extend rod side (B port)
260
263
3770
138(220†) 138 138 275 241 241
140(223†) 140 140 280 245 245
2000(3190†) 2000 2000 3987 3500 3500
Rams Boom Lift Boom Extension Tilt Displacement Hitch
Bore mm in 140 5.5 70 2.7 110 4.3 120 4.7 50 1.9
Rod Dia. mm in 75 2.9 50 1.9 50 1.9 60 2.3 25 0.9
Stroke mm in 753 29.6 2470 97.2 474 18.6 294 11.5 429 16.8
Open centre mm in 1894 74.5 5225 205.7 1306 51.4 946 37.2 1028 40.4
Closed centre mm in 1141 44.9 2755 108.4 832 32.7 652 25.6 599 23.5
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 10 microns (0.0004 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in)
Hydraulic Tank Capacity
112 litres (24.6 UK gals)
Fan Motor Oil Flow Max fan speed at Max engine rev/min
30.0 litres/min (6.6 UK gal/min) at 190 bar (2760 lbf/in2) 2200
† Machines with pick-up hitch. Since this ARV also controls the pressure to the boom auxiliary service, ensure that this pressure will not cause damage to attachments used with the machine.
9804/1103
20 - 05 - 02/14A
3630 - E/1-3.4
Issue 1
Loadalls
CONTENTS
20 - 05 - 02/14B
540 Construction
From m/c no. 767001
Data - Hydraulics Triple Pump Type
Main pump 2PR036 Fan pump 2PR016 (Machines to S/N 771429) Fan pump 1PX160 (Machines from S/N 771430) Steer pump 2PR019 Priority valve 2VP-EAF-JIJ2V1-00-00-56
82.0 litres/min (18.0 UK gal/min) 35.0 litres/min (7.7 UK gal/min) 36.5 litres/min (8.0 UK gal/min) 43.3 litres/min (9.5 UK gal/min)
Control Valves Type
Parallel service, 4 double acting spools.
Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4
Boom Raise & Lower Boom Extend & Retract Carriage Tilt Auxiliary/Sway (electro/servo operated)
Servo Pressure Range
bar
kgf/cm2
lbf/in2
Machines to S/N 771429; Machines from S/N 771430;
10 - 20 10 - 30
10.2 - 20.4 10.2 - 30.6
145 - 290 145 - 435
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Auxiliary, rod side — Auxiliary, head side — Carriage Tilt Dump, head side (A port) — Carriage Tilt Crowd, rod side (B port) — Boom Extend head side (A port) — Boom Extend rod side (B port)
260
263
3770
138(220†) 138 138 275 241 241
140(223†) 140 140 280 245 245
2000(3190†) 2000 2000 3987 3500 3500
Rams Boom Lift Boom Extension Tilt Displacement Hitch
Bore mm in 140 5.5 70 2.7 110 4.3 120 4.7 50 1.9
Rod Dia. mm in 75 2.9 50 1.9 50 1.9 60 2.3 25 0.9
Stroke mm in 753 29.6 2470 97.2 474 18.6 294 11.5 429 16.8
Open centre mm in 1894 74.5 5225 205.7 1306 51.4 946 37.2 1028 40.4
Closed centre mm in 1141 44.9 2755 108.4 832 32.7 652 25.6 599 23.5
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 10 microns (0.0004 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in)
Hydraulic Tank Capacity
112 litres (24.6 UK gals)
Fan Motor Oil Flow Max fan speed at Max engine rev/min
30.0 litres/min (6.6 UK gal/min) at 190 bar (2760 lbf/in2) 2200
† Machines with pick-up hitch. Since this ARV also controls the pressure to the boom auxiliary service, ensure that this pressure will not cause damage to attachments used with the machine.
9804/1103
20 - 05 - 02/14B
3630 - E/1-4.4
Issue 1
Loadalls
CONTENTS
20 - 05 - 02/14C
535
From m/c no. 767001
Data - Hydraulics 535 Machines Triple Pump Type gal/min)
Main pump 2PR036
82.0
litres/min
(18.0
UK
Fan pump 1PX160 Steer pump 2PR019 Priority valve 2VP-EAF-JIJ2V1-00-00-56
36.5 litres/min (8.0 UK gal/min) 43.3 litres/min (9.5 UK gal/min)
Control Valves Type
Parallel service, 4 double acting spools.
Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4
Boom Raise & Lower Boom Extend & Retract Carriage Tilt Auxiliary
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Auxiliary, rod side — Auxiliary, head side — Carriage Tilt Dump, rod side (A port) — Carriage Tilt Crowd, head side (B port)
240
244
3480
220 220 250 275
224 224 255 280
3190 3190 3626 3988
Note: Since the auxiliary ARV also controls the pressure to the boom auxiliary service, ensure that this pressure will not cause damage to attachments used with the machine. Rams Boom Lift Boom Extension (inner) Boom Extension (outer) Tilt Displacement Hitch
Bore mm in 120 4.7 80 3.1 100 4.0 130 4.3 70 2.7 50 2.0
Rod Dia. mm in 70 2.7 50 2.0 60 2.4 75 1.9 40 1.5 25 1.0
Stroke mm in 1114 43.9 2653 104.5 2653 104.5 336 13.2 750 29.5 530 21.0
Open centre mm in 2571 101.3 5688 224.1 5700 224.6 1110 43.7 1745 68.7 1230 48.4
Closed centre mm in 1457 57.4 3035 119.6 3047 120.0 774 30.5 995 39.1 700 27.5
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 10 microns (0.0004 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in)
Hydraulic Tank Capacity
121 litres (26.6 UK gals)
Fan Motor Oil Flow Max fan speed at Max engine rev/min
9804/1103
30.0 litres/min (6.6 UK gal/min) at 190 bar (2760 lbf/in2) 2200
20 - 05 - 02/4C
3630 - E/1-5.4
Issue 1
Loadalls
CONTENTS
20 - 05 - 02/15
532
From m/c no. 567362
Data - Hydraulics Triple Pump Type
Main pump 2PR029 Fan pump 2PR016 (to m/c no. 771428) Fan pump 1Px160 (from m/c no. 771429) Steer pump 2PR019 C1W3 B1B1-240 Priority valve 2VP-EAF-JIJ2V1-00-00-56
63.0 litres/min (13.8 UK gall/min) 35.0 litres/min (7.7 UK gall/min) 36.5 litres/min (8.0 UK gall/min) 41.0 litres/min (9.0 UK gall/min)
Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 Unloader section — Spool 5 — Spool 6
Kontak, parallel service, 6 spools.
Boom Raise & Lower Boom Extend & Retract Carriage Tilt Auxiliary/Sway (electro/servo operated from m/c no. 767001) Right Hand Stabiliser Left Hand Stabiliser
Servo Pressure Range
bar
kgf/cm2
lbf/in2
M/c nos. to 771428 M/c nos. from 771429
10-20 10-30
10.2-20.4 10.2-30.6
145-290 145-435
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Auxiliary, rod side — Auxiliary, head side — Carriage Tilt Crowd, head side (A port) — Carriage Tilt Dump, rod side (B port)
241
245
3500
138 138 330 275
140 140 336 280
2000 Sway ram option A.R.V. 2000 Sway ram option A.R.V. 4785 3987
Rams Boom Lift Boom Extension Outer Boom Extension Inner Tilt Displacement Stabiliser Sway
Bore mm in 130 5.1 120 4.7 100 3.9 130 5.1 90 3.5 110 4.3 110 4.3
Rod Dia. mm in 75 3.0 65 2.5 60 2.3 70 2.7 50 2.0 60 2.3 50 2.0
Stroke mm in 1344 44.6 3170 124.8 3225 127.0 362 14.3 282 11.1 392 15.4 150 5.9
Open centre mm in 3098 122 6734 265.1 6832 269.0 1115 44.0 1047 41.2 1135 44.7 675 26.5
Closed centre mm in 1754 69.0 3564 140.3 3607 142.0 753 30.0 765 30.3 743 29.3 525 20.6
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 12 microns (0.0005 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in)
Hydraulic Tank Capacity
131 litres (28.8 gals)
Fan Motor Oil Flow * Max fan speed at Max engine rev/min
9804/1103
30.0 litres/min (6.6 gall/min) at 190 bar (2760 lbf/in2) 2200 (to machine S/N 785165) 1800 nominal (from machine S/N 785166)
20 - 05 - 02/15
3630 - E/1-1.2
Issue 3*
Loadalls
CONTENTS
20 - 05 - 02/16
537, 550
From m/c no. 767001
Data - Hydraulics Triple Pump Type
Main pump 2PR029 Fan pump 2PR016 (to m/c no. 771428) Fan pump 1PX160 (from m/c no. 771429) Steer pump 2PR019 C1W3 B1B1-240 Priority valve 2VP-EAF-JIJ2V1-00-00-56
63.0 litres/min (13.8 UK gall/min) 35.0 litres/min (7.7 UK gall/min) 36.5 litres/in (8.0 UK gall/min) 43.3 litres/min (9.5 UK gall/min)
Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 Unloader section — Spool 5 — Spool 6
Kontak, parallel service, 6 spools.
Boom Raise & Lower Boom Extend & Retract Carriage Tilt Auxiliary/Sway (electro servo operated from m/c no. 767001) Right Hand Stabiliser Left Hand Stabiliser
Servo Pressure Range
bar
kgf/cm2
lbf/in2
M/c nos. to 771428 M/c nos. from 771429
10-20 10-30
10.2-20.4 10.2-30.6
145-290 145-345
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Auxiliary, rod side — Auxiliary, head side — Carriage Tilt Crowd, head side (A port) — Carriage Tilt Dump, rod side (B port)
241
245
3500
138 138 330 275
140 140 336 280
2000 Sway ram option A.R.V. 2000 Sway ram option A.R.V. 4785 3987
Rams Boom Lift Boom Extension Outer Boom Extension Inner Tilt Displacement Stabiliser Sway
Bore mm in 160 6.2 130 5.1 110 4.3 140 5.5 90 3.5 110 4.3 110 4.3
Rod Dia. mm in 80 3.1 70 2.7 65 2.6 75 3.0 50 2.0 60 2.3 50 2.0
Stroke mm in 1344 52.9 3826 150.6 3794 149.0 362 14.3 330 13.0 392 15.4 150 5.9
Open centre mm in 3110 122.4 8046 316.7 7970 314.0 1115 44.0 1070 42.1 1135 44.7 675 26.5
Closed centre mm in 1766 69.5 4220 166.1 4176 164.0 753 30.0 740 29.1 743 29.3 525 20.6
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 12 microns (0.0005 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in)
Hydraulic Tank Capacity
131 litres (28.8 gals)
Fan Motor Oil Flow * Max fan speed at Max engine rev/min
9804/1103
30.0 litres/min (6.6 gall/min) at 190 bar (2760 lbf/in2) 2200 (to machine S/N 785165) 1800 nominal (from machine S/N 785166)
20 - 05 - 02/16
3630 - E/1-2.2
Issue 3*
Loadalls
CONTENTS
20 - 05 - 02/17
528-70, 528S
From m/c no. 796000
Data - Hydraulics Pump Type Displacement
Gear type 36 cc/rev
Flow at 2200 engine rev/min: — at zero pressure — at system pressure
79.0 litres/min 75.0 litres/min
17.4 UK gal/min 16.5 UK gal/min
21.0 US gal/min 20.0 US gal/min
Control Valves Type
Parallel service, double acting spools.
Loading Pattern: Services Operated
— Spool 1 — Spool 2 — Spool 3 — Spool 4
Servo Pressure:
Mode of Operation 528-70 Mechanical Mechanical Mechanical Mechanical
Auxiliary Boom Raise & Lower Carriage Tilt Boom Extend & Retract bar 10 - 30
528S Servo operated Mechanical Mechanical Servo operated
lbf/in2 145 - 435
kgf/cm2 10.2 - 30.6
Note: Spools 3 and 4 are reversed on 528-70 machines fitted with a placing control pattern. Relief Valve Operating Pressures
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Auxiliary (Port A) — Auxiliary (Port B) — Carriage Tilt Crowd, head side (Port A) — Carriage Tilt Dump, rod side (Port B) Rams
Boom Lift Boom Extension 101.7 Tilt Ram (528-70) Tilt Ram (528S) Displacement
Weight kg
bar
kgf/cm2
lbf/in2
240
244
3480
193 193 250 276
196 196 254 280
2798 2798 3625 4000
Bore mm in
Rod Dia. mm in
Stroke mm in
Open centre mm in
Closed centre mm in
94 91
110 70
4.3 2.7
60 50
2.3 1.9
1163 2300
45.7 90.5
2666 4885
104.9 192.3
1503 2585
59.1
63 71 30
120 130 70
4.7 5.1 2.7
70 75 40
2.7 2.9 1.5
384 334 750
15.1 13.1 29.5
1126 1026 1745
44.3 40.4 68.7
742 692 995
29.2 27.2 39.1
Filter Return Filter Type Filtration Size Relief Valve Setting
Partial flow 5 microns (0.00025 in) 3 bar
Suction Strainer Type Filtration Size
'spin on' 125 microns (0.005 in)
9804/1103
20 - 05 - 02/17
3650 - E/1-1.2
Issue 1
Loadalls
CONTENTS
20 - 05 - 02/18
506B, 506C Data - Hydraulics Pump
506B
506C
Type Displacement Flow at 2200 engine rev/min — at zero pressure — at system pressure
Gear type 40 cc/rev
Gear Type 41 cc/rev
88.0 litres/min (23.2 US gal/min) 85.0 litres/min (22.5 US gal/min)
90.2 litres (23.8 US gal/min) 87.0 litres (23.0 US gal/min)
Control Valves Type
Parallel service, double acting spools, except for sway, which is a motor spool. On 506B extension spool is a half motor spool to m/c no. 572655.
Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 — Spool 5
Boom Raise & Lower Auxiliary Service Tilt Forwards and Backwards Boom Extend and Retract Sway
Boom Raise & Lower Auxiliary Service Tilt Forwards and Backwards Boom Extend and Retract Sway
Anti-cavitation check valves fitted to all services Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.)
238
241
3450
238
241
3450
Auxiliary Relief Valves (A.R.V.) — Attachments (Port A) — Attachments (Port B) — Carriage Tilt, rod side (Port A) — Carriage Tilt, head side (Port B) — Boom Extend, head side (Port A) — Boom Retract, In-line ARV (If fitted)
138 138 138 275 193 207
140 140 140 280 196 210
2000 2000 2000 4000 2800 3000
138 138 138 275 230 207
140 140 140 280 233 210
2000 2000 2000 4000 3335 3000
From m/n serial no. 585208 — Boom extend (Port A) — Boom retract (Port B)
-
-
-
230 2193
233 196
3335 2800
Rams
Bore mm in 110 4.3 110 4.3 120 4.7 120 4.7 110 4.3
Boom Lift Boom Extension Tilt Ram Displacement Sway
Rod Dia. mm in 65 2.5 70 2.7 65 2.5 65 2.5 50 1.9
Stroke mm in 1020 40.1 2625 103.3 422 16.6 335 13.2 178 7.0
Bore mm 110 110 120 120 110
in 4.3 4.3 4.7 4.7 4.3
Rod Dia. mm in 70 2.7 70 2.7 65 2.5 65 2.5 50 1.9
Stroke mm in 102040.1 2625103.3 422 16.6 335 13.2 178 7.0
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)
Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)
Gear type (8.4 cc/rev) 18 in. fan 40°C to 46°C 2400 rev/min
Gear type (15 cc/rev) 20 in. fan 40°C to 46°C 2400 rev/min
Fan Motor Type Ambient temperature zone Max fan speed at Max engine rev/min
9804/1103
20 - 05 - 02/18
3640U - E/1-1.3 & E1/1-2.3
Issue 1
Loadalls
CONTENTS
20 - 05 - 02/19
506C (HL), 508C Data - Hydraulics Pump Type Displacement Flow at 2200 engine rev/min — at zero pressure — at system pressure
Gear type 50 cc/rev 110.0 litres/min 105.0 litres/min
29.0 US gal/min 27.6 US gal/min
Control Valves Type
Parallel service, double acting spools, except for sway which is a motor spool.
Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 — Spool 5
Boom Raise & Lower Auxiliary Service Tilt Forwards and Backwards Boom Extend and Retract Sway
Anti-cavitation check valves fitted to all services Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.)
238
241
3450
Auxiliary Relief Valves (A.R.V.) — Auxiliary (Port A) — Auxiliary (Port B) — Carriage Tilt, rod side (Port A) — Carriage Tilt, head side (Port B) — Boom Extend (Port A) — Boom Retract, In-line ARV (If fitted)
138 138 138 241 193 207
140 140 140 246 196 210
2000 2000 2000 3500 2800 3000
230 207
206 210
2944 3000
From machine serial number 585196: — Boom Extend (Port A) — Boom Retract (Port B) Rams
Bore mm 120 110 120 120 110
Boom Lift Boom Extension Tilt Ram Displacement Sway
Rod Dia. mm in 75 3.0 75 3.0 65 2.5 65 2.5 50 1.9
in 4.7 4.3 4.7 4.7 4.3
Stroke mm 1020 3,187 422 335 178
in 40.1 125.5 16.6 13.2 7.0
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 25 microns (0.001 in) 2 bar 125 microns (0.005 in)
Fan Motor Type Ambient temperature zone Max fan speed at Max engine rev/min
9804/1103
Gear type (8.4 cc/rev) 20 in. fan 40°C to 46°C 2600 rev/min
20 - 05 - 02/19
3640U - E/1-3.3
Issue 1
CONTENTS
Loadalls
540-170, 5508 with Servo Controls
20 - 05 - 02/20
From m/c no. 780925
Data - Hydraulics Triple Pump Type
Main pump 2PR041 Steer pump 2PR033 Fan pump 1PX160
89 litres/min 19.6 UK gal/min) 72 litres/min 15.8 UK gal/min) 16 litres/min (3.5 UK gal/min)
Main Control Valve Type Servo Operation — Spool 1 — Spool 2 — Spool 3 Manual Operation — Spool 4 — Spool 5 — Spool 6
Parallel service, 6 spools.
Boom Raise & Lower Boom Extend & Retract Carriage Tilt Auxiliary Right Hand Stabiliser Left Hand Stabiliser bar
kgf/cm2
lbf/in2
10 - 30
10.2 - 30.6
145 - 435
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Auxiliary, rod side — Auxiliary, head side — Carriage Tilt Dump, rod side (A port) — Carriage Tilt Crowd, head side (B port)
260
265
3770
138 138 276 330
140 140 280 336
2000 2000 4000 4785
Servo Pressure Range
Remote Control Valve Type
Parallel service, 2 spools.
Servo Operation — Spool 1 — Spool 2
Boom Raise & Lower Boom Extend
Servo Pressure Range
bar
kgf/cm2
lbf/in2
10 - 30
10.2 - 30.6
145 - 435
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.)
240
245
3481
Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer
Partial flow ('spin on') 10 microns (0.0004 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in)
Hydraulic Tank Capacity
180 litres (40 UK gals) approx.
Fan Motor Oil Flow Max fan speed at Max engine rev/min 9804/1103
30.0 litres/min (6.6 UK gal/min) at 190 bar (2760 lbf/in2) 2200 rev/min
20 - 05 - 02/20
3660 - E/51-1.2 3660 - E/51-2.2
Issue 1
Loadalls
CONTENTS
20 - 05 - 03/1
ALL MODELS
From m/c no. 567362
Data - Engine Type
Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance - Cold Oil Pressure (Hot) at maximum speed Maximum Air Cleaner Restriction
Perkins 1000 Series 4 cylinder Engines AA - naturally aspirated (76 HP) AB - turbocharged (94.5 HP) AB - turbocharged (102 HP) 100mm (3.937 in) 127mm (5.000 in) 4 litres (243 in3) Naturally aspirated 16.5:1 Turbocharged 16.0:1 28 bar (400 lbf/in2) [maximum variation between cylinders 3.5 bar (50 lbf/in2)] 1,3,4,2 - Inlet 0.20mm (0.008 in) - Exhaust 0.45mm (0.018 in) - AA 2.1 bar (30 lbf/in2) - AB 2.6 bar (40 lbf/in2) 635mm (25 in H2O)
Fuel System
AA Build (76 HP)
AB (94.5 HP) Build
AB (102 HP) Build
Injection Pump Type Governing Pump Setting Code Static Timing Idling Speed 525-58 & 67, 530-95 & 110, 505-19 & 22, 506-36 Idling Speed 530-120, 508-40 & 510-40 Maximum Governed Speed Maximum No-load Speed Injector Codes Injector Setting Pressure
C.A.V. D.P.A. Mechanical DM55L/1000/1/2420 16.5° BTDC
C.A.V. D.P.A. Mechanical CM78L/1100/1/2420 15.5° BTDC
C.A.V. D.P.A. Mechanical AM77L/800/1/2420 19.5° BTDC
850 rev/min
850 rev/min
850 rev/min
900 rev/min 2200 rev/min 2420 rev/min HZ 220 atm
900 rev/min 2200 rev/min 2420 rev/min JG 230 atm
900 rev/min 2200 rev/min 2420 rev/min JF 250 atm
Cooling System Coolant Pressure Coolant Temperature (Normal) Temperature Warning Light operates at:
0.48 bar (7 lbf/in2) 80-85 °C (176-185 °F) 98 °C (208 °F)
Steer/Fan Pump - Fan section Type Flow at max. engine rev/min at zero pressure
Sundstrand, gear type 25 litres/min 5.5 UK gal/min
Fan Motor
See Page 2/1-1
6.6 US gal/min
For further engine details see Engine Manual Publication No. 9806/0100
9804/1103
20 - 05 - 03/1
Issue 1
CONTENTS
Loadalls
520-55, 526-55,526, 526S
20 - 05 - 03/2
From m/c no. 277001
Data - Engine Type * Build Codes:
Bore (nominal): Stroke: * Swept Volume: Compression Ratio:
* Compression Pressure: Injection Sequence Valve Clearance - Cold or Hot - Inlet - Exhaust * Idling Speed Injection system details Maximum Governed Speed Maximum No-load speed
JCB diesel engine, 4 cylinder, water cooled AA50640 - naturally aspirated (76 HP) AB50594 - turbo charged (106HP) AB50514 - turbo charged (106HP) AR50662 - naturally aspirated, low emission (80HP) AK50652 - turbo charged, low emission (100 HP) AA, AB, AK Builds - 100 mm (3.937 in) AR Builds - 103 mm (4.055 in) 127 mm (5.000 in) AA, AB, AK builds - 4 litres (243 in3) AR Builds - 4.23 litres (258 in3) AA, AB Builds - 16.5 :1 AR Builds - 17.25 : 1 AK Builds 18.5 : 1 20 - 30 bar (290 - 435 lbf/in2) 1,3,4,2 0.20 mm (0.008 in) 0.45 mm (0.018 in) AA, AB builds - 750 rev/min AR, AK builds - 800 rev/min Refer to appropriate engine service manual. 2200 rev/min 2350 rev/min
Induction System Air Cleaner Type Maximum Air Cleaner Restriction
2 stage, dry element 635 mm (25 in H2O)
* Lubrication System Oil Pump Type Oil Pressure (Hot) at maximum speed
Eccentric rotor AA Builds - 2.1 bar (30 lbf/in2) AB, AK Builds - 2.6 bar (40 lbf/in2) AR Builds - 2.0 bar (29 lbf/in2)
Cooling System * Coolant Pressure Coolant Pressure (Normal) Temperature Warning Light operates at:
1 bar (14.5 lbf/in2) 80 - 85 °C (176 - 185°F) 98 °C (208 °F)
For further engine details see Engine Manual Publication No. 9806/0100 (AA and AB Builds), 9806/2140 (AR and AK Builds).
9804/1103
20 - 05 - 03/2
3610 - K/1-1.3
Issue 5*
CONTENTS
* 520-50, * Data
Loadalls
20 - 05 - 03/3
525-50, 525-52
From m/c no. 754000
- Engine
Type:
JCB diesel engine, 4 cylinder, water cooled
Build Codes: 520-50, 525-50 525-52
AA 50550- naturally aspirated (76 HP) AR 50690 - naturally aspirated, low emission (75 HP) AK - turbocharged, low emission (100 HP)
Bore (nominal) AA, AK builds AR builds
100mm (3.937 in) 103mm (4.055 in)
Stroke
127mm (5.000 in)
Swept Volume AA, AK builds
4 litres (243 in3)
Compression Ratio AA builds AR builds AK builds
16.5:1 17.25:1 18.5:1
Compression Pressure
20-30 bar (300-450 lbf/in2)
Injection Sequence
1,3,4,2
Valve Clearance - Cold or Hot - Inlet - Exhaust
0.20mm (0.008 in) 0.45mm (0.018 in)
Idling Speed
750 rev/min
Maximum Governed Speed
2000 rev/min
Maximum No-load Speed AA builds AR builds AK builds
2200 rev/min 2260 rev/min 2420 rev/min
Injection System Details - Refer to appropriate service manual. Induction System Air Cleaner Type Maximum Air Cleaner Restriction
2 stage, dry element 635mm (25 in H2O)
Lubrication System Oil Pump Type Oil Pressure (Hot) at maximum speed
Eccentric rotor 2.1 bar (30 lbf/in2)
Cooling system Coolant Pressure Coolant Temperature (Normal) Temperature Warning Light operates at:
0.48 bar (7 lbf/in2) 80-85 °C (176-185 °F) 98 °C (208 °F)
For further engine details see Engine Manual Publication No. 9806/0100 (AA builds), 9806/2140 (AR and AK builds).
9804/1103
20 - 05 - 03/3
3620 - K/1-1.3
Issue 2*
CONTENTS
Loadalls
530, 535, 540 532, 537, 550
20 - 05 - 03/4
From m/c no. 767001
Data - Engine Type
JCB diesel engine, 4 cylinder, water cooled AA - 50590, naturally aspirated 76HP AB - 50592, turbocharged 96HP AB - 50645, turbocharged 106HP 85A Alternator AB - 50591, turbocharged 106HP 65A Alternator AR - 50659, naturally aspirated, 80HP AK - 50667, turbocharged, 102HP 65A Alternator AK - 50671, turbocharged, 102HP 85A Alternator
Bore (nominal): AA, AB, AK Builds AR Builds
100mm (3.937 in) 103 mm (4.055 in)
Stroke
127mm (5.000 in)
Swept Volume AA, AB, AK Builds AR Builds
4 litres (243 in3) 4.23 litres (258 in3)
Compression Ratio AA, AB Builds AR Builds AK Builds
16.5 : 1 17.25 : 1 18.5 : 1
Compression Pressure Injection Sequence Valve Clearance - Cold
28 bar (400 lbf/in2) maximum variation between cylinders 3.5 bar (50 lbf/in2) 1,3,4,2 - Inlet 0.20mm (0.008 in) - Exhaust 0.45mm (0.018 in)
Idling Speed
750 rev/min (AA/AB) 800 rev/min (AR/AK)
Maximum Governed Speed
2200 rev/min
Maximum No-load Speed AA/AB Build AR/AK Build
2420 rev/min 2350 rev/min
Injection System Details
- refer to appropriate Engine Service Manual (see below)
Lubrication System Oil Pump type Oil Pressure (Hot) at maximum speed: AA Builds AB, AK Builds AR Builds Cooling System * Fan Speed Coolant Pressure Coolant Temperature (Normal) Temperature Warning Light operates at:
Eccentric rotor 2.1 bar (30 lbf/in2) 2.6 bar (40 lbf/in2) 2.0 bar (29 lbf/in2)
2200 rev/min (to machine S/N 785165) 1800 rev/min nominal (from machine S/N 785166) 1 bar (14.5 lbf/in2) 80-85 °C (176-185 °F) 98 °C (208 °F)
For further engine details see Engine Service Manual, Publication No. 9806/0100 (AA and AB builds), 9806/2140 (AR and AK builds).
9804/1103
20 - 05 - 03/4
3630 - K/1-1.5 & 3660 - K/1-1.2
Issue 2*
CONTENTS
Loadalls
20 - 05 - 03/5
506B, 506C, 506C (HL), 508C Data - Engine Type Engine Build Codes 506B:
JCB Diesel Engine, 4 cylinder, water cooled
AA - naturally aspirated (76 HP) AB - turbo charged (106 hp)
506C:
AA - naturally aspirated (76 HP) AB - turbo charged (96 hp) AR - naturally aspirated (low emission) 80 hp AK - turbo charged (low emission) 100 hp
506C(HL):
AR - naturally aspirated (low emission) 80 hp
508C:
AB - turbo charged (96 hp) AK - turbo charged (low emission) 100 hp
Bore (nominal) AA, AK builds AR builds
3.937 in (100mm) 4.055 in (103mm)
Stroke
5.000 in (127mm)
Swept Volume AA, AK builds AR builds
243 in3 (4 litres) 258 in3 (4.23 litres)
Compression Ratio
AA Builds 16.5:1
Compression Pressure Variance between cylinders Injection Sequence Valve Clearance - Cold or Hot - Inlet - Exhaust
300-500 lbf/in2 (20 to 35 bar) typical 3.5 bar (50 lbf/in2) maximum 1,3,4,2
Idling Speed
AA, AB Builds 750 rev/min (±2)
Maximum Governed Speed High Idle Speed (AA, AB Builds) High Idle Speed (AR, AK Builds)
2200 rev/min 2420 rev/min 2350 rev/min
Induction System Air Cleaner Type Maximum Air Cleaner Restriction
2 stage, dry element 635mm (25 in H2O)
Lubrication System Oil Pump Type
Eccentric rotor
Oil Pressure (Hot) at maximum speed
Cooling system Coolant Pressure Coolant Temperature (Normal) Temperature Warning Light operates at Fan Speed (506) Fan Speed (506HL, 508)
AR Builds 17.25:1
AK Builds 18.5:1
0.008 in (0.20mm) 0.018 in (0.45mm)
AA Builds 30 lbf/in2 (2.1 bar)
AR, AK Builds 800 rev/min (±25)
AB, AK Builds 2.6 bar (40 lbf/in2)
AR Builds 2.0 bar (30 lbf/in2)
0.48 bar (7 lbf/in2) 80-85°C (176-185°F) 98°C (208°F) 2400 rev/min 2600 rev/min
For further engine details see Engine Manual Publication No. 9806/0100 (AA builds), 9806/2140 (AR and AK builds).
9804/1103
20 - 05 - 03/5
3640U - K/1-1.3
Issue 1
Loadalls
CONTENTS
525-58/67, 527-58/67, 530-67/95 & 535-67, 505-19, 505-22
20 - 05 - 04/1
From m/c no. 567362
Data - Axles FRONT AXLE Type Weight (approximate) Overall Gear Ratio Crownwheel & Pinion Ratio Hub Reduction
JCB Spiral bevel with epicyclic hub reduction 490 kg (1100 lb) 18.16:1 (Germany 13.7:1) 3.36:1 (Germany 2.54:1) 5.4:1
REAR AXLE Type Weight (approximate) Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction Oscillation Castor Angle Camber Angle King-pin Inclination Toe-in
JCB Spiral bevel with epicyclic hub reduction 352 kg (776 lb) 23.625:1 (Germany 18.6:1) 4.38:1 (Germany 3.44:1) 5.4:1 ± 9° 2° 2° Positive Zero Zero
530-120, 537-120/130, 508-40, 510-40 FRONT AXLE Type Weight (approximate) Overall Gear Ratio Crownwheel & Pinion Ratio Hub Reduction
JCB Spiral bevel with epicyclic hub reduction 490 kg (1100 lb) 18.16:1 (Germany 13.7:1) 3.36:1 (Germany 2.54:1) 5.4:1
REAR AXLE Type Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction Oscillation Castor Angle Camber Angle King-pin Inclination Toe-in
JCB Spiral bevel with epicyclic hub reduction 24.97:1 (Germany 18.16:1) 4.62:1 (Germany 3.36:1) 5.4:1 ± 10° Zero 1° Zero Zero
530-110, 506-36 FRONT AXLE Type Weight (approximate) Overall Gear Ratio Crownwheel & Pinion Ratio Hub Reduction
JCB Spiral bevel with epicyclic hub reduction 490 kg (1100 lb) 18.16:1 (Germany 13.7:1) 3.36:1 (Germany 2.54:1) 5.4:1
REAR AXLE Type Weight (approximate) Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction Oscillation Castor Angle Camber Angle King-pin Inclination Toe-in
JCB Spiral bevel with epicyclic hub reduction 352 kg (776 lb) 23.625:1 (Germany 18.6:1) 4.38:1 (Germany 3.44:1) 5.4:1 ± 10° 0° 1° Zero Zero
9804/1103
20 - 05 - 04/1
Issue 3
Loadalls
CONTENTS
20 - 05 - 04/2
Data - Axles *
520-55 RS Machines from m/c no. 277001 Front Axle Type Axle Reduction
Rigid, 2 wet brake packs, standard or limited slip differential 10.667:1
Drop Box Location Reduction ratio
Rear face of front axle, housing parking brake, 2/4 wheel disconnect (if fitted) 1.178:1
Rear Axle Type Axle Reduction Steer angle Toe in
Steer, non braked, standard or limited slip differential, hydraulic track rod 10.667:1 50° non adjustable 0°
520-55 4 Wheel Steer Machines up to Serial No. 2768610 Front Axle Type Axle Reduction Steer angle Toe in
Steer, 2 wet brake packs, standard or limited slip differential, hydraulic track rod 10.667:1 40° non adjustable 0°
Drop Box Location Reduction ratio
Rear face of front axle, housing parking brake, 2/4 wheel disconnect (if fitted) 1.178:1
Rear Axle Type Axle Reduction Steer angle Toe in
Steer, 2 wet brake packs, standard or limited slip differential, hydraulic track rod 10.667:1 40° non adjustable 0°
* 520-55 4 Wheel Steer Machines from * 526-55, 526, 526S Machines to Serial Front Axle & Rear Axle Type Designation Type of Brakes Overall Gear Ratio Crownwheel & Pinion Ratio Number of Teeth Crownwheel Pinion Hub reduction Toe-in Castor angle Camber angle Kingpin inclination Drop Box Location Reduction ratio
9804/1103
Serial No. 2768611 No. 280299
JCB spiral bevel input with epicyclic hub reduction SD55 (with brakes) Oil immersed multi-plate disc located in hubs 10.46:1 1.9375:1 31 16 5.4:1 0° 0° 1° 0°
Rear face of front axle, housing parking brake 1.545:1
20 - 05 - 04/2
3610 - F/1-1.5
Issue 5*
Loadalls
CONTENTS
* 520-50,
20 - 05 - 04/3
526-55, 526, 526S
Data - Axles * All
526-55 Machines, 526 & 526S Machines to Serial No. 280299
Front Axle & Rear Axle Type Designation Type of Brakes Weight (with no steer rams and without wheels) Overall Gear Ratio Crownwheel & Pinion Ratio Number of Teeth Crownwheel Pinion Hub reduction Toe-in Castor angle Camber angle Kingpin inclination
JCB spiral bevel input with epicyclic hub reduction SD55 (with brakes) Oil immersed multi-plate disc located in hubs 330 kg (728 lb) approx 16.2:1 3:1 33 11 5.4:1 0° 0° 1° 0°
3610 - F/1-2.4
From m/c no. 754000
* 520-50/525-50 * Front Axle and Rear Axle Type Designation Type of Brakes Weight * (with no steer rams and without wheels) * Overall Gear Ratio Crownwheel & Pinion Ratio Number of Teeth * Crownwheel * Pinion * Hub reduction Toe-in Castor angle Camber angle Kingpin inclination * 526,
520-50 525-50 JCB spiral bevel input with epicyclic hub reduction SD40 (with brakes) SD55 (with brakes) Oil immersed multi-plate disc located in hubs 245 kg (540lb) approx 16.154 1 France (21.82:1) 2.692 1 France (3.626:1)
330kg (728lb) approx 16.2 : 1 3:1
35 13 6 :1 0° 0° 1° 0°
33 11 5.4 : 1 0° 0° 1° 0°
526S
3610 - F/1-1.3
From m/c no. 280300
Front Axle Type Brakes Steering Weight (approximate) Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction
JCB SD70. Spiral bevel with epicyclic hub reduction Oil immersed multi-plate disc located in centre section Powered track rod mounted on rear of axle Standard 15.78:1 Standard 2.923:1 Extra Low 3.364:1 5.4:1
Extra Low 18.16:1 Colour Code: Orange Colour Code: Blue
Rear Axle Type Steering Weight (approximate) Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction
JCB SD55. Spiral bevel with epicyclic hub reduction Powered track rod mounted on rear of axle 23.62:1 4.375:1 5.4:1
Colour Code: Blue
3610 - F/1-2.4
9804/1103
20 - 05 - 04/3
Issue 5*
Loadalls
CONTENTS
20 - 05 - 04/4
* 528-70 from m/c no. 796000 * 528S from m/c no. 796102 * Data-
Continued
Axles
Front Axle Type Brakes Steering Overall Gear Ratio Overall Gear Ratio (Germany) Crownwheel and Pinion Ratio Hub Reduction
JCB SD70. Spiral bevel with epicyclic hub reduction Oil immersed multi-plate disc located in centre section Powered track rod mounted on rear of axle 16.19:1 (including drop box) 12.39:1 (including drop box) 16/31 teeth 5.4:1
Drop Box Drop Box Ratio Drop Box Ratio (Germany)
1.547:1 1.184:1
Rear Axle Type Steering Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction
JCB SD55. Spiral bevel with epicyclic hub reduction Powered track rod mounted on rear of axle 12.34:1 (including dropbox) 16/31 teeth 5.4:1
Tyres and Pressures 528-70 Size 1300-24 15.5/80-24
Ply 15 12
lbf/in2 78 58.0
Bar 5.4 4.0
lbf/in2 54.0
Bar 3.7
528S Size 17.5LR24
Ply -
IMPORTANT: A different load chart is needed if the 17.5LR24 tyre is fitted as a replacement for the 15.5/80-24 tyre. Contact your JCB Distributor for advice. Note: If the tyres fitted to your machine are not listed, then contact your JCB Distributor for advice, DO NOT guess tyre pressures.
9804/1103
20 - 05 - 04/4
3650 - F/1-1.2
Issue 4*
CONTENTS
Loadalls
20 - 05 - 04/5
506B, 506C, 506C (HL), 508C Data - Axles Front Axle 506B & 506C Type Weight (approximate) Overall Gear Ratio Crownwheel & Pinion Ratio Hub Reduction
JSB Spiral bevel with epicyclic hub reduction 450 kg (992 lb) 18.16:1 3.36:1 5.4:1
506C (HL) & 508C Type Weight (approximate) Overall Gear Ratio Crownwheel & Pinion Ratio Hub Reduction
JCB Spiral bevel with epicyclic hub reduction 490 kg (1100 lb) 18.16:1 3.36:1 5.4:1
Rear Axle 506B & 506C Type Weight (approximate) Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction Oscillation Castor Angle Camber Angle King-pin Inclination Toe-in
JCB Spiral bevel with epicyclic hub reduction 352 kg (776 lb) 24.98:1 4.63:1 5.4:1 ± 10° 0° 1° Zero Zero
506C (HL) & 508C Type Weight (approximate) Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction Oscillation Castor Angle Camber Angle King-pin Inclination Toe-in
JCB Spiral bevel with epicyclic hub reduction 352 kg (776 lb) 23.625:1 4.38:1 5.4:1 ± 10° 0° 1° Zero Zero
9804/1103
20 - 05 - 04/5
3640U-F/1-3.3
Issue 2*
Loadalls
CONTENTS
20 - 05 - 04A/1
All Models except 530, 532, 535, 537, 540, 550 Data - Tyres Note: The maximum pressure embossed on the tyre may differ from the pressure stated below. Inflate to pressures below, these are agreed with the tyre manufacturer/s in accordance with the European Tyre and Rim Technical Organisation (ETRTO) standards to satisfy machine stability performance. If the tyres fitted to your machine are not listed, contact your JCB Distributor for advice, DO NOT guess tyre pressures.
525-58, 527-58 Size 17.5 - LR 24 15.5/80 - 24 15.5-25
Front Ply 10 12
Bar 3.0 3.0 2.45
525-67, 527-67 Size 17.5 - LR 24 15.5/80 - 24 15.5-25
10 12
Bar 3.7 4.0 4.0
10 12
Bar 3.7 4.0 4.0
Ply 10 12
Bar 4.0 4.0
Ply 12
Bar 4.0
Ply 12
Bar 2.45
Ply 12
Bar 3.9
Ply 10 12
Bar 4.0 4.0 4.0
Bar 4.0 4.0
lbf/in2 58
Bar 4.0
lbf/in2 35.5
Bar 2.45
lbf/in2 57
Bar 3.9
lbf/in2 58 58 58
Bar 4.0 4.0 4.0
lbf/in2 58
Bar 4.0
530-120 Bar 4.0 4.0
Manufacturer/Type Michelin/Traction Sure Grip/Traction Industrial Traction
lbf/in2 54 58 58
Manufacturer/Type Michelin/Traction Sure Grip/Traction Industrial Traction
lbf/in2 58 58
Manufacturer/Type Sure Grip/Traction Industrial Traction
lbf/in2 58
Manufacturer/Type Sure Grip/Traction
lbf/in2 35.5
Manufacturer/Type Firestone
lbf/in2 57
Manufacturer/Type Firestone
lbf/in2 58 58 58
Manufacturer/Type Sure Grip/Traction Industrial Traction Michelin/Traction
lbf/in2 58
Manufacturer/Type Firestone
lbf/in2 58 58
Manufacturer/Type Industrial Traction Sure Grip/Traction
Rear
Rear
Rear
Rear
Rear
Front Ply 12 12
lbf/in2 54 58 58
Rear
Front
Size Ply Bar 15.5-25 12 4.0 Note: All tyres are water/calcium choride ballasted.
9804/1103
lbf/in2 58 58
Manufacturer/Type Michelin/Traction Sure Grip/Traction Industrial Traction
Rear
Front
506-36
Size 15.5-25 15.5/80 - 24
Bar 3.7 4.0 4.0
Front
530-110 Size 17.5 - LR 24 15.5-25 15.5 R25
lbf/in2 54 58 58
lbf/in2 43.5 43.5 35.5
Rear
Front
505-22 Size 15.5-25
Bar 3.7 4.0 4.0
Front
505-19 Size 15.5-25
lbf/in2 54 58 58
Front
530-95 Size 17.5 - LR 24
Bar 3.0 3.0 2.45
Front Ply
535-67 Size 15.5/80 - 24 15.5-25
43.5 43.5 35.5
Front Ply
530-67 Size 17.5 - LR 24 15.5/80 - 24 15.5-25
Rear lbf/in2
Rear lbf/in2 58 58
Bar 4.0 4.0
20 - 05 - 04A/1
Issue 1
Loadalls
CONTENTS
20 - 05 - 04A/2
All Models except 530, 532, 535, 537, 540, 550 Data - Tyres Note: The maximum pressure embossed on the tyre may differ from the pressure stated below. Inflate to pressures below, these are agreed with the tyre manufacturer/s in accordance with the European Tyre and Rim Technical Organisation (ETRTO) standards to satisfy machine stability performance. If the tyres fitted to your machine are not listed, contact your JCB Distributor for advice, DO NOT guess tyre pressures.
537-120 Size 15.5-25
Front Ply 14
Size 15.5-25
lbf/in2 58
Bar 4.0
537-130 Ply 14
Bar 4.0
Front
510-40
Bar 4.0
Front
520-55
lbf/in2 65
526-55 & 526
Bar 4.48
Type Industrial Traction
lbf/in2 65
Type Industrial Traction
Rear lbf/in2 58 58 42
Bar 4.0 4.0 2.9
lbf/in2 58
lbf/in2 51 44 51 58 51 58
Bar 3.5 3.0 3.5 4.0 3.5 4.0
Front Ply 10
Type Industrial Traction
Rear lbf/in2 51 44 51 58 51 58
Bar 3.5 3.0 3.5 4.0 3.5 4.0
lbf/in2 58
Rear
Front Ply 10 10 10
Type Industrial Traction
Rear lbf/in2 58
Size Ply Bar 17.5-25 14 4.48 Note: All tyres are water/calcium choride ballasted.
lbf/in2 58
Rear lbf/in2 58
Bar 4.0
Size Ply Bar 15.5-25 12 4.0 Note: All tyres are water/calcium choride ballasted.
Size 405 x 70 x R20 375 x 75 x R20 16.0/20-70
Bar 4.0
Front
508-40
Size 12.5 x 18 x 80 12.5 x 20 335 x 80 x R18 375 x 75 x R20 335 x 80 x R20 14.5 - 20
Rear
3610 - F/1-3.2
3610 - F/1-3.2
lbf/in2 58 58 42
Bar 4.0 4.0 2.9
3610 - F/1-3.2
526S (526 N.Am) Size 15.5/80-24 17.5LR 24
Front Ply 10 -
Size 10.5/80 x 80 10.5/18 MPT 15.0/55-17
lbf/in2 44 44
Bar 3.0 3.0
520-50
Rear
Front Ply 10 10 10
Bar 3.0 4.0 3.5
lbf/in2 44 44
Bar 3.0 3.0
Rear lbf/in2 44 58 51
Bar 3.0 4.0 3.5
3620 - F/1-1.3
lbf/in2 44 58 51 3620 - F/1-1.3
9804/1103
20 - 05 - 04A/2
Issue 1
Loadalls
CONTENTS
20 - 05 - 04A/3
All Models except 530, 532, 535, 537, 540, 550 Data - Tyres Note: The maximum pressure embossed on the tyre may differ from the pressure stated below. Inflate to pressures below, these are agreed with the tyre manufacturer/s in accordance with the European Tyre and Rim Technical Organisation (ETRTO) standards to satisfy machine stability performance. If the tyres fitted to your machine are not listed, contact your JCB Distributor for advice, DO NOT guess tyre pressures.
525-50 Size 12.5 x 18 335/80 R18
Front Ply 10/12 10
Size 405/70R20 16.0/70-20
lbf/in2 58 65
Bar 4.0 4.5
525-52
Rear
Front Ply 10 14
506B, 506C
3620 - F/1-1.3
Rear lbf/in2 TBA TBA
Bar TBA TBA
lbf/in2 58 65
Bar 4.0 4.5
Bar TBA TBA
Front
lbf/in2 TBA TBA
Type 3620 - F/1-1.3
Rear
Ply
Bar
lbf/in2
Bar
lbf/in2
Type
12 14
4.0 5.4
58 78
4.0 5.4
58 78
Industrial Traction
Size
Ply
Bar
lbf/in2
Bar
lbf/in2
Type
15.5-25 1300-24
12 14
4.0 5.4
58 78
4.0 5.4
58 78
Industrial Traction
Size 15.5-25 1300-24
3640U - F/1-4.3
506C (HL), 508C
3640U - F/1-4.3
Note Tires are not water/calcium chloride ballasted on 506C High Lift (HL) machines.
528-70, 506C
Front
Rear
Size
Ply
Bar
lbf/in2
Bar
lbf/in2
13.0-24 15.5/80-24
14 12
5.4 4.0
78 58
5.4 4.0
78 58
528S Size 17.5LR24 460/70R24 15.5/80-24 13.0-24
9804/1103
Front
8450/192
Rear
Ply
Bar
lbf/in2
Bar
lbf/in2
12 14
3.7 3.7 4.0 5.4
54 54 58 78
3.7 3.7 4.0 5.4
54 54 58 70
20 - 05 - 04A/3
8450/192
Issue 1
Loadalls
CONTENTS
20 - 05 - 04A/4
All Models except 530, 532, 535, 537, 540, 550 Data - Tyres Note: The maximum pressure embossed on the tyre may differ from the pressure stated below. Inflate to pressures below, these are agreed with the tyre manufacturer/s in accordance with the European Tyre and Rim Technical Organisation (ETRTO) standards to satisfy machine stability performance. If the tyres fitted to your machine are not listed, then contact your JCB Distributor for advice, DO NOT guess tyre pressures.
530
Front
Size 17.5 LR 24 15.5/80 x 24 15.5 - 25 12.00 R24 X MINE D2
Ply -10 12 --
Bar 3.7 4.0 4.0 4.0
Ply 12 10 ---
Bar 4.0 4.0 4.0 4.0
Size
Ply
Bar
15.5-25 15.5/80 x 24 16.5/85 x 24 15.5 R25 (L2/L3) 12.00 R24 (L5)
12 12/16 14
4.0 4.0 4.0 4.5 5.8
Ply 12 14 12 16
Bar 4.0 4.0 4.0 4.0 4.5
Ply
Bar
12
4.0
* 535,
540
Size 15.5 - 25 15.5/80 x 24 445/70 R24 XM47 12.00 R24 X MINE D2
* 550 Size 17.5-25
Rear Bar 3.7 4.0 4.0 4.0
Front
* 532
* 537 Size 15.5-25 16.5/85 x 24 17.5 -25 15.5/80 - 24 15.5 R25 (L2/L30
lbf/in2 53 58 58 58
lbf/in2 58 58 58 58
Front 4.0 4.0 4.0 4.5 5.8
Type Industrial traction Sure Grip/Traction Traction
lbf/in2 †Ballast litres/US gal 58 58 58 65 84
Type Industrial Traction Sure Grip/Traction
Rear Bar 4.0 4.0 4.0 4.0 4.5
Front lbf/in2 †Ballast litres/US gal 58 288.5 (76.25)
lbf/in2 58 58 58 58
Rear Bar
Front lbf/in2 58 58 58 58 65
Type Traction Sure Grip/Traction Industrial traction
Rear Bar 4.0 4.0 4.0 4.0
lbf/in2 †Ballast litres/US gal 58 58 58 65 84
lbf/in2 53 58 58 58
lbf/in2 58 58 58 58 65
Type Industrial Traction Sure Grip/Traction Sure Grip/Traction
Rear Bar 4.0
lbf/in2 †Ballast litres/US gal 58 288.5 976.25)
Type Industrial Traction
† North America only (if applicable)
9804/1103
20 - 05 - 04A/4
Issue 1
CONTENTS
Loadalls
20 - 05 - 05/1
ALL MODELS
From m/c no. 567362
Data - Transmission TECHNICAL DATA Syncro Shuttle
Combined torque converter, reverser, and gearbox unit with integral parking brake.
Weight (dry) Torque Converter Dia. Torque Multiplication at Stall
157 kg (345 lb) 279mm (11in.) 2.20:1
Gear Ratios
1st 2nd 3rd 4th
5.55:1 3.45:1 1.83:1 1.00:1
Converter Pressures (in neutral)
bar
kgf/cm2
lbf/in2
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
2.4 - 3.4 0.7 - 6.2 1.3 - 2.0 5.2 - 5.9
2.5 - 3.5 0.7 - 6.3 1.4 - 2.1 5.3 - 6.0
35 - 50 10 - 90 20 - 30 75 - 85
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
1.0 - 1.7 0 - 2.1 0.3 - 0.6 1.0 - 1.7
1.1 - 1.8 0 - 2.1 0.3 - 0.6 1.1 - 1.8
15 - 25 0 - 30.5 4.0 - 8.0 15 - 25
6.5
6.7
95
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
0.2 - 0.3 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6
0.2 - 0.4 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6
3.0 - 5.0 6.0 - 10.0 2.0 - 3.0 4.0 - 8.0
At 50 deg. C
1000 rev/min 2000 rev/min
9.3 - 10.3 10.7 - 11.7
9.5 - 10.5 10.9 - 12.0
135 - 150 155 - 170
At 100 deg.C
1000 rev/min 2000 rev/min
9.3 - 10.3 9.3 - 10.3
9.5 - 10.5 9.5 - 10.5
135 - 150 135 - 150
Converter In at 50 deg.C Converter In at 100 deg.C
Converter Out at 50 deg.C Converter Out at 100 deg.C
Converter Inlet Relief Valve Pressure (max.) Lubrication Pressures (in neutral) At 50 deg.C At 100 deg.C
Main Line Pressure (in neutral)
Clutch Pressure (forward and reverse) At 50 deg. C
1000 rev/min 2000 rev/min
5.5 - 6.2 7.6 - 9.6
5.6 - 6.3 7.7 - 9.8
80 - 90 110 - 140
At 100 deg.C
1000 rev/min 2000 rev/min
5.5 - 6.2 6.2 - 6.9
5.6 - 6.3 6.3 - 7.0
80 - 90 90 - 100
9804/1103
20 - 05 - 05/1
Issue 4*
Loadalls
CONTENTS
20 - 05 - 05/2
ALL MODELS
From m/c no. 567362
Data - Transmission Flow Rates (in neutral)
L/min
US gal/min
UK gal/min
Cooler at 50 deg.C
1000 rev/min 2000 rev/min
10.4 - 13.6 14.5 - 20.0
2.8 - 3.6 3.8 - 5.3
2.3 - 3.0 3.2 - 4.4
Cooler at 100 deg.C
1000 rev/min 2000 rev/min
10.2 - 12.5 22.7 - 26.1
2.7 - 3.3 6.0 - 6.9
2.3 - 2.8 5.0 - 5.7
Pump at 50 deg.C
1000 rev/min 2000 rev/min
11.0 - 15.0 22.5 - 29.5
2.9 - 4.0 6.0 - 7.8
2.5 - 3.3 5.0 - 6.5
520-55
From m/c no. 277001
Data - Transmission As “All Models’.above except for the following: Weight (dry) Torque Converter Dia. Torque Multiplication at Stall
157 kg (345 lb) 279mm (11in.) 2.20:1
Gear Ratios
1st 2nd 3rd 4th
5.55:1 3.45:1 1.83:1 1.00:1
Minimum Engine Rev/Min at Converter Stall
Engine Type AA50261
Rev/Min 1800
* 520-5,
525-50, 525-52
From m/c no. 754000
Data - Transmission
3620 - F/1-2.3
As ‘All Models’ above except for the following: Clutch Pressure (forward and reverse)
At 50°C
1000 rev/min 2000 rev/min
bar 7.6 - 9.6 9.0 - 11.0
At 100 °C
1000 rev/min 2000 rev/min
7.6 - 9.6 7.6 - 9.6
9804/1103
20 - 05 - 05/2
kgf/cm2 7.7 - 9.8 9.1 - 11.2
lbf/in2 110 - 140 130 - 160
7.7 - 9.8 7.7 - 9.8
110 - 140 110 - 140
Issue 3*
Loadalls
CONTENTS
20 - 05 - 05/3
* 520,
526 from m/c no. 277001 528 from m/c no. 796000, 506, 508 Data - Transmission Powershift Designation Weight (dry)
Full electro-hydraulic transmission unit with input, reverse, layshaft, mainshaft and 4 wheel drive clutch packs. Torque converter and parking brake integral . PS740 (4 wheel drive) 107 kg (236 lb)
* Number of Teeth Transfer Gear Layshaft Input Gear (4WD) Output Gear (4WD) * Gear Ratios
Torque Converter Dia. Torque Multiplication at Stall
Converter Out at 50 deg.C
Mainline Pressure (in neutral) At 50 deg. C Flow Rates (in neutral) Cooler at 50 deg.C Pump at 50 deg.C
45 18 -
46 16 -
Std Ratio
Low Ratio 6.58:1 3.71:1 1.77:1 1.00:1
Extra Low Ratio (506, 508) 47 15 21 44 Extra Low Ratio (506, 508) 7.17:1 4.04:1 1.77:1 1.00:1
2.20:1 Ratio 2 (506/508-1) Purple 1 White
2.40:1 Ratio 2 Orange 1 (506/508-2) Green
2.80:1 Ratio 3 Brown
1000 rev/min 2000 rev/min
bar 2.8 - 4.1 4.8 - 6.2
kgf/cm2 2.8 - 4.2 4.9 - 6.3
lbf/in2 40 - 60 70 - 90
1000 rev/min 2000 rev/min
1.9 - 2.3 2.3 - 2.7
1.9 - 2.3 2.3 - 2.7
27 - 33 33 - 39
6.5
6.7
95
1000 rev/min 2000 rev/min
bar 0.14 - 0.28 0.28 - 0.55
kgf/cm2 0.14 - 0.28 0.28 - 0.56
lbf/in2 2.0 - 4.0 4.0 - 8.0
1000 rev/min 2000 rev/min
bar 9.0 - 10.0 9.7 - 11.0
kgf/cm2 9.1 - 10.2 9.8 - 11.3
lbf/in2 130 - 145 140 - 160
1000 rev/min 2000 rev/min
litres/min 10.4 - 13.6 14.5 - 20.0
US gal/min 2.8 - 3.6 3.8 - 5.3
UK gal/min 2.3 - 3.0 3.2 - 4.4
1000 rev/min 2000 rev/min
11.0 - 15.0 22.5 - 29.5
2.9 - 4.0 6.0 - 7.8
2.5 - 3.3 5.0 - 6.5
Converter Inlet Relief Valve Pressure (max.) Lubrication Pressures (in neutral) At 50 deg.C
Low Ratio
1st 5.72:1 2nd 3.23:1 3rd 1.77:1 4th 1.00:1 279mm (11in.) 2.20:1 or 2.40:1 or 2.80:1
* Torque Converter Colour Code Identification Colour Coded Dots
Converter Pressures (in neutral) Converter In at 50 deg.C
Std Ratio
The following clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2): Input Clutch Pressure (high and low ratio) Reverse Clutch Pressure (high and low ratio) Layshaft Clutch Pressure Mainshaft Clutch Pressure 2/4 Wheel Drive Clutch Pressure * Note 1: For brand new gearboxes (i.e. under 100 hours service) or gear boxes that have been fully serviced the pressures will be slightly higher by approximately 0.7 - 1.0 bar (10 - 15 lbf/in2) than those shown. * Note 2: Using 2nd and 3rd gears in forward and reverse drive will ensure that ALL clutches are energised during the stall test refer to 'Torque Converter Stall Test'.
9804/1103
20 - 05 - 05/3
3610 - F/1-5.1
3650 - F/1-3.1 3640U - F/1-2.2
Issue 3*
Loadalls
CONTENTS
20 - 05 - 05/3A
520, 526 from m/c no. 277001 528 from m/c no. 796000 506, 508 Data - Transmission Syncro Shuttle CAUTION: Before attempting to tow the machine read carefully the instructions, see Towing Procedure, this Section.
Syncro Shuttle Combined torque converter, reverser, and gearbox unit
*
Weight (dry) Torque Converter Dia. Torque Multiplication at Stall
157 kg (345 lb) 279mm (11in.) 2.20:1
Gear Ratios
1st 2nd 3rd 4th
Stall Speeds Hydraulic only Converter only Hydraulics and Converter
AA/AR Builds (Nat Asp) 2290 rev/min 2000 rev/min 1589 rev/min
Converter Pressures (in neutral)
5.55:1 3.45:1 1.83:1 1.00:1
AK Build (Turbo) 2296 rev/min 2156 rev/min 1815 rev/min
506, 508 AA/AB Builds 1650-1750/1830-1930
bar
kgf/cm2
lbf/in2
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
2.4 - 3.4 0.7 - 6.2 1.3 - 2.0 5.2 - 5.9 1.0 - 1.7 0 - 2.1 0.3 - 0.6 1.0 - 1.7
2.5 - 3.5 0.7 - 6.3 1.4 - 2.1 5.3 - 6.0 1.1 - 1.8 0 - 2.1 0.3 - 0.6 1.1 - 1.8
35 - 50 10 - 90 20 - 30 75 - 85 15 - 25 0 - 30.5 4.0 - 8.0 15 - 25
6.5
6.7
95
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
0.2 - 0.3 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6
0.2 - 0.4 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6
3.0 - 5.0 6.0 - 10.0 2.0 - 3.0 4.0 - 8.0
At 50 deg. C
1000 rev/min 2000 rev/min
9.3 - 10.3 10.7 - 11.7
9.5 - 10.5 10.9 - 12.0
135 - 150 155 - 170
At 100 deg.C
1000 rev/min 2000 rev/min
9.3 - 10.3 9.3 - 10.3
9.5 - 10.5 9.5 - 10.5
135 - 150 135 - 150
At 50 deg. C
1000 rev/min 2000 rev/min
5.5 - 6.2 7.6 - 9.6
5.6 - 6.3 7.7 - 9.8
80 - 90 110 - 140
At 100 deg.C
1000 rev/min 2000 rev/min
5.5 - 6.2 6.2 - 6.9
5.6 - 6.3 6.3 - 7.0
80 - 90 90 - 100
L/min
US gal/min UK gal/min
10.4 - 13.6 14.5 - 20.0 10.2 - 12.5 22.7 - 26.1 11.0 - 15.0 22.5 - 29.5
2.8 - 3.6 3.8 - 5.3 2.7 - 3.3 6.0 - 6.9 2.9 - 4.0 6.0 - 7.8
Converter In at 50 deg.C Converter In at 100 deg.C Converter Out at 50 deg.C Converter Out at 100 deg.C Converter Inlet Relief Valve Pressure (max.) Lubrication Pressures (in neutral) At 50 deg.C At 100 deg.C Main Line Pressure (in neutral)
Clutch Pressure (forward and reverse)
Flow Rates (in neutral) Cooler at 50 deg. C At 100 deg.C Pump at 50 deg. C
9804/1103
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
20 - 05 - 05/3A
36400 - F/1-1.2
2.3 - 3.0 3.2 - 4.4 2.3 - 2.8 5.0 - 5.7 2.5 - 3.3 5.0 - 6.5
3610 - F/1-4.2 3650 - F/1-2.2
Issue 1
CONTENTS
Loadalls
20 - 05 - 05/4
530, 532, 535, 537, 540, 550 Data - Transmission Powershift Description
Full electro-hydraulic transmission 4 or 5 speed (3 Germany) unit with input, layshaft, mainshaft, reverse, 5th gear (if applicable) and 4 wheel drive clutch packs.
Designation
PS700 or PS750
Weight (dry)
2WD 4WD
157 kg (346 lb) 176 kg (388 lb) Extra Low Ratio 1.495
Std Ratio 1.307
Input Gear Output Gear
21 44
23 44
4 Speed 279mm (11in) 2.20:1 Ratio 2 purple/1 White
5 Speed 310mm (12.2in) 2.24:1 Ratio 2 Blue
1000 rev/min 2000 rev/min
bar 2.8 - 4.1 4.8 - 6.2
kgf/cm2 2.8 - 4.2 4.9 - 6.3
lbf/in2 40 - 60 70 - 90
1000 rev/min 2000 rev/min
1.9 - 2.3 2.3 - 2.7
1.9 - 2.3 2.3 - 2.7
27 - 33 33 - 39
Converter Relief (Safety) Valve Setting
6.5
6.7
95
Lubrication Pressures (in neutral) At 50 deg.C
1000 rev/min 2000 rev/min
bar 0.14 - 0.28 0.28 - 0.55
kgf/cm2 0.14 - 0.28 0.28 - 0.56
lbf/in2 2.0 - 4.0 4.0 - 8.0
1000 rev/min 2000 rev/min
bar 9.0 - 10.0 9.7 - 11.0
kgf/cm2 9.1 - 10.2 9.8 - 11.3
lbf/in2 130 - 145 140 - 160
1000 rev/min 2000 rev/min
litres/min 10.4 - 13.6 14.5 - 20.0
US gal/min 2.8 - 3.6 3.8 - 5.3
UK gal/min 2.3 - 3.0 3.2 - 4.4
1000 rev/min 2000 rev/min
11.0 - 15.0 22.5 - 29.5
2.9 - 4.0 6.0 - 7.8
2.5 - 3.3 5.0 - 6.5
2/4 Wheel Drive Ratio 4 Wheel Drive Number of Teeth
Torque Converter Dia. Torque Converter Colour Coded Dots
Converter Pressures (in neutral) Converter In at 50 deg.C
Converter Out at 50 deg.C
Mainline Pressure (in neutral) At 50 deg. C
Flow Rates (in neutral) Cooler at 50 deg.C
Pump at 50 deg.C
All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2). Note: For new gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2 ).
9804/1103
20 - 05 - 05/4
3630 - F/1-1.5
Issue 3*
Loadalls
CONTENTS
20 - 05 - 05/5 *
532, 537, 550
From m/c no. 767001
Data - Transmission Front Axle Type Brakes Steering Weight (approximate) Overall Gear Ratio
JCB SD80. Spiral bevel with epicyclic hub reduction Oil immersed multi-plate disc located in centre section 2 steer rams mounted on rear of axle
Crownwheel and Pinion Ratio Hub Reduction
18.16:1 15.78:1 Germany 3.364:1 2.923 Germany 5.4:1
Colour Code: Blue Colour Code: Orange
Rear Axle Type Brakes Steering Weight (approximate) Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction
* Pump/Transmission
JCB SD80. Spiral bevel with epicyclic hub reduction Oil immersed multi-plate disc located in hubs 2 steer rams mounted on rear of axle 24.97:1 4.625:1 5.4:1
Colour Code: Pink
3660 - F/1-2.1
Stall Speed Combinations - with 11 inch Converters
* The figures given below apply to ‘bedded-in’ engines. ie. engines that have done a minimum of 250 working hours, therefore they should not be used for pre-delivery inspection (PDI) checks. They are intended to be used as guideline figures only and should not be considered as servicing parameters.
JCB Diesel Engine Build Codes AA/AB AK/AR
* Torque Converter Stall 106 hp Turbo (rpm) 76 hp NA (rpm) 102 hp Turbo (rpm) 80 hp NA (rpm)
1965 ±100 1640 ±100 -
1950 ±100 1740 ±100
* Combined Stall 106 hp Turbo 76 hp NA 102 hp Turbo 80 hp NA
1205 ±100 855 ±100 -
1490 ±100 960 ±100
Pump Size (l/min)
110
110
Converter Type (W11)
2.2:1
2.2:1
(rpm) (rpm) (rpm) (rpm)
Note: Combined stall tests are performed with the crowd service operated until the relief valve lifts. * 3660 - F/1-3.1
9804/1103
20 - 05 - 05/5
Issue 2*
CONTENTS
Loadalls
530, 532, 537, 540, 550
20 - 05 - 05/6
From m/c no. 767001
Data - Transmission Front Axle Type Brakes Steering Weight (approximate) Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction
JCB SD70. Spiral bevel with epicyclic hub reduction Oil immersed multi-plate disc located in centre section Powered track rod mounted on rear of axle Standard 15.78:1 Standard 2.923:1 Extra Low 3.364:1 5.4:1
Extra Low 18.16:1 Colour Code: Orange Colour Code: Blue
Rear Axle Type Steering Weight (approximate) Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction
JCB SD55. Spiral bevel with epicyclic hub reduction Powered track rod mounted on rear of axle 23.62:1 4.375:1 5.4:1
Colour Code: Blue
3630 - F/1-2.4
Pump/Transmission Stall Speed Combinations - 11 inch & 12.2 inch Converter JCB Diesel Engines - Build Codes AM JCB Diesel Engines - Build Codes AA and AB Torque Converter Stall 106 hp Turbo (rpm) 76 hp NA (rpm)
1960 1685
Combined Stall 106 hp Turbo 76 hp NA
1280 1185
(rpm) (rpm)
Torque Converter Stall 120 hp Turbo intercooled (rpm)
1980
Hydraulic Stall 120 hp Turbo intercooled (rpm)
2320
Combined Stall 120 hp Turbo intercooled (rpm)
1620
Pump Size (l/min) Pump Size (l/min)
82
Converter Type (11in)
Converter Type (12.2in)
82 2.24:1
2.2:1
JCB Diesel Engines - Build Codes AK and AR Torque Converter Stall 102 hp Turbo (rpm) 80 hp NA (rpm)
1950 TBA
Hydraulic Stall 102 hp Turbo 80 hp NA
(rpm) (rpm)
2280 TBA
Combined Stall 102 hp Turbo 80 hp NA
(rpm) (rpm)
1620 TBA
Pump Size (l/min) Converter Type (11in)
82 2.2:1
Note: Combined stall tests are performed with the crowd service operated until the relief valve is
9804/1103
20 - 05 - 05/6
3630 - F/1-3.4
Issue 2*
CONTENTS
Loadalls
525-58/67, 527-58/67, 530-67 & 535-67, 505-19/22
20 - 05 - 07/1
From m/c no. 567362
Data - Brakes Service Brake Type Actuation Location
JCB Oil-Immersed Disc Single Circuit Hydraulic, Direct Actuation Front Axle (2 Brake Packs)
Friction Plates (5 per brake pack) Outside Diameter Inside Diameter Nominal Facing Area Hydraulic Piston Diameter
220 mm (8.66 in) 180 mm (7.10 in) 12616 mm2 (19.3 in2) 216 mm (8.5 in)
Master Cylinder Type Frenos Iruna Piston Diameter
35 mm (1.125 in)
Parking Brake Type Disc Diameter
Manually Adjusted Caliper 279.4 mm (11 in)
530-95, 530-110, 506-36
From m/c no. 567362
Data - Brakes Service Brake Type Actuation Location
JCB Oil-Immersed Discs Tandem Circuit Hydraulic, Direct Actuation Front Axle (2 Brake Packs)
Friction Plates ( front axle 5 per brake pack) Outside Diameter Inside Diameter Nominal Facing Area Hydraulic Piston Diameter
220 mm (8.66 in) 180 mm (7.10 in) 12616 mm2 (19.3 in2) 216 mm (8.5 in)
Master Cylinder Type Piston Diameter
Frenos Iruna 35 mm (1.125 in)
Parking Brake Type Disc Diameter
9804/1103
Manually Adjusted Caliper 279.4 mm (11 in)
20 - 05 - 07/1
Issue 3
CONTENTS
Loadalls
20 - 05 - 07/2
530-120, 537-120/130, 508-40, 510-40
From m/c no. 567362
Data - Brakes Type Actuation Location
JCB Oil-Immersed Discs Tandem Circuit Hydraulic, Direct Actuation Front Axle (2 Brake Packs) Rear Axle (2 Brake Packs)
Friction Plates ( front axle 5 per brake pack and rear axle 3 per brake pack) Outside Diameter 220 mm (8.66 in) Inside Diameter 180 mm (7.10 in) Nominal Facing Area 12616 mm2 (19.3 in2) Hydraulic Piston Diameter 216 mm (8.5 in) Master Cylinder Type Piston Diameter
Frenos Iruna Tandem Cylinder 38.1mm (1.50 in)
Servo Unit Type Piston Diameter
Frenos Iruna 203.2mm (8 in)
Exhauster Type Ratio
Clayton Dewandre H175 1.4 times engine speed driven off timing gear
Parking Brake Type Disc Diameter
Manually Adjusted Caliper 279.4 mm (11 in)
520-55 RS
From m/c no. 277001 to 279119
Data - Brakes Service Brakes Type Actuation Location
Single Circuit, Oil-Immersed Multi-Plate Disc Actuation Hydraulic Front Axle (2 Brake Packs)
Master Cylinder Number of Cylinders Type Stroke Bore
1 Frenos compensated master cylinder 36 mm (1.4 in) 19.05 mm (0.75 in)
Parking Brake Type Location
Manually Adjusted Disc, cable operated Top rear face of front axle drop box
3610-G/1-1.5
9804/1103
20 - 05 - 07/2
Issue 4*
CONTENTS
Loadalls
20 - 05 - 07/3 *
520-55 AWS
From m/c no. 277001 to 279119
Data - Brakes Service Brakes Type Actuation Location
Single Circuit, Oil-Immersed Multi-Plate Disc Actuation Hydraulic Front Axle (2 Brake Packs), Rear Axle (2 Brake Packs)
Master Cylinder Number of Cylinders Type Stroke Bore
1 Frenos 35 mm (1.4 in) 25.4 (1.0 in)
Parking Brake Type Location
Manually Adjusted Disc, cable operated Top rear face of front axle drop box
3610 - G/1-1.5
* 526-55,
526, 526S from m/c no. 277467 to 280299 AWS from m/c no. 279120
* 520-50
Data - Brakes Service Brakes Type Actuation Location Accumulator Pressure Brake Circuit Operating Pressure Cut-in Cut-out
JCB oil-immersed multi-plate disc high pressure brakes with hydraulic accumulators for emergency application. Hydraulic ON, spring OFF. Front Axle (2 Brake Packs), Rear Axle (2 Brake Packs) 25 bar (363 lbf/in2). 90 bar (1305 lbf/in2). 110 bar (1595 lbf/in2).
Parking Brake Type Location * 520-50,
Manually Adjusted Disc, cable operated Top rear face of front axle drop box
525-50, 525-52
3610 - G/1-1.5
From m/c no. 754000
Data - Brakes Type Actuation Location * System Pressure
Single Circuit, Oil-Immersed Multi-Plate Disc Hydraulic Front Axle (2 Brake Packs), Rear Axle (2 Brake Packs) 90 - 110 bar (1303 - 1595 lbf/in2)
3620 - G/1-1.2
9804/1103
20 - 05 - 07/3
Issue 3*
CONTENTS
Loadalls
526-55, 526, 526S & 520-55 4 Wheel Steer
20 - 05 - 07/4
From m/c no. 2768611
Data - Brakes Service Brakes Type Actuation Location Accumulator Pressure Brake Circuit Operating Pressure Cut-in Cut-out
JCB oil-immersed multi-plate disc high pressure brakes with hydraulic accumulators for emergency application. Hydraulic ON, spring OFF. Front Axle (2 Brake Packs), Rear Axle (2 Brake Packs) 25 bar (363 lbf/in2). 90 bar (1305 lbf/in2). 110 bar (1595 lbf/in2).
Parking Brake Type Location
Manually Adjusted Disc, cable operated Top rear face of front axle drop box
532, 537
From m/c no. 2768611
Data - Brakes Service Brakes Type Actuation Location
Single Circuit, Oil-Immersed Multi-Plate Disc Hydraulic- vacuum servo assisted Front Axle Centre Mounted (2 Brake Packs), Rear Axle Hub Mounted (2 Brake Packs)
Master Cylinder Type Piston diameter Stroke
Frenos master cylinder with remote servo unit 38.1 mm (1.5 in) 25 mm (1.0 in)
Servo Unit Type Vacuum cylinder diameter Hydraulic cylinder diameter
9804/1103
Frenos vacuum assisted hydraulic valve 201 mm (7.9 in) 21.6 mm (0.85 in)
20 - 05 - 07/4
Issue 2*
CONTENTS
Loadalls
20 - 05 - 07/5
528-70 From m/c no. 796000 528S From m/c no. 796102 Data-Brakes Service Brakes Type Actuation Location
JCB oil-immersed multi-plate disc with inboard brakes Hydraulic Front axle centre mounted (2 brake packs)
Parking Brake Type Location
Manually Adjusted Disc, cable operated Transmission output shaft
General Description The service brakes act on the front axle half shafts of all machines. The brakes are oil immersed, multi-disc types which are operated hydraulically by a single pedal and master cylinder arrangement. The brake cylinder reservoir is situated in front of the instrument panel in the cab. The cable operated parking brake acts on a disc which is mounted on the gearbox output shaft to the front axle.
9804/1103
20 - 05 - 07/5
3650 - G/1-1.2
Issue 1
CONTENTS
Loadalls
20 - 05 - 07/6
530, 535, 540
From m/c no. 767001
Data - Brakes * Service Brakes Type Actuation Location
Single Circuit, Oil-Immersed Multi-Plate Disc 530 - Hydraulic 535, 540, 530FS Super, 540FS Super, 530 SXL, 540 SXL - Hydraulic, servo assisted All Machines - Front Axle Centre Mounted (2 Brake Packs)
* Master Cylinder Type
Stroke
530 - master cylinder 535, 540, 530FS Super, 540FS Super, 530 SXL, 540 SXL - master cylinder with remote sservo unit 530 - 35 mm (1.38 in) 535, 540, 530FS Super, 540FS Super, 530 SXL, 540 SXL - 25 mm (1.0 in)
* Servo Unit Type Vacuum cylinder diameter Hydraulic cylinder diameter
9804/1103
Vacuum assisted hydraulic valve 535, 540 - 135.5 mm (5.33 in) 535, 540, 530FS Super, 540FS Super, 530 SXL, 540 SXL - 19 mm (0.75 in)
20 - 05 - 07/6
3630 - G/1-1.4
Issue 2*
CONTENTS
Loadalls
20 - 05 - 07/7
506B, 506C, 506C(HL), 508C Data - Brakes Service Brakes Type Actuation Location
JCB Oil-Immersed Discs Tandem Circuit Hydraulic, Direct Actuation Front Axle (2 Brake Packs) Rear Axle (2 Brake Packs)
Master Cylinder Piston Diameter
35 mm (1.125 in)
Parking Brake Type Disc Diameter
9804/1103
Manually Adjusted Caliper 279.4 mm (11 in)
20 - 05 - 07/7
3640U-G/1-1.3
Issue 1
CONTENTS
Loadalls
20 - 05 - 08/1
ALL MODELS
From m/c no. 567362
Data - Steering System Type
Full power hydrostatic with selectable 2/4/crab steer
Tandem Steer/Fan Pump - Steer Section Type
Sundstrand, gear type AFGP8L/12.5L-31207, double gear type
Controlled Flow Steer, at 1000 engine rev/min and neutral pressure Fan, at max. engine rev/min at zero pressure Total Flow through tank return line at 2200 engine rev/min (pressure outlet blocked)
litres/min 18.2 25.0
UK gal/min 4.0 5.5
US gal/min 4.8 6.6
48
10.5
12.7
Note: The outer section of the pump (furthest from the timing case) drives the steering system. The inner section (nearest the timing case) drives the engine cooling fan. Single Priority Steer/Fan Pump (For 527-58, 527-67, 535-67 from machine serial No. 574296 only) Type
Ultra 1PX090, Gear type
Flow at max. engine rev/min at zero pressure steering at neutral flow out of EF port
litres/min 34.3
UK gal/min 7.5
US gal/min 9.0
Control Unit (525-58, 67, 527-58, 67, 530-67, 535-67, 530-95, 110) (530-120) Relief Valve Pressure
Danfoss Orbitrol OSPV 160 Danfoss Orbitrol OSPB 200 138 bar 2000 lbf/in2
With priority steer/fan pump (527-58, 67, 535-67) Relief Valve Pressure
Danfoss Orbitrol OSPC 160 175 bar 2537.5 lbf/in2
Ram Dimensions (525-58, 67, 527-58, 67 and 530-67, 95, 110) Bore 50 mm (1.97 in) Rod Dia. 25 mm (0.98 in) Stroke 206 mm (8.11 in) Ram Dimensions (530-120 & 537-120, 130) Bore Rod Dia. Stroke
60 mm (23.62 in) 30 mm (1.18 in) 209.5 mm (8.25 in)
Note: 530-120 & 537-120, 130 machines from Serial Number 574481, the rams are supplied by an alternative source. The rams must all be the same type, DO NOT mix rams on a machine. The seal kits are also different.
520-55, 526-55, 526, 526S
From m/c no. 277001
Data - Steering System Type Pump Control Unit Type Relief Valve Operating Pressure Shock Relief Valve Operating Pressure Powered Track Rod Stroke for each side
Full power hydrostatic, powered track rod on rear axle (see Data - Hydraulics) OSPC 125LS 2 2 175 bar (178 kgf/cm ; 2500 lbf/in ) 2 235 bar (239 kgf/cm ; 3407 lbf/in2) 130 mm (5.11 in)
3610-H/1-1.3
9804/1103
20 - 05 - 08/1
Issue 5*
CONTENTS
* ALL
Loadalls
MODELS
20 - 05 - 08/1A
From m/c no. 773135
Data - Steering System Type
Fully hydraulic load sensing with selectable 2-wheel, 4-wheel and crab steer modes. Anti-cavitation valve on 540-170 and 5508 machines. On other machines, the anti-cavitation valve was discontinued from Serial No. 773135 Double acting cylinders on all wheels
Pump
Gear type (19cc/rev) with load sensing priority flow divider delivering 41 litres/min (9 UK Gal/min, 10.8 US Gal/min)
Steering Valve Machines except 540-170, 5508 Displacement Relief Valve Operating Pressure Shock Relief Valve Operating Pressure
200 cc/rev 2 2 175 bar (178 kgf/cm ; 2500 lbf/in ) 2 2 235 bar (239 kgf/cm ; 3407 lbf/in )
540-170, 5508 Machines Relief Valve Operating Pressure Shock Relief Valve Operating Pressure
95 cc/rev (2:1 ratio) 175 bar (178 kgf/cm2; 2500 lbf/in2) 2 2 235 bar (239 kgf/cm ; 3407 lbf/in )
9804/1103
20 - 05 - 08/1A
3630 - H/1-2.3
Issue 1*
CONTENTS
* 520-50,
Loadalls
525 - 50, 525 - 52
20 - 05 - 08/2
From m/c no. 754000
Data - Steering System Type Pump Control Unit Type Relief Valve Operating Pressure Shock Relief Valve Operating Pressure Powered Track Rod Stroke for each side
Full power hydrostatic, powered track rod on rear axle (see Data - Hydraulics) OSPC 125LS 175 bar (178 kgf/cm2; 2500 lbf/in2) 235 bar (239 kgf/cm2; 3407 lbf/in2) 3620-H/1-1.1
130 mm (5.11 in)
From m/c no. 754000
530, 532, 537 Data - Steering System Type 530 532, 537
Full power hydrostatic with selectable 2, 4 and crab steer Powered track rod on rear of axles Steer rams on rear of axles
Pump Control Unit Type 530 532, 537 Relief Valve Operating Pressure Shock Relief Valve Operating Pressure
(see Data - Hydraulics)
9804/1103
OSPV 160 LS OSPB 200 LS 2 2 175 bar (178 kgf/cm ; 2500 lbf/in ) 2 235 bar (239 kgf/cm ; 3407 lbf/in2)
20 - 05 - 08/2
Issue 3*
CONTENTS
Loadalls
20 - 05 - 08/3
528-70 from m/c no. 796000 528S from m/c no. 796102 Data-Steering System Type
Fully hydraulic load sensing with optional 2-wheel, 4-wheel and crab steer modes. Powered trackrods on both axles.
Pump
Gear type (36 cc/rev) with load sensing priority flow divider.
Control Unit Type
OSPC 125LS
Relief Valve Operating Pressure Shock Relief Valve Operating Pressure
175 bar (178 kgf/cm2; 2500 lbf/in2) 235 bar (239 kgf/cm2; 3407 lbf/in2)
9804/1103
20 - 05 - 08/3
3650 - H/1-1.2
Issue 1
CONTENTS
Loadalls
20 - 05 - 08/4
530, 535, 540 532, 537, 550 Data - Steering
From m/c no. 767001
530, 535, 540 System Type
Fully hydraulic load sensing with selectable 2-wheel, 4-wheel and crab steer modes. Anti-cavitation valve on Machines to Serial No. 773053. Powered track rod on both axles
Pump
Gear type (19cc/rev) with load sensing priority flow divider delivering 41 litres/min (9 UK Gal/min, 10.8 US Gal/min)
Control Unit Type
OSPV 160 LS
Relief Valve Pressure: Shock Relief Valve Pressure:
175 bar (178 kgf/cm2; 2500 lbf/in2) 235 bar (239 kgf/cm2; 3407 lbf/in2) 3630 - H/1-1.3
532, 537, 540 System Type
Fully hydraulic load sensing with selectable 2-wheel, 4-wheel and crab steer modes. Anti-cavitation valve on Machines to Serial No. 773134. Double acting cylinders on all wheels
Pump
Gear type (19cc/rev) with load sensing priority flow divider delivering 41 litres/min (9 UK Gal/min, 10.8 US Gal/min)
Control Unit Type
OSPB 200 LS
Relief Valve Pressure: Shock Relief Valve Pressure:
175 bar (178 kgf/cm ; 2500 lbf/in ) 235 bar (239 kgf/cm2; 3407 lbf/in2)
9804/1103
2
20 - 05 - 08/4
2
3660 - H/1-1.1
Issue 1
CONTENTS
Loadalls
20 - 05 - 08/5
506B, 506C, 506C(HL), 508C Data - Steering System Type
Full power hydrostatic with selectable 2/4/crab steer
506B Tandem Steer/Fan Pump - Steer Section Type
Double gear type
Controlled Flow Steer, at 1000 engine rev/min and neutral pressure Fan, at max. engine rev/min at neutral pressure Total Flow through tank return line at 2200 engine rev/min (pressure outlet blocked)
litres/min 12.5 18.8
UK gal/min 2.75 4.1
US gal/min 3.3 4.9
27.5
6.0
7.2
Note: The outer section of the pump (furthest from the timing case) drives the steering system. The inner section (nearest the timing case) drives the engine cooling fan. Control Unit Type Ram Dimensions Bore Rod Dia. Stroke
OSPB 160
50 mm (1.97 in) 25 mm (0.98 in) 205.4 mm (8 in)
506C Note: Hydraulic pressure supply from priority valve in main hydraulic circuit. Control Unit Type Relief Valve Pressure Ram Dimensions Bore Rod Dia. Stroke
OSPC 160 175 bar (2500 lbf/in2)
50 mm (1.97 in) 25 mm (0.98 in) 205.4 mm (8 in)
506C (HL), 508C Tandem Steer/Fan Pump - Steer Section Type
Double gear type
Controlled Flow Steer, at 1000 engine rev/min and neutral pressure Fan, at max. engine rev/min at neutral pressure Total Flow through tank return line at 2200 engine rev/min (pressure outlet blocked)
litres/min 12.5 18.8
UK gal/min 2.75 4.1
US gal/min 3.3 4.9
27.5
6.0
7.2
Note: The outer section of the pump (furthest from the timing case) drives the steering system. The inner section (nearest the timing case) drives the engine cooling fan. Control Unit Type Ram Dimensions Bore Rod Dia. Stroke 9804/1103
OSPB 200
60 mm (2.36 in) 30 mm (1.18 in) 209.5 mm (8.25 in)
20 - 05 - 08/5
3640U - H/1-1.2 & H/1-2.2
Issue 1
Loadalls
CONTENTS
20 - 15 - 01/1
ALL MODELS
From m/c no. 567362
Circuit Diagram - Electrical
48
A
48
600
27
17
5
G/Y
47
26
11 N
46
37
24 202
204
44
208
205
51
811
812
50
815
413 414B 413B
34
203
814 841
839
402
21 42
801 416
400
206
600
60
52
403
414 413A
59
54
414A
2
53
45
U 415
49
405
408
55
404
409
406 412
407
43
56
N G/Y U 805
10
806
807
210
32
212
214
57
804
36
842
40
41
209
211
213
58
215
803
16
31
103A
9
003
810
207 808
800
101
+
401
30
19
25
39 411
6
105
106A
100
300
15
809
803A
802
3
1
808A
23
20
200
61
104
103
800 106
100 200
842
A2
A1
A4
A5
A6
A7
A8
A9
B1
B2
004
200 103
4
000
000
000R
000R
200
200
004 842
A215190
9804/1103
20 - 15 - 01/1
Issue 2
Loadalls
CONTENTS
20 - 15 - 01/2
ALL MODELS
From m/c no. 567362
Circuit Diagram - Electrical
A 48
48
48
600
66
69
216
220
219
229
78 73
217 67
225
221
226
227
231
232
233
78B 78C 78D
65 218
235
234
78E
230
78F
835
818 834
829P
63
838 837
78A 301 831
99
847
B9 C1 72
816
62
821
823 822
829 830
848 826
824
86
825
B8
C2
844 817
77
68
B6
B7 112
828 410
71B 76
79
820
222
223
224
833
83
836
88 75
855
106D
819
80
71 108
B3
93
827
B4
81
82
832 110
109
87 B5
C4
103 000 000R 200
A215200
9804/1103
20 - 15 - 01/2
Issue 2
Loadalls
CONTENTS
20 - 15 - 01/3
ALL MODELS
From m/c no. 567362
Circuit Diagram - Electrical The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on page 20-15-01/1 and continued on page 20-15-01/2. WIRING DIAGRAM (All 527, 535 machines; 525-58/67, 530-95/110 from Serial No. 572168; 530-120 from Serial No. 572242) * For SLI system circuit for machines from serial No. 576404 and 537-120/130 see page 20-15-01/11 Note: Item A is Syncro Shuttle option. For Powershift option see page 10/10-14. Main Components 1 Battery 2 Starter Motor 3 Starter Solenoid 4 Starter Switch 5 Thermostart 6 Starter Relay 9 Safe Load Indicator Readout Box 10 Rear SLI Boss 11 Front SLI Boss 15 Heater Switch 16 Heater Resistor 17 Heater Motor 19 Seat Relay Swedish 20 Parking Brake Switch machines 21 Seat Switch only 23 Horn Push 24 Horn 25 Wash/Wipe Switch 26 Front Wiper Motor 27 Washer Pump 30 Hazard Switch 31 Indicator Relay 32 Indicator Switch 34 Fuel Shut-off Solenoid 36 Reverse Alarm Relay 37 Reverse Alarm 39 Forward/Reverse Selector Switch 40 Neutral Start Relay 41 Parking Brake Warning Relay 42 Reverse Relay 43 Forward Relay 44 Reverse Solenoid 45 Forward Solenoid 46 Transmission Dump Switch 47 Parking Brake Switch 48 Trailer Socket 49 Air Filter Switch 50 Engine Oil Pressure Switch 51 Transmission Oil Temperature Switch 52 Transmission Oil Pressure Switch 53 Water Temperature Switch
54 55 56 57 58 59 60 61 62 63 65 66 67 68 69 71 71B 72 73 75 76 77 78 78A 78B 78C 78D 78E 78F 79 80 81 82 83 86 87 88 93 99 100 101
Hourmeter Alternator Tachometer Fuel Gauge Water Temperature Gauge Fuel Gauge Sender Water Temperature Gauge Sender Warning Buzzer L. H. Stabiliser Switch R. H. Stabiliser Switch Interior Light Switch Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch Beacon Brake Switch Brake Switch Relay 2/4 Wheel Drive Switch (not fitted on permanent 4 wheel drive) 2 Wheel Drive Solenoid Front Axle Proximity Switch Rear Axle Proximity Switch Steering Mode Selector Switch Steer Mode Printed Circuit Board Relay 2 Relay 1 Relay 1 (latch) Relay 2 (unlatch) Relay 1 (unlatch) Relay 2 (latch) 4 Wheel/Crab Steer Solenoid 4 Wheel Steer Solenoid Crab Steer Solenoid 2 Wheel Steer Solenoid Side Lights Relay Working Light Switch Road Light Switch Headlamp Dip Switch Headlamp Flasher Radio (Optional) Transmission Dump Relay Transmission Dump Switch
Lamps 202 Trailer Indicator Warning 203 Hazard Warning 204 L.H. Indicators 205 R.H. Indicators 206 Indicator Warning 207 Hazard Indicator Warning 208 Reversing Lights 209 Parking Brake Warning 210 Air Filter Blocked Warning 211 Engine Oil Pressure Warning 212 Transmission Oil Temperature Warning 213 Transmission Oil Pressure Warning 214 Water Temperature Warning 215 Alternator Warning 216 Stabiliser Indicators 217 Interior Light 218 Beacon Warning 219 2 Wheel Drive Warning 220 L.H. Brake Lights 221 R.H. Brake Lights 222 4 Wheel Steer Warning 223 Crab Steer Warning 224 2 Wheel Steer Warning 225 Instrument Panel Illumination 226 L.H. Side Light 227 R.H. Side Light 229 Number Plate Light 230 Working Light Warning 231 Cab Working Light 232 Headlamp Dip Beam 233 Headlamp Main Beam 234 Headlamp Main Beam Warning 235 Inclinometer Illumination Fuses Fuses are numbered as shown on the fuse box in the cab. Cable Colour Code G N U Y
Green Brown Blue Yellow
Note: For machines without road lights a link is fitted (as shown) in place of Working Light Switch 86 and switch 87 operates the Working Lights. 9804/1103
20 - 15 - 01/3
Issue 4*
Loadalls
CONTENTS
* 520-55
20 - 15 - 01/4
(504B N. Am), 520-55 RS
From m/c no. 277001 to 277535
Circuit Diagram - Electrical 48 600
11
37
12
47
27
17
5
44
102 850
51
53 54
108
105
50
24 10
104
49
45 52
26
851
805
103
806
811
34
812
403
405
815 402
404
42
814
106
21
60
57
58
406
2 801
59 55 412
407
43
56
415 414
807
400
413
110
32
23
109
853 839
19 20
9
3
31
16 802
113
115
809
401
804 803 810
30 101
111
840 808A
116
114
41
842
40
36
841
112
25
39
808
800
+
114
1
411
106
107
15
200
113
003
6
13
105 300
135
61
104 813 107
102
46
100 200
103
842
106
A1
4
200
A2
A3
A4
A6
A7
A8
A9
B1
B2 004
000
000
000
001
001
001
200
200
200
004 842 102
102
829
829
103
103
A190160
9804/1103
20 - 15 - 01/4
3610 - C/41-2.1
Issue 3*
Loadalls
CONTENTS
* 520-55
(504B N. Am), 520-55 RS
20 - 15 - 01/5
From m/c no. 277001 to 277535
Circuit Diagram - Electrical The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. 1 2 3 4 5 6 9 10 11 12 13 15 16 17 19 20 21 23 24 25 26 27 30 31 32 34 36 37 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
Battery Starter Motor Starter Solenoid Starter Switch Thermostart Starter Relay Safe Load Indicator Readout Box Rear Axle Transducer Trailer Hitch Diverter Valve Auxiliary Diverter Valve Transmission Dump Relay Heater Switch Heater Resistor Heater Motor Trailer Hitch Selector Switch Auxiliary Selector Switch Auxiliary Relay Horn Push Horn Wash/Wipe Switch Front Wiper Motor Washer Pump Hazard Switch Indicator Relay Indicator Switch Fuel Shut-off Solenoid Reverse Alarm Relay Reverse Alarm Forward/Reverse Switch Neutral Start Relay Parking Brake Warning Relay Reverse Relay Forward Relay Reverse Solenoid Forward Solenoid Transmission Dump Switches Parking Brake Switch Trailer Socket Air Filter Switch Engine Oil Pressure Switch Transmission Temperature Switch Transmission Oil Pressure Switch Water Temperature Switch Hourmeter
55 56 57 58 59 60 61 65 66 67 68 69 71 83 86 87 88 93 99 100 101
Alternator Tachometer Temperature Gauge Fuel Gauge Temperature Sender Fuel Sender Warning Buzzer Interior Light Switch Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch Beacon Brake Switch Side Lights Relay Working Light Switch Road Light Switch Headlamp Dip Switch Headlamp Flasher Radio (optional) Roof Wiper Switch Brake Light Relay
102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 125 126 127 128 129 130 131 132 133 134 135 136 137
Trailer Indicator Hazard Warning L.H. Indicators R.H. Indicators Indicator Warning Hazard Indicator Warning Reversing Lights Parking Brake Warning Air Filter Blocked Warning Engine Oil Pressure Warning Transmission Temperature Warning Transmission Oil Pressure Warning Water Temperature Warning Alternator Warning Hitch Warning Interior Light Beacon Warning Roof Wiper Warning L.H. Brake Lights R.H. Brake Lights Instrument Panel Illumination L.H. Side Light R.H. Side Light Trailer Number Plate Working Light Warning Cab Working Lights Headlamp Dip Beam Headlamp Main Beam Headlamp Main Beam Warning Heater Switch Warning Road Light Warning Inclinometer Light
Fuses are numbered as shown on the fuse box in the cab.
9804/1103
20 - 15 - 01/5
3610 - C/41-1.5
Issue 3*
Loadalls
CONTENTS
* 520-55
20 - 15 - 01/6
(504B N. Am), 520-55 RS
From m/c no. 277001 to 277535
Circuit Diagrams - Electrical
48
48
600
48
600
69
120 121
129
134
117 67
65
137
126
125
127
131
132
133
128 66
835 844
834
838 837
816 831
301
86
849
100 119
99
829 830
68
101 130 B9 C1
118
855
B8 B6
71
C2
B7 112
828 833
83
836
88 108
93
827
87
832
110
136 B3
B4
B5
C3
C4
000 001
200
102 829 103
A190170
9804/1103
3610 - C/41-3.2
20 - 15 - 01/6
Issue 3*
Loadalls
CONTENTS
20 - 15 - 01/7
* 520-55
(from m/c no. 277536) * 526-55 (to m/c no. 278965) Circuit Diagram - Electrical
48 600
11
37
12
5
47
27
17
44 202
10
204
49
51
53 54
208
205
50
24 850
203
102
45 52
59
26
851
805
806
811
34 42
2
402
43
814
405
60
55
404
406
408 412
407
815
106
21
403
812
56
409
415A 414
807
400
413
210
32
23
36
841
19 216
40
57 209
3
809
31
16 802
213
215
401
804 803 810
30 101
211
58
840
801
20
9
214
41
853 839
212
107 842
25
39
808
800
+
114
1 003
411
106
207
15
6
46
105
61
300
235
200
104
13 102 100 200
103
842
106
A1
200
A2
A3
A4
A6
A7
A8
A9
B1
B2 004 810
4
000
000
000
001
001
001
200
200
200
004 842 102
102
829
829
103
103
A215620
9804/1103
20 - 15 - 01/7
3610 - C/41-5.1
Issue 2*
Loadalls
CONTENTS
* 520-55 * 526-55
20 - 15 - 01/8
(from m/c no. 277536) (to m/c no. 278965)
Circuit Diagram - Electrical The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. * 1 2 3 4 5 6 9 10 11 12 13
Battery Starter Motor Starter Solenoid Starter Switch Thermostart Starter Relay Safe Load Indicator Readout Box Rear Axle Transducer Trailer Hitch Diverter Valve Solenoid Auxiliary Diverter Valve Solenoid Transmission Dump Relay
55 56 57 58 59 60 61 65 66 67 68
Alternator Tachometer Temperature Gauge Fuel Gauge Temperature Sender Fuel Sender Warning Buzzer Interior Light Switch Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch
202 203 204 205 206 207 208 209 210 211 212
15
Heater Switch
69
Beacon
213
16 17 19 20 21 23 24 25 26 27 30 31 32 34 36 37 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
Heater Resistor Heater Motor Trailer Hitch Selector Switch Auxiliary Selector Switch Auxiliary Relay Horn Push Horn Wash/Wipe Switch Front Wiper Motor Washer Pump Hazard Switch Indicator Relay Indicator Switch Fuel Shut-off Solenoid Reverse Alarm Relay Reverse Alarm Forward/Reverse Switch Neutral Start Relay Parking Brake Warning Relay Reverse Relay Forward Relay Reverse Solenoid Forward Solenoid Transmission Dump Switches Parking Brake Switch Trailer Socket Air Filter Switch Engine Oil Pressure Switch Transmission Temperature Switch Transmission Oil Pressure Switch Water Temperature Switch Hourmeter
71 83 86 87 88 93 99 99A 99B 99C 99D 100 101 102
Brake Switch Side Lights Relay Working Light Switch Road Light Switch Headlamp Dip Switch Headlamp Flasher Radio (optional) Machine 18 Pin Socket Radio 18 Pin Plug Aerial Speakers Roof Wiper Switch Brake Light Relay Hydraulic Low Pressure Switch (526-55 Only) 103 Front Proximity Switch (526-55 Only) 104 Rear Proximity Switch (526-55 Only) 105 Face Level Fan (if fitted)
214 215 216 217 218 219 220 221 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239
Trailer Indicator Hazard Warning L.H. Indicators R.H. Indicators Indicator Warning Hazard Indicator Warning Reversing Lights Parking Brake Warning (see note) Air Filter Blocked Warning Engine Oil Pressure Warning Transmission Temperature Warning Transmission Oil Pressure Warning Water Temperature Warning Alternator Warning Hitch Warning Interior Light Beacon Warning Roof Wiper Warning L.H. Brake Lights R.H. Brake Lights Instrument Panel Illumination L.H. Side Light R.H. Side Light Trailer Number Plate Working Light Warning Cab Working Lights Headlamp Dip Beam Headlamp Main Beam Headlamp Main Beam Warning Heater Switch Warning Road Light Warning Inclinometer Light Front Axle Alignment Indicator Rear Axle Alignment Indicator
Colour Code B Black R Red B/W Black/White S Slate G Green W/K White/Pink Fuses are numbered as shown on the fuse box in the cab. Note: On the 526-55 machines Warning lamp 209 also indicates Low Brake Pressure.
9804/1103
20 - 15 - 01/8
3610 - C/41-4.4
Issue 3*
Loadalls
CONTENTS
* 520-55 * 526-55
20 - 15 - 01/9
(from m/c no. 277536) (to m/c no. 278965)
Circuit Diagram - Electrical
48
48
600
48
600
69
220 221
229
234
217
105
67
65
239
238
226
225
227
231
232
233 601AG
228 66
835 844
834
838
99D
837
816
+
-
+
-
831
301
86
849
100 219
820
68
819
829 830
101 230
B
B9 C1 218
855
B8 B6
71
C2
S S
S S
W/K
18 17 14 13
8 7
3
18 17 14 13
8 7
3
B7
828 833
83
99A 99B
836 B
R 112
115
B/W B
88 108
103
104
99C
G
S
93
827
87
832
110
99
236 B3
B4
810
C3
C4
C5
810 000 001
200
102 829 103
A215630
9804/1103
3610- C/41-6.2
20 - 15 - 01/9
Issue 2*
Loadalls
CONTENTS
20 - 15 - 01/10
ALL MODELS
From m/c no. 567362
Circuit Diagram - Electrical The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on page 20-15-01/1 and continued on page 20-15-01/2. WIRING DIAGRAM (Powershift option) Main Components 1 Neutral Drive Relay 2 Forward Drive Relay 3 Forward High/Low Relay 4 Reverse High/Low Relay 5 Driveshaft Relay 6 Reverse Relay 7 Layshaft Solenoid 8 Mainshaft Solenoid 9 Reverse High Solenoid 10 Reverse Low Solenoid 11 Forward High Solenoid 12 Forward Low Solenoid
13 14 39 40 41 46 47 71 71B 73 100
8 9
11
858
73 219
220
860
857
859
811
46
812
47
3
4
5
807
12
10
7
37 208
221
Lamps 208 Reversing Lights 220 L.H. Brake Light 221 R.H. Brake Light 219 2 Wheel Drive Warning
Column Gear Selector 2 Wheel Drive Switch Forward/Reverse Selector Switch Neutral Start Relay Parking Brake Warning Relay Transmission Dump Relay Parking Brake Switch Brake Switch Brake Switch Relay 2 Wheel Drive Solenoid Transmission Dump Relay
815
C9 816
818
2 865
863
862
863
71B
862
1
6 40
871
41
852
39 810 107
71
401
852
14
100 2 1
B4
3 4
107
13
B1
B2
108 000 000R 200 004
A215210 842
9804/1103
20 - 15 - 01/10
Issue 1
Loadalls
CONTENTS
20 - 15 - 01/11
ALL MODELS
From m/c no. 576404
Circuit Diagram - Electrical * WIRING DIAGRAM (All machines from serial No. 576404 except 530-120 & 537-120/130 machines)
* WIRING DIAGRAM (530-120 from serial No. 576404 & all 537-120/130) Safe Load Indicator Circuit
Safe Load Indicator Circuit 9 10
Safe Load Indicator Readout Box Transducer
9 10 11
Safe Load Indicator Readout Box Rear SLI Boss Front SLI Boss
600
600
11
9 N
G/Y
414A 414 413A 413 414B 413
413B
414 N G/Y
10
10
101
9 101
A2 A221890
A2 A215191
9804/1103
20 - 15 - 01/11
Issue 2*
CONTENTS
* 520-55, * 526-55,
Loadalls
20 - 15 - 01/12
520S (from m/c no. 278966) 526S (526 N. Am) (from m/c no. 278966 to 280299)
Circuit Diagram - Electrical The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on page 20-15-01/13 and continued on page 20-15-01/14. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 * 37 38 39 40 41 42 43
Battery 44 Battery Isolator 45 Fuse Links 46 Starter Motor 47 Starter Solenoid 48 Starter Switch 49 Thermostart 50 Starter Relay 51 Safe Load Indicator Readout Box 52 Rear Axle Transducer 53 Hitch/Auxiliary Selector Switch 54 Hitch Diverter Valve Solenoid 55 Auxiliary Circuit Selector Switch 56 Auxiliary Diverter Valve Solenoid 57 Heater Switch 58 Heater Resistor 59 Heater Motor 60 Wash/Wipe Switch 61 Washer Pump 62 Front Wiper Motor 63 Hazard Warning Switch 64 Indicator Relay 65 Trailer Socket 66 Indicator Switch 67 Fuel Shut-off Solenoid * 68 Reverse Alarm * 69 Neutral Start Relay * 70 Forward/Reverse Switch * 71 Reverse Relay 72 Reverse Solenoid 73 Transmission Dump Switches Transmission Dump Relay 74 Forward Relay 75 Forward Solenoid Parking Brake Switch 76 Parking Brake Warning Relay Accumulator Pressure Switch (if fitted) Air Filter Switch Engine Oil Pressure Switch Transmission Temperature Switch Transmission Oil Pressure Switch Water Temperature Switch Hourmeter
Alternator * 100 Warning Buzzer 101 Tachometer 102 Temperature Sender 103 Temperature Gauge 104 Fuel Sender 105 Fuel Gauge 106 Interior Light Switch * 107 Roof Wiper Switch 108 Roof Wiper Motor and Parking Switch 109 Rear Wiper Motor and Switch Beacon Switch 110 Beacon 111 Brake Switch 112 Front Proximity Switch (526-55 Only) 113 Rear Proximity Switch (526-55 Only) 114 Horn Push 115 Horn 116 Side Lights Relay 117 Working Light Switch 118 Road Light Switch 119 Headlamp Dip Switch 120 Headlamp Flasher 121 Radio (optional) 122 N/A 123 N/A 124 N\A 125 N/A 126 Face Level Fan (optional) 127 Air Conditioning Compressor 128 Clutch Relay (optional) 129 Air Conditioning Thermostat (optional) 130 Air Conditioning Reciever Drier 131 Pressure Switch (optional) 132 Air Conditioning Compressor 133 Clutch (optional)
Hitch/Aux. Warning Indicator Heater Indicator Trailer Direction Indicator Hazard Warning Indicator L.H. Indicators R.H. Indicators Direction Indicator Hazard Warning Indicator Reversing Lights Accumulator Pressure Warning (see note) Air Filter Blocked Warning Engine Oil Pressure Warning Transmission Temperature Warning Transmission Oil Pressure Warning Water Temperature Warning Alternator Warning Interior Light Roof Wiper Indicator Beacon Indicator L.H. Brake Lights R.H. Brake Lights Front Axle Alignment Indicator Rear Axle Alignment Indicator Instrument Panel Illumination L.H. Side Lights R.H. Side Lights Trailer Lights Number Plate Cab Working Lights Working Light Indicator Road Light Switch Indicator Headlamp Dip Beam Headlamp Main Beam Headlamp Main Beam Warning
Colour Code B Black R Red B/W Black/White S Slate G Green W/K White/Pink Fuses are numbered as shown on the fuse box in the cab. Note: On the 526-55 machines Warning lamp 109 also indicates Low Brake Pressure.
9804/1103
20 - 15 - 01/12
3610 - C/41-7.3
Issue 2*
Loadalls
CONTENTS
* 520-55, * 526-55,
20 - 15 - 01/13
520S (from m/c no. 278966) 526S (526 N. Am) (from m/c no. 278966 to 280299)
Circuit Diagram - Electrical
23
601 600
12
14
17
19
102
26
103 104
4
7
850
851
20
839
400
105
805
806
108
105
5
106
413
16
35
37
38
811
812
29
33
815
402
401
808
22 800 801
840 841
802
803
18 8
100
403
43
41 404
405
44 406
407
200
110
112
114
24 109
11
42
36
A6
9
1
40 39
807
27 414
34
25
10
2
30
804
809
004 842
113
115
107
28
21
15
810
111
107
13
31 32
101 200
842
003
200
104 003
101 114
411
107
102
45 110
3
A1
B1
A9
B3
B5
C7
C6
A2
A4
B8
6 000R 001 810 200H 200G 829 100A 110 883
A248190
9804/1103
3610 - C/41-8.1
20 - 15 - 01/13
Issue 2*
Loadalls
CONTENTS
* 520-55, * 526-55,
20 - 15 - 01/14
520S (from m/c no. 278966) 526S (526 N. Am) (from m/c no. 278966 to 280299)
Circuit Diagram - Electrical
23
600
600
116 412
48
50
54 51
61 56
119
127
123
133
120 124
125 126
128
131
72
132
76
814
46
53
829 830
831
834 834 838 838
75 67 409
408 301
849 854
52 117 47
844
816
129
55
74
63
118
49
60
121
C2
C1
C3
C4
112
122
828
57
833
836
62 819 820
108
58
66
59 827
832 103 106
C5
115
829
810
B6
73
65
130 B2
B7
B4
64
000R 102 810 200H 200G 829 100A 110 883
A248200
9804/1103
20 - 15 - 01/14
3610 - C/41-9.2
Issue 2*
CONTENTS
Loadalls
526-55, 526, 526 N.Am 526S (fitted with Powershift ECU gearbox control)
20 - 15 - 01/15
From m/c no. 280300 to 280576
Circuit Diagrams - Electrical Component Key The complete electrical circuit is shown on pages 20-15-01/16 to 20-15-01/21. Fuses are numbered as shown on the fuse box in the cab. Component Key Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 * 47 48 49 50A 50B 50C 50D 51 52
Description Page 20-15-01/16 Battery Starter Motor Starter Solenoid Fusible Links 1 Thermostart Ignition Switch Neutral Start Relay Fusible Link 2 Ignition Solenoid Engine Shut Off Solenoid (ESOS) Reverse Light Reverse Alarm Reverse Light/Alarm Relay Auxiliary Solenoid Auxiliary Relay Hydraulic Hitch Solenoid Hydraulic Hitch Switch Load Indicator Transducer Load Indicator Page 20-15-01/17 Heater Switch Face Fan Air Conditioning Compressor Clutch (if fitted) Air Conditioning Relay (if fitted) Air Conditioning Switch (if fitted) Heater Fan Receiver Drier Switch (if fitted) Roof Wiper Roof Wiper Switch Front Wiper Rear Wiper Interior Light Beacon Switch Beacon Radio Power Page 20-15-01/18 Buzzer Instrument Panel Air Filter Switch Engine Oil Pressure Switch Transmission Oil Temperature Switch Water Temperature Switch Alternator Fuel Sender Water Temperature Sender Rear Axle Alignment Indicator Light Front Axle Alignment Indicator Light Front Proximity Axle Switch Rear Proximity Axle Switch Trailer Socket - L.H. Indicator Pin Trailer Socket - R.H. Indicator Pin Trailer Socket - Side Light Pin Trailer Socket - Brake Light Pin Page 20-15-01/19 Side Lights Relay Road Lights - Switch
9804/1103
53A 53B 54A 54B 55A 55B 56A 56B 56C 56D 57 57A 57B 57C 57D 58 59 60 61 62 63 64 65 66A 66B 67 67A 67B 67C 68 69 70 71 72 73 74 75 76 77 78 79 79 80 81A 81B 84 85 86 87 88 89 90 91
20 - 15 - 01/15
L.H. Side Light - Front L.H. Indicator - Front L.H. Side Light - Rear L.H. Side Indicator - Rear L.H. Dip Beam L.H. Main Beam R.H. Dip Beam R.H. Main Beam R.H. Side Light - Front R.H. Indicator - Front Column Switch Dip/Main Beam Switch Indicator Switch Wiper Switch Washer Switch Washer Pump Page 20-15-01/20 L.H. Brake Lights R.H. Brake Lights Brake Lights - Switch Hazard Switch Flasher Relay Trailer Indicator - Cab Warning LIght Diode R.H. Indicator - Front R.H. Side Light Column Switch Forward/Reverse Switch Transmission Switch Horn Switch Horn Park Brake Switch Transmission ECU - Input Signal Connectors Transmission ECU - Output Signal Connectors Page 20-15-01/21 Transmission Oil Pressure Switch Transmission ECU Test Point Speed Sensor Mainshaft Solenoid Layshaft Solenoid Forward High Solenoid Forward Low Solenoid Reverse HI/LOW Relay Reverse High Solenoid Reverse Low Solenoid Work Light Work Light Number Plate Light Joy Stick Control (if fitted) Diode Pack (if fitted) Valve Block Solenoid (if fitted) Valve Block Solenoid (if fitted) Valve Block Solenoid (if fitted) Valve Block Solenoid (if fitted) Joystick Isolation Switch (if fitted) 3610 - C/41-10.2
Issue 3*
Loadalls
CONTENTS
*
526-55, 526, 526S (526 N.Am) (fitted with Powershift ECU gearbox control)
20 - 15 - 01/16
From m/c no. 280300 to 280576
Circuit Diagrams - Electrical (cont’d) 1 +
2
3
5
6 7
4 9
8 FA1
10
FA2
FA3
FA4
FA5
11
13
FA6
FA7 12
FA8
14
15
FA9
16
17 18 19
FB1
FB2
A282270
9804/1103
20 - 15 - 01/16
3610 - C/41-11.1
Issue 2*
Loadalls
CONTENTS
*
526-55, 526, 526S (526 N.Am) (fitted with Powershift ECU gearbox control)
20 - 15 - 01/17
From m/c no. 280300 to 280576
Circuit Diagrams - Electrical (cont’d)
* PHB3
20 21
PHB4 24 23
25 26 28
PHB5 29
30
31 32
33
PHB6
35
34
PHB6 36
A282280
9804/1103
20 - 15 - 01/17
3610 - C/41-12.1
Issue 2*
Loadalls
CONTENTS
*
20 - 15 - 01/18
526-55, 526, 526S (526 N.Am) (fitted with Powershift ECU gearbox control)
From m/c no. 280300 to 280576
Circuit Diagrams - Electrical (cont’d)
37
PHB8
38 39 40 41 42 43
44 45
46 47
48
49
A282290
9804/1103
20 - 15 - 01/18
3610 - C/41-13.1
Issue 2*
Loadalls
CONTENTS
*
20 - 15 - 01/19
526 55, 526, 526S (526 N.Am) (fitted with Powershift ECU gearbox control)
From m/c no. 280300 to 280576
Circuit Diagrams - Electrical (cont’d) 50A 50B
PHB9
PHC1 51 52 53A
PHC2
50C
53B
54A 54B 55A
PHC3
55B
56A
PHC4 56B
56C
56D 57
57A 57B 57C
57D 58
A282300
9804/1103
20 - 15 - 01/19
3610 - C/41-14.1
Issue 2*
Loadalls
CONTENTS
*
20 - 15 - 01/20
526-55, 526, 526S (526 N.Am) (fitted with Powershift ECU gearbox control)
From m/c no. 280300 to 280576
Circuit Diagrams - Electrical (cont’d)
50D 59
61
PHC5
60
PHC6
PHC7 62 63
PHC8 65 64
PHC9 66A 66B R
67A
67
F
67B 67C 68 69 70
71
A282310
9804/1103
20 - 15 - 01/20
3610 - C1-15.1
Issue 2*
Loadalls
CONTENTS
*
20 - 15 - 01/21
526-55, 526, 526S (526N.Am) (fitted with Powershift ECU gearbox control)
From m/c no. 280300 to 280576
Circuit Diagrams - Electrical (cont’d)
72 73 74 75 76 77 78 79 80
81A
83
81B 84
85
86
87 88 89
20 - 15 - 01/21
90
91
A282320
9804/1103
3610 - C/41-16.1
Issue 2*
CONTENTS
Loadalls
20 - 15 - 01/22
520-55, 526, 526S (from m/c no. 280300) 520-55 (From m/c no. 281847) * (fitted with Syncro Shuttle Transmission) Circuit Diagrams - Electrical Component Key Fuses are numbered as shown on the fuse box in the cab. * Component Key Sheet 1 Item
Description
1 2 3 4 5 6 7 8 9 10 11 11A 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Battery isolator Battery Fuse links Starter motor Starter solenoid Key switch Thermostart Neutral start relay Fuse link Ignition relay Sender unit Cold start advance unit (see Note 1) Engine shut-off solenoid (ESOS) Rear work light Rear work light switch Front work lights Front worklights switch Brake lights Brake light switch Trailer brake lights connector Reverse alarm Reverse light Parkbrake switch Parkbrake relay Front axle alignment lamp Front axle proximity switch Rear axle alignment lamp Rear axle proximity switch Radio Load Moment Indicator (LMI) transducer Load Moment Indicator (LMI) Instrument panel Warning buzzer Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge sender Water temperature sender Alternator
Note 1: Cold start advance unit 11A is part of fuel injection pump.
9804/1103
20 - 15 - 01/22
3610 - C/41-17.2
Issue 3*
F7 F6 F29 F17 F16 F15
F9 F10 F8 F19 F20 F18
3610 - C/41-18.2
F12
Loadalls
7
40 31 27 16 8
30 23 2
20 - 15 - 01/23
F11
11
39
526, 526S (from m/c no. 280300) 520-55 (From m/c no. 281847) * (fitted with Syncro Shuttle Transmission) Circuit Diagrams - Electrical (cont’d)
9804/1103
9 3
18
38 33 34 35 36 37 26
29 24 22
28 25 14 10 5
17 15
20 21 13 4
12 11A
19 7 1
*
CONTENTS
32
20 - 15 - 01/23
Issue 3*
F4 F2 F28 F1
76 71
79 78 75 72 67 64 60
F30 F5 F27 F26 F24 F25 F21 F23
Loadalls
20 - 15 - 01/24
3610 - C/41-19.2
F22
57 58 54 52 49 50
59 51 45
62 61
68
74 73 69 66 65 63 53 47 42
48 43
44 46 41
55 56
77
70
526, 526S From m/c no. 280300 520-55 (From m/c no. 281847 * (fitted with Syncro Shuttle Transmission) Circuit Diagrams - Electrical (cont’d)
9804/1103
CONTENTS
20 - 15 - 01/24
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/25
526, 526S (From m/c no. 280300) 520-55 (From m/c no. 281847) * (fitted with Syncro Shuttle Transmission) Circuit Diagrams - Electrical (cont’d) * Fuses are numbered as shown on the fuse box in the cab. * Component Key Sheet 2 Item
Description
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79
Rear indicator - right hand Rear side light - right hand Trailer light socket Number plate light Sidelights relay Front side light - left hand Front indicator - left hand Rear side light - left hand Rear indicators - left hand Trailer side light connection - left hand Road lights switch Dip beam - left hand Main beam - left hand Dip beam - right hand Main beam - right hand Front side lights - right hand Front indicators - right hand Fog lamp Fog light switch Steering column switch - right hand Trailer indicators Wash pump Roof wiper motor Roof wiper switch Front wiper motor Rear wiper motor Hazard warning lights switch Flasher relay Trailer indicator light Interior light Warning beacon Warning beacon switch Face level fan Air conditioning compressor Air conditioning relay Heater Receiver dryer Air conditioning switch Heater switch
9804/1103
20 - 15 - 01/25
3610 - C/41-20.2
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/26
526, 526S (From m/c no. 280300) 520-55 (From m/c no. 281847) * (fitted with Syncro Shuttle Transmission) Circuit Diagrams - Electrical (cont’d) * Fuses are numbered as shown on the fuse box in the cab. * Component Key Sheet 3 Item
Description
80 81 82 83 84 85 86 87 88 89 90 91 92
Column switch - left hand Horn Forward solenoid Forward relay Reverse solenoid Reverse relay Second auxiliary solenoid Second auxiliary relay Transmission dump relay Hitch solenoid Hitch switch Transmission dump switch (control lever) Transmission dump switch (gear change lever)
Single lever control (SLC) option: 93 94 95 96 97 98 99 100
Extend solenoid Auxiliary solenoid Retract solenoid Single lever control joystick Diodes Transmission dump switch (joystick) Auxiliary solenoid Lever isolation switch & auxiliary solenoid
9804/1103
20 - 15 - 01/26
3610 - C/41-21.2
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/27
526, 526S (From m/c no. 280300) 520 - 55(From m/c no. 281847) * (fitted with Syncro Shuttle Transmission) Circuit Diagrams - Electrical (cont’d)
99
100
*
86
80
81
82
83
85
84
F3
87
88
89
90
91
92
SLC
93
97
96
94
95
98
F14 F13
9804/1103
20 - 15 - 01/27
3610 - C/41-21.2
Issue 3*
CONTENTS
Loadalls
526, 526S with Powershift Transmission)
20 - 15 - 01/29
From m/c no. 280577
* (fitted
Circuit Diagrams - Electrical * Component Key Fuses are numbered as shown on the fuse box in the cab. Item
Description
1 2 3 4 5 6 7 8 9 10 11 11A 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
Battery isolator Battery Fuse links Starter motor Starter solenoid Key switch Thermostart Neutral start relay Ignition relay Fuse link Sender unit Cold start advance unit (see Note 1) Engine shut-off solenoid (ESOS) Rear work light Rear work light switch Front work lights Front worklights switch Brake lights Brake light switch Trailer brake lights connector Reverse alarm Reverse light Reverse 2 relay Parkbrake switch Parkbrake relay Front axle alignment lamp Front axle proximity switch Rear axle alignment lamp Rear axle proximity switch Radio Load Moment Indicator (LMI) Load Moment Indicator (LMI) transducer Instrument panel Warning buzzer Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge sender Water temperature sender Alternator
Note 1: Cold start advance unit 11A is part of fuel injection pump.
9804/1103
20 - 15 - 01/29
3610 - C/41-24.2
Issue 3*
Loadalls
CONTENTS
20 - 15 - 01/30
526, 526S * (fitted with Powershift Transmission)
From m/c no. 280577
Circuit Diagrams - Electrical (cont’d)
39 40
41
*
F10
34 35 36 37 38
F9 F8
30 29
31
32
33
F7
18
20
F17
19
22
21
23
24
25
26
27
28
F29
16
17
F16 F20
15
F19
14
F15
12
13
F18
9
11
3
2
1
4
5
6
7
8
10
F11
11A
F12
9804/1103
20 - 15 - 01/30
3610 - C/41-23.2
Issue 3*
CONTENTS
*
Loadalls
526, 526S (fitted with Powershift Transmission)
20 - 15 - 01/31
From m/c no. 280577
Circuit Diagrams - Electrical (cont’d) Fuses are numbered as shown on the fuse box in the cab. * Component Key Sheet 2 Item
Description
42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
Rear indicator - right hand Rear side light - right hand Trailer light socket Number plate light Sidelights relay Front side light - left hand Front indicator - left hand Rear side light - left hand Rear indicators - left hand Trailer side light - left hand Road lights switch Dip beam - left hand Main beam - left hand Dip beam - right hand Main beam - right hand Front side lights - right hand Front indicators - right hand Fog lamp Foglight switch Column switch - right hand Trailer indicators Wash pump Roof wiper motor Roof wiper switch Front wiper motor Rear wiper motor Hazard warning lights switch Flasher relay Trailer indicator light Interior light Warning beacon Warning beacon switch Face level fan Air conditioning compressor Air conditioning relay Heater Receiver dryer Air conditioning switch Heater switch
9804/1103
20 - 15 - 01/31
3610 - C/41-25.2
Issue 3*
Loadalls
CONTENTS
20 - 15 - 01/32
526, 526S * (fitted with Powershift Transmission)
From m/c no. 280577
Circuit Diagrams - Electrical (cont’d)
80
*
74
76
75
77
78
79
F4
73
72
F2
70
71
F28
67
68
69
F1
64
65
66
F30
61
62
63
F5 F27 F26
60
F21
52
50
47
48
49
51
53
54
F23
55
F25
56 57 58
59
F24
42
43
44
46
45
F22
9804/1103
20 - 15 - 01/32
3610 - C/41-26.2
Issue 3*
CONTENTS
Loadalls
526, 526S * (fitted with Powershift Transmission)
20 - 15 - 01/33
From m/c no. 280577
Circuit Diagrams - Electrical (cont’d) Fuses are numbered as shown on the fuse box in the cab. * Component Key Sheet 3 Item
Description
81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101
Column switch - left hand Horn Reverse low solenoid Reverse high solenoid Reverse high/low relay Diodes Reverse relay Forward solenoid Forward high solenoid Forward low solenoid Forward high/low solenoid Drive interlock Driveshaft relay Layshaft solenoid Mainshaft solenoid Second auxiliary solenoid Second auxiliary relay Transmission dump relay Hitch solenoid Hitch switch Transmission dump switch (control lever)
Single lever control (SLC) option: 102 103 104 105 106 107 108 109
Extend solenoid Auxiliary solenoid Retract solenoid Single lever control joystick Transmission dump switch (joystick) Diodes Auxiliary solenoid Single lever control isolation switch and auxiliary solenoid
9804/1103
20 - 15 - 01/33
3610 - C/41-28.2
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/34
526, 526S with Powershift Transmission)
From m/c no. 280577
* (fitted
Circuit Diagrams - Electrical (cont’d)
108
109
*
81
82
83
85
84
86
87
88
89
91
90
92
94
93
95
F3
96
97
98
99
100
101
SLC
102
107
105
103
104
106
F14 F13
9804/1103
20 - 15 - 01/34
3610 - C/41-27.2
Issue 3*
Loadalls
CONTENTS
*
20 - 15 - 01/35 *
526, 526S (526 N.Am) (fitted with Powershift Gearbox)
From m/c no. 280577
Circuit Diagrams - Electrical (cont’d)
14E 14F
72
73
74 75 76 77
78
22
79 79A 80 81
A282250
9804/1103
20 - 15 - 01/35
3610 - C/41-30.1
Issue 2*
Loadalls
CONTENTS
*
20 - 15 - 01/36 *
526, 526S (526 N, Am) (fitted with Powershift Gearbox)
From m/c no. 280577
Circuit Diagrams - Electrical
83
82
82A
84
86
85
87
85A
A282260
9804/1103
20 - 15 - 01/36
3610 - C/41-31.1
Issue 2*
CONTENTS
Loadalls
528-70 With Syncro Shuttle Transmission Circuit Diagrams - Electrical Component Key 1
20 - 15 - 01/37
From m/c no. 796000
The complete electrical circuit is shown on pages 20-15-01/38 and 20-15-01/39. Fuses are numbered as shown on the fuse box in the cab.
Item 1 2 3 4 5 6 7 8 9 10 10A 11 12 13 14 15 16 17 18
Description Fuse links Battery Battery isolator Starter motor solenoid Starter motor Ignition switch Thermostart Ignition relay Safe Load Indicator (SLI) Auxiliary change-over switch Auxiliary solenoid Face level fan Heater switch Heater motor Hazard warning light switch Indicator relay Left hand indicators Indicator switch Indicator warning lamp
9804/1103
20 - 15 - 01/37
3650 - C/41-1.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/38
528-70 with Syncro Shuttle Transmission Circuit Diagrams - Electrical (cont’d)
To m/c no. 796000
11
16
13
19
5
20
27
23
22
29
31
21
10A
7
3
26
28
30
F17
18
9
25 15
4
14
12
2 8
17
24
10
1
F13
F12
F30
F1
F4
F2
F3
F7
F11
F10
32
6
9804/1103
20 - 15 - 01/38
3650- C/41-2.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/39
528-70 with Syncro Shuttle Transmission Circuit Diagrams - Electrical (cont’d)
From m/c no. 796000
54
50
68
70
71 73
76
F23
64
F25
Fuel Gauge
Water Gauge
Tacho
Hourmeter
Handbrake
67
56
47
33
66
52
49
45
65
F21
48
43
59
F22
42
62
57
F24
41
35 36 37 38 39
55
46 72 63
51
44
75
58 53 69
61
74
60 34
9804/1103
20 - 15 - 01 /39
F20
F19
F26
F18
F27
F14
F28
F29
F6
F8
40
3650- C/41-3.1
Issue 1
CONTENTS
Loadalls
528-70 with Syncro Shuttle Transmission Circuit Diagrams - Electrical Component Key 2
20 - 15 - 01/40
From m/c no. 796000
The complete electrical circuit is shown on pages 20-15-01/38 and 20-15-01/39. Fuses are numbered as shown on the fuse box in the cab.
Item 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76
Description Instrument panel Buzzer Air filter switch Oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Alternator Water temperature sender Fuel sender Washer pump Wash/wipe switch Front wiper Roof wiper warning lamp Roof wiper Rear wiper Radio Interior light Rotating beacon switch Rotating beacon Brake light switch Left hand brake light Right hand brake light Fog light switch Fog light Horn push Horn Main beam flash Main lights relay Dip beam Road lights switch Dip beam switch Main beam Main bean warning lamp Instrument panel illumination Left hand side lights Front worklight relay Right hand side lights Number plate light Front work light switch and warning lamp Front work lights Rear work light relay Rear work light switch and warning lamp Rear worklight
9804/1103
20 - 15 - 01/40
3650 - C/41-4.1
Issue 1
CONTENTS
Loadalls
528S With Powershift Transmission Circuit Diagrams - Electrical Component Key 1
20 - 15 - 01/41
From m/c no. 796102
The complete electrical circuit is shown on pages 20-15-01/42, 20-15-01/43 and 20-15-01/46. Fuses are numbered as shown on the fuse box in the cab. Item
Description
1 2 3 4 5 6 7 8 9 10 11 11A 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
Battery isolator Battery Fuse links Starter motor Starter solenoid Key switch Thermostart Neutral start relay Ignition relay Fuse link Sender unit Cold start advance unit (see Note 1) Engine shut-off solenoid (ESOS) Rear work light Rear work light switch Front work lights Front worklights switch Brake lights Brake light switch Trailer brake lights connector Reverse alarm Reverse light Reverse 2 relay Parkbrake switch Parkbrake relay Front axle alignment lamp Front axle proximity switch Rear axle alignment lamp Rear axle proximity switch Radio Load Moment Indicator (LMI) Load Moment Indicator (LMI) transducer Instrument panel Warning buzzer Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge sender Water temperature sender Alternator
Note 1: Cold start advance unit 11A is part of fuel injection pump.
9804/1103
20 - 15 - 01/41
3650 - C/41-5.1
Issue 1
Loadalls
CONTENTS
20 - 15 - 01/42
528S with Powershift Transmission
From m/c no. 796102
Circuit Diagrams - Electrical (cont’d)
11A
17
15
12
4 1
7 11
23
25
34 35 36 37 38
27
14
29
16
18
22
24
26
9
8
39 40
31
20
13
5 2
21
19
30 41
32
28
20 - 15 - 01/42
F9 F10
F7
F29
F8
F16
F17
F18
F15
F19 9804/1103
F12
6
F20
10
3
F11
33
3650 - C/41-6.1
Issue 1
20 - 15 - 01/43
Loadalls
CONTENTS
528S With Powershift Transmission Circuit Diagrams-Electrical cont’d
From m/c no. 796102
78 42
45
43
49
47
44
48
51 50
53
55
59
62
64
63
66
67
74
70
75 77
69 54
72
56 57 58
71
61
60
46
73
68
65
76
79
52
9804/1103
20 - 15 - 01/43
F4
F2
F28
F1
F30
F5
F27
F26
F24
F25
F21
F23
F22
80
3650 - C/41-7.1
Issue 1
CONTENTS
Loadalls
528S With Powershift Transmission Circuit Diagrams - Electrical (cont’d) Component Key 2
20 - 15 - 01/44
From m/c no. 796102
The complete electrical circuit is shown on pages 20-15-01/42, 20-15-01/43 and 20-15-01/46. Fuses are numbered as shown on the fuse boxc in the cab. Item
Description
42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
Rear indicator - right hand Rear side light - right hand Trailer light socket Number plate light Sidelights relay Front side light - left hand Front indicator - left hand Rear side light - left hand Rear indicators - left hand Trailer side light - left hand Road lights switch Dip beam - left hand Main beam - left hand Dip beam - right hand Main beam - right hand Front side lights - right hand Front indicators - right hand Fog lamp Foglight switch Column switch - right hand Trailer indicators Wash pump Roof wiper motor Roof wiper switch Front wiper motor Rear wiper motor Hazard warning lights switch Flasher relay Trailer indicator light Interior light Warning beacon Warning beacon switch Face level fan Air conditioning compressor Air conditioning relay Heater Receiver dryer Air conditioning switch Heater switch
9804/1103
20 - 15 - 01/44
3650 - C/41-8.1
Issue 1
CONTENTS
Loadalls
528S With Powershift Transmission Circuit Diagram- Electrical (cont’d) Component Key 3
20 - 15 - 01/45
From m/c no. 796102
The complete electrical circuit is shown on pages 20-15-01/42, 20-15-01/43 and 20-15-01/46. Fuses are numbered as shown on the fuse boxc in the cab. Item
Description
81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101
Column switch - left hand Horn Reverse low solenoid Reverse high solenoid Reverse high/low relay Diodes Reverse relay Forward solenoid Forward high solenoid Forward low solenoid Forward high/low solenoid Drive interlock Driveshaft relay Layshaft solenoid Mainshaft solenoid Second auxiliary solenoid Second auxiliary relay Transmission dump relay Hitch solenoid Hitch switch Transmission dump switch (control lever)
Single lever control (SLC) option: 102 103 104 105 106 107 108 109
Extend solenoid Auxiliary solenoid Retract solenoid Single lever control joystick Transmission dump switch (joystick) Diodes Auxiliary solenoid Single lever control isolation switch and auxiliary solenoid
9804/1103
20 - 15 - 01/45
3650 - C/41-9.1
Issue 1
Loadalls
CONTENTS
20 - 15 - 01/46
528S with Powershift Transmission
From m/c no. 796102
Circuit Diagrams - Electrical (cont’d)
SLC 83
96
84
82
94
89 90
102
99
95
103
108
104
101
109
86
88 85
97
91
105
100
106
87 93
F3
F13
92
9804/1103
98
20 - 15 - 01/46
107
F14
81
3650 - C/41-10.1
Issue 1
Loadalls
CONTENTS
20 - 15 - 01/47
528S with Syncro Shuttle Transmission
From m/c no. 796102
Circuit Diagrams-Electrical
11A 4
12
15
17
13
19
7
1
20 21
22
24
33 34 35 36 37
26
38
29
39
11
14
10
5
28
25
18
2
23 8
16
30 27
40
31
9804/1103
F9 F10
F8 F7
F6
F29
F17
F16
F15
F12
F18
7
F19 F20
9
3
F11
32
20 - 15 - 01/47
3650 - C/41-11.1
Issue 1
CONTENTS
Loadalls
528S With Syncro Shuttle Transmission Circuit Diagrams - Electrical (cont’d) Component Key 1
20 - 15 - 01/48
From m/c no. 796102
The complete electrical circuit is shown on pages 20-15-01/47, 20-15-01/50 and 20-15-01/51. Fuses are numbered as shown on the fuse box in the cab. Item
Description
1 2 3 4 5 6 7 8 9 10 11 11A 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Battery isolator Battery Fuse links Starter motor Starter solenoid Key switch Thermostart Neutral start relay Fuse link Ignition relay Sender unit Cold start advance unit (see Note 1) Engine shut-off solenoid (ESOS) Rear work light Rear work light switch Front work lights Front worklights switch Brake lights Brake light switch Trailer brake lights connector Reverse alarm Reverse light Parkbrake switch Parkbrake relay Front axle alignment lamp Front axle proximity switch Rear axle alignment lamp Rear axle proximity switch Radio Load Moment Indicator (LMI) transducer Load Moment Indicator (LMI) Instrument panel Warning buzzer Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge sender Water temperature sender Alternator
Note 1: Cold start advance unit 11A is part of fuel injection pump.
9804/1103
20 - 15 - 01/48
3650 - C/41-12.1
Issue 1
CONTENTS
Loadalls
528S With Syncro Shuttle Transmission Circuit Diagrams - Electrical (cont’d) Component Key 2
20 - 15 - 01/49
From m/c no. 796102
The complete electrical circuit is shown on pages 20-15-01/47, 20-15-01/50 and 20-15-01/51. Fuses are numbered as shown on the fuse box in the cab. Item
Description
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79
Rear indicator - right hand Rear side light - right hand Trailer light socket Number plate light Sidelights relay Front side light - left hand Front indicator - left hand Rear side light - left hand Rear indicators - left hand Trailer side light connection - left hand Road lights switch Dip beam - left hand Main beam - left hand Dip beam - right hand Main beam - right hand Front side lights - right hand Front indicators - right hand Fog lamp Fog light switch Steering column switch - right hand Trailer indicators Wash pump Roof wiper motor Roof wiper switch Front wiper motor Rear wiper motor Hazard warning lights switch Flasher relay Trailer indicator light Interior light Warning beacon Warning beacon switch Face level fan Air conditioning compressor Air conditioning relay Heater Receiver dryer Air conditioning switch Heater switch
9804/1103
20 - 15 - 01/49
3650 - C/41-13.1
Issue 1
Loadalls
CONTENTS
20 - 15 - 01/50
528S With Syncro Shuttle Transmission
From m/c no. 796102
Circuit Diagrams - Electrical (cont’d)
77 42
47
41 43
44 46
55 56
53 48
49 50
52
54
57 58
61
63
62
65
66
73
69 68
74 76
71 70
9804/1103
F2
F28
75
78
79
F4
72
67
F30
F5
F26
F24
F25
F21
F23
20 - 15 - 01/50
64
F1
60
59
F27
51
F22
45
3650 - C/41-14.1
Issue 1
Loadalls
CONTENTS
20 - 15 - 01/51
528S With Syncro Shuttle Transmission
From m/c no. 796102
Circuit Diagrams - Electrical (cont’d)
SLC 82
84
86
94
93
89
81
99
95
91 80
100
92
9804/1103
87
88
96
90
97
98
F14
85
F3
F13
83
20 - 15 - 01/51
3650 - C/41-15.1
Issue 1
CONTENTS
Loadalls
528S With Syncro Shuttle Transmission Circuit Diagrams - Electrical (cont’d) Component Key 3
20 - 15 - 01/52
From m/c no. 796102
The complete electrical circuit is shown on pages 20-15-01/47, 20-15-01/50 and 20-15-01/51. Fuses are numbered as shown on the fuse box in the cab. Item
Description
80 81 82 83 84 85 86 87 88 89 90 91 92
Column switch - left hand Horn Forward solenoid Forward relay Reverse solenoid Reverse relay Second auxiliary solenoid Second auxiliary relay Transmission dump relay Hitch solenoid Hitch switch Transmission dump switch (control lever) Transmission dump switch (gear change lever)
Single lever control (SLC) option: 93 94 95 96 97 98 99 100
Extend solenoid Auxiliary solenoid Retract solenoid Single lever control joystick Diodes Transmission dump switch (joystick) Auxiliary solenoid Lever isolation switch & auxiliary solenoid
9804/1103
20 - 15 - 01/52
3650 - C/41-16.1
Issue 1
Loadalls
CONTENTS
20 - 15 - 02/1
48
601
601
600
601
600
600
601
601
601
601
601
601
600
600
600
600
601
600
601
600
601
From m/c no. 767001 to 768836
600
600
601
601
601
601
530 Without Neutral Start Relay Circuit Diagrams - Electrical
411
M
601
601
841
800
8
57
44
28
105
42
16
49
M
854
120
917
9
31 22
25
851
884
829
F3
F4
115
F2
101
004
120
F1
M
104
34 102
21
120
003
38
M
600
(SLC)
15
106
51
4
3
100
1 2 3
925
911
926
55
109
56
33 901
1
64
52
17 26
824
M 41
39
826
M
2
23
601
59
801
6
66
61
820
7
601
65 848
5
50
885
883
37
601
27
825
60 600
45
43 24
47
601
32
18
601
14
840
12
601
856
400
856
58
F5
F7
F6
F8
F9
F11 F12
000
000
200
200
F13
001
+++ 914
414
19 30 413
11 20
54
46 36
35
40
53
601
62
1
2
3
4
5
6
7
886
8
819
853
29
1 2
13 10
9804/1103
823
907
W
20 - 15 - 02/1
X
Y
Z
3 4
822
5
821
6
3630 - C/26-1.5 3630 - C/25-1.1
Z X Y 63
Issue 1
CONTENTS
Loadalls
530 Without Neutral Start Relay Circuit Diagram - Electrical (cont’d) Component Key 1
20 - 15 - 02/2
From m/c no. 767001 to 768836
To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. The complete electrical circuit is shown on pages 20 - 15 - 02/1 and 20 - 15 - 02/4 Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
Battery Battery isolator Starter motor Ignition switch Starting aid Auto relay High Speed Control relay Pump dump switch Single lever control Sway isolation relay Sway/Auxiliary change-over Auxiliary change-over valve 1 Sway isolation switch Auxiliary A solenoid Auxiliary A/B switch Auxiliary B relay Auxiliary A relay Auxiliary B solenoid Auxiliary change-over switch Auxiliary change-over relay Auxiliary change-over valve 2 Boom extend switch Extend relay Extend solenoid Boom retract switch Retract relay Retract solenoid Transmission dump switch Safe Load Indicator (SLI) SLI transducer Heater/air conditioning fan Heater/air conditioning unit Air conditioning switch Face level fan Air conditioning compressor Air conditioning relay Binary Switch Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/cassette Heater seat Digital clock Warning buzzer Trailer indicators Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Ignition relay ESOS Two wheel steer solenoid
9804/1103
59 60 61 62
63
64 65 66
Four-wheel/crab steer solenoid Four wheel steer solenoid Crab steer solenoid Steer Mode Control Unit W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front sensor Rear sensor Instrument panel
Steer Sensor Wiring: Terminal 1 2 3
20 - 15 - 02/02
Wire Code 820 or 819 600 or 601 810 or 109
Wire Colour Black Blue Brown
3630 - C/25-2.4
Description Signal Earth Feed
Issue 1
CONTENTS
Loadalls
530 Without Neutral Start Relay Circuit Diagram - Electrical (cont’d) Component Key 2
20 - 15 - 02/3
From m/c no. 767001 to 768836
To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. The complete electrical circuit is shown on pages 20 - 15 - 02/1 and 20 - 15 - 002/4.
68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111
Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Water temperature sender Alternator Fuel sender Water temperature switch Steering column switch Horn Reverse relay Powershift control unit Park brake Four wheel brake relay Foot brake Two wheel drive switch Brakelights Brakelights Trailer rear Reverse alarm Auxiliary power socket Rear worklight switch Rear worklight Sidelight relay Main light switch Primary fuse Right hand sidelights Trailer rear Left hand sidelights Trailer rear Left hand worklights Front worklight switch Right hand worklights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear foglight switch Trailer rear Steering column switch Screen wash pump Right hand indicators Trailer rear Left hand indicators Trailer rear
Note: Powershift control unit (78) only shows input connections from the mainframe harness. Refer to the ECU fault finding information in this section for control unit output connections.
9804/1103
20 - 15 - 02/3
3630 - C/25-3.4
Issue 1
20 - 15 - 02/4
Loadalls
CONTENTS
To m/c no. 767001 to 768836
601
600
530 Without Neutral Start Relay Circuit Diagrams - Electrical (cont’d)
304
84
G 80
871
75
9 15 16 1 13 10 7 2 5 4 3 17 18 12 6
74
89
83
79
873
85
86
87 88
94 92
101
99 96
100
106
98
90
109 108
104
82
78 123
108
119
95 118
73
840
105
91
200
808
97
898
70
833
77
831
68
841
76
72
450
69
832
827
71
601
600
601
600
81
103
93
102
111
107
304
110 304 806 805 838 301 840 841 110
F19
F17
F15
836
F30
838
F28
F23
F29
F22
874
F26
F21
F25
F14
F24
F16
F18
832
A313920
9804/1103
20 - 15 - 02/4
3630 3630 - C/25-4.5 - C/26-1.5
Issue 1
20 - 15 - 02/5
Loadalls
CONTENTS
49
601
601
601
600
600
600
601
601
601
601
601
From m/c to 768837 to 770053
601
600
600
600
600
601
600
601
600
411
856
28
M
601
601
848
800
60
801
925
58
45
53
16
29
56 854
911
901
1 2 3
120
917
50
M
926
10 106
M
600
32
22
26 120
23
35 102
(SLC)
003
15
104
52 39
5
105
43
18
100
1
57
34
27
901
24
65
109
9
824
M 42
40
826
M
2
7
67
62
820
8
601
66
883
6
601
601
601
51
841
38
825
61 600
46
44 25
48
601
14
840
33
19
59 601
856
17
400
600
601
600
600
601
601
601
530 With Neutral Start Relay and ECU Controlled Transmission Circuit Diagram - Electrical
F12
F11
874
F13
F9
F8
301
F6
F5
115
F4
F3
101
F2
120
F7
810
F1
004
851
884
3 M
200
200
+++ 842
414
20 853
31 413
12 21
55
47 37
36
41
54
601
63
1
2
3
4
5
6
7
886
8 819
30
4
1 2
13 11
907
823 W
X
Y
Z
3 4
822
5
821
6
Z X Y 64 A313890
9804/1103
20 - 15 - 02/5
3630 - C/26-1.5
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/6
530 From m/c no. 768837 to 770053 with Neutral Start Relay and ECU Controlled Transmission Circuit Diagrams - Electrical (cont’d) Component Key 1 To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. The complete electrical circuit is shown on pages 20-15-02/5 and 20-15-02/8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57
Battery Battery isolator Starter motor Neutral start Ignition switch Starting aid Auto relay High Speed Control relay Pump dump switch Single lever control Sway isolation relay Sway/Aux change-over Sway isolation switch Auxiliary change-over valve 1 Auxiliary A/B switch Auxiliary A relay Auxiliary A solenoid Auxiliary B relay Auxiliary B solenoid Auxiliary change-over switch Auxiliary change-over relay Auxiliary change-over valve 2 Boom extend switch Extend relay Extend solenoid Boom retract switch Retract relay Retract solenoid Transmission dump switch Safe Load Indicator (SLI) SLI Transducer Heater/air conditioning fan Air conditioning unit Air conditioning switch Face level fan Air conditioning compressor Air conditioning relay Binary switch Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/cassette Heated seat Digital clock Warning buzzer Trailer indicators Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Ignition relay
9804/1103
58 59 60 61 62 63
64
65 66 67
Engine Shut-Off Solenoid Two wheel steer solenoid Four-wheel/crab steer solenoid Four wheel steer solenoid Crab steer solenoid Steer Mode Control Unit W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front sensor Rear sensor Instrument panel
Steer Sensor Wiring: Terminal 1 2 3
20 - 15 - 02/6
Wire Code 820 or 819 600 or 601 810 or 109
Wire Colour Black Blue Brown
3630 - C/26-2.4
Description Signal Earth Feed
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/7
530 From m/c no. 768837 to 770053 with Neutral Start Relay and ECU Controlled Transmission Circuit Diagram - Electrical (cont’d) Component Key 2 To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. The complete electrical circuit is shown on pages 20-15-02/5 and 20-15-02/8. 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112
Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Water temperature sender Alternator Fuel sender Water temperature switch Steering column switch Horn Reverse relay Powershift control unit Parkbrake Two wheel drive switch Four wheel drive brake switch Foot brake Brakelights Brakelights Trailer rear Reverse alarm Auxiliary power socket Rear worklight switch Rear worklights Sidelight relay Main light switch Primary fuse Right hand Sidelights Trailer rear Left hand sidelights Trailer rear Front worklight switch Left hand worklights Right hand worklights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear foglight switch Trailer rear Steering column switch Front wash/wipe motor Right hand indicators Trailer rear Left hand indicators Trailer rear
Note: Powershift control unit (79) only shows input connections from the mainframe harness. Refer to the ECU fault finding information in this section for control unit output connections.
9804/1103
20 - 15 - 02/7
3630 - C/26-3.3
Issue 1
20 - 15 - 02/8
Loadalls
CONTENTS
530 With Neutral Start Relay and ECU Controlled Transmission Circuit Diagram - Electrical (cont’d)
From m/c no 768837 to 770053
601
600
803
304
G 82
871
76
9 15 16 1 13 10 7 2 5 4 3 17 18 12 6
75
90
84
80
873
86
87
88 89
106
92 95
200
808
840
99
93
100 97
102
110
101
109
107
98
91
300
85
898
71
833
78
831
69
841
77
73
450
70
832
827
72
601
600
601
600
83
105
81
79 123
108
72
119
118
96
104
94
103
112
108
304 124
111
803
100 401 806 805 838 301 840 841 110 829
836
F30 F28
F29
F19
F17
F15
874
F26
F25
F24
F23
F22
F21
F14
F16
F18
832
810
A313900
9804/1103
20 - 15 - 02/8
3630 - C/26-4.4
Issue 1
20 - 15 - 02/9
Loadalls
CONTENTS
47
601
411
400
601
27
M
601
601
58
41 48
M
820
100
926
854
11
54 1 2 3
901
15
105
901
4
109
55
31
26
63
51
200
23
56
43
824
40
925
8 004
M
38
826
M
17 (PP)
7
65
848
800
12
64
60
801
5
601
601
601
49
883
18
003
16
36
841
003
32
825
59 600
44
42 24
46
601
13
57 601
840
6
601
601
601
600
600
601
601
601
601
601
601
600
600
600
600
601
601
600
601
600
601
600
601
From m/c no. 770054 to 770958
601
601
601
530 with Relay Controlled Transmission, ECU not fitted Circuit Diagram - Electrical
30 22
25
33 102
20
106
M
600
14 9
104
50 37
840
2
884
841
851
110 829
F12
F9
F8
F7
F6
F5
115
F3
101
F4
F2
120
120
F1
1
F11
810 810
3
000
000
200
200
F13
842
874
001
M
414
21
917
10
29 413
19
53
45 35
34
39
52
601
61
1
2
3
4
5
6
7
886
8 819
+++
301
853
28
1 2 823
W
X
Y
Z
3 4
822
5
821
6
Z X Y 62 A313870
9804/1103
20 - 15 - 02/9
3630 - C/27-1.5
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/10
530 with Relay Controlled Transmission, ECU not fitted
From m/c no. 770054 to 770958
Circuit Diagram - Electrical (cont’d) Component Key 1 The complete electrical circuit is shown on pages 20-15-02/9 and 20-15-02/12. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57
Battery Battery isolator Starter motor Neutral start relay Ignition switch Starting aid not used High Speed Control relay Ppump dump switch not used Sway/Auxiliary change-over Auxiliary A relay Auxiliary A solenoid Auxiliary A/B switch Auxiliary B relay Auxiliary B solenoid Auxiliary change-over relay 2 Auxiliary change-over valve 1 Auxiliary change-over relay Auxiliary change-over valve 2 Auxiliary change-over switch Boom extend switch Extend relay Extend solenoid Boom retract switch Retract relay Retract solenoid Safe Load Indicator (SLI) SLI transducer Heater/air conditioning fan Air conditioning switch Heater/air conditioning unit Face level fan Air conditioning compressor Air conditioning relay Binary switch (air con) Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/cassette Heated seat Digital clock Warning buzzer Trailer indicators Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Ignition relay Engine Shut-Off Solenoid Two wheel steer solenoid
9804/1103
58 59
Four-wheel/crab steer solenoid Four wheel steer solenoid
60 61
Crab steer solenoid Steer Mode Control Unit W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front sensor Rear sensor Instrument panel
62
63 64 65
Steer Sensor Wiring: Terminal 1 2 3
20 - 15 - 02/10
Wire Code 820 or 819 600 or 601 810 or 109
Wire Colour Black Blue Brown
3630 - C/27-2.4
Description Signal Earth Feed
Issue 1
CONTENTS
Loadalls
530 with Relay Controlled Transmission, ECU not fitted Circuit Diagrams - Electrical (cont’d) Component Key 2
20 - 15 - 02/11
From m/c no. 770054 to 770958
The complete electrical circuit is shown on pages 20-15-02/9 and 20-15-02/12. 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127
Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Steering column switch Alternator Fuel sender Water temperature switch Steering column switch Horn Reverse relay 2 Ignition relay 2 Transmission dump switch Pump dump relay Reverse 1 relay Forward relay Drive relay Parkbrake relay Reverse HI/LOW relay Reverse high solenoid Reverse low solenoid Forward HI/LOW relay Forward high solenoid Forward low solenoid Driveshaft relay Layshaft solenoid Mainshaft solenoid Two/four wheel drive solenoid Transmission oil temperature switch Parkbrake switch Footbrake switch Four wheel drive brake relay Two wheel drive switch Brakelights Brakelights Trailer rear Reverse alarm Auxiliary power socket Rear worklight switch Rear worklight Sidelight relay Main light switch Primary fuse Right hand sidelight Trailer rear Left hand sidelight Trailer rear Front work light switch Left hand work lights Right hand work lights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear fog light switch Rear fog light Steering column switch Front wash/wipe motor Right hand indicators Trailer rear Left hand indicators Trailer rear
9804/1103
20 - 15 - 02/11
3630 - C/27-3.4
Issue 1
20 - 15 - 02/12
Loadalls
CONTENTS
530 with Relay Controlled Transmission, ECU not fitted Circuit Diagram - Electrical (cont’d)
From m/c 770054 to 770958
601
600
600 601
600
601
601 600
601
809
601
601
803
601
856 807
827
97
117
108
111
119
106
103
600 601
120
109
118
601
124
815
127
108 98
116
126
113
600
200 601
600
104
119
872
93
890
83
115 112
92 90
79
75
812
852
861
78
G
87
91
857
71
82
110
105
99
88
871
874
121 450
94
859
86
114 107
601
84
600
81
100
600
76
808
601
69
80
863
808
72
96
89
125
85
73 70
67 68
811
601
600
600
300
304
401
118
807
124
806 805 838 301 840 841
F30 F29
F26
F25
F24
F23
F22
827
123
839
F19
F21
F18 F17
F15
815
F16
102
3 SPEED ONLY
77
809
101
601
107
95
F28
110
122
107
74
A313880
9804/1103
20 - 15 - 02/12
3630 - C/27-4.4
Issue 1
20 - 15 - 02/13
Loadalls
CONTENTS
601
601
901 926
22
105
51
52
601
820
1 2 3 854
19
45
901
14
38 M
933
12
53
100
21 882
17
61
48 200
934
6
54
40
28
931
826
37
925
004
932
824
M
109
M 35
935
63
56
883
4
62
58 848
841
601
46
853
24
601
600
M
33
825
57
601
801
43
41
39 800
18
13
601
840 851
15
55 601
29
20
601
601
601
600
600
600
601
601
601
601
601
601
601
411
5 7
44
23
400
11
600
600
600
From m/c no. 770959
600
600
600
600
601
601
601
530, 540 Sway Machines Circuit Diagrams - Electrical
47
120
9
106
30
102
2
850
810
34 M
27
301 840
884
16
114
451
841 110 829
829
810
F12
F11
F9
F8
F7
F6
F5
115
F4
F3
F13
842
F2
F1
F10
10
1
101
810
874
874 000
3
200
200
001
M
+++ 414
+++
8
25 413
50
42 32
31
36
601
301
26
49
59
1
2
3
4
5
6
7
8 819
886
1 2 823
W
X
Y
Z
3 4
822
5
821
6
Z X Y 60 A314050
9804/1103
20 - 15 - 02/13
3630 - C/28-1.5
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/14
530, 540 Sway Machines Circuit Diagram - Electrical (cont’d)
From m/c no. 770959
Component Key 1 The complete electrical circuit is shown on pages 20-15-02/13 and 20-15-02/16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
Battery Battery isolator Starter motor Ignition switch Starting aid Neutral start relay not used HSC pump dump switch Auxiliary change-over valve 2 Sway/Auxiliary change-over switch Auxiliary change-over valve 1 Auxiliary A switch Auxiliary A solenoid Auxiliary B switch Auxiliary B solenoid Joystick isolation switch Single lever control - extend Extend solenoid Single lever control - retract Retract solenoid Auxiliary 2 A switch Auxiliary 2 B switch Auxiliary change-over valve 2 Auxiliary change-over relay Safe Load Indicator (SLI) SLI transducer Heater/air conditioning fan Air conditioning switch Heater/air conditioning unit Face level fan Air conditioning compressor Air conditioning relay Binary switch (air conditioning) Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/cassette Heated seat Digital clock Warning buzzer Trailer indicators Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Primary fuse Ignition relay Engine Shut-Off Solenoid Two wheel steer solenoid Four-wheel/crab steer solenoid Four wheel steer solenoid Crab steer solenoid
9804/1103
59
60
61 62 63
Steer Mode Control Unit W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front sensor Rear sensor Instrument panel
Steer Sensor Wiring: Terminal 1 2 3
20 - 15 - 02/14
Wire Code 820 or 819 600 or 601 810 or 109
Wire Colour Black Blue Brown
3630 - C/28-2.3
Description Signal Earth Feed
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/15
530, 540 Sway Machines circuit Diagram - Electrical (cont’d)
From m/c no. 770959
Component Key 2 Component Key 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124
Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Steering column switch Alternator Fuel sender Water temperature switch Steering column switch Horn Reverse relay 2 Ignition relay 2 Transmission dump switch Transmission dump relay Reverse 1 relay Forward relay Drive relay Parkbrake relay Reverse HI/LOW relay Reverse high solenoid Forward HI/LOW relay Reverse low solenoid Forward high solenoid Forward low solenoid Driveshaft relay Layshaft solenoid Mainshaft solenoid Two/Four wheel drive solenoid Transmission oil temperature switch Parkbrake Four wheel drive brake relay Footbrake Two wheel drive switch Brakelights Brakelights Trailer rear Reverse alarm Auxiliary power socket Rear worklight switch Rear worklight Sidelight relay Primary fuse 3 Main light switch Primary fuse 2 Right hand sidelight Trailer rear Left hand sidelight Trailer rear Front work light switch Left hand work lights Right hand work lights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear fog light switch Trailer rear Steering column switch Front wash/wipe motor Right hand indicators Trailer rear
9804/1103
125 Left hand indicators 126 Trailer rear
20 - 15 - 02/15
3630 - C/28-3.4
Issue 2*
20 - 15 - 02/16
Loadalls
CONTENTS
530, 540 Sway Machines Circuit Diagram - Electrical (cont’d)
601
600
600 601
600
601
601 600
601
79
85
82
98
109
103
97
300
120
106
94
116
114
600
86
600
600
601
601
601 601
600
600 118
92
859
600
74
808
601
67
78
811
65
113 450
70
95
87
827
600
601
807
83
863
68
808
66
601
807
71
601
601
601
601
601
809
601
601
From m/c no. 770959
126
118
600
110
200
104
600 601
119 601
200
601
816
857
890
858 601
815
105
117
108
123
81
107 96
115
125
872
73
112
101
90 88
77
102
91
124
861
76
111
119
852
69
G
89 600
84
80 874
812
871
304 124
108
118
100 401 806 805 838 301 840 841
F30
F28 F29
F26
F25
F24
F23
F22
F21 F19
F17
F15
815
F18
601
100
F16
F35
F34
F33
F31
99 807
122
3 SPEED ONLY
75
F32
93
107
121
839
809
110 829
832
107
F14
72
A314060
9804/1103
20 - 15 - 02/16
3630 - C/28-4.4
Issue 1
Loadalls
CONTENTS
20 - 15 - 02/17
601
601
601
820
824
826
1 2 3 854
47
30
102
120
106
34 M
26
810
52
100
51
(DR)
2
105
45
926
21
53
38 M
901
16
48 200
901 882
18 933
11
54
40
61
109
925
37
931
9
601
848
883
M
27
934
004
932
14
63
56 M 35
6
62
58
853
4
601
46
841
19
825
57 600
601
601
55 601
840 800
801
M
33
931
43
41
39
15 932
601
601
601
600
600
600
601
601
601
601
601
601
851
10
7
600
28
17
12
400
5
44
23
411
20
601
601
600
600
From m/c no. 770959
600
600
600
601
601
601
530, 540 Non-Sway Machines Circuit Diagram - Electrical
301 840
884 451
841
13
22
110 829
829
810
F12
F11
F9
F8
F7
F6
F5
115
F4
F3
101
F13
842
F2
F1
1
F10
114
810
874
874 000
3
200
200
001
M
+++ 414
+++
8
24 413
50
42 32
31
36
601
301
25
49
59
1
2
3
4
5
6
7
819
886
8
1 2 823
W
X
Y
Z
3 4
822
5
821
6
Z X Y
60 A314070
9804/1103
20 - 15 - 02/17
3630 - C/26-1.5 3630 - C/29-1.3
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/18
530, 540 Non-Sway Machines Circuit Diagram - Electrical (cont’d) Component Key 1
From m/c no. 770959
The complete electrical circuit is shown on pages 20 - 15 - 02/17 and 20 - 15 - 02/20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
Battery Battery isolator Starter motor Ignition switch Starting aid Neutral start relay not used Pump dump switch Auxiliary A switch Auxiliary A solenoid Auxiliary B switch Auxiliary B solenoid Joystick isolation switch Boom extend switch Extend solenoid Boom retract switch Retract solenoid Auxiliary 2 A switch Auxiliary change-over relay Auxiliary change-over valve 2 Auxiliary 2 B switch Stabilizer isolation switch Auxiliary change-over valve 1 Safe Load Indicator (SLI) SLI transducer Heater/air conditioning fan Air conditioning switch Heater/air conditioning unit N/A Face level fan Air conditioning compressor Air conditioning relay Binary switch (air conditioning) Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/cassette Heated seat Digital clock Warning buzzer Trailer indicators Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Primary fuse Ignition relay Engine Shut-Off Solenoid Two wheel steer solenoid Four-wheel/crab steer solenoid Four wheel steer solenoid Crab steer solenoid
9804/1103
59
60
61 62 63
Steer Mode Control Unit W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front sensor Rear sensor Instrument panel
Steer Sensor Wiring: Terminal 1 2 3
20 - 15 - 02/18
Wire Code 820 or 819 600 or 601 810 or 109
Wire Colour Black Blue Brown
3630 - C/29-2.2
Description Signal Earth Feed
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/19
530, 540 Sway Machines circuit Diagram - Electrical (cont’d)
From m/c no. 770959
Component Key 2 The complete electrical circuit is shown on pages 20-15-02/17 to 20-15-02/20. 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123
Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Steering column switch Alternator Fuel sender Water temperature switch Steering column switch Horn Reverse relay 2 Ignition relay 2 Transmission dump switch Transmission dump relay Reverse 1 relay Forward relay Drive relay Parkbrake relay Reverse HI/LOW relay Reverse high solenoid Forward HI/LOW relay Reverse low solenoid Forward high solenoid Forward low solenoid Driveshaft relay Layshaft solenoid Mainshaft solenoid Two/Four wheel drive solenoid Transmission oil temperature switch Parkbrake Four wheel drive brake relay Footbrake Two wheel drive switch Brakelights Brakelights Trailer rear Reverse alarm Auxiliary power socket Rear worklight switch Rear worklight Sidelight relay Primary fuse 3 Main light switch Primary fuse 2 Right hand sidelight Trailer rear Left hand sidelight Trailer rear Front work light switch Left hand work lights Right hand work lights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear fog light switch Trailer rear Steering column switch Front wash/wipe motor Right hand indicators
9804/1103
124 Trailer rear 125 Left hand indicators 126 Trailer rear
20 - 15 - 02/19
3630 - C/29-3.3
Issue 2*
CONTENTS
20 - 15 - 02/20
Loadalls
530, 540 Non-Sway Machines Circuit Diagram - Electrical (cont’d)
601
600
600 601
600
601
601 600
601
79
118
98
94
300
120 109
103
97
116
114
600
86
600
600
601
601
601 601
600
113 106 450
85
82
92
859
600
78
74
808
811
67
601
65
600
95
87
827
600
601
807
70
863
68
83 808
66
601
807
71
601
601
601
601
601
809
601
601
From m/c no. 770959
126
118
600
110
200
104
600 601
119 601
200
601
816
857
107 96
115
858 601
105
117
108
123
815
125
872
890
81
112
101
90 88
77
73
102
91
124
861
76
111
119
852
69
G
84
89 600
80 874
812
871
304 124 108
118
100 401 806 805 838 301 840 841
F30
F28 F29
F26
F25
F24
F23
F22
F21 F19
F17
F15
815
F18
601
100
F16
F35
F34
F33
F31
99 807
122
3 SPEED ONLY
75
F32
93
107
121
839
809
110 829
832
107
F14
72
A314060
9804/1103
20 - 15 - 02/20
3630 3630 - C/29-4.3 - C/26-1.5
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/21
530, 540 From m/c no. 775402 535 From m/c no. 777362 all with Manual Auxiliary Controls Circuit Diagram - Electrical Component Key 1 The complete electrical circuit is shown on pages 20-15-02/22, 20-15-02/23 and 20-15-02/26
Key 1 2 3 4 5 5A 6 7 8 9 10 11 11A 12 12A 12B 13 13A 14 15 16 17 17A 18 19 19A 20 21 22 23 24 25 26 27 28 29 30 31 32 33
Battery Battery isolator Starter motor Starter solenoid Ignition switch Fuse link 2 Starting aid Neutral start relay Ignition feed relay 1 Ignition feed relay 2 E.S.O.S. Rear work lamp switch Rear work lamp Front work lamps switch Front work lamps Auxiliary power connector 2/4WD brake relay Brake lamps Brake switch 2/4WD switch 2/4WD solenoid Reverse relay Reverse lamp Reverse alarm Park brake relay Park brake switch Heated seat Radio/cassette Digital clock Transducer - Load Moment Indicator (LMI) Instrument panel Warning buzzer Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge Water temperature gauge Alternator
* Optional fan reversing circuit shown at inset X 131 Fan reverse switch 132 Fan reverse solenoid 133 Fan reverse horn Note: All the items listed here are not necessarily fitted to all machines in the range.
9804/1103
20 - 15 - 02/21
3630 - C/30-1.3
Issue 2*
Loadalls
CONTENTS
20 - 15 - 02/22
530, 540 From m/c no. 775402 535 From m/c no. 777362 All with Manual Auxiliary Controls Circuit Diagram - Electrical (cont’d)
16
2
6
31 17A
11A 12A
12B
13A
18
19A 20
23 21
32
26 27 28 29 30
10
X
3
1 11
12
13 15
17
19
132 133 1840a
33 24
601JM
22
9
601JN
8
1840
7
601JR
4
25 14 5
171
131
5A
417050
160-02292-1
9804/1103
20 - 15 - 02/22
3630 - C/30-2.3
Issue 2*
20 - 15 - 02/23
Loadalls
CONTENTS
530, 540 From m/c no. 775402 535 From m/c no. 777362 all with Manual Auxiliary Controls Circuit Diagram - Electrical (cont’d)
54 35
36
38
39
41
43
44
57
45 46
47
48
49
53
60
62
65
61
55 58
40 37 34
42
56 50 51
52
59
63
64
34A
160-02292-2
9804/1103
20 - 15 - 02/23
3630 - C/30-3.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/24
530, 540 From m/c no. 775402 535 From m/c no. 777362 all with Manual Auxiliary Controls Circuit Diagram - Electrical Component Key 2 The complete electrical circuit is shown on pages 20-15-02/22, 20-15-02/23 and 20-15-02/26. 34 34A 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65
Sidelight relay Fuse link 2 RH side lights LH side lights Main light switch RH/LH dip beam RH/LH main beam Rear fog light switch Rear fog lamp (optional) Column switch - RH LH indicators RH indicators Front washer pump Front wiper motor Rear wiper motor Roof/rear washer pump Roof wiper motor Rear wiper switch Roof wiper switch Hazard warning switch Hazard warning relay Trailer indicator warning light Interior light/switch Beacon switch Beacon lamp Face level fan Air conditioning relay Air conditioning - compressor motor Air conditioning - freeze switch Air conditioning - receiver drier Air conditioning switch Heater/heater fan switch Heater
Note: All the items listed here are not necessarily fitted to all machines in the range.
9804/1103
20 - 15 - 02/24
3630 - C/30-4.1
Issue 1
CONTENTS
Loadalls
20 - 05 - 02/25
530, 540 From m/c no, 775402 535 From m/c no. 777362 all with Manual Auxiliary Controls Circuit Diagram - Electrical (cont’d) The complete electrical circuit is shown on pages 20-15-02/22, 20-15-02/23 and 20-15-02/26. 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93
Column switch - LH Horn Reverse Hi/Lo relay Reverse Lo relay Reverse Hi relay Diode pack (see Note below) Reverse relay Forward relay Forward Hi/Lo relay Forward Hi solenoid Forward Lo solenoid Drive interlock relay Drive shaft relay Layshaft solenoid Mainshaft solenoid Transmission dump relay 2nd auxiliary relay 2nd auxiliary solenoid Hitch/boom hydraulics solenoid Hitch switch Sway switch Sway diverter solenoid Sway valve Sway valve 2nd auxiliary push button Isolation switch Transmission dump push button Steer mode control unit A Four wheel/crab steer relay B Two wheel steer relay C Crab steer relay D Four wheel steer relay 94 Steer mode selector switch X Two wheel steer Y Crab Steer Z Four wheel steer 95 2WS solenoid 96 4WS solenoid 97 AWS solenoid 98 Crab steer solenoid 99 Proximity switch - front axle 100 Proximity switch - rear axle Note: All the items listed here are not necessarily fitted to all machines in the range. Note: Diode indicated (†) not fitted to 3-speed machines.
9804/1103
20 - 15 - 02/25
3630 - C/30-5.1
Issue 1
20 - 15 - 02/26
Loadalls
CONTENTS
530, 540 From m/c no. 775402 535 From m/c no. 777362 all with Manual Auxiliary Controls Circuit Diagram - Electrical (cont’d)
95 69
70
96
67 75
79
76
80
83 84
97
87 88 89 98
71 86 90
66
94 Z X Y
92 91 68
72
73
74
77
78
81
82
99
85
100 93
160-02292-3
9804/1103
20 - 15 - 02/26
3630 - C/30-6./1
Issue 1
Loadalls
CONTENTS
20 - 15 - 02/27
2
13
16
6
18
27
31 32 33 34 35
10
36 37
530, 540 From m/c no. 775402 535 From m/c no. 777362 All with Single Lever Controls (SLC) Circuit Diagram - Electrical
23
20
11A 12A 24
21
25
X
3 8
9
26 11
12
15
17
19
601JR
1 30
22
601JM
7
601JN
4
132 1840a
28 29
1840
133
14 5 131 171
5A
417050
160-02291-1
9804/1103
20 - 15 - 02/27
3630 - C/31-1.2
Issue 2*
CONTENTS
Loadalls
20 - 15 - 02/28
530, 540 From m/c no. 775402 535 From m/c no. 777362 all with Single Lever Controls (SLC) Circuit Diagram - Electrical (cont’d) Component Key 1 The complete electrical circuit is shown on pages 20-15-02/27, 20-15-02/30 and 20-15-02/31.
Key 1 2 3 4 5 5A 6 7 8 9 10 11 11A 12 12A 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
Battery Battery isolator Starter motor Starter solenoid Ignition switch Fuse link 2 Starting aid Neutral start relay Ignition feed relay 1 Ignition reed relay 2 E.S.O.S. Rear work lamp switch Rear work lamp Front work lamp switch Front work lamps Auxiliary power connector Brake switch 2/4WD brake relay Brake lamps 2/4WD switch 2/4WD solenoid Reverse relay Reverse lamp Reverse alarm Park brake relay Park brake switch Heated seat Radio/cassette Digital clock Transducer - load moment indicator (LMI) Instrument panel Warning buzzer Alternator Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge Water temperature gauge
* Optional fan reversing circuit shown at inset X 131 Fan reverse switch 132 Fan reverse solenoid 133 Fan reverse horn Note: All the items listed here are not necessarily fitted to all machines in the range.
9804/1103
20 - 15 - 02/28
3630 - C/31-2.2
Issue 2*
CONTENTS
Loadalls
20 - 15 - 02/29
530, 540 From m/c no. 775402 535 From m/c no. 777362 all with Single Lever Controls (SLC) Circuit Diagram - Electrical (cont’d) Component Key 2 The complete electrical circuit is shown on pages 20-15-02/27, 20-15-02/30 and 20-15-02/31. 38 38A 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
Sidelight relay Fuse link 1 RH side lights LH side lights Main light switch RH/LH dip beam RH/LH main beam Rear fog light switch Rear fog lamp (optional) Column switch - RH LH indicators RH indicators Front washer pump Front wiper motor Rear wiper motor Rear wiper switch Rear/roof washer pump Roof wiper motor Roof wiper switch Hazard warning switch Hazard warning relay Interior light/switch Beacon switch Beacon lamp Face level fan Air conditioning relay Air conditioning - compressor motor Air conditioning - freeze switch Air conditioning - receiver drier Air conditioning switch Heater/heater fan switch Heater
Note: All the items listed here are not necessarily fitted to all machines in the range.
9804/1103
20 - 15 - 02/29
3630 - C/31-3.1
Issue 1
20 - 15 - 02/30
Loadalls
CONTENTS
530, 540 From m/c no. 775402 535 From m/c no. 777362 all with Single Lever Controls (SLC) Circuit Diagram - Electrical (cont’d)
39
40
42
43
47 45
48
50
51 53
54
41
65
60
49
63
58
46
38
61
57
56
59
62
64
66
68
67
44 52
55
160-02291-2
9804/1103
20 - 15 - 02/30
3630 - C/31-4.1
Issue 1
Loadalls
CONTENTS
20 - 15 - 02/31
530, 540 From m/c no. 775402 535 From m/c no. 777362 all with Single Lever Controls (SLC) Circuit Diagram - Electrical (cont’d)
100 70
72
73
78
83
79
87
101 91
82
93
95
102
96
86
103
69 99 Z X Y
104
89 71
75
76
77
80
81
84
85
88
90
92
94
97
105 98
160-02291-3
9804/1103
20 - 15 - 02/31
3630 - C/31-5.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/32
530, 540 From m/c no. 775402 535 From m/c no. 777362 all with Single Lever Controls (SLC) Circuit Diagram - Electrical (cont’d) Component Key 3 The complete electrical circuit is shown on pages 20-15-02/27, 20-15-02/30 and 20-15-02/31. 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98
99
100 101 102 103 104 105
Column switch - LH Horn Reverse Hi/Lo relay Reverse Lo Solenoid Reverse Hi solenoid Diode pack (see Note below) Reverse relay Forward relay Forward Hi/Lo relay Forward Hi solenoid Forward Lo solenoid Drive interlock relay Drive shaft relay Layshaft solenoid Mainshaft solenoid Transmission dump relay 2nd auxiliary relay 2nd auxiliary solenoid Hitch/boom hydraulics solenoid Hitch switch Joystick isolation switch/lamp 2nd auxiliary extend switch 2nd auxiliary extend solenoid 2nd auxiliary retract switch 2nd auxiliary retract solenoid Auxiliary A/B switch Auxiliary A solenoid Auxiliary B solenoid Transmission dump push button Steer mode control unit A Four wheel/crab steer relay B Two wheel steer relay C Crab steer relay D Four wheel steer relay Steer mode selector switch X Two wheel steer Y Crab steer Z Four wheel steer 2WS solenoid 4WS solenoid AWS solenoid Crab steer solenoid Proximity switch - front axle Proximity switch - rear axle
Note: All the items listed here are not necessarily fitted to all machines in the range. Note: Diode indicated (†) not fitted to 3-speed machines.
9804/1103
20 - 15 - 02/32
3630 - C/31-6.1
Issue 1
CONTENTS
Loadalls
530, 535, 540 Circuit Diagram - Electrical
20 - 15 - 02/33
From m/c no. 767001
530FS Super, 540FS Super, 530 SXL, 540 SXL Component Key 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
Battery Battery isolator Starter motor Starter solenoid Ignition switch Fuse link 2 Starting aid Neutral start relay Ignition feed relay 1 Ignition feed relay 2 Wax Thermostat E.S.O.S. Rear work lamp switch Rear work lamp Front work lamps switch Front work lamps Auxiliary power connector 2/4WD brake relay Brake lamps Brake switch 2/4WD switch 2/4WD solenoid Reverse relay Reverse lamp Reverse alarm Heated seat Radio/cassette Digital clock Tracker Transducer - Load Moment Indicator (LMI) Fuse link 1 Instrument panel Warning buzzer Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Water temperature switch Fuel gauge Water temperature gauge Alternator Air suspension seat
* Optional fan reversing circuit shown at inset X 131 Fan reverse switch 132 Fan reverse solenoid 133 Fan reverse horn Note: All the items listed here are not necessarily fitted to all machines in the range.
9804/1103
20 - 15 - 02/33
3630 - C/32-1.1
Issue 1
Loadalls
CONTENTS
20 - 15 - 02/34
530, 535, 540 Circuit Diagram - Electrical
From m/c no. 767001
601
601
600
601
600
601
600
601 601
600
601
601
601
601 601
601
600
601
601
601
601
601
601
601
601
601
601
601
601
530FS Super, 540FS Super, 530 SXL, 540 SXL
30A
9
8
10
13
24
M
41
3536 409
408
412
406
407
405A
404
403
402
838
401
825
807
413
26
824
27 826
22 818
866 816
17
39
37 38
34 804
19
831
16
904
200
M
200
11 12 004
3
14
25 414
7
LEAD
2
*
X
28
15 23
30B
40
33
132 133 1840a
829
32
411
106
806
805
101
301
112
808
124
118
816
119
906
829
123
105
000
100
000
810
003
842
LEAD
151
29
601JM
21
18
4
601JN
+
1840
1 2 3
601JR
1
450
-
106 8
31 32 33 34 35
3
30
28
29
7
19
15
17
16
25
18
12
11
200
5
200
108
003
20
131
6 31
171
001 +++
000 001 100 300 301 304 804 805 806 808 810 824 825 826 827 829 838 401 A374060 160/13114-1
9804/1103
417050
405A
20 - 15 - 02/34
3630 - C/32 - 2.3
Issue 2*
CONTENTS
Loadalls
20 - 15 - 02/35
530, 535, 540 Circuit Diagram - Electrical 530FS Super, 540FS Super, 530 SXL, 540 SXL Component Key 2 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
Sidelight relay Fuse link 1 RH side lights LH side lights Main light switch RH/LH dip beam RH/LH main beam Rear fog light switch Rear fog lamp (optional) Column switch - RH LH indicators RH indicators Front washer pump Front wiper motor Rear wiper motor Roof/rear washer pump Roof wiper motor Rear wiper switch Roof wiper switch Hazard warning switch Hazard warning relay Trailer indicator warning light Interior light/switch Beacon switch Beacon lamp Face level fan Air conditioning relay Air conditioning - compressor motor Air conditioning - freeze switch Air conditioning - receiver drier Air conditioning switch Heater/heater fan switch Heater Sway switch Sway diverter solenoid Sway valve Sway valve Sway isolator relay Sway isolator proximity switch
Note: All the items listed here are not necessarily fitted to all machines in the range.
9804/1103
20 - 15 - 02/35
3630 - C/32-4.1
Issue 1
Loadalls
CONTENTS
20 - 15 - 02/36
530, 535, 540 Circuit Diagram - Electrical
46
600
600
600
600
600
601
601
600
601
77 931
850
882
801 800
76 885
886
74
70
78 932
71
M
69
66
803
802
601
601
601
601 854
601
M
64 849
926
67
400
57
56 841
62
58
M
901
54 55
M
63
884 883
M
601
600
601
600 M
839
806
898
805
53
925
M
52
48 838
73
75
829
115
301
72
102
68
65 104
805 804
61
60 300
803 841 840
59 304
836
833
832
905
200
51
829
42
909
49
110
829 827
830
828
47 834
45
44
840
50
600
601
600
601
600
601
601
600
600
600
600
601
601
600
601
600
601
530FS Super, 540FS Super, 530 SXL, 540 SXL
79 907
1
4
5
9
6
24
27
23
22
21
121
80
43
000 001 100 300 301 304 804 805 806 808 810 824 825 826 827 829 838 401
000 001
301 304
808 810 824 825 826 829 401
405A
9804/1103
A374070 160/13114-2
405A
20 - 15 - 02/36
3630 - C/32 - 3.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/37
530, 535, 540 Circuit Diagram - Electrical 530FS Super, 540FS Super, 530 SXL, 540 SXL Component Key 3 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115
116
117 118 119 120 121 122
Transmission oil pressure switch 5th gear solenoid Speed sensor Mainshaft solenoid Layshaft solenoid Forward high solenoid Forward low solenoid Reverse high solenoid Reverse low solenoid Speedometer Speedometer illumination Throttle switch Column switch - LH Electronic control unit Diagnostic port Horn Parkbrake switch 2nd auxiliary relay 2nd auxiliary solenoid Hitch switch Hitch/boom hydraulics solenoid Joystick isolation switch Diode pack 2nd auxiliary B push button Extend push button Extend solenoid 2nd auxiliary A push button Retract push button Retract solenoid Auxiliary A push button Auxiliary A solenoid Auxiliary B push button Auxiliary B solenoid Transmission dump push button Steer mode control unit A Four wheel/crab steer relay B Two wheel steer relay C Crab steer relay D Four wheel steer relay Steer mode selector switch X Two wheel steer Y Crab Steer Z Four wheel steer 2WS solenoid 4WS solenoid AWS solenoid Crab steer solenoid Proximity switch - front axle Proximity switch - rear axle
Note: All the items listed here are not necessarily fitted to all machines in the range.
9804/1103
20 - 15 - 02/37
3630 - C/32-5.1
Issue 1
Loadalls
CONTENTS
20 - 15 - 02/38
530, 535, 540 Circuit Diagram - Electrical
600
600
600
600
600
601
106
113
A
315
116
103
6
94 12
15
18
29
28
27
26
25
24
23
7 8 9 10 11 12 13 15 16 17 18 20
102
104 105
107 108
5
6
Z X Y
819
121 820
931
930 932
4
C
110 112 114 122 D
98 100
115 109
5
2
3
13
4
856
3
451 120
2
1
2
1
114
1
10
2
933
873
3
929 934
B
600J
107
823 822 821
45
93
4 5 6 7 8
601
120
853
850
851
815
871
F
109 111
119
0
600
601 600
601
601
118
814
874
97
872
R N
117
101 99
1807
860
811
859
86 87 88 89 90 812
857
858
894
480 893
405
85
84
808
92
81
809
96
601
91
82 83
600
600
600
600
600
600
600
600
600
601
530FS Super, 540FS Super, 530 SXL, 540 SXL
14
000
808 810 824 825 826
474
470
470A
001 473
001 301 304
A374080 160/13114-3
95 824 825 826
829 401 405A
9804/1103
20 - 15 - 02/38
363s0 - C/32 - 6.1
Issue 1
CONTENTS
Loadalls
532, 537 without Neutral Start Relay Circuit Diagrams - Electrical Component Key 1
20 - 15 - 03/1
From m/c no. 767001 to 768956
To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. The complete electrical circuit diagram is shown on pages 20-15-03/2 and 20-15-03/3. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
Battery Battery isolator Starter motor Ignition switch Starting aid not used Sway isolation relay Sway/Aux change-over Sway/Aux 1 solenoid Sway isolation switch Auxiliary A relay Auxiliary B relay Aux A/B switch Auxiliary A solenoid Auxiliary B solenoid Stabilizer isolation valve Stabilizer isolation relay Stabilizer isolation switch Stabilizer isolation proximity switch Transmission dump switch Not applicable Safe Load Indicator (SLI) SLI transducer Heater/air conditioning switch Heater/air conditioning unit Air conditioning switch Face level fan Air conditioning compressor Air conditioning relay Binary switch (air conditioning) Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/Cassette Heated seat Digital clock Left hand stabilizer warning light Right hand stabilizer warning light Warning buzzer Hazard switch Indicator relay Interior light Rotating beacon switch Rotating beacon Primary fuse Ignition relay Engine Shut-Off Solenoid Two wheel steer solenoid All wheel steer solenoid Four wheel steer solenoid Crab steer solenoid
9804/1103
55
Steer Mode Control Unit W All wheel steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay
56
Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front steer sensor Rear steer sensor Instrument panel
57 58 59
20 - 15 - 03/1
3660 - C/21-1.1
Issue 1
Loadalls
CONTENTS
20 - 15 - 03/2
532, 537 without Neutral Start Relay Circuit Diagrams - Electrical (cont’d)
D C
15
F B
601
58
54
59
53 42
27
19
26
912
36
50 39
M
28
820
43
46
819
910
34
57
51 824
M
52
45
M
826
M 32
848
883
2
913
47
35
A
11
6
44
M
30
825
25
601
600
38
23
601
856
16
601
14
9
5
From m/c no. 767001 to 768956
49
48
10
31 20
907
24
22
29
33 RT
911
18
109
40 41
851
7
37
100
21
12
882
1
105
8
17
003
13
4
F2
F3
F4
F5
F6
F7
F8
F9
F11 F12
004
F1
874
3
874
000
F13
200
M +++
601 2
3
4
5
6
7
8 819
55
1
1 2 823
W
X
Y
Z
3 4
822
5
821
6
Z X Y 57 A312010
9804/1103
20 - 15 - 03/2
3630 - C/26-1.5 3660 - C/21-2.1
Issue 1
20 - 15 - 03/3
Loadalls
CONTENTS
From m/c no. 767001 to 768956
601
601
532, 537 without Neutral Start Relay Circuit Diagrams - Electrical (cont’d)
70
77
G 73
67
871
9 15 16 1 13 10 7 2 5 4 3 17 18 12 6
78
79
80 81
98 87
200
68
82
76
72
873
91 84 450
69
65 63
827
62 61
601
600
601
601
74 64
85
102
89
99 90
83
93
101
97
75
71 123
108
119
88 118
66
94
92
96
86
95
104
100
F30
F28
F29
F26
F25
F22
F19
F15
F17
F21
F24
F16
F23
F14
F18
103
A312020
9804/1103
20 - 15 - 03/3
3660 3630 - C/21-3.1 - C/26-1.5
Issue 1
CONTENTS
Loadalls
532, 537 without Neutral Start Relay Circuit Diagrams - Electrical (cont’d) Component Key 2
20 - 15 - 03/4
From m/c no. 767001 to 768956
To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. The complete electrical circuit is shown on pages 20 - 15 - 03/2 and 20 - 15 - 03/3 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104
Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Steering column switch Alternator Fuel sender Water temperature sender Steering column switch Horn Reverse relay Powershift control unit Parkbrake switch Two wheel drive brake relay Foot brake switch Two wheel drive switch Brakelights Brakelights Rear light harness Reverse alarm Auxiliary power socket Rear worklight switch Rear worklight Sidelight relay Main light switch Primary fuse Right hand front sidelight Right hand rear sidelight Left hand front sidelight Left hand rear sidelight Front worklight switch Left hand worklights Right hand worklights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear foglight switch Rear foglight Steering column switch Screen wash pump Right hand front indicator Right hand rear indicator Left hand front indicator Left hand rear indicator
Note: Powershift control unit (71) only shows input connections from the mainframe harness. Refer to the ECU fault finding information in this section for control unit output connections..
9804/1103
20 - 15 - 03/4
3660 - C/21-4.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/5
532, 537 From m/c no. 768957 to 770063 with Neutral Start Relay and ECU Controlled Transmission Circuit Diagrams - Electrical Component Key 1 To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. The complete electrical circuit is shown on pages 20-15-03/6 and 20-15-03/7.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
Battery Battery isolator Starter motor Neutral start relay Ignition switch Starting aid not used Sway isolation relay Sway/Aux change-over switch Sway isolation switch Sway/Aux 1 solenoid Auxiliary A relay Auxiliary B relay Aux A/B switch Auxiliary A solenoid Auxiliary B solenoid Stabilizer isolation valve Stabilizer isolation relay Stabilizer isolation switch Stabilizer isolation proximity switch Transmission dump switch Not applicable Safe Load Indicator (SLI) SLI transducer Heater/air conditioning fan Air conditioning switch Heater/air conditioning unit Face level fan Air conditioning compressor Air conditioning relay Binary switch Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/Cassette Heated seat Digital clock Left hand stabilizer warning light Right hand stabilizer warning light Warning buzzer Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Ignition relay Engine Shut-Off Solenoid (ESOS) Two wheel steer solenoid Four wheel/crab steer solenoid Four wheel steer solenoid Crab steer solenoid
9804/1103
57
58
59 60 61
Steer Mode Control Unit (SMCU) W Four wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front steer sensor Rear steer sensor Instrument panel
20 - 15 - 03/5
3660 - C/22-1.1
Issue 1
20 - 15 - 03/6
Loadalls
CONTENTS
600
601
601
601
600
600
600
601
601
601
From m/c no. 768957 to 770063
601
601
411
856
856
M 883
601
601
61
54
42
13
200
36
44 50
41 1 2 3
911
854
901
912
882
926
M
9
51 410
884
901
26
4
826
47
100
19
52
38
59
109
925
35
824
M
33
105
M
12 004
60
56
801
908
10
601
600 848
800
5
826
45
841
31
601
27 20
825
55
601
17
601
840
39
37
856
7
43
601
16
15
601
11
601
53
6
820
601
601
600
600
601
601
600
601
601
600
532, 537 with Neutral Start Relay and ECU Controlled Transmission Circuit Diagrams - Electrical (cont’d)
46
21
18
102
14
106
M
25
28
120
(SLC)
2
22
(SLC)
(SLC)
907
8
32
3 M
874
000
000
200
200
001
001
F12
F11
F9
F8
301
F7
F6
F5
115
F4
F3
F2
874
F13
842
F1
1
101
810
414 +++
23
24 413
49
40 30
29
34
48
601
57
1
2
3
4
5
6
7
819
886
8
1 2 823
W
X
Y
Z
3 4
822
5
821
6
Z X Y 58 A313830
9804/1103
20 - 15 - 03/6
3660 - C/22-2.1
Issue 1
20 - 15 - 03/7
Loadalls
CONTENTS
532, 537 with Neutral Start Relay and ECU Controlled Transmission Circuit Diagrams - Electrical (cont’d)
From m/c no. 768957 to 770063
65
832
806
600 601
805 600
600 809 405
304
841
71
67
833
72
79
G 75
871
70
N F
R
80
9 15 16 1 13 10 7 2 5 4 3 17 18 12 6
69
86
84
78
74
873
100
81
82
89
83
96
94
87
200
808
840
93 450
63
76
827
64
600
66
601
600
601 601
601
601
803
104
91 95
92
85
103
101 99
77
73 123
108
68
119
118
90
98
88
97
106
102 110
105
839
803
832
836
304
401 806 805 838 301 840 841
F30 F29
F28
F26
F25
F24
F23
F22
F21 827
F19
F17
F15
F14
F16
810
F18
110 829
A313840
9804/1103
20 - 15 - 03/7
3660 - C/22-3.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/8
532, 537 From m/c no. 768957 to 770063 with Neutral Start Relay and ECU Controlled Transmission Circuit Diagrams - Electrical (cont’d) Component Key 2 To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. The complete electrical circuit is shown on pages 20-15-03/6 and 20-15-03/7. 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106
Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Water temperature switch Alternator Fuel sender Water temperature sender Steering column switch Horn Reverse relay Powershift control unit Parkbrake switch Two wheel drive brake relay Footbrake switch Two wheel drive switch Brakelights Brakelights Reverse lights Reverse alarm Auxiliary power socket Rear worklight switch Rear worklight Sidelight relay Main light switch Fusible link 1 Right hand front sidelight Right hand rear sidelight Left hand front sidelight Left hand rear sidelight Front worklight switch Left hand worklights Right hand worklights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear foglight switch Rear foglight Steering column switch Front wash/wipe motor Right hand front indicator Right hand rear indicator Left hand front indicator Left hand rear indicator
Note: Powershift control unit (73) only shows input connections from the mainframe harness. Refer to the ECU fault finding information in this section for control unit output connections.
9804/1103
20 - 15 - 03/8
3660 - C/22-4.1
Issue 1
CONTENTS
Loadalls
532, 537 with Relay Controlled Transmission, ECU not fitted Circuit Diagrams - Electrical Component Key 1
20 - 15 - 03/9
From m/c no. 770064 to 770958
The complete electrical circuit is shown on pages 20-15-03/10 and 20-15-03/11. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
Battery Battery isolator Starter motor Neutral start relay Ignition switch Starting aid not used Sway isolation relay Sway/auxiliary change over Sway isolation proximity switch Auxiliary A relay Auxiliary A solenoid Auxiliary B relay Auxiliary B solenoid Auxiliary A/B switch Auxiliary change over relay 2 Sway/auxiliary solenoid Stabilizer isolation relay Stabilizer isolation valve Stabilizer isolation switch Stabilizer isolation proximity switch Not applicable Safe load indicator (SLI) SLI transducer Heater/air conditioning fan motor Air conditioning switch Heater/air conditioning unit Face level fan Air conditioning compressor Air conditioning relay Binary switch - air conditioning Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper motor Front wiper motor Radio/cassette Heated seat Digital clock Left hand stabilizer warning light Right hand stabilizer warning light Warning buzzer Hazard warning light Indicator relay Hazard diode Interior light Beacon switch Beacon Primary fuse Ignition relay Engine shut-off system (ESOS) Two-wheel steer solenoid Four-wheel/crab steer solenoid Four-wheel steer solenoid Crab steer solenoid
9804/1103
57
58
59 60 61
Steer mode control unit (SMCU) W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front steer sensor Rear steer sensor Instrument panel
Steer Sensor Wiring: Terminal 1 2 3
20 - 15 - 03/9
Wire Code 820 or 819 600 or 601 810 or 109
Wire Colour Black Blue Brown
3660 - C/23-1.1
Description Signal Earth Feed
Issue 1
20 - 15 - 03/10
Loadalls
CONTENTS
600
411
M
601
601
848
50
41
909
820
46
18
28
102
(SLC)
301 840
884
(SLC)
15
M
25
22
106
32
907
8 2
109
854
911
44
1 2 3
901
912
926
M
51 105
901
36
200
42
13
824
47
26
9
826
52
38
410
004
20
59
100
35
925
11
M
33
410
M
4
61
54
801
908
10
60
56
800
5
601
45
841
883
601
31
601
27 21
825
55 600
39
37 19
601
840
7
43
601
53
14
12
601
600
601
601
601
600
600
600
601
601
601
601
601
600
600
601
601
600
601
601
17
From m/c no. 770064 to 770958
601
6
600
601
601
601
532, 537 with Relay Controlled Transmission, ECU not fitted Circuit Diagrams - Electrical (cont’d)
841 110 829
120
829
810
F12
F11
F9
F8
F7
F6
F5
115
F4
F3
F2
842
F1
874
874 000
3
F13
1
101
810
200
M
001 +++ 414
24 413
16
49
40 30
29
34
601
301
23
+++
48
57
1
2
3
4
5
6
7
819
886
8
1 2 823
W
X
Y
Z
3 4
822
5
821
6
Z X Y 58
A313850
9804/1103
20 - 15 - 03/10
3660 - C/23-2.1
Issue 1
20 - 15 - 03/11
Loadalls
CONTENTS
532, 537 with Relay Controlled Transmission, ECU not fitted Circuit Diagrams - Electrical (cont’d)
601
600
600 601
600
601
601 600
601
601
601
601
601
809
601
601
From m/c no. 770064 to 770958
807
81
77
82
80
118
90
859
600
811
76
72
117
93
106
101
95
84
113
111
600
808
601
65
96
109 103 450
68
94
85
808
63 64
863
66
827
69
116 115
105
114
121
99
601
120
815
122
107
102
123
112
600 601
110
600
100
601
200 601
890
79
108
104 92 119
872
89
88 86
75
71
600
861
74
G
83
87
857
67
78
852
874
812
871
304 124 108
118
100 401 806 805 838 301 840 841
F30 F29
F26
F25
F24
F23
F22
F21 F19
F17
F15
815
F18
601
98
F16
F35
F34
F33
97 807
119
3 SPEED ONLY
73
F32
F31
91
F28
110 829
839
118 832
107
F14
70
A313860
9804/1103
20 - 15 - 03/11
3660 - C/23-3.1
Issue 1
CONTENTS
Loadalls
532, 537 with Relay Controlled Transmission, ECU not fitted Circuit Diagrams - Electrical (cont’d) Component Key 2
20 - 15 - 03/12
From m/c no. 770064 to 770958
The complete electrical circuit is shown on pages 20-15-03/10 and 20-15-03/11. 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120
Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Water temperature switch Alternator Fuel sender Water temperature sender Steering column switch Horn Reverse 2 relay Ignition relay 2 Transmission dump switch Transmission dump relay Reverse 1 relay Forward relay Drive relay Parkbrake relay Rev HI/LO relay Reverse high/low solenoid Reverse low solenoid Forward HI/LO relay Forward high solenoid Forward low solenoid Driveshaft relay Layshaft solenoid Mainshaft solenoid Two/four wheel drive solenoid Transmission oil temperature switch Parkbrake switch Two-wheel drive switch Two-wheel drive brake relay Footbrake switch Brake lights Brake lights Reverse lights Reverse alarm Auxiliary power socket Rear work light switch Rear work light Side light relay Main light switch Primary fuse Right hand front sidelight Right hand rear sidelight Left hand front sidelight Left hand rear sidelight Left hand worklight Front worklight switch Right hand worklights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear foglight switch Rear foglight Steering column switch Front wash/wipe motor Right hand front indicator
9804/1103
121 Right hand rear indicator 122 Left hand front indicator 123 Left hand rear indicator
20 - 15 - 03/12
3660 - C/23-4.1
Issue 1
CONTENTS
Loadalls
532, 535, 537 Circuit Diagrams - Electrical Component Key 1
20 - 15 - 03/13
From m/c no. 770959
The complete electrical circuit is shown on pages 20-15-03/14 and 20-15-03/15. 1 2 3 4 5 6 7 8 9 10 11
Battery Battery isolator Starter motor Ignition switch Starting aid Neutral start relay not used Sway isolation relay Sway/auxiliary change over switch Sway/auxiliary change-over valve Sway isolation proximity switch (Not N. American 532 or 550) 11A Link Harness (N. American 532 and 550 only) 12 Sway/auxiliary solenoid 13 Auxiliary A solenoid 14 Joystick isolation switch 15A Auxiliary A button 15B Auxiliary B button 16 Auxiliary B solenoid 17 Stabilizer isolation relay 18 Stabilizer isolation valve 19 Stabilizer isolation switch 20 Stabilizer isolation proximity switch 21 Safe load indicator (SLI) 22 SLI transducer 23 Heater/air conditioning fan motor 24 Heater/air conditioning unit 25 Air conditioning switch 26 Face level fan 27 Air conditioning compressor 28 Air conditioning relay 29 Binary switch - air conditioning 30 Rear wiper switch 31 Rear wiper motor 32 Roof wiper switch 33 Roof wash pump 34 Roof wiper motor 35 Front wiper motor 36 Heated seat 37 Radio/cassette 38 Digital clock 39 Left hand stabilizer warning light 40 Right hand stabilizer warning light 41 Warning buzzer 42 Hazard warning light 43 Indicator relay 44 Hazard diode 45 Interior light 46 Beacon switch 47 Beacon 48 Primary fuse 1 49 Fusible link 50 Ignition relay 51 Engine shut-off system (ESOS) 52 Two-wheel steer solenoid 53 Four-wheel/crab steer solenoid 54 Four-wheel steer solenoid 55 Crab steer solenoid
9804/1103
56
57
58 59 60
Steer mode control unit (SMCU) W All wheel steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front steer sensor Rear steer sensor Instrument panel
20 - 15 - 03/13
3660 - C/24-1.1
Issue 1
20 - 15 - 03/14
Loadalls
CONTENTS
From m/c no. 770959
52
18
49
26 M 31
M
33 935
51 38
27
42
601
60
53
45
M
601
600
41
59
55 848
M
601
35
826
25
47
601
34
13
43
M
29 4
200
22
825
54
36
16
46
824
12
10
58
820
600
24
800
50
882
9
39
15B
100
926
15A
37
105
20 109
5
600
600
532, 535, 537 Circuit Diagrams - Electrical (cont’d)
1 2 3
6
30 21
11
14
451
842
8
907
7
2
28
23
32
40
48
RT
44
17
1
120
11A
F12
F11
F9
F8
F7
F6
F5
F4
F3
F2
F1
810
F13
000
3
200
200
19 601
56
2
3
4
5
6
7
8 819
+++
1
1 2 823
W
X
Y
Z
3 4
822
5
821
6
Z X Y 57 A311990
9804/1103
20 - 15 - 03/14
3660 - C/24-2.1
Issue 1
20 - 15 - 03/15
Loadalls
CONTENTS
532, 535, 537 Circuit Diagram - Electrical (cont’d)
601
600
600 601
600
106
100
890
110
112
116 115
98 105
114
601
815
102
304
120
78
101
107 91 119
F30 F29
F26
F25
F24
F23
F22
F19
F17
F21
F18
601
F16
97
F15
815
F35
F34
F33
96
119
3 SPEED ONLY
72
F32
F31
90
F28
124
118
839
872
70
99
87 85
74
88
122
861
73
857
66
G
601
600
812
852
82
108
86
123
600
104
871
113
111
600 601
94
600
92
83
77
117 450
81
79
89
859
600
95
109 103
601
827
76
811
75
71
808
601
64
863
808
67
93
84
121
80
68 65
62 63
601
601 600
601
601
601
601
601
From m/c no. 770959
107
F14
69
A312000
9804/1103
20 - 15 - 03/15
3660 - C/24-3.1
Issue 1
CONTENTS
Loadalls
532, 535, 537 Circuit Diagrams - Electrical (cont’d) Component Key 2
20 - 15 - 03/16
From m/c no. 770959
Tthe complete electrical circuit diagram is shown on pages 20-15-03/14 and 20-15-03/15. 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121
Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Water temperature switch Alternator Fuel sender Water temperature sender Steering column switch Horn Reverse 2 relay Ignition relay 2 Transmission dump switch Transmission dump relay Reverse 1 relay Forward relay Drive relay Parkbrake relay Rev HI/LO relay Reverse high/low solenoid Reverse low solenoid Forward HI/LO relay Forward high solenoid Forward low solenoid Driveshaft relay Layshaft solenod Mainshaft solenoid Two/Four wheel drive solenoid Transmission oil temperature switch Parkbrake switch Two-wheel drive switch Two-wheel drive brake relay Footbrake Brake lights Brake lights Reverse lights Reverse alarm Auxiliary power socket Rear work light switch Rear work light Side light relay Fusible link 3 Main light switch Fusible link 2 Right hand front sidelight Righ hand rear sidelight Left hand front sidelight Left hand rear sidelight Left hand worklight Front worklight switch Right hand worklights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear foglight switch Rear foglight Steering column switch Front wash/wipe motor Right hand front indicator Right hand rear indicator
9804/1103
122 Left hand front indicator 123 Left hand rear indicator
20 - 15 - 03/16
3660 - C/24-4.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/17
532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402 5508 with Servo Controls to m/c no. 1004130 Circuit Diagrams - Electrical Component Key 1
* 540-170,
The complete electrical circuit is shown on pages 20 - 15 - 03/18, 20-15-03/19, 20 - 15 - 03/22 and 20 - 15 - 03/23. Key 1 2 3 4 5 5A 6 7 8 9 10 11 11A 12 12A 12B 13 13A 14 15 16 17 17A 18 19 19A 20 21 22 22A 23 24 25 26 27 28 29 30 31 32 33 34 35
Battery Battery isolator Starter motor Starter solenoid Ignition switch Fuse link 2 Starting aid Neutral start relay Ignition feed relay 1 Ignition feed relay 2 E.S.O.S. Rear work lamp switch Rear work lamp Front work lamp switch Front work lamps Auxiliary power connector 2/4WD brake relay Brake lamps Brake switch 2/4WD switch 2/4WD solenoid Reverse relay Reverse lamp Reverse alarm Park brake relay Park brake switch Heated seat Radio/cassette Digital clock Fuse link 1 Transducer - load moment indicator (LMI) Instrument panel Warning buzzer Alternator Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge Water temperature gauge LH stabiliser lamp switch RH stabiliser lamp switch
Note 1: All the items listed here are not necessarily fitted to all machines in the range. Note 2: 540-17- machines only. See page 20 - 15 - 03/23 for additional circuits. Note 3: Fuses 31 and 32 for 540-170 machines are shown on page 20 - 15 - 03/23.
9804/1103
20 - 15 - 03/17
3630 - C/25-1.4
Issue 3*
CONTENTS
Loadalls
20 - 15 - 03/18
2
6
11A
17A 12A
12B
13A
18
23
34
19A
32
33
35
27 28 29 30 31
10
1828
532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402 540-170, 5508 with Servo Controls to m/c no. 1004130 Circuit Diagrams - Electrical (cont’d)
16
20
See Sheet 4
35
21
3 34 7
8
9
11
12 13
22
15 19
26
410
17
4
410
1
24 25 14 See Note 2 540-170 (5508 N.Am) Only
5A
22A
5
160-02290-1
9804/1103
20 - 15 - 03/18
3660 - C/25-2.2
Issue 3*
CONTENTS
Loadalls
20 - 15 - 03/19
* 532, *
46
43
45
41
40
38
37
537, 550 with Manual Auxiliary Controls from m/c no. 775402 540-170, 5508 with Servo Controls to m/c no. 1004130 Circuit Diagrams - Electrical (cont’d)
47
48
49 50
51
55
59 61
66 58
56
36
44
39 42
63
54
57
62
60
64
52 53
65
36A
160-02290-2
9804/1103
20 - 15 - 03/19
3630- C/25-3.1 - C/26-1.5 3660
Issue 3*
CONTENTS
Loadalls
20 - 15 - 03/20
532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402 5508 with Servo Controls to m/c no. 1004130 Circuit Diagrams - Electrical (cont’d) Component Key 2
* 540-170,
The complete electrical circuit is shown on pages 20-15-03/18, 20-15-03/19, 20-15-03/22 and 20-15-03/23. 36 36A 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66
Sidelight relay Fuse link 1 RH side lights LH side lights Main light switch RH/LH dip beam RH/LH main beam Rear fog light switch Rear fog lamp (optional) Column switch - RH LH indicator lamps RH indicator lamps Front washer pump Front wiper motor Rear wiper motor Rear/roof washer pump Roof wiper motor Rear wiper switch Roof wiper switch Hazard warning switch Hazard warning relay Interior light/switch Beacon switch Beacon lamp Face level fan Air conditioning relay Air conditioning - compressor motor Air conditioning - freeze switch Air conditioning - receiver drier Air conditioning switch Heater/heater fan switch Heater
Note: All the items listed here are not necessarily fitted to all machines in the range.
9804/1103
20 - 15 - 03/20
3660 - C/25-4.4
Issue 3*
CONTENTS
Loadalls
20 - 15 - 03/21
532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402 540-170, 5508 with Servo Controls to m/c no. 1004130 Circuit Diagrams - Electrical (cont’d) Component Key 3 The complete electrical circuit is shown on pages 20-15-03/18, 20-15-03/19, 20-15-03/22 and 20-15-03/23. 67 68 69 70 71 71A 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93
Column switch - LH Horn Reverse Hi-Lo relay Reverse Lo solenoid Reverse Hi solenoid Diode pack (see Note below) Reverse relay Forward relay Forward Hi/Lo relay Forward Hi solenoid Forward Lo solenoid Drive interlock relay Drive shaft relay Layshaft solenoid Mainshaft solenoid Transmission dump relay Stabiliser isolation switch Stabiliser isolation relay Stabiliser isolation solenoid Stabiliser isolation switch Sway isolation switch Sway isolation relay Sway switch Sway diverter solenoid Sway solenoid Sway solenoid Transmission dump push button Steer mode control unit A Four wheel/crab steer relay B Two wheel steer relay C Crab steer relay D Four wheel steer relay 94 Steer mode selector switch X Two wheel steer Y Crab steer Z Four wheel steer 95 2WS solenoid 96 4WS solenoid 97 AWS solenoid 98 Crab steer solenoid 99 Proximity switch - front axle 100 Proximity switch - rear axle
Note: All the items listed here are not necessarily fitted to all machines in the range. Note: Diode indicated (†) not fitted to 3-speed machines.
9804/1103
20 - 15 - 03/21
3660 - C/25-5.4
Issue 3*
CONTENTS
Loadalls
20 - 15 - 03/22
532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402 5508 with Servo Controls to m/c no. 1004130 Circuit Diagrams - Electrical (cont’d)
* 540-170,
95 79 68
70
75
71
80
90
76
84
91
96
89
97 98
71A
67
88 A
94 69
72
73
74 77
78
81
82
83 85
86
87
92
B
Z X Y
99
C
100 D
93
160-02290-3
9804/1103
20 - 15 - 03/22
3660 3630 - C/25-6.2 - C/26-1.5
Issue 3*
Issue 1 170B
171
102 170J
103 1822A
1824
1821
1833
119
108 116
1830A
1830
1829
601FY
1825
601JB
601HZ
114 115
1822
601GA
601FW
1820
1825A
1820
601HS
601HR
1830B
1829A
110 1829B
170H
170C
1833
101
170D
170E
1825B 170L
1825C
1833A
601FL
601GM
107
112 117
113 1830C
1828
111
20 - 15 - 03/23
To m/c no. 1004130
000 170
104 109
F32
From Sheet 1 106
Loadalls
3660 - C/25-7.2 170F
105 BOOM WORKLIGHT
DUMP LOCK SOL. 601HV
601GB
CROWD LOCK SOL.
FULL LOCK SOL.
STAB. LIFT ISOL. SW.
STAB LIFT UNLOADER SOL
STABILISER LIFT RELAY
LIFT ISOL. SW.
LIFT UNLOADER SOL
LIFT ISOL. RELAY
EXT. DIVERTER SOL.
601HX
601HW
601FZ
601TH
601FN
EXT INTERLOCK
EXT. RELAY
EXT ISOL. SW.
540-170, 5508 with Servo Controls Circuit Diagrams - Electrical (cont’d)
20 - 15 - 03/23 1823
9804/1103
F31
CONTENTS
118
CONTENTS
Loadalls
20 - 15 - 03/24
540-170, 5508 with Servo Controls
To m/c no. 1004130
Circuit Diagrams - Electrical (cont’d) Component Key 4 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119
Extend isolation switch Extension relay Inner boom extension switch Extension interlock Extension diverter valve solenoid Lift/unloader solenoid Lift solenoid relay Lift solenoid switch Stabiliser lift unloader solenoid Stabiliser lift relay Stabiliser lift isolation solenoid Full lock solenoid Diode Lock solenoid - tilt back Lock solenoid - tilt forward Joystick isolation switch Boom worklight Boom worklight switch Diode
9804/1103
20 - 15 - 03/24
3660 - C/25-8.3
Issue 2*
CONTENTS
Loadalls
20 - 15 - 03/25
* 540-170,
5508 with Servo Controls from m/c no. 1004130 Circuit Diagrams - Electrical Component Key 1 1 2 3 4 5 5A 6 7 8 9 10 11 11A 12 12A 12B 13 13A 14 15 16 17 17A 18 19 19A 20 21 22 22A 23 24 25 26 27 28 29 30 31 32 33 34 35
Battery Battery isolator Starter motor Starter solenoid Ignition switch Fuse link 2 Starting aid Neutral start relay Ignition feed relay 1 Ignition feed relay 2 E.S.O.S. Rear work lamp switch Rear work lamp Front work lamp switch Front work lamps Auxiliary power connector 2/4WD brake relay Brake lamps Brake switch 2/4WD switch 2/4WD solenoid Reverse relay Reverse lamp Reverse alarm Park brake relay Park brake switch Heated seat Radio/cassette Digital clock Fuse link 1 Transducer - load moment indicator (LMI) Instrument panel Warning buzzer Alternator Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge Water temperature gauge LH stabiliser lamp switch RH stabiliser lamp switch
9804/1103
20 - 15 - 03/25
3630 - C/26-1.4
Issue 1*
CONTENTS
Loadalls
20 - 15 - 03/26
* 540-170,
5508 with Servo Controls from m/c no. 1004131 Circuit Diagrams - Electrical Component Key 1 36 36A 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66
Sidelight relay Fuse link 1 RH side lights LH side lights Main light switch RH/LH dip beam RH/LH main beam Rear fog light switch Rear fog lamp (optional) Column switch - RH LH indicator lamps RH indicator lamps Fornt washer pump Front wiper motor Rear wiper motor Rear/roof washer pump Roof wiper motor Rear wiper switch Roof wiper switch Hazard warning switch Hazard warning relay Interior light/switch Beacon switch Beacon lamp Face level fan Air conditioning relay Air conditioning - compressor motor Air conditioning - freeze switch Air conditioning - receiver drier Air conditioning switch Heater/heater fan switch Heater
9804/1103
20 - 15 - 03/26
3630 - C/2641.4
Issue 1*
CONTENTS
Loadalls
20 - 15 - 03/27
* 540-170,
5508 with Servo Controls from m/c no. 1004131 Circuit Diagrams - Electrical Component Key 3 67 68 69 70 71 71A 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93
Column switch - LH Horn Reverse Hi-Lo relay Reverse Lo solenoid Reverse Hi solenoid Diode pack Reverse relay Forward relay Forward Hi-Lo relay Forward Hi solenoid Forward Lo solenoid Drive interlock relay Drive shaft relay Layshaft solenoid Mainshaft solenoid Transmission dump relay Stabiliser isolation switch Stabiliser isolation relay Stabiliser isolation solenoid Stabiliser isolation switch Sway isolation switch Sway isolation relay Sway switch Sway diverter solenoid Sway solenoid Sway solenoid Transmission dump push button Steer mode control unit A Four wheel/crab steer relay B Two wheel steer relay C Crab steer relay D Four wheel steer relay 94 Steer mode selector switch X Two wheel steer Y Crab steer Z Four wheel steer 95 2WS solenoid 96 4WS solenoid 97 AWS solenoid 98 Crab steer solenoid 99 Proximity switch - front axle 100 Proximity switch - rear axle
9804/1103
20 - 15 - 03/27
3630 - C/26-5.4
Issue 1*
CONTENTS
Loadalls
20 - 15 - 03/28
* 540-170,
5508 with Servo Controls from m/c no. 1004131 Circuit Diagrams - Electrical Component Key 4 101 102 103 104 105 106 111 112 113 114 115 116 117 118 119 120 121
Right hand stabiliser relay Right hand stabiliser LED Left hand stabiliser relay Left hand stabiliser LED Inner boom extension switch Inner boom extension relay Lift/unloader solenoid Lift isolation switch Lift isolation relay Stabiliser left unloader solenoid Stabiliser lift relay Stabiliser lift isolation switch Fork lock solenoid Fork lock solenoid Joystick isolation switch Boom worklight Boom worklight switch
9804/1103
20 - 15 - 03/28
3630 - C/26-8.4
Issue 1*
CONTENTS
Loadalls
20 - 15 - 03/29
* 540-170,
481
410
409
408
407
406
405
404
403
402
401
825
838
826
824
8 04 101
24
106
26
106
23
301
112
856
401
808
124
816
118
119
906
829
123
105
000
100
000
601
600
30 31 601
601
601
601
601
601
19 22B
810
35
829
17
003
414
413
8 15
807
818
1 2 3 4
34
22
15
13
411
12
21
106
11
816
831
20
806
9
16
805
8
+
13A
12B
33
32
18
450
7
904
200
200
004
3 M
842
601
600
601
601
601
601
601
601
600
601
601
601
23A
19A
22A
6
12A
1
601
601
17A
866
2
11A
412
10
601
6 01
601
601
601
601
601
27 28 29
5508 Machines from m/c no. 1004131 Circuit Diagrams - Electrical (cont’d)
25
106
8
22A
3
33 34 35
200
28 30
29
7
19
17 15
16
25
18
12
11
200
108
003
14
5A 001
+++ 000 000 001 100 300 301 304 804 805 806 808 810 824 825 826 827 829 838
160-13328
856
9804/1103
20 - 15 - 03/29
3660 - C/26-2.4
Issue 1*
CONTENTS
Loadalls
20 - 15 - 03/30
* 540-170,
46
43
45
41
40
38
37
5508 Machines from m/c no. 1004131 Circuit Diagrams - Electrical (cont’d)
47
48
49 50
51
55
59
61
63 66
58
56
36
44
39 42
54
57
62
60
64
52 53
65
36A
160-13328-2
9804/1103
20 - 15 - 03/30
3660 - C/26-3.4
Issue 1*
CONTENTS
Loadalls
20 - 15 - 03/31
* 540-170,
5508 Machines from m/c no. 1004131 Circuit Diagrams - Electrical (cont’d)
95 79 68
70
75
71
80
90
76
84
91
96
89
97 98
71A
67
88 A
69
72
73
74 77
78
81
82
83 85
86
87
92
B
94 Z X Y
99
C
100 D 93
160-13328-3
9804/1103
20 - 15 - 03/31
3660 - C/26-6.4
Issue 1*
CONTENTS
Loadalls
20 - 15 - 03/32
* 540-170,
601GB
601HV
601HW
120
1820
1830A
601FY
601FW
115
1830C
1830B
1829A
601HR
1825A 1825B
1842
112
1829B
119*
1834A
103
1822
601GA 1824
1821
1833A
1833
315 0 45
105
1834
1834B
116
106
121
170D
170E
170J
1823
101
170H
170C
170L
1828
106
1822A
170K
1850
113
102
118
117
601FL
601GM
601HS
1833
109
1825
601JB
104
114
111
1829
110
108
601FZ
601HT
601JS
601JA
601FN
601JY
601JX
601JY
601JW
5508 Machines from m/c no. 1004131 Circuit Diagrams - Electrical (cont’d)
171
107
170
F36
F31
481
170F
170B
410
000 828 160-13328-4
9804/1103
20 - 15 - 03/32
3660 - C/26-7.4
Issue 1*
20 - 15 - 04/1
Loadalls
CONTENTS
506B Syncroshuttle Circuit Diagrams - Electrical (cont’d)
To m/c no. 578676
48
48 600
17
5
27
G/Y
47
26
11 N
46
37
24 202
204
44
208
205
51
811
812
50
815
841
839
413 414B 413B
34
203
814
402
21 42
801 416
400
206
600
60
52
403
414 413A
59
54
414A
2
53
45
U 415
49
405
408
55
404
409
406 412
407
43
56
N G/Y U 805
10
806
807
210
32
212
214
57
804
36
842
40
41
209
211
213
58
215
803 808A
23
20 16
31
803A
802
3
103A
9
401
30 810
19
25
207 808
1
-
800
101
+
003
39 411
6
105
106A
100
300
15
809
200
61
104
103
800 106
100 200
842
A2
A1
A4
A5
A6
A7
A8
A9
B1
B2
004
200 103
4
000
000
000R
000R
200
200
004 842
9804/1103
20 - 15 - 04/1
3640U - C/10-1.2
Issue 1
Loadalls
CONTENTS
20 - 15 - 04/2
506B Syncroshuttle Circuit Diagrams - Electrical (cont’d) Component Key
To m/c no. 578676
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on pages 20-15-04/1 and 20-15-04/3. 1 2 3 4 5 6 9 10 11 15 16 17 19 20 21 23 24 25 26 27 30 31 32 34 36 37 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53
Battery Starter Motor Starter Solenoid Starter Switch Thermostart Starter Relay Safe Load Indicator Readout Box Rear SLI Boss Front SLI Boss Heater Switch Heater Resistor Heater Motor Seat Relay Swedish Parking Brake Switch machines Seat Switch only Horn Push Horn Wash/Wipe Switch Front Wiper Motor Washer Pump Hazard Switch Indicator Relay Indicator Switch Fuel Shut-off Solenoid Reverse Alarm Relay Reverse Alarm Forward/Reverse Selector Switch Neutral Start Relay Parking Brake Warning Relay Reverse Relay Forward Relay Reverse Solenoid Forward Solenoid Transmission Dump Switch Parking Brake Switch Trailer Socket Air Filter Switch Engine Oil Pressure Switch Transmission Oil Temperature Switch Transmission Oil Pressure Switch Water Temperature Switch
54 55 56 57 58 59 60 61 62 63 65 66 67 68 69 71 71B 72 73 75 76 77 78 78A 78B 78C 78D 78E 78F 79 80 81 82 83 86 87 88 93 99 100
Hourmeter Alternator Tachometer Fuel Gauge Water Temperature Gauge Fuel Gauge Sender Water Temperature Gauge Sender Warning Buzzer L. H. Stabiliser Switch R. H. Stabiliser Switch Interior Light Switch Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch Beacon Brake Switch Brake Switch Relay 2/4 Wheel Drive Switch (not fitted on permanent 4 wheel drive) 2 Wheel Drive Solenoid Front Axle Proximity Switch Rear Axle Proximity Switch Steering Mode Selector Switch Steer Mode Printed Circuit Board Relay 2 Relay 1 Relay 1 (latch) Relay 2 (unlatch) Relay 1 (unlatch) Relay 2 (latch) 4 Wheel/Crab Steer Solenoid 4 Wheel Steer Solenoid Crab Steer Solenoid 2 Wheel Steer Solenoid Side Lights Relay Working Light Switch Road Light Switch Headlamp Dip Switch Headlamp Flasher Radio (Optional) Transmission Dump Relay
Lamps 202 Trailer Indicator Warning 203 Hazard Warning 204 L.H. Indicators 205 R.H. Indicators 206 Indicator Warning 207 Hazard Indicator Warning 208 Reversing Lights 209 Parking Brake Warning 210 Air Filter Blocked Warning 211 Engine Oil Pressure Warning 212 Transmission Oil Temperature Warning 213 Transmission Oil Pressure Warning 214 Water Temperature Warning 215 Alternator Warning 216 Stabiliser Indicators 217 Interior Light 218 Beacon Warning 219 2 Wheel Drive Warning 220 L.H. Brake Lights 221 R.H. Brake Lights 222 4 Wheel Steer Warning 223 Crab Steer Warning 224 2 Wheel Steer Warning 225 Instrument Panel Illumination 226 L.H. Side Light 227 R.H. Side Light 229 Number Plate Light 230 Working Light Warning 231 Cab Working Light 232 Headlamp Dip Beam 233 Headlamp Main Beam 234 Headlamp Main Beam Warning 235 Inclinometer Illumination Fuses Fuses are numbered as shown on the fuse box in the cab. Cable Colour Code G N U Y
Green Brown Blue Yellow
Note: For machines without road lights a link is fitted (as shown) in place of Working Light Switch 86 and switch 87 operates the Working Lights. On North American machines the Safe Load Indicator System is not normally fitted, items 9, 10 and 11.
9804/1103
20 - 15 - 04/2
3640U - C/10-2.2
Issue 1
Loadalls
CONTENTS
20 - 15 - 04/3
506B Syncroshuttle Circuit Diagrams - Electrical (cont’d)
To m/c no. 578676
48
48
48
600
66
69
216
220
219
229
78 73
217 67
225
221
226
227
231
232
233
78B 78C 78D
65 218
235
234
78E
230
78F
835
818 834
829P
63
838 837
78A 301 831
99
847
B9 C1 72
816
62
821
823 822
829 830
848 826
824
86
825
B8
C2
844 817
77
68
B6
B7 112
828 410
71B 76
79
820
222
223
224
833
83
836
88 75
855
106D
819
80
71 108
B3
93
827
B4
81
82
832 110
109
87 B5
C4
103 000 000R 200
9804/1103
20 - 15 - 04/3
3630 -- C/10-3.1 C/26-1.5 3640U
Issue 1
20 - 15 - 04/4
Loadalls
CONTENTS
506B Syncroshuttle Circuit Diagrams - Electrical
From m/c no. 578677
14
19
16
25
28
29
32
6 10 2
12
5
9
11
3 26 15 31
7 30 20
1
27
18 13 17 21 22
23
24
8
A1
A2
A3
A4
A5
A6
4
A269320
9804/1103
20 - 15 - 04/4
3640U3630C/10-4.2 - C/26-1.5
Issue 1
CONTENTS
Loadalls
506B Syncroshuttle Circuit Diagrams - Electrical (cont’d) Component Key
20 - 15 - 04/5
From m/c no. 578677
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on pages 20-15-04/4 and 20-15-04/6. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 19A 19B 19C 19D 19E 19F 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Battery Starter Motor Starter Solenoid Starter Switch Thermostart Fuel Shut-off Solenoid Neutral Start Relay Forward/Reverse Selector Switch Reverse Relay Reverse Solenoid Forward Relay Forward Solenoid Transmission Dump Relay Transmission Dump Switch Parking Brake Warning Relay Parking Brake Switch Rear Axle Proximity Switch Front Axle Proximity Switch Steer Mode Printed Circuit Board Relay 2 Relay 1 Relay 1 (latch) Relay 2 (unlatch) Relay 1 (unlatch) Relay 2 (latch) Steering Mode Selector Switch 4 Wheel/Crab Steer Solenoid 4 Wheel Steer Solenoid Crab Steer Solenoid 2 Wheel Steer Solenoid Heater Motor Heater Resistor Heater Switch Horn Front Wiper Motor Horn Push Wash/Wipe Switch Washer Pump Air Filter Switch Engine Oil Pressure Switch Transmission Oil Temperature Switch Transmission Oil Pressure Switch Water Temperature Switch Warning Buzzer Hourmeter Alternator Tachometer Fuel Gauge Fuel Gauge Sender Water Temperature Gauge Water Temperature Gauge Sender Reverse Alarm Working Light Switch Interior Light Switch
9804/1103
49 50 51 52
Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Beacon Switch
Lamps 80 Parking Brake Warning 81 4 Wheel Steer Warning 82 Crab Steer Warning 83 2 Wheel Steer Warning 84 Air Filter Blocked Warning 85 Engine Oil Pressure Warning 86 Transmission Oil Temperature Warning 87 Transmission Oil Pressure Warning 88 Water Temperature Warning 89 Alternator Warning 90 Instrument Panel Illumination 91 Cab Working Light 92 Working Light Warning 93 Interior Light 94 Beacon Warning 95 Beacon Fuses Fuses are numbered as shown on the fuse box in the cab.
20 - 15 - 04/5
3640U - C/10-5.2
Issue 1
Loadalls
CONTENTS
20 - 15 - 04/6
506B Syncroshuttle Circuit Diagrams - Electrical (cont’d)
From m/c no. 578677
33
35
43
37
45
46
93 95
34
91
36
48 39
81 82 83 84
85 86 87 88 89
49
50
40
42 80
51
44
41
52
94
90
47
92
38
A7
9804/1103
A8
B1
A9
20 - 15 - 04/6
3640U - C/10-6.1
Issue 1
Loadalls
CONTENTS
20 - 15 - 04/7
506C, 508C Syncroshuttle Circuit Diagrams - Electrical
To m/c no. 585396
14
6
17
5 10
2
28
26
16 20
21
24
30 36
32
25
27
12
38
39 88
29
90 89
33
35 80
18
3 9
11
82 81
86
84 83
42
43
41 37
34
85
15
7
44
22 23 1
87
19
13
40
31
8 45 4
9804/1103
20 - 15 - 04/7
3640U - C/10-7.2
Issue 1
CONTENTS
Loadalls
506C, 508C Syncroshuttle Circuit Diagrams - Electrical (cont’d) Component Key
20 - 15 - 04/8
To m/c no. 585396
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on page 20-15-04/7. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
Battery Starter Motor Starter Solenoid Starter Switch Thermostart Fuel Shut-off Solenoid Neutral Start Relay Forward/Reverse Selector Switch Reverse Relay Reverse Solenoid Forward Relay Forward Solenoid Transmission Dump Relay Transmission Dump Switch Parking Brake Warning Relay Parking Brake Switch Heater Motor Heater Resistor Heater Switch Horn Front Wiper Motor Horn Push Wash/Wipe Switch Washer Pump Face Fan Air Filter Switch Engine Oil Pressure Switch Transmission Oil TemperatureSwitch Transmission Oil Pressure Switch Water Temperature Switch Warning Buzzer Hourmeter Alternator Tachometer Fuel Gauge Fuel Gauge Sender Water Temperature Gauge Water Temperature Gauge Sender Reverse Alarm Working Light Switch Auxiliary Earth Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch Ignition relay
9804/1103
Lamps 80 Parking Brake Warning 81 Air Filter Blocked Warning 82 Engine Oil Pressure Warning 83 Transmission Oil Temperature Warning 84 Transmission Oil Pressure Warning 85 Water Temperature Warning 86 Alternator Warning 87 Instrument Panel Illumination 88 Cab Working Light 89 Interior Light and Switch 90 Beacon Fuses Fuses are numbered as shown on the fuse box in the cab.
20 - 15 - 04/8
3640U - C/10-8.2
Issue 1
CONTENTS
Loadalls
506C, 508C Syncroshuttle Circuit Diagram - Electrical Component Key
20 - 15 - 04/9
From m/c no. 585397
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on page 20-15-04/10. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
Battery Starter Motor Starter Solenoid Starter Switch Thermostart Fuel Shut-off Solenoid Neutral Start Relay Forward/Reverse Selector Switch Reverse Relay Reverse Solenoid Forward Relay Forward Solenoid Transmission Dump Relay Transmission Dump Switch Parking Brake Warning Relay Parking Brake Switch Heater Motor Heater Resistor Heater Switch Horn Front Wiper Motor Horn Push Wash/Wipe Switch Washer Pump Face Fan Air Filter Switch Engine Oil Pressure Switch Transmission Oil TemperatureSwitch Transmission Oil Pressure Switch Water Temperature Switch Warning Buzzer Hourmeter Alternator Tachometer Fuel Gauge Fuel Gauge Sender Water Temperature Gauge Water Temperature Gauge Sender Reverse Alarm Working Light Switch Auxiliary Earth Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch Ignition relay
9804/1103
Lamps 80 Parking Brake Warning 81 Air Filter Blocked Warning 82 Engine Oil Pressure Warning 83 Transmission Oil Temperature Warning 84 Transmission Oil Pressure Warning 85 Water Temperature Warning 86 Alternator Warning 87 Instrument Panel Illumination 88 Cab Working Light 89 Interior Light 90 Beacon Fuses Fuses are numbered as shown on the fuse box in the cab.
20 - 15 - 04/9
3640U - C/10-9.1
Issue 1
Loadalls
CONTENTS
20 - 15 - 04/10
506C, 508C Syncroshuttle Circuit Diagram - Electrical (cont’d)
From m/c no. 585397
14
30
17 20 10
2
28
26
16
6
21
24
27
12
38
36
32
25
39 88
29
89
33
5
11
82 81
7
3
80
18
84
86
90
37
34 44
85
83
43
41 35
9
42
15 22 87
1
19
40
23
13
31 8 45 4
9804/1103
20 - 15-04/10
3640U - C/10-10.1
Issue 1
Loadalls
CONTENTS
20 - 15 - 04/11
506C, 508C Powershift with 6 Transmission Relays Circuit Diagrams - Electrical
To m/c no. 585396
33 6 2
8
10 9
5
12
22 20
17 11
24
21
35
37
31
27
34
32
46
88
89
50
48 49 42 80
25
18
82 81
14
84 83
86
44
41
85 51
29 30
19
7
1
87
26 15
90
40
13
3
45
36
28
23
43
39
16
47 38
4
9804/1103
20 - 15 - 04/11
3640U - C/10-11.1
Issue 1
CONTENTS
Loadalls
506C, 508C Powershift with 6 Transmission Relays Circuit Diagrams - Electrical (cont’d) Component Key
20 - 15 - 04/12
To m/c no. 585396
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on page 20-15-04/11. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
Battery Starter Motor Starter Solenoid Starter Switch Thermostart Fuel Shut-off Solenoid Transmission Dump Relay Transmission Dump Switch Parking Brake Warning Relay Parking Brake Switch Drive Shaft Relay Layshaft Solenoid Forward Relay Reverse Relay Forward/Reverse Selector Switch Ratio Selector Switch Forward High/Low Relay Neutral Start Relay Reverse High/Low Relay Forward High Solenoid Forward Low Solenoid Reverse High Solenoid Reverse Low Solenoid Heater Motor Heater Resistor Heater Switch Horn Front Wiper Motor Horn Push Wash/Wipe Switch Washer Pump Face Fan Air Filter Switch Engine Oil Pressure Switch Transmission Oil TemperatureSwitch Transmission Oil Pressure Switch Water Temperature Switch Warning Buzzer Hourmeter Alternator Tachometer Fuel Gauge Fuel Gauge Sender Water Temperature Gauge Water Temperature Gauge Sender Reverse Alarm Working Light Switch Auxiliary Earth Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch
9804/1103
Lamps 80 Parking Brake Warning 81 Air Filter Blocked Warning 82 Engine Oil Pressure Warning 83 Transmission Oil Temperature Warning 84 Transmission Oil Pressure Warning 85 Water Temperature Warning 86 Alternator Warning 87 Instrument Panel Illumination 88 Cab Working Light 89 Interior Light and Switch 90 Beacon Fuses Fuses are numbered as shown on the fuse box in the cab.
20 - 15 - 04/12
3640U - C/10-12.1
Issue 1
CONTENTS
Loadalls
506C, 508C Powershift with 7 Transmission Relays Circuit Diagram - Electrical Component Key
20 - 15 - 04/13
To m/c no. 585396
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on page 20-15-04/14. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53
Battery Starter Motor Starter Solenoid Starter Switch Thermostart Fuel Shut-off Solenoid Transmission Dump Relay Transmission Dump Switch Parking Brake Warning Relay Parking Brake Switch Drive Interlock Relay Drive Shaft Relay Layshaft Solenoid Mainshaft Solenoid Forward Relay Reverse Relay Forward/Reverse Selector Switch Ratio Selector Switch Forward High/Low Relay Neutral Start Relay Reverse High/Low Relay Forward High Solenoid Forward Low Solenoid Reverse High Solenoid Reverse Low Solenoid Heater Motor Heater Resistor Heater Switch Horn Front Wiper Motor Horn Push Wash/Wipe Switch Washer Pump Face Fan Air Filter Switch Engine Oil Pressure Switch Transmission Oil TemperatureSwitch Transmission Oil Pressure Switch Water Temperature Switch Warning Buzzer Hourmeter Alternator Tachometer Fuel Gauge Fuel Gauge Sender Water Temperature Gauge Water Temperature Gauge Sender Reverse Alarm Working Light Switch Auxiliary Earth Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch
9804/1103
Lamps 80 Parking Brake Warning 81 Air Filter Blocked Warning 82 Engine Oil Pressure Warning 83 Transmission Oil Temperature Warning 84 Transmission Oil Pressure Warning 85 Water Temperature Warning 86 Alternator Warning 87 Instrument Panel Illumination 88 Cab Working Light 89 Interior Light and Switch 90 Beacon Fuses Fuses are numbered as shown on the fuse box in the cab.
20 - 15 - 04/13
3640U - C/10-13.1
Issue 1
Loadalls
CONTENTS
20 - 15 - 04/14
506C, 508C Powershift with 7 Transmission Relays Circuit Diagram - Electrical (cont’d)
8
10
6 2
To m/c no. 585396
29
11 13
5
9
14
24 22
19
12
35
39
37
33 26
41 36
34
23
88
30
89 50
44 80
27
52
42
15 20
47
38
25
16
90
48 45
82 81
84 83
86
51
46
43
85
3 53
31 32
87
21
7
1
28 17
18
49 40
4
9804/1103
20 - 15 - 04/14
3640U - C/10-14.1
Issue 1
Loadalls
CONTENTS
20 - 15 - 04/15
506C, 508C Powershift Circuit Diagrams - Electrical
From m/c no. 585397
10 6 2
29
11
8
5
13 9
14
24 22
19
12
35
39
37
33 30
26
23
45
41 36
34
48
38
88
89
52
90
42
25
50
15
44 20
47
80
27
82
84
86
51
46
43
16 81
83
85
3 53
31 87
21
7
1
49
32 28
17
18
40
4
9804/1103
20 - 15 - 04/15
3640U - C/10-15.1
Issue 1
CONTENTS
Loadalls
506C, 508C Powershift Circuit Diagrams - Electrical (cont’d)
20 - 15 - 04/16
From m/c no. 585397
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on page 20-15-04/15. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53
Battery Starter Motor Starter Solenoid Starter Switch Thermostart Fuel Shut-off Solenoid Transmission Dump Relay Transmission Dump Switch Parking Brake Warning Relay Parking Brake Switch Drive Interlock Relay Drive Shaft Relay Layshaft Solenoid Mainshaft Solenoid Forward Relay Reverse Relay Forward/Reverse Selector Switch Ratio Selector Switch Forward High/Low Relay Neutral Start Relay Reverse High/Low Relay Forward High Solenoid Forward Low Solenoid Reverse High Solenoid Reverse Low Solenoid Heater Motor Heater Resistor Heater Switch Horn Front Wiper Motor Horn Push Wash/Wipe Switch Washer Pump Face Fan Air Filter Switch Engine Oil Pressure Switch Transmission Oil TemperatureSwitch Transmission Oil Pressure Switch Water Temperature Switch Warning Buzzer Hourmeter Alternator Tachometer Fuel Gauge Fuel Gauge Sender Water Temperature Gauge Water Temperature Gauge Sender Reverse Alarm Working Light Switch Auxiliary Earth Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch
9804/1103
Lamps 80 Parking Brake Warning 81 Air Filter Blocked Warning 82 Engine Oil Pressure Warning 83 Transmission Oil Temperature Warning 84 Transmission Oil Pressure Warning 85 Water Temperature Warning 86 Alternator Warning 87 Instrument Panel Illumination 88 Cab Working Light 89 Interior Light and Switch 90 Beacon Fuses Fuses are numbered as shown on the fuse box in the cab.
20 - 15 - 04/16
3640U - C/10-16.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 05/1
* 533-105
Machines Circuit Diagrams - Electrical Key 1 2 3 4 5 5A 6 7 8 9 10 11 11A 12 12A 12B 13 13A 14 15 16 17 17A 18 19 19A 20 21 22 22A 23 24 25 26 27 28 29 30 31 32 33 34 35
Battery Battery isolator Starter motor Starter solenoid Ignition switch Fuse link 2 Starting aid Neutral start relay Ignition feed relay 1 Ignition feed relay 2 E.S.O.S. Rear work lamp swich Rear work lamp Front work lamp switch Front work lamps Auxiliary power connector 2/4WD brake relay Brake lamps Brake switch 2/4WD switch 2/4WD solenoid Reverse relay Reverse lamp Reverse alarm Park brake relay Park brake switch Heated seat Radio/cassette Digital clock Fuse link 1 Transducer - load moment indicator (LMI) Instrument panel Warning buzzer Alternator Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge Water temperature gauge LH stabiliser lamp switch RH stabiliser lamp switch
Optional fan reversing circuit shown at X 131 Fan reverse switch 132 Fan reverse solenoid 133 Fan reverse horn
Note: all the items listed here are not necessarily fitted to all machines in the range.
9804/1103
20 - 15 - 05/1
3630 - C/33-2.2
Issue 1*
Loadalls
CONTENTS
20 - 15 - 05/2
2
6
11A
17A 12A
12B
13A
18
23
34
19A
32
35
33
27 28 29 30 31
10
1828
533-105 Machine Circuit Diagrams - Electrical
16
20
See Sheet 4
35
21
X
3 11
12 13
22
15
601JM
9
601JR
8
601JN
34 7
132 133 1840a
26 24
1840
19
410
17
4
410
1
25 14 See Note 2 540-170 (5508 N.Am) Only
131 171
5A
22A
5
417050
160-02290-1
9804/1103
20 - 15 - 05/2
3660 - C/33-1.2
Issue 1*
CONTENTS
Loadalls
20 - 15 - 05/3
* 533-105
Machines Circuit Diagrams - Electrical Key 36 36A 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66
Sidelight reelay Fuse link 1 RH side lights LH side lights Main light switch RH/LH dip beam RH/LH main beam Rear fog light switch Rear fog lamp Column switch - RH LH indicator lamps RH indicator lamps Front washer pump Front wiper motor Rear wiper motor Rear/roof washer pump Roof wiper motor Rear wiper switch Roof wiper switch Hazard warning switch Hazard warning relay Interior light/switch Beacon switch Beacon lamp Face level fan Air conditioning relay Air conditioning - compressor motor Air conditioning - freeze switch Air conditioning - receiver drier Air conditioning switch Heater/heater fan switch Heater
Note: all the items listed here are not necessarily fitted to all machines in the range.
9804/1103
20 - 15 - 05/3
3630 - C/33-3.2
Issue 1*
Loadalls
CONTENTS
20 - 15 - 05/4
46
43
45
41
40
38
37
533-105 Machine Circuit Diagrams - Electrical
47
48
49 50
51
55
59 61
66 58
56
36
44
39 42
63
54
57
62
60
64
52 53
65
36A
160-02290-2
9804/1103
20 - 15 - 05/4
3660 - C/33-4.1
Issue 1*
CONTENTS
Loadalls
20 - 15 - 05/5
* 533-105
Machines Circuit Diagrams - Electrical Key 67 68 69 70 71 71A 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93
Column switch - LH Horn Reverse Hi-Lo relay Reverse Lo solenoid Reverse Hi solenoid Diode pack Reverse relay Forward relay Forward Hi-Lo relay Forward Hi solenoid Forward Lo solenoid Drive interlock relay Drive shaft relay Layshaft solenoid Mainshaft solenoid Transmission dump relay Stabiliser isloation switch Stabiliser isolation relay Stabiliser isolation solenoid Stabiliser isolation switch Sway isolation switch Sway isolation relay Sway switch Sway diverter solenoid Sway solenoid Sway solenoid Transmission dump push button Steer mode control unit A Four wheel/crab steer relay B Two wheel steer relay C Crab steer relay D Four wheel steer relay 94 Steer mode selector switch X Two wheel steer Y Crab steer Z Four wheel steer 95 2WS solenoid 96 4WS solenoid 97 AWS solenoid 98 Crab steer solenoid 99 Proximity switch - front axle 100 Proximity switch - rear axle
Note: all the items listed here are not necessarily fitted to all machines in the range.
9804/1103
20 - 15 - 05/5
3630 - C/33-6.1
Issue 1*
Loadalls
CONTENTS
20 - 15 - 05/6
533-105 Machine Circuit Diagrams - Electrical
95 79 68
70
75
71
80
90
76
84
91
96
89
97 98
71A
67
88 A
94 69
72
73
74 77
78
81
82
83 85
86
87
92
Z X Y
B
99
C
100 D
93
160-02290-3
9804/1103
20 - 15 - 05/6
3660 - C/33-5.1
Issue 1*
Loadalls
CONTENTS
* 525-58/67,
20 - 20 - 02/1
527-58/67 530-95
From m/c no. 567362 to 574295
Circuit Diagram - Hydraulics 35
12 34A
13
34B
42 34 13A
12A
11 36
15B 15A
10
15
V
10
C P
43
10A
10A
33 P
29 C
14
V
2M
2P
P2
2K
2H
2Y
2X
S2
2
P3
31 2A P1
S3
30
S1
2Q
2L
2N
2J
F P4
2G
2F 2W
2E 2V
2D 2U
2B
2C 2T
2S
2X
1B
2R 1A
F1
40
32
T 41
41
a
a b 41A
b 2CC
A166543
2S
9804/1103
20 - 20 - 02/1
A166543
Issue 3*
CONTENTS
Loadalls
525-58/67, 527-58/67, 530-95
20 - 20 - 02/2
From m/c no. 567362 to 574295
Circuit Diagram - Hydraulics Note 1: Includes machines up to 567217 with TI 5/033 Revised Hydraulic Circuit incorporated. Component Key F P1 P2 P3 P4 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2CC 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 2Q 2Y 2R 2S 2T 2U 2V 2W 2X 10 10A 11 12 12A 13 13A 14 15 15A 15B 29
Filter Main pump Steering pump Cooling fan pump Supplementary pump (Farm Special Plus Only) Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Extension spool (Half motor spool type, 530-95 Only) Auxiliary spool see note 2 Tilt spool Auxiliary spool Sway spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) see note 3 Auxiliary relief valve (A.R.V) see note 3 Auxiliary relief valve (A.R.V) (530-95 Only) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test point Lift rams Lift ram check valves Displacement ram Extension ram Extension ram check valve Tilt ram Tilt ram check valve Non-return valve (525-58 Only) Sway ram (530-95) Sway ram check valve Optional Sway isolation valve Steering Anti-cavitation valve
9804/1103
30 31 32 33 34 34A 34B 35 36 40 41 41A 42 43
Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steering mode valve Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan pressure test point Cooling fan motor (inset is for later machines) Cooling fan motor relief valve Auxiliary attachment ram Displacement ram isolation valve (530-95 Only)
Note 2: The circuit illustrated includes most of the services likely to be found on these machines. The exact order of the spools in the valve block may vary from machine to machine. Note 3: On later machines ARV's 2P and 2Q are not fitted.
20 - 20 - 02/2
Issue 2
Loadalls
CONTENTS
20 - 20 - 02/2A
527-58/67, 535-67
From m/c no. 574296
Circuit Diagram - Hydraulics
35
12 P
T 34A
34B
13 42
34D
34C
13A
A
B
12A
36 11 15B 15A
10
10
15
L
R
33
33B
33B
10A
10A
41 29
P
C
V
14
33A
2K
2M
2H
16A 2X 33C P
2
P1
16
2X
2A
T
2L
2N
LS
P
EF
2J
P2 2G
2F
2E
2D
2C
2B
1B P2B S1
2W
P4
2V
2U
2T
2S
2R 1A
P2A
F S2 C F1
T
A230120
9804/1103
20 - 20 - 02/2A
Issue 1
CONTENTS
Loadalls
527-58/67, 535-67
20 - 20 - 02/2B
From m/c no. 574296
Circuit Diagram - Hydraulics Component Key C F F1 P1 P2 P4 S1 S2 T 1A 1B 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2R 2S 2T 2U 2V 2W 2X 10 10A 11 12 12A 13 13A 14 15 15A 15B 16 16A 29
Tank cap Filter Filter by-pass Main pump Steering/Cooling fan pump Supplementary pump (if fitted) Main pump suction line Steering/Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary 1 spool Tilt spool Auxiliary 2 spool Sway spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test points Lift rams Lift ram check valves Displacement ram Extension ram Extension ram check valve Tilt ram Tilt ram check valve Non-return valve (527-58) Sway ram Sway ram check valve Sway isolation valve Oil cooler (535-67 turbo machines only) Check valve (535-67 turbo machines only) Steering anti-cavitation valve
9804/1103
33 33A 33B 33C 34A 34B 35 36 41 42
Steering unit Steer valve Shock valves (option) Main relief valve Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan motor Auxiliary attachment ram
Note: The circuit illustrated includes most of the services likely to be found on these machines. The exact order of the spools in the valve block may vary from machine to machine.
20 - 20 - 02/2B
Issue 1
Loadalls
CONTENTS
20 - 20 - 02/3
530-120
From m/c no. 567362
Circuit Diagram - Hydraulics 23A 35 18
19
13 21
17
23
20 T
P
13A
34A
34B
34 25
34D
34C B
16C
24A
A
16A
11
16B
16D
16 10
V P
42
36 22
10
C
24
15B L
33
R
15A 15
33B
33B
10A
10A
26
14 29 33A V
C
P 2X 33C
2P
T
P
2K
2H
P1
31
2
1B
30
2A
P2 32
2J
2L
2Q
1A 2G 40
2Z
2E
2D
2C
2B
2CC 2S
S1
2W
2V
2U
2T
2SS
2S
2R
S2
S3
P3
2Y
41 F 41A
C
T
A142773
9804/1103
20 - 20 - 02/3
Issue 1
CONTENTS
Loadalls
530-120
20 - 20 - 02/4
From m/c no. 567362
Circuit Diagram - Hydraulics Component Key F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2D 2E 2G 2Y 2Z 2H 2J 2K 2L 2P 2Q 2R 2S 2T 2U 2V 2W 2X 10 10A 11 13 13A 14 15 15A 15B 16 17 18 19 20
Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary spool Tilt spool Sway spool Stabiliser Spool Stabiliser Spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test point Lift rams Lift ram check valves Displacement ram Tilt ram Tilt ram check valve Non-return valve (530-110 Only) Sway ram (Optional on 530-110) Sway ram check valve Sway isolation valve Regenerative valve Inner extension ram check valve Inner extension ram Outer extension ram Regenerative circuit bleed point
9804/1103
21 22 23 23A 24 24A 25 26 29 30 31 32 33 34 34A 34B 35 36 40 41 41A 42
Right stabiliser ram Left stabiliser ram Right stabiliser ram check valve Right stabiliser weight on switch Left stabiliser ram check valve Left stabiliser weight on switch Right stabiliser ram isolation valve Left stabiliser ram isolation valve Steering Anti-cavitation valve Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steering mode valve (Machines without IP67 electrics) Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan pressure test point Cooling fan motor Cooling fan motor relief valve Displacement ram isolation valve
Note: The circuit illustrated includes most of the services likely to be found on these machines. The exact order of the spools in the valve block may vary from machine to machine. Note: 2CC is extension spool half motor type.
20 - 20 - 02/4
Issue 1
Loadalls
CONTENTS
20 - 20 - 02/5
530-110
From m/c no. 567362
Circuit Diagram - Hydraulics
23A 35 18
19
13 21
17
23
20 T
P
13A
34A
34B
34 25
34D
34C B
16C
24A
A
16A
11
16B
16D
16 10
V P
42
36 22
10
C
24
15B L
33
R
15A 15
33B
33B
10A
10A
26
14 29 33A V
C
P 2X 33C
2P
T
P
2K
2H
P1
31
2
1B
30
2A
P2 32
2J
2L
2Q
F
1A 2G 40
2Z
2E
2D
2C
2B
2CC 2S
S1
2W
2V
2U
2T
2SS
2S
2R
S2
S3
P3
2Y
41
41A
C
T
A166551
9804/1103
20 - 20 - 02/5
Issue 1
CONTENTS
Loadalls
530-110
20 - 20 - 02/6
From m/c no. 567362
Circuit Diagram - Hydraulics Component Key F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2D 2E 2G 2Y 2Z 2H 2J 2K 2L 2P 2Q 2R 2S 2T 2U 2V 2W 2X 10 10A 11 13 13A 14 15 15A 15B 16 17 18 19 20
Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary spool Tilt spool Sway spool Stabiliser Spool Stabiliser Spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test point Lift rams Lift ram check valves Displacement ram Tilt ram Tilt ram check valve Non-return valve (530-110 Only) Sway ram Sway ram check valve Sway isolation valve Regenerative valve Inner extension ram check valve Inner extension ram Outer extension ram Regenerative circuit bleed point
9804/1103
21 22 23 23A 24 24A 25 26 29 30 31 32 33 34 34A 34B 35 36 40 41 41A
Right stabiliser ram Left stabiliser ram Right stabiliser ram check valve Right stabiliser weight on switch Left stabiliser ram check valve Left stabiliser weight on switch Right stabiliser ram isolation valve Left stabiliser ram isolation valve Steering Anti-cavitation valve Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steering mode valve (Machines without IP67 electrics) Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan pressure test point Cooling fan motor Cooling fan motor relief valve
Note: The circuit illustrated includes most of the services likely to be found on these machines. The exact order of the spools in the valve block may vary from machine to machine. Note: 2CC is extension spool half motor type.
20 - 20 - 02/6
Issue 1
Loadalls
CONTENTS
20 - 20 - 02/7
505-19 & 505-22
From m/c no. 567362 to 574295
Circuit Diagram - Hydraulics 35
12 34A
13
34B
42 34 13A
12A
11 36
15B 15A
10
15
V
10
C P
43
10A
10A
33 P
29 C
14
V
2M
2P
P2
2K
2H
2Y
2X
S2
2
P3
31 2A P1
S3
30
S1
2Q
2L
2N
2J
F P4
2G
2F 2W
2E 2V
2D 2U
2B
2C
2T
2S
2X
1B
2R 1A
F1
40
32
T 41
41
a
a b 41A
b 2CC A166543
2S
9804/1103
20 - 20 - 02/7
A166543
Issue 2
CONTENTS
Loadalls
505-19, 505-22
20 - 20 - 02/8
From m/c no. 567362 to 574295
Circuit Diagram - Hydraulics Component Key F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 2Q 2R 2S 2T 2U 2V 2W 2X 10 10A 11 12 12A 13 13A 14 15 15A 29
Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary spool Tilt spool Auxiliary spool Sway spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test point Lift rams Lift ram check valves Displacement ram Extension ram Extension ram check valve Tilt ram Tilt ram check valve Non-return valve (505-19 Only) Sway ram (Optional) Sway ram check valve Steering anti-cavitation valve (if fitted)
9804/1103
30 31 32 33 34 34A 34B 35 36 40 41 41A 42
Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steering mode valve (Machines without IP67 electrics) Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan pressure test point Cooling fan motor Cooling fan motor relief valve Auxiliary attachment ram
Note: The circuit illustrated includes most of the services likely to be found on these machines. The exact order of the spools in the valve block may vary from machine to machine. The test point may be at the valve block or the hydraulic pump.
20 - 20 - 02/8
Issue 2
Loadalls
CONTENTS
20 - 20 - 02/8A
505-19 & 505-22
From m/c no.574296
Circuit Diagram - Hydraulics 35
12 P
T 34A
34B
13 42
34D
34C
13A
A
B
12A
36 11 15B 15A
10
10
15
L
R
33
33B
33B
10A
10A
41 29
P
C
V
14
33A
2K
2M
2H
16A 2X
P
2
P1
33C
16
2X
2A
T
2L
2N
LS
P
EF
2J
P2 2G
2F
2E
2D
2C
2B
1B P2B S1
2W
P4
2V
2U
2T
2S
2R 1A
P2A
F S2 C F1
T
A230120
9804/1103
20 - 20 - 02/8A
Issue 1
CONTENTS
Loadalls
505-19 & 505-22
20 - 20 - 02/8B
From m/c no. 574296
Circuit Diagram - Hydraulics Component Key C F F1 P1 P2 S1 S2 T 1A 1B 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2R 2S 2T 2U 2V 2W 2X 10 10A 11 12 12A 13 13A 14 15 15A 15B 29
Tank cap Filter Filter by-pass Main pump Steering pump/Cooling fan pump Main pump suction line Steering/Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary 1 spool Tilt spool Auxiliary 2 spool Sway spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test points Lift rams Lift ram check valves Displacement ram Extension ram Extension ram check valve Tilt ram Tilt ram check valve Non-return valve (505-19) Sway ram Sway ram check valve Sway isolation valve Steering anti-cavitation valve (if fitted)
9804/1103
33 33A 33B 33C 34A 34B 35 36 41 42
Steering unit Steering valve Shock valves (option) Main relief valve Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan motor Auxiliary attachment ram
Note: The circuit illustrated includes most of the services likely to be found on these machines. The exact order of the spools in the valve block may vary from machine to machine.
20 - 20 - 02/8B
Issue 1
Loadalls
CONTENTS
20 - 20 - 02/9
506-36
From m/c no.567362
Circuit Diagram - Hydraulics 23A 35 18
19
13 21
17
23
20 T
P
13A
34A
34B
34C
34D
34 B
25 16C
24A
A
16A
11
16B
16D
16 10
V
C P
42
36 22
10
24
15B L
33
R
15A 15
33B
33B
10A
10A
26
14 29 33A V
C
P 2X 33C
2P T
P
2K
2H
P1
31
2
1B
30
2A
P2 32
2J
2L
2Q
F
1A 2G 40
2Z
2E
2D
2C
2B
2CC 2S
S1
2W
2V
2U
2T
2SS
2S
2R
S2
S3
P3
2Y
41
41A
C
T
A166552
9804/1103
20 - 20 - 02/9
Issue 1
CONTENTS
Loadalls
506-36
20 - 20 - 02/10
From m/c no. 567362
Circuit Diagram - Hydraulics Component Key F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2D 2E 2Y 2Z 2H 2J 2K 2L 2R 2S 2T 2U 2V 2W 2X 10 10A 11 13 13A 14 16 17 18 19 20 21 22 23 23A 24 24A 25 26
Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary spool Tilt spool Stabilizer spool Stabilizer spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test point Lift rams Lift ram check valves Displacement ram Tilt ram Tilt ram check valve Non-return valve Regenerative valve Inner extension ram check valve Inner extension ram Outer extension ram Regenerative circuit bleed point Right stabilizer ram Left stabilizer ram Right stabilizer ram check valve Weight on switch Left stabilizer ram check valve Weight on switch Right stabilizer ram isolation valve Left stabilizer ram isolation valve
9804/1103
29 30 31 32 33 34 34A 34B 35 36 40 41 41A 42
Steering Anti-cavitation valve Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steering mode valve (Machines without IP67 electrics) Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan pressure test point Cooling fan motor Cooling fan motor relief valve Displacement ram isolation valve
Note: The circuit illustrated includes most of the services likely to be found on these machines. The exact order of the spools in the valve block may vary from machine to machine. Note: 2CC is extension spool half motor type.
20 - 20 - 02/10
Issue 1
Loadalls
CONTENTS
20 - 20 - 02/11
508-40
From m/c no.567362
Circuit Diagram - Hydraulics
18
19
13
35
17 20 13A 34A 34B
16C
15A
15
34
16A 16B
16
16D
10
11 V 36
10
C P
42
10A
33
10A
29 14
2P
2M
2K
2H
31 30
P2
2X
2
32
2A S2
2Q
P3
2L
2N
2J
P1 S1
40
F
2G
2F
2E
2D
2C
2B
1B
2CC 2S
2W
S3
2V
2U
2T
2S
2R
1A
T
41 41A
A142782
9804/1103
20 - 20 - 02/11
Issue 1
CONTENTS
Loadalls
508-40
20 - 20 - 02/12
From m/c no. 567362
Circuit Diagram - Hydraulics Component Key F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 2Q 2R 2S 2T 2U 2V 2W 2X 10 10A 11 13 13A 14 15 15A 16 17 18 19 20
Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary spool Tilt spool Auxiliary spool Sway spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test point Lift rams Lift ram check valves Displacement ram Tilt ram Tilt ram check valve Non-return valve Sway ram Sway ram check valve Regenerative valve Inner extension ram check valve Inner extension ram Outer extension ram Regenerative circuit bleed point
29 30 31 32 33 34 34A 34B 35 36 40 41 41A 42
Steering anti-cavitation valve Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steering mode valve (Machines without IP67 electrics) Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan pressure test point Cooling fan motor Cooling fan motor relief valve Displacement ram isolation valve
Note: The circuit illustrated includes most of the services likely to be found on these machines. The exact order of the spools in the valve block may vary from machine to machine. Note: 2CC is extension spool half motor type.
9804/1103
20 - 20 - 02/12
Issue 1
Loadalls
CONTENTS
20 - 20 - 02/13
510-40
From m/c no.567362
Circuit Diagram - Hydraulics 23A
18
19
13
35 21
17
23
20 13A 34A 34B
24A
34
25
11
16
10 V 36
C P
42
22
10
24
15A 15
10A
10A
26 33 14
29
31 30
P2
2X
32 S2
2P
P3
2K
2H
P1 S1
40
F
2
1B 2A
S3
2J
2L
2Q
1A T 41
2G
2Y
2W
2Z
2V
2E
2U
2D
2T
2C
2B
2S
2R
41A
A154531
9804/1103
20 - 20 - 02/13
Issue 2
CONTENTS
Loadalls
510-40
20 - 20 - 02/14
From m/c no. 567362
Circuit Diagram - Hydraulics Component Key F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2D 2E 2G 2Y 2Z 2H 2J 2K 2L 2P 2Q 2R 2S 2T 2U 2V 2W 2X 11 13 13A 14 16 17 18 19 20 21 22 23 23A 24 24A 25 26
Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary spool Tilt spool Sway spool Stabilizer spool Stabilizer spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test point Displacement ram Tilt ram Tilt ram check valve Non-return valve Regenerative valve Inner extension ram check valve Inner extension ram Outer extension ram Regenerative circuit bleed point Right stabilizer ram Left stabilizer ram Right stabilizer ram check valve Weight on switch Left stabilizer ram check valve Weight on switch Right stabilizer ram isolation valve Left stabilizer ram isolation valve
29 30 31 32 33 34 34A 34B 35 36 40 41 41A 42
Steering anti-cavitation valve Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steering mode valve (Machines without IP67 electrics) Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan pressure test point Cooling fan motor Cooling fan motor relief valve Displacement ram isolation valve
Note: The circuit illustrated includes most of the services likely to be found on these machines. The exact order of the spools in the valve block may vary from machine to machine.
9804/1103
20 - 20 - 02/14
Issue 1
Loadalls
CONTENTS
* 520-55
20 - 20 - 02/15
RS and 520-55 4 Wheel Steer
From m/c no. 277001 to 278610
Circuit Diagram-Hydraulics 5
7 7A
4
5B
8
5C
7B
8A 8B
5A a
b 3 a 3B
b
9
3B 6
9A 9B
2 3A
2K
2K
2B
2C
14
2E
2D
2K
1A 3C 12
LS
P
P1
EF
2H
2F
2J
2G
13
2A
15
P1C 1C
P1B P1A
A
B
A
A
B 17
C
B
A
B
16 18
1B S1
T 10 F 11
9804/1103
20 - 20- 02/15
3610 - E/2-2.5
Issue 4*
CONTENTS
* 520-55
Loadalls
20 - 20 - 02/16
From m/c no. 277001 to 278610
RS and 520-55 4 Wheel Steer
Circuit Diagram Component Key C F P1 P1A P1B P1C S1 T 1A 1B 1C 2 2A 2B * 2C 2D * 2E 2F 2G 2H 2J 2K 3 3A 3B 3C 4 5 5A 5B 5C 6 7 7A 7B 8 8A 8B 9 9A 9B 10 11 12 13 14 15 16 * 17 * 18
Cap Filter Main pump assembly Pump Pressure test point Priority valve Main pump suction line Tank Neutral circuit feed line Neutral circuit return line Steer circuit return line Valve block Main relief valve (M.R.V.) Auxiliary spool Lift spool (see Note) Tilt spool Extension spool (see Note) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valves (L.H.C.V’s) Steer unit assembly Steer valve Shock valves (option) Main relief valve RS machine rear axle steer track rod AWS machine steer circuit Front axle steer track rod Rear axle steer track rod Steer alignment valve Auxiliary 1 circuit (standard all machines) Q Fit Carriage pin locking (option) Q Fit Carriage pin locking ram Q Fit Carriage manual diverter valve Auxiliary 2 circuit (option) Diverter valve Auxiliary 2 ram Hydraulic hitch (option) Diverter valve Hitch ram Lift ram check valve Lift ram Displacement ram Tilt ram Tilt ram check valve Extension ram check valve Extension ram Port restrictor Port restrictor
Note: On early machines spools 2C and 2E are half motor type.
9804/1103
20 - 20 - 02/16
3610 - E/2-1.5
Issue 4*
Loadalls
CONTENTS
* 520-55 * 526-55,
20 - 20 - 02/17
4 Wheel Steer From m/c 278611 526, 526S From m/c no. 277001 to 280299
Circuit Diagram-Hydraulics * 19
5A
5D
5D 5C
7
A P B
7A
18A T
8
18C
18B
18A
18 7B 5B
5D
5D
3
L
3B
8A 8B
17B 17
17C
R 9
3B
6
17A
9A 1A
9B
2 3A
2K
2B
2K
2C
2K
14
2E
2D
3C 12
LS P
EF
P1
2H
2F
2J
2G
13
2A
15
P1C 1C
P1B P1A
A 20
C
B
A
B
A 22
B
A
B
16 23
1B S1
T 10 F 11
9804/1103
20 - 20 - 02/17
3610 - E/2-4.3
Issue 3*
CONTENTS
* *
* *
Loadalls
20 - 20 - 02/18
520-55 Wheel Steer From m/c no. 278611 526-55, 526, 526S From m/c no. 277001 to 280299 Circuit Diagram - Hydraulics Component Key C F P1 P1A P1B P1C S1 T 1A 1B 1C 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 3 3A 3B 3C 5A 5B 5C 5D 6 7 7A 7B 8 8A 8B 9 9A 9B 10 11 12 13 14 15 16 17 17A 17B 17C 18 18A 18B 18C 19 20 21 22 23
Cap Filter Main pump assembly Pump Pressure test point Priority valve Main pump suction line Tank Neutral circuit feed line Neutral circuit return line Steer circuit return line Valve block Main relief valve (M.R.V.) Auxiliary spool Lift spool Tilt spool Extension spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valves (L.H.C.V's) Steer unit assembly Steer valve Shock valves (option) Main relief valve Front axle steer track rod Rear axle steer track rod Steer mode selector valve Brake packs Auxiliary 1 circuit (standard all machines) Q Fit Carriage pin locking (option) Q Fit Carriage pin locking ram Q Fit Carriage manual diverter valve Auxiliary 2 circuit (option) Diverter valve Auxiliary 2 ram Hydraulic hitch (option) Diverter valve Hitch ram Lift ram check valve Lift ram Displacement ram Tilt ram Tilt ram check valve Extension ram check valve Extension ram Brake circuit charge valve Main spool Relief valve Compensating valve (not used) Accumulator manifold Accumulator spheres Pressure/vent connector Brake pressure switch Brake valve Liquid/liquid cooler (not fitted) not fitted Port restrictor Port restrictor
9804/1103
20 - 20 - 02/16
3610 - E/2-3.4
Issue 3*
Loadalls
CONTENTS
20 - 20 - 02/19
537-120, 537-130
From m/c no. 572900
Circuit Diagram - Hydraulics
35
23A
P
T 34A
34B
34C
34D
18
19
13
A
B
21
17
23
20 13A
36 16C
25
16A
24A L
33
16B
11
R
16D
16
10 33B
V
33B
C P
12
22
10
24
15B 15A 15
10A
33A
10A
26
29 C
33C
P
V
P
T
31 30
P2
2X
32 S2 2K
2L
P1 S1 40
P3
2
1B 2A
S3
F
41
2M
2J
C
1A
41A 2F
2H
2G
2E
2D
2C
2B
T 2U
2T
2S
2R
2Q
2P
2N
A229130 9804/1103
20 - 20 - 02/19
Issue 1
CONTENTS
Loadalls
537-120, 537-130
20 - 20 - 02/20
From m/c no. 572900
Circuit Diagram - Hydraulics Component Key C F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 2Q 2R 2S 2T 2U 2X 10 10A 11 12 13 13A 15 15A 15B 16 16A 16B 16C 16D 17 18 19 20
Tank cap Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary spool Tilt spool see note 1 Sway spool Stabiliser Spool Stabiliser Spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Load hold check valves (L.H.C.V.) Load hold check valves (L.H.C.V.) Load hold check valves (L.H.C.V.) Load hold check valves (L.H.C.V.) Load hold check valves (L.H.C.V.) Load hold check valves (L.H.C.V.) Load hold check valves (L.H.C.V.) Pressure test point Lift rams Lift ram check valves Displacement ram Displacement ram isolation valve Tilt ram Tilt ram check valve Sway ram Sway ram check valve (if fitted) Sway isolation valve Regenerative valve Hose burst check valve Relief valve Check valve Non return valve Inner extension ram check valve Inner extension ram Outer extension ram Regenerative circuit bleed point
9804/1103
21 22 23 23A 24 24A 25 26 29 30 31 32 33 33A 33B 33C 34A 34B 34C 34D 35 36 40 41 41A
Right stabiliser ram Left stabiliser ram Right stabiliser ram check valve Right stabiliser weight on switch Left stabiliser ram check valve Left stabiliser weight on switch Right stabiliser ram isolation valve Left stabiliser ram isolation valve Steering Anti-cavitation valve Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steer valve Shock valves (option) Main relief valve 2 Wheel steer solenoid 4 Wheel and crab steer solenoid 4 Wheel steer solenoid Crab steer solenoid Front axle steering rams Rear axle steering rams Cooling fan pressure test point Cooling fan motor Cooling fan motor relief valve
Note 1: The circuit illustrated includes most of the services likely to be found on these machines. The exact order of the spools in the valve block may vary from machine to machine.
20 - 20 - 02/20
Issue 1
Loadalls
CONTENTS
* 520-50,
20 - 20 - 02/21
525-50, 525-52
From m/c no. 754000
Circuit Diagram-Hydraulics 22
20
7 10
21
7A
11
14 C
13
T F
24
S 12 S1 15
P1
24A
17
16
X 17A 1C 23
23
1B
2
1A 2F
2H
2G
2J
T
EF 3
P
P 3C
F
17D T
F
LS
LS 17C
17E 2A
17B 3A A2
A1 X
2E
2D 2K
2C 2K
2B 2K
18 3B
2K 25
3B
A
18 19
B 5C 5A
5B 5D
5D
5D
5D A234942
9804/1103
20 - 20 - 02/21
3620 - E/2-2.3
Issue 3*
CONTENTS
Loadalls
520-50, 525-50, 525-52
20 - 20 - 02/22
From m/c no. 754000
Circuit Diagram - Hydraulics Component Key Component Key C F LS P1 S S1 T X 1A 1B 1C 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 3 3A 3B 3C 5A 5B 5C 5D 7 7A 10 11 12 13 14 15 16 17 17A 17B 17C 17D 17E 18 19 20 21 22 23 * 24 * 25 * 26
Cap Filter Load Sensing line Main pump Suction strainer Main pump suction line Tank Pressure test point Neutral circuit feed line Neutral circuit return line Steer circuit return line Valve block Main relief valve (M.R.V.) Auxiliary spool Lift spool Tilt spool Extension spool Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Load hold check valves (L.H.C.V's) Steer unit assembly Steer valve Shock valves (option) Relief valve Front steer ram Rear steer ram Steering alignment valve Brake packs Q Fit Carriage pin locking Q Fit Carriage manual diverter valve Lift ram check valve Lift ram Displacement ram Tilt ram Tilt ram check valve Extension ram check valve Extension ram Brake charge/priority valve Priority valve Distributor valve Pilot valve Relief valve Brake pressure switch Accumulator Brake valve Auxiliary 1 quick release couplings Electrical diverter valve (if fitted) Auxiliary 2 quick release couplings One-way restrictor Hydraulic Hitch (Option) Electrical Diverter Valve Trailer Brake Valve (Option)
9804/1103
20 - 20 - 02/22
3620 - E/2-1.2
Issue 3*
CONTENTS
Loadalls
520-55 RS and 520-55 4 Wheel Steer
20 - 20 - 02/23
To m/c no. 278610
Circuit Diagram - Hydraulics Component Key C F P1 P1A P1B P1C S1 T 1A 1B 1C 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 3 3A 3B 3C 4 5 5A 5B 5C 6 7 7A 7B 8 8A 8B 9 9A 9B 10 11 12 13 14 15 16
Cap Filter Main pump assembly Pump Pressure test point Priority valve Main pump suction line Tank Neutral circuit feed line Neutral circuit return line Steer circuit return line Valve block Main relief valve (M.R.V.) Auxiliary spool Lift spool, see note Tilt spool Extension spool, see note Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Load hold check valves (L.H.C.V's) Steer unit assembly Steer valve Shock valves (option) Main relief valve RS machine rear axle steer track rod AWS machine steer circuit Front axle steer track rod Rear axle steer track rod Steer alignment valve Auxiliary 1 circuit (standard all machines) Q Fit Carriage pin locking (option) Q Fit Carriage pin locking ram Q Fit Carriage manual diverter valve Auxiliary 2 circuit (option) Diverter valve Auxiliary 2 ram Hydraulic hitch (option) Diverter valve Hitch ram Lift ram check valve Lift ram Displacement ram Tilt ram Tilt ram check valve Extension ram check valve Extension ram
Note: On early machines spools 2C and 2E are half motor type.
9804/1103
20 - 20 - 02/23
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/24
520-55 RS and 520-55 4 Wheel Steer
To m/c no. 278610
Circuit Diagram - Hydraulics (contÕd) 5
7 7A
4
5B
8
5C
7B
8A 8B
5A a
b 3 a 3B
b
9
3B 6
9A 9B
2 3A
2K
2B
2K
2C
2K
2D
14
2E
1A 3C 12
LS
P
P1
EF
2H
2F
2J
2G
13
2A
15
P1C 1C
P1B P1A
16 C
1B S1
T 10 F 11
A183561 9804/1103
20 - 20 - 02/24
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/25
520-55 4 Wheel Steer from Serial No. 278611 & 526-55, 526, 526S to Serial No. 280299 Circuit Diagram - Hydraulics Component Key C F P1 P1A P1B P1C S1 T 1A 1B 1C 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 3 3A 3B 3C 5A 5B 5C 5D 6 7 7A 7B 8 8A 8B 9 9A 9B 10 11 12 13 14 15 16 17 17A 17B 17C 18 18A 18B 18C 19 20 21
Cap Filter Main pump assembly Pump Pressure test point Priority valve Main pump suction line Tank Neutral circuit feed line Neutral circuit return line Steer circuit return line Valve block Main relief valve (M.R.V.) Auxiliary spool Lift spool Tilt spool Extension spool Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Load hold check valves (L.H.C.V's) Steer unit assembly Steer valve Shock valves (option) Main relief valve Front axle steer track rod Rear axle steer track rod Steer mode selector valve Brake packs Auxiliary 1 circuit (standard all machines) Q Fit Carriage pin locking (option) Q Fit Carriage pin locking ram Q Fit Carriage manual diverter valve Auxiliary 2 circuit (option) Diverter valve Auxiliary 2 ram Hydraulic hitch (option) Diverter valve Hitch ram Lift ram check valve Lift ram Displacement ram Tilt ram Tilt ram check valve Extension ram check valve Extension ram Brake circuit charge valve Main spool Relief valve Compensating valve (not used) Accumulator manifold Accumulator spheres Pressure/vent connector Brake pressure switch Brake valve Liquid/liquid cooler (if fitted) Restrictor (526-55, 526 & 526S)
9804/1103
20 - 20 - 02/25
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/26
520-55 4 Wheel Steer from Serial No. 278611 & 526-55, 526, 526S to Serial No. 280299 Circuit Diagram - Hydraulics (contÕd) 19
5A
5D
5D 5C
7
A P B
7A
18A T
8
18C
18B
18A
18 7B 5B
5D
5D
3
L
3B
8A 8B
17B 17
17C
R 9
3B
6
17A
9A 1A
9B
2 3A
2K
2B
2K
2C
2D
2K
14
2E
3C 12
LS P
EF
P1
2H
2F
2J
2G
13
2A
15
P1C 1C
P1B P1A
16 20 C
1B
21
S1
T 10 F 11
A210540 9804/1103
20 - 20 - 02/26
Issue 1
CONTENTS
Loadalls
526, 526S Machines with Dual Lever Control Circuit Diagram - Hydraulics Component Key C F P1 P1A P1B P1C S1 1A 1B 1C 2 2A 2B 2C 2D 2E * 2F * 2G * 2H * 2J 2K *3 3A 3B 3C *4 * 4A * 4B 5A 5B 5C 6 *7 7A 7B * 7C * 7D *8 * 8A *9 * 9A * 9B * 9C * 9D * 10 11 12 13 * 14 * 15 16 19 19A * 19B 19C 19D 20 21 22 23
20 - 20 - 02/27
From m/c no. 280300
Cap Filter Main pump assembly Pump Pressure test point Priority valve Main pump suction line Return line to tank Steer circuit return line Trailer brake valve return line Valve block Main relief valve (MRV) Auxiliary spool Raise/lower spool Tilt spool Extend/retract spool Auxiliary relief valve (ARV) head side (Port A) Auxiliary relief valve (ARV) rod side (Port B) Auxiliary relief valve (ARV) (Port B) Auxiliary relief valve (ARV) (Port A) Load hold check valves (LHCVs) Steer unit assembly (with shock valves) Steer valve Main relief valve Shock valves (option) Steer unit assembly (without shock valves) Steer valve Main relief valve Front axle steer track rod Rear axle steer track rod Steer mode selector valve Auxiliary 1 circuit (standard all machines) Twin auxiliary option with hydraulic pin locking option Quickfit carriage locking pin ram Quickfit carriage manual diverter valve Solenoid diverter valve (boom mounted) Tool carrier locking pin ram Twin auxiliary option Solenoid diverter valve (boom mounted) Hydraulic pick-up hitch (option) Solenoid diverter valve (chassis mounted) Pick-up hitch cylinder Restrictor Quick release coupling Counter balance valve Lift ram Displacement ram Tilt ram Counter balance valve Counter balance valve Extension ram Trailer brake valve (option) Pilot valve Trailer brake valve Trailer brake coupling Brake circuit connection Liquid/liquid cooler (if fitted) Check valve Port restrictor (3.5 mm) Port restrictor (3.5 mm)
9804/1103
20 - 20 - 02/27
3610 - E/2-6.3
Issue 3*
Loadalls
CONTENTS
20 - 20 - 02/28
526, 526S Machines with Dual Lever Control
To m/c no. 280300
Circuit Diagram - Hydraulics (cont’d) * 5A
2 P
16
15
23 B
Extend
A
Retract
A B
2E 5C
12
T
2K 5B
Crowd
B
a
b
3 L
a
R
3C
2D
b
4
13
14
22
2F
2G
Dump
A
21
2K
Raise
B
2C
A
11
10
Lower
c
6 d
3A
4A
2K B
3B
4B
a
2H
2J
A P1
g
f
a
2K
g
f
d
C
7C 19C
P1B
B AUX2
Ls
Ef
AUX1
D P2
P
A
c
2A
7D
7A
7B
T
Ls
P
2B
P
T
P1C
P1 c
P1A S
P2
8
A
D
AUX2
C
B
AUX1
d
8A C
S1 B
R
19B F
N
c
19A 19D
P
9804/1103
3610 - E/2-5.3
20 - 20 - 02/28
19
AUX1 A
P1
Y
D P2
9C
d
B
9
9D 9B
C
9A
Issue 3*
CONTENTS
Loadalls
20 - 20 - 02/29
526, 526S Machines with Single Lever Control Option
From m/c no. 280300
Circuit Diagrams - Hydraulics The single lever control option provides servo operated boom extend/retract and auxiliary functions. The spools, 2F and 2G respectively, are solenoid operated from lever mounted switches which select the required function. The raise/lower spool 2D and tilt spool 2E are both mechanically operated with spring loading to the neutral (central) position. * Component C F P1 P1A P1B P1C S1 1A 1B 1C 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 3 3A 3B 3C 4 4A 4B 5A 5B 5C 6 7 7A 7B 7C 7D 8 8A 9 9A 9B 9C 9D 10 11 12 13
Key
Cap Filter Main pump assembly Pump Pressure test point Priority valve Main pump suction line Return line to tank Steer circuit return line Trailer brake valve return line Valve block Main relief valve (MRV) Pressure reducing valve (20 bar) Pressure maintaining valve (10 bar) Auxiliary spool Raise/lower spool Tilt spool Extend/retract spool Auxiliary relief valve (ARV) rod side (Port B) Auxiliary relief valve (ARV) head side (Port A) Auxiliary relief valve (ARV) (Port A) Auxiliary relief valve (ARV) (Port B) Load hold check valves LHCVs Accumulator Filter Steer unit assembly (with shock valves) Steer valve Main relief valve Shock valves (option) Steer unit assembly (without shock valves) Steer valve Main relief valve Front axle steer track rod Rear axle steer track rod Steer mode selector valve Auxiliary 1 circuit (standard all machines) Twin auxiliary option with hydraulic pin locking option Quickfit carriage locking pin ram Quickfit carriage manual diverter valve Solenoid diverter valve (boom mounted) Tool carrier locking pin ram Twin auxiliary option Solenoid diverter valve (boom mounted) Hydraulic pick-up hitch option Solenoid diverter valve (chassis mounted) Pickup hitch cylinder Restrictor Quick release coupling Counterbalance valve Lift ram Displacement ram Tilt ram
9804/1103
14 15 16 19 19A 19B 19C 19D 21 22 23 24
20 - 20 - 02/29
Counterbalance valve Counterbalance valve Extension ram Trailer brake valve (option) Pilot valve Brake valve Trailer brake coupling Brake circuit connection Check valve Port restrictor (3.5mm) Port restrictor (3.5mm) Port restrictor (2.5mm)
3610 - E/2-7.3
Issue 3*
CONTENTS
Loadalls
20 - 20 - 02/30
526, 526S Machines with Single Lever Control Option
To m/c no. 280300
Circuit Diagram - Hydraulics (cont’d) * 5A
P B
2
A
5C
16
15
24
A 2G
T
B
5B
3
a
b
a
L
14
13
10
11
A
b 2F
R
3C
12 22
2M
4
2H
2J
B
2M
21 A 2E
B
2M c A
4A
3A
2D 2K
2L
6 d
B
2M
3B
4B
7 P
P1 f
e
2C
T
Ls
2P
g
e
f
g
2B
c
2A
P
D
C
d
2N
Ls
Ef
A B
P2
P1
7D
7A
7B
P
T
7C
19C P1B
1B
P1C
P1 c
P1A
P2
S
1C
8
B
C
d
1A
C
A D
8A
S1 F B
R
19B
P1 D
c
P 19A N
A
P2 19D
9C
d
B
9
9D 9B
C
19 9A
9804/1103
3610 - E/2-8.3
20 - 20 - 02/30
Issue 3*
CONTENTS
Loadalls
20 - 20 - 02/31
528-70 from m/c no. 796000 528S from m/c no. 796102 Circuit Diagram - Hydraulics Component Key C F F1 N1 N2 S S1 T 1 1A 1B 1C 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 3 3A 3B 3C 3D 3E 4 4A 4B 4C 5A 5B 5C 5D 6 7 8 8A 8B 8C 9 9A 10 10A 10B 10C 10D
Pressure cap breather Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Main pump suction line Suction strainer Hydraulic tank Main pump assembly Pump Pressure test point Load sensing valve Valve block Main relief valve (MRV) Auxiliary spool Raise/lower spool Tilt spool Extend/retract spool Auxiliary relief valve (ARV) head side - Port A Auxiliary relief valve (ARV) rod side - Port B Auxiliary relief valve (ARV) - Port B Auxiliary relief valve (ARV) - Port A Load Hold Check Valve (LHCVs) Steer unit assembly (with shock valves) Steer valve Main relief valve Shock valves (option) Non-return valve Steer circuit return line Steer unit assembly (without shock valves) Steer valve Main relief valve Non-return valve Front axle steer track rod Rear axle steer track rod Steer mode selector valve (steer mode option only) AWS setting lever Single auxiliary connectors High flow auxiliary option Twin auxiliary option with hydraulic pin locking option Diverter valve - boom mounted Quick-fit carriage manual isolation valve Pin locking cylinder Twin auxiliary option Diverter valve - boom mounted Hydraulic pick up hitch option Diverter valve - chassis mounted Pickup hitch cylinder Restrictor Quick release coupling
11
Lift cylinder
9804/1103
11A 12 12A 12B 13 14 15 15A 15B 16 16A 16B 17 18
Counterbalance valve Tilt cylinder Counterbalance valve Port restrictor (3.5mm) Displacement cylinder Check valve Extension cylinder Counterbalance valve Port restrictor (3.5mm) Trailer brake valve (option) Trailer brake coupling Hydraulic hitch return line Hydraulic cooler: Liquid/liquid - 528-70 with high flow Aux option Hydraulic cooler: liquid/air blast - 528S
Note: Spools 2D and 2E are reversed on machines fitted with a placing control pattern.
20 - 20 - 02/31
3650 - E/2-1.2
Issue 1
Loadalls
CONTENTS
20 - 20 - 02/32
528-70 From m/c no. 796000 528S From m/c no. 796102 Circuit Diagram - Hydraulics (cont’d)
5A
2 15B
5B
15
15A
5C 2E 5D
13
5B
2K
5A
2D 3
4
12
12A
12B
2G
2F
14
2K
11
11A
3C 2C 6 3A
4A
3B
4B
3D
7
2K
2B
2H
2J
8C
8B
4D
8
2K 2A
1 16A
3E
1B
9
1C
17 N1
1A 16B C
8A
9A N2
S T
B
R
10
16 Y
F
F1
10D
18
10B
N
10C
S1 P
9804/1103
3650 - E/2-2.2
20 - 20 - 02/32
10A
Issue 1
20 - 20 - 02/33
Loadalls
CONTENTS
528S With Single Lever Controls (SLC) Circuit Diagram - Hydraulics
From m/c no. 796102
5A
2 15B
5B
15
15A
5C 2E 5D
13
5B
2K
5A
12B
2D 3
4
12
12A
2G
2F
14
2K
11
11A
3C 2C 6 3A
4A
3B
4B
3D
7
2K
2B
2H
2J
8C
8B
4D
8
2K 2A
1 16A
3E
1B
9
1C
17 N1
1A 16B C
8A
9A N2
S T
B
R
10
16 Y
F
F1
10D
18
10B
N
10C
S1 P
9804/1103
10A
20 - 20 - 02/33
3650 - E/2-3.1
Issue 1
CONTENTS
Loadalls
528S With Single Lever Control (SLC) Circuit Diagram - Hydraulics (cont’d) Component Key C F F1 N1 N1 S S1 T 1 1A 1B 1C 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 3 3A 3B 3C 3D 3E 4 4A 4B 4C 5A 5B 5C 5D 6 7 8 8A 8B 8C 9 9A 10 10A 10B 10C 10D
From m/c no. 796102
Pressure Cap breather Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Main pump suction line Suction strainer Hydraulic tank Main pump assembly Pump Pressure test point Load sensing valve Valve block Main relief valve (MRV) Pressure reduction valve Accumulator Pressure maintaining valve Auxiliary spool Raise/lower spool Tilt spool Extend/retract spool Auxiliary relief valve (ARV) rod side - Port B Auxiliary relief valve (ARV) head side - Port A Auxiliary relief valve (ARV) - Port B Auxiliary relief valve (ARV) - Port A Load Hold Check-Valves (LHCVs) Steer unit assembly (with shock valves) Steer valve Main relief valve Shock valves (option) Non-return valve Steer circuit return line Steer unit assembly (without shock valves) Steer valve Main relief valve Non-return valve Front axle steer track rod Rear axle steer track rod Steer mode selector valve (steer mode option only) AWS setting lever Single auxiliary connectors High flow auxiliary option Twin auxiliary option with hydraulic pin locking option Diverter valve - boom mounted Quick-fit carriage manual isolation valve Pin locking cylinder twin auxiliary option Diverter valve - boom mounted Hydraulic pick up hitch option Diverter valve - chassis mounted Pick up hitch cylinder Restrictor Quick release coupling
9804/1103
20 - 20 - 02/34
11 11A 12 12A 12B 13 14 15 15A 15B 16 16A 16B 17 18
Lift cylinder Counterbalance valve Tilt cylinder Counterbalance valve Port restrictor (3.5mm) Displacement cylinder Check valve Extension cylinder Counterbalance valve Port restrictor (3.5mm) Trailer brake valve (option) Trailer brake coupling Hydraulic hitch return line Not fitted Hydraulic cooler: liquid/air blast
Note: Spools 2D and 2E are reversed on machines equipped with a placing control pattern.
20 - 20 - 02/34
3650 - E/2-4.1
Issue 1
CONTENTS
Loadalls
530, 540 Agricultural Circuit Diagrams - Hydraulic Component Key B F F1 F2 N1 N2 S T 1 1A 1B 1C 1D 1E 1F 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 3 3A 3B 3C 4 4A 5 8 8A 9 10 10A 11 11A 11B 11C 12 13 13A 13B 13C 13D 13E 14 14A 14B 14C 15 15A 15B 15D 15E
Pressure cap breather (if fitted) Filter Filter by-pass See Note 1 Neutral circuit feed line Neutral circuit return line Pump suction line Tank Pump assembly - see Note 2 Main pump Fan pump Steer pump Priority valve Test points Test point (if fitted) Valve block Main relief valve (M.R.V.) Pressure reducing valve (20 bar) Pressure maintaining valve (10 bar) Lift spool Tilt spool Extension spool Auxiliary spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.)- see Note 3 Auxiliary relief valve (A.R.V.)- see Note 3 Load hold check valves (L.H.C.V's) Accumulator Steering unit Steer valve Shock valves (option) Main relief valve Cooling fan motor Cooling fan motor drain line (if fitted) Cooler (if fitted) Lift ram Lift ram check valve Displacement ram Tilt ram Tilt ram check valve Extension ram Extension ram check valve Auxiliary relief valve (A.R.V.) (540 only) Auxiliary relief valve (A.R.V.) (540 only) Auxiliary 1 boom quick release couplings Auxiliary 1 with trailer hitch option Diverter valve (chassis) - see Note 4 Trailer hitch ram Auxiliary 1 boom quick release couplings Trailer/Auxiliary quick release coupling Restrictor adaptor - See Note 5. Auxiliary 1 and 2 option Diverter valve (boom) - see Note 4 Auxiliary 2 boom quick release couplings Auxiliary 1 boom quick release couplings Auxiliary 1 and 2 with carriage pin locking option Diverter valve (boom) - see Note 4 Auxiliary 2 boom quick release couplings Manual change over valve Hydraulic pin locking ram
9804/1103
20 - 20 - 02/35
From m/c no. 767001
16 17 17A 17B 17C 17D 17E 18 19 19A 19B 19C 19D 20
Rear power track rod Steer mode valve 2 Wheel steer solenoid 4 Wheel and crab steer solenoid 4 Wheel steer solenoid Crab steer solenoid Steering anti-cavitation valve - See Note 6. Front power track rod Trailer brake valve assembly option Pilot valve Brake valve Trailer brake coupling Brake circuit connection Restricted non return valve
Note 1: Later machines have direct return to tank from the Filter F. Note 2: From machine S/N 771430 the positions of fan pump 1B and steer pump 1C of pump assembly 1 are reversed. Note 3: Early machines have auxiliary relief valves which incorporate check valves. Note 4: Ports B and C of items 13A, 14A and 15A were Ports A and D on machines prior to serial number 775468. Note 5: Restrictor adaptor 13E fitted to improve hitch control on machines fitted with a pickup hitch option. See Technical Information Bulletin 5/195 (E191). Note 6: Steering anti-cavitation valve 17E is by-passed via connector Y, as shown on inset Z, on machines from S/N 773054.
20 - 20-02/35
3630 - E/5-1.5
Issue 1
20 - 20 - 02/36
Loadalls
CONTENTS
530, 540 Agricultural Circuit Diagrams - Hydraulics (cont’d)
From m/c no. 767001
17 17A
15
Z
17C
15D
18 17B
15E
17E
16
15B
17D
15C 15A
Y
17E
14
B3
14B 3 14C 14A 5 3
13
19C
13E
3B
13D
13C 4
2
13B
T
13A
4A 3A
19D 12
A 2G B2
3C
19A
19B
B
2M 2K
B1
B
2M
11B 11C
1F A
1
2E 1E
2H
2M
B 2J
1B A
F 1C
11
A 2F
19
1D
11A
2L
2D
1A
B
2M
F1
10 9
10A
20 2C
B N2
S T F2
2B
2A
2N N1
8A
8 A293711
9804/1103
20 - 20 - 02/36
3620 - E/5-2.4
Issue 1
CONTENTS
20 - 20 - 02/37
Loadalls
530 Construction Circuit Diagram - Hydraulic
From m/c no. 767001 to 770616
14 P1
14B
B A C
A
D
P2
14C
B
17
14A T
17A
17C
B 16
18
A
P 17D
17B
13
17E P1
V
C
13C
B A C
A 13G
P2
D
B
2K
2L
13A
13D 13B
5 R
L 3
3B 4
T
3A A 3C P
2G
LS 2
T
12
B
2M
2L
2K A 2E
2J
2H
B
10 9
11
2M
LS
EF
P
1E
11A
A
1
2F
10A
B
1E 2M 1B
1D F
A 1C
2D
1A N1
F1 S
2M 20
2C
N2
B
B
2N 2B T
2A 8A
P
8 A259692
9804/1103
20 - 20 - 02/37
3630 - E/5-3.3
Issue 1
CONTENTS
Loadalls
530 Construction Circuit Diagrams - Hydraulic (cont’d) Component Key B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 3 3A 3B 3C 4 5 8 8A 9 10 10A 11 11A 12 13 13A 13B 13C 13D 13G 14 14A 14B 14C 16 17 17A 17B 17C 17D 17E 18
From m/c no. 767001 to 770616
Pressure cap breather Filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction line Tank Pump assembly - see Note 1. Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (M.R.V.) Pressure reducing valve (20 bar) Pressure maintaining valve (10 bar) Lift spool Tilt spool Extension spool Auxiliary spool (open centre, see 13G) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) (Sway ram option A.R.V) Auxiliary relief valve (A.R.V.) (Sway ram option A.R.V) Load hold check valves (L.H.C.V's) Accumulator Steering unit Steer valve Shock valves (option) Main relief valve Cooling fan motor Cooler Lift ram Lift ram check valve Displacement ram Tilt ram Tilt ram check valve Extension ram Extension ram check valve Auxiliary 1 boom quick release couplings Auxiliary 1 with sway option Sway ram Sway ram check valve Auxiliary 1 boom quick release couplings Diverter valve (chassis) Sway/auxiliary spool (motor spool, see 2G) Auxiliary 1 and 2 option Diverter valve (boom) Auxiliary 2 boom quick release couplings Auxiliary 1 boom quick release couplings Rear power track rod Steer mode valve 2 Wheel steer solenoid 4 Wheel and crab steer solenoid 4 Wheel steer solenoid Crab steer solenoid Steering anti-cavitation valve Front power track rod
9804/1103
20 - 20 - 02/38
20
Restricted non return valve
Note 1: From machine S/N 771430 the positions of fan pump 1B and steer pump 1C of pump assembly 1 are reversed.
20 - 20 - 02/38
3630 - E/5-4.3
Issue 1
CONTENTS
Loadalls
530, 540 Construction with Single Lever Controls Circuit Diagrams - Hydraulics Component Key
From m/c no. 767001 to 770617
B Pressure cap breather F Filter F1 Filter by-pass F2 See Note 1. N1 Neutral circuit feed line N2 Neutral circuit return line S Pump suction strainer T Tank 1 Pump assembly - see Note 2. 1A Main pump 1B Fan pump 1C Steer pump 1D Priority valve 1E Test points 2 Valve block 2A Main relief valve (M.R.V.) 2B Pressure reducing valve (20 bar) 2C Pressure maintaining valve (10 bar) 2D Lift spool 2E Extension spool 2F Tilt spool 2G Auxiliary spool 2H Auxiliary relief valve (A.R.V.) 2J Auxiliary relief valve (A.R.V.) 2K Auxiliary relief valve (A.R.V.) (Sway ram option A.R.V.) 2L Auxiliary relief valve (A.R.V.) (Sway ram option A.R.V.) 2M Load hold check valves (L.H.C.V's) 2N Accumulator 3 Steering unit 3A Steer valve 3B Shock valves (option) 3C Main relief valve 4 Cooling fan motor 5 Cooler (if fitted) 8 Lift ram 8A Lift ram check valve 9 Displacement ram 10 Tilt ram 10A Tilt ram check valve 11 Extension ram 11A Extension ram check valve 11B Auxiliary relief valve (A.R.V.) (540 only) 11C Auxiliary relief valve (A.R.V.) (540 only) 12 Auxiliary 1 boom quick release couplings 13 Auxiliary 1 with sway option (if fitted) 13A Sway ram (if fitted) 13B Sway ram check valve (if fitted) 13C Auxiliary 1 boom quick release couplings 13D Diverter valve (chassis) 13E Diverter valve 13G Sway/auxiliary spool 14 Auxiliary 1 and 2 option 14A Diverter valve (boom) - See Note 3. 14B Auxiliary 2 boom quick release couplings 14C Auxiliary 1 boom quick release couplings 15 Auxiliary 1 and 2 with hydraulic pin lock option 15A Diverter valve - See Note 3. 15B Auxiliary 1 boom quick release couplings 15C Auxiliary 2 boom quick release couplings 15D Hydraulic pin lock ram 15E Manual change over valve
9804/1103
20 - 20 - 02/39
16 16A 16B 16C 16D 16E 17 17A 17B 17C 17D 17E 18 19 19A 19B 19C 19D 20 21
Auxiliary 1 with trailer hitch option Diverter valve (chassis) - See Note 3. Trailer hitch ram Auxiliary 1 boom quick release couplings Trailer/Auxiliary quick release coupling Restrictor adaptor - See Note 4. Steer mode valve 2 Wheel steer solenoid 4 Wheel and crab steer solenoid 4 Wheel steer solenoid Crab steer solenoid Steering anti-cavitation valve - See Note 5. Front power track rod Trailer brake valve assembly option Pilot valve Brake valve Trailer brake coupling Brake circuit connection Restricted non return valve Rear power track rod
Note 1: Later machines have direct return to tank from the filter F. Note 2: From machine S/N 771430 the positions of fan pump 1B and steer pump 1C of pump assembly 1 are reversed. Note 3: Ports B and C of items 14A, 15A and 16A were Ports A and D on machines prior to serial number 775468. Note 4: Restrictor adaptor 16E fitted to improve hitch control on machines fitted with a pickup hitch option. See Technical Information Bulletin 5/195 (E191). Note 5: Steering anti-cavitation valve 17E is by-passed, as shown on inset Z, on machines from S/N 773054.
20 - 20 - 02/39
3630 - E/5-5.5
Issue 1
CONTENTS
20 - 20 - 02/40
Loadalls
530, 540 Construction with Single Lever Control Circuit Diagram - Hydraulic (cont’d)
From m/c no. 767001 to 770617
16
16E
16D
16C Z 17
15
17E 17A
16B
16A
17C
18
15E
15B
21
15D 15C
17B
Y
17D
15A 17E 14
3
14C
14B
14A 13 13G
5
3 3B
2M
19C
2K
2L
4
13A 2
13B
3A
13E
13D 13C 2G
19D 3C
2M B2
19A
2K
2L
2H
2J
12
11A
11
19B 2F
B1 2M
19 1
2E 1E 2M
11B 11C
1B
1D F 1C
10 9
1A
F1
2D N1
2M 20
B
N2 2B T S
10A
2C 2A
2N 8A
F2
8 A293721
9804/1103
20 - 20 - 02/40
3620 - E/5-6.4
Issue 1
CONTENTS
20 - 20 - 02/41
Loadalls
530 Construction with Single Lever Control Circuit Diagram - Hydraulic (cont’d)
From m/c no. 775402
16 16A
15 16C
17
18 15B
16D
16B
15A
15C 14D 14F 14E
14 L
3
14B
14C
13B
13C
R
3B 14A
A
13 2 3A
4 A
LS
13A
2G
3C P
B
B
12
2M
T
2K
11A
11
2L A
2F B
2M 2H
2J A
LS
P
1
EF
2E
B
1E 2M 1C 1D
10
P
F
1B
F1
9
A
1A
2D B
2280 rev/min
2M
19 B
2A
S
N1
T
8A N2
9804/1103
10A
20 - 20 - 02/41
3630 - E/5-7.3
8
Issue 1
CONTENTS
Loadalls
530 Construction with Manual Auxiliary Controls Circuit Diagrams - Hydraulics (cont’d) Component Key B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 3 3A 3B 3C 4 8A 9 10 10A 11 11A 12 13 13A 13B 13C 14 14A 14B 14C 14D 14E 14F 15 16 16A 16B 16C 16D 17 18 19
Pressure cap breather Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (MRV) Lift spool Extension spool Tilt spool Auxiliary spool Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Load hold check valves (LHCVs) Steering unit Steer valve Shock valves (option) Main relief valve Cooling fan motor8 Lift ram Counter-balance valve Displacement ram Tilt ram Counter-balance valve Extension ram Counter-balance valve Auxiliary 1 boom quick release couplings Second auxiliary option Diverter valve (boom) Auxiliary 1 boom quick release couplings Auxiliary 2 boom quick release couplings Second auxiliary with hydraulic pin locking option Diverter valve (boom) Auxiliary 1 boom quick release couplings Auxiliary 2 boom quick release couplings Manual change-over valve Flow restrictor Hydraulic pin locking cylinder Sway option Steer mode valve - See Note 1. Two Wheel steer solenoid Four Wheel and crab steer solenoid Four Wheel steer solenoid Crab steer solenoid Front power track-rod Rear power track-rod Restricted non return valve
9804/1103
20 - 20 - 02/42
From m/c no. 775402
Note 1: Pump flow goes direct to the fan motor on non-sway machines. Note 2: Electrically operated steer mode valve shown. Manual version also available.
20 - 20 - 02/42
3630 - E/5-8.3
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/41A
530 Construction Machines with Manual Auxiliary Controls - fitted with 2-stage pump (From Serial No. TBA) Circuit Diagrams - Hydraulics Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The two stage pump assembly comprises two sections each of which supplies oil to parts of the circuit as follows: 1A Steer/valve block/auxiliary options 1B Fan motor The main services pump 1A has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve, oil flows from the EF port to the control valve to provide loading auxiliary services. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 N1 N2 S T 1 1A 1B 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 3 3A 3B 3C 4 4A 5 5A 5B 8 8A 9 10
Pressure cap breather (if fitted) Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly Main pump Fan pump Priority valve Test points Valve block Main relief valve (MRV) Lift Spool Extension spool Tilt spool Auxiliary spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Load hold check valves (LHCVs) Steer unit assembly (Early type shown on main circuit at X, later type shown in inset Y) Steer valve Shock valves (option) Main relief valve Cooling fan motor (non-reversible) Relief valve - 190 bar (to M78434) Relief valve - 108 bar (from M78435) Reversible cooling fan motor option Relief valves Fan change-over solenoid Lift ram Counter-balance valve Displacement ram Tilt ram
9804/1103
10A 11 11A 12
Counter-balance valve Extension ram Counter-balance valve Auxiliary 1 boom quick release couplings (standard build) 13 Second auxiliary option 13A Diverter valve (boom) 13B Auxiliary 1 boom quick release couplings 13C Auxiliary 2 boom quick release couplings 14 Second auxiliary with hydraulic pin locking option 14A Diverter valve (boom) 14B Auxiliary 1 boom quick release couplings 14C Auxiliary 2 boom quick release couplings 14D Manual change-over valve 14E Flow restrictor 14F Hydraulic pin locking cylinder 15 Sway control valve option 15A One way restrictors 15B Pilot operated check-valve 15C Sway hydraulic cylinder 16 Steer mode valve - See Note 2 16A Two wheel steer solenoid 16B Four wheel and crab steer solenoid 16C Four wheel steer solenoid 16D Crab steer solenoid 17 Front power track rod 18 Rear power track rod 19 Restricted non return valve 20 Lift circuit with optional Smooth Ride System (SRS) 20A Solenoid valve 20B Solenoid valve 20C Accumulators 20D Pressure switch
Note 1: Pump flow goes directt to the fan motor on nonsway machines Note 2: Electrically operated steer mode valve shown. Manual version also available.
20 - 20 - 02/41A
3630 - E/5-9.5
Issue 1*
Loadalls
CONTENTS
20 - 20 - 02/42A
530 Construction Machines with Manual Auxiliary Controls - fitted with 2-stage pump Circuit Diagram - Hydraulic
From Serial No. TBA
16 16A
15
16C
18
17
15B
16D
16B
15A
4A 15C B
A
T
P
14D 14F 14E
3
14
L
14B
14C
R
3C 14A
A
3A
13
2
B
13C
13B
4
LS
3B T
A
2G
3D
12
2M
P
13A
B
2K
11
11A
2L A
2F B
1E LS
P
2M
1
EF
2H
2J A
2E
1D
1B
1A 16
B
2M
10
36
A
2280 RPM
9
2D
F
B
F1
2M
19 B
10A
2A
8 8A
S
N1
T
20
20D
N2 8A
8
20B
20A 4
20C
9804/1103
20 - 20 - 02/42A
160-02300-4
3660 - E/5-10.5
Issue 1*
CONTENTS
Loadalls
20 - 20 - 02/41B
530 Construction Machines with Manual Auxiliary Controls - fitted with 3-stage pump (From Serial No. 775402) Circuit Diagram - Hydraulics Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The two stage pump assembly comprises two sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/auxiliary options 1B Fan motor 1C Steer valve The steer pump 1C has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve, oil returns back to the tank. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 3 3A 3B 3C 4 4A 5 5A 5B 8 8A 9 10
Pressure cap breather (if fitted) Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (MRV) Lift Spool Extension spool Tilt spool Auxiliary spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Load hold check valves (LHCVs) Steer unit assembly (Early type shown on main circuit at X, later type shown in inset Y) Steer valve Shock valves (option) Main relief valve Cooling fan motor (non-reversible) Relief valve - 190 bar (to M78434) Relief valve - 108 bar (from M78435) Reversible cooling fan motor option Relief valves Fan change-over solenoid Lift ram Counter-balance valve Displacement ram Tilt ram
9804/1103
10A 11 11A 12
Counter-balance valve Extension ram Counter-balance valve Auxiliary 1 boom quick release couplings (standard build) 13 Second auxiliary option 13A Diverter valve (boom) 13B Auxiliary 1 boom quick release couplings 13C Auxiliary 2 boom quick release couplings 14 Second auxiliary with hydraulic pin locking option 14A Diverter valve (boom) 14B Auxiliary 1 boom quick release couplings 14C Auxiliary 2 boom quick release couplings 14D Manual change-over valve 14E Flow restrictor 14F Hydraulic pin locking cylinder 15 Sway control valve option 15A One way restrictors 15B Pilot operated check-valve 15C Sway hydraulic cylinder 16 Steer mode valve - See Note 2 16A Two wheel steer solenoid 16B Four wheel and crab steer solenoid 16C Four wheel steer solenoid 16D Crab steer solenoid 17 Front power track rod 18 Rear power track rod 19 Restricted non return valve 20 Lift circuit with optional Smooth Ride System (SRS) 20A Solenoid valve 20B Solenoid valve 20C Accumulators 20D Pressure switch
Note 1: Pump flow goes directt to the fan motor on nonsway machines Note 2: Electrically operated steer mode valve shown. Manual version also available.
20 - 20 - 02/41B
3630 - E/5-8.5
Issue 1*
Loadalls
CONTENTS
20 - 20 - 02/42B
530 Construction Machines with Manual Auxiliary Controls - fitted with 3-stage pump Circuit Diagram - Hydraulic
From Serial No. 775402
16 16A
15 16C
17
18 16D
16B
15B 15A
4A 15C B
A
T
P
14D 14F
a
Y
L
3
b R
a
X
L
3
14E
b
14
14B
14C
13B
13C
R
3B
3C
14A
A
13 B
2 3A
3A
3B
3D
3D
A
13A
2G
3C
P
P
T
4
LS
LS
B
12
2M
T
2K
11A
11
2L A
2F
c
B
c 2M
d
d
2H
2J A
LS
P
1
EF
2E
B
1E 2M 1C 1D
10
P
A
16 19 32
F
1B
F1
1A
9
2D B
2280 rev/min
2M
19 B
10A
2A
8 8A
S
N1
T
20
N2
20D
8A
8
20B
20A 4
160-02300-2
20C
9804/1103
20 - 20 - 02/42B
3660 - E/5-7.5
Issue 1*
CONTENTS
Loadalls
540 Construction with Manual Auxiliary Controls Circuit Diagrams - Hydraulics Component Key B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 3 3A 3B 3C 4 8 8A 9 10 10A 11 11A 12 13 13A 13B 13C 14 14A 14B 14C 14D 14E 14F 15 16 16A 16B 16C 16D 17 18 19
Pressure cap breather Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (MRV) Lift spool Extension spool Tilt spool Auxiliary spool Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Load hold check valves (LHCVs) Steering unit Steer valve Shock valves (option) Main relief valve Cooling fan motor Lift ram Counter-balance valve Displacement ram Tilt ram Counter-balance valve Extension ram Counter-balance valve Auxiliary 1 boom quick release couplings Second auxiliary option Diverter valve (boom) Auxiliary 1 boom quick release couplings Auxiliary 2 boom quick release couplings Second auxiliary with hydraulic pin locking option Diverter valve (boom) Auxiliary 1 boom quick release couplings Auxiliary 2 boom quick release couplings Manual change-over valve Flow restrictor Hydraulic pin locking cylinder Sway option Steer mode valve - See Note 1. Two Wheel steer solenoid Four Wheel and crab steer solenoid Four Wheel steer solenoid Crab steer solenoid Front power track-rod Rear power track-rod Restricted non return valve
9804/1103
20 - 20 - 02/43
From m/c no. 775402
Note 1: Electrically operated steer mode valve shown. Manual version also available.
20 - 20 - 02/43
3630 - E/5-9.3
Issue 1
Loadalls
CONTENTS
20 - 20 - 02/44
540 Construction with Manual Auxiliary Controls Circuit Diagrams - Hydraulic (cont’d)
From m/c no. 775402
16 16A
16C
17
14D
18
14E 14F
16D
16B
14B
14C
13B
13C
14 14A
13 L
3
13A
R
3B
2 3A
4
12
A
LS
2G B
3C P
2P
T
11A 2M
2N
11
A
2F B
2P 2K
2L
2E
1
A B
1E 2P 1C
2H
1D 1B
1A
F
10
2J A
2D
9
B
2280 rev/min
2P
B
19
F1
10A
2A
N2
8 T
9804/1103
3630 - E/5-10.3
S
N1
20 - 20 - 02/44
8A
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/43A
540 Construction Machines with Manual Auxiliary Controls - fitted with 3-stage pump (From Serial No. 775402) Circuit Diagram - Hydraulics Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The two stage pump assembly comprises two sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/auxiliary options 1B Fan motor 1C Steer valve The steer pump 1C has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve, oil returns back to the tank. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 3 3A 3B 3C 4 4A 5 5A 5B 8 8A
Pressure cap breather Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (MRV) Lift Spool Extension spool Tilt spool Auxiliary spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Load hold check valves (LHCVs) Steer unit assembly (Early type shown on main circuit at X, later type shown in inset Y) Steer valve Shock valves (option) Main relief valve Cooling fan motor (non-reversible) Relief valve - 190 bar (to M78434) Relief valve - 108 bar (from M78435) Reversible cooling fan motor option Relief valves Fan change-over solenoid Lift ram Counter-balance valve
9804/1103
9 Displacement ram 10 Tilt ram 10A Counter-balance valve 11 Extension ram 11A Counter-balance valve 12 Auxiliary 1 boom quick release couplings 13 Second auxiliary option 13A Diverter valve (boom) 13B Auxiliary 1 boom quick release couplings 13C Auxiliary 2 boom quick release couplings 14 Second auxiliary with hydraulic pin locking option 14A Diverter valve (boom) 14B Auxiliary 1 boom quick release couplings 14C Auxiliary 2 boom quick release couplings 14D Manual change-over valve 14E Flow restrictor 14F Hydraulic pin locking cylinder 15 Sway option 16 Steer mode valve - See Note 1 16A Two wheel steer solenoid 16B Four wheel and crab steer solenoid 16C Four wheel steer solenoid 16D Crab steer solenoid 17 Front power track rod 18 Rear power track rod 19 Restricted non return valve 20 Lift circuit with optional Smooth Ride System (SRS) 20A Solenoid valve 20B Solenoid valve 20C Accumulators 20D Pressure switch
Note 1: Electrically operated steer mode valve shown. Manual version also available.
20 - 20 - 02/43A
3630 - E/5-12.4
Issue 1*
Loadalls
CONTENTS
20 - 20 - 02/44A
540 Construction Machines with Manual Auxiliary Controls Circuit Diagram - Hydraulic
From Serial No. 775402
17
13
17A
T
17C
T
B
18 P
F
16
A
13G 13F
P
17B
17D
13C
19C
SA
13B
19D
5
19
B
A
T
P
SB
13E
Y
13A
150 BAR
13D
19B
15C
5B
15B 15A
5A
a
Y
L
3
b R
a
X
b
L
3
R
P1
R
P2 B N
4
3C
20
19A P
12
3C
P1 c
2 4A
3A
3D
20E
2K
2L
B
21
2M
T
c
c A
2F
2H
d
d e
C
3B
P
P
20B
20A 2G
3D
20D
D
A
LS
LS
T
B P2
20C
A
d
3A
3B
15D
25
B
2J
24
2M
e
23
22
A LS
P
1
EF
24A
2E
B
1E 1D
1A 1B
F
2M
1C
P 16
19
A
32
2D
2280 rev/min
F1
B
28
27
2M
26
B 2A
T S F2
P
T
29
N1 N2
30 31 A343503 160/12719
9804/1103
20 - 20 - 02/44A
3660 - E/5-11.4
Issue 1*
20 - 20 - 02/45
Loadalls
CONTENTS
535-95 Circuit Diagrams - Hydraulic
From m/c no. 777362
17
13
17A
T
17C
T
B
18 P
17B
F
16
A
13G 13F
P
17D
19C
13C
13B
13D
15C
SA
19D
19
SB
13E
Y
13A
150 BAR
19B
15B 15A P1
R
15D
P2 B
3
L
N
R
20
19A
12
P
P1
4 c
3C
2
B P2
20C
A
20B
D
C
20E
d
3A
20D
20A A
2G
LS
3D
2K
3B
P
2L
21
B
2M
T
A
2F
2H
25
B
2J
24
2M
LS
P
1
EF
1A 1B
F
16
19
B
Retract
23
22
2M
1C
P
Extend 24A
2E 1E
1D
A
A
32
2D
2280 rev/min
F1
B
28
27
2M
26
Crowd
B N2
2A
N1
Dump
T S
P
29
T Dump
F2 Lift
30 31
A343501
9804/1103
20 - 20 - 02/45
3630 - E/5-11.2
Issue 1
CONTENTS
Loadalls
535-95 Circuit Diagrams - Hydraulic (cont’d) Component Key B F F1 F2 S T N1 N2 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 3 3A 3B 3C 3D 4 12 13 13A 13B 13C 13D 13E 13F 13G 15A 15B 15C 15D 16 17 17A 17B 17C 17D 18 19 19A 19B 19C 19D 20 20A 20B 20C
From m/c no. 777362
Pressure cap breather Return line filter Filter by-pass Direct return to tank Pump suction strainer Tank Neutral circuit feed line Neutral circuit return line Pump assembly Main pump Fan pump Steer pump Priority valve Test point Valve block Main relief valve (MRV) Lift spool Extend spool Tilt spool Auxiliary spool Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Load hold check valves (LHCVs) Steer unit assembly Steering valve Main relief valve Shock valves (option) Non return valve Cooling fan motor Auxiliary 1 boom quick release couplings (standard build) Sway control valve (option) Sway ram Pilot operated check valve One-way restrictor One-way restrictor Relief valve Diverter valve Sway valve spool Hydraulic pin lock ram Restrictor Manual changeover valve Auxiliary 2 boom quick release couplings Rear power track rod Steer mode valve (option) 2 wheel steer solenoid 4 wheel and grab steer solenoid 4 wheel steer solenoid Crab steer solenoid Front power track rod Trailer brake valve assembly (option) Pilot valve Brake valve Trailer brake coupling Brake circuit connection Pick-up hitch (option) Solenoid diverter valve (chassis mounted) Pick-up hitch ram Auxiliary 1 boom quick release couplings
9804/1103
20 - 20 - 02/46
20D 20E 21 22 23 24 24A 25 26 27 28 29 30 31
Trailer/Auxiliary quick release coupling Restrictor adaptor - see Note 2 High flow auxiliary (option) Inner extension ram Extension ram check/counter balance valve Outer extension ram Bleed point Regenerative valve Tilt ram Tilt check/counterbalance valve Displacement ram Displacement lift valve Lift ram Lift check/counterbalance valve
Note 1: The schematic shows sway and trailer brake options. Pump flow goes direct to fan motor if sway is not fitted. Note 2: Restrictor adaptor 20E is fitted to improve hitch control on machines fitted with pick-up hitch option. See Technical Information Bulletin 5/195 (E191).
20 - 20-02/46
3630 - E/5-12.2
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/45A
535-95 Machines - fitted with 3-stage pump (From Serial No. 777362) Circuit Diagram - Hydraulics Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The two stage pump assembly comprises two sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/auxiliary options 1B Fan motor 1C Steer valve The steer pump 1C has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve, oil returns back to the tank. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 F2 S T N1 N2 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 3 3A 3B 3C 3D 4 4A 5 5A 5B 12 13 13A
Pressure cap breather Return line filter Filter by-pass Direct return to tank Pump suction strainer Tank Neutral circuit feed line Neutral circuit return line Pump assembly Main services pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (MRV) Lift Spool Extension spool Tilt spool Auxiliary spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Steer unit assembly Steer valve Main relief valve Shock valves (option) Non-return valve Cooling fan motor (non-reversible) Relief valve - 190 bar (to M78434) Relief valve - 108 bar (from M78435) Reversible cooling fan motor option Relief valves (108 bar) Fan change-over solenoid Auxiliary 1 boom quick release couplings (standard build) Sway control valve (option) Sway ram
9804/1103
13B Pilot operated check valve 13C One-way restrictor 13D One-way restrictor 13E Relief valve 13F Diverter valve 13G Sway valve spool 15A Hydraulic pin lock ram 15B Restrictor 15C Manual changeover valve 15D Auxiliary 2 boom quick release couplings 16 Rear power track rod 17 Steer mode valve (option) 17A 2 wheel steer solenoid 17B 4 wheel and grab steer solenoid 17C 4 wheel steer solenoid 17D Crab steer solenoid 18 Front power track rod 19 Trailer brake valve assembly (option) 19A Pilot valve 19B Brake valve 19C Trailer brake coupling 19D Brake circuit connection 20 Pick-up hitch (option) 20A Solenoid diverter valve (chasis mounted) 20B Pick-up hitch ram 20C Auxiliary 1 boom quick release couplings 20D Trailer/Auxiliary quick release coupling 20E Restrictor adaptor 21 High flow auxiliary (option) 22 Inner extension ram 23 Extension ram check/counter balance valve 24 Outer extension ram 24A Bleed point 25 Regenerative valve 26 Tilt ram 27 Tilt check/counterbalance valve 28 Displacement ram 29 Displacement lift valve 30 Lift ram 31 Lift check/counterbalance valve
Note 1: The schematic shows sway and trailer brake options. Pump flow goes direct to fan motor if sway is not fitted. Note 2: Restrictor adaptor 20E is fitted to improve hitch control on machines fitted with pick-up hitch option. See Technical Information Bulletin 5/195 (E191).
20 - 20 - 02/45A
3630 - E/5-13.2
Issue 1*
Loadalls
CONTENTS
20 - 20 - 02/46A
535-95 Machines - fitted with 3-stage pump Circuit Diagram - Hydraulic
From Serial No. 777362
17
13
17A
T
17C
T
B
18
F
16
A
P
13G 13F
P
17B
17D
19C
13C
13B
13D
15C
SA
19D
5
19
B
A
T
P
SB
13E
Y
13A
150 BAR
19B
5B
15B 15A
5A
P1
R
15D
P2 B
3
L
R
N
4
20
19A P
12
P1 c
3C
2
B P2
20C
A
4A
20B
D
C
20E
d
3A
20D
20A A
2G
LS
3D
2K
2L
21
B
3B
P
2M
T
A
d
b b c 1E LS
P
Y
LS
P
P
1
EF
16
36
1A
a
e
B
Retract
23
22
A
32
a
F1
2280 rev/min
19
Extend
2M 1A
16
A
24A
2E
1C
P
1B
F 1B
24
1E 1D
1D
25
B
2J
X
1
EF
2H
2M
c
d
2F
2280 rev/min
2D
e
B
28
27
2M
26
B N2
2A
N1
N1
T
P
29
T
S F2
30 31 A343502 A343502
9804/1103
20 - 20 - 02/46A
3660 - E/5-14.2
Issue 1*
CONTENTS
Loadalls
20 - 20 - 02/45B
535-95 Machines - fitted with 2-stage pump (From Serial No. TBA) Circuit Diagram - Hydraulics Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The two stage pump assembly comprises two sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/auxiliary options 1B Fan motor 1C Steer valve The steer pump 1C has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve, oil returns back to the tank. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 F2 S T N1 N2 1 1A 1B 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 3 3A 3B 3C 3D 4 4A 5 5A 5B 12
Pressure cap breather Return line filter Filter by-pass Direct return to tank Pump suction strainer Tank Neutral circuit feed line Neutral circuit return line Pump assembly Main services pump Fan pump Priority valve Test points Valve block Main relief valve (MRV) Lift Spool Extend spool Tilt spool Auxiliary spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Steer unit assembly Steering valve Main relief valve Shock valves (option) Non-return valve Cooling fan motor (non-reversible) Relief valve - 108 bar Reversible cooling fan motor option Relief valves (108 bar) Fan change-over solenoid Auxiliary 1 boom quick release couplings (standard build) 13 Sway control valve (option) 13A Sway ram
9804/1103
13B Pilot operated check valve 13C One-way restrictor 13D One-way restrictor 13E Relief valve 13F Diverter valve 13G Sway valve spool 15A Hydraulic pin lock ram 15B Restrictor 15C Manual changeover valve 15D Auxiliary 2 boom quick release couplings 16 Rear power track rod 17 Steer mode valve (option) 17A 2 wheel steer solenoid 17B 4 wheel and grab steer solenoid 17C 4 wheel steer solenoid 17D Crab steer solenoid 18 Front power track rod 19 Trailer brake valve assembly (option) 19A Pilot valve 19B Brake valve 19C Trailer brake coupling 19D Brake circuit connection 20 Pick-up hitch (option) 20A Solenoid diverter valve (chasis mounted) 20B Pick-up hitch ram 20C Auxiliary 1 boom quick release couplings 20D Trailer/Auxiliary quick release coupling 20E Restrictor adaptor 21 High flow auxiliary (option) 22 Inner extension ram 23 Extension ram check/counter balance valve 24 Outer extension ram 24A Bleed point 25 Regenerative valve 26 Tilt ram 27 Tilt check/counterbalance valve 28 Displacement ram 29 Displacement lift valve 30 Lift ram 31 Lift check/counterbalance valve
Note 1: The schematic shows sway and trailer brake options. Pump flow goes direct to fan motor if sway is not fitted. Note 2: Restrictor adaptor 20E is fitted to improve hitch control on machines fitted with pick-up hitch option. See Technical Information Bulletin 5/195 (E191).
20 - 20 - 02/45B
3630 - E/5-16.1
Issue 1*
Loadalls
CONTENTS
20 - 20 - 02/46B
535-95 Machines - fitted with 2-stage pump Circuit Diagram - Hydraulic
From Serial No. TBA
17
13
17A
T
17C
T
B
18 P
F
16
A
13G 13F
P
17B
17D
13C
19C
SA
13B
19D
5
19
B
A
T
P
SB
13E
Y
13A
150 BAR
13D
19B
15C
5B
15B 15A
5A
a
Y
L
3
b R
a
X
b
L
3
R
P1
R
P2 B N
4
3C
20
19A P
12
3C
P1 c
2 4A
3A
3D
C
2K
2L
B
21
2M
T
c
c A
2F
2H
d
d e
20E
3B
P
P
20B
20A 2G
3D
20D
D
A
LS
LS
T
B P2
20C
A
d
3A
3B
15D
25
B
2J
24
2M
e
23
22
A LS
P
1
EF
24A
2E
B
1E 1D
1A 1B
F
2M
1C
P 16
19
A
32
2D
2280 rev/min
F1
B
28
27
2M
26
B 2A
T S F2
P
29
T
N1 N2
30 31 A343503 160/12719
9804/1103
20 - 20 - 02/46B
3660 - E/5-15.1
Issue 1*
20 - 20 - 02/47
Loadalls
CONTENTS
532 to m/c no. 770638 537, 550 to m/c no. 770613 Circuit Diagrams - Hydraulic
6 T
6A
B
6D
5 P
7 T
A 6B
6C A
6E C
2K
V
5
7
22
22A
B
2Q A 2J 2
21A
21
B
2Q 20A C3
3
L
R
C1
2H
9
A
3B 4
20
2G
B
2Q
2M
2L
18A
19
A
3A 2F
2N
LS
16A
B
3C T
16
17
2P
2Q P
18 C4
C2
A 2E
B 15
2Q
13E
13 13B
A 2D LS
P
1E
EF
1
13D
1B 1C
14
13C
2Q
1E 1D
B
11A 13A
2C
12
11
2R
1A
2B 2A
8A
N2
B
F1
P
T
9804/1103
8
F
S
A260812
N1
20 - 20 - 02/47
3660 - E/5-1.1
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/48
532 to m/c no. 770638 537, 550 to m/c no. 770613 Circuit Diagrams - Hydraulic (cont’d) B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 2Q 2R 3 3A 3B 3C 4 5 6 6A 6B 6C 6D 6E 7 8 8A 9 11 11A 12 13 13A 13B 13C 13D 13E 14 15 16 16A 17 18
Pressure cap breather Filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction line Tank Pump assembly - see Note 1. Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (M.R.V.) Pressure reducing valve (20 bar) Pressure maintaining valve (10 bar) Lift spool Extension spool Tilt spool Sway/Auxiliary spool (motor spool with sway only) Unloader valve Right hand stabiliser spool Left hand stabiliser spool Auxiliary relief valve (A.R.V) (Sway ram option A.R.V.) Auxiliary relief valve (A.R.V) (Sway ram option A.R.V.) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valves (L.H.C.V's) Accumulator (only fitted with auxiliary circuit) Steering unit Steer valve Shock valves (option) Main relief valve Cooling fan motor Front steer rams Steer mode valve 2 Wheel steer solenoid 4 Wheel and crab steer solenoid 4 Wheel steer solenoid Crab steer solenoid Steering anti-cavitation valve Rear steer rams Lift ram Lift ram check valve Cooler Inner extension ram Inner extension ram check valve Outer extension ram Regenerative valve Hose burst check valve Relief Valve Check valve Non-return valve Non-return valve Regenerative circuit bleed valve Restricted non return valve Tilt ram Tilt ram check valve Displacement rams Sway ram
9804/1103
18A 19 20 20A 21 21A 22 22A
Sway ram check valve Auxiliary 1 boom quick release couplings Diverter valve (chassis) Diverter valve - see Note 2. Right hand stabiliser ram Right hand stabiliser ram check valve Left hand stabiliser ram Left hand stabiliser ram check valve
Note 1: From machine S/N 771429 the positions of fan pump 1B and steer pump 1C of pump assembly 1 are reversed. Note 2: See FSI 5/151 (E164 N.Am) and 5/152 (E166 N.Am) for details of diverter valve 20A.
20 - 20 - 02/48
3660 - E/5-2.1
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/49
532 from m/c no. 770689 to 775401 537, 550 from m/c no. 770614 to 775401 Circuit Diagrams - Hydraulics B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 2Q 2R 2S 3 3A 3B 3C 4 5 6 6A 6B 6C 6D 6E 7 8 8A 9 11 11A 12 13 13A 13B 13C 13D 13E 14 15 16 16A 17
Pressure cap breather Filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly -see Note 1. Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (M.R.V.) Pressure reducing valve (20 bar) Pressure maintaining valve (10 bar) Lift spool Extension spool Tilt spool Sway/Auxiliary spool Unloader valve Right hand stabiliser spool Left hand stabiliser spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valves (L.H.C.V's) Accumulator (only fitted with auxiliary circuit) Extension motor spool - see Note 2 Steering unit Steer valve Shock valves (option) Main relief valve Cooling fan motor Front steer rams Steer mode valve 2 Wheel steer solenoid 4 Wheel and crab steer solenoid 4 Wheel steer solenoid Crab steer solenoid Steering anti-cavitation valve - see Note 3. Rear steer rams Lift ram Lift ram check valve Cooler Inner extension ram Inner extension ram check valve Outer extension ram Regenerative valve Hose burst check valve Relief Valve Check valve Non-return valve Non-return valve Regenerative circuit bleed valve Restricted non return valve Tilt ram Tilt ram check valve Displacement rams
9804/1103
18 18A 18B 19 20 20A 21 21A 22 22A
Sway ram Pilot check valve (sway ram) Sway function in-line restrictor Auxiliary 1 boom quick release couplings Diverter valve (chassis) Diverter valve (chassis) Right hand stabiliser ram Right hand stabiliser ram check valve Left hand stabiliser ram Left hand stabiliser ram check valve
Note 1: From machine S/N 771429 the positions of fan pump 1B and steer pump 1C of pump assembly 1 are reversed. Note 2: Revised extend spool fitted due to boom over-run on machines prior to S/N 772366. Note 3: Steering anti-cavitation valve 6E is by-passed via connector Y, as shown on inset Z, on machines from S/N 773135. The anti-cavitation valve is not fitted from machine S/N 773630.
20 - 20 - 02/49
3660 - E/5-3.1
Issue 1
CONTENTS
20 - 20 - 02/50
Loadalls
532 from m/c no. 770639 to 775401 537, 550 from m/c no. 770614 to 775401 Circuit Diagrams - Hydraulic (cont’d)
6 6A
6D
7
5
T 6B
2
6C
22A 6E
2K 22
5
7 21A
2J 2Q 3
21 20
9
3B
20A
2H 4
18B 18A
2G
3A
18 2Q 2L
3C
2M
19
2F 1E
2N
2Q 1
6E
2P
1E
16
17
2E 1B 1D Y
15
2Q
13E
1A
1C
13 13B 14
2D 3
13C
2Q
N2
13D
13A B
F
F1
16A
12
11A
11
2C 2R 2B
2A
T S
8A
P N1
9804/1103
8 A293731
20 - 20 - 02/50
3660 - E/5-4.1
Issue 1
CONTENTS
20 - 20 - 02/51
Loadalls
532, 537, 550 with Manual Auxiliary Controls Circuit Diagrams - Hydraulics
From m/c no. 775402
19 19C
19A
18B 19B
19D
18A
2
21
20
18C
A
2K
17A B
2R
17
A
2J L
19
17B B
L
16A
2R 2H
4
16 16B
15 LS
A
2G B
T
P
2R
1E
2N 1E
2P
A
2F
1
B
1E
14A
2R
1C
2L
1D
2M
A
2E 1B
14
13
12
11
B
1A
11B
2R A
2D B
N2
10A
11C
10
9
11D
9A
2R
B
11A
F
F1 2A
8
S T
9804/1103
8A N1
20 - 20 - 02/51
3660 - E/5-5.1
Issue 1
CONTENTS
Loadalls
532, 537, & 550 Machines with Manual Auxiliary Controls Circuit Diagram - Hydraulics
20 - 20 - 02/52
From Serial No. 775402
Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The pump assembly comprises three sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/auxiliary options 1B Fan motor 1C Steer valve The pump is mounted on the rear face of the bevel box. The valve block is mounted under the cab on the inboard side The steer pump 1C has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve, oil returns back to the tank. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 2R 3 3A 3B 3C
Pressure cap breather Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (M.R.V.) Lift spool Extension spool Tilt spool Auxiliary spool Unloader valve Right hand stabilizer Left hand stabilizer Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Load hold check-valves (LHCVs) Steering unit Steer valves Shock valves Main relief valve
9804/1103
4 Cooling fan motor (non-reversible) * 4A Reversible cooling fan motor option (from Serial No. 785165) 8 Lift ram 8A Counter balance valve 9 Inner extension ram 9A Counter balance valve 10 Outer extension ram 11 Regenerative valve 11A Hose burst check-valve (HBCV) 11B Relief valve 11C Check valve 11D Non-return valve 11E Non return valve 12 Restricted non-return valve 13 Displacement cylinders 14 Tilt ram 14A Counter-balance valve 15 Auxiliary 1 boom quick release couplings 16 Right hand stabilizer hydraulic cylinder 16A Stabilizer lock-out valve 16B Pressure switch (option) 17 Left hand stablizer hydraulic cylinder 17A Stabilizer lock-out valve 17B Pressure switch (option) 18 Sway control valve option 18A One-way restrictor 18B Pilot operated check-valve 18C Sway hydraulic cylinder * 18D relief valve (150 bar) 19 Steer mode valve - see Note 2 19A Two wheel steer solenoid 19B Four wheel and crab steer solenoid 19C Four wheel steer solenoid 19D Crab steer solenoid 20 Front steer cylinders 21 Rear steer cylinders
Note 1: Pump flows goes direct ro the fan motor on nonsway machines. Note 2: Electrically operated steer mode valve shown. Manual version also available.
20 - 20 - 02/52
3630 - E/5-6.2
Issue 2*
CONTENTS
Loadalls
20 - 20 - 02/53
506B Circuit Diagrams - Hydraulics Component Key
C F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2E 2F 2G 2L 2M 2N 2P 2Q 2R 2S 2T 2U 2V 2X 10 10A 11 12 13 13A 14 15 15A 16 17 18 29 30 31 32 33 34A 34B 35 36 41 42 43
Cap Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Auxiliary spool Tilt spool Extension spool (See Note 1) Sway spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Load hold check valve (L.H.C.V.) Load hold check valve (L.H.C.V.) Load hold check valve (L.H.C.V.) Load hold check valve (L.H.C.V.) Load hold check valve (L.H.C.V.) Pressure test point Lift cylinders Lift cylinder check valves Displacement cylinder Extension cylinder Tilt cylinder Tilt cylinder check valve Non-return valve Sway cylinder Sway cylinder check valve Regenerative valve Hose burst protection valve Combined load hold check and regenerative valve Steering anti-cavitation valve Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steering mode valve Steering mode valve Front axle steering cylinders Rear axle steering cylinders Cooling fan motor Auxiliary attachment cylinder In-line ARV (See Note 2)
9804/1103
Note 1: Machines from serial number 572655 have a combined load hold check and regenerative valve 18 with a closed centre spool 2F fitted as standard. Some machines before 572655 may have valve 18 fitted. Check your machine. Note 2: An in-line ARV 43 is available for the boom retract service. See Technical Bulletin E193.
20 - 20 - 02/53
3640U - E/4-1.2
Issue 1
Loadalls
CONTENTS
20 - 20 - 02/54
506B Circuit Diagrams - Hydraulics (cont’d)
12 12 16 35
18
C2
16C
C1
42
16D
16B
13
18B
13A
17 34A 18A
C2 34B
18C
11
P V1
V2 T
V2
36 15A
15
2F
10
L
33 R
P
10A
10A
P
29
T
14 V
C
2Q
2P A S2
B
A
B
A
B
A
B
A
B
2 2X
31
P2
S3
P3
C P1
30
2M
43
2L
2N
2A
S1 2G
F
2E
2F 2V
2U
2T
1B
2B
2C 2S
2R
1A
32 41
9804/1103
3640U - E/4-2.2
20 - 20 - 02/54
T
Issue 1
20 - 20 - 02/55
Loadalls
CONTENTS
506C Circuit Diagrams - Hydraulics (cont’d)
35
P A
B
34
16 13 T
12 13A
36 18
C2
C1
11
18B L
33
R 18C
15
15A
18A
10
33A V2
V1
10A
33C
10A
See Note P
T
29
14 V
C LS
P
EF
P1
2W A
B
A
B
2Q
2P A
B
A
B
A
B
2 C P1C
S1
2A
P1B S3
P1A
42 2G
P3
2V
2M
2N
2L
2F
2E
2C
2U
2T
1B
2B 2S
2R
1A
F 41 T
9804/1103
20 - 20 - 02/55
3640U - E/4-3.2
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/56
506C Circuit Diagrams - Hydraulics (cont’d) Component Key C Cap F Filter P1 Main pump assembly P1A Pump P1B Pressure test point P1C Priority valve P3 Cooling fan pump S1 Main pump suction line S3 Cooling fan pump suction line T Tank 1A Neutral circuit feed line 1B Neutral circuit return line 2 Valve block 2A Main relief valve (M.R.V.) 2B Lift spool 2C Auxiliary spool 2E Tilt spool 2F Extension spool 2G Sway spool 2L Auxiliary relief valve (A.R.V.) 2M Auxiliary relief valve (A.R.V.) 2N Auxiliary relief valve (A.R.V.) 2P Auxiliary relief valve (A.R.V.) 2Q Auxiliary relief valve (A.R.V.) 2R Load hold check valve (L.H.C.V.) 2S Load hold check valve (L.H.C.V.) 2T Load hold check valve (L.H.C.V.) 2U Load hold check valve (L.H.C.V.) 2V Load hold check valve (L.H.C.V.) 2W Auxiliary relief valve (A.R.V.) (See Note 2) 10 Lift cylinders 10A Lift cylinder check valves 11 Displacement cylinder 12 Extension cylinder 13 Tilt cylinder 13A Tilt cylinder check valve 14 Non-return valve 15 Sway cylinder 15A Sway cylinder check valve 16 Auxiliary attachment cylinder 18 Combined load hold check and regenerative valve 18A Retract load hold check valve 18B Regenerative check valve 18C Extend load hold check valve 29 Steering anti-cavitation valve (See Note 1) 33 Steering unit 33A Steer valve 33C Main relief valve 34 Steering mode selctor valve 35 Front axle steering cylinders 36 Rear axle steering cylinders 41 Cooling fan motor 42 In-line ARV (See Note 2) Note 1: Anti-cavitation valve (item 29) is not fitted to machines from serial number 585873. Note 2: An in-line ARV 42 is available for the boom retract service on machines prior to 585208. See Technical Bulletin E193. Machines after 585208 have an ARV 2W fitted within the valve block.
9804/1103
20 - 20-02/56
3640U - E/4-4.1
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/57
506C (HL), 508C Circuit Diagrams - Hydraulics Component Key C F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2E 2F 2G 2L 2M 2N 2P 2Q 2R 2S 2T 2U 2V 2W 2X 10 10A 11 12 13 13A 15 15A 16 18 18A 18B 18C 29 30 31 32 33 33A 34 35 36 41 42 43
Cap Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Auxiliary spool Tilt spool Extension spool Sway spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Load hold check valve (L.H.C.V.) Load hold check valve (L.H.C.V.) Load hold check valve (L.H.C.V.) Load hold check valve (L.H.C.V.) Load hold check valve (L.H.C.V.) Auxiliary relief valve (A.R.V.) Pressure test point Lift cylinders Lift cylinder check valves Displacement cylinder Extension cylinder Tilt cylinder Tilt cylinder check valve Sway cylinder Sway cylinder check valve Auxiliary attachment cylinder Combined load hold check and regenerative valve Retract load hold check valve Regenerative check valve Extend load hold check valve Steering anti-cavitation valve Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steer valve Steering mode selctor valve Front axle steering cylinders Rear axle steering cylinders Cooling fan motor In-line ARV (See Note 1) Non-return valve (See Note 2)
9804/1103
Note 1: An in-line ARV 42 is available for the boom retract service on machines between 579569 and 585196. See Technical Bulletin E193. Machines after 585196 have an ARV 2W fitted within the valve block. Note 2: Non-return valve 43 fitted to 506C (HL) machines only.
20 - 20 - 02/57
3640U - E/4-5.2
Issue 1
20 - 20 - 02/58
Loadalls
CONTENTS
506C (HL), 508C Circuit Diagrams - Hydraulic (cont’d)
35
P A
B
34 16 13
T
12
13A
36 11 18
C2 L
33
C1
R 18B 15A
15 10
18C
18A 33A V2
P
V1 10A
T
10A
P
29
43 V
C
2W
A
S2
B
A
B
2Q
2P
A
B
A
B
A
B
2 31
2X
C
P3
S3
P1
P2
2L
2N
2M
42
30
2A
S1 2F
2G
F
2V
2E 2U
2T
1B
2B
2C 2S
2R
1A
32 41 T
9804/1103
20 - 20 - 02/58
3640U - E/4-6.2
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/59
540-170, 5508 with Servo Controls
From m/c no. 780925
Circuit Diagrams - Hydraulics 12
T
F
P
13B
13A
SA
T
5
SA
B
13
11 13B A
P
14A
A 11A
7
6
B
11Q
14
16 A
A
T
B
14B
11B B
15A
11Q
11C L
15
R
26
15B
1
8
11L 26A 26B 26C
T
26E 2
T
P LS
P
P2
3
26D
18
11R
17A
19
Extr
P
11N 11P Retm
A
11E
20
B
Ret
P4
21
Retr
2
11Q
16 33 41 P3 P2 P1
23
Lowm
4 Low
A Lowr
9 1
17
P1 Extm
1
3A
B
11Q
Ext
EF
3
A
11M
11D
4
B A
22
Liftr
T1
T
T
D
P1
11Q
Lift P
B
22A
C P2
Liftm
2
2
11F
V1
11G
B
Crdm
Crd
24
C1
11Q
1
24B
T2
C2
Dumpm
11J V2
Dump
24A
11K 11H T
25 10
25A A 10A
B
10E A 10B
B
10E
10C
9804/1103
20 - 20 - 02/59
3630- E/52-1.2 - C/26-1.5 3660
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/60
540-170, 5508 with Servo Controls Circuit Diagrams - Hydraulic (cont’d)
From m/c no. 780925
Component Key T P P1 P2 P3 P4 1 2 3 4 5 6 7 8
9
10 10A 10B 10C 10E 11 11A 11B 11C 11D 11E 11F 11G 11H 11J 11K 11L 11M 11N 11P 11Q 11R 12 13 13A 13B 14 14A 14B 15 15A 15B 16 17 17A 18 19 20 21 22
Tank Pump Main services pump Steer pump Sway/fan pump Priority flow diverter Pressure cap breather Return line filter Steering valve Engine cooling fan motor Steer mode valve Front steering cylinders Rear steering cylinders Two axis servo hand controller: Port 1 Lift Port 2 Retract Port 3 Lower Port 4 Extend Single axis servo hand controller: Port 1 Crowd Port 2 Dump Two spool valve block Extension spool Lift spool MRV Port A (240 bar) Load hold check valves (LHCV) Six spool valve block Left hand stabiliser spool Right hand stabiliser spool Unloader section Tilt spool Auxiliary spool Extension spool Lift spool MRV (260 bar) Pressure maintaining valve (10 bar) Pressure reducing valve (20 bar) Tilt ARV Port B (330 bar) Tilt ARV Port A (276 bar) Auxiliary ARV Port B ( 138 bar) Auxiliary ARV Port A (138 bar) Load hold check valves (LHCV) Tilt isolator section Sway control valve Sway cylinder Pilot operated check valve One way restrictor Left hand stabiliser cylinder Stabiliser lockout valve Pressure switch (35 bar) Right hand stabiliser cylinder Stabiliser lockout valve Pressure switch (35 bar) Stabiliser isolation valve Tilt cylinder Counterbalance valve Displacement cylinders Restricted check-valve Auxiliary connectors, inner boom section Auxilliary high flow connectors, outer boom section (if fitted) Inner extension cylinder
9804/1103
22A 23 24 24A 24B 25 25A 26 26A 26B 26C 26D 26E 26F 26G 26H
20 - 20 - 02/60
Counterbalance valve Boom section diverter valve Outer telescopic extension cylinder Regeneration valve Pressure switch (100 bar) Lift cylinder Counterbalance valve Servo diverter valve Filter Check valve Test point Accumulator Control isolate valve Lift isolate valve Crowd isolate valve Dump isolate valve
3660 - C/52-2.2 3660 - E/52-3.2
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/61
533-105 Machines (from serial No. 786756) Circuit Diagram - Hydraulics Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The pump assembly comprises two sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/auxiliary options 1B Fan motor The pump has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve oil flows from the EF port to the control valve to provide loading services. Component Key B Pressure cap breather F Return line filter F1 Filter by-pass F2 Direct return to tank S Pump suction strainer T Tank N1 Neutral circuit feed line N2 Neutral circuit return line 1 Pump assembly 1A Main pump 1B Fan pump 1D Priority valve 1E Test point 2 Valve block 2A Main relief valve 2D Lift spool 2E Extend spool 2F Tilt spool 2G Auxiliary spool 2H Auxiliary relief valve (ARV) 2J Auxiliary relief valve (ARV) 2K Auxiliary relief valve (ARV) 2L Auxiliary relief valve (ARV) 2M Load hold check-valves (LHCVs) 3 Steer unit assembly 3A Steering valve 3B Main relief valve 3C Shock valves 3D Non return valve 4 Cooling fan motor (non-reversible) 4A Relief valve (108 bar) 5 Reversible cooling fan motor option 5A Relief valves (108 bar) 5B Fan reversing valve 10 Left stabilizer ram 10A Left stabilizer lock out valve 10B Pressure switch 11 Right stabilizer ram 11A Right stabilizer lock out valve 11B Pressure switch (optional) 12 Auxiliary 1 boom quick release couplings (standard build)
9804/1103
15A Hydraulic ram pin lock 15B Restrictor 15C Manual changeover valve 15D Auxiliary 2 boom quick release couplings 16 Rear power track rod 17 Steer mode valve 17A 2 wheel steer solenoid 17B 4 wheel and grab steer solenoid 17C 4 wheel steer solenoid 17D Crab steer solenoid 18 Front power track rod 21 High flow auxiliary (option) 22 Inner extension ram 23 Extension ram check/counter balance valve 24 Outer extension ram 24A Bleed point 25 Regenerative valve 26 Tilt ram 27 Tilt check/counterblance valve 28 Displacement ram 29 Displacement lift valve 30 Lift ram 31 Lift check/counterbalance valve
20 - 20 - 02/61
3630 - E/5-17.1
Issue 1*
Loadalls
CONTENTS
20 - 20 - 02/62
533-105 Machines Circuit Diagram - Hydraulic
From Serial No. 786756
17
T
18
B
P
A
10A
2
10 A
2Q
5
10B
B
2M B
A
T
P
5B 2P
5A
11A
A
11
B
2M
3
11B
R
L
15C
4 3C
12
2N 3A 2G
LS
3B
T
2K
2J
A
2F
1
EF
B
21 2H
P
2L
2M
1E LS
15A
15D
A
4A 3D P
15B
B
25
2M
24
1A 1B
22
A
1C 16
23
2E
36
B
2280 RPM
2M A
B
2D
F
B
28
2M
27
26
F1 S
T F2
2A N1
P
29 T
30 N2
9804/1103
160-13379
31
20 - 20 - 02/62
3660 - E/5-17.1
Issue 1*
RTFL
CONTENTS
Contents 1
926, 930 Contents Page No. General Information - Fluids, Lubricants and Capacities (926, 930) - Fluids, Lubricants and Capacities - (926, 930, 940 N.Am) - Static Dimensions (926, 930) - Static Dimensions (926, 930, 940 N.Am)
95 - 00 - 01/1,2 95 - 00 - 01/3,4 95 - 00 - 02/1,2 95 - 00 - 02/3,4
Data - Electrical - Hydraulic - Transmission - Brakes - Steering - Engine
95 - 05 - 01/1 to 5 95 - 05 - 02/1,2 95 - 05 - 03/1 95 - 05 - 04/1 95 - 05 - 05/1,2 95 - 05 - 06/1
Fault Finding - Transmission
95 - 10 - 01/1 to 3
* Circuit Diagrams
- Electrical - Hydraulic
9804/1103
95 - 15 - 01/1 to 8 95 - 20 - 01/1,2
RTFL Contents - 1
Issue 2*
RTFL
CONTENTS
95 - 00 - 01/1
926 from m/c 602000 930 from m/c 607700 Fluids, Lubricants & Capacities (Type AA Engine Builds) Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Mutigrade oil. This oil should be drained after the first 100 hours of operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Mutigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY Litres (Gal)
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
88 (19.3)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
10.5 (2.3)
JCB Super Multigrade 15W/40 -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40 API CF4/SG
JCB Super Multigrade 10W/30 -15 °C to 40 °C (5 °F to 104 °F)
SAE10W/30 API CF4/SG
Engine (Coolant)
17 (3.7)
JCB Four Seasons Antifreeze And Summer Coolant (See Coolant Mixtures)
ASTM D3306-74
Transmission (2WD)
17.3 (3.8)
JCB Special Transmission Fluid
ESP-M2C 33G
Transmission (4WD)
18.3(4)
Front Axle
29.5 (6.5)
JCB High Performance Gear Oil
ESEN-M2C 86A/B
Rear Axle (4WD) Differential Hubs (x2)
15 (3.3) 1.3 (0.3)
JCB HD90 Gear Oil
API GL-5
JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID
ISO VG15
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F)
ISO VG46
JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)
ISO VG32
Grease Points and Fork Pivot Pins
JCB HP Grease
Lithium based, No. 2 consistency
Mast Chains
JCB Chain Lubricant
Brake System
Hydraulic System
†64 (14)
†Note: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Watch level sight glass when filling.
9804/1103
95 - 00 - 01/1
7576 - 108
Issue 1
RTFL
CONTENTS
95 - 00 - 01/2
926 from m/c 602000 930 from m/c 607700 Fluids, Lubricants & Capacities (Type AR Engine Builds) Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Mutigrade oil. This oil should be drained after the first 100 hours of operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Mutigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY Litres (Gal)
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
88 (19.3)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
10.5 (2.3)
JCB Super Multigrade 15W/40 -10 °C to 50 °C (14 °F to 122 °F)
SAE15W/40 API CF4/SG
JCB Super Multigrade 10W/30 -15 °C to 40 °C (5 °F to 104 °F)
SAE10W/30 API CF4/SG
Engine (Coolant)
17 (3.7)
JCB Four Seasons Antifreeze And Summer Coolant (See Coolant Mixtures)
ASTM D3306-74
Transmission (2WD)
17.3 (3.8)
JCB Special Transmission Fluid
ESP-M2C 33G
Transmission (4WD)
18.3(4)
Front Axle
29.5 (6.5)
JCB High Performance Gear Oil
ESEN-M2C 86A/B
Rear Axle (4WD) Differential Hubs (x2)
15 (3.3) 1.3 (0.3)
JCB HD90 Gear Oil
API GL-5
JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID
ISO VG15
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F)
ISO VG46
JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)
ISO VG32
Grease Points and Fork Pivot Pins
JCB HP Grease
Lithium based, No. 2 consistency
Mast Chains
JCB Chain Lubricant
Brake System
Hydraulic System
†64 (14)
†Note: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Watch level sight glass when filling.
9804/1103
95 - 00 - 01/2
7576 - 109
Issue 1
RTFL
CONTENTS
95 - 00 - 01/3
926 (N. Am) from m/c 603110 to 605999 and from m/c 660300 930 (N. Am) from m/c 608300 to 609999 and from m/c 660300 940 (N. Am) from m/c 660001 Fluids, Lubricants & Capacities (Type AA Engine Builds) Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Mutigrade oil. This oil should be drained after the first 100 hours of operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Mutigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY FLUID/LUBRICANT US Gal (Liters)
INTERNATIONAL SPECIFICATION
Fuel Tank
23.25 (88)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
2.8 (10.5)
JCB Super Multigrade 15W/40 14 °F to 122 °F (-10 °C to 50 °C)
SAE15W/40 API CF4/SG
JCB Super Universal Agricultural 5 °F to 86 °F (-15 °C to 30 °C)
SAE10W/30 API CD/SF
JCB Torque Converter Fluid 0 °F to 32 °F (-18 °C to 0 °C)
SAE10W API CD/SF
JCB For Seasons Antifreeze And Summer Coolant (See Coolant Mixtures)
ASTM D3306-74
JCB Special Transmission Fluid
ESP-M2C 33G
Engine (Coolant)
4.5 (17)
Transmission (2WD)
5.0 (18.9)
Transmission (4WD)
5.5 (20.8)
Front Axle
7.8 (29.5)
JCB Special Gear Oil Plus
ESEN-M2C 86A/B
Rear Axle (4WD) Differential Hubs (x2)
4.0 (15) 0.4 (1.3)
JCB HD90 Gear Oil
API GL-5
JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID
ISO VG15
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F)
ISO VG46
JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)
ISO VG32
Grease Points and Fork Pivot Pins
JCB HP Grease
Lithium based, No. 2 consistency
Mast Sideshift Carrier
JCB Waxoyl
Mast Chains
JCB Chain Lubricant
Brake System
Hydraulic System
†16.9 (64)
†Note: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Watch level sight glass when filling.
9804/1103
95 - 00 - 01/3
7591 - 107
Issue 1
RTFL
CONTENTS
95 - 00 - 01/4
926 (N. Am) from m/c 603110 to 605999 and from m/c 660300 930 (N. Am) from m/c 608300 to 609999 and from m/c 660300 940 (N. Am) from m/c 66001 Fluids, Lubricants & Capacities (Type AR Engine Builds) Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Mutigrade oil. This oil should be drained after the first 100 hours of operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Mutigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM
CAPACITY FLUID/LUBRICANT US Gal (Liters)
INTERNATIONAL SPECIFICATION
Fuel Tank
23.25 (88)
Diesel Oil (See Types of Fuel)
ASTM D975-66T Nos. 1D, 2D
Engine (Oil)
2.8 (10.5)
JCB Super Multigrade 15W/40 14 °F to 122 °F (-10 °C to 50 °C)
SAE15W/40 API CF4/SG
JCB Super Multigrade 10W/30 5 °F to 104 °F (-15 °C to 40 °C)
SAE10W/30 API CF4/SG
JCB Four Seasons Antifreeze And Summer Coolant (See Coolant Mixtures)
ASTM D3306-74
JCB Special Transmission Fluid
ESP-M2C 33G
Engine (Coolant)
4.5 (17)
Transmission (2WD)
5.0 (18.9)
Transmission (4WD)
5.5 (20.8)
Front Axle
7.8 (29.5)
JCB Special Gear Oil Plus
ESEN-M2C 86A/B
Rear Axle (4WD) Differential Hubs (x2)
4.0 (15) 0.4 (1.3)
JCB HD90 Gear Oil
API GL-5
JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID
ISO VG15
JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F)
ISO VG46
JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)
ISO VG32
Grease Points and Fork Pivot Pins
JCB HP Grease
Lithium based, No. 2 consistency
Mast Sideshift Carrier
JCB Waxoyl
Mast Chains
JCB Chain Lubricant
Brake System
Hydraulic System
†16.9 (64)
†Note: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Watch level sight glass when filling.
9804/1103
95 - 00 - 01/4
7591 - 108
Issue 1
RTFL
CONTENTS
95 - 00 - 02/1
926 from m/c 602000 930 from m/c 607700 Static Dimensions
K
L
J
H A G D
F
E B
C
151800
9804/1103
95 - 00 - 02/1
7576 - 111
Issue 1
RTFL
CONTENTS
95 - 00 - 02/2
926 from m/c 602000 930 from m/c 607700 Static Dimensions (cont’d) Note: Unless otherwise indicated the following data applies to both the 926 and 930 machines. A B C D E F
G
H
J
K L
Overall cab height Overall width (over tyres) Overall length to front carriage (industrial or bar) Inside width of cab Front track Wheel base (2 wheel drive) (4 wheel drive) Ground clearance (2 wheel drive) (4 wheel drive) Mast Closed Height 3.6 m mast 4.5 m mast 5.5 m mast 6.55 m mast Mast Open Height 3.6 m mast 4.5 m mast 5.5 m mast 6.55 m mast Free lift (4.5 m mast only) Mast Tilt Forwards Mast Tilt Backwards
2.57 m 2.20 m 3.60 m
(8 ft 5 in) (7 ft 3 in) (11 ft 10 in)
1.16 m 1.80 m
(3 ft 10 in) (5 ft 11 in)
2.07 m 2.13 m
(6 ft 10 in) (7 ft 0 in)
0.37 m 0.37 m
(1 ft 2 in) (1 ft 2 in)
2.95 m 2.41 m 2.95 m 3.32 m
(9 ft 8 in) (7 ft 10 in) (9 ft 8 in) (10 ft 11 in)
4.78 m 5.41 m 6.61 m 7.67 m 1.46 m 18° 10°
(15 ft 8 in) (17 ft 9 in) (21 ft 8 in) (25 ft 2 in) (4 ft 10 in)
3.6 m 4.49 m
(11 ft 10 in) (14 ft 9 in)
Forklift Performance Outside turning radius (2 wheel drive) (4 wheel drive) Departure angle - 926 machine (2 wheel drive) (4 wheel drive) Departure angle - 930 machine (2 wheel drive) (4 wheel drive) Obstruction angle (2 wheel drive) (4 wheel drive) Lift capacity Lift height
46° 53° 38° 43° 57° 51° † †
† †
†See Rating Plate
Weight (With Cab and 5.5 m Mast) 926 Machine 2 Wheel drive 4 Wheel drive
5880 kg 5910 kg
(12966 lb) (13032 lb)
930 Machine 2 Wheel drive 4 Wheel drive
6310 kg 6380 kg
(13914 lb) (14068 lb)
Note: The above data is based on a standard fork size of 1067 mm x 100 mm x 50 mm (42 in x 4 in x 2 in)
9804/1103
95 - 00 - 02/2
7576 - 112
Issue 1
RTFL
CONTENTS
95 - 00 - 02/3
926 (N. Am) from m/c 603110 to 605999 and from m/c 660300 930 (N. Am) from m/c 608300 to 609999 and from m/c 660300 940 (N. Am) from m/c 660001 Static Dimensions
K
B
M
C
J
D L
A
H E F G 9804/1103
95 - 00 - 02/3
7576 - 110
Issue 1
RTFL
CONTENTS
95 - 00 - 02/4
926 (N. Am) from m/c 603110 to 605999 and from m/c 660300 930 (N. Am) from m/c 608300 to 609999 and from m/c 660300 940 (N. Am) from m/c 660001 Static Dimensions (cont’d) 926
930
940
A B
Height to top of cab Overall width (over tires)
8 ft 5 in (2.565 m) 7 ft 5 in (2.26 m)
8 ft 5 in (2.565 m) 7 ft 11 in (2.41 m)
8 ft 5 in (2.565 m) 3 7ft 5 /4 in (2.279 m)
C D E
Inside width of cab Front track Wheel base (2-Wheel drive) (4-Wheel drive)
3 ft 7 in (1.1 m) 6 ft 2 in (1.88 m)
3 ft 7 in (1.1 m) 6 ft 2 in (1.88 m)
3 ft 7 in (1.1 m) 6 ft 2 in (1.88 m)
6 ft 9 in (2.06 m) 7 ft 0 in (2.13 m)
6 ft 10 in (2.07 m) 7 ft 0 in (2.13 m)
7ft 1 in (2.159 m) 7ft 21/2 in (2.197 m)
Overall length to front tires Overall length to front of carriage Ground clearance (2-Wheel drive)
11 ft 1 in (3.3 m) 11 ft 11 in (3.6 m)
11 ft 1 in (3.3 m) 11 ft 11 in (3.6 m)
11 ft 1 in (3.3 m)
0 ft 11 in (280 mm)
1 ft 3 /4 in (400 mm)
1ft 4 in (406 mm)
(4-Wheel drive)
0 ft 11 in (280 mm)
0 ft 11 in (280 mm)
1 ft 01/2 in (318 mm)
15036 lb (6820 kg) 15991 lb (7253 kg)
14,740 lb (6,700kg)
11 ft 10 in (3.6 m) 3 14 ft 8 /4 in (4.49 m)
11 ft 10 in (3.6 m) 3 14 ft 8 /4 in (4.49 m)
12 ft 5 in (3.789 m) 14 ft 9 in (4.495 m)
† †
† †
† †
20° 37° 10°
20° 37° 10°
20° 42° 9.5°
F G H
3
WEIGHT (With Cab) 2- Wheel drive 4- Wheel drive 2- Wheel drive & 12 ft mast 4- Wheel drive & 12 ft mast 2- Wheel drive & 21 ft 6 in mast 4- Wheel drive & 21 ft 6 in mast
12520 lb (5679 kg) 12860 lb (5834 kg) 13305 lb (6035 kg) 13645 lb (5989 kg)
FORKLIFT PERFORMANCE Outside turning radius, unbraked (2-Wheel drive) (4-Wheel drive)
K L M
Lift capacity Lift height Mast tilt Maximum tilt forward (jobsite) Maximum tilt forward (transporting) Maximum tilt back †See Rating Plate
9804/1103
95 - 00 - 02/4
7591 - 111
Issue 1
CONTENTS
RTFL
95 - 05 - 01/1
926, 930 Data - Electrical System Type Battery Cranking Performance at - 18 °C (0 °F) Reserve capacity (minutes) for 25 amp load Alternator Starter Motor
12 volt, negative earth 410 amps to 1.4 V.P.C. 180 Lucas A127-65, 65 amp maximum output Lucas M127
Light Bulbs Headlights Side/tail lights Stop lights Reversing light Direction indicators Number plate light Instruments Beacon
60/55 W H4 Halogen 5 W SBC 21 W SBC 21 W SBC 21 W SBC 10 W 3W 55 W Halogen
IP67 Electrics Machines from serial No. 602902 (926) and 608656 (930) are fitted with IP67 electrics which features different loom construction and method of attachment.
9804/1103
95 - 05 - 01/1
5100 - 10/1-1.2
Issue 1
RTFL
CONTENTS
926, 930
95 - 05 - 01/2
To m/c no. 602073 (926), 607717 (930)
Data - Electrical Fuses The electrical circuits are protected by fuses. The fuses are located in a fuse box near the instrument panel. They are in two rows, labelled A and B. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one. Circuit Protection
Fuse Number
Circuits
Fuse Rating (Amps)
A1
Dip Beam - left hand
10
A2
Dip Beam - right hand
10
A3
Main Beam - left hand
10
A4
Main Beam - right hand Main Beam Warning Light
10
A5
Roof Wiper Rear Wiper Beacon
10
A6
Hazard Warning Lights
10
B1
Back-up Alarm Transmission Solenoids Parking Brake Buzzer Engine Shut Off Solenoid
10
B2
Sidelights - left hand
10
B3
Sidelights - right hand
10
B4
Heater Direction Indicators
10
B5
Gauges Parking Brake Light Instrument Panel Warning Lights Brake Lights
10
B6
Horn Washer Front Wiper Headlight Flasher
10
9804/1103
95 - 05 - 01/2
5100 - 10/1-2.2
Issue 1
RTFL
CONTENTS
926, 930
95 - 05 - 01/3
From m/c no. 602074 (926), 607718 (930) & machines with IP67 Electrics
Data - Electrical Fuses The electrical circuits are protected by fuses. The fuses are located in fuse boxes near the instrument panel. They are in three rows, labelled A, B and C. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one. Circuit Protection Fuse Number
Circuits
Fuse Rating (Amps)
A1
Dip Beam - left hand
10
A2
Dip Beam - right hand
10
A3
Main Beam - left hand
10
A4
Main Beam - right hand Main Beam Warning Light
10
A5
Rear Wiper Beacon or as above plus Roof Wiper
10
A6
Hazard Warning Lights
10
B1
Forward/Reverse Solenoids via Relays
10
B2
Sidelights - left hand
10
B3
Sidelights - right hand Number Plate Light
10
B4
Heater
10
B5
Gauges Parking Brake Light Instrument Panel Warning Lights Brake Lights
10
B6
Horn Front Wiper Direction Indicators
10
C1
Engine Shut-Off Solenoid
5
C2
Back-Up Alarm Reversing Light Circuit
5
C3
Headlight Flasher
10
9804/1103
15
126820
95 - 05 - 01/3
5100 - 10/1-3.3
Issue 1
CONTENTS
RTFL
95 - 05 - 01/3A
926, 930
From m/c no. TBA
Data - Electrical Fuses The electrical circuits are protected by fuses. The primary fuses are located in the engine bay adjacent to the battery. The individual circuit fuses are located in fuse boxes near the instrument panel. They are in two rows labelled A and B. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one. PRIMARY FUSES PR1 Feeding circuit fuses B1 - B4 PR2 Feeding circuit fuses A7 - A9, B5 - B7 PR3 Feeding ignition switch, circuit fuses A1 - A6 PR4 Feeding air conditioning
CIRCUIT FUSES Row A A1 Transmission A2 Instrumentation A3 Brake Lights A4 ESOS/Cold Start Advance A5 Rear/Roof Wiper, Face Fan (Option) A6 Front Wipe/Wash A7 Beacon A8 Hazard Warning Lights A9 Horn, Headlamp Flash A10 Thermostart Row B B1 Direction Indicators B2 Dip Beam B3 Worklamp B4 Heater Fan B5 Left Hand Sidelights B6 Right Hand Sidelights B7 Fog Light B8 Not used B9 Not used B10 Not used
9804/1103
50A 60A 70A 60A
7.5A 5A 7.5A 10A 10A(15A) 10A 7.5A 10A 15A 20A
PR1
PR2 60A
50A
7.5A 15A 10A 10A 5A 5A 5A
95 - 05 - 01/3A
70A
PR3
817/17132
60A
PR4 A370770
5100 - 10/1-6.1
Issue 1
CONTENTS
RTFL
95 - 05 - 01/4
926, 930 Data - Electrical Relay Location The relays are located as follows: A B C D E F G
Neutral start relay Flasher relay Reverse alarm relay Side lights relay Parking brake relay Forward relay Reverse relay
9804/1103
95 - 05 - 01/4
5100 - 10/1-4.1
Issue 1
RTFL
CONTENTS
95 - 05 - 01/5
926, 930
From m/c 664290
Data - Electrical Fuses
Relay Location
The electrical circuits are protected by fusews. The fuses are located in fuse boxes near the instrument panel. They are in three rows, labelled A, B and C. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one.
A B C D E F G H
ROW A Circuit 1 2 3 4 5 6
Brake Light Rotation Beacon Laft hand sidelights Right hand sidelights Engine shut-off Solenoid (ESOS) Hazard Warning Lights
Rating
Buzzer Flashers Parbrake lamp Ignition Neutral start Transmission dump Foeward Reverse
7.5A 7.5A 5A 5A 5A 10A
ROW B
1 2 3 4 5 6
Circuit Heater Fan Warning Lights Dip beam Main beam Worklamp Direction Indicators
Rating 15A 5A 15A 15A 7.5A 7.5A
ROW C
1 2 3 4 5 6
Circuit Front wash/wipe Horn/headlamp flash Transmission Thermostart Rear/roof wiper - with fan level fan Main lighting
9804/1103
Rating 7.5A 15A 10A 20A 10A 15A 25A
95 - 05 - 01/5
5100 - 10/1-5.1
Issue 1
CONTENTS
RTFL
95 - 05 - 02/1
926, 930 940 (N. Am. only) Data Hydraulic Pump Type Flow at MRV pressure Control Valves Type build. Spool 1 Spool 2 Spool 3
Sundstrand gear AFGP25L27689 55 litres/min 12 UK gal/min 14 US gal/min
Kontak Unit 18 Sectional, two to four spools according to Double-acting, carriage lift. Double-acting, mast tilt. Double-acting, attachments as required.
Relief Valve Operating Pressures Main Relief Valve (M.R.V.)
bar 220
kgf/cm@ 225
lbf/in@ 3200
Carriage Lift A.R.V. (UK and Rest of World) - JCB 926, 3.6 m Mast - JCB 926, 4.5 m Free Lift Mast - JCB 926, 5.5 & 6.55 m Masts - JCB 930, 3.6 m Mast - JCB 930, 4.5 m Free Lift Mast - JCB 930, 5.5 & 6.55 m Masts
138 207 193 152 234 172
141 211 197 155 239 176
2000 3000 2800 2200 3400 2500
Carriage Lift A.R.V. (North America Machines only) - 926, 144 Standard 2-rail Mast - 926, 171 Duplex 2-rail Mast - 926, 258 3-rail Mast - 930, All Masts - JCB 930, Sideshift 11 ft 9 in Duplex Mast - JCB 930, Sideshift 14 ft 9 in Free Lift Mast - JCB 930, Sideshift 21 ft 6 in Mast - JCB 930, 28 ft Mast - 940, All Masts
110 131 134 128 145 234 207 162 155
113 134 137 130 148 239 211 165 159
1600 1900 1940 1850 2100 3400 3000/3050 2350 2250
Note: For North America machines with JCB masts, refer to UK and Rest of World A.R.V. settings. Multi-hitch A.R.V.'s (top & bottom) Other Attachments Sideshift A.R.V. (North America only) - Top Port - Bottom Port Deration Relief Valve - JCB 926, 5.5 m Mast - JCB 926, 6.55 m Mast - JCB 926, 6.55 m Mast (narrow track) - JCB 930, 5.5 m Mast - JCB 930, 6.55 m Mast - JCB 930, 6.55 m Mast (narrow track)
172 145
176 148
2500 2100
158 124
161 126
2300 1800
179/183 155/159 145/148 152/155 134/138 121/124
183/186 158/162 148/151 155/158 137/141 123/126
2600/2650 2250/2300 2100/2150 2200/2250 1950/2000 1750/1800
Tilt A.R.V. 69 70 1000 Note: All hydraulic pressure settings to be carried out at maximum engine revs and hydraulic oil hot at 40 °C. Rams JCB 926 3.6 m Mast
- Lift - Tilt 4.5 m Mast - Lift (outer) - Lift (centre) - Tilt 5.5 m Mast - Lift - Tilt 6.55 m Mast - Lift - Tilt 9804/1103
Bore mm in 60 2.3 70 2.8 60 2.3 82 3.2 70 2.8 60 2.3 70 2.8 60 2.3 70 2.8
95 - 05 - 02/1
Rod Dia mm in 50 1.9 40 1.6 50 1.9 80 3.1 40 1.6 50 1.9 40 1.6 50 1.9 40 1.6
Stroke mm in 1833 72.2 254 10.0 1525 60.0 725 28.5 254 10.0 1833 72.2 254 10.0 2172 85.5 254 10.0 5100 - 2/1-1.6
Issue 1
RTFL
CONTENTS
95 - 05 - 03/1
926, 930 940 (N. Am. only) Data Transmission Syncro Shuttle Torque Converter Diameter. Torque Multiplication at Stall Minimum Engine Speed at Converter Stall
Combined torque converter, reverser and gearbox unit with optional four wheel drive output. 279 mm (11 in) 2.2 : 1 1650 - 1750 rev/min
Gear Ratios 1st 2nd 3rd 4th
5.55 : 1 3.45 : 1 1.83 : 1 1.00 : 1
Converter Pressures (in neutral)
bar
kgf/cm2
lbf/in2
Converter In at 50 deg C
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
2.4 - 3.4 5.9 - 7.9 1.3 - 2.0 5.2 - 5.9
2.5 - 3.5 6.0 - 8.1 1.4 - 2.1 5.3 - 6.0
35 - 50 85 - 115 20 - 30 75 - 85
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
1.0 - 1.7 2.1 - 3.1 0.3 - 0.6 1.0 - 1.7
1.1 - 1.8 2.1 - 3.2 0.3 - 0.6 1.1 - 1.8
15 - 25 30 - 45 4-8 15 - 25
7.9
8.1
115
Converter In at 100 deg C
Converter Out at 50 deg C Converter Out at 100 deg C
Converter Inlet Protection Pressure (max.) Lubrication Pressures (in neutral) At 50 deg C
1000 rev/min 2000 rev/min
0.2 - 0.3 0.4 - 0.7
0.2 - 0.4 0.4 - 0.7
3-5 6 - 10
At 100 deg C
1000 rev/min 2000 rev/min
0.1 - 0.2 0.3 - 0.6
0.1 - 0.2 0.3 - 0.6
2-3 4-8
At 50 deg C
1000 rev/min 2000 rev/min
9.3 - 10.3 10.7 - 11.7
9.5 - 10.5 10.9 - 12.0
135 - 150 155 - 170
At 100 deg C
1000 rev/min 2000 rev/min
9.3 - 10.3 9.3 - 10.3
9.5 - 10.5 9.5 - 10.5
135 - 150 135 - 150
Main Line Pressure
Clutch Pressure (forward and reverse) At 50 deg C
1000 rev/min 2000 rev/min
8.3 - 9.0 9.0 - 10.0
8.4 - 9.1 9.1 - 10.2
120 - 130 130 - 145
At 100 deg C
1000 rev/min 2000 rev/min
8.3 - 9.0 8.3 - 9.0
8.4 - 9.1 8.4 - 9.1
120 - 130 120 - 130
l/min
UK gal/min
US gal/min
11.4 - 13.6 20.5 - 22.7 10.2 - 12.5 22.7 - 26.1 11.0 - 15.0 22.5 - 29.5
2.5 - 3.0 4.5 - 5.0 2.25 - 2.75 5.0 - 5.75 2.5 - 3.3 5.0 - 6.5
3.0 - 3.6 5.4 - 6.0 2.7 - 3.3 6.0 - 6.9 3.0 - 4.0 6.0 - 8.0
Flow Rates Cooler at 50 deg C Cooler at 100 deg C Pump at 50 deg C
9804/1103
1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
95 - 05 - 03/1
5100 - 6/1-1.2
Issue 1
RTFL
CONTENTS
95 - 05 - 03/2
926, 930 940 (N. Am. only) Data Transmission (cont’d) Drive Axle - Front Type Weight (approximate) Overall Gear Ratio
Epicyclic 386 kg (852 lb) 18.16 : 1 24.975 : 1 German
Steering Axle - Rear (2WD) Weight with Steer Rams (but without wheels) Toe-in Camber Angle Castor Angle King-pin Angle Oscillation
278 kg (613 lb) Zero 3° Positive 2° Zero + 6°
Steering Axle - Rear (4WD) Weight with Steer Rams (but without wheels) Overall Gear Ratio (JCB Syncro Shuttle) Crownwheel and Pinion Ratio Oscillation Castor Angle Camber Angle King-pin Inclination Toe-in
352 kg (776 lb) 18.6 : 1 3.44 : 1 ± 9° 2° 2° Positive Zero Zero
Tyre Pressures Front
bar
lbf/in2
15.5/80 x 24 x 10 15.5 x 25 x 8 16.5/85 x 24 x 8 16.9 x 24 x 12 (926 only)
3.0 3.0 3.0 2.0
44 44 44 29
3.9 2.5 3.6 1.5 1.7 1.7 1.7
57 36 52 22 25 25 25
3.7 2.1 2.1 2.1
5.4 30 30 30
Rear - JCB 926 9.00 x 16 x 8 10.5 x 18 x 10 11L x 16 x 10 12.5/80 x 18 x 8 12.5 x 18 x 10 12.5/80 x 18 x 10 14 x 17.5 x 10 (N. Am 4WD only) Rear - JCB 930 10.5 x 18 x 10 12.5/80 x 18 x 8 12.5 x 18 x 10 12.5/80 x 18 x 10 14 x 17.5 x 10 (N. Am 4WD only) 14.5/75 x 16.1 x 10 (N. Am 4WD only) Wheel Nut Torques Front lbf ft 500
9804/1103
Rear Nm 678
lbf ft 500
Nm 678
95 - 05 - 03/2
5100 - 7/1-1.3
Issue 1
CONTENTS
RTFL
95 - 05 - 04/1
926, 930 Data - Brakes Service Brakes Type Actuation Location Friction Plates (5 per brake pack) Outside Diameter Inside Diameter Nominal Facing Area Hydraulic Piston Diameter
JCB Oil-Immersed Multi-plate Disc Hydraulic Front Axle 222 mm (8.74 in) 180 mm (7.10 in) 13266 mm2 (20 in2) 216 mm (8.5 in)
Master Cylinder, Single Brake Pedal Machines Piston diameter (each) Piston Area (each) Pedal Ratio
28.58 mm (1.125 in) 641.4 mm (0.994 in2) 5.1 : 1
Master Cylinder, Dual Brake Pedal Machines Total Stroke
35 mm (1.4in)
Parking Brake Type Disc Diameter
9804/1103
Manually Adjusted Caliper 279.4 mm (11 in)
95 - 05 - 04/1
5100 - 8/1-1.5
Issue 1
CONTENTS
RTFL
926, 930
95 - 05 - 05/1
To m/c nos. 602749 (926), 608299 (930)
Data - Steering System Type Pump Controlled Flow at 1300 engine rev/min and neutral pressure Total Flow through tank return line at 2200 engine rev/min (pressure outlet blocked) Relief Valve Operating Pressure Control Unit Ram Dimensions (2 Wheel Drive) Bore Rod Dia. Stroke Ram Dimensions (4 Wheel Drive) Bore Rod Dia. Stroke
9804/1103
Full power hydrostatic A12.5/29926, gear type litres/min UK gal/min 27.5 6.0 45.5 10.0 120 bar (123 kgf/cm2; 1750 lbf/in2) Danfoss Orbitrol OSPB 160 50.8 mm (2.0 in) 25.4 mm (1.0 in) 275 mm (10.83 in) 50.0 mm (1.97 in) 25.0 mm (0.98 in) 250 mm (9.84 in)
95 - 05 - 05/1
5100 - 9/1-1.2
Issue 1
CONTENTS
926, 930
RTFL
95 - 05 - 05/2
From m/c no. 602750 to 602797 (926), 608300 to 608418 (930)
Data - Steering System Type Pump Control Unit Type 2 Wheel Drive Control Unit Type 4 Wheel Drive Priority Valve Type Relief Valve Operating Pressure Shock Relief Valve Operating Pressure 2 Wheel Drive 4 Wheel Drive Ram Dimensions (2 and 4 Wheel Drive) Bore Rod Dia. Stroke
926, 930
Full power hydrostatic (see Data - Hydraulics) OSPC 160 OSPC 200 OLSB 80 150 bar (153 kgf/cm2; 2175 lbf/in2) 250 bar (255 kgf/cm2; 3625 lbf/in2) 240 bar (245 kgf/cm2; 3480 lbf/in2) 50.0 mm (1.97 in) 25.0 mm (0.98 in) 275 mm (10.83 in)
From m/c no. 602798 (926), 608419 (930)
Data - Steering System Type Pump Control Unit Type 2 Wheel Drive Control Unit Type 4 Wheel Drive Priority Valve Type Relief Valve Operating Pressure Shock Relief Valve Operating Pressure 2 Wheel Drive 4 Wheel Drive Ram Dimensions (2 Wheel Drive) Bore Rod Dia. Stroke Ram Dimensions (4 Wheel Drive) Bore Rod Dia. Stroke
9804/1103
Full power hydrostatic (see Data - Hydraulics) OSPC 160 OSPC 200 OLSB 80 150 bar (153 kgf/cm2; 2175 lbf/in2) 250 bar (255 kgf/cm2; 3625 lbf/in2) 240 bar (245 kgf/cm2; 3480 lbf/in2) 70.0 mm (2.75 in) 30.0 mm (1.18 in) 275 mm (10.83 in) 70.0 mm (2.75 in) 30.0 mm (1.18 in) 290 mm (11.42 in)
95 - 05 - 05/2
5100 - 9/1-2.2
Issue 1
RTFL
CONTENTS
95 - 05 - 06/1
926, 930 Data - Engine Type
Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance - Hot or Cold Idling Speed Max. Governed Speed Max. No Load Speed
Perkins 1000 Series 4 cylinder Engine AA - 50430, naturally aspirated AR - 50681, naturally aspirated (low emission)
- Inlet - Exhaust
AA Build (76 HP) 100 mm (3.937 in) 127 mm (5.000 in) 4 litres (243 in3) 16.5:1 20-30 bar (300-450 lbf/in2) 1,3,4,2 0.20 mm (0.008 in) 0.45 mm (0.018 in) 750 rev/min 2000 rev/min 2420 rev/min
AR Build (75 HP) 103 mm (4.055 in) 127 mm (5.000 in) 4.23 litres (258 in3) 18.5:1 25-35 bar (375-525 lbf/in2) 1,3,4,2 0.20 mm (0.008 in) 0.45 mm (0.018 in) 750 rev/min 2200 rev/min 2350 rev/min
CAV DPA Mechanical DM55L/1000/1/2420 16 deg BTDC 220 atm HZ
Lucas DP203 Mechanical 2644G002RG/2350 3 deg BTDC Dynamic 290 atm KW
Fuel System Injection Pump Type Governing Injector Pump Setting Code Injection Timing Injector Setting Pressure Injector Codes
For further engine details see Engine Manual Publication No. 9806/0100 for AA Engine builds 9806/2140 for AR Engine builds
9804/1103
95 - 05 - 06/1
5100 - 5/1-1.4
Issue 1
RTFL
CONTENTS
95 - 10 - 01/1
926, 930 Fault Finding - Transmission Before carrying out the checks listed the machine should, if possible, be operated to determine the fault area(s), and bring the systems to their normal working temperatures. Ensure that the correct quantity and grade of oil is used and that there are no obvious leaks. A
If the transmission is noisy, start at check 1.
B
If the transmission is overheating, start at check 4.
C
If the transmission will not pull, start at check 12.
D
If there is no drive in one or both directions, start at check 17.
E
If the transmission is jumping out of gear, start at check 29.
F
If the transmission is sticking in gear, start at check 39.
G
If ratios are 'crash changing', start at check 41.
CHECK
ACTION
1
Is there noise when selecting direction?
YES: Check 3 NO: Check 2
2
Is there noise when running with direction selector in neutral and ratio selector in 1st?
YES: Check 9 NO: Check 19
3
Is there air in the hydraulic system?
YES: Continue running to expel air. NO: Check 4
4
Is the fluid level correct?
YES: Check 5 NO: Check level only when machine is cold and top up as required.
5
Are the oil passages restricted?
YES: Clear the restriction. NO: Check 6
6
Is the suction strainer restricted?
YES: Remove and clean strainer. NO: Check 7
7
Is pump pressure as specified?
YES: Check 9 NO: Check clutch pressure maintenance valve is to operate.
free 8
When flow testing pump, is output low?
YES: Renew pump. NO: Check converter sprag clutch for wear or slip.
9
Does the noise continue when direction selector is in forward or reverse?
YES: Check 10 NO: Check 11
10
Is transmission misaligned?
YES: Renew mountings and check position. NO: Check 'converter out' pressure and flow.
11
Are the pump bushes worn?
YES: Renew NO: Check converter for wear or cooler for
restriction to flow. 12
Is the transmission not pulling in one direction only?
YES: Check 16 NO: Check 13
13 .
Is the transmission not pulling in both Forward and Reverse?
YES: Stall test machine, Check 14 NO: Check 16
9804/1103
95 - 10 - 01/1
5100 - 6/4-1.1
Issue 1
CONTENTS
RTFL
95 - 10 - 01/2
926, 930 Fault Finding - Transmission (cont’d)
CHECK
ACTION
14
Is 'converter in' pressure as specified?
YES: Check 15 NO: Inspect converter relief valve for damage.
15
Is pump being driven by converter?
YES: Check pump pressure. NO: Renew damaged parts.
16
Are clutch sealing rings damaged? monitor pressure.
YES: Tap pressure gauge into clutch feed lines to NO:
Check clutch plates for damage.
17
Is there drive in one direction only?
YES: Check 19 NO: Check 18
18
Is the start switch in the run position and supplying current to the neutral start relay?
YES: Check 19 NO: Rectify.
19
Is the fault only when the transmission is hot?
YES: Dismantle solenoid and check components. NO: Check microswitches, relay and wiring loom.
20
Is the noise a growl, hum or grinding?
YES: Check gears for damage or wear. NO: Check 21
21
Is the noise a hiss, thump or bumping?
YES: Check bearings for damage or wear. NO: Check 22
22
Is the noise a squeal?
YES: Check free running gears for seizure. NO: Check 23
23
Is the noise present when in neutral or when in gear? NEUTRAL:Check 24 IN GEAR: Check 27
24
Is the countershaft or its bearings worn or damaged?
YES: Renew damaged parts. NO: Check 25
25
Is there excessive backlash in the gears?
YES: Adjust by checking shaft end float. NO: Check 26
26
Is the mainshaft pilot bearing worn?
YES: Renew. NO: Check gear teeth for scuffing.
27
Is the mainshaft rear bearing worn?
YES: Renew. NO: Check 28
28
Are the sliding gear teeth worn or damaged?
YES: Renew gears. NO: Check 29
29
Are the selector forks loose?
YES: Tighten screws. NO: Check 30
30
Are the selector fork pads or grooves in gears worn?
YES: Renew worn parts. NO: Check 31
31
Are the dog gear teeth worn?
YES: Renew NO: Check 32
32 .
Are the selector rod detent springs broken?
YES: Renew NO: Check 33
9804/1103
95 - 10 - 01/2
5100 - 6/4-2.1
Issue 1
CONTENTS
RTFL
95 - 10 - 01/3
926, 930 Fault Finding - Transmission (cont’d)
CHECK
ACTION
33
Are the selector rods worn or damaged?
YES: Renew. NO: Check 34
34
Are the selector fork pads out of position?
YES: Reposition or renew (check interlock). NO: Check 35
35
Is there excessive end float in gears or shafts?
YES: Adjust. NO: Check thrust washers and mating faces.
36
Is the synchroniser bronze worn?
YES: Renew synchro pack. NO: Check 37
37
Are steel chips embedded in the bronze? bronze or be rejected.
YES: Continue using, chips will either embed below NO:
38
Are the synchroniser components damaged?
Check 38
YES: Renew. NO: Check free running gears for seizure or
damage. 39
Are the sliding gears tight on the splines?
YES: Free or renew. NO: Check 40
40
Are chips wedged between splines of shaft or gear? pedal is pressed.
YES: Remove chips. NO: Ensure that clutch is disengaged when dump
41
Are steel chips embedded in the bronze? bronze or be rejected.
YES: Continue using, chips will either embed below NO:
Check 42
42
Are the synchroniser spring pins damaged?
YES: Renew synchro. NO: Check 43
43
Is the synchroniser bronze worn?
YES: Renew synchro. NO: Check blocker pins.
9804/1103
95 - 10 - 01/3
5100 - 6/4-3.1
Issue 1
CONTENTS
RTFL
95 - 15 - 01/1
926 to m/c 602902 930 to m/c 608656 Circuit Diagram - Electrical Machines without IP67 electrics
9804/1103
95 - 15 - 01/1
5100 - 10/7-1.2
Issue 1
CONTENTS
RTFL
95 - 15 - 01/2
926 to m/c 602902 930 to m/c 608656 Circuit Diagrams -Electrical (cont’d) Machines without IP67 electrical Main Components & Switches 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 50 51 52 53 54 55 56 57
Battery Starter Solenoid Starter Motor Starter Switch Thermostart Fuse B4 Heater Switch Resistor Heater Motor Fuse B6 Horn Push Horn Wash/Wiper Switch Washer Pump Front Wiper Hazard Warning Switch Indicator Relay Direction Indicator Switch Fuse A6 Fuse A5 Rear Wiper Roof Wiper Beacon Engine Stop Solenoid Fuse C1 Fuse C2 Back-up Alarm Relay Back-up Alarm Fuse B1 Forward/Reverse Switch Parking Brake Buzzer Relay Forward Relay Reverse Relay Diode Reverse Solenoid Forward Solenoid Dump Switch Parking Brake Switch Fuse B5 Brake Switch Fuel Gauge Fuel Gauge Sender Air Filter Switch Oil Pressure Switch Transmission Oil Temperature Switch Transmission Oil Pressure Switch Water Temperature Switch Diode Alternator Hourmeter Hourmeter Diode Bank Buzzer Fuse C3 Headlight Flasher Switch Dip Switch Fuse A4 Fuse A3
9804/1103
58 59 60 61 62 63 64 65 66 67
Fuse A2 Fuse A1 Fuse B3 Fuse B2 Road Lights Switch Side Lights Relay Diode Diode Neutral Start Relay Battery Isolator (optional)
Lights 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99
Direction Indicator Warning Hazard Warning L.H. Front Indicator L.H. Rear Indicator R.H. Front Indicator R.H. Rear Indicator Rear Working R.H. Stop L.H. Stop Beacon Blocked Air Filter Warning Engine Oil Pressure Warning Transmission Oil Temperature Warning Transmission Oil Pressure Warning Engine Coolant Temperature Warning Alternator Warning Parking Brake Warning Fuel Gauge/Hourmeter Illumination L.H. Side L.H. Tail R.H. Side R.H. Tail Number Plate Light L.H. Dip Beam R.H. Dip Beam L.H. Main Beam R.H. Main Beam Main Beam Warning Hazard Warning Switch Repeater Front Working Light (fitted to later machines)
Cable Colour Code B Black G Green K Pink LG Light Green N Brown O Orange P Purple R Red S Slate U Blue W White Y Yellow Note: On machines from No. 602750 (926) and 608300 (930) the fuse A5, 20 for the rear wiper 21 and roof wiper
95 - 15 - 01/2
5100 - 10/7-2.4
Issue 1
CONTENTS
RTFL
95 - 15 - 01/3
926 from m/c 602903 to 664289 930 from m/c 608657 to 664289 Circuit Diagrams - Electrical (contd) Machines with IP67 electerics
9804/1103
95 - 15 - 01/3
5100 - 10/7-3.2
Issue 1
CONTENTS
RTFL
95 - 15 - 01/4
926 from m/c 602903 to 664289 930 from m/c 608657 to 66289 Circuit Diagrams -Electrical (cont’d) Machines without IP67 electrical Main Components & Switches 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 50 51 52 53 54 55 56 57 58 59 60
Battery Starter Solenoid Starter Motor Starter Switch Thermostart Fuse B4 Heater Switch Resistor Heater Motor Fuse B6 Horn Push Horn Wash/Wiper Switch Washer Pump Front Wiper Hazard Warning Switch Indicator Relay Direction Indicator Switch Fuse A6 Fuse A5 Rear Wiper Roof Wiper Beacon Engine Stop Solenoid Fuse C1 Fuse C2 Back-up Alarm Relay Back-up Alarm Fuse B1 Forward/Reverse Switch Parking Brake Buzzer Relay Forward Relay Reverse Relay Diode Reverse Solenoid Forward Solenoid Dump Switch Parking Brake Switch Fuse B5 Brake Switch Fuel Gauge Fuel Gauge Sender Air Filter Switch Oil Pressure Switch Transmission Oil Temperature Switch Transmission Oil Pressure Switch Water Temperature Switch Diode Alternator Hourmeter Hourmeter Diode Bank Buzzer Fuse C3 Headlight Flasher Switch Dip Switch Fuse A4 Fuse A3 Fuse A2 Fuse A1 Fuse B3
9804/1103
61 Fuse B2 62 Road Lights Switch 63 Side Lights Relay 64 Diode 65 Diode 66 Neutral Start Relay 67 Battery Isolator (optional) Lights 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99
Direction Indicator Warning Hazard Warning L.H. Front Indicator L.H. Rear Indicator R.H. Front Indicator R.H. Rear Indicator Rear Working R.H. Stop L.H. Stop Beacon Blocked Air Filter Warning Engine Oil Pressure Warning Transmission Oil Temperature Warning Transmission Oil Pressure Warning Engine Coolant Temperature Warning Alternator Warning Parking Brake Warning Fuel Gauge/Hourmeter Illumination L.H. Side L.H. Tail R.H. Side R.H. Tail Number Plate Light L.H. Dip Beam R.H. Dip Beam L.H. Main Beam R.H. Main Beam Main Beam Warning Hazard Warning Switch Repeater Front Working Light (fitted to later machines)
Cable Colour Code B G K LG N O P R S U W Y
95 - 15 - 01/4
Black Green Pink Light Green Brown Orange Purple Red Slate Blue White Yellow
5100 - 10/7-4.3
Issue 1
CONTENTS
RTFL
926, 930
95 - 15 - 01/5
From m/c 664290
Circuit Diagram - Electrical (cont’d) Machines without IP67 electrics
9804/1103
95 - 15 - 01/5
5100 - 10/7-6.1
Issue 1
CONTENTS
RTFL
926, 930
95 - 15 - 01/6
From m/c 664290
Circuit Diagrams -Electrical (cont’d) Machines without IP67 electrical
*Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
Battery Thermostart Starter Motor Starter Solenoid Neutral start relay Starter Switch Dump pedal Forward/reverse switch Forward Relay Forward solenoid Reverse relay Transmission dump relay Reverse solenoid Reverse alarm Reverse lights - right hand side Reverse lights - left hand side Ignition relay Parking brake buzzer relay Parking brake switch Buzzer Parkbrake warning lamp Water temperature warning lamp Water temperature switch Transmission oil temperature warning lamp Transmission oil temperature switch Engine oil pressure warning lamp Engine oil pressure switch Transmission oil pressure warning lamp Transmission oil pressure switch Alternator warning lamp Alternator diode Hourmeter Alternator Brake lights switch Brake light - right hand Brake light - left hand Fuel gauge Fuel sender Engine shut-off solenoid (ESOS) Heater Switch Heater resistor Heater Motor Front indicator - right hand Rear indicator - right hand Hazard warning lights switch
9804/1103
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76
95 - 15 - 01/6
Indicator switch Indicator repeater Front indicator - left hand Rear indicator - left hand Flasher unit Beacon Beacon switch Rear wiper motor Roof wiper motor Face fan motor - optional Front wash/wipe switch Washer pump Front wiper motor Horn switch Horn Main beam indication lamp Main beam - right hand Headlight flash Main beam - left hand Dip beam - right hand Dip beam - left hand Side lights - left hand Road light switch Main beam/dip beam switch Rear light - left hand Number plate light - left hand Side light - right hand Rear light - right hand Number plate light - right hand Worklight switch Worklight
5100 - 10/7-5.1
Issue 2*
95 - 15 - 01/7 102
87 3
-7 1
800E
LINK
2
800B
3
1
71
701/60001
2
1
2 701/60016
4
962A
962
800
961
600H
600BG
600EG
600JF
600BD
600
600HT
600JA
600CE
600G
600BC
600AZ
600AZ
600H
600AX
600BC
600G
600AU
600DW
600B
600W
600AZ
600H
600BL
600G
600BC
600DX
600AP
600DY
600AZ
600EK
81
5100 - 10/7-7.2
77
X
600MX
600JG
600MY
600FB
600BH
600EB
600AR
600CJ
600G
600H
600N
600BC
TRANS OIL PRESS SWITCH
COMPRESSOR CLUTCH
CONDENSER RELAY CONDENSER FAN
HEATER MOTOR
AIR CON SWITCH
HEATER MOTOR
HEATER SWITCH
WORKLIGHT
WORKLIGHT SWITCH
RHS FOGLIGHT
LHS FOGLIGHT
FOGLIGHT SWITCH
MAIN BEAM IND RH MAIN BEAM LH MAIN BEAM
RH No PLATE LIGHT RH TAIL LIGHT RH SIDE LIGHT RH DIP BEAM LH DIP BEAM
ROADLIGHTS SWITCH LH No PLATE LIGHT LH TAIL LIGHT LH SIDE LIGHT
FRONT HORN
RH FRONT INDICATOR IGNITION RELAY
RH REAR INDICATOR
FLASHER UNIT
LH FRONT INDICATOR LH REAR INDICATOR
HAZARD SWITCH
BEACON
BEACON SWITCH
FRONT WIPER
WASHER PUMP
FACE FAN (OPTIONAL)
ROOF WIPER
REAR WIPER
E.S.O.S.
COLD START ADVANCE
FUEL SENDER
LH BRAKE LIGHT
RH BRAKE LIGHT
ALTERNATOR
HOURMETER
RTFL
M
82 963
980
30/925403
M
73
2
76
6
800
31
5
3
-7 1
835B
835A
78
+8
102F
2
+10
835
837B
52
SPLIT IF AIR CON FITTED.
2
855
3
-7
600HS
600AK
75
106AT
102
106R
70 701/60000
3
-7
701/60000
2
1
M
M
M
M
M
M
3
ENGINE OIL PRESS SWITCH
TRANS OIL TEMP SWITCH
WATER TEMP SWITCH
SHOWN WITH HANDBRAKE OFF
HANDBRAKE
REVERSE LIGHT LHS
REVERSE LIGHT RHS
REVERSE ALARM
REVERSE SOLENOID
REVERSE RELAY
FORWARD SOLENOID
FORWARD RELAY
STARTER MOTOR
THERMOSTART
926, 930 Circuit Diagrams-Electrical
FUSE B4
FUSE B3
74 1
2
+8
837A
837C
69
2
+8
FUSE B8
832A
837
67
72
116
314A
834B
834A
65
68
106L
106J
2
834A 834B
830D
0
66
701/60004
832
6
434B 830A 830R
830B
830G
829E
829D
829C
806E
806F
805F
805E
103N
63
5
FUSE B7
103F
103H
4
600BU
600HH
600C
600CK
600BF
600CV
600G
600H
600CD
64
138
58 828
105B
105A
816F
816G
200A
200
407
106D
4
415B
403B
600BS
600AC
600V
600AD
62
+3
-7
56
1
814
806D
406A 407A
407 407A
406B
404B
61
2
54 829A
805B
404A 816C
434
815A 815B
59
8+
FUSE B6
803A
806B
840
53 60
310P
314B
31
403A
839
3
1
2
49 57
106K
701/60005
49a
49
5
4
600BT
51
FUSE B2
314
+8
805 803B
5
802
894
43
17 18
2
105
408
411
401H
810A
815
811F
811G
811A
811
50
FUSE A9
27 106F
3
2
47
104
1
2
48
FUSE B1
300
11 701/60000
-
411B
401E
3
1 811B
46
3
200N
-10
45 3
-7
+
S
434 434A
415 415B
403 403B
404 404B
406 406B
401E 401H
5
2
812
33 34
FUSE A8
6 1
875A
4
3
1
2
44
2
+8
830A
106 V
106AA
106AF
106AD
106AC
106AB
106AK
808
875 5
4
32
42
303G
106N
815B
838
809
40 41
FUSE A7
110
103
108
411 411B
4
100C
2
1
3
R
810C
39
FUSE A6
106C
5
100B
F N
2
842
35
38
FUSE A5
100A
4
1
3
18 20 22 24 26 29
FUSE A4
FUSE A3
106E
FUSE A1
100
FUSE A10
FUSE A2
003
810A 810C
5
M
37
5
IGN
5
PRE HEAT
002
003A
004
17 36
1
2
9
8
7
4
6 001A
5 001
7
4
2
1
4 16 30
310L
001A
310B
310A
OFF 30
9804/1103 15/54 17
PRI FUSE 4 50a
PRI FUSE 1 60A 19
123
1 9 14 28
828 - 2 WAY BUSBAR IN FUSEBOX
PRI FUSE 2 60A
12 19 21 23 25
803A 803B
10
415A
8 15
806A
2 13
805A
CONTENTS
95 - 15 - 01/7
All m/c’s from May2001
Machines without IP67 electrics
83 M
86
M
3 85
84
80
79
001 - 6 WAY BUSBAR IN FUSEBOX
002 - 4 WAY BUSBAR IN FUSEBOX
55
PRI FUSE 3 50A 70A
310D 310L
305
310G - 3 WAY BUSBAR IN FUSEBOX
A370710
Issue 1
START
CONTENTS
RTFL
926, 930
95 - 15 - 01/8
All m/c’s from May 2001
Circuit Diagrams -Electrical (cont’d) Component Key
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Battery Thermostart Starter motor/solenoid Neutral start relay Starter switch Dump pedal Forward/reverse switch Forward relay Reverse relay Forward solenoid Transmission dump relay Reverse solenoid Reverse alarm Reverse lights - right hand side Reverse lights - left hand side Parking brake switch Parking brake buzzer relay Parkbrake warning lamp Water temperature switch Water temperature warning lamp Transmission oil temperature switch Transmission oil temperature warning lamp Engine oil pressure switch Engine oil pressure warning lamp Transmission oil pressure switch Transmission oil pressure warning lamp Buzzer Hourmeter Alternator warning lamp Alternator Alternator diode Brake lights switch Brake light - right hand Brake light - left hand Fuel gauge Fuel sender Cold start advance Engine shut-off solenoid (ESOS) Rear wiper motor Roof wiper motor
9804/1103
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87
95 - 15 - 01/8
Face fan (optional) Front wash/wipe switch Washer pump Front wiper motor Beacon switch Beacon Hazard warning lights switch Flasher unit Left hand front indicator Left hand rear indicator Right hand rear indicator Right hand front indicator Indicator repeater lamp Indicator switch Ignition relay Horn switch Horn Road lights switch Left hand number plate lamp Left hand tail light Left hand side light Right hand number plate Right hand tail light Right hand side light Right hand dip beam Left hand dip beam Main beam indicator lamp Right hand main beam Left hand main beam Main beam/dip beam switch/light flash Fog light switch Left hand fog light Right hand fog light Work light switch Work light Heater switch Heater resistor Heater motor Air conditioning switch Resistor switch - air conditioning Heater motor - air conditioning Condenser relay - air conditioning Condenser fan motor - air conditioning Thermostat - air conditioning Pressure switch - air conditioning Compressor clutch - air conditioning Link removed if air conditioning fitted
5100 - 10/7-8.1
Issue 1
RTFL
CONTENTS
95 - 20 - 01/1
926, 930 Circuit Diagrams - Hydraulics
1B
12
2
11 2E
2E
2D
2C
1A
2F
2G
2A
P
2X
10 S P1 13
F
14
T
15
16
A184641
9804/1103
95 - 20 - 01/21
5100 - 2/11 -1.2
Issue 1
RTFL
CONTENTS
95 - 20 - 01/2
926, 930 Circuit Diagrams - Hydraulics (cont’d) Component Key F P P1 T S 1A 1B 2 2A 2C 2D 2E 2F 2G 2X 10 11 12 13 14 15 16
Filter Priority valve Pump Tank Combined steering unit and shock valve Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Tilt spool Auxiliary spool Load hold check valve (L.H.C.V) Auxiliary relief valves (A.R.V's) System pressure test point Lift rams Tilt rams Steer ram Flow regulator cartridge Hose burst protection valve Deration diverter valve Deration valve
9804/1103
95 - 20 - 01/2
5100 - 2/11 -2.2
Issue 1
CONTENTS
Excavators
Contents 1
* JS
70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180, 200, 200W, 210, 220, 240, 260, 300, 330, 450LC, 460
Contents Page No. General Information Fluids, Lubricants and Capacities - JS 70 to m/c no. 695500 45 - 00 - 01/1 - JS 110, 130 to m/c no. 757999, 150LC 45 - 00 - 01/2 - JS 200LC to m/c no. 705000, 240LC to m/c no. 780500, 300LC, 450LC 45 - 00 - 01/3 - JS 130W, 150W 45 - 00 - 01/4 - JS 70 from m/c no. 695501 45 - 00 - 01/4A - JS130 from m/c no. 758000, JS160 from m/c no. 702000 45 - 00 - 01/5 - JS180 45 - 00 - 01/5A - JS130W frm m/c no. 716500, JS145W from m/c no. 810000, JS160W from m/c no. 718500 45 - 00 - 01/4B - JS200, 220 from m/c no. 705001, JS210 from m/c no. 705648,JS240 from m/c no.708001, * JS260 from m/c no. 708501 45 - 00 - 01/6 - JS200W from m/c no. 0802000 to 802999 45 - 00 - 01/6A & 45 - 00 - 01/6B - JS330 from m/c no. 712501, JS450 from m/c no. 714501, JS460 from m/c no. 714550 45 - 00 - 01/7 - JS200W from m/c no. 809000 45 - 00 - 01/6C & 45 - 00 - 01/6D
*
Static Dimensions - JS 70 to m/c no. 695500 - JS 110 - JS 130 to m/c no. 757999 - JS 150LC - JS 200LC - JS 240LC - JS 300LC - JS 450LC - JS 130W - JS 150W - JS 70 from m/c no. 695501 - JS130 from m/c no. 758000 - JS160 from m/c no. 702000 - JS180 - JS200, 220 from m/c no. 705001 - JS210 - JS240, 260 from m/c no. 708501 - JS220LC Long reach (LR) from m/c no. 705001 - JS330 from m/c no. 712501 - JS450 from m/c no. 714501 - JS130W from m/c no. 0716500 - JS160W from m/c no. 0718500 - JS200W from m/c no. 0802000 to 802999 - JS200W from m/c no. 809000 - JS460 from m/c no. 714550 Shipping Weights - JS 70 to m/c no. 695500 - JS 110, 130, 150LC - JS 200LC to m/c no. 70500, 240LC to m/c no. 780500, 300LC, 450LC - JS 70 from m/c no. 695501 - JS130 from m/c no. 758000, JS160, 180 from m/c no. 702000 - JS200, 210, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 - JS330 from m/c no. 712501, JS450 from m/c no. 714501, JS460 from m/c no. 714550 - JS130W from m/c no. 0716501, JS160W from 0718501 - JS200W from m/c no. 0802000 to 802999
9804/1103
Excavator Contents - 1
45 - 00 - 02/1 45 - 00 - 02/2 45 - 00 - 02/3 45 - 00 - 02/4 45 - 00 - 02/5 45 - 00 - 02/6 45 - 00 - 02/7 45 - 00 - 02/8 45 - 00 - 02/9 45 - 00 - 02/10 45 - 00 - 02/10A 45 - 00 - 02/11 45 - 00 - 02/12 45 - 00 - 02/12A 45 - 00 - 02/13 45 - 00 - 02/13A 45 - 00 - 02/14 45 - 00 - 02/15 45 - 00 - 02/16 45 - 00 - 02/16A 45 - 00 - 02/17 45 - 00 - 02/18 45 - 00 - 02/19 45 - 00 - 02/20 45 - 00 - 02/21
45 - 00 - 03/1 45 - 00 - 03/2 45 - 00 - 03/3 45 - 00 - 03/3A 45 - 00 - 03/4 45 - 00 - 03/4 45 - 00 - 03/4 45 - 00 - 03/5 45 - 00 - 03/6
Issue 9*
CONTENTS
Excavators
Contents 2
* JS
70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180, 200, 200W, 210, 220, 240, 260, 300, 330, 450LC, 460
Contents Data Electrical - JS 70 to m/c no. 695500 - JS 110, 130, 150LC - JS 200LC, 240LC, 300LC, 450LC - JS 130W, 150W - JS130 from m/c no. 758000, JS160 from m/c no. 702000 - JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 - JS130W from m/c no. 0716501, JS160W from m/c no. 0718501 * - JS70 from m/c no. 695501 - JS 200W from m/c no. 809000 * - JS330 from m/c no. 712501, JS450 from m/c no. 714501 JS460 from m/c 714550 - The A.M.S. System Data Hydraulic - JS 70 to m/c no. 695500 - JS 110 - JS 130 to m/c no. 757999 - JS 150 - JS 200LC to m/c no. 705000 - JS 240LC - JS 300LC - JS 450LC - JS 130W from m/c no. 0716501, JS145W from m/c no. 810000 - JS 70 from m/c no. 695501 - JS130 from m/c no. 758000 - JS160 from m/c no. 702000 - JS200, 220 from m/c no. 705001 - JS240, 260 from m/c no. 708501 * - JS 200W from m/c no. 809000 - JS330 from m/c no. 712501 - JS450 from m/c no. 714501, JS460 from m/c no. 714550 *
Track Motor/Gearbox - JS130 from m/c no. 758000, JS160 from m/c no. 702000 - JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 - JS330 from m/c no. 712501, JS450 from m/c no. 714501 JS460 from m/c no 714550
Page No. 45 - 05 - 01/1 45 - 05 - 01/2 45 - 05 - 01/3 45 - 05 - 01/4 & 45 - 05 - 01/5 45 - 05 - 01/6 45 - 05 - 01/6 45 - 05 - 01/7 45 - 05 - 01/8 45 - 05 - 01/9 & 45 - 05 - 01/10 45 - 05 - 01/11 45 - 05 - 01/12,13
45 - 05 - 02/1 45 - 05 - 02/2 45 - 05 - 02/3 45 - 05 - 02/4 45 - 05 - 02/5 45 - 05 - 02/6 45 - 05 - 02/7 45 - 05 - 02/8 45 - 05 - 02/9 to 45 - 05 - 02/10D 45 - 05 - 02/11 45 - 05 - 03/1 & 45 - 05 - 03/2 45 - 05 - 03/3 & 45 - 05 - 03/4 45 - 05 - 03/5 & 45 - 05 - 03/6 45 - 05 - 03/7 & 45 - 05 - 03/8 45 - 05 - 03/9 to 45 - 05 - 03/11 45 - 05 - 03/12 & 45 - 05 - 03/13 45 - 05 - 03/14
45 - 05 - 04/1 45 - 05 - 04/2 45 - 05 - 04/3 to 45 - 05 - 04/5
Control Valve - JS 200W from m/c no. 809000
45 - 05 - 05/1
Drive Gearbox - JS 200W from m/c no. 809000
45 - 05 - 06/1
Front Axle - JS 200W from m/c no. 809000 - JS130W from m/c no. 716500 (SD70 PT) - JS130W from m/c no. 716500, JS160W from m/c no. 718500 (SD80PT)
45 - 05 - 07/1 45 - 07 - 07/1A 45 - 07 - 07/1B
Rear Axle - JS 200W from m/c no. 809000 - JS130W from m/c no. 716500 (PD70) - JS130W from m/c no. 716500, JS160W from m/c no. 718500 (PD80)
45 - 05 - 07/2 45 - 07 - 07/2A 45 - 07 - 07/2B
Engine - JS 70 to m/c no. 695500 - JS 110, 130, 150LC - JS 200LC, 240LC - JS 300LC, 450LC - JS 70 from m/c no. 695501 - JS 130W from m/c no. 785001, JS160W from m/c no. 702001
45 - 05 - 08/1 45 - 05 - 08/2 45 - 05 - 08/3 45 - 05 - 08/4 45 - 05 - 08/4A 45 - 05 - 08/5
9804/1103
Issue 7*
CONTENTS
Excavators
Contents 3
* JS
70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180, 200, 200W, 210, 220, 240, 260, 300, 330, 450LC, 460
Contents *
*
Engine (cont’d) Page No. - JS 330 from m/c no. 712501, JS450 from m/c no. 714501 45 - 05 - 08/6 JS460 from m/c no.714550 - JS460 Tier 2 45 - 05 - 08/6A - JS 130 from m/c no. 716501, JS160 from m/c no. 718501 45 - 05 - 08/7 - JS130W from m/c no. 716500, JS145 from m/c no. 810000 45 - 05 - 08/7A - JS175W from m/c no. 875000 45 - 05 - 08/8 JS160W from m/c no. 718500, - JS 200W from m/c no. 809000 45 - 05 - 08/9 - JS200, 220 from m/c no. 705001, JS210 from m/c no. 705648,JS240 from m/c no.708001, JS260 from m/c no. 708501 45 - 05 - 08/10 Track and Running Gear - JS330 from m/c no. 712501, JS450 from m/c no. 714501 Fault Finding Hydraulics - JS 70 to m/c no. 695500 - JS 110, 130 - JS 150LC - JS 200LC, 300LC - JS 240LC - JS 450LC - JS70 from m/c no. 695501 - JS 200W from m/c no. 809000
45 - 05 - 09/1 & 45 - 05 - 09/2
45 - 10 - 01/1 to 45 - 10 - 01/3 45 - 10 - 01/4 to 45 - 10 - 01/8 45 - 10 - 01/9 to 45 - 10 - 01/13 45 - 10 - 01/14 to 45 - 10 - 01/19 45 - 10 - 01/20 45 - 10 - 01/21 to 45 - 10 - 01/23 45 - 10 - 01/24 & 45 - 10 - 01/25 45 - 10 - 01/26 to 45 - 10 - 01/31
Track Gearbox - JS 110, 130, 150LC - JS 200LC, 240LC, 300LC, 450LC
45 - 10 - 02/1 & 45 - 10 - 02/2 45 - 10 - 02/3 & 45 - 10 - 02/4
Swing Gearbox - JS70, 110, 130, 150LC, 200LC, 240LC, 300LC, 450LC - JS130W from m/c no. 716500, JS160W from m/c no. 718500 - JS200 from m/c no. 705001, JS240 from m/c no. 708501 - JS 200W from m/c no. 809000
45 - 10 - 03/1 45 - 10 - 03/6 45 - 10 - 03/2 to 45 - 10 - 03/3 45 - 10 - 03/6
Pump/ Regulator - JS130 from m/c no. 758000, JS160 from m/c no. 702000 - JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 - JS330 from m/c no. 712501, JS450 from m/c no. 714501 - JS330 from m/c no. 712501, JS460 from m/c no. 714550
45 - 10 - 05/1 to 45 - 10 - 05/2 45 - 10 - 06/1 to 45 - 10 - 06/2 45 - 10 - 06/3 & 45 - 10 - 06/4 45 - 10 - 06/5
*
* Remote Control Valve - JS130 from m/c no. 758000, JS160 from m/c no. 702000 - JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501, JS 200W from m/c no. 809000 - JS330 from m/c no. 712501, JS450 from m/c no. 714501 JS460 from m/c no. 714550
45 - 10 - 07/1 45 - 10 - 07/1 45 - 10 - 07/1
Control Valve - JS70 from m/c no. 695501
45 - 10 - 07/2 & 45 - 10 - 07/3
Multiple Valve - JS70 from m/c no. 695501
45 - 10 - 07/4
Rams - JS70 from m/c no. 695501 - JS130 from m/c no. 758000, JS160 from m/c no. 702000 - JS130W from m/c no. 716500, JS160W from m/c no. 718500 - JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501
45 - 10 - 08/1 to 45 - 10 - 08/5 45 - 10 - 08/1 to 45 - 10 - 08/5 45 - 10 - 08/1 to 45 - 10 - 08/5 45 - 10 - 08/1 to 45 - 10 - 08/5
Track Motor/Gearbox - JS70 from m/c no. 695501
45 - 10 - 09/1 to 45 - 10 - 09/3
9804/1103
Excavator Contents - 3
Issue 7*
CONTENTS
Excavators
Contents 4
* JS
70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180, 200, 200W,210, 220, 240, 260, 300, 330, 450LC, 460
Contents - JS130 from m/c no. 758000, JS160 from m/c no. 702000 - JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 - JS330 from m/c no. 712501, JS450 from m/c no. 714501 Fault Finding (cont’d) Slew Motor - JS70 from m/c no. 695501 - JS130 from m/c no. 758000, JS160 from m/c no. 702000 * - JS130W from m/c no. 716500, JS145W from m/c no. 810000 JS160W from m/c no. 718500, JS175W from m/c no. 875000 - JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501, JS 200W from m/c no. 809000 - JS330 from m/c no. 712501, JS450 from m/c no. 714504 JS460 from m/c no. 714550
*
45 - 10 - 09/1 to 45 - 10 - 09/3 45 - 10 - 10/1 to 45 - 10 - 10/5 45 - 10 - 10/6 to 45 - 10 - 10/11 Page No. 45 - 10 - 03/4 & 45 - 10 - 03/5 45 - 10 - 11/1 to 45 - 10 - 11/2 45 - 10 - 11/1 to 45 - 10 - 11/2 45 - 10 - 11/1 to 45 - 10 - 11/2 45 - 10 - 11/3
Engine - JS70 from m/c no. 695501
45 - 10 - 12/1
Monitor Display - JS70 from m/c no. 695501
45 - 10 - 13/1
Operating Controls - JS70 from m/c no. 695501
45 - 10 - 13/2
Hydraulic Pump - JS70 from m/c no. 695501
45 - 10 - 13/2
Working Attachments - JS70 from m/c no. 695501
45 - 10 - 13/2
Travelling - JS70 from m/c no. 695501
45 - 10 - 13/3
Slewing - JS70 from m/c no. 695501
45 - 10 - 13/3
Hydraulic Rams - JS70 from m/c no. 695501
45 - 10 - 13/3
Electrics - JS330 from m/c no. 712501, JS450 from m/c no. 714501 JS460 from m/c no. 714550 Circuit Diagrams Electrical - JS70 to m/c no. 695500 - JS70 from m/c no. 695501 - JS110, 130 to m/c no. 757999 - JS150LC - JS200LC to m/c no. 705000 - JS240LC to m/c no. 780500 - JS300LC - JS450LC - JS130W, 150W (Common with JS130, JS150 Tracked Excavators) - JS130W, 150W (Additional to JS130, JS150 Tracked Excavators) - JS130W, 150W (Relay Box P.C.B.) - JS130W from m/c no. 716501, 160W from 718501 - JS130 from m/c no. 758000, JS160 from m/c no. 702000 * - JS200W from m/c no. 809000 - JS200, 220 from m/c no.705001, JS240 from m/c no. 708501 - JS330 from m/c no. 712501 - JS450 from m/c no. 714501 - JS330/JS460 (AMS) - JS460 Tier2 9804/1103
Excavator Contents - 4
45 - 10 - 14/1 to 45 - 10 - 14/19
45 - 15 - 01/1 & 45 - 15 - 01/2 45 - 15 - 01/2A & 45 - 15 - 01/2B 45 - 15 - 01/3 & 45 - 15 - 01/4 45 - 15 - 01/5 & 45 - 15 - 01/6 45 - 15 - 01/7 & 45 - 15 - 01/8 45 - 15 - 01/9 & 45 - 15 - 01/10 45 - 15 - 01/11 & 45 - 15 - 01/12 45 - 15 - 01/13 & 45 - 15 - 01/14 45 - 15 - 02/1 & 45 - 15 - 02/2 45 - 15 - 02/3 & 45 - 15 - 02/4 45 - 15 - 02/5 & 45 - 15 - 02/6 45 - 15 - 02/7 to 45 - 15 - 02/11 45 - 15 - 02/11A & 45 - 15 - 02/11B 45 - 15 - 02/12 & 45 - 15 - 02/13 45 - 15 - 02/13A & 45 - 15 - 02/13B 45 - 15 - 02/14 & 45 - 15 - 02/15 45 - 15 - 02/16 & 45 - 15 - 02/17 45 - 15 - 02/18 & 45 - 15 - 02/19 45 - 15 - 02/20 & 45 - 15 - 02/21 Issue 4*
CONTENTS
Excavators
Contents 5
JS 70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180,, 200, 200W, 210, 220, 240, 260, 300, 330, 450LC, 460
Contents Hydraulic - JS70 (Standard Boom to m/c 695001) - JS70 (Offset Boom to m/c 695001) - JS70 (Standard Boom from m/c 695002 to m/c 695500) - JS70 (Offset Boom from m/c 695002 to m/c 695500) Circuit Diagrams Hydraulic (cont’d) - JS70 from m/c no. 695501 - JS110 (To m/c 697013) & 130 (To m/c 699036) - JS110 (From m/c 697014) & 130 (From m/c 699037 to m/c no. 757999) - JS150LC (To m/c 701044) - JS150LC (From m/c 701045) - JS200LC (To m/c 704074) - JS200LC (From m/c 704075 to m/c no. 705000) - JS240LC to m/c no. 780500 - JS300LC - JS450LC - JS130W from m/c no. 716501, JS145W from m/c no. 810000, 160W from m/c no. 718501, JS175W from m/c no. 875000 - JS160W from m/c no. 718501, JS175W from m/c no. 875000 - TAB Option - JS130W from m/c no. 716501, 160W from m/c no. 718501 - JS130 from m/c no. 758000 - JS160 from m/c no. 702000 - JS175W from m/c no. 875000 - JS200, 220 from m/c no. 705001 - JS240, 260 from m/c no. 708001 - JS330 from m/c no. 712501 - JS450 from m/c no. 714501 - JS460 from m/c no. 714550 - JS330/JS460 Tier2 - JS450/JS460 - Control Valve - JS460 Tier2 - Control Valve - JS460 Tier2 - Circuit Descriptions
9804/1103
Excavators Contents - 5
45 - 20 - 01/1 & 45 - 20 - 01/2 45 - 20 - 01/3 & 45 - 20 - 01/4 45 - 20 - 01/5 & 45 - 20 - 01/6 45 - 20 - 01/7 & 45 - 20 - 01/8 Page No. 45 - 20 - 01/8A &45 - 20 - 01/8B 45 - 20 - 01/9 & 45 - 20 - 01/10 45 - 20 - 01/11 & 45 - 20 - 01/12 45 - 20 - 01/13 & 45 - 20 - 01/14 45 - 20 - 01/15 & 45 - 20 - 01/16 45 - 20 - 01/17 & 45 - 20 - 01/18 45 - 20 - 01/19 & 45 - 20 - 01/20 45 - 20 - 01/21 & 45 - 20 - 01/22 45 - 20 - 01/23 & 45 - 20 - 01/24 45 - 20 - 01/25 & 45 - 20 - 01/26 45 - 20 - 02/1 & 45 - 20 - 02/2 45 - 20 - 02/3 45 - 20 - 02/4 45 - 20 - 02/4A & 45 - 20 - 02/4B 45 - 20 - 02/4C & 45 - 20 - 02/4D 45 - 20 - 02/4E & 45 - 20 - 02/4F 45 - 20 - 02/6A & 45 - 20 - 02/6B 45 - 20 - 02/6C & 45 - 20 - 02/6D 45 - 20 - 02/7 & 45 - 20 - 02/8 45 - 20 - 02/9 & 45 - 20 - 02/10 45 - 20 - 02/11 & 45 - 20 - 02/12 45 - 20 - 02/13 & 45 - 20 - 02/14 45 - 20 - 02/15 45 - 20 - 02/16 45 - 20 - 02/17 to 45 - 20 - 02/42
Issue 2*
CONTENTS CONTENTS
* JS
Excavators
45 - 00 - 01/1
70 to m/c no. 695500
Lubricants & Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
* Item
Lubricant
Capacity
ENGINE
To Class API CD (see separate chart below)
6 litres (1.32 UK gal)
TRACK GEARBOX
JCB HD90 Gear Oil
2 x 1.7 litres (2 x 0.37 UK gal)
SWING GEARBOX
JCB HD90 Gear Oil
6 litres (1.3 UK gal) 0.9 litres (0.18 UK gal)
*JCB HP Grease
TRACK ROLLERS AND IDLER WHEEL
Engine Oil
HYDRAULIC SYSTEM
JCB Hydraulic Fluid 46
92 litres (20.26 UK gal)
SWING RING - BEARINGS - GEAR TEETH
*JCB HP Grease *JCB HP Grease
3.2 kg (7.14 lb)
ALL OTHER GREASE POINTS
*JCB HP Grease
-
COOLING SYSTEM
10.4 litres (2..29 UK gal)
FUEL TANK
130 litres (28.6 UK gal)
ENGINE LUBRICATION CHART
*
Use according to ambient temperature (°C) -20
-10
0
10
20
30
40
JCB 15W/40 MULTIGRADE ENGINE OIL API CD MIL L-2104C JCB SUPER UNIVERSAL AGRICULTURAL (10W/30) API CD/SF
9804/1103
45 - 00 - 01/1
Issue 4*
CONTENTS CONTENTS
Excavators
45 - 00 - 01/2
JS 110, 130, 150LC Lubricants & Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
Item
Lubricant
Capacity JS110
JS130
JS150LC
ENGINE
To Class API CD (see separate chart below)
13.8 litres (3 UK gal)
13.8 litres (3 UK gal)
13.8 litres (3 UK gal)
TRACK GEARBOX
JCB HD90 Gear Oil
SWING GEARBOX
JCB HD90 Gear Oil
2 x 2.5 litres (2 x 0.55 UK gal) 1.7 litres (0.37 UK gal) 0.47 litres (0.1 UK gal)
2 x 2.5 litres (2x 0.55 UK gal) 1.7 litres (0.37 UK gal) 0.47 litres
2 x 3 litres (2x0.55UK gal) 6 litres (1.32 UK gal) Not applicable
*JCB HP Grease (0.1 UK gal) TRACK ROLLERS AND IDLER WHEEL
Engine Oil
HYDRAULIC SYSTEM
JCB Hydraulic Fluid 46
157 litres (34.5 UK gal)
157 litres (34.5 UK gal)
170 litres (37.4 UK gal)
SWING RING - BEARINGS - GEAR TEETH
*JCB HP Grease *JCB HP Grease
10 kg (22 lb)
10 kg (22 lb)
13 kg (28.7 lb)
EXCAVATOR GREASE POINTS
*JCB HP Grease
COOLING SYSTEM
17.8 litres (3.9 UK gal)
17.8 litres (3.9 UK gal)
17.8 litres (3.9 UK gal)
FUEL TANK
240 litres (52.8 UK gal)
240 litres (52.8 UK gal)
240 litres (52.8 UK gal)
-
-
-
ENGINE LUBRICATION CHART
Use according to ambient temperature (°C) -20
-10
0
10
20
30
40
JCB 15W/40 MULTIGRADE ENGINE OIL API CD MIL L-2104C JCB SUPER UNIVERSAL AGRICULTURAL (10W/30) API CD/SF
9804/1103
45 - 00 - 01/2
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 00 - 01/3
JS 200LC,240LC,300LC,450LC Lubricants & Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently runin. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
Item
Lubricant
Capacity JS200LC
JS240LC
JS300LC
JS450LC
20 litres (4.4 UK gal)
33 litres (7.26 UK gal)
45 litres (9.9 UK gal)
ENGINE
To Class API CD (see separate chart)
22.6 litres (5 UK gal)
TRACK GEARBOX
JCB HD90 Gear Oil
Serial Nos up to 2 x 3.3 litres 2 x 8.5 litres 2 x 7 litres 704597 (2 x 0.73 UK gal) 2 x 1.87 UK gal) (2 x 1.54 UK gal) 2 x 5.6 litres (2 x 1.23 UK gal) Serial Nos from 704598 on 2 x 3.5 litres (2 x 0.77 UK gal)
SWING GEARBOX
JCB HD90 Gear Oil (1.3 UK gal) JCB HP Grease (0.18 UK gal)
6 litres (2.4 UK gal) 0.9 litres -
TRACK ROLLERS AND IDLER WHEEL Engine Oil
-
11 litres (3.9 UK gal) -
-
14.5 litres (4 UK gal) -
18 litres
-
-
-
HYDRAULIC SYSTEM
JCB Hydraulic Fluid 46
233 litres (51.3 UK gal)
350 litres (77 UK gal)
320 litres (68.4 UK gal)
450 litres (99 UK gal)
SWING RING - BEARINGS - GEAR TEETH
JCB HP Grease JCB HP Grease
13 kg (28.6 lb)
22 kg (48.4 lb)
27 kg (59.4 lb)
31 kg (68.2 lb)
ALL OTHER GREASE POINTS
JCB HP Grease
COOLING SYSTEM
25.8 litres (5.7 UK gal)
25 litres (5.5 UK gal)
34 litres (7.5 Uk gal)
50 litres (11 UK gal)
FUEL TANK
280 litres (61.6 UK gal)
280 litres (61.6 UK gal)
500 litres (110 UK gal)
500 litres (110 UK gal)
ENGINE LUBRICATION CHART
Use according to ambient temperature (°C) -20
-10
0
10
20
30
40
JCB 15W/40 MULTIGRADE ENGINE OIL API CD MIL L-2104C JCB SUPER UNIVERSAL AGRICULTURAL (10W/30) API CD/SF
9804/1103
45 - 00 - 01/3
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 00 - 01/4
JS 130W, 150W Lubricants & Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
Capacity Item
Lubricant JS130W
JS150W
ENGINE
To Class API CD (see separate chart)
13.8 litres (3 UK gal)
13.8 litres (3 UK gal)
SWING GEARBOX
JCB HD90 Gear Oil
1.7 litres (0.37 UK gal) 0.47 litres (0.1 UK gal)
6 litres (1.32 UK gal) Not Applicable
JCB HP Grease
HYDRAULIC SYSTEM
JCB Hydraulic Fluid 46
157 litres (34.5 UK gal)
170 litres (37.4 UK gal)
SWING RING - BEARINGS - GEAR TEETH
JCB HP Grease JCB HP Grease
10 kg (22lb)
13 kg (28.7 lb)
PROPSHAFTS
JCB HP Grease
ALL OTHER GREASE POINTS
JCB HP Grease
COOLING SYSTEM
17.8 litres (3.9 UK gal)
17.8 litres (3.9 UK gal)
FUEL TANK
240 litres (52.8 UK gal)
240 litres (52.8 UK gal)
9 litres (2 UK gal) 0.9 litres (0.2 UK gal)
9 litres (2 UK gal) 1.5 litres (0.33 UK gal)
12 litres (2.64 UK gal) 0.9 litres (0.2 UK gal)
12 litres (2.64 UK gal) 1.5 litres (0.33 UK gal)
3.4 litres (0.8 gal)
3.4 litres (0.8 gal)
FRONT AXLE - DIFFERENTIAL - HUB (x 2)
JCB Gear Oil LS JCB Gear Oil LS
REAR AXLE - DIFFERENTIAL - HUB (x 2)
JCB Gear Oil LS JCB Gear Oil LS
DRIVE GEARBOX
JCB 15W/40 Multigrade Oil
Use according to ambient temperature (°C) -20
-10
0
10
20
30
40
JCB 15W/40 MULTIGRADE ENGINE OIL API CD MIL L-2104C JCB SUPER UNIVERSAL AGRICULTURAL (10W/30) API CD/SF
9804/1103
45 - 00 - 01/4
Issue 2
CONTENTS CONTENTS
Excavators
45 - 00 - 01/4A
JS 70 from m/c no. 695501 Lubricants & Capacities Note: New engines DO NOT require a running-in period. The engine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
Item
Fluid/Lubricant
International Specification
Capacity
ENGINE
See separate chart
-
6.8 litres (1.49 UK gal)
SLEW GEARBOX
JCB HP Grease
Lithium based, No. 2 consistency
0.2 kg (0.44 lb)
TRACK GEARBOXES
JCB Gear Oil HD90
API-GL-5, MIL-L-2105C
2 x 1.7 litres (0.37 UK gal)
TRACK ROLLERS AND IDLER WHEEL
Engine Oil (see separate chart)
-
-
JCB Special Hydraulic Fluid HP46
Vickers 35VQ25/V104C: Sundstrand, Denison and FZG Approval Tests
92 litres (20.26 UK gal)
SLEW RING - BEARINGS - GEAR TEETH
JCB HP Grease JCB HP Grease
Lithium based, No. 2 consistency
3.2 kg (7.14 lb)
ALL OTHER GREASE POINTS
JCB HP Grease
Lithium based, No. 2 consistency
HYDRAULIC SYSTEM
COOLING SYSTEM
ASTM D3306-74
10.1 litres (2.22 UK gal)
FUEL TANK
ASTM D975-66T Nos 1D, 2D
140 litres (30.8 UK gal)
Engine Lubrication Chart
*
Use according to ambient temperature (°C) -20
-10
0
10
20
30
40
JCB SUPER 15W/40 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F JCB SUPER UNIVERSAL AGRICULTURAL (10W/30) API CE/SF MIL L-2104D
9804/1103
45 - 00 - 01/4A
Issue 1
Excavators
CONTENTS CONTENTS
45 - 00 - 01/4B
JS 130W from m/c no. 716500, JS160W from m/c no. 718500 Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
Item
International Specification
Fluid/Lubricant
Capacity JS130W
JS160W
12.1 litres (2.7 UK gal)
12.1 litres (2.7 UK gal)
ENGINE
See separate chart
SLEW GEARBOX
JCB Gear Oil HD90
API-GL-5: MIL-L-2105C
5 litres (1.09 UK gal)
5 litres (1.09 UK gal)
HYDRAULIC SYSTEM
JCB Special Hydraulic Fluid HP46
Vickers 35VQ25/V104C: Sundstrand, Denison and FZG Approval Tests
124 litres (27.3 UK gal)
124 litres (27.3 UK gal)
SLEW RING - BEARINGS - GEAR TEETH
JCB HP Grease JCB HP Grease
Lithium complex (NLGI) inc. extreme pressure additives
17 kg (37.48 lb)
17 kg (37.48 lb)
PROPSHAFTS
JCB HP Grease
Lithium complex (NLGI) inc. extreme pressure additives
ALL OTHER GREASE POINTS
JCB HP Grease
Lithium complex (NLGI) inc. extreme pressure additives
COOLING SYSTEM
See Coolant Mixtures
ASTM D3306-74
16.4 litres (3.6 UK gal)
17.2 litres (3.78 UK gal)
FUEL TANK
See Fuel System, Types of Fuel
ASTM D975-66T Nos 1D, 2D
240 litres (52.8 UK gal)
240 litres (52.8 UK gal)
JCB Special Gear Oil Plus JCB Special Gear Oil Plus
API GL4: M2C-41B/134D, JD20C MGF M1135/M1141/ M1143
18 litres (3.9 Uk gal) 1.5 litres (0.33 UK gal)
18 litres (3.9 Uk gal) 1.5 litres (0.33 UK gal)
JCB Special Gear Oil Plus
API GL4: M2C-41B/134D JD20C, MGF M1135/M1141/ M1143
17.7 litres (3.9 UK gal)
17.7 litres (3.9 UK gal)
JCB Super 15W/40 Multigrade Engine Oil
API CF4/SG: MIL-L-2104F
3.8 litres (0.83 UK gal)
3.8 litres (0.83 UK gal)
FRONT AXLE - DIFFERENTIAL - HUB (x 2)
REAR AXLE - DIFFERENTIAL AND HUBS (x 2)
DRIVE GEARBOX
Engine Lubrication Chart - All Machines Use according to ambient temperature (°C) -30
-20
-10
0
10
20
30
40
50
JCB SUPER 15W/40 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F JCB SUPER 10W/30 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F
9804/1103
45 - 00 - 01/4B
6980 - 127.1
Issue 1
Excavators
CONTENTS CONTENTS
45 - 00 - 01/5
JS 130 from m/c no. 758000, JS160 from m/c no. 702000 *
Lubricants and Capacities Capacity
International Item
Lubricant
Specification
JS130
JS160
12.1 litres (2.7 UK gal) (3.2 US gal)
12.1 litres (2.7 UK gal) (3.2 US gal)
ENGINE
(see separate chart)
TRACK GEARBOX
JCB HD90 Gear Oil
API-GL-5, MIL-L-2105
2 x 3.0 litres (2 x 0.66 UK gal) (2 x 0.79 US gal)
2 x 3.0 litres (2 x 0.66 UK gal) (2 x 0.79 US gal)
SLEW GEARBOX
JCB HD90 Gear Oil
API-GL-5, MIL-L-2105
JCB Special HP Grease
Lithium based No. 2 consistency
5 litres (1.09 UK gal) (1.31 US gal) 1 litre (0.22 UK gal) (0.26 US gal)
5 litres (1.09 UK gal) (1.31 US gal) 1 litre (0.22 UK gal) (0.26 US gal)
TRACK ROLLERS IDLER WHEEL
JCB HD 90 Gear OIl
API-GL-5, MIL-L-2105
-
-
RECOIL SPRING CYLINDER
JCB Special HP Grease
Lithium based, No. 2 consistency
-
-
HYDRAULIC SYSTEM
JCB Hydraulic Fluid 46
ISO VG46
124 litres (27.3 UK gal) (32.8 US gal)
124 litres (27.3 UK gal) (32.8 US gal)
SLEW RING - BEARING
JCB Special HP Grease
-
-
- GEAR TEETH
JCB Special HP Grease
Lithium based No. 2 consistency Lithium based No. 2 consistency
11kg (24.25 lb)
17kg (37.48 lb)
-
-
ALL OTHER GREASE POINTS
JCB Special HP Grease
Lithium based No. 2 consistency
COOLING SYSTEM
see Coolant Mixtures
-
16.4 litres (3.6 UK gal) (4.3 US gal)
17.2 litres (3.78 UK gal) (4.5 US gal)
FUEL TANK
see Type of Fuel
-
240 litres (52.8 UK gal) (63.4 US gal)
240 litres (52.8 UK gal) (63.4 US gal)
ENGINE LUBRICATION CHART - ALL COUNTRIES EXCEPT NORTH AMERICAN -30
Use according to ambient temperature (°C) -10 0 10 20
-20
30
JCB SUPER 15W/40 MULTIGRADE ENGINE OIL API CF4/SG JCB SUPER 10W/30 MULTIGRADE ENGINE OIL API CF4/SG ENGINE LUBRICATION CHART - NORTH AMERICAN Use according to ambient temperature (°F) -22
-5
0
14
32
50
68
90
JCB 15W/40 MULTIGRADE ENGINE OIL API CF4/SG JCB 10W ENGINE OIL API CF4/SG 9804/1103
45 - 00 - 01/5
6410 - 3/1-1.2
Issue 3*
Excavators
CONTENTS CONTENTS
*
JS 180 from m/c no. 702132
*
Lubricants & Capacities
Item
Lubricant
45 - 00 - 01/5A
International
Capacity
Specification
JS180
ENGINE
(see separate chart)
TRACK GEARBOX
JCB HD90 Gear Oil
API-GL-5, MIL-L-2105
2 x 3.5 litres (2 x .77 UK gal) (2 x .92 US gal)
SLEW GEARBOX
JCB HD90 Gear Oil
API-GL-5, MIL-L-2105
5 litres (1.09 UK gal) (1.31 US gal)
TRACK ROLLERS IDLER WHEEL
JCB HD 90 Gear OIl
API-GL-5, MIL-L-2105
-
RECOIL SPRING CYLINDER
JCB Special HP Grease
Lithium complex (NLGI) inc. extreme pressure additives
-
HYDRAULIC SYSTEM
JCB Hydraulic Fluid 46
ISO VG46
124 litres (27.3 UK gal) (32.8 US gal)
SLEW RING - BEARING
JCB Special HP Grease
- GEAR TEETH
JCB Special HP Grease
Lithium complex (NLGI) inc. extreme pressure additives Lithium complex (NLGI) inc. extreme pressure additives
ALL OTHER GREASE POINTS
JCB Special HP Grease
12.1 litres (2.7 UK gal) (3.2 US gal)
Lithium complex (NLGI) inc. extreme pressure additives
17kg (37.48 lb)
-
COOLING SYSTEM
see Coolant Mixtures
-
17.2 litres (3.78 UK gal) (4.54 US gal)
FUEL TANK
see Type of Fuel
-
240 litres (52.8 UK gal) (63.4 US gal)
ENGINE LUBRICATION CHART Use according to ambient temperature (¡C)
JCB SUPER 15W/40 MULTIGRADE ENGINE OIL
JCB SUPER 10W/30 MULTIGRADE ENGINE OIL
9804/1103
45 - 00 - 01/5A
6950 - 88
Issue 2*
Excavators
CONTENTS CONTENTS
45 - 00 - 01/6
*
JS 200, 220 and variants from m/c no. 705001, JS 240, 260 from m/c no. 708501
*
Lubricants & Capacities
Capacity Item
Lubricant
International Specification
ENGINE
(see separate chart)
TRACK GEARBOX
JCB HD90 Gear Oil
API-GL-5, MIL-L-2105
2 x 3.5 litres (2 x 0.77 UK gal) (2 x 0.92 US gal)
SLEW GEARBOX
JCB HD90 Gear Oil
API-GL-5, MIL-L-2105
5 litres (1.09 UK gal) (1.31 US gal)
TRACK ROLLERS AND IDLER WHEEL
JCB HD90 Gear Oil
API-GL-5, MIL-L-2105
--
RECOIL SPRING CYLINDER
JCB Special HP Grease Lithium complex (NLGI) inc. extreme pressure additives
HYDRAULIC SYSTEM JCB Hydraulic Fluid 46
SLEW RING - BEARING - GEAR TEETH
ALL OTHER GREASE POINTS
21.5 litres (4.72 UK gal) (5.67 US gal)
ISO VG46
JCB Special HP Grease Lithium complex (NLGI) inc. extreme pressure additives JCB Special HP Grease Lithium complex (NLGI) inc. extreme pressure additives
JCB Special HP Grease Lithium complex (NLGI) inc. extreme pressure additives
--
--
203 litres (44.64 UK gal) (53.6 US gal)
-JS 200, JS 220 17 kg (37.48 lb) JS 240, JS 260 20 kg (44.10 lb)
--
COOLING SYSTEM
25.5 litres (5.6 UK gal) (6.7 US gal)
FUEL TANK
310 litres (68.19 UK gal)
Use according to ambient temperature (¡C)
JCB SUPER 15W/40 MULTIGRADE ENGINE OIL
JCB SUPER 10W/30 MULTIGRADE ENGINE OIL
9804/1103
45 - 00 - 01/6
6950 - 89
Issue 3*
Excavators
CONTENTS
45 - 00 - 01/6A
JS 200W from m/c no. 0802000 to 802999 Lubricants & Capacities Note: New engines DO NOT require a running-in period. The engine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
Item
Fluid/Lubricant
International Specification
Capacity JS200W
ENGINE
See separate chart
SLEW GEARBOX
JCB Gear Oil HD90
API-GL-5: MIL-L-2105C
JCB HP Grease
Lithium based, No. 2 consistency
JCB Special Hydraulic Fluid HP46
Vickers 35VQ25/V104C: Sundstrand, Denison and FZG Approval Tests
124 litres (27.3 UK gal) (32.7 US gal)
SLEW RING - BEARINGS - GEAR TEETH
JCB HP Grease JCB HP Grease
Lithium based, No. 2 consistency
17 kg (37.48 lb)
PROPSHAFTS
JCB HP Grease
Lithium based, No. 2 consistency
ALL OTHER GREASE POINTS
JCB HP Grease
Lithium based, No. 2 consistency
COOLING SYSTEM
See Coolant Mixtures
ASTM D3306-74
27 litres (5.9 UK gal) (7.1 US gal)
FUEL TANK
See Fuel System, Types of Fuel in Operator Handbook
ASTM D975-66T
310 litres (68.2 UK gal) (81.2 US gal)
JCB Gear Oil HD90
API GL-5: MIL-L-2105D
9.0 litres (1.98 UK gal) (2.37 US gal) 2.0 litres (0.44 UK gal) (0.52 US gal)
JCB Gear Oil HD90
API GL-5: MIL-L-2105D
17.0 litres (3.74 UK gal) (4.49 US gal)
JCB Super 15W/40 Multigrade Engine Oil
API CF4/SG: MIL-L-2104F
3.8 litres (0.836 UK gal) (1.0 US gal)
HYDRAULIC SYSTEM
FRONT AXLE - DIFFERENTIAL
18.5 litres (4.0 UK gal) (4.9 US gal)
Nos 1D, 2D
- HUB (x 2)
REAR AXLE - DIFFERENTIAL AND HUBS (x 2)
DRIVE GEARBOX
9804/1103
45 - 00 - 01/6A
5 litres (1.09 UK gal) (1.31 US gal) 1 litre (0.22 UK gal) (0.26 US gal)
Issue 1
Excavators
CONTENTS
45 - 00 - 01/6B
JS 200W from m/c no. 0802000 to 802999 Lubricants & Capacities (cont’d) Engine Lubrication Chart
Use according to ambient temperature (°C) -30
20
-10
0
10
20
30
40
50
JCB SUPER 15W/40 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F JCB SUPER 10W/30 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F
9804/1103
45 - 00 - 01/6B
Issue 1
Excavators
CONTENTS CONTENTS
*
JS 200W from m/c no. 809000
*
Lubricants & Capacities
45 - 00 - 01/6C
Note: New engines DO NOT require a running-in period. The engine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
Item
Fluid/Lubricant
International Specification
Capacity JS200W
ENGINE
See separate chart
SLEW GEARBOX
JCB Gear Oil HD90
API-GL-5: MIL-L-2105C
5 litres (1.09 UK gal) (1.31 US gal)
HYDRAULIC SYSTEM
JCB Special Hydraulic Fluid HP46
Vickers 35VQ25/V104C: Sundstrand, Denison and FZG Approval Tests
124 litres (27.3 UK gal) (32.7 US gal)
SLEW RING - BEARINGS - GEAR TEETH
JCB HP Grease JCB HP Grease
Lithium complex (NLGI) inc. extreme pressure additives
17 kg (37.48 lb)
PROPSHAFTS
JCB HP Grease
Lithium complex (NLGI) inc. extreme pressure additives
ALL OTHER GREASE POINTS
JCB HP Grease
COOLING SYSTEM
FUEL TANK
FRONT AXLE - DIFFERENTIAL
18.5 litres (4.0 UK gal) (4.9 US gal)
Lithium complex (NLGI) inc. extreme pressure additives ASTM D3306-74
27 litres (5.9 UK gal) (7.1 US gal)
See Fuel System, Types of Fuel in Operator Handbook
ASTM D975-66T
310 litres (68.2 UK gal) (81.2 US gal)
JCB Gear Oil HD90
API GL-5: MIL-L-2105D
9.0 litres (1.98 UK gal) (2.37 US gal) 2.0 litres (0.44 UK gal) (0.52 US gal)
JCB Gear Oil HD90
API GL-5: MIL-L-2105D
17.0 litres (3.74 UK gal) (4.49 US gal)
JCB Super 15W/40 Multigrade Engine Oil
API CF4/SG: MIL-L-2104F
3.8 litres (0.836 UK gal) (1.0 US gal)
Nos 1D, 2D
- HUB (x 2)
REAR AXLE - DIFFERENTIAL AND HUBS (x 2)
DRIVE GEARBOX
9804/1103
45 - 00 - 01/6C
6980 - 128
Issue 1
Excavators
CONTENTS
45 - 00 - 01/6D
JS 200W from m/c no. 809000 Lubricants and Capacities (cont’d)
Use according to ambient temperature (°C) -30
20
-10
0
10
20
30
40
50
JCB SUPER 15W/40 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F JCB SUPER 10W/30 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F
9804/1103
45 - 00 - 01/6D
6320 - 3/1-2.1
Issue 1
Excavators
CONTENTS
45 - 00 - 01/7
* JS
330 from m/c no. 712501, JS 450 from m/c no. 714501, JS 460 from m/c no. 714550 Lubricants & Capacities
Capacity Item
Lubricant
International Specification JS330
JS450/JS460
34 litres (7.5 Uk gal)
34 litres (7.5 UK gal)
ENGINE
(see separate chart)
TRACK GEARBOX
JCB HD90 Gear Oil
API-GL-5, MIL-L-2105
2 x 8.5 litres (2 x 1.9 UK gal)
2 x 7.0 litres (2 x 1.5 UK gal)
SLEW GEARBOX
JCB HD90 Gear Oil
API-GL-5, MIL-L-2105
14.5 litres (3.2 UK gal)
18 litres (4 UK gal)
TRACK ROLLERS IDLER WHEEL
JCB HD90 Gear Oil
API-GL-5, MIL-L-2105
-
-
RECOIL SPRING CYLINDER
JCB Special HP Grease
Lithium based, No. 2 consistency
-
-
HYDRAULIC SYSTEM
JCB Hydraulic Fluid 46
ISO VG46
320 litres (70.5 UK gal)
450 litres (99 UK gal)
SLEW RNG - BEARING
JCB Special HP Grease
-
-
- GEAR TEETH
JCB Special HP Grease
Lithium based, No. 2 consistency Lithium based, No. 2 consistency
17 kg (34. 48 lb)
17 kg (34. 48 lb)
-
-
ALL OTHER GREASE POINTS
JCB Special HP Grease
Lithium based, No. 2 consistency
COOLING SYSTEM
see Coolant Mixtures
-
38 litres (8.4 UK gal)
43 litres (9.5 UK gal)
FUEL TANK
see Type of Fuel
-
580 litres (128 UK gal)
650 litres (143 UK gal)
ENGINE LUBRICATION CHART
Use according to ambient temperature (°C) -30
-20
-10
0
10
20
30
40
JCB SUPER 15W/40 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F JCB SUPER 10W/30 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F
9804/1103
45 - 00 - 01/7
6420 - 3/1-1.2
Issue 3*
Excavators
CONTENTS CONTENTS *JS
70 to m/c no. 695500
Static Dimensions
A
Track length on ground
2050 mm (6 ft 9 in)
B
Undercarriage - overall length
2680 mm (8 ft 10 in)
C
Tail height
760 mm (2 ft 6 in)
D
Tailswing radius
1600 mm (5 ft 3 in)
E
Tail length
1600 mm (5 ft 3 in)
F
Superstructure width
2200 mm (7 ft 3 in)
G Height over cab
2550 mm (8 ft 4 in)
H
Ground clearance
360 mm (1 ft 2 in)
J
Track gauge
1700 mm (5 ft 8 in)
K
Track width
- 450 mm (18 in) shoes - 600 mm (24 in) shoes - 700 mm (28 in) shoes
2150 mm (7 ft 1 in) 2300 mm (7 ft 7 in) 2400 mm (7 ft 11 in)
L
Transport length
- standard boom - offset boom
5860 mm (19 ft 3 in) 5950 mm (19 ft 6 in)
M Transport height
- standard boom - offset boom
2540 mm (8 ft 4 in) 2740 mm (9 ft 0 in)
N
Track height
620 mm (2 ft 0 in)
P
Dozer blade width
2250 mm (7 ft 5 in)
R
Dozer blade height
460 mm (1 ft 6 in)
S
Dozer blade reach in front of tracks
480 mm (1 ft 7 in)
9804/1103
45 - 00 - 02/1
Issue 3*
Excavators
CONTENTS CONTENTS
45 - 00 - 02/2
JS 110 Static Dimensions
A
Track length on ground
2610 mm (8 ft 7 in)
B
Undercarriage - overall length
3380 mm (11 ft 1 in)
C
Tail Height
920 mm (3 ft 0 in)
D
Tailswing radius
2150 mm (7 ft 1 in)
E
Tail length
2080 mm (6 ft 10 in)
F
Superstructure width
2420 mm (7 ft 11 in)
G Height over cab
2695 mm (8 ft 10 in)
H
Ground clearance
460 mm (1 ft 6 in)
J
Track gauge
1990 mm (6 ft 6 in)
K
Track width
-
L
Transport length
- 1.96 m dipper - 2.26 m dipper - 2.91 m dipper*
7320 mm (24 ft 0 in) 7340 mm (24 ft 1 in) 7380 mm (24 ft 3 in)
M Transport height
- 1.96 m dipper - 2.26 m dipper - 2.91 m dipper*
2600 mm (8 ft 6 in) 2660 mm (8 ft 9 in) 2630 mm (8 ft 8 in)
N
500 mm (20 in) shoes 600 mm (24 in) shoes 700 mm (28 in) shoes 850 mm (34 in) shoes
Track height
2490 mm (8 ft 2 in) 2590 mm (8 ft 6 in) 2690 mm (8 ft 10 in) 2840 mm (9 ft 4 in)
795 mm (2 ft 7 in)
*Dipper ram in transport position (as shown).
9804/1103
45 - 00 - 02/2
Issue 1
Excavators
CONTENTS CONTENTS
45 - 00 - 02/3
JS 130 Static Dimensions
A
Track length on ground
2780 mm (9 ft 1 in)
B
Undercarriage - overall length
3550 mm (11 ft 8 in)
C
Tail Height
920 mm (3 ft 0 in)
D
Tailswing radius
2200 mm (7 ft 3 in)
E
Tail length
2130 mm (7 ft 0 in)
F
Superstructure width
2420 mm (7 ft 11 in)
G Height over cab
2695 mm (8 ft 10 in)
H
Ground clearance
460 mm (1 ft 6 in)
J
Track gauge
1990 mm (6 ft 6 in)
K
Track width
-
L
Transport length
- 1.96 m dipper - 2.50 m dipper - 2.91 m dipper*
7660 mm (25 ft 2 in) 7690 mm (25 ft 3 in) 7700 mm (25 ft 4 in)
M Transport height
- 1.96 m dipper - 2.50 m dipper - 2.91 m dipper*
2550 mm (8 ft 4 in) 2650 mm (8 ft 8 in) 2540 mm (8 ft 4 in)
N
500 mm (20 in) shoes 600 mm (24 in) shoes 700 mm (28 in) shoes 850 mm (34 in) shoes
Track height
2490 mm (8 ft 2 in) 2590 mm (8 ft 6 in) 2690 mm (8 ft 10 in) 2840 mm (9 ft 4 in)
800 mm (2 ft 5 in)
*Dipper ram in transport position (as shown).
9804/1103
45 - 00 - 02/3
Issue 1
Excavators
CONTENTS CONTENTS
45 - 00 - 02/4
JS 150LC Static Dimensions
A
Track length on ground
B
Undercarriage - overall length
C
Tail Height
D
Tailswing radius
E
Tail length
F
Superstructure width
3100 mm (10 ft 2 in)
1050 mm (3 ft 5 in) 2350 mm (7 ft 9 in) 2235 mm (7 ft 4 in) 2500 mm (8 ft 3 in)
G Height over cab
2850 mm (9 ft 4 in)
H
Ground clearance
J
Track gauge
K
Track width
- 500 mm (20 in) shoes - 600 mm (24 in) shoes - 700 mm (28 in) shoes
L
Transport length
- 2.70 m dipper - 3.15 m dipper*
M Transport height
- 2.70 m dipper - 3.15 m dipper*
N
3900 mm (12 ft 10 in)
460 mm (1 ft 6 in) 1990 mm (6 ft 6 in)
Track height
2490 mm (8 ft 2 in) 2590 mm (8 ft 6 in) 2690 mm (8 ft 10 in) 8320 mm (27 ft 4 in) 8380 mm (27 ft 6 in) 2850 mm (9ft 4 in) 2865 mm (9ft 5 in) 870 mm (2 ft 10 in)
*Dipper ram in transport position.
9804/1103
45 - 00 - 02/4
Issue 1
Excavators
CONTENTS CONTENTS
45 - 00 - 02/5
JS 200LC Static Dimensions
A
Track length on ground
3640 mm (11 ft 11 in)
B
Undercarriage - overall length
4440 mm (14 ft 7 in)
C
Tail Height
1065 mm (3 ft 6 in)
D
Tailswing radius
2850 mm (9 ft 4 in)
E
Tail length
2800 mm (9 ft 2 in)
F
Superstructure width
2650 mm (8 ft 8 in)
G Height over cab
2850 mm (9 ft 4 in)
H
Ground clearance
485 mm (1 ft 7 in)
J
Track gauge
2300 mm (7 ft 7 in)
K
Track width
- 600 mm (24 in) shoes - 700 mm (28 in) shoes - 800 mm (32 in) shoes
2900 mm (9 ft 6 in) 3000 mm (9 ft 10 in) 3100 mm (10 ft 2 in)
L
Transport length
- 1.90 m dipper - 2.36 m dipper - 2.94 m dipper
9510 mm (31 ft 2 in) 9480 mm (31 ft 1 in) 9380 mm (30 ft 9 in)
M Transport height
- 1.90 m dipper - 2.36 m dipper - 2.94 m dipper
3010 mm (9 ft 11 in) 3010 mm (9 ft 11 in) 2850 mm (9 ft 4 in)
N
Track height
9804/1103
910 mm (3 ft 0 in)
45 - 00 - 02/5
Issue 1
Excavators
CONTENTS CONTENTS
45 - 00 - 02/6
JS 240LC Static Dimensions
A
Track length on ground
3850 mm (12 ft 8 in)
B
Undercarriage - overall length
4710 mm (15 ft 5 in)
C
Tail Height
1155 mm (3 ft 9 in)
D
Tailswing radius
3040 mm (10 ft 0 in)
E
Tail length
2930 mm (9 ft 7 in)
F
Superstructure width
2700 mm (8 ft 10 in)
G Height over cab
2987 mm (9 ft10 in)
H
Ground clearance
475 mm (1 ft 7 in)
J
Track gauge
2590 mm (8 ft 6 in)
K
Track width
- 600 mm (24 in) shoes - 700 mm (28 in) shoes - 800 mm (32 in) shoes
3190 mm (10 ft 6 in) 3290 mm (10 ft 10 in) 3390 mm (11 ft 2 in)
L
Transport length
-
2.00 m dipper 2.41 m dipper 3.05 m dipper 3.51 m dipper
9980 mm (32 ft 9 in) 9960 mm (32 ft 8 in) 9870 mm (32 ft 5 in) 9920 mm (32 ft 7 in)
M Transport height
-
2.00 m dipper 2.41 m dipper 3.05 m dipper 3.51 m dipper
3200 mm (10 ft 6 in) 3230 mm (10 ft 7 in) 3040 mm (10 ft 0 in) 3300 mm (10 ft 10 in)
N
Track height
9804/1103
1016 mm (3 ft 4 in)
45 - 00 - 02/6
Issue 1
Excavators
CONTENTS CONTENTS
45 - 00 - 02/7
JS 300LC Static Dimensions
A
Track length on ground
3910 mm (12 ft 10 in)
B
Undercarriage - overall length
4840 mm (15 ft 11 in)
C
Tail Height
1225 mm (4 ft 0 in)
D
Tailswing radius
3350 mm (11 ft 0 in)
E
Tail length
3250 mm (10 ft 8 in)
F
Superstructure width
3140 mm (10 ft 4 in)
G Height over cab
3020 mm (9 ft 11 in)
H
Ground clearance
525 mm (1 ft 9 in)
J
Track gauge
2600 mm (8 ft 6 in)
K
Track width
- 600 mm (24 in) shoes - 700 mm (28 in) shoes - 800 mm (32 in) shoes
3200 mm (10 ft 6 in) 3300 mm (10 ft 10 in) 3400 mm (11 ft 2 in)
L
Transport length
-
2.21 m dipper 2.63 m dipper 3.23 m dipper 4.03 m dipper
11070 mm (36 ft 4 in) 10970 mm (36 ft 0 in) 10870 mm (35 ft 8 in) 10970 mm (36 ft 0 in)
M Transport height
-
2.21 m dipper 2.63 m dipper 3.23 m dipper 4.03 m dipper
3590 mm (11 ft 9 in) 3540 mm (11 ft 7 in) 3330 mm (10 ft 11 in) 3820 mm (12 ft 6 in)
N
Track height
9804/1103
1015 mm (3 ft 4 in)
45 - 00 - 02/7
Issue 1
Excavators
CONTENTS CONTENTS
45 - 00 - 02/8
JS 450LC Static Dimensions
A
Track length on ground
4260 mm (14 ft 0 in)
B
Undercarriage - overall length
5290 mm (17 ft 4 in)
C
Tail Height
1395 mm (4 ft 7 in)
D
Tailswing radius
3620 mm (11 ft 11 in)
E
Tail length
3530 mm (11 ft 7 in)
F
Superstructure width
3140 mm (10 ft 4 in)
G Height over cab
3230 mm (10 ft 7 in)
H
Ground clearance
585 mm (1 ft 11 in)
J
Track gauge
2740 mm (9 ft 0 in)
K
Track width
- 600 mm (24 in) shoes - 760 mm (30 in) shoes
3400 mm (11 ft 2 in) 3500 mm (11 ft 6 in)
L
Transport length
-
2.50 m dipper 3.36 m dipper 4.00 m dipper 4.76 m dipper
12100 mm (39 ft 8 in) 12060 mm (39 ft 7 in) 12070 mm (39 ft 7 in) 12160 mm (39 ft 11 in)
M Transport height
-
2.50 m dipper 3.36 m dipper 4.00 m dipper 4.76 m dipper
3530 mm (11 ft 7 in) 3430 mm (11 ft 3 in) 3460 mm (11 ft 4 in) 4060 mm (13 ft 4 in)
N
Track height
9804/1103
1150 mm (3 ft 9 in)
45 - 00 - 02/8
Issue 1
CONTENTS
Excavators
JS 130W Static Dimensions
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J@@H ?V4@@@@6K? ?V'@@)K?h?I4@@@@0Y?e3@)X V4@@@@)Ke?V'@@)K? ?3@@(M I@M?e?I40M?f?I4@@@@@@@1? @@1? ?N@? @@5? ?I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5heV4@0?'@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0M? ?N@)X?fW2@@@6X?fI'@@@@6X ?W&@5? ?I'@@@@6X? V'@@@6X? N@@1 ?I'@@@@6X?V'@@@@ ?N@@H? @@@? @@@? ?J@? @@ ?I4@@@@@@@@@@@@@0Y ?N@@@@ @@1?e?W&@@@@@)Xf?V'@@@@)K? ?7@@H? V4@@@@)X ?V'@@@)X ?@@@ V4@@@@)X?V'@@@L? ?J@@ @@@? @@@? ?7@? @@1? @@@@ 3@@Le?7@@@@@@@1gN@@@@@@6K? J@@5 I'@@@)K? V'@@@)X? ?@@@ I'@@@)X?V'@@)X ?7@@ @@@? @@@@@@@@6?2@@@@@@6KO2@@6K??O@KO@K??O26K?g?O2@@@@6?2@@6?@?2@@6?@K?hf?@@? ?J@@@? @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K @@@@ N@@1e?@@@@@@@@@g?@@@@@@@@6K? ?W&@(Y ?V4@@@@6X? ?V4@@@)X ?3@@L? ?V4@@@)K?V'@@)X? ?@@@ @@@? 3@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K O&@@5? @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6X @@@@ ?@@@e?@@Xe?@@@f?@@@@@@@@@@@@@6K ?7@@H? I'@@)K ?I'@@)X? ?N@@1? ?I'@@@6XV'@@1? ?@@@ @@@? V4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@H? @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1 3@@@ ?3@@L??@@)X?J@@@fJ@@@@@@@@@@@@@@@6K ?@@@ ?V'@@@6X V'@@)X 3@@? V'@@@)XV'@@L ?@@@ @@@? W2@@@@@? ?I'@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@e?@@?e@@@@@?@@@@hf?@@@e@@@@@@@@@(M?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5 @@(Me?I@M @@ N@@@ ?N@@1??3@@)?&@@5e?W&@@@(MeI4@@@@@@@@6K J@@5 V'@@@)K? ?V'@@)X? N@@L ?V'@@@)XN@@)X?hf?@@@ @@@? ?W&@@@@@@L N@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6KO2@@@@@@@@@@@@@@@@@Ye@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@f@@@@?@@@@@@?e?@@@@@@@e@@@@@@@@0Y ?J@@H? @@ ?@@5 3@@L?N@@@@@@@HeW&@@@(Y?f?@@@@@@@@@@6K? 7@@H ?V'@@@@6X? V'@@)X ?@@1 V'@@@)T@@@1?hf?@@@ @@@? O&@@@@@@@1 ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@(M? ?@@@ @@ ?@@H N@@1e3@@@@@5??W&@@@@Hg?@@@@@@@@@@@@@6X ?J@@5? V4@@@@)X ?V'@@1 ?3@@ ?V4@@@@R'@@?hf?@@@ @@@? W2@@@@@@@@@@@@ J@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@H ?N@@ @@ ?@@? ?3@@eV4@@@0Y?O&@@@@@?g?@@@@@@@@@@@@@@)K? W&@@H? I4@@@)K? V'@@L?hf?N@@L? ?I
?)X? ?@1? ?@5? ?@ ?@1? ?@@? ?@@? ?@5? ?@ ?@1? ?@@? ?@5? ?@@@@@@@@@@6K? ?@ ?@@@@@@@@@@@@6X? ?@1? ?@@@@@@@@@@@@@)X ?@@? ?@@@@@@@@@@@@@@1 ?@@? ?@@@@@@@0?4@@@@@ ?@@?eO2@6X? ?@@@@Xf?W@@@@ ?@@?W2@@@@)K ?@@@@)K?eO&@@@@ ?@@?7@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6?26?2@@@@@@@@@@@@@@@@6KO2@6?26KO2@@6?2@@6?@?@K?O2@@6K ?@@@@@@@@@@@@@@5 ?@@?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6X? ?@@@@@@@@@@@@@@? ?@@??I4@@@@0M?I@M?I@?4@0?@MI4@0?@MI40?@?4@@0?@?4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1? ?@@@@@@@@@@@@@@1 ?@@? I@M? I4@@0M I@MI4@0?4@0?4@0MI4@@@@@@@@@@@@@@@0?4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? ?@@@@@@@@@@@@@@@L? ?@@? ?@@@@(M?f@@@@1? ?@@? ?@@@@Hg@@@@@? ?@@? ?@@@@?f?J@@@@@? ?@@? ?@@@@@@@@6?&@@@@5? ?@@? ?@@@@@@@@@@@@@@@H? ?@@? ?@@@@@@@@@@@@@@@ ?@@? ?@@@@@@@@@@@@(M? ?@@? ?@@@@@@@@@@@0Y J@@? @@@? N@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? J@@? @@@? N@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@5? ?@ ?@1? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? J@@? @@@? N@@? ?@@? ?@@? ?@@? ?@@? ?@5? ?@H? ?@ ?@L? ?@1? J@@? @@@? N@@? J@5? 7@ 3@@? ?@H? @@L? N@1? ?@5? ?@ ?@1? ?@@? ?@@? ?@@? J@@? @@5? N@H? ?@ ?@ ?@ ?@ ?@ ?@ ?@ ?@L? ?@1? ?@5? ?@ ?@@? ?@H? ?@ ?@ J@ 7@ @@L? @@)K W2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6?2@@6?2@6KO@?2@@@@@@@@@@@@@@@@@@@6?26?@K?O@KgO26Kh?O@K?O@?26KO@KO@KO2@6?2@@6?@KO@K?O26?@KO2@@@@@@@6?2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6?26Kf?O@K &@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6?2@6KO26?2@@@@@@6?@?@?2@@@@6?2@@6K?gO@KO2@6K ?I4@@@@@@@@@@@0MI4@@@@@@@@0?4@@0MI4@@@@@0?4@0?40M?eI4@0M?I40?@?4@@@@(?4@@@@@@@@0?4@@@@@@@@@@@@@@@@@@@@@@0?4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@ ?@@@@? @@(Y ?I@Mh?I@?4@@0M?eI4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5 J@@@@? @@H? I@M?hf?I@MI@M?eI4@0?40MI4@@@@@@@@@@@@@@@@@@@@0MI4@@@@@@@@@@@@@@@@@@@@@@@@@@@@0Y 7@@@@? @@ ?O2@@@@@6K 3@@@@? @@L? ?O2@@@@@@@@@6K V'@@5? @@@? ?O2@@@@@@@@@@@@@6K ?N@@H? @@H? ?O2@@@@@@@@@@@@@@@@@@6K? @@ @@ ?O2@@@@@@@@@@@@@@@@@@@@@@6K? @@ @@ ?O2@@@@@@@@@@@@@@@@@@@@@@@@@@6K? @@ @@ O2@@@@@@@@@@@@(MW@@@@@W@@@@X?I4@@@@@6K @@ @@ ?O2@@@@@@@@@@@@@@@HW&@@@@@@>@@@)X??I4@@@@@6X @@ @@ @@ @@
@@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @5 @? @@ @H ?J@L ?7@1 ?@@@ ?@@5 ?@@H ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? ?@@? J@@? @@@? N@@? ?@@? ?@@? ?@@? ?@@? ?@5? ?@H? J@L? @@1? N@@? J@5? '@H? V'
?@@@@@ J@@@@@L? 7@@@@@1? ?J@@@@@@@L ?7@@@@@@@1 ?@@@@@@@@@L? J@@@@?@@@@1? 7@@@5?@@@@@? @@@@H?3@@@@? ?J@@@@eN@@@@L ?7@@@@e?@@@@1 J@@@@@@@@@@@@@L? 7@@@@@@@@@@@@@1? ?J@@@@@@@@@@@@@@@? ?7@@@@@@@@@@@@@@@L ?@@@@@@@@@@@@@@@@1 ?@@@@(M?fI'@@@@ ?@@@(Yg?N@@@@ ?@@0Y?h@@@@
?@ ?@ ?@ J@ 7@
3@L? ?@@? @@ ?@1? @@@? N@@? ?@@? J@@? @@@? N@@? ?@@? ?@@? ?@5? ?@ J@1? 7@@? @@@? 3@@? N@@? ?@@?
Monoboom
Articulated
Dipper Lengths
Dipper Lengths
1.96m
2.26m
2.5m
2.91m
1.96m
2.26m
2.5m
2.91m
A
3040
3040
3040
3040
3040
3040
3040
3040
B
7680
7680
7700
7700
7540
7550
7570
7590
Shipping Weights Mach ne equ pped w h 2 26 m d ppe and 0 46m s anda d excava ng bucke
12350 o 14110 kg depend ng whe he s ab se s and o doze a e
9804/1103
ed
45 - 00 - 02/9
Issue 1
CONTENTS
Excavators
JS 150W Static Dimensions
Monoboom
Articulated
Dipper Lengths
Dipper Lengths
2.1m
2.7m
3.15m
2.1m
2.7m
3.15m
A
3060
3060
3060
3060
3060
3060
B
8320
8320
8320
8000
8010
8020
Shipping Weights Machine equipped with 2.1 m dipper and 0.62m3 standard excavating bucket:
14150 to 16510 kg depending whether stabilisers and/or dozer are fitted.
9804/1103
45 - 00 - 02/10
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 02/10A
JS 70 from m/c no. 695501 Static Dimensions
L D E
F
G
M R
C S
A B
N
H J K P
A
Tracked length on ground
2050 mm (6 ft 9 in)
B
Undercarriage - overall length
2680 mm (8 ft 10 in)
C
Tail height
760 mm (2 ft 6 in)
D
Tailswing radius
1740 mm (5 ft 9 in)
E
Tail length
1740 mm (5 ft 9 in)
F
Superstructure width
2200 mm (7 ft 3 in)
G
Height over cab
2560 mm (8 ft 5 in)
H
Ground clearance
380 mm (1 ft 3 in)
J
Track gauge
1700 mm (5 ft 8 in)
K
Track width
-
450 mm (18 in) shoes 600 mm (24 in) shoes
2150 mm (7 ft 1 in) 2300 mm (7 ft 7 in)
L
Transport length
-
Standard boom (1.74 m dipper) Standard boom (2.18 m dipper) Offset Boom
6010 mm (19 ft 9 in) 5990 mm (19 ft 8 in) 5950 mm (19 ft 6 in)
M
Transport height
-
Standard boom (1.74 m dipper) Standard boom (2.18 m dipper) Offset Boom
2640 mm (8 ft 8 in) 2930 mm (9 ft 7 in) 2740 mm (9 ft 0 in)
N
Track height
660 mm (2 ft 2 in)
P
Dozer blade width
2250 mm (7 ft 5 in)
R
Dozer blade height
460 mm (1 ft 6 in)
S
Dozer blade reach in front of tracks
480 mm (1 ft 7 in)
9804/1103
45 - 00 - 02/10A
JS08420
Issue 1
Excavators
CONTENTS CONTENTS
45 - 00 - 02/11
JS 130, from m/c no. 758000 *
Static Dimensions Monoboom
J D
E
F
K C
G A B
L
H I JS03463
ILLUSTRATION NOT AVAILABLE AT THIS TIME Dimensions in millimetres (ft. in)
MONOBOOM
T.A. BOOM
A Track length on ground
2780
(9ft 1 in)
2780
(9ft 1 in)
B Undercarriage overall length
3550
(11 ft 8 in)
3550
(11 ft 8 in)
C Counterweight clearance
910
(3 ft 0 in)
910
(3 ft 0 in)
D Tailswing radius
2050
(6 ft 9 in)
2050
(6 ft 9 in)
E Overall width of superstructure
2410
(7 ft 11 in)
2410
(7 ft 11 in)
F Height over cab
2695
(8 ft 11 in)
2695
(8 ft 11 in)
G Ground clearance
460
(1 ft 6 in)
460
(1 ft 6 in)
H Track gauge
1990
(6 ft 6 in)
1990
(6 ft 6 in)
I Width over tracks (500 mm shoes)
2490
(8 ft 2 in)
2490
(8 ft 2 in)
I Width over tracks (600 mm shoes)
2590
(8 ft 6 in)
2590
(8 ft 6 in)
I Width over tracks (700 mm shoes)
2690
(8 ft 10 in)
2690
(8 ft 10 in)
I Width over tracks (850 mm shoes)
2840
(9 ft 4 in)
2840
(9 ft 4 in)
J Transport length (2.10 m dipper)
7580
(24 ft 10 in)
7310
(24 ft 1 in)
J Transport length (2.50 m dipper)
7600
(24 ft 11 in)
7650
(25 ft 1 in)
J Transport length (3.00 m dipper) *
7630
(25 ft 0 in)
7890
(25 ft 11 in)
K Transport height (2.10 m dipper)
2695
(8 ft 11 in)
3040
(11 ft 2 in)
K Transport height (2.50 m dipper)
2695
(8 ft 11 in)
3040
(11 ft 2 in)
K Transport height (3.00 m dipper) *
2695
(8 ft 11 in)
3040
(11 ft 2 in)
L Track height
815
(2ft 8 in)
815
(2ft 8 in)
* Machine in transport position.
T.A. Boom
J D
E
F
K C
G A B
L
H I JS03463
ILLUSTRATION NOT AVAILABLE AT THIS TIME
9804/1103
45 - 00 - 02/11
6950 - 142
Issue 2*
Excavators
CONTENTS
45 - 00 - 02/12
JS 160 from m/c 702000 Static Dimensions
K F
G
L
H
E I A B
J
C D JS03510
Dimensions in millimetres (ft. in)
NLC
LC
A Track length on ground
3090 (10 ft 2 in)
3090 (10 ft 2 in)
B Undercarriage overall length
3940 (12 ft 11 in)
3940 (12 ft 11 in)
C Track gauge 1990 (6 ft 6 in)
2200 (7 ft 3 in)
2200 (7 ft 3in)
D Width over tracks (500 mm shoes)
2490 (8 ft 2 in)
2700 (8 ft 10 in)
D Width over tracks (600 mm shoes)
2590 (8 ft 6 in)
2800 (9 ft 2 in)
D Width over tracks (700 mm shoes)
2690 (8 ft 10 in)
2900 (9 ft 6 in)
D Width over tracks (800 mm shoes)
-
3000 (9 ft 10 in)
D Width over tracks (900 mm shoes)
-
3100 (10 ft 2 in)
E Counterweight clearance
1050 (3 ft 5 in)
1050 (3 ft 5 in)
F Tailswing radius
2350 (7 ft 9 in)
2350 (7 ft 9 in)
G Width of superstructure †
2500 (8 ft 2 in)
2500 (8 ft 2 in)
H Height over cab
2840 (9 ft 4 in)
2840 (9 ft 4 in)
I Ground clearance †
470 (1 ft 7 in)
470 (1 ft 7 in)
J Track height
880 (2 ft 11 in)
880 (2 ft 11 in)
2.70 m
3.05 m
† Machine in transport position.
Dipper lengths
9804/1103
K Transport length with Monoboom
8310 (27 ft 3 in)
8400 (27 ft 7 in)
L Transport height with Monoboom
2790 (9 ft 2 in)
3095 (27 ft 2 in)
45 - 00 - 02/12
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 02/12A
JS 180 from m/c no. 702000 Static Dimensions
K F
G
L
H
E I A B
J
C D JS03511
Dimensions in millimetres (ft. in) A Track length on ground
3370
(11 ft 1 in)
B Undercarriage overall length
4170
(13 ft 8 in)
C Track gauge
2200
(7 ft 2 in)
D Width over tracks (600 mm shoes)
2800
(9 ft 2 in)
D Width over tracks (700 mm shoes)
2900
(9 ft 6 in)
E Counterweight clearance
1066
(3 ft 6 in)
F Tailswing radius
2350
(7 ft 9 in)
G Width of superstructure *
2500
(8 ft 2 in)
H Height over cab
2855
(9 ft 4 in)
I
Ground clearance *
486
(1 ft 7 in)
J
Track height
885
(2 ft 11 in)
* Machine in transport position.
Dipper lengths
9804/1103
2.25 m
2.70 m
3.05 m
A Transport length
8366 (27 ft 5 in)
8326 (27 ft 4 in)
8415 (27 ft 7 in)
B Transport height
8265 (9 ft 5 in)
2790 (9 ft 5 in)
3095 (10 ft 2 in)
45 - 00 - 02/12A
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 02/13
JS 200, 220 from m/c no. 705001 Static Dimensions Note: The information given below applies also to all variants of the JS220 range, except the LR.
Monoboom
E J
F
K
L
JS200LC
I
N
M A B
C D JS03050
Dimensions in millimetres (ft. in)
S
N
LC
A Track length on ground
3370
(11ft 1 in)
3370
(11 ft 1 in)
3660
(12 ft 0 in)
B Undercarriage overall length
4170
(13 ft 8 in)
4170
(13 ft 8 in)
4460
(14 ft 8 in)
C Track gauge
2200
(7 ft 2 in)
1990
(6 ft 6 in)
2390
(7 ft 10 in)
-
2490
(8 ft 2 in)
(9 ft 2 in)
2590
(8 ft 6 in)
2990
(9 ft 10 in)
(9 ft 6 in)
2690
D Width over tracks (500 shoes) D Width over tracks (600 shoes)
2800
D Width over tracks (700 shoes)
2900
-
(8 ft 10 in)
3090
(10 ft 2 in)
D Width over tracks (800 shoes)
-
-
3190
(10 ft 6 in)
D Width over tracks (900 shoes)
-
-
3290
(10 ft 10 in)
Dipper lengths
1.91 m
2.40 m
3.0 m
E Transport length with Monoboom
9570
(31 ft 5 in)
9560
(31 ft 4 in)
9440
(31 ft 0 in)
F Transport height with Monoboom
3055
(10 ft 0 in)
3060
(10 ft 0 in)
2860
(9 ft 5 in)
G Transport length with T.A. Boom
9598
(31 ft 6 in)
9573
(31 ft 5 in)
9499
(31 ft 2 in)
H Transport height with T.A. Boom
3128
(10 ft 3 in)
3065
(10 ft 1 in)
2913
(9 ft 7 in)
Dimensions in millimetres (ft in)
S/N/LC
I Counterweight clearance
1066
(3 ft 6 in)
J Tailswing radius
2770
(9 ft 1 in)
K Width of superstructure*
2500
(8 ft 2 in)
L Height over cab
2886
(9 ft 6 in)
M Ground clearance
486
(1 ft 7 in)
N Track height
885
(2 ft 11 in)
* with cab handrail removed
T.A. Boom
G J
K
H
L
JS200LC
I M A B
9804/1103
45 - 00 - 02/13
C D
N
JS03060
Issue 1
Excavators
CONTENTS CONTENTS
45 - 00 - 02/13A
JS 130, from m/c no. 705001 Static Dimensions
E J
K
F
L
I M A B
N
C D JS03051
JSO3051
Dimensions in millimetres (ft. in) A Track length on ground
3370 (11 ft 1 in)
B Undercarriage overall length
4170 (13 ft 8 in)
C Track gauge
2200 (7 ft 2 in)
D Width over tracks (700 mm shoes)
2900 (9 ft 6 in)
Dimensions in millimetres (ft. in) I Counterweight clearance
1066 (3 ft 6 in)
F Tailswing radius
2770 (9 ft 1 in)
G Width of superstructure *
2500 (8 ft 2 in)
H Height over cab 2886
(9 ft 6 in)
I Ground clearance
486 (1 ft 7 in)
J Track height
885 (2 ft 11 in)
* with cab handrail removed
*
Dipper lengths
1.91 m
2.40 m
3.0 m
E Transport length with Monoboom
9570 (31 ft 5 in)
9560 (31 ft 4 in)
9440 (31 ft 0 in)
F Transport height with Monoboom
3055 (10 ft 0 in)
3060 (10 ft 0 in)
2860 (9 ft 5 in)
9804/1103
45 - 00 - 02/13A
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 00 - 02/14
JS 240, 260 from m/c no 708501 Static Dimensions Monoboom
Note: The information given below applies also to all variants of the JS260 range. E
K
J
F
L
JS240LC
I
N
M A B
Dimensions in millimetres (ft. in)
C D
S
JS03070
NLC
LC
A Track length on ground
3460
(11ft 4 in)
3840
(12 ft 7 in)
3840
(12 ft 7 in)
B Undercarriage overall length
4260
(14 ft 0 in)
4640
(15 ft 83 in)
4640
(15 ft 3 in)
C Track gauge
2390
(7 ft 10 in)
2390
(7 ft 10 in)
2590
(8 ft 6 in)
D Width over tracks (600 shoes)
2990
(9 ft 10 in)
2990
(9 ft 10 in)
3190
(10 ft 6 in)
D Width over tracks (700 shoes)
3090
(10 ft 2 in)
3090
(10 ft 2 in)
3290
(10 ft 9 in)
D Width over tracks (800 shoes)
3190
(10 ft 6 in)
3190
(10 ft 6 in)
3390
(11 ft 1 in)
D Width over tracks (900 shoes)
3290
(10 ft 9 in)
3290
(10 ft 9 in)
3490
(11 ft 5 in)
Dipper lengths
2.00 m
2.44 m
3.09 m
3.53 m
E Transport length with Monoboom
10083
(33 ft 0 in)
10060
(33 ft 0 in)
9960 (32 ft 8 in)
10010 (32 ft 10 in)
F Transport height with Monoboom
3173
(10 ft 5 in)
3230
(10 ft 7 in)
3050 (10 ft 0 in)
3220
(10 ft 7 in)
G Transport length with T.A. Boom
10449
(34 ft 3 in)
10424
(34 ft 2 in)
10386 (34 ft 1 in)
10373 (34 ft 0 in)
H Transport height with T.A. Boom
3006
(9 ft 10 in)
3086
(10 ft 1 in)
2950 (9 ft 8 in)
3209
(10 ft 6 in)
Dimensions in millimetres (ft in) I Counterweight clearance
1125
(3 ft 8 in)
J Tailswing radius
3000
(9 ft 10 in)
K Width of superstructure*
2500
(8 ft 2 in)
L Height over cab
2920
(9 ft 10 in)
M Ground clearance
486
(1 ft 7 in)
N Track height
940
(3 ft 1 in)
* with cab handrail removed
T.A. Boom
G K
J
H
L
JS240LC
I M A B
9804/1103
45 - 00 - 02/14
C D
N
JS03080
Issue 1
Excavators
CONTENTS
45 - 00 - 02/15
JS 220LC Long Reach (LR) from m/c no. 705001 Static Dimensions
F
E
JS03821
With the exception of E and F detailed in the table below, the following dimensions are the same as those for the JS200/JS220 LC machine as listed on page 45 - 00 - 02/13, i.e. A, B, C, D (900 shoes), I, J, K, L, M, N.
Dimension E Transport length
12520 mm (41 ft 1 in)
F Transport height
3000 mm (9 ft 10 in)
9804/1103
45 - 00 - 02/15
Issue 1
Excavators
CONTENTS
45 - 00 - 02/16
JS 330 from m/c no. 712501 Static Dimensions Note: The information given below applies also to all variants of the JS330 range. E
J
H
F
K
JS240LC
G L A B
C D
JS09740
Dimension in millimetres
LC
NLC
A Track length on ground
3910 (12 ft 10 in)
3910 (12 ft 10 in)
B Undercarriage overall length
4810 (15 ft 9 in)
4810 (15 ft 9 in)
C Track gauge
2600 (8 ft 6 in)
2390 (7 ft 10 in)
D Width over tracks (600 shoes)
3200 (10 ft 6in)
2990 (9 ft 9 in)
D Width over tracks (700 shoes)
3300 (10 ft 10 in)
3090 (10 ft 2 in)
D Width over tracks (800 shoes)
3400 (11 ft 2 in)
3190 (10 ft 6 in)
D Width over tracks (900 shoes)
3500 (11 ft 6 in)
3290 (10 ft 10 in)
E Transport length (2.21 m dipper)
11050 (36 ft 3 in)
11050 (36 ft 3 in)
E Transport length (2.63 m dipper)
10960 (35 ft 11 in)
10960 (35 ft 11 in)
E Transport length (3.23 m dipper)
10860 (35 ft 7 in)
10860 (35 ft 7 in)
E Transport length (4.03 m dipper)
10950 (35 ft 11 in)
10950 (35 ft 11 in)
F Transport height (2.21 m dipper)
3610 (11 ft 10 in)
3610 (11 ft 10 in)
F Transport height (2.63 m dipper)
3570 (11 ft 9 in)
3570 (11 ft 9 in)
F Transport height (3.23 m dipper)
3360 (11 ft 0 in)
3360 (11 ft 0 in)
F Transport height (4.03 m dipper)
3850 (12 ft 8 in)
3850 (12 ft 8 in)
G Counterweight clearance
1190 (3 ft 10 in)
1190 (3 ft 10 in)
H Tailswing radius
3260 (10 ft 9 in)
3260 (10 ft 9 in)
J
2990 (9 ft 10 in)
2990 (9 ft 10 in)
3030 (10 ft 0 in)
3030 (10 ft 0 in)
500 (1 ft 7 in)
500 (1 ft 7 in)
Width of superstructure
K Height over cab L Ground clearance
9804/1103
45 - 00 - 02/16
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 02/16A
JS 450 from m/c no. 714501 Static Dimensions Note: The information given below applies also to all variants of the JS 450 range.
E
J
H
F
K
G L A B
C D
A296890
Dimensions in millimetres (ft. in)
9804/1103
A Track length on ground
4400 (14 ft 5 in)
B Undercarriage overall length
5470 (17 ft 11 in)
C Track gauge
2750 (9 ft 0 in)
D Width over tracks (600 shoes)
3430 (11 ft 3 in)
E Transport length (3.36 m dipper)
11700 (38 ft 4 in)
F Transport height (3.36 m dipper)
3510 (11 ft 6 in)
G Counterweight clearance
1380 (4 ft 6 in)
H Tailswing radius
3300 (10 ft 10 in)
J
2990 ( 9 ft 10 in)
Width of superstructure
K Height over cab
3260 (10 ft 8 in)
L Ground clearance
550 (1 ft 10 in)
45 - 00 - 02/16A
Issue 1
Excavators
CONTENTS
45 - 00 - 02/17
JS 130W from m/c no. 0716500 Static Dimensions 2050 mm
A 1240 mm 498 mm 519 mm B
2410 mm
3040 mm
350 mm 1330 mm 2490 mm
JS08090
Monoboom Dipper Length (m)
9804/1103
Articulated Boom
2.10
2.50
3.00
2.10
2.50
3.00
A (mm)
3040
3040
3040
3040
3040
3040
B (mm)
7580
7600
7630
7310
7650
7890
45 - 00 - 02/17
Issue 1
Excavators
CONTENTS
45 - 00 - 02/18
JS 160W from m/c no. 0718500 Static Dimensions 2190 mm
A 1270 mm 498 mm 519 mm B
2500 mm
3070 mm
360 mm 1330 mm 2490 mm
JS08800
Monoboom Dipper Length (m)
9804/1103
Articulated Boom
2.25
2.70
3.05
2.25
2.70
3.05
A (mm)
2765
2765
8240
2806
2874
3136
B (mm)
8145
8135
8306
8123
8118
8083
45 - 00 - 02/18
Issue 1
Excavators
CONTENTS
45 - 00 - 02/19
JS 200W from m/c no. 0802000 to 802999 Static Dimensions
2530 mm
A
1310 mm 556 mm 511 mm B
2500 mm
3200 mm
350 mm 1240 mm 2500 mm
Monoboom Dipper Length (m)
9804/1103
JS08801
Articulated Boom
1.90
2.40
3.00
1.90
2.40
3.00
A (mm)
3310
3300
3100
3290
3290
3120
B (mm)
9430
9420
9310
9160
9150
9040
45 - 00 - 02/19
Issue 1
Excavators
CONTENTS
45 - 00 - 02/20
JS 200W from m/c no. 809000 *
Static Dimensions 2530 mm (8ft 3in)
A 1310 mm (4ft 3in)
556 mm (1ft 10in) 511 mm (1ft 8in)
B
2500 mm (8ft 2in)
3150 mm (10ft 4in)
350 mm (1ft 2in) 1240 mm (4ft 1in) 2500 mm (8ft 2in)
JS08801
Monoboom Dipper Length (m)
Articulated Boom
1.90
2.40
3.00
1.90
2.40
3.00
A (mm)
3360 (10ft 0in)
2985(9ft 9in)
2875(9ft 5in)
3290(10ft 9in)
3290(10ft 9in)
3120(10ft 3in)
B (mm)
9450 (31ft 0in)
9350(30ft 8in)
9280(29ft 5in)
9160(30ft 0in)
9150(30ft 0in)
9040(29ft 8in)
9804/1103
45 - 00 - 02/20
6980 - 144
Issue 2*
CONTENTS
Excavators
45 - 00 - 02/21
JS 460 from m/c no. 714550 *
Static Dimensions Note: The information given below applies also to all variants of the JS460 range.
E
J
H
F
K
G L A B
C D
JS09741
6950 - 149.2
Issue 1*
Dimension in millimetres
9804/1103
A
Track length on ground
4360 (14 ft 4 in)
B
Undercarriage overall length
5343 (17 ft 7 in)
C
Track gauge
D
Width over tracks (600 shoes)
3430 (11 ft 3 in)
E
Transport length (3.36 m dipper)
11700 (38 ft 4 in)
F
Transport height (3.36 m dipper)
3510 (11 ft 6 in)
G
Counterweight clearance
1380 (4 ft 6 in)
H
Tailswing radius
J
Width of superstructure
K
Height over cab
L
Ground clearance
2750 (9ft 0 in)
3300 (10 ft 10 in) 2990 (9ft 10 in) 3330 (10 ft 11 in) 590 (1 ft 11 in)
45 - 00 - 02/21
CONTENTS
* JS
Excavators
45 - 00 - 03/1
70 from m/c no. 695501
Shipping Weights Machine equipped with Boom; 1.74 m (5 ft 8 in) Dipper Arm, Dozer Blade, Standard Excavating Bucket, operator and full fuel tank. * Standard
* Offset
9804/1103
Boom
Shoe Width
Operating Weight
Ground Bearing Pressure
450 mm (18 in)
6800 kg (14994 lb)
0.33 kgf/cm2 (4.69 lb/in2)
600 mm (24 in)
7000 kg (15435 lb)
0.25 kgf/cm2 (3.56 lbf/in2)
Shoe Width
Operating Weight
Ground Bearing Pressure
450 mm (18 in)
7300 kg (16060 lb)
0.35 kgf/cm2 (4.97 lb/in2)
600 mm (24 in)
7500 kg (16500 lb)
0.27 kgf/cm2 (3.84 lbf/in2)
Boom
45 - 00 - 03/1
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 00 - 03/2
JS 110,130,150LC Shipping Weights MODEL JS110 Machine equipped with 4.35 m (14 ft 3 in) Boom, 2.26 m (7 ft 5 in) Dipper Arm, Standard Excavating Bucket, operator and full fuel tank. Shoe Width
Operating Weight
Ground Bearing Pressure
500 mm (20 in)
11150 kg (24600 lb)
0.39 kgf/cm2 (5.55 lbf/in2)
600 mm (24 in)
11325 kg (25000 lb)
0.33 kgf/cm2 (4.69 lbf/in2)
700 mm (28 in)
11500 kg (25350 lb)
0.29 kgf/cm2 (4.12 lbf/in2)
850 mm (34 in)
11780 kg (25970 lb)
0.24 kgf/cm2 (3.42 lbf/in2)
Basic machine weight, with 1860 kg (4100 lb) counterweight and 600 mm (24 in) shoes but no boom or dipper arm: 9300 kg (20500 lb)
MODEL JS130 Machine equipped with 4.35 m (14 ft 3 in) Boom, 2.26 m (7 ft 5 in) Dipper Arm, Standard Excavating Bucket, operator and full fuel tank. Shoe Width
Operating Weight
Ground Bearing Pressure
500 mm (20 in)
12290 kg (27100 lb)
0.39 kgf/cm2 (5.55 lbf/in2)
600 mm (24 in)
12480 kg (27500 lb)
0.33 kgf/cm2 (4.69 lbf/in2)
700 mm (28 in)
12680 kg (28000 lb)
0.29 kgf/cm2 (4.12 lbf/in2)
850 mm (34 in)
12970 kg (28600 lb)
0.24 kgf/cm2 (3.47 lbf/in2)
Basic machine weight, with 2560 kg (56448 lb) counterweight and 600 mm (24 in) shoes but no boom or dipper arm: 10000 kg (22050 lb).
MODEL JS150LC Machine equipped with 5.15 m (16 ft 11 in) Boom; 2.7 m (8ft 10 in) Dipper Arm, Standard Excavating Bucket, operator and full fuel tank. Shoe Width
Operating Weight
Ground Bearing Pressure
500 mm (20 in)
15870 kg (34990 lb)
0.47 kgf/cm2 (6.70 lb//in2)
600 mm (24 in)
16110 kg (35520 lb)
0.38 kgf/cm2 (5.60 lbf/in2)
700 mm (28 in)
16360 kg (36070 lb)
0.33 kgf/cm2 (4.80 lbf/in2)
Basic machine weight, with 3000 kg (6615 lb) counterweight and 600 mm (24 in) shoes but no boom or dipper arm; 13460 kg (29680 lb)
9804/1103
45 - 00 - 03/2
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 03/3
JS 200LC,240LC,300LC,450LC Shipping Weights MODEL JS200LC Machine equipped with 5.63 m (18 ft 6 in) Boom; 2.94 m (9 ft 8 in) Dipper Arm, Standard Excavating Bucket, operator and full fuel tank. Shoe Width
Operating Weight
Ground Bearing Pressure
600 mm (24 in)
19610 kg (43240 lb)
0.41 kgf/cm2 (5.83 lbf/in2)
700 mm (28 in)
19900 kg (43880 lb)
0.36 kgf/cm2 (5.12 lbf/in2)
800 mm (32 in)
20180 kg (44500 lb)
0.31 kgf/cm2 (4.41 lbf/in2)
Basic machine weight, with 3900 kg (8600 lb) counter weight and 600 mm (24 in) shoes but no boom or dipper arm; 15790 kg (34820 lb)
MODEL JS240LC Machine equipped with 5.85 m (19 ft 2 in) Boom, 3.06 m (10 ft 0 in) Dipper Arm, Standard Excavating Bucket, operator and full fuel tank. Shoe Width
Operating Weight
Ground Bearing Pressure
600 mm (24 in)
23900 kg (52700 lb)
0.48 kgf/cm2 (6.881 lbf/in2)
700 mm (28 in)
24200 kg (53350 lb)
0.43 kgf/cm2 (6.17 lbf/in2)
800 mm (32 in)
24500 kg (54000 lb)
0.37 kgf/cm2 (5.30 lbf/in2)
Basic machine weight, with 4200 kg (9260 lb) counter weight and 600 mm (24 in) shoes but no boom or dipper arm; 18910 kg (41690 lb)
MODEL JS300LC Machine equipped with 6.45 m (21 ft 2 in) boom, 3.23 m (10 ft 7 in) arm, standard bucket, operator and full fuel tank. Shoe Width
Operating Weight
Ground Bearing Pressure
600 mm (24 in)
31000 kg (683401 lb)
0.60 kgf/cm2 (8.61 lbf/in2)
700 mm (28 in)
31400 kg (69200 lb)
0.52 kgf/cm2 (7.40 lbf/in2)
800 mm (32 in)
31750 kg (70000 lb)
0.47 kgf/cm2 (6.72 lbf/in2)
Basic machine weight, with 6000 kg (13230 lb) counter weight and 600 mm (24 in) triple grouser track without boom or dipper 24400 kg (53800 lb).
MODEL JS450LC Machine equipped with 7.10 m (23 ft 4 in) boom, 3.36 m (11 ft 0 in) dipper arm, standard bucket, operator and full fuel tank. Shoe Width
Operating Weight
Ground Bearing Pressure
600 mm (24 in)
43530 kg (95961 lb)
0.79 kgf/cm2 (11.2 lbf/in2)
760 mm (30 in)
44340 kg (97740 lb)
0.63 kgf/cm2 (8.96 lbf/in2)
Basic machine weight, with 9050 kg (19950 lb) counterweight and 600 mm (24 in) triple grouser shoes, without boom and dipper 34600 kg (76280 lb).
9804/1103
45 - 00 - 03/3
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 03/3A
JS 70 from m/c no. 695501 Shipping Weights Machine equipped with Boom; 1.74 m (5 ft 8 in) Dipper Arm, Dozer Blade, Standard Excavating Bucket, operator and full fuel tank.
Standard Boom Shoe Width
Operating Weight
Ground Bearing Pressure
450 mm (18 in)
6800 kg (14994 lb)
0.33 kgf/cm2 (4.69 lb/in2)
600 mm (24 in)
7000 kg (15435 lb)
0.25 kgf/cm2 (3.56 lbf/in2)
Shoe Width
Operating Weight
Ground Bearing Pressure
450 mm (18 in)
7300 kg (16060 lb)
0.35 kgf/cm2 (4.97 lb/in2)
600 mm (24 in)
7500 kg (16500 lb)
0.27 kgf/cm2 (3.84 lbf/in2)
Offset Boom
9804/1103
45 - 00 - 03/3A
Issue 1
Excavators
CONTENTS
45 - 00 - 03/4
JS 130, 160, 180, 200, 210 220, 240, 260, JS330, 450 Shipping Weights Approximate weight when equipped with monoboom, medium length dipper, bucket, operator and full fuel tank.
JS130 from m/c no. 758000
JS220 from m/c no. 705001
Model
Track Shoe Width
Weight
Model
Track Shoe Width
Weight
130
500 mm
13210 kg
220S
600 mm
21310 kg
130
600 mm
13400 kg
220LC
700 mm
21990 kg
130
700 mm
13600 kg
220N XD
500 mm
21430 kg
130
850 mm
13890 kg
†220 LC LR
700 mm
22590 kg
220S LC XD
700 mm
22490 kg
220S XD
600 mm
20560 kg
JS160 from m/c no. 702000
† Machine eqipped with 15 metre long reach boom/dipper
Model
Track Shoe Width
Weight
160NLC
500 mm
16000 kg
160 LC
600 mm
16220 kg
160LC
700 mm
16470 kg
160LC
800 mm
16710 kg
Model
Track Shoe Width
Weight
160LC
900 mm
16940 kg
240S
600 mm
23750 kg
240NLC
600 mm
24270 kg
240LC
700 mm
24620 kg
JS180 from m/c no. 702000 Model
Track Shoe Width
Weight
180
600 mm
18120 kg
180
700 mm
18475 kg
JS200 from m/c no. 705001
JS240 from m/c no. 708501
JS260 from m/c no. 708501 Model
Track Shoe Width
Weight
260S
600 mm
24750 kg
260NLC
600 mm
25270 kg
Model
Track Shoe Width
Weight
260LC
700 mm
25620 kg
200N
500 mm
19630 KG
260S XD
600 mm
25250 kg
200S
600 mm
20010 kg
220 NLC XD
600 mm
25770 kg
200LC
700 mm
20690 kg
220LC XD
700 mm
26120 kg
JS330 from m/c no. 712501
JS210 from m/c no. 705001 Model
Track Shoe Width
Weight
Model
Track Shoe Width
Weight
210
700 mm
21500 kg
330
600 mm
31900 kg
330
700 mm
32250 kg
330
800 mm
32600 kg
330
900 mm
32850 kg
JS210 from m/c no. 705001 Model
Track Shoe Width
Weight
††460
600 mm
46000 kg
†† Machine weight without bucket/full tank of fuel
JS450 from m/c no. 714501 Model
Track Shoe Width
Weight
††450
600 mm
46000 kg
†† Machine weight without bucket/full tank of fuel
9804/1103
45 - 00 - 03/4
6950 - 150
Issue 4*
Excavators
CONTENTS
45 - 00 - 03/5
JS 130W from m/c no. 0716501, JS 160W from m/c no. 0718501 Shipping Weights JS130W Basic Machine i.e. without dozer blade or stabilisers
Basic Machine Basic Machine with dozer blade with 2 stabilisers
Basic Machine with dozer blade and 2 stabilisers
Basic Machine with 4 stabilisers
Monoboom
12700 kg
13140 kg
13580 kg
14120 kg
14460 kg
Triple Articulated Boom
13200 kg
13640 kg
14080 kg
14620 kg
14960 kg
Machine equipped with 2.5 m dipper, 0.55 m3 standard excavating bucket and dual wheels. For single wheels subtract 400 kg.
JS160W Basic Machine i.e. without dozer blade or stabilisers
Basic Machine Basic Machine with dozer blade with 2 stabilisers
Basic Machine with dozer blade and 2 stabilisers
Basic Machine with 4 stabilisers
Monoboom
15410 kg
15850 kg
16290 kg
16830 kg
17170 kg
Triple Articulated Boom
16010 kg
16450 kg
16890 kg
17430 kg
17770 kg
Machine equipped with 2.7 m dipper, 0.72 m3 standard excavating bucket and dual wheels. For single wheels subtract 400 kg.
9804/1103
45 - 00 - 03/5
Issue 1
Excavators
CONTENTS
45 - 00 - 03/6
JS 200W from m/c no. 0802000 to 802999 Shipping Weight (Approximate) Basic Machine i.e. without dozer blade or stabilisers
Basic Machine Basic Machine with dozer blade with 2 stabilisers
Basic Machine with dozer blade and 2 stabilisers
Basic Machine with 4 stabilisers
Monoboom
18700 kg
19400 kg
19660 kg
20360 kg
20640 kg
Triple Articulated Boom
19130 kg
19820 kg
20090 kg
20790 kg
21050 kg
Machine equipped with 2.4 m dipper, 0.81 m3 standard excavating bucket and dual wheels. For single wheels subtract 400 kg.
9804/1103
45 - 00 - 03/6
Issue 1
Excavators
CONTENTS CONTENTS
45 - 00 - 03/7
JS 130W from m/c no. 716500, JS 160W from m/c no. 718500 JS200W from m/c no. 809000 Shipping Weight (Approximate) JS130W Basic Machine i.e. without dozer blade or stabilisers
Basic Machine Basic Machine with dozer blade with 2 stabilisers
Basic Machine with dozer blade and 2 stabilisers
Basic Machine with 4 stabilisers
Monoboom
12700 kg
13140 kg
13580 kg
14120 kg
14460 kg
Triple Articulated Boom
13200 kg
13640 kg
14080 kg
14620 kg
14960 kg
Machine equipped with 2.5 m dipper, 0.55 m3 standard excavating bucket and dual wheels. For single wheels subtract 400 kg.
JS160W Basic Machine i.e. without dozer blade or stabilisers
Basic Machine Basic Machine with dozer blade with 2 stabilisers
Basic Machine with dozer blade and 2 stabilisers
Basic Machine with 4 stabilisers
Monoboom
15410 kg
15850 kg
16290 kg
16830 kg
17170 kg
Triple Articulated Boom
16010 kg
16450 kg
16890 kg
17430 kg
17770 kg
Machine equipped with 2.7 m dipper, 0.72 m3 standard excavating bucket and dual wheels. For single wheels subtract 400 kg.
JS200W Basic Machine i.e. without dozer blade or stabilisers
Basic Machine Basic Machine with dozer blade with 2 stabilisers
Basic Machine with dozer blade and 2 stabilisers
Basic Machine with 4 stabilisers
Monoboom
18700 kg
19400 kg
19660 kg
20360 kg
20640 kg
Triple Articulated Boom
19130 kg
19820 kg
20090 kg
20790 kg
21050 kg
Machine equipped with 2.4 m dipper, 0.81 m3 standard excavating bucket and dual wheels. For single wheels subtract 400 kg.
9804/1103
45 - 00 - 03/7
6980 - 145
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 01/1
JS 70 to m/c no. 695500 Data - Electrical System Battery Alternator
12 Volt, negative earth 12 Volt Heavy Duty, 110 Ah 12 Volt, 50 Amp
Light Bulbs Working, Boom Mounted Working, Tank Mounted Cab Engine Compartment Beacon
55 Watts 55 Watts 10 Watts x 1 10 Watts 70 Watts
Fuse Box Circuits Radio/Cab Light Operation Control Switch/Travel Control Switch Heater Refuelling Pump (optional) Systems Control Monitor Idle Switch Working Lamps/Horn Windscreen Wiper/Washer
Rating (Amps) 10 20 20 20 10 30 20 15
Fuse No. 1 2 3 4 5 6 7 8
S267430
9804/1103
45 - 05 - 01/1
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 05 - 01/2
JS 110,130,150LC Data - Electrical System Battery Alternator Starter Motor
24 Volt, negative earth 2 x 12 Volt Heavy Duty, 120Ah 24 Volt, 40 Amp 24 Volt, 3.5 or 4.5 kW, 30 secs.
Light Bulbs Working, Boom Mounted Working, Tank Mounted Cab Engine Compartment
70 Watt 55 Watt 10 Watt x 2 10 Watt
Circuit Protection Circuits Controller Electric Control Horn/Working Light Windscreen Wiper Cab Light/Radio Oil Pressure Heater/Cooler (Optional) Spare
Rating (Amps) 10 15 15 15 10 10 15 15
Fuse No. 1 2 3 4 5 6 7 8
S26744-0
9804/1103
45 - 05 - 01/2
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 01/3
JS 200LC,240LC,300LC,450LC Data - Electrical System (All Machines) Battery (All Machines) Alternator (JS 200, 240, 300LC) Alternator (JS 450LC) Starter Motor (JS 200, 240LC) Starter Motor (JS 300LC) Starter Motor (JS 450LC)
24 Volt, negative earth 2 x 12 Volt Heavy Duty, 120Ah 24 Volt, 40 Amp 24 Volt, 25 Amp 24 Volt, 4.5 kW, 30 secs. 24 Volt, 5.5 kW, 30 secs. 24 Volt, 11 kW, 30 secs.
Light Bulbs JS 240LC
JS 200LC Working, Boom Mounted Working, Tank Mounted Cab Engine Compartment
70 Watt 70 Watt 10 Watt x 2 10 Watt
Working, Boom Mounted Working, Tank Mounted Cab Engine Compartment
80 Watt 80 Watt 10 Watt x 2 10 Watt
JS 450LC
JS 300LC Working, Boom Mounted
80 Watt
Working, Tank Mounted Cab Engine Compartment
80 Watt 10 Watt x 2 10 Watt
Working, Boom Mounted Working, Tank Mounted Working, Rear Mounted Cab Engine Compartment
80 Watt 80 Watt 80 Watt 10 Watt x 2 10 Watt
Circuit Protection Circuits Controller Electric Control Horn/Working Light Windscreen Wiper Cab Light/Radio Oil Pressure Heater/Air Conditioning (Optional) Spare
Rating (Amps) 10 15 15 15 10 10 15 15
Fuse No. 1 2 3 4 5 6 7 8
S267450
9804/1103
45 - 05 - 01/3
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 01/4
JS 130W,150W Data - Electrical System Battery Alternator Starter Motor
24 Volt, negative earth 2 x 12 Volt Heavy Duty, 120Ah 24 Volt, 40 Amp 24 Volt, 4.5 kW, 30 secs.
Light bulbs Working (boom) Working (tank) Cab Interior Engine Compartment Beacon Headlights Indicator Lights Number Plate Light Brake Lights Reversing Lights Fog Lights Side Lights
70 W 55 W 2 x 10 W 10 W 70 W 75/70 W 21 W 5 W (Festoon) 21 W 21 W 21 W 10 W
Circuit Protection The electrical circuits are protected by fuses. Some of the fuses are located in fuse box 1 on the inside face of the right console, others are located in fuse box 2 situated to the right of the seat (see Service Manual, page C/1 - 2). If a fuse blows, find out why before fitting a new one. Fuse Box 1 Fuse No.
Circuit(s) Protected
Rating
1
Service Check Maintenance Monitor
10A
2
Engine Throttle, Redundant (Back-up) Switch
15A
3
Work Lamp, Horn, Travel Control Switch
15A
4
Windscreen Wiper/Washer
15A
5
Radio (plus 2A in-line fuse), Cab Light, Attachment Cushion Switch
10A
6
Operation Control Switch
10A
7
Heater, Air Conditioner (Optional)
15A
8
Feed to Relay Box, Refuelling Pump (Optional)
10A
Fuse Box 2
9804/1103
See next page
45 - 05 - 01/4
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 01/5
JS 130W,150W Data - Electrical (cont’d) Fuse Box 2 Fuse No.
Circuit(s) Protected
Rating
1
Headlights
10A
2
Foglights
5A
3
Cigar Lighter
5A
4
Sidelights RH
5A
5
Left Stabiliser (Optional)
5A
6
Right Stabiliser (Optional)
5A
7
Triple Articulated Boom
5A
8
Axle Lock Relay
5A
9
Brake Inhibit
5A
10
Touch Sensitive Panel (switched)
5A
11
Brake Lights
5A
12
Reversing Lights
5A
13
Dozer Relay
5A
14
Park Brake Relay
5A
15
Range Change Relay
5A
16
Creep Speed Relay
5A
17
Grab Rotate/Hammer (Optional)
5A
18
Drive Isolator Relay
5A
19
Relays (switched)
5A
20
Hazard
5A
21
Relays (unswitched)
5A
22
Sidelights LH
5A
23
Touch Sensitive Panel (unswitched)
5A
24
Hazard (unswitched)
5A
9804/1103
45 - 05 - 01/5
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 01/6
JS 130 from m/c no. 758000, JS160 from m/c no. 702000, JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 Data - Electrical Circuit Protection; Fuse rating and circuit names BACK UP 10A
COMPUTER P. 15A
KEY SW. 10A
COMPUTER C. 10A
AIRCON., HEATER 20A
SHUT DOWN 15A
LAMP 15A
LEVER LOCK 10A
LAMP (SPARE) 15A
LUBRICATOR 10A
LAMP (SPARE) 15A
WARNING BEACON 10A
LAMP (SPARE) 15A
OIL PUMP 20A
WIPER, WASHER 15A
CONDENSER MOTOR 15A
HORN, ROOM LAMP 10A
SPARE 10A
RADIO, LIGHTER 10A
SPARE 10A
(A)
Fuse Replacement See illustration on the right for location of Fuse Box (A). 1. Prepare the machine, stop the engine remove the starter key. 2. Prepare an appropriate fuse of the correct amperage, remove cover. Note: The fuse cover’s right corner is the grip. 3. Replace the blown fuse with a new one. 4. Install the fuse cover. Note: If the reason for the blown fuse is unknown or the fuse fails repeatedly, check the electrical circuit(s) concerned.
Lighting and Horn
Working light
Tank
Boom Roof light Horn
9804/1103
Cab
Voltage
Wattage
No. off
24 V
70 W
1
24 V
70 W
1
24 V
10 W
1
24 V
2
45 - 05 - 01/6
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 01/7
JS 130W from m/c no. 0716501, JS 160W from m/c no. 0718501 Data - Electrical Circuit Protection The electrical circuits are protected by fuses. Some of the fuses are located in fuse box A on the rear console to the right behind the drivers seat. Others are located in fuse box B situated to the left rear of the seat. If a fuse blows, find out why before fitting a new one. Fuse Box A Fuse No.
Circuit(s) Protected
Rating
1
Emergency Back-up Switch
10 A
2
Ignition Switch
10 A
3
Air Conditioning Blower (if fitted)
20 A
A
Heater
*
4
Working Lights
15 A
1 2
5
Spare
15 A
3
6
Optional Working Lights
15 A
7
Spare
15 A
4 5
8
Windscreen Wiper/Washer
10 A
9
Horn
10 A
6 7 8 9 0
Cab Light 10
Radio
10 A
15 10 15 10 10 10 20 15 10 10
10 10 20 15 15 15 15 10 10 10
! @ £ $ % ^ & * ( )
Cigar Lighter 11
Computer (Power)
15 A
12
Computer (Control)
10 A
13
Emergency Engine Stop Switch
15 A
14
Servo Isolation
10 A
15
Spare
10 A
16
Flashing Beacon
10 A
17
Re-fuelling Pump
20 A
18
Air Conditioning Unit (if fitted)
15 A
19
Load Indicator (optional)
10 A
20
Spare
10 A
JS06070
Fuse Box B Fuse No.
Circuit(s) Protected
Rating
1
Lights - left side †
10 A
2
Lights - right side †
10 A
3
Stabilisers
Brake Lights
5A
6
Reverse Lights
5A
5
6
5
5
B
4
5
5A
3
5
Drive Isolator Solenoid
2
5
4
1
10
5A
10
Park Brake
Rockbreaker Circuit (if fitted) †
Headlights, sidelights, indicators. JS06080
9804/1103
45 - 05 - 01/7
Issue 2*
Excavators
CONTENTS
45 - 05 - 01/8
JS 70 from m/c no. 695501 Data - Electrical Circuit Protection; Fuse rating and circuit names ! CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5
Fuses The electrical circuits are protected by fuses located in fuse box A on the front face of the right console (below the Right Excavator Joystick). If a fuse blows, find out why before fitting a new one. Fuse Box A Fuse No.
Circuit(s) Protected
Rating
1
Emergency Back-up Switch
10 A
2
Ignition Switch
10 A
3
Air Conditioning Blower (if fitted)
20 A
Heater 4
Working Lights
15 A
5
Spare
15 A
6
Working Lights (Optional)
15 A
7
Spare
15 A
8
Windscreen Wiper/Washer
10 A
9
Horn
10 A
Cab Light 10
Radio
10 A
Cigar Lighter 11
Computer (Power)
15 A
12
Computer (Control)
10 A
13
Emergency Engine Stop Switch
15 A
14
Servo Isolation
10 A
15
Spare
10 A
16
Flashing Beacon
10 A
17
Re-fuelling Pump
20 A
18
Air Conditioning Condenser (if fitted)
15 A
19
Spare
10 A
20
Spare
10 A
A 1 2 3 4 5 6 7 8 9 0
10 10 20 15 15 15 15 10 10 10
15 10 15 10 10 10 20 15 10 10
! @ £ $ % ^ & * ( )
JS08750
Lighting and Horn Working light
Tank
Boom Roof light Horn 9804/1103
Cab
Voltage
Wattage
No. off
24 V
70 W
1
24 V
70 W
1
24 V
10 W
1
24 V
2
45 - 05 - 01/8
Issue 1
Excavators
CONTENTS CONTENTS
45 - 05 - 01/9
JS 200W from m/c no. 809000 Data - Electrical Circuit Protection Fuse Rating and Circuit Names ! CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5
Fuses The electrical circuits are protected by fuses. Some of the fuses are located in fuse box A on the rear console to the right behind the drivers seat. Others are located in fuse box B situated to the left rear of the seat (see next page).
A
If a fuse blows, find out why before fitting a new one. 1 2
Fuse Box A Fuse No.
Circuit(s) Protected
Rating
1
Emergency Back-up Switch
10 A
2
Ignition Switch
10 A
3
Air Conditioning Blower (if fitted)
20 A
Heater 4
Working Lights
15 A
5
Spare
15 A
6
Optional Working Lights
15 A
7
Spare
15 A
8
Windscreen Wiper/Washer
10 A
9
Horn
10 A
3 4 5 6 7 8 9 0
10 10 20 15 15 15 15 10 10 10
15 10 15 10 10 10 20 15 10 10
Radio
£ $ % ^ & * ( )
JS06070
Cab Light 10
! @
10 A
Cigar Lighter 11
Computer (Power)
12
Computer (Control)
10 A
13
Emergency Engine Stop Switch
15 A
14
Servo Isolation
10 A
15
Spare
10 A
16
Flashing Beacon
10 A
17
Re-fuelling Pump
20 A
18
Air Conditioning Unit (if fitted)
15 A
19
Load Indicator (optional)
10 A
20
Spare
10 A
9804/1103
15 A
45 - 05 - 01/9
6320 - C/2-1.1
Issue 1
Excavators
CONTENTS
45 - 05 - 01/10
JS200W from m/c no. 809000 Data - Electrical (cont’d) Circuit Protection Fuse Rating and Circuit Names (cont’d) Fuses (cont’d) ! CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5
Fuse Box B Fuse No. Circuit(s) Protected
Rating
Park Brake
5A
4
Drive Isolator Solenoid
5A
5
Brake Lights
5A
Reverse Lights
5A
6
B
1
2
3
4
5
6
5
Stabilisers
5
3
5
10 A
5
10 A
Lights - right side †
10
Lights - left side †
2
10
1
Rockbreaker Circuit (if fitted) †
JS06080
Headlights, sidelights, indicators.
9804/1103
45 - 05 - 01/10
3270 - 6320 - C/2-2.1
Issue 1
Excavators
CONTENTS
45 - 05 - 01/11
JS 330 from m/c no. 712501, JS 450 from m/c no. 714501 JS 460 from m/c no. 714550 Data - Electrical (cont’d) Circuit Protection; Fuse rating and circuit names
BACKUP 10A
COMPUTER P. 15A
KEY SW. 10A
COMPUTER C. 10A
AIRCON., HEATER 20A
SHUT DOWN 15A
LAMP 15A
LEVER LOCK 10A
LAMP (SPARE) 15A
LUBRICATOR 10A
LAMP (SPARE) 15A
WARNING BEACON 10A
LAMP (SPARE) 15A
OIL PUMP 20A
WIPER, WASHER 15A
CONDENSER MOTOR 15A
HORN, CAB LAMP 10A
SPARE 10A
RADIO, LIGHTER 10A
SPARE 10A
A
Fuse Replacement See illustration on the right for location of Fuse Box (A). 1. Prepare the machine, stop the engine and remove the starter key. 2. Prepare and appropriate fuse of the correct amperage, remove cover.
JS11030
Note: The fuse cover’s right corner is the grip. 3. Replace the blown fuse with a new one. 4. Install the fuse cover. Note: If the reason for the blown fuse is unknown or the fuse fails repeatedly, check the elctrical circuit(s) concerned.
Lighting and Horn Working Light
Tank
Boom Roof light Horn
9804/1103
Cab
Voltage
Wattage
No. off
24 V
70 W
1
24 V
70 W
1
24 V
10 W
1
24 V
2
45 - 05 - 01/11
6420 - C/2-1.2
Issue 2*
CONTENTS
Excavators
45 - 05 - 01/12
Data - Electrical The A.M.S. System The JCB A.M.S. system (Advanced Management System) is a whole machine electronic control system which replaces the CAPS II system. The system controls engine speed, pump power, transmission, excavator functions, lights, wiper, auxiliary circuits, warning lamps, etc. The AMS manual supplement 9803/6450 is an addition to the following JS XO Machine Service Manuals: Manual No. 9803/6410
Machine No. JS 130 JS 160/180
Serial No. 759561 703075
9803/6310
JS 130W JS 145W JS 160W JS 175W
717027 810001 718966 875001
9803/6400
JS 200/210 JS 220 JS 240 JS 260
706966 706966 709004 709004
9803/6320
JS 200W
809056
9803/6420
JS 330 JS460
712847 714550
A296531
AMS JS330/460 Tracked Machine
Note: Only those areas of the machines which detail the AMS system are covered in the supplement. For all other aspects refer to the above manuals.
9804/1103
45 - 05 - 01/12
6420 - C/1-1.1
Issue 1*
CONTENTS
Excavators
45 - 05 - 01/13
Data - Electrical ! CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5
Fuses - AMS Machines
A
The elctrical circuits are protected by fuses. Some of the fuses are located in fuse box A on the rear console to the right behind the driver’s seat.
A296853
If a fuse blows, find out why before fitting a new one. Fuse Box A Fuse Circuit(s) Protected
1
2
3
4
5
6
A
2
15
15
15
10
10
B
20
10
20
15
10
2
C
10
10
15
15
20
2
Rating
A1
Controller (std), Monitor, fascia switch panel
2A
A2
Controller (std) outputs 1 ~ 6
15A
A3
Controller (std) outputs 7 ~ 12
15A
A4
Controller (std) outputs 13 ~ 16
15A
A5
Controller (std) outputs 17 ~ 22
10A
A6
Controller (std) outputs 23 ~ 28
10A
B1
Heater/air conditioner, auto fan
20A
B2
Radio, lighter, room lamp
10A
B3
Refuelling pump (if fitted), auxiliary, wiper
20A
B4
Work lights, optional hydraulic circuits (if fitted)
15A
B5
Key Switch
10A
B6
Controller (std), monitor
2A
C1
Spare
10A
C2
Spare
10A
C3
Spare
15A
C4
Spare
15A
C5
Spare
20A
C6
Spare
2A
D1
Not Used (Wheeled Machine Only)
D2
Not Used (Wheeled Machine Only)
D3
Not Used (Wheeled Machine Only)
D4
Not Used (Wheeled Machine Only)
D5
Unused
D6
Unused
D
336891
9804/1103
R T S
U
V A370310 JS330 and JS460 R
Pre-heat relay
S
Main fuses
T
Pre-heat resistor
U
Battery isolator relay
V
Safety relay
45 - 05 - 01/13
6420 - C/2-1A.1
Issue 1*
CONTENTS
* JS
Excavators
45 - 05 - 02/1
70 to m/c no. 695500
Data - Hydraulic Pump Type
Two variable displacement axial piston pumps. Integral gear servo pump.
Control Valve
Manufactured in two halves and bolted together.
Side A
Servo actuation of dipper, swing, blade and L.H. track (from Machine No 695002). Track mechanically actuated by lever/pedal prior to Machine No. 695002.
Side B
Servo actuation of boom, bucket and R.H. track (from Machine No 695002). Track mechanically actuated by lever/pedal prior to Machine No. 695002.
Offset Boom Control Valve (if fitted)
Mechanically actuated by pedal.
Pressures - All pressure checks should be undertaken at maximum engine speed with the hydraulic fluid at 50° C ± 5° (3 to 4 LED's). bar
kgf/cm2
lbf/in2
Servo
39 + 5/ - 0
40 + 5/ - 0
569 + 72.5/ - 0
Main Relief Valve (MRV)
275 ± 5
280 ± 5
3982 ± 72.5
294 ± 5 245 ± 5 294 ± 5 294 ± 5 206 ± 5 294 ± 5
300 ± 5 250 ± 5 300 ± 5 300 ± 5 210 ± 5 300 ± 5
4266 ± 72.5 3555 ± 72.5 4266 ± 72.5 4266 ± 72.5 2986 ± 72.5 4266 ± 72.5
196 ± 5
200 ± 5
2844 ± 72.5
294 ± 5 196 ± 5
300 ± 5 200 ± 5
4266 ± 72.5 2844 ± 72.5
Bore 100mm (3.93 in) 95mm (3.74 in) 85mm (3.34 in) 70mm (2.75 in) 100mm (3.93 in)
Rod Dia. 65mm (2.55 in) 60mm (2.36 in) 55mm (2.16 in) 45mm (1.77 in) 45mm (1.77 in)
Stroke 932mm (36.7 in) 900mm(35.43 in) 668mm (26.2 in) 180mm (7.08 in) 415mm (16.4 in)
Control Valve Mounted Auxiliary Relief Valve (ARV's) Boom Raise (Head Side) Boom Lower (Rod Side) Bucket Open/Close Dipper In/Out Dozer Blade raise Dozer Blade lower
Component Mounted Relief Valves Swing Cross Line Relief Valves Offset Boom/Attachment Control Valve Ram Rod Side Ram Head Side
Rams Boom Dipper Bucket Dozer Blade Offset Boom (if fitted) Motors Track Swing
9804/1103
Two speed, axial piston type Fixed displacement, axial piston type
45 - 05 - 02/1
Issue 3*
CONTENTS CONTENTS
Excavators
45 - 05 - 02/2
JS 110 Data - Hydraulic Pump Type
Variable displacement, two element piston pump in tandem. Integral gear servo pump.
* Control Valve
Manufactured in two halves and bolted together.
Left Hand Valve
Servo actuation of bucket, boom and right track (from Serial No 697014 on).†
Right Hand Valve
Servo actuation of dipper, swing and left track (from Serial No 697014 on).† † Mechanical track actuation on earlier Serial Nos.
* Pressures (All pressure checks should be undertaken at maximum speed in the 'S' mode with the hydraulic fluid at 50° C ± 5° (3 to 4 LED's illuminated).
bar
kgf/cm2
lbf/in2
Servo
39 + 5/ - 0
40 + 5/ - 0
570 + 72.5/ - 0
Main Relief Valve (M.R.V.)
294 ± 5
300 ± 5
4270 ± 72.5
245 ± 5 206 ± 5 255 ± 5 255 ± 5 255 ± 5 255 ± 5
250 ± 5 210 ± 5 260 ± 5 260 ± 5 260 ± 5 260 ± 5
3555 ± 72.5 2985 ± 72.5 3700 ± 72.5 3700 ± 72.5 3700 ± 72.5 3700 ± 72.5
Swing Cross Line Relief Valves
211 ± 5
215 ± 5
3057 ± 72.5
Track Cross Line Relief Valves
323 ± 5
330 ± 5
4700 ± 72.5
Bore 100mm (3.9in.) 110mm (4.3in.) 100mm (3.9in.)
Rod Dia. 65mm (2.6in.) 75mm (3.0in.) 65mm (2.6in.)
Stroke 1043mm (41.1in.) 1282mm (50.5in.) 890mm (35.0in.)
Control Valve MountedAuxiliary Relief Valves (ARV's) Boom Raise (Head Side) Boom Lower (Rod Side) Bucket Open (Rod Side) Bucket Close (Head Side) Dipper In (Head Side) Dipper Out (Rod Side) Component Mounted Relief Valves
Rams Boom (2 off) Dipper Bucket Motors Track Swing
9804/1103
Variable displacement, axial piston motor Fixed displacement, axial piston motor
45 - 05 - 02/2
Issue 2*
CONTENTS CONTENTS
* JS
Excavators
45- 05 - 02/3
130
to machine no. 757999
Data - Hydraulic Pump Type
Variable displacement, two element piston pump in tandem. Integral gear servo pump.
Control Valve
Manufactured in two halves and bolted together.
Left Hand Valve
Servo actuation of bucket, boom and right track (from Serial No 699037 on).†
Right Hand Valve
Servo actuation of dipper, swing and left track (from Serial No 699037 on).† † Mechanical track actuation on earlier Serial Nos.
Pressures (All pressure checks should be undertaken at maximum speed in the 'S' mode with the hydraulic fluid at 50° C ± 5° (3 to 4 LED's illuminated). bar
kgf/cm2
lbf/in2
Servo
39 + 5/ - 0
40 + 5/ - 0
570 + 72.5/ - 0
Main Relief Valve (M.R.V.)
294 ± 5
300 ± 5
4270 ± 72.5
245 ± 5 206 ± 5 255 ± 5 255 ± 5 255 ± 5 255 ± 5
250 ± 5 210 ± 5 260 ± 5 260 ± 5 260 ± 5 260 ± 5
3555 ± 72.5 2985 ± 72.5 3700 ± 72.5 3700 ± 72.5 3700 ± 72.5 3700 ± 72.5
Swing Cross Line Relief Valves
211 ± 5
215 ± 5
3057 ± 72.5
Track Cross Line Relief Valves
323 ± 5
330 ± 5
4700 ± 72.5
Bore 100mm (3.9in.) 110mm (4.3in.) 100mm (3.9in.)
Rod Dia. 65mm (2.6in.) 75mm (3.0in.) 65mm (2.6in.)
Stroke 1043mm (41.1in.) 1282mm (50.5in.) 890mm (35.0in.)
Control Valve MountedAuxiliary Relief Valves (ARV's) Boom Raise (Head Side) Boom Lower (Rod Side) Bucket Open (Rod Side) Bucket Close (Head Side) Dipper In (Head Side) Dipper Out (Rod Side) Component Mounted Relief Valves
Rams Boom (2 off) Dipper Bucket Motors Track Swing
9804/1103
Variable displacement, axial piston motor Fixed displacement, axial piston motor
45 - 05 - 02/3
Issue 3*
CONTENTS CONTENTS
Excavators
45- 05 - 02/4
JS 150 Data - Hydraulic Pump Type
Variable displacement, two element piston pump in tandem. Integral gear servo pump.
Control Valve
Manufactured in two halves and bolted together.
Left Hand Valve
Servo actuation of bucket, boom and right track (from Serial No 701045 on).†
Right Hand Valve
Servo actuation of dipper, swing and left track (from Serial No 701045 on).† † Mechanical track actuation on earlier Serial Nos.
Pressures (All pressure checks should be undertaken at maximum speed in the 'S' mode with the hydraulic fluid at 50° C ± 5° (3 to 4 LED's illuminated). bar
kgf/cm2
lbf/in2
Servo
39 + 5/ - 0
40 + 5/ - 0
570 + 72.5/ - 0
Main Relief Valve (M.R.V.)
294 ± 5
300 ± 5
4266 ± 72.5
275 ± 5 206 ± 5 275 ± 5 275 ± 5 275 ± 5 275 ± 5 240 ± 5
280 ± 5 210 ± 5 280 ± 5 280 ± 5 280 ± 5 280 ± 5 3413 ± 72.5
3980 ± 72.5 3000 ± 72.5 3980 ± 72.5 3980 ± 72.5 3980 ± 72.5 3980 ± 72.5
Swing Cross Line Relief Valves
226 ± 5
230 ± 5
3270 ± 72.5
Track Cross Line Relief Valves
294 ± 5
300 ± 5
4266 ± 72.5
Bore 120mm (4.7in.) 125mm (4.9in.) 110mm (4.3in.)
Rod Dia. 80mm (3.1in.) 85mm (3.3in.) 70mm (2.8in.)
Stroke 1184mm (46.6in.) 1448mm (57.0in.) 997mm (39.3in.)
Control Valve Mounted Auxiliary Relief Valves (ARV's) Boom Raise (Head Side) Boom Lower (Rod Side) Bucket Open (Rod Side) Bucket Close (Head Side) Dipper In (Head Side) Dipper Out (Rod Side) Swing 235 ± 5 Component Mounted Relief Valves
Rams Boom (2 off) Dipper Bucket Motors Track Swing
9804/1103
Variable displacement, axial piston motor Fixed displacement, axial piston motor
45 - 05 - 02/4
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 05 - 02/5
JS 200LC Data - Hydraulic Pump Type
Variable displacement, two element axial piston pump. Integral gear servo pump.
Control Valve Manufactured in two halves and bolted together. Side A
Servo actuation of dipper and swing. Lever/pedal actuation of right track.
Side B
Servo actuation of boom and bucket. Lever/pedal actuation of left track.
Pressures All pressure checks should be undertaken at maximum speed in the 'S mode' with the hydraulic fluid at 50° C ± 5° (3 to 4 LED's). bar
kgf/cm2
lbf/in2
Servo
39 + 5 - 0
40 + 5/ - 0
569 + 72.5/ - 0
Main Relief Valve (MRV) A Main Relief Valve (MRV) B
338 ± 5 338 ± 5
345 ± 5 345 ± 5
4906.5 ± 72.5 4906.5 ± 72.5
304 ± 5 206 ± 5 294 ± 5 294 ± 5 294 ± 5 294 ± 5
310 ± 5 210 ± 5 300 ± 5 300 ± 5 300 ± 5 300 ± 5
4408 ± 72.5 2986 ± 72.5 4266 ± 72.5 4266 ± 72.5 4266 ± 72.5 4266 ± 72.5
Swing Cross Line Relief Valves
245 ± 5
250 ± 5
3555 ± 72.5
Track Cross Line Relief Valves
353 ± 5
360 ± 5
5119 ± 72.5
324 ± 5 314 ± 5
330 ± 5 320 ± 5
4693 ± 72.5 4550 ± 72.5
Bore 125mm (4.9 in.) 140mm (5.5 in.) 120mm (4.7 in.)
Rod Dia. 85mm (3.4 in.) 95mm (3.7 in.) 80mm (3.0 in.)
Stroke 1265mm (49.8 in.) 1515mm (60.0 in.) 1025mm (40.4 in.)
Control Valve Mounted Auxiliary Relief Valve (ARV's) Boom Raise (Head Side) Boom Lower (Rod Side) Bucket Open (Rod Side) Bucket Close (Head Side) Dipper In (Head Side) Dipper Out (Rod Side) Component Mounted Relief Valves
Hose Burst Check Valves Boom Dipper Rams Boom (2 off) Dipper Bucket Motors Track Swing
9804/1103
Two speed, axial piston type Fixed displacement, axial piston type
45 - 05 - 02/5
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 02/6
JS 240LC Data - Hydraulic Pump Type
Variable displacement, two element axial piston pump in tandem. Integral gear servo pump.
Control Valve Manufactured in two halves and bolted together. Side A
Servo actuation of bucket, boom and right track.
Side B
Servo actuation of dipper, swing and left track.
Pressures All pressure checks should be undertaken at maximum speed in the 'S mode' with the hydraulic fluid at 50° C ± 5° (3 to 4 LED's). bar
kgf/cm2
lbf/in2
Servo
39 + 5/- 0
40 + 5/- 0
569 + 72.5/- 0
Main Relief Valve (MRV) A Main Relief Valve (MRV) B
294 ± 5 294 ± 5
300 ± 5 300 ± 5
4266 ± 72.5 4266 ± 72.5
314 ± 5 255 ± 5 314 ± 5 314 ± 5 314 ± 5 314 ± 5 275 ± 5 275 ± 5
320 ± 5 260 ± 5 320 ± 5 320 ± 5 320 ± 5 320 ± 5 280 ± 5 280 ± 5
4550 ± 72.5 3697 ± 72.5 4550 ± 72.5 4550 ± 72.5 4550 ± 72.5 4550 ± 72.5 3982 ± 72.5 3982 ± 72.5
Swing Cross Line Relief Valves
255 ± 5
260 ± 5
3697 ± 72.5
Track Cross Line Relief Valves
314 ± 5
320 ± 5
4550 ± 72.5
324 ± 5 324 ± 5
330 ± 5 330 ± 5
4693 ± 72.5 4693 ± 72.5
Bore 130mm (5.1 in.) 150mm (5.9 in.) 130mm (5.1 in.)
Rod Dia. Stroke 85mm (3.3 in.) 1253mm (49.3 in.) 105mm (4.1 in.) 1574mm (62.0 in.) 90mm (3.5 in.) 1125mm (44.3 in)
Control Valve Mounted Auxiliary Relief Valves (ARV's) Boom Raise (Head Side) Boom Lower (Rod Side) Bucket Open (Rod Side) Bucket Close (Head Side) Dipper In (Head Side) Dipper Out (Rod Side) Swing Right Swing Left Component Mounted Relief Valves
Hose Burst Check Vlaves Boom Dipper Rams Boom (2 off) Dipper Bucket Motors Track Swing
9804/1103
Two speed, axial piston type Fixed displacement, axial piston type
45 - 05 - 02/6
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 02/7
JS 300LC Data - Hydraulic Pump Type
Variable displacement, two element axial piston pump. Integral gear servo pump.
Control Valve Manufactured in two halves and bolted together. Side A
Servo actuation of bucket, boom and right track.
Side B
Servo actuation of dipper, swing and left track.
Pressures Checks of servo pressure and of MRV settings should be undertaken at maximum speed in the 'S mode'. Checks of ARV and cross line relief valve settings should be undertaken at maximum speed in the 'L mode'. In all cases the hydraulic fluid should be at 50° C ± 5° (3 to 4 LED's). bar
kgf/cm2
lbf/in2
Servo
44 + 5/-0
45 + 5/- 0
640 + 72.5/- 0
Main Relief Valve (MRV) A Main Relief Valve (MRV) B
314 ± 5 314 ± 5
320 ± 5 320 ± 5
4550 ± 72.5 4550 ± 72.5
245 ± 5 333 ± 5 333 ± 5 333 ± 5 333 ± 5 294 ± 5 294 ± 5
250 ± 5 340 ± 5 340 ± 5 340 ± 5 340 ± 5 300 ± 5 300 ± 5
3555 ± 72.5 4835 ± 72.5 4835 ± 72.5 4835 ± 72.5 4835 ± 72.5 4266 ± 72.5 4266 ± 72.5
Swing Cross Line Relief Valves
265 ± 5
270 ± 5
3839 ± 72.5
Track Cross Line Relief Valves
324 ± 5
330 ± 5
4692 ± 72.5
333 ± 5 333 ± 5
340 ± 5 340 ± 5
4835 ± 72.5 4835 ± 72.5
Bore 140mm (5.5 in.) 160mm (6.3 in.) 140mm (5.5 in.)
Rod Dia. Stroke 100mm (3.9 in.) 1480mm (58.3 in.) 110mm (4.3 in.) 1733mm (68.2 in.) 95mm (3.7 in.) 1275mm (50.2 in.)
Control Valve Mounted Auxiliary Relief Valves (ARV's) Boom Lower (Rod Side) Bucket Open (Rod Side) Bucket Close (Head Side) Dipper In (Head Side) Dipper Out (Rod Side) Swing Right Swing Left Component Mounted Relief Valves
Hose Burst Check Valves Boom Dipper Rams Boom (2 off) Dipper Bucket Motors Track Swing
9804/1103
Two speed, axial piston type Fixed displacement, axial piston type
45 - 05 - 02/7
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 02/8
JS 450LC Data - Hydraulic Pump Type
Variable displacement, two element axial piston pump. Integral gear servo pump.
Control Valve Mono-block construction. A half
Servo actuation of bucket, boom and right track.
B half
Servo actuation of dipper, swing and left track.
Pressures Checks of servo pressure and of MRV settings should be undertaken at maximum speed in the 'S mode'. Checks of ARV and cross line relief valve settings should be undertaken at maximum speed in the 'L mode'. In all cases the hydraulic fluid should be at 50° C ± 5° (3 to 4 LED's).
bar
kgf/cm2
lbf/in2
Servo
44 + 5/- 0
45 + 5/- 0
640 + 72.5/- 0
Main Relief Valve (MRV)
314 ± 5
320 ± 5
4550 ± 72.5
245 ± 5 333 ± 5 333 ± 5 333 ± 5 333 ± 5
250 ± 5 340 ± 5 340 ± 5 340 ± 5 340 ± 5
3555 ± 72.5 4835 ± 72.5 4835 ± 72.5 4835 ± 72.5 4835 ± 72.5
Swing Cross Line Relief Valves
279 ± 5
285 ± 5
4053 ± 72.5
Track Cross Line Relief Valves
314 ± 5
320 ± 5
4550 ± 72.5
333 ± 5
340 ± 5
4835 ± 72.5
Bore 160mm (6.3 in.) 180mm (7.1 in.) 160mm (6.3 in.)
Rod Dia. Stroke 110mm (4.3 in.) 1580mm (62.2 in.) 130mm (5.1 in.) 1910mm (75.2 in.) 110mm (4.3 in.) 1306mm (51.4 in.)
Control Valve Mounted Auxiliary Relief Valve (ARV) Boom Lower (Rod Side) Bucket Open (Rod Side) Bucket Close (Head Side) Dipper In (Head Side) Dipper Out (Rod Side) Component Mounted Relief Valves
Holding Valve Boom Rams Boom (2 off) Dipper Bucket Motors Track Swing
9804/1103
Two speed, axial piston type Fixed displacement, axial piston type
45 - 05 - 02/8
Issue 1
CONTENTS
* JS
Excavators
45 - 05 - 02/9
130W from m/c no. 0716501, JS 160W from m/c no. 0718501
Data - Hydraulic (contÕd) Pump Type
Variable displacement, two element piston pumps in tandem. Integral gear servo pumps.
* Control Valve Manufactured in two halves and bolted together. Left Hand Valve (3 spool)
Servo actuation of bucket, boom options/dozer.
Right Hand Valve (4 spool)
Servo actuation of dipper, swing, options and travel.
* Rams (JS130W) Boom (2 off) (mono boom only) Dipper Bucket Dozer (2 off) (optional) Stabilisers (optional) Axle Lock (2 off) Triple Articulated Boom (if fitted) Boom Raise/Lower Boom Position
Bore 110 mm (4.3 in) 120 mm (4.7 in) 105 mm (4.1 in) 110 mm (4.3 in) 120 mm (4.7 in) 85 mm (3.3 in)
Rod Diameter 70 mm (2.8 in) 80 mm (3.1 in) 65 mm (2.6 in) 60 mm (2.4 in) 65 mm (2.6 in) 85 mm (3.3 in)
Stroke 1055 mm (41.5 in) 1282 mm (50.5 in) 890 mm (35.0 in) 192 mm (7.5 in) 476 mm (18.7 in) 160 mm (6.3 in)
110 mm (4.3 in) 110 mm (4.3 in)
70 mm (2.8 in) 70 mm (2.8 in)
835 mm (32.9 in) 815 mm (32.1 in)
120 mm (4.7 in) 125 mm (4.9 in) 110 mm (4.3 in) 110 mm (4.3 in) 120 mm (4.7 in) 85 mm (3.3 in)
80 mm (3.1 in) 85 mm (3.3 in) 70 mm (2.8 in) 60 mm (2.4 in) 65 mm (2.6 in) 85 mm (3.3 in)
1184 mm (46.6 in) 1448 mm (57.0 in) 997 mm (39.3 in) 192 mm (7.5 in) 476 mm (18.7 in) 160 mm (6.3 in)
120 mm (4.7 in) 120 mm (4.7 in)
80 mm (3.1 in) 80 mm (3.1 in)
927 mm (36.5 in) 927 mm (36.5 in)
* Rams (JS160W) Boom (2 off ) (mono boom only Dipper Bucket Dozer (2 off) (optional) Stabilisers (optional) Axle Lock (2 off) Triple Articulated Boom (if fitted) Boom Raise/Lower Boom Position
Motors Drive Swing
9804/1103
Variable displacement, axial piston motor. Fixed displacement, axial piston motor.
45 - 05 - 02/9
Issue 2*
Excavators
CONTENTS
* JS
45 - 05 - 02/10
130W from m/c no. 0716501, JS 160W from m/c no. 0718501
Data - Hydraulic (contÕd) * Pressures All pressure checks should be undertaken at maximum engine speed in the ‘S’ mode. 2 Stage
JS 130W Bar
(lbf/in2)
JS 160W Bar
(lbf/in2)
Main Relief Boom Raise Arm in/out Bucket open/close Standard
312 (4524)
315
(4568)
Boost/’F’ Mode
340 (4930)
340
(4930)
Boom Service Relief - Boom Lower Stall
295 (4227)
295
(4227)
Swing Service Relief (x 2) - Left/Right Stall
295 (4227)
285
(4132)
Overload Relief - Boom/Arm/Bucket
365 (5292)
365
(5292)
Hammer Service Relief (x 2) - Hammer/Auxiliary Stall
180 (2610)
180
(2610)
Boom Position Ram Service Relief - TAB Stall
365 (5292)
365
(5292)
Blade/Stabiliser Service Relief (x 2) - Service Stall
250 (3625)
250
(3625)
Steer/Brakes Service Relief - Steer Stall
175 (2538)
175
(2538)
Hand Steer Valve Overload - Steer Stall
185 (2682)
185
(2682)
Grab Rotate Cross-line Relief (x 2) - Rotate Stall
150 (2175)
150
(2175)
Negative Control - ‘S’ Mode, Neutral, Maximum RPM
40
(580)
40
(580)
Pilot Control Relief - Continuous
40
(580)
40
(580)
Clutch Pilot Pressure - Continuous
32
(464)
32
(464)
Service Brake Pressure - On Latch
48
(696)
48
(696)
Park Brake Pressure - Clutch Residual
15
(218)
15
(218)
Service Brake Charge - Cut In on Falling Pressure
130 (1885)
130
(1885)
Service Brake Charge - Cut Out on Rising Pressure
150 (2175)
150
(2175)
Hose Burst Check Valve Relief - Boom Ram Head Side
365 (5292)
365
(5292)
Hose Burst Check Valve Relief - Position Ram Head Side
365 (5292)
365
(5292)
Hose Burst Check Valve Relief - Arm Ram Rod Side
365 (5292)
365
(5292)
100% Swing Brake - Normal Residual Pressure
13
(188)
15
(218)
Service Brake Accumulators (x 4) - Nitrogen Pre-charge
37
(536)
37
(536)
Park Brake Accumulator - Nitrogen Pre-charge
6
(87)
6
(87)
Service Brake Warning Lamp - Pressure Switch Falling
105 (1522)
105
(1522)
Rear Brake Lights - Pressure Switch Rising
5
(72)
5
(72)
Reverse Lights - Pressure Switch Rising
5
(72)
5
(72)
Park Brake (Drive Inhibit and Alarm) - Pressure Switch Falling
26
(377)
26
(377)
P22 Pump Signal - Drive at 90% Flow
28
(406)
28
(406)
Pressure Sequence Valve - Clutch Priority
28
(406)
28
(406)
Clutch Priority Accumulator - Nitrogen Pre-charge
8
(16)
8
(16)
9804/1103
45 - 05 - 02/10
Issue 2*
CONTENTS
Excavators
45 - 05 - 02/11
JS 70 from m/c no. 695501 Data - Hydraulic (contÕd)
Pump Type
2 stage tandem, variable capacity swash plate type axial piston pump
Displacement Volume
36 cm3/rev x 2 (2.196 in3/rev x 2)
Working Pressure
284.4 bar (4125 lbf/in2)
Maximum Output
79 l/min (17 U.K. gal/min)
Fixed Displacement Gear Pump
Pilot
Blade cm3/rev
(0.65
in3/rev)
Displacement Volume
10.7
Working Pressure
39.2 bar ( 569 lbf/in2)
Maximum Output
23 l/min (5 U.K. gal/min)
Total Dry weight
58kg (62 lb)
12.1
cm3/rev
(0.74 in3/rev)
217 bar ( 3146 lbf/in2) 26 l/min (5.7 U.K. gal/min)
Control Valve (Main) Type
Hydraulic Pilot System
Operating System
Set pressure relief
Main Relief Standard Pressure Rated Flow
279 - 284 bar (4046 - 4119 lb/in2) 79.2 l/min (17.4 gal/min)
Oil Temperature
-25 °C - 95 °C (-13 °F - 208 °F)
Auxiliary Relief Valve Pressure Boom Raising, Dipper, Bucket Boom Lowering Pressure
304 - 314 bar (4409 - 4554 lb/in2) 255 - 265 bar (3698 - 3843 lb/in2)
Function
Travel priority, Slew priority, Boom and Dipper holding valves, Boom and Dipper 2-Speed internal confluence
Dry Weight
66 kg (145.5 lb)
Control Valve (Blade) Type
Hydraulic Pilot System
Operating System
Set pressure relief
Main Relief Auxiliary Relief Valve Pressure Dry Weight
221 - 231 bar (3205 - 3350 lb/in2) 250 - 260 bar (3626 - 3771 lb/in2) 4.5 kg (9.92 lb)
Slew Motor Type
Fixed displacement piston motor
Suction Capacity
45.5 cm3/rev (2.78in3/rev)
Working Pressure
206 bar (2987 lbf/in2)
Work Flow
75.6 l/min (16.63 U.K. gal/min)
Set Pressure Relief Reduction Gears
201 - 209 bar (2915 - 3031 lb/in2) Planetary gears with 2 gear reduction
Reduction Gear Ratio
19.464 : 1
Slew Brake Brake Torque Brake Pressure Release
More than 16.8 kgf m (121.5 lbf ft) (not including reduction gear) Min 32.3 bar (469 lbf/in2)
Dry Weight
67 kg (148 lb)
9804/1103
45 - 05 - 02/11
Issue 1
CONTENTS
Excavators
45 - 05 - 02/12
JS 70 from m/c no. 695501 Data - Hydraulic (contÕd) Travel Equipment Type
Variable Displacement Piston Motor (automatic 2-speed change)
Suction Capacity
37.22/25.75 cm3/rev (2.27/1.57 in3/rev)
Working Pressure
284.4 bar (4125 lbf/in2)
Working Flow
75.6 l/min (16.6 U.K. gal/min)
Reduction Gear Ratio
52.8 : 1
Parking Brake Brake Torque Brake Pressure Release Dry Weight
8.4 kgf/m (60.7 lbf ft) excluding reduction gear 4.5 bar (65.42 lbf/in2) 90 kg (198.4 lb)
Boom Ram Cylinder Inside Diameter
100 mm (3.94 in)
Rod Diameter
65 mm (2.56 in)
Max Contracted Length
1383 mm (54.45 in)
Stroke
927 mm (36.49 in)
Dry Weight
85 kg (187.42 lb)
Dipper Ram Cylinder Inside Diameter
95 mm (3.74 in)
Rod Diameter
60 mm (2.36 in)
Max Contracted Length
1364 mm (53.74 in)
Stroke
878 mm (34.56 in)
Dry Weight
81 kg (178.60 lb)
Bucket Ram Cylinder Inside Diameter
85 mm (3.35 in)
Rod Diameter
55 mm (2.16 in)
Max Contracted Length
1050 mm (41.34 in)
Stroke
688 mm (27.09 in)
Dry Weight
52 kg (114 lb)
Offset Boom Ram Cylinder Inside Diameter
95 mm (3.74 in)
Rod Diameter
65 mm (2.56 in)
Max Contracted Length
1255 mm (49.41 in)
Stroke
788 mm (31.02 in)
Dry Weight
TBA
Blade Ram Cylinder Inside Diameter
70 mm (2.75 in)
Rod Diameter
45 mm (1.77 in)
Max Contracted Length
496 mm (19.53 in)
Stroke
180 mm (7.08 in)
Dry Weight
20 kg (44.1 lb)
9804/1103
45 - 05 - 02/12
Issue 1
CONTENTS CONTENTS
Excavators
45- 05 - 03/1
JS 130 from m/c no 758000 Data - Hydraulic Note: For full specification details see information in service manual
Pump Type
2 stage tandem, variable capacity swash plate type axial piston pump
Displacement Volume
55 cm3/rev x 2 (3.36 in3/rev x 2)
Working Pressure
320 kgf/cm2 (4551 lbf/in2)
Maximum Output
122.7 l/min (27 gal/min)
Fixed Displacement Gear Pump Displacement Volume
9.08 cm3/rev (0.55 in3/rev)
Working Pressure
43 kgf/cm2 ( 612 lbf/in2)
Maximum Output
20.2 l/min (4.5 gal/min)
Dry weight
TBA
Control Valve Type
Hydraulic Pilot System
Operating System
Set pressure relief
Main Relief Standard Pressure Maximum Pressure
320 kgf/cm2 (4550 lbf/in2) at 91 l/min (20.02 gal/min) 350 kgf/cm2 (4977 lbf/in2) at 83 l/min (18.26 gal/min)
Overload Relief Pressure Boom Raising, Dipper, Bucket Boom Lowering Pressure
365 kgf/cm2 (5190.3 lbf/in2) at 30 l/min (6.6 gal/min) 300 kgf/cm2 (4266 lbf/in2) at 30 l/min (6.6 gal/min)
Function
Travel priority, Slew priority, Boom and Dipper holding valves, Boom and Dipper 2-Speed internal confluence
Dry Weight
104 kg (229.3 lb)
Slew Motor Type
Fixed displacement piston motor
Suction Capacity
65 cm3/rev (3.97 in3/rev)
Working Pressure
285 kgf/cm2 (4052 lbf/in2)
Work Flow
121 l/min (26.62 gal/min)
Set Pressure Relief
285 kgf/cm2 (4052 lbf/in2) at 107 l/min (23.54 gal/min) 275 kgf/cm2 (3953.2 lbf/in2) at 40 l/min (8.8 gal/min)
Reduction Gears Reduction Gear Ratio
Planetary gears with 2 gear reduction 17.03 : 1
Slew Brake Brake Torque Brake Pressure Release
More than 30 kgf m (217 lbf ft) (not including reduction gear) Min 30 kgf/cm2 (426 lbf/in2)
Dry Weight
99 kg (218 lb)
9804/1103
45 - 05 - 03/1
Issue 1
CONTENTS
Excavators
45 - 05 - 03/2
JS 130 from m/c no 758000 Data - Hydraulic Travel Equipment Type
Fixed Displacement Piston Motor (automatic 2-speed change)
Suction Capacity
86.3 cm3/rev (5.27 in3/rev)
Working Pressure
350 kgf/cm2 (4977 lbf/in2)
Working Flow
TBA
Reduction Gear Ratio
39 : 1
Parking Brake Brake Torque Brake Pressure Release Brake Valve Pressure Relief
26 kgf/m (188 lbf ft) including reduction gear > 10 kgf/cm2 (142 lbf/in2) TBA
Dry Weight
165 kg (364 lb)
Boom Ram Cylinder Inside Diameter
100 mm (3.94 in)
Rod Diameter
75 mm (2.95 in)
Max Contracted Length
1561 mm (61.46 in)
Stroke
1081 mm (42.56 in)
Dry Weight
116 kg (256 lb)
Dipper Ram *
Cylinder Inside Diameter
115 mm (4.53 in)
Rod Diameter
80 mm (3.15 in)
Max Contracted Length
1714 mm (67.48 in)
Stroke
1205 mm (47.44 in)
Dry Weight
160 kg (353 lb)
Bucket Ram Cylinder Inside Diameter
95 mm (3.74 in)
Rod Diameter
70 mm (2.76 in)
Max Contracted Length
1422 mm (55.99 in)
Stroke
924 mm (36.38 in)
Dry Weight
97 kg (214 lb)
9804/1103
45 - 05 - 03/2
Issue 2*
CONTENTS CONTENTS
*
Excavators
45 - 05 - 03/3
JS 160 from m/c no 702000
Note: For full specification details see information in service manual
Pump Type Displacement Volume Working Pressure Maximum Output Fixed Displacement Gear Pump Displacement Volume Working Pressure Maximum Output Dry Weight Control Valve Type Operating System Main Relief Standard pressure Maximum pressure Overload Relief Pressure Boom Raising, Arm, Bucket Boom Lowering Pressure Function Dry Weight Slew Motor Type Suction Capacity Working Pressure Work Flow Set Pressure Relief Reduction Gears Reduction Gear Ratio Slew Brake Brake Torque Brake Pressure Release Dry Weight
9804/1103
2 stage tandem, variable capacity swash plate type axial piston pump 60 cm 3 /rev x 2 (3.66 in 3 /rev x 2) 320 kgf/cm 2 (4551 lbf/in 2 ) 139.8 l/min (30.75 gal/min) 9.08 cm 3 /rev (0.55 in 3 /rev) 43 kgf/cm 2 (612 lbf/in 2 ) 21.2 l/min (4.6 gal/min) TBA
Hydraulic Pilot System Set relief pressure 320 kgf/cm 2 (4550 lbf/in 2 ) at 91 l/min (20.02 gal/min) 350 kgf/cm 2 (4977 lbf/in 2 ) at 83 l/min (18.26 gal/min) 365 kgf/cm 2 (5190 lbf/in 2 ) at 30 l/min (6.6 gal/min) 300 kgf/cm 2 (4266 lbf/in 2 ) at 30 l/min (6.6 gal/min) Travel priority, Slew priority, Boom and Dipper holding valves, Boom and Dipper 2-Speed internal confluence 104 kg (229.3 lb)
Fixed displacement piston motor 151 cm 3 /rev (9.21 in 3 /rev) 285 kgf/cm 2 (4052.7 lbf/in 2 ) 138 l/min (36.5 gal/min) 285 kgf/cm 2 (4052.7 lbf/in 2 ) at 126 l/min (27.72 gal/min) 275 kgf/cm 2 (3910.5 lbf/in 2 ) at 40 l/min (8.8 gal/min) Planetary gears with 2 gear reduction 13.34 : 1 More than 68.5 kgf m (495.3 lbf ft) (Not including reduction gear) Min 32 kgf/cm 2 (455 lbf/in 2 ) 197 kg (434 lb)
45 - 05 - 03/3
Issue 2*
CONTENTS
*
Excavators
45 - 05 - 03/4
JS 160 from m/c no. 702000 Data - Hydraulic Travel Equipment Motor Suction Capacity Working Pressure Working Flow Reduction Gear Ratio Parking Brake Brake Torque Brake Pressure Release Brake valve pressure relief Dry Weight
Fixed displacement piston motor (automatic 2-speed change) 104.8 cm 3 /rev (6.39 in 3 /rev) 350 kgf/cm 2 (4977 lb/in 2 ) TBA 48 : 1 26 kgf/m (188 lbf ft) including reduction gear > 11 kgf/cm 2 (156 lbf/in 2 ) TBA 225 kg (496 lb)
Boom Rams Cylinder Inside Diameter Rod Diameter Max Contracted Length Stroke Dry Weight
115 mm (4.53 in) 80 mm (3.15 in) 1689 mm (66.65 in) 1184 mm (46.61 in) 157 kg (346 lb)
Dipper Ram Cylinder Inside Diameter Rod Diameter Max Contracted Length Stroke Dry Weight
125 mm (4.92 in) 90 mm (3.54 in) 1875 mm (73.82 in) 1335 mm (52.56 in) 210 kg (463 lb)
Bucket Ram Cylinder Inside Diameter Rod Diameter Max Contracted Length Stroke Dry Weight
105 mm (4.13 in) 75 mm (2.95 in) 1057 mm (59.33 in) 997 mm (39.25 in) 117 kg (258 lb)
9804/1103
45 - 05 - 03/4
Issue 2*
CONTENTS CONTENTS
Excavators
45- 05 - 03/4
JS 160 Data - Hydraulic Travel Equipment Motor Suction Capacity
Fixed displacement piston motor (automatic 2-speed change) 104.8 cm3/rev (6.39 in3/rev)
Working Pressure
350 kgf/cm2 (4977 lb/in2)
Working Flow
TBA
Reduction Gear Ratio Parking Brake Brake Torque Brake Pressure Release Brake valve pressure relief
48 : 1 26 kgf/m (188 lbf ft) including reduction gear > 11 kgf/cm2 (156 lbf/in2) TBA
Dry Weight
225 kg (496 lb)
Boom Rams Cylinder Inside Diameter
115 mm (4.53 in)
Rod Diameter
80 mm (3.15 in)
Max Contracted Length
1689 mm (66.65 in)
Stroke
1184 mm (46.61 in)
Dry Weight
157 kg (346 lb)
Dipper Ram Cylinder Inside Diameter
125 mm (4.92 in)
Rod Diameter
90 mm (3.54 in)
Max Contracted Length
1875 mm (73.82 in)
Stroke
1335 mm (52.56 in)
Dry Weight
210 kg (463 lb)
Bucket Ram Cylinder Inside Diameter
105 mm (4.13 in)
Rod Diameter
75 mm (2.95 in)
Max Contracted Length
1057 mm (59.33 in)
Stroke
997 mm (39.25 in)
Dry Weight
117 kg (258 lb)
9804/1103
45 - 05 - 03/4
Issue 1
CONTENTS CONTENTS
Excavators
45- 05 - 03/5
JS 200 & 220 from m/c no. 705001 Data - Hydraulic Pump Type
Twin variable displacement piston pump
Displacement Volume
96.6 (cc/rev) x2
Working Pressure
350 kgf/cm2 (343 bar, 4977 lb/in2)
Maximum Output
198.7 litre/min (43.7 UK gal)
Fixed Displacement Gear Pump Displacement Volume
10 cc/rev
Working Pressure
40 kgf/cm2 (39.2 bar, 569 lb/in2)
Maximum Output
20.5 litre/min (4.5 UK gal)
Dry weight
132 kg (291 lb)
Control Valve Type
Hydraulic Pilot System
Operating System
Set pressure relief
Main Relief Pressure Standard Pressure Raising
320 kgf/cm2 (309 bar, 4550 lb/in2) at 138 litre/min (30.3 UK gal) 350 kgf/cm2 (343 bar,4977 lb/in2) at 155 litre/min (34 UK gal)
Overload Relief Pressure Boom Raising, Dipper, Bucket Boom Lowering Pressure
370 kgf/cm2 (351 bar, 5161lb/in2) at 20 litre/min (4.4 UK gal) 250 kgf/cm2 (245 bar, 3555 lb/in2) at 20 litre/min (4.4 UK gal)
Function
Travel priority, Slew priority, Boom and Dipper Load Holding Valve, Boom and Dipper 2 Speed Confluence
Dry Weight
165 kg (364 lb)
Slew Equipment Type
Fixed displacement piston motor
Suction Capacity
151 cc/rev
Working Pressure
285 kgf/cm2 (279 bar, 4052 lb/in2)
Work Flow
198.7 litre/min (43.6 gal/min)
Set Pressure Relief
285 kgf/cm2 (279 bar, 4053 lb/in2) at 155 litre/min (34 UK gal) 275 kgf/cm2 (269 bar, 3911 lb/in2) at 40 litre/min (8.8 UK gal)
Reduction Gear Ratio
16.757 : 1
Slew Brake Brake Torque Brake Pressure Release
More than 75.4 kgf m (739.4 Nm, 545 ft lbs) (not including reduction gear) Min 30 kgf/cm2 (29.4 bar, 426 lb/in2)
Dry Weight
197 kg (434 lb)
9804/1103
45 - 05 - 03/5
Issue 1
CONTENTS CONTENTS
Excavators
45- 05 - 03/6
JS 200 & 220 from m/c no. 705001 Data - Hydraulic Travel Equipment Type
Fixed Displacement Piston Motor (automatic 2-speed change)
Suction Capacity
157.8/92.9 cc/rev
Working Pressure
350 kgf/cm2 (338 bar, 4977 lb/in2)
Working Flow
199 litre/min (43.7 UK gal)
Reduction Gears Deceleration Ratio
44.384
Parking Brake Brake Torque Brake Pressure Release Brake Valve Pressure Relief Dry Weight
2135 kgf/m (20.9 kN/m) including reduction gear > 14 kgf/cm2 (6.8 bar, 101 lb/in2) 360 kgf/cm2 (348 bar, 5119 lb/in2) at 40 litre/min (8.8 UK gal) 270 kg (595 lb)
Boom Ram Cylinder Inside Diameter
125 mm
Rod Diameter
85 mm
Max Contracted Length
1790 mm
Stroke
1295 mm
Dry Weight
176 kg (388 lb)
Dipper Ram Cylinder Inside Diameter
135 mm
Rod Diameter
100 mm
Max Contracted Length
2150 mm
Stroke
1580 mm
Dry Weight
275 kg (606 lb)
Bucket Ram Cylinder Inside Diameter
120 mm
Rod Diameter
80 mm
Max Contracted Length
1582 mm
Stroke
1012 mm
Dry Weight
146 kg (322 lb)
9804/1103
45 - 05 - 03/6
Issue 1
CONTENTS CONTENTS
Excavators
45- 05 - 03/7
JS 240 & 260 from m/c no. 708501 Data - Hydraulic Pump Type
Twin variable displacement piston pump
Displacement Volume Working Pressure
96.4 cc/rev x2 320 kgf/cm2 (309 bar, 4550lb/in2)
Maximum Output
212.2 litre/min (46.6 UK gal)
Fixed Displacement Gear Pump Displacement Volume
10 cc/rev
Working Pressure
40 kgf/cm2 (39.2 bar, 568lb/in2)
Maximum Output
22.0 litre/min (4.8 UK gal)
Dry Weight
132 kg (291 lb)
Control Valve Type
Hydraulic Pilot System
Operating System
Set relief pressure
Main Relief Standard Pressure Raising
320 kgf/cm2 (309 bar, 4550 lb/in2) at 168 litre/min (37 UK gal) 350 kgf/cm2 (343 bar, 4977 lb/in2) at 155 litre/min (34 UK gal)
Overload Relief Pressure Boom Raising, Arm, Bucket Boom Lowering Pressure
370 kgf/cm2 (351 bar, 5161 lb/in2) at 20 litre/min (4.4 UK gal) 250 kgf/cm2 (245 bar, 3555 lb/in2) at 20 litre/min (4.4 UK gal)
Function
Travel priority, Slew priority, Boom and Dipper Load Holding Valve, Boom and Dipper 2 Speed Confluence
Dry Weight
165 kg (364 lb)
Slew Equipment Type
Fixed displacement piston motor
Suction Capacity
151 cc/rev
Working Pressure
285 kgf/cm2 (275 bar, 4052 lb/in2)
Work Flow
212.2 litre/min (46.6 gal/min)
Set Pressure Relief
285 kgf/cm2 (279 bar, 4052 lb/in2) at 188 litre/min (41.3 UK gal) 275 kgf/cm2 (269 bar, 3911 lb/in2) at 40 litre/min (8.8 UK gal)
Reduction Gear Ratio
22.097 : 1
Slew Brake Brake Torque Brake Pressure Release
More than 75.4 kgf m (739.4 Nm, 545 ft lbs) (Not including reduction gear) Min 30 kgf/cm2 (min 29.4 bar, 426 lb/in2)
Dry Weight
325 kg (716 lb)
9804/1103
45 - 05 - 03/7
Issue 1
CONTENTS CONTENTS
Excavators
45- 05 - 03/8
JS 240 & 260 from m/c no. 708501 Data - Hydraulic Travel Equipment Motor
Fixed displacement piston motor (automatic 2-speed change)
Suction Capacity
164.4/98.1 cc/rev
Working Pressure
350 kgf/cm2 (343 bar, 4977 lb/in2)
Working Flow
211 litre/min (46.4 UK UK gal)
Reduction Gears Deceleration Ratio
44.384
Parking Brake Brake Torque Brake Pressure Release Brake valve pressure relief
2135 kgf/m (20.9 kNm, 15436 ft/lb) including reduction gear > 14 kgf/cm2 (13.5 bar, 199 lb/in2) 360 kgf/cm2 (348 bar, 5119l b/in2) at 40 litre/min (8.8 UK gal)
Dry Weight
270 kg (595 lb)
Boom Rams Cylinder Inside Diameter
130 mm
Rod Diameter
90 mm
Max Contracted Length
1843 mm
Stroke
1278 mm
Dry Weight
214 kg (472 lb)
Dipper Ram Cylinder Inside Diameter
150 mm
Rod Diameter
105 mm
Max Contracted Length
2234 mm
Stroke
1632 mm
Dry Weight
341 kg (752 lb)
Bucket Ram Cylinder Inside Diameter
135 mm
Rod Diameter
90 mm
Max Contracted Length
1687 mm
Stroke
1073 mm
Dry Weight
211 kg (465 lb)
9804/1103
45 - 05 - 03/8
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 03/9
JS 200Wfrom m/c no. 809000 Data - Hydraulic Pump Type
Variable displacement, piston pump with integral gear servo pumps.
Main pump max. flow Pilot pump max. flow
408 litre/min (90 U.K. gal/min) (108 U.S. gal/min) 32 l/min (7.0 U.K. gal/min) (8.4 U.S. gal/min)
Rams (JS200W) Bore 125 mm (4.9 in) in) 135 mm (5.3 in) in) 120 mm (4.7 in)
Boom (2 off ) (mono boom only) Dipper Bucket
Rod Diameter 85 mm (3.3 in)
Stroke 1295 mm (51.0
100 mm (3.9 in)
1580 mm (62.2
80 mm (3.1 in)
1012 mm (39.8in)
Motors Drive Max. Displacement Min Displacement Displacement Control
Variable displacement, axial piston motor. 140cc/rev 75cc/rev Automatic - High pressure related Mounted with counterbalance valve size 25
Swing
Fixed displacement, axial piston motor.
9804/1103
45 - 05 - 03/9
6320 - E/1-1.1
Issue 1
Excavators
CONTENTS
45 - 05 - 03/10
JS200W from m/c no. 809000 Data - Hydraulics (cont’d) Service Max Engine Speed, ‘S’ Mode
JS 200W
Tolerance
Bar
(lbf/in2)
Bar
(lbf/in2)
Standard
320
(4641)
±5
(72)
Boost/’F’ Mode
350
(5076)
±5
(72)
Boom Service Relief - Boom Lower Stall
245
(3553)
±5
(72)
Swing Crossline Relief (x 2) - Left/Right Stall
230
(3335)
±5
(72)
Overload Relief - Boom/Arm/Bucket
360
(5221)
±5
(72)
Hammer Service Relief (x 2) - Hammer Stall
190
(2755)
± 10
(145)
Hammer Service Relief (x 2) - Auxiliary Stall
360
(2610)
± 10
(145)
Boom Position Ram Service Relief - TAB Stall
360
(5221)
±5
(72)
Blade/Stabiliser Service Relief (x 2) - Service Stall
250
(3626)
±5
(72)
Steer/Brakes Service Relief - Steer Stall
175
(2538)
±5
(72)
Hand Steer Valve Overload - Steer Stall
185
(2683)
±5
(72)
Grab Rotate Cross-line Relief (x 2) - Rotate Stall
200
(2900)
±5
(72)
Servo Pressure - Continuous
35
(507)
±3
(43)
Clutch Pilot Pressure - Continuous
32
(464)
±2
(29)
Service Brake Pressure - On Latch
65
(943)
±2
(29)
Park Brake Pressure - Clutch Residual
15
(218)
±1
(14.5)
Service Brake Charge - Cut In on Falling Pressure
120
(1740)
±5
(72)
Service Brake Charge - Cut Out on Rising Pressure
150
(2175)
±5
(72)
Hose Burst Check Valve Relief - Boom Ram Head Side
355
(5148)
±5
(72)
Hose Burst Check Valve Relief - Position Ram Head Side
TBA
Hose Burst Check Valve Relief - Arm Ram Rod Side
370
(5366)
±10
(145)
100% Swing Brake - Normal Residual Pressure
15
(218)
±1
(14.5)
Service Brake Accumulators (x 4) - Nitrogen Pre-charge
61
(885)
±2
(29)
Park Brake Accumulator - Nitrogen Pre-charge
8
(116)
±1
(14.5)
Service Brake Warning Lamp - Pressure Switch Falling
105
(1522)
± 10
(145)
Rear Brake Lights - Pressure Switch Rising
5
(72)
±1
(14.5)
Reverse Lights - Pressure Switch Rising
6
(87)
±1
(14.5)
Park Brake (Drive Inhibit and Alarm) - Pressure Switch Falling
26
(377)
±3
(43)
Pressure Sequence Valve - Clutch Priority
26
(377)
±2
(29)
Clutch Priority Accumulator - Nitrogen Pre-charge
8
(116)
±1
(14.5)
Creep Speed Pilot Relief Valve Setting
15
(218)
±1
(14.5)
Boom Lower Pilot Relief Valve Setting
19
(275)
±1
(14.5)
Hammer Pilot Relief Valve Setting
19
(275)
±1
(14.5)
2 Stage
Main Relief Boom Raise ARV Arm in/out ARV Bucket open/close ARV
9804/1103
45 - 05 - 03/10
6320 - E/1-2.1
Issue 1
Excavators
CONTENTS
45 - 05 - 03/11
JS 200W from m/c no. 809000 Data - Hydraulics (cont’d) Hydraulic Pump/Regulator The pump/regulator consists of a variable displacement type axial piston pump (Pp) supplying pressurised oil to operate machine functions, plus two gear type pilot pumps, one (Pa) to provide pilot circuit pressure for operator control of machine functions. The other (Pb) to provide pressure for brake and steering functions. The Pump incorporates a regulator which adjusts the output flow rate according to system demand.
Axial Piston Pumps Maximum displacement
JS 200W cm3 (in3)/rev
190 (11.6)
set
319 bar (4551 lbf/in2 ,320 kgf/cm2)
maximum
343 bar (4978 lbf/in2 ,350 kgf/cm2)
Working pressure (travel)
Speed
rpm
1950
Maximum flow
l (gal)/min
363 (79.8 UK gal) (95.9 US gal)
Maximum input torque
Nm (lbf ft)
441 (325)
kg (lb)
119 (262)
Front
16.0 (0.97)
Rear
16.0 (0.97)
Weight
Gear pump Displacement cm3 (in3)/ rev
30 bar (435 lbf/in2, 30.6 kgf/cm2)
Working pressure Maximum flow l (gal)/min
9804/1103
Front
31.2 (6.86 UK gal) (8.24 US gal)
Rear
31.2 (6.86 UK gal) (8.24 US gal)
45 - 05 - 03/11
6320 - E/27-1.1
Issue 1
CONTENTS
Excavators
45 - 05 - 03/12
JS 330 from m/c no. 712501 Data Hydraulics
Pump Type
Twin variable displacement piston pump
Displacement Volume Working Pressure
134.6 cm3/rev (8.2 in3/rev ) 348 bar (355 kgf/cm2)
Maximum Output Fixed Displacement Gear Pump Displacement Volume
270 l/min x 2 (59 gal/min x 2)
Working Pressure
44.1 bar (45 kgf/cm2)
Maximum Output
24.8 l/min (5.5 gal/min)
Dry Weight
220 kg (485 lb)
12.4 cm3/rev (0.76 in3/rev)
Control Valve Type
Hydraulic Pilot System
Operating System
Set pressure relief
Main Relief Standard pressure Maximum pressure Overload Relief Pressure Boom Raising, Arm, Bucket Boom Lowering Pressure
319 bar (325 kgf/cm2) 348 bar (355 kgf/cm2) 363 bar (370 kgf/cm2) 245 bar (250 kgf/cm2)
Function
Travel priority, Slew priority, Boom and Dipper holding valves, Boom and Dipper 2-Speed internal confluence
Dry Weight
180 kg (397 lb)
Slew Motor Type Suction Capacity Working Pressure
Fixed displacement piston motor 210.1 cm3/rev (12.8 in3/rev) 279 bar (285 kgf/cm2)
Work Flow
276.1 l/min (60.7 gal/min)
Set Pressure Relief
279 bar (285 kgf/cm2)
Reduction Gears Reduction Gear Ratio
Planetary gear reduction 23.25
Slew Brake Brake Torque
965 Nm (98 kgf m, 712 lbf ft)
Brake Pressure Release
34.5 bar (35.2 kgf/cm2)
Dry Weight
410 kg (904 lb)
9804/1103
45 - 05 - 03/12
6420 - E/1-1.2
Issue 1
CONTENTS
Excavators
45 - 05 - 03/13
JS 330 from m/c no 712501 Data Hydraulics (cont’d) Travel Equipment Motor Suction Capacity
Fixed displacement piston motor (automatic 2-speed change) 153.4/102.4 cm3/rev (9.4/6.25 in3/rev)
Working Pressure
319 bar (326 kgf/cm2)
Working Flow
276 l/min (60.7 gal/min)
Reduction Gear Ratio Parking Brake Brake Torque Brake valve pressure relief
74.3 472 Nm (48.1 kgf m, 348 lbf ft) 324 bar (330 kgf/cm2)
Dry Weight
360 kg (794 lb)
Boom Rams Cylinder Inside Diameter
140 mm (5.512 in)
Rod Diameter
100 mm (3.937 in)
Max Contracted Length
2095 mm (82.48 in)
Stroke
1480 mm (58.268 in)
Dry Weight
279 kg (615 lb)
Dipper Ram Cylinder Inside Diameter
160 mm (6.299 in)
Rod Diameter
110 mm (4.331 in)
Max Contracted Length
2425 mm (95.472 in)
Stroke
1733 mm (68.228 in)
Dry Weight
400 kg (882 lb)
Bucket Ram Cylinder Inside Diameter
140 mm (5.512 in)
Rod Diameter
95 mm (3.740 in)
Max Contracted Length
1890 mm (74.409 in)
Stroke
1275 mm (50.197 in)
Dry Weight
240 kg (529 lb)
9804/1103
45 - 05 - 03/13
6420 - E/1-2.2
Issue 1
CONTENTS
Excavators
45 - 05 - 03/14
JS 450 from m/c no. 714501 JS 460 from m/c no. 714550 Data - Hydraulic Note: For full specification details see information in each section
Pump Type Displacement Volume Working Pressure Maximum Output Fixed Displacement Gear Pump Displacement Volume Working Pressure Maximum Output Dry Weight
Twin bariable displacement piston pump 170 cm3/rev (8.2 in3/rev) x 2 325 bar (331 kgf/cm2 348.5 l/min x 2 (77 gal/min x 2) 12.4 cm3/rev (0.76 in3/rev) 44.1 bar (45 kgf/cm2) 31.9 l/min (7.0 gal/min) 220 kg (485 lb)
Control Valve Type Operating System Main Relief Standard Pressure Maximum Pressure Overload Relief Pressure Boom Raising, Arm, Bucket Boom Lowering Pressure Function Dry Weight
Hydraulic Pilot System Set pressure relief 319 bar (325 kgf/cm2) 348 bar (355 kgf/cm2) 363 bar (370 kgf/cm2) 245 bar (250 kgf/cm2) Travel priority, Slew priority, Boom and Dipper holding valves, Boom and Dipper 2-Speed internal confluence 375 kg (826 lb)
Slew Motor Type Suction Capacity Working Pressure Work Flow Set Pressure Relief Reduction Gears Reduction Gear Ration Slew Brake Brake Torque Brake Pressure Release Dry Weight
9804/1103
Fixed Displacement Piston Motor 249.9 cm3 (15.2 in3/rev) 300 bar (305 kgf/cm2) 348.5 l/min (77 gal/min) 279 bar (285 kgf/cm2) Planetary gear reduction 27.14 1192 Nm (121.5 kgf m, 712 lbf ft) 18.6 bar (18.9 kgf/cm2) 583 kg (1285 lb)
45 - 05 - 03/14
6420 - E/1-3.1
Issue 1*
CONTENTS CONTENTS
Wheeled Loaders
45 - 05 - 04/1
JS 130 from m/c no. 758000, JS160 Data - Track Motor/Gearbox
JS130
JS160
39 : 1
48 : 1
86.3 cc (5.27 in3)
104. 8 cc (6.39 in3)
Reduction gear ratio Hydraulic motor Maximum stroke volume/rev Maximum rotational speed
2400 rpm
Maximum pressure
2800 rpm 343 bar (4978
lbf/in2,
350
kgf/cm2)
19.6 - 68.6 bar (284 - 296 lbf/in2, 20 - 70 kgf/cm2)
2-Speed switching pressure Parking brake Braking torque Release pressure Overall weight
9804/1103
255 Nm (188 lbf ft, 26 kgf m) 9.8 bar (142
lbf/in2,
10 kgf/cm2)
165 kg (364 lbs)
45 - 05 - 04/1
10.8 bar (156 lbf/in2, 11 kgf/cm2) 225 kg (496 lbs)
Issue 1
CONTENTS CONTENTS
Wheeled Loaders
45 - 05 - 04/2
JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 Data - Track Motor/Gearbox JS200/220 Motor * cm3/rev
JS240/260
1st
157.8
164.4
2nd
92.9
98.2
1st
7004
7297
2nd
4123
4359
Displacement Reduction gear, etc. value * cm3/rev Cross over relief Valve Double counter balance valve
2-speed switch valve
Reduction gear Parking brake
Cracking pressure
MPa (kgf/cm2)
31.1 {317} at 1.2 l/min
Full flow pressure
MPa (kgf/cm2)
35.3 {360} at 40 l/min
Plunger switch pressure
MPa (kgf/cm2)
0.6~1.3 {6~13}
Check valve cracking pressure
MPa (kgf/cm2)
less than 0.03 {0.3}
Pilot pressure for 2-speed switch
MPa (kgf/cm2)
3.9 {40}
1➝2
MPa (kgf/cm2)
23.2 {237}
2 ➝1
MPa (kgf/cm2)
25.3 {259}
Structure
Planetary gear 3 step reduction gear
Speed Parking brake torque KNm {kgf/cm2} Release pressure
1/44.384 Motionless
more than 20.94 {2135}
Moving
more than 16.67 {1700}
MPa (kgf/cm2)
less than 1.4 {14}
Pressure MPa (kgf/cm2)
34.3 {350} 1st speed
198.7
212.2
2nd speed
198.7
212.2
1st speed
0.862 {87.9}
0.898 {91.6}
2nd speed
0.507 {51.7}
0.536 {54.7}
1st speed
1259
1291
2nd speed
2139
2161
Supply flow L/min
Output torque kNm {kgf m}
Output revolutions rpm Normal
less than 0.2 {2.0}
Maximum instant
less than 0.5 {5.0}
Oil temperature
°C
-20 ~ +95
Total dry weight
kg
270
Drain pressure Mpa {kgf/cm2}
9804/1103
45 - 05 - 04/2
Issue 1
Excavators
CONTENTS
45 - 05 - 04/3
JS 330 from m/c no. 712501 JS 450 from m/c no. 714501 Data - Track Motor/Gearbox JS330
JS450
74.3 : 1
59 : 1
Maximum stroke volume/rev
153.4 cc (9.36 in3)
104.8 cc (6.39 in3)
Maximum rotational speed
2400 rpm
2800 rpm
Maximum pressure
313 bar (4550 lbf/in2, 320 kgf/cm2)
2-Speed switching pressure
44 bar (640 lbf/in2, 45 kgf/cm2)
Reduction Gear Ratio Hydraulic Motor
Parking Brake Braking torque (stationary)
472 Nm (640 lbf ft, 48.1 kgf m)
Release Pressure
14 bar (199 lbf/in2, 14 kgf/cm2)
16.7 bar (242 lbf/in2, 17 kgf/cm2)
360 kg (792 lb)
726 kg (1600 lb)
Overall Weight
Schematic (JS330, JS450)
9804/1103
45 - 05 - 04/3
6420 - F/2-1.1
Issue 1*
CONTENTS
Excavators
45 - 05 - 04/4
JS 460 from m/c no. 714550 Data - Traction Motor Component List Item 1 2 3 4 4-1 4-2 5 6 7 7-1 7-2 -8 -9 10 - 11 11 - 1 11 - 2 - 12 - 13 - 14 - 15 16 17 18 19 20 21 22 23 24 25 26 27 28 - 29 - 30 - 31 31 - 1 31 - 2 31 - 3 31 - 4 31 - 5 31 - 6 31 - 7 31 - 8 31 - 9 31 - 10 31 - 11 31 - 12 31 - 13 31 - 14 31 - 15 31 - 16 31 - 17 32
9804/1103
Description Housing Screw Not Used Carrier Gear Circlip Washer Gear Carrier Gear Circlip Washer Gear Gear Carrier Gear Shaft Washer Seal Cover Bolt Screw Nut Washer Washer Washer Bearing Seal Hub Spacer Seal Spacer Beam Screw Seal Valve Brake Circlip Washer Circlip Bearing Hub Ring Seal Disc Disc Gasket Gasket Sleeve Piston Spring Spring Cover Circlip Seal
Qty 1 1 2 5 5 1 1 1 3 3 1 1 1 1 3 3 1 1 1 12 2 1 1 2 3 2 1 1 1 1 1 1 2 3 1 1 1 2 1 1 1 2 10 9 1 1 1 1 14 14 1 1 1
45 - 05 - 04/4
6420 - F/7-10.1
Issue 1*
CONTENTS
Excavators
45 - 05 - 04/5
JS 460 from m/c no. 714550 Data - Traction Motor
4-1
2
4-2 7-1 7-2
11-1 11-2
1
10 5 4
13
6
14 7
8
32
9
29 30
11
28
12 27
25 31
21
16
15
31-16 26
22 24
31-17 31-15 31-14
20
23
31-10
18
31-12 31-6 31-13
31-11
31-6 31-8 31-9
21
31-4 31-7
19
31-2
17
31-5
31-1
31-2 31-3
9804/1103
45 - 05 - 04/5
374760
6420 - F/7-9.1
Issue 1*
Excavators
CONTENTS CONTENTS
*
45 - 05 - 05/1
JS 200W from m/c no. 809000 Data - Control Valve Technical Data Rated flow
- JS200W
400 l/min (88 UK gal/min) (105 US gal/min)
Maximum pressure for normal use
350 bar 356.9 kgf/cm2 (5076 lbf/in2)
Oil temperature range
-20 to 80˚C (-4˚ to 176˚F)
Maximum oil temperature
100˚C (212˚ F)
Pilot maximum allowable pressure
35 bar 35.6 kgf/cm2 (507.6 lbf/in2)
Pilot operation pressure
3.1 to 21.8 bar 3.2 - 22 kgf/cm2 (45 - 316 lbf/in2)
Spool stroke
11mm (0.43 in)
Control method
Hydraulic pilot operation
Main relief valve Standard pressure setting
320 bar 326.3 kgf/cm2 (4641 lbf/in2)
Maximum pressure setting
350 bar 356.9 kgf/cm2 (5076 lbf/in2)
Overload relief valve Standard pressure setting (boom raise, dipper, bucket)
360 bar 367.1 kgf/cm2 (5221 lbf/in2)
Maximum pressure setting (boom lower)
245 bar 249.8 kgf/cm2 (3553 lbf/in2)
Options/dozer/stabiliser
250 bar 255 kgf/cm2 (3625 lbf/in2)
Spool
Solid type
Weight
150 kg (330.7 lb)
Function
Travel priority, slew priority, boom/dipper with load holding, bucket, auxiliary
9804/1103
45 - 05 - 05/1
6320 - E/20-1.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 06/1
JS 200W from m/c no. 809000 Data - Drive Gearbox Gearbox
2HL-100, Two speed powershift transmission.
Installed position
Horizontal - Separate installation.
Brake
Parking Brake
Dry Weight
125 kg
9804/1103
45 - 05 - 06/1
6320 - F/4-1.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 07/1
JS 200W from m/c no. 809000 Data - Front Axle
Type
Spiral bevel input with epicyclic hub reduction
Designation
APL-B 765
Installation
Centre pivot
Steering
Power track rod, integral cylinder
Weight
649 kg (1431 lb)
Half (Axle) Shaft Braking
3 plate (each half shelf)
Ratio: Overall Crown wheel and pinion
17.6 : 1 2.75 : 1
Number of teeth: Crownwheel Pinion
33 12
Hub reduction
6.4 :1
Input type
Din 120 dia.
Toe in
0˚
Castor Angle
0˚
Camber Angle
0˚
King pin inclination
0˚
Oscillation
± 8˚
Service Brake Type
Oil immersed multi plate disc, positive retraction
Actuation
Hydraulic
Location
Wheel hubs
Friction plates Outside diameter Inside diameter
3 per pack 232 mm (9.1 in) 154 mm (6 in)
Hydraulic piston stroke
2.4 - 2.8 mm (0.094 - 0.11in)
9804/1103
45 - 05 - 07/1
6320 - F/14-1.1
Issue 1
CONTENTS
Excavators
45 - 05 - 07/1A
JS 130 from m/c no. 716500 Data - Front Axle (SD 70PT) Note: Earlier JS130W Wheeled Excavators are fitted with SD 70PT Front Axles. Later machines are fitted with SD 80PT Front Axles. SD70 with Power Track Rod Type
ITL spiral bevel input with epicyclic hub reduction
Designation
SD70PT
Installation
Centre pivot
Steering
Power track rod, integral cylinder
Weight
536 kg (1,182 lb)
Half (Axle) Shaft Braking
4 plate (each half shaft)
Ratio: Overall Crown wheel and pinion
15.78 : 1 2.923 : 1
Number of teeth: Crownwheel Pinion
38 13
Hub reduction
5.4 : 1
Input type
1480 half yoke
Toe in
0°
Castor Angle
0°
Camber Angle
1°
King pin inclination
0°
Oscillation
± 5°
Service Brake Type
Oil immersed multi-plate disc, positive retraction
Actuation
Hydraulic
Location
Wheel hubs
Friction plates Outside diameter Inside diameter Nominal facing area/plate
4 per pack 220 mm (8.66 in) 160 mm (6.29 in) 17,900 mm2 (27.75 in2)
Hydraulic piston diameter
208 mm (8.18 in)
9804/1103
45 - 05 - 07/1A
6310 - F/14-1.1
Issue 1
CONTENTS
Excavators
45 - 05 - 07/1B
JS 130W from m/c no. 716500, JS 160 from m/c no. 718500 Data - Front Axle (SD 80PT) Note: Earlier JS130W Wheeled Excavators are fitted with SD 70PT front axles. On later excavators both JS130W and JS160W machines are fitted with SD 80PT Front Axles. SD80 with Power Track Rod Type
ITL spiral bevel input with epicyclic hub reduction
Designation
SD80PT
Installation
Centre pivot
Steering
Power track rod, integral cylinder
Weight
540 kg (1,191 lb)
Half (Axle) Shaft Braking
4 plate (each half shaft)
Ratio: Overall Crown wheel and pinion
18.16 : 1 3.363 : 1
Number of teeth: Crownwheel Pinion
37 11
Hub reduction
5.4 : 1
Input type
1480 half yoke
Toe in
0°
Castor Angle
0°
Camber Angle
1°
King pin inclination
0°
Oscillation
± 5°
Service Brake Type
Oil immersed multi-plate disc, positive retraction
Actuation
Hydraulic
Location
Wheel hubs
Friction plates Outside diameter Inside diameter Nominal facing area/plate
4 per pack 220 mm (8.66 in) 160 mm (6.29 in) 17,900 mm2 (27.75 in2)
Hydraulic piston diameter
208 mm (8.18 in)
9804/1103
45 - 05 - 07/1B
6310 - F/30-1.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 07/2
JS 200W from m/c no. 809000 Data - Rear Axle Technical Data (JS200W) Type
Spiral bevel input with epicyclic hub reduction
Designation
AP-765
Installation
Pad mounted
Weight
495 kg (1091 lb)
Half (Axle) Shaft Braking
3 plate (each half shelf)
Ratio: Overall Crown wheel and pinion
17.6 : 1 2.75 : 1
Number of teeth: Crownwheel Pinion
33 12
Hub reduction
6.4 :1
Input type
Din 120 dia.
Toe in
0˚
Castor Angle
0˚
Camber Angle
0˚
King pin inclination
0˚
Service Brake Type
Oil immersed multi plate disc, positive retraction
Actuation
Hydraulic
Location
Wheel hubs
Friction plates Outside diameter Inside diameter
3 per pack 232 mm (9.1 in) 154 mm (6 in)
Hydraulic piston stroke
2.4 - 2.8 mm (0.094 - 0.11in)
9804/1103
45 - 05 - 07/2
6320 - F/23-1.1
Issue 1
CONTENTS
Excavators
45 - 05 - 07/2A
JS 130 from m/c no. 716500 Data - Rear Axle (PD70) Note: Earlier JS130W Wheeled Excavators are fitted with PD 70 Rear Axles. Later machines are fitted with PD 80 Rear Axles. Type
ITL spiral bevel input with epicyclic hub reduction
Designation
PD70
Installation
Pad mounted
Weight
386 kg (851 lb) approx.
Half (Axle) Shaft Braking
4 plate (each half shaft)
Ratio: Overall Crown wheel and pinion
15.78 : 1 2.923 : 1
Number of teeth: Crownwheel Pinion
38 13
Hub reduction
5.4 : 1
Input type
1480 half yoke
Toe in
0°
Castor Angle
0°
Camber Angle
1°
King pin inclination
0°
Service Brake Type
Oil immersed multi-plate disc, positive retraction
Actuation
Hydraulic
Location
Wheel hubs
Friction plates Outside diameter Inside diameter Nominal facing area/plate
4 per pack 220 mm (8.66 in) 160 mm (6.29 in) 17,900 mm2 (27.75 in2)
Hydraulic piston diameter
208 mm (8.18 in)
9804/1103
45 - 05 - 07/2A
6310 - F/23-1.2
Issue 1
CONTENTS
Excavators
45 - 05 - 07/2B
JS 130W from m/c no. 716500, JS 160W from m/c no. 718500 Data - Rear Axle (PD80) Note: Earlier JS130W Wheeled Excavators are fitted with PD 70 rear axles. On later excavators both JS130W and JS160W machines are fitted with PD 80 Rear Axles. Type
ITL spiral bevel input with epicyclic hub reduction
Designation
PD80
Installation
Pad mounted
Weight
386 kg (851 lb) approx.
Half (Axle) Shaft Braking
4 plate (each half shaft)
Ratio: Overall Crown wheel and pinion
18.16 : 1 3.363 : 1
Number of teeth: Crownwheel Pinion
37 11
Hub reduction
5.4 : 1
Input type
1480 half yoke
Toe in
0°
Castor Angle
0°
Camber Angle
1°
King pin inclination
0°
Service Brake Type
Oil immersed multi-plate disc, positive retraction
Actuation
Hydraulic
Location
Wheel hubs
Friction plates Outside diameter Inside diameter Nominal facing area/plate
4 per pack 220 mm (8.66 in) 160 mm (6.29 in) 17,900 mm2 (27.75 in2)
Hydraulic piston diameter
208 mm (8.18 in)
9804/1103
45 - 05 - 07/2B
6310 - F/32-1.1
Issue 1
CONTENTS CONTENTS *JS
Excavators
70 to m/c no. 695500
Data - Engine Type Model Bore Stroke Swept Volume Compression Ratio Gross Power Net power at 2200 rev/min Firing Order Valve Clearance - Inlet - Exhaust Dry Weight (approximately)
Isuzu 4JB1, 4 cylinder turbocharged, diesel 4JB1 PA-15 93 mm (3.7 in) 102 mm (4 in) 2771 cm3 (170 in3) 18.2 : 1 43 kW (57 hp) 41 kW (55 hp) 1,3,4,2 0.4 mm (0.016 in) 0.4 mm (0.016 in) 220 kg (485 lb)
Fuel System Diesel Fuel Specification - Cetane Number (minimum) - Viscosity at 40 °C (104 °F) - Density - Sulphur (maximum) - Distillation at 350 °C (662 °F) Injection Timing (static) Injector Opening Pressure
45 2.5/4.5 cSt 0.836/0.866 kg/litre (1.046/1.084 lb/pint) 0.5% of mass 85% 17° BTDC 181.4 bar (2631 lbf/in2)
Induction System Air Cleaner Type
2 stage, dry element
For further details, see engine service manual, Publication No.
9803/6920
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately. Glazing of the cylinder bores resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming up without load).
9804/1103
45 - 05 - 08/1
Issue 3*
CONTENTS CONTENTS
Excavators
45 - 05 - 08/2
JS 110,130,150LC Data - Engine Type Model - JS110 - JS130 - JS150LC Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately)
Isuzu 4BD1, 4 cylinder turbocharged 4BD1PTA-05 4BD1PTA-14 4BD1PTA-15 102 mm (4.016 in) 118 mm (4.646 in) 3856 cm3 (235.3 in3) 17.5 : 1 30 bar (440 lbf/in2) 1,3,4,2 0.4 mm (0,016 in) 0.4 mm (0.016 in) 350 kg
Fuel System Max. Speed (No Load) - JS110 - JS130 - JS150LC Injection Timing (static) Injector Opening Pressure
Less than 2230 rev/min Less than 2425 rev/min Less than 2550 rev/min 18° BTDC 180 bar (2630 lbf/in2)
Induction System Air Cleaner Type
2 stage, dry element
For further details, see engine service manual, Publication No.
9803/6910
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
9804/1103
45 - 05 - 08/2
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 08/3
JS 200LC,240LC Data - Engine Machine
JS200LC
JS240LC
Type Model Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately)
Isuzu 6 cylinder turbocharged 6BD1TLE-02 102 mm (4.016 in) 118 mm (4.646 in) 5785 cm3 (353 in3) 17.5 : 1 30 bar (440 lbf/in2) 1,5,3,6,2,4
Isuzu 6 cylinder turbocharged 6BG1TPC-01 105 mm (4.13 in) 125 mm (4.92 in) 6494cm3 (396 in3) 17 : 1 30 bar (440 lbf/in2) 1,5,3,6,2,4
0.4 mm (0,016 in) 0.4 mm (0.016 in) 470 kg (1036 lb)
0.4 mm (0,016 in) 0.4 mm (0,016 in) 470 kg (1036 lb)
Less than 2250 rev/min 16° BTDC 180 bar (2630 lbf/in2)
Less than 2420 rev/min 13° BTDC 180 bar (2630 lbf/in2)
Air Cleaner Type
2 stage, dry element
2 stage, dry element
For further details, see engine service manual, publication No.
9803/6910
9803/6910
Fuel System Max. Speed (No Load) Injection Timing (static) Injector Opening Pressure Induction System
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
9804/1103
45 - 05 - 08/3
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 08/4
JS 300LC,450LC Data - Engine Machine
JS300LC
JS450LC
Type Model Bore Stroke Swept Volume Compression Ratio Compression Pressure at 220 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately)
Isuzu 6 cylinder turbocharged 6SD1TPB 120 mm (4.72 in) 145 mm (5.7 in) 9839 cm3 (600.2 in3) 16.5 : 1 28 bar (412 lbf/in2) 1,5,3,6,2,4
Isuzu 6 cylinder turbocharged 6RB1TPE-01 135 mm (5.31 in) 160 mm (6.30 in) 13741cm3 (838 in3) 16.5 : 1 28 bar (412 lbf/in2) 1,4,2,6,3,5
0.4 mm (0,016 in) 0.4 mm (0.016 in) 700 kg (1543 lb)
0.6 mm (0,024 in) 0.6 mm (0,024 in) 1085 kg (2392 lb)
Less than 2450 rev/min 18° BTDC 200 bar (2845 lbf/in2)
Less than 2200 rev/min 18° BTDC 200 bar (2845 lbf/in2))
Air Cleaner Type
2 stage, dry element
2 stage, dry element
For further details, see engine service manual, publication No.
9803/6930
9803/6940
Fuel System Max. Speed (No Load) Injection Timing (static) Injector Opening Pressure Induction System
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
9804/1103
45 - 05 - 08/4
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 08/4A
JS 70 from m/c no. 695501 Data - Engine Technical Data Type Model Bore Stroke Swept Volume Compression Ratio Firing Order Valve Clearance - Inlet - Exhaust Dry Weight (approximately)
Isuzu 4JB1, 4 cylinder turbocharged,diesel 4JB1 PAA-04 93mm (3.7 in) 102 mm (4 in) 2771cm3 (170 in3) 18.2 :1 1-3-4-2 0.4mm (0.016 in) 0.4mm (0.016 in) 220 kg (486lb)
Fuel System Injection Timing (static) Injector Opening Pressure
17° BTDC 185 bar (2630 lbf/in2)
Induction System Air Cleaner Type For further details see engine service manual, Publication No. 9803/6920
9804/1103
45 - 05 - 08/4A
Issue 1
CONTENTS
* JS
Excavators
45 - 05 - 08/5
130W from m/c no. 785001, JS 160W from m/c no. 702001
* Data
- Engine
Type Model - JS130W - JS160W Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately)
Isuzu A4BG1T, 4 cylinder in-line, turbocharged, direct injection diesel. A4BG1T-S1 A4BG1T-S2 105 mm (4.13 in) 125 mm (4.92 in) 4329 cm3 (264.2 in3) 17.0 : 1 31 bar (450 lbf/in2) 1, 3, 4, 2 0.4 mm (0.016 in) 0.4 mm (0.016 in) 361 kg
Fuel System Max. Speed (No Load) - JS130W - JS160W Injector Timing (static) Injector Opening Pressure
Less than 2570 rev/min Less than 2571 rev/min 12° BTDC 180 bar (2630 lbf/in2)
Induction System Air Cleaner Type
2 stage, dry element with in-cab warning indicator.
For further details, see engine service manual, Publication No.
9803/6910
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
9804/1103
45 - 05 - 08/5
Issue 2*
CONTENTS
Excavators
45 - 05 - 08/6
JS 330 from m/c no. 712501 Data - Engine Type
Isuzu 6SD1, 6 cylinder turbo charged
Model - JS330
6SD1TQB-02
Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately)
120 mm (4.42 in) 145 mm (5.7 in) 9839 cm3 (600 in2) 15.7 : 1 30 bar (440 lbf/in2) 1, 5, 3, 6, 2, 4 0.4 mm (0.016 in) 0.4 mm (0.016 in) 700 kg 1540 lb)
Fuel System Max. Speed (no load) - JS330 Injection Timing (Static) Injector Opening Pressure
2250 + 50 rev/min 12 BTDC 196 bar (2842 lbf/in2)
Induction System Air Cleaner Type
2 stage, dry element
o
For further details, see JS330 Engine Service Manual, Publication No. 9806/2160 For further details, see JS330 Tier 2 Engine Service Manual Publication No. 9806/2200
JS 450 from m/c no. 714501 JS 460 from m/c no. 714550 Type
Isuzu 6RB1, 6 cylinder turbo charged
Model - JS450/460
6RB1TQB-02
Bore Stroke Swept volume Compression Ratio Compression Pressure at 220 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately)
135 mm (5.32 in) 160 mm (6.30 in) 13741 cm3 (838 in2) 16.5 : 1 28.4 bar (412 lbf/in2) 1, 4, 2, 6, 3, 5 0.6 mm (0.024 in) 0.6 mm (0.024 in) 1076 kg (2375 lb)
Fuel System Max. Speed (No Load) - JS 450/460 Injection Timing (static) Injector Opening Pressure
2250 + 50 rev/min 17 BTDC 220 bar (3191 lbf/in2)
Induction System Air Cleaner Type
2 Stage, dry element
o
For further details, see JS450/460 Engine Service Manual, Publication No. 9806/2166 Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores resulting in excessive oil consumption, could occor if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming up without load).
9804/1103
45 - 05 - 08/6
6420 - K/1-1.2
Issue 2*
CONTENTS
Excavators
45 - 05 - 08/6A
JS460 Tier 2 Data - Engine Type Model
Isuzu AA 6SD1T, 6 cylinder turbo charged.
- JS460 Tier2 Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately)
AA 6SD1TQB-01 120 mm (4.72 in) 145 mm (5.7 in) 9839 cm3 (600 in3) 16.8 : 1 28 bar (411 lbf/in2) 1, 5, 3, 6, 2, 4 0.4 mm (0.016 in) 0.4 mm (0.016 in) 693 kg(1528 lb)
Fuel System Max. Speed (No Load) - JS460 Tier2 Injector Timing (static) Injector Opening Pressure
2300 + or _ 30 rev/min 7° BTDC 177 bar (2567 lbf/in2)
Induction System Air Cleaner Type
2 stage, dry element with in-cab warning indicator.
For further details, see engine service manual, Publication No.
9806/2240
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
9804/1103
45 - 05 - 08/6A
36420 - K/1- 2.170 -6420
Issue 1
CONTENTS
Excavators
45 - 05 - 08/7
JS 130W from m/c no. 0716501, JS 160W from m/c no. 0718501 Data - Engine Technical Data Type Model - JS130W - JS160W Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately)
Isuzu A4BG1T, 4 cylinder in-line, turbocharged, direct injection diesel. A4BG1T-S1 A4BG1T-S2 105 mm (4.13 in) 125 mm (4.92 in) 4329 cm3 (264.2 in3) 17.0 : 1 31 bar (450 lbf/in2) 1, 3, 4, 2 0.4 mm (0.016 in) 0.4 mm (0.016 in) 361 kg
Fuel System Max. Speed (No Load) - JS130W - JS160W Injector Timing (static) Injector Opening Pressure
Less than 2570 rev/min Less than 2571 rev/min 12° BTDC 180 bar (2630 lbf/in2)
Induction System Air Cleaner Type
2 stage, dry element.
For further details, see engine service manual, Publication No.
9803/6910
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
9804/1103
45 - 05 - 08/7
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 08/7A
JS 130 from m/c no. 758000, JS 160 from m/c no. 702000 Data - Engine Type Model - JS130 - JS160 Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately)
Isuzu A4BG1T, 4 cylinder in-line, turbocharged, direct injection diesel. A4BG1T-S1 A4BG1T-S2 105 mm (4.13 in) 125 mm (4.92 in) 4329 cm3 (264.2 in3) 17.0 : 1 31 bar (450 lbf/in2) 1, 3, 4, 2 0.4 mm (0.016 in) 0.4 mm (0.016 in) 361 kg
Fuel System Max. Speed (No Load) - JS130 - JS160 Injection Timing (static) Injector Opening Pressure
Less than 2570 rev/min Less than 2571 rev/min 12° BTDC 180 bar (2630 lbf/in2)
Induction System Air Cleaner Type
2 stage, dry element with in-cab warning indicator.
For further details, see engine service manual, Publication No.
9806/2120
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
9804/1103
45 - 05 - 08/7A
6410 - K/1-1.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 08/8
JS 130W from m/c no. 716500, JS 160 from m/c no. 718500 Data - Engine Type Model - JS130W - JS160W Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately)
Isuzu A4BG1T, 4 cylinder in-line, turbocharged, direct injection diesel. A4BG1T-S1 A4BG1T-S2 105 mm (4.13 in) 125 mm (4.92 in) 4329 cm3 (264.2 in3) 17.0 : 1 31 bar (450 lbf/in2) 1, 3, 4, 2 0.4 mm (0.016 in) 0.4 mm (0.016 in) 361 kg
Fuel System Max. Speed (No Load) - JS130W - JS160W Injector Timing (static) Injector Opening Pressure
Less than 2570 rev/min Less than 2571 rev/min 12° BTDC 180 bar (2630 lbf/in2)
Induction System Air Cleaner Type
2 stage, dry element with in-cab warning indicator.
For further details, see engine service manual, Publication No.
9803/6910
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
9804/1103
45 - 05 - 08/8
6310 - K/1-1.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 08/9
JS 200W from m/c no. 809000 Data - Engine Type
YH 50727, 6 cylinder in-line, turbocharged, direct injection diesel.
Model - JS200W Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately)
YH50727 100 mm (3.937 in) 127 mm (5.00 in) 5985 cm3 (365.2 in3) 17.25 : 1 31 bar (450 lbf/in2) 1, 5, 3, 6, 2, 4 0.4 mm (0.016 in) 0.4 mm (0.016 in) 480 kg
Fuel System Max. Speed (No Load) - JS200W Injector Timing (static) Injector Opening Pressure
Less than 2350 rev/min 12° BTDC 180 bar (2630 lbf/in2)
Induction System Air Cleaner Type
2 stage, dry element with in-cab warning indicator.
For further details, see engine service manual, Publication No.
9806/2140
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
9804/1103
45 - 05 - 08/9
6320 - K/1-1.1
Issue 1
CONTENTS
Excavators
45 - 05 - 08/10
JS 200,220 from m/c no. 705001,JS 210 from m/c no.705648, JS 240 from m/c no. 708001, JS 260 from m/c no. 708501. Data - Engine Type
Isuzu A4BG1T,6 cylinder in-line,turbocharged,direct injection diesel.
Model - JS200 - JS210 - JS220
A-6BG1TQB-04 A-6BG1TQB-04 A-6BG1TQB-04
- JS240 - JS260
A-6BG1TQB-05 A-6BG1TQB-05
Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately)
105 mm (4.13 in) 125 mm (4.92 in) 6,494 cm3 (396 in3) 17.5 : 1 31 bar (450 lbf/in2) 1, 5, 3, 6, 2, 4 0.4 mm (0.016 in) 0.4 mm (0.016 in) 458 kg (1007.6 lb.)
Fuel System Max. Speed (No Load) - JS200 - JS210 - JS220
Less than 2100 rev/min Less than 2100 rev/min Less than 2100 rev/min
- JS240 - JS260
Less than 2300 rev/min Less than 2100 rev/min
Injector Timing (static) Injector Opening Pressure
12° BTDC 185 bar (2682.5 lbf/in2)
Induction System Air Cleaner Type
2 stage, dry element with in-cab warning indicator.
For further details, see engine service manual, Publication No.
9806/2120
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
Excavators
CONTENTS
45 - 05 - 09/1
JS 330 from m/c no. 712501 JS 450 from m/c no. 714501 Data - Tracks and Running Gear - Torque Specifications Component Drive Sprocket fastening Bolts
JS330 JS450
Idler Wheels mounting Bolts
Nm
kgf m
lbf ft
521 - 608 900 - 1051
53 - 62 92 - 107
384 - 448 663 - 775
267 - 312
27.2 - 31.8
197 - 230
Top Roller mounting bolts
(STD) (HD)
267 - 312 371 - 432
27.2 - 31.8 38 - 44
197 - 230 273 - 318
Bottom roller mounting bolts
JS330 JS450
521 - 608 900 - 1051
53 - 62 92 - 107
384 - 448 606 - 775
267 - 312
27.2 - 31.8
197 - 230
Grease cylinder mounting bolts Track Guard
JS330 JS450
521 - 608 900 - 1051
53 - 62 92 - 107
384 - 448 663 - 775
Shoe Bolts
(STD) (HD)
775 - 931 980 - 1180
77 - 95 100 - 120
557 - 687 723 - 871
Note: Apply JCB Threadlocker and Sealer to the threads of the above bolts.
9804/1103
45 - 05 - 09/1
6420 - J/1-1.2
Issue 1*
CONTENTS
Excavators
45 - 05 - 09/2
JS 330 from m/c no. 712501 JS 450 from m/c no. 714501 Data - Tracks and Running Gear - Bottom Roller Wear Limits Item
Standard Size mm in
Service Limit mm in
Action
JS330 JS450
180 210
7.09 8.27
172 198
6.77 7.79
Renew Renew
b
JS330 JS450
20 25
0.79 0.98
20
0.79
Renew Renew
Inner flange width
c
JS330 JS450
100 -
3.94 -
92 -
3.62 -
Renew Renew
Outer flange width
d
JS330 JS450
200 250
7.87 9.84
208 260
8.19 10.24
Renew Renew
Shaft Diameter
e
JS330 JS450
70 90
2.76 3.54
69 89
2.72 3.50
Renew Renew
Bushing diameter
e
JS330 JS450
70 90
2.76 3.54
71.5 91
2.82 3.58
Renew Renew
Length
f
JS330 JS450
82.5 93
3.25 3.66
81.5 92
3.21 3.62
Renew Renew
Collar
g
JS330 JS450
20.5 24.6
0.81 0.97
20 24
0.79 0.94
Renew Renew
Roller Diameter
Dimension
Machine
a
Inner Flange
Outer Flange
9804/1103
45 - 05 - 09/2
6420 - J/14-1.1
Issue 1*
CONTENTS
*JS
Excavators
45 - 10 - 01/1
70 to m/c no. 695500
Fault Finding - Hydraulics Some problems which may occur in the hydraulic system are listed below, either for the system as a whole or for individual components. SYMPTOM
POSSIBLE CAUSE
ACTION
1. Hydraulic System a. The hydraulic system is defective or does not operate at all.
2.
1. The pump is defective.
Check pump pressure and renew if defective.
2. Dirt is clogging the inside of the relief valve.
Dismantle and clean the relief valve.
3. The relief valve is defective.
Strip and check the relief valve.
4. A ram is worn.
Repair or renew the ram.
5. Negative pressure is low.
Check circuit pressure.
6. A valve is cracked.
Renew the valve.
7. A spool is not operating over its full stroke.
Check the movement of the spool or the operational linkage.
8. The oil level in the tank is too low.
Replenish the oil.
9. Circuit filters are clogged.
Clean or renew filters.
10. The circuit pipes are restricted.
Check the piping.
Oil temperature abnormally high.
Check for correct fluid, see Lubricants and Capacities, page 45-00-01/1. Check oil cooler and grille for blockage.
2. The hydraulic fluid is dirty.
Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system. Fill with clean hydraulic fluid.
3. The service pipe connection is over tightened.
Check tightening torque.
4. The valve housing was twisted during installation.
Loosen retaining bolts and tighten to correct torque figures.
5. Pressure too high.
Check system pressure, see page 10 - 1†.
6. A control linkage is bent.
Disconnect the linkage, see page 25 - 5†. Repair the linkage if possible, or fit a new one.
7. A spool is bent.
Dismantle the control valve as detailed in the section starting on page 25 - 1†. Renew spool as necessary.
8. A return spring is broken.
Renew as necessary.
9. A return spring or cap is out of alignment.
Remove the cap, check that the spring is in the correct position. Refit cap and torque tighten bolts.
10. Temperature distribution within control valve not uniform.
Warm the entire system up before using service.
Control Valve
a. A spool is sticking.
Note: † refers to Service Manual. 9804/1103
45 - 10 - 01/1
Issue 2*
CONTENTS
*JS
Excavators
45 - 10 - 01/2
70 to m/c no. 695500
Fault Finding - Hydraulics (cont'd) SYMPTOM 2.
POSSIBLE CAUSE
ACTION
Control Valve (cont'd)
b. A spool does not move over its full stroke.
1. Dirt is clogging the inside of the valve.
Remove the dirt by flushing out the valve.
2. A control linkage is bent or restricted.
Disconnect the linkage, see page 25 - 5†. Repair the linkage, if possible, or replace it and/or remove the restriction.
1. Oil is leaking past the dipper/boom ram piston seals.
Consult JCB Service for repairs, or fit a new ram.
2. Oil is bypassing dipper/boom spool.
Renew spool.
3. Oil is leaking past dipper/boom ARV.
Remove ARV and clean housing seat and relief valve seat. Refit ARV.
4. Faulty boom load hold check valve.
Dismantle and check boom load hold check valve, see page 26 - 1†. Replace faulty components.
1. Dirt is clogging the boom load hold check valve.
Dismantle and clean the boom load hold check valve, see page 26 - 1†.
2. The boom load hold check valve seat is scratched or damaged.
Renew the poppet or smooth the poppet and seat with very fine emery cloth.
1. Paint or dirt on the seal face.
Remove the seal and clean.
2. The back pressure in the valve circuit is excessively high.
Check circuit pressures, see page 10 - 1†. Adjust if possible. Otherwise investigate thoroughly.
3. Spool damaged.
Dismantle. Inspect all parts. Renovate or renew as necessary.
4. The seal is not secured.
Clean the seal and tighten the retaining bolts to the correct torque.
5. The seal is cut or damaged.
Fit a new seal.
a. System pressure does not rise at all.
1. The main poppet, check valve poppet or pilot poppet is sticking open, or dirt is caught in the valve seat.
Remove MRV and dismantle as detailed in the section starting on page 25 - 1†. Inspect and clean all parts. Assemble MRV, ensuring that all parts slide freely. Refit the MRV.
b. Relief pressure is unstable or incorrect.
1. The pilot poppet seat is scratched or the pilot piston is sticking with the main poppet. Parts worn.
Remove MRV and dismantle as detailed in the section starting on page 25 - 1†. Inspect and clean all parts. Renew damaged parts or remove scratches with very fine emery cloth. Assemble MRV, ensuring that all parts slide freely. Refit MRV.
2. The lock nut and adjusting screw are loose.
Reset MRV pressure, see page 10 - 2† and tighten the lock nut.
c. The dipper/boom falls under load with the spool in neutral.
d. The boom falls under load when the spool is moved to the 'raise' position.
e. Leaking oil seal.
3. Main Relief Valve
Note: † refers to Service Manual. 9804/1103
45 - 10 - 01/2
Issue 2*
CONTENTS
*JS
Excavators
45 - 10 - 01/3
70 to m/c no. 695500
Fault Finding - Hydraulics (cont'd) SYMPTOM
POSSIBLE CAUSE
ACTION
3. Main Relief Valve (cont'd) c. Oil leak
1. Worn 'O' rings, damaged seals, contamination.
Remove and dismantle MRV. Check for scratches, dents and contamination. Renovate or replace damaged parts, and replace all 'O' rings and seals. Clean thoroughly.
1. Servo pressure is low.
Check servo pressure as detailed on page 10 - 1† and adjust as necessary.
2. Spring 241 is damaged.
Renew spring.
3. The clearance between the spools and casing is too large.
Renew spool and casing assembly
4. The handle unit is loose.
Renew the handle unit.
1. Sliding parts are sticking.
Dismantle and inspect as detailed in section starting on page 40 - 1†. Repair or renew as necessary.
2. Air is trapped in the pipes.
Operate the valve several times to remove the air.
1. Sliding parts are sticking.
Dismantle and inspect as detailed in section starting on page 40 - 1†. Repair or renew as necessary.
4. Servo Hand Control Valves a. Low secondary pressure.
b. Unstable secondary pressure.
c. High secondary pressure.
Note: † refers to Service Manual.
9804/1103
45 - 10 - 01/3
Issue 2*
Excavators
CONTENTS CONTENTS
45 - 10 - 01/4
JS 110,130 Fault Finding - Hydraulics (cont'd) Some problems which may occur in the hydraulic system are listed below, either for the system as a whole or for individual components. SYMPTOM
POSSIBLE CAUSE
ACTION
1. Hydraulic System a. The hydraulic system is defective or does not operate at all.
1. The pump is defective.
Check pump pressure and replace if defective.
2. Dirt is clogging the inside of the relief valve.
Dismantle and clean the relief valve.
3. The relief valve is defective.
Strip and check the relief valve as detailed on page 21-1†.
4.
A ram is worn.
Repair or replace the ram.
5.
Negative pressure is low.
Check circuit pressure.
6.
A valve is cracked.
Replace the valve.
7.
A spool is not operating over its full stroke.
Check the movement of the spool or the operational linkage.
8. The oil level in the tank is too low.
Replenish the oil.
9. Circuit filters are clogged.
Clean or replace filters.
10. The circuit pipes are restricted.
Check the piping.
1. The tank strainer or intake pipe is blocked or closed.
Clean the strainer and open the intake pipe.
2. The end of the inlet pipe is above the tank oil level.
Replenish the oil tank.
3. One or more of the pump major components is damaged or the input shaft or coupling are defective.
Dismantle and inspect pump as detailed on page 20-1†. Renew damaged components and reassemble the pump. Renew shaft or coupling.
1. The pressure does not increase because of problems with the hydraulic pump or control valve.
Check hydraulic pump and control valve. Renew as required.
2. Internal leakage within the hydraulic pump with excessive fluid drain from pump drain port.
Strip and inspect the hydraulic pump as detailed on page 20-1†, paying particular attention to sliding surfaces. Repair or renew as necessary. Reassemble the pump.
3. Air is being drawn into the pump from the inlet side.
Check tank oil level and strainer for clogging. Correct as necessary. If OK, check tightness of pump inlet connection.
4. Inlet resistance causing cavitation.
Check correct oil . Check pump low pressure inlet pipe for collapse. Renew as required.
2. Hydraulic Pump a. Oil is not discharged from the pump.
b. Pump output is low. Hydraulic pressure does not increase.
Note: † refers to Service Manual.
9804/1103
45 - 10 - 01/4
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/5
JS 110,130 Fault Finding - Hydraulics (cont'd) SYMPTOM
POSSIBLE CAUSE
ACTION
2. Hydraulic Pump (cont'd) c. The pump makes an abnormal noise.
d. Engine overload (engine speed very low or engine stalled).
e. Oil leakage.
1. Oil level is low and the pump is drawing in air.
Check and replenish oil level. Run the pump under no load to bleed air from the hydraulic system.
2. Clogging of the tank strainer.
Clean strainer. If strainer is severely clogged, drain and flush hydraulic system.
3. Oil temperature is too low or wrong oil specification.
Check correct oil for ambient temperature, see Lubrication Chart, page 45-00-01/2.
4. Coupling defective.
Check shaft run out.
5. The pump is resonating with external equipment.
Check pump mounting bolts for tightness. Tighten as required.
6. Internal damage to pump.
Dismantle and inspect pump, as detailed on page 20-1†, paying particular attention to bearings and sliding surfaces.
1. Regulator torque set too high.
Adjust as necessary.
2. The servo flow within the regulator is blocked or internal components are seized.
Remove the regulator from the pump and check filter for blockage. Clean as necessary. If filter OK, dismantle and inspect regulator, see page 20-1†.
3. Pump is seized or worn.
Dismantle and inspect pump as detailed on page 20-1†, paying particular attention to sliding surfaces. Repair or renew as necessary. Reassemble the pump.
1. Internal leakage within the pump causing oil seal damage and oil leakage.
Dismantle and inspect pump as detailed on page 20-1†, paying particular attention to oil seals and sliding surfaces. Renew as necessary, ensuring that lips of oil seals are not damaged when installed.
2. Damaged or blocked drain pipe.
Inspect and renew as necessary.
1. Oil temperature abnormally high.
Check correct oil, see Lubrication Chart, page 45-00-01/2. Check oil cooler and grille for blockage.
2. The hydraulic oil is dirty.
Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system.
3. The service pipe connection is overtightened.
Check tightening torque.
4. The valve housing was twisted during installation.
Loosen retaining bolts and tighten to correct torque figures.
5. Pressure too high.
Check system pressure, see page 10-1†.
3. Control Valve a. A spool is sticking.
Note: † refers to Service Manual.
9804/1103
45 - 10 - 01/5
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/6
JS 110,130 Fault Finding - Hydraulics (cont'd) SYMPTOM
POSSIBLE CAUSE
ACTION
3. Control Valve (cont'd) 6. A spool is bent.
Dismantle the control valve as detailed on page 25-1†. Renew spool as necessary.
7. A return spring is broken.
Renew as necessary.
8. A return spring or cap is out of alignment.
Remove the cap, check that the spring is in the correct position. Refit cap and torque tighten bolts.
9. Temperature distribution within control valve not uniform.
Warm the entire system up before using service.
b. A spool does not move over its full stroke.
1. Dirt is clogging the inside of the valve.
Remove the dirt (flush out the valve.
c. The dipper/boom falls under load with the spool in neutral.
1. Oil is leaking past the ram/ boom piston seals.
Renew piston seals.
2. Oil is bypassing dipper/boom spool.
Renew spool.
3. Oil is leaking past dipper/boom ARV.
Remove ARV and clean housing seat and relief valve seat. Refit ARV.
1. Dirt is clogging the load hold check valve.
Dismantle and clean the load hold check valve.
2. The load hold check valve seat is scratched or damaged.
Renew the poppet or smooth the poppet and seat with very fine emery cloth.
a. System pressure does not rise at all.
1. The main poppet, check valve poppet or pilot poppet is sticking open, or dirt is caught in the valve seat.
Remove MRV and dismantle as detailed on page 26-1†. Inspect and clean all parts Assemble MRV, ensuring that all parts slide freely. Refit the MRV.
b. Relief pressure is unstable.
1. The pilot poppet seat is scratched or the pilot piston is sticking with the main poppet. Parts worn.
Remove MRV and dismantle as detailed on page 26-1†. Inspect and clean all parts. Renew damaged parts or remove scratches with very fine emery cloth. Assemble MRV, ensuring that all parts slide freely. Refit MRV.
2. The lock nut and adjusting screw are loose.
Tighten the lock nut and reset MRV pressure.
1. Worn 'O' rings.
Remove MRV and renew 'O' rings.
d. The dipper/boom falls under load when the spool is moved to a position higher than neutral. 4.
Main Relief Valve
c. Oil leak
Note: † refers to Service Manual.
9804/1103
45 - 10 - 01/6
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/7
JS 110,130 Fault Finding - Hydraulics (cont'd) SYMPTOM
POSSIBLE CAUSE
ACTION
5. Swing Motor a.
Motor does not turn.
b. Large slip.
c. Insufficient torque.
d. Abnormal noise.
e. Abnormal heating.
1. Internal damage to the motor.
Measure the oil drain volume. If the supply volume approaches drain volume, dismantle and inspect as detailed on page 35-1†. Repair or renew as necessary.
2. Internal damage to the motor.
Disconnect motor inlet and outlet ports and apply servo pressure of 19.6 bar (284 lb. in2) to the brake release port. Try to rotate shaft with a torque of approximately 4.8 9.8 Nm (3.6 - 7.2 ft. lbs.). If the shaft does not rotate smoothly, dismantle and inspect as detailed on page 35-1†. Repair or renew as necessary.
3. Relief valve in the circuit not correctly set.
Fit a pressure gauge and measure load pressure, as detailed on page 10-1†. Reset as necessary.
1. Wear or damage to the motor sliding surfaces or high pressure seal.
Measure the oil drain volume. If the volume exceeds 5 litres/min, dismantle and inspect as detailed on page 35-1†. Repair or renew as necessary.
2. Oil hot and large leakage in the motor.
Reduce oil temperature.
1. Wear or burning of the motor sliding
Disconnect motor inlet and outlet ports and apply servo pressure of 19.6 bar (284 lb. in2) to the brake release port. Try to rotate shaft with a torque of approximately 4.8 9.8 Nm (3.6 - 7.2 ft. lbs.). If the shaft does not rotate smoothly, dismantle and inspect as detailed on page 35-1†. Repair or renew as necessary.
2. Relief valve in the circuit not correctly set.
Fit a pressure gauge and measure load pressure, as detailed on page 10-1†. Reset as necessary.
1. Internal damage to the motor.
Check for metallic particles in the motor drain oil or drain filter. If particles found, dismantle and inspect as detailed on page 35-1†. Repair or renew as necessary.
2. Large amounts of air in the oil.
Check the oil in the tank and motor casing. Bleed the system.
3. Loosening of bolts or connections.
Check pipe connections, mounting bolts for tightness. Retighten to specified torque.
1. Burning of the motor sliding or turning parts.
Check for metallic particles in the motor drain oil or drain filter. Also apply servo pressure of 19.6 bar (284 lb. in2) to the brake release port. Try to rotate the shaft with a torque of approximately 4.8 9.8 Nm (3.6 - 7.2 ft. lbs.). If particles found or the shaft does not rotate smoothly, dismantle and inspect as detailed on page 35-1†. Repair or renew as necessary.
Note: † refers to Service Manual.
9804/1103
45 - 10 - 01/7
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/8
JS 110,130 Fault Finding - Hydraulics (cont'd) SYMPTOM
POSSIBLE CAUSE
ACTION
5. Swing Motor (cont'd) f.
Leaks from the oil seal.
g. Oil leaks from mating surface.
1. Damage or wear to oil seal lip.
Renew the oil seal, as detailed on page 35-1†.
2. Damage or wear to shaft seal.
Repair the problem or renew the motor assembly.
3. Abnormal pressure in the casing.
Set the pressure in the casing to below 2.9 bar (43 lb. in2) and check drain volume. If drain volume large, dismantle and inspect as detailed on page 35-1†. Renew the oil seal and, if possible, repair or renew other damaged parts.
1. An 'O' ring is damaged.
Renew 'O' ring.
2. The seal face is damaged.
Repair seal face or renew.
3. Bolts are loose.
Check bolts and tighten to the specified torque.
1. Servo pressure is low.
Check servo pressure as detailed on page 10-1† and adjust as necessary.
2. Spring 241 is damaged.
Renew spring.
3. The clearance between the spools and casing is too large.
Renew spool and casing assembly
4. The handle unit is loose.
Renew the handle unit.
1. Sliding parts are sticking.
Dismantle and inspect as detailed on page 40-1†. Repair or renew as necessary.
2. Air is trapped in the pipes.
Operate the valve several times to remove the air.
1. Sliding parts are sticking.
Dismantle and inspect as detailed on page 40-1†. Repair or renew as necessary.
6. Hand Control Valves a. Low secondary pressure
b. Unstable secondary
c. High secondary pressure.
Note: † refers to Service Manual.
9804/1103
45 - 10 - 01/8
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/9
JS 150LC Fault Finding - Hydraulics (cont'd) Some problems which may occur in the hydraulic system are listed below, either for the system as a whole or for individual components. SYMPTOM
POSSIBLE CAUSE
ACTION
1. Hydraulic System a. The hydraulic system is defective or does not operate at all.
1. The pump is defective.
Check pump pressure and replace if defective.
2. Dirt is clogging the inside of the relief valve.
Dismantle and clean the relief valve.
3. The relief valve is defective.
Strip and check the relief valve as detailed on page 26-1†.
4.
A ram is worn.
Repair or replace the ram.
5.
Negative pressure is low.
Check circuit pressure.
6.
A valve is cracked.
Replace the valve.
7.
A spool is not operating over its full stroke.
Check the movement of the spool or the operational linkage.
8. The oil level in the tank is too low.
Replenish the oil.
9. Circuit filters are clogged.
Clean or replace filters.
10. The circuit pipes are restricted.
Check the piping.
1. The tank strainer or intake pipe is blocked or closed.
Clean the strainer and open the intake pipe.
2. The end of the inlet pipe is above the tank oil level.
Replenish the oil tank.
3. One or more of the pump major components is damaged or the input shaft or coupling are defective.
Dismantle and inspect pump as detailed on page 20-1†. Renew damaged components and reassemble the pump. Renew shaft or coupling.
1. The pressure does not increase because of problems with the hydraulic pump or control valve.
Check hydraulic pump and control valve. Renew as required.
2. Internal leakage within the hydraulic pump with excessive fluid drain from pump drain port.
Strip and inspect the hydraulic pump as detailed on page 20-1†, paying particular attention to sliding surfaces. Repair or renew as necessary. Reassemble the pump.
3. Air is being drawn into the pump from the inlet side.
Check tank oil level and strainer for clogging. Correct as necessary. If OK, check tightness of pump inlet connection.
4. Inlet resistance causing cavitation.
Check correct oil . Check pump low pressure inlet pipe for collapse. Renew as required.
2. Hydraulic Pump a. Oil is not discharged from the pump.
b. Pump output is low. Hydraulic pressure does not increase.
Note: † refers to Service Manual. 9804/1103
45 - 10 - 01/9
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/10
JS 150LC Fault Finding - Hydraulics (cont'd) SYMPTOM
POSSIBLE CAUSE
ACTION
2. Hydraulic Pump (cont'd) c. The pump makes an abnormal noise.
d. Engine overload (engine speed very low or engine stalled).
e. Oil leakage.
1. Oil level is low and the pump is drawing in air.
Check and replenish oil level. Run the pump under no load to bleed air from the hydraulic system.
2. Clogging of the tank strainer.
Clean strainer. If strainer is severely clogged, drain and flush hydraulic system.
3. Oil temperature is too low or wrong oil specification.
Check correct oil for ambient temperature, see Lubrication Chart, page 45-00-01/1.
4. Coupling defective.
Check shaft run out.
5. The pump is resonating with external equipment.
Check pump mounting bolts for tightness. Tighten as required.
6. Internal damage to pump.
Dismantle and inspect pump, as detailed on page 20-1†, paying particular attention to bearings and sliding surfaces.
1. Regulator torque set too high.
Adjust as necessary.
2. The servo flow within the regulator is blocked or internal components are seized.
Remove the regulator from the pump and check filter for blockage. Clean as necessary. If filter OK, dismantle and inspect regulator, see page 20-1†.
3. Pump is seized or worn.
Dismantle and inspect pump as detailed on page 20-1†, paying particular attention to sliding surfaces. Repair or renew as necessary. Reassemble the pump.
1. Internal leakage within the pump causing oil seal damage and oil leakage.
Dismantle and inspect pump as detailed on page 20-1†, paying particular attention to oil seals and sliding surfaces. Renew as necessary, ensuring that lips of oil seals are not damaged when installed.
2. Damaged or blocked drain pipe.
Inspect and renew as necessary.
1. Oil temperature abnormally high.
Check correct oil, see Lubrication Chart, page 45-00-01/1. Check oil cooler and grille for blockage.
2. The hydraulic oil is dirty.
Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system.
3. The service pipe connection is overtightened.
Check tightening torque.
4. The valve housing was twisted during installation.
Loosen retaining bolts and tighten to correct torque figures.
5. Pressure too high.
Check system pressure, see page 11-1†.
3. Control Valve a. A spool is sticking.
Note: † refers to Service Manual. 9804/1103
45 - 10 - 01/10
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/11
JS 150LC Fault Finding - Hydraulics (cont'd) SYMPTOM
POSSIBLE CAUSE
ACTION
3. Control Valve (cont'd) 6. A spool is bent.
Dismantle the control valve as detailed on page 25-1†. Renew spool as necessary.
7. A return spring is broken.
Renew as necessary.
8. A return spring or cap is out of alignment.
Remove the cap, check that the spring is in the correct position. Refit cap and torque tighten bolts.
9. Temperature distribution within control valve not uniform.
Warm the entire system up before using service.
b. A spool does not move over its full stroke.
1. Dirt is clogging the inside of the valve.
Remove the dirt (flush out the valve).
c. The dipper/boom falls under load with the spool in neutral.
1. Oil is leaking past the ram/ boom piston seals.
Consult JCB Service for repairs of fit new ram.
2. Oil is bypassing dipper/boom spool.
Renew spool.
3. Oil is leaking past dipper/boom ARV.
Remove ARV and clean housing seat and relief valve seat. Refit ARV.
1. Dirt is clogging the load hold check valve.
Dismantle and clean the load hold check valve.
2. The load hold check valve seat is scratched or damaged.
Renew the poppet or smooth the poppet and seat with very fine emery cloth.
a. System pressure does not rise at all.
1. The main poppet, check valve poppet or pilot poppet is sticking open, or dirt is caught in the valve seat.
Remove MRV and dismantle as detailed on page 21-1†. Inspect and clean all parts. Assemble MRV, ensuring that all parts slide freely. Refit the MRV.
b. Relief pressure is unstable.
1. The pilot poppet seat is scratched or the pilot piston is sticking with the main poppet. Parts worn.
Remove MRV and dismantle as detailed on page 21-1†. Inspect and clean all parts. Renew damaged parts or remove scratches with very fine emery cloth. Assemble MRV, ensuring that all parts slide freely. Refit MRV.
2. The lock nut and adjusting screw are loose.
Tighten the lock nut and reset MRV pressure.
1. Worn 'O' rings.
Remove MRV and renew 'O' rings.
d. The dipper/boom falls under load when the spool is moved to a position higher than neutral. 4.
Main Relief Valve
c. Oil leak
Note: † refers to Service Manual. 9804/1103
45 - 10 - 01/11
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/12
JS 150LC Fault Finding - Hydraulics (cont'd) SYMPTOM
POSSIBLE CAUSE
ACTION
5. Swing Motor a.
Motor does not turn.
b. The direction of rotation is reversed.
c. Motor speed low.
d. The superstructure over swings when neutral is selected.
1. The pressure does not rise because the relief valve is incorrectly set.
Set the relief valve to the correct setting, see page 11-1†.
2. The relief valve plunger sticks.
Dismantle and inspect the relief valve, as detailed on page 26-1†. Repair or renew as necessary.
3. The relief valve plunger choke is blocked.
Dismantle and inspect the relief valve, as detailed on page 26-1†.Clean or renew as necessary.
4. The relief valve plunger seat is defective.
Dismantle and inspect the relief valve, as detailed on page 26-1†, paying particular attention to the valve seat. Renew the seat if abrasions or damage is found.
5. The load is too heavy.
Release the load.
6. The motor is thermally seized.
Dismantle and inspect the motor, as detailed on page 36-1†. Repair or renew as necessary.
7. The brake piston is stuck.
Dismantle and check the brake, as detailed in Section F, page 11-1†. Repair or renew as necessary.
8. The brake friction plate is thermally seized.
Dismantle and check the brake, as detailed in Section F, page 11-1†. Renew as necessary.
1. Motor assembled incorrectly.
Dismantle and assemble as detailed on page 36-1†.
2. The inlet and outlet pipe connections are reversed.
Fit pipes to correct positions.
1. The oil flow rate is insufficient.
Check the hydraulic pump delivery rate and the circuit up to the motor.
2. The oil temperature is high and leakage abnormally high.
Check the oil cooler and grille for damage and blockage.
3. The motor sliding surfaces are worn or damaged.
Dismantle and inspect the motor, as detailed on page 36-1†. Repair or renew as necessary.
1. High drainage rate within the pump.
Check the motor drain flow. If the flow exceeds 500 cc/min., dismantle and inspect the motor, as detailed on page 36-1†, paying particular attention to the sliding surfaces. Repair or renew as necessary.
2. The relief valve is incorrectly set.
Set the relief valve to the correct setting, see page 11-1†.
Note: † refers to Service Manual. 9804/1103
45 - 10 - 01/12
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/13
JS 150LC Fault Finding - Hydraulics (cont'd) SYMPTOM
POSSIBLE CAUSE
ACTION
5. Swing Motor (cont'd)
e. Oil leak at the oil seal.
f.
Oil leaks from mating face.
3. The relief valve plunger seat is defective.
Dismantle and inspect the relief valve, as detailed on page 26-1†, paying particular attention to the valve seat. Renew the seat if damage is found.
1. Damage or wear to oil seal lip.
Renew oil seal, as detailed on page 36-1†.
2. The shaft is damaged or worn.
Renew shaft and oil seal , as detailed on page 36-1†.
3. Abnormal pressure in the casing.
Check drain line for damage or blocking. Clear or renew drain pipe.
1. 'O' ring damaged or missing.
Dismantle and inspect, as detailed on page 36-1†, and renew 'O' rings.
2. The seal face is damaged.
Dismantle and inspect, as detailed on page 36-1†, and repair as necessary.
3. Bolts are loose.
Check bolts and torque tighten to specified torque.
1. Servo pressure is low.
Check servo pressure as detailed on page 10-1† and adjust as necessary.
2. Spring 241 is damaged.
Renew spring.
3. The clearance between the spools and casing is too large.
Renew spool and casing assembly
4. The handle unit is loose.
Renew the handle unit.
1. Sliding parts are sticking.
Dismantle and inspect as detailed on page 40-1†. Repair or renew as necessary.
2. Air is trapped in the pipes.
Operate the valve several times to remove the air.
1. Sliding parts are sticking.
Dismantle and inspect as detailed on page 40-1†. Repair or renew as necessary.
6. Hand Control Valves a. Low secondary pressure
b. Unstable secondary
c. High secondary pressure.
Note: † refers to Service Manual. 9804/1103
45 - 10 - 01/13
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/14
JS 200LC,300LC Fault Finding - Hydraulics (cont'd) Some problems which may occur in the hydraulic system are listed below, either for the system as a whole or for individual components.
SYMPTOM
POSSIBLE CAUSE
ACTION
1. Hydraulic System a. The hydraulic system is defective or does not operate at all.
1. The pump is defective.
Check pump pressure and renew if defective.
2. Dirt is clogging the inside of the relief valve.
Dismantle and clean the relief valve.
3. The relief valve is defective.
Strip and check the relief valve as detailed on page 25-1†.
4. A ram is worn.
Repair or renew the ram.
5. Negative pressure is low.
Check circuit pressure.
6. A valve is cracked.
Renew the valve.
7. A spool is not operating over its full stroke.
Check the movement of the spool or the operational linkage.
8. The oil level in the tank is too low.
Replenish the oil.
9. Circuit filters are clogged.
Clean or renew filters.
10. The circuit pipes are restricted.
Check the piping.
1. Air in the system due to low oil level.
Check the hydraulic oil level and replenish if necessary.
2. Pressure loss due to blocked filter.
Check the filter elements, clean or renew filter if necessary.
3. Pressure loss due to high hydraulic oil viscosity in cold periods.
Check the temperature of oil and warm if necessary. Check type of hydraulic oil, renew with correct type if wrong type used.
4. The speed of the input shaft is too high.
Check and readjust as necessary.
5. Mechanical damage to bearings.
Renew the damaged parts of the pump.
2. Hydraulic Pump a. The pump makes an abnormal noise.
Check pressures to find cause of overloading, readjust if necessary. Check hydraulic oil for contamination and flush the circuit or renew hydraulic oil.
Note: † refers to Service Manual. 9804/1103
45 - 10 - 01/14
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/15
JS 200LC,300LC Fault Finding - Hydraulics (cont'd) SYMPTOM
POSSIBLE CAUSE
ACTION
2. Hydraulic Pump (cont'd) b. Insufficient flow rate.
c. No rise in pressure.
1. The speed of the input shaft is too low.
Check speed and readjust if necessary.
2. Hydraulic oil temperature is too high.
Stop operation and check the oil temperature.
3. Hydraulic oil viscosity is too low.
Check the temperature and type of hydraulic oil used, renew if necessary.
4. Leakage of the selector valves or actuators.
Check if the leakage occurs in a particular actuator only. Renew the actuator or selector valve.
5. Low pump volumetric efficiency.
Check if the problem occurs in a particular pump only, if so renew the pump.
6. Power adjusting screw is loose.
Check if the locknuts are loose, reset and lock if necessary.
7. Air in system due to low oil level.
Check the hydraulic oil level, replenish if necessary.
8. Pressure loss due to blocked filter.
Check the filter elements and clean or renew as necessary.
9. Pressure loss due to high hydraulic oil viscosity in cold periods.
Check the temperature of oil and warm if necessary. Check type of hydraulic oil, renew with correct type if wrong type used.
10. The external command pressure exceeds the upper limit.
Measure pressure and readjust if necessary.
11. Power setting is low due to a change in the pressure reduction of the secondary choke.
Check the operation of the secondary choke. Dismantle and clean.
12. Defective solenoid pressure reduction valve.
Check and renew the valve if necessary.
1. Relief valve is set too low.
Check pressure in the circuit, and readjust the relief valve as necessary.
2. Selector valves or actuators leaking.
Check the operation of each actuator and valve and renew any which are defective.
3. Low pump volumetric efficiency.
Check if the problem occurs in a particular pump only, if so renew the pump.
Note: † refers to Service Manual. 9804/1103
45 - 10 - 01/15
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/16
JS 200LC,300LC Fault Finding - Hydraulics (cont'd) SYMPTOM
POSSIBLE CAUSE
ACTION
2. Hydraulic Pump (cont'd) d. Engine overload (engine speed very low or engine stalled).
1. Power setting is too high due to a change in the pressure reduction ratio of the secondary choke.
Check the filter in the regulator cover, dismantle and clean or renew. Check operation of the secondary choke. Dismantle and clean. Check the command current and adjust if necessary.
e. Low shaft speed.
2. Malfunction of the control equipment.
Check if the sliding surfaces in the control equipment are sticking and repair or renew any damaged ones.
3. Mechanical damage to bearings.
Check for overheating of the housing or abnormal noises around the bearings. Renew as necessary.
1. Defective relief valve.
Renew the relief valve.
2. Poor response of the control equipment.
Check for damage and repair or renew as necessary. Check the filters in the regulator cover. Dismantle and clean or renew.
f.
Pump overheats.
g. Oil leakage.
3.
Mechanical damage to bearings.
Check for overheating of the housing or abnormal noises around the bearings. Repair or renew damaged parts.
1. Damaged 'O' rings/packing or loose plugs.
Locate the leaks and check for abnormally high pressure. Renew the seal and tighten.
2. Damaged oil seals.
Check for scratching caused by foreign matter and check for abnormally high pressure. Renew the oil seal.
3. Wear to the contact faces of the shaft oil seal.
Check for foreign matter and abnormally high pressure. Renew the pump.
1. Oil temperature abnormally high.
Check correct oil, see Lubrication Chart, page 45-00-01/3. Check oil cooler and grille for blockage.
2. The hydraulic oil is dirty.
Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system.
3. The service pipe connection is overtightened.
Check tightening torque.
4. The valve housing was twisted during installation.
Loosen retaining bolts and tighten to correct torque figures.
Control Valve
a. A spool is sticking.
Note: † refers to Service Manual. 9804/1103
45 - 10 - 01/16
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/17
JS 200LC,300LC Fault Finding - Hydraulics (cont'd) SYMPTOM 3.
POSSIBLE CAUSE
ACTION
Control Valve (cont'd) 5. Pressure too high.
Check system pressure, see page 10-1†.
6. A spool is bent.
Dismantle the control valve as detailed on page 25-1†. Renew spool as necessary.
7. A return spring is broken.
Renew as necessary.
8. A return spring or cap is out of alignment.
Remove the cap, check that the spring is in the correct position. Refit cap and torque tighten bolts.
9. Temperature distribution within control valve not uniform.
Warm the entire system up before using service.
b. A spool does not move over its full stroke.
1. Dirt is clogging the inside of the valve.
Remove the dirt (flush out the valve).
c. The dipper/boom falls under load with the spool in neutral.
1. Oil is leaking past the ram/ boom piston seals.
Renew piston seals.
2. Oil is bypassing dipper/boom spool.
Renew spool.
3. Oil is leaking past dipper/boom ARV.
Remove ARV and clean housing seat and relief valve seat. Refit ARV.
1. Dirt is clogging the load hold check valve.
Dismantle and clean the load hold check valve.
2. The load hold check valve seat is scratched or damaged.
Renew the poppet or smooth the poppet and seat with very fine emery cloth.
a. System pressure does not rise at all.
1. The main poppet, check valve poppet or pilot poppet is sticking open, or dirt is caught in the valve seat.
Remove MRV and dismantle as detailed on page 25-1†. Inspect and clean all parts. Assemble MRV, ensuring that all parts slide freely. Refit the MRV.
b. Relief pressure is unstable.
1. The pilot poppet seat is scratched or the pilot piston is sticking with the main poppet. Parts worn.
Remove MRV and dismantle as detailed on page 25-1†. Inspect and clean all parts. Renew damaged parts or remove scratches with very fine emery cloth. Assemble MRV, ensuring that all parts slide freely. Refit MRV.
2. The lock nut and adjusting screw are loose.
Tighten the lock nut and reset MRV pressure.
1. Worn 'O' rings.
Remove MRV and renew 'O' rings.
d. The dipper/boom falls under load when the spool is moved to a position higher than neutral. 4.
Main Relief Valve
c. Oil leak
Note: † refers to Service Manual. 9804/1103
45 - 10 - 01/17
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/18
JS 200LC,300LC Fault Finding - Hydraulics (cont'd) SYMPTOM
POSSIBLE CAUSE
ACTION
5. Swing Motor a.
Motor does not turn.
b. Large slip.
c. Insufficient torque.
d. Abnormal noise.
e. Abnormal heating.
1. Internal damage to the motor.
Measure the oil drain volume. If the supply volume approaches drain volume, dismantle and inspect as detailed on page 35-1†. Repair or renew as necessary.
2. Internal damage to the motor.
Disconnect motor inlet and outlet ports and apply servo pressure of 19.6 bar (284 lbf/ in2) to the brake release port. Try to rotate shaft with a torque of approximately 4.8 9.8 Nm (3.6 - 7.2 ft lb). If the shaft does not rotate smoothly, dismantle and inspect as detailed on page 35-1†. Repair or renew as necessary.
3. Relief valve in the circuit not correctly set.
Fit a pressure gauge and measure load pressure, as detailed on page 10-1†. Reset as necessary.
1. Wear or damage to the motor sliding surfaces or high pressure seal.
Measure the oil drain volume. If the volume exceeds 5 litres/min (1.1 gal/min), dismantle and inspect as detailed on page 35-1†. Repair or renew as necessary.
2. Oil hot and large leakage in the motor.
Reduce oil temperature.
1. Wear or burning of the motor sliding surfaces.
Disconnect motor inlet and outlet ports and apply servo pressure of 19.6 bar (284 lbf/ in2) to the brake release port. Try to rotate shaft with a torque of approximately 4.8 9.8 Nm (3.6 - 7.2 ft lb). If the shaft does not rotate smoothly, dismantle and inspect as detailed on page 35-1†. Repair or renew as necessary.
2. Circuit relief not correctly set.
Fit a pressure gauge and measure load pressure, as detailed on page 10-1†. Adjust as necessary.
1. Internal damage to the motor.
Check for metallic particles in the motor drain oil or drain filter. If particles found, dismantle and inspect as detailed on page 35-1†. Repair or renew as necessary.
2. Large amounts of air in the oil.
Check the oil in the tank and motor casing. Bleed the system.
3. Loosening of bolts or connections.
Check pipe connections, mounting bolts for tightness. Retighten to specified torque.
1. Burning of the motor sliding or turning parts.
Check for metallic particles in the motor drain oil or drain filter. Also apply servo pressure of 19.6 bar (284 lbf/ in2) to the brake release port. Try to rotate the shaft with a torque of approximately 4.8 9.8 Nm (3.6 - 7.2 lbf ft). If particles found or the shaft does not rotate smoothly, dismantle and inspect as detailed on page 35-1†. Repair or renew as necessary.
Note: † refers to Service Manual. 9804/1103
45 - 10 - 01/18
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/19
JS 200LC,300LC Fault Finding - Hydraulics (cont'd) SYMPTOM
POSSIBLE CAUSE
ACTION
5. Swing Motor (cont'd) f.
Leaks from the oil seal.
g. Oil leaks from mating surface.
1. Damage or wear to oil seal lip.
Renew the oil seal, as detailed on page 35-1†.
2. Damage or wear to shaft seal.
Repair or renew the motor assembly.
3. Abnormal pressure in the casing.
Set the pressure in the casing to below 2.9 bar (43 lbf/ in2) and check drain volume. If drain volume large, dismantle and inspect as detailed on page 35-1†. Renew the oil seal and repair or renew other damaged parts as necessary.
1. An 'O' ring is damaged.
Renew 'O' ring.
2. The seal face is damaged.
Repair or renew seal face.
3. Bolts are loose.
Check bolts and tighten to the specified torque.
1. Servo pressure is low.
Check servo pressure as detailed on page 10-1† and adjust as necessary.
2. Spring 241 is damaged.
Renew spring.
3. The clearance between the spools and casing is too large.
Renew spool and casing assembly
4. The handle unit is loose.
Renew the handle unit.
1. Sliding parts are sticking.
Dismantle and inspect as detailed on page 40-1†. Repair or renew as necessary.
2. Air is trapped in the pipes.
Operate the valve several times to remove the air.
1. Sliding parts are sticking.
Dismantle and inspect as detailed on page 40-1†. Repair or renew as necessary.
6. Hand Control Valves a. Low secondary pressure.
b. Unstable secondary pressure.
c. High secondary pressure.
Note: † refers to Service Manual.
9804/1103
45 - 10 - 01/19
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/20
JS 240LC Fault Finding - Hydraulics (cont'd) Some problems which may occur in the hydraulic system are listed below, either for the system as a whole or for individual components.
SYMPTOM
POSSIBLE CAUSE
ACTION
1. Hand Control Valves a. Low secondary pressure.
b. Unstable secondary pressure.
c. High secondary pressure.
1. Servo pressure is low.
Check servo pressure as detailed on page 10-5† and adjust as necessary.
2. Spring 241 is damaged.
Renew spring.
3. The clearance between the spools and casing is too large.
Renew spool and casing assembly
4. The handle unit is loose.
Renew the handle unit.
1. Sliding parts are sticking.
Dismantle and inspect as detailed on page 40-1†. Repair or renew as necessary.
2. Air is trapped in the pipes.
Operate the valve several times to remove the air.
1. Sliding parts are sticking.
Dismantle and inspect as detailed on page 40-1†. Repair or renew as necessary.
Note: † refers to Service Manual.
9804/1103
45 - 10 - 01/20
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/21
JS 450LC Fault Finding - Hydraulics (cont'd) Some problems which may occur in the hydraulic system are listed below, either for the system as a whole or for individual components.
SYMPTOM
POSSIBLE CAUSE
ACTION
1. Air in the system due to low oil level.
Check the hydraulic oil level and replenish if necessary.
2. Pressure loss due to blocked filter.
Check the filter elements, clean or renew filter if necessary.
3. Pressure loss due to high hydraulic oil viscosity in cold periods.
Check the temperature of oil and warm if necessary. Check type of hydraulic oil, renew with correct type if wrong type used.
4. The speed of the input shaft is too high.
Check and readjust as necessary.
5. Mechanical damage to bearings.
Renew the damaged parts of the pump.
1. Hydraulic Pump a. The pump makes an abnormal noise.
Check pressures to find cause of overloading, readjust if necessary. Check hydraulic oil for contamination and flush the circuit or renew hydraulic oil. b. Insufficient flow rate.
1. The speed of the input shaft is too low.
Check speed and readjust if necessary.
2. Hydraulic oil temperature is too high.
Stop operation and check the oil temperature.
3. Hydraulic oil viscosity is too low.
Check the temperature and type of hydraulic oil used, renew if necessary.
4. Leakage of the selector valves or actuators.
Check if the leakage occurs in a particular actuator only. Renew the actuator or selector valve.
5. Low pump volumetric efficiency.
Check if the problem occurs in a particular pump only if so renew the pump.
6. Power adjusting screw is loose.
Check if the locknuts are loose, reset and lock if necessary.
7. Air in system due to low oil level.
Check the hydraulic oil level, replenish if necessary.
8. Pressure loss due to blocked filter.
Check the filter elements and clean or renew as necessary.
9. Pressure loss due to high hydraulic oil viscosity in cold periods.
Check the temperature of oil and warm if necessary. Check type of hydraulic oil, renew with correct type if wrong type used.
10. The external command pressure exceeds the upper limit.
Measure pressure and readjust if necessary.
Note: † refers to Service Manual. 9804/1103
45 - 10 - 01/21
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/22
JS 450LC Fault Finding - Hydraulics (cont'd) SYMPTOM
POSSIBLE CAUSE
ACTION
1. Hydraulic Pump (cont'd)
c. No rise in pressure.
d. Engine overload (engine speed very low or engine stalled).
11. Power setting is low due to a change in the pressure reduction of the secondary choke.
Check the operation of the secondary choke. Dismantle and clean.
12. Defective solenoid pressure reduction valve.
Check and renew the valve if necessary.
1. Relief valve is set too low.
Check pressure in the circuit, and readjust the relief valve as necessary.
2. Selector valves or actuators leaking.
Check the operation of each actuator and valve and renew any which are defective.
3. Low pump volumetric efficiency.
Check if the problem occurs in a particular pump only if so renew the pump.
1. Power setting is too high due to a change in the pressure reduction ratio of the secondary choke.
Check the filter in the regulator cover, dismantle and clean or renew. Check operation of the secondary choke, Dismantle and clean. Check the command current and adjust if necessary.
e. Low shaft speed.
2. Malfunction of the control equipment.
Check if the sliding surfaces in the control equipment are sticking and repair or renew any damaged ones.
3. Mechanical damage to bearings.
Check for overheating of the housing or abnormal noises around the bearings. renew as necessary.
1. Defective relief valve.
Renew the relief valve.
2. Poor response of the control equipment.
Check for damage and repair or renew as necessary. Check the filters in the regulator cover. Dismantle and clean or renew.
f.
Pump overheats.
g. Oil leakage.
Mechanical damage to bearings.
Check for overheating of the housing or abnormal noises around the bearings. Repair or renew damaged parts.
1. Damaged 'O' rings/packing or loose plugs.
Locate the leaks and check for abnormally high pressure. Renew the seal and tighten.
2. Damaged oil seals.
Check for scratching caused by foreign matter and check for abnormally high pressure. Renew the oil seal.
3. Wear to the contact faces of the shaft oil seal.
Check for foreign matter and for abnormally high pressure. Renew the pump.
Note: † refers to Service Manual. 9804/1103
45 - 10 - 01/22
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/23
JS 450LC Fault Finding - Hydraulics (cont'd) SYMPTOM
POSSIBLE CAUSE
ACTION
2. Hand Control Valves a. Low secondary pressure.
b. Unstable secondary pressure.
c. High secondary pressure.
1. Servo pressure is low.
Check servo pressure as detailed on page 10-15† and adjust as necessary.
2. Spring 241 is damaged.
Renew spring.
3. The clearance between the spools and casing is too large.
Renew spool and casing assembly
4. The handle unit is loose.
Renew the handle unit.
1. Sliding parts are sticking.
Dismantle and inspect as detailed on page 40-1†. Repair or renew as necessary.
2. Air is trapped in the pipes.
Operate the valve several times to remove the air.
1. Sliding parts are sticking.
Dismantle and inspect as detailed on page 40-1†. Repair or renew as necessary.
Note: † refers to Service Manual.
9804/1103
45 - 10 - 01/23
Issue 1
Excavators
CONTENTS
45 - 10 - 01/24
JS 70 from m/c no. 695501 Fault Finding - Hydraulics (contÕd) Hydraulic Pump As a first step towards locating a fault, carry out the following checks. 1
Check the hydraulic filter for the presence of excessive foreign materials. The nature of the foreign materials could yield a clue as to the source of damage or wear.
2
Check the flow rate and condition of the oil drained from the pump.
3
Check for abnormal sounds and vibration.
4
Check the pressure at each of the pump pressure test points.
Symptom 1
2
Pump is producing abnormal noise.
Insufficient flow.
9804/1103
Possible cause
Remedy
a
Air is being drawn in due to low oil level in the hydraulic oil tank.
Top up the hydraulic oil and bleed air from the system.
b
Pump cavitation due to a clogged suction strainer.
Clean the strainer. If excessively clogged, flush the hydraulic system and/or renew the hydraulic oil.
c
Excessively low oil temperature, or pump cavitation due to high oil viscosity.
Check that the correct hydraulic oil for the ambient conditions is being used. If not, renew the oil.
d
Input shaft rotation speed abnormally high.
Adjust the rotation speed.
e
Component mechanically damaged, Bearing etc.
Replace the damaged parts Reset the pressure. Flush the circuit. Change the hydraulic oil.
a
Input shaft rotation speed decrease.
Adjust the rotation speed.
b
Oil temperature abnormally high.
Stop the operation and re-check after the oil temperature has dropped.
c
Oil viscosity abnormally high.
Check that the correct hydraulic oil for the ambient conditions is being used. If not, renew the oil.
d
Switching valve or actuator leakage.
Replace the switching valve and actuator.
e
Inadequate pump displacement.
Replace the pump.
f
Power adjustment screw is loose.
Reset and lock.
g
Air is being drawn in due to low oil level in the hydraulic oil tank.
Top up the hydraulic oil and bleed air from the system.
h
Pump cavitation due to a clogged suction strainer.
Clean the strainer. If excessively clogged, flush the hydraulic system and/or renew the hydraulic oil.
j
Excessively low oil temperature, or pump cavitation due to high viscosity.
Check that the correct hydraulic oil for the ambient conditions is being used. If not, renew the oil.
45 - 10 - 01/24
Issue 1
Excavators
CONTENTS
45 - 10 - 01/25
JS 70 from m/c no. 695501 Fault Finding - Hydraulics (contÕd) Hydraulic Pump (contÕd)
Symptom 3
4
5
Pressure does not increase.
Overload at static load.
Rotation speed low in dynamic load.
Possible cause
Remedy
a
Relief valve is set low.
Reset the relief valve.
b
Switching valve or actuator leakage.
Replace the switching valve actuator.
c
Inadequate pump displacement.
Replace the pump.
a
Pump horsepower settings
Reset the pump.
b
Fault on control devise.
Fix damage caused by foreign matter or replace the pump.
c
Component mechanically damaged, Bearing etc.
Replace the damaged parts Reset the pressure. Flush the circuit. Change the hydraulic oil.
a
Peak pressure occurs due to decrease in responsiveness of the relief valve.
Check for abnormal vibration of the circuit and measure pressure, if found replace the relief valve. Check for foreign matter clogging the servo line. If found remove the foreign matter.
6
7
Pump produces abnormal heat.
Oil leakage
9804/1103
b
Decrease in responsiveness of the control device.
Check for debris on each sliding part of the control devices. Fix the damage caused by the foreign matter.
a
Increase in pump leakage.
Measure actuator speed, replace pump.
b
Component mechanically damaged, Bearing etc.
Replace the damaged parts Reset the pressure. Flush the circuit/change the hydraulic oil.
c
Seizure or wear of pump internal parts.
Replace damaged parts or pump.
a
Damage to o-rings or seals, confirm the oil leakage points and measure for abnormal pressure.
Replace damaged seals.
b
Damage to oil seal, check for damage due to foreign matter and measure for abnormal pressure.
Replace damaged seals.
c
Wear of seal due to contact with input shaft.
Replace input shaft or pump.
d
Loose plugs.
Tighten plugs or replace seals.
45 - 10 - 01/25
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 01/26
JS130W from m/c no. 716500 JS 160W from m/c no. 718500 JS 200W from m/c no. 809000 Fault Finding - Hydraulics Some problems which may occur in the hydraulic system are listed below, either for the system as a whole or for individual components Symptom 1
Hydraulic System
a
The hydraulic system is defective or does not operate at all.
2
Hydraulic Pump
a
Oil is not discharged from the pump.
b Pump output is low. valve. Hydraulic pressure does not increase.
Possible Cause
Action
1
The pump is defective.
Check pump pressure and renew if defective.
2
Dirt is clogging the inside of the relief valve.
Dismantle and clean the relief valve.
3
The relief valve is defective.
Strip and check the relief valve.
4
A ram is worn.
Repair or renew the ram.
5
Negative pressure is low.
Check circuit pressure.
6
A valve is cracked.
Renew the valve.
7
A spool is not operating over its full stroke.
Check the movement of the spool or the operational linkage.
8
The oil level in the tank is too low.
Replenish the oil.
9
Circuit filters are clogged.
Clean or renew filters.
10 The circuit pipes are restricted.
Check the piping.
1
The tank strainer or intake pipe is blocked.
Clean the strainer and clean the intake pipe.
2
The end of the inlet pipe is above the tank oil level.
Replenish the oil tank.
3
One or more of the pump major components is damaged or the input shaft or coupling are defective.
Dismantle and inspect pump. Renew damaged components and reassemble the pump. Renew shaft or coupling.
1
The pressure does not increase
Check hydraulic pump and control
because of problems with the hydraulic pump or control valve.
Renew as required.
Internal leakage within the hydraulic pump with excessive fluid drain from pump drain port.
Strip and inspect the hydraulic pump, paying particular attention to sliding surfaces. Repair or renew as
2
necessary. Reassemble the pump. 3
Air is being drawn into the pump from the inlet side.
Check tank oil level and strainer for clogging. Correct as necessary. If OK, check tightness of pump inlet
4
Inlet resistance causing cavitation.
Check correct oil . Check pump low pressure inlet pipe for collapse. Renew as required.
1
Oil level is low and the pump is drawing in air.
Check and replenish oil level. Run the pump under no load to bleed air from hydraulic system.
connection.
c
The pump makes an abnormal noise.
the 9804/1103
45 - 10 - 01/26
6320 - E/3-1.1
Issue 1
Excavators
CONTENTS
45 - 10 - 01/27
JS130W from m/c no. 716500 JS 160W from m/c no. 718500 JS 200W from m/c no. 809000 Fault Finding - Hydraulic (cont’d) Symptom 2
d
e
Possible Cause
Action
Hydraulic Pump (cont'd)
Engine overload (engine speed very low or engine stalled).
Oil leakage.
3
Control Valve
a
A spool is sticking.
2
Clogging of the tank strainer.
Clean strainer. If strainer is severely clogged, drain and flush hydraulic system.
3
Oil temperature is too low or wrong oil specification
Check correct oil for ambient temperature, see Fluids Lubricants and Capacities
4
Coupling defective.
Check shaft run out.
5
The pump is resonating with external equipment.
Check pump mounting bolts for tightness. Tighten as required.
6
Internal damage to pump.
Dismantle and inspect pump, paying particular attention to bearings and sliding surfaces.
1
Regulator torque set too high.
Adjust as necessary.
2
The servo flow within the regulator is blocked or internal components are seized.
Remove the regulator from the pump and check filter for blockage. Clean as necessary. If filter OK, dismantle and inspect regulator.
3
Pump is seized or worn.
Dismantle and inspect pump, paying particular attention to sliding surfaces. Repair or renew as necessary. Reassemble the pump.
1
Internal leakage within the pump causing oil seal damage and oil leakage.
Dismantle and inspect pump, paying particular attention to oil seals and sliding surfaces. Renew as necessary, ensuring that lips of oil seals are not damaged when installed.
2
Damaged or blocked drain pipe.
Inspect and renew as necessary.
1
Oil temperature abnormally high.
Check correct oil, see Fluids, Lubricants and Capacities. Check oil cooler and grille for blockage.
2
The hydraulic oil is dirty.
Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system.
3
The service pipe connection is overtightened.
Check tightening torque.
4
The valve housing was twisted during installation.
Loosen retaining bolts and tighten to correct torque figures.
5
Pressure too high.
Check system pressure.
6
A spool is bent.
Renew the control valve section.
7 A return spring is broken.
9804/1103
45 - 10 - 01/27
Renew as necessary.
6320 - E/3-2.1
Issue 1
Excavators
CONTENTS
45 - 10 - 01/28
JS 130W from m/c no. 716500 JS 160 from m/c no. 718500 JS 200W from m/c no. 809000 Fault Finding - Hydraulics (cont’d) Symptom 3
Possible Cause
Action
Control Valve (cont'd) 8
A return spring or cap is out of alignment.
Remove the cap, check that the spring is in the correct position. Refit cap and torque tighten bolts.
9
Temperature distribution within control valve not uniform.
Warm the entire system up before using service.
b
A spool does not move over its full stroke.
1
Dirt is clogging the inside of the valve.
Remove the dirt (flush out the valve).
c
The dipper/boom falls under load with the spool in neutral.
1
Oil is leaking past the ram/ boom piston seals.
Renew piston seals.
2
Oil is bypassing dipper/boom spool.
Renew control valve section.
3
Oil is leaking past dipper/boom ARV.
Remove ARV and clean housing seat and relief valve seat. Refit ARV.
1
Dirt is clogging the load hold check valve.
Dismantle and clean the load hold check valve.
2
The load hold check valve seat is scratched or damaged.
Renew the poppet or smooth the poppet and seat with very fine emery cloth.
d
The dipper/boom falls under load when the spool is moved to a position higher than neutral.
4
Main Relief Valve
a
System pressure does not rise at all.
1
The main poppet, check valve poppet or pilot poppet is sticking open, or dirt is caught in the valve seat.
Remove MRV and dismantle. Inspect and clean all parts. Assemble MRV, ensuring that all parts slide freely. Refit the MRV.
b
Relief pressure is unstable.
1
The pilot poppet seat is scratched or the pilot piston is sticking with the main poppet. Parts worn.
Remove MRV and dismantle. Inspect and clean all parts. Renew damaged parts or remove scratches with very fine emery cloth. Assemble MRV, ensuring that all parts slide freely. Refit MRV.
2
The lock nut and adjusting screw are loose.
Tighten the lock nut and reset MRV pressure.
1
Worn 'O' rings.
Remove MRV and renew 'O' rings.
1
Internal damage to the motor.
Measure the oil drain volume. If the supply volume approaches drain volume, dismantle and inspect. Repair or renew as necessary.
2
Internal damage to the motor.
Disconnect motor inlet and outlet ports and apply servo pressure of 19.6 bar (284 lb. in2) to the brake release port. Try
c
Oil leak
5
Slew Motor
a
Motor does not turn.
to rotate shaft with a torque of approximately 4.8 - 9.8 Nm (3.6 - 7.2 lbf ft.). If the shaft does not rotate smoothly, dismantle and inspect. Repair or renew as necessary.
9804/1103
45 - 10 - 01/28
6320 - E/3-3.1
Issue 1
Excavators
CONTENTS
45 - 10 - 01/29
JS 130W from m/c no. 716500 JS 160W from m/c no. 718500 JS 200W from m/c 809000 Fault Finding - Hydraulics (cont’d) Symptom 5
Slew Motor (cont'd)
a
Motor does not turn. (cont’d)
b
c
d
The direction of rotation is reversed.
Motor speed low.
The superstructure over swings when neutral is selected.
9804/1103
Possible Cause
Action
3
Relief valve in the circuit not correctly set.
Fit a pressure gauge and measure load pressure. Reset as necessary.
4
The pressure does not rise because the relief valve is incorrectly set.
Set the relief valve to the correct setting.
5
The relief valve plunger sticks.
Dismantle and inspect the relief valve. Repair or renew as necessary.
6
The relief valve plunger choke is blocked.
Dismantle and inspect the relief valve. Clean or renew as necessary.
7
The relief valve plunger seat is defective.
Dismantle and inspect the relief valve, paying particular attention to the valve seat. Renew the seat if abrasions or damage is found.
8
The motor is thermally seized.
Dismantle and inspect the motor.Repair or renew as necessary.
9
The brake piston is stuck.
Dismantle and check the brake. Repair renew as necessary.
10 The brake friction plate is thermally seized.
Dismantle and check the brake. Renew as necessary.
1
Motor assembled incorrectly.
Dismantle and assemble.
2
The inlet and outlet pipe connections are reversed.
Fit pipes to correct positions.
1
The oil flow rate is insufficient.
Check the hydraulic pump delivery rate and the circuit up to the motor.
2
The oil temperature is high and leakage abnormally high.
Check the oil cooler and grille for damage and blockage.
3
The motor sliding surfaces are worn or damaged.
Dismantle and inspect the motor. Repair or renew as necessary.
1
High drainage rate within the motor.
Check the motor drain flow. If the flow exceeds 500 cc/min., dismantle and inspect the motor, paying particular attention to the sliding surfaces. Repair or renew as necessary.
45 - 10 - 01/29
6320 - E/3-4.1
Issue 1
Excavators
CONTENTS
45 - 10 - 01/30
JS 130W from m/c no. 716500 JS 160W from m/c no. 718500 JS 200W from m/c no. 809000 Fault Finding - Hydraulic (cont’d)
Symptom 5
Slew Motor (cont'd)
d
The superstructure over swings when neutral is selected. (cont’d)
e
f
g
h
Large slip.
Insufficient torque.
Abnormal noise.
Abnormal heating.
9804/1103
Possible Cause
Action
2
The A.R.V. is incorrectly set.
Set the relief valve to the correct setting.
3
The relief valve plunger seat is defective.
Dismantle and inspect the relief valve, paying particular attention to the valve seat. Renew the seat if damage is found.
1
Wear or damage to the motor sliding surfaces or high pressure seal.
Measure the oil drain volume. If the volume exceeds 5 litres/min, dismantle and inspect. Repair or renew as necessary.
2
Oil hot and large leakage in the motor.
Reduce oil temperature.
1
Wear or burning of the motor sliding surfaces.
Disconnect motor inlet and outlet ports and apply servo pressure of 19.6 bar (284 lb. in2) to the brake release port. Try to rotate shaft with a torque of approximately 4.8 - 9.8 Nm (3.6 - 7.2 lbf ft). If the shaft does not rotate smoothly, dismantle and inspect Repair or renew as necessary.
2
ARV in the circuit not correctly set.
Fit a pressure gauge and measure load pressure, Reset as necessary.
1
Internal damage to the motor.
Check for metallic particles in the motor drain oil or drain filter. If particles found, dismantle and inspect. Repair or renew as necessary.
2
Large amounts of air in the oil.
Check the oil in the tank and motor casing. Bleed the system.
3
Loosening of bolts or connections.
Check pipe connections, mounting bolts for tightness. Retighten to specified torque.
1
Burning of the motor sliding or turning parts.
Check for metallic particles in the motor drain oil or drain filter. Also apply servo pressure of 19.6 bar (284 lb. in2) to the brake release port. Try to rotate the shaft with a torque of approximately 4.8 9.8 Nm (3.6 - 7.2 lbf ft). If particles found or the shaft does not rotate smoothly, dismantle and inspect. Repair or renew as necessary.
45 - 10 - 01/30
6320-E/3-5.1
Issue 1
Excavators
CONTENTS
45 - 10 - 01/31
JS 130W from m/c no. 716500 JS 160W from m/c no. 718500 JS 200W from m/c no. 809000 Fault Finding - Hydraulics (cont’d) Symptom 5
Slew Motor (cont'd)
j
Leaks from the oil seal.
k
Oil leaks from mating surface.
6
Remote Control Valves
a
Low secondary pressure
b
c
Unstable secondary
High secondary pressure.
9804/1103
Possible Cause
Action
1
Damage or wear to oil seal lip.
Renew the oil seal.
2
Damage or wear to shaft seal.
Repair the problem or renew the motor assembly.
3
Abnormal pressure in the casing.
Set the pressure in the casing to below 2.9 bar (43 lb in2) and check drain volume. If drain volume large, dismantle and inspect. Renew the oil seal and, if possible, repair or renew other damaged parts.
1
An 'O' ring is damaged.
Renew 'O' ring.
2
The seal face is damaged.
Repair seal face or renew.
3
Bolts are loose.
Check bolts and tighten to the specified torque.
1
Servo pressure is low.
Check servo pressure and adjust as necessary.
2
Spring 14 is damaged.
Renew spring.
3
The clearance between the spools
Renew spool and casing assembly. and casing is too large.
4
The handle unit is loose.
Renew the handle unit.
1
Sliding parts are sticking.
Dismantle and inspect. Repair or renew as necessary.
2
Air is trapped in the pipes.
Operate the valve several times to remove the air.
1
Sliding parts are sticking.
Dismantle and inspect. Repair or renew as necessary.
45 - 10 - 01/31
6320 - E/3-6.1
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 02/1
JS 110,130,150LC Fault Finding - Track Gearbox Motor Section Faults SYMPTOM 1. The motor does not run
POSSIBLE CAUSE
1. Oil not reaching the motor
Check flow at control valve, pump etc.
2.
Renew excessively worn part. Remove damage and burrs from the surfaces and completely clean all parts.
Motor excessively worn.
3. Gearbox damaged. 4. Main relief valve blowing due to overload or incorrect setting.
2. Motor speed insufficient
1. Oil flow at motor not sufficient due to a fault in pump, control valve etc. 2. Motor efficiency low
3. Main relief valve leaking or set too low.
3. Oil leakage
1. Oil seal damaged.
2. Oil seal leaking due to excessive internal leakage.
4. Abnormal noise and speed variation
9804/1103
ACTION
Renew or repair the gearbox.
Reduce the load and check relief valve setting.
Check flow at control valve, pump etc. Check internal oil leakage rate. If this is excessive, check motor pistons, bores, timing plate etc. for excessive wear. Renew if required.
Check relief valve condition and reset.
Renew the seal, taking care not to damage the lip of the seal. Note: On the JS110/130 gearbox, the maximum working temperature of the oil seal is 80° C (175° F).
Check leak-off pressure. Note: On the JS110/130 gearbox, the maximum pressure resistance of the oil seal is 4.8 bar (70 lbf/in2). Excessive leak-off pressure may be caused by back pressure due to dirt in the return lines.
3. Gasket damaged or not installed.
Renew gasket.
4. Loose fasteners.
Tighten fasteners. If leak continues, dismantle joint, renew gasket and re-assemble correctly.
5. Damaged joint faces.
Dismantle joint, renew damaged parts, renew gasket and re-assemble correctly.
1. Cavitation under over-run conditions.
45 - 10 - 02/1
Check brake valve setting. When correct and noise continues, dismantle motor and check for damaged parts.
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 02/2
JS 110,130,150LC Fault Finding - Track Gearbox (cont'd) Parking Brake Faults SYMPTOM 1. Braking force insufficient or uneven.
2. Abnormal heat generation.
9804/1103
POSSIBLE CAUSE
ACTION
1. Brake plates worn.
Renew brake plates. Remove foreign materials and repair damaged areas.
2.
Renew brake springs. Remove foreign materials and repair damaged areas.
Deformed brake springs.
1. Brake not releasing correctly due to fluid leaks or clogged orifice.
45 - 10 - 02/2
Clean out the hydraulic components and renew seals.
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 02/3
JS 200LC,240LC,300LC,450LC Fault Finding - Track Gearbox (cont'd) Motor Section Faults
SYMPTOM 1. The motor does not run
POSSIBLE CAUSE
1. Oil not reaching the motor
Check flow at control valve, pump etc.
2.
Renew excessively worn part. Remove damage and burrs from the surfaces and completely clean all parts.
Motor excessively worn.
3. Gearbox damaged. 4. Main relief valve blowing due to overload or incorrect setting.
2. Motor speed insufficient
1. Oil flow at motor not sufficient due to a fault in pump, control valve etc. 2. Motor efficiency low
3. Main relief valve leaking or set too low.
3. Oil leakage
1. Oil seal damaged.
2. Oil seal leaking due to excessive internal leakage.
4. Abnormal noise and speed variation
9804/1103
ACTION
Renew or repair the gearbox.
Reduce the load and check relief valve setting.
Check flow at control valve, pump etc. Check internal oil leakage rate. If this is excessive, check motor pistons, bores, timing plate etc. for excessive wear. Renew if required.
Check relief valve condition and reset.
Renew the seal, taking care not to damage the lip of the seal. Note: On the JS200LC gearbox, the maximum working temperature of the oil seal is 80° C (175° F).
Check leak-off pressure. Note: On the JS200LC/300LC gearbox, the maximum pressure resistance of the oil seal is 4.8 bar (70 lbf/in2). Excessive leak-off pressure may be caused by back pressure due to dirt in the return lines.
3. Gasket damaged or not installed.
Renew gasket.
4. Loose fasteners.
Tighten fasteners. If leak continues, dismantle joint, renew gasket and re-assemble correctly.
5. Damaged joint faces.
Dismantle joint, renew damaged parts, renew gasket and re-assemble correctly.
1. Cavitation under over-run conditions.
45 - 10 - 02/3
Check brake valve setting. When correct and noise continues, dismantle motor and check for damaged parts.
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 02/4
JS 200LC,240LC,300LC,450LC Fault Finding - Track Gearbox (cont'd) Parking Brake Faults
SYMPTOM 1. Braking force insufficient or uneven.
2. Abnormal heat generation.
9804/1103
POSSIBLE CAUSE
ACTION
1. Brake plates worn.
Renew brake plates. Remove foreign materials and repair damaged areas.
2.
Renew brake springs. Remove foreign materials and repair damaged areas.
Deformed brake springs.
1. Brake not releasing correctly due to fluid leaks or clogged orifice.
45 - 10 - 02/4
Clean out the hydraulic components and renew seals.
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 03/1
JS 70,110,130,150LC,200LC,240LC,300LC,450LC * JS 130W from m/c no. 716500, JS 160W from m/c no. 718500 Fluids, Lubricants & Capacities SYMPTOM 1
Output gear not turning
A
Relief valve is blowing.
POSSIBLE CAUSE
ACTION
1. Overload.
1.
Reduce the load.
2. Brake not releasing
2a. Check release pressure. 2b. Release brake and check brake condition.
3. Gearbox damaged.
3.
Renew or repair the gearbox.
1) Motor can be heard turning.
1. Broken motor shaft. 2. Gearbox damaged.
1. 2.
Renew motor. Renew or repair the gearbox.
2) Motor cannot be heard turning.
1. Pump or valves defective.
1.
Check flow through pump, valves, etc.
1. Gasket damaged or not installed.
1.
Renew gasket.
2. Loose fasteners.
2a. Tighten fasteners. 2b. Dismantle joint, renew gasket and re-assemble correctly.
3. Damaged joint faces.
3.
Dismantle joint, renew damaged parts, renew gasket and re-assemble correctly.
1. Oil seal damaged.
1.
Renew the seal.
B. Relief valve is not blowing.
2.
Oil leakage
A. Oil leaking from joints.
B. Oil leaking at shaft.
9804/1103
45 - 10 - 03/1
Issue 2*
Excavators
CONTENTS
45 - 10 - 03/2
JS 200 from m/c no. 705001, JS 240 from m/c no. 708501 Fault Finding - Swing Gearbox Table 1.
Leakage from oil seals
Abnormal heating
Excessive slip
Motor does not run
Symptom
9804/1103
Cause
External Inspection
Countermeasure
Repair
Internal damage to the motor.
Measure the oil drain volume.
High possibility of damage to the sliding surfaces if the supply volume is approximately equal to the drain volume. Dismantle and inspect.
Refer to Table 2.
Internal damage to the motor.
Open the motor inlet and outlet ports and apply 20 kg/cm2 (284.46 lbf/in2) pilot pressure to the brake release port. Try to rotate the shaft with a torque of approx. 39.32 Nm (29 lbf ft).
High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect.
Replace damaged parts or renew the motor assembly.
Relief valve in circuit not set correctly.
Measure pressure.
Reset to the prescribed setting.
Wear or damage to the motor sliding surfaces or to the high-pressure seal.
Measure the oil drain volume.
Leakage is too high if the oil drain volume exceeds 5 l/min (1.1 gal/min). Dismantle and inspect.
Refer to table 2.
Oil hot and excessive leakage in the motor.
Measure the oil temperature.
Reduce the oil temperature.
Refer to table 2.
Seizure of motor sliding parts or circuit.
Check for any metallic matter deposited in motor drain oil or drain filter. Apply a 30 kgf/cm2 (427 lbf/in2)pilot pressure to the brake release port and try to rotate the shaft with a torque of approx. 39.32 Nm (29 lbf ft).
If metallic matter is discovered or the supply shaft does not rotate smoothly when torque is applied, there is a high possibility of internal damage to the motor. Dismantle and inspect.
Repair or renew the damaged parts. Renew the motor assembly.
Damage or wear to oil seal lip.
Renew the oil seals.
Damage or wear of the shaft seal.
Repair the problem or renew the motor assembly.
Abnormal pressure in the casing.
Check the pressure in the casing and measure the drain volume.
45 - 10 - 03/2
Set the pressure in the casing below 3 kg/cm2 (43 lbf/in2) Disassemble and inspect if drain volume is excessive.
Renew the oil seal. Repair or renew the damaged parts. Renew the motor assembly.
Issue 1
Excavators
CONTENTS
45 - 10 - 03/3
JS 200 from m/c no. 705001, JS 240 from m/c no. 708501 Fault Finding - Swing Gearbox (contÕd)
Oil leakage from mating surfaces
Abnormal noise
Insufficient torque
Symptom
Cause
External Inspection
Countermeasure
Wear or seizure of the motor sliding surfaces.
Open motor inlet and outlet ports and apply 20 kgf/cm2 (284 lbf/in2) pilot pressure to the brake release port. Try to rotate the shaft with a torque of approx. 39.32 Nm (28.93 lbf ft).
High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect.
Relief valve in the circuit is not set correctly.
Measure relief pressure.
Reset to the prescribed setting.
Internal damage to the motor.
Check if any metallic matter is deposited in the motor drain oil or drain filter.
High possibility of internal damage to the motor if metallic matter is discovered. Dismantle and inspect.
Large amount of air mixed in the oil.
Check the oil in the tank and motor casing.
Thoroughly bleed the air.
Loosening of bolts or pipes
Check if the piping connections, attachment mounting bolts, motor attachment bolts or other bolts are loose.
Tighten to the specified torque.
Repair Inspect the parts and bearing according to Table 2 a-e and renew any defective parts.
Repair or renew damaged parts. Renew the motor assembly.
O-ring is damaged
Renew O-rings.
Seal face is damaged.
Repair seal face or renew.
Bolts are loose.
Check the bolt tightness.
Tighten the bolts to the correct torque.
Table 2. No.
Part Inspected
Repair
a
Wear of the sliding surface of balance plate 21. †
Repair or renew the part
b
Damage to sliding surface of swash plate 6. †
Repair the part or renew the motor.
c
Damage to sliding surface of the piston assemblies 8. †
Repair the part or renew the motor.
d
External wear to the piston assemblies 8. †
Repair the part or renew the motor.
e
Wear to piston bores in cylinder assembly 24. †
Renew the motor.
f
Damage to Teflon rings 19 or ‘O’-rings 52. †
Renew the part.
Note: † refers to Service Manual
9804/1103
45 - 10 - 03/3
Issue 1
Excavators
CONTENTS
45 - 10 - 03/4
JS 70 from m/c no. 695501 Fault Finding - Swing Motor Table 1.
Leakage from oil seals
Abnormal heating
Excessive slip
Motor does not run
Symptom
9804/1103
Cause
External Inspection
Countermeasure
Repair
Internal damage to the motor.
Measure the oil drain volume.
High possibility of damage to the sliding surfaces if the supply volume is approximately equal to the drain volume. Dismantle and inspect.
Refer to Table 2.
Internal damage to the motor.
Open the motor inlet and outlet ports and apply 40 kgf/cm2 (569lbf/in2) pilot pressure to the brake release port. Try to rotate the shaft with a torque of approx. 24.40 Nm (18 lbf ft).
High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect.
Renew damaged parts or renew the motor assembly.
Relief valve in circuit not set correctly.
Measure pressure.
Reset to the prescribed setting.
Wear or damage to the motor sliding surfaces or to the high-pressure seal.
Measure the oil drain volume.
Leakage is too high if the oil drain volume exceeds 5 l/min (1.1 gal/min). Dismantle and inspect.
Refer to table 2.
Oil hot and excessive leakage in the motor.
Measure the oil temperature.
Reduce the oil temperature.
Refer to table 2.
Seizure of motor sliding parts or circuit.
Check for any metallic matter deposited in motor drain oil or drain filter. Apply a 40 kgf/cm2 (569 lbf/in2) pilot pressure to the brake release port and try to rotate the shaft with a torque of approx. 24.40 Nm (18 lbf ft).
If metallic matter is discovered or the supply shaft does not rotate smoothly when torque is applied, there is a high possibility of internal damage to the motor. Dismantle and inspect.
Repair or renew the damaged parts. Renew the motor assembly.
Damage or wear to oil seal lip.
Renew the oil seals.
Damage or wear of the shaft seal.
Repair the problem or renew the motor assembly.
45 - 10 - 03/4
Issue 1
Excavators
CONTENTS
45 - 10 - 03/5
JS 70 from m/c no. 695501 Fault Finding - Swing Motor (contÕd)
Oil leakage from mating surfaces
Abnormal noise
Insufficient torque
Symptom
Cause
External Inspection
Countermeasure
Wear or seizure of the motor sliding surfaces.
Open motor inlet and outlet ports and apply 40 kgf/cm2 (569 lbf/in2) pilot pressure to the brake release port.Try to rotate the shaft with a torque of approx. 24.40 Nm (18 lbf ft).
High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect.
Relief valve in the circuit is not set correctly.
Measure relief pressure.
Reset to the prescribed setting.
Internal damage to the motor.
Check if any metallic matter is deposited in the motor drain oil or drain filter.
High possibility of internal damage to the motor if metallic matter is discovered. Dismantle and inspect.
Large amount of air mixed in the oil.
Check the oil in the tank and motor casing.
Thoroughly bleed the air.
Loosening of bolts or pipes
Check if the piping connections, attachment mounting bolts, motor attachment bolts or other bolts are loose.
Tighten to the specified torque.
Repair Inspect the parts and bearing according to Table 2 a-e and renew any defective parts.
Repair or renew damaged parts. Renew the motor assembly.
O-ring is damaged
Renew O-rings.
Seal face is damaged.
Repair seal face or renew.
Bolts are loose.
Check the bolt tightness.
Tighten the bolts to the correct torque.
Table 2. No.
Part Inspected
Repair
a
Wear of the sliding surface of balance plate 7. †
Repair or renew the part
b
Damage to sliding surface of swash plate 20. †
Repair the part or renew the motor.
c
Damage to sliding surface of the piston assemblies 18. †
Repair the part or renew the motor.
d
External wear to the piston assemblies 18. †
Repair the part or renew the motor.
e
Wear to piston bores in cylinder assembly 16. †
Renew the motor.
f
Damage to Teflon ring 13 . †
Renew the part.
Note: † Refers to Service Manual.
9804/1103
45 - 10 - 03/5
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 03/6
JS 200W from m/c no. 809000 Fault Finding - Swing Gearbox Symptom 1
Output gear not turning
a
Relief valve is blowing.
Possible cause
Remedy
1
Overload.
1
2
Brake not releasing.
2a Check release pressure.
Reduce the load.
2b Release brake and check brake condition.
b
Gearbox damaged.
3
Renew or repair the gearbox.
1
Broken motor shaft.
1
Renew motor.
2
Gearbox damaged.
2
Renew or repair the gearbox.
1
Pump or valves defective.
1
Check flow through pump, valves etc.
1
Gasket damaged or not installed.
1
Renew gasket.
2
Loose fasteners.
2a Tighten fasteners.
Relief valve is not blowing. 1 Motor can be heard turning.
2 Motor cannot be heard turning.
2
3
Oil Leakage a Oil leaking from joints.
2b Dismantle joint, renew gasket and re-assemble correctly.
b Oil leaking at shaft.
9804/1103
3
Damaged joint faces.
3
1
Oil seal damaged.
1
45 - 10 - 03/6
Dismantle joint, renew damaged parts, renew gasket and reassemble correctly.
6320-F/11-1.1
Renew the seal.
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 05/1
JS 130 from m/c no. 75800, JS 160 from m/c no. 702000 Fault Finding - Pump As a first step towards locating a fault, carry out the following checks. 1
Check the hydraulic filter for the presence of excessive foreign materials. The nature of the foreign materials could yield a clue as to the source of damage or wear.
2
Check the flow rate and condition of the oil drained from the pump.
3
Check for abnormal sounds and vibration.
4
Check the pressure at each of the pump pressure test points.
Symptom 1
2
No oil is delivered from the pump.
Low pump flow rate, or circuit pressure does not build-up.
Possible cause a
Suction strainer or suction line is blocked.
Clean the suction strainer or clear the suction line.
b
The suction strainer is above the oil level of the tank.
Top up the hydraulic oil tank and bleed air from the system.
c
The pump itself is faulty.
Dismantle and renew worn or damaged parts.
a
Incorrect operation of various control valves or hydraulic motors served by the pump, causing low flow rate or loss of pressure.
Renew or inspect and repair the defective control valve or hydraulic motor.
b
The sliding area of the pump is worn, allowing a large amount of pressurised oil to escape from the drain port.
Dismantle the pump and, if possible, polish or repair by lapping.
Air is being drawn into the pump.
i
Check the hydraulic connections for looseness and tighten if necessary.
ii
Check the hydraulic lines and seals for damage.
c
9804/1103
Remedy
If repair is not possible fit new parts.
d
The suction strainer is blocked or above the oil level of the tank.
Clean the suction strainer or, if necessary, renew. Top up the hydraulic oil tank and bleed air from the system.
e
Excessive suction resistance.
Check for abnormal oil temperature or viscosity, or other factors causing cavitation. Take the necessary remedial steps.
45 - 10 - 05/1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 05/2
JS 130 from m/c no. 75800, JS 160 from m/c no. 702000 Fault Finding - Pump (continued) Symptom 3
4
5
Pump is producing abnormal noise.
Engine overload - engine operates at extremely low speeds or stops.
Oil leakage.
9804/1103
Possible cause
Remedy
a
Air is being drawn in due to low oil level in the hydraulic oil tank.
Top up the hydraulic oil and bleed air from the system.
b
Pump cavitation due to a clogged suction strainer.
Clean the strainer. If excessively clogged, flush the hydraulic system and/or renew the hydraulic oil
c
Excessively low oil temperature, or pump cavitation due to high viscosity.
Check that the correct hydraulic oil for the ambient conditions is being used. If not, renew the oil.
d
Resonance with external parts.
Check mounting bolts and tighten if necessary.
a
The torque regulator is set too high.
Readjust the regulator.
b
The filter incorporated in the pump is clogged.
Clean the filter. If excessively clogged, flush the hydraulic system and/or replace the hydraulic oil.
c
The pilot oil passage and orifice inside the regulator are clogged, or some parts are thermally seized or damaged.
Readjust the regulator. If no changes are observed, dismantle the regulator for inspection and repair.
d
Seizure or wear of pump internal parts.
Dismantle and renew worn or damaged parts.
a
Oil seal failure originating from an increased drain flow and raised pump internal pressure.
Dismantle and renew the oil seal, taking particular care not to damage the lip when fitting the new oil seal.
b
Oil seal failure originating from restricted drain line and raised pump internal pressure.
Change the drain lines so that pressure no higher than 3 bar (43 lb/in 2 ) is exerted on the oil seal. Renew the oil seal. (Take particular care not to damage the lip when fitting the new oil seal.)
45 - 10 - 05/2
Issue 1
Excavators
CONTENTS
45 - 10 - 06/1
JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 Fault Finding - Pump Often the regulator and attendant valves or pump are combined which makes it very difficult to discover the reason for the trouble. Inspect the following categories which will assist in discovering the abnormal point. 1. Filter and Drain Oil Inspection. Inspect the filter element. Check to see whether there is an abnormally large amount of foreign matter. There will be a small amount of metallic powder due to wear of the shoe or cylinder, but if there is a large amount of metallic powder in the filter, it may be due to trouble with the shoe. Also check the drain oil in the pump casing. 2. Abnormal Vibration and Sound. Check to see if there is any abnormal vibration or sound in the pump main body. Check to see if it is like the regular frequency sound of the regulator's working or attendant valve relief working. If it is an abnormal vibration or sound, it is possible that there is damage or cavitation inside the pump. 3. Measure Pressure of Each Part. When it is a control problem, do not unnecessarily open ports for inspection purposes, measure the pressure for each section and find the abnormal item.
Prime Mover Overload Cause
Treatment
Note
1. Are the revolutions - pressure higher than pre-determined values?
1. Set to pre-determined value.
2. Is the regulator torque setting too high?
2. Re-inspect regulator.
2. Refer to regulator instructions.
3. Seizure or damage of pumps internal parts
3. Replace damaged parts.
3. Check the filter or drain oil for signs of abnormal wear.
4. Wrong regulator hose connection.
4. Correct hose lines.
* When pump flow is extremely low, delivery pressures do not increase Cause
Treatment
Note
1. Regulator breakdown
1. Repair the regulator
1. Refer to regulator instructions
2. Seizure or damage of pump internal parts.
2. Replace damaged parts.
2. Check filter, drain oil.
3. Pump breakdown.
3. Replace damaged parts.
3. Remove pump and inspect shaft coupling.
4. Attendant valve breakdown.
4. Inspect attendant valve.
5. Incorrect regulator hose connection.
5. Correct hose lines.
9804/1103
45 - 10 - 06/1
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 10 - 06/2
JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 Fault Finding - Pump (continued) Abnormal Sound and Vibration Cause
Treatment
1. Cavitation.
1. Prevent cavitation. Check to see if hydraulic oil is white and cloudy.
2. Damage of shoe caulking part.
2. Replace piston, shoe, shoe plate.
3. Crack in cylinder.
3. Replace cylinder.
4. Bad installation of pump.
4. Correct installation.
5. Relief valve bouncing.
5. Repair relief valve.
9804/1103
45 - 10 - 06/2
Note 1.1. Boost pressure is low 1.2. Pump is broken. 1.3. Air is sucked by suction pipe. 1.4. Suction resistance is high.
5. Refer to relief valve instructions.
Issue 1
Excavators
CONTENTS
45 - 10 - 06/3
JS 330 from m/c no. 712501 JS 450 from m/c no. 714501 * JS 460 from m/c no. 714550 Fault Finding - Hydraulic Pump/Regulator As a first step towards locating a fault, carry out the following checks. 1
Check the hydraulic filter for the presence of excessive foreign materials. The nature of the foreign materials could yield a clue as to the source of damage or wear.
2
Check the flow rate and condition of the oil drained from the pump.
3
Check for abnormal sounds and vibration.
4
Check the pump pressure. Symptom 1
2
Abnormal noise.
Insufficient flow amount.
9804/1103
Possible cause
Remedy
a
Air suction due to low hydraulic fluid level.
Top-up hydraulic tank.
b
Suction pressure drop increase due to filter clogging.
Clean or renew element.
c
Suction pressure drop increase due to increased viscosity of hydraulic fluid at low temperature.
Clean the cooler/fill with suitable fluid.
d
Input shaft rotation speed abnormally high.
Adjust rotation speed.
e
Bearing etc. mechanically.
Renew damaged parts or pump. Reset pressure. Flush the circuit. Change hydraulic fluid.
a
Input shaft rotation speed low.
Adjust rotation speed.
b
Hydraulic fluid temperature abnormally high.
Stop operation and recheck flow after fluid temperature has dropped.
c
Viscosity abnormally high.
Fill with hydraulic fluid of suitable viscosity.
d
Switching valve, actuator leakage amount increase.
Renew switching valve and actuator.
e
Pump displacement efficiency low.
Renew pump.
f
Horsepower setting adjustment screw loose.
Reset and lock.
g
Air suction due to low hydraulic fluid level.
Top-up hydraulic fluid.
h
Suction pressure drop due to filter clogging.
Clean or renew element.
i
Suction pressure drop due to increased viscosity of hydraulic fluid at low temperature.
Clean the cooler/fill with suitable fluid.
j
External command pressure too high.
Adjust external command pressure.
45 - 10 - 06/3
damaged
6420-E/12-1.2
Issue 2*
Excavators
CONTENTS
45 - 10 - 06/4
JS 330 from m/c no. 712501 JS 450 from m/c no. 714501 * JS 460 from m/c no. 714550 Fault Finding - Hydraulic Pump/Regulator (cont’d) Symptom 3
4
Pressure does not increase.
Overload at static load.
5
Rotation speed dynamic load.
6
Overheating.
7
Possible cause
Oil leakage
9804/1103
falling
at
Remedy
a
Relief valve setting low.
b
Switching valve, leakage increase.
c
Pump displacement efficiency low.
Renew pump.
a
Pump horsepower increases.
Adjust pump horsepower setting.
b
Control device does not work.
Repair damage caused or renew.
c
Bearing, etc. mechanically damaged.
Renew damaged parts or the pump.
a
Peak pressure occurs due to failure of relief valve/control device.
Renew relief valve/control device. Remove foreign matter. Repair damage caused by foreign matter or renew.
a
Increase of pump leakage.
Renew pump.
b
Mechanical damage of the bearing etc.
Renew damaged parts or pump.
c
Seizure of sliding parts.
Renew damaged parts or pump.
a
Damage to O-ring, packing.
Renew seals.
b
Damage to oil seal.
Renew seal.
c
Wear to oil seal due to contact with input shaft.
Renew input shaft or pump.
d
Looseness of plugs.
Tighten or renew seals.
45 - 10 - 06/4
Reset relief valve. actuator
setting
Renew switching valve, actuator.
6420-E/12-2.2
Issue 2*
CONTENTS
Excavators
45 - 10 - 06/5
JS 330, JS 460 Fault Finding - Hydraulic Regulator (cont’d) Regulator Trouble Shooting Engine Overloads Put a load on each pump to determine if the front or rear pump is malfunctioning. If both pumps are abnormal, check 1 and 2. If only one pump is abnormal, begin with 3. 1
Check to see if the power shift command current value I is norrmal or not.
2
Power shift pressure is too low
Check the fluctuation of solenoid current. Renew the proportional pressure reducing valve. 3
Disassemble and clean the compensatory piston, compensatory rod.
4
Disassemble and clean the pin (898).
Maximum Flow Rate Is Not Achieved 1
Confirm that the pilot pressure Pi is normal or not.
2
Disassemble and clean the pilot piston.
3
Disassemble and clean the piston (648).
4
Disassemble and clean the spool.
Note: If any of the parts shows wear of scratches replace it.
Checking the Proportional Solenoid Current Service Procedure Method 1 Refer to Self Test, Test Function, Pump Input Amperage.
Method 2 1
Switch engine off.
2
Pull apart bullet connector on any of the two wires leading from the Proportional Solenoid on the Hydraulic Pump.
Note: Depending on which wire is disconnected will determine the polarity of the current reading. 3
Insert an appropriate Multimeter in series between the bullet connector and the wire that has been disconnected.
4
Ensure that the Multimeter is scaled to mAmps not Amps.
5
Switch engine on to maximum revs.
6
Measure the current at the Proportional Solenoid.
9804/1103
45 - 10 - 06/5
6420 - E/21-1.1
Issue 1*
Excavators
CONTENTS
45 - 10 - 07/1
JS 130 from m/c no. 758001, JS160 from m/c no. 702000 JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 JS 200W from m/c no. 809000 JS 330 from m/c no. 712501, JS 450 from m/c no. 714501 * JS 460 from m/c no. 714550 Fault Finding - Remote Control Valve Symptom 1
2
3
Low secondary pressure.
Unstable secondary pressure.
High secondary pressure.
9804/1103
Possible cause
Remedy
a
Primary pressure is low.
Apply the correct primary pressure.
b
Spring is damaged.
Renew the spring.
c
Clearance between the spool and seating is too large.
Renew the remote control valve assembly.
d
The handle unit is loose.
Dismantle, reassemble or renew the handle unit.
a
Sliding parts are sticking.
Release the sticking part.
b
Fluctuations in the tank line pressure.
Check return line and filter for blockage.
c
Air is trapped in the piping.
Operate the valve several times to remove the air.
a
The tank line pressure is too high.
Check return line and filter for blockage.
b
Sliding parts are sticking.
Release the sticking part.
45 - 10 - 07/1
6420 - E/42-1.3
Issue 3*
Excavators
CONTENTS CONTENTS
45 - 10 - 07/2
JS 70 from m/c no. 695501 JS 200, 220 from m/c no. 705001 JS 240, 260 from m/c no. 708501 Fault Finding - Control Valve Symptoms Spool sticking
Possible Causes
Countermeasures
1. Oil temperature is abnormally high.
Remove the obstruction.
2. Hydraulic oil is dirty
Replace the hydraulic oil and clean the circuit at the same time.
3. Port connector is tightened too much
Check the torque.
4. Valve housing is deformed due to Installation
Loosen the installation bolt and check.
5. Pressure is too high
Attach pressure gauge to pump port and ram port and check the pressure.
6. Spool is bent
Replace the valve assembly.
7. Return spring is damaged
Replace the damaged parts.
8. Spring or cap is not on straight
Loosen the cap and after aligning, tighten.
9. Temperature inside valve is not even.
Warm up the circuit.
Spool does not stroke
1. Valve is clogged inside with dirt
Remove the dirt (flushing).
Load cannot be maintained
1. Oil leakage from the ram
Check the ram.
2. Oil is by-passing from the valve spool
Replace the valve assembly.
3. Oil leakage from the port relief valve
Remove the port relief from the housing and clean the housing seat and relief valve seat.
4. Oil leakage from the lock valve
Disassemble the lock valve and clean the poppet seat and sleeve, plug seat. If the seat is damaged, replace the poppet, or lap the poppet and seat.
1. Foreign matter in load check valve
Disassemble the check valve and clean.
2. Check valve poppet or seat damaged
Replace the poppet or lap the poppet and seat part.
When the spool is selected from neutral to raise position, the load falls.
9804/1103
45 - 10 - 07/2
6020 - E/32-1.1
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 07/3
JS 70 from m/c no. 695501 JS 200, 220 from m/c no. 705001 JS 240, 260 from m/c no. 708501 Fault Finding - Control Valve (cont’d) Relief Valve Symptoms Pressure does not rise at all
Possible Causes 1. The main poppet, sleeve or pilot poppets are sticking open or foreign matter is in the valve seat.
Countermeasures Check whether foreign matter is in each poppet. Check whether each part is sliding smoothly. Clean all the parts.
Relief pressure is unstable
Relief pressure is out of control
Oil leakage
1. The pilot poppet seat is damaged.
Replace the damaged parts.
2. The piston is sticking to the main poppet.
Remove the surface scratches. Clean all the parts.
1. Wear due to foreign matter.
Replace the worn parts
2. Lock nut and adjuster are loose.
Reset the pressure and tighten the lock nut to the rated torque.
1. Damaged seat or worn O-ring.
Replace damaged or worn parts. Check whether each part is sliding smoothly.
2. Parts are sticking due to foreign matter.
Check for scratches, cuts or foreign matter. Clean all the parts.
Hydraulic System Symptoms The hydraulic system is not working well or not at all
9804/1103
Possible Causes
Countermeasures
1. Pump problem.
Check the pressure or replace the pump.
2. Foreign matter clogging inside the relief valve.
Disassemble the relief valve and clean.
3. Relief valve trouble.
Check according to the maintenance procedures.
4. Ram trouble.
Repair or replace.
5. Load is too heavy.
Check the circuit pressure.
6. Crack in the valve.
Replace the valve assembly.
7. Spool does not stroke fully.
Check the spool movement and operation link.
8. Oil level too low.
Replenish hydraulic oil.
9. Filters inside circuit are clogged.
Clean filter or replace.
10. Hose runs are kinked.
Check the hoses.
45 - 10 - 07/3
6020 - E/32-2.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 07/4
JS 70 from m/c no. 695501
Shut off Valve 2
Shut off Valve 1
Check Valve
Relief Valve
Fault Finding - Multiple Valve Trouble
Causes
Solutions
Set pressure is high
Back pressure on port T. Small hole in the Poppet 4 is blocked.
Adjust the port T back pressure. Dismantle and clean valve, reassemble.
Set pressure is low
Spring setting 19 Small hole in the Poppet 4 is blocked.
Replace the spring or add shim. Dismantle and clean valve, reassemble.
Does not relieve pressure
Malfunction of the poppet 4
Dismantle and clean valve, repair/replace if any fault identified.
The leakage value from the ACC port P1 or P2 is more than normal.
Damage to the check seat section 8 or contamination.
Dismantle and clean valve, Check the bearing, repair/replace.
Does not return to neutral.
Malfunction of the solenoid valve 2 Malfunction of the spool 18
Refer to solenoid valve section. Dismantle and clean valve, repair/replace if any fault identified. Replace the spring.
Spring 9 defective
Does not return to neutral.
Spring 7 defective
Pressure Reducing Valve 2
During Operation Set pressure is low
Low inlet pressure Malfunction of the spool 13 Spring 21 defective
Set pressure is high
Adjust the relief valve. Dismantle and clean valve, repair/replace if any fault identified. Replace the spring or add shim 1.
Back pressure at port T Malfunction of the solenoid valve 2
During Locking No inlet pressure
Malfunction of the solenoid valve 2
Refer to solenoid valve section.
The leakage value is more than normal.
Damage to the seat section or contamination.
Dismantle and clean valve, Check the bearing, repair/replace.
Defective operation
Low voltage Malfunction of the solenoid coil 20 Malfunction of the spools 23 and 24
Ensure correct voltage. Replace coil Dismantle and clean valve, repair/replace if any fault identified. Replace the spring.
9804/1103
Malfunction of the spool 13
Dismantle and clean valve, repair/replace if any fault identified. Replace the spring.
Dismantle and clean valve, repair/replace if any fault identified. Adjust the port T back pressure. Refer to solenoid valve section.
Solenoid Valve
Shuttle Valve
Malfunction of the spool 16
Spring 6 defective
45 - 10 - 07/4
6020 - E/60-3.1
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 08/1
JS 70 from m/c no. 695501 JS 130 from m/c no. 75800, JS 160 from m/c no. 702000 * JS 130W from m/c no. 716500, JS 160W from m/c no. 718500 JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 *
Fault Finding - Rams The chart below lists some possible problems and suggested remedies. The types of problems fall into four main categories as follows:
Item
Item Symptoms
Symptoms
1
Oil leakage from piston rod sliding part.
2
Oil leakage from cylinder head joint.
3
Oil leakage from pipe and cylinder tube welds.
4
Faulty operation
Related Parts
Trouble On the sliding surface, there are scratches and rust that can be felt by the fingernail.
Treatment 1 Use an oil stone and remove the scratch and make the sliding surface smooth. If oil leakage continues even though the rod surface is made smooth, the scratch may have damaged the U-ring and other seals, so dismantle and inspect.
Piston rod 2 If the scratches and rust cover such a wide area that they cannot be repaired by an oil stone, renew the piston rod and U-ring, wiper ring and seals and the piston rod bearing member.
1
Piston rod sliding part oil leakage
Rod packing (Buffer ring U-ring)
The plating is peeling.
Re-plate or renew the piston rod. Also inspect the seal and piston rod bearing member and renew if damaged.
Foreign matter is biting into the inner and outer surfaces of the packing.
Remove foreign matter. If there is damage to packing, renew it.
There is a scratch on the inner surface.
Renew.
The lip and groove parts are locally carbonised (burned).
9804/1103
45 - 10 - 08/1
Possibly due to burning caused by adiabatic compression from air remaining inside the ram. After renewing the packing, first operate the ram at low-pressure, low speed to sufficiently
Issue 2*
Excavators
CONTENTS CONTENTS
45 - 10 - 08/2
JS 70 from m/c no. 695501 JS 130 from m/c no. 75800, JS 160 from m/c no. 702000 * JS 130W from m/c no. 716500, JS 160W from m/c no. 718500 JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 *
Fault Finding - Rams (continued)
Item Symptoms
Related Parts
Trouble Packing rubber is perished.
Treatment The packing life or hydraulic oil deterioration and high temperature are possible reasons. 1 Renew hydraulic oil.
Rod packing (Buffer ring, U-ring)
2 Check the hydraulic oil temperature. (Below 80 °C is advisable). 3 Check if high temperature locally. Lip is deficient all around.
Renew. It is possible that abnormally high pressure is working on the packing. 1 Check the operation pressure, cushion pressure. 2 Part which is attached to the buffer ring may be abnormal. Inspect the buffer ring.
The protrusion of the heel of the packing is excessive. 1
Piston rod oil leakage
Back up ring
As a rule, renew the rod packing at the same time. (It is desirable to renew parts which are attached to the buffer ring at the same time). It is possible that abnormally high pressure is the cause. Check the same as above (heel of packing protruding).
Wiper ring
Bushing
Cylinder head
9804/1103
Foreign matter is biting into the lip. The lip is damaged.
Remove the foreign matter.
There is also other abnormal damage.
Renew.
Wear is excessive and the clearance Renew. with piston rod exceeds the *maximum permissible value. (*Refer to maintenance standards for maximum permissible value.) Large scratch on the sliding part.
Renew. Also inspect the piston rod.
Scratches, rust on the seal attachment parts.
Remove scratch, rust with oil stone. If it cannot be repaired, renew the cylinder head.
45 - 10 - 08/2
Issue 2*
Excavators
CONTENTS CONTENTS
45 - 10 - 08/3
JS 70 from m/c no. 695501 JS 130 from m/c no. 75800, JS 160 from m/c no. 702000 * JS 130W from m/c no. 716500, JS 160W from m/c no. 718500 JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 *
Fault Finding - Rams (continued)
Item Symptoms
Related Parts
Trouble Foreign matter on inner and outer diameters. O-ring damaged.
‘O’-ring
Back up ring
2
Oil leakage from cylinder head joint
Treatment • Remove foreign matter. • Renew 'O'-ring if damaged. • Inspect inside tube: if any scratches or rust, make surface smooth with oil stone. • Inspect cylinder head 'O'-ring groove: if any scratches or rust, make surface smooth with oil stone. • Inspect back up ring: if any deformation or protrusion, renew. Confirm the above and renew 'O'-ring.
Deformation, protrusion
• Renew, with the 'O'-ring.
Looseness
• Dismantle cylinder head and inspect 'O'-ring and back up ring. • Check tube and cylinder head thread for damage. If any damage, renew.
Cylinder head
• After inspection, tighten to specified torque. Bolt
Looseness, stretching, broken
Renew all bolts and tighten to specified torque.
Abnormal bulge
Replace with new parts. Oil leakage from connecting parts may be caused by abnormal pressure (including cushion pressure). Inspect the tube for bulges, deformation and check the circuit pressure.
Cylinder tube
Crack in welding
3
Oil leakage from pipe and cylinder tube welded seam
9804/1103
Replace with new parts. • Cracks will develop into fractures. Fractures are very dangerous, so if any cracks are found, stop work immediately and replace with new parts. • Welding on top of cracks will have no effect.
Cylinder tube pipe (hollow piston rod)
45 - 10 - 08/3
Issue 2*
Excavators
CONTENTS CONTENTS
45 - 10 - 08/4
JS 70 from m/c no. 695501 JS 130 from m/c no. 75800, JS 160 from m/c no. 702000 * JS 130W from m/c no. 716500, JS 160W from m/c no. 718500 JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 *
Fault Finding - Rams (continued)
Item Symptoms Poor operation
4-1 Movement not smooth
Related Parts
Piston rod cylinder tube
4-2 Inner oil leakage. Piston rod extends when work stops or lowers abnormally during work. Also, specified operating speed is not achieved.
Treatment
Bending to more than the specified limit. (Bending distortion: refer to maintenance standards)
• Replace with new part. The seal and sliding part material may be damaged too, so inspect. If abnormal, renew.
Tube scored
• Replace with new part. As above, inspect the seal and sliding part material.
Abnormal wear, damage of sliding area
• Replace with new part. As above, inspect the seal and sliding part material. • Remove foreign material. As above, inspect the seal and sliding part material.
Cylinder tube
Piston rod cylinder rod sliding part
4
Trouble
Foreign matter intruding on piston and cylinder head sliding area
Scratches, wear are present
• Replace with new part. Inspect the cylinder tube inner surface also.
Scratches, rust on inside
• Remove the scratches, rust by honing or with an oil stone and make the surface smooth. If the scratch is deep and cannot be repaired, renew cylinder tube.
Piston seal
Cylinder tube
• Renew piston seal. Piston nut Valves
Loose nut
• Tighten to specified torque.
Leak from valve
• Inspect the valve leakage amount and service.
Note: Hydraulic oil expands and contracts due to changes in temperature and pressure. Accordingly, the ram also expands and this can be mistaken for internal leakage. When inspecting for internal leakage, do so at set conditions.
9804/1103
45 - 10 - 08/4
Issue 2*
Excavators
CONTENTS CONTENTS
45 - 10 - 08/5
JS 70 from m/c no. 695501 JS 130 from m/c no. 75800, JS 160 from m/c no. 702000 * JS 130W from m/c no. 716500, JS 160W from m/c no. 718500 JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 *
Fault Finding - Rams (continued)
Item Symptoms
Related Parts
4-3
Trouble
Treatment
Air remaining inside ram. Operation is unsteady
• Bleed the air. For rams that do not have an air bleeder, operate back and forth several times at low pressure and low speed to bleed the air. For rams with an air bleeder, remove the load to reduce the pressure then loosen the air bleeder and completely bleed the air.
Air
Note: The ram may expand if it is stopped suddenly. This is due to the compression of the hydraulic oil. This occurs especially with long stroke rams. 4 4-4 Heavy shock loading when changing from extension to retraction and back 4-5 Noisy operation
Pin bushing/pin
Oil supply Pin bushing/pin
Gap between mounting and pin bushing is too large.
Measure the pin and pin bushing and renew parts if measurements exceed the specifications.
Insufficient oil.
• Add oil.
Scuffing at connecting part.
• Replace with new part and add oil.
Note: If left in the state where operation is poor, the ram will no longer move and other parts will be affected adversely. Inspect early and carry out appropriate measures.
9804/1103
45 - 00 - 08/5
Issue 2*
Excavators
CONTENTS CONTENTS
* *
45 - 10 - 09/1
JS 70 from m/c no. 695501 JS 130 from m/c no. 758000, JS 160 from m/c no. 702000 Fault Finding - Track Motor/Gearbox Symptom 1 Motor does not start - no oil pressure present.
2 Motor does not start - oil pressure present.
3 Oil leakage from mating surfaces.
4 Oil leakage from case.
5 Oil leakage from floating seal.
6 Oil leakage from hydraulic motor.
7 Slips down on slope.
9804/1103
Possible cause
Remedy
a Low relief valve set pressure.
Set correct pressure.
b Pump failure.
Check operation of services other than travel. Repair pump if necessary.
c Direction switching valve failure.
Check spool for damage. Repair if necessary.
a Brake valve failure
If spool or valve is thermally seized, repair or renew.
b Hydraulic motor failure.
Check hydraulic oil and renew if necessary.
c Gear teeth are broken.
Dismantle reduction gear and renew broken parts.
d Overloaded.
Remove load.
a Mating surface is scratched.
Lap surfaces using wet stone or emery paper.
b Bolts loose.
Tighten bolts and recheck.
a Plug is loose.
Tighten plug.
b Cracks caused by stone, etc.
Dismantle reduction gear and renew damaged parts.
a Sliding surface is worn.
Dismantle reduction gear and renew damaged parts.
b Seepage past ‘O’-ring.
Dismantle reduction gear and renew damaged parts.
a Mounting bolts loose.
Retighten bolt(s).
b ‘O’-ring is damaged.
Renew ‘O’-ring.
c Seal surface is scratched.
Lap surface using wet stone or emery paper.
a Poor motor efficiency.
Renew traction motor.
b Excessive leakage inside brake valve.
Renew brake valve and/or rear flange.
c Parking brake spring broken.
Renew spring.
d Parking brake friction plate worn.
Renew friction plate and/or other plate
45 - 10 - 09/1
Issue 2*
Excavators
CONTENTS CONTENTS
* *
45 - 10 - 09/3
JS 70 from m/c no. 695501 JS 130 from m/c no. 758000, JS 160 from m/c no. 702000 Fault Finding - Track Motor/Gearbox Possible cause
Symptom
Remedy
a
Insufficient gear oil.
Top up oil
b
Pitching is generated in bearing.
Dismantle and renew damaged parts.
c
Entry of hydraulic oil into gear case.
Renew oil seal.
a
Uneven delivery flow between right and left sides.
Repair pump and/or regulator.
b
Uneven motor drain leakage between right and left sides.
Dismantle motor/reduction gear and repair.
a
Uneven delivery flow between right and left sides.
Repair pump and/or regulator.
b
Uneven motor drain between right and left sides.
Dismantle motor/reduction gear and repair.
c
Non-uniform operation of right and left brake valves.
Renew brake valve and/or rear flange.
d
Drop in relief pressure in right or left control valve.
Set correct pressure and/or renew relief valve.
a
Pump regulator and/or related parts faulty.
Repair regulator and/or related parts.
b
Leakage outside pump is excessive.
Repair or renew pump.
12 Does not speed up.
a
Internal leakage is excessive.
Dismantle reduction gear and repair.
13 Abnormal sound.
a
Motor or reduction gear is broken.
Dismantle motor and/or reduction gear and repair.
b
Vibration of pipework.
Clamp pipework securely.
a
Faulty operation of high pressure selection check valve.
Inspect and repair or renew if necessary.
b
Faulty operation of switching valve.
Check to see if spool is normal, and repair or renew if necessary.
c
Low pilot pressure.
Set to specified pressure.
d
Faulty operation of 2-speed switching piston.
Inspect and repair or renew if necessary.
8 High temperature of reduction gear case surface.
9 Does not travel in a straight line at ‘low speed’.
10 Does not travel in a straight line at ‘high speed’.
11 Does not speed up - pump delivery slow.
14 Does not change from low speed to high speed.
9804/1103
45 - 10 - 09/2
Issue 2*
Excavators
CONTENTS CONTENTS
* *
45 - 10 - 09/3
JS 70 from m/c no. 695501 JS 130 from m/c no. 758000, JS 160 from m/c no. 702000 Fault Finding - Track Motor/Gearbox (continued) Possible cause
Symptom 15 Does not change from high speed to low speed.
9804/1103
Remedy
a
Faulty operation of switching valve.
Check for spool damage. Repair or renew if necessary.
b
Faulty operation of 2-speed switching piston.
Inspect and repair or renew if necessary.
45 - 10 - 09/3
Issue 2*
Excavators
CONTENTS CONTENTS
45 - 10 - 10/1
JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 Fault finding - Track Motor/Gearbox Motor
Fault 1. Motor does not run
2. Motor revolution speed is insufficient
3. Motor revolution speed varies greatly
4. Oil leaks
9804/1103
Possible cause
Countermeasure or remedy
1. Device other than the piston motor or reduction gear may have malfunctioned.
Check whether or not the specified pressurised oil is delivered to the motor input side and then inspect each device and repair if necessary.
2. Sliding area of motor is abnormally worn allowing the pressurised oil to escape.
Replace the excessively worn part. Remove scratches and burrs from the surface and completely clean all parts. Reassemble the parts.
3. Improper operation resulting from damage of important motor part. In this case, abnormal noise is heard from the motor itself.
Disassemble and replace the damaged part. Completely clean all parts and reassemble.
4. Relief valve is activated because the motor is excessively loaded.
Check the load state and operate the machine under a load which matches the relief pressure.
1. Oil not supplied to motor at specified rate due to problems in hydraulic pump, pressure control valve, etc.
Check whether the specified pressurised oil is delivered to the motor input side and then inspect each device and repair if necessary.
2. Specified revolution speed cannot be achieved due to reduced volume efficiency of motor.
After disassembly, check for abnormal wear of the sliding area and repair or replace worn parts.
1. Pressurised oil escaping through the drain port due to wear on the sliding area of the motor. Also, revolution speed variation resulting from wear in the bearing.
Disassemble and replace excessively worn parts. Completely clean all parts and reassemble them.
2. Motor load is excessive and the automatic 2-speed function is working.
Check the load state and operate the machine under a load which matches the automatic 2-speed set pressure.
1. Oil leaks due to damage of the oil seals or 'O'-rings.
Replace a broken oil seal or 'O'-ring with a new one. When inserting the oil seal, be careful not to damage the lip. Since the safe working temperature limit of the oil seal and 'O'-ring is up to 80°C, it is necessary to take steps to prevent the hydraulic oil temperature from exceeding 80°C.
45 - 10 - 10/1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 10/2
JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 Fault finding - Track Motor/Gearbox (continued) Fault 4. Oil Leaks (continued)
Possible cause
Countermeasure or remedy
2. Motor case excessively pressurised resulting in oil leakage. Oil seal pressure resistance Ordinary 0.2 MPa {2 kgf/cm2} Maximum 0.5 MPa {5 kgf/cm2}
Repair the motor and replace oil seal. When inserting new oil seal, be careful not to damage the lip.
3. Due to clogging, etc. by foreign matter in drain pipe, pressure rises causing the oil seal to leak.
Clean the clogged drain piping. There should not be more than 0.3 MPa {3 kgf/cm2} pressure on the oil seal. Renew oil seal. When inserting new oil seal, be careful not to damage the lip.
Oil seal pressure resistance Ordinary 0.2 MPa {2 kgf/cm2} Maximum 0.5 MPa {5 kgf/cm2} 5. Abnormal noise, excessive revolution variation and pressure variation due to cavitation.
1. When the motor works as a pump, when the closed circuit is used, when the boost pressure is low (standard: 0.4~0.5 MPa {4~5 kgf/cm2}) or when the double counterbalance valve operates incorrectly, negative pressure is generated on the suction side of the motor, resulting in cavitation.
Recheck the hydraulic circuit and repair or replace the double counterbalance valve. Disassemble the motor and replace any abnormally worn or broken parts. After cleaning all parts, reassemble them.
Parking Brake Fault 1. Oil Leaks
2. Abnormal heat generated from brake drag.
9804/1103
Possible cause
Countermeasure or remedy
1. Disk is worn.
Replace the disk. Completely remove foreign matter and repair damaged areas. After cleaning, reassemble.
2. Disk surface has changed in quality or the contact is incorrect.
Grind and recondition the affected area. Reassemble after cleaning and replace if change in quality of the surface is excessive.
3. Spring is deformed or damaged.
Replace the spring. Completely remove foreign matter and reassemble after cleaning.
1. Brake release incorrect. 1) Oil leaks due to broken 'O'-ring. 2) Orifice is clogged.
45 - 10 - 10/2
Replace the broken 'O'-ring. Reassemble after cleaning.
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 10/3
JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 Fault Finding - Track Motor/Gearbox (continued) * Relief Valve Fault
Possible cause
Countermeasure or remedy
I. Motor does not run or rotation speed is slow.
1. Relief valve closing incorrectly. 1) Foreign matter is clogging components.
Completely remove foreign matter, repair damaged part and reassemble after cleaning. Replace if damage or leakage is excessive.
2) Spring is broken
Replace the spring. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive.
2. The cracking pressure of relief valve is low. 1) Spring is deformed 2) Poppet orifice is clogged II. Motor does not stop or stops slowly.
1. Relief valve closing incorrectly. 1) Foreign matter is clogging components.
2) Spring is broken.
2. The cracking pressure of relief valve is low. 1) Spring is deformed.
Replace relief valve sub assembly. After cleaning, reassemble.
Completely remove foreign matter, repair damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Replace the spring. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Replace relief valve sub assembly. After cleaning, reassemble.
2) Poppet orifice is clogged. III.Excessive shock when travel is stopped.
1. Shockless function does not work. 1) Foreign matter caught up in shockless piston section.
2) Spring is deformed. 3) Relief pressure set too high.
9804/1103
45 - 10 - 10/3
Completely remove foreign matter, repair damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Replace the spring. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Readjust the relief valve set pressure.
Issue 2*
Excavators
CONTENTS CONTENTS
45 - 10 - 10/4
JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 Fault Finding - Track Motor/Gearbox (continued) * Double Counterbalance Valve Fault
Possible cause
Countermeasure or remedy
1. Motor does not run or rotation speed is slow.
1. Plunger is not switched 1) Pressurised oil from the pilot not there. 2) Foreign matter caught between plunger and body.
Inspect the piping for damage.
3) Orifice is clogged.
4) Foreign matter caught between dumper piston and cap.
2. Motor does not stop or stops slowly.
1. Plunger does not return. 1) Foreign matter is caught.
2) Spring is broken.
3) Spring is not assembled correctly. 4) Orifice is clogged. 3. Rotation varies.
1. Plunger does not return. 1) Foreign matter is caught.
2) Orifice is clogged. 4. Abnormal noise is heard.
1. Plunger does not return. 1) Foreign matter is caught.
2) Spring is broken.
3) Orifice is clogged. 5. Travel not linear.
9804/1103
1. Dumper piston or cap is abnormally worn.
45 - 10 - 10/4
Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Reassemble after cleaning. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Replace spring. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Assemble spring in specified position. Reassemble after cleaning. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Reassemble after cleaning. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Replace spring. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Reassemble after cleaning. Replace dumper piston and cap. Completely remove foreign matter, repair the damaged part and reassemble after cleaning.
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 10 - 10/5
JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 Fault finding - Track Motor/Gearbox (continued) 2-Speed Control Function Fault 1. Travel is not linear
Possible cause 1. Plunger is not switched 1) Foreign matter is caught between plunger and body. * 2) Spring is not assembled correctly. 3) Spring is broken. * 4) Foreign matter is trapped in spool galleries.
2.Will not go into 2nd.
9804/1103
Completely remove foreign matter, repair the damage and reassemble after cleaning. Replace if damage or leakage is excessive. Assemble spring in specified position. * Renew spring. Completely remove foreign matter, repair the damage and reassemble after cleaning. Replace if damage or leakage is large.
2. Pressurised oil leaks due to abnormal wear of 2-speed control piston
Replace the 2-speed control piston. Completely remove foreign matter and reassemble after cleaning.
3. 2-speed control piston is not assembled correctly
Assemble 2-speed control piston to the specified position.
4. Steel ball is abnormally worn.
Replace steel balls. Completely remove foreign matter and reassemble after cleaning.
5. Set pressure is rising due to abnormal wear of spools.
Replace spool. Completely remove foreign matter and reassemble after cleaning.
6. The orifice of the 2-speed piston cavity drain is incorrect.
Confirm orifice diameter.
7. The orifice of the 2-speed piston cavity drain is clogged.
Reassemble after cleaning.
8. Number of washers is different and set pressure is different on the left and right.
Reassemble using correct number of washers.
1. Plunger is not switched 1) Foreign matter is caught between plunger and body. * 2) Foreign matter is trapped in spool galleries.
3.Will not go into 1st.
Countermeasure or remedy
Completely remove foreign matter, repair the damage and reassemble after cleaning. Replace if damage or leakage is excessive. Completely remove foreign matter, repair the damage and reassemble after cleaning. Replace if damage or leakage is excessive.
2. Pressurised oil leaks due to abnormal wear of 2-speed control piston.
Replace the 2-speed control piston. Completely remove foreign matter and reassemble after cleaning.
3. 2-speed control piston is not assembled correctly.
Assemble 2-speed control piston to the specified position.
4. The orifice of the 2-speed piston cavity drain is clogged.
Reassemble after cleaning.
1. Spring is not assembled correctly.
Assemble spring to specified position.
2. Spring is broken.
Replace spring. Completely remove foreign matter, repair the damage and reassemble after cleaning. Replace if the damage or leakage is excessive.
3. Set pressure is rising due to abnormal wear of spools.
Replace spool. Completely remove foreign matter, repair the damage and reassemble after cleaning. Replace if the damage or leakage is excessive.
45 - 10 - 10/5
Issue 1
Excavators
CONTENTS
45 - 10 - 10/6
JS 330 from m/c no. 712501, JS 450 from m/c no. 714501, JS460 from m/c no. 714550 Fault Finding - Track Motor/Reduction Gear 1
Traction Motor Symptom
a
b
c
d
e
Motor does not run.
Motor speed low.
Motor greatly.
speed
varies
1
Device external to the piston motor or reduction gear malfunctioning.
Check that the specified pressurised oil is delivered to the motor input side. Inspect all associated devices and repair if necessary.
2
Sliding area of motor is excessively worn, allowing pressurised oil to escape.
Renew the excessively worn part. Remove scratches and burrs from the surface and completely clean all parts. Reassemble.
3
Malfunction resulting from damaged motor part(s), resulting in excessive noise.
Dismantle and renew the damaged part(s). Completely clean all parts and then reassemble.
4
Relief valve operating due to excessive motor loading.
Check the load and only operate the machine with a suitable load.
1
Oil not supplied to motor at specified rate due to problems in hydraulic pump, pressure control valve etc.
Check that the specified pressurised oil is delivered to the motor input side. Inspect all associated devices and repair if necessary.
2
Volume efficiency of motor low.
After dismantling, check for abnormal wear of the sliding area and repair or renew the worn parts.
1
Large amount of pressurised oil escapes and flows out of the drain port due to wear on the sliding area of the motor.
Dismantle and renew excessively worn parts. Clean all parts and reassemble.
2
Wear in the bearings.
Renew motor bearings.
3
Motor load is excessive and automatic 2-speed function is operating.
Check the load and only operate the machine with a suitable load.
1
Oil leaks due to damaged oil seals or O-rings.
Renew damaged oil seals or O-rings. When fitting an oil seal, be careful not to damage the lip. Check the system to ensure the running temperature does not exceed 80 °C. Take the necessary steps to ensure the temperature remains within the acceptable range.
2
Refer to a2 and/or c1.
Refer to a2 and/or c1.
3
Clogging due to foreign matter in drain pipe or long, narrow pipes causing the oil seal to break.
Clean the clogged drain piping. Recheck the piping system and reduce the passage resistance. Renew the oil seal taking care not to damage the lip.
1
When the motor works as a pump, when the closed circuit is used, when the boost pressure is low (standard: 0.4 ~5 kgf/cm2) or when the double counterbalance valve operates improperly, negative pressure is generated on the suction side of the motor, resulting in cavitation.
Recheck the hydraulic circuit and by remedying or renewing the double counterbalance valve, prevent the generation of negative pressure. Dismantle the motor and renew any abnormally worn or broken parts. After cleaning all parts, reassemble.
Oil leaks.
Abnormal noise, excessive speed and pressure variation due to cavitation.
9804/1103
Remedy
Possible Cause
45 - 10 - 10/6
6420 - F/5-1.2
Issue 2*
Excavators
CONTENTS
45 - 10 - 10/7
JS 330 from m/c no. 712501, JS 450 from m/c no. 714501, JS460 from m/c no. 714550 Fault Finding - Track Motor/Reduction Gear (cont’d) 2
Parking Brake Symptom
a
Braking force is low or insufficient.
Remedy
Possible Cause 1
Friction plates worn.
Renew discs. Completely remove foreign matter and repair damaged areas. After cleaning, reassemble.
2
Counter places surface damaged or making poor contact.
Grind and recondition the affected area. Reassemble after cleaning. Renew plates if excessively damaged.
3
Spring is deformed or damaged. Renew the spring. Completely remove foreign matter and reassemble after cleaning.
b
Abnormal heat generated from brake drag.
9804/1103
1
Brake not releasing. i
Oil leaks due to broken O-ring.
Renew broken O-ring.
ii
Orifice is clogged.
Clean and reassemble.
45 - 10 - 10/7
6420 - F/5-2.2
Issue 3*
Excavators
CONTENTS CONTENTS
45 - 10 - 10/8
JS 330 from m/c no. 712501, JS 450 from m/c no. 714501 Fault Finding - Track Motor/Reduction Gear (cont’d) 3
Relief Valve Symptom
a
Motor does not run or rotation speed is slow.
1
2
b
c
Motor does not stop or stops slowly.
Motor does not run or rotation speed is slow.
1
Relief valve not closing fully: i
Foreign matter clogging components.
Completely remove foreign matter, repair damaged part and reassemble after cleaning. Renew if damage or leakage is excessive.
ii
Spring broken.
Renew the spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.
The cracking pressure of relief valve is low. i
Spring is deformed.
Renew relief valve sub-assembly.
ii
Poppet orifice is clogged.
After cleaning, reassemble.
Relief valve not closing fully. i
Foreign matter clogging components.
Completely remove foreign matter, repair damaged part(s) and reassemble after cleaning. Renew if damage or leakage is excessive.
ii
Spring broken.
Renew the spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.
2
Refer to 3a 2
1
Shockless function does not work.
Refer to 3a 2.
i
Foreign matter in piston section.
Completely remove foreign matter, repair damaged part and reassemble after cleaning. Renew if damage or leakage is excessive.
ii
Spring broken.
Renew the spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.
iii Relief valve pressure set too high.
9804/1103
Remedy
Possible Cause
45 - 10 - 10/8
Adjust the relief valve set pressure.
6420 - F/5-3.1
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 10/9
JS 330 from m/c no. 712501, JS 450 from m/c no. 714501 Fault Finding - Track Motor/Reduction Gear (cont’d) 4
Counterbalance Valve Symptom
a
b
c
d
e
Motor does not run or rotation speed is slow.
Motor does not stop or stops slowly.
Rotation varies.
Abnormal noise is heard.
Travel not linear.
9804/1103
Possible Cause 1
1
1
1
1
Remedy
Plunger not switching. i
External pilot pressure not present.
Inspect the piping for damage.
ii
Foreign matter between plunger and body.
Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.
iii Orifice clogged.
Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.
iv Foreign matter caught between dumper piston and cap.
Renew spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.
Plunger does not return. i
Foreign matter between plunger and body.
Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Renew if damage or leakage is excessive.
ii
Spring broken.
Renew spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.
iii Spring not fitted.
Fit spring in specified position.
iv Orifice clogged.
Reassemble after cleaning.
Plunger does not move smoothly. i
Foreign matter between plunger and body.
Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.
ii
Orifice clogged.
Reassemble after cleaning.
Plunger does not return. i
Foreign matter between plunger and body.
Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.
ii
Spring broken.
Renew spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.
iii Orifice clogged.
Reassemble after cleaning.
Dumper piston or cap is excessively worn.
Renew dumper piston and cap. Completely remove foreign matter, repair any damage and reassemble after cleaning.
45 - 10 - 10/9
6420 - F/5-4.1
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 10/10
JS 330 from m/c no. 712501, JS 450 from m/c no. 714501 Fault Finding - Track Motor/Reduction Gear (cont’d) 4
Speed Range Changing Symptom
a
b
Travel is not linear.
Will not go into high speed.
9804/1103
Possible Cause 1
Remedy
Plunger not switching. i
Foreign matter between plunger and body.
Completely remove foreign matter, repair the damage and reassemble after cleaning. Replace if the damage or leakage is large.
ii
Spring not installed.
Install spring.
iii Spring broken.
Renew spring. Completely remove foreign matter, repair any damage, reassemble after cleaning. Renew if the damage or leakage is excessive.
iv Foreign matter is caught between the two spools.
Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if the damage or leakage is large.
2
Pressurised oil leaks due to excessive wear of 2-speed control piston.
Renew the 2-speed control piston. Completely remove foreign matter and reassemble after cleaning.
3
2-speed control piston is not installed.
Install 2-speed control piston.
4
Steel balls badly worn.
Renew steel balls. Completely remove foreign matter and reassemble after cleaning.
5
Set pressure is rising due to excessive spool wear.
Renew the two spools. Completely remove foreign matter and reassemble after cleaning.
6
The orifice of the 2-speed piston compartment oil passage is incorrect.
Fit a new orifice of correct diameter.
7
The orifice of the 2-speed piston compartment oil passage is clogged.
Reassemble after cleaning.
8
Number of washers is different, making set pressure different between the left and right.
Confirm number of washers.
1
Plunger not switching. i
Foreign matter between plunger and body.
Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if the damage or leakage is excessive.
ii
Foreign matter is caught between the two spools.
Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if the damage or leakage is excessive.
2
Pressurised oil leaking due to excessive wear of 2-speed control piston.
Renew 2-speed control piston. Completely remove foreign matter and reassemble after cleaning.
3
2-speed control piston not installed.
Install the 2-speed control piston.
4
The orifice of the 2-speed piston compartment oil passage is clogged.
Reassemble after cleaning.
45 - 10 - 10/10
6420 - F/5-5.1
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 10/11
JS 330 from m/c no. 712501, JS 450 from m/c no. 714501 Fault Finding - Track Motor/Reduction Gear (cont’d) 4
Speed Range Changing (continued)
Symptom c
Will not go into low speed.
9804/1103
Possible Cause
Remedy
1
Spring is not installed.
Install spring.
2
Spring is broken.
Renew spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if the damage or leakage is excessive.
3
Set pressure rising due to excessive wear of one or both spools.
Renew one or both spools. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if the damage or leakage is excessive.
45 - 10 - 10/11
6420 - F/5-6.1
Issue 1
Excavators
CONTENTS
45 - 10 - 11/1
JS 130 from m/c no. 75800, JS 160 from m/c no. 702000 130W from m/c no. 716500, JS 160W from m/c no. 718500 JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 * JS 200W from m/c no. 809000 * JS
Fault finding - Slew Motor
Table 1.
Leakage from oil seals
Abnormal heating
Excessive slip
Motor does not run
Symptom
9804/1103
Cause
External Inspection
Countermeasure
Repair
Internal damage to the motor.
Measure the oil drain volume.
High possibility of damage to the sliding surfaces if the supply volume is approximately equal to the drain volume. Dismantle and inspect.
Refer to Table 2.
Internal damage to the motor.
Open the motor inlet and outlet ports and apply 20 kgf/cm 2 (284 lbf/in 2 ) pilot pressure to the brake release port. Try to rotate the shaft with a torque of approx. 39.32 Nm (29 lbf ft).
High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect.
Renew damaged parts or renew the motor assembly.
Relief valve in circuit not set correctly.
Measure pressure.
Reset to the prescribed setting.
Wear or damage to the motor sliding surfaces or to the high-pressure seal.
Measure the oil drain volume.
Leakage is too high if the oil drain volume exceeds 5 l/min (1.1 gal/min). Dismantle and inspect.
Refer to table 2.
Oil hot and excessive leakage in the motor.
Measure the oil temperature.
Reduce the oil temperature.
Refer to table 2.
Seizure of motor sliding parts or circuit.
Check for any metallic matter deposited in motor drain oil or drain filter. Apply a 30 kgf/cm2 (427 lbf/in2 ) pilot pressure to the brake release port and try to rotate the shaft with a torque of approx. 39.32 Nm (29 lbf ft).
If metallic matter is discovered or the supply shaft does not rotate smoothly when torque is applied, there is a high possibility of internal damage to the motor. Dismantle and inspect.
Repair or renew the damaged parts. Renew the motor assembly.
Damage or wear to oil seal lip.
Renew the oil seals.
Damage or wear of the shaft seal.
Repair the problem or renew the motor assembly.
Abnormal pressure in the casing.
Check the pressure in the casing and measure the drain volume.
45 - 10 - 11/1
Set the pressure in the casing below 3 kg/cm2 . (43 lbf/in2 ) Dismantle and inspect if drain the volume is excessive.
Renew the oil seal. Repair or renew the damaged parts. Renew motor assembly.
Issue 2*
Excavators
CONTENTS
45 - 10 - 11/2
JS 130 from m/c no. 75800, JS 160 from m/c no. 702000 * JS 130W from m/c no. 716500, JS 160W from m/c no. 718500 JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 * JS 200W from m/c no. 809000 Fault finding - Slew Motor (continued)
Oil leakage from mating surfaces
Abnormal noise
Insufficient torque
Symptom
Cause
External Inspection
Countermeasure
Wear or seizure of the motor sliding surfaces.
Open motor inlet and outlet ports and apply 20 kgf/cm2 (284 lbf/in2) pilot pressure to the brake release port.Try to rotate the shaft with a torque of approx. 39.32 Nm (29 lbf ft).
High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect.
Relief valve in the circuit is not set correctly.
Measure relief pressure.
Reset to the prescribed setting.
Internal damage to the motor.
Check if any metallic matter is deposited in the motor drain oil or drain filter.
High possibility of internal damage to the motor if metallic matter is discovered. Dismantle and inspect.
Large amount of air mixed in the oil.
Check the oil in the tank and motor casing.
Thoroughly bleed the air.
Loosening of bolts or pipes
Check if the piping connections, attachment mounting bolts, motor attachment bolts or other bolts are loose.
Tighten to the specified torque.
Repair Inspect the parts and bearing according to Table 2 a-e and renew any defective parts.
Repair or renew damaged parts. Renew the motor assembly.
O-ring is damaged
Renew O-rings.
Seal face is damaged.
Repair seal face or renew.
Bolts are loose.
Check the bolt tightness.
Tighten the bolts to the correct torque.
Table 2. No.
Part Inspected
Repair
a
Wear of the sliding surface of balance plate 21 †.
Repair or renew the part
b
Damage to sliding surface of swash plate 6 †.
Repair the part or renew the motor.
c
Damage to sliding surface of the piston assemblies 8 †.
Repair the part or renew the motor.
d
External wear to the piston assemblies 8 †.
Repair the part or renew the motor.
e
Wear to piston bores in cylinder assembly 24 †.
Renew the motor.
f
Damage to Teflon ring 19 † or ‘O’-rings 52 †.
Renew the part.
Note: † refers to Service Manual
9804/1103
45 - 10 - 11/2
Issue 3*
CONTENTS
Excavators
45 - 10 - 11/3
JS 330 from m/c no. 712501, JS 450 from m/c no. 714501, JS460 from m/c no. 714550 Fault Finding - Slew Motor 1
Motor Does Not Rotate Symptom
a
b
2
The pressure is low.
The pressure is correct but no rotation.
Possible Cause 1
The relief valve is not set correctly.
Set to the correct value.
2
The relief balve does not work properly. i Plunger sticking.
Repair or renew the plunger.
ii
Dismantle and clean.
3
Plunger not seating correctly.
Renew the plunger seat.
1
Overload protection operating
Remove the cause of overload.
2
The moving part is burnt
Check and repair the piston/shoe, cylinder/valve plate, etc.
3
No release pressure acting on the brake.
Check and repair the circuit.
4
The brake piston is sticking.
Dismantle and clean/repair.
5
The brake friction plate is burnt and sticking to the counter plate.
Dismantle and renew the damaged parts.
Motor Rotates in the Reverse Direction
Reverse rotation
Possible Cause
Remedy
1
The motor has been incorrectly assembled.
Check step 16 of the Assembly procedure to verify that the valve housing 303 and main housing 301 are in their correct relative positions. Rectify is necessary.
2
Inlet/outlet hose reversed.
Relocate hoses.
Motor Speed is Low Symptom
a
Plunger orifice contaminated.
3
Symptom a
Remedy
Slow rotation
9804/1103
Possible Cause
Remedy
1
The oil volume is low.
Check the pump output and the circuit to the motor.
2
The temperature is high and leakage is serious
Check the oil cooling circuit.
2
The sliding part are worn out or broken.
Renew suspect parts.
45 - 10 - 11/3
6420 - F/95-1.1
Issue 1*
Excavators
CONTENTS
45 - 10 - 12/1
JS 70 from m/c no. 695501 Fault Finding To extend the service life and improve the operation of the machine, daily inspection and lubrication are necessary as well as immediately isolating any problem found and dealing with it. If the machine is operated with the problem uncorrected, it may lead to larger trouble and possibly to a big accident. If trouble occurs, search for the cause in the items below and make adjustments, repairs, etc. as necessary. If the cause cannot be isolated, contact your JCB Distributor. † Indicates jobs which should be done by a specialist. Refer to Engine Service Manual.
Engine Problem
Cause
Remedy
•Defective starter switch (Starter does not run) •Defective rotation of starter (Starter rotates slowly)
•Possible seizure in engine •Incomplete air bleeding of fuel system •No fuel in fuel tank •Fuel quality unsuitable •Fuel filter clogged •Low compression •Defective fuel injection pump
Connect, repair connection Discharged battery, starter problems, contaminated or loose wiring connection Inspect and replace as necessary Preheat with air heater Warm up the coolant (add hot water) † Repair Completely bleed air Refill Inspect and replace as necessary Clean or replace † Repair † Repair
•No fuel in fuel tank •Fuel filter clogged •Air is mixed in the fuel system
Refill Clean and replace Retighten fuel pipe connections and bleed system
•Low oil •Defective oil pressure switch •Oil filter clogged •Low oil viscosity •Improper operation of oil pump •Oil leakage at connections
Refill † Replace Replace element Replace with oil of viscosity matching temperature † Replace parts Tighten connections
•Improper viscosity of engine oil •Excessive cooling of engine (Cold weather) Engine does not start
Engine stops during operation
Low oil pressure
•Excessive oil consumption •Excessively low oil viscosity Exhaust gas from engine •Excessive cooling by radiator is white or blue •Improper fuel injection timing •Low compression
† Disassemble and repair, replace parts Replace with correct oil Adjust † Adjust or replace if necessary † Disassemble and repair, replace parts
•Improper fuel •Improper valve clearance Exhaust gas from engine •Defective fuel injection pump is black or dark grey •Low compression •Insufficient air intake (air cleaner clogged)
Replace with correct fuel Adjust † Adjust or replace if necessary † Disassemble and repair, replace parts Clean or replace the element
Excessive fuel consumption
•Defective fuel injection pump •Improper spray from fuel injection nozzle •Improper fuel injection timing •Improper fuel •Low compression •Insufficient air intake
† Adjust or replace if necessary † Adjust or replace if necessary † Adjust or replace if necessary Replace with correct fuel † Disassemble and repair, replace parts Clean or replace element
Excessive engine oil consumption
•Excessive oil •Low oil viscosity •Oil leakage •Worn cylinder piston rings
Drain oil to proper level Replace with oil of viscosity matching temperature Retighten and replace parts if necessary † Disassemble and repair, replace parts
Abnormal noise.(Fuel or mechanical)
•Bad fuel •Damage inside muffler
Replace Replace
9804/1103
45 - 10 - 12/1
Issue 1
Excavators
CONTENTS
45 - 10 - 12/2
JS 70 from m/c no. 695501 Fault Finding (contÕd) Engine (contÕd) Problem
Cause
Remedy
Engine overheating (Water temperature reads too high)
•Low coolant •Water leakage •Elongated or oil dirtied belt •Defective radiator •Broken fan •Incorrect mixture of anti-freeze solution •Defective thermostat •Defective water pump •Defective water sensor
Refill Repair Clean or replace † Repair or replace † Replace Replace † Replace † Replace † Replace
Defective battery charge
•Improper belt tension •Wiring trouble •Defective battery •Defective regulator •Defective alternator
Adjust Repair Replace † Replace † Replace
9804/1103
45 - 10 - 12/2
Issue 1
Excavators
CONTENTS
45 - 10 - 13/1
JS 70 from m/c no. 695501 Fault Finding (contÕd) Monitor Display Problem
Cause
Remedy
•Water leakage •Belt elongation, soiled with oil •Defective radiator •Broken fan •Improper anti-freeze mixture •Defective thermostat •Defective water pump •Dirty oil cooler (clogged) •Dirty radiator (clogged) •Defective dust protection net (clogged) •Defective monitor
Repair Clean or replace † Repair or replace † Replace Replace † Replace † Replace Clean Clean Clean † Replace
•Low Engine oil •Oil leakage at connections •Defective engine oil pressure sensor •Engine oil viscosity low •Defective engine oil pump •Defective monitor
Refill Repair † Replace Replace with oil of viscosity matching the temperature † Adjust, clean, replace † Replace
AIR FILTER
•Air filter element clogged •Intake system clogged, foreign matter inside
Clean, replace Clean
LOW FUEL LEVEL
•Fuel low •Defective sensor
Refill † Replace
•Belt tension •Wiring fault •Defective battery •Defective regulator •Defective alternator
Adjust Repair Replace † Replace † Repair or replace
LOW COOLANT
•Coolant low •Defective sensor
Refill † Replace
ENG. OIL FILTER
•Engine oil dirty •Defective sensor
Refill † Replace
ELEC. PROBLEM
•Short circuit, etc abnormalities
† Inspect, repair
OVERHEAT
LOW OIL PRESSURE
ALTERNATOR
† Indicates jobs which should be done by a specialist. Refer to Service Manual.
9804/1103
45 - 10 - 13/1
Issue 1
Excavators
CONTENTS
45 - 10 - 13/2
JS 70 from m/c no. 695501 Fault Finding (contÕd) Operating Controls Problem Operating controls hard to operate
Cause
Remedy
•Foreign matter caught on control valve spool •Valve sticking •Improper lubrication of lever link •Lever link seizure
† Wash the control valve † Repair or replace valve assembly Grease Grease
Hydraulic Pump Problem Oil not delivered by
Cause
Remedy
oil pump
•Low hydraulic oil •Clogged suction filter
Refill Repair
Hydraulic pump does not build pressure
•Oil leakage inside hydraulic pump •Air inside the hydraulic pump •Main relief valve pressure set too low
† Replace hydraulic pump Refill oil or check hose on suction side † Adjust pressure
Abnormal noise from hydraulic pump
Oil leakage from hydraulic pump
•Cavitation resulting from deformed hose on the suction side or suction filter clogged •Joint of the suction side is loose or hydraulic oil is low and air is being sucked in •Cavitation resulting from excessively high viscosity of hydraulic oil
Replace with hydraulic oil of suitable viscosity
•Defective seal in hydraulic pump
† Replace seal or hydraulic pump
Replace filter, replace hydraulic oil if dirty Retighten or grease the joints Check that oil is filled to proper level inside casing
Working Attachments Problem
Overall low power
Defective operations
Insufficient work power
Attachment sinks down
Abnormal noise from joints of the attachment
Cause
Remedy
•Insufficient engine output •Function drops due to wear of hydraulic pump •Defective main relief valve •Low hydraulic oil •Viscosity of hydraulic oil incorrect •Suction filter clogged
Refer to Engine Service Manual † Replace hydraulic pump † Adjust the pressure or replace Refill Replace with hydraulic oil of proper viscosity Replace suction filter
•Hydraulic pump broken •Hydraulic oil low
† Replace hydraulic pump Replace suction filter
•Set pressure for main or port relief valve is low or incorrect •Damaged hydraulic ram seals •Damaged hydraulic ram, cylinder
† Adjust pressure or replace relief valve
•Damaged hydraulic ram, seals •Damaged hydraulic ram, cylinder •Oil leakage inside control valve •Oil leakage inside holding valve
† Replace hydraulic ram seals † Replace hydraulic ram/cylinder or the assembly †Repair valve assembly, replace † Repair valve assembly, replace
•Insufficient grease •Connecting pin seizure
Grease Replace the bushing and/or pin
† Replace hydraulic ram seals † Replace hydraulic ram/cylinder or the assembly
† Indicates jobs which should be done by a specialist. Refer to service Manual. 9804/1103
45 - 10 - 13/2
Issue 1
Excavators
CONTENTS
45 - 10 - 13/3
JS 70 from m/c no. 695501 Fault Finding (contÕd) Travelling Problem Insufficient travel force
Rough travel
Crooked travel
Cause
Remedy
•Pressure setting for main relief valve is too low •Defective counterbalance valve •Performance reduction of travel motor •Swivel joint packing damage •Performance reduction of hydraulic pump
† Adjust the pressure † Replace the counterbalance valve † Replace travel motor † Replace swivel joint packing † Replace hydraulic pump
•Excessively tightened track •Stone or foreign matter caught in track •Defective valve •Performance reduction of travel motor •Air in travel motor
Adjust to proper tension Remove stone or foreign matter † Repair valve or replace † Replace travel motor Refill with oil
•Left and right tracks are not equally tightened
Bleed air from left and right, adjust tracks to equal tension † Replace hydraulic pump † Replace travel motor † Replace valve housing assembly † Replace swivel joint packing Adjust
•Performance reduction of hydraulic pump •Performance reduction of travel motor •Oil leakage inside control valve •Swivel joint packing damage •Loose lever link
Slewing Problem
Cause
Remedy
Insufficient slew force
•Performance reduction of slew motor •Thermal seizure of slew shaft
† Replace slew motor † Supply grease or replace the slew shaft
Poor braking performance
•Low setting of brake valve •Clogged valve •Performance reduction of slew motor •Internal oil leakage of control valve
† Adjust the pressure † Wash the valve † Replace slew motor † Repair or replace valve assembly
Poor stopping performance
•Low setting of brake valve or port relief valve •Clogged valve •Performance reduction of slew motor •Internal oil leakage of control valve
† Adjust the pressure † Wash the valve † Replace slew motor † Repair or replace valve assembly
Abnormal noise during slew
•Air in slew motor •Insufficient greasing of slew bearing
Refill with oil Add grease
Hydraulic Rams Problem
Cause
Remedy
Insufficient force of hydraulic ram
•Low pressure setting for the relief valve •Oil leakage inside the hydraulic ram •Damage of the hydraulic ram or rod •Oil leakage inside the control valve
† Adjust the pressure † Replace the ram seals † Replace the hydraulic ram or rod † Repair or replace the valve assembly
Oil leakage outside the hydraulic ram
•Defective hydraulic ram seals •Hydraulic cylinder rod damage
† Replace hydraulic ram seals † Replace hydraulic ram rod
† Indicates jobs which should be done by a specialist. Refer to Service Manual.
9804/1103
45 - 10 - 13/3
Issue 1
CONTENTS
Excavators
45 - 10 - 14/1
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) This section is designed to simplify the task of Fault Finding. When a message is displayed the description of the fault is shown and the Problem No. is shown; this in turn then relates to the relevant page showing the problem No. Procedure Depending on the result of the inspection or measurement inside the box, continue on to either the YES or NO branch and onto the next box. Inside each box the inspection or measurement method or values are written. the necessary preparatory work, operations and values are listed. Make sure the preparatory work is carried out, that is checking the procedures and equipment as mistakes in judgements and procedures can seriously damage the equipment. Note: When removing or checking a piece of electrical equipment turn the key switch OFF.
9804/1103
45 - 10 - 14/1
6420 - C/9-1.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/2
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) This explains how to troubleshoot in the event that the message does not go out even though suitable measures are taken to check and clear the problem. !Mark
Message Display
Trouble Description
Problem No.
!
Engine emergency stop
Even though the emegency stop button is pressed, the message does not go out.
1
!
Refuel
Even though fuel is supplied, the message does not go out.
2
!
Refill coolant
Even though cooling water is suppplied, the message does not go out.
3
!
Replenish battery fluid
Battery fluid sensor not fitted, fault should not be displayed.
4
!
Air cleaner clogged
Even though filter is cleaned, the message does not go out.
5
!
Engine oil pressure drop
Even though the engine oil is correct, the message does not go out.
6
!
Engine filter clogged
Even though the engine oil filter is replaced and the engine oil is correct, the messge does not go out.
7
!
Over heat
Even though hydraulic oil temperature is less than 84 C and the engine cooling water temperature is less than 92 C, the message does not go out.
8
o
o
!
Battery Charging Deficient
The message does not go out
9
!
Electric system abnormality The message does not go out.
10
This explains how to troubleshoot when an operation is not indicated on a message, but it does not operate normally. 1
Engine Control Area Trouble Description
Engine does not start.
Trouble No.
“Electric system abnormality” is indicated on monitor.
Refer to trouble No. 10. 11
Controlling engine rotation is not possible.
9804/1103
Engine rotation does not change with throttle volume.
45 - 10 - 14/2
6420 - C/9-2.2
12
Issue 1*
Excavators
CONTENTS
45 - 10 - 14/3
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Judgement Value
Measure
1. Fuel amount check
-
Refuel
2. Inspection for fuel containment
-
Clean, drain
3. Hydraulic oil amount check
-
Refill oil
4. Inspection of hydraulic oil strainer
-
Clean, drain
5. Inspection of oil amount for each reduction gear
-
Refill oil
6. Inspection of engine oil amount (amount in oil pan)
-
Refill oil
7. Coolant amount check
-
Refill water
8. Dust indicator clogging check
-
Clean or replace
9. Inspection for looseness, corrosion of battery terminal and wiring
-
Tighten or replace
10. Inspection for looseness, corrosion of alternator terminal and wiring
-
Tighten or replace
11. Inspection for looseness, corrosion of starter terminal and wiring
-
Tighten or replace
12. Abnormal sound, smell check
-
Repair
13. Oil leakage check
-
Repair
14. Air bleeding
-
Air bleeding
25-26 V
Replacement
16. Battery fluid sensor not fitted, fault should not be displayed
-
Replensih or replace
17. Inspection for discolouration, burning, peeling of wiring
-
Replacement
18. Inspection for wiring clamp removal, sagging
-
Repair
19. Inspection for wet wiring (special attention to wet connector and terminal)
-
Disconnect and dry
20. Inspection for fuse breakage, corrosion
-
Replacement
27.5~29.5 V
Replacement
-
Replacement
Lubricants z Coolants Hydraulic z Mechanical Equipment
Electrical Equipment
Start-up Inspection items
Item
Electricity z Electric Equipment
Other Inspection Items
15. Battery voltage (engine stopped) check
21. Alternator voltage check (engine revolution more than 1/2 throttle) (When battery insufficiently charged may be about 25 V soon after starting.( 22. Battery relay making noise (when starter switch is ON or OFF)
9804/1103
45 - 10 - 14/3
6420 - C/9-3.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/4
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Emergency Engine Stop, Problem No.1 Note: Even if the emergency stop button is pressed the message does not go out. Prior Confirmation Items 1
The "MODE" of the mode display is not flashing.
2
Confirm that the fuses in the fuse box are normal.
3
The engine does not run.
Troubleshoot
Cause
Remedy
Key switch ON When CN11 connector is removed, does message go out?
Defective LW wiring from switch panel or switch panel defective.
YES
NO Remove CN2 connector and measure voltage of female side of LB. Is it within the range of 20~30V?
NO
YES
Measure voltage of LW with shut down relay 1 connector connected. Is it within the range of 20~30V. NO
YES
Remove shut off relay 1 connector and measure NO (°°) resistance of 1 and 2 of relay side. Connect 1 to +, 2 to -. Is it 250 . YES
9804/1103
45 - 10 - 14/4
Repair wiring or replace switch panel.
Bad connection of CN2 connector or controller defect.
Clean CN2 connector terminal or replace controller.
Breakage of LW wiring between shut off relay 1 and controller.
Repair LW wiring.
Defective shut off relay 1.
Breakage of LR wiring between shut off relay 1 and fuse.
6420 - C/9-4.2
Replace shut off relay 1.
Repair LR wiring.
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/5
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Refuel, Problem No.2 Note: Message does not go out even if refuelled Prior Confirmation Items 1
The "MODE" of the mode display is not flashing.
2
Fuel bar graph displays one.
Troubleshoot Key switch ON Measure resistance value of sensor at self-check. Is it within the range of values in chart below? (Refer to resistance values in chart below.)
NO
Cause
YES
Controller defect
Remedy
Replace controller.
Key switch OFF
Remove sensor coupler and measure resistance on sensor side. Is it within the range of values in chart below? (Refer to resistance values in chart below.)
YES
NO
Remove CNE connector and measure resistance between male side terminal YR and GR. Is it within the range of values in chart below? (Refer to resistance values in chart below.)
YES
NO
Remove CN10 connector and measure resistance between female side terminal YR and GR. Is it within the range of values in chart below? (Refer to resistance values in chart below.)
NO
Fuel sensor defect
Replace sensor or inspect it.
Bad connection of fuel sensor connector
Clean connector terminal.
Bad connection of CNE
Clean CNE connector terminal.
Controller defect or bad connection of CN10
YES
Replace controller or clean CN10 connector terminal.
Note: When there is breakage in the wiring, the bar graph goes out completely. Resistance Value between YR and GR Monitor
1 Refuel.
2
Resistance Value (OHM)
80~78
78~59
9804/1103
3
4
5
59~44 44~34 34~27
6
7
8
27~21 21~13 13~10
45 - 10 - 14/5
6420 - C/9-5.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/6
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Coolant Refill, Problem No 3 Note: Message does not go out even if coolant is refilled Prior Confirmation Items 1
The "MODE" of the mode display is not flashing.
Troubleshoot
Cause
Remedy
Key switch ON
When reserve tank level switch connector is removed, does message go out?
NO
YES
Reserve tank level switch defect
When reserve tank level switch connector is removed, does message go out?
Defective YW wiring between reserve tank level switch and CNB
YES
YES
NO
9804/1103
45 - 10 - 14/6
Replace reserve tank switch.
Repair YW wiring.
Defective YW wiring between CNB and CN7
Repair YW wiring.
Controller
Replace controller.
6420 - C/9-6.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/7
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Air Cleaner clogged, Problem No. 5 Note: Message does not go out even if the filter is renewed. Prior Confirmation Items 1
The "MODE" of the mode display is not flashing.
Troubleshoot
Cause
Remedy
Air filter switch defect
Replace air filter switch.
Key switch ON When spade terminal of air filter switch on YL side is removed, does message go out?
NO
YES
When CNB connector is removed, does message go out?
NO
Breakage or bad connection of BW wiring between CNB and air filter switch
YES
When CN7 connector is removed, does message go out?
YES
NO
9804/1103
Breakage or bad connection of BW wiring between CNB and CN5
Controller defect
45 - 10 - 14/7
6420 - C/9-7.2
Repair BW wiring.
Repair BW wiring.
Replace controller
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/8
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Low Engine Oil Pressure. Problem No. 6 Note: Message does not go out even if engine oil is satisfactory. Prior Confirmation Items 1
The "MODE" of the mode display is not flashing.
Troubleshoot
Cause
Remedy
Confirm after 12 seconds have passed after starting the engine. YES
When oil pressure switch connector is removed, does message go out?
NO
When CNB connector is removed, does message go out?
NO
YES
When CN5 connector is removed, does message go out?
YES
NO
9804/1103
Oil pressure switch defect
Replacement
Defective YG wiring between CNB and oil pressure switch
Repair YG wiring.
Defective YG wiring between CNB and oil pressure switch
Controller defect
45 - 10 - 14/8
6420 - C/9-8.2
Repair YG
Replace controller
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/9
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Engine Oil Filter Blocked, Problem No 7 Note: Message does not go out even if the engine oil filter is replaced and the oil is satisfactory. Prior Confirmation Items 1
The "MODE" of the mode display is not flashing.
Troubleshoot
Cause
Remedy
Oil filter switch defect
Replace switch.
Defective LB wiring between CNB and oil filter switch
Repair LB wiring.
Defective LB wiring between CN7 and CNB
Repair wiring.
Controller defect
Replace controller.
Engine starts
YES
When oil filter connector is removed, does message go out?
NO
When CNB connector is removed, does message go out?
NO
YES
When CN7 connector is removed, does message go out?
YES
NO
9804/1103
45 - 10 - 14/9
6420 - C/9-9.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/10
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Fluid Overheating, water, oil, Problem No 8 Note: Message does not go out even if the actual temperature is below the following; Hydraulic Oil Temperature 84°C. Engine Coolant Temperature 92°C. Prior confirmation Items 1 3
The "MODE" of the mode display is not flashing. 2. Each bar graph displays more than one graduation. Confirm that the water and oil temperature bar graph is lit at 8 graduations.
Troubleshoot 1. Water temperature bar graph lit at 8 graduations. Key switch ON Is thermo sensor (water) temperature abnormal at selfcheck? (comparison of actual and indicated temperature) • Display water temperature with self-check • Measure actual temperature
NO
When thermo switch (water) connector is removed, does message go out?
YES
NO
Key switch OFF Remove thermo sensor (water) connector and measure resistance of sensor side. Is it within the range of values in separate chart? (Refer to resistance values in separate chart)
YES
Remedy
Thermo switch (water) defect
Replace switch
Defective YR wiring between CNB and thermo switch
Repair YR wiring
Defective YR wiring between CN3 and CNB
Repair YR wiring.
YES
When CNB connector is removed, does message go out? NO
Cause
YES YES
When CN3 connector is removed, does message go out?
Controller defect
Replace controller
Thermo switch (water) defect
Replace sensor.
Bad connection of thermo (water) connector
Clean sensor connector terminal
NO NO
Remove CNE connector and measure resistance between male side terminal YB and GR. Is it within the range of values in separate chart? (Refer to resistance values in separate chart)
YES
NO
Remove CN10 connector and measure resistance between female side terminal YB and GR. Is it within the range of values in separate chart? (Refer to resistance values in separate chart)
YES
NO
Bad connection of CNE
Controller defect or bad connection CN10
Clean CNE connector terminal Replace controller or clean CN10 connector terminal
Note: When there is breakage in the wiring, the bar graph goes out completely. 9804/1103
45 - 10 - 14/10
6420 - C/9-10.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/11
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Fluid Overheating, water, oil, Problem No 8 (continued) Note: Message does not go out even if the actual Temperature is below the following:Hydraulic Oil Temperature 84°C Engine Coolant Temperature 92°C
Troubleshoot 1. Oil temperature bar graph lit at 8 graduations. Key switch ON Is thermo sensor (oil) temperature abnormal at self-check? (comparison of actual and indicated temperature) • Display oil temperature with self-check • Measure actual temperature
NO
When thermo switch (oil) connector is removed, does message go out?
YES
NO
Key switch OFF Remove thermo sensor (oil) connector and measure resistance of sensor side. Is it within the range of values in separate chart? (Refer to resistance values in separate chart)
YES
Remedy
Thermo switch (oil) defect
Replace switch
Defective Br wiring between CNB and thermo switch (oil)
Repair Br wiring
Defective Br wiring between CN3 and CNB
Repair Br wiring.
YES
When CNB connector is removed, does message go out? NO
Cause
YES YES
When CN3 connector is removed, does message go out?
Controller defect
Replace controller
Thermo switch (oil) defect
Replace sensor.
Bad connection of thermo sensor (oil) connector
Clean sensor connector terminal
NO NO
Remove CNE connector and measure resistance between male side terminal BrW and GR. Is it within the range of values in separate chart? (Refer to resistance values in separate chart)
YES
NO
Remove CN10 connector and measure resistance between female side terminal BrW and GR.
YES
NO
Bad connection of CNE
Controller defect or bad connection CN10
Clean CNE connector terminal Replace controller or clean CN10 connector terminal
Note: When there is breakage in the wiring, the bar graph goes out completely.
9804/1103
45 - 10 - 14/11
6420 - C/9-11.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/12
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Battery Charging, Problem No 9 Note: Message does not go out. Prior Confirmation Items 1
The "MODE" of the mode display is not flashing.
Troubleshoot
Does hour meter operate?
Cause
Remove CN2 connector and measure voltage between female side terminal WR and ground? Is it more than 10V?
YES
NO
YES
NO
Remove spade terminal of alternator R and measure voltage between female side and ground. Is it more than 10V?
Defective WR wiring between CN2 and CNC
Repair WR
Bad connection of CN2 or controller defect
Clean CN2 connector terminal or replace controller.
NO
Alternator defect
YES Remove CNC connector and measure voltage between male side terminal WR and ground? Is it more than 10V?
NO
Breakage of WR wiring between CNC and alternator or bad connection of alternator spade terminal
YES
9804/1103
45 - 10 - 14/12
Remedy
6420 - C/9-12.2
Replace alternator
Repair WR wiring between CNC and alternator or clean spade terminal.
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/13
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Electrical Systems, Message Fault, Problem No 10 Note: Message does not go out.
9804/1103
45 - 10 - 14/13
6420 - C/9-13.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/14
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Electrical System, Message Fault, Problem No. 10 (continued) Note: Message does not go out. Troubleshoot
Cause
Remedy
Key switch ON
Does Clock display “0000”?
When transistor output is carried out with self-check, are any abnormal points found?
NO
NO
When electro magnetic proportional valve is removed, does message go out?
YES
YES
YES
NO
When display solenoid valve YES connector is removed, does message go out?
For example when swing lock no. 11 is displayed (Display number explanation on separate sheet).
Electro-magnetic proportional valve defect or defective BrB wiring
When CNB connector is removed, does message go out?
Repair BrB wiring
NO When CN8 connector is removed, does message go out?
NO
Defective BrB wiring between CNB and electro-magnetic proportional valve
YES
Replace electro magnetic proportional valve or repair BrB wiring
YES
NO
When CNA connector is removed, does message go out? NO
Defective BrB wiring between CNB and CN8
Repair BrB wiring.
Controller defect
Replace controller.
Solenoid valve defect
Replace solenoid valve.
Defective wiring between CNA and solenoid valve
Repair wiring.
Defective wiring between CN6 and CNA
Repair wiring.
Controller defect
Replace controller.
YES When CN7 connector is removed, does message go out? NO
When CN6 connector is also removed, does message go out?
* When there are multiple abnormalities the smaller number is displayed and after it is repaired, the next number is displayed.
YES
NO
Reconnect CN6, CN7 connectors.
Throttle link system abnormality
YES Is throttle motor out of step?
NO NO Does throttle motor operate with redundancy?
Remove throttle motor connector, measure resistances between B and Br, B and R, B and O, B and Y. (Are they within NO range of 3.0~3.6 ?)
Throttle motor abnormality (energising coil defect)
YES
YES
Remove throttle motor connector. Is it continuous between W and L on NO throttle motor side?
Throttle motor abnormality (limit switch defect)
YES Remove CNI and measure resistances between male side terminals R and B, R and G, R and W, R and Y.. (Are they within range of 3.0~3.6 ?) Throttle motor or driver abnormality Continues to next page B
YES
NO Remove CNI. Is it continuous between male side terminal GL and LgR? YES
9804/1103
NO
Inspect and adjust throttle motor. (Automatic adjustment necessary) Replace throttle motor. (Automatic adjustment necessary) Replace throttle motor. (Automatic adjustment necessary)
Breakage or defective wiring between CNI and throttle motor
Repair wiring.
Breakage or defective wiring between CNI and throttle motor
Repair wiring.
Continues to next page A
45 - 10 - 14/14
6420 - C/9-14.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/15
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Electrical System, Message Fault, Problem No.10 (continued) Note: Message does not go out. Troubleshoot
Cause
Remedy
B Continued from previous page A
Remove driver connector CN15 and measure resistances between female side terminals R and B, R AND G R and W, R and Y. Are they within the range of 3.0~3.6 .
YES
NO
Breakage or defective wiring between CNI and CN15
Repair wiring
Breakage or defective wiring between CNI and CN15
Repair wiring
Breakage of wiring P between CN15 and fuse box
Repair P wiring
Breakage of wiring RY between CN15 and key switch
Repair RY wiring
Same work as *1 YES Remove driver connector CN15. Is it continuous between female side terminals GL and LgR?
NO
Ignition switch YES
Remove driver connector CN15 and measure voltage between female side terminals P and BG, connecting P to + and BG to -. Is it within the range of 20~30V?.
NO
* Ignition switch YES
Remove driver connector CN15 and measure voltage between female side terminals RY and BG, connecting RY to + and BG to -. Is it within the range of 20~30V?
NO
YES
Driver defect
Replace driver
Controller defect
Replace controller
Redundancy switch OFF, ignition switch
Remove controller side connector CN8 and measure voltage between GY and ground. YES Is it 0V? Measure voltage between GR and ground. Control System Is it 5V?
NO
Abnormalities
Breakage of wiring GY or GR between controller CN8 and driver CN15
YES
9804/1103
45 - 10 - 14/15
6420 - C/9-15.2
Repair GR or GY wiring
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/16
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Engine Trouble, Problem No 11 Note: Engine does not start even though the message "electrical system abnormal" is not displayed. Prior Confirmation Items ● ● ● ● ●
No abnormalities in engine or fuel system. Fuse is not blown. The message "Engine emergency stop" is not displayed. Redundancy switch is OFF. Starter motor rotates and engine is cranking.
9804/1103
45 - 10 - 14/16
6420 - C/9-16.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/17
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Engine Trouble, Problem No 11 (continued) Troubleshoot
Cause
Remedy
Engine system Abnormality
Inspect engine system.
Key switch ON YES
Is fuel cut lever on stop side
NO Remove the stop motor connector and connect female side (cab side) to service connector (6 pin). Measure voltage between LR and ground, connecting LR to + and ground to -. Is it within the range of 20~30V.
Breakage of LR wiring between stop motor connector and CND or between CND and fuse
NO
Repair LR wiring.
YES Remove the stop motor connector and attach service connector to female side. Confirm continuity between L and LW. Is the following true? Key switch ON: Continuity Key switch OFF: °°
NO
YES
Stop motor defect
Measure voltage between shut down relay 1 connector L and ground, connecting L to + and ground to -. Is the following true? Emergency stop button ON: 0V Emergency stop button OFF: 20~30V
NO
YES
Shut down relay defect
Replace shut down relay 1.
Shut down relay 2 Defect or breakage of L wiring between shut down 1 and 2
Replace shut down relay 2 or repair L wiring.
To judge if relay is defective or not, interchanging the relay with one in the centralized relay is another method.
9804/1103
45 - 10 - 14/17
Replace stop motor.
6420 - C/9-17.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/18
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Engine Problem, Problem No 12 Note: Engine revolutions do not change with throttle volume control. Prior Confirmation Items 1
The message "Engine emergency stop" is not displayed
Troubleshoot
Cause
Remedy
Key switch ON Change voltage moving throttle volume with self-check. Is it within the range of 0~4.5V?
YES
NO
Without removing CN10 connector, change the voltage between GrR + and Gr - moving the throttle volume. Is it within the range of 0~4.5V?
YES
Controller defect or bad connection of CN10 connector
NO Remove throttle volume connector, measure resistance between throttle volume side connector GrR and GrL. Is it within the range of 0~1 ?
YES
NO
Replace throttle volume.
Breakage or defective wiring GrL, GrR, Gr between CN10 and throttle volume
Repair of the GrL, GrR, Gr.
Controller defect
Replace controller.
Breakage of GL wiring
Repair GL wiring
Driver defect
Replace driver.
NO Remove throttle volume connector, measure resistance between throttle volume side connector GrR and Gr. Is it within the range of 0~1 ?
Check motor transmitted pulse by self-check. Is it within the range of 500~1023?
Throttle volume defect.
NO
YES
YES
Remove controller CN4 and driver CN15. Is GL wiring continuous?
NO
Even though the throttle motor is moving. YES
9804/1103
Replace controller or clean CN10 connector terminal.
45 - 10 - 14/18
6420 - C/9-18.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/19
JS 330, JS 450, JS 460 Fault Finding (cont’d) - Electrics (CAPS II) Sensor Resistance Value
9804/1103
Water temperature (Oil temperature)
Minimum
Maximum
20°C
8.00k
10.20k
30°C
5.35k
6.50k
40°C
3.60k
4.55k
50°C
2.50k
3.10k
60°C
1.70k
2.20k
70°C
1.20k
1.55k
80°C
0.85k
1.15k
45 - 10 - 14/19
6420 - C/9-19.2
Issue 1*
Excavators
CONTENTS
45 - 10 - 13/4
JS 200W from m/c no. 809000 Fault Finding - Hydraulic Rams The chart below lists some possible problems and suggested remedies. The types of problems fall into four main categories as follows:
Item
Item Symptoms
Symptoms
1
Oil leakage from piston rod sliding part.
2
Oil leakage from cylinder head joint.
3
Oil leakage from pipe and cylinder tube welds.
4
Faulty operation
Related Parts
Trouble On the sliding surface, there are scratches and rust that can be felt by the fingernail.
Treatment 1 Use an oil stone and remove the scratch and make the sliding surface smooth. If oil leakage continues even though the rod surface is made smooth, the scratch may have damaged the U-ring and other seals, so dismantle and inspect.
Piston rod 2 If the scratches and rust cover such a wide area that they cannot be repaired by an oil stone, renew the piston rod and U-ring, wiper ring and seals and the piston rod bearing member.
1
Piston rod sliding part oil leakage
Rod packing (Buffer ring U-ring)
The plating is peeling.
Re-plate or renew the piston rod. Also inspect the seal and piston rod bearing member and renew if damaged.
Foreign matter is biting into the inner and outer surfaces of the packing.
Remove foreign matter. If there is damage to packing, renew it.
There is a scratch on the inner surface.
Renew.
The lip and groove parts are locally carbonized (burned).
9804/1103
45 - 10 - 13/4
Possibly due to burning caused by adiabatic compression from air remaining inside the ram. After renewing the packing, first operate the ram at low-pressure, low speed to sufficiently bleed the air.
6320 - E/46-1.1
Issue 1
Excavators
CONTENTS
45 - 10 - 13/5
JS 200W from m/c no. 809000 Fault Finding - Hydraulic Rams (cont’d) Item Symptoms
Related Parts
Trouble Packing rubber is perished.
Treatment The packing life or hydraulic oil deterioration and high temperature are possible reasons. 1 Renew hydraulic oil.
Rod packing (Buffer ring, U-ring)
2. Check the hydraulic oil temperature. (Below 80 °C is advisable). 3 Check if high temperature locally. Lip is deficient all around.
Renew. It is possible that abnormally high pressure is working on the packing. 1 Check the operation pressure, cushion pressure. 2 Part which is attached to the buffer ring may be abnormal. Inspect the buffer ring.
The protrusion of the heel of the packing is excessive. 1
Piston rod oil leakage
Back up ring
As a rule, renew the rod packing at the same time. (It is desirable to renew parts which are attached to the buffer ring at the same time). It is possible that abnormally high pressure is the cause. Check the same as above (heel of packing protruding).
Wiper ring
Bushing
Cylinder head
9804/1103
Foreign matter is biting into the lip. The lip is damaged.
Remove the foreign matter.
There is also other abnormal damage.
Renew.
Wear is excessive and the clearance with piston rod exceeds the maximum permissible value. (Refer to Maintenance Specifications for maximum permissible value.)
Renew.
Large scratch on the sliding part.
Renew. Also inspect the piston rod.
Scratches, rust on the seal attachment parts.
Remove scratch, rust with oil stone. If it cannot be repaired, renew the cylinder head.
45 - 10 - 13/5
6320 - E/46-2.1
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 13/6
JS 200W from m/c no. 809000 Fault Finding - Hydraulic Rams (cont’d) Item Symptoms
Related Parts
Trouble Foreign matter on inner and outer diameters.
Treatment • • •
O-ring damaged. ‘O’-ring
•
•
Remove foreign matter. Renew 'O'-ring if damaged. Inspect inside tube: if any scratches or rust, make surface smooth with oil stone. Inspect cylinder head 'O'-ring groove: if any scratches or rust, make surface smooth with oil stone. Inspect back up ring: if any deformation or protrusion, renew.
Confirm the above and renew 'O'-ring. Back up ring 2
Oil leakage from cylinder head joint
Deformation, protrusion
•
Renew, with the 'O'-ring.
Looseness
•
Dismantle cylinder head and inspect 'O'-ring and back up ring. Check tube and cylinder head thread for damage. If any damage, renew.
Cylinder head
• •
Bolt
Looseness, stretching, broken
Renew all bolts and tighten to specified torque.
Abnormal bulge
Replace with new parts. Oil leakage from connecting parts may be caused by abnormal pressure (including cushion pressure). Inspect the tube for bulges, deformation and check the circuit pressure.
Cylinder tube
Crack in welding
3
Oil leakage from pipe and cylinder tube welded seam
9804/1103
After inspection, tighten to specified torque.
Replace with new parts. •
Cylinder tube pipe (hollow piston rod) •
45 - 10 - 13/6
Cracks will develop into fractures. Fractures are very dangerous, so if any cracks are found, stop work immediately and renew the parts. Welding on top of cracks will have no effect.
6320 - E/46-3.1
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 13/7
JS 200W from m/c no. 809000 Fault Finding - Hydraulic Rams (cont’d) Item Symptoms Poor operation
4-1 Movement not smooth
Related Parts Piston rod cylinder tube
4-2 Inner oil leakage. Piston rod extends when work stops or lowers abnormally during work. Also, specified operating speed is not achieved.
Treatment
Bending to more than the specified limit. (Bending distortion: refer to Maintenance Specifications)
•
Replace with new part. The seal and sliding part material may be damaged too, so inspect. If abnormal, renew.
Tube scored
•
Replace with new part. As above, inspect the seal and sliding part material.
Abnormal wear, damage of sliding area
•
Foreign matter intruding on piston and cylinder head sliding area
•
Replace with new part. As above, inspect the seal and sliding part material. Remove foreign material. As above, inspect the seal and sliding part material.
Scratches, wear are present
•
Replace with new part. Inspect the cylinder tube inner surface also.
Scratches, rust on inside
•
Remove the scratches, rust by honing or with an oil stone and make the surface smooth. If the scratch is deep and cannot be repaired, renew cylinder tube.
•
Renew piston seal.
Loose nut
•
Tighten to specified torque.
Leak from valve
•
Inspect the valve leakage amount and service.
Cylinder tube
Piston rod cylinder head sliding part
4
Trouble
Piston seal
Cylinder tube
Piston nut Valves
Note: Hydraulic oil expands and contracts due to changes in temperature and pressure. Accordingly, the ram also expands and this can be mistaken for internal leakage. When inspecting for internal leakage, do so at set conditions.
9804/1103
45 - 10 - 13/7
6320 - E/46-4.1
Issue 1
Excavators
CONTENTS CONTENTS
45 - 10 - 13/8
JS 200W from m/c no. 809000 Fault Finding - Hydraulic Rams (cont’d) Item Symptoms
Related Parts
4-3
Trouble Air remaining inside ram. Operation is unsteady
Treatment •
Air
Bleed the air. For rams that do not have an air bleeder, operate back and forth several times at low pressure and low speed to bleed the air. For rams with an air bleeder, remove the load to reduce the pressure then loosen the air bleeder and completely bleed the air.
Note: The ram may expand if it is stopped suddenly. This is due to the compression of the hydraulic oil. This occurs especially with long stroke rams. 4 4-4 Heavy shock loading when changing from extension to retraction and back 4-5 Noisy operation
Pin bushing/pin
Oil supply Pin bushing/pin
Gap between mounting and pin bushing is too large.
Measure the pin and pin bushing and renew parts if measurements exceed the specifications.
Insufficient oil.
•
Add oil.
Scuffing at connecting part.
•
Replace with new part and add oil.
Note: If left in the state where operation is poor, the ram will no longer move and other parts will be affected adversely. Inspect early and carry out appropriate measures.
9804/1103
45 - 10 - 13/8
6320 - E/46-5.1
Issue 1
CONTENTS CONTENTS
*JS 70 to m/c no. 695500 Circuit Diagrams - Electrical
CONTENTS CONTENTS
Excavators
45 - 15 - 01/2
*JS 70 to m/c no. 695500 Circuit Diagrams - Electrical Main Components 1 2 3 4A 4B 5 6 7 8 9 10 11 12 13 14 15 16A 16B 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
Monitor Display Unit Systems Control Monitor System Control Solenoid 2-Speed Travel Solenoid Swing Parking Brake Solenoid Idle Switch Swing Pressure Sensing Switches Idle Solenoid Resistor Diode Unit Horn Refuelling Pump (optional) Working Lamp (Boom) Working Lamp (Tank) Filter Blocked Switch Fuel Level Sensor Hydraulic Oil Temperature Sensor Water Temperature Sensor Engine Engine Intake Heater Relay Safety Relay Battery Battery Relay Horn Switch Horn Relay Wiper Relay Working Lamp Switch Intermittent Wipe Relay Wiper Motor Idle Relay System Control Switch 2-Speed Travel Switch Wiper Switch Heater Motor Heater Switch Cab Lamp Switch Screen Washer Fuse Box Fuses Stop Motor Starter Switch Buzzer Off Switch Radio Aerial Radio Loudspeaker Radio Beacon Switch
Cable Colour Code B Br G L Lg R V W Y
Black Brown Green Blue Light Green Red Violet White Yellow
9804/1103
Monitor Display and Monitor Controller Plug Pin Positions Monitor Display 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
POWER (+12 V) GND HOUR METER BATTERY CHARGE LAMP FUEL LAMP FUEL METER WATER TEMPERATURE METER OVERHEAT LAMP HYDRAULIC OIL TEMPERATURE METER ENGINE OIL PRESSURE LAMP AIR FILTER LAMP BACK-UP LAMP SWING BRAKE LAMP IDLE LAMP CONTROL OFF LAMP BUZZER GLOW LAMP OPTION (1) LAMP OPTION (2) LAMP (No Connection)
Monitor Controller CN 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
POWER (+12V) GND GND BATTERY CHARGE FUEL METER (LAMP) FUEL METER WATER TEMPERATURE METER HYDRAULIC OIL TEMPERATURE METER ENGINE OIL PRESSURE SWITCH AIR FILTER SWITCH WORKING LAMP SWING PRESSURE SWITCH SWING BRAKE OUT IDLE SWITCH CONTROL OFF SWITCH BUZZER STOP SWITCH
CN 2 1 2 3 4 5 6
45 - 15 - 01/2
HEAT RELAY (IN) HEAT RELAY (OUT) OPTION (1) OPTION (2) IDLE RELAY (No Connection)
Issue 2*
Excavators
CONTENTS
45 - 15 - 01/2A
JS 70 from m/c no. 695501 Circuit Diagrams - Electrical
REFER TO THE SERVICE MANUAL FOR THIS ILLUSTRATION
9804/1103
45 - 15 - 01/2A
6020 - C/2-4.1
Issue 1
CONTENTS
Excavators
45 - 15 - 01/2B
JS 70 from m/c no. 695501 Circuit Diagrams - Electrical (cont’d) Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13A 13B 13C 13D 13E 13F 13G 13H 13J 13K 13L 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
Cigar Lighter Radio Aerial Lead Panel (LH) Limit Switch (Gate) Horn Button Panel (RH) Pressure Switch (Breaker) - Optional Switch (Breaker) - Optional Switch (2 Stage Travel) Monitor Motor Driver Switch - One Touch Idle Relay - Ran 1 Relay - Fan 2 Relay - Ran 3 Relay - Horn Relay - Plug (Glow) Relay - Washer Relay - Wiper Relay - Cab Light Relay - Working Lights (Boom Mounted) Relay - Engine Shutdown Relay - Lever Lock Cab - Wiper/Light Fuse Box Starter Switch Fuse Fuse Relay - Battery Battery Battery Relay - Safety Relay - Heating Washer - Tank Horn Working lights - House Mounted Stop Solenoid Sensor - Thermo Switch - Thermo (Hydraulic Oil) Engine Block Sensor - Fuel Level Valve Block Solenoid (Breaker) - Optional Over Heat Switch (Oil) Throttle Motor Radio Loudspeaker Working Lights - Boom Mounted Glow Plug
9804/1103
KEY B W Br P V G O
45 - 15 - 01/2B
BLACK WHITE BROWN PINK VioLET GREEN ORANGE
R Y Lg Sb L Gr
6020 - C/2-3.1
RED YELLOW LIGHT GREEN SKY BLUE BLUE GREY
Issue 1
CONTENTS CONTENTS
Excavators
45 - 15 - 01/4
JS 110,130 Circuit Diagrams - Electrical Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Hourmeter Monitor Display Unit Proportional Solenoid 2-speed Travel Solenoid Swing Park Solenoid Free Swing Solenoid Swing Brake Pressure Switch Throttle Motor Engine Compartment Lamp Refuelling Pump (optional) Horn (110 dB) Horn (120 dB) Working Lamp, Boom Working Lamp, Tank Air Filter Vacuum Switch Fuel Reserve Tank Level Switch Fuel Level Sensor Hydraulic Fluid Temperature Sensor Alternator Low Oil Pressure Switch Filter Switch Engine Coolant Temperature Sensor Engine Intake Heater Starter Motor Engine Intake Heater Relay Horn Selector Switch Horn Relay Emergency By-pass Switch Resistor } CR Filter Condenser } Diode Resistor Resistor Controller Idle/F Selection Switch Mode Switch Throttle Switch Free Swing Switch Lamp Check Switch Buzzer Idle Switch (Hand Controller) Cushion Switch Emergency Throttle By-pass Switch Windscreen Wiper Switch Cab Heater Switch Working Lamp Switch Cab Heater Cab Lamp Control Switch (Servo Isolator) Beacon Switch 2-speed Travel Switch Horn Switch Limit Switch Engine Stop Relay Timer (Engine Stop) Intermittent Wipe Relay Windscreen Wiper Relay Cushion Valve Relay Windscreen Washer Windscreen Wiper Motor Shut-off Solenoid
9804/1103
61 62 63 64 65 66 67 68 69 70 71
Cushion Valve Solenoid Starter Switch Fuse Box Battery Relay Battery Sensor Batteries Speaker Aerial Radio Cab Fan Beacon
Fuses 1 - 8 See 45 - 00 - 01/2.
Cable Colour Code B Br G GY L Lg O P R Sb V W Y
Black Brown Green Grey Blue Light Green Orange Pink Red Sky Blue Violet White Yellow
Note : On the JS 110 (from Machine No. 697014) and 130 (from Machine No. 699037), sealed electrical connectors have been introduced on the throttle motor 8 and the swing brake pressure switch 7 (see below).
A183550
45 - 15 - 01/4
Issue 1
CONTENTS
JS 150LC Circuit Diagrams - Electrical
CONTENTS CONTENTS
Excavators
45 - 15 - 01/6
JS 150LC Circuit Diagrams - Electrical Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Hourmeter Monitor Display Unit Proportional Solenoid 2-speed Travel Solenoid Swing Park Solenoid Swing Brake Pressure Switch Throttle Motor Engine Compartment Lamp Refuelling Pump (optional) Horn (110 dB) Horn (120 dB) Working Lamp, Boom Working Lamp, Tank Air Filter Vacuum Switch Fuel Reserve Tank Level Switch Fuel Level Sensor Hydraulic Fluid Temperature Sensor Alternator Low Oil Pressure Switch Filter Switch Engine Coolant Temperature Sensor Engine Intake Heater Engine Intake Heater Relay Horn Selector Switch Horn Relay Emergency Throttle By-pass Switch Emergency By-pass Switch Resistor } CR Filter Condenser } Diode Resistor Resistor Controller Idle/F Selection Switch Mode Switch Throttle Switch Lamp Check Switch Buzzer Idle Switch (Hand Controller) 2-speed Travel Switch Control Switch Horn Switch Engine Stop Relay Timer (Engine Stop) Intermittent Wipe Relay Windscreen Wiper Relay Cushion Valve Relay Windscreen Wiper Motor Windscreen Washer Control Solenoid Cushion Valve Solenoid Starter Switch Beacon Switch Control Switch (Servo Isolator) Cushion Switch Windscreen Wiper Switch Heater Switch Working Lamp Switch Cab Lamp Cab Heater Fuse Box
9804/1103
61 62 63 64 65 66 67 68 69
Battery Relay Battery Sensor Batteries Speaker Aerial Radio Fan Starter Motor Beacon
Fuses 1 - 8 See 45 - 00 - 01/2.
Cable Colour Code B Br G GY L Lg O P R Sb V W Y
Black Brown Green Grey Blue Light Green Orange Pink Red Sky Blue Violet White Yellow
Note: From Machine No. 701045, sealed electrical connectors have been introduced on the throttle motor 7 and the swing brake pressure switch 6 (see below).
CN15
TR1
TR2
R R Br G Y W B
Br G Y W B L
LS1
R1 R3
M
R2 R4
LS2 R5
TR3
TR4
R6
B/L
Br/Y B Br/Y W B
R Br G Y
A183550
45 - 15 - 01/6
Issue 1
CONTENTS
JS 200LC Circuit Diagrams - Electrical
CONTENTS
Excavators
JS 200LC Circuit Diagrams - Electrical Main Components 1 Hourmeter 2 Monitor Display Assembly 3 Proportional Solenoid 4 2-speed Tracking Solenoid 5 Free Swing Solenoid 6 Swing Park Solenoid 7 Swing Brake Pressure Switch 8 Throttle Motor 9 Engine Compartment Lamp 10 Refuelling Pump 11 Horn (110dB) 12 Horn (120 dB) 13 Working Lamp, Boom 14 Working Lamp, Tank 15 Air Filter Vacuum Switch 16 Fuel Reserve Tank Level Switch 17 Fuel Level Sensor 18 Hydraulic Fluid Temperature Sensor 19 Alternator 20 Engine Low Oil Pressure Switch 21 Oil Filter Switch 22 Engine Coolant Temperature Sensor 23 Engine Intake Heater 24 Starter Motor 25 Engine Intake Heater Relay 26 Horn Selector Switch 27 Horn Relay 28 Emergency By-pass Switch 29 Resistor } CR Filter 30 Condenser } 31 Diode 32 Controller (see page 7-9 for plug pin connectors) 33 Idle/F Selector Switch 34 Mode Selector Switch 35 Throttle Selector Switch 36 Free Swing Switch 37 Buzzer Off/Lamp Check Switch 38 Idle Switch (Hand Controller) 39 Cushion Switch 40 Control Switch (Servo Isolator) 41 Throttle Emergency By-pass Switch 42 Windscreen Wiper Switch 43 Heater Switch 44 Working Lamp Switch 45 Cab Heater 46 Cab Lamp and Switch 47 Beacon Switch 48 2-speed Tracking Switch 49 Horn Switch 50 Limit Switch 51 Engine Stop Relay 52 Timer (Engine Stop) 53 Windscreen Wiper Relay 54 Intermittent Wipe Relay 55 Cushion Valve Relay 56 Timer (Boom Down) 57 Windscreen Washer 58 Windscreen Wiper Motor Boom Down Negative Control Delay Switch * 59 60 Cushion Valve Solenoid
* 61 62 63 64 65 66 67 68 69 70 * †71 72 * †73 * †74 * †75 * †76 * ††77 * ††78 * ††79
Servo Isolator Solenoid Boom Down Delay Solenoid Starter Switch Fuse Box Battery Relay Battery Sensor Batteries Speaker Aerial Radio Cab Fan Beacon Air Conditioner Unit Air Conditioner Panel Air Conditioning Drier Air Conditioning Compressor Auxiliary Circuit - Fuse Auxiliary Circuit - Relay Auxiliary Circuit - Flow Priority Valve
*†
Optional
* ††
Only fitted to JS200LR (long reach) models
Fuses * 1-8
See page 45 - 05 - 01/3.
Cable Colour Code B Black Br Brown G Green GY Grey L Blue Lg Light Green O Orange P Pink R Red Sb Sky Blue V Violet W White Y Yellow Note: From Machine No. 704075, sealed electrical connectors have been introduced on the throttle motor 8 and the swing brake pressure switch 7 (see below).
CN15
TR1
TR2
R R Br G Y W B
Br G Y W B L
LS1
R1 R3
M
R2 R4
LS2 R5
TR3
TR4
R6
B/L
Br/Y B Br/Y W B
R Br G Y
A183550
9804/1103
45 - 15 - 01/8
Issue 2*
CONTENTS
JS 240LC Circuit Diagrams - Electrical
CONTENTS
Excavators
JS 240LC Circuit Diagrams - Electrical Main Components 1 Hourmeter 2 Monitor Display Assembly 2-speed Tracking Solenoid *3 4 Free Swing Solenoid 5 Swing Park Solenoid 6 Proportional Solenoid 7 Swing Brake Pressure Switch 8 Throttle Motor 9 Engine Compartment Lamp 10 Refuelling Pump 11 Horn (110 dB) 12 Horn (120 dB) 13 Working Lamp, Boom 14 Working Lamp, Tank 15 Air Filter Vacuum Switch 16 Fuel Reserve Tank Level Switch 17 Fuel Level Sensor 18 Hydraulic Fluid Temperure Sensor 19 Alternator 20 Engine Low Oil Pressure Switch 21 Oil Filter Switch 22 Engine Coolant Temperature Sensor 23 Engine Intake Heater 24 Starter Motor 25 Engine Intake Heater Relay 26 Horn Selector Switch 27 Horn Relay 28 Emergency Throttle By-pass Switch 29 Emergency By-pass Switch 30 Resistor } CR Filter 31 Condenser } 32 Diode 33 Controller (see page 7-9 for plug pin positions) 34 Idle/F Selector Switch 35 Mode Switch 36 Throttle Switch 37 Free Swing Switch 38 Buzzer Off/Lamp Check Switch 39 Idle Switch (Hand Controller) 40 2-speed Tracking Switch 41 Limit Switch 42 Horn Switch 43 Engine Stop Relay 44 Timer (Engine Stop) 45 Windscreen Wiper Relay 46 Intermittent Wipe Relay 47 Cushion Valve Relay 48 Windscreen Washer 49 Windscreen Wiper Motor 50 Servo Isolator Solenoid 51 Cushion Valve Solenoid 52 Starter Switch 53 Beacon Switch 54 Control Switch (Servo Isolator) 55 Cushion Switch 56 Windscreen Wiper Switch 57 Cab Heater Switch 58 Working Lamp Switch 59 Cab Lamp and Switch 60 Cab Heater
9804/1103
61 62 63 64 65 66 67 68 69
Fuses * 1-8
Fuse Box Battery Relay Battery Sensor Batteries Speaker Aerial Radio Cab Fan (Optional) Beacon
See page 45 - 05 - 01/3.
Cable Colour Code B Black Br Brown G Green GY Grey L Blue Lg Light Green O Orange P Pink R Red Sb Sky Blue V Violet W White Y Yellow Note: From Machine No. 708040, sealed electrical connectors have been introduced on the throttle motor 8 and swing brake pressure switch 7 (see below).
45 - 15 - 01/10
A183550
Issue 2*
CONTENTS
JS 300LC Circuit Diagrams - Electrical
CONTENTS
Excavators
JS 300LC Circuit Diagrams - Electrical Main Components 1 Controller 2 Proportional Solenoid 3 2-speed Tracking Solenoid 4 Swing Park Solenoid 5 Cushion Valve Solenoid 6 Free Swing Solenoid 7 Swing Brake Pressure Switch 8 Working Lamp (Tank) 9 Working Lamp (Boom) 10 Horn 11 Air Horn 12 Refuelling Pump 13 Engine Compartment Lamp 14 Throttle Motor 15 Hydraulic Tank Air Pressure Switch 16 Air Filter Vacuum Switch 17 Fuel Reserve Tank Level Switch 18 Fuel Level Sensor 19 Hydraulic Fluid Temperature Sensor 20 Alternator 21 Low Oil Pressure Switch 22 Oil Filter Switch 23 Engine Coolant Temperature Sensor 24 Engine Intake Heater 25 Starter Motor 26 Safety Relay 27 Engine Intake Heater Relay 28 Diode 29 Emergency By-pass Switch 30 Resistor } CR Filter 31 Condenser } 32 Diode 33 Swing Park Switch 34 Buzzer Off/Lamp Check Switch 35 Mode Switch 36 Throttle Switch 37 Emergency By-pass Throttle Switch 38 Beacon Switch 39 Horn Selector Switch 40 Horn Relay 41 Control Switch (Servo Isolator) 42 Cushion Switch 43 Idle Switch (Hand Controller) 44 Free Swing Switch 45 Hourmeter 46 Monitor Display Unit 47 Engine Stop Relay 48 Horn Switch 49 Timer (Engine Stop) 50 Limit Switch 51 Windscreen Wiper Relay 52 Intermittent Wipe Relay 53 Cushion Valve Relay 54 Windscreen Wiper Motor 55 2-speed Tracking Switch 56 Servo Isolator Solenoid 57 Windscreen Washer 58 Cab Lamp and Switch 59 Radio
60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77
Aerial Speaker Beacon Cab Fan Switch (Optional) Cab Fan (Optional) Fuse Box Starter Switch Working Lamp Switch Windscreen Wiper Switch Heater Switch Air Conditioning Compressor (Optional) Drier (Optional) Air Conditioner Panel (Optional) Air Conditioner Unit (Optional) Cab Heater Batteries Battery Sensor Battery Relay
Fuses * 1-8
*
See page 45 - 05 - 01/3.
Cable Colour Code B Black Br Brown G Green GY Grey L Blue Lg Light Green O Orange P Pink R Red Sb Sky Blue V Violet W White Y Yellow Note: From Machine No. 712020, sealed electrical connectors have been introduced on the throttle motor 14 and the swing brake pressure switch 7 (see below).
CN15
TR1
TR2
R R Br G Y W B
Br G Y W B L
LS1
R1 R3
M
R2 R4
LS2 R5
TR3
TR4
R6
B/L
Br/Y B Br/Y W B
R Br G Y
A183550
9804/1103
45 - 15 - 01/12
Issue 2*
CONTENTS
JS 450LC Circuit Diagrams - Electrical
Excavators
CONTENTS
Excavators
JS 450LC Circuit Diagrams - Electrical Main Components 1 Controller 2 Proportional Solenoid 3 2-speed Tracking Solenoid 4 Swing Park Solenoid 5 Cushion Valve Solenoid 6 Free Swing Solenoid 7 Swing Brake Pressure Switch 8 Working Lamp (Tank) 9 Working Lamp (Boom) 10 Horn 11 Air Horn 12 Refuelling Pump 13 Rear Working Lamp 14 Engine Compartment Lamp 15 Throttle Motor 16 Hydraulic Tank Air Pressure Switch 17 Air Filter Vacuum Switch 18 Fuel Reserve Tank Level Switch 19 Fuel Level Sensor 20 Hydraulic Fluid Temperature Sensor 21 Alternator 22 Low Oil Pressure Switch 23 Engine Coolant Temperature Sensor 24 Air Intake Pre-heater 25 Magnetic Valve 26 Starter Motor 27 Safety Relay 28 Air Intake Heater Resistor 29 Heater Relay 30 Diode 31 Emergency By-pass Switch 32 Resistor { CR Filter 33 Condenser { 34 Idle/F Selector Switch 35 Buzzer Off/Lamp Check Switch 36 Mode Switch 37 Throttle Switch 38 Emerency Throttle By-pass Switch 39 Beacon Switch 40 Horn Selection Switch 41 Horn Relay 42 Control Switch (Servo Isolator) 43 Cushion Valve Switch 44 Idle Switch (Hand Controller) 45 Free Swing Switch 46 Hourmeter 47 Monitor Display Unit 48 Engine Stop Relay 49 Horn Switch 50 Limit Switch 51 Timer (Engine Stop) 52 Windscreen Wiper Relay 53 Intermittent Wipe Relay 54 Cushion Valve Relay 55 Windscreen Wiper Motor 56 2-speed Tracking Switch 57 Servo Isolator Solenoid 58 Windscreen Washer 59 Cab Lamp and Switch 60 Radio
9804/1103
61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77
Aerial Speaker Working Lamp Switch Windscreen Wiper Switch Heater Switch Air Conditioning Compressor Air Conditioning Drier Air Conditioning Panel Air Conditioning Unit Batteries Battery Sensor Battery Realy Cab Heater Seat Heater Seat Heater Switch Starter Switch Fuse Box
Fuses * 1 - 8 See page 45 - 05 - 01/3. Cable Colour Code B Black Br Brown G Green GY Grey L Blue Lg Light Green O Orange P Pink R Red Sb Sky Blue V Violet W White Y Yellow Note: From Machine No. 714004, sealed electrical connectors have been introduced on the throttle motor 15 and the swing brake pressure switch 7 (see below).
CN15
TR1
TR2
R R Br G Y W B
Br G Y W B L
LS1
R1 R3
M
R2 R4
LS2 R5
TR3
TR4
R6
B/L
Br/Y B Br/Y W B
R Br G Y
A183550
45 - 15 - 01/14
Issue 2*
CONTENTS
JS 130W,150W Circuit Diagrams - Electrical (Common with JS130, JS150 Tracked Excavators)
CONTENTS
Excavators
JS 130W,150W Circuit Diagrams - Electrical (Common with JS130, JS150 Tracked Excavator) Main Components 1 Hourmeter 2 Monitor Display Unit 3 Proportional Solenoid 4 Gear Change Solenoid 5 Swing Park Solenoid 6 Swing Brake Pressure Switch 7 Throttle Motor 8 Engine Compartment Lamp 9 Refuelling Pump (optional) 10 Horn (110 dB) 11 Horn (120 dB) 12 Working Lamp, Boom 13 Working Lamp, Tank 14 Air Filter Vacuum Switch 15 Fuel Reserve Tank Level Switch 16 Fuel Level Sensor 17 Hydraulic Fluid Temperature Sensor 18 Alternator 19 Low Oil Pressure Switch 20 Filter Switch 21 Engine Coolant Temperature Sensor 22 Engine Intake Heater 23 Engine Intake Heater Relay 24 Horn Selector Switch 25 Horn Relay 26 Emergency Throttle By-pass Switch 27 Emergency By-pass Switch 28 Resistor } CR Filter 29 Condenser } 30 Diode 31 Resistor 32 Resistor 33 Controller 34 Idle/F Selection Switch 35 Mode Switch 36 Throttle Switch 37 Lamp Check Switch Buzzer 38 Idle Switch (Hand Controller) 39 Gearbox Ratio Change 40 Control Switch 41 Horn Switch 42 Engine Stop Relay 43 Timer (Engine Stop) 44 Intermittent Wipe Relay 45 Windscreen Wiper Relay 47 Windscreen Wiper Motor 48 Windscreen Washer 49 Control Solenoid 51 Starter Switch 52 Beacon Switch 53 Control Switch (Servo Isolator) 55 Windscreen Wiper Switch 56 Heater Switch 57 Working Lamp Switch 58 Cab Lamp 59 Cab Heater 60 Fuse Box 61 Battery Relay 62 Battery Sensor 63 Batteries
9804/1103
64 65 66 67 68 69
Speaker Aerial Radio Fan Starter Motor Beacon
Fuses See pages 45 - 05 - 01/4, 01/5. Note: Some cables are colour coded, others are numbered at intervals along their whole length. Cable Colour Code B Black Br Brown G Green GY Grey L Blue Lg Light Green O Orange P Pink R Red Sb Sky Blue V Violet W White Y Yellow
45 - 15 - 02/2
Issue 1
CONTENTS
JS 130W,150W Circuit Diagrams - Electrical (additional to JS130, JS150 Tracked Excavator)
CONTENTS
JS 130W,150W Circuit Diagrams - Electrical (additional to JS130, JS150 Tracked Excavator) Key A B C D E F G H J K L M N P R S T U V W X Y Z
Relay Box Brake Pressure Switch Low Accumulator Pressure Switch Steering Column Switch Assembly Light Cluster - Left Front Light Cluster - Right Front Dipper Side Light (optional) Hazard Light Switch Grab/Rockbreaker Left Switch (Joystick Mounted) Isolator Relay Batteries Binnacle and SCM Monitor Light Cluster - Left Rear Light Cluster - Right Rear Number Plate Lamp Pressure Switch - Drive Isolator Solenoid Cigar Lighter Ignition Switch Grab/Rockbreaker Right Switch (Joystick Mounted) Working Lights Switch Windscreen Wash/Wipe Switch Reverse Pressure Switch Gear Change Signal
Solenoids SOL 3 SOL 4 SOL 5 SOL 6 SOL 7 SOL 8 SOL 9 SOL 10 SOL 13 SOL 14 SOL 15 SOL 16 SOL 17 SOL 18 SOL 19 SOL 20 SOL 21 SOL 22 SOL 23
Drive Motor Range Change Brake Inhibit Creep Speed Drive Isolator Triple Articulation - Down Triple Articulation - Up Creep Speed Creep Speed Boom/Dozer-Up Boom/Dozer-Down Axle Lock Stabiliser - Right Stabiliser - Left Gear Change Park Brake Grab Rotate - Left Grab Rotate - Right Rockbreaker/Auxiliary - Left Rockbreaker/Auxiliary - Right
Wire Functions (cont'd)
Wire Functions (cont'd)
Wire No 013 014 015 016 017 018 020 021 022 024 025 026 027 028 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 049 050 051
Hazard Lights - Switched Drive Isolator Axle Lock Reverse Lights Creep Speed Binnacle - Switched Brake Inhibit Signal Grab/Rockbreaker Switch Feed Cigar Lighter Feed Ignition ON Signal Wash/Wipe Supply Headlights 24V, Switched Brake Switch Feed Full Flash Pressure Switch Feed to S Grab/Rockbreaker Feed Low Accumulator Switch Feed Headlights - Fused Side Fog Lights - Fused Side Cigar Lighter - Fused Side Stabiliser Left - Fused Side Stabiliser Right - Fused Side Triple Articulation - Fused Side Axle Lock - Fused Side Brake Inhibit - Fused Side Binnacle Switched - Fused Side Brake Lights - Fused Side Reversing Lights - Fused Side Dozer - Fused Side Park Brake - Fused Side Drive Motor Range Change - Fused Side Creep Speed - Fused Side Grab Rotate/Rockbreaker - Fused Side Drive Isolator - Fused Side Relays, Switched - Fused Side Hazard Lights, Switched- Fused Side
Wire No 600 601 602 603 604 605 606 607 613 614 615 616 617
200 201 202 203 205
Relays, Unswitched Sidelights, Right Binnacle, Unswitched Hazard Lights, Unswitched 24V, Unswitched
618 619 620 621 622 623 624 625 626 627 628 629 630
Cigar Lighter, Earth Wash/Wipe, Earth Earth Full Beam/Low Accumulator, Return Drive Isolator Solenoid, -ve Triple Articulation Solenoids, -ve Creep Speed Solenoids, -ve Boom/Dozer Solenoids, -ve Earth, Left Rear Light Cluster Earth, Right Rear Light Cluster Earth, Left Front Light Cluster Wash/Wipe Earth to Switch Earth, Right Front Light Cluster/Dipper Side (optional) Axle Lock Solenoid, -ve Stabiliser Right Solenoid, -ve Stabiliser Left Solenoid, -ve Rockbreaker Right Solenoid, -ve Grab Rotate Left Solenoid, -ve Grab Rotate Right Solenoid, -ve Rockbreaker Left, -ve Range Change Solenoid, -ve Brake Inhibit Solenoid, -ve Park Brake Solenoid, -ve Earth Battery -ve Vehicle Chassis
800 801 802 803 804 805 806 807 808 809 810 811 812 813 814
Working Lights Supply Grab/Rockbreaker Switch Return Cigar Lighter Lamp Intermittent Wipe Output Continuous Wipe Output Screen Wash Output Axle Lock Axle Lock With Brake Stabiliser, Right Triple Articulation Stabiliser, Left Fog Light Creep Speed Park Brake Range Change
CONTENTS
JS 130W,150W Circuit Diagrams - Electrical (Relay Box P.C.B.) Key Relays RL1 RL2 RL3 RL4 RL5 RL6 RL7 RL8 RL9 RL10 RL11 RL12 RL13 RL14 RL15 RL16 RL17 RL18 RL19
Auxiliary Stabiliser, Left Stabiliser, Right Triple Articulation Creep Speed Timer Dozer Park Brake Drive Motor Range Change Fog Lights Headlights Intermittent Wipe Sidelights Brake/Axle Lock Continuous Wipe Working Lights Axle Lock Flasher Ignition
Test Points P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P20
Function 24V Unswitched 24V Switched Main Beam/Accummulator Low Return Earth Earth from TSP* 'Dozer' Switch Earth from TSP* 'Auxiliary' Switch Sidelights Relay Input Emergency Steer Warning Light Output Earth from TSP* 'Axle Lock/Brake' Switch Earth from TSP* 'Park Brake' Switch Earth from TSP* 'Stabiliser Left' Switch Earth from TSP* 'Range Change' Switch Earth from TSP* 'Fog Light' Switch Earth from TSP* 'Stabiliser Right' Switch Indicator Warning Light Main Beam Warning Light Indicator Warning Light Earth from TSP* 'Axle Lock' Switch Earth from TSP* 'Triple Articulation' Switch Earth from TSP* 'Headlights' Switch
Test Points P34 P35 P36 P37 P38 P39 P40 P41 P42 P43 P44 P45 P46 P47 P48 P49 P50 P51 P52 P53 P54 P55 P56 P57 P58 P59 P60 P61 P62 P63 P64 P65 P66 P67 P68 P69 P70 P71 P72 P73 P74 P75 P76 P77
Function Binnacle Switch (to P83) Cigar Lighter (to P69) Relay P.C.B. Switch (to P69) Grab Rotate/Rockbreaker (to P86) Creep (to P75) Drive Motor Range Change (P85) Wiper Supply Ignition ON Signal to Ignition Relay Drive Isolator (to P87) Dozer (to P70) 24V Unswitched, Relay P.C.B. Triple Articulation (to P82) Stabiliser, Left (to P72) Stabiliser, Right (to P73) 24V Switched, from Ignition Switch 'C' Brake Inhibit (to P74) Park Brake (to P71) Right Toggle Switch, N/O Axle Lock (to P84) Sidelights, Right Sidelights, Left Supply to Working Lights Not used 24V Unswitched, Hazard Cigar Lighter Lamp Output 24V Switched, Headlights 24V Switched, Fog Lights 24V Switched, Hazard Switch 24V Switched, Brake Lights 24V Switched, Reverse Lights Screen Wash Output Cigar Lighter Output Continuous Wipe Output 24V Unswitched, Relay P.C.B. 24V Unswitched, Binnacle 24V Switched, Relay P.C.B. Switch 24V Switched, Dozer 24V Switched, Park Brake 24V Switched, Stabiliser Left 24V Switched, Stabiliser Right 24V Switched, Brake Inhibit 24V Switched, Creep Earth, Wash/Wipe Intermittent Wipe Output
Test Points P91 P92 P93 P94 P95 P96 P97 P98 P99 P100 P101 P102 P103 P104 P105 P106 P107 P108 P109 P110 P111 P112 P113 P114 P115 P116 P117 P118 P119 P120 P121 P122 P123 P124 P125 P126 P127 P128 P129 P130 P131 P132 P133 P134
Function Axle Lock Solenoid, Return Grab Rotate Left Solenoid Return Stabiliser Right Solenoid, Return Grab Rotate Solenoid Right Return Stabiliser Left Solenoid Return Rockbreaker Left Solenoid Return Rockbreaker Right Solenoid Return Grab Rotate Left Solenoid Feed Grab Rotate Right Solenoid Feed Rockbreaker Left Solenoid Feed Rockbreaker Right Solenoid Feed Gearchange Pressure Switch Supply Range Change Solenoid, Return Brake Inhibit Solenoid Return Park Brake Solenoid Return Park Brake Solenoid Feed Range Change Solenoid Feed Gear Change Pressure Switch Return Brake Inhibit Solenoid Feed Right Brake Light Output Left Brake Light Output Fog Light Left Output Fog Light Right Output Reverse Light Left Output Reverse Light Right Output Sidelight, Rear Right Output Sidelight, Rear Left Output Left Rear Indicator Output Right Rear Indicator Output Earth, Left Rear Light Earth, Right Rear Light Sidelight, Front Right Output Full Beam Output, Right Right Front Indicator Output Dipped Beam Output, Right Earth, Right Front Lights Horn Output Left Toggle Switch, Common Left Toggle Switch, N/O 24V Switched, to Hazard Switch Hazard Switch Lamp 24V Unswitched to Hazard Switch Earth, Hazard Switch Flash Output to Hazard
CONTENTS
JS 130W,150W Circuit Diagrams - Electrical (Relay Box P.C.B.)
CONTENTS
Excavators
45 - 15 - 02/7
JS 130W from m/c no. 716501,160W from m/c no. 718501 Circuit Diagrams - Electrical Component Key 1 2 3 4 6 7 8 10 11 12 13 14 15 16 17 18 19A 19B 19C 20A 20B 20C 20D 20E 20F 20G 20H 20J 20K 20L 20M 20N 21A 21B 22 23 24 25 26/28 30A 30B 31 32 33 34 35 36 37 38A 38B 38C 38D 39 40A 40B 41 42 43 44 45 46
Cigar Lighter Loudspeaker Radio Aerial Lead Radio (Standard) System Controller (Computer) Fuse Box Switch Panel - Left Hand (Standard) Limit Switch - Lever Lock (Gate) Limit Switch - Lever Lock (Console) Switch - Free Swing (Optional) Horn Push Switch Panel - Right Hand Switch - Speed Change Switch - One Touch Idle Monitor, Controller Driver Push-button - Breaker Pilot Pressure Push-button - Boom Pilot Pressure Push-button - Swing Pilot Pressure Relay - Fan 1 Relay - Fan 2 Relay - Fan 3 Relay - Horn Relay - Horn Volume Relay - Screenwasher Relay - Screenwiper Relay - Lamp (Boom) Relay - Auxiliary Lamps (Optional) Relay - Cab Working Light Relay - Lever Lock Relay - Engine Shutdown 1 Relay - Engine Shutdown 2 Wiper Motor Cab Light Air Conditioning Unit Cab Heater Starter Switch Motor - Engine Shut-down Batteries Fusible Link - Starter Switch/Back-up Fuses Fusible Link - Engine Shut-down Fuse Fusible Link - Fuse Box Relay - Battery Solenoid Valve Free Swing (Optional) Solenoid Valve Block Solenoid Valve - Swing Brake/Swing Lock Alternator Starter Motor Oil Pressure Sensor Oil Filter Pressure Sensor Water Temperature Sensor Engine Speed Sensor Glow Plugs Sensor - Water Temperature Sensor - Hydraulic Oil Temperature Warning Buzzer Air Conditioning - Drier Switch Air Conditioning - Compressor Magnetic Clutch Motor - Screen Washer Relay - Engine Glow Plugs Horn - Loud
9804/1103
47 48 49 50 51 52 53 54 57 58 59 60 61 62 63 64A 64B 64C 65 66
Horn - Standard Working Lights - Cab Mounted Working Lights - Boom Mounted Sensor - Fuel Level Switch - Hydraulic Oil Overheat Switch - Hydraulic Oil Tank Level Switch - Air Filter Blocked Control - Hydraulic Pump Pressure Switch - Upper Pilot Pressure Motor - Engine Throttle Solenoid - Breaker Pilot Pressure (Optional) Pressure Switch - Travel Pilot Pressure Pressure Switch - Angle Sensor (Optional) Controller - Optional Monitor - Optional Angle Sensor - Dipper (Optional) Angle Sensor - Bucket (Optional) Angle Sensor - Boom (Optional) Solenoid (3) - (Optional) Switch - Double (Optional)
Cable Colour Code B W Br P V G O R Y Lg Sb L Gr
45 - 15 - 02/7
Black White Brown Pink Violet Green Orange Red Yellow Light Green Sky Blue Blue Grey
Issue 1
Excavators
CONTENTS CONTENTS
45 - 15 - 02/8
JS 130W from m/c no. 716501, JS 160W from m/c no. 718501 Circuit Diagrams - Electrical * 25 13
37
26
20
18
32
12
29
24 17
19
39 36
8
30
11 3
5
4
6
7
27
15
16
14
32A
32E
32F
32B 32C
28
23
32G 33
35
34
32D 39A
39C 39B
39E
39F
39K 39H
39G 39D
39L
39J
22 2
10
1
21
9
38
31
70
40
56
54
67
57
66
41
66A
40A
52
66C 66E 66B 66D
68
68A
68B
68C
68D
68E
68F
68G
55H 55E
43C 43B
43D
43E 55G
43F 43A
59
55F 51
43G 43H 43J 43K
47
53 50 55 63
50A
46
58 50J
43
45
49
50B
50C 50E 50G 50D 50F
55A
55B
55C
50H 61 65
X 62
48
Y
64
42 44
9804/1103
45 - 15 - 02/8
Issue 2*
CONTENTS
Excavators
45 - 15 - 02/9
JS 130W from m/c no. 716501,160W from m/c no. 718501 Circuit Diagrams - Electrical Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
33 34 35 36 37 38 39
40 40A 41
Plug 1 Switch Box 1 Park Brake Solenoid Stabiliser Up Solenoid Stabiliser Down Solenoid Stabiliser Right Hand Side Stabiliser Left Hand Side Fuse 3 Plug 2 Switch Box 2 Lamp Box Left Hand Side Front Lights Lamp Box Left Hand Side Rear Lights Lamp Box Arm Sidelights - German Homologation Option Axle Lock Solenoid Dozer Solenoid Fuse 1 Fuse Box Brake Light Switch Fuse 5 Fuse Box Reverse Light Pressure Switch Fuse 6 Plug 3 Switch Box 3 Lamp Box Right Hand Side Front LIghts Lamp Box Right Hand Side Rear Lights Number Plate Lights Number Plate Lights Grab Clockwise Solenoid Grab Counter Clockwise Solenoid Low Flow Priority Valve - Option Fuse 2 Socket 1 Stabiliser Switch Panel A Left Hand Stabiliser Up B OV C Illumination Supply D Back Light Feed E Left Hand Stabiliser Down F Right Hand Stabiliser Up G Right Hand Stabiliser Down Dozer Switch Dozer Switch Hazard Switch Connections to Diagram 1 Horn Switch Socket 2 Column Switch A Continuous Wiper B Intermittent Wiper C Screen Wash D Horn E Earth F Headlight Return G Headlight In H Headlight Flash J Indicator Left K Indicator Right L Indicator Return Plug 4, Axle Lock with Brakes Signal Low Accumulator Pressure Switch
9804/1103
42 43 44 45 46 47 48 49 50
51 52 53 54 55
56 57 58 59 61 62 63 64 65 66
67 68
70
45 - 15 - 02/9
Battery Isolator (Item 32 on Diagram 1) X and Y indicate connection points to Diagram 1. Fuse Box Connections to Item 6 on Diagram 1 (CN6) Gear Change Solenoid P2 Solenoid Valve P1 Solenoid Valve Connections to Item 6 on Diagram 1 (CN5) Travel Pressure Switch Connections to Diagram 1 A Computer Control Fuse in Item 7 B Item 14 (CN14) C Item 20F D Item 20G E Item 20K F Item 20H G Item 14 on Diagram 1 (CN14) H Item 8 on Diagram 1 (CN11) J Item 14 on Diagram 1 (CN12) Grab Counter Clockwise Switch - Right Hand Control Machine Ignition Switch Grab Clockwise Switch - Right Hand Control Socket 3 Connections to Diagram 1 A Item 6 (CN3) B Item 6 (CN7) C Item 6 (CN5) E Item 6 (CN2) F Item 6 (CN5) G Item 6 (CN5) H Item 6 (CN5) Socket 4 Main Frame Earth Left Hand Hand Control Switch Hammer Relay 1 Reverse Lights Press Switch Hammer Solenoid Drive Isolator Relay Drive Isolator Switch Drive Isolator Solenoid Status Monitor A Main Beam B Indicators/Hazard C Low Accumulator Warning Light D Emergency Steer Warning Light E Dozer Select Plug 5 Sub Monitor A Headlights B Sidelights C Fog Light D Park Brake E Axle Lock with Brakes F Axle Lock G Creep Speed Wheel Controller
Issue 1
CONTENTS
Excavators
45 - 15 - 02/10
JS 130W from m/c no. 716501,160W from m/c no. 718501 Circuit Diagrams - Electrical Cable Colour Code R BL G Y W BK
Red Blue Green Yellow White Black
9804/1103
V O P T GY BN
Violet Orange Pink Torquoise Grey Brown
45 - 15 - 02/10
Issue 1
CONTENTS
JS 70 (Standard Boom to m/c 695001) Circuit Diagrams - Hydraulic
CONTENTS
Excavators
45 - 15 - 02/11A
JS 130 from m/c no. 758000, JS 160 from m/c no. 702000 Circuit Diagrams - Electrical Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19A 19B 19C 20A 20B 20C 20D 20E 20F 20G 20H 20J 20K 20L 20M 20N 21 22 23 24 25 26/28 27/29 30A 30B 31 32 33 34 35 36 40A 40B 41 42 43 44 45 46 47 48
Cigar Lighter Loudspeaker Radio Aerial Lead Radio (Standard) Radio (AM/FM) (Optional) System Controller (Computer) Fuse Box Switch Panel - Left Hand (Standard) Switch Panel - Left Hand (Optional) Limit Switch - Lever Lock (Gate) Limit Switch - Lever Lock (Console) Switch - Free Swing (Optional) Horn Push Switch Panel - Right Hand Switch - Speed Change Switch - One Touch Idle Monitor, Controller Driver Push-button - Breaker Pilot Pressure Push-button - Boom Pilot Pressure Push-button - Swing Pilot Pressure Relay - Fan 1 Relay - Fan 2 Relay - Fan 3 Relay - Horn Relay - Horn volume Relay - Screen Washer Relay - Screen Wiper Relay - Lamp (Boom) Relay - Auxiliary Lamps (Optional) Relay - Cab Light Relay - Lever Lock Relay - Engine Shutdown 1 Relay - Engine shutdown 2 Indicator Lamp-wiper Motor Air Conditioning Unit Cab Heater Starter Switch Motor - Engine Shut-down Batteries - Standard Batteries - Heavy Duty (Optional) Fusible Link - Starter Switch/Back-up Fuses Fusible Link - Engine Shut-down Fuse Fusible Link - Fuse Box Relay - Battery Solenoid Valve Free Swing (Optional) Solenoid Valve Block Solenoid Valve - Swing Brake/Swing Lock Engine Block Sensor - Water Temperature Sensor - Hydraulic Oil Temperature Warning Buzzer Air Conditioning - Drier Switch Air Conditioning - Compressor Magnetic Clutch Motor - Screen Washer Relay - Engine Glow Plugs Horn - Loud Horn - Standard Working Lights - Cab Mounted
9804/1103
49 50 51 52 53 54 57 58 59 60 61 62 63 64A 64B 64C 65 66 67
45 - 15 - 02/11A
Working Lights - Boom Mounted Sensor - Fuel Level Switch - Hydraulic Oil Overheat Switch - Hydraulic Oil Reserve Tank Level Switch - Air Filter Blocked Control - Hydraulic Pump Pressure Switch - Upper Pilot Pressure Motor - Engine Throttle Solenoid - Breaker Pilot Pressure (Optional) Pressure Switch - Travel Pilot Pressure Pressure Switch - Angle Sensor (Optional) Controller - Optional Monitor - Optional Angle Sensor - Dipper (Optional) Angle Sensor - Bucket (Optional) Angle Sensor - Boom (Optional) Solenoid (3) - Optional Switch - Double (Optional) Monitor - Optional
6410 - C/2-3.1
Issue 1
Excavators
CONTENTS CONTENTS
45 - 15 - 02/11B
JS 130 from m/c no. 758000, JS 160 from m/c no. 702000 Circuit Diagrams - Electrical
ILLUSTRATION NOT AVAILABLE AT THIS TIME
9804/1103
45 - 15 - 02/11B
6410 - C/2-4.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 15 - 02/12
JS 200W from m/c no. 809000 Circuit Diagrams - Electrical Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 59
Headlamp (RH dip) Headlamp (LH dip) Number Plate Lamp Pressure Switch Coolant Overheat Switch Engine Oil Pressure Switch Refuelling Pump A/C Compressor Washer Heater Assembly Air Conditioning Assembly Battery Work Lamps Fuse Box Relay Oil Temperature Sensor Oil Overheat Switch Changeover Solenoid Valve Stabiliser Solenoid Valve Column Switch Horn Stabiliser Switch Panel Sub Monitor Wheel Controller Status Monitor Harness Harness Harness Harness Harness Controller Assembly Rear Lamp LH Rear Lamp RH Air Filter Switch A/C Pressure Switch Engine Speed Sensor Sensor - Water Temperature Sensor - Hydraulic Oil Temperature Proportional Solenoid Valve Low Flow (Grab) Transmission Valve Solenoid Valve Assembly Low Flow (W/Cut) Amplifier Low Accumulator Pressure Switch Brake Valve Pressure Switch Fuel Level Sensor Resistor Assembly Travel Pilot Pressure Switch Upper Pressure Switch Swing Solenoid Valve Battery Relay Throttle Motor Panel Switch Assembly LH Panel Switch Assembly RH Key Switch Throttle Driver Monitor
9804/1103
45 - 15 - 02/12
6320 - C/2-4.1
Issue 1
CONTENTS
Excavators
45 - 15 - 02/13
JS 200W from m/c no. 809000 Circuit Diagrams - Electrical (cont’d)
SEE SERVICE MANUAL
9804/1103
45 - 15 - 02/13
6320 - C/2-5.1
Issue 1
CONTENTS
Excavators
45 - 15 - 02/13A
JS 200, 220 from m/c no. 705001 JS 240 from m/c no. 708501 Circuit Diagrams - Electrical Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19A 19B 19C 20A 20B 20C 20D 20E 20F 20G 20H 20J 20K 20L 20M 20N 21 22 23 24 25 26/28 27/29 30A 30B 31 32 33 34 35 36 40A 40B 41 42 43 44 45 46 47
Cigar Lighter Loudspeaker Radio Aerial Lead Radio (Standard) Radio (AM/FM) (Optional) System Controller (Computer) Fuse Box Switch Panel - Left Hand (Standard) Switch Panel - Left Hand (Optional) Limit Switch - Lever Lock (Gate) Limit Switch - Lever Lock (Console) Switch - Free Swing (Optional) Horn Push Switch Panel - Right Hand Switch - Speed Change Switch - One touch Idle Monitor, Controller Driver Push-button - Breaker Pilot Pressure Push-button - Boom Pilot Pressure Push-button - Swing Pilot Pressure Relay - Fan 1 Relay - Fan 2 Relay - Fan 3 Relay - Horn Relay - Horn Volume Relay - Screenwasher Relay - Screenwiper Relay - Lamp (Boom) Relay - Auxiliary Lamps (Optional) Relay - Cab Light Relay - Lever Lock Relay - Engine Shutdown 1 Relay - Engine Shutdown 2 Indicator Lamp-wiper Motor Air Conditioning Unit Cab Heater Starter Switch Motor - Engine Shut-down Batteries - Standard Batteries - Heavy Duty (Optional) Fusible Link - Starter Switch/Back-up Fuses Fusible Link - Engine Shut-down Fuse Fusible Link - Fuse Box Relay - Battery Solenoid Valve Free Swing (Optional) Solenoid Valve Block Solenoid Valve - Swing Brake/Swing Lock Engine Block Sensor - Water Temperature Sensor - Hydraulic Oil Temperature Warning Buzzer Air Conditioning - Drier Switch Air Conditioning - Compressor Magnetic Clutch Motor - Screen Washer Relay - Engine Glow Plugs Horn - Loud Horn - Standard
9804/1103
48 49 50 51 52 53 54 57 58 59 60 61 62 63 64A 64B 64C 65 66 68
45 - 15 - 02/13A
Working Lights - Cab Mounted Working Lights - Boom Mounted Sensor - Fuel Level Switch - Hydraulic Oil Overheat Switch - Hydraulic Oil Reserve Tank Level Switch - Air Filter Blocked Control - Hydraulic Pump Pressure Switch - Upper Pilot Pressure Motor - Engine Throttle Solenoid - Breaker Pilot Pressure (Optional) Pressure Switch - Travel Pilot Pressure Pressure switch - Angle Sensor (Optional) Controller - Optional Monitor - Optional Angle Sensor - Dipper (Optional) Angle Sensor - Bucket (Optional) Angle Sensor - Boom (Optional) Solenoid (3) - Optional Switch - Double (Optional) Monitor (Optional)
6400 - C/2-3.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 15 - 02/13B
JS 200, 220 from m/c no. 705001 JS 240 from m/c no. 708501 Circuit Diagrams - Electrical (cont’d)
ILLUSTRATION NOT AVAILABLE AT THIS TIME
9804/1103
45 - 15 - 02/13B
6400 - C/2-?.?
Issue 1
CONTENTS
Excavators
45 - 15 - 02/14
JS 330 from m/c no. 712501 Circuit Diagrams - Electrical Main Components - JS330 (CAPS II) 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 19 20 20A 21A 21B 21C 21D 21E 21F 21G 21J 21K 21L 21M 22 23 24 25 26A 26B 27 29 30 31 32 33 34 35 36 37 38A 38B 39 40 41 42 43 44 45 46 47 48 49
Cigar Lighter Speaker Antenna Cord Radio Set Controller (Computer) Fusebox Switch Panel - L(LH) Switch Switch (Option) Limit Switch (Gate) Limit Switch (Console) Horn Throttle Volume Switch Switch Panel (RH) Travel Switch One Touch Idle Switch Driver Pilot Pressure Switch (Boom Down) Option Relay - Beacon Relay - Boom Light Relay - Cab Light Relay - Windshield wiper Relay - Windshield washer Relay - Horn Relay - Fan 3 Relay - Fan 2 Relay - Fan 1 Relay - Engine Shutdown 1 Relay - Engine shutdown 2 Cab Light/Wiper Motor Air Conditioner (Unit) Starter Switch Battery Fusible Link - Starter Switch/Back-up Fuses Fusible Link - Engine Shut Down Fuse Fusible Link - Main Battery Relay Battery Safety Relay Solenoid Valve Solenoid Valve - Swing Brake/Lock Solenoid Valve Solenoid Valve - High Dump Diesel Engine Diesel Engine Water Temperature Sensor Hydraulic Oil Temperature Sensor Warning buzzer Relay - Heating (Engine Glow Plugs) Washer Tank Compressor Cooler Cooler/Drier Unit Horn (Air) Horn (Standard) Working Light (Cab) Working Light (Boom) Hydraulic Pump Control - Hydraulic Pump
9804/1103
50 51 52 53 54 55 56 57 59 60 61 62 63 64 65
45 - 15 - 02/14
Throttle Motor Fuel Sensor Thermo Switch (Hyd.) Level Switch (Reserve Tank) Air Filter Sensor Pressure Switch (Sump Tank) Pressure Switch (Upper Pilot) Pressure Switch (Travel Pilot) Pilot Pressure Switch (Boom Up) Solenoid Valve (Option) Solenoid Valve (Option) Switch Panel (LH) Switch Panel (RH) (Beacon) Switch (Option) Monitor
6420 - C/2-3.3
Issue 2*
Excavators
CONTENTS
45 - 15 - 02/15
JS 330 from m/c no. 712501 Circuit Diagrams - Electrical (cont’d)
SEE SERVICE MANUAL
9804/1103
45 - 15 - 02/15
6420 - C/2-4.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 15 - 02/16
JS 450 from m/c no. 714501 Circuit Diagrams - Electrical Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15A 15B 15C 15D 15E 15F 15G 15H 15J 15K 15L 15M 15N 16 17 18 19 20 21A 21B 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40A 40B 40C 41 42A 42B 43
Cigar Lighter Controller (Computer) Fuse Box Starter Switch Switch Panel (LH) High Dump Switch Limit Switch (Gate) Limit Switch (Console) Switch (Horn) Switch (Throttle Volume) Switch Panel (RH) Travel Switch Switch (One Touch Idle) Monitor Relay - Beacon Relay - Boom Light Relay - Cab Light Relay - Windshield Wiper Relay - Windshield Washer Relay - Horn Volume Relay - Horn Relay - Fan 3 Relay - Fan 2 Relay - Fan 1 Relay - Engine Shutdown 1 Relay - Engine Shutdown 2 Relay - Lever Lock Air conditioner (Unit) Cab Driver Engine Shutdown Motor Batteries Fuse - Key Switch Back-up Fuse - Shutdown Fuse - Main Battery Relay Solenoid Valve Safety Relay Valve (Swing Lock/Brake) Diesel Engine Solenoid Valve - High Dump Cooler/Drier Unit Compressor Cooler Washer Tank Relay - Heating (Engine Glow Plugs) Resistor (Air Heater) Horn (Air) Horn (Standard) Working Light (Cab) Working Light (Boom) Hydraulic Pump Pressure Switch (Upper Pilot) Pressure Switch (Swing Pilot) Pressure Switch (Boom Up) Pressure Switch (Boom Down) Pressure Switch (Travel Pilot) Thermo Sensor (Hyd) Thermo Sensor (Water) Fuel Sensor
9804/1103
44 45 46 47 48 49
45 - 15 - 02/16
Thermo Switch (Hyd) Level Switch (Reserve Tank) Air Filter Sensor Pressure Switch (Sump Tank) Throttle Motor Warning Buzzer
6420 - C/2-5.1
Issue 1
Excavators
CONTENTS
* JS
45 - 15 - 01/17
450 from m/c no. 714501
Circuit Diagrams - Electrical (cont’d)
SEE SERVICE MANUAL
9804/1103
45 - 15 - 01/17
640 - C/-6.1
Issue 1
CONTENTS
Excavators
45 - 15 - 02/18
JS330/JS460 - AMS Circuit Diagrams - Electrical Main Components - JS330/JS460 - AMS Refer to Service Manual Supplement 9803/6450 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57
Electronic Control Unit Electronic Monitor System Fascia Switch Panel Fuse Box Assembly Fuse Box Assembly Throttle Dial Key Switch Switch (Limp mode) Air Conditioner Heater Switch Body Switch Cap (Worklamp) Switch Cap (Boom Priority) Cigar Lighter Radio Cassette Limit Switch (Lever) Limit Switch (Console) Switch (Travel Change) Work Lamp Work Lamp Breaker Pilot Switch LH Lever Switch RH Lever Switch Relay (Radio) Relay (Stop Solenoid) Wiper Room Lamp Battery Relay Battery (JS330) Fuse Link (25A) Fuse Link (60A) Stop Solenoid Valve Solenoid Valve Solenoid Engine (JS330) Pilot Switch, Upper Pilot Switch, Travel Pilot Switch Throttle Position Sensor Engine Control Solenoid Travel Alarm Pump (JS330) Refuel Pump A/C Suppression LEad Beacon Air Con Compressor Air Con Binary Switch Horn Washer Pre Heat Relay Temperature Sensor Overheat Switch Fuel Level Sensor Coolant Level Switch Air FIlter Blocked Switch Overload Pressure Switch Electronic Control Unit LH Switch Panel
9804/1103
58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 86 88 89
45 - 15 - 02/18
Switch Cap (Road Lamps) Switch Body Switch Cap (Fog Lamps) Switch Cap (Hazards) Column Switch Headlamp (RH Dip) Headlamp (LH Dip) Rear Lamp RH Rear Lamp LH Number Plate Lamp Arm Side Lamp Stabiliser Solenoid Assembly Transmission Valve Grab Rotate Valve Priority Valve Solenoid Valve Breaker Solenoid Valve Dig Isolate Solenoid Dozer Solenoid Valve Transmission Pressure Valve Pressure Switch Low Brake Pressure Switch Connector Switch Body Switch Harness Harness Harness Heater Switch Direction Control Valve Solenoid Valve
6420 - C/2-7.1
Issue 1*
CONTENTS
* JS330/JS460
Excavators
45 - 15 - 02/19
- AMS
Circuit Diagrams - Electrical (cont’d) Refer to Service Manual Supplement 9803/6450
SEE SERVICE MANUAL
9804/1103
45 - 15 - 02/19
640 - C/-4.2
Issue 1*
CONTENTS
Excavators
45 - 15 - 02/20
JS460 Tier 2 Circuit Diagrams - Electrical The item numbers in the following list are identified on the wiring schematic. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 38 39 40 41 42 43 44 45 46 47 48 50 51 52 53 54 55 59 86 88 89
Electronic Control Unit (ECU) Electonic Montior System (EMS) Facia Switch Panel Fuse Box Assembly Throttle Dial Key Switch Switch (Redundancy) Air Conditioner Switch ( Air Conditioner) Switch Body (Work Lamp) Switch Cap (Work Lamp) Switch (Boom Priority) Cigar Lighter Radio Limit Switch (Lever) Limit Switch (Console) Switch (Travel Change) Work Lamp Work Lamp Breaker Pilot Switch Left Hand Lever Switch Right Hand Lever Switch Relay (Radio) Relay (Stop Solenoid) Wiper Room Lamp Battery Relay Battery Fuse Link (25A) Fuse Link (60A) Stop Solenoid Solenoid Valve Solenoid Valve Engine Pilot Switch, Upper Pilot Switch, Travel Throttle Position Sensor Engine Control Solenoid Travel Alarm Pump Refuel Pump A/C Suppression Lead Beacon Air Conditioning Compressor Air Conditioning Binary Switch Horn Washer Temperature Sensor Over Heat Switch Fuel Level Sensor Coolant Level Switch Air Filter Blocked Switch Over Load Pressure Switch Switch Body Heater Switch Direction Control Valve Solenoid Valve
9804/1103
45 - 15 - 02/20
6420 - C/2-8.1
Issue 1
11 10
BLOWER SWITCH
C49
C24
+
1
2
86
2
0.5 B
3
3
6
5
1.0 B
2
1
2
5
6
3
7
8
7
WORKLAMP SW
8
C16
HI
ME
LO
OFF
0.5 P
0.5 B
0.5 P
0.5 B
LIGHTER
CIGAR
MONITOR (EMS)
18 17 16 15 14 13 12 11 10 9
9
8
7
6
5
4
3
2
0.5 UW
0.5 UB
0.5 UO
C14
1.0 B
1
4
1.0 B
0.5 BW
I/P21 LOWER WIPER
0.5 B
0.5 B
0.5 BW
0.5 YW
I/P37 RES TANK SW
0.5 B
0.5 B
0.5 BW
0.5 BW
0.5 YG
I/P35 ENG OIL PRESS
0.5 UY
0.5 B
0.5 BW
0.5 BW
0.5 B
0.5 BW
0.5 GW
I/P25 HYD OIL LEVEL
0.5 RS
IGNIION SUPPLY
0.5 UR
I/P30 GRAB CW
1.0 B
0.5 OB
I/P26 UPPER PILOT
0.5 YR
0.5 BW
9 10
C41
C40
13
8
0.5 RW
0.5 RS
0.5 Y
0.5 UY
0.5 UO
0.5 UB
0.5 UW
0.5 UK
0.5 U
0.5 U
0.5 R
0.5 B
0.5 PU
0.5 SR
0.5 P
3
2
1
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0.5 Y
0.5 UY
0.5 UO
0.5 UB
0.5 UW
0.5 UK
0.5 U
0.5 U
0.5 R
0.5 B
0.5 PU
0.5 SR
0.5 P
C180
C181
1
2
3
C39
4
5
6
7
0.5 BW
0.5 LG
0.5 BW
0.5 Y
0.5 R
6
4
5
2
3
C37
4
5
4
3
2
0.5 NU
C15
C8
CONNECTOR A
1
2
3
4
5
6
7
2
2
8
7
6
5
4
3
2
0.5 UK
8
C9
SYSTEM
C156
2
3
1
M
5
9
8
7
6
5
4
3
2
1
2
1
POWER UP SW
C13
9
LAMP
A/C IND
0.5 O
3 4
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
C11
0.5 U
0.5 UG
C17
0.5 UB
0.5 U
C18
0.5 UW 1.0 UG
2
1
0.5 UB 0.5 UO
1
C19
0.5 UB
C20
6
1
0.5 W 0.5 U
5
0.5 UG 0.5 BU
3 4
0.5 G
2
C21
C30
22
1
4
3
GRAB CCW SW
2
DIAGNOSTIC CONNECTOR
2
1
GRAB CW SW
1
C31
A/C SW
4
3
ONE TOUCH IDLE SW
RH LEVER SWITCHES
AIR CONDITIONER
C32
6
C155
3
REDUNDANCY SW
7
C33
2
1
HAM/BOOM PRIORITY SW
4
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
CONNECTOR B
9
1.0 SR
C34
4
3
2
1
3
2
1
1
2
3
C115
DOZER ON SW
DOZER OFF SW
HORN S W
2
2
1
1
C35
1
21
2
1
TRAVEL CHANGE SW
0.5 OG
C29
C10
CONNECTOR C
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
OUTPUTS
10
9
8
7
6
5
4
3
0.5 BU
1.0 P
C118
17
0.5 BU
0.5 BU
0.5 BU
0.5 BU
0.5 BU
1
AUTO FAN
30
2
1
THROTTLE VOL DIAL
C22
C27
5
0.5 BW
2
1
AUX 1
2 3
CAN LINK
0.5 R
1
C12
CRANK
IGN
OFF
HEAT
6 B
2
1
2
BREAKER PILOT SW
0.5 BO
0.5 BO
0.5 BO
0.5 BO
0.5 BO
0.5 BO
1
AUX 2
10
0.5 U
C26
20
9
8
7
6
5
4
3
2
2
1
R1
3
6
5
4
R2 Acc
KEY SWITCH
C112
C23
Br
C
ECU-STD O/P 17-22 ECU-STD O/P 23-28
ECU-STD O/P 7-12 ECU-STD O/P 13-16
ECU-STD,EMS, FASCIA IGN SUPPLY ECU-STD O/P 1-6
A5 A6
A3 A4
A1 A2
FUSE A
2
4
2A
0.5 BO
15A
1
15A
B1
6
5
4
3
2
1
B6
B5
B4
B3
B2
HEATER/AIR CON, AUTO FAN
ECU-STD,EMS BATT SUPPLY
KEW SWITCH
WORK LAMPS, OPT HYDS
REFUEL PUMP, AUX, WIPER
8
7
C43
8
1
2
3
4
5
6
7
OPT HYDS SWITCH (SEE 2/2)
2
3
7
8
BOOM PRIORITY SW
9 10 11 12 13 14
C25
RADIO, LIGHTER, ROOM LAMP
15A
EARTH HEADER 4
15A
EARTH HEADER 2
C161
C160
59 12 24
SHUTDOWN RELAY
C42
0.5 LG
0.5 PS
0.5 YG
0.5 Y
0.5 YU
0.5 YB
3.0 B
2.5 W
2.5 R
0.5 G
0.5 GU
0.5 K
0.5 NW
0.5 YR
0.5 SG
0.5 RY
0.5 WY
0.5 YB
0.5 BW
0.5 BU
0.5 BR
0.5 WG
0.5 UR
0.5 S
0.5 SG
0.5 U
0.5 R
C2
0.5 GU
0.5 NW
0.5 RG
0.5 RU
0.5 GW
0.5 O
0.5 W
0.5 G
0.5 GW
0.5 RW
0.5 RS
0.5 WR
0.5 YR
0.5 LG
0.5 NY
0.5 OB
0.5 UO
0.5 O
0.5 UG
0.5 SB
0.5 NB
0.5 GB
0.5 YG
0.5 UB
0.5 YW
0.5 YU
0.5 SR
0.5 SG
0.5 UB
0.5 UR
0.5 OG
0.5 BG
0.5 RG
0.5 UW
1
1
1
0.5 R
8.5 R
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
C4
6
5
4
3
2
1
2
1
4
3
2
1
W
V
U
T
S
R
P
N
M
L
K
J
H
G
F
E
D
C
B
A
0.5 B 0.5 RG
2
C94 1
LEVER LOCK SOL V (RET)
0.5 UR
SWING BRAKE SOL V
SOFT/HARD SOL V AIR FILTER SW RESERVE TANK SW OIL FILTER SW OIL PRESSURE SW
BOOM LWR PILOT SW
0.5 OB UPPER PILOT SW
TRAVEL PILOT SW
SWING PILOT SW
1
SENSOR 0V REF
STARTER RELAY
FUEL SENSOR
3.0 B
2.5 W
2.5 R
EARTH 1 2
0.5 G
0.5 K 0.5 B
1 2
2
1 2
2
2
2
1
1
2
1
C93
0.5 B
0.5 R
C83
QUICK HITCH
C157
2
3
A/C BINARY S W
REFUEL PUMP
OVERLOAD PRESSURE SW
55
28
1
39
A408460
1
2
3
E
R
C110
0.5 B
0.5 YR
0.5 RS
0.5 RG
0.5 RG
0.5 RW
1
2
1
C28
2
2
1
2
1
1 2
0.5 B
C71
2
1
C70
M
WASHER
C69
0.5 UO
0.5 B
0.5 LG
0.5 B
0.5 OB
C79
2
1
27
BOOM UP P I LOT P SW
36
35
BW
TRAVEL PILOT P SW
UPPER PILOT P SW
48
BOOM LAMP
18
TOOLBOX LAMP
18
HORN
47
C108
C107
4.5
49
C105
C'WEIGHT LAMP
18
HEAT RELAY
C173
4.5 BW
C171
33
0.5 BU
C101
0.5 RG
C82
2
1
B
C
0.5 BR
4.5 R
C81
2
0.5 GW
12V
- +
C80 1
0.5 RG
0.5 RU
SAFETY RELAY
0.5 B
2
0.5 B
C172 0.5 BW
C116
41
1
0.5 UR
S
2
0.5 B
C55
1
12V
- +
0.5 UB
C56
29 4.5 WB
0.5 WR
25A
42
38
46
PUMP CONTROL SOL V
2
M
ENGINE CONTROL SOLV
THROTTLE POSITION SENSOR
2
0.5 WG 0.5 S
C68
1
C89 0.5 SG
C67
0.5 0
C88
1
0.5 OW 0.5 B
C64
1
0.5 SR 0.5 B
C63
1
0.5 UW 0.5 B
C62
0.5 OG 0.5 BG
C61
1
0.5 SB 0.5 B
2
4
STOP SOLENOID
STOP SOL SUPPLY
2
1
3 0.5 B
0.5 GU
1
C60
0.5 UY 0.5 B
C59
0.5 LGW 0.5 B
0.5 NB
OVERLOAD FUEL PUMP
2
1
C66
1
C58
0.5 UG
32
C92 4.5 W
0.5 B
C57
0.5 B
0.5 G
QUICK HITCH
OIL TEMP SENSOR
SENSOR +V REF
0.5 G
0.5 GU
0.5 K
0.5 NW
0.5 YR
ENGINE OVERHEAT
ENG REV SENSOR
WATER TEMP SENSOR
0.5 SG
0.5 RY
0.5 WY
0.5 YB
0.5 BW
KEY SW - BATT RELAY
THROTTLE LEVER SIG HEAT RELAY
0.5 BR 0.5 BU
0.5 WG
HAMMER PILOT SW
ENG SHUT DOWN THROTTLE LEVER +V REF
0.5 SG
BEACON
C166
0.5 S
ENG CONT SOL (OUT)
2
0.5 U
0.5 R
44
AUX
BEACON
LAMP SUPPLY
CWT LAMP
HYD OIL LEVEL
A/C BINARY SW 2
0.5 GU
0.5 NW
0.5 RG
0.5 RU
0.5 0
A/C BINARY SW 1 A/C COMPRESSOR
0.5 W
0.5 G
TOOLBOX WORKLAMP HORN
BOOM WORKLAMP
ALTERNATOR SIGNAL
WINDOW WASHER
0.5 RW 0.5 GW
0.5 RS
0.5 WR
0.5 YR
0.5 LG
0.5 NY
BOOM UP PILOT SW
BOOM PRIORITY SOL V
0.5 UO
0.5 O
PUMP PROP SOL V (OUT)
0.5 UG
0.5 NB
MERGED FLOW SOL V
0.5 UB 0.5 YG 0.5 GB
0.5 YU 0.5 YW
SWING LOCK SOL V
0.5 SR
0.5 UB
LEVER LOCK SOL V (OUT)
TRAVEL ALARM
0.5 OG
0.5 BG
SWING SHUT OFF SOL V
TRAVEL CHANGE SOL V
MAX FLOW CONT SOL V
2 STAGE RELIEF SOL V
NEG FLOW SOL V
40
+12V RADIO SUPPLY
+24V IGNITION SUPPLY
0.5 RG
0.5 UW
0.5 LGW
0.5 OW
0.5 UY
0.5 SB
CONNECTOR B
C164
0.5 LGW
0.5 OW
0.5 UY
0.5 SB
C1
C7
0.5 R
C6
+24V BATT SUPPLY
MAIN FRAME
4.5 W
CONNECTOR A
CAB
C5
0.5 BU
1
C109 0.5 B
1
1 2
0.5 B
1 2
C74 0.5 NW
2
1
2
0.5 B
2
1
C73
0.5 B
0.5 NY
1
1
C174
C99
C98
C97
OIL FILTER
OIL PRESS
43
SWING PILOT P SW
BOOM LWR P I LOT P SW
54
52
37
37
A/C COMP
AIR FILTER
51
50
FUEL SENSOR
RESERVE TANK LSW
HYD OIL OVERHEAT SW
HYD OIL TEMP SENSOR
GLOW PLUG
C100
ENG REV SENSOR
53
45
31 E N G STO P SOLENOID
OVERHEAT SW
M
WATER TEMP SENSOR
C162
ALTERNATOR
2 R
3 L
B
E
STARTER MOTOR
C72
1
2
1
2
1
2
1
2
0.5 O
0.5 W
C90
0.5 B
0.5 YU
C77
0.5 B
0.5 YW
C76
0.5 S
0.5 YR
C75
0.5 SG
0.5 NW
C163
0.5 SG
1
2
4.5 BW
1
0.5 WY 0.5 S
C87
0.5 YB 0.5 SG
C86
0.5 RY
0.5 UB
C85
0.5 YG
C84
0.5 BU
0.5 WR
8.5 R
1.0 B
4.5 BW
C111
30
ISUZU ENGINE
C 2.5 B
C
PULL
B
C54
HOLD
A
B
60A
2.5 W
2
0.5 U
60 B
8.5 R
C91
8.5 R
C104
50
34
Excavators
INPUTS
1
1
C117
C36
8
EMERG STOP
SLEW BRAKE
O/LOAD
CUSHION
ISOLATOR
QUICK HITCH
BEACON
WASHER
WIPER
AUTO IDLE
FACIA SW PANEL
1
0.5 GR
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
+V REF
0.5 Y
GND
8
I/P20 HAMMER PILOT
0.5 RW
GND
7
I/P36 PREHEAT
6
I/P34 TRAVEL CHANGE
5
I/P24 HORN
4
I/P31 GRAB CCW
3
I/P27 TRAVEL PILOT
2
I/P12 OIL FILTER
1
I/P2 WATER TEMP
0.5 P
BATT SUPPLY
0.5 LG
I/P1 HYD OIL TEMP
0.5 BW
C159
0V REF
EARTH HEADER 3
I/P19 BOOM UP PILOT
0.5 YU
3
I/P18 BOOM PRI/HAM
1.0 B
I/P11 AIR FILTER
2
I/P15 POWER UP
1.0 P
I/P4 FUEL LEVEL
1
I/P28 BOOM LWR PILOT
0.5 BW
BATT SUPPLY
I/P13 O/LOAD PRESS
1.0 PU
C38
I/P9 STD LAMPS
0.5 SR
SPARE
0.5 RB
12V RADIO RELAY
I/P8 THROTTLE VOL
0.5 P
PROG (SPARE)
0.5 LGY
1
I/P7 SPARE
0.5 SR
RS 232 RX (SPARE)
0.5 GR
23
I/P33 AIR PRESS
GND
GROUND
0.5 LG
IGN SUPPLY
0.5 NW
12V RADIO
0.5 S
RS 232 TX (SPARE)
0.5 UW
RS 232 SHIELD (SPARE)
CAN H
SHLD
0.5 RW
0.5 UO
14
I/P23 DOZER ON
9 10
I/P17 ENG SPEED
0.5 WR
CAN L
MTSR-E (SPI)
0.5 UG
0.5 SB
86
SPARE
8
I/P32 LEVER LOCK
7
I/P22 DOZER OFF
REDUNDANCY
1.0 B
0.5 SG
I/P3 ALTERNATOR
0.5 SR
0.5 LGR
CAN SHIELD
0.5 R
0.5 UB
0.5 U
0.5 YB
MRST-E (SPI)
0.5 OG
0.5 NU
0.5 NU
SCLK-E (SPI)
0.5 LG
0.5 PG
0.5 BW
0.5 LG
EMERG STOP
I/P16 KEY SW (CRANK)
6
0.5 GY
85
0.5 WY
EMERG STOP
I/P29 SWING PILOT
5
0.5 O
0.5 BW
0.5 UY
0.5 LG
0.5 SR
87
0.5 R
0.5 G
MRST-E (SPI)
0.5 UK
30
0.5 GU
87A
SHLD
0.5 U
0.5 U
0.5 OG
0.5 PU
0.5 RW
0.5 NY
SCLK-E (SPI)
0.5 BW
MTSR-E (SPI)
0.5 LG
0.5 BY
0.5 UG
0.5 Y
IGNITION SUPPLY
4
1.0 O
SUPPLY O/P17-22
EARTH HEADER 1
1.0 S
SUPPLY O/P23-28
0.5 RB
RS232 RX
SPARE
GND
I/P14 ONE TOUCH IDLE
1.0 RB
0.5 B
I/P10 OPT LAMPS
0.5 R
0.5 RY
1.0 RB
1.0 SR
BATT
IGN
0.5 P
NC
RS232 TX
0.5 WG
I/P6 THROTTLE LEVER
NO
SPARE
1.0 PU
0.5 BO
OV
0.5 RY
I/P5 ENGINE OVERHEAT
1.0 N
0.5 U
0.5 U
SPARE
1.0 GB
3
0.5 OW
O/P3 MAX FLOW CUT
2
0.5 NB
O/P7 PUMP PROP
1
0.5 UB
0.5 BW
SUPPLY O/P13-16
LH LEVER SWITCHES
0.5 UR
LOCK LEVER SW
0.5 RB
O/P8 SWING LOCK 1
M
0.5 RY
O/P9 SWING BRAKE 2
0.5 BG
0.5 B
C114
0.5 LGW
O/P13 CAB LH LIGHT
COM
0.5 BG
0.5 YR
O/P14 CAB RH LIGHT
15
0.5 B
O/P15 HIGH SPEED TRAVEL
MAIN WIPER
GND
FUSE B
C113
O/P2 BOOMSPEED REG
0.5 GR
SUPPLY O/P13-16
0.5 YR
O/P7A SPARE
1.0 GB
0.5 BW
0.5 NU
1.0 PU
O/P5 BOOM PRIORITY
0.5 OG
0.5 BW
0.5 UG
1.0 PG
0.5 GW
O/P6 HORN
0.5 G
0.5 BU
ALARM TRAVEL
0.5 BG
O/P11 LOWER WIPER
1.0 N
SUPPLY O/P7-12
0.5 UW
O/P10 SWING SHUT OFF 3
0.5 BU
CAB RH LAMP
O/P12 WIPER
0.5 R
SUPPLY O/P7-12
0.5 GR
0.5 BG
0.5 B
GND
O/P16 WASHER
0.5 BU
0.5 GY 0.5 RU
O/P33 CWT LIGHT
0.5 G
CAN Hi
0.5 RW
O/P30 TOOLBOX LAMP
1.0 B
PROG
0.5 SG
0.5 BW
0.5 BY 0.5 R
O/P1 THROTTLE CONT
0.5 BW
GND I/P9-14
0.5 NW
O/P4 BEACON
0.5 BW
CAN SLD
0.5 RG
O/P26 TRAVEL ALARM
0.5 G
CAB LH LAMP
O/P28 SOFT/HARD
0.5 WU
0.5 LGR
CAB ROOM LAMP
O/P22 ENG SHUTDOWN
BOOM PRIORITY
26
O/P24 2 STAGE RELIEF
0.5 SG
0.5 BU
O/P25 QUICK HITCH
0.5 SR
25
O/P36 SPARE
0.5 UG 0.5 S
0.5 UW
0.5 SR 0.5 PS
O/P27 BREAKER
0.5 BU
0.5 BU
O/P31 SHUTDOWN RELAY
0.5 BW
1.0 GB
1.0 P
10A
1.0 RB
1.0 N
0.5 UR 0.5 R
0.5 P 0.5 SR
0.5 G
0.5 UK
0.5 U 0.5 UY
0.5 U
0.5 K
0.5 B 0.5 YR
0.5 R
O/P1A SPARE
0.5 RY
2.0 R
SWING LOCK
JOIN CONNECTORS TOGETHER FOR TRACKED MACHINES
1.0 RG
0.5 PG
SUPPLY O/P1-6
0.5 YB
O/P17 DOZER
0.5 U
SUPPLY O/P1-6
0.5 YU
O/P18 CW GRAB
0.5 B
CAN Lo
0.5 Y
O/P19 CCW GRAB
1.0 B
CHASSIS
0.5 YG
O/P20 LOW FLOW PRI
0.5 R
0.5 RB
C103
19
1.5 G
10A
1.0 S
1.0 O
20A 1.0 LG
1.0 UG
10A 0.5 RY
0.5 PU
GND I/P7,8,15,16
0.5 OG
O/P21 LEVER LOCK
0.5 RG
30
0.5 BU 0.5 SB
O/P23 NEG FLOW CONT
0.5 GU
86 0.5 BW
10A
0.5 RG
0.5 GB
85 0.5 BG
1.0 SR
0.5 BO
0.5 WU
87 2.5 R
2.5 W
2A
0.5 BO
0.5 BO
0.5 NW
20A 1.0 R
0.5 NU
0.5 LGR
0.5 B
0.5 LGY 0.5 RS
O/P34 SPARE
PREHEAT 0.5 RB
1.0 P
RS/SPI SHLD
0.5 BR
O/P29 BOOM LIGHT
6420 - C/2-9.1 O/P32 HEAT RELAY
45 - 15 - 02/21 O/P35 SPARE
0.5 B
HIGH SPEED TRAVEL 2 STAGE RELIEF NEG FLOW CONT LEVER LOCK SWING SHUT OFF SOFT/ HARD MAX FLOW CONT
0.5 WR 4.5 R
SWING BRAKE
C102
8.5 W
9804/1103 0.5 UR
CONTENTS
45 - 15 - 02/21
JS460 Tier 2
Circuit Diagrams - Electrical
Issue 1
CONTENTS CONTENTS
Excavators
45 - 20 - 01/2
JS 70 (Standard Boom to m/c 695001) Circuit Diagrams - Hydraulic Component Key M P1 P2 1 2 3 4 5 6 7 8 9 9A 9B 9C 9D 9E 9F 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Engine Main pump elements Servo pump element Blade rams Track motors Rotary coupling Swing gearbox Swing motor Boom ram Boom holding valve Bucket ram Control valve Swing motor spool Dipper spools Boom spools Bucket spool Blade spool Track motor spools Return manifold Dipper ram Attachment control valve Oil cooler Tank air breather Servo hand control valves Return filter Hydraulic tank Relief valve Suction strainer Pressure switches Selector valve Manifold Solenoid valve block Accumulator Line filter Hydraulic pump Boom servo cushion valves Dipper servo cushion valve
9804/1103
45 - 20 - 01/2
Issue 1
CONTENTS
JS 70 (Offset Boom to m/c 695001) Circuit Diagrams - Hydraulic
CONTENTS
Excavators
45 - 20 - 01/4
JS 70 (Offset Boom to m/c 695001) Circuit Diagrams - Hydraulic Component Key M P1 P2 1 2 3 4 5 6 7 8 9 9A 9B 9C 9D 9E 9F 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Engine Main pump elements Servo pump element Blade rams Track motors Rotary coupling Swing gearbox Swing motor Boom ram Boom holding valve Bucket ram Control valve Swing motor spool Dipper spools Boom spools Bucket spool Blade spool Track motor spools Return manifold Dipper ram Offset boom control valve Oil cooler Tank air breather Servo hand control valves Return filter Hydraulic tank Relief valve Suction strainer Pressure switches Selector valve Manifold Solenoid valve block Accumulator Line filter Hydraulic pump Boom offset check valves Offset boom ram
9804/1103
45 - 20 - 01/4
Issue 1
CONTENTS
* JS
Excavators
45 - 20 - 01/5
70 (Standard Boom from m/c 695002 to m/c 695500)
Circuit Diagrams - Hydraulic
ILLUSTRATION NOT AVAILABLE AT THIS TIME
9804/1103
45 - 20 - 01/5
Issue 2*
CONTENTS * JS
Excavators
45 - 20 - 01/6
70 (Standard Boom from Machine No. 695002 to Machine No. 695500)
Circuit Diagrams - Hydraulic Component Key M P1 P2 P3 1 2 2A 2B 2C 2D 2E 2F 3 4 5 5A 5B 6 7 8 9 9A 9B 9C 9D 9E 9F 9G 9H 9J 9K 9L 9M 9N 9P 9R 9S 10 11 12 12A 13 14 15 16 17 18 19 20 21 22 22A 22B 22C 22D 22E 23 24 25
Engine No. 1 pump element No. 2 pump element Servo pump element Blade rams Track motors Counterbalance spool Brake release piston Brake release valve Cross line relief valves Speed selection spool Speed actuator Rotary coupling Swing gearbox Swing motor Cross line relief valves Counterbalance spool Boom ram Boom holding valve Bucket ram Control valve Swing motor spool Dipper spools Boom spools Bucket spool Blade spool Track motor spools MRV Blade rod side ARV Blade head side ARV Dipper rod side ARV Dipper head side ARV Boom rod side ARV Boom head side ARV Bucket rod side ARV Bucket head side ARV Straight ahead track valve Return manifold Dipper ram Attachments control valve Attachments relief valves Oil cooler Tank air breather Servo hand control valves Return filter (10µ) Hydraulic tank Filter by-pass relief valve (1.03 bar/14.9 lb in2) Suction strainer (150 Mesh) Pressure switches Manifold Solenoid valve block Servo relief valve Quick-heat valve Servo isolator solenoid Two speed tracking solenoid Swing brake solenoid Accumulator Line filter (10µ) Hydraulic pump
9804/1103
25A 25B 25C 26 27 28 29 30
45 - 20 - 01/6
Control piston Control spool Summator spool Boom servo cushion valves Dipper servo cushion valve Servo track control RH Servo track control LH Servo blade control
Issue 3*
CONTENTS
Excavators
JS 70 (Standard Boom from Machine No. 695002) Circuit Diagrams - Hydraulic Component Key M P1 P2 P3 1 2 2A 2B 2C 2D 2E 2F 3 4 5 5A 5B 6 7 8 9 9A 9B 9C 9D 9E 9F 9G 9H 9J 9K 9L 9M 9N 9P 9R 9S 10 11 * 12 * 12A 13 14 15 16 17 18 19 20 21 22 22A 22B 22C 22D 22E 23 24 25 25A
Engine No. 1 pump element No. 2 pump element Servo pump element Blade rams Track motors Counterbalance spool Brake release piston Brake release valve Cross line relief valves Speed selection spool Speed actuator Rotary coupling Swing gearbox Swing motor Cross line relief valves Counterbalance spool Boom ram Boom holding valve Bucket ram Control valve Swing motor spool Dipper spools Boom spools Bucket spool Blade spool Track motor spools MRV Blade rod side ARV Blade head side ARV Dipper rod side ARV Dipper head side ARV Boom rod side ARV Boom head side ARV Bucket rod side ARV Bucket head side ARV Straight ahead track valve Return manifold Dipper ram Attachments control valve Attachments relief valves Oil cooler Tank air breather Servo hand control valves Return filter (10µ) Hydraulic tank Filter by-pass relief valve (1.03 bar/14.9 lb in2) Suction strainer (150 Mesh) Pressure switches Manifold Solenoid valve block Servo relief valve Quick-heat valve Servo isolator solenoid Two speed tracking solenoid Swing brake solenoid Accumulator Line filter (10µ) Hydraulic pump Control piston
9804/1103
25B 25C 26 27 28 29 30
45 - 20 - 01/6
Control spool Summator spool Boom servo cushion valves Dipper servo cushion valve Servo track control RH Servo track control LH Servo blade control
Issue 2*
CONTENTS * JS
Excavators
45 - 20 - 01/7
70 (Offset Boom from m/c 695002 to m/c 695500)
Circuit Diagrams - Hydraulic
ILLUSTRATION NOT AVAILABLE AT THIS TIME
9804/1103
45 - 20 - 01/7
Issue 3*
CONTENTS
Excavators
45 - 20 - 01/8
* JS70
Circuit Diagrams - Hydraulic (Offset Boom from Machine No. 695002 to 695028) (from machine No. 695029 to 695500, see Note) Component Key M P1 P2 P3 1 2 2A 2B 2C 2D 2E 2F 3 4 5 5A 5B 6 7 8 9 9A 9B 9C 9D 9E 9F 9G 9H 9J 9K 9L 9M 9N 9P 9R 9S 10 11 12 12A 13 14 15 16 17 18 19 20 21 22 22A 22B 22C 22D 22E 23 24 25
Engine No. 1 pump element No. 2 pump element Servo pump element Blade rams Track motors Counterbalance spool Brake release piston Brake release valve Cross line relief valves Speed selection spool Speed actuator Rotary coupling Swing gearbox Swing motor Cross line relief valves Counterbalance spool Boom ram Boom holding valve Bucket ram Control valve Swing motor spool Dipper spools Boom spools Bucket spool Blade spool Track motor spools MRV Blade rod side ARV Blade head side ARV Dipper rod side ARV Dipper head side ARV Boom rod side ARV Boom head side ARV Bucket rod side ARV Bucket head side ARV Straight ahead track valve Return manifold Dipper ram Offset boom control valve Offset boom, ARV's Oil cooler Tank air breather Servo hand control valves Return filter (10µ) Hydraulic tank Filter by-pass relief valve (1.03 bar/14.9 lb in2) Suction strainer (150 Mesh) Pressure switches Manifold Solenoid valve block Servo relief valve Quick-heat valve Servo isolator solenoid Two speed tracking solenoid Swing brake solenoid Accumulator Line filter (10µ) Hydraulic pump
9804/1103
25A 25B 25C 26 27 28 29 30
Control piston Control spool Summator spool Boom offset check valves (see Note) Offset boom ram Servo track control RH Servo track control LH Servo blade control
* Note: Machines from serial no. 695029 to 695500 are fitted with a different Offset Boom Control Valve (item 12) to earlier machines. The replacement Control Valve incorporates a different metering arrangement with the result that these machines are not fitted with Boom Offset Check Valves (item 26).
45 - 20 - 01/8
Issue 3*
Excavators
CONTENTS
45 - 20 - 01/8A
JS 70 from m/c no. 695501 Circuit Diagrams - Hydraulic
ILLUSTRATION NOT AVAILABLE AT THIS TIME
9804/1103
45 - 20 - 01/8A
6020 - E/3-2.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 20 - 01/8B
JS 70 from m/c no. 695501 Circuit Diagrams - Hydraulic (cont’d) Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
Blade Ram (Left) Blade Ram (Right) Traction Motor Rotary Coupling Line Filter Slew Motor Filter Radiator Control Valve Return Manifold Relief Valve Control Valve Stop Valve Relief Valve Manifold Line Filter Oil Tank Air Breather Relief Valve Return Filter Strainer Pressure Switch Cushion Valve Cushion Valve Cushion Valve Manifold Remote Control Valve Filter Remote Control Valve Remote Control Valve Valve Accumulator Line Filter Flat Flange Hydraulic Pump Bucket Ram Boom Ram Dipper Ram
9804/1103
45 - 20 - 01/8B
6020 - E/3-1.1
Issue 1
CONTENTS
JS 110 (To m/c 697013) & JS 130 (To m/c 699036) Circuit Diagrams - Hydraulic
@@
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