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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

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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

●

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.

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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.

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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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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

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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

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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

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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

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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

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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

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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

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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

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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

@@@( N@(Y ?(Y?

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@@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @@ @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

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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

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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

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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

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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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CONTENTS CONTENTS

Excavators

45 - 20 - 01/10

JS 110 (To m/c 697013) & JS 130 (To m/c 699036) Circuit Diagrams - Hydraulic Component Key P1 P2 P3 M 1 2 2A 3 4 5 6 6A 6B 6C 6D 6E 7 8 9 10 11 11A 11B 11C 11D 11E 11F 11G 11H 11J 11K 11L 11M 11N 11O 11P 11R 11S 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Front Pump Element Rear Pump Element Servo Pump Engine Swing Park Brake Solenoid Valve Swing Motor Cross Line Relief Valves Dipper Ram Free Swing Restrictor Free Swing Solenoid Valve Track Motor LH Counterbalance Spool Cross Line Relief Valves Brake Release Piston Speed Selector Spool Speed Actuator Rotary Coupling Track Motor RH Bucket Ram Boom Rams Control Valve Main Relief Valve Track Spools Boom Spool Bucket Spool Dipper Boost Spool Dipper Spool Swing Spool Boom Boost Spool Straight Ahead Track Valve Boom Rod Side ARV Boom Head Side ARV Bucket Head Side ARV Bucket Rod Side ARV Dipper Rod Side ARV Dipper Head Side ARV Negative Control Pressure Relief Valves Swing Priority Valve Shuttle Valve Swing Brake Release Pressure Switch Cooler Cooler Check Valve (0.49 bar, 7.1 lb. in2) Breather Cooler Check Valve (2.9 bar, 42.7 lb. in2) Return Filter (10µ) Filter By-pass Relief Valve (0.98 bar, 14.2 lb. in2) Suction Strainer (150 µ) Hydraulic Tank Drain Line Filter (10µ) Servo Hand Control Valve LH Servo Hand Control Valve RH Warm Up Filter (100 x 800 Mesh) Warm Up Restrictor Cushion Valve Solenoid Cushion Valve Servo/Drain Manifold Accumulator

9804/1103

31 32 33 34 35 36 36A 36B 36C 36D 36E 37 38

Servo Isolator Solenoid Valve Check Valve Servo Filter (10µ) Boom Holding Valve Auxiliary Control Valve Hydraulic Pump Proportional Solenoid Valve Swing Pump Control Summator Assembly Pump Control Spool Pump Control Actuators Servo Pump Relief Valve Speed Change Solenoid

Note: To aid the clarity of the diagram, some servo lines have been omitted. To assist in tracing these lines, an identification letter has been included where the line terminates, e.g. f. The component to which the line connects has been added after the letter, e.g. f(28). Therefore, reference f(28) means that the line connects to line f on component 28, the cushion valve.

45 - 20 - 01/10

Issue 1

CONTENTS

JS 110 (From m/c 697014) & JS 130 (From m/c 699037) Circuit Diagrams - Hydraulic

CONTENTS CONTENTS

Excavators

45 - 20 - 01/12

JS 110 (From m/c 697014) & JS 130 (From m/c 699037) Circuit Diagrams - Hydraulic Component Key P1 P2 P3 M 1 2 2A 3 4 5 6 6A 6B 6C 6D 6E 7 8 9 10 11 11A 11B 11C 11D 11E 11F 11G 11H 11J 11K 11L 11M 11N 11O 11P 11R 11S 12 13 14 15 16 17 18 19 20 21 22 22A 23 24 25 26 27 28 29 30

Front Pump Element Rear Pump Element Servo Pump Engine Swing Park Brake Solenoid Valve Swing Motor Cross Line Relief Valves Dipper Ram Free Swing Restrictor Free Swing Solenoid Valve Track Motor LH Counterbalance Spool Cross Line Relief Valves Brake Release Piston Speed Selector Spool Speed Actuator Rotary Coupling Track Motor RH Bucket Ram Boom Rams Control Valve Main Relief Valve Track Spools Boom Spool Bucket Spool Dipper Boost Spool Dipper Spool Swing Spool Boom Boost Spool Straight Ahead Track Valve Boom Rod Side ARV Boom Head Side ARV Bucket Head Side ARV Bucket Rod Side ARV Dipper Rod Side ARV Dipper Head Side ARV Negative Control Pressure Relief Valves Swing Priority Valve Shuttle Valve Swing Brake Release Pressure Switch Cooler Cooler Check Valve (0.49 bar/7.1 lb in2) Breather Cooler Check Valve (2.9 bar/42.7 lb in2) Return Filter (10µ) Filter By-pass Relief Valve (0.98 bar/14.2 lb in2) Suction Strainer (150 µ) Hydraulic Tank Drain Line Filter (10µ) Filter By-pass Relief Valve (0.6 bar/8.5 lb in2) Servo Hand Control Valve LH Servo Hand Control Valve RH Warm Up Filter (100 x 800 Mesh) Warm Up Restrictor Cushion Valve Solenoid Cushion Valve Servo/Drain Manifold Accumulator

9804/1103

31 32 33 33A 34 35 35A 35B 36 36A 36B 36C 36D 36E 37 38 39 40 41

Servo Isolator Solenoid Valve Check Valve (0.4 bar/5.7 lb in2) Servo Filter (10µ) Filter By-pass Relief Valve (1.0 bar/14.9 lb in2) Boom Holding Valve Auxiliary Control Valve Auxiliary Service ARV's Auxiliary Control Valve MRV Hydraulic Pump Proportional Solenoid Valve Swing Pump Control Summator Assembly Pump Control Spool Pump Control Actuators Servo Pump Relief Valve (39.2 bar/568.8 lb in2) Speed Change Solenoid Servo Track Control RH Servo Track Control LH Servo/Drain Manifold

Note: To aid the clarity of the diagram, some servo lines have been omitted. To assist in tracing these lines, an identification letter has been included where the line terminates, e.g. f. The component to which the line connects has been added after the letter, e.g. f(28). Therefore, reference f(28) means that the line connects to line f on component 28, the cushion valve.

45 - 20 - 01/12

Issue 1

CONTENTS

JS 150LC (To m/c 701044) Circuit Diagrams - Hydraulic

CONTENTS CONTENTS

Excavators

45 - 20 - 01/14

JS 150LC (To m/c 701044) Circuit Diagrams - Hydraulic Component Key P1 P2 P3 M 1 2 3 3A 4 5 6 6A 6B 6C 6D 6E 6F 7 8 9 10 11 12 12A 12B 12C 12D 12E 12F 12G 12H 12J 12K 12L 12M 12N 12O 12P 12R 12S 12T 12U 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Front Pump Element Rear Pump Element Servo Pump Engine Swing Park Brake Solenoid Valve Shuttle Valve Swing Motor Cross Line Relief Valves Dipper Ram Dipper Hose Burst Check Valve Track Motor LH Counterbalance Spool Brake Release Piston Brake Release Valve Cross Line Relief Valve Speed Selection Spool Speed Actuator Rotary Coupling Track Motor RH Bucket Ram Boom Rams Boom Hose Burst Check Valves Control Valve Main Relief Valve Track Spools Boom Spool Bucket Spool Dipper Boost Spool Dipper Spool Swing Spool Boom Boost Spool Straight Ahead Track Valve Boom Rod Side ARV Boom Head Side ARV Bucket Rod Side ARV Bucket Head Side ARV Dipper Rod Side ARV Dipper Head Side ARV Swing Left ARV Swing Right ARV Negative Control Pressure Relief Valves Swing Priority Valve Swing Brake Release Pressure Switch Cooler Cooler Check Valve (0.49 bar, 7.1 lb. in2) Breather Cooler Check Valve (3.4 bar, 49.8 lb. in2) Return Filter (10µ) Filter By-pass Relief Valve (0.98 bar, 14.2 lb. in2) Suction Strainer (150 µ) Hydraulic Tank Drain Line Filter (10µ) Servo Hand Control Valve LH Servo Hand Control Valve RH Warm Up Filter (100 x 800 Mesh) Warm Up Restrictor Cushion Valve Solenoid Cushion Valve Servo/Drain Manifold

9804/1103

30 31 32 33 34 35 35A 35B 35C 35D 35E 36 37

Accumulator Servo Isolator Solenoid Valve Check Valve Servo Filter (10µ) Auxiliary Control Valve Hydraulic Pump Proportional Solenoid Valve Swing Pump Control Summator Assembly Pump Control Spool Pump Control Actuators Servo Pump Relief Valve Speed Change Solenoid

Note: To aid the clarity of the diagram, some servo lines have been omitted. To assist in tracing these lines, an identification letter has been included where the line terminates, e.g. f. The component to which the line connects has been added after the letter, e.g. f(12). Therefore, reference f(12) means that the line connects to line f on component 12, the control valve.

45 - 20 - 01/14

Issue 1

CONTENTS

JS 150LC (From m/c 701045) Circuit Diagrams - Hydraulic

CONTENTS CONTENTS

Excavators

45 - 20 - 01/16

JS 150LC (From m/c 701045) Circuit Diagrams - Hydraulic Component Key P1 P2 P3 M 1 2 3 3A 4 5 6 6A 6B 6C 6D 6E 6F 7 8 9 10 11 12 12A 12B 12C 12D 12E 12F 12G 12H 12J 12K 12L 12M 12N 12O 12P 12R 12S 12T 12U 13 14 15 16 17 18 19 20 21 22 22A 23 24 25 26 27 28 29

Front Pump Element Rear Pump Element Servo Pump Engine Swing Park Brake Solenoid Valve Shuttle Valve Swing Motor Cross Line Relief Valves Dipper Ram Dipper Hose Burst Check Valve Track Motor LH Counterbalance Spool Brake Release Piston Brake Release Valve Cross Line Relief Valve Speed Selection Spool Speed Actuator Rotary Coupling Track Motor RH Bucket Ram Boom Rams Boom Hose Burst Check Valves Control Valve Main Relief Valve Track Spools Boom Spool Bucket Spool Dipper Boost Spool Dipper Spool Swing Spool Boom Boost Spool Straight Ahead Track Valve Boom Rod Side ARV Boom Head Side ARV Bucket Rod Side ARV Bucket Head Side ARV Dipper Rod Side ARV Dipper Head Side ARV Swing Left ARV Swing Right ARV Negative Control Pressure Relief Valves Swing Priority Valve Swing Brake Release Pressure Switch Cooler Cooler Check Valve (0.49 bar, 7.1 lb in2) Breather Cooler Check Valve (3.4 bar, 49.8 lb in2) Return Filter (10µ) Filter By-pass Relief Valve (0.98 bar, 14.2 lb in2) Suction Strainer (150 µ) Hydraulic Tank Drain Line Filter (10µ) Filter By-pass Relief Valve (0.6 bar/8.5 lb in2) Servo Hand Control Valve LH Servo Hand Control Valve RH Warm Up Filter (100 x 800 Mesh) Warm Up Restrictor Cushion Valve Solenoid Cushion Valve Servo/Drain Manifold

9804/1103

30 31 32 33 33A 34 34A 34B 35 35A 35B 35C 35D 35E 36 37 38 39 40

Accumulator Servo Isolator Solenoid Valve Check Valve (0.4 bar/5.7 lb in2) Servo Filter (10µ) Filter By-pass Relief Valve (1.03 bar/14.9 lb in2) Auxiliary Control Valve Auxiliary Services ARV's Auxiliary Control Valve MRV Hydraulic Pump Proportional Solenoid Valve Swing Pump Control Summator Assembly Pump Control Spool Pump Control Actuators Servo Pump Relief Valve Speed Change Solenoid Servo Track Control RH Servo Track Control LH Servo/Drain Manifold

Note: To aid the clarity of the diagram, some servo lines have been omitted. To assist in tracing these lines, an identification letter has been included where the line terminates, e.g. f. The component to which the line connects has been added after the letter, e.g. f(12). Therefore, reference f(12) means that the line connects to line f on component 12, the control valve.

45 - 20 - 01/16

Issue 1

CONTENTS

JS 200LC (To m/c 704074) Circuit Diagrams - Hydraulic

CONTENTS CONTENTS

Excavators

45 - 20 - 01/18

JS 200LC (To m/c 704074) Circuit Diagrams - Hydraulic Component Key PS P1 P2 M 1 1A 2 3 3A 4 5 6 7 8 9 9A 9B 9C 9D 9E 10 11 12 13 14 15 15A 15B 15C 15D 15E 15F 15G 15H 15J 15K 15L 15M 15N 15P 15R 15S 15T 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Servo Pump No. 1 Pump Element No. 2 Pump Element Engine Swing Brake Release Solenoid Valve Swing Parking Brake Release Switch Shuttle Valve Swing Motor Cross Line Relief Valves Free Swing Restrictor Free Swing Solenoid Reverse Prevention Valve Dipper Ram Dipper Hose Burst Check Valve Track Motor LH Counterbalance Spool Brake Release Piston Cross Line Relief Valves Speed Selector Control Spool Speed Actuators Track Motor RH Rotary Coupling Bucket Ram Boom Rams Boom Hose Burst Check Valves Control Valves (A & B) Neative Control Pressure Relief Valves Track Left Spool Dipper Spool Swing Spool Track Right Spool Option Spool Bucket Spool Boom Spool Main Relief Valve (A) Main Relief Valve (B) Dipper Rod Side ARV Dipper Head Side ARV Bucket Rod Side ARV Bucket Head Side ARV Boom Head Side ARV Boom Rod Side ARV Logic Valves Restrictor Cooler Cooler Check Valve (0.5 bar/7.25 lb in2) Tank Breather Cooler Check Valve (1.96 bar/28.4 lb in2) Return Filter (10µ) Filter By-pass Relief Valve (0.98 bar/14.2 lb in2) Suction Strainer Warm Up Filter (100 x 800 Mesh) Hydraulic Tank Drain Filter (10µ) Servo Hand Control Valve LH Servo Hand Control Valve RH Cushion Valve Cushion Valve Solenoid Valve Servo/Drain Manifold Accumulator

9804/1103

33 34 35 36 36A 37 37A 37B 37C 38 39

45 - 20 - 01/18

Servo Isolator Solenoid Valve Check Valve Servo Filter Boom Down Negative Control Delay Solenoid Valve Boom Down Negative Control Delay Switch Hydraulic Pump Proportional Solenoid Valve Summator Assembly Pump Control (Swing Operation) Servo Pump Relief Valve Speed Change Solenoid Valve

Issue 1

CONTENTS

JS 200LC (From m/c 704075) Circuit Diagrams - Hydraulic

Excavators

CONTENTS CONTENTS

Excavators

45 - 20 - 01/20

JS 200LC (From m/c 704075) Circuit Diagrams - Hydraulic Component Key PS P1 P2 M 1 1A 2 3 3A 4 5 6 7 8 9 9A 9B 9C 9D 9E 10 11 12 13 14 15 15A 15B 15C 15D 15E 15F 15G 15H 15J 15K 15L 15M 15N 15P 15R 15S 15T 16 17 18 19 20 21 22 23 24 25 26 26A 27 28 29 30

Servo Pump No. 1 Pump Element No. 2 Pump Element Engine Swing Brake Release Solenoid Valve Swing Parking Brake Release Switch Shuttle Valve Swing Motor Cross Line Relief Valves Free Swing Restrictor Free Swing Solenoid Reverse Prevention Valve Dipper Ram Dipper Hose Burst Check Valve Track Motor LH Counterbalance Spool Brake Release Piston Cross Line Relief Valves Speed Selector Control Spool Speed Actuators Track Motor RH Rotary Coupling Bucket Ram Boom Rams Boom Hose Burst Check Valves Control Valves (A & B) Neative Control Pressure Relief Valves Track Left Spool Dipper Spool Swing Spool Track Right Spool Option Spool Bucket Spool Boom Spool Main Relief Valve (A) Main Relief Valve (B) Dipper Rod Side ARV Dipper Head Side ARV Bucket Rod Side ARV Bucket Head Side ARV Boom Head Side ARV Boom Rod Side ARV Logic Valves Restrictor Cooler Cooler Check Valve (0.5 bar/7.25 lb in2) Tank Breather Cooler Check Valve (1.96 bar/28.4 lb in2) Return Filter (10µ) Filter By-pass Relief Valve (0.98 bar/14.2 lb in2) Suction Strainer Warm Up Filter (100 x 800 Mesh) Hydraulic Tank Drain Filter (10µ) Filter By-pass Relief Valve (0.6 bar/8.5 lb in2) Servo Hand Control Valve LH Servo Hand Control Valve RH Cushion Valve Cushion Valve Solenoid Valve

9804/1103

31 32 33 34 35 35A 36 36A 37 37A 37B 37C 38 39 40 41 42

45 - 20 - 01/20

Servo/Drain Manifold Accumulator Servo Isolator Solenoid Valve Check Valve (0.4 bar/5.7 lb in2) Servo Filter (10µ) Filter By-pass Relief Valve (1.1 bar/14.9 lb in2) Boom Down Negative Control Delay Solenoid Valve Boom Down Negative Control Delay Switch Hydraulic Pump Proportional Solenoid Valve Summator Assembly Pump Control (Swing Operation) Servo Pump Relief Valve (39 bar/565.5 lb in2) Speed Change Solenoid Valve Servo/Drain Manifold Servo Track Control RH Servo Track Control LH

Issue 1

CONTENTS

JS 240LC Circuit Diagrams - Hydraulic

CONTENTS CONTENTS

Excavators

45 - 20 - 01/22

JS 240LC Circuit Diagrams - Hydraulic Component Key PS P1 P2 M 1 2 3 4 4A 4B 4C 4D 4E 4F 4G 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20A 20B 20C 21 22 22A 22B 22C 22D 22E 22F 22G 22H 22J 22K 22L 22M 22N 22P 22R 22S 22T 22U 22V 22W 22X 23 23A 23B

Servo Pump No. 1 Pump Element No. 2 Pump Element Engine Speed Change Solenoid Valve Rotary Coupling Track Motor LH Track Motor RH Counterbalance Spool Brake Release Piston Speed Change Spool Brake Release Valve Brake Release Pressure Control Cross Line Relief Valve Speed Actuator Servo Hand Control Valve LH Track Control LH Track Control RH Servo Hand Control Valve RH Hydraulic Swing Lock Valve Swing Brake Release Switch Cushion Valve Solenoid Valve Cushion Valve Dipper Ram Dipper Hose Burst Check Valve Bucket Ram Boom Rams Boom Hose Burst Check Valves Shuttle Valve Swing Brake Release Solenoid Valve Swing Motor Cross Line Relief Valve Swing Brake Release Piston Swing Anti- reversal Valves Free Swing Solenoid Valve Control Valves (A & B) Negative Control Pressure Relief Valves Dipper Boost Spool Option Spool Bucket Spool Boom Spool Track Right Spool Main Relief Valve (A) Dipper Spool Swing Spool Boom Boost Spool Track Left Spool Straight Ahead Track Valve Main Relief Valve (B) Bucket Head Side ARV Bucket Rod Side ARV Boom Rod Side ARV Boom Head Side ARV Dipper Rod Side ARV Dipper Head Side ARV Swing Left ARV Swing Right ARV Hydraulic Pump Negative Control Valves Swing Cut-off Valve

9804/1103

23C 24 25 26 27 28 29 30 31 32 33 34 35 36

45 - 20 - 01/22

Constant Power Valves Cooler Cooler Check Valve (1.96 bar/28.4 lb in2) Restrictor Servo Filter (10µ) Check Valve Accumulator Servo Isolator Valve Drain Filter (10µ) Return Filter (10µ) Filter By-pass Relief Valve (1.47 bar/21.3 lb in2) Suction Strainer (105µ) Hydraulic Tank Tank Breather

Issue 1

CONTENTS

JS 300LC Circuit Diagrams - Hydraulic

Excavators

CONTENTS CONTENTS

Excavators

45 - 20 - 01/24

JS 300LC Circuit Diagrams - Hydraulic Component Key PS P1 P2 M 1 2 3 3A 3B 3C 3D 3E 3F 4 5 6 7 8 8A 8B 8C 8D 8E 8F 8G 8H 8J 8K 8L 8M 8N 8P 8R 8S 8T 8U 8V 8W 8X 9 10 10A 10B 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Servo Pump No. 1 Pump Element No. 2 Pump Element Engine Dipper Ram Track Motor LH Track Motor RH Counterbalance Spool Cross Line Relief Valves Speed Change Spool Speed Actuator Brake Release Piston Relief Valve Damping Rotary Coupling Bucket Ram Boom Rams Boom Holding Valve Control Valve (A & B) Negative Control Pressure Relief Valves Dipper Boost Spool Bucket Spool Boom Spool Option Spool Track Left Spool Main Relief Valve (A) Dipper Spool Swing Spool Boom Boost Spool Track Right Spool Straight Ahead Track Valve Main Relief Valve (B) Bucket Head Side ARV Bucket Rod Side ARV Boom Rod Side ARV Dipper Head Side ARV Dipper Rod Side ARV Swing Left ARV Swing Right ARV Logic Valve Shuttle Valve Swing Motor Cross Line Relief Valves Swing Brake Release Piston Free Swing Solenoid Valve Servo Foot Control Valve RH Servo Foot Control Valve LH Service Pedal (Optional) Manifold Servo Hand Control Valve LH Servo Hand Control Valve RH Cushion Valve Cushion Valve Solenoid Valve Swing Brake Release Solenoid Valve Speed Change Solenoid Valve Servo Isolator Solenoid Valve Accumulator Check Valve Servo Relief Valve Servo Filter

9804/1103

27 28 29 30 31 31A 31B 31C 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49

45 - 20 - 01/24

Restrictor Swing Brake Release Switch Line Filter Restrictor Hydraulic Pump Proportional Solenoid Valve Summator Assembly Pump Control (Swing Operation) Check Valve Drain Valve Air Horn Safety Valve Air Tank Governor Reducing Valve Cooler Check Valve Cooler Check Valve Drain Filter (10µ) Tank Relief Valve (1.47 bar/21.3 lb in2) Pressure Switch Hydraulic Tank Drain Valve Suction Strainer (150 Mesh) Filter By-pass Relief Valve (1.47 bar/21.3 lb in2) Return Filter (10µ)

Issue 1

CONTENTS

JS 450LC Circuit Diagrams - Hydraulic

CONTENTS CONTENTS

Excavators

45 - 20 - 01/26

JS 450LC Circuit Diagrams - Hydraulic Component Key PS P1 P2 M 1 2 3 4 5 5A 5B 5C 5D 5E 6 7 8 8A 8B 9 10 11 12 13 13A 13B 13C 13D 13E 13F 13G 13H 13J 13K 13L 13M 13N 13P 13R 13S 13T 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Servo Pump No. 1 Pump Element No. 2 Pump Element Engine Bucket Ram Boom Rams Holding Valve Track Motor RH Track Motor LH Counterbalance Valve Cross Line Relief Valves Speed Change Spool Speed Actuator Brake Release Piston Rotary Coupling Dipper Ram Swing Motor Cross Line Relief Valves Swing Brake Release Piston Shuttle Valve Manifold Free Swing Solenoid Restrictor Control Valve Swing Spool Dipper Spool Boom Boost Spool Option Spool Track Left Spool Pressure Maintenance Valve (Negayive Control) Dipper Boost Spool Boom Spool Bucket Spool Track Right Spool Straight Ahead Track Valve Main Relief valve Dipper Head Side ARV Dipper Rod Side ARV Boom Rod Side ARV Bucket Head Side ARV Bucket Rod Side ARV Servo Foot Control RH Servo Foot Control LH Service Pedal (Optional) Manifold Servo Hand Control RH Servo Hand Control LH Cushion Valve Line Filter Restrictor Cushion Valve Solenoid Valve Speed Change Solenoid Valve Swing Brake Release Solenoid Valve Servo Isolator Solenoid Valve Accumulator Check Valve Servo Relief Valve Servo Filter Swing Brake Release Switch

9804/1103

32 32A 32B 32C 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

45 - 20 - 01/26

Hydraulic Pump Proportional Solenoid Valve Summator Assembly Pump Control (Swing Operation) Check Valve Drain Valve Air Horn Safety Valve Air Tank Governor Reducing Valve Cooler Check Valve (1.47 bar/21.3 lb in2) Cooler Check Valve Drain Filter (10µ) Tank Relief Valve (1.47 bar/21.3 lb in2) Pressure Switch Suction Strainer (150 Mesh) Hydraulic Tank Drain Valve Filter By-pass Relief Valve (1.47 bar/21.3 lb in2) Return Filter (10µ)

Issue 1

CONTENTS CONTENTS

Excavators

JS 130W (From m/c no. 716501), JS 160W (From m/c no. 718501) Circuit Diagrams - Hydraulic * 67

1

4

6

8 8

68

10

7

13

9 11 11 12

15

3 2 69

69 68

26

14

24

5 68

17

17

25

16 17 18

29

56

39 28

30

31

32 38 33 20

34

21 17

A

19

71

35 45

36

37

D

H

C

G

17

23 22

B

65

64

F

A

E

27 C

49

42

B

52

46

74 48

D

47

76 72

53 A

D

B

A

B

C

73 43

43

13

44

59

54

57 62

58

63 61

55 55 60

50

9804/1103

66

45 - 20 - 02/1

Issue 2*

CONTENTS

* JS

Excavators

45 - 20 - 02/2

130W (From m/c no. 716501), JS 160W (From m/c no. 718501)

Circuit Diagrams - Hydraulic Component Key 1 2

3 4 5 6 7 8 9 Unit 10 11 12 13 14 15 16 17 18 19

Swing Motor Swing Brake Control: A Swing Lock Solenoid Valve B Swing Brake Solenoid Valve Arm Cylinder Arm Cylinder Hose Burst Check Valve (HBCV) Bucket Cylinder Boom Cylinder (Left) Boom Cylinder (Right) Hose Burst Check Valve - Boom Steering Control Valve and Steering Priority Valve

Brake Valve Accumulators Pressure Switch (Charge Warning) Pressure switch (Brake Light Warning) In-line Filter Manifold Hydraulic Pump Test Point Main Control Valve Solenoid Valves: A Drive B Swing Shut-off C 2 Stage Relief D Cushion Control E Boom Speed Control F Boom Down Delay GMaximum Flow Control H Servo Isolator 20 Accumulator 21 Accumulator 22 Transmission Control Valve: A P1 Flow Limiter B P2 Flow Limiter C Gear Change D Park Brake 23 In-line Filter ‡‡24 Pressure Switch (Overload Warning) 25 Pressure Switch 26 Relief Valve 27 Test Point 28 Oil Cooler 29 Return Manifold 30 In-line Filter 31 Nephron Group 32 Air breather 33 Sump Tank 34 Suction Strainer 35 Relief Valve 36 Return Line Filter 37 In-line Filter 38 Check Valve †39 Solenoid Valves: A Grab Lift B Grab Right 42 Servo Control Valve (Bucket/Boom) 43 Pressure Switch (Boom/Swing Control) 44 Shuttle Valve 45 Servo Control Valve (Swing/Arm) 46 Pressure Switch (Transmission Control)

9804/1103

47 ‡48 49 50 52

Accumulator Servo Control (Foot Operated, TAB) Transmission Control Valve Spool Valve (Servo Controls) Solenoid Valves: A Drive Isolate B Axle Lock ††53 Solenoid Valves (Dozer/Stabiliser): A Stabiliser LHS B Stabiliser RHS C Stabiliser Down D Stabiliser Up 54 Rotary Coupling ††55 Stabiliser Rams 56 Shuttle Valve ††57 Logic Valve 58 Front Axle 59 Axle Lock Rams 60 Drive Motor 61 Transmission 62 Left Hand Dozer Ram 63 Right Hand Dozer Ram #64 Remote Control Valve (Hammer) #65 Control Valve (Hammer) 66 Rear Axle ‡67 Boom Position Ram (TAB) ‡68 Hose Burst Check Valve (TAB) ‡69 Boom Lift Rams #71 In-line Filter 72 Shuttle Valve 73 Dozer/Arm Control Solenoid Valve 74 Pressure Switch 75 Manifold (JS160W) 76 Pilot Shuttle Valve ‡‡ † ‡ # ††

Overload Warnings Grab Rotate Option Triple Articulated Boom Option Hammer Option Stabiliser Option

Note: The diagram on page 45-20-02/1 is for the JS130W. The circuit for the JS160W is identical except for the TAB boom option (see page 45-20-02/3).

45 - 20 - 02/2

Issue 2*

CONTENTS

Excavators

45 - 20 - 02/3

JS 160W (From m/c 718501) JS 160W Boom Circuit (TAB Option) For key see page 45 - 20 - 02/2

9804/1103

45 - 20 - 02/3

Issue 1

CONTENTS

Excavators

45 - 20 - 02/4

JS 130W (From m/c 716501), JS 160W (From m/c 718501) JS 130W and JS160W (Circuit to m/c TBA) For complete circuit see page 45 - 20 - 02/1.

9804/1103

45 - 20 - 02/4

Issue 1

Excavators

CONTENTS CONTENTS

45 - 20 - 02/4A

JS 130 from m/c no. 758000 Circuit Diagrams - Hydraulic

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

9804/1103

MOTOR; SLEW RAM; DIPPER VALVE; ASSEMBLY MOTOR; TRACTION ROTARY COUPLING RAM; BUCKET RAM; BOOM (L) RAM; BOOM (R) VALVE; SHUTTLE VALVE; CONTROL VALVE; SOLENOID ORIFICE FILTER; LINE VALVE; CHECK VALVE; CHECK RADIATOR RADIATOR BREATHER; AIR TANK; SUMP FILTER; LINE STRAINER VALVE; RELIEF FILTER; RETURN VALVE; STOP NEPHRON FILTER VALVE; STOP VALVE; CHECK SWITCH; PRESS. VALVE; SOLENOID

30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

45 - 20 - 02/4A

VALVE; SHUTTLE ACCUMULATOR VALVE; CHECK FILTER; LINE PUMP; HYD VALVE; REMOTE CONT VALVE; REMOTE CONT VALVE; SHUTTLE SWITCH; PRESS VALVE; STOP CUSHION VALVE SWITCH PRESS. VALVE; STOP VALVE; SPL VALVE; RELIEF FILTER; LINE

6410 - E/3-1.1

Issue 1

CONTENTS CONTENTS

Excavators

45 - 20 - 02/4B

JS 130 from m/c no. 758000 Circuit Diagrams - Hydraulic (cont’d)

ILLUSTRATION NOT AVAILABLE AT THIS TIME

9804/1103

45 - 20 - 02/4B

6410 - E/3-2.1

Issue 1

Excavators

CONTENTS CONTENTS

45 - 20 - 02/4C

JS 160 from m/c no. 702000 Circuit Diagrams - Hydraulic

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

9804/1103

MOTOR; SLEW RAM; DIPPER VALVE; ASSEMBLY MOTOR; TRACTION ROTARY COUPLING RAM; BUCKET RAM; BOOM (L) RAM; BOOM (R) VALVE; SHUTTLE VALVE; CONTROL VALVE; SOLENOID ORIFICE FILTER; LINE VALVE; CHECK VALVE; CHECK RADIATOR RADIATOR BREATHER; AIR TANK; SUMP FILTER; LINE STRAINER VALVE; RELIEF FILTER; RETURN VALVE; STOP NEPHRON FILTER VALVE; STOP VALVE; CHECK SWITCH; PRESS. VALVE; SOLENOID

30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

45 - 20 - 02/4C

VALVE; SHUTTLE ACCUMULATOR VALVE; CHECK FILTER; LINE PUMP; HYD VALVE; REMOTE CONT VALVE; REMOTE CONT VALVE; SHUTTLE SWITCH; PRESS VALVE; STOP CUSHION VALVE SWITCH PRESS. VALVE; STOP VALVE; SPL VALVE; RELIEF FILTER; LINE

6410 - E/3-4.1

Issue 1

CONTENTS CONTENTS

Excavators

45 - 20 - 02/4D

JS 160 from m/c no. 702000 Circuit Diagrams - Hydraulic (cont’d)

ILLUSTRATION NOT AVAILABLE AT THIS TIME

9804/1103

45 - 20 - 02/4D

6410 - E/3-3.1

Issue 1

CONTENTS CONTENTS

Excavators

45 - 20 - 02/5

JS 200W from m/c no. 809000 Circuit Diagrams - Hydraulic Component Key 1 2 3 4 4/1 5 5/2 5/16 6 7 8 8/3 8/4 9 10 11 12 13 13/5 13/6 13/7 13/8 13/9 13/10 13/11 13/12 13/13 14 15 15/17 15/18 15/19 15/20 16 17 18 18/14 18/15 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Sump tank Suction Strainer Breather Main Pump Pump Proportional Solenoid Proportional Valve Fine Mode Proportional Solenoid Boom Priority Solenoid Servo Filter Test Point Transmission Control Valve Park Brake Solenoid Gear Change Solenoid Clutch Accumulator Servo Accumulator Pressure Switch Park Brake Accumulator 9 Station Solenoid Valve Servo Isolator Solenoid Swing Shut Off Solenoid Drive Isolation Solenoid Axle Lock Solenoid Actuator Isolation Solenoid Boom Down Speed Regulation Solenoid Creep Speed Regulation Solenoid Hammer Speed Regulation Solenoid Boost Pressure Solenoid Manifold Stabiliser Control Valve Stabiliser Up Solenoid Stabiliser LHS Solenoid Stabiliser RHS Solenoid Stabiliser Down Solenoid Joystick RH Servo Valve Pedal Change Over Valve Arm/Dozer Solenoid TAB /Hammer - Aux Solenoid Joystick LH Shuttle Valve Pressure Switch Manifold Hose Burst Check Valve Manifold Tank Servo Drain Filter Bypass Filter Relief Valve Steering/Brake Filter Steer Valve Unit Brake Valve Pressure Switch Pressure Switch Brake Accumulator Stop Tap Oil Cooler Return Filter Pressure Switch Main Control Valve Swing Motor Swing Gearbox Swing Brake Valve

9804/1103

40/21 40/22 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 70/23 70/24 71 72 73 74 75 76 77 78

45 - 20 - 02/5

Swing Lock Solenoid Swing Brake Solenoid Bucket Ram Arm Ram Arm Hose Burst Check Valve Monoboom Boom Ram TAB Boom Ram Boom Hose Burst Check Valve Pressure Switch TAB Ram TAB Hose Burst Check Valve Change Over Valve Hammer Relief Hammer Filter Coupling Coupling Rotary Coupling Drive Motor Transmission Rear Axle Front Axle Axle Lock Ram Tank Manifold Left Hand Dozer Ram Right Hand Dozer Ram Logic Valve Stabiliser Ram Check Valve Relief Valve Check Valve TAB Section Valve Low Flow Valve Low Flow Option Solenoid Low Flow Option Solenoid Low Flow Valve Test Point Pressure Switch Drive Motor Manifold Tee Stabiliser Manifold Brake Manifold Tee Relief Valve

6410 - E/2-1.1

Issue 1

CONTENTS CONTENTS

Excavators

45 - 20 - 02/6

JS 200W from m/c no. 809000 Circuit Diagrams - Hydraulic (cont’d)

ILLUSTRATION NOT AVAILABLE AT THIS TIME

9804/1103

45 - 20 - 02/6

6320 - E/2-2.1

Issue 1

Excavators

CONTENTS CONTENTS

45 - 20 - 02/6A

JS 200, 220 from m/c no. 705001 Circuit Diagrams - Hydraulic

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

9804/1103

MOTOR; SLEW RAM; DIPPER VALVE; ASSEMBLY MOTOR; TRACTION ROTARY COUPLING RAM; BUCKET RAM; BOOM (L) RAM; BOOM (R) VALVE; SHUTTLE VALVE; CONTROL VALVE; SOLENOID ORIFICE FILTER; LINE VALVE; CHECK VALVE; CHECK RADIATOR RADIATOR BREATHER; AIR TANK; SUMP FILTER; LINE STRAINER VALVE; RELIEF FILTER; RETURN VALVE; STOP NEPHRON FILTER VALVE; STOP VALVE; CHECK SWITCH; PRESS. VALVE; SOLENOID

30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

45 - 20 - 02/6A

VALVE; SHUTTLE ACCUMULATOR VALVE; CHECK FILTER; LINE PUMP; HYD VALVE; REMOTE CONT VALVE; REMOTE CONT VALVE; SHUTTLE SWITCH; PRESS VALVE; STOP VALVE; SPL SWITCH PRESS. VALVE; STOP VALVE; SPL VALVE; RELIEF FILTER; LINE

6400 - E/3-1.2

Issue 1

Excavators

CONTENTS CONTENTS

45 - 20 - 02/6B

JS 200, 220 from m/c no., 705001 Circuit Diagrams - Hydraulic (cont’d)

ILLUSTRATION NOT AVAILABLE AT THIS TIME

9804/1103

45 - 20 - 02/6B

6400 - E/3-2.1

Issue 1

CONTENTS CONTENTS

Excavators

45 - 20 - 02/6C

JS 240, 260 from m/c no. 708501 Circuit Diagrams - Hydraulics

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

9804/1103

MOTOR; SLEW RAM; DIPPER VALVE; ASSEMBLY MOTOR; TRACTION COUPLING; ROTARY RAM; BUCKET RAM; BOOM (L) RAM; BOOM (R) VALVE; SHUTTLE VALVE; CONTROL VALVE; SOLENOID ORIFICE FILTER; LINE VALVE; CHECK VALVE; CHECK RADIATOR RADIATOR BREATHER; AIR TANK; SUMP FILTER; LINE STRAINER VALVE; RELIEF FILTER; RETURN VALVE; STOP FILTER; NEPHRON VALVE; STOP VALVE; CHECK SWITCH; PRESS. VALVE; SOLENOID

30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

45 - 20 - 02/6C

VALVE; SHUTTLE ACCUMULATOR VALVE; CHECK FILTER; LINE PUMP; HYD VALVE; REMOTE CONT VALVE; REMOTE CONT VALVE; SHUTTLE SWITCH; PRESS VALVE; STOP VALVE; SPL SWITCH PRESS. VALVE; STOP VALVE; SPL VALVE; RELIEF FILTER; LINE

6400 - E/3-4.2

Issue 1

Excavators

CONTENTS CONTENTS

45 - 20 - 02/6D

JS 240, 260 from m/c no., 708501 Circuit Diagrams - Hydraulic (cont’d)

ILLUSTRATION NOT AVAILABLE AT THIS TIME

9804/1103

45 - 20 - 02/6D

6400 - E/3-3.1

Issue 1

CONTENTS CONTENTS

Excavators

45 - 20 - 02/7

JS 330 from m/c no. 712501 Circuit Diagrams - Hydraulic 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 61 62 63

Solenoid Valve (optional) Restrictor (optional) Slew Motor Slew Reduction Gears Dipper Ram Traction Motor Rotary Coupling Bucket Ram Left Boom Ram Right Boom Ram Control Valve Check Valve Solenoid Valve (optional) Solenoid Valve (optional) Pressure Switch (optional) Shuttle Valve (optional) Remote Control Valve Filter Filter (optional) Remote Control Valve (optional) Slew Valve Remote Control Valve Filter Solenoid Valve Pressure Switch Shuttle Valve Cushion Valve Solenoid Valve Check Valve Accumulator Relief Valve Line Filter Shuttle Valve Line Filter Pressure Switch Pressure Switch Hydraulic Pump Engine Stop Valve (optional) Stop Valve (optional) Relief Valve (optional) Line Filter (optional) Spool Valve (optional) Return Filter Relief Valve Suction Strainer Hydraulic Tank Drain Tap Hydraulic Tank Pressure Switch Relief Valve Line filter Check valve Check valve Reducing Valve Oil Cooler Isolating Cock Filter Governor Air Tank Check valve Safety Valve Check Valve (optional) Holding Valve (optional)

9804/1103

45 - 20 - 02/7

6420 - E/3-1.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/8

JS 330 from m/c no. 712501 Circuit Diagrams - Hydraulic (cont’d)

Refer to Service Manual

9804/1103

45 - 20 - 02/8

6420 - E/3-2.1

Issue 2*

CONTENTS CONTENTS

Excavators

45 - 20 - 02/9

JS 450 from m/c no. 714501 Circuit Diagrams - HydraulicS 1 2 3 4 5 6 6A 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

Solenoid Valve (optional) Restrictor (optional) Slew Motor Slew Reduction Gears Dipper Ram Traction Motor Traction Reduction Gear Rotary Coupling Bucket Ram Left Boom Ram Right Boom Ram Control Valve Solenoid Valve (optional) Solenoid Valve (optional) Solenoid Valve (optional) Pressure Switch (optional) Shuttle Valve (optional) Remote Control Valve Filter Filter (optional) Remote Control Valve (optional) Slew Valve Remote Control Valve Filter Solenoid Valve Pressure Switch Shuttle Valve Cushion Valve Solenoid Valve Check Valve Accumulator Relief Valve Line Filter Shuttle Valve Line Filter Pressure Switch Pressure Switch Hydraulic Pump Engine Stop Valve (optional) Stop Valve (optional) Relief Valve (optional) Line Filter (optional) Spool Valve (optional) Return Filter Relief Valve Suction Strainer Hydraulic Tank Drain Tap Hydraulic Tank Pressure Switch Relief Valve Line filter Check valve Check valve Reducing Valve Oil Cooler Isolating Cock Filter Governor Air Tank Check valve

9804/1103

61 62 63

45 - 20 - 02/9

Safety Valve Check Valve (optional) Holding Valve (optional)

6420 - E/3-3.2

Issue 1

CONTENTS

Excavators

45 - 20 - 02/10

JS 460 from m/c no. 714501 Circuit Diagrams - Hydraulic (cont’d)

Refer to Service Manual

9804/1103

45 - 20 - 02/10

6420 - E/3-4.1

Issue 2*

CONTENTS

Excavators

45 - 20 - 02/11

JS460 from m/c no. 714550 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 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59

Bucket Ram Left Boom Ram Right Boom Ram Track Motor Track Gearbox Rotary Coupling Dipper Ram Hose Burst Check Valve (optional) Hose Burst Check Valve (optional) Slew Motor Slew Gearbox Main Control Valve Solenoid Valve (optional) Shuttle Valve (optional) Pressure Switch 200 bar (optional) Pressure switch 10 bar (optional) Slew Brake Valve Remote Control Valve Remote Control Valve Nipple Remote Control Valve RH Manifold (optional) Filter Adaptor Remote Control Valve LH Pressure Switch 5 bar Multi Shuttle Block Cushion Valve 8 Stattion Solenoid Valve Pressure Switch Accumulator Servo Manifold Not Used Not Used Not Used Line Filter Pressure Switch 20 bar Not Used Merged Valve (optional) Nephron Filter Stop Valve Oil Cooler Check Valve Hydraulic Pump Engine Hammer Return Filter (optional) Not Used Hammer/Auxiliary Valve RH (optional) Hammer/Auxiliary Valve LH (optional) Stop Valve (optional) Low Flow Pump (optional) Air Tank Actuator Proportional Valve Quick Release Valve Coupling (optional) Check Valve Servo Return Filter Relief Valve Pressure Switch Strainer

9804/1103

60 61 62 63

45 - 02 - 02/11

Hydraulic Tank Directional Valve (optional) Relief Valve (optional) Return Filter (optional)

6420 - E/3-6.1

Issue 1*

CONTENTS

Excavators

45 - 20 - 02/10

JS 460 from m/c no. 714550 Circuit Diagrams - Hydraulic (cont’d)

Refer to Service Manual 9803/640

9804/1103

45 - 20 - 02/1

6420 - E/3-7.1

Issue 1*

CONTENTS

Excavators

45 - 20 - 02/13

JS330/JS460 Tier Circuit Diagrams - Hydraulic The item numbers in the following list are identified on the Hydraulic schematic.

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 35 36 39 40 41 42 43 44 45 47 48 49 50 52 53 54 56 59 60 61 62 63

Description Bucket Ram Boom Ram Left Hand Boom Ram Right Hand Track Motor Track Gearbox Rotary Coupling Dipper Ram Hose Burst Check Valve Hose Burst Check Valve Swing Motor Swing Gearbox Main Control Valve Solenoid Valve (Merged Valve) Shuttle Valve Pressure Switch (200 bar) Pressure Switch (10 bar) Swing Brake Valve Remote Control Valve (Travel) Remote Control Valve (Option) Adapter Filter Remote Control Valve Right Hand Manifold Adaptor Filter Remote Control Valve Left Hand Pressure Switch (5 bar) Multi Shuttle Valve Cushion Valve 8 Station Solenoid Valve Pressure Switch (12 bar) Accumulator Servo Manifold Servo Filter Filter Line Pressure Switch (20 bar) Plexus Filter Stop Valve Oil Cooler Check Valve Hydraulic Pump Engine Hammer Return Filter Hammer/Auxiliary Valve Right Hand Hammer/Auxiliary Valve Left Hand Stop Valve Low Flow Pump Actuator Proportional Valve Quick Release Coupling Servo Return Filter Strainer Hydraulic Tank Directional Valve Relief Valve Return Filter

9804/1103

Part No. KTV 1021 KTV 0939 KTV 0937 50/100113 50/100058 JSA 0155 KTV 1063 928/60086 928/60087 20/925266 05/202400 25/221026 25/220536 KHJ 0579U-A 701/80198 JRR0076 25/220998 KSJ 2465 JRJ 0162 JHJ 0168 25/221904 JRJ0132 JHJ0168 25/221904 701/80824 25/220830 25/220042 928/60061 JHR 0185 JHJ0050 KHJ 0658 32/925214 KHJ 0568 JHR 0184 JHJ 0238 KHJ 0897 30/925506 KHJ 0982 20/925278 01/145166 JBJ0066 JSV 0328 JSV 0327 JSV 0352 20/925311 331/14519 928/60027 45/910400 KHJ0287 KTJ 1081Y-A 215/10658 JSJ 0083 928/60066 581/10866

45 - 20 - 02/13

6420 - E/3-8.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/14

JS330/JS460 Tier 2 Circuit Diagrams - Hydraulic (cont’d) 1

2

3

Z=15

4

5

Z=15

Z=104

9

*

6

7

8

9

10

11 160-110-1306

Z=104 i=19.3

MIN L 2580

MA

7

cc/rpm

CC/rev

11

145.9

8 1

A

325 bar at 40 / min

B

325 bar at 40 / min

PIL

380 bar

T V2

3

TRACK MOTOR

6

CENTRE JOINT

7

ARM CYLINDER

C2

C2

T

E

PIL

E

B

A Gri

MB

380 bar

C

M

6

BACKWARD LEFT B RIGHT

FORWARD LEFT

Pi

* * * *

I-13

*

15

A

B

V2

2

T PSW

*

22

T

L P T

P

7 L-1

BP

MA

D

A LEFT

T P L

Gri

PIL

BACKWARD RIGHT

*

FORWARD RIGHT

Dr

9

HOSE BURST CHECK VALVE

10

SWING MOTOR

11

SWING GEARBOX

12

MAIN CONTROL VALVE

13

VALVE SOLENOID

14

VALVE SHUTTLE

15

200 bar

*

49

29 DIA SOL VALVE D MERGED VALVE (HYD TANK)

x

D

13

B

D-10

*

ps1

T3

A

T1

pc5

ps2

47 bar at 60 l/min

B

15bar

47 bar at 60 l/min

pa10

pa11

*

x

D-3

DR1'

16

DR1

A

17

C

PRESSURE SWITCH 10 bar

17

SWING BRAKE VALVE

18

VALVE REMOTE CONTROL

19

VALVE REMOTE CONTROL

20

NIPPLE

21

VALVE REMOTE CONTROL RH

22

MANIFOLD

23

ADAPTER FILTER

H-3

B5 T v

18

E

w

F-6

pb5

h

F-6

OUT

FORWARD RIGHT

BACKWARD RIGHT

FORWARD LEFT

BACKWARD LEFT

1

L-2

14

*

19

*

IN

363bar at20 /min

OUT

pa5

g

5

4

pc4 B4

w

E-3

OPEN

CLOSE

1

2

3

G-6

G-11

4

l

k

j

G-6

T

pb3 pa3

L-1

24

G

21

23

T

23

P

T

d

J-1

u K-5

3

SWING

ARM

4

1

RIGHT LEFT

IN

2

3

3

OUT

BUCKET

CLOSE

H

4

1

OPEN

BOOM

DOWN

a

b

F-11

F-11

F-1

13

pb7

e

3.5 bar

*

SOL VALVE C HAMMER/AUX CHANGEOVER (UNDER CAB)

L-1

f L-1

pb6

45

3

*

*

A2

A3

LEFT

TRAVEL (R)

pa6

F-1

31

SERVO MANIFOLD

32

SERVO FILTER

PT

PA

PH

PRESSURE SWITCH 20 bar

E

39

NEPHRON FILTER

40

VALVE STOP

41

OIL COOLER VALVE CHECK

43

HYDRAULIC PUMP

44

ENGINE DIESEL

45

HAMMER RTN FILTER

47

HAM/AUX VALVE RH

48

HAM/AUX VALVE LH

49

STOP VALVE

50

LOW FLOW PUMP

A4

A5

UP

C9

* * * 40

39

52

ACTUATOR

53

PROPORTIONAL VALVE QUICK REL COUPLING

G SERVO RETURN FILTER

1) UPPER VALUES

42

P2

59

STRAINER

60

HYDRAULIC TANK

61

DIRECTIONAL VALVE

62

RELIEF VALVE

63

RETURN FILTER

H

NOTES

pr2

SHOW THE CONNECTION POINTS AND

LOWER VALUES SHOW THE ZONE NUMBER OF THIS DRAWING.

41

3 G-12

IN

1

2

B-4

C-13

I

ARM

SWING

56 28

B1

B2 c

26

C2 B4

B3 C1

B5 C3

s

d

G-6

G-6

n

G-10

30

C4 B6

B1 SOFT/HARD

p

F-10

GAS PRESS. 15 bar CAPACITY 300 cm

T1 LEVER LOCK

32

31

Pm2

2-STAGE RELIEF

27

0.5 bar

63

10µ

A

Pb2 Dr2

MAX FLOW CUT

C3

Dr3

Pi2

C5 B

C4

C7

C3

0.05bar 10 µ

3

P

0.6 bar

43

14

C4

F-10

J

C2 C1

F

A

a2

1.03 bar

B SWING SHUT OFF

T

C2

NEGATIVE FLOW CON.

A2

15

a3

K

170.0 i=1.0

62

B3 B1

CC/rev

B 20

A1

BOOM PRIORITY OVER SWING C5

CC/rev

61

44

H-6

E1

G

H

7

C-12

C

A1

D

IN

UP

e

G B-4

f G-10

G-11

g E-6

Pb1

50

T2

54

200 bar

* ISUZU 228 KW @ 2000rpm

K

B

T

OUT

35

3.0

A

Pm1

52

L

h

E-6

T

P

r G-6

A408440

53

2

*

A

Pi1

ARM

BOOM DOWN

B2

R

D0

*

175 bar

M

a1 u

200 bar

P

A

C1

S

59

60

CC/rev

164.7 CC/rev i=1.032

C6

Psv

2-STAGE TRAVEL

J

0.3 bar 150MESH

10µ

44 bar / min a4 at 26 A3

E

L

*

3.0 bar

29

C5 A6

OUT

DOWN

ON 12 bar OFF 9 bar

F

58

l

40

319 bar at 240 /min 348 bar at 220 /min

FILTER LINE

36

2) COMPONENTS MARKED THUS ARE OPTIONS

S2 S3

D

57

STRAIGHT TRAVEL

TRAVEL (L)

35

56

12

FORWARD

ON 20 bar OFF 15 bar

C6

9804/1103

ACCUMULATOR

55

I-12

F-2

BACKWARD

pr1

BOOM

1

PRESSURE SWITCH 12 bar

30

54

m

B1

q

S1

8 STATION SOL VALVE

29

51

F-2

36

C8 RIGHT C7

A

FORWARDA6

BACKWARD

D-6

A1

10* C

25

ON 5 bar 25 OFF 4 bar

t E-6

B

s

pa7 B6

LEFT

P1

I

DOWN

pa2 pc6

pa1

j

UP

28

46

* * * *

L-1

B7 UP

A1 pb1

k

2

F-6

A7

BOOM2

SWING

*

4

b

BOOM1

DR3

B

T

a

UP

DOWN

A2 RIGHT pb2

J-1

P

A

T

DR2 pc2

B2

c

P

P

DR2'

245 bar at20 /min

B3

r

VALVE CUSHION

42

H-2

363 bar at 20 l/min

CLOSE

A3

m

G-11

A8 pb8 pa8

OPEN

20

D

D

BUCKET

E-3

P

A

H-3

pa4

v

T

F-6

B8

OPTION

F

B

5

p

J-3

363 bar at20 /min

A4 pb4

F-13

27

38

T

n

pa9 t

F-11

P

*

48

pb9

ARM2

L-2

I-1

PRESSURE SWITCH 5 bar

26

MULTI SHUTTLE BLOCK

37

J-3

2 OPTION

A9

IN

ARM1 ON 10 bar OFF 8 bar

VALVE REMOTE CONTROL LH

25

34

*

47

B9

A5

190 bar

P

C

33

pc1

q

B

PRESSURE SWITCH 200 bar

16

24

*

A

HOSE BURST CHECK VALVE

8

* *

4 V2

BP

B RIGHT

BOOM CYLINDER RH

TRACK GEARBOX

380 bar

A LEFT

BOOM CYLINDER LH

3

5

B

M

BUCKET CYLINDER

2

4

R/G

6

C

1

*

8

CC/rev

L-2

10

Component

5

1

280 bar l/min at 200

16 No.

*

Bre

Bre

I-12

280 bar l/min at 200

15

i=121:1

5

cc/rpm

DB

14

MIN L 2230

2

MB

X

R/G

PG

145.9

S

107/160

i=121:1 PG

S

X

107/160 C2

DB

13 160-110-1580

MIN L 1976

180-130-1910

i=19.3

A

12

4

3

4

5

6

7

8

9

10

11

12

13

14

45 - 20 - 02/14

15

16

6320 - E/3-9.1

Issue 1

Excavators

CONTENTS

45 - 20 - 02/15

JS450/JS460 Circuit Diagrams - Hydraulic Control Valve T1

4Ps

T2

5P.P2

5P 5Dr2 5Pa1 5Pb1 5Pa1 SWING 5Pb1

4A4 4B4 4Pb4

4T1

ARM(2)

4Pa4 4A3

3B3

5Pb2 5B1 5Pb2 5Pb2 5A2

ARM (1)

5T1

BL3 BOOM(1)

4Dr1

5B2 5Dr1

4P.P1

4Pb3' 4Pb3 4Pa3 4A2 4B2 4Pb2' 4Pb2 4Pa2 4A1 4B1

BOOM (2)

5A3 5B3

5P.P1

5P 5Pa4 5Pb4 OPTION

4Pb1 4Pa1

5A4 5B4

TRAVEL (L) TRAVEL (R) 5Pa5

PG2

5Pb5 5A5 5B5

PG1 5PS

PG3 Pp

4P

T4

4P.P3

T3

PG5

9804/1103

PG5

PG4

A357600

45 - 20 - 02/15

6420 - E/32-4.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/16

JS460 Tier 2 Circuit Diagrams - Hydraulic Control Valve

ps1

T3

T1 pc5

ps2

pa10

pa11 DR1' DR1 pc1

DHV

B5

B9

A5 pb5 DIPPER 1

A9

a f

pa5

DIPPER 2 pb9

SDV

pc4

pa9

B4 A4 pb4 OPTION

b

g

B8 A8 BUCKET pb8

pa4

pa8

B3

B2 A2

DR2'

BHV

A3

DR2 pc2 A7 pb3 BOOM2

c h

pa3 pb2

SLEW

pa7

d

DR3

i BPV

pa2 pc6

B6 A6 TRAVEL pb6

pa6

B1 A1 pb1 pa1

B7 BOOM1 pb7

TRAVEL

j

e

LINEAR TRAVEL

pr1 R1

P1

PT

pr2

R2

R3

PP

PA

PH

A1

P2

A2

A408690

9804/1103

45 - 20 - 02/16

6420 - E/32-5.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/17

JS460 Tier 2 - Neutral Circuit Circuit Diagrams - Hydraulic With all the controls in the neutral position, flow from pump A1 enters the main control valve 12 at port P1 and flow from pump A2 enters the main control valve 12 at port P2. Oil is allowed to flow across all of the spools via the neutral gallery when all controls are in the neutral position. Oil from pump A1 exits port Ps1 and oil from pump A2 exits port Ps2 at the top of the main control valve. Both flows of oil meet a separate restrictor and relief valve. Some oil will pass through the restrictor and back to tank, creating back pressure in the line. Oil is exhausted across the relief valves at 40 bar. The back pressure is sensed at ports Ps1 and Ps2 and ports Pi1 and Pi2 of the pumps, holding the pumps on minimum flow.

a b c d e f g h i j

Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool

Flow from the servo pump enters the valve block at port Pp, where it meets 3 restrictors. These maintains the pressure on the input side at full servo pressure. Oil that crosses the restrictors, is allowed back to tank after passing over the neutral gallery of the spools. No pressure is created in this line whilst all controls are in neutral, allowing all pressure switches to remain in the open position.

9804/1103

45 - 20 - 02/17

6420 - E/38-1.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/18

JS460 Tier 2 - Neutral Circuit Circuit Diagrams - Hydraulic (cont’d)

12 ps1

ps2

T3 T1 pc5

pa10

pa11 DR1' DR1 pc1

DHV

B5

B9

A5 pb5

DIPPER 1 a

A9

f DIPPER 2

pb9

pa5 Pm2

43

pc4

44 bar / min a4 at 26

B4 A4 pb4

Dr3

Pi2 Pb2 Dr2

SDV

pa9

b

a2

15

a3

170.0 i=1.0

pa4

B1 20

CC/rev

B3

A

M

a1

pb3 BOOM2 c

B2 A2

ISUZU 228 KW @ 2000rpm

52

pb2

h BOOM1 pb7

SLEW

A T

30 B1 A1

C5

31

B

0.5 bar

C4

A

C3

TRAVEL

pb1 pa1

i

BPV

pa2 pc6

P

Exhaust

TRAVEL

B6 A6

pb6

pa6

j

e

LINEAR TRAVEL

C2 C1

pr1 R1

Pressure Servo Neutral

B7

pa7

d

DR3

Pm1

Full Pressure

DR2 pc2 A7

pa3

D0

Pi1

DR2'

BHV

A3

1.03 bar

B

A1

A1

Key to Oil Flow & Pressure

pa8

B3

CC/rev

Pb1

pb8

CC/rev

164.7 CC/rev i=1.032

Psv

B8 A8

OPTION

10µ

A3

A2 A2

g BUCKET

R3 P1

PT

pr2

R2 PP

PA PH

P2

Cavitation Lock Up

A408770

9804/1103

45 - 20 - 02/18

6420 - E/38-2.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/19

JS460 Tier 2 - Neutral Circuit Circuit Diagrams - Hydraulic (cont’d)

ps1

12

ps2

T3 T1 pc5

6

Key to Oil Flow & Pressure pa10

pa11 DR1' DR1 pc1

Full Pressure Pressure Servo Neutral

DHV

B5

Exhaust

B9

A5

Cavitation

pb5

DIPPER 1 a

A9

Lock Up

f pa5

DIPPER 2

pc4

pa9

B4 A4

pb4 OPTION

b

B8 A8

g

BUCKET

pa4

pb3

MA

X

S

S

B2 A2 pb2

MB

X

107/160

107/160 CC/rev

325 bar at 40 / min

i=121:1

A

B

pc2

c

325 bar at 40 / min

i=121:1

R/G

R/G

MA

C

BP

i

BPV TRAVEL

B6 A6 pb6

pa6

j

e

pb1 Gri

D

pa7

B7 pb7

B1

A

MB

h

d

pa2 pc6

Gri BP

BOOM1

SLEW

A1 B

A7

BOOM2

DR3

CC/rev

Bre

Bre

DR2' DR2

BHV

pa3

4

pb8

pa8

A3 B3

pb9

SDV

pa1

LINEAR TRAVEL

TRAVEL

pr1 R1

A

R3 P1

PT

36

pr2

R2 PP

P2

PA PH

29 A1

A2

A408790

9804/1103

45 - 20 - 02/19

6420 - E/38-3.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/20

JS460 Tier 22 - Straight Line Travel Circuit Diagrams - Hydraulic Control Valv (Travel and exavator services selected) Refer to Travel Middle Speed for servo function of travel circuit and Boom Up for servo function of Boom up function. Servo pressure entering at port Pp on the main control valve 12 is blocked from tank by the Travel spools and the Boom (2) spool, this causes back pressure which selects the travel and excavator pressure switchs 36 and 29 and selects the Linear travel spool. Flow from pump A1 is available to the left hand Travel spool and the Linear travel spool which diverts the flow to the right hand Travel motor. Flow from pump A2 is available to all the other functions of the Main control valve 12 via the parrallel working galleries. If any excavator function is selected at slow speed and does not require the full flow from pump A2, then the extra flow is used in the travel circuit (as long as the travel circuit is working at a lower pressure) via the check valve at the right hand travel spool, a restrictor gives low priority to the travel circuit. If the Boom up is selected both Boom 1 and 2 spools are fed from the pump A2 through the left and right hand parrallel working gallery.

a b c d e f g h i j

Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool

When both Travel spools are selected, the loss of pressure in the neutral gallery is sensed at the pumps through ports Ps1 and Ps2 on the main controll valve 12. The pumps come into full flow.

9804/1103

45 - 20 - 02/20

6420 - E/38-4.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/21

JS460 Tier 22 - Travel - Middle Speed Circuit Diagrams - Hydraulic When both tracks are selected, servo pressure from port 2 (LH travel lever),and port 4 (RH travel lever) 18 enters the main control valve 12 at Pb1 and Pa6 respectively, selecting the left and right hand travel spools. Flow from pump A1 is available at the Left hand travel spool and is directed to the Left hand travel motor via port A1 of the Main control valve 12, through the rotary coupling and in to port P1 on the LH travel motor. Exhaust oil from the motor enters the main control valve 12 at port B1 and is directed to the Left hand travel spool to the tank port. Flow from pump A2 is available at the Right hand travel spool and is directed to the Right hand travel motor via port A6 of the main control valve 12, through the rotary coupling and in to port P2 on the Right hand travel motor. Exhaust oil from the motor enters the Main control valve 12 at port B6 and is directed to the Right travel spool to the tank port.

a b c d e f g h i j

Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool

The servo oil flowing over restrictors R1 and R2 is available to tank causing the excavator pressure switch 36 to stay open and the straight line travel spool to remain un-selected. Pressure is lost on both negative control ports Ps1 and Ps2, which is sensed at the pumps which come into full flow.

9804/1103

45 - 20 - 02/21

6420 - E/38-5.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/22

JS460 Tier 2 - Travel - Middle Speed Circuit Diagrams - Hydraulic

ps1

pa10

pa11 DR1' DR1 pc1

Key to Oil Flow & Pressure Full Pressure

12

ps2

T3 T1 pc5

DHV

Pressure B5

Servo Neutral

B9

A5 pb5 DIPPER 1

Exhaust

a

A9

Cavitation Lock Up

f pa5

DIPPER 2

pb9

SDV

pc4

pa9

B4 A4

pb4 OPTION

b

g

B8 A8 BUCKET

pa4

pb8

pa8 DR2'

BHV

A3

DR2 pc2 A7

B3 pb3

BOOM2

c h

pa3 B2 A2 pb2

SLEW

BOOM1

pa7

d

DR3

TRAVEL BPV

pa2 pc6

i

B1 A1

j

e

pb1

B7 pb7 B6 A6 pb6

pa6

LINEAR TRAVEL

TRAVEL

pa1

18

pr1 R1 R3 P1

4 MA

X

S

S

PT

pr2

R2 PP

P2

PA PH

MB

X

107/160

107/160 CC/rev

325 bar at 40 / min

i=121:1

A

B

CC/rev

325 bar at 40 / min

i=121:1

A1

A2

1

2

T

P

4

3

Bre R/G

R/G

Bre

B

A

Gri

Gri BP

MB

MA

BP

C

D A

A408800

9804/1103

45 - 20 - 02/22

6320 - E/38-6.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/23

JS460 Tier 2 - Travel - Middle Speed Circuit Diagrams - Hydraulic

2 ps1

ps2

T3 T1 pc5

12

8

8

pa10

pa11 DR1' DR1 pc1

DHV

B5

B9

A5 pb5

3

DIPPER 1 a

A9

V2

T

E

PIL

E

380 bar

f pa5

DIPPER 2

T

V2

pb9

pa9

B4 A4

pb4 OPTION

b

g

B8 A8 BUCKET

pa4

pb8

pa8 DR2'

BHV

A3

pb3 pa3 B2 A2 pb2

PIL

SDV

pc4

B3

380 bar

pc2

DR2

21

A7 B7

c BOOM2

SLEW

E

T

F

A

B

27 T

BOOM1

h

d

DR3

i

BPV

pa2 pc6 B1 A1 pb1 TRAVEL pa1

P

pb7 pa7

B6 A6 TRAVEL pb6

BUCKET OPEN CLOSE

pa6

j

e

1

UP 3

2

BOOM DOWN 4

S

LINEAR TRAVEL

E1

G

pr1

H

C

A1

R

D

25 R1 R3 PT

P1

36

pr2

R2 PP

22 A1

P2

PA PH

S1

C8 RIGHT

29

A2 LEFT

A3

S2 S3

A4 DOWN

UP

BOOM

Key to Oil Flow & Pressure

C7

A5

C9

C5 A6

OUT

IN

ARM

SWING

C6

Full Pressure A1

A2

Pressure

B1

B2

B3 C1

C2 B4

B5 C3

C4 B6

Servo Neutral Exhaust Cavitation Lock Up

9804/1103

45 - 20 - 02/23

6420 - E/38-7.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/24

JS460 Tier 22 - Boom Up Circuit Diagrams - Hydraulic Servo pressure from the handcontroller 21 enters the servo shuttle valve 26 at port A3 and is disributed to: 1

Boom up pressure switch 25 at port S2.

2

Port B3 through the Cushion control valve 27, the signal is then divided between the Boom 1 spool valve at port Pa7 and Boom(2) spool at port Pa3 on the main control valve 12.

Flow from pump A2 is stopped by the Boom(1) spool and is diverted via the parrallel working passage to the Boom(1) spool. The oil passes through the spool and merges with the flow from pump A1. Flow from pump A1 is stopped by the Boom(2) spool and is diverted via the parrallel working passage to the boom 2 spool.The oil passes through the spool and merges with the flow from pump A2.

a b c d e f g h i j

Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool

The pressure lifts the Boom holding valve BHV off it’s seat allowing oil to leave the main control valve at port A7 to enter the Hose Burst Protection valve (HBPV) 22 (if fitted) and the Boom rams 2 and 3. Exhaust oil enters the Main control valve 12 at port B7 and crosses the Boom 1 spool to tank. Pressure is lost on both negative control ports Ps1 and Ps2, which is sensed at the pumps, which comes into full flow. The Excavator pressure switch 29 is closed by back pressure resulting from Boom 2 spool closing the servo route to tank. The travel pressure switch 36 remains open.

9804/1103

45 - 20 - 02/24

6420 - E/38-8.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/25

JS460 Tier 22 - Boom Down Circuit Diagrams - Hydraulic Servo pressure from the Handcontroller enters the Servo Shuttle valve 26 at port A4 and is disributed to: 1

Port S3 to activate the Boom down pressure switch 25.

2

Port C2 to the Main control valve 12 at port Pc2. The Boom holding spool valve is moved across allowing pressure at the top of the Boom Holding Valve BHV to exhaust to tank.

3

Port B4 to port E of the Cushion control valve 27. The oil flows across the unrestricted part of the spool and out of port G to the main control valve 12 at port Pb7, moving the spool to the down position. Note. If HBCV’s 12 are fitted a signal is also sent from port E1 of the Cushion control valve 27 to the P ports of the HBCV’s to move the HBCV spool over and allow oil to return from the rams.

a b c d e f g h i j

Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool

Flow from pump A2 travels through the neutral gallery to the Boom 1 spool. The flow is restricted allowing a reduced pressure at port Ps2 which is sensed at Pm2 of the pump A2 which increases flow (less than full flow). Oil flow also passes through the parallel working gallery to the Boom(1) spool and is directed to the Boom rams 2 and 3 via port B7. Exhaust oil passes through the HBVC’s 12 (if fitted) to the Main controll valve 12 at port A8, lifts the Boom Holding Valve BHV off it’s seat and passes through the Boom (1) spool and exhausts to tank. Exhaust oil passing through the spool can be regenerated into the feed side of the rams. A check valve in the spool (see Fig 1) allows oil to enter the pressure side of the spool if the returning oil is a a higher pressure, due to the wieght of the boom/load. The restrictor also creates back pressure so causing the check valve to open.

9804/1103

45 - 20 - 02/25

6420 - E/38-9.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/26

JS460 Tier 2 - Boom Down Circuit Diagrams - Hydraulic

ps1

12

ps2

T3 T1

pa10

pa11 DR1' DR1 pc1

DHV

B9

3

2

A9

f pa5

DIPPER 2

B4 A4

pb4 OPTION

b

g

B8 A8 BUCKET

pc2

SLEW

E

BL

P

P

BL

E

V2

DR2 A7

c h

BOOM1

pa7

d

DR3

i

BPV

pa2 pc6 Key to Oil Flow & Pressure B1 A1 Full Pressure pb1 TRAVEL Pressure Servo pa1

V2

DR2'

BHV

pa3 B2 A2 pb2

pb8

pa8

A3 BOOM2

C2

C2

pa9

pa4

B3 pb3

C2

C2

pc4

Fig 1

pb9

SDV

B7 pb7 B6 A6

TRAVEL

21 P

pb6

E

F

A

27

B

T

T

pa6

j

e

LINEAR TRAVEL

BUCKET OPEN CLOSE 1

Neutral pr1 Exhaust

R1

Cavitation

R3

Lock Up P1

PT

3

2

BOOM DOWN 4

S

E1

pr2

R2 PP

UP

G

H

C

A1

R

D

P2

PA PH

25 26 A1

A2

A1

S1

C8 RIGHT

A2 LEFT

A3 UP

S2 S3 DOWN

BOOM C7 Pm2

A4

A5

C9

C5 A6

OUT

IN

ARM

SWING

C6 B1

B2

B3 C1

C2 B4

B5 C3

C4 B6

A408850

9804/1103

45 - 20 - 02/26

6320 - E/38-10.1

Issue 1

Excavators

CONTENTS

45 - 20 - 02/27

JS460 Tier 2 - Boom Down Circuit Diagrams - Hydraulic

ps1

ps2

T3 T1 pc5

12

Key to Oil Flow & Pressure T

7

Full Pressure

C2

Servo Neutral

M D

D

Exhaust

B5

Cavitation

A5

P

Lock Up

BL E

pa10

pa11 DR1' DR1 pc1

C2

Pressure

V2

DHV

B9 DIPPER 1 a

A9

pb5

f DIPPER 2

pa5 pc4 B4 A4

pb4 OPTION

b

g

pa9 B8 A8 BUCKET

pa4

T

P

E

F

27

A

24

B T

DR2'

BHV

pc2 BOOM2

SLEW

h

1

SWING RIGHT 2

ARM IN 3

B1 A1 pb1 TRAVEL pa1

S

E1

G

H

C

A1

R

D

B7 pb7

pa7

i

BPV

pa2 pc6

OUT 4

BOOM1

d

DR3 LEFT

DR2 A7

c

pa3 B2 A2 pb2

pb8

pa8

A3 B3 pb3

pb9

SDV

B6 A6 TRAVEL

pb6

pa6

j

e

LINEAR TRAVEL

pr1 R1 R3 P1

A1

S1

C8 RIGHT

A2 LEFT

A3 UP

S2 S3 DOWN

BOOM C7

A4

A5

C9

C5 A6

OUT

IN

PT

pr2

R2 PP

P2

PA PH

26

ARM

SWING

A1

A2

C6 B1

B2

B3 C1

C2 B4

B5 C3

C4 B6

A408910

9804/1103

45 - 20 - 02/27

6420 - E/38-11.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/28

JS460 Tier 22 - Dipper Out Circuit Diagrams - Hydraulic Servo pressure from the Handcontroller 24 is sent to port A5 of the shuttle valve 26 and is disributed to: 1

Port C3 to port Pb9 of the Main control valve 12 to activate the Dipper 2 spool.

2

Port B5 to port B of the Cushion valve 27, through the valve leaving at port D. The signal is sent to port P b 5 on the Main contol valve 12 activating the Dipper 1 spool.

Flow from pump A1 is available at the Dipper 1 spool via the left hand neutral passage and the Linear travel spool via the parrallel working passage. Flow from pump A2 is diverted at the Dipper 2 spool and joins the flow from pump A1 after it has crossed the Dipper 1 spool.

a b c d e f g h i j

Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool

Exhaust oil from the ram enters the Main controll valve 12 at port A5 and has a path to tank via the Dipper 1 spool.

9804/1103

45 - 20 - 02/28

6420 - E/38-12.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/29

JS460 Tier 22 - Dipper In Circuit Diagrams - Hydraulic Servo pressure from the Hand controller 24 is sent to port A6 of the servo shuttle valve 26 and is dritributed to: 1

Port C4 to port Pa9 on the Main controll valve 12 to the Dipper 2 spool.

2

Port B6 to port A on the Cushion valve 27, through the valve leaving at port C (if machine is fitted with HBCV 11, pressure is also sent via port A1 to port P on the HBCV to allow trapped oil in the ram to exit). From port C to port Pa5 and port Pc1 on the Main controll valve 12 to select the Dipper Spool.

3

Port C5 to select the Dipper Holding Valve DHV.

a b c d e f g h i j

Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool

Flow from pump A1 is avaiable at the Dipper spool via the left hand neutral gallery or after passing over the straight line travel spool via the parrallel working passage. At the Dipper 1 spool the flow is diverted to the Dipper ram 2. Pressure is sensed at the regeneration spoolRGS and moves it to the lesser restricted position (Fig 2). Flow from pump A2 is blocked at the Dipper 1 spool and joins the flow of pump A1 after it has crossed the Dipper 1 spool. The pressure from both pumps is now cut off from the negative control ports Ps1 and Ps2. This reduced pressure is sensed at both pumps which now come into full flow. Exhaust oil from the ram passes (through the HBCV 11 if fitted) to the Main controll valve 12 at port B5 through the Dipper hold check valve DHV (that has been released by servo pressure) to the Dipper 1 spool. Exhaust oil from the Dipper ram 2 can be at a hgher pressure than the feed oil due to the effect of gravity on the dipper arm when first selected. This causes the regeneration check valve RG to open, feeding a proportion of exhaust oil into the feed side. The remaining exhaust oil returns to tank passing over the regeneration spool RGS. The regeneration spool has two restrictors, one more restricted than the other. The restrictors cause back pressure incouraging the regeneration check valve to open. As the return pressure drops the regeneration spool moves across to the less retricted position. When the feed pressure is greater than the exhaust pressure the regeneration check valve will close. Servo pressure travels over restrictors R2 and R3 and to tank via the unselected travel spools. Oil passing over R1 has no passage to tank, creating back pressure that selects the excavator pressure switch 36.

9804/1103

45 - 20 - 02/29

6420 - E/38-13.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/30

JS460 Tier 2 - Dipper In Circuit Diagrams - Hydraulic

Key to Oil Flow & Pressure

ps1

T

7

12

C2

Full Pressure

ps2

T3 T1 pc5

C2

Pressure

M

Servo Neutral

D

pa10

pa11 DR1' DR1 pc1

D

Exhaust

DHV

Cavitation B5

Lock Up

P

BL E

V2

A5

B9

a

pb5

A9 DIPPER 1

E

F

A

B

27

f pb9

pa5

T

SDV

DIPPER 2

pc4 P

B4 A4

24

T

pb4 OPTION

pa9

b

g

B8 A8 BUCKET

pa4

pa8

S

E1

G

H

C

A1

SWING LEFT RIGHT 1 2

R

D

IN 3

OUT 4

B3 pb3

DR2'

BHV

A3

ARM

DR2 pc2 A7 BOOM2

c h

pa3 B2 A2 pb2

26 A1

S1

A2

C8 RIGHT

A3

LEFT

UP

S2 S3 DOWN

BOOM C7

A4

A5

C9

C5 A6

OUT

IN

ARM

SWING

C6 B1

B2

B3 C1

C2 B4

B5 C3

C4 B6

pb8

SLEW

B7 pb7

pa7

d

DR3

i

BPV

pa2 pc6 B1 A1 pb1 TRAVEL pa1

BOOM1

B6 A6 TRAVEL

pb6

pa6

j

e

LINEAR TRAVEL

pr1 R1 R3

Fig 2

A5 pb5

DHV

P1

PT

pr2

R2 PP

P2

PA PH

29

36

a A1

A2

DIPPER 1

A408850

pa5 A408920

9804/1103

45 - 20 - 02/30

6320 - E/38-14.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/31

JS460 Tier 2 - Bucket Opening Circuit Diagrams - Hydraulic

ps1

T3 T1

12

ps2

pa10

pa11 DR1' DR1 pc1

DHV

B5

B9

A5 pb5

DIPPER 1 a

A9

f pa5

DIPPER 2

pc4 B4 A4

pb4 OPTION

pb9

SDV

1

pa9 B8

g

b

A8 pb8

BUCKET

pa4

pa8

B3 pb3

DR2'

BHV

A3

pc2 BOOM2

c h

pa3 B2 A2 pb2

SLEW

Full Pressure Pressure Servo Neutral

B7 pb7

pa7

i

BPV

pa2 pc6 B1 A1 pb1 TRAVEL pa1

BOOM1

d

DR3

Key to Oil Flow & Pressure

DR2 A7

21

B6 A6 TRAVEL

P

T

pb6

pa6

j

e

BUCKET CLOSE OPEN

LINEAR TRAVEL

3

1

BOOM DOWN UP 4 2

pr1

Exhaust

R1

Cavitation

R3

P

Lock Up

P PP1

36

PSW1

pr2

R2

T

PT

PP

PA PH

29

P2

A2

A408940

9804/1103

45 - 20 - 02/31

6420 - E/38-15.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/32

JS460 Tier 22 - Bucket Opening Circuit Diagrams - Hydraulic Servo pressure from port 1 of the Handcontroller 21 selects the bucket spool open position via port Pa8 of the Main control valve 12. Flow from pump A2 is avaiable to the Bucket spool via the parrallel working gallery. At the spool the flow is diverted to port A8 of the Main control valve 12 to the Bucket ram 1. Returning oil enters the Main control valve 12 at port A8 and is diverted by the Bucket spool to the tank port. Pressure in the neutral circuit drops after the selected Bucket spool, this is sensed at the port Ps2 and at the pump bringing it into full flow.

a b c d e f g h i j

Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool

Servo pressure entering the Main contol valve at port Pp is blocked by the bucket spool causing back pressure to the restrictor which activates the Excavator pressure switch 36.

9804/1103

45 - 20 - 02/32

6420 - E/38-16.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/33

JS460 Tier 22 - Bucket Closing Circuit Diagrams - Hydraulic Servo pressure from the handcontroller is sent from port 3 to port Pb8 of the Main control valve 12 and moves the Bucket spool into the bucket close position. Flow from pump A2 is avaible at the Bucket spool via the parrallel working gallery. Flow is dirverted to port B8 of the Main control valve to the Bucket ram 1. Returning oil from the Bucket ram enters the Main control valve at port A8 and is dirverted to tank by the Bucket spool. When returning oil from the Bucket ram enters the spool it crosses a restrictor which causes back pressure so preventing cavitation.

a b c d e f g h i j

Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool

Servo pressure entering the main contol valve at port Pp is blocked by the bucket spool causing back pressure to the restrictor which activates the Excavator pressure switch 29.

9804/1103

45 - 20 - 02/33

6420 - E/38-17.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/34

JS460 Tier 2 - Bucket Closing Circuit Diagrams - Hydraulic

ps1

12

ps2

T3 T1 pc5

pa10

pa11 DR1' DR1 pc1

DHV

B5

B9

A5 pb5 DIPPER 1

a

A9

f pa5

DIPPER 2

pc4 B4 A4

pb4 OPTION

pb9

SDV

pa9

1

A8

g

b

B8

BUCKET

pb8 pa4

pa8

B3 pb3

DR2'

BHV

A3

DR2 pc2 A7 BOOM2

c h

pa3 B2 A2 pb2

SLEW

B7 pb7

pa7

d

DR3

i

BPV

pa2 pc6 B1 A1 pb1 TRAVEL pa1

BOOM1

B6 A6 TRAVEL

pb6

pa6

j

e

LINEAR TRAVEL

pr1 R1 R3 P1

PT

pr2

R2 PP

21

P2

PA PH

P

Key to Oil Flow & Pressure Full Pressure

T

Pressure

36

Servo Neutral

29

Exhaust

A1

A2

BUCKET CLOSE OPEN 3 1

BOOM DOWN 4

Cavitation Lock Up

UP 2

A408930

9804/1103

45 - 20 - 02/34

6320 - E/38-18.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/35

JS460 Tier 2 - Priority Valves Circuit Diagrams - Hydraulic

A

SDV

Key to Oil Flow & Pressure Full Pressure

26

Pressure

A1

Servo Neutral

C8 RIGHT

Exhaust

C7

S1

A2 LEFT

A3

S2 S3

A4 DOWN

UP

A5

C9

C5 A6

OUT

BOOM

IN

ARM

SWING

C6

Cavitation Lock Up

B1

B2

B3 C1

C2 B4

B5 C3

12

C4 B6

ps1

T3 T1 pc5

ps2

pa10

pa11 DR1' DR1 pc1

DHV

B5

B9

A5 pb5

DIPPER 1 a

A9

B

f pa5

DIPPER 2

pc4 B4 A4

pb4 OPTION

pa9

b

g

B8 A8 BUCKET

pa4

B1 SOFT/HARD

B3 pb3

T1

DR2'

BHV

pc2 BOOM2

h

pa3 P 2-STAGE RELIEF

C7

SWING SHUT OFF

C2

NEGATIVE FLOW CON.

SLEW

C6

B7 pb7

pa7

i

BPV

pa2 pc6 B1 A1 pb1 TRAVEL pa1

BOOM1

d

DR3

MAX FLOW CUT

C3

B2 A2 pb2

DR2 A7

c

LEVER LOCK

C4

pb8

pa8

A3

28

pb9

SDV

B6 A6 TRAVEL

pb6

pa6

j

e

LINEAR TRAVEL

pr1 2-STAGE TRAVEL

BOOM PRIORITY OVER SWING C5

R1

C1

R3 P1 B2

PT

pr2

R2 PP

PA PH

P2

T2 A408740

9804/1103

45 - 20 - 02/35

6420 - E/38-19.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/36

JS460 Tier 22 - Priority Valves Circuit Diagrams - Hydraulic Swing over Dipper Priority (A) This a non-selectable function automatically carried out within the Main controll valve 12 when Slew and Dipper are used together. When Swing is selected a signal is sent from the servo Shuttle valve 26 via port C8 to the Main control valve 12 at port Pc4. This selects Slew over Dipper prioity valve A and limits the flow to the Dipper from pump A1 only. This makes it possible to have maximum Slew torque with high slew pressure when the Dipper is used at the same time.

Boom over Slew Priority (B)

a b c d e f g h i j

Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool

This is selected by the operator via EMS. When operated the Boom priorty solenoid on the 8 spool block 28 is energised sending a signal via port C5 to the Main control valve 12 at port Pc6. This selects the Boom over Slew priority. Oil now being fed to the Slew spool is restricted to give priority to the boom.

9804/1103

45 - 20 - 02/36

6420 - E/38-20.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/37

JS460 Tier 22 - Slew Circuit Circuit Diagrams - Hydraulic Servo pressure from the Handcontroller 24 enters the Servo shuttle valve 26 at port A2 and is disributed to: 1

Port C7 to port A on Slew brake valve 17.

2

Port C8 to port Pc4 on Slew over Dipper priority s p o o l SDV in the Main control valve.

3

Port S1 to the Slew pressure switch 25.

4

Port B2 to the Slew spool at port Pa2 on the Main control valve 12 to move spool across.

Flow from pump A1 is stopped in the neutral gallery by the Swing spool. The flow passes through the Linear travel spool into the parrallel working passage over the unrestricted side of the Boom priority spool BPV and to the Slew spool. the flow is then directed via port A2 to the Slew motors 10. Exhaust oil enters the Main control valve at B2 to the Slew spool to the tank line.

9804/1103

45 - 20 - 02/37

a b c d e f g h i j

Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool

6420 - E/38-21.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/38

JS460 Tier 2 - Slew Circuit Circuit Diagrams - Hydraulic B1 SOFT/HARD

T1

28

LEVER LOCK

C4 P 2-STAGE RELIEF

P

P

12

MAX FLOW CUT

C3

ps1

C7

ps2

T3 T1 pc5

Dr

Dr

SWING SHUT OFF

C2

2-STAGE TRAVEL

NEGATIVE FLOW CON.

pa11 DR1' DR1 pc1

C6

BOOM PRIORITY OVER SWING C5

pa10

DHV

B5

B9

A5

C1

pb5 DIPPER 1 a

RIGHT

B

A

B2

Mu

Mu RIGHT

LEFT

B

A

f

T2

pa5

LEFT

DIPPER 2

B4 A4

pb4 OPTION

pa9

b

B8 A8

g

BUCKET

pa4

DR2'

BHV

DR2 pc2 A7 BOOM2

c h

pa3 B2 A2 pb2

17

B

T

B7 pb7

pa7

DR3 SLEW

B1 A1 pb1 TRAVEL pa1

A

BOOM1

d i

BPV

pa2 pc6

A

pb8

pa8

A3 B3 pb3

pb9

SDV

pc4

10

10

A9

B6 A6 TRAVEL

pb6

pa6

j

e

LINEAR TRAVEL

pr1

T

P

R1 R3 P1

PT

pr2

R2 PP

P2

PA PH

24

26

Key to Oil Flow & Pressure A1

S1

C8 RIGHT

A2 LEFT

A3

S2 S3

A4 DOWN

UP

BOOM C7

A5

C9

C5 A6

OUT

Full Pressure

IN

ARM

SWING

C6

LEFT

SWING RIGHT

A1

A2

Pressure Servo Neutral Exhaust

B1

B2

B3 C1

C2 B4

B5 C3

C4 B6

Cavitation Lock Up A408950

9804/1103

45 - 20 - 02/38

6320 - E/38-22.1

Issue 1

Excavators

CONTENTS

45 - 20 - 02/39

JS460 Tier 2 - Auxiliary Flow Merged Circuit Diagrams - Hydraulic

Key to Oil Flow & Pressure

12

Full Pressure ps1

Pressure

ps2

T3 T1 pc5

Servo Neutral Exhaust

pa10

pa11 DR1' DR1 pc1

Cavitation Lock Up

49

DHV

B5

B9

A5 T

47 190 bar

48 B

f pa5

P

P

T

A

B

T

13

A4

pb9

pa9

b

B

A

DIPPER 2

SDV

pc4 B4 pb4

C

A9

D

A

D

pb5

DIPPER 1 a

g

B8 A8 BUCKET

pb8

OPTION

pa4

10µ

pa8

3.5 bar

45

B3 pb3

DR2'

BHV

A3

pc2 BOOM2

c

B

h

pa3 A

C

B2 A2 pb2

SLEW

2 OPTION

19

i

BPV

j

e

TRAVEL

pb6

LINEAR TRAVEL

pr1 R1

P

B6 A6

pa6

R3 T

B7 pb7

pa7

pa2 pc6

1

BOOM1

d

DR3

B1 A1 pb1 TRAVEL pa1

DR2 A7

P1

PT

pr2

R2 PP

P2

PA PH

A1

A2

M

A408960

9804/1103

45 - 20 - 02/39

6420 - E/38-23.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/40

JS460 Tier 2 - Auxiliary Flow Circuit Diagrams - Hydraulic An auxiliary circuit gives a bi-directional flow to the equipment being used. The Option pedal 19 can be selected back or forward depending on the direction the operator wants the equipment to move. Servo pressure from the pedal, enters the main control valve at either port Pa4 or Pb4 depending on the direction the pedal is selected. This in turn moves the spool in the selected direction. Oil from pump A1 is blocked at the option spool and is diverted to the parallel-working gallery via the linear travel spool, where it is available to the now selected option spool. Depending on the direction selected, the oil will exit the valve block through ports A4 or B4.

a b c d e f g h i j

Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool

In the example shown, oil flows from Port A4 to the direction valve, which is set in the auxiliary position. The oil travels across the valve and to the attachment fitted. In Auxiliary mode, solenoid 13 is energised allowing the change-over valves to vent to tank and select the auxiliary position. Returning oil again goes across the direction valve and back to the option spool via port B4 were it is diverted to the tank port. In Auxiliary the oil from pump A2 is in a neutral state. (See neutral circuit)

JS460 Tier 2 - Merged This option allows the flow of both pumps to come together where the attachment requires high oil flow. The operation is similar to auxiliary except, a shuttle valve 14 is placed between the direction hoses, which allows pressure from either side of the option pedal to be available to the merge solenoid 13. When the merged option is selected, using the auxiliary switch in the cab, the merge solenoid 13 is energised. Pressure from either side of the pedal crosses the solenoid and selects the Merge Spool at port Pa10 spool, which blocks the flow of oil to tank from pump A2. Oil from pump A2 is directed to merge with the flow of oil from pump A1 at the option spool.

9804/1103

45 - 20 - 02/40

6420 - E/38-24.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/41

JS460 Tier 2 - Hammer Circuit Circuit Diagrams - Hydraulic The hammer function only works when the hammer pedal 19 is pressed in a forward direction. In this position pressure from the foot pedal is available to the hammer pressure switch 16, to reduce engine RPM to supply the required oil flow for the hammer. Servo pressure from the foot pedal enters the main control valve 12 at port Pa4 and selects the option spool. Oil from pump A1 is then blocked at the option spool and is diverted through the linear travel spool and into the parallel working gallery, where it is able to cross the now selected option spool and exit the valve block at port A4.

a b c d e f g h i j

Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool

On hammer only systems, the oil flow is will now go directly to the hammer. The pressure required to drive the hammer is set at the option spool ARV on the main valve block. Oil returning from the hammer flows through the hammer filter 45 and direct to tank. Note: When the machine is equipped for hammer only (not auxiliary) the hose from Port2 of the hammer pedal will be connected to the tank port of the cab manifold and the hose from Port Pb4 of the main control valve 12 will be connected to the tank manifold. When a machine that is fitted with a hammer/auxiliary combined option the ARV's in the valve block are set to the pressure required for the auxiliary system and not the hammer. In hammer mode oil flowing from the main control valve 12, has to cross the hammer /auxiliary change over valve 47. At the valve the flow is diverted in 2 directions: 1. To feed the hammer. 2. To the hammer ARV 47, so pressure going to the hammer can be regulated. Returning oil from the hammer enters the change over valve 48 and is diverted direct to tank via the hammer filter 45. The Hammer/auxiliary change over solenoid 13 is deenergised and allows a 40 bar servo pressure to cross and hold the change over valve 47 in the hammer position.

9804/1103

45 - 20 - 02/41

6420 - E/38-25.1

Issue 1

CONTENTS

Excavators

45 - 20 - 02/42

JS460 Tier 2 - Hammer Circuit Circuit Diagrams - Hydraulic

12 ps1

pa10

pa11 DR1' DR1 pc1

49

ps2

T3 T1 pc5

DHV

B5

B9

A5

48

47 190 bar

T

B

f pa5

P

P

T

A

B

T

13

pc4 B4 pb4

A

DIPPER 2

A4

pb9

SDV

pa9

b

B

C

A9

D

A

D

pb5

DIPPER 1 a

g

B8 A8 BUCKET

pb8

OPTION

pa4

10µ

pa8

3.5 bar

45 13

A3 B3 pb3

B

A

DR2'

BHV

pc2 BOOM2

c h

pa3

C

B2 A2 pb2

SLEW

1

2 OPTION

19

i

BPV

j

e

R1 R3 P

TRAVEL

pb6

LINEAR TRAVEL

pr1

Pressure T

B6 A6

pa6

Full Pressure Servo Neutral

B7 pb7

pa7

pa2 pc6

Key to Oil Flow & Pressure

BOOM1

d

DR3

B1 A1 pb1 TRAVEL pa1

DR2 A7

P1

PT

pr2

R2 PP

P2

PA PH

Exhaust Cavitation Lock Up A1

A2

A408970

9804/1103

45 - 20 - 02/42

6320 - E/38-26.1

Issue 1

CONTENTS

Wheeled Loaders

Contents i

ALL MODELS Contents Page No. General Information -Lubricants and Capacities - 406, 408 - 407, 409 - 407B ZX, 408B ZX, 409B ZX (1000 Series Engines) - 407B ZX, 408B ZX, 409B ZX (N. America) (1000 Series Engines) - 407B ZX, 408B ZX, 409B ZX (New 1000 Series Engines) - 407B ZX, 408B ZX, 409B ZX (N. America) (New1000 Series Engines) - 410B ZX, 411B ZX - 412S, 414S, 416S - Pre-Smoothshift Transmission - 412S, 414S, 416S - Smoothshift Transmission - 412S, 414S, 416S (N.America) - Pre- Smoothshift Transmission - 411, 416 * - 411, 416, 411B, 416B - 426, 436 - 426B, 436B, 446B - 426B, 436B. 446B (N. America) - 436B from m/c no. 533692 - 456B - 456 to m/c no. 539249 (N. America) * - 446 from m/c no. 540000, 456 from m/c no. 539250 * - 446 from m/c no. 540000, 456 from m/c no. 539250 (N. America) * - TM200, TM270 - TM200, TM270 (N. America) Static Dimensions and Wieghts - 406, 407, 408, 409 - 407B, 408B, 409B, 410B - 409TM - 411, 416 - 412S, 414S - 426, 436 - 426B - 436B to m/c n. 533691 - 436B from m/c no. 533692 - 446B - 456B to m/c no. 539249 - 456B from m/c no. 539250 - TM200 - TM270

Data Electrical - 406, 407, 408, 409 - 407B, 408B, 409B,to serial no. 755182 - 407B, 408B, 409B from serial no. 755183 to 755490 - 410B ZX to m/c no 755490 - 407B ZX, 408B ZX, 409B ZX from m/c no. 755491 to 757399 - 407B ZX, 408B ZX, 409B ZX from m/c no. 7557400 - 410B ZX, 411B ZX from m/c no. 755491 - 411, 416 - 411 to m/c no. 527375, 416 to m/c no. 529431 - 411 from m/c no. 527400, 416 from m/c no. 529500 * - 411 from m/c no. 527850, 416 from m/c no. 530100 * - 411 from m/c no. 527850, 416 from m/c no. 530100 - 412S, 414S, 416S - 412S to m.c no. 535116 - 412S from m/c no. 535117 to 535349, 414S to m/c no. 537149 - 412S from m/c no. 535350, 414S from m/c no. 537150 - 416S from m/c no. 543000 - 412S from m/c no. 535500, 414S from m/c no. 537300, 416S from m/c no. 543100 - 426, 436 - 426B, 436B, 446B 9804/1103

Wheeled Loaders Contents - 1

50 - 00 - 01/1 50 - 00 - 1/2 50 - 00 - 01/6 50 - 00 - 01/6A 50 - 00 - 01/6B 50 - 00 - 01/6C 50 - 00 - 01/7,7A 50 - 00 - 01/5 50 - 00 - 01/5A 50 - 00 - 01/5B 50 - 00 - 01/3 50 - 00 - 01/3A 50 - 00 - 01/4 50 - 00 - 01/10 50 - 00 - 01/11 50 - 00 - 01/12 50 - 00 - 01/8 50 - 00 - 01/8A 50 - 00 - 01/8B 50 - 00 - 01/8C 50 - 00 -01/9,9A 50 - 00 - 01/9B 50 - 00 - 02/1 50 - 00 - 02/6 50 - 00 - 02/5 50 - 00 - 02/2 50 - 00 - 02/4 50 - 00 - 02/3 50 - 00 - 02/10 50 - 00 - 02/10 50 - 00 - 02/10A 50 - 00 - 02/11 50 - 00 - 02/7 50 - 00 - 02/7A 50 - 00 - 02/8 50 - 00 - 02/9

50 - 05 - 01/1 50 - 05 - 01/9 50 - 05 - 01/10 50 - 05 - 01/11 50 - 05 - 01/11A 50 - 05 - 01/11B 50 - 05 - 01/11A 50 - 05 - 01/2 50 - 05 - 01/3 50 - 05 - 01/3A 50 - 05 - 01/3B 50 - 05 - 01/3C 50 - 05 - 01/6 50 - 05 - 01/7 50 - 05 - 01/8 50 - 05 - 01/8A 50 - 05 - 01/8B 50 - 05 - 01/8C 50 - 05 - 01/4 & 5 50 - 05 - 01/15 Issue 8*

CONTENTS

Wheeled Loaders

Contents ii

Contents (continued)

*

- 426B to serial no. 531064, 436B to serial no. 533069 - 426B from serial no. 531065, 436B from serial no. 533070 - 426B from serial no. 531300, 436B from serial no. 533300 - 446B from serial no. 540000 - 436B from m/c no. 533692 - 456B - TM200 - TM270 to m/c no. 787040 - TM270 from m/c no. 787041 Hydraulics - 406, 407 - 408, 409 - 407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX - 409TM - 411 - 412S, 414S, 416S - 416 - 426 - 436 - 426B - 436B, 446B - 456B - 426, 436 Smoothshift - TM200 - TM270 Transmission, Axles & Tyres - 406, 407, 408, 409 - 407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX - 411, 416 - 412S, 414S, 416S - 426, 436 - 426B, 436B, 446B - 456B - TM200, TM270 - TM200, TM270 Syncro Shuttle - TM200, TM270 Powershift - TM200, TM270 Transfer Gearbox Brakes - 406, 407, 408, 409 - 407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX - 411, 416 - 412S, 414S, 416S - 426, 436 - 426B, 436B, 446B - 456B - TM200, TM270 Steering - 406, 407, 408, 409 - 407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX - 411, 416, 426, 436 - 412S, 414S, 416S - 426B, 436B, 446B - 456B - TM200, TM270 Engine - 406, 407 - 408, 409 - 407B ZX, 408B ZX, 409B ZX, 410B ZX - 411B ZX - 407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX (Darwin Engines) - 411 - 412S - 414S - 412S, 414S, 416S 9804/1103

Wheeled Loader Contents - 2

50 - 05 - 01/16 50 - 05 - 01/17 50 - 05 - 01/18 50 - 05 - 01/19 50 - 05 - 01/20, 21 50 - 05 - 01/12 50 - 05 - 01/13 50 - 05 - 01/14 50 - 05 - 01/14A 50 - 05 - 02/1 50 - 05 - 02/2 50 - 05 - 02/9,10 50 - 05 - 02/8 50 - 05 - 02/3 50 - 05 - 02/7 50 - 05 - 02/4 50 - 05 - 02/5 50 - 05 - 02/6 50 - 05 - 02/14 50 - 05 - 02/15 50 - 05 - 02/11 50 - 05 - 02/16 & 16A 50 - 05 - 02/12 50 - 05 - 02/13 50 - 05 - 03/1 to 3 50 - 05 - 03/7 50 - 05 - 03/4, 4A 50 - 05 - 03/6, 6A 50 - 05 - 03/5 50 - 05 - 03/14, 15 50 - 05 - 03/8 50 - 05 - 03/9, 10 50 - 05 - 03/11 50 - 05 - 03/12 50 - 05 - 03/13 50 - 05 - 05/1 50 - 05 - 05/5 50 - 05 - 05/2 50 - 05 - 05/4 50 - 05 - 05/3 50 - 05 - 05/8 50 - 05 - 05/6 50 - 05 - 05/7 50 - 05 - 06/1 50 - 05 - 06/4 50 - 05 - 06/2 50 - 05 - 06/3 50 - 05 - 06/7 50 - 05 - 06/5 50 - 05 - 06/6 50 - 05 - 07/1 50 - 05 - 07/2 50 - 05 - 07/8 50 - 05 - 07/8A 50 - 05 - 07/8B 50 - 05 - 07/3 50 - 05 - 07/6 50 - 05 - 07/7 50 - 05 - 07/7A Issue 8*

CONTENTS

Wheeled Loaders

Contents iii

Contents (continued) Engine (continued) - 412S from m/c no. 535650 (RJ Build) - 416 - 411B, 416B - 416 from m/c no. 530350 (RJ Build) - 426, 436 * - 426 from m/c no. 532500 - 426B, 436B - 446B - 426B, 436B, 446B, (Darwin Engines) - 456B - TM200, TM270 - TM200, TM270 (Darwin Engines) Fault Finding Hydraulics - 407B, 408B, 409B, 410B - 426, 436 - 426B, 436B, 446B - 456B Circuit Diagrams Electrical - 406, 407, 408, 409, Syncro Shuttle Machines from serial no. 632700 - 406, 407, 408, 409 Powershift Machines from serial no. 632700 - 407B, 408B,409B to serial no. 755182 - 407B, 408B,409B from serial no. 755183 - 409TM - 410B ZX to m/c no. 755490 - 407B ZX, 408B ZX, 409B ZX from m/c no. 755491 to 757399 - 407B ZX, 408B ZX, 409B ZX from m/c no. 757400 - 410B ZX, 411B ZX from m/c no. 755491 - 411 to serial no. 527012, 416 to serial no. 529014 - 411 to serial no. 527013, 416 to serial no. 529015 - 411 from m/c no. 527400, 416 from m/c no. 529500 - 411, 411B from m/c no. 527850, 416, 416B from m/c no. 530100 - 412S to serial no. 535116 - 412S from serial no. 535117 - 412S from m/c no. 535375 - 414S from serial no. 537000 to 537193 - 414S from m/c no. 537194, 416S from m/c no. 543000 - 426, 436 - 426 m/c’s from 532100, 436 m/c’s from 533692 * - 426B to serial no. 531064, 436B to serial no. 533069 - 426B from serial no. 531065, 436B from serial no. 533070 - 426B from serial no. 531300, 436B from serial no. 533300 - 426B, 436B m/c’s from March 1998 - 436B from m/c no. 533692 - 446B m/c’s from March 1998 - 446B m/c’s from no 540000 - 456B - TM200 - TM270 to m/c no. 787040 - TM270 from m/c no. 787041 Hydraulic - 406, 407, 408, 409 - 407B ZX, 408B ZX, 409B ZX Servo to m/c no. 757399 - 407B ZX, 408B ZX, 409B ZX Manual to m/c no. 757399 - 407B ZX, 408B ZX, 409B ZX from m/c no. 757400 - 410B ZX - 411B ZX - 411 - 412S, 414S - 416 to machine no. 529342 - 416 from m/c no. 529343 - 416S Circuit Diagrams (continued) 9804/1103

Wheeled Loaders Contents - 3

50 - 05 - 07/7B 50 - 05 - 07/4 50 - 05 - 07/10B 50 - 05 - 07/10C 50 - 05 - 07/5 50 - 05 - 07/5A 50 - 05 - 07/11 50 - 05 - 07/12 50 - 05 - 07/13 50 - 05 - 07/9 50 - 05 - 07/10 50 - 05 - 07/10A

50 - 10 - 01/2 to 9 50 - 10 - 01/1 50 - 10 - 01/11 50 - 10 - 01/10

50 - 15 - 01/1 to 4 50 - 15 - 01/5 to 8 50 - 15 - 04/2 to 5 50 - 15 - 05/1 to 4 50 - 15 - 04/1 50 - 15 - 06/1 to 4 50 - 15 - 06/5 to 8 50 - 15 - 06/8A to 8D 50 - 15 - 06/5 to 8 50 - 15 - 01/9 & 10 50 - 15 - 01/11 & 12 50 - 15 - 01/13 to 20 50 - 15 - 01/21 to 34 50 - 15 - 02/1 & 2 50 - 15 - 02/3 to 6 50 - 15 - 02/7 to 14 50 - 15 - 03/1 to 4 50 - 15 - 03/5 to 12 50 - 15 - 01/21, 22 50 - 15 - 10/45 to 58 50 - 15 - 10/1,2 50 - 15 - 10/3 to 6 50 - 15 - 10/7 to 10 50 - 15 - 10/15 to 22 50 - 15 - 10/31 to 44 50 - 15 - 10/23 to 30 50 - 15 - 10/11 to 14 50 - 15 - 07/1 to 4 50 - 15 - 08/1 to 4 50 - 15 - 09/1 to 4 50 - 15 - 09/5 to 8 50 - 20 - 01/1, 2 50 - 20 - 03/1, 2 50 - 20 - 03/3, 4 50 - 20 - 03/5, 6 50 - 20 - 04/1, 2 50 - 20 - 04/3, 4 50 - 20 - 01/3 & 4 50 - 20 - 02/1 & 2 50 - 20 - 01/5 & 6 50 - 20 - 01/6A, 6B 50 - 20 - 02/3, 4

Issue 6*

CONTENTS

Wheeled Loaders

Contents iv

Contents (continued) *

Hydraulic (continued) - 426 machines with 4-ram loader - 426 machines with Z-bar loader - 426B machines with Z-bar loader to serial no. 531203 - 426B machines with 4-ram loader from serial no. 531204 - 426B machines with Z-bar loader from serial no. 531204 - 426B machines 4-ram loader to serial no. 531203 - 436 machines with 4-ram loader - 436 machines with Z-bar loader - 436B machines with 4-ram loader to serial no. 533195 - 436B machines with Z-bar loader to serial no. 533195 - 436B machines with 4-ram loader from serial no. 533196 - 436B machines with Z-bar loader from serial no. 533196 - 446B ZX from m/c no. 540000 - 436B from m/c no.533692 - 456 to m/c no. 539249 - 456 from m/c no. 539250, 446 from m/c no. 540013 - TM200 - TM270 - TM270 from m/c no. 787118

9804/1103

Wheeled Loaders Contents - 4

50 - 20 - 01/7 & 8 50 - 20 - 01/9 & 10 50 - 20 - 08/3, 4 50 - 20 - 08/9, 10 50 - 20 - 08/11, 12 50 - 20 - 08/1, 2 50 - 20 - 01/11 & 12 50 - 20 - 01/13 & 14 50 - 20 - 08/5, 6 50 - 20 - 08/7, 8 50 - 20 - 08/13, 14 50 - 20 - 08/15, 16 50 - 20 - 08/15, 16 50 - 20 - 08/17, 18 50 - 20 - 05/1, 2 50 - 20 - 05/1A, 2A 50 - 20 - 06/1, 2 50 - 20 - 07/1, 2 50 - 20 - 07/3, 4

Issue 3*

Wheeled Loaders

CONTENTS

50 - 00 - 01/1

406,408 Fluids, 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

Engine Oil -18 to 0° C -10 to 50° C

406 7.2 litres (1.6 UK gal) 408 10.7 litres (2.4 UK gal)

Gearbox

Syncro Shuttle †19 litres (4.2 UK gal) Powershift †19 litres (4.2 UK gal)

FLUID/LUBRICANT

SPECIFICATION

JCB Torque Converter Fluid JCB 15W/40 Multigrade

API CD MIL-L-2104C

JCB Special Transmission Fluid

Ford ESN-M2C 33G

JCB Special Transmission Fluid

Ford ESN-M2C 33G

Transfer box

1.3 litres (0.3 UK gal)

JCB HD 90 Gear Oil

API-GL-5, MIL-L-2105C

Axles - Hurth (406) Differential Housing Hubs (Individual)

5.0 litres (1.1 UK gal) 0.2 litres (0.04 UK gal)

JCB Special Gear Oil JCB Special Gear Oil

Ford ESE-M2C 86B Ford ESE-M2C 86B

JCB Special Gear Oil

Ford ESE-M2C 86B

JCB Special Gear Oil

Ford ESE-M2C 86B

Axles - JCB

406 5.0 litres (1.1 UK gal) 408 16 litres (3.6 UK gal)

Hydraulic System Up to 38° C Above 38°C

406 59 litres (13.2 UK gal) 408 63 litres (14.1 UK gal)

JCB Special Hydraulic Fluid JCB High Performance Hydraulic Fluid

ISO 32 ISO 46

Brake System

1.2 litres (0.27 UK gal)

JCB Light Hydraulic Fluid

ISO 15

CAUTION: DO NOT USE ORDINARY BRAKE FLUID Cooling System

406 12.5 litres (2.8 UK gal) 408 15.5 litres (3.5 UK gal)

Water/Anti-freeze

ASTM D3306-74

Fuel System

406 65 litres (14.5 UK gal) 408 90 litres (20.2 UK gal)

Diesel Oil

ASTM D975-66T Nos. 1D, 2D.

JCB Special MPL Grease

Lithium based, No. 2 consistency

Grease Points

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.

9804/1103

50 - 00 - 01/1

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 01/2

407,409 Fluids, 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

Engine Oil -18 to 0° C -10 to 50° C

10.7 litres (2.4 UK gal)

Gearbox

Syncro Shuttle †19 litres (4.2 UK gal) Powershift †13 litres (2.9 UK gal)

Transfer box

1.3 litres (0.3 UK gal)

Axles

407 5.0 litres (1.1 UK gal) 409 16 litres (3.6 UK gal)

FLUID/LUBRICANT

SPECIFICATION

JCB Torque Converter Fluid JCB 15W/40 Multigrade

API CD MIL-L-2104C

JCB Special Transmission Fluid

Ford ESN-M2C 33G

JCB Special Transmission Fluid

Ford ESN-M2C 33G

JCB HD 90 Gear Oil

API-GL-5, MIL-L-2105C

JCB Special Gear Oil

Ford ESE-M2C 86B

JCB Special Gear Oil

Ford ESE-M2C 86B

Hydraulic System Up to 38° C Above 38°C

63 litres (14.1 UK gal)

JCB Special Hydraulic Fluid JCB High Performance Hydraulic Fluid

ISO 32 ISO 46

Brake System

1.2 litres (0.27 UK gal)

JCB Light Hydraulic Fluid

ISO 15

CAUTION: DO NOT USE ORDINARY BRAKE FLUID Cooling System

15.5 litres (3.5 UK gal)

Water/Anti-freeze

ASTM D3306-74

Fuel System

90 litres (20.2 UK gal)

Diesel Oil

ASTM D975-66T Nos. 1D, 2D.

JCB Special MPL Grease

Lithium based, No. 2 consistency

Grease Points

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.

9804/1103

50 - 00 - 01/2

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 01/3

411,416 Fluids, 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.

411 ITEM

CAPACITY

Engine Oil -18 to 0° C -10 to 50° C

10.7 litres (2.4 UK gal)

Gearbox

FLUID/LUBRICANT

SPECIFICATION

JCB Torque Converter Fluid JCB 15W/40 Multigrade

API CE, MIL-L-2104C/D

†18 litres (4.1 UK gal)

JCB Torque Converter Fluid

API CE, MIL-L-2104C/D

Axles

25.0 litres (5.6 UK gal)

JCB Special Gear Oil

Ford ESE-M2C 86B

Hydraulic System

110 litres (24.8 UK gal)

JCB HP32 Hydraulic Fluid

ISO VG32

Brake System

0.7 litres (0.15 UK gal)

JCB Light Hydraulic Fluid

ISO 15

* 411 machines up to ser. no. 527163 ONLY

CAUTION: DO NOT USE ORDINARY BRAKE FLUID

Cooling System

26 litres (5.9 UK gal)

Water/Anti-freeze

ASTM D3306-74

Fuel System

125 litres (28.1 UK gal)

Diesel Oil

ASTM D975-66T Nos. 1D, 2D.

JCB HP Grease

Lithium based

Grease Points

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. * Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals.

416 ITEM

CAPACITY

Engine Oil -18 to 0° C -10 to 50° C

10.7 litres (2.4 UK gal)

Gearbox

FLUID/LUBRICANT

SPECIFICATION

JCB Torque Converter Fluid JCB 15W/40 Multigrade

API CE, MIL-L-2104C/D

†19 litres (4.3 UK gal)

JCB Torque Converter Fluid

API CE, MIL-L-2104C/D

Axles

23.0 litres (5.2 UK gal)

JCB Special Gear Oil

Ford ESE-M2C 86B

Hydraulic System

125 litres (27.5 UK gal)

JCB HP32 Hydraulic Fluid

ISO VG32

Cooling System

26 litres (5.9 UK gal)

Water/Anti-freeze

ASTM D3306-74

Fuel System

140 litres (31.5 UK gal)

Diesel Oil

ASTM D975-66T Nos. 1D, 2D.

JCB HP Grease

Lithium based

Grease Points

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. * Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals. 9804/1103

50 - 00 - 01/3

Issue 2*

Wheeled Loaders

CONTENTS

* 411,

50 - 00 - 01/3A

416, 411B, 416B

Fluids, 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 Engine Oil (A) -18°C to 0°C -10°C to 50°C Engine Oil (B)

Gearbox †

Axles

Hydraulic System

CAPACITY

FLUID/LUBRICANT

SPECIFICATION

10.7 litres (2.4 UK gal)

JCB Torque Converter Fluid JCB 15W/40 Multigrade

API CE, MIL-L-2104C/D

10.7 litres (2.4 UK gal)

JCB Super Multigrade 15W/40 -10°C to +50°C (14°F to 122°F) JCB Super Multigrade 15W/40 -15°C to +40°C (5°F to 104°F)

CF-4/SG, SAE 15W/40

411 †18 litres (4.1 UK gal) 416 †19 litres (4.3 UK gal) 411 24.0 litres (5.3 UK gal) 416 25.0 litres (5.6 UK gal) 4111 110 litres (24.2 UK gal) 414 125 litres (27.5 UK gal)

CF-4/SG, SAE 10W/30

JCB Torque Converter Fluid

API CE, MIL-L-2104C/D

JCB Torque Converter Fluid

API CE, MIL-L-2104C/D

JCB Special Gear Oil Plus

API GL4 §

JCB Special Gear Oil Plus

API GL4 §

JCB HP32 Hydraulic Fluid

ISO VG32

JCB HP32 Hydraulic Fluid

ISO VG32

Brake System 0.7 litres (0.15 UK gal) 411 machines up to ser. no. 527163 ONLY

JCB Light Hydraulic Fluid ISO 15 CAUTION: DO NOT USE ORDNINARY BRAKE FLUID

Cooling System

26 litres (5.9 UK gal)

Water/Anti-feeze (see Coolant Mixture)

ASTM D3306-74

Fuel System

411 125 litres (27.5 UK gal) 416 140 litres (30.8 UK gal)

Diesel Oil (see Types of Fuel)

ASTM D975-66T Nos. 1D, 2D.

Diesel Oil (see Types of Fuel)

ASTM D975-66T Nos. 1D, 2D.

JCB HP Grease

Lithium based

Grease Points

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals. Engine Oil (A)

411 to serial number 527504, 416 to serial number 529618

Engine Oil (B)

411 from serial number 527505, 416 from serial number 529619

§ Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).

9804/1103

50 - 00 - 05/3A

4150 - 3/1-1.7

Issue 1*

Wheeled Loaders

CONTENTS

50 - 00 - 01/4

426,436 Fluids, 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

Engine Oil -18 to 0° C -10 to 50° C

16 litres (3.6 UK gal)

FLUID/LUBRICANT

SPECIFICATION

JCB Torque Converter Fluid JCB 15W/40 Multigrade

API CE, MIL-L-2104C/D

Gearbox 426 436

†23 litres (5.2 UK gal) †24 litres (5.4 UK gal)

JCB Torque Converter Fluid

API CE, MIL-L-2104C/D

Front Axle 426 * 436

26.0 litres (5.8 UK gal) 40.0 litres (9.0 UK gal)

JCB LS Gear Oil

API GL4, MIL-L-2105A

Rear Axle 426 * 436

26.0 litres (5.8 UK gal) 38.0 litres (8.5 UK gal)

JCB LS Gear Oil

API GL4, MIL-L-2105A

Hydraulic System 426 436

200 litres (44.9 UK gal) 210 litres (47.2 UK gal)

JCB HP32 Hydraulic Fluid

ISO VG32

Fuel System 426 436

212 litres (47.6 UK gal) 230 litres (51.7 UK gal)

Diesel Oil

ASTM D975-66T Nos. 1D, 2D

Cooling System

50 litres (11.2 UK gal)

Water/Anti-freeze

ASTM D3306-74

JCB HP Grease

Lithium based

Grease Points

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.

9804/1103

50 - 00 - 01/4

Issue 2*

CONTENTS

* 412S,

Wheeled Loaders

50 - 00 - 01/5

414S, 416S - Pre-Smoothshift Transmission

Fluids, Lubricants & Capacities

ITEM

CAPACITY

FLUID/LUBRICANT

SPECIFICATION

Engine Oil -18 to 0° C -10 to 50° C

412S To Ser. No 535352 10.7 litres (2.4 UK gal) 414S To Ser. No 537160 16.0 litres (3.5 UK gal)

JCB Torque Converter Fluid JCB 15W/40 Multigrade

API CE, MIL-L-2104C/D

Engine Oil

412S From Ser. No 535353 10.7 litres (2.4 UK gal) 414S From Ser. No 537161 16.0 litres (3.5 UK gal)

Gearbox

Axles

Hydraulic System

Cooling System

Fuel System§

412S †18 litres (4.1 UK gal) 414S †23 litres (5.1 UK gal) 412S 24.0 litres (5.3 UK gal) 414S 23.0 litres (5.1 UK gal) 416S 25.0 litres (5.6 UK gal)

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)

CF-4/SG, SAE 15w/40

JCB Torque Converter Fluid

API CE, MIL-L-2104C/D

CF-4/SG, SAE 10w/30

API CE, MIL-L-2104C/D

JCB Special Gear Oil Plus

API GL4††

JCB HP32 Hydraulic Fluid

ISO VG32

Water/Anti-freeze

ASTM D3306-74 50 litres (11 UK gal)

412S 125 litres (27.5 UK gal)

Diesel Oil

ASTM D975-66T Nos. 1D,

414S 140 litres (30.8 UK gal)

Diesel Oil

ASTM D975-66T Nos. 1D,

JCB HP Grease

Lithium based

412S 110 litres (24.8 UK gal) 414S 125 litres (27.5 UK gal) 412S 26 litres (5.9 UK gal) 414S

2D.

2D. Grease Points

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be caried out at TEN (10) HOUR intervals. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. §

A 75 litre (16.5 UK gal) auxiliary fuel tank is available as an option.

Note: Biodegradeable Hydraulic Fluid is a factory option ONLY. Replenish with JCB Biodegradeable Multigrade Hydraulic Fluid. For further information, contact Wheeled Loader Technical Service. †† Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).

9804/1103

50 - 00 - 01/5

4170 - 3/1 - 1.4

Issue 3*

Wheeled Loaders

CONTENTS

* 412S,

50 - 00 - 01/5A

414S, 416S - Smoothshift Transmission

Fluids, 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

Engine Oil -10°C to 50°C

412S 10.7 litres (2.4 UK gal) 414S/416S 16.0 litres (3.5 UK gal)

JCB Extreme Performance Engine Oil 15W/40

ACEA E3/B3/A3 API CH-4/A3

Gearbox †

24 litres (5.3 UK gal)

JCB HP Universal ATF

ZF TE-MIL 09, 11, 12, 14

Axles

412S 24.0 litres (5.3 UK gal) 414S 23.0 litres (5.1 UK gal) 416S 25.0 litres (5.6 UK gal)

JCB Special HP Gear Oil

API GL4 ††

JCB Special Gear Oil Plus

API GL4 ††

JCB Special Gear Oil Plus

API GL4 ††

JCB HP32 Hydraulic Fluid

ISO VG32

JCB Extreme Performance Multigrade Hydraulic Fluid 46

ISO VG46

JCB HP32 Hydraulic Fluid

ISO VG32

Four Seasons Anti-freeze & Summer Coolant/Water

ASTM D3306, BS6580

Diesel Oil

ASTM D975-66T Nos. 1D, 2D.

JCB HP Grease

Lithium based

Hydraulic System

FLUID/LUBRICANT

412S 110 litres (24.2 UK gal) 414S 125 litres (27.5 UK gal) 416S 125 litres (27.5 UK gal)

Cooling System

Fuel System §

Grease Points

412S 26 litres (5.7 UK gal) 414S/416S 50 litres (11.0 UK gal) 412S 125 litres (27.5 UK gal) 414S/416S 140 litres (30.8 UK gal)

SPECIFICATION

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. § A 75 litre (16.5 UK gal)(412S), 110 litre (16.5 UK gal)(414S/416S) auxiliary fuel tank is available as an option. †† Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). Note: Biodegradable Hydraulic Fluid is a factory option ONLY. Replenish with JCB Biodegradable Multigrade Hydraulic Fluid. For further information, contact Earthmovers Technical Service. Note: Smoothshift machine serial numbers as follows: 412S from Serial No. 535500, 414S from Serial No. 537300, 416S from Serial No. 543100

9804/1103

50 - 00 - 05/5A

4170 - 3/1-2.4

Issue 2*

CONTENTS

Wheeled Loaders

50 - 00 - 01/5B

412S, 414S, 416S (N. America) - Pre-Smoothshift Transmission Fluids, 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

FLUID/LUBRICANT

SPECIFICATION

Engine Oil -18 to 0° C -10 to 50° C

412S To Ser. No 535352 10.7 litres (2.8 US gal) 414S To Ser. No 537160 16.0 litres (4.2 US gal)

JCB 10W or JCB 15W/40 JCB 30W

MIL-L-2104E API CE

Engine Oil

412S From Ser. No 535353 10.7 litres (2.8 US gal) 414S From Ser. No 537161 16.0 litres (4.2 US gal)

JCB 15w/40 Engine Oil -10°C to +50°C (14°F to 122°F) JCB Engine Oil 10w -20°C to +10°C (-4°F to 50°F)

CF-4/SG, SAE 15w/40

JCB Torque Converter Fluid

MIL-L-2104E

Gearbox

Axles

Hydraulic System

412S †18 litres (4.8 US gal) 414S †23 litres (6.1 US gal) 412S 24.0 litres (6.3 US gal) 414S 23.0 litres (6.1 US gal) 416S 25.0 litres (6.6 US gal) 412S 110 litres (29.1 US gal) 414S 125 litres (33.0 US gal)

Cooling System

26 litres (6.9 US gal)

Fuel System§

412S 125 litres (33.0 US gal) 414S 140 litres (37.0 US gal)

Grease Points

CF-4/SG, SAE 10w

JCB Torque Converter Fluid

JCB GL-5 80w/90 or 85w/140

API GL-5††

JCB GL-5 80w/90 or 85w/140 JCB GL-5 80w/90 or 85w/140

†† †JCB HP32 Hydraulic Fluid

ISO VG32

†† †JCB HP32 Hydraulic Fluid Water/Anti-freeze

ASTM D3306-74

Diesel Oil

ASTM D975-66T Nos. 1D, 2D.

Diesel Oil JCB MOLY EP # Grease

Lithium based, NO. 2

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be caried out at TEN (10) HOUR intervals. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. §

A 75 litre (19.8 US gal) auxiliary fuel tank is available as an option.

†† Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). ††† Above 32°F (0°C). In conditions below 32°F (0°C) use JCB HP32 Hydraulic Fluid (ISO VG32).

9804/1103

50 - 00 - 01/5B

4170-3/1-2.3

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 01/6

407B ZX, 408B ZX, 409B ZX Fluids, 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

FLUID/LUBRICANT

SPECIFICATION

Engine Oil -18 to 0° C -10 to 50° C

8.0 litres (1.8 UK gal)

JCB Torque Converter Fluid JCB 15W/40 Multigrade

API CD MIL-L-2104C

Axle Hubs (each)

1.75 litres (0.4 UK gal)

JCB Special Gear Oil Plus

API GL4

Front Differential

6.0 litres (1.3 UK gal)

JCB Special Gear Oil Plus

API GL4

Rear Differential/ Transfer Gearbox

7.0 litres (1.5 UK gal)

JCB Special Gear Oil Plus

API GL4

Hydraulic System

70 litres (15.4 UK gal)

JCB 10W/30 Multigrade

API CD MIL-L-2104C

Cooling System

15.5 litres (3.5 UK gal)

Water/Anti-freeze

ASTM D3306-74

Fuel System

100 litres (22 UK gal)

Diesel Oil

ASTM D975-66T Nos. 1D, 2D.

Grease Points

JCB HP Grease

Lithium based

Brake System

JCB Light Hydraulic fluid

ISO 15

CAUTION: DO NOT USE ORDINARY BRAKE FLUID

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.

9804/1103

50 - 00 - 01/6

Issue 1

Wheeled Loaders

CONTENTS

*

50 - 00 - 01/6A

407B ZX, 408B ZX, 409B ZX (N. America)(1000 Series Engine) Fluids, 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

FLUID/LUBRICANT

SPECIFICATION

Engine Oil -18 to 0° C -10 to 50° C

*8 litres (2.2 US gal)

JCB 10W or JCB 15W/40 JCB 30W

API CD, MIL-L-2104D API CD, MIL-L-2104D

Axle Hubs (each)

1.75 litres (0.5 US gal)

JCB GL-5 80W/90 or JCB GL-5 85W/140

API-GL-5

Front Differential

6.0 litres (1.6 US gal)

JCB GL-5 80W/90 or JCB GL-5 85W/140

API-GL-5

Rear Differential/ Transfer Gearbox

7.0 litres (1.8 US gal)

JCB GL-5 80W/90 or JCB GL-5 85W/140

API-GL-5

Hydraulic System

70 litres (18.5 US gal)

JCB 10W/30 Multigrade

API CD MIL-L-2104C

Cooling System

15.5 litres (4.1 US gal)

Water/Anti-freeze

ASTM D3306-74

Fuel System

100 litres (26.4 US gal)

Diesel Oil

ASTM D975-66T Nos. 1D, 2D.

Grease Points

JCB Moly EP # 2 Grease

Lithium based, No. 2

Brake System

Light Hydraulic fluid

ISO VG15

CAUTION: DO NOT USE ORDINARY BRAKE FLUID

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.

9804/1103

50 - 00 - 01/6A

4210 - 3/1 - 2 .2

Issue 2*

Wheeled Loaders

CONTENTS

50 - 00 - 01/6B

407B ZX, 408B ZX, 409B ZX (New 1000 Series Engine) Fluids, 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

FLUID/LUBRICANT

SPECIFICATION

Engine Oil (AS Build)

† 8.0 litres (1.8 UK gal)

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)

CF-4/SG, SAE 15w/40 CF-4/SG, SAE 15w/40

Axle Hubs (each)

1.75 litres (0.4 UK gal)

JCB Special Gear Oil Plus

API GL4§

Front Differential

6.0 litres (1.3 UK gal)

JCB Special Gear Oil Plus

API GL4§

Rear Differential/ Transfer Gearbox

7.0 litres (1.5 UK gal)

JCB Special Gear Oil Plus

API GL4§

Hydraulic System

70 litres (15.4 UK gal)

JCB 10w/30 Super Multigrade

CF-4/SG, SAE 10w/30

Cooling System

15.5 litres (3.5 UK gal) †† 16.0 litres (3.52 UK gal)

Water/Anti-freeze (see Coolant mixture)

ASTM D3306-74

Fuel System

100 litres (22 UK gal)

Diesel Oil (see Types of Fuel)

ASTM D975-66T Nos. 1D, 2D.

Grease Points

JCB HP Grease

Lithium based

Braking System

JCB Light Hydraulic Fluid ISO 15 CAUTION: DO NOT USE ORDINARY BRAKE FLUID

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. § Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). † The figure quoted is the TOTAL system capacity. Use the ‘MAX’ and ‘MIN’ marks on the dipstick when refilling the system. †† 407 - 409B ZX, S/N. 757400 on.

9804/1103

50 - 00 - 01/6B

4210 - 3/1 - 4 .2

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 01/6C

407B ZX, 408B ZX, 409B ZX (N. America)(New 1000 Series Engine) Fluids, 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

FLUID/LUBRICANT

SPECIFICATION

Engine Oil (AS Build)

† 8.0 litres (2.2 US Gal)

JCB 15w/40 Engine Oil -10°C to +50°C (14°F to 122°F) JCB Engine Oil 10w -20°C to +10°C (-4°F to 50°F)

CF-4/SG, SAE 15w/40 CF-4/SG, SAE 10w

Axle Hubs (each)

1.75 litres (0.5 US Gal)

JCB GL-5 80w/90 or 85w/140

API GL-5§

Front Differential

6.0 litres (1.6 US Gal)

JCB GL-5 80w/90 or 85w/140

API GL-5§

Rear Differential/ Transfer Gearbox

7.0 litres (1.8 US Gal)

JCB GL-5 80w/90 or 85w/140

API GL-5§

Hydraulic System

70 litres (18.5 US Gal)

JCB Engine Oil 10w

CF-4/SG, SAE 10w

Cooling System

15.5 litres (4.1 US Gal)

Water/Anti-freeze (see Coolant mixture)

ASTM D3306-74

Fuel System

100 litres (26.4 US Gal)

Diesel Oil (see Types of Fuel)

ASTM D975-66T Nos. 1D, 2D.

Grease Points

JCB HP Grease

Lithium based, No. 2

Braking System

Light Hydraulic Fluid ISO VG15 CAUTION: DO NOT USE ORDINARY BRAKE FLUID

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. § Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). † The figure quoted is the TOTAL system capacity. Use the ‘MAX’ and ‘MIN’ marks on the dipstick when refilling the system.

9804/1103

50 - 00 - 01/6C

4210 - 3/1 - 5.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 01/7

410B ZX, 411B ZX Fluids, 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

FLUID/LUBRICANT

SPECIFICATION

10.7 litres (2.4 UK gal)

JCB Torque Converter Fluid JCB 15W/40 Multigrade

API CD MIL-L-2104C

10.9 litres (2.4 UK gal)

JCB Torque Converter Fluid JCB 15W/40 Multigrade

API CD MIL-L-2104C

Front Axle

16.0 litres (3.5 UK gal)

JCB Special Gear Oil Plus

API GL4

Rear Axle/ Transfer Gearbox

18.0 litres (4.0 UK gal)

JCB Special Gear Oil Plus

API GL4

Hydraulic System

130 litres (28.6 UK gal)

JCB 10W/30 Multigrade

API CD MIL-L-2104C

Cooling System

18.0 litres (4.0 UK gal)

Water/Anti-freeze

ASTM D3306-74

Fuel System

110 litres (24 UK gal)

Diesel Oil

ASTM D975-66T Nos. 1D, 2D.

Grease Points

JCB HP Grease

Lithium based

Brake System 410B ZX

JCB Light Hydraulic Fluid

ISO 15

Engine Oil 410B ZX -18 to 0° C -10 to 50° C 411B ZX -18 to 0° C -10 to 50° C

CAUTION: DO NOT USE ORDINARY BRAKE FLUID Inching System 411B ZX

JCB Light Hydraulic Fluid

ISO 15

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator.

9804/1103

50 - 00 - 01/7

4210 - 3/1 - 3 .2

Issue 2*

Wheeled Loaders

CONTENTS

50 - 00 - 01/7A

410B ZX, 411B ZX Fluids, 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

FLUID/LUBRICANT

SPECIFICATION

Engine Oil 410B ZX (AS Build)

† 10.7 litres (2.4 UK gal)

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)

CF-4/SG, SAE 15w/40

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)

CF-4/SG, SAE 15w/40

411B ZX (AQ Build)

† 10.9 litres (2.4 UK gal)

CF-4/SG, SAE 15w/40

CF-4/SG, SAE 15w/40

Front Axle

16.0 litres (3.5 UK gal)

JCB Special Gear Oil Plus

API GL4§

Rear Axle/ Transfer Gearbox

18.0 litres (4.0 UK gal)

JCB Special Gear Oil Plus

API GL4§

Hydraulic System

130 litres (28.6 UK gal)

JCB 10w/30 Super Multigrade -15°C to 40°C (5°F to 104°F)

CF-4/SG, SAE 10w/30

Cooling System

18.0 litres (4.0 UK gal)

Water/Anti-freeze (see Coolant mixture)

ASTM D3306-74

Fuel System

110 litres (24.2 UK gal)

Diesel Oil (see Types of Fuel)

ASTM D975-66T Nos. 1D, 2D.

Grease Points

JCB HP Grease

Lithium based

Inching System

JCB Light Hydraulic Fluid ISO 15 CAUTION: DO NOT USE ORDINARY BRAKE FLUID

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. § Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). † The figure quoted is the TOTAL system capacity. Use the ‘MAX’ and ‘MIN’ marks on the dipstick when refilling the system.

9804/1103

50 - 00 - 01/7A

4210 - 3/1 - 6.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 01/8

456B 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

Engine Oil -18 to 0° C -10 to 50° C

18.9 litres (4.2 UK gal)

Gearbox

FLUID/LUBRICANT

SPECIFICATION

JCB Torque Converter Fluid JCB 15W/40 Multigrade

API CE, MIL-L-2104C/D

†28 litres (6.2 UK gal)

JCB Torque Converter Fluid

API CE, MIL-L-2104C/D

Axles

51 litres (11.2 UK gal)

JCB Special Gear Oil Plus

API GL4

Hydraulic System

215 litres (47.3 UK gal)

JCB HP32 Hydraulic Fluid

ISO VG32

Cooling System

38 litres (8.4 UK gal)

Water/Anti-freeze

ASTM D3306-74

Fuel System

325 litres (71.5 UK gal)

Diesel Oil

ASTM D975-66T Nos. 1D, 2D.

JCB HP Grease

Lithium based

Grease Points

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.

9804/1103

50 - 00 - 01/8

Issue 1

Wheeled Loaders

CONTENTS

* 456

50 - 00 - 01/8A

to Serial Number 539249

Fluids, Lubricants & Capacities - North America 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 machies 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 usd 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

Engine Oil 0 to 32°C

5.0 gal (18.9 liters)

JCB Genuine Engine Oil SAE 15W/40

MIL-L-2104C/D API CE

Gearbox

†7.4 gal (28.0 liters)

JCB 10W Engine Oil

APi CE, MIL-L-2104C/D

Axles

13.5 gal (51.0 liters)

JCB 80 - 90

API GL4, MIL-L-2105A

Hydraulic System

56.8 gal (215 liters)

§ JCB 46 AW

ISO 46

Cooling System

10.1 gal (37 liters)

Water/Anti-feeze (see Coolant Mixture)

ASTM D3306-74

Fuel System

85.9 gal (325 liters)

Diesel Oil (See Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

JCB Molygrease EP2

Lithium based No. 2

Grease Points

FLUID/LUBRICANT

SPECIFICATION

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. § Above 32°F (0°C). In conditions below 32°F (0°C) use JCB HP32 Hydraulic Fluid

9804/1103

50 - 00 - 05/8A

4180 - 3/1-3.3

Issue 1*

Wheeled Loaders

CONTENTS

50 - 00 - 01/8B

* 446

from Serial Number 540000 456 from Serial Number 539250

Fluids, 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 machies 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 usd 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

Engine Oil -10 to 50°C §

18.9 litres (4.2 UK gal)

JCB Extreme Performance Engine Oil 15W/40

ACEA E/3B/3A/3 API CH-4A3

Gearbox

†28 litres (6.2 UK gal)

JCB HP Universal HTF

ZF TE-ML 09, 11, 12, 14

Axles

51 litres (11.2 UK gal)

JCB Gear Oil LS

API GL4, MIL-L-2105B††

Hydraulic System

215 litres (47.3 UK gal)

JCB HP32 Hydraulic Fluid

ISO VG32

Cooling System

38 litres (8.4 UK gal)

Water/Anti-feeze (see Coolant Mixture)

ASTM D3306-74

Fuel System

325 litres (71.5 UK gal)

Diesel Oil (See Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

JCB HP Grease

Lithium based

Grease Points

FLUID/LUBRICANT

SPECIFICATION

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carriewd out at TEN (10) HOUR intervals. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. †† Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). § If API CH-4 or ACEA E3/B3/A3 engine oil is not available, then the engine oil must be changed every 250 hours.

9804/1103

50 - 00 - 05/8B

4180 - 3/1-4.2

Issue 1*

Wheeled Loaders

CONTENTS

50 - 00 - 01/8C

* 446

from Serial Number 540000 456 from Serial Number 539250

Fluids, Lubricants & Capacities - North America Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal qork cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil cinsumption, 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 oils 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

Engine Oil 14 to 122°F

5.0 gal (18.9 liters)

JCB Genuine Engine Oil SAE 15W/40

ACEA E/3B/3A/3 API CH-4A3

Gearbox

†7.4 gal (28.0 liters)

JCB MP Automatic Transmission Fluid

ZF TE-ML 09, 11, 12, 14

Axles

16.5 gal (51.0 liters)

JCB 80 - 90

API GL4, MIL-L-2105A††

Hydraulic System

56.8 gal (215 liters)

§ JCB 46 AW

ISO 46

Cooling System

10.1 gal (38 liters)

Water/Anti-feeze (see Coolant Mixture)

ASTM D3306-74

Fuel System

85.9 gal (325 liters)

Diesel Oil (See Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

JCB Molygrease EP2

Lithium based No. 2

Grease Points

FLUID/LUBRICANT

SPECIFICATION

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. § Above 32°F (0°). In conditions below 32°F (0°C) use JCB HP32 Hydraulic FLuid (ISO VG32) †† Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). § If API CH-4 or ACEA E3/B3/A3 engine oil is not available, then the engine oil must be changed every 250 hours.

9804/1103

50 - 00 - 05/8C

4180 - 3/1-5.2

Issue 1*

Wheeled Loaders

CONTENTS

*

50 - 00 - 01/9

TM200, TM270 (1000 Series Engines) Fluids, 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

Engine Oil -18 to 0° C -10 to 50° C

10.7 litres (2.4 UK gal)

JCB Torque Converter Fluid JCB 15W/40 Multigrade

API CD MIL-L-2104C

Gearbox Syncro Shuttle Powershift

19 litres (4.2 UK gal) 13 litres (2.9 UK gal)

JCB Special Transmission Fluid JCB Special Transmission Fluid

Ford ESN-M2C 33G Ford ESN-M2C 33G

Transfer box

1.3 litres (0.3 UK gal)

JCB HD 90 Gear Oil

API-GL-5, MIL-L-2105C

Axles (TM 200)

16 litres (3.6 UK gal)

JCB Special Gear Oil

Ford ESE-M2C 86B

(TM 270)

20 litres (4.4 UK gal)

JCB Special Gear Oil

Ford ESE-M2C 86B

63 litres (14.1 UK gal)

JCB Special Hydraulic Fluid JCB High Performance Hydraulic Fluid

ISO 32 ISO 46

(TM270) Up to 38° C Above 38°C

90 litres (20.2 UK gal)

JCB Special Hydraulic Fluid JCB High Performance Hydraulic Fluid

ISO 32 ISO 46

Cooling System

15.5 litres (3.5 UK gal)

Water/Anti-freeze

ASTM D3306-74

Fuel System

90 litres (20.2 UK gal)

Diesel Oil

ASTM D975-66T Nos. 1D, 2D.

Grease Points

JCB Special MPL Grease

Lithium based, No. 2 consistency

Wear Pad Runways

JCB Waxoyl

Hydraulic System (TM200) Up to 38° C Above 38°C

FLUID/LUBRICANT

SPECIFICATION

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.

9804/1103

50 - 00 - 01/9

4225 - 3/1 - 1 . 1

Issue 2

Wheeled Loaders

CONTENTS

50 - 00 - 01/9A

TM200, TM270 (New 1000 Series Engines) Fluids, 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

FLUID/LUBRICANT

SPECIFICATION

Engine Oil 10.7 litres (2.4 UK gal)

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)

CF-4/SG, SAE 15w/40 CF-4/SG, SAE 10w/30

Gearbox

13 litres (2.9 UK gal)

JCB Special Transmission Fluid

Ford ESN-M2C 33G

Transfer box

1.3 litres (0.3 UK gal)

JCB HD 90 Gear Oil

API-GL-5, MIL-L-2105C

Axles (TM200) (TM270)

16 litres (3.6 UK gal) 20 litres (4.4 UK gal)

JCB Special Gear Oil JCB Special Gear Oil

Ford ESE-M2C 86B Ford ESE-M2C 86B

63 litres (14.1 UK gal)

JCB Special Hydraulic Fluid JCB High Performance Hydraulic Fluid

ISO 32 ISO 46

90 litres (20.2 UK gal)

JCB Special Hydraulic Fluid JCB High Performance Hydraulic Fluid

ISO 32 ISO 46

Cooling System

15.5 litres (3.5 UK gal)

Water/Anti-freeze

ASTM D3306-74

Fuel System

90 litres (20.2 UK gal)

Diesel Oil

ASTM D975-66T Nos. 1D, 2D.

Grease Points

JCB Special MPL Grease

Lithium based, No. 2 consistency

Wear Pad Runways

JCB Waxoyl

Hydraulic System (TM200) Up to 38° C Above 38°C (TM270) Up to 38° C Above 38°C

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. Note: Biodegradable Hydraulic Fluid is a factory option ONLY. Replenish with JCB Biodegradable Multigrade Hydraulic Fluid. For further information, contact Wheeled Loader Technical Service.

9804/1103

50 - 00 - 01/9A

4225 - 3/1 - 2.2

Issue 1

CONTENTS

Wheeled Loaders

50 - 00 - 01/9B

TM200, TM270 (New 1000 Series Engines) (N. America) Fluids, 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. NORTH AMERICA

ITEM

CAPACITY

FLUID/LUBRICANT

SPECIFICATION

Engine Oil 10.7 litres (2.82 US gal) JCB 15w/40 Engline Oil -10°C to +50°C (14°F to 122°F) JCB Engine Oil 10w -20°C to +10°C (-4°F to +50°F)

CF-4/SG, SAE 15w/40

Gearbox

13 litres (3.34 US gal)

JCB Special Transmission Fluid

Ford ESN-M2C 33G

Transfer box

1.3 litres (0.34 US gal)

JCB HD 90 Gear Oil

API-GL-5, MIL-L-2105C

Axles (TM200) (TM270)

16 litres (4.2 US gal) 20 litres (5.28 US gal)

JCB Special Gear Oil JCB Special Gear Oil

Ford ESE-M2C 86B Ford ESE-M2C 86B

63 litres (16.6 US gal)

JCB Special Hydraulic Fluid JCB High Performance Hydraulic Fluid

ISO VG32 ISO VG46

90 litres (23.78 USgal)

JCB Special Hydraulic Fluid JCB High Performance Hydraulic Fluid

ISO VG32 ISO VG46

Cooling System

15.5 litres (4.1 US gal)

Water/Anti-freeze

ASTM D3306-74

Fuel System

90 litres (23.78 US gal)

Diesel Oil

ASTM D975-66T Nos. 1D, 2D.

Grease Points

JCB Special MPL Grease

Lithium based, No. 2 consistency

Wear Pad Runways

JCB Waxoyl

Hydraulic System (TM200) Up to 38° C Above 38°C (TM270) Up to 38° C Above 38°C

CF-4/SG, SAE 10w

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. Note: Biodegradable Hydraulic Fluid is a factory option ONLY. Replenish with JCB Biodegradable Multigrade Hydraulic Fluid. For further information, contact Wheeled Loader Technical Service.

9804/1103

50 - 00 - 01/9B

4225 - 3/1 - 3.1

Issue 1

CONTENTS

Wheeled Loaders

50 - 00 - 01/10

426B, 436B, 446B 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

Engine Oil -18 to 0° C -10 to 50° C

426, 436 16 litres (3.5 UK gal)

FLUID/LUBRICANT

SPECIFICATION

JCB Torque Converter Fluid JCB 15W/40 Multigrade

API CE, MIL-L-2104C/D

446 18.9 litres (4.2 UK gal) Gearbox 426 436

†24 litres (5.3 UK gal) †23 litres (5.1 UK gal)

JCB Torque Converter Fluid

API CE, MIL-L-2104C/D

Front Axle

40.0 litres (8.8 UK gal)

JCB LS Gear Oil

API GL4, MIL-L-2105A

Rear Axle

38.0 litres (8.5 UK gal)

JCB LS Gear Oil

API GL4, MIL-L-2105A

Hydraulic System 426 436

200 litres (44.0 UK gal) 210 litres (46.2 UK gal)

JCB HP32 Hydraulic Fluid

ISO VG32

Fuel System 426 436, 446

212 litres (46.6 UK gal) 230 litres (50.6 UK gal)

Diesel Oil (see Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

Cooling System 426, 436 446

50 litres (11.0 UK gal) 38 litres (8.4 UK gal)

Water/Anti-freeze (see Coolant mixture)

ASTM D3306-74

JCB HP Grease

Lithium based

Grease Points

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.

9804/1103

50 - 00 - 01/10

4160 - 3/1 - 1.4

Issue 1

CONTENTS

Wheeled Loaders

50 - 00 - 01/11

426B,436B, 446B (N. America) Fluids, 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.

North American Capacities and Lubricant Equivalent ITEM

CAPACITY

FLUID/LUBRICANT

SPECIFICATION

Engine Oil -18 to 0°C -10 to 50°C

426 To Ser. No. 531347 16 liters (4.2 US gal) 436 To Ser. No. 533408 16 liters (4.2 US gal) 446 18.9 liters (5.0 US gal)

JCB 10W or JCB 15W/40 JCB 30W

MIL-L-2104E API CD/CE

Engine Oil -20 to +10°C (-4 to +50°F) -10 to +50°C (14 to 122°F)

426 From Ser. No. 531348 16 liters (4.2 US gal) 436 From Ser. No. 533409 16 liters (4.2 US gal)

JCB 10W JCB 15W40

CF-4/SG, SAE 10W CF-4/SG, SAE 15W40

†24 liters (6.3 US gal) †23 liters (6.1 US gal)

JCB 10W or JCB 15W/40

MIL-L-2104E

Front Axle

40.0 liters (10.6 US gal)

JCB LS Gear Oil

MIL-L-2105A

Rear Axle

38.0 liters (10.0 US gal)

JCB LS Gear Oil

MIL-L-2105A

Hydraulic System 426 436 $

200 liters (52.8 US gal) 210 liters (55.5 US gal)

§ JCB Hydraulic Fluid

ISO VG46

Fuel System 426 436, 446

212 liters (56.0 US gal) 230 liters (60.8 US gal)

Diesel Oil (see Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

Cooling System 426, 436 446

50 liters (13.2 US gal) 38 liters (10.0 US gal)

Water/Anti-freeze (see Coolant mixture)

ASTM D3306-74

JCB MOLY EP # Grease

Lithium based, No. 2

Gearbox 426 436

Grease Points

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.

§ Above 32°F (0°C). In conditions below 32°F (0°C) use JCB HP32 Hydraulic Fluid (ISO VG32). $ Also 426 machines built after November 1998.

9804/1103

50 - 00 - 01/11

4160-3/1-2.3

Issue 1

Wheeled Loaders

CONTENTS

436B

50 - 00 - 01/12

From m/c no. 533692

Fluids, 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). 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

SPECIFICATION

Engine Oil 16.0 litres (3.5 UK gal)

Gearbox †

34 litres (7.5 UK gal)

Axles

(Front) 39.0 litres (8.6 UK gal) (Rear) 37.0 litres (8.1 UK gal)

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))

CF-4/SG, SAE 15w/40

Transmission Oil Auto 15

ATF Auto 15

JCB Gear Oil LS

API GL4, MIL-L-2105B ††

JCB Gear Oil LS

API GL4, MIL-L-2105B ††

CF-4/SG, SAE 10w/30

Hydraulic System

210 litres (46.2 UK gal)

JCB Special Hydraulic Fluid

ISO VG32

Cooling System

50 litres (11.0 UK gal)

Four Seasons Anti-freeze & Summer Coolant/Water

ASTM D3306, BS6580

Fuel System

230 litres (50.6 UK gal)

Diesel Oil

ASTM D975-66T Nos. 1D, 2D.

JCB HP Grease

Lithium based

Grease Points

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. †† Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). Note: Biodegradable Hydraulic Fluid is a factory option ONLY. Replenish with JCB Biodegradable Multigrade Hydraulic Fluid. For further information, contact Earthmovers Technical Service.

9804/1103

50 - 00 - 01/12

4160-3/1-3.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 02/1

406,407,408,409 Static Dimensions 406/407

408/409

mm

ft

in

mm

ft

in

A

Overall length (including standard shovel)

5090

16

8

5350

17 7

B

Wheelbase

1900

6

3

2200

7

3

C

Centre of gravity

1253

4

1

1373

4

6

D

Minimum ground clearance (to transfer gearbox)

398

1

4

400

1

4

E

Height over cab

2543

8

4

2530

8

4

F

Width over tyres

1745

5

9

1916

6

4

G

Load over height (maximum)

2867

9

5

3013

9 11

H

Pin height

3100

10

2

3280

10 9

J

Chassis oscillation

9°

K

Dump angle at full height

45°

L

Roll back angle at full height

50°

Articulation angle

80°

Unladen weight

kg

lb

kg

lb

4700

10363

5500

12127

Note: Dimensions based on a machine equipped with the standard shovel and 14.5 - 20 tyres.

E

C A

J

D B

F

L K G H A199070

9804/1103

50 - 00 - 02/1

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 02/2

411,416 Static Dimensions 411

416

mm

ft

in

mm

ft

in

A

Overall length (including standard shovel)

5965

19

7

6080

20

0

B

Wheelbase

2700

8

10

2800

9

2

* C

Centre of Gravity (No attachment fitted)

1666

5

6

1749

5

9

* D

Minimum ground clearance

400

1

4

438

1

5

* E

Height over cab

(without plastic roof) (with plastic roof)

3000 3108

9 10 10 2

3082 3190

10 10

1 5

* F

Width

(Over tyres- without bulge) (Maximum - Shovel Toeplate)

2200 2250

7 7

2 4

2400 2330

7 7

10 8

* G

Pin height (maximum)

3487

11

5

3633

11 11

* H

Maximum height

4427

14

6

4605

15

1

* J

Dump height

2671

8

9

2773

9

1

* K

Axle oscillation

* L

Dump angle at full height

50°

* M

Roll back angle at full height

58°

Articulation angle

80°

12.5°

Weight

Kg

lb

Kg

lb

7300

16096

8600

18963

Note: Dimensions based on a 411 machine equipped with the standard 1.1 m3 shovel and 15.5R25 tyres. Note: Dimensions based on a 416 machine equipped with the standard 1.3 m3 shovel and 17.5R25 tyres.

E

C

A M

D

K F

B

H L J

G

A203190

9804/1103

50 - 00 - 02/2

Issue 2*

50 00 02/3

CONTENTS

50 - 00 - 02/3

Wheeled Loaders

426,436 Static Dimensions 426

436

436Z

mm

ft in

mm

ft in

mm

ft in

A

Overall length (including standard shovel)

6540

21 5

6990

22 11

6990

22 11

B

Wheelbase

2900

9

6

3000

9 10

3000

9 10

C

Centre of gravity

1621

5

4

1749

5

9

1675

5

6

D

Minimum ground clearance

375

1 3

459

1

6

459

1

6

E

Height over cab

3245

10 8

3340

10 11

3340

10 11

F

Width

2403 2498

7 11 8 2

2597 2700

8 6 8 10

2597 2700

8 6 8 10

G

Pin height (maximum)

3829

12 6

3996

13 1

3996

13 1

H

Maximum height

5027

16 6

5310

17 5

5310

17 5

J

Dump height (at 45° Dump)

2961

9

3050

10 0

3050

10 0

K

Axle oscillation

L M

(Over tyres- without bulge) (Maximum - Shovel Toeplate)

9

12.5°

12.5°

12.5°

Dump angle at full height

49°

49°

47°

Roll back angle at full height

58°

58°

58°

Articulation angle

80°

80°

80°

Unladen weight

Kg

lb

10945

21134

Kg

lb

Kg

lb

13470

29701

14060

30990

3

Note: Dimensions based on a 426 machine equipped with the standard 1.8m shovel and 17.5R25 tyres. Note: Dimensions based on a 436/436Z machine equipped with the standard 2.3m3 shovel and 20.5R25 tyres.

E

C

A L

H

D

K F

B

M J

G

A218290

9804/1103

50 - 00 - 02/3

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 02/4

412S, 414S Static Dimensions 412S

414S

mm

ft in

mm

ft in

A

Overall length (to front of Quickhitch)

5488

18 0

5797

20 9

B

Wheelbase

2700

8 10

2800

9

C

Centre of gravity (No attachment fitted)

1510

4 11

1493

4 11

D

Minimum ground clearance

410

1 4

410

1

4

E

Height over cab

2843

9

4

2930

9

7

F

Width

2375

7

9

2375

7

9

G

Pin height (maximum)

3635

11 11

3670

12 0

H

Maximum height

4532

14 10

4663

15 4

J

Load over Height

3429

11 3

3464

11 4

K

Axle oscillation

12.5°

L

Dump angle at full height

47.6°

M

Roll back angle at full height

59°

Articulation angle

80°

(Over tyres- without bulge)

Kg Unladen weight

lb

Kg

6660 14685

2

lb

7340 16185

Note: Dimensions based on a machine equipped with the standard Quickhitch and 19.5LR24tyres.

E

A L

C

H

D

K F

B

M

J

G

S228720

9804/1103

50 - 00 - 02/4

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 02/5

409 Telemaster Static Dimensions STATIC DIMENSIONS

mm

ft

in

A

Overall length to front of Quickhitch

4755

15

7

B

Overall length to front of tyres

4175

13

8

C

Wheelbase

2200

7

3

D

Centre of gravity

1090

3

7

E

Minimum ground clearance (to transfer gearbox)

400

1

4

F

Height over cab

2550

8

5

G

Width over tyres

1916

6

4

H

Pin Height (Maximum)

4620

15

2

J

Chassis oscillation

9°

Articulation angle

80°

Unladen weight

kg

lb

5790

12767

Note: Dimensions based on a machine equipped with Cone and Pin Quickhitch and 14.5 - 20 tyres.

F J

E D A

C

G B

H

A227700

9804/1103

50 - 00 - 02/5

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 02/6

407B ZX, 408B ZX, 409B ZX, 410B ZX Static Dimensions 407B ZX

408B ZX

409B ZX

410B ZX

mm

ft in

mm

ft in

mm

ft in

mm

ft in

A

Overall length to front of Quickhitch

4278

14 0

4278

14 0

4278

14 0

4732

15 6

B

Wheelbase

2000

6

7

2000

6

7

2000

6 7

2250

7 5

C

Centre of gravity

1196

3 11

1248

4

1

1298

4 3

-

D

Minimum ground clearance (to axle)

367

1

2

410

1

4

433

1 5

383

1 3

E

Height over cab

2597

8

6

2640

8

8

2663

8 9

2824

9 3

F

Width over tyres

1692

5

7

1712

5

7

1845

6 0

2017

6 7

G

Load over height

2901

9

6

2944

9

8

2967

9 9

3220

10 7

H

Pin height (Maximum)

3099

10 2

3142

10 4

3165

10 5

3470

11 5

J

Chassis oscillation

±10°

±10°

±10°

±10°

K

Dump angle at full height

45°

45°

45°

45°

L

Roll back at full height

69°

69°

69°

65°

Articulation angle

±40°

±40°

±40°

±40°

Unladen weight

kg

lb

kg

lb

kg

lb

kg

lb

4293

9446

4493

9907

4793

10568

6860

15125

Note: Dimensions based on a machine equipped with : 12.5 - 18 tyres. 12.5 - 20 tyres.

J

F

C A

-

14.5 - 20 tyres. 405/70R24 tyres.

E

D B

L K

H G A243220

9804/1103

50 - 00 - 02/6

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 02/7

456B

To m/c no. 539245

Static Dimensions

STATIC DIMENSIONS

mm

ft

in

A

Overall length (including standard shovel)

7558

24 10

B

Wheelbase

3200

10

6

C

Centre of Gravity (No attachment fitted)

2083

6

10

D

Minimum ground clearance

450

1

6

E

Height over cab

3240

10

8

F

Width

2702 2800

8 9

10 2

G

Pin height (maximum)

4107

13

6

H

Maximum height

5571

18

3

J

Dump height

3039

10

0

K

Axle oscillation

L

Dump angle at full height

50°

M

Roll back angle at full height

58°

Articulation angle

40°

(Over tyres- without bulge) (Maximum - Shovel Toeplate)

12.5°

Unladen Weight

Kg

lb

18125

39960

Note: Dimensions based on a 456B machine equipped with the standard 2.8 m3 shovel and 23.5R25 tyres.

E K

A M

D

C

F

B

H L G

J

A260490

9804/1103

50 - 00 - 02/7

8210-153

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 02/7A

456

from m/c no. 539250

Static Dimensions

mm

ft in

A

Overall length (including standard shovel)

7908

26

B

Wheelbase

3300

10 10

C

Centre of Gravity (No attachment fitted)

2200

7

3

D

Minimum ground clearance

450

1

6

E

Height over cab

3305

10 10

F

Width

2702 2800

8 9

10 2

G

Pin height (maximum)

4107

13

6

H

Maximum height

5571

18

3

J

Dump height

2950

9

8

K

Axle oscillation

L

Dump angle at full height

45°

M

Roll back angle at full height

67°

Articulation angle

40°

(Over tyres- without bulge) (Maximum - Shovel Toeplate)

2

12.5°

Unladen Weight

Kg

lb

18600

41005

Note: Dimensions based on a 456 machine equipped with the standard 3.0 m3 shovel and 23.5R25 L3 tyres.

E K A M

C

D F

B

H L J

G

A260490

9804/1103

50 - 00 - 02/7A

8570-153

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 02/ 9

TM 270 Static Dimensions

mm

ft

A

Overall length to front of carriage

5119

16 10

B

Axle to pivot point

1069

3

6

C

Wheelbase

2500

8

2

D

Axle to counterweight face

1420

4

8

E

Minimum ground clearance (to transfer gearbox)

440

1

5

F

Pin Height (Maximum)

5169

17

0

G

Width over cab

1148

3

9

H

Width over tyres

2240

7

4

I

Wheel track

1836

6

0

J

Height over cab

2660

8

9

K

Overall operating height

5724

18

9

Inside radius

2314

7

7

Maximum radius

4545

14 11

Articulation angle

in

80° (± 40°) kg

lb

Front axle weight

2600

5733

Rear axle weight

3940

8688

Total weight

6540

14421

Note: Dimensions based on a machine equipped with Cone and Pin Quickhitch 17.5 x 24 X M27 tyres and ROPS/FOPS cab.

G K F J

E I B

C

D

H

A

9804/1103

50 - 00 - 02/9

8470-153.1

A272460

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 02/10

426B, 436B, 446B Static Dimensions 426B HT

426B ZX

436B HT

436B ZX

mm

ft in

mm

ft in

mm

ft in

mm

ft in

A

Overall length (including standard shovel) 6540

21 5

6540

21 5

6990

22 11

6990

22 11

B

Wheelbase

2900

9

6

2900

9

6

3000

9 10

3000

9 10

C

Centre of gravity

1621

5

4

1621

5

4

1749

5

9

1749

5

9

D

Minimum ground clearance

375

1 3

375

1

3

459

1

6

459

1

6

E

Height over cab

3155

10 4

3155

10 4

3250

10 8

3250

10 8

F

Width

2403 2498

7 11 8 2

2403 2498

7 11 8 2

2597 2700

8 6 8 10

2597 2700

8 6 8 10

G

Pin height (maximum)

3839

12 7

3839

12 7

3996

13 1

3996

13 1

H

Maximum height

5027

16 6

5027

16 6

5310

17 5

5310

17 5

J

Dump height (at 45° Dump)

2961

9

2961

9

3050

10 0

3050

10 0

K

Axle oscillation

L M

(Over tyres- without bulge) (Maximum - Shovel Toeplate)

9

9

12.5°

12.5°

12.5°

12.5°

Roll back angle at full height

58°

52°

58°

58°

Dump angle at full height

49°

46°

49°

47°

Articulation angle

±40°

±40°

±40°

±40°

Unladen weight

Kg

lb

10945

21134

Kg

lb

11060 24380

Kg

lb

Kg

lb

13470

29701

14060

30990

Note: Dimensions based on a 426BHT/426BZX machine equipped with the standard 1.8m3 shovel and 17.5R25 tyres. Note: Dimensions based on a 436BHT/436BZX machine equipped with the standard 2.3m3 shovel and 20.5R25 tyres.

E

C

A L

H

D B

K F

M J

G

A218290

9804/1103

50 - 00 - 02/10

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 02/ 10A

436

From m/c no. 533692

Static Dimensions

436HT

436ZX

mm

ft in

mm

ft in

A

Overall length (including standard shovel) 6920

22 8

7140

23 5

B

Wheelbase

3000

9 10

3000

9 10

C

Centre of gravity

1736

5

8

1670

5

5

D

Minimum ground clearance

459

1

6

459

1

6

E

Height over cab

3315

10 10

3315

10 10

F

Width

2597 2700

8 6 8 10

2597 2700

8 6 8 10

G

Pin height (maximum)

3996

13 1

3996

13 1

H

Maximum height

5310

17 5

5310

17 5

J

Dump height (at 45° Dump)

3050

10 0

3050

10 0

K

Axle oscillation

L M

(Over tyres- without bulge) (Maximum - Shovel Toeplate)

12.5°

12.5°

Roll back angle at full height

43°

58°

Dump angle at full height

50°

45°

Articulation angle

±40°

±40°

Kg Unladen weight

lb

13923 30695

Kg

lb

14232 31376

Note: Dimensions based on a 436HT/436ZX machine equipped with the standard 2.4m3 shovel and 20.5R25 tyres.

E

C

A L

D B

K F

H M G

J

A218290

9804/1103

50 - 00 - 02/10A

8450-153.2

Issue 1

Wheeled Loaders

CONTENTS

50 - 00 - 02/11

426B, 436B, 446B Static Dimensions 446B mm

ft in

A

Overall length (including standard shovel)

7300

23 11

B

Wheelbase

3000

9 10

C

Centre of gravity

1769 1734

5 10 5 8

D

Minimum ground clearance

430

1

E

Height over cab

3215

10 7

F

Width

2597 2700

8 6 8 10

G

Pin height (maximum)

3996

13 1

H

Maximum height

5399

17 9

J

Dump height (at 45° Dump)

2900

9 6

K

Axle oscillation

L

Roll back angle at full height

58°

M

Dump angle at full height

47°

Articulation angle

±40°

HT ZX

(Over tyres- without bulge) (Maximum - Shovel Toeplate)

5

±12.5°

Unladen weight

HT ZX

Kg

lb

14880 15179

32810 33470

Note: Dimensions based on a 446B machine equipped with the standard 2.6m3 shovel and 20.5R25 tyres.

E

C

A L

H

D B

K F

M J

G

A218290

9804/1103

50 - 00 - 02/11

Issue 1

Wheeled Loaders

CONTENTS

50 - 05 - 01/1

406,407,408,409 Data - Electrical System Battery Cranking Performance at -18 deg. C (0 deg. 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 amp max. output Lucas M127/2.A

Light Bulbs Side Stop/Tail Direction Indicators Head Number Plate Interior Rear Working/Reversing Fog Instrument/Warning Beacon (optional)

Relays

5 W SBC 5/21 W SBC 21 W SBC 60/55 W H4 5 W MCC 10 W Festoon 55 W H3 Halogen 21 W SBC 1.2 W Capless 55 W H3 Halogen

Transmission Dump Rear Working Light Forward High/Low Forward

A1 A2 A3 A4

Parking Brake Front Working Light Reverse High/Low Reverse

B1 B2 B3 B4

Flasher Neutral Start Buzzer Drive

C1 C2 C3 C4

Start

D1

Circuit Protection Fuses Circuit

Rating (Amps) Fuse No.

Headlamp Main Beam and Warning Light Headlamp Dipped Beam and Rear Fog Light Side/Tail Light LH Side/Tail Light RH and Instrument Panel Front Working Lights Rear Working Lights Reverse Lights Hazard Switch and Stop Lights Road Lights

10 10 5 5 10 10 10 15 20

A1 A2 A3 A4 A5 A6 A7 A8 A9

LH Column Switch (Power Shift only) and Dump Switch Neutral Start Relay Interior Light, Beacon and Radio Heater Rear Wash/Wipe Engine Shut-off System (ESOS) Blank Blank Blank

10 20 10 10 10 5 -

B1 B2 B3 B4 B5 B6 B7 B8 B9

Buzzer Hazard Lights (permanent feed) Instrument Panel Blank RH Column Switch and Switch Illumination Blank Blank Blank Blank

10 10 5 25 -

C1 C2 C3 C4 C5 C6 C7 C8 C9

9

A4

B4

C4

A3

B3

C3

A2

B2

C2

A1

B1

C1

8 7 6 5 4 3 2 1 A

B

C

D1

D3

D2 A199600

9804/1103

50 - 05 - 01/1

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 01/2

411,416 Data - Electrical System Type

12 Volts, negative earth

Battery Cold Crank Amps for 1 minute to 1.4VPC at -18 °C (0 °F) Reserve Capacity (minutes) for 25 Amp load

410 Amps 180

Alternator

Lucas A127-65, 65 Amp maximum output

Starter Motor

Lucas M127

Light Bulbs Headlights - main Headlights - dip Indicators Indicator repeater Instruments Work lights Number plate light Tail lights Front sidelights Interior lights Stop lights Beacon Rear fog Warning lights

Rating (Watts) 65 W 60 W 21 W 5W 1.2 W 55 W Halogen 5W 5W 4W 10 W 21 W 55 W Halogen 21 W 1.2 W

9804/1103

50 - 05 - 01/2

Issue 1

CONTENTS

* *

Wheeled Loaders

50 - 05 - 01/ 3

411 to m/c no. 527375 416 to m/c no. 529431 Data - Electrical (continued) Fuses

Relays

The electrical circuits are protected by fuses. The fuses are located in a fuse box underneath the oddments tray in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one.

A1 A2 A3 A4 A5 B1 B2 B3 B4

Fuse Circuit No. A1 A2

Fuse Rating (Amps)

A3 A4 A5 A6 A7 A8 A9

Direction Indicators Right Sidelights and Gauge Illumination Rear Fog Light Reverse Alarm/Dump Switch Brake Lights, Loader Arm and Bucket Reset Warning lights, Heater Fan and Gauges Main Beam Blank Blank

B1 B2 B3 B4 B5 B6 B7 B8 B9

Hazard Warning Lights Dip Beam Rear Work Lights/Reversing Lights Rear Wash/Wipe Interior Light and Beacon Engine shut off system (ESOS) Air Conditioning (Optional) Blank Blank

10 10 10 10 10 5 10

Left Sidelights Front Work Lights Transmission Blank Horn and Front Wash/Wipe Blank Blank Blank Blank

10 25 10 10 -

C1 * C2 C3 C4 C5 C6 C7 C8 C9

5

Neutral Start Rear Work Lights/Reverse Lights Reverse Alarm Hazard Seat Warning (Optional) Start Front Work Lights Buzzer Transmission Timer

10 5 10 10 20 10

A1

B1

A2

B2

A3

B3

A4

B4

A5

1 A

B

C

2 3 4 5 6 7 8 9

9804/1103

50 - 05 - 01/3

Issue 2*

Wheeled Loaders

CONTENTS

50 - 05 - 01/ 3A

411 from m/c no. 527400 416 from m/c no. 529500 Data - Electrical ( continued ) Fuses

Relays

The electrical circuits are protected by fuses. The fuses are located in a fuse box underneath the armrest in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one.

1 2 3 4 5 6 7 8 9 10 11 12

! CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5

Hazard Warning Lights and Direction Indicators 5 Right Side/Tail Lights and Switch Illumination 5 Rear Fog Light 5 Anti-stall (if fitted) 5 Brake Lights, Float, Lift and Shovel Reset 10 Computer Feed Relay Solenoid 1 Main Beam 15 EMS Battery Feed 1 Blank -

B1 B2 B3 B4 B5

10 10 15 10

B6 B7 B8 B9

Hazard Warning Lights (Battery Feed) Dip Beam Rear Work Lights and Reverse Alarm Rear Wash/Wipe Radio, Under Bonnet Lights, Interior Light and Beacon Engine shut off system (ESOS) Air Conditioning Thermostart Blank

C1 C2 C3 C4 C5 C6 C7 C8 C9

Left Side/Tail Lights and No. Plate Lights Front Work Lights EMS and ZF Computer Feed Blank Horn and Front Wash/Wipe Heater Blower and Cigar Lighter Hydraulic Dump Valve ACCS Road Lights

5 25 10 10 25 5 5 25

1

A1 A2 A3 A4 A5 A6 A7 A8 A9

A

Fuse Rating (Amps)

B

Circuit

C

Fuse No.

Direction Indicators Intermittent Wipers Computer Feed Engine Shut Down Start Inhibit ACCS (If fitted) Blank Heater Fan Front Work Lights Anti-stall (if fitted) Reverse Alarm Rear Work Lights

9

12

2

5

8

11

1

4

7

10

3

6

2 4 5 6 7 8 9

9804/1103

3

A270230

10 5 10 15 -

50 - 05 - 01 / 3A

4150-C/1 - 3.2

Issue 1

Wheeled Loaders

CONTENTS

*

50 - 05 - 01/ 3B

411 from m/c no. 527850 416 from m/c no. 530100 Data - Electrical (continued) Fuses The electrical circuits are protected by fuses. The fuses are located in a fuse box to the rear of the side console. If a fuse ruptures, find out why and recitfy the fault before fitted a new one.

! CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage.

D1 D2 D3 D4 D5 D6 D7 D8 D9 D10

EMS (Ignition Feed) ZF COmputer (Ignition Feed) Front Work Lights Dipped Beam Main Beam Rear Fog Lights Blank Thermostart Dump Relay Ignition Relays

3 7.5 5 5 5 10 7.5 7.5

8-3-3-5

Fuse Circuit No.

Fuse Rating (Amps)

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

Rear Work Lights Road Lights Front Work Lights Dipped Beam Main Beam Rear Fog Lights Blank Thermostart Dump Relay Ignition Relays

10 15 20 10 10 5 30 3 3

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and No. Plate Lights 12 Volt Trailer Electrics (Option) EMS (Battery Feed) ZF Computer (Battery Feed) Hazard Warning Beacon and Interior Light Radio (24 Volt) Headlight Flash Side Lights

3 3 10 3 7.5 10 7.5 10 15 5

C1 C2 C3 C4 C5 C6

Starter Relay Solenoid Cigar Lighter (24 Volt) See Note Blank Rear Wash/Wipe Front Wash/Wipe and Horn Heated Seat/Mirrors and Air Suspension Seat (Option) Air Conditioning (Option) Heater Blower Direction Indicators Heated Rear Screen

3 10 7.5 10

C7 C8 C9 C10

10 9 8 7 6 5 4 3 2 1 3

2

1

A

13

6

5

4

B

14

9

8

7

C

15

12

11

10

D

X

Y A336170

Note: To gain access to the underside of the fuse/relay panel. Remove the securing screw and unhook the rear of the panel. Manipulate the panel until it is clear. Make sure the panel is refitted securely.

10 5 15 5 15

Note: Not fitted if in-cab 24/12 Volt converter fittted.

9804/1103

50 - 05 - 01/3B

4180 - C/1-4.1

Issue 1*

CONTENTS

Wheeled Loaders

50 - 05 - 01/ 3C

411 from m/c no. 527850 416 from m/c no. 530100 Data - Electrical ( continued ) Primary Fuses

Relays

The primary fuses are located in a fuse box attached to the battery positive terminal. If a new fuse ruptures, find out why and recitfy the fault before fitting a new one.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Fuse No.

Circuits

Fuse Rating (Amps)

PF1

40 Front Work Lights Rear Work Lights Main Beam Dip Beam Fog Lights

PF2

40 RH Side/Tail Lights & Switch Illumination LH Side/Tail Lights & No. Plate Lights Headlight Flash Radio (24 Volt) Beacon and Interior Light Hazard Warning EMS (Battery Feed) ZF Computer (Battery Feed) 12 Volt Trailer Electrics

Heated Rear Screen Ignition 2 Flasher Front Work Lights Lights Reverse Alarm/Lights Dump Air Conditioning Blank ESOS Ignition 1 Ignition 3 Wash/Wipe Interval Timer Start Blank

Diagnostic Connectors X Y

PF3

ZF Transmission EMS

40 Starter Solenoid Thermostart Heater Blower Air Conditioning Direction Indicators Heated Seat, Mirrors and Air Suspension Seat Heated Rear Screen Ignition Relays

PF4

PF4

PF2

PF3

PF1

50 EMS (Ignition Feed) ZF Computer (Ignition Feed) Rear Wash/Wipe Front Wash/Wipe and Horn Cigar Lighter (24 Volt) ESOS and Cold Start Advance Reverse Alarm/Lights Headlight Flash Brake Lights Shovel and Arm Reset CCTV In-Cab 24/12 Volt Converter

10 9 8 7 6 5 4 3 2 1 3

2

1

A

13

6

5

4

B

14

9

8

7

C

15

12

11

10

D

X

Y A336170

9804/1103

50 - 05 - 01 / 3C

4150-C/1 - 5.1

Issue 1*

CONTENTS

*

Wheeled Loaders

50 - 05 - 01/ 6

412S, 414S, 416S Data - Electrical System Type Battery

12 Volts, negative earth Cold Crank Amps for 1 minute to 1.4VPC at -18 °C (0 °F) Reserve Capacity (minutes) for 25 Amp load

410 Amps 180

Alternator

Lucas A127-65, 65 Amp maximum output

Starter Motor

Lucas M127

Bulbs Bulb Headlights - main Headlights - dip Indicators Indicator repeater Instruments Work lights Number plate light Tail lights Front sidelights Interior lights Stop lights Beacon Rear fog Warning lights Master Warning Light

9804/1103

Rating (Watts) 65 W 60 W 21 W 5W 1.2 W 55 W Halogen 5W 5W 4W 10 W 21 W 55 W Halogen 21 W 1.2 W 5W

50 - 05 - 01/6

4170-C/1-1.2

Issue 2*

Wheeled Loaders

CONTENTS

50 - 05 - 01/ 7

*To m/c no. 535116

412S Data - Electrical (continued) Fuses

Relays

The electrical circuits are protected by fuses. The fuses are located in a fuse box underneath the oddments tray in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one.

A1 A2 A3 A4 A5

Neutral Start Rear Work Lights/Reverse Lights Reverse Alarm Hazard Seat Warning (Optional)

B1 B2 B3 B4

Start Front Work Lights Buzzer Transmission Timer

! CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5

B3

A4

B4

A5

7

10 25 10 10 -

A3

6

Left Sidelights Front Work Lights Transmission Blank Horn and Front Wash/Wipe Blank Blank Blank Blank

B2

5

10 10 10 10 10 5 10 -

A2

4

Hazard Warning Lights Dip Beam Rear Work Lights/Reversing Lights Rear Wash/Wipe Interior Light and Beacon Engine shut off system (ESOS) Air Conditioning (Optional) Blank Blank

B1

3

B1 B2 B3 B4 B5 B6 B7 B8 B9

A1

2

5 10 5 10 10 20 10 -

1

Direction Indicators Right Sidelights and Gauge Illumination Rear Fog Light Reverse Alarm/Dump Switch Brake Lights, Loader Arm and Bucket Reset Warning lights, Heater Fan and Gauges Main Beam Blank Blank

A

A1 A2 A3 A4 A5 A6 A7 A8 A9

C1 C2 C3 C4 C5 * C6 C7 C8 C9

Fuse Rating (Amps)

B

Circuit

C

Fuse No.

8 9 A200630

9804/1103

50 - 05 - 01 / 7

4170-C/1 - 2.2

Issue 2*

CONTENTS

* 412S * 414S

Wheeled Loaders

50 - 05 - 01/ 8

From m/c no. 535117 to 535349 to m/c no. 537149

Data - Electrical ( continued ) Fuses

Relays

The electrical circuits are protected by fuses. The fuses are located in a fuse box underneath the oddments tray in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one.

1 2 3 4 5 6 7 8 9 10 11 12

!CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5

1

2

3

4

5

6

7

8

9

10

11

12 A

B

C

1 2 3

Fuse Circuit Fuse Rating No. (Amps) A1 Direction Indicators 5 A2 Right Sidelights and Switch/Panel Illumination 10 A3 Fog Lights 5 A4 Reverse Alarm/Dump Switch 10 A5 Brake Lights, Loader Arm, Shovel Reset and Tow Hitch Solenoids 10 A6 Warning Lights, Heater Fan, Gauges, Cigar Lighter, Transmission Disconnect Relay, Timer and Hourmeter 20 A7 Main Beam 10 A8 Blank A9 Blank B1 Hazard Warning Lights and Clock 10 B2 Dip Beam 10 B3 Reversing Lights 10 B4 Rear Wash/Wipe 10 B5 Interior Light, Beacon and Radio (Optional) 10 B6 Engine shut off system (ESOS) 5 B7 Air Conditioning (Optional) 10 B8 Blank B9 Blank C1 Left Sidelights and Number Plate Lights 10 C2 Work Lights 25 C3 Transmission 10 C4 Blank C5 Horn and Front Wash/Wipe 10 C6 Blank C7 Hydraulic Dump Valve 5 C8 Blank Blank -

Hazard Blank Transmission Timer Neutral Start Start Blank Blank Transmission Disconnect Front Work Lights Blank Reverse Alarm Rear Work Lights

4 5 6 7 8 9 A248620

9804/1103

50 - 05 - 01 / 8

4170-C/1-3.1

Issue 2*

Wheeled Loaders

CONTENTS

50 - 05 - 01/ 8A

412S From m/c no. 535350 414S From m/c no. 537150 Data - Electrical ( continued ) Fuses

Relays

The electrical circuits are protected by fuses. The fuses are located in a fuse box underneath the armrest in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one.

! CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage.

1 2 3 4 5 6 7 8 9 10 11 12

Direction Indicators Intermittent Wipers Computer Feed Engine Shut Down Start Inhibit ACCS (if fitted) Blank Heater Fan Front Work Lights Anti-stall (if fitted) Reverse Alarm Rear Work Lights

8-3-3-5

5

3

6

9

12

2

5

8

11

1

4

7

10

3 4 5

5 5 5 5 5 5 10 5 1 1 15 10 1 1 - 1

2

A3 A4 A5 A6 A7 A8 A9

5

1

Hazard Warning Lights and Direction Indicators Right Side/Tail Lights and Switch Illumination Rear Fog Light Anti-stall (if fitted) Brake Lights, Float, Lift and Shovel Reset Computer Feed Relay Solenoid Main Beam EMS Battery Feed Blank

A

A1 A2

Fuse Rating (Amps) A B

B

Circuit

C

Fuse No.

6

Left Side/Tail Lights and No. Plate Lights Front Work Lights EMS and ZF Computer Feed Blank Horn and Front Wash/Wipe Heater Blower and Cigar Lighter Hydraulic Dump Valve ACCS Road Lights

5 25 10 10 25 5 5 25

9

C1 C2 C3 C4 C5 C6 C7 C8 C9

5 10 10 10

8

10 10 15 10

B6 B7 B8 B9

Hazard Warning Lights (Battery Feed) Dip Beam Rear Work Lights and Reverse Alarm Rear Wash/Wipe Radio, Under Bonnet Lights, Interior Light and Beacon Engine shut off system (ESOS) Air Conditioning Thermostart Blank

7

B1 B2 B3 B4 B5

A270230

10 10 5 5 10 10 15 30 5 15 10 10 20 5 5 15

Column A - To Ser. No. 535374 (412S) 537193 (414S) Column B - From Ser. No. 535375 (412S) 537194 (414S)

9804/1103

50 - 05 - 01 / 8A

4170 - C/1 - 4.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 05 - 01/ 8B

416S

From m/c no. 543000

Data - Electrical (continued) Relays

Fuses The electrical circuits are protected by fuses. The fuses are located in a fuse box underneath the armrest in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one.

! CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage.

1 2 3 4 5 6 7 8 9 10 11 12

Direction Indicators Intermittent Wipers Computer Feed Engine Shut Down Start Inhibit ACCS (if fitted) Blank Heater Fan Front Work Lights Anti-stall (if fitted) Reverse Alarm Rear Work Lights

8-3-3-5

3

6

9

12

2

5

8

11

1

4

7

10

3 4 5 6

5 5 5 5 1 10 1 1

2

A3 A4 A5 A6 A7 A8 A9

5

1

Hazard Warning Lights and Direction Indicators Right Side/Tail Lights and Switch Illumination Rear Fog Light Anti-stall (if fitted) Brake Lights, Float, Lift and Shovel Reset Computer Feed Relay Solenoid Main Beam EMS Battery Feed Blank

A

A1 A2

Fuse Rating (Amps)

B

Circuit

C

Fuse No.

7

10 5 10 30 -

C1 C2 C3 C4 C5 C6 C7 C8 C9

Left Side/Tail Lights and No. Plate Lights Front Work Lights EMS and ZF Computer Feed Blank Horn and Front Wash/Wipe Heater Blower and Cigar Lighter Hydraulic Dump Valve ACCS Road Lights

5 15 10 10 20 5 5 15

9804/1103

5 10 10 10

50 - 05 - 01 / 8B

9

B6 B7 B8 B9

Hazard Warning Lights (Battery Feed) Dip Beam Rear Work Lights and Reverse Alarm Rear Wash/Wipe Radio, Under Bonnet Lights, Interior Light and Beacon Engine shut off system (ESOS) Air Conditioning Thermostart Blank

8

B1 B2 B3 B4 B5

A270230

4170 - C/1-5.1

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 01/8C

* 412S

from m/c no. 535500 414S from m/c no. 537300 416S from m/c no. 543100 Data Electrical Primary Fuses

Relays

The primary fuses are located in a fuse box attached to the battery positive terminal. If a fuse ruptures, find out why and rectify the fault before fitting a new one. Fuse No.

Circuits

Fuse Rating (Amps)

PF1

40 Front Work Lights Rear Work Lights Main Beam Dip Beam Fog Lights

PF2

40 RH Side/Tail Lights & Switch Illumination LH Side/Tail Lights & No. Plate Lights Headlight Flash Radio (24 Volt) Beacon & Interior Light Hazard Warning EMS (Battery Feed) ZF Computer (Battery Feed) 12 Volt Trailer Electrics

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Heated Rear Screen Ignition 2 Flasher Front Work Lights Lights Reverse Alarm/Lights Dump Air Conditioning Blank ESOS Ignition 1 Ignition 3 Wash/Wipe Interval Timer Start Blank

Diagnostic Connectors X Y

PF3

ZF Transmission EMS

40 Starter Solenoid Thermostart Heater Blower Air Conditioning Direction Indicators Heated Seat, Mirrors & Air suspension Seat Heated Rear Screen Ignition Relays

PF4

50 EMS (Ignition Feed) ZF Computer (Ignition Feed) Rear Wash/Wipe Front Wash/Wipe & Horn Cigar Lighter (24 Volt) ESOS & Cold Start Advance Reverse Alarm/Lights Headlight Flash Brake Lights Shovel and Arm Reset CCTV In-cab 24/12 Volt Converter

10 9 8 7 6 5 4 3 2 1 3

2

1

A

13

6

5

4

B

14

15

PF4

PF2

9

8

7

C

PF3

PF1

12

11

10

D

X A336180

9804/1103

50 - 05 - 01/8C

Y A336170

4170 - C/1-6.1

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 01/4

426,436 Data - Electrical System Type

24 Volts, negative earth

Battery (Two 12 Volt batteries in series) Cold Crank Amps for 1 minute to 1.4VPC at -18 °C (0 °F)

410 Amps

Reserve Capacity (minutes) for 25 Amp load * Alternator Starter Motor

180

BUTEC A5524, 65 Amp maximum output S115 24-7

Light Bulbs Bulb Headlights - main Headlights - dip Indicators Indicator repeater Instruments Work lights Number plate light Tail lights Front sidelights Interior lights Stop lights Beacon Rear fog Warning lights Master warning light

9804/1103

Rating (Watts) 75 W 70 W 21 W 5W 1.2 W 70 W Halogen 10 W 5W 5W 10 W 21 W 70 W Halogen 21 W 1.2 W 5W

50 - 05 - 01/4

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 01/5

426,436 Data - Electrical (continued) Fuses

Relays

The electrical circuits are protected by fuses. The fuses are located in a fuse box underneath the oddments tray in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one.

A1 A2 A3 A4 A5

Neutral Start Rear Work Lights/Reverse Lights Reverse Alarm Hazard Seat Warning (Optional)

B1 B2 B3 B4

Start Front Work Lights Buzzer Transmission Timer

Circuit

Fuse Rating (Amps)

A1 A2 A3 A4 A5 A6 A7 A8 A9

Direction Indicators Right Sidelights and Gauge Illumination Rear Fog Light Reverse Alarm/Dump Switch Brake Lights, Loader Arm and Bucket Reset Warning lights, Heater Fan and Gauges Main Beam Blank Blank

5 10 5 10 10 20 10 -

B1 B2 B3 B4 B5 B6 B7 B8 B9

Hazard Warning Lights Dip Beam Rear Work Lights/Reversing Lights Rear Wash/Wipe Interior Light and Beacon Engine shut off system (ESOS) Air Conditioning (Optional) Blank Blank

10 10 10 10 10 5 10 -

C1 C2 C3 C4 C5 C6 C7 C8 C9

Left Sidelights Front Work Lights Transmission Blank Horn and Front Wash/Wipe Blank Blank Blank Blank

10 20 10 10 -

A1

B1

A2

B2

A3

B3

A4

B4

A5

1

Fuse No.

A

B

C

2 3 4 5 6 7 8 9 A200630

9804/1103

50 - 05 - 01/5

Issue 1

Wheeled Loaders

CONTENTS

50 - 05 - 01/6

412S, 414S Data - Electrical System Type

12 Volts, negative earth

Battery Cold Crank Amps for 1 minute to 1.4VPC at -18 °C (0 °F) Reserve Capacity (minutes) for 25 Amp load

410 Amps 180

Alternator

Lucas A127-65, 65 Amp maximum output

Starter Motor

Lucas M127

Bulbs Bulb Headlights - main Headlights - dip Indicators Indicator repeater Instruments Work lights Number plate light Tail lights Front sidelights Interior lights Stop lights Beacon Rear fog Warning lights Master Warning Light

9804/1103

Rating (Watts) 65 W 60 W 21 W 5W 1.2 W 55 W Halogen 5W 5W 4W 10 W 21 W 55 W Halogen 21 W 1.2 W 5W

50 - 05 - 01/6

Issue 1

Wheeled Loaders

CONTENTS

50 - 05 - 01/7

412S Data - Electrical (continued) Fuses

Relays

The electrical circuits are protected by fuses. The fuses are located in a fuse box underneath the oddments tray in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one.

A1 A2 A3 A4 A5

Neutral Start Rear Work Lights/Reverse Lights Reverse Alarm Hazard Seat Warning (Optional)

B1 B2 B3 B4

Start Front Work Lights Buzzer Transmission Timer

! CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5

Fuse No.

Circuit

Fuse Rating (Amps)

A1 A2 A3 A4 A5 A6 A7 A8 A9

Direction Indicators Right Sidelights and Gauge Illumination Rear Fog Light Reverse Alarm/Dump Switch Brake Lights, Loader Arm and Bucket Reset Warning lights, Heater Fan and Gauges Main Beam Blank Blank

5 10 5 10 10 20 10 -

B1 B2 B3 B4 B5 B6 B7 B8 B9

Hazard Warning Lights Dip Beam Rear Work Lights/Reversing Lights Rear Wash/Wipe Interior Light and Beacon Engine shut off system (ESOS) Air Conditioning (Optional) Blank Blank

10 10 10 10 10 5 10 -

C1 C2 C3 C4 C5 C6 C7 C8 C9

Left Sidelights Front Work Lights Transmission Blank Horn and Front Wash/Wipe Blank Blank Blank Blank

10 25 10 10 -

A1

B1

A2

B2

A3

B3

A4

B4

A5

1 A

B

C

2 3 4 5 6 7 8 9 A200630

9804/1103

50 - 05 - 01/7

Issue 1

Wheeled Loaders

CONTENTS

50 - 05 - 01/8

414S Data - Electrical (continued) Fuses

Relays

The electrical circuits are protected by fuses. The fuses are located in a fuse box underneath the oddments tray in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one.

! CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5

Fuse No.

Circuit

A1 A2

A7 A8 A9

Direction Indicators Right Sidelights and Switch/Panel Illumination Fog Lights Reverse Alarm/Dump Switch Brake Lights, Loader Arm, Shovel Reset and Tow Hitch Solenoids Warning Lights, Heater Fan, Gauges, Cigar Lighter, Transmission Disconnect Relay, Timer and Hourmeter Main Beam Blank Blank

B1 B2 B3 B4 B5 B6 B7 B8 B9

Hazard Warning Lights and Clock Dip Beam Reversing Lights Rear Wash/Wipe Interior Light, Beacon and Radio (Optional) Engine shut off system (ESOS) Air Conditioning (Optional) Blank Blank

10 10 10 10 10 5 10 -

C1 C2 C3 C4 C5 C6 C7 C8 C9

Left Sidelights and Number Plate Lights Work Lights Transmission Blank Horn and Front Wash/Wipe Blank Hydraulic Dump Valve Blank Blank

10 25 10 10 5 -

A3 A4 A5 A6

1 2 3 4 5 6 7 8 9 10 11 12

Hazard Blank Transmission Timer Neutral Start Start Blank Blank Transmission Disconnect Front Work Lights Blank Reverse Alarm Rear Work Lights

Fuse Rating (Amps) 5

1

2

3

10

4

5

6

20 10 -

7

8

9

10

11

12

10 5 10

A

B

C

1 2 3 4 5 6 7 8 9 A248620

9804/1103

50 - 05 - 01/8

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 01/9

407B ZX, 408B ZX, 409B ZX, 410B ZX

To m/c no. 755182

Data - Electrical System Type Battery Cold Crank Amps for 1 minute to 1.4VPC at -18 °C (0 °F) Reserve Capacity (minutes) for 25 Amp load Alternator Starter Motor

12 Volts, negative earth JCB 708/00300 410 Amps 180 Lucas A127-65, 65 Amp maximum output Lucas M127 Relays

Bulbs Bulb Headlights - main Headlaights - dip Indicators Instruments Work lights Number plate light Side lights Tail lights Interior lights Stop lights Beacon Rear fog Warning lights Switch illumination

Rating (Watts) 60 W 55 W 21 W 1.7 W 55 W Halogen 5W 5W 5W 10 W 21 W 55 W Halogen 21 W 3W 1.2 W

1 2 3 4 5 6 7 8 9 10 11 12

Front Work Lights Lights Indicator Flasher Buzzer Forward Reverse Parking Brake Light Dump Ignition 2 Ignition 1 Neutral Start 2 Neutral Start 1

Relay Not Shown 13

Hydraulic Oil Cooler Fan (Located adjacent to brake fluid reservoir).

Circuit Protection to Serial No. 755182 Fuse No.

Circuit

Fuse Rating (Amps)

A1 A2 A3 A4 A5 A6 A7 A8 A9

Brake Lights Warning Lights; Buzzer LH side/tail lights; LH No. Plate Light RH side/tail lights; RH No. Plate Light Rear Wash/Wipe Hazard Warning Beacon; Clock and Front Wiper Radio; Interior Light Front Wash/Wipe; Head Light Flasher; Horn

10 10 5 5 5 10 10 5 10

B1 B2 B3 B4 B5 B6 B7 B8 B9

Junction Box Engine shut off system (ESOS) Dip Beam Main Beam Front Work Lights Directional Indicators Servo Control Lever Switches Heater Motor/Air Conditioning Hydraulic Cooler Fan Relay

10 5 10 10 10 5 10 20 5

C1 C2 C3 C4 C5 C6 C7 C8 C9

Rear Work/Reverse Light Speed Control Unit; Servo Cut-off Solenoid Forward/Reverse Relay; Reverse Alarm Fog Light Thermostart Cigar Lighter Blank Blank Blank

10 10 10 5 15 10 -

1

2

3

4 5

1

2

3

4

5

6

7

8

9

A

6

B

7 C

8 12

11

10

9

A242480

Note: The 30 Amp inline fuse controlling the hydraulic cooler fan is located with its relay. 9804/1103

50 - 05 - 01/9

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 01/10

407B ZX, 408B ZX, 409B ZX Data - Electrical (continued) System Type Battery Cold Crank Amps for 1 minute to 1.4VPC at -18 °C (0 °F) Reserve Capacity (minutes) for 25 Amp load Alternator Starter Motor Bulbs Bulb Headlights - main Headlaights - dip Indicators Instruments Work lights Number plate light Side lights Tail lights Interior lights Stop lights Beacon Rear fog Warning lights Switch illumination

12 Volts, negative earth JCB 708/00300 410 Amps 180 Lucas A127-65, 65 Amp maximum output Lucas M127 Relays Rating (Watts) 60 W 55 W 21 W 1.7 W 55 W Halogen 5W 5W 5W 10 W 21 W 55 W Halogen 21 W 3W 1.2 W

1 2 3 4 5 6 7 8 9 10 11 12

Front Work Lights Lights Indicator Flasher Buzzer Forward Reverse Dump Ignition 2 Ignition 1 Neutral Start 2 Neutral Start 1 Speed Control

Relay Not Shown 13

Hydraulic Oil Cooler Fan (Located adjacent to brake fluid reservoir).

Circuit Protection from Serial No. 755183 Fuse No. A1 A2 A3 A4 A5 A6 A7 A8 A9

Circuit

Fuse Rating (Amps) Brake Lights 10 Warning Lights; Buzzer 10 LH side/tail lights; LH No. Plate Light 5 RH side/tail lights; RH No. Plate Light 5 Rear Wash/Wipe 5 Hazard Warning 10 Beacon; Clock 10 Radio; Interior Light 5 Front Wash/Wipe; Head Light Flasher; Horn 10

B1 B2 B3 B4 B5 B6 B7 B8 B9

Junction Box Engine shut off system (ESOS) Dip Beam Main Beam Front Work Lights Directional Indicators Servo Control Lever Switches Heater Motor Thermostart

10 5 10 10 10 5 10 20 15

C1 C2 C3 C4 C5 C6 C7 C8 C9

Reverse Light Speed Control Unit; Servo Cut-off Solenoid Forward/Reverse Relay; Reverse Alarm Fog Light Blank Blank Blank Blank Blank

10 10 10 5 -

1

2

3

4 5

1

2

3

4

5

6

7

8

9

A

6

B

7 C

8 12

11

10

9

A242480

Note: The 30 Amp inline fuse controlling the hydraulic cooler fan is located with its relay. 9804/1103

50 - 05 - 01/10

Issue 2*

CONTENTS

* 410B

Wheeled Loaders

50 - 05 - 01/11

ZX

To m/c no. 755490

Data - Electrical (continued) System Type Battery Cold Crank Amps for 1 minute to 1.4VPC at -18 °C (0 °F) Reserve Capacity (minutes) for 25 Amp load Alternator Starter Motor Bulbs Bulb Headlights - main Headlaights - dip Indicators Instruments Work lights Number plate light Side lights Tail lights Interior lights Stop lights Beacon Rear fog Warning lights Switch illumination

12 Volts, negative earth JCB 708/00300 410 Amps 180 Lucas A127-65, 65 Amp maximum output Lucas M127 Relays Rating (Watts) 60 W 55 W 21 W 1.7 W 55 W Halogen 5W 5W 5W 10 W 21 W 55 W Halogen 21 W 3W 1.2 W

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Front Work Lights Lights Indicator Flasher Buzzer Parking Brake Light Forward Reverse Aux 1 Aux 2 Ignition 2 Ignition 1 Dump Neutral Start Speed Control 1

2

3

4

5

Circuit Protection - 410B ZX 1

Fuse No. A1 A2 A3 A4

Circuit

A5 A6 A7 A8 A9

Fuse Rating (Amps) Brake Lights 10 Warning Lights; Buzzer 7.5 LH side/tail lights; LH No. Plate Light 5 RH side/tail lights; RH No. Plate Light; Front Work Light Relay 5 Rear Wash/Wipe 7.5 Hazard Warning 10 Beacon; Clock; Front Wiper Park 10 Radio; Interior Light 5 Front Wash/Wipe; Head Light Flasher; Horn 20

B1 B2 B3 B4 B5 B6 B7 B8 B9

Junction Box Engine shut off system (ESOS) Dip Beam Main Beam Front Work Lights Directional Indicators Servo Control Lever Switches Heater Motor Hydraulic Oil Cooler Relay (when fitted)

10 5 15 15 15 5 10 20 5

C1 C2 C3 C4 C5 C6 C7 C8 C9

Thermostart Speed Control Unit; Servo Cut-off Solenoid Forward/Reverse Relay; Reverse Alarm Rear Fog Light Rear Work Lights Blank Blank Blank Blank

15 10 10 5 15 -

2

3

4

5

6

7

8

6

9

A

7 B

8

C

9

14

13

10

11

12

A277350

Fuse Box Decal

9804/1103

10A 7.5A

5A

5A

7.5A 10A

10A

5A

20A

10A

5A

15A

15A

15A

10A

20A

5A

15A

10A

10A

5A

15A

5A

10A

5A

15A

A277360

50 - 05 - 01/11

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 01/11A

407B ZX, 408B ZX, 409B ZX from m/c no. 755491 to 757399 410B ZX, 411B ZX from m/c no. 755491 Data - Electrical System Type Battery Cold

12 Volts, negative earth JCB 708/00300 Crank Amps for 1 minute to 1.4VPC at -18 °C (0 °F) Reserve Capacity (minutes) for 25 Amp load

Alternator Starter Motor

410 Amps 180 Lucas A127-65, 65 Amp maximum output Lucas M127

Bulbs Bulb Headlights - main Headlaights - dip Indicators Instruments Work lights Number plate light Side lights Tail lights Interior lights Stop lights Beacon Rear fog Warning lights Switch illumination

Rating (Watts) 60 W 55 W 21 W 1.7 W 55 W Halogen 5W 5W 5W 10 W 21 W 55 W Halogen 21 W 3W 1.2 W

Relays 1 Front Work Lights 2 Lights 3 Indicator Flasher 4 Buzzer 5 Parking Brake Light 6 Forward 7 Reverse 8 Aux 1 9 Aux 2 10 Ignition 2 11 Ignition 1 12 Dump 13 Neutral Start 14 Speed Control

1

Circuit Protection Fuse Circuit No.

2

Fuse Rating (Amps)

1

2

3

3

4

5

4

6

7

8

5

6

9

A

A1 A2 A3 A4 A5 A6 A7 A8 A9

Brake Lights Warning Lights; Buzzer LH side/tail lights; LH No. Plate Light RH side/tail lights; RH No. Plate Light; Front Work Light Relay Rear Wash/Wipe Hazard Warning Beacon; Clock; Front Wiper Park Radio; Interior Light Front Wash/Wipe; Head Light Flasher; Horn

10 7.5 5 5 7.5 10 10 5 20

B1 B2 B3 B4 B5 B6 B7 B8 B9

Junction Box Engine shut off system (ESOS) Dip Beam Main Beam Front Work Lights Directional Indicators Servo Control Lever Switches Heater Motor Hydraulic Oil Cooler Relay (when fitted)

10 5 15 15 15 5 10 20 5

C1 C2 C3 C4 C5 C6 C7 C8 C9

Thermostart Speed Control Unit; Servo Cut-off Solenoid Forward/Reverse Relay; Reverse Alarm Rear Fog Light Rear Work Lights Blank Blank Blank Blank

15 10 10 5 15 -

7 B

8

C

9

14

13

10

11

12

A277350

Fuse Box Decal

10A 7.5A

5A

5A

7.5A 10A

10A

5A

20A

10A

5A

15A

15A

15A

10A

20A

5A

15A

10A

10A

5A

15A

5A

10A

5A

15A

A277360

9804/1103

50 - 05 - 01/11A

4210-C/1-5.2

Issue 2*

Wheeled Loaders

CONTENTS

50 - 05 - 01/11B

407B ZX, 408B ZX, 409B ZX

From m/c no. 757400

Data - Electrical System Type Battery Cold

Alternator Starter Motor

12 Volts, negative earth JCB 708/00300 Crank Amps for 1 minute to 1.4VPC at -18 °C (0 °F) = 410 Amps Reserve Capacity (minutes) for 25 Amp load = 180 Lucas A127-65, 65 Amp maximum output Lucas M127

C1 C2 C3 C4 C5 C6 C7 C8 C9

Bulbs Bulb Headlights - main Headlaights - dip Indicators Instruments Work lights Number plate light Side lights Tail lights Interior lights Stop lights Beacon Rear fog Warning lights Switch illumination

Thermostart Servo Cut-off Solenoid Forward/Reverse Relay; Reverse Alarm Rear Fog Light Rear Work Lights Speed Control Unit Blank Blank Blank

15 5 10 5 15 5 -

Relays Rating(Watts) 60 W 55 W 21 W 1.7 W 55 W Halogen 5W 5W 5W 10 W 21 W 55 W Halogen 21 W 3W 1.2 W

1 2 3 4 5 6 7 8 9

Front Work Lights Lights Indicator Flasher Buzzer Parking Brake Parking Brake Light Forward Reverse Neutral Start

1

1

2

3

10 11 12 13 14 15 16 17

2

4

5

6

Dump Aux 1 Aux 2 Not used Not used Ignition 1 Ignition 2 Not used

3

7

8

9

4

5

6

7

8

A

Fuses The electrical circuits are protected by fuses. The fuses are located in a fuse box below the loader control console. If a fuse ruptures, find out why and rectify the fault before fitting a new one.

B

9 10

C

! CAUTION

11 12

Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage.

17

16

15

14 13

8-3-3-5

Fuse No. A1 A2 A3 A4

Circuit

Fuse Rating (Amps)

A5 A6 A7 A8 A9

Brake Lights Warning Lights; Buzzer LH side/tail lights; LH No. Plate Light RH side/tail lights; RH No. Plate Light; Front Work Light Relay Rear Wash/Wipe Hazard Warning Beacon; Clock; Front Wiper Park Radio; Interior Light Front Wash/Wipe; Head Light Flasher; Horn

5 7.5 10 10 5 20

B1 B2 B3 B4 B5 B6 B7 B8 B9

Junction Box Engine shut off system (ESOS) Dip Beam Main Beam Front Work Lights Directional Indicators Servo Control Lever Switches Heater Motor Hydraulic Oil Cooler Relay (when fitted)

10 5 15 15 15 5 10 20 5

9804/1103

10 7.5 5

A370790

Fuse Box Decal

50 - 05 - 01/11B

4210-C/1-6.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 05 - 01/12

456 Data - Electrical System Type Battery

24 Volts, negative earth Cold Crank Amps for 1 minute to 1.4VPC at -18 °C (0 °F) 410 Amps Reserve Capacity (minutes) 180 for 25 Amp load

Alternator Starter Motor Bulbs Headlights - main Headlights - dip Indicators Indicator repeater Instruments Work lights Number plate light Tail lights Front sidelights Interior lights Stop lights Beacon Rear fog Warning lights Master Warning Light Circuit Fuse Rating

6

9

12

2

5

8

11

1

4

7

10

3

3

2 4 5 6 7 8 9

9804/1103

(Amps) 5 5 5 A5 5 1 10 1 5 5 10 10 10

1

Hazard Warning Lights and Direction Indicators RH Side/Tail Lights and Switch Illumination Rear Fog Lights Blank Brake Lights, Float, Lift and Shovel Reset ZF Computer Feed Relay Solenoid Main Beam EMS Battery Feed Parking Brake Hazard Warning Lights (Battery Feed) Dip Beam Rear Work Lights and Reverse Alarm Rear Wash/Wipe Radio, Under Bonnet Lights, Interior Light and Beacon Engine shut off system (ESOS Hold Coil) Air Conditioning Engine shut off system (ESOS Pull Coil) Blank LH Side/Tail Lights and No. Plate Lights Front Work Lights EMS and ZF Computer Feed Hydraulic Mode Switch Horn and Front Wash/Wipe Heater Blower and Cigar Lighter Grid Heater Relay and Hydraulic Dump Valve ACCS 5 Blank

A

* B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9

Relays 1 Direction Indicators 2 Intermittent Wipers 3 Computer Feed 4 Engine Shut Down 5 Start Inhibit 6 ACCS 7 Blank 8 Heater Fan 9 Front Work Lights 10 Blank 11 Reverse Alarm 12 Rear Work Lights

B

A6 A7 A8 A9 B1 B2 B3 B4 B5

Rating (Watts) 75 W 70 W 21 W 5W 1.2 W 70 W Halogen 5W 5W 4W 10 W 21 W 70 W Halogen 21 W 1.2 W 5W

C

Fuse No. A1 A2 A3 A4

BOSCH 0120-488-206 DELCO REMY 42-MT/400

A270230

10 5 10 30 5 15 10 5 10 20 5 -

50 - 05 - 01/12

Issue 2*

Wheeled Loaders

CONTENTS

50 - 05 - 01/ 13

TM200, TM270 Data - Electrical TM200 System Battery

12 volt, negative earth Cranking Performance at - 18 deg. C (0 deg. F) Reserve capacity (minutes) for 25 amp load 180

* Alternator * Starter Motor

410 amps to 1.4 V.P.C A127, 65 amp max. output M127/2.A

Bulbs Bulb

Rating (Watts) 60 W 55 W 21 W 1.7 W 55 W Halogen 5W 5W 5W 10 W 21 W 55 W Halogen 21 W 3W 1.2 W

Headlights - main Headlights - dip Indicators Instruments Work lights Number plate light Side lights Tail lights Interior lights Stop lights Beacon Rear fog Warning lights Switch illumination Circuit Protection Fuse Circuit No. A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9

Fuse Rating (Amps)

Brake lights Instruments/Instrument illumination; Buzzer LH side/tail lights RH side/tail lights Rear Wash/Wipe Hazard Warning Lights Beacon; Front Wiper Park Interior Light/Radio Front Wash/Wipe; Horn; Flasher Auxiliary Plug Engine shut off system (ESOS) Dip Beam Main Beam Work lights Direction Indicators Auxiliary 1; Auxiliary 2 (Hyd.) Heater Boom Extend/Retract Thermostart Transmission; Transmission Dump Relay Blank Fog Light Blank Load Indicator Tow Hitch Speed Sensor Blank

9804/1103

10 5 5 5 10 10 7.5 5 15 10 5 10 10 20 10 10 20 10 15 15 5 5 7.5 5 -

50 - 05 - 01/13

Relays 1 Reverse 2 Forward 3 Reverse Lights 4 5 6

Neutral Start Parking Brake Flasher

7 8 9

Road Lights Ignition 2 Ignition 1

10 11 12

Front and Rear Work Lights Transmission Dump Buzzer

13 14 15 * 16

Forward Hi/Low (P/S Only) Reverse Hi/Low (P/S Only) Layshaft (P/S Only) Mainshaft (P/S 6-Solenoid gearboxes only)

9

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

8 7 6 5 4 3 2 1 A

B

C

16 A274141

4225-C/1-3.1

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 01/ 14

TM200, TM270 Data - Electrical (continued) TM270 to m/c no. 787040 System 12 volt, negative earth Battery Cranking Performance at - 18 deg. C (0 deg. F) Reserve capacity (minutes) for 25 amp load Alternator Starter

410 amps to 1.4 V.P.C 180 A127 12V 65A M127 12V

Bulbs Bulb Headlights - main Headlights - dip Indicators Instruments Work lights Number plate light Side lights Tail lights Interior lights Stop lights Beacon Rear fog Warning lights Switch illumination Reversing Light

Rating (Watts) 60 W 55 W 21 W 1.7 W 55 W Halogen 5W 5W 5W 10 W 21 W 55 W Halogen 21 W 3W 1.2 W 21 W

Circuit Protection

Relays 1 2 3

Layshaft Front work lights Road Lights

4 5 6

Indicator/Flasher Buzzer Forward Hi/Low

7 8 9

Reverse Hi/Low Forward Reverse

10 11 12

Parking Brake Dump Relay Ignition 2 relay

13 14

Ignition 1 relay Neutral start relay

Fuse Circuit Fuse Rating No. (Amps) A1 Brake lights 10 A2 Warning lights/Buzzer 5 A3 LH side/tail lights 5 A4 RH side/tail lights 5 A5 Rear Wash/Wipe 7.5 A6 Hazard Warning Lights 10 A7 Beacon and clock; Front Wiper Park 10 A8 Interior Light/Radio 5 A9 Front Wash/Wipe; Horn; Head Light Flasher 15 B1 Cab junction box 10 B2 Engine shut off solenoid (ESOS) 5 B3 Dip Beam 10 B4 Main Beam 10 B5 Front Work lights 10 B6 Direction Indicators 5 (with trailer indication) (7.5) B7 Joystick switches, Boom solenoids 10 B8 Heater Motor 20 (with optional Air conditioning) (20) B9 Joystick switches, Auxiliary solenoids 10 C1 Rear work lights 10 C2 Drive solenoids, Layshaft FWD HI/LO, REV HI/LO 10 C3 Drive controls relays, Dump neutral start park brake lights 5 C4 Rear Fog Light 5 C5 Thermostart 15 C6 Load Indicator 5 C7 Servo cut off solenoid 5 (with Tow Hitch Solenoid) 7.5 C8 Speedometer 5 C9 Blank -

9804/1103

50 - 05 - 01/14

A277210

4225-C/1-3.1

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 01/ 14A

TM200, TM270 Data - Electrical (continued) TM270 from m/c no. 787041 System Battery

12 volt, negative earth

Cranking Performance at - 18 deg. C (0 deg. F) Reserve capacity (minutes) for 25 amp load Alternator Starter Motor

410 amps to 1.4 V.P.C 180 A127 12V 65A M127 12V

Bulbs Bulb Headlights - main Headlights - dip Indicators Instruments Work lights Number plate light Side lights Tail lights Interior lights Stop lights Beacon Rear fog Warning lights Switch illumination Reversing Light

Relays Rating (Watts) 60 W 55 W 21 W 1.7 W 55 W Halogen 5W 5W 5W 10 W 21 W 55 W Halogen 21 W 3W 1.2 W 21 W

Circuit Protection Fuse Circuit No. A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9

Layshaft Front work lights Road Lights

4 5 6

Indicator/Flasher Buzzer Mainshaft

7 8 9

Forward Hi/Low Reverse Hi/Low Forward

10 11 12

Reverse Parking Brake Dump Relay

13 14 15

Ignition 2 relay Ignition 1 relay Neutral start relay

Fuse Rating (Amps)

Brake lights Warning lights/Buzzer LH side/tail lights RH side/tail lights Rear Wash/Wipe Hazard Warning Lights Beacon and clock; Front Wiper Park Interior Light/Radio Front Wash/Wipe; Horn; Head Light Flasher Cab junction box Engine shut off solenoid (ESOS) Dip Beam Main Beam Front Work lights Direction Indicators (with trailer indication) Joystick switches, Boom solenoids Heater Motor (with optional Air conditioning) Joystick switches, Auxiliary solenoids Rear work lights Drive solenoids, Layshaft FWD HI/LO, REV HI/LO Drive controls relays, Dump neutral start park brake lights Rear Fog Light Thermostart Load Indicator Servo cut off solenoid (with Tow Hitch Solenoid) Speedometer Blank

9804/1103

1 2 3

10 5 5 5 7.5 10 10 5 15

1

10 5 10 10 10 5 (7.5) 10 20 (20) 10

2

3

4

5

6 7

A

8 B

9

C 1

2

3

4

5

6

7

8

9

10 15

14

13

12 11 A310330

10 10 5 5 15 5 5 7.5 5 -

50 - 05 - 01/14A

4225-C/1-3.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 05 - 01/15

426B, 436B, 446B Data - Electrical System Type

24 Volts, negative earth

Battery (Two 12 Volt batteries in series) Cold Crank Amps for 1 minute to 1.4VPC at -18 °C (0 °F)

410 Amps

Reserve Capacity (minutes) for 25 Amp load

180

Alternator 426, 436 446

Butec A5524, 65 Amp maximum output BOSCH 0120-488-206

Starter Motor 426, 436 446

S115 24-7 DELCO REMY 42-MT/400

Light Bulbs Bulb Headlights - main Headlights - dip Indicators Indicator repeater Instruments Work lights Number plate light Tail lights Front sidelights Interior lights Stop lights Beacon Rear fog Warning lights Master warning light

9804/1103

Rating (Watts) 75 W 70 W 21 W 5W 1.2 W 70 W Halogen 10 W 5W 5W 10 W 21 W 70 W Halogen 21 W 1.2 W 5W

50 - 05 - 01/15

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 01/16

426B, 436B, 446B

m/cÕs to 531064 (426B) m/cÕs to 533069 (436B)

Data - Electrical (continued) Fuses

Relays

Fuse No.

Circuit

Fuse Rating (Amps)

A1 A2 A3 A4 A5 A6 A7 A8 A9

Direction Indicators Right Sidelights and Gauge Illumination Rear Fog Light Reverse Alarm/Dump Switch Brake Lights, Loader Arm and Bucket Reset Warning lights, Heater Fan and Gauges Main Beam Blank Blank

5 10 5 10 10 20 10 -

B1 B2 B3 B4 B5 B6 B7 B8 B9

Hazard Warning Lights Dip Beam Rear Work Lights/Reversing Lights Rear Wash/Wipe Interior Light and Beacon Engine shut off system (ESOS) Air Conditioning (Optional) Blank Blank

10 10 10 10 10 5 10 -

C1 C2 C3 C4 C5 C6 C7 C8 C9

Left Sidelights Front Work Lights Transmission Blank Horn and Front Wash/Wipe Blank Blank Blank Blank

10 25 10 10 -

A1 A2 A3 A4 A5

Neutral Start Rear Work Lights/Reverse Lights Reverse Alarm Hazard Seat Warning (Optional)

B1 B2 B3 B4

Start Front Work Lights Buzzer Transmission Timer

A1

B1

A2

B2

A3

B3

A4

B4

A5

1 A

B

C

2 3 4 5 6 7 8 9 A200630

9804/1103

50 - 05 - 01/16

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 01/17

426B, 436B, 446B

m/cÕs from 531065 (426B) m/cÕs from 533070 (436B)

Data - Electrical (continued) Fuses

Relays

20 10 -

B1 B2 B3 B4 B5 B6 B7 B8 B9

Hazard Warning Lights and Clock Dip Beam Rear Work Lights/Reversing Lights Rear Wash/Wipe Interior Light, Beacon and Radio (Optional) Engine shut off system (ESOS) Air Conditioning (Optional) Blank Blank

10 10 10 10 10 5 10 -

C1 C2 C3 C4 C5 C6 C7 C8 C9

Left Sidelights and Number Plate Lights Front Work Lights Transmission Blank Horn and Front Wash/Wipe Blank Hydraulic Dump Valve Blank Blank

10 25 10 10 5 -

5 10 5 10 10

Hazard Blank Transmission timer Neutral Start Start Blank Blank Transmission Disconnect Front Work Lights Anti-Stall Reverse Alarm Rear Work Lights/Reverse Lights

1

2

3

4

5

6

7

8

9

10

11

12

1

A7 A8 A9

Direction Indicators Right Sidelights and Gauge Illumination Rear Fog Light Reverse Alarm, Dump Switch, Anti-Stall Relay and Solenoid Valve Brake Lights, Loader Arm and Bucket Reset Warning lights, Heater Fan, Gauges, Cigar Lighter, Transmission Disconnect Relay, Timer and Hourmeter Main Beam Blank Blank

1 2 3 4 5 6 7 8 9 10 11 12

A

A1 A2 A3 A4 A5 A6

Fuse Rating (Amps)

B

Circuit

C

Fuse No.

2 3 4 5 6 7 8 9 A248620

9804/1103

50 - 05 - 01/17

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 01/18

426B, 436B, 446B

m/cÕs from 531300 (426B) m/cÕs from 533300 (436B)

Data - Electrical (continued) Fuses

Relays

Fuse No.

Circuit

Fuse Rating (Amps)

A1 A2 A3 A4 A5 A6 A7 A8 A9

Hazard Warning Lights and Direction Indicators 5 Right Side/Tail Lights and Switch Illumination 5 Rear Fog Light 5 Anti-stall (if fitted) 5 Brake Lights, Float, Lift and Shovel Reset 10 Computer Feed Relay Solenoid 1 Main Beam 15 EMS Battery Feed 1 Blank -

B1 B2 B3 B4 B5 B6 B7 B8 B9

Hazard Warning Lights (Battery Feed) Dip Beam Rear Work Lights and Reverse Alarm Rear Wash/Wipe Radio, Under Bonnet Lights, Interior Light and Beacon Engine shut off system (ESOS) Air Conditioning Thermostart Blank

10 5 10 15 -

C1 C2 C3 C4 C5 C6 C7 C8 C9

Left Side/Tail Lights and No. Plate Lights Front Work Lights EMS and FZ Computer Feed Blank Horn and Front Wash/Wipe Heater Blower and Cigar Lighter Hydraulic Dump Valve Blank Blank

5 25 10 10 25 5 -

1 2 3 4 5 6 7 8 9 10 11 12

Direction Indicators Blank Computer Feed Engine Shut Down Start Inhibit ACCS (If fitted) Blank Heater Fan Front Work Lights Anti-stall (if fitted) Reverse Alarm Rear Work Lights

10 10 15 10

A

B

C

1

9

12

2

5

8

11

1

4

7

10

3

6

2

3

4 5 6 7 8 9

A270230

9804/1103

50 - 05 - 01/18

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 01/19

426B, 436B, 446B

m/cÕs from 540000 (446B)

Data - Electrical (continued) Fuses Fuse Circuit No.

Relays Fuse Rating (Amps)

A1 A2 A3 A4 A5 A6 A7 A8 A9

Hazard Warning Lights and Direction Indicators 5 Right Side/Tail Lights and Switch Illumination 5 Rear Fog Lights 5 Blank Brake Lights, Float, Lift and Shovel Reset 5 Computer Feed Relay Solenoid 1 Main Beam 10 EMS Battery Feed 1 Blank -

B1 B2 B3 B4 B5 B6 B7 B8 B9

Hazard Warning Lights (Battery Feed) Dip Beam Rear Work Lights and Reverse Alarm Rear Wash/Wipe Radio, Under Bonnet Lights, Interior Light and Beacon Engine shut off system (ESOS Hold Coil) Air Conditioning Engine shut off system (ESOS Pull Coil) Blank

10 1 10 30 -

C1 C2 C3 C4 C5 C6 C7 C8 C9

Left Side/Tail Lights and No. Plate Lights Front Work Lights EMS and ZF Computer Feed Blank Horn and Front Wash/Wipe Heater Blower and Cigar Lighter Grid Heater Relay and Hydraulic Dump Valve ACCS Blank

5 15 10 10 20 5 5 -

1 2 3 4 5 6 7 8 9 10 11 12

Direction Indicators Intermittent Wipers Computer Feed Engine Shut Down Start Inhibit ACCS Blank Heater Fan Front Work Lights Blank Reverse Alarm Rear Work Lights

5 10 10 10

A

B

C

1

9

12

2

5

8

11

1

4

7

10

3

6

2

3

4 5 6 7 8 9

A270230

9804/1103

50 - 05 - 01/19

Issue 1

Wheeled Loaders

CONTENTS

50 - 05 - 01/20

426B, 436B, 446B

m/c’s from 533692 (436B)

Data - Electrical (continued) Fuses The electrical circuits are protected by fuses. The fuses are located in a fuse box to the rear of the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one.

! CAUTION

Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage.

D1 D2 D3 D4 D5 D6 D7 D8 D9 D10

EMS (Ignition Feed) ZF Computer (Ignition Feed) CCTV (Option) Blank ESOS and Cold Start Advance Reverse Lights and Alarm In-cab 24/12 Volt Converter (Option) Blank Brake Lights Float, Lift and Shovel Reset and 4th Spool

3 7.5 5 5 5 10 7.5 7.5

8-3-3-5

Fuse Circuit No.

Fuse Rating (Amps)

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

Rear Work Lights Road Lights Front Work Lights Dipped Beam Main Beam Rear Fog Lights Blank Thermostart Dump Relay Ignition Relays

10 15 20 10 10 5 30 3 3

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and No. Plate Lights 12 Volt Trailer Electrics (Option) EMS (Battery Feed) ZF Computer (Battery Feed) Hazard Warning Beacon and Interior Light Radio (24 Volt) Headlight Flash Side Lights

3 3 10 3 7.5 10 7.5 10 15 5

Starter Relay Solenoid Cigar Lighter (24 Volt) See Note Blank Rear Wash/Wipe Front Wash/Wipe and Horn Heated Seat/Mirrors and Air Suspension Seat (Option) C7 Air Conditioning (Option) C8 Heater Blower C9 Direction Indicators C10 Heated Rear Screen

3 10 7.5 10

C1 C2 C3 C4 C5 C6

10 9 8 7 6 5 4 3 2 1 3

2

1

A

13

6

5

4

B

14

9

8

7

C

15

12

11

10

D

X

Y

A336170

Note: To gain access to the underside of the fuse/relay panel, remove the securing screw and unhook the rear of the panel. Manipulate the panel until it is clear. Make sure the panel is refitted securely.

10 5 15 5 15

Note: Not fitted if in-cab 24/12 Volt converter fitted.

9804/1103

50 - 05 - 01/20

4160-C/1-6.2

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 01/21

426B, 436B, 446B

M/c’s from 533692 (436B)

Data - Electrical (continued) Relays

Primary Fuses The primary fuses are located in a fuse box attached to the battery positive terminal. If a fuse ruptures, find out why and rectify the fault before fitting a new one. Fuse No.

Circuits

Fuse Rating (Amps)

PF1

40 Front Work Lights Rear Work Lights Main Beam Dip Beam Fog Lights

PF2

* PF3

PF4

40 RH Side/Tail Lights & Switch Illumination LH Side/Tail Lights & No. Plate Lights Headlight Flash Radio (24 Volt) Beacon & Interior Light Hazard Warning EMS (Battery Feed) ZF Computer (Battery Feed) 12 Volt Trailer Electrics 426 - 40 436 - 50 Starter Solenoid Thermostart Heater Blower Air Conditioning Direction Indicators Heated Seat, Mirrors & Air suspension Seat Heated Rear Screen Ignition Relays 50 EMS (Ignition Feed) ZF Computer (Ignition Feed) Rear Wash/Wipe Front Wash/Wipe & Horn Cigar Lighter (24 Volt) ESOS & Cold Start Advance Reverse Alarm/Lights Headlight Flash Brake Lights Shovel and Arm Reset CCTV In-cab 24/12 Volt Converter

PF4 PF3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Heated Rear Screen Ignition 2 Flasher Front Work Lights Lights Reverse Alarm/Lights Dump Air Conditioning Blank ESOS Ignition 1 Ignition 3 Wash/Wipe Interval Timer Start Blank

Diagnostic Connectors X Y

ZF Transmission EMS

10 9 8 7 6 5 4 3 2 1 3

2

1

A

13

6

5

4

B

14

9

8

7

C

15

12

11

10

D

PF2 PF1 X

Y

A336170

A336180

9804/1103

50 - 05 - 01/21

4160-C/1-7.2

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 02/1

406,407 Data - Hydraulic Pump Type Flow at 2000 rev/min and186 bar (2700lbf/in2)

Sundstrand AFGP 28L-30442 (gear type) 56 litres/min 12.3 UK gal/min 14.8 US gal/min bar 186

kgf/cm2 190

lbf/in2 2700

158 227

160 230

2300 3300

By-pass pressure

1.05

1.07

15.0

Ram Torque Settings Piston Head (all rams except steer ram) End Cap (all rams except steer ram) Piston Head (steer ram) End Cap (steer ram)

Nm 405 678 300 450

kgf m 41.3 69.2 30.6 45.9

lbf ft 300 500 221 332

Stroke

Rod Dia.

Piston Head A/F 40 45 75 75 75 75 -

Main Relief Valve Operating Pressure

Auxiliary Relief Valves Operating Pressures Shovel Ram Rod Side Shovel Ram Head Side Filter

Ram Dimensions [mm (in.)] Steering Ram (to m/c 631796) Steering Ram (from m/c 631797) Shovel Ram (to m/c 631796) Shovel Ram (from m/c 631797) Lift Ram (to m/c 631796) Lift Ram (from m/c 631797) Quick Hitch (Twin piston cylinder)

9804/1103

Bore 60 (2.36) 60 (2.36) 100 (3.94) 100 (3.94) 100 (3.94) 100 (3.94) 60 (2.36)

245.5 (9.67) 245.5 (9.67) 387.5 (15.26) 387.5 (15.26) 715.0 (28.15) 715.0 (28.15) 54.0 (2.13)

50 - 05 - 02/1

30 (1.18) 30 (1.18) 60 (2.36) 60 (2.36) 60 (2.36) 60 (2.36) 44.4 (1.75)

Cap A/F 50 55 95 85 95 85 73

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 02/2

408,409 Data - Hydraulic Pump Type Flow at 2000 rev/min and 207 bar (3000lbf/in2)

Sundstrand AFGP 36L-31805 (gear type) 72 litres/min 15.8 UK gal/min

19 US gal/min

Main Relief Valve Operating Pressure

bar 207

kgf/cm2 211

lbf/in2 3000

172 228

175 233

2494 3306

1.05

1.07

15.0

Nm 405 678

kgf m 41.3 69.2

lbf ft 300 500

Auxiliary Relief Valves Operating Pressures Shovel Ram Rod Side Shovel Ram Head Side Filter By-pass pressure Ram Torque Settings Piston Head (all rams) End Cap (all rams) Ram Dimensions [mm (in.)] Steering Ram Shovel Ram (to m/c 631870) Shovel Ram (from m/c 631871) Lift Ram (to m/c 631870) Lift Ram (from m/c 631871) Quick Hitch (Twin piston cylinder)

9804/1103

Bore

Stroke

Rod Dia.

70 (2.76) 100 (3.94) 100 (3.94) 110 (4.33) 110 (4.33) 60 (2.36)

246 (9.69) 397 (1563) 397 (1563) 708 (27.87) 708 (27.87) 54 (2.13)

40 (1.58) 60 (2.36) 60 (2.36) 60 (2.36) 60 (2.36) 44.4 (1.75)

50 - 05 - 02/2

Piston Head A/F 55 75 75 75 85 -

Cap A/F 65 95 85 95 95 73

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 02/3

411 Data - Hydraulics Pump Type

Ultra 2PRO332PRO23 Fixed Displacement Gear Double Pump

Pump 1 flow at 2200 engine rev/min † Flow at 200 bar

45.5 l/min 37.0 l/min

10.0 gal/min 8.1 gal/min

Pump 2 flow at 2200 engine rev/min † Flow at 200 bar

65.3 l/min 60.0 l/min

14.4 gal/min 13.2 gal/min

† - Minimum acceptable flow rate for a worn pump. Relief Valve Operating Pressres

bar

kgf/cm2

lbf/in2

Main Relief Valve (P1) Main Relief Valve (P2) Auxiliary Releif Valve - Shovel Ram Head Side †† - Shovel Ram Rod Side †† - Lift Ram Head Side Unloader Servo

220 195

224 194

3190 2755

150 240 345 170 38

153 245 352 173 38.8

2175 3480 5002 2465 551

Rod Dia. mm in 50 1.9 50 1.9 30 1.2

Stroke mm in 927 36.5 742 29.2 312 12.3

†† From machine No. 527210 Rams

Shovel Ram Lift Ram Steer Ram

Bore mm 80 90 60

in 3.1 3.5 2.4

Filter Filtration Size By pass Setting Suction Strainer Size

10 Micron 1.5 bar 140 Micron

20 - 05 - 02/3

4160 - E/1-1.3

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 02/4

416 Data - Hydraulic Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure (220 bar)

Rexroth. Variable displacement axial piston AV10VO 71DFR 1/31 RPS C2 NOO 5.0 litres/min 1.1 UK gal/min 156.0 litres/min 34.3 UK gal/min 5.0 litres/min 1.1 UK gal/min

1.3 US gal/min 41.2 US gal/min 1.3 US gal/min

Loader Valve Type Ref Services Operated — Spool 1 (LV1) * — Spool 2 (LV2) — Spool 3 (LV3) — Spool 4 (LV4)

Rexroth, stacked directional control, model MP18. 4 spool 3 spool

2 spool

Loader arms Shovel Quickhitch (optional) Auxiliary (optional)

Relief Valve Operating Pressures

bar

kgf/cm2

lbf/in2

System pressure (pump relief valve) Standby pressure (pump relief valve) Auxiliary Relief Valves (A.R.V.) — Steering priority — Lift ram, head side * — Shovel ram, head side (1st stage) * — Shovel, head side (2nd stage) * — Shovel ram, rod side — Servo Brake (non-adjustable)

220 27

224 27.5

3190 391.5

175 350 80 220 248 30 60

178.5 357 81.6 224 253 30.6 61.2

2537.5 5075 1160 3190 3596 435 870

By-pass Pressures Filter Oil Cooler

bar 1.5 3.0

kgf/cm2 1.53 3.06

lbf/in2 22 44

Tank Capacities

Litres 125 82 70

UK gall 27.5 18 15.4

US gall 33 21.7 18.5

Rams

Shovel Ram Lift Ram Steer Ram

Bore mm 90 100 70

in 3.5 3.9 2.8

Rod Dia. mm in 50 1.9 60 2.4 40 1.6

Stroke mm in 927 36.5 740 29.1 312 12.3

Filter Filtration Size By pass Setting Suction Strainer Size

9804/1103

10 Micron 1.5 bar 140 Micron

50 - 05 - 02/4

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 02/5

426 Data - Hydraulic Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure (220 bar)

Rexroth. Variable displacement axial piston AV10VO 100DFR 1/3R-PSC 12NOO-50420 5 litres/min 1.1UK gal/min 220 litres/min 48.4 UK gal/min 210 litres/min 46.2 UK gal/min

1.3 US gal/min 58.1 US gal/min 55.5 US gal/min

Loader Valve

* * * *

Type

Rexroth, stacked directional control, model MP-22.

Services Operated — Spool 1 (LV1) — Spool 2 (LV2) — Spool 3 (LV3) (optional) — Spool 4 (LV4) (optional)

Loader arms Shovel Auxiliary (Quickhitch) Auxiliary (Clam)

Relief Valve Operating Pressures

bar

kgf/cm2

lbf/in2

System pressure (pump relief valve) Standby pressure (pump relief valve) Auxiliary Relief Valves (A.R.V.) — Lift ram, head side — Shovel ram, head side (1st stage)* — Shovel ram, head side (2nd stage) — Shovel ram, rod side — Servo Brake (non-adjustable)(max) Steer relief pressure (at ram) Steer relief pressure (at pump)

220 27

224 27.5

3190 391.5

345 80 225 248 27-35 80 175 190

352 81.6 230 253 27.5-35.6 61.2 178.5 193.8

4985 1160 3262 3596 391.5-508 870 2537.5 2755

By-pass Pressures Filter Oil Cooler

bar 1.5 3.0

kgf/cm2 1.53 3.06

lbf/in2 22 44

Capacities Hydraulic tank

Litres 164

UK gal 36.1

US gal 43.4

* Not fitted on Z-bar machines

Rams

Shovel Ram Lift Ram Steer Ram

Bore mm 100 110 80

in 3.9 4.3 3.1

Rod Dia. mm in 60 2.4 60 2.4 50 2.0

Stroke mm in 1056 41.6 821 32.3 312 12.3

Filter Filtration Size By pass Setting Suction Strainer Size

9804/1103

10 Micron 1.5 bar 140 Micron

50 - 05 - 02/5

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 02/6

436 Data - Hydraulic Primary Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure (220 bar)

Rexroth. Variable displacement axial piston AV10VO 71DFR 1/31 RPS C2 NOO 5 litres/min 1.1 UK gal/min 1.3 US gal/min 156 litres/min 34.3 UK gal/min 41.2 US gal/min 5 litres/min 1.1 UK gal/min 1.3 US gal/min

Secondary Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure

Rexroth. Variable displacement axial piston AA10VO 45OFR 1/50L PSC 11NOO-50420 3 litres/min 0.7 UK gal/min 0.8 US gal/min 99 litres/min 21.8 UK gal/min 26.1 US gal/min 94 litres/min 20.7 UK gal/min 24.8 US gal/min

Loader Valve

* * * *

* * * *

Type

Rexroth, stacked directional control, model MP-22.

Services Operated — Spool 1 (LV1) — Spool 2 (LV2) — Spool 3 (LV3) (optional) — Spool 4 (LV4) (optional)

Loader arms Shovel Auxiliary (Quickhitch) Auxiliary (Clam)

Relief Valve Operating Pressures

bar

kgf/cm2

lbf/in2

System pressure (main pump relief valve) Standby pressure (main pump relief valve) System pressure (secondary pump return valve) Standby pressure (secondary pump Auxiliary Relief Valves (A.R.V.) — Lift ram, head side — Shovel ram, head side (1st stage)* — Shovel ram, head side (2nd stage) — Shovel ram, rod side — Servo Brake (non-adjustable) Steer relief pressure (at ram) Steer relief pressure (at pump)

220 27 220 25

224 27.5 224 25.5

3190 391.5 3190 362.5

345 80 225 248 27-35 80 175 190

352 81.6 230 253 27.5-35.6 61.2 178.5 193.8

4985 1160 3262 3596 391.5-508 870 2537.5 2755

By-pass Pressures Filter Oil Cooler

bar 1.5 3.0

kgf/cm2 1.53 3.06

lbf/in2 22 44

Capacities Hydraulic tank

Litres 181

UK gal 39.8

US gal 47.9

Bore mm

in

Rod Dia. mm in

Stroke mm in

110 130 80

4.3 5.1 3.1

60 2.4 70 2.8 50 2.0

1056 41.6 814 32.0 312 12.3

* Not fitted on Z-bar machines

Rams

Shovel Ram Lift Ram Steer Ram Filter Filtration Size By pass Setting Suction Strainer Size 9804/1103

10 Micron 1.5 bar 140 Micron

50 - 05 - 02/6

Issue 2*

CONTENTS

*

Wheeled Loaders

50 - 05 - 02/7

412S, 414S, 416S Data - Hydraulics Pump 412S Type

Ultra 2PRO33/2PRO23 Fixed Displacement Gear Double Pump

Pump 1 flow at 2200 engine rev/min † Flow at 200 bar

45.5 l/min 37.0 l/min

10.0 gal/min 8.1 gal/min

Pump 2 flow at 2200 engine rev/min † Flow at 200 bar

65.3 l/min 60.0 l/min

14.4 gal/min 13.2 gal/min

* 414S/416S Type Pump 1 flow at 2200 engine rev/min † Flow at 200 bar Pump 2 flow at 2200 engine rev/min † Flow at 200 bar

Ultra 2PRO41/2PRO29 Fixed Displacement Gear Double Pump 63.8 l/min 51.0 l/min 90.2 l/min 72.0 l/min

14.0 gal/min 11.2 gal/min 19.8 gal/min 15.8 gal/min

† - Minimum acceptable flow rate for a worn pump. Relief Valve Operating Pressures Main Relief Valve (P1) Main Relief Valve (P2) Auxiliary Relief Valve - Shovel Ram Head Side - Shovel Ram Rod Side - Lift Ram Head Side Unloader Servo

bar 220 195

kgf/cm 2 224 194

lbf/in 2 3190 2755

150 240 345 170 38

153 224 352 173 38.8

2175 3190 5002 2465 551

Shovel Ram Lift Ram Steer Ram

Bore m in 80 3.1 90 3.5 60 2.4

Rod Dia. mm in 50 1.9 50 1.9 30 1.2

Stroke mm 927 742 312

Filter Filtration Size By pass Setting Suction Strainer Size

10 Micron 1.5 bar 140 Micron

Rams

20 - 05 - 02/7

in 36.5 29.2 12.3

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 02/8

409 Telemaster Data - Hydraulic Pump Type Flow at 2250 rev/min and 207 bar (3000lbf/in2)

Sundstrand AFGP 36L-31805 (gear type) 81 litres/min 17.8 UK gal/min

21.4 US gal/min

Main Relief Valve Operating Pressure

bar 207

kgf/cm2 211

lbf/in2 3000

280 280

286 286

4060 4060

1.05

1.07

15.0

Nm 405 678

kgf m 41.3 69.2

lbf ft 300 500

Auxiliary Relief Valves Operating Pressures Forward Tilt (G) Backward Tilt (F) Filter By-pass pressure Ram Torque Settings Piston Head (all rams) End Cap (all rams) Ram Dimensions [mm (in.)] Steering Ram Tilt Ram Compensating Ram Lift Ram Extending Ram Quickhitch (Twin piston cylinder)

9804/1103

Bore

Stroke

Rod Dia.

70 (2.76) 120 (4.73) 70 (2.76) 110 (4.33) 70 (2.76) 40 (1.58)

246 (9.69) 285 (11.23) 630 (24.82) 842 (33.18) 1,200 (47.28) 40 (1.58)

40 (1.58) 70 (2.76) 40 (1.58) 60 (2.36) 40 (1.58) 30 (1.18)

50 - 05 - 02/8

Piston Head A/F 55 95 55 85 55 -

Cap A/F 65 105 65 95 65 -

Issue 1

CONTENTS

*

Wheeled Loaders

50 - 05 - 02/9

407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX Data - Hydraulics 407B ZX, 408B ZX, 409B ZX

410B ZX, 411B ZX

Transmission Pump Type Frame size

Variable displacement axial piston 75 (75 cc/rev displacement)

Charge pressure setting

Charge pump displacement High pressure setting port A High pressure setting port B Rotation Main Hydraulic Pump Type Flow at 2200 rev/min (no load) Max. cont. pressure Flow at 2150 rev/min (full load)

Fan Pump Type Flow at 2000 rev/min (zero pressure) Flow at 2000 rev/min (system pressure)

Variable displacement axial piston † 55 (55 cc/rev displacement) †† 56 (56 cc/rev displacement) † 24 bar (24.5 kgf/cm2, 348 lbf/in2) †† 28 bar (28.5 kgf/cm2, 406 lbf/in2) (minimum) † 14 cc/rev †† 11 cc/rev † 470 bar (479.4 kgf/cm2, 6817 lbf/in2) †† 468 bar (477 kgf/cm2, 6786 lbf/in2) † 470 bar (479.4 kgf/cm2, 6817 lbf/in2) †† 468 bar (477 kgf/cm2, 6786 lbf/in2) Clockwise

Fixed displacement gear pump † 70.4 lpm (15.5 UK gal/min, 18.6 US gal/min) †† 72.6 lpm (16 UK gal/min, 19.2 US gal/min) † 240 bar (245 kgf/cm2, 3480 lb/in2) † 68.8 lpm (15.1 UK gal/min, 18.2 US gal/min) †† 71 lpm (15.7 UK gal/min, 18.8 US gal/min)

28 bar (28.6 kgf/cm2, 406 lbf/in2)

17 cc/rev 440 bar (448.8 kgf/cm2, 6382 lbf/in2) 440 bar (448.8 kgf/cm2, 6382 lbf/in2) Clockwise

Fixed displacement gear pump (41 cc/rev) 90 lpm (19.8 UK gal/min, 23.8 US gal/min) 250 bar (255 kgf/cm2, 3625 lb/in2) 88.2 lpm (19.4 UK gal/min, 23.3 US gal/min)

Fixed displacement gear pump

Fixed displacement gear pump (10 cc/rev)

† 14.1 lpm (3.1 UK gal/min, 3.7 US gal/min)

22 lpm (4.8 UK gal/min, 5.8 US gal/min)

† 13.5 lpm (2.9 UK gal/min, 3.5 US gal/min)

21 lpm (4.6 UK gal/min, 5.5 US gal/min)

†† 10 cc/rev pump 18.3 lpm (4 UK gal/min, 4.8 US gal/min) †† 12 cc/rev pump 21.9 lpm (4.8 UK gal/min, 5.8 US gal/min)

Steer Pump Type Flow at 2200 rev/min Max. cont. pressure Fan Motor Type Max. fan speed

Transmission Motor Type Frame size

Fixed displacement gear pump (17 cc/rev) 37.4 lpm (8.2 UK gal/min, 9.9 US gal/min) 210 bar (215 kgf/cm2, 3045 lb/in2)

Fixed displacement gear motor † 1710 rev/min ††2150 rev/min

Fixed displacement gear motor 3500 rev/min

Bent axis

Bent axis

† 110 (110 cc/rev displacement) †† 107 (107 cc/rev displacement)

160 (161 cc/rev displacement)

† 407B ZX, 408B ZX, 409B ZX, to S/N. 757399. †† 407B ZX, 408B ZX, 409B ZX, S/N. 757400 on.

9804/1103

20 - 05 - 02/9

4210 - E/1-1.6

Issue 3*

CONTENTS

*

Wheeled Loaders

50 - 05 - 02/10

407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX Data - Hydraulics (continued)

Valve Block Type Ref

Max. flow Services Operated — Spool 1 (S1) — Spool 2 (S2) — Spool 3 (S3) — Spool 4 (S4) * — Spool PS1

407B ZX, 408B ZX, 409B ZX

410B ZX, 411B ZX

Husco International AR1325-001 (4-spool, servo) AR1325-004 (3-spool, servo) AR1325-005 (4-spool, manual) AR1325-006 (3-spool, manual) 63 litres/min

Commercial Hydraulics KA18 346 9204 166 (4-spool, servo) KA18 346 9203 192 (3-spool, servo)

Crowd Lift Auxiliary (Quickhitch) Auxiliary Priority Steer

Crowd Lift Auxiliary 1 Auxiliary 2

90 litres/min

kgf/cm2

Relief Valve Operating Pressures bar 2

bar

2

kgf/cm Main Relief Valve, ‘B’ - 407B Main Relief Valve, ‘B’ - 408B

lbf/in 220 230

223 233

3190 3335

Main Relief Valve, ‘B’ - 409B Auxiliary Relief Valve — Crowd ram, ‘A’ — Crowd ram, ‘B’ — Lift ram, ‘B’ — Priority steer, ‘B’

240

243

3480

250 250 260 138

253 253 264 140

3625 3625 3770 2001

By-pass Pressures Filter

bar 3.0

kgf/cm2 3.06

lbf/in2 44

Capacities Hydraulic system

Litres 70

UK gall 15.4

US gall 18.5

Rams

Bore mm in 90 3.5 80 3.1 50 2.0

Crowd Ram Lift Ram Steer Ram

lbf/in2

Rod Dia. mm in 50 2.0 50 2.0 30 1.2

410B ZX 230 411B ZX 245

233 250

3335 3553

260 260 270

264 264 275

3770 3770 3916

Litres 130

UK gall 28.6

US gall 34.3

Stroke mm in 515 20.3 530 20.9 305 12.0

Bore mm in 110 4.3 90 3.5 60 2.4

Rod Dia. mm in 60 2.4 60 2.4 30 1.2

Stroke mm in 520 20.5 60.5 23.8 305 12

411B ZX with optional ‘Volvo style’ Quick-hitch

Crowd Ram

9804/1103

Bore mm in 120 4.7

Rod Dia. mm in 65 2.6

Stroke mm in 520 20.5

20 - 05 - 02/10

4210 - E/1 - 2.3

Issue 3*

CONTENTS

Wheeled Loaders

50 - 05 - 02/11

456B Data - Hydraulic Primary Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure (220 bar)

Rexroth. Variable displacement axial piston A 10VS0 100DFR 1/31 RPS C12 NOO 5 litres/min 1.1 UK gal/min 220 litres/min 48.4 UK gal/min 5 litres/min 1.1 UK gal/min

1.3 US gal/min 58.1 US gal/min 1.3 US gal/min

Rexroth. Variable displacement axial piston A 10VS0 45DFR 1/50L PSC 11NOO-50420 3 litres/min 0.7 UK gal/min 99 litres/min 21.8 UK gal/min 3 litres/min 0.7 UK gal/min

0.8 US gal/min 26.1 US gal/min 0.8 US gal/min

Secondary Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure Loader Valve Type

Rexroth, stacked directional control, model MP-22.

Services Operated — Spool 1 (LV1) — Spool 2 (LV2) — Spool 3 (LV3) (optional) — Spool 4 (LV4) (optional)

Loader arms Shovel Auxiliary (Quickhitch) Auxiliary (Clam)

Relief Valve Operating Pressures

bar

kgf/cm2

lbf/in2

System Control Pressure (pressure control valve) System control pressure (main pump relief valve) Standby pressure (main pump relief valve) System pressure (secondary pump relief valve) Standby pressure (secondary pump) Auxiliary Relief Valves (A.R.V.) — Lift ram, head side — Shovel ram, head side — Shovel ram, rod side — Servo Brake (non-adjustable) Steer relief pressure (at ram) Steer relief pressure (at pump)

190 220 27 190 25

194 224 27.5 194 25.5

2755 3190 391.5 2755 362.5

345 225 248 27-35 80 175 190

352 230 253 27.5-35.6 81.6 178.5 193.8

4985 3262 3596 391.5-508 1160 2537.5 2755

By-pass Pressures

bar

kgf/cm2

lbf/in2

Filter Oil Cooler

1.5 3.0

1.53 3.06

22 44

Capacities

Litres

UK gal

US gal

Hydraulic tank

181

39.8

47.9

Bore mm 180 160 90

in 7.1 6.3 3.5

Rod Dia. mm in 90 3.5 80 3.1 50 2.0

Rams

Shovel Ram Lift Ram Steer Ram

Stroke mm 560 727 312

in 22.05 28.6 12.3

Filter Filtration Size By pass Setting

9804/1103

10 Micron 1.5 bar

50 - 05 - 02/11

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 02/12

TM200, TM270 Data - Hydraulics TM200 Pump Type Flow at 2250 rpm

Sunstrand AFGP 36L - 31805 (gear type) 81 litres/min 17.80 UK gal/min

21.4 US gal/min

bar 207

kgf/cm 2 211

lbf/in 2 3000

280 280 30

286 286 30

4060 4060 435

Filter Filtration Size By-pass Pressure

25 microns 1.05

1.07

15

Ram Dimensions Steering Tilt Compensating Lift Extension Quickhitch

Bore 70 120 70 110 70 40

Rod Dia 40 70 40 60 40 30

Stroke 246 285 630 842 1200 40

Hydraulic Tank Capacity

63 litres

13.9 UK gal

16.6 US gal

Relief Valve Operating Pressure * Main Relief Valve Auxiliary Relief Valves Forward Tilt (G) Backward Tilt (F) Servo Pressure

9804/1103

20 - 05 - 02/12

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 02/13

TM200, TM270 Data - Hydraulics (continued) TM270 Pump Main Pump Flow at 2200 rpm Auxiliary Pump Flow at 2200 rpm

79 litres/min 42 litres/min

Relief Valve Operating Pressure

bar

kg/cm2

lbf/in2

210

214

3045

230 230 150 30

235 235 153 30

3335 3335 2175 435

Filter Filtration Size By-pass Pressure

25 microns 1.05

1.07

15

Ram Dimensions

Bore

Main Relief Valve Auxiliary Relief Valves Forward Tilt Backward Tilt Unloader Valve Servo Pressure

Steering Tilt Compensating Lift Extension Quickhitch Hydraulic Tank Capacity

9804/1103

60 130 60 120 80 40

90 litres

50 - 05 - 02/13

17.4 UK gal/min 9.2 UK gal/min

Rod Dia 30 75 35 70 50 30

19.8 UK gal

21.0 US gal/min 11.0 US gal/min

Stroke 288 342 600 1040 1275 40

23.8 US gal

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 02/14

426B, 436B, 446B Data - Hydraulics 426 Machines Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure (220 bar)

Rexroth. Variable displacement axial piston AV10VO 100DFR 1/3R-PSC 12NOO-50420 5 litres/min 1.1UK gal/min 220 litres/min 48.4 UK gal/min 5 litres/min 1.1UK gal/min

1.3 US gal/min 58.1 US gal/min 1.3 US gal/min

Loader Valve Type

Rexroth, stacked directional control, model MP-22.

Services Operated — Spool 1 (LV1) — Spool 2 (LV2) — Spool 3 (LV3) (optional) — Spool 4 (LV4) (optional)

Loader arms Shovel Auxiliary (Quickhitch) Auxiliary (Clam)

Relief Valve Operating Pressures bar

kgf/cm2 lbf/in2

System control pressure (pump relief valve) 220 224 3190 Standby pressure (pump relief valve) 27 27.5 391.5 Auxiliary Relief Valves (A.R.V.) — Lift ram, head side 345 352 4985 — Shovel ram, head side (1st stage)† 80 81.6 1160 — Shovel ram, head side (2nd stage) 225 230 3262 — Shovel ram, rod side 248 253 3596 — Servo 27-35 27.5-35.6 391.5-508 Brake (non-adjustable)(max) 80 81.6 1160 Steer relief pressure (at ram) 175 178.5 2537.5 Steer relief pressure (at pump) 190 193.8 2755 Idle control pressure 140 142.8 2030 (up to 1150-1250 rev/min) † Not fitted on Z-bar machines By-pass Pressures Filter Oil Cooler

bar 1.5 3.0

kgf/cm2 1.53 3.06

lbf/in2 22 44

Capacities Hydraulic tank

Litres 164

UK gal 36.1

US gal 43.4

Rams

Shovel Ram Lift Ram Steer Ram

Bore mm 100 110 80

in 3.9 4.3 3.1

Rod Dia. mm in 60 2.4 60 2.4 50 2.0

Stroke mm in 1056 41.6 821 32.3 312 12.3

Filter Filtration Size By pass Setting Suction Strainer Size

9804/1103

10 Micron 1.5 bar 140 Micron

20 - 05 - 02/14

4160 - E/1-1.3

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 02/15

426B, 436B, 446B Data - Hydraulics (continued) 436, 446 Machines Primary Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure (220 bar)

Rexroth. Variable displacement axial piston AV10VO 71DFR 1/31 RPS C2 NOO 5 litres/min 1.1 UK gal/min 156 litres/min 34.3 UK gal/min 5 litres/min 1.1 UK gal/min

1.3 US gal/min 41.2 US gal/min 1.3 US gal/min

Rexroth. Variable displacement axial piston AA10VO 45OFR 1/50L PSC 11NOO-50420 3 litres/min 0.7 UK gal/min 99 litres/min 21.8 UK gal/min 3 litres/min 0.7 UK gal/min

0.8 US gal/min 26.1 US gal/min 0.8 US gal/min

Secondary Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure Loader Valve Type

Rexroth, stacked directional control, model MP-22.

Services Operated — Spool 1 (LV1) — Spool 2 (LV2) — Spool 3 (LV3) (optional) — Spool 4 (LV4) (optional)

Loader arms Shovel Auxiliary (Quickhitch) Auxiliary (Clam)

Relief Valve Operating Pressures

bar

kgf/cm2

lbf/in2

245 - 255 27 155 - 165 25

250 - 260 27.5 158 - 168 25.5

3552 - 3697 391.5 2247 - 2392 362.5

345 80 225 248 125 27 - 35 80 175 190 25

352 81.6 230 253 127 27.5 - 35.6 81.6 178.5 193.8 25.5

4985 1160 3262 3596 1813 391.5 - 508 1160 2537.5 2755 362.5 (Secondary pump remains at standby up to 1150-1250 rev/min)

By-pass Pressures Filter Oil Cooler

bar 1.5 3.0

kgf/cm2 1.53 3.06

lbf/in2 22 44

Capacities Hydraulic tank

Litres 181

UK gal 39.8

US gal 47.9

System control pressure (main pump relief valve) Standby pressure (main pump relief valve) System pressure (secondary pump return valve) Standby pressure (secondary pump) Auxiliary Relief Valves (A.R.V.) — Lift ram, head side — Shovel ram, head side (1st stage)† — Shovel ram, head side (2nd stage) * — Shovel ram, rod side (HT) * — Shovel ram, rod side (ZX) — Servo Brake (non-adjustable) Steer relief pressure (at ram) Steer relief pressure (at pump) Idle control pressure † Not fitted on Z-bar machines

Rams

Shovel Ram Lift Ram Lift Ram (446) Steer Ram

Bore mm 110 130 140 80

in 4.3 5.1 5.5 3.1

Rod Dia. mm in 60 2.4 70 2.8 75 2.9 50 2.0

Stroke mm in 1056 41.6 814 32.0 814 32.0 312 12.3

Filter Filtration Size By pass Setting 9804/1103

10 Micron 1.5 bar

50 - 05 - 02/15

4160 - E/1-2.5

Issue 2

CONTENTS

Wheeled Loaders

50 - 05 - 02/16

Smoothshift Machines Data - Hydraulics (continued) 426 Machines from serial number 532100 436 Machines from serial number 533692 Pump Type Ref

Rexroth. Tandem variable displacement axial piston A20VO60 DFR1/10R-NSD24K01-S1296

Pump 1 Standby flow Full flow at 2200 rev/min Flow at max. pressure (220 bar)

litres/min 5 132 5

UK gal/min 1.1 29.0 1.1

US gal/min 1.3 34.8 1.3

Pump 2 Standby flow Full flow at 2200 rev/min Flow at max. pressure (160 bar)

5 132 5

1.1 29.0 1.1

1.3 34.8 1.3

Loader Valve Type

Rexroth, stacked directional control, model MP-22.

Services Operated — Spool 1 (SV) — Spool 2 (LV1) — Spool 3 (LV2) — Spool 4 (LV3) — Spool 5 (LV4)

Priority Steer Loader arms Shovel Auxiliary (Quickhitch) Auxiliary (Clam) (optional) bar

kgf/cm2

lbf/in2

27 245 - 255

27.5 250 - 260

391.5 3552 - 3697

25 155 - 165

25.5 158 - 168

362.5 2247 - 2394

Auxiliary Relief Valves (A.R.V.) — Lift ram, head side — HT Shovel ram, head side — ZX Shovel ram, head side — Shovel ram, rod side — Servo Brake (non-adjustable) Steer relief pressure (at ram) Steer relief pressure (at pump) Idle control pressure

345 125 125 260 27-35 80 175 190 25

352 127 127 265 27.5-35.6 81.6 178.5 193.8 25.5

4985 1812 1812 3770 391.5-508 1160 3262 2755 362.5)

By-pass Pressures Filter Oil Cooler

bar 1.5 3.0

kgf/cm2 1.53 3.06

lbf/in2 22 44

Capacities Hydraulic tank Hydraulic Tank (446)

Litres 181 173

UK gal 39.8 38.0

US gal 47.9 45.8

Relief Valve Operating Pressures Pump 1 Standby pressure (pump compensator valve) System control pressure (pump relief valve) Pump 2 Standby pressure (pump compensator valve) System control pressure (pump relief valve)

9804/1103

50 - 05 - 02/16

4160 - 3/1-3.1

Issue 1*

CONTENTS

Wheeled Loaders

50 - 05 - 02/16A

Smoothshift Machines Data - Hydraulics (continued) 426 Machines from serial number 532100 436 Machines from serial number 533692 Rams

Shovel Ram (HT 426) Shovel Ram (HT 436) Shovel Ram (ZX 426) Shovel Ram (ZX 436, 446)

Bore mm in 100 3.9 110 4.3 130 5.1 160 6.3

Rod Dia. mm in 60 2.4 65 2.6 70 2.8 80 3.1

Stroke mm in 1056 41.6 1056 41.6 575 22.6 530 20.9

Lift Ram (426) Lift Ram (436) Lift Ram (446)

130 5.1 130 5.1 140 6.3

70 70 75

2.8 2.8 3.1

814 814 744

32.0 32.0 29.3

Steer Ram

80

50

2.0

312

12.3

3.1

Filter Filtration Size By pass Setting Suction Strainer Size

9804/1103

10 Micron 1.5 bar 140 Micron

50 - 05 - 02/16A

4160 - 3/1- 4.1

Issue 1*

Wheeled Loaders

CONTENTS

50 - 05 - 03/1

406,407,408,409 Data - Transmission, Axles & Tyres Syncro Shuttle brake.

Combined torque converter, reverser and gearbox unit with integral parking

Weight (dry) Torque Converter Dia. Torque Multiplication at Stall Minimum Engine Speed at Converter Stall Gear Ratios

1st 2nd 3rd 4th

406/407 157 kg (345 lb) 279 mm (11 in) 2.45:1 D3.152 (CE build) 2160 rev/min

408/409 185 kg (408 lb) 279 mm (11 in) 2.83:1 1004-LR (AA build) 2040 rev/min

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 5.2-6.5 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

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

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 At 100 deg.C

1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min

Main Line Pressure (in neutral) 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

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

80-90 100-110

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

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

5.0-5.7 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

50 - 05 - 03/1

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 03/2

406,407,408,409 Data - Transmission, Axles & Tyres (continued) Drive Axles - Front & Rear 406/407 Machines with Hurth axle Type Weight (dry, less wheels; approx.) Overall Gear Ratio Crownwheel & Pinion Ratio Hub Reduction Mounting

Spiral bevel with epicyclic hub reduction 170 kg (375 lb) 21.857:1 5.143:1 4.25:1 Direct to front and rear frames

406/407 Machines with JCB axle Type Weight (dry, less wheels; approx.) Overall Gear Ratio Crownwheel & Pinion Ratio Hub Reduction Mounting

PD 40 - Spiral bevel with epicyclic hub reduction 195 kg (430 lb) 21.82:1 3.636:1 6:1 Direct to front and rear frames

408/409 Machines Type Weight (dry, less wheels; approx.) Overall Gear Ratio Crownwheel & Pinion Ratio Hub Reduction Mounting

PD55 Rigid 280 kg (618 lb) 20.925:1 3.875:1 5.4:1 Direct to front and rear frames

Tyre Sizes and Pressures 406/407 Industrial

Front Axle bar

lbf/in2

Rear Axle bar

lbf/in2

12.5 x 18MPT x 10ply Continental

2.2

32.0

2.2

32.0

14.5 x 20MPT x 10ply Continental

2.8

45.0

2.0

29.0

405/70 R20 XM27 1 Star Michelin

2.5

36.5

1.6

23.0

406/407 Farm

Front Axle bar

lbf/in2

Rear Axle bar

lbf/in2

12.5/80 x 18 x 10ply Continental

2.2

32.0

2.2

32.0

12.5/80 x 18 x 10ply Goodyear

2.2

32.0

2.2

32.0

335/80 R18 XM27 1 Star Michelin

2.5

36.5

1.6

23.0

9804/1103

50 - 05 - 03/2

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 03/3

406,407,408,409 Data - Transmission, Axles & Tyres (continued) Tyre Sizes and Pressures (cont’d) 408/409 Industrial

Front Axle bar

lbf/in2

Rear Axle bar

lbf/in2

12.5 x 20MPT x 10ply Goodyear

2.2

32.0

1.5

21.8

14.5 x 20MPT x 10ply Continental

2.8

40.0

1.5

21.8

408/409 Farm

Front Axle bar

lbf/in2

Rear Axle bar

lbf/in2

12.5/80 x 20 x 10ply Continental

2.5

36.3

1.5

21.8

12.5/80 x 18 x 10ply Goodyear

2.8

40.0

1.5

21.8

405/70 R20 XM27 1 Star Michelin

2.5

36.3

1.5

21.8

9804/1103

50 - 05 - 03/3

Issue 1

Wheeled Loaders

CONTENTS

50 - 05 - 03/4

411, 416 Data - Transmission, Axles & Tyres CAUTION: Before attempting to tow the machine, read carefully Towing Procedure in the Service Manual.

Torque Converter Dia. Torque Multiplication at Stall Gear Ratios

Charge pump flow Oil Temperature

411 280mm (11in.) 2.63:1

416 280mm (11in.) 2.45:1

Forward 1st 2nd 3rd 4th

Reverse 4.516:1 2.333:1 1.042:1 0.686:1

1st 4.516:1 2nd 2.333:1 3rd 1.042:1 Not Applicable

55 l/min (12.4 gal/min) at 2200 rev/min. 82 to 93°C (180 to 200°F

STALL TESTING Note: Switch off transmission dump (transmission disconnect); the switch on the cab roof panel should not be illuminated. Engage the parking brake and apply the foot brake. Select Forward Drive, keep brake pedal pushed down, push the accelerator pedal down fully and record the engine speed. To stall hydraulic system, operate shovel crowd to blow off Main Relief Valve. Maximum engine speed (rev/min) at: - Converter stall only - Combined converter and hydraulic system stall

411 2050 ±50 1500 ±50

416 2190 ±50 2140 ±50

416 Machines Only If combined converter and hydraulic system stall result is outside the figures given, before rejecting the torque converter, carry out the following procedure * Set the shovel head side A.R.V. (2nd Stage) pressure to 200 bar (204 kgf/cm 2 )(2090 lbf/in 2 ) see page E/36-3, Service Manual 9803/4150 Note: Shovel head side A.R.V. (2nd Stage) pressure is normally 220 bar (224 kgf/cm 2 )(3190 lbf/in 2 ) and should be returned to this setting when the procedure is complete. * Check pump maximum pressure is set at 220 (224 kgf/cm 2 )(3190 lbf/in 2 ) see page E/36-1, Service Manual 9803/4150 Operate the service, maximum engine speed (rev/min) should be 1950 to 2100. If the result is lower, the possible cause is low engine power. Drive Axle -Front and Rear Type slipdifferential Crownwheel & Pinion Ratio Hub Ratio Overall Axle Ratio

411 JCB Epicyclic (PD70), standard or limited slip differential

416 JCB Epicyclic (PD90), standard or limited

3.36:1 3.36:1 5.4:1 6.0:1 18.16:1

20.18:1

Tyre Sizes and Pressures 411

416

Front 15.5 - 25 15.5 R25

12 ply -

2.5 bar (36 lbf/in2) 2.25 bar (33 lbf/in2)

17.5 - 25 17.5 R25

12 ply -

2.5 bar (36 lbf/in2) 2.25 bar (33 lbf/in2)

15.5 - 25 15.5 R25

12 ply -

1.75 bar (25 lbf/in2) 1.75 bar (25 lbf/in2)

17.5 - 25 17.5 R25

12 ply -

1.75 bar (25 lbf/in2) 1.75 bar (25 lbf/in2)

Rear

9804/1103

20 - 05 - 03/4

Issue 3*

CONTENTS

* 411,

Wheeled Loaders

50 - 05 - 03/4A

416

Data - Transmission WG - 110 Pump Flow @ 2000 r.p.m.

501 (11.0 UK gal, 13.2 US gal)

System Pressure

16+2 bar (232+29 lb/in2)

Torque Converter - input pressure (max) - output pressure (max) - output temperature (max) - continuous - short duration

9 bar (130 lb/in2) 3.5 bar (51lb/in2) 100°C (212°F) 120°C (248°F)

Inductive Transmitters (engine, turbine central geartrain) Resistance @ 20°C (68°F) Temperature range Torque limit - securing bolts

1050+105 ohms -40°C (-40°F) - 150°C (302°F) 30 Nm (22lbf ft, 3 kgf m)

Speed Sensor Output Temperature range Working range Supply Voltage

-40°C (-40°F) - 150°C (302°F) 2 Hz - 5 kHz 24V

Proportional valves in control valve Resistance @ 20°C (68°F) current (mA) Pressure range

19+1.9 ohms 100 - 500 0.8 - 8.3 bar 11.6 - 120lb/in2)

Stall Data Engine Idle Engine max no-load Transmission Hydraulic Combined - transmission/hydraulic

780+20 r.p.m. 2360+20 r.p.m. 2220+20 r.p.m. 2330+20 r.p.m. 2040+20 r.p.m.

9804/1103

50 - 05 - 03/4A

4150 - F/1-3.1

Issue 1*

Wheeled Loaders

CONTENTS

50 - 05 - 03/5

426,436 Data - Transmission, Axles & Tyres Transmission CAUTION: Before attempting to tow the machine, read carefully Towing Procedure, in the Service Manual.

Type Torque Converter Dia. Torque Multiplication at Stall

Gear Ratios

426

436

ZF Powershift Type WG-150 300mm (11in.) 2.91:1

ZF Powershift Type WG-200 300mm (11in.) 2.66:1

Forward 1st 4.222:1 2nd 2.296:1 3rd 0.984:1 4th 0.629:1

Forward 1st 4.278:1 2nd 2.368:1 3rd 1.126:1 4th 0.648:1

Reverse 1st 4.222:1 2nd 2.296:1 3rd 0.984:1 Not Applicable

Reverse 1st 4.278:1 2nd 2.368:1 3rd 1.126:1 Not Applicable

Charge pump flow

25 l/min (5.6 gal/min) @ 1000 rev/min

35 l/min (7.9 gal/min) @ 1000 rev/min

Oil Temperature

82 to 93°C (180 to 200°F)

82 to 93°C (180 to 200°F)

Drive Axle - Front Type Crownwheel & Pinion Ratio 3.909:1 Hub Ratio 5.167:1 Overall Axle Ratio 20.197:1 Drive Axle - Rear Type Crownwheel & Pinion Ratio 3.909:1 Hub Ratio 5.167:1 Overall Axle Ratio 20.197:1 Tyre Sizes and Pressures 426

436

Standard Front 17.5 - 25 17.5 R25

16 ply -

2.75 bar (40 lbf/in2) 2 3.75 bar (54 lbf/in )

20.5 - 25 20.5 R25

12 ply -

2.75 bar (40 lbf/in2) 2.75 bar (40 lbf/in2)

Rear 17.5 - 25 17.5 R25

16 ply -

1.75 bar (25 lbf/in2) 2 1.75 bar (25 lbf/in )

20.5 - 25 20.5 R25

12 ply -

1.75 bar (25 lbf/in2) 1.75 bar (25 lbf/in2)

Front 20.5 - 25 20.5 R25

12 ply -

2.0 bar (29 lbf/in2) 2.0 bar (29 lbf/in2)

Rear 20.5 - 25 20.5 R25

12 ply -

1.75 bar (25 lbf/in2) 2 1.75 bar (25 lbf/in )

Optional

9804/1103

50 - 05 - 03/5

Issue 1

Wheeled Loaders

CONTENTS

50 - 05 - 03/6

412S, 414S Data - Transmission, Axles & Tyres

Gear Ratios 2nd 3rd 4th

412S 280mm (11in.) 2.63:1 Forward 1st 4.516:1 2.333:1 1.042:1 0.686:1

Charge pump flow - 412S Charge pump flow - 414S Oil Temperature

55 l/min (12.4 gal/min) at 2200 rev/min. 25 l/min (5.6 gal/min) at 1000 rev/min. 82 to 93°C (180 to 200°F)

Clutch Pressure

16 to 18 bar (232 to 261 lb/in 2 )

Torque Converter Dia. Torque Multiplication at Stall

414S/416S 300mm (12in.) 2.91:1 Reverse 1st 4.222:1 2nd 2.296:1 3rd 0.984:1 Not Applicable

STALL TESTING *Note: Switch off transmission dump at the cab roof panel (with this switch off, the transmission is disconnected and there is no engine braking; maximum power is thus used for tearing out etc.).Engage the parking brake and apply the foot brake. Select Forward Drive (4) keep brake pedal pushed down, push the accelerator pedal down fully and record the engine speed. To stall hydraulic system, operate shovel crowd to blow off Main Relief Valve. Maximum engine speed (rev/min) at:

412S

*414S/416S

- Converter stall only - Combined converter and hydraulic system stall

2000 - 2050 1800 - 1850

2100 - 2130 1910 - 1940

Drive Axle - Front and Rear

412S

414S

Type (Standard or limited slip differentials) Crownwheel & Pinion Ratio Hub Ratio Overall Axle Ratio

JCB Epicyclic (PD70) 3.36:1 5.4:1 18.16:1

JCB Epicyclic (PD90) 3.909:1 5.167:1 20.197:1

Tyre Sizes and Pressures 412S

*414S/416S

Front 15.5/80 - 24 10 ply 17.5LR24 19.5 LR24

2.25 bar (33 lbf/in2) - 2.5 bar (36 lbf/in2) - 2.0 bar (29 lbf/in2)

17.5 LR24 19.5 LR24

-

1.8 bar (26 lbf/in2) 1.4 bar (20 lbf/in2)

15.5/80 - 24 10 ply 1.75 bar (25 lbf/in2) 17.5LR24 - 1.75 bar (25 lbf/in2) 19.5 LR24 - 1.75 bar (25 lbf/in2)

17.5 LR24 19.5 LR24

-

1.5 bar (22 lbf/in2) 1.2 bar (17 lbf/in2)

Rear

9804/1103

50 - 05 - 03/6

4170 -F/1-1.1 4170 - F/1-2.1

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 03/6A

412S, 414S, 416S Data - Transmission WG - 110 (412S) Pump Flow@ 2000 r.p.m. System pressure

WG - 160 (414S/416S)

50 l (11.0 UK gal, 13.2 US gal) 80 l (17.6 UK gal, 21 US gal) 412S/414S/416S 16+2 bar (232+29lb/in2)

Torque converter - input pressure (max) -output pressure (max) -output temperature (max) -continuous -short duration

9 bar (130 lb/in2) 3.5 bar (51 lb/in2) 100°C (212°F) 120°C (248°F)

Inductive transmitters (engine, turbine, central geartrain) Resistance @ 20°C (68°F) Temperature range Torque limit - securing bolts

1050 ±105 ohms -40°C (-40°F) - 150°C (302°F) 30Nm (22lbf ft, 3 kgf m)

Speed sensor output Temperature range Working range Supply voltage

-40°C (-40°F) - 150°C (302°F) 2Hz - 5kHz 24V

Proportional valves in control valve Resistance @ 20°C (68°F) Current (mA) 100 - 500 Pressure range

19 ±1.9 ohms. 0.8 - 8.3 bar (11.6 - 120lb/in2)

Stall data Engine idle Engine max no-load Transmission Hydraulic Combined - transmission/hydraulic

9804/1103

412S

414S

416S

780 ±20 r.p.m. 2360±20 r.p.m. 2220±20 r.p.m. 2330±20 r.p.m. 2040±20 r.p.m.

780 ±10 r.p.m. 2300±20 r.p.m. 2100±20 r.p.m. 2270±20 r.p.m. 1900±20 r.p.m.

780±20 r.p.m. 2320±20 r.p.m. 2140±20 r.p.m. 2310±20 r.p.m. 2120±20 r.p.m.

50 - 05 - 03/6A

4170 - F/1-3.1

Issue 1

CONTENTS

*

Wheeled Loaders

50 - 05 - 03/7

407B ZX, 408B ZX, 409B ZX, 411B ZX Data - Transmission, Axles & Tyres 407B ZX , 408B ZX , 409B ZX

410B ZX, 411B ZX

4.375:1 3.67:1 16:04:1

3:1 5.4:1 16.2:1

Axial piston, variable displacement. † 55 cc/rev †† 56 cc/rev

75 cc/rev

Bent axis † 110 cc/rev †† 107 cc/rev

161 cc/rev

Axles Crownwheel & Pinion Ratio Hub Ratio Overall Axle Ratio Transmission Pump Type Displacement

Transmission Motor Type Displacement

Transfer Box Type Gear Ratio

Single-speed, directly driving rear axle and driving front axle via propshaft 2.217:1 2.217:1

Tyre Sizes 407B ZX 408B ZX 409B ZX 410B ZX 411B ZX

12.5 x 18 12.5 x 20 14.5 x 20 405/70 R24 405/80 R25

† 407B ZX, 408B ZX, 409B ZX, to S/N. 757399. †† 407B ZX, 408B ZX, 409B ZX, S/N. 757400 on.

9804/1103

50 - 05 - 03/7

4210 - F/1-1.4

Issue 3*

CONTENTS

Wheeled Loaders

50 - 05 - 03/8

456B Data - Transmission Axles (Available with Standard or Limited Slip Differential) Drive Axle - Front Type Crownwheel & Pinion Ratio Hub Ratio Overall Axle Ratio

Drive Axle - Rear Graziano 10/908800 (S) 10/909000 (LS) 4.77:1 5.16:1 24.65:1

Type Crownwheel & Pinion Ratio Hub Ratio Overall Axle Ratio

Graziano 10/908900 (S) 10/909100 (LS) 4.77:1 5.16:1 24.65:1

Note: Front and rear axles can have Standard Differential (S) or Limited Slip Differential (LS). Tyre Sizes and Pressures Standard 23.5 R25 XTLA.TL Optional 23.5 R25 XHA.TL Maximum inflation pressure 3.5 bar

Transmission Type Torque Converter Dia. Torque Multiplication at Stall

Gear Ratios

ZF Powershift Type 4WG-200 300mm (11 in) 2.55:1 Forward 1st 4.278:1 2nd 2.368:1 3rd 1.126:1 4th 0.648:1

Reverse 1st 4.278:1 2nd 2.368:1 3rd 1.126:1 Not Applicable

Charge pump flow

35 l/min (7.9 gal/min) @ 1000 rev/min

Oil Temperature

82 to 93°C (180 to 200°F)

Stall Testing Note: Switch off transmission dump (transmission disconnect); the switch on the cab roof panel should not be illuminated. Engage the parking brake and apply the foot brake. Select Forward Drive, keep brake pedal pushed down, push the accelerator pedal down fully and record the engine speed. To stall hydraulic system, operate shovel crowd to blow off Main Relief Valve. Maximum engine speed (rev/min) at: - Converter stall only - Combined converter and hydraulic system stall

9804/1103

2165 - 2115 2130 - 2080

50 - 05 - 03/8

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 03/9

TM200, TM270 Data - Transmission TM200 Front and Rear Axles 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. 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

PD55 Rigid pad mount 280 kg (618 lb) approx. 3 friction plate, 4 counter plate (each half shaft) Yoke 5.4:1 16.2:1 3.0:1 33 13

TM270 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.

Front Axle 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

3 piece, JCB spiral bevel input with epicyclic hub reduction, and inboard braking PD70 Rigid pad mount 386 kg (851 lb) approx. 5 friction plate, 6 counter plate (each half shaft) Yoke 5.4:1 13.7:1 2.538:1 33 13

Rear Axle Type Designation Installation Weight (dry and without wheels) 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. PD70 Rigid pad mount 386 kg (851 lb) approx. Yoke 5.4:1 13.7:1 2.538:1 33 13

50 - 05 - 03/9

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 03/10

TM200, TM270 Data - Transmission (continued) Tyre Pressures Note : If the tyres fitted to your machine are not listed, then contact JCB for advice, DO NOT guess tyre pressures.

TM200 Item

Size x Ply

Type

IND

Make

Front Pressure

Rear Pressure

bar

lbf/in2

bar

lbf/in2

CONTINENTAL

2.8

41

1.5

22

1

14.5 x 20 x 10PR

2

14.5 x 20 x 10PR

CONTINENTAL

2.8

41

1.5

22

3

405/70 R20

MICHELIN

2.5

36

1.5

22

4

425/75 R20

MICHELIN

2.8

41

1.5

22

5

9.00 R20

MICHELIN

2.8

41

1.5

22

6

15.5 x 24

GOODYEAR

3.5

51

2.0

29

7

17.5 x 24

XM27

MICHELIN

3.5

51

2.0

29

8

17.5LR x 24

TRAC

GOODYEAR

3.5

51

2.0

29

TM270

9804/1103

50 - 05 - 03/10

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 03/11

TM200, TM270 Data - Transmission (continued) Syncro Shuttle Description Weight (dry) Gear Ratios 1st 2nd 3rd 4th Torque Converter Torque Converter Dia. Torque Converter Identification Torque Multiplication at Stall Torque Converter Colour Coded Dots

Combined torque converter, reverser, and gearbox unit with integral parking brake. 157 kg (346 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

Converter Pressures (in neutral) Converter In at 50 °C 1000 rev/min 2000 rev/min Converter In at 100 °C 1000 rev/min 2000 rev/min Converter Out at 50 °C 1000 rev/min 2000 rev/min Converter Out at 100 °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

lbf/in2 35 - 50 75 - 95 20 - 30 75 - 85 15 - 25 29 max 4.0 - 8.0 15 - 25 95

Lubrication Pressures (in neutral) At 50 °C 1000 rev/min 2000 rev/min At 100 °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 °C

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

At 100 °C

Clutch Pressures

1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min

All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (lbf/in2)

Flow Rates (in neutral) Cooler at 50 °C Cooler at 100 °C Pump at 50 °C

1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min

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

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

50 - 05 - 03/11

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 03/12

TM200, TM270 Data - Transmission (continued) Powershift Description

Weight (dry) Gear Ratios 1st 2nd 3rd 4th Torque Converter Torque Converter Dia. Torque Converter Identification Torque Multiplication at Stall Torque Converter Colour Coded Dots

Full electro-hydraulic transmission unit with input, reverse, layshaft and mainshaft clutch packs. Torque converter and parking brake integral. 220 kg (484 lb) 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 1.00:1 310 mm (12.2 in) 12.2 - D 12.2 - P 2.82:1 2.54:1 2 Purple 2 Orange 1 Yellow 1 Yellow

Converter Pressures (in neutral) Converter In at 50 °C 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

Converter Out at 50 °C

1.9 - 2.3 2.3 - 2.7

1.9 - 2.3 2.3 - 2.7

27 - 33 33 - 39

Converter Inlet Relief Valve Pressure (max.)

6.5

6.7

95

Lubrication Pressures (in neutral) At 50 °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 °C

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

At 100 °C Clutch Pressures

Flow Rates (in neutral) Cooler at 50 °C Pump at 50 °C

1000 rev/min 2000 rev/min

1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min

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

50 - 05 - 03/12

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 03/13

TM200, TM270 Data - Transmission (continued) Transfer Gearbox Type Installation Weight (dry) Ratio Drop Dimension Oil Type Oil Capacity Nominal Rating Maximum Input Speed Input and Output Drive

9804/1103

ITL helical gears 3 bolt mounting 67 kg (147 lb) 1.1 (Permanently engaged) 300 mm Mobil HD90 1 litre 56.7 kW (76 bhp) 3000 rpm 1480 Half Yoke

50 - 05 - 03/13

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 03/14

426B, 436B, 446B Data - Transmission Drive Axle - Front Type Crownwheel & Pinion Ratio Hub Ratio Overall Axle Ratio

Drive Axle - Rear Type Crownwheel & Pinion Ratio Hub Ratio Overall Axle Ratio

3.909:1 5.167:1 20.197:1

Tyre Sizes and Pressures * 426 (to Ser. No 531762)

3.909:1 5.167:1 20.197:1

436, 446 (See Note $)

Standard Front 17.5 - 25 17.5 R25

16 ply -

2.75 bar (40 lbf/in2) 3.75 bar (54 lbf/in2)

20.5 - 25 20.5 R25 555/70 R25

12 ply -

2.75 bar (40 lbf/in2) 2.75 bar (40 lbf/in2) 2.00 bar (29lbf/in2)

Rear 17.5 - 25 17.5 R25

16 ply -

1.75 bar (25 lbf/in2) 1.75 bar (25 lbf/in2)

20.5 - 25 20.5 R25 * 555/70 R25

12 ply -

1.75 bar (25 lbf/in2) 1.75 bar (25 lbf/in2) 2.00 bar (29lbf/in2)

Optional

*

Front 20.5 - 25 20.5 R25

12 ply 2.0 bar (29 lbf/in2) - 2.0 bar (29 lbf/in2)

Rear 20.5 - 25 20.5 R25

12 ply 1.75 bar (25 lbf/in2) - 1.75 bar (25 lbf/in2)

Note $: Also 426 (USA machines) built after November 1998. 426 From Serial No. 532100

FRONT

REAR

Model

Size

Ply

Bar

lbf/in2

Bar

lbf/in2

426

17.5 - 25

16

2.75

40

1.75

25

426

17.5R25

-

3.75

55

1.75

25

426

20.5 - 25

12

2.50

36

1.75

25

426

20.5 R25

-

2.50

36

1.75

25

426

555/70R25

-

3.25

47

1.75

25

Note: If the tyres fitted to your machine are not listed, then contact your JCB Distrubutor for advice, DO NOT guess tyre pressures.

9804/1103

50 - 05 - 03/14

4160 - F/1-1.5

Issue 3*

CONTENTS

Wheeled Loaders

50 - 05 - 03/15

426B, 436B, 446B Data - Transmission (continued) Transmission * Model Torque Converter Dia. Torque Multiplication at Stall

Gear Ratios

Oil Temperature

Model Torque Converter Dia. Torque Multiplication at Stall

Gear Ratios

Oil Temperature

426

436

446

WG-150 300mm (11in.)

WG-200 300mm (11in.)

WG-200 340 (13in.)

2.91:1

2.66:1

2.879:1

Forward 1st 4.222:1 2nd 2.296:1 3rd 0.984:1 4th 0.629:1

Reverse 1st 4.222:1 2nd 2.296:1 3rd 0.984:1 Not Applicable

Forward 1st 4.278:1 2nd 2.368:1 3rd 1.126:1 4th 0.648:1

Reverse 1st 4.278:1 2nd 2.368:1 3rd 1.126:1 Not Applicable

82 to 93°C (180 to 200°F)

82 to 93°C (180 to 200°F)

426 (From S/N 532100)

436 (From S/N. 533692)

WG-160 300mm (11in)

WG-190 340mm (13in.)

2.549:1

2.873:1

Forward 1st 4.012:1 2nd 2.024:1 3rd 1.088:1 4th 0.619:1

Reverse 3.424:1 1.919:1 1.031:1 Not Applicable

82 to 93° C (180 to 200°F)

Forward 1st 3.745:1 2nd 2.089:1 3rd 1.072:1 4th 0.636:1

Forward 1st 4.278:1 2nd 2.368:1 3rd 1.126:1 4th 0.648:1

Reverse 1st 4.278:1 2nd 2.368:1 3rd 1.126:1 Not Applicable

82 to 93°C (180 to 200°F)

Reverse 1st 3.745:1 2nd 2.089:1 3rd 1.072:1 Not Applicable

82 to 93°C (180 to 200°F)

Stall Testing Note: Switch off transmission dump (transmission disconnect); the switch on the cab roof panel should not be illuminated. Engage the parking brake and apply the foot brake. Select Forward Drive, keep brake pedal pushed down, push the accelerator pedal down fully and record the engine speed.

Maximum engine speed (rev/min) at: - Converter stall only

9804/1103

426

436

446

2290 - 2240

2165 - 2115

2184

426 (From S/N 532100)

436 (From S/N. 533692)

2207

2146

50 - 05 - 03/15

4160-F/1-2.2

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 03/16

426B, 436B, 446B Technical Data WG - 160 (426)

WG - 190 (436)

Pump Flow @ 2000 r.p.m.

80 I (17.6 UK gal, US gal)

105 I (23 UK gal, 28 US gal)

Ststem pressure

16+2 bar (232+29lb/in2)

16+2 bar (232+29lb/in2)

9 bar (130 lb/in2) 3.5 bar (51 lb/in2)

9 bar (130 lb/in2) 3.5 bar (51 lb/in2)

100°C (212°F) 120°C (248°F)

100°C (212°F) 120°C (248°F)

Torque converter - input pressure (max) - output pressure (max) - output pressure (max) - continuous - short duration

Inductive transmitters (engine, turbine, central geartrain) Resistance @ 20°C (68°F) 1050 ± 105 ohms Temperature range -40°C (-40°F) - 150°C (302°F) Torque limit - securing bolts 30Nm (22lbf ft, 3 kgf m)

1050 ± 105 ohms -40°C (-40°F) - 150°C (302°F) 30Nm (22lbf ft, 3 kf m)

Speed sensor output Temperature range Working Range Supply voltage

-40C (-40°F) - 150°C (302°F) 2Hz - 5kHz 24V

-40°C (-40°F) - 150C (302°F) 2Hz - 5kHz 24V

Proportional valves in control valve Resistance @ 20C (68F) Current (mA) Pressure range

19 ± 1.9 ohms. 100 - 500 0.8 - 8.3 bar (11.6 - 120lb/in2)

19 ± 1.9 ohms. 100 - 500 0.8 - 8.3 bar (11.6 - 120lb/in2)

Stall data Engine idle Engine max no-load Transmission Hydraulic Combined - transmission/hydraulic

780±20 r.p.m. 2340±20 r.p.m. 2200 r.p.m. 2330 r.p.m. 2180 r.p.m.

850±10 r.p.m. 2340±20 r.p.m. 200 r.p.m. 2330 r.p.m. 2180 r.p.m.

9804/1103

50 - 05 - 03/16

4160 - F/1-3.1

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 05/1

406,407,408,409 Data - Brakes 406 Machines with Hurth Axles Service Brake Type Actuation Location Friction Plates Outside Dia. Inside Dia. Nominal Facing Area/Plate

Oil-immersed Multi-plate Disc Hydraulic Half shaft mounted within intermediate axle housings 5 per brake (ie) 10 per axle 155 mm (6.10 in) 115 mm (4.53 in) 0.017m2 (26.25 in2)

Master Cylinder Type Piston Dia.

Girling CV single 25.4 mm (1 in)

Parking Brake Type Disc Dia.

Manually Adjusted Caliper, cable operated, acting on disc at transmission output 279.4 mm (11.0 in)

Machines with JCB Axles Service Brake Type Actuation Location Friction Plates Outside Dia. Inside Dia. Nominal Facing Area/Plate

Oil-immersed Multi-plate Disc Hydraulic Outboard - Axle Hub 3 per brake (ie) 6 per axle 220 mm (8.66 in) 180 mm (7.09 in) 0.025 m2 (38.75 in2)

Master Cylinder Type Piston Dia.

Frenos Iruna Single Circuit 31.75 mm (1.25 in)

Parking Brake Type Disc Dia.

9804/1103

Manually Adjusted Caliper, cable operated, acting on disc at transmission output 279.4 mm (11.0 in)

50 - 05 - 05/1

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 05/2

411, 416 Data - Brakes 411 Service Brakes Type Actuation Location

Oil-Immersed Multi-Plate Disc Actuation Hydraulic, Vacuum Servo Assisted Front and Rear Axle (2 Brake Packs each axle)

Master Cylinder Type Stroke Bore

Frenos Iruna Dual Diaphragm 39 mm (1.5 in) 38.1 mm (1.5 in)

Parking Brake Type Location

Manually Adjusted Disc, cable operated Front face of transmission

416 Service Brakes Type Actuation Location

Oil-Immersed Multi-Plate Disc Actuation Dual Circuit, Full Hydraulic with compact valve and pressure accumulators Front and Rear Axle (2 Brake Packs each axle)

Brake Valve Type Rexroth Compact Type LT13 Parking Brake Type Location

9804/1103

Manually Adjusted Disc, cable operated Front face of transmission

50 - 05 - 05/2

Issue 3*

Wheeled Loaders

CONTENTS

50 - 05- 05/3

426,436 Data - Brakes Service Brakes Type Actuation Location

Oil-Immersed Multi-Plate Disc Actuation Dual Circuit, Full Hydraulic with compact valve and pressure accumulators Front and Rear Axle (4 plates per hub)

Accumulator Capacity (per circuit) Pre-charge Charge Valve - cut in - cut out

0.75 litre 57 bar

1.3 pint 826 lbf/in2

164 bar 200 bar

2378 lbf/in2 2900 lbf/in2

Parking Brake Type Location

9804/1103

Manually Adjusted Disc, cable operated Front face of transmission

50 - 05 - 05/3

Issue 1

CONTENTS

* 412S,

Wheeled Loaders

50 - 05 - 05/4

414S, 416S

Data - Brakes Service Brakes Type Actuation Location

Oil-Immersed Multi-Plate Disc Actuation Hydraulic Front and Rear Axle (2 Brake Packs each axle)

Brake Valve Type Piston Diameter (each) Piston Area (each)

Ultra Hydraulics Modulating Valve 25.4 mm (1 in) 507 mm 2 (0.79 in 2 )

Controlled Pressure to Brake Piston

50 bar (725 lbf/in 2 )

Charge Valve Type

Ultra Hydraulics Accumulator Charge Valve

Cut-in Pressure Cut-out Pressure

412S to Ser. No. 535112

412S from Ser. No. 535113 and 414S

160 bar (2320 lbf/in 2 ) 200 bar (2900 lbf/in 2 )

90 bar (1305 lbf/in 2 ) 110 bar (1595 lbf/in 2 )

Parking Brake Type Location

9804/1103

Manually Adjusted Disc, cable operated Front face of transmission

50 - 05 - 05/4

4170 - G/1-1.3

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 05/5

407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX Data - Brakes All except 411B ZX Service Brake Type Actuation Location Disc dia.

Stilfreni Caliper 2/60 Hydraulic Attached to transfer gearbox 280 mm (11 in)

Parking Brake Type Disc dia. Location Disc dia. *

Stilfreni Caliper 2/60 EOPM Cable 280 mm (11in) 280 mm (11 in)

411B ZX only Service Brake Type Actuation Location Friction Plates Outside Diameter Inside Diameter Nominal Facing Area per Plate

JCB Oil-immersed Multi-Plate Disc Hydraulic Front and Rear Axle Hubs 2 per brake (i.e.) 4 per Axle 220 mm (8.66 in) 180 mm (7.09 in) 0.025 m2 (38.75 in2)

Parking Brake Type Disc dia.

9804/1103

Manually Adjusted Calliper, cable operated, mounted on transmission output 280 mm (11 in.)

50 - 05 - 05/5

4210 - G/1-1.3

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 05/6

456B Data - Brakes System Type

Rexroth Full Hydraulic with Compact valve and pressure accumulators. These operating on integral axle mounted, oil immersed service brakes and a single transmission parking brake. Hydraulic supply is from a main, engine driven pump.

Pump

See Data - Hydraulic

Control Valve Type

Rexroth Compact.

Pressure Regulator Setting Cut-in Cut-out

150 bar (2175 lbf/in2) 125 bar (1812.5 lbf/in2)

Service Brake Operating Pressure

80 bar (1160 lbf/in2)

Parking Brake Operating Pressure

80 bar (1160 lbf/in2)

Pressure Switch Operating Pressure Low pressure warning on Parking brake warning off Stop lamp on

105 bar (1522.5 lbf/in2) 65 bar (942.5 lbf/in2) 3 bar (43.5 lbf/in2)

Accumulator Gas

Nitrogen.

Accumulator Gas Pressure

65 bar (942.5 lbf/in2)

Parking Brake

Hydraulically released, fail safe design, operating on the transmission propeller shaft. Operating warning system to indicate brake position with vehicle unattended.

9804/1103

50 - 05 - 05/6

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 05/7

TM200, TM270 Data - Brakes TM200 Service Brake Type Actuation Location Friction Plates Outside Diameter Inside Diameter Nominal Facing Area per Plate

JCB Oil-Immersed Multi-Plate Disc Hydraulic Front and Rear Axle Hubs 3 per brake (ie) 6 per Axle 220 mm (8.66 in) 180 mm (7.09 in) 0.025 m2 (38.75 in2)

Parking Brake Type Disc Diameter

Manually Adjusted Calliper, cable operated, mounted on transmission output 279.4 mm (11 in)

TM270 Service Brake Type Actuation Location Friction Plates Outside Diameter Inside Diameter Nominal Facing Area per Plate Hydraulic Piston Diameter

JCB Oil-Immersed Multi-Plate Disc Hydraulic Front Axle Centre Casing (2 brake packs) 3 per brake (ie) 6 per Axle 220 mm (8.66 in) 180 mm (7.09 in) 0.025 m2 (38.75 in2) 216 mm (8.5 in)

Parking Brake Type Disc Diameter

Manually Adjusted Calliper, cable operated, mounted on transmission output 279.4 mm (11 in)

Note: Because the service brakes are located in the axles, instructions for dismantling and assembly are shown in the Transmission Section.

9804/1103

50 - 05 - 05/7

Issue 1

Wheeled Loaders

CONTENTS

50 - 05 - 05/8

426B, 436B, 446B Data - Brakes Service Brakes Type Actuation Location

Oil-Immersed Multi-Plate Disc Actuation Dual Circuit, Full Hydraulic with compact valve and pressure accumulators Front and Rear Axle (4 plates per hub)

Accumulator Capacity (per circuit) Pre-charge Charge Valve - cut in - cut out

0.75 litre 57 bar

1.3 pint 826 lbf/in2

164 bar 200 bar

2378 lbf/in2 2900 lbf/in2

Parking Brake Type Location

9804/1103

Manually Adjusted Disc, cable operated Front face of transmission

50 - 05 - 05/8

Issue 1

Wheeled Loaders

CONTENTS

50 - 05 - 06/1

406,407,408,409 Data - Steering 406 Machines with Hurth Axles System Type Pump Control Unit Priority Valve

Full Power Hydrostatic (pivot steer) (see Section 2) Danfoss Orbitrol type OSPC 160 LS Danfoss type OLSB 80 with 4 bar (58 lbf/in2) standby pressure

Relief Valve Operating Pressure

175 bar

2535 lbf/in2

Shock Valve Operating Pressure

250 bar

3625 lbf/in2

Ram Dimensions

mm 60.0 245.5 30 40 50

in 2.36 9.67 1.18 -

- Bore - Stroke - Rod Dia. - Piston Head A/F - Cylinder Cap A/F

Machines with JCB Axles System Type Pump Control Unit Priority Valve

Full Power Hydrostatic (pivot steer) (see Section 2) Danfoss Orbitrol type OSPC 200 LS Danfoss Ref. HN 29CA 02

Relief Valve Operating Pressure

175 bar

2535 lbf/in2

Shock Valve Operating Pressure

240 bar

3480 lbf/in2

Ram Dimensions

mm 70.0 246 40 55 65

in 2.756 9.685 1.575 -

- Bore - Stroke - Rod Dia. - Piston Head A/F - Cylinder Cap A/F

9804/1103

50 - 05 - 06/1

Issue 1

Wheeled Loaders

CONTENTS

50 - 05 - 06/2

411,416,426,436 Data - Steering Pump Supply from hydraulic system. See section 50 - 0 5 - 02. Steering Valve Type

Eaton Steering Control Unit ABV. 411/416

426/436

Relief Valve Operating Pressures

bar

kgf/cm2

lbf/in2

bar

kgf/cm2

lbf/in2

Priority Shock valve(s)

175 235

178 240

2537 3407

176

180

2550

Ram Dimensions 411

Bore Rod Dia. Stroke

9804/1103

mm(in) 60(2.4) 30(1.2) 305(12.0)

416

426/436

mm(in) 70(2.8) 40(1.6) 312(12.3)

mm(in) 80(3.1) 50(2.0) 312(12.3)

50 - 05 - 06/2

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 06/3

412S, 414S, 416S Data - Steering Pump Supply from hydraulic system. Refer to page 50-05-02/7 Steering Valve Type Eaton

Steering Control Unit ABV. 412S

Relief Valve Operating Pressures

* Priority * Shock valves

414S/416S

bar

kgf/cm2

lbf/in2

bar

kgf/cm2

lbf/in2

175 235

178 240

2537 3407

220 272

224 277

3191 3945

Ram Dimensions

Bore Rod Dia. Stroke

9804/1103

412S mm 60 30 305

50 - 05 - 06/3

414S/416S mm 70 40 312

4170 - H/1-1.2

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 06/4

407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX Data - Steering 407B ZX, 408B ZX, 409B ZX

410B ZX, 411B ZX

See Data-Hydraulics OSPC 200 LS Integral with valve block bar kgf/cm2 lbf/in2 138 140.7 2001

See Data-Hydraulics 263-4339-002

Turns, Lock-to-Lock Left-to-right Right-to-left

5.75 4.75

5 5

Ram dimensions Bore Stroke Rod dia.

50 mm (2.0 in) 305 mm (12.0 in) 30 mm (1.2 in)

60 mm (2.4 in) 305 mm (12.0 in) 30 mm (1.2 in) two off

System Details Pump * Steer valve * Priority valve * Relief valve setting

* Steering Valve Type

9804/1103

bar 175

kgf/cm2 lbf/in2 178.5 2538

Load sensing (295 cc/rev)

50 - 05 - 06/4

4210 - H/1-1.4

Issue 3*

CONTENTS

Wheeled Loaders

50 - 05 - 06/5

456B Data - Steering Pump Supply from hydraulic system. See Data - Hydraulics. Steering Valve Type

Eaton Steering Control Unit ABV.

Relief Valve Operating Pressure

bar

kgf/cm2

lbf/in2

176

180

2550

Ram Dimensions Bore Rod Dia. Stroke

mm 90 50 312

in 3.5 2.0 12.3

General Description Steering is hydraulically controlled. Two rams, one either side of a centre pivot articulate the front chassis in the required direction. Hydraulic oil is delivered from the pump via a steering priority valve to the steering valve. When the steering is turned the steering valve is actuated and a pressure demand signal sent to the priority valve spool. The spool moves and directs pressurised oil from the pump to the steering valve and then the steering rams. Pressurised oil enters the ram cylinders (rod side first ram and head side second ram) and causes the rams to extend or retract to turn the machine in the required direction. A pressure relief valve is fitted to guard against shock steering loads. A gearbox driven emergency steer pump may be fitted which provides pressure for steering in the event of hydraulic pump or engine failure.

9804/1103

50 - 05 - 06/5

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 06/6

TM200, TM270 Data - Steering TM200 System Type Hydraulic Supply Control Unit Priority Valve

Full Power Hydrostatic (pivot steer) From Main Hydraulic Pump via Priority Valve Danfoss Orbitrol type OSPC 200 LS Danfoss Ref. HN 29CA 02

Relief Valve Operating Pressure

175 bar

2535 lbf/in2

Shock Valve Operating Pressure

240 bar

3480 lbf/in2

TM270 System Type Hydraulic Supply Control Unit

Full Power Hydrostatic (pivot steer) From Main Hydraulic Pump via Priority Valve Eaton Load Sensing Steer Valve

Relief Valve Operating Pressure

175 bar

2535 lbf/in2

Shock Valve Operating Pressure

235 bar

3408 lbf/in2

9804/1103

50 - 05 - 06/6

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 06/7

426B, 436B, 446B Data - Steering Pump Supply from hydraulic system. Steering Valve Type

Eaton Steering Control Unit ABV.

Relief Valve Operating Pressure

bar

kgf/cm2

lbf/in2

Shock valve

176

180

2550

Ram Dimensions Bore Rod Dia. Stroke

mm 80 50 312

in 3.1 2.0 12.3

General Description Steering is hydraulically controlled. Two rams, one either side of a centre pivot articulate the front chassis in the required direction. Hydraulic oil is delivered from the pump via a steering priority valve to the steering valve. When the steering is turned the steering valve is actuated and a pressure demand signal sent to the priority valve spool. The spool moves and directs pressurised oil from the pump to the steering valve and then the steering rams. Pressurised oil enters the ram cylinders (rod side first ram and head side second ram) and causes the rams to extend or retract to turn the machine in the required direction. A pressure relief valve is fitted to guard against shock steering loads. A gearbox driven emergency steer pump provides pressure for steering in the event of hydraulic pump or engine failure.

9804/1103

50 - 05 - 06/7

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 07/1

406,407 Data - Engine Type Number of cylinders Bore and Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance - Cold Oil Pressure (Hot) at maximum speed

Perkins D3.152 naturally aspirated 3 91.44 mm (3.60 in) x 127.0 mm (5.00 in) 2500 cm3 (152.7 in3) 18.5:1 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)

Fuel System Injection Pump Type Injection Pump Setting Codes

Maximum Governed Speed Maximum No-load Speed Idling Speed Injection Timing Static

Injectors - Working Pressure - Setting Pressure

C.A.V., D.P.A., mechanically governed Original: TW48E/800/2/2470 CAV/ISO: TW49L/800/2/2470 Perkins/ISO: 36960TW/2/2470 2250 rev/min 2470 rev/min 750 rev/min 20° BTDC (equivalent to 0.192in. displacement) Engine Angle 27° (checked at TDC compression) Fuel Pump Angle 37° 170 atm 185 atm

Cooling System Coolant Pressure Coolant Temperature (normal) Temperature Warning Light operates at

0.48 bar (7 lbf/in2) 80-85 deg C 98 deg C

For further details see engine manual, Publication No. 9806/0052

9804/1103

50 - 05 - 07/1

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 07/2

408,409 Data - Engine Model Type Number of cylinders Bore and Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance (hot or cold) - Inlet - Exhaust Max. Speed (No Load) Governed Speed Idling Speed

Perkins 1004 - 4LR2, naturally aspirated (AA) 4 100 mm (3.937 in) x 127 mm (5 in) 3990 cm3 (243.5 in3) 16.5 : 1 20 to 34 bar (290 to 493 lbf/in2) [max. variation between cylinders of 3.5 bar (50 lbf/in2)] 1, 3, 4, 2 0.20 mm (0.008 in) 0.45 mm (0.018 in) 2160 rev/min 2000 rev/min 820 rev/min

Fuel System Injection Pump Type Injection Pump Setting Code Governing Injection Timing Injection Setting Pressure Lift Pump Type

CAV DPA 2643C621/HM46L/850/7/2160 Mechanical 16° ± 2° BTDC 250 atm AC Diaphragm

Induction System Air Cleaner Type Max. Restriction (at which warning light operates).

2 stage, dry element 635 mm (25 in) H20

Lubrication System Oil Pump Type Oil Pressure (hot) at maximum speed.

Eccentric rotor 2.0 bar (30 lbf/in2) (minimum)

Cooling System Coolant Pressure Cooling Temperature (normal) Temperature Warning Light operates at

0.48 bar (7 lbf/in2) 80 to 85 deg C 98 deg C

For further details see engine manual, Publication No. 9806/0100

9804/1103

50 - 05 - 07/2

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 07/3

411 Data - Engine Type Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance - Cold or Hot - Inlet 0.20mm (0.008 in) - Exhaust 0.45mm (0.018 in) * Idling Speed * Maximum Governed Speed Maximum No-load Speed

Perkins 1004-4TLR 1000 Series, 4 cylinder, water cooled AB - Turbocharged (84 HP Gross - SAE J1349) 100mm (3.937 in) 127mm (5.000 in) 4 litres (243 in3) 16.5:1 20-30 bar (240-493 lbf/in2) 1,3,4,2

880 - 920 rev/min 2360 - 2400 rev/min 2420 rev/min

Fuel System Injection Pump Type Governing Injector Pump Setting Code Injector Timing Injector Setting Pressure

C.A.V. Mechanical GM 58L 1000/2/2420 19.5° BTDC 220 atm

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 2.07 bar (30 lbf/in2)

Cooling system Coolant Pressure Coolant Temperature (Normal) Temperature warning light operates at:

0.69 bar (10 lbf/in2) 80-85 °C (176-185 °F) 98°C (208°F)

For further engine details see Engine Manual Publication No. 9806/0100

9804/1103

50 - 05 - 07/3

Issue 2*

CONTENTS

*

Wheeled Loaders

50 - 05 - 07/4

416 Data - Engine Type

Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance - Cold or Hot - Inlet 0.20mm (0.008 in) - Exhaust 0.45mm (0.018 in) * Idling Speed * Maximum Governed Speed Maximum No-load Speed

Perkins 1004-4THR3 1000 Series, 4 cylinder, water cooled AB - Turbocharged (106 HP Gross - SAE J1349) 100mm (3.937 in) 127mm (5.000 in) 4 litres (243 in3) 16.5:1 20-30 bar (240-493 lbf/in2) 1,3,4,2

880-920 rev/min 2360-2400 rev/min 2420 rev/min

Fuel System Injection Pump Type Governing Injector Pump Setting Code Injector Timing Injector Setting Pressure

C.A.V. Mechanical T.B.A. 12¡ BTDC 250 atm

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 2.07 bar (30 lbf/in2)

Cooling system Coolant Pressure Coolant Temperature (Normal) Temperature warning light operates at:

0.69 bar (10 lbf/in2) 80-85 ¡C (176-185 ¡F) 98¡C (208¡F)

For further engine details see Engine Manual Publication No. 9806/0100

9804/1103

50 - 05 - 07/4

Issue 2*

CONTENTS

Wheeled Loaders

50 - 05 - 07/5

426,436 Data - Engine

Type Number of Cylinders Capacity Bore (nominal) Stroke Compression Ratio Power Output @ 1000mm barometric, 25°C Max Nett Torque Idling Speed Maximum Governed Speed Maximum No-load Speed

426

436

Perkins 1006-6T7 4 Stroke, direct injection 6 in-line vertical 6.0 litres (365 in3) 100mm (3.937 in) 127mm (5.000 in) 16:1

Perkins 1006-6T4 4 Stroke, direct injection 6 in-line vertical 6.0 litres (365 in3) 100mm (3.937 in) 127mm (5.000 in) 16:1

93kW ±5% @ 2200 rev/min 404.9Nm @ 2200 rev/min 750 rev/min 2200 rev/min 2420 rev/min

122kW ±5% @ 2200 rev/min 629.5Nm @ 2200 rev/min 750 rev/min 2200 rev/min 2420 rev/min

Lucas DPA rotary KK75L 1100/1/2420 18° BTDC 250 atm Mechanical Diaphragm 2641A070

Lucas DPA rotary RK90L1100/3/2310 17° BTDC 250 atm Mechanical Diaphragm 2641A070

2 stage, dry element 635mm (25 in H2O)

2 stage, dry element 635mm (25 in H2O)

2.07 bar (30 lbf/in2) Integral Plate Cooler 125°C (257°F)

2.07 bar (30 lbf/in2) Integral Plate Cooler 125°C (257°F)

0.7 bar (10 lbf/in2) 80-85 °C (176-185 °F) 103 °C (217.4 °F) 98°C (208°F)

0.7 bar (10 lbf/in2) 80-85 °C (176-185 °F) 103 °C (217.4 °F) 98°C (208°F)

Fuel System Injection Pump Type Injector Pump Setting Code Injector Timing Injector Setting Pressure Lift Pump Type Induction System Air Cleaner Type Maximum Air Cleaner Restriction Lubrication System Oil Pressure Oil Cooler Max. Oil Temperature Cooling system Coolant Pressure Coolant Temperature (Normal) Coolant Temperature (Max) Temperature warning light operates at:

For further engine details see Engine Manual Publication No. 9806/0100

9804/1103

50 - 05 - 07/5

Issue 1

CONTENTS

Wheeled Loaders

426

50 - 05 - 07/5A

from m/c no. 532500

Data - Engine Type Number of Cylinders Capacity Bore (nominal) Stroke Compression Ratio Power Output @ 1000 mm barometric, 25 °C Max Nett Torque Idling Speed Maximum Governed Speed Maximum No-load Speed

BTAA5.9 - C/50 18487 Tier 2 4 Stroke, direct injection 6 in-line vertical 6.0 litres (365 in3) 100mm (3.937 in) 127mm (5.000 in) 16:1 93kW ± 5% @ 2200 rev/min 404.9 Nm @ 2200 rev/min 750 rev/min 2200 rev/min 2420 rev/min

Fuel System Injection Pump Type Injector Pump Setting Code Injector Timing Injector Setting Pressure Lift Pump Type

Lucas DPA rotary KK75L 1100/1/2420 18° BTDC 250 atm Mechanical Diaphragm 2541A070

Induction System Air Cleaner Type Maximum Air Cleaner Restriction

2 stage, dry element 635mm (25 in H2O)

Lubrication System Oil Pressure Oil Cooler Max. Oil Temperature

2.07 bar (30 lbf/in2) Integral Plate Cooler 125 °C (257 °F)

Cooling system Coolant Pressure Coolant Temperature (Normal) Coolant Temperature (Max) Temperature warning light operates at:

0.7 bar (10 lbf/in2) 80-85 °C (176-185 °F) 103 °C (217.4 °F) 98°C (208°F)

For further engine details see Engine Manual Publication No. 9806/0100

9804/1103

50 - 05 - 07/5A

4160 - K/1-4/1

Issue 1*

CONTENTS

Wheeled Loaders

50 - 05 - 07/6

412S Data - Engine Type Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance - Cold or Hot - Inlet - Exhaust Idling Speed Maximum Governed Speed Maximum No-load Speed

Perkins 1004-4TLR 1000 Series, 4 cylinder, water cooled AB - Turbocharged (84 HP Gross - SAE J1349) 100mm (3.937 in) 127mm (5.000 in) 4 litres (243 in3) 16.5:1 20-30 bar (240-493 lbf/in2) 1,3,4,2 0.20mm (0.008 in) 0.45mm (0.018 in) 700-750 rev/min 2200 rev/min 2420 rev/min

Fuel System Injection Pump Type Governing Injector Pump Setting Code Injector Timing Injector Setting Pressure

C.A.V. Mechanical GM 58L 1000/2/2420 19.5° BTDC 220 atm

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 2.07 bar (30 lbf/in2)

Cooling system Coolant Pressure Coolant Temperature (Normal) Temperature warning light operates at:

0.69 bar (10 lbf/in2) 80-85 °C (176-185 °F) 98°C (208°F)

For further engine details see Engine Manual Publication No. 9806/0100.

9804/1103

50 - 05 - 07/6

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 07/7

414S Data - Engine Type Bore (nominal) Stroke Swept Volume Compression Ratio Power Output @ 1000 mm barometric, 25°C Max Nett Torque Idling Speed Maximum Governed Speed Maximum No-load Speed

Perkins 1006-6T7 1000 Series, 6 cylinder, water cooled 4 stroke, direct injection 100mm (3.937 in) 127mm (5.000 in) 6 litres (365 in3) 16:1 93 kW ±5% @ 2200 rev/min 404.9 Nm @ 2200 rev/min 750 rev/min 2200 rev/min 2420 rev/min

Fuel System Injection Pump Type Lift Pump Type Injector Pump Setting Code Engine Check Angle Pump Mark Angle Injector Setting Pressure

Stanadyne Mechanical diaphragm 2641A070 JL 325° 334.5° 250 atm

Induction System Air Cleaner Type Maximum Air Cleaner Restriction

2 stage, dry element 635mm (25 in H2O)

Lubrication System Oil Cooler Oil Pressure Max Oil Temp

Integral plate cooler 208 kNm2 125°C (257°F)

Cooling system Coolant Pressure Coolant Temperature (Normal) Temperature warning light operates at: Coolant Temperature (Max)

0.7 bar (10 lbf/in2) 80-85 °C (176-185 °F) 98°C (208°F) 103°C (217°F)

For further engine details see Engine Manual Publication No. 9806/0100.

9804/1103

50 - 05 - 07/7

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 07/7A

412S, 414S, 416S Data - Engine Type

New 1000 Series, 4 cylinder, water cooled, direct injection 412S AM50684 build

414S/416S YH50605 build

Bore (nominal)

100mm (3.937 in)

100mm (3.937 in)

Stroke

127mm (5.000 in)

127mm (5.000 in)

Cylinder Capacity

4 litres (243 in3)

4 litres (243 in3)

Gross Power Output at 2200 rev/min

85.3 kW (115 HP)

113.1 kW (151 HP)

Compression Ratio

17.25:1

17.25:1

Idling Speed

900 rev/min

800 rev/min

Rated Speed (Full Load)

2200 rev/min

2200 rev/min

Max. No-Load Speed

2310 rev/min

2400 rev/min

Max. Net Torque at 1400 rev/min

448.5 Nm (331 lbf ft)

620 Nm (457 lbf ft)

Injection Pump Type

C.A.V. Rotary Distributor

C.A.V. Rotary Distributor

Governing

Mechanical

Mechanical

ISO Setting Code

2644F404 FG/1/2350

2644K606 FH/1/2370

Injector Setting Pressure

250 atm

290 atm

Fuel System

Induction System Air Cleaner Type

2 stage, dry element

Maximum Air Cleaner Restriction

635 mm (25 in) H2O

Lubrication System Oil Pump Type

Eccentric rotor

Oil Pressure at maximum speed

2.8 bar (40 lbf/in2) (min)

Oil Temperature

125°C (52°F)(Continuous), 135°C (58°F) (Intermittent)

Oil Capacity

5000 cm3 (305 in3)(min), 6500 cm3 (396 in3) (max)

Cooling System Coolant Pressure

0.8 bar (11.6 lbf/in2)

Coolant Temperature (Normal)

80-90 °C (176-194 °F)

Capacity

15.5 litres (3.5 UK galls)

For further engine details see Engine Manual Publication No. 9806/2140

50 - 05 - 07/7A

4170 - K/1-3.1

Issue 1

CONTENTS

Wheeled Loaders

412S

50 - 05 - 07/7B

From m/c no. 535650 (RJ Build)

Data - Engine Type

1104C-44TA to Power Curve T2174 412S From Serial No. 535650 (RJ Build)

Bore (nominal)

105 mm (4.133 in)

Stroke

127 mm (5.000 in)

Cylinder Capacity

4.4 litres (268 in3)

Gross Power Output at 2200 rev/min

121 hp @ 2200 rev/min (90.23 kW)

Compression Ratio

19.3 : 1

Idling Speed

850 rev/min

Rated Speed (Full Load)

2200 rev/min

Max. No-Load Speed

2370 rev/min

Max. Net Torque at 1400 rev/min

434 Nm @ 1400 rev/min (320 lbf ft)

Fuel System Injection Pump Type

Delphi mechanical DP210, rotary

Governing

Mechanical

ISO Setting Code

Not Used

Injection Timing

N/A Dynamically timed only

Injector Setting Pressure

290 bar +8, -0 (286 +7, -0 atm)

Induction System Air Cleaner Type

2 stage, dry element

Maximum Air Cleaner Restriction

635 mm (25 in) H2O

Restriction Indicator

Vacuum switch on air cleaner inlet

Lubrication System Oil Pump Type

Concentric gear

Oil Pressure at maximum speed

300 KPa (45.5 lbf/in2)

Oil Temperature

Anything up to 125°C max, depending on load, speed and ambient conditions

Oil Capacity Without/With Filter

9.4 litre / 10.9 litre (2.1 UK gal / 2.4 UK gal)

Cooling System Coolant Pressure

95 KPa (13.8 lbf/in2)

Coolant Temperature (Normal)

82 °C - 110°C (179-203 °F)

Capacity

23 litres (5.5 UK gal)

50 - 05 - 07/7B

4170 - K/1-4.1

Issue 1*

CONTENTS

Wheeled Loaders

50 - 05 - 07/8

407B ZX, 408B ZX, 409B ZX, 410B ZX Data - Engine Type

1000 Series, 4 cylinder, water cooled, direct injection, naturally aspirated. 407B ZX & 408B ZX Perkins 1004-4LR2 409B ZX Perkins 1004-4HR 410B ZX Perkins 1004-4

Bore (nominal)

100mm (3.937 in)

Stroke

127mm (5.000 in)

Cylinder Capacity

4 litres (243 in3)

Power Output at 2000 rev/min

407B ZX & 408B ZX 409B ZX 410B ZX

Compression Ratio Idling Speed

16.5:1 407B ZX, 408B ZX, 409B ZX 410B ZX

Rated Speed (Full load) Maximum No-load Speed

47.4 kW (65 HP) 53 kW (71 HP) 59 kW (80 HP)

820 - 850 rev/min 700 - 750 rev/min 2000 rev/min

407B ZX, 408B ZX, 409B ZX 410B ZX

Maximum Net Torque at 1200 rev/min

2160 rev/min 2150 rev/min 4LR - 246.1 Nm (181.5 lbf ft), 4HR - 286.5 Nm (211.3 lbf ft)

Fuel System Tank Capacity

407B ZX, 408B ZX, 409B ZX 410B ZX

100 litres (22 UK Gal) 110 litres (24.2 UK Gal)

Injection Pump Type

C.A.V. Rotary Distributor

Governing

Mechanical

ISO Setting Code

407B ZX & 408B ZX 409B ZX & 410B ZX

DSA685 DSA626

Injector Timing

407B ZX & 408B ZX 409B ZX

16° ± 2° BTDC 16.5° ± 2° BTDC

Injector Setting Pressure

250 atm

Lift Pump

Engine mounted, mechanical Diaphragm

Induction System Air Cleaner Type

2 stage, dry element

Maximum Air Cleaner Restriction

635 mm (25 in) H2O

Lubrication System Oil Pump Type

Eccentric rotor

Oil Pressure at maximum speed

2.0 bar (30 lbf/in2) (min)

Oil Temperature (Intermittent)

125°C

Oil Capacity

5000 cm3 (305 in3)(min), 6500 cm3 (396 in3) (max)

(52°F)(Continuous),

135°C

(58°F)

Cooling system Coolant Pressure

0.8 bar (11.6 lbf/in2)

Coolant Temperature (Normal)

80-90 °C (176-194 °F)

Capacity

407B ZX, 408B ZX, 409B ZX 410B ZX

15.5 litres (3.5 UK galls) 18 litres (3.96 UK galls)

For further engine details see Engine Manual Publication No. 9806/0100 9804/1103

50 - 05 - 07/8

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 07/8A

411B ZX Data - Engine Type

Perkins TN440 (1004 - 4 TLR2) Build No. AH50613

Bore (nominal)

100 mm (3.937 in)

Stroke

127 mm (5.000 in)

Cylinder Capacity

4 litres (243 in3)

Power Output at 2200 rev/min

67.5 kW (90.5 HP)

Compression Ratio

16:1

Idling Speed

750 rev/min

High Idling Speed

2420 rev/min

Torque at 1200 rev/min

300 Nm (221.3 lbf ft)

Sump Oil Capacity

Max. 9.4 litres Min. 7.6 litres

Total Engine Capacity

Add 1.5 litres (includes filter)

9804/1103

50 - 05 - 07/8A

4210 - K/1-2.1

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 07/8B

407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX Data - Engine Type

New 1000 Series, 4 cylinder, water cooled, direct injection 407B ZX/408B ZX/409B ZX AS50693 build

410B ZX AS50675 build

411B ZX AQ50697 build

Bore (nominal)

103mm (4.055 in)

103mm (4.055 in)

100mm (3.937 in)

Stroke

127mm (5.000 in)

127mm (5.000 in)

127mm (5.000 in)

Cylinder Capacity

4.23 litres (258 in3)

4.23 litres (258 in3)

4 litres (243 in3)

Power Output at 2000 rev/min

57.5 kW (77 HP)

60 kW (80 HP)

68.5 kW (92 HP)

Compression Ratio

18.5:1

18.5:1

17.25:1

Idling Speed

820 - 850 rev/min

700 - 750 rev/min

750 rev/min

Rated Speed (Full Load)

2000 rev/min

2200 rev/min

2200 rev/min

Max. No-Load Speed

2150 rev/min

2420 rev/min

2420 rev/min

Max. Net Torque at 1200 rev/min

285 Nm (210 lbf ft)

285 Nm (210 lbf ft)

350 Nm (258 lbf ft)

Tank Capacity

100 litres (22 UK Gal)

100 litres (22 UK Gal)

100 litres (22 UK Gal)

Injection Pump Type

C.A.V. Rotary Distributor

C.A.V. Rotary Distributor

C.A.V. Rotary Distributor

Governing

Mechanical

Mechanical

Mechanical

ISO Setting Code

2644G525 YG/1/2180

2644G521 YG/1/2350

2644C707 FG/1/2180

Injector Timing

4° ± 2° BTDC

3° ± 2° BTDC

1° ± 2° BTDC

Injector Setting Pressure

250 atm

250 atm

250 atm

Air Cleaner Type

2 stage, dry element

2 stage, dry element

2 stage, dry element

Maximum Air Cleaner Restriction

635 mm (25 in) H2O

635 mm (25 in) H2O

635mm (25m) H2o

Oil Pump Type

Eccentric rotor

Eccentric rotor

Eccentric rotor

Oil Pressure (min) at maximum speed

2.1 bar (30 lbf/in2) (min)

2.1 bar (301bf/in2)

2.1 bar (301bf/in2)

Fuel System

Induction System

Lubrication System

Oil Temperature Oil Capacity

125°C (52°F)(Continuous), 135°C(58°F)(Intermittent) 3

3

3

3

5000 cm (305 in )(min), 6500 cm (396 in ) (max)

Cooling System (407-409B ZX) 2

2

2

Coolant Pressure

0.8 bar (11.6 lbf/in )

0.8 bar (11.6 lbf/in )

0.8 bar (11.6 lbf/in )

Coolant Temperature (Normal)

80-90 °C (176-194 °F)

80-90 °C (176-194 °F)

80-90 °C (176-194 °F)

Capacity

15.5 litres (3.5 UK galls)

15.5 litres (3.5 UK galls)

15.5 litres (3.5 UK galls)

For further engine details see Engine Manual Publication No. 9806/2140

9804/1103

50 - 05 - 07/8B

4210 - K/1-3.1 4210 - K/1-4.1

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 07/9

456B Data - Engine Type Model Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately) HP @ 2200 rev/min Fuel System Max. Speed (No Load) Injection Timing (static) Injector Opening Pressure Fuel Pump

Cummings C Series, 6 cylinder diesel, turbocharged, water cooled. C8.3-C205

1, 5, 3, 6, 2, 4

153 kW (205 bhp)

Bosch MW

Induction System Air Cleaner Type Electrical Alternator Starter Motor

Bosch 24 V 40 A Delco Remy 42MT Type 400

For further details, see engine service manual. 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

50 - 05 - 07/9

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 07/10

TM200, TM270 Data - Engine TM200 Type Engine Build List Number Bore (nominal) Stroke Swept Volume Compression Ratio Max variation in compression pressure between cylinders Injection Sequence Valve Clearance - Cold Oil Pressure (hot) at maximum speed Maximum Air Cleaner Restriction

Perkins 1000 Series 4 cylinder turbocharged Engine AB50541 - 71.5kw (96bhp) 100mm (3.937 in) 127mm (5.000 in) 4 litres (243 in3) 16.0:1 3.5 bar 1,3,4,2 - Inlet 0.20mm (0.008 in) - Exhaust 0.45mm (0.018 in) 2.6 bar (40 lbf/in2) 559mm (22 in H2O)

Injection System Details - Refer to Perkins Manual, publication number 9806/0100. Idling Speed Maximum Governed Speed Maximum No-load Speed (High Idle)

750 rev/min 2200 rev/min 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)

TM270 Type Engine Build List Number Bore (nominal) Stroke Swept Volume Compression Ratio Max variation in compression pressure between cylinders Injection Sequence Valve Clearance - Cold Oil Pressure (hot) at maximum speed Maximum Air Cleaner Restriction

Perkins 1000 Series 4 cylinder turbocharged Engine AB50630 - 79kw (106bhp) 100 mm (3.937 in) 127 mm (5.000 in) 4 litres (243 in3) 16.0:1 3.5 bar 1,3,4,2 - Inlet 0.20 mm (0.008 in) - Exhaust 0.45 mm (0.018 in) 2.6 bar (40 lbf/in2) 559 mm (22 in H2O)

Injection System Details - Refer to Perkins Manual, publication number 9806/0100. Idling Speed Maximum Governed Speed Maximum No-load Speed (High Idle)

750 rev/min 2200 rev/min 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)

9804/1103

50 - 05 - 07/10

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 07/10A

TM200, TM270 Data - Engine (continued) Type

New 1000 Series, 4 cylinder, water cooled, direct injection, turbo charged TM200 AK50753 build

TM270 AK50729 build

Bore (nominal)

100mm (3.937 in)

100mm (3.937 in)

Stroke

127mm (5.000 in)

127mm (5.000 in)

Cylinder Capacity

4.0 litres (243 in3)

4.0 litres (243 in3)

Power Output at 2200 rev/min

68.5 kW (92 HP)

76.6 kW (100 HP)

Compression Ratio

17.25:1

17.25:1

Idling Speed

750 - 800 rev/min

750 - 800 rev/min

Rated Speed (Full Load)

2200 rev/min

2200 rev/min ?

Max. No-Load Speed

2350 rev/min

2350 rev/min

Max. Net Torque at 1200 rev/min

350 Nm (258 lbf ft)

350 Nm (258 lbf ft)

Tank Capacity

75 litres (16.5 UK Gal)

90 litres (19.8 UK Gal)

Injection Pump Type

C.A.V. Rotary Distributor

C.A.V. Rotary Distributor

Governing

Mechanical

Mechanical

ISO Setting Code

2644F30//CG/1/2350

2644C705 BG/1/2350

Injector Timing

Pre-set

Pre-set

Injector Setting Pressure

250 atm

250 atm

Air Cleaner Type

2 stage, dry element

2 stage, dry element

Maximum Air Cleaner Restriction

635 mm (25 in) H2O

635 mm (25 in) H2O

Oil Pump Type

Eccentric rotor

Eccentric rotor

Oil Pressure at maximum speed

2.1 bar (30 lbf/in2) (min)

2.1 bar (30 lbf/in2) (min)

Fuel System

Induction System

Lubrication System

Oil Temperature Oil Capacity

125°C (52°F)(Continuous), 135°C (58°F) (Intermittent) 5000 cm3 (305 in3)(min), 6500 cm3 (396 in3) (max)

Cooling System Coolant Pressure

0.8 bar (11.6 lbf/in2)

Coolant Temperature (Normal)

80-90 °C (176-194 °F)

Capacity

15.5 litres (3.5 UK galls)

0.8 bar (11.6 lbf/in2) 80-90 °C (176-194 °F) 15.5 litres (3.5 UK galls)

For further engine details see Engine Manual Publication No. 9806/2140

50 - 05 - 07/10A

4225 - K/1-2.1 4225 - K/1-2.2

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 07/10B

411B, 416B Data - Engine Type

New 1000 Series, 4 cylinder, water cooled, direct injection 411 AK50646 build

416B AM50684 build

Bore (nominal)

100mm (3.937 in)

100mm (3.937 in

Stroke

127mm (5.000 in)

127mm (5.000 in)

Cylinder Capacity

4.0 litres (243 in3)

4.0 litres (243 in3)

Power Output at 2200 rev/min

60 kW (80 HP)

68.5 kW (92 HP)

Compression Ratio

17.25:1

17.25:1

Idling Speed

900+20 rev/min

900+20 rev/min

Rated Speed (Full Load)

2200 rev/min

2200 rev/min

Max. No-Load Speed

2360+20 rev/min

2360+20 rev/min

Max. Net Torque at 1200 rev/min

359.6 Nm (265.2 lbf ft)

439.9 Nm (324.4 lbf ft)

Injection Pump Type

C.A.V. Rotary Distributor

C.A.V. Rotary Distributor

Governing

Mechanical

Mechanical

ISO Setting Code

2644F304 CG/1/2350

2644F404 FG/1/2350

Injector Setting Pressure

250 atm

250 atm

Fuel System

Induction System Air Cleaner Type

2 stage, dry element

Maximum Air Cleaner Restriction

635 mm (25 in) H2O

Lubrication System Oil Pump Type

Eccentric rotor

Oil Pressure at maximum speed

2.8 bar (40 lbf/in2) (min)

Oil Temperature

125°C (52°F)(Continuous), 135°C (58°F) (Intermittent)

Oil Capacity

5000 cm3 (305 in3)(min), 6500 cm3 (396 in3) (max)

Cooling System Coolant Pressure

0.8 bar (11.6 lbf/in2)

Coolant Temperature (Normal)

80-90 °C (176-194 °F)

Capacity

15.5 litres (3.5 UK galls)

For further engine details see Engine Manual Publication No. 9806/2140

9804/1103

50 - 05 - 07/10B

4150 - K/1-3.1

Issue 1*

Wheeled Loaders 416

50 - 05 - 07/10C

From m/c no. 530350 (RJ Build)

Data - Engine Type

1104C-44TA to Power Curve T2174 416 From Serial No. 535650 (RJ Build)

Bore (nominal)

105 mm (4.133 in)

Stroke

127 mm (5.000 in)

Cylinder Capacity

4.4 litres (268 in3)

Gross Power Output at 2200 rev/min

121 hp @ 2200 rev/min (90.23 kW)

Compression Ratio

19.3 : 1

Idling Speed

850 rev/min

Rated Speed (Full Load)

2200 rev/min

Max. No-Load Speed

2370 rev/min

Max. Net Torque at 1400 rev/min

434 Nm @ 1400 rev/min (320 lbf ft)

Fuel System Injection Pump Type

Delphi mechanical DP210, rotary

Governing

Mechanical

ISO Setting Code

Not Used

Injection Timing

N/A Dynamically timed only

Injector Setting Pressure

290 bar +8, -0 (286 +7, -0 atm)

Induction System Air Cleaner Type

2 stage, dry element

Maximum Air Cleaner Restriction

635 mm (25 in) H2O

Restriction Indicator

Vacuum switch on air cleaner inlet

Lubrication System Oil Pump Type

Concentric gear

Oil Pressure at maximum speed

300 KPa (45.5 lbf/in2)

Oil Temperature

Anything up to 125°C max, depending on load, speed and ambient conditions

Oil Capacity Without/With Filter

9.4 litre / 10.9 litre (2.1 UK gal / 2.4 UK gal)

Cooling System Coolant Pressure

95 KPa (13.8 lbf/in2)

Coolant Temperature (Normal)

82 °C - 110°C (179-203 °F)

Capacity

23 litres (5.5 UK gal)

50 - 05 - 07/10C

4150 - K/1-4.1

Issue 1*

CONTENTS

Wheeled Loaders

50 - 05 - 07/11

426B, 436B, 446B Data - Engine

Type Number of Cylinders Capacity Bore (nominal) Stroke Compression Ratio Power Output @ 1000mm barometric, 25°C Max Nett Torque Idling Speed Maximum Governed Speed Maximum No-load Speed

426

436

Perkins 1006-6T7 4 Stroke, direct injection 6 in-line vertical 6.0 litres (365 in3) 100mm (3.937 in) 127mm (5.000 in) 16:1

Perkins 1006-6T4 4 Stroke, direct injection 6 in-line vertical 6.0 litres (365 in3) 100mm (3.937 in) 127mm (5.000 in) 16:1

93kW ±5% @ 2200 rev/min 404.9Nm @ 2200 rev/min 780 - 820 rev/min 2200 rev/min 2370 - 2410 rev/min

122kW ±5% @ 2200 rev/min 629.5Nm @ 2200 rev/min 780 - 820 rev/min 2200 rev/min 2240 - 2280 rev/min

Lucas DPA rotary KK75L 1100/1/2420 18° BTDC 250 atm Mechanical Diaphragm 2641A070

Lucas DPA rotary RK90L1100/3/2310 17° BTDC 250 atm Mechanical Diaphragm 2641A070

2 stage, dry element 635mm (25 in H2O)

2 stage, dry element 635mm (25 in H2O)

280kNm2 Integral Plate Cooler 125°C (257°F)

280kNm2 Integral Plate Cooler 125°C (257°F)

0.7 bar (10 lbf/in2) 80-85 °C (176-185 °F) 103 °C (217.4 °F) 98°C (208°F)

0.7 bar (10 lbf/in2) 80-85 °C (176-185 °F) 103 °C (217.4 °F) 98°C (208°F)

Fuel System Injection Pump Type Injector Pump Setting Code Injector Timing Injector Setting Pressure Lift Pump Type Induction System Air Cleaner Type Maximum Air Cleaner Restriction Lubrication System Oil Pressure Oil Cooler Max. Oil Temperature Cooling system Coolant Pressure Coolant Temperature (Normal) Coolant Temperature (Max) Temperature warning light operates at:

For further engine details see Engine Manual Publication No. 9806/0100

9804/1103

50 - 05 - 07/11

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 07/12

426B, 436B, 446B Data - Engine (continued) 446 Type Model Power Bore Stroke Displacement Compression Ratio Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately)

Cummings C Series, 6 cylinder turbocharged diesel, water cooled 6CT 8.3 - 170 170 hp @ 2200 rpm governed speed 114 mm (4.49 in) 135 mm (5.32 in) 8.3 litres (504.5 in3) 17.3:1 1, 5, 3, 6, 2, 4

Fuel System

BOSCH MW/RSV

Injection Timing (static) Injector Opening Pressure

16° BTDC 207-210 bar

0.3 mm 0.61 mm 590 kg

Induction System Air Cleaner Type

2 stage, dry element

For further details, see engine service manual. 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

50 - 05 - 07/12

Issue 1

CONTENTS

Wheeled Loaders

50 - 05 - 07/13

426B, 436B, 446B Data - Engine (continued) 426B

436B

1006-6T New 1000 Series

1006-TW New 1000 Series

YK50598 build

YK50559 build

Bore (nominal)

100mm (3.937 in)

100mm (3.937 in)

Stroke

127 mm (5.000 in)

127mm (5.000 in)

Cylinder Capacity

6 litres (365 in3)

6 litres (365 in3)

Power Output at 2200 rev/min

107.4 kW (144 HP)

119.3 kW (160HP)

Compression Ratio

17.25:1

17.25:1

Idling Speed

800±20 rev/min

850±10 rev/min

Rated Speed (Full Load)

2200 rev/min

2200rev/min

Max. No Load Speed

2350 rev/min

2350 rev/min

Peak Torque at 1400 rev/min

588 Nm (433.6 lbf ft)

439.9 Nm (324.4 lbf ft)

Injection Pump Type

C.A.V. Rotary Distributor

C.A.V. Rotary Distributor

Governing

Mechanical

Mechanical

ISO Setting Code

2644K206 BH/1/2350

2644K504 DH//1/2350

Injector Setting Pressure

250 atm

250 atm

Air Cleaner Type

2 stage, dry element

2 stage, dry element

Maximum Air Cleaner Restriction

635 mm (25 in) H2O

635 mm (25 in) H2O

Oil Pump Type

Eccentric rotor

Eccentric rotor

Oil Pressure at maximum speed

2.8 bar (40 lbf/in2) (min)

2.8 bar (40 lbf/in2) (min)

Type

Fuel System

Induction System

Lubrication System

Oil Temperature Oil Capacity

125°C (52°F)(Continuous), 135°C (58°F) (Intermittent) 5000 cm3 (305in3)(min), 6500 cm3 (396in3) (max)

Cooling System Coolant Pressure

0.8 bar (11.6 lbf/in2)

0.8 bar (11.6 lbf/in2)

Coolant Temperature (Normal)

80-90°C (176-194 °F)

80-90°C (176-194 °F)

Capacity

15.5 litres (3.5UK galls)

15.5 litres (3.5UK galls)

For further engine details see Engine Manual Publication No. 9806/2140

9804/1103

50 - 05 - 07/13

4160 - K/1-3.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 10 - 01/1

426,436 Fault Finding - Hydraulics Fault 1

Probable Cause

Lack of power in all hydraulic functions. Insufficient hydraulic fluid.

Action Check for leaks and top up as required.

Hydraulic leaks in system.

Check hoses, replace as required.

Engine performance.

Check engine performance.

M.R.V. setting incorrect.

Check and adjust as required.

Low pump flow.

Check for external leaks, replace seals.

Priority valve sticking.

Check priority valve. Replace pump.

2

All hydraulic rams slow to operate.

Neutral circuit or low pressure lines leaking, damaged, trapped or kinked.

Check pipe lines, replace as required.

M.R.V setting incorrect.

Check and adjust as required.

Low pump flow

Check pump flow. Check for external leaks, replace seals. Check for priority valve sticking. Replace pump.

3

One hydraulic service fails to operate or is slow to operate.

Associated service pipe lines leaking, damaged, trapped or kinked.

Check hoses, replace as required.

Associated ram leaking.

Replace seals.

A.R.V. setting incorrect.

Check and adjust as required.

Associated valve block section leaking or not operating.

Check for leaks, rectify as required. Check that the control lever is operating the spool, rectify as required.

4

5

The engine tends to stall when hydraulics are under load.

Ram creep.

9804/1103

Associated check valve not opening to allow return of oil to tank.

Check and rectify as required.

Diverter not opening.

Check electrical power supply and valve operation, rectify as required.

M.R.V setting incorrect.

Check and adjust as required.

Engine performance.

Check engine performance.

Associated ram or pipe lines from ram leaking.

Check and rectify as required.

Check valve.

Check operation, rectify as required.

50 - 10 - 01/1

Issue 1

CONTENTS

Wheeled Loaders

50 - 10 - 01/2

407B ZX, 408B ZX, 409B ZX, 410B ZX Fault Finding - Hydraulics - Hydrostatic Pump Neutral difficult or impossible to find

CHECK CONTROL LINKAGE

OK

INSPECT CONTROL VALVE

DEFECTIVE

DEFECTIVE

REPAIR OR REPLACE

REPLACE CONTROL VALVE

OK

REPLACE PUMP

A246030

9804/1103

50 - 10 - 01/2

Issue 1

CONTENTS

Wheeled Loaders

50 - 10 - 01/3

407B ZX, 408B ZX, 409B ZX, 410B ZX Fault Finding - Hydraulics - Hydrostatic Pump (continued) Transmission operates in one direction only

CHECK INPUT SIGNAL

OK

INSPECT PCOR AND RELIEF VALVES

DEFECTIVE

DEFECTIVE

REPAIR OR REPLACE CONTROL VALVE

REPAIR OR REPLACE

INSPECT LOOP FLUSHING VALVE

INSPECT CONTROL VALVE

OK

DEFECTIVE

DEFECTIVE

REPLACE LOOP FLUSHING VALVE

REPLACE CONTROL VALVE

OK

A246040

9804/1103

50 - 10 - 01/3

Issue 1

CONTENTS

Wheeled Loaders

50 - 10 - 01/4

407B ZX, 408B ZX, 409B ZX, 410B ZX Fault Finding - Hydraulics - Hydrostatic Pump (continued) System response sluggish

CHECK CHARGE PRESSURE

OK

INSPECT CONTROL VALVE

OK

INSPECT BYPASS VALVE

DEFECTIVE

DEFECTIVE

REPLACE CONTROL VALVE

REPAIR OR REPLACE

REPLACE PUMP AND MOTOR

OK

TOO LOW IN NEUTRAL

TOO LOW IN FORWARD AND REVERSE

TOO LOW IN NEUTRAL AND FORWARD OR REVERSE

INSPECT PUMP CHARGE PRESSURE RELIEF VALVE

INSPECT MOTOR PURGE PRESSURE RELIEF VALVE

INSPECT PUMP CHARGE PRESSURE RELIEF VALVE

DEFECTIVE

DEFECTIVE

DEFECTIVE

CLOGGED

DEFECTIVE

REPAIR OR REPLACE

REPAIR OR REPLACE

REPAIR OR REPLACE

REPLACE

REPAIR OR REPLACE

OK

INSPECT INLET FILTER

OK

INSPECT CHARGE PUMP

A246050

9804/1103

50 - 10 - 01/4

Issue 1

CONTENTS

Wheeled Loaders

50 - 10 - 01/5

407B ZX, 408B ZX, 409B ZX, 410B ZX Fault Finding - Hydraulics - Hydrostatic Pump (continued) System will not operate in either direction

CHECK HYDRAULIC OIL LEVEL

OK

OK

INSPECT CONTROL VALVE

INSPECT BYPASS VALVE

OK

OK

CHECK CHARGE PRESSURE

TOO LOW

DEFECTIVE

DEFECTIVE

FILL TO PROPER LEVEL

REPAIR OR REPLACE

REPAIR OR REPLACE

TOO LOW IN NEUTRAL, FORWARD OR REVERSE

TOO LOW IN NEUTRAL

TOO LOW IN FORWARD OR REVERSE

INSPECT INLET FILTER

INSPECT PUMP CHARGE PRESSURE RELIEF VALVE

INSPECT MOTOR PURGE PRESSURE RELIEF VALVE

INSPECT CHARGE PUMP

OK

OK

DEFECTIVE

CLOGGED

DEFECTIVE

DEFECTIVE

REPAIR OR REPLACE

REPLACE

REPAIR OR REPLACE

REPAIR OR REPLACE

REPLACE PUMP AND MOTOR

OK

INSPECT CONTROL VALVE

OK

INSPECT PCOR

DEFECTIVE

DEFECTIVE

REPAIR OR REPLACE

REPAIR OR REPLACE

OK

OK

CHECK SYSTEM PRESSURE

A246060

9804/1103

50 - 10 - 01/5

Issue 1

CONTENTS

Wheeled Loaders

50 - 10 - 01/6

407B ZX, 408B ZX, 409B ZX, 410B ZX Fault Finding - Hydraulics - Hydrostatic Motor System response sluggish

CHECK OIL LEVEL IN RESERVOIR

OK

CHECK SYSTEM RELIEF VALVE PRESSURE SETTINGS

OK

CHECK PUMP INLET PRESSURE

OK

CHECK PUMP SPEED

LOW

DEFECTIVE

LOW

FILL TO CORRECT LEVEL

ADJUST OR REPLACE

INSPECT INLET FILTER AND REPLACE IF NECESSARY

ADJUST

REPLACE PUMP AND MOTOR

CHECK SYSTEM INTERNAL LEAKAGE

CHECK CHARGE AND CONTROL PRESSURES

OK

LOW

OK

OK

HIGH

INCORRECT

REPAIR AS REQUIRED

REPAIR AS REQUIRED

A246070

9804/1103

50 - 10 - 01/6

Issue 1

CONTENTS

Wheeled Loaders

50 - 10 - 01/7

407B ZX, 408B ZX, 409B ZX, 410B ZX Fault Finding - Hydraulics - Hydrostatic Motor (continued) System operating hot

CHECK HYDRAULIC OIL LEVEL

OK

INSPECT OIL COOLER

OK

CHECK CHARGE PRESSURE

OK

CHECK PUMP INLET PRESSURE

LOW

DEFECTIVE

INCORRECT

FILL TO CORRECT LEVEL

CLEAN, REPAIR OR REPLACE

REPAIR AS REQUIRED

INSPECT INLET FILTER AND REPLACE IF NECESSARY

REPLACE PUMP AND MOTOR

CHECK SYSTEM PRESSURE

CHECK FOR INTERNAL SYSTEM LEAKAGE

CHECK SYSTEM RELIEF PRESSURE SETTINGS

OK

OK

LOW

OK

OK

HIGH

HIGH

LOW

REDUCE LOAD ON TRANSMISSION

REPAIR AS REQUIRED

ADJUST OR REPLACE

A246090

9804/1103

50 - 10 - 01/7

Issue 1

Wheeled Loaders

CONTENTS

50 - 10 - 01/8

407B ZX, 408B ZX, 409B ZX, 410B ZX Fault Finding - Hydraulics - Hydrostatic Motor (continued) Motor operates normally in one direction only

CHECK CHARGE PRESSURE

OK

CHECK PUMP CONTROL SYSTEM

OK

INTERCHANGE SYSTEM RELIEF VALVES AND/OR CHARGE CHECK VALVES

DECAYS IN ONE DIRECTION (FORWARD OR REVERSE) ONLY

DEFECTIVE

PROBLEM CHANGES DIRECTION

INSPECT AND REPAIR LOOP FLUSHING VALVE

REPAIR OR REPLACE

REPAIR OR REPLACE APPROPRIATE VALVE

REPLACE PUMP AND MOTOR

OK

A246100

Excessive noise and/or vibration

CHECK HYDRAULIC OIL LEVEL

OK

AIR IN SYSTEM

OK

CHECK PUMP INLET PRESSURE

OK

INSPECT SHAFT COUPLINGS

OK

INSPECT SHAFT ALIGNMENT

LOW

LOOSE FITTINGS

LOW

DEFECTIVE

DEFECTIVE

FILL TO PROPER LEVEL

PURGE AIR AND TIGHTEN FITTINGS

INSPECT INLET FILTER AND REPLACE IF NECESSARY

REPAIR OR REPLACE

ALIGN SHAFTS

A246080

9804/1103

50 - 10 - 01/8

Issue 1

CONTENTS

Wheeled Loaders

50 - 10 - 01/9

407B ZX, 408B ZX, 409B ZX, 410B ZX Fault Finding - Hydraulics - Hydrostatic Motor (continued) Low torque output

CHECK MOTOR INLET PRESSURE

OK

LOW

CORRECT SYSTEM

CHECK MOTOR OUTLET PRESSURE

MOTOR AT INCORRECT (MINIMUM) DISPLACEMENT

OK

HIGH/LOW

INCORRECT

CORRECT SYSTEM

CHECK CONTROL SUPPLY PRESSURE AND/OR REPAIR DISPLACEMENT CONTROL

OK

REPAIR OR REPLACE MOTOR

A246110

Output speed incorrect

CHECK HYDRAULIC OIL LEVEL

OK

CHECK CHARGE PRESSURE

CHECK PUMP OUTPUT FLOW

OK

LOW

INCORRECT

INCORRECT

FILL TO CORRECT LEVEL

REPAIR CHARGE SYSTEM

REPAIR PUMP CONTROL AND/OR PUMP

CHECK AND REPAIR CONTROL SYSTEM AND DISPLACEMENT CONTROLS (PUMP AND MOTOR)

OK

CHECK MOTOR DISPLACEMENT

INCORRECT

OK

REPAIR OR REPLACE MOTOR

A246120

9804/1103

50 - 10 - 01/9

Issue 1

Wheeled Loaders

CONTENTS

50 - 10 - 01/10

456B Fault Finding - Hydraulics To use this section, look for the fault in the list below and refer to the probable causes and actions required listed against the fault. Remember safety must always be the first priority, refer to the 'Care and Safety' section for a reminder on safety practices.

Fault 1

2

Probable Cause

Lack of power in all hydraulic functions. Insufficient hydraulic fluid.

All hydraulic rams slow to operate.

Action Check for leaks and top up as required.

Hydraulic leaks in system.

Check hoses, replace as required.

Engine performance.

Check engine performance.

Pump control setting incorrect.

Check and adjust as required.

Low pump flow.

Check for external leaks, replace seals.

Priority valve sticking.

Check priority valve.

Neutral circuit or low pressure lines leaking, damaged, trapped or kinked.

Check pipe lines and replace as required.

Pump control setting incorrect.

Check and adjust as required.

Low pump flow

Check pump flow. Check for external leaks, replace seals. Check for priority valve sticking.

3

One hydraulic service fails to operate or is slow to operate.

Associated service pipe lines leaking, damaged, trapped or kinked.

Check hoses, replace as required.

Associated ram leaking.

Replace seals.

A.R.V. setting incorrect.

Check and adjust as required.

Associated valve block section leaking or not operating.

Check for leaks, rectify as required. Check that the control lever is operating the spool, rectify as required.

4

5

The engine tends to stall when hydraulics are under load.

Ram creep.

Associated check valve not opening to allow return of oil to tank.

Check and rectify as required.

Diverter not opening.

Check electrical power supply and valve operation, rectify as required.

Pump control setting incorrect.

Check and adjust as required.

Engine performance.

Check engine performance.

Ram seals.

Check and rectify as required.

A.R.V.

50 - 10 - 01/10

4180-E/90-1.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 10 - 01/11

426B, 436B, 446B Fault Finding - Hydraulics To use this section, look for the fault in the list below and refer to the probable causes and actions required listed against the fault. Remember safety must always be the first priority, refer to the 'Care and Safety' section for a reminder on safety practices.

Fault 1

Probable Cause

Lack of power in all hydraulic functions. Insufficient hydraulic fluid.

2 All hydraulic rams slow to operate. required.

Action Check for leaks and top up as required.

Hydraulic leaks in system.

Check hoses, replace as required.

Engine performance.

Check engine performance.

Pump control setting incorrect.

Check and adjust as required.

Low pump flow.

Check for external leaks, replace seals.

Priority valve sticking.

Check priority valve.

Neutral circuit or low pressure lines

Check pipe lines and replace as

leaking, damaged, trapped or kinked. Pump control setting incorrect.

Check and adjust as required.

Low pump flow

Check pump flow. Check for external leaks, replace seals. Check for priority valve sticking.

3

One hydraulic service fails to operate or is slow to operate.

Associated service pipe lines leaking, damaged, trapped or kinked.

Check hoses, replace as required.

Associated ram leaking.

Replace seals.

A.R.V. setting incorrect.

Check and adjust as required.

Associated valve block section leaking or not operating.

Check for leaks, rectify as required. Check that the control lever is operating the spool, rectify as required.

4

5

The engine tends to stall when hydraulics are under load.

Ram creep.

Associated check valve not opening to allow return of oil to tank.

Check and rectify as required.

Diverter not opening.

Check electrical power supply and valve operation, rectify as required.

Pump control setting incorrect.

Check and adjust as required.

Engine performance.

Check engine performance.

Ram seals.

Check and rectify as required.

A.R.V. 9804/1103

50 - 10 - 01/11

4160 - E/90-1.2

Issue 1

CONTENTS

Wheeled Loaders

406, 407, 408, 409

50 - 15 - 01/1

Syncro Shuttle m/c's from 632700

Circuit Diagrams - Electrical Main Components and Switches

Lamps

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

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

Battery Starter Motor Solenoid and Motor Start Relay Thermostart Starter Switch Dump Relay Hand Dump Switch (Gear Lever) Hand Dump Switch (Loader Control) Forward Solenoid Forward Relay Reverse Solenoid Reverse Relay Forward/Reverse Switch Horn Push Parking Brake Relay Parking Brake Switch Horn Headlight Dip Switch Headlight Flash Switch Direction Indicator Switch Wiper Motor Front Wiper Switch Front Washer Motor Front Washer Switch Front Speed Transducer Speedometer Hourmeter Water Temperature Sender Water Temperature Gauge Fuel Gauge Sender Fuel Gauge Diode Buzzer Transmission Oil Temperature Switch Water Temperature Switch Air Filter Switch Alternator Engine Oil Pressure Switch Transmission Oil Pressure Switch Flasher Unit Hazard Switch Brake Light Switch Road Light Switch Front Work Light Relay Front Work Light Switch Rear Work Light Relay Rear Work Light Switch Reverse Alarm Engine Shut Off Solenoid Heater Motor Heater Resistor Heater Switch Fog Light Switch Beacon Motor Beacon Switch Washer Motor Rear Wash/Wipe Switch Rear Wiper Motor Rear Interior Light Switch Radio Carrier

9804/1103

50 - 15 - 01/1

Dipped Beam Main Beam LH Indicators RH Indicators Transmission Oil Temperature Warning Water Temperature Warning Air Filter Warning Indicator Warning Main Beam Warning Hazard Warning Alternator Warning Engine Oil Pressure Warning Transmission Oil Pressure Warning Parking Brake Warning Panel Illumination Hazard Switch Stop Lights RH Side/Tail Lights LH Side/Tail Lights Road Light Switch Illumination Front Work Lights Front Work Light Switch Illumination Rear Work Lights Rear Work Light Switch Illumination Fog Light Fog Light Switch Illumination Heater Switch Illumination Beacon Beacon Switch Illumination Interior Light Rear Wash/Wipe Switch Illumination

Issue 1

CONTENTS

Wheeled Loaders

50 - 15 - 01/2

406, 407, 408, 409

Syncro Shuttle m/c’s from 632700

Circuit Diagrams - Electrical

16 9

4

11

65

66

67

68

17 2

10

23 M

12 21 M

14

1 6

-

A2

A1

13

+

19 7

18

24 20

22

8 3 15

B1

B2

C5

5

A214050

9804/1103

50 - 15 - 01/2

Issue 1

Wheeled Loaders

CONTENTS

406, 407, 408, 409

50 - 15 - 01/3

Syncro Shuttle m/c’s from 632700

Circuit Diagrams - Electrical

34

59

37 39

25

28

56

35

30

50

48 81

36

83

82

87

85

M

89 M

94

38 92

49

M

54

58

42

M

27

44

46

40

51

78 29

26

31

74

72

69 70

71

73

76 75

79

60

77

32 A3

33

41

45

A4

80

53

86

43

47

57

88

84

91

52 C3

C1

A8

C2

A9

A5

A6

95

90

A7

B6

B4

93 55 B3

B5

A214060

9804/1103

50 - 15 - 01/3

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 01/6

406, 407, 408, 409

Powershift m/c’s from 632700

Circuit Diagrams - Electrical

13

18 14

3 6

22 19

23

80

81

82

83

9

32

M

24

2

31 M

26 11

12

16

17

A1

A2

- +

8

1

21 10

20

25

27

28

29

30

7 4 15

B1

B2

C5

5

A201710

9804/1103

50 - 15 - 01/6

Issue 1

Wheeled Loaders

CONTENTS

406, 407, 408, 409

50 - 15 - 01/7

Powershift m/c’s from 632700

Circuit Diagrams - Electrical

42 38

35

40

67

45

47 65

43 99

46

100

101

102

105

60

44

M

104

M

108

57 106 56

63

M

66 50

34

36

37

M

53

39

87

89

91

93

88

90

92

59

49

84 85

55

68

94

86

33 52

54

97

98

61

64 103

41

C3

C1

107

95 48

51

A8

C2

96

A9

58

A5

A6

A7

B6

B4

62

B3

B5

A201720

9804/1103

50 - 15 - 01/7

Issue 1

CONTENTS

Wheeled Loaders

406, 407, 408, 409

50 - 15 - 01/8

Powershift m/c's from 632700

Circuit Diagrams - Electrical Main Components 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 61 62

Battery Starter Motor Solenoid Starter Motor Start Relay Starter Switch Thermostart Hand Dump Switch(Loader Control) Dump Relay Drive Relay Neutral Start Relay Reverse Relay Forward Relay Layshaft Solenoid Mainshaft Solenoid Parking Brake Relay Forward High/Low Relay Reverse High/Low Relay Forward Low Solenoid Forward High Solenoid Forward/Reverse Switch Gear Selector Switch Reverse High Solenoid Reverse Low Solenoid Parking Brake Switch Horn Push Horn Headlight Dip Switch Headlight Flash Switch Direction Indicator Switch Front Wash/Wipe Switch Front Wiper Motor Front Washer Motor Diode Speedometer Speed Transducer Hourmeter Water Temperature Gauge Water Temperature Gauge Sender Fuel Gauge Fuel Gauge Sender Buzzer Transmission Oil Temperature Switch Water Temperature Switch Air Filter Switch Alternator Engine Oil Pressure Switch Transmission Oil Pressure Switch Hazard Warning Switch Flasher Unit Brake Light Switch Road Light Switch Front Working Light Switch Front Working Light Relay Rear Working Light Switch Rear Working Light Relay Reverse Alarm Engine Shut Off Solenoid Heater Switch Heater Resistor Heater Motor Fog Light Switch Beacon Switch

9804/1103

63 64 65 66 67 68

Beacon (Socket) Rear Wash/Wipe Switch Rear Washer Motor Rear Wiper Motor Interior Light Switch Radio Carrier

Lamps 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

50 - 15 - 01/8

Dipped Beam Main Beam LH Indicators RH Indicators Transmission Oil Temperature Warning Water Temperature Warning Air Filter Warning Indicator Warning Main Beam Warning Hazard Warning Alternator Warning Engine Oil Pressure Warning Transmission Oil Pressure Warning Parking Brake Warning Panel Illumination Hazard Switch Road Light Switch Illumination Front Work Light Switch Illumination Rear Work Light Switch Illumination Stop Lights RH Side/Tail Lights LH Side/Tail Lights Front Working Lights Fog Light Switch Illumination Fog Light Rear Working Lights Beacon Rear Wash/Wipe Switch Illumination Interior Light

Issue 1

CONTENTS

Wheeled Loaders

411, 416

50 - 15 - 01/9

411 m/c’s to 527012 416 m/c’s to 529014

Circuit Diagrams - Electrical Main Components 1 2 3 4 5 6 7 8 9 9A 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 54A 55 55A 56

Battery Starter Switch Thermo Coil Start Relay Starter Solenoids Starter Motor Neutral Start Relay Parking Brake Switch Reverse Alarm Relay Reverse Alarm Reverse Light Relay Dump Pressure Switch Dump Switch Reverse Light Switch Transmission Solenoid Switches (Y1 (M1), Y2 (M2), Y3 (M3), Y4 (M4), Y5 (M5)) Transmission Automatic Control Transmission Hand Control Output Speed Sensor Throttle Switch Water Temperature Gauge Fuel Gauge Speedometer Timer Relay Diode Buzzer Test Button Clutch Pressure Switch Engine Oil Pressure Switch Water Temperature Switch Vacuum Switch Transmission Oil Temperature Switch Brake Pressure Switch Alternator Hourmeter Heater Switch Resistor Heater Blower Cigar Lighter Changeover Switch Lift Arm Reset Bucket Ram Reset Clock Brake Switch Hazard Relay Hazard Switch Column Switch Sidelight Switch Column Switch Fog Light Switch Work Light Switch Work Light Relay Interior Light Switch Front Wiper Switch Front Wiper Motor Front Washer Switch Front Wash Motor Horn Push Horn Rear Wash/Wipe Switch

9804/1103

56A 56B 57 58

Rear Wiper Motor Rear Washer Motor E.S.O.S. Brake Dump Valve

Lamps 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

Parking Brake Warning Light Reverse Light (Left Hand) Reverse Light (Right Hand) Master Warning Light Transmission Pressure Light Engine Oil Pressure Light Water Temperature Light Air Filter Light Transmission Oil Temperature Light Brake Pressure Light Alternator Warning Light Indicator Warning Light Brake Light (Left Hand) Brake Light (Right Hand) Indicator (Front Left Hand) Indicator (Rear Left Hand) Indicator (Front Right Hand) Indicator (Rear Right Hand) Hazard Warning LIght Sidelight (Right Hand) Sidelight (Left Hand) Rear Fog Light Dipped Beam Main Beam Work Light (Front) Interior Light Beacon

Fuses A1 A2 A4 A5 A6 A7 B1 B2 B3 B4 B5 B6 C1 C2 C3 C5

Direction Indicators Right Sidelights and Gauge Illumination Gear Selection Brake Lights, Loader Arm and Bucket Reset Warning Lights, Heater Fan and Gauges Main Beam Hazard Warning Lights Dipped Beam Rear Work Lights Rear Wash/Wipe Interior Light and Beacon E.S.O.S. Left Sidelights Front Work Lights Forward/Reverse Select Horn, Wash/Wipe (Front)

Note: For bulb and fuse ratings see pages 50 - 05 - 01/2, 01/3. Note: For manual transmission machines, Item 18 (Throttle Switch) is not fitted. Wires 9508 and 9508A are linked.

50 - 15 - 01/9

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 01/10

411, 416

411 m/c’s to 527012 416 m/c’s to 529014

Circuit Diagrams - Electrical

55A 9A

27

71 72 14

26

414 420

420

29 28

31

33

82 83

30

84 85 86 87

846B 835E 836G 846A 835D 836F

413

32

844B

6

37

861

852

89 90 91 92 93 801

826G

5

7

844

9

20

21

851

408 405

400 416

422

38

418

18

10

39

104G 104B

40 104C

88

81 104H

22

106C

A2

A7 53

835

25

C1

B2

800

804

800B

304C

805

9588

16

813

839

845 9584

74

406

9434 9442

1

9430

9464 9524

9438 9446 9460

+

8

003

33

11

421

15

32

14

31

27

17

8

58

8358

9536

9512

302A

840 22

12

822

106S

104

49

9504

26

23

25

19

24

57

9658

56 56

306

9600

1

2

9650

820

5

18

9666

35

9678

800

75 76 77 78 79 80

23

29

803

302

24

9654

9612

200E

A4

B3

C3

70

51

420

73

44

34 106A

100 300B

002B

54 55

802

35

3 200

52

8360

9674

15

4

837

13 101

004

9528

47

41

4 6 5

-

814 815

23

23

3

816A 819

45

7 8 1 2

818 817

50

9508 9588A

56A

304E

104A 838

9508A

810

803C

42

411

807

48

36

17

54A

812

844C

19

94 95 96

806

802

56B

106B

A6

B6

105

102

100A

107

106

304D

46

838 300

A5

A1

B1

837A

C5

43

B4

200 & 200A

200K

002A 000A

200H

200F

000F

000C

001 304 000

2 C2

B5

2000 200S

200M

A211591

9804/1103

50 - 15 - 01/10

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 01/11

411, 416

411 m/c’s from 527013 416 m/c’s from 529015

Circuit Diagrams - Electrical

55A 9A

27

71 72 14 420

17A

844B

6

26

414 420

29 28

31

33

37

82 83

30

84 85 86 87

846B 835E 836G 846A 835D 836F

413

32

861

852

89 90 91 92 93 801

54A

806

802

812

56B

94 95 96

807

810

56A

304E

62

851

844C

862

19 826G

5

7

844

9

20

36

21 408

17

405

400 416

422

39

418

411

104G 104B

18

10

42

38 40 104C

88

81 104H

A2

22

106C

A7 53

104A 838

9508A

A3

835

25

C1

B2

800

804

800B

304C

805

9588A

9588

16

813

839

45

845 9584

803C

74

+

003

12

421

4

33

14

31

9

34

27

8

26

302A

22 9600

1

822

23

25

19

24

106S

104

49

54 55

56 56

802

35

306

63

9658

9650

9612

70 B3

002B 200K

18

9666

35

9678

24

C3

58

59

800 803

51

420

9654

9612A 302

820

75 76 77 78 79 80

23

29

2

101H

A4

863

8358

9536

5

15

9600A

200E

17

101M

3

52

8360

9674

57

200

15

32

101

64

837

13

840 004

47

41

9438 9446 9470 9460 9528 9512 9504

11

8

862

60

406

4 6 5

1

814 815

23

23

3

9434 9442 9430 9474 9464 9524

816A 819

48

7 8 1 2

818 817

50

9508

61

73

44

34 106A

100 300B

9536A

107 106B

106

B6

A5

105

102

100

100A 300

A6

304D

46

838

A1

B1

837A

C5

43

B4

B7

200 & 200A

002A 000A

200H

200F

000F

000C

000

001 304 000

2 C2

B5

2000 200S

200M

A217091

9804/1103

50 - 15 - 01/11

Issue 1

CONTENTS

Wheeled Loaders

411, 416

50 - 15 - 01/12

411 m/c’s from 527013 416 m/c’s from 529015

Circuit Diagrams - Electrical Main Components 1 2 3 4 5 6 7 8 9 9A 10 11 12 13 14 15 16 17 17A 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 54A 55 55A 56 56A 56B 57 58 59 60

Battery Starter Switch Thermo Coil Start Relay Starter Solenoids Starter Motor Neutral Start Relay Parking Brake Switch Reverse Alarm Relay Reverse Alarm Reverse Light Relay Dump Pressure Switch Dump Switch Reverse Light Switch Transmission Solenoid Switches (Y1 (M1), Y2 (M2), Y3 (M3), Y4 (M4), Y5 (M5)) Transmission Automatic Control Transmission Hand Control Output Speed Sensor Turbine Sensor Throttle Switch Water Temperature Gauge Fuel Gauge Speedometer Timer Relay Diode Buzzer Test Button Clutch Pressure Switch Engine Oil Pressure Switch Water Temperature Switch Vacuum Switch Transmission Oil Temperature Switch Brake Pressure Switch Alternator Hourmeter Heater Switch Resistor Heater Blower Cigar Lighter Changeover Switch Lift Arm Reset Bucket Ram Reset Clock Brake Switch Hazard Relay Hazard Switch Column Switch Sidelight Switch Column Switch Fog Light Switch Work Light Switch Work Light Relay Interior Light Switch Front Wiper Switch Front Wiper Motor Front Washer Switch Front Wash Motor Horn Push Horn Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Motor Dump Switch (Loader Control) Kickdown Switch (Loader Control) Air Conditioning Switch Air Conditioning Thermostat

9804/1103

61 62 63 64

Air Conditioning Pressure Switch Compressor Clutch Field Coil E.S.O.S. Brake Dump Valve

Lamps 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

Parking Brake Warning Light Reverse Light (Left Hand) Reverse Light (Right Hand) Master Warning Light Transmission Pressure Light Engine Oil Pressure Light Water Temperature Light Air Filter Light Transmission Oil Temperature Light Brake Pressure Light Alternator Warning Light Indicator Warning Light Brake Light (Left Hand) Brake Light (Right Hand) Indicator (Front Left Hand) Indicator (Rear Left Hand) Indicator (Front Right Hand) Indicator (Rear Right Hand) Hazard Warning Light Sidelight (Right Hand) Sidelight (Left Hand) Rear Fog Light Dipped Beam Main Beam Work Light (Front) Interior Light Beacon

Fuses A1 A2 A3 A4 A5 A6 A7 B1 B2 B3 B4 B5 B6 B7 C1 C2 C3 C5

Direction Indicators Right Sidelights and Gauge Illumination Rear Fog Light Gear Selection Brake Lights, Loader Arm and Bucket Reset Warning Lights, Heater Fan and Gauges Main Beam Hazard Warning Lights Dipped Beam Rear Work Lights Rear Wash/Wipe Interior Light and Beacon E.S.O.S. Air Conditioning Left Sidelights Front Work Lights Forward/Reverse Select Horn, Wash/Wipe (Front)

Note: For bulb and fuse ratings see pages 50 - 05 - 01/2, 01/3. Note 2: For manual transmission machines, Item 18 (Throttle Switch) is not fitted. Wires 9508 and 9508A are linked. Note 3: For Germany ONLY, Wire 9588 is not connected to Item 10 (Reverse Light Relay).

50 - 15 - 01/12

Issue 1

CONTENTS

Wheeled Loaders

411, 416

50 - 15 - 01/13

411 m/c’s from 527400 416 m/c’s from 529500

Circuit Diagrams - Electrical Main Components

Lamps

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

110 111 112

Starter Switch Battery Isolator Starter Relay Starter Solenoids Starter Motor Hydraulic Dump Valve Thermostart Coil Shut down Relay E.S.O.S. Electronic Monitoring system (EMS) Computer Feed Relay ZF Computer Transmission Solenoids Turbine Speed Sensor Output Speed Sensor Throttle Switch Kickdown Switch Hand Controller Relays Forward/Reverse Control Relays Hand Controller Forward/Reverse Switch Reverse Alarm Relay Reverse Alarm Reverse Lights Switch Reverse Lights Relay ACCS Relay ACCS Override Switch ACCS Solenoid Valve

LH Reverse Light RH Reverse Light ACCS Operating Indication Light

Fuses 6A 8A

Computer Feed Relay Solenoid EMS Battery Feed

3B 6B 8B

Reverse Alarm and Rear Work Lights Engine Shut Off System (ESOS) Thermostart

3C 7C 8C

EMS and ZF Computer Feed Hydraulic Dump Valve (416 Only) ACCS

Note 1: For fuse ratings see Fuses, Relays in Technical Data.

Note: Arrows marked § indicate remote connection (not shown), ie. B5 goes to connection B5 on EMS (Item 11).

50 - 15 - 01/13

4150 - C/6-5.2

Issue 2*

Wheeled Loaders

CONTENTS

50 - 15 - 01/14

411, 416

411 m/c’s from 527400 416 m/c’s from 529500

Circuit Diagrams - Electrical 2 3 5 4

6

1 7C

7

8B

8 10

6B

9 8A 11

12

3C 6A

13 14

15

17

16

20

19

18

21

22 24 23 26

3B

110

25 §

27

111

8C 28

29 112

9804/1103

50 - 15 - 01/14

A298570 4150 - C/6-6.2

Issue 3*

CONTENTS

Wheeled Loaders

411, 416

50 - 15 - 01/15

411 m/c’s from 527400 416 m/c’s from 529500

Circuit Diagram - Electrical Main Components

Lamps

1 11 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

113

Starter Switch Electronic Monitoring system (EMS) Warning Light Test Button Buzzer Fuel Contents Sender Water Temperature Sender Transmission Oil Temperature Sender Hydraulic Oil Temperature Sender Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Engine Oil Level Sensor Coolant Level Sensor Transmission Oil LevelSensor Hydraulic Oil Level Sensor Emergency Steer Switch Water in Fuel Sensor Parking Brake Switch Alternator Heater Switch Heater Relay Heater Blower Cigar Lighter Air Conditioning Switch Air Conditioning Temperature Switch Air Conditioning Pressure Switch Air Conditioning Compressor Clutch

Master Warning Light

Fuses 8A

EMS Battery Feed

7B

Air Conditioning

6C

Heater Blower and Cigar Lighter

Note 1: For fuse ratings see Fuses, Relays in Technical Data.

Note: Arrows marked § indicate remote connection (not shown), ie. 3C goes to Fuse 3C via. Relay (Item 12).

9804/1103

50 - 15 - 01/15

4150 - C/6-7.2

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 01/16

411,416

411 m/c’s from 527400 416 m/c’s from 529500

Circuit Diagrams - Electrical 1

30 113 31

8A 32 33 §

34 35 36 37

11

38 39 40 41 42 43 44 45 46 47

48 50 51 6C 49

52 7B

9804/1103

53

54

50 - 15 - 01/16

55

56

4150 - C/6 - 8.2

Issue 1

CONTENTS

Wheeled Loaders

411,416

50 - 15 - 01/17

411 m/c’s from 527400 416 m/c’s from 529500

Circuit Diagrams - Electrical Main Components

Lamps

1 57 58 59 60 61 62 63 64 65 66

114 115 116 117 118 119 120 121 122 123 124 125 126 127 128

Starter Switch Hazard Relay Hazard Warning Switch Column Switch Diode Road Light Switch Head Light Flasher Switch Fog Light Switch Front Work Lights Switch Front Work Lights Inhibit Relay (Italy Only)† Front Work Lights Relay

† On all machines other than Italy, relay 65 is not fitted and wires 853A and 808A are connected

LH Front Indicator LH Rear Indicator RH Front Indicator RH Rear Indicator RH Front Side Light RH Tail Light LH Front Side Light LH Tail Light RH Number Plate Light LH Number Plate Light Dipped Beam Main Beam Fog Lights LH Front Work Lights RH Front Work Lights

Note: Arrows marked § indicate remote connection (not shown), ie. B4 goes to connection B4 on EMS (Item 11). B6 goes to connection B6 on EMS (Item 11). B10 goes to connection B10 on EMS (Item 11). B11 goes to connection B11 on EMS (Item 11). B12 goes to connection B12 on EMS (Item 11). B16 goes to connection B16 on EMS (Item 11). B17 goes to connection B17 on EMS (Item 11). B18 goes to connection B18 on EMS (Item 11).

Fuses 1A 2A 3A

Hazard Warning Lights and Direction Indicators RH Side/Tail Lights and Switch/Panel Illumination Fog Lights

1B 2B

Hazard Battery Feed Dip Beam

1C 2C 9C

LH Side/Tail Lights and Number Plate Lights Front Work Lights Road Lights

Note 1: For fuse ratings see Fuses, Relays in Technical Data.

9804/1103

50 - 15 - 01/17

4150 - C/6 - 9.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 01/18

411, 416

411 m/c’s from 527400 416 m/c’s from 529500

Circuit Diagrams - Electrical 1

§

1A

114 58

1B

115 59

57

116 117

60 § §

118 2A 119 §

120 121 1C 122 123

2B

124

61 §

62

9C

125

7A

§

63

3A

126 §

127

65 64 2C

128 66

§

9804/1103

50 - 15 - 01/18

4150 -C/6 - 10.1

Issue 1

CONTENTS

Wheeled Loaders

411,416

50 - 15 - 01/19

411 m/c’s from 527400 416 m/c’s from 529500

Circuit Diagrams - Electrical Main Components 1 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90

Starter Switch Lift Ram Proximity Switch Detent Coil (Lift Arm Reset) Shovel Ram Proximity Switch Detent Coil (Shovel Ram Reset) Detent Coil (Float) Brake Light Switch Heated Mirror Switch LH Heated Mirror RH Heated Mirror Heated Seat Switch Heated Seat Heated Seat Thermostat Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Pump Horn Front Wiper Motor Column Switch Intermittent Wiper Relay Front Washer Pump Beacon Switch Interior Light Radio (Option) Under Bonnet Lights Switch

9804/1103

Lamps 129 130 131 132 133 134

LH Brake Light RH Brake Light Beacon Interior Light LH Under Bonnet Light RH Under Bonnet Light

Fuses 5A

Brake Lights, Float, Lift and Shovel Reset

4B 5B

Rear Wash/Wipe Beacon, Interior Light, Radio and Under Bonnet Lights

4C 5C

Heated Mirror and Heated Seat Front Wash/Wipe and Horn

Note 1: For fuse ratings see Fuses, Relays in Technical Data.

50 - 15 - 01/19

4150 - C/6 - 11.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 01/20

411,416

411 m/c’s from 527400 416 m/c’s from 529500

Circuit Diagrams - Electrical

1 67 68 69

70

5A 71

129

72

130

74 73 75 4C 76

77 78

80

79

4B

81 82 83

5C

84 85

86 87 131

5B

132

88

89 133 90 134

9804/1103

50 - 15 - 01/20

4150 - C/6 - 12.1

Issue 1

CONTENTS

Wheeled Loaders

50 - 15 - 01/21

426, 436 Circuit Diagrams - Electrical Main Components 1 2 3 4 5 6 7 8 9 9A 10 11 12 13 14 15 16 17 17A 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 54A 55 55A 56 56A

Battery Starter Switch Thermo Coil Start Relay Starter Solenoids Starter Motor Neutral Start Relay Parking Brake Switch Reverse Alarm Relay Reverse Alarm Reverse Light Relay Dump Pressure Switch Dump Switch Reverse Light Switch Transmission Solenoid Switches (Y1 (M1), Y2 (M2), Y3 (M3), Y4 (M4), Y5 (M5)) Transmission Automatic Control Transmission Hand Control Output Speed Sensor Turbine Sensor Throttle Switch Water Temperature Gauge Fuel Gauge Speedometer Timer Relay Diode Buzzer Test Button Clutch Pressure Switch Engine Oil Pressure Switch Water Temperature Switch Vacuum Switch Transmission Oil Temperature Switch Brake Pressure Switch Alternator Hourmeter Heater Switch Resistor Heater Blower Cigar Lighter Changeover Switch Lift Arm Reset Bucket Ram Reset Clock Brake Switch Hazard Relay Hazard Switch Column Switch Sidelight Switch Column Switch Fog Light Switch Work Light Switch Work Light Relay nterior Light Switch Front Wiper Switch Front Wiper Motor Front Washer Switch Front Wash Motor Horn Push Horn Rear Wash/Wipe Switch Rear Wiper Motor

9804/1103

60 61 62 63 64

Air Conditioning Thermostat Air Conditioning Pressure Switch Compressor Clutch Field Coil E.S.O.S. Brake Dump Valve

Lamps 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

Parking Brake Warning Light Reverse Light (Left Hand) Reverse Light (Right Hand) Master Warning Light Transmission Pressure Light Engine Oil Pressure Light Water Temperature Light Air Filter Light Transmission Oil Temperature Light Brake Pressure Light Alternator Warning Light Indicator Warning Light Brake Light (Left Hand) Brake Light (Right Hand) Indicator (Front Left Hand) Indicator (Rear Left Hand) Indicator (Front Right Hand) Indicator (Rear Right Hand) Hazard Warning Light Sidelight (Right Hand) Sidelight (Left Hand) Rear Fog Light Dipped Beam Main Beam Work Light (Front) Interior Light Beacon

Fuses A1 Direction Indicators A2 Right Sidelights and Gauge Illumination A3 Rear Fog Light A4 Gear Selection A5 Brake Lights, Loader Arm and Bucket Reset A6 Warning Lights, Heater Fan and Gauges A7 Main Beam B1 Hazard Warning Lights B2 Dipped Beam B3 Rear Work Lights B4 Rear Wash/Wipe B5 Interior Light and Beacon B6 E.S.O.S. B7 Air Conditioning C1 Left Sidelights C2 Front Work Lights C3 Forward/Reverse Select C5 Horn, Wash/Wipe (Front) Note 1: For bulb and fuse ratings see pages 50 - 05 - 01/4, 01/5. Note 2: For manual transmission machines, Item 18 (Throttle Switch) is not fitted. Wires 9508 and 9508A are linked. Note 3: For Germany ONLY, Wire 9588 is not connected to Item 10 (Reverse Light Relay).

50 - 15 - 01/21

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 01/22

426, 436 Circuit Diagrams - Electrical

55A 9A

27

71 72 14

26

414 420

420

29 28

31

33

82 83

30

84 85 86 87

846B 835E 836G 846A 835D 836F

413

32

844B

6

37

861

852

89 90 91 92 93 801 812

851

826G

5

7

844

9

20

36

21 408

17

405

400 416

422

39 104G 104B

18

10

40 104C

88

81

22

106C

9588A

9588

813

104H

53

104A

835

25 839

C1

B2

800

804

8008

304C

805

845 9584

74

+

11

8

003

9464 9524

9438 9446 9460

9528

60

004

-

421

12

33

15

32

14

31

27

17

302A

15

64 101M 22

57

9600

863

104

49

9504

8

26

23

25

19

24

A4

56 56

306

9658

63

1

2

9650

820

5

18

9666

35

9678

800

75 76 77 78 79 80

23

29

B3

C3

51

420

24

9654

9612

59

803

73

44

34 106A

100 300B

70 002B

54 55

802

35

101H 302

200E

106S

9600A

3

52

8360 8358

822

9674

4

200

837

101

1

47

41

9536

9512

862

13

840

+

9430

814 815

406

4 6 5 9434 9442

816A 819

23

23

3

818 817

50

61

45

7 8 1 2

62

A7

9508

16

56A

304E

862

A2

838 9508A

810

803C

42

38

418

411

807

48

844C

19

54A

806

802

56B

94 95 96

106B

300

A6

B6

105

102

100

100A

107

106

304D

46

838

A5

A1

B1

837A

C5

43

B4

B7

200 & 200A

200K

002 000H

000A

200H

200F

000F

000C

000

001 304 000

2 C2

B5

200D 200S

9804/1103

50 - 15 - 01/22

200M

Issue 1

CONTENTS

*

Wheeled Loaders

50 - 15 - 01/ 21

411, 411B from m/c no. 527850 416, 416B from m/c no. 530100 Circuit Diagram - Electrical Main Components

Lamps

1 2 3 4 5 6 7 8 9

120 121 122 123 124

Battery Isolator Light Relay Road Light Switch Fog Light Switch Column Switch Front Work Light Relay Front Work Light Switch Rear Work Light Switch

Fuses

Note: Items marked $ indicate remote connections (not shown), i.e. $1 $2 $3 $4 $5 $6

From EMS A23 To EMS B6 To EMS B12 To EMS B11 To EMS B10 To EMS B5

9804/1103

Fog Lights Dipped Beam Main Beam Front Work Lights Rear Work Lights

A1 A2 A3 A4 A5 A6

Rear Work Lights Road Lights Front Work Lights Dipped Beam Main Beam Rear Fog Lights

B1 B2

Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and Number Plate Lights

P1

Front Work Lights Rear Work Lights Main Beam Dip Beam Fog Lights

50 - 05 - 01/21

4150 - C/6-13.1

Issue 1*

Wheeled Loaders

CONTENTS

*

50 - 15 - 01/ 22

411, 411B from m/c no. 527850 416, 416B from m/c no. 530100 Circuit Diagram - Electrical 1

1

2

-

+

-

+

B1

See C/6-16

B2

See C/6-16

4 3 See C/6-18

See C/6-16

132A 005

201

A2

303

812D

800

120

5

812C

A6

812

803

6

804

P1 805

305

A4 A5

812B

$3 To EMS B12 LH

121

806

806B

RH

807

807A

LH

810E

006

A3

122 122A

$1 From EMS A23 808

122B

8

RH

806C

807C

7

120

806A

807B

201A

LH

812A

803B

See C/6-16

$2 To EMS B6

810

122

RH

$4 To EMS B11 $5 To EMS B10

810A LH

See C/6-24

810B

123 810C RH 810D

LH

813C

A1

121

9

124 813

813A

813B

9804/1103

50 - 05 - 01/22

813D

RH

$6 To EMS B5

4150 - C/6-14.1

Issue 1*

CONTENTS

*

Wheeled Loaders

50 - 15 - 01/ 23

411, 411B from m/c no. 527850 416, 416B from m/c no. 530100 Circuit Diagram - Electrical Main Components

Lamps

1 2 10 11 12 13 14 15 16

125 126 127 128 129 130 131 132 133 134 135

Battery Isolator Electronic Monitoring System (EMS) ZF Computer Hazard Warning Switch Hazard Warning Relay Column Switch Beacon Switch 24 Volt Radio

Note: Items marked $ indicate remote connections (not shown), i.e.

Left Front Indicator Left Rear Indicator Right Front Indicator Right Rear Indicator Beacon Interior Light Right Front Side Light Right Rear Side Light Left Front Side Light Left Rear Side Light Number Plate Lights

Fuses $7 $8 $9 $10 $11 $12

12 Volt Trailer Electrics To EMS B18 To EMS B16 Headlight Flash Switch Illumination To EMS B18

9804/1103

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Rigth Side/Tail Lights and Switch Illumination Left Side/Tail Lights and Number Plate Lights 12 Volt Trailer Electrics (Option) EMS (Battery Feed) ZF Computer (Battery Feed) Hazard Warning Beacon and Interior Light 24 Volt Radio Headlight Flash Side Lights

C9

Direction Indicators

P2

Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and Number Plate Lights Headlight Flash Radio (24 Volt) Beacon and Interior Light Hazard Warning EMS (Battery Feed) ZF Computer (Battery Feed) 12 Volt Trailer Electrics

50 - 05 - 01/23

4150 - C/6-15.1

Issue 1*

Wheeled Loaders

CONTENTS

*

50 - 15 - 01/ 24

411, 411B from m/c no. 527850 416, 416B from m/c no. 530100 Circuit Diagram - Electrical 1

1

-

+

-

+

2

B3 $7 12 Volt Trailer Electrics

B4

10

301

See C/6-42

9832

B5

11 9836

See C/6-40

202A

C9 See C/6-20

202

835A

12

B6

30

300 838

49

L

835B

R

836B

LH FRONT

125 835D

LH REAR

126

836A

RH FRONT

127

836

49A

837A

14

15

13

$8 To EMS B18

835

P2

835C 100

RH REAR

836D

128

837 836C

304E

15

$9 To EMS B16

823

129

B7

304D

304

130 B8

16

309

802D

B9

305

802C

B1 B10

4 303

See C/6-14

$11 Switch Illumination

$10 Headlight Flash See C/6-14

800

B2

120

802A

131

802

802B

132

801

801A

133

801C

134

801B 803B

$12 To EMS B18

See C/6-14 801D

LH

801E

RH

135

9804/1103

50 - 05 - 01/24

4150 - C/6-16.1

Issue 1*

CONTENTS

*

Wheeled Loaders

50 - 15 - 01/ 25

411, 411B from m/c no. 527850 416, 416B from m/c no. 530100 Circuit Diagram - Electrical Main Components

Lamps

1 2 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

136

Battery Isolator Starter Solenoids Starter Motor Start Relay Starter Switch Not Applicable Start-up Dump Solenoid Thermostart Resistor Thermostart Not Applicable Dump Relay Heater Speed Switch Heater Blower Air Conditioning Switch Air Conditioning Temperature Switch Air Conditioning Pressure Switch Air Conditioning Compressor Heated Mirror Switch Heated Mirrors Heated Seat Switch Seat Heating Elements Air Suspension Switch Air Suspension Compressor Heated Rear Screen Switch Heated Rear Screen Relay Heated Rear Screen Lights Relay Solenoid Ignition Relay Solenoid 1 Ignition Relay Solenoid 2 Ignition Relay Solenoid 3

Road Light Switch Illumination

Fuses A7 A8 A9 A10

Blank Thermostart Dump Relay Ignition Relays

C1 C6 C7 C8 C9 C10

Starter Relay Solenoid Heated Seat/Mirrors and Air Suspension Seat (Option) Air Conditioning (Option) Heater Blower Direction Indicators Heated Rear Screen

P3

Starter Solenoid Thermostart Heater Blower Air Conditioning Direction Indicators Heated Seat, Mirrors and Air Suspension Seat Heated Rear Screen Ignition Relays

Note: Items marked $ indicate remote connections (not shown), i.e. $13 $14 $15 $16

To EMS A34 Indicators To EMS A24 To EMS B4

9804/1103

50 - 05 - 01/25

4150 - C/6-17.1

Issue 1*

Wheeled Loaders

CONTENTS

*

50 - 15 - 01/ 26

411, 411B from m/c no. 527850 416, 416B from m/c no. 530100 Circuit Diagram - Electrical 1

1

-

+

-

+

2

17

19

203A

C1

001

A7

2 8 9

1

203

127

128

$13 To EMS 34 See C/6-24

20

7

P3

18

002

21

111

6 5

22 A8

23

113

24 25

000

A9 129

C8

28

27

822

112

821 820

26

C7

29

109

30

863

862

31

862A

32

873A

33

873

34

119A 873

830

C6

36

35

119

872

C9

100

$14 Indicators See C/6-16

39 103A

C10

38

37

119B

103

$16 To EMS B4 See C/6-24

826

$15 To EMS A24 See C/6-24

834 841

41

40

000A

A10

132

132A

42

132C

43

132D

44

132E

45

132F

9804/1103

50 - 05 - 01/26

136

4150 - C/6-18.1

Issue 1*

CONTENTS

*

Wheeled Loaders

50 - 15 - 01/ 27

411, 411B from m/c no. 527850 416, 416B from m/c no. 530100 Circuit Diagram - Electrical Main Components

Lamps

1 2 10 11 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69

137 138 139 140

Battery Isolator Electronic Monitoring System (EMS) ZF Computer Ignition Relay 1 Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Pump Horn Ignition Relay 2 Coluumn Switch Front Wiper Motor Intermittent Wiper Relay Front Washer Pump 24 Volt Cigar Lighter Shutdown Relay E.S.O.S. Reverse Relay Reverse Alarm Ignition Relay 3 Brake Light Switch Changeover Switch Changeover Solenoid Lift Ram Proximity Switch Detent Coil (Lift Ram Reset) Shovel Ram Proximity Switch Detent Coil (Shovel Ram Reset) Detent Coil (Float)

Fuses C2 C3 C4 C5

24 Volt Cigar Lighter Blank Rear Wash/Wipe Front Wash/Wipe and Horn

D1 D2 D3 D5 D6 D7 D8 D9 D10

EMS (Ignition Feed) ZF Computer (Ignition Feed) CCTV (Option) E.S.O.S. and Cold Start Advance Reverse Lights and Alarm In-cab 24/12 Volt Converter (Option) Blank Brake Lights Float, Lift and Shovel Reset and 4th Spool

P4

EMS (Ignition Feed) ZF COmputer (Ignition Feed) Rear Was/Wipe Front Wash/Wipe Cigar Lighter (24 Volt) E.S.O.S. and Cold Start Advance Reverse Alarm/Lights Headlight Flash Brake Lights Shovel and Arm Reset CCTV In-cab 24/12 Volt Converter

Note: Items marked $ indicate remote connections (not shown), i.e. $17 $18 $19 $20

CCTV Spare To EMS A11 To CCTV

9804/1103

Left Fog Light Right Fog Light Left Brake Light Right Brake Light

50 - 05 - 01/27

4150 - C/6-19.1

Issue 1*

CONTENTS

*

Wheeled Loaders

50 - 15 - 01/ 28

411, 411B from m/c no. 527850 416, 416B from m/c no. 530100 Circuit Diagram - Electrical

1

008

2

-

+

132C 204

118

$17 CCTV See C/6-26

D1

46 See C/6-20

-

+ D3

1

125

D2

10

See C/6-24

11

9916A

See C/6-40 102B

827

47 C4

102

48

102A

815

C3

49

814

$18 Spare

50

816 105B

53 817 818

51

829

132D

See C/6-18

204B

007

C5

105

831

52

105A

54

105C 828 819B

P4

D5

204A

55

819A

819

C2

124

$19 To EMS A11 See C/6-24

56

57

811

58

809

107

60

59 D6

204C

See C/6-18

61

009

See C/6-22

9916J 844

115

844A

137

844B

138 844D

D7

108

$20 To CCTV See C/6-26

See C/6-26

132E

D8 $18 Spare

D9

62

126

847

63

847A

139

847B

140

64

861

104G

D10

104

104B

104H

9804/1103

65

852

66

851

104C

50 - 05 - 01/28

67

68

69

4150 - C/6-20.1

Issue 1*

CONTENTS

*

Wheeled Loaders

50 - 15 - 01/ 29

411, 411B from m/c no. 527850 416, 416B from m/c no. 530100 Circuit Diagram - Electrical Main Components

Fuses

70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90

B5

ZF Computer (Battery Feed)

D2

ZF Computer (Ignition Feed)

Gear Box Controller Unit Torque Converter Out Temperature Sensor Reverse Relay Solenoid Load Suspension Solenoid Load Suspension On/Off Switch Parking Brake On/Off Switch (411 to 446) Parking Brake On/Off Switch (456) Auto/Manual Switch On/Off Switch Pressure Switch Transmission Disconnect Switch Parking Brake Solenoid Internal Gear Chain Speed Sensor Turbine Speed Sensor Engine Speed Sensor Output Speed Sensor Forward Reverse Rocker Switch Hand Controller Transmission Kick Down Button ZF Diagnostic Port ZF Display Plug

Note: Items marked $ indicate remote connections (not shown), i.e. $21 $22

CAN-BUS to EMS To EMS A30 (456 Only)

9804/1103

50 - 05 - 01/29

4150 - C/6-21.1

Issue 1*

CONTENTS

*

Wheeled Loaders

50 - 15 - 01/ 30

411, 411B from m/c no. 527850 416, 416B from m/c no. 530100 Circuit Diagram - Electrical

70 Y3

Y4

Y5

Y6

VSP1

2

3

4

5

6

7

TEMP 9

Y2

1

TEMP 8

Y1

$21 CAN-BUS to EMS See C/6-24

$22 To EMS A30 (456 Only)

421

9462A

9454

9574

71 438

439

9570

9462

9458

9908

9904

9450

9446

9442

9438

9434

9430

10

32

55

09

51

12

13

39

AIP1

AIP2

AIP3

AIP4

AIP5

AIP6

VPS1

VPS1

ER1

46 VMGA2

56

CANF-H

ADM2

CANF-T

9920

9852

848

57

75

VM1

01

9916F

896

9856

30

74

438A

02

VM2

9916H

27

897

438B

05

73

9916M

26

CANF-L

25

9808

07

72

9916J

9820B

ED10

9824

29

ED11

9820

11

82 9414

EF2

ED9

41

66

9816 9816A

9410

83 9404

VPI

9836

68

VPE2

9832

23

VPE1

9400

84

14 15 18

22

64

ED7

67

65

ED5

43

ED2

ED6

31

63

ED4

20

ED1

ED3

44

ED13

ED8

EF4 62

881

882

880

1

2

9532A

9500

9504

85

3

9508

VMG2 04

See C/6-16

EF1

19

45

9916

See C/6-20

B5

9424

9816B

80

9916A

9420

840

9916B

D2

EF3

9900

42

9916A

79

03

VMG1

78

893

08

77

9916G

81

9820A

21

76 9916D

9524

9528

9544

9548

9540

1

9532

4

3

2

86

9536A

9864 9644

9648

9652

KD

B2

B1

88 2

1

89

3

4

9640

4

50 - 05 - 01/30

3

1

9590

9804/1103

9594

87

9598

9916K

R

N

F

9536

4150 - C/6-22.1

90

Issue 1*

CONTENTS

*

Wheeled Loaders

50 - 15 - 01/ 31

411, 411B from m/c no. 527850 416, 416B from m/c no. 530100 Circuit Diagram - Electrical Main Components

Fuses

1 2 10 91 92 93 94 95 96 97 98 99 100 101 102 103 104

B4

EMS (Battery Feed)

D1

EMS (Ignition Feed)

Battery Isolator Electronic Monitoring System (EMS) EMS Diagnostic Port Buzser Fuel Level Sender Water Temperature Sender Transmission Oil Temperature Sender Engine Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Emergency Steer Switch Shutdown Relay Coil Front Work Light Relay Coil Heated Rear Screen Relay Coil Alternator

Note: Items marked $ indicate remote connections (not shown), i.e. $21 $23 $24 $25 $26 $27 $28 $29 $30 $31 $32 $33 $34

CAN-BUS to EMS From Fuse A6 From Fuse A4 From Fuse A5 From Front Work Light Switch From Rear Work Light Switch From LH Indicator Feed From RH Indicator Feed From Side Light Feed From Heated Rear Screen Switch From ZF Computer (Park Brake Status-456 Only) From Start Relay Coil 120 ohm Resistor

9804/1103

50 - 05 - 01/31

4150 - C/6-23.1

Issue 1*

Wheeled Loaders

CONTENTS

*

50 - 15 - 01/ 32

411, 411B from m/c no. 527850 416, 416B from m/c no. 530100 Circuit Diagram - Electrical 1

1

-

+

-

+

2

91

424

423

425

125A

A2

5 600BX

2

1

3

4

A26

A3 A35 A13

600G 600DU

139

420

B4 See C/6-16

301

D1 See C/6-20

A25

A12

B7 125

A36

10

B14 B1

$23 From Fuse A6 $24 From Fuse A4 $25 From Fuse A5 $26 From Front Work Light Switch $27 From Rear Work Light Switch $28 From LH Indicator Feed $29 From RH Indicator Feed $30 From Side Light Feed $31 From Heated Rear Screen Switch

812D 806C 807C 810E 813B 835C 836C 802C 826

128

93

415

94

401

95

B12 B11

A16

B10

A4

B5

A15

B18

A6

B16

A18

408

96

400

97

412

98

422

99

432

100

B18 B4

A23 421

431

B6

A11

$32 From ZF Computer (Park Brake Status-456 Only)

92

420A

811

101

808

102

834

103

A30 A24

A34

A27

B15

B9

B3

418

438E

439E

650

$34 120 ohm Resistor

$21 CAN-BUS To EMS See C/6-22

104

9804/1103

50 - 05 - 01/32

4150 - C/6-24.1

Issue 1*

CONTENTS

*

Wheeled Loaders

50 - 15 - 01/ 33

411, 411B from m/c no. 527850 416, 416B from m/c no. 530100 Circuit Diagram - Electrical Main Components

Fuses

1 2 105 106 107 108 109 110

D3 D7

Battery Isolator 24/12 Volt Converter 12 Volt Radio 12 Volt Cigar Lighter 12 Volt Auxiliary Plug Closed Circuit Television Display (CCTV) CCTV Camera

CCTV (Option) In-cab 24/12 Volt Converter (Option)

Note: Items marked $ indicate remote connections (not shown), i.e. $35 $36

Reverse Light/Alarm RFeed From Side Light Feed

9804/1103

50 - 05 - 01/33

4150 - C/6-25.1

Issue 1*

CONTENTS

*

Wheeled Loaders

50 - 15 - 01/ 34

411, 411B from m/c no. 527850 416, 416B from m/c no. 530100 Circuit Diagram - Electrical 1

1

-

+

-

+

2

600DZ

308A

D7

108

See C/6-20

105

308

308B

308C

106

107

108

603A

603B

603C

603

$35 Reverse Light/Alarm Feed See C/6-20

844D

D3

118

See C/6-20

$36 From Side Light Feed

109

802M

110

9804/1103

50 - 05 - 01/34

4150 - C/6-26.1

Issue 1*

CONTENTS

Wheeled Loaders

412S

50 - 15 - 02/1

m/c’s to 535116

Circuit Diagrams - Electrical Main Components 1 2 3 4 5 6 7 8 9 9A 10 11 12 13 14 15 16 17 17A 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 54A 55 55A 56 56A 56B

Battery Starter Switch Thermo Coil Start Relay Starter Solenoids Starter Motor Neutral Start Relay Parking Brake Switch Reverse Alarm Relay Reverse Alarm Reverse Light Relay Dump Pressure Switch Dump Switch Reverse Light Switch Transmission Solenoid Switches (Y1 (M1), Y2 (M2), Y3 (M3), Y4 (M4), Y5 (M5)) Transmission Automatic Control Transmission Hand Control Output Speed Sensor Turbine Sensor Throttle Switch Water Temperature Gauge Fuel Gauge Speedometer Timer Relay Diode Buzzer Test Button Clutch Pressure Switch Engine Oil Pressure Switch Water Temperature Switch Vacuum Switch Transmission Oil Temperature Switch Brake Pressure Switch Alternator Hourmeter Heater Switch Resistor Heater Blower Cigar Lighter Changeover Switch Lift Arm Reset Bucket Ram Reset Clock Brake Switch Hazard Relay Hazard Switch Column Switch Sidelight Switch Column Switch Fog Light Switch Work Light Switch Work Light Relay Interior Light Switch Front Wiper Switch Front Wiper Motor Front Washer Switch Front Wash Motor Horn Push Horn Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Motor

9804/1103

57 58 59 60 61 62 63 64

Dump Switch (Loader Control) Kickdown Switch (Loader Control) Air Conditioning Switch Air Conditioning Thermostat Air Conditioning Pressure Switch Compressor Clutch Field Coil E.S.O.S. Brake Dump Valve

Lamps 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

Parking Brake Warning Light Reverse Light (Left Hand) Reverse Light (Right Hand) Master Warning Light Transmission Pressure Light Engine Oil Pressure Light Water Temperature Light Air Filter Light Transmission Oil Temperature Light Brake Pressure Light Alternator Warning Light Indicator Warning Light Brake Light (Left Hand) Brake Light (Right Hand) Indicator (Front Left Hand) Indicator (Rear Left Hand) Indicator (Front Right Hand) Indicator (Rear Right Hand) Hazard Warning Light Sidelight (Right Hand) Sidelight (Left Hand) Rear Fog Light Dipped Beam Main Beam Work Light (Front) Interior Light Beacon

Fuses A1 A2 A3 A4 A5 A6 A7 B1 B2 B3 B4 B5 B6 B7 C1 C2 C3 C5

Direction Indicators Right Sidelights and Gauge Illumination Rear Fog Light Gear Selection Brake Lights, Loader Arm and Bucket Reset Warning Lights, Heater Fan and Gauges Main Beam Hazard Warning Lights Dipped Beam Rear Work Lights Rear Wash/Wipe Interior Light and Beacon E.S.O.S. Air Conditioning Left Sidelights Front Work Lights Forward/Reverse Select Horn, Wash/Wipe (Front)

Note 1: For fuse and bulb ratings see pages 50-05-01/6&7 Note 2 For Germany ONLY, Wire 9588 is not connected to Item 10 (Reverse Light Relay).

50 - 15 - 02/1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 02/2

412S

To m/c no. 535116

Circuit Diagrams - Electrical

55A 9A

27

71 72 14

6

420

17A

844B

26

414 420

29 28

31

33

37

82 83

30

84 85 86 87

846B 835E 836G 846A 835D 836F

413

32

861

852

89 90 91 92 93 801

54A

806

802

812

56B

94 95 96

807

810

56A

304E

62

851

844C

862

19 826G

5

7

844

9

20

36

21 408

17

405

400 416

422

39

411

104G 104B

18

10

42

38

418

40 104C

88

81 104H

A2

22

106C

A7 53

838 9508A

A3

104A

835

25

C1

B2

800

804

800B

304C

805

9588A

9588

16

813

839

45

845 9584

803C

74

+

003

12

421

4

33

14

31

9

34

27

17

302A

22 9600

9600A

1

822

23

25

19

24

106S

104

49

54 55

56 56

802

35

306

63

9658

9650

B3

9666

35

9678

C3

002B

803

51

420

24 58

59

800

75 76 77 78 79 80

23

18

9654

9612

70

820

29

2

9612A 302

A4

863

8358

9536

5

15

101H

200E

8

26

101M

3

52

8360

9674

57

200

15

32

101

64

837

13

840 004

47

41

9438 9446 9470 9460 9528 9512 9504

11

8

862

60

406

4 6 5

1

814 815

23

23

3

9434 9442 9430 9474 9464 9524

816A 819

48

7 8 1 2

818 817

50

9508

61

73

44

34 106A

100 300B

9536A

107 106B

106

B6

A5

105

102

100

100A 300

A6

304D

46

838

A1

B1

837A

C5

43

B4

B7

200 & 200A

200K 002A

000A

200H

200F

000F

000C

000

001 304 000

2 C2

B5

2000 200S

200M

A217091

9804/1103

50 - 15 - 02/2

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 02/3

412S

From m/c no. 535117

Circuit Diagrams - Electrical

17 7

102

39

103 24

10 844B

2

844C

38

414 415

25

431

41 40

43

45

49

42

413

44

13 850

50

855

31

5 3

826G

8

11

844

18

14

32

46

33 408

26

400

405

422

416

411

862A

27

22 9508A

34

106C

37

9588A

9588

30

813

51

35

9508 839

8 7 4 3 845 9584

9520

101L

2

9516

1

C7

003

-

9434 9442 9430 9474 9464 9524

15

+

52

1 6 5 106S

33

15

32

14

31

8

26

23

25

19

24

47

822

9658 9674

16

421A

4 107 307

9

302A 840

101

5

28

21

20

22

1

101A

9600

2

9650

18

9666

35

9678

420A

101H

302

A6

A4

820

109

53

36 106D

104

108

110 48 106A

109

106M

9536A

9612

200E

B6

107

106

420B

29 9612A 106

105

420

9654

12

35

106B

29

101M

106F 101C

308

863

9536

9600A

19

421B

004

200

406

9536B

23

9600B 9600C

002C

103

9438 9446 9470 9460 9528 9512 9504

421 002B

862

35

B3

C3

106

B7 200 & 200A

002

00H 000K

001

000G

002A

000B

000L

000S

000

6 200D

202

A251550

9804/1103

50 - 15 - 02/3

Issue 1

CONTENTS

Wheeled Loaders

412S

50 - 15 - 02/4

From m/c no. 535117

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

Battery Starter Motor Starter Solenoids Start Relay Hydraulic Dump Valve Starter Switch Glow Plug 1 Glow Plug 1 Relay 60A Fuse Glow Plug 2 Glow Plug 2 Relay 60A Fuse E.S.O.S. Neutral Start Relay Park Brake Switch Park Brake Transmission Disconnect Reverse Alarm Reverse Alarm Relay Dump Pressure Switch Dump Switch Dump Switch (Loader Control) Reverse Light Relay Rear Work Light Switch Transmission Solenoids (Y1 (M1), Y2 (M2), Y3 (M3), Y4 (M4), Y5 (M5) Turbine Sensor Output Speed Sensor Throttle Switch Transmission Automatic Control Kickdown Switch (Loader Control) Transmission Hand Control Water Temperature Gauge Fuel Gauge Speedometer Timer Diode Buzzer Test Button Clutch Pressure Switch Engine Oil Pressure Switch Water Temperature Switch Vacuum Switch Transmission Oil Temperature Switch Brake Pressure Switch Alternator Hourmeter Heater Blower Resistor Heater Switch Cigar Lighter Air Conditioning Compressor Air Conditioning Pressure Switch Air Conditioning Temperature Switch Air Conditioning Switch

9804/1103

Lamps 101 102 103 104 105 106 107 108 109 110

Parking Brake Warning Light Reverse Light (Left Hand) Reverse Light (Right Hand) Master Warning Light Engine Oil Pressure Light Water Temperature Light Air Filter Light Transmission Oil Temperature Light Brake Pressure Light Alternator Warning Light

Fuses A4 Reverse Alarm/Dump Switch A6 Warning Lights, Heater Fan Gauges, Cigar Lighter, Transmission Disconnect Relay, Timer and Hourmeter B3 Reversing Lights B6 E.S.O.S. B7 Air Conditioning (Optional) C3 Transmission C7 Hydraulic Dump Valve

Note 1: For fuse and bulb ratings see pages C1-1 and C1 - 2. Note 2 For Germany ONLY, Wire 9588 is not connected to Item 22 (Reverse Light Relay).

50 - 15 - 02/4

4170 - C/6 - 5.1

Issue 1

CONTENTS

Wheeled Loaders

412S

50 - 15 - 02/5

From m/c no. 535117

Circuit Diagrams - Electrical Main Components

Fuses

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

A1 A2 A3 A5

Clock Column Switch Hazard Switch Hazard Relay Sidelight Switch Column Switch Fog Light Switch Work Light Relay Work Light Switch Detent Coil (Lift Arm) Proximity Switch (Lift Arm) Detent Coil (Shovel Ram) Proximity Switch (Shovel Ram) Detent Coil (Float) Brake Light Switch Tow Hitch Solenoids Tow Hitch Switch Rear Wiper Motor Rear Wash/Wipe Switch Rear Washer Motor Front Washer Motor Front Washer Switch Horn Horn Push Front Wiper Motor Front Wiper Switch Interior Light Switch Radio

A7 B1 B2 B4 B5 C1 C2 C5

Directions Indicators Right Sidelights and Switch/Panel Illumination Fog Lights Brake Lights, Loader Arm, Shovel Reset and Tow Hitch Solenoids Main Beam Hazard Warning Lights and Clock Dip Beam Rear Wash/Wipe Interior Light, Beacon and Radio (Optional) Left Sidelights and Number Plate Lights Work Lights Horn and Front Wash/Wipe

Lamps 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141

Indicator (Trailer Left Hand) Indicator (Front Left Hand) Indicator (Rear Left Hand) Indicator (Front Right Hand) Indicator (Rear Right Hand) Indicator (Trailer Right Hand) Indicator Warning Hazard Warning Light Indicator (Trailer Warning) Sidelight (Front Right Hand) Sidelight (Rear Right Hand) Trailer Light Sidelight (Front Left Hand) Sidelight (Rear Left Hand) Numberplate Light (Right Hand) Numberplate Light (Left Hand) Trailer Light Dipped Beam (Left Hand) Dipped Beam (Right Hand) Main Beam (Left Hand) Main Beam (Right Hand) Main Beam Warning Fog Lights Fog Lights (Trailer) Work Lights (Left Hand) Work Lights (Right Hand) Brake Light (Left Hand) Brake Light (Right Hand) Brake Light (Trailer) Beacon Interior Light

9804/1103

50 - 15 - 02/5

4170 - C/6-5.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 02/6

412S

From m/c no. 535117

Circuit Diagrams - Electrical

111 113 112

115

114

121

116

120

835B 835E 836G 835D 836F 836J

123

122

125

124

802A

801C 802B

801A

127

126

801H 801E

129 128

131 130

806A

132

807A 806B

133

137

136 65

67

78

138 863

812B 812A

139 69

63

134

807C 807B

135

812D

810A 810C

810B

846A

810D 852

846D

864

846B

851

140

141

81

70 802

117

71

104F

118

73

74 76 817 818

801

806

807

812

64

810

A2

C1

55

B2

A7

A3

815

66

8008

804

814

819

816

79 61

104B

104C

104H

304E

104E

72

812C

35

80

68

75 77

304C

304B

304D

805

60 59 54

837

803B

808

8360 8358

62

802N 800A

306

104

102

105

304

800

119

803

300B

56 100 300

58

838 837A

A1

B1

C2

B4

A5

C5

B5

57 000A

200H

200F

200S

000E

000C

000F

200M

A251560

9804/1103

50 - 15 - 02/6

Issue 1

CONTENTS

Wheeled Loaders

412S

50 - 15 - 02/7

From m/c no. 535375

Circuit Diagrams - Electrical Main Components

Lamps

1 2 3 4 5 6 7A 7B 8A 8B 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

110 111 112

Starter Switch Battery Isolator Starter Relay Starter Solenoids Starter Motor Glow Plug 1 Relay Glow Plug 2 Relay Glow Plug 1 Glow Plug 2 Shut down Relay E.S.O.S. Electronic Monitoring system (EMS) Computer Feed Relay ZF Computer Transmission Solenoids Turbine Speed Sensor Output Speed Sensor Throttle Switch Kickdown Switch Hand Controller Relays Forward/Reverse Control Relays Hand Controller Forward/Reverse Switch Reverse Alarm Relay Reverse Alarm Reverse Lights Switch Reverse Lights Relay ACCS Relay ACCS Override Switch ACCS Solenoid Valve

LH Reverse Light RH Reverse Light ACCS Operating Indication Light

Fuses 6A 8A

Computer Feed Relay Solenoid EMS Battery Feed

3B 6B 8B

Reverse Alarm and Rear Work Lights Engine Shut Off System (ESOS) Thermostart

3C 8C

EMS and ZF Computer Feed ACCS

Note: For fuse ratings see Fuses, Relays in Technical Data.

Note: Arrows marked § indicate remote connection (not shown), ie. B5 goes to connection B5 on EMS (Item 11).

9804/1103

50 - 15 - 02/7

4170 - C/6 - 11.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 02/8

412S

From m/c no. 535375

Circuit Diagrams - Electrical 2 3

5

6

4 1

7A 8A 7B 8B

9

6B

10

8A 11

12

3C 6A

14 15

17

13

16 20

19

18

21

22 24 23 26

3B 25

110

27

§

111

8C 28

29 112

9804/1103

50 - 15 - 02/8

4170 - C/6 - 12.1

Issue 1

CONTENTS

Wheeled Loaders

412S

50 - 15 - 02/9

From m/c no. 535375

Circuit Diagrams - Electrical Main Components

Lamps

1 11 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

113

Starter Switch Electronic Monitoring system (EMS) Warning Light Test Button Buzzer Fuel Contents Sender Water Temperature Sender Transmission Oil Temperature Sender Hydraulic Oil Temperature Sender Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Engine Oil Level Sensor Coolant Level Sensor Transmission Oil LevelSensor Hydraulic Oil Level Sensor Emergency Steer Switch Water in Fuel Sensor Parking Brake Switch Alternator Heater Switch Heater Relay Heater Blower Cigar Lighter Air Conditioning Switch Air Conditioning Temperature Switch Air Conditioning Pressure Switch Air Conditioning Compressor Clutch

Master Warning Light

Fuses 8A

EMS Battery Feed

7B

Air Conditioning

6C

Heater Blower and Cigar Lighter

Note: For fuse ratings see Fuses, Relays in Technical Data.

Note: Arrows marked § indicate remote connection (not shown), ie. 3C goes to Fuse 3C via. Relay (Item 12).

9804/1103

50 - 15 - 02/9

4170 - C/6 - 13.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 02/10

412S

From m/c no 535375

Circuit Diagram - Electrical 1

30 113 31

8A 32 33 §

34 35 36 37

11

38 39 40 41 42 43 44 45 46 47

48 50 51 6C 49

52 7B

53

54

55

50 - 15 - 02/10

56

4170 - C/6-14.1

Issue 1

CONTENTS

Wheeled Loaders

412S

50 - 15 - 02/11

From m/c no 535375

Circuit Diagram - Electrical Main Components

Lamps

1 57 58 59 60 61 62 63 64 65 66

114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134

Starter Switch Hazard Relay Hazard Warning Switch Column Switch Diode Road Light Switch Head Light Flasher Switch Fog Light Switch Front Work Lights Switch Front Work Lights Inhibit Relay (Italy Only)† Front Work Lights Relay

† On all machines other than Italy, relay 65 is not fitted and wires 853A and 808A are connected Note: Arrows marked § indicate remote connection (not shown), ie. B4 goes to connection B4 on EMS (Item 11). B6 goes to connection B6 on EMS (Item 11). B10 goes to connection B10 on EMS (Item 11). B11 goes to connection B11 on EMS (Item 11). B12 goes to connection B12 on EMS (Item 11). B16 goes to connection B16 on EMS (Item 11). B17 goes to connection B17 on EMS (Item 11). B18 goes to connection B18 on EMS (Item 11).

Trailer Indicator Warning LH Trailer Indicator LH Front Indicator LH Rear Indicator RH Front Indicator RH Rear Indicator RH Trailer Indicator RH Front Side Light RH Tail Light Trailer Switch/Panel Illumination LH Front Side Light LH Tail Light RH Number Plate Light LH Number Plate Light Trailer Dipped Beam Main Beam Fog Lights Trailer Fog Light LH Front Work Lights RH Front Work Lights

Fuses 1A 2A 3A

Hazard Warning Lights and Direction Indicators RH Side/Tail Lights and Switch/Panel Illumination Fog Lights

1B 2B

Hazard Battery Feed Dip Beam

1C 2C 9C

LH Side/Tail Lights and Number Plate Lights Front Work Lights Road Lights

Note: For fuse ratings see Fuses, Relays in Technical Data.

9804/1103

50 - 15 - 02/11

4170 - C/6-15.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 02/12

412S

From m/c no 535375

Circuit Diagram - Electrical 1 §

115 1A 116

58

1B

117 59

57

118 119

60

114

§

120 §

121

2A

122 123 §

124 125

1C

126 127 128

2B 129 61 §

62

9C

7A

130 §

63

3A

131 132 §

133 65 64 2C 134

66

§

9804/1103

50 - 15 - 02/12

4170-C/6-16.1

Issue 1

CONTENTS

Wheeled Loaders

50 - 15 - 02/13

412S

From m/c no 535375

Circuit Diagram - Electrical Main Components

Lamps

1 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

135 136 137 138 139 140

Starter Switch Lift Ram Proximity Switch Detent Coil (Lift Arm Reset) Shovel Ram Proximity Switch Detent Coil (Shovel Ram Reset) Detent Coil (Float) Brake Light Switch Tow Hitch Switch Tow Hitch Solenoids Heated Mirror Switch LH Heated Mirror RH Heated Mirror Heated Seat Switch Heated Seat Heated Seat Thermostat Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Pump Horn Front Wiper Motor Column Switch Intermittent Wiper Relay Front Washer Pump Beacon Switch Interior Light Radio (Option) Under Bonnet Lights Switch

9804/1103

LH Brake Light RH Brake Light Beacon Interior Light LH Under Bonnet Light RH Under Bonnet Light

Fuses 5A

Brake Lights, Float, Lift and Shovel Reset

4B 5B

Rear Wash/Wipe Beacon, Interior Light, Radio and Under Bonnet Lights

4C 5C

Heated Mirror and Heated Seat Front Wash/Wipe and Horn

Note: For fuse ratings see Fuses, Relays in Technical Data.

50 - 15 - 02/13

4170-C/6-17.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 02/14

412S

From m/c no 535375

Circuit Diagram - Electrical 1 67 68 69 70 5A 71 135 72 136 73 74 76 77

75 4C

79 78

80

81 4B

82

83 84

85

5C

86 87

88 89

137

5B 138

91

92

9804/1103

50 - 15 - 02/14

90

139 140

4170-C/6-18.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 03/1

414S

From m/c no. 537000 to 537193

Circuit Diagrams - Electrical

17

102

39

103 24

844B

2

5

7

844C

38

414 415

25

431

41 40

43

45

49

42

413

44

13

50 31 826G

3

844

18

14

32

46

33 408

26

400

405

422

416

411

862A

27

22 9508A

34

106C

37

9588A

9588

30

813

51

35

9508 002C

839

8 4 3 845 9584

9520

101L

2

9516

1

C7

003

-

9434 9442 9430 9474 9464 9524

15

+

103

52

1 6 5

9536B

23

9600B 9600C

106S

33

15

32

14

31

8

26

23

25

19

24

47

822

9658 9674

16

421A

4 107

302A 840

101

5

28

21

20

22

1

2

101A

9600

9650

9654

106

101H

302

18

9666

35

9678

A4

107

820

109

53

420 420A

106

420B

36 106D

104

108

110 48 106A

109

106M

9536A

9612

200E

A6

105

29

29 9612A

35

106B

101M

106F 101C

B6

863

9536

9600A

19

421B

004

200

406

9438 9446 9470 9460 9528 9512 9504

421 002B

862

35

7

B3

C3

106

B7 200 & 200A

002

00H 000K

001

000G

002A

000B

000L

000S

000

6 200D

9804/1103

50 - 15 - 03/1

3270 - E/6-2.4

Issue 2*

CONTENTS

Wheeled Loaders

414S

50 - 15 - 03/2

*From m/c no 537000 to 537193

Circuit Diagram - Electrical Main Components 1 Battery 2 Starter Motor 3 Starter Solenoids 4 Start Relay 5 Hydraulic Dump Valve 6 Starter Switch 7 Thermostart 13 E.S.O.S. 14 Neutral Start Relay 15 Park Brake Switch 16 Park Brake Transmission Disconnect 17 Reverse Alarm 18 Reverse Alarm Relay 19 Dump Pressure Switch 20 Dump Switch 21 Dump Switch (Loader Control) 22 Reverse Light Relay 23 Rear Work Light Switch 24 Transmission Solenoids (Y1 (M1), Y2 (M2), Y3 (M3), Y4 (M4), Y5 (M5) 25 Turbine Sensor 26 Output Speed Sensor 27 Throttle Switch 28 Transmission Automatic Control 29 Kickdown Switch (Loader Control) 30 Transmission Hand Control 31 Water Temperature Gauge 32 Fuel Gauge 33 Speedometer 34 Timer 35 Diode 36 Buzzer 37 Test Button 38 Clutch Pressure Switch 39 Engine Oil Pressure Switch 40 Water Temperature Switch 41 Vacuum Switch 42 Transmission Oil Temperature Switch 43 Brake Pressure Switch 44 Alternator 45 Hourmeter 46 Heater Blower 47 Resistor 48 Heater Switch 49 Cigar Lighter 50 Air Conditioning Compressor 51 Air Conditioning Pressure Switch 52 Air Conditioning Temperature Switch 53 Air Conditioning Switch

Lamps 101 Parking Brake Warning Light 102 Reverse Light (Left Hand) 103 Reverse Light (Right Hand) 104 Master Warning Light 105 Engine Oil Pressure Light 106 Water Temperature Light 107 Air Filter Light 108 Transmission Oil Temperature Light 109 Brake Pressure Light 110 Alternator Warning Light Fuses A4 A6 A7 B3 B6 B7 C3 C7

Reverse Alarm/Dump Switch Warning Lights, Heater Fan,Gauges, Cigar Lighter, Transmission Disconnect Relay, Timer and Hourmeter Main Beam Reversing Lights E.S.O.S. Air Conditioning (Optional) Transmission Hydraulic Dump Valve

Note 1: For fuse and bulb ratings see pages 50-05-01/6&8 Note 2 For Germany ONLY, Wire 9588 is not connected to Item 22 (Reverse Light Relay).

50 - 15 - 03/2

Issue 2*

CONTENTS

Wheeled Loaders

414S

50 - 15 - 03/3

*From m/c no 537000 to 537193

Circuit Diagrams - Electrical Main Components 54 Clock 55 Column Switch 56 Hazard Switch 57 Hazard Relay 58 Sidelight Switch 59 Column Switch 60 Fog Light Switch 61 Work Light Relay 62 Work Light Switch 63 Detent Coil (Lift Arm) 64 Proximity Switch (Lift Arm) 65 Detent Coil (Shovel Ram) 66 Proximity Switch (Shovel Ram) 67 Detent Coil (Float) 68 Brake Light Switch 69 Tow Hitch Solenoids 70 Tow Hitch Switch 71 Rear Wiper Motor 72 Rear Wash/Wipe Switch 73 Rear Washer Motor 74 Front Washer Motor 75 Front Washer Switch 76 Horn 77 Horn Push 78 Front Wiper Motor 79 Front Wiper Switch 80 Interior Light Switch 81 Radio

Fuses A1 A2 A3 A5 A7 B1 B2 B4 B5 C1 C2 C5

Direction Indicators Right Sidelights and Switch/Panel Illumination Fog Lights Brake Lights, Loader Arm, Shovel Reset and Tow Hitch Solenoids Main Beam Hazard Warning Lights and Clock Dip Beam Rear Wash/Wipe Interior Light, Beacon and Radio (Optional) Left Sidelights and Number Plate Lights Work Lights Horn and Front Wash/Wipe

Note 1: For fuse and bulb ratings see pages 50-05-01/6&8

Lamps 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141

Indicator (Trailer Left Hand) Indicator (Front Left Hand) Indicator (Rear Left Hand) Indicator (Front Right Hand) Indicator (Rear Right Hand) Indicator (Trailer Right Hand) Indicator Warning Hazard Warning Light Indicator (Trailer Warning) Sidelight (Front Right Hand) Sidelight (Rear Right Hand) Trailer Light Sidelight (Front Left Hand) Sidelight (Rear Left Hand) Numberplate Light (Right Hand) Numberplate Light (Left Hand) Trailer Light Dipped Beam (Left Hand) Dipped Beam (Right Hand) Main Beam (Left Hand) Main Beam (Right Hand) Main Beam Warning Fog Lights Fog Lights (Trailer) Work Lights (Left Hand) Work Lights (Right Hand) Brake Light (Left Hand) Brake Light (Right Hand) Brake Light (Trailer) Beacon Interior Light

9804/1103

50 - 15 - 03/3

Issue 2*

Wheeled Loaders

CONTENTS

50 - 15 - 04/1

409 Telemaster Circuit Diagrams - Electrical

950

1 B

22A

647E

4

A C

D B7 22

+12v

647D

951

4 647G

2

7

A

B 957

1 -ve

4

2

3

2 +ve

5

22B

952

5

3 450

452

451

3

647C

1

954

C

4

2

452B

452A

647F

3

A 2

4

B

2

955

1

3 6

22C

22D

953 5

647B

1

5

3

956

647

5

6 647A

A233140

Main Components and Switches 1 2 3 4 5 6 7 C D

Solenoid Control Switch - Boom Extend/Retract Solenoid Control Switch - Auxiliary Service Solenoid Relays Solenoids - Boom Extend/Retract Valve Solenoids - Auxiliary Valve Safe Load Indicator Strain Gauge Connections to Auxiliary Solenoid Control Valve ‘C’ Connections to Boom Extend/Retract

9804/1103

50 - 15 - 04/1

Issue 1

CONTENTS

Wheeled Loaders

50 - 15 - 03/5

414S From m/c no. 537194 416S From m/c no. 543000 Circuit Diagram - Electrical Main Components

Lamps

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

110 111 112

Starter Switch Battery Isolator Starter Relay Starter Solenoids Starter Motor Not Used Thermostart Coil Shut down Relay E.S.O.S. Electronic Monitoring system (EMS) Computer Feed Relay ZF Computer Transmission Solenoids Turbine Speed Sensor Output Speed Sensor Throttle Switch Kickdown Switch Hand Controller Relays Forward/Reverse Control Relays Hand Controller Forward/Reverse Switch Reverse Alarm Relay Reverse Alarm Reverse Lights Switch Reverse Lights Relay ACCS Relay ACCS Override Switch ACCS Solenoid Valve

LH Reverse Light RH Reverse Light ACCS Operating Indication Light

Fuses 6A 8A

Computer Feed Relay Solenoid EMS Battery Feed

3B 6B 8B

Reverse Alarm and Rear Work Lights Engine Shut Off System (ESOS) Thermostart

3C 8C

EMS and ZF Computer Feed ACCS

Note: For fuse ratings see Fuses, Relays in Technical Data.

Note: Arrows marked § indicate remote connection (not shown), ie. B5 goes to connection B5 on EMS (Item 11).

9804/1103

50 - 15 - 03/5

4170-C/6-19.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 03/6

414S From m/c no. 537194 416S From m/c no. 543000 Circuit Diagram - Electrical 2

2 3 5 6

4 1 8B

6B

8

9

10

8A 11

12

3C 6A

14

15

17

13

16

20

19

18

21

22 24 23 26

3B 25

110 §

111

27 8C 28

29 112

9804/1103

50 - 15 - 03/6

4170-C/6-20.1

Issue 1

CONTENTS

Wheeled Loaders

50 - 15 - 03/7

414S From m/c no. 537194 416S From m/c no. 543000 Circuit Diagram - Electrical Main Components

Lamps

1 11 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

113

Starter Switch Electronic Monitoring system (EMS) Warning Light Test Button Buzzer Fuel Contents Sender Water Temperature Sender Transmission Oil Temperature Sender Hydraulic Oil Temperature Sender Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Engine Oil Level Sensor Coolant Level Sensor Transmission Oil LevelSensor Hydraulic Oil Level Sensor Emergency Steer Switch Water in Fuel Sensor Parking Brake Switch Alternator Heater Switch Heater Relay Heater Blower Cigar Lighter Air Conditioning Switch Air Conditioning Temperature Switch Air Conditioning Pressure Switch Air Conditioning Compressor Clutch

Master Warning Light

Fuses 8A

EMS Battery Feed

7B

Air Conditioning

6C

Heater Blower and Cigar Lighter

Note: For fuse ratings see Fuses, Relays in Technical Data.

Note: Arrows marked § indicate remote connection (not shown), ie. 3C goes to Fuse 3C via. Relay (Item 12).

9804/1103

50 - 15 - 03/7

4170-C/6-21.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 03/8

414S From m/c no. 537194 416S From m/c no. 543000 Circuit Diagram - Electrical 1

30 113 31

8A 32 33 §

34 35 36 37

11

38 39 40 41 42 43 44 45 46 47

48 50 51 6C 49

52 7B

9804/1103

53

54

50 - 15 - 03/8

55

56

4170-C/6-22.1

Issue 1

CONTENTS

Wheeled Loaders

50 - 15 - 03/9

414S From m/c no. 537194 416S From m/c no. 543000 Circuit Diagram - Electrical Main Components

Lamps

1 57 58 59 60 61 62 63 64 65 66

114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134

Starter Switch Hazard Relay Hazard Warning Switch Column Switch Diode Road Light Switch Head Light Flasher Switch Fog Light Switch Front Work Lights Switch Front Work Lights Inhibit Relay (Italy Only)† Front Work Lights Relay

† On all machines other than Italy, relay 65 is not fitted and wires 853A and 808A are connected Note: Arrows marked § indicate remote connection (not shown), ie. B4 goes to connection B4 on EMS (Item 11). B6 goes to connection B6 on EMS (Item 11). B10 goes to connection B10 on EMS (Item 11). B11 goes to connection B11 on EMS (Item 11). B12 goes to connection B12 on EMS (Item 11). B16 goes to connection B16 on EMS (Item 11). B17 goes to connection B17 on EMS (Item 11). B18 goes to connection B18 on EMS (Item 11).

Trailer Indicator Warning LH Trailer Indicator LH Front Indicator LH Rear Indicator RH Front Indicator RH Rear Indicator RH Trailer Indicator RH Front Side Light RH Tail Light Trailer Switch/Panel Illumination LH Front Side Light LH Tail Light RH Number Plate Light LH Number Plate Light Trailer Dipped Beam Main Beam Fog Lights Trailer Fog Light LH Front Work Lights RH Front Work Lights

Fuses 1A 2A 3A

Hazard Warning Lights and Direction Indicators RH Side/Tail Lights and Switch/Panel Illumination Fog Lights

1B 2B

Hazard Battery Feed Dip Beam

1C 2C 9C

LH Side/Tail Lights and Number Plate Lights Front Work Lights Road Lights

Note: For fuse ratings see Fuses, Relays in Technical Data.

9804/1103

50 - 15 - 03/9

4170-C/6-23.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 03/10

414S From m/c no. 537194 416S From m.c no. 543000 Circuit Diagram - Electrical 1 §

115 1A 116

58

1B

117 59

57

118 119

60

114

§

120 §

121

2A

122 123 §

124 125

1C

126 127 128

2B 129 61 §

62

9C

7A

130 §

63

3A

131 132 §

133 65 64 2C 134

66

§

9804/1103

50 - 15 - 03/10

4170-C/6-24.1

Issue 1

CONTENTS

Wheeled Loaders

50 - 15 - 03/11

414S From m/c no. 537194 416S From m/c no. 543000 Circuit Diagram - Electrical Main Components

Lamps

1 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

135 136 137 138 139 140

Starter Switch Lift Ram Proximity Switch Detent Coil (Lift Arm Reset) Shovel Ram Proximity Switch Detent Coil (Shovel Ram Reset) Detent Coil (Float) Brake Light Switch Tow Hitch Switch Tow Hitch Solenoids Heated Mirror Switch LH Heated Mirror RH Heated Mirror Heated Seat Switch Heated Seat Heated Seat Thermostat Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Pump Horn Front Wiper Motor Column Switch Intermittent Wiper Relay Front Washer Pump Beacon Switch Interior Light Radio (Option) Under Bonnet Lights Switch

9804/1103

LH Brake Light RH Brake Light Beacon Interior Light LH Under Bonnet Light RH Under Bonnet Light

Fuses 5A

Brake Lights, Float, Lift and Shovel Reset

4B Rear Wash/Wipe 5B Beacon, Interior Light, Radio and Under Bonnet Lights 4C 5C

Heated Mirror and Heated Seat Front Wash/Wipe and Horn

Note: For fuse ratings see Fuses, Relays in Technical Data.

50 - 15 - 03/11

4170-C/6-25.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 03/12

414S From m/c no. 537194 416S From m/c no. 543000 Circuit Diagram - Electrical 1 67 68 69 70 5A 71 135 72 136 73 74 76 77

75 4C

79 78

80

81 4B

82

83 84

85

5C

86 87

88 89

5B

137

138

91

92

9804/1103

50 - 15 - 03/12

90

139 140

4170-C/6-26.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 04/1

409 Telemaster Circuit Diagrams - Electrical

950

1 B

22A

647E

4

A C

D B7 22

+12v

647D

951

4 647G

2

7

A

B 957

1 -ve

4

2

3

2 +ve

5

22B

952

5

3 450

452

451

3

647C

1

954

C

4

2

452B

452A

647F

3

A 2

4

B

2

955

1

3 6

22C

22D

953 5

647B

1

5

3

956

647

5

6 647A

A233140

Main Components and Switches 1 2 3 4 5 6 7 C D

Solenoid Control Switch - Boom Extend/Retract Solenoid Control Switch - Auxiliary Service Solenoid Relays Solenoids - Boom Extend/Retract Valve Solenoids - Auxiliary Valve Safe Load Indicator Strain Gauge Connections to Auxiliary Solenoid Control Valve ‘C’ Connections to Boom Extend/Retract

9804/1103

50 - 15 - 04/1

Issue 1

CONTENTS

Wheeled Loaders

407B ZX, 408B ZX, 409B ZX

50 - 15 - 04/2

m/cÕs to 755182

Circuit Diagrams - Electrical Main Components

Lamps

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

104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126

Battery Thermostart Starter Motor Starter Solenoid Neutral Start Relay 1 Starter Switch Ignition Relay 1 Forward Relay Forward/Reverse Switch Forward Solenoid Transmission Dump Relay Reverse Solenoid Reverse Relay Diode Diode Reverse Alarm Speed Control Relay Speed Control Switch Diode Speed Control Unit Neutral Start Relay 2 Parking Brake Switch Parking Brake Light Relay Servo Cut-off Solenoid Servo Arm Switch Servo Cut-off Switch Junction Box E.S.O.S. Hazard Warning Light Switch Direction Indicator Switch Diode Flasher Unit Trailer Indicator Alarm (option) Water Temperature Sender Water Temperature Gauge Hydraulic Oil Temperature Sender Hydraulic Oil Temperature Gauge Fuel Sender Fuel Gauge Hourmeter Alternator Buzzer Warning Light Panel Water Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Filter Blockage Switch Hydraulic Filter Blockage Switch

9804/1103

Servo Cut-off Switch LH Trailer Indicator LH Front Indicator LH Rear Indicator Hazard Switch RH Trailer Indicator RH Front Indicator RH Rear Indicator Water Temperature Gauge Hydraulic Oil Temperature Gauge Fuel Gauge Indicator Warning Master Warning Master Warning Master Warning Master Warning Alternator Warning Water Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Filter Blockage Warning Hydraulic Filter Blockage Warning Main Beam Warning

Fuses A2 A6 B1 B2 B6 C2 C3 C5

Warning Lights and Buzzer Hazard Warning Junction Box E.S.O.S. Direction Indicators Speed Control Unit and Servo Cut-off Solenoid Forward/Reverse Relay and Reverse Alarm Thermostart

Note 1: For fuse and bulb ratings see page 50-05-01/9

50 - 15 - 04/2

Issue 1

Wheeled Loaders

CONTENTS

50-15-04/3

407B ZX, 408B ZX, 409B ZX

m/cÕs to 755182

Circuit Diagram - Electrical (continued)

10 2

12

105

22

16

109 107

111

34

24

3

36

38

45 47 41

28 4

46 48

23

20

17

106

110

33

27

13

8

44

18

25

43

21

14

42

15 30

31

35

37

116 118 120 122 124 126

39 40

1

26 5

32

112

113

115 117 119 121 123 125

114

104

9

29

19

108

11 C5 C3 6

C2

B1

B2

B6

A6

A2

7

A244950

9804/1103Issue 1

50-15-04/3

Wheeled Loaders

CONTENTS

50-15-04/4

407B ZX, 408B ZX, 409B ZX

m/cÕs to 755182

Circuit Diagram - Electrical (continued)

129

139 135

130

49

140

133

131

128

58

51

136

61

138

B4 134

148

76

150

65

69

78

88

A4

92

71

147 62

83

151

155 72

74

153 89

66

C6

156

70 127

B5 A1

A5

91

87

149

57

53

86

80

152

C4

132

82 79

A3 64

59

55

154

73

146

B3

63

52

145 68

142

90

75

144

141

85

77

60

56

50

143

137

84

157 93

81

C1

A9

B7 A7

A8

B9

94

67 54

B8

A244960

9804Issue 1

50-15-04/4

CONTENTS

Wheeled Loaders

407B ZX, 408B ZX, 409B ZX

50 - 15 - 04/5

m/cÕs to 755182

Circuit Diagrams - Electrical (continued) Main Components 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

Loader Auxiliary 1 Solenoids Loader Auxiliary 1 Switch Loader Auxiliary 2 Solenoids Loader Auxiliary 2 Switch Auxiliary 2 Hydraulics Switch Ignition Relay 2 Brake Light Switch Rear Wiper Rear Wash/Wipe Switch Front Washer Pump Front Wash/Wipe Switch Front Wiper Motor Horn Horn Switch Fog Light Switch Head Light Flasher Dipswitch Road Lights Switch Road Lights Relay Cigar Lighter Clock Front Work Lights Relay Front Work Lights Switch Rear Work Lights Switch Beacon Beacon Switch Interior Light Radio (option) LH Speaker RH Speaker Hydraulic Cooler Fan Switch Hydraulic Cooler Fan Motor Hydraulic Cooler Fan Relay

Machines with Air Conditioning 82 83 84 85 86 87 88 89 90

Heater Motor Heater Resistor Heater Switch High Pressure Switch Low Pressure Switch Freeze Valve Air Condioning Relay Air Conditioning Switch Air Conditioning Compressor Clutch

Machines with Heater 91 92 93

9804/1103

Heater Motor Heater Resistor Heater Switch

Lamps 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155

Auxiliary 2 Hydraulics Switch LH Brake Light LH Trailer Brake Light RH Trailer Brake Light RH Brake Light Rear Wash/Wipe Switch Fog Light Fog Light Switch LH Main Beam RH Main Beam LH Dip Beam RH Dip Beam LH Trailer Light LH Number Plate Light LH Tail Light LH Side Light RH Trailer Light RH Number Plate Light RH Tail Light RH Side Light Road Lights Switch Front Work Lights Front Work Lights Switch Rear Work/Reverse Light Rear Work/Reverse Light Switch Beacon Beacon Switch Interior Light Air Conditioning Switch

Machines with Air Conditioning 156

Heater Switch

Machines with Heater 157

Heater Switch

Fuses A1 A3 A4 A5 A7 A8 A9 B3 B4 B5 B7 B8 B9 C1 C4 C6

Brake Lights LH Side/Tail Lights and LH Number Plate Light RH Side/Tail Lights and RH Number Plate Light Rear Wash/Wipe Beacon, Clock and Front Wiper Radio and Interior Light Front Wash/Wipe, Headlight Flasher and Horn Dip Beam Main Beam Front Work Lights Servo Control Lever Switches Air Conditioning and Heater Hydraulic Cooler Fan Relay Rear Work/Reverse Light Fog Light Cigar Lighter

94

In-line Fuse (Hydraulic Cooler Fan)

50 - 15 - 04/5

Issue 1

CONTENTS

Wheeled Loaders

407B ZX, 408B ZX, 409B ZX

50 - 15 - 05/1

m/cÕs from 755183

Circuit Diagrams - Electrical Main Components

Lamps

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

104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126

Battery Thermostart Starter Motor Starter Solenoid Neutral Start Relay 1 Starter Switch Ignition Relay 1 Forward Relay Forward/Reverse Switch Forward Solenoid Transmission Dump Relay Reverse Solenoid Reverse Relay Diode Diode Reverse Alarm Speed Control Relay Speed Control Switch Speed Control Unit Neutral Start Relay 2 Parking Brake Switch Servo Cut-off Solenoid Servo Arm Switch Servo Cut-off Switch Junction Box E.S.O.S. Hazard Warning Light Switch Direction Indicator Switch Diode Flasher Unit Water Temperature Sender Water Temperature Gauge Hydraulic Oil Temperature Sender Hydraulic Oil Temperature Gauge Fuel Sender Fuel Gauge Hourmeter Alternator Buzzer Warning Light Panel Water Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Filter Blockage Switch

9804/1103

Servo Cut-off Switch LH Trailer Indicator LH Front Indicator LH Rear Indicator Hazard Switch RH Trailer Indicator RH Front Indicator RH Rear Indicator Water Temperature Gauge Hydraulic Oil Temperature Gauge Fuel Gauge Indicator Warning Parking Brake Warning Parking Brake Warning Parking Brake Warning Parking Brake Warning Alternator Warning Water Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Filter Blockage Warning Hazard Warning Main Beam Warning

Fuses A2 A6 B1 B2 B6 B9 C2 C3

50 - 15 - 05/1

Warning Lights and Buzzer Hazard Warning Junction Box E.S.O.S. Direction Indicators Thermostart Speed Control Unit and Servo Cut-off Solenoid Forward/Reverse Relay and Reverse Alarm

Issue 1

CONTENTS

Wheeled Loaders

410B ZX

50 - 15 - 06/1

*To m/c no. 755490

Circuit Diagrams - Electrical Main Components

Lamps

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

102 103 104 105 106 107 107A 108 109 110 111 111A 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126

Battery Thermostart Starter Motor Starter Solenoid Neutral Start Relay 1 Starter Switch Ignition Relay 1 Forward Relay Forward/Reverse Switch Forward Solenoid Transmission Dump Relay Reverse Solenoid Reverse Relay Brake Assist Switch Diode Reverse Alarm Speed Control Relay Speed Control Switch Speed Control Unit Park Brake Light Relay Parking Brake Switch Servo Cut-off Solenoid Servo Arm Switch Servo Cut-off Switch Junction Box E.S.O.S. Hazard Warning Light Switch Direction Indicator Switch Diode Flasher Unit Water Temperature Sender Water Temperature Gauge Hydraulic Oil Temperature Sender Hydraulic Oil Temperature Gauge Fuel Sender Fuel Gauge Hourmeter Alternator Buzzer Warning Light Panel Water Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Filter Blockage Switch

9804/1103

Forward Indicator Light Reverse Indicator Light Servo Cut-off Switch LH Trailer Indicator LH Front Indicator LH Rear Indicator LH Reverse Light Hazard Switch RH Trailer Indicator RH Front Indicator RH Rear Indicator RH Reverse Light Water Temperature Gauge Hydraulic Oil Temperature Gauge Fuel Gauge Indicator Warning Master Warning - Park Brake Master Warning - Park Brake Master Warning - Park Brake Master Warning - Park Brake Alternator Warning Water Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Filter Blockage Warning Hazard Warning Main Beam Warning

Fuses A2 A6 B1 B2 B6 B9 C1 C2 C3

50 - 15 - 06/1

Warning Lights and Buzzer Hazard Warning Junction Box E.S.O.S. Direction Indicators Hydraulic Oil Cooler Relay (when fitted) Thermostart Speed Control Unit and Servo Cut-off Solenoid Forward/Reverse Relay and Reverse Alarm

Issue 2*

Loadalls

CONTENTS

50 - 15 - 06/2

410B ZX

*To m/c no. 755490

4

105

811H

21

109 107

111

31

22

33

35

42 44 38

26

41 43

811

2

10

103 107A 16 12 111A

800AD

3

102 812H

800AC

Circuit Diagrams - Electrical (continued)

106

110

868

107E 107B

5

9

32

37 30

24

112

113

912

803

107M

7

1

3

6 830

107

5

002

C2

B1

B2

B6

8

2 300

10

104

108 101

107N

402

115 117 119 121 123 125

114

802

104 27

C3 6

403

116 118 120 122 124 126

36

11

C1

404

407

408

34

105

979

870

888

808

810 824A 824

10

004

123

7

9

15

29

28

809

18

40 39

14

20 1

806

23

815A

5

406

8

461

25

17

409

13

805

812

815

800FA

842

800

19

A6

A2

002

003

824

7 948A 001

200

A276890

9804/1103

50 - 15 - 06/2

Issue 2*

Wheeled Loaders

CONTENTS

50 - 15 - 06/3

410B ZX

*To m/c no. 755490

868

A4

149

009

67

860

894

77

82

149A

71

147

71A 117

832

63

602

830

A3

110

125

58

M

69

66

81

152

M

146

B3

C4

864

132

65

72

150

828

56

51

841

840

862

863

60

75

148A

148

855

836

64

959

958

134

142

145

73

151

116

B4

141

855

839

103

816

M

74

200

57

138

76

144

829

61 M

50B

136 837

M

140

62

M

143

137

834

59

57A 50A

133

133A

131

135

833

800FF

800FU

800GE

800GF

139 130

128

52

50

129

814

972

600KN

600HY

600HX 971

800KM

Circuit Diagram - Electrical (continued)

830

941

830

A1

A5

110

103

108

127

54

153

70 B5

83 C5

A9

B7 A7

007

A8

68 55

B8

A276900

9804/1103

50 - 15 - 06/3

Issue 2*

CONTENTS

Wheeled Loaders

410B ZX

50 - 15 - 06/4

*To m/c no 755490

Circuit Diagrams - Electrical (continued) Main Components

Lamps

50 50A 50B 51 52 53 54 55 56 57 57A 58 59 60 61 62 63 64 65 66 67 68 69 70 71 71A 72 73 74 75 76 77 78 79 80 81 82 83

127 128 129 130 131 132 133 133A 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 148A 149 149A 150 151 152 153

Loader Auxiliary 1 Solenoids Auxiliary 1 Relay Auxiliary 2 Relay Loader Auxiliary 1 Switch Loader Auxiliary 2 Solenoids Auxiliary 2 Hydraulics Switch Ignition Relay 2 Brake Light Switch Rear Wiper Rear Washer Pump Rear Wash/Wipe Switch Front Washer Pump Front Wash/Wipe Switch Front Wiper Motor Horn Horn Switch Fog Light Switch Head Light Flasher Dipswitch Road Lights Switch Road Lights Relay Clock Front Work Lights Relay Front Work Lights Switch Rear Work Lights Switch Beacon Beacon Switch Interior Light Radio (option) LH Speaker RH Speaker Hydraulic Cooler Fan Switch Hydraulic Cooler Fan Motor Hydraulic Cooler Fan Relay Heater Motor Heater Resistor Heater Switch

* Fuses A1 A3 A4 A5 A7 A8 A9 B3 B4 B5 B7 B8 C4 C5

84

9804/1103

Auxiliary 2 Hydraulics Switch LH Brake Light LH Trailer Brake Light RH Trailer Brake Light RH Brake Light Rear Wash/Wipe Switch RH Fog Light LH Fog Light Fog Light Switch LH Main Beam RH Main Beam LH Dip Beam RH Dip Beam LH Trailer Light LH Number Plate Light LH Tail Light LH Side Light RH Trailer Light RH Number Plate Light RH Tail Light RH Side Light Road Lights Switch Front Work Lights Rear Work Lights Front Work Lights Switch Rear Work Lights Switch Beacon Beacon Switch Interior Light Heater Switch

50 - 15 - 06/4

Brake Lights LH Side/Tail Lights and LH Number Plate Light RH Side/Tail Lights and RH Number Plate Light/ Front Work Lights Relay Rear Wash/Wipe Beacon, Clock and Front Wiper Radio and Interior Light Front Wash/Wipe, Headlight Flasher and Horn Dip Beam Main Beam Front Work Lights Servo Control Lever Switches and Auxiliary Solenoids Heater Motor Fog Light Rear Work Lights

In-line Fuse (Hydraulic Cooler Fan) (Option - may be fitted)

Issue 2*

CONTENTS

Wheeled Loaders

50 - 15 - 06/5

407B ZX, 408B ZX, 409B ZX from m/c no. 755491 to 757399 410B ZX, 411B ZX from m/c no. 755491 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

9804/1103

Battery Thermostart Starter Motor Starter Solenoid Neutral Start Relay Key Switch Parkbrake Switch Parkbrake Light Relay Ignition Relay 1 Forward Relay Forward/Reverse Switch Forward Solenoid Transmission Dump Relay Reverse Solenoid Reverse Relay Reverse Alarm Speed Control Relay Brake Assist Switch Speed Control Switch Speed Control Unit Servo Cut-off Solenoid Servo Arm Switch Servo Cut-off Switch Junction Box Engine Shut-off Solenoid Indicator Switch Hazard Switch Flasher Unit Water Temperature Sender Water Temperature Gauge Hydraulic Oil Temperature Sender Hydraulic Oil Temperature Gauge Fuel Sender Fuel Gauge Hourmeter Alternator Warning Buzzer Brake Malfunction Switch Water Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Filter Blockage Switch Warning Light Panel

Lamps 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

Forward Indicator Light Reverse Indicator Light LH Reversing Light RH Reversing Light Speed Control Servo Cut-off LH Trailer Indicator LH Front Indicator LH Rear Indicator Hazard Warning RH Trailer Indicator RH Front Indicator RH Rear Indicator Water Temperature Gauge Hydraulic Oil Temperature Gauge Fuel Gauge Turn Signal Master Warning Master Warning Alternator Warning Hydraulic Oil Pressure Warning Brake Malfunction Warning Water Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Filter Blockage Warning Hazard Warning Main Beam Warning

Fuses A2 A6 B1 B2 B6 C1 C2 C3

50 - 15 - 06/5

Warning Lights and Buzzer Hazard Warning Junction Box Engine Shut-off Solenoid Direction Indicators Thermostart Speed Control Unit and Servo Cut-off Forward, Reverse and Transmission Dump Relays

4210 - C/6-13.2

Issue 2*

Wheeled Loaders

CONTENTS

50 - 15 - 06/6

407B ZX, 408B ZX, 409B ZX from m/c no. 755491 to 757399 410B ZX, 411B ZX from m/c no. 755491 Circuit Diagrams - Electrical (continued)

100

2

3

106

101 102 103

108

110

112

36

16

7

12

29

14

21

4

25

107

31

38 40 42

33

111

39 41

20 10

15

17

24 26

43

18 30 22

1

28

8

32

34

113

114

35 115

37

117 119 121 123 125 127 116 118 120 122 124 126

19 104

11

23

5

27

105

13 109 C1

C3

C2

B1

B2

B6 A6

6

A2

9

A296120

9804/1103

50 - 15 - 06/6

4210 - C/6-14.2

Issue 2*

Wheeled Loaders

CONTENTS

50 - 15 - 06/7

407B ZX, 408B ZX, 409B ZX from m/c no. 755491 to 757399 410B ZX, 411B ZX from m/c no. 755491 Circuit Diagrams - Electrical (continued)

44 45

46

53

47

129

141

135 134

131

52

M

140 142

138 139

58

M

M

132

55

137

73

145 146

143

150

147

153

151

M

144

56

148

M

60

B4

68

C4

54

62 A3

61

57

156

A4 152

63

66

149

M

2

B

1

A

158

74 79

155 67

70 157

59

133

80

65

159 76

128 A1

A5

B5

A9

C5

128

49

78

77 M

978

51

75

71

B3

136 48

72

69

154

977

130

B7 A7

64

A8

160

50

B8 001

A296130

9804/1103

50 - 15 - 06/7

4210 - C/6-15.2

Issue 2*

CONTENTS

Wheeled Loaders

50 - 15 - 06/8

407B ZX, 408B ZX, 409B ZX from m/c no. 755491 to 757399 410B ZX, 411B ZX from m/c no. 755491 Circuit Diagrams - Electrical (continued) Main Components

Lamps

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

128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159

76 77 78 79 80

9804/1103

Loader Auxiliary 1 Solenoids Loader Auxiliary 1 Relay 1 Loader Auxiliary 1 Relay 2 Loader Auxiliary 2 Solenoids Joystick Switch Auxiliary 1 Loader Auxiliary 2 Hydraulics Switch Ignition Relay 2 Brake Lights Switch Rear Washer Pump Rear Wiper Rear Wash/wipe Switch Front Washer Pump Front Wiper Front Wash/wipe Switch Horn Horn Switch Fog Light Switch Headlight Flasher Switch Dipped Headlight Switch Road Lights Switch Road Lights Relay Front Work Lights Relay Front Work Lights Switch Rear Work Lights Switch Clock Beacon Beacon Switch Interior Light Switch Radio (if fitted) LH Speaker (if fitted) RH Speaker (if fitted) Oil Cooler Fan Switch (407B ZX, 408B ZX, 409B ZX) Oil Cooler Relay (407B ZX, 408B ZX, 409B ZX) Oil Cooler Fan Motor (407B ZX, 408B ZX, 409B ZX) Heater Motor Heater Resistor Heater Switch

Loader Auxiliary 2 Hydraulics Switch LH Brake Light LH Trailer Brake Light RH Trailer Brake Light RH Brake Light Rear Wash/wipe Switch Light LH Fog Light RH Fog Light Fog Light Switch LH Main Beam RH Main Beam LH Dip Beam RH Dip Beam LH Trailer Light LH Number Plate Light LH Tail Light LH Side Light RH Trailer Light RH Number Plate Light RH Tail Light RH Side Light Road Lights Switch Front Work Light Front Work Light Front Work Light Switch Rear Work Light Rear Work Light Rear Work Light Switch Beacon Beacon Switch Interior Light Heater Switch

Fuses A1 A3 A4 A5 A7 A8 A9 B3 B4 B5 B7 B8 C4 C5

Brake Lights LH Side/tail and Number Plate Lights RH Side/tail and Number Plate Lights Rear Wash/wipe Beacon Interior Light and Radio Front Wash/wipe, Horn and Headlight Flasher Dip Beam Main Beam Front Work Lights Auxiliary Hydraulics Heater Fog Lights Rear Work Lights

160

In-line Fuse, Oil Cooler (407B ZX, 408B ZX, 409B ZX)

50 - 15 - 06/8

4210-C/6-16.2

Issue 2*

CONTENTS

Wheeled Loaders

407B ZX, 408B ZX, 409B ZX

50 - 15 - 06/8A

From m/c no. 757400

Circuit Diagrams - Electrical (continued)

Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14A 15 16 17 17A 18 18A 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 Thermostart Starter Motor Starter Solenoid Neutral Start Relay Key Switch Parkbrake Switch Parkbrake Light Relay Ignition Relay 1 Forward Relay Forward/Reverse Switch Forward Solenoid Transmission Dump Relay Pump Reverse Solenoid Motor Reverse Solenoid Reverse Relay Reverse Alarm Low Speed Solenoid Creep Speed Solenoid Brake Assist Switch Transmission Pressure Switch Speed Control Switch Speed Control Unit Servo Cut-off Solenoid Servo Arm Switch Servo Cut-off Switch Junction Box Engine Shut-off Solenoid Indicator Switch Hazard Switch Flasher Unit Water Temperature Sender Water Temperature Gauge Hydraulic Oil Temperature Sender Hydraulic Oil Temperature Gauge Fuel Sender Fuel Gauge Hourmeter Alternator Warning Buzzer Brake Malfunction Switch Water Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Filter Blockage Switch Warning Light Panel

9804/1103

Lamps 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

Forward Indicator Light Reverse Indicator Light LH Reversing Light RH Reversing Light Speed Control Servo Cut-off LH Trailer Indicator LH Front Indicator LH Rear Indicator Hazard Warning RH Trailer Indicator RH Front Indicator RH Rear Indicator Water Temperature Gauge Hydraulic Oil Temperature Gauge Fuel Gauge Turn Signal Master Warning Master Warning Alternator Warning Hydraulic Oil Pressure Warning Brake Malfunction Warning Water Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Filter Blockage Warning Hazard Warning Main Beam Warning

Fuses A2 A6 B1 B2 B6 C1 C2 C3 C6

50 - 15 - 06/8A

Warning Lights and Buzzer Hazard Warning Junction Box Engine Shut-off Solenoid Direction Indicators Thermostart Speed Control Unit and Servo Cut-off Forward, Reverse and Transmission Dump Relays Speed Control Unit

4210 - C/6 - 17.1

Issue 1

4

5

1

3

2

9 002

C3

50 - 15 - 06/8B C6 C2 B1 B2 109

27 6

3

104

23

002

B6 A6

4210 - C/6 - 18.1

3

2

600HV

600JB

600HT

600JA

4

1

6

7

402

403

404

406

458

407

38

8

9

13

14

10

11

1

600HS

408

461

409

36

2

3

3

600HW

3

806

811A

811G

811F

811J

600EK

600CF

600C

600CK

600EK

600BL

600H

600G

600DX

600

600CC

600JS

600JR

600HN

600ND

600NF

600CD

600JL

600JV

600NE

600BT

600CA

600AD

600BS

600BX

600AC

600FR

600BF

600W

407B ZX, 408B ZX, 409B ZX

804

106B

0

37

12

4

115 4

-

S

35 106E

824

114 1

+

806B

600JC

34

830U

113 106V

-

S

-

S

32

830V

+

+

28 106W

31

30

830W

106X

49

49a

803

26

31

5

106D

802

804A

1 805

803A

805B

2

805

1805

969

811H

812

111 29

200

824

9 7

5 106F

10

803

5

24

2

105

1

804

980

811

812

15

5

1

18 20 9

105

22

107

8

2 10

25

803

3

979

969A

969B

969D

969E

969C

875A

809

875

809

812H

17 21

10

13

17A

300

101

18A 8 6 4

106Y

7 5 1

124

N

R

102

1805A

1

F

815

842

16

113A

815A

810

967

14A 103

113B

824A

107A/G

2

3

19

113D

107M

107N

5

4

11 14

113E

113C

824

1

3

3

600

101

104

107

004

2

003

6 5

123

12

4

4 5

5 2

9804/1103

8 1

1 10 3

C1 7

4

4

2

2 3

5

100

4

CONTENTS

Wheeled Loaders 50 - 15 - 06/8B

From m/c no. 757400

Circuit Diagrams - Electrical (continued)

106 108 110 112 600

33 39 41 40 42

117 119 121 123 125 127 116 118 120 122 124 126 43 837D

806H

830

946A

A2

824

007

946A

001 001

200 200

106

A370910

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 06/8C

407B ZX, 408B ZX, 409B ZX

From m/c no. 757400

Circuit Diagrams - Electrical (continued)

600?

859

601 860

600FB

978

79

977

A

304 1

894

861

B

67

10

1

63

3

2

5

9

5

9

9

152 200

70

1

10

5

9

600GR

10

155

157

800

1

800A

66

10

149 009

982

2

800B

832

864

59

133

8

1

981

9

74

68

A3A4 62

868

841

840

862 816

125B

125

7

71 158

828

4 3

2

10

78 M

83

117

S-839

1

51

5

77

75 M

154

830 9

5 1

4

151

156

M

B3

C4

54

148

144

833

5

B4 836

10

110

3

863A

816

959

814

5

4

125G

1

136 61 57

69

855

4

125F

60

2

51A

48

72

147

116

2 5

1

56

73

153

602

138

150

146

143

3

M

600?

600?

600?

600?

600?

600FJ

600AK

600BJ

837

816E

816D

2

52

46 958

139

58

M M

834

M

132

835

129

103

972

971

45

145

140 142

55

53

47

137

134

141

829

131

44

135

600AK

600AK

600BG

600LV

600BD

600BP

600H

600LV

600G

600FF

600FU

600GE

600GF

600KN

600KM

600HX

600HY

130

600?

600

837D

159

830

007

800E

600FB

007

A7

64

A8

B9

2

701/60001

3

-7 1

81

L1

1

009

A9

2

A5

+8

A1

102D

49

102DA

C5

B5

10

B1

102D

125A

B7

2

116B

128 3

80

102DA

9

126

2

126A

6

303

8

103

1

108

5

108A

7

C1

B5

110

941A

941

946A

A3

B4

65

102DF

830

82

200

50 001

001

200

200

106

106

B8

A370920

9804/1103

50 - 15 - 06/8C

4210 - C/6 - 19.1

Issue 1

CONTENTS

Wheeled Loaders

407B ZX, 408B ZX, 409B ZX

50 - 15 - 06/8D

From m/c no. 757400

Circuit Diagrams - Electrical (continued) Main Components

Lamps

44 45 46 47 48 49 50 51 51A 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

128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159

82 83

Loader Auxiliary 1 Solenoids Loader Auxiliary 1 Relay 1 Loader Auxiliary 1 Relay 2 Loader Auxiliary 2 Solenoids Joystick Switch Auxiliary 1 Loader Auxiliary 2 Hydraulics Switch Ignition Relay 2 Brake Lights Switch Brake Lights Relay Rear Washer Pump Rear Wiper Rear Wash/wipe Switch Front Washer Pump Front Wiper Front Wash/wipe Switch Horn Horn Switch Fog Light Switch Headlight Flasher Switch Dipped Headlight Switch Road Lights Switch Road Lights Relay Front Work Lights Relay Front Work Lights Switch Rear Work Lights Switch Clock Beacon Beacon Switch Interior Light Switch Radio (if fitted) LH Speaker (if fitted) RH Speaker (if fitted) Oil Cooler Fan Switch Oil Cooler Relay Oil Cooler Fan Motor Heater Motor Heater Resistor Heater Switch Removeable Link (removed if air conditioning is fitted) Air Conditioning Switch (if fitted) Air Conditioning Plug (if fitted)

9804/1103

Loader Auxiliary 2 Hydraulics Switch LH Brake Light LH Trailer Brake Light RH Trailer Brake Light RH Brake Light Rear Wash/wipe Switch Light LH Fog Light RH Fog Light Fog Light Switch LH Main Beam RH Main Beam LH Dip Beam RH Dip Beam LH Trailer Light LH Number Plate Light LH Tail Light LH Side Light RH Trailer Light RH Number Plate Light RH Tail Light RH Side Light Road Lights Switch Front Work Light Front Work Light Front Work Light Switch Rear Work Light Rear Work Light Rear Work Light Switch Beacon Beacon Switch Interior Light Heater Switch

Fuses A1 A3 A4 A5 A7 A8 A9 B3 B4 B5 B7 B8 B9 C4 C5

Brake Lights LH Side/tail and Number Plate Lights RH Side/tail and Number Plate Lights Rear Wash/wipe Beacon Interior Light and Radio Front Wash/wipe, Horn and Headlight Flasher Dip Beam Main Beam Front Work Lights Auxiliary Hydraulics Heater/Air Conditioning Oil Cooler Fan Motor Switch Relay Fog Lights Rear Work Lights

L1

In-line Fuse, Oil Cooler Fan Motor

50 - 15 - 06/8D

4210 - C/6 - 20.1

Issue 1

CONTENTS

Wheeled Loaders

456B

50 - 15 - 07/1

From m/c no. 755491

Circuit Diagrams - Electrical Main Components

Lamps

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 56A 56B 56C

Isolator Battery Starter Motor Starter Solenoids Starter Relay Grid Heater Grid Heater Relay Hydraulic Dump Valve Starter Switch E.S.O.S. Pull Coil (25 Amp) E.S.O.S. Hold Coil (0.2 Amp) Shut Down Relay Alternator Electronic Monitoring system (EMS) Buzzer Fuel Contents Sender Water Temperature Sender Transmission Oil Temperature Sender Hydraulic Oil Temperature Sender Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Engine Oil Level Sensor Coolant Level Sensor Transmission Oil Level Sensor Hydraulic Oil Level Sensor Emergency Steer Pressure Switch Water in Fuel Sensor Parking Brake Switch Transmission Disconnect Switches Transmission Solenoids ZF Transmission Computer Computer Feed Relay Turbine Speed Sensor Output Speed Sensor Throttle Switch Transmission Hand Control Kick Down Switch Reverse Alarm Reverse Alarm Relay Rear Work Lights Relay Rear Work Lights Switch ACCS Solenoid Valve ACCS Override Switch ACCS Relay Heater Relay Heater Switch Heater Blower Cigar Lighter Air Conditioning Compressor Clutch Air Conditioning Pressure Switch Air Conditioning Temperature Switch Air Conditioning Switch High Flow/Normal Pressure Solenoid Low Flow/High Pressure Solenoid Hydraulic Mode Changeover Switch

109 110 111 112

100

Changeover Switch (Hydraulic Mode/Transmission Dump)

9804/1103

Mode Switch Illumination Master Warning Light Rear Work Lights ACCS Operating Indication Light

Fuses 6A 8A

Computer Feed Relay Solenoid EMS Battery Feed

3B 6B 7B 8B

Reverse Alarm and Rear Work Lights E.S.O.S. Hold Coil Air Conditioning E.S.O.S. Pull Coil

3C 4C 6C 7C 8C

EMS and ZF Computer Feed Hydraulic Mode Switch Heater Blower and Cigar Lighter Grid Heater Relay and Hydraulic Dump Valve ACCS

Note 1: For fuse ratings see Fuses, Relays in Technical Data.

50 - 15 - 07/1

4180-C/6-1.2

Issue 2*

Wheeled Loaders

CONTENTS

456B Circuit Diagrams - Electrical (continued)

1

16

7

3

41

8

6

11

10

111B

56

21

23

25

27

29

826G

17

19 20

22

24

26

28

42

38

33

9508

43

113

13

111

3 6 5 8 7 4 2 1

9520 9516

9584 9430B 9446B 9442B 9438B 9434B

409 418

9588A

39

600DU 420 431 411 839 405 412 402 404 432 421 600G 419 415 401 408 400 422 403 406 407

12

811 B3

2 002B

52

45

9588

813A

896A

A13 A12 A28 A15 A17 A5 A18 A30 A20 A33 A10 A31 B7 B2 A23 B14 B1 A14 A35 A16 A4 A6 A29 A19 A7 A8 A9 A21

18 413

A1

003

A24

14

A11

33 35

002C

9600C

32

31

15

14

25 29

8 5

23 26

896B

862A

825

44

53

896 115A

48

115C

112B

115B

46

9678 9438 9446 9674 9658 9524 9504 9666 9434 9422 9430 9508A 9528 9512 9536

+ 8B

51

813

9536B

7C

844C

9438A 9446A 9434A 9422A 9430A

+

844B

50

30

809

111A

112

31

15 110

4

18

111

822

54

895

24 19

862

821 820

863 9536A

11 9600

22

34

47

40

55

49

9600B 9600A

112C 112A

A34 B10

B6

B11

B12

B17

B16

B4

B18

B5

A25

A3

A2

A36

A26

840

107

002

810C

812D

807C

806C

836E

836D

835C

813B

301

5

001

9

9650

9654

9470

9612A

200P

27

17

13

897

9474 9460

9464 115

103

112

109

9612E

36

9612

8A

000H

34

9612B

UART/ UART/ TxD RxD MODA/ MODB

6B

2

9612A

9612D 004

1

32

37 3B

35 302

3C

106

000L

8C 000M

6C 000P

7B 000K

6A

200N 000G 000 813B

9

835C

200E

836D 836E 200W & 200X

200 & 220A 806C 807C 812D 810C

A261140

9804/1103

50 - 15 - 07/2

Issue 1

Wheeled Loaders

CONTENTS

456B Circuit Diagrams - Electrical (continued)

68 114

116

117

119

121

123

124

125

126

129

130

131

86

79 113

115

118 120

835E 836G 835D 836F

802B 802A

122

801C 801A

127

801H 801E

806B 806A

807B 807A

128

812B 812A

810A 810C

810B

810D

76 70

66

836E

802

801

806

807

74 846A

898A 898B 899A 899B 835C

72

852

81

85

82

78

846B

1C

2B

7A

800B

804

3A 810

899

63

815

814

823

105B

846

71

824

105C 819B 819A

816

73

69

75

84

102B

88

77 818

64

104D

89

803B 837

824B

87

132

851

827 898

805

58

824A

812

812C

57

830

83

829

2A

133 134

104B

104C

104H

104E

817

102A

813

828

819

304E

304D

304B

304C

836E

62

8358

80

808 803

65

894

59 808A

67

100

104

105A

102

304

300 838 800

306

108 105

837A

1A 000A

1B

60

61

2C

9A

5A

4B

5C

5B

200H 200F

200S

000N

000E

000C

000F

200M

835C 836D 836E 802C 806C 807C 812D 810C

A261150

9804/1103

50 - 15 - 07/3

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 07/3

456B Circuit Diagrams - Electrical (continued)

68 114

116

117

119

121

123

124

125

126

129

130

131

86

79 113

115

118 120

835E 836G 835D 836F

802B 802A

122

801C 801A

127

801H 801E

806B 806A

807B 807A

128

812B 812A

810A 810C

810B

810D

76

836E

802

801

806

807

72

74 846A

898A 898B 835C

70

66

899A 899B

852

81

85

82

78

846B

1C

2B

7A

800B

804

3A

827

71

810

823

64

814

105B

824

105C 819B 819A

816

73

69

63

815

846

75

84

102B

88

77

898

818 104D

104B

803B 837

824B

87

132

851

899

805

58

824A

812

812C

57

830

83

829

2A

133 134

104C

104H

104E

817

102A

813

828

819

304E

304D

304B

304C

836E

62

8358

80

808 803

65

59 808A

67

100

104

105A

102

304

300 838 800

306

108 105

837A

1A 000A

1B

60

61

2C

9A

5A

4B

5C

5B

200H 200F

200S

000N

000E

000C

000F

200M

835C 836D 836E 802C 806C 807C 812D 810C

A261150

9804/1103

50 - 15 - 07/3

Issue 1

CONTENTS

Wheeled Loaders

456B

50 - 15 - 07/4

From m/c no. 755491

Circuit Diagrams - Electrical Main Components 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 88 * 89

Column Switch Diode Hazard Warning Switch Hazard Relay Road Light Switch Head Light Flasher Switch Fog Light Switch Front Work Lights Relay Front Work Lights Switch Parking Brake Solenoids Parking Brake Switch Float Coils Float Pressure Switch Detent Coil (Lift Ram Reset) Lift Ram Proximity Switch Detent Coil (Shovel Ram Reset) Shovel Ram Proximity Switch Detent Coil (Float) Brake Light Switch Rear Wiper Motor Rear Wash/Wipe Switch Rear Washer Pump Horn Column Switch Front Wiper Motor Intermittent Wiper Relay Front Washer Pump Beacon Switch Interior Light Interior Light Door Switch Radio (Option) Under Bonnet Lights Switch Parking Brake Controller

Lamps 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134

Fuses 1A 2A 3A 5A 7A 9A 1B 2B 4B 5B 1C 2C 5C

9804/1103

LH Front Indicator LH Rear Indicator RH Front Indicator RH Rear Indicator RH Side Light RH Tail Light Switch Illumination LH Side Light LH Tail Light RH Number Plate Light LH Number Plate Light Dip Beam Main Beam Fog Lights LH Front Work Lights RH Front Work Lights LH Brake Light RH Brake Light Beacon Interior Light LH Under Bonnet Light RH Under Bonnet Light

50 - 15 - 07/4

Hazard Warning Lights and Direction Indicators RH Side/Tail Lights and Switch/Panel Illumination Fog Lights Brake Lights, Float, Lift and Shovel Reset Main Beam Parking Brake Hazard Battery Feed Dip Beam Rear Wash/Wipe Beacon, Interior Light, Radio and Under Bonnet Lights LH Side/Tail Lights and Number Plate Lights Front Work Lights Front Wash/Wipe and Horn

Issue 2*

CONTENTS

Wheeled Loaders

50 - 15 - 08/1

TM200, TM270 Circuit Diagrams - Electrical TM200 Main Components and Switches

Lamps

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

100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118

Battery Thermostart Starter Switch Neutral Start Relay 1 Starter Solenoid Starter Motor Ignition Relay 1 Neutral Start Relay 2 Park Brake Switch Diode Forward/Reverse Switch Forward Relay Reverse Relay Forward Solenoid Reverse Solenoid Dump Relay Reverse Alarm Speed Control Switch Speed Control Relay Speed Control Unit Servo Cut-off Switch Servo Arm Switch Servo Cut-off Solenoid Junction Box E.S.O.S. Hazard Switch Flasher Relay Direction Indicator Switch Water Temperature Gauge Water Temperature Sender Oil Temperature Gauge Oil Temperature Sender Fuel Gauge Fuel Sender Hourmeter Alternator Warning Buzzer Water Temperature Switch Transmissions Oil Temperature Switch Engine Oil Pressure Switch Air Filter Vacuum Switch

9804/1103

50 - 15 - 08/1

Reverse Light LH Trailer Indicator LH Front Indicator LH Rear Indicator RH Trailer Indicator RH Front Indicator RH Rear Indicator Turn Signal Park Brake Warning Light Park Brake Warning Light Park Brake Warning Light Park Brake Warning Light Alternator Warning Light Water Temperature Warning Light Transmission Oil Temperature Warning Light Engine Oil Pressure Warning Light Air Filter Warning Light Hazard Warning Light Main Beam Warning Light

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 08/2

TM200, TM270 Circuit Diagrams - Electrical (continued) TM200

17

100

20

14

6

15

104

101

9

106

103

23

30

25

32

38

34

40

36

19

39

2 102

5 13

41

105

24

12

18

10

10 22 28 37

8

1

27 10

29

31

33

108 110 112 114 116 118 107 109 111 113 115 117

35

4 21 16

26

11

3 7

A282070

9804/1103

50 - 15 - 08/2

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 08/3

TM200, TM270

Manual

Circuit Diagrams - Electrical (continued) TM200

120 121

122

125 124

123 52

55

128

132

127 126

136

133 134

129

67

137

70

73

65

119 43

69

45

50

130

53

135

131

56

66

42

48

44

59

51

63

60

62

58

49

72

64

54

71

61 68 46

57 47

A282080

9804/1103

50 - 15 - 08/3

Issue 1

CONTENTS

Wheeled Loaders

50 - 15 - 08/4

TM 200, TM270 Circuit Diagrams - Electrical (continued) Main Components and Switches

Lamps

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

119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137

Joystick Switch Auxiliary 1 Loader Auxiliary 1. Solenoids Joystick Switch Auxiliary 2 Loader Auxiliary 2. Solenoids Auxiliary 2. Hydraulics Switch Ignition Relay 2 Brake Lights Switch Rear Wash/Wiper Switch Rear Wiper Motor Front Wash/Wiper Switch Front Washer Pump Front Wiper Motor Horn Switch Front Horn Fog Light Switch Road Lights Relay Road Lights Switch Head Light Flasher Switch Head Light Dip Switch Front Work Lights Relay Front Work Lights Switch Clock Beacon Switch Beacon Interior Light/Switch Radio Oil Cooler Relay Oil Cooler Fan Switch Oil Cooler Fan Motor Heater Switch Heater Resistor Heater Motor

9804/1103

50 - 15 - 08/4

LH Brake Light LH Trailer Brake Light RH Trailer Brake Light RH Brake Light Fog Light LH Main Beam RH Main Beam LH Dip Beam RH Dip Beam LH Trailer Light LH Number Plate Light LH Tail Light LH Side Light RH Trailer Light RH Number Plate Light RH Tail Light RH Side Light Front Work Light Front Work Light

4225-C/30-4.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 09/1

TM200, TM270 * Diagrams

- Electrical (continued)

TM270 to m/c no. 787040

Lamps

Main Components and Switches

100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118

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 Thermostart Starter Switch Neutral Start Relay Starter Solenoid Starter Motor Parking Brake/Handbrake Relay Handbrake Switch Dump Switch Diode Layshaft Relay Layshaft Solenoid Ignition Relay Transmission Dump Relay Forward Relay Forward Hi/Low Relay Forward Solenoid - Low Column Switch Forward Solenoid - High Reverse Hi/Low Relay Reverse Solenoid - High Reverse Solenoid - Low Reverse Relay Reverse Alarm Front Horn Joystick Auxiliary 1. Solenoid Auxiliary 2. Solenoid Boom Out Solenoid Boom In Solenoid Servo Cut-off Solenoid Servo Cut-off Switch Arm Rest Switch Auxiliary Solenoid Switch Hydraulic Tow Hitch Solenoid Safe Load Indicator (SLI) Unit Junction Box E.S.O.S Hazard Switch Direction Indicator Switch Flasher Unit Speed Transducer Transducer Resistor Speedometer Water Temperature Gauge Water Temperature Sender Fuel Gauge Fuel Sender Hourmeter Alternator Warnings Buzzer Brake Pressure Switch Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Air Filter Vacuum Switch Transmission Oil Pressure Switch (Blocked Oil Filter)

9804/1103

50 - 15 - 09/1

Reverse Light LH Trailer Indicator LH Front Indicator LH Rear Indicator RH Trailer Indicator RH Front Indicator RH Rear Indicator Turn Signal Master Warning Lights Master Warning Lights Brake Malfunction Alternator Water Temperature Transmission Oil Temperature Engine Oil Pressure Air Filter Transmission Oil Pressure Main Beam Hazard

Issue 2*

Wheeled Loaders

CONTENTS

50 - 15 - 09/2

TM200, TM270 Circuit Diagrams - Electrical (continued) * TM270 to m/c no. 787040

24 100

2

8

6

12

9

21

17

22

35

5

10

16

46

37 25

11

103

38

19

43

104

101 27 28 29 30 31

106 102

52

50

48

53

55

57

42 54

56

105

20

10 23

36

15

33

40 108 110 112 114 116 118

41 44

26

1

51 45

107 109 111 113 115 117

47 49

14 4

7 18

3

32

34

39

10 13

A282090

9804/1103

50 - 15 - 09/2

Issue 2*

Wheeled Loaders

CONTENTS

50 - 15 - 09/3

TM200, TM270 Circuit Diagrams - Electrical (continued) * TM270 to m/c no. 787040

120

129

123 125 122

63

61

M

126

124

M

139 75

121 119

137

133

127

134 138

M

140

77 80

64

131

M

68

M

136

132 65

84

M

135

128 130

85

83

76

69

82 70

72

59

73

74 79

60 67

81

71

62

78

66 58

A282100

9804/1103

50 - 15 - 09/3

Issue 2*

CONTENTS

Wheeled Loaders

50 - 15 - 09/4

TM 250, TM270 Circuit Diagrams - Electrical (continued) *

TM270 to m/c 787040 Main Components and Switches

Lamps

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

119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140

Ignition Relay 2. Brake Lights Switch Rear Wash/Wiper Switch Rear Wiper Motor Front Wash/Wiper Switch Washer Pump Front Wiper Motor Fog Light Switch Road Lights Relay Road Lights Switch Headlight Flasher Switch Dip Switch Clock Front Work Lights Relay Front Work Lights Switch Rear Work Lights Switch Beacon Switch Beacon Interior Light/Switch Radio Heater Switch Heater Resistor Heater Motor Air Conditioning Switch Air Conditioning Relay Freeze Valve Switch Air Conditioning Fan motor Pressure Switch

9804/1103

50 - 15 - 09/4

LH Brake Light LH Trailer Brake Light RH Trailer Brake Light RH Brake Light Trailer Fog Light Fog Light LH Main Beam RH Main Beam LH Dip Beam RH Dip Beam LH Trailer Light LH Number Plate Light LH Tail Light LH Side Light RH Trailer Light RH Number Plate Light RH Tail Light RH Side Light Front Work Light Front Work Light Rear Work Light Rear Work Light

Issue 2*

CONTENTS

Wheeled Loaders

50 - 15 - 09/5

TM 200, TM270 Circuit Diagrams - Electrical (continued) TM270 From m/c no. 787041 Main Components and Switches

Lamps

1 2 3 4 5 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 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118

Battery Thermostart Starter Switch Neutral Start Relay Starter Solenoid Starter Motor Parking Brake/Handbrake Relay Handbrake Switch Dump Switch Diode Layshaft Relay Mainshaft Relay Layshaft Solenoid Mainshaft Solenoid Ignition Relay Transmission Dump Relay Forward Relay Forward Hi/Low Relay Forward Solenoid - Low Column Switch Forward Solenoid - High Reverse Hi/Low Relay Reverse Solenoid - High Reverse Solenoid - Low Reverse Relay Reverse Alarm Front Horn Joystick Auxiliary 1. Solenoid Auxiliary 2. Solenoid Boom Out Solenoid Boom In Solenoid Servo Cut-off Solenoid Servo Cut-off Switch Arm Rest Switch Auxiliary Solenoid Switch Hydraulic Tow Hitch Solenoid Safe Load Indicator (SLI) Unit Junction Box E.S.O.S Hazard Switch Direction Indicator Switch Flasher Unit Speed Transducer Transducer Resistor Speedometer Water Temperature Gauge Water Temperature Sender Fuel Gauge Fuel Sender Hourmeter Alternator Warnings Buzzer Brake Pressure Switch Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Air Filter Vacuum Switch Transmission Oil Pressure Switch (Blocked Oil Filter)

9804/1103

50 - 15 - 09/5

Reverse Light LH Trailer Indicator LH Front Indicator LH Rear Indicator RH Trailer Indicator RH Front Indicator RH Rear Indicator Turn Signal Master Warning Lights Master Warning Lights Brake Malfunction Alternator Water Temperature Transmission Oil Temperature Engine Oil Pressure Air Filter Transmission Oil Pressure Main Beam Hazard

4225-C/30-9.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 09/6

TM200, TM270 Circuit Diagrams - Electrical (continued) TM270 from m/c no. 787041

24 100 12A

9

12

17

22

35

5 10

10

11A

16

46

37 25

11

103

38

19

43

104

101 27 28 29 30 31

851

2

8

6

21

106 102

52

50

48

53

55

57

42 54

56

105

20

23

36

15

33

857

40 108 110 112 114 116 118

41 44

26

45

47

107 109 111 113 115 117

49 106D

1

51

14 4

7

3

18

858

817

830

32

34

39

10 13

A311630

9804/1103

4225-C/30-10.1

50 - 15 - 09/6

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 09/7

TM200, TM270 Circuit Diagrams - Electrical (continued) TM270 from m/c no. 787041

120

129

123 125

122

64

61 M

62

M

126

124

M

139 76

121 119

137

133

127

134

M

138

135

128 130

140

78 81

65

131

M

132 66

69

M

136 77

70

103H

71

73

74

75

59

600FB

600GR

80 60 68

84

72

83 2

1

79

800E

830

102DA

830

600FB

63

67

102D

102D

102DF

82

58

A311640

9804/1103

50 - 15 - 09/7

4225-C/30-11.1

Issue 1

CONTENTS

Wheeled Loaders

50 - 15 - 09/8

TM 200, TM270 Circuit Diagrams - Electrical (continued) TM270 From m/c no. 787041 Main Components and Switches 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

Ignition Relay 2. Brake Lights Switch Rear Wash/Wiper Switch Roof Wiper Motor Rear Wiper Motor Front Wash/Wiper Switch Washer Pump Front Wiper Motor Fog Light Switch Road Lights Relay Road Lights Switch Headlight Flasher Switch Dip Switch Clock Front Work Lights Relay Front Work Lights Switch Rear Work Lights Switch Beacon Switch Beacon Interior Light/Switch Radio Heater Switch Heater Resistor Heater Motor Link (Remove when Air Conditioning is fitted) Air Conditioning Switch (optional) Air Conditioning Plug (optional)

Lamps 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140

LH Brake Light LH Trailer Brake Light RH Trailer Brake Light RH Brake Light Trailer Fog Light Fog Light LH Main Beam RH Main Beam LH Dip Beam RH Dip Beam LH Trailer Light LH Number Plate Light LH Tail Light LH Side Light RH Trailer Light RH Number Plate Light RH Tail Light RH Side Light Front Work Light Front Work Light Rear Work Light Rear Work Light

9804/1103

50 - 15 - 09/8

4225-C/30-12.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B Circuit Diagrams - Electrical Main Components 1 2 3 4 5 6 7 8 9 9A 10 11 12 13 14 15 16 17 17A 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 54A 55 55A 56 56A 56B

Battery Starter Switch Thermo Coil Start Relay Starter Solenoids Starter Motor Neutral Start Relay Parking Brake Switch Reverse Alarm Relay Reverse Alarm Reverse Light Relay Dump Pressure Switch Dump Switch Reverse Light Switch Transmission Solenoid Switches (Y1 (M1), Y2 (M2), Y3 (M3), Y4 (M4), Y5 (M5)) Transmission Automatic Control Transmission Hand Control Output Speed Sensor Turbine Sensor Throttle Switch Water Temperature Gauge Fuel Gauge Speedometer Timer Relay Diode Buzzer Test Button Clutch Pressure Switch Engine Oil Pressure Switch Water Temperature Switch Vacuum Switch Transmission Oil Temperature Switch Brake Pressure Switch Alternator Hourmeter Heater Switch Resistor Heater Blower Cigar Lighter Changeover Switch Lift Arm Reset Bucket Ram Reset Clock Brake Switch Hazard Relay Hazard Switch Column Switch Sidelight Switch Column Switch Fog Light Switch Work Light Switch Work Light Relay Interior Light Switch Front Wiper Switch Front Wiper Motor Front Washer Switch Front Wash Motor Horn Push Horn Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Motor

50 - 15 - 10/1

m/c’s to 531064 (426B) m/c’s to 533069 (436B) 57 58 59 60 61 62 63 64

Dump Switch (Loader Control) Kickdown Switch (Loader Control) Air Conditioning Switch Air Conditioning Thermostat Air Conditioning Pressure Switch Compressor Clutch Field Coil E.S.O.S. Brake Dump Valve

Lamps 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

Parking Brake Warning Light Reverse Light (Left Hand) Reverse Light (Right Hand) Master Warning Light Transmission Pressure Light Engine Oil Pressure Light Water Temperature Light Air Filter Light Transmission Oil Temperature Light Brake Pressure Light Alternator Warning Light Indicator Warning Light Brake Light (Left Hand) Brake Light (Right Hand) Indicator (Front Left Hand) Indicator (Rear Left Hand) Indicator (Front Right Hand) Indicator (Rear Right Hand) Hazard Warning Light Sidelight (Right Hand) Sidelight (Left Hand) Rear Fog Light Dipped Beam Main Beam Work Light (Front) Interior Light Beacon

Fuses A1 A2 A3 A4 A5 A6 A7 B1 B2 B3 B4 B5 B6 B7 C1 C2 C3 C5

Direction Indicators Right Sidelights and Gauge Illumination Rear Fog Light Gear Selection Brake Lights, Loader Arm and Bucket Reset Warning Lights, Heater Fan and Gauges Main Beam Hazard Warning Lights Dipped Beam Rear Work Lights Rear Wash/Wipe Interior Light and Beacon E.S.O.S. Air Conditioning Left Sidelights Front Work Lights Forward/Reverse Select Horn, Wash/Wipe (Front)

* Note 1: For fuse and bulb ratings see pages 50-05-01/16 to 20 * Note 2: For manual transmission machines, Item 18 (Throttle Switch) is not fitted. Wires 9508 and 9508A are linked. * Note 3: For Germany ONLY, Wire 9588 is not connected to Item 10 (Reverse Light Relay).

9804/1103

50 - 15 - 10/1

Issue 2*

Wheeled Loaders

CONTENTS

50 - 15 - 10/2

426B, 436B, 446B

m/cÕs to 531064 (426B) m/cÕs to 533069 (436B)

Circuit Diagrams - Electrical (continued)

55A 9A

27

71 72 14

26

414 420

420

29 28

31

33

82 83

30

84 85 86 87

846B 835E 836G 846A 835D 836F

413

32

844B

6

37

861

852

89 90 91 92 93 801 812

851

826G

5

7

844

9

20

36

21 408

17

405

400 416

422

39 104G 104B

18

10

40 104C

88

81 104H

22

106C

9588A

9588

813

835

25 839

A2

A7 53 C1

B2

800

804

8008

304C

805

845 9584

3

+

11

8

003

9464 9524

9438 9446 9460

837

004

822

-

12

4

33

15

32

14

31

27

17

302A

15

64 101M 22

57

863

104

49

9504

8

26

23

25

19

24

306

9600

1

2

9650

820

5

18

9666

35

9678

800

75 76 77 78 79 80

23

29

302

70 B3 200K

C3

51

420

24

9654

9612

59

803

73

44

34 106A

100 300B

A4

56 56

63

101H

002B

54 55

802

35 9658

9600A

3 200E

106S

9674

421

52

8360 8358

9536

9512

47

41

13

840

200

9528

862

60

101

1

+

9430

814 815

406

4 6 5 9434 9442

816A 819

23

23 74

818 817

50

61

45

7 8 1 2

62 862

9508

16

56A

304E

104A 838

9508A

810

803C

42

38

418

411

807

48

844C

19

54A

806

802

56B

94 95 96

106B

300

A6

B6

105

102

100

100A

107

106

304D

46

838

A5

A1

B1

837A

C5

43

B4

B7

200 & 200A

002 000H

000A

200H

200F

000F

000C

000

001 304 000

2 C2

B5

200D 200S

200M

A221980

9804/1103

50 - 15 - 10/2

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B Circuit Diagrams - Electrical

m/c’s from 531065 (426B) m/c’s from 533070 (436B)

Main Components

Lamps

1 2 3 4 5 6 7 13 14 15 16 17 18 19 20 21 22 23 24

101 102 103 104 105 106 107 108 109 110 142

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 82 83 84

Battery Starter Motor Starter Solenoids Start Relay Hydraulic Dump Valve Starter Switch Thermostart E.S.O.S. Neutral Start Relay Park Brake Switch Park Brake Transmission Disconnect Reverse Alarm Reverse Alarm Relay Dump Pressure Switch Dump Switch Dump Switch (Loader Control) Reverse Light Relay Rear Work Light Switch Transmission Solenoids (Y1 (M1), Y2 (M2), Y3 (M3), Y4 (M4), Y5 (M5) Turbine Sensor Output Speed Sensor Throttle Switch Transmission Automatic Control Kickdown Switch (Loader Control) Transmission Hand Control Water Temperature Gauge Fuel Gauge Speedometer Timer Diode Buzzer Test Button Clutch Pressure Switch Engine Oil Pressure Switch Water Temperature Switch Vacuum Switch Transmission Oil Temperature Switch Brake Pressure Switch Alternator Hourmeter Heater Blower Resistor Heater Switch Cigar Lighter Air Conditioning Compressor Air Conditioning Pressure Switch Air Conditioning Temperature Switch Air Conditioning Switch A.C.C.S. Solenoid Valve (Optional 436 Only) A.C.C.S. Override Switch (Optional 436 Only) A.C.C.S. Relay (Optional 436 Only)

9804/1103

50 - 15 - 10/3

Parking Brake Warning Light Reverse Light (Left Hand) Reverse Light (Right Hand) Master Warning Light Engine Oil Pressure Light Water Temperature Light Air Filter Light Transmission Oil Temperature Light Brake Pressure Light Alternator Warning Light A.C.C.S. Switch Light (Optional 436 Only)

Fuses A4 A6 A7 B3 B6 B7 C3 C7 C8

Reverse Alarm/Dump Switch Warning Lights, Heater Fan,Gauges, Cigar Lighter, Transmission Disconnect Relay, Timer and Hourmeter Main Beam Reversing Lights E.S.O.S. Air Conditioning (Optional) Transmission Hydraulic Dump Valve A.C.C.S. (Optional 436 Only))

* Note 1: For fuse and bulb ratings see pages 50-05-01/16 to 20 * Note 3: For Germany ONLY, Wire 9588 is not connected to Item 22 (Reverse Light Relay).

50 - 15 - 10/3

Issue 2*

Wheeled Loaders

CONTENTS

50 - 15 - 10/4

426B, 436B, 446B

m/cÕs from 531065 (426B) m/cÕs from 533070 (436B)

Circuit Diagrams - Electrical (continued)

17

102

39

103 24

844B

2

5

7

844C

38

414 415

25

431

41 40

43

45

49

42

413

44

13

50 31 826G

3

844

18

14

32

46

33 408

26

400

405

422

416

411

862A

27

22 9508A

34

106C

37

002C 9588A

9588

30

813

51

35

9508 839

8 7 4 3 845 9584

9520

101L

2

9516

1

C7

003

-

9434 9442 9430 9474 9464 9524

15

+

103

52

1 6 5

9536B

23

9600B 9600C

106S

33

15

32

14

31

8

26

23

25

19

24

47

822

9658 9674

16

421A

4 107

302A 840

101

5

28

21

20

22

1

2

101A

9600

9650

9654

101H

302

18

9666

35

9678

A4

107

820

109

53

420 420A

106

420B

36 106D

104

108

110 48 106A

109

106M

9536A

9612

200E

A6

105

29

29 9612A 106

35

106B

101M

106F 101C

B6

863

9536

9600A

19

421B

004

200

406

9438 9446 9470 9460 9528 9512 9504

421 002B

862

35

B3

C3

106

B7 200 & 200A

002

00H 000K

001

000G

002A

000B

000L

000S

000

6 200D

A251570

9804/1103

50 - 15 - 10/4

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 10/5

426B, 436B, 446B

m/cÕs from 531065 (426B) m/cÕs from 533070 (436B)

Circuit Diagrams - Electrical (continued)

111 113 112

115

114

121

116

120

835B 835E 836G 835D 836F 836J

123

122

125

124

802A

801C 802B

801A

127

126

801H 801E

129 128

131 130

806A

132

807A 806B

133

137

136 65

67

78

138 863

812B 812A

139 69

63

134

807C 807B

135

812D

810A 810C

810B

846A

810D 852

846D

864

846B

851

140

141

81

70 802

117

71

104F

118

73

74 76 817 818

801

806

807

812

64

810

A2

C1

55

B2

A7

A3

815

66

8008

804

814

819

816

79 61

104B

104C

104H

304E

104E

72

812C

35

80

68

75 77

304C

304B

304D

805

60 59 54

837

803B

808

8360 8358

62

802N 800A

306

104

102

105

304

800

119

803

300B

56 100 300

58

838 837A

A1

B1

C2

B4

A5

C5

B5

57 000A

200H

200F

200S

000E

000C

000F

200M

A251580

9804/1103

50 - 15 - 10/5

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/6

m/c’s from 531065 (426B) m/c’s from 533070 (436B)

Circuit Diagrams - Electrical (continued) Main Components

Fuses

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

A1 Direction Indicators A2 Right Sidelights and Switch/Panel Illumination A3 Fog Lights A5 Brake Lights, Loader Arm, Shovel Reset and Tow

Clock Column Switch Hazard Switch Hazard Relay Sidelight Switch Column Switch Fog Light Switch Work Light Relay Work Light Switch Detent Coil (Lift Arm) Proximity Switch (Lift Arm) Detent Coil (Shovel Ram) Proximity Switch (Shovel Ram) Detent Coil (Float) Brake Light Switch Tow Hitch Solenoids Tow Hitch Switch Rear Wiper Motor Rear Wash/Wipe Switch Rear Washer Motor Front Washer Motor Front Washer Switch Horn Horn Push Front Wiper Motor Front Wiper Switch Interior Light Switch Radio

Hitch Solenoids A7 Main Beam B1 Hazard Warning Lights and Clock B2 Dip Beam B4 Rear Wash/Wipe B5 Interior Light, Beacon and Radio (Optional) C1 Left Sidelights and Number Plate Lights C2 Work Lights C5 Horn and Front Wash/Wipe * Note1: For fuse and bulb ratings see pages 50-05-01/16 to 20

Lamps 111 Indicator (Trailer Left Hand) 112 Indicator (Front Left Hand) 113 Indicator (Rear Left Hand) 114 Indicator (Front Right Hand) 115 Indicator (Rear Right Hand) 116 Indicator (Trailer Right Hand) 117 Indicator Warning 118 Hazard Warning Light 119 Indicator (Trailer Warning) 120 Sidelight (Front Right Hand) 121 Sidelight (Rear Right Hand) 122 Trailer Light 123 Sidelight (Front Left Hand) 124 Sidelight (Rear Left Hand) 125 Numberplate Light (Right Hand) 126 Numberplate Light (Left Hand) 127 Trailer Light 128 Dipped Beam (Left Hand) 129 Dipped Beam (Right Hand) 130 Main Beam (Left Hand) 131 Main Beam (Right Hand) 132 Main Beam Warning 133 Fog Lights 134 Fog Lights (Trailer) 135 Work Lights (Left Hand) 136 Work Lights (Right Hand) 137 Brake Light (Left Hand) 138 Brake Light (Right Hand) 139 Brake Light (Trailer) 140 Beacon 141 Interior Light

9804/1103

50 - 15 - 10/6

Issue 2*

CONTENTS

Wheeled Loaders

426B, 436B, 446B

m/c’s from 531300 (426B) m/c’s from 533300 (436B)

Fault Finding - Electrical Main Components

Lamps

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

110 111 112

Isolator Battery Starter Motor Starter Solenoids Starter Relay Thermostart Resistor Anti-Stall Solenoid Hydraulic Dump Valve Starter Switch Thermostart Coil E.S.O.S. Shut Down Relay Alternator Electronic Monitoring system (EMS) Buzzer Fuel Contents Sender Water Temperature Sender Transmission Oil Temperature Sender Hydraulic Oil Temperature Sender Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Engine Oil Level Sensor Coolant Level Sensor Transmission Oil Level Sensor Hydraulic Oil Level Sensor Emergency Steer Switch Water in Fuel Sensor Parking Brake Switch Transmission Disconnect Switches Transmission Solenoids ZF Transmission Computer Computer Feed Relay Turbine Speed Sensor Output Speed Sensor Throttle Switch Transmission Hand Control Kick Down Switch Reverse Alarm Reverse Alarm Relay Rear Work Lights Relay Rear Work Lights Switch ACCS Solenoid Valve ACCS Override Switch ACCS Relay Heater Relay Heater Switch Heater Blower Cigar Lighter Air Conditioning Compressor Clutch Air Conditioning Pressure Switch Air Conditioning Temperature Switch Air Conditioning Switch

9804/1103

50 - 15 - 10/7

Master Warning Light Rear Work Lights ACCS Operating Indication Light

Fuses 6A 8A 3B 6B 7B 8B 3C 6C 7C 8C

Computer Feed Relay Solenoid EMS Battery Feed Reverse Alarm and Rear Work Lights E.S.O.S. Air Conditioning Thermostart EMS and ZF Computer Feed Heater Blower and Cigar Lighter Hydraulic Dump Valve ACCS

* Note 1: For fuse ratings see pages 50-05-01/16 to 20

50 - 15 - 10/7

Issue 2*

Wheeled Loaders

CONTENTS

50 - 15 - 10/8

426B, 436B, 446B

m/cÕs from 531300 (426B) m/cÕs from 533300 (436B)

Circuit Diagrams - Electrical (continued)

41

8 16 1

11

10

3

7

18

56

21

23

25

27

29

826G

17

19 20

22

24

26

28

809

111

9508

13 56

113

002B

51

52

45

9588

813A

896A

B3

A13 A12 A28 A15 A17 A5 A18 A30 A20 A33 A10 A31 B7 B2 A23 B14 B1 A14 A35 A16 A4 A6 A29 A19 A7 A8 A9 A21

18

003

413

A1

A22

A24

14

A11

33 35

002C

9600C

32

31

15

14

25 29

8 5

23 26

825

53

896 115A

48

115C

112B

115B

46

822

54

24 19

862

821 820

895 863 9536A

11 9600

22

34

47

40

55

49

9600B 9600A

2

862A

44

9678 9438 9446 9674 9658 9524 9504 9666 9434 9442 9430 9508A 9528 9512 9536

811

896B

813

9536B

+

3 6 5 8 7 4 2 1

9520 9516

9584 9430B 9446B 9442B 9438B 9434B

409 418

8B

43

9588A

39

600DU 420 431 411 839 405 412 402 404 432 421 600G 419 415 401 408 400 422 403 406 407

865 864

7C

844C

9438A 9446A 9434A 9442A 9430A

12

42

38

33

809

6

844B

50

30

111A

4

112

31

15 110

111

112C 112A

A34 B10

B6

B11

B12

B17

B16

B4

B18

B5

A25

A3

A2

A36

A26

840

+ 107

002

114

810C

812D

807C

806C

836E

836D

835C

813B

301

5

001

4A

000H

9

9650

9654

9470

9612A

200P

27

17

897

9474 9460

9464 115

103

112

109

9612E

36

9612

8A

000B

34

9612B

UART/ UART/ TxD RxD MODA/ MODB

6B

2

32 9612A

9612D 004

1

13

37 3B

35 302

3C

106

000L

8C 000M

6C 000P

7B 000K

6A

200N 000G 000 813B

9

835C

200E

836D 836E 200W & 200X

200 & 220A 806C 807C 812D 810C

A282620

9804/1103

50 - 15 - 10/8

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 10/9

426B, 436B, 446B

m/cÕs from 531300 (426B) m/cÕs from 533300 (436B)

Circuit Diagrams - Electrical (continued)

114

116

117

119

121

123

124

125

126

129

130

131

86

79 113

115

118 120

835E 836G 835D 836F

802B 802A

122

801C 801A

127

801H 801E

806B 806A

807B 807A

128

812B 812A

76 70

810A 810C

810B

72

836E

802

801

806

807

74

810D

846A

852 835C

81

85

82

78

846B

1C

2B

7A

800B

804

827

815

814

823

105B

846

71

810

73 75

63 64

824

105C 819B 819A

816

805

84

102B

88

77 818

104B

803B 837

824B

87

132

851

3A

58

824A

812

812C

57

830

83

829

2A

133 134

104C

104H

104E

817

102A

813

828

819

304E

304D

304B

304C

836E

62

8358

80

808 803

65

59 808A

104

100

105A

102

304

300 838 800

306 105

837A

1A 000A

1B

60

61

2C

5A

4B

5C

5B

200H 200F

200S

000E

000C

000F

200M

835C 836D 836E 802C 806C 807C 812D 810C

A282630

9804/1103

50 - 15 - 10/9

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

m/c’s to 531300 (426B) m/c’s to 533300 (436B)

Circuit Diagrams - Electrical (continued) Main Components

Lamps

56 57 58 59 60 61 62 63 64 65 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88

113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134

Anti-Stall Relay Column Switch Diode Hazard Warning Switch Hazard Relay Road Light Switch Head Light Flasher Switch Fog Light Switch Front Work Lights Relay Front Work Lights Switch Detent Coil (Lift Ram Reset) Lift Ram Proximity Switch Detent Coil (Shovel Ram Reset) Shovel Ram Proximity Switch Detent Coil (Float) Brake Light Switch Rear Wiper Motor Rear Wash/Wipe Switch Rear Washer Pump Horn Column Switch Front Wiper Motor Intermittent Wiper Relay Front Washer Pump Beacon Switch Interior Light Interior Light Door Switch Radio (Option) Under Bonnet Lights Switch

50 - 15 - 10/10

LH Front Indicator LH Rear Indicator RH Front Indicator RH Rear Indicator RH Side Light RH Tail Light Switch Illumination LH Side Light LH Tail Light RH Number Plate Light LH Number Plate Light Dip Beam Main Beam Fog Lights LH Front Work Lights RH Front Work Lights LH Brake Light RH Brake Light Beacon Interior Light LH Under Bonnet Light RH Under Bonnet Light

Fuses 1A 2A 3A 5A 7A 9A

Hazard Warning Lights and Direction Indicators RH Side/Tail Lights and Switch/Panel Illumination Fog Lights Brake Lights, Float, Lift and Shovel Reset Main Beam Blank

1B 2B 4B 5B

Hazard Battery Feed Dip Beam Rear Wash/Wipe Beacon, Interior Light, Radio and Under Bonnet Lights

1C 2C 5C

LH Side/Tail Lights and Number Plate Lights Front Work Lights Front Wash/Wipe and Horn

Note 1: For fuse ratings see pages 50-05-01/16 to 20.

9804/1103

50 - 15 - 10/10

4160-C/6-10.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/11

m/c’s from 540000 (446B)

Circuit Diagrams - Electrical Main Components

Lamps

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

110 111 112

Isolator Battery Starter Motor Starter Solenoids Starter Relay Grid Heater Grid Heater Relay Hydraulic Dump Valve Starter Switch E.S.O.S. Pull Coil (25 Amp) E.S.O.S. Hold Coil (0.2 Amp) Shut Down Relay Alternator Electronic Monitoring system (EMS) Buzzer Fuel Contents Sender Water Temperature Sender Transmission Oil Temperature Sender Hydraulic Oil Temperature Sender Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Engine Oil Level Sensor Coolant Level Sensor Transmission Oil Level Sensor Hydraulic Oil Level Sensor Emergency Steer Pressure Switch Water in Fuel Sensor Parking Brake Switch Transmission Disconnect Switches Transmission Solenoids ZF Transmission Computer Computer Feed Relay Turbine Speed Sensor Output Speed Sensor Throttle Switch Transmission Hand Control Kick Down Switch Reverse Alarm Reverse Alarm Relay Rear Work Lights Relay Rear Work Lights Switch ACCS Solenoid Valve ACCS Override Switch ACCS Relay Heater Relay Heater Switch Heater Blower Cigar Lighter Air Conditioning Compressor Clutch Air Conditioning Pressure Switch Air Conditioning Temperature Switch Air Conditioning Switch

Master Warning Light Rear Work Lights ACCS Operating Indication Light

Fuses 6A 8A

Computer Feed Relay Solenoid EMS Battery Feed

3B 6B 7B 8B

Reverse Alarm and Rear Work Lights E.S.O.S. Hold Coil Air Conditioning E.S.O.S. Pull Coil

3C 6C 7C 8C

EMS and ZF Computer Feed Heater Blower and Cigar Lighter Grid Heater Relay and Hydraulic Dump Valve ACCS

Note 1: For fuse ratings see pages 50-05-01/16 to 20.

Note: 56 is not used.

9804/1103

50 - 15 - 10/11

4160-C/6-11.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 10/12

m/c’s from 540000 (446B)

426B, 436B, 446B Circuit Diagrams - Electrical (continued)

6 1

16

7

3

41

8 11

10

111B

56

21

23

25

27

29

826G

17

19 20

22

24

26

28

42

38

33

9508

113

43

13

111

3 6 5 8 7 4 2 1

9520 9516

9584 9430B 9446B 9442B 9438B 9434B

409 418

9588A

39

600DU 420 431 411 839 405 412 402 404 432 421 600G 419 415 401 408 400 422 403 406 407

12

811 B3

2 002B

52

45

9588

813A

896A

A13 A12 A28 A15 A17 A5 A18 A30 A20 A33 A10 A31 B7 B2 A23 B14 B1 A14 A35 A16 A4 A6 A29 A19 A7 A8 A9 A21

18 413

A1

003

A24

14

A11

33 35

002C

9600C

32

31

15

14

25 29

8 5

23 26

896B

862A

825

44

53

896 115A

48

115C

112B

115B

46

9678 9438 9446 9674 9658 9524 9504 9666 9434 9422 9430 9508A 9528 9512 9536

+ 8B

51

813

9536B

7C

844C

9438A 9446A 9434A 9422A 9430A

+

844B

50

30

809

111A

112

31

15 110

4

18

111

822

54

895

24 19

862

821 820

863 9536A

11 9600

22

34

47

40

55

49

9600B 9600A

112C 112A

A34 B10

B6

B11

B12

B17

B16

B4

B18

B5

A25

A3

A2

A36

A26

840

107

002

810C

812D

807C

806C

836E

836D

835C

813B

301

5

001

9

9650

9654

9470

9612A

200P

27

17

9474 9460

9464 115

103

112

109

9612E

36

9612

8A

000H

34

32

9612B

UART/ UART/ TxD RxD MODA/ MODB

6B

2

897

9612A

9612D 004

1

13

37 3B

35 302

3C

106

000L

8C 000M

6C 000P

7B 000K

6A

200N 000G 000 813B

9

835C

200E

836D 836E 200W & 200X

200 & 220A 806C 807C 812D 810C

9804/1103

4160-C/6-12.1

50 - 15 - 10/12

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 10/13

426B, 436B, 446B

m/c’s from 540000(446)

Circuit Diagrams - Electrical (continued)

114

116

117

119

121

123

124

125

126

129

130

131

86

79 113

115

118 120

835E 836G 835D 836F

802B 802A

122

801C 801A

127

801H 801E

806B 806A

807B 807A

128

812B 812A

76 70

810A 810C

810B

72

836E

802

801

806

807

74

810D

846A

852 835C

81

85

82

78

846B

1C

2B

7A

800B

804

827

815

814

823

105B

846

71

810

73

805

75

63 64

824

105C 819B 819A

816

84

102B

88

77 818

104B

104C

104H

104E

102A

803B 837

817

813

828

819

304E

304D

304B

836E

62

8358

80

808 803

65

59 808A

104

100

102

105A

304

300 838 800

306 105

837A

1A 000A

1B

60

61

2C

5A

4B

5C

5B

200H 200F

200S

000E

000C

000F

200M

835C 836D 836E 802C 806C 807C 812D 810C

9804/1103

824B

87

132

851

3A

58

824A

812

812C

57

830

83

829

2A

133 134

50 - 15 - 10/13

4160-C/6-13.1

Issue 1

304C

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/14

m/c’s from 540000 (446)

Circuit Diagrams - Electrical Main Components

Lamps

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 88

113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134

Column Switch Diode Hazard Warning Switch Hazard Relay Road Light Switch Head Light Flasher Switch Fog Light Switch Front Work Lights Relay Front Work Lights Switch Not Used Not Used Not Used Not Used Detent Coil (Lift Ram Reset) Lift Ram Proximity Switch Detent Coil (Shovel Ram Reset) Shovel Ram Proximity Switch Detent Coil (Float) Brake Light Switch Rear Wiper Motor Rear Wash/Wipe Switch Rear Washer Pump Horn Column Switch Front Wiper Motor Intermittent Wiper Relay Front Washer Pump Beacon Switch Interior Light Interior Light Door Switch Radio (Option) Under Bonnet Lights Switch

LH Front Indicator LH Rear Indicator RH Front Indicator RH Rear Indicator RH Side Light RH Tail Light Switch Illumination LH Side Light LH Tail Light RH Number Plate Light LH Number Plate Light Dip Beam Main Beam Fog Lights LH Front Work Lights RH Front Work Lights LH Brake Light RH Brake Light Beacon Interior Light LH Under Bonnet Light RH Under Bonnet Light

Fuses 1A 2A 3A 5A 7A

Hazard Warning Lights and Direction Indicators RH Side/Tail Lights and Switch/Panel Illumination Fog Lights Brake Lights, Lift and Shovel Reset Main Beam

1B 2B 4B 5B Lights

Hazard Battery Feed Dip Beam Rear Wash/Wipe Beacon, Interior Light, Radio and Under Bonnet

1C 2C 5C

LH Side/Tail Lights and Number Plate Lights Front Work Lights Front Wash/Wipe and Horn

Note 1: For fuse ratings see pages 50-05-01/16 to 20

9804/1103

50 - 15 - 10/14

4160-C/6-14.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/15

m/c’s from March’98 (426B, 436B)

Circuit Diagrams - Electrical Main Components

Lamps

1 2 3 4 5 6 7 8A 8B 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

110 111 112

Starter Switch Battery Isolator Starter Relay Starter Solenoids Starter Motor Hydraulic Dump Valve Thermostart Restistor Thermostart Coil Shut down Relay E.S.O.S. Electronic Monitoring system (EMS) Computer Feed Relay Transmission Disconnect ZF Computer Transmission Solenoids Turbine Speed Sensor Output Speed Sensor Throttle Switch Kickdown Switch Hand Controller Relays Forward/Reverse Control Relays Hand Controller Forward/Reverse Switch Reverse Alarm Relay Reverse Alarm Reverse Lights Switch Reverse Lights Relay ACCS Relay ACCS Override Switch ACCS Solenoid Valve

LH Reverse Light RH Reverse Light ACCS Operating Indication Light

Fuses 6A 8A

Computer Feed Relay Solenoid EMS Battery Feed

3B 6B 8B

Reverse Alarm and Rear Work Lights Engine Shut Off System (ESOS) Thermostart

3C 7C 8C

EMS and ZF Computer Feed Hydraulic Dump Valve (416 Only) ACCS

Note : For fuse ratings see pages 50-05-01/16 to 20

Note: Arrows marked § indicate remote connection (not shown), ie. B5 goes to connection B5 on EMS (Item 11).

9804/1103

50 - 15 - 10/15

4160-C/6-15.1

Issue 1

Wheeled Loaders

CONTENTS

426B, 436B, 446B

50 - 15 - 10/16

m/c’s from March’98 (426B, 436B)

Circuit Diagrams - Electrical (continued) 2

2 3 5

4

6

1 7C

7 8A

8B 6B

8B

10

9 8A 11

13 12

3C 6A

14 15

16

18

17

21

20

19

22

23 25 24 27

3B

110

26 §

28

111

8C 29

30 112

9804/1103

50 - 15 - 10/16

4160-C/6-16.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/17

m/c’s from March’98 (426B, 436B)

Circuit Diagrams - Electrical (continued) Main Components 1 11 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

Lamps

Starter Switch Electronic Monitoring system (EMS) Warning Light Test Button Buzzer Fuel Contents Sender Water Temperature Sender Transmission Oil Temperature Sender Hydraulic Oil Temperature Sender Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Engine Oil Level Sensor Coolant Level Sensor Transmission Oil LevelSensor Hydraulic Oil Level Sensor Emergency Steer Switch Water in Fuel Sensor Parking Brake Switch Alternator Heater Switch Heater Relay Heater Blower Cigar Lighter Air Conditioning Switch Air Conditioning Temperature Switch Air Conditioning Pressure Switch Air Conditioning Compressor Clutch

115

Master Warning Light

Fuses 8A

EMS Battery Feed

7B

Air Conditioning

6C

Heater Blower and Cigar Lighter

Note 1: For fuse ratings see pages 50-05-01/16 to 20

Note: Arrows marked § indicate remote connection (not shown), ie. 3C goes to Fuse 3C via Relay (Item 12).

9804/1103

50 - 15 - 10/17

4160-C/6-17.1

Issue 1

Wheeled Loaders

CONTENTS

426B, 436B, 446B

50 - 15 - 10/18

m/c’s from March’98 (426B, 436B)

Circuit Diagrams - Electrical (continued) 1

35 115 36

8A 37 38 §

39 40 41 42

11

43 44 45 46 47 48 49 50 51 52

53 55 56 6C 54

57 7B

9804/1103

58

59

50 - 15 - 10/18

60

61

4160-C/6-18.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/19

m/c’s from March’98 (426B, 436B)

Circuit Diagrams - Electrical (continued) Main Components 1 66 67 68 69 70 71 72 73 74 75

Lamps

Starter Switch Hazard Relay Hazard Warning Switch Column Switch Diode Road Light Switch Head Light Flasher Switch Fog Light Switch Front Work Lights Switch Front Work Lights Inhibit Relay (Italy Only)† Front Work Lights Relay

† On all machines other than Italy, relay 74 is not fitted and wires 853A and 808A are connected Note: Arrows marked § indicate remote connection (not shown), ie. B4 goes to connection B4 on EMS (Item 11). B6 goes to connection B6 on EMS (Item 11). B10 goes to connection B10 on EMS (Item 11). B11 goes to connection B11 on EMS (Item 11). B12 goes to connection B12 on EMS (Item 11). B16 goes to connection B16 on EMS (Item 11). B17 goes to connection B17 on EMS (Item 11). B18 goes to connection B18 on EMS (Item 11).

120 121 122 123 124 125 126 127 128 129 130 131 132 133 134

LH Front Indicator LH Rear Indicator RH Front Indicator RH Rear Indicator RH Front Side Light RH Tail Light LH Front Side Light LH Tail Light RH Number Plate Light LH Number Plate Light Dipped Beam Main Beam Fog Lights LH Front Work Lights RH Front Work Lights

Fuses 1A 2A 3A

Hazard Warning Lights and Direction Indicators RH Side/Tail Lights and Switch/Panel Illumination Fog Lights

1B 2B

Hazard Battery Feed Dip Beam

1C 2C 9C

LH Side/Tail Lights and Number Plate Lights Front Work Lights Road Lights

Note 1: For fuse ratings see pages 50-05-01/16 to 20

9804/1103

50 - 15 - 10/19

4160-C/6-19.1

Issue 1

Wheeled Loaders

CONTENTS

426B, 436B, 446B

50 - 15 - 10/20

m/c’s from March’98 (426B, 436B)

Circuit Diagrams - Electrical (continued) 1

§

1A

120 67

1B

121 68

66

122 123

69 § §

124 2A 125 §

126 127 1C 128 129

2B

130

70 §

71

9C

131

7A

§

72

3A

132 §

133

74 73 2C

134 75

§

9804/1103

50 - 15 - 10/20

4160-C/6-20.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/21

m/c’s from March’98 (426B, 436B)

Circuit Diagrams - Electrical (continued) Main Components 1 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103

Starter Switch Lift Ram Proximity Switch Detent Coil (Lift Arm Reset) Shovel Ram Proximity Switch Detent Coil (Shovel Ram Reset) Detent Coil (Float) Brake Light Switch Heated Mirror Switch LH Heated Mirror RH Heated Mirror Heated Seat Switch Heated Seat Heated Seat Thermostat Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Pump Horn Front Wiper Motor Column Switch Intermittent Wiper Relay Front Washer Pump Beacon Switch Interior Light Radio (Option) Under Bonnet Lights Switch

9804/1103

Lamps 140 141 142 143 144 145

LH Brake Light RH Brake Light Beacon Interior Light LH Under Bonnet Light RH Under Bonnet Light

Fuses 5A

Brake Lights, Float, Lift and Shovel Reset

4B Rear Wash/Wipe 5B Beacon, Interior Light, Radio and Under Bonnet Lights 4C 5C

Heated Mirror and Heated Seat Front Wash/Wipe and Horn

Note 1: For fuse ratings see pages 50-05-01/16 to 20

50 - 15 - 10/21

4160-C/6-21.1

Issue 1

Wheeled Loaders

CONTENTS

426B, 436B, 446B

50 - 15 - 10/22

m/c’s from March’98 (426B, 436B)

Circuit Diagrams - Electrical (continued) 1 80 81 82

83

5A 84

140

85

141

87 86 88 4C 89

90 91

93

92

4B

94 95 96

5C

97 98

99 100 142

5B

143

101

102 144 103 145

9804/1103

50 - 15 - 10/22

4160-C/6-22.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/23

m/c’s from March’98 (446B)

Circuit Diagrams - Electrical (continued) Main Components 1 2 3 4 5 6 7A 7B 8 9 10A 10B 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Starter Switch Battery Isolator Starter Relay Starter Solenoids Starter Motor Grid Heater Solenoid Grid Heater Hydraulic Dump Valve Shut down Relay E.S.O.S. Pull Coil (25 Amp) E.S.O.S. Hold Coil (0.2 Amp) Electronic Monitoring system (EMS) Computer Feed Relay Transmission Disconnect ZF Computer Transmission Solenoids Turbine Speed Sensor Output Speed Sensor Throttle Switch Kickdown Switch Hand Controller Relays Forward/Reverse Control Relays Hand Controller Forward/Reverse Switch Reverse Alarm Relay Reverse Alarm Reverse Lights Switch Reverse Lights Relay ACCS Relay ACCS Override Switch ACCS Solenoid Valve

Lamps 110 111 112

LH Reverse Light RH Reverse Light ACCS Operating Indication Light

Fuses 6A 8A

Computer Feed Relay Solenoid EMS Battery Feed

3B 6B 8B

Reverse Alarm and Rear Work Lights Engine Shut Off System (ESOS) Thermostart

3C 7C 8C

EMS and ZF Computer Feed Hydraulic Dump Valve (416 Only) ACCS

Note 1: For fuse ratings see pages 50-05-01/16 to 20

Note: Arrows marked § indicate remote connection (not shown), ie. B5 goes to connection B5 on EMS (Item 11).

9804/1103

50 - 15 - 10/23

4160-C/6-23.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 10/24

426B, 436B, 446B

m/c’s from March’98 (446B)

Circuit Diagrams - Electrical (continued) 2

2 3 5

4

6

7B

7A

1 7C 8B

8

10A

6B

10B 9

8A 11

13 12

3C 6A

14 15

16

18

17

21

20

19

22

23 25 24 27

3B

110

26 §

28

111

8C 29

30 112

9804/1103

50 - 15 - 10/24

4160-C/6-24.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/25

m/c’s from March’98 (446B)

Circuit Diagrams - Electrical (continued) Main Components 1 11 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

Lamps

Starter Switch Electronic Monitoring system (EMS) Warning Light Test Button Buzzer Fuel Contents Sender Water Temperature Sender Transmission Oil Temperature Sender Hydraulic Oil Temperature Sender Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Engine Oil Level Sensor Coolant Level Sensor Transmission Oil Level Sensor Hydraulic Oil Level Sensor Emergency Steer Switch Water in Fuel Sensor Parking Brake Switch Alternator Heater Switch Heater Relay Heater Blower Cigar Lighter Air Conditioning Switch Air Conditioning Temperature Switch Air Conditioning Pressure Switch Air Conditioning Compressor Clutch

115

Master Warning Light

Fuses 8A

EMS Battery Feed

7B

Air Conditioning

6C

Heater Blower and Cigar Lighter

Note 1: For fuse ratings see pages 50-05-01/16 to 20

Note: Arrows marked § indicate remote connection (not shown), ie. 3C goes to Fuse 3C via Relay (Item 12).

9804/1103

50 - 15 - 10/25

4160-C/6-25.1

Issue 1

Wheeled Loaders

CONTENTS

426B, 436B, 446B

50 - 15 - 10/26

m/c’s from March’98 (446B)

Circuit Diagrams - Electrical (continued) 1

35 115 36

8A 37 38 §

39 40 41 42

11

43 44 45 46 47 48 49 50 51 52

53 55 56 6C 54

57 7B

9804/1103

58

59

50 - 15 - 10/26

60

61

4160-C/6-26.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/27

m/c’s from March’98 (446B)

Circuit Diagrams - Electrical (continued) Main Components

Lamps

1 66 67 68 69 70 71 72 73 74 75

120 121 122 123 124 125 126 127 128 129 130 131 132 133 134

Starter Switch Hazard Relay Hazard Warning Switch Column Switch Diode Road Light Switch Head Light Flasher Switch Fog Light Switch Front Work Lights Switch Front Work Lights Inhibit Relay (Italy Only)† Front Work Lights Relay

† On all machines other than Italy, relay 74 is not fitted and wires 853A and 808A are connected

LH Front Indicator LH Rear Indicator RH Front Indicator RH Rear Indicator RH Front Side Light RH Tail Light LH Front Side Light LH Tail Light RH Number Plate Light LH Number Plate Light Dipped Beam Main Beam Fog Lights LH Front Work Lights RH Front Work Lights

Note: Arrows marked § indicate remote connection (not shown), ie. B4 goes to connection B4 on EMS (Item 11). B6 goes to connection B6 on EMS (Item 11). B10 goes to connection B10 on EMS (Item 11). B11 goes to connection B11 on EMS (Item 11). B12 goes to connection B12 on EMS (Item 11). B16 goes to connection B16 on EMS (Item 11). B17 goes to connection B17 on EMS (Item 11). B18 goes to connection B18 on EMS (Item 11).

Fuses 1A 2A 3A

Hazard Warning Lights and Direction Indicators RH Side/Tail Lights and Switch/Panel Illumination Fog Lights

1B 2B

Hazard Battery Feed Dip Beam

1C 2C 9C

LH Side/Tail Lights and Number Plate Lights Front Work Lights Road Lights

Note 1: For fuse ratings see pages 50-05-01/16 to 20

9804/1103

50 - 15 - 10/27

4160-C/6-27.1

Issue 1

Wheeled Loaders

CONTENTS

426B, 436B, 446B

50 - 15 - 10/28

m/c’s from March’98 (446B)

Circuit Diagrams - Electrical (continued) 1

§

1A

120 67

1B

121 68

66

122 123

69 § §

124 2A 125 §

126 127 1C 128 129

2B

130

70 §

71

9C

131

7A

§

72

3A

132 §

133

74 73 2C

134 75

§

9804/1103

50 - 15 - 10/28

4160-C/6-28.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/29

m/c’s from March’98 (446B)

Circuit Diagrams - Electrical (continued) Main Components

Lamps

1 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103

140 141 142 143 144 145

Starter Switch Lift Ram Proximity Switch Detent Coil (Lift Arm Reset) Shovel Ram Proximity Switch Detent Coil (Shovel Ram Reset) Detent Coil (Float) Brake Light Switch Heated Mirror Switch LH Heated Mirror RH Heated Mirror Heated Seat Switch Heated Seat Heated Seat Thermostat Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Pump Horn Front Wiper Motor Column Switch Intermittent Wiper Relay Front Washer Pump Beacon Switch Interior Light Radio (Option) Under Bonnet Lights Switch

9804/1103

LH Brake Light RH Brake Light Beacon Interior Light LH Under Bonnet Light RH Under Bonnet Light

Fuses 5A

Brake Lights, Float, Lift and Shovel Reset

4B Rear Wash/Wipe 5B Beacon, Interior Light, Radio and Under Bonnet Lights 4C 5C

Heated Mirror and Heated Seat Front Wash/Wipe and Horn

Note 1: For fuse ratings see pages50-05-01/16 to 20

50 - 15 - 10/29

4160-C/6-29.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 10/30

426B, 436B, 446B

m/c’s from March’98 (446B)

Circuit Diagrams - Electrical (continued) 1 80 81 82

83

5A 84

140

85

141

87 86 88 4C 89

90 91

93

92

4B

94 95 96

5C

97 98

99 100 142

5B

143

101

102 144 103 145

9804/1103

50 - 15 - 10/30

4160-C/6-30.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/31

m/c’s from 533692 (436B)

Circuit Diagrams - Electrical Main Components Lamps 1 2 3 4 5 6 7 8 9

Battery Isolator Light Relay Road Light Switch Fog Light Switch Column Switch Front Work Light Relay Front Work Light Switch Rear Work Light Switch

120 121 122 123 124

Fuses

Note: Items marked $ indicate remote connections (not shown), ie. $1 $2 $3 $4 $5 $6

From EMS A23 To EMS B6 To EMS B12 To EMS B11 To EMS B10 To EMS B5

Fog Lights Dipped Beam Main Beam Front Work Lights Rear Work Lights

A1 A2 A3 A4 A5 A6

Rear Work Lights Road Lights Front Work Lights Dipped Beam Main Beam Rear Fog Lights

B1 B2

Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and Number Plate Lights

P1

Front Work Lights Rear Work Lights Main Beam Dip Beam Fog Lights

Note 1: for Fuse ratings, see pages 50-05-01/16 to 20

9804/1103

50 - 15 - 10/31

4160-C/6-31.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 10/32

426B, 436B, 446B

m/c’s from 533692 (436B)

Circuit Diagrams - Electrical (continued) 1

1

2

-

+

-

+

B1 See C/6-34

B2 See C/6-34

4 See C/6-34 303

3 See C/6-36

132A 005

201

A2

812D

800

LH

812A

120 803B

5

812C

A6

120 812

803

6

804

P1 805

305

See C/6-34

$2 To EMS B6

A4 A5

812B

RH

806C

$3 To EMS B12

806A

LH

121 806

806B

RH

807

807A

LH

122 RH

807B 807C

810E

7 201A

006

A3

122

122B

8

810

$4 To EMS B11 $5 To EMS B10

810A

122A

$1 From EMS A23 808

LH

See C/6-42

810B

123 810C RH 810D

LH

813C

A1

121

9

124 813

813A

813B

9804/1103

50 - 15 - 10/32

813D

RH

$6 To EMS B5

4160-C/6-32.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/33

m/c’s from 533692 (436B)

Circuit Diagrams - Electrical (continued) Main Components

Lamps

1 2 10 11 12 13 14 15 16

125 126 127 128 129 130 131 132 133 134 135

Battery Isolator Electronic Monitoring System (EMS) ZF Computer Hazard Warning Switch Hazard Warning Relay Column Switch Beacon Switch 24 Volt Radio

Note: Items marked $ indicate remote connections (not shown), ie.

Left Front Indicator Left Rear Indicator Right Front Indicator Right Rear Indicator Beacon Interior Light Right Front Side Light Right Rear Side Light Left Front Side Light Left Rear Side Light Number Plate Lights

Fuses $7 $8 $9 $10 $11 $12

12 Volt Trailer Electrics To EMS B18 To EMS B16 Headlight Flash Switch Illumination To EMS B18

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and Number Plate Lights 12 Volt Trailer Electrics (Option) EMS (Battery Feed) ZF Computer (Battery Feed) Hazard Warning Beacon and Interior Light 24 Volt Radio Headlight Flash Side Lights

C9

Direction Indicators

P2

Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and Number Plate Lights Headlight Flash Radio (24 Volt) Beacon and Interior Light Hazard Warning EMS (Battery Feed) ZF Computer (Battery Feed) 12 Volt trailer Electrics

Note 1: for Fuse ratings, see pages 50-05-01/16 to 20

9804/1103

50 - 15 - 10/33

4160-C/6-33.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 10/34

426B, 436B, 446B

m/c’s from 533692 (436B)

Circuit Diagrams - Electrical (continued) 1

1

-

+

-

+

2

B3 $7 12 Volt Trailer Electrics

B4

10

301

See C/6-42

9832

B5

11 9836

See C/6-40

202A

835C

C9 See C/6-38

$8 To EMS B18

100 835A

202

12

B6

30

300 838

49

14

15

LH FRONT

125

835

P2

835D

LH REAR

126 13

835B

R

836B

836A

RH FRONT

127

836

49A

837A

L

RH REAR

836D

128

837 836C

304E

15

$9 To EMS B16

823

129

B7

304D

304

130 B8

16

309

B9

305

802D

$11 Switch Illumination

802C

$12 To EMS B18

$10 Headlight Flash See C/6-32

802A

B1

B10

4 303

See C/6-32

B2 800

120

802

802B

132

801

801A

133

801C

134

801B 803B

131

See C/6-32 801D

LH

801E

RH

135

9804/1103

50 - 15 - 10/34

4160-C/6-34.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/35

m/c’s from 533692 (436B)

Circuit Diagrams - Electrical (continued) Main Components

Lamps

1 2 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

136 Road Light Switch Illumination

Battery Isolator Starter Solenoids Starter Motor Start Relay Starter Switch Not Applicable Start-up dump Solenoid Thermostart Resistor Thermostart Not Applicable Dump Relay Heater Speed Switch Heater Blower Air Conditioning Switch Air Conditioning Temperature Switch Air Conditioning Pressure Switch Air Conditioning Compressor Heated Mirror Switch Heated Mirrors Heated Seat Switch Seat Heating Elements Air Suspension Switch Air Suspension Compressor Heated Rear Screen Switch Heated Rear Screen Relay Heated Rear Screen Lights Relay Solenoid Ignition Relay Solenoid 1 Ignition Relay Solenoid 2 Ignition Relay Solenoid 3

Fuses A7 A8 A9 A10

Blank Thermostart Dump Relay Ignition Relays

C1 C6

Starter Relay Solenoid Heated Seat/Mirrors and Air Suspension Seat (Option) C7 Air Conditioning (Option) C8 Heater Blower C9 Direction Indicators C10 Heated Rear Screen P3

Starter Solenoid Thermostart Heater Blower Air Conditioning Direction Indicators Heated Seat, Mirrors and Air Suspension Seat Heated RearScreen Ignition Relays

Note 1: for Fuse ratings, pages 50-05-01/16 to 20

Note: Items marked $ indicate remote connections (not shown), ie. $13 $14 $15 $16

To EMS A34 Indicators To EMS A24 To EMS B4

9804/1103

50 - 15 - 10/35

4160-C/6-35.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 10/36

426B, 436B, 446B

m/c’s from 533692 (436B)

Circuit Diagrams - Electrical (continued) 1

1

-

+

-

+

2

17

19

203A

C1

001

127

128

$13 To EMS 34 See C/6-42 7

20

A7

2

P3

8 9

1

203

18

002

21

111

6 5

22 A8

23

113

24 25

000

A9 129

28

27 C8

822 112

821 820

26

C7

29

109

30

863

862

31

862A

32

873A

33

873

34

119A 873

830

C6

36

35

119

872

C9

100

38

37

119B

$14 Indicators See C/6-34

39 103A

C10

103

$16 To EMS B4 See C/6-42

826

$15 To EMS A24 See C/6-42

834 841

41

40

000A

A10

132

132A

42

132C

43

132D

44

132E

45

132F

9804/1103

50 - 15 - 10/36

136

4160-C/6-36.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/37

m/c’s from 533692 (436B)

Circuit Diagrams - Electrical (continued) Main Components Lamps 1 2 10 11 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69

Battery Isolator Electronic Monitoring System (EMS) ZF Computer Ignition Relay 1 Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Pump Horn Ignition Relay 2 Column Switch Front Wiper Motor Intermittent Wiper Relay Front Washer Pump 24 Volt Cigar Lighter Shutdown Relay E.S.O.S. Reverse Relay Reverse Alarm Ignition Relay 3 Brake Light Switch Changeover Switch Changeover Solenoid Lift Ram Proximity Switch Detent Coil (Lift Ram Reset) Shovel Ram Proximity Switch Detent Coil (Shovel Ram Reset) Detent Coil (Float)

137 138 139 140

Fuses C2 C3 C4 C5

24 Volt Cigar Lighter Blank Rear Wash/Wiipe Front Wash/Wipe and Horn

D1 D2 D3 D5 D6 D7 D8 D9 D10

EMS (Ignition Feed) ZF Computer (Ignition Feed) CCTV (Option) ESOS and Cold Start Advance Reverse Lights and Alarm In-cab 24/12 Volt Converter (Option) Blank Brake Lights Float, Lift and Shovel Reset and 4th Spool

P4

EMS (Ignition Feed) ZF Computer (Ignition Feed) Rear Wash/Wipe Front Wash/Wipe and Horn Cigar Lighter (24 Volt) ESOS and Cold Start Advance Reverse Alarm/Lights Headlight Flash Brake Lights Shovel and Arm Reset CCTV In-cab 24/12 Volt Converter

Note: Items marked $ indicate remote connections (not shown), ie. $17 $18 $19 $20

Left Fog Light Right Fog Light Left Brake Light Right Brake Light

CCTV Spare To EMS A11 To CCTV

Note 1: for Fuse ratings, pages 50-05-01/16 to 20

9804/1103

50 - 15 - 10/37

4160-C/6-37.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 10/38

426B, 436B, 446B

m/c’s from 533692 (436B)

Circuit Diagrams - Electrical (continued) 1

118

$17 CCTV See C/6-44

D1

125

46 See C/6-38

2

-

+

-

+ D3

1

10

See C/6-42

132C 008

204

D2

11

9916A

See C/6-40 102B

827

47 C4

102

48

102A

815

C3

49

814

$18 Spare

50

816 105B

53 817 818 829

51 132D

See C/6-36

204B

007

C5

105

105A

831

52

105C

54

828 819B

C2

P4

D5

204A

55

819A

819

124

$19 To EMS A11 See C/6-42

56

57

811

58

809

107

60

59 D6

See C/6-40

9916J 844

115

844A

137

844B

138 844D

61 204C

See C/6-36

009

$20 To CCTV See C/6-44

D7 108

See C/6-44

132E

D8 $18 Spare

D9

62

126

847

847A

847B

63

139 140

64

861

104G

D10

65 104

852

67

104C

66 104B

851

68

104H

69

9804/1103

50 - 15 - 10/38

4160-C/6-38.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/39

m/c’s from 533692 (436B)

Circuit Diagrams - Electrical (continued) Main Components 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90

Fuses

Gear Box Controller Unit Torque Converter Out Temperature Sensor Reverse Relay Solenoid Load Suspension Solenoid Load Suspension On/Off Switch Parking Brake On/Off Switch(411 to 446) Parking Brake On/Off Switch (456) Auto/Manual Switch On/Off Switch Pressure Switch Transmission Disconnect Button Parking Brake Solenoid Internal Gear Chain Speed Sensor Turbine Speed Sensor Engine Speed Sensor Output Speed Sensor Forward/Reverse Rocker Switch Hand Controller Transmission Kick Down Button ZF Diagnostic Port ZF Display Plug

B5

ZF Computer (Battery Feed)

D2

ZF Computer (Ignition Feed)

Note 1: for Fuse ratings, see pages 50-05-01/16 to 20.

Note: Items marked $ indicate remote connections (not shown), ie. $21 CAN-BUS To EMS $22 To EMS A30 (456 Only)

9804/1103

50 - 15 - 10/39

4160-C/6-39.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 10/40

426B, 436B, 446B

m/c’s from 533692 (436B)

Circuit Diagrams - Electrical (continued)

70 Y3

Y4

Y5

Y6

VSP1

2

3

4

5

6

7

TEMP 9

Y2

1

TEMP 8

Y1

$21 CAN-BUS to EMS See C/6-42

$22 To EMS A30 (456 Only)

421

9462A

9454

9574

71 438

439

9570

9462

9458

9908

9904

9450

9446

9442

9438

9434

9430

10

32

55

09

51

12

13

39

AIP1

AIP2

AIP3

AIP4

AIP5

AIP6

VPS1

VPS1

ER1

46 VMGA2

56

CANF-H

ADM2

VM1

9852

848

57

75

9916F

9920

30

896

9856

01

74

02

VM2

9916H

438A

05

897

438B

27

CANF-T

73

9916M

26

CANF-L

25

9808

07

72

9916J

9820B

ED11

11

9824

EF3

9900

42

9916A

79

03

VMG1

78

893

08

77

9916G

81 ED10

29

9820A 9820

21

76 9916D

9420

9424

82

840 9816B

9816A

EF2

ED9

41

9816

9916B

66

80

9414 9410

83 9404

D2

9916

EF1

9832

23

VPE1

64

18

67

22

ED5

65

ED6

43

ED7

ED4

31

ED2

ED13

20

63

ED3

44

ED1

ED8

EF4 62

881

882

880

1

2

9532A

9500

9504

85

3

9508

VMG2 04

See C/6-34

84

15

VPE2

9400

14

68

B5

VPI

9836

19

45

9916A

See C/6-38

9524

9528

9544

9548

9540

1

9532

4

3

2

86

9536A

9864 9648

9644

9652

KD

B2

B1

R

N

F

9536

88 2

1

3

4

9640

89

4

50 - 15 - 10/40

3

1

9590

9804/1103

9594

9916K

9598

87

90

4160-C/6-40.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/41

m/c’s from 533692 (436B)

Circuit Diagrams - Electrical (continued) Main Components

Fuses

1 2 10 91 92 93 94 95 96 97 98 99 100 101 102 103 104

B4

EMS (Battery Feed)

D1

EMS (Ignition Feed)

Battery Isolator Electronic Monitoring System (EMS) EMS Diagnostic Port Buzzer Fuel Level Sender Water Temperature Sender Transmission Oil Temperature Sender Engine Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Emergency Steer Switch Shutdown Relay Coil Front Work Light Relay Coil Heated Rear Screen Relay Coil Alternator

Note 1: for Fuse ratings, see pages 50-05-01/16 to 20

Note: Items marked $ indicate remote connections (not shown), ie. $21 $23 $24 $25 $26 $27 $28 $29 $30 $31 $32 $33 $34

CAN-BUS To EMS From Fuse A6 From Fuse A4 From Fuse A5 From Front Work Light Switch From RearWork Light Switch From LH Indicator Feed From RH Indicator Feed From Side Light Feed From Heated Rear Screen Switch From ZF Computer (Park Brake Status-456 Only) From Start Relay Coil 120 ohm Resistor

9804/1103

50 - 15 - 10/41

4160-C/6-41.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 10/42

426B, 436B, 446B

m/c’s from 533692 (436B)

Circuit Diagrams - Electrical (continued) 1

1

-

+

-

+

2

91

424

423

425

125A

A2

5 600BX

2

1

3

4

A26

A3 A35

A13

600G

600DU

139

420

B4 See C/6-34

301

D1 See C/6-38

A25

A12

B7 125

A36

10

B14

B1

$23 From Fuse A6 $24 From Fuse A4 $25 From Fuse A5

812D

806C

807C

$26 From Front Work Light Switch

810E

$27 From Rear Work Light Switch

813B

$28 From LH Indicator Feed $29 From RH Indicator Feed $30 From Side Light Feed $31 From Heated Rear Screen Switch

835C

836C 802C

826

128

93

415

94

401

95

B12

B11

A16

B10

A4

B5

A15

B18

A6

B16

A18

408

96

400

97

412

98

422 432

99 100

B18 B4

A23 421

431

B6

A11

$32 From ZF Computer (Park Brake Status-456 Only)

92

420A

811

101

808

102

834

103

A30 A24

A34

A27

B15

B9

B3

418

438E

439E

650

$34 120 ohm Resistor

$21 CAN-BUS To EMS See C/6-40

104

9804/1103

50 - 15 - 10/42

4160-C/6-42.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 15 - 10/43

m/c’s from 533692 (436B)

Circuit Diagrams - Electrical (continued) Main Components

Fuses

1 2 105 106 107 108 109 110

D3 D7

Battery Isolator 24/12 Volt Converter 12 Volt Radio 12 Volt Cigar Lighter 12 Volt Auxiliary Plug Closed Circuit Television Display (CCTV) CCTV Camera

CCTV (Option) In-cab24/12 Volt Converter (Option)

Note 1: for Fuse ratings, see pages 50-05-01/16 to 26.

Note: Items marked $ indicate remote connections (not shown), ie. $35 Reverse Light/Alarm Feed $36 From Side Light Feed

9804/1103

50 - 15 - 10/43

4160-C/6-43.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 15 - 10/44

426B, 436B, 446B

m/c’s from 533692 (436B)

Circuit Diagrams - Electrical (continued) 1

1

-

+

-

+

2

600DZ

308A

D7

108

See C/6-38

105

308

308B

308C

106

107

108

603A

603B

603C

603

844D

$35 Reverse Light/Alarm Feed See C/6-38

D3

118

See C/6-38

$36 From Side Light Feed

109

802M

110

9804/1103

50 - 15 - 10/44

4160-C/6-44.1

Issue 1

CONTENTS CONTENTS

Wheeled Loaders

426, 436

426 m/c’s from 532100 436 m/c’s from 533692

Circuit Diagrams - Electrical (continued) Main Components

Lamps

1 2 3 4 5 6 7 8 9

120 121 122 123 124

Battery Isolator Light Relay Road Light Switch Fog Light Switch Column Switch Front Work Light Relay Front Work Light Switch Rear Work Light Switch

From EMS A23 To EMS B6 To EMS B12 To EMS B11 To EMS B10 To EMS B5

Fog Lights Dipped Beam Main Beam Front Work Lights Rear Work Lights

Fuses

Note: Items marked $ indicate remote connections (not shown), ie. $1 $2 $3 $4 $5 $6

50 - 15 - 10/45

A1 A2 A3 A4 A5 A6

Rear Work Lights Road Lights Front Work Lights Dipped Beam Main Beam Rear Fog Lights

B1 B2

Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and Number Plate Lights

P1

Front Work Lights Rear Work Lights Main Beam Dip Beam Fog Lights

Note 1: for Fuse ratings, see Fuses 50-05-01/20

9804/1103

50 - 15 - 10/45

4160-C/6 - 31.2

Issue 1*

CONTENTS CONTENTS

Wheeled Loaders

50 - 15 - 10/46

426, 436

426 m/c’s from 532100 436 m/c’s from 533692

Circuit Diagrams - Electrical (continued) 1

1

2

-

+

-

+

B1 B2

See 50 - 15 - 10/48 See C/6-34

See50 C/6-34 See - 15 - 10/48

4 3 See 50See - 15 C/6-36 - 10/50

See 50See - 15 C/6-34 - 10/48 303

132A 005

201

A2

812D

800

120

5

812C

A6

812

803

6

804

P1 805

305

A4 A5

812B

806A

LH

121

806

806B

RH

807

807A

LH

810E

006

A3

122 122A

$1 From EMS A23 808

122B

8

RH

$3 To EMS B12

807C

7

120

806C

807B

201A

LH

812A

803B

C/6-34 See See 50-15-10/48

$2 To EMS B6

810

122

RH

$4 To EMS B11 $5 To EMS B10

810A LH

SeeSee C/6-42 50-15-10/56

810B

123 810C RH 810D

LH

813C

A1

121

9

124 813

813A

813B

9804/1103

50 - 15 - 10/46

813D

RH

$6 To EMS B5

4160-C/6 - 32.2

Issue 1*

CONTENTS CONTENTS

Wheeled Loaders

50 - 15 - 10/47

426, 436

426 m/c’s from 532100 436 m/c’s from 533692

Circuit Diagrams - Electrical (continued) Main Components Lamps 1 2 10 11 12 13 14 15 16

Battery Isolator Electronic Monitoring System (EMS) ZF Computer Hazard Warning Switch Hazard Warning Relay Column Switch Beacon Switch 24 Volt Radio

Note: Items marked $ indicate remote connections (not shown), ie. $7 $8 $9 $10 $11 $12

12 Volt Trailer Electrics To EMS B18 To EMS B16 Headlight Flash Switch Illumination To EMS B18

125 126 127 128 129 130 131 132 133 134 135

Left Front Indicator Left Rear Indicator Right Front Indicator Right Rear Indicator Beacon Interior Light Right Front Side Light Right Rear Side Light Left Front Side Light Left Rear Side Light Number Plate Lights

Fuses B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and Number Plate Lights 12 Volt Trailer Electrics (Option) EMS (Battery Feed) ZF Computer (Battery Feed) Hazard Warning Beacon and Interior Light 24 Volt Radio Headlight Flash Side Lights

C9

Direction Indicators

P2

Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and Number Plate Lights Headlight Flash Radio (24 Volt) Beacon and Interior Light Hazard Warning EMS (Battery Feed) ZF Computer (Battery Feed) 12 Volt trailer Electrics

Note 1: for Fuse ratings, see Fuses 50-05-01/20

9804/1103

50 - 15 - 10/47

4160-C/6 - 33.2

Issue 1*

CONTENTS CONTENTS

Wheeled Loaders

50 - 15 - 10/48

426, 436

426 m/c’s from 532100 436 m/c’s from 533692

Circuit Diagrams - Electrical (continued) 1

1

-

+

-

+

2

B3 $7 12 Volt Trailer Electrics

B4

10

301

See See C/6-42 50-15-10/56

9832

B5

11 9836

See 50-15-10/54 See C/6-40

202A

See 50 - 15 10/52 See- C/6-38

202

835A

12

B6

30

300 838

49

L

835B

R

836B

LH FRONT

125 835D

LH REAR

126

836A

RH FRONT

127

836

49A

837A

14

15

13

$8 To EMS B18

100

835

P2

835C

C9

RH REAR

836D

128

837 836C

304E

15

$9 To EMS B16

823

129

B7

304D

304

130 B8

B9

16

309

802D 305

$10 Headlight Flash See SeeC/6-32 50 - 15 - 10/46

802C

B1 B10

4 303

See- C/6-32 See 50 - 15 10/46

800

B2

120

$12 To EMS B18

802A

131

802

802B

132

801

801A

133

801C

134

801B 803B

$11 Switch Illumination

See SeeC/6-32 50 - 15 - 10/46 801D

LH

801E

RH

135

9804/1103

50 - 15 - 10/48

4160-C/6 - 34.2

Issue 1*

CONTENTS CONTENTS

Wheeled Loaders

426, 436

50 - 15 - 10/49

426 m/c’s from 532100 436 m/c’s from 533692

Circuit Diagrams - Electrical (continued) Main Components Lamps 1 2 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 32A 33 34 35 36 37 38 39 40 41 42 43 44 45

Battery Isolator Starter Solenoids Starter Motor Start Relay Starter Switch Not Applicable Start-up dump Solenoid Thermostart Resistor Thermostart Not Applicable Dump Relay Heater Speed Switch Heater Blower Air Conditioning Switch Air Conditioning Temperature Switch Air Conditioning Pressure Switch Air Conditioning Compressor Air Conditioning Relay Heated Mirror Switch Heated Mirrors Heated Seat Switch Seat Heating Elements Air Suspension Switch Air Suspension Compressor Heated Rear Screen Switch Heated Rear Screen Relay Heated Rear Screen Lights Relay Solenoid Ignition Relay Solenoid 1 Ignition Relay Solenoid 2 Ignition Relay Solenoid 3

136 Road Light Switch Illumination

Fuses A7 A8 A9 A10

Blank Thermostart Dump Relay Ignition Relays

C1 C6

Starter Relay Solenoid Heated Seat/Mirrors and Air Suspension Seat (Option) C7 Air Conditioning (Option) C8 Heater Blower C9 Direction Indicators C10 Heated Rear Screen P3

Starter Solenoid Thermostart Heater Blower Air Conditioning Direction Indicators Heated Seat, Mirrors and Air Suspension Seat Heated RearScreen Ignition Relays

Note 1: for Fuse ratings, see Fuses 50-05-01/20

Note: Items marked $ indicate remote connections (not shown), ie. $13 $14 $15 $16

To EMS A34 Indicators To EMS A24 To EMS B4

9804/1103

50 - 15 - 10/49

4160-C/6 - 35.2

Issue 1*

CONTENTS CONTENTS

Wheeled Loaders

50 - 15 - 10/50

426, 436

426 m/c’s from 532100 436 m/c’s from 533692

Circuit Diagrams - Electrical (continued) 1

1

-

+

-

+

2

17

19

203A

C1

001

18

127

128

$13 To EMS 34 7

A7

2

1

203

8 9

P3

20

002

See C/6-42 See 50-15-10/56

21

111

6 5

22 A8

23

113

24 25

000

A9 129

C8

28

27

822

112

821 820

26 32A C7

29

109

863

863A

30

863B

33

31

862

825

862

32

600BY

873A 873

34

119A 873

830

C6

36

35

119

872

C9

100

$14 Indicators See SeeC/6-34 50-15-10/48

39 103A

C10

38

37

119B

$15 To EMS A24 103

$16 To EMS B4

826

See C/6-42 See 50-15-10/56 834

See C/6-42 See 50-15-10/56

841

41

40

000A

A10

132

132A

42

132C

43

132D

44

132E

45

132F

9804/1103

50 - 15 - 10/50

136

4160-C/6 - 36.2

Issue 1*

CONTENTS CONTENTS

Wheeled Loaders

426, 436

426 m/c’s from 532100 436 m/c’s from 533692

Circuit Diagrams - Electrical (continued) Main Components

Lamps

1 2 10 11 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69

137 138 139 140

Battery Isolator Electronic Monitoring System (EMS) ZF Computer Ignition Relay 1 Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Pump Horn Ignition Relay 2 Column Switch Front Wiper Motor Intermittent Wiper Relay Front Washer Pump 24 Volt Cigar Lighter Shutdown Relay E.S.O.S. Reverse Relay Reverse Alarm Ignition Relay 3 Brake Light Switch Changeover Switch Changeover Solenoid Lift Ram Proximity Switch Detent Coil (Lift Ram Reset) Shovel Ram Proximity Switch Detent Coil (Shovel Ram Reset) Detent Coil (Float)

CCTV Spare To EMS A11 To CCTV

9804/1103

Left Fog Light Right Fog Light Left Brake Light Right Brake Light

Fuses C2 C3 C4 C5

24 Volt Cigar Lighter Blank Rear Wash/Wiipe Front Wash/Wipe and Horn

D1 D2 D3 D5 D6 D7 D8 D9 D10

EMS (Ignition Feed) ZF Computer (Ignition Feed) CCTV (Option) ESOS and Cold Start Advance Reverse Lights and Alarm In-cab 24/12 Volt Converter (Option) Blank Brake Lights Float, Lift and Shovel Reset and 4th Spool

P4

EMS (Ignition Feed) ZF Computer (Ignition Feed) Rear Wash/Wipe Front Wash/Wipe and Horn Cigar Lighter (24 Volt) ESOS and Cold Start Advance Reverse Alarm/Lights Headlight Flash Brake Lights Shovel and Arm Reset CCTV In-cab 24/12 Volt Converter

Note: Items marked $ indicate remote connections (not shown), ie. $17 $18 $19 $20

50 - 15 - 10/51

Note 1: for Fuse ratings, see Fuses 50-05-01/20

50 - 15 - 10/51

4160-C/6 - 37.2

Issue 1*

CONTENTS CONTENTS

Wheeled Loaders

50 - 15 - 10/52

426, 436

426 m/c’s from 532100 436 m/c’s from 533692

Circuit Diagrams - Electrical (continued) 1

008

2

-

+

132C 204

118

$17 CCTV See C/6-44 See 50-15-10/58

D1

46 See C/6-38 See 50-15-10/52

-

+ D3

1

125

D2

10

See 50-15-10/56 See C/6-42

11 See See C/6-40 50-15-10/54

9916A

102B

827

47 C4

102

48

102A

815

C3

49

814

$18 Spare

50

816 105B

53 817 818

51

829

132D

See C/6-36

204B

007

C5

105

831

52

105A

54

105C 828 819B

P4

D5

204A

55

819A

819

C2

124

56

57

811

$19 To EMS A11 See C/6-42 See 50-15-10/56

58

809

107

60

59 D6

204C

See C/6-36 See 50-15-10/50

61

009

See C/6-40 See 50-15-10/54

9916J 844

115

844A

137

844B

138 844D

D7

108

$20 To CCTV See C/6-44 See 50-15-10/58

See SeeC/6-44 50-15-10/58

132E

D8 $18 Spare

D9

62

126

847

63

847A

139

847B

140

64

861

104G

D10

104

104B

104H

9804/1103

65

852

66

851

104C

50 - 15 - 10/52

67

68

69

4160-C/6 - 38.2

Issue 1*

CONTENTS CONTENTS

Wheeled Loaders

426, 436

426 m/c’s from 532100 436 m/c’s from 533692

Circuit Diagrams - Electrical (continued) Main Components 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90

50 - 15 - 10/53

Fuses

Gear Box Controller Unit Torque Converter Out Temperature Sensor Reverse Relay Solenoid Load Suspension Solenoid Load Suspension On/Off Switch Parking Brake On/Off Switch(411 to 446) Parking Brake On/Off Switch (456) Auto/Manual Switch On/Off Switch Pressure Switch Transmission Disconnect Button Parking Brake Solenoid Internal Gear Chain Speed Sensor Turbine Speed Sensor Engine Speed Sensor Output Speed Sensor Forward/Reverse Rocker Switch Hand Controller Transmission Kick Down Button ZF Diagnostic Port ZF Display Plug

B5

ZF Computer (Battery Feed)

D2

ZF Computer (Ignition Feed)

Note 1: for Fuse ratings, see Fuses 50-05-01/20

Note: Items marked $ indicate remote connections (not shown), ie. $21 CAN-BUS To EMS $22 To EMS A30 (456 Only)

9804/1103

50 - 15 - 10/53

4160-C/6 - 39.2

Issue 1*

CONTENTS CONTENTS

Wheeled Loaders

50 - 15 - 10/54

426, 436

426 m/c’s from 532100 436 m/c’s from 533692

Circuit Diagrams - Electrical (continued) 70 Y3

Y4

Y5

Y6

VSP1

2

3

4

5

6

7

TEMP 9

Y2

1

TEMP 8

Y1

$21 CAN-BUS to EMS C/6-42 See See 50-15-10/56

$22 To EMS A30 (456 Only)

421

9462A

9454

9574

71 438

439

9570

9462

9458

9908

9904

9450

9446

9442

9438

9434

9430

10

32

55

09

51

12

13

39

AIP1

AIP2

AIP3

AIP4

AIP5

AIP6

VPS1

VPS1

ER1

46 VMGA2

56

CANF-H

ADM2

CANF-T

01

75

VM1

9920

9852

848

57

9916F

896

9856

30

74

438A

02

VM2

9916H

27

897

438B

05

73

9916M

26

CANF-L

25

9808

07

72

9916J

9820B

ED10

9824

29

ED11

9820

11

82 9414

EF2

ED9

41

66

9816 9816A

9410

83 9404

VPI

9836

68

VPE2

9832

23

VPE1

9400

84

14 15

ED7

65

22

18

ED2

64

63

ED5

67

ED1

ED6

31

43

20

ED4

ED3

44

ED13

ED8

EF4 62

881

882

880

1

2

9532A

9500

9504

85

3

9508

VMG2 04

See C/6-34 See 50-15-10/48

EF1

19

45

9916

See C/6-38 See 50-15-10/52

B5

9424

9816B

80

9916A

9420

840

9916B

D2

EF3

9900

42

9916A

79

03

VMG1

78

893

08

77

9916G

81

9820A

21

76 9916D

9524

9528

9544

9548

9540

1

9532

4

3

2

86

9536A

9864 9644

9648

9652

KD

B2

B1

88 2

1

89

3

4

9640

4

50 - 15 - 10/54

3

1

9590

9804/1103

9594

87

9598

9916K

R

N

F

9536

4160-C/6 - 40.2

90

Issue 1*

CONTENTS CONTENTS

Wheeled Loaders

50 - 15 - 10/55

426 m/c’s from 532100 436 m/c’s from 533692

426, 436 Circuit Diagrams - Electrical (continued) Main Components

Fuses

1 2 10 91 92 93 94 95 96 97 98 99 100 101 102 103 104

B4

EMS (Battery Feed)

D1

EMS (Ignition Feed)

Battery Isolator Electronic Monitoring System (EMS) EMS Diagnostic Port Buzzer Fuel Level Sender Water Temperature Sender Transmission Oil Temperature Sender Engine Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Emergency Steer Switch Shutdown Relay Coil Front Work Light Relay Coil Heated Rear Screen Relay Coil Alternator

Note 1: for Fuse ratings, see Fuses 50-05-01/20

Note: Items marked $ indicate remote connections (not shown), ie. $21 $23 $24 $25 $26 $27 $28 $29 $30 $31 $32 $33 $34

CAN-BUS To EMS From Fuse A6 From Fuse A4 From Fuse A5 From Front Work Light Switch From RearWork Light Switch From LH Indicator Feed From RH Indicator Feed From Side Light Feed From Heated Rear Screen Switch From ZF Computer (Park Brake Status-456 Only) From Start Relay Coil 120 ohm Resistor

9804/1103

50 - 15 - 10/55

4160-C/6 - 41.2

Issue 1*

CONTENTS CONTENTS

Wheeled Loaders

50 - 15 - 10/56

426, 436

426 m/c’s from 532100 436 m/c’s from 533692

Circuit Diagrams - Electrical (continued) 1

1

-

+

-

+

2

91

424

423

425

125A

A2

5 600BX

2

1

3

4

A26

A3 A35 A13

600G 600DU

139

420

B4 See 50-15-10/48 See C/6-34

301

D1 See C/6-38 See 50-15-10/52

A25

A12

B7 125

A36

10

B14 B1

$23 From Fuse A6 $24 From Fuse A4 $25 From Fuse A5 $26 From Front Work Light Switch $27 From Rear Work Light Switch $28 From LH Indicator Feed $29 From RH Indicator Feed $30 From Side Light Feed $31 From Heated Rear Screen Switch

812D 806C 807C 810E 813B 835C 836C 802C 826

128

93

415

94

401

95

B12 B11

A16

B10

A4

B5

A15

B18

A6

B16

A18

408

96

400

97

412

98

422

99

432

100

B18 B4

A23 421

431

B6

A11

$32 From ZF Computer (Park Brake Status-456 Only)

92

420A

811

101

808

102

834

103

A30 A24

A34

A27

B15

B9

B3

418

438E

439E

650

$34 120 ohm Resistor

$21 CAN-BUS To EMS See 50-15-10/54 C/6-40

104

9804/1103

50 - 15 - 10/56

4160-C/6 - 42.2

Issue 1*

CONTENTS CONTENTS

Wheeled Loaders

50 - 15 - 10/57

426 m/c’s from 532100 436 m/c’s from 533692

426, 436 Circuit Diagrams - Electrical (continued) Main Components Fuses 1 2 105 106 107 108 109 110

Battery Isolator 24/12 Volt Converter 12 Volt Radio 12 Volt Cigar Lighter 12 Volt Auxiliary Plug Closed Circuit Television Display (CCTV) CCTV Camera

D3 D7

CCTV (Option) In-cab24/12 Volt Converter (Option)

Note 1: for Fuse ratings, see Fuses 50-05-01/20

Note: Items marked $ indicate remote connections (not shown), ie. $35 Reverse Light/Alarm Feed $36 From Side Light Feed

9804/1103

50 - 15 - 10/57

4160-C/6 - 43.2

Issue 1*

CONTENTS CONTENTS

Wheeled Loaders

50 - 15 - 10/58

426, 436

426 m/c’s from 532100 436 m/c’s from 533692

Circuit Diagrams - Electrical (continued) 1

1

-

+

-

+

2

600DZ

308A

D7

108

See 50-15-10/52 See C/6-38

105

308

308B

308C

106

107

108

603A

603B

603C

603

844D

$35 Reverse Light/Alarm Feed See 50-15-10/52 C/6-38 See

D3

118

See 50-15-10/52 See C/6-38

$36 From Side Light Feed

109

802M

110

9804/1103

50 - 15 - 10/58

4160-C/6 - 44.2

Issue 1*

Wheeled Loaders

CONTENTS

*

50 - 20 - 01/1

406, 407, 408, 409 Circuit Diagrams - Hydraulic 1 2 2A 2B 2C

Steering Priority Valve Loader Control Valve Main Relief Valve Pressure Test Point Quick Hitch Control Spool

2D 2E 2F 2G 2H

Lift Control Spool Shovel Control Spool Auxiliary Control Spool Auxiliary Relief Valve Auxiliary Relief Valve

3 3A 3B 4 5

Orbitrol Steering Unit Steering System Relief Valve Steering Shock Valves Filter Tank

6 7 8 9 10

Pump Shovel Ram Lift Ram Quick Hitch Ram Steering Ram

10

3 3B 2 2B

2F

2C

2D

2E

3A 2G

2A 2H

1

6

9

8

7

4

5

A216700

9804/1103

50 - 20 - 01/1

Issue 2*

Wheeled Loaders

CONTENTS

50 - 20 - 01/5

416

*To m/c no. 529342

Circuit Diagrams - Hydraulic 6 4

2

3

5

1

8

34 9

10

11

12

13

32

14

15

31

21

17 16

22

7 36

33

36

36

36 19

37

37

37

30

37

18

20

40

41

26 24

39

28 23 27 25

29

9804/1103

4150 - E/2-3.3

50 - 20 - 01/5

28

38 35

Issue 2*

CONTENTS

Wheeled Loaders

416

50 - 20 - 01/6

*To m/c no. 529342

Circuit Diagrams - Hydraulic 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

Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Inlet Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valves Controls Isolator Valve Steer Priority Relief Valve. Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. (2 Stage) Shovel Ram Rod Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather

9804/1103

50 - 20 - 01/6

Issue 2*

CONTENTS

Wheeled Loaders

416

50 - 20 - 01/6A

*From m/c no. 529343

Circuit Diagrams - Hydraulic 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

Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Not Used Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Inlet Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valves Controls Isolator Valve Steer Priority Relief Valve. Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. (2 Stage) Shovel Ram Rod Side A.R.V. Not Used Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Engine Driven Gear Pump

9804/1103

50 - 20 - 01/6A

4150-E/2-5.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 20 - 01/6B

416

*From m/c no. 529343

Circuit Diagrams - Hydraulic 6 4

2

3

5

1

9

10

11

12

13

32

14

15

31

21

17 16

22

7 36

33

36

36

36 19

37

37

37

30

37

42 18

20

40

41

26 24

39

28 23 27 25

29

28

38 35

A211071

9804/1103

4150 - E/2-6.1

50 - 20 - 01/6B

Issue 1

CONTENTS

Wheeled Loaders

50 - 20 - 01/7

426 Machines with 4-Ram Loader Circuit Diagrams - Hydraulic 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

Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. (2 Stage) Shovel Ram Rod Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump

9804/1103

50 - 20 - 01/7

Issue 1

Wheeled Loaders

CONTENTS

50 - 20 - 01/8

426 Machines with 4-Ram Loader Circuit Diagrams - Hydraulic 6 4

2

3

5

1

42

8

33

41 9

10

11

12

13

31

14

15

21

17

30

16

22

7 35

32

35 36

36

35

35 36

36

19

18

20

39

40

24

38 28

23

27 25 34

37

26 29

9804/1103

50 - 20 - 01/8

A220352 A220352

Issue 2

Wheeled Loaders

CONTENTS

50 - 20 - 01/9

426 Machines with Z-Bar Loader Circuit Diagrams - Hydraulic 6 2

4

5

1

3

42

8

33

41 9

10

11

12

13

31

14

15

21

17

30

16

22

7 35

32

35 36

36

35

35 36

36

19

18

20

39

40

24

38 28

23

27 25 34

37

26 29

9804/1103

A220342 A220342

50 - 20 - 01/9

Issue 2

CONTENTS

Wheeled Loaders

50 - 20 - 01/10

426 Machines with Z-Bar Loader Circuit Diagrams - Hydraulic 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

Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Shovel Ram Head Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump

9804/1103

50 - 20 - 01/10

Issue 1

CONTENTS

Wheeled Loaders

50 - 20 - 01/12

436 Machines with 4-Ram Loader Circuit Diagrams - Hydraulic 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 46

Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Main Pump Control Piston Main Pump Stroking Piston Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. (2 Stage) Shovel Ram Rod Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump

9804/1103

50 - 20 - 01/12

Issue 1

Wheeled Loaders

CONTENTS

50 - 20 - 01/13

436 Machines with Z-Bar Loader Circuit Diagrams - Hydraulic 6 5 2

4

1

3

46

25 45 26 9 23 10

11

12

13

35

14

15

17

34

16 24

7 39

36

39 40

40

39

39 40

40

37

8

21 22 18 19

20

28

43

44

32

27

31 29 38

42

30 33 41

9804/1103

50 - 20 - 01/13

A220372 A220372

Issue 2

CONTENTS

Wheeled Loaders

50 - 20 - 01/14

436 Machines with Z-Bar Loader Circuit Diagrams - Hydraulic 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 46

Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Main Pump Control Piston Main Pump Stroking Piston Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Shovel Ram Head Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump

9804/1103

50 - 20 - 01/14

Issue 1

CONTENTS

Wheeled Loaders

50 - 20 - 02/1

412S, 414S Circuit Diagrams - Hydraulic 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

Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Charge Valve Accumulators Pump P1 M.R.V. Pump P2 M.R.V. Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Unloader Valve Servo Filter Steer Relief Valve Lift Spool Shovel Spool Quickhitch Spool Auxiliary Spool Pump P1 Pump P2 Changeover Valve Servo Control Valve Controls Isolator Valve Steer Valve Steer Rams Oil Cooler and By-pass Tank Steer Priority Valve Steer Shock Valves Suction Strainer Return Filter/Diffuser Filler/Breather Lift Ram Head Side A.R.V. Pressure Reducing Valve Brake Valve Brakes Trailer Brake Option Trailer Hitch Option

9804/1103

50 - 20 - 02/1

4170-E/2-1.3

Issue 2*

Wheeled Loaders

CONTENTS

50 - 20 - 02/2

412S, 414S Circuit Diagrams - Hydraulic 36 6

4

2

3

1

35 34 37

12

5 9

10

33

32

7 15 8

14

13

18

17

16 11 19

27

30

31

23 21 25

20

28 24 29

28

22

9804/1103

4170 - E/2-2.4

50 - 20 - 02/2

26

Issue 2*

CONTENTS

Wheeled Loaders

50 - 20 - 02/3

416S Circuit Diagram - Hydraulics

40

27

28

41

35 39 38

24 42 26

8 23 25

21

29

22 37 11

13

36

31

37

15

36

32

30 37 36

37

17 33

19

37 36 18

20

7 10

12

14

16

6 9

3 34

5

6 4

9804/1103

2

1

50 - 20- 02/3

4170-E/2-3.1

Issue 1

CONTENTS

Wheeled Loaders

50 - 20 - 02/4

416S Circuit Diagrams - Hydraulic 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

Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Servo Filter with Bypass Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Inlet Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valves Controls Isolator Valve Steer Priority Relief Valve. Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Emergency Steer Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Engine Driven Gear Pump

9804/1103

50 - 20 - 02/4

4170-E/2-4.1

Issue 1

CONTENTS CONTENTS

* 407B

Wheeled Loaders

50 - 20 - 03/1

To m/c no. 757399

Zx, 408B ZX, 409B ZX - Servo

Circuit Diagrams - Hydraulic Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14A 14B 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

Steer Ram Steer Valve Steer Shock Valves Brake Fluid Reservoir Brake Valve Brake Caliper Hydrostatic Pump Hydrostatic System Charge Pump Inching Valve Forward/Reverse Valve FBA Amplifier Valve Loop Relief Valve Loop Relief Valve Hydrostatic Pump Case Drain Hydrostatic Motor Case Drain Sequence Valve Purge and Relief Valve Brake Pressure Defeat Valve Proportional Solenoid Valve Hi/Low Range Valve Hydrostatic Motor Transmission Oil Cooler Filler/Breather Hydraulic Return Line Filter Hydraulic Tank Cooling Fan Pump Cooling Fan Motor Main Hydraulic Pump Steering Priority Valve Main Relief Valve Steering Relief Valve Shovel Spool Lift Spool Auxiliary 1 Spool Auxiliary 2 Spool Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Lift Ram Head Side A.R.V. Servo Control Isolator Valve Servo Control Valve Shovel Ram Lift Rams Quickhitch Locking Ram Power Diverter Valve Auxiliary 1 Circuit Quick Release Couplings Auxiliary 2 Circuit Quick Release Couplings Hose Burst Check Valve (option) Hose Burst Check Valve (option) Hose Burst Check Valve (option) Balancing Valve (A to G) Test Points

9804/1103

50 - 20 - 03/1

4210-E/2-1.1

Issue 2*

Wheeled Loaders

CONTENTS

50 - 20 - 03/2

407B ZX, 408B ZX, 409B ZX - Servo

To m/c no. 757399

Circuit Diagrams - Hydraulic

50D 50B 11

9

1

50E 16

4 10

20

15

50C 50A

3

17

5 12

19

2 21

6

8

18 50F

7

13 14B

46

14A

40

47 49

22

41 23

35

30

36

39

48

37 25

26

24

29

38

27 42 28

31

32

33

34

44

CONTENTS

50G

9804/1103

50 - 20 - 03/2

43

45

4210 - E/2 - 2.2

Issue 2*

Wheeled Loaders

CONTENTS CONTENTS

50 - 20 - 03/3

* 407B ZX, 408B ZX, 409B ZX - Manual

To m/c no. 757399

Circuit Diagrams - Hydraulic

48D 48B 11

9

1

48E 16

4 10

20

15

48C 48A

3

17

5 12

19

2 21

6

8

18 48F

7

13 14B 14A

44 38

45 47

22

39 23

35

30 25

36

37

46

26

24

29 27 40 48G

28

31

32

33

41

34

42

43

9804/1103

50 - 20 - 03/3

4210 - E/2 - 3.1

Issue 2*

CONTENTS CONTENTS

* 407B

Wheeled Loaders

50 - 20 - 03/4

To m/c no. 757399

ZX, 408B ZX, 409B ZX - Manual

Circuit Diagrams - Hydraulics (continued) Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14A 14B 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

Steer Ram Steer Valve Steer Shock Valves Brake Fluid Reservoir Brake Valve Brake Caliper Hydrostatic Pump Hydrostatic System Charge Pump Inching Valve Forward/Reverse Valve FBA Amplifier Valve Loop Relief Valve Loop Relief Valve Hydrostatic Pump Case Drain Hydrostatic Motor Case Drain Sequence Valve Purge and Relief Valve Brake Pressure Defeat Valve Proportional Solenoid Valve Hi/Low Range Valve Hydrostatic Motor Transmission Oil Cooler Filler/Breather Hydraulic Return Line Filter Hydraulic Tank Cooling Fan Pump Cooling Fan Motor Main Hydraulic Pump Steering Priority Valve Main Relief Valve Steering Relief Valve Shovel Spool Lift Spool Auxiliary 1 Spool Auxiliary 2 Spool Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Lift Ram Head Side A.R.V. Shovel Ram Lift Rams Quickhitch Locking Ram Power Diverter Valve Auxiliary 1 Circuit Quick Release Couplings Auxiliary 2 Circuit Quick Release Couplings Hose Burst Check Valve (option) Hose Burst Check Valve (option) Hose Burst Check Valve (option) Balancing Valve (A to G) Test Points

9804/1103

50 - 20 - 03/4

4210-E/2-4.1

Issue 2*

CONTENTS

Wheeled Loaders

50 - 20 - 03/5

From m/c no. 757400

407B ZX, 408B ZX, 409B ZX Circuit Diagrams - Hydraulics (continued) Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14A 14B 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

Steer Ram Steer Valve Steer Shock Valves D/A Valve Pump Control Piston Thermostatic Valve Hydrostatic Pump Hydrostatic System Charge Pump Inching Valve Forward/Reverse Solenoid Charge Relief Valve Loop Relief Valve Loop Relief Valve Hydrostatic Pump Case Drain Hydrostatic Motor Case Drain Travel Direction Valve Purge and Relief Valve Brake Pressure Defeat Valve Pressure Override Valve Hi/Low Range Valve Hydrostatic Motor Transmission Oil Cooler Filler/Breather Hydraulic Return Line Filter Hydraulic Tank Cooling Fan Pump Cooling Fan Motor Main Hydraulic Pump Steering Priority Valve Main Relief Valve Steering Relief Valve Shovel Spool Lift Spool Auxiliary 1 Spool Auxiliary 2 Spool Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Lift Ram Head Side A.R.V. Servo Control Isolator Valve Servo Control Valve Shovel Ram Lift Rams Quickhitch Locking Ram Power Diverter Valve Auxiliary 1 Circuit Quick Release Couplings Auxiliary 2 Circuit Quick Release Couplings Hose Burst Check Valve (option) Hose Burst Check Valve (option) Hose Burst Check Valve (option) Creep Speed Kit (option) (A to H) Test Points Brake Valve Brake Caliper Brake Reservoir Hydrostatic Motor Control Piston Loop Flushing Valve Smooth Ride System (option)

9804/1103

50 - 20 - 03/5

4210-E/2-5.2

Issue 1

Wheeled Loaders

CONTENTS

50 - 20 - 03/6

407B ZX, 408B ZX, 409B ZX

From m/c no. 757400

Circuit Diagrams - Hydraulic (continued)

1

9 10

53

50

14A 12

2

51

3

4

54

55

8 5

15

16

7

19 13

20

56

18 11

52 14B

50

49 6 46 21 40

47

41 22 48 37

30

23 25

35 36

41

39

26

24

29

38

27 42 31

32

33

43

34

50

44

45

A370780

9804/1103

50 - 20 - 03/6

4210 - E/2 - 6.2

Issue 1

CONTENTS CONTENTS

Wheeled Loaders

50 - 20 - 04/1

410B ZX Circuit Diagrams - Hydraulic Component Key 1A 1B 2 3 4 5 6 7 8 9 10 11 12 13 14A 14B 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

Steer Ram Steer Ram Steer Valve Steer Shock Valves Steer Pump Thermostatic Valve Hydrostatic Pump Hydrostatic System Charge Pump Inching Valve Forward/Reverse Valve FBA Amplifier Valve Loop Relief Valve Loop Relief Valve Hydrostatic Pump Case Drain Hydrostatic Motor Case Drain Sequence Valve Purge and Relief Valve Brake Pressure Defeat Valve Proportional Solenoid Valve Hi/Low Range Valve Hydrostatic Motor Transmission Oil Cooler Filler/Breather Hydraulic Return Line Filter Hydraulic Tank Cooling Fan Pump Cooling Fan Motor Main Hydraulic Pump Steering Priority Valve Main Relief Valve Steering Relief Valve Shovel Spool Lift Spool Auxiliary 1 Spool Auxiliary 2 Spool Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Lift Ram Head Side A.R.V. Servo Control Isolator Valve Servo Control Valve Shovel Ram Lift Rams Quickhitch Locking Ram Power Diverter Valve Auxiliary 1 Circuit Quick Release Couplings Auxiliary 2 Circuit Quick Release Couplings Hose Burst Check Valve (option) Hose Burst Check Valve (option) Hose Burst Check Valve (option) (A to H) Test Points Brake Valve Brake Caliper Brake Reservoir Low Range Pressure Switch Pressure Differential Valve

9804/1103

50 - 20 - 04/1

4210-E/2 - 8.2

Issue 2*

Wheeled Loaders

CONTENTS CONTENTS

50 - 20 - 04/2

410B ZX Circuit Diagrams - Hydraulic (continued)

54

53 1A

50D 50B

1B

11

9

X6

XA

16

52 50A

20

17

A

12

M4

19 M5

6 8

LS

B

7 P

50E

15

50C

M11 M1 M5

51

M3

M3.1

10

2

M4

M1

X13

3

L2

A

M9

55

XB

21

T

13

M2

18

B

X1

L2 S

M2

M7

L1

14B

14A

L1

50F

46 40

47

22

28

EF

CF

LS

30 23

T

P

35 29

5

50H

37

39 41

38

36

48

24 27 25

26 50G

31

32

33

34

2 4 1 3

T P

42

43 44

45 A275630

9804/1103

4210 - E/2 - 7.2

50 - 20 - 04/2

Issue 2*

CONTENTS

Wheeled Loaders

50 - 20 - 04/3

411B ZX Circuit Diagrams - Hydraulic 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 46 47

Steer Rams Load Sensing Steer Valve Steer Shock Valves Filler/Breather Return Line Filter Axle Brakes Brake Modulating Valve Accumulator Block Steering/Accumulator Charge Valve Steering Pressure Relief Valve Steer Pump Service Pump Fan Pump Fan Motor Brake Reservoir Inching Pedal Thermostatic Valve Oil Cooler Inching Valve Forward/Reverse Solenoid Transmission Pump Charge Relief Valve Feedback Amplifier Loop Relief Valves 4 Spool Valve Block Main Relief Valve Auxiliary Relief Valves (Shovel Ram) Auxiliary Relief Valve (Lift Rams) Shovel Spool Lift Spool Auxiliary 1 Spool Auxiliary 2 Spool Servo Cut Off Valve Servo Control Valve Sequence Valve Brake Pressure Defeat Valve Proportional Solenoid Valve Purge and Relief Valve Hi/Low Range Valve Transmission Motor Hose Burst Check Valves Quickhitch Rams Quickhitch Diverter Valve Shovel Ram Lift Rams Auxiliary 1 Quick Release Couplings Auxiliary 2 Quick Release Couplings

9804/1103

50 - 20 - 04/3

4210-E/2-9.1

Issue 2*

Wheeled Loaders

CONTENTS

50 - 20 - 04/4

411B ZX Circuit Diagrams - Hydraulics (continued)

15

1

19

6

23 16

38

20

35

7

40

3

2

36

39

8 17

21

24

22

37 18 41

44

9 41

10 4

5 25

45

1B 1A 2B 2A 3B 3A 4B 4A

41

34 26

27

28 33

11 12 13

42

14

30

31

43

32

29 46

47

A296150

9804/1103

4210 - E/2-10.1

50 - 20 - 04/4

Issue 2*

CONTENTS

Wheeled Loaders

50 - 20 - 05/ 1

456 to m/c no. 539249 Circuit Diagrams - Hydraulic 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

Auxiliary Ram Shovel Ram Lift Rams Brake Valve Service Brake Accumulators Parking Brake Accumulator Parking Brake Valve Loader Valve Emegency Steer Valve Emergency Steer Pump Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Start Up Valve Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Main Pump Control Piston Main Pump Stroking Piston Shuttle Valve Priority Valve Return Filter/Diffuser Filler/Breather Suction Strainer Tank Oil Cooler and By-Pass Steer Valve Steer Shock Vlave Steer rams Servo Control Accumulator Controls Isolator Valve Servo Control Valve Servo Pressure Regulating Valve Auxiliary Circuit Spool Shovel Circuit Spool Lift Circuit Spool Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Head Side Float Solenoid Rod Side Float Solenoid Surge Protection Valve Hydraulic Mode Valve, P2 Disconnect Hydraulic Mode Valve, P1 Pressure Control

* Note: 446 machines from serial no. 540000 to 540012 use the same hydraulic circuit as 436 machines. For these machines refer to hydraulic diagram on pages 50 - 20 - 01/13 and 14

9804/1103

50 - 20 - 05/1

4180 - E/3-7.4

Issue 2*

CONTENTS

*

Wheeled Loaders

50 - 20 - 05/2

456 to m/c no. 539249 Circuit Diagrams - Hydraulic (continued) 6

5

7 4 3

2 1

10

11 8

9 40

12

41

39

13 37

33

36

38 34

42

14

35

43 44 15 20

20

20 16 20

17

21 18 3 19

32

22

23

28 29 30 26

24

27 31 25 9804/1103

50-20-05/2

A263630

Issue 2*

CONTENTS

Wheeled Loaders

50 - 20 - 05/ 1A

456 from m/c no. 539250 446 from m/c no. 540013 Circuit Diagrams - Hydraulic 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 46 47 48 49 50 51

Lift Rams Shovel Rams Quickhitch Ram Quickhitch Isolator Brake Valve Brake Accumulators Filter and Bypass Valve (446 to 540009; 456 to 539399) Cooling Fan Motor (446 from 540050; 456 from 539400) Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Main Pump Control Piston Main Pump Stroking Piston Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Not Used Oil Cooler and By-Pass Primary Shuttle Valve Secondary Shuttle Valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump Clipper Valve Engine Driven Gear Pump and Charge Valve Parking Brake Valve Parking Brake Parking Brake Accumulator and Check Valve (Germany Only)

9804/1103

50 - 20 - 05/1A

4180 - E/3-10.3

Issue 1*

Wheeled Loaders

CONTENTS

*

456 from m/c no. 539250, 446 from m/c no. 540013

50-20-05/2A

Circuit Diagrams - Hydraulic (continued) EF

6

S

A2 A1

48

S2

27

IN

29 28

S1 T

OUT

33 5 49

9 35 40

40

39

40

39

40

34

39

50

10

13

12

15

41

43

A C

44

40

42

39 18

11

B

47

36

51

14

17

16

38

4 21

22 20

2

19

1

3

30 32 25

31

26

45

24 23 46

A352802

9804/1103

50-20-05/2A

4180 - E/3-9.3

Issue 1*

CONTENTS

Wheeled Loaders

50 - 20 - 06/1

TM200, TM270 Circuit Diagrams - Hydraulic TM200 1 2 2A 2B 2C 2D 2E 2F 2G 3 3A 3B 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Servo Control Lever Loader Control Valve Main Relief Valve Tilt Control Spool Lift Control Spool Auxiliary Control Spool Extension Control Spool Auxiliary Relief Valve Auxiliary Relief Valve Orbitrol Steering Unit Steering System Relief Valve Steering Shock Valves Servo Pressure Reducing Valve Brake Valve Steer Priority/Charge Valve Tilt Ram Compensating Ram Lift Ram Quick Hitch Rams Extension Ram Steer Ram Pump Quickhitch lock/Auxiliary Diverter Valve Quick Release Couplings Accumulator Pressure Test Point Filter Breather Sealed Cap Brakes Hydraulic Tank Check Valve

9804/1103

50 - 20 - 06/1

Issue 1

CONTENTS

Wheeled Loaders

50 - 20 - 06/2

TM200, TM270 Circuit Diagrams - Hydraulic (continued)

17

TM200

5

4 12 1

7

17

8

16 3

21

3B 17

11 9 10 14 3A 15 2

17 2F

2B

2G

2C

6

2D

2E

2A

17 13

19 20

18

22

A240271 A240271

9804/1103

50 - 20 - 06/2

Issue 1

CONTENTS

Wheeled Loaders

50 - 20 - 07/1

TM200, TM270 Circuit Diagrams - Hydraulic (continued) TM270

9

1

12

3 3A 10

11 2 4 1 3

8

7 15

16

S

LS

T

P

T

17 2F

4

2E 2G 4

1

23

17 EF

P

18

5

G

13 2A

2B

3

2

2C

2D

20 2

6

14 21

18 19

22 A277190

9804/1103

50 - 20 - 07/1

Issue 1

CONTENTS

Wheeled Loaders

50 - 20 - 07/2

TM200, TM270 Circuit Diagrams - Hydraulic (continued) TM270 1 2 2A 2B 2C 2D 2E 2F 2G 3 3A 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Servo Control Lever Loader Control Valve Auxillary Control Spool Extension Control Spool Tilt Control Spool Lift Control Spool Main Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Eaton Load Sensing/Steer Valve Steering Shock Valves Brake modulating Valve Accumulator Charge Valve Unloader Valve Quickhitch Rams Extension Ram Tilt Ram Lift Ram Compensating Rams Steer Rams Main Pump Auxillary Pump Quickhitch lock/Auxiliary Diverter Valve Quick Release Couplings Accumulator Pressure Test Point Filter Breather Sealed Cap Hydraulic Tank Front Axle Brakes

9804/1103

50 - 20 - 07/2

Issue 1

CONTENTS

Wheeled Loaders

50 - 20 - 07/3

TM270 from m/c no. 787118

TM200, TM270 Circuit Diagrams - Hydraulic (continued) 1 2 2A 2B 2C 2D 2E 2F 2G 3 3A 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Servo Control Lever Loader Control Valve Auxillairy Conrol Spool Extension Control Spool Tilt Control Spool Lift Control Spool Main Relif Valve Auxiliary Releif Valve Auxiliary Releif Valve Load Sensing Steer Valve Steering Shock Valves Brake Modulating Valve Accumulator Charge Valve Unloader Valve Quickhitch Rams Extension Ram Tilt Ram Lift Ram Compensating Rams Steer Rams Main Pump Auxiliary Pump Quickhitch Lock/Auxiliary Diver Valve Quick Release Couplings Accumulator Block Pressure Test Point Filter Breather Sealed Cap Hydraulic Tank Front Axle Brakes Servo Cut-off Valve Pressure Reducing Valve Hydraulic Tow Hitch (Option) Oil Cooler

9804/1103

50 - 20 - 07/3

4225-E/26-1.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 20 - 07/4

TM200, TM270

TM270 from m/c no. 787118

10

9

2E

14

22

21

3

20

3A

12

27

4

13

23

19

5

17

18

24

25

2A

6

2B

2C

2F 2G

2D

2

26

1

7

15

8

16

11

Circuit Diagrams - Hydraulics (continued)

9804/1103

50 - 20 - 07/4

4225-E/26-2.1

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 20 - 08/1

m/cÕs to 531203

Circuit Diagrams - Hydraulics 426 Machines with 4-Ram Loader 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

Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. (2 Stage) Shovel Ram Rod Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump

9804/1103

50 - 20 - 08/1

Issue 1

Wheeled Loaders

CONTENTS

50 - 20 - 08/2

426B, 436B, 446B

m/cÕs to 531203

Circuit Diagrams - Hydraulic (continued) 426 Machines with 4-Ram Loader 6 4

2

3

5

1

42

8

33

41 9

10

11

12

13

31

14

15

21

17

30

16

22

7 35

32

35 36

36

35

35 36

36

19

18

20

39

40

24

38 28

23

27 25 34

37

26 29

9804/1103

50 - 20 - 08/2

A220352

Issue 1

Wheeled Loaders

CONTENTS

50 - 20 - 08/3

426B, 436B, 446B

m/cÕs to 531203

Circuit Diagrams - Hydraulic 426 Machines with Z-Bar Loader 2

4

5

1

3

42

8

33

41 9

10

11

12

13

31

14

15

21

17

30

16

22

7 35

32

35 36

36

35

35 36

36

19

18

20

39

40

24

38 28

23

27 25 34

37

26 29

9804/1103

A220342

50 - 20 - 08/3

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 20 - 08/4

m/cÕs to 531203

Circuit Diagrams - Hydraulics (continued) 426 Machines with Z-Bar Loader 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

Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Shovel Ram Head Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump

9804/1103

50 - 20 - 08/4

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 20 - 08/5

m/cÕs to 533195

Circuit Diagrams - Hydraulics 436 Machines with 4-Ram Loader 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 46

Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Main Pump Control Piston Main Pump Stroking Piston Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. (2 Stage) Shovel Ram Rod Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump

9804/1103

50 - 20 - 08/5

Issue 1

Wheeled Loaders

CONTENTS

50 - 20 - 08/6

426B, 436B, 446B

m/cÕs to 533195

Circuit Diagrams - Hydraulic (continued) 436 Machines with 4-Ram Loader 6 5 4

2

3

1

46

25 45 26 9 23 10

11

12

13

35

14

15

17

34

16 24

7 39

36

39 40

40

39

39 40

40

37

8

21 22 18 19

20

28

43

44

32

27

31 29 38

42

30 33 A220362

41 9804/1103

50 - 20 - 08/6

Issue 1

Wheeled Loaders

CONTENTS

50 - 20 - 08/7

426B, 436B, 446B

m/cÕs to 533195

Circuit Diagrams - Hydraulic (continued) 436 Machines with Z-Bar Loader 6 5 2

4

1

3

46

25 45 26 9 23 10

11

12

13

35

14

15

17

34

16 24

7 39

36

39 40

40

39

39 40

40

37

8

21 22 18 19

20

28

43

44

32

27

31 29 38

42

30 33 A220372

41 9804/1103

50 - 20 - 08/7

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 20 - 08/8

m/cÕs to 533195

Circuit Diagrams - Hydraulic (continued) 436 Machines with Z-Bar Loader 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 46

Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Main Pump Control Piston Main Pump Stroking Piston Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump

9804/1103

50 - 20 - 08/8

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 20 - 08/9

m/cÕs from 531204

Circuit Diagrams - Hydraulic 426 Machines with 4-Ram Loader 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

Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Not Used Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. (2 Stage) Shovel Ram Rod Side A.R.V. Not Used Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump Clipper Valve Engine Driven Gear Pump

9804/1103

50 - 20 - 08/9

Issue 1

Wheeled Loaders

CONTENTS

50 - 20 - 08/10

426B, 436B, 446B

m/cÕs from 531204

Circuit Diagrams - Hydraulic (continued) 426 Machines with 4-Ram Loader 6 4

2

3

5

1

42

41 9

10

11

12

13

31

14

15

21

17

30

16

22

7 35

32

35 36

36

35

35 36

19

18

36 43

44

20

39

40

24

38 28

23

27 25 34

37

26 29

9804/1103

50 - 20 - 08/10

A220353

Issue 1

Wheeled Loaders

CONTENTS

50 - 20 - 08/11

426B, 436B, 446B

m/cÕs from 531204

Circuit Diagrams - Hydraulic (continued) 426 Machines with Z-Bar Loader 6 2

4

5

1

3

42

41 9

10

11

12

13

31

14

15

21

17

30

16

22

7 35

32

35 36

36

35

35

36

36

19

18 43

44

20

39

40

24

38 28

23

27 25 34

37

26 29

9804/1103

A220343

50 - 20 - 08/11

Issue 1

CONTENTS

Wheeled Loaders

50 - 20 - 08/12

m/c’s from 531204

426B, 436B, 446B Circuit Diagrams - Hydraulic (continued) 426 Machines with Z-Bar Loader 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

Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Not Used Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Shovel Ram Head Side A.R.V. Not Used Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump Clipper Valve Engine Driven Gear Pump

9804/1103

50 - 20 - 08/12

Issue 1

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 20 - 08/13

m/cÕs from 533196

Circuit Diagrams - Hydraulic 436 Machines with 4-Ram Loader 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 46 47 48

Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Not Used Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Main Pump Control Piston Main Pump Stroking Piston Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. (2 Stage) Shovel Ram Rod Side A.R.V. Not Used Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump Clipper Valve Engine Driven Gear Pump

9804/1103

50 - 20 - 08/13

Issue 1

Wheeled Loaders

CONTENTS

50 - 20 - 08/15

426B, 436B, 446B

m/c’s from 533196 (436B ZX) m/c’s from 540000 (446B ZX)

Circuit Diagrams - Hydraulics (continued) 436 and 446 Machines with Z-Bar Loader 6 5 2

4

1

3

46

25 45 26 9 23 10

11

12

13

35

14

15

17

34

16 24

7 39

36

39 40

40

39

39 40

40

47 21 22 18 19

48

20

28

43

44

32

27

31 29 38

42

30 33 A220373

41 9804/1103

50 - 20 - 08/15

Issue 2*

CONTENTS

Wheeled Loaders

426B, 436B, 446B Circuit Diagrams - Hydraulic (continued) 436 and 446 Machines with Z-Bar Loader

50 - 20 - 08/16

m/c’s from 533196 (436B ZX) m/c’s from 540000 (446B ZX)

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 46 47 48

Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Not Used Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Main Pump Control Piston Main Pump Stroking Piston Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Shovel Ram Head Side A.R.V. Not Used Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump Clipper Valve Engine Driven Gear Pump

9804/1103

50 - 20 - 08/16

Issue 2*

CONTENTS

Wheeled Loaders

426B, 436B, 446B

50 - 20 - 08/17

From m/c no. 533692

Circuit Diagram - Hydraulic (continued) 436 Machines with 4-Ram Loader 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 46 47 48

Lift Rams Shovel Rams Quickhitch Ram Quickhitch Isolator Brake Valve Brake Accumulators Not Used Not Used Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Main Pump Control Piston Main Pump Stroking Piston Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Not Used Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump Clipper Valve Engine Driven Gear Pump

9804/1103

50 - 20 - 08/17

4160-E/3-23.1

Issue 1

Wheeled Loaders

CONTENTS

50 - 20 - 08/18

426B, 436B, 446B

From m/c no. 533692

Circuit Diagrams - Hydraulics (continued) 436 Machines with 4-Ram Loader

6 5 48 27

29 28

33

47 40

40

39

40

39

40

39

10

13

12

15

44

6

42

40

39 18

11

41

43

14

17

16

38

21

22 20 19

2 3

30 32 25

31

26

45

24 23 46

9804/1103

4160 - E/3-24.1

50 - 20 - 08/18

Issue 1

INDEX CONTENTS

Fastrac

Contents 1

ALL MODELS Contents Page No. General Information Fluids, Lubricants and Capacities - 125, 135, 145, 150, 155 (not N. Am. machines) - 125, 135, 145, 150, 155 (N. Am. machines) - 185 (not N. Am. machines) - 185 (N. Am. machines) - 1115 & 1135 - 2000 Series Machines - 2000 Series Machines (N. America) - 3155 - 3155 (N. America) - 3185 - 3185 (N. America) - Engine Oil (All 2000, 3000 Series Machines)

60 - 00 - 01/1 60 - 00 - 01/2 60 - 00 - 01/3 60 - 00 - 01/3A 60 - 00 - 01/4 60 - 00 - 01/5 60 - 00 - 01/6 60 - 00 - 01/7 60 - 00 - 01/8 60 - 00 - 01/9 60 - 00 - 01/10 60 - 00 - 01/11

Static Dimensions and Weights - 125, 135, 145, 150, 155 to m/c no. 636000 - 125, 135, 145, 150, 155 from m/c no. 636001 to 636368 - 125, 135, 145, 150, 155, 185 from m/c no. 636369 - 1115 & 1135 - 2000 Series Machines - 3000 Series Machines

60 - 00 - 02/1 60 - 00 - 02/2 60 - 00 - 02/3 & 60 - 00 - 02/4 60 - 00 - 02/5 & 60 - 00 - 02/6 60 - 00 - 02/7 & 60 - 00 - 02/8 60 - 00 - 02/9 & 60 - 00 - 02/10

Data Electrical - General - 125, 135, 145, 150, 155, 185, 1115 & 1135 - 2000 Series Machines - 3000 Series Machines - Fuses - 125, 135, 145, 150, 155 UK machines to serial no. 635329 - 125, 135, 145, 150, 155 UK machines from m/c no. 635330 to 636000 - 125, 135, 145, 150, 155 Export machines to m/c no. 636000 - 125, 135, 145, 150, 155, 185 from m/c no. 636001 - 1115 & 1135 - 2000 & 3000 Series Machines * - Relay Identification - 125, 135, 145, 150, 155 to m/c no. 636000 - 125, 135, 145, 150, 155, 185 from m/c no. 636001 to 637739 - 155, 185 from m/c no. 637740 - 1115 & 1135 to m/c no. 736577 - 1115 and 1135 from m/c no. 736578 - 2000 & 3000 Series Machines External Hydraulics - 125, 135, 145, 150, 155, 185, 1115 & 1135 - 2000 & 3000 Series Machines Front Axle - 125, 135, 145, 150, 155, 185, 1115 & 1135 Rear Axle - 125, 135, 145, 150, 155, 185, 1115 & 1135 Clutch Gearboxes - 125, 135, 145, 150, 155, 185, 1115 & 1135 - 2000 & 3000 Series Machines Transmission - 2000 & 3000 Series Machines Tyre Pressures, Speeds and Loads - 125, 135, 145, 150, 155, 185 - 1115 & 1135 - High Traction Tyres - 2000 Series Machines - 3000 Series Machines

9804/1103

Fastrac Contents - 1

60 - 05 - 01/1 60 - 05 - 01/1A 60 - 05 - 01/1B 60 - 05 - 01/2 60 - 05 - 01/3 60 - 05 - 01/3 60 - 05 - 01/4 & 60 - 05 - 01/5 60 - 05 - 01/6 60 - 05 - 01/6A, 6B 60 - 05 - 01/7 60 - 05 - 01/8 & 60 - 05 - 01/9 60 - 05 - 01/9A 60 - 05 - 01/10 & 60 - 05 - 01/11 60 - 05 - 01/11A & 60 - 05 - 01/11B 60 - 05 - 01/12 & 60 - 05 - 01/13 60 - 05 - 02/1 60 - 05 - 02/1A 60 - 05 - 02/2 60 - 05 - 02/2 60 - 05 - 02/2 60 - 05 - 04/1 60 - 05 - 04/2 60 - 05 - 04/3 60 - 05 - 06/1 60 - 05 - 06/2 60 - 05 - 06/3 60 - 05 - 06/4 60 - 05 - 06/5

Issue 11*

INDEX CONTENTS

Fastrac

Contents 2

ALL MODELS Contents

*

Data (continued) Brakes -125, 135, 145, 150, 155, 185 -1115, 1135 - 2000 & 3000 Series Machines Steering - 125, 135, 145, 150, 155, 185 - 1115, 1135 - 2000 & 3000 Series Machines Suspension - 125, 135, 145, 150, 155, 185 - 1115, 1135 - 2000 & 3000 Series Engine (Perkins) - 125, 135, 145, 150, 155, 185 - 2000 Series Machines - 3000 Series Machines Selectronic System Air Conditioning System - 2115 & 2150

Page No. 60 - 05 - 10/1 60 - 05 - 10/3 60 - 05 - 10/3A 60 - 05 - 10/1 60 - 05 - 10/4 60 - 05 - 10/4A 60 - 05 - 10/2 60 - 05 - 10/5 60 - 05 - 10/5A 60 - 05 - 15/1 60 - 05 - 15/2 & 60 - 05 - 15/3 60 - 05 - 15/4 60 - 05 - 16/1 60 - 05 - 17/1

Fault Finding Electronic Draft Control - 125, 135, 145, 150, 155, 185 to m/c no. 637733 - 125, 135, 145, 150, 155, 185 from m/c no. 637734, 1115, 1135, 2000 & 3000 Series (E.C.U.’s Type D+ and Type B) Vehicle Electrics - 2000 Series, 3000 Series Electronic Management System - 2000 & 3000 Series Machines Complete Transmission Wet Master Clutch - 2000 & 3000 Series Machines PTO Clutches 2/4 Wheel Drive NoSPIN Differential (Front Axle) Differential Lock (Rear Axle) - 125, 135, 145, 150, 155, 185 - 1115, 1135, 2115, 2125, 2135, 2150 - 2000 Series, 3000 Series Brakes - 125, 135, 145, 150, 155, 185 - 1115 & 1135 - 2000 Series, 3000 Series Steering - 125, 135, 145, 150, 155, 185 - Fastrac 1115, 1135, 2115, 2125, 2135, 2150 - 2000 Series (Front Axle) - 2115, 2125, 2135 (Rear Axle, 4WS) - 3000 Series

9804/1103

Fastrac Contents - 2

60 - 10 - 04/1 to 60 - 10 - 04/3 60 - 10 - 05/1 to 60 - 10 - 05/5A 60 - 10 - 05/6 to 60 - 10 - 05/9 60 - 10 - 05/10 to 60 - 10 - 05/23 60 - 10 - 06/1 60 - 10 - 06/2 60 - 10 - 07/1 & 60 - 10 - 07/2 60 - 10 - 08/1 60 - 10 - 10/1 60 - 10 - 11/1 60 - 10 - 11/2 60 - 10 - 11/3 60 - 10 - 15/1 to 60 - 10 - 15/3 60 - 10 - 15/4 to 60 - 10 - 15/7 60 - 10 - 15/8 to 50 - 10 - 15/10 60 - 10 - 16/1 & 60 - 10 - 16/2 60 - 10 - 17/1 & 60 - 10 - 17/2 60 - 10 - 18/1 & 60 - 10 - 18/2 60 - 10 - 18/3 to 60 - 10 - 18/7 60 - 10 - 19/1 & 60 - 10 - 19/2

Issue 8*

INDEX CONTENTS

Fastrac

Contents 3

ALL MODELS Contents *

Circuit Diagrams Electrical - 125, 135, 145, 150, 155, 185 to m/c no. 635329 - 125, 135, 145, 150, 155, 185 from m/c no. 635330 and all export machines to 636000 - 2000 Series, 3000 Series - Introduction - Main Connectors - Connector Terminals - Splice Identification - Wiring Diagrams, Contents - Wiring Diagrams, Component Key - Wiring Diagrams, Alphabetical Index - Wiring Diagrams

Hydraulic - 125, 135, 145, 150, 155, 185 to m/c no. 637733 - 125, 135, 145, 150, 155, 185 from m/c no. 637734 - Fastrac 1115, 1135, 2115, 2125, 2135, 2150 - 2000 Series Machines - 3000 Series Machines

9804/1103

Fastrac Contents - 3

60 - 15 - 01/1 & 60 - 15 - 01/2 60 - 15 - 01/3 & 60 - 15 - 01/4 60 - 15 - 01/5 & 60 - 15 - 01/6 60 - 15 - 01/7 60 - 15 - 01/7 to 60 - 15 - 01//9 60 - 15 - 01/10 60 - 15 - 01/11 60 - 15 - 01/12 60 - 15 - 01/13 60 - 15 - 01/14 to 60 - 15 - 01/56

60 - 20 - 02/1 60 - 20 - 02/2 & 60 - 20 - 02/3 60 - 20 - 03/1 & 60 - 20 - 03/2 60 - 20 - 03/3 & 60 - 20 - 03/4 60 - 20 - 03/5 & 60 - 20 - 03/6

Issue 4*

CONTENTS CONTENTS

*

Fastrac

60 - 00 - 01/1

125, 135, 145, 150, 155 (not N. Am. machines) 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. DO NOT use a special running-in oil but use the oil recommended below from new.

ITEM

CAPACITY FLUID/LUBRICANT Litres (UK Gal)

Engine Oil

16.5 (3.6)

JCB Super Multigrade 15W/40 -10 °C to 50 °C (14 °F to 122 °F)

INTERNATIONAL SPECIFICATION SEE

SAE15W/40, API CF4/SG

Note JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)

ABOVE

SAE10W/30 API CE/SF

Coolant (to 636000) (from 636001)

28 (6.2) 34 (7.5)

JCB Four Seasons Antifreeze & Summer Coolant/water (See Coolant Mixtures)

ASTM D3306, BS6580

PTO and Range Boxes (to 636000)

20 (4.49)

JCB Super Universal Agricultural

API-GL-4, MIL-L-2105

Speed Box (to 636000)

10 (2.2)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

PTO/Speed/Range Box (combined from 636001)

38 (8.4)

JCB Super Universal Agricultural

API-GL-4, MIL-L-2105

Front Axle Housing Hubs (x2)

11.5 (2.6) 1.5 (0.34)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Rear Axle

21 (4.6)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Brake System Front Rear

JCB Universal Brake Fluid

SAE J1703 DOT 4

0.75 (0.17) 0.75 (0.17)

! CAUTION Do not use ordinary hydraulic fluid in the brake or clutch systems. 13-3-1-13

Clutch System

0.5 (0.11)

JCB Universal Brake Fluid

SAE J1703 DOT 4

† Hydraulic System

75 (16.5)

JCB Special Hydraulic Fluid HP46 (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid HP32 (Below 38 °C, 100 °F)

ISO VG46

Lithium complex NLGI No. 2 consistency including extreme pressure additives

Grease Points

---

JCB HP Grease

Front PTO Transfer Box (optional)

3.0 (0.67)

JCB HD90 Gear Oil

Air Conditioning System - Refrigerant - Compressor Lubricant

0.9 kg (2 lb) 0.24 (0.05)

HFC 134c Polyalkalineglycol

ISO VG32

API-GL-5, MIL-L-2105C

CH2 FC F3 PAG SP20

† Note: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank.

9804/1103

60 - 00 - 01/1

8000 - 3/1-1.11

Issue 5*

CONTENTS

* 125,

Fastrac

60 - 00 - 01/2

135, 145, 150, 155 (N. Am. machines)

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. DO NOT use a special running-in oil but use the oil recommended below from new.

ITEM

CAPACITY FLUID/LUBRICANT US Gal (Liters)

Engine (Oil)

4.36 (16.5)

JCB Engine Oil 15W/40 14 °F to 122 °F (-10 °C to 50 °C)

INTERNATIONAL SPECIFICATION SEE

SAE15W/40, API CF4SG

Notice JCB Engine Oil 10W/30 5 °F to 104 °F (-15 °C to 40 °C)

SAE10W/30, API CE/SF ABOVE

Coolant

9.0 (34)

JCB Permanent Antifreeze/water (See Coolant Mixtures)

ASTM D3306-74

PTO, Speed and Range Boxes (combined)

10.0 (38)

JCB AG-Transmission Fluid

API-GL-4, MIL-L-2105

Front Axle Housing Hubs (x2)

3.04 (11.5) 0.40 (1.5)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

Rear Axle

5.55 (21)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

Brake System Front Rear

JCB Universal Brake Fluid

SAE J1703 DOT 4

0.20 (0.75) 0.20 (0.75)

! CAUTION

Do not use ordinary hydraulic oil in the brake or clutch systems. 13-3-1-13

Clutch System

0.13 (0.5)

JCB Universal Brake Fluid

SAE J1703 DOT 4

† Hydraulic System

19.82 (75)

JCB Special Hydraulic Fluid HP46

ISO VG46

Grease Points

---

JCB HP Grease

Lithium complex NGLI # 2 consistency including extreme pressure additives

Front PTO Transfer Box (optional)

0.80 (3.0)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

Air Conditioning System - Refrigerant - Compressor Lubricant

2 lb (0.9 kg) 0.05 (0.24)

HFC 134c Polyalkalineglycol

CH2 FC F3 PAG SP20

† Notice: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank.

9804/1103

60 - 00 - 01/2

8000 - 3/1-1A.2

Issue 3*

CONTENTS * 185

Fastrac

60 - 00 - 01/3

(not N. Am. machines)

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. DO NOT use a special running-in oil but use the oil recommended below from new. While 15W/40 oil is recommended for most climates, limited use of low viscosity oils such as 10W/30 is permitted to provide easier starting and sufficient oil flow at ambient temperatures below -5 °C (23 °F). Continued use of low viscosity oils can decrease engine life.

ITEM

CAPACITY FLUID/LUBRICANT Litres (UK Gal)

Engine (Oil)

15 (3.3)

JCB Super Multigrade 15W/40 -10 °C to 50 °C (14 °F to 122 °F)

INTERNATIONAL SPECIFICATION SEE

SAE15W/40, API CF4/SG

Note JCB Super Multigrade 10W/30 -25 °C to 20 °C (-13 °F to 68 °F)

ABOVE

SAE10W/30, API CF4/SG

Coolant

33 (7.3)

JCB Four Seasons Antifreeze & Summer Coolant/water (See Coolant Mixtures)

ASTM D3306, BS6580

PTO, Speed and Range Boxes (combined)

38 (8.4)

JCB Super Universal Agricultural

API-GL-4, MIL-L-2105

Front Axle Housing Hubs (x2)

11.5 (2.6) 1.5 (0.34)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Rear Axle

27 (6)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Brake System Front Rear

JCB Universal Brake Fluid

SAE J1703 DOT 4

0.75 (0.17) 0.75 (0.17)

! CAUTION Do not use ordinary hydraulic fluid in the brake or clutch systems. 13-3-1-13

Clutch System

0.5 (0.11)

JCB Universal Brake Fluid

SAE J1703 DOT 4

† Hydraulic System

75 (16.5)

JCB Special Hydraulic Fluid HP46 (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid HP32 (Below 38 °C, 100 °F)

ISO VG46

Lithium complex NLGI No 2 consistency including extreme pressure additives

Grease Points

---

JCB HP Grease

Front PTO Transfer Box (optional)

3.0 (0.67)

JCB HD90 Gear Oil

Air Conditioning System - Refrigerant - Compressor Lubricant

0.9 kg (2 lb) 0.24 (0.05)

HFC 134c Polyalkalineglycol

ISO VG32

API-GL-5, MIL-L-2105C

CH2 FC F3 PAG SP20

† Note: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank.

9804/1103

60 - 00 - 01/3

8000 - 3/1-2.5

Issue 3*

CONTENTS

* 185

Fastrac

60 - 00 - 01/3A

(N. Am. machines)

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. DO NOT use a special running-in oil but use the oil recommended below from new. While 15W/40 oil is recommended for most climates, limited use of low viscosity oils such as 10W/30 is permitted to provide easier starting and sufficient oil flow at ambient temperatures below 23 °F (-5 °C). Continued use of low viscosity oils can decrease engine life. ITEM

CAPACITY FLUID/LUBRICANT US Gal (Liters)

INTERNATIONAL SPECIFICATION

Engine (Oil)

3.96 (15)

JCB Engine Oil 15W/40 14 °F to 122 °F (-10 °C to 50 °C)

Coolant

8.7 (33)

JCB Permanent Antifreeze/water (See Coolant Mixtures)

PTO, Speed and Range Boxes (combined)

10.0 (38)

JCB Ag-Transmission Fluid

API-GL-4, MIL-L-2105

Front Axle Housing Hubs (x2)

3.04 (11.5) 0.40 (1.5)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

Rear Axle

7.13 (27)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

Brake System Front Rear

JCB Universal Brake Fluid

SAE J1703 DOT 4

0.20 (0.75) 0.20 (0.75)

SEE Notice ABOVE

SAE15W/40, API CF4/SG

ASTM D3306-74

! CAUTION

Do not use ordinary Hydraulic oil in the brake or clutch systems. 13-3-1-13

Clutch System

0.13 (0.5)

JCB Universal Brake Fluid

SAE J1703 DOT 4

† Hydraulic System

19.82 (75)

JCB Hydraulic Fluid HP46 (Above 100 °F, 38 °C ambient)

ISO VG46

JCB Hydraulic Fluid HP32 (Below 100 °F, 38 °C ambient)

ISO VG32

Grease Points

---

JCB HP Grease

Lithium complex NGLI # 2 consistency including extreme pressure additives

Front PTO Transfer Box (optional)

0.80 (3.0)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Air Conditioning System - Refrigerant - Compressor Lubricant

0.9 kg (2 lb) 0.24 (0.05)

HFC 134c Polyalkalineglycol

CH2 FC F3 PAG SP20

† Notice: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank.

9804/1103

60 - 00 - 01/3A

8000 - 3/1-2A.3

Issue 1

CONTENTS * 1115

Fastrac

60 - 00 - 01/4

& 1135

Fluids, Lubricants & Capacities * Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately. DO NOT use a special running-in oil but use the oil recommended below from new. ITEM

CAPACITY FLUID/LUBRICANT Litres (UK Gal)

INTERNATIONAL SPECIFICATION

Fuel

220 (48)

Diesel Oil (See Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

Engine (Oil)

16.5 (3.6)

JCB Super Multigrade 15W/40 -10 °C to 50 °C (14 °F to 122 °F)

SAE15W/40, API CF4/SF SEE

JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)

Note

SAE10W/30, API CE/SF

ABOVE JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)

SAE10W, API CD/SF

Engine (Coolant)

20 (4.4)

JCB Four seasons Antifreeze & Summer Coolant/water (See Coolant Mixtures)

ASTM D3306, BS6580

PTO, Speed and Range Boxes (combined)

38 (8.4)

JCB Super Universal Agricultural

API-GL-4, MIL-L-2105

7 (1.56) 1.9 (0.4)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

23 (5.0)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105

17 (3.7) 2.0 (0.4)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Front Axle Housing Hubs (x2) Rear Axle (2WS) Rear Axle (4WS) Housing Hubs (x2) Brake System (Machines to Serial No. 737000)

Supplied from main hydraulic system (see below)

Brake System (Machines from Serial No. 737001) Front 0.75 (0.17) Rear 0.75 (0.17)

JCB Universal Brake Fluid

SAE J1703 DOT 4

! CAUTION

Do not use ordinary hydraulic fluid in the brake or clutch systems. 13-3-1-13

Clutch System

0.5 (0.11)

JCB Universal Brake Fluid

SAE J1703 DOT 4

† Hydraulic System

75 (16.5)

JCB Special Hydraulic Fluid HP46 (Above 38 °C, 100 °F)

ISO VG46

JCB Special Hydraulic Fluid HP32 (Below 38 °C, 100 °F)

ISO VG32

JCB HP Grease

Lithium complex NLGI No. 2 consistency including extreme pressure additives

Grease Points

---

Air Conditioning System - Refrigerant (Machines to Serial No. 736115) 1.15 kg (2 lb 4 oz) HFC 134c (Machines from Serial No. 736116) 0.9 kg (2 lb) HFC 134c - Compressor Lubricant 0.24 (0.05) Polyalkalineglycol

CH2 FC F3 PAG SP20

Front PTO Transfer Box (optional)

API-GL-5, MIL-L-2105C

3.0 (0.67)

JCB HD90 Gear Oil

CH2 FC F3

† Note: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank. 9804/1103

60 - 00 - 01/4

8010 - 3/1-1.4

Issue 2*

Fastrac

CONTENTS

* 1115

60 - 00 - 01/4A

& 1135 (N. American Machines)

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. DO NOT use a special running-in oil but use the oil recommended below from new. ITEM

CAPACITY FLUID/LUBRICANT US Gal (Liters)

INTERNATIONAL SPECIFICATION

Fuel

57.6 (220)

Diesel Oil (See Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

Engine (Oil)

4.3 (16.5)

JCB Engine Oil 15W/40 14 °F to 122 °F (-10 °C to 50 °C) JCB Engine Oil 10W/30 5 °F to104 °F (-15 °C to 40 °C)

SEE Notice ABOVE

SAE10W, API CF4/SG

Engine (Coolant)

5.3 (20.0)

JCB Permanent Antifreeze/water (See Coolant Mixtures)

ASTM D3306-74

PTO, Speed and Range Boxes (combined)

10 (38.0)

JCB AG Transmission Fluid

API-GL-4, MIL-L-2105

1.8 (7.0) 0.5 (1.9)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

6.1 (23.0)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

4.5 (17.0) 0.5 (2.0)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

Front Axle Housing Hubs (x2) Rear Axle (2WS) Rear Axle (4WS) Housing Hubs (x2) Brake System (Machines to Serial No. 737000)

Supplied from main hydraulic system (see below)

Brake System (Machines from Serial No. 737001) Front 0.2 (0.75) Rear 0.2 (0.75)

JCB Universal Brake Fluid

! CAUTION

SAE J1703 DOT 4

Do not use ordinary hydraulic oil in the brake or clutch systems. 13-3-1-13

Clutch System

0.13 (0.5)

JCB Universal Brake Fluid

ISO VG15

† Hydraulic System

19.8 (75.0)

JCB Special Hydraulic Fluid HP46

ISO VG46

Grease Points

---

JCB HP Grease

Lithium complex NGLI # 2 consistency including extreme pressure additives

Air Conditioning System - Refrigerant (Machines to Serial No. 736115) 2 lb 4 oz (1.15 kg) HFC 134c (Machines from Serial No. 736116) 2 lb (0.9 kg) HFC 134c - Compressor Lubricant 0.05 (0.24) Polyalkalineglycol

CH2 FC F3 PAG SP20

Front PTO Transfer Box (optional)

API-GL-5, MIL-L-2105C

0.8 (3.0)

JCB GL5 80W/90 Gear Oil

CH2 FC F3

† Notice: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank.

9804/1103

60 - 00 - 01/4A

8010 - C/1-1A.1

Issue 1

CONTENTS

Fastrac

60 - 00 - 01/5

2000 SERIES MACHINES Fluids, Lubricants and Capacities ITEM

CAPACITY FLUID/LUBRICANT Litres (UK Gal)

MINIMUM INTERNATIONAL SPECIFICATION

220 (48) 350 (77)

Diesel Oil (See Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

Engine (Oil)

16.5 (3.6)

See Engine Oil (All 2000, 3000 Series Machines) on page 60-00-01/11

Engine (Coolant)

34 (7.5)

JCB Four Seasons Antifreeze & Summer Coolant/water (See Coolant Mixtures)

ASTM D3306, BS6580

PTO, Speed and Range Boxes (combined)

38 (8.4)† 42 (9.3)††

JCB Super Universal Agricultural

API-GL-4, MIL-L-2105

Front Axle Housing Hubs (x2)

7 (1.56) 1.9 (0.4)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Fuel 2115, 2125, 2135 2150

Rear Axle (2WS) Rear Axle (4WS) Housing Hubs (x2)

23 (5.0)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

17 (3.7) 2.0 (0.4)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Brake System Front Rear

JCB Universal Brake Fluid

SAE J1703 DOT 4

0.75 (0.17) 0.75 (0.17)

! CAUTION

Do not use ordinary hydraulic fluid in the brake system. 13-3-2-6

†Clutch System

---

JCB Light Hydraulic Fluid - see Note 2

ISO VG15

Hydraulic System - see Note 1

82 (18.0)† 120 (26.4)††

JCB High Performance Hydraulic Oil

ISO VG46 (Above 38 °C, 100 °F)

JCB Hydraulic Fluid HP32 (Below 38 °C, 100 °F)

ISO VG32

JCB HP Grease

Lithium complex NLGI No. 2 consistency including extreme pressure additives

Air Conditioning System - Refrigerant 0.9 kg (2 lb) - Compressor Lubricant 0.24 (0.05)

HFC R134a Polyalkalineglycol

CH2 FC F3 PAG SP20

Front PTO Transfer Box (optional)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Grease Points

*

---

3.0 (0.67)

Note 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank. Note 2: It is essential that the correct specification fluid is used. Contact your JCB Distributor for further information. † ††

2000 Series to S/N 739999 2000 Series from S/N 740000

9804/1103

60 - 00 - 01/5

8020 - 3/1-2.7

Issue 4*

Fastrac

CONTENTS CONTENTS

60 - 00 - 01/6

2000 SERIES MACHINES (N. America) Fluids, Lubricants and Capacities ITEM

CAPACITY FLUID/LUBRICANT US Gal (Liters)

MINIMUM INTERNATIONAL SPECIFICATION

57.6 (220) 92.5 (350)

Diesel Oil (See Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

Engine (Oil)

4.3 (16.5)

See Engine Oil (All 2000, 3000 Series Machines) on page 60-00-01/11

Engine (Coolant)

9.0 (34.0)

JCB PermanentAntifreeze/water (See Coolant Mixtures)

ASTM D3306-74

PTO, Speed and Range Boxes (combined)

10 (38.0) † 11.2 (42.0) ††

JCB AG Transmission Fluid

API-GL-4, MIL-L-2105

Front Axle Housing Hubs (x2)

1.8 (7.0) 0.5 (1.9)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

6.1 (23.0)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

4.5 (17.0) 0.5 (2.0)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

JCB Universal Brake Fluid

SAE J1703 DOT 4

Fuel 2115, 2125, 2135 2150

Rear Axle (2WS) Rear Axle (4WS) Housing Hubs (x2) Brake System Front Rear

0.2 (0.75) 0.2 (0.75)

! CAUTION Do not use ordinary hydraulic oil in the brake system. 13-3-2-6

† Clutch System

---

JCB Light Hydraulic Fluid - see Notice 2

ISO VG15

Hydraulic System - see Notice 1

21.7 (82.0) † 31.7 (120) ††

JCB High Performance Hydraulic Oil

ISO VG46

Grease Points

---

JCB HP Grease

Lithium complex NLGI No. 2 consistency including extreme pressure additives

HFC R134a Polyalkalineglycol

CH2 FC F3 PAG SP20

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

Air Conditioning System - Refrigerant 2 lb (0.9 kg) * - Compressor Lubricant 0.06 (0.24) Front PTO Transfer Box (optional)

0.8 (3.0)

Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank. Notice 2: It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information. † ††

2000 Series to S/N 739999 2000 Series from S/N 740000

9804/1103

60 - 00 - 01/6

8020 - 3/1-3.7

Issue 4*

CONTENTS

Fastrac

60 - 00 - 01/7

FASTRAC 3155 Fluids, Lubricants and Capacities ITEM

CAPACITY FLUID/LUBRICANT Litres (UK Gal)

MINIMUM INTERNATIONAL SPECIFICATION

Fuel

350 (77)

Diesel Oil (See Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

Engine (Oil)

16.5 (3.6)

See Engine Oil (All 2000, 3000 Series Machines) on page 60-00-01/11

Engine (Coolant)

34 (7.5)

JCB Four Seasons Antifreeze & Summer Coolant/water (See Coolant Mixtures)

ASTM D3306, BS6580

PTO, Speed and Range Boxes (combined)

38 (8.4) † 42 (9.3) ††

JCB Super Universal Agricultural

API-GL-4, MIL-L-2105

Front Axle Housing Hubs (x2)

20 (4.4) 2.5 (0.55)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Rear Axle

21 (4.6)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Brake System Front Rear

JCB Universal Brake Fluid

SAE J1703 DOT 4

0.75 (0.17) 0.75 (0.17)

! CAUTION

Do not use ordinary hydraulic fluid in the brake system. 13-3-2-6

† Clutch System

-

JCB Light Hydraulic Fluid - see Note 2

ISO VG15

Hydraulic System - see Note 1

82 (18.0) † 120 (26.4) ††

JCB High Performance Hydraulic Oil

ISO VG46 (Above 38 °C, 100 °F)

JCB Hydraulic Fluid HP32 (Below 38 °C, 100 °F)

ISO VG32

JCB HP Grease

Lithium complex NLGI No. 2 consistency including extreme pressure additives

Air Conditioning System - Refrigerant 0.9 kg (2 lb) - Compressor Lubricant 0.24 (0.05)

HFC R134a Polyalkalineglycol

CH2 FC F3 PAG SP20

Front PTO Transfer Box (optional)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Grease Points

*

---

3.0 (0.67)

Note 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank. Note 2: It is essential that the correct specification fluid is used. Contact your JCB Distributor for further information. † ††

3000 Series to S/N 641999 3000 Series from S/N 642000

9804/1103

60 - 00 - 01/7

8020 - 3/1-4.6

Issue 4*

CONTENTS

Fastrac

60 - 00 - 01/8

FASTRAC 3155 (N. America) Fluids, Lubricants and Capacities ITEM

CAPACITY FLUID/LUBRICANT US Gal (Liters)

MINIMUM INTERNATIONAL SPECIFICATION

92.5 (350)

Diesel Oil (See Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

Engine (Oil)

4.3 (16.5)

See Engine Oil (All 2000, 3000 Series Machines) on page 60-00-01/11

Engine (Coolant)

9 (34.0)

JCB Permanent Antifreeze/water (See Coolant Mixtures)

ASTM D3306-74

PTO, Speed and Range Boxes (combined)

10.1 (38.0) † 11.2 (42.0) ††

JCB AG Transmission Fluid

API-GL-4, MIL-L-2105

Front Axle Housing Hubs (x2)

5.3 (20.0) 0.66 (2.5)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

Rear Axle (2WS)

7.1 (27.0)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

Brake System Front Rear

JCB Universal Brake Fluid

SAE J1703 DOT 4

0.2 (0.75) 0.2 (0.75)

Fuel

! CAUTION Do not use ordinary hydraulic oil in the brake system. 13-3-2-6

*

† Clutch System

---

JCB Light Hydraulic Fluid - see Notice 2

ISO VG15

Hydraulic System - see Notice 1

21.7 (82.0) † 31.7 (120) ††

JCB High Performance Hydraulic Oil

ISO VG46

Grease Points

---

JCB HP Grease

Lithium complex NLGI No. 2 consistency including extreme pressure additives

Air Conditioning System - Refrigerant 2 lb (0.9 kg) - Compressor Lubricant 0.06 (0.24)

HFC R134a Polyalkalineglycol

CH2 FC F3 PAG SP20

Front PTO Transfer Box (optional)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

0.8 (3.0)

Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank. Notice 2: It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information.

† ††

3000 Series to S/N 641999 3000 Series from S/N 642000

9804/1103

60 - 00 - 01/8

8020 - 3/1-5.6

Issue 4*

CONTENTS

Fastrac

60 - 00 - 01/9

FASTRAC 3185 Fluids, Lubricants and Capacities ITEM

CAPACITY FLUID/LUBRICANT Litres (UK Gal)

MINIMUM NTERNATIONAL SPECIFICATION

Fuel

350 (77)

Diesel Oil (See Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

Engine (Oil)

15 (3.3)

See Engine Oil (All 2000, 3000 Series Machines) on page 60 - 00 - 01/11

Engine (Coolant)

33 (7.3)

JCB Four Seasons Antifreeze & Summer Coolant/water (See Coolant Mixtures)

ASTM D3306, BS6580

PTO, Speed and Range Boxes (combined)

38 (8.4) † 42 (9.3) ††

JCB Super Universal Agricultural

API-GL-4, MIL-L-2105

Front Axle Housing Hubs (x2)

20 (4.4) 2.5 (0.55)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Rear Axle

27 (6.0)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Brake System Front Rear

JCB Universal Brake Fluid

SAE J1703 DOT 4

0.75 (0.17) 0.75 (0.17)

! CAUTION

Do not use ordinary hydraulic fluid in the brake system. 13-3-2-6

† Clutch System

-

JCB Light Hydraulic Fluid - see Note 2

ISO VG15

Hydraulic System - see Note 1

82 (18.0) † 120 (26.4) ††

JCB High Performance Hydraulic Oil

ISO VG46 (Above 38 °C, 100 °F)

JCB Hydraulic Fluid HP32 (Below 38 °C, 100 °F)

ISO VG32

JCB HP Grease

Lithium complex NLGI No. 2 consistency including extreme pressure additives

Air Conditioning System - Refrigerant 0.9 kg (2 lb) - Compressor Lubricant 0.24 (0.05)

HFC R134a Polyalkalineglycol

CH2 FC F3 PAG SP20

Front PTO Transfer Box (optional)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Grease Points

*

---

3.0 (0.67)

Note 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank. Note 2: It is essential that the correct specification fluid is used. Contact your JCB Distributor for further information.

† ††

3000 Series to S/N 641999 3000 Series from S/N 642000

9804/1103

60 - 00 - 01/9

8020 - 3/1-6.6

Issue 4*

CONTENTS

Fastrac

60 - 00 - 01/10

FASTRAC 3185 (N. America) Fluids, Lubricants and Capacities ITEM

CAPACITY FLUID/LUBRICANT US Gal (Liters)

MINIMUM INTERNATIONAL SPECIFICATION

92.5 (350)

Diesel Oil (See Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

Engine (Oil)

4 (15)

See Engine Oil (All 2000, 3000 Series Machines) on page 60 - 00 - 01/11

Engine (Coolant)

8.77 (33.0)

JCB Permanent Antifreeze/water (See Coolant Mixtures)

ASTM D3306-74

PTO, Speed and Range Boxes (combined)

10 (38.0) † 11.2 (42.0) ††

JCB AG Transmission Fluid

API-GL-4, MIL-L-2105

Front Axle Housing Hubs (x2)

5.3 (20.0) 0.66 (2.5)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

Rear Axle

7.1 (27.0)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

Brake System Front Rear

JCB Universal Brake Fluid

SAE J1703 DOT 4

0.2 (0.75) 0.2 (0.75)

Fuel

! CAUTION Do not use ordinary hydraulic oil in the brake system. 13-3-2-6

*

† Clutch System

---

JCB Light Hydraulic Fluid - see Notice 2

ISO VG15

Hydraulic System - see Notice 1

21.7 (82.0) † 31.7 (120) ††

JCB High Performance Hydraulic Oil

ISO VG46

Grease Points

---

JCB HP Grease

Lithium complex NLGI No. 2 consistency including extreme pressure additives

Air Conditioning System - Refrigerant 2 lb (0.9 kg) - Compressor Lubricant 0.06 (0.24)

HFC R134a Polyalkalineglycol

CH2 FC F3 PAG SP20

Front PTO Transfer Box (optional)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

0.8 (3.0)

Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank. Notice 2: It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information.

† ††

3000 Series to S/N 641999 3000 Series from S/N 642000

9804/1103

60 - 00 - 01/10

8020 - 3/1-7.3

Issue 3*

CONTENTS

Fastrac

60 - 00 - 01/11

FASTRAC 3185 (N. America) Fluids, Lubricants and Capacities Engine Oil New Engines New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately. DO NOT use a special running-in oil but use the oil recommended below from new.

Engine Oil Specification Recommended Oil JCB Extreme Performance Engine Oil SAE 15W/40 API CH-4 or ACEA E3/B3A3 IMPORTANT NOTE: IF SAE 15W/40, API CH-4 OR ACEA E3/B3A3 ENGINE OIL IS NOT AVAILABLE, THEN THE ENGINE OIL MUST BE CHANGED AT 250 HOURS. Alternative Oil If the oil recommended above is not available then the alternatives listed below should be used according to the ambient temperature. Note: (3185 machines only). While 15W/40 oil is recommended for most climates, limited use of low viscosity oils such as 10W/30 is permitted to provide easier starting and sufficient oil flow at ambient temperatures below -5 °C (23 °F). Continued use of low viscosity oils can decrease engine life. JCB Super Multigrade 15W/40 SAE15W/40, API CF4/SG -10 °C to 50 °C (14 °F to 122 °F) JCB Super Multigrade 10W/30 SAE10W/30, API CF4/SG † -15 °C to 40 °C (5 °F to 104 °F) † The temperature range for 3185 machines is - 20 °C to 20 °C (-4 °F to 68 °F).

Engine Oil Specification (N. America) Recommended Oil JCB Genuine Engine Oil SAE 15W/40, Grade CH-4/SJ IMPORTANT NOTICE: IF SAE 15W/40, GRADE CH-4/SJ ENGINE OIL IS NOT AVAILABLE, THEN THE ENGINE OIL MUST BE CHANGED AT 250 HOURS. Alternative Oil If the oil recommended above is not available then the alternatives listed below should be used according to the ambient temperature. Notice: (3185 machines only). While 15W/40 oil is recommended for most climates, limited use of low viscosity oils such as 10W/30 is permitted to provide easier starting and sufficient oil flow at ambient temperatures below -5 °C (23 °F). Continued use of low viscosity oils can decrease engine life. JCB 15W/40 Engine Oil SAE15W/40, API CF4/SG -10 °C to 50 °C (14 °F to 122 °F) JCB Engine Oil 10W/30 SAE10W/30, API CE/SF † -15 °C to 40 °C (5 °F to 104 °F) † The temperature range for 3185 machines is -4 °F to 68 °F (- 20 °C to 20 °C).

9804/1103

60 - 00 - 01/11

8020 - 3/1-1.6

Issue 1

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I'@@L?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1?g ?@@H ?N@@1?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@? @@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W2@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>)?&R1?*>1?7R1?*>1?7R1?*>)T&>)?&R)?&R)?&R)?&R1?7R1?*>)T&>)?&R)?&R1?7R1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@9V@@@@@@LV'@?@@@?S@@X@@@LV'@@R@@@@@@@@@@@@@@@@@@X@@@LV'@@R@@@@@@@@@@X@@@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S@@@@@@@@)XN@@@@@@@8S@@@@)XN@@W@@@@@@@@?@@@@@@@?S@@@@)XN@@W@@@@@@@@?S@@@@)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@X@@@@)X@@@V'@@W&U@@@@1?@@@R'X@@@X@?@@@V'X@?*U@@@@1?@@@R'X@@@X@?7@@V'@1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LN@@XI4@XI4@@@@@LV'@@R'@@@@@?@@@LV'@@V4@X@@@?V@@LV'@@@@@?@@@LV'@@V4@T@@@?V@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X@@)X?S)X?W@@?S)XN@@LN@@?@@@@@S)XN@@L?S@@@@@@@@)XN@@?@@@@@S)XN@@L?S@>@@@@@V)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>@@@V1?*>)T&@@?*>1?@@1?@@@@@?@@@>1?@@1?*U@@@@@@@>1?@@@@@?@@@>1?@@1?*>@R'@@@@@1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@@@@@LN@@@R'@LV4@X@@@X@@@T@@@@V4@X@@@LV'@@V4@XI4@X@@@T@@@@V4@X@@@LV'@LV4@X@@@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?W@@@V)X@@@LN@)K?V@@?S@@@S@U@@@L?S@@@S)XN@@??V)K?S@@@S@U@@@L?S@@@S)XN@)K?V@@@>)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@@@@@>1?3@@@@@@?*U@@@>@@@@1?*U@@@>1?@@@@@@@@@U@@@>@@@@1?*U@@@>1?3@@@@@@V'>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@@@@@XI4@LV4@@@@@LV4@@V4@T@@@LV4@@V4@T@@@@@@@@V4@@V4@T@@@LV4@@V4@LV4@@@@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?W@X?S)X?S)X?W@X?S)X?W@L?S@U?S)X?W@L?S@U?W@X?W@L?W@L?S@U?S)X?W@L?S)X?W@X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?W2@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@W&@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5?g ?@@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@5?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@(Y?g I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0Yh

CONTENTS

* 125,

Fastrac

60 - 00 - 02/1

135, 145, 150, 155

To m/c no. 636000

Static Dimensions

B

A

D C K

J E F G H

A170051

With 495/70 R 24 Tyres With 480/70 R 30 Tyres mm in mm in A Height to top of Cab 2781 109.5 2881 113.5 B Height to top of Exhaust 2765 109 2865 113 C Overall Width 2270 89.4 2490 98 D Track Width 1879 74 2015 79 E Minimum Ground Clearance 390 15.4 490 19.3 Note: The position of the minimum ground clearance varies according to machine specification. When a clevis drawbar is fitted, the clearance is reduced by 60 mm (2.4 in) F Wheelbase 3006 118 3006 118 G Overall Length (less Front Linkage) 4923 193.8 4923 193.8 H Overall Length (with Front Linkage) 5523 217 5523 217 J Height to Trailer Coupling (Adjustable) 540-1010 21.3-39.3 640-1110 25.2-43.3 K Length of Load Deck 1572 61.9 1572 61.9 Turning Radius (Kerb to kerb with 1829 mm/72 in track) 7050 277.5 7050 277.5 Unladen Weights Total with Oil and Coolant On Front Axle On Rear Axle

9804/1103

kg 6378 2812 3566

lb 14060 6199 7861

60 - 00 - 02/1

kg 6458 2852 3606

lb 14237 6287 7950

Issue 4*

W2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K?h ?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@h

?7@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@L?g ?7@(M? I'@@L?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1?g ?@@H ?N@@1?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@? @@@?g ?@@?e?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W2@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>)?&R1?*>1?7R1?*>1?7R1?*>)T&>)?&R)?&R)?&R)?&R1?7R1?*>)T&>)?&R)?&R1?7R1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@9V@@@@@@LV'@?@@@?S@@X@@@LV'@@R@@@@@@@@@@@@@@@@@@X@@@LV'@@R@@@@@@@@@@X@@@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S@@@@@@@@)XN@@@@@@@8S@@@@)XN@@W@@@@@@@@?@@@@@@@?S@@@@)XN@@W@@@@@@@@?S@@@@)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@X@@@@)X@@@V'@@W&U@@@@1?@@@R'X@@@X@?@@@V'X@?*U@@@@1?@@@R'X@@@X@?7@@V'@1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LN@@XI4@XI4@@@@@LV'@@R'@@@@@?@@@LV'@@V4@X@@@?V@@LV'@@@@@?@@@LV'@@V4@T@@@?V@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X@@)X?S)X?W@@?S)XN@@LN@@?@@@@@S)XN@@L?S@@@@@@@@)XN@@?@@@@@S)XN@@L?S@>@@@@@V)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>@@@V1?*>)T&@@?*>1?@@1?@@@@@?@@@>1?@@1?*U@@@@@@@>1?@@@@@?@@@>1?@@1?*>@R'@@@@@1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@@@@@LN@@@R'@LV4@X@@@X@@@T@@@@V4@X@@@LV'@@V4@XI4@X@@@T@@@@V4@X@@@LV'@LV4@X@@@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?W@@@V)X@@@LN@)K?V@@?S@@@S@U@@@L?S@@@S)XN@@??V)K?S@@@S@U@@@L?S@@@S)XN@)K?V@@@>)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@@@@@>1?3@@@@@@?*U@@@>@@@@1?*U@@@>1?@@@@@@@@@U@@@>@@@@1?*U@@@>1?3@@@@@@V'>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@@@@@XI4@LV4@@@@@LV4@@V4@T@@@LV4@@V4@T@@@@@@@@V4@@V4@T@@@LV4@@V4@LV4@@@@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?W@X?S)X?S)X?W@X?S)X?W@L?S@U?S)X?W@L?S@U?W@X?W@L?W@L?S@U?S)X?W@L?S)X?W@X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?W2@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@W&@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5?g ?@@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@5?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@(Y?g I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0Yh

CONTENTS

* 125,

Fastrac

60 - 00 - 02/2

135, 145, 150, 155

* M/c

nos. 636001 to 636368

Static Dimensions

A

D C K

B J E F G H

A194480

With 495/70 R 24 Tyres With 480/70 R 30 Tyres mm in mm in A Height to top of Cab 2905 114.3 2973 117.0 B Deck Height 1587 62.5 1655 65.2 C Overall Width 2370 93.3 2485 97.8 D Track Width 1875 73.8 2015 79.3 E Minimum Ground Clearance 458 18 558 22 Note: The position of the minimum ground clearance varies according to machine specification. When a clevis drawbar is fitted, the clearance is reduced by 60 mm (2.4 in) F Wheelbase 3006 118 3006 118 G Overall Length (less Front Linkage) 5008 197 5008 197 H Overall Length (with Front Linkage) 5608 221 5608 221 J Height to Trailer Coupling (Adjustable) 540-1010 21.3-39.3 640-1110 25.2-43.3 K Length of Load Deck 1572 61.9 1572 61.9 Turning Radius (Kerb to kerb with 1829 mm/72 in track) 7050 277.5 7050 277.5 Unladen Weights (excluding front hitch & trailer coupling) Total with Oil and Coolant On Front Axle On Rear Axle

9804/1103

kg 6199 3362 2837

lb 13666 7412 6254

60 - 00 - 02/2

kg 6279 3402 2877

lb 13843 7500 6343

Issue 3*

W2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K?h ?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@h ?7@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@L?g ?7@(M? I'@@L?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1?g ?@@H ?N@@1?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@? @@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W2@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>)?&R1?*>1?7R1?*>1?7R1?*>)T&>)?&R)?&R)?&R)?&R1?7R1?*>)T&>)?&R)?&R1?7R1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@9V@@@@@@LV'@?@@@?S@@X@@@LV'@@R@@@@@@@@@@@@@@@@@@X@@@LV'@@R@@@@@@@@@@X@@@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S@@@@@@@@)XN@@@@@@@8S@@@@)XN@@W@@@@@@@@?@@@@@@@?S@@@@)XN@@W@@@@@@@@?S@@@@)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@X@@@@)X@@@V'@@W&U@@@@1?@@@R'X@@@X@?@@@V'X@?*U@@@@1?@@@R'X@@@X@?7@@V'@1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LN@@XI4@XI4@@@@@LV'@@R'@@@@@?@@@LV'@@V4@X@@@?V@@LV'@@@@@?@@@LV'@@V4@T@@@?V@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X@@)X?S)X?W@@?S)XN@@LN@@?@@@@@S)XN@@L?S@@@@@@@@)XN@@?@@@@@S)XN@@L?S@>@@@@@V)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>@@@V1?*>)T&@@?*>1?@@1?@@@@@?@@@>1?@@1?*U@@@@@@@>1?@@@@@?@@@>1?@@1?*>@R'@@@@@1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@@@@@LN@@@R'@LV4@X@@@X@@@T@@@@V4@X@@@LV'@@V4@XI4@X@@@T@@@@V4@X@@@LV'@LV4@X@@@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?W@@@V)X@@@LN@)K?V@@?S@@@S@U@@@L?S@@@S)XN@@??V)K?S@@@S@U@@@L?S@@@S)XN@)K?V@@@>)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@@@@@>1?3@@@@@@?*U@@@>@@@@1?*U@@@>1?@@@@@@@@@U@@@>@@@@1?*U@@@>1?3@@@@@@V'>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@@@@@XI4@LV4@@@@@LV4@@V4@T@@@LV4@@V4@T@@@@@@@@V4@@V4@T@@@LV4@@V4@LV4@@@@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?W@X?S)X?S)X?W@X?S)X?W@L?S@U?S)X?W@L?S@U?W@X?W@L?W@L?S@U?S)X?W@L?S)X?W@X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?W2@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@W&@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5?g ?@@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@5?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@(Y?g I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0Yh

CONTENTS

Fastrac

60 - 00 - 02/3

125, 135, 145, 150, 155, 185

From m/c no. 636369

Static Dimensions

A

D C K

B J E F G H

A194481

With 495/70 R 24 Tyres With 520/70 R 30 Tyres mm in mm in A Height to top of Cab - Fastrac 185 2965 117 3040 120 - All other models 2905 114 2980 117 B Deck Height 1425 56 1496 59 C Overall Width 2370 93 2535 100 D Track Width 1875 74 2015 79 E Minimum Ground Clearance 400 16 493 19 Note: The position of the minimum ground clearance varies according to machine specification. When a clevis drawbar is fitted, the clearance is reduced by 60 mm (2.4 in) F Wheelbase 3006 118 3006 118 G Overall Length (less Front Linkage) 5157 203 5157 203 H Overall Length (with Front Linkage) 5757 227 5757 227 J Height to Trailer Coupling (Adjustable) 540-1010 21.3-39.3 640-1110 25.2-43.3 K Length of Load Deck 1572 61.9 1572 61.9

Turning Radius (Kerb to kerb with 1829 mm/72 in track) 7050

9804/1103

60 - 00 - 02/3

277.5

7050

277.5

Issue 2

I'@@L?g ?N@@1?g @@@?g

W2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K?h ?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@h ?7@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@L?g ?7@(M? ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1?g ?@@H ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@? ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W2@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>)?&R1?*>1?7R1?*>1?7R1?*>)T&>)?&R)?&R)?&R)?&R1?7R1?*>)T&>)?&R)?&R1?7R1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@9V@@@@@@LV'@?@@@?S@@X@@@LV'@@R@@@@@@@@@@@@@@@@@@X@@@LV'@@R@@@@@@@@@@X@@@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S@@@@@@@@)XN@@@@@@@8S@@@@)XN@@W@@@@@@@@?@@@@@@@?S@@@@)XN@@W@@@@@@@@?S@@@@)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@X@@@@)X@@@V'@@W&U@@@@1?@@@R'X@@@X@?@@@V'X@?*U@@@@1?@@@R'X@@@X@?7@@V'@1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LN@@XI4@XI4@@@@@LV'@@R'@@@@@?@@@LV'@@V4@X@@@?V@@LV'@@@@@?@@@LV'@@V4@T@@@?V@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X@@)X?S)X?W@@?S)XN@@LN@@?@@@@@S)XN@@L?S@@@@@@@@)XN@@?@@@@@S)XN@@L?S@>@@@@@V)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>@@@V1?*>)T&@@?*>1?@@1?@@@@@?@@@>1?@@1?*U@@@@@@@>1?@@@@@?@@@>1?@@1?*>@R'@@@@@1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@@@@@LN@@@R'@LV4@X@@@X@@@T@@@@V4@X@@@LV'@@V4@XI4@X@@@T@@@@V4@X@@@LV'@LV4@X@@@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?W@@@V)X@@@LN@)K?V@@?S@@@S@U@@@L?S@@@S)XN@@??V)K?S@@@S@U@@@L?S@@@S)XN@)K?V@@@>)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@@@@@>1?3@@@@@@?*U@@@>@@@@1?*U@@@>1?@@@@@@@@@U@@@>@@@@1?*U@@@>1?3@@@@@@V'>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@@@@@XI4@LV4@@@@@LV4@@V4@T@@@LV4@@V4@T@@@@@@@@V4@@V4@T@@@LV4@@V4@LV4@@@@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?W@X?S)X?S)X?W@X?S)X?W@L?S@U?S)X?W@L?S@U?W@X?W@L?W@L?S@U?S)X?W@L?S)X?W@X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?W2@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@W&@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5?g 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CONTENTS

Fastrac

60 - 00 - 02/4

*125, 135, 145, 150, 155, 185

From m/c no. 636369

Unladen Weights With 495/70 R 24 Tyres kg lb

With 520/70 R 30 Tyres kg lb

Basic Machine with rear linkage and rear PTO On Front Axle On Rear Axle Total Machine

3400 2974 6374

7495 6556 14051

3510 3014 6524

7740 6644 14384

Machine with front linkage and front PTO On Front Axle On Rear Axle Total Machine

3700 2920 6620

8157 6437 14594

3740 2960 6700

8245 6525 14770

Front 3-point Linkage

3000

6613

3000

6613

Rear Pick-up Hitch (Maximum vertical down-load)

3000

6613

3000

6613

Rear 3-point Linkage (load on hook end) with 80 mm lift cylinders with 85 mm lift cylinders

6000 7000

13227 15432

6000 7000

13227 15432

Load Capacities

Rear Load Deck Trailer Coupling and Ladder

2500

5511 2500 Refer to data plates on the components

5511

Laden Weights Maximum permissible laden weights are in some cases governed by legislation which varies from country to country. You must not exceed the total mass and load figures shown on the machine identification plate.

Note 1: The maximum load on the rear load deck is permitted only if placed over the centre-line of the rear axle. For advice on loads in other positions, consult JCB Landpower. Note 2: In some cases, maximum permissible tyre loadings may be less than the stated loadings given above (see Tyres and Wheels in MAINTENANCE section). You must never exceed either of these limits. Note that the figures quoted on the Tyres and Wheels page are the maximum loads per tyre. If in doubt, refer to the tyre supplier or JCB Landpower.

! CAUTION

! WARNING

The Fastrac has to comply with certain braking regulations which in some countries control weight distribution between front and rear axles. Travelling on the road with implements or weights carried on the front when no implement is on the rear may break the law. In this case you should transfer the front mounted equipment to the rear linkage. It is the operator's responsibility to know and observe the laws in the country concerned.

The machine must never be loaded such that less than 20% of the unladen vehicle weight is carried on the front axle. 13-1-1-11

13-2-2-5

9804/1103

60 - 00 - 02/4

Issue 2*

W2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K?h ?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@h ?7@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@L?g ?7@(M? I'@@L?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1?g ?@@H ?N@@1?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@? @@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W2@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>)?&R1?*>1?7R1?*>1?7R1?*>)T&>)?&R)?&R)?&R)?&R1?7R1?*>)T&>)?&R)?&R1?7R1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@9V@@@@@@LV'@?@@@?S@@X@@@LV'@@R@@@@@@@@@@@@@@@@@@X@@@LV'@@R@@@@@@@@@@X@@@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S@@@@@@@@)XN@@@@@@@8S@@@@)XN@@W@@@@@@@@?@@@@@@@?S@@@@)XN@@W@@@@@@@@?S@@@@)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@X@@@@)X@@@V'@@W&U@@@@1?@@@R'X@@@X@?@@@V'X@?*U@@@@1?@@@R'X@@@X@?7@@V'@1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LN@@XI4@XI4@@@@@LV'@@R'@@@@@?@@@LV'@@V4@X@@@?V@@LV'@@@@@?@@@LV'@@V4@T@@@?V@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X@@)X?S)X?W@@?S)XN@@LN@@?@@@@@S)XN@@L?S@@@@@@@@)XN@@?@@@@@S)XN@@L?S@>@@@@@V)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>@@@V1?*>)T&@@?*>1?@@1?@@@@@?@@@>1?@@1?*U@@@@@@@>1?@@@@@?@@@>1?@@1?*>@R'@@@@@1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@@@@@LN@@@R'@LV4@X@@@X@@@T@@@@V4@X@@@LV'@@V4@XI4@X@@@T@@@@V4@X@@@LV'@LV4@X@@@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?W@@@V)X@@@LN@)K?V@@?S@@@S@U@@@L?S@@@S)XN@@??V)K?S@@@S@U@@@L?S@@@S)XN@)K?V@@@>)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@@@@@>1?3@@@@@@?*U@@@>@@@@1?*U@@@>1?@@@@@@@@@U@@@>@@@@1?*U@@@>1?3@@@@@@V'>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@@@@@XI4@LV4@@@@@LV4@@V4@T@@@LV4@@V4@T@@@@@@@@V4@@V4@T@@@LV4@@V4@LV4@@@@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?W@X?S)X?S)X?W@X?S)X?W@L?S@U?S)X?W@L?S@U?W@X?W@L?W@L?S@U?S)X?W@L?S)X?W@X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?W2@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@W&@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5?g ?@@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@5?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@(Y?g I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0Yh

CONTENTS

Fastrac

60 - 00 - 02/5

FASTRAC 1115 & 1135 Static Dimensions

B

E F G

A

H D

A230380

C

A B C D E F G H

9804/1103

1115

1135

Dimensions on 480/70 R28 Tyres

Dimensions on 480/70 R30 Tyres

mm

in

mm

in

Height to top of Cab Deck Height Overall Width Track Width Minimum Ground Clearance Wheelbase Overall Length Width between Tyres

2800 1471 2310 1830 465 2782 5164 1350

110 58 91 72 18 110 203 53

2830 1500 2310 1830 495 2782 5164 1350

111 59 91 72 19 110 203 53

Turning Circle (Kerb to kerb) on 16.9 R28 tyres on 480/70 R28 tyres

12.75m (41.8 ft) 13.13m (43.1 ft)

60 - 00 - 02/5

on 480/70 R30 tyres 13.4m (43 ft 11 in)

Issue 1

W2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K?h ?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@h

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CONTENTS

Fastrac

60 - 00 - 02/6

FASTRAC 1115 & 1135 Unladen Weights kg

lb

Basic Machine with rear linkage and rear PTO On Front Axle On Rear Axle

2720 2580

5996 5688

Machine with front linkage and front PTO On Front Axle On Rear Axle

3700 2920

8157 6437

Front 3-point Linkage (total load on hook ends)

2500

5511

Rear Pick-up Hitch

3000

6613

Rear 3-point Linkage (total load on hook ends) with 75 mm lift cylinders with 80 mm lift cylinders

5250 6000

11574 13227

Rear Load Deck Trailer Coupling and Ladder

2500 5511 Refer to data plates on the components

Load Capacities

Laden Weights Maximum permissible laden weights are in some cases governed by legislation which varies from country to country. You must not exceed the total mass and load figures shown on the machine identification plate.

Note 1: The maximum load on the rear load deck is permitted only if placed over the centre-line of the rear axle. For advice on loads in other positions, consult JCB Landpower. Note 2: In some cases, maximum permissible tyre loadings may be less than the stated loadings given above. You must never exceed either of these limits. Note that the figures quoted on the Tyres and Wheels page are the maximum loads per tyre. If in doubt, refer to the tyre supplier or JCB Landpower.

! CAUTION

! WARNING

The Fastrac has to comply with certain braking regulations which in some countries control weight distribution between front and rear axles. Travelling on the road with implements or weights carried on the front when no implement is on the rear may break the law. In this case you should transfer the front mounted equipment to the rear linkage. It is the operator's responsibility to know and observe the laws in the country concerned.

The machine must never be loaded such that less than 20% of the unladen vehicle weight is carried on the front axle. 13-1-1-11

13-2-2-5

9804/1103

60 - 00 - 02/6

Issue 1

CONTENTS

Fastrac

60 - 00 - 02/7

2000 SERIES MACHINES Static Dimensions

B

E F G

A

H D A262630

C

Fastrac 2115, 2125, 2135

Fastrac 2150

Dimensions on 480/70 R28 Tyres A B C D E F G H

Height to top of Cab Deck Height Overall Width Track Width Minimum Ground Clearance Wheelbase Overall Length Width between Tyres

Turning Circle (Kerb to kerb) on 16.9 R28 tyres on 480/70 R28 tyres

9804/1103

mm 2825 1500 2310 1830 400 2782 5080 1350

in 112 59 91 72 16 110 200 53

12.75m (41 ft 7 in) 13.13m (43 ft 1 in)

Dimensions on 480/70 R30 Tyres mm in 2950 116 1524 60 2310 91 1830 72 385 15 3006 118 5150 203 1350 53

on 480/70 R30 tyres

60 - 00 - 02/7

13.4m (43 ft 11 in)

Issue 1

CONTENTS

Fastrac

60 - 00 - 02/8

2000 SERIES MACHINES Unladen Weights Fastrac 2115, 2125, 2135 480/70 R28 Tyres

Fastrac 2150 480/70 R30 Tyres

kg

lb

kg

lb

Basic Machine with rear linkage and rear PTO Front Axle Rear Axle

3080 2850

6790 6283

3248 3117

7160 6871

Machine with front linkage and front PTO Front Axle Rear Axle

3320 2845

7319 6272

3498 3102

7712 6839

Maximum design load Front Axle Rear Axle

4400 5300

9700 11684

4400 5300

9700 11684

Maximum gross vehicle weight

9000

19841

9000

19841

Front 3-point Linkage (total load on hook ends)

2500

5511

Rear Pick-up Hitch

3000

6613

Rear 3-point Linkage (total load on hook ends) with 75 mm lift cylinders with 80 mm lift cylinders with 85 mm lift cylinders

5250 6000 7000

11574 13227 15432

Rear Load Deck Trailer Coupling and Ladder

2500 5511 Refer to data plates on the components

Load Capacities

Laden Weights Maximum permissible laden weights are in some cases governed by legislation which varies from country to country. You must not exceed the total mass and load figures shown on the machine identification plate.

Note 1: The maximum load on the rear load deck is permitted only if placed over the centre-line of the rear axle. For advice on loads in other positions, consult JCB Landpower. Note 2: In some cases, maximum permissible tyre loadings may be less than the stated loadings given above (see Tyres and Wheels in MAINTENANCE section). You must never exceed either of these limits. Note that the figures quoted on the Tyres and Wheels page are the maximum loads per tyre. If in doubt, refer to the tyre supplier or JCB Landpower.

! CAUTION

! WARNING

The Fastrac has to comply with certain braking regulations which in some countries control weight distribution between front and rear axles. Travelling on the road with implements or weights carried on the front when no implement is on the rear may break the law. In this case you should transfer the front mounted equipment to the rear linkage. It is the operator's responsibility to know and observe the laws in the country concerned.

The machine must never be loaded such that less than 20% of the vehicle weight is carried on the front axle. 13-1-1-11/1

13-2-2-5

9804/1103

60 - 00 - 02/8

Issue 1

CONTENTS CONTENTS

* 3000

Fastrac

60 - 00 - 02/9

Series

Static Dimensions

A

D C

B

E F G A303791

Dimensions With 495/70 R 24 Tyres With 520/70 R 30 Tyres mm in mm in A Height to top of Exhaust 3075 121 3150 124 B Deck Height 1475 58 1550 61 C Overall Width 2370 93 2535 100 D Track Width 1875 74 2015 79 E Minimum Ground Clearance 320 12 395 15 Note: The position of the minimum ground clearance varies according to machine specification. F Wheelbase 3006 118 3006 118 G Overall Length (less Front Linkage) 5157 203 5157 203 H Overall Length (with Front Linkage) 5757 227 5757 227 J Height to Trailer Coupling (Adjustable) 540-1010 21.3-39.3 640-1110 25.2-43.3

9804/1103

60 - 00 - 02/9

1371 - 171-2

Issue 2*

CONTENTS

Fastrac

60 - 00 - 02/10

FASTRAC 3155 & 3185 Unladen Weights With 495/70 R 24 Tyres kg lb

With 520/70 R 30 Tyres kg lb

Basic Machine with rear linkage and rear PTO On Front Axle On Rear Axle Total Machine

3598 3103 6701

7933 6842 14775

3688 3193 6881

8132 7040 15172

Machine with front linkage and front PTO On Front Axle On Rear Axle Total Machine

3848 3088 6936

8484 6809 15293

3938 3178 7116

8683 7007 15690

Front 3-point Linkage

3000

6613

3000

6613

Rear Pick-up Hitch (Maximum vertical down-load)

3000

6613

3000

6613

Rear 3-point Linkage (load on hook end) with 80 mm lift cylinders with 85 mm lift cylinders

6000 7000

13227 15432

6000 7000

13227 15432

Load Capacities

Rear Load Deck Trailer Coupling and Ladder

2500

5511 2500 Refer to data plates on the components

5511

Laden Weights Maximum permissible laden weights are in some cases governed by legislation which varies from country to country. You must not exceed the total mass and load figures shown on the machine identification plate.

Note 1: The maximum load on the rear load deck is permitted only if placed over the centre-line of the rear axle. For advice on loads in other positions, consult JCB Landpower. Note 2: In some cases, maximum permissible tyre loadings may be less than the stated loadings given above (see Tyres and Wheels in MAINTENANCE section). You must never exceed either of these limits. Note that the figures quoted on the Tyres and Wheels page are the maximum loads per tyre. If in doubt, refer to the tyre supplier or JCB Landpower.

! CAUTION

! WARNING

The Fastrac has to comply with certain braking regulations which in some countries control weight distribution between front and rear axles. Travelling on the road with implements or weights carried on the front when no implement is on the rear may break the law. In this case you should transfer the front mounted equipment to the rear linkage. It is the operator's responsibility to know and observe the laws in the country concerned.

The machine must never be loaded such that less than 20% of the vehicle weight is carried on the front axle. 13-1-1-11/1

13-2-2-5

9804/1103

60 - 00 - 02/10

Issue 1

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I'@@L?g ?N@@1?g @@@?g

CONTENTS

Fastrac

60 - 05 - 01/1

*125, 135, 145, 150, 155, 185, 1115 & 1135 *

Data - Electrics (125, 135, 145, 150, 155, 185) System Type Batteries Cold crank amps for 1 minute to 1.4 Volts per cell at -18 deg C (0 deg F) Reserve capacity (minutes) for 25 Amp load

* Alternator Maximum output at maximum engine speed

12 Volts, negative earth Two batteries, each 12 Volts, in parallel 800, each battery 200, each battery

Lucas A133: 80 Amps Magneti Marelli: 85 Amps Bosch: 85 Amps

Starter Motor Starter motor

Lucas M127/2.8 Lucas M127/2.8

Light Bulbs Headlights main/dip Working lamps Front side lamps Tail lamps Stop lamps Indicator lamps Indicator side repeater lamps Reversing lamps Number plate lamps Fog lamps Interior lamps Panel/Warning lamps Beacon

60W/55W (Halogen) 55W (Halogen) 4W 10W 21W 21W 5W 21W 10W 21W 10W 1.7W 55W (Halogen)

Data - Electrics (1115 & 1135) System Type Battery Cold crank amps for 1 minute to 1.4 Volts per cell at -18 deg C (0 deg F) Reserve capacity (minutes) for 25 Amp load

12 Volts, negative earth

800 200

Alternator Maximum output at maximum engine speed

65 Amps

Starter motor

Lucas M127/2.8

Light Bulbs Headlights main/dip Working lamps Front side lamps Tail lamps Stop lamps Indicator lamps Indicator side repeater lamps Reversing lamps Number plate lamps Fog lamps Interior lamps Panel/Warning lamps Beacon

60W/55W (Halogen) 55W (Halogen) 4W 10W 21W 21W 5W 21W 10W 21W 10W 1.7W 55W (Halogen)

9804/1103

60 - 05 - 01/1

Issue 4*

CONTENTS

Fastrac

60 - 05 - 01/1A

* 2000 SERIES MACHINES Data - Electrics

System Type Battery Cold crank amps for 1 minute to 1.4 Volts per cell at -18 deg C (0 deg F) Reserve capacity (minutes) for 25 Amp load

12 Volts, negative earth

Alternator

100 Amps

Starter motor

Lucas M127/2.8

800 200

Light Bulbs (12V rated unless specified otherwise) Headlights main/dip Working lamps Front side lamps Tail lamps Stop lamps Indicator lamps Indicator side repeater lamps Reversing lamps Number plate lamps Fog lamps Interior lamps Panel/Warning lamps Beacon 4WS Quadtronic control panel †

{

60W/55W (Halogen) 55W (Halogen) 4W 10W 21W 21W 5W 21W 10W 21W 10W 1.7W 55W (Halogen) 14 volts 18 volts

† See Electronic Control Unit, Bulb Renewal for further details.

Note: This machine is fitted with a “CAN-BUS” system which links certain Electronic Control Units (ECUs) on the vehicle. This stands for “Controlled Area Network” and uses a special cable in the vehicle harness which carries two (2) twisted signal wires. These carry digital messages and are covered by a metal foil casing called a “screen” to help prevent corruption from electrical interference. The CAN-BUS is used to send text and fault codes from the transmission controller to the instrument cluster as well as to share information between each other, such as vehicle set-up.

9804/1103

60 - 05 - 01/1A

Issue 2*

CONTENTS

Fastrac

60 - 05 - 01/1B

* 3000 SERIES MACHINES Data - Electrics

System Type Battery Cold crank amps for 1 minute to 1.4 Volts per cell at -18 deg C (0 deg F) Reserve capacity (minutes) for 25 Amp load

12 Volts, negative earth

Alternator

100 Amps

Starter motor

Lucas M127/2.8

800 200

Light Bulbs (12V rated unless specified otherwise) Headlights main/dip Working lamps Front side lamps Tail lamps Stop lamps Indicator lamps Indicator side repeater lamps Reversing lamps Number plate lamps Fog lamps Interior lamps Panel/Warning lamps Beacon 4WS Quadtronic control panel †

{

60W/55W (Halogen) 55W (Halogen) 4W 10W 21W 21W 5W 21W 10W 21W 10W 1.7W 55W (Halogen) 14 volts 18 volts

† See Electronic Control Unit, Bulb Renewal for further details.

Note: This machine is fitted with a “CAN-BUS” system which links certain Electronic Control Units (ECUs) on the vehicle. This stands for “Controlled Area Network” and uses a special cable in the vehicle harness which carries two (2) twisted signal wires. These carry digital messages and are covered by a metal foil casing called a “screen” to help prevent corruption from electrical interference. The CAN-BUS is used to send text and fault codes from the transmission controller to the instrument cluster as well as to share information between each other, such as vehicle set-up.

9804/1103

60 - 05 - 01/1B

Issue 2*

h h g g g g g g g g g g g g g g g g g g g g g g g g g g g g g g g g h

CONTENTS * 125,

Fastrac

135, 145, 150, 155

60 - 05 - 01 2

UK Machines to Serial No 635329

Data - Fuses The electrical circuits are protected by fuses. The fuses are located in a fuse box on the side of the switch console. If a fuse blows, find out why and rectify the fault before fitting a new one.

Note: The draft control, screenwipers, speedometer and radio are each protected by more than one fuse. The auxiliary sockets each have an individual 10 amp in-line fuse in addition to fuse B7. The in-line fuses are located behind the electronic linkage control panel. Fuse No.

Circuit

A1 A2 A3 A4 A5 A6 A7 A8

Spare Brake lights Rear wash/wipe, radio, draft control Front wash/wipe, horn Engine shut-off solenoid Beacon Powered windows 2WD, front & rear PTO solenoids (including PTO brakes), differential lock solenoid A9 Spare

Fuse Rating (Amps) 10 15 10 5 15 30 10

Fuse No.

Circuit

B1 Radio memory, interior lights, darft control memory B2 Hazard warning light B3 Front working lights B4 Rear working lights B5 Headlight flasher B6 Dip beam B7 Auxiliary sockets B8 Tachograph (when fitted) B9 Air conditioning and heater system C1 Reverse lights, neutral start switch, air conditioning and heater relay C2 Direction Indicators C3 Front wiper: park, intermittent relay C4 Instrument cluster, buzzer, switch position lights, speedometer C5 LH side light, rear fog light and number plate light C6 RH side light, front working light relay C7 Main Beam C8 Spare C9 Spare

Fuse Rating (Amps) 10 15 20 20 10 10 30 10 30 10 15 5 5 7.5 7.5 10

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160780

9804/1103

60 - 05 - 01/2

Issue 3*

h h g g g g g g g g g g g g g g g g g g g g g g g g g g g g g g g g h

CONTENTS * 125,

Fastrac

135, 145, 150, 155

UK Machines from 635330 to 636000 All Export Machines to 636000

Data - Fuses The electrical circuits are protected by fuses. The fuses are located in a fuse box on the side of the switch console. If a fuse blows, find out why and rectify the fault before fitting a new one.

Note: The draft control, screenwipers, speedometer and radio are each protected by more than one fuse. The auxiliary socket has a 10 amp in-line fuse in addition to fuse B7. The in-line fuse is located behind the electronic linkage control panel. Fuse No. A1 A2 A3 A4 A5 A6 A7 A8

* A9

Circuit

Fuse Rating (Amps) Neutral Start Circuit 5 Brake lights 10 Rear wash/wipe, radio, draft control 15 Front wash/wipe, horn 10 Engine shut-off solenoid 5 Electronic draft control (starter switch feed) 5 Spare 2WD, front & rear PTO solenoids (including PTO brakes), differential lock solenoid, 4WD engaged 10 Speedometer/tachograph 7.5

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60 - 05 - 01 3

Fuse No. B1 B2 B3 B4 B5 B6 B7 * B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9

Circuit

Fuse Rating (Amps) Radio memory, interior light 10 Hazard warning lights 15 Front working lights 20 Rear working lights 20 Headlight flasher 10 Dip beam 10 Auxiliary socket 30 Speedometer/tachograph 7.5 Air conditioning and heater system 30 Reverse lights, air conditioning and heater relay 10 Direction Indicators 15 Front wiper: park, intermittent relay 5 Instrument cluster, buzzer, switch position lights, speedometer 5 LH side light, instrument panel illumination, front and rear working light relays 7.5 RH side light, number plate lights, radio illumination, outline marker lights 7.5 Main Beam 10 Rear fog lights 5 Electronic draft control (permanent feed) 5

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170030

9804/1103

60 - 05 - 01/3

Issue 4*

I'@@L?g ?N@@1?g @@@?g

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?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>)?&R1?*>1?7R1?*>1?7R1?*>)T&>)?&R)?&R)?&R)?&R1?7R1?*>)T&>)?&R)?&R1?7R1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@9V@@@@@@LV'@?@@@?S@@X@@@LV'@@R@@@@@@@@@@@@@@@@@@X@@@LV'@@R@@@@@@@@@@X@@@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S@@@@@@@@)XN@@@@@@@8S@@@@)XN@@W@@@@@@@@?@@@@@@@?S@@@@)XN@@W@@@@@@@@?S@@@@)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@X@@@@)X@@@V'@@W&U@@@@1?@@@R'X@@@X@?@@@V'X@?*U@@@@1?@@@R'X@@@X@?7@@V'@1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LN@@XI4@XI4@@@@@LV'@@R'@@@@@?@@@LV'@@V4@X@@@?V@@LV'@@@@@?@@@LV'@@V4@T@@@?V@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X@@)X?S)X?W@@?S)XN@@LN@@?@@@@@S)XN@@L?S@@@@@@@@)XN@@?@@@@@S)XN@@L?S@>@@@@@V)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>@@@V1?*>)T&@@?*>1?@@1?@@@@@?@@@>1?@@1?*U@@@@@@@>1?@@@@@?@@@>1?@@1?*>@R'@@@@@1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@@@@@LN@@@R'@LV4@X@@@X@@@T@@@@V4@X@@@LV'@@V4@XI4@X@@@T@@@@V4@X@@@LV'@LV4@X@@@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?W@@@V)X@@@LN@)K?V@@?S@@@S@U@@@L?S@@@S)XN@@??V)K?S@@@S@U@@@L?S@@@S)XN@)K?V@@@>)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@@@@@>1?3@@@@@@?*U@@@>@@@@1?*U@@@>1?@@@@@@@@@U@@@>@@@@1?*U@@@>1?3@@@@@@V'>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g 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CONTENTS

Fastrac

60 - 05 - 01/4

125, 135, 145, 150, 155, 185

*From m/c no. 636001

Data - Fuses The electrical circuits are protected by fuses. The main fuse block A contains 27 fuses. It is located, together with an inline fuse W, under switch panel B. Machines with Anti-lock Braking System (ABS) for trailers have the additional fuses X, Y and Z. There are also six lighting circuit fuses behind a panel to the left of the steering column and some enginemounted fuses on Perkins 160TW (Euro 1) and Cummins engines (see next page). Note: When a priority flow service is fitted, a 5 Amp in-line fuse V is fitted inside the switch console. If a fuse blows, find out why and rectify the fault before fitting a new one. To gain access to the main fuse block and fuses X, Y and Z, remove screws C and carefully lift panel B. Fuse No.

Circuit

A1 Clutch depressed start circuit, Selectronic range change solenoids (when fitted) A2 Brake lights. A3 Rear wash/wipe, air conditioning relay. A4 Front wash/wipe, horn. A5 Engine shut-off solenoid. A6 Electronic draft control (starter switch feed). A7 Powersplit. A8 2WD, front & rear PTO solenoids (including PTO brakes), differential lock solenoid, 4WD engaged. A9 Tachograph IGN feed. Also (from m/c no 636369) Selectronic IGN feed and speedometer

Fuse Rating (Amps)

5 10 10 10 5 5 7.5

10

Fuse No.

Circuit

B1

Radio memory, interior lights, beacon socket, digital clock 7.5 Hazard warning lights 15 Front working lights 20 Rear working lights 20 Headlight flasher 15 Radio/cassette power feed 7.5 Auxiliary socket 20 Tachograph (battery feed). Also (from m/c no 636369) Selectronic anti-surge 7.5 Air conditioning and heater system 30 Reverse lights 10 Direction Indicators 7.5 Cold start system 15 Speedometer to m/c no 636368 only, Instrument cluster, buzzer, switch position lights, delay relay for transmission oil pressure warning, cigar lighter 15 Selectronic range change solenoids (when fitted) 3 Starter solenoid 20 13 Pin trailer socket (charging circuit) 10 13 Pin trailer socket (permanent feed) 15 Electronic draft control (permanent feed) 3 Feed to main side and head light switch. 40 ABS solenoids 25 ABS electronics 5 ABS bulbs 3

B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4

C5 C6 C7 C8 C9 W X Y Z

Fuse Rating (Amps)

7.5

S193072

9804/1103

60 - 05 - 01/4

Issue 5*

h h g g g g g g g g g g g g g g g g g g g g g g g g g g g g g g g g h

CONTENTS

Fastrac

125, 135, 145, 150, 155, 185

60 - 05 - 01 5

All Machines from 636001

Data - Fuses (continued) Fuses from m/c no. 636001 (continued) To ga n access o he s x gh ng c cu s acken sc ew A and open he pane Fuse No

D1 D2 D3 D4 D5 D6

uses s ed be ow

C rcu

Fuse Ra ng Amps

Ma n beam D p beam Rea og gh s LH s de gh ns umen pane um na on RH s de gh cab oo um na on Aux a y gh e ays

15 15 10 75 75 5

Eng ne moun ed Fuses Perk ns 160TW Euro 1 on y E F G

Eng ne Shu o Sys em ESOS Man o d Hea e on Man o d Hea e ea

40 60 60

* Eng ne moun ed Fuses Cumm ns To ga n access o he eng ne moun ed uses pu o he e evan p as c cove as shown The man o d hea e uses ed om mach ne numbe 637635 on a e each e a ned by wo nu s L H J K

Eng ne Shu o sys em ESOS Man o d Hea e s a e mach nes Man o d Hea e s a e mach nes

40 100 100

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N@@@@)X?fV4@@@@@@6K @@@@5? J@@@@@@5 ?@@@@?h3@@@ 7@@@@H N@@@@1 @@@L ?W&@@@@@ ?3@@@@)XgI4@@@@@@6KeO@K? ?J@@@@ ?W&@@@@@(Y ?@@@@LhN@@@L? ?J@@@@5? ?3@@@@ @@@1 W&@@@@ ?V'@@@@)X?gI'@@@@@@@@@@@@@6?2@6?2@@@@@@@6?&@@@@1? W&@@@@@(Y? ?@@@@@hJ@@@)Xe?W&K?O@KheO&@@@@H? ?N@@@@L? @@@5 ?W&@@@@@ V'@@@@)Xg?V4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? ?W&@@@@@@H ?@@@@Hh7@@@@)K?O&@@@@@@@@@@@@@@@@@@@@@@ 3@@@1? @@@H O&@@@@ ?V'@@@@)K?heI4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? W&@@@@@@5? ?@@@@?h3@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5 N@@@@? @@@? W2@@@@@@ V4@@@@@6K? ?I4@@@@@0M?I4@@@0Y@@@@@? 7@@@@@@(Y? ?@@@@LhN@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@H ?@@@@? @@@? ?O&@@@@(M? I'@@@@@6X? @@@@@? ?J@@@@@@@H ?@@@@@h?@@@@@@@@0M? ?@@@@? ?3@@@? @@@? O2@@@@@@0Y ?V4@@@@@)K @@@@@? W&@@@@@@5? ?@@@@Hh?@@@(M ?3@@@? ?N@@@? @@@? O2@@@@@@0M ?I'@@@@@6K @@@@@? ?W&@@@@@@(Y? ?@@@@?h?@@@H? ?N@@@? @@@L @@@? O2@@@@@@0M V4@@@@@@@6K? @@@@@? ?7@@@@@@@H ?@@@@?h?@@@ ?J@@5? @@@1 @@@?h?O2@@@6?2@@@@@@@@@@@0M I4@@@@@@@@@@6K @@@@@? J@@@@@@@5? ?@@@@Lh?@@@ ?7@@H? @@@@ @@@?f?W&?2@@@@@@@@@@@@@@@@@(M I4@@@@@@@@@@@@@6?@K? @@@@@? ?W&@@@@@@(Y? ?@@@@1hJ@@@ ?3@@ @@@@ @@@?f?7@@@@@@@@@@@@@@@@@@@0Y? I4@@@@@@@@@@@@@@@@@@@6KO@?g@@@@@L O@K?gO@K? ?O26K? ?O@?@K O@K? ?O@Ke?O2@@6?2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6?@K?O@?2@@6?26K ?7@@@@@@@H ?@@@@@g?W&@@@ @@ @@@@ @@@?f?@@@@@@@@@@@@@@@0M ?I4@@@@@@@@@@@@@@@@@@?g@@@@@)K?eO@K?eO@?26KO@K?eO@K?f?O@K?O@?2@6KfO@?@K?eO26Kf?O@?@K?O26KO@?26K??O@?@?@KO2@6?@K?eO@K?fO@?2@@@6?@?@?2@@@@@6?2@@@@@6?2@@@@@6KO2@@@6KO@KO@KO2@6?2@@@@@@@@@@6KO26?2@6?2@@@6?26?@?@?2@@@@@@@@@@6?2@@@6?2@@@@@@@@@@@@@@@@@@@@@@@@@ @6?2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? J@@@@@@@5? J@@@@@gO&@@@@ ?7@@ @@@@ @@@?f?@@@@? ?I4@@@@@@@@@@@5?g@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@ @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5? ?W&@@@@@@(Y? 7@@@@@@@@@@@@@@@@@ ?@@@ @@@@ @@@?f?@@@@? ?@@@H?g@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@ @@@@@@@@@@0?4@@@@@@@0M I40MeI4@0MI40MI4@@0?4@@@@@0Y? ?7@@@@@@(Y 3@@@@@@@@@@@@@@@@@ ?@@@ @@@@ @@@?f?@@@@? ?@@@h@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0MI4@@@@0M?eI40M ?I'@@@@@@@@? J@@@@@@(Y? V4@@@@@@@@@@@@@@@@ ?@@@ @@@@ @@@?f?@@@@? ?@@@h@@@@@(M? V'@@@@@@@? ?W&@@@@@@H @@@@ ?@@@L? @@@@ @@@?f?@@@@? ?@@@h@@@@@H ?N@@@@@@@? ?7@@@@@@5? @@@@ ?@@@1? @@@@ @@@?f?@@@@? ?@@@h@@@@@? @@@@@@@? J@@@@@@(Y? @@@@ ?@@@@? @@@@ @@@?f?@@@@? ?@@@h@@@@@? @@@@@@@? ?W&@@@@@@H @@@@ ?@@@5? @@@@ @@@?f?@@@@? ?@@@h@@@@@? @@@@@@@? W&@@@@@@5? @@@@ ?@@@H? @@@@ @@@?f?@@@@? ?@@@h@@@@@? @@@@@@@? 7@@@@@@(Y? @@@@ ?3@@ @@@@ @@@?f?@@@@? ?@@@h@@@@@? @@@@@@@? ?J@@@@@@(Y 3@@@ @@L? @@@@ @@@?f?@@@@? ?@@@h@@@@@? @@@@@@@? W&@@@@@@H? ?@@@ ?@@@1? @@@@ @@@?f?@@@@? ?@@@h@@@@@? @@@@@@@? 7@@@@@@@ 7@@@ @@@? @@@@ @@@?f?@@@@? ?@@@h@@@@@? @@@@@@@? ?J@@@@@@@5 @@@@ ?7@@5? @@@@ @@@?f?@@@@? ?@@@h@@@@@? @@@@@@@? W&@@@@@@(Y @@@@L? ?@@@ @@@@ @@@?f?@@@@? ?@@@h@@@@@? @@@@@@@? 7@@@@@@(Y? @@@@@? ?@@@@? @@@5 @@@?f?@@@@? ?@@@h@@@@5? @@@@@@@? ?J@@@@@@@H @@@@H? ?@@@H? @@@? @@@?f?@@@@? ?@@@h@@@@ @@@@@@@? W&@@@@@@5? @@@@L? ?@@@L? @@@1 @@@?f?@@@@? ?@@@h@@@@1? @@@@@@@? 7@@@@@@(Y? @@@@@? ?@@@@? @@@5 @@@?f?@@@@? ?@@@h@@@@@? @@@@@@@? ?J@@@@@@@H @@@@H? ?@@@H? @@@H @@@?f?@@@@? ?@@@h@@@@@? @@@@@@@? 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J@@@@@@(Y? @@@@ ?@@@ @@@@ @@@?f?@@@@? ?@@@h@@@@ ?O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@)X @@@@@@5? ?W&@@@@@(Y @@@@ ?@@@ @@@@ @@@?f?@@@@? ?@@@h@@@@ @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1 @@@@@@H? ?7@@@@@@H? @@@@ ?@@@ @@@@ @@@?f?@@@@? ?@@@h@@@@ ?J@@@@(M ?I'@@@@@ @@@@@@ J@@@@@@@ @@@@ ?@@@ @@@@ @@@?f?@@@@? ?@@@h@@@@ ?7@@@@H? V'@@@@ @@@@@@L? 7@@@@@@@ @@@@ ?@@@ @@@5 @@@?f?@@@@? ?@@@h@@@@ ?@@@@@ W2@@@@@@6X ?N@@@@ @@@@@@1? ?J@@@@@@ @@@@ ?@@@ @@@H @@@?f?@@@@? ?@@@h@@@@ ?@@@@@ ?W&@@@@@@@@, @@@@ @@@@@@5?

D6 D5 D4 D3 D2 D1

S193081

9804/1103

60 - 05 - 01/5

Issue 3*

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?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S@@@@@@@@)XN@@@@@@@8S@@@@)XN@@W@@@@@@@@?@@@@@@@?S@@@@)XN@@W@@@@@@@@?S@@@@)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@X@@@@)X@@@V'@@W&U@@@@1?@@@R'X@@@X@?@@@V'X@?*U@@@@1?@@@R'X@@@X@?7@@V'@1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LN@@XI4@XI4@@@@@LV'@@R'@@@@@?@@@LV'@@V4@X@@@?V@@LV'@@@@@?@@@LV'@@V4@T@@@?V@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X@@)X?S)X?W@@?S)XN@@LN@@?@@@@@S)XN@@L?S@@@@@@@@)XN@@?@@@@@S)XN@@L?S@>@@@@@V)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>@@@V1?*>)T&@@?*>1?@@1?@@@@@?@@@>1?@@1?*U@@@@@@@>1?@@@@@?@@@>1?@@1?*>@R'@@@@@1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@@@@@LN@@@R'@LV4@X@@@X@@@T@@@@V4@X@@@LV'@@V4@XI4@X@@@T@@@@V4@X@@@LV'@LV4@X@@@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?W@@@V)X@@@LN@)K?V@@?S@@@S@U@@@L?S@@@S)XN@@??V)K?S@@@S@U@@@L?S@@@S)XN@)K?V@@@>)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@@@@@>1?3@@@@@@?*U@@@>@@@@1?*U@@@>1?@@@@@@@@@U@@@>@@@@1?*U@@@>1?3@@@@@@V'>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@@@@@XI4@LV4@@@@@LV4@@V4@T@@@LV4@@V4@T@@@@@@@@V4@@V4@T@@@LV4@@V4@LV4@@@@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?W@X?S)X?S)X?W@X?S)X?W@L?S@U?S)X?W@L?S@U?W@X?W@L?W@L?S@U?S)X?W@L?S)X?W@X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?W2@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@W&@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5?g ?@@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@5?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@(Y?g I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0Yh

CONTENTS

Fastrac

60 - 05 - 01/6

FASTRAC 1115 & 1135 Data - Fuses Fuses The electrical circuits are protected by fuses. The main fuse block A contains 27 fuses. It is located, together with an inline fuse W, under switch panel B. There are also six lighting circuit fuses D1 - D6 behind a panel to the left of the steering column. If a fuse blows, find out why and rectify the fault before fitting a new one. To gain access to the main fuse block, remove screws C and carefully lift panel B. Fuse No.

A1 A2 A3 A4 A5 A6 A7 A8

A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4

C5 C6 C7 C8 C9 W D1 D2 D3 D4 D5 D6

Circuit

Clutch depressed start circuit, Selectronic range change solenoids Brake lights. Rear wash/wipe, air conditioning relay Front wash/wipe, horn Engine shut-off solenoid. Electronic draft control (starter switch feed). Powershift 2WD, front & rear PTO solenoids (including PTO brakes), differential lock solenoid, 4WD engaged Selectronic IGN feed and speedometer Radio memory, interior lights, beacon socket, digital clock. Hazard warning lights. Front working lights. Rear working lights. Headlight flasher. Radio/cassette power feed. Auxiliary socket. Selectronic anti-surge. Air conditioning and heater system. Reverse lights. Direction indicators. Cold start system Instrument cluster, buzzer, switch position lights, delay relay for transmission oil pressure warning, cigar lighter. Selectronic range change solenoids Starter solenoid 13 Pin trailer socket (charging circuit). 13 Pin trailer socket (permanent feed). Electronic draft control (permanent feed). ‘Maxifuse’ - Feed to main side and head light switch. Main beam. Dip beam. Rear fog lights. LH sidelight, instrument panel illumination. RH sidelight, cab roof illumination. Auxiliary light relays.

9804/1103

Fuse Rating (Amps)

5 10 10 10 5 5 7.5

10 7.5 7.5 15 20 20 15 7.5 20 7.5 30 10 7.5 15

15 3 20 10 15 3 40 15 15 10 7.5 7.5 5

60 - 05 - 01/6

D6 D5 D4 D3 D2 D1

A229261

Issue 3

CONTENTS

Fastrac

60 - 05 - 01/6A

2000 & 3000 SERIES MACHINES Data - Fuses * Fuses The electrical circuits are protected by fuses. The main fuse block A contains 27 fuses. It is located, together with fuses E, F, W and X (Series 2000 only), under switch panel B. To gain access, disconnect the battery, remove screws C and carefully lift panel B. There are also six lighting circuit fuses D1 - D6 behind a panel to the left of the steering column. If a fuse blows, find out why and rectify the fault before fitting a new one. Fuse No. A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1

C1 C2 C3 C4

C5 C6 C7

C7

C8 C8

Circuit

Fuse Rating (Amps) Clutch start. 5 Brake lights. 10 Rear wash/wipe, suspension seat, 2WD dump relay, fuse E3. 15 Front wash/wipe, horn. 10 ESOS start relay (3185 only), ESOS, Waxstat. 7.5 EDC IGN. 5 Transmission controller. 15 2WD, front & rear PTO, differential lock solenoids, PTO brake relay. 15 Cab heater (3000 series only), ACU, compressor clutch, 30 Radio memory, interior light, beacon socket, AG panel illumination. Hazard warning lamps. Front work lights. Rear work lights. Headlight flasher. Radio/cassette power supply. Auxiliary socket. Cigar lighter. EDC battery, instrument cluster battery.

7.5 15 30 20 15 7.5 20 10

Air drier, gearbox neutral start.

10

D1 D2 D3 D4 D5 D6

15 15 10 7.5 7.5

E1 E2 E3 E4 E5 * †F1 * †F2 * †F3 * †F4

Main beam Dipped beam Rear fog lights LH sidelights RH sidelights Auxiliary lights switching (3000 series) Not used (2000 series) ABS trailer socket ABS trailer socket Flow divider 4 wheel steer (2000 series, except 2150) Not used Tractor ABS Tractor ABS Tractor ABS Tractor ABS

W *X

‘Maxifuse’ - Feed to side and headlight switch 40 Steering control system (4WS) (2000 Series only) 5

5 25 5 5 5 3 10 10 5

Engine-mounted Fuses (3185 machines) To gain access to the engine-mounted fuses, pull off the relevant plastic cover as shown. The manifold heater fuses are each retained by two nuts J. F G H

Engine Shut-off System (ESOS) Manifold Heaters (Megafuse) Manifold Heaters (Megafuse)

40 Amps 100 Amps 100 Amps

* † Refer to appropriate schematic for Fuse Functions.

3

13 pin trailer socket reverse lights supply (2000 Series to S/N 738748, 3000 Series to S/N 640777) Reverse lights ( 2000 Series from S/N 738749, 3000 Series from S/N 640778) Direction indicators. Thermostart (all except 3185), starter heater relays (3185 only) Instrument cluster, lights switch illumination, speedometer sender, diagnostic connector, differential lock cut-out switch, fuse C5, warning bleeper. Radar, fuel flow meter. Starter motor solenoid. 13 Pin trailer socket ignition supply (2000 Series to S/N 738748, 3000 Series to S/N 640777). Auxiliary socket ignition supply (2000 Series from S/N 738749, 3000 Series from S/N 640778) 13 Pin trailer socket battery supply (2000 Series to S/N 738748, 3000 Series to S/N 640777). Auxiliary socket battery supply (2000 Series from S/N 738749, 3000 Series from S/N 640778)

9804/1103

C9

5 10 7.5 30

7.5 3 20

10

5 15

20

60 - 05 - 01/6A

8020 - C/1-2.5

Issue 3*

CONTENTS

Fastrac

60 - 05 - 01/6B

2000 & 3000 SERIES MACHINES Data - Fuses (continued) *

F

E 1 2

W

3 4

1 A

2

3

4

5

6

7

8

9

F

A

B C

X B 1 3 5

0

IG N

G

H HS

C

2 4 6

C

H

J

A286502

D2 D3 D4 D5 D6

D1 D5 D4 D3 D2 D1 2000 Series 9804/1103

A302640

A302650

3000 Series

60 - 05 - 01/6B

8020-C/1-2A.3

Issue 3*

h h g g g g g g g g g g g g g g g g g g g g g g g g g g g g g g g g h

CONTENTS *

Fastrac

60 - 05 - 01 7

125, 135, 145, 150, 155

To Machine number 636000

Data - Relay Identification Although some 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 the correct relay part number is used, otherwise the machine electrical circuits will not function properly. All the relays shown at A or B are housed in the front console behind access panel X. In addition, the two neutral start relays are positioned to the right of the steering column. The rear wiper relay is positioned near the rear wiper switch.

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J@@5 ?31? ?O2@@0M?g?O2@@0M?e?7@@@@@@@@@@@@@@@@@@?@@?@1g@0M?e?@?@@@@?@@?@@@@@@@@@@@@@@@e?@@@@@@@@@@@@@@@@@@@@@@@V@@@@@@@@(YJ@@@?@6X@@@@@@@0Y ?@)KgI4@6K? ?W&5 75e?O&@e?@H?hfO&5??7@5 ?@1?e@@ ?3L?e31 3@1? 7@@@@(Y? ?N@? ? @? 7@@H ?N@L O2@0M?hO2@0M?g?@@@@?I'@@@@@@@@@?g@@ ?I'@@@@@@@@@@@@@@@@@@@eJ@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@H?@@@@X@V@@@@@@(M I46KgI4@6X? ?7@HeW. @Y?O2@@@W2@5hf?@@(Y?J@@H ?@@?e3@ ?N)XeN@L? N@@? ?J@@@@@H @? ? @? @@@? @1 O2@0M?g?O2@@0M?h?@@@@?e@@@@@@@@@?O@?@6T@@ ?@@@@@@@e@@@@@@@@@@e7@@@@@@@@@@@@@@@@@@@@@@@@@@@@@e@Lf;@@?@@@@@0Y? I'6XgI4)K ?@5?e7H @@@@@@@@@@@?e'6X?gJ@(Ye7@5? ?@@?eN@ 31e?31? ?3@L W&@@@@5? @? ? ?J5? @@@? 3@L? O2@0M?g?O2@@0M?he?@@@@?O&@@@@@@@@@@@@?@@0M?hfW&f7@V'@W@@@@@@@@@@@@@5e@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@)?@?@X@@@@@@0M? ?V4)K?gI46K J(Y??J5? @@@@@@@@@@@)K?V4)Kf?W&(Y?e@(Y? ?@@?e?@ N@e?N@L ?N@1 ?W&@@@@0Y? @@g?J@? ? ?7H? ?J@@5? 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J@H??J(Y ?V4@@)X?V'?J@5eO&@(Y? ?3@?e?@ 3Le?3L? ?@ W&@@(Y 7@H?g?@H? ? 7H ?@@@ N@f?W2@@?h?O2@0M J@@@H?@@@@@@@@@@@@X?W-X?e@( @??78?V@@?@@@?@@@@@@@?e@@@@@@@@@@@@@@@@@@@@@@@@@X@@@@@?@@@@@@0M I4@6K?f?I'@6X 75e?7H? @@)Xe?7(Y?@@@(Y ?N@?e?@ N1e?N)X ?@ ?W&@@(Y? ?J@5h?@ ? @? ?@@5 ?3L?e?&0Mhe@0M? 7@@@e@@@@@@@@@?@@1?*@1?e(Y @??3T2@@@?@@@@@@@@@@@?e@@@@@@@@@@@@@@@@@@@@@@@@V@@@@@@?@@@@0M I4@6K?fV4@)K? ?J(YeJ5 ?C@@@)K??@H??@@(Y? @?e?@ ?3L?e31 ?@ W&@@(Y W&(Yh?@ ? @? ?@@H ?N1?hfW2@? @@@@?J@?@@@@@@@@@@@?S@@?f?@e'@(??@g?N@@@@@@@@@@@@@@@@@?e@@@@@@@@@@@@@@@@@@@@@@@@@@@@?@@@@(M? I4@6K?f?I'6K? W&H??W&H ?W2(MI'@@@@@W2@@(Y @?e?@ ?V/?eN@ ?@ ?W&@@@H? 7(Y?hJ@ ? J@@? @Lhf.M @@@@?@@?@@@@@@@@@@@?7R'Lf?@eV+Y??@g?C@@W@@@@@@@@@@@@@@?e@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@(Y I'@6X?fV4@6X? 75e?75? O&(YeV'@@@@@@@(Y? @?e?@ ?@L? ?@ O&@@@@ ?J@Hhe75 ? ?@ @@@L 3)X? @@@@?N@?3@@@@@@@@@@W@LN1e@K ?'@@R40Y@@X@@@@@@@@@@?e@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0Y? ?V4@)KgI4)K ?J@HeJ(Y? W2@(Y?e?V4@@@@@0Y @?e?@ ?31? ?@ W2@@@(M? W&5?h?J@H ? ?@ ?@@1 V'1? @@@@e@??@@@@@@@@@@@R)T5?J@@@?hf?S@@e?:(R@@@@@@@@@@@?e@@@@@@@@@@@@@@@@@@@@@@@@@@@@(M I'6KgI'@6X? ?75?e7H ?W&@0Yg?I4@0M @?e?@ ?N@L ?@ ?W&@@@0Y 7(Y?h?7@? ? J@ 7@@5 ?V'L @@@@e@?7@@@@@@@@@@@@@@UO&>@@?hf@(M??W2@Y?@@@@@@@@@@@?e@@@@@@@@@@@@@@@@@@@@@@@@@@@0Y? ?V'@6Xf?V4@)K J@H??J@? W&(M @?e?@ 31 ?@ O&@@@? ?J@Hhe?@5? ? 75 @@@? V/K? ?O2@@@@5f@@@@@@@@@@@@@(R4@@@R'??@he(YeO&@@@@@@@@@@@@@@@?e@@@@@@@@@@@@@@@@@@@@@@@@@0M? V4@)K?f?I4@6K ?W&5eW&5? ?O&0Y? @?e?@g?@ N@L? ?@ W2@@@@@? W&5?he?@H? ? @H @@@1 ?V'6X? ?W2@@@@@@??@@@@@@@@@@@@@@@@Ye?W5? ?@@
Y

X 174790

View A - UK Machines to serial No. 635329 C D E F G H

Buzzer Front wiper intermittent Air conditioning Front working lights Rear working lights Flasher Unit

C D E

H G F

174800

A

View B - UK Machines from Serial No. 635330 to 636000 and all Export Machines to 636000 J K L M N P

4WD Engaged light Front wiper intermittent Air conditioning Front working lights Rear working lights Buzzer

J K L

Note: When a second trailer flasher warning is fitted, the flasher unit is mounted on the fuse block, behind panel Y.

B 9804/1103

60 - 05 - 01/7

P N M

174810

Issue 3*

W2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K?h ?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@h ?7@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@L?g ?7@(M? I'@@L?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1?g ?@@H ?N@@1?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@? @@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W2@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>)?&R1?*>1?7R1?*>1?7R1?*>)T&>)?&R)?&R)?&R)?&R1?7R1?*>)T&>)?&R)?&R1?7R1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@9V@@@@@@LV'@?@@@?S@@X@@@LV'@@R@@@@@@@@@@@@@@@@@@X@@@LV'@@R@@@@@@@@@@X@@@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S@@@@@@@@)XN@@@@@@@8S@@@@)XN@@W@@@@@@@@?@@@@@@@?S@@@@)XN@@W@@@@@@@@?S@@@@)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@X@@@@)X@@@V'@@W&U@@@@1?@@@R'X@@@X@?@@@V'X@?*U@@@@1?@@@R'X@@@X@?7@@V'@1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LN@@XI4@XI4@@@@@LV'@@R'@@@@@?@@@LV'@@V4@X@@@?V@@LV'@@@@@?@@@LV'@@V4@T@@@?V@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X@@)X?S)X?W@@?S)XN@@LN@@?@@@@@S)XN@@L?S@@@@@@@@)XN@@?@@@@@S)XN@@L?S@>@@@@@V)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>@@@V1?*>)T&@@?*>1?@@1?@@@@@?@@@>1?@@1?*U@@@@@@@>1?@@@@@?@@@>1?@@1?*>@R'@@@@@1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@@@@@LN@@@R'@LV4@X@@@X@@@T@@@@V4@X@@@LV'@@V4@XI4@X@@@T@@@@V4@X@@@LV'@LV4@X@@@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?W@@@V)X@@@LN@)K?V@@?S@@@S@U@@@L?S@@@S)XN@@??V)K?S@@@S@U@@@L?S@@@S)XN@)K?V@@@>)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@@@@@>1?3@@@@@@?*U@@@>@@@@1?*U@@@>1?@@@@@@@@@U@@@>@@@@1?*U@@@>1?3@@@@@@V'>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@@@@@XI4@LV4@@@@@LV4@@V4@T@@@LV4@@V4@T@@@@@@@@V4@@V4@T@@@LV4@@V4@LV4@@@@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?W@X?S)X?S)X?W@X?S)X?W@L?S@U?S)X?W@L?S@U?W@X?W@L?W@L?S@U?S)X?W@L?S)X?W@X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?W2@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@W&@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5?g ?@@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@5?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@(Y?g I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0Yh

CONTENTS

* 125,

Fastrac

135, 145, 150, 155, 185

60 - 05 - 01/8

From Machine number 636001

Data - Relay Indentification

*

S198891

9804/1103

60 - 05 - 01/8

Issue 3*

CONTENTS * 125,

Fastrac

135, 145, 150, 155, 185

60 - 05 - 01/9

From m/no. 636001 to 637739

Data - Relay Identification (continued) Note: Relays which form part of the JCB Selectronic control circuit are identified by an alpha/numeric suffix, e.g. (PR5). This suffix is also used on the wiring diagram for the Selectronic system. Relays - Cab mounted 1 Neutral Start (2 relays) 2 Buzzer/Timer Latching (PR5) 3 High (H4) 4 Medium (H5) 5 Buzzer Earth (PR15) 6 Splitter Dump Latching ( H3) 7 Selectronic Splitter Dump (H1) 8 4WD Engaged Light 9 Air Conditioning 10 Powersplit 2 (Low) 11 Front Working Light 12 Timer Circuit Anti-surge (PR16) - early position 12A Timer Circuit Anti-surge (PR16) - later position 13 Rear Work Light 14 Intermittent Rear Wiper 15 Powersplit 1 (High) 16 Low (H6) 17 Rev (H7) 18 Speed Inhibit (H2) 19 Main Beam 20 Dipped Beam 21 RH Side Light Machines with auxiliary head 22 LH Side Light lights only. 23 LH Direction Indicator 24 RH Direction Indicator 25 Time Delay - Transmission Warning Light 26 Intermittent Front Wiper 27 Flasher 28 Differential Lock/Area Cut-out 29 Neutral Select (PR18) - from machine no. 636369 30 Buzzer

Relays - Electronic Draft Control (135, 155 and 185 from Machine No. 637734) Some 135, 155 and 185 machines may be fitted in service with an additional relay in the Alternator Signal line. See T.I. 10/100 (C45/N.Am) for details.

Other JCB Selectronic Components 31 Buzzer/Timer Unit 32 Diodes - Range Warning Lights - Splitter Latching.

A B C

198880

D

Relays - Engine Mounted (160TW Euro 1 Engine only) * A ESOS B Manifold Heater C Manifold Heater

E

Relays - Engine Mounted (185 from Machine No. 637635) D Manifold Heater E Manifold Heater

A277260

Relays - Engine Mounted (185 from Machine No. 637635) D Manifold Heater E Manifold Heater

9804/1103

60 - 05 - 01/9

8000 - C/1-8.5

Issue 3*

CONTENTS

* 155,

Fastrac

185

60 - 05 - 01/9A

From m/no. 637740

Data - Relay Identification (continued) Note: The illustration on page 60 - 05 - 01/8 is still generally applicable, see the illustrations on this page for the alterations. Relays - Cab mounted (Selectronic Transmission) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 29 33 34 35

Neutral Start (2 relays) Buzzer/Timer Latching (PR5) High (H4) Medium (H5) Buzzer Earth (PR15) Splitter Dump Latching ( H3) Selectronic Splitter Dump (H1) 4WD Engaged Light Air Conditioning Powersplit 2 (Low) Brakelights Timer Circuit Anti-surge (PR16) Rear Work Light Intermittent Rear Wiper Powersplit 1 (High) Low (H6) Rev (H7) Speed Inhibit (H2) Neutral Select (PR18) Front Work Lights Clutch Buzzer and Clutch Buzzer Delay (2 relays) Reverse Lights

S198891A

Other JCB Selectronic Components 31 Buzzer/Timer Unit 32 Diodes - Range Warning Lights - Splitter Latching

Relays - Cab mounted (Manual Transmission) 1 7 8 9 10 11 13 14 15 33 34 35

Neutral Start (2 relays) Selectronic Splitter Dump (H1) 4WD Engaged Light Air Conditioning Powersplit 2 (Low) Brakelights Rear Work Light Intermittent Rear Wiper Powersplit 1 (High) Front Work Lights Clutch Buzzer and Clutch Buzzer Delay (2 relays) Reverse Lights

9804/1103

S198891B

60 - 05 - 01/9A

8000 - C/1-9.1

Issue 1

CONTENTS

* 1115

Fastrac

& 1135

60 - 05 - 01/10

To m/no. 736577

* Data - Relay Identification

130 71 29 129 63 108B 108A

A234891

9804/1103

60 - 05 - 01/10

8010 - C/1-3

Issue 5*

CONTENTS * 1115

Fastrac

& 1135 (2WS)

60 - 05 - 01/11

From m/no. 736577

Data - Relay Identification (continued) (2WS machines to No. 736577) Note 1: The component identification key numbers listed below correspond with those used on the wiring diagrams. Note 2: Relays which form part of the JCB Selectronic circuit are identified by an alpha/numeric suffix , e.g. (PR5). This suffix is also used on the Selectronic system wiring diagram. * Note 3: Some machines may be fitted in service with an additional relay in the Alternator Signal line (Part of the Electronic Draft Control). See T.I. 10/100 (C45/N.Am) for details.

Wiring Diagram Key No.

Description

Wiring Diagram Page No.

7

Inhibit start 1

12 - 3

8

Inhibit start 2

12 - 3

22

Air conditioning (Ignition switched)

23

Intermittent rear wiper

29

Intermittent front wiper

12 - 7

32

Powersplit 1 (High)

12 - 11

33

Powersplit 2 (Low)

12 - 11

37

Neutral dump (H1)

12 - 11

43

4WD engaged light

12 - 12

53

2WD dump

12 - 12

12 - 5, 12 - 26 12 - 5

† 63

First trailer turn relay

12 - 15

† 71

Second trailer turn relay

12 - 15

75

Front work light

12 - 16

81

Rear work light

12 - 17

††108A

Main beam

12 - 23

††108B

Dipped beam

12 - 23

113

Air conditioning (compressor clutch)

12 - 26

129

Buzzer

12 - 29

130

Time delay - transmission warning light

12 - 29

153 (H4/H)

Range select - High (H4)

12 - 33

153 (H5/M)

Range select - Medium (H5)

12 - 33

153 (H6/L)

Range select - Low (H6)

12 - 33

153 (H7/R)

Range select - Rev (H7)

12 - 33

154 (H2)

Speed inhibit (H2)

12 - 33

157

Buzzer/timer latching (PR5)

12 - 35

158

Buzzer earth (PR15)

12 - 35

159

Neutral dump latching (H3) (PR11)

12 - 35

161

Neutral select (PR18)

12 - 33

162

Timer circuit anti-surge (PR16)

12 - 36

167

Area/diff. lock cut-out

12 - 38

Other Components †††

36

Diode connector packs

12 - 11, 12 - 33, 12 - 35, 12 - 36

†

Alternative items, fitted according to purchaser specification.

††

Fitted only on machines with auxiliary headlights.

†††

To identify a specific diode connector pack, cross check the wire numbers from the mating connectors against the wiring diagrams.

9804/1103

60 - 05 - 01/11

8010 - C/1- 4.4

Issue 3*

Fastrac

CONTENTS

60 - 05 - 01/11A

1115 & 1135 (2WS)

From m/c no. 736578

Data - Relay Identification (continued)

130 71 29 129 63 108B 108A

A234891

*

EE

A

EE

EE

FF

B

C

D

J

K

E

F

G

H

DD

R

S

T

X

Y

Z

U

V

L

M

N

P

W

AA BB CC A249151

9804/1103

60 - 05 - 01/11A

8010 - C/1-5.2

Issue 1

CONTENTS

Fastrac

60 - 05 - 01/11B

1115 & 1135 2WS machines from No. 736578, all 4WS Machines Data - Relay Identification (continued) Note 1: The component identification key numbers listed below correspond with those used on the wiring diagrams. Note 2: Relays which form part of the JCB Selectronic circuit are identified by an alpha/numeric suffix , e.g. (PR5). This suffix is also used on the Selectronic system wiring diagram. Note 3: Some 2WS machines may be fitted in service with an additional relay in the Alternator Signal line (Part of the Electronic Draft Control). See T.I. 10/100 (C45/N.Am) for details. Item

Colour

A B C D E F G (2WS)

Black Black Blue Green Green Green Green

7 8 162 161 53 175 167

G (4WS) H J K L M N P R S T U V W X Y Z AA BB CC DD

Blue Blue Green Green Green Blue Black Blue Green Green Blue Green Blue Green Green Green Green Black Blue Green

C16 C8 158 159 37 43 113 176 157 153 (H4/H) 153 (H5/M) 22 33 75 154 153(H7/R) 153 (H6/L) 32 23 81 167

FF

Other Components EE

† †† †††

Wiring Diagram Key No.

Description

122A 29 † 63 † 71 †† 108A †† 108B 130

Inhibit start 1 Inhibit start 2 Selectronic anti-surge (PR16) Neutral select (PR18) 2WD Dump Clutch warning Area/diff. lock cut-out (2WS machines only) - located at position DD on 4WS Diff. lock cut-out (4WS machines only) Alternator signal (4WS machines only) Buzzer earth (PR15) Neutral dump latching (H3) (PR11) Neutral dump (H1) 4WD Engaged Air conditioning (compressor clutch) Clutch warning delay relay (CR42) Buzzer/timer latching (PR5) Range select - High Range select - Medium Air conditioning (Ignition switched) Powersplit 2 (low) Front work light Speed inhibit Range select - Reverse Range select - Low Powersplit 1 (high) Intermittent rear wiper Rear work light Area/diff. lock cut out (4WS machines only) - located at position G on 2WS Reversing lights relay (CR11) Intermittent front wiper First trailer turn relay Second trailer turn relay Main beam Dipped beam Time delay - transmission warning light

††† 36

Diode connector packs

129 Buzzer (service malfunction) Alternative items, fitted according to purchaser specification. Fitted only on machines with auxiliary headlights. To identify a specific diode connector pack, cross check the wire numbers from the mating connector against the wiring diagrams.

9804/1103

60 - 05 - 01/11B

8010 - C/1-6.3

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 05 - 01/12

2000 & 3000 SERIES MACHINES *

Data - Relay Identification (Front of Cab)

M J

G

L

K

H

E

C

A

F

D

B

With Auxiliary Lights

A

B

C

D

E

F

E

C

A

F

D

B

Without Auxiliary Lights A303131

2000 Series

Item A B C D E F G H J K L M

9804/1103

Colour Blue Blue Blue Green Green Green Green Green Green Green

3000 Series

Description

Installation

Brake lights ‘A’ post work lights Fog lights Intermittent front wiper Single trailer turn Warning buzzer Auxiliary lights Auxiliary lights Auxiliary lights Auxiliary lights Auxiliary lights Auxiliary lights

60 - 05 - 01/12

Standard - all machines Optional - all machines Standard - all machines Standard - all machines Optional - all machines Standard - all machines Optional - 3000 Series Optional - 3000 Series Optional - 3000 Series Optional - 3000 Series Optional - 3000 Series Optional - 3000 Series

8020 - C/1-3.4

Issue 2*

CONTENTS

Fastrac

60 - 05 - 01/13

2000 & 3000 SERIES MACHINES Data - Relay Identification (continued) Relay Identification (Rear of Cab) * N

P

R

S

T

U

A1 B1 C1 D1 E1

F1

4 3 2 1 8 7 6 5

A303122

Item

Colour

N

Blue

P R S T U

Green Blue Green Black Blue

Description

Installation

Air conditioning unit compressor clutch 2WD dump Start inhibit 2 Diff. lock cut-out Intermittent rear wiper Start inhibit 1

Standard - all machines Standard - all machines Standard - all machines Standard - all machines Standard - all machines Standard - all machines

13 - pin trailer socket reverse lights relay Rear PTO drive cut-out relay 4WS diff. lock cut-out relay

Optional - all machines Optional - all machines Optional - 2115, 2125, 2135 only

Reverse lights relay Splitter safety dump Rear PTO drive cut-out relay Tractor ABS Tractor ABS 4WS diff. lock-out relay

Standard - all machines Standard - all machines Standard - all machines ABS Machines ABS Machines Optional - 2115, 2125, 2135 only

* Machines with Dry Clutch Transmission

V

Blue

W X

Green Green

* Machines with Wet Clutch Transmission

* * *

A1 B1 C1 D1 E1 F1

9804/1103

Blue Green Green Black Green Green

60 - 05 - 01/13

8020 - C/1-4.6

Issue 3*

CONTENTS

Fastrac

60 - 05 - 02/1

125, 135, 145, 150, 155, 185, 1115 & 1135 Data - External Hydraulics

Pump Type on

Front section (P3) of gear type double pump (triple pump 4WS machines), driven by PTO gearbox.

* Pump Flow at Maximum System Pressure All models except 1115 & 1135 to m/c no. 636000 at 2600 engine rev/min.

61 litres/min (13.4 UKgal/min, 16.1 US gal/min) 57 litres/min (12.5 UK gal/min,15.6 US gal/min) 73 litres/min (16 UK gal/min, 20 US gal/min)

All later machines - Standard pump at 2400 engine rev/min All later machines - Optional pump at 2400 engine rev/min Main Relief Valve Pressure - External Hydraulics

At 2400 rev/min

bar

kgf/cm2

lbf/in2

210

214

3045

Control Valve * Husco Valve (all models except 1115 and 1135 to Serial No. 637733 2115, 2125, 2135, 2150) Spool I

4-position, double acting spool with hydraulic kick-out and float. For single/double acting rams or motors.

Spool II and III

3-position, double acting spool without detent. For single double acting rams. Note: On some machines these spools are double acting with hydraulic kick-out and float.

Spool III

4-position, double acting spool with hydraulic kick-out and float. For 3-point linkage operation.

* Bosch Valve (all 1115 & 1135 machines from m/c no. 637734) Two-spool valve - spool I

Variable flow, 3-position, double acting spools with

Three-spool valve - spools I and II

hydraulic kick-out. For single/double acting rams or motors.

Four-spool valve - spools I and II Two-spool valve - spool II

Fixed flow, 4-position, double acting spools with hydraulic

Three-spool valve - spool III motors. Four-spool valve - spool III

kick-out and float. For single/double acting rams or

Four-spool valve - spool IIII

Fixed flow, 4-position, double acting spools with hydraulic kick-out and float. For front 3-point linkage operation.

9804/1103

60 - 05 - 02/1

8010 - E/1-1.4

Issue 7*

CONTENTS

Fastrac

60 - 05 - 02/1A

2000 & 3000 SERIES MACHINES * Data - External Hydraulics Pump Type

Front section (P3) of gear type double pump (triple pump on 4WS machines), driven by PTO gearbox.

Type 1† Flow at Maximum System Pressure Standard pump at 2400 engine rev/min Optional pump at 2400 engine rev/min

77 litres/min (17 UK gal/min; 20.3 US gal/min) 96 litres/min (21 UK gal/min; 25.4 US gal/min)

Type 1† Main Relief Valve Pressure At 2400 rev/min Early machines - non adjustable Later machines - adjustable

bar 210 210 + 0/-5

Type 1† Control Valve Two-spool valve - spool I Three-spool valve - spools I and II Four-spool valve - spools I and II

kgf/cm2 214 214 + 0/-5

lbf/in2 3045 3045 + 0/-72.5

Variable flow, 3-position, double acting spools with hydraulic kick-out. For single/double acting rams or motors.

Two-spool valve - spool II Three-spool valve - spool III Four-spool valve - spool III

Fixed flow, 4-position, double acting spools with hydraulic kick-out and float. For single/double acting rams or motors. Fitted with zero leak check valve.

Four-spool valve - spool IIII

Fixed flow, 4-position, double acting spools with hydraulic kick-out and float. For front 3-point linkage operation. Fitted with zero leak check valave.

Type 2 †† Flow at Maximum System Pressure At 1500 engine rev/min

60 litres/min (13.2 UK gal/min; 15.9 US gal/min)

Type 2 †† Main Relief Valve Pressure at 1500 rev/min

bar 210 + 0/-5

kgf/cm2 214 + 0/-5

lbf/in2 3045 + 0/-72.5

Type 2 †† Control Valve

† ††

Two-spool valve - spool I Three-spool valve - spools I and II or motors. Four-spool valve - spools I and II

Variable flow, 4-position, double acting spools with hydraulic kick-out and float. For single/double acting rams

Two-spool valve - spool II Three-spool valve - spool III Four-spool valve - spool III

Fixed flow, 4-position, double acting spools with hydraulic kick-out and float. For single/double acting rams or motors. Fitted with zero loak check valve.

Four-spool valve - spool IIII

Fixed flow, 4-position, double acting spools with hydraulic kick-out and float. For front 3-point linkage operation. Fitted with zero leak check valave.

Fitted with zero leak check valve.

2000 Series to S/N 739999, 3000 Series to S/N 641999 2000 Series from S/N 740000, 3000 Series from S/N 642000

DO NOT EXCEED STATED PRESSURE

Other Hydraulic Circuits Note: For technical data of other hydraulic systems, refer to the following pages: Transmission: 60 - 05 - 04/3 Steering: 60 - 05 - 10/4A Suspension: 60 - 05 - 10/5A

9804/1103

60 - 05 - 02/1A

8020-E/1-1.4

Issue 4*

CONTENTS * 125,

Fastrac

60 - 05 - 02/2

135, 145, 150, 155, 185, 1115, 1135

Data - Axles Front Axle Model Type Weight (approximate) Differential (from machine no. 636001) (to machine no. 636000)

SD55 Crown wheel and pinion primary reduction with epicyclic hub reduction 510 kg (1124 lb) Optional Maxtrac NoSPIN standard NoSPIN standard

Rear Axle Model Type Weight (approximate) Brakes

PD70 except Fastrac 185 (has PD90) Crown wheel and pinion primary reduction with epicyclic hub reduction 590 kg (1300 lb) Single caliper solid disc on each hub

Control Valve (from machine no. 636000) Type

Pressure Maintenance Valve Setting Check Valve Cracking Pressure Solenoid Valves Lubrication Pressure at 1500 rev/min

Remote, chassis-mounted control valve. Incorporates pressure maintenance valve, check valve and solenoid valves. Incorporates Differential Lock Control. 13.5 bar (195 lbf/in2) 1.5 bar (22 lb/in2) 12V dc, 3 position, 4-way 1 - 2 bar (14.5 - 29 lbf/in2)

Differential Lock Control Valve (from machine no. 636001) Type Pressure Maintenance Valve Setting at maximum engine speed

Solenoid and pressure maintenance valve for 'soft-engage' diff. lock mounted in suspension valve block 38 bar (550 lbf/in2)

Pump Type Flow Rate at 13.5 bar (195 lbf/in2) to machine no. 636000 from machine no. 636001

Rear section (P4) of gear type double pump, driven by P.T.O. gearbox. 16.4 litres/min (3.7 UK gal/min) at 2600 rev/min 28.8 litres/min (6.5 UK gal/min) at 2400 rev/min

Data - Main Clutch Type Nominal Diameter

9804/1103

Cover Plate: Diaphragm sprung with live drive for P.T.O. Box. Driven Plate: Spring centre, non-asbestos single dry plate. 350 mm (14 in)

60 - 05 - 02/2

Issue 3*

CONTENTS * 125,

Fastrac

60 - 05 - 04/1

135, 145, 150, 155, 185, 1115 & 1135

Data - Gearboxes

Power Take Off Gearbox Type Output to machine no. 636000 Output from machine no. 636001 Power Take Off Clutches

Live drive from engine; constant mesh with sliding sleeve non-synchromesh. 540 PTO rev/min at 1894 Engine rev/min or 1000 PTO rev/min at 2428 Engine rev/min 540 PTO rev/min at 2118 Engine rev/min or 1000 PTO rev/min at 2196 Engine rev/min Electro-hydraulic engagement. Multi-plate oil-immersed clutches with yoke output connections.

JCB Powersplit from machine no. 636001 Type Low Clutch Direct Drive High Clutch, Indirect Drive - early machines - later machines Clutch Pressure at 1500 rev/min

Low and High Splitter Clutches in PTO/Splitter Box 1 : 1 Ratio 1.27 : 1 Ratio 1.225 : 1 Ratio 13.5 bar (195 lbf/in2)

Speed Gearbox Type

6 speed (all forward) synchromesh

Note: Where local legislation demands, the speed gearbox may be limited to 5 speeds by the addition of a stop in the remote control housing to prevent engagement of 6th speed. Range Gearbox Type 4 Wheel Drive Clutch

High, medium, low and reverse ranges, all synchromesh. Yoke output to front axle. Flange output to rear axle. Spring-engaged, multi-plate, oil-immersed clutch. Electro-hydraulic disengagement to select 4WD.

Pump Type Flow Rate at 13.5 bar (195 lbf/in2) to machine no. 636000 from machine no. 636001

Rear section (P4) of gear type double pump, driven by PTO gearbox 16.4 litres/min (3.68 UK gal/min) at 2600 rev/min 28.8 litres/min (6.47 UK gal/min) at 2400 rev/min

Control Valve Type

Pressure Maintenance Valve Setting Check Valve Cracking Pressure Solenoid Valves Lubrication Pressure at 1500 rev/min

Remote, chassis-mounted control valve. Incorporates pressure maintenance valve, check valve and solenoid valves. Incorporates Differential Lock Control to machine no. 636000. 13.5 bar (195 lbf/in2) 1.5 bar (22 lbf/in2) 12V dc, 3 position, 4-way 1 - 2 bar (14.5 - 29 lbf/in2)

Differential Lock Control Valve (from machine no. 636001 and 736001) Type Pressure Maintenance Valve Setting at maximum engine speed

9804/1103

Solenoid and pressure maintenance valve for 'soft-engage' diff. lock mounted in suspension valve block 38 bar (550 lbf/in2)

60 - 05 - 04/1

Issue 5*

CONTENTS

Fastrac

60 - 05 - 04/2

2000 & 3000 SERIES MACHINES *

Data - Gearboxes Main Clutch (Dry Clutch Transmission †) Type

Cover Plate: Diaphragm sprung with live drive for P.T.O. Box. Driven Plate: Spring centre, non-asbestos single dry plate.

Nominal Diameter

350 mm (14 in)

Master Clutch (Wet Clutch Transmission ††) Type

Multiplate oil-immersed hydraulically actuated (pressure on to engage). Clutch drum/drum carrier transmit a live drive for P.T.O. box. Actuating hydraulic pressure measured at the control valve test point (TPE) at 1500 rev/min: Minimum - Clutch disengaged (pedal fully down) 0.7 - 1.4 bar (10 - 20 lbf/in2). Maximum - Clutch engaged (pedal fully up) 12 - 13 bar† (175 - 190 lbf/in2).

Power Take Off Gearbox Type

Live drive from engine; constant mesh with sliding sleeve - non synchromesh.

Output

540 PTO rev/min at 2118 Engine rev/min. or 1000 PTO rev/min at 2196 Engine rev/min.

Power Take Off Clutches clutches with yoke output connections.

Electro-hydraulic engagement. Multi-plate oil-immersed

JCB Powershift Type

Low, medium and High Splitter Clutches in PTO/Splitter Box

Clutch Pressure at 1500 rev/min

13.5 bar (195 lbf/in2)

Clutch Pack End Float

2 - 3 mm (when refitting used plates) 1.75 - 2.5 mm (when fitting new plates)

Transmission brake (wet clutch machine only)

Operating Pressure at 1500 rev/min - 13.5 bar (195 lbf/in2)

Speed Gearbox Type

6 speed (all forward) synchromesh

Range Gearbox Type

High, medium, low and reverse ranges, all synchromesh. Flange outputs to front and rear axles.

4 Wheel Drive Clutch

Spring-engaged, multi-plate, oil-immersed clutch. Electro-hydraulic dis-engagement to select 2WD.

† 2000 Series to S/N 739999, 3000 Series to S/N 641999 †† 2000 Series from S/N 740000, 3000 Series from S/N 642000

9804/1103

60 - 05 - 04/2

8020 - F/1-1.3

Issue 2*

CONTENTS

Fastrac

60 - 05 - 04/3

2000 & 3000 SERIES MACHINES *

Data - Transmission Pump (Dry Clutch Transmission †) Type

Rear section (P4) of gear type double pump (triple pump on 4WS machines), driven by PTO gearbox.

Flow Rate at 13.5 bar (195 lbf/in2)

28.5 litres/min (6.3 UK gal/min; 7.6 US gal/min) at 2400 rev/min

Pump (Wet Clutch Transmission ††) Type

Rear section (P4) of gear type double pump (triple pump on 4WS machines), driven by PTO gearbox.

Flow Rate at 13.5 bar (195 lbf/in2)

28.5 litres/min (6.3 UK gal/min; 7.6 US gal/min) at 1500 rev/min.

Control Valve (Dry Clutch Transmission †) Type

Remote, chassis-mounted control valve. Incorporates pressure maintenance valve, check valve and solenoid valves.

Pressure Maintenance Valve Setting

13.5 bar (195 lbf/in2)

Check Valve Cracking Pressure

1.5 bar (22 lbf/in2)

Solenoid Valves

12V dc, 3 position, 4-way

Lubrication Pressure at 1500 rev/min.

1 - 2 bar (14.5 - 29 lbf/in2)

Control Valve (Wet Clutch Transmission††) Type

Remote, chassis-mounted control valve. Incorporates pressure maintenance valve, check valve and solenoid valves.

Pressure Maintenance Valve Setting (CT1)

13.5 bar (195 lbf/in2)

Check Valve Cracking Pressure CT2 CT3 CT4

2 bar (29 lbf/in2) 5 bar (72.5 lbf/in2) 2 bar (29 lbf/in2)

Solenoid Valves

12V dc, 3 position, 4-way

Low Pressure Lubrication (LPL) at 1500 rev/min.

1 - 2 bar (14.5 - 29 lbf/in2)

† ††

2000 Series to S/N 739999, 3000 Series to S/N 641999 2000 Series from S/N 740000, 3000 Series from S/N 642000

9804/1103

60 - 05 - 04/3

8020 - F/1-2.3

Issue 2*

CONTENTS

Fastrac

60 - 05 - 04/4

2000 & 3000 SERIES MACHINES Data - Transmission Differential Lock Control Valve Type

Solenoid and pressure maintenance valve for 'soft-engage' diff. lock mounted in suspension valve block

Pressure Maintenance Valve Setting

38 bar (550 lbf/in2) at 2400 rev/min.

Front Axle Model

SD55 (2000 Series) SD70 (3000 Series)

Type

Crown wheel and pinion primary reduction with epicyclic hub reduction

Mounting

3 leading link control arms and Panhard rod

Weight (approximate)

SD55 - 510 kg (1124 lb) SD70 - TBA

Differential

SD55 - NoSPIN (standard) Maxtrac (optional) SD70 - Soft engaged differential lock with electro - hydraulic control

Rear Axle Model

PD70 (all 2WS machines except 3185) PD90 (3185 machines only) SD70 (4WS machines)

Type

Crown wheel and pinion primary reduction with epicyclic hub reduction

Mounting

2 trailing link control arms and 'V' link

Weight (approximate)

PD70 - 590 kg (1300 lb) PD90 - 555 kg (1224 lb) SD70 - TBA

Brakes

Single caliper solid disc on each hub

Differential

Soft-engaged differential lock with electro-hydraulic control

Note: For technical data on wheels and tyres, see Routine Maintenance, Section 3.

9804/1103

60 - 05 - 04/4

8020 - F/1-3.1

Issue 1

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CONTENTS

* 125,

Fastrac

60 - 05 - 06/1

135, 145, 150, 155, 185

Data - Tyre Pressures, Speeds and Loads The versatility of the JCB Fastrac dictates a range of tyre types which may be operated at differing loads and widely differing speeds. Agricultural type tyres are designated according to both their load carrying ability and their ability to operate at certain speeds.

! WARNING Running tyres outside recommended guidelines may result in failure of the tyres which at high speeds may endanger life. BE WARNED. 13-3-1-6

Generally, the speed at which a given tyre can operate depends upon inflation pressure and the load carried.

! WARNING

The table below gives the load carrying capacity per tyre at varying pressures and speeds. All tyres supplied as original equipment may be operated over the full speed range of the vehicle provided the pressure is correct and their loading is no higher than that given below.

High traction tyres available as optional equipment have maximum permitted speeds below the maximum speed of the vehicle. Brake efficiency is slightly reduced and stopping distance is increased when these tyres are fitted. They will suffer damage if operated at speeds higher than those recommended and may endanger life. 13-3-1-5

Note 1: Whatever the loading, it is desirable to inflate rear tyres to 0.3 bar (4.4 lbf/in2) higher than the pressures given which are for the front tyres. This results in improved handling. Note 2: It is recommended that tyres larger than 495 mm section width are not used on machines fitted with a NoSPIN Differential except for special applications as agreed with JCB Landpower.

! WARNING Wheels are heavy. Handle and store with care to ensure that they cannot fall and cause injury. 13-3-1-7

HIGH SPEED TYRES Tyre Size

Speed Designation

Pressure bar lbf/in2

Max load per tyre at speed of 30 kph (19 mph) 40 kph (25 mph) 70 kph (44 mph)

445/70 R 24 G 90 kph (56 mph) †It is unsafe to operate this tyre at this speed and pressure.

1.0 1.8 2.6 3.5

15 26 38 51

1675 kg (3693 lb) 2510 kg (5533 lb) 3350 kg (7385 lb) 4310 kg (9502 lb)

1540 kg (3395 lb) † 2310 kg (5093 lb) 2167 kg (4777 lb) 3080 kg (6790 lb) 2707 kg (5968 lb) 3970 kg (8752 lb) 3285 kg (7242 lb)

495/70 R 24

1.0 1.8 2.6 3.5

15 26 38 51

1890 kg (4167 lb) 2650 kg (5842 lb) 3415 kg (7529 lb) 4350 kg (9590 lb)

1725 kg (3803 lb) 2450 kg (5401 lb) 3180 kg (7011 lb) 4000 kg (8818 lb)

G

Max Speed

90 kph (56 mph)

1659 kg (3657 lb) 2301 kg (5073 lb) 2943 kg (6488 lb) 3665 kg (8080 lb)

HIGH TRACTION TYRES Tyre Size

Pressure bar lbf/in2

Max load per tyre at speed of 30 kph (19 mph) 40 kph (25 mph) 65 kph (40 mph)

16.9 R 30 A8 30 kph (19 mph) †† It is unsafe to operate this tyre above 30 kph (25 mph).

0.6 1.2 1.6

9 17 23

1605 kg (3538 lb) 2035 kg (4486 lb) 2460 kg (5423 lb)

480/70 R 30

D

65 kph (40 mph)

0.6 1.2 1.6 2.4

9 17 23 35

1820 kg (4012 lb) 2380 kg (5247 lb) 2755 kg (6074 lb) 3800 kg (8377 lb)

1700 kg (3748 lb) 2225 kg (4905 lb) 2575 kg (5677 lb) 3550 kg (7826 lb)

520/70 R 30

D

65 kph (40 mph)

0.6 1.2 1.6 2.1

9 17 23 35

2030 kg (4475 lb) 2680 kg (5908 lb) 3100 kg (6834 lb)

1900 kg (4189 lb) 2500 kg (5511 lb) 2900 kg (6393 lb) 2505 kg (5522 lb) 3550 kg (7826 lb) 3075 kg (6779 lb)

540/65 R 30

D

65 kph (40 mph)

0.6 1.3 1.6 2.4

9 19 23 35

1705 kg (3759 lb) 2400 kg (5291 lb) 2820 kg (6217 lb) 4010 kg (8840 lb)

1580 kg (3483 lb) 2245 kg (4949 lb) 2640 kg (5820 lb) 3750 kg (8267 lb)

9804/1103

Speed Designation

Max Speed

60 - 05 - 06/1

†† †† ††

†† ††

1450 kg (3197 lb) 1915 kg (4222 lb) 2220 kg (4894 lb) 3075 kg (6779 lb)

2000 kg (4409 lb) 2300 kg (5071 lb) 3250 kg (7165 lb) Issue 4

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CONTENTS

Fastrac

60 - 05 - 06/2

1115 & 1135 Data - Tyre Pressures, Speeds and Loads General

! WARNING

The versatility of the JCB Fastrac dictates a range of tyre types which may be operated at differing loads and widely differing speeds. Agricultural type tyres are designated according to both their load carrying ability and their ability to operate at certain speeds. Generally, the speed at which a given tyre can operate depends upon inflation pressure and the load carried. The table below gives the load carrying capacity per tyre at varying pressures and speeds. All tyres supplied as original equipment may be operated over the full speed range of the vehicle provided the pressure is correct and their loading is no higher than that given below. Note 1: Whatever the loading, it is desirable to inflate rear tyres to 0.3 bar (4.4 lbf/in2) higher than the pressures given which are for the front tyres. This results in improved handling.

Running tyres outside recommended guidelines may result in failure of the tyres which at high speeds may endanger life. BE WARNED. 13-3-1-6

! WARNING Certain tyres fitted as after-market equipment may have maximum permitted speeds below the maximum speed of the vehicle. Brake efficiency is slightly reduced and stopping distance is increased when these tyres are fitted. They will suffer damage if operated at speeds higher than those recommended and may endanger life. 13-3-2-5

! WARNING Wheels are heavy. Handle and store with care to ensure that they cannot fall and cause injury. 13-3-1-7

Note 2: It is recommended that tyres larger than 495 mm section width are not used on machines fitted with a NoSPIN Differential except for special applications as agreed with JCB Landpower.

Pressures, Speeds and Loads HIGH TRACTION TYRES Tyre Size

Speed Designation

Max Speed

Pressure bar lbf/in2

Max load per tyre at speed of 30 kph (19 mph) 40 kph (25 mph) 50 kph (31 mph)

16.9 R 28

A8/B

50 kph (31 mph)

1.0 1.3 1.5 1.7

15 19 22 24

1835 kg (4050 lb) 1975 kg (4354 lb) 2185 kg (4817 lb) 2395 kg (5280 lb)

1710 kg (3770 lb) 1845 kg (4067 lb) 2045 kg (4508 lb) 2240 kg (4938 lb)

1575 kg (3472 lb) 1695 kg (3736 lb) 1880 kg (4144 lb) 2060 kg (4541 lb)

480/70 R 28

A8/B

50 kph (31 mph)

1.0 1.3 1.5 1.7 2.0

15 19 22 24 29

2130 kg (4695 lb) 2410 kg ((5313 lb) 2590 kg (5709 lb) 2680 kg (5908 lb)

1990 kg (4378 lb) 2240 kg (4938 lb) 2420 kg (5335 lb) 2500 kg (5511 lb)

1810 kg (3990 lb) 2050 kg (4519 lb) 2200 kg (4850 lb) 2300 kg (5070 lb) 2900 kg (6393 lb)

540/65 R 28

A8/B

50 kph (31 mph)

1.0 1.3 1.5 1.7

15 19 22 24

1960 kg (4320 lb) 2210 kg (4872 lb) 2460 kg (5423 lb) 2585 kg (5699 lb)

1840 kg (4056 lb) 2070 kg (4563 lb) 2300 kg (5070 lb)

1680 kg (3704 lb) 1900 kg (4189 lb) 2120 kg (4674 lb)

480/70 R 30

D

50 kph (31 mph)

0.6 1.2 1.6 2.4

9 17 23 35

1820 kg (4012 lb) 2380 kg (5247 lb) 2755 kg (6074 lb) 3800 kg (8377 lb)

1700 kg (3748 lb) 2225 kg (4905 lb) 2575 kg (5677 lb) 3550 kg (7826 lb)

1540 kg (3395 lb) 2030 kg (4475 lb) 2310 kg (5093 lb) 3230 kg (7121 lb)

9804/1103

60 - 05 - 06/2

Issue 1

CONTENTS

Fastrac

60 - 05 - 06/3

1115 & 1135 Data - Tyre Pressures, Speeds and Loads (continued) Pressures, Speeds and Loads HIGH TRACTION TYRES Tyre Size 16.9 R 30

Speed Designation

bar

Pressure lbf/in2

30 kph (19 mph)

Max load per tyre at speed of 40 kph (25 mph) 50 kph (31 mph)

A8/B

0.6 0.8 1.2 1.6

9 12 17 23

1600 kg (3527 lb) 1770 kg (3902 lb) 2120 kg (4674 lb) 2460 kg (5423 lb)

1500 kg (3306 lb) 1660 kg (3660 lb) 1980 kg (4365 lb) 2300 kg (5070 lb)

1400 kg (3086 lb) 1540 kg (3395 lb) 1830 kg (4034 lb) 2120 kg (4673 lb)

420/70 R28

A8

1.0 1.3 1.5 1.7

15 19 22 24

1760 kg (4036 lb) 1980 kg (4365 lb) 2140 kg (4718 lb) 2210 kg (4872 lb)

1640 kg (3615 lb) 1850 kg (4078 lb) 1990 kg (4387 lb) 2060 kg (4541 lb)

1490 kg (3285 lb) 1690 kg (3726 lb) 1820 kg (4012 lb) 1900 kg (4189 lb)

480/70 R 28

A8/B

0.6 1.2 1.6 2.0 2.4

9 17 23 29 35

1870 kg (4123 lb) 2495 kg (5500 lb) 2815 kg (6206 lb) 3090 kg (6812 lb) 3335 kg (7352 lb)

1780 kg (3924 lb) 2375 kg (5236 lb) 2680 kg (5908 lb) 2940 kg (6481 lb) 3175 kg (7000 lb)

1705 kg (3759 lb) 2280 kg (5026 lb) 2570 kg (5665 lb) 2820 kg (6217 lb) 3045 kg.(6713 lb)

480/70 R 30

A8/D

0.6 1.2 1.6 2.4

9 17 23 35

1820 kg (4012 lb) 2380 kg (5247 lb) 2755 kg (6074 lb) 3800 kg (8377 lb)

1690 kg (3725 lb) 2225 kg (4905 lb) 2575 kg (5677 lb) 3550 kg (7826 lb)

1540 kg (3395 lb) 2030 kg (4475 lb) 2360 kg (5202 lb) 3230 kg (7121 lb)

540/65 R 30

A8/D

0.6 1.2 1.6 2.4

9 17 23 35

1705 kg (3759 lb) 2270 kg (5004 lb) 2820 kg (6217 lb) 4010 kg (8840 lb)

1580 kg (3483 lb) 2125 kg (4685 lb) 2640 kg (5820 lb) 3750 kg (8267 lb)

1460 kg (3219 lb) 1955 kg (4310 lb) 2425 kg (5346 lb) 3400 kg (7496 lb)

580/70 R 26

B

0.6 1.2 1.6

9 17 23

1840 kg (4012 lb) 2500 kg (5511 lb) 3100 kg (6834 lb)

1720 kg (3792 lb) 2320 kg (5115 lb) 2900 kg (6393 lb)

1590 kg (3505 lb) 2130 kg (4696 lb) 2650 kg (5842 lb)

Adjustable Track Width

Lock Stops

The standard wheels provide a track width of 72 in (1829 mm). To obtain an alternative track of 76 in (1930 mm), move the wheels from one side of the machine to the other and reverse the wheels on the hubs. The 'V' of the tyre tread pattern must always point forward when at the top of the wheel .

To prevent the tyres from fouling on the vehicle chassis, lock stops must be fitted to the inside of each steering axle swivel. The correct size of lock stop is fitted at the factory to suit the tyre and wheel configuration supplied as original equipment. If a different tyre and wheel configuration is to be used, consult JCB Landpower about the need to change the lock stops.

Checking Wheel Nut Torques On a new machine check the wheel nut torques every ten hours until they stay correct. If a wheel has been removed and refitted, check the wheel nut torques every ten hours until they stay correct. Do not apply oil to the wheel nut threads. Wheel nut torque setting

9804/1103

Nm 500

kgf m 51.0

lbf ft 370

60 - 05 - 06/3

Issue 2*

CONTENTS

Fastrac

60 - 05 - 06/4

2000 SERIES MACHINES Data - Tyre Pressures, Speeds and Loads * Tyre Size

Speed Designation

Rolling Pressure Max load per tyre at speed of Circumference bar lbf/in2 10 kph (6 mph) 40 kph (25 mph) 50 kph (31 mph)

16.9 R24 (1)

D

3.933 m

1.5 2.1 2.7 3.0

22 30 39 43

2200 kg 2790 kg 3300 kg 3530 kg

2070 kg 2620 kg 3100 kg 3250 kg

16.9 R28 (1)

B

4.305 m

1.0 1.2 1.4 1.6

14 17 20 23

1770 kg 1930 kg 2080 kg 2240 kg

1640 kg 1780 kg 1920 kg 2060 kg

16.9 R28

D

4.222 m

1.5 2.3 2.6 2.9

22 33 38 42

2360 kg 2180 kg 3450 kg 3765 kg

2220 kg 2990 kg 3240 kg 3550 kg

16.6 R30

B

4.398 m

1.0 1.2 1.4 1.6

14 17 20 23

2470 kg 2690 kg 2910 kg 3120 kg

1950 kg 2120 kg 2290 kg 2460 kg

1820 kg 1980 kg 2140 kg 2300 kg

16.9 R30

D

4.398 m

1.5 2.1 2.5 2.9

22 30 36 42

2950 kg 3740 kg 4200 kg 4630 kg

2360 kg 2990 kg 3360 kg 3705 kg

2220 kg 2810 kg 3160 kg 3450 kg

480/70 R28 (1)

D

4.240 m

0.6 1.2 1.6 2.4

9 17 23 35

1870 kg 2495 kg 2815 kg 3335 kg

1780 kg 2375 kg 2680 kg 3175 kg

1705 kg 2280 kg 2570 kg 3045 kg

480/70 R30

E

4.395 m

0.6 1.2 1.6 2.4

9 17 23 35

1810 kg 2380 kg 2760 kg

1690 kg 2230 kg 2580 kg 3075 kg

1540 kg 2030 kg 2360 kg 2800 kg

520/65 R30

D

4.430 m

1.5 1.9 2.1 2.4

22 28 30 35

3480 kg 4130 kg 4410 kg 4830 kg

2780 kg 3300 kg 3530 kg 3860 kg

2610 kg 3100 kg 3320 kg 3550 kg

520/70 R30 (2)

E

4.615 m

0.6 1.2 1.6 2.1

9 17 23 30

2030 kg 2680 kg 3100 kg

1900 kg 2500 kg 2900 kg 3550 kg

1730 kg 2280 kg 2650 kg 3230 kg

540/65 R28 (1)

D

4.230 m

0.6 1.2 1.6 2.1

9 17 23 30

2250 kg 3020 kg 3540 kg 4580 kg

1600 kg 2250 kg 2690 kg 3560 kg

1520 kg 2120 kg 2510 kg 3310 kg

540/65 R28

E

4.230 m

0.6 1.2 1.6 2.4

9 17 23 35

1500 kg 2245 kg 2745 kg

1425 kg 2140 kg 2610 kg 3560 kg

1370 kg 2050 kg 2505 kg 3415 kg

540/65 R30

D

4.432 m

0.6 1.2 1.6 2.4

9 17 23 35

2750 kg 3320 kg 3890 kg 5030 kg

1870 kg 2550 kg 2770 kg 3670 kg

1830 kg 2460 kg 2670 kg 3520 kg

540/65 R30

E

4.432 m

0.6 1.2 1.6 2.4

9 17 23 35

1545 kg 2315 kg 2830 kg

1470 kg 2205 kg 2685 kg 3670 kg

1410 kg 2115 kg 2580 kg 3520 kg

580/70 R26 (3)

B

4.300 m

0.6 1.0 1.2 1.6

9 14 17 23

2880 kg 3490 kg 3800 kg 4410 kg

2260 kg 2570 kg 2800 kg 3250 kg

2110 kg 2390 kg 2590 kg 3000 kg

600/65 R28 (3)

E

4.415 m

0.6 1.2 1.6 2.4

9 17 23 35

1545 kg 2315 kg 2830 kg

1470 kg 2205 kg 2685 kg 3670 kg

1410 kg 2115 kg 2580 kg 3520 kg

Notes: (1) Not approved for 2150 machines. (2) Approved for 2150 machines only. (3) Front AXLE load must not exceed 4700 kg (10360 lb). 9804/1103

2410 kg 2620 kg 2830 kg 3040 kg

(4)

60 - 05 - 06/4

Whatever the loading, it is desirable to inflate rear tyres to 0.3 bar (4.4 lbf/in2) higher than the pressures given which are for the front tyres. This results in improved handling. 8020-3/12-2.6

Issue 2*

CONTENTS

Fastrac

60 - 05 - 06/5

3000 SERIES MACHINES Data - Tyre Pressures, Speeds and Loads * Tyre Size

Speed Designation

Rolling Pressure Circumference bar lb/in2

10 kph (6 mph)

Max load per tyre at speed of 40 kph 65 kph 70 kph (25 mph) (40 mph) (44 mph)

16.9 R30

D

4.398 m

1.5 2.1 2.5 2.9

22 30 36 42

2950 kg 3740 kg 4200 kg 4630 kg

2360 kg 2990 kg 3360 kg 3705 kg

2060 kg 2610 kg 2935 kg 3250 kg

480/70 R30

E

4.395 m

0.6 1.2 1.6 2.4

9 17 23 35

1810 kg 2380 kg 2760 kg

1690 kg 2230 kg 2580 kg 3550 kg

2255 kg 3075 kg

2055 kg 2800 kg

495/70 R24

G

3.913 m

1.0 1.6 2.4 3.5

14 23 35 50

2430 kg 3310 kg 4480 kg 6090 kg

1550 kg 2110 kg 2860 kg 3890 kg

1440 kg 1970 kg 2660 kg 3620 kg

520/65 R30

D

4.430 m

1.5 1.9 2.1 2.4

22 28 30 35

3480 kg 4130 kg 4410 kg 4830 kg

2780 kg 3300 kg 3530 kg 3860 kg

2430 kg 2880 kg 3085 kg 3350 kg

520/70 R30

E

4.615 m

0.6 1.2 1.6 2.1

9 17 23 30

2030 kg 2680 kg 3100 kg

1900 kg 2500 kg 2900 kg 3550 kg

2505 kg 3075 kg

2280 kg 2800 kg

0.6 1.2 1.6 2.4

9 17 23 35

1545 kg 2315 kg 2830 kg

1470 kg 2205 kg 2685 kg 3670 kg

2460 kg 3350 kg

2240 kg 3075 kg

0.6 1.2 1.6 2.4

9 17 23 35

2460 kg 3320 kg 3890 kg 5030 kg

1650 kg 2320 kg 2770 kg 3670 kg

2410 kg 3350 kg

540/65 R30

540/65 R30

E

D

4.432 m

4.432 m

580/70 R26 (1)

B

4.300 m

0.6 1.0 1.2 1.5

9 14 17 23

2880 kg 3490 kg 3800 kg 4410 kg

2370 kg 2880 kg 3140 kg 3650 kg

600/65 R28

E

4.415 m

0.6 1.2 1.6 2.4

9 17 23 35

1730 kg 2590 kg 3165 kg

1645 kg 2465 kg 3015 kg 4110 kg

0.6 1.0 1.2 1.6

9 14 17 23

3230 kg 3920 kg 4270 kg 4960 kg

2370 kg 2880 kg 3140 kg 3650 kg

620/70 R26

B

4.469 m

2750 kg 3750 kg

90 kph (60 mph)

1350 kg 1840 kg 2490 kg 3390 kg

2505 kg 3450 kg

Notes: (1) Approved for 3155 machines only. (2) Whatever the loading, it is desirable to inflate rear tyres to 0.3 bar (4.4 lbf/in2) higher than the pressures given which are for the front tyres. This results in improved handling.

9804/1103

60 - 05 - 06/5

8020 - 3/12-3.5

Issue 2*

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?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S@@@@@@@@)XN@@@@@@@8S@@@@)XN@@W@@@@@@@@?@@@@@@@?S@@@@)XN@@W@@@@@@@@?S@@@@)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@X@@@@)X@@@V'@@W&U@@@@1?@@@R'X@@@X@?@@@V'X@?*U@@@@1?@@@R'X@@@X@?7@@V'@1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LN@@XI4@XI4@@@@@LV'@@R'@@@@@?@@@LV'@@V4@X@@@?V@@LV'@@@@@?@@@LV'@@V4@T@@@?V@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X@@)X?S)X?W@@?S)XN@@LN@@?@@@@@S)XN@@L?S@@@@@@@@)XN@@?@@@@@S)XN@@L?S@>@@@@@V)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>@@@V1?*>)T&@@?*>1?@@1?@@@@@?@@@>1?@@1?*U@@@@@@@>1?@@@@@?@@@>1?@@1?*>@R'@@@@@1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@@@@@LN@@@R'@LV4@X@@@X@@@T@@@@V4@X@@@LV'@@V4@XI4@X@@@T@@@@V4@X@@@LV'@LV4@X@@@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?W@@@V)X@@@LN@)K?V@@?S@@@S@U@@@L?S@@@S)XN@@??V)K?S@@@S@U@@@L?S@@@S)XN@)K?V@@@>)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@@@@@>1?3@@@@@@?*U@@@>@@@@1?*U@@@>1?@@@@@@@@@U@@@>@@@@1?*U@@@>1?3@@@@@@V'>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@@@@@XI4@LV4@@@@@LV4@@V4@T@@@LV4@@V4@T@@@@@@@@V4@@V4@T@@@LV4@@V4@LV4@@@@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?W@X?S)X?S)X?W@X?S)X?W@L?S@U?S)X?W@L?S@U?W@X?W@L?W@L?S@U?S)X?W@L?S)X?W@X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?W2@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@W&@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5?g ?@@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@5?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@(Y?g I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0Yh

CONTENTS

Fastrac

60 - 05 - 10/1

125, 135, 145, 150, 155, 185 Data - Brakes Operating Pressure (Air)

8 bar

(120 lbf/in2)

Minimum Lining Thickness (at renewal)

3 mm

(0.125 in)

Disc Thickness - New - Minimum after Skimming

9.5 mm 8.9 mm

(0.374 in) (0.350 in)

Minimum Lining Thickness (at renewal)

3 mm

(0.125 in)

Front Disc Thickness - New - Minimum after Skimming

22 mm 19.8-20.2 mm

(0.866 in) (0.780-0.795 in)

Rear Disc Thickness - New - Minimum after Skimming

16 mm 14.3-14.7 mm

(0.630 in) (0.563-0.579 in)

Parking Brake

Foot (Service) Brake

Data - Steering Pump Type

Rear section (P2) of gear type double pump, driven by engine.

Controlled Flow at 2600 rev/min and system pressure

14 litres/min (3 UK gal/min)

Relief Valve Pressure * At engine speed of 1500 rev/min To machine no. 636371 From machine no. 636372

bar

kgf/cm2

lbf/in2

140 135

143 138

2030 1958

IMPORTANT: The steering pressure must not be set above the specified figure under any circumstances.

9804/1103

60 - 05 - 10/1

Issue 4*

W2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K?h ?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@h ?7@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@L?g ?7@(M? I'@@L?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1?g ?@@H ?N@@1?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@? @@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W2@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>)?&R1?*>1?7R1?*>1?7R1?*>)T&>)?&R)?&R)?&R)?&R1?7R1?*>)T&>)?&R)?&R1?7R1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@9V@@@@@@LV'@?@@@?S@@X@@@LV'@@R@@@@@@@@@@@@@@@@@@X@@@LV'@@R@@@@@@@@@@X@@@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S@@@@@@@@)XN@@@@@@@8S@@@@)XN@@W@@@@@@@@?@@@@@@@?S@@@@)XN@@W@@@@@@@@?S@@@@)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@X@@@@)X@@@V'@@W&U@@@@1?@@@R'X@@@X@?@@@V'X@?*U@@@@1?@@@R'X@@@X@?7@@V'@1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LN@@XI4@XI4@@@@@LV'@@R'@@@@@?@@@LV'@@V4@X@@@?V@@LV'@@@@@?@@@LV'@@V4@T@@@?V@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X@@)X?S)X?W@@?S)XN@@LN@@?@@@@@S)XN@@L?S@@@@@@@@)XN@@?@@@@@S)XN@@L?S@>@@@@@V)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>@@@V1?*>)T&@@?*>1?@@1?@@@@@?@@@>1?@@1?*U@@@@@@@>1?@@@@@?@@@>1?@@1?*>@R'@@@@@1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@@@@@LN@@@R'@LV4@X@@@X@@@T@@@@V4@X@@@LV'@@V4@XI4@X@@@T@@@@V4@X@@@LV'@LV4@X@@@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?W@@@V)X@@@LN@)K?V@@?S@@@S@U@@@L?S@@@S)XN@@??V)K?S@@@S@U@@@L?S@@@S)XN@)K?V@@@>)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@@@@@>1?3@@@@@@?*U@@@>@@@@1?*U@@@>1?@@@@@@@@@U@@@>@@@@1?*U@@@>1?3@@@@@@V'>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@@@@@XI4@LV4@@@@@LV4@@V4@T@@@LV4@@V4@T@@@@@@@@V4@@V4@T@@@LV4@@V4@LV4@@@@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?W@X?S)X?S)X?W@X?S)X?W@L?S@U?S)X?W@L?S@U?W@X?W@L?W@L?S@U?S)X?W@L?S)X?W@X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?W2@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@W&@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5?g ?@@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@5?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@(Y?g I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0Yh

CONTENTS

* 125,

Fastrac

60 - 05 - 10/2

135, 145, 150, 155, 185

Data - Suspension Pump Type

Front section (P1) of gear type double pump, driven by engine.

Maximum Flow To machine no. 636000, at 2600 rev/min and system pressure From machine no. 636001, at 2400 rev/min and system pressure

10 litres/min (2.2 UK gal/min) 9.2 litres/min (2.0 UK gal/min)

bar

kgf/cm2

lbf/in2

Pressure Maintaining Valve Cut out pressure Cut in pressure

200 180

204 184

2900 2610

Accumulator Charge Pressure

75

76

1088

37

38

537

35

36

508

Gas Spring Charge Pressure To machine no 636323 (except when fitted with 45 mm suspension cylinders) From machine no. 636324 and all machines with 45 mm suspension cylinders

Note: The 35 bar gas springs may be fitted to earlier machines but only in complete sets of four.

9804/1103

60 - 05 - 10/2

Issue 2*

CONTENTS * FASTRAC

Fastrac

60 - 05 - 10/3

1115, 1135

Data - Brakes Operating Pressure (hydraulic) (to machine no. 737000)

140 - 160 bar

(2030 - 2320 lbf/in2)

Operating Pressure (hydraulic) (from machine no. 737001)

8 bar

(120 lbf/in2)

Minimum Permissible Lining Thickness - Outboard Liner - Inboard Liner

1 mm 3.4 mm

(0.04 in) (0.13 in)

Maximum Lining Thickness (i.e. New Liners) - Outboard Liner - Inboard Liner

3 mm 5.4 mm

(0.12 in) (0.21 in)

Disc Thickness - New - Minimum after Skimming

9.5 mm 8.9 mm

(0.374 in) (0.350 in)

Minimum Lining Thickness (at renewal)

3 mm

(0.125 in)

Front Disc Thickness - New - Minimum after Skimming

22 mm 19.8-20.2 mm

(0.866 in) (0.780-0.795 in)

Rear Disc Thickness - New - Minimum after Skimming

16 mm 14.3-14.7 mm

(0.630 in) (0.563-0.579 in)

Hydraulic Accumulator Pressure - front and rear (from machine no. 737000 only)

40 bar

(580 lbf/in2)

Parking Brake

Foot (Service) Brake

9804/1103

60 - 05 - 10/3

Issue 3*

CONTENTS

Fastrac

60 - 05 - 10/3A

2000 & 3000 Series Machines Data - Brakes Brake System 8 bar

(120 lbf/in2)

Minimum Permissible Lining Thickness

3 mm

(0.12 in)

Disc Thickness - New - Minimum after Skimming

9.5 mm 8.9 mm

(0.374 in) (0.350 in)

Minimum Lining Thickness (at renewal)

3 mm

(0.125 in)

Front Disc Thickness - New - Minimum after Skimming

22 mm 19.8-20.2 mm

(0.866 in) (0.780-0.795 in)

Rear Disc Thickness - New - Minimum after Skimming

16 mm 14.3-14.7 mm

(0.630 in) (0.563-0.579 in)

Operating Pressure (air) Parking Brake

Foot (Service) Brake

9804/1103

60 - 05 - 10/3A

Issue 1

CONTENTS

Fastrac

60 - 05 - 10/4

2000 & 3000 SERIES MACHINES Data - Transmission Differential Lock Control Valve Type

Solenoid and pressure maintenance valve for 'soft-engage' diff. lock mounted in suspension valve block

Pressure Maintenance Valve Setting

38 bar (550 lbf/in2) at 2400 rev/min.

Front Axle Model

SD55 (2000 Series) SD70 (3000 Series)

Type

Crown wheel and pinion primary reduction with epicyclic hub reduction

Mounting

3 leading link control arms and Panhard rod

Weight (approximate)

SD55 - 510 kg (1124 lb) SD70 - TBA

Differential

SD55 - NoSPIN (standard) Maxtrac (optional) SD70 - Soft engaged differential lock with electro - hydraulic control

Rear Axle Model

PD70 (all 2WS machines except 3185) PD90 (3185 machines only) SD70 (4WS machines)

Type

Crown wheel and pinion primary reduction with epicyclic hub reduction

Mounting

2 trailing link control arms and 'V' link

Weight (approximate)

PD70 - 590 kg (1300 lb) PD90 - 555 kg (1224 lb) SD70 - TBA

Brakes

Single caliper solid disc on each hub

Differential

Soft-engaged differential lock with electro-hydraulic control

Note: For technical data on wheels and tyres, see Routine Maintenance, Section 3.

9804/1103

60 - 05 - 10/4

8020 - F/1-3.1

Issue 1

CONTENTS

Fastrac

60 - 05 - 10/4A

2000 & 3000 SERIES MACHINES *

Data - Steering 2WS (Front Axle) Circuit (Fastrac 2000 and 3000 Series) Pump (Type 1†) Type

Rear section (P2) of gear type double pump, driven by engine. 18.2 litres/min (4 UK gal/min; 4.8 US gal/min)

Controlled Flow at 2400 rev/min and system pressure Pump Relief Valve Pressure (at 1500 r.p.m. engine speed) Fastrac 2000 Series

200 bar (2900 lb/in2)

Fastrac 3000 Series

135 bar (1958 lb/in2)

IMPORTANT: The steering pump relief valve pressure must not be set above the specified figure under any circumstances. Steering Unit Relief Valve Pressure (Fastrac 2000 Series)

180 bar (2610 lb/in2)

4WS (Rear Axle ) Circuit (Fastrac 2115, 2125, 2135 only) Pump Type PTO Flow rate @ 100 bar (1450 lbf/in2) and *1500 rev/min

Centre section (P5) of gear type triple pump, driven by gearbox 43 litres/min (9.5 UK gal/min; 11.4 US gal/min)

4WS Main Relief Valve Pressure At 1500 r.p.m. engine speed

100 bar (1450 lbf/in2)

4WS Dump Valve Pressure At 1500 r.p.m. engine speed

10 bar (145 lbf/in2)

* Air Pressure Regulator

9804/1103

7 bar (100 lbf/in2)

60 - 05 - 10/4A

8020 - H/1-1.4

Issue 2*

CONTENTS

Fastrac

60 - 05 - 10/5

FASTRAC 1115, 1135 Data - Suspension Pump Type

Front section (P1) of gear type double pump, driven by engine.

Maximum Flow

9.2 litres/min (2.0 UK gal/min)

Pressures bar

kgf/cm2

lbf/in2

Pressure Maintaining Valve (Machines to Serial No. 737000) Cut out pressure Cut in pressure

160 140

163 143

2320 2030

Pressure Maintaining Valve (Machines from Serial No. 737001) Cut out pressure Cut in pressure

200 180

204 184

2900 2610

Accumulator Charge Pressure Machines to Serial No. 737000 Machines from Serial No. 737001

40 75

41 76.5

580 1087

Gas Spring Charge Pressure

26

27

377

9804/1103

60 - 05 - 10/5

Issue 2*

CONTENTS

Fastrac

60 - 05 - 10/5A

2000 & 3000 SERIES MACHINES Data - Suspension Pump Type by

Front section (P1) of gear type double pump, driven engine.

Maximum Flow

9.2 litres/min (2.0 UK gal/min; 2.4 US gal/min)

Pressures bar

kgf/cm2

lbf/in2

Pressure Maintaining Valve Cut-out pressure Cut-in pressure

200 180

204 184

2900 2610

Accumulator Charge Pressure

75

76.5

1087

26 35 35

27 36 36

377 508 508

* Gas Spring Charge Pressure Fastrac 2115, 2125, 2135 (1 x) (1 x) Fastrac 2150 and 3000 Series (2 x)

9804/1103

60 - 05 - 10/5A

8020 - S/1-1.3

Issue 2*

CONTENTS * 125,

Fastrac

60 - 05 - 15/1

135, 145, 150, 155, 185, 1115, 1135

Data - Engine Perkins Engines GENERAL Model Bore Stroke Swept Volume Compression Ratio - Naturally aspirated 1000 Series - Turbocharged 1000 Series - Turbocharged New 1000 Series Compression Pressure Firing Order Valve Clearance (hot or cold) - Inlet - Exhaust Oil Pressure (hot) at maximum speed - Naturally aspirated 1000 Series - Turbocharged 1000 Series - Turbocharged New 1000 Series Idling Speed

Perkins 1000 Series or New 1000 Series, 6 cylinder, water cooled, 100 mm (3.937 in) 127 mm (5 in) 5985 cm3 (365.2 in3) 16.5 : 1 16.0 : 1 17.25 : 1 20 to 34 bar (290 to 500 lbf/in2) with maximum variation between cylinders of 3.5 bar (50 lbf/in2) 1, 5, 3, 6, 2, 4 0.20 mm (0.008 in) 0.45 mm (0.018 in) 2.1 bar (30 lbf/in2) minimum 2.8 bar (40 lbf/in2) minimum 4.0 bar (58 lbf/in2) minimum 750 rev/min

FUEL SYSTEM Engine Type Rating

Engine No. Prefix

Pump Type

Setting Code

Max Governed speed

Max No Load Speed

1006-6 1006-6 1006-6LR4 1006-6T 1006-6T 1006-6T 1006-6T4 1006-6T4 1006-6T HR5 1006-6T HR5 1006-6T HR5

YA50347 YA50474 YA50532 YB50375 YB50431 YB50436 YB50472 YB50477 YB50473 YB50478 YB50558

CAV CAV CAV CAV CAV CAV CAV CAV Stanadyne Stanadyne CAV

FK59L/750/1/2860 FK59L/750/4/2640 2643 D805/MK/3/2570 AK77L/800/1/2860 2643M010AK/1/2860 AK77L/800/1/2860 RK90L/1100/3/2520 RK90L/1100/3/2520 JL JL 2643 U610/JL/1/2660

2600 rev/min 2400 rev/min 2400 rev/min 2600 rev/min 2600 rev/min 2600 rev/min 2400 rev/min 2400 rev/min 2400 rev/min 2400 rev/min 2400 rev/min

2830 rev/min 2540/2640 rev/min 2470/2520 rev/min 2830 rev/min 2830 rev/min 2860 rev/min 2470/2520 rev/min 2470/2520 rev/min 2520/2620 rev/min 2520/2620 rev/min 2470/2520 rev/min

145T 145T 160T 160T 160TW

YB50400 YB50437 YB50403 YB50438 YD50494

Bosch (rotary) Bosch (rotary) Bosch (rotary) Bosch (rotary) Bosch (in-line)

2643J605 CK/1/2960 2643J605 CK/1/2960 2643J601 EK/1/2960 2643J601 EK/1/2960 PL

2600 rev/min 2600 rev/min 2600 rev/min 2600 rev/min 2400 rev/min

2930 rev/min 2930 rev/min 2930 rev/min 2930 rev/min 2736 rev/min

1941/2300 1929/2300 1947/2300 1930/2300

YH50595 YH50596 YH50597 YH50600

CAV CAV CAV CAV

2644 D106/EH/-/2460 2644 D102/BH/-/2460 2644 D109/FH/-/2460 TBA

2300 rev/min 2300 rev/min 2300 rev/min 2200 rev/min

2460 ± 50 rev/min 2460 ± 50 rev/min 2460 ± 50 rev/min 2530 ± 50 rev/min

For further details, see engine service manual, publication No. 9806/0100 Note: New engines DO NOT require a running-in period. The engine 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

60 - 05 - 15/1

Issue 6*

CONTENTS

Fastrac 2150

Perkins New 1000 Series, Turbocharged, 6 cylinder,

Perkins New 1000 Series, Turbocharged, 6 cylinder,

Perkins New 1000 Series, Turbocharged, 6 cylinder,

Perkins New 100 Series

water cooled

water cooled

water cooled

6 cylinder, water cooled

Rating

1941/2300

1929/2300

1947/2300

1930/2200

Bore

100 mm (3.937 in)

100 mm (3.937 in)

100 mm (3.937 in)

100 mm (3.937 in)

Stroke

127 mm (5 in)

127 mm (5 in)

127 mm (5 in)

127 mm (5 in)

Swept Volume

5985 cm3 (365.2 in3)

5985 cm3 (365.2 in3)

5985 cm3 (365.2 in3)

5985 cm3 (365.2 in3)

Compression Ratio

17.25 : 1

17.25 : 1

17.25 : 1

17.25 : 1

Model Turbocharged/intercooled,

20-34 bar (290-500 lbf/in2)

20-34 bar (290-500 lbf/in2)

20-34 bar (290-500 lbf/in2)

20-34 bar (290-500 lbf/in2)

3.5 bar (50 lbf/in2)

3.5 bar (50 lbf/in2)

3.5 bar (50 lbf/in2)

3.5 bar (50 lbf/in2)

Firing Order

1, 5, 3, 6, 2, 4

1, 5, 3, 6, 2, 4

1, 5, 3, 6, 2, 4

1, 5, 3, 6, 2, 4

Valve Clearance (hot or cold) - Inlet - Exhaust

0.20 mm (0.008 in) 0.45 mm (0.018 in)

0.20 mm (0.008 in) 0.45 mm (0.018 in)

0.20 mm (0.008 in) 0.45 mm (0.018 in)

0.20 mm (0.008 in) 0.45 mm (0.018 in)

Oil Pressure (hot) at maximum speed

4 bar (58 lbf/in2)

4 bar (58 lbf/in2)

4 bar (58 lbf/in2)

4 bar (58 lbf/in2)

Idling Speed

750 rev/min

750 rev/min

750 rev/min

750 rev/min

Fastrac

60 - 05 - 15/2

Compression Pressure - Permitted range - Maximum variation between cylinders

CONTENTS

Fastrac 2135

SERIES MACHINES

Fastrac 2125

* 2000

Fastrac 2115

Data - Engine Perkins Engines

9804/1103

General

60 - 05 - 15/2

Issue 3*

CONTENTS CONTENTS

Fastrac

60 - 05 - 15/3

2000 SERIES MACHINES Data - Engine (continued) Perkins Engines Fuel System Engine Rating

Engine No. Prefix

Pump Type

Setting Code

Max Governed speed

Max No Load Speed

1941/2300 1929/2300 1947/2300 1930/2200

YH50595 YH50596 YH50597 YK50600

CAV CAV CAV CAV

2644 D106/EH/-/2460 2644 D102/BH/-/2460 2644 D109/FH/-/2460

2300 rev/min 2300 rev/min 2300 rev/min 2200 rev/min

2460 ± 50 rev/min 2460 ± 50 rev/min 2460 ± 50 rev/min 2530 ± 50 rev/min

For further details, see engine service manual, publication No. 9806/2140 (Perkins New 1000 Series). Note: New engines DO NOT require a running-in period. The engine 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

60 - 05 - 15/3

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 05 - 15/4

3000 SERIES MACHINES Data - Engine General Fastrac 3155

Fastrac 3185

Model

1000 Series, Turbocharged, 6-cylinder, water cooled.

Cummins 6 BTA, Turbocharged, 6-cylinder, water cooled, after cooled.

Rating

1702/2400

-

Bore

100 mm (3.937 in)

102 mm (4.02 in)

Stroke

127 mm (5 in)

120 mm (4.72 in)

Swept Volume

5985 cm3 (365.2 in3)

5880 cm3 (359 in3)

Compression Pressure - permitted range - maximum variation between cylinders

20 - 34 bar (290 - 500 lbf/in2)

-

3.5 bar (50 lbf/in2)

-

Compression Ratio

16.0 : 1

16.5 : 1

Firing Order

1, 5, 3, 6, 2, 4

1, 5, 3, 6, 2, 4

Valve Clearance Inlet Exhaust Oil Pressure at idle (minimum allowable) Oil Pressure at maximum speed (minimum allowable) Idling Speed

0.20 mm (0.008 in) 0.45 mm (0.018 in)

0.25 mm (0.010 in) 0.51 mm (0.020 in)

-

0.7 bar (10 lbf/in2)

2.8 bar (40 lbf/in2)

2.1 bar (30 lbf/in2)

750 rev/min

750 rev/min

Governor Run-out Speed

-

2550 - 2650 rev/min

Boost Pressure at rated speed

1.37 bar (19.9 lbf/in2)

-

Injector Type

JL

-

Working Pressure

253 bar (3847 lbf/in2)

-

Note: Injectors supplied from new are set at 7 to 10 bar (106 to 152 lbf/in2) higher than working pressure.

Fuel System Fastrac 3155 Engine Type

Engine No. Prefix

Pump Type

Setting Code

Max. Governed Speed

Max. No Load Speed

1006 - 6T4

YB 50694

CAV

RK90L/1100/3/2520

2400 rev/min

2470/2520 rev/min

1006 - 6T4

YB50695

CAV

RK90L/1100/3/2520

2400 rev/min

2470/2520 rev/min

For further information, see engine service manual, publication number 9806/0100 (Fastrac 3155) or 9806/1170 (Fastrac 3185).

9804/1103

60 - 05 - 15/4

8020 - T/1-3.3

Issue 1

CONTENTS

Fastrac

60 - 05 - 16/1

ALL MODLES Data - Selectronic System (125, 135, 145, 150, 155, 185 Pneumatic Cylinders Type CQ2B40 - 40 +40 XC10 Piston Bore and Stroke Maximum Operating Pressure Microswitches Reed Switch Type

500 mA

Solenoid Valves Type Maximum Operating Pressure 4 Station Manifold1 Supply Voltage

Double Solenoid Valve - VZ3220-60-115 6.8 bar (99lbf/in 2 ) WSZ3-20-041 12V DC (-15% to +10%)

Pressure Regulator Type Pressure Setting

Pressure Reducing Valve RV-1 5.5 bar (80lbf/in 2 )

40mm (1.58 in) x 40mm (1.58 in) 9.6 bar (140 lbf/in 2 )

Data - Selectronic System (Fastrac 1115, 1135, 2000 Series, 3000 Series) Pneumatic Cylinders * Piston Bore and Stroke (Dry Clutch) * Piston Bore and Stroke (Wet Clutch) Maximum Operating Pressure

32 mm (1.26 in) x 50 mm (1.97 in) 40 mm (1.57 mm) x 50 mm (1.97 in) See Pressure Regulator and Filter Pressure Setting

Microswitches Reed Switch Type

500 mA

Solenoid Valves 7.0 bar (102 lbf/in 2 ) 12V DC ( -15% to +10%)

Maximum Operating Pressure Supply Voltage Pressure Regulator and Filter Type

Pressure Reducing Valve

Pressure Setting 2000 Series to S/N 739999, 3000 Series to S/N 641999

7.0 bar (102 lbf/in 2 )

2000 Series from S/N 740000, 3000 Series from S/N 642000

4.5 bar (65 lbf/in 2 )

9804/1103

60 - 05 - 16/1

8020 - D/1-1.3

Issue 6*

CONTENTS CONTENTS

* FASTRAC

Fastrac

60 - 05 - 17/1

2000 Series, 3000 Series

Data - Air Conditioning System Refrigerant Refrigerant Type Refrigerant Charge Weight Compressor Lubricant - Type - Quantity

PAG SP20 240 c.c. (0.05 UK gal)

Switch Pressures Low Pressure Switch - Cut in - Cut out

> 2.35 bar (> 34 lb/in2) < 0.4 bar (< 6 lb/in2)

High Pressure Switch - Cut in - Cut out

9804/1103

HFC R134a 0.9 kg (2 lb)

< 19.3 bar (< 280 lb/in2) > 27.6 bar (> 400 lb/in2)

60 - 05 - 17/1

8020 - B/1-1.1

Issue 2*

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CONTENTS

* 125,

Fastrac

60 - 10 - 05/1

135, 145, 150, 155, 185 from 637734, 1115, 1135, 2000 & 3000 Series

Fault Finding - Electronic Draft Control Introduction The Electronic Draft Control System is self-monitoring for faults. These are identified by error codes indicated by a diagnostic LED. Refer to Interpreting the Diagnostic LED under Fault Diagnosis. Experience has shown that faults are unlikely to lie within the electronic components. Understand how the system works before attempting rectification (see Introduction, System Activation Procedure and Operation to ensure that all controls are set to allow full linkage movement). Note: If you are unable to diagnose a fault by following the fault finding procedure or by visual examination, contact JCB Landpower Service for further assistance.

9804/1103

60 - 10 - 05/1

Issue 4*

W2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K?h ?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@h ?7@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@L?g ?7@(M? 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?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>)?&R1?*>1?7R1?*>1?7R1?*>)T&>)?&R)?&R)?&R)?&R1?7R1?*>)T&>)?&R)?&R1?7R1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@9V@@@@@@LV'@?@@@?S@@X@@@LV'@@R@@@@@@@@@@@@@@@@@@X@@@LV'@@R@@@@@@@@@@X@@@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S@@@@@@@@)XN@@@@@@@8S@@@@)XN@@W@@@@@@@@?@@@@@@@?S@@@@)XN@@W@@@@@@@@?S@@@@)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@X@@@@)X@@@V'@@W&U@@@@1?@@@R'X@@@X@?@@@V'X@?*U@@@@1?@@@R'X@@@X@?7@@V'@1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LN@@XI4@XI4@@@@@LV'@@R'@@@@@?@@@LV'@@V4@X@@@?V@@LV'@@@@@?@@@LV'@@V4@T@@@?V@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X@@)X?S)X?W@@?S)XN@@LN@@?@@@@@S)XN@@L?S@@@@@@@@)XN@@?@@@@@S)XN@@L?S@>@@@@@V)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>@@@V1?*>)T&@@?*>1?@@1?@@@@@?@@@>1?@@1?*U@@@@@@@>1?@@@@@?@@@>1?@@1?*>@R'@@@@@1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@@@@@LN@@@R'@LV4@X@@@X@@@T@@@@V4@X@@@LV'@@V4@XI4@X@@@T@@@@V4@X@@@LV'@LV4@X@@@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?W@@@V)X@@@LN@)K?V@@?S@@@S@U@@@L?S@@@S)XN@@??V)K?S@@@S@U@@@L?S@@@S)XN@)K?V@@@>)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@@@@@>1?3@@@@@@?*U@@@>@@@@1?*U@@@>1?@@@@@@@@@U@@@>@@@@1?*U@@@>1?3@@@@@@V'>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@@@@@XI4@LV4@@@@@LV4@@V4@T@@@LV4@@V4@T@@@@@@@@V4@@V4@T@@@LV4@@V4@LV4@@@@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?W@X?S)X?S)X?W@X?S)X?W@L?S@U?S)X?W@L?S@U?W@X?W@L?W@L?S@U?S)X?W@L?S)X?W@X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?W2@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@W&@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5?g ?@@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@5?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@(Y?g I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0Yh

CONTENTS

Fastrac

60 - 10 - 05/2

* 125, 135, 145, 150, 155, 185 from 637734, 1115, 1135, 2000 & 3000 Series Fault Finding - Electronic Draft Control (continued)

Functional Test of Control Valve If the rear lift arms do not function correctly carry out the following tests.

1

Start engine.

2

When button A on the control valve is pressed, the lift arms should lower to their lowest position.

3

When button B on the control valve is pressed, the lift arms should rise to their highest position.

4

If the functions at steps 2 and 3 operate correctly, the fault is electrical. If the arms do not raise or lower smoothly at steps 2 and 3, the fault is hydraulic.

5

Use the Fault Finding table on the next page to identify the fault.

Note: In order to test the control valve, draft links must be loaded to approximately 800 kg (1700 lb).

! WARNING The procedure below must be carried out with the engine running. Apply the parking brake, chock the wheels and ensure that no-one enters the cab. SUS 1-1

B

A 227140

9804/1103

60 - 10 - 05/2

Issue 3*

W2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K?h ?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@h ?7@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@L?g ?7@(M? 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CONTENTS

Fastrac

60 - 10 - 05/3

* 125, 135, 145, 150, 155, 185 from 637734, 1115, 1135, 2000 & 3000 Series Fault Finding - Electronic Draft Control (continued)

Arms Cannot be Raised or Lowered Run engine at tickover CHECK

ACTION

1

Do hydraulics move when control valve solenoids are pressed manually?

YES: NO:

Check 2. Check 3.

2

Are the relevant fuses intact?

YES: NO:

Check Diagnostic LED indication. Renew fuses.

3

Are pump P3 flow and MRV settings correct?

YES: NO:

Renew defective control valve. Check and adjust MRV/overhaul pump.

Arms Cannot be Lowered Run engine at tickover, adjust setpoint control to fully lowered. CHECK

ACTION

1

Is rate of drop control on minimum rate setting?

YES: NO:

Move to mid position. Check 2.

2

Do arms move when control valve solenoids are pressed manually?

YES: NO:

Check Diagnostic LED indication. Renew defective control valve.

Arms Cannot be Raised Run engine at tickover, set height limitation control to maximum height. ACTION CHECK 1

Do arms move when control valve solenoids are pressed manually?

9804/1103

YES: NO:

60 - 10 - 05/3

Check Diagnostic LED indication. Renew defective control valve.

Issue 3*

CONTENTS CONTENTS

Fastrac

60 - 10 - 05/4

125, 135, 145, 150, 155, 185 from 637734, 1115, 1135, 2000 & 3000 Series Fault Finding - Electronic Draft Control (continued) Fault Diagnosis The faults indicated by the flashing diagnostic LED (see Interpreting the Diagnostic LED) are classified in three categories, see Error Codes, and the control unit reacts accordingly.

3

1

Major Fault As a result of such a fault the draft control is inhibited and locked up. The control unit shuts down to protect its output stages. Until the fault is cleared, control will remain inhibited and the diagnostic LED will flash every time an attempt is made to activate draft control. Once the fault has been cleared, draft control can be resumed by switching the ignition from OFF to ON and then carrying out the System Activation Procedure.

Interpreting the Diagnostic LED

Moderate Fault Moderate faults cause the same reaction as for major faults except that the control unit does not automatically shut down. Once the fault has been cleared, draft control can be resumed, with the ignition already ON, by carrying out the System Activation Procedure.

Note: Some of the error codes utilise the same two digits, e.g. 13 and 31. To avoid confusion, remember that the first digit follows a long pause, the second digit follows a short pause.

2

* Error

Minor Faults Draft control is maintained, but the diagnostic LED operates. Wherever draft control is activated, the LED will operate until the fault has been rectified.

All fault codes consist of two digits. The LED flashes the same number of times as the digit, e.g. six flashes for the number 6. It is therefore necessary to count the flashes following a long pause and then count the flashes following a short pause in order to decipher the digits, e.g. error code 36, shows as: long pause - three flashes - short pause - six flashes. The LED keeps on repeating the two digit code.

Refer to Error Codes for fault details.

Codes (E.C.U. Type D+)

All 125, 135, 145, 150, 155, 185 Machines from S/N 637734 All 1115, 1135 Machines All 2000 Series machines to S/N 738694 2000 Series machines with radar from S/N 738695 All 3000 Series machines to S/N 640709 3000 Series machines with radar from S/N 640710 Major Faults Error Code

Fault

Control Unit pin no.

Possible Cause

11

No output (raise circuit)

37

i ii iii

Raise solenoid output stage faulty. Open circuit solenoid lead to pin 35. No voltage at pin 29 - check fuse C9.

12

No output (lower circuit)

19

i ii iii

Lower solenoid output stage faulty. Open circuit solenoid lead to pin 35. No voltage at pin 29 - check fuse C9.

13

Short circuit (raise/lower circuit).

35

Short circuit between pins 35 and 19 or pins 35 and 37. Possible solenoid short circuit.

Excessive current at pin 35. 14

Open circuit (raise/lower circuit). No current at pin 35 when solenoid actuated.

35

15

Rear button(s) not working.

9

16

Control unit supplies faulty.

2 20

Stabilised supply faulty. Poor earth connection

17

Battery non-switched voltage.

29

Check battery.

18

Control lever A inoperative

21

Check continuity between control unit and control panel.

9804/1103

60 - 10 - 05/4

i ii iii

Open circuit in lead(s) from pins 19, 37, 35 to solenoids. Possible solenoid fault (open circuit). No voltage at pin 29 - check fuse C9.

i ii

Open circuit from pin 9 to button feeds. Faulty button(s).

8020 - C/55-1.1

Issue 4*

CONTENTS CONTENTS

Fastrac

60 - 10 - 05/5

125, 135, 145, 150, 155, 185 from 637734, 1115, 1135, 2000 & 3000 Series Fault Finding - Electronic Draft Control (continued) *

Error Codes (E.C.U. Type D+) (continued) Moderate Faults Error Code

Fault

Control Unit pin no.

Possible Cause

22

Position sensor signal faulty.

6

i ii iii

Sensor open circuit or not connected. Possible short circuit or short to earth. Position sensor needs adjusting.

23

Set command control D potentiometer signal faulty.

22

Potentiometer open circuit or not connected.

24

Upper limit control E potentiometer signal faulty.

3

Potentiometer open circuit or not connected.

Minor Faults Error Code

Fault

Control Unit pin no.

}

Possible Cause

31

Right force-sensing pin signal faulty.

26

32

Left force-sensing pin signal faulty.

7

33

Battery switched voltage below 11.5V.

24

Check battery.

34

Lowering control C potentiometer signal faulty.

23

Potentiometer open circuit or not connected.

36

Mix control H potentiometer signal faulty.

4

Potentiometer open circuit or not connected.

37

Hitch fails to lift with active current at pin 37.

37

41

Radar signal absent, transmission signal present with Differential Lock selected.

42

Transmission signal absent, radar signal present with Differential Lock selected.

9804/1103

i ii iii

Sensor open circuit or not connected. Possible short circuit or short to earth. Possible overload of force sensing pin.

i ii

If engine running: No oil pressure. Valve seized.

10

i ii

Sensor open circuit or not connected. Possible short circuit or short to earth.

11

i ii

Sensor open circuit or not connected. Possible short circuit or short to earth.

60 - 10 - 05/5

8020 - C/55-2.1

Issue 4*

CONTENTS CONTENTS

Fastrac

60 - 10 - 05/5A

125, 135, 145, 150, 155, 185 from 637734, 1115, 1135, 2000 & 3000 Series Fault Finding - Electronic Draft Control (continued) Error Codes (E.C.U. Type B) Only available on 2000 Series machines not fitted with radar from S/N 738695 Only available on 3000 Series machines not fitted with radar from S/N 640710 Major Faults Error Code

Fault

Control Unit pin no.

Possible Cause

11

No output (raise circuit)

2

i ii

Raise solenoid output stage faulty. Open circuit solenoid lead to pin 6.

12

No output (lower circuit)

14

i ii

Lower solenoid output stage faulty. Open circuit solenoid lead to pin 6.

13

Short circuit (raise/lower circuit)

6

Short circuit between pins 6 and 2 or pins 6 and 14. Possible solenoid short circuit.

Excessive current at pin 6. 14

Rear up button not working

10

i ii

Open circuit from pin 10 to button feed. Faulty button.

15

Rear down button not working.

20

i ii

Open circuit from pin 20 to button feed. Faulty button.

16

Control unit supply faulty

12

Supply faulty. Poor earth connection.

18

Control lever A inoperative

8

Check continuity between control unit and control panel.

Moderate Faults Error Code

Fault

Control Unit pin no.

Possible Cause

22

Position sensor signal faulty.

19

i ii iii

Sensor open circuit or not connected. Possible short circuit or short to earth. Position sensor needs adjusting.

23

Set command control D potentiometer signal faulty.

16

Potentiometer open circuit or not connected.

24

Upper limit control E potentiometer signal faulty.

22

Potentiometer open circuit or not connected.

Minor Faults Error Code

Fault

Control Unit pin no.

}

Possible Cause

31

Right force-sensing pin signal faulty.

18

32

Left force-sensing pin signal faulty

17

34

Lowering control C potentiometer signal faulty.

24

Potentiometer open circuit or not connected.

36

Mix control H potentiometer signal faulty.

4

Potentiometer open circuit or not connected.

9804/1103

60 - 10 - 05/5A

i ii iii

Sensor open circuit or not connected. Possible short circuit or short to earth. Possible overload of force sensing pin.

8020 - C/55-3.1

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 10 - 05/6

2000 Series, 3000 Series Fault Finding - Vehicle Electrics Starting Circuit Circuit Description With the 6-speed gearbox lever set to neutral and starter switch A turned to 'IGN', the battery supply is fed via fuse Ca and the 6-speed gearbox neutral switch C (now closed as shown on the diagram) to the solenoids of the two inhibit start relays D and E. To eliminate the need to select neutral in the 6-speed gearbox, an alternative supply route to the solenoids of the start inhibit relays is provided via Ba the clutch depressed switch H (see Note). With the front and rear power take off (PTO) switches F and G turned to the braking position, as shown in the diagram, an earth return is provided for the inhibit start relay solenoids, causing them to energise. When the starter switch is turned to the start ('HS') position, the battery supply is fed via fuse Bb and the relay contacts of the inhibit start relays D and E to the starter solenoid J, which energises and connects the battery supply to the starter motor K. Note: The clutch operating system is power assisted when the engine is running. With the engine switched off considerably greater effort than normal is required to depress the clutch pedal.

Ca

F

G

O IGN

C H

Ba

HS

A

D

J1

Bb

E

J2

J +

K1

K

-

K2

A297190

9804/1103

60 - 10 - 05/6

8020 - C/21-1.3

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 10 - 05/7

2000 Series, 3000 Series Fault Finding - Vehicle Electrics (contÕd) Starting Circuit (contÕd) Testing The following test procedure covers the starter motor, starter solenoid and battery. faulty or a poor connection may exist between the battery and the starter solenoid, or between the starter solenoid and the main terminal K1.

Before carrying out the voltmeter tests, check the condition of the battery (see Battery - Specific Gravity) and ensure that all connections are clean and tight. 3

Connect the voltmeter between the solenoid terminal J1 (+) and a good earth. Minimum reading with starter switch in 'HS' position should be 8.0 Volts.

4

Connect the voltmeter between starter motor earth connection K2 (+) and battery negative. The voltage reading with the starter switch in position 'HS' should be practically zero. If the reading is appreciably above zero, a high resistance in the earth lead or connections is indicated.

5

Connect the voltmeter between battery positive (+) and the starter motor main terminal K1 (-). With the starter switch 'OFF', the voltmeter should indicate battery voltage, but it should fall to practically zero when the switch is turned to position 'HS'. If the reading is appreciably above zero, a high resistance is present in the insulated lead or in the solenoid. Connect the voltmeter between the battery positive (+) and solenoid connection D. If the voltmeter now reads zero with the switch closed, the fault is in the solenoid.

To prevent the engine from starting during the tests ensure that the engine shut off solenoid is disconnected. Check the readings in the following sequence using a voltmeter (+ or - in the text indicates which voltmeter lead to use at the particular test point). Unless otherwise stated, the readings must be taken with the starter switch in the 'HS' position, the 6-speed gearbox gear lever set to nuetral and the front and rear PTO switches turned to the ' brake' positions. 1

Connect the voltmeter across the battery terminals. With starter switch in 'HS' position and starter motor running, the voltage reading should be approximately 10 volts. A low reading probably indicates a fault in the starter motor.

2

Connect the voltmeter between the starter motor main terminal K1 (+) and the starter motor earth connection K2 (-). With starter switch in 'HS' position and starter motor running, the voltage reading should not be more than 0.5 volt below the reading in Test 1. If the voltage reading is significantly more than 0.5 volt below the reading in Test 1, the starter solenoid contacts may be

Finally, reconnect the engine shut off solenoid.

Ca

F

G

O IGN

C H

Ba

HS

A

D

J1

Bb

E

J2

J +

K1

K

-

K2

A297190

9804/1103

60 - 10 - 05/7

8020 - C/21-2.3

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 10 - 05/8

2000 Series, 3000 Series Fault Finding - Vehicle Electrics (contÕd) Charging Circuit Test Note: The illustration below shows the battery location on Fastrac 2115, 2125 and 2135 machines. On Fastrac 2150 machines, the battery is on the left hand side of the machine and on 3000 Series machines the battery is in the cab. Before doing the following test, make sure that the battery and alternator connections are in good condition and that the fan belt is correctly adjusted. If the battery is in a fully charged condition, switch on the working lights for 3 minutes before commencing the test. Alternatively, operate the starter for a few moments with fuse A5 removed.

Start the engine and run at maximum speed (see Technical Data, Section T). Meter should show the maximum alternator output in Amps (see Technical Data, in this section). Note: The meter reading should be taken as soon as possible after starting the engine, as the charging current will fall rapidly. A zero reading indicates failure of the alternator and may be caused by one of the following conditions. These are listed in the order of probability. a

Defective suppression capacitor.

Disconnect the positive lead from battery terminal A.

b

Dirty sliprings or worn brushes.

Install a 100 Amp open-type shunt between the positive lead and the battery positive terminal A.

c

Defective regulator.

d

Defective rectifier.

e

Open or short-circuited field (rotor) windings.

f

Open or short-circuited power (stator) windings.

Connect a multimeter positive lead to vehicle side of the shunt and negative lead to battery side of the shunt. Connect the leads to the meter and set the meter to the relevant range as follows: AVO 2002

AVO 2003

FLUKE 85

To check for fault a, disconnect the capacitor and repeat the charging test. Renew the capacitor if necessary.

Red lead to volts (middle) socket on meter. Black lead to negative on meter. RH slider to DC voltage. LH slider as illustrated below. Red lead to amps socket (marked A) on meter. Black lead to negative on meter. RH slider to DC voltage. LH slider to 200 Ω Shunt.

To check for faults b and c, remove the regulator and brush box assembly. Check the condition of the brushes and, if necessary, clean the sliprings using extra-fine glasspaper. The regulator may only be checked by substitution. Faults d, e, and f may be checked only by removing and dismantling the alternator for further testing.

Red lead to volts socket (marked V Ω) on meter. Black lead to COM socket on meter. Set dial to mV.

A

A290400

9804/1103

60 - 10 - 05/8

8020 - C/22-1.3

Issue 1

CONTENTS

Fastrac

60 - 10 - 05/9

2000 Series, 3000 Series Fault Finding - Vehicle Electrics (cont’d) Tachometer Feed Test Use the hand throttle to set the engine speed to a value higher than idling speed, so that the charge lamp is extinguished. Using a pointer type (analogue) multimeter set to DC 10 volts range, measure the voltage at the small stud on the alternator with respect to the alternator casing. The voltage reading should be between 6 volts and 8 volts.

9804/1103

60 - 10 - 05/9

8020 - C/22-2.2

Issue 1

CONTENTS

Fastrac

60 - 10 - 05/10

2000 Series, 3000 Series Fault Finding - Electronic Management System Diagnostic Error Code Tables Error codes are able to identify individual faults within the system. It is unlikely that individual error codes will be generated erroneously by either the EMS or Transmission ECU. In the unlikely event that either of these units should fail, there will be a major failure. Before any diagnostic work is carried out, it is recommended that the initial start up sequence is watched closely to ensure that the both the EMS and the Transmission ECU are functioning correctly. To check both units, turn the starter key to ‘ON’. For a period of approximately 3 seconds the display is tested. Ensure that each of the display segments on the EMS display are functioning. Check that all of the display lamps are also illuminated. Ensure that the external buzzer sounds following display test; if not check the buzzer. If any of this does not happen, suspect a fault within the EMS. Reprogramming the EMS may cure this; if this fails, change the EMS. Following directly on from this, the centre display will display “HELLO” (dry clutch transmission) or “HI THERE” (wet clutch transmission) for approximately 2 seconds. This is done to inform the operator that the data link between the Transmission ECU and the EMS has been established correctly. If this does not happen, suspect the Transmission ECU is disconnected, or has an internal fault. Check all connections between the EMS and Transmission ECU, particularly the CAN bus. Turn the ignition off and on again to retest; if the fault persists, change the Transmission ECU. The dashboard will then revert back to its normal operation mode. * Non-displayable Fault Codes There are certain fault codes (D224 - D236 and T230) that are used for datalogging purposes but are not displayed to the driver. This is because these codes represent “abuse” information as opposed to an actual failure of the vehicle electrical system. E.g. If the oil pressure warning lamp is on for more than 10 seconds of engine running a fault code will be generated inside the EMS for datalogging purposes. The driver does not see this code as it is already supported by the warning lamp. Remember that the codes are historical data and oil levels, etc., may have been corrected since the faults were recorded In the following tables, the possible causes for each error code are listed in order of probability, and should always be checked in the order given.

Instrument Cluster Internal Error Codes Code

Description

Possible Cause

Action and Remedy

D001 EMS ROM memory error.

EMS internal fault.

Reprogram EMS using updated software. Change EMS if problem persists.

D002 EMS EPROM memory error.

May occur once after updating EMS software or setup values.

Switch off ignition and switch on. This should clear code.

EMS internal fault.

Change EMS.

EMS has detected a problem with the CAN Bus link.

Check CAN Bus link for short or open circuit.

D003 EMS CAN Bus switched off.

(continued)

9804/1103

60 - 10 - 05/10

8020 - C/40-1.3

Issue 2*

CONTENTS

Fastrac

60 - 10 - 05/11

2000 Series, 3000 Series Fault Finding - Electronic Management System (cont’d) Diagnostics Error Code Tables (continued) *

Instrument Cluster Internal Error Codes Code D010

D020

D021

Description Datalog memory full.

Speed sensor “present” line disconnected.

Speed sensor is assumed to have failed.

Possible Cause

Action and Remedy

The Datalog memory has reached capacity and can no longer store new error codes.

Download Datalog memory, investigate codes and erase Datalog memory.

Note: This code was removed at new software introduction JCBV0400.HEX. Handbook warning icon now illuminates if datalog becomes full.

If required, update EMS software to latest version.

Speed sensor supply fuse ruptured.

Check speed sensor supply fuse.

Speed sensor disconnected.

Check speed sensor connected.

Poor continuity of speed sensor supply line and “present” line.

With the ignition turned on, check for the presence of +12V at “present” line input to EMS.

This error is an ASSUMPTION, as the tractor appears to have been driven, but the EMS has not received any signals from the speed sensor.

Check function and operation of the speed sensor using a multimeter or the diagnostics function of the PSION Workabout.

May be caused by repeatedly operating the Selectronic range change with the tractor stationary and the park brake off.

Advise operator of cause to prevent further recurrences.

Damaged wiring.

Check continuity of signal line from speed sensor to the EMS.

Note: If this error occurs, the EMS sets the speed triggers to illegal settings which make the tractor usable but safe, causing error code T060, and disabling Selectronic High and Medium ranges. D030

Radar sense line disconnected.

Radar supply fuse ruptured.

Check radar supply fuse.

Radar disconnected.

Check radar connected.

Poor continuity of radar supply line and “present” line.

With the ignition turned on, check for the presence of +12V at “present” line input to EMS.

This code is deleted from JCBV0301 onwards, replaced by flashing radar symbol and non-displayed code D236. D031

No Bosch slip point signal.

Break in wiring between EMS and Bosch Hitchtronic ECU.

Check integrity of wiring from EMS to the Bosch ECU.

Options connectors have been joined on tractor without option package fitted (radar and fuel meters).

Disconnect options connectors; refer to wiring diagrams.

Faulty Bosch ECU, or wrong type of Bosch ECU fitted.

Check Bosch ECU part number is correct for options package fitted or change ECU. (continued)

9804/1103

60 - 10 - 05/11

8020 - C/40 - 2.2

Issue 2*

CONTENTS

Fastrac

60 - 10 - 05/12

2000 Series, 3000 Series Machines Fault Finding - Electronic Management System (cont’d) Diagnostic Error Code Tables (cont’d) Instrument Cluster Internal Error Codes Code

Description

D032

No fuel meter return signal.

D033

No fuel meter feed signal.

Possible Cause

Action and Remedy

Air in fuel lines means meter is not turning. (Can occur briefly in return line when first starting engine; from JCB V0500 software, condition must persist for 20 seconds).

Check fuel lines and check Datalog to see engine rpm when fault recorded.

Fuel meter is sticking.

Check fuel meter function and operation.

Options connectors have been joined on tractor without option package fitted (radar and fuel meters).

Disconnect options connectors; refer to wiring diagrams.

Damaged wiring.

Check integrity of wiring from fuel meter to the EMS.

D034

Fuel meter signal lines appear to have been swapped over.

This code was used in JCBV0301 only.

Check connections, referring to wiring diagrams. Update EMS software.

D040

Both PTO 1000 and PTO 540 selected.

Sometimes occurs when changing PTO speed selector if ignition is on, as the two switches are close to each other and lever has short travel.

Check Datalog to ensure that engine rpm was zero when code was logged. Advise operator of need to switch engine off before changing PTO speed.

Damaged wiring or short circuit switch.

Check integrity of wiring from PTO selector to the EMS and operation of both switches .

Tampering with fuel injection pump settings.

Check fuel injection pump; refer to engine manual.

Engine over sped by, for example, travelling downhill.

Check for signs of overspeeding; refer to engine manual.

EMS calibration figures incorrectly set up.

Check calibration figures in EMS setup.

Faulty alternator/voltage regulator.

Check supply voltage.

Jump start attempted from 24V battery.

Only use 12V battery for jump start.

Faulty sensor.

Check sensor for operation and function.

Damaged wiring.

Check continuity of wiring from sensor to the EMS.

Faulty sensor.

Check sensor for correct operation and function.

Damaged wiring.

Check integrity of wiring from sensor to the EMS.

Sometimes occurs when fuel tank filled. This code deleted from JCBV0200 onwards.

Update EMS software.

D041

D042

D050

D051

D052

Engine rpm over 2850 rpm.

Over voltage detected (>16V)

Coolant temperature sensor open circuit (after 20 minutes running). Coolant temperature sensor short circuit.

Fuel tank level sensor short circuit.

9804/1103

60 - 10 - 05/12

8020 - C/40 - 3.3

Issue 2*

CONTENTS

Fastrac

60 - 10 - 05/13

2000 Series, 3000 Series Machines Fault Finding - Electronic Management System (cont’d) Diagnostic Error Code Tables (continued) * Notes for Non-displayable Fault Codes: † †† ‡

Fault must be present for 10 seconds with the engine running before the code is logged. Fault must be present for 1 minute before the code is logged. Code will be logged if the vehicle has been moving at > 1 kph and the fault present for 5 seconds.

Non-displayable Fault Codes Code

Description

D224† Engine oil pressure low.

D225† Transmission oil pressure low.

D226† Transmission oil filter blocked.

Possible Cause

Action and Remedy

Low engine oil pressure.

Check engine oil pressure; refer to engine service manual for causes of low oil pressure.

Faulty engine oil pressure switch.

Check pressure switch for correct operation.

Damaged wiring.

Check integrity of wiring from switch to EMS.

Low transmission oil pressure.

Check transmission oil pressure.

Faulty transmission oil pressure switch.

Check pressure switch for correct operation.

Damaged wiring between switch and Transmission ECU.

Check integrity of wiring from transmission oil pressure switch to Transmission ECU, noting that one pressure switch pin connects to two ECU pins; refer to wiring diagrams.

Damaged wiring between Transmission ECU and EMS.

Check integrity of warning light wiring from Transmission ECU to EMS; refer to wiring diagrams.

Blockage in transmission oil filter.

Change filter.

Note: It is important also to investigate the cause of the filter blockage.

D227† Air filter blocked

D228†

Trailer ABS fault

Faulty blockage switch.

Check pressure switch for correct operation.

Damaged wiring.

Check integrity of wiring from switch to EMS.

Blockage in air filter.

Change the outer air filter and also the inner filter if required.

Faulty blockage switch.

Check pressure switch for correct operation.

Damaged wiring.

Check integrity of wiring from switch to EMS.

Signal from trailer ABS system.

Investigate trailer system. (continued)

9804/1103

60 - 10 - 05/13

8020 - C/40 - 4.2

Issue 2*

CONTENTS

Fastrac

60 - 10 - 05/14

2000 Series, 3000 Series Machines Fault Finding - Electronic Management System (cont’d) Diagnostic Error Code Tables (cont’d) Non-displayable Fault Codes (cont’d) Code D229†

D230†

Description Alternator “No Charge” warning.

Action and Remedy

Slack or worn alternator drive belts.

Check alternator drive belt tension and condition.

Internal alternator fault.

Check alternator output and operation.

Brake fluid level low. Low brake fluid level in one or both actuator reservoirs.

Check level of fluid on both brake fluid reservoirs.

D231‡

Air tank 1 pressure low.

D232‡

Air tank 2 pressure low.

D233‡

Air tank 3 pressure low.

D234

Possible Cause

Faulty fluid level switch.

Check operation of switches by pressing test buttons on switch body.

Low pressure in air tank.

Check for leaks, etc.

Faulty air pressure switch.

Check air pressure switch fo correct operation and function.

Air tank not charging.

Check operation of circuit protection valve.

Damaged wiring.

Check integrity of wiring from switch to EMS.

Handbrake on when Driving before handbrake is released. moving. Faulty air pressure switch.

Check air pressure switch for correct operation and function.

Damaged wiring.

Check integrity of wiring from switch to EMS.

Excessive datalogging by older versions of EMS software.

Check version of software. Update to current version.

The code will be logged if the vehicle has been moving at > 3 kph for 10 seconds and: (i) instantly the handbrake is applied(up to JCBV0400) (ii) the handbrake has been on for 10 seconds (from JCBV0500) D235†† Engine coolant over temperature.

Blocked radiator. Note: From JCBV0400 on, Insufficient coolant in radiator. Fault must be present for 1 minute Slack or worn drive belts before it is logged. Faulty thermostat. Faulty temperature switch. Damaged wiring.

Check radiator and grille for blockage.

Check operation of thermostat. Check operation of temperature switch. Check integrity of wiring from temperature switch to EMS. (continued)

9804/1103

60 - 10 - 05/14

8020 - C/40 - 5.3

Issue 2*

CONTENTS

Fastrac

60 - 10 - 05/15

2000 Series, 3000 Series Machines Fault Finding - Electronic Management System (cont’d) Diagnostic Error Code Tables (cont’d) Non-displayable Fault Codes (cont’d) Code D236†

Description Radar not connected.

Possible Cause Options connectors have been joined on tractor without option package fitted (radar and fuel meters).

(Radar symbol also Break in wiring between radar unit and EMS. flashes).

Action and Remedy Disconnect options connectors; refer to wiring diagrams.

Check integrity of wiring from radar unit to EMS.

Note: This code replaces D030 from JCBV0301 on.

Transmission ECU Internal Error Codes Code T000

Description

Possible Cause

No CAN Alive Power supply to Transmission ECU failed signals from the Transmission ECU Open circuit in CAN Bus wiring arriving at the EMS Short circuit in CAN Bus wiring

Action and Remedy Check fuse and power supply Check connections Check integrity of insulation with multimeter

Faulty resistor in CAN Bus wiring diagram

Check CAN Bus resistors; refer to wiring

Transmission ECU faulty

Change Transmission ECU

T001

EPROM memory not working

Transmission ECU internal fault

Change Transmission ECU

T002

Suspect data in EPROM memory

Transmission ECU internal fault

Change Transmission ECU

T003

EPROM memory continually busy

Transmission ECU internal fault

Change Transmission ECU

T004

Factory default values not valid

Transmission ECU internal fault

Change Transmission ECU

T005

Wet clutch calibration values out of range

Wet clutch not calibrated or calibrated incorrectly

Re-calibrate the clutch. See Powershift and Master Clutch Calibration

9804/1103

60 - 10 - 05/15

8020 - C/40 - 6.2

Issue 2*

CONTENTS

Fastrac

60 - 10 - 05/16

2000 Series, 3000 Series Machines Fault Finding - Electronic Management System (cont’d) Diagnostic Error Code Tables (cont’d) Powershift Error Codes Code T010

T011

T012

T013

T014

T015

T016

Description Snail solenoid open circuit

Snail solenoid short

Snail solenoid driver over temperature

Tortoise solenoid open circuit

Tortoise solenoid short circuit

Tortoise solenoid driver over temperature

Hare solenoid open circuit

Possible Cause

Action and Remedy

Internal breakdown of solenoid coil

Check solenoid for continuity

Damaged wiring

Check continuity of wiring from solenoid to both Transmission ECU and earth; refer to wiring diagram

Solenoid coil faulty internally circuit

Check solenoid resistance, which should be 5 ohms

Damaged wiring

Check for short circuit to earth in wiring between solenoid and Transmission ECU

Caused by abnormally high current drawn from Transmission ECU (the driver is inside the ECU and is not serviceable) Solenoid coil faulty internally

Check solenoid resistance, which should be 5 ohms

Damaged wiring

Check for short circuit or low resistance to earth in wiring between solenoid and Transmission ECU

Internal breakdown of solenoid coil

Check solenoid for continuity

Damaged wiring

Check continuity of wiring from solenoid to both Transmission ECU and earth; refer to wiring diagram

Internal breakdown of solenoid coil

Check solenoid for continuity

Damaged wiring

Check for short circuit to earth in wiring between solenoid and Transmission ECU

Caused by abnormally high current drawn from Transmission ECU (the driver is inside the ECU and is not serviceable) Solenoid coil faulty internally

Check solenoid resistance, which shoiuld be 5 ohms

Damaged wiring

Check for short circuit or low resistance to earth in wiring between solenoid and Transmission ECU

Internal breakdown of solenoid coil

Check solenoid for continuity

Damaged wiring

Check continuity of wiring from solenoid to both Transmission ECU and earth; refer to wiring diagram (continued)

9804/1103

60 - 10 - 05/16

8020 - C/40 - 7.2

Issue 2*

CONTENTS

Fastrac

60 - 10 - 05/17

2000 Series, 3000 Series Machines Fault Finding - Electronic Management System (cont’d) Diagnostic Error Code Tables (cont’d) Powershift Error Codes (cont’d) Code T017

T018

Description Hare solenoid short

Hare solenoid driver over temperature

Possible Cause

Action and Remedy

Solenoid coil faulty internally circuit

Check solenoid resistance, which should be 5 ohms

Damaged wiring

Check for short circuit to earth in wiring between solenoid and Transmission ECU

Caused by abnormally high current drawn from Transmission ECU (the driver is inside the ECU and is not serviceable) Solenoid coil faulty internally

Check solenoid resistance, which shoiuld be 5 ohms

Damaged wiring

Check for short circuit or low resistance to earth in wiring between solenoid and Transmission ECU

Wet Clutch Lubrication Error Codes Code T019

T020

Description Clutch lubrication solenoid open circuit

Clutch lubrication

Possible Cause

Action and Remedy

Solenoid coil faulty internally

Check solenoid for continuity

Damaged wiring

Check for short circuit to earth in wiring between solenoid and Transmission ECU

Solenoid coil faulty internally solenoid short

Check solenoid resistance, which should be 5 ohms

Damaged wiring

Check for short circuit to earth in wiring between solenoid and Transmission ECU

circuit

T021

9804/1103

Clutch lubrication solenoid driver over temperature

Caused by abnormally high current drawn from Transmission ECU (the driver is inside the ECU and is not serviceable) Solenoid coil faulty internally

Check solenoid resistance, which should be 5 ohms

Damaged wiring

Check for short circuit or low resistance to earth in wiring between solenoid and Transmission ECU

60 - 10 - 05/17

8020 - C/40 - 8.3

Issue 2*

CONTENTS

Fastrac

60 - 10 - 05/18

2000 Series, 3000 Series Machines Fault Finding - Electronic Management System (cont’d) Diagnostic Error Code Tables (cont’d) * Reverse Lamp Error Codes - Dry Clutch Machines only Code T022

Description

Possible Cause

Reversing lamp open For this circuit to be open, both reversing circuit. bulbs and the trailer reverse light relay (if fitted) must all have failed open circuit. Damaged wiring

Action and Remedy Check reversing light bulbs and relay (if fitted); refer to wiring diagrams.

Check continuity of wiring from Transmission ECU to reversing lights and trailer reverse lights relay (if fitted); refer to wiring diagram.

T023

Reversing lamp short Trailer reversing light bulb or relay short circuit. Check reversing light bulbs and relay. circuit. Damaged wiring Check integrity of wiring from Transmission ECU to reversing lights and trailer reverse lights relay (if fitted); refer to wiring diagram.

T024

Reversing lamp driver over temperature.

Caused by abnormally high current drawn from Transmission ECU (the driver is inside the ECU and is not serviceable). Internal failure of the relay.

Check relay for function.

Damaged wiring

Check for short circuit or low resistance to earth in wiring from ECU to reversing lights and trailer reverse lights relay (if fitted); refer to wiring diagram.

Incorrect wattage bulbs fitted.

Check bulbs and replace as necessary.

Selectronic Air Solenoid Error Codes Code

Description

Possible Cause

Action and Remedy

T025

L ram neutral air Internal breakdown of a solenoid coil. solenoid open circuit.

Check individual solenoid for continuity, as guided by the individual fault code.

T026

R ram engage air Wiring fault. solenoid open circuit.

Check supply and return wiring between Transmission ECU and relevant solenoid(s); refer to wiring diagram.

T027

M ram engage air solenoid open circuit.

T028

H ram neutral air solenoid open circuit.

T029

L ram engage air solenoid open circuit.

T030

R ram neutral air solenoid open circuit.

T031

M ram neutral air solenoid open circuit.

T032

H ram engage air solenoid open circuit.

9804/1103

Note: If either all four neutral solenoids or all four engage solenoids are showing failures, it is likely to be a supply fault. If there is only one solenoid failure, it is likely to be an individual solenoid return.

60 - 10 - 05/18

8020 - C/40 - 9.2

Issue 2*

CONTENTS

Fastrac

60 - 10 - 05/19

2000 Series, 3000 Series Machines Fault Finding - Electronic Management System (cont’d) Diagnostic Error Code Tables (cont’d) Selectronic Air Solenoid Error Codes Code

Description

Possible Cause

Action and Remedy

T033

One air solenoid has short circuit.

Internal solenoid failure.

Check solenoid resistance, which should be 75 to 80 ohms. Determine which solenoid has failed by sequencing through all Selectronic gear changes.

T034

Air solenoid valve block 12V supply line short circuit.

Damaged wiring.

Check that the common air valve supply lines from the Transmission ECU are not shorting to earth; refer to wiring diagrams.

T035

Air solenoid valve block 12V supply over temperature.

Caused by abnormally high current drawn from Transmission ECU (the driver is inside the ECU and is not serviceable). Internal solenoid failure.

Check all air solenoid resistances, which should each be 75 to 80 ohms.

Damaged wiring.

Check for short circuit or low resistance to earth in common supply from Transmission ECU to air solenoids.

T040

REV engage.

All these switches appear to be OPEN and should be CLOSED.

T041

LOW engage.

T042

MED engage.

These codes can also result from attempting Check air pressure and operation of to use Selectronic with insufficient air pressure, cylinders. causing insufficient cylinder movement to operate the switches normally, or air cylinder Check for air cylinder leaks. leaks which also cause slow or weak air cylinder movement.

T043

HIGH engage.

T044

REV neutral.

T045

LOW neutral.

T046

MED neutral.

T047

HIGH neutral.

9804/1103

Failed switch (open circuit).

Check switch operation using a magnet and multimeter, or by using the diagnostics function of the Psion Workabout.

Wiring faulty.

Check supply and return wiring between Transmission ECU and switches; refer to wiring diagram.

60 - 10 - 05/19

8020 - C/40 - 10.3

Issue 2*

CONTENTS

Fastrac

60 - 10 - 05/20

2000 Series, 3000 Series Machines Fault Finding - Electronic Management System (cont’d) Diagnostic Error Code Tables (cont’d) Selectronic Air Solenoid Error Codes Code

Description

Possible Cause

Action and Remedy

T050

REV engage.

All these switches appear to be CLOSED and should be OPEN .

T051

LOW engage.

T052

MED engage.

These codes can also result from attempting Check air pressure and operation of to use Selectronic with insufficient air pressure, cylinders. causing insufficient cylinder movement to operate the switches normally, or air cylinder Check for air cylinder leaks. leaks which also cause slow or weak air cylinder movement.

T053

HIGH engage.

T054

REV neutral.

T055

LOW neutral.

T056

MED neutral.

T057

HIGH neutral.

Failed switch.

Check switch operation using a magnet and multimeter, or by using the diagnostics function of the Psion Workabout.

Wiring faulty.

Check supply and return wiring between Transmission ECU and switches; refer to wiring diagram.

Illegal Speed Trigger Error Codes Code T060

Description Triggers <1, <3 and >20 kph.

Possible Cause

Action and Remedy

The EMS sets the speed triggers to these Check for error codes D020 or D021. values if it detects a speed sensor fault. These settings make the tractor systems safe but useable; for example, Quadtronic is forced to 2WS. Break in 20 kph signal line from EMS to Transmission ECU.

Check continuity of 20 kph line, referring to wiring diagrams.

T061

Triggers >1, <3 and >20 kph.

Break in 3 kph and/or 20 kph line from EMS to Transmission ECU.

Check continuity of 3 kph and/or 20 kph lines, referring to wiring diagrams.

T062

Triggers <1, >3 and >20 kph.

Break in 1 kph line from EMS to Transmission ECU.

Check continuity of 1 kph line, referring to wiring diagrams.

T063

Triggers <1, >3 and <20 kph.

Break in 1 kph line from EMS to transmission ECU.

Check continuity of 1 kph line, referring to wiring diagrams.

Short to 12V on 3 kph line from EMS to Transmission ECU.

Check for short on 3 kph line, referring to wiring diagrams.

9804/1103

60 - 10 - 05/20

8020 - C/40 - 11.2

Issue 2*

CONTENTS

Fastrac

60 - 10 - 05/21

2000 Series, 3000 Series Machines Fault Finding - Electronic Management System (cont’d) Diagnostic Error Code Tables (cont’d) Clutch Switch Error Codes *(Dry clutch transmission) Code T070

Description

Possible Cause

Clutch switches show One of clutch pedal switches is faulty or clutch pedal both jammed. fully up and fully down at the same time.

Action and Remedy Check both switches for correct operation and function.

Wet Clutch Transmission Error Codes Code T071

T072

Description Transmission brake solenoid open circuit

Transmission brake

Possible Cause

Action and Remedy

Solenoid coil faulty internally

Check solenoid for continuity

Damaged wiring

Check for short circuit to earth in wiring between solenoid and Transmission ECU

Solenoid coil faulty internally solenoid short

Check solenoid resistance, which should be 5 ohms

Damaged wiring

Check for short circuit to earth in wiring between solenoid and Transmission ECU

circuit

T073

T077

Transmission brake solenoid driver over temperature

Transmission oil over temperature *Note: The low transmission oil pressure light will flash when this fault is present

T078

Wet clutch over temperature *Note: The low transmission oil pressure light will flash when this fault is present

T079

9804/1103

Oil temperature sensor fault

Caused by abnormally high current drawn from Transmission ECU (the driver is inside the ECU and is not serviceable) Solenoid coil faulty internally

Check solenoid resistance, which should be 5 ohms

Damaged wiring

Check for short circuit or low resistance to earth in wiring between solenoid and Transmission ECU

Low transmission oil level

Check and correct oil level

Blocked or damaged oil cooler

Clean or renew cooler

Faulty sensor unit

Renew sensor unit, check potentiometer operation Service clutch

Low transmission oil level

Check and correct oil level

Lubrication oil supply failure

Check clutch lubrication oil pressures

Excessive clutch slip

Check clutch control valve operation, potentiometer operation. Service clutch

Faulty sensor unit

Renew sensor

Damaged wiring

Check for short circuit or low resistance to earth in wiring between sensor and Transmission ECU

60 - 10 - 05/21

8020 - C/40 - 12.1

Issue 2*

CONTENTS

Fastrac

60 - 10 - 05/22

2000 Series, 3000 Series Machines Fault Finding - Electronic Management System (cont’d) Column Switch Connection Error Codes Code

Description

Possible Cause

Action and Remedy

T080

Low and reverse Faulty column switch. appear both selected.

Check switch for correct operation and function, using a multimeter or the diagnostics function of the PSION Workabout.

T081

Low and medium Damaged wiring. appear both selected.

Check integrity of wiring from column switch to both the EMS and the Transmission ECU.

T082

Low and high appear both selected.

T083

High and reverse appear both selected.

T084

Medium and reverse appear both selected.

T085

Medium and high appear both selected. Wet Clutch Control Error Codes

Code T100

T101

T102

T103

9804/1103

Description Wet clutch solenoid open circuit

Wet Clutch solenoid short circuit

Wet Clutch solenoid driver over temperature

Not enough wet clutch solenoid valve current when clutch pedal up.

Possible Cause

Action and Remedy

Solenoid coil faulty internally

Check solenoid for continuity

Faulty inching resistor

Check resistance of inching resistor, which should be 4.7 ohms

Damaged wiring

Check for open circuit in wiring between solenoid and Transmission ECU

Solenoid coil faulty internally

Check solenoid resistance, which should be 7 to 14 ohms

Faulty inching resistor

Check resistance of inching resistor, which should be 4.7 ohms

Damaged wiring

Check for short circuit to earth in wiring between solenoid and Transmission ECU

Caused by abnormally high current drawn from Transmission ECU (the driver is inside the ECU and is not serviceable) Solenoid coil faulty internally

Check solenoid resistance

Damaged wiring

Check for short circuit or low resistance to earth in wiring between solenoid and Transmission ECU

Solenoid coil faulty internally.

Check solenoid for continuity

Faulty inching resistor.

Check resistance of inching resistor, which should be 4.7 ohms.

Damaged wiring.

Check for open circuit in wiring between solenoid and transmission ECU.

Low ECU supply voltage.

Check ECU supply wiring.

60 - 10 - 05/22

8020 - C/40 - 13.1

Issue 2*

CONTENTS

Fastrac

60 - 10 - 05/23

2000 Series, 3000 Series Machines Fault Finding - Electronic Management System (cont’d) Diagnostic Error Code Tables (cont’d) Wet Clutch Control Error Codes (cont’d) Code T114

T115

Description Clutch pedal is fully down but clutch switch has not operated

Clutch pedal is fully up but clutch down switch has not released

Possible Cause

Action and Remedy

Clutch pedal not adjusted correctly

Adjust pedal

Faulty clutch switch

Check switch operation

Damaged wiring

Check for open circuit

Faulty clutch switch

Check switch operation

Damaged wiring

Check for short circuit

T120

Clutch potentiometer Faulty potentiometer or installation calibrated position is too high

Check potentiometer mounting and operation

T121

Clutch potentiometer See code T120 calibrated position is too low

See code T120

T122

Clutch potentiometer See code T120 above calibrated limits

See code T120

T123

Clutch potentiometer See code T120 below calibrated limits

See code T120

T124

Clutch potentiometer Faulty potentiometer is above electrical limits Faulty wiring

Check potentiometer operation

T125

Check related wires for damage

Clutch potentiometer Faulty potentiometer is below electrical limits Faulty wiring

Check potentiometer operation Check related wires for damage

T126

Clutch pedal calibrated range too small

Clutch operation not calibrated correctly

Calibrate clutch

T130

Splitter safety dump relay does not operate when clutch pedal is fully depressed.

Relay faulty

Check relay

Relay wiring faulty

Check wiring.

Splitter safety dump relay operates even though clutch pedal released.

Relay faulty

Check relay

Relay wiring faulty

Check wiring

T131

9804/1103

60 - 10 - 05/23

8020 - C/40 - 14.1

Issue 2*

CONTENTS

Fastrac

60 - 10 - 05/24

2000 Series, 3000 Series Machines Fault Finding - Electronic Management System (cont’d) Diagnostic Error Code Tables (cont’d) Non-displayable Fault Codes Code T230

9804/1103

Description

Possible Cause

Action and Remedy

“Limp Home” mode activated.

Driver used “Limp Home” mode.

Find reason for use of this mode and rectify any faults.

Note: This mode is not available on Transmission ECU Part Number 704/33700.

Damaged wiring.

Check integrity of wiring from switch to EMS.

60 - 10 - 05/24

8020 - C/40 - 15.1

Issue 2*

CONTENTS

Fastrac

60 - 10 - 06/1

ALL MODELS *

Fault Finding - Complete Transmission Complete Transmission If the problem is noise rather than loss of drive start at check 7. CHECK

ACTION

1

Is drive being transmitted to the road wheels?

YES: NO:

Check 7. Check 2.

2

Is the clutch actuation system functioning?

YES: NO:

Check 3. Check clutch actuation. See Note 2 below.

3

Is the clutch slipping?

YES: NO:

Examine and repair clutch. See Note 2 below. Check 4.

4

Are range and speed gearboxes both in gear?

YES: NO:

Check 5. Engage gear/check gearchange linkages.

5

Is 6-speed gearbox heard to drive with the range gearbox in neutral?

YES: NO:

Check 6. Remove and examine 6-speed gearbox.

6

Does rear axle driveshaft rotate with both gearboxes in gear?

YES: NO:

Check rear axle. Check range gearbox.

7

Is fault noise rather than loss of drive?

YES: NO:

Check 8. Check 10.

8

Is transmission noisy with speed gearbox in gear and range gearbox in neutral?

YES:

Examine speed gearbox for worn/damaged components. Check 9.

NO: 9

Isolate noise source to range box or rear axle or front axle by disconnecting relevant drive shafts.

10

Is transmission oil level low?

Examine relevant transmission element for worn/damaged components. YES:

Fill to correct level.

Note 1: When carrying out fault finding on the transmission always check for any error codes that may have been generated by the electronic management system. See Fault Finding (Electronic Management System) Section C. Note 2: For machines fitted with a wet master clutch transmission see Fault Finding - Wet Master Clutch.

9804/1103

60 - 10 - 06/1

8020 - F/5-1.2

Issue 2*

CONTENTS

Fastrac

60 - 10 - 06/2

2000 AND 3000 SERIES MACHINES * Fault

Finding - Wet Master Clutch

Symptom A Clutch fails to engage. Clutch slips. Clutch engages erratically. CHECK

ACTION

1

Is the transmission oil level low?

YES: NO:

Fill to correct level. Check 2.

2

Is the pressure maintenance valve set correctly?

YES: NO:

Check 3. Set the valve to the correct pressure.

3

Is the clutch pedal potentiometer faulty?

YES: NO:

Renew the potentiometer. Check 4.

4

Is the clutch hydraulic pressure low?

YES:

NO:

Recheck 2, check related external pipework for leaks. Check 5. Check 5.

Is the clutch control valve operating correctly?

YES: NO:

Check 6. Renew the valve.

*6

Is pedal calibration correct?

YES: NO:

Check 7. Re-calibrate pedal

*7

Are the clutch piston seals leaking?

YES: NO:

Renew piston seals, see the Note below. Check 8.

5

Note: The following checks can only be carried out after the complete gearbox assembly has been removed from the machine. Make sure that all other checks have been carried out correctly before contemplating removal of the gearbox. *8

Is the clutch piston check valve faulty?

YES:

Renew the check valve.

*9

Are the clutch friction plates worn?

YES:

Renew the plates.

* 10

Are steps visible in the drive tangs on the clutch drum?

YES:

Renovate or renew the drum as required.

Symptom B Clutch fails to disengage correctly when machine is in motion (clutch drag). CHECK

ACTION

1

Is the transmission oil level too high?

YES: NO:

Adjust oil level, check for oil contamination. Check 2.

2

Is the clutch external return line pipework damaged?

YES: NO:

Renew pipes as required. Check 3.

3

Is the clutch pedal potentiometer faulty?

YES: NO:

Renew the potentiometer. Check 4.

4

Is the clutch control valve operating correctly?

YES: NO:

Check 5. Renew the valve.

Is pedal calibration correct?

YES: NO:

Check 6. Re-calibrate pedal.

*5

Note: The following checks can only be carried out after the complete gearbox assembly has been removed from the machine. Make sure that all other checks have been carried out correctly before contemplating removal of the gearbox. *6

Is the clutch piston check valve faulty?

YES:

Renew the check valve.

*7

Are steps visible in the drive tangs on the clutch drum?

YES:

Renovate or renew the drum as required.

*8

Are the clutch return springs worn or broken?

YES: NO:

Renew the springs. Always renew the springs even if they appear serviceable.

9804/1103

60 - 10 - 06/2

8020 - F/5-2.2

Issue 2*

CONTENTS

Fastrac

60 - 10 - 06/3

2000 AND 3000 SERIES MACHINES *

Fault Finding - Wet Master Clutch (cont’d)

Symptom C Clutch fails to disengage correctly when selecting a gear with the machine stationary (clutch drag). CHECK

ACTION

1

Carry out checks 1 to 4 for symptom B then carry out check 2 below.

2

Is the transmission brake hydraulic pressure low?

YES: NO:

Check 3. Check 5.

3

Is the transmission oil level low?

YES: NO:

Fill to correct level. Check 4.

4

Is the pressure maintenance valve set correctly?

YES: NO:

Check 5. Set the valve to the correct pressure.

5

Is the brake solenoid valve operating correctly?

YES: NO:

Check 5. Renew the valve.

6

Are the brake piston seals leaking?

YES: NO:

Renew piston seals, see the Note below. Check 7.

Note: The following checks can only be carried out after the complete gearbox assembly has been removed from the machine. Make sure that all other checks have been carried out correctly before contemplating removal of the gearbox. 7

Are the brake friction plates worn?

8

Carry out checks 5 to 7 for symptom B.

9804/1103

YES: NO:

60 - 10 - 06/3

Renew the plates. Check 8.

8020 - F/5-3.1

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 10 - 07/1

ALL MODELS Fault Finding - Power Take Off Clutches If the problem is a partial or complete lack of drive to PTO drive lines start at check 1. If the problem is that the PTO shaft continues to rotate when selector switch is in the 'brake' position, start at check 12.

ACTION

CHECK 1

Are both front and rear PTO drive lines fitted?

YES: NO:

Check 2. Check 3.

2

Has drive been lost to both shafts?

YES: NO:

Check 3. Check 4.

3

Is the PTO speed selector lever engaged and cable/selector mechanism intact?

YES: NO:

Rectify fault in PTO gearbox. Rectify cable/selector mechanism and engage gear.

Note: Checks from 4 onwards refer to either front or rear PTO operating mechanism. 4

Is PTO drive line intact?

YES: NO:

Check 5. Repair as necessary.

5

Is there a leak in the extended pipework to the PTO drive clutch?

YES: NO:

Rectify leak. Check 6.

6

Is the transmission hydraulic circuit pressure correct?

YES: NO:

Check 7. Adjust pressure.

7

Is the transmission hydraulic circuit pressure filter blocked?

YES: NO:

Replace filter element. Check 8.

8

Is current reaching the PTO drive solenoid?

YES: NO:

Check 9. Check 10.

9

Is the PTO drive solenoid defective?

YES: NO:

Replace the defective solenoid. Check 10.

10

Is the PTO selector switch passing current in the PTO 'drive' position?

YES: NO:

Check 11. Replace PTO selector switch.

11

Is the PTO drive solenoid spool sticking?

YES: NO:

Free off or renew valve. Remove and dismantle PTO clutch pack and inspect condition.

12

Does the PTO shaft continue to rotate when the PTO selector switch is in the 'brake' position?

YES: NO:

Check 13. Check 14.

13

Is there a leak in the external pipework to the PTO brake?

YES: NO:

Rectify leak. Check 14.

14

Is the transmission hydraulic circuit pressure correct?

YES: NO:

Check 15. Adjust pressure.

15

Is the transmission hydraulic circuit pressure filter blocked?

YES: NO:

Replace filter element. Check 16.

16

Is current reaching the PTO brake solenoid?

YES: NO:

Check 17. Check 18.

9804/1103

60 - 10 - 07/1

CONTENTS CONTENTS

Fastrac

60 - 10 - 07/2

ALL MODELS Fault Finding - Power Take Off Clutches (continued)

ACTION

CHECK 17

Is the PTO brake solenoid defective?

YES: NO:

Replace solenoid. Check 18.

18

Is the PTO selector switch passing current in the PTO 'brake' position?

YES: NO:

Check 19. Replace PTO selector switch.

19

Is the PTO brake solenoid spool sticking?

YES: NO:

Free off or renew valve. Dismantle and examine PTO brake assembly.

9804/1103

60 - 10 - 07/2

CONTENTS CONTENTS

Fastrac

60 - 10 - 08/1

ALL MACHINES 2/4 Wheel Drive - Fault Finding

No four-wheel drive but all gears functioning in two-wheel drive. CHECK

ACTION

1

Is the front axle drive train intact?

YES: NO:

Check 2. Repair as required.

2

Is 2WD dump switch permanently closed with parking brake on?

YES: NO:

Replace 2WD dump switch. Check 3.

3

Is the 2/4WD solenoid spool sticking?

YES: NO:

Dismantle/renew valve. Check 4.

4

Put the starter switch in "IGN" position. Select 4WD. Is there a voltage reading at the 4WD relay?

YES: NO:

Renew 2/4WD switch. Check 5.

5

Put the starter switch in"'IGN" position. Select 4WD. Is there a voltage reading at the 2/4WD solenoid socket?

YES: NO:

Renew 2/4WD drive relay. Dismantle 4WD clutch and inspect condition.

Two-wheel drive cannot be engaged (or four-wheel drive will not disengage). CHECK

ACTION

1

Is there a leak in the external pipework to the 2/4WD clutch?

YES: NO:

Rectify leak. Check 2.

2

Is the transmission hydraulic circuit pressure correct?

YES: NO:

Check 3. Adjust pressure.

3

Is the transmission hydraulic circuit pressure filter blocked?

YES: NO:

Replace filter element. Check 4.

4

Is current reaching the 2/4WD solenoid when the starter switch is in "IGN" position and 2WD is selected'?

YES: NO:

Check 5. Check 6.

5

Is the 2WD dump switch permanently open, even with the park brake disengaged?

YES: NO:

Renew 2/4WD dump switch. Dismantle 4WD clutch and check condition, particularly the piston seals.

6

Is the 2/4WD solenoid defective?

YES: NO:

Replace the defective solenoid. Check 7.

7

Is the 2/4WD selector switch passing current in the 2WD position?

YES: NO:

Check 8. Renew 2/4WD selector switch.

8

Is the 2/4WD solenoid spool sticking?

YES:

Free off or renew valve.

9804/1103

60 - 10 - 08/1

8020 - F/7-1.1

Issue 1

CONTENTS

Fastrac

125, 135, 145, 150, 155, 185 Fault Finding - Differential Lock (rear axle)

Differential lock will not engage. CHECK

ACTION

1

Is there a leak in the external pipework to the differential lock?

YES: NO:

Rectify leak. Check 2.

2

Is the transmission hydraulic circuit pressure correct?

YES: NO:

Check 3. Adjust pressure.

3

Is the transmission hydraulic circuit pressure filter blocked?

YES: NO:

Replace filter element. Check 4.

4

Is current reaching the 4WD/differential lock solenoid?

YES: NO:

Check 5. Check 6.

5

Is the 4WD/differential lock solenoid defective?

YES: NO:

Replace the defective solenoid. Check 7.

6

Is the 4WD/differential lock selector switch passing current in the 4WD and diff. lock position?

YES: NO:

Check 7. Replace 4WD drive/differential lock selector switch.

7

Is the 4WD/differential lock solenoid spool sticking?

YES: NO:

Free off or renew valve. Dismantle differential lock mechanism and check condition of drive dogs and piston seals.

Differential lock will not disengage. CHECK

ACTION

1

Put the starter switch in "IGN" position. Is current reaching the 4WD/differential lock solenoid when only 4WD is selected?

YES: NO:

Renew 4WD/differential lock selector switch. Check 2.

2

Is the 4WD/differential lock solenoid spool sticking?

YES: NO:

Free off or renew valve. Dismantle 4WD/differential lock mechanism and check condition of release spring and piston for sticking.

60 - 10 - 11/1

Issue 3

9804/1103

CONTENTS

Fastrac

* FASTRAC 1115, 1135, 2115, 2125, 2135, 2150 Fault Finding - Differential Lock

Differential lock will not engage. CHECK

ACTION

1

Is there a leak in the external pipework to the differential lock?

YES: NO:

Rectify leak. Check 2.

2

Is the transmission hydraulic circuit pressure correct?

YES: NO:

Check 3. Adjust pressure.

3

Is the transmission hydraulic circuit pressure filter blocked?

YES: NO:

Replace filter element. Check 4.

4

Is current reaching the differential lock solenoid?

YES: NO:

Check 5. Check 6.

5

Is the differential lock solenoid defective?

YES: NO:

Replace the defective solenoid. Check 7.

6

Is the 4WD/differential lock selector switch passing current in the 4WD and diff. lock position?

YES: NO:

Check 7. Replace 4WD drive/differential lock selector switch.

7

Is the differential lock solenoid spool sticking?

YES: NO:

Free off or renew valve. Dismantle differential lock mechanism and check condition of drive plates and piston seals.

Differential lock will not disengage. ACTION

CHECK 1

Put the starter switch in "IGN" position. Is current reaching the differential lock solenoid when only 4WD is selected?

YES: NO:

Renew 4WD/differential lock selector switch. Check 2.

2

Is the differential lock solenoid spool sticking?

YES: NO:

Free off or renew valve. Dismantle differential lock mechanism and check condition of release spring and piston for sticking.

60 - 10 - 11/2

Issue 2*

9804/1103

CONTENTS CONTENTS

Fastrac

60 - 10 - 11/3

2000 Series, 3000 Series Fault Finding - Differential Lock Differential lock will not engage. CHECK

ACTION

1

Is there a leak in the external pipework to the differential lock?

YES: NO:

Rectify leak. Check 2.

2

Is the transmission hydraulic circuit pressure correct?

YES: NO:

Check 3. Adjust pressure.

3

Is the transmission hydraulic circuit pressure filter blocked?

YES: NO:

Replace filter element. Check 4.

4

Is current reaching the differential lock solenoid?

YES: NO:

Check 5. Check 6.

5

Is the differential lock solenoid defective?

YES: NO:

Replace the defective solenoid. Check 7.

6

Is the 4WD/differential lock selector switch passing current in the 4WD and diff. lock position?

YES: NO:

Check 7. Replace 4WD drive/differential lock selector switch.

7

Is the differential lock solenoid spool sticking?

YES: NO:

Free off or renew valve. Dismantle differential lock mechanism and check condition of drive plates and piston seals.

Differential lock will not disengage. ACTION

CHECK 1

Put the starter switch in "IGN" position. Is current reaching the differential lock solenoid when only 4WD is selected?

YES: NO:

Renew 4WD/differential lock selector switch. Check 2.

2

Is the differential lock solenoid spool sticking?

YES: NO:

Free off or renew valve. Dismantle differential lock mechanism and check condition of release spring and piston for sticking.

9804/1103

60 - 10 - 11/3

3820 - F/8-1.1

Issue 1

CONTENTS * 125,

Fastrac

135, 145, 150, 155, 185

Fault Finding - Brakes

Introduction

Safety Precautions

For diagnostic purposes the air brake system is fitted with five test points, one on each 'dry' tank and two on the output side of the footbrake valve. Diagnosis of system faults requires the use of suitable gauges (three are usually sufficient). A service kit of gauges, hoses and fittings is available as JCB Service Tool 892/00311.

! WARNING

Before working on or around the brake system, always observe the following precautions: 1

Stop the engine and chock all four wheels.

2

When the air system is being exhausted, keep hands away from the parking brake actuator pushrod and caliper, as they may move and trap your fingers.

3

Take care if disconnecting an air hose containing pressure as it may whip as air escapes.

4

Never remove or dismantle a component until air pressure has been exhausted and you have read and understood the recommended procedures.

5

Wear safety glasses when working with air pressure.

The brake system air pressure should be 8 bar (120 lbf/in ). 2

General air leaks are usually audible with the engine stopped. For smaller air leaks on valves, soak the valve in soap solution and watch for the formation of bubbles. The illustration below will aid identification of the components mentioned in the fault finding procedure.

BRAK 8-3/1

Component Key A B C E F G1 G2 G3 L

Feed from Compressor Unloader Valve Wet Tank Schrader valve Circuit Protection Valve Front Circuit Reservoir Rear Circuit Reservoir Trailer and Parking Brake Reservoir Trailer Brake Air Valve

*M Air/hydraulic Actuators * Note: To machine no. 636000, the front actuator feeds the rear brakes and the rear actuator feeds the front brakes. From machine no. 636001 the front actuator feeds the front brakes and the rear actuator feeds the rear brakes. S Non-return Valve * TP1 Test Point, Front Circuit * TP2 Test Point, Rear Circuit * TP3 Test Point, Trailer and Parking Brake Circuit Note: Test point TP3(1) is alternative to TP3(2). Test points TP4 and TP5 are on the footbrake valve (see circuit diagram) Z(f) Threshold Valve (front) - if fitted

S162623

9804/1103

60 - 10 - 15/1

Issue 3*

CONTENTS *

Fastrac

125, 135, 145, 150, 155, 185 Fault Finding - Brakes (continued)

Low Pressure Warning Lights On CHECK

ACTION

1

Are all three warning lights on?

YES: NO:

Check 2. Check 4.

2

Is there a leak between the compressor and the circuit protection valve?

YES: NO:

Rectify leak. Check 3.

3

Is air continually pumping from unloader valve exhaust?

YES: NO:

Renew defective unloader valve. Strip and examine compressor.

4

If only one light is on, pressure test relevant tank. Is pressure OK?

YES: NO:

Renew defective low pressure switch. Check 5.

5

Drain air from complete system. Recharge. Does fault still exist?

YES: NO:

Renew circuit protection valve. System now OK.

Service Brakes Poor CHECK

ACTION

1

Do disc pads have a minimum of 3 mm (0.12 in) friction material?

YES: NO:

Check 2. Renew pads (in complete axle sets).

2

Do both brake fluid reservoirs have adequate fluid?

YES: NO:

Check 3. Top up and check for leaks.

3

Have brakes been bled?

YES: NO:

Check 4. Bleed brakes.

4

Fit gauges first to TP1 and TP4 and then to TP2 and TP5. Do the gauges indicate that the footbrake valve is functioning?

YES: NO:

Check 5 Strip and inspect footbrake valve

5

Are air/hydraulic actuators functioning?

YES: NO: .

Bleed brakes. Strip and inspect actuator(s).

Poor Front Brakes, Good Rear Brakes CHECK

ACTION

1

Fit gauges to TP1 and TP4. Charge system. Does TP1 reach system pressure?

YES: NO:

Check 2. Check for leaks or faulty circuit protection valve.

2

Operate footbrake. Does TP4 reach TP1?

YES: NO:

Check 3. Check footbrake valve.

3

Has the front hydraulic circuit been bled?

YES: NO:

Check air/hydraulic actuator. Bleed front hydraulic circuit.

9804/1103

60 - 10 - 15/2

Issue 3*

CONTENTS *

Fastrac

125, 135, 145, 150, 155, 185 Fault Finding - Brakes (continued)

Poor Rear Brakes, Good Front Brakes CHECK

ACTION

1

Fit gauges to TP2 and TP5. Charge system. Does TP2 reach system pressure?

YES: NO:

Check 2. Check for leaks or faulty circuit protection valve.

2

Operate footbrake. Does TP5 reach TP2?

YES: NO:

Check 3. Check footbrake valve.

3

Has the rear hydraulic circuit been bled?

YES: NO:

Check air/hydraulic actuator. Bleed rear hydraulic circuit.

Trailer Brakes Poor CHECK

ACTION

1

Fit gauge to TP3. Charge system. Is tank up to system pressure?

YES: NO:

Check 3. Check 2.

2

Drain air from complete system. Recharge. Is tank up to system pressure?

YES: NO:

System now OK. Renew circuit protection valve.

3

Fit gauges to trailer tappings TS and TC. Is TS at system pressure?

YES: NO:

Check 4. Defective trailer brake valve.

4

Operate footbrake. Is TC at system pressure?

YES: NO:

Fault on trailer brakes. Defective trailer brake valve.

Park Brake Not Holding CHECK

ACTION

1

Do disc pads have a minimum of 3 mm (0.12 in) friction material?

YES: NO:

Check 2. Renew pads.

2

Are pads adjusted correctly?

YES: NO:

Check 3. Adjust.

3

Is caliper clamping on disc?

YES: NO:

Suspect fault in rear axle. Suspect fault in spring brake actuator.

Park Brake Not Releasing CHECK

ACTION

1

Fit gauge to TP3 and TP4. Charge system. Is pressure OK?

YES: NO:

Check 3. Check 2.

2

Is there a leak between the trailer brake valve and the park brake actuator?

YES: NO:

Rectify leak. Defective park brake valve.

3

Are pads adjusted correctly?

YES: NO:

Suspect fault in spring brake actuator. Adjust.

9804/1103

60 - 10 - 15/3

Issue 3*

CONTENTS

Fastrac

FASTRAC 1115 & 1135 Introduction

Safety Precautions

For diagnostic purposes the air system is fitted with a test point up-stream of the trailer brake reservoir. Diagnosis of system faults requires the use of suitable gauges. A service kit of gauges, hoses and fittings is available as JCB Service Tool 892/00311.

! WARNING

Before working on the air system, always observe the following precautions: 1

Stop the engine and chock all four wheels.

The system air pressure should be 8 bar (120 lbf/in2).

2

Take care if disconnecting an air hose containing pressure as it may whip as air escapes.

General air leaks are usually audible with the engine stopped. For smaller air leaks on valves, soak the valve in soap solution and watch for the formation of bubbles.

3

Never remove or dismantle a component until air pressure has been exhausted and you have read and understood the recommended procedures.

The illustration below will aid identification of the components mentioned in the fault finding procedure.

4

Wear safety glasses when working with air pressure.

BRAK-8-9

Component Key C D E F G H K P R T

Unloader Valve Silencer Low air pressure switch Test Point Wet Tank (Trailer Brake Reservoir) Auto-drain Valve Circuit Protection Valve Dry Tank (Tractor Supplies Reservoir) Manual Drain Valve Alcohol Injector

9804/1103

60 - 10 - 15/4

Issue 1

CONTENTS

Fastrac

FASTRAC 1115 & 1135 Fault Finding - Brakes (continued)

Service Brakes - Low Pressure Warning Lights On ACTION

CHECK 1

Are both warning lights (1 and 2) on?

YES: NO: NO:

All the time. Check 2. Check 4. But intermittently when the foot brake in pressed. Check the acumulator(s) on the faulty circuit(s).

2

Is there a leak between the steer/suspension pump and the pressure maintenance valve?

YES: NO:

Mend the leak. Check 3.

3

Install a pressure gauge into the pressure maintenance valve (brakes, suspension, differential lock). Does the gauge indicate the correct pressure (see Data)?

YES: NO:

Check pressure switch(es) and circuits. Remove valve. Fit new ‘O’ rings and check for debris inside. Clean and reset valve to correct pressure.

Note: If the correct pressure cannot be achieved, check the pump flow and pressure

4

Are the oil pipes from the foot brake valve to the pressure maintenance valve broken/leaking?

YES: NO:

Carry out remedial work. Check the pressure switch.

Trailer Brakes - Low Pressure Warning Light On CHECK

ACTION

1

Is the low air pressure warning light (3) on?

YES: NO:

Check 2. Check 4.

2

Is there a leak between the compressor and the circuit protection valve?

YES: NO:

Rectify leak. Check 3.

3

Is air continually pumping from unloader valve exhaust?

YES: NO:

Renew defective unloader valve. Strip and examine compressor.

4

Drain air from complete system. Does the trailer brake air tank fail to re-charge?

YES: NO:

Renew circuit protection valve. System now OK.

Service Brakes Poor CHECK

ACTION

1

Do disc pads have a minimum of 3 mm (0.12 in) friction material?

2

Is the brake pressure correct at pressure maintenance valve?

3

Have brakes been bled?

4

5

YES: NO:

Check 2. Renew pads (in complete axle sets).

YES: NO:

Check 3. Adjust valve.

YES: NO:

Check 4. Bleed brakes.

Fit a pressure gauge in place of the bleed screw into one caliper on the front and rear axles. Press the foot pedal. Is full pressure being seen?

YES: NO:

Check 5 Replace the footbrake valve

Are the accumulators faulty? (See Service Manual Section S, Gas Spring and Accumulators, Testing for procedure.)

YES: NO:

Replace faulty accumulator(s). Bleed brakes.

9804/1103

60 - 10 - 15/5

Issue 1

CONTENTS

Fastrac

FASTRAC 1115 & 1135 Fault Finding - Brakes (continued)

Park Brake Not Holding CHECK

ACTION

1

Are disc pads within wear limits?

YES: NO:

Check 2. Renew pads.

2

Are pads adjusted correctly?

YES: NO:

Check 3. Adjust.

3

Is caliper clamping on disc?

YES: NO:

Suspect fault in rear axle. Check and adjust linkage.

Poor Front Brakes, Good Rear Brakes CHECK

ACTION

1

Check condition of front brake pads/discs. Are they serviceable?

YES: NO:

Check 2. Replace pads/discs as required.

2

Have the brakes been bled?

YES: NO:

Check 3. Bleed brakes.

3

Is the pressure setting of the pressure maintenance valve correct?

YES: NO:

Check 4. Adjust valve.

4

Fit a pressure gauge in place of the bleed screw in one of the front calipers. With the foot brake pedal fully depressed, is fuel system pressure indicated?

YES:

Check to see if the caliper pistons have seized. If necessary, carry our repairs. Check the hydraulic foot brake valve.

NO:

Poor Rear Brakes, Good Front Brakes CHECK

ACTION

1

Check condition of rear brake pads/discs. Are they serviceable?

YES: NO:

Check 2. Replace pads/discs as required.

2

Have the brakes been bled?

YES: NO:

Check 3. Bleed brakes.

3

Is the pressure setting of the pressure maintenance valve correct?

YES: NO:

Check 4. Adjust valve.

4

Fit a pressure gauge in place of the bleed screw in one of the rear calipers. With the foot brake pedal fully depressed, is fuel system pressure indicated?

YES:

Check to see if the caliper pistons have seized. If necessary, carry our repairs. Check the hydraulic foot brake valve.

9804/1103

NO:

60 - 10 - 15/6

Issue 1

CONTENTS

Fastrac

FASTRAC 1115 & 1135 Fault Finding - Brakes (continued)

Trailer Brakes Poor CHECK

ACTION

1

Fit a pressure gauge to the air system test point. Is the reading correct?

YES: NO:

Check 2. Check for air leaks, the unloader valve or the compressor.

2

Fit a gauge to trailer coupling TS. Is the gauge reading system pressure?

YES: NO:

Check 3. Check the coupling and the pipework feeding it.

3

Fit the gauge to trailer coupling TC. With the foot brake pedal pressed, is the gauge reading system pressure?

YES: NO:

Trailer brakes faulty. Check 4.

4

Are the tractor service brakes operating correctly?

YES: NO:

Check 5. Rectify the fault.

5

Is there hydraulic pressure at the pilot port of the trailer brake valve?

YES: NO:

The trailer brake valve is faulty. Check the pilot circuit pipework and the shuttle valve.

9804/1103

60 - 10 - 15/7

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 10 - 15/8

2000 Series, 3000 Series Fault Finding - Brakes Introduction

Safety Precautions

Note: The illustration below shows the component layout on the right side of Fastrac 2115, 2125 and 2135 machines. On Fastrac 2150 and 3000 series machines the components are on the left side and are a mirror image of the layout below.

Before working on or around the brake system, always observe the following precautions:

! WARNING

1

Stop the engine and chock all four wheels.

2

When the air system is being exhausted, keep hands away from the parking brake actuator pushrod and caliper, as they may move and trap your fingers.

3

Take care if disconnecting an air hose containing pressure as it may whip as air escapes.

The brake system air pressure should be 8 bar (120 lbf/in2).

4

General air leaks are usually audible with the engine stopped. For smaller air leaks on valves, soak the valve in soap solution and watch for the formation of bubbles.

Never remove or dismantle a component until air pressure has been exhausted and you have read and understood the recommended procedures.

5

Wear safety glasses when working with air pressure.

For diagnostic purposes the air brake system is fitted with five test points, one on each brake circuit reservoir (TP1, TP2) one on the trailer/parking brake reservoir (TP3) and two on the foot brake air valve (TP4, TP5). Diagnosis of system faults requires the use of suitable gauges (three are usually sufficient). A service kit of gauges, hoses and fittings is available as JCB Service Tool 892/00311.

The illustration below will aid identification of the components mentioned in the fault finding procedure.

BRAK 8-3/1

Component Key

N P U V TP1 TP2 TP3

C D E F G1 G2 G3 K1 K2

Pressure Reducing Valve (Failure Conscious) Trailer Brake Air Valve Tractor Services Reservoir Non-return Valve Test Point, Front Circuit (not shown) (on rear of G1) Test Point, Rear Circuit (not shown) (on rear of G2) Test Point, Trailer and Parking Brake Circuit (not shown) (on rear of G3) TP4 Test Point, Front Circuit TP5 Test Point, Rear Circuit Note: For positions of TP4 and TP5 see Foot Brake Air Valve Removal and Replacement.

Air Dryer/Unloader Valve System Reservoir Schrader Valve Circuit Protection Valve Front Circuit Reservoir Rear Circuit Reservoir Trailer/Parking Brake Reservoir Front Brake Air/Hydraulic Actuator Rear Brake Air/Hydraulic Actuator

F

K2 K1

C P

E

N

U

V

D G3

G2 A258160

G1 9804/1103

60 - 10 - 15/8

8020 - G/3-1.3

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 10 - 15/9

2000 Series, 3000 Series Fault Finding - Brakes (contÕd) Low Pressure Warning Lights On CHECK

ACTION

1

Are all three warning lights on?

YES: NO:

Check 2. Check 4.

2

Is there a leak between the compressor and the circuit protection valve?

YES: NO:

Rectify leak. Check 3.

3

Is air continually pumping from air dryer/unloader valve exhaust?

YES: NO:

Renew defective air dryer/unloader valve. Strip and examine compressor.

4

If only one light is on, pressure test relevant tank. Is pressure OK?

YES: NO:

Renew defective low pressure switch. Check 5.

5

Drain air from complete system. Recharge. Does fault still exist?

YES: NO:

Renew circuit protection valve. System now OK.

Service Brakes Poor CHECK

ACTION

1

Do disc pads have a minimum of 3 mm (0.12 in) friction material?

YES: NO:

Check 2. Renew pads (in complete axle sets).

2

Do both brake fluid reservoirs have adequate fluid?

YES: NO:

Check 3. Top up and check for leaks.

3

Have brakes been bled?

YES: NO:

Check 4. Bleed brakes.

4

Fit a gauge first to TP1 and then to TP2. Does the gauge indicate that air system pressure is reaching the footbrake valve.

YES: NO:

Check 5 Check that air system pressure is reaching the circuit protection valve. If not check for a leak in the circuit from the compressor. If pressure is reaching the circuit protection valve check the valve for faults.

5

Are air/hydraulic actuators functioning?

YES: NO:

Check 6. Strip and inspect actuator(s).

6

Is there evidence of oil leakage at the failure conscious pressure relief valve?

YES: NO: .

Fit a new valve. Bleed brakes.

Poor Front Brakes, Good Rear Brakes ACTION

CHECK 1

Fit a gauge to TP1. Charge system. Does TP1 reach system pressure?

2

Operate footbrake. Does the front air/hydraulic actuator function?

3 4

YES: NO:

Check 2. Check for leaks or faulty circuit protection valve.

YES: NO:

Check 3. Check footbrake valve.

Is there evidence of oil leakage at the failure conscious pressure relief valve?

YES: NO:

Fit a new valve. Check 4.

Has the front hydraulic circuit been bled?

YES:

Check operation of the caliper and serviceability of the brake friction pads. Bleed front hydraulic circuit.

NO:

9804/1103

60 - 10 - 15/9

8020 - G/3-2.1

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 10 - 15/10

2000 Series, 3000 Series Fault Finding - Brakes (contÕd) Poor Rear Brakes, Good Front Brakes CHECK

ACTION

1

Fit a gauge to TP2. Charge system. Does TP2 reach system pressure?

YES: NO:

Check 2. Check for leaks or faulty circuit protection valve.

2

Operate footbrake. Does the rear air/hydraulic actuator function?

YES: NO:

Check 3. Check footbrake valve.

3

Is there evidence of oil leakage at the failure conscious pressure relief valve?

YES: NO:

Fit a new valve. Check 4.

4

Has the rear hydraulic circuit been bled?

YES:

Check operation of the calipers and serviceability of the brake friction pads. Bleed rear hydraulic circuit.

NO:

Trailer Brakes Poor CHECK

ACTION

1

Fit gauge to TP3. Charge system. Is tank up to system pressure?

YES: NO:

Check 3. Check 2.

2

Drain air from complete system. Recharge. Is tank up to system pressure?

YES: NO:

System now OK. Renew circuit protection valve.

3

Fit gauges to trailer tappings TS and TC. Is TS at system pressure?

YES: NO:

Check 4. Defective trailer brake valve.

4

Operate footbrake. Is TC at system pressure?

YES: NO:

Fault on trailer brakes. Defective trailer brake valve.

Park Brake Not Holding CHECK

ACTION

1

Do disc pads have a minimum of 3 mm (0.12 in) friction material?

YES: NO:

Check 2. Renew pads.

2

Are pads adjusted correctly?

YES: NO:

Check 3. Adjust.

3

Is caliper clamping on disc?

YES: NO:

Suspect fault in rear axle. Suspect fault in spring brake actuator.

Park Brake Not Releasing ACTION

CHECK 1

Fit gauge to TP1 and TP3. Charge system. Is pressure OK?

YES: NO:

Check 3. Check 2.

2

Is there a leak between the trailer brake valve and the park brake actuator?

YES: NO:

Rectify leak. Defective park brake valve.

3

Are pads adjusted correctly?

YES: NO:

Suspect fault in spring brake actuator. Adjust.

9804/1103

60 - 10 - 15/10

8020 - G/3-3.1

Issue 1

CONTENTS * 125,

Fastrac

135, 145, 150, 155, 185

Fault Finding - Steering

Introduction Before assuming that the steering box or the pump is the cause of a steering problem, ensure that all other steering system faults have been rectified. Carry out the following checks before using the fault finding procedure: 1

Question the driver and drive the machine to establish the exact nature of the fault.

2

Check that the hydraulic oil level is correct and that there are no signs of oil leakage from the circuit.

3

Check that the steering box mountings and all linkages are correctly tightened.

Heavy Steering CHECK

ACTION

1

Is the front axle overloaded?

YES: NO:

Reduce load. Check 2.

2

Are the correct tyres fitted and correctly inflated?

YES: NO:

Check 3. Replace / inflate tyres.

3

Are the steering swivels free?

YES: NO:

Check 4. Lubricate and free off.

4

Is the oil cooler free of air blockage?

YES: NO:

Check 5. Clean out debris.

5

Is the pump relief valve pressure too low?

YES: NO:

Check for dirt at relief valve. Check 6.

6

Is the pump flow rate too low?

YES: NO:

Check for flow control valve sticking and check 11. Check 7.

7

Is the steering column turning freely?

YES: NO:

Check 8. Free off / check universal joint phasing.

8

Is front wheel alignment correct?

YES: NO:

Check 9. Adjust.

9

Are suspension and steering geometry correct?

YES: NO:

Check 10. Renew parts as required.

10

Is steering box leaking oil?

YES: NO:

Renew seals. Check 11.

11

Is oil temperature high?

YES: NO:

Check cooler and pipework for free flow. Suspect fault in steering box.

9804/1103

60 - 10 - 16/1

Issue 3*

CONTENTS * 125,

Fastrac

135, 145, 150, 155, 185

Fault Finding - Steering (continued)

Steering Wander or Free Play If the fault is wander, start at check 1. If the fault is free play, start at check 4. CHECK

ACTION

1

Is the rear axle overloaded?

YES: Reduce load. NO: Check 2.

2

Are the correct tyres fitted and correctly inflated?

YES: Check 3. NO: Replace / inflate tyres.

3

Is the front wheel alignment correct?

YES: Check 4. NO: Adjust.

4

Are the column or steering linkages worn or loose?

YES: Tighten or renew. NO: Check 5.

5

Is the pump flow correct?

YES: Check 6. NO: Check condition of flow control.

6

Is air trapped in the hydraulic oil?

YES: Bleed out air (see Service Manual). NO: Suspect fault in steering box.

9804/1103

60 - 10 - 16/2

Issue 4*

CONTENTS CONTENTS

Fastrac

60 - 10 - 17/1

* FASTRAC 1115, 1135, 2115, 2125, 2135, 2150 Fault Finding - Steering

Introduction Before assuming that the steering control unit or the pump is the cause of a steering problem, ensure that all other steering system faults have been rectified. Carry out the following checks before using the fault finding procedure: 1

Question the driver and drive the machine to establish the exact nature of the fault.

2

Check that the hydraulic oil level is correct and that there are no signs of oil leakage from the circuit.

3

Check that the steering box mountings and all linkages are correctly tightened.

Heavy Steering CHECK

ACTION

1

Is the front axle overloaded?

YES: NO:

Reduce load. Check 2.

2

Are the correct tyres fitted and correctly inflated?

YES: NO:

Check 3. Replace / inflate tyres.

3

Are the steering swivels free?

YES: NO:

Check 4. Lubricate and free off.

4

Is the oil cooler free of air blockage?

YES: NO:

Check 5. Clean out debris.

5

Is the pump relief valve pressure too low?

YES: NO:

Check for dirt at relief valve. Check 6.

6

Is the pump flow rate too low?

YES: NO:

Check for flow control valve sticking and check 10. Check 7.

7

Is the steering column turning freely?

YES: NO:

Check 8. Free off / check universal joint phasing.

8

Is front wheel alignment correct?

YES: NO:

Check 9. Adjust.

9

Are suspension and steering geometry correct?

YES: NO:

Check 10. Renew parts as required.

10

Is oil temperature high?

YES: NO:

Check cooler and pipework for free flow. Suspect fault in steering control unit.

9804/1103

60 - 10 - 17/1

Issue 2*

CONTENTS CONTENTS

Fastrac

60 - 10 - 17/2

* FASTRAC 1115, 1135, 2115, 2125, 2135, 2150 Fault Finding - Steering (continued)

Steering Wander or Free Play If the fault is wander, start at check 1. If the fault is free play, start at check 4. CHECK

ACTION

1

Is the rear axle overloaded?

YES: Reduce load. NO: Check 2.

2

Are the correct tyres fitted and correctly inflated?

YES: Check 3. NO: Replace / inflate tyres.

3

Is the front wheel alignment correct?

YES: Check 4. NO: Adjust.

4

Are the column or steering linkages worn or loose?

YES: Tighten or renew. NO: Check 5.

5

Is the pump flow correct?

YES: Check 6. NO: Check condition of flow control.

6

Is air trapped in the hydraulic oil?

YES: Bleed out air (see Service Manual). NO: Suspect fault in steering control unit.

9804/1103

60 - 10 - 17/2

Issue 2*

CONTENTS CONTENTS

Fastrac

60 - 10 - 18/1

2000 Series Fault Finding - Steering (Front Axle)

Introduction Before assuming that the steering control unit or the pump is the cause of a steering problem, ensure that all other steering system faults have been rectified. Follow the fault finding procedure on the next page but first carry out the following checks: 1

Question the driver and drive the machine to establish the exact nature of the fault.

2

Check that the hydraulic oil level is correct and that there are no signs of oil leakage from the circuit.

3

Check that the steering linkages are correctly tightened.

9804/1103

60 - 10 - 18/1

8020 - H/3-1.2

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 10 - 18/2

2000 Series Fault Finding - Steering (Front Axle) (contÕd)

Heavy Steering CHECK

ACTION

1

Is the front axle overloaded?

YES: Reduce load. NO: Check 2.

2

Are the correct tyres fitted and correctly inflated?

YES: Check 3. NO: Replace / inflate tyres.

3

Are the steering swivels free?

YES: Check 4. NO: Lubricate and free off.

4

Is the oil cooler free of air blockage?

YES: Check 5. NO: Clean out debris.

5

Is the pump relief valve pressure too low?

YES: Check for dirt at relief valve. NO: Check 6.

6

Is the pump flow rate too low?

YES: Check for flow control valve sticking and check 10. NO: Check 7.

7

Is the steering column turning freely?

YES: Check 8. NO: Free off / check universal joint phasing.

8

Is front wheel alignment correct?

YES: Check 9. NO: Adjust.

9

Are suspension and steering geometry correct?

YES: Check 10. NO: Renew parts as required.

10

Is oil temperature high?

YES: Check cooler and pipework for free flow. NO: Suspect fault in steering control unit.

Steering Wander or Free Play If the fault is wander, start at check 1. If the fault is free play, start at check 4. CHECK

ACTION

1

Is the rear axle overloaded?

YES: Reduce load. NO: Check 2.

2

Are the correct tyres fitted and correctly inflated?

YES: Check 3. NO: Replace / inflate tyres.

3

Is the front wheel alignment correct?

YES: Check 4. NO: Adjust.

4

Are the column or steering linkages worn or loose?

YES: Tighten or renew. NO: Check 5.

5

Is the pump flow correct?

YES: Check 6. NO: Check condition of flow control.

6

Is air trapped in the hydraulic oil?

YES: Bleed out air. NO: Suspect fault in steering control unit.

9804/1103

60 - 10 - 18/2

8020 - H/3-2.2

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 10 - 18/3

2115, 2125, 2135 Fault Finding - Steering (Front Axle, 4WS) Introduction Panel Self-Test

Fuses

When the ignition is first switched on, all the indicator lamps should light and the buzzer should sound for half a second as a test. Replace any faulty lamps and rectify an inoperative buzzer. During operation, if the red cross X lights up or if the buzzer sounds continually, a steering system fault is indicated. Only if the green tick Y is lit, as an indication that the system is functioning correctly, should the machine be used.

The circuits associated with the 4WS system are covered by the following fuses. (For locations see Section C.) 4WS Main Supply Alternator Supply Axle Lock Switch Supply Axle lock air solenoid valve Sprayer or implement override 1 kph and 20 kph signal from instrument cluster Draft control override

Fuse X (5 Amp)

Fuse C4 (15 Amp) Fuse A6 (5 Amp)

If the fault continues, use the table below to trace and rectify the cause.

Diagnosis FAULT

ACTION

1

1

2WS selected but rear wheels remain off-centre when the machine is driven above 1 kph.

This is likely to be an electrical fault. To get the machine going the rear wheels can be centralised and locked manually as follows:

1.1 Make sure that there is no air pressure to the axle lock. Air pressure should normally be released when the 2WS button is pressed but if air pressure fails to release, disconnect the electrical supply from the air solenoid valve. 1.2 Disconnect the electrical supply from the each of the two 4WS hydraulic valve solenoids. 1.3 Start the engine and set to low idle.

! WARNING Keep clear of the rear wheels when the engine is running as you could be injured by unexpected wheel movement. HYD ST 5-5

1.4 Operate the 4WS hydraulic valve by pushing a suitable piece of rod or a small screwdriver into either access hole in the solenoid valves until the rear wheels steer to the centre and the lock is heard to click into place. (Trial and error will determine which solenoid is the correct one.) 1.5 Once the rear wheels are locked, the machine can be driven safely on the road and used to perform normal duties in 2WS until the 4WS system can be repaired.

9804/1103

60 - 10 - 18/3

8020 - H/4-1.1

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 10 - 18/4

2115, 2125, 2135 Fault Finding - Steering (Rear Axle, 4WS) (contÕd)

FAULT

ACTION

2

2

Red X lights up and buzzer sounds

Note: A buzzer may be heard (without the red cross showing) if a foot is resting on the clutch pedal. This is a warning of operator malpractice and should not be confused with a machine fault indication.

This indicates a fault in either a front or rear 4WS sensor (potentiometer), or in the sensor wiring harness. 4WS will not work when the red X is showing. If the fault is intermittent, the warning can be cleared by turning the ignition switch off and on. The system will then operate normally until the fault re-occurs.

To trace the fault: 2.1 Disconnect the front axle sensor from the wiring harness swivel connector. Substitute a known sensor and manually turn to approximately half way. Switch on the ignition (no need to start the engine). If the green tick is now showing, the original front axle sensor is at fault and should be renewed. Note: When a sensor has been changed the system must be re-calibrated (see Sensors, Section C). 2.2 Repeat step 2.1 for the rear axle sensor. 2.3 If both sensors are functional and the fault remains, there is a fault in the wiring harness. Remove the Electronic Control Unit (ECU) from the ‘B’ post and disconnect the machine wiring harness. Trace the fault by simple continuity tests from this point down to the swivel connectors at the sensors. 2.4 If both sensors and wiring harness are OK then the fault must be in the ECU. This cannot be serviced and must be renewed as a complete unit. Note: A fault in the ECU is extremely unlikely and the unit should not be renewed unless it is absolutely certain that it is at fault.

9804/1103

60 - 10 - 18/4

8020 - H/4-2.1

Issue 1

CONTENTS

CONTENTS

Fastrac

60 - 10 - 18/5

2115, 2125, 2135 Fault Finding - Steering (Rear Axle, 4WS) (cont’d) FAULT

ACTION

3

3

4WS Fails to engage, rear axle remains locked in 2WS

Check the Diagnostic LED’s

3.1 Remove the 4WS control panel to reveal the diagnostic LED’s (see Diagnostic LED’s). 3.2 When the ignition switch is turned on, LED’s 2 and 3 should be on, indicating the rear axle is locked and the machine is stationary. 3.3 When the engine is started, LED’s 2, 3 and 5 should be on (LED 5 indicates engine running.) 3.4 When an attempt to select 4WS is made, LED 6 should come on (air solenoid valve signal) and LED’s 7 and 8 should cycle off in turn. Check each of the 4WS modes and crab steer in turn. If each of the LED’s operates in the sequence shown above, then check for the following faults: a) Rear axle power track rod lock failed to release. b) Rear axle power track rod switch has failed. c) 4WS electronics out of calibration. d) The rear axle sensor mechanical linkage has developed backlash. a a1 a2 a3

b) b1

b2

b3

b4

9804/1103

Rear axle power track rod lock failed to release. Check that air pressure is present at the power track rod feed. In 2WS there should be no pressure. As 4WS is selected, pressure should be present to unlock the axle. If no pressure is detected, check the air solenoid valve (inside cab) is operating correctly. Rear axle power track rod switch has failed. If the power track rod lock has released but the switch has failed to signal the ECU, the rear wheels will be seen to ‘dither’ ( slowly oscillate from side to side) while the 4WS selection is being made. The switch may be out of adjustment and can be checked by removing the copper washer fitted behind the switch. If the switch still fails to operate, a replacement is required. Be sure to replace the copper washer if a new switch is fitted. If the unit still fails to operate, check the wiring harness continuity.

c) c1

4WS electronics out of calibration. As 4WS selection is attempted, observe LED’s 7 and 8. The LED’s should cycle on and off in turn. If there is a bias towards one of the LED’s or if one of the LED’s remains lit continually, then the 4WS electronic panel is out of calibration. Calibration is normally needed only after sensors or control unit have been dismantled. If frequent calibration is needed, the rear axle sensor has probably developed backlash.

d)

The rear axle sensor mechanical linkage has developed backlash. Remove sensor (potentiometer) top cover. Check the sensor linkage for backlash by fitting an open ended spanner over the spindle where it protrudes above the sensor. Apply moderate pressure in each direction. There should be no detectable backlash.

60 - 10 - 18/5

8020 - H/4-3.2

Issue 2*

CONTENTS CONTENTS

Fastrac

60 - 10 - 18/6

2115, 2125, 2135 Fault Finding - Steering (Rear Axle, 4WS) (contÕd) Diagnostic LEDÕs

O/R

2

2

4

4

4

4

X O/R

2

Fm

4

4

T

4

4

SP P5

A

BP

TP

T

P

A CT1

5

4

1

3

6

7

CT3 B

CT2

AWS 1.75

T

AD

AE Q

A243471

2 9804/1103

60 - 10 - 18/6

8 8020 - H/5-1.1

A249140

Issue 1

CONTENTS

CONTENTS

Fastrac

60 - 10 - 18/7

2115, 2125, 2135 Fault Finding - Steering (Rear Axle, 4WS) (cont’d) Diagnostic LED’s (cont’d) Eight diagnostic LED’s can be found by removing the front panel of the Electronic Control Unit as shown on page 60 - 10 - 18/6. LED Number 1

LED Name Draft Control or Sprayer Override

Indication when ON a)

On when linkage override button 2 (illustration X) is pressed and linkage is down.

OR b)

On when linkage override button (2) is pressed and sprayer or implement remote switch is closed. Note: Active 2WS is operative when LED is on.

*

2

Rear axle lock signal

On when rear axle is locked in 2WS.

3

20 kph Override

On at forward speeds under 20 kph. Goes off at speeds over 20 kph.

4

1 kph Override

On at forward speeds over 1 kph. Goes off at speeds less than 1 kph.

5

Not Used

6

Rear axle unlock - Air solenoid valve signal

7

Hydraulic solenoid valve signal

On when air solenoid valve (AE) is energised to unlock the rear axle.

On when the proportional valve (SP) is energised to turn the rear wheels to the left. Note: In 4WS steer mode (not crab) the machine will turn to the right.

8

Hydraulic solenoid valve signal

On when the proportional valve (SP) is energised to turn the rear wheels to the right. Note: In 4WS steer mode (not crab) the machine will turn to the left.

9804/1103

60 - 10 - 18/7

8020 - H/5-2.2

Issue 2*

CONTENTS CONTENTS

Fastrac

60 - 10 - 19/1

3000 Series Fault Finding - Steering

Introduction Before assuming that the steering box or the pump is the cause of a steering problem, ensure that all other steering system faults have been rectified. Follow the fault finding procedure on the next page but first carry out the following checks: 1

Question the driver and drive the machine to establish the exact nature of the fault.

2

Check that the hydraulic oil is clean and to the correct and that there are no signs of oil leakage from the circuit.

3

Check that the steering box mountings and all steering and suspension linkages are correctly tightened.

9804/1103

60 - 10 - 19/1

8020 - H/31-1.1

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 10 - 19/2

3000 Series Fault Finding - Steering (contÕd) Heavy Steering CHECK

ACTION

1

Is the front axle overloaded?

YES: Reduce load. NO: Check 2.

2

Are the correct tyres fitted and correctly inflated?

YES: Check 3. NO: Replace / inflate tyres.

3

Are the steering swivels free?

YES: Check 4. NO: Lubricate and free off.

4

Is the oil cooler free of air blockage?

YES: Check 5. NO: Clean out debris.

5

Is the pump relief valve pressure too low?

YES: Check for dirt at relief valve. NO: Check 6.

6

Is the pump flow rate too low?

YES: Check for flow control valve sticking and check 11. NO: Check 7.

7

Is the steering column turning freely?

YES: Check 8. NO: Free off / check universal joint phasing.

8

Is front wheel alignment correct?

YES: Check 9. NO: Adjust.

9

Are suspension and steering geometry correct?

YES: Check 10. NO: Renew parts as required.

10

Is steering box leaking oil?

YES: Renew seals. NO: Check 11.

11

Is oil temperature high?

YES: Check cooler and pipework for free flow. NO: Suspect fault in steering box.

Steering Wander or Free Play If the fault is wander, start at check 1. If the fault is free play, start at check 4. CHECK

ACTION

1

Is the rear axle overloaded?

YES: Reduce load. NO: Check 2.

2

Are the correct tyres fitted and correctly inflated?

YES: Check 3. NO: Replace / inflate tyres.

3

Is the front wheel alignment correct?

YES: Check 4. NO: Adjust.

4

Are the column or steering linkages worn or loose?

YES: Tighten or renew. NO: Check 5.

5

Is the pump flow correct?

YES: Check 6. NO: Check condition of flow control.

6

Is air trapped in the hydraulic oil?

YES: Bleed out air. NO: Suspect fault in steering box.

9804/1103

60 - 10 - 19/2

8020 - H/31-2.1

Issue 1

CONTENTS CONTENTS

* 125,

Fastrac

135, 145, 150, 155, 185

60 - 15 - 01/1

UK Machines to serial No. 635329

Electrical Circuit - Component Key 1 2 3 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 1 Battery 2 Beacon Switch Illumination Rear Working Light Switch Illumination Left Hand Window Switch Illumination Right Hand Window Switch Illumination Side & Head Lights Switch Illumination Alternator Starter Switch Thermostart Starter Motor Starter Solenoid Inhibit Start Relay 1 Inhibit Start Relay 2 Neutral Start Switch Fuse A5 Engine Shut Off Solenoid Rear Power Take Off Switch Front Power Take Off Switch 2-Wheel Drive/Diff Lock Switch Rear Power Take Off Drive Solenoid Rear Power Take Off Brake Solenoid Front Power Take Off Drive Solenoid Front Power Take Off Brake Solenoid Diff Lock Solenoid 2-Wheel Drive Solenoid Fuse A8 2-Wheel Drive Dump Switch Instrument Cluster Fuse C4 Buzzer Tachometer Feed Alternator Warning Feed Blocked Air Filter Switch Handbrake Switch Test Button Diff Locked Switch Engine Oil Pressure Switch Fuel Level Sender Low Air Tank 1 Switch Low Air Tank 2 Switch Low Air Tank 3 Switch Water Temperature Sender Brake Front Reservoir Switch Brake Rear Reservoir Switch Transmission Oil Filter Switch Transmission Low Oil Pressure Switch Fuse A2 Left Hand Brake Light Switch Right Hand Brake Light Switch

9804/1103

52 53 54 55 56 57 58 59 60 61 62 63 65 66 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

Left Hand Brake Light Right Hand Brake Light Trailer Socket, Brake Light Speedometer Speedometer Illumination Speed Transducer Left Hand Reversing Light Right Hand Reversing Light Reversing Light Switch Fuse C1 Fuse A6 Beacon Switch Beacon Light Beacon Motor Flasher Unit Hazard Switch Fuse C2 Fuse B2 L H Direction Indicator, Front L H Direction Indicator, Rear L H Direction Indicator, Repeater Trailer Socket, L H Direction Indicator R H Direction Indicator, Front R H Direction Indicator, Rear R H Direction Indicator, Repeater Trailer Socket, R H Direction Indicator Direction Indicator Switch Fuse A7 Window Switch, Right Hand Window Motor, Right Hand Window Switch, Left Hand Window Motor, Left Hand Compressor Low Pressure Switch High Pressure Switch Heater Air Conditioner Air Conditioner Relay Fuse B9 Fuse B7 In Line Fuse 1 In Line Fuse 2 In Line Fuse 3 Auxiliary Socket 1 Auxiliary Socket 2 Auxiliary Socket 3 Front Work Light Switch Illumination Rear Fog Light Switch Illumination Fuse A3 Radio (Optional) Radio Illumination (Optional) Left Hand Speaker (Optional) Right Hand Speaker (Optional) Front Left Hand Side Light

60 - 15- 01/1

109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161

Rear Left Hand Side Light Left Hand Number Plate Light Right Hand Number Plate Light Fuse C5 Road Lights Switch Left Hand Rear Fog Lamp Right Hand Rear Fog Lamp Trailer Socket, Fog Lamp Fog Lamps Switch Trailer Socket, L H Side Light Trailer Socket, R H Side Light Front Right Hand Side Light Rear Right Hand Side Light Fuse C6 Front Work Light Relay Front Work Light Switch Fuse B3 Left Hand Front Work Light Right Hand Front Work Light Rear Wiper Intermittent Relay Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Motor Fuse B1 Electronic Draft Control Connector Left Hand Interior Light Right Hand Interior Light Left Hand Door Switch Right Hand Door Switch Trailer Socket, Battery Negative Left Hand Dip Beam Right Hand Dip Beam Fuse B6 Dip Switch Left Hand Main Beam Right Hand Main Beam Fuse C7 Head Light Flasher Fuse B5 Rear Work Light Relay Rear Work Light Switch Fuse B4 Left Hand Rear Work Light Right Hand Rear Work Light Horn Horn Push Front Wiper Intermittent Relay Front Wiper Motor Front Wiper Switch Fuse A4 Front Washer Motor Front Washer Push Fuse C3

Issue 3*

CONTENTS CONTENTS * 125,

Fastrac

135, 145, 150, 155, 185

60 - 15 - 01 2

UK Machines to serial no. 635329

Electrical Circuit ? ?

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9804/1103

60 - 15 - 01/2

Issue 3*

CONTENTS CONTENTS

* 125,

Fastrac

135, 145, 150, 155, 185

60 - 15 - 01/4

UK Machines from 635330 to 636000 All Export Machines to 636000

Electrical Circuit - Component Key

Note: The item numbers on this page correspond to the large numbers on the diagram. The small numbers and letters on the diagram identify terminals and connections. 104 Front Work Light Switch 51 Speedometer Transducer 1 Battery 1 105 Fuse B3 52 Left Hand Reversing Light 2 Battery 2 106 L H Front Work Light, Inner 53 Right Hand Reversing Light 3 Rear Working Light Switch 107 R H Front Work Light, Inner 54 Reversing Light Switch Illumination 108 L H Front Work Light, Outer 55 Fuse C1 4 Side & Head Lights Switch 109 R H Front Work Light, Outer 56 Fuse A6 Illumination 110 Rear Wiper Intermittent Relay 57 Fuse C9 5 Alternator 111 Rear Wash/Wipe Switch 58 Electronic Draft Control 6 Starter Switch 112 Rear Wiper Motor Connector 7 Thermostart 113 Rear Washer Motor 59 Flasher Unit 8 Starter Motor 114 Fuse B1 60 Hazard Switch 9 Starter Solenoid 115 Rear Wiper Switch Illumination 61 Fuse C2 10 Inhibit Start Relay 1 116 Interior Light 62 Fuse B2 11 Inhibit Start Relay 2 117 Left Hand Door Switch 63 L H Direction Indicator, Front 12 Neutral Start Switch 119 Trailer Socket, Battery Negative 64 L H Direction Indicator, Rear 13 Fuse A5 120 Left Hand Dip Beam 65 L H Direction Indicator, Repeater 14 Engine Shut Off Solenoid 121 Right Hand Dip Beam 66 Trailer Socket, L H Direction 15 Rear Power Take Off Switch 122 Fuse B6 Indicator 16 Front Power Take Off Switch 123 Dip Switch 67 R H Direction Indicator, Front 17 2-Wheel Drive/Diff Lock Switch 124 Left Hand Main Beam 68 R H Direction Indicator, Rear 18 Rear Power Take Off Drive 125 Right Hand Main Beam 69 R H Direction Indicator, Repeater Solenoid 126 Fuse C7 70 Trailer Socket, R H Direction 19 Rear Power Take Off Brake 132 Head Light Flasher Indicator Solenoid 133 Fuse B5 71 Direction Indicator Switch 20 Front Power Take Off Drive 134 Rear Work Light Relay 72 Compressor Solenoid 135 Rear Work Light Switch 73 Low Pressure Switch 21 Front Power Take Off Brake 136 Fuse B4 74 High Pressure Switch Solenoid 137 Rear Work Light 1 75 Heater 22 Diff Lock Solenoid 138 Rear Work Light 2 76 Air Conditioner 23 2-Wheel Drive Solenoid 139 Rear Work Light 3 77 Air Conditioner Relay 24 Fuse A8 140 Rear Work Light 4 78 Fuse B9 25 2-Wheel Drive Dump Switch 141 Horn 79 Fuse B7 26 Instrument Cluster 142 Horn Push 80 Auxiliary Socket 27 Fuse C4 143 Front Wiper Intermittent Relay 81 Front Work Light Switch 28 Alternator Warning Feed 144 Front Wiper Motor Illumination 29 Blocked Air Filter Switch 145 Front Wiper Switch 82 Rear Fog Light Switch Illumination 30 Handbrake Switch 146 Fuse A4 83 Fuse A3 31 Test Button 147 Front Washer Motor 84 Radio (Optional) 32 Diff Lock Switch 148 Front Washer Switch 85 Radio Illumination (Optional) 33 Engine Oil Pressure Switch 149 Fuse C3 86 Left Hand Speaker (Optional) 34 Fuel Level Sender 150 Fuse B8 87 Right Hand Speaker (Optional) 35 Low Air Tank 1 Switch 151 Fuse A9 88 Front Left Hand Side Light 36 Low Air Tank 2 Switch (when 152 Tachograph (if fitted) 89 Rear Left Hand Side Light fitted) 153 Panel Light 1 90 L H Number Plate Light 37 Low Air Tank 3 Switch 154 Panel Light 2 91 R H Number Plate Light 38 Water Temperature Sender 155 Panel Light 3 92 Fuse C5 39 Brake Front Reservoir Switch 156 Panel Light 4 93 Road Lights Switch 40 Brake Rear Reservoir Switch 157 Air Tank Gauge Illumination (If 94 L H Rear Fog Lamp 41 Transmission Oil Filter Switch fitted) 95 R H Rear Fog Lamp 42 Transmission Low Oil Pressure 158 L H Marker Light 96 Trailer Socket, Fog Lamp Switch 159 R H Marker Light 97 Fog Lamps Switch 43 Fuse A2 160 Fuse C8 98 Trailer Socket, Left Hand Side 44 Left Hand Brake Light Switch 161 Buzzer Light 45 Right Hand Brake Light Switch 162 Fuse A1 99 Trailer Socket, Right Hand Side 46 Left Hand Brake Light 163 4WD Warning Light Relay Light 47 Right Hand Brake Light 164 Second Trailer Direction Indicator 100 Front Right Hand Side Light 48 Trailer Socket, Brake Light Warning Light 101 Rear Right Hand Side Light 49 Speedometer 165 Tachometer Feed 102 Fuse C6 50 Speedometer Illumination 103 Front Work Light Relay Note: Item 50 is for the analogue speedo. The optional digital speedo does not have separate illumination but in other respects is wired as the analogue speedo. 9804/1103

60 - 15 - 01/4

Issue 4*

CONTENTS CONTENTS

Fastrac

60 - 15 - 01/5

2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams Introduction As an aid to fault finding and repair of wiring, the sectional diagrams show every wire and wire number on the machine together with all the harness connectors and the pins to which each wire is connected. In order to show this amount of detail the sectional diagrams are spread over a series of figures (12-1 to 12-42), details of which are listed under Contents. The first figure shows the main feed from the batteries to the starter motor, alternator and fuses etc. The second figure shows the common earth returns to the battery. The remaining figures show fused circuits, usually starting from the relevant fuse. The key for the diagrams is listed under Component Key. The page should be used in conjunction with the sectional diagrams. The diagram extracts on page 60-15-01/6 show examples of the way various items are identified on individual diagrams, as follows:

Connectors Some connectors are featured on a number of diagrams. These and other important connectors are identified under Main Connectors. Terminal details of large connectors to the Instrument Cluster, the two Electronic Control Units (ECU’s) and the Electronic Draft Control (EDC) Control Panel are given under Connector Terminals. Bulkhead and other connectors which join two harnesses are shown on the diagrams in two parts (i.e. the plug and the socket) linked by dotted lines. Each part of the connector is denoted by one or more letters (to identify the harness to which it is fitted) followed by a number, e.g. C5 denotes Chassis harness connector 5 and CR1 denotes Cab Roof harness connector 1 (view A). Pin letters and numbers are shown on the connectors to indicate the wire positions. Some other connectors on the diagrams may not be labelled. These can usually be found close to the components which they are feeding. Splices

i

The item numbers shown in large bold type correspond to the numbers in the component key, e.g. Item 131 denotes Trailer Socket Reverse Light Relay (view A).

ii

Fuses are denoted by alpha-numeric annotations in bold type, e.g. C1 (view A).

iii

Wire numbers are shown in smaller plain type alongside the lines representing wires on the diagram. The wire number is followed by a number in brackets indicating the wire size. e.g. 877 (0.6) (view A). Where lines representing wires intersect, there is no electrical joint unless a solid black circle is shown at the point of intersection (view B).

iv

Where a cross reference is required from one figure to another, an arrow is shown on the diagram, followed by the number of the figure where the information is continued or, for clarity, repeated e.g. ➭12-22 (view B).

v

Relays are shown by the conventional relay symbol (e.g. 131) as well as the relay base (view A).

vi

The diagrams cover both 2000 Series and 3000 Series machines, except where specified otherwise. Where such a circuit differs from one series to the other (e.g. view C) the wires are shown as broken lines with an appropriate identification, i.e. 2000 SERIES and 3000 SERIES. Such an identification indicates that all machines in the range are wired in this way. If only a single model from one of the series is wired as shown, a specific identification is given, e.g. 2150 or 3155 (view D).

Individual harnesses incorporate splices, i.e. points where two or more wires are joined within the harness. Splices are denoted on the wiring diagrams by rectangles containing code letters, e.g. CRES3 (view A). In the majority of cases the first or first and second letters indicate the harnesses containing the splice, e.g. C = Chassis harness, CR = Cab Roof harness. Subsequent letters or letters and numbers describe the electrical function of the splice, e.g. CRES3 = earth splice 3 in the Cab Roof harness. Other codes do not include a harness reference, but simply refer to the electrical function, e.g. ASS = Alternator Supply splice, RS = raise splice. The splices are not visible without dismantling the harnesses but they are shown on the diagrams to act as cross reference points between one figure and another. The same splice may therefore appear on more than one figure to provide continuity when following a circuit. For a full list of splices refer to Splice Identification.

9804/1103

60 - 15 - 01/5

8020 - C/7-1.2

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 15 - 01/6

2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams Introduction (contÕd) Examples of Component Identification

A

131

C1

A309750

B

C

1

W

1A

12-22 2000 SERIES

1

1A

3

3000 SERIES A307150

11

11A A307160

3185

3185

D

2000 3155 SERIES

137 2150

138

9804/1103

60 - 15 - 01/6

8020 - C/7-2.1

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 15 - 01/7

2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams Main Connectors Connector A2 ABS1 ABS2 AHL1 AHL2 C1 (14-pin) C1 (10-pin) C2 C4 C5 C28 CP1 CP2 CP3 CR1

Description Rear bulkhead ABS trailer socket Rear bulkhead Auxiliary lights connector Auxiliary lights connector Trailer socket Control module Control module 4WS interconnect - if fitted (2000 Series) Rear bulkhead Front bulkhead Control module Control module Control module Rear bulkhead

Mating Connector ABS 2 --A2 ------CP3 CP2 CR64 CR1 CR51 --C2 C1 (10-pin) C5

Connector CR43 CR49 CR50 CR51 CR64 CR65 CR66 CR73 CR74 CR87 CR89 E1 E2 E4 E15 E16

Description

Mating Connector Column switch --Powershift ECU 1 (Black) --Powershift ECU 2 (Red) --Front bulkhead C28 4WS option (2000 Series) C4 Instrument cluster 1 (Black) --Instrument cluster 2 (Red) --Panel - auxiliary light interconnect --Panel - auxiliary light interconnect --Vansco instrument cluster E4 Diagnostic connector --EDC ECU --Control panel --Vansco instrument cluster CR87 Bulkhead E16 Bulkhead E15

Connector Terminals Instrument Cluster CR65 (Black) Terminal 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 9804/1103

Wire 406 409 408 434 899A 415 482 473 476 474 420 880B 511 402 405 444 445 440 481 857B 477B 475 861G 418 419 417 496 407 400A 404 480B 848B 509B

Instrument Cluster CR66 (Red) Function Low air pressure - 2 Low brake fluid level Low air pressure - 3 Low transmission oil pressure

Differential lock solenoid Area cut-out Low range Auto Snail Hare 2WD selected Side lights Option present Low engine oil pressure Transmission oil filter blocked 540 PTO range selected 1000 PTO range selected Trailer ABS warning Reverse range Rear PTO drive selected Low range selected Tortoise Right turn signal Main beam 2nd trailer turn signal 1st trailer turn signal 4WS tracking (2000 Series - if fitted) Low air pressure - 1 Park brake ON Air filter blocked Reverse range selected Front PTO drive selected EDC lower signal

Terminal 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

60 - 15 - 01/7

Wire 479B 512 502 414A 410 411 500A 517 423 898 485 505 484 859G 483 478B 403A 510 516 486 508 416 514F 515F 501 497 412A 513 300B 160B 710C 626

Function High range selected Fuel feed signal Fuel return signal Transmission speed signal Engine water temperature Fuel level Radar speed signal RS232 RX Buzzer out <20 kph speed trigger >3 kph speed trigger Increase wheel slip output High range Left turn signal Medium range Medium range selected Alternator charge Wheel slip setpoint RS232 TX >1 kph speed trigger Decrease wheel slip output Differential lock cut-out CANL CANH Radar presence signal Transmission speed sensor presence

Engine rpm Program + 12V Battery + 12V ignition Battery earth Chassis earth 8020 - C/8-1.1

Issue 1

CONTENTS

Fastrac

60 - 15 - 01/8

2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams (cont’d) Connector Terminals (cont’d) * Powershift - Electronic Control Unit (ECU) Dry Clutch Transmission CR50 (Red)

* Powershift - Electronic Control Unit (ECU) Dry Clutch Transmission CR49 (Black) Terminal 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

9804/1103

Wire 514 810B 400C 877 Link 1 900 435A 901 660J 125B 515 434 450 898B 476 475 474 473 660H 125A Link 2 Link 2 413 470 471 472 412B Link 1 625 447 435B 902

Function CANL Clutch down Handbrake on Reverse lamps Link to terminal 32 Snail clutch solenoid Transmission oil pressure Tortoise clutch solenoid Battery negative + 12v ignition CANH Transmission oil pressure warning Bleeper <20 kph speed trigger Snail indicator Tortoise indicator Hare indicator Auto indicator Battery negative + 12v ignition Link to terminal 26 Link to terminal 25 Accelerator pedal up Up shift switch Down shift switch Auto mode Engine rpm signal Link to terminal 7 Chassis ground Transmission oil pressure switch Transmission oil pressure switch Hare clutch solenoid

Terminal Wire 1 477A 2 478A 3 479A 4 480A 5 495 6 485 7 8 126 9 10 489 11 660N 12 125C 13 14 437 15 442 16 436 17 438 18 443 19 441 20 446 21 439 22 492 23 24 25 486, 486A 26 481 27 484 28 483 29 482 30 491 31 490 32 493 33 488 34 487 35 494 36 629

60 - 15 - 01/8

Function Low range selected Medium range selected High range selected Reverse range selected Clutch up >3 kph speed trigger + 12v output (air valve) Medium range neutral solenoid Battery negative + 12v ignition Low range engaged switch Medium range neutral switch Reverse range engaged switch Medium range engaged switch High range neutral switch Low range neutral switch Reverse range neutral switch High range engaged switch Low range engage solenoid

> 1 kph speed trigger Reverse range indicator High range indicator Medium range indicator Low range indicator Reverse range engage solenoid High range neutral solenoid Medium range engage solenoid Low range neutral solenoid Reverse range neutral solenoid High range engage solenoid Can bus screen

8020 - C/8-2.2

Issue 2*

CONTENTS

Fastrac

60 - 15 - 01/8A

2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams (cont’d) Connector Terminals (cont’d) Powershift - Electronic Control Unit (ECU) Wet Clutch Transmission CR49 (Black)

Powershift - Electronic Control Unit (ECU) Wet Clutch Transmission CR50 (Red)

Terminal Wire 1 514 2 3 810B 4 400C 5 820 6 822 7 823 8 900 9 821A 10 901 11 660J 12 125B 13 14 515 15 434 16 450 17 898, 898B 18 816 19 20 21 22 523 23 660H 24 125A 25 522 26 521 27 413 28 470A 29 471A 30 472A 31 412B 32 33 625 34 35 36 902

Terminal 1 2 3 4 5 6 7

Wire 477A 478A 479A 480A 435 485 526

8 9 10 11 12 13

126 524A 489 660N 125C 525

14 15 16 17 18 19 20 21 22 23 24

437 442 436 438 443 441 446 439 492 524B

25 26 27 28 29 30 31 32 33 34 35 36

486, 486A 491 490 493 488 487 494 629

9804/1103

Function CANL Clutch down Handbrake Wet clutch solenoid Wet clutch lubrication solenoid Transmission brake solenoid Snail clutch solenoid Wet clutch current sense resistor Tortoise clutch solenoid Battery negative + 12v ignition CANH Transmission oil pressure warning Buzzer 20 kph speed trigger Reversing lamps relay coil Clutch pedal potentiometer return Battery negative + 12v ignition Clutch pedal potentiometer wiper Clutch pedal potentiometer supply Throttle deceleration switch Up shift switch Down shift switch Auto mode switch Engine rpm signal EMC ground Hare clutch solenoid

60 - 15 - 01/8A

Function Low range selected Medium range selected High range selected Reverse range selected Transmission oil pressure switch 3 kph speed trigger Transmission temperature sender 2 return Ram solenoid 12V supply Link to CN2 pin 24 Medium range neutral solenoid Battery negative +12 V ignition Transmission temperature sender 1 return Low range neutral switch Medium range neutral switch Reverse range engage switch Medium range engage switch High range neutral switch Low range neutral switch Reverse range neutral switch High range engage switch Low range engage switch Transmission oil temperature senders (link to CN2 pin 9) 1 kph speed trigger Reverse range engage solenoid High range neutral solenoid Medium range engage solenoid Low range neutral solenoid Reverse range neutral solenoid High range engage solenoid Can bus screen

8020 - C/8-2A.1

Issue 2*

CONTENTS CONTENTS

Fastrac

60 - 15 - 01/9

2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams (contÕd) Connector Terminals (contÕd) Electronic Draft Control - Electronic Control Unit (ECU) (Type D+) E1 All 2000 Series machines to S/N 738694 2000 Series machines with radar from S/N 738695 All 3000 Series machines to S/N 640709 3000 Series machines with radar from S/N 640710 Terminal Wire 1 725 2 506 3 427 4 431 5 505 6 424 7 425 8 518 9 930 10 500B 11 414B 12 13 403B 14 15 16 509 17 922 18 19 504/504A 20 507 21 428 22 429 23 430 24 135 25 26 426 27 28 660GA 29 300A 30 31 433 32 33 34 510 35 924 36 928 37 503/503A 38 715 39 920 40 41 508 42-55 -

9804/1103

All 2000 Series machines to S/N 738694 2000 Series machines with radar from S/N 738695 All 3000 Series machines to S/N 640709 3000 Series machines with radar from S/N 640710

Function Draft sensor earth Control panel supply Raise limit signal Draft/position mix signal Slip setpoint increase Position sensor signal Left draft sensor signal Slip setpoint decrease Remote raise/lower switch-common Radar signal Transmission speed signal Alternator charge signal

Lower signal out Remote switch raise signal Control valve lower signal Control panel earth Control lever signal Setpoint level signal Lower speed signal +12v ignition

Electronic Draft Control (EDC) (Type D+) - Control Panel E2

Terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Wire 431 506 507 429 428 430 504A 503A 427 433 508 -

Function Draft/position mix signal Power supply in Earth Setpoint level signal Control lever signal Lower speed signal Control valve lower signal Control valve raise signal Raise limit signal Diagnostic LED (+ve) Diagnostic LED (-ve)

Right draft sensor signal Battery earth +12v battery Diagnostic LED (+ve)

Slip setpoint feedback signal Control valve common Remote switch lower signal Control valve raise signal Position sensor earth Position/draft sensor supply Diagnostic LED (-ve)

60 - 15 - 01/9

8020 - C/8-3.1

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 15 - 01/9A

2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams (cont’d) Connector Terminals (cont’d) Electronic Draft Control - Electronic Control Unit (ECU) (Type B) E1 2000 Series machines not fitted with radar from S/N 738695 3000 Series machines not fitted with radar from S/N 640710 Terminal Wire 1 508/660GA 2 503/503A 3 507 4 431 5 403B 6 924 7 8 428 9 433 10 922 11 509 12 506/930 13 920 14 504/504A 15 715/725 16 429 17 425 18 426 19 424 20 928 21 22 427 23 24 430 25 135

Function Battery 0v Control valve raise signal Control panel earth Draft/position mix signal Alternator charge signal Control valve common Control lever signal Diagnostic LED+ Fender raise switch Lowered signal (area cut-out) Fender switch, control panel common Position/draft sensor supply Control valve lower signal Position/draft sensor earth Setpoint level signal Left draft sensor signal Right draft sensor signal Position sensor signal Fender lower switch Top end position signal

4WS - Electronic Control Module C1 - Inputs Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 C2 - Outputs Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 Pin 13 Pin 14

+12V ignition (main) Earth (main) +12V sidelights Not used +12V > 1 kph + 12V < 20 kph +12V EDC power override +12V axle locked +12V sprayer override - audible warning Not used

Left steering valve solenoid Right steering valve solenoid Axle unlock signal Front axle sensor (potentiometer)

Rear axle sensor (potentiometer) Differential lock cut-out signal Not used

Lower speed signal +12 v ignition

Electronic Draft Control (EDC) (Type B) - Control Panel E2 2000 Series machines not fitted with radar from S/N 738695 3000 Series machines not fitted with radar from S/N 640710 Terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

9804/1103

Wire 431 506 common 507 429 428 430 504A 503A 427 433 508 -

Function Draft/position mix signal Fender switch, control panel

Control panel earth Setpoint level signal Control lever signal Lower speed signal Control valve lower signal Control valve raise signal Top end position signal Diagnostic LED+ Battery 0v

60 - 15 - 01/9A

8020 - C/8 - 3A.2

Issue 1

CONTENTS CONTENTS

Fastrac

60 - 15 - 01/10

2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams (cont’d) Splice Identification

*

*

*

*

Splice ABSSS ADBS ADCOS ALES ALSS AMBS APWLS ASS ASSS AWS BATS BLS BMS CANHS CANLS CDS CES CRES CRPFS CRSIS C9CS DBS DSSS EDCES EDCS ELSS FDES FDSS FLES FLS FPDS FWLSS HSS IGNS IFWLS IRWLS ISRS LHIS LHSLS LS LSLS MBS OCES

9804/1103

Description ABS supply splice Auxiliary dipped beam splice Area differential lock cut-out splice Auxiliary lights earth splice Auxiliary lights supply splice Auxiliary main beam splice ‘A’ post work lights splice Alternator signal splice Autoshift switch splice Alternator ‘W’ splice Battery splice Brake lights splice Brakes malfunction splice CAN high splice CAN low splice Clutch down splice Chassis earth splice Cab roof earth splice Cab roof permanent feed splice Cab roof start inhibit splice Fuse C9 chassis splice Dipped beam splice Downshift switch splice Electronic draft control earth splice Electronic draft control splice EDC lower signal splice Flow divider earth splice Flow divider supply splice Front lights earth splice Fog lights splice Front PTO drive splice Front working lights supply splice Hare solenoid splice Ignition splice Inner front working light supply splice Inner rear working light supply splice Inching solenoid resistor splice Left hand indicator splice Left hand side lights splice Lower splice Left side lights splice Main beam splice Option-chassis earth splice

Splice OCSS OFWLS ORWLS PES PFS PHS PIS PLIS PRSFS PRHS PRIS PRLS PRMS PRRS PSSS RHIS RHSLS RLSS RPBS RPCOS RPDS RS RSLS RSS RWLSS SA SD SES SFS * SSS * SSS * SSS * SSS SWFS * TAES * TAIS TOPS * TOTS * TSS * USSS VSS 1KSS 2WDDS

60 - 15 - 01/10

Description Option-chassis supply splice Outer front working lights splice Outer rear working lights splice Panel earth splice Permanent feed splice Panel headlights splice Panel ignition splice Panel left indicator splice Power range solenoid feed splice Power range high splice Panel right indicator splice Power range low splice Power range medium splice Power range reverse splice Powershift supply splice Right hand indicator splice Right hand side lights splice Reverse lights switching splice Rear PTO brake splice Rear PTO cut-out splice Rear PTO drive splice Raise splice Right side lights splice Radar signal splice Rear working lights supply splice 4WS ignition splice 4WS earth splice Starter motor earth splice Solenoid feed splice Speed signal splice (Fig. 12 - 34) Solenoid supply splice (Fig. 12 - 9) Sensor supply splice (Fig. 12 - 10) Snail solenoid splice (Fig. 12 - 13A) Switched feed splice Tractor ABS earth splice Tractor ABS ignition splice Transmission oil pressure splice Transmission oil temperature splice Tortoise solenoid splice Upshift switch splice Valve supply splice 1 kph signal splice 2WD dump splice

8020 - C/8-4.2

Issue 2*

CONTENTS

Fastrac

60 - 15 - 01/11

2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams (cont’d) Figure No. 12 - 1 12 - 2 12 - 3

12 - 4 12 - 5 12 - 6 12 - 7 12 - 8 12 - 8A 12 - 9 12 - 10 12 - 10A 12 - 11 12 - 12 12 - 13 12 - 13A 12 - 13B 12 - 13C 12 - 14 12 - 15 12 - 16 12 - 17 12 - 18 12 - 19 12 - 20 12 - 21 12 - 22 12 - 23 12 - 24 12 - 25 12 - 26 12 - 27 12 - 28 12 - 29 12 - 30 12 - 31 12 - 32 12 - 32A 12 - 33 12 - 34 12 - 35 12 - 35A 12 - 35B 12 - 36 12 - 37 12 - 37A 12 - 38 * 12 - 39 12 - 40 12 - 41 12 - 42

9804/1103

Supply Circuit Earth Circuit Fuse A1 - Neutral Start (Clutch) Fuse C6 - Starter Solenoid Fuse C9 - Air Drier; Neutral Start (Gearbox) Fuse A2 - Brake Lights Fuse A3 - Rear Wash/Wipe Fuse A4 - Front Wash/Wipe; Horn Fuse A4 (cont’d) Fuse A5 - Engine Shut-Off Solenoid (E.S.O.S.) (2000 Series, 3155 Dry Clutch Transmission) Fuse A5 - Engine Shut-Off Solenoid (E.S.O.S.) (2000 Series, 3155 Wet Clutch Transmission) Fuse A5 - Engine Shut-Off Solenoid (E.S.O.S.) (3185 only) - E.S.O.S. Maxifuse Fuse A6 - Electronic Draft Control (EDC) D +, Ignition Cab Side. Fuse B9 - Electronic Draft Control (EDC) D +, Battery Cab Side Fuse A6 - Electronic Draft Control (EDC) B, Ignition Cab Side. Fuse B9 - Electronic Draft Control (EDC) B, Battery Cab Side Fuse A6 - Electronic Draft Control (EDC) D+ and B, Ignition Chassis Side Fuse B9 - Electronic Draft Control (EDC) D+ and B, Battery Chassis Side Fuse A7 - Powershift ECU - 3-Speed Splitter (Dry Clutch Transmission) Fuse A7 (cont’d) - Powershift ECU - Selectronic (Dry Clutch Transmission) Fuse A7 - Powershift ECU - Selectronic (Wet Clutch Transmission) Fuse A7 (cont’d) - Powershift ECU - Selectronic (Wet Clutch Transmission) Fuse A7 (cont’d) - Wet Clutch Control (Wet Clutch Transmission) Fuse A7 (cont’d) - Powershift ECU - Selectronic Fuse A8 - Front/Rear PTO; 2WD and Differential Lock Solenoids; Rear PTO Cut-Out Rear PTO Cut-Out Option Fuse A9 - Air Conditioning Circuit Fuse B1 - Interior Lights; Radio/Cassette; Beacon Socket Fuse B2 - Hazard Warning LIghts Fuse C2 - Direction Indicators Fuse B3 - Front Work Lights Fuse B4 - Rear Work Lights Fuse B5 - Headlight Flash Fuse W (Maxifuse) - Main Lights Fuse D1 - Main Beam Fuse D2 - Dipped Beam Fuse D3 - Rear Fog Lights Fuse D4 - Side Lights (Left Side) Fuse D5 - Side Lights (Right Side) Auxiliary Lights Switching (2000 Series) Fuse D6 - Auxiliary Lights Switching (3000 Series) Fuse B6 - Radio Cassette Fuse B7 - Auxiliary Jack-Plug Socket Fuse B8 - Cigar Lighter Fuse C1 - Trailer Socket Reverse Light (Dry Clutch Transmission) Fuse C1 - Reverse Lights (Wet Clutch Transmission) Fuse C3 - Thermostart Fuse C4 - Lights Switch Illumination; Bleeper; Instrument Cluster; Differential Lock Cut-Out; Diagnostic Supply Connector; Speedo Sensor; Fuse C5 (Dry Clutch Transmission) Fuse C4 (Dry Clutch Transmission ) (cont’d) Fuse C4 - Lights Switch Illumination; Bleeper; Instrument Cluster; Differential Lock Cut-Out; Diagnostic Supply Connector; Speedo Sensor; Fuse C5 (Wet Clutch Transmission) Fuse C4 (Wet Clutch Transmission) (cont’d) Fuse C4 (cont’d) - Canbus; Diagnostic Connector Fuse C5 - Fuel Flow Sensor; Ground Speed Radar Sensor (Dry Clutch Transmission) Fuse C5 - Fuel Flow Sensor; Ground Speed Radar Sensor (Wet Clutch Transmission) Fuse C7 - 13-pin Trailer Socket (Ignition) Fuse C8 - 13-pin Trailer Socket (Battery) Fuses E1, E2 - Trailer ABS Fuses F1, F2, F3, F4 - Tractor ABS Fuse E3 - Flow Divider Fuse E4 - Four Wheel Steer (4WS) Circuit Trailer Sockets

60 - 15 - 01/11

8020 - C/8-5.3

Issue 3*

9804/1103

60 - 15 - 01/12 54 55 56 57 58 59 60 61 62 63 64 65 66

53

51 52

49A 50

Column Switch Powershift Range Neutral Solenoid Connector Powershift Range Engaged Solenoid Connector 4WS Option Connector Clutch Warning/Selectronic Bleeper Powershift Low/Reverse Air Ram Powershift Medium/High Air Ram 2WD/Differential Lock Switch Rear PTO Switch Front PTO Switch Differential Lock Switch Differential Lock Cut-Out Relay 2WD Dump Relay 2WD Solenoid Differential Lock Solenoid Rear PTO Brake Solenoid

Battery (all machines) Second Battery (3000 Series only) Ignition Switch Starter Motor Alternator Trailer ABS Socket Tractor ABS Supply (if fitted) Tractor ABS Return (if fitted) Ignition Relay Worklights Relay Heater Unit (3000 Series) Auxiliary Connector Auxiliary Power Socket (if fitted) Air Conditioning Connector (2000 Series) Air Conditioning Connector (3000 Series) Auxiliary Lights Earth Connector (2000 Series) Auxiliary Lights Supply Connector (3000 Series) Suspension Seat/Flow Divider Connector Horn Connector Start Inhibit Relay 1 Start Inhibit Relay 2 Clutch Start Micro-switch Diode Connector Front PTO Switch Rear PTO Switch Brake Lights Switch Brake Lights Relay Rear Wiper Motor Rear Wash/Wipe Switch Connector - Rear Washer Pump (2000 Series) Connector - Rear Washer Pump (3000 Series) Rear Intermittent Wipe Relay Rear Wiper Connectors Front Washer Pump Connector (2000 Series) Front Washer Pump Connector (3000 Series) Horn Washer/Horn Switch Front Wiper Motor Front Intermittent Wipe Relay Front Wiper Switch Cold Advance Switch (2000 Series only) Waxstat E.S.O.S. (2000 Series, 3155) E.S.O.S. Relay (3185 only) E.S.O.S. (3185 only) Timer (3185 only) Area Cut-out Switch (EDC) Connector - EDC Unit Pin position identification for 39 Raise/Lower Switch (EDC) (In cab) Draft Pin (EDC) (Left Hand) Draft Pin (EDC) (Right Hand) Position Sensor (EDC) Raise Push-Button (EDC) (RH Fender) Raise Push-Button (EDC) (LH Fender) Lower Push-Button (EDC) (RH Fender) Lower Push-Button (EDC) (LH Fender) Raise Solenoid (EDC) Lower Solenoid (EDC) Gear Lever Powershift Switches a Down b Up c Auto Duplicate Powershift Switches (if fitted) Powershift Solenoids a Snail b Tortoise c Hare Splitter Dump Relay Accelerator Pedal Switch 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 120A 121 121A 122 123 124 125 126 127 128A 128B 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149

102

84 85 86 87 88 89 90 91 92 93 94 95A 95B 96 97 98 99 100 101

83

82

77 78 79 80 81

76

72 73 74 75

71b

67 68 69 70 71 71a

Front PTO Brake Solenoid Rear PTO Drive Solenoid Front PTO Drive Solenoid Park Brake Switch Rear PTO Cut-Out Connector Rear PTO Termination Connector (machines without rear PTO cut-out option) Rear PTO Interconnecting Connector (machines with rear PTO cut-out option) Diode Connector (E21) (PTO Cut-Out) PTO Cut-Out Push-Button (LH Fender) PTO Cut-Out Push Button (RH Fender) Air Conditioning Blower Switch (2000 Series only) Air Conditioning Switch (2000 Series only) Heater Unit (3000 Series only) Air Conditioning Unit Air Conditioning Compressor Switch Air Conditioning Compressor Clutch Air Conditioning Compressor Pressure Switch (High) Air Conditioning Compressor Pressure Switch (Low) Air Conditioning Compressor Clutch Relay Radio/Cassette Interior LIght (RH) Interior Light (LH) Door Switch (LH) Beacon Switch Beacon Socket Hazard Switch Single Trailer Turn Relay Second Trailer Turn Relay Outer Indicator Lights (RH) Outer Indicator Lights (LH) Auxiliary Lights Connector (In) Auxiliary Lights Connector (Out) Side Repeater (LH) (3000 Series only) Side Repeater (RH) (3000 Series only) Trailer Socket Rear Light Cluster (LH) Connector Rear Light Cluster (RH) Connector Front Light Cluster (RH) Connector (3000 Series only) Front Light Cluster (LH) Connector (3000 Series only) Front Worklights Switch ‘A’ Post Worklights Relay Front Working Light (RH outer) Front Working Light (RH inner) Front Working Light (LH inner) Front Working Light (LH outer) Front Working Light (RH ‘A’ post) Front Working Light (LH ‘A’ post) Rear Worklights Switch Rear Working Light (RH outer) Rear Working Light (RH inner) Rear Working Light (LH inner) Rear Working LIght (LH outer) Main Lights Switch Rear Fog Lights Switch Rear Fog LIghts Relay Column Lights Switch (Main/Dip/Flash) Headlight Connector (LH) (3000 Series) Sidelight Connector (LH) (2000 Series) Headlight Connector (RH) (3000 Series) Sidelights Connector (RH (2000 Series) Air Gauge Illumination Lamp Number Plate Lamp (LH) Number Plate Lamp (RH) Auxiliary Lights Switch (3000 Series) Auxiliary Headlights (RH) Auxiliary Headlights (LH) Speaker (LH) Speaker (RH) Auxiliary Socket Cigar Lighter Trailer Socket Reverse Light Relay Mega Fuses - Thermostart (3185 only) Thermostart Heater Relay 1 (3185 only) Thermostart Heater Relay 2 (3185 only) Thermostart Heater 1 (3185 only) Thermostart Heater 2 (3185 only) Thermostart 1 (2000 Series, 3155) Thermostart 2 (2150 only) Buzzer Relay Clutch ‘Up’ Switch Water Temperature Sender Air Pressure Switch - Tank 1 Air Pressure Switch - Tank 2 Air Pressure Switch - Tank 3 Fuel Level Sender Transmission Oil Filter Switch Air Filter Switch Front Brake Reservoir Level Rear Brake Reservoir Level * * * * * * * * * * * * *

*

48A 49

28 29 30 31 32 33 33A 34 35 36 37 38 39 40 41 42L 42R 43 44A 44B 45A 45B 46 47 48

27A

25 26 27

24A

12 13 14 15 16 17 18 19 20 21 22 23 24

11A

1 1A 2 3 4 5 5A 5B 6 7 8 9 9A 10 10A 11

Sectional Diagrams Component Key

188 189 190 191 192 193 194 195 196 197 198 199 200

187

186

185

180 181 182 183 184

175 176 177 178 179

165 166 167 168 169 170 171 172 173 174

149A 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164

Rear Brake Reservoir Level (ABS) Transmission Oil Pressure Switch Speedometer Pick-up Engine Oil Pressure Switch Canbus Cable Screen RF Ground Diagnostic Connector 4WS Interconnecting Connector Non-4WS Connector Fuel Flow Sensor Radar Speed Sensor ABS Trailer Socket Suspension Seat Connector Flow Divider Switch Flow Divider Valve Connector Rear Axle Ram Lock Switch (closed when locked) Rear Axle Ram Lock Valve Steer Valve (RH) Steer Valve (LH) Front Potentiometer (4WS) Rear Potentiometer (4WS) 4WS Differential Lock Cut-Out Relay Trailer Socket (7-pin) Trailer Socket (13-pin) 4WS Jack Socket Wheel Slip Enable Switch (machines with optional software package only) (2000 Series from serial no. 788376; 3000 Series from serial no. 640305) Inching Solenoid Resistor - 4.7 ohm Column Switch Button Clutch Potentiometer Transmission Oil Temperature Sensor 1 Transmission Oil Temperature Sensor 2 (clutch housing oil sump) Clutch Lubrication Solenoid Transmission Brake Solenoid Clutch Control Solenoid Cab Auxiliary Supply Connector Cab Auxiliary Battery Supply - Terminal Ports Cab 3-pin Auxiliary Power Socket (battery and ignition supplies) Cab Auxiliary Power Convenience Socket (Option - N.Am. machines) Ignition Switched Relay (supplied with item 186) ABS Diagnostic Interconnect Tractor Diagnostic Interconnect Tractor ABS Diagnostic Relay Diagnostic Switch Tractor ABS Ignition Relay ABS Speed Sensor (Front RH) ABS Speed Sensor (Front LH) ABS Speed Sensor (Rear RH) ABS Speed Sensor (Rear LH) ABS Pressure Modulating Valve (Front) ABS Pressure Modulating Valve (Rear LH) ABS Pressure Modulating Valve (Rear RH) Tractor ABS ECU Connectors

CONTENTS

Fastrac 60 - 15 - 01/12

2000 Series, 3000 Series

Electrical Circuit - Sectional Wiring Diagrams (cont’d) Wiring Diagrams - Component Key

8020 - C/8-6.5

Issue 4*

CONTENTS

Fastrac

60 - 15 - 01/13

2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams (cont’d) Wiring Diagrams - Alphabetical Index Fuses A1 A2 A3 A4 * A5 A6 12-11 * A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 12-11 * C1 C2 C3 * C4 * C5 C6 C7 C8 C9 D1 D2 D3 D4 D5 D6 E1 E2 E3 E4 W

9804/1103

Item

Figure No. 12-3 12-4 12-5 12-6 & 12-7 12-8, 12-8A & 12-9 12-10, 12-10A & 12-12, 12-13 ,12-13A,12-13B 12-13C & 12-14 12-15 12-17 12-18 12-19 12-20 12-21 12-22 12-29 12-30 12-31 12-10, 12-10A & 12-32 & 12-32A 12-19 12-33 12-34, 12-35,12-35A 12-35B & 12-36 12-37 & 12-37A 12-3 12-38 12-38 12-3 12-23 12-23 12-24 12-25 12-26 12-28 12-39 12-39 12-40 12-41 12-22

Figure No.

Air Conditioning Air Dryer Alternator Auxiliary Lights Switching Area Cut-out Switch Auxiliary Jack Plug Socket Battery Beacon Socket Bleeper Brake Lights Cigar Lighter Diagnostic Supply Connector Differential Lock Cut-out Direction Indicators Earth Circuit Electronic Draft Control system * ESOS Flow Divider Fog Lights - Rear Four Wheel Steer (if fitted) * Fuel Flow Sensor * Ground Speed Radar Sensor Hazard Warning Lights Head Lights Horn Instrument Cluster Interior Lights Light Switch Illumination Main Lights Maxifuse (W) Neutral Start (Clutch & Gearbox) Powershift ECU - 3-Speed Splitter * Powershift ECU - Selectronic

12-17 12-3 12-1 12-27 & 12-28 12-10 12-30 12-1 12-18 12-34 12-4 12-31 12-36 12-15 12-19 12-2 12-10 & 12-11 12-8, 12-8A & 12-9 12-40 12-24 12-41 12-37, 12-37A 12-37, 12-37A 12-19 12-22 & 12-23 12-6 12-34 12-18 12-34 12-22 12-22 12-3 12-12 12-13, 12-13A, 12-13B 12-13C & 12-14 PTO - Front 12-15 PTO - Rear 12-15 & 12-16 Radio/Cassette 12-29 Side Lights - LH 12-25 Side Lights - RH 12-26 Solenoid - Two Wheel Drive 12-15 Solenoid - Differential Lock 12-15 * Speedometer Sensor 12-35, 12-35A & 12-35B Starter Solenoid 12-3 Supply Circuit 12-1 Thermostart 12-33 Trailer ABS Socket 12-39 * Trailer Socket Reverse Lights 12-32 &12-32A Trailer Sockets 12-38 &12-42 * Transmission Oil Pressure Switch 12-35, 12-35A & 12-35B Two Wheel Drive Solenoid 12-15 Wash/Wipe-front 12-6 & 12-7 Wash/Wipe-rear 12-6 * Wet Clutch Control 12-13C * Wheelslip Enable Switch 12-37 &12-37A Work Lights - Front 12-20 Work Lights - Rear 12-21

60 - 15 - 01/13

8020 - C/8-7.3

Issue 2*

CONTENTS

2

2

6

12-26

7 5A 12-39

21

W

12-22 12-3

8020 - C/12-1.4

1 12-4

1A

3

4

12-3

A2

12-4

A3

12-5

A4

12-6

A5

12-8

A6

12-10

A7

12-12

A8

12-15

A9

12-17

B1

12-18

B2

12-19

B3

12-20

B4

12-21

B5

12-22

B6

12-29

B7

12-30

B8

12-31

B9

12-10

C1

12-32

C2

12-19

C3

12-33

C4 C5

12-34

C6

12-3

C7

12-38

C8

12-38

C9

12-3

Fastrac

60 - 15 - 01/14

7

A1

2000 Series, 3000 Series

5

Electrical Circuit - Sectional Wiring Diagrams (cont’d) Wiring Diagrams

*

9804/1103

12-39

12-37

A307153

60 - 15 - 01/14

Issue 4*

FIG. 12-1 SUPPLY CIRCUIT: BATTERY TO STARTER MOTOR; ALTERNATOR; FUSES A1 - A9, B1 - B9, C1 - C9, W (Maxifuse); TRAILER ABS CONNECTOR, TRACTOR ABS CONNECTOR

Fastrac

10A

A307162

3000 SERIES 8020 - C/12-2.3

12-9 3185

9A

60 - 15 - 01/15

Issue 3*

FIG12-2 EARTH CIRCUIT

11A 3000 SERIES

13 1A 1

60 - 15 - 01/15

10

3 9

11 2000 SERIES

2000 Series, 3000 Series

12-4

Electrical Circuit - Sectional Wiring Diagrams (cont’d) Wiring Diagrams (cont’d)

*

8 9804/1103

5B 12-39A

2000 SERIES

CONTENTS

12

CONTENTS

854 (0.6)

14

C 6

C5

CR8

3

CRSIS

CR86

3 4

1

A D

A

B

D

C

854 (0.6)

6

19

2/4

660C (0.6)

CR7

855 (0.6)

5

CR36

182 (4.0)

182 (4.0) C41

CR4-D

60 - 15 - 01/16

16

CES7 D8

810B (0.6)

aa

bb

D

855 (0.6)

D 6

D5

1 D 4

C

hh

856B (0.6)

gg

D 2

5

P

3

181 (4.0)

bb

A

B

D J

H

aa

E K

R

F L

S W

ff

ee

G

cc

N U

B

cc

G M

T

V

2

2

N dd

F M

U

E

S

7

6

5

4

3

2

R

4

W

4

H P

2

gg

V

C6

3 ff

3

4 1

1

CR51

811 (0.6)

8

C J

dd

ee

9

hh D

K

L T

1

A

24 23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25

C28 TH2

Fastrac

182 (4.0)

2

12 11 10

A D

1 8

2

1

B C

640K (1.4)

2

4

B C

3

15

181 (4.0)

2

856B (0.6)

4 3

12-13A

B C

1 2

2 1

810C (0.6)

A D

1 BRAKE

17

856 (0.6) CDS

18

2/4 856C (0.6)

810A (0.6)

1

3

856A (0.6)

105 (0.6)

810 (0.6)

180 (4.0)

C 2

5

A1

856A (0.6)

C 4

8

2

+12V IGN

660B (0.6)

CRES3

811 (0.6)

+12V

181 (4.0)

C8

6

2000 Series, 3000 Series

C

4

180 (4.0)

Electrical Circuit - Sectional Wiring Diagrams (cont’d) Wiring Diagrams (cont’d)

*

9804/1103

CR4-C C6

1 2

C9CS

195A (1.4)

195B (0.6)

195 (1.4) CR49 1 2 3 4 9

+12V IGN

8020 - C/12-3.4

C9

195 (1.4)

14 15

10 16

20

28 36 37

40 41

42 43

38 44

45 46

47

25 32

32

39

39

33 34

35

29 30

31

26

2

26

22 30 37 43

46 47

17 24

29 36

42

10 16

23

28 35

41

9 15

21

34 40 45

8 14

27

195B (0.6)

4

7 13

20

33

3

6 12

19 25

27

22

24

11 18

18 19

21

23

17

5 11

12 13

8

1

5 6

7

811 (0.6)

31 38

44 48

48

X

W

B J

H

K L M N

C

A

D O

E P

W V

V

H U

G F

T S

Q R

U T S

X J

K B

G A F E R Q P

L M

C

N

D O

C5 CR1

C72

Issue 4*

FIG12-3 FUSE A1 - NEUTRAL START (CLUTCH); FUSE C6 - STARTER SOLENOID; FUSE C9 - AIR DRIER, NEUTRAL START (GEARBOX)

60 - 15 - 01/16

A309863

TH1

CONTENTS

CONTENTS

2000 Series, 3000 Series

21

Fastrac

60 - 15 - 01/17

12-42

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

3

gg V

ff 4 W ee

dd

H J K

P R S T U

L M N

C D E F G

hh aa 1 A B

bb 2 cc

20

A307170

8020 - C/12-4.1

60 - 15 - 01/17

Issue 1

FIG. 12-4 FUSE A2 - BRAKE LIGHTS

Wiring Diagrams (contÕd)

9804/1103

A2

CONTENTS

2000 Series, 3000 Series

2000 SERIES

Fastrac

gg ff

Electrical Circuit - Sectional Wiring Diagrams (contÕd) Wiring Diagrams (contÕd)

A3

12-15 9804/1103

60 - 15 - 01/18

12-25

A307180 8020 - C/12-5.1

26 26 22 24A

12

60 - 15 - 01/18

Issue 1

FIG. 12-5 FUSE A3 - REAR WASH/WIPE

25 23 24

3 V

4 W ee dd

H J K

P R S T U

L M N

C D E

hh cc

F G

aa 1 A B

bb 2

12-40 3000 SERIES

CONTENTS

Fastrac

ff

A307190 8020 - C/12-6.1

12-7

29

27 27A

28

60 - 15 - 01/19

Issue 1

FIG. 12-6 FUSE A4 - FRONT WASH/WIPE; HORN

3

gg V

dd

4 W ee

P R S T U

H J K L

C D E F G

CONTENTS

60 - 15 - 01/19

cc

M N

hh aa 1 A

bb 2

B

2000 Series, 3000 Series

3000 SERIES

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

12-7

Wiring Diagrams (contÕd)

12-7 A4 9804/1103

2000 SERIES

CONTENTS

CONTENTS

CONTENTS

Fastrac

A307200

8020 - C/12-7.1

12-6

60 - 15 - 01/20

Issue 1

FIG. 12-7 FUSE A4 (CONTÕD) - FRONT WASH/WIPE

2000 Series, 3000 Series

32 ff

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

60 - 15 - 01/20

3

gg V

4 W ee dd

H J K

P R S T U

L M N

C D E

hh cc

F G

aa 1 A B

bb 2

Wiring Diagrams (contÕd)

9804/1103

31 30

CONTENTS

Fastrac

33 8020 - C/12-8.2

60 - 15 - 01/21

Issue 2*

FIG. 12-8 *FUSE A5 - ENGINE SHUT-OFFF SOLENOID (ESOS) (2000 SERIES, 3155) - DRY CLUTCH TRANSMISSION

2000 Series, 3000 Series

60 - 15 - 01/21

34

Electrical Circuit - Sectional Wiring Diagrams (cont’d)

9804/1103

A5

2000 SERIES

CONTENTS

(3155)

34

Fastrac

60 - 15 - 01/21A

(2000)

2000 Series, 3000 Series

Electrical Circuit - Sectional Wiring Diagrams (cont’d)

9804/1103

A5

3155 ONLY 8020 - C/12-8A.1

2000 SERIES ONLY

33 WAXSTAT

A353910

60 - 15 - 01/21A

Issue 1

FIG. 12-8A FUSE A5 - ENGINE SHUT OFF SOLENOID (ESOS) (2000 SERIES, 3155 - WET CLUTCH TRANSMISSION)

CONTENTS

CONTENTS

2000 Series, 3000 Series

35

Fastrac

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

37 60 - 15 - 01/22

8020 - C/12-9.1

3 A5

60 - 15 - 01/22

Issue 1

FIG. 12-9 FUSE A5 - ENGINE SHUT-OFF SOLENOID (ESOS) (3185 ONLY) ESOS MAXIFUSE

Wiring Diagrams (contÕd)

9804/1103

ESOS (40A)

3

36

A309870

CONTENTS

12-34

12-37

40

12-37

60 - 15 - 01/23

38

A6

Fastrac

860RB (0.6)

CONTENTS

39

2000 Series, 3000 Series

42R

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

Wiring Diagrams (contÕd)

9804/1103 42L

B9 3000 SERIES

8020 - C/12-10.3

2000 SERIES

41 12-11

12-41

† All 2000 Series machines to S/N 738694 2000 Series machines with radar from S/N 738695 All 3000 Series machines to S/N 640709 3000 Series machines with radar from S/N 640710

60 - 15 - 01/23

Issue 1

FIG. 12-10 ELECTRONIC DRAFT CONTROL (EDC) TYPE D+ FUSE A6 - IGNITION CAB SIDE FUSE B9 - BATTERY CAB SIDE

A307222

CONTENTS

40

Fastrac

60 - 15 - 01/24 A6

CONTENTS

39

2000 Series, 3000 Series

42R

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

Wiring Diagrams (contÕd)

9804/1103 42L

B9 3000 SERIES

8020 - C/12-10A.1

2000 SERIES

12-41 41 12-11

† 2000 Series machines not fitted with radar from S/N 738695 3000 Series machines not fitted with radar from S/N 640710

A343740

60 - 15 - 01/24

Issue 1

FIG. 12-10A ELECTRONIC DRAFT CONTROL (EDC) TYPE B FUSE A6 - IGNITION CAB SIDE FUSE B9 - BATTERY CAB SIDE

CONTENTS

CONTENTS

Fastrac

47

A307250

8020 - C/12-11.2

45A

60 - 15 - 01/25

Issue 1

FIG. 12-11 ELECTRONIC DRAFT CONTROL (EDC) TYPES D+ AND B FUSE A6 - IGNITION CHASSIS SIDE FUSE B9 - BATTERY CHASSIS SIDE

2000 Series, 3000 Series

45B

60 - 15 - 01/25

44B

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

43

Wiring Diagrams (contÕd)

9804/1103

44A

46

CONTENTS

b

60 - 15 - 01/26

3 V

ff 4 W ee

P R S T U

c

A307240

8020 - C/12-12.2

dd

J K

C D E F G

L M N

aa 1 A B

bb 2 cc

154

60 - 15 - 01/26

Issue 2*

FIG. 12-12 *FUSE A7 - POWERSHIFT ECU - 3 SPEED SPLITTER (DRY CLUTCH TRANSMISSION)

Fastrac

c 48

b 49

2000 Series, 3000 Series

50

Electrical Circuit - Sectional Wiring Diagrams (cont’d)

a

Wiring Diagrams (cont’d)

9804/1103

A7

a

CONTENTS

Fastrac

60 - 15 - 01/27

A307260

8020 - C/12-13.2

51

12-34

60 - 15 - 01/27

Issue 2*

FIG 12-13 *FUSE A7 (CONT’D) - POWERSHIFT ECU - SELECTRONIC (DRY CLUTCH TRANSMISSION)

2000 Series, 3000 Series

52

Electrical Circuit - Sectional Wiring Diagrams (cont’d) Wiring Diagrams (cont’d)

55

9804/1103

12-3

53

2000 SERIES

54

CONTENTS

4

6

660ZA (0.6)

49A

660H (1.0)

CRES3

125C (1.0)

12 11 10

6

7

5

4

2

3

1

CR50

36 35 34 33 32 31 30 29 28 27 26 25

CR95

A

B

B

A

D

C

C

D

901 (0.6)

901A (0.6)

TSS

154 900 (0.6)

471B (0.6) 472B (0.6)

125B (1.0)

SSS

CR49

125A (1.0)

902A (0.6)

HSS

8

9

12 11 10

901B (0.6)

902 (0.6)

625 (1.0)

900A (0.6)

(0.6)

CR96

6

7

5

4

2

3

1

24 23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25

127 (2.0)

472 (0.6)

413 (0.6)

472A (0.6)

ASSS

A B

A

CR62

PSSS

470B

48A DOWN

A7

+12V IGN

660ZC (0.6)

UP

B

8

9

24 23 22 21 20 19 18 17 16 15 14 13

660X (1.0)

5

815 (1.0)

660N (1.0)

660J (1.0)

CRES3

8

2 CR97

660L (0.6)

660ZB (0.6)

12-3

810C (0.6)

1 2

471A (0.6)

DSSS

471 (0.6)

2 1

3

470A (0.6)

USSS

AUTO

720E (0.6)

C21

PES3

127 (2.0)

60 - 15 - 01/27A

UP

b c

901B (0.6)

1

1 2

2

2 1

3 4

3 4

AUTO

9 10

14

640B (1.4)

31

35

37

gg

42

45

P

bb

A

B E

K R

3

46

aa

D J

H

39 40

41

43 44

C

hh

32 33

34

36

38

CES7

26 27

29

1

25

20

28

30

18 19

21 22

23 24

11 12

13

15 16

17

5 6

7 8

4 3

47

900B (0.6)

2 F

L S

G M

T

V

W

ff

ee

902B (0.6) cc

N U

dd

660ZD (0.6)

CRES3

4 412 (0.6)

48

412B (0.6)

AWS

2

1 CR102

4

5

3 7

6 9 10

8 CR51

900 (0.6)

514H (0.6) 631 (1.0)

900 (0.6)

472 (1.4)

12 11 10

bb

1 5

49

W

TH7

1 2

b

815A (0.6)

V H U

SDS

T

815B (0.6)

S

X J

K B

L

C

G A F E

D

R Q P

O

L

X

K B

M

M

C

N

N

D O

J A E

P

11

W

18

V

12 19

H

25

U

32 39

T

34

28

41

8020 - C/12-13A.2

47

TH4

c

1 2

C5

815C (0.6)

23

17

M U

24

E L

W

C28

ee

8

7

6

901 (0.6) 902 (0.6)

TH1

C72

815 (1.0) 901 (0.6) 902 (0.6)

4

3

2

1

515H (0.6) 125 (2.0)

36 35 34 33 32 31 30 29 28 27 26 25

hh C J R

SNAIL LOW

TORTOISE MEDIUM

CR66

H

HARE HIGH

P

gg

V

3

3 ff

10

1

2 6

7 C50 W

815 (1.0)

5

810D (0.6)

D K

S

T

4

9

24 23 22 21 20 19 18 17 16 15 14 13

1

A

dd

31 38

44 48

N

30 37

43

46

F

G

10

aa B

cc

9 16

29 36

42

45

4 8 15

22

35

40

S

Q R

7 14 21

27

2

3

13 20

26 33

G F

2 6

(0.6)

a

12-36

CR1

471 (1.4)

470 (1.4)

1 2

412A

TH5

Fastrac

a 48

1 3

3

470 (0.6)

DOWN

50

CR61

902B (0.6)

2000 Series, 3000 Series

125 (2.0) CDS

Electrical Circuit - Sectional Wiring Diagrams (cont’d)

Wiring Diagrams (cont’d)

*

9804/1103

810D (0.6)

4

5 9

3

8

6

7

+12v SUPPLY

1

2

10

C'DOWN SPLICE

4

5 9

8

412 (1.4) CAN L CAN H P'SHIFT SUPPLY

MH1

Issue 3*

FIG 12-13A FUSE A7 (CONT’D) - POWERSHIFT ECU - SELECTRONIC (WET CLUTCH TRANSMISSION)

CAN SCRN

60 - 15 - 01/27A

A353921

CONTENTS

54 8020 - C/12-13B.1

55 51

60 - 15 - 01/27B

Issue 1

FIG 12-13B FUSE A7 (CONT’D) - POWERSHIFT ECU - SELECTRONIC (WET CLUTCH TRANSMISSION)

Fastrac

60 - 15 - 01/27B

A353940

2000 Series, 3000 Series

52

Electrical Circuit - Sectional Wiring Diagrams (cont’d) Wiring Diagrams (cont’d)

12-35A

9804/1103

12-3

53

2000 SERIES

CONTENTS

5

6

4

3

2

1

820 (0.6)

7

M

498 (0.6)

C72

821 (0.6)

821 (0.6)

N

820 (0.6)

175

C

W

J A E

P

V H U G F

T

W V H U G F

T

S

S

Q R

X

K

J

B

A

C

E

D

R QP

C5

28 29

24 30

ISRS

821A (0.6)

31

36 37

38

40

35 42

21

34 40

28

41

45

45

46

23

36

17 24

30 37

43 47

10 16

29

42 46

47

9 15

22

35

48

4 8

14

27

39

41

43 44

26 33

39

3 7

13 20

32

33 34

25

31 38

44 48

660A (0.6)

822 (0.6) 823 (0.6)

822 (0.6)

23

27

2 6

19

32

26

12

823 (0.6)

17

21 22

11 18

25

640M (0.6)

16

5

18 19

20

526 (0.6)

15

1

11 12

13 14

640N (0.6)

10

5 6

7 8

9

524D (0.6)

3 4

4R7

N

524D (0.6)

2

2 1

821B (0.6)

M

O

526 (0.6)

1 2

L

TH1

CR1 1

CRES3

B

D O

CR99

X

K

640N (0.6)

L

499 (0.6)

821 (0.6)

820 (0.6)

36 35 34 33 32 31 30 29 28 27 26 25

640M (0.6)

24 23 22 21 20 19 18 17 16 15 14 13

RT

12 11 10

9

8

7

6

5

4

3

2

1

24 23 22 21 20 19 18 17 16 15 14 13

525 (0.6)

524 (0.6)

5K

TOTS2

D.O.R.

60 - 15 - 01/27C

CR49

1K

RP

36 35 34 33 32 31 30 29 28 27 26 25 CLUTCH PEDAL UP

3

2

1

177

CR53 1

2

524D (0.6)

526 (0.6)

3

Fastrac

823 (0.6) 822 (0.6) CLUTCH PEDAL DOWN

2000 Series, 3000 Series

8

2 1

Electrical Circuit - Sectional Wiring Diagrams (cont’d)

9

179

CES7 1 2

2 1 12 11 10

TH3

176

Wiring Diagrams (cont’d)

*

9804/1103

CR98 CR66

521 (0.6)

TH9

182

524B (0.6) 524A (0.6)

524C (0.6)

523 (0.6) 522 (0.6)

TH8

TH6

C71

178

181

180

1 2

1 2

1 2

524 (0.6)

TOTS1

1 2

525 (0.6) 12 11 10

9

8

7

6

5

4

3

2

1

A353892

24 23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25

CR50

Issue 3*

FIG 12-13C FUSE A7 (CONT’D) - WET CLUTCH CONTROL (WET CLUTCH TRANSMISSION)

60 - 15 - 01/27C

8020 - C/12-13C.3

526 (0.6)

CONTENTS

CONTENTS

2000 Series, 3000 Series

Fastrac

60 - 15 - 01/28

57

A309580

8020 - C/12-14.1

60 - 15 - 01/28

Issue 1

FIG. 12-14 FUSE A7 (CONTÕD) - POWERSHIFT ECU - SELECTRONIC (CONTÕD)

Electrical Circuit - Sectional Wiring Diagrams (contÕd) Wiring Diagrams (contÕd)

9804/1103

56

CONTENTS

66

67

68

70

60 - 15 - 01/29

69

12-34

59 63

Fastrac

58

2000 Series, 3000 Series

65

†

Electrical Circuit - Sectional Wiring Diagrams (cont’d)

Wiring Diagrams (cont’d)

9804/1103

64

60 12-34

12-26 12-34 12-3

62

8020 - C/12-15.3

61

A8 71a 71

A309591

71b

* † Wire 400A only fitted on later machines

12-16

60 - 15 - 01/29

Issue 2*

FIG. 12-15 FUSE A8 - FRONT/REAR PTO; 2WD AND DIFFERENTIAL LOCK SOLENOIDS; REAR PTO CUT-OUT

CONTENTS

CONTENTS

Fastrac

60 - 15 - 01/30

A309950

8020 - C/12-16.1

60 - 15 - 01/30

Issue 1

FIG. 12-16 REAR PTO CUT-OUT OPTION

2000 Series, 3000 Series

71b

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

73

Wiring Diagrams (contÕd)

9804/1103

72

74

2000 SERIES

Fastrac

3000 SERIES

CONTENTS

3000 SERIES 3000 SERIES

79

82 81

78

60 - 15 - 01/31

A309620

8020 - C/12-17.1

A9

60 - 15 - 01/31

Issue 1

FIG. 12-17 FUSE A9 - AIR CONDITIONING CIRCUIT

2000 Series, 3000 Series

2000 SERIES 2000 SERIES

80

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

2000 SERIES

Wiring Diagrams (contÕd)

9804/1103

76

3000 SERIES 2000 SERIES

75

3000 SERIES

CONTENTS

77

83

CONTENTS

CONTENTS

Fastrac

89

A309630 8020 - C/12-18.1

84

85

60 - 15 - 01/32

Issue 1

FIG. 12-18 FUSE B1 - INTERIOR LIGHTS; RADIO/CASSETTE; BEACON SOCKET

2000 Series, 3000 Series

3000 SERIES

60 - 15 - 01/32

87

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

2000 SERIES

88

86

Wiring Diagrams (contÕd)

9804/1103

B1

CONTENTS

cc

bb 2 G

93

N

3000 SERIES

dd

K

L S

T

4 ee

aa 1

W

hh

C

D

E

F M

U

A

B

H

J R

V

3000 SERIES

P

gg

3 ff

3000 SERIES 3000 SERIES

C2

96

B2

97 3000 SERIES

90

99

Fastrac

60 - 15 - 01/33

98

CONTENTS

95A

2000 Series, 3000 Series

95B

2000 SERIES

Electrical Circuit - Sectional Wiring Diagrams (cont’d)

2000 SERIES

Wiring Diagrams (cont’d)

9804/1103

3000 SERIES

94

3000 SERIES

51

101

92

8020 - C/12-19.2

91 100

3000 SERIES

102

Issue 2*

FIG. 12-19 FUSE B2 - HAZARD WARNING LIGHTS FUSE C2 - DIRECTION INDICATORS

60 - 15 - 01/33

A309601

CONTENTS

2000 Series, 3000 Series

Fastrac

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

104

60 - 15 - 01/34

A309640

8020 - C/12-20.1

103

60 - 15 - 01/34

Issue 1

FIG. 12-20 FUSE B3 - FRONT WORK LIGHTS

Wiring Diagrams (contÕd)

9804/1103

3000 SERIES

108 107 106 105 B3

110 109

2000 SERIES

CONTENTS

2000 SERIES

CONTENTS

CONTENTS

2000 Series, 3000 Series

Fastrac

60 - 15 - 01/35

Electrical Circuit - Sectional Wiring Diagrams (contÕd) Wiring Diagrams (contÕd)

9804/1103

8020 - C/12-21.1

B4

111

60 - 15 - 01/35

Issue 1

FIG. 12-21 FUSE B4 - REAR WORK LIGHTS

115 114 113 112

A309650

CONTENTS

CONTENTS

Fastrac

12-23

12-23 117

D3

60 - 15 - 01/36

D5

12-26

12-27

8020 - C/12-22.1

119

116

D1

12-24

60 - 15 - 01/36

Issue 1

FIG. 12-22 FUSE B5 - HEADLIGHT FLASH FUSE W (MAXIFUSE) - MAIN LIGHTS

D2 118

D6

A309660

3000 SERIES

2000 Series, 3000 Series

12-34

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

B5

Wiring Diagrams (contÕd)

9804/1103

W

D4

12-25

CONTENTS

120

3000 SERIES

95A

95B

3000 SERIES 2000 SERIES

2000 SERIES

121

2000 SERIES 2000 SERIES

cc

bb 2 G

N

8020 - C/12-23.1

dd

K

L T

4 W ee

aa 1

S

hh

C

D

E

F M

U

A

B

Fastrac

60 - 15 - 01/37

3000 SERIES

2000 SERIES

3000 SERIES

3000 SERIES

3000 SERIES

CONTENTS

2000 SERIES

2000 Series, 3000 Series

D2

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

Wiring Diagrams (contÕd)

9804/1103

D1

H

J R

V

P

gg

3 ff A309670

60 - 15 - 01/37

Issue 1

FIG. 12-23 FUSE D1 - MAIN BEAM FUSE D2 - DIPPED BEAM

CONTENTS

CONTENTS

Fastrac

A309680 8020 - C/12-24.1

60 - 15 - 01/38

Issue 1

FIG. 12-24 FUSE D3 - REAR FOG LIGHTS

2000 Series, 3000 Series

60 - 15 - 01/38

3

gg V

ff 4 W ee

P R S T U

dd

H J K L M N

C D E

hh B

bb 2 cc

F G

A

aa 1

99

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

98

Wiring Diagrams (contÕd)

9804/1103

D3

100

121

Fastrac

121A

60 - 15 - 01/39

12-31

8020 - C/12-25.1

2000 SERIES

60 - 15 - 01/39

Issue 1

FIG. 12-25 FUSE D4 - SIDE LIGHTS (LEFT SIDE)

A309690

12-1

CONTENTS

123 12-29

124 12-10

2000 Series, 3000 Series

100

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

95B 95A

98

Wiring Diagrams (contÕd)

9804/1103

3 V W

4

C D

H J K

P R S T U

1 A B

2

E F G

L M N

12-41 D5

2000 ES SERI

3000 SERIES 3000 SERIES

CONTENTS

12-15

121A

123 12-29

60 - 15 - 01/40

12-31

8020 - C/12-26.1

2000 SERIES

100

60 - 15 - 01/40

Issue 1

FIG. 12-26 FUSE D5 - SIDE LIGHTS (RIGHT SIDE)

Fastrac

95A

98 121 H

A309690

12-1

CONTENTS

C D

124 12-10

2000 Series, 3000 Series

95B

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

3 V W

4

P R S T U

J K L M N

A B

2

E F G

1

Wiring Diagrams (contÕd)

9804/1103

12-41 D5

2000 ES SERI

3000 SERIES 3000 SERIES

CONTENTS

12-15

CONTENTS

CONTENTS

2000 Series, 3000 Series

Fastrac

A309710 8020 - C/12-27.1

60 - 15 - 01/41

Issue 1

FIG. 12-27 AUXILIARY LIGHTS SWITCHING (2000 SERIES)

12-19 12-26

12-19 12-26 12-19 12-19

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

60 - 15 - 01/41

12-23

12-23 12-25 12-23 12-23 12-25

126 125

Wiring Diagrams (contÕd)

9804/1103

127

95A

95B

CONTENTS

CONTENTS

2000 Series, 3000 Series

125

126

Fastrac

60 - 15 - 01/42

95A

Electrical Circuit - Sectional Wiring Diagrams (contÕd) Wiring Diagrams (contÕd)

9804/1103

A309700

8020 - C/12-28.1

60 - 15 - 01/42

Issue 1

FIG. 12-28 FUSE D6 - AUXILIARY LIGHTS SWITCHING (3000 SERIES)

12-19 12-19 12-26

12-23 12-25 12-23 12-26 12-19 12-19

127 12-23 12-23 12-25

11A D6

95B

CONTENTS

CONTENTS

Fastrac

A309720 8020 - C/12-29.1

60 - 15 - 01/43

Issue 1

FIG. 12-29 FUSE B6 - RADIO/CASSETTE

2000 Series, 3000 Series

60 - 15 - 01/43

84

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

B6

Wiring Diagrams (contÕd)

9804/1103

12-18 12-26

128B 128A

CONTENTS

CONTENTS

2000 Series, 3000 Series

Fastrac

CR30

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

129 60 - 15 - 01/44

A309730 8020 - C/12-30.1

+12V BAT

330 (3)

60 - 15 - 01/44

Issue 1

FIG. 12-30 FUSE B7 - AUXILIARY JACK-PLUG SOCKET

Wiring Diagrams (contÕd)

9804/1103

B7

680 (3)

CONTENTS

CONTENTS

Fastrac

8020 - C/12-31.1

60 - 15 - 01/45

Issue 1

FIG. 12-31 FUSE B8 - CIGAR LIGHTER

2000 Series, 3000 Series

130 60 - 15 - 01/45

B8

Electrical Circuit - Sectional Wiring Diagrams (contÕd) Wiring Diagrams (contÕd)

9804/1103

12-26

A309740

CONTENTS

100 8020 - C/12-32.2

99

60 - 15 - 01/46

Issue 2*

FIG. 12-32 *FUSE C1 - TRAILER SOCKET REVERSE LIGHTS (DRY CLUTCH TRANSMISSION)

Fastrac

98 60 - 15 - 01/46

A309750

2000 Series, 3000 Series

C1

Electrical Circuit - Sectional Wiring Diagrams (cont’d) Wiring Diagrams (cont’d)

9804/1103

131

CONTENTS

Fastrac

99 60 - 15 - 01/46A

A354000 8020 - C/12-32A.1

60 - 15 - 01/46A

Issue 2*

FIG. 12-32A *FUSE C1 - TRAILER SOCKET REVERSE LIGHTS (WET CLUTCH TRANSMISSION)

2000 Series, 3000 Series

C1

Electrical Circuit - Sectional Wiring Diagrams (cont’d) Wiring Diagrams (cont’d)

9804/1103

131

100

CONTENTS

2000 Series, 3000 Series

Fastrac

3185

C3

136

2000 3155 SERIES

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

134 60 - 15 - 01/47

138

A309760 8020 - C/12-33.1

135 132

133

60 - 15 - 01/47

Issue 1

FIG. 12-33 FUSE C3 - THERMOSTART

Wiring Diagrams (contÕd)

3 9804/1103

3185

CONTENTS

137 2150

CONTENTS

12-15

2000 SERIES

3000 SERIES

139

12-35(C28)

2000 SERIES 3000 SERIES

2000 SERIES

2000 SERIES

Fastrac

60 - 15 - 01/48

12-41

CONTENTS

C5

2000 Series, 3000 Series

C4

Electrical Circuit - Sectional Wiring Diagrams (cont’d)

140 12-22 12-36 12-15

Wiring Diagrams (cont’d)

9804/1103

55

2000 SERIES

12-10

8020 - C/12-34.3

12-15 A309771

60 - 15 - 01/48

Issue 3*

FIG. 12-34 FUSE C4 - LIGHTS SWITCH ILLUMINATION; BLEEPER; INSTRUMENT CLUSTER; DIFFERENTIAL LOCK CUT-OUT; DIAGNOSTIC SUPPLY CONNECTOR; SPEEDO SENSOR; FUSE C5 (DRY CLUTCH TRANSMISSION)

CONTENTS

146 145

Fastrac

148

147

149

60 - 15 - 01/49

150

151 8020 - C/12-35.2

C

ff

60 - 15 - 01/49

Issue 2*

FIG. 12-35 FUSE C4-DRY CLUTCH TRANSMISSION (CONT’D)

A309780

152

2000 Series, 3000 Series

H J

gg

Electrical Circuit - Sectional Wiring Diagrams (cont’d)

3 V

dd

4 W ee

P R S T

K L M N

hh A B

D E

142 12-34(CR51) aa 1 bb 2 cc

F G

144

U

Wiring Diagrams (cont’d)

9804/1103

143 141

4

CONTENTS

12-15

2000 SERIES

3000 SERIES

139

12-35B(C28)

2000 SERIES 3000 SERIES

2000 SERIES

2000 SERIES

Fastrac

60 - 15 - 01/49A

12-41

2000 Series, 3000 Series

C5

Electrical Circuit - Sectional Wiring Diagrams (cont’d)

12-22 12-36 12-15

C4

Wiring Diagrams (cont’d)

9804/1103

55

2000 SERIES

12-10

8020 - C/12-35A.1

12-15 A353980

60 - 15 - 01/49A

Issue 1

FIG. 12-35A FUSE C4 - LIGHTS SWITCH ILLUMINATION; BLEEPER; INSTRUMENT CLUSTER; DIFFERENTIAL LOCK CUT-OUT; DIAGNOSTIC SUPPLY CONNECTOR; SPEEDO SENSOR; FUSE C5 (WET CLUTCH TRANSMISSION)

CONTENTS

1

2

650F (0.6)

2

650D (0.6)

143

CES9

CES9 C33

410 (0.6)

2

640H (0.6)

1

408 (0.6)

2 G

144 CES7

B

cc N

F M

U

C20

C54 2

411 (0.6)

1

2

hh D

K

W

ee

A B H

R

S

P

gg

V

C3

C28

C J

dd 4

640A (0.6)

E L

T

1

A

3

650C (0.6)

142

12 - 35A (CR51)

aa

bb

2

1

407 (0.6)

C8

405 (0.6)

A

640C (0.6)

CES7

B

ff

C14

146

145

409A (0.6)

1 1

2

1

640F (0.6)

148

2

C9

650G (0.6)

147 640L (0.6)

409 (0.6)

1

409B (0.6)

BMS

2

640G (0.6)

149

CES9 404 (0.6)

C49/C50

409C (0.6)

C31 412 (1.4)

640P (0.6)

C73 2

650E (0.6)

149A

CES9

4

B

C55

1 18

6

25 32

13 21

26

39

27 34

29 36

17 24 31

C72

38

43 47

152

10

30 37

42 46

1

16 23

28

41 45

9 15

22

35

40

4 8

14

20

33

3 7

12 19

150

2

5 11

A

160E (1.4)

C5 435 (0.6)

414 (1.4)

2

710P (1.4)

60 - 15 - 01/49B

1

402 (0.6)

403 (1.4)

IND

2

1

Fastrac

W

CES7

2000 Series, 3000 Series

141

1

406 (0.6)

Electrical Circuit - Sectional Wiring Diagrams (cont’d)

Wiring Diagrams (cont’d)

*

9804/1103

C34 C52

TH1

44

414 (0.6)

48 L

X

K B

M

C

N

D O

W

J A E

P

W V

V

H U G F

Q R

T S

H U T S

X J

K B

G A F E R Q P

TH10 L M

C

2 1

N

D O

4 3

8020 - C/12-35B.2

710P (0.6)

151 160E (0.6)

497 (1.4)

497 (0.6)

A353951

Issue 2*

60 - 15 - 01/49B

FIG. 12-35B FUSE C4-WET CLUTCH TRANSMISSION (CONT’D)

CONTENTS

514H (0.6)

515H (0.6)

C2

515C (0.6)

515A (0.6) 3000 SERIES

155

8 7 6 5

4

11 10

9

8

13 12

14

514 (0.6) 514 or (514B) (0.6)

CANLS2

R1

514G (0.6)

2

3

1

CR49

1

8

9

7

6

5

4

2

3

1

C4

156 CR50

153

629 (1.0) 1

A17 2 1

9

8

7

6

5

4

3

2

1

157

CR66

24 23 22 21 20 19 18 17 16 15 14 13

3

36 35 34 33 32 31 30 29 28 27 26 25

CR83 H

A N

F

L

K

C

G

M

J B

E D

2

626 (1.0) 560 (1.0)

8020 - C/12-36.2

10

A2 1

6

7

561 (1.0)

153

2000 SERIES

154

1

2

3

2 5

8

6

7

9 10

4

5 9

4

8 2000 SERIES

CR64

515 (1.0)

12 11 10

7

6 9 10

36 35 34 33 32 31 30 29 28 27 26 25

188 12 - 39A

3

2 5

8

515C (0.6)

12 11 10

24 23 22 21 20 19 18 17 16 15 14 13

514F (0.6)

515F (0.6)

A14

516 (0.6)

517 (0.6)

1 2

514B (0.6)

4

514 (1.0)

515G (0.6)

A16

561 (1.0)

5

6

36 35 34 33 32 31 30 29 28 27 26 25

514C (0.6)

CANLS1

F G

H

CANHS1

A J

7

CANHS1

514D (1.0)

660Y (1.0)

160F (1.0)

B

8

9

24 23 22 21 20 19 18 17 16 15 14 13

4

560(1.0)

E

CANLS3

Fastrac

60 - 15 - 01/50

D

12 11 10

514E (0.6)

R1

SCRN (1.0) C

CR89

515B (0.6)

160F (0.6)

515A (0.6)

A15 PISC4

1 5

514A (0.6)

SCRN (0.6)

153

5 6 7 8

2 6

514A (0.6) 514D (0.6)

4 3 2 1

1 2 3 4

515D (1.0)

515D (0.6)

513 (0.6)

3 7

CANHS2

R1

660Y (0.6)

CRES3

189

515 (0.6)

515 or (515B) (0.6)

CANHS3

CANLS1

515E (0.6)

514C (0.6)

CR102

CONTENTS

9 10

2000 Series, 3000 Series

7

6

5 8

153

3

2

Electrical Circuit - Sectional Wiring Diagrams (cont’d)

4

Wiring Diagrams (cont’d)

*

9804/1103

631 (1.0) 1

R1

627 (1.0)

A309791

60 - 15 - 01/50

Issue 2*

FIG. 12-36 FUSE C4 (CONT’D) - CANBUS; DIAGNOSTIC CONNECTOR

CONTENTS

EDCIS

161C (0.6)

2000 Series, 3000 Series

40

C5

Fastrac

60 - 15 - 01/51

Electrical Circuit - Sectional Wiring Diagrams (cont’d)

Wiring Diagrams (cont’d)

9804/1103

39

12-34(CR66)

158

12-10

161D (0.6) 432 (0.6)

660RB (0.6)

+8

8020 - C/12-37.4

174

1

4

6

2

1

-7

159

+3

2

5 660GJ (0.6) 660GK (0.6)

Issue 2*

FIG. 12-37 FUSE C5 - FUEL FLOW SENSOR; GROUND SPEED RADAR SENSOR WHEELSLIP ENABLE SWITCH (DRY CLUTCH TRANSMISSION)

60 - 15 - 01/51

A309801

CONTENTS

2000 Series, 3000 Series

Fastrac

60 - 15 - 01/51A

A353960

8020 - C/12-37A.1

40 C5

60 - 15 - 01/51A

Issue 1

FIG. 12-37A FUSE C5 - FUEL FLOW SENSOR; GROUND SPEED RADAR SENSOR WHEELSLIP ENABLE SWITCH (WET CLUTCH TRANSMISSION)

Electrical Circuit - Sectional Wiring Diagrams (cont’d)

9804/1103

159

Wiring Diagrams (cont’d)

39 12-35A

12-10

174

CONTENTS

CONTENTS

Fastrac

A309810

8020 - C/12-38.2

C8

60 - 15 - 01/52

Issue 2*

FIG. 12-38 FUSE C7 - 13 PIN TRAILER SOCKET (IGNITION) FUSE C8 - 13 PIN TRAILER SOCKET (BATTERY) * (2000 SERIES TO S/N 738748, 3000 SERIES TO S/N 640777)

2000 Series, 3000 Series

60 - 15 - 01/52

98

Electrical Circuit - Sectional Wiring Diagrams (cont’d) Wiring Diagrams (cont’d)

9804/1103

C7

C1

CONTENTS

191 (1.0)

APS3 15/30

A

B

B

C

C APS1

185

191 (1.0) 685 (3.0)

PSES

685C (3.0)

3 2

191A (1.0) 191 (1.0)

1

186 4

6

Fastrac

60 - 15 - 01/52A

APS4

192 (3.0)

685 (3.0)

A

685B (3.0)

685D (1.0)

191 (1.0)

183

PFSC8

82

5A C7

CR94

31

355B (3.0)

355C (3.0)

+12V IGN

355 (3.0)

355 (3.0)

355D (3.0)

+12V BAT

20A C8

CONTENTS

184

2000 Series, 3000 Series

685A (3.0)

355A (3.0)

Electrical Circuit - Sectional Wiring Diagrams (cont’d)

Wiring Diagrams (cont’d)

9804/1103

APS2 RED BLACK

8

2

187 8020 - C/12-38A.1

4 191 (1.0)

355D (3.0)

2

191A (1.0)

6 8

685D (1.0) 192 (3.0)

APS5

Issue

FUSE C7 - AUXILIARY SOCKET (IGNITION SUPPLY) FUSE C8 - AUXILIARY SOCKET (BATTERY SUPPLY) (2000 SERIES FROM S/N 738749, 3000 SERIES FROM S/N 640778)

60 - 15 - 01/52A

A370430

CONTENTS

6

5 8

5A

6

665E (0.6)

265A (2.0)

8

2

20A (2.0)

20 (4) 20B (2.0)

TAIS

1

F2

A7

265B (2.0)

A8

5

20C (1.0)

2

F4

153 (1.0) 4

ABS8

1

2

1

2

1

2

883 (1.4)

6

5

2

F3

196

195 ABS9

ABS11

ABS10

A6

+12V BAT

194

193

TAES

BROWN (1.0)

C D

A12 4

154 (0.6)

F1

BLACK (1.0)

D C

15K (1.0)

BROWN (1.0)

B A

BLACK (1.0)

A B

A5

BROWN (1.0)

A9

BLACK (1.0)

883D (0.6)

192

+12V BAT

BROWN (1.0)

12 - 1

CR100

BLACK (1.0)

+12V IGN

A13 8

4

12 - 2

6

190

153A (1.0)

200

191 A

B

5

7

6

12

6

12

6

12

2

E1

370B (3) 370A (3)

ABS7

A J H B K M G L D F E

A17

23

34

22

33

21

32

20

31

19

30

18

29 28

17 16

36

11

35

23

10

34

22

9

33

21

9

8

32

20

8

7

31

19

6

30

18

5

29

17 16

1

4

28

15

3

27

15

3

2

26

14

7

2

25

13

1

25

13

4

3 6

4 5

1

L

J B K

C

E

2

2

D

2

6

14

A

M N

F

E D

5

G

F

L

K

1

H G

M N

B C

7

H

A J

560(1.0)

10

26

8020 - C/12-39.2

CR65

1 561(1.0)

11

27

CR66

2 1

12

A2

605 (1.4)

J

ABS2

H M

G F

615 (6.0)

160

12 - 39

1 3

ABSSS

2

370B (3)

440 (1.4) 150 (1.4)

E

AP1

370A (3) 370 (6)

A K B C D

L

1803 (1.4) 1800 (1.4) 1801 (1.4)

35

24

12

1807 (1.4) 1806 (1.4) 1808 (1.4)

24

C

1804 (1.4)

12 - 36 36

1802 (1.4) 1801 (1.4) 1800 (1.4) 1804 (1.4) 1803 (1.4) 1805 (1.4)

1807 (1.4) 1808 (1.4)

561 (1.0) 465 (1.0) 883 (1.4) 1806 (1.4)

1

152 (2.0)

260 (3) 270 (3)

+12V BAT

560 (1.0)

D C

C D

A3

665D (2.0)

150 (1.0)

151 (2.0)

2

A B

665C (2.0)

152 (2.0)

A4

E2

151 (2.0)

1

015J (1.0)

200

Fastrac

60 - 15 - 01/53

+12V IGN B A

200

665D (2.0)

440 (1.4)

A1

CR47

5

1

665C (2.0) TAES

665B (3)

+12V BAT

7

ABS4

665A (3)

665B (3)

440 (0.6)

1

A11

448 (1.0)

665A (3)

12 - 1

7

C B A

448 (1.0)

BAT -VE

ABS6

ABS5

1

1802 (1.4)

5B

A B C

465 (1.0)

A B

8

2

A9

CR101

449 (1.0)

2000 Series, 3000 Series

4

Electrical Circuit - Sectional Wiring Diagrams (cont’d)

Wiring Diagrams (cont’d)

*

9804/1103

2

3

1805 (1.4)

2

2

AP4

AP2

197

1 3

1

AP3

198

199

A387670

60 - 15 - 01/53

Issue 2*

FIG. 12-39 FUSES E1, E2 - TRAILER ABS * FUSES F1, F2, F3, F4 (TRACTOR ABS)

CONTENTS

CONTENTS

Fastrac

162

60 - 15 - 01/54

8020 - C/12-40.1

60 - 15 - 01/54

Issue 1

FIG. 12-40 FUSE E3 - FLOW DIVIDER

2000 Series, 3000 Series

12

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

163

Wiring Diagrams (contÕd)

9804/1103

E3

161

A309830

CONTENTS

12-34 153 8020 - C/12-41.1

168

169

58 E4

A309840

12-36

60 - 15 - 01/55

12-34

Fastrac

12-36 12-36

CONTENTS

12-13 153

2000 Series, 3000 Series

12-15

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

165

Wiring Diagrams (contÕd)

12-15 170

60 - 15 - 01/55

Issue 1

FIG. 12-41 FUSE E4 - FOUR WHEEL STEER (4WS) CIRCUIT

12-1 54 156 173

167 166

9804/1103

164

12-26

12-34

CONTENTS

11

3 13

98

Fastrac

10 2

4 5

CONTENTS

9

1

6

2000 Series, 3000 Series

60 - 15 - 01/56

8

7

Electrical Circuit - Sectional Wiring Diagrams (contÕd)

Wiring Diagrams (contÕd)

9804/1103

171

12

172

8020 - C/12-42.2 A309851

Connector C1 (98) Pin Functions 1 2 3 4

LH Direction Indicator (see Fig. 12 - 19) Rear Fog Light (see Fig. 12 - 24) Earth for pins 1 to 8 RH Direction Indicator (see Fig. 12 - 19)

5 6 7 8

RH Side Light (see Fig. 12 - 26) Brake Lights (see Fig. 12 - 4) LH Side Light (see Fig. 12 - 25) Rev. Lights (see Fig. 12 - 32)

9 Battery Feed (see Fig. 12 - 38) 10 IGN Feed (see Fig. 12 - 38) 11/12/14 Spare 13 Earth for Pins 9 to 12 (see Fig. 12 - 38)

60 - 15 - 01/56

Issue 1

FIG. 12-42 TRAILER SOCKETS

CONTENTS CONTENTS

125, 135, 145, 150, 155, 185 to machine no. 637733 * Hydraulic

Circuit R V

N

X S

N

D T

D1 P

B

1

P3

P4

6 1A

B1 2

P1

P2

TH

2A

CONTENTS CONTENTS

*

Fastrac

60 - 20 - 02/2

125, 135, 145, 150, 155, 185 from machine no. 637734 Hydraulic Circuit Component Key A A1 B B1 CS D D1 F G H N P1 P2 P3 P4 R RR S SB T V X

External Hydraulics/Draft Control Valve Main Relief Valve Hydraulic Trailer Brake Valve (optional) Feed to Hydraulic Trailer Brake Connector TH Steering Circuit Cooler Flow Regulator Valve (optional) Flow Regulator Valve Auxiliary Output Circuit Main Filter Front Auxiliary Circuit (optional) Rear Auxiliary Circuits Ride Height Corrector Valves Suspension Pump Steering Pump External Hydraulics Pump Transmission Pump Front Lift Rams Rear Lift Rams Suspension Cylinders Steering Box Tank Suspension Pressure Maintenance Valve Differential Lock

9804/1103

60 - 20 - 02/2

Issue 2

CONTENTS

125, 135, 145, 150, 155, 185 from machine no. 637734 Hydraulic Circuit

A

V

N

X S

N

F

1

F

1

1

P3

P4

1

6

1A

B1 2

TH 1

P1

P2

2A

CONTENTS * FASTRAC

Fastrac

60 - 20 - 03/1

1115, 1135, 2115

Circuit Diagrams- Hydraulic Description

Component Key

The diagram shows the hydraulic circuits of the machine to clarify the way in which they relate to each other.

A AA AB AC AD AE AE1 AWS A1 B CS Fm G H M N P1 P2 P3 P4 P5 Q R RR S SP SU T V

The circuits each have their own pump section: P1 P2 P3 P4 P5

Suspension/Rear Axle Differential Lock Steering (front axle) (2WS/4WS) External Hydraulic Services/Draft Control Transmission Steering (rear axle) (4WS) (if fitted)

P1 and P2 are the two sections of the engine-driven pump. P3, P4 and P5 (if fitted) are the sections of the gearboxdriven pump. The external hydraulics and draft control circuits are described in detail in this section of the manual. More details on the other circuits are given in the relevant sections of the manual. When a machine is fitted with provision for hydraulic trailer brakes, line 1 from the pump feeds the hydraulic trailer brake valve B and line 1A is not fitted. When there is no hydraulic trailer brake valve, line 1A is fitted to give a direct feed to control valve A which controls feeds to the external services by means of spools l, ll and lll. A four spool control valve is illustrated but two and three spool valves are also available to the same general design. When the four spool valve is fitted, spool llll feeds the front linkage lift rams R. When the machine is fitted with the optional Flow Regulator Valve AE, line 2A is not required, the oil flow to External Hydraulics/Draft Control Valve A coming from port B of valve AE. Flow Regulator Valve AE provides the means of adjusting flow to external implements from 5 to 55 l (1 to 12 UK gal/min).

X Y

External Hydraulics/Draft Control Valve Steering Rams (front axle) Steering Pump Relief Valve Feed to Hydraulic Trailer Brake Connector TH Power Track Rod (rear wheel steering) (optional) Flow Regulator Valve (optional) Flow Regulator Valve Auxiliary Output Circuit Four-wheel Steer Valve (optional) Main Relief Valve Hydraulic Trailer Brake Valve (optional) Steering Circuit Cooler Main Filter Front Auxiliary Circuit (Optional) Rear Auxiliary Circuits Accumulator - Ride Height Adjustment Ride Height Corrector Valves Pump - Suspension/Rear Axle Differential Lock Pump - Steering (front axle) Pump - External Hydraulics/Draft Control Pump - Transmission Pump - Steering (rear axle) (optional) Pilot Feed from Front Brakes Hydraulic Brake Fluid Line Front Lift Rams (Optional) Rear Lift Rams Suspension Cylinders Proportional Solenoid Valve (optional) Steering Unit Tank Suspension Pressure Maintenance/Differential Lock Valve Rear Axle Differential Lock Differential Lock Relief Valve

Note: Certain ports of valve A are identified by the letters a and b cast into the valve block. These identifications are included in the schematic opposite but do not relate to the letters A and B on the control lever decal or the quick release coupling decals.

Control valve A incorporates the main relief valve A1. It also incorporates a draft control section which feeds the rear lift rams RR. Exhaust oil returns from control valve A to tank through filter Fm.

9804/1103

60 - 20 - 03/1

Issue 2*

CONTENTS

Fastrac

* FASTRAC 1115, 1135 Circuit Diagrams - Hydraulic N

V

RR

M TP1 S1

A

N

X

T

S

a

R Y T R1

D

T b 0 F

a 2

1

IIII

SP

Fm

1A

AC

b

AD

0 P A

BP

N

G

1.2

B

F

a 2

1

III

TP

T

P

A

1.2

R

B

CT1

Fm b 0

CT3 B

CT2

AWS

a 2

1

T

II

Y T

Q CS

P1

1.2

Fm

P2

b

2A 1

Fm

AB T

0 1

AE1

P3

P5

T

P4

P

1.2

B

Z

a

A1 R2

AA

3A

SU

9804/1103

I

AE

Fm

3

a 2

P

Fm B

A

B

I b

T

60 - 20 - 03/2

II

A

B

A

III A249311

H

Issue 2*

CONTENTS * 2000 *

Fastrac

60 - 20 - 03/3

SERIES MACHINES (TYPES 1 AND 2)

Circuit Diagrams- Hydraulic Description The diagram shows the hydraulic circuits of the machine to clarify the way in which they relate to each other. Note that later machines are fitted with a different External Hydraulics/Draft Control Valve A (Type 2††). Be sure to refer to the correct circuit diagram, Circuit DiagramsHydraulic,2000 Series Machines (Type 1†) or Circuit Diagrams-Hydraulic, 2000 Series Machines (Type 2††) as applicable. The circuits each have their own pump section: P1 P2 P3 P4 P5

Suspension/Rear Axle Differential Lock Steering (front axle) (2WS/4WS) External Hydraulic Services/Draft Control Transmission Steering (rear axle) (4WS) (if fitted)

P1 and P2 are the two sections of the engine-driven pump. P3, P4 and P5 (if fitted) are the sections of the gearboxdriven pump. The external hydraulics and draft control circuits are described in detail in this section of the manual. More details on the other circuits are given in the relevant sections of the manual. When a machine is fitted with provision for hydraulic trailer brakes, line 1 from the pump feeds the hydraulic trailer brake valve B and line 1A is not fitted. When there is no hydraulic trailer brake valve, line 1A is fitted to give a direct feed to control valve A which controls feeds to the external services by means of spools l, ll and lll. A four spool control valve is illustrated but two and three spool valves are also available to the same general design. When the four spool valve is fitted, spool llll feeds the front linkage lift rams R. The optional lift ram drop flow control valve RD can be fitted when extra control is required while lowering front attachments, especially heavy attachments. When the machine is fitted with the optional Flow Regulator Valve AE, line 2A is not required, the oil flow to External Hydraulics/Draft Control Valve A coming from port B of valve AE. Flow Regulator Valve AE provides the means of adjusting flow to external implements. Note 1: The optional Flow Regulator Valve AE is shown in outline only. For the internal details see page 60-20-03/7. Control valve A incorporates the main relief valve A1. It also incorporates a draft control section which feeds the rear lift rams RR. Exhaust oil returns from control valve A to tank through filter Fm.

Component Key A AA AB AC AD AE AE1 AWS A1 B CS Fm G H M N P1 P2 P3 P4 P5 Q R RD RR S SP SU T V X Y

External Hydraulics/Draft Control Valve Steering Rams (front axle) Steering Pump Relief Valve Feed to Hydraulic Trailer Brake Connector TH Power Track Rod (rear wheel steering) (optional) Flow Regulator Valve (optional) Flow Regulator Valve Auxiliary Output Circuit Four-wheel Steer Valve (optional) Main Relief Valve Hydraulic Trailer Brake Valve (optional) Steering Circuit Cooler Main Filter Front Auxiliary Circuit (Optional) Rear Auxiliary Circuits Accumulator - Ride Height Adjustment Ride Height Corrector Valves Pump - Suspension/Rear Axle Differential Lock Pump - Steering (front axle) Pump - External Hydraulics/Draft Control Pump - Transmission Pump - Steering (rear axle) (optional) Pilot Feed from Front Brakes Hydraulic Brake Fluid Line Front Lift Rams (Optional) Drop Flow Control Valve (front lift rams) (optional) Rear Lift Rams Suspension Cylinders Proportional Solenoid Valve (optional) Steering Unit Tank Suspension Pressure Maintenance/Differential Lock Valve Rear Axle Differential Lock Differential Lock Relief Valve

Note 2: Certain ports of valve A are identified by the letters a and b cast into the valve block. These identifications are included in the schematic opposite but do not relate to the letters A and B on the control lever decal or the quick release coupling decals. Note 3: Machines with Type 2†† External Hydraulics/Draft Control Valves use colour codes on the relevant control and hydraulic coupling decals. The valve spools correspond with the colour code as follows: Valve Spool

Colour Code

I

Green

II

Blue

III

Brown

IIII

Orange

The above colour code key only relates to the Type 2†† circuit diagram. Do not relate the key to the Type 1† circuit.

9804/1103

60 - 20 - 03/3

8020 - E/2-1.4

Issue 3*

CONTENTS

Fastrac

* 2000 SERIES MACHINES (TYPE 1) * Circuit Diagrams Hydraulic (cont’d) N

V

RR

M TP1 S1

A

N

X

T

S

a

RD R Y T R1

D

T b 0 F

a 2

1

IIII

SP

Fm

1A

AC

b

AD

0 P A

BP

N

G

1.2

F

B

a 2

1

III

TP

T

P

A

1.2

R

B

CT1

Fm b 0

CT3 B

CT2

T

AWS

a 2

1

II

Y T

Q CS

P1

1.2

Fm

P2

b

2A 1

Fm

AB T

P3

P5

0 1

a 2

I

AE1 b

P4

c

1.2

d

Fm a

A1

AE R2

AA

3 3A

SU

P

Fm B

A

B

I

II

A

B

A

III

a

b

T

H A249312

9804/1103

60 - 20 - 03/4

8020 - E/2-2.4

Issue 2*

CONTENTS

Fastrac

60 - 20 - 03/4A

2000 SERIES MACHINES (TYPE 2) Circuit Diagrams Hydraulic (cont’d) N

V

M TP1 S1

N

X

RR

T

S

a R1

T

Y T D

b a 1

0

2

F

I 1.2

SP

b

1A

AC

a 1

AD P A

BP

N

0

II P

A

F

B

TP

T

2

Fm 1.2

G

R

B

CT1

Fm

b a 1

0

2

F

CT3 B

CT2

T

AWS

B

III

Y T

P1

2A 1 AB T

P3

P5

b

A

II

III

c

0

2

F

IIII 1.2

AE1

P4

B

H

a 1

Fm

A

b

Fm

P2

B

I

Q CS

A

Fm

1.2

d

RD

R

Fm a

R1

AE R2

P

M

AA

3 3A

SU

a

b

T A358860

9804/1103

60 - 20 - 03/4A

8020 - E/2-3.3

Issue 1

CONTENTS * 3000 *

Fastrac

60 - 20 - 03/5

SERIES MACHINES (TYPES 1 AND 2)

Circuit Diagrams- Hydraulic Description The diagrams show the four hydraulic circuits of the machine to clarify the way in which they relate to each other. Note that later machines are fitted with a different External Hydraulics/Draft Control Valve A (Type 2††). Be sure to refer to the correct circuit diagram, Circuit Diagrams - Hydraulic, 3000 Series Machines (Type 1†) or Circuit Diagrams Hydraulic, 3000 Series Machines (Type 2††) as applicable. The four circuits each have their own pump section: P1 P2 P3 P4

Suspension Steering External Hydraulic Services Transmission

P1 and P2 are the two sections of the engine-driven pump. P3, P4 are the two sections of the gearbox-driven pump. The external and draft control circuits are described in detail in this section of the manual. More details on the other circuits are given in the relevant sections of the manual. When a machine is fitted with provision for hydraulic trailer brakes, line 1 from the pump feeds the hydraulic trailer brake valve B and line 1A is not fitted. When there is no hydraulic trailer brake valve, line 1A is fitted to give a direct feed to the main control valve A which controls feeds to the external services by means of spools l, ll and lll. A four spool control valve is illustrated but two and three spool valves are also available to the same general design. When the four spool valve is fitted, spool llll feeds the front linkage lift rams R. The optional lift ram drop flow control valve RD can be fitted when extra control is required while lowering front attachments, especially heavy attachments. When the machine is fitted with the optional Flow Regulator Valve D, line 2A is not required, the oil flow to External Hydraulics Control Valve A coming from port B of valve D. Flow Regulator Valve D provides the means of adjusting flow to external tools. Note 1: The optional Flow Regulator Valve D is show in outline only. For the internal details see page 60 - 20 - 03/7. The main control valve also incorporates the main relief valve A1. The neutral circuit continues through the control valve via line 3 to draft control valve C which feeds the rear lift rams RR.

Component Key A A1 B B1 CS D D1 F G H N P1 P2 P3 P4 R RD RR S SB

External Hydraulics/Draft Control Valve Main Relief Valve Hydraulic Trailer Brake Valve (optional) Feed to Hydraulic Trailer Brake Connector TH Steering Circuit Cooler Flow Regulator Valve (optional) Flow Regulator Valve Auxiliary Output Circuit Main Filter Front Auxiliary Circuit (optional) Rear Auxiliary Circuits Ride Height Corrector Valves Pump - Suspension Pump Pump - Steering Pump Pump - External Hydraulics Pump Pump - Transmission Pump Front Lift Rams Drop Flow Control Valve (front lift rams ) (optional) Rear Lift Rams Suspension Cylinders Steering Box

Note 2: Certain ports of valve A are identified by the letters a and b cast into the valve block. These identifications are included in the schematic opposite but do not relate to the letters A and B on the control lever decal or the quick release coupling decals. Note 3: Machines with Type 2†† External Hydraulics/Draft Control Valves use colour codes on the relevant control and hydraulic coupling decals. The valve spools correspond with the colour code as follows: Valve Spool

Colour Code

I

Green

II

Blue

III

Brown

IIII

Orange

The above colour code key only relates to the Type 2†† circuit diagram. Do not relate the key to the Type 1† circuit.

Exhaust oil returns via lines 4, 5, 6 and 8 to tank where it passes through filter F.

9804/1103

†

3000 Series to S/N 641999

††

3000 Series from S/N 642000

60 - 20 - 03/5

8020 - E/2-4.3

Issue 2*

CONTENTS

Fastrac

60 - 20 - 03/6

* 3000 SERIES MACHINES (TYPE 1) * Circuit Diagrams - Hydraulic (cont’d)

RR

A

V

N a

RD R

X R1

S

N

T b 0 F

1

a 2

IIII

F

G

1.2 b 0 F

a 2

1

1

P3

III 1.2

P4 b 0

6

1A

a 2

1

II

1.2

B1

b

TH

2

1

P1

a

0

2A

P2

2

I

1.2

D1

F

,,,, ,,,, ,,,, ,,,,

SB

b

c

d

A1 R2

B

D

8

P

F B

A

B

I

II

A

B

A

III

H

T a

CS

9804/1103

60 - 20 - 03/6

A243311

8020 - E/2-5.1

Issue 3*

CONTENTS

Fastrac

60 - 20 - 03/6A

* 3000 SERIES MACHINES (TYPE 2) * Circuit Diagrams - Hydraulic (cont’d)

V

N

X

RR a

S

N

R1

T

b a 1

0

2

F

I 1.2

b

1

a 1

P3

0

P4

2

F

II

Fm 1.2

G

b a

6

1A

1

0

2

F

B

III

B1

B

I

TH

2

A

A

B

A

Fm

1.2

II

III

b

H

a

P1

1

2A

P2

0

2

F

IIII

D1

1.2

F

b

c

d

RD

B

SB

D

8

R

R1 R2

P

M

T a

CS

A360010

9804/1103

60 - 20 - 03/6A

8020 - E/2-6.1

Issue 1

CONTENTS * 2000 *

Fastrac

60 - 20 - 03/7

SERIES & 3000 SERIES

Circuit Diagrams- Hydraulic Flow Regulator Valves

c

b

d

a

A343830

55 litre Flow Regulator Valve

CT2 a

c CT1

CT3

CT4

A343840 d

b

90 litre Flow Regulator Valve

9804/1103

60 - 20 - 03/7

8020 - E/2-7.1

Issue 1

CONTENTS

A

Front PTO clutch housing (both with and without a front PTO fitted) - 1/2 inch BSP male x 3/8 inch BSP female with 2.5 mm restrictor.

B

Rear PTO clutch housing - 1/2 inch BSP male x 3/8 inch BSP female with 2.5 mm restrictor.

Port A1 of solenoid 1 pressurises the 4WD clutch W in the range gearbox. Port B1 is not used.

Fastrac

Solenoid 2 is only fitted to machines having the optional front PTO. Port A2 of this solenoid pressurises the front PTO clutch pack in the main PTO gearbox PB. Port B2 pressurises the front PTO brake. Solenoid 3 supplies the rear PTO clutch in the same way.

Note: Special adapters with restrictor orifices are fitted to certain lubrication inlets on the gearboxes and it is essential that the correct size restrictors are fitted as follows.

Restrictors Splitter clutch - high Splitter clutch - low Splitter clutch - medium Transmission oil cooler Transmission oil filter Restrictors PTO gearbox Pump - differential lock/suspension circuits Pump - transmission circuit Range gearbox Splitter solenoid valve Solenoid valve block-transmission 4WD clutch Main drive clutch booster

SERIES & 3000 SERIES

60 - 20 - 03/8

Oil from the cooler flows via filter F1 to the solenoid valve block TS which contains a pressure maintenance valve and three solenoids 1, 2 and 3.

Additional pipework provides air balance and lubrication links between the PTO, speed and range gearboxes which all use the same oil.

A-F CH CL CM CT F1 LH, LM PB P1 P4 RB S TS W X

Circuit Diagrams- Hydraulic

Transmission oil is drawn from the range gearbox RB by pump P4 and delivered first to the cooler CT.

Key

* 2000

*

Note: Pump P4 is the rear section of a pump which is driven by the PTO gearbox. The front section(s) of the pump supply the external hydraulic services and 4WS (if fitted), and use hydraulic oil. The sections of the pump are separated by oil seals.

Each end of the solenoid valve block has a port marked P. The one on the end of the block nearest the right side of the machine is for the feed from the pump via filter F1. Port P on the opposite end of the block feeds the splitter solenoid valve S (port L of which provides lubrication feeds to the PTO clutches and the gearbox bearings) and the main drive clutch booster X which is actuated from the clutch pedal via port X1 to operate the clutch mechanism via port X2.

Dry Clutch Transmission

9804/1103

Pump P4 feeds the PTO clutches, the 4WD clutch, the splitter solenoid valve, the main drive clutch booster and the lubrication circuit. The circuit is selfcontained, using transmission oil.

C and D Speed gearbox - 3/8 inch BSP male x 1/4 inch BSP male with 2 mm restrictor. 8020 - E/13-2.4

Range gearbox front bearing - 1/2 inch BSP male x 1 / 4 inch BSP male with 1.5 mm positional restrictor (see Range Gearbox Removal and Replacement for fitting instructions).

F

Range gearbox rear bearing - 7/ 16 inch UNF x 1 / 4 inch BSP male with 1 mm restrictor.

Issue 1

60 - 20 - 03/8

E

CONTENTS * 2000

60 - 20 - 03/9

SERIES & 3000 SERIES

Circuit Diagrams- Hydraulic

L

T

A293504

Dry Clutch Transmission (cont’d)

1

AC

LH LMLL

CL

CM

9804/1103

60 - 20 - 03/9

TPH

TPM

CT

TPL

S

P4

A

CH

PB

B

P

L

C

D

X2

E

X

W

RB

F

X1

A1

B1

A2

B2

A3

B3

TS

3

2

P

P

F1

*

Fastrac

8020 - E/13-1.5

Issue 1

CONTENTS

Transmission oil is drawn from the range gearbox RB by pump P4 and delivered first to the cooler CT.

Low pressure lubrication oil from port LPL is supplied to clutches and bearings throughout the transmission. Many of these lubrication connections incorporate restrictors inside special adaptors. It is essential that the correct restrictors are fitted as follows:

8020 - F/13-4.1

Solenoid 2 is only fitted to machines having the optional front PTO. Port A2 of this solenoid pressurises the front PTO clutch pack in the main PTO gearbox PB. Port B2 pressurises the front PTO brake. Solenoid 3 supplies the rear PTO clutch in the same way.

PTO/Splitter Gearbox C 200 psi engagement feed D 2 bar lube - Splitter clutch H E 2 bar lube - Splitter clutch M F 2 bar lube - Splitter clutch L G Input/Idler gear mesh H Idler shaft J Intermediate shaft K Front PTO pod or blanking plate L Rear PTO pod

1.0 mm dia 1.0 mm dia 1.0 mm dia 2.5 mm dia 2.5 mm dia

Speed Gearbox M Front restrictor N Rear restrictor

1.5 mm dia 1.5 mm dia

Range Box P Top shaft front feed (angled) R Top shaft rear feed (in plate) S Output shaft front feed T Output shaft rear feed

1.5 mm dia No restrictor 1.0 mm dia 1.0 mm dia

Port A1 of solenoid 1 pressurises the 4WD clutch W in the range gearbox. Port P2 on the solenoid valve block is for the feed from the pump via filter F1. Port P1 on the opposite end of the block feeds the splitter and transmission brake solenoid control valves VCL, VCM, VCH and VTB. Note that the valves are mounted on a valve block SB that is an integral part of the PTO/Splitter gearbox housing. A feed is also provided for the wet clutch control valve VWC.

Wet Clutch A High flow lubrication B Low flow lubrication

3.0 mm dia 3.0 mm dia

3.0 mm dia

Pressure Test Points TP Clutch engagement feed TPB Transmission Brake TPE Master clutch TPL Low splitter Clutch TPM Medium splitter clutch TPH High splitter Clutch TPG Low pressure lubrication

60 - 20 - 03/10

Issue 1

Lubrication Restrictors

Fastrac

60 - 20 - 03/10

Oil from the cooler flows via filter F1 to the solenoid valve block TS which contains a pressure maintenance valve and three solenoids 1, 2 and 3. A pressure switch PS is fitted to activate a low oil pressure warning in the cab.

TB TS VCH VCM VCL VL VTB VWC W

Restrictors Splitter clutch - high Splitter clutch - low Splitter clutch - medium Transmission oil cooler Transmission oil filter PTO gearbox Pump - transmission circuit Pressure Switch Range gearbox Transmission oil temperature sensor 1 Transmission oil temperature sensor 2 Splitter solenoid valve block (integral with PTO/Splitter gearbox housing) Transmission brake Solenoid valve block-transmission Splitter clutch control valve - high Splitter clutch control valve - medium Splitter clutch control valve - low Wet clutch lubrication control valve Transmission brake control valve Wet clutch control valve 4WD clutch

2000 SERIES & 3000 SERIES

Note that the Wet master clutch, PTO/Splitter, speed and range gearboxes all use the same oil.

A-T CH CL CM CT F1 PB P4 PS RB S1 S2 SB

Circuit Diagrams- Hydraulic

Note: Pump P4 is the rear section of a pump which is driven by the PTO gearbox. The front section(s) of the pump supply the external hydraulic services and 4WS (if fitted), and use hydraulic oil. The sections of the pump are separated by oil seals.

Key

Wet Clutch Transmission

9804/1103

Pump P4 feeds the PTO clutches, the 4WD clutch, the splitter solenoid valve and the lubrication circuit. The circuit is self-contained, using transmission oil.

The solenoid control valve block TS also incorporates feeds for lubrication circuits from ports HPL and LPL. High pressure lubrication (HPL) and low pressure lubrication (LPL) feeds are connected to wet clutch lubrication valve VL. When the clutch is ‘slipped’ by the operator the valve supplies high pressure lubrication to the clutch plates. Note that the valve is mounted on the wet clutch housing integral valve block CB. Sensors S1 and S2 warn of overheating transmission oil. S2 is fitted to the clutch housing oil sump. S1 is fitted in the pipe next to the transmission oil filter.

CONTENTS * 2000

60 - 20 - 03/11

SERIES & 3000 SERIES

Circuit Diagrams- Hydraulic Wet Clutch Transmission (cont’d) TP

PS

T CT4

A358460

LPL CT3

CT2 HPL

CT1

DRAIN

1 A1

A2

R

B2

A3

T

B3

S1

TS

3

2

P2

F1

P1

9804/1103

AC

VCH

VCM

SB

A

VL

TPH TPM TPB TPL

D E

TB

B

S2

VWC

CT

CB

K

P4

AC

VTB

F

VCL

CL

CM

G H J

PB

CH

L

C

L

P

M

N

P

W

S

RB

TPG

TPE

*

Fastrac

60 - 20 - 03/11

8020 - F/13-3.1

Issue 1

CONTENTS INDEX

Skidsteer Range

ROBOT 185, 1105 Contents Page No. General Information Fluids, Lubricants and Capacities General Specification Tyre Specification Static Dimensions

Data Electrical Hydraulics from m/c no. 746001 to 804423 Hydraulics from m/c no. 804424 Engine - Standard and High-flow Machines to m/c no. 746805 Engine - High-flow Machines from m/c no. 746806 Circuit Diagrams Electrical from m/c no. 746001 to 746216 Electrical from m/c no. 746217 Hydraulic Standard Machines from m/c no. 746001 to 746998 - Single Lever Drive Control Hydraulic - High-flow Machines from m/c no. 746001 to 746998 - Single Lever Drive Control Hydraulic - Standard Machines - Dual Lever Drive Control from m/c no. 746001 to 746998 Hydraulic - High-flow Machines - Dual Lever Drive Control from m/c no. 746001 to 746998 Hydraulic - Standard Machines - Single Lever Drive Control from m/c no. 746999 to 804423 Hydraulic - High-flow Machines - Single Lever Drive Control from m/c no. 746999 to 804423 Hydraulic - Standard Machines - Dual Lever Drive Control from m/c no. 746999 to 804423 Hydraulic - High-flow Machines - Dual Lever Drive Control from m/c no. 746999 tp 804423 Hydraulic - Standard Machines - Single Lever Drive Control from m/c no. 804424 Hydraulic - High-flow Machines - Single Lever Drive Control from m/c no. 804424 Hydraulic - Standard Machines - Dual Lever Drive Control from m/c no. 804424 Hydraulic - High-flow Machines - Dual Lever Drive Control from m/c no. 804424

9804/1103

Skidsteer Contents - 1

70 - 00 - 01/1A 70 - 00 - 01/2 70 - 00 - 01/2 70 - 00 - 02/3,4

70 - 05 - 01/1 & 4 70 - 05 - 03/1-3 20 - 05 - 03/2B, 2C 70 - 05 - 05/1 70 - 05 - 05/2

70 - 15 - 02/1-4 70 - 15 - 02/5-8 70 - 20 - 02/1,2 70 - 20 - 02/3,4 70 - 20 - 02/5,6 70 - 20 - 02/7,8 70 - 20 - 02/9, 10 70 - 20 - 02/11, 12 70 - 20 - 02/13, 14 70 - 20 - 02/15, 16 70 - 20 - 02/17, 18 70 - 20 - 02/19, 20 70 - 20 - 02/21, 22 70 - 20 - 02/23, 24

Issue7*

Skidsteer Range

INDEX

*ROBOT 160, 170, 170HF Contents Page No General Information Fluids Capacities and Lubricants General Specification Tyre Specification Static Dimensions

70 - 00 - 01/1B 70 - 00 - 01/3 70 - 00 - 01/3 70 - 00 - 02/5,6

Data Electrical Hydraulic Engine from m/c no. 680001 to 681290 Engine from m/c no. 681291

70 - 05 - 01/1 & 5 70 - 05 - 03/3 70 - 05 - 06/1 70 - 05 - 06/2

Circuit Diagrams Electrical up to m/c no. 681290 Electrical from m/c no. 681291 Hydraulic Single Lever Drive Control Standard Servo Machine High-flow Servo Machine Hydraulic Dual Lever Drive Control Standard Servo Machine High-flow Servo Machine Manual Machines Standard Circuit High-flow Circuit

9804/1103

Skidsteer Contents - 2

70 - 15 - 3/1, 2 70 - 15 - 3/3, 4 70 - 20 - 01/15,16 70 - 20 - 01/17,18 70 - 20 - 01/19,20 70 - 20 - 01/21,22 70 - 20 - 03/5, 6 70 - 20 - 03/7, 8

Issue 8*

Skidsteer Range

INDEX

* ROBOT

150, 165

Contents Fault Finding Go to the CD “Contents”, select Problem Solving, then Robot. Circuit Diagrams Electrical

70 - 15 - 03/1

Hydraulic - Standard Servo Machines - High Flow Servo Machine - Standard Manual Machine - High Flow Manual Machine General Information Lubricants and Capacities General Specification Tyre Specification Static Dimensions

70 - 00 - 01/1 70 - 00 - 01/2 70 - 00 - 01/2 70 - 00 - 01/1,2

Data Electrical Hydraulics to m/c no. 677000 Hydraulics from m/c no. 677001 to 677999 Hydraulics from m/c no. 678000 Engine to m/c no. 677000 (Peugeot) Engine from m/c no. 677001 (Perkins)

70 - 05 - 01/1-3 70 - 05 - 02/1 70 - 05 - 02/4 70 - 05 - 02/6 70 - 05 - 04/1 70 - 05 - 04/2

Circuit Diagrams Electrical from m/c no. 675001 to 675357 Electrical from m/c no. 675358 to 677000 Electrical, Basic Canopy - Servo Controls from m/c no. 677001 Electrical, Cab and Options - Servo Controls from m/c no. 677001 Electrical, Basic Canopy - Manual Controls from m/c no. 677001 Electrical, Cab and Options - Manual Controls from m/c no. 677001 Hydraulic from m/c no. 675001 to 675573 Hydraulic from m/c no. 675574 to 677000 Hydraulic from m/c no. 677001 to 677999 Single Lever Drive Control Dual Lever Drive Control Manual Control Hydraulic from m/c no. 678000 Servo machines Standard Circuit High Flow Circuit Manual Controls Standard Circuit High Flow Circuit

9804/1103

70 - 20 - 03/1,2 70 - 20 - 03/3,4 70 - 20 - 03/5,6 70 - 20 - 03/7,8

Skidsteer Contents - 3

70 - 15 - 01/1,2 70 - 15 - 01/3,4 70 - 15 - 01/5,6 70 - 15 - 01/7,8 70 - 15 - 01/9,10 70 - 15 - 01/11,12 70 - 20 - 01/1,2 70 - 20 - 01/3,4 70 - 20 - 01/5,6 70 - 20 - 01/7,8 70 - 20 - 01/9,10

70 - 20 - 01/11 70 - 20 - 01/12 70 - 20 - 01/13 70 - 20 - 01/14

Issue1

Skidsteer Range

CONTENTS

70 - 00 - 01/1

From m/c no. 675001

ROBOT 150,165 Lubricants & Capacities ITEM

CAPACITY

FLUID/LUBRICANT

SPECIFICATION

Engine Oil Peugeot XUD Perkins 104

5 litres (1.32 US gal) JCB 15W/40 Multigrade 8.2 litres (2.17 US gal) JCB 10W/30 Multigrade

API CE 15W 40 API CE 10W 30

Hydraulic System

65 litres (17.2 US gal)

API CE 15W 40 API CC 10W 30

Cooling System Peugeot XUD Total coolant cap. Antifreeze Perkins 104 Total coolant cap. Antifreeze

JCB 15W/40 Multigrade JCB 10W/30 Multigrade

11 litres (2.9 US gal) Water/Anti-freeze (see Coolant Mixtures) 5.5 litres (1.45 US gal)

Inhibited Ethanediol AL - 39

11 litres (2.9 US gal) JCB Universal Antifreeze/water 5.5 litres (1.45 US gal) (see Coolant Mixtures)

ASTM D3306-74

Fuel System

60 litres (15.8 US gal)

Diesel oil (see Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

Grease Points

-

JCB Special HP Grease or JCB Special MPL Grease

Lithium based, No. 2 consistency

Chain Case

Fill to level plug

Engine Oil

API CE 15W 40 or API CC 10W 30

9804/1103

70 - 00 - 01/1

Issue 5*

CONTENTS

Skidsteer Range

70 - 00 - 01/1A

To m/c no. 746537

ROBOT 185, 1105 Fluids, Capacities and Lubricants

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 a 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 Engine Oil

CAPACITY 10.7 litres (2.4 UK gal)

FLUID/LUBRICANT

SPECIFICATION

JCB Super Multigrade 15W/40 -10 °C to 50 °C (14 °F to 122 °F)

CF-4/SG, SAE15W/40

JCB Super Multigrade 10W/30 -15 °C to 40 °C (5 °F to 104 °F)

CF-4/SG, SAE10W/30

Hydraulic System Hydraulic Tank

70 litres (15.4 UK gal) 58 litres (12.75 UK gal)

JCB Super Multigrade 10W/30 CF-4/SG, SAE10W/30 JCB Super Multigrade 15W/40 (top up only) CF-4/SG, SAE15W/40

Cooling System Antifreeze Total coolant mixture

5.5 litres (9.7 UK pints) 11 litres (19.4 UK pints)

JCB Universal Antifreeze/water (see Coolant Mixtures)

ASTM D3306-74

Fuel System

99 litres (21.8 UK gal)

Diesel oil (see Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

Grease Points

-

JCB Special HP Grease or JCB Special MPL Grease

Lithium based, No. 2 consistency

Chain Case

Fill to level plug

Engine Oil

North American Capacities and Lubricant Equivalents ITEM Engine Oil

CAPACITY 10.7 litres (2.8 US gal)

FLUID/LUBRICANT

SPECIFICATION

JCB 15W/40 Engine Oil 14 °F to 122 °F (-10 °C to +50 °C)

CF-4/SG, SAE 15W/40

JCB Engine Oil 10W -4 °F to +50 °F (-20 °C to +10 °C)

CF-4/SG, SAE 10W

Hydraulic System Hydraulic Tank

70 litres (18.5 US gal) 58 litres (15.3 US gal)

JCB 10W JCB 15W/40 (top up only)

MIL-L-2104D MIL-L-2104D

Cooling System Antifreeze Total coolant mixture

5.5 litres (11.6 US pints) 11 litres (23 US pints)

JCB Universal Antifreeze/water (see Coolant Mixtures)

ASTM D3306-74

Fuel System

99 litres (26 US gal)

Diesel oil (see Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

Grease Points

-

JCB Moly EP #2 Grease

Lithium based, No. 2

Chain Case

Fill to level plug

Engine Oil

9804/1103

70 - 00 - 01/1A

Issue 2*

CONTENTS

Skidsteer Range

70 - 00 - 01/1B

From m/c no. 680002

ROBOT 160, 170, 170HF

Fluids, Capacities and Lubricants - except North America ITEM

CAPACITY

FLUID/LUBRICANT

* Engine Oil To machine no. 681290: From machine no. 681291:

8.2 litres (1.8 UK gal) 10.5 litres (2.3 UK gal)

JCB High Performance 15W/40

ACEA E2:B2:A2, API CF4/SG

* Hydraulic System

26 litres (5.7 UK gal)

JCB High Performance 10W/30 JCB High Performance 15W/40 (top up only)

ACEA E2:B2:A2, API CF4/SG ACEA E2:B2:A2, API CF4/SG

* Cooling System Total Coolant Antifreeze

JCB Four Seasons Antifreeze & Summer Coolant/Water (see Coolant Mixtures)

ASTM D3306, BS6580

8 litres (1.8 UK gal) 4 litres (0.9 UK gal)

* Fuel System

80 litres (17.6 UK gal)

Diesel oil (see Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

JCB Special HP Grease

Lithium complex NLGI No. 2 consistency including extreme pressure additives. Lithium based NLGI No. 2 consistency including extreme pressure additives.

* Grease Points

or JCB Special MPL-EP Grease

* Chain Case

27 litres (5.9 UK gal)

SPECIFICATION

Engine Oil

Fluids, Capacities and Lubricants - North America ITEM

CAPACITY

FLUID/LUBRICANT

SPECIFICATION

* Engine Oil To machine # 681290: From machine # 681291:

2.16 US gal (8.2 liters) 2.8 US gal (10.5)

JCB Genuine Engine Oil 15W/40

CH-4/SJ, SAE 15W/40

* Hydraulic System

6.8 US gal (26 liters)

JCB Genuine Engine Oil 10W/30 JCB Genuine Engine Oil 15W/40 (top up only)

CH-4/SJ, SAE 15W/40 CH-4/SJ, SAE 15W/40

* Cooling System Total coolant cap. Antifreeze

2.2 US gal (8 liters) 1.1 US gal (4 liters)

Permanent Antifreeze

ASTM D3306-74

* Fuel System

21.1 US gal (80 liters)

Diesel oil (see Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

JCB Moly EP #2 Grease

Lithium based NLGI # 2 consistency including extreme pressure additives.

* Grease Points

* Chain Case

9804/1103

7.0 US gal (27 liters)

Engine Oil

70 - 00 - 01/1B

8520 - 3/1-1.6

Issue 3*

CONTENTS * ROBOT

Skidsteer Range *

150,165,185, 1105

From m/c no. 675001

General Specification * Robot 150 kg (lb)

Robot 165 kg (lb)

Robot 185 kg (lb)

Robot 1105 kg (lb)

Rated lifting capacity

500 (1102)

650 (1433)

850 (1874)

1050 (2314)

SAE tipping load

1000 (2205)

1300 (2866)

1700 (3748)

2100 (4628)

Total weight (inc. standard shovel and driver)

2300 (5071)

2430 (5358)

3240 (7143)

3455 (7615)

30/70

30/70

30/70

30/70

Weight distribution (unloaded) front/rear %

Tyre Specification

* Robot 150 size

pressure - bar (lbf/in2)

27 x 8.5 x 15

3.5 (50)

Goodyear or Dico/Armstrong (tubeless)

10 x 16.5

2.4 (35)

Michelin XZM (tubeless)

700 x R15

3.0 (43)

Pneumatic tyres Goodyear (tubed) or Dico/Armstrong (tubeless)

Non-inflatable tyres (on special rim) Airboss

10 x 16.5 & 7.5 x 15

Solid

7.00 x 15 - 5.5

Robot 165 size

pressure - bar (lbf/in2)

Goodyear or Dico/Armstrong (tubeless)

10 x 16.5

2.4 (35)

Michelin XZM (tubeless)

700 x R15

3.0 (43)

Pneumatic tyres

Non-inflatable tyres (on special rim) Airboss

10 x 16.5 & 7.5 x 15

Solid

7.00 x 15 - 5.5

Robot 185, 1105 size

pressure - bar (lbf/in2)

Dico/Armstrong (tubeless)

12 x 16.5

3.5 (50)

Dico/Armstrong HD 2000 (tubeless)

12 x 16.5

3.5 (50)

Michelin X MINE D2 (tubeless)

7.50 x 15

3.5 (50)

33 x 15.5 x 16.5

4.0 (60)

Pneumatic tyres

Galaxy (tubeless) - (Robot 1105 only) Non-inflatable tyres (on special rim) Segmented - standard and heavy duty Solid - standard and heavy duty 9804/1103

70 - 00 - 01/2

Issue 2

CONTENTS

Skidsteer Range

70 - 00 - 01/3

From m/c no. 680001

ROBOT 160, 170, 170HF

General Specification

Robot 160 - kg (lb)

Robot 170 - kg (lb)

Rated operating capacity with standard bucket with JCB approved fork carrier and forks

600 (1325) 495 (1090)

700 (1545) 555 (1225)

SAE tipping load with standard bucket with JCB approved fork carrier and forks

1200 (2650) 990 (2180)

1400 (3090) 1110 (2450)

Total weight (inc. standard bucket)

2410 (5315)

2510 (5535)

30/70

30/70

Weight distribution (unloaded) front/rear %

Tyre Specification

size

pressure - bar (lbf/in2)

Solideal

10 x 16.5, 6 Ply

3.1 (45)

Solideal

10 x 16.5, 8 Ply

3.1 (45)

Galaxy - North America only

10 x 16.5, 8 Ply

3.1 (45)

Solideal

7.00 x 15, 6 Ply

4.1 (60)

Solideal

7.00 x 15, 14 Ply

4.1 (60)

31.5/1300 x 16.5, 10 Ply

4.1 (60)

Pneumatic tyres

Galaxy- North America only Non-inflatable tyres (on special rim) Airboss Solids

9804/1103

10 x 16.5 & 7.50 x 15 6.50 x 16, 7.50 x 15 & 7.50 x 16

70 - 00 - 01/3

4300 - 131

Issue 1

CONTENTS

Skidsteer Range

70 - 00 - 01/5

From m/c no. 680001

ROBOT 160, 170, 170H Static Dimensions

Robot 160

Robot 170

A

Overall length (including Quickhitch)

2530 mm (99.6 in)

2583 mm (101.7 in)

B

Overall length (including standard shovel)

3210 mm (126.4 in)

3264 mm (128.5 in)

C

Height to cab roof

1929 mm (76.0 in)

1938 mm (76.3 in)

D

Height to loader tower

1606 mm (63.2 in)

1615 mm (63.6 in)

E

Width over tyres (7 x 15)

1372 mm (54 in)

1372 mm (54 in)

Width over tyres (10 x 16.5)

1524 mm (60 in)

1524 mm (60 in)

F

Ground clearance

169 mm (6.7 in)

178 mm (7 in)

G

Wheel base

980 mm (38.6 in)

1033 mm (40.7 in)

H

Maximum pin height

2800 mm (110.2 in)

2929 mm (115.3 in)

J

Shovel roll back angle (from horizontal)

30°

30°

K

Shovel dump angle at maximum height

40°

40°

L

Shovel maximum lift height

2645 mm (104.1 in)

2775 mm (109.3 in)

M

Shovel dump height at maximum dump angle

2158 mm (85.0 in)

2288 mm (90.1 in)

N

Shovel reach at maximum dump angle

562 mm (22.1 in)

470 mm (18.5 in)

O

Shovel reach at ground level

870 mm (34.3 in)

857 mm (33.8 in)

P

Shovel reach at maximum height

852 mm (33.5 in)

759 mm (29.9)

Q

Shovel width (standard)

1430 mm (56.0 in)

1580 mm (62.0 in)

9804/1103

70 - 00 - 01/5

4300 - 132

Issue 1

Skidsteer Range

CONTENTS

70 - 00 - 01/6

From m/c no. 680001

ROBOT 160, 170, 170H Static Dimensions (cont’d)

K

H

L

N M

P C D

J O

G

F

A B

Q

E

332751

9804/1103

70 - 00 - 01/6

4300 - 133

Issue 1

Skidsteer Range

CONTENTS

From m/c no. 675001

ROBOT 150, 165 Static Dimensions Robot 150

Robot 165

A

Overall length (including standard shovel)

3010 mm (118.50 in)

3060 mm (120.50 in)

B

Height to cab roof

1850 mm (72.80 in)

1860 mm (73.20 in)

C

Width over tyres

1363 mm (53.70 in)

1500 mm (59.00 in)

D

Ground clearance at sides

165 mm (6.50 in)

175 mm (6.90 in)

E

Ground clearance at centre

255 mm (10.00 in)

265 mm (10.40 in)

F

Wheel base

988 mm (38.90 in)

1043 mm (41.10 in)

G

Rear overhang

942 mm (37.10 in)

915 mm (36.00 in)

H

Maximum pin height

2980 mm (117.30 in)

2976 mm (117.20 in)

J - roll back angle (from horizontal)

39°

39°

K - dump angle at maximum height

45°

45°

L - dump height at maximum dump angle

2366 mm (93.10 in)

2345 mm (92.32 in)

- reach at maximum dump angle

570 mm (22.50 in)

690 mm (27.20 in)

- width

1430 mm (56.30 in)

1580 mm (62.20 in)

Standard shovel

*

B

E

D F

G

C

A S174470

9804/1103

70 - 00 - 02/1

Issue 3*

CONTENTS

Skidsteer Range *

ROBOT 150, 165

From m/c no. 675001

Static Dimensions

H

J

K

L

9804/1103

70 - 00 - 02/2

Issue 2*

CONTENTS

Skidsteer Range From m/c no. 746001

ROBOT 185, 1105 Static Dimensions * Robot 185

Robot 1105

A Overall length (including standard shovel)

3406 mm (11 ft 2 in)

3412 mm (12 ft 10 in)

B Height to cab roof

2020 mm (6 ft 6 in)

2020 mm (6 ft 6 in)

C Width over tyres

1700 mm (5 ft 7 in)

1700 mm (5 ft 7 in)

255 mm (10 in)

255 mm (10 in)

E Wheel base

1130 mm (3 ft 7 in)

1130 mm (3 ft 7 in)

F Maximum pin height

3315 mm (10 ft 9 in)

3315 mm (10 ft 9 in)

G - roll back angle (from horizontal)

39°

39°

H - dump angle at maximum height

45°

45°

2645 mm (8 ft 7 in)

2645 mm (8 ft 7 in)

650 mm (2 ft 1 in)

650 mm (2 ft 1 in)

1800 mm (5 ft 11 in)

std. 1800 mm (5 ft 11 in) opt. 1950 mm (6 ft 5 in)

D Ground clearance at centre

Standard shovel

J - dump height at maximum dump angle - reach at maximum dump angle - width

9804/1103

70 - 00 - 02/3

Issue 2*

Skidsteer Range

CONTENTS * ROBOT

From m/c no. 746001

185, 1105

Static Dimensions

B

D E

C

A

A225940

H

F J

G A225950

9804/1103

70 - 00 - 02/4

Issue 2*

CONTENTS CONTENTS

Skidsteer Range

70 - 05 - 01/2

From m/c no. 675001 to 675367

ROBOT 150,165 Data - Electrical (cont) Fuses

Relays

The electrical circuits are protected by fuses. The fuses are located towards the rear of the switch/warning indicator panel as shown in the illustration.

Indicator Flasher Unit Door Open/Close Switch Alarm Buzzer Harness Plugs Cover Glow Plugs Relay Auxiliary Isolation Relay

A B C D E F

E

D A B

Y X

F

C

S174431

Y

S174511

7

8

9

X 1 Fuse Number 1

2

3

4

5

6

Canopy Machine

Cab Machine / Options

Fuse Size

Interior light Front work lights

10 amp

Beacon Rear work light

10 amp

Pressure reducing solenoid valve Interlock relay

Pressure reducing solenoid valve Interlock relay

10 amp

4

Auxiliary hydraulics

Auxiliary hydraulics

10 amp

5

ESOS, warning lights and buzzer

ESOS, warning lights and buzzer

5 amp

6

Horn Low water warning

Horn Low water warning

10 amp

7

Spare

Indicators, Sidelights, Dip and Number plate

10 amp

2 3

Spare

A174431

Note: The canopy machine has only fuse board X fitted, the standard cab machine and the cab machine with options have both fuse boards X and Y fitted.

Spare

8

Spare

Wipers and Washer

10 amp

9

Spare

Heater/Blower Reverse Alarm

10 amp

9804/1103

70 - 05 - 01/2

Issue 2

CONTENTS

Skidsteer Range

70 - 05 - 01/1

ROBOT 150,165 From m/c no. 675001 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

12 Volts, negative earth

420 to 585 170 to 230

Alternator Peugeot Engines Perkins Engines Starter Motor Peugeot Engines Perkins Engines

according to battery type

Lucas A127-65, 65 Amp maximum output Lucas A127-55, 55 Amp maximum output Lucas M127/2.8 Mitsubishi M002T54091, 2Kw

Light Bulbs 55W (Halogen) 21W 10W 1.2W 70W 5W

Working Lights Indicator Lights Interior Light Warning Light Beacon (if fitted) Side Lights * ROBOT

185, 1105 From m/c no. 746001

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

12 Volts, negative earth

Alternator Starter Motor

Magneti Marelli A127-65, 65 Amp maximum output Magneti Marelli M127

420 to 585 170 to 230

according to battery type

Light Bulbs 55W (Halogen) 21W 10W 1.2W 70W 5W

Working Lights Indicator Lights Interior Light Warning Light Beacon (if fitted) Side Lights * Robot

160, 170, 170HF From m/c no. 680001

System Type Battery up to machine number 680579 Cold Crank Amps for 1 minute to 1.4 VPC at -18 °C (0 °F) Reserve capacity (minutes) for 25 Amp load Battery from machine number 680580 Cold Crank Amps for 1 minute to 1.4 VPC at -18 °C (0 °F) Reserve capacity (minutes) for 25 Amp load Alternator

12 Volts, negative earth 420 to 585 170 to 230

according to battery type

535 135 55 Amp maximum output

Light Bulbs Working Lights Headlights Indicator Lights Brake Lights Interior Light Warning Lights Beacon (if fitted) Side Lights 9804/1103

55W (Halogen) 55/60W (Halogen) 21W 21W 10W 1.2W 55W 5W

70 - 05 - 01/1

Issue 5*

CONTENTS

Skidsteer Range From m/c no. 675358

ROBOT 150,165 Data - Electrical (cont) *

*

Fuses - later machines The electrical circuits are protected by fuses. The fuses are located towards the rear of the switch/warning indicator panel as shown in the illustration.

Relays - later machines Relays (A) Indicator Flasher Unit Door Open/Close Switch Alarm Buzzer Auxiliary Isolation Relay

Relay type PC MF (Blue relay) PD PS (Black relay)

Glow Plug Relay B The Glow Plug Relay for Perkins engines is visually different but in the same location.

B

A

S201900

* Note: Depending on the number of options specified, the machine may be fitted with either one fuse board X or both fuse boards X and Y.

S174511

* Fuse Number

Machine with fuse board X only

Fuse Size

Machine with fuse boards X and Y

Fuse Size

1

Interior light, Beacon

10 amp

Interior light, Roadlights

15 amp

2

Front and rear working lights

15 amp

Beacon

10 amp

3

Interlock relay, Brake solenoid, Operational solenoid (servo only), Reverse alarm

5 amp

Interlock relay, Brake solenoid, Operational solenoid (servo only)

10 amp

4

Auxiliary hydraulics (servo only), High-flow solenoid

Heated seat, Auxiliary hydraulics (servo only)

10 amp

5

ESOS, warning lights and buzzer, Hour meter, Float solenoid (servo only)

5 amp

ESOS, warning lights and buzzer, Hour meter, High-flow solenoid, Float solenoid (servo only)

6

Horn

15 amp

Horn, Front working lights, Brake lights

10 amp

7

Not used

Hazard lights

10 amp

8

Not used

Wipers and Washer

10 amp

9

Not used

Heater/Blower, Reverse Alarm

10 amp

10

Not used

Rear working light, Indicators

10 amp

11

Not used

L.H. Sidelights, Number plate light

5 amp

12

Not used

R.H. Sidelights

5 amp

9804/1103

5 amp (10 High-flow)

70 - 05 - 01/3

5 amp (10 High-flow)

Issue 3

CONTENTS

Skidsteer Range From m/c no. 746001

ROBOT 185 Data - Electrical (cont) Relays Relay Indicator Flasher Unit * Interlock Relay † Alarm Buzzer Auxiliary Isolation Relay Horn Relay Two Speed Relay

Position at A PC (Black) MF (Blue) PD (Black) PS (Black) PZ (Blue) TS (Blue)

* † Deleted from machine no. 746218 (Sept. 96)

Fuses

A

The electrical circuits are protected by fuses. The fuses are located towards the rear of the switch/warning indicator panel as shown in the illustration. Note: The canopy machine has only fuse board X fitted, the standard cab machine and the cab machine with options have both fuse boards X and Y fitted.

X

Y

S236102

*

Fuse Number

Standard Machine

Machine with Options

Fuse Size

1

Interior light

Interior light, Roadlights

15 amp

2

Beacon (Sequence unit up to m/c no. 746217)

Beacon (Sequence unit up to m/c no. 746217)

10 amp

3

Parking brake, Front working lights (Interlock relay up to m/c no. 746217)

Parking brake, Front working lights (Interlock relay up to m/c no. 746217)

15 amp

4

Auxiliary hydraulics

Auxiliary hydraulics

5 amp

5

ESOS, warning lights and buzzer 2 speed switch

ESOS, warning lights and buzzer, 2 speed switch Float solenoid, Hi-flow solenoid

10 amp

6

Horn, 2 speed solenoid

Brake lights, Horn, 2 speed solenoid

10 amp

7

Spare

Hazard lights

10 amp

8

Spare

Wipers and Washer, Indicators

10 amp

9

Spare

Reverse Alarm, Wiper

5 amp

10

Spare

Rear working lights, Heater/Blower

15 amp

11

Spare

L.H. Sidelights, Number plate light

5 amp

12

Spare

R.H. Sidelights

5 amp

9804/1103

70 - 05 - 01/4

Issue 3

CONTENTS

Skidsteer Range

70 - 05 - 01/5

From m/c no. 680001

ROBOT 160, 170, 170H Data - Electrical (cont’d) Fuses

Primary Fuses

The electrical circuits are protected by fuses. The fuses are located behind a cover on the right hand side of the cab as shown at X.

To further protect the machine wiring harnesses and electrical circuits, a primary fuse box is fitted to the battery positive terminal as shown at A. Remember to check the main fuses as well as the primary fuses shown below.

Note: Depending on the number of options specified, some fuses may not be fitted. Fuse No. Circuits Protected A1

Size

Spool Lock, Restraint Switch, Cut-off Solenoid (Servo)

10 Amp

A2

Junction Box

10 Amp

A3

Ignition Circuits

5 Amp

A4

ESOS

5 Amp

A5

Front Work Lights

15 Amp

A6

Rear Work Light

7.5 Amp

A7

Reverse Alarm

5 Amp

A8

Float Circuit

5 Amp

A9

Horn

5 Amp

A10

Beacon, Interior Light

B1

Right Hand Side and Tail Lights

5 Amp

B2

Left Hand Side and Tail Lights, Number Plate Light

5 Amp

1 2 3 4 5

Starter switch, all ignition switched circuits Beacon, horn, road lights, indicators Not used Not used Ignition relay

2

3

30A

30A

60 Amp 30 Amp 30 Amp 80 Amp 40 Amp

A MAIN

60A

40A

80A

1

5

4

326590

7.5 Amp

B

Head Light Dip Beam

15 Amp

B4

Indicators

5 Amp

B5

High Flow Hydraulics

5 Amp

B6

Heater Blower

10 Amp

B7

Wipers and Washers

10 Amp

B8

Brake Lights

5 Amp

B9

Self Level Circuit

5 Amp

B10

Hazard Warning

10 Amp

10 10 5 5 15 7.5 5 5 5 7.5

5 5 15 5 5 10 10 5 5 10

B3

A

@ ! 0 9 8 67

Relays The relays are located under fuse cover X on the right hand side of the cab as shown in the illustration. 6 Parking Brake 10 Float 7 Horn 11 High-flow 8 Neutral Start 12 Indicator Flasher Unit 9 Ignition

X

Note: Relay 7 is located behind relay 6. Relays 10, 11 and 12 are for optional circuits and are only fitted as required.

9804/1103

70 - 05 - 01/5

332851

8520 - C/1-2.2

Issue 1

CONTENTS

Skidsteer Range *

ROBOT 150,165

From m/c no. 675001 to 677000

Data - Hydraulics Auxiliary Pump - Standard Type Displacement Maximum Working Pressure Maximum Speed Maximum Input Torque

Sauer Sundstrand SP2 250/16.0, gear type 48 l/min (10.5 UK gal, 12.7 US gal/min) at 3000 rev/min 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 3200 rev/min 121 Nm (89 lbf ft, 12 kgf m)

Auxiliary Pump - High-Flow Type Displacement - Front Section Displacement - Rear Section Maximum Working Pressure Maximum Speed Maximum Input Torque

Sauer Sundstrand AJJ 0100 16/28LC 57 l/min (12.5 UK gal, 15 US gal/min) at 3600 rev/min 90 l/min (19.8 UK gal, 23.8 US gal/min) at 3600 rev/min 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 3600 rev/min 121 Nm (89 lbf ft, 12 kgf m)

Main Pump (2-off) up to machine no. 676354 * Type Displacement Control Maximum Working Pressure Maximum Speed Maximum Input Torque Charge Pressure (oil temperature at 50° C)

Sauer Sundstrand tandem axial piston Series 40 M35 35 cc/rev (2.13 in3/rev) Servo non-feedback proportional, 18 bar (261 lbf/in 2) to give max pump displacement. 280 bar (4060 lbf/in2) 3600 rev/min 121 Nm (89 lbf ft, 12 kgf m) 6 bar (87 lbf/in2) at engine idle; 18 bar (261 lbf/in2) at 3000 rev/min

Main Pump (2-off) from machine no. 676355 * Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50° C)

Sauer Sundstrand tandem axial piston Series 42 M28 28 cc/rev (1.71 in3/rev) Servo non-feedback proportional, 15 bar (218 lbf/in 2) to give max pump displacement. 350 bar (5076 lbf/in2) 3900 rev/min 7.5 bar (109 lbf/in2) at engine idle; 19.5 bar (283 lbf/in2) at 3000 rev/min

Loader & Transmission Joysticks Type Maximum Working Pressure Output Characteristics - all 4 positions

Vickers HRC4 - J1Q - 1 - 30 24 bar (348 lbf/in2) 3.3 to 3.7 bar (48 to 53 lbf/in2) at 15% stroke. 14.5 to 16.5 bar (210 to 234 lbf/in2) at 95% stroke.

Hydraulic Motors up to machine no. 676354 Type Displacement Maximum Working Pressure Maximum Speed Maximum Flow

Danfoss OMT 400 FX 410.9 cc/rev (25 in3/rev) 280 bar (4061 lbf/in2) continuous 306 rev/min continuous 125 l/min (27.5 gal/min, 33 US gal/min) continuous

Hydraulic Motors from machine no. 676355 Type Displacement Maximum Working Pressure Maximum Speed Maximum Flow

9804/1103

Rexroth MCR03 328 cc/rev (20 in3/rev) 414 bar (6000 lbf/in2) continuous 237 rev/min continuous 84 l/min (18.5 gal/min, 24 US gal/min) continuous

70 - 05 - 02/1

Issue 4*

CONTENTS

Skidsteer Range *

ROBOT 150,165

From m/c no. 675001 to 677000

Data - Hydraulics (cont) Loader Valve Block to machine no. 675573 Type Maximum Working Pressure * Maximum Return Pressure Services Operated: - Spool 1 - Spool 2 - Spool 3 (Optional) Maximum Leakage (all spools)

Husco 5000 C824 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 20 bar (290 lbf/in2, 20 kgf/cm2) Boom Ram - Hydraulic Servo Crowd Raise Lower - Hydraulic Servo Auxiliary - Electrical Solenoid 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)

Loader Valve Block from machine No. 675574 Type Maximum Working Pressure * Maximum Return Pressure Services Operated: - Spool 1 - Spool 2 - Spool 3 (Optional) Maximum Leakage (all spools)

Husco 5000 B815 (2 spool), C842 (3 spool) 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 20 bar (290 lbf/in2, 20 kgf/cm2) Crowd Raise Lower - Hydraulic Servo Boom Ram - Hydraulic Servo Auxiliary - Electrical Solenoid 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)

High-Flow Valve Block Type Maximum Working Pressure * Maximum Return Pressure Maximum Leakage Relief Valve Operating Pressures (at normal working temperature) Main Relief Valve: at 1500 rev/min (24 litres/min) Auxiliary Relief Valve - Spool 1 - Spool 2 - Spool 3 A.R.V. ports tapped and plugged

Husco 6000 (single acting spool) 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 20 bar (290 lbf/in2, 20 kgf/cm2) 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)

bar

lbf/in2

kgf/cm2

185 - 192

2683 - 2785

188 - 196

230 - 237 230 - 237

3335 - 3436 3335 - 3436

234 - 242 234 - 242

Pressure Reducing Solenoid Valve Maximum Inlet Pressure Regulated Pressure Minimum Rated Flow Maximum Leakage Oil Temperature Range Solenoid Valve (including Diodes) Reducing Valve Electrics

185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 24 bar (348 lbf/in2, 24 kgf/cm2) 10 l/min (2.2 gal/min) 25 cc/min (1.5 in3/min) at 210 bar (3045 lbf/in2) and 10 cSt - 40 °C to +106 °C 3 Position, 3 Port Cartridge Valve Cartridge Type 12 Volt

Filter Type Main Hydraulic * High-Flow * * Suction Strainer

9804/1103

High Pressure Spin - On 5 micron 17 micron 125 micron

70 - 05 - 02/2

Issue 4*

Skidsteer Range

CONTENTS

From m/c no. 675001

ROBOT 150,165 Data - Hydraulics (cont) Rams Boom Lift Crowd Compensating

(80 x 40) (100 x 50) (60 x 30) (50 x 25)

Ram Torque Settings Piston Head: Boom Lift Crowd

(80 x 40) (100 x 50) Compensating (60 x 30) (50 x 25)

End Cap: Boom Lift Crowd

(80 x 40) (100 x 50) Compensating (60 x 30) (50 x 25)

* General

Bore mm 70 80 100 60 50

in 2.75 3.15 3.94 2.36 1.97

Rod Dia mm in 40 1.57 40 1.57 50 1.97 30 1.18 25 0.98

Stroke mm 677 233 234 264 288

Nm

lbf ft

Kg fm

405 405 405 300 250

299 299 299 221 184

41.3 41.3 41.3 30.6 25.5

678 678 678 450 400

500 500 500 331 295

69.2 69.2 69.2 45.9 40.8

in 26.65 9.17 9.21 10.39 11.32

Description

The main components of the hydraulic circuit are the tank, pumps, drive motors, control valves, filters, cooler and rams. Two types of control system are used, servo and manual. On servo machines, hydraulic joystick controls are used to operate the loader and drive functions. The pumps are driven by the engine and are mounted in tandem. they deliver pressurised oil to the valves and motors. Servo Machines When a drive control is operated, oil is fed from the joystick to the transmission pump servo-controls. The pump swashplate moves to vary or change the flow direction to the motors and hence the speed or direction of rotation. When a loader control is operated, servo oil is fed from the joystick to a loader valve spool which then moves to direct pressurised oil to operate the appropriate ram. Relief valves in the loader and transmission circuits prevent system pressure from rising too far. On machines prior to serial number 678000, hydraulic pressure for the joysticks is regulated by the Pressure Reducing Solenoid Valve which, together with its associated electrical circuitry, is designed to ensure that the controls cannot be operated without the operator being seated correctly, with the Safety Restraint Bar in the operating position and the door closed and latched. On machines from serial number 678000, hydraulic pressure for the joysticks is regulated by the transmission pump charge valve and is fed to the joysticks via the solenoid operated Brake Valve. The Brake Valve, together with its associated electrical circuitry, is designed to ensure that the controls cannot be operated without the operator being seated correctly, with the Safety Restraint Bar in the operating position and the door closed and latched. Manual Machines The control levers are mechanically connected to the transmission pump and to the loader valve block. When a drive control is operated, the pump swashplate is moved to change or reverse the flow direction to the motors. When a loader control is operated, the loader valve spool moves to direct pressurised oil to operate the appropriate ram. Relief valves in the loader and transmission circuits prevent system pressure from rising too far. As an option on machines after serial number 678000, the loader functions can be controlled by dual foot pedals. A mechanical interlock prevents the controls from being moved unless the Safety Restraint is in the operating position. In addition, on machines after serial number 678000, solenoid operated lockout valves also prevent the boom service from being operated until the operator is seated correctly in his seat, with the door closed and latched.

9804/1103

70 - 05 - 02/3

Issue 3*

CONTENTS

Skidsteer Range *

ROBOT 150,165

From m/c no. 677001 to 677999

Data - Hydraulics Auxiliary Pump - Standard Type Displacement Maximum Working Pressure Maximum Speed

Sauer Sundstrand SP2 250/16.0, gear type 48 l/min (10.5 UK gal, 12.7 US gal/min) at 3000 rev/min 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 3000 rev/min

Auxiliary Pump - High-Flow Type Displacement - Front Section Displacement - Rear Section Maximum Working Pressure Maximum Speed

Sauer Sundstrand AJJ 0100 16/28LC 48 l/min (10.5 UK gal, 12.7 US gal/min) at 3000 rev/min 106 l/min (23.3 UK gal, 28 US gal/min) at 3000 rev/min 207 bar (3002 lbf/in2, 211 kgf/cm2) 3000 rev/min

Main Pump (2-off) - Servo Machines * Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50° C)

Sauer Sundstrand tandem axial piston Series 42 M28 28 cc/rev (1.71 in3/rev) Servo non-feedback proportional, 18 bar (261 lbf/in 2) to give max pump displacement. 414 bar (6004 lbf/in2) 3000 rev/min 7.5 bar (109 lbf/in2) at 800 rev/min; 19.5 bar (283 lbf/in2) at 3000 rev/min

Main Pump (2-off) - Manual Machines Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50° C)

Sauer Sundstrand tandem axial piston Series 40 M35 35 cc/rev (2.14 in3/rev) Direct Displacement Manual Control 345 bar (5003 lbf/in2) 3000 rev/min 17 bar (246 lbf/in2)

Servo Joysticks Type Maximum Working Pressure * Output Characteristics - Transmission control spools * Output Characteristics - Loader control spools

Vickers HRC4 - J1Q - 1 - 30 24 bar (348 lbf/in2) 5 bar (72 lbf/in2) at 15% stroke. 15 bar (217 lbf/in2) at 100% stroke. 3.3 to 3.7 bar (48 to 53 lbf/in2) at 15% stroke. 14.5 to 16.5 bar (210 to 239 lbf/in2) at 95% stroke.

Hydraulic Motors - Servo Machines Type Displacement Maximum Working Pressure * Maximum Speed * Maximum Flow

Rexroth MCR3 328 cc/rev (20 in3/rev) 414 bar (6000 lbf/in2) continuous 305 rev/min continuous 100 l/min (22 gal/min, 26 US gal/min)

Hydraulic Motors - Manual Machines Type Displacement Maximum Working Pressure Maximum Speed Maximum Flow

9804/1103

Rexroth MCR3 400 cc/rev (24.4 in3/rev) 414 bar (6003 lbf/in2) continuous 305 rev/min continuous 122 l/min (26.8 gal/min, 32 US gal/min)

70 - 05 - 02/4

Issue 3*

CONTENTS

Skidsteer Range *

ROBOT 150,165

From m/c no. 677001 to 677999

Data - Hydraulics (cont) Loader Valve Block - Servo Machines Type Maximum Working Pressure * Maximum Return Pressure Services Operated: - Spool 1 - Spool 2 - Spool 3 (Optional) Maximum Leakage (all spools)

Commercial Hydraulic KA18 207 bar (3002 lbf/in2, 211 kgf/cm2) 20 bar (290 lbf/in2, 20 kgf/cm2) Shovel Ram - Hydraulic Servo Boom Ram - Hydraulic Servo Auxiliary - Electrical Solenoid 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)

Loader Valve Block - Manual Machines Type Maximum Working Pressure Maximum Return Pressure Services Operated: - Spool 1 (Optional) - Spool 2 - Spool 3 Maximum Leakage (all spools)

Commercial Hydraulic KA10 207 bar (3002 lbf/in2, 211 kgf/cm2) 30 bar (435 lbf/in2, 31 kgf/cm2) Auxiliary - Manually operated Shovel Ram - Manually operated Boom Ram - Manually operated 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)

High-Flow Valve Block Type Maximum Working Pressure * Maximum Return Pressure Maximum Leakage Relief Valve Operating Pressures (at normal working temperature) Main Relief Valve: at 1500 rev/min (24 litres/min) Auxiliary Relief Valve - Lift Service - Shovel Service - Auxiliary Service A.R.V. ports plugged

Husco 6000 (single acting spool) 185 bar (2683 lbf/in2, 188 kgf/cm2) 20 bar (290 lbf/in2, 20 kgf/cm2) 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)

bar

lbf/in2

kgf/cm2

185 ± 3.5

2683 ± 50

188 ± 3.57

230 - 237 230 - 237

3335 - 3436 3335 - 3436

234 - 242 234 - 242

Pressure Reducing Solenoid Valve - Servo Machines Maximum Inlet Pressure Regulated Pressure Minimum Rated Flow Maximum Leakage Oil Temperature Range Solenoid Valve (including Diodes) Reducing Valve Electrics

185 bar (2683 lbf/in2, 188 kgf/cm2) 24 bar (348 lbf/in2, 24 kgf/cm2) 10 l/min (2.2 gal/min) 25 cc/min (1.5 in3/min) at 210 bar (3045 lbf/in2) and 10 cSt - 40 °C to +106 °C 3 Position, 3 Port Cartridge Valve Cartridge Type 12 Volt

* Filter Type Main Hydraulic High-Flow Suction Strainer

9804/1103

High Pressure Spin - On 5 micron 17 micron 125 micron

70 - 05 - 02/5

Issue 2*

CONTENTS

Skidsteer Range *

ROBOT 150,165

From m/c no. 678000

Data - Hydraulics (cont) * Auxiliary Pump - Standard Type Displacement Maximum Working Pressure Maximum Speed

Sauer Sundstrand SP2 250/16.0, gear type 54 l/min (11.9 UK gal, 14.2 US gal/min) at 3000 rev/min 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 3200 rev/min

* Auxiliary Pump - High-Flow Type Displacement - Front Section Displacement - Rear Section Maximum Working Pressure Maximum Speed

Sauer Sundstrand AJJ 0100 16/28LC 54 l/min (11.9 UK gal, 14.2 US gal/min) at 3000 rev/min 106 l/min (23.3 UK gal, 28 US gal/min) at 3000 rev/min 207 bar (3002 lbf/in2, 211 kgf/cm2) 3200 rev/min

* Main Pump (2-off) - Servo Machines Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50° C)

Sauer Sundstrand tandem axial piston Series 42 M28 28 cc/rev (1.71 in3/rev) Servo non-feedback proportional, 18 bar (261 lbf/in 2) to give max pump displacement. 414 bar (6004 lbf/in2) 3000 rev/min 7.5 bar (109 lbf/in2) at 800 rev/min; 19.5 bar (283 lbf/in2) at 3000 rev/min

* Main Pump (2-off) - Manual Machines Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50° C)

Sauer Sundstrand tandem axial piston Series 40 M35 35 cc/rev (2.14 in3/rev) Direct Displacement Manual Control 385 bar (5584 lbf/in2) 3100 rev/min 11 bar (160 lbf/in2) non adjustable

* Servo Joysticks Type Maximum Working Pressure Output Characteristics - Transmission control spools Output Characteristics - Loader control spools

Vickers HRC4 - J1Q - 1 - 30 24 bar (348 lbf/in2) 5 bar (72 lbf/in2) at 15% stroke. 15 bar (217 lbf/in2) at 100% stroke. 3.3 to 3.7 bar (48 to 53 lbf/in2) at 15% stroke. 14.5 to 16.5 bar (210 to 239 lbf/in2) at 95% stroke.

* Hydraulic Motors - Servo Machines Type Displacement Maximum Working Pressure Maximum Speed Maximum Flow

Rexroth MCR3 328 cc/rev (20 in3/rev) 414 bar (6000 lbf/in2) continuous 305 rev/min continuous 100 l/min (22 UK gal/min, 32 US gal/min)

* Hydraulic Motors - Manual Machines Type Displacement Maximum Working Pressure Maximum Speed Maximum Flow

9804/1103

Rexroth MCR3 400 cc/rev (24.4 in3/rev) 414 bar (6000 lbf/in2) continuous 305 rev/min continuous 122 l/min (27 UK gal/min, 32 US gal/min)

70 - 05 - 02/6

Issue 2*

CONTENTS

Skidsteer Range From m/c no. 678000

ROBOT 150,165 Data - Hydraulics (cont) Loader Valve Block - Servo Machines Type Maximum Working Pressure Maximum Return Pressure Services Operated: - Spool 1 - Spool 2 - Spool 3 (Optional) Maximum Leakage (all spools)

Commercial Hydraulic KA18 207 bar (3002 lbf/in2, 211 kgf/cm2) 20 bar (290 lbf/in2, 20 kgf/cm2) Shovel Ram - Hydraulic Servo Boom Ram - Hydraulic Servo Auxiliary - Manually operated 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)

Loader Valve Block - Manual Machines Type Maximum Working Pressure Maximum Return Pressure Services Operated: - Spool 1 (Optional) - Spool 2 - Spool 3 Maximum Leakage (all spools)

Commercial Hydraulic KA10 207 bar (3002 lbf/in2, 211 kgf/cm2) 20 bar (290 lbf/in2, 20 kgf/cm2) Auxiliary - Manually operated Shovel Ram - Manually operated Boom Ram - Manually operated 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)

High-Flow Valve Block Type Maximum Working Pressure Maximum Return Pressure Maximum Leakage

Husco 6000 (single acting spool) 185 bar (2683 lbf/in2, 188 kgf/cm2) 20 bar (290 lbf/in2, 20 kgf/cm2) 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)

Relief Valve Operating Pressures (at normal working temperature)

bar

lbf/in2

kgf/cm2

185 ± 3.5

2683 ± 50

188 ± 3.57

230 - 237 230 - 237

3335 - 3436 3335 - 3436

234 - 242 234 - 242

Main Relief Valve: at 1500 rev/min (24 litres/min) Auxiliary Relief Valve - Lift Service - Shovel Service - Auxiliary Service A.R.V. ports plugged Solenoid Brake Valve Type - Servo Machines - Manual Machines Electrics

3 Position, 4 way Directional Control 2 Position, 4 way Directional Control 12 Volt

Filter Type Main Hydraulic High-Flow Suction Strainer

9804/1103

High Pressure Spin - On 5 micron 17 micron 125 micron

70 - 05 - 02/7

Issue 1

CONTENTS

Skidsteer Range

ROBOT 185, 1105

*

70 - 05 - 03/1

From m/c no. 746001 to 804423

Data - Hydraulics * To machine no. 804434 Note: System Cleanliness is to be to ISO 16/13. * Auxiliary Pump Type Displacement Maximum Working Pressure

SP2 250/36.0, gear type 75 litres (16.5 UK gal; 19.8 US gal) per min. at 2200 rev/min 220 - 227 bar (3190 - 3292 lbf/in2, 223 - 232 kgf/cm2)

* High-Flow Pump (up to June 1997) Type Displacement Maximum Working Pressure

16 cc/rev 65 litres (14.3 UK gal; 17.2 US gal) per min. at 2200 engine rev/min 205 - 212 bar (2973 - 3074 lbf/in2, 208 - 216 kgf/cm2)

* High-Flow Pump (from July 1997) Type Displacement Maximum Working Pressure

12.8 cc/rev 45 litres (9.8 UK gal; 11.8 US gal) per min. at 2200 engine rev/min 205 - 212 bar (2973 - 3074 lbf/in2, 208 - 216 kgf/cm2)

* Main Pump (2-off) Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50° C) Charge Pump Flow

Tandem axial piston Series 40 M35 35 cc/rev Servo non-feedback proportional, 18 bar (261 lbf/in2) to give max pump displacement. 414 bar (6003 lbf/in2) 2400 rev/min 20 - 30 bar (290 - 435 lbf/in2) at 2200 rev/min 38 - 40 litres (8.4 - 8.8 UK gal; 10.0 - 10.5 US gal) per min. at 2200 rev/min

* Loader Joystick - Single lever drive control Output Characteristics - Forward/Reverse positions - Left/Right positions

5 bar (72.5 lbf/in2) at 15% stroke, 19 bar (275 lbf/in2) at 100% stroke. 1 bar (14.5 lbf/in2) at 15% stroke, 15 bar (217.5 lbf/in2) at 100% stroke.

* Transmission Joystick - Single lever drive control Output Characteristics - Forward/Reverse positions - Left/Right positions

5 bar (72.5 lbf/in2) at 15% stroke, 19 bar (275 lbf/in2) at 100% stroke. 1 bar (14.5 lbf/in2) at 15% stroke, 25 bar (363 lbf/in2) at 100% stroke.

* Servo Joysticks - Dual lever drive control Output Characteristics - Transmission control spools Output Characteristics - Loader control spools

9804/1103

5 bar (72.5 lbf/in2) at 15% stroke, 15 bar (217.5 lbf/in2) at 100% stroke. 3.5 bar (51 lbf/in2) at 15% stroke, 15 bar (217.5 lbf/in2) at 100% stroke.

70 - 05 - 03/1

8510 - E/1-1.6

Issue 6*

CONTENTS

Skidsteer Range

70 - 05 - 03/2 * From

ROBOT 185, 1105

m/c no. 746001 to 804423

Data - Hydraulics (cont) * To machine no. 804423 Hydraulic Motors Displacement Maximum Working Pressure Maximum Speed Maximum Flow

520 cc/rev (32 in3/rev) 414 bar (6003 lbf/in2) continuous 310 rev/min continuous 80 litres (17.6 gal; 21.1 US gal) per min. continuous

Loader Valve Block Maximum Working Pressure Maximum Return Pressure Services Operated: - Spool 1 - Spool 2 - Spool 3 (Optional) Maximum Leakage (all spools)

220 - 227 bar (3190 - 3292 lbf/in2, 223 - 232 kgf/cm2) 12 bar (174 lbf/in2, 12 kgf/cm2) Crowd/Raise/Lower - Hydraulic Servo Boom Ram - Hydraulic Servo Auxiliary - Electrical Solenoid 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)

High-Flow Valve Block Maximum Working Pressure Maximum Return Pressure * Relief Valve Operating Pressures (at normal working temperature) Main Relief Valve (at maximum rev/min) Auxiliary Relief Valve - Spool 1 - Spool 2 - Spool 3 A.R.V. ports tapped and plugged High-flow Relief Valve *

205 - 212 bar (2973 - 3074 lbf/in2, 208 - 216 kgf/cm2) 12 bar (174 lbf/in2, 12 kgf/cm2)

bar

lbf/in2

kgf/cm2

220 - 227

3190 - 3292

223 - 232

250 - 257 250 - 257

3625 - 3756 3625 - 3756

253 - 262 253 - 262

205 - 212

2973 - 3074

208 - 216

Pressure Reducing Solenoid Valve * To machine no. 746998 Maximum Inlet Pressure Regulated Pressure Minimum Rated Flow Maximum Leakage Oil Temperature Range Solenoid Valve (including Diodes) Reducing Valve Electrics

220 - 227 bar (3190 - 3292 lbf/in2, 223 - 232 kgf/cm2) 25 bar (363 lbf/in2, 25.5 kgf/cm2) 10 l/min (2.2 gal/min) 25 cc/min (1.5 in3/min) at 210 bar (3045 lbf/in2) and 10 cSt - 40 °C to +106 °C 3 Position, 3 Port Cartridge Valve Cartridge Type 12 Volt

* Solenoid Brake Valve (from machine no. 746999) Type Electrics

3-position, 4-way directional control 12 volt

Filter Type Main Hydraulic High-Flow Suction Strainer

9804/1103

High Pressure Spin - On 5 micron 17 micron 125 micron

70 - 05 - 03/2

8510 - E/1-2.6

Issue 5*

Skidsteer Range

CONTENTS

70 - 05 - 03/2A

From m/c no. 746001 to 804423

Robot 185, 1105 Data - Hydraulics (cont’d) To machine no. 804423 Rams Boom Lift Crowd Compensating

(80 x 50) (110 x 50) (60 x 30)

Bore mm 80 110 60

in 3.14 4.33 2.36

Rod Dia mm in 50 1.97 50 1.97 30 1.18

Stroke mm 688.5 233 331

Ram Torque Settings

Nm

lbf ft

Kg fm

Piston Head: Boom Lift (80 x 50) Crowd (110 x 50) Compensating (60 x 30)

405 405 405

299 299 299

41.3 41.3 41.3

End Cap: Boom Lift (80 x 50) Crowd (110 x 50) Compensating (60 x 30)

678 678 678

500 500 500

69.2 69.2 69.2

9804/1103

70 - 05 - 03/2A

8510 - E/1-3.4

in 27.1 9.17 13.03

Issue 1

CONTENTS

Skidsteer Range

70 - 05 - 03/2B

From m/c no. 804424

Robot 185, 1105 Data - Hydraulics Note: System Cleanliness is to be to ISO 16/13.

Auxiliary Pump Type Displacement Maximum Working Pressure

Sauer Sundstrand gear type 90 litres (19.8 UK gal; 23.8 US gal) per min. at 2350 rev/min 220 - 227 bar (3190 - 3292 lbf/in2, 223 - 232 kgf/cm2)

High-Flow Pump Type Displacement Maximum Working Pressure

Sauer Sundstrand gear type 50 litres (11 UK gal; 13.2 US gal) per min. at 2350 engine rev/min 205 - 212 bar (2973 - 3074 lbf/in2, 208 - 216 kgf/cm2)

Main Pump (2-off) Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50° C)

Sauer Sundstrand tandem axial piston Series 42 M35 35 cc/rev Servo non-feedback proportional, 18 bar (261 lbf/in2) to give max pump displacement. 414 bar (6003 lbf/in2) 2400 rev/min 20 - 30 bar (290 - 435 lbf/in2) at 2200 rev/min

Loader Joystick - Single lever drive control Type Output Characteristics - All 4 spools

Rexroth 3.5 bar (51 lbf/in2) at 15% stroke, 20 - 30 bar (290 - 435 lbf/in2) at 100% stroke.

Transmission Joystick - Single lever drive control Type Output Characteristics - Forward/Reverse spools - Left/Right spools

Rexroth 3.5 bar (51 lbf/in2) at 15% stroke, 20 - 30 bar (290 - 435 lbf/in2) at 100% stroke. 5.5 bar (80 lbf/in2) at 15% stroke, 20 - 30 bar (290 - 435 lbf/in2) at 100% stroke.

Servo Joysticks - Dual lever drive control Type Output Characteristics - Transmission control spools Output Characteristics - Loader control spools

Vickers 5 bar (72.5 lbf/in2) at 15% stroke, 20 - 30 bar (290 - 435 lbf/in2) at 100% stroke. 3.5 bar (51 lbf/in2) at 15% stroke, 20 - 30 bar (290 - 435 lbf/in2) at 100% stroke.

Hydraulic Motors Displacement Maximum Working Pressure Maximum Speed Maximum Flow

9804/1103

520 cc/rev (32 in3/rev) 414 bar (6003 lbf/in2) continuous 310 rev/min continuous 80 litres (17.6 gal; 21.1 US gal) per min. continuous

70 - 05 - 03/2B

8510 - E/1-4.3

Issue 1

CONTENTS

Skidsteer Range

70 - 05 - 03/2C

From m/c no. 804424

Robot 185, 1105 Data - Hydraulics (cont’d) Loader Valve Block Maximum Working Pressure Maximum Return Pressure Services Operated: - Spool 1 - Spool 2 - Spool 3 (Optional) Maximum Leakage (all spools)

220 - 227 bar (3190 - 3292 lbf/in2, 223 - 232 kgf/cm2) 12 bar (174 lbf/in2, 12 kgf/cm2) Crowd Raise Lower - Hydraulic Servo Boom Ram - Hydraulic Servo Auxiliary - Electrical Solenoid 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)

High-Flow Valve Block Maximum Working Pressure Maximum Return Pressure

205 - 212 bar (2973 - 3074 lbf/in2, 208 - 216 kgf/cm2) 12 bar (174 lbf/in2, 12 kgf/cm2)

Relief Valve Operating Pressures (at normal working temperature)

bar

lbf/in2

kgf/cm2

220 - 227

3190 - 3292

223 - 232

250 - 257 250 - 257

3625 - 3756 3625 - 3756

253 - 262 253 - 262

Main Relief Valve (at maximum rev/min) Auxiliary Relief Valve - Spool 1 - Spool 2 - Spool 3 A.R.V. ports tapped and plugged High-Flow Relief Valve

205 - 212 bar (2973 - 3074 lbf/in2, 208 - 216 kgf/cm2)

Solenoid Brake Valve 3 Position, 4 way Directional Control 12 Volt

Type Electrics Filter Type Main Hydraulic High-Flow Suction Strainer Rams Boom Lift Crowd Compensating

(80 x 50) (110 x 50) (60 x 30)

High Pressure Spin - On 5 micron 17 micron 125 micron Bore mm 80 110 60

in 3.14 4.33 2.36

Rod Dia mm in 50 1.97 50 1.97 30 1.18

Stroke mm 688.5 233 331

Ram Torque Settings

Nm

lbf ft

Kg fm

Piston Head: Boom Lift (80 x 50) Crowd (110 x 50) Compensating (60 x 30)

405 405 405

299 299 299

41.3 41.3 41.3

End Cap: Boom Lift (80 x 50) Crowd (110 x 50) Compensating (60 x 30)

678 678 678

500 500 500

69.2 69.2 69.2

9804/1103

70 - 05 - 03/2C

8510 - E/1-5.1

in 27.1 9.17 13.03

Issue 1

Skidsteer Range

CONTENTS

70 - 05 - 03/3

From m/c no. 680001

ROBOT 160, 170, 170H Data - Hydraulics Note: System Cleanliness is to be ISO 16/13

Loader Pump - Standard Type Maximum displacement at 205 bar (2972 lbf/in2) - Robot 160 - Robot 170

Gear 55 l/min (12.1 UK gal/min, 14.5 US gal/min) 60 l/min (13.2 UK gal/min, 15.8 US gal/min)

Loader Pump - High-Flow Type Maximum displacement at 150 bar (2175 lbf/in2) - Front Section - Rear Section Priority Valve setting

Tandem gear with integral priority valve 54 l/min (11.9 UK gal/min, 14.2 US gal/min) 61 l/min (13.4 UK gal/min, 16.1 US gal/min) 19 l/min (4.2 UK gal/min, 5 US gal/min) at 20 bar (290 lbf/in2)

Transmission Pump - Servo Machines Type Displacement Control Charge Pressure (oil temperature at 50° C) - Standard Machines - High-flow Machines High Pressure ‘Loop’ Valve Pressure

Tandem axial piston Series 42 41 cc/rev (2.5 in3/rev) Servo non-feedback proportional. 19 - 22 bar (275 - 319 lbf/in2) at max. rev/min 19 - 22 bar (275 - 319 lbf/in2) at max. rev/min (controlled by priority valve) 385 bar (5582 lbf/in2)

Transmission Pump - Manual Machines Type Displacement Control Charge Pressure (oil temperature at 50° C) - Standard Machines - High-flow Machines High Pressure ‘Loop’ Valve Pressure

Tandem axial piston Series 40 44 cc/rev (2.68 in3/rev) Direct Displacement Manual Control 19 - 22 bar (275 - 319 lbf/in2) at max. rev/min 19 - 22 bar (275 - 319 lbf/in2) at max. rev/min (controlled by priority valve) 385 bar (5582 lbf/in2)

Hydraulic Motors Geroter 395 cc/rev (24 in3/rev)

Type Displacement Loader Valve Block - Servo Machines Services Operated: - Spool 1 - Spool 2 - Spool 3 (Optional)

P

1

2

3

T

Boom Lift - Hydraulic Servo with Solenoid Spool Lock Quickhitch Tilt - Hydraulic Servo with Solenoid Spool Lock Auxiliary - Manually operated

Loader Valve Block - Manual Machines Services Operated: - Spool 1 - Spool 2 - Spool 3 (Optional)

9804/1103

P

1

2

3

T

Boom Lift - Manually operated with Solenoid Spool Lock Quickhitch Tilt - Manually operated with Solenoid Spool Lock Auxiliary - Manually operated

70 - 05 - 03/3

8520 - E/1-1.3

Issue 1

CONTENTS

Skidsteer Range

70 - 05 - 03/4

From m/c no. 680001

ROBOT 160, 170, 170H Data - Hydraulics Relief Valve Operating Pressures (at normal working temperature) * Main Relief Valve: at max. rev/min (see Note 1) * Tilt Ram Head Side Auxiliary Relief Valve (see Note 2)

bar

lbf/in2

180 230

2610 3335

* Note 1: Test point will show both M.R.V. and Transmission Pump Charge Pressure. * Note 2: Fitted to all machines from Jan 2001. Should be fitted to earlier machines whenever breaker is used. Self Level Valve (optional) Solenoid controlled in line, adjustable split flow, level to lift only

Type

High-Flow Valve Block (optional) Ventable relief valve 185 bar (2683 lbf/in2)

Type Relief Valve Setting Filter Type Main Hydraulic High-flow

High Pressure Spin - On Charge pressure filtration Return oil filtration

Rams Boom Lift Crowd

Bore mm in 75 2.95 90 3.54

Ram Torque Settings

Nm

lbf ft

Piston Head: Boom Lift Crowd

405 450

299 332

End Cap: Boom Lift Crowd

678 678

500 500

Rod Dia mm in 50 1.97 40 1.57

Stroke mm in 898 35.35 324 12.75

Hydraulic Tank 0.31 to 0.38 bar (4.5 to 5.5 lbf/in2)

Tank pressurised to: Loader Cycle Times (average) at normal working temperature, unladen and at max. rev/min

160

170

Standard machine Boom Lift Boom Lower Bucket Crowd Bucket Dump

3.7 secs 2.9 secs 1.6 secs 1.9 secs

3.9 secs 3.0 secs 1.7 secs 2.0 secs

High-flow machine Boom Lift Boom Lower Bucket Crowd Bucket Dump

3.7 secs 2.9 secs 1.6 secs 2.0 secs

3.9 secs 3.0 secs 1.7 secs 2.0 secs

9804/1103

70 - 05 - 03/4

8520 - E/1-2.3

Issue 2*

CONTENTS

Skidsteer Range From m/c no. 675001 to 677000

ROBOT 150,165 Data - Peugeot Engine * Type Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure (Measured with warm engine turned by the starter) Injection Sequence Valve Clearance - Cold - Inlet Exhaust Maximum Air Cleaner Restriction Maximum Back Pressure (Exhaust)

4 cylinder in-line, overhead camshaft, compression ignition, naturally aspirated. 83 mm (3.268 in) 88 mm (3.465 in) 1905 cm3 (116.24 in3) 23.5 : 1 25 - 30 bar (363 - 435 lbf/in2, 25.5 - 33 kgf/cm2) Maximum variation between cylinders 5 bar (72.5 lbf/in2, 5.1 kgf/cm2) 1,3,4,2 0.15 - 0.20 mm (0.0059 - 0.0078 in) 0.30 - 0.35 mm (0.0118 - 0.0138 in) 20 mbar (0.29 lbf/in2, 0.02 kgf/cm2) at 3600 rev/min 140 mbar (2.03 lbf/in2, 0.143 kgf/cm2) at 3600 rev/min

Speeds Model

Loaded Max. rev/min

No. Load Max. rev/min

Robot 150 Robot 165 Robot 165 High-flow

2630 2630 3600

3000 3000 3860

Idling Speed

880 - 920 rev/min

Oil Pressure (hot) (at loaded speeds) 110 °C (230 °F) 3.6 bar (52.2 lbf/in2, 3.7 kgf/cm2) 3.7 bar (53.7 lbf/in2, 3.8 kgf/cm2) 3.8 bar (55.1 lbf/in2, 3.9 kgf/cm2)

Fuel System Injection Pump Type Governing Pump Setting Code Static Timing Injector Codes Injector Setting Pressure

Lucas CAV DPC R84 43 Mechanical 063 16 ± 1° BTDC RDN O5DC 6730 115 ± 5 bar (1667.5 ± 72.5 lbf/in2, 117 ±5.1 kgf/cm2)

Cooling System Fan Type Coolant Pressure Temperature Warning Light operates at

Mechanical 1 bar (14.5 lbf/in2, 1.02 kgf/cm2) 105 ± 2 °C (221 ± 35.6 °F)

Note: If at anytime during the life of a machine it is necessary to fit a new engine, then after the first 50 operating hours a new engine oil filter must be fitted and the engine oil changed. Failure to complete this could damage the engine. Note: Should further details be required for the refitting of the engine refer to Engine Service Manual 9803/8600.

9804/1103

70 - 05 - 04/1

Issue 2*

CONTENTS

Skidsteer Range From m/c no. 677001

ROBOT 150,165 Data - Perkins Engine Type Bore (nominal) Stroke Swept Volume Compression Ratio Injection Sequence Valve Clearance - Cold - Inlet and Exhaust Oil Pressure * Speeds 150 up to machine serial number 677999 and 165 Rated Speed Idling Speed 150 from machine serial number 678000 Rated Speed Idling Speed

4 cylinder in-line, compression ignition, naturally aspirated. 84 mm (3.31 in) 100 mm (3.94 in) 2216 cm3 (135.2 in3) 22 : 1 1,3,4,2 0.2 mm (0.0078 in) 2.6 - 3.5 bar (38 - 52 lbf/in2, 2.7 - 3.6 kgf/cm2)

2800 rev/min 850 - 950 rev/min 2600 rev/min 890 - 910 rev/min

Fuel System Injection Pump Type Governing Static Timing Injector Codes Injector Setting Pressure

Bosch 104135-4010 Mechanical 19° BTDC Bosch 105148-1170 147 bar (2133 lbf/in2, 150 kgf/cm2)

Cooling System Fan Type Coolant Pressure Thermostat operating temperature Temperature Warning Light operates at

Mechanical 1 bar (14.5 lbf/in2, 1.02 kgf/cm2) 82 - 94 °C (180 - 200 °F) 97 - 103 °C (207 - 217 °F)

Note: If at anytime during the life of a machine it is necessary to fit a new engine, then after the first 50 operating hours a new engine oil filter must be fitted and the engine oil changed. Failure to complete this could damage the engine. Note: Should further details be required, refer to Engine Service Manual 9806/2100.

9804/1103

70 - 05 - 04/2

Issue 2*

CONTENTS * ROBOT

Skidsteer Range

185, 1105 (Standard, High-flow machines)

70 - 05 - 05/1 *

To m/c no. 746805

Data - Engine Type Build Number - 185 Build Number - 1105 Number of cylinders Bore Stroke Swept Volume Compression Ratio Compression Pressure Maximum variation between cylinders Injection Sequence Valve Clearance - Hot or Cold - Inlet - Exhaust Maximum Speed (no load) Governed Speed Idling Speed

Perkins 1004-4HR naturally aspirated AA50530 AA50688 4 100 mm (3.937 in) 127 mm (5.00 in) 3990 cm3 (243.5 in3) 16.5 : 1 20 - 34 bar (240 - 493 lbf/in2) 3.5 bar (50 lbf/in2) 1,3,4,2 0.20 mm (0.008 in) 0.45 mm ( 0.018 in) 2400-2420 rev/min 2200 rev/min 700-750 rev/min

Fuel System - Robot 185 Injection Pump Type Governing Pump Setting Code Static Timing Injector Code Injector Setting Pressure

Lucas CAV DPC R84 43 Mechanical 063 16 ± 1° BTDC NJ 223 bar (3234 lbf/in2, 227 kgf/cm2)

Fuel System - Robot 1105 Injection Pump Type Governing Pump Setting Code Static Timing Injector Code Injector Setting Pressure

Lucas CAV DPA 334B F790 Mechanical 059 16 ± 1° BTDC JB 253 bar (3675 lbf/in2, 258 kgf/cm2)

Induction System Air Cleaner Type Maximum Restriction (at which warning light operates)

2 stage, dry element 635 mm (25 in) H2O

Lubrication System Oil Pump Type Oil Pressure (hot) at maximum speed

Eccentric Rotor 2.0 bar (30 lbf/in2) (minimum)

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 (209 °F)

Note: For further details of the engine refer to Engine Service Manual 9806/0100.

9804/1103

70 - 05 - 05/1

Issue 4*

CONTENTS * ROBOT

Skidsteer Range

70 - 05 - 05/2 *

185, 1105 (High-flow machines)

From m/c no. 746806

Data - Engine

Type Build Number Number of cylinders Bore Stroke Swept Volume Compression Ratio Compression Pressure Maximum variation between cylinders Injection Sequence Valve Clearance - Hot or Cold - Inlet - Exhaust Maximum Speed (no load) Governed Speed Idling Speed

Robot 185

Robot 1105

Perkins 1004-42AR (75hp) naturally aspirated AR50679 4 103 mm (4.055 in) 127 mm (5.00 in) 4230 cm3 (258 in3) 18.5 : 1 25 - 35 bar (375 - 525 lbf/in2) 3.5 bar (50 lbf/in2) 1,3,4,2

Perkins 1004-42AR (80hp) naturally aspirated AR50674 4 103 mm (4.055 in) 127 mm (5.00 in) 4230 cm3 (258 in3) 18.5 : 1 25 - 35 bar (375 - 525 lbf/in2) 3.5 bar (50 lbf/in2) 1,3,4,2

0.20 mm (0.008 in) 0.45 mm ( 0.018 in) 2350 rev/min 2200 rev/min 750 rev/min

0.20 mm (0.008 in) 0.45 mm ( 0.018 in) 2460 rev/min 2200 rev/min 750 rev/min

Lucas DP 203 Mechanical 2644G002RG/1/2350 3° BTDC Dynamic KW 294 bar (4263 lbf/in2, 4182 kgf/cm2)

Lucas DP 203 Mechanical 2644G601PG/1 /2460 2° BTDC Dynamic KW 294 bar (4263 lbf/in2, 4182 kgf/cm2)

2 stage, dry element

2 stage, dry element

635 mm (25 in) H2O

635 mm (25 in) H2O

Eccentric Rotor 2.0 bar (30 lbf/in2) (minimum)

Eccentric Rotor 2.0 bar (30 lbf/in2) (minimum)

0.48 bar (7 lbf/in2) 80 - 85 °C (176 - 185 °F) 98 °C (209 °F)

0.48 bar (7 lbf/in2) 80 - 85 °C (176 - 185 °F) 98 °C (209 °F)

Fuel System Injection Pump Type Governing Pump Setting Code Static Timing Injector Code Injector Setting Pressure Induction System Air Cleaner Type Maximum Restriction (at which warning light operates) Lubrication System Oil Pump Type Oil Pressure (hot) at maximum speed Cooling System Coolant Pressure Coolant Temperature (normal) Temperature Warning Light operates at

Note: For further details of the engine refer to Engine Service Manual 9806/2140.

9804/1103

70 - 05 - 05/2

Issue 2*

CONTENTS

Skidsteer Range

70 - 05 - 06/1

*From m/c no. 680001 to 681290

ROBOT 160,170, 170HF Data - Engine Type Bore (nominal) Stroke Swept Volume Compression Ratio Injection Sequence Valve Clearance - Cold - Inlet and Exhaust Oil Pressure Speeds Robot 160 Rated Speed Idling Speed Robot 170 Rated Speed Idling Speed

4 cylinder in-line, compression ignition, naturally aspirated. 84 mm (3.31 in) 100 mm (3.94 in) 2216 cm3 (135.2 in3) 22 : 1 1,3,4,2 0.2 mm (0.0078 in) 2.6 - 3.5 bar (38 - 52 lbf/in2)

2600 rev/min 890 - 910 rev/min 2800 rev/min 850 - 950 rev/min

Fuel System Governing Static Timing Injector Codes Injector Setting Pressure

Mechanical 19° BTDC 105148-1170 147 bar (2133 lbf/in2)

Cooling System Fan Type Coolant Pressure Thermostat operating temperature Temperature Warning Light operates at

Mechanical 1 bar (14.5 lbf/in2) 82 - 94 °C (180 - 200 °F) 97 - 103 °C (207 - 217 °F)

Note: If at anytime during the life of a machine it is necessary to fit a new engine, then after the first 50 operating hours a new engine oil filter must be fitted and the engine oil changed. Failure to complete this could damage the engine. Note: Should further details be required, refer to Engine Service Manual 9806/2100.

9804/1103

70 - 05 - 06/1

8520-K/1-1.2

Issue 2*

CONTENTS

Skidsteer Range From m/c no. 681291

ROBOT 160, 170, 170H Data - Engine Type Bore (nominal) Stroke Swept Volume Compression Ratio Injection Sequence Valve Clearance - Cold - Inlet and Exhaust Oil Pressure Speeds Robot 160 Rated Speed Idling Speed Robot 170 Rated Speed Idling Speed

400 Series 4 cylinder in-line, compression ignition, naturally aspirated. 84 mm (3.31 in) 100 mm (3.94 in) 2216 cm3 (135.2 in3) 23.3 : 1 1,3,4,2 0.2 mm (0.0078 in) 1 bar (15 lbf/in2) min

2600 rev/min 900 ±25 rev/min 2800 rev/min 900 ±25 rev/min

Fuel System Governing Static Timing Injector Codes Injector Setting Pressure

Mechanical 19° - 21° BTDC 131 406 360 147 bar (2133 lbf/in2)

Cooling System Fan Type Coolant Pressure Thermostat operating temperature - opens at: - fully open at: Temperature Warning Light operates at

Mechanical 1 bar (14.5 lbf/in2) 82 °C (180 °F) 95 °C (202 °F) 97 - 103 °C (207 - 217 °F)

Note: If at anytime during the life of a machine it is necessary to fit a new engine, then after the first 50 operating hours a new engine oil filter must be fitted and the engine oil changed. Failure to complete this could damage the engine. Note: Should further details be required, refer to Engine Service Manual 9806/2190.

9804/1103

70 - 05 - 06/2

8520 - K/1 - 2.1

Issue 1

CONTENTS CONTENTS

Skidsteer Range

70 - 15 - 01/1

From m/c no. 675001 to 675357

ROBOT 150,165 Circuit Diagrams - Electrical Lamps

Main Components Option 1 2 3 4 5 6 7 8 8A 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 Glow Plugs Glow Plugs Glow Plugs Glow Plugs Pre-heat Timer Relay Starter Switch Starter Solenoid Starter Motor Interior Light Switch Auxiliary Neutral Start Relay Front Work Light Switch Rear Work Light Switch Beacon Interlock Relay Brake Switch Brake Solenoid on Pressure Reducing Operational Solenoid Solenoid Valve Door Switch Restraint Switch Auxiliary Attachments Control Switch Auxiliary Attachments Detent Switch Auxiliary Hydraulics - Forward Solenoid Auxiliary Hydraulics - Reverse Solenoid High-flow Hydraulics Switch High-flow Hydraulics Solenoid Valve Warning Buzzer Alternator Hourmeter Diodes Engine Oil Pressure Switch Engine Water Temperature Switch Air Cleaner Warning Switch Low Fuel Warning Switch Charge Pump Pressure Switch Hydraulic Oil Temperature Switch Engine Shut Off Solenoid Horn Push Horn Low Water Float Switch Later Machines only Low Water E.C.U. Flasher Relay Indicator Switch Side Lights Switch Rear Wash/Wipe Switch Rear Wash/Wipe Motor Windscreen Wiper Switch Windscreen Wiper Motor Windscreen Washer Motor Switch Windscreen Washer Motor Heater Blower Switch Heater Blower Resistor Heater Blower Motor Reverse Alarm Switch 1 Reverse Alarm Switch 2 Reverse Alarm Buzzer Brake Light Pressure Switches

9804/1103

1 1 1 1 1 1 1 1 1 3 1 3 3 3 1 1 1 1 1 1 1 1 1 1 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3/4 3/4 3/4 4 4 2 2 2 2 2 2 2 3 3 3 4

Option 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

Pre-heat Warning Interior Light Right Hand Front Work Light Left Hand Front Work Light Work Light Switches Illumination (Front) Rear Work Light Work Light Switches Illumination (Rear) Beacon Lamp Brake Switch Illumination Auxiliary Attachments Detent Switch Illumination Alternator Warning Oil Pressure Warning Water Temperature Warning Air Cleaner Warning Low Fuel Warning Charge Pump Pressure Hydraulic Oil Temperature Warning Indicator Repeater Left Hand Indicator (Front) Left Hand Indicator (Rear) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Sidelight (Rear) Right Hand Side Light (Rear) Left Hand Side Light (Front) Right Hand Side Light (Front) Number Plate Side Light Warning Left Hand Dip Beam Right Hand Dip Beam Left Hand Brake Light Right Hand Brake Light

1 3 3 3 3 3 3 3 1 1 1 1 1 1 1 1 1 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 4 3/4 3/4 3/4 4 4

Fuses 110 111 112 113 114 115 116 117 118

Interior/Front Work Lights Beacon/Rear Work Light Pressure Reducing Solenoid Valve Auxiliary Hydraulics ESOS/Warning Lights and Buzzer Horn, Low Water ECU Indicators/Dip/Sidelights and Number Plate Wipers and Washer Heater/Blower plus Reverse Alarm

3 3 1 1 1 1 3/4 2 2 3

Note: See pages 70-05-01/1 for bulb ratings and page 70-05-01/2 for fuse ratings.

Equipment Options Standard Cab Standard Optional Homologation

70 - 15 - 01/1

1 2 3 4

Issue 2

26

9804/1103

70 - 15 - 01/2

113 29 29

114

40

42

87 45

75 99

86 98

97 48

46

116

421

96

422

94

812

38

811

92

810

407

420

807

620

618

616

637

622

615

614

613

604

609

629

610

628

93

809

M

426

417

416

411

409

605

91

8

90 826

639

402

403

641

635

640

631

632 633

634

612

603

602

600

601

611

626

642

608

ROBOT 150,165

50 18

29 12

41

815

818

805

88

824

39 425

27

813

37

29

85

28

406

83

15

424

419

84

207

418

81

414

413

G

82

34

13

29

32 33

89

27

26 415

80 31

209

6

20

401

29

408

7

3

839

29

404

836

21

11

14 400

18 837

838

16 17 24

30

9

112

79 28

412

29

23

401

15 835

77 21

29 22

25

405

111 829

29

832

12 831

13

19

39

110 78

25

11 830

76

834

22

74 803

71

23

+

804

802

800

70

206

6 827

9 801

8A

202

205

EARTH SPLICES 606, 623, 624, 625

72

24

10 200

203

410

8

201

204

208

73

5

4

7 20

204

30

16

17

1

42

3

1

607

2 3 4 5

14

14

2

10

-

CONTENTS CONTENTS

Skidsteer Range 70 - 15 - 01/2

From m/c no. 675001 to 675357

Circuit Diagrams - Electrical

95 100

35 36

49

54

43

117

53

101

47 52 55

56

44 51

56

29

118

115

A167872

Issue 2

Skidsteer Range

CONTENTS CONTENTS

70 - 15 - 01/3

From m/c no. 675358

ROBOT 150,165 Circuit Diagrams - Electrical

615 812

803

422

39

38

18

53

58 59

6

15

121

120

11

115

117

118

119

9

5

116

9804/1103

14

14

26

4

2

114

27

34

25

873

13

15 209

15

209

15

54

8

12

811

45

810

827

52

44 201

421

809

801 854

55

46

42

642

210

49

418

414

56

M

855 857

858

40 852

29

28

406

419

415

424

204

26 20

99

42

43

413

401

24

200

22

425

37

853

36

42

3

41

425

88

15

11 113

4

856

639 805

86

50

47 100

401

7 400

836

837

832

84

614 800

407

420

417

426

83

412

201

204

835

203 32

834

23

206

824

205

208

12

16 1 10

416

402

15

15

5

89 90

408

80

9

87

25

3

110

411

409

403 G

839

838

21

404

77

85

60

93

91

3

112

405

607

111

10

878

78

211

+

829

8

79 830

848

410 17

6

23 15

15

13 14 847

71

20

19

15

15

849

70 1

76

74

831

72

48

101

51

35 7

98

97

804

2

-

96

34

31

33

57

802

32

95

602

609

629

610

30 31

94

616

29

28

27

82

17

16

24

92

637

850

851

81

628

605 641

635

640

632 633

634

612

611

626

642

608

18 75

73

70 - 15 - 01/3

A206390

Issue 1

CONTENTS

Skidsteer Range *

ROBOT 150,165

From m/c no. 675358 to 677000

Circuit Diagrams - Electrical Main Components

Lamps Option

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 Glow Plugs Pre-heat Timer Relay Starter Switch Auxiliary Neutral Start Relay Starter Solenoid Starter Motor Interior Light Switch Side Lights Switch Beacon Interlock Relay Brake Switch Brake Solenoid on Pressure Reducing Operational Solenoid Solenoid Valve Diodes Restraint Switch Door Switch Sequence E.C.U. (See Note 2) Auxiliary Hydraulics - Forward Solenoid Auxiliary Hydraulics - Reverse Solenoid Auxiliary Attachments Detent Switch Auxiliary Attachments Control Switch High-flow Hydraulics Switch High-flow Hydraulics Solenoid Valve Alternator Warning Buzzer Hourmeter Engine Oil Pressure Switch Engine Water Temperature Switch Air Cleaner Warning Switch Low Fuel Warning Switch Charge Pump Pressure Switch Hydraulic Oil Temperature Switch Engine Shut Off Solenoid Horn Horn Push Low Water Float Switch Low Water E.C.U. Hazard Warning Switch Flasher Relay Indicator Switch Brake Light Pressure Switches Front Work Light Switch Rear Work Light Switch Windscreen Wiper Switch Rear Wash/Wipe Switch Rear Wash/Wipe Motor Windscreen Wiper Motor Windscreen Washer Motor Switch Windscreen Washer Motor Heater Blower Motor Heater Blower Resistor Heater Blower Switch Reverse Alarm Switch 1 Reverse Alarm Switch 2 Reverse Alarm Buzzer Float Solenoid Float Switch Heated Seat Switch Heated Seat

9804/1103

1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

Option 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

Pre-heat Warning Interior Light Left Hand Side Light (Rear) Right Hand Side Light (Rear) Left Hand Side Light (Front) Right Hand Side Light (Front) Number Plate Side Light Warning Left Hand Dip Beam Right Hand Dip Beam Beacon Lamp Brake Switch Illumination Auxiliary Attachments Detent Switch Illumination Alternator Warning Oil Pressure Warning Water Temperature Warning Air Cleaner Warning Low Fuel Warning Charge Pump Pressure Hydraulic Oil Temperature Warning Indicator Repeater Left Hand Indicator (Front) Left Hand Indicator (Rear) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Right Hand Front Work Light Left Hand Front Work Light Work Light Switches Illumination (Front) Rear Work Light Work Light Switches Illumination (Rear)

1 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 1 1 1 2 2

Fuses 110 111 112 * 113 114 115 116 117 118 119 120 121

Interior/Headlights/Sidelights and Number Plate Left Hand Sidelights Right Hand Sidelights Beacon/Sequence E.C.U. (See Note 2) Pressure Reducing Solenoid Valve Auxiliary Hydraulics ESOS/Warning Lights & Buzzer/Float/High Flow Horn/Low Water ECU/Front Work Lights Indicators Rear Work Lights/Hazard Warning Wipers and Washers Heater/Blower/Reverse Alarm

* Note: For fuse ratings see pages 70-05-01/2. For bulb ratings see page 70-05-01/1. * Note 2: The Sequence E.C.U. was deleted from machines manufactured after May 1996.

Equipment Options Standard Optional

70 - 15 - 01/4

1 2 Issue 2*

CONTENTS

Skidsteer Range From m/c no. 677001

ROBOT 150,165 Basic Canopy - Servo Controls Circuit Diagrams - Electrical Main Components

Lamps Option

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

Battery Starter Solenoid Starter Motor Auxiliary Neutral Start Relay Starter Switch Glow Plug Relay Glow Plugs Beacon Motor Front Work Light Switch Rear Work Light Switch Reverse Alarm Switches Reverse Alarm Buzzer Operational Solenoid Brake Solenoid Brake Switch Interlock Relay Door Switch Restraint Switch High-Flow Hydraulics Solenoid Valve High-Flow Hydraulics Switch Warning Buzzer Alternator Hourmeter Charge Pump Pressure Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Engine Water Temperature Switch Air Cleaner Warning Switch Low Fuel Warning Switch Engine Shut Off Solenoid Float Solenoid Pressure Switch Latching Relay Float Switch Horn Push Horn Engine Earth

9804/1103

1 1 1 1 1 1 1 0 0 0 0 0 1 1 1 1 1 1 0 0 1 1 1 1 1 1 1 1 1 1 0 0 0 0 1 1 1

Option 60 61 62 63 64 65 66 67 68 69 70

Beacon Lamp Interior Light Front Work Lights Rear Work Light Alternator Warning Charge Pump Pressure Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Water Temperature Warning Air Cleaner Warning Low Fuel Warning

0 0 0 0 1 1 1 1 1 1 1

Note: For fuse ratings see pages 70-05-01/2. For bulb ratings see page 70-05-01/1.

Equipment Options Standard Optional

70 - 15 - 01/5

1 0

Issue 1

9804/1103

5 INTERLOCK RELAY

70 - 15 - 01/6 9 10

8 11 15

18

6 61

16 23 24

21 64

25

65

26

66

28

67 29

17

68 69

FLOAT SOLENOID

19 27

30

20

11 70 33

34

STANDARD

LATCHING RELAY

14 RESTRAINT SWITCH

7 31

22 ENGINE EARTH

PRESS. SWITCH

63 13

DOOR SWITCH

62 12

BRAKE SWITCH

60

REAR WORK LIGHT

3

FRONT WORK LIGHT SWITCH

GLOW PLUG RELAY

HORN

FLOAT SOLENOID

E.S.O.S..

LOW FUEL

AIR CLEANER

WATER TEMP. SWITCH

ENGINE OIL PRESSURE

HYDRAULIC OIL TEMP.

CHARGE PUMP PRESSURE

ALTERNATOR FAILURE

HOURMETER

ALTERNATOR

HIGH FLOW SOLENOID

DOOR/RESTRAINT SWITCH

BRAKE SOLENOID

OPERATIONAL SOLENOID

REVERSE ALARM

WORK LIGHT WARNING

REAR WORK LIGHT

FRONT WORK LIGHTS

INTERIOR LIGHT

BEACON

GLOW PLUGS

AUX. NEUTRAL START RELAY

STARTER MOTOR

STARTER SOLENOID

ROBOT 150,165 Basic Canopy - Servo Controls

FLOAT SWITCH

4 STARTER SWITCH

1 START SOLENOID

2

AUX/NEUTRAL START RELAY

BATTERY

CONTENTS

Skidsteer Range From m/c no. 677001

Circuit Diagrams - Electrical

37

32 36

35

EQUIPMENT OPTIONS

OPTIONAL

246/90901

Issue 1

CONTENTS

Skidsteer Range From m/c no. 677001

ROBOT 150,165 Cab & Options - Servo Controls Circuit Diagrams - Electrical Main Components

Lamps Option

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Battery Starter Solenoid Starter Motor Auxiliary Neutral Start Relay Starter Switch Glow Plug Relay Glow Plugs Road Light Switch Beacon Motor Brake Switch Interlock Relay Operational Solenoid Brake Solenoid Restraint Switch Door Switch High-Flow Hydraulics Solenoid Valve High-Flow Hydraulics Switch

1 1 1 1 1 1 1 0Y 0Y 1 1 1 1 1 1 0Y 0Y

Option 70 71 72 73 74 75 76 77 78 79 80

Interior Light L.H. Dip Beam (Italian) R.H. Dip Beam (Italian) L.H. Dip Beam (German) R.H. Dip Beam (German) L.H. Rear Light No. Plate Light L.H. Side Light R.H. Rear Light R.H. Side Light Beacon Lamp

1Y 0Y 0Y 0Y 0Y 0Y 0Y 0Y 0Y 0Y 0Y

Note: For fuse ratings see page 70-05-01/2. For bulb ratings see page 70-05-01/1.

Equipment Options Standard Optional Cab Optional Canopy

9804/1103

70 - 15 - 01/7

1 0 Y

Issue 1

BATTERY

9804/1103

4

70 - 15 - 01/8 5

71

73

8

76

75 79

72 78

77

6 9 DOOR SWITCH

70 74

INTERLOCK RELAY

GLOW PLUG RELAY

3

ROAD LIGHT SWITCH

STARTER SWITCH

1

AUX/NEUTRAL START RELAY

2 START SOLENOID

7 14

12 13

80

EQUIPMENT OPTIONS

RESTRAINT SWITCH

GERMAN

ITALIAN

HIGH FLOW SOLENOID

DOOR/RESTRAINT SWITCH

BRAKE SOLENOID

OPERATIONAL SOLENOID

BEACON

RH SIDE LIGHT

RH TAIL LIGHT

LH SIDE LIGHT

NO. PLATE LIGHT

LH TAIL LIGHT

RH DIP BEAM

LH DIP BEAM

RH DIP BEAM

LH DIP BEAM

INTERIOR LIGHT

GLOW PLUGS

AUX. NEUTRAL START RELAY

STARTER MOTOR

STARTER SOLENOID

CONTENTS

Skidsteer Range

ROBOT 150,165 Cab and Options - Servo Controls From m/c no. 677001

Circuit Diagrams - Electrical

16

15 17

10

11

STANDARD

OPTIONS CAB 246/91001 1 OF 2

OPTIONS CANOPY

Issue 1

9804/1103

4 8 9

7

70 - 15 - 01/9 10 11

13

11 15 21

14 27

19 22

23

24

44 45

25

46

26

47

28

48

STANDARD

49

29

17

50

20 30

34

ENGINE EARTH

FLOAT SOLENOID

600JR

600JS

HORN

FLOAT SOLENOID

E.S.O.S..

LOW FUEL

AIR CLEANER

WATER TEMP. SWITCH

ENGINE OIL PRESSURE

HYDRAULIC OIL TEMP.

CHARGE PUMP PRESSURE

ALTERNATOR FAILURE

ALTERNATOR

HOURMETER

HIGH FLOW SOLENOID

DOOR/RESTRAINT SWITCHES

BRAKE SOLENOID

LIFT CUTOUT SWITCHES

REVERSE ALARM

WORK LIGHT WARNING

REAR WORK LIGHT

FRONT WORK LIGHTS

INTERIOR LIGHT

BEACON

ROBOT 150,165 Basic Canopy - Manual Controls

16 33 LATCHING RELAY

18

PRESS. SWITCH

23C

43 12

BRAKE SWITCH

41 23B

42

23A

40

REAR WORK LIGHT SW.

3

FRONT WORK LIGHT SW.

5

INTERLOCK RELAY

6 GLOW PLUG RELAY

GLOW PLUGS

AUX. NEUTRAL START RELAY

STARTER MOTOR

STARTER SOLENOID

Skidsteer Range

FLOAT SWITCH

BUZZER

aa STARTER SWITCH

1 STARTER SOLENOID

2

AUX/NEUTRAL/ST. RELAY

BATTERY

CONTENTS

Skidsteer Range From m/c no. 677001

Circuit Diagrams - Electrical

31

32 35

37

36

EQUIPMENT OPTIONS 246/91401

OPTIONAL

Issue 1

CONTENTS

Skidsteer Range From m/c no. 677001

ROBOT 150,165 Basic Canopy - Manual Controls Circuit Diagrams - Electrical Main Components

Lamps Option

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

Battery Starter Solenoid Starter Motor Auxiliary Neutral Start Relay Glow Plugs Glow Plug Relay Starter Switch Beacon Motor Front Work Light Switch Rear Work Light Switch Reverse Alarm Switches Reverse Alarm Buzzer Lift Cutout Switches Brake Solenoid Brake Switch Interlock Relay Door Switch Restraint Switch High-Flow Hydraulics Solenoid Valve High-Flow Hydraulics Switch Hourmeter Alternator Warning Buzzer Charge Pump Pressure Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Engine Water Temperature Switch Air Cleaner Warning Switch Low Fuel Warning Switch Engine Shut Off Solenoid Float Solenoid Pressure Switch Latching Relay Float Switch Horn Horn Push Engine Earth

9804/1103

1 1 1 1 1 1 1 0 0 0 0 0 1 1 1 1 1 1 0 0 1 1 1 1 1 1 1 1 1 1 0 0 0 0 1 1 1

Option 40 41 42 43 44 45 46 47 48 49 50

Beacon Lamp Interior Light Front Work Lights Rear Work Light Alternator Warning Charge Pump Pressure Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Water Temperature Warning Air Cleaner Warning Low Fuel Warning

0 0 0 0 1 1 1 1 1 1 1

Note: Link wire aa is not used when High-Flow circuit is fitted. Note: For fuse ratings see page 70-05-01/2. For bulb ratings see page 70-05-01/1.

Equipment Options Standard Optional

70 - 15 - 01/10

1 0

Issue 1

CONTENTS

Skidsteer Range From m/c no. 677001

ROBOT 150,165 Cab & Options - Manual Controls Circuit Diagrams - Electrical Main Components

Lamps Option

1 2 3 4 5 6 7 8 9 10 11 11A 12 13 14 15 16 17 18 19

Battery Starter Solenoid Starter Motor Auxiliary Neutral Start Relay Starter Switch Glow Plug Relay Glow Plugs Road Light Switch Beacon Motor Lift Cutout Switches Brake Switch Brake Solenoid Interlock Relay Door Switch Restraint Switch Heated Seat Heated Seat Switch High-Flow Hydraulics Solenoid Valve High-Flow Hydraulics Switch Engine Shut Off Relay

1 1 1 1 1 1 1 0Y 0Y 1 1 1 1 1 1 0 0 0Y 0Y 1

Option 60 61 62 63 64 65 66 67 68 69 70

Interior Light L.H. Dip Beam (Italian) R.H. Dip Beam (Italian) L.H. Dip Beam (German) R.H. Dip Beam (German) L.H. Rear Light No. Plate Light L.H. Side Light R.H. Rear Light R.H. Side Light Beacon Lamp

1Y 0Y 0Y 0Y 0Y 0Y 0Y 0Y 0Y 0Y 0Y

Note: Link wire aa is not used when High-Flow circuit is fitted. Note: For fuse ratings see page 70-05-01/2. For bulb ratings see page 70-05-01/1.

Equipment Options Standard Optional Cab Optional Canopy

9804/1103

70 - 15 - 01/11

1 0 Y

Issue 1

aa 4

9804/1103

70 - 15 - 01/12 62 68

63 65

5 8 69 70 11A

67 9

11 14

600JR

600JS

RESTRAINT SWITCH

DOOR SWITCH

10

16

12

EQUIPMENT OPTIONS

HEATED SEAT SWITCH

61 66

BRAKE SWITCH

64 23C

60 23B

7

INTERLOCK RELAY

23A

6 GLOW PLUG RELAY

3

ROADLIGHT SWITCH

STARTER SWITCH

1 STARTER SOLENOID

2

AUX/NEUTRAL/ST. RELAY

BATTERY

GERMAN

ITALIAN

15

OPTIONS CAB

E.S.O.S. RELAY

HIGH FLOW SOLENOID

HEATED SEAT

DOOR/RESTRAINT SWITCH

BRAKE SOLENOID

LIFT CUTOUT SWITCHES

BEACON

RH SIDE LIGHT

RH TAIL LIGHT

LH SIDE LIGHT

NO. PLATE LIGHT

LH TAIL LIGHT

RH DIP BEAM

LH DIP BEAM

RH DIP BEAM

LH DIP BEAM

INTERIOR LIGHT

GLOW PLUGS

AUX. NEUTRAL START RELAY

STARTER MOTOR

STARTER SOLENOID

CONTENTS

Skidsteer Range

ROBOT 150,165 Cab and Options - Manual Controls From m/c no. 677001

Circuit Diagrams - Electrical

17

13 18

19

STANDARD 246/91501 1 OF 2

OPTIONS CANOPY

Issue 1

9804/1103 1

70 - 15 - 03/1

310A 310B 310D

8520-C/4-2.4

5

80A

810A

830L 5 2

8

138

135 4

139

6

A

310L

2

001A 4

3

2

310E

53

6 +8

139

102

10 SEC. TIMER

53

3

5

864 4

1

53

53

2

1 4

893

877E

806C

600DH

103C

600JF

600ED

103F

REAR WIPER MOTOR 600BK

600EF 600BD

816E

816D

WASHER MOTOR

816

600CU

600GR

600BG

600HE

600CD

-7

+8

140

600LV

600LW

600H

600G

600MJ

600AW

600JF

600GR

600W

600CU

600H

600G

600DX 600LA 600BL

600G

600AV

600H

600DW

600AJ

600AP

600DY

600GZ

600EY

600HZ

600BH

600EB

600DE

600AK FRONT WIPER MOTOR

BRAKE LIGHT TIMER RELAY

914

2

127D

3

869A

805E 805C

834A

834B

829E

WASHER MOTOR

5

141

49

57

106AM

1

127C

M

10 SEC. TIMER

5A

1 3

50 863

829C 829D

903

600HD

600LX

600AY

600AS

600AR

600CJ

X

600CS

600CF

X

600JT

X

SPOOL LOCK SOLENOID 1

SELF LEVEL SOLENOID

SELF LEVEL SWITCH ILLUM.

RH BRAKE LIGHT

LH BRAKE LIGHT

BRAKE LIGHT TIMER RELAY

BRAKE LIGHT TIMER UNIT

FRONT AND REAR WASH WIPE

HEATER MOTOR

HI-FLOW HYDRAULICS

RH FRONT INDICATOR RH REAR INDICATOR

FLASHER UNIT LH FRONT INDICATOR LH REAR INDICATOR

HAZARD SWITCH ILLUM.

LH DIP BEAM RH DIP BEAM

LH TAIL LIGHT LH SIDE LIGHT

ROADLIGHT SWITCH RH SIDE LIGHT RH TAIL LIGHT No. PLATE LIGHT

INTERIOR LIGHT

BEACON

BEACON SWITCH ILLUM.

FRONT HORN

FLOAT SOLENOID

REVERSE ALARM

REAR WORKLIGHT

LH FRONT WORKLIGHT

RH FRONT WORKLIGHT

FRONT WORKLIGHT SWITCH

E.S.O.S.

CHARGE PUMP PRESS. SWITCH

AIR FILTER SWITCH

ENGINE OIL PRESS. SWITCH

HYD. OIL TEMP. SWITCH

COOLANT TEMP. SWITCH

ALTERNATOR

HOURMETER

FUEL GAUGE FUEL GAUGE ILLUMINATION

FUEL SENDER

JUNCTION BOX

LOADER CUT OFF SWITCH (GERMAN AND ITALIAN ONLY)

RESTRAINT SWITCH

SPOOL LOCK SOLENOID 2

Skidsteer Range

FUSE B9

10

3

BRAKE SWITCHES

+8

2

M

816L

-7 2

127B

4

51

5A

6

862

841

106H

FAST

830B 830D

806E

800JD

877

HEATER RESISTOR

840

839

805B

600DD

46

103F

2

1

REAR WASH WIPE SWITCH

806B

834

829

830

415

402

403

414

406

X

600HS

600JA 600HT

600CE

600CC

600HB

600CL

600CP

PARK BRAKE LIGHT (Italian only)

NEUTRAL START RELAY

STARTER SOLENOID

STARTER MOTOR

GLOW PLUGS

ROBOT 160, 170, 170HF

FUSE B8

HI-FLOW SWITCH

47 864

5

103B

1

106P

1 3

3

106H

5

M

M

600G

137

5 10

2

48

600H

43

1

103C

2

FRONT WASH WIPE SWITCH

2

841

42 -7

106P

+10

6

4

10A

2

4

103

1

3

103

-7 1

SLOW

800B

902

HORN SWITCH

INDICATOR SWITCH

44

FUSE B7

2

800

877C

HEATER SWITCH

6

102

3

102

106R

-7 1

LATCHING RELAY

5

10A

2

106R

874

877B

40

600AW

136

129

106AK

877A +8

129

810A

803A

5A

5A FUSE B2

4

3 M

816E

2 +8

1

45

816D

5 6 3 4 7 8 9

38

17

2

FUSE B6

3

18

106AK

5 17

39

5A

1

2

FUSE B5

2

002

133

-10

805

37 803

870

901A

LATCHING RELAY 871

FUSE B1

1

810A

5 31 49a 49

803A

FLASHER UNIT

142A

LINK WHEN ROADLIGHTS ARE NOT FITTED

10 2

806P

2

HAZARD SWITCH

1

98 41

816

855C

2

132

106F

8+

6

300

35

-7 6 +3

101

IGN. RELAY

STARTER SWITCH

36

828

807B

861

92 94 96

FUSE B10

2

+3

802

1

-7

104

2

BEACON SWITCH

10A

3

131

ROADLIGHT SWITCH

17

828M

855C

855B

855A

900B 902A PRESSURE SWITCH

90

FUSE B4

+8

830L

894

407

408

100

310L

15/54 17 50 19

5A

129

-7

106B

8

W

15A

6

HORN RELAY

-7

33

138

900C

10

89

310P

31

106K

901

32

303A

2

7

M

310L

123 FUSE B3

128

9

312A

1

30

303B

106N

+8

901B

5 5

312B

3 4 6

600LX

900

FLOAT SWITCH

434B

29

303

REVERSE SWITCHES 807A

900A

3

312

861

+9 1

4

1

FUSE A10

127 142A

2

142

106AN

855

25

-10 2

2

34

10A

126

26

FUSE A8

117

1

26

5A

125

127

5

116

6

18 99

869A

3 +3

5A

2

106M

105

434

FUSE A7

8+

27

91 93 95 97

816L

30A

87

10A

124

FUSE A6

80 81 82 83 84 85 855C

AIR FILTER CHARGE PUMP PRESS.

-7

15A

106AF

ENGINE OIL PRESS.

HYD. OIL TEMP.

WATER TEMP.

815C

600V

BATTERY LEAD

F RESTRAINT SWITCH

24

FUSE A5

5A

FUSE A4

122 106AE

BUZZER

18

106AD

14 ALTERNATOR

17

106AC

1 3

411

407A

8

106AB

106AA

13 HOURMETER

5 2

106C

5

106D

FUEL GAUGE

1

415A 403C 414A 406A

88

FUSE A9

5A

121 6

106

3

830L

815B

10

5A

FUSE A3

1 2

101

5 +3

10A

4 2

7 SPOOL LOCK RELAY

815

810

X

FUSE A2

6 Y 865

10a DIODE PACK

86 28

BRAKE SWITCHES

4 -7

11

200 200A

001B

6

122B

122A

8

122

4

10A

2

FUSE A1

810

3 12 21 22 23

127B

30A

810A

842

5 9 19 20

001A

30 1 2 5

310G

120 001A

004

NEUTRAL START RELAY

BATTERY LEAD

BATTERY

1

310L

001B

003E

79 15 16

5A

127C

60A

301B

301A

START PRE HEAT IGN OFF

4

FUSE B8

PRIMARY FUSE BOX

CONTENTS

70 - 15 - 03/1

Up to m/c no. 681290

Circuit Diagrams - Electrical

102 103

54

52 2

1 2

1 3

Z

2

SELF LEVEL SWITCH

55

106S

134

130

56 103

40A 2

1

52

321202

Issue 1

CONTENTS

Skidsteer Range

70 - 15 - 03/2

Up to m/c no. 681290

ROBOT 160,170, 170HF Circuit Diagrams - Electrical (cont’d) Main Components

Lamps

1 2 3 4 5 6 7 8 9 10 10a 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

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

Park Brake Warning (Italian only) Alternator Warning Water Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Cleaner Warning Charge Pump Pressure Right hand Front Worklight Left hand Front Worklight Rear Worklight Beacon Lamp Interior Light Right Hand Side Light Right Hand Tail Light Number Plate Light Left Hand Tail Light Left Hand Side Light Left Hand Dip Beam Right Hand Dip Beam Left Hand Indicator (Front) Left Hand Indicator (Rear) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light

W X Y Z

Link when road lights are not fitted Link Wire (except German and Italian) Wire fitted up to machine no. 680076 except High-flow Wire 893 was connected to terminal 3 of switch 55 up to machine no. 680077.

Battery Starter Switch Glow Plugs Starter Motor Starter Solenoid Neutral Start Relay Spool Lock Relay Spool Lock Solenoid 1 Spool Lock Solenoid 2 Restraint Switch Loader Cut Off Switch (German and Italian only) Junction Box Fuel Gauge Sender Fuel Gauge Hourmeter Alternator Diode Pack Diode Warning Buzzer Engine Water Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Cleaner Warning Switch Charge Pump Pressure Switch Engine Shut Off Solenoid Work Light Switch Reverse Switches Reverse Alarm Float Solenoid Pressure Switch Latching Relay Float Switch Horn Relay Horn Switch Front Horn Beacon Switch Road Lights Switch Flasher Unit Hazard Switch Indicator Switch Latching Relay High-Flow Hydraulics Solenoid Valve High-Flow Hydraulics Switch Heater Blower Switch Heater Blower Resistor Heater Blower Motor Front Wiper Motor Front Wash/Wipe Switch Front Washer Motor Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Motor 10 Second Timer Brake Light Switches Self Level Solenoid Self Level Switch Ignition Relay Brake Light Timer Relay (from July 2000 on)

Fuses 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140

Note 1: Diagram A shows brake light timer circuit prior to July 2000 9804/1103

Primary Fuse Box (On Battery) Spool Lock, Restraint Switch, Cut-off Solenoid (Servo) Junction Box Ignition Circuits ESOS Front Work Lights Rear Work Light Reverse Alarm Float Circuit Horn Beacon, Interior Light Right Hand Side and Tail Lights Left Hand Side and Tail Lights, Number Plate Light Head Light Dip Beam Indicators Hazard Warning High Flow Hydraulics Heater Blower Wipers and Washers Brake Lights Self Level Circuit

Note 2: For fuse ratings see page70-05-01/5. For bulb ratings see page 70-05-01/1.

70 - 15 - 03/2

8520 - C/4-1.4

Issue 1

CONTENTS

Skidsteer Range

70 - 15 - 03/4

From m/c no. 681291

ROBOT 160,170, 170HF Circuit Diagrams - Electrical (cont’d) Main Components

Lamps

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

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

Park Brake Warning (Italian only) Alternator Warning Water Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Cleaner Warning Charge Pump Pressure Right hand Front Worklight Left hand Front Worklight Rear Worklight Beacon Lamp Interior Light Right Hand Side Light Right Hand Tail Light Number Plate Light Left Hand Tail Light Left Hand Side Light Left Hand Dip Beam Right Hand Dip Beam Left Hand Indicator (Front) Left Hand Indicator (Rear) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light

W X

Link when road lights are not fitted Link Wire (except German and Italian)

Battery Starter Switch Glow Plugs Starter Motor Starter Solenoid Neutral Start Relay Spool Lock Relay Spool Lock Solenoid 1 Spool Lock Solenoid 2 Loader Cut Off Switch (German and Italian only) Restraint Switch Junction Box Fuel Gauge Sender Fuel Gauge Hourmeter Alternator Diode Pack Diode Warning Buzzer Engine Water Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Cleaner Warning Switch Charge Pump Pressure Switch Engine Shut Off Solenoid Work Light Switch Reverse Switches Reverse Alarm Float Solenoid Pressure Switch Latching Relay Float Switch Horn Relay Horn Switch Front Horn Beacon Switch Road Lights Switch Flasher Unit Hazard Switch Indicator Switch High-Flow Hydraulics Solenoid Valve High-Flow Hydraulics Switch Heater Blower Switch Heater Blower Resistor Heater Blower Motor Front Wiper Motor Front Washer Motor Front Wash/Wipe Switch 10 Second Timer Brake Light Switches Brake Light Timer Relay Self Level Solenoid Self Level Switch Ignition Relay

Fuses 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140

Primary Fuse Box (On Battery) Spool Lock, Restraint Switch, Cut-off Solenoid (Servo) Junction Box Ignition Circuits ESOS Front Work Lights Rear Work Light Reverse Alarm Float Circuit Horn Beacon, Interior Light Right Hand Side and Tail Lights Left Hand Side and Tail Lights, Number Plate Light Head Light Dip Beam Indicators Hazard Warning High Flow Hydraulics Heater Blower Wipers and Washers Brake Lights Self Level Circuit

Note 2: For fuse ratings see page70-05-01/5. For bulb ratings see page 70-05-01/1.

9804/1103

70 - 15 - 03/4

8520 - C/4-4.1

Issue 1

CONTENTS * ROBOT

Skidsteer Range *

185, 1105

From m/c no. 746001 to 746216

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

Battery Thermostat Starter Motor Starter Solenoid Starter Switch Auxiliary Neutral Start Relay Front Work Light Switch Interlock Relay Parking Brake Switch Operational Solenoid Brake Solenoid Sequence Module Restraint Switch Door Switch Road Light Switch Road Light Connector (German only) Hazard Light Switch Indicator Switch Flasher Unit Windscreen Wiper Switch Windscreen Washer Pump Windscreen Wiper Motor Beacon Switch

*

Lamps 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94

*

L.H. Front Work Light R.H. Front Work Light Front L.H. Sidelight Rear L.H. Sidelight Number Plate Light Rear R.H. Sidelight Front R.H. Sidelight R.H. Dip Beam L.H. Dip Beam Interior Light L.H. Rear Indicator L.H. Front Indicator R.H. Rear Indicator R.H. Front Indicator Rotating Beacon

Fuses 110 111 112 113 114 115 116 117

Front Working Lights, Interlock Relay Beacon, Sequence Unit Interior Light, Road Lights L.H. Sidelights, Number Plate Light R.H. Sidelights Hazard Lights Wipers, Washers, Indicators Reverse Alarm, Wiper

Note: See pages 70-05-01/1 for bulb ratings and page 7005-01/4 for fuse ratings.

9804/1103

70 - 15 - 02/1

Issue 2*

Skidsteer Range

CONTENTS * ROBOT

*

185, 1105

From m/c no. 746001 to 746216

Circuit Diagrams - Electrical 1

203

2

10 15

3 1

14

5

4 32

3

6

2

646

877

80 4

215

801

110

7

802

219

608 810

803

81 20

653

9 830

24

10

634 633

829

8

11

831 401 632

13 200

21

212

213

12

218

111

216 214

878

206

208

652

22

14 82 83 851 84

850 203A

824 847

848

113 114

850

201

112

879 880 827

27 207

87

881

89

205

611

637

115

818 816

17

861

210

18

43

116 853

44

841

860

870

252

3

869 28

646

88

602

209

645 674

86

880

16

645 646

85

851 848

15

646

840

19

8

815

1 2

90 91 92 93

673 648 645 674 616

211

21

20 809

853

22 805

853

16 806 662 12 18

117

94 23 990

853

991 890 5 205 204 401

877

18

C234283

9804/1103

70 - 15 - 02/2

Issue 2*

CONTENTS CONTENTS * ROBOT

Skidsteer Range *

185, 1105

From m/c no. 746001 to 746216

Circuit Diagrams - Electrical

401

204 205

877

5 18

28 641

845 839 835

836

27

837

118

832 834

9

29

838

26

846

640

30 899

845

898

868

31

119

11

603

35

202

874 200

206 207

201

32

604

35

204 605

203 875 45

208

34

9A

39

33

205

606

601

876

36

38

36

44

39

39 863

40

890

691

41 675

42

38

37 40

41A

120

38A

864 220 6

42 655

654

41

36

39A

37

607

43 44

44 421

422

673

45 24

24 43

802

1

4

3

2

628

95

652

891

46

96

862

674

673

25 994

663 995

47 39

997

40

681

998

48

41

49 662

50 29A

803

31

121

674

804

97 827

401

45

13

51 810 811

204 205

812

52

867

615

53

845

C234292

9804/1103

70 - 15 - 02/3

Issue 2*

CONTENTS * ROBOT

Skidsteer Range *

185, 1105

From m/c no. 746001 to 746216

Circuit Diagrams - Electrical * Main 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 38A 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

Components (contÕd)

Brake Light Pressure Switches Auxiliary Ouput Plug Auxiliary Hydraulic Switch Joystick Auxiliary Hydraulic Switch Forward Solenoid Reverse Solenoid Diodes E.S.O.S. (Engine Shut Off Solenoid) Hydraulic Float Switch Hydraulic Float Pressure Switch Hydraulic Float Relay Hydraulic Float Solenoid Pressure Switches (fitted up to October 1995) 2 Speed Switch 2 Speed Relay Diode (fitted from November 1995) Pressure Switches 2 Speed Solenoid Horn Relay Horn switch Horn Pressure Switches Reverse Alarm Breka Light timer Plug High-flow Switch High-flow Solenoid Rear Work Light Switch Heater Blower Switch Resistor Heater Blower Motor Warning Buzzer Diode Gate

401

56 57 58 59 60 61 62 63 *

Lamps (contÕd) 95 96 97 98 99 100 101 102 103 104 105

*

Hydraulic Oil temperature Switch Engine Oil Pressure Switch Water Temperature Switch Air Cleaner Blocked Switch Low Fuel Switch Charge Pressure Switch Alternator Hour Meter

L.H. Brake Light R.H. Brake Light Rear Working Light Hydraulic Oil Pressure Warning Light Engine Oil Pressure Warning Light Water Temperature Warning Light Air Cleaner Blocked Warning Light Low Fuel Warning Light Charge Pressure Alternator Failure Warning Park Brake Master Warning LIght

Fuses (contÕd) 118 119 120 121

Auxiliary Hydraulics E.S.O.S., Float Solenoid, 2 Speed, High-flow 2 Speed Switch, Brake Lights, Horn Rear Work Light, Heater Blower

Note: For fuse ratings see page 70-05-01/2. For bulb ratings see page 70-05-01/1.

45 405

204 205

400

55 54

406

415

408 7

404

98

424

99 100 101

414

409

418

411

57 58 59 60

417

103

401

56

407

416

102

45

419

104

444

420

413

402

61

629 601

802 628 610 609

62

105

605 403 204 205

63 9804/1103

70 - 15 - 02/4

C234302 661

Issue 2*

CONTENTS

Skidsteer Range From m/c no. 746217

ROBOT 185, 1105 Circuit Diagrams - Electrical Main Components

Lamps

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

80 81 82 83 84 85 86 87 88 89 90

Battery Thermostart Starter Motor Neutral Start Relay Starter Switch Diodes Auxiliary Hydraulic Switch Joystick Switches Forward Solenoid (Front) Reverse Solenoid (Front) Output Plug High-flow Solenoid High-flow Switch Restraint Switch Door Switch Park Brake Switch Operational Solenoid Park brake Solenoid Front Worklight Switch Hourmeter Alternator Warning buzzer Diode Gate Hydraulic Oil Temperature Sender Engine OIl Pressure Sender Engine Water Temperature Sender Air Filter Switch Low Fuel Switch Charge Pressure Switch E.S.O.S. (Engine Shut Off Solenoid) Float Switch Pressure Switch Latching Relay Float Solenoid

9804/1103

L.H. Front Work Light R.H. Front Work Light Park Brake Warning Lights Engine Pre-heat Alternator Failure Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Water Temperature Warning Air Cleaner Blocked Warning Low Fuel Warning Charge Pressure Warning

Fuses 110 Auxiliary Hydraulics 111 Operation and Park Brake Solenoids, Front Worklights 112 E.S.O.S. Warning Lights and Buzzer, 2 Speed Switch, Float Solenoid, High-flow Solenoid, Spare Circuit Note: For fuse ratings see page 70-05-01/2. For bulb ratings see page 70-05-01/1.

70 - 15 - 02/5

Issue 1

Skidsteer Range

CONTENTS

70 - 15 - 02/6

From m/c no. 746217

ROBOT 185, 1105 Circuit Diagrams - Electrical 1

203

2

10 15

3 1

14

5

4 32

3

6

2

646

877

80 4

215

801

110

7

802

219

608 810

803

81 20

653

9 830

24

10

634 633

829

8

11

831 401 632

13 200

213

21

212

12

218

111

216 214

878

206

208

652

22

14 82 83 851 84

850 203A

824 847

848

113 114

850

201

112

879 880 827

27 207

87

881

89

205

611

637

115

818 816

17

861

210

18

43

116 853

44

841

860

870

252

3

869 28

646

88

602

209

645 674

86

880

16

645 646

85

851 848

15

646

840

19

8

815

1 2

90 91 92 93

673 648 645 674 616

211

21

20 809

853

22 805

853

16 806 662 12 18

117

94 23 990

853

991 890 5 205 204 401

877

18

C234283

9804/1103

70 - 15 - 02/6

Issue 1

CONTENTS

Skidsteer Range

70 - 15 - 02/7

From m/c no. 746217

ROBOT 185, 1105 Circuit Diagrams - Electrical

41 39

35

44 9A FUSE PE 6

40

41A

864

2 SPEED SWITCHES

3

38

113

37

863

1

2

38

36 40

802

43

220

628

4

1

39

39

10 SECOND 891 3 TIMER 2

91

862

673 674

852

41

92

42

37

4

6 36

691 675

4

5

BRAKE LIGHT SWITCHES

39A

37

890

42

655

654

1

2

43

853

637 645

93

860 INDICATOR SWITCH

HAZARD SWITCH

45

7

210

27

FUSE PH 2

207

5

43

209

1

211

8

49a 49 31

6 2

FUSE PH 1

1

10

9

841

840

46

WASH/WIPE SWITCH 2 7 9

117

200

805

51

BEACON SWITCH

52

206

5

49

47

662

10

806

422

50

421

990

97 690

10

98 99 100 101 102 103

881 827

879

6

201

2

53

FUSE PE 1 9

880

880 TO TUV ROOF FUSE PH 5 MTD DIP BEAM 824 848

3

118

203A

673

51

991 9

847

10

850 851

120

850

FUSE PH 6

849

121

851

645 646 672 673 645 674 646

104

ROADLIGHTS SWITCH

602

INTERIOR LIGHT

611

205

105 HEATER SWITCH

29A

FUSE PH 4

5

3

119

810

1

54

13

811

867 9

1

803

5

57

804 9

SLOW

FRONT HORN HORN RELAY HAZARD SWITCH ILLUM. L.H. FRONT INDICATOR L.H. REAR INDICATOR

10

R.H. FRONT INDICATOR R.H. REAR INDICATOR FLASHER UNIT WASHER MOTOR FRONT WIPER MOTOR WASH/WIPE SWITCH ILLUM.

REVERSE ALARM BEACON BEACON SWITCH ILLUM. L.H. DIP BEAM R.H. DIP BEAM NO. PLATE LIGHT L.H. TAIL LIGHT L.H. SIDE LIGHT R.H. TAIL LIGHT R.H. SIDE LIGHT ROADLIGHT SWITCH ILLUM. INTERIOR LIGHT

FAST

55

812

56

10

REAR W/LIGHT SWITCH

31

L.H. BRAKE LIGHT R.H. BRAKE LIGHT

12

672

5

1

614 609

REVERSE SWITCHES

18

FUSE PE 2

48

809

12

116

616

4

16 FUSE PH 3

646 674

861

8

29

95

818

96

FLASHER UNIT

115

BRAKE LIGHT TIMER UNIT

869

816

3

44A

5

94

815

252 44

44 114

673

870

7

10

607

3

2 SPEED RELAY 2 SPEED SOLENOID

106

615 645

674 627

HEATER MOTOR HEATER SWITCH ILLUM. REAR WORKLIGHT REAR W/LIGHT SWITCH ILLUM. 852/90103-2

9804/1103

70 - 15 - 02/7

Issue 1

CONTENTS

Skidsteer Range From m/c no. 746217

ROBOT 185, 1105 Circuit Diagrams - Electrical Main Components (contÕd)

Lamps

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106

2 Speed Switch 2 Speed Relay 2 Speed Switches 2 Speed Solenoid Brake Light Switches Brake Light Timer Horn Relay Horn Horn Switch Hazard Switch Direction Indicator Switch Flasher Unit Wash/Wipe Switch Washer Motor Front Wiper Motor Reverse Alarm Reverse Switches Beacon Switch Roadlights Switch Heater Blower Switch Resistor Heater Blower Motor Rear Worklight Switch

9804/1103

L.H. Brake Light R.H. Brake Light L.H. Front Indicator L.H. Rear Indicator R.H. Front Indicator R.H. Rear Indicator Rotating Beacon L.H. Dip Beam R.H. Dip Beam Number Plate Light L.H. Tail Light L.H. Sidelight R.H. Tail Light R.H. Sidelight Interior Light Rear Worklight

Fuses 113 114 115 116 117 118 119 120 121

70 - 15 - 02/8

2 Speed Solenoid, Brake Lights, Front Horn Wipers, Washers, Indicators Hazard Lights Reverse Alarm Beacon Roadlights, Interior Light Heater, Rear Working Light L.H. Sidelight, L.H. Tail Light, Number Plate Light R.H. Sidelight, R.H. Tail Light

Issue 1

9804/1103 1

70 - 15 - 03/1

310A 310B 310D

8520-E/4-1

5

80A

810A

830L 5 2

8

138

135 4

139

6

A

310L

49

001A 4

3

2

310E

53

6

10 SEC. TIMER

+8

139

102

53

864 4

2 3

53

53

3 1

1

893

829E

805E 805C

834A

834B

877E

806C

600DH

600JF

600JF

600ED

103C

103F

REAR WIPER MOTOR

816

816E

816D

WASHER MOTOR

600BK

600EF 600BD

600BG

-7

+8

140

600LV

600LW

600H

600G

600MJ

600AW

600GR

600W

600CU

600GR

600CU

600H

600G

600DX 600LA 600BL

600G

600AV

600H

600DW

600AJ

600AP

600DY

600GZ

600EY

600HZ

600HE

600CD

600AY

600AS

600AR

600CJ

X

600CS

600CF

X

600BH

600EB

600DE

600AK FRONT WIPER MOTOR

WASHER MOTOR

4

BRAKE LIGHT TIMER RELAY

914

863

2 2

141

FAST

5

106AM

862

839

840

M

10 SEC. TIMER

5A

1

57

127D

5

869A

877

829C 829D

806E

800JD

600DD

HEATER RESISTOR

SLOW

800B

805B

830B 830D

903

600HD

600LX

X

600JT

JUNCTION BOX

SELF LEVEL SOLENOID

SELF LEVEL SWITCH ILLUM.

RH BRAKE LIGHT

LH BRAKE LIGHT

BRAKE LIGHT TIMER RELAY

BRAKE LIGHT TIMER UNIT

FRONT AND REAR WASH WIPE

HEATER MOTOR

HI-FLOW HYDRAULICS

RH FRONT INDICATOR RH REAR INDICATOR

FLASHER UNIT LH FRONT INDICATOR LH REAR INDICATOR

HAZARD SWITCH ILLUM.

LH DIP BEAM RH DIP BEAM

ROADLIGHT SWITCH RH SIDE LIGHT RH TAIL LIGHT No. PLATE LIGHT LH TAIL LIGHT LH SIDE LIGHT

INTERIOR LIGHT

BEACON

BEACON SWITCH ILLUM.

FRONT HORN

FLOAT SOLENOID

REVERSE ALARM

REAR WORKLIGHT

LH FRONT WORKLIGHT

RH FRONT WORKLIGHT

FRONT WORKLIGHT SWITCH

E.S.O.S.

CHARGE PUMP PRESS. SWITCH

AIR FILTER SWITCH

ENGINE OIL PRESS. SWITCH

HYD. OIL TEMP. SWITCH

COOLANT TEMP. SWITCH

ALTERNATOR

HOURMETER

FUEL GAUGE FUEL GAUGE ILLUMINATION

FUEL SENDER

Skidsteer Range

FUSE B9

1 3

50

127C

2

M

BRAKE SWITCHES

10

3

816L

+8

2

127B

-7

51

5A

6

4

106H

806B

834

829

830

LATCHING RELAY

841

103F

47 864

HORN SWITCH

INDICATOR SWITCH

46

REAR WASH WIPE SWITCH

1 3

106P

800

874

877B

5A

5A FUSE B2

FUSE B1

902

415

402

403

414

406

X

600HS

600JA 600HT

600CE

LOADER CUT OFF SWITCH (GERMAN AND ITALIAN ONLY)

RESTRAINT SWITCH

SPOOL LOCK SOLENOID 2

SPOOL LOCK SOLENOID 1

PARK BRAKE LIGHT (Italian only)

NEUTRAL START RELAY

STARTER SOLENOID

STARTER MOTOR

GLOW PLUGS

ROBOT 160, 170, 170HF

FUSE B8

HI-FLOW SWITCH

FRONT WASH WIPE SWITCH

2

106H

5 10

5 1

600H

137

5 1

M

600G

43 841

2 2

3

103B

2 6

M

103C

+10

4 -7

106P

2

3

HEATER SWITCH

-7 1

103

2

42

103

1

102

6

102

106R

803A

877C

4

10A

2

106R

129

106AK

877A

805

3

600AW

136

129

106AK

810A

803

+8

5

FUSE B7

+8

40 44

1

48

816E

2 -7 1

3 M

816D

5 6 3 4 7 8 9

38

4

45

10A

3

18

17

1

FUSE B6

1 5 17

39

5A

2

803A

FLASHER UNIT

828

870

901A

LATCHING RELAY 871

LINK WHEN ROADLIGHTS ARE NOT FITTED

10 2

806P

37

002

133

-10

HAZARD SWITCH

2 2

FUSE B5

5

1

2

41

816

855C

2

132

810A

8+

-7 6 +3

106F

35 1

31 49a 49

300

36 6

FUSE B10

2

+3

98

IGN. RELAY

STARTER SWITCH -7

802

1

828M

855C

17

104

2

BEACON SWITCH

10A

3

131

FUSE B4

+8

830L

807B

861

92 94 96 101

001A

15/54 17 50 19

5A

129

-7

106B

5

894

142A

90

ROADLIGHT SWITCH

8

W

138

6

33

15A

-7

HORN RELAY

10

89

310P

7

M

310L

123 FUSE B3

128

31

106K

900C

32

303A

2

30

303B

1

9

312A

901 5

5

303

106N

+8

901B

855B

855A

900B 902A PRESSURE SWITCH

29

312B

3 4 6

600LX

900

900A

3

312

2

142A

FLOAT SWITCH +9 1

4

1

FUSE A10

127

-10 2

5A

25

142

REVERSE SWITCHES 807A

26 2

34

10A

126 106AN

1

26

FUSE A8

127

861 6

FUSE A7

117

105

434

5A

125 10A

855

+3

18 100

869A

3

87

27

99

816L

30A 2

FUSE A6

124 8+

116

-7

15A

106M

80 81 82 83 84 85 855C

AIR FILTER CHARGE PUMP PRESS.

434B

407

408

600CC

600HB

600CL

600CP

600V

BATTERY LEAD

F RESTRAINT SWITCH

24

FUSE A5

106AF

ENGINE OIL PRESS.

HYD. OIL TEMP.

WATER TEMP.

815C

415A 403C 414A 406A

5A

FUSE A4

122 106AE

BUZZER

18

106AD

14 ALTERNATOR

17

106AC

1 3

411

407A

8

106AB

13 HOURMETER

5

106

106AA

5 2

106C

1

FUEL GAUGE

6

106D

815B

10a DIODE PACK

FUSE A9

5A

121 830L

815

810

10

5A

FUSE A3

3

101

1

SPOOL LOCK RELAY

5 +3

10A

4 2

7 2

FUSE A2

6 Y 865

X 15 28

BRAKE SWITCHES

4 -7

11

200 200A

001B

6

122B

122A

8

10A

4

122

810A

2

FUSE A1

3 12 88

127B

30A

810

842

5 9 86 91 93 95 97

310L

30 1 2 5

310G

120 001A

004

NEUTRAL START RELAY

BATTERY LEAD

BATTERY

1

310L

001B

003E

79 16 21 22 23

5A

127C

60A

301B

301A

START PRE HEAT IGN OFF

4 19 20

FUSE B8

PRIMARY FUSE BOX

CONTENTS

70 - 15 - 03/1

From m/c no. 680001

Circuit Diagrams - Electrical

103

102

54

52 2

1 2

1 3

Z

2

SELF LEVEL SWITCH

55

106S

134

130

56 103

40A 2

1

52

321202

Issue 1

CONTENTS

Skidsteer Range

70 - 15 - 03/2

From m/c no. 680001

ROBOT 16 0,170, 170HF Circuit Diagrams - Electrical (cont’d) Main Components

Lamps

1 2 3 4 5 6 7 8 9 10 10a 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

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

Park Brake Warning (Italian only) Alternator Warning Water Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Cleaner Warning Charge Pump Pressure Right hand Front Worklight Left hand Front Worklight Rear Worklight Beacon Lamp Interior Light Right Hand Side Light Right Hand Tail Light Number Plate Light Left Hand Tail Light Left Hand Side Light Left Hand Dip Beam Right Hand Dip Beam Left Hand Indicator (Front) Left Hand Indicator (Rear) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light

W X Y Z

Link when road lights are not fitted Link Wire (except German and Italian) Wire fitted up to machine no. 680076 except High-flow Wire 893 was connected to terminal 3 of switch 55 up to machine no. 680077.

Battery Starter Switch Glow Plugs Starter Motor Starter Solenoid Neutral Start Relay Spool Lock Relay Spool Lock Solenoid 1 Spool Lock Solenoid 2 Restraint Switch Loader Cut Off Switch (German and Italian only) Junction Box Fuel Gauge Sender Fuel Gauge Hourmeter Alternator Diode Pack Diode Warning Buzzer Engine Water Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Cleaner Warning Switch Charge Pump Pressure Switch Engine Shut Off Solenoid Work Light Switch Reverse Switches Reverse Alarm Float Solenoid Pressure Switch Latching Relay Float Switch Horn Relay Horn Switch Front Horn Beacon Switch Road Lights Switch Flasher Unit Hazard Switch Indicator Switch Latching Relay High-Flow Hydraulics Solenoid Valve High-Flow Hydraulics Switch Heater Blower Switch Heater Blower Resistor Heater Blower Motor Front Wiper Motor Front Wash/Wipe Switch Front Washer Motor Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Motor 10 Second Timer Brake Light Switches Self Level Solenoid Self Level Switch Ignition Relay Brake Light Timer Relay (from July 2000 on)

Fuses 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140

Note 1: Diagram A shows brake light timer circuit prior to July 2000 9804/1103

Primary Fuse Box (On Battery) Spool Lock, Restraint Switch, Cut-off Solenoid (Servo) Junction Box Ignition Circuits ESOS Front Work Lights Rear Work Light Reverse Alarm Float Circuit Horn Beacon, Interior Light Right Hand Side and Tail Lights Left Hand Side and Tail Lights, Number Plate Light Head Light Dip Beam Indicators Hazard Warning High Flow Hydraulics Heater Blower Wipers and Washers Brake Lights Self Level Circuit

Note 2: For fuse ratings see page70-05-01/5. For bulb ratings see page 70-05-01/1.

70 - 15 - 03/2

8520 - E/4-2.3

Issue 1

CONTENTS CONTENTS

Skidsteer Range

70 - 20 - 01/1

From m/c no. 675001 to 675573

ROBOT 150,165 Circuit Diagrams - Hydraulic Component Key Standard Circuit C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 3 4 5 5A 6 7 8 9 10

Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Loader Joystick Main Loader Valve Block Lift Spool Crowd Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Pressure Test Points/Hand Pump Connectors Check Valve (5 bar) Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Drive Control Joystick Pressure Reducing Solenoid Valve Filter By-pass and Oil Cooler Relief Valve

Optional High-flow Circuit F2 S2 11 12 12A 13 14

High-flow Filter High-flow Pump Suction Strainer High-flow Pump High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor

Note: Neutral Circuit shown in bold line

9804/1103

70 - 20 - 01/1

Issue 3

CONTENTS CONTENTS

Skidsteer Range

70 - 20 - 01/2

ROBOT 150,165

From m/c no. 675001 to 675573

Circuit Diagrams - Hydraulic

5A 2E

2F

2G 2H

2J T

7

2

6

2X

5 2A

2B

2C 2D

10

14 F1

1

2X

3

13 12

9

P3

2X 12A

8 P1 M1

11 P2

M2

4

2X F2 C

S1

S2 T

9804/1103

70 - 20 - 01/2

A167843

Issue 3

CONTENTS

Skidsteer Range *

ROBOT 150,165

From m/c no. 675574 to 677000

Circuit Diagrams - Hydraulic

2K 5A 2E

2F

2G 2H

2J T

7

6 2 2X

5 2A

2B

2C 2D

10

14 1

F1

2X

3

13 12

9

P3

2X 12A

8 P1 M1

11 P2

M2

4

2X F2 C

S1

S2 T

9804/1103

A167845

70 - 20 - 01/3

Issue 3*

CONTENTS CONTENTS

Skidsteer Range

70 - 20 - 01/4

From m/c no. 675574 to 677000

ROBOT 150,165 Circuit Diagrams - Hydraulic Standard Circuit C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 5A 6 7 8 9 10

Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Loader Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) One-way Restrictor Pressure Test Points Check Valve (8 bar) Oil Cooler By-pass Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Drive Control Joystick Pressure Reducing Solenoid Valve Filter By-pass and Oil Cooler Relief Valve

Optional High-flow Circuit F2 S2 11 12 12A 13 14

High-flow Filter High-flow Pump Suction Strainer High-flow Pump High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor

Note: Neutral Circuit shown in bold line

9804/1103

70 - 20 - 01/4

Issue 2

CONTENTS

Skidsteer Range *

ROBOT 150,165

From m/c no. 677001 to 677999

Circuit Diagrams - Hydraulic Component Key - Servo machines Single Drive Lever Control Standard Circuit C1 F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 5A 6 7 8 9 10

Cooler (see note 2) Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Loader Joystick Main Loader Valve Block Auxiliary Spool Lift Spool Crowd Spool Main Relief Valve (MRV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) One-way Restrictor Pressure Test Points Drive Control Joystick Check Valve (8 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Pressure Reducing Solenoid Valve Check Valve (2 bar) Filter By-pass and Oil Cooler Relief Valve

Optional High-flow Circuit C2 F2 S2 11 12 12A 13 14

Cooler High-flow Filter High-flow Pump Suction Strainer High-flow Pump High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor

Note 1: Neutral Circuit shown in bold line Note 2: On High-flow machines, the line to cooler C1 is blanked off at the main pump.

9804/1103

70 - 20 - 01/5

Issue 2*

CONTENTS

Skidsteer Range

ROBOT 150,165

From m/c no. 677001

Circuit Diagrams - Hydraulic

2K 5

5A

2E

2G 2H

2F

2J

6

7

2 2D

T

2A

2B

2C

10

14 F1

4

2X

1

3

2X

13 12 2X 12A

8

M1

P3

C2

M2

P1

11

P2 2X

9

F2

C1

S1

S2 T

9804/1103

70 - 20 - 01/6

A257392

Issue 2*

CONTENTS

Skidsteer Range

ROBOT 150,165

From m/c no. 677001

Circuit Diagrams - Hydraulic

2K 5

5A

2E

2G 2H

2F

2J

6

7

2 2D

T

2A

2B

2C

10

14 F1

4

2X

2X

13

1

3 12 2X 12A

8

M1

P3

C2

M2

P1

11

P2 2X

F2

9 C1

S1

S2 T

9804/1103

A257372

70 - 20 - 01/7

Issue 2*

CONTENTS

Skidsteer Range *

ROBOT 150,165

From m/c no. 677001 to 677999

Circuit Diagrams - Hydraulic Component Key - Servo machines Dual Drive Lever Control Standard Circuit C1 F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 5A 6 7 8 9 10

Cooler (see note 2) Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Left Hand Joystick Main Loader Valve Block Auxiliary Spool Lift Spool Crowd Spool Main Relief Valve (MRV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) One-way Restrictor Pressure Test Points Drive Control Joystick Check Valve (8 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Pressure Reducing Solenoid Valve Check Valve (2 bar) Filter By-pass and Oil Cooler Relief Valve

Optional High-flow Circuit C2 F2 S2 11 12 12A 13 14

Cooler High-flow Filter High-flow Pump Suction Strainer High-flow Pump High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor

Note 1: Neutral Circuit shown in bold line Note 2: On High-flow machines, the line to cooler C1 is blanked off at the main pump.

9804/1103

70 - 20 - 01/8

Issue 2*

CONTENTS

Skidsteer Range *

ROBOT 150,165

From m/c no. 677001 to 677999

Circuit Diagrams - Hydraulic * Component Key - Manual machines Standard Circuit C1 F1 P1 P2 P3 M1 M2 S1 T 1 *2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 3 4 5 6 7 8

Cooler (see note 2) Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Brake Valve Main Loader Valve Block Lift Spool Crowd Spool Auxiliary Spool Main Relief Valve (MRV) Anti-cavitation Valve Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valves (if required) Pressure Test Points One-way Restrictor Lift Ram Compensating Ram Crowd Ram Filter By-pass and Oil Cooler Relief Valve Check Valve (2 bar)

Optional High-flow Circuit C2 F2 S2 9 10 11 11A 12

Cooler High-flow Filter High-flow Pump Suction Strainer High-flow Pump High-flow Control Valve High-flow Valve High-flow Circuit Relief Valve Attachment Motor

Note 1: Neutral Circuit shown in bold line Note 2: On High-flow machines, the line to cooler C1 is blanked off at the main pump.

9804/1103

70 - 20 - 01/9

Issue 2*

CONTENTS

Skidsteer Range

ROBOT 150,165

From m/c no. 677001

Circuit Diagrams - Hydraulic

3 2F

2G

2H

2J

2J

2

5

6

2E

4

2D

2A

2B

2C

7 12 F1 2X

2X

10 11

1 P3

2X 11A

8

C2 M1

M2

P1

9

P2 2X

F2

C1

S1

S2 T

9804/1103

70 - 20 - 01/10

A257152

Issue 2*

CONTENTS

Skidsteer Range

ROBOT 150, 165

Servo machines from m/c no. 678000

Circuit Diagrams - Hydraulic Component Key - Standard Circuit

2K 4

5

2E

2G 2H

2F

2J

6

7

2 T

2D

2A

2B

2C

10 F1

2X

1

3

2X

C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 6 7 8 9 10

Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Loader Joystick Main Loader Valve Block Auxiliary Spool Lift Spool Crowd Spool Main Relief Valve (MRV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) One-way Restrictor Pressure Test Points Drive Control Joystick Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Brake Valve Check Valve (2 bar) Filter By-pass and Oil Cooler Relief Valve

Note 1: Neutral Circuit shown in bold line

P3 8 M1

M2

P1 P2 CONTENTS

2X

9

C S1 T

9804/1103

A257393-1

70 - 20 - 01/11

Issue 1

CONTENTS

Skidsteer Range

ROBOT 150, 165

Servo machines from m/c no. 678000

Circuit Diagrams - Hydraulic Component Key - High-flow Circuit C F1 F2 P1 P2 P3 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 6 7 8 9 10 11 12 12A 13 14

Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Pump Suction Strainer Tank Loader Joystick Main Loader Valve Block Auxiliary Spool Lift Spool Crowd Spool Main Relief Valve (MRV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) One-way Restrictor Pressure Test Points Drive Control Joystick Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Brake Valve Check Valve (2 bar) Filter By-pass High-flow Pump High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor

2K 4

5

2E

2G 2H

2F

2J

6

7

2 T

2D

2A

2B

2C

10

14 F1

2X

1

3

2X

13 12 2X 12A

Note 1: Neutral Circuit shown in bold line

P3

C

8 M1

M2

P1

11

P2 F2

2X

9 S1

S2 T

9804/1103

A257393-2

70 - 20 - 01/12

Issue 1

CONTENTS

Skidsteer Range

ROBOT 150, 165

Manual machines from m/c no. 678000

Circuit Diagrams - Hydraulic Component Key - Standard Circuit

3 6

5 3 2E

2E

2F

2G

2H

2

2J

2D

2A

2C

2B

7

2X

F1

2X

1

M1

P1

P2

P3

4

C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 3 4 5 6 7 8

Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Brake Valve Main Loader Valve Block Auxiliary Spool Crowd Spool Lift Spool Main Relief Valve (MRV) Attachment Auxiliary Relief Valves (if required) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Anti-cavitation Valve Pressure Test Points Cutout Valve Lift Ram Compensating Ram Crowd Ram Filter By-pass and Oil Cooler Relief Valve Check Valve (2 bar)

Note 1: Neutral Circuit shown in bold line

M2

2X

8

C S1 T

9804/1103

A257153-1

70 - 20 - 01/13

Issue 1

CONTENTS

Skidsteer Range

ROBOT 150, 165

Manual machines from m/c no. 678000

Circuit Diagrams - Hydraulic

Component Key - High-flow Circuit C F1 F2 P1 P2 P3 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 3 4 5 6 7 8 9 10 11 11A 12

Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Pump Suction Strainer Tank Brake Valve Main Loader Valve Block Auxiliary Spool Crowd Spool Lift Spool Main Relief Valve (MRV) Attachment Auxiliary Relief Valves (if required) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Anti-cavitation Valve Pressure Test Points Cutout Valve Lift Ram Compensating Ram Crowd Ram Filter By-pass Check Valve (2 bar) High-flow Pump High-flow Control Valve High-flow Valve High-flow Circuit Relief Valve Attachment Motor

3 6

5 4

3 2E

2E

2F

2G

2H

2

2J

2D

2A

2C

2B

7

2X

12

F1

2X

10 11 1

P3 2X 11A

Note 1: Neutral Circuit shown in bold line

C M1

P1

P2

M2 9 2X F2 8 S1

S2 T

9804/1103

70 - 20 - 01/14

A257153-2

Issue 1

CONTENTS

Skidsteer Range

70 - 20 - 01/15

ROBOT 160, 170, 170H Circuit Diagrams - Hydraulic (cont’d) Standard Servo Machine - Single Lever Control Component Key

* * * * *

C F1 P1 P2 P3 M1 M1a M2 M2a S1 T X1 X2 Y Z

Cooler Filter Transmission Pump Run in Tandem Transmission Pump Loader Gear Pump Left Hand (upper) Drive Motor Left Hand Motor Shuttle Valve Right Hand (lower) Drive Motor Right Hand Motor Shuttle Valve Suction Strainer Tank Pressure Test Point Pressure Test Point Plan View of Pump showing Servo Connections Plan View of Valve Block showing Servo Connections

1 2 2a 2b 2c 2d 2e 3 3a 3b 3c 3d 4 4a 4b 4c 4d 4e 4f 4g 5 6 7 8 9 10 11 12 13 14 15 16 17

Oil Cooler By-pass Valve (3 bar [see note 2]) Drive Servo Control Valve Forward Right Left Reverse Shuttle Valves Loader Servo Control Valve Crowd (joystick in) Tip (joystick out) Lift (joystick back) Lower (joystick forward) Loader Valve Block Main Relief Valve (MRV) Lift Spool Tilt Spool Auxiliary Spool One Way Restrictor Anti-cavitation Valve Auxiliary Relief and Anti-cavitation Valve (see note 3) Auxiliary Couplings Tilt Ram Levelling Valve (Optional) Float Valve (Optional) Lift Ram Manual Load Lower Valve Suction Manifold Cut Off Valve (see note 4) Charge Pressure Swtich Hydraulic Oil Temperature Switch Reverse Alarm Pressure Switches (Optional) Brake Light Pressure Switches (Optional) Float Pressure Switch (Optional)

9804/1103

Note 1: Neutral Circuit shown in bold line Note 2: Machines manufactured prior to July 2000 were fitted with a 2 bar by-pass valve. The 3 bar valve may be fitted to earlier machines. Note 3: When machine is fitted with a breaker, item 4g is used instead of 4f. Note 4: This valve was fitted on production from machine no. 681091. Some earlier machines may also be fitted with the valve.

70 - 20 - 01/15

8520 - E/15 - 1.5

Issue 2*

CONTENTS

Skidsteer Range

ROBOT 160, 170, 170H Circuit Diagrams - Hydraulic (cont’d) Standard Servo Machine - Single Lever Control 14

M2

LEFT HAND (UPPER)

RIGHT HAND (LOWER) MOTOR

M1 MOTOR

DRIVE SERVO CONTROL VALVE

T

T

PLAN VIEW OF PUMP SHOWING

Y SERVO CONNECTIONS

2

REV

B

P2

B

P1 REAR PUMP

FRONT PUMP

C

REV

2a FWD

B

ENGINE M4

P

M5

2b

A

T

B

2c

RIGHT

C

LEFT

2d

D M5

REV

M2a

M4

M1a

A

A

FWD

D

FWD

A

2e

C COOLER M5

16

B

16

D

17

12

F1 FILTER

LEVELLING VALVE (OPTIONAL)

CUT OFF VALVE

13

6 TILT RAM

A

5

C B

AUX. COUPLINGS

10

FEMALE

MANUAL LOWER VALVE

B1

4 LOADER VALVE BLOCK

TANK

S1

A1

A2

B2

B3

3 LOADER SERVO CONTROL VALVE

MALE

3a CROWD

A3

(JOYSTICK LEFT)

4e 4b LOWER

4d

3c

LIFT (JOYSTICK BACK)

4c TIP

3d

T

11

P3

4

GEAR PUMP

3

X2

A2

3b

9804/1103

CROWD

4f

4g

2

3

4

TIP (JOYSTICK RIGHT) 1

T

P

T

P

Z

LOWER (JOYSTICK FORWARD)

4a LIFT

A1

D

X1

9

T

C

15

FLOAT VALVE (OPTIONAL)

7 LIFT RAM

A

15

1

8

M4

M5

M4

B1

B2

2

1

PLAN VIEW OF VALVE BLOCK SHOWING SERVO CONNECTIONS

321234

70 - 20 - 01/16

8520 - E/15 - 2.5

Issue 2*

CONTENTS

Skidsteer Range

ROBOT 160, 170, 170H Circuit Diagrams - Hydraulic (cont’d) High - flow Servo Machine - Single Lever Control 17

M2

LEFT HAND (UPPER)

RIGHT HAND (LOWER) MOTOR

M1 MOTOR

T

PLAN VIEW OF PUMP SHOWING

Y SERVO CONNECTIONS

2

DRIVE SERVO CONTROL VALVE

T REV

B

B

P2

2a FWD

P1 REAR PUMP

FRONT PUMP

REV

C

B P

ENGINE

2b

M5

M4 A

T

B

2c

RIGHT

LEFT

2d C

REV

D M5

M2a

M4

M1a

A

FWD

A

FWD

D

A

2e

HIGH-FLOW COOLER

C2

M5

M4

M5

M4

9 LIFT RAM

D

19

X1

FLOAT VALVE (OPTIONAL)

7

B

18 19

8

C

A

18

F1

LEVELLING VALVE (OPTIONAL) D

20

15

FILTER

CUT OFF VALVE

16

6 TILT RAM

A

T TANK

C

10

S1

5

B

AUX. COUPLINGS

MANUAL LOWER VALVE

FEMALE

3 LOADER SERVO CONTROL VALVE

MALE

P3 GEAR PUMP

B1

1 PRIORITY VALVE

A1

A2

B2

B3

3a CROWD

A3

(JOYSTICK LEFT)

4 LOADER VALVE BLOCK

11

4e 4b LOWER

4

3

4d 4c

3c

LIFT (JOYSTICK BACK)

T

TIP

A1

A2 T

P

12 HIGH-FLOW FILTER

P4

HPCO

HIGH-FLOW GEAR PUMP

14 ATTACHMENT MOTOR

X2

C1

13 HIGH-FLOW VALVE

B2

2

1

3d

LOWER (JOYSTICK FORWARD)

3b

4a LIFT

COOLER

B1

CROWD

4f

4g

Z

PLAN VIEW OF VALVE BLOCK SHOWING SERVO CONNECTIONS

2

3

4

1

TIP (JOYSTICK RIGHT) T

P

T TANK 321254

9804/1103

70 - 20 - 01/17

8520 - E/15 - 3.5

Issue 2*

CONTENTS

Skidsteer Range

70 - 20 - 01/18

ROBOT 160, 170, 170H Circuit Diagrams - Hydraulic (cont’d) High - flow Servo Machine - Single Lever Control Component Key

* * * * *

C1 C2 F1 P1 P2 P3 P3 M1 M1a M2 M2a S1 T X1 X2 Y Z

Cooler High-flow Cooler Filter Transmission Pump Run in Tandem Transmission Pump Loader Gear Pump High-flow Pump Left Hand (upper) Drive Motor Left Hand Motor Shuttle Valve Right Hand (lower) Drive Motor Right Hand Motor Shuttle Valve Suction Strainer Tank Pressure Test Point Pressure Test Point Plan View of Pump showing Servo Connections Plan View of Valve Block showing Servo Connections

1 2 2a 2b 2c 2d 2e 3 3a 3b 3c 3d 4 4a 4b 4c 4d 4e 4f 4g 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Charge Pressure Priority Valve Drive Servo Control Valve Forward Right Left Reverse Shuttle Valves Loader Servo Control Valve Crowd (joystick in) Tip (joystick out) Lift (joystick back) Lower (joystick forward) Loader Valve Block Main Relief Valve (MRV) Lift Spool Tilt Spool Auxiliary Spool One Way Restrictor Anti-cavitation Valve Auxiliary Relief and Anti-cavitation Valve (see note 2) Auxiliary Couplings Tilt Ram Levelling Valve (Optional) Float Valve (Optional) Lift Ram Manual Load Lower Valve Suction Manifold High-flow Filter High-flow Control Valve Attachment Motor Cut Off Valve (see note 3) Charge Pressure Swtich Hydraulic Oil Temperature Switch Reverse Alarm Pressure Switches (Optional) Brake Light Pressure Switches (Optional) Float Pressure Switch (Optional)

9804/1103

Note 1: Neutral Circuit shown in bold line Note 2: When machine is fitted with a breaker, item 4g is used instead of 4f. Note 3: This valve was fitted on production from machine no. 681091. Some earlier machines may also be fitted with the valve.

70 - 20 - 01/18

8520 - E/15 - 4.5

Issue 2*

CONTENTS

Skidsteer Range

70 - 20 - 01/19

ROBOT 160, 170, 170H Circuit Diagrams - Hydraulic (cont’d) Standard Servo Machine - Dual Lever Control Component Key

* * * * *

C F1 P1 P2 P3 M1 M1a M2 M2a S1 T X1 X2 Y Z

Cooler Filter Transmission Pump Run in Tandem Transmission Pump Loader Gear Pump Left Hand (upper) Drive Motor Left Hand Motor Shuttle Valve Right Hand (lower) Drive Motor Right Hand Motor Shuttle Valve Suction Strainer Tank Pressure Test Point Pressure Test Point Plan View of Pump showing Servo Connections Plan View of Valve Block showing Servo Connections

1 2 2a 2b 2c 2d 3 3a 3b 3c 3d 4 4a 4b 4c 4d 4e 4f 4g 5 6 7 8 9 10 11 12 13 14 15 16 17

Oil Cooler By-pass Valve (3 bar) Left Hand Joystick Forward Drive Reverse Drive Lift Arm Lower Lift Arm Raise Right Hand Joystick Forward Drive Reverse Drive Shovel Tip Shovel Crowd Loader Valve Block Main Relief Valve (MRV) Lift Spool Tilt Spool Auxiliary Spool One Way Restrictor Anti-cavitation Valve Auxiliary Relief and Anti-cavitation Valve (see note 2) Auxiliary Couplings Tilt Ram Levelling Valve (Optional) Float Valve (Optional) Lift Ram Manual Load Lower Valve Suction Manifold Cut Off Valve (see note 3) Charge Pressure Swtich Hydraulic Oil Temperature Switch Reverse Alarm Pressure Switches (Optional) Brake Light Pressure Switches (Optional) Float Pressure Switch (Optional)

9804/1103

Note 1: Neutral Circuit shown in bold line Note 2: When machine is fitted with a breaker, item 4g is used instead of 4f. Note 3: This valve was fitted on production from machine no. 681091. Some earlier machines may also be fitted with the valve.

70 - 20 - 01/19

8520 - E/15 - 5.2

Issue 2*

CONTENTS

Skidsteer Range

ROBOT 160, 170, 170H Circuit Diagrams - Hydraulic (cont’d) Standard Servo Machine - Dual Lever Control 14

M2

RIGHT HAND (LOWER) MOTOR

M1

PLAN VIEW OF PUMP SHOWING

2

LEFT HAND JOYSTICK

T

T

Y SERVO CONNECTIONS

LEFT HAND (UPPER) MOTOR

REV

B

P2

B

P1 REAR PUMP

FRONT PUMP

C

REV

B

2a FORWARD

ENGINE M4

M5

2c LOWER

L.H. 1

L.H. 3

2d LIFT

R.H. 3

R.H. 1 M5

M2a

M4

M1a 2b

A

A

FWD

D

FWD

A

REVERSE 2

C

3

4

12

CUT OFF VALVE

1

T

P

COOLER M5

15

1

8

15 16

16

FLOAT VALVE (OPTIONAL)

7

X1 F1

LEVELLING VALVE (OPTIONAL)

9

FILTER D

17

LIFT RAM

M4

M5

M4

13

6 TILT RAM

A

5

C B

AUX. COUPLINGS

10

FEMALE

MANUAL LOWER VALVE

T

B1

4 LOADER VALVE BLOCK

TANK

S1

A1

A2

B2

B3

4e 4b LOWER

3

MALE

RIGHT HAND JOYSTICK

A3

3a FORWARD

4d 3c TIP

4c TIP

T

11

P3

L.H. 4

GEAR PUMP

R.H. 2

X2

3b

4a

REVERSE LIFT

A1

A2

B1

L.H. 2

9804/1103

CROWD

4f

4g

2

3

4

1

T

P

T

P

Z

3d CROWD

B2

R.H. 4

PLAN VIEW OF VALVE BLOCK SHOWING SERVO CONNECTIONS

387221

70 - 20 - 01/20

8520 - E/15 - 6.2

Issue 2*

CONTENTS

Skidsteer Range

ROBOT 160, 170, 170H Circuit Diagrams - Hydraulic (cont’d) High - flow Servo Machine - Dual Lever Control 17

M2

LEFT HAND (UPPER)

RIGHT HAND (LOWER) MOTOR T

Y

PLAN VIEW OF PUMP SHOWING SERVO CONNECTIONS

2

M1 MOTOR

LEFT HAND JOYSTICK

T REV

B

B

P2

P1 REAR PUMP

FRONT PUMP

REV

C

B

2a FORWARD

ENGINE

2c LOWER

M5

M4 L.H. 3

L.H. 1

R.H. 1

R.H. 3

2d LIFT M5

M2a

M4

M1a 2b

A

C2

FWD

A

FWD

D

REVERSE

A

HIGH-FLOW COOLER

2 M5

18

1

T

P

18 19

8

4

M4

M5

M4

3

19

X1

FLOAT VALVE (OPTIONAL)

15

CUT OFF VALVE

F1 7

9 LIFT RAM

LEVELLING VALVE (OPTIONAL)

FILTER

D

20

16

6 TILT RAM

A

T

3

TANK

C

10

S1

5

B

3a FORWARD

AUX. COUPLINGS

MANUAL LOWER VALVE

FEMALE

MALE

P3 GEAR PUMP

B1

1 PRIORITY VALVE

4b

COOLER

B2

B3

3c TIP

A3

4d 4c

T

3d CROWD

TIP

3b

P4

REVERSE

HPCO

HIGH-FLOW GEAR PUMP

2

14 ATTACHMENT MOTOR

X2

3

4

1

T

P

4a LIFT

C1

A2

4e LOWER

HIGH-FLOW FILTER

A1

4 LOADER VALVE BLOCK

11

12

RIGHT HAND JOYSTICK

CROWD

4f

4g

L.H. 4

R.H. 2

Z

13 HIGH-FLOW VALVE

A1

A2 T

P B1

T

PLAN VIEW OF VALVE BLOCK SHOWING SERVO CONNECTIONS

B2

TANK L.H. 2

9804/1103

70 - 20 - 01/21

R.H. 4

8520 - E/15 - 7.2

387231

Issue 2*

CONTENTS

Skidsteer Range

70 - 20 - 01/22

ROBOT 160, 170, 170H Circuit Diagrams - Hydraulic (cont’d) High - flow Servo Machine - Dual Lever Control Component Key C1 C2 F1 P1 P2 P3 P3 M1 M1a M2 M2a S1 T X1 X2 Y Z 1 2 2a 2b 2c 2d 3 3a 3b 3c 3d 4 4a 4b 4c 4d 4e 4f 4g 5 6 7 8 9 10 11 12 13 14 15 * 16 * 17 * 18 * 19 * 20

Cooler High-flow Cooler Filter Transmission Pump Run in Tandem Transmission Pump Loader Gear Pump High-flow Pump Left Hand (upper) Drive Motor Left Hand Motor Shuttle Valve Right Hand (lower) Drive Motor Right Hand Motor Shuttle Valve Suction Strainer Tank Pressure Test Point Pressure Test Point Plan View of Pump showing Servo Connections Plan View of Valve Block showing Servo Connections

Note 1: Neutral Circuit shown in bold line Note 2: When machine is fitted with a breaker, item 4g is used instead of 4f. Note 3: This valve was fitted on production from machine no. 681091. Some earlier machines may also be fitted with the valve.

Charge Pressure Priority Valve Left Hand Joystick Forward Drive Reverse Drive Lift Arm Lower Lift Arm Raise Right Hand Joystick Forward Drive Reverse Drive Shovel Tip Shovel Crowd Loader Valve Block Main Relief Valve (MRV) Lift Spool Tilt Spool Auxiliary Spool One Way Restrictor Anti-cavitation Valve Auxiliary Relief and Anti-cavitation Valve (see note 2) Auxiliary Couplings Tilt Ram Levelling Valve (Optional) Float Valve (Optional) Lift Ram Manual Load Lower Valve Suction Manifold High-flow Filter High-flow Control Valve Attachment Motor Cut Off Valve (see note 3) Charge Pressure Swtich Hydraulic Oil Temperature Switch Reverse Alarm Pressure Switches (Optional) Brake Light Pressure Switches (Optional) Float Pressure Switch (Optional)

9804/1103

70 - 20 - 01/22

8520 - E/15 - 8.2

Issue 2*

CONTENTS

Skidsteer Range

70 - 20 - 02/1

*

From m/c no. 746001 to 746998

ROBOT 185, 1105 Circuit Diagrams - Hydraulic

12 2G 2E

2F

2K

2H

2J

5A 4 T

7

2

6

5

2D

2X

2A

2B

2C

1

F1 10 T

2X P4

9

11 4

8 P3 B

A X

8A Z

Z

X A

8B 8C

8D

B

C 1

P1

P3

2

P2

4

M1 L2

M2

L1

3

L1

a

b

c

d

L2

b

c

a

d

S2

S1 T

9804/1103

70 - 20 - 02/1

Issue 3*

CONTENTS CONTENTS

Skidsteer Range

70 - 20 - 02/2 *

ROBOT 185, 1105

From m/c no. 746001 to 746998

Circuit Diagrams - Hydraulic Component Key Standard machines with single lever drive control C1 F1 P1 P2 P3 P4 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 2 5 5A 6 7 8 8A 8B 8C 8D 9 10 11 12

Cooler Filter Main Pump Run in Tandem Main Pump Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Suction Strainer Tank Loader Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Anti-cavitation Check Valve Pressure Test Points/Hand Pump Connectors Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Pressure Reducing Solenoid Valve Filter By-pass Valve 2-speed Control Float Solenoid Valve (optional)

Motor Ports A B L1 L2 X Z

Main Port Main Port Motor Flush In Motor Flush Out 2- Speed Port Brake Port

Note: Neutral Circuit shown in bold line

9804/1103

70 - 20 - 02/2

Issue 3*

CONTENTS CONTENTS

Skidsteer Range *

ROBOT 185, 1105

70 - 20 - 02/3

From m/c no. 746001 to 746998

Circuit Diagrams - Hydraulic Component Key High-flow machines with single lever drive control C1 F1 P1 P2 P3 P4 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 5A 6 7 8 8A 8B 8C 8D 9 10 11 12 13 14 14A 14B 15

Cooler Filter Main Pump Run in Tandem Main Pump Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Suction Strainer Tank Loader Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Anti-cavitation Check Valve Pressure Test Points/Hand Pump Connectors Check Valve (5 bar) Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Pressure Reducing Solenoid Valve Filter By-pass Valve 2-speed Control Float Solenoid Valve (optional) High-flow Pump High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor

Motor Ports A B L1 L2 X Z

Main Port Main Port Motor Flush In Motor Flush Out 2 Speed Port Brake Port

Note: Neutral Circuit shown in bold line Note: Line X is the feed to the High-flow valve on machines up to serial number 746105. Line Y is the High-flow feed from machine serial number 746106.

9804/1103

70 - 20 - 02/3

Issue 3*

CONTENTS CONTENTS

Skidsteer Range

70 - 20 - 02/4 *

ROBOT 185, 1105

From m/c no. 746001 to 746998

Circuit Diagrams - Hydraulic

12 2G 2E

2F

2K

2H

2J

5A 4 T

7

2

6

5

2D

2X

2A

2B

2C

1

F1

14

10 T

2X

14B

14A

Y

15

P4

9

F2

3 11

X

4

8 P3 B

A X

8A Z

Z

X A

8B 8C

T 8D

B

13 1

P1

P3

4

M1 L2

M2

L1

3

L1

a

c

b

C

2

P2

d

L2

b

c

a

d

S2

S1 T

9804/1103

70 - 20 - 02/4

Issue 3*

CONTENTS CONTENTS

Skidsteer Range

70 - 20 - 02/5 * From

ROBOT 185, 1105

m/c no. 746001 to 746998

Circuit Diagrams - Hydraulic Component Key Standard machines with dual lever drive control C1 F1 P1 P2 P3 P4 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 4 5 5A 6 7 8 9 10 11 12

Cooler Filter Main Pump Run in Tandem Main Pump Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Suction Strainer Tank Left Hand Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Anti-cavitation Check Valve Pressure Test Points/Hand Pump Connectors Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Drive Control Joystick Pressure Reducing Solenoid Valve Filter By-pass Valve 2-speed Control Float Solenoid Valve (optional)

Motor Ports A B L1 L2 X Z

Main Port Main Port Motor Flush In Motor Flush Out 2 Speed Port Brake Port

Note: Neutral Circuit shown in bold line

9804/1103

70 - 20 - 02/5

Issue 2*

CONTENTS CONTENTS

Skidsteer Range

70 - 20 - 02/6 * From

ROBOT 185, 1105

m/c no. 746001 to 746998

Circuit Diagrams - Hydraulic

12 2G 2E

2F

2K

2H

2J

5A 4 T

7

2

6

2A

a

2B

b

2C

d

c

8

1

F1

5

2D

2X

10 T

2X

P4 11

4

P3 B

A X

Z

Z

X A

9

B

C P1

P3

P2

M1 L2

M2

L1

L1

a

b

c

L2

d

S2

S1

A275690A

T 9804/1103

70 - 20 - 02/6

Issue 2*

CONTENTS CONTENTS

Skidsteer Range

70 - 20 - 02/7 * From

ROBOT 185, 1105

m/c no. 746001 to 746998

Circuit Diagrams - Hydraulic

12 2G 2E

2F

2K

2H

2J

5A 4 T

7

2

6

2A

a

2B

b

2C

d

c

14

8

1

F1

5

2D

2X

10 T

14B

14A

15 2X 3

F2

P4 11

4

T P3 B

A X

Z

Z

X A

9

B

13 C P1

P3

P2

M1 L2

M2

L1

L1

a

b

c

L2

d

S2

S1 A275690

T 9804/1103

70 - 20 - 02/7

Issue 2*

CONTENTS CONTENTS CONTENTS

Skidsteer Range

70 - 20 - 02/8 * From

ROBOT 185, 1105

m/c no. 746001 to 746998

Circuit Diagrams - Hydraulic Component Key High-flow machines with dual lever drive control C1 F1 F2 P1 P2 P3 P4 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 5A 6 7 8 9 10 11 12 13 14 14A 14B 15

Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Suction Strainer Tank Left Hand Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Anti-cavitation Check Valve Pressure Test Points/Hand Pump Connectors Check Valve (5 bar) Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Drive Control Joystick Pressure Reducing Solenoid Valve Filter By-pass Valve 2-speed Control Float Solenoid Valve (optional) High-flow Pump Hifh-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor

Motor Ports A B L1 L2 X Z

Main Port Main Port Motor Flush In Motor Flush Out 2 Speed Port Brake Port

Note: Neutral Circuit shown in bold line

9804/1103

70 - 20 - 02/8

8510-E/30-8.2

Issue 2*

CONTENTS CONTENTS CONTENTS

Skidsteer Range

70 - 20 - 02/9

From m/c no. 746999 to 804423

ROBOT 185, 1105 Circuit Diagrams - Hydraulic Component Key Standard machines with single lever drive control. C F1 P1 P2 P3 P4 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 4 5 5A 6 7 8 8A 8B 8C 8D 9 10 11 12

Cooler Filter Main Pump Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Suction Strainer Tank Loader Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Anti-cavitation Check Valve Pressure Test Points/Hand Pump Connectors Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Solenoid Brake Valve Filter By-pass Valve 2-speed Control Float Solenoid Valve (optional)

Motor Ports A Main Port B Main Port L1 Motor Flush In L2 Motor Flush Out X 2 Speed Port Z Brake Port

Note: Neutral Circuit shown in bold line

9804/1103

70 - 20 - 02/9

8510-E/30-9.2

Issue 1

CONTENTS

Skidsteer Range

70 - 20 - 02/10

ROBOT 185, 1105

From m/c no. 746999 to 804423

Circuit Diagrams - Hydraulic

12 2G 2E

2F

2K

2H

2J

5A T

7

2

6

2A

2X

5

2D

2X

2B

2C

1 F1

10 P4 T LJ

BL

9 P

TJ

T BR

11

4

8 P3 B

A X

8A Z

Z

X A

8B 8C

B

8D

C

1

P1

P3

2

P2

4

M1 L2

M2

L1

3

L1

a

b

c

d

L2

b

c

a

d

S2

S1 T

9804/1103

70 - 20 - 02/10

8510 - E/30-10

Issue 1

Skidsteer Range

CONTENTS

70 - 20 - 03/1

ROBOT 160, 170, 170HF Circuit Diagrams - Hydraulic Standard Servo Machine

From m/c no. 680001

* M2

LEFT HAND (UPPER)

RIGHT HAND (LOWER) MOTOR

M1 MOTOR

PLAN VIEW OF PUMP SHOWING

Y SERVO CONNECTIONS

2

DRIVE SERVO CONTROL VALVE

T

T REV

B

B

P2

P1 REAR PUMP

FRONT PUMP

C

REV

2a FWD

B

ENGINE M4

P

M5

2b

A

T

B

2c

RIGHT

C

2d

D M5

REV

M2a

M4

M1a

A

C

LEFT

A

FWD

D

FWD

A

2e COOLER M5

M4

M4 M5

A

C

B

D

1

8

FLOAT VALVE (OPTIONAL)

7

X1 F1

LEVELLING VALVE (OPTIONAL)

9

D

LIFT RAM

6 TILT RAM

A

5

C B

AUX. COUPLINGS

10

FEMALE

MANUAL LOWER VALVE

T

FILTER

B1

4 LOADER VALVE BLOCK

TANK

S1

A1

A2

B2

B3

MALE

3 LOADER SERVO CONTROL VALVE 3a CROWD

A3

(JOYSTICK IN)

4e 4b LOWER

4d

3c

LIFT (JOYSTICK BACK)

4c TIP

3d

T

11

LOWER (JOYSTICK FORWARD)

P3 GEAR PUMP

4

X2

3

3b TIP

4a LIFT

A1

4g

2

3

4

1

(JOYSTICK OUT)

T

P

A2 T

P

Z

CROWD

4f

B1

B2

2

1

PLAN VIEW OF VALVE BLOCK SHOWING SERVO CONNECTIONS

321232

INCREASED BY 130%

9804/1103

70 - 20 - 03/1

8520 - E/5-2.3

Issue 2*

CONTENTS

Skidsteer Range

70 - 20 - 02/11

From m/c no. 746999 to 804423

ROBOT 185, 1105 Circuit Diagrams - Hydraulic Component Key High-flow machines with single lever drive control. C F1 F2 P1 P2 P3 P4 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 5A 6 7 8 8A 8B 8C 8D 9 10 11 12 13 14 14A 14B 15

Cooler Filter High-flow Filter Main Pump Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Suction Strainer Tank Loader Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Anti-cavitation Check Valve Pressure Test Points/Hand Pump Connectors Check Valve (5 bar) Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Solenoid Brake Valve Filter By-pass Valve 2-speed Control Float Solenoid Valve (optional) High-flow Pump High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor

Motor Ports A Main Port B Main Port L1 Motor Flush In L2 Motor Flush Out X 2 Speed Port Z Brake Port

Note: Neutral Circuit shown in bold line

9804/1103

70 - 20 - 02/11

8510-E/30-12.2

Issue 1

CONTENTS

Skidsteer Range

70 - 20 - 02/12

ROBOT 185, 1105

From m/c no. 746999 to 804423

Circuit Diagrams - Hydraulic

12 2G 2E

2F

2K

2H

2J

5A T

7

2

6

2A

2X

5

2D

2X

2B

2C

14

1 F1

10 P4 T

14B

14A

15 LJ

BL

9 F2

3

P

TJ

T

11

BR

4 T 8 P3 B

A X

8A Z

Z

X A

8B 8C

8D

B

13 1

P1

P3

4

M1 L2

M2

L1

3

L1

a

b

c

C

2

P2

d

L2

b

c

a

d

S2

S1 T

9804/1103

70 - 20 - 02/12

8510 - E/30-11

Issue 1

CONTENTS

Skidsteer Range

70 - 20 - 02/13

From m/c no. 746999 to 804423

ROBOT 185, 1105 Circuit Diagrams - Hydraulic Component Key Standard machines with dual lever drive control. C F1 P1 P2 P3 P4 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 4 5 5A 6 7 8 9 10 11 12

Cooler Filter Main Pump Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Suction Strainer Tank Left Hand Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Anti-cavitation Check Valve Pressure Test Points/Hand Pump Connectors Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Right Hand Joystick Solenoid Brake Valve Filter By-pass Valve 2-speed Control Float Solenoid Valve (optional)

Motor Ports A Main Port B Main Port L1 Motor Flush In L2 Motor Flush Out X 2 Speed Port Z Brake Port

Note: Neutral Circuit shown in bold line

9804/1103

70 - 20 - 02/13

8510-E/30-13.2

Issue 1

Skidsteer Range

CONTENTS

70 - 20 - 02/14

ROBOT 185, 1105

From m/c no. 746999 to 804423

Circuit Diagrams - Hydraulic

12 2G 2E

2F

2H

2K

2J

5A T

7

2

6

2A

a

2X

5

2D

2X

2B

b

2C

d

c

8

1 F1

10 T P4

11

4

9

P3 B

A X

Z

Z

X A

LJ

BL

B

C

P

TJ

T

P1

P3

P2

BR

M1 L2

M2

L1

L1

a

b

c

L2

d

S2

S1 T

9804/1103

70 - 20 - 02/14

8510 - E/30-14

Issue 1

CONTENTS

Skidsteer Range

70 - 20 - 02/15

From m/c no. 746999 to 804423

ROBOT 185, 1105 Circuit Diagrams - Hydraulic Component Key High-flow machines with dual lever drive control. C F1 F2 P1 P2 P3 P4 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 5A 6 7 8 9 10 11 12 13 14 14A 14B 15

Cooler Filter High-flow Filter Main Pump Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Suction Strainer Tank Left Hand Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Anti-cavitation Check Valve Pressure Test Points/Hand Pump Connectors Check Valve (5 bar) Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Right Hand Joystick Solenoid Brake Valve Filter By-pass Valve 2-speed Control Float Solenoid Valve (optional) High-flow Pump High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor

Motor Ports A Main Port B Main Port L1 Motor Flush In L2 Motor Flush Out X 2 Speed Port Z Brake Port

Note: Neutral Circuit shown in bold line

9804/1103

70 - 20 - 02/15

8510-E/30-16.2

Issue 1

CONTENTS

Skidsteer Range

70 - 20 - 02/16

ROBOT 185, 1105

From m/c no. 746999 to 804423

Circuit Diagrams - Hydraulic

12 2G 2E

2F

2H

2K

2J

5A T

7

2

6

2A

a

2X

5

2D

2X

2B

b

2C

d

c

14

8

1 F1

10 14B

14A

15

T P4

3

4

F2

11

T 9

P3 B

A X

Z

Z

X A

LJ

BL

B P

TJ

T

P1

P3

P2

C BR

M1 L2

13

M2

L1

L1

a

b

c

L2

d

S2

S1 T

9804/1103

70 - 20 - 02/16

8510 - E/30-15

Issue 1

CONTENTS

Skidsteer Range

70 - 20 - 02/17

From m/c no. 804424

ROBOT 185, 1105 Circuit Diagrams - Hydraulic Component Key - Standard machines with single lever drive control. C F1 P1 P2 P3 Pa M1 M2 S1 T 1 2 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 3K 4 5 6 7 8 9 10 10A 10B 10C 10D 11 12

Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Charge Pump (disabled) Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Charge Pressure Priority Valve Pressure Test Points Main Loader Valve Block Main Relief Valve (MRV) Crowd Spool Lift Spool Auxiliary Spool Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Anti-cavitation Check Valve Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Crowd Ram Compensating Ram Lift Ram Float Solenoid Valve (optional) Emergency Lower Valve 2-speed Control Drive Control Joystick Forward Spool Right Turn Spool Left Turn Spool Reverse Spool Solenoid Brake Valve Loader Joystick

X

Plan of Main Pump showing joystick connections

Note: Neutral Circuit shown in bold line

9804/1103

70 - 20 - 02/17

8510-E/30-17.1

Issue 1

Skidsteer Range

CONTENTS

70 - 20 - 02/18

ROBOT 185, 1105

From m/c no. 804424

Circuit Diagrams - Hydraulic

T

M4

C

10

1

A

B

D

M2 M5

10A

T

T

B

Pa

P

10B

M1

4

T

2

E

P2

P1

10C

3

10D E

F

M5

M4

F

D A

B

C

A C

D

X

Z

X

M5

M4 M5

X

M4

Z

BR

11

9

6 5

CT1

CT2 TJ

P

8 2

4

T

T T

7 F1

T S1

1

B1

3 C

BL

LJ

A1

A2

B2

3F 3G

3E

A3

B3

3H 3J

3K T

3A P3 12 3B

3C

2

3D

2 1

3

4

T

P

361600

9804/1103

70 - 20 - 02/18

8510 - E/30-18.1

Issue 1

CONTENTS CONTENTS

Skidsteer Range

70 - 20 - 02/19

From m/c no. 804424

ROBOT 185, 1105 Circuit Diagrams - Hydraulic Component Key High-flow machines with single lever drive control. C F1 F2 P1 P2 P3 P4 Pa M1 M2 S1 S2 T 1 2 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 3K 4 5 6 7 8 9 10 10A 10B 10C 10D 11 12 13 14 14A 14B 15

Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump High-flow Pump Charge Pump (disabled) Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Suction Strainer Tank Charge Pressure Priority Valve Pressure Test Points Main Loader Valve Block Main Relief Valve (MRV) Crowd Spool Lift Spool Auxiliary Spool Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Anti-cavitation Check Valve Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Crowd Ram Compensating Ram Lift Ram Float Solenoid Valve (optional) Emergency Lower Valve 2-speed Control Drive Control Joystick Forward Spool Right Turn Spool Left Turn Spool Reverse Spool Solenoid Brake Valve Loader Joystick Check Valve (10 bar) High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor

X

Plan of Main Pump showing joystick connections

Note: Neutral Circuit shown in bold line

9804/1103

70 - 20 - 02/19

8510-E/30-20.1

Issue 1

CONTENTS

Skidsteer Range

70 - 20 - 02/20

ROBOT 185, 1105

From m/c no. 804424

Circuit Diagrams - Hydraulic

T

M5

M4

C

10

1

A

B

M2

10A

T

T

D

B

Pa

P

10B

M1

4

T

2

E

P2

P1

10C

3

10D E

F

M5

M4

D

A

B

C

F

A D

X

X

Z

M5

M4 M5

X

M4

C

Z

BR

9

6 5

11

CT2

CT1

TJ

P

8 2

4

T

T 7

T BL

LJ

F1 T S2

S1

1

B1

C

A1

3

B2

B3

3H 3J

A3

3K T

3A

13

P3

3B F2

A2

3F 3G

3E

3C

3D

12

2

2

P4

1

3

4

15 P2

T

P1

P

14

14A T

9804/1103

70 - 20 - 02/20

14B

T

8510 - E/30-19.1

361610

Issue 1

CONTENTS

Skidsteer Range

70 - 20 - 02/21

From m/c no. 804424

ROBOT 185, 1105 Circuit Diagrams - Hydraulic Component Key Standard machines with dual lever drive control. C F1 P1 P2 P3 Pa M1 M2 S1 T 1 2 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 3K 4 5 6 7 8 9 10 10A 10B 10C 10D 11 12 12A 12B 12C 12D

Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Charge Pump (disabled) Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Charge Pressure Priority Valve Pressure Test Points Main Loader Valve Block Main Relief Valve (MRV) Crowd Spool Lift Spool Auxiliary Spool Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Anti-cavitation Check Valve Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Crowd Ram Compensating Ram Lift Ram Float Solenoid Valve (optional) Emergency Lower Valve 2-speed Control Left Hand Control Joystick Left Hand Motor Forward Spool Arm Lower Spool Arm Raise Spool Left Hand Motor Reverse Spool Solenoid Brake Valve Right Hand Control Joystick Right Hand Motor Forward Spool Bucket Crowd Spool Bucket Tip Spool Right Hand Motor Reverse Spool

X

Plan of Main Pump showing joystick connections

Note: Neutral Circuit shown in bold line

9804/1103

70 - 20 - 02/21

8510-E/30-21.1

Issue 1

CONTENTS

Skidsteer Range

70 - 20 - 02/22

ROBOT 185, 1105

From m/c no. 804424

Circuit Diagrams - Hydraulic

T T

T

A

B

D

M2 M5

M4

C

10A

B

1

M1

Pa

10 P2 T

E

P2

10B

P1

P1

4

2

10C 3

F

M5

M4

D A

X

Z

B

C

X

X

M4

M4 M5

M5

10D

A

Z

BR

11

9

6 5

CT1

CT2 TJ

P

8 2

4

T

T T

7 F1

T S1

1

B1

3 C

BL

LJ

A1

A2

B2

3F 3G

3E

A3

B3

3H 3J

3K T

3A P3

3B 2

3C

3D

P2

12

12B 2

12A

12D

1

3

4

12C T

P1

361620

9804/1103

70 - 20 - 02/22

8510 - E/30-22.1

Issue 1

CONTENTS CONTENTS

Skidsteer Range

70 - 20 - 02/23

From m/c no. 804424

ROBOT 185, 1105 Circuit Diagrams - Hydraulic Component Key High-flow machines with dual lever drive control. C F1 F2 P1 P2 P3 P4 Pa M1 M2 S1 S2 T 1 2 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 3K 4 5 6 7 8 9 10 10A 10B 10C 10D 11 12 12A 12B 12C 12D 13 14 14A 14B 15

Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump High-flow Pump Charge Pump (disabled) Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Suction Strainer Tank Charge Pressure Priority Valve Pressure Test Points Main Loader Valve Block Main Relief Valve (MRV) Crowd Spool Lift Spool Auxiliary Spool Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Anti-cavitation Check Valve Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Crowd Ram Compensating Ram Lift Ram Float Solenoid Valve (optional) Emergency Lower Valve 2-speed Control Left Hand Control Joystick Left Hand Motor Forward Spool Arm Lower Spool Arm Raise Spool Left Hand Motor Reverse Spool Solenoid Brake Valve Right Hand Control Joystick Right Hand Motor Forward Spool Bucket Crowd Spool Bucket Tip Spool Right Hand Motor Reverse Spool Check Valve (10 bar) High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor

X

Plan of Main Pump showing joystick connections

Note: Neutral Circuit shown in bold line

9804/1103

70 - 20 - 02/23

8510-E/30-24.1

Issue 1

Skidsteer Range

CONTENTS

70 - 20 - 02/24

ROBOT 185, 1105

From m/c no. 804424

Circuit Diagrams - Hydraulic

T T

T

M2 M5

M4

C

A

B

D

10A

B

1

M1

Pa

10 P2 T

E

P2

10B

P1

P1

4

2

10C 3

F

M5

M4

D

A

X

Z

B

X

M5

M4 M5

10D

A

C

X

M4

Z

BR

9

6 5

11

CT2

CT1

TJ

P

8 2

4

T

T 7

T BL

LJ

F1 T S2

S1

1

B1

A1

B2

B3

3H 3J

A3

3K T

3A

13

P3

3B F2

A2

3F 3G

3E

3

C

2

P4

3C

3D

P2

12

12B 2

12A

12D

1

3

15 P2

4

P1

12C

14

T

P1

14A T

9804/1103

14B

70 - 20 - 02/24

T

8510 - E/30-23.1

361630

Issue 1

CONTENTS

Skidsteer Range

70 - 20 - 03/2

From m/c no. 680001

ROBOT 160,170, 170HF Circuit Diagrams - Hydraulic (Cont’d) Standard Servo Machine Component Key C F1 P1 P2 P3 * M1 M1a * M2 M2a S1 T X1 X2 1 *2 * 2a * 2b * 2c * 2d * 2e *3 * 3a * 3b * 3c * 3d *4 * 4a * 4b * 4c * 4d * 4e * 4f * 4g 5 6 7 8 9 10 11

Cooler Filter Transmission Pump Run in Tandem Transmission Pump Loader Gear Pump Left Hand (upper) Drive Motor Left Hand Motor Shuttle Valve Right Hand (lower) Drive Motor Right Hand Motor Shuttle Valve Suction Strainer Tank Pressure Test Point Pressure Test Point Oil Cooler By-pass Valve (3 bar [see Note 2]) Drive Servo Control Valve Forward Right Left Reverse Shuttle Valves Loader Servo Control Valve Crowd (joystick in) Tip (joystick out) Lift (joystick back) Lower (joystick forward) Loader Valve Block Main Relief Valve (MRV) Lift Spool Tilt Spool Auxiliary Spool One Way Restrictor Anti-cavitation Valve Auxiliary Relief and Anti-cavitation Valve (see Note 3) Auxiliary Couplings Tilt Ram Levelling Valve (Optional) Float Valve (Optional) Lift Ram Manual Load Lower Valve Suction Manifold

Note 1: Neutral Circuit shown in bold line Note 2: Machines manufactured prior to July 2000 were fitted with a 2 bar by-pass valve. The 3 bar valve may be fitted to earlier machines. * Note 3: When machine is fitted with a breaker, item 4g is used instead of item 4f.

9804/1103

70 - 20 - 03/2

8520 - E/15-1.3

Issue 2*

Skidsteer Range

CONTENTS

70 - 20 - 03/3

ROBOT 160, 170, 170HF Circuit Diagram - Hydraulic High Flow Servo Machine

From m/c no. 680001

* M2

LEFT HAND (UPPER)

RIGHT HAND (LOWER) MOTOR

M1 MOTOR

T

PLAN VIEW OF PUMP SHOWING

Y SERVO CONNECTIONS

2

DRIVE SERVO CONTROL VALVE

T REV

B

B

P2

2a FWD

P1 REAR PUMP

FRONT PUMP

REV

C

B P

ENGINE

2b

M5

M4 A

T

B

2c

RIGHT

LEFT

2d C

REV

D M5

M2a

M4

M1a

A

C2

FWD

A

FWD

D

A

HIGH-FLOW COOLER

2e

8

A

7

C

D

6 TILT RAM

A

C

10

5

B

AUX. COUPLINGS

MANUAL LOWER VALVE

FEMALE

3 LOADER SERVO CONTROL VALVE

MALE

P3 B1

1 PRIORITY VALVE

A1

A2

B2

B3

3a CROWD

A3

(JOYSTICK IN)

4 LOADER VALVE BLOCK

11

4e 4b LOWER

4

3

A1

A2

4d 4c

3c

LIFT (JOYSTICK BACK)

T

TIP

T

P

12 HIGH-FLOW FILTER

P4

HPCO

HIGH-FLOW GEAR PUMP

14 ATTACHMENT MOTOR

X2

CROWD

4f

4g

13

C1

B1

B2

2

1

3d

LOWER (JOYSTICK FORWARD)

3b TIP

4a LIFT

HIGH-FLOW VALVE

COOLER

D

F1 FILTER

LEVELLING VALVE (OPTIONAL)

T

GEAR PUMP

B

X1

LIFT RAM

S1

M4

FLOAT VALVE (OPTIONAL)

9

TANK

M5

M4

M5

Z

PLAN VIEW OF VALVE BLOCK SHOWING SERVO CONNECTIONS

2

3

4

1

(JOYSTICK OUT)

T

P

T TANK 321252

INCREASED BY 130%

9804/1103

70 - 20 - 03/3

8520 - E/15-3.3

Issue 2*

CONTENTS

Skidsteer Range

70 - 20 - 03/4

From m/c no. 680001

ROBOT 160,170, 170HF Circuit Diagrams - Hydraulic (Cont’d) High Flow Servo Machines Component Key

* *

* * * * * * * * * * * * * * * * * **

C1 C2 F1 P1 P2 P3 P3 M1 M1a M2 M2a S1 T X1 X2 1 2 2a 2b 2c 2d 2e 3 3a 3b 3c 3d 4 4a 4b 4c 4d 4e 4f 4g 5 6 7 8 9 10 11 12 13 14

Cooler High-flow Cooler Filter Transmission Pump Run in Tandem Transmission Pump Loader Gear Pump High-flow Pump Left Hand (upper) Drive Motor Left Hand Motor Shuttle Valve Right Hand (lower) Drive Motor Right Hand Motor Shuttle Valve Suction Strainer Tank Pressure Test Point Pressure Test Point Charge Pressure Priority Valve Drive Servo Control Valve Forward Right Left Reverse Shuttle Valves Loader Servo Control Valve Crowd (joystick in) Tip (joystick out) Lift (joystick back) Lower (joystick forward) Loader Valve Block Main Relief Valve (MRV) Lift Spool Tilt Spool Auxiliary Spool One Way Restrictor Anti-cavitation Valve Auxiliary Relief and Anti-cavitation Valve (see Note 2) Auxiliary Couplings Tilt Ram Levelling Valve (Optional) Float Valve (Optional) Lift Ram Manual Load Lower Valve Suction Manifold High-flow Filter High-flow Control Valve Attachment Motor

* Note 1: Neutral Circuit shown in bold line. * Note 2: When machine is fitted with a breaker, item 4g is used instead of item 4f.

9804/1103

70 - 20 - 03/4

8520 - E/15-4.3

Issue 2*

CONTENTS

Skidsteer Range

70 - 20 - 03/5

ROBOT 160, 170, 170HF Circuit Diagrams - Hydraulic Standard Manual Machine

From m/c no. 680001

*

M2

RIGHT HAND (LOWER) MOTOR

LEFT HAND (UPPER)

11

M1 MOTOR

T

T REV

B

B

P2

P1 REAR PUMP

FRONT PUMP

REV

C

B

M2a

M1a

A

C COOLER

FWD

A

D

FWD

A

X1

1

F1

FILTER

6 FLOAT VALVE (OPTIONAL) 10

5

7 LIFT RAM

LEVELLING VALVE (OPTIONAL) D

12

4 TILT RAM

A

C

3

B

8

AUX. COUPLINGS FEMALE

MALE

MANUAL LOWER VALVE B1

T

A1

A2

B2

B3

2 TANK

LOADER VALVE BLOCK

S1

2e

2d

2b LOWER

A3

2c TIP

T

9

P3 GEAR PUMP

X2

2f

2a LIFT

CROWD

2g 321243

9804/1103

70 - 20 - 03/5

8520 - E/16-2.4

Issue 3*

CONTENTS

Skidsteer Range

70 - 20 - 03/6

From m/c no. 680001

ROBOT 160,170, 170HF Circuit Diagrams - Hydraulic (Cont’d) Standard Manual Machine Component Key - Standard Manual Machine C F1 P1 P2 P3 M1 M1a M2 M2a S1 T X1 X2 1 2 2a 2b 2c 2d 2e 2f 2g 3 4 5 6 7 8 9 * 10 * 11 * 12

Cooler Filter Transmission Pump Run in Tandem Transmission Pump Loader Gear Pump Left Hand (upper) Drive Motor Left Hand Motor Shuttle Valve Right Hand (lower) Drive Motor Right Hand Motor Shuttle Valve Suction Strainer Tank Pressure Test Point Pressure Test Point Oil Cooler By-pass Valve (3 bar [see Note 2]) Loader Valve Block Main Relief Valve (MRV) Lift Spool Tilt Spool Auxiliary Spool One Way Restrictor Anti-cavitation Valve Auxiliary Relief and Anti-cavitation Valve (see Note 3) Auxiliary Couplings Tilt Ram Levelling Valve (Optional) Float Valve (Optional) Lift Ram Manual Load Lower Valve Suction Manifold Charge Pressure Switch Hydraulic Oil Temperature Switch Float Pressure Switch (Optional)

Note 1: Neutral Circuit shown in bold line Note 2: Machines manufactured prior to July 2000 were fitted with a 2 bar by-pass valve. The 3 bar valve may be fitted to earlier machines. Note 3: When machine is fitted with a breaker, item 2g is used instead of item 2f.

9804/1103

70 - 20 - 03/6

8520 - E/16-1.4

Issue 4*

Skidsteer Range

CONTENTS

70 - 20 - 03/7

ROBOT 160, 170, 170HF Circuit Diagrams - Hydraulic High Flow Manual Machine

From m/c no. 680001

*

M2

RIGHT HAND (LOWER) MOTOR

LEFT HAND (UPPER)

14

M1 MOTOR

T B

C2

T REV

P2

B

P1 REAR PUMP

FRONT PUMP

C

REV

B

M2a

HIGH-FLOW COOLER

A

M1a FWD

A

D

A

FWD

X1 F1

FILTER

13

6 FLOAT VALVE (OPTIONAL)

5

LEVELLING VALVE (OPTIONAL)

7 T

TANK

D

15

LIFT RAM

4

1

S1 P3

PRIORITY VALVE

GEAR PUMP

A

3

C

8

9

TILT RAM

B

AUX. COUPLINGS FEMALE

MANUAL LOWER VALVE B1

2

10 HIGH-FLOW FILTER

P4

HIGH-FLOW GEAR PUMP

LOADER VALVE BLOCK

12 ATTACHMENT MOTOR

A1

A2

B2

B3

2e 2b

LOWER

2d

A3

T

2c TIP

11

C1

MALE

HPCO

HIGH-FLOW VALVE

COOLER

X2 T

2f

2a LIFT

CROWD

2g

TANK 321263

9804/1103

70 - 20 - 03/7

8520 - E/16-3.4

Issue 3*

CONTENTS

Skidsteer Range

70 - 20 - 03/8

From m/c no. 680001

ROBOT 160,170, 170HF Circuit Diagram - Hydraulic (Cont’d) High Flow Manual Machine Component Key C1 C2 F1 P1 P2 P3 P4 M1 M1a M2 M2a S1 T X1 X2 1 2 2a 2b 2c 2d 2e 2f 2g 3 4 5 6 7 8 9 10 11 12 * 13 * 14 * 15

Cooler High-flow Cooler Filter Transmission Pump Run in Tandem Transmission Pump Loader Gear Pump High-flow Pump Left Hand (upper) Drive Motor Left Hand Motor Shuttle Valve Right Hand (lower) Drive Motor Right Hand Motor Shuttle Valve Suction Strainer Tank Pressure Test Point Pressure Test Point Charge Pressure Priority Valve Loader Valve Block Main Relief Valve (MRV) Lift Spool Tilt Spool Auxiliary Spool One Way Restrictor Anti-cavitation Valve Auxiliary Relief and Anti-cavitation Valve (see Note 2). Auxiliary Couplings Tilt Ram Levelling Valve (Optional) Float Valve (Optional) Lift Ram Manual Load Lower Valve Suction Manifold High-flow Filter High-flow Control Valve Attachment Motor Charge Pressure Switch Hydraulic Oil Temperature Switch Float Pressure Switch (Optional)

Note 1: Neutral Circuit shown in bold line. Note 2: When machine is fitted with a breaker, item 2g is used instead of item 2f.

9804/1103

70 - 20 - 03/8

8520-E/16-4.4

Issue 4*

INDEX

Skidsteer Range

1CX (208S) Contents Page No. General Information Lubricants and Capacities Static Dimensions & Specification Data Electrical From m/c no. 727000 From m/c no. 727000 to 751599 To m/c no. 752370 From m/c no. 752371 Hydraulics To m/c no. 752462 From m/c no. 752463 Engine (XUD) * Engine (100 and 400 Series) * Circuit Diagrams Electrical To m/c no. 751599 To m/c no. 752370 From m/c no. 752371 to 752675 From m/c no. 752676 Hydraulic Standard Machine - Single Lever Drive Control To m/c no. 751011 From m/c no. 751012 to 752462 From m/c no 752463 Standard Machine - Dual Lever Drive Control From m/c no. 751012 to 752462 From m/c no. 752463 High-flow Machine - Single Lever Drive Control To m/c no. 751001 From m/c no. 751012 to 752462 From m/c no. 752463 High-Flow Machone - Dual Lever Drive Control From m/c no. 751012 to 752462 From m/c no. 752463 Optional Hand Tool Circuit

9804/1103

Skidsteer Range Contents - 1

75 - 00 - 01/1 75 - 00 - 02/2

75 - 05 - 01/1 75 - 05 - 01/2 75 - 05 - 01/3 75 - 05 - 01/4 75 - 05 - 02/1 75 - 05 - 02/3 75 - 05 - 03/1 75 - 05 - 03/2-3

75 - 15 - 01/1 75 - 15 - 01/3 75 - 15 - 01/5 75 - 15 - 01/7

75 - 20 - 01/1 75 - 20 - 01/3 75 - 20 - 01/5 75 - 20 - 01/7 75 - 20 - 01/9 75 - 20 - 01/11 75 - 20 - 01/13 75 - 20 - 01/15 75 - 20 - 01/17 75 - 20 - 01/19 75 - 20 - 01/21

Issue 5*

CONTENTS

Skidsteer Range

75 - 00 - 01/1

From m/c no. 727000

1CX (208S) Fluids, Lubricants & Capacities - except North America ITEM

CAPACITY

Engine Oil * XUD 5 litres * 100 Series up to m/c no. 807552 8.2 litres * 400 Series from m/c no. 807553 10.5 litres

FLUID/LUBRICANT

SPECIFICATION

JCB High Performance 15W/40 (See note)

ACEA E2:B2:A2, API CF4/SG

45 litres

JCB High Performance 10W/30 JCB High Performance 15W/40 (top up only)

ACEA E2:B2:A2, API CF4/SG ACEA E2:B2:A2, API CF4/SG

11 litres 5.5 litres

Water/Anti-freeze (see Coolant Mixtures)

Inhibited Ethanediol AL - 39 11

11 litres 5.5 litres

JCB Four Seasons Antifreeze and Summer Coolant/Water (see Coolant Mixtures)

ASTM D3306, BS6580

Fuel System

45 litres

Diesel oil (see Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

Grease Points

-

JCB Special HP Grease

Lithium complex NLGI, No. 2 consistency including extreme pressure additives Lithium based NLGI No. 2 consistency including extreme pressure additives

Hydraulic System

Cooling System * XUD Total coolant cap. Antifreeze * 100 and 400 Series Total coolant cap Antifreeze

or JCB Special MPL-EP Grease

Chain Case

Fill to level plug

Engine Oil

Slew Oil up to m/c 807225 Slew Oil from m/c no. 807226

Fill to level mark Fill to level plug

JCB HD90 Gear Oil JCB High Performance 10W/30

API GL 5 ACEA E2:B2:A2, API CF4/SG

Note: From machine number 807553, providing the above specified oil is used, the engine oil may be changed at 500 hour intervals. On earlier machines, or if a lower specification oil is used, the engine oil must be changed at 250 hours.

9804/1103

75 - 00 - 01/1

8550 - 3/1-1 . 6

Issue 6*

Skidsteer Range

CONTENTS

75 - 00 - 01/1A

From m/c no. 727000

1CX (208S) Fluids, Lubricants & Capacities - North America ITEM

CAPACITY

Engine Oil * XUD 1.32 US gal * 100 Series up to m/c no. 807552 2.17 US gal * 400 Series from m/c no. 807553 2.8 US gal

FLUID/LUBRICANT

SPECIFICATION

JCB 15W/40 (See note)

ACEA E2:B2:A2, API CF4/SG

11.89 US gal

JCB 30W JCB 15W/40 (top up only)

ACEA E2:B2:A2, API CF4/SG ACEA E2:B2:A2, API CF4/SG

2.9 US gal 1.45 US gal

Water/Anti-freeze (see Coolant Mixtures)

Inhibited Ethanediol AL - 39 11

2.9 US gal 1.45 US gal

Permanent Antifreeze

ASTM D3306, BS6580

Fuel System

11.89 US gal

Diesel oil (see Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

Grease Points

-

JCB Moly EP #2 Grease Grease

Lithium complex NLGI #2 consistency including extreme pressure additives

Chain Case

Fill to level plug

Engine Oil

Slew Oil up to m/c 807225 Slew Oil from m/c no. 807226

Fill to level mark Fill to level plug

Gear Oil EP90 JCB 30W

Hydraulic System

Cooling System * XUD Total coolant cap. Antifreeze * 100 and 400 Series Total coolant cap Antifreeze

API GL 5 ACEA CD/CE

Note: From machine number 807553, providing the above specified oil is used, the engine oil may be changed at 500 hour intervals. On earlier machines, or if a lower specification oil is used, the engine oil must be changed at 250 hours.

9804/1103

75 - 00 - 01/1A

8550 - 3/1-2 . 3

Issue 3

Skidsteer Range

CONTENTS CONTENTS

75 - 00 - 01/2

From m/c no. 727000

1CX (208S) Static Dimensions & Specification

J

F H

G A

B

E D

C

203860

Dimensions A B C D E F G H J

Overall length (including standard shovel) Height to cab roof Width over tyres Width over shovel Ground clearance under stabilisers Ground clearance at centre Wheel base Rear overhang Height to top of backhoe

Weight Total SAE (inc. standard shovel, bucket and driver)

3400 mm (11ft 2in) 2252 mm (7ft 4in) 1556 mm (5ft 1in) 1580 mm (5ft 2in) 258 mm (10in) 323mm (1ft 0in) 1070 mm (3ft 6in) 977 mm (3ft 2in) 2209 mm (7ft 3in)

2780 kg (6120 lb)

Tyres Pneumatic - size - pressure - manufacturer

Non-inflatable (on special rim)

9804/1103

bar (lbf/in2)

10 x 16.5 7 x 15 3.1(45) 4.1 (60) Goodyear (tubeless) Dico/Armstrong (tubed) Airboss

75 - 00 - 01/2

Issue 1

Skidsteer Range

CONTENTS

From m/c no. 727000

1CX (208S) 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 XUD Engines 100 and 400 Series Engines

12 Volts, negative earth

420 to 585 170 to 230

according to battery type

12V, 50 Amp output 12V, 55 Amp output

Light Bulbs Working Lights Indicator Lights Warning Lights Beacon (if fitted) Interior Light (if fitted) Side Lights (if fitted)

55W (Halogen) 21W 1.2W 70W 10W 5W

Relays up to machine no. 751599 Overheat Delay Relay Alarm Buzzer Indicator Flasher Relay Neutral Start Relay Loader Isolation Relay Horn Relay Glow Plug Relay

A

B

A B C D E F G

C

E

F

G

D

203821

202800

9804/1103

75 - 05 - 01/1

8550 - C/1-1 . 5

Issue 3*

Skidsteer Range

CONTENTS

*

1CX (208S)

From m/c no. 727000 to 751599

Data - Electrical (cont) Fuses The electrical circuits are protected by fuses. The fuses are located behind the panel A as shown in the illustration.

Fuse Number 1

Service

Fuse Size

Beacon Side lights and headlights

10 amp

2

Front worklights (see note)

10 amp

3

Interlock relay Pressure reducing solenoid valve

4

5

6

7

8

9

10

Auxiliary hydraulics Rear worklights Warning lights and buzzer ESOS

A

5 amp

203810

10 amp

5 amp

Horn Low coolant warning Stabiliser warning

15 amp

Hazard warning Rear wiper Interior light

10 amp

Front wiper Washer bottle Direction indicators

10 amp

Heater Heated seat

10 amp

Reverse alarm Brake light unit

10 amp

11

R. H. front & rear sidelights

5 amp

12

L. H. front & rear sidelights

5 amp

203802

Note: Fuse 2 also supplies, where fitted, Hydraulic Float, Brake Lights and High-flow Hydraulics. If any or all of these are fitted, the fuse rating is increased to 15 amps.

9804/1103

75 - 05 - 01/2

Issue 2*

CONTENTS

Skidsteer Range

75 - 05 - 01/3

* To m/c no. 752370

1CX (208S) Data - Electrical Circuit Protection Fuses The electrical circuits are protected by fuses. The fuses are located behind panel H. A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Parkbrake Auxiliary Hydraulics High-flow Hydraulics Instrumentation Front / Rear Horn Hazard Indicators Direction Indicators Engine Shut-off Solenoid Front Wash/wipe, Rear Wiper Heater Motor Dip Beam L.H. Side Lights R.H. Side Lights Front Work Lights Rear Work Lights Reverse Alarm, Brake Lights Hand Held Attachments, Float Hydraulics Face Level Fan Junction Box Beacon, Interior Light

H

S203811

Fuse Colour Code Orange 5 amp Red 10 amp Blue 15 amp

1

2

3

4

5

6

7

8

9

10

B

10

5

5

10

10

10

10

15

10

10

A

5

5

5

5

15

5

10

5

10

15

Relays 1 2 3 4 5 6 7 8

Work Light Park Brake Ignition Isolator Horn Neutral Start Indicator Flasher Alarm Buzzer

9804/1103

1

2

3

4

5

6

7

8 S262020

75 - 05 - 01/3

Issue 2*

CONTENTS

Skidsteer Range

75 - 05 - 01/4

From m/c no. 752371

1CX (208S) Data - Electrical Circuit Protection Fuses The electrical circuits are protected by fuses. The fuses are located behind panel H. A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Park Brake Auxiliary Hydraulics High-flow Hydraulics Instrumentation Engine Shut-off Solenoid Float Hydraulics Rear Wiper Front / Rear Horn Beacon, Interior Light Hazard Indicators Dip Beam L.H. Side Lights R.H. Side Lights Front Work Lights Rear Work Lights Junction Box Heater Motor Front Wash/wipe Reverse Alarm, Brake Lights Direction Indicators

S203811

Fuse Colour Code Orange 5 amp Red 10 amp Blue 15 amp

Relays The relays are located behind panel H. 1 2 3 4 5 6

SS262021

Neutral Start Isolator Ignition Park Brake Alarm Buzzer Indicator Flasher

9804/1103

75 - 05 - 01/4

Issue 1

CONTENTS

Skidsteer Range

75 - 05 - 02/1

* To m/c no. 752462

1CX (208S) Data - Hydraulic Note: System Cleanliness is to be to ISO 16/13. Auxiliary Pump - Standard Type Displacement Maximum Working Pressure Maximum Speed Maximum Input Torque

Gear 48 l/min (10.5 UK gal/min, 12.7 US gal/min) at 3000 rev/min 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 3200 rpm 121 Nm (89 lbf ft, 12 kgf m)

Auxiliary Pump - High-Flow Type Displacement - Front Section Displacement - Rear Section Maximum Working Pressure Maximum Speed Maximum Input Torque

Tandem gear 90 l/min (19.8 UK gal/min, 23.8 US gal/min) at 3600 rev/min 57 l/min (12.5 UK gal/min, 15 US gal/min) at 3600 rev/min 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 3600 rpm 121 Nm (89 lbf ft, 12 kgf m)

Main Pump (2-off) up to machine no. 751011 Type Displacement Control Maximum Working Pressure Maximum Speed Maximum Input Torque Charge Pressure (oil temperature at 50° C)

Sauer Sundstrand tandem axial piston Series 40 M35 35 cc/rev (2.13 in3/rev) Servo non-feedback proportional, 18 bar (261 lbf/in2) to give max pump displacement. 280 bar (4060 lbf/in2) 3600 rpm 121 Nm (89 lbf ft, 12 kgf m) 6 bar (87 lb/in2) at engine idle; 18 bar (261 lb/in2) at 3000 rev/min

Main Pump (2-off) from machine no. 751012 Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50° C)

Sauer Sundstrand tandem axial piston Series 42 M28 28 cc/rev (1.71 in3/rev) Servo non-feedback proportional, 15 bar (218 lbf/in2) to give max pump displacement. 350 bar (5076 lbf/in2) 3900 rpm 7.5 bar (109 lb/in2) at engine idle; 19.5 bar (283 lb/in2) at 3000 rev/min

* Servo Joysticks Type Output Characteristics - Transmission control spools Output Characteristics - Loader control spools

Vickers 5 bar (72 lb/in2) at 15% stroke. 15 bar (217.5 lb/in2) at 95% stroke. 3.3 - 3.7 bar (48 - 53 lb/in2) at 15% stroke. 14.5 - 16.5 bar (210 - 239 lb/in2) at 95% stroke.

Hydraulic Motors up to machine no. 751011 Type Displacement Maximum Working Pressure Maximum Speed Maximum Flow

Danfoss OMT 400 FX 410.9 cc/rev (25 in3/rev) 280 bar (4061 lbf/in2) continuous 306 rpm continuous 125 l/min (27.5 UK gal/min, 33 US gal/min) continuous

Hydraulic Motors from machine no. 751012 Type Displacement Maximum Working Pressure Maximum Speed Maximum Flow

9804/1103

Rexroth MCR03 328 cc/rev (20 in3/rev) 414 bar (6000 lbf/in2) continuous 237 rpm continuous 84 l/min (18.5 UK gal/min, 24 US gal/min) continuous

75 - 05 - 02/1

Issue 5*

CONTENTS

Skidsteer Range

75 - 05 - 02/3

From m/c no. 752463

1CX (208S) Data - Hydraulic (cont’d) Note: System Cleanliness is to be to ISO 16/13. Auxiliary Pump - Standard Type Displacement Maximum Working Pressure Maximum Speed Maximum Input Torque

Gear 48 l/min (10.5 UK gal/min, 12.7 US gal/min) at 3000 rev/min 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 3200 rpm 121 Nm (89 lbf ft, 12 kgf m)

Auxiliary Pump - High-Flow Type Displacement - Front Section Displacement - Rear Section Maximum Working Pressure Maximum Speed Maximum Input Torque

Tandem gear 90 l/min (19.8 UK gal/min, 23.8 US gal/min) at 3600 rev/min 57 l/min (12.5 UK gal/min, 15 US gal/min) at 3600 rev/min 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 3600 rpm 121 Nm (89 lbf ft, 12 kgf m)

Main Pump (2-off) Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50° C) up to machine number 807734 from mahcine number 807735

Sauer Sundstrand tandem axial piston Series 42 M28 28 cc/rev (1.71 in3/rev) Servo non-feedback proportional, 15 bar (218 lbf/in2) to give max pump displacement. 350 bar (5076 lbf/in2) 3900 rpm 7.5 bar (109 lb/in2) at engine idle; 19.5 bar (283 lb/in2) at 3000 rev/min 11.5 bar (167 lb/in2) at engine idle 23.5 - 24 bar (340 - 348 lb/in2) at 3000 rev/min

Note: When the charge pressure is set correctly it is not possible to move the lift arms when the engine is idling.

Servo Joysticks Type Output Characteristics - Transmission control spools Output Characteristics - Loader control spools

Vickers 5 bar (72 lb/in2) at 15% stroke. 15 bar (217.5 lb/in2) at 95% stroke. 3.3 - 3.7 bar (48 - 53 lb/in2) at 15% stroke. 14.5 - 16.5 bar (210 - 239 lb/in2) at 95% stroke.

Hydraulic Motors Type Displacement Maximum Working Pressure Maximum Speed Maximum Flow

9804/1103

Rexroth MCR03 328 cc/rev (20 in3/rev) 414 bar (6000 lbf/in2) continuous 237 rpm continuous 84 l/min (18.5 UK gal/min, 24 US gal/min) continuous

75 - 05 - 02/3

8550 - E/1-3 . 3

Issue 3*

CONTENTS

Skidsteer Range

75 - 05 - 02/4

From m/c no. 752463

1CX (208S) Data - Hydraulic (cont’d) Relief Valve Operating Pressures

bar

kgf/cm2

lbf/in2

Main Relief Valve (M.R.V.) at 1500 rev/min Auxiliary Relief Valves (A.R.V.) Loader Shovel Crowd Shovel Dump Lift Ram Raise Excavator Slew Rams Boom Raise Boom Lower Dipper In Dipper Out Bucket Crowd Bucket Dump Auxiliary Spool (optional) - both ports (see note) Optional Hand Tool Circuit

207

211

3006

235 100-103 235

240 102-105 240

3410 1450-1494 3410

241 241 241 241 241 241 241 241 138

246 246 246 246 246 246 246 246 141

3500 3500 3500 3500 3500 3500 3500 3500 2001

Note: The return line auxiliary A.R.V. should be set to zero when a Rockbreaker is fitted (Refer to Technical Information 1/011). The A.R.V. must be returned to the correct setting when the Rockbreaker is removed. Solenoid Brake Valve 3 position, 4 way Directional Control 12 Volt

Type Electrics Filter Type Suction Strainer

High Pressure Spin On - 5 micron 125 micron

Rams

Bore mm 60 60 70 70 70 60

Lift Shovel Boom Dipper Bucket Stabiliser

(60 x 30) (60 x 30) (70 x 40) (70 x 40) (70 x 40) (Long and Short Dipper) (60 x 30)

Ram Torque Settings

*

*

Piston Head Lift Rams Shovel Rams (Crowd) 6-in-1 Shovel Boom Ram Stabiliser Rams Dipper Ram Bucket Ram End Cap Lift Rams Shovel Rams 6-in-1 Shovel Boom Ram Stabiliser Rams Dipper Ram Bucket Ram

9804/1103

Rod Dia mm in 30 1.18 30 1.18 40 1.57 40 1.57 40 1.57 30 1.18

Stroke mm 500 500 600 500 400 500

Nm

lbf ft

Kgf m

300 300 405 405 300 405 405

222 222 300 300 222 300 300

30.7 30.7 41.5 41.5 30.7 41.5 41.5

450 450 678 678 450 678 678

332 332 500 500 332 500 500

45.9 45.9 69.2 69.2 45.9 69.2 69.2

75 - 05 - 02/4

in 2.36 2.36 2.75 2.75 2.75 2.36

in 19.69 19.69 23.62 19.69 15.75 19.69

8550 - E/1-4 . 2

Issue 2*

CONTENTS

Skidsteer Range

75 - 05 - 02/2

* To m/c no. 752462

1CX (208S) Data - Hydraulic (cont’d) * Relief Valve Operating Pressures

kgf/cm2

bar

lbf/in2

Main Relief Valve (M.R.V.) at 1500 rev/min 207 211 3006 Auxiliary Relief Valves (A.R.V.) Loader Shovel Crowd 235 240 3410 Shovel Dump 100-103 102-105 1450-1494 Lift Ram Raise 235 240 3410 Excavator 241 246 3500 Slew Rams 241 246 3500 Boom Raise 241 246 3500 Boom Lower 241 246 3500 Dipper In 241 246 3500 Dipper Out 241 246 3500 Bucket Crowd 241 246 3500 Bucket Dump 241 246 3500 Auxiliary Spool (optional) - both ports (see note) 138 141 2001 Optional Hand Tool Circuit Note: The return line auxiliary A.R.V. should be set to zero when a Rockbreaker is fitted (Refer to Technical Information 1/011). The A.R.V. must be returned to the correct setting when the Rockbreaker is removed. * Pressure Reducing Solenoid Valve Maximum Inlet Pressure Regulated Pressure Minimum Rated Flow Maximum Leakage Oil Temperature Range Solenoid Valve (including Diodes) Reducing Valve Electrics

207 Bar (3006 lbf/in2, 211 kgf/cm2) 24 Bar (348 lbf/in2, 24.47 kgf/cm2) 10 l/min (2.2 UK gal/min, 2.64 US gal/min) 25 cc/min (1.52 in3/min) at 210 Bar (3045 lbf/in2) and 10 cSt - 40 °C to +106 °C 3 Position, 3 Port Cartridge Valve Cartridge Type 12 Volt

* Filter Type Suction Strainer * Rams Lift Shovel Boom Dipper Bucket Stabiliser

(60 x 30) (60 x 30) (70 x 40) (70 x 40) (70 x 40) (Long and Short Dipper) (60 x 30)

* Ram Torque Settings Piston Head Lift Rams Shovel Rams (Crowd) Boom Ram Stabiliser Rams Dipper Ram Bucket Ram End Cap Lift Rams Shovel Rams Boom Ram Stabiliser Rams Dipper Ram Bucket Ram

9804/1103

High Pressure Spin On - 5 micron 125 micron Bore mm 60 60 70 70 70 60

Rod Dia mm in 30 1.18 30 1.18 40 1.57 40 1.57 40 1.57 30 1.18

Stroke mm 500 500 600 500 400 500

Nm

lbf ft

Kgf m

300 300 405 300 405 405

222 222 300 222 300 300

30.7 30.7 41.5 30.7 41.5 41.5

450 450 678 450 678 678

332 332 500 332 500 500

45.9 45.9 69.2 45.9 69.2 69.2

75 - 05 - 02/2

in 2.36 2.36 2.75 2.75 2.75 2.36

in 19.69 19.69 23.62 19.69 15.75 19.69

Issue 4*

CONTENTS

Skidsteer Range

From m/c no. 727000

1CX (208S) * Technical

75 - 05 - 03/1

Data - XUD Engine

Type Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure (Measured with warm engine turned by the starter) Injection Sequence Valve Clearance - Cold - Inlet Exhaust Maximum Air Cleaner Restriction Maximum Back Pressure (Exhaust)

4 cylinder in-line, overhead camshaft, compression ignition, naturally aspirated. 83 mm (3.268 in) 88 mm (3.465 in) 1905 cm3 (116.24 in3) 23.5 : 1 25 - 30 bar (363 - 435 lbf/in2, 25.5 - 33 kgf/cm2) Maximum variation between cylinders 5 bar (72.5 lbf/in2, 5.1 kgf/cm2) 1,3,4,2 0.15 - 0.20 mm (0.0059 - 0.0078 in) 0.30 - 0.35 mm (0.0118 - 0.0138 in) 20 mbar (0.29 lbf/in2, 0.02 kgf/cm2) at 3600 rev/min 140 mbar (2.03 lbf/in2, 0.143 kgf/cm2) at 3600 rev/min

Speeds Maximum Loaded Maximum No Load - standard machines Maximum No Load - High-flow machines

2630 rev/min 3000 rev/min 3500 rev/min

Idling Speed

880 - 920 rev/min

Oil Pressure at 110 °C (230 °F) at loaded speed

3.6 bar (52.2 lbf/in2, 3.7 kgf/cm2)

Fuel System Injection Pump Type Governing Pump Setting Code Static Timing Injector Codes Injector Setting Pressure

Lucas CAV DPC R84 43 Mechanical 063 16 +/- 1° BTDC RDN O5DC 6730 115 +/- 5 bar (1667.5 +/- 72.5 lbf/in2, 117

+/-

5.1 kgf/cm2)

Cooling System Fan Type Coolant Pressure Temperature Warning Light operates at

Mechanical 1 bar (14.5 lbf/in2, 1.02 kgf/cm2) 105 +/- 2 °C (221 +/- 3.6 °F)

Note: If at anytime during the life of a machine it is necessary to fit a new engine, then after the first 50 operating hours a new engine oil filter must be fitted and the engine oil changed. Failure to complete this could damage the engine. Note: Should further details be required for the refitting of the engine refer to Engine Service Manual 9803/8600.

9804/1103

75 - 05 - 03/1

8550 - K/1-1 . 4

Issue 4*

CONTENTS

Skidsteer Range

Up to m/c no. 807552

1CX (208S) * Technical

75 - 05 - 03/2

Data - 100 Series Engine

* Type Bore (nominal) Stroke Swept Volume Compression Ratio Injection Sequence Valve Clearance - Cold - Inlet and Exhaust Oil Pressure Speeds Rated Speed Idling Speed

4 cylinder in-line, compression ignition, naturally aspirated. 84 mm (3.31 in) 100 mm (3.94 in) 2216 cm3 (135.2 in3) 22 : 1 1,3,4,2 0.2 mm (0.0078 in) 2.6 - 3.5 bar (38 - 52 lbf/in2, 2.7 - 3.6 kgf/cm2)

2800 rev/min 850 - 950 rev/min

Fuel System Governing Static Timing Injector Codes Injector Setting Pressure

Mechanical 19°-21° BTDC PN: 130506140 150-162 bar (2175-2350 lbf/in2, 153-165 kgf/cm2)

Cooling System Fan Type Coolant Pressure Thermostat operating temperature Temperature Warning Light operates at

Mechanical 1 bar (14.5 lbf/in2, 1.02 kgf/cm2) 82 - 94 °C (180 - 200 °F) 97 - 103 °C (207 - 217 °F)

Note: If at anytime during the life of a machine it is necessary to fit a new engine, then after the first 50 operating hours a new engine oil filter must be fitted and the engine oil changed. Failure to complete this could damage the engine. Note: Should further details be required, refer to Engine Service Manual 9806/2100.

9804/1103

75 - 05 - 03/2

8550 - K/1-2 . 4

Issue 4*

CONTENTS

Skidsteer Range

From m/c no. 807553

1CX (208S) * Technical

75 - 05 - 03/3

Data - 400 Series Engine

* Type Bore (nominal) Stroke Swept Volume Compression Ratio Injection Sequence Valve Clearance - Cold - Inlet and Exhaust Oil Pressure Speeds Rated Speed Idling Speed

4 cylinder in-line, compression ignition, naturally aspirated. 84 mm (3.31 in) 100 mm (3.94 in) 2216 cm3 (135.2 in3) 22 : 1 1,3,4,2 0.2 mm (0.0078 in) 1 bar (15 lbf/in2) min

2800 rev/min 900 + 25 rev/min

Fuel System Governing Static Timing Injector Codes Injector Setting Pressure

Mechanical 19°-21° BTDC 131 406 360 147 bar (2133 lbf/in2)

Cooling System Fan Type Coolant Pressure Thermostat operating temperature Temperature Warning Light operates at

Mechanical 1 bar (14.5 lbf/in2) 82 °C (180 °F) 97 - 103 °C (207 - 217 °F)

Note: If at anytime during the life of a machine it is necessary to fit a new engine, then after the first 50 operating hours a new engine oil filter must be fitted and the engine oil changed. Failure to complete this could damage the engine. Note: Should further details be required, refer to Engine Service Manual TBA.

9804/1103

75 - 05 - 03/3

8550 - K/1-3 . 2

Issue 2*

CONTENTS

Skidsteer Range

1CX (208S)

*

From m/c no. 727000 to 751599

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 61

Battery Glow Plugs Glow Plugs Glow Plugs Glow Plugs Pre-heat Timer Relay Starter Switch Starter Solenoid Starter Motor Neutral Start Relay Side Lights Switch Head Lights Switch Beacon Motor Beacon Switch Front Worklight Switch Interlock Relay Park Brake Switch Operational Solenoid Park Brake Solenoid Seat Switch Override Switch Auxiliary Attachments Control Switch Auxiliary Attachments Detent Switch Auxiliary Hydraulics - Forward Solenoid Auxiliary Hydraulics - Reverse Solenoid Rear Worklight Switch Alternator Hourmeter Warning Buzzer Engine Oil Pressure Switch Engine Coolant Temperature Switch Air Cleaner Warning Switch Charge Pump Pressure Switch Hydraulic Oil Temperature Switch L. H. Stabiliser Switch R. H. Stabiliser Switch Engine Shut Off Solenoid Brake Pressure Switch Horn Pushbutton Low Coolant E.C.U. Low Coolant Float Switch Horn Relay Front Horn Rear Horn Hazard Warning Switch Flasher Relay Indicator Switch & Warning Light Wash/Wipe Switch & Warning Light Rear Wiper Switch Front Wiper Motor Rear Wiper Motor Washer Bottle Interior Light Switch Heater Blower Switch Heater Blower Restrictor Heater Blower Heated Seat Reverse Alarm Reverse Alarm Switches Heated Seat Switch Brake Light Switches

9804/1103

62 63 64 65 66 67 68

Brake Light Timer Hydraulic Float Switch Hydraulic Float Pressure Switch Hydraulic Float Relay Hydraulic Float Solenoid High-flow Hydraulic Solenoid High-flow Hydraulic Switch

Lamps 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

Pre-heat Warning Number Plate Light R. H. Rear Side Light L. H. Front Side Light L. H. Rear Side Light L. H. Front Side Light R. H. Headlight Dip L. H. Headlight Dip Beacon Light Left Hand Front Worklight Right Hand Front Worklight Worklight Warning Park Brake Warning Auxiliary Hydraulic Warning Left Hand Rear Worklight Right Hand Rear Worklight Rear Worklight Warning Alternator Warning Engine Oil Pressure Warning Engine Coolant Temperature Warning Air Cleaner Warning Charge Pump Pressure Warning Hydraulic Oil temperature Warning Stabiliser Warning L. H. Rear Direction Indicator L. H. Front Direction Indicator R. H. Rear Direction Indicator R. H. Front Direction Indicator Interior Light L. H. Rear Brake Light R. H. Rear Brake Light High-flow Hydraulic Warning

Fuses 210 Beacon, Sidelights, Headlights 211 Front Worklights, Brake Lights, Hydraulic Float, Highflow Hydraulics 212 Interlock Relay, Pressure Reducing Solenoid Valve 213 Auxiliary Hydraulics, Rear Worklights 214 Engine Shut Off Solenoid, Warning Lights and Buzzer 215 Horn, Low Coolant E.C.U., Stabiliser Warning 216 Hazard Warning, Rear Wiper, Interior Light 217 Front Wiper/Washer, Direction Indicators 218 Heater, Heated seat 219 Reverse Alarm, Rear Brake Lights 220 R. H. Front/Rear Sidelights 221 L. H. Front/Rear Sidelights Note: See page 75-05-01/1 for bulb ratings and page 75-0501/2 for fuse ratings.

75 - 15 - 01/1

Issue 2*

Skidsteer Range

CONTENTS CONTENTS

75 - 15 - 01/2

1CX (208S)

From m/c no. 727000

3

663

64 605

61 204

50

995

68 39

215 207

220

219

13

8

112 63 201

209

54

41

811

216

60 59

205

217

49 810

996

856

208

809 871

48

662

661 997

208

221

206

873

M

M

M

M 854

55

61 45

40 427

849

252

851

213

212

111

62

59

29

28

46

67

65

53

601

639

218

805

842

424

426

606

604

660 611

603

603

605

604

654 860

855

850 425

406 407

420

419

411

415

408 401

7

39 38

601

6

43

25

212

654

655 861

854

648

650 416 409

414

41

405

20

211

413

103

11

218

210

10

210

101 102

29

813 214

100

66

58

200

31

24

47

211

22

32

10

42

33

26

35

1

7

99

56

49

853

16

201

206

12

50 51 52

110 109

57

403 402

98

202

15

34 35 36

804

400

836

832

837

22 23

14

16

11

97

23

412

30

108

839

838

M

17

46

221

220

27

404

828

835

834

23

829

830

25 94

21 24

33

32

31

107

43 855

95

841

18

19 831

827

92

842

843

890

891

13

863

1

867

865

869

410 208

90

866

8

859

17

642

82

88

30

28

655

649

601

649

651

96

106

105 637

93

91

840

89

803

87 86

84

868

9

6

203

614

600

605

627

643

644

609

635

607

616

610

612

613

632

602

645

647

648

655

654

655

654

85

20

2

+

83

81

80

3

-

654

653

608

4

104

44

37

864

604

5

655

660

Circuit Diagram - Electrical

213

215

214

216

217

218

219

216

45

42 204 2

200

4

5

9

26

26

14

14

27

36

A204781

9804/1103

75 - 15 - 01/2

Issue 1

9804/1103

75 - 15 - 01/3 45

WORKING LIGHT RELAY

FUSE A6

FUSE A7

38

37

IGN. RELAY

HAZARD SWITCH

FUSE B9

56

13

18

60

56

51

BUZZER

AIR FILTER

57

55

65

FAST

62

61 LATCHING RELAY

PRESS. SWITCH

H/H ATTACHMENT SOLENOID

10 SECOND TIMER

55

52

SLOW

50 53

121

64

59

63

123

122

49

47

120

117

119

116

115

113

111

114

118

54

112

48

110

109

107

21

17

16

31 32

25 26 27 28 29

23

106

108

35

30

FUSE B3

WASH/WIPE SWITCH

10

9

JOYSTICK

14

SEAT

FUSE B2

INDICATOR SWITCH

44

5

11OVERRIDE SWITCH

INTERIOR LIGHT

FUSE B1

CHARGE PUMP PRESS.

15

6

THERMOSTART

19 LATCHING RELAY

24

ENGINE OIL PRESS.

HYD. OIL TEMP.

46

66

22

WATER TEMP.

FLOAT SWITCH

58

HEATER MOTOR

43 FLASHER UNIT

REAR WORKLIGHT

41

40

FRONT WORKLIGHT

20 SEAT SWITCH

ALTERNATOR

33

4

12 ISOLATION RELAY

P. BRAKE

7 SWITCH

ROAD LIGHT SWITCH

36

39

BEACON SWITCH

34

101 102 103 104 105

100

HI FLOW SWITCH

AUX. SWITCH

BRAKE 8 P.RELAY

N/START RELAY

1

JUNCTION BOX

FACE LEVEL FAN

FLOAT SOLENOID

HAND HELD ATTACHMENT SOLENOID

L.H. BRAKE LIGHT R.H. BRAKE LIGHT

BRAKE LIGHT TIMER UNIT

REVERSE ALARM

HEATER MOTOR

REAR WIPER MOTOR

FRONT WIPER MOTOR

WASHER MOTOR

R.H. FRONT INDICATR R.H. REAR INDICATOR FLASHER UNIT

L.H. FRONT INDICATR L.H. REAR INDICATOR

L.H. REAR WORK LIGHT R.H. REAR WORK LIGHT

L.H. FRONT WORK LIGHT R.H. FRONT WORK LIGHT

L.H. DIP BEAM R.H. DIP BEAM NO. PLATE LIGHT L.H. TAIL LIGHT L.H. SIDE LIGHT R.H. TAIL LIGHT R.H. SIDE LIGHT

BEACON

INTERIOR LIGHT

REAR HORN FRONT HORN

CHARGE PUMP PRESSURE E.S.O.S.

AIR FILTER

ENGINE OIL PRESSURE

ENGINE WATER TEMP. HYD. OIL TEMP.

ALTERNATOR

HOURMETER

HI-FLOW HYDRAULICS

AUX. HYD. REV (FRONT)

AUX. HYD. FWD (FRONT)

ISOLATOR RELAY

PARKBRAKE SOLENOID

OPERATIONAL SOLENOID

NEUTRAL START RELAY

STARTER SOLENOID

STARTER MOTOR

GLOW PLUGS

1CX

FUSE B8

FUSE B7

FUSE B6

FUSE A10

FUSE A9

42

FUSE B5

FUSE B4

FUSE B10

FUSE A5

FUSE A8

FUSE A4

FUSE A3

FUSE A2

FUSE A1

2

3

BATTERY

CONTENTS

Skidsteer Range * To m/c no. 752370

Circuit Diagrams - Electrical

852/95001/1

Issue 2*

CONTENTS

Skidsteer Range

75 - 15 - 01/4

* To m/c no. 752370

1CX (208S) 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 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

Battery Starter Switch Neutral Start Relay Glow Plugs Starter Motor Starter Solenoid Park Brake Switch Park Brake Relay Operational Solenoid Park Brake Solenoid Override Switch Isolator Relay Auxiliary Attachments Switch Seat Switch Joystick Switch Auxiliary Hydraulics - Forward Solenoid Auxiliary Hydraulics - Reverse Solenoid High-flow Hydraulic Switch Latching Relay Seat Switch High-flow Hydraulic solenoid Hourmeter Alternator Warning Buzzer Engine Coolant Temperature Switch Hydraulic Oil temperature switch Engine Oil Pressure Switch Air Cleaner Warning Switch Charge Pump Pressure Switch Engine Shut Off Solenoid Rear Horn (when fitted) Front Horn Horn Relay Horn Pushbutton Interior Light and Switch Beacon switch Ignition Relay Working Light Relay road Lights Switch Front Worklight Switch Rear Worklight Switch Hazard Warning Switch Flasher Unit Indicator Switch & Warning Light Wash/Wipe Switch & Warning Light Washer Motor Front Wiper Motor Rear Wiper Motor Rear Wiper Switch Heater Blower Switch Heater Blower Restrictor Heater Blower Reverse Alarm Reverse Alarm Switches Brake Light Switches Brake Light Timer Hand Held Attachment Switch & Warning Light Hand Held Attachment Solenoid Hydraulic Float Switch

9804/1103

61 62 63 64 65 66

Hydraulic Float Pressure Switch Latching Relay Hydraulic Float Solenoid Face Level Fan Face Level Fan Switch Junction Box

Lamps 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123

Alternator Warning Engine Coolant Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Cleaner Warning Charge Pump Pressure Warning Beacon Light L. H. Headlight Dip R. H. Headlight Dip Number Plate Light L. H. Rear Side Light L. H. Front Side Light R. H. Rear Side Light R. H. Front Side Light Left Hand Front Worklight Right Hand Front Worklight Left Hand Rear Worklight Right Hand Rear Worklight L. H. Front Direction Indicator L. H. Rear Direction Indicator R. H. Front Direction Indicator R. H. Rear Direction Indicator L. H. Rear Brake Light R. H. Rear Brake Light

Fuses Note: For fuse applications and ratings, see page 70-0501/2; for bulb ratings, see page 70-05-01/1.

75 - 15 - 01/4

Issue 2*

CONTENTS

Skidsteer Range

75 - 15 - 01/5

*From m/c no. 752371 to 752675

1CX (208S) Circuit Diagrams - Electrical Main Components

Lamps

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

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

Battery Glow Plugs Starter Motor Starter Solenoid Neutral Start Relay Starter Switch Park Brake Relay Park Brake Switch Operational Solenoid Park Brake Solenoid TUV Seat Switch (German machines only) Override Switch Seat Switch Isolator Relay Auxiliary Attachments Switch Joystick Switch Auxiliary Hydraulics - Forward Solenoid (Front) Auxiliary Hydraulics - Reverse Solenoid (Front) High-flow Hydraulic Solenoid Latching Relay Seat Switch High-flow Hydraulic Switch Diode Ignition Relay Hourmeter Engine Speed Indicator Unit Warning Buzzer Alternator Engine Coolant Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Cleaner Warning Switch Charge Pump Pressure Switch Engine Shut Off Solenoid Hydraulic Float Pressure Switch Hydraulic Float Switch Latching Relay Hydraulic Float Solenoid Rear Wiper Motor Road Lights Switch Front Worklight Switch Rear Worklight Switch Indicator Switch & Warning Light Hazard Warning Switch Flasher Unit Horn Switch Front Horn Rear Horn (when fitted) Beacon Switch Junction Box Heater Blower Switch Heater Blower Resistor Heater Blower Washer Motor Wiper Motor Wash/Wipe Switch & Warning Light Reverse Alarm Switches Reverse Alarm Brake Light Timer Brake Light Switches

9804/1103

Alternator Warning Engine Coolant Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Cleaner Warning Charge Pump Pressure Warning L. H. Headlight Dip R. H. Headlight Dip Number Plate Light L. H. Tail Light L. H. Side Light R. H. Tail Light R. H. Side Light Left Hand Front Worklight Right Hand Front Worklight Left Hand Rear Worklight Right Hand Rear Worklight L. H. Front Direction Indicator L. H. Rear Direction Indicator R. H. Front Direction Indicator R. H. Rear Direction Indicator Interior Light and Switch Beacon Light L. H. Rear Brake Light R. H. Rear Brake Light

Fuses Note: For fuse applications and ratings, see page 75-05-01/4 for bulb ratings, see page 75-05-01/1

75 - 15 - 01/5

Issue 2*

9804/1103

75 - 15 - 01/6 205B

24 127B

57 869A

56 10 SEC. TIMER

816

807B

57

816E

816D

55

816L

840

839

58

BRAKE SWITCHES

807A

10

5

4

600BH 600EB

600AW

600CD

600ED

800AK

600BG

800GR

800CC

600DY

600AP

600AJ

600EL

600EY

600BL

600H

RH BRAKE LIGHT

LH BRAKE LIGHT

BRAKE LIGHT TIMER UNIT

REVERSE ALARM

W/WIPE SWITCH ILLUM.

WIPER MOTOR

WASHER MOTOR

HEATER MOTOR

JUNCTION BOX

BEACON SWITCH ILLUM.

BEACON

INTERIOR LIGHT

REAR HORN

FRONT HORN

FLASHER UNIT

RH FRONT INDICATOR RH REAR INDICATOR

HAZARD SWITCH ILLUM. LH FRONT INDICATOR LH REAR INDICATOR

REAR WORKLIGHT SWITCH

RH REAR WORKLIGHT

LH REAR WORKLIGHT

FRONT WORKLIGHT SWITCH

RH FRONT WORKLIGHT

LH FRONT WORKLIGHT

ROADLIGHT SWITCH

RH SIDE LIGHT

RH TAIL LIGHT

LH SIDE LIGHT

LH TAIL LIGHT

NO. PLATE LIGHT

RH DIP BEAM

LH DIP BEAM

REAR WIPER MOTOR

Skidsteer Range

127C

49

REVERSE SWITCHES

51

127A

8

7

2

800D

HEATER RESISTOR

54

FUSE B9

SLOW

52 WASH/WIPE SWITCH

800

101

106H

HEATER SWITCH

5

102

10

FAST

53

103

3

800B

47

8

1

894

100

FUSE B8

106R

BEACON SWITCH

10

1

INTERIOR LIGHT

50

102

9

5

871B 871A

808C

806E

48

FUSE B7

101

303G

871

806H

806B

600G

600DX

600CK

600AV

600AY

600CJ

600AR

600AS

600DW

600BD

FLOAT SOLENOID

1CX

FUSE B8

106N

45 HORN SWITCH

46

303

43

303A

FLASHER UNIT

49a 49 31

7 10 805G

99

FUSE A9

312

HAZARD SWITCH

802

9

5

805E 805C

95

FUSE A8

2

6

805 806P

40

300

44 1 3

42 803B

803A

1 805B

IND. SWITCH

861A

861B

97

5 8

10

861

98

FUSE A10

104

7

1 10

96

FUSE B10

106F

803

9

5

41

117

855A

94

106M

10

855B

93

FUSE B5

9

855

92

106L

1

830D

830B

829E

829D

829C

834A

91

5

830

829

834

834B

89

855C

FUSE B3

FUSE B2

1

2

3

FLOAT SWITCH ILLUM.

E.S.O.S.

CHARGE PUMP PRESS. SWITCH X

AIR FILTER SWITCH 600CS

ENGINE OIL PRESS. SWITCH

HYD. OIL TEMP. SWITCH

ENGINE WATER TEMP. SWITCH

ALTERNATOR

HOURMETER

IGNITION RELAY ENGINE SPEED INDICATOR UNIT

HIGH-FLOW HYDRAULICS

AUX. SWITCH ILLUM.

AUX. HYD. REV. (FRONT)

AUX. HYD. FWD. (FRONT)

SEAT POSITION SWITCH

OVERRIDE SWITCH

P/BRAKE SWITCH ILLUM.

PARK BRAKE SOLENOID

OPERATION SOLENOID

NEUTRAL START RELAY

STARTER SOLENOID

STARTER MOTOR

GLOW PLUGS

600CF

X

600JT

X

X

600HS

600HR

600W

600DE

90

116

10

36 833

37 FUSE B1

5

4

LATCHING RELAY

PRESSURE SWITCH

39

828M

828

10

6

3

415

403

414

87

6

3

9

8

7 2

1

34

88

9

105

402 415B

35 86

106K

23 2

AIR FILTER CHARGE PUMP PRESS.

403B

414B

600CU

600JU

600HY

600HX

600HB

600HC

600GN

600CP

600GV

600V

600DH

38

205D

106AF

FLOAT SWITCH

83 84 85 106AE

ENGINE OIL PRESS.

434B

406

415A 403C 414A

114

81 82 106AD

HYD. OIL TEMP.

WATER TEMP.

434

411

'W'

30 31 32 33

FUSE A7

80 106AC

27

BUZZER ALTERNATOR 434A

407A

407B

407

412

877E

23

101AR

25

106C

HOURMETER

3

2

3

2

26

106AB

106AA

1

ENGINE SPEED INDICATOR UNIT

21

28

FUSE A6

106

23 106D

1

877 1 3

600DD

2

LATCHING RELAY

5

881 4

29

FUSE A5

FUSE A4

106T

874

SEAT SWITCH

877B

C

18

FUSE B4

2

10

7

2

4 877C

972

F

JOYSTICK

A

865A

865B

19

200 200A

4

1

9

5

22 877D

15 HIGH-FLOW SWITCH

B

16

001A

002

129

877A

887

873A

865

20

3

FUSE A3

810B

9

2

6

8

1

971

2 886

1

3

TUV SEAT SWITCH (GERMAN BUILD ONLY)

12 13

810C

810A

7 14 5

7

4

125E 5

8 125D

938B 938A

ISOLATION RELAY

10

1

7

11

10

3

866A

9 815A

5

4

125B

1 2

815

P/BRAKE SWITCH

842

10

125

810

4

3

2

1

3

17

5

6 5

4

5

5

122B

122A

P/BRAKE RELAY

810

9

FUSE A2

122

004

1

FUSE A1

15/54

50a

N/START RELAY

THERMOSTART

3

IGN. RELAY

30

17

BATTERY

2

205A

001

200B 200C

19

003E

CONTENTS

75 - 15 - 01/6

From m/c no. 752371 to 752675

Circuit Diagrams - Electrical

104

103

59

60

60

Issue 2*

CONTENTS

Skidsteer Range

75 - 15 - 01/7

From m/c no. 752676

1CX (208S) Circuit Diagrams - Electrical Main Components

Lamps

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 61

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

Battery Glow Plugs Starter Motor Starter Solenoid Neutral Start Relay Starter Switch Park Brake Relay Park Brake Switch Operational Solenoid Park Brake Solenoid TUV Seat Switch (German machines only) Override Switch Seat Switch Isolator Relay Auxiliary Attachments Switch Joystick Switch Auxiliary Hydraulics - Forward Solenoid (Front) Auxiliary Hydraulics - Reverse Solenoid (Front) High-flow Hydraulic Solenoid Latching Relay Seat Switch High-flow Hydraulic Switch Diode Ignition Relay Hourmeter Engine Speed Indicator Unit Warning Buzzer Alternator Engine Coolant Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Cleaner Warning Switch Charge Pump Pressure Switch Engine Shut Off Solenoid Hydraulic Float Pressure Switch Hydraulic Float Switch Latching Relay Hydraulic Float Solenoid Rear Wiper Motor Road Lights Switch Front Worklight Switch Rear Worklight Switch Indicator Switch & Warning Light Flasher Unit Hazard Warning Switch Horn Switch Front Horn Rear Horn (when fitted) Beacon Switch Junction Box Heater Blower Switch Heater Blower Resistor Heater Blower Wiper Motor Washer Motor Wash/Wipe Switch & Warning Light Reverse Alarm Switches Reverse Alarm Brake Light Timer Brake Light Switches Brake Light Timer Relay

9804/1103

Alternator Warning Engine Coolant Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Cleaner Warning Charge Pump Pressure Warning L. H. Headlight Dip R. H. Headlight Dip Number Plate Light L. H. Tail Light L. H. Side Light R. H. Tail Light R. H. Side Light Left Hand Front Worklight Right Hand Front Worklight Left Hand Rear Worklight Right Hand Rear Worklight L. H. Front Direction Indicator L. H. Rear Direction Indicator R. H. Front Direction Indicator R. H. Rear Direction Indicator Interior Light and Switch Beacon Light L. H. Rear Brake Light R. H. Rear Brake Light

Fuses Note: For fuse applications and ratings, see page 75-05-01/4 for bulb ratings, see page 75-05-01/1.

75 - 15 - 01/7

8550-C/6-8.1

Issue 2

205B

001

75 - 15 - 01/8 103

8550-C/6-7.1

869A

10 SEC TIMER

57 816

839

807B

M

54 58

60

60

816E

816D

M

M

600EB

55

BRAKE SWITCHES

816L

6

840

800D

53

127C

127A

2

3

-7 1

REVERSE SWITCHES 807A

+8

1

56

127B

106H

WASH/WIPE SWITCH 5

2

FAST

HEATER RESISTOR SLOW

48

840A

800B

800

600BH

600W

LH REAR INDICATOR

600G

600AW

600CD

600BG

600AK

600ED

600GR

600CC

600AP

600DY

600AJ

600EL

600EY

600H

RH BRAKE LIGHT

LH BRAKE LIGHT

BRAKE LIGHT TIMER UNIT

REVERSE ALARM

WASHER MOTOR

WIPER MOTOR

W/WIPE SWITCH ILLUM

HEATER MOTOR

JUNCTION BOX

BEACON

BEACON SWITCH ILLUM

INTERIOR LIGHT

REAR HORN

FRONT HORN

RH FRONT INDICATOR RH REAR INDICATOR

FLASHER UNIT INDICATOR SWITCH LH FRONT INDICATOR 600LA

600BL

HAZARD SWITCH ILLUM

LH REAR WORKLIGHT RH REAR WORKLIGHT

600AV

600DX

REAR WORKLIGHT SWITCH

600CK

RH FRONT WORKLIGHT

LH FRONT WORKLIGHT

FRONT WORKLIGHT SWITCH

RH SIDE LIGHT

RH TAIL LIGHT

LH SIDE LIGHT

LH TAIL LIGHT

No PLATE LIGHT

RH DIP BEAM

LH DIP BEAM

ROADLIGHT SWITCH

REAR WIPER MOTOR

FLOAT SOLENOID

FLOAT SWITCH ILLUM

E.S.O.S.

CHARGE PUMP PRESS SWITCH

AIR FILTER SWITCH

ENGINE OIL PRESS SWITCH

HYD. OIL TEMP SWITCH

ENGINE WATER TEMP SWITCH

ALTERNATOR

HOURMETER

ENGINE SPEED INDICATOR UNIT

IGNITION RELAY

HI FLOW HYDRAULICS

AUX HYD REV (FRONT)

AUX HYD FWD (FRONT)

AUX SWITCH ILLUM

600AY

600AR

600AS

600CJ

600DW

600BD

X

600CS

600CF

X

600JT

X

X

600HS

600HR

OVERRIDE SWITCH SEAT POSITION SWITCH

Skidsteer Range

FUSE B9

FUSE B8

2

51 102A

52

6

M

806C

806E

805C

102

4

3

50

5

871B 871A INTERIOR LIGHT

805B 806B

600HY

600HX

600JU

600HB

600HC

PARKBRAKE SOLENOID

OPERATION SOLENOID

NEUTRAL START RELAY P/BRAKE SWITCH ILLUM

STARTER SOLENOID

STARTER MOTOR

GLOW PLUGS

1CX (208S)

102A

2

49 1

46 -7 1

894

101

HEATER SWITCH

+10

BEACON SWITCH

3

+3

-7 +1

47

102

106R

2

1

2

1

IND SWITCH

100

FUSE B7

101

2

+8

44

-7

871

43

303A

HORN SWITCH

8

2

99

FUSE B6

45 303G

806P

106AP

803A

97

106N

HAZARD SWITCH

803B

95

303

106AP

+8

805 803

802

805E

98

FUSE A9

312

106F

17 18

5

2

-10

35

3

2

FLASHER UNIT

861A

861B

96

FUSE A8

300

1

31

42 49a

49

861

REAR WORKLIGHT SWITCH

3

-7

94

FUSE A10

24 104

2

1

41

2

855A

855B

830D

93

117

2

23

+8

855

829E 830B

91

FRONT WORKLIGHT SWITCH

3

829C 829D

600DE

92

106M

2

40 -7

83 84 85 1

830

829

600GV

600CP

600CU

90

116

+8

FUSE B3

FUSE B2

89

855C

828M

828

834A

87

ROADLIGHT SWITCH

2

+3

834

834B

M

415

403

414

600V 600GN

600DH

88

106L

2

833

FUSE B1

2 1 3

’W’

877E

JOYSTICK

F

86

200F

6

-7

5

877

600DD

412

407

PRESSURE SWITCH

415B

402

403B

414B

406

434B

411

LATCHING RELAY 4

1

2

3 LATCHING RELAY

37

5

1

6

10

434

407A

4 5

C

A

865A

SEAT

O/R

39

200N

23 8+

9

8

434A

407B

881

874

B

865

865B

23

106K

7 2

3

36

114

105

CHARGE PUMP PRESS

AIR FILTER

ENGINE OIL PRESS

HYD OIL TEMP

WATER TEMP

ALTERNATOR

FLOAT SWITCH

25 1

3

2

106C BUZZER

3

3

2

877C

SEAT SWITCH

972

873A

2 866

1

3

TUV SEAT SWITCH (GERMAN BUILD ONLY)

34

FUSE A7

101AR

106AF

81 82 106AE

0

27

106AD

80 106AC

4

HOURMETER

4

ENGINE SPEED INDICATOR UNIT

6

877B

ISOL RELAY

936B 936A

23

106AB

22 106AA

1

1

2

3

-7 1

4

5

3

-7 1

23

FUSE A6

FUSE A5

23 106D

5

2

+8

867

971

125D

125E

2

1

26

28 38

FUSE B10

FUSE A4

106T

6

4

3

-7 1

2

+8

HI FLOW SWITCH

2

1

AUXILIARY SWITCH

866A

815

P/BRAKE SWITCH

21

30 31 32 33

FUSE B5

2

877D

877A

2

1

3

106AK

842

29

FUSE B4

200 200A

4

002

810C

5

125C +8

2

10

125B

4

5

P/BRAKE RELAY

2

1

3

16

129

810B

810A

5

4

7 20

3

125

810

122B

122A

810

15

FUSE A3

FUSE A2

FUSE A1 122

004

N/START RELAY

13

1

50a

6 8

106AR

17

5 14

5

15/54

19

THERMOSTART

4 12

001A

200D

30

BATTERY

1 11

IGN RELAY

200B 200C

003E

2 10 19

414A

9804/1103 9 406A

3 18

403C

17

415A

CONTENTS

75 - 15 - 01/8

From m/c no. 752676

Circuit Diagrams - Electrical

104

103

59

57

347380

Issue 1

Skidsteer Range

CONTENTS

*

1CX (208S)

* Component C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 8A 8B 8C 8D 9 11 12 30 32 33 34 35

Standard Machine up to m/c no. 751011 - Single Lever Drive Control

Key

Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Loader Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (5 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Pressure Reducing Solenoid Valve Filter By-pass Valve (3 bar) Auxiliary Feeds Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram

9804/1103

75 - 20 - 01/1

36 37 38 50 51

Boom Ram Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor

Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.

75 - 20 - 01/1

Issue 3*

CONTENTS

Skidsteer Range

1CX (208S)

75 - 20 - 01/2

* Standard Machine up to m/c. no. 751011 - Single Lever Drive Control

Schematic Diagram

32 5

7

37 4

2 12

2F

2H

4A

2J

38

4J

6

2G

2E

36

51

T

2D

4K 4B

2X

2B

2A

4L

2C 50 4M 4C 34

F1 1

3 4D

11

35

4N 4E

2Y 9

4P

P3

4Q 4F 8 2Z

8A

8B

8C

4R

8D

33

4S 4G

P1

P2 4T

M1

M2 4H

C

T

9804/1103

30

S1

A204773A A204773A

70 - 20 - 01/2

Issue 3*

CONTENTS

Skidsteer Range

1CX (208S)

75 - 20 - 01/3

* Standard Machine from m/c. no. 751012 to 752462 - Single Lever Drive Control

Schematic Diagram 52

32

5

7

37 4

2 12

2F

2H

4A

2J

38

4J

6

2G

2E

36

51

T

2D

4K 4B

2X

2B

2A

4L

2C 50 4M 4C 34

F1 1

3 4D

11

35

4N 4E

2Y 9

4P

P3

4Q 4F 8 2Z

8A

8B

8C

4R

10

8D

33

4S 4G

P1

P2 4T

M1

M2 4H 30

C

T

9804/1103

S1

A243002A A243002A

75 - 20 - 01/3

Issue 3*

Skidsteer Range

CONTENTS

*

1CX (208S)

* Component C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 8A 8B 8C 8D 9 10 11 12 30

Standard Machine from m/c no. 751012 to 752462 - Single Lever Drive Control

Key

Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Loader Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Pressure Reducing Solenoid Valve Check Valve (2 bar) Filter By-pass Valve (3 bar) Auxiliary Feeds Hydraclamp

9804/1103

75 - 20 - 01/4

32 33 34 35 36 37 38 50 51 52

Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor One-way Restrictor

Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.

75 - 20 - 01/4

Issue 3*

Skidsteer Range

CONTENTS

1CX (208S)

* Component C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 8A 8B 8C 8D 9 10 11 12 30

*

Standard Machine from m/c no. 752463 - Single Lever Drive Control

Key

Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Loader Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Brake Valve Check Valve (2 bar) Filter By-pass Valve (3 bar) Auxiliary Feeds Hydraclamp

9804/1103

75 - 20 - 01/5

32 33 34 35 36 37 38 50 51 52 *X

Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor One-way Restrictor Return line fitted from machine no. 807226

Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.

75 - 20 - 01/5

8550 - E/30-6 . 3

Issue 3*

CONTENTS

Skidsteer Range

1CX (208S)

75 - 20 - 01/6

* Standard Machine from m/c. no. 752463 - Single Lever Drive Control

Schematic Diagram 52

32

5

7

37 4

2 12

2F

2H

4A

2J

38

4J

6

2G

2E

36

51

T

2D

4K 4B

2X

2B

2A

4L

2C 50 4M 4C 34

F1 1

3 4D

11

35

4N 4E

2Y

9

4P

P3

4Q 4F 8 2Z

8A

8B

8C

4R

10

8D

33

4S 4G

P1

P2 4T

M1

M2 4H 30

C

T

9804/1103

S1

316740

75 - 20 - 01/6

Issue 3*

CONTENTS

Skidsteer Range

1CX (208S)

75 - 20 - 01/7

* Standard Machine from m/c. no. 751012 to 752462 - Dual Lever Drive Control

Schematic Diagram 52

32

5

7

37 4

2 12

2F

4A

2G

2E

2J

38

4J

6

2H

36

51

T

2D

4K 4L

4B

2X

2B

2A

2C 50 4M 4C 34

F1 3

8

1

4D

11

35

4N

2Y

4E

4P

9 P3

4Q 4F

4R

33

4S

2Z

4G

10 P1 M1

4T

P2 4H

M2

30

C

T

9804/1103

S1

A243003A

75 - 20 - 01/7

Issue 3*

Skidsteer Range

CONTENTS

1CX (208S)

* Component C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 9 10 11 12 30 32 33 34 35 36

* Standard Machine from m/c no. 751012 to 752462 - Dual Lever Drive Control Key

Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Left Hand Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Right Hand Joystick Pressure Reducing Solenoid Valve Check Valve (2 bar) Filter By-pass Valve (3 bar) Auxiliary Feeds Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram

9804/1103

75 - 20 - 01/8

37 38 50 51 52

Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor One-way Restrictor

Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.

75 - 20 - 01/8

Issue 3*

Skidsteer Range

CONTENTS

1CX (208S)

* Component C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 9 10 11 12 30 32 33 34 35 36

* Standard Machine from m/c no. 752463 - Dual Lever Drive Control Key

Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Left Hand Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Right Hand Joystick Brake Valve Check Valve (2 bar) Filter By-pass Valve (3 bar) Auxiliary Feeds Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram

9804/1103

75 - 20 - 01/9

37 38 50 51 52 *X

Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor One-way Restrictor Return line fitted from machine no. 807226

Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.

75 - 20 - 01/9

8550 - E/31-3 . 2

Issue 2*

CONTENTS

Skidsteer Range

1CX (208S)

75 - 20 - 01/10

* Standard Machine from m/c. no. 752463 - Dual Lever Drive Control

Schematic Diagram 52

32

5

7

37 4

2 12

2F

4A

2J

38

4J

6

2H 2G

2E

36

51

T

2D

4K 4B

2X

2B

2A

4L

2C 50 4M 4C 34

F1 3

8

1

4D

11

35

4N

2Y

4E

4P P3

4Q

9

4F

4R

33

4S

2Z

4G

10 P1 M1

4T

P2 4H

M2

30

C

T

9804/1103

S1

316760

75 - 20 - 01/10

Issue 2*

CONTENTS

Skidsteer Range

1CX (208S)

75 - 20 - 01/11

* High-flow Machine up to m/c. no. 751011 - Single Lever Drive Control

Schematic Diagram 32 5

7

37 4

2 12

2F

4A

2G

2E

2J

38

4J

6

2H

36

51

T

2D

4K 4B

2X

2B

2A

4L

2C 50 4M 4C 34 14B

F1 1

14C

3

4D

15

14

11

35

F2 14A

4N 4E

2Y

13 9 4P P3

4Q 4F

8 2Z

8A

8B

8C

8D

4R

C

33

4S 4G

P1

P2 4T

M1

M2 4H 30

T

9804/1103

S1

S2

A204773B

75 - 20 - 01/11

Issue 2*

CONTENTS

Skidsteer Range

1CX (208S)

* Component C F1 F2 P1 P2 P3 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 8A 8B 8C 8D 9 11 12

* High-flow Machine up to m/c no. 751011 - Single Lever Drive Control Key

Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Pump Suction Strainer Tank Loader Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (5 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Pressure Reducing Solenoid Valve Filter By-pass Valve (3 bar) Auxiliary Feeds

9804/1103

75 - 20 - 01/12

13 14 14A 14B 14C 15 30 32 33 34 35 36 37 38 50 51

High-flow Pump High-flow Valve High-flow Pilot Valve High-flow Control Valve High-flow Circuit Relief Valve Attachment Motor Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor

Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.

75 - 20 - 01/12

Issue 2*

CONTENTS

1CX (208S)

Skidsteer Range

75 - 20 - 01/13

High-flow Machine from m/c no. 751012 to 752462 - Single Lever Drive Control

Component Key C F1 F2 P1 P2 P3 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2W 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 8A 8B 8C 8D 9 10 11 12

Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Pump Suction Strainer Tank Loader Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (High-flow Relief Valve) Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Pressure Reducing Solenoid Valve Check Valve (2 bar) Filter By-pass Valve (3 bar) Auxiliary Feeds

9804/1103

13 14 14A 14B 14C 15 30 32 33 34 35 36 37 38 50 51 52

High-flow Pump High-flow Valve High-flow Pilot Valve High-flow Control Valve High-flow Circuit Relief Valve Attachment Motor Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor One-way Restrictor

Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.

75 - 20 - 01/13

Issue 1

CONTENTS

Skidsteer Range

1CX (208S)

75 - 20 - 01/14

High-flow Machine from m/c. no. 751012 to 752462 - Single Lever Drive Control

Schematic Diagram

52

32

5

7

37 4

2 12

2F

4A

2G

2E

2J

38

4J

6

2H

36

51

T

2D

4K 4B

2X

2B

2A

4L

2C 50 4M 2W

4C 34 14B

F1 14C

3

1 11

4D

15

14

35

F2 14A

4N 4E

2Y

13 9 4P P3

4Q 4F

8 2Z

8A

8B

8C

8D

4R

C

33

4S 4G

P1

P2 4T

M1

M2 4H 30

10

T

9804/1103

S1

S2

A243000B A243000B

75 - 20 - 01/14

Issue 1

CONTENTS

Skidsteer Range

1CX (208S)

75 - 20 - 01/15

High-flow Machine from m/c. no. 752463 - Single Lever Drive Control

Schematic Diagram 52

32

5

7

37 4

2 12

2F

4A

2G

2E

2J

38

4J

6

2H

36

51

T

2D

4K 4B

2X

2B

2A

4L

2C 50 4M 2W

4C 34 14B

F1 14C

3

1 11

4D

15

14

35

F2 14A

4N 4E

2Y

13

4P 9

P3

4Q 4F

8 2Z

8A

8B

8C

8D

4R

C

33

4S 4G

P1

P2 4T

M1

M2 4H 30

10

T

9804/1103

S1

S2

316750

75 - 20 - 01/15

Issue 1

CONTENTS

Skidsteer Range

1CX (208S)

75 - 20 - 01/16

High-flow Machine from m/c no. 752463 - Single Lever Drive Control

Component Key C F1 F2 P1 P2 P3 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2W 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 8A 8B 8C 8D 9 10 11 12

Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Pump Suction Strainer Tank Loader Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (High-flow Relief Valve) Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Brake Valve Check Valve (2 bar) Filter By-pass Valve (3 bar) Auxiliary Feeds

9804/1103

13 14 14A 14B 14C 15 30 32 33 34 35 36 37 38 50 51 52

High-flow Pump High-flow Valve High-flow Pilot Valve High-flow Control Valve High-flow Circuit Relief Valve Attachment Motor Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor One-way Restrictor

*X

Return line fitted from machine no. 807226

Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.

75 - 20 - 01/16

8550 - E/32-6 . 2

Issue 2

CONTENTS

1CX (208S)

Skidsteer Range

75 - 20 - 01/17

High-flow Machine from m/c no. 751012 to 752462 - Dual Lever Drive Control

Component Key C F1 F2 P1 P2 P3 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2W 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 9 10 11 12

Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Pump Suction Strainer Tank Left Hand Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (High-flow Relief Valve) Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Right Hand Joystick Pressure Reducing Solenoid Valve Check Valve (2 bar) Filter By-pass Valve (3 bar) Auxiliary Feeds

9804/1103

13 14 14A 14B 14C 15 30 32 33 34 35 36 37 38 50 51 52

High-flow Pump High-flow Valve High-flow Pilot Valve High-flow Control Valve High-flow Circuit Relief Valve Attachment Motor Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor One-way Restrictor

Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.

75 - 20 - 01/17

Issue 1

CONTENTS

Skidsteer Range

1CX (208S)

75 - 20 - 01/18

High-flow Machine from m/c. no. 751012 to 752462 - Dual Lever Drive Control

Schematic Diagram 52

32

5

7

37 4

2 12

2F

4A

2J

38

4J

6

2H 2G

2E

36

51

T

2D

4K 4B

2X

2B

2A

4L

2C 50 4M 4C 34

F1 3

8

1

4D

11

35

4N

2Y

4E 2W 14B 9

4P

14C

P3

4Q

15 14

14

F2

4F

14A 4R 4G

13

P1 M1

4T

P2

C 4H

M2

30

10

T

9804/1103

33

4S

2Z

S1

S2

A243004

75 - 20 - 01/18

Issue 1

CONTENTS

Skidsteer Range

1CX (208S)

75 - 20 - 01/19

High-flow Machine from m/c. no. 752463 - Dual Lever Drive Control

Schematic Diagram 52

32

5

7

37 4

2 12

2F

4A

2J

38

4J

6

2H 2G

2E

36

51

T

2D

4K 4B

2X

2B

2A

4L

2C 50 4M 4C 34

F1 3

8

1

4D

11

35

4N

2Y

4E 2W 14B 14 P3

4P

14C

4Q

15

9

14

F2

4F

14A 4R 4G

13

P1 M1

4T

P2

C 4H

M2

30

10

T

9804/1103

33

4S

2Z

S1

S2

316770

75 - 20 - 01/19

Issue 1

CONTENTS

Skidsteer Range

1CX (208S)

75 - 20 - 01/20

High-flow Machine from m/c no. 752463 - Dual Lever Drive Control

Component Key C F1 F2 P1 P2 P3 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2W 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 9 10 11 12

Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Pump Suction Strainer Tank Left Hand Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (High-flow Relief Valve) Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Right Hand Joystick Brake Valve Check Valve (2 bar) Filter By-pass Valve (3 bar) Auxiliary Feeds

9804/1103

13 14 14A 14B 14C 15 30 32 33 34 35 36 37 38 50 51 52

High-flow Pump High-flow Valve High-flow Pilot Valve High-flow Control Valve High-flow Circuit Relief Valve Attachment Motor Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor One-way Restrictor

*X

Return line fitted from machine no. 807226

Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.

75 - 20 - 01/20

8550 - E/33-4 . 2

Issue 2

CONTENTS

Skidsteer Range

75 - 20 - 01/21

1CX (208S)

Optional Hand Tool Circuit Description The oil supply for the optional hand tool circuit is taken from the excavator valve auxiliary circuit feed lines. When the auxiliary circuit is selected by the foot pedal, oil is fed via the Manual Valve 2 to the Flow Regulator Valve 3. Flow Regulator Spool 3a controls the flow to the hand tool circuit 4, dumping excess oil back to tank via the return line of the excavator auxiliary circuit. Return oil from the hand tool is fed directly back to tank. Relief Valve 3b prevents pressure in the hand tool circuit from rising too far.

1

2 3a

3 4

Manual Valve 2 is turned off to isolate the hand tool circuit when the excavator auxiliary circuit is to be used for other applications.

3b

Component Key

5 T 1 2 3 3a 3b 4 5

Tank Excavator Valve Block Auxiliary Lines Manual Valve Flow Regulator Valve Flow Regulator Spool Relief Valve Hand Tool Connection Return Line from Brake Valve

9804/1103

T 303930

75 - 20 - 01/21

Issue 1

Teletruk

INDEX

All Models Contents Page No. General Information Fluids, Lubricants and Capacities Static Dimensions Weights and Lifting Capacities

*

Data Electrical Hydraulic Transmission Hydraulics Tyres Steering Brakes Engine - Diesel - LPG

80 - 00 - 01/1 80 - 00 - 02/1 80 - 00 - 02/2

80 - 05 - 01/1 to 80 - 05 - 01/3 80 - 05 - 02/1 80 - 05 - 03/1 80 - 05 - 03/1 80 - 05 - 04/1 80 - 05 - 04/1 80 - 05 - 05/1 80 - 05 - 05/1

* Circuit Diagrams

Electrical All Models to m/c no. 788000 All Models (Diesel Engine, Single Pedal) from m/c no. 788001 to 788643 All Models (Diesel Engine, Single Pedal) from m/c no. 788644 All Models (Diesel Engine, Twin Pedal) from m/c no. 788001 to 788643 All Models (Diesel Engine, Twin Pedal) from m/c no. 788644 All Models (LPG Engine, Single Pedal) from m/c no. 788001 to 788643 All Models (LPG Engine, Single Pedal) from m/c no. 788644 All Models (LPG Engine,Twin Pedal) from m/c no. 788001 to 788643 All Models (LPG Engine, Twin Pedal) from m/c no. 788644 All Models (Diesel Engine - TCR) from m/c no. 788001 All Models (2 Speed Option - Intelligent Transmission) from m/c no. 788644 All Models (2 Speed/Traction Control Option - Intelligent Transmission) from m/c no. 788644 Hydraulic All Models to m/c no. 788390 All Models to m/c no. 788390 - Transmission Circuit All Models from m/c no. 788391 All Models from m/c no. 788391 - Transmission and Valve Circuit

9804/1103

Teletruk Contents - 1

80 - 15 - 01/1 to 80 - 15 - 01/3 80 - 15 - 01/4 to 80 - 15 - 01/6 80 - 15 - 01/6A to 80 - 15 - 01/6C 80 - 15 - 01/7 to 80 - 15 - 01/9 80 - 15 - 01/09A to 80 - 15 - 01/9C 80 - 15 - 01/10 to 80 - 15 - 01/12 80 - 15 - 01/12A to 80 - 15 - 01/12C 80 - 15 - 01/13 to 80 - 15 - 01/15 80 - 15 - 01/15A to 80 - 15 - 01/15C 80 - 15 - 01/16 to 80 - 15 - 01/18 80 - 15 - 01/19

80 - 15 - 01/20 80 - 20 - 01/1 to 80 - 20 - 01/2 80 - 20 - 01/3 80 - 20 - 0/4 to 80 - 20 - 01/5 80 - 20 - 01/6

Issue 2*

CONTENTS

Teletruk

80 - 00 - 01/1

All Models Fluids, Lubricants and Capacities ITEM

CAPACITY

FLUID/LUBRICANT

SPECIFICATION

Engine Oil Diesel

8.2 litres

JCB 10W/30 Multigrade

SAE 10W/30 API CF4/SG API CC 10W 30

Hydraulic System

55 litres

JCB 15W/40 Multigrade JCB 10W/30 Multigrade

API CE 15W 40 API CC 10W 30

JCB Universal Antifreeze/water

ASTM D3306-74

Cooling System Diesel Total coolant cap. 11 litres Antifreeze 5.5 litres Fuel System

90 litres

Diesel oil

ASTM D975-66T Nos. 1D, 2D

Grease Points

-

JCB Special HP Grease or JCB Special MPL Grease

Lithium based, No. 2 consistency

Waxoyl

-

Boom Runways

9804/1103

80 - 00 - 01/1

Issue 2*

CONTENTS

Teletruk

80 - 00 - 02/1

All Models Static Dimensions Dimensions

2.0/2.5

3.0

A Overall length to fork face

2625 mm

2750 mm

B Overall machine width

1175 mm

1280 mm

C Height of overhead guard standard container

2190 mm 2090 mm

2195 mm 2095 mm

4580 mm

4625 mm

D Wheelbase

1700 mm

1700 mm

Ground clearance E at centre of wheelbase F at lowest point

135 mm 105 mm

160 mm 130 mm

Height - boom extended

C

F E B

D A A286920

9804/1103

80 - 00 - 02/1

Issue 2*

CONTENTS

Teletruk

80 - 00 - 02/2

Models To S/N 0788000 Weight and Lifting Capacity Weight Unladen TLT20D Diesel engine TLT20G LPG engine

4100 kg 4160 kg

TLT25D Diesel engine TLT25G LPG engine

4400 kg 4460 kg

Lifting Capacity TLT20D TLT20G

2000 kg 2000 kg

TLT25D TFL25G

2500 kg 2500 kg

Models - S/N 0788001 Onwards

Weight

2.0/2.5

3.0

Unladen Diesel engine LPG engine

4220 kg 4280 kg

4850 kg 5010 kg

Lifting Capacity TLT 20D TLT 20G

2000 kg 2000 kg

TLT 25D TLT 25G

2500 kg 2500 kg

TLT30D TLT 30G

3000 kg 3000 kg

9804/1103

80 - 00 - 02/2

Issue 1

CONTENTS

Teletruk

80 - 05 - 01/1

All Models Data - Electrical General

* Main

Fuses to m/c no. 788643

The electrical system is a 12 volt DC system with a negative earth.

The main fuse box is situated on the left side of the dash. The fuses and their respective circuits are shown below.

Bulbs

Fuse

In the event of a bulb failure, change the bulb. The specification for each bulb is given below:

A1

Note: These bulbs fitted to your machine will be dependant on which options were selected during manufacture. Headlights (Main/Dip) Worklights Front Sidelights Stop/Tail Lights Turn Indicators Interior Light Beacon

60/55 W 55 W 5W 21/5 W 21 W 10 W 55 W

A2 A3 A4 A5 A6 A7 A8 A9 A10

Fuses Various fuses are installed in the machine to protect the electrical circuits. If a circuit fails to operate, change the relevant fuse and then test the circuit for operation. If a fuse continually ‘blows’, there will probably be a fault in the circuit that will require rectification.

B1 B2 B3 B4 B5 B6 B7

Primary Fuses

B8 B9 B10

The primary fuse box is mounted on the battery. The fuses and their respective circuits are shown below.

C1

Circuit 1 Roadlights Relay Supply (optional) 2 Ignition Relay 1 Supply 3 Ignition Switch 4 Ignition Relay 2 Supply 5 Not Used

C2 C3

Rating 60 amp 30 amp 40 amp 30 amp

C4 C5 C6 C7 C8 C9 C10

Load Moment Indicator (from m/c S/NO788001 onwards) Reverse Alarm, Rear Worklight Engine Stop (E.S.O.S.) Transmission Control Box Parking Brake Solenoid Rear Worklight Information Display Centre (Switched) Rocker Switch Warning Lights Horn IDC Buzzer (Low Pressure. Low Fuel. High Temperatures) Front Worklights Beacon (Optional) Rear Wiper (Optional) Front Wiper (Optional) Interior Light (Optional) Radio (Optional) Heater (Optional) Face Fan (Optional) Information Display Centre (Un-switched Clock Memory) Low Fuel Switch Electrical Ancillaries (Optional Not Used

4 5

1

B

5 amp 10 amp 10 amp 5 amp 10 amp 10 amp 5 amp 5 amp 15 amp 15 amp 3 amp 10 amp 10 amp

Hazard Switch (Un-switched) (Optional) Brake Lights (Optional) Hazard Switch (Switched) (Optional) Headlight Main Beam (Optional) Headlight Dip Beam (Optional Left Hand Sidelights Right Hand Sidelights Not Used Not Used Not Used

A

Circuit Rating 5 amp 3 amp 10 amp 5 amp 10 amp 5 amp 5 amp

10 amp 5 amp 10 amp 15 amp 15 amp 5 amp 5 amp

C

2

3

S245110

9804/1103

80 - 05 - 01/1

3400 - C/1-1.2

Issue 3*

Teletruk

CONTENTS

80 - 05 - 01/2

All Machines

From m/c no. 788644

Data - Electrical (cont’d) Main Fuses Torque Convertor Response

Relays Torque Convertor Response

The main fuse box is situated on the left side of the dash. The fuses and their respective circuits are shown below.

1 2 3 4 5 6 7 8

A1 A2 A3 A4 A5 A6 A7

Circuit Rating 3 amp 10 amp 5 amp 10 amp 5 amp 5 amp

A9 A10

Load Moment Indicator Reverse Alarm, Rear Worklight Engine Stop (E.S.O.S.) Transmission Control Box Parking Brake Solenoid Rear Worklight Information Display Centre (Switched) Rocker Switch Warning Lights 5 amp Horn, Warning Buzzer (Low Pressure. Low Fuel. High Temperatures) 10 amp Front Worklights 10 amp Beacon (Optional) 5 amp

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Rear Wiper (Optional) Front Wiper (Optional) Interior Light (Optional) Radio (Optional) Heater (Optional) Face Fan (Optional) Differential Lock (Optional) Low Fuel Switch Electrical Ancillaries (Optional) Man Platform Option

10 amp 10 amp 5 amp 5 amp 15 amp 15 amp 5 amp 10 amp 10 amp 10 amp

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10

Hazard Switch (Un-switched) (Optional) Brake Lights (Optional) Hazard Switch (Switched) (Optional) Headlight Main Beam (Optional) Headlight Dip Beam (Optional) Left Hand Sidelights Right Hand Sidelights Not Used Not Used Front Working Lights (Optional)

10 amp 5 amp 10 amp 15 amp 15 amp 5 amp 5 amp

A8

C

B

A 5A

10A

10A

10A

9

10A

10A

8

5A

5A

5A

7

5A

15A

5A

6

5A

15A

15A

5

FNR

10A

5A

15A

4

STOP

5A

5A

10A

3

10A

10A

5A

2

3A

10A

10A

1

1 2 3

817/17019

Fuse

Parking Brake Neutral Start Ignition 1 Not Used Reverse Ignition 2 Direction Indicators Headlights

6

5

7

10A

10

8

10 amp 371300

A

B

1

C

2 3

4 5 67 8 281321

281321

9804/1103

80 - 05 - 01/2

3400 - C/1-2.1

Issue 1

Teletruk

CONTENTS

80 - 05 - 01/3

All Machines

From m/c no. 788644

Data - Electrical (cont’d) Main Fuses Intelligent Transmission

Relays Intelligent Transmission

The main fuse box is situated on the left side of the dash. The fuses and their respective circuits are shown below.

1 2 3 4 5 6 7 8 9

A1 A2 A3 A4 A5 A6 A7

Circuit Rating 3 amp 10 amp 5 amp 10 amp 5 amp 5 amp

A9 A10

Load Moment Indicator Reverse Alarm, Rear Worklight Engine Stop (E.S.O.S.) Transmission Control Box Parking Brake Solenoid Rear Worklight Information Display Centre (Switched) Rocker Switch Warning Lights 5 amp Horn, Warning Buzzer (Low Pressure. Low Fuel. High Temperatures) 10 amp Front Worklights 10 amp Beacon (Optional) 5 amp

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Rear Wiper (Optional) Front Wiper (Optional) Interior Light (Optional) Radio (Optional) Heater (Optional) Face Fan, Differential Lock (Optional) Not Used Low Fuel Switch Electrical Ancillaries (Optional) Man Platform Option

10 amp 10 amp 5 amp 5 amp 15 amp 10 amp

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10

Hazard Switch (Un-switched) (Optional) Brake Lights (Optional) Hazard Switch (Switched) (Optional) Headlight Main Beam (Optional) Headlight Dip Beam (Optional) Left Hand Sidelights Right Hand Sidelights Not Used Not Used Front Working Lights (Optional)

10 amp 5 amp 10 amp 15 amp 15 amp 5 amp 5 amp

A8

A

B

1

5A

10A

10A

10A

9

10A

10A

8

STOP

2 3

10 amp 10 amp 10 amp

4

C

B

A

10A

5A

10

5A

7

5A

15A

5A

6

5A

15A

15A

5

FNR

10A

5A

15A

4

STOP

5A

5A

10A

3

10A

10A

5A

2

3A

10A

10A

1

817/04894

Fuse

Engine Shut Off Solenoid Neutral Start Ignition 1 Reverse Ignition 2 Direction Indicators Headlights Main Beam Hazard Warning Lights

6

5

7

8 9

10 amp

371310

1

C

2 3 8 4 5 679 281321

281321

9804/1103

80 - 05 - 01/3

3400 - C/1-3.1

Issue 1

CONTENTS

Teletruk

80 - 05 - 02/1

All Models Data - Hydraulics Description The main components of the hydraulic circuit are the tank, pumps, control valve, filter, cooler, rams and unloader valve. The pumps are driven by the engine and are mounted in tandem. The tranmission pump is electronically operated via the drive controls and delivers pressurised oil to the wheel motors. The main pump delivers pressurised oil to the control valve. When a valve is operated by a control lever, it delivers the oil to one end of the appropriate ram. The pressurised oil forces the ram’s piston along the bore of the ram. Relief valves prevent system pressure from rising too far. The steering pump delivers pressurised oil to the steering ram via the orbitrol steering unit. The unloader valve dumps flow back to tank when pressure from the valve block increases above a preset level due to the load on the circuit, e.g. lifting a heavy weight on the forks. This reduces the load on the engine.

Relief Valve Operating Pressures (Oil temperature at 50 ˚C) Main Relief Valve (at 2800 rev/min) Auxiliary RElief Valves Brake Pressure Reducing Valve Unloader Valve 2.5 tonne 3.0 tonne Check Valve Steering Orbitrol Unit

245 bar (3553 lbf/in2) 255 bar (3698 lbf/in2) 25 bar (363 lbf/in2) At idle 80 bar (1160 lbf/in2) At max RPM 110-120 bar (1595-1740 lbf/in2) At idle 95 bar (1377 lbf/in2) At max RPM 190 bar (2755 lbf/in2) 3 bar (43.5 lbf/in2) 150 bar (2175 lbf/in2)

Pressure Tapping Points Four hydraulic tapping points are provided on the Teletruk for maintenance, these are listed in the table below: Position

Gauge

Pressure bar

Main Use bar

1 Transmission pump

40

30 (max.)

Charge pressure

2 Hydraulic pump

400

150

Unloader pressure

3 Steering Pump

400

245 150 17 - 18

MRV at full lift During turning At idle

4 Brake

40

25 17

At full lift At idle

Note: Hydraulic oil temperature should be at 50 degrees C.

Attachments

2.0/2.5

3.0

Working Pressure Oil Flow OR Working Pressure Oil Flow

110 bar 70 litres/min

110 bar 70 litres/min

245 bar 31 litres

245 bar 31 litres/min

9804/1103

80 - 05 - 02/1

Issue 2*

CONTENTS

Teletruk

80 - 05 - 03/1

All Models Data - Transmission Hydraulics Description The transmission pump and motor are combined in a system that provides an infinitely variable speed range between zero and maximum in both forward and reverse. The variable displacement pump has a parallel axial piston/slipper design in conjunction with a tiltable cradle swashplate to vary the pumps displacement. Reversing the direction of tilt of the swashplate reverses the flow of oil from the pump and thus the direction of rotation of the motor output. The pump is controlled by an electrical input signal. Two multi-function valves are included in the pump design to provide the check valve, pressure limiter, high pressure relief and bypass functions. The fixed displacement motors also use the parallel axial piston slipper design in conjunction with a fixed displacement swashplate. The motors include a multiple disc brake pack, held ‘on’ by spring force and released by hydraulic pressure. Note: JCB recommends that only minor repairs and replacements be carried out on the transmission pump and drive motors. Should anything more be required a reconditioned or new replacement unit should be fitted. The procedures in this section reflect this policy.

Data - Tyres General The Teletruk may be fitted with either pneumatic tyres or solid tyres. This section describes the maintenance procedures for both types of tyre.

Specification 2.0/2.5 Models up to S/N 0788000 Type Semi solid or pneumatic Standard size front rear

7.00 x 12 6.00 x 9

Do not fit pneumatic tyres on a wheel made for a solid tyre. Do not fit a solid tyre on a wheel made for a pneumatic tyre. If you are unsure of the correct specification for your machine, contact your local JCB Distributor or a trained specialist.

Pressure (pneumatic) front 7.00 x 12 rear 6.00 x 9

9 bar 8.5 bar

12-6-1-1

Models S/N0788001 Onwards

!WARNING

!CAUTION

2.0/2.5

3.0

The wheels and tyres are heavy. Take care when lifting or moving them. 12-6-1-2

Type - Semi solid or pneumatic standard size front 7.00 x 12 rear 6.00 x 9 Pressure (pnuematic) Front 7.00 x 12 Crossply Watts Radial Michelin Front 27 x 10 x 12 Radials Continential Radials Michelin Rear 6.00 x 9 Crossply Watts Rear 6.5 x 10 Radials Continential Radials Michelin

9804/1103

80 - 05 - 03/1

27 x 10 x 12 6.5 x 10

9.5 bar (137.75 lbf/ in2) 7.0 bar (101.5 lbf/ in2) 10.0 bar (140.5 lbf/in2) 7.5 bar (108.75 lbf/in2)

8.5 bar (123.25 lbf/in2) 10.0 bar (140.lbf/in2) 9.0 bar (130.5 lb/ in2)

Issue 2

CONTENTS

Teletruk

80 - 05 - 04/1

All Models Data - Steering Description Steering is hydraulically controlled by a power track rod. Hydraulic oil is delivered from the steering pump via the flow/relief valve section to the steering unit. When the steering is turned the steering valve is actuated and a pressure demand signal sent to the priority inlet spool. The spool moves and directs pressurised oil from the pump to the steering valve and then the power track rod. Pressurised oil enters the power track rod and causes the ram to move to turn the wheels in the required direction. Shock valves are fitted to guard against shock steering loads. The steering pump and circuit is included in the Circuit Diagrams - Hydraulics.

Data - Brakes The brake circuit is included in Circuit Diagrams - Hydraulic.

9804/1103

80 - 05 - 04/1

Issue 1

CONTENTS

Teletruk

80 - 05 - 05/1

All Models Data - Engine Technical Data - Diesel engine Type Bore (nominal) Stroke Swept Volume Compression Ratio Injection Sequence Valve Clearance - Cold - Inlet and Exhaust Oil Pressure Manf. type

4 cylinder in-line, compression ignition, naturally aspirated. 84 mm (3.31 in) 100 mm (3.94 in) 2216 cm3 (135.2 in3) 22 : 1 1,3,4,2 0.2 mm (0.0078 in) 2.6 - 3.5 bar (38 - 52 lbf/in2, 2.7 - 3.6 kgf/cm2) Perkins 104 2.2

Speeds Rated Speed Idling Speed

2800 rev/min 850 - 950 rev/min

Fuel System Injection Pump Type Governing Static Timing Injector Codes Injector Setting Pressure

Bosch 104135-4010 Mechanical 19° BTDC Bosch 105148-1170 147 bar (2133 lbf/in2, 150 kgf/cm2)

Cooling System Fan Type Coolant Pressure Thermostat operating temperature Temperature Warning Light operates at

Mechanical 1 bar (14.5 lbf/in2, 1.02 kgf/cm2) 82 - 94 °C (180 - 200 °F) 97 - 103 °C (207 - 217 °F)

Note: Should further details be required, refer to Engine Service Manual 9806/2100.

Technical Data - LPG engine Type Bore (nominal) Stroke Swept Volume Compression Ratio Firing Sequence Valve Clearance - Cold - Inlet Exhaust Maximum Air Cleaner Restriction Maximum Back Pressure (Exhaust) Manf. type Speeds Rated Speed Idling Speed

4 cylinder in-line, spark ignition, naturally aspirated. 101.6 mm (4 in) 91.44 mm (3.6 in) 2966.59 cm3 (181 in3) 9.25 : 1 1,3,4,2 Refer to Engine Service Manual 9806/2150

GM 3.0 L4 3000 rev/min 850 - 900 rev/min

Fuel System LPG Carburettor, vapouriser and water heated filter. Cooling System Fan Type Coolant Pressure Thermostat operating temperature Temperature Warning Light operates at

Mechanical 1 bar (14.5 lbf/in2, 1.02 kgf/cm2) 82 - 94 °C (180 - 200 °F) 97 - 103 °C (207 - 217 °F)

Note: Should further details be required for the refitting of the engine refer to Engine Service Manual 9806/2150

9804/1103

80 - 05 - 05/1

Issue 2

CONTENTS

Teletruk

80 - 15 - 01/1

All Models up to S/N 0788000 Circuit Diagrams - Electrical Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 13A 14 15 16 16A 17 18 19 20 21 22 23 24 25 26 27A 27B 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 44A 45 46 47 48 49 50 51 52 53 54 55 56

Battery Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valv Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Solenoid Key Switch Glow Plugs Glow Plugs Glow Plugs Glow Plugs Starter Solenoid Starter Motor Neutral Start Relay Starter Relay Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Reverse Relay Reverse Alarm Buzzer Engine Shut Off Solenoid - Relay Engine Shut Off Solenoid Electronic Brake Control Unit Park Brake Switch EDC (Pump Swash Operation) Susmic 12 PPU (Pump Speed Sensor) Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal SAS Actuator (Engine Revs) Clock (IDC Internal) Hourmeter (IDC Internal) Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Low Fuel Oil Level Air Filter Vacuum Switch Filter Bypass IDC Buzzer Head Light LED Mini Relay Alternator Alternator Resister Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch Beacon Switch Beacon Motor Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Flasher Unit Brake Light Switch Ignition Relay 2

9804/1103

58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76

Rear Wash/Wipe Switch Rear Washer Motor Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Head Light Flash Switch Road Lights Relay Road Lights Switch Dip Switch Interior Light Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor

Lamps 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

Rear Work Light Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Low Fuel Level Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam Warning LED Indicator Warning LED Right Hand Front Work Light Left Hand Front Work Light Beacon Lamp Left Hand Indicator (Rear) Hazard Switch Warning LED Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light

Primary Fuses F1 Roadlights Relay Supply (optional) F2 Ignition Relay 1 Supply F3 Key Switch F4 Starter Relay 2 Supply Note: For bulb and fuse ratings see page 80-05-01/1 (LEDS not service parts)

80 - 15 - 01/1

Issue 2*

CONTENTS

Teletruk

80 - 15 - 01/2

All Models up to S/N 0788000 Circuit Diagram - Electrical (continued)

600

600

21 4

7

9 10

25

13A 19

22

982

981

12

13 11

6

3

16A

972

971

5

18

14

20

24

425

417F

416F

424

GREEN

23

417E

416E

125C

125B

125D

2

125A

1

G

80 16

17 8

RED

A3

F2

31

32 33

30 A5

001K

27B

A6

15

F3

27A

BLACK

A2

A1

29

A4 26

28

B9

A283260

9804/1103

80 - 15 - 01/2

Issue 2*

Teletruk

CONTENTS

80 - 15 - 01/3

All Models up to S/N 0788000 Circuit Diagram - Electrical (continued)

38 40 41 37 39

94

91 44

53

47 92

50

104

101

98 100

93

99

97

96

70B 107

105 57

59

62

102

68 108

103 106

109

69 602

60

73 860

36

63

76

70A

35 64 42

48

34

67

49 52

58

54

82 84 86 88 90

61

45 81

83 85 87 89

72

46

75

66

55

51

71

43

74

95 C2 A9

B8

A7

B7

A8

65

A10 C3

B1

C1

B3

B4

B2

001K

56 B5 F4

B6

F1

A283270

9804/1103

80 - 15 - 01/3

Issue 2

CONTENTS

Teletruk

80 - 15 - 01/4

All Models

* M/c

nos. 788001 to 788643

Circuit Diagrams Electrical Main Components (Diesel Engine, Single Pedal) 1 2 3 4 5 6 7 8 9 10 11 12 13 13A 14 15 16 16A 17 18 19 20 21 22 23 24 25 26 27A 27B 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 44A 45 46 47 48 49 50 51 52 53 54 55 56

Battery Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Solenoid Key Switch Glow Plugs Glow Plugs Glow Plugs Glow Plugs Starter Solenoid Starter Motor Neutral Start Relay Starter Relay Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Reverse Relay Reverse Alarm Buzzer Engine Shut Off Solenoid - Relay Engine Shut Off Solenoid Electronic Brake Control Unit Park Brake Switch EDC (Pump Swash Operation) Susmic 12 PPU (Pump Speed Sensor) Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal SAS Actuator (Engine Revs) Clock (IDC Internal) Hourmeter (IDC Internal) Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Low Fuel Oil Level Air Filter Vacuum Switch Filter Bypass IDC Buzzer Head Light LED Mini Relay Alternator Alternator Resister Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch Beacon Switch Beacon Motor Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Flasher Unit Brake Light Switch Ignition Relay 2

9804/1103

58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76

Rear Wash/Wipe Switch Rear Washer Motor Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Head Light Flash Switch Road Lights Relay Road Lights Switch Dip Switch Interior Light Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor

Lamps 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

Rear Work Light Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Low Fuel Level Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam Warning LED Indicator Warning LED Right Hand Front Work Light Left Hand Front Work Light Beacon Lamp Left Hand Indicator (Rear) Hazard Switch Warning LED Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light

Primary Fuses F1 Roadlights Relay Supply (optional) F2 Ignition Relay 1 Supply F3 Key Switch F4 Starter Relay 2 Supply Note: For bulb and fuse ratings see page 80 - 05 - 01/1. (LEDs not service part)

80 - 15 - 01/4

3400 - C/3-2.4

Issue 4*

Teletruk

CONTENTS *

80 - 15 - 01/5 * M/c

All Models

nos. 788001 to 788643

Circuit Diagrams - Electrical Main Components (Diesel Engine, Single Pedal

600 9

11

21 13A

401

25

19

13 10

22

12 80 16

16A

18

20

1

24

14

23

17 A2

A1 8

A3

A6

15

A5 F3

F2

31 27A 27B 26

30

32 33

29

A4 28

002 108 001K

9804/1103

80 - 15 - 01/5

Issue 2*

CONTENTS *

Teletruk

80 - 15 - 01/6 * M/c

All Models

nos. 788001 to 788643

Circuit Diagrams - Electrical Main Components (Diesel Engine, Single Pedal

37 39 41

600 36 401

94

38 40

91 44 47

99

96

50

92

53

57

100

98

93

62 63

59

99

107

104 101 103 102

105 106

70 68

108 109

4

7

76 69

3

73

6

35 42 34

82 84 86 88 90 81 83 85 87 89

49

48

72 52

54

55

45

58

46

61

75 2

51

5

71 43 B8

A7

95 A8

A9

65 C3

B7

74

C2

A10 C1

B1

B3

B2

56 F4

B4

B5

B6 B9

F1

002 108 001K

9804/1103

80 - 15 - 01/6

Issue 2*

9804/1103 F3 001

F2 30A 30A

F4

F1 60A 40A

F3

10

F2

001A

80 - 15 - 01/6A A6 A5 A4

A3 24

23 25 26

28

27

RS232 DIAGNOSTIC CONNECTOR ON PSION UNIT 29

ACCELERATOR

MAIN FUSE BOX DETAILS

3400 - C/3-3A.1

1 2 3 4 5 6

B

809E

401J

31 428

28 AN.IN ACH2

27 DIG.INP1.1

26 RS232 GND

25 AN.IN ACH3

24 SENSOR +

23 SENSOR +

Teletruk

427

426

416G

R

W

430

808F

429

21 D OUT 1 22 SENSOR -

HANDBRAKE EARTH

E.S.O.S

REVERSE ALARM

REAR WORKLIGHT

S.L.I.

IGNITION RELAY 1

STARTER SOLENOID

STARTER MOTOR

GLOW PLUGS

All Models

417G

C B A

417B 428

417A

416B

427

20 D OUT 0

19 AN.IN ACH1 426

425

17 TXD

16 RXD

15 DIG INP 1.3

14 PPU/IN 1

13 SENSOR-

12 IGNITION

11 PPU/IN 0

10 +BATTERY

9 DIG INP 1.0

8 DIG INP 1.2

7 BID OUT 2

6 BID OUT 1

5 +SENSOR

4 -SENSOR

3 CHASSIS

18 AN.IN ACHO

422

429

1 +BATTERY 2 -BATTERY

424

423

422

421

416A

130C

423

30

PEDAL

INCH/BRAKES

A B C

418 419

431

A B

130B

808

808

21

842B

GREEN

ELEVATION

7

PEDAL

20

1 2 3 4 5 6 7 8 9

401

417

416

600HJ

600HG

130A

416J

417J

420

418

22

TILT

A2 HANDBRAKE SWITCH

1 8

RED

3

17

BLACK

4 122

14 600JY

1 2 3 4 5 6

F N R

1

E.S.O.S RELAY

807

19

3 1 4

6 REVERSE RELAY

7

130

2 105

807

6

FUSE A4

13 2

15

FUSE A3

5 107E

861A

TRANSDUCER

12

122

A1 FUSE A2

861

18

PPU

002 REAR WORKLIGHT SWITCH

974

S.L.I. UNIT

NEUTRAL START RELAY

842

16

FUSE A5

2 FUSE A1

004

463

FUSE A6

KEY SWITCH

11 464

009

9 4 3 7

5

AUX

6 5

8

9

IGNITION RELAY 1

1

1

30A

2

600

4

F5

310B

310A

BATTERY

3

80A

40A

003

CONTENTS

80 - 15 - 01/6A

From m/c no. 788644

Circuit Diagrams - Electrical Main Components (Diesel Engine, Single Pedal)

600

8

SUSMIC 12 401

ELECTRONIC BRAKE CONTROL UNIT

SAS

ACTUATOR 32

002 108 001K

Issue 1

9804/1103

80 - 15 - 01/6B 007

F4

B2 5

8 6

2

79 2

2

80 1

3

6

3

5 2 4

B3

310

69 B5

001A

3400 - C/3-3C.1

7

3 2

94

7

8

B6 B9

98

100

125D

101 972

125B

FUSE C5

C5 971

800B

800B

830

829

FUSE C4

834

859

SOL1

SOL1

600EG

SPEAKER

601

102

AUX BUTTON 2

304

303A

FUSE C7

FUSE C6

DIP SWITCH

C6C7

AUX BUTTON 1

HEATER RESISTOR

82

828

832

81

91 93

125C

76

833

836

78

125A

8

837

M

001K 114E

1

90

FACE FAN SWITCH

3

H/LIGHT FLASH

2

89

114E

66

303

M

106

22

7

800

73

2

841

C4

88

HEATER SWITCH

8

5

FRONT W/W SWITCH

839

75

87

FUSE B9

B1

1

840

BRAKE LIGHT

AUX SOLENIOD 2

AUX SOLENIOD 1

FACE FAN

HEATER MOTOR

RADIO

INTERIOR LIGHT

LIGHT SWITCH

RH SIDE LIGHT

RH TAIL LIGHT

LH SIDE LIGHT

LH TAIL LIGHT

RH DIP BEAM

LH DIP BEAM

RH MAIN BEAM

LH MAIN BEAM

LIGHTS RELAY

FRONT WIPER

FRONT WASHER PUMP

REAR WIPER

ROOF WASHER AND REAR WASHER PUMP

IGNITION RELAY 2

BRAKE LIGHT

Teletruk

FUSE B6

C2 C1

3 7

M

FUSE B4

66 2

103

84 85

FUSE B3

70 77

ROAD LIGHTS SWITCH

5

864

863

885

REAR W/W SWITCH

862

M

86

310

816

FLASHER UNIT

RH REAR INDICATOR

RH FRONT INDICATOR

LH FRONT INDICATOR

LH REAR INDICATOR

HAZARD SWITCH

BEACON

FRONT WORKING LIGHTS

FRONT HORN

ALTERNATOR

ENGINE SHUT DOWN

FILTER BYPASS

AIR FILTER VAC. SWITCH

LOW FUEL LEVEL

ENGINE OIL PRESS SWITC

TRANS OIL TEMP SWITCH

WATER TEMP SWITCH

All Models

FUSE B5

C3

1

BRAKE LIGHTS SWITCH

74

ROAD LIGHTS RELAY

5

83

102

A10

M

009

106

18

C2

67

110

17 49

31

66

FUSE B1

10

61

68

103

8

806

63 72

FUSE B2

50 108D

8

FUSE C2

2

300

3 7

FUSE C1

1

49a

62

802

8 2

104

3 7

804

55 DIR.IND LED RELAY

600

71

F1

A9 2

65 64

FUSE C3

A8 59 805

M

INDICATOR SWITCH

814

60

803

56 BEACON SWITCH

894

855

57 58

HAZARD SWITCH

54 106F

1

F/W/L SWITCH

2

303

49

FUSE A10

53

HORN SWITCH (BUTTON)

407

116

110J

411B

413

402

408

403

404

406

401

51

FUSE A9

WARNING LIGHTS HORN SWITCH (COLUMN)

411

44 46 48

FUSE A8

310A

887

106

TURN SIGNAL

MAIN BEAM

FILTER BYPASS

AIR FILTER

LOW FUEL LEVEL

ENGINE OIL PRES

TRANS OIL TEMP

37 39 40 42 36 38 41

HEADLIGHT LED RELAY

A7 WATER TEMP

35

HAND BRAKE

34

ALTERNATOR

MASTER W/LIGHT

MASTER W/LIGHT

HOURS COUNTER

43 45 47

60A

IGNITION RELAY 2

B8 106

1 3 2

33

FUSE A7

106V

52

30A

F4

FUSE B8

CONTENTS

80 - 15 - 01/6B

From m/c no. 788644

Circuit Diagrams - Electrical Main Components (Diesel Engine, Single Pedal) (cont’d)

105

99 M

92 96 104

95 103

97

B4

837

001A

001K 106

Issue 1

CONTENTS

Teletruk

80 - 15 - 01/6C

All Models

From m/c no. 788644

Circuit Diagrams - Electrical Main Components (Diesel Engine, Single Pedal) (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 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 Key Switch Glow Plugs Glow Plugs Glow Plugs Glow Plugs Starter Solenoid Starter Motor Neutral Start Relay Ignition 1 Relay Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Rear Work Light Reverse Relay Reverse Alarm Buzzer Engine Shut Off Solenoid - Relay Engine Shut Off Solenoid Electronic Brake Control Unit Park Brake Switch Electric Displacement Control (Pump Swash Operation) Susmic S1X Pluse Pick-up (Pump Speed Sensor) Forward/Reverse Selector Switch Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal Throttle Motor Actuator (Engine Revs) Hourmeter Master Warning LED Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Low Fuel Level Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Low Fuel Level Air Filter Vacuum Switch Filter Bypass Information Display Centre Buzzer Head Light LED Mini Relay Alternator Engine Shut Down Solenoid Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch Right Hand Front Work Light

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 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105

Left Hand Front Work Light Beacon Switch Beacon Motor/Light Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Left Hand Indicator (Rear) Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Flasher Unit Ignition Relay 2 Brake Light Switch Left Hand Brake Light Right Hand Brake Light Rear Wash/Wipe Switch Roof and Rear Washer Pump Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Road Lights Relay Road Lights Switch Head Light Flash Switch Dip Switch Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light and Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor Auxiliary 1 Valve Switch Auxiliary 1 Valve Relay Auxiliary 1 Valve Solenoid Auxiliary 2 Valve Switch Auxiliary 2 Valve Relay Auxiliary 2 Valve Solenoid

Primary Fuses F1 Roadlights Relay Supply (optional) F2 Ignition Relay 1 Supply F3 Key Switch F4 Starter Relay 2 Supply Note: For bulb and fuse ratings see pages 80 - 05 - 01/1 and 80 - 05 - 01/2. (LEDs not service part)

80 - 15 - 01/6C

3400 - C/3-3B.1

Issue 1

CONTENTS

Teletruk

80 - 15 - 01/7

* All

Models Circuit Diagrams - Electrical Main Components (Diesel Engine, Twin Pedal) 1 2 3 4 5 6 7 8 9 10 11 12 13 13A 14 15 16 16A 17 18 19 21 22 23 24 25 26 27A 27B 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 44A 45 46 47 48 49 50 51 52 53 54 55 56 57 58

Battery Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Solenoid Key Switch Glow Plugs Glow Plugs Glow Plugs Glow Plugs Starter Solenoid Starter Motor Neutral Start Relay Starter Relay Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Reverse Alarm Relay Reverse Alarm Buzzer Engine Shut Off Solenoid Electronic Brake Control Unit Park Brake Switch EDC (Pump Swash Operation) Susmic 12 PPU (Pump Speed Sensor) Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal SAS Actuator (Engine Revs) Clock (IDC Internal) Hourmeter (IDC Internal) Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Low Fuel Oil Level Air Filter Vacuum Switch Filter Bypass IDC Buzzer Head Light LED Mini Relay Alternator Alternator Resister Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch Beacon Switch Beacon Motor Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Flasher Unit Brake Light Switch Ignition Relay 2 Roof and Rear Screen Washer Motor Rear Wash/Wipe Switch

9804/1103

* M/c

60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 77A 78 78A

Nos. 788001 to 788643

Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Head Light Flash Switch Road Lights Relay Road Lights Switch Dip Switch Interior Light Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor Reverse Relay Reverse Microswitch Forward Relay Forward Microswitch

Lamps 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

Rear Work Light Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Low Fuel Level Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam Warning LED Indicator Warning LED Right Hand Front Work Light Left Hand Front Work Light Beacon Lamp Left Hand Indicator (Rear) Hazard Switch Warning LED Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light

Primary Fuses F1 Roadlights Relay Supply (optional) F2 Ignition Relay 1 Supply F3 Key Switch F4 Starter Relay 2 Supply Note: For bulb and fuse ratings see page 80 - 05 - 01/1. (LEDs not service part)

80 - 15 - 01/7

3400 - C/3-5.2

Issue 4*

Teletruk

CONTENTS *

80 - 15 - 01/8 * M/c

All Models

Nos. 788001 to 788643

Circuit Diagrams - Electrical Main Components (Diesel Engine, Twin Pedal)

600 21 9

11 13A

19 22

13 10

401

25

12 16

16A

18

1

24

14 23

17 A1

8

78

77

27A 27B

A2 A3 A6

15

9804/1103

F2

80 - 15 - 01/8

31

32

33

29

A5 F3

30

A4 77A

78A

26 28

3400 - C/3-4.1

Issue 2*

Teletruk

CONTENTS *

80 - 15 - 01/9 * M/c

All Models

no.s 788001 to 788643

Circuit Diagrams - Electrical Main Components (Diesel Engine, Twin Pedal)

37 39 41 36 38 40 53

104

91 44

47

99 50

92

94

98

93

57

100

60

62

97

63

101 103 102

107

4 68

105

73 106 108

96 C4

70 7

76

69 109

C5

6

3

35 44A 34

48

42 82 84 86 88 90 81 83 85 87 89

C6 67 C7

49 54

52

55

45

75

64 58

61

2

51

46

72

5

66 71

43 B8

A7

95 A8

B7

A9

A10

C2 C3

74

65

C1

B1

B3

B2

B4

56 B5

B6

B9

F1

9804/1103

80 - 15 - 01/9

3400 - C/3-6.1

Issue 2*

9804/1103 F2 30A 30A

F4

F1 60A 40A

F3 001

F2

10

80 - 15 - 01/9A A5 18 20 A4 30

26 29

28 RS232 DIAGNOSTIC CONNECTOR ON PSION UNIT

31

3400 - C/3-6A.1

PEDAL

32 INCH/BRAKES

PEDAL

1 2 3 4 5 6

33 427

28 AN.IN ACH2

27 DIG.INP1.1

26 RS232 GND

25 AN.IN ACH3

Teletruk

426

416G

C B C A

430

808F

429

HANDBRAKE EARTH

E.S.O.S

REVERSE HORN

REAR WORKLIGHT

S.L.I.

IGNITION RELAY 1

STARTER SOLENOID

STARTER MOTOR

GLOW PLUGS

All Models

428

417G

429

428

24 SENSOR +

22 SENSOR -

21 D OUT 1

20 D OUT 0

19 AN.IN ACH1

18 AN.IN ACHO

17 TXD

16 RXD

15 DIG INP 1.3

14 PPU/IN 1

13 SENSOR-

12 IGNITION

11 PPU/IN 0

10 +BATTERY

9 DIG INP 1.0

8 DIG INP 1.2

7 BID OUT 2

6 BID OUT 1

5 +SENSOR

4 -SENSOR

3 CHASSIS

417B

416B

427

426

425

424

423

422

421

416A

130C

431

130B

809E

401J

419

418

417

416

600HJ

1 +BATTERY 2 -BATTERY

422

A B

130A 600HG

23 SENSOR +

808

417A

A B C

7

ACCELERATOR

1 2 3 4 5 6 7 8 9

24

423

GREEN

ELEVATION

27

TILT

RED BLACK

23

AUX

3 1 4

21 FOWARD RELAY

817

809E

600AC

HANDBRAKE SWITCH

PPU

130

9

7

10

416J

417J

420

418

1 2 3 4 5 6

401

8

842B

808

600AB

6

6

4

REVERSE RELAY

A3 2

22

FUSE A4

A2 5

19

896

13 600JY

5

FOWARD MICROSWITCH

1 8

122G

3

1

4 122

14

REVERSE MICROSWITCH

A6 807

842

7

3

1

17

122F

2

122

6

2 105

5

15 REVERSE RELAY

12

FUSE A3

807

TRANSDUCER

463

107E

861A

S.L.I. UNIT

NEUTRAL START RELAY

464

FUSE A5

A1 FUSE A2

861

974

REAR WORKLIGHT SWITCH

004

16

897

002

FUSE A6

FUSE A1

KEY SWITCH

11

009

IGNITION RELAY 1

7

2

2(7)

3

9

1

30A

6 5

8

9

1(6)

F5

1

600

4

310B

2

BATTERY

3

80A

310A

40A F3

003

CONTENTS

80 - 15 - 01/9A

From m/c n. 788644

Circuit Diagrams - Electrical Main Components (Diesel Engine, Twin Pedal)

8 25

ELECTRONIC BRAKE CONTROL UNIT

34 SAS

ACTUATOR

001A

MAIN FUSE BOX DETAILS

5(10)

MICRORELAY BASE CONNECTIONS 4(9)

3(8)

Issue 1

9804/1103

80 - 15 - 01/9B C1

B1

837

B2 8

832

86

2

5 2 1

2

6

85

3

84 3

310

74

001A

3400 - C/3-6C.1

B3 B4

B5

7

98 6 3

5 2 4

FACE FAN

HEATER RESISTOR

304

303A

FUSE C7

FUSE C6

DIP SWITCH

99

2

7

8

B6 102

B9

104

125D

FUSE C5

105 972

125B

971

800B

800B

830

829

833

FUSE C4

834

859

SOL1

SOL1

600EG

SPEAKER

601

106

AUX BUTTON 2

83

C5

125C

80 837

303

M

AUX BUTTON 1

8

828

C6 C7

125A

1

836

103

97

001K 114E

3

841

839

95

FACE FAN SWITCH

66

94

114E

77 7

H/LIGHT FLASH

2

93

106

8

2

FRONT W/W SWITCH

840

C4

800

1 5

92

HEATER SWITCH

22

90

FUSE B4

3 7

M

91

FUSE B3

66 2

864

863

M

88 89

310

5

REAR W/W SWITCH

862

67

FUSE B9

C3

AUX SOLENIOD 2

AUX SOLENIOD 1

FACE FAN

HEATER MOTOR

RADIO

INTERIOR LIGHT

LIGHT SWITCH

RH SIDE LIGHT

RH TAIL LIGHT

LH SIDE LIGHT

LH TAIL LIGHT

RH DIP BEAM

LH DIP BEAM

RH MAIN BEAM

LH MAIN BEAM

LIGHTS RELAY

FRONT WIPER

FRONT WASHER PUMP

REAR WIPER

ROOF WASHER AND REAR WASHER PUMP

IGNITION RELAY 2

BRAKE LIGHT

BRAKE LIGHT

FLASHER UNIT

RH REAR INDICATOR

RH FRONT INDICATOR

LH FRONT INDICATOR

LH REAR INDICATOR

Teletruk

FUSE B6

A10 1

73

M

ROAD LIGHTS SWITCH

816

885

82 81

ROAD LIGHTS RELAY

72 BRAKE LIGHTS SWITCH

87

102

5 C2

70

79 78

009

106

18

76

110

17

M

FUSE B2

10

65 49

71

FUSE B1

8

75

103

8

108D

2

FUSE C2

3 7

300

1

31

63

802

66 806

69 DIR.IND LED RELAY

68

FUSE C1

A8 104

8

HAZARD SWITCH

BEACON

FRONT WORKING LIGHTS

FRONT HORN

ALTERNATOR

ENGINE SHUT DOWN

FILTER BYPASS

AIR FILTER VAC. SWITCH

LOW FUEL LEVEL

ENGINE OIL PRESS SWITC

TRANS OIL TEMP SWITCH

WATER TEMP SWITCH

All Models

FUSE B5

A9 2

2

49a

805

59

INDICATOR SWITCH

M

804

3 7 803

60 BEACON SWITCH

894

814

64

FUSE C3

58 106F

1

F/W/L SWITCH

855

411B

413

402

408

403

404

62

HAZARD SWITCH

303

2

FUSE A10

HORN SWITCH (BUTTON)

411

401 406

55

F1

54 116

110J

57

FUSE A9

TURN SIGNAL

MAIN BEAM

FILTER BYPASS

AIR FILTER

407

FUSE A8

WARNING LIGHTS HORN SWITCH (COLUMN)

106

39 42 40 45 41 43 44 46 53 38

LOW FUEL LEVEL

ENGINE OIL PRES

TRANS OIL TEMP

WATER TEMP

HAND BRAKE

61

60A

A7 ALTERNATOR

MASTER W/LIGHT

HOURS COUNTER

56

IGNITION RELAY 2

B8 310A

887

MASTER W/LIGHT

36 37

HEADLIGHT LED RELAY

106

1 3 2

35

FUSE A7

106V

47 49 51 48 50 52

30A

F4

FUSE B8

CONTENTS

80 - 15 - 01/9B

From m/c n. 788644

Circuit Diagrams - Electrical Main Components (Diesel Engine, Twin Pedal)

600

109

103

96 M

100 108

107

101

007

007 001A

001K 106

Issue 1

CONTENTS

Teletruk

80 - 15 - 01/9C

All Models

Fromm m/c no. 788644

Circuit Diagrams Electrical Main Components From No. 788644 (Diesel Engine, Twin Pedal) 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 Key Switch Glow Plugs Glow Plugs Glow Plugs Glow Plugs Starter Solenoid Starter Motor Neutral Start Relay Ignition 1 Relay Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Rear Work Light Reverse Alarm Relay Reverse Alarm Buzzer Engine Shut Off Solenoid Reverse Microswitch Reverse Relay Forward Microswitch Forward Relay Electronic Brake Control Unit Park Brake Switch Electric Displacement Control (Pump Swash Operation) Susmic 12 Pulse Pick-up (Pump Speed Sensor) Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal Throtle Motor Actuator (Engine Revs) Hourmeter Master Warning LED Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Low Fuel Level Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam Warning LED Indicator Warning LED Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Low Fuel Level Air Filter Vacuum Switch Filter Bypass Information Display Centre Buzzer Head Light LED Mini Relay Alternator Engine Shut Down Solenoid Horn Switch - Column Horn Switch - Push Horn Front Work 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 99 100 101 102 103 104 105 106 107 108 109

Right Hand Front Work Light Left Hand Front Work Light Beacon Switch Beacon Motor/Light Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Left Hand Indicator (Rear) Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Flasher Unit Brake Light Switch Ignition Relay 2 Left Hand Brake Light Right Hand Brake Light Rear Wash/Wipe Switch Rear and Roof Washer Motor Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Head Light Flash Switch Road Lights Relay Road Lights Switch Dip Switch Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light and Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor Auxiliary 1 Valve Switch Auxiliary 1 Valve Relay Auxiliary 1 Valve Solenoid Auxiliary 2 Valve Switch Auxiliary 2 Valve Relay Auxiliary 2 Valve Solenoid

Primary Fuses F1 Roadlights Relay Supply (optional) F2 Ignition Relay 1 Supply F3 Key Switch F4 Starter Relay 2 Supply Note: For bulb and fuse ratings see pages 80 - 05 - 01/1 and 80 - 05 - 01/2. (LEDs not service part).

80 - 15 - 01/9C

3400 - C/3-6B.1

Issue 1

CONTENTS * All

Teletruk

80 - 15 - 01/10

Models

*

M/c Nos. 788001 to 788643

Circuit Diagrams - Electrical Main Components (LPG Engine, Single Pedal) 1 2 3 4 5 6 7 8 9 10 13 13A 14 15 16 16A 17 18 19 20 22 23 24 25 26 27A 27B 28 29 30 31 32 33 34 35 36 37 38 40 41 42 43 44 44A 45 46 47 48 49 50 51 52 53 54 55 56 57

Battery Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Solenoid Key Switch Distributor Ignition Coil Starter Solenoid Starter Motor Neutral Start Relay Starter Relay Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Reverse Relay Reverse Alarm Buzzer Coil Relay Electronic Brake Control Unit Park Brake Switch EDC (Pump Swash Operation) Susmic 12 PPU (Pump Speed Sensor) Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal SAS Actuator (Engine Revs) Clock (IDC Internal) Hourmeter (IDC Internal) Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Air Filter Vacuum Switch Filter Bypass IDC Buzzer Head Light LED Mini Relay Alternator Alternator Resister Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch Beacon Switch Beacon Motor Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Flasher Unit Brake Light Switch Ignition Relay 2 Roof and Rear Screen Washer Motor

9804/1103

58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76

Rear Wash/Wipe Switch Rear Washer Motor Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Head Light Flash Switch Road Lights Relay Road Lights Switch Dip Switch Interior Light Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor

Lamps 80 81 82 83 84 85 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109

Rear Work Light Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam Warning LED Indicator Warning LED Right Hand Front Work Light Left Hand Front Work Light Beacon Lamp Left Hand Indicator (Rear) Hazard Switch Warning LED Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light

Primary Fuses F1 Roadlights Relay Supply (optional) F2 Ignition Relay 1 Supply F3 Key Switch F4 Starter Relay 2 Supply Note: For bulb and fuse ratings see page 80 - 05 - 01/1. (LEDs not service part)

80 - 15 - 01/10

3400 - C/3-8.2

Issue 2*

Teletruk

CONTENTS *

80 - 15 - 01/11 * M/c

All Models

nos. 788001 to 788643

Circuit Diagrams - Electrical Main Components (LPG Engine, Single Pedal)

9 13A

25

19

13

10

22

80 16

16A

18

20

24

1 14

23 17 A1 8

A2

27A 27B

A3

A6 15

A5

26 A4

30

31

32

33

29 28

9804/1103

3400 - C/3-7.1

80 - 15 - 01/11

Issue 2*

Teletruk

CONTENTS * All

80 - 15 - 01/12 * M/c

Models

nos. 788001 to 788643

Circuit Diagrams - Electrical Main Components (LPG Engine, Single Pedal)

37 41 36 38 40

44

47

94

91

99

96

50

92

104

53

93

98

100

57

62 60

63

97

105

101

107 68

103 102

106 108 109

73

76

69 70

35 44A 34

82 84 88 90 81 83 85 87 89

48

42

49 52

45

C8 C7 67

55

54

75

64 58

46

72

61

51

66 71

A7

B7

43

A9

A10

74

C2 C3

C1

B1

B2

B3

65

56 F4

9804/1103

3400 - C/3-9.1

80 - 15 - 01/12

B4

B5

B6

B9

F1

CONTENTS

95 A8

Issue 2*

CONTENTS

Teletruk

80 - 15 - 01/12A

All Models

From m/c no. 788644

Circuit Diagrams - Electrical Main Components (LPG Engine, Single Pedal) 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 61

Battery Key Switch Ignition 1 Relay Neutral Start Relay Starter Solenoid Starter Motor Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Rear Work Light Reverse Relay Reverse Alarm Buzzer Coil Relay Ignition Coil Distributor To Ignition Module To Tachometer To Ignition Module Electronic Brake Control Unit Park Brake Switch Electric Display Centre (Pump Swash Operation) Susmic 12 Forward/Reverse Selector Pulse Pick-up (Pump Speed Sensor) Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal Throttle Motor Actuator (Engine Revs) Hourmeter Master Warning LED Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Low Fuel Level Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam LED Direction Indicator LED Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Low Fuel Level Air Filter Vacuum Switch Filter Bypass Information Display Centre Buzzer Head Light LED Mini Relay Alternator Engine Shut Down Solenoid Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch Right Hand Front Work Light Left Hand Front Work Light Beacon Switch

9804/1103

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

Beacon Motor/Light Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Left Hand Indicator (Rear) Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Flasher Unit Ignition Relay 2 Brake Light Switch Left Hand Brake Light Right Hand Brake Light Rear Wash/Wipe Switch Roof and Rear Washer Pump Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Road Lights Relay Road Lights Switch Head Light Flash Switch Dip Switch Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light and Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor Auxiliary 1 Valve Switch Auxiliary 1 Valve Relay Auxiliary 1 Valve Solenoid Auxiliary 2 Valve Switch Auxiliary 2 Valve Relay Auxiliary 2 Valve Solenoid

Primary Fuses F1 Roadlights Relay Supply (optional) F2 Ignition Relay 1 Supply F3 Key Switch F4 Starter Relay 2 Supply Note: For bulb and fuse ratings see page 80 - 05 - 01/1 and 80 - 05 - 01/2. (LEDs not service part)

80 - 15 - 01/12A

3400 - C/3-9B.1

Issue 1

9804/1103 F2 30A 30A

F4

F1 60A 40A

F3 F5

80A

310A

3

001

3400 - C/3-9A.1 001A

80 - 15 - 01/12B A3

A5 A4 23 26

28

24 27

RS232 DIAGNOSTIC CONNECTOR ON PSION UNIT 29

INCH/BRAKES

122

809E

401J

419

418

417

416

600HJ

600HG

130A

416J

417J

420

418

417G

429

417B

30 31 427

426

28 AN.IN ACH2

27 DIG.INP1.1

26 RS232 GND

25 AN.IN ACH3

24 SENSOR +

23 SENSOR +

22 SENSOR -

21 D OUT 1

20 D OUT 0

19 AN.IN ACH1

18 AN.IN ACHO

17 TXD

16 RXD

15 DIG INP 1.3

14 PPU/IN 1

13 SENSOR-

12 IGNITION

11 PPU/IN 0

10 +BATTERY

9 DIG INP 1.0

8 DIG INP 1.2

7 BID OUT 2

6 BID OUT 1

5 +SENSOR

4 -SENSOR

3 CHASSIS

All Models

428

1 +BATTERY 2 -BATTERY

HANDBRAKE EARTH

IGNITION COIL

REVERSE ALARM

REAR WORKLIGHT

S.L.I.

IGNITION RELAY 1

STARTER SOLENOID

STARTER MOTOR

Teletruk

416G

430

808F

429

428

417A 422

416B

427

426

425

424

423

422

421

416A

130C

423

C B A

1 2 3 4 5 6

808

431

21

130B

A B C

ACCELERATOR

18

808

A B

16

842B

GREEN

ELEVATION 25

PEDAL

20

1 2 3 4 5 6 7 8 9

401

7

PEDAL

1 8

RED

9 HANDBRAKE SWITCH

13

TILT

A2

1 2 3 4 5 6

BLACK

3

3 1 4

4

19

F N R

1 600JY

PRIMARY

14

130

2 105

5 22

PPU

A6 17

TO IGN MODULE TO TACHO TO IGN MODULE APPLIED

807

842

15

FUSE A4

6

2

11 REVERSE RELAY

10

FUSE A3

5 COIL RELAY

463 TRANSDUCER

8

107E

807

861A

S.L.I. UNIT

NEUTRAL START RELAY

464

SECONDARY

122

A1 FUSE A2

861

974

REAR WORKLIGHT SWITCH

004

12

FUSE A5

002

FUSE A6

FUSE A1

KEY SWITCH

7

009

4 3 7

9

600

DISTRIBUTOR

AUX

6 5

8

2

F2

1

4

30A

2

1

IGNITION RELAY 1

310B

40A F3

BATTERY

CONTENTS

80 - 15 - 01/12B

From m/c no. 788644

Circuit Diagrams - Electrical (cont’d) Main Components (LPG Engine, Single Pedal)

SUSMIC 12

6 ELECTRONIC BRAKE CONTROL UNIT

32

SAS

ACTUATOR

MAIN FUSE BOX DETAILS

Issue 1

9804/1103 3400 - C/3-9C.1

80 - 15 - 01/12C 001A

C3 C1

310

B1 B2 8

81 2

5 2 1

2

6

82 3

71

B3 B4

B5

78 7

96 6 3

5 2 4

FACE FAN

HEATER RESISTOR

304

303A

FUSE C7

FUSE C6

DIP SWITCH

97

2

7

8

B6

860

101

95 103

100 102

B9

972

834

98

125D

RH SPEAKER

602

FUSE C5

M

125B

971

800B

800B

830

829

FUSE C4

837

303

859

SOL1

SOL1

600EG

LH SPEAKER

601

104

AUX BUTTON 2

832

833

836

C5

95

125C

83 84

94 M

AUX BUTTON 1

8

93

125A

1 7

H/LIGHT FLASH

80

92

001K 114E

3

90

FACE FAN SWITCH

66

30

114E

2

91

106

75 2

800

8

5

841

C4

89

HEATER SWITCH

22

FRONT W/W SWITCH

839

77

88

FUSE B4

1 7

M

87

FUSE B3

C2

3

840

M 103

79

ROAD LIGHTS SWITCH

66 2

864

76

828

862

65

FUSE B9

A10 3

5

REAR W/W SWITCH

885 863

85

310

816

59

102

A8 1

72

M

ROAD LIGHTS RELAY

5

BRAKE LIGHTS SWITCH

70 86

M

009

106

18

C2

68

110

17

74

FUSE B2

10

63 49

69

FUSE B1

8

73

103

108D

8

FUSE C2

3 7

300

2

31

61 806

64

FUSE C1

1

AUX SOLENIOD 2

AUX SOLENIOD 1

FACE FAN

HEATER MOTOR

RADIO

INTERIOR LIGHT

LIGHT SWITCH

RH SIDE LIGHT

RH TAIL LIGHT

LH SIDE LIGHT

LH TAIL LIGHT

RH DIP BEAM

LH DIP BEAM

RH MAIN BEAM

LH MAIN BEAM

LIGHTS RELAY

FRONT WIPER

FRONT WASHER PUMP

REAR WIPER

ROOF WASHER AND REAR WASHER PUMP

IGNITION RELAY 2

BRAKE LIGHT

BRAKE LIGHT

FLASHER UNIT

RH REAR INDICATOR

RH FRONT INDICATOR

LH FRONT INDICATOR

LH REAR INDICATOR

HAZARD SWITCH

BEACON

FRONT WORKING LIGHTS

FRONT HORN

Teletruk

FUSE B6

A9 8

67

802

3

66

FUSE C3

2

2

49a

57

804

M DIR.IND LED RELAY

60

803

805

62

INDICATOR SWITCH

54

104

1

7

HAZARD SWITCH

56 106F

58 BEACON SWITCH

894

814

ALTERNATOR

ENGINE SHUT DOWN

FILTER BYPASS

AIR FILTER VAC. SWITCH

LOW LPG FUEL

ENGINE OIL PRESS SWITC

TRANS OIL TEMP SWITCH

WATER TEMP SWITCH

All Models

FUSE B5

52 2 F/W/L SWITCH

51

303

855

411B

413

402

53

FUSE A10

WARNING LIGHTS

55

116

44

HORN SWITCH (BUTTON)

43

110J

411

408

403

404

406

401

50

FUSE A9

MAIN BEAM

42

TURN SIGNAL

HOURS COUNTER

407

FUSE A8

40

FILTER BYPASS

41

HORN SWITCH (COLUMN)

106

37

AIR FILTER

39

LOW FUEL LEVEL

38

ENGINE OIL PRES

TRANS OIL TEMP

WATER TEMP

36 48 49

F1 60A

A7 310A

887

ALTERNATOR

HAND BRAKE

35 46 47

IGNITION RELAY 2

B8 MASTER W/LIGHT

MASTER W/LIGHT

1 3 2

34

HEADLIGHT LED RELAY

106

BULKHEAD CONNTR

33

FUSE A7

106V

45

30A

F4

FUSE B8

CONTENTS

80 - 15 - 01/12C

From m/c no. 788644

Circuit Diagrams - Electrical (cont’d) Main Components (LPG Engine, Single Pedal)

600

107

106

105

99

837 007

001A

001K 106

Issue 1

Teletruk

CONTENTS

* All

80 - 15 - 01/13

Models

* M/c

nos. 788001 to 788043

Circuit Diagrams - Electrical Main Components (LPG Engine, Twin Pedal) 1 2 3 4 5 6 7 8 9 10 13 13A 14 15 16 16A 17 18 19 22 23 24 25 26 27A 27B 28 29 30 31 32 33 34 35 36 37 38 40 41 42 43 44 44A 45 46 47 48 49 50 51 52 53 54 55 56 57 58

Battery Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Solenoid Key Switch Distributor Ignition Coil Starter Solenoid Starter Motor Neutral Start Relay Starter Relay Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Reverse Alarm Relay Reverse Alarm Buzzer Electronic Brake Control Unit Park Brake Switch EDC (Pump Swash Operation) Susmic 12 PPU (Pump Speed Sensor) Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal SAS Actuator (Engine Revs) Clock (IDC Internal) Hourmeter (IDC Internal) Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Air Filter Vacuum Switch Filter Bypass IDC Buzzer Head Light LED Mini Relay Alternator Alternator Resister Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch Beacon Switch Beacon Motor Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Flasher Unit Brake Light Switch Ignition Relay 2 Roof and Rear Screen Washer Motor Rear Wash/Wipe Switch

60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 77A 78 78A

Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Head Light Flash Switch Road Lights Relay Road Lights Switch Dip Switch Interior Light Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor Reverse Relay Reverse Microswitch Forward Relay Forward Microswitch

Lamps 80 81 82 83 84 85 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109

Rear Work Light Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam Warning LED Indicator Warning LED Right Hand Front Work Light Left Hand Front Work Light Beacon Lamp Left Hand Indicator (Rear) Hazard Switch Warning LED Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light

Primary Fuses F1 Roadlights Relay Supply (optional) F2 Ignition Relay 1 Supply F3 Key Switch F4 Starter Relay 2 Supply Note: For bulb and fuse ratings see page 80 - 05 - 01/1. (LEDs not service part)

9804/1103

80 - 15 - 01/13

3400 - C/3-11.2

Issue 2*

Teletruk

CONTENTS *

80 - 15 - 01/14

All Models

*

M/c nos. 788001 to 788643

Circuit Diagrams - Electrical Main Components (LPG Engine, Twin Pedal)

25 13A

19

9 22

13 80 16

10

16A

24

1

18 14

23 78

77

17

27A 27B

30

31

32

33

8 15 26 77A

9804/1103

3400 - C/3-10.2

80 - 15 - 01/14

78A

29 28

Issue 2*

CONTENTS *

Teletruk

80 - 15 - 01/15 * M/c

All Models

nos. 788001 to 788643

Circuit Diagrams - Electrical Main Components (LPG Engine, Twin Pedal)

41 37 36 38 40 53 91 44 47 92

50

99

94 93

96

57

98 100

60

63

97

7

107

101

62

4

70

104 105

103 102

68 106 108 109

73

76

69

6

3

35 44A 48

42 82 84 88 90 81 83 85 87 89

46 45

49

72

67 95 52

54

64

55 58

34

61

75 2

5

66 71 51

65

74

43

56

9804/1103

3400 - C/3-12.2

80 - 15 - 01/15

Issue 2*

CONTENTS

Teletruk

80 - 15 - 01/15A

All Models

From m/c no. 788644

Circuit Diagrams - Electrical Main Components (LPG Engine, Twin Pedal) 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 Key Switch Ignition 1 Relay Neutral Start Relay Starter Solenoid Starter Motor Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Rear Work Light Reverse Relay Reverse Alarm Buzzer Ignition Coil Distributor To Ignition Module To Tachometer To Ignition Module Electronic Brake Control Unit Park Brake Switch Electric Display Centre (Pump Swash Operation) Susmic Reverse Microswitch Reverse Relay Forward Microswitch Forward Relay Pulse Pick-up (Pump Speed Sensor) Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal Throttle Motor Actuator (Engine Revs) Hourmeter Master Warning LED Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Low Fuel Level Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam LED Direction Indicator LED Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Low Fuel Level Air Filter Vacuum Switch Filter Bypass Information Display Centre Buzzer Head Light LED Mini Relay Alternator Engine Shut Down Solenoid Horn Switch - Column Horn Switch - Push Horn Front Work 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 99 100 101 102 103 104 105 106 107 108 109

Right Hand Front Work Light Left Hand Front Work Light Beacon Switch Beacon Motor/Light Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Left Hand Indicator (Rear) Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Flasher Unit Ignition Relay 2 Brake Light Switch Left Hand Brake Light Right Hand Brake Light Rear Wash/Wipe Switch Roof and Rear Washer Pump Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Road Lights Relay Road Lights Switch Head Light Flash Switch Dip Switch Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light and Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor Auxiliary 1 Valve Switch Auxiliary 1 Valve Relay Auxiliary 1 Valve Solenoid Auxiliary 2 Valve Switch Auxiliary 2 Valve Relay Auxiliary 2 Valve Solenoid

Primary Fuses F1 Roadlights Relay Supply (optional) F2 Ignition Relay 1 Supply F3 Key Switch F4 Starter Relay 2 Supply Note: For bulb and fuse ratings see pages 80 - 05 - 01/1 and 80 - 05 - 01/2. (LEDs not service part)

80 - 15 - 01/15A

3400 - C/3-12B.1

Issue 1

9804/1103 F2 30A 30A

F4

F1 60A 40A

F3 001

3400 - C/3-12A.1 FUSE A5

3

80 - 15 - 01/15B A5 22 24 A4 29

30

TILT

26 28

RS232 DIAGNOSTIC CONNECTOR ON PSION UNIT 31

PEDAL

32

INCH/BRAKES

PEDAL

1 2 3 4 5 6

22 SENSOR -

21 D OUT 1

20 D OUT 0

19 AN.IN ACH1

18 AN.IN ACHO

17 TXD

16 RXD

15 DIG INP 1.3

14 PPU/IN 1

13 SENSOR-

12 IGNITION

11 PPU/IN 0

10 +BATTERY

9 DIG INP 1.0

8 DIG INP 1.2

7 BID OUT 2

6 BID OUT 1

5 +SENSOR

4 -SENSOR

3 CHASSIS

33 427

426

28 AN.IN ACH2

27 DIG.INP1.1

26 RS232 GND

25 AN.IN ACH3

Teletruk

416G

C B A

430

808F

429

HANDBRAKE EARTH

REVERSE HORN

REAR WORKLIGHT

S.L.I.

IGNITION RELAY 1

STARTER SOLENOID

STARTER MOTOR

All Models

428

417G

429

428

24 SENSOR +

416B

427

426

425

424

423

422

421

416A

130C

431

130B

809E

401J

419

418

417

416

600HJ

1 +BATTERY 2 -BATTERY

23 SENSOR +

A B

130A 600HG

417B

808

417A

20

422

A B C

19

ACCELERATOR

1 2 3 4 5 6 7 8 9

15 17

423

GREEN

ELEVATION 27

AUX

4

RED BLACK

HANDBRAKE SWITCH

PPU 1

25

3

130

7

401

817

809E

600AC

416J

417J

420

418

1 2 3 4 5 6

FOWARD RELAY

9

7

10

122 600JY

PRIMARY

18

FUSE A4

8

842B

808

APPLIED

SECONDARY

6

23 REVERSE RELAY

A3 122G

A2 2

600AB

1 8 4

3

896

A6 4

16

TO TACHO TO IGN MODULE

13

1

5

1

3

2

11

TO IGN MODULE

5

122F

6

2

807

10

105

5 REVERSE RELA Y

861A

8

107E

807

463 TRANSDUCER

464

FUSE A3

REAR WORKLIGHT SWITCH

974

S.L.I. UNIT

NEUTRAL START RELAY

842

DISTRIBUTOR

FOWARD MICROSWITCH

002 FUSE A2

861

9

FUSE A6

FUSE A1

004

7 14

122

KEY SWITCH

600

12

REVERSE MICROSWITCH

7

BATTERY

6

897

3

9

A1

009

IGNITION RELAY 1

6 5

8

2

F2

30A

1

1

2(7)

310B

2

4

1(6)

F5

80A

310A

40A F3

003

CONTENTS

80 - 15 - 01/15B

From m/c no. 788644

Circuit Diagrams - Electrical (cont’d) Main Components (LPG Engine, Twin Pedal)

21

ELECTRONIC BRAKE CONTROL UNIT

34

SAS

ACTUATOR

001A

MAIN FUSE BOX DETAILS

5(10)

MICRORELAY BASE CONNECTIONS 4(9)

3(8)

Issue 1

9804/1103 3400 - C/3-12C.1

80 - 15 - 01/15C 001A

C1 B1

310

B2 2

5

8 2 1

2

6

84

83

73

3

B3

80 7

98 6

B4

B5

3

5 2 4

FACE FAN

HEATER RESISTOR

304

303A

FUSE C7

FUSE C6

DIP SWITCH

99 102 104

2

7

8

B6 B9

972

105 125D

C5 125B

FUSE C5

FUSE C4

834

100

971

800B

800B

830

829

833

836

837

303

96 859

SOL1

SOL1

600EG

SPEAKER

601

106

AUX BUTTON 2

85 86

H/LIGHT FLASH

C6 C7

97

125C

8

841

839

M

AUX BUTTON 1

2

95

125A

1

93

001K 114E

3

832

840

81

FACE FAN SWITCH

22

7

800

66

82

HEATER SWITCH

77 2

92

FUSE B4

8

5

FRONT W/W SWITCH

C4

91

FUSE B3

1

103

M

114E

C2

3

79

ROAD LIGHTS SWITCH

66 7

M

89

310

74 2

864

M

90

FUSE B9

C3

AUX SOLENIOD 2

AUX SOLENIOD 1

FACE FAN

HEATER MOTOR

RADIO

INTERIOR LIGHT

LIGHT SWITCH

RH SIDE LIGHT

RH TAIL LIGHT

LH SIDE LIGHT

LH TAIL LIGHT

RH DIP BEAM

LH DIP BEAM

RH MAIN BEAM

LH MAIN BEAM

LIGHTS RELAY

FRONT WIPER

FRONT WASHER PUMP

REAR WIPER

ROOF WASHER AND REAR WASHER PUMP

IGNITION RELAY 2

BRAKE LIGHT

BRAKE LIGHT

FLASHER UNIT

RH REAR INDICATOR

RH FRONT INDICATOR

LH FRONT INDICATOR

LH REAR INDICATOR

Teletruk

FUSE B6

A10 3

88

828

862

67

106

A8 1

5

REAR W/W SWITCH

885 863

87

102

5

78

ROAD LIGHTS RELAY

18

76

009

106

72 BRAKE LIGHTS SWITCH

816

70

110

17

M

FUSE B2

10

65 C2

DIR.IND LED RELAY

71

FUSE B1

8

75

103

108D

8

FUSE C2

2

300

3 7

FUSE C1

1

31

63

49

66 806

59 69

802

8

68

FUSE C3

3 HAZARD SWITCH

BEACON

FRONT WORKING LIGHTS

FRONT HORN

ALTERNATOR

ENGINE SHUT DOWN

FILTER BYPASS

AIR FILTER VAC. SWITCH

LOW FUEL LEVEL

ENGINE OIL PRESS SWITC

TRANS OIL TEMP SWITCH

WATER TEMP SWITCH

All Models

FUSE B5

A9 2

2

49a

M

804

1

7 803

805

62

INDICATOR SWITCH

64

104

58 106F

60 BEACON SWITCH

894

61

60A

54 2 F/W/L SWITCH

53

HAZARD SWITCH

WARNING LIGHTS

57

303

814

411B

55

FUSE A10

855

43

116

45

HORN SWITCH (BUTTON)

46

110J

411

413

402

408

403

404

406

401

52

FUSE A9

44

TURN SIGNAL

MAIN BEAM

407

FUSE A8

AIR FILTER FILTER BYPASS

HOURS COUNTER

56

F1

A7 42

HORN SWITCH (COLUMN)

106

39 41

LOW FUEL LEVEL

40

ENGINE OIL PRES

TRANS OIL TEMP

WATER TEMP

38 50 51

310A

887

ALTERNATOR

HAND BRAKE

37 49

IGNITION RELAY 2

B8 MASTER W/LIGHT

MASTER W/LIGHT

36 48

HEADLIGHT LED RELAY

106

1 3 2

35

FUSE A7

106V

47

30A

F4

FUSE B8

CONTENTS

80 - 15 - 01/15C

From m/c no. 788644

Circuit Diagrams - Electrical (cont’d) Main Components (LPG Engine, Twin Pedal)

600

109

94 M

103 108

107

101

837 007

007 001A

001K 106

Issue 1

CONTENTS

Teletruk

80 - 15 - 01/16

All Models S/N 0788001 Onwards Circuit Diagrams - Electrical Main Components (Diesel Engine - TCR) 1 2 3 4 5 6 7 8 9 10 11 12 13 13A 14 15 16 16A 17 18 19 20 21 22 23 24 25 26 * 27 * 27A * 27B 28 29 30 31 32 33 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 54 55 56 58

Battery Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Solenoid Key Switch Glow Plugs Glow Plugs Glow Plugs Glow Plugs Starter Solenoid Starter Motor Neutral Start Relay Starter Relay Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Reverse Relay Reverse Alarm Buzzer Engine Shut Off Solenoid - Relay Engine Shut Off Solenoid Park Brake Solenoid Park Brake Switch Proportional Pressure Reducing Valve Susmic 12 PPU (Pump Speed Sensor) 2 Speed/Traction Control Selector Switch 2 Speed/Traction Control Solenoid 2 Speed/Traction Control Pressure Switch Relay FNR Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal Auxiliary Connector Hourmeter Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Low Fuel Oil Level Air Filter Vacuum Switch Filter Bypass IDC Buzzer Head Light LED Mini Relay Alternator Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch Beacon Switch Beacon Motor Hazard Switch Indicator Switch Flasher Unit Brake Light Switch Ignition Relay 2 Rear Wipe Switch

60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76

Rear Wiper Motor Front Wipe Switch Front/Rear Wash Switch Front Wiper Motor Head Light Flash Switch Road Lights Relay Road Lights Switch Dip Switch Interior Light Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor

Lamps 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

Rear Work Light Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Low Fuel Level Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam Warning LED Indicator Warning LED Right Hand Front Work Light Left Hand Front Work Light Beacon Lamp Left Hand Indicator (Rear) Hazard Switch Warning LED Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light Master Work Light Master Work Light

Primary Fuses F1 Roadlights Relay Supply (optional) F2 Ignition Relay 1 Supply F3 Key Switch F4 Starter Relay 2 Supply Note: For bulb and fuse ratings see page 80 - 05 - 01/1. (LEDs not service part)

9804/1103

80 - 15 - 01/16

3400 - C/3-14.2

Issue 2*

9804/1103 F2 30A 30A

F4

F1 60A 40A

F3 F5

MAIN FUSE BOX DETAILS PRESSURE SWITCH RELAY

F3

3400 - C/3-13.2

80 - 15 - 01/17 A5

001A

A4 8

26 RS232 DIAGNOSTIC CONNECTOR ON PSION UNIT

30 106V

3

27

417

2

425

6

2

WHITE

5

416

1

808

7

809E

448

431

600

417

429

NFPE VALVES

421

419

426

401A

995

808F

429

130B

425

600

130A

418

422

842

422

7 423

20

423

UNUSED

28

1 2 3 4 5 6 7 8 9

959

23

BLACK

A3

F N R

24

GREEN

1 8

416

S1X ECU 42 PIN

42 BATTERY ( +)

41 NC

40 NC

39 NC

38 NC

37 NC

36 NC

35 NC

34 NC

33 NC

32 A NALOG INPUT 1

31 A NALOGUE INPUT 0

30 N C

29 B ATTERY (-)

28 B ATTERY (+)

27 N C

26 N C

25 N C

24 H IGH CURRENT 5 (+)

23 N C

22 H IGH CURRENT 4 (+)

21 R S232 RXD

20 R S232 TXD

19 N C

18 N C

17 P PU INPUT 1

16 P PU INPUT 0

15 B ATTERY (-)

14 S ENSOR (+)

13 R S232 GROUND

12 N C

11 H IGH CURRENT 1 FB (-)

10 L OW CURRENT 0 FB(-)

9 H IGH CURRENT 1 FB (-)

8 H IGH CURRENT 0 FB (-)

7 H IGH CURRENT 1 (+)

6 H IGH CURRENT 0 (+)

5 D IG INP 3

4 D IG INP 2

3 D IG INP 1

2 D IG INP 0

1 - SENSOR

S1X ECU 42 PIN

13

960

918

FLOW DIVIDER SOLENOID

HANDBRAKE SOLENOID

E.S.O.S

REVERSE ALARM

REAR WORKLIGHT

S.L.I.

IGNITION RELAY 1

STARTER SOLENOID

STARTER MOTOR

GLOW PLUGS

Teletruk

B8 FUSE B8

F2 A2 444

10

RED

3 HANDBRAKE RELAY

19

FUSE A4

4 401

1

130

6

2

HANDBRAKE SWITCH

2

18

122

5 105

12

BRAKE PEDAL

A6

807

16A

FUSE A3

17 REVERSE RELAY

TRANSDUCER

463

107E

807

861A

S.L.I. UNIT

464

FUSE A5

A1 FUSE A2

861

974

NEUTRAL START RELAY

842

11

A B C D

001 918

002 REAR WORKLIGHT SWITCH

004

16

FUSE A6

FUSE A1

KEY SWITCH

13A 22

R

15

F

8

009

9 4 3 7

14

IGNITION RELAY 1

6 5

8

1

30A

1

600

21

PPU

449

310B

2

BATTERY

9

80A

310A

40A

003

CONTENTS

80 - 15 - 01/17

All Models S/N 0788001 Onwards

Circuit Diagrams - Electrical Main Components (Diesel Engine, TCR)

25

27A

80

32

27B

Issue 2*

9804/1103

A7

3400 - C/3-15.2

A9

80 - 15 - 01/18 A10 B3

001A

B4 C3 C1

F4 B1 B2

51 2 1

66

C6 C7 67

43

65

310

56

3

72

B5

2

71 2

B6 972

73 600EG

4

1250

M

971

108

1258

106

800B

104

125C

64

800B

102

125A

2

830

834

AUX SOLENOID 2

AUX SOLENOID 1

FACE FAN

HEATER MOTOR

RH SIDE LIGHT LIGHT SWITCH

RH TAIL LIGHT

LH SIDE LIGHT

LH TAIL LIGHT

RH DIP BEAM

LH DIP BEAM

RH MAIN BEAM

LH MAIN BEAM

LIGHTS RELAY

FRONT WIPER

FRONT & REAR WASHER PUMP

REAR WIPER

BRAKE LIGHT IGNITION RELAY 2

BRAKE LIGHT

FLASHER UNIT

RH REAR INDICATOR

RH FRONT INDICATOR

LH FRONT INDICATOR

LH REAR INDICATOR

HAZARD SWITCH

RADIO

INTERIOR LIGHT

BEACON

FRONT WORKING LIGHTS

FRONT HORN

ALTERNATOR

ENGINE SHUT DOWN

FILTER BYPASS

LOW FUEL LEVEL AIR FILTER VAC SWITCH

ENGINE OIL PRESS SWITCH

TRANS OIL TEMP SWITCH

WATER TEMP SWITCH

Teletruk

004B

61 829

C4

105

114E

C2

M

828

58

832

63

833

60

800

54 M

837

100

836

69

59 303

M

103

310

52 841

840

805 806 839

101

106

95

816

859

94

009

49 106

1

99

110

48 109

96 97

103

2

108D

47 93 94

806

68 601

91

300

46 M

805

42 304

70

802

45 1

303A

894

411B

41

102

A8 104

89 803

83 85 87 110 81 82 84 86 88 90 814

407

50

106F

111

92

303

855

35 411

38 40 44

116

110J

106

413

402

408

403

404

406

401

36

310A

106

CONTENTS

80 - 15 - 01/18

All Models S/N 0788001 Onwards

Circuit Diagrams - Electrical Main Components (Diesel Engine, TCR)

*

600

37 39

107 7

76 M

6

C5

75

2

55 5

74

007

837

F1 B9

001A

001K 106

A355400

Issue 2*

Teletruk

CONTENTS

80 - 15 - 01/19

All Models Circuit Diagrams - Electrical Main Components (2 Speed Option - Intelligent Transmission) Susmic Mode Selector Switch Forward/Reverse Selector Switch Neutral Isolation Relay Fixed Resistor Relay Brake Pedal Differential Solenoid

130

10A FUSE

10A FUSE

R

3 N 918

2 DIFF LOCK SWITCH

4

5

960

600B

416K

600C

443

960B

6

417K

C B A

959A

425A

417F

425

416F

959

100

100

10k

842B

3

8 6

2

1

2

5

7 600A

416A

425

417A

F

1

A4

158

STANDARD SUSMIC ECU

B6 13 SENSOR -

23 SENSOR +

19 ANALOG INPUT

007M

1 2 3 4 5 6 7

From m/c no. 788644

STANDARD BRAKE PEDAL

960A

2.7K

2.3K

FIXED VALUE RESISTOR NETWORK

7 600D

DIFF LOCK SOLENOID

9804/1103

80 - 15 - 01/19

3400 - C/3-16.1

A371960

Issue 1

Teletruk

CONTENTS

80 - 15 - 01/20

All Models Circuit Diagrams - Electrical Main Components (2 Speed/Traction Control Option - Intelligent Transmission) Susmic Mode Selector Switch Forward/Reverse Selector Switch Neutral Relay Fixed Resistor Relay Brake Pedal Differential Solenoid

130

10A FUSE

10A FUSE

R

3 N 918

2 DIFF LOCK SWITCH

959A

425A

4

STANDARD BRAKE PEDAL

960

416K

600C

600B

960B

5 6

417K

960A

2.3K

FIXED VALUE RESISTOR NETWORK

2.7K

C B A

443

425

417F

416F

959

100

100

10k

842B

3

8 6

2

1

2

5

7 600A

416A

425

417A

F

1

A4

158

STANDARD SUSMIC ECU

B6 13 SENSOR -

23 SENSOR +

19 ANALOG INPUT

007M

1 2 3 4 5 6 7

From m/c no. 788644

7 600D

DIFF LOCK SOLENOID

A371970

9804/1103

80 - 15 - 01/20

3400 - C/3-17.1

Issue 1

CONTENTS

Teletruk

80 - 20 - 01/1

Models to machine No M788390 Circuit Diagrams - Hydraulic Component Key (To Machine Number M788390) 1 2 3A 3B 4A 4B 4C 4D 5A 5B 5C 6 7 8 9 9A 9B 9C 9D 9E 9F 9G 9H 9J 9K 9L 9M 9N 9P 10A 10B 10C 10D 11 12A 12B 13A 13B 14A 14B 14C 14D 15 16 17 18 19 20 20A 20B 20C 20D 21A 21B 22

Filler/Breather Tank Suction Strainer - Main/Steering Pumps Suction Strainer - Transmission Demand Pump Main Pump Steering Priority Valve Steering Pressure Relief Valve Test Point Test Point Test Point Unloader Valve Steering Ram Hydraulic Steering Unit Valve Block Main Relief Valve Tilt/Crowd Spool Lift Spool Extension Spool Auxiliary 1 Spool Auxiliary 2 Spool Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Tilt/Crowd Ram Tilt/Crowd Ram Hose Burst Check Valve Hose Burst Check Valve Compensation Ram Lift Ram Hose Burst Check Valve Extension Ram Hose Burst Check Valve Quick Release Hoses (If fitted) Quick Release Hoses (If fitted) Quick Release Hoses (If fitted) Quick Release Hoses (If fitted) Auxiliary Ram 1 (If fitted) Auxiliary Ram 2 (If fitted) Cooler Check Valve - 3 Bar Filter Transmission Pump Assembly Pump Charge Valve Forward/Reverse Direction Control Multi-Function Valves Drive Motor and Brake Drive Motor and Brake Park Brake Valve

9804/1103

80 - 20 - 01/1

Issue 2*

Teletruk

CONTENTS

80 - 20 - 01/2

Models to Machine S/N M788390 Circuit Diagram - Hydraulic (continued)

7 1

R

L

19

8

D

2

E

X3

20

S

3A

5B

20A

3B

M3

20B

18 T

LS

M4 M5

L2

P

10C

11

10D

20C

M1

M2

17

6 5C 4A

10A

10B

L1

1

2

12A

3

4D

20D

4

LS

12B

A

B

P

4B EF

T

22

13A

4C

P

13B 9

5A

B

A

B

A

B

A

B

A

B

A

14A 9J

9G

9L

BR

15

21A

9N 14B

9H

9K

9M

9P

9A

14C

16

21B 14D 9B

9804/1103

80 - 20 - 01/2

9C

9D

9E

9F

Issue 2*

CONTENTS

Teletruk

80 - 20 - 01/3

Models to Machine S/N M788390 Circuit Diagram - Hydraulic (continued) Transmission Circuit

IMAGE NOT AVAILABLE AT THIS TIME

9804/1103

80 - 20 - 01/3

Issue 1

CONTENTS

Teletruk

80 - 20 - 01/4

Models from Machine No M788391 Circuit Diagrams - Hydraulic Transmission and Valve Hydraulic Circuit Component Key The transmission circuit is on page 80-20-01/3 and the valve block circuit is on page 80-20-01/5. Some components have been duplicated, this is to enable the reader to appreciate how the various components fit into the circuit. 1 2 3A 3B 4A 4B 4C 4D 5A 5B 5C 5D 6 7 8 9 9A 9B 9C 9D 9E 9F 9G 9H 9J 9K 9L 9M 9N 9P 10A 10B 10C 10D 11 12A 12B 13A 13B 14A 14B 14C 14D 15 16 17 18 19

Filler/Breather Tank Suction Strainer - Main/Steering Pumps Suction Strainer - Transmission Demand Pump Main Pump Steering Priority Valve Steering Pressure Relief Valve Test Point Test Point Test Point Test Point Unloader Valve Steering Ram Hydraulic Steering Unit Valve Block Main Relief Valve Tilt/Crowd Spool Extension Spool Lift Spool Auxiliary 1 Spool Auxiliary 2 Spool Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Tilt/Crowd Ram Tilt/Crowd Ram Hose Burst Check Valve Hose Burst Check Valve Compensation Ram Lift Ram Hose Burst Check Valve Extension Ram Hose Burst Check Valve Quick Release Hoses (If fitted) Quick Release Hoses (If fitted) Quick Release Hoses (If fitted) Quick Release Hoses (If fitted) Auxiliary Ram 1 (If fitted) Auxiliary Ram 2 (If fitted) Cooler Check Valve - 3 Bar Filter

9804/1103

20 20A 20B 20C 20D 21A 21B 22

80 - 20 - 01/4

Transmission Pump Assembly Pump Charge Valve Forward/Reverse Direction Control Multi-Function Valves Drive Motor and Brake Drive Motor and Brake Park Brake Valve

Issue 1

CONTENTS

Teletruk

80 - 20 - 01/5

Models from Machine S/N M788391 Circuit Diagram - Hydraulic (continued)

IMAGE NOT AVAILABLE AT THIS TIME

9804/1103

80 - 20 - 01/5

Issue 1

CONTENTS

Teletruk

80 - 20 - 01/6

Models from Machine No M788391 Circuit Diagrams - Hydraulic (Cont’d) TRANSMISSION & VALVE HYDRAULIC CIRCUIT The schematic below refers to the TCR transmission, see pages 80 - 20 - 01/4 and 80 - 20 - 01/5 for the remainder of the hydraulic circuit. Component Key - TCR 5B 19 20 20A 20B 20C 20D

Charge Pressure Test Point Filter Transmission Pump Assembly Pump Charge Valve Proportional Pressure Reducing Valve Multi Function Valves

IMAGE NOT AVAILABLE AT THIS TIME

9804/1103

80 - 20 - 01/6

Issue 1

INDEX

Articulated Dump Trucks

714 and 718 Contents Page No.

9804/1103

General Information Fluids, Lubricants and Capacities General Specification Tyre Specification Static Dimensions

90 - 00 - 01/1 90 - 00 - 01/2 90 - 00 - 01/2 90 - 00 - 01/3,4

Data Electrical Hydraulics Transmission Brakes

90 - 05 - 01/1 90 - 05 - 02/1 90 - 05 - 03/1 90 - 05 - 04/1

Fault Finding Hydraulics Transmission * Suspension

90 - 10 - 02/1 90 - 10 - 03/1 90 - 10 - 04/1

Circuit Diagrams Electrical Hydraulic

90 - 15 - 01/1 90 - 20 - 01/1

Articulated Dump Truck Contents - 1

Issue 2*

90 - 00 - 01/1

Articulated Dump Trucks

CONTENTS

714 and 718 Fluids, Capacities and Lubricants 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 10/ 30W Multigrade oil.

This should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grades as shown in the lubrication chart. JCB 10W/30 Multigrade should 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.

* ADT 714 Machine ITEM

CAPACITY

FLUID/LUBRICANT

SPECIFICATION

-10 to 50° C (14 to 122° F)

16.3 litres (3.58 UK gal) (including filter)

JCB Extreme Performance Engine Oil 15W/40

††ACEA E3/B3A3 API CH-4/A3

Transmission

35 Litres (7.7 UK gal)

JCB HP Universal ATF

Axles Housings (x2)

21 Litres (4.6 UK gal)

JCB LS Gear Oil

API GL4, MIL-L-2105A

Hubs (x4)

6 Litres (1.3 UK gal)

† Engine Oil

Propshaft Centre Bearing

3.3 litres (0.73 UK gal)

JCB 15W/40 Multigrade

SAE 15W/40, API CF4/SG

† Hydraulic Tank

88 litres (19.3 UK gal)

JCB Hydraulic Fluid HP32

ISO VG32

Cooling System

30 Litres (6.6 UK gal)

JCB Four Seasons Antifreeze & Summer Coolant & Water (see Coolant Mixture)

ASTM D3306-74, BS6580

† Fuel System

200 litres (44 UK gal)

Diesel Oil (see Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

JCB HP Grease

Lithium based

* *

Grease Points

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals. Note: † The figure quoted is the service capacity. Use the ‘MAX’ and ‘MIN’ marks on the dipstick when refilling the system. Note:†† If API CH-4 or ACEA E3/B3A3 engine oil is not available, then the engine oil must be changed at 250 hours. Note: JCB Biodegradable Multigrade Hydraulic Fluid is a factory option ONLY. Replenish with JCB Biodegradable Multigrade Fluid. For further information, contact ADT Technical Service.

9804/1103

90 - 00 - 01/1

7160 - 3/27-1 . 2

Issue 2

90 - 00 - 01/1A

Articulated Dump Trucks

CONTENTS

714 and 718 Fluids, Capacities and Lubricants ADT 718 Machine ITEM

CAPACITY

FLUID/LUBRICANT

SPECIFICATION

-10 to 50° C (14 to 122° F)

16.3 litres (3.58 UK gal) (including filter)

JCB Extreme Performance Engine Oil 15W/40

††ACEA E3/B3A3 API CH-4/A3

Transmission

37 Litres (8.1 UK gal)

JCB HP Universal ATF

Axles Housings (x2)

22 Litres (4.8 UK gal)

JCB LS Gear Oil

API GL4, MIL-L-2105A

Hubs (x4)

7 Litres (1.5 UK gal)

† Engine Oil

Propshaft Centre Bearing

3.3 litres (0.73 UK gal)

JCB 15W/40 Multigrade

SAE 15W/40, API CF4/SG

† Hydraulic Tank

88 litres (19.3 UK gal)

JCB Hydraulic Fluid HP32

ISO VG32

Cooling System

33 Litres (7.3 UK gal)

JCB Four Seasons Antifreeze & Summer Coolant & Water (see Coolant Mixture)

ASTM D3306-74, BS6580

† Fuel System

200 litres (44 UK gal)

Diesel Oil (see Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

JCB HP Grease

Lithium based

Grease Points

Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals. Note: † The figure quoted is the service capacity. Use the ‘MAX’ and ‘MIN’ marks on the dipstick when refilling the system. Note:†† If API CH-4 or ACEA E3/B3A3 engine oil is not available, then the engine oil must be changed at 250 hours. Note: JCB Biodegradable Multigrade Hydraulic Fluid is a factory option ONLY. Replenish with JCB Biodegradable Multigrade Fluid. For further information, contact ADT Technical Service.

9804/1103

90 - 00 - 01/1A

7160 - 3/27-2 . 1

Issue 1

90 - 00 - 01/2

Articulated Dump Trucks

CONTENTS

714 General Specification Total - Unladen Weight 10140 Kg (22308 lb)

Total - Laden Weight 23140 Kg (50908 lb)

Front Axle

6370 kg (14014 lb)

8973 kg (19740 lb)

Rear Axle

3770 kg (8294 lb)

14167 kg (31167 lb

Note: All the weights given above are with 20.5R25 tyres, fitted, a full fuel tank and the operator in the cab. All rated capacities are based on the criteria of the machine being level and on a firm supporting ground. When the machine is operated in conditions that deviate from these criteria (e.g. on soft or uneven ground, on a slope or when subject to side loads), these conditions shall be taken into account by the operator.

Tyre Pressures 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 Organisation (ETRTO) standards to satisfy machine stability performance.

FRONT

REAR

Ply

Bar

lbf/in2

Bar

lbf/in2

20.5 R25 (Bridgestone)

-

2.0

30

4.0

59

20.5 R25 (Michelin)

-

2.1

31

3.4

50

660/55 R25 (Michelin)

-

2.1

31

3.4

50

Size

Note: If the tyres fitted to your machine are not listed, then contact your JCB Distributor for advice. DO NOT guess the tyre pressures.

9804/1103

90 - 00 - 01/2

7160 - 95

Issue 1

90 - 00 - 01/3

Articulated Dump Trucks

CONTENTS

714 Static Dimensions

C

T K J L

S D

E

B

A

H

M F G

R N

P

344950 9804/1103

90 - 00 - 01/3

7160 - 97

Issue 1

CONTENTS

90 - 00 - 01/4

Articulated Dump Trucks

714 Static Dimensions 714 mm

ft

in

A

Overall length

6620

21

8

B

Axle to front bumper

2010

6

7

C

Wheelbase

3650

11

11

D

Axle to end of body

960

3

2

E

Axle to pivot point

1250

4

1

F

Wheel track

1955

6

5

G

Overall width

2500

8

2

H

Height over Cab

3180

10

5

J

Load over height

2340

7

8

K

Overall operating height

4275

14

-

L

Clearance - Body tipped

1000

3

3

M

Minimum ground clearance

490

1

7

N

Turning radius (centre wheel)

7070

23

2

P

Clearance radius

7315

24

-

R

Articulation angle

36°

S

Front clearance angle

28.5°

T

Body tip angle

70°

9804/1103

90 - 00 - 01/4

7160 - 96

Issue 1

CONTENTS

90 - 05 - 01/1

Articulated Dump Trucks

714 and 718 Data - Electrical Fuses CAB REAR

The electrical circuits are protected by fuses. The majority of the fuses are located in the main fuse box ‘CAB REAR’ to the right of the operators seat, rearward of the right console. The lighting fuse box ‘CAB FRONT’ is located directly in front of the operators left knee. A set of five primary fuses are located in the battery compartment. For details of how to gain access to the fuses and relays, refer to Accessing the Fuse Locations Operator Handbook. If a fuse ruptures, find out why and rectify the fault before fitting a new one.

714

C

B

A

V

! CAUTION

1 2 3 4 5 6 7 8 9

CAB REAR

Always replace fuses with ones of correct ampere rating to avoid electrical system damage.

CAB FRONT C 1 2 3 4 5 6

W

FUSES

CAB FRONT

RELAYS

R1

R2

R3

R7

R8

R9

R4

R5

R6

R10 R11

R12

8-3-3-5

Primary Fuse Box Fuse No. A1 A2 A3 A4 A5 A6 A7 A8 A9

Circuit

B1 B2 B3 B4 B5 B6

Brake Lamps Reverse Lamp/Alarm Front Wash/Wipe Rear Wash/Wipe Heater/Air Conditioning Radio/Interior Lighting 12-24V Convertor 7.5 Rear Camera Park Brake Transmission Control System Ignition Horn Heated Mirrors Transmission Control System Battery Accessory/Suspension Seat Radio/Cigar Lighter Hydraulic Suspension (ADT 718 machine only)

B7 B8 * B9 C1 C2 * C3 C4 C5 C9

Ignition Relay Engine Stop Engine Start Pre-Heat EMS Ignition EMS Battery Back-up Beacon Front Work Lights Tipper Work Light

Fuse Rating (Amps) 5 10 25 30 5 5 10 15 7.5

Circuit Hazard Lights Direction Indicators Left Sidelights Right Sidelights Dip Beam Main Beam

9804/1103

Y

344601

ADT 714 Machine - Fuse and Relay Layout Decal

CAB FRONT C 1 2 3 4 5 6

CAB REAR

718

5 5 15 10 30

C

B

A 1 2 3 4 5 6 7 8 9

V

W FUSES

7.5 10 10 7.5 15 10

CAB REAR

RELAYS

R1 R2

R7 R8

R3 R4

R9 R10

CAB FRONT

R13 R14 R15 R5 R6

R16 R17 R18

R11 R12

X

7.5

Y 354680

10 10

ADT 718 Machine - Fuse and Relay Layout Decal

15

Key

Lighting Fuse Box - ‘CAB FRONT’ Fuse No. C1 C2 C3 C4 C5 C6

X

Fuse Rating (Amps) 10 10 10 10 10 10

V W X Y

90 - 05 - 01/1

Cab Rear - Fuses Cab Front - Fuses Cab Rear - Relays Cab Front - Relays

7160 - C/1-2 . 3

Issue 3*

CONTENTS

90 - 05 - 01/2

Articulated Dump Trucks

714 and 718 Data - Electrical Pre-heat Fuses (ADT 718 Machine Only)

Primary Fuse Box

The ADT 718 machine has a set of pre-heat fuses mounted on the right hand side of the engine, just below the starter motor.

Fuse No.

Circuit

1 2 3 4 5

Cab Ancillaries Instrument Cluster Radio/Beacon Alternator Ignition Switch

Fuse No.

Circuit

P1 P2

Pre-heat Fuse Pre-heat Fuse

Fuse Rating (Amps) 100 100

Fuse Rating (Amps) 50 40 40 80 50

4 1

5

2

3

A

P1

P2

354430 354800

9804/1103

90 - 05 - 01/2

7160 - C/1-3 . 2

Issue 3

CONTENTS

90 - 05 - 01/3

Articulated Dump Trucks

714 and 718 Data - Electrical Relays - 714 Machine CAB REAR

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12

Air Conditioning Blank Blank Start Inhibit Ignition Alarm Mute Hazard Warning Lights Reverse Alarm Latch Relay Shut Down Park Inhibit Lights

714

Blank Blank Left Hand Raise Right Hand Lower Left Hand Lower Right Hand Raise Start Inhibit Air Conditioning Ignition Blank Alarm Mute Blank Hazard Warning Lights Reverse Alarm Latch Relay Shut Down Park Inhibit Lights

B

A

V

1 2 3 4 5 6 7 8 9

CAB REAR

Relays - 718 Machine R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18

C

CAB FRONT C 1 2 3 4 5 6

W

FUSES

CAB FRONT

RELAYS

R1

R2

R3

R7

R8

R9

R4

R5

R6

R10 R11

R12

X

Y

344601

ADT 714 Machine - Fuse and Relay Layout Decal

CAB FRONT C 1 2 3 4 5 6

CAB REAR

718

C

B

A 1 2 3 4 5 6 7 8 9

V

W FUSES

CAB REAR

RELAYS

Key

R1 R2

R7 R8

V W X Y

R3 R4

R9 R10

CAB FRONT

R13 R14 R15 Cab Rear - Fuses Cab Front - Fuses Cab Rear - Relays Cab Front - Relays

R5 R6

R16 R17 R18

R11 R12

X

Y 354680

ADT 718 Machine - Fuse and Relay Layout Decal

9804/1103

90 - 05 - 01/3

7160 - C/1-4 . 1

Issue 2

90 - 05 - 01/3A

Articulated Dump Trucks

CONTENTS

714 and 718 Data - Electrical Accessing the Relay Locations There are two blocks of relays. One block is located in the lighting fuse book ‘CAB FRONT’ (refer to Accessing the Fuse Locations for details on how to access the lighting fuse box in Operator Handbook). The other block is located in a compartment at the rear of the cab behind the operators seat ‘CAB REAR’.

CAB REAR

714

To access the rear relay block compartment, proceed as follows:

Stop the engine and remove the ignition key. Isolate the battery by turning the isolator key anti-clockwise.

2

Move the operators seat as far forward as possible. If greater access is required, remove the operators seat completely.

3

B

A

V

Note: This compartment also provides access to the transmission system diagnostic tool communications port. 1

C

CAB FRONT C 1 2 3 4 5 6

1 2 3 4 5 6 7 8 9

CAB REAR

W

FUSES

CAB FRONT

RELAYS

R1

R2

R3

R7

R8

R9

R4

R5

R6

R10 R11

R12

X

Y

344601

Remove the three screws F and lift off the cover G.

Refer to the Technical Data pages and the Fuse and Relay Layout Decals for details of the relay locations and functions.

ADT 714 Fuse and Relay Layout Decal

Replacement is the reverse of removal. CAB FRONT C 1 2 3 4 5 6

CAB REAR

718

F F

C

B

1 2 3 4 5 6 7 8 9

V

G

A

W FUSES

F

CAB REAR

RELAYS

R1 R2

R7 R8

R3 R4

R9 R10

R5 R6

R11 R12

CAB FRONT

R13 R14 R15 R16 R17 R18

X

Y

354420

354680

ADT 718 Fuse and Relay Layout Decal Key V W X Y

9804/1103

90 - 05 - 01/3A

Cab Rear - Fuses Cab Front - Fuses Cab Rear - Relays Cab Front - Relays

7160 - C/20 - 3.1

Issue 1

CONTENTS

90 - 05 - 01/4

Articulated Dump Trucks

714 and 718 Data - Electrical System Type Battery ADT 714 Machine ADT 718 Machine

Batteries (x 2) Batteries (x2)

410 Amps 425 Amps

Alternator

22SI 24V/70A

Starter Motor ADT 714 Machine ADT 718 Machine

28MT Type 171 37-MT/300

Bulbs Bulb Headlights - main Headlights - dipped Indicators Work Lights Number plate light Tail lights Front sidelights Stop lights Beacon Rear Fog

9804/1103

Rating (Watts) 70W 70W 21W 70W 5W 6W 14W 24W 70W 21W

90 - 05 - 01/14

7160 - C/1-1.2

Issue 1

CONTENTS

90 - 05 - 01/5

Articulated Dump Trucks

714 and 718 Data - Electrical Remove and Replace the Pre-heat Fuses (ADT 718 Machine Only) 1

Stop the engine and remove the ignition key. Isolate the battery by turning the isolator key anti-clockwise.

2

Remove the relevant cover E.

3

Remove the nuts A, washers B (2 off) and the cable ends C and D from the fuse P1 and/or P2 as required.

4

Withdraw the fuse P1 and/or P2.

Replacement is the reverse of removal. Ensure that the covers E are replaced securely.

C P1

P2

E

A

B

B D

354810

9804/1103

90 - 05 - 01/5

7160 - C/20 - 2A.1

Issue 1

CONTENTS

Articulated Dump Trucks

90 - 05 - 02/1

714 and 718 Data - Hydraulics Primary Pump ADT 714 Machine Type Flow at 2200 rev/min. * ADT 718 Machine Type Flow at 2500 rev/min.

Gear Type 114 L/min. (25 UK gal/min.; 30 US gal/min.)

Gear Type 130 L/min. (28.6 UK gal/min.; 34.3 US gal/min

Secondary Pump ADT 714 Machine Type Flow at 2200 rev/min. * ADT 718 Machine Type Flow at 2500 rev/min.

Gear Type 17.6 L/min. (4 UK gal/min.; 5 US gal/min.)

Gear Tpye 20 L/min. (4.4 UK gal/min; 5.32 UDS gal/min.)

Control Valve Spool 1

Body Tip

Main Relief Valve Operating Pressure

bar

kgf/cm2

lbf/in2

* ADT 714 Machine

175 ± 2

183.5 ± 2.1

2500 ± 29

* ADT 718 Machine

210

214

3050

Steer Relief Valve Operating Pressure

bar

kgf/cm2

lbf/in2

ADT 714 Machine

175 ± 2

183.5 ± 2.1

2500 ± 29

210

214

3050

Steering Stand-by Pressure

bar 14 ± 2

kgf/cm2 14.7 ± 2.1

lbf/in2 203 ± 29

Rams

Bore mm 110 110 80 80 80

Rod Dia. mm in 60 2.36 60 2.36 50 1.97 40 1.57 80 3.15

Stroke mm 980 1061 312 312 140

* ADT 718 Machine

Lift Ram (up to machine serial no. 830032) Lift Ram (from machine serial no. 830033) Steer Ram (ADT 714 machine) (ADT 718 machine) Suspension Ram (ADT 718 machine only)

in 4.3 4.3 3.15 3.15 3.15

in 38.6 41.8 12.3 12.3 5.5

Filter (Return Line) Filtration Size

9804/1103

10 Micron

90 - 05 - 02/1

7160 - E/1-1.2

Issue 2

Articulated Dump Trucks

CONTENTS

90 - 05 - 03/1

714 and 718 Data - Transmission *

Axles Note: Both the front and rear axles have limited slip differentials fitted as standard. ADT 714 Machine

Drive Axle - Front

Drive Axle - Rear

Type Drive Head Ratio Hub Reduction Ratio Overall Reduction

Beam with hub reduction 1 : 3.909 1 : 5.167 1 : 21.197

Beam with hub reduction 1 : 3.909 1 : 5.167 1 : 21.197

ADT 718 Machine

Drive Axle - Front

Drive Axle - Rear

Type Drive Head Ratio Hub Reduction Ration Overall Reduction

Benam with hub reduction 1 : 4.555 1 : 5.167 1 : 23.538

Beam with hub reduction 1 : 4.555 1 : 5.167 1 : 23.538

Tyres

ADT 714 Machine

ADT 718 Machine

Standard Pressure

20.5 R 25 Bridgestone Front: 2 bar Rear: 4 bar

650/65 R25 Michelin Front: 3.0 Rear: 4.0

Options Pressure

20.5 R 25 Michelin Front: 2.1 bar Rear: 3.4 bar

850/45 x 30.5 Trelleborg † Front: 2.0 Rear: 3.5

Pressure

660/55 R25 Michelin Front: 2.1 bar Rear: 3.4 bar

750/55 x 26.5 Nokian † Front: 2.25 Rear: 4.0

Pressure

750/55 X 26.5 Front: 3.2 bar Rear: 4.0 bar

† Speed limited to 40 kph. * Transmission

ADT 714 Machine

ADT 718 Machine

Type Torque Convertor Dia. Torque Multiplication

6 speed powershift 300 mm (11.8 in) 1.9 : 1

6 speed powershift 340 mm (13.4 in) with lock-up 1.9 : 1

Gear Ratios

Forward 1st: 2nd 3rd 4th 5th 6th

Reverse 1st 4.939 : 1 2nd 2.078 : 1 3rd 0.895 : 1

5.202 : 1 3.367 : 1 2.191 : 1 1.418 : 1 0.944 : 1 0.611 : 1

Stall Testing Engage the parking brake and apply the foot brakes. Select the forward manual fifth gear. Press the accelerator pedal to maximum. Record the engine rpm. Note: do not carry out this test for more than 2 minutes. * Stall Speed

9804/1103

ADT 714 Machine ADT 718 Machine

1750 - 1800 rpm 1780 - 1880 rpm

90 - 05 - 03/1

7160 - F/1-1.2

Issue 2

CONTENTS

* 714

90 - 05 - 04/1

Articulated Dump Trucks

and 718

Data - Brakes

System Type

Full power brakes with accumulator back-up. Two independent circuits operating outboard dry discs.

Pressure Regulator Setting Cut-in Cut-out

140 bar (2030 lbf/in2) 175 bar (2537.5 lbf/in2)

Service Brake Operating Pressure

120 bar (1740 lbf/in2)

Low Pressure Warning Switch Operating Pressure

120 bar (1740 lbf/in2)

Accumulator Gas

Nitrogen

* Accumulator Pre-charge Pressure Parking Brake

9804/1103

80 bar (1160 lbf/in2) Spring applied hydraulic release fail safe type mounted on the front axle.

90 - 05 - 04/1

7160 - G/1-1.2

Issue 2*

CONTENTS

90 - 10 - 02/1

Articulated Dump Trucks

714 and 718 Fault Finding - Hydraulics To use this section, look for the fault in the list below and refer to the probable causes and actions required listed against the fault. Remember, safety must always be the first priority. Refer to Section 2, Care and Safety section for a reminder on safety practices.

Fault 1

Lack of power

Probable Cause

Action

Insufficient hydraulic fluid

Check for leaks and top up as required

Hydraulic leaks in the system

Check hoses and replace as required

Engine performance

Check engine performance

MRV setting incorrect

Check and adjust as required

Low pump flow

Check for external leaks. Replace seals Priority valve Sticking Replace pump

2

Hydraulic rams slow to operate

Neutral circuit or low pressure lines leaking, damaged, trapped or kinked

Check pipe lines and replace as required

MRV setting incorrect

Check and adjust as required

Low pump flow

Check pump flow Check for external leaks. Replace seals Check for priority valve sticking Replace pump

3

4

5

One hydraulic service fails to operate or is slow to operate

The engine tends to stall when hydraulics are under load

Ram creep

9804/1103

Associated service pipe lines leaking, damaged, trapped or kinked

Check hoses. Replace as required

Associated ram leaking

Replace seals

Associated valve block section leaking or not operating

Check for leaks and rectify as required. Check that the control lever is operating the spool. Rectify as required

Associated check valve not opening to allow return of oil to tank

Check and rectify as required

MRV setting incorrect

Check and adjust as required

Engine performance

Check engine performance

Associated ram or pipe lines from ram are leaking

Check and rectify as required

Check valve

Check operation and rectify as required

90 - 10 - 02/1

7160 - E/90-1.2

Issue 2

CONTENTS

90 - 10 - 03/1

Articulated Dump Trucks

714 Fault Finding - Transmission Error Codes In the event of a fault developing in the transmission system the Electronic Monitoring System (EMS) will display an error code. The code will be displayed on the top line of the operators EMS display panel in the format: ZFCB ERROR xx. Note: TCU = Transmission Control Unit Fault Code 11

Fault Detected

Logical error at gear range signal

Possible Causes

● ●

●

12

Logical error at direction select signal

● ●

●

25

Short circuit to battery voltage or open circuit at transmission sump temperature sensor input

● ● ● ●

26

Short circuit to earth at transmission sump temperature sensor input

● ● ●

27

Short circuit to battery voltage or open circuit at converter output temperature sensor input

● ● ● ●

28

Short circuit to earth at converter output temperature sensor input

● ● ●

31

Short circuit to battery voltage or open circuit at engine speed input

● ● ● ●

9804/1103

Action

Cable from shift lever to TCU is broken Cable is defective and is contacted to battery voltage or earth Shift lever is defective

●

Cable from shift lever to TCU is broken Cable is defective and is contacted to battery voltage or earth Shift lever is defective

●

Cable is defective and is contacted to battery voltage Cable has no connection to TCU Temperature sensor has an internal defect Connector pin is contacted to battery voltage or is broken

●

Cable is defective and is contacted to vehicle ground Temperature sensor has an internal defect Connector pin is contacted to vehicle ground

●

Cable is defective and is contacted to battery voltage Cable has no connection to TCU Temperature sensor has an internal defect Connector pin is contacted to battery voltage or is broken

●

Cable is defective and is contacted to vehicle ground Temperature sensor has an internal defect Connector pin is contacted to vehicle ground

●

Cable is defective and is contacted to battery voltage Cable has no connection to TCU Speed sensor has an internal defect Connector pin is contacted to battery voltage or is broken

●

90 - 10 - 03/1

●

●

● ●

● ●

● ●

● ●

● ●

Check cables from TCU to shift lever Check signal combinations of shift lever positions for gear range

Check cables from TCU to shift lever Check signal combinations of shift lever positions F-N-R

Check the cable from the TCU to the sensor Check the connectors Check the temperature sensor

Check the cable from the TCU to the sensor Check the connectors Check the temperature sensor

Check the cable from the TCU to the sensor Check the connectors Check the temperature sensor

Check the cable from the TCU to the sensor Check the connectors Check the temperature sensor

Check the cable from the TCU to the sensor Check the connectors Check the speed sensor

7160 - F/10-1.1

Issue 1

CONTENTS

90 - 10 - 03/2

Articulated Dump Trucks

714 Fault Finding - Transmission Fault Code 32

Fault Detected

Short circuit to earth at engine speed input

Possible Causes

● ●

33

Logical error at engine speed input

● ● ●

34

Short circuit to battery voltage or open circuit at turbine speed input

● ● ● ●

35

Short circuit to earth at turbine speed input

● ●

36

Logical error at turbine speed input

● ● ●

37

Short circuit to battery voltage or open circuit at internal speed input

● ● ● ●

38

Short circuit to earth at internal speed input

● ●

39

Logical error at internal speed input

● ● ●

3A

Short circuit to battery voltage or open circuit at output speed input

● ● ● ●

9804/1103

Action

Cable/connector is defective and is contacted to vehicle earth Speed sensor has an internal defect

●

Cable/connector is defective and is contacted to vehicle earth Speed sensor has an internal defect Sensor gap is the wrong size

●

Cable is defective and is contacted to battery voltage Cable has no connection to TCU Speed sensor has an internal defect Connector pin is contacted to battery voltage or has no contact

●

Cable/connector is defective and is contacted to vehicle earth Speed sensor has an internal defect

●

Cable/connector is defective and is contacted to vehicle earth Speed sensor has an internal defect Sensor gap is the wrong size

●

Cable is defective and is contacted to battery voltage Cable has no connection to TCU Speed sensor has an internal defect Connector pin is contacted to battery voltage or has no contact

●

Cable/connector is defective and is contacted to vehicle earth Speed sensor has an internal defect

●

Cable/connector is defective and is contacted to vehicle earth Speed sensor has an internal defect Sensor gap is the wrong size

●

Cable is defective and is contacted to battery voltage Cable has no connection to TCU Speed sensor has an internal defect Connector pin is contacted to battery voltage or has no contact

●

90 - 10 - 03/2

● ●

● ● ●

● ●

● ●

● ● ●

● ●

● ●

● ● ●

● ●

Check the cable from the TCU to the sensor Check the connectors Check the speed sensor Check the cable from the TCU to the sensor Check the connectors Check the speed sensor Check the sensor gap Check the cable from the TCU to the sensor Check the connectors Check the speed sensor

Check the cable from the TCU to the sensor Check the connectors Check the speed sensor Check the cable from the TCU to the sensor Check the connectors Check the speed sensor Check the sensor gap Check the cable from the TCU to the sensor Check the connectors Check the speed sensor

Check the cable from the TCU to the sensor Check the connectors Check the speed sensor Check the cable from the TCU to the sensor Check the connectors Check the speed sensor Check the sensor gap Check the cable from the TCU to the sensor Check the connectors Check the speed sensor

7160 - F/10-2.1

Issue 1

CONTENTS

90 - 10 - 03/3

Articulated Dump Trucks

714 Fault Finding - Transmission Fault Code 3B

Fault Detected

Short circuit to earth at output speed input

Possible Causes

● ●

3C

Logical error at output speed input

● ● ●

3E

Output speed zero does not fit to other speed signals

● ●

Action

Cable/connector is defective and is contacted to vehicle earth Speed sensor has an internal defect

●

Cable/connector is defective and has bad contact Speed sensor has an internal defect Sensor gap is the wrong size

●

Speed sensor has an internal defect Sensor gap is the wrong size

●

● ●

● ● ●

● ●

71

Short circuit to battery voltage at clutch K1

● ●

●

72

Short circuit to earth at clutch K1

● ●

Cable/connector is defective and has contact to battery voltage Cable/connector is defective and has contact to another regulator output of the TCU Regulator has an internal defect

●

Cable/connector is defective and is contacted to vehicle earth Regulator has an internal defect

●

● ● ●

● ● ●

73

Open circuit at clutch K1

● ●

Cable/connector is defective and has no contact to TCU Regulator has an internal defect

● ● ● ●

74

Short circuit to battery voltage at clutch K2

● ●

●

9804/1103

Cable/connector is defective and has contact to battery voltage Cable/connector is defective and has contact to another regulator output of the TCU Regulator has an internal defect

90 - 10 - 03/3

● ● ● ●

Check the cable from the TCU to the sensor Check the connectors Check the speed sensor Check the cable from the TCU to the sensor Check the connectors Check the speed sensor Check the sensor gap Check the cable from the TCU to the sensor Check the sensor signal of the output speed sensor Check the sensor gap of the output speed sensor Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox

7160 - F/10-3.1

Issue 1

CONTENTS

90 - 10 - 03/4

Articulated Dump Trucks

714 Fault Finding - Transmission Fault Code 75

Fault Detected

Short circuit to earth at clutch K2

Possible Causes

● ●

Cable/connector is defective and is contacted to vehicle earth Regulator has an internal defect

Action

● ● ● ●

76

Open circuit at clutch K2

● ●

Cable/connector is defective and has no contact to TCU Regulator has an internal defect

● ● ● ●

77

Short circuit to battery voltage at clutch K3

● ●

●

78

Short circuit to earth at clutch K3

● ●

Cable/connector is defective and has contact to battery voltage Cable/connector is defective and has contact to another regulator output of the TCU Regulator has an internal defect

●

Cable/connector is defective and is contacted to vehicle earth Regulator has an internal defect

●

● ● ●

● ● ●

79

Open circuit at clutch K3

● ●

Cable/connector is defective and has no contact to TCU Regulator has an internal defect

● ● ● ●

81

Short circuit to battery voltage at clutch K4

● ●

●

82

Short circuit to earth at clutch K4

● ●

Cable/connector is defective and has contact to battery voltage Cable/connector is defective and has contact to another regulator output of the TCU Regulator has an internal defect

●

Cable/connector is defective and is contacted to vehicle earth Regulator has an internal defect

●

● ● ●

● ● ●

9804/1103

90 - 10 - 03/4

Check the cable from TCU to the gearbox Check the connectorss from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox

7160 - F/10-4.1

Issue 1

CONTENTS

90 - 10 - 03/5

Articulated Dump Trucks

714 Fault Finding - Transmission Fault Code 83

Fault Detected

Open circuit to clutch K4

Possible Causes

● ●

Cable/connector is defective and has no contact to TCU Regulator has an internal defect

Action

● ● ● ●

84

Short circuit to battery voltage at clutch KV

● ●

●

85

Short circuit to earth at clutch KV

● ●

Cable/connector is defective and has contact to battery voltage Cable/connector is defective and has contact to another regulator output of the TCU Regulator has an internal defect

●

Cable/connector is defective and is contacted to vehicle earth Regulator has an internal defect

●

● ● ●

● ● ● ●

86

Open circuit at clutch KV

● ●

Cable/connector is defective and has no contact to TCU Regulator has an internal defect

● ● ● ●

87

Short circuit battery voltage at clutch KR

● ●

●

88

Short circuit to earth at clutch KR

● ●

Cable/connector is defective and has contact to battery voltage Cable/connector is defective and has contact to another regulator output of the TCU Regulator has an internal defect

●

Cable/connector is defective and is contacted to vehicle earth Regulator has an internal defect

●

● ● ●

● ● ●

89

Open circuit at clutch KR

● ●

Cable/connector is defective and has no contact to TCU Regulator has an internal defect

● ● ● ●

9804/1103

90 - 10 - 03/5

Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox

7160 - F/10-5.1

Issue 1

CONTENTS

90 - 10 - 03/6

Articulated Dump Trucks

714 Fault Finding - Transmission Fault Code 91

Fault Detected

Short circuit to earth at the reverse warning alarm relay

Possible Causes

● ● ●

92

Short circuit to battery voltage at the reverse warning alarm relay

● ● ●

93

Open circuit at the reverse warning alarm relay

● ● ●

A1

Short circuit to earth at difflock solenoid

● ● ●

A2

Short circuit to battery voltage at difflock solenoid

● ● ●

A3

Open circuit at difflock solenoid

● ● ●

A4

Short circuit to ground at warning signal output

● ● ●

A5

Open circuit at warning signal output

● ● ●

9804/1103

Action

Cable is defective and is contacted to vehicle earth Backup alarm device has an internal defect Connector pin is connected to vehicle earth

●

Cable is defective and is contacted to battery voltage Backup alarm device has an internal defect Connector pin is connected to battery voltage

●

Cable is defective and has no connection to the TCU Backup alarm device has an internal defect Connector has no connection to TCU

●

Cable is defective and is contacted to vehicle earth Difflock solenoid has an internal defect Connector pin is connected to vehicle earth

●

Cable is defective and is contacted to battery voltage Difflock solenoid has an internal defect Connector pin is connected to battery voltage

●

Cable is defective and has no connection to the TCU Difflock solenoid has an internal defect Connector has no connection to TCU

●

Cable is defective and is contacted to vehicle earth Warning device has an internal defect Connector pin is connected to vehicle earth

●

Cable is defective and has no connection to the TCU Warning device has an internal defect Connector has no connection to TCU

●

90 - 10 - 03/6

● ●

● ●

● ●

● ●

● ●

● ●

● ●

● ●

Check the cable from TCU to the backup alarm device Check the connectors from the backup alarm device to the TCU Check the resistance of the backup alarm device Check the cable from TCU to the backup alarm device Check the connectors from the backup alarm device to the TCU Check the resistance of the backup alarm device Check the cable from TCU to the backup alarm device Check the connectors from the backup alarm device to the TCU Check the resistance of the backup alarm device Check the cable from TCU to the difflock solenoid Check the connectors from the difflock solenoid to the TCU Check the resistance of the difflock solenoid Check the cable from TCU to the difflock solenoid Check the connectors from the difflock solenoid to the TCU Check the resistance of the difflock solenoid Check the cable from TCU to the diff solenoid Check the connectors from the difflock solenoid to the TCU Check the resistance of the difflock solenoid Check the cable from TCU to the warning device Check the connectors from the warning device to the TCU Check the resistance of the warning device Check the cable from TCU to the warning device Check the connectors from the warning device to the TCU Check the resistance of the warning device

7160 - F/10-6.1

Issue 1

CONTENTS

90 - 10 - 03/7

Articulated Dump Trucks

714 Fault Finding - Transmission Fault Code A6

Fault Detected

Short circuit to battery voltage at warning signal output

Possible Causes

● ● ●

B1

Slippage at clutch K1

● ● ● ● ● ●

Action

Cable is defective and is contacted to battery voltage Difflock solenoid has an internal defect Connector pin is connected to battery voltage

●

Low pressure at clutch K1 Low main pressure Wrong signal at internal speed sensor Wrong signal at output speed sensor Wrong size of the sensor gap Clutch is defective

●

● ●

● ● ● ● ● ●

B2

Slippage at clutch K2

● ● ● ● ● ●

Low pressure at clutch K2 Low main pressure Wrong signal at internal speed sensor Wrong signal at output speed sensor Wrong size of the sensor gap Clutch is defective

● ● ● ● ● ● ●

B3

Slippage at clutch K3

● ● ● ● ● ●

Low pressure at clutch K3 Low main pressure Wrong signal at internal speed sensor Wrong signal at output speed sensor Wrong size of the sensor gap Clutch is defective

● ● ● ● ● ● ●

9804/1103

90 - 10 - 03/7

Check the cable from TCU to the warning device Check the connectors from the warning device to the TCU Check the resistance of the warning device Check pressure at clutch K1 Check main pressure in the system Check sensor gap at internal speed sensor Check sensor gap at output speed sensor Check signal at internal speed sensor Check signal at output speed sensor Replace clutch Check pressure at clutch K2 Check main pressure in the system Check sensor gap at internal speed sensor Check sensor gap at output speed sensor Check signal at internal speed sensor Check signal at output speed sensor Replace clutch Check pressure at clutch K3 Check main pressure in the system Check sensor gap at internal speed sensor Check sensor gap at output speed sensor Check signal at internal speed sensor Check signal at output speed sensor Replace clutch

7160 - F/10-7.1

Issue 1

CONTENTS

90 - 10 - 03/8

Articulated Dump Trucks

714 Fault Finding - Transmission Fault Code B4

Fault Detected

Slippage at clutch K4

Possible Causes

● ● ● ● ● ●

Low pressure at clutch K4 Low main pressure Wrong signal at internal speed sensor Wrong signal at output speed sensor Wrong size of the sensor gap Clutch is defective

Action

● ● ● ● ● ● ●

B5

Slippage at clutch KV

● ● ● ● ● ●

Low pressure at clutch KV Low main pressure Wrong signal at internal speed sensor Wrong signal at turbine speed sensor Wrong size of the sensor gap Clutch is defective

● ● ● ● ● ● ●

B6

● ● ● ● ● ●

Slippage at clutch KR Low main pressure Wrong signal at internal speed sensor Wrong signal at turbine speed sensor Wrong size of the sensor gap Clutch is defective

● ● ● ● ● ● ●

B7

B8

Excessively hot sump

Excessively hot retarder

●

●

Measured temperature of oil in the sump is above allowed maximum

●

Measured temperature of the retarder oil is above allowed maximum

●

B9

Overspeed engine

Not used

BA

Differential pressure oil filter

● ●

●

9804/1103

Oil filter is polluted Cable/connector is broken or cable/connector is contacted to battery voltage or vehicle ground Differential pressure switch is defective

90 - 10 - 03/8

● ●

● ●

● ● ●

Check pressure at clutch K4 Check main pressure in the system Check sensor gap at internal speed sensor Check sensor gap at output speed sensor Check signal at internal speed sensor Check signal at output speed sensor Replace clutch Check pressure at clutch KV Check main pressure in the system Check sensor gap at internal speed sensor Check sensor gap at turbine speed sensor Check signal at internal speed sensor Check signal at turbine speed sensor Replace clutch Low pressure at clutch KR Check main pressure in the system Check sensor gap at internal speed sensor Check sensor gap at turbine speed sensor Check signal at internal speed sensor Check signal at turbine speed sensor Replace clutch Cool down machine Check oil level Check temperature sensor Cool down machine Check oil level Check temperature sensor

Check oil filter Check wiring from TCU to differential pressure switch Check differential pressure switch (measure resistance)

7160 - F/10-8.1

Issue 1

CONTENTS

90 - 10 - 03/9

Articulated Dump Trucks

714 Fault Finding - Transmission Fault Code D1

Fault Detected

Short circuit to battery voltage at power supply for sensors

Possible Causes

●

The TCU measures more than 6V at the pin AU1 (5V sensor supply)

Action

●

●

D2

Short circuit to earth at power supply for sensors

●

The TCU measures less than 4V at the pin AU1 (5V sensor supply)

●

●

D3

Low power at battery

●

Measured voltage at power supply is less than 24V

● ● ●

D4

High power at battery

●

Measured voltage at power supply is more than 24V

● ● ●

D5

Error at switch 1 for valve power supply VPS1

Cable or connectors are defect and are contacted to battery voltage Cable or connectors are defect and are contacted to vehicle ground Permanent power supply KL30 missing TCU has an internal defect

●

●

●

Cable or connectors are defective and are contacted to battery voltage Cable or connectors are defective and are contacted to vehicle ground Permanent power supply KL30 missing TCU has an internal defect

●

●

● ●

D6

Error at switch 2 for valve power supply VPS2

●

●

● ● ●

● ●

Check cables and connectors to sensors, which are supplied from AU1 Check the power supply at the pin AU1 (should be appx. 5V) Check cables and connectors to sensors, which are supplied from AU1 Check the power supply at the pin AU1 (should be appx. 5V) Check power supply battery Check cables from batteries to TCU Check connectors from batteries to TCU Check power supply battery Check cables from batteries to TCU Check connectors from batteries to TCU Check fuse Check cables from gearbox to TCU Check connectors from gearbox to TCU Replace TCU

Check fuse Check cables from gearbox to TCU Check connectors from gearbox to TCU Replace TCU

F1

General EEPROM fault

●

TCU is defective

●

Replace TCU

F2

Configuration lost

●

Interference during saving data on non volatile memory TCU is brand new or from another vehicle

●

Reprogram the correct configuration for the vehicle (e.g. with cluster controller,...)

●

F3

Application error

●

Something in the application is wrong

●

Replace TCU

F5

Clutch failure

●

One of the AEB values is out of limit

●

Check clutch

9804/1103

90 - 10 - 03/9

7160 - F/10-9.1

Issue 1

CONTENTS

90 - 10 - 03/10

Articulated Dump Trucks

714 Fault Finding - Transmission Fault Code F6

Fault Detected

Clutch adjustment data lost

Possible Causes

● ●

9804/1103

Interference during saving data on non volatile memory TCU is brand new or from another vehicle

90 - 10 - 03/10

Action

●

Execute AEB

7160 - F/10-10.1

Issue 1

CONTENTS

90 - 10 - 04/1

Articulated Dump Trucks

718 Fault Finding - Suspension Error Codes In the event of a fault developing in the hydraulic suspension system the Electronic Monitoring System (EMS) will display an error code. The code will be displayed on the top line of the operators EMS display panel in the format: FAULT xx.

IMPORTANT: When any errors in the hydraulic suspension system are detected, the hydraulic suspension system will shutdown and drain down to the hydraulic tank. The machine will lower onto the bump stops.

! WARNING Do not attempt to drive the machine in this condition. Stop the machine as soon as it is safe to do so and switch off the engine. 0080

Fault Code

Fault Detected

Possible Causes

Action

S1

No signal is detected from the self levelling suspension switches to the EMS

! Cable from self levelling ! suspension switches to the EMS is broken ! Cable is defective and is ! contracted to earth ! Self levelling suspension switch is defective

Check cables and connectors from self levelling suspension switches to the EMS Check signals generated by self levelling suspension switches over a range of positions of the suspension

S2

Out of range or incorrect signal received from the self levelling suspension switches

! Self levelling suspension switches are defective ! Self levelling suspension rods are incorrectly adjusted

Check self levelling suspension switches Check self levelling suspension rod adjustment

Suspension system is not adjusting

! Hydraulic system is defective

to changes in the suspension loading (signals from the self levelling suspension switches are outside the dead band in excess of the set time)

! Suspension solenoids are defective

S3

9804/1103

90 - 10 - 04/1

! !

!

Check the hydraulic system for

!

leaks, loose pipework and/or blockages Check suspension solenoids

7160 -S/90 - 1.1

Issue 1

CONTENTS

90 - 15 - 01/1

Articulated Dump Truck

714 Circuit Diagrams - Electrical Main Components

Fuses

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

P1 P2

Battery Isolator Battery Starter Motor Alternator Starter Switch Starter Relay Ignition Relay Start Inhibit Relay Shutdown Relay Pre-heater Body Up Switch Diagnostic Tool Connector Instrument Cluster and Monitoring System Air Cleaner Blockage Switch Brake Accumulator Pressure Sensor Steer Pressure Sensor Engine Oil Pressure Sensor Emergency Steering Pressure Sensor Fuel Level Sensor

9804/1103

P3 P4 P5

Cab Auxiliaries (50A) Instrument Cluster/Work Lights/Transmission Controller (40A) Radio/Beacon/24 to 12V Converter Lights (40A) Alternator (80A) Ignition Switch (50A)

A1 A2 A3 A4 A5 A6

Ignition Relay Engine Stop Engine Start Pre-Heat EMS Ignition EMS Battery Backup

90 - 15 - 01/1

7160 - C/6-1.1

Issue 1

90 - 15 - 01/2

Articulated Dump Trucks

CONTENTS

714 Circuit Diagrams - Electrical (cont’d) PRIMARY FUSES P2

201

P3

202

P1

203

201 202 005

005

204 P5

204A

P4

200

101B

101B

438B

407

439B

412

101B

842

206

424 001

205

001 002

002 829C

SHIELD

201A

A6

401

817A

861C

855C

829C

412

407

300A

J4/30

J5/6

J5/5

J5/10

J5/17

J4/27

J5/15

J5/9

J4/14

J5/18

J5/16

J5/12

J5/11

J4/35

J4/13

J5/7

J4/18

J4/15

J4/7

J4/16

806C

805C

834C

837C

632

631

408

419

417

104B

403

18

FUEL LEVEL

17

19

628

608

423

429

421

102B

ESOS 601

16

615

800 003

15

EMERGENCY STEERING

5

ENGINE OIL PRESSURE

PRE-HEAT

STEER PRESSURE

8

415

14

2

802

10

13

423

402

205

J4/6

J4/4

800

421 429

6

104

642

B-

4

803

662

U

7

KEY SWITCH

J4/2

613

W

4

INSTRUMENT CLUSTER AND MONITORING

AIR CLEANER

006

0

802

661

D+

I

710

B-

3

3

G

II

J4/3

SHUTDOWN

A3

A4

2

J5/3

J4/11

J4/25

811

J4/26

6

8

4 6

III

103

2 003

B+ 50

001A

J4/08

862

9 8 5 3

A2

PRE-HEATER

BATTERY ISOLATOR

1

30

002

001 204

204A

801

1

ISOLATOR CABLE

001B

412

407

200

205

863

643

BATTERY CABLE -

BATTERY CABLE +

4

M

A5

424C

811

9

401

2

424B

643

439E

6

438E

4

BRAKE ACCUMULATOR

863

205

12 V

8

8

800

-

START INHIBIT

817A

102A

2

8

+

447

6

J4/36

4

643

2

102

START

861C

447 706

8

102B

-

6

2

11

102C

101A

855C BODY UP SWITCH

424

101

6

005

12 V

001C

4

7 842

A1

206

+

203

IGNITION

805C 806C

837C 834C

6

5

4

3

2

1

12

VANSCO DIAGNOSTIC TOOL 345350 9804/1103

90 - 15 - 01/2

7160 - C/6-2.1

Issue 1

CONTENTS

90 - 15 - 01/3

Articulated Dump Trucks

714 Circuit Diagrams - Electrical (cont’d) Main Components

Lamps

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

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

Hazard Warning Switch Indicator Switch Brake Light Switch Beacon Switch Beacon Motor Front Work Light Switch Horn Switch Horn Body Lamp Switch Side Lights Switch Side Light Relay Dip/Main Beam Switch Fog Lamp Switch Reversing Warning Horn Mute Relay Reversing Warning Horn Latch Relay Reversing Light Relay Reversing Warning Horn Reversing Warning Mute Switch

Front Indicator Light (LH) Rear Indicator Light (LH) Display Panel Repeater Lamp (LH) Front Indicator Light (RH) Rear Indicator Light (RH) Display Panel Repeater Lamp (RH) Rear Stop Light (RH) Rear Stop Light (LH) Beacon Light Inner Light (RH) Inner Light (LH) Outer Light (RH) Outer Light (LH) Body Lamp Front Side Light (LH) Rear Side Light (LH) Number Plate Light (LH) Front Side Light (RH) Rear Side Light (RH) Number Plate Light (RH) Main Beam Light (RH) Main Beam Light (LH) Dip Beam Light (RH) Dip Beam Light (LH) Fog Lamp Reversing Light

Fuses A7 A8 A9 B1 B2 C1 F1 F2 F3 F4 F5 F6

9804/1103

90 - 15 - 01/3

Beacon Front Work Lights Body Lamp Brake Lamps Reverse Lamp/Reverse Alarm Horn Hazard Lights Direction Indicator Lights LH Side Lights RH Side Lights Dip Beam Main Beam

7160 - C/6-4.1

Issue 1

90 - 15 - 01/4

834C 709

122 36 707

R 665

7

6

4

2

820D

819

819A

438B

439B 439B

IG SW 2

861B 855D 447

817A 101D

2 5

124

37

35 + ALARM RELAY

B2

IG SW 1

REVERSE LIGHT

105A

105B

105

101C

302B

201B

201A

A9

C1

A8

438B

105E

825

302

109

855C

A7

424

807

820A

829F

B1

F1

F2

829E

807B

820B

34

LATCH RELAY

819B

820

MUTE RELAY

807B

303

106

IG RELAY

807A

8

5

820C

7

2

32

105D

10

33

3

1

7

1

9

8

663

664

3

810

3

810

101B

110

825

1

REVERSE WARNINGS

123

105C

7

817

635

2

705

833

834D

F5

836

31

834C

834B

834

F6

855D

2

FOG LAMP

121

605

120

834A

837

829C

636

30

RH MAIN BEAM

604

118

837C

837B

837A

829D

201C

3

RH DIP BEAM

LH MAIN BEAM

119

RH MAIN BEAM

117 635

703

116

NO PLT RH

115

824C

824A

2 1

829B

F3

2

REAR RH

829

1

829A

8

636

114

824

109A

FRONT RH

303 824B

2

830C

830

110A

3

634

27

704

113

830B

26 F4

2

NO PLT LH

110

28

REAR LH

8

830A

110B

109C

667

305

107

109B

FRONT LH

111 112

861A

806D

683

7

BODY LAMP

3

302A

2

814

7

606

1

633

1

HORN

856B

855

633

109

603

856A

855B

821B

23

LH OUTER

602

107

RH OUTER

106 108

LH INNER

24 855A

2

692

822

816

805

806

8

RH INNER

681

105 816B

816A

805D

BEACON

103 805E

805B

805A

805C

17

LH STOP

701

104

RH STOP

102

REPEATER

RH

101

REAR

837C 806E

18

FRONT

806C

REPEATER

100

201

6

805C 806B

FL 2 BEACON NORN HAZARDS

4

106B

22 5

2

106A RH

856

29

8

20 LH 8

6

6

2

21 2

4

+8

821A

25

2

3

702

821 6

8

1

LH

447

REAR

829C

6

631

101B

4

10(-)

806A

FL 1 LIGHTS WORKLIGHTS REV LIGHT

2

5

806C

401

6

FRONT

855C

4

631

002

M

9804/1103 632

001

2

632

005

8

804

202

821B

201

8

106B

CONTENTS

Articulated Dump Trucks 90 - 15 - 01/4

714

Circuit Diagrams - Electrical (cont’d)

201

202

005

440/ZF808

829E

424

807C

002

401

440/ZF808

2

125

345360

7160 - C/6-3.1

Issue 1

CONTENTS

90 - 15 - 01/5

Articulated Dump Trucks

714 Circuit Diagrams - Electrical (cont’d) Main Components

Lamps

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 79 80 81

126

Wiper Switches Front Wiper Motor Front Screen Washer Pump Switch Front Screen Washer Pump Rear Wiper Relay Front Wiper Relay Rear Wiper/Screen Washer Switch Rear Wiper Motor Rear Screen Washer Pump Switch Air Conditioning Blower Switch Air Conditioning Switch Air Conditioning Blower Motor Air Conditioning Relay Air Conditioning Low Pressure Switch Air Conditioning High Pressure Switch 24V/12V Convertor Radio/Cassette Player Speakers Cigar Lighter Element Interior Light Switch Interior Light Door Switch Rear View Monitor Rear View Camera Park Brake Switch Park Brake Solenoid Park Brake Solenoid Air Conditioning Compressor Clutch Solenoid Heated Mirrors Switch Heated Mirrors Suspension Seat Compressor Motor

9804/1103

Interior Light

Fuses B3 B4 B5 B6 B7 B8 B9 C2 C3 C4 C5

90 - 15 - 01/5

Front Wash/Wipe Rear Wash/Wipe Heater/AC Radio/Interior Light/24 to 12 Convertor Rear Camera Park Brake Transmission Control System Ignition Heated Mirrors Transmission Control System Battery Suspension Seat Radio/Cigar Lighter (12V)

7160 - C/6-5.1

Issue 1

90 - 15 - 01/6

Articulated Dump Trucks

CONTENTS

714 Circuit Diagrams - Electrical (cont’d)

C5

FL 1 LIGHTS WORKLIGHTS REV LIGHT

201

FL 2 BEACON NORN HAZARDS

202

IG RELAY

005 438B

438B

439B

439B

829E

301

440/ZF808

440/ZF808 B9

424 002

424

002

100

807C

447

401

853C

447

101D

118

117

117B

117A

853C

829G

401

116

115

24V GND

8 3

304C

80

858B

858A

853B

682

474

473

472

471

470

2

79 853A

687

858

7

2

62

306C-12V

63

126 57

M

852

56

81

58

FRONT WIPER

REAR WIPER

HEATER/AIR CON

RADIO

LIGHTER

INTERIOR LIGHT

REAR VISION SYSTEM

PARK BRAKE

HEATED MIRRORS

642

689

688

688

626

625

668

682

622

621

620

624

694

693

623

609

641

686

685

55

118

687 CIGAR

503

501

3

1

60

721-12V

52

64

2

304B

306B-12V

304A 500

684 113D

C4

C2

B8

B7

304

51

41

720-12V

849

M

P

54

620

848

113D

840

46

851

831B

R

207-12V

50

850

M

304D -12V

5

HI p

112C

M

839

306A-12V

1

8

61

C

49

LO p

831

45

306-12V

720-12V

6

831A

826A

827

828

P

114B

843 847

2

6

838B

39 R

44

7

0

I

0

I

844

II

3

1

853

C5

114B

3

5

M

40

24V/12V CONVERTOR

t

1

113A

2

+12V

845

2

4

M

838

826

3

113C

2

832

4

846

112D

826B

J

+8

O

838A

2

I

III

43

835

53

+24V

697

-7

II

59

1

839

831B

FRT WIPE RELAY

112A

48

502

113E

826B

47

722-12V

835

38

B6

B5

696

+

841

831B

807C

114B

843

832

REV WIPE RELAY

114A

112

112B

113

42

828

641

B4

B3

101D

SUSP SEAT

345370

9804/1103

90 - 15 - 01/6

7160 - C/6-6.1

Issue 1

CONTENTS

90 - 15 - 01/7

Articulated Dump Trucks

714 Circuit Diagrams - Electrical (cont’d) Main Components 65 66 67 68 69 70 71 72 73 74 75 76 77 78

Transmission Diagnostic Tool Connector Transmission Shift Lever Transmission Control Unit Front Axle Connect Solenoid Front Axle Connected Switch Front Axle Connect Switch Convertor Oil Temperature Sensor Blocked Filter Switch Engine Speed Sensor Turbine Speed Sensor Gear Chain Speed Sensor Output Shaft Speed Sensor Transmission Control Module Sump Oil Temperature Sensor

9804/1103

90 - 15 - 01/7

7160 - C/6-8.1

Issue 1

CONTENTS

90 - 15 - 01/8

Articulated Dump Trucks

714 Circuit Diagrams - Electrical (cont’d)

449/ZF928

27 CANF_T

TRANSMISSION 26 CANF_L

CONTROL

VPS1 12

438/ZF924

450A/ZF904

MODULE HSG94

77

438B 439B 439/ZFBL1

25 CAN_H

VPS1 13

23 VPE1

AIP1 56

450B/ZF908

450/ZF454

301

7 Y1

440/ZF808 301A/ZF832

431/ZF430

431/ZF430

424

450A

1 Y2

100 301B/ZF836

68 VPE2

AIP2 10

432/ZF434

432/ZF434

853C/ZF820

450B

2 Y3

447 440/ZF808

7 ADM2

AIP3 32

433/ZF438

433/ZF438

475

450C

3 Y4

101D 424/ZF936

67 ED6

AIP4 55

434/ZF442

434/ZF442

450D

4 Y5

100A/ZF916

AIP5 9

45 VPI

435/ZF446

435/ZF446

450E

5 Y6

AIP6 51

ER1 39

436/ZF450

436/ZF450

441/ZF458

441/ZF458

6

78

450F

8 SUMP OIL TEMP SENSOR

21 ED10 853C/ZF820

65

447

71

VMGA2 46 460/ZF940

66 ED9

ER2 49

ZF TRANSMISSION

444/ZF570

460C/ZF574

72

CONTROL UNIT EST 37

6 475

67

44 ED8

ER3 17

ZF DIAGNOSTIC TOOL

5

446/ZF480

EF1 19

4

460B/ZF462

460A/ZF484

437/ZF400

BLOCKED FILTER SWITCH

437/ZF400

3

430/ZF652

VMG1 3

675/ZF648

2

461/ZF900

461A/ZF404

442/ZF410

442/ZF410

EF2 41

74 TURBINE SPEED SENSOR

15 SDDK 428/ZF644

73 ENGINE SPEED SENSOR

18 EUPR 430/ZF652

9

CONVERTOR OIL TEMP SENSOR

428/ZF644 461B/ZF414

1

100F/ZF648

EF3 42 443/ZF420

443/ZF420

75 GEAR CHAIN SPEED SENSOR

461C/ZF424

VMG2 4

64 ED5

EF4 62

63 ED1

ED12 30

445/ZF504

8 VPS2

813/ZF524

53 VPS2

65 ED2 800/ZF540

11 ADM6

812/ZF528 F

462/ZF500

ED13 31

FRONT AXLE

UP

859A

FRONT AXLE

CONNECT SW

69

1 8

2

CONNECTED SW

671/ZF920

813/ZF524

66

101D

672/ZF856

812/ZF528 DN

LEVER

859B

860

808/ZF544

SHIFT

100H/ZF508

R

TRANSMISSION

76 OUTPUT SHAFT SPEED SENSOR

100H/ZF508 808/ZF544

2 VM2

424A/ZF548

43 ED4

1 VM1

N

800/ZF540 675/ZF648

100B/ZF536

68

3

70

7

2

FRONT AXLE CONNECT SOLENOID 101D

345380

9804/1103

90 - 15 - 01/8

7160 - C/6-7.1

Issue 1

CONTENTS

Articulated Dump Trucks

90 - 20 - 01/1

714 and 718 Circuit Diagrams - Hydraulic Components Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 * X

Ground Driven Pump Emergency Steer Valve Priority Steer Valve Load Sensing Steer Valve Steer Rams Tipping Valve Block Front and Rear Chassis Umbilical Main Body Lift Rams Main Return Filter Brake Modulating Valve Front Axle Brake Piston Rear Axle Brake Piston Service Brake Accumulator Accumulator Charge Valve Park Brake Valve Propshaft Mounted Disc Park Brake Accumulator Main Tank Return Manifold Tank Strainers Secondary Supply Pump Main Supply Pump ADT 718 machine hydraulic suspension circuit insert. Refer to Hydraulic Suspension Circuit - ADT 718 Machine Only.

9804/1103

90 - 20 - 01/1

7160 - E/3-7.2

Issue 2

Articulated Dump Trucks

CONTENTS

90 - 20 - 01/2

714 and 718 Circuit Diagrams - Hydraulic (cont’d)

R

L

5

T

4 LS LS

CF P

P

EF

2

P

T

3

GP

1 T

6

T

7

1B 1A

13

14

ACC A1

S

22

A2 ACC

13

21

10

G

EF

P1

P2

X

T1

PS

15

P 5

16

2

BR

17

ACC

B1

B2 5

3

7

8

4

12

11

T

19 18

9

20 344961

90 - 20 - 01/2

7160 - E/3-8.2

CONTENTS

9804/1103

Issue 2

90 - 20 - 01/3

Articulated Dump Trucks

CONTENTS

714 and 718 Circuit Diagrams - Hydraulic Hydraulic Suspension Circuit - ADT 718 Machine only 26 X P

C

28

C

29

T

24

23 P

27 S

T

P

30 31 T

T

T

25

354711

* Note: All other areas of the ADT 718 machine’s hydraulic circuit are as the other machines as shown on the other pages.

Hydraulic Suspension Circuit Component Key - ADT 718 Machine Only 23 24 25 26 27 28 29 * 30 * 31 T X

Main Suspension Control Valve Right Hand Suspension Control Valve Left Hand Suspension Control Valve Right Hand Suspension Accumulators Left Hand Suspension Accumulators Right Hand Suspension Hydraulic Cylinder Left Hand Suspension Hydraulic Cylinder Accumulator Cooler To tank return manifold Connection from the Accumulator Charge Valve

9804/1103

90 - 20 - 01/3

7160 - E/3-9 . 2

Issue 2*

CONTENTS

90 - 20 - 01/4

Articulated Dump Trucks

714 up to Machine Serial No. 830153 718 up to Machine Serial No. 832019 Circuit Diagrams - Hydraulic Component Key 1 2 3 4 5 6 6A

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 X

Ground Driven Pump Emergency Steer Valve Priority Steer Valve Load Sensing Steer Valve Steer Rams Tipping Valve Block Tipping Valve Block (with ARV) (ADT 714 from machine serial no. 830107; ADT 718 from machine serial no. 832012) Front and Rear Chassis Umbilical Main Body Lift Rams Main Return Filter Brake Modulating Valve Front Axle Brake Piston Rear Axle Brake Piston Service Brake Accumulator Accumulator Change Valve Park Brake Valve Propshaft Mounted Disc Park Brake Accumulator Main Tank Return Manifold Tank Strainers Secondary Supply Pump Main Supply Pump Over Centre Valve ADT 718 machine hydraulic suspension circuit insert. Refer to Hydraulic Suspension Circuit - ADT 718 Machine Only.

9804/1103

90 - 20 - 01/4

7160 - E/3-7.3

Issue 1*

CONTENTS

90 - 20 - 01/5

Articulated Dump Trucks

714 up to Machine Serial No. 830153 718 up to Machine Serial No. 832019 Circuit Diagrams - Hydraulic (cont’d) R

L

5

T

4 LS LS

CF P

P

EF

2

P

T

3

GP

1 T

6

T

7

1B 1A

13

14

ACC A1

23

S

22

6A

A2 ACC

13

21

10

G

EF

1A 1B

P1

P2

X

T1

PS

15

P 5

16

2

BR

17

ACC

B1

B2 5

3

7

8

4

12

11

T

19 18

9

20 344962 9804/1103

90 - 20 - 01/5

7160 - E/3 - 8.3

Issue 1*

90 - 20 - 01/6

Articulated Dump Trucks

CONTENTS

714 from Machine Serial No. 830154 718 from Machine Serial No. 832020 Circuit Diagrams - Hydraulic (cont’d) R

L

5

T

4 LS LS

CF P

P

EF

2

P

T

3

GP

1 T P

T

7

1A

6

T

1B

13

14

ACC A1

23

S

22

A2 ACC

13

21 EF

P1

P2

X 2 PS

15

3

24

16

BR

2 1

B1

B2

5

2

ACC

P T

T1

25 3

P 5

17

10

G

7

8

4

12

11

T

19 18

9

20 354890

9804/1103

90 - 20 - 01/6

7160 - E/3 - 8A.1

Issue 1*

CONTENTS

90 - 20 - 01/7

Articulated Dump Trucks

714 from Machine Serial No. 830154 718 from Machine Serial No. 832020 Circuit Diagrams - Hydraulic 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

Ground Driven Pump Emergency Steer Valve Priority Steer valve Load Sensing Steer Valve Steer Rams Tipping Valve Block (with ARV) Front and Rear Chassis Umbilical Main Body Lift Rams Main Return Filter Brake Modulating Valve Front Axle Brake Piston Rear Axle Brake Piston Service Brake Accumulator Accumulator Charge Valve Park Brake Valve Propshaft Mounted Disc Park Brake Accumulator Main Tank Return Manifold Tank Strainers Secondary Supply Pump Main Supply Pump Over Centre Valve Servo Controller Pressure Reducing Valve

X

ADT 718 machine hydraulic suspension circuit insert. Refer to Hydraulic Suspension Circuit - ADT 718 Machine Only.

9804/1103

90 - 20 - 01/7

7160 - E/3-8B . 1

Issue 1*