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Introduction General Information Backhoe Loaders

Service Data Book 1992 on


SEPTEMBER 2003

Loadalls RTFL Excavators Wheeled Loaders Fastrac Skidsteer Range Teletruk


Robot 1CX

PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; ROCESTER, STAFFORDSHIRE, ST14 5LS, ENGLAND Tel. ROCESTER (01889) 590312 PRINTED IN ENGLAND

Articulated Dump Trucks

Publication No. 9804/1103

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

1-1 1-2 1-3 1-4 1-5 1-6 1-7 2-1 3-1 4-1

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General Section Contents

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General

1-1

Metrication - S.I.Units
The following list gives the units and symbols to be found in technical publications. Quantity Angle Name of Unit second minute degree square millimetre litre Current Resistance Tension Ampere ohm Volt litre per minute Newton millimetre metre kilometre kilogram Newton metre bar kilometre per hour degree Celsius second minute hour day cubic millimetre cubic centimetre cubic metre Unit Symbol " ' 0 mm2 l A V l/m N mm m km kg Nm bar km/h C s min h d mm3 cm3 m3

Area Capacity Electric

Flow Force Length

Mass Moment of force Pressure Speed Temperature Time

Volume

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CONTENTS CONTENTS

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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. Quantity Area Imperial in2 ft2 yd2 Capacity pintsUK pintsUS gallonUK gallonUS gal/minUK gal/minUS Ibf in mile Ib Ibf in Ibf ft Ibf ft Ibf/in2 Ibf/in2 ft/s mile/h in3 yd3 Metric mm2 m2 m2 I I I l l/min I/min N mm km kg Nm Nm kgf m bar kgf/cm2 m/s km/h cm3 m3 Conversion Factor 645.2 0.0929 0.8361 0.5683 0.4731 4.5461 3.785 4.5461 3.785 4.45 25.4 1.6093 0.4536 0.112 985 1.3558 0.1383 0.068 95 0.070 31 0.3048 1.6093 16.387 0.7646

Flow

Force Length

Mass Moment of force

Pressure

Speed

Volume

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1-3

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 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 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 Litres 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 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 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

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1-4

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 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 Millimetre 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 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 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 Feet 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 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 Metres 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

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1-5

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 10 20 30 40 50 60 70 80 90 100 200 300 400 500 600 700 800 900 1000 2000 3000 kgf/cm2 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 10 20 30 40 50 60 70 80 90 100 200 300 400 500 600 700 800 900 1000 2000 3000 Bar 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

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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

Deg F

Deg C

Deg F

- 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

- 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

- 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

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

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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)

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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. 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 Hexagon (A/F) (mm.) in. (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 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

Nm 14 28 49 78 117 170 238 407 650 970 1940 3390

lbf ft 10 20 36 58 87 125 175 300 480 715 1430 2500

Metric Grade 8.8 Bolts Bolt Size No. M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 Hexagon (mm.) (5) (6) (8) (10) (12) (16) (20) (24) (30) (36) Torque Settings kgf m 0.7 1.2 3.0 5.7 10 25 48 84 166 291

mm. 8 10 13 17 19 24 30 36 46 55

Nm 7 12 28 56 98 244 476 822 1633 2854

lbf ft 5 9 21 42 72 180 352 607 1205 2105

Metric Socket-head Capscrews Torque Settings kgfm 1.1 2.0 4.8 9.5 16 40 79 135

Bolt Size No. M5 M6 M8 M10 M12 M16 M20 M24

(mm) (5) (6) (8) (10) (12) (16) (20) (24)

Nm 11 19 46 91 159 395 770 1332

lbf ft 8 12 34 67 120 290 570 980

9804/1103

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CONTENTS

General

Torque Settings - continued (for all machines except JS Range)


RIVET NUT BOLTS/SCREWS Bolt Size (mm) M3 M4 M5 M6 M8 M10 M12 (3) (4) (5) (6) (8) (10) (12) Torque Settings (for steel rivet nuts) Nm kgf m lbf ft 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 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

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

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

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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 Maintains circulation down to deg C deg F -36 -33 Protects against damage down to deg C deg F -41 -42

55%

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

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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. General (Basic & Functional Symbols) Pumps & Motors

Fixed capacity pump one direction of flow

Fixed capacity pump two directions of flow

Variable capacity pump one direction of flow

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

Indication of direction and paths of flow Variable control

Fixed capacity motor two directions of flow

Variable capacity motor one direction of flow Rams

Single acting

Variable capacity motor two directions of flow

Double acting

Double ended

Double acting with damping at rod area end

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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

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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 Reservoir - return line below fluid level

Drain lines

Flexible pipe

Header tank

Line junction

Pressure sealed tank

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

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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

Pedal operated

Pressure gauge

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 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. 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. 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'. 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 Port 1 Port 3 Position 2 Position 3

FIG 2

Port 2

Port 4

FIG 4

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. 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. 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

A B

C D E F

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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 * 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 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 - 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

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

* 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

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Issue 6*

Backhoe Loader Contents - 1

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

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

9804/1103

Backhoe Loader Contents - 2

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

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*

Backhoe Loader Contents - 3

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 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

9804/1103

Backhoe Loader Contents - 4

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 (contd) - 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) -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 - Brakes (All Models (except 2CX) from m/c no. 400001) - Standard Machines - Servo Machines

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

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 15 - 20 - 04/7,8 15 - 20 - 04/9,10 15 - 20 - 04/11

15 - 25 - 01/1 15 - 25 - 02/1

9804/1103

Backhoe Loaders Contents - 5

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

10 - 00 - 01/1

2CX Lubricants & Capacities

From m/c no. 655000 to 656500

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) 64 (14) 7.2 (1.6)

FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104D SAE10W/30, MIL-L-2105, API CD/SE, MIL-L-2104C MIL-L-46152 SAE10W, MIL-L-46152, API CD/SE, MIL-L-2104D ASTM D3306-74

Fuel Tank Engine (Oil)

Diesel Oil (See Types of Fuel) JCB 15W/40 Multigrade -10 C to 50 C (14 F to 122 F) 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) Engine (Coolant) 12.5 (2.75) JCB Universal Antifreeze/water (See Coolant Mixtures) JCB Special Transmission Fluid

Syncro Shuttle Front Axle Housing Hubs (x2) Rear Axle Housing Hubs (x2) Brake System Hydraulic System

19 (4.2)

ESP-M2C 33G

4 (0.88) 1 (0.22)

JCB HD90 Gear Oil JCB HD90 Gear Oil

API-GL-5 MIL-L-2105

4 (0.88) 1 (0.22)

JCB Special Gear Oil JCB Special Gear Oil JCB Light Hydraulic Fluid

ESEN-M2C 86A/B

ISO VG15 ISO VG46

70 (15.4) (including tank)

JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Special Hydraulic Fluid (Below 38 C, 100 F)

ISO VG32

Grease Points

---

JCB MPL Grease

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. DO NOT USE ORDINARY BRAKE FLUID.

9804/1103

10 - 00 - 01/1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 00 - 01/2

210S Lubricants & Capacities (210S)

From m/c no. 655000 to 656500

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) 16.81 (64) 1.92 (7.2)

FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104D SAE10W/30, MIL-L-2105, API CD/SE, MIL-L-2104C MIL-L-46152 SAE10W, MIL-L-46152, API CD/SE, MIL-L-2104D ASTM D3306-74

Fuel Tank Engine (Oil)

Diesel Oil (See Types of Fuel) JCB 15W/40 Multigrade 14 F to 122 F (-10 C to 50 C) JCB Super Universal Agricultural 5 F to 86 F (-15 C to 30 C)

JCB Torque Converter Fluid 0 F to 32 F (-18 C to 0 C) Engine (Coolant) 3.30 (12.5) JCB Universal Antifreeze/water (See Coolant Mixtures) JCB Special Transmission Fluid

Syncro Shuttle Front Axle Housing Hubs (x2) Rear Axle Housing Hubs (x2) Brake System Hydraulic System

5.04 (19.0)

ESP-M2C 33G

1.05 (4.0) 0.26 (1.0)

JCB HD90 Gear Oil JCB HD90 Gear Oil

API-GL-5 MIL-L-2105

1.05 (4.0) 0.26 (1.0)

JCB Special Gear Oil JCB Special Gear Oil JCB Light Hydraulic Fluid

ESEN-M2C 86A/B

ISO VG15 ISO VG46

18.49 (70.0) (including tank)

JCB High Performance Hydraulic Oil (Above 100 F, 38 C) JCB Special Hydraulic Fluid (Below 100 F, 38 C)

ISO VG32

Grease Points

---

JCB MPL Grease

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. DO NOT USE ORDINARY BRAKE FLUID.

9804/1103

10 - 00 - 01/2

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 00 - 01/3

2CX, 2CXL, 210S, 210SL Lubricants and Capacities

From m/c no. 657001

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 ASTM D975-66T Nos. 1D, 2D SAE15W/40, MIL-L-46152B, API CE/SF, MIL-L-2104D SAE10W/30, MIL-L-2105, API CD/SE, MIL-L-2104C MIL-L-46152 SAE10W, MIL-L-46152, API CD/SE, MIL-L-2104D ASTM D3306-74

Fuel Tank Engine (Oil)

83.2 10.7

18.3 2.4

22.0 2.9

Diesel Oil JCB 15W/40 Multigrade -10 C to 50 C (14 F to 122 F) 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) Engine (Coolant) 11 2.4 2.9 JCB Universal Antifreeze/water (See Coolant Mixtures) JCB Special Transmission Fluid

Syncro Shuttle Axles (2CX, 210S) Housing Hubs (x4)

17.5

3.8

4.6

ESP-M2C 33G

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 Hydraulic System 77 17 20.4 (including tank)

JCB Special Gear Oil JCB Special Gear Oil JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Special Hydraulic Fluid (Below 38 C, 100 F)

ESEN-M2C 86A/B

ISO VG46

ISO VG32

Grease Points

---

JCB MPL Grease

Lithium based, No. 2 consistency. Lithium based, No. 2 consistency.

---

JCB HP Grease (High Performance)

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

CONTENTS CONTENTS

Backhoe Loaders

10 - 00 - 01/4

2DX Lubricants and Capacities

From m/c no. 659249

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 83.2 11.1 18.3 2.5 FLUID/LUBRICANT USA Gal 22 2.9 Diesel Oil (See Types of Fuel) JCB 15W/40 Multigrade -10 C to 50 C (14 F to 122 F) 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) Engine (Coolant) 12.0 2.6 3.2 JCB Universal Antifreeze/water (See Coolant Mixtures) JCB Special Transmission Fluid INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104D SAE10W/30, MIL-L-2105, API CD/SE, MIL-L-2104C MIL-L-46152 SAE10W, MIL-L-46152, API CD/SE, MIL-L-2104D ASTM D3306-74

Fuel Tank Engine (Oil)

Syncro Shuttle Axles (SD55) Housing Hubs (x4) Hydraulic System*

17.5

3.8

4.6

ESP-M2C 33G

8.8 1.8

1.94 0.4

2.3 0.5 21.7

JCB Special Gear Oil

ESEN-M2C 86A/B JCB Special Gear Oil

82 18.04 (including tank)

JCB High Performance Hydraulic Oil JCB Special Hydraulic Fluid (Below 38 C, 100 F)

ISO VG46 (Above 38 C, 100 F) ISO VG32

Grease Points

-----

JCB MPL Grease JCB HP Grease (High Performance)

Lithium based, No. 2 consistency. 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

CONTENTS CONTENTS

Backhoe Loaders

10 - 00 - 01/5

2CX Lubricants and Capacities

From m/c no. 659598

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 ASTM D975-66T Nos. 1D, 2D SAE15W/40, MIL-L-46152B, API CE/SF, MIL-L-2104D SAE10W/30, MIL-L-2105, API CD/SE, MIL-L-2104C MIL-L-46152 SAE10W, MIL-L-46152, API CD/SE, MIL-L-2104D ASTM D3306-74

Fuel Tank Engine (Oil)

83.2 10.7

18.3 2.4

22.0 2.9

Diesel Oil JCB 15W/40 Multigrade -10 C to 50 C (14 F to 122 F) 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) Engine (Coolant) 11 2.4 2.9 JCB Universal Antifreeze/water (See Coolant Mixtures) JCB Special Transmission Fluid

Syncro Shuttle Axles (2CX, 210S) Housing Hubs (x4)

17.5

3.8

4.6

ESP-M2C 33G

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 Hydraulic System 77 17 20.4 (including tank)

JCB Special Gear Oil JCB Special Gear Oil JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Special Hydraulic Fluid (Below 38 C, 100 F)

ESEN-M2C 86A/B

ISO VG46

ISO VG32

Grease Points

---

JCB MPL Grease

Lithium based, No. 2 consistency. Lithium based, No. 2 consistency.

---

JCB HP Grease (High Performance)

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

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 01/6

2CX, 2DX North American Machines to m/c no. 762079 Lubricants and Capacities

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 83.2 11.1 18.3 2.5 FLUID/LUBRICANT USA Gal 22 2.9 Diesel Oil (See Types of Fuel) JCB 15W/40 Multigrade -10 C to 50 C (14 F to 122 F) 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) Engine (Coolant) 12.0 2.6 3.2 JCB Universal Antifreeze/water (See Coolant Mixtures) JCB Special Transmission Fluid INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104D SAE10W/30, MIL-L-2105, API CD/SE, MIL-L-2104C MIL-L-46152 SAE10W, MIL-L-46152, API CD/SE, MIL-L-2104D ASTM D3306-74

Fuel Tank Engine (Oil)

Syncro Shuttle

17.5

3.8

4.6

ESP-M2C 33G

Axles Housing (SD55) 8.8 Housing (SD40) 4.0 Hubs (x4 - SD55) 1.8 Hubs (x4 - SD40) 1.0 Hydraulic System (including tank) 82

1.94 0.88 0.4 0.22 18.04

2.3 1.0 0.5 0.25 21.7

JCB Special Gear Oil JCB Special Gear Oil JCB Special Gear Oil JCB Special Gear Oil JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Special Hydraulic Fluid (Below 38 C, 100 F)

API-GL4 API-GL4 API-GL4 API-GL4 ISO VG46 ISO VG32

Grease Points

-----

JCB MPL Grease JCB HP Grease (High Performance)

Lithium based, No. 2 consistency. 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

15 - 00 - 01/6

7110 - 3/1-2.3

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 00 - 01/7

210S, 212S Lubricants and Capacities

From m/c no. 762080

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 22 2.9 FLUID/LUBRICANT Litres 83.2 11.1 Diesel Oil (See Types of Fuel) 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) Engine (Coolant) 3.2 12.0 JCB Universal Antifreeze/water (See Coolant Mixtures) JCB Special Transmission Fluid INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D CF-4/SG, SAE15W/40

Fuel Tank Engine (Oil)

CF-4/SG, SAE10W ASTM D3306-74

Syncro Shuttle Axles Housing (SD55) Hubs (x4 - SD55) Hydraulic System (including tank)

4.6

17.5

ESP-M2C 33G

2.3 0.5 21.7

8.8 1.8 82

JCB Special Gear Oil JCB Special Gear Oil JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Special Hydraulic Fluid (Below 38 C, 100 F)

API-GL4 API-GL4 ISO VG46 ISO VG32

Grease Points

---

JCB Moly EP#2 Grease

Lithium based, No. 2

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

15 - 00 - 01/8

214e (N. America) Fluids, Lubricants and Capacities (contd)

From m/c no. 460001

!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

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

10 - 00 - 02/1

2CX, 210S Static Dimensions

From m/c no. 655000 to 656500

S136710

9804/1103

10 - 00 - 02/1

Issue 1

CONTENTS

Backhoe Loaders

10 - 00 - 02/2

2CX, 210S Static Dimensions and Weight

From m/c no. 657001

Item A B C D E F G

Description Overall length Overall height Height to top of cab Wheelbase Minimum ground clearance Slew ground clearance Width Machine weight - Fully operational with 6-in-1 shovel, 450mm (18in.) excavator bucket, full fuel tank and 80kg operator.

Dimensions 4.88m (16ft 0in) 2.67m (8ft 9in) 2.63m (8ft 6in) 1.92m (6ft 3in) 0.35m (1ft 2in) 0.46m (1ft 6in) 1.85m (6ft 1in)

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.

E D G A

A182671

9804/1103

10 - 00 - 02/2

3060/179

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

10 - 00 - 02/3

2CX, 210S with Extending Dipper Static Dimensions and Weight 2CX (with Extending Dipper)
Item A B C D E F G Description Overall length Overall height Height to top of cab Wheelbase Minimum ground clearance Slew ground clearance Width Machine weight - Fully operational with 6-in-1 shovel, 450mm (18in.) excavator bucket, full fuel tank and 80kg operator. 5310kg (11708lb) Dimensions 4.88m (16ft 0in) 2.67m (8ft 9in) 2.63m (8ft 6in) 1.92m (6ft 3in) 0.35m (1ft 2in) 0.46m (1ft 6in) 1.85m (6ft 1in)

From m/c no. 657001

Note: Dimensions based on standard tyres fitted (12.5 x 18, 10 PR traction). For Backhoe and Loader dimensions contact your JCB Distributor.

E D

G A

A208661

9804/1103

10 - 00 - 02/3

3060/180

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

10 - 00 - 02/4

2CXL, 210SL
* Static Item A B C D

From m/c no. 657001

Dimensions and Weight


Description Overall length Overall height Wheelbase Width Dimensions 4.43m (14ft 6in) 2.63m (8ft 6in) 1.92m (6ft 3in) 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.

D A

A198341

9804/1103

10 - 00 - 02/4

3060/181

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

10 - 00 - 02/5

2CX Airmaster Static Dimensions

From m/c no. 657001

1.92m (6ft 3in) 4.90m (16ft 1in)

2.49m (8ft 2in)

1.80m (5ft 11in)

1.37m (4ft 6in)


10 - 00 - 02/5

9804/1103

3060/179

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

10 - 00 - 02/6

2CX Farm Master Static Dimensions and Weight


Item A B C D Description Overall length Overall height Wheelbase Width Dimensions 4.44m (14ft 7in) 2.68m (8ft 8in) 1.92m (6ft 3in) 1.95m (6ft 5in)

From m/c no. 657001

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.

C A

A220291

9804/1103

10 - 00 - 02/6

3060/182

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 00 - 02/7

2CXU, 210SU Static Dimensions and Weight


Item A C D E G Description Overall length Height to top of cab Wheelbase Minimum ground clearance Width Machine weight - Base unit With cab Dimensions 4.47 m (14 ft 8 in) 2.68 m (8 ft 7 in) 1.92 m (6 ft 3 in) 0.33 m (1 ft 1 in) 1.95 m (6 ft 5 in) 4907 Kg (10814 lbs) 5088 Kg (11214 lbs)

From m/c no. 657001

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 Maximum load on each axle 3000 Kg (3 tonne) 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.

E D G A
A182672

9804/1103

10 - 00 - 02/7

3060/183

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 00 - 03/1

2DX, 212S Static Dimensions and Weight


Item A B C D Description Overall length Width over tyres Overall height Standard shovel width Operating weight with 1.37m shovel Dimensions 5.10m (16ft 9in) 1.95m (6ft 5in) 3.41m (11ft 2in) 2.10m (6ft 10in) 6500kg (14326lbs)

From m/c no. 659249

Note: Dimensions based on standard tyres fitted (12.5 x 20, 10 PR traction). For Backhoe and Loader dimensions contact your JCB Distributor.

B
A227680

9804/1103

10 - 00 - 03/1

3270 - F/1-3.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 00 - 03/2

2DX, 212S with Extending Dipper Static Dimensions and Weight


Item A B C D Description Overall length Width over tyres Overall height Standard shovel width Machine weight - Fully operational with 6-in-1 shovel, 610mm (24in.) excavator bucket, and full fuel tank. 6840 kg (15082 lbs) Dimensions 5.40m (17ft 8in) 1.95m (6ft 5in) 3.39m (11ft 3in) 2.10m (6ft 10in)

From m/c no. 659249

Note: Dimensions based on standard tyres fitted (12.5x20 industrial traction). For Backhoe and Loader dimensions contact your JCB Distributor.

A279700

9804/1103

10 - 00 - 03/2

3060/178

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 01/1

2CX, 210S 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) 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) 12 Volt, negative earth

From m/c no. 655000 to 656500

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)

Rating (Amps) 5 5 5 5 10 10 - (10) 10 5 5 10 10 10 5 5 10 5 10 - (20) - ( 5) - (5) - (5)

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 to C8 C9

S136670

9804/1103

10 - 05 - 01/1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders
From m/c no. 657001

2CX, 2CXL, 210S, 210SL 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
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 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 15 5 Circuit

Bulbs
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

B1 B2 B3 B4 B5 B6 B7 B8 B9

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 (where fitted) Air conditioning unit (where fitted)/ High output heater (where fitted)

10 5 5 15 15 15 5 20

A201931

9804/1103

10 - 05 - 01/2

Issue 1

CONTENTS CONTENTS

Backhoe Loaders
From m/c no. 659249

2DX 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 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 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 Circuit

Bulbs
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

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)

R1 R3 R5

R2 R4 R6

R7 R9

R8 R10

S227260

R11 R12 R13 R14


15

9 8 7 6 5 4 3 2 1

10 5 10 10 5 5 5 5 5

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

R15 R16 R17 R18


10

R19 R20

A230370

9804/1103

10 - 05 - 01/3

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 01/4

2CX, 2DX, 210S, 212S and Variants 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)

From m/c no. 657001

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
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

9804/1103

10 - 05 - 01/4

3270 - C/1-1.5

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 01/5

2CX Data - Electrics Fuses


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

From m/c no. 655030 to 656999 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

B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9

A201931 S181851

9804/1103

10 - 05 - 01/5

7110 - C/1-2.3

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 01/6

2DX from m/c no. 657001 2CX from m/c no. 659600 to 761891 Data-Electrics Fuses
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 C1 C2 C3 C4 C5 Attachments socket Engine shut off system Dipped beam Main beam; warning lights Front work lights Direction indicators Parking brake solenoid Heater motor Horn (rear) Rear work lights 2/4WS steering circuit; compressor; stabiliser leg interlock Dump relay; forward/reverse solenoid; reverse alarm Rear fog light Thermostart 15 5 10 10 10 5 5 20 10 10 5 10 5 15

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 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

R1 R3 R5

R2 R4 R6

R7 R9

R8 R10

R11 R12 R13 R14


15

9 8 7 6 5 4 3 2 1

10 5 10 10 10 5 5 5 5

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

R15 R16 R17 R18


10

R19 R20

C
A230371 S227260

9804/1103

10 - 05 - 01/6

7110 - C/1-3.2

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 01/7

2CX, 2DX, 210S, 212S Data - Electrics Fuses


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) 10 5 15 15 10 5 5 15 10

From m/c no. 760841

Relays
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

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

R1 R3 R5

R2 R7 R4 R9 R6 R11

R8 R10 R12

A
9 8 7 6 5 4 3 2 1 A B C
A300850 S227260

R13 R15 R17 R19 R21

R14 R16 R18 R20 R22

9804/1103

10 - 05 - 01/7

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 01/8

212SU (N.Am) Data - Electrics Fuses


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 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 Fuse Rating (Amps) 5 5 5 5 7.5 10 15 5 20 10 5 15 15 10 5 5 15 15

From m/c no. 657001

Relays
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

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 6 5 4 3 2 1 A B C
A300870 S227260

R1 R3 R5

R2 R4 R6

R7 R9

R8 R10

9804/1103

10 - 05 - 01/8

7110 - C/1-5.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 02/1

2CX, 210S Data - Machine Hydraulics


Pump Type Flow at 2250 rev/min and system pressure Relief Valve Operating Pressures Main Relief Valve (M.R.V.) 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 (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) Return Line Filter By-pass pressure Ram Torque Settings Piston Head Lift Ram Shovel Ram Slew Ram Boom Ram Stabiliser Ram Dipper Ram Bucket Ram Hydraclamp Ram End Cap Lift Ram Shovel Ram Slew Ram Boom Ram Stabiliser Ram Dipper Ram Bucket Ram Hydraclamp Ram

From m/c no. 655000 to 656500

550 56.25 litres/min bar 220

12.38 UK gal/min (14.87 US gal/min) lbf/in2 3200

kgf/cm2 225

207 207 241 241

211 211 246 246

3000 3000 3500 3500

241 241 241 262 241 241 241 bar 1.72 Nm

246 246 246 267 246 246 246 kgf/cm2 1.76 kgf m

3500 3500 3500 3800 3500 3500 3500 lbf/in2 25 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

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

9804/1103

10 - 05 - 02/1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 02/2

2CX, 2CXL, 210S, 210SL Data - Machine Hydraulics


Hydraulic Pump (to machine serial number 657447) Model/Reference Rotation Mounting Flow at 2000 rev/min and system pressure Hydraulic Pump (from machine serial number 657448) Model/Reference Rotation Mounting Flow at 2000 rev/min and system pressure

From m/c no. 657001 to 658960

Single-Priority/3939 Clockwise Engine Timing Case (with adapter) litres/min UK gal/min US gal/min 58 12.76 15.32

Single-Priority/4506 Clockwise Engine Timing Case (direct - no adapter required) litres/min UK gal/min US gal/min 58 12.76 15.32 bar 220 kgf/cm2 225 lbf/in2 3200

Relief Valve Operating Pressures Main Relief Valve (M.R.V.) 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) Return Line Filter 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

241 277.7 241 241 241 241 262 241 241 241 241 138 bar 1.72 Nm

246 281 246 246 246 246 267 246 246 246 246 141 kgf/cm2 1.76 kgf m

3500 4000 3500 3500 3500 3500 3800 3500 3500 3500 3500 2000 lbf/in2 25 lbf ft

405 405 405 405 405 405 405 405 678 678 678 678 678 678 678 450

41.5 41.5 41.5 41.5 41.5 41.5 41.5 41.5 69.2 69.2 69.2 69.2 69.2 69.2 69.2 45.9

300 300 300 300 300 300 300 300 500 500 500 500 500 500 500 332

9804/1103

10 - 05 - 02/2

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 02/3

2CX, 2DX Data - Machine Hydraulics


Main Hydraulic Pump Model/Reference Rotation Mounting Flow at 2000 rev/min and system pressure Auxiliary Hydraulic Pump (2DX only) Model/Reference Rotation Mounting Flow at 2000 rev/min and system pressure

From m/c no. 658961

Single/5910P Clockwise Engine Timing Case (with adapter) litres/min UK gal/min US gal/min 58 12.76 15.32

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. bar Main Relief Valve (M.R.V.) 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) Return Line Filter 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 240 kgf/cm2 246 lbf/in2 3500

241 277.7 241 241 262 262 248 316 248 248 248 138 bar 1.72 Nm

246 281 246 246 267 267 253 267 253 253 253 141 kgf/cm2 1.76 kgf m

3500 4000 3500 3500 3800 3800 3600 4495 3600 3600 3600 2000 lbf/in2 25 lbf ft

405 405 405 405 405 405 405 405 678 678 678 678 678 678 678 450

41.5 41.5 41.5 41.5 41.5 41.5 41.5 41.5 69.2 69.2 69.2 69.2 69.2 69.2 69.2 45.9

300 300 300 300 300 300 300 300 500 500 500 500 500 500 500 332

9804/1103

10 - 05 - 02/3

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 03/1

2CX, 210S Data - Steer Hydraulics


System Type Pump Steering Unit Type Priority Valve Type 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) Steer Ram Torque Settings Piston Head End Cap

From m/c no. 655000 to 656500

Full power hydrostatic (See Page 10 - 05 - 02/1) OSPC 100LS OLS 80 bar 125 138 250 192 Nm 405 678 kgf/cm2 128 141 255 197 kgf m 41.5 69.2 lbf/in2 1800 2000 3625 2800 lbf ft 300 500

2CX, 2CXL, 210S, 210SL Data - Steer Hydraulics


System Type Pump Steering Unit Priority Valve Operation Pressures Relief Valve Operating Pressure Shock Valve Operating Pressure Anti-cavitation Valve - 2CX Farm Master m/cs only (optional on 2CXL, 210SL m/cs) Steer Ram Torque Settings Piston Head End Cap

From m/c no. 657001 to 658960

Full power hydrostatic (See Page 10 - 05 - 02/2) OSPCLS Integral with pump bar 139 193 20 kgf/cm2 142 197 20.4 lbf/in2 2000 2800 290

Nm 300 450

kgf m 30.6 45.9

lbf ft 221 332

2CX, 2CXL, 2DX, 210S, 210SL Data - Steer Hydraulics


System Type Pump Steering Unit Priority Valve Operation Pressures Relief Valve Operating Pressure Shock Valve Operating Pressure Anti-cavitation Valve Steer Ram Torque Settings Piston Head End Cap Brakes Charge/Steering/Priority Valve Brake Circuit Operating Pressures Cut-in Cut-out

From m/c no. 658961

Full power hydrostatic (See Page 10 - 05 - 02/3) OSPCLS Integral with brakes charge valve bar 139 193 20 Nm 300 450 kgf/cm2 142 197 20.4 kgf m 30.6 45.9 lbf/in2 2000 2800 290 lbf ft 221 332

90 bar (1305 lbf/in2) 110 bar (1595 lbf/in2)

9804/1103

10 - 05 - 03/1

Issue 3

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 04/1

2CX, 210S 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

From m/c no. 655000 to 656500


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

21.818:1 (TUV) 11:40 (TUV)

2CX, 210S 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

From m/c no. 657001

2CXAM, 2CXL, 210FM, 210SL, 2DX 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 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

From m/c no. 657001

9804/1103

10 - 05 - 04/1

Issue 3

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 05/1

2CX 210S 2CX, Data - Syncro Shuttle


Syncro Shuttle Type Drive Output Weight (dry) Torque Converter Dia. Torque Multiplication at Stall Gear Ratios

From m/c no. 655000 to 656500

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 2100 rev/min

Minimum Engine Rev/Min at Converter Stall

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

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

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 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

Main Line Pressure (in neutral) At 50 deg. C 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 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

At 100 deg.C

Clutch Pressure (forward and reverse) At 50 deg. C 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 5.5 - 6.2 6.9 - 7.6 5.5 - 6.2 6.2 - 6.9 5.6 - 6.3 7.0 - 7.7 5.6 - 6.3 6.3 - 7.0 80 - 125 100 - 145 80 - 125 90 - 140

At 100 deg.C

Flow Rates (in neutral) Cooler at 50 deg.C 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min

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

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
Issue 1

Cooler at 100 deg.C

Pump at 50 deg.C

9804/1103

10 - 05 - 05/1

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 05/2

2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL Data - Synchro Shuttle
Syncro Shuttle Type Drive Output Weight (dry) Gear Ratios 1st 2nd 3rd 4th Torque Converters Ratio Colour Coded Dots Designation Stall Figures 2CX 2CXL Engine Stall Speed 1 Converter only max r.p.m. min. r.p.m. 2 Converter + MRV max. r.p.m. min. r.p.m. Build Specification Engine Size 1825 1725 1825 1725 1490 1400 2127 2027 2127 2027 1790 1700 Airmaster Farm Master 2.8:1 3 Brown SSL11

From m/c no. 657001

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

2.78:1 1 Pink & 1 Yellow SSS11

2.4:1 2 Orange & 1 Green WH11

2CX - 20 kph

210SU

2DX

2170 2070

2127 2027

N/A N/A

1848 1748

1825 1725

N/A N/A

65 bhp 74 bhp SSL11 (2.8:1) SSS11 (2.78:1) WH11 (2.4:1) 58 l/min (12.7 gal/min) (15.3 USA gal/min) 1 to 1 1 to 1.25

G G

G G

Converter Type

G G G

Pump Size

Fan Ratio

G G

G G G

Converter Pressures (in neutral) Converter In at 50 deg.C Converter In at 100 deg.C 1000 rev/min 2000 rev/min 1000 rev/min 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 Out (measure at 50 deg.C and 2000 rev/min)

Converter Relief (Safety) Valve Pressure

6.5

6.7

95 max

9804/1103

10 - 05 - 05/2

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 05/3

2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL Data - Synchro Shuttle (cont'd)
Lubrication Pressures (in neutral) At 50 deg.C At 100 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

From m/c no. 657001

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

Main Line Pressure (in neutral) At 50 deg. C 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 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

At 100 deg.C

Clutch Pressure (forward and reverse) At 50 deg. C 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 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

At 100 deg.C

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 1000 rev/min

litres/min 10.4 - 13.6 2000 rev/min 10.2 - 12.5 2000 rev/min 11.0 - 15.0 2000 rev/min

UK gal/min 2.3 - 3.0 14.5 - 20.0 2.3 - 2.8 22.7 - 26.1 2.5 - 3.3 22.5 - 29.5

US gal/min 2.8 - 3.6 3.2 - 4.4 2.7 - 3.3 5.0 - 5.7 2.9 - 4.0 5.0 - 6.5

3.8 - 5.3

Cooler at 100 deg.C

1000 rev/min

6.0 - 6.9

Pump at 50 deg.C

1000 rev/min

6.0 - 7.8

9804/1103

10 - 05 - 05/3

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 05/4

2CXAM Data - Synchro Shuttle


Syncro Shuttle with PTO (Power Take Off) Description Type Drive Output PTO Weight (dry without converter) Gear Ratios 1st 2nd 3rd 4th Torque Converter Ratio Colour Coded Dots Engine Rev/Min at Converter Stall Engine Rev/Min at Converter Stall + MRV Operating 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) Converter Relief (Safety) Valve Pressure Lubrication Pressures (in neutral) At 50 deg.C 1000 rev/min 2000 rev/min At 100 deg.C 1000 rev/min 2000 rev/min Main Line Pressure (in neutral) At 50 deg. C At 100 deg.C

From m/c no. 657001

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

2.83:1 2 Yellow, 1 Orange 2027 - 2127 1725 - 1825 bar 2.4 - 3.4 5.2 - 6.5 1.3 - 2.0 5.2 - 5.9 3.4 6.5 kgf/cm2 2.5 - 3.5 5.3 - 6.7 1.4 - 2.1 5.3 - 6.0 3.5 6.7 lbf/in2 35 - 50 75 - 95 20 - 30 75 - 85 50 max 95 max

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

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

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

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

7.6 - 9.7 9 - 11 7.6 - 9.7 7.6 - 9.7 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

7.7 - 9.8 9.1 - 11.25 7.7 - 9.8 7.7 - 9.8 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

110 - 140 130 - 160 110 - 140 110 - 140 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

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

10 - 05 - 06/1

2CX, 210S Data - Tyre Sizes & Pressures Cross Ply


Front Type Size Ply

From m/c no. 655000 to 656500

Pressure (Normal Duty) bar lbf/in2 3.3 48

Pressure (Heavy Duty) bar lbf/in2 3.75 54 Not 210S

Industrial Traction Industrial Traction Rear Type

10.5 - 18

10

12.5 - 18

10

2.3

34

3.4

49

Size

Ply

Pressure (Normal Duty) bar lbf/in2 2.3 34

Pressure (Heavy Duty) bar lbf/in2 2.75 40 Not 210S

Industrial Traction Industrial Traction

10.5 - 18

10

12.5 - 18

10

1.8

26

2.5

36

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 bar XM27 Rear Type Size bar XM27 335/80R18 1.8 Pressure lbf/in2 26 335/80R18 1.8 Pressure lbf/in2 26

9804/1103

10 - 05 - 06/1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 06/2

2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL Data - Tyre Sizes & Pressures

From m/c no. 657001

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 1.5 2.5 1.75 1.8 2.5 2.5 1.4 22 36 26 26 36 36 20 Pressure (Heavy Duty) bar lbf/in2 2.1 3.5 2.55 2.7 3.8 3.5 2.4 30 51 37 39 55 51 34

Firestone Super Traction Lug Goodyear Sure Grip Lug Continental AS Farmer Michelin X M27 Dunlop SP PG7 Goodyear SG Implement Michelin X M27

12.5 x 18

10

12.5/80 x 18 10 12.5 x 18 335/80 R18 385/55 R18 10 -

12.5/80 x 18 10 405/70 R 20 -

REAR
Type Size Ply Pressure (Normal Duty) bar lbf/in2 Pressure (Heavy Duty) bar lbf/in2

Firestone Super Traction Lug Traction S.G. Goodyear Continental AS Farmer Michelin X M27 Dunlop SP PG7 Goodyear SG Implement Michelin X M27

12.5 x 18

10

1.7 2.25 1.75 1.8 2.25 2.25 1.4

25 33 26 26 33 33 20

1.9 2.5 2.0 2.2 3.0 2.5 1.8

28 36 29 32 44 36 26

12.5/80 x 18 10 12.5 x 18 335/80 R18 385/55 R18 10 -

12.5/80 x 18 10 405/70 R 20 -

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

10 - 05 - 07/1

2CX, 210S 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

From m/c no. 655000 to 656500

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 Data - Brakes


Service Brakes Type Actuation Location Friction Plates Counter Plates Accumulator Pressure Brake Circuit Operating Pressure Cut-in Cut-out

From m/c no. 657001

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 Oil-immersed multi-plate disc. Spring ON, hydraulic OFF. Within the gearbox. 9 off 6 off 10 off 7 off

9804/1103

10 - 05 - 07/1

Issue 3

CONTENTS CONTENTS

Backhoe Loaders

10 - 05 - 08/1

2CX, 210S Data Engine


Type Number of cylinders Bore and Stroke Swept Volume Compression Compression

From m/c no. 655000 to 656500


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) 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)

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 Engine Angle 27 (checked at TDC compression) Fuel Pump Angle 37 - Working Pressure 170 atm - Setting Pressure 185 atm

Injectors

Cooling System Coolant Pressure Coolant Temperature Temperature Warning Light operates at

0.48 bar (7 lbf/in2) (normal) 80-85 deg C 98 deg C

9804/1103

15 - 05 - 08/1

7110 - C/1-.5

Issue 4*

CONTENTS

Backhoe Loaders

10 - 05 - 08/1A

2CX, 210S 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

From m/c no. 657001

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 )] 1, 3, 4, 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 Fuel System Injection Pump Type Injection Pump Setting Code Injection Timing Injection Setting Lift Pump Type Induction System Air Cleaner Typ Max. 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

2160 rev/min 2000 rev/min 820 rev/min C.A.V., D.P.A., mechanically governed 2643C621/HM46L/850/7/2160 16 2 BTDC Pressure 250 atm AC Diaphragm 2 stage, dry element 635 mm (25 in) H 2 0 Eccentric rotor 2.0 bar (30 lbf/in 2 ) (minimum) 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

10 - 05 - 08/1A

7110 - C/1-.5

Issue 1*

CONTENTS

Backhoe Loaders

10 - 05 - 08/2

2DX Range (including 212S to m/c no. 762079) Data Engine


Type Build Number Number of cylinders Bore and Stroke Swept Volume Compression Ratio Compression Pressure

From m/c no. 659249

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 )] 1, 3, 4, 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 Fuel System Injection Pump Type Injection Pump Setting Code Injection Timing Injection Setting Pressure Lift Pump Type Induction System Air Cleaner Type Max. 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

2320 - 2420 rev/min 2200 rev/min 750 rev/min

C.A.V., D.P.A., mechanically governed DM55L/1000/1/2420 16.5 BTDC 220 atm AC Diaphragm

2 stage, dry element 559mm (22 in) H 2 0

Eccentric rotor 2.0 bar (30 lbf/in 2 ) (minimum)

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

10 - 05 - 09/1

2CXAM Data - Pneumatics


Performance
Maximum working pressure Rated F.A.D. at full output to ISO 1217 Maximum air delivery temperature at full output - at compressor unit discharge - at delivery manifold Maximum permissible ambient temperature (continuous full load) 6.9 bar (100 Ibf/in2) 73.2 Itr/sec (4.4 m3/min, 155 ft3/min)

From m/c no. 657001

120C (248F) 110C (230F)

50C (122F)

Compressor
Air delivery Air filter Load control method Oil filter Method of lubrication Oil cooler Oil reclamation Oil system capacity (approx.) Two 3/4 BSP Cocks dry paper element speed control and inlet throttling single bowl, spin-on cartridge type pressure feed to bearings and rotors air blast combined kinetic/filtration 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 Fault Finding - Syncro Shuttle - Mechanical

From m/c no. 655000

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 B C D E F G If the transmission is noisy, start at check 1. If the transmission is overheating, start at check 4. If the transmission will not pull, start at check 12. If there is no drive in one or both directions, start at check 17. If the transmission is jumping out of gear, start at check 29. If the transmission is sticking in gear, start at check 39. If ratios are 'crash changing', start at check 41. ACTION YES: NO: YES: NO: YES: NO: YES: NO: Check 3 Check 2 Check 9 Check 19 Continue running to expel air. Check 4 Check 5 Check level only when machine is cold and top-up as required. Clear the restriction. Check 6 Remove and clean strainer. Check 7 Check 9 Check clutch pressure maintenance valve is free to operate. Renew pump. Check converter sprag clutch for wear or slip. Check 10 Check 11 Renew mountings and check position. Check 'converter out' pressure and flow. Renew Check converter for wear or cooler for restriction to flow. Check 16 Check 13 Stall test machine, Check 14. Check 16

CHECK 1 Is there noise when selecting direction?

Is there noise when running with direction selector in neutral and ratio selector in a gear? Is there air in the hydraulic system?

Is the fluid level correct?

Are the oil passages restricted?

YES: NO: YES: NO: YES: NO:

Is the suction strainer restricted?

Is pump pressure as specified?

When flow testing pump, is output low?

YES: NO:

Does the noise continue when direction selector is in forward or reverse? Is transmission misaligned?

YES: NO: YES: NO:

10

11

Are the pump bushes worn?

YES: NO:

12

Is the transmission not pulling in one direction only?

YES: NO: YES: NO:

13

Is the transmission not pulling in both Forward and Reverse?

9804/1103

10 - 10 - 01/1

3270 - F/1-3.1

Issue 3*

CONTENTS

Backhoe Loaders

10 - 10 - 01/2

2CX, 2DX, 210S, 212S Fault Finding - Syncro Shuttle - Mechanical


CHECK 14 Is 'converter in' pressure as specified? YES: NO: ACTION

From m/c no. 655000

Check 15 Inspect converter relief valve for damage. Check the relief valve pressure setting. Check pump pressure. Renew damaged parts. Tap pressure gauge into clutch feed lines to monitor pressure. Check clutch plates for damage. Check 19 Check 18 Check 19 Rectify. Dismantle solenoid and check components. Check microswitches, relay and wiring loom. Check gears for damage or wear. Check 21 Check bearings for damage or wear. Check 22 Check free running gears for seizure. Check 23 Check 24 Check 27 Renew damaged parts. Check 25 Adjust by checking shaft end float. Check 26 Renew. Check gear teeth for scuffing. Renew. Check 28 Renew gears. Check 29 Tighten screws. Check 30 Renew worn parts. Check 31 Renew. Check 32 Renew. Check 33

15

Is pump being driven by converter?

YES: NO: YES:

16

Are clutch sealing rings damaged?

17

Is there drive in one direction only?

NO: YES: NO: YES: NO: YES: NO:

18

Is the start switch in the run position and supplying current to the neutral start relay? Is the fault only when the transmission is hot?

19

20

Is the noise a growl, hum or grinding?

YES: NO: YES: NO: YES: NO: NEUTRAL: IN GEAR: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO:

21

Is the noise a hiss, thump or bumping?

22

Is the noise a squeal?

23

Is the noise present when in neutral or when in gear?

24

Is the countershaft or its bearings worn or damaged?

25

Is there excessive backlash in the gears?

26

Is the mainshaft pilot bearing worn?

27

Is the mainshaft rear bearing worn?

28

Are the sliding gear teeth worn or damaged?

29

Are the selector forks loose?

30

Are the selector fork pads or grooves in gears worn?

31

Are the dog gear teeth worn?

32

Are the selector rod detent springs broken?

9804/1103

10 - 10 - 01/2

3270 - F/1-2.2

Issue 3*

CONTENTS

Backhoe Loaders

10 - 10 - 01/3

2CX, 2DX, 210S, 212S Fault Finding - Syncro Shuttle - Mechanical


CHECK 33 Are the selector rods worn or damaged? YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: 38 Are the synchroniser components damaged? YES: NO: ACTION Renew. Check 34

From m/c no. 655000

34

Are the selector fork pads out of position?

Reposition or renew (check interlock). Check 35 Adjust. Check thrust washers and mating faces. Renew synchro pack. Check 37 Continue using, chips will either embed below bronze or be rejected. Check 38 Renew. Check free running gears for seizure or damage. Free or renew. Check 40 Remove chips. Ensure that clutch is disengaged when dump pedal is pressed. Continue using, chips will either embed below bronze or be rejected. Check 42 Renew synchro. Check 43 Renew synchro. Check blocker pins.

35

Is there excessive end float in gears or shafts?

36

Is the synchroniser bronze worn?

37

Are steel chips embedded in the bronze?

39

Are the sliding gears tight on the splines?

YES: NO: YES: NO:

40

Are chips wedged between splines of shaft or gear?

41

Are steel chips embedded in the bronze?

YES: NO:

42

Are the synchroniser spring pins damaged?

YES: NO: YES: NO:

43

Is the synchroniser bronze worn?

9804/1103

10 - 10 - 01/3

3270 - F/1-2.2

Issue 3*

CONTENTS CONTENTS

Backhoe Loaders

10 - 10 - 01/4

2CX, 210S Fault Finding - Syncro Shuttle - Hydraulic

From m/c no. 655000

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 High stall speeds. Low stall speeds. Overheating.

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'.

LOW MAINLINE PRESSURE (in neutral) Possible Cause 1 Worn pump. 2 Blocked suction strainer. 3 Pressure maintaining valve sticking/leaking. 4 Oil aerated (foaming).

Oil leak through parking brake on/off circuit.

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.

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

10 - 10 - 01/5

2CX, 210S Fault Finding - Syncro Shuttle - Hydraulic (contd)


HIGH CONVERTER OUT PRESSURE Possible Cause 1 Oil cooler/lines blocked. 2 Converter in pressure incorrect 3 Converter relief valve faulty.

From m/c no. 655000

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.

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.

LOW COOLER FLOW Possible Cause 1 Converter relief valve faulty. 2 Leak at pump to case joint . 3 Worn pump. 4 Internal leakage. 5 Restriction in converter feed.

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'.

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

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.

9804/1103

10 - 10 - 01/5

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

10 - 10 - 02/1

2CX 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL 2CX, Fault Finding - Parking Brake

From m/c no. 657001

PARKING BRAKE INOPERATIVE BUT TRANSMISSION FUNCTIONS IN FORWARD AND REVERSE


Check 1 Is distance spacer fitted to centre bolt? Action YES: Check 2. NO: Fit spacer. YES: Free off or renew valve. NO: Check 3. YES: Dismantle parking brake and check condition. NO: Check 4.

Is the parking brake solenoid spool sticking?

Put the starter switch in 'IGN' position. Disengage the parking brake, is there a voltage reading at the parking brake feed wire? 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 1 Is the parking brake solenoid spool sticking? Action YES: Free off or renew valve. NO: Check 2. YES: Check 4. NO: Check 3.

Put the starter switch in 'IGN' position. Disengage the parking brake, is there a voltage reading at the parking brake feed wire? Put the starter switch in 'IGN' position. Is there a voltage reading at the parking brake solenoid feed wire? Has the parking brake been dismantled recently?

YES: Check 4. NO: Check switch and wiring. YES: Dismantle and check for correct build. NO: Check 5. YES: Check 6. NO: See Transmission Fault Finding. YES: Dismantle parking brake and check condition. NO: See Transmission Fault Finding.

Is the transmission main line pressure correct?

Is the main line pressure correct with the parking brake circuit isolated?

9804/1103

10 - 10 - 02/1

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

10 - 10 - 03/1

2CXAM Fault Finding - Pneumatics


FAULT Compressor fails to build up to working pressure a b c d POSSIBLE CAUSE Choked air intake filter Suction unloader valve stuck on seat Faulty blow down valve Faulty gauge a b c d

From m/c no. 657001

REMEDY Change air intake filter element Inspect and release valve through unloader air intake Overhaul or change blow down valve Overhaul or change gauge

Compressor fails to off-load (safety valve blowing)

a b c d e

Suction unloader valve stuck open Suction unloader/compressor joint leak Punctured diaphragm on pressure regulator or unloader piston Safety valve faulty Air/oil separator faulty

a b c d e

Inspect and release valve through unloader air intake Tighten or renew joint Inspect and renew Inspect and rectify Clean or change element

Plant not operating at correct minimum or maximum speed

a b

Speed control faulty Engine fault

a b

Reset speed control Refer to engine Service Manual

Excessive compressor oil consumption

a b c

Receiver scavenge oil restrictor choked Air/oil separator faulty Incorrect grade of oil

a b c

Clean oil restrictor Clean or change element Drain and refill with correct grade of oil

Shut down due to high air delivery temperature

a b c d e f g

Machine not standing level or sited badly Air receiver level low Incorrect grade of compressor oil Air/oil separator choked External surface of oil cooler clogged Clogging of compressor oil circulating system Faulty temperature switch or circuit

a b c d e f g

Level machine or resite for maximum air flow Top up air receiver oil Drain and refill with correct grade of oil Clean or change element Clean external surface of oil cooler Drain, flush and refill oil circulating system Check circuit and/or change faulty switch(es) Engage parking brake, put transmission in neutral Change fuse Check circuit and change solenoid if necessary

Compressor drive will not engage

a b c

Parking brake not applied, transmission not in neutral Power take-off solenoid fuse (A8) blown Power take-off solenoid faulty

a b c

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 A B C D E F

DESCRIPTION Air Conditioning Power (from fuse C9) Controls Pressure Switch Pressure Switch Compressor Splice

B A

WIRE 20 21 685 686 687 688 689

DESCRIPTION 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

C
A201500

9804/1103

10 - 10 - 04/1

7110 - B/3-2.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 10 - 04/2

2CX, 2DX, 210S, 212S Fault Finding - Air Conditioning (contd)


No Air Conditioning CHECK 1 Are the controls set correctly, i.e. air conditioning selected, thermostat switch set to coldest position and blower switched on? Is the air conditioning (evaporator) blower working? YES: NO: ACTION

From m/c no. 657001

Check 2 Reset controls and retest.

YES: NO: YES: NO: YES: NO: YES: NO: YES: NO:

Check 3. Check 4. Check11. Check 7. Renew fuse and retest. Check 5. Check 6. Check 9. Check 7. Renew the compressor clutch and retest.

Is the compressor running (visual check of pulley/clutch)?

Is the air conditioning fuse (B8) blown?

Is there a 12V supply to the pressure switch harness? (See Pressure Switch Testing) Does the compressor clutch engage with both pressure switches bypassed? (See Pressure Switch Testing) Does the compressor clutch engage with HP switch bypassed? (See Pressure Switch Testing) Does the compressor clutch engage with LP switch bypassed? (See Pressure Switch Testing) Does the clutch engage with thermostat switch bypassed?

YES: NO:

Renew high pressure switch and retest. Check 8.

YES: NO:

Renew low pressure switch and retest. Charge check required by refrigeration engineer.

YES: NO: YES: NO: YES: NO: YES: NO: YES: NO:

Renew thermostat switch and retest. Check all electrical connections. Renew blower motor. Renew switch or wiring. Check 12. Charge check required by refrigeration engineer. Clean condensor and radiator. Check 13. Clean filter and, if necessary the evaporator. Call in refrigeration engineer.

10 Are blower switch and wiring OK?

11 Is sight glass indication OK?

12 Is condensor air flow blocked?

13 Is evaporator air flow blocked?

9804/1103

10 - 10 - 04/2

7110 - B/3-3.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 15 - 01/1

2CX, 210S Circuit Diagrams - 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 51 52 53 54 55 56 57 58 59 60 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

From m/c no. 655000 to 656500

Fuses
A1 - A9 B1 - B9 C1 - C9 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 Black Green Pink Light Green Brown Orange Purple Red Slate Blue White Yellow

9804/1103

10 - 15 - 01/1

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

Backhoe Loaders

10 - 15 - 01/2

2CX, 210S Circuit Diagrams - Electrical

From m/c no. 655000 to 656500

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 Circuit Diagrams - Electrical

From m/c no. 657001

22

17

202

201

204 200

817

3 4

251 10 203

9 8

10 226

6 807

256

7 258 205 4

C7

C2 C6

C1

C5

C4
882 880

803

415

A1
211 830

B2
838 223 217

A2
219

A8
224

B7
806

B9

804

A9 97
18 16 883

A7 B8

B6

A6 B1

C3
254

17 16

21
225

81
232

79
233 229 230 841

71
826 861

57
855

45
827 412 414

23
865

7
805 257 11 812

99 100

856

237

236

410

810

221

243

80
227

41
239

19 32
249 413

18
245

15

8
681 244 1/2

70 67 66 63 62
833 808 800 863 862 218

228 234

212

207

859

255 411

857

49
250

46

40

37 36 35 34 33

9
247

249

56

48

42

209 + -

98

248

825

238

884

B3

B4

101

82
231

400

242

842

A4
235 216 214 820

A3
213

B5
836

253

64
409 814

61

55
850 849 866 252

47 44 43

39
401

38
241 408 404

246

96

78

68

65

50

A5 3 14 10 5

102

844/845

222

851

853

811

802

416

848

847 846

215 819

822 821

818 886 839 837

832 831

835 834

816 815

60 59

25
860 407 406 402 405 403

24

853

20

12
809

11 4

93 95 94
684 619 680 651 624 660 658

91

89 87 86 84 77

75 74 72

53 51 31 30 29 28 27 26

92
638 649

90
661 659

88
637 637 637

85 83
639 648 623 652 633

76
646/647 639 638

73
637 638

69
648 649 614 604 642 669 654

58 54 52
656 653 643 639 649 637 633 627 644 657 637 640 664 603 618 637 637 602 636 622 631 620 682

605 630

621

607 631

13

801

655

639

648

638

612

A183041

617

A183040-1

9804/1103

10 - 15 - 01/3

10 - 15 - 01/3

668

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

10 - 15 - 01/4

2CX, 2CXL, 2CXFM, 210S, 210SL 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 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

From m/c no. 657001

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

9804/1103

10 - 15 - 01/4

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

10 - 15 - 01/5

2DX from m/c no. 659249 to 760840 2CX from m/c no. 659599 to 760840 Circuit Diagram - Electrical

10 3 2 63 64 5 6 7 8 9

15

111 71 112 17

114 116 115

117 118

26

27 80 77 74 76 75

81

82

119 20

110 4 177 11 174 171 175 12

113

29 78 79 179 19 21 28 121 123 125 127 129 120 122 25 18 22 23 24 131 132 133

13 176 1 170 62 65 66

69

14

73 16

124 126 128 130

A1 67 178 68

173

72 70

C5

C3

B7

C2

B1

B6

A6

61 172

9804/1103

10 - 15 - 01/5

3270 - C/18-1.3

Issue 2*

CONTENTS

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 10 Compressor Temperature Sender 11 Compressor Temperature Gauge 12 Compressor Hourmeter 13 Stabiliser Leg Solenoids 14 Steer Mode Solenoids 15 Steer Mode Unit 16 Junction Box 17 Hammer Solenoid 18 Flasher Unit 19 Diode 20 Trailer Indicator Warning Buzzer 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) 30 Engine Shut Off System 31 Front Instrument Console 32 Alternator 33 Rear Horn 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 41 Beacon Motor 42 Tracker 4 Radio 44 RH Speaker 4 LH Speaker 4 Heater Resistor 47 Heater Motor 48 Air Conditioning Motor 4 Heater Resistor 50 Heater Motor 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 67 Front Proximity Switch 68 Rear Proximity Switch 69 Steer Mode Selector Switch 70 Brake Lights Switch 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 81 Air Receiver Temperature Switch 82 Air/Oil Delivery Temperature Switch 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 95 Air Conditioning Switch 96 Freeze Valve 97 Low Pressure Switch 98 High Pressure Switch 99 Heater Switch 100 Rear Fog Light Switch

9804/1103

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 112 Right Hand Trailer Brake Light 113 Right Hand Brake Light 114 Left Hand Trailer Indicator Light 115 Left Hand Indicator Light - Front 116 Left Hand Indicator Light - Rear 117 Right Hand Trailer Indicator Light 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 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 144 Left Hand Number Plate Light 145 Left Hand Tail Light 146 Left Hand Side Light 147 Right Hand Trailer Light 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 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 180 Shutdown Relay 181 Ignition Relay 2 182 Road Lights Relay 183 Air Conditioning Relay

Fuses A1 - A9 B1 - B9 - See Technical Data pages for fuse details C1 - C9 Note : Indicates non standard equipment Note : Link wire to be fitted to neutral lock relay on non Airmaster machines. Note : On standard build when no optional shutdown system is fitted, a link wire is fitted on wire 105.

9804/1103

10 - 15 - 01/7

7110 - C/1-1.5

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

10 - 15 - 01/8

2DX from m/c no. 659249 to 760840 2CX from m/c no. 659599 to 760840 Circuit Diagram - Electrical

30 180 36 34 37 33 32 35 38 153

139 140

142 144 141 143 145

148 147 149 150

43 39 151 152 40 93 41 47 45

98 48 50 97

146

44 B4 100 88 89 A3 A4 46 85 96 49 B3 42 183

31 128 135 130 137 134 133 131 136 138 83 84 86 C4 90 87 91

92

95

94

99

B5 B2 A2 B9 A5 A9

C1

A7 181 182

A8 B8

9804/1103

10 - 15 - 01/8

3270 - C/18-1.3

Issue 2*

CONTENTS

Backhoe Loaders
To m/c no. 658332

2CX AM 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

CONTENTS

Backhoe Loaders
to m/c no. 658332

2CX AM Electrical Schematic Circuit (continued)


1

C3

3 4 8

7 A8 6

10

11

12

13 14 15 16

17 C2 18
9804/1103
A212850

10 - 15 - 01/10

Issue 1

CONTENTS

Backhoe Loaders
From m/c no. 658333 to 659598

2CX AM Electrical Schematic Circuit

2 3

4 5 8

7 9 10 11

12

13

14 15 16

17

18

A252070

9804/1103

10 - 15 - 01/11

Issue 1

CONTENTS

Backhoe Loaders
From m/c no. 658333 to 659598

2CX AM 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
from m/c no. 659599

2CX AM 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

CONTENTS CONTENTS

Backhoe Loaders

10 - 15 - 01/14

2CX, 2DX, 210S, 212S Circuit Diagram - Electrical

From m/c no. 760841

10 3 2 63 5 6 7 154 8 64 9 14

111 112 71 17 110 113

114 116 115

117 118

26 27 75 74 76 77 78 79

79 29

81 82

119 20

4 174 171 175 177

11

12 185 179 184 28 19 73 69 16 23 24 22 25 130 132 121 123 125 127 120 122 124 126 128129 131 133

2 176 1 170 62 66

13

18 21

173 65 178 67 68 70 72

61 172

9804/1103

10 - 15 - 01/14

7110 - C/7-8.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 15 - 01/15

2CX, 2DX, 210S, 212S 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 10 Compressor Temperature Sender 11 Compressor Temperature Gauge 12 Compressor Hourmeter 13 Stabiliser Leg Solenoids 14 Steer Mode Solenoids 15 Steer Mode Unit 16 Junction Box 17 Hammer Solenoid 18 Flasher Unit 19 Diode 20 Trailer Indicator Warning Buzzer 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) 30 Engine Shut Off System 31 Front Instrument Console 32 Alternator 33 Rear Horn 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 41 Beacon Motor 42 Tracker 43 Radio 44 RH Speaker 45 LH Speaker 46 Heater Resistor 47 Heater Motor 48 Air Conditioning Motor 49 Heater Resistor 50 Heater Motor

From m/c no. 760841

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 67 Front Proximity Switch 68 Rear Proximity Switch 69 Steer Mode Selector Switch 70 Brake Lights Switch 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 81 Air Receiver Temperature Switch 82 Air/Oil Delivery Temperature Switch 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 95 Air Conditioning Switch 96 Freeze Valve 97 Low Pressure Switch 98 High Pressure Switch 99 Heater Switch 100 Rear Fog Light Switch

9804/1103

10 - 15 - 01/15

7110 - C/7-9.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 15 - 01/16

2CX, 2DX, 210S, 212S Circuit Diagrams - Electrical


Lights 110 Left Hand Brake Light 111 Left Hand Trailer Brake Light 112 Right Hand Trailer Brake Light 113 Right Hand Brake Light 114 Left Hand Trailer Indicator Light 115 Left Hand Indicator Light - Front 116 Left Hand Indicator Light - Rear 117 Right Hand Trailer Indicator Light 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 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 144 Left Hand Number Plate Light 145 Left Hand Tail Light 146 Left Hand Side Light 147 Right Hand Trailer Light 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 154 Reverse light

From m/c no. 760841

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 180 Shutdown Relay 181 Ignition Relay 2 182 Road Lights Relay 183 Air Conditioning Relay 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 : Indicates non standard equipment Note : Link wire to be fitted to neutral lock relay on non Airmaster machines. Note : On standard build when no optional shutdown system is fitted, a link wire is fitted on wire 105.

9804/1103

10 - 15 - 01/16

7110 - C/7-10.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 15 - 01/17

2CX, 2DX, 210, 212 Circuit Diagram - Electrical

From m/c no. 760841

9804/1103

10 - 15 - 01/17

7110 - C/7-11.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 15 - 01/18

2CXU, 212SU (N. America only) Circuit Diagram - Electrical

From m/c no. 657001

600

7 2 3 4 64 63 5 6 8

119 9 30 114 115 117 118 116 32 79 75 74 76 78 77 26 27

16 174 175 19

73 18 176 1 62 65 31 173 66 176 72 28 121 133 127 122 124 125 130 120 123 126 131 25 22 23 24

61 172

001 830Y 837C 200 160AH


9804/1103

10 - 15 - 01/18

7110 - C/7-12.2

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 15 - 01/19

2CXU, 210SU (N. America) 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 44 RH Speaker 45 LH Speaker 49 Heater Resistor 50 Heater Motor

From m/c no. 657001

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 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

9804/1103

10 - 15 - 01/19

7110 - C/7-13.2

Issue 1

CONTENTS

Backhoe Loaders

10 - 15 - 01/20

2CXU, 210SU (N. America only) Circuit Diagrams - Electrical


Lights 110 Left Hand Brake Light 111 Left Hand Trailer Brake Light 112 Right Hand Trailer Brake Light 113 Right Hand Brake Light 114 Left Hand Trailer Indicator Light 115 Left Hand Indicator Light - Front 116 Left Hand Indicator Light - Rear 117 Right Hand Trailer Indicator Light 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 144 Left Hand Number Plate Light 145 Left Hand Tail Light 146 Left Hand Side Light 147 Right Hand Trailer Light 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

From m/c no. 657001


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 : Indicates non standard equipment

9804/1103

10 - 15 - 01/20

7110 - C/7-14.2

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 15 - 01/21

2CXU, 212SU (N. America only) Circuit Diagrams - Electrical

From m/c no. 657001

600

143 145 111 110 112 113 35 50 151 34 36 38 144 146

147 149 153 139 141 140 142 148 150 152 41 43

45

49 93 44

89 88 70 85 178 84 86 87 99 90

100

91

92

181 001 830Y 837C 200 160AH

9804/1103

10 - 15 - 01/21

7110 - C/7-15.2

Issue 1

FUSE P4 FUSE P2 FUSE P3 010 FUSE C7 003

FUSE P1

THERMOSTART BATTERY

CONTENTS

31

110

839

840 841 303 110 FUSE B2 FRONT HORN SWITCH 814

JUNCTION BOX JUNCTION BOX

36

101 FUSE A1

803

37

HAZARD SWITCH

805

805

41

INDICATOR SWITCH
8 10

39

FLASHER RELAY
5 18 2

806
804
17

40

806 104 FUSE A3


2 49a 1 31 4

802 300 FUSE C4


3

49 C2

401

44

45

WATER TEMP GAUGE


-

46

47

FUEL GAUGE
-

TACHOMETER

HOURMETER
9 9 9 9 9 9

ILLUMINATION

FRONT W/W SWITCH

9804/1103
IGNITION SWITCH BATTERY

6 3
STARTER MOTOR STARTER SOLENOID NEUTRAL START RELAY IGNITION RELAY 1
810 FUSE C9
3 5

NEUTRAL START RELAY


5

200B 004
8 2

200C
2 6 4

2CX, 2DX and Variants

9 8 7 3 4 5 6

842

FORWARD RELAY

FUSE A5
2 1

FOR / REV SWITCH F 809

FORWARD RELAY

10

002 107
4

N 812

200
8 5

Circuit Diagram - Electrical

FORWARD SOLENOID REVERSE RELAY

R
8 10

7
808
7 4 6

IGNITION RELAY 1 811


9

12 13

912
2

REVERSE SOLENOID REVERSE ALARM

REVERSE RELAY

3 5

PARKBRAKE RELAY

11

15

14
10 8

TRANS DUMP RELAY


7 6

001

011

200G/200L 401
9

200E/200R 934

200D/200M

16

DUMP SWITCH (GEAR)

17
1 5

DUMP SWITCH (LOADER)

934
7

18

Backhoe Loaders

10 - 15 - 01/22
967 122 FUSE A4 936
2 8 9

PARKBRAKE
10

19

953 121 FUSE A6

COMPRESSOR CONNECTOR

COMPRESSOR CONNECTOR

20

952

COMPRESSOR SOLIENOID

21

BRAKE LIGHTS SWITCH

LH BRAKE LIGHT

22

126

933

816 FUSE A8

RH BRAKE LIGHT

23

FUSE B6

105 FUSE A2

E.S.O.S.
REAR WASH/ WIPE SWITCH
5

24 25

863
6

REAR WASHER PUMP

27

26

862
2 3

FUSE B5
103

REAR WIPER
864
8 7

BATTERY FEED
829 829

102 FUSE C8

HEATER/AIR CON CONNECTOR

28
HEATER/AIR CON CONNECTOR

29

INTERIOR LIGHT

30

303 FUSE C5

FACE LEVEL FAN

FRONT WASHER PUMP FRONT WIPER

32

33
828

34
FRONT HORN

35
HAZARD SWITCH LH FRONT INDICATOR

38

LH REAR INDICATOR

42

RH FRONT INDICATOR RH REAR INDICATOR


6

FLASHER UNIT

43 48

409

WATER TEMP SENDER

408

FUEL SENDER

TACHOMETER

49

From m/c no. 489724

7110 - C/7-16.1
011 007 829 830 106 828 110 804 806

401

412 407

805

10 - 15 - 01/22

50

Issue 1

110

011

007

829

830

804

806

106

828

401

805

407

412

CONTENTS

FUSE B10 314

894
3 2 1

H/LIGHT FLASH

FUSE C1
2

835
3

862

FOG LT SWITCH

ROAD LIGHTS RELAY

88

85

834
5 3

FUSE C2
2 5 1

312
4

127 FUSE B8 FUSE C3


2

833
6

834 832 836 837

834 837 311 FUSE C10


3

DIP/MAIN BEAM SWITCH


7

91

837

92

828 FUSE A9

ROAD LIGHTS SWITCH

829 830 FUSE A10

93

829

From m/c no. 489724

95

10 - 15 - 01/23

830

9804/1103
200G/200L
11

2CX, 2DX and Variants

Circuit Diagram - Electrical (contd)

200D/200M

200E/200R

FRONT CONSOLE INSTRUMENTS


MASTER WARNING LIGHTS

51
12
2 W STEER TURN SIGNAL

52

5
SIDE LIGHRS

53

3
MAIN BEAM HAZARD WARNING

54

55

6
REAR W/L

56

8
FRONT W/L

57

7
REAR FOG

58

9 16
ALTERNATOR

7 3
HAND BRAKE

458 406 404 403 405

BRAKE PRESS SWITCH WATER TEMP SWITCH TRANS OIL TEMP SWITCH ENGINE OIL PRESS SWITCH TRANS OIL PRESS SWITCH

18

WATER TEMP

12

BATTERY FEED
TRANS OIL TEMP

Backhoe Loaders

10 - 15 - 01/23 60 61 62 63 64 65
SIDE CONSOLE INSTRUMENTS
ENGINE OIL PRES

11

TRANS OIL PRES

10

59
AIR FILTER

66
6 2

402
17

AIR FILTER VAC. SWITCH


411 407

106 FUSE B1

67

68

BUZZER

ALTERNATOR

69

RADIO SOCKET

304 FUSE C6
8 7

71

70
3

871
2

REAR HORN
118
1

FUSE B3 114
5

73
8 2 4 6

REAR HORN SWITCH

72

POWER SOCKET

FUSE B4

IGNITION RELAY 2
F/W/L SWITCH
5

IGNITION RELAY 2

76
4

855 116
6 2 3

75

LINK REQUIRED FOR UK BUILD 011

FRONT WORKING LIGHTS


2

855
8 7

74

310
5

FUSE B9

011
8

861
2 1

78

309
5

117 FUSE B7

2 3

REAR WORKING LIGHTS


861
7

77

79

R/W/L SWITCH

BEACON SWITCH
8 7

80

BEACON

81
8 7

82

83
1

FOG LIGHT

84 87 86

LIGHTS RELAY RH DIP BEAM

89 90

LH DIP BEAM LH MAIN BEAM RH MAIN BEAM

LH TAIL LIGHT LH SIDE LIGHT DIPPER SOCKET

7110 - C/7-18.1

94

RH TAIL LIGHT RH SIDE LIGHT

Issue 1

CONTENTS

Backhoe Loaders

10 - 15 - 01/24

2CX, 2DX and Variants Circuit Diagrams - Electrical (Contd)


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 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

From m/c no. 489724

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

9804/1103

10 - 15 - 01/24

7110 - C/7-17.1

Issue 1

212SU

CONTENTS

36

110

839

840 841 303

39

40

110 FUSE B2 FRONT HORN SWITCH

814

803

44

HAZARD SWITCH

805

805

42

INDICATOR SWITCH
8 10

46

806
5 18

47

804
17

806 104 FUSE A3 300 FUSE C4


3 49a 1 31

802
2

49 C2

From m/c no. 489724

7110 - C/7-19.1
110 011 007 829

FLASHER RELAY

411

37

9804/1103

Circuit Diagram - Electrical

FUSE P4 FUSE P2 FUSE P3 010 FUSE C7 003

FUSE P1

THERMOSTART BATTERY

IGNITION SWITCH BATTERY

5 4

6 3
STARTER MOTOR STARTER SOLENOID NEUTRAL START RELAY IGNITION RELAY 1
892 967 NEUTRAL START RELAY
5 1

200B 004
8 2

200C
2 6 4

9 8 7 3 4 5 6

842

9
FORWARD RELAY
5

FUSE C9
3 4

FOR / REV SWITCH

FUSE A5
2 1

809

FORWARD RELAY

10

002
4 8 5

200 R
8 10

107

N 812

FORWARD SOLENOID REVERSE RELAY

7
IGNITION RELAY 1 808
7 4 6

12

912
9

811

REVERSE SOLENOID REVERSE ALARM

11

13

REVERSE RELAY

810

3 5

PARKBRAKE RELAY
10 8

14 15
TRANS DUMP RELAY
7 6

001

011

200G
9

200E/200R

200D/200M

16

411

824

DUMP SWITCH (GEAR)


934

DUMP SWITCH (LOADER)

17

Backhoe Loaders

10 - 15 - 01/25
936
1 5 7

18

122 FUSE A4
6

936
2

815
8

PARKBRAKE
10

PARKBRAKE SWITCH

19

21

PTO SWITCH

5 6 1 2 3

891
7

20
8

22

JUNCTION BOX

101 FUSE A1 BRAKE LIGHTS SWITCH 126 933 FUSE A8

24

LH BRAKE LIGHT

25

816

RH BRAKE LIGHT
105

23

FUSE B6 FUSE A2

E.S.O.S.

26 28

REAR WASH/ WIPE SWITCH FUSE B5


103

27
6 1 3

5 2

863

REAR WASHER PUMP M

29

862 864
8 7

BATTERY FEED 102 FUSE C8

REAR WIPER

829

30

829

AIR CON CONNECTOR

HEATER SWITCH
1

31 33 32
2 3 4 5 6 7 8

HEATER RESISTOR 800 800B

HEATER FAN MOTOR

HEATER

34

INTERIOR LIGHT

35

303 FUSE C5
FRONT W/W SWITCH

FACE LEVEL FAN

FRONT WASHER PUMP FRONT WIPER

38

FRONT HORN

HAZARD SWITCH

LH FRONT INDICATOR

45

LH REAR INDICATOR
828

41
804 806 828

RH FRONT INDICATOR
2 4 6

RH REAR INDICATOR FLASHER UNIT

43

10 - 15 - 01/25

411

805

Issue 1

212SU

110

011

007

829

804

806

828

411

805

CONTENTS CONTENTS

FUSE B10
2

894
3

314

FUSE C1
2

835
3

862

H/LIGHT FLASH

84

ROAD LIGHTS RELAY

80

FOG LT SWITCH

FUSE C2
5 3

85

833
2
5

834
1

FUSE B8 312

127
4
2

832
6

86

836 FUSE C10


3

837

87

83

311 FUSE C3

DIP/MAIN BEAM SWITCH

ROAD LIGHTS SWITCH

88

828 FUSE A9

829 830 FUSE A10

89

From m/c no. 489724

7110 - C/7-21.1

829

10 - 15 - 01/26

92

830

9804/1103
200G 200E/200R 200D/200M

48

409
WATER TEMP GAUGE

WATER TEMP SENDER

Circuit Diagram - Electrical (contd)

49
+ -

50

408
FUEL GAUGE

FUEL SENDER

CONTENTS

51
+ TACHOMETER HOURMETER
9 9 9 9 9 9

52 53
TACHOMETER
ILLUMINATION

411

407

412

TURN SIGNAL

55 56 57 58

5 4
HAZARD WARNING

3 1
MAIN BEAM

2
MASTER WARNING LIGHTS

BATTERY FEED

Backhoe Loaders

10 - 15 - 01/26
54
10
ALTERNATOR

59 60 61 62 63 64 65

12 11
HAND BRAKE

458 406 404

BRAKE PRESS SWITCH WATER TEMP SWITCH TRANS OIL TEMP SWITCH

13

WATER TEMP

TRANS OIL TEMP

ENGINE OIL PRES

FRONT CONSOLE INSTRUMENTS


17
TRANS OIL PRES

403 405
14

ENGINE OIL PRESS SWITCH TRANS OIL PRESS SWITCH


402
6

AIR FILTER

AIR FILTER VAC. SWITCH


411 407

106

67

FUSE B1

BUZZER

66

W ALTERNATOR
8 7

68

RADIO SOCKET
304

FUSE C6
5 8 2 4

IGNITION RELAY 2

IGNITION RELAY 2
F/W/L SWITCH
5 4 6 6

69
011
8

72

855 116
5 2 3

FRONT WORKING LIGHTS

310

70

FUSE B9

855
7

71
4 5

75

011
8

861
2 1

309
5

117

2 3

REAR WORKING LIGHTS

73

FUSE B7

861
7 8

74
R/W/L SWITCH

BEACON SWITCH
8 8 7

76
1 7

77

BEACON

78
1

79

FOG LIGHT

LIGHTS RELAY RH DIP BEAM

81

LH DIP BEAM LH MAIN BEAM RH MAIN BEAM


7

82

LH TAIL LIGHT LH SIDE LIGHT

90 91

DIPPER SOCKET

RH TAIL LIGHT RH SIDE LIGHT

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 15 - 01/27

212SU Circuit Diagrams - Electrical (contd)


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 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

From m/c no. 489724

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

9804/1103

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


1 2 46 47 48 49 50 51 52 53 54 69 70 103 104 105 106 107 108 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 C6
101AL 10 203

2 A1
211

101AM

922

B6

A6
223 217

107

45 70

238

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.
600GC

946

237

236

243

48 49 50
253
410 455

46
255

108
850 849

47
816 815 649

851

805K

853

600GD

806L

239

853

53 51 106 54 52
639 649

104
600GE

69

633

648

105

648

638

9804/1103

10 - 15 - 02/1

637

103

7110 - C/7-7.1

Issue 1

816J

+ -

CONTENTS

Backhoe Loaders

10 - 15 - 02/2

2CX, 2DX, 212SU Electrical Circuit Options and Variants


Worklights Circuit - German/Italian Builds Main Components 1 2 3 4 5 6 7 8 9 10 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 11 12 13 14 15 16 17 18 19 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

From m/c no. 489724

FRONT WORKING LIGHTS

DIPPER SOCKET

REAR WORKING LIGHTS

RH MAIN BEAM

LH MAIN BEAM

LIGHTS RELAY

11

12

14 13

16 17

19

834

837

829

834

837

15

18

834

837

833

836

FUSE C10

855

855

861

861

FUSE C2

829

TO INST PANEL TO FOG LT SW


6 3 7

116

R/W/L SWITCH

10
832 828

117

1
6 8

4
6 8

DIP/MAIN BEAM SWITCH

F/W/L SWITCH

TO INST PANEL

011

011

TO HAZARD SW

TO INST PANEL

SW ILUMINATION

TO INST PANEL

H/LIGHT FLASH

LINK NOT REQUIRED ON GERMAN/ITALIAN BUILDS

310

309

ROAD LIGHTS RELAY

127

FUSE B9

FUSE B7

011 IGN FEED

8
FUSE B8
312

FUSE P4 FUSE P1

FUSE C3

110 FEED

311

ROAD LIGHTS SWITCH

FUSE A10

FUSE A9

830

830

RH SIDE LIGHT

LH SIDE LIGHT

RH TAIL LIGHT

LH TAIL LIGHT

RH DIP BEAM

LH DIP BEAM

A363450

9804/1103

10 - 15 - 02/2

7110 - C/7-22.1

Issue 1

CONTENTS

Backhoe Loaders
Heater/Air Conditioning Circuit Main Components 1 2 3 4 5 6 7 8 9 Heater switch Air conditioning switch Heater resistor Heater fan motor Freeze valve switch Air conditioning relay Low pressure switch High pressure switch Compressor clutch

10 - 15 - 02/3

2CX, 2DX, 212SU Electrical Circuit Options and Variants


Heater Circuit Main Components 1 2 3 Heater switch Heater resistor Heater fan motor

From m/c no. 489724

HEATER FAN MOTOR

965

HIGH PRESS SWITCH

AIR CON.
LOW PRESS SWITCH

HEATER

HEATER

9
M

4
M

964

HEATER RESISTOR

6
4 5

800B

800B

FREEZE VALVE

963

HEATER RESISTOR

800

5
7

962

HEATER SWITCH

800B

800A

800

B4 B5

B3

800E

A4

C1

HEATER SWITCH

B1

102

829

600

102

829

AIR CON SWITCH

AIR CON RELAY


600

FUSE C8

A363460

FUSE C8

961

A363470

9804/1103

10 - 15 - 02/3

7110 - C/7-23.1

Issue 1

CONTENTS

Backhoe Loaders

10 - 15 - 02/4

2CX, 2DX, 212SU Electrical Circuit Options & Variations


Compressor Circuit - 2CX, 2DX Main Components 1 2 3 4 5 6 7 8 9 10 11 12 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) Radio Circuit Main Components 1 2 3 Radio unit Loudspeaker Loudspeaker

Later Machines

COMPRESSOR TEMP SENDER

COMPRESSOR SOLENOID

COMPRESSOR TEMP GAUGE

COMPRESSOR HOURMETER

AIR FILTER SW

AIR RECIEVER TEMP SW

AIR DELIVERY TEMP SW

12 7

RADIO

2
511

6
952

602

9 10 11

10

COMPRESSOR INTERLOCK RELAY

952

5
8 6

1
955 459 459 459

601

4 2
1 3

COMPRESSOR SHUTDOWN RELAY

859

951

860

3
5 2

3
959
3 1

START BUTTON

2
953

600

600

PARKBRAKE LIGHTS RELAY

FUSE A6

STOP/START SWITCH

121

304

157

COMPRESSOR START RELAY

FUSE C6

A363480

A363490

9804/1103

10 - 15 - 02/4

7110 - C/7-24.1

Issue 1

CONTENTS

Backhoe Loaders

10 - 15 - 02/5

2CX, 2DX, 212SU Electrical Circuit Options & Variations


Hammer Circuit Main Components 1 2 3 Hammer relay Hammer solenoid Hammer ON/OFF switch 1 2 Hand Held Hydraulic Tools Circuit Main Components Selector switch Actuating solenoid

Later Machines

Hydraclamp Circuit Main Components 1 2 Selector switch Actuating solenoid

HAND HELD TOOLS SOLENOID

HAMMER SOLENOID

2 2
801

3
966

801

899

HYDROCLAMP SOLENOID
7

1
2 8

HAMMER RELAY

AUXILIARY FEED SKT

AUXILIARY FEED SKT

101

829

101

829

101

600

600

FUSE A1

A364130

FUSE A1

A364140

FUSE A1

600

A364150

9804/1103

10 - 15 - 02/5

711 0 - C/7-25.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 20 - 01/1

2CX, 210S Circuit Diagrams - Hydraulic


Component Key T S P 1A 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 Tank Suction Line Pump Neutral Circuit Lines 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. 23 24 25 30 31 32 33 34 35 36 37 38 39 50 51 52 53

From m/c no. 655000 to 656500

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 Circuit Diagrams - Hydraulic

From m/c no. 655000 to 656500

S9808/9047-1

9804/1103

10 - 20 - 01/2

10 - 20 - 01/2

Issue 3

CONTENTS CONTENTS

Backhoe Loaders

10 - 20 - 01/3

2CX, 210S Circuit Diagram - Hydraulic

From m/c no. 657001 to 658960

20 11

26 27

21 1 5 10 22
R L

4 4A 4W 4H 19 3 4B 3A 24
LS

28 19

2 7

9B

4W

4J 4L 19

8 6 6A
P

3E

3F 3J 4C

4W 4K

9 9A
T

3B

4D

4W 29

30

31

3J

4E

4W

4N

13 15 17 25 3G 3D 16 14 8 14 8 18 23 3H

3C 4F 3J

4W 4M 4R

19

4W 4S 4P 4T 12 4V 4U 1 27

12

32

4G 12 A210610
9804/1103

33

10 - 20 - 01/3

7110 - E/2-2.6

Issue 4*

CONTENTS CONTENTS

Backhoe Loaders

10 - 20 - 01/4

2CX, 210S Circuit Diagrams - Hydraulic


Component Key 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 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 Rams 22 23 24 25 26 27 28 29 30 31 32 33

From m/c no. 657001 to 658960

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).

9804/1103

10 - 20 - 01/4

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

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

A173420 A173420

9804/1103

10 - 20 - 01/5

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

10 - 20 - 02/1

2CX, 2DX 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 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

From m/c no. 658961

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.

9804/1103

10 - 20 - 02/1

3270 - F/1-3.1

Issue 4*

CONTENTS CONTENTS

Backhoe Loaders

10 - 20 - 02/2

2CX, 2DX, 210S, 212S Circuit Diagram - Hydraulic

From m/c no. 658961

26 27 10
R L

1 5 2A 36

9B 20 35 22
LS

8 4A 4W

4 4H 19 28 19 4W 4B 4J 4L 19 4W 3J 4C 4K

21

11 3

9 7 2
P

9A
T

3A 24 3E 3F

8
G1 S

13

6 6A 3B
G2

4D

4W 29

30

31

16 3J 4E 4W 4N

EF

LS

A1

A2

25 15 8 14 17 3G 3D 3H

3C 4F 3J

4W 4M

19

14 8

23 18
34

4P 4G

27

33A 33 33B

12

32

9804/1103

10 - 20 - 02/2

7110 - E/2-2.6

Issue 4*

CONTENTS

CONTENTS CONTENTS

Backhoe Loaders

10 - 20 - 02/3

2CXL, 210SL, 2CXFM Circuit Diagrams - Basic Machine


Component Key 1 2 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 5 6 6A 7 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 8 9 9A 9B 10 11 13 14 15 16 17 18 20 21 22 23 24 25 40

From m/c no. 657001

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
V C

20 21

5 1

10 22
R L

11

2 7

9B

3A 24
LS

8 6 6A
P

3E

3F 3J

9 9A
T

3B

3J

13 15 17 25 3G 3D 16 14 8 14 8 18 23 3H

3C

3J

A221000
A221000

9804/1103

10 - 20 - 02/3

Issue 3

CONTENTS CONTENTS

Backhoe Loaders

10 - 20 - 02/4

2CX, 212SU 9N. America only) Circuit Diagram - Hydraulic

From m/c no. 657001

4 29 4E 4A

4G 28 4B

27

4G 4F 4C

40
V C

4G 26 4D

10 31 5 1 22
L R

4G 32 30

2 7

9B

3A 24
LS

8 6 6A
P

3E

3F 3J

9 9A
T

3B

3J

13 15 17 25 3G 3D 16 14 8 14 8 18 23 3H

3C

3J

11

20

21

9804/1103

10 - 20 - 02/4

7110 - E/2-6.2

Issue 1

CONTENTS CONTENTS CONTENTS

Backhoe Loaders

10 - 20 - 02/5

2CX, 212SU (N. America only) 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

From m/c no. 657001

9804/1103

10 - 20 - 02/5

7110 - E/2-7.2

Issue 1

CONTENTS CONTENTS CONTENTS

Backhoe Loaders

10 - 20 - 03/1

2CX, 210S 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

From m/c no. 655000 to 656500

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

10 - 20 - 03/2

2CX, 2CXL, 210S, 210SL 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

From m/c no. 657001

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

CONTENTS CONTENTS

Backhoe Loaders

10 - 20 - 03/3

2CXAM Circuit Diagram - Pneumatics


Component Key 1 2 3 4 5 6 7 8 Air Reciever Hose Oil Cooler Hose Oil Filter Hose Compressor Hose

From m/c no. 657001

8 1

A213330

9804/1103

10 - 20 - 03/3

3270 - F/1-3.1

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 01/1

3CX, 4CX, (200 Series) General Information - Fluids, Lubricants and Capacities
ITEM CAPACITY Litres UK Gal FLUID/LUBRICANT

From m/c no. 400001

INTERNATIONAL SPECIFICATION

Fuel Tank

100

22

Diesel Oil JCB 15W/40 Multigrade -10 C to 50 C (14 F to 122 F)

ASTM D975-66T Nos. 1D, 2D SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104D SAE10W/30, MIL-L-2105, MIL-L-46152, API CD/SE, MIL-L-2104C SAE10W, MIL-L-46152, MIL-L-2104D, API CD/SE

Engine (Oil) 2 Wheel Steer Machines - Build AA 9.7 - Build AA (Hot Climate) 11.0 - Build AB 10.0 4 Wheel Steer Machines - Build AB 10.0

2.1 2.4 2.2

JCB Super Universal Agricultural -15 C to 30 C (5 F to 86 F)

2.2

JCB Torque Converter Fluid -18 C to 0 C (0 F to 32 F)

Engine (Coolant) Syncro Shuttle (2WD)

20.0 15.75

4.4 3.5

JCB Universal Antifreeze/water JCB Special Transmission Fluid

ASTM D3306-74 ESP-M2C 33G

Syncro Shuttle (4WD) 16.25 3.6 (machines up to serial number 431230) Syncro Shuttle (2WD) 13.0 2.9 JCB Special Transmission Fluid ESP-M2C 33G

Syncro Shuttle (4WD) 14.0 3.1 (machines from serial number 431230) Powershift Front Axle (4WD) Housing (2WS) Housing (AWS) Hubs (x2) Rear Axle (AWS) Housing Hubs (x2) Rear Axle (2WS) Slew Gearbox Brake System - Standard - Servo Hydraulic System 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

18 2.0 23 4.3

3.96 0.44 5.0 0.9

JCB Special Gear Oil

ESEN-M2C 86A/B

JCB Special Gear Oil JCB HD90 Gear Oil

ESEN-M2C 86A/B API-GL-5, MIL-L-2105C

1.2 1.4 135

0.26 0.31 29.7

JCB Light Hydraulic Fluid

ISO VG15

! CAUTION: DO NOT USE ORDINARY BRAKE FLUID JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Hydraulic Fluid HP32 (Below 38 C, 100 F) ISO VG46

ISO VG32

Air Conditioning System Boom Lock

1544 g 1.0

3.4 lb 0.22

Refrigerant JCB Light Hydraulic Fluid

R134a ISO VG15

.............continued
9804/1103

15 - 00 - 01/1

Issue 3

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 01/2

3CX, 4CX, (200 Series) General Information - Fluids, Lubricants and Capacities (contd)
ITEM CAPACITY Litres UK Gal FLUID/LUBRICANT

From m/c no. 400001

INTERNATIONAL SPECIFICATION

Grease Points

---

JCB MPL Grease or JCB HP Grease Waxoyl

Lithium based, No. 2 consistency.

Extending Dipper 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 on the 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 a high specification grease, in certain applications this grease must be used, for instance transmission bearings during an overhaul. ! 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

Note: AWS axles with limited slip differential must use JCB Special Gear Oil.

9804/1103

15 - 00 - 01/2

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 01/3

3CX, 4CX and Variants Lubricants and Capacities


ITEM CAPACITY FLUID/LUBRICANT Litres UK Gal

From m/c no. 460001

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/cs) 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) 2 Wheel Steer Machines - Build AA - Build AA (Hot Climate) - Build AB 4 Wheel Steer Machines - Build AB 2 Wheel Steer Machines - Build AR - Build AK 4 Wheel Steer Machines - Build AK Engine (Coolant) JCB 15W/40 Multigrade -10 C to 50 C (14 F to 122 F) 9.7 11.0 10 2.1 2.4 2.2 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) SAE15W/40 API CF4/SG SAE10W/30 API CE/SF SAE10W API CD/SF

10.0

2.2

11.0 10

2.4 2.2

JCB Super Multigrade 15W/40 -10C to +50C (14F to 122F) JCB Super Multigrade 10W/30 -15C to +40C (5F to 104F) JCB Four Seasons Antifreeze & Summer Coolant/Water (see Coolant Mixtures) JCB Special Transmission Fluid

SAE15W/40 CF-4/SG SAE10W/30 CF-4/SG ASTM D3306, BS6580

10.0 23.0

2.2 5.1

Syncro Shuttle (2WD) Syncro Shuttle (4WD) Powershift

14.4 15.4 14.75 15.4

3.2 3.4 3.25 3.4

ESP-M2C 33G

Friction modified oils MUST NOT be used (eg. Dexron ATF type) JCB Special Transmission Fluid ESP-M2C 33G Friction modified oils MUST NOT be used (eg. Dexron ATF type). 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).

Front Axle (4WD) Housing (2WS) Housing (4WS) Hubs (x2) Rear Axle (4WS) Housing Hubs (x2) Rear Axle (2WS) Brake System - Standard - Servo Hydraulic System

13 18 2.0

2.86 3.96 0.44

18 2.0 23

3.96 0.44 5.0

JCB Special Gear Oil Plus API-GL-4 Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).

1.2 1.4 130

0.26 0.31 28.6

JCB Light Hydraulic Fluid

ISO VG15

! CAUTION: DO NOT USE ORDINARY BRAKE FLUID JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Hydraulic Fluid HP32 (Below 38 C, 100 F) ISO VG46

ISO VG32

9804/1103

15 - 00 - 01/3

3270 - 3/1-2.2

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 01/4

3CX, 4CX and Variants Fluids, Lubricants and Capacities (Contd)

From m/c no. 460001

ITEM

CAPACITY FLUID/LUBRICANT Litres UK Gal --JCB HP Grease

INTERNATIONAL SPECIFICATION Lithium complex NLGI No.2

Grease Points consistency

including extreme pressure additives or JCB Special MPL-EP Grease Lithium based NLGI No.2 consistency including extreme pressure additives Extending Dipper Electrical connections Power Sideshift Chains ----Waxoyl As a corrosion and moisture inhibitor all exposed connections should be coated liberally with petroleum jelly. JCB Chain Lubricant

---

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 a high specification grease, in certain applications this grease must be used, for instance transmission bearings during an overhaul. !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

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

CONTENTS

Backhoe Loaders

15 - 00 - 01/5

214, 214E, 215, 215E, 217 (N. America) Fluids, Lubricants and Capacities

From m/c no. 460001

ITEM

CAPACITY US Gal Liters

FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION

Fuel Tank (with toolbox) Fuel Tank (without toolbox) Fuel Tank (All later m/cs) Engine (Oil) 2 Wheel Steer Machines - Build AA - Build AA (Hot Climate) - Build AB 4 Wheel Steer Machines - Build AB 2 Wheel Steer Machines - Build AR - Build AK 4 Wheel Steer Machines - Build AK Engine (Coolant) Syncro Shuttle (2WD) Syncro Shuttle (4WD) Powershift Front Axle (4WD) Housing (2WS) Housing (4WS) Hubs (x2) Rear Axle (4WS) Housing Hubs (x2) Rear Axle (2WS) Brake System - Standard - Servo Hydraulic System Grease Points Extending Dipper Electrical connections ---

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

2.6 2.9 2.7

9.7 11.0 10

JCB 10W or JCB 15W/40 Below 32 F (0C) JCB 30W or JCB 15W/40 Above 32 F (0C)

API CF4/SG, MIL-L-2104F Note: spec given for 15W/40

2.7

10.0

13.2 12.0

2.4 2.2

JCB 15W/40 Engine Oil -10C to +50C (14F to 122F) JCB 10W Engine Oil -20C to +10C (-4F to 50F) Anti-freeze/Water JCB Special Transmission Fluid

SAE15W/40 CF-4/SG SAE10W CF-4/SG ASTM D3306-74 ESP-M2C 33G

12.0 6.07 3.2 3.4 3.9

2.2 23 14.4 15.4 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

4.8 0.5 6.1

18 2.0 23

JCB Special Gear Oil Plus

API-GL-4

JCB Special Gear Oil Plus

API-GL-4

0.32 0.37 34.3 -----

1.2 1.4 130

Light Hydraulic Fluid

ISO VG15

! CAUTION: DO NOT USE ORDINARY BRAKE FLUID JCB Hydraulic Fluid JCB Moly EP # 2 Grease Waxoyl As a corrosion and moisture inhibitor all exposed connections should be coated liberally with petroleum jelly. ISO VG46 Lithium based, No. 2

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

15 - 00 - 01/6

214, 214E, 215, 215E, 217 (N. America) Fluids, Lubricants and Capacities (Contd)

From m/c no. 460001

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 a high specification grease, in certain applications this grease must be used, for instance transmission bearings during an overhaul. !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

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

CONTENTS

Backhoe Loaders

15 - 00 - 01/7

214e (N. America) Fluids, Lubricants and Capacities


NORTH AMERICAN MACHINES - 214e & 214Se ITEM CAPACITY US Gal Liters 34.3 130 FLUID/LUBRICANT

From m/c no. 460001

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

Fuel Tank Engine (Oil) ! 2 Wheel Steer Machines - Build AR

Diesel Oil

2.6

9.7

JCB 15W/40 -10C to + 50C (14F to 122F) JCB 10W -20C to + 10C (-4F to 50F) Anti-freeze/Water JCB Special Transmission Fluid

CF 4/SG, SAE 15W/40 CF 4/SG, SAE 10W

Engine (Coolant) Syncro Shuttle (2WD) " Syncro Shuttle (4WD) " Front Axle Housing (2WS) Hubs (x2) Rear Axle Brake System - Standard - Servo Hydraulic System # Grease Points Extending Dipper Electrical connections ---

6.07 3.8 4.0

23 14.4 15.4

ASTM D3306-74 ESP-M2C 33G

3.4 0.5 6.1

13 2.0 23

JCB GL-5 80W/90

API-GL-5

JCB Special Gear Oil Plus

API-GL-4

0.32 0.37 34.3 -----

1.2 1.4 130

Light Hydraulic Fluid ISO VG15 ! CAUTION: DO NOT USE ORDINARY BRAKE FLUID JCB Hydraulic Fluid JCB Moly EP # 2 Grease Waxoyl $ As a corrosion and moisture inhibitor all exposed connections should be coated liberally with petroleum jelly. ISO VG46 Lithium based, No. 2

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

15 - 00 - 01/8

214e (N. America) Fluids, Lubricants and Capacities (contd)

From m/c no. 460001

!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

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
* 3CX,

Backhoe Loaders

15 - 00 - 01/9

4CX and Variants

From m/c no. 930000

General Information - Service Capacities and Lubricants


ITEM CAPACITY FLUID/LUBRICANT Litres UK Gal 150 33 Diesel Oil INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D

Fuel Tank Engine (Oil) 2 Wheel Steer Machines - Build AR - Build AK 4 Wheel Steer Machines - Build AK Engine (Coolant)

11.0 10

2.4 2.2

JCB Super Multigrade 15W/40 -10C to +50C (14F to 122F) JCB Super Universal Agricultural -15C to +40C (5F to 122F) JCB Four Seasons Antifreeze & Summer Coolant/Water (see Coolant Mixtures) JCB Extreme Performance (Below 40C, 104F) JCB Extreme Performance (Below 40C, 104F)

SAE15W/40 CF-4/SG SAE10W/30 CF-4/SG ASTM D3306, BS6580

10.0 23.0

2.2 5.1

Syncro Shuttle (2WD) Syncro Shuttle (4WD) Powershift 6 speed Powershift 4 speed

14.4 15.5

3.2 3.4

SAE10W SAE10W

16 15.5

3.5 3.4

JCB Extreme Performance (Below 40C, 104F) JCB Extreme Performance (Below 40C, 104F)

SAE10W SAE10W

Front Axle (4WD) Housing (2WS) Housing (4WS) Hubs (x2) Rear Axle (4WS) Housing Hubs (x2) Rear Axle (2WS) Brake System Hydraulic System

13 18 2.0

2.86 3.96 0.44

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).

18 2.0 23 1.4

3.96 0.44 5.0 0.3

JCB Special Gear Oil Plus API-GL-4 Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).

JCB Light Hydraulic Fluid ISO VG15 ! CAUTION: DO NOT USE ORDINARY BRAKE FLUID JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Hydraulic Fluid HP32 (Below 38 C, 100 F) ISO VG32 ISO VG46

130

28.6

9804/1103

15 - 00 - 01/9

3280 - 3/28-1.1

Issue 1*

CONTENTS

Backhoe Loader

15 - 00 - 01/10

3CX, 4CX and Variants General Information - Service Capacities and Lubricants

From m/c no. 930000

ITEM

CAPACITY FLUID/LUBRICANT Litres UK Gal --JCB HP Grease or JCB Special MPL-EP Grease Waxoyl

INTERNATIONAL SPECIFICATION Lithium based NLGI No.2 consistency including extreme pressure additives Lithium based NLGI No.2 consistency including extreme pressure additives

Grease Points

Extending Dipper Electrical connections Power Sideshift Chains

-----

As a corrosion and moisture inhibitor all exposed connections should be coated liberally with petroleum jelly. JCB Chain Lubricant

---

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

Note: 4WS alxes with liited slup differential must use JCB Special Gear Oil Plus

Coolant Mixtures ! WARNING


Antifreeze can be harmful. Obey the manufacturers 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 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. 55% Solution - Maintains circulation down to -36C (-33F), protects agains damage down to -41C (-42F) 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 coolants 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*

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/1

3CX (214) 4X4 SIDESHIFT General Information - Static Dimensions


Item A B C D Description Overall length Overall height Height to top of cab Wheelbase - 2WD - 4WD E F G J H Minimum ground clearance Slew ground clearance Width Centreline of rear axle/centreline of kingpost Cabless build, Maximum fixed height 2.11m(6ft 11in) 2.17m(7ft 1in) 0.36m(1ft 2in) 0.5m(1ft 8in) 2.35m(7ft 8in) 1.32m(4ft 4in) 2.06m(6ft 9in) Dimensions 6.00m(19ft 8in) 3.54m(11ft 7in) 2.84m(9ft 4in)

From m/c no. 400001

C H F

E J D A
A163130

B
A163130

G
9804/1103

15 - 00 - 02/1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/2

3CX (214) 4X4 CENTREMOUNT General Information - Static Dimensions


Item A B C D Description Overall length Overall height Height to top of cab Wheelbase - 2WD - 4WD E F G J H Minimum ground clearance Slew ground clearance Width Centreline of rear axle/centreline of kingpost Cabless build, Maximum fixed height 2.21m(7ft 3in) 2.27m(7ft 5in) 0.36m(1ft 2in) 0.50m(1ft 8in) 2.35m(7ft 8in) 1.22m(4ft 0in) 2.06m(6ft 9in) Dimensions 7.08m(23ft 3in) 3.54m(11ft 7in) 2.84m(9ft 4in)

From m/c no. 400001

C H F

E J D A

B
A163140

9804/1103

15 - 00 - 02/2

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/3

4C (215) 4X4 General Information - Static Dimensions


Item A B Description Overall length Overall height - with Extra-Dig C D Height to top of cab Wheelbase - 2WD - 4WD E F G J H Minimum ground clearance Slew ground clearance Width Centreline of rear axle/centreline of kingpost Cabless build, Maximum fixed height 2.21m(7ft 3in) 2.27m(7ft 5in) 0.36m(1ft 2in) 0.50m(1ft 8in) 2.35m(7ft 8in) 1.20m(3ft 11in) 2.06m(6ft 9in) Dimensions 7.47m(24ft 6in) 3.89m(12ft 9in) 3.96m(13ft 1in) 2.84m(9ft 4in)

From m/c no. 400001

C H F

E J D A

B
A163140

9804/1103

15 - 00 - 02/3

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/4

4CN (216) 4X4 General Information - Static Dimensions


Item A B C D Description Overall length Overall height Height to top of cab Wheelbase - 2WD - 4WD E F G J H Minimum ground clearance Slew ground clearance Width Centreline of rear axle/centreline of kingpost Cabless build, Maximum fixed height 2.21m(7ft 3in) 2.27m(7ft 5in) 0.36m(1ft 2in) 0.50m(1ft 8in) 2.24m(7ft 4in) 1.20m(3ft 11in) 2.06m(6ft 9in) Dimensions 7.44m(24ft 5in) 3.73m(12ft 3in) 2.84m(9ft 4in)

From m/c no. 400001

C H F

E J D A

B
A163150

9804/1103

15 - 00 - 02/4

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/5

3CX (214) 4X4 SITEMASTER (SIDESHIFT) General Information - Static Dimensions


Item A B C D Description Overall length Overall height Height to top of cab Wheelbase - 2WD - 4WD E F G J H Minimum ground clearance Slew ground clearance Width Centreline of rear axle/centreline of kingpost Cabless build, Maximum fixed height 2.11m(6ft 11in) 2.17m(7ft 1in) 0.36m(1ft 2in) 0.50m(1ft 8in) 2.35m(7ft 8in) 1.32m(4ft 4in) 2.06m(6ft 9in) Dimensions 6.00m(19ft 8in) 3.58m(11ft 9in) 2.84m(9ft 4in)

From m/c no. 400001

C H F E

D A

B
A163160

9804/1103

15 - 00 - 02/5

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/6

3CX (214) 4X4 SITEMASTER (CENTREMOUNT) General Information - Static Dimensions


Item A B C D Description Overall length Overall height Height to top of cab Wheelbase - 2WD - 4WD E F G J H Minimum ground clearance Slew ground clearance Width Centreline of rear axle/centreline of kingpost Cabless build, Maximum fixed height 2.21m(7ft 3in) 2.27m(7ft 5in) 0.36m(1ft 2in) 0.50m(1ft 8in) 2.35m(7ft 8in) 1.32m(4ft 4in) 2.06m(6ft 9in) Dimensions 7.59m(24ft 11in) 3.58m(11ft 9in) 2.84m(9ft 4in)

From m/c no. 400001

C H F

E J D A

B
A166290

9804/1103

15 - 00 - 02/6

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/7

HAMMERMASTER 4X4 General Information - Static Dimensions


Item A B C D Description Overall length Overall height Height to top of cab Wheelbase - 2WD - 4WD E F G J H Minimum ground clearance Slew ground clearance Width Centreline of rear axle/centreline of kingpost Cabless build, Maximum fixed height 2.11m(6ft 11in) 2.17m(7ft 1in) 0.36m(1ft 2in) 0.50m(1ft 8in) 2.35m(7ft 8in) 1.32m(4ft 4in) 2.06m(6ft 9in) Dimensions 6.00m(19ft 8in) 3.54m(11ft 7in) 2.84m(9ft 4in)

From m/c no. 400001

C H F

E J D A
A163130

B
A163130

G
9804/1103

15 - 00 - 02/7

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/8

217 General Information - Static Dimensions


Item A B Description Overall length Overall height - with Extra-Dig C D Height to top of cab Wheelbase - 2WD - 4WD E F G J H Minimum ground clearance Slew ground clearance Width Centreline of rear axle/centreline of kingpost Cabless build, Maximum fixed height 0.36m(1ft 2in) 0.50m(1ft 8in) 2.44m(8ft 0in) Not available at print Not available at print 2.26m(7ft 5in) Dimensions 7.48m(24ft 6in) 4.14m(13ft 7in) 4.22m(13ft 10in) 2.84m(9ft 4in)

From m/c no. 400001

C H F

E J D A

B
A163140

9804/1103

15 - 00 - 02/8

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/9

4CX (214S) 4x4x4 (SIDESHIFT) General Information - Static Dimensions


Item A B C D E F G H J Description Overall length Overall height Height to top of cab Wheelbase Minimum ground clearance Slew ground clearance Width Cabless build, Maximum fixed height Centreline of rear axle/centreline of kingpost Dimensions 6.07m (19ft 11in) 3.49m (11ft 5in) 2.78m (9ft 2in) 2.22m (7ft 3in) 0.31m (1ft 0in) 0.45m (1ft 6in) 2.35m (7ft 8in) 2.01m (6ft 7in) 1.32m (4ft 4in)

From m/c no. 400001

C H F

E J D A

B
A162830

G
9804/1103

15 - 00 - 02/9

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/10

4CX (214S) 4x4x4 (CENTREMOUNT) General Information - Static Dimensions


Item A B C D E F G H Description Overall length Overall height Height to top of cab Wheelbase Minimum ground clearance Slew ground clearance Width Cabless build, Maximum fixed height Dimensions 6.07m (19ft 11in) 3.49m (11ft 5in) 2.83m (9ft 3in) 2.32m (7ft 7in) 0.40m (1ft 4in) 0.48m (1ft 7in) 2.35m (7ft 8in) 2.06m (6ft 9in)

From m/c no. 400001

C H F

E D

A170890

9804/1103

15 - 00 - 02/10

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/11

4C (215S) 4x4x4 General Information - Static Dimensions


Item A B Description Overall length Overall height - with Extra-Dig C D E F G H Height to top of cab Wheelbase Minimum ground clearance Slew ground clearance Width Cabless build, Maximum fixed height Dimensions 8.53m (28ft 0in) 3.89m (12 ft 9in) 3.96 (13ft 1in) 2.82m (9ft 3in) 2.32m (7ft 8in) 0.40m (1ft 4in) 0.48m (1ft 7in) 2.35m (7ft 8in) 2.06m (6ft 9in)

From m/c no. 400001

C H F

E D

A170890

9804/1103

15 - 00 - 02/11

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/12

4CN 4x4x4 General Information - Static Dimensions


Item A B C D E F G H Description Overall length Overall height Height to top of cab Wheelbase Minimum ground clearance Slew ground clearance Width Cabless build, Maximum fixed height Dimensions 8.53m (28ft 0in) 3.89m (12 ft 9in) 2.82m (9ft 3in) 2.32m (7ft 8in) 0.40m (1ft 4in) 0.48m (1ft 7in) 2.35m (7ft 8in) 2.06m (6ft 9in)

From m/c no. 400001

C H F E D G A

B
A171020

9804/1103

15 - 00 - 02/12

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/13

4CX (214S) 4x4x4 SITEMASTER (SIDESHIFT) General Information - Static Dimensions


Item A B C D E F G H J Description Overall length Overall height Height to top of cab Wheelbase Minimum ground clearance Slew ground clearance Width Cabless build, Maximum fixed height Centreline of rear axle/centreline of kingpost Dimensions 6.07m (19ft 11in) 3.53m (11ft 7in) 2.78m (9ft 2in) 2.22m (7ft 3in) 0.31m (1ft 0in) 0.45m (1ft 6in) 2.35m (7ft 8in) 2.01m (6ft 7in) 1.32m (4ft 4in)

From m/c no. 400001

C H F E

D A

B
A162850

9804/1103

15 - 00 - 02/13

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/14

4CX (214S) 4x4x4 SITEMASTER (CENTREMOUNT) General Information - Static Dimensions


Item A B C D E F G H J Description Overall length Overall height Height to top of cab Wheelbase Minimum ground clearance Slew ground clearance Width Cabless build, Maximum fixed height Centreline of rear axle/centreline of kingpost Dimensions 8.53m (28ft 0in) 3.53m (11ft 7in) 2.78m (9ft 2in) 2.32m (7ft 8in) 0.31m (1ft 0in) 0.45m (1ft 6in) 2.35m (7ft 8in) 2.01m (6ft 7in) 1.32m (4ft 4in)

From m/c no. 400001

C H F

E J D A

B
A170771

9804/1103

15 - 00 - 02/14

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/15

217S General Information - Static Dimensions


Item A B Description Overall length Overall height - with Extra-Dig C D E F G J H Height to top of cab Wheelbase Minimum ground clearance Slew ground clearance Width Centreline of rear axle/centreline of kingpost Cabless build, Maximum fixed height Dimensions 9.14m(30ft 0in) 4.19m(13ft 9in) 4.27m(14ft 0in) 2.87m(9ft 5in) 2.32m(7ft 8in) Not available at print 0.43m(1ft 5in) 2.44m(8ft 0in) Not available at print Not available at print

From m/c no. 400001

C H F

E J D A

B
A165850

G
9804/1103

15 - 00 - 02/15

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/16

3CX Super 4x4x4 General Information - Static Dimensions


Item A B C D E F G H J Description Overall length Overall height Height to top of cab Wheelbase Minimum ground clearance Slew ground clearance Width Cabless build, Maximum fixed height Centreline of rear axle/centreline of kingpost Machine weight - 4WD with 610mm (24in) excavator bucket, General Purpose shovel and full fuel Dimensions 6.00m (19ft 8in) 3.53m (11ft 7in) 2.78m (9ft 2in) 2.22m (7ft 3in) 0.31m (1ft 0in) 0.45m (1ft 6in) 2.24m (7ft 4in) 2.01m (6ft 7in) 1.32m (4ft 4in)

From m/c no. 400001

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*

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/17

4CX Super 4x4x4 General Information - Static Dimensions


Item A B C D E F G H J Description Overall length Overall height Height to top of cab Wheelbase Minimum ground clearance Slew ground clearance Width Cabless build, Maximum fixed height Centreline of rear axle/centreline of kingpost Machine weight - 4WD with 610mm (24in) excavator bucket, 6-in-1 shovel, bucket mounted forks and full fuel Dimensions 6.07m (19ft 11in 3.93 m ( 12ft 10in) 2.78m (9ft 2in) 2.22m (7ft 3in) 0.31m (1ft 0in) 0.45m (1ft 6in) 2.35m (7ft 8in) 2.01m (6ft 7in) 1.32m (4ft 4in)

From m/c no. 400001

8460kg (18654lb)

* Note: Dimensions based on standard tyres fitted (16.9/14 x 24 -12PR).

C H F E

D A

B
A162850

9804/1103

15 - 00 - 02/17

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

15 - 00 - 02/18

3CXE (214E) General Information - Static Dimensions


Item A B C D Description Overall length Overall height Height to top of cab Wheelbase - 2WD - 4WD E F G Minimum ground clearance Slew ground clearance Width Machine weight - 4WD with 610mm (24in) excavator bucket, 0.95m3 loader bucket 2.21m (7ft 3in) 2.26m (7ft 5in) 0.33m (1ft 1in) 0.43m (1ft 5in) 2.24m (7ft 4in) 6641kg (14870lbs) Dimensions 7.11m (23ft 4in) 3.43 m ( 11ft 3in) 2.83m (9ft 3in)

From m/c no. 400001

Note: Dimensions based on following tyres fitted -rear: 18.4 x 26 industrial; front: 10.5/80 x 18PR.

E D

B
A257120

9804/1103

15 - 00 - 02/18

Issue 1

CONTENTS

Backhoe Loaders

15 - 00 - 03/1

3CX Sideshift General Information - Static Dimensions

From m/c no. 460001

B C

E G

D A

A B

Overall length Overall height - standard backhoe fitted - extending dipper fitted Height to top of cab Wheelbase Ground clearance - stabiliser Ground clearance - kingpost Width

3CX 5.62

3CX Sitemaster 5.62

3CX Sitemaster Plus 5.62

3CX Powermaster 5.62

3.52 3.60 2.87 2.17 0.37 0.52 2.23

3.60 2.87 2.17 0.37 0.52 2.23

3.60 2.87 2.17 0.37 0.52 2.23

3.60 2.87 2.17 0.37 0.52 2.23

C D E F G

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

CONTENTS

Backhoe Loaders

15 - 00 - 03/2

4CX Sideshift General Information - Static Dimensions

From m/c no. 460001

B C

E G

D A

A B

Overall length Overall height - standard backhoe fitted - extending dipper fitted Height to top of cab Wheelbase Ground clearance - stabiliser Ground clearance - kingpost Width

4CX 5.91

4CX Sitemaster 5.91

4CX Super 5.91

4CX Super Sitemaster 5.91

3.59 3.67 2.84 2.22 0.34 0.50 2.33

3.67 2.84 2.22 0.34 0.50 2.33

3.92 2.84 2.22 0.34 0.50 2.33

3.96 2.84 2.22 0.34 0.50 2.33

C D E F G

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

CONTENTS

Backhoe Loaders

15 - 00 - 03/3

3CX Super General Information - Static Dimensions

From m/c no. 460001

B C

E G

D A
A270000

A B C D E F G

Overall length Overall height Height to top of cab Wheelbase Ground clearance - stabiliser Ground clearance - kingpost Width

3CX Super 5.91 3.49 2.82 2.22 0.33 0.48 2.23

3CX Super Sitemaster 5.91 3.57 2.82 2.22 0.33 0.48 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

CONTENTS

Backhoe Loaders

15 - 00 - 03/4

3CX Centremount General Information - Static Dimensions

From m/c no. 460001

B C

E G

D A

A B

Overall length Overall height - standard backhoe fitted - extending dipper fitted Height to top of cab Wheelbase - 2WD - 4WD Ground clearance - mainframe Ground clearance - front axle Width

3CX 7.19

3CX Sitemaster 7.19

3CXE 7.19

3.43 3.53 2.84

3.53 2.84

3.43 2.84

C D

2.21 2.28 0.33 0.28 2.23

2.21 2.26 0.33 0.28 2.23

2.21 2.26 0.33 0.28 2.23

E F G

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

CONTENTS

Backhoe Loaders

15 - 00 - 03/5

4CX Centremount General Information - Static Dimensions

From m/c no. 460001

B C

E D

Sitemaster machine shown.


A260730

A B

Overall length Overall height - standard backhoe fitted - extending dipper fitted Height to top of cab Wheelbase Ground clearance - mainframe Ground clearance - front axle Width

4CX 7.37

4CX Sitemaster 7.37

3.43 3.53 2.84 2.31 0.34 0.45 2.33

3.53 2.84 2.31 0.34 0.45 2.33

C D E F G

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

CONTENTS

Backhoe Loaders

15 - 00 - 03/6

4C, 4CN General Information - Static Dimensions

From m/c no. 460001

B C

E D G

A260770

A B

Overall length Overall height - standard backhoe fitted - extending dipper fitted Height to top of cab Wheelbase Ground clearance - mainframe Ground clearance - front axle Width

4C 4X4 7.49

4C 4X4X4 7.47

4CN 4X4X4 TBA

3.89 3.91 2.84 2.31 0.34 0.28 2.33

3.89 3.91 2.84 2.31 0.34 0.45 2.33

3.89 3.91 2.84 2.31 0.34 0.45 2.35

C D E F G

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

15 - 05 - 01/1

3CX, 4CX, (200 Series) Data - Electrical


System Type Battery (Heavy Duty) - 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 Battery (Temperate) - 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 2WS 4WS 4WS (air conditioning or ServoPlus builds) Starter Motor 410 170 550 220 12 Volt, negative earth

From m/c no. 400001

Lucas - 65 Amp maximum output Magnetti Marelli - 72 Amp maximum output Magneti Marelli - 85 Amp maximum output Lucas

Light Bulbs Head lights - main/dip Work lights Front side lights Tail/stop lights Fog light Direction turn indicators Instruments Warning lights Number plate light Interior light Beacon 45/37.5W 55W Halogen (front & rear) 5W 5/21W 21W 21W (front & rear) 1.2W 3W 2 x 5W 10W 70W Halogen

Note: These items are not apllicable to U.S.A.

9804/1103

15 - 05 - 01/1

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 01/2

3CX, 4CX, (200 Series) Data - Electrical

From m/c no. 400001 to 430000

?@

Circuit Protection
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).

O2@@@@@@@@@@@@@6?2@@@@6KO2@@6?2@@@6K?O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6Kf?O@K O2@@6K @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@ @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6KO@?@K??O2@@@@@@6K? ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6?26K?fO@K? 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! CAUTION
Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage.
8-3-3-5

COLUMN 'A' 1 2 3 4 5 6 7 8 9 Reverse alarm, brake lights, 2/4WD solenoid . Gauges, stabiliser lock relay. Left hand sidelights, dipper light. Gauge illumination, right hand sidelights. Rear wiper. Hazard warning lights. Beacon, Interior light. Radio. Horn, headlight flash, front wiper/washer.

Fuse Rating 10 Amp 5 Amp 5 Amp 5 Amp 5 Amp 10 Amp 10 Amp 5 Amp 10 Amp 10 Amp 5 Amp 10 Amp 10 Amp 10 Amp 5 Amp 5 Amp 15 Amp 5 Amp Machines from serial number 404852 have the brake lights, and 2/4WD solenoid protected by fuse A1 (as indicated in the fuse identification chart). Machines from serial number 403025 to 404851 have the brake lights protected by fuse C3. 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.
S143211

COLUMN 'B' 1 2 3 4 5 6 7 8 9 Junction box, remote unload solenoid (HSC). Fuel pump solenoid (engine stop). Dip beam. Main beam. Front work lights. Direction turn indicators. Dump relay. Heater. Hand dump, buzzer.

Note: Machines up to serial number 403024 have the brake lights protected by fuse A1.

COLUMN 'C' 1 2 3 Rear work lights. Steering solenoids, proximity switches . 2/4 WD switch & relay, forward relay and solenoid, reverse relay and solenoid. Powershift only - forward high/low relay & solenoid, reverse high/low relay & solenoid, drive (mainshaft/layshaft) relay & solenoid, neutral relay. 4 5 Fog light . When applicable - heated seat, clock & cigar lighter. 10 Amp 5 Amp

10 Amp 10 Amp 15 Amp

9804/1103

15 - 05 - 01/2

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 01/3

3CX, 4CX, (200 Series) Data - Electrical

From m/c no. 430001

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*

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 01/4

3CX, 4CX, (200 Series) Data - Electrical

From m/c no. 400001 to 430000

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.

DC

F H K

G J L

T U R S V

9804/1103

15 - 05 - 01/4

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 01/5

3CX, 4CX, (200 Series)

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 D C B

F R K

G S L

T U H J M N P Q V
S215400

9804/1103

15 - 05 - 01/5

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 01/6

3CX, 4CX, (200 Series) Data - Electrical

From m/c no. 430001

Relay Identification - All Machine Models


* 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.

* Note 1: On 3CXE (214E) machines the lights relay (item 15)


will be fitted at position 7 (in place of the hydraulic speed control relay). Items 13 to 24 will not be fitted.

* Note

2: Earlier Powershift machines had the neutral relay (item 24) located in position 5.

Relay Identification
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 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 2 Wheel Drive Reverse High/Low Ratio Drive (Layshaft/Mainshaft) Neutral - see Notes 2 & 3 Powershift Machines Only All Wheel Steer Machines Only

* Note 3: On 3CX 4x4x4 machines, the neutral relay (item 24)


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).

* *

* *

A
S247030

X
23

S247490

24

10

13

16

19

21

11

14

17

20

22

12

15

18

23

24

S247020

9804/1103

15 - 05 - 01/6

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 01/10

ALL MODELS (EXCEPT 2CX) Data - Electrical (Servo Machines)

From m/c no. 400001

General
System Type Alternator Logic Control Box 12V, negative earth 85amp maximum output 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 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

system

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*

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 01/11

ALL MODELS (EXCEPT 2CX) Data - Electrical (Servo Machines)

From m/c no. 400001

Fuses
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
Bulbs Headlights - main/dip Work lights Front Side lights Tail/stop lights Fog light Indicators Instruments Warning lights Number plate light Fuse Rating 10 Amp 5 Amp 5 Amp 5 Amp 5 Amp 10 Amp 10 Amp 5 Amp 10 Amp Interior light Beacon Bulb Rating 45/37.5 W 55 W Halogen (front & rear) 5W 5/21 W 21 W 21 W (front & rear) 1.2 W 3W 2x5W 10 W 70 W Halogen

! 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 A2 Instruments, Reverse Alarm A3 Left Hand Sidelights A4 Right Hand Sidelights A5 Rear Wiper, Rear Wash A6 Hazard Warning Lights A7 Beacon, Interior Light A8 Radio A9 Horn, Front Wash/Wiper COLUMN 'B' B1 Hydraulic Options B2 Fuel Pump solenoid (Engine Stop) B3 Dipped Beam B4 Main Beam B5 Front Work Lights B6 Indicators B7 Dump Relay Feed B8 Heater B9 Hand Dump, Buzzer COLUMN 'C' C1 Rear Work Lights. C2 Steering solenoids, proximity switches. C3 Gearbox Control, 2 Wheel Drive C4 Fog light C5 Heated seat, clock & cigar lighter C6 Servo Controls

10 Amp 5 Amp 10 Amp 10 Amp 10 Amp 5 Amp 10 Amp 15 Amp 5 Amp

10 Amp 5 Amp 10 Amp 5 Amp 15 Amp 20 Amp

Note: Items marked with a '' are available as optional extras.

S190050

9804/1103

15 - 05 - 01/11

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 01/12

ALL MODELS (EXCEPT 2CX) Data - Electrical (Servo Machines)

From m/c no. 400001

4 3

2 1

5 7 9

6 8 10

16 15 14 13 12 11

22 21 23 25 24 20

S193280

17
9804/1103

18

19
Issue 1

15 - 05 - 01/12

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 01/13

ALL MODELS (EXCEPT 2CX) Data - Electrical (Servo Machines)

From m/c no. 400001

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 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 Description Ignition Neutral Start Reverse Alarm Buzzer Road Lights Parking Brake 2/4WD Brake 2WD Select Flasher Transmission Dump Neutral (Powershift) Drive (Layshaft/Mainshaft) Reverse Drive Forward Drive Reverse High/Low Ratio Forward High/Low Ratio Hydraulic Speed Control Steering Loader Backhoe Hammer Hydraclamp Horn Horn Change Over Jaw (aux)

9804/1103

15 - 05 - 01/13

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 01/14

ALL MODELS (EXCEPT 2CX) Data - Electrical (Servo Machines)

From m/c no. 400001

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 Connector B 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 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 PIN A B C D E F G H J K L M N P R S T U V 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

A244360

M L K T J H S U

A N V R

B C P D E L

M U

A N V

B C P R D E L

M U

A N V

B C P R D E

K T J H S

K T J H S

G F

G F

G F

Harness Connector 'A'


9804/1103

Harness Connector 'B'

Harness Connector 'C'


Issue 2*

15 - 05 - 01/14

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 01/15

ALL MODELS (EXCEPT 2CX) Data - Electrical (Servo Machines)

From m/c no. 400001

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 E F P R

A N

M U L K T J
A244100

V S G H

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) WIRE 885 112K 423 427 425 890 110G 426 429 424 445 421E 421F 446 428 -

9804/1103

15 - 05 - 01/15

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 01/16

ALL MODELS (EXCEPT 2CX) Data - Electrical (Servo Machines)

From m/c no. 400001

H L 6 8 J 5 K

F 3

7 D 7

B 1

A
S193310

9804/1103

15 - 05 - 01/16

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 01/17

ALL MODELS (EXCEPT 2CX) Data - Electrical (Servo Machines)

From m/c no. 400001

Harness Identification
Key 1 Mainframe Harness A B C D E 2 Mainframe to Panel Connector 1 Mainframe to Panel Connector 2 Mainframe to Cab Connector Backhoe Valve Block Solenoid Connectors Loader Valve Block Solenoid Connectors

Cab Harness C F G H J 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 Panel to Mainframe Connector 1 Panel to Mainframe Connector 2 Panel to Cab Connector

Seat Harness H K L Seat to Cab Connectors Left Hand Joystick Connectors Right Hand Joystick Connectors

Cab Roof Harness J Roof to Cab Harness (2 off)

6 7

Seat Proximity Switch Harness 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 General


System Type Battery (Heavy Duty) - 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 Battery (Temperate) - 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 Electronic Control Unit Shift points Hz 2nd to 3rd 449/05401 693 3rd to 4th 1467 4th to 3rd 1304 410 170 550 220 12 Volt, negative earth

From m/c no. 460001

3rd to 2nd 570

2nd to 1st 326

Note: The part number and ECU settings can be verified and checked on the Psion Workabout. Alternator 2WS 4WS 4WS (air conditioning or ServoPlus builds) 65 Amp nominal output 72 Amp nominal output 85 Amp nominal output

9804/1103

15 - 05 - 01/19

3270 - C/1-1.3

Issue 1

CONTENTS

Backhoe Loaders

15 - 05 - 01/20

3CX, 4CX and Variants Data - Electrical Fuse Identification ! CAUTION


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

From m/c no. 460001

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 3 4 5 6 7 8 9 10 Fuel pump solenoid (engine stop) Indicators Steer mode, proximity switches Gearbox Control, Transmission Powered rear window Brake lights 4WD (automatic brake) Left hand sidelights Right hand sidelights 5 Amp 7.5 Amp 7.5 Amp 10 Amp 20 Amp 5 Amp 3 Amp 3 Amp 3 Amp Fuse Rating 5 Amp 15 Amp 7.5 Amp 15 Amp 5 Amp 10 Amp 25 Amp 20 Amp 25 Amp Fuse Rating 3 Amp 7.5 Amp 15 Amp 10 Amp 5 Amp 20 Amp 30 Amp 3 Amp 15 Amp 15 Amp
S252511
0

COLUMN 'B' 1 Instruments, buzzer 2 3 4 5 6 7 8 9 10 Front Horn, front wiper/washer Rear horn Heated seat, cigar lighter, face level fan Rear wiper/washer Brake switch Rear work lights Headlights Front work lights Spare

10

8
4W

1 A

3A

3A

3A

5A

20A 10A 7.5A 7.5A

5A

10A

R
B
25A 20A 25A 10A 5A 15A 7.5A 15A 5A

C
3A 30A 20A 5A 10A 15A 7.5A 3A
A276790

15A 15A

COLUMN 'C' 1 Fog light 2 3 4 5 6 7 8 9 10 Main lights Hazard lights Beacon, interior light Radio Thermostart Heater Ignition relay coils Main Beam Dip Beam

9804/1103

15 - 05 - 01/20

3270 - 3/1-2.3

Issue 2*

CONTENTS

Backhoe Loaders
Relay Identification
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

15 - 05 - 01/20A

3CX, 4CX and Variants Data - Electrical Fuse 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 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 Fuse Rating 3 Amp 7.5 Amp 15 Amp 10 Amp

From m/c no. 460001

10

8
4W

1 A

3A

3A

3A

5A

20A 10A 7.5A 7.5A

5A

10A

R
B
25A 20A 25A 10A 5A 15A 7.5A 15A 5A

C
3A 30A 20A 5A 10A 15A 7.5A 3A
A276790

A333470

15A 15A

0 1

0 4

0 2

F R
9 @

R
A265070

9804/1103

15 - 05 - 01/20A

3270 - 3/1-4.3

Issue 1

CONTENTS

Backhoe Loaders

15 - 05 - 01/21

3CX, 4CX and Variants Data - Electrical Link Box Fuses


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 2 3 4 Hazard warning lights, Beacon, Lights Wash/Wipe, Transmission, Indicators Work lights, Fog Lights, Brake lights Ignition, Heater, Thermostart 30 Amp 50 Amp 50 Amp 50 Amp

From m/c no. 460001

Bulbs
Head lights - main/dip Front Lights Work lights Front side lights Tail/stop lights Fog light Direction turn indicators Instruments Warning lights Number plate light Interior light Beacon 45/37.5W 55W Halogen 55 Halogen (front & rear) 5W 5/21W 21W 21W (front & rear) 1.2W 3W 1 x 5W 10W 70W Halogen

Note: These items are not applicable to North America Note: These items are applicable to North America only

S254320

B 2

A254310

9804/1103

15 - 05 - 01/21

3270 - C/1-3.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 01/22

3CX, 4CX and Variants Data - Electrical


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.

From m/c no. 460001

3CXE, 214E only


B C D E F G H J K L M N Ignition Neutral Start Indicators Ignition Front Work Lights Transmission Dump Rear Work Lights Forward Drive Buzzer Parking Brake Reverse Drive Reverse Horn

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.

0
B

0
E H

P
L

0
C F

F R
J M

R
D G K N A265070

S252511

25

26

27

10

13

16

19

22

0
28 29 30

P
8 11 14 17

F
20

R
23

F R
9 12 15 18

D
21 24

R
A260440

4W

AUTO

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 Data - Electrical Fuse Identification - Servo Command
The relays and fuses are located in the side console underneath cover A. Fuse Rating 5 Amp 5 Amp 1 amp 10 Amp 3 Amp 15 Amp

From m/c no. 460001

Relay Identification - Servo Command


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

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

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 R19
A334090

R20 R21

R22 R23

R24 R25

9804/1103

15 - 05 - 01/23

3270 - C/1-5.2

Issue 1

CONTENTS

Backhoe Loaders

15 - 05 - 01/24

3CX, 4CX and Variants Data Electrical Fuse 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 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 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 5 Amp 5 Amp 7.5 Amp 10 Amp 3 Amp 5 Amp 3 Amp 3 Amp Fuse Rating 5 Amp 15 Amp 20 Amp 15 Amp 10 Amp 25 Amp 20 Amp 25 Amp 10 Amp Fuse Rating 15 Amp 7.5 Amp 15 Amp 10 Amp 1 Amp 20 Amp 30 Amp 3 Amp 15 Amp

From m/c no. 460001

Relay Identification 214Se


A B C D E F G H J K L M N 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

A
4W 4W

B E H

C F J L
1

D
10 A A
3A 3A 3A

7
4W

5A 5A 3A

10A 10A

7.5A 7.5A

5A 5A 5A 5A

G K

B B
10A 15A 20A 10A 25A 25A 20A 20A 25A 10A 15A 15 5A 5A 15A
1

N
2

C
15A 3A 3A 30A 20A 1A 10A 15A 15A 7.5A 7.5A 15A 15A 15A
345740
2

817/16774
3270 - C/1-6.2

345741

9804/1103

15 - 05 - 01/24

Issue 1

CONTENTS

Backhoe Loaders

15 - 05 - 01/25

3CX, 4CX and Variants Data - Electrical


Fuse Identification
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 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

From m/c no. 495455


Relay Identification
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

A
A356072

A357830 A356071

21

22

23

24

25

26

27

28

29

30

4WD

10

11

12

13

14 15

16

17

18

19

20
Issue 1

9804/1103

15 - 05 - 01/25

3270 - C/1-7.2

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 01/26

3CX, 4CX and Variants Data - Electrical Relay Identification - Autoshift Only
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

From m/c no. 460001 Relay Identification - Powershift Transmission From Serial No. 495455
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)

1 5

2 6

3 7

4 8

A359330

Relay Identification - Syncro Shuttle Transmission From Serial No. 495455


1 2 3 4 Transmission dump Forward drive Spare Reverse drive

A333470

0 ! @

^ & *

2 3

8 9

$ %

1 3

2 4

A334100

A357840

9804/1103

15 - 05 - 01/26

3270 - C/1-8.2

Issue 1

CONTENTS

Backhoe Loaders

15 - 05 - 01/27

3CX, 4CX and Variants Data Electrical Harness Identification

From m/c no. 460001

ITEM 1 2 3 4 5 6 7

DESCRIPTION Note: The illustration shows a typical machine. Mainframe Harness Panel Harness Cab Harness Cab Roof Harness Solenoid Harness Rear Light Harnesses Engine Shut Off Harness

9804/1103

15 - 05 - 01/27

3270 - C/40-1.2

Issue 1

CONTENTS

Backhoe Loaders

15 - 05 - 01/28

3CX, 4CX and Variants Data - Electrical Harness Identification

From m/c no. 460001

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

15 - 05 - 01/29

3CX, 4CX and Variants Data Electrical Harness Identification

From m/c no. 495455

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

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 02/1

3CX, 4CX Data - Hydraulic (Standard Machines)

From m/c no. 400001

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 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 Hydraulic Pump Applicability Chart Pump Type 190906 2-Wheel Steer Machines 3CX S/Master H/Master All Wheel Steer Machines 4CX 4C 4CN S/Master 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 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 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 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

* 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*

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 02/2

3CX, 4CX Data - Hydraulic (Standard Machines)

From m/c no. 400001

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 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: 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: 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 Applicability Chart Pump Type 4071 4075 4072 2-Wheel Steer Machines 3CX S/Master H/Master All Wheel Steer Machines 4CX 4C 4CN S/Master 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 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 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 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

* 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

15 - 05 - 02/3

ALL MODELS (EXCEPT 2CX) Data - Hydraulic (Standard Machines) (continued)


*

From m/c no. 400001

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 Hydraulic Pump Applicability Chart Pump Type 2-Wheel Steer Machines 214 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. 215 216 217 S/Master All Wheel Steer Machines 214S 215S 216S 217S S/Master 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

9804/1103

15 - 05 - 02/3

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 02/4

ALL MODELS (EXCEPT 2CX) Data - Hydraulic (Standard Machines) (continued)


*

From m/c no. 400001

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 Hydraulic Pump Applicability Chart Pump Type 2-Wheel Steer Machines 214 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

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 All Wheel Steer Machines

215

216

217

S/Master

214S 215S 216S 217S S/Master

15 - 05 - 02/4

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 02/5

3CX, 4CX, (200 Series) Data - Hydraulic (Standard Machines)

From m/c no. 400001

Machine Hydraulics
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 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 bar 228 - 240 207 - 220 kgf/cm2 233 - 245 211 - 225 lbf/in2 3300 - 3500 3000 - 3200

165 - 200 303 - 317 241 - 255 303 - 317 338 - 352 303 - 317 241 - 255 241 - 255 303 - 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 303 - 317 303 - 317 303 - 317

168 - 204 309 - 323 246 - 260 309 - 323 344 - 358 309 - 323 246 - 260 246 - 260 309 - 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 309 - 323 309 - 323 309 - 323

2400 - 2900 4400 - 4600 3500 - 3700 4400 - 4600 4900 - 5100 4400 - 4600 3500 - 3700 3500 - 3700 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 4400 - 4600 4400 - 4600 4400 - 4600

250 250 250 303 - 317 bar 1.4

255 255 255 309 - 323 kgf/cm2 1.4

3625 3625 3625 4400 - 4600 lbf/in2 20

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) Data - Hydraulic (Standard Machines)

From m/c no. 400001

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 Front Steer Ram(s) Dimensions Bore Rod Diameter Stroke End Cap Assembly A/F Piston Head Assembly A/F Rear Steer Ram(s) Dimensions Bore Rod Diameter Stroke End Cap Assembly A/F Piston Head Assembly A/F Steer Ram Torque Settings Piston Head End Cap 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 1740 50 lbf/in2 2538 - 2756

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)

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) Nm 405 678 kgf m 41 69 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 Steer Ram(s) Dimensions 2 Wheel Drive Machines Location Bore Rod Diameter Stroke End Cap Assembly A/F Piston Head Assembly A/F 4 Wheel Drive Machines Location Bore Rod Diameter Stroke End Cap Assembly A/F Piston Head Assembly A/F Steer Ram Torque Settings Piston Head End Cap 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 1740 50 lbf/in2 178 - 199 kgf/cm2 2538 - 2756

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)

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) Nm 405 678 kgf m 41 69 lbf ft 300 500

9804/1103

15 - 05 - 02/6

Issue 3

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 02/7

3CX, 4CX, (200 Series) Data - Hydraulic (3CXE (214E) Machines)

From m/c no. 400001

Machine Hydraulics
Hydraulic Pump Model/Reference: Rotation: Mounting: Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Maximum working pressure Relief Valve Operating Pressures Main Relief Valve (M.R.V.) @ 1500 RPM 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 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 bar 228 - 240 kgf/cm2 233 - 245 lbf/in2 3300 - 3500

172 - 176 308 - 312

175 - 179 314 - 318

2500 - 2550 4475 - 4525

245 - 252 308 - 312 245 - 252 245 - 252 245 - 252 245 - 252 258 - 266 303 - 317 120 - 125

249 - 257 314 - 318 249 - 257 249 - 257 249 - 257 249 - 257 263 - 271 309 - 323 122 - 127

3550 - 3650 4475 - 4525 3550 - 3650 3550 - 3650 3550 - 3650 3550 - 3650 3750 - 3850 4400 - 4600 1740 - 1813

3 1 2

2A 6

2B

3
A248220

Fig 1
9804/1103

15 - 05 - 02/7

Issue 3

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 02/8

ALL MODELS (EXCEPT 2CX) Data - Hydraulic (Servo Machines)

From m/c no. 400001

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 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

- Shovel

- Clam

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 F
A

E C 1 2 3

A193570

9804/1103

15 - 05 - 02/8

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 02/9

ALL MODELS (EXCEPT 2CX) Data - Hydraulic (Servo Machines) (continued)

From m/c no. 400001

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. 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.
D

2 3 G 4 5

C
B B A A B

E
A A

FIG 2

A193580

9804/1103

15 - 05 - 02/9

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 02/10

ALL MODELS (EXCEPT 2CX) Data - Hydraulic (Servo Machines) (continued)

From m/c no. 400001

Machine Hydraulics
Backhoe Valve (continued) Output Descriptions (ISO + Pattern) - Boom - Dipper - Bucket - Slew Auxiliary Valve Relief Valve Pressures - Main - Auxiliary Head Rod Side Slew Motion Control Valve - see Note 1 Relief Valve Pressures - Slew Left and Right Unloader Valve Relief Valve Pressures - Unloader Hose Burst Protection Valves Relief Valve Pressures High Pressure Filter By-pass pressure Filter 'Clogged' Indicator - see Note 2 Operation Lift Lower Lift Lower Dump Crowd Left Right Bar 227 138 - 145 207 - 214 Bar 235 Bar 207 Port A B B A B A B A kgf/cm2 231.5 141-148 211 - 218 kgf/cm2 238.5 kgf/cm2 211 Neutral 6V 6V 6V 6V 6V 6V 6V 6V lbf/in2 3300 2000-2100 3000 - 3100 lbf/in2 3408 lbf/in2 3000 Full Deflection 3V 9V 9V 3V 9V 3V 3V 9V

Bar 200

kgf/cm2 204

lbf/in2 2900

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

15 - 05 - 02/11

3CX, 4CX and Variants 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

From m/c no. 460001

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

15 - 05 - 02/11A

3CX, 4CX and Variants Data - Hydraulics (contd) 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

From m/c no. 460001

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 Data Hydraulic (contd) 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 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

From m/c no. 460001

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) 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

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) bar 303 - 317 kgf/cm2 309 - 323 lbf/in2 4400 - 4600

Hydraulic Filter Element


Relief Valve Operating Pressures: By-pass pressure bar 3.0 - 3.5 kgf/cm2 3.0 - 3.6 lbf/in2 43.5

9804/1103

15 - 05 - 02/12

3270 - E/1-2.2

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 02/13

3CX, 4CX and Variants Data - Hydraulic (contd) 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 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 Weight 25kg (55lbs)

From m/c no. 460001

ITEM 8 9 10 11 12 13 14

DESCRIPTION Unloader solenoid Auxiliary relief valve Tank port High pressure carry-over (HPCO) port Service ports Load hold check valve assemblies Data plate kgf/cm2 233 - 235 207 - 211 lbf/in2 3300 - 3335 2950 - 3000

bar 228 - 230 203 - 207

165 - 179 303 - 317

168 - 183 309 - 323

2400 - 2600 4400 - 4600

1 7

2 9

8 @ $ 0 !

@ 6 5 @

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 Data - Hydraulic (contd) 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

From m/c no. 460001

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 Weight: 8kg (17.6lbs)

bar 228 - 230

kgf/cm2 233 - 235

lbf/in2 3300 - 3335

170 - 174 308 - 312

173 - 177 314 - 318

2465 - 2520 4475 - 4525

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 Data Hydraulic (contd) 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

From m/c no. 460001

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 Data - Hydraulic (contd) Loader Valve


Machine Models Applicable to: 4CX, 4CX Super

From m/c no. 460001

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

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

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

bar 170 - 176 170 - 174 306 - 314

kgf/cm2 173 - 179 173 - 177 312 - 320

lbf/in2 2450 - 2550 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

CONTENTS

Backhoe Loaders

15 - 05 - 02/17

3CX, 4CX and Variants Data - Hydraulic (contd) 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

From m/c no. 460001

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 Weight: 44 kg (97 lbs) - Centremount 46 kg (101 lbs) - Sideshift

bar 241 - 255 338 - 352 303 - 317 241 - 255 241 - 255 241 - 255 241 - 255 241 - 255 255 - 269

kgf/cm2 246 - 260 344 - 358 309 - 323 246 - 260 246 - 260 246 - 260 246 - 260 246 - 260 260 - 274

lbf/in2 3500 - 3700 4900 - 5100 4400 - 4600 3500 - 3700 3500 - 3700 3500 - 3700 3500 - 3700 3500 - 3700 3700 - 3900

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.

2 7

5 7

6 7

0 ! 0

0 ! 0

0 ! 0

0 ! 0

0 ! 0

0 ! 0

9 @

FIG SHOWS A CENTREMOUNT VALVE


9804/1103

7
15 - 05 - 02/17

7
A262520 3270 - 3/1-2.2

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 03/1

2DX, 212 and Variants (except 2CX) Data Transmission

From m/c no. 460001

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 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 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

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

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

Centre pivot 239 kg (525 lbs) 5 0 0 3 positive

9804/1103

15 - 05 - 03/1

3270 - F/1-2.2

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 04/1

3CX, 4CX and Variants Data Hydraulic (contd) Rear Axle

From m/c no. 460001

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 38 13 37 11

OPTION 3 13.7:1 2.538:1 33 13

* 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

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 33 13

9804/1103

15 - 05 - 04/1

3270 - F/1-2.2

Issue 3*

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 05/1

3CX, 4CX, (200 Series) Data - Transmission (continued)

From m/c no. 400001

Tyre Sizes and Pressures


TWO WHEEL STEER MACHINES
Type Front - 2WD Ribbed (Armstrong) Ribbed (Goodyear) Industrial Industrial Industrial Front - 4WD Industrial Traction Industrial (Firestone) Industrial (Olympic) Radial Industrial Radial Radial Industrial Rear - 2WD & 4WD Industrial Industrial Industrial Industrial Traction (Goodyear) Traction (Olympic) Industrial Traction Industrial Radial Industrial Size Ply bar 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 Pressure lbf/in2 64 60 64 55 50

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

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

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 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)

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

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 05/2

3CX, 4CX and Variants Data - Transmission (continued) Tyre Sizes and Pressures Front Wheels

From m/c no. 460001

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 1 2 3 4 5 6 7 8 9 10 11 12 13 Size x Ply 16.9x24x12 16.9x24x12 15.5x25 16.9x28x12 16.9x28x12 16.9x28x10 16.9x28 16.9x28x14 16.9x24x12 16.9x28x12 16.9x28x12 14.9x24x12 16.9x28 Type IND IND XTLA IND IND IND XM27 IND IND TRAC IND IND IND Make ARMSTRONG GOODYEAR MICHELIN ARMSTRONG GOODYEAR GOODYEAR MICHELIN NOKIA GOODYEAR OLYMPIC OLYMPIC GOODYEAR GOODYEAR Remarks bar TUBELESS TUBELESS TUBELESS TUBELESS TUBELESS TUBELESS TUBELESS TUBE TUBELESS TUBELESS TUBE TUBELESS TUBELESS 2.6 2.6 2.5 2.6 2.6 2.2 2.7 2.6 2.6 2.6 2.6 2.75 2.5 Pressure lbf/in2 38 38 36 38 38 32 39 38 38 38 38 40 36

2WS/2WD MACHINES
21 22 23 24 25 11.0x16x12 11.0x16x12 11Lx16x12 10.5x18x10 12.0x18x12 RIB RIB IND IND IND ARMSTRONG GOODYEAR ARMSTRONG FIRESTONE FIRESTONE TUBELESS TUBELESS TUBELESS TUBELESS TUBELESS 4.4 4.2 4.4 3.8 3.5 64 61 64 55 51

2WS/4WD MACHINES
31 32 34 35 36 37 38 39 14x17.5x10 14x17.5x10 12.0x18x12 12.0x18x12 335 x18 12.5x18x10 335 x20 340 x18 IND IND IND IND XM27 IND XM27 IND ARMSTRONG GOODYEAR FIRESTONE OLYMPIC MICHELIN GOODYEAR MICHELIN GOODYEAR TUBELESS TUBELESS TUBELESS TUBELESS TUBELESS TUBELESS TUBE TUBELESS 3.8 3.8 3.5 4.25 3.5 4.25 3.0 3.2 55 55 51 62 51 62 43.5 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

CONTENTS

Backhoe Loaders

15 - 05 - 05/3

3CX, 4CX and Variants Data - Transmission (continued) Tyre Sizes and Pressures Rear Wheels

From m/c no. 460001

Note: If the tyres fitted to your machine are not listed, then contact JCB for advice, DO NOT guess tyre pressures.

AWS MACHINES
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Size x Ply 16.9x24x12 16.9x24x12 15.5x25 16.9x28x12 16.9x28x12 16.9x28x10 16.9x28 16.9x28x14 16.9x24x12 16.9x28x12 16.9x28x12 14.9x24x12 16.9x28 Type IND IND XTLA IND IND IND XM27 IND IND TRAC IND IND IND Make ARMSTRONG GOODYEAR MICHELIN ARMSTRONG GOODYEAR GOODYEAR MICHELIN NOKIA GOODYEAR OLYMPIC OLYMPIC GOODYEAR GOODYEAR Remarks bar TUBELESS TUBELESS TUBELESS TUBELESS TUBELESS TUBELESS TUBELESS TUBE TUBELESS TUBELESS TUBE TUBELESS TUBELESS 2.6 2.6 2.5 2.6 2.6 2.2 2.7 2.6 2.6 2.6 2.6 2.75 2.5 Pressure lbf/in2 38 38 36 38 38 32 39 38 38 38 38 40 36

2WS MACHINES 21 22 23 24 25 26 27 28 29 30 31 32 33 34 16.9x24x10 16.9x24x12 19.5x24x10 19.5x24x12 21L x24x12 18.4x26x12 18.4x26x12 18.4x26x12 16.9x28x12 16.9x28x12 16.9x28x12 16.9x28 18.4x30x14 16.9x28 IND IND IND IND IND TRAC TRAC IND TRAC TRAC IND XM27 IND IND ARMSTR0NG GOOOYEAR ARMSTRONG ARMSTRONG GOODYEAR GOODYEAR OLYMPIC GOODYEAR OLYMPIC FIRESTONE GOODYEAR MICHELIN GOODYEAR GOODYEAR TUBELESS TUBELESS TUBELESS TUBELESS TUBELESS TUBELESS TUBELESS TUBELESS TUBELESS TUBE TUBELESS TUBELESS TUBE TUBELESS 2.2 2.2 1.9 2.3 2.2 2.5 2.4 2.0 2.2 2.2 2.2 2.5 2.0 2.5 32 32 28 33 32 36 35 29 32 32 32 36 29 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

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 06/1

3CX, 4CX, (200 Series) Data - Transmission (contd)

From m/c no. 400001

Syncro Shuttle
Description 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 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 24 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 2.20:1 Ratio 2 purple 1 White 26 24 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

2.40:1 Ratio 2 Orange 1 Green

2.80:1 Ratio 3 Brown

Minimum Engine Rev/Min at Converter Stall 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 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min

See pages 15 - 05 - 07/3 and 07/4 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 bar 0.2 - 0.3 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6 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 kgf/cm2 0.2 - 0.4 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6 lbf/in2 35 - 50 75 - 95 20 - 30 75 - 85 15 - 25 29 max 4.0 - 8.0 15 - 25 95 lbf/in2 3.0 - 5.0 6.0 - 10.0 2.0 - 3.0 4.0 - 8.0

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 1000 rev/min 2000 rev/min At 100 deg.C 1000 rev/min 2000 rev/min

.....cont'd

9804/1103

15 - 05 - 06/1

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 06/2

3CX, 4CX, (200 Series) Data - Transmission (contd)

From m/c no. 400001

Syncro Shuttle (cont'd)


Main Line Pressure (in neutral) At 50 deg. C 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min bar 9.3 - 10.3 10.7 - 11.7 9.3 - 10.3 9.3 - 10.3 bar 8.3 - 9.0 9.0 - 10.0 8.3 - 9.0 8.3 - 9.0 kgf/cm2 9.5 - 10.5 10.9 - 12.0 9.5 - 10.5 9.5 - 10.5 kgf/cm2 8.4 - 9.1 9.1 - 10.2 8.4 - 9.1 8.4 - 9.1 lbf/in2 135 - 150 155 - 170 135 - 150 135 - 150 lbf/in2 120 - 130 130 - 145 120 - 130 120 - 130

At 100 deg.C

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

Clutch Pressure (to disconnect 4 wheel drive) At 50 deg. C 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

Flow Rates (in neutral) Cooler at 50 deg.C

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

Cooler at 100 deg.C

Pump at 50 deg.C

9804/1103

15 - 05 - 06/2

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 07/1

3CX, 4CX, (200 Series) Data - Transmission (contd)

From m/c no. 400001

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 26 24 26 or 25 24

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 Torque Converter Colour Code Identification Colour Coded Dots

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 2.20:1 Ratio 2 Purple 1 White 1 Black 1 Orange 2.40:1 Ratio 2 Orange 1 Green 2 Black 1 Green 2.80:1 Ratio 3 Brown

5-Speed Gearboxes Only -

N/A

Minimum Engine Rev/Min at Converter Stall Converter Pressures (in neutral) Converter In at 50 deg.C 1000 rev/min 2000 rev/min Converter Out at 50 deg.C 1000 rev/min 2000 rev/min Converter Inlet Relief Valve Pressure (max.) Lubrication Pressures (in neutral) At 50 deg.C 1000 rev/min 2000 rev/min

See pages 15-05-07/3 & 15-05-07/4 bar 2.8 - 4.1 4.8 - 6.2 1.9 - 2.3 2.3 - 2.7 6.5 bar 0.14 - 0.28 0.28 - 0.55 kgf/cm2 2.8 - 4.2 4.9 - 6.3 1.9 - 2.3 2.3 - 2.7 6.7 kgf/cm2 0.14 - 0.28 0.28 - 0.56 lbf/in2 40 - 60 70 - 90 27 - 33 33 - 39 95 lbf/in2 2.0 - 4.0 4.0 - 8.0

9804/1103

15 - 05 - 07/1

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 07/2

3CX, 4CX, (200 Series) Data - Transmission (contd)

From m/c no. 400001

Powershift (cont'd)
Mainline Pressure (in neutral) At 50 deg. C 1000 rev/min 2000 rev/min Flow Rates (in neutral) Cooler at 50 deg.C bar 9.0 - 10.0 9.7 - 11.0 litres/min 10.4 - 13.6 14.5 - 20.0 11.0 - 15.0 22.5 - 29.5 kgf/cm2 9.1 - 10.2 9.8 - 11.3 US gal/min 2.8 - 3.6 3.8 - 5.3 2.9 - 4.0 6.0 - 7.8 lbf/in2 130 - 145 140 - 160 UK gal/min 2.3 - 3.0 3.2 - 4.4 2.5 - 3.3 5.0 - 6.5

1000 rev/min 2000 rev/min

Pump at 50 deg.C

1000 rev/min 2000 rev/min

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

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 07/2A

3CX, 4CX and Variants 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

From m/c no. 460001

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 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 bar 0.2 - 0.3 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6 bar 9.7 - 12.8 11.4 - 14.1 11.4 - 12.8 11.4 - 13.4 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 kgf/cm2 0.2 - 0.4 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6 kgf/cm2 9.8 - 13.0 11.6 - 14.4 11.6 - 13.0 11.6 - 13.7 lbf/in2 35 - 50 75 - 95 20 - 30 75 - 85 15 - 25 29 max 4.0 - 8.0 15 - 25 95 lbf/in2 3.0 - 5.0 6.0 - 10.0 2.0 - 3.0 4.0 - 8.0 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 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.) Lubrication Pressures (in neutral) At 50 deg.C 1000 rev/min 2000 rev/min At 100 deg.C 1000 rev/min 2000 rev/min 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 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) 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

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

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

CONTENTS

Backhoe Loaders

15 - 05 - 07/2B

3CX, 4CX and Variants Data - Transmission (continued) Powershift


Description

From m/c no. 460001

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 Converter Pressures (in neutral) Converter In at 50 deg.C 1000 rev/min 2000 rev/min Converter Out at 50 deg.C 1000 rev/min 2000 rev/min Converter Inlet Relief Valve Pressure (max.) Lubrication Pressures (in neutral) At 50 deg.C 1000 rev/min 2000 rev/min 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 Clutch Pressures Flow Rates (in neutral) Cooler at 50 deg.C Pump at 50 deg.C

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 1.9 - 2.3 2.3 - 2.7 6.5 bar 0.14 - 0.28 0.28 - 0.55 bar 9.7 - 12.8 11.4 - 14.1 11.4 - 12.8 11.4 - 13.4 1.9 - 2.3 2.3 - 2.7 6.7 kgf/cm2 0.14 - 0.28 0.28 - 0.56 kgf/cm2 9.8 - 13.0 11.6 - 14.4 11.6 - 13.0 11.6 - 13.7

lbf/in2 40 - 60 70 - 90 27 - 33 33 - 39 95 lbf/in2 2.0 - 4.0 4.0 - 8.0 lbf/in2 140 - 185 165 - 205 165 - 185 165 - 195

All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2) 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

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

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

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 07/3

3CX, 4CX, (200 Series) Data - Transmission (contd)

From m/c no. 400001

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.

Engine Stall Speed 1 Converter only max r.p.m. min. r.p.m. 2 Converter + MRV max. r.p.m. min. r.p.m. 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 1 to 1.36
G G G G G G G G G G G G G G G G G

2170 2100

2130 2065

2160 2085

2120 2055

2100 2030

1795 1700

1770 1670

1685 1575

1660 1550

1640 1530

G G G

9804/1103

15 - 05 - 07/3

Issue 1

CONTENTS
9804/1103

Data - Transmission (contd)

3CX, 4CX, (200 Series)

CONTENTS

Stall Figures
TWO WHEEL STEER MACHINES Note: All tests conducted with single pump option selected unless specified thus #, then tests to be conducted with double pump option selected.

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.

Engine Stall Speed

Backhoe Loaders

Convertor Only

max r.p.m. min r.p.m. max r.p.m. min r.p.m.

1755 1695 1360 1260

1735 1670 1340 1245

2215# 2145# 1830# 1730#

1900 1830 1525 1420

1875 1810 1510 1405

1890 1820 1515 1410

1870 1800 1495 1390

1880 1810 1380 1220

1860 1790 1365 1200

2070 2000 1730 1630

2065 1995 1675 1570

1915 1840 1465 1345

Convertor + MRV

15 - 05 - 07/4
Issue 1

Build Specification Engine Size N.A. (74 bhp) T2 (90 bhp) T3 (96 bhp) SSL 11 (2.8:1) WH 11 (2.4:1) W11 (2.2:1) 26 UK gal. 28 UK gal. 30 UK gal. 34 UK gal. 1 to 1 1 to 1.25 1 to 1.36
G G G G G G G G G G G G

Convertor Type

G G G G G G G G G G G G

Pump Size (U.K. gals)

G G

G G

From m/c no. 400001

G G G

G G

Fan Ratio

G G G

G G

G G

G G G G G

15 - 05 - 07/4

CONTENTS
9804/1103

Data - Transmission (continued)

3CX, 4CX and Variants

Pump/Transmission Stall Speed Combinations 2WS Machines, 12.2 Convertor, Gear Pump, 1000 Series Engine
Note. On all double pump options the test is to be carried out with single pump option selected.
3CXE 3CX 3CXT 3CXT 3CXT 3CXT 3CXT 3CXT 214E N. Am. 214 N. Am. 214T/215E N. Am. 214T/215E N. Am. 215/217 215/217 N. Am. N. Am.

CONTENTS

Engine Speed @ Stall Combination 1.Convertor only. Max.r.p.m. 1880 1905 Min.r.p.m. 1790 1800 2.Convertor + M.R.V. Max.r.p.m. Min.r.p.m. 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 Fan Ratio. 1 to 0.85 1 to 1.06 1 to 1.16 Air Conditioning None (Europe) None (R.O.W.) Europe Europe (Hot) R.O.W.

2040 1935

2015 1910

2040 1935

2015 1910

2100 2000

2070 1980

2160 2050

2200 2095

2230 2170

2220 2160

2070 1975

2060 1960

1100 stall

1465 1365

1575 1430

1550 1405

1475 1310

1445 1270

1655 1560

1635 1545

1345 1140

1650 1575

1745 1620

1720 1580

1630 1540

1620 1540

Backhoe Loaders

G G G G G G G

G G G G G

15 - 05 - 07/5
3270 - F/1-7.1

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

G G G G

From m/c no. 460001

G G

G G

G G G G G

G G G G G

G G G G G

15 - 05 - 07/5

Isssue 1

CONTENTS
9804/1103

Data - Transmission (continued)

3CX, 4CX and Variants

Pump/Transmission Stall Speed Combinations - AWS Machines, 12.2 Convertor, Gear Pump, 1000 Series Engine
Note. On all double pump options the test is to be carried out with single pump option selected.
3CXSuper 3CXSuper 4CX 4CX 4C/4CN 4C/4CN 4C/4CN 214S N. Am. 214S N. Am. 215S/217S N. Am. 215S/217S N. Am.

CONTENTS

Engine Speed @ Stall Combination 1.Convertor only. Max.r.p.m. 2040 Min.r.p.m. 1935 2.Convertor + M.R.V. Max.r.p.m. Min.r.p.m. 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 Fan Ratio. 1 to 0.85 1 to 1.06 1 to 1.16 Air Conditioning None (Europe) None (R.O.W.) Europe Europe (Hot) R.O.W.

2015 1910

2100 2000

2070 1980

2095 2000

2070 1975

2060 1960

2100 2000

2075 1980

2070 1975

2060 1960

1575 1430

1550 1405

1655 1560

1635 1545

1650 1560

1630 1540

1620 1530

1655 1560

1635 1545

1630 1540

1620 1530

Backhoe Loaders

G G G G G G G G G G

15 - 05 - 07/6
3270 - F/1-8.1

G G G G G G G G G G

G G

G G

G G G

G G G G

From m/c no. 460001

G G G G

G G G G G

G G G

15 - 05 - 07/6

G G G

Issue 1

CONTENTS
9804/1103

Data Transmission (contd)

3CX, 4CX and Variants

Pump/Transmission Stall Speed Combinations - AWS Machines, 12.2 Convertor, Variable Pump, 1000 Series Engine
4CX 4CX 4CXSuper 4CXSuper 4CXSuper

CONTENTS

Engine Speed @ Stall Combination 1.Convertor only. Max.r.p.m. 2155 Min.r.p.m. 2055 Build specification. Engine size. N.A. (75hp) (56kw) T2 (91hp) (68kw) T3 (96hp) (72kw) Convertor type 12.2D (2.82) 12.2P (2.54)

2130 2035

2155 2055

2130 2035

2155 2020

Backhoe Loaders

15 - 05 - 07/7
3270 - F/1-9.2

Pump size. 74 Variable Fan Ratio. 1 to 0.85 1 to 1.06 1 to 1.16 Air Conditioning None (Europe) None (R.O.W.) Europe Europe (Hot) R.O.W.

G G

G G G

G G G G G

G G G G G

From m/c no. 460001

15 - 05 - 07/7

Issue 1

CONTENTS
9804/1103

Data Transmission (contd)

3CX, 4CX and Variants

Low Emission Engine Stall Speed Combinations - 2WS Machines


Note. On all double pump options the test is to be carried out with single pump option selected.
3CX 3CXT Std lift Engine Speed @ Stall Combination 1.Convertor only. Max.r.p.m. 1965 2080 Min.r.p.m. 1850 1975 2.Convertor + M.R.V. Max.r.p.m. Min.r.p.m. 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 3CXT 3CXT 3CXT Hi. lift 3CX
Contractor

CONTENTS

3CX
Contractor

214E N. Am.

214e N. Am.

214 N. Am.

214e.T N. Am.

Std lift Hi. lift

215E 214T N. Am.

215E 214T N. Am.

215 217 N. Am.

2070 1960

2080 1980

2070 1965

2135 2030

2125 2020

2170 2075

2240 2170

2220 2110

2240 2170

2240 2165

2230 2160

2120 2015

1520 1380

1735 1615

1720 1600

1675 1545

1660 1530

1770 1660

1760 1650

1415 stall

1555 1280

1770 1625

1745 1580

1890 1760

1875 1745

1760 1645

Backhoe Loaders

G G G G G G G

G G G G G

15 - 05 - 07/8
3270 - F/1-10.2

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

From m/c no. 460001

Fan Ratio. 1 to 0.85 1 to 1.06 1 to 1.16 Air Conditioning None Europe ROW

G G G G G G G

G G G G G G G G

15 - 05 - 07/8

G G G

G G G

G G G

Issue 1

CONTENTS
9804/1103

Data Transmission (contd)

3CX, 4CX and Variants

Low Emission Engine Stall Speed Combinations - AWS Machines


Note. On all double pump options the test is to be carried out with single pump option selected.
3CXS Std lift Engine Speed @ Stall Combination 1.Convertor only. Max.r.p.m. 2080 Min.r.p.m. 1975 2.Convertor + M.R.V. Max.r.p.m. Min.r.p.m. Build specification. Engine size. N.A. (75hp) (56kw) T2 (91hp) (68kw) T3 (100hp) (74kw) Convertor type 12.2D (2.82) 12.2P (2.54) Pump size. 50cc 33/23cc 36/26cc 41/26cc 41/29cc 74 Variable Fan Ratio. 1 to 0.85 1 to 1.06 1 to 1.16 Air Conditioning None (Europe) None Europe Europe (Hot) R.O.W. 3CXS Std lift 3CXS Hi. lift 3CXS Hi. lift 4CX 4CX 4CXS/4C 4CXS/4C 4CXS 4CX 4CXS 4CX 214S N. Am. 215S/217S N. Am.

CONTENTS

2070 1965

2080 1980

2070 1965

2135 2030

2125 2020

2135 2030

2120 2015

2180 2080

2170 2065

2125 2020

2120 2015

1735 1615

1720 1600

1675 1545

1660 1530

1770 1660

1760 1650

1770 1660

1760 1645

1760 1650

1760 1645

Backhoe Loaders

G G G G G G G G G

15 - 05 - 07/9
3270 - F/1-11.1

G G G G G G G G G G G

From m/c no. 460001

G G

G G

G G

G G

G G G G G G G

15 - 05 - 07/9

G G G

G G G

G G G

G G G

G G G G

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 08/1

ALL MODELS (EXCEPT 2CX) Data - Brakes


STANDARD MACHINES Service Brake Type Actuation Location Friction Plates (5 per brake pack) Outside Diameter Inside Diameter Nominal Facing Area per Plate Hydraulic Piston Diameter Master Cylinder (combined servo assistance) Number of Cylinders Type Piston Diameter (each) Exhauster Type Parking Brake Type output Disc Diameter

From m/c no. 400001

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)

220 mm (7.992 in) 180 mm (6.811 in) 12616 mm2 (19.3 in2) 216 mm (8.5 in)

2 Frenos compensated master cylinder 22.22 mm (0.875 in)

Frenos Iruna

Manually Adjusted Caliper, cable operated, mounted on transmission 279.4 mm (11 in)

SERVO MACHINES Service Brake Type Actuation Location Friction Plates (5 per brake pack) Outside Diameter Inside Diameter Nominal Facing Area per Plate Hydraulic Piston Diameter Master Cylinder Number of Cylinders Type Front Rear Piston Diameter Front (each) Rear Brake Changeover Valve Number of Changeover Valves Purpose Exhauster Type Parking Brake Type Disc Diameter
9804/1103

As 'Standard Machines' As 'Standard Machines' As 'Standard Machines'

As 'Standard Machines' As 'Standard Machines' As 'Standard Machines' As 'Standard Machines'

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)

2 Isolate front brake system from rear brake system

As 'Standard Machines'

As 'Standard Machines' As 'Standard Machines'

15 - 05 - 08/1

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 08/2

3CX, 4CX and Variants Data - Brakes


Service Brake Type Actuation JCB Oil-Immersed Multi-Plate Disc

From m/c no. 460001

Hydraulic - vacuum servo assisted for machines powered by model AB turbocharged engine Rear Axle Centre Casing (2 brake packs)

Location 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 Piston Diameter (each) Parking Brake Type Disc Diameter Compensated master cylinder 22.22 mm (0.875 in)

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) Data - Engine


Type Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance - Cold

From m/c no. 400001

- Inlet - Exhaust Oil Pressure (hot) at maximum speed - AA - AB Maximum Air Cleaner Restriction Fuel System Injection System Details Engine Model Type BHP

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)

Injection Pump Code Static Timing Code

Injectors Working/Setting Pressures

All Wheel Steer Machines AB50364 Turbocharged 2 Wheel Steer Machines AA50386 Naturally Aspirated AB50388 Turbocharged AB50389 Turbocharged

96

CM78L/1100/1/2420

15.5 BTDC

JG

230 atm

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 Cooling System Coolant Pressure Coolant Temperature (Normal) Temperature Warning Light operates at:

750 rev/min 2200 rev/min 2320 - 2420 rev/min

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

CONTENTS CONTENTS

Backhoe Loaders

15 - 05 - 09/2

3CX, 4CX and Variants Data - Engine


Type 1000 Series 4 cylinder Engines AB - Turbocharged AA - Naturally Aspirated AK - Turbocharged AM - Turbocharged and Intercooled AR - Naturally Aspirated

From m/c no. 460001

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)

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) Cooling System Coolant Pressure Coolant Temperature (Normal) Temperature Warning Light operates at: - All builds - All builds - All builds 880 - 930 rev/min 2200 rev/min 2400 - 2440 rev/min

Bore AA, AB, AK, AM AR Stroke Swept Volume

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

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 01/1

3CX, 4CX and Variants Fault Finding - Electrical Contents


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 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

From m/c no. 460001

Introduction
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. Make simple checks before say, stripping a major component. Make any relevant electrical checks before commencing work.

Fault
No drive on power-up.

Probable Cause
Blown ECU fuse. ECU mainframe connector loose. Gear twist switch not in neutral.

Action
Check ECU fuse A5 Check connector is mating correctly with ECU. Gear switch must be in neutral on power up before a gear can be selected.

No drive and continuous warning buzzer. No drive.

Attempting to select drive with the handbrake engaged. Faulty gear switch. Handbrake sticking. Faulty gearbox harness.

Release handbrake. Check switches and wiring. Check handbrake assembly. Check gearbox harness and connector for continuity. Check dump switch and wiring. Check solenoid(s) and wiring. Check switch and wiring Check clutch pack pressures, see Section F. Check mainline pressure, see Section F. See Section F. Check speed sensor and wiring. Check speed sensor installation.

Faulty dump input. Missing gears Faulty solenoid(s) Fault gear switch Low oil pressures

Mechanical failure No 4th gear (4 speed machine only) Faulty speed signal

..... continued

9804/1103

15 - 10 - 01/1

3270 - C/6-1.1

Issue 1

CONTENTS

Backhoe Loaders

15 - 10 - 01/2

3CX, 4CX and Variants Fault Finding - Electrical


Fault
Downshift protection not operating

From m/c no. 460001

Probable Cause
Faulty speed signal

Action
Check speed sensor and wiring. Check speed sensor installation. Check dump switch and wiring. Check 4 wheel drive switch and wiring. Check solenoid and wiring. Check 4 wheel drive switch and wiring.

No dump selection No 4 wheel drive (if fitted)

Faulty dump input Faulty 4 wheel drive input Faulty 4 wheel drive solenoid

Intermittent 4 wheel drive

Faulty 4 wheel drive input 2/4 wheel drive brake switch operating

Check brake switch and wiring. Slow the machine. Check kickdown switch and wiring. Slow the machine. Check kickdown switch and wiring. Slow machine. Check lead connection. Turn ignition ON. Check fuse A5. Check power supply to ECU.

Transmission will not downshift Lower gear engaged than selected Kickdown not operating

Speed too fast for selected downshift Kickdown engaged Speed too fast to engage lower gear Faulty kickdown input

Reverse will not operate Psion will not communicate

Speed too fast to reverse direction Faulty connecting lead. No power to ECU

9804/1103

15 - 10 - 01/2

3270 - C/6-2.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 02/1

ALL MODELS (EXCEPT 2CX) Fault Finding - Hydraulic (Standard Machines)

From m/c no. 400001

Fault Finding Contents


Page No. Introduction Lack of power in all hydraulic functions All hydraulic rams slow to operate One hydraulic service fails to operate or is slow to operate The engine tends to stall when the hydraulics are under load A spool is sticking Leaking Oil Seal (Control Valves) Ram creep Hydraulic oil becomes too hot Steering fails to operate or is stiff to operate Steering fails to respond to selected mode 15 - 10 - 02/1 15 - 10 - 02/1 15 - 10 - 02/2

Introduction
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. Make simple checks before say, stripping a major component. Make sure that the hydraulic fluid is at correct working temperature (50 C, 122 F). What ever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary. Make any relevant electrical checks before moving on to the hydraulics. Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit. Replace any seals such as 'O' rings before reassembling hydraulic components.

15 - 10 - 02/2

15 - 10 - 02/2 15 - 10 - 02/3 15 - 10 - 02/3 15 - 10 - 02/3 15 - 10 - 02/4

5 15 - 10 - 02/4 6 15 - 10 - 02/4 7

Fault
1 Lack of power in all hydraulic functions.

Probable Cause
Insufficient hydraulic fluid. Hydraulic leaks in system. Engine performance.

Action
Check for leaks and top up as required. Check hoses, replace as required. Check engine performance, see transmission section for stall speed test procedures. Check and adjust as required.

Main relief valve (MRV) setting incorrect. Low pump flow.

Check pump flow, if required service or replace pump. Clean or replace the breather Check condition of hydraulic filter Check pressure setting of the unloader valve.

Hydraulic tank breather Tank filter by-pass valve Unloader valve pressure setting too high

..... continued
9804/1103

15 - 10 - 02/1

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 02/3

ALL MODELS (EXCEPT 2CX) Fault Finding - Hydraulic (Standard Machines) (continued)
Fault
5 A spool is sticking.

From m/c no. 400001

Probable Cause
Oil temperature abnormally high.

Action
Check for correct fluid, see Lubricants and Capacities. Check oil cooler and grille for blockage. Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system Fill with clean hydraulic fluid. Check tightening torque.

The hydraulic fluid is dirty.

The service pipe connection is over tightened. The valve housing was twisted during installation. Pressure too high. A control linkage is bent

Loosen retaining bolts and tighten to correct torque figures. Check system pressure. Disconnect the linkage. Repair the linkage if possible, or fit a new one Dismantle the control valve. Renew spool as necessary. Renew as necessary. Remove the cap, check that the spring is in the correct position. Refit cap and torque tighten bolts Warm the entire system up before using service.

A spool is bent

A return spring is broken. A return spring or cap is out of alignment.

Temperature distribution within control valve not uniform.

Leaking Oil Seal (Control Valves)

Paint or dirt on the seal face. The back pressure in the valve circuit is excessively high. Spool damaged.

Remove the seal and clean. Check circuit pressures. Adjust if possible. Otherwise investigate thoroughly. Dismantle. Inspect all parts. Renovate or renew as necessary. Clean the seal and tighten the retaining bolts to the correct torque. Fit a new seal.

The seal is not secured.

The seal is cut or damaged.

Ram creep.

Associated ram or pipe lines from ram leaking. Check valve malfunctioning (if fitted, e.g. stabiliser circuit) Associated valve section spools leaking. Associated ARV leaking

Check and rectify as required.

Test check valve, rectify as required.

Rectify, check for contamination.

Rectify, check for contamination.

..... continued

9804/1103

15 - 10 - 02/3

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 02/4

ALL MODELS (EXCEPT 2CX) Fault Finding - Hydraulic (Standard Machines) (continued)
Fault
8 Hydraulic oil becomes too hot

From m/c no. 400001

Probable Cause
Oil cooler obstructed Restriction in neutral circuit lines Hydraulic filter clogged and by-pass valve not working

Action
Remove debris from cooler fins Check hoses, replace as necessary

Change hydraulic filter

Steering fails to operate or is stiff to operate

Tyres not inflated to correct pressure Insufficient hydraulic fluid. Low pump flow.

Inflate tyres to correct pressure

Check for leaks and top up as required. Check pump flow, if required service or replace pump. Check hoses and connections for leaks

Leaks in the relevant hoses or component connections Steer relief valve set incorrectly Priority valve not operating correctly

Check pressure setting of steer unit relief valve, adjust as required. 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 Proximity switches not operating correctly Steer mode valve not operating correctly

Check selector switch, replace as required Check setting of proximity switches, reset or replace switches as required. Check if spools sticking, rectify as required Check if solenoids operating, replace solenoids as required.

Leaks in the relevant hoses or component connections Electrical failure

Check hoses and connections for leaks

Check relevant electrical connectors, if problem still persists, do a wiring continuity check on relevant circuits.
Issue 2

9804/1103

15 - 10 - 02/4

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 03/1

ALL MODELS (EXCEPT 2CX) Fault Finding - Hydraulic (Servo Machines)

From m/c no. 400001

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 Check seat alignment. Check proximity switch adjustment. Check that stop switch is not depressed 2 Seat Rear and Seat Forward Functions Mixed Up. Check that proximity switches are connected correctly 3 System Is Completely Dead Check that fuse C6 has not blown 4 LH Joystick is Inoperative Check feed from control box at wire 423. Remember when seat is forwards that LH joystick is inoperative 5 RH Joystick is Inoperative Check feed from control box at wire 430 6 RH Mode Switch Inoperative Check feed from control box at wire 421. Check that wire 446 is connected to control box 7 LH Mode Switch Inoperative Check that RH mode works correctly. Check that wire 445 is connected to control box 8 Horn Inoperative Check wiring to switch. Check relay and wiring. Check that seat forward proximity switch is switching change over relay 9 Hydraclamp Inoperative 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 18 17 16 14 Loader Valve Block Inoperative Check relay and wiring. Check wire 440 to control box 15 Excavator Valve Block Inoperative Check relay and wiring. Check wire 450 to control box 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) Joystick Steering Inoperative Check wiring to switch. Check relay and wiring. Check logic box output at wire 444 Hydraulic Services Inoperative Check output from logic box at relevant valve block solenoid. Check relevant valve block. Check input to logic box from joysticks 13 RTD Inoperative Check shovel reset switch. Check wiring to switch 12 11 Aux. Solenoid (e.g. Jaw) Inoperative Check wiring to switch. Check relay and wiring. Check wiring to solenoid. Check fuse B1 Float Inoperative Check wiring to switch. Check that hose burst check valves are not fitted on the loader arm circuit

9804/1103

15 - 10 - 03/1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 03/2

ALL MODELS (EXCEPT 2CX) Fault Finding - Variable Flow Hydraulics Fault Finding Contents
Page No. Introduction High or low system pressure Pump stays at high pressure Pressure or flow obtained at one port only No pressure or flow at either port High work port leakage Leaks between sections Sticking spool Detent will not hold Electrical detent will not hold 15 - 10 - 03/3 15 - 10 - 03/3 1 15 - 10 - 03/3 15 - 10 - 03/3 15 - 10 - 03/3 3 15 - 10 - 03/3 15 - 10 - 03/4 15 - 10 - 03/4 5 15 - 10 - 03/4 15 - 10 - 03/4 6 4 2

From m/c no. 460001

Introduction
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). Before you begin fault finding, read the Safety information at the beginning of this manual. Make simple checks before say, stripping a major component. Make sure that the hydraulic fluid is at correct working temperature (50 C, 122 F). What ever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary. Make any relevant electrical checks before moving on to the hydraulics. Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit. 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 7 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

CONTENTS

Backhoe Loaders

15 - 10 - 03/3

ALL MODELS (EXCEPT 2CX) Fault Finding - Variable Flow Hydraulics (contd)
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.

From m/c no. 460001

PROBLEM: POSSIBLE CAUSE: CORRECTIVE ACTION:

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.

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

15 - 10 - 06/1

ALL MODELS (EXCEPT 2CX) Fault Finding - Syncro Shuttle Gearbox

From m/c no. 400001

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 B C D E F G If the transmission is noisy, start at check 1. If the transmission is overheating, start at check 4. If the transmission will not pull, start at check 12. If there is no drive in one or both directions, start at check 17. If the transmission is jumping out of gear, start at check 29. If the transmission is sticking in gear, start at check 39. If ratios are 'crash changing', start at check 41. ACTION YES: Check 3 NO: Check 2 YES: Check 9 NO: Check 19 YES: Continue running to expel air. NO: Check 4 YES: Check 5 NO: Check level only when machine is cold and top-up as required. YES: Clear the restriction. NO: Check 6 YES: Remove and clean strainer. NO: Check 7 YES: Check 9 NO: Check clutch pressure maintenance valve is free to operate. YES: Renew pump. NO: Check converter sprag clutch for wear or slip. YES: Check 10 NO: Check 11 YES: Renew mountings and check position. NO: Check 'converter out' pressure and flow. YES: Renew NO: Check converter for wear or cooler for restriction to flow. YES: Check 16 NO: Check 13 YES: Stall test machine, Check 14. NO: Check 16

CHECK 1 Is there noise when selecting direction?

Is there noise when running with direction selector in neutral and ratio selector in 1st? Is there air in the hydraulic system?

Is the fluid level correct?

Are the oil passages restricted?

Is the suction strainer restricted?

Is pump pressure as specified?

When flow testing pump, is output low?

Does the noise continue when direction selector is in forward or reverse? Is transmission misaligned?

10

11

Are the pump bushes worn?

12

Is the transmission not pulling in one direction only?

13

Is the transmission not pulling in both Forward and Reverse?

9804/1103

15 - 10 - 06/1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 06/2

ALL MODELS (EXCEPT 2CX) Fault Finding - Syncro Shuttle Gearbox (continued)
CHECK 14 Is 'converter in' pressure as specified? ACTION

From m/c no. 400001

YES: Check 15 NO: Inspect converter relief valve for damage. Check cooler bypass valve pressure setting. YES: Check pump pressure. NO: Renew damaged parts. YES: Tap pressure gauge into clutch feed lines to monitor pressure. NO: Check clutch plates for damage. YES: Check 19 NO: Check 18 YES: Check 19 NO: Rectify. YES: Dismantle solenoid and check components. NO: Check microswitches, relay and wiring loom. YES: Check gears for damage or wear. NO: Check 21 YES: Check bearings for damage or wear. NO: Check 22 YES: Check free running gears for seizure. NO: Check 23

15

Is pump being driven by converter?

16

Are clutch sealing rings damaged?

17

Is there drive in one direction only?

18

Is the start switch in the run position and supplying current to the neutral start relay? Is the fault only when the transmission is hot?

19

20

Is the noise a growl, hum or grinding?

21

Is the noise a hiss, thump or bumping?

22

Is the noise a squeal?

23

Is the noise present when in neutral or when in gear? NEUTRAL: Check 24 IN GEAR: Check 27 Is the countershaft or its bearings worn or damaged? YES: Renew damaged parts. NO: Check 25 YES: Adjust by checking shaft end float. NO: Check 26 YES: Renew. NO: Check gear teeth for scuffing. YES: Renew. NO: Check 28 YES: Renew gears. NO: Check 29 YES: Tighten screws. NO: Check 30 YES: Renew worn parts. NO: Check 31 YES: Renew. NO: Check 32 YES: Renew. NO: Check 33

24

25

Is there excessive backlash in the gears?

26

Is the mainshaft pilot bearing worn?

27

Is the mainshaft rear bearing worn?

28

Are the sliding gear teeth worn or damaged?

29

Are the selector forks loose?

30

Are the selector fork pads or grooves in gears worn?

31

Are the dog gear teeth worn?

32

Are the selector rod detent springs broken?

9804/1103

15 - 10 - 06/2

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 06/3

ALL MODELS (EXCEPT 2CX) Fault Finding - Syncro Shuttle Gearbox (continued)
CHECK 33 Are the selector rods worn or damaged? ACTION YES: Renew. NO: Check 34

From m/c no. 400001

34

Are the selector fork pads out of position?

YES: Reposition or renew (check interlock). NO: Check 35 YES: Adjust. NO: Check thrust washers and mating faces. YES: Renew synchro pack. NO: Check 37 YES: Continue using, chips will either embed below bronze or be rejected. NO: Check 38 YES: Renew. NO: Check free running gears for seizure or damage. YES: Free or renew. NO: Check 40 YES: Remove chips. NO: Ensure that clutch is disengaged when dump pedal is pressed. YES: Continue using, chips will either embed below bronze or be rejected. NO: Check 42 YES: Renew synchro. NO: Check 43 YES: Renew synchro. NO: Check blocker pins.

35

Is there excessive end float in gears or shafts?

36

Is the synchroniser bronze worn?

37

Are steel chips embedded in the bronze?

38

Are the synchroniser components damaged?

39

Are the sliding gears tight on the splines?

40

Are chips wedged between splines of shaft or gear?

41

Are steel chips embedded in the bronze?

42

Are the synchroniser spring pins damaged?

43

Is the synchroniser bronze worn?

9804/1103

15 - 10 - 06/3

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 06/4

3CX, 4CX, (200 Series) Fault Finding - 2/4 Wheel Drive Clutch

From m/c no. 400077 to 415011

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 7 Low mainline pressure (Minimum pressure required to disengage 2/4WD clutch is 8.6 bar; 125 lb/in2). 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 Low mainline pressure (due to 2/4WD clutch): 8.1 2/4WD solenoid spool sticking. 8 Rectify fault: 8.1 Strip, clean and re-assemble solenoid valve, renew valve if required. 8.2 Check the 2/4WD relay and select switch, replace as necessary. 8.3 Renew O-ring. 8.4 Renew clutch shaft sealing rings. 8.5 Rectify fault, renew parts as required, reset end float (should not exceed 0.03 mm; 0.001 in) 8.6 Fit correct type clutch piston (ie, without bleed hole). 8.7 Replace clutch piston O-ring. 9 Rectify fault: 9.1 Inspect pressure plate, renew as required. 9.2 Measure length of actuating sleeve and renew as required, sleeve length should be 60.70 mm; 2.390 inches 9.3 Measure clutch pack end float (should be 0.75 - 1.5 mm; 0.030 - 0.059 inches). Correct as required.

8.2 2/4WD solenoid permanently energised.

8.3 2/4WD solenoid spool O-ring failed. 8.4 Clutch shaft sealing rings leaking. 8.5 Excessive clutch shaft end float.

8.6 Wrong type clutch piston fitted. 8.7 Clutch piston O-ring failed. 9 Defective 2/4WD clutch: 9.1 Worn pressure plate 9.2 Worn actuating sleeve.

9.3 Incorrect clutch pack end float.

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

15 - 10 - 06/5

3CX, 4CX, (200 Series) Fault Finding - 2/4 Wheel Drive Clutch

From m/c no. 415012

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 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.

Low mainline pressure (due to 2/4WD clutch): 8.1 2/4WD solenoid spool sticking.

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 in) 8.5 Fit correct type clutch piston (ie, without bleed hole). 8.6 Replace clutch piston O-ring.

8.2 2/4WD solenoid spool O-ring failed. 8.3 Clutch shaft sealing rings leaking. 8.4 Excessive clutch shaft end float.

8.5 Wrong type clutch piston fitted.

8.6 Clutch piston O-ring failed.

Defective 2/4WD clutch: 9.1 Worn friction/counter plates

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 to 2.3 mm). Correct as required.

9.2 Mechanical failure of 4WD unit

9.3 Incorrect clutch pack end float.

9804/1103

15 - 10 - 06/5

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 06/6

3CX, 4CX, (200 Series) Fault Finding - 2/4 Wheel Drive Clutch (contd)

From m/c no. 415012

Pressure-On to 4WD Type Clutch


2WD CANNOT BE ENGAGED (CONTD) 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

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.

12

Check the 2/4WD relay and select switch, replace as necessary.

9804/1103

15 - 10 - 06/6

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 06/7

3CX, 4CX and Variants Fault Finding - Syncro Shuttle Transmission 2/4 Wheel Drive Clutch
4WD CANNOT BE ENGAGED

From m/c no. 460001

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.

Low mainline pressure (due to 2/4WD clutch): 8.1 2/4WD solenoid spool sticking.

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

8.2 2/4WD solenoid spool O-ring failed. 8.3 Clutch shaft sealing rings leaking. 8.4 Excessive clutch shaft end float. in) 8.5 Wrong type clutch piston fitted.

8.5 Fit correct type clutch piston (ie, without bleed hole). 8.6 Replace clutch piston O-ring.

8.6 Clutch piston O-ring failed.

Defective 2/4WD clutch: 9.1 Worn friction/counter plates

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.

9.2 Mechanical failure of 4WD unit

9.3 Incorrect clutch pack end float. to

9804/1103

15 - 10 - 06/7

3270 - F/61-4.1

Issue 1

CONTENTS

Backhoe Loaders

15 - 10 - 06/8

3CX, 4CX and Variants Fault Finding - Syncro Shuttle Transmission 2/4 Wheel Drive Clutch (cont'd)
2WD CANNOT BE ENGAGED

From m/c no. 460001

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

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.

12

Check the 2/4WD relay and select switch, replace as necessary.

9804/1103

15 - 10 - 06/8

3270 - F/61-5.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 07/1

ALL MODELS (EXCEPT 2CX) Fault Finding - Powershift Gearbox

From m/c no. 400001

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 Low Mainline Pressure High Stall Speeds (On All Clutches) Low Stall Speeds (On All Clutches) Low Converter Out Pressure Low Pump Flow High Converter Out Pressure Low Lubrication Pressure 15 - 10 - 07/2 15 - 10 - 07/2 15 - 10 - 07/2 15 - 10 - 07/2 15 - 10 - 07/2 15 - 10 - 07/2 15 - 10 - 07/3 15 - 10 - 07/3

* Low Clutch Pressure and/or Clutch Slipping 15 - 10 - 07/3


Overheating 15 - 10 - 07/3

9804/1103

15 - 10 - 07/1

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 07/2

ALL MODELS (EXCEPT 2CX) 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 LOW MAINLINE PRESSURE Possible Cause 1 Worn pump. 2 Blocked suction strainer. 3 Pressure maintaining valve sticking/leaking. 4 Oil aerated (foaming).

From m/c no. 400001

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'.

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. LOW STALL SPEEDS (ON ALL CLUTCHES) Possible Cause 1 Poor engine condition. 2 Torque converter reaction member clutch slipping. LOW CONVERTER OUT PRESSURE Possible Cause 1 Low mainline pressure. 2 Converter internal leakage. 3 Converter relief valve faulty. 4 Restriction in converter feed. LOW PUMP FLOW Possible Cause 1 Low oil level 2 Blocked suction strainer. 3 Worn 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 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.

Remedy 1 Check and if necessary repair engine. 2 Check and if necessary repair torque converter.

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'.

Remedy 1 Top up system. 2 Clean suction strainer. 3 Repair or renew pump

* *

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

15 - 10 - 07/3

ALL MODELS (EXCEPT 2CX) 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 LOW CLUTCH PRESSURE AND/OR CLUTCH SLIPPING Possible Cause Low mainline pressure. Worn pump. Blocked restrictor orifice in solenoid valve block. Clutch seals worn. Clutch piston rings worn. Mechanical failure.

From m/c no. 400001

* *

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'

*1 *2 *3 *4 *
5 6

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.

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

15 - 10 - 07/4

3CX, 4CX and Variants 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.

From m/c no. 460001

Powershift Fault Finding - Index


Page No. Lack of Power Low Mainline Pressure High Stall Speeds (On All Clutches) Low Stall Speeds (On All Clutches) Low Converter Out Pressure Low Pump Flow High Converter Out Pressure Low Lubrication Pressure Low Clutch Pressure and/or Clutch Slipping Overheating 4WD Cannot Be Engaged 2WD Cannot Be Engaged Transmission Oil Contaminated with Water 15 - 10 - 07/5 15 - 10 - 07/5 15 - 10 - 07/5 15 - 10 - 07/5 15 - 10 - 07/5 15 - 10 - 07/5 15 - 10 - 07/5 15 - 10 - 07/6 15 - 10 - 07/6 15 - 10 - 07/6 15 - 10 - 07/7 15 - 10 - 07/7 15 - 10 - 07/8

9804/1103

15 - 10 - 07/4

3270 - F/101-1.2

Issue 1

CONTENTS

Backhoe Loaders

15 - 10 - 07/5

3CX, 4CX and Variants Fault Finding - Powershift Transmision (contd)


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).

From m/c no. 460001

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.

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 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. LOW STALL SPEEDS (ON ALL CLUTCHES) Possible Cause 1 Poor engine condition. 2 Torque converter reaction member clutch slipping. LOW CONVERTER OUT PRESSURE Possible Cause 1 Low mainline pressure. 2 Converter internal leakage. 3 Converter relief valve faulty. 4 Restriction in converter feed. LOW PUMP FLOW Possible Cause 1 Low oil level 2 Blocked suction strainer. 3 Worn Pump. HIGH CONVERTER OUT PRESSURE Possible Cause 1 Oil cooler/lines blockage. 2 Converter in pressure incorrect. 3 Converter 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.

Remedy 1 Check and if necessary repair engine. 2 Check and if necessary repair torque converter.

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'.

Remedy 1 Top up system. 2 Clean suction strainer. 3 Repair or renew pump

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

15 - 10 - 07/6

3CX, 4CX and Variants Fault Finding - Powershift Transmission (contd)


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 5 6 Clutch seals worn. Clutch piston rings worn. Mechanical failure.

From m/c no. 460001

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.

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 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.

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).

9804/1103

15 - 10 - 07/6

3270 - F/101-3.1

Issue 1

CONTENTS

Backhoe Loaders

15 - 10 - 07/7

3CX, 4CX and Variants Fault Finding - Powershift Transmission (contd) 2/4 Wheel Drive Clutch
4WD CANNOT BE ENGAGED

From m/c no. 460001

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 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 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.

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.

Defective 2/4WD clutch: 9.1 Worn friction/counter plates 9.2 Mechanical failure of 4WD unit

9.3 Incorrect clutch pack end float. to

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 12 Check the 2/4WD relay and select switch, replace as necessary. Replace piston or rectify as required.

11 12

2/4WD solenoid permanently energised. Piston ball valve blocked.

9804/1103

15 - 10 - 07/7

3270 - F/101-4.2

Issue 1

CONTENTS

Backhoe Loaders

15 - 10 - 07/8

3CX, 4CX and Variants Fault Finding - Powershift Transmission (contd)


Transmission Oil Contaminated with Water

From m/c no. 460001

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 1 Water ingress during filling/topping up. Remedy Carry out flushing procedure. Refill with JCB Special Transmission Fluid. Renew missing/incorrect/damaged components. Carry out flushing procedure. Refill with JCB Special Transmission Fluid. Carry out flushing procedure. Refill with JCB Special Transmission Fluid. Remove, inspect, test oil cooler. Renew if applicable. Carry out flushing procedure. Refill with JCB Special Transmission Fluid. Inspect, renew damaged components. Carry out flushing procedure. Refill with JCB Special Transmission Fluid. Inspect, renew damaged components. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.

Missing/incorrect dipstick, damaged filler tube.

Machine operated in deep water.

Oil cooler failure.

Gearbox or bevel gearbox casings damaged.

Gearbox oil circuit pipes/hoses damaged.

Gearbox faults caused typically by water contamination and other factors related to the transmission oil: Fault 1 Pressurisation of transmission casing - Dipstick blows out/oil leaking from dipstick tube. Possible Cause Water in oil combined with heat from torque converter causes steam. Gearbox over filled with oil. Remedy Replace/renew dipstick. Carry out flushing procedure. Refill with JCB Special Transmission Fluid. Drain the oil level to the correct level, see Routine Maintenance - Checking Transmission Oil Level. Renew friction plates. Carry out flushing procedure. Refill with JCB Special Transmission Fluid. 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.

Clutch Failure - Friction Lining Separation.

Water ingress.

Clutch Failure - Clutch Piston Seizing.

Water ingress causing nylon components to swell and stick when hot.

Overheating transmission oil. 4 Badly worn/noisy bearings. Water ingress. Insufficient lubrication.

See Fault Finding - Overheating.


Fit new bearings. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.

9804/1103

15 - 10 - 07/8

3270 - F/101-5.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 08/1

ALL MODELS (EXCEPT 2CX) Fault Finding - Brakes

From m/c no. 460001

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 A One or both brakes do not apply. (Brake travel not excessive, brakes not pulling to one side) POSSIBLE CAUSE 1 2 1 B Pedal travel excessive (but not touching floor). 2 Leak in hydraulic system. 2 Check master fault Friction/counter plate distortion. Air in Hydrualic system. POSSIBLE CAUSE 1 2 1 Check master cylinder in Check friction/counterplates. Check fluid reservoir level. Check for fluid/air leaks,rectify as required. Check for fluid loss at master cylinder and brake piston, all pipes and fittings for loose connections. Rectify as required. Renew friction/counter plates BOTH sides. Renew master cylinder position.

Friction/counter plate distortion.

Applying one brake (pedals unlocked) also partially engages the other brake. Pedal hard to operate.

Valve stem seal inside (non-active) 1 master cylinder piston not sealing.

Tightness at pedal pivot.

Inspect pedal pivot. Free-off/lubricate. Flush system and renew all hydraulic seals. Check and rectify as required. Check/renew brake pipwork.

Fluid contamination seal damage.

3 4

Misaligned push rod/pedal. Kinked or crushed brake pipes.

3 4

Items 5 to 7 are for machines fitted with servo assisted brakes only: 5 Vacum failure due to low vacim at source. Blocked/leaking vacum pipe. Servo defect. 5 Inspect/service engine mounted exhauster unit as required. Check/renew vacum pipe. Renew servo unit.

6 7

6 7

Pedals touch floor under constant pressure - no fluid loss

Master cylinder fault.

Check master cylinder in single and coupled pedal modes to identify fault area, service as required. Renw friction/counter [plates BOTH sides. See item B. 1.

Friction/counter plate distortion.

Air in hydraulic system.

Pedals touch floor under constant pressure - and fluid loss

External fluid leaks.

Visually Check brake circuit for fluid loss, service as required. See Brake Piston Seal Leakage Test on page 15-10-08/04.

I nternal fluid leaks.

9804/1103

15 - 10 - 08/1

3270 - F/101-1.2

Issue 2*

CONTENTS

Backhoe Loaders
POSSIBLE CAUSE 1 Compensating feature not working. POSSIBLE CAUSE 1

15 - 10 - 08/2

ALL MODELS (EXCEPT 2CX) Fault Finding - Brakes (contd)


FAULT G Pulling to one side when pedals locked together.

From m/c no. 460001

Inspect master cylinder compensating. Check if blockage in bridging pipe. Service as required. Unlatch pedals to test circuits individually. Renew friction counter plates BOTH sides. Adjust push rod (1mm minimum). Adjust servo operating rod. See item J6. Renew friction/counter plates BOTH sides. Check master cylinder in single and coupled pedal modes to identify fault area, service as required. See itemJ6. Fill axle with correct type of oil. Inspect vacum source/pipes, service as required. Fit a new spring Service as required. Fit a new resvoir cap Adjust pedal free travel. Flush system and renew hydraulic seals.

2 3 4 5 6 H Poor braking (not pulling to one side). 1

Braking system inoperative on one side. Friction plates worn beyond limits or distortion on one side. Badley adjusted push rods. Servo operating rod out of adjustment. Annular piston fault (see item J6) Friction plates worn beyond limits or distorted on one side. Master cylinder fault.

2 3 4 5 6 1

3 4 5 J One or both brakes not releasing. 1 2 3 4 5 6

Annular piston fault (see item J6) Incorrect/low axle oil.

3 4

Vacum failure (machines fitted with 5 servo assisted brakes only). Brake pedal spring fault. 1

Master cylinder fault (plunger stuck 2 in bore). Blocked hole in master cylinder resvoir cap. Brake pedal free travel incorrect. Fluid contamination/seal damage. Annular brake piston(s) binding in axle. 3 4 5

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).

Kinked or crushed brake pipes.

Check and renew pipes as required. Check friction/counter plates for free movement, replace if required - BOTH sides.
3270 - F/101-2.2

8 Friction/counter plates not free on 8 splines and/or dowels.


9804/1103

15 - 10 - 08/2

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 08/3

ALL MODELS (EXCEPT 2CX) Fault Finding - Brakes (continued)


FAULT K Poor braking when hot. POSSIBLE CAUSE 1 Moisture in system vapourizing when axle is hot. ACTION 1

From m/c no. 400001

Strip axle and clean annular piston to remove moisture. Remove master cylinders and check for corrosion, service as required. Flush hydraulic brake system. Change axle oil.

L Excessive brake noise in operation. 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.

Deterioration of axle oil or wrong type of axle oil. Axle oil loss.

Refill axle with correct oil and check for leaks. Renew friction/counter plates. Check for distortion or surface pitting and/or roughness of friction/counter plates (annular grooving of counter plates is acceptable). Strip axle, replace seal.

3 4

Friction plates worn beyond limits. Friction/counter plates in poor condition.

3 4

M Fluid loss when machine standing, for instance - overnight (see note). Note: Confirm fault is as indicated by checking that the pedals DO NOT touch floor under constant pressure.

Slight cut or nick in the brake piston 1 seal, see 'Brake Piston Seal Leakage Test' page 15-10-08/4.

9804/1103

15 - 10 - 08/3

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 08/4

ALL MODELS (EXCEPT 2CX) Fault Finding - Brakes (continued)

From m/c no. 400001

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 6 Repeat steps 1 to 4 for the opposite brake piston seal. Reconnect all brake pipes and bleed the brake system as recommended in the service manual (publication no. 9803/3260).

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

WARNING !

1 2

Remove and cap brake piston feed pipe A. Fill the brake piston housing with JCB Light Hydraulic Fluid. Check for severe piston seal damage: 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.

Use illustration 107710 and amend to show clear tube fitted, also show level indicator mark on tube.

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

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 09/1

3CX, 4CX and Variants Fault Finding - Steering Contents


Page No. Introduction Steering wheel difficult to turn Steering wheel turns on its own Machine will not turn when the steering wheel turned. Steering fails to respond to selected mode (4WS Machines only) 15 - 10 - 09/1 15 - 10 - 09/1 15 - 10 - 09/2

From m/c no. 460001

Introduction
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. Make simple checks before say, stripping a major component. Make sure that the hydraulic fluid is at correct working temperature (50 C, 122 F). What ever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary. Make any relevant electrical checks before moving on to the hydraulics. Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit. Replace any seals such as 'O' rings before reassembling hydraulic components. Action

15 - 10 - 09/2

15 - 10 - 09/3

Fault

Probable Cause

Steering wheel difficult to turn.

Tyres not inflated to correct pressure Insufficient hydraulic fluid. Leaks in the relevant hoses or component connections Air in the hydraulic system. Low pump flow. Steer relief valve set incorrectly Worn or damaged parts in the steer control valve.

Inflate tyres to correct pressure Check for leaks and top up as required. Check hoses and connections for leaks Bleed system - bleed the load sense line. Check pump flow, if required service or replace pump. Check pressure setting of steer unit relief valve, adjustas required. Remove and inspect.

....... continued

9804/1103

15 - 10 - 09/1

3270 - H/4-1.1

Issue 1*

CONTENTS

Backhoe Loaders

15 - 10 - 09/2

3CX, 4CX and Variants Fault Finding - Steering (contd)


Fault
1 Steering wheel difficult to turn. (continued)

From m/c no. 460001


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

Check for damaged axle components, such as rams, trackrods, linkages etc. Clean and inspect unit. Check unit. See page H/16-4, step 9. Correct as required. Check for leaks and top up as required. Check hoses and connections for leaks Bleed system - bleed the load sense line. Check pump flow, if required service or replace pump. Check pressure setting of steer unit relief valve, adjust as required. Remove and inspect. 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.

Steering wheel turns on its own.

Dirt in the steer control unit (causing sleeves to stick open) Steer control valve centring springs damaged, broken or missing. Steer control valve - position of rotor to shaft slot incorrect.

Machine will not turn when the steering wheel turned.

Insufficient hydraulic fluid. Leaks in the relevant hoses or component connections Air in the hydraulic system. Low pump flow.

Steer relief valve set incorrectly Worn or damaged parts in the steer control valve. Priority valve not operating correctly

9804/1103

15 - 10 - 09/2

3270 - H/4-2.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 10 - 09/3

3CX, 4CX and Variants Fault Finding - Steering (contd)


Fault
3 Machine will not turn when the steering wheel turned (continued).

From m/c no. 460001

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

Mechanical failure

Check for damaged axle components, such as rams, trackrods, linkages etc. Check shaft engagement.

Steer column splined shaft not fully engaged in steer valve. Power track rod failure

Check power track rod for signs of damge, leaks etc.

Steering fails to respond to selected mode (4WS Machines only)

Selector switch faulty

Check selector switch, replace as required Check setting of proximity switches, reset or replace switches as required. Check if spools sticking, rectify as required Check if solenoids operating, replace solenoids as required.

Proximity switches not operating correctly

Steer mode valve not operating correctly

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.

9804/1103

15 - 10 - 09/3

3270 - H/4-3.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 01/1

3CX, 4CX, (200 Series) Circuit Diagrams - Electrical

From m/c no. 400001 to 430000

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 Brake Lights 2/4 Wheel Drive Solenoid 2/4 Wheel Drive Relay 2/4 Wheel Drive Brake Relay 2/4 Wheel Drive Select Switch 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

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 Rear Fog Light Switch Rear Washer Motor Rear Washer Switch Note: Machines prior to serial number 400077 have the fog light circuit protected by fuse B3, not C4 as indicated. 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).

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.

9804/1103

15 - 15 - 01/1

Issue 2

CONTENTS CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 01/2

3CX, 4CX (200 Series) Circuit Diagrams - Electrical

From m/c no. 400001 to 430000

Basic Machine (2WS with Syncro Shuttle)

600G 600AD 600AC 600Y 600V 600BS 600BN 600CE 600BF 600C 600CK 600BU 600CF 600CD 600S 812 811 816D 816E 600H 600CB 600BL 600AZ 600H 600G 600AJ 600AP 600BG 600AK 600DY 600AZ 600BC 600B 600

600AZ 600BC 600BM 600DW

600G 600AU 600H

600AX 604 600T 600P 600AS 600AV 600BJ

604A 600DF

600BT

34 32
600BD

600BC

10

13 14
815

16 18

52 50 53
M

63 62 61
834A

78 81 83 79 84

21

23 77

43

44

45

75

600AR

600AY

89

71 85 82 67
855A 855B 603 861B 861A 867B

600AA 600AB 816

600BK

3 4
M

40
853

8
912

12 20
912A

36 22 24
807

804

M
M
303A 894 837A

834B 837B

35
M

5
003

809

808A

46
806 805

55
839

57
841

76
877A

15
842

17
108 808

125
877

38
864

80
834 840 837 829 830 831

855

47
600BH 804A

56

B5 69

119
600N

88

863 909 862 853B 108B 802 815A 103A

F 1 + 6
810C 838 004

N R
852 815 912

41
803 800A

26

27

31

48
600EB 800B

56 58 51
814

830D

B4
836

B3
833

A3 A4
828 828A

835 101A

11
810A 401

126
404 406 403 405 402 200 200A 412 407

11A
107M 107N

49
102A

866

865

60
868A 303F 868 110B 104B 110A 908

42 39
103E 108 103 303 105 104A 300 102

120

59
110C

C4 87
861 101P

100A

9A
100 106 111A

30

28 19

64 70
832B 828B

907

37 A1
001C 002C 002A 000C 002J

110

B7 B9
000E 002L 111 000D 002K

A2
001D 002B

107 411 107D

29

A5
001E

B2 B6
001F 002D

104C

600BE 832

90
103C 101

A6
200J

B8
000B 002H

A7
200H

A9
000A 002G

72 65
302 200E 104C 103B 002F

C3
001B

B1
000F

C2

2
601

C1
200G 859 860

602

A8
200K 304

54

600R

A214640

A214640

9804/1103

15 - 15 - 01/2

15 - 15 - 01/2

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 01/3

3CX, 4CX, (200 Series) Circuit Diagrams - Electrical (continued)

From m/c no. 400001 to 430000

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

822 821

823

112

826A 824B

824A 825B

825A

845 819 820 600BW

826B

115

116

117

109C 600BV

109D

109F

114

110
109A

111
109B 109E

2
002E 109

C2
002B

A2

A216990

9804/1103

15 - 15 - 01/3

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 01/4

3CX, 4CX, (200 Series) Circuit Diagrams - Electrical (continued)

From m/c no. 400001 to 430000

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.

600BZ 600BY

600BX 600BS 600AF

600BT

142
600AG

144

600AC

149
600CA

141
851

145
600AE 812 848

148
600AH 600AD 811
X

600BF

810

849

14
850

600Y 600V

143 6 140
107F

846

146
813

817

147

847 600BN

815

810C

152
884B 809

107B

153
808A

107E

810A

11
401

883B 884C

30

A2

7
838A

R N

2 4 3

29

1 +
2
600W

9A
111A 852

150

107 100 001A

C3

151 B9
200C 200D 002

B7

A216980

9804/1103

15 - 15 - 01/4

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 01/5

3CX, 4CX, (200 Series) Circuit Diagrams - Electrical (continued)

From m/c no. 400001 to 430000

Circuit Diagram Component Lists 2/4 Wheel Drive (all machines up to serial number 409434)
2 31 32 34 35 36 37 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

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 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

600CB

34

600AB

600BR

600AD 600AC 600Y 600V 600BS

600BN

A216960

32

600BT 600BF

10
812

13
811

853 600AA

14
815

8
816

12
107B 107E

809

808A

35
853A 854 818

36

F
108B 877

N R
852 815

37

6
810C 838

11
810A 401

107D

31
108

100A

9A
100 106 111A

30 19 B7 B9
000D

A1

A2

107 411

29

C3
000E

C3
111 001B

A216950

9804/1103

15 - 15 - 01/5

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 01/6

3CX, 4CX, (200 Series) Circuit Diagrams - Electrical (continued)

From m/c no. 400001 to 430000

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

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

600C

600BU

600BP

600CF

21
600CK

23

25

85
22 24
867A

20

89
410
101A

86 88
867 867B

88
866A 101C

866

404 406 403

405 402

87
101A

A2

19 29

101

B9
A216970

B1
A216940

9804/1103

15 - 15 - 01/6

Issue 2

CONTENTS CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 01/7

3CX, 4CX (200 Series) Circuit Diagrams - Electrical

From m/c no. 430001

Basic Machine (2WS with Syncro Shuttle)

19 143 3 1 5 60 61 6 7 8 9 140 141 10 142 144 145

20

73 74 75 76 77

11

12

13

14

15

63

68

113

114

116 16 117 118 72 69 21 17 18 70 22 23 146 24 147 149 151 153 155 156 148 150 152 154 155 54

110 62

115

65

67 112 66

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

15 - 15 - 01/8

3CX, 4CX, (200 Series) Circuit Diagrams - Electrical (continued)

From m/c no. 430001

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

15 - 15 - 01/9

3CX, 4CX, (200 Series) Circuit Diagrams - Electrical (continued)

From m/c no. 430001

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) Circuit Diagrams - Electrical

From m/c no. 430001

Basic Machine (2WS with Syncro Shuttle)

162

164 165 163 166

167 169 170 172 168 36 171 173 174 89 37 39 41 90 40 42

33 27 26 34 28 30 32 29 31

35

84 25 82 157 158 156 154 153 159 160 161 80 83 91 78 79 86

95

94 87 88

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

Powershift Transmission & Steer Circuit - AWS Machines Only

FUSE C3

9804/1103

Circuit Diagrams - Electrical (contd)

3CX, 4CX, (200 Series)

CONTENTS

8 9 3 1 5 61 63

43 44

45 46 47

48

102 16 16

Backhoe Loaders

123 116 115 125 113 16 110 114 124

126 16

16 101 53

15 - 15 - 01/11
2

127 16

16 16 16 100 49 175 176 177 178

16 112 62 96 64 97

50

51

52

From m/c no. 430001

98
FUSE C6

99

15 - 15 - 01/11

111

119
A228972

A228972

Issue 2

CONTENTS

Powershift Transmission & Steer Circuit - AWS Machines Only


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. 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 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

Circuit Diagrams - Electrical (contd)

9804/1103

3CX, 4CX, (200 Series)

CONTENTS

Backhoe Loaders

15 - 15 - 01/12
Issue 2*

Lights 175 4 Wheel Steer Indicator Light 176 Crab Steer Indicator Light 177 2 Wheel Steer Indicator Light 178 Front Instrument Console Illumination 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.

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)

From m/c no. 430001

CONTENTS

Powershift Transmission - 2WS Machines Only and Steer Circuit for 3CX 4x4x4 Machines

9804/1103

Circuit Diagrams - Electrical (contd)

3CX, 4CX, (200 Series)

CONTENTS

8 9 3 1 5 61 63

140 141

43 44

45 46 47

48

Backhoe Loaders

123

129
116 4 115 125 113 16 110 147 65 16 16 16 114 127 126

130

15 - 15 - 01/13
A228981

100 50
112 62 64 97

52

177 178

98

99

From m/c no. 430001

111
FUSE C6

119

15 - 15 - 01/13

FUSE C2

Issue 2

CONTENTS

Powershift Transmission - 2WS Machines Only - and Steer Circuit for 3CX 4x4x4 Machines
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. 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 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 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

9804/1103

Circuit Diagrams - Electrical (contd)

3CX, 4CX, (200 Series)

CONTENTS

Backhoe Loaders

15 - 15 - 01/14
Issue 2

* *

* *

* * *

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

* *

Wire Number Identification Refer to pages C/42-1 on for full wire number identification and descriptions.

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.

15 - 15 - 01/14

CONTENTS CONTENTS
3CX, 4CX and Variants

Backhoe Loaders

15 - 15 - 01/15

From m/c no. 460001

Circuit Diagram - Electrical (contd) Basic Machine

60

61 143 63 B 9 140 10 57 11 12 13 14 15 142 B/N 116 141 6 7 56 68 B 144 B/O 145

19

20

73 74

75

76

77 106

3 1

5 8 112

4 113 114 118 105 117 69 72 146 65 110 115 62 71 64 67 66 70 17 22 23 21 24 18 16 147 149 151 175 148 150 152 54

155

111 2

9804/1103

15 - 15 - 01/15

3270 - C/18-1.3

Issue1

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 01/16

3CX, 4CX and Variants Circuit Diagram - Electrical (contd) Basic Machine Component List 1
Refer to pages 15 - 15 - 01/15 and 15 - 15 - 01/18

From m/c no. 460001

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

15 - 15 - 01/17

3CX, 4CX and Variants Circuit Diagram - Electrical (contd) 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 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

From m/c no. 460001

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

9804/1103

15 - 15 - 01/17

3270 - C/18-3.3

Issue 1

CONTENTS CONTENTS CONTENTS


3CX, 4CX and Variants

Backhoe Loaders

15 - 15 - 01/18

From m/c no. 460001

Circuit Diagram - Electrical (contd) Basic Machine

34 27 29 31 33

35

162

164 165 163 166

167 169 170 172 168 36 171 173 174 89 37 39 41 95 40 42

30 26

32

90

84 25 78 79 157 156 158 160 154 159 161 153 80 86 86 87 94

83 82 85 121 88 91 93

132

133

92

81

120

119

9804/1103

15 - 15 - 01/18

15 - 15 - 01/18

3270 - C/18-4.3

Issue 1

CONTENTS CONTENTS CONTENTS


3CX, 4CX and Variants

Backhoe Loaders

15 - 15 - 01/19

From m/c no. 460001

Circuit Diagram - Electrical (contd) Powershift (PS700) Transmission and Steer Circuit - AWS Machines only

63

16 43 44 8 136 9 140

61

12 68 16 112 46 45 47 48 117 101 134 53 102

3 1

141 114

102 4 115 135 124 67 116

127 110 113 114 64 96 62 97

100

49 50

175 51

176 52

177 178

98

99

111 119

9804/1103

15 - 15 - 01/19

15 - 15 - 01/19

3270 - C/18-5.?

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 01/20

3CX, 4CX and Variants Circuit Diagram - Electrical (contd)

From m/c no. 460001

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 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

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

15 - 15 - 01/20

3270 - C/18-6.3

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 01/21

3CX, 4CX and Variants Circuit Diagram - Electrical (contd) 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

From m/c no. 460001

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

9804/1103

15 - 15 - 01/21

3270 - C/18-7.3

Issue 1

CONTENTS CONTENTS CONTENTS


3CX, 4CX and Variants

Backhoe Loaders

15 - 15 - 01/22

From m/c no. 460001

Circuit Diagram - Electrical (contd) Powershift (PS700) - AWS Machines only Steer Circuit 2CX 4X4X4 Machines

63 3 1 136 115 4 135 116 5 43 44 49 140 141 8 65

61 112

12 68 117 46 47 48 134 129 130

45

124 147 110 113 114

126 67 135 100 50 175

127

62

64 52 177 178

131 97 2 111 119 99 98

9804/1103

15 - 15 - 01/22

15 - 15 - 01/22

3270 - C/18-8.3

Issue 1

CONTENTS CONTENTS CONTENTS


3CX, 4CX and Variants Circuit Diagram - Electrical (contd) 3CXE (214E Series 3) only

Backhoe Loaders

15 - 15 - 01/23

From m/c no. 460001

TO PAGE C/18 - 11 19 143 3 1 61 5 60 6 7 9 8 141 63 4 113 114 118 37 16 96 110 62 115 70 112 72 17 16 54 140 10 15 142 145 144 20 73 74 75 76 77

147 149 151 146 22 23 21 24 18 148 150 152 155

71 64
A274310 (CAD 852/30213)

111

9804/1103

15 - 15 - 01/23

15 - 15 - 01/23

3270 - C/18-9.?

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 01/24

3CX, 4CX and Variants Circuit Diagram - Electrical (contd) 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

From m/c no. 460001

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.

9804/1103

15 - 15 - 01/24

3270 - C/18-10.2

Issue 1

CONTENTS CONTENTS

CONTENTS

Backhoe Loaders

15 - 15 - 01/25

3CX, 4CX and Variants Circuit Diagram - Electrical (contd) 3CXE (214 E Series) only

From m/c no. 460001

FROM PAGE C/18 - 9

173 35 26

174

25

87 156 153 88

159 160

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 Circuit Diagram - Electrical (contd) 214E Series 4 only

From m/c no. 460001

19 35 3 1 61 141 113 4 116 80 115 110 62 112 64 71 92 96 83 22 82 41 97 72 114 17 32 34 5 60 6 7 8 9 140 10 40 37 31 13 58 142 33 144 143 145

20

25 23 21

111 2

9804/1103

15 - 15 - 01/26

3270 - C/18-12.12

Issue1

CONTENTS CONTENTS

Backhoe Loader

15 - 15 - 01/27

3CX, 4CX and Variant Circuit Diagram - Electrical (contd) 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

From m/c no. 460001

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.

9804/1103

15 - 15 - 01/27

3270 - C/18-13.2

Issue 1

CONTENTS CONTENTS

Backhoe Loader

15 - 15 - 01/28

3CX, 4CX and Variants Circuit Diagram - Electrical (contd) 214 E Series 4 only

From m/c no. 460001

74 59 73 75

76 77 39 26 60 29 173 174

54

87 78

24

88

147 149 151 146 148 150 152

28

18 132

133

119

9804/1103

15 - 15 - 01/28

3270 - C/18-14.2

Issue1

CONTENTS CONTENTS

Backhoe Loader

15 - 15 - 01/29

3CX, 4CX and Variants Circuit Diagram - Electrical (contd) Autoshift Transmission - 2WS Machines Only
1 2 4 3 70 71 50 72 6 73 5

From m/c no. 460001

90

8 51 9 52 53 54 10 11 16 12 13 55 77
180D

14 15

74

17

18

56

75 57 76

19

9804/1103

15 - 15- 01/29

3270 - C/18-15.2

Issue 1

CONTENTS CONTENTS

Backhoe Loader

15 - 15 - 01/30

3CX, 4CX and Variants Circuit Diagram - Electrical (contd) 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.

From m/c no. 460001

9804/1103

15 - 15 - 01/30

3270 - C/18-16.2

Issue 1

CONTENTS CONTENTS

Backhoe Loader

15 - 15 - 01/31

3CX, 4CX and Variants Circuit Diagram - Electrical (contd) Autoshift Transmission - AWS Machines Only
1 2 4 3 70 90 71 50 72 6

From m/c no. 460001

73

8 51 9 52 53 54 11 16 12 13 14 55 17 74 15 10

18

56

75 57

19

76

9804/1103

15 - 15 - 01/31

3270 - C/18-17.1

Issue 1

CONTENTS CONTENTS

Backhoe Loader

15 - 15 - 01/32

3CX, 4CX and Variants Circuit Diagram - Electrical (contd) 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.

From m/c no. 460001

9804/1103

15 - 15 - 01/32

3270 - C/18-18.1

Issue 1

CONTENTS CONTENTS

Backhoe Loader

15 - 15 - 01/33

3CX, 4CX and Variants Circuit Diagram - Electrical (contd)

From m/c no. 460001

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 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

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

15 - 15 - 01/33

3270 - C/18-19.2

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 01/34

3CX, 4CX and Variants Circuit Diagram (contd) Powershift (PS750) Transmision and Steer Circuit - AWS Machines only

From m/c no. 460001

63 5 1

16 43 44 8 9 140

61

12 68

112 141 136 46 116 135 115 124 126 67 100 101 45 48 47 117 134

53 102

127 110 142 113 114 16 64 96 62 16 97 16

49 50

175 51

176 52

177 178

98

99

2 111 119

9804/1103

15 - 15 - 01/34

3270 - C/18-20.1

Issue1

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 01/35

3CX, 4CX and Variants Circuit Diagram - Electrical (contd) Powershift (PS750) Transmission - 2WS Machines Steer Circuit - 3CX 4X4X4 Machines only

From m/c no. 460001

63 3 1 125 5 16 43 44 49 140 141 8 65 46 116 63 124 114 126 127 45 48 47 61 112

12

68 117 132 134 131

115

135

110

147

113

67 130

16 16 62 64 16

100

50

178

52 177

129 97 99 98

2 111 119

9804/1103

15 - 15 - 01/35

3270 - C/18-21.?

Issue1

CONTENTS

Backhoe Loaders

15 - 15 - 01/36

3CX, 4CX and Variants Circuit Diagram - Electrical (contd) 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

From m/c no. 460001

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

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

15 - 15 - 01/36

3270 - F/18-22.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 01/37

3CX, 4CX and Variants Circuit Diagram - Electrical (contd) Auxiliary Options

From m/c no. 460001

Hand Held Tools (Gear Pump) 1 2 3 Switch Indicator Lamp Solenoid

Dedicated Quick Hitch 1 2 3 4 5 6 Hydraulic Enable Switch Indicator Lamp Warning Buzzer Operator Switches Relay Solenoid Pole Planter 1 2 3 Selector Switch Grab Solenoid Rotation Solenoid Smooth Ride System (SRS) 1 Selector Switch/LED 2 Accumulator Solenoids

9804/1103

15 - 15 - 01/37

3270 - C/18-23.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 01/38

3CX, 4CX and Variants Circuit Diagrams - Electrical (contd) Auxiliary Options (contd)

From m/c no. 460001

Hammer 1 2 3 4 Micro Switch Relay Panel Switch Hammer Solenoid

Hand Held Tools (Variable Flow Pump) 1 2 3 4 Switch Indicator Lamp Solenoid (normally open) Solenoid

9804/1103

15 - 15 - 01/38

3270 - C/18-24.1

Issue 1

CONTENTS

Backhoe Loaders

15 - 15 - 01/39

3CX, 4CX and Variants Circuit Diagram - Electrical (contd) Auxiliary Options (contd)

From m/c no. 460001

Powershift (PS750) 2/4WD Powered On 2WD (Germany) 1 2 3 4 5 Brake Light Switch Brake Mode Switch Auto 2WD Relay 4 Wheel Brake Relay 4WD/4WB Relay

Power Sideshift with Hammer Circuit 1 2 3 4 5 6 7 8 Micro Switch Hammer Relay Hammer Switch Hydraclamp Switch Hammer Solenoid Hydraclamp Solenoid Power Sideshift Solenoid Buzzer
3270 - C/18-25.1

9804/1103

15 - 15 - 01/39

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 02/5

ALL MODELS (EXCEPT 2CX) Circuit Diagrams - Electrical (Servo Machines)

From m/c no. 400001

446

446

9804/1103

15 - 15 - 02/5

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 02/6

ALL MODELS (EXCEPT 2CX) Circuit Diagrams - Electrical (Servo Machines) (continued)

From m/c no. 400001

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

FUSE C5 1
THERMOSTART
010 003

9804/1103
2
BATTERY
BATTERY ISOLATOR

CONTENTS CONTENTS

BATTERY

6 7
STARTER MOTOR STARTER SOLENOID NEUTRAL START RELAY

200
8 2

NEUTRAL START RELAY

004 200
KEY SWITCH
4 6

842 810

PRIMARY FUSE 4 5
200

ALTERNATOR

3CX, 4CX and Variants

FROM NEUTRAL SELECT

Circuit Diagrams - Electrical Basic Machine

FUSE C7
407 412
6 4

001 133

IGNITION RELAY 1

FUSE A5 11 13
002 107

200
8

WAXSTAT

14
TO GEARBOX CONTROL FEED

10

PRIMARY FUSE 3
IGNITION RELAY 1

COLD START ADVANCE E.S.O.S.

12

105

FUSE A2
6 4

133
2 8

IGNITION RELAY 2

200

15
007

IGNITION RELAY 2

Backhoe Loaders

15 - 15 - 03/1
803
HAZARD SWITCH INDICATOR SWITCH
8

HAZARD SWITCH

19

LH REAR INDICATOR

20

B/N

LH FRONT INDICATOR

21

25

FUSE A3
802
49 C2 2

PRIMARY FUSE 1 17
200

FUSE C2

002
10

LH REAR INDICATOR ROOF-USA

18

22

805

LH FRONT INDICATOR ROOF-USA

830

16
5 18

806

23

B/O 804
49a 31

RH FRONT INDICATOR

24

806

RH REAR INDICATOR

17

104
1

26

300
3
U

RH FRONT INDICATOR ROOF-USA RH REAR INDICATOR ROOF-USA FLASHER UNIT

FLASHER UNIT

27

409

WATER TEMP SENDER

29
+

106

WATER TEMP GAUGE


-

FUSE B1

28

408

FUEL SENDER

30
+ -

FUEL GAUGE

31

CLOCK

617

DIRECT EARTH

CLOCK

32

304

TACHOMETER

TACHOMETER

FUSE C4
HOURMETER

33 34 SIDE CONSOLE
INSTRUMENTS
830 806 804

HOURMETER

35 36 37 38 39 40 41 42 46 47 48 49 50 51 52 45 45 45 45

ALTERNATOR

HAND BRAKE

WATER TEMP

406
TRANS OIL TEMP

WATER TEMP SWITCH


404
ENGINE OIL PRES

TRANS OIL TEMP SWITCH


403
TRANS OIL PRES

ENGINE OIL PRESS SWITCH


405
AIR FILTER

TRANS OIL PRESS SWITCH


402

53 54 55 56 57

AIR FILTER VAC. SW

ILLUMINATION

INSTRUMENT PANEL BUZZER

43
411
MASTER

805

WARNING

LIGHTS

TURN SIGNAL

SIDE LIGHTS

WARNING CLUSTER
HAZARD WARNING

44

RH SPEAKER

LH SPEAKER

MAIN BEAM

FRONT CONSOLE INSTRUMENTS

REAR W/L

FRONT W/L

601

602

860

59

60

859

From m/c no. 495455

3270 - C/19_1.1
001 133 002 007 200 830 837 861 855 835

REAR FOG

304A
EARTH

RADIO

15 - 15 - 03/1

58

401

407

Issue1

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 03/2

3CX, 4CX and Variants Circuit Diagrams - Electrical Basic Machine (contd)

From m/c no. 495455

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 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

9804/1103

15 - 15 - 03/2

3270 - C/19-2.1

Issue 1

001

133

007

200

830

829

837

861

855

835

407

9804/1103

CONTENTS CONTENTS

61

114

FUSE B4
830

CIGAR LIGHTER

3CX, 4CX and Variants

HEATED SEAT SWITCH

63 62

FACE LEVEL FAN HEATED SEAT

Circuit Diagrams - Electrical Basic Machine (contd)

65 64
M

68

863

REAR WASHER PUMP REAR WIPER

REAR WASH/ WIPE SWITCH

67

862
2

103 864
7

66

FUSE B5
M

70

839

FRONT WASHER PUMP

FUSE B2
110

FRONT W/W SWITCH 983

72
M

69
982 984 H/LIGHT FLASH

Backhoe Loaders

15 - 15 - 03/3
110
INTERMITTENT ECU

FRONT WIPER

REMOVED FOR TERRITORIES ITALY, GERMAN ONLY

73
FRONT HORN SWITCH

71

841

840 814
7 8

74
829

75
FOG LIGHT SWITCH

FRONT HORN

FOG LIGHT

76

78 79

TERRITORIAL OPTION ITALY, GERMAN ONLY


3 2

77

835 868

FUSE C1 83
B/U B DIP SWITCH
4

LIGHTS RELAY LH MAIN BEAM

ROAD LIGHTS RELAY 1133


10
5

FUSE C10
836 837 B/U

84 85

86

PRIMARY FUSE 2
8

FUSE B9
311

FUSE C1

FUSE B10
6 4

97

FUSE B8

FUSE C3
BEACON SWITCH
7 8

From m/c no. 495455

3270 - C/19-4.1

105 106

FUSE C7

80
127
7 6

RH MAIN BEAM

82
832
6

833
2 3 7

834

FUSE A9
829
ROAD LIGHTS SWITCH

FUSE C9
830 828

B/Y B/Y

B B

LH DIP BEAM RH DIP BEAM

FUSE A10 81

88
B/G

87
B

LH TAIL LIGHT LH SIDE LIGHT

89 90 91 92
B/P B

DIPPER SOCKET No PLATE LIGHT RH TAIL LIGHT RH SIDE LIGHT LIGHT SWITCH

ENGINE RUNING RELAY


3

93 5

407
1

1133

1853

96
F/W/L SWITCH
5

94
4 6

FRONT WORKING LIGHTS


6

855 116
2
2 3

98

310

855
8
4 7 5 6 1

117
2

2 3

309

REAR WORKING LIGHTS

99

861
7

95

861

R/W/L SWITCH 303

100

INTERIOR LIGHT

101
3

894
2

102
HEATER FAN MOTOR HEATER RELAY
8

BEACON

104 2

102 HEATER SWITCH 800


6 4

935

HEATER
HEATER RESISTOR

HEATER RELAY

103
7 8

15 - 15 - 03/3

107
AIR-CON SWITCH
3 2

110

109

108
902

Issue1

904

903 AIR-CON COMPRESSOR

AIR-CONDITIONING

9 1

13

9804/1103
TO NEUTRAL START RELAY

401 401

10

CONTENTS CONTENTS

810

3CX, 4CX and Variants

Circuit Diagrams - Electrical Transmission and Steering

TO FUSE A5
6

815

815

810 934
TRANS DUMP RELAY

934

815

P/BRAKE SWITCH

4 8 5 6
3 5

107
FORWARD RELAY
1 1 2 4

DUMP SWITCH (LOADER) DUMP SWITCH (GEARLEVER) FORWARD SOLENOID

10

812 852 809


3 5

7
F N R REVERSE RELAY
10 8

107

FORWARD/REVERSE RELAY

FOR / REV SWITCH

808

12

811

REVERSE SOLENOID

11
811 847

14

Backhoe Loaders

15 - 15 - 03/5
1 9 14
TO NEUTRAL START RELAY

REVERSE ALARM

401 810

TO FUSE A5 2
815 810 934
TRANS DUMP RELAY

815

P/BRAKE SWITCH

4 8
3 5

DUMP SWITCH (LOADER)

10

107
1 4

FORWARD RELAY
1 2 4

13

INTERLOCK RELAY
1

DRIVE RELAY
4 1

851

MAINSHAFT SOLENOID

15

852

11

809

850
3 5 3 3 5 5

LAYSHAFT SOLENOID

7
F N R

107

TRANSMISSION EARTH
REVERSE RELAY
10 8

12
883

FOR / REV SWITCH

808
7

16

847
6

REVERSE ALARM

883
POWER SHIFT GEAR SELECTOR 1
REVERSE H/L RELAY
6

18
849
9

REVERSE LOW SOLENOID

6
2
8

811

REVERSE HIGH SOLENOID

19

107

3 4

856

10

17

21

858
FORWARD H/L RELAY
6 7

848
9

FORWARD LOW SOLENOID


812

FORWARD HIGH SOLENOID

22

10

20

FRONT PROX SW

1 6
819 002 109 821
CRAB RELAY

PROXIMITY SWITCHES

FUSE A4

820
REAR PROX SW

CRAB/4WS RELAY

822

2WS RELAY

STR MODE SW CRAB/4WS SOLENOID

823

4WS RELAY

11

007

106

845

FUSE B1
4WS SOLENOID

STEER MODE P.C.B.

12
826

13

4WS WRNG LGHT

824

14

From m/c no. 495455

3270 - C/19-5.1

CRAB SOLENOID

4WS/CRAB MODE SELECTOR

2WS/4WS MODE SELECTOR

2WS SOLENOID (SIDE CONSOLE)

15
CRAB WRNG LGHT

10

STEER MODE P.C.B.

16 17

825

15 - 15 - 03/5

Issue1

2WS WRNG LIGHTS

18

(FRONT CONSOLE)

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 03/6

3CX, 4CX and Variants Circuit Diagrams - Electrical Transmission And Steering
Manual Transmission
1 2 3 4 5 6 7 8 9 10 11 12 13 14 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

From m/c no. 495455

Steer Mode - 4CX and 3CX Super (4x4x4)


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 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

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

15 - 15 - 03/6

3270 - C/19-6.1

Issue 1

FROM 4 GEAR SELECTOR

1
858
TH

818

2
9 6

9804/1103
107
854

FUSE A5
10

CONTENTS CONTENTS

AUTO 2WD RELAY BRAKE LIGHTS SWITCH

AUTO 2WD RELAY

4 5

3
853
1

2WD/2WB 2WD/4WB 4WD/4WB SOLENOID 4 WB RELAY

126
2

933

BR MODE SW
922
5

3CX, 4CX and Variants

FUSE B6
877
3

FUSE A8 7
4WB RELAY

Circuit Diagrams - Electrical Options

LH BRAKE LIGHT RH BRAKE LIGHT

816

FUSE A7

ILLUNINATION
7 8

830
9 6

4WD SWITCH

FUSE A5
8 10
3

AUTO 2WD RELAY

922

Backhoe Loaders

15 - 15 - 03/7
107 AUTO 2WD RELAY
1 2

853

4WD SOLENOID

818 BRAKE LIGHTS SWITCH


3

877

4WB RELAY
5

FUSE A8
933 4WB RELAY

126

LH BRAKE LIGHT

FROM 4 GEAR SELECTOR

ILLUMINATION 7 8
829

1
858
TH

FUSE B6
816

FUSE A7

RH BRAKE LIGHT

5
JAW RELAY
3

1
875 873

874
1 4

JAW SOLENOID

FUSE A1
2
101

872

2
AUX HYD SWITCH

5 6

6 7

898 899
8

870
10

HAMMER SOLENOID

3
HAMMER RELAY

101

1830

HYDRACLAMP SWITCH

4
2 3

920

HYDRACLAMP SOLENOID
4 5

FUSE A4
109

SPEED SENSOR

SPEED SENSOR

974

FUSE C4
304

FUSE A5
107

SPEEDO

FUSE A10
830

From m/c no. 495455

3270 - C/19-8.1

15 - 15 - 03/7

Issue1

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 03/8

3CX, 4CX and Variants Circuit Diagrams - Electrical Options (contd)


2 Wheel Steer/Brake Mode
1 2 3 4 5 6 7 8 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

From m/c no. 495455

Auxiliary and Hydraclamp Hydraulics


1 2 3 4 5 6 7 8 9 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

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

Speedometer Option
1 2 3 Speed Sensor Speedometer Illumination

9804/1103

15 - 15 - 03/8

3270 - C/19-7.1

Issue 1

CONTENTS

Backhoe Loaders

15 - 15 - 03/9 From m/c no. 495455

3CX, 4CX and variants Circuit Diagrams - Electrical Options (contd) Auxiliary
4WD/AWB SOLENOID AUTO 2WD RELAY

4 WB RELAY

2WD/4WB

7
ROADBREAKER SOLENOID
932

QUICK-HITCH RELAY

3
853

QUICK-HITCH SOLENOID

2WD/2WB

4WD/4WB

2
7

931

AUTO 2WD RELAY

2 5
OPERATOR HOLD-IN SWITCHES

10

1855

930

972

877

107

854

801

ROADBREAKER SWITCH

BR MODE SW

3 FUSE A8

FUSE A5

2
858 114 929

QUICK-HITCH FEED SWITCH

933

1 FUSE B4 1
BRAKE LIGHTS SWITCH

101

114

FUSE A1

FUSE B4

126

801

ROTATION SOLENOID

HAND HELD TOOLS

GRAB SOLENOID

QUICK HITCH

A370070

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

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

Pole Planter 1 Selector Switch 2 Grab Solenoid 3 Rotation Solenoid

9804/1103

15 - 15 - 03/9

3270 - C/19-11.1

Issue 1

CONTENTS

Backhoe Loaders

15 - 15 - 03/10

3CX, 4CX and Variants Circuit Diagrams - Electrical Options (contd) Auxiliary (contd)
H.S.C. SOLENOID
ACCUMULATOR SOLENOIDS

From m/c no. 495455

3
6 10

867

H.S.C. RELAY

LEVER 'HOLD' SOLENOID

4
H.S.C. RELAY
4

2
844
9 7 8

CROWD RAM PROXIMITY SWITCH

2
1801 1851

H.S.C. SWITCH

1 6

SHOVEL RESET SWITCH

1
8 2

SRS SWITCH

1
8 2

1856

829

1857

866

865

H.S.C. BUTTON
101

830

829

FUSE A9

818

Smooth Ride System (SRS) 1 Selector Switch 2 Accumulator Solenoids

FUSE B7

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

9804/1103

15 - 15 - 03/10

FUSE A1

FROM 4 GEAR SELECTOR

132

132

TH

3270 - C/19-12.1

Issue 1

CONTENTS

Backhoe Loaders

15 - 15 - 03/11

3CX, 4CX and Variants Circuit Diagrams - Electrical Autoshift Transmission

From m/c no. 495455

A378770

9804/1103

15 - 15 - 03/11

3270 - C/19-9.1

Issue 1

CONTENTS

Backhoe Loaders

15 - 15 - 03/12

3CX, 4CX and Variants Circuit Diagrams - Electrical Autoshift Transmission (contd)
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 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

From m/c no. 495455

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 Circuit Diagrams - Electrical Servo Command Pilot Circuit
1
IGN SW
200V 1816 1808

From m/c no. 495455

D3

D4

FUSE 10A

FUSE 15A

FUSE 3A

12V +VE FEED

101AB

SERVO BUZZER
101

107
FROM TRANS DUMP RELAY

37
1808

931

844

D10

PUMP DUMP

R1
012

R7
MODE STAB
AUTO DUMP RELAY

1821
EXISTING +VE FEED TO HORN

1851

17 LH AMPLIFIER
3 2 1

7 4

S2

131

2
L2

5
8 3 6

830 1846 1840 1839


7 2 8 2 5

L1
8

S1
112

3 ENABLE
SWITCH
7 6 7

4
1809 1824

1857

934

RTD

1813
FUSE 1A

1805

S3

1804

10 FLOAT

TO AUTO ECU

AUX FEED

QUICK HITCH SWITCHES

SERVO

L3

SWEEPER BLOWER SWITCH

929

1826

FUSE 3A

921

1825

16 18
930

1827

1822

0.5k 0V 1V

4k 9V

0.5k 10V

1811

1814

D6

1806

FROM TACHO ILLUMINATION

AUX

D1

REAR HORN

11 RTD

TRANS DUMP

TO HSC RELAY

875

1805 1824

D7

14

16

D9

13

15
D8
6

D5

1812 1810
D2 D11

1833

1850

RH AMPLIFIER
3 2 1

19

7 4

R2

R3

R4

R5

1807

FUSE 3A

1807

HAMMER SOLENOID FEED


870 1844 870

PROPORTIONAL SWITCH. CLAM, AUX, RH STAB.

1843

1841

1823

12

PROPORTIONAL SWITCH. LH STAB, AUX.OPT.

934

20
0.5k 4k 1V 9V 0.5k 10V

R8

R9

R10

R12

R13

R14

R15

R16

R17

R18

R19

0V

1838 1834 1849 1807 947

1845

1832 1847

1829

1848

1836

959

957

954

958

953

L.STAB H T

L.STAB H B

R.STAB R T

R.STAB H B

1
21 22

2
23

3
24

4
H T B R

955

CLAM

CLAM

AUX EXT DIP

AUX EXT DIP R

FUSE 5A

FUSE 5A

1837

R20

R21

R22

R23

AUX OPTION

1802

1803

6
R

5
34
LH/RH PILOT PRESSURE VALVE

25
LOADER VALVE

26

27
AUX VALVE

28

29

30
EXCAVATOR VALVE

31

32

33

1828

35
AUX VALVE

36
GROUND

ARMS/BOOM CHANGEOVER VALVE

SHOVEL/BUCKET CHANGEOVER VALVE

LH PILOT PRESSURE VALVE

9804/1103

15 - 15 - 03/13

1831

AUX OPTION

960

956

1842

3270 - C/19-14.1

Issue1

CONTENTS CONTENTS

Backhoe Loaders

15 - 15 - 03/14

3CX, 4CX and Variants Circuit Diagrams - Electrical Servo Command Pilot Circuit (contd)
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 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

From m/c no. 495455

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

15 - 15 - 03/14

3270 - C/19-13.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 02/1

3CX, 4CX (200 Series) Circuit Diagrams - Hydraulic (Standard Machines)

From m/c no. 402174

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. 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.

9804/1103

15 - 20 - 02/1

Issue 3

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 02/2

3CX, 4CX (200 Series) Circuit Diagrams - Hydraulic

From m/c no. 402174

62A 35 62 4G T 6 33 31 4R 4A
E P

54 4

4X 4H
C2

61 58
P E

6A

C2

1B
T V2

4S S 3 66
T V2

4J 59 4K 65 65

4B P2 P1
C

3E 4T 25 3G 3D
V1 V

4L 64 56

52

55

51

3K 4C

V2

3F

4U 3J 4D
C2 E

61

V2

3C 4V 64 4M 4E 3M 3Q 3L 4W 4N 4P 4F 3N 3P 59 3H 57

26

P C2 E

V2

1A

66 13 2A 1A

34

32

3B

3A 36 7B
EF CF P

53 P2A
9808/9555-2

PP

9808/9555-2

9804/1103

15 - 20 - 02/2

15 - 20 - 02/2

Issue 3

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 02/3

ALL MODELS (EXCEPT 2CX) Circuit Diagrams - Hydraulic (Standard Machines)

From m/c no. 400001

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 V2 V1 4L C1 52 C2

Component Key 4 4S 4K 4L 4B 52 61 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)

A196780

'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. 3 Component Key 3L 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

1A 3M

3N 3P 3Q T

P2 P1
A197090

9804/1103

15 - 20 - 02/3

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 02/4

ALL MODELS (EXCEPT 2CX) Circuit Diagrams - Hydraulic (Standard Machines)

From m/c no. 400001

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 4 62 4G 4X

4R 4A

4H

A217690

9804/1103

15 - 20 - 02/4

Issue 3

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 02/5

ALL MODELS (EXCEPT 2CX) Circuit Diagrams - Hydraulic (Standard Machines)

From m/c no. 400001

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 10

43

(L)

(R)

42
(LS)

(T)

(P)

P2 P1 8
(P)

44 (T)

(CF) (LS) (A) (B)

(P)

7 P2A 12 11

9808/9510-3

9804/1103

15 - 20 - 02/5

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 02/6

ALL MODELS (EXCEPT 2CX) Circuit Diagrams - Hydraulic (Standard Machines)

From m/c no. 400001

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

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 02/7

3CX, 4CX Steer Hydraulics (4WS Machines)


System Type Hydraulic Supply Control Unit Type 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

From m/c no. 460001

Full Power Hydrostatic From Main Hydraulic Pump Via Priority Valve Load Sensing With Integral Relief Valve

160 OSPC 160 cc/rev Fitted Fitted Fitted 120 3 bar 175 - 190bar

122 3.5 kgf/cm2 178 - 199 kgf/cm2

1740 50 lbf/in2 2538 - 2756 lbf/in2

PRIORITY VALVE - FIG 2 Stand by Pressure

7 bar

7.1 kgf/cm2

102 lbf/in2

LS

EF

P
LS

LS

FIG 1

FIG 2

9804/1103

15 - 20 - 02/7

3270 - H/1-1.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 02/8

3CX, 4CX Steer Hydraulics (2WS Machines)


System Type Hydraulic Supply Control Unit Type 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)

From m/c no. 460001

Full Power Hydrostatic From Main Hydraulic Pump Via Priority Valve Load Sensing With Integral Relief Valve

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

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

PRIORITY VALVE - FIG 2 Stand by Pressure

7 bar

7.1 kgf/cm2

102 lbf/in2

LS

EF

P
LS

LS

FIG 1

FIG 2

9804/1103

15 - 20 - 02/8

3270 - H/1-2.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 03/1

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 11 12 12A 12B 12C 12D 12E 12F 13 14 15 16 17 18

From m/c no. 400001 to 420484

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 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

9804/1103

15 - 20 - 03/1

Issue 2

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 03/2

ALL MODELS (EXCEPT 2CX) Circuit Diagrams - Hydraulic (Servo Machines)


31 10 40 33 37 3 35 3H 39 3M 9B 3H 9A 3F 3E 3L 4D 3J 3H 3G 3G 3K
LS L LS

From m/c no. 400001 to 420485

16

4D 36 4C 4W 48

15

38

4D 17 4T

4C

44

46 4R 4E 4S 45

8A

3J 8B
P P T LS EF

4H 41 4Z 4J

42

43

34

3C

32 3D

3B
CF

P2A
P

4D 4N 4G 4P 4Q

18 18 47

3A 30 T TA
LS

14

4D 4K 4G 5
P

HPCO

4L

4M

5C 6 5A P1 5B
T

12F 4X 4A 4B P1A 12E 4


MA P

S P2

12D 2 11 12A 1A

12C 49

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) Circuit Diagrams - Hydraulic (Servo Machines)


31 10 40 33 37 3 35
B A

From m/c no. 420486

LS

4D 36 3H 39 3M 9B
B

15 48

4X 4C
B

38

4W 4D
A

17 44

3H 3F 9A 3L

4C

4U

4V

4D 3E
B

4T
A

46

3J 3H

8A 4R 4E 4S 45

3G 3G

3K
LS

3J 8B
P P T LS EF

4H 41 4Z 4J
B A

42

43

34

3C

32 3D

3B
CF

P2A
P

4D 4N 4G 4P 4Q

18 18 47

3A 30 T TA
LS

7
B A

14

4D 4K 4G 5
P

HPCO

4L

4M

5C 6 5A P1 5B
T

12F 4Y

S P2

4B P1A 12E 4
MA P

12D 2 11 12A 1A

12C 49

12B
P

13 50

12

A245980

9804/1103

15 - 20 - 03/3

15 - 20 - 03/3

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 03/4

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 8 8A 8B 9 9A 9B 10 11 12 12A 12B 12C 12D 12E 12F 13 14 15 17 18

From m/c no. 420486

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)

Rams 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

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.

9804/1103

15 - 20 - 03/4

Issue 1

CONTENTS CONTENTS

Backhoe Loaders
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

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


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 M MM

67 11

68
MM

EXTENDING DIPPER

15 - 20 - 04/1

3270 - E/6-1.4

Issue 2*

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 04/2

3CX, 4CX, 214, 215, 217, S Series Circuit Diagrams - Hydraulic (contd)

From m/c no. 460001

C 31

35 1B 4 T 62 4G 33 4H 40 S 3 3E 3F P2 P1 3J 34
P1 P2

54

6 6A 6B

4A 4J 4B 38 4C 4D 43 55 4M 4N 59 4F
JJ

59 4K 4L

65 56

39

52

3D 3G 3C 3B 3Q 3M 3L 16 3N 8 32 36 P2A 3J 3A

41

66

57 51
JJ

15

42 44

4E

2A 26
T ACC

4P 7 10 12 9 14 11

53

13

1A
M

5A

5B 5C

9804/1103

15 - 20 - 04/2

3270 - E/6-2.6

Issue 3*

CONTENTS

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 04/3

3CXE (214E Series 3) Circuit Diagram - Hydraulic (contd)

From m/c no. 460001

Component Key
A B C D E F G H J 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 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 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 CONTENTS

9804/1103

15 - 20 - 04/3

3270 - E/7-1.2

Issue 3*

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 04/4

214e Series 4 only Circuit Diagram - Hydraulic


GG

From m/c no. 460001

P F A

NEUTRAL CIRCUIT H.P.C.O.

EE B DD
SLEW

SHOVEL

J4 F

2WS FRONT POWER TRACK ROD


BOOM

ENGINE

Y D
LOADER

Y Z

J3
L R

STABILISER

BB N
AUX

CC

J2

STABILISER

AA Z Y

C
P
MRV

LS

DIPPER

J1

J
EF CF

LS P

Q
PP

BUCKET

H E

FF

EE
H.P.C.O.

W F P L
NEUTRAL CIRCUIT / TANK RETURN
B A

HAMMERMASTER 260L

HAMMERMASTER 280

HAMMERMASTER 360

M
HAMMER RETURN HAMMER FEED

Component Key A B C D E F G H J J1 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 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

9804/1103

15 - 20 - 04/4

3270 - E/7-2.2

Issue 2*

CONTENTS

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 04/4A

214 Se Series 4 Only Circuit Diagrams - Hydraulic


NEUTRAL CIRCUIT H.P.C.O.

From m/c no. 460001

GG

P F A 2 S1 H 4
SHOVEL

EE
SLEW

DD

J4
L R

S2

BOOM

ENGINE

D
LOADER

3 J3 S3
STABILISER

Y Z BB CC HH

N
AUX

J2

S4

STABILISER

AA Z Y

C
P
MRV

LS

S5

DIPPER

J1

J
EF CF

LS P

L H E

Q
PP

J4 FF

BUCKET

EE
H.P.C.O.

W F P L
NEUTRAL CIRCUIT / TANK RETURN
B A

HAMMERMASTER 260L

HAMMERMASTER 280

HAMMERMASTER 360

M
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

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

15 - 20 - 04/4A

3270 - E/6-9.1

Issue 1

CONTENTS

Backhoe Loaders

15 - 20 - 04/5

3CX, 4CX Circuit Diagrams - Hydraulic 3CX S Series & 4CX Gear Pump 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. Component Key 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

From m/c no. 460001

3CX S Series Options


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 HPCO 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 11 10 HPCO 76

77 11

HPCO

76

72 M 74 T
M

72 74 T

73

73

9804/1103

15 - 20 - 04/5

3270 - E/6-3.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 04/6

3CX S Series 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

From m/c no. 460001

69

77 11

HPCO

76 T
M M

9804/1103

15 - 20 - 04/6

3270 - E/6-4.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

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 7 P 3 B S 5 4 L L1 47 16 P T 16 43 T 17 P PRLS 1 10 PR 17 21 22 12 B A 19 18 13 B A 24 T ACC 23 14 22 21 20 P1 P2 B A LS 16A 19 18 17 16 17 15 16 18 41 34 B A 15 17 15 18 B A 17 32 B A 40 33 39 17 18 44 19 18 17 31 B A 38 17 11 LS T 9 15 28 18 37 30 15 18 B A 29 B 36 A 17 6 46 LS 28 18 48 T P B A 15A 51 52 15 27 B A 53 P T T LS 25 P 50 54

8 L R 45 17

26 18

49

2 20

9804/1103

15 - 20 - 04/7

3270 - E/7-10.3

Issue1

CONTENTS CONTENTS

Backhoe Loaders

15 - 20 - 04/8

4CXE, 4CX Super - Variable Flow Hydraulics (7 - Spool with High Flow Options) Circuit Diagrams - Hydraulic 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 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

From m/c no. 460001

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.

9804/1103

15 - 20 - 04/8

3270 - E/7-11.3

Issue 1

CONTENTS

Backhoe Loaders

15 - 20 - 04/9

4CXE, 4CX Super - Variable Flow Hydraulics (6 - Spool with High/Low Flow Options) Circuit Diagrams - Hydraulic 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

From m/c no. 460001

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.

9804/1103

15 - 20 - 04/9

3270 - E/7-12.1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

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 P 3 B S 5 4 L L1 47 16 P T 16 43 T 17 P PRLS 1 10 PR 17 21 22 12 B A 19 18 13 B A 24 T ACC 23 14 22 21 20 P1 P2 B A LS 16A 19 18 17 16 17 15 16 18 41 34 B A 15 17 15 18 B A 17 32 B A 40 33 39 17 18 44 19 18 17 31 B A 38 17 11 LS T 9 15 28 18 37 30 15 18 B A 29 B 36 A X 6 46 LS 28 17 18 48 T P B A T LS P 25 P T 50 54 8 L R 45 55 49

2 20

9804/1103

15 - 20 - 04/10

3270 - E/7-13.1

Issue1

CONTENTS

Backhoe Loaders

15 - 20 - 04/11

4CXE, 4CX Super - Variable Flow Hydraulics Circuit Diagrams - Hydraulic Hand Held Tools Option

From m/c no. 460001

X
1

2
LS

9
LS

25
LS

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

CONTENTS CONTENTS

Backhoe Loaders

15 - 25 - 01/1

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

From m/c no. 400001

1 4 3

6 5

8
A198310

9804/1103

15 - 25 - 01/1

Issue 1

CONTENTS CONTENTS

Backhoe Loaders

15 - 25 - 02/1

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

From m/c no. 400001

7 12 4 3

11 6 5

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 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 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 20 - 05 - 01/1 20 - 05 - 01/2 20 - 05 - 01/3

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. 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

20 - 05 - 01/6 20 - 05 - 01/6 20 - 05 - 01/7 20 - 05 - 01/8 20 - 05 - 01/8 20 - 05 - 01/9

9804/1103

Loadall Contents - 1

Issue 6*

INDEX

Loadalls

Contents ii

ALL MODELS Contents (continued)


Page No. Data - Electrical (contd) 520-55, 526-55, 526, 526S (526 N.Am) From m/c no. 279000 to 280299 Relay Identification Fuse Identification 526, 526S (526N. Am) Relay Identification Fuse Identification 530, 535, 540 From m/c no 767001 Relay Identification Fuse Identification * 532, 537, 540-170, 550, 5508 From m/c no. 767001 Relay Identification Fuse Identification Fuse Links 528-70 Syncro Shuttle Transmission From m/c no. 796000 Fuse and Relay Identification 528S From m/c 796102 Relay Identification Fuse Identification 528-70, 528S From m/c no. 796000 Fuse Links 506B, 506C, 506C(HL), 508C Relay Identification Fuse Identification 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

20 - 05 - 01/10 20 - 05 - 01/12

20 - 05 - 01/11 20 - 05 - 01/13

20 - 05 - 01/14 ,14A, 14B,15, 15A 20 - 05 - 01/16

20 - 05 - 01/17, 18, 18A, 18B, 20 - 05 - 01/19 20 - 05 - 01/19

20 - 05 - 01/20, 23

20 - 05 - 01/21 20 - 05 - 01/22

20-05-01/23

20 - 05 - 01/24 20 - 05 - 01/25

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*

Loadall Contents - 2

INDEX

Loadalls

Contents iii

ALL MODELS Contents (continued)

- 506B, 506C, 506C (HL), 508C * 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 Data-Tyres - All models, except 530, 532, 535, 537, 540, 550 - 530, 532, 535, 537, 550, 540 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 - 03/5 Page No. 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

20 - 05 - 04A/1 20 - 05 - 04A/4

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 * 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

9804/1103

Loadall Contents - 5

Issue 3*

CONTENTS

Loadalls
525-67, 527-58, 527-67, 530-95

20 - 00 - 01/1

* 525-58,

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) 90 (20) 10 (2.2) FLUID/LUBRICANT INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104 SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE ASTM D3306-74

Fuel Tank Engine (Oil)

Diesel Oil (See Types of Fuel) JCB 15W/40 Multigrade -10 C to 50 C (14 F to 122 F) 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)

Engine (Coolant)

17 (3.7)

JCB Universal Antifreeze/water ( See Coolant Mixtures)

Gearbox Syncro Shuttle * Powershift Front Axle Housing Hubs (x2) Rear Axle Housing Hubs (x2) Brake System

18.25 (4.0) 15.0 (3.3)

JCB Special Transmission Fluid JCB Special Transmission Fluid

ESP-M2C 33G ESP-M2C 33G

18 (3.9) 2.0 (0.4)

JCB Special Gear Oil JCB Special Gear Oil

ESEN-M2C 86A/B ESEN-M2C 86A/B

13 (2.8) 2.0 (0.4)

JCB Special Gear Oil JCB Special Gear Oil JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID

ESEN-M2C 86A/B ESEN-M2C 86A/B ISO VG15

* Hydraulic System

152 (33.5)

JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Special Hydraulic Fluid (Below 38 C, 100 F) JCB Special MPL Grease JCB Waxoyl JCB Special Slide Lubricant

ISO VG46 ISO VG32

Grease Points Wear Pad Runways Boom Hoses

Lithium based, No. 2 consistency

* 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 % 55 Antifreeze 9.35 litres (2.04 gal) Starts to Freeze -36 C (-33 F)

9804/1103

20 - 00 - 01/1

Issue 3*

CONTENTS

Loadalls

20 - 00 - 01/2

530-110 Fluids, Lubricants and Capacities

From m/c no. 567362

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) 90 (20) 10 (2.2) FLUID/LUBRICANT INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104 SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE ASTM D3306-74

Fuel Tank Engine (Oil)

Diesel Oil (See Types of Fuel) JCB 15W/40 Multigrade -10 C to 50 C (14 F to 122 F) 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)

Engine (Coolant)

18 (3.9)

JCB Universal Antifreeze/water ( See Coolant Mixtures) JCB Special Transmission Fluid

Syncro Shuttle Front Axle Housing Hubs (x2) Rear Axle Housing Hubs (x2) Brake System

18.25 (4.0)

ESP-M2C 33G

18 (3.9) 2.0 (0.4)

JCB Special Gear Oil JCB Special Gear Oil

ESEN-M2C 86A/B ESEN-M2C 86A/B

13 (2.8) 2.0 (0.4)

JCB Special Gear Oil JCB Special Gear Oil JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID

ESEN-M2C 86A/B ESEN-M2C 86A/B ISO VG15

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) JCB Special MPL Grease JCB Waxoyl JCB Special Slide Lubricant

ISO VG46 ISO 32 ISO VG15

Grease Points Wear Pad Runways Boom Hoses

Lithium based, No. 2 consistency

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 % 55 Antifreeze 10 litres (2.2 gal) Starts to Freeze -36 C (-33 F)

9804/1103

20 - 00 - 01/2

Issue 2

CONTENTS

Loadalls

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) 90 (20) 10 (2.2) FLUID/LUBRICANT INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40 API CF4/SG (ACEA E2:B2:A2) SAE10W/30 API CF4/SG (ACEA E2:B2:A2) ASTM D3306-74

Fuel Tank Engine (Oil)

Diesel Oil (See Types of Fuel) JCB High Performance Engine oil -10C to 50C (14F to 122F) JCB High Performance Engine oil -15 C to 30 C (5 F to 86 F)

Engine (Coolant) 55% Concentration

18 (3.9) 10 (2.2)

JCB Four Seasons Antifreeze/water And Summer Coolant (See Coolant Mixtures) JCB High Performance Transmission Fluid

Syncro Shuttle

18.25 (4.0)

JCB 4000/0900 Friction modified oils MUST NOT be used (eg. Dexron ATF type).

Front Axle Housing Hubs (x2) Rear Axle Housing Hubs (x2) Brake System

18 (3.9) 2.0 (0.4)

JCB High Performance Gear Oil Plus

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 DO NOT USE ORDINARY BRAKE FLUID ISO VG15

Hydraulic Tank

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) JCB HP Grease

ISO VG46 ISO VG32

Grease Points

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 Boom Hoses

JCB Waxoyl JCB Special Slide Lubricant

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

CONTENTS

Loadalls
537-120 & 537-130

20 - 00 - 01/3

* 530-120,

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) 90 (20) 10 (2.2) FLUID/LUBRICANT INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104 SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE ASTM D3306-74

Fuel Tank Engine (Oil)

Diesel Oil (See Types of Fuel) JCB 15W/40 Multigrade -10 C to 50 C (14 F to 122 F) 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)

Engine (Coolant)

23.5 (5.2)

JCB Universal Antifreeze/water ( See Coolant Mixtures) JCB Special Transmission Fluid

Syncro Shuttle Front Axle Housing Hubs (x2) Rear Axle Housing Hubs (x2) Brake System

18.25 (4.0)

ESP-M2C 33G

17 (3.7) 2.0 (0.4)

JCB Special Gear Oil JCB Special Gear Oil

ESEN-M2C 86A/B ESEN-M2C 86A/B

18 (3.9) 0.75 (0.16)

JCB Special Gear Oil JCB Special Gear Oil JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID

ESEN-M2C 86A/B ESEN-M2C 86A/B ISO VG15

Hydraulic System

292 (64.3)

JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB HP32 (Below 38 C, 100 F) JCB Special MPL Grease JCB Waxoyl JCB Special Slide Lubricant

ISO VG46 ISO 32

Grease Points Wear Pad Runways Boom Hoses

Lithium based, No. 2 consistency

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 % 55 Antifreeze 12.92 litres (2.84 gal) Starts to Freeze -36 C (-33 F)

9804/1103

20 - 00 - 01/3

Issue 3*

CONTENTS

Loadalls

20 - 00 - 01/4

505-19, 505-22 Fluids, Lubricants and Capacities

From m/c no. 567362

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) 24.8 (93) 2.6 (10) FLUID/LUBRICANT INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104 SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE ASTM D3306-74

Fuel Tank Engine (Oil)

Diesel Oil (See Types of Fuel) JCB 15W/40 Multigrade -10 C to 50 C (14 F to 122 F) 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)

Engine (Coolant)

4.4 (17)

JCB Universal Antifreeze/water (See Coolant Mixtures) JCB Special Transmission Fluid

Syncro Shuttle Front Axle Housing Hubs (x2) Rear Axle Housing Hubs (x2) Brake System

5.7 (22)

ESP-M2C 33G

4.7 (18) 0.6 (2.0)

JCB Special Gear Oil JCB Special Gear Oil

ESEN-M2C 86A/B ESEN-M2C 86A/B

3.4 (13) 0.5 (2.0)

JCB Special Gear Oil JCB Special Gear Oil JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID

ESEN-M2C 86A/B ESEN-M2C 86A/B ISO VG15

Hydraulic System

28.8 (110)

JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB HP32 (Below 38 C, 100 F) JCB Special MPL Grease JCB Waxoyl JCB Special Slide Lubricant

ISO VG46 ISO 32

Grease Points Wear Pad Runways Boom Hoses

Lithium based, No. 2 consistency

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 % 55 Antifreeze 2.45 gal (9.35 liters) Starts to Freeze -22 F (-36 C)

9804/1103

20 - 00 - 01/4

Issue 2

CONTENTS

Loadalls

20 - 00 - 01/5

506-36 Fluids, Lubricants and Capacities

From m/c no. 567362

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) 23.7 (90) 2.6 (10) FLUID/LUBRICANT INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104 SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE ASTM D3306-74

Fuel Tank Engine (Oil)

Diesel Oil (See Types of Fuel) JCB 15W/40 Multigrade -10 C to 50 C (14 F to 122 F) 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)

Engine (Coolant)

4.7 (18)

JCB Universal Antifreeze/water (See Coolant Mixtures) JCB Special Transmission Fluid

Syncro Shuttle Front Axle Housing Hubs (x2) Rear Axle Housing Hubs (x2) Brake System

4.8 (18.25)

ESP-M2C 33G

4.7 (18) 0.5 (2.0)

JCB Special Gear Oil JCB Special Gear Oil

ESEN-M2C 86A/B ESEN-M2C 86A/B

3.4 (13) 0.5 (2.0)

JCB Special Gear Oil JCB Special Gear Oil JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID

ESEN-M2C 86A/B ESEN-M2C 86A/B ISO VG15

Hydraulic System

50.2 (190)

JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB HP32 (Below 38 C, 100 F) JCB Special MPL Grease JCB Waxoyl JCB Special Slide Lubricant

ISO VG46 ISO 32

Grease Points Wear Pad Runways Boom Hoses

Lithium based, No. 2 consistency

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 % 55 Antifreeze 2.6 gal (10 liters) Starts to Freeze -22 F (-36 C)

9804/1103

20 - 00 - 01/5

Issue 2

CONTENTS

Loadalls

20 - 00 - 01/6

508-40, 510-40 Fluids, Lubricants and Capacities

From m/c no. 567362

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) 23.7 (90) 2.6 (10) FLUID/LUBRICANT INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104 SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE ASTM D3306-74

Fuel Tank Engine (Oil)

Diesel Oil (See Types of Fuel) JCB 15W/40 Multigrade -10 C to 50 C (14 F to 122 F) 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)

Engine (Coolant)

6.2 (23.5)

JCB Universal Antifreeze/water (See Coolant Mixtures) JCB Special Transmission Fluid

Syncro Shuttle Front Axle Housing Hubs (x2) Rear Axle Housing Hubs (x2) Brake System

4.8 (18.25)

ESP-M2C 33G

4.5 (17) 0.5 (2.0)

JCB Special Gear Oil JCB Special Gear Oil

ESEN-M2C 86A/B ESEN-M2C 86A/B

4.7 (18) 0.2 (0.75)

JCB Special Gear Oil JCB Special Gear Oil JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID

ESEN-M2C 86A/B ESEN-M2C 86A/B ISO VG15

Hydraulic System

77.0 (292)

JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB HP32 (Below 38 C, 100 F) JCB Special MPL Grease JCB Waxoyl JCB Special Slide Lubricant

ISO VG46 ISO 32

Grease Points Wear Pad Runways Boom Hoses

Lithium based, No. 2 consistency

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 % 55 Antifreeze 3.4 gal (12.92 liters) Starts to Freeze -22 F (-36 C)

9804/1103

20 - 00 - 01/6

Issue 2

CONTENTS

Loadalls

20 - 00 - 01/7

525-58 FS Plus, 530-67, 535-67 Fluids, Lubricants and Capacities

From m/c no. 567362

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) 90 (20) 10 (2.2) FLUID/LUBRICANT INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104 SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE ASTM D3306-74

Fuel Tank Engine (Oil)

Diesel Oil (See Types of Fuel) JCB 15W/40 Multigrade -10 C to 50 C (14 F to 122 F) 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)

Engine (Coolant)

17 (3.7)

JCB Universal Antifreeze/water ( See Coolant Mixtures)

Gearbox Syncro Shuttle Powershift Front Axle Housing Hubs (x2) Rear Axle Housing Hubs (x2) Brake System

18.25 (4.0) 15.0 (3.3)

JCB Special Transmission Fluid JCB Special Transmission Fluid

ESP-M2C 33G ESP-M2C 33G

18 (3.9) 2.0 (0.4)

JCB Special Gear Oil JCB Special Gear Oil

ESEN-M2C 86A/B ESEN-M2C 86A/B

13 (2.8) 2.0 (0.4)

JCB Special Gear Oil JCB Special Gear Oil JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID

ESEN-M2C 86A/B ESEN-M2C 86A/B ISO VG15

Hydraulic Tank

152 (34.5)

JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Special Hydraulic Fluid (Below 38 C, 100 F) JCB Special MPL Grease JCB Waxoyl JCB Special Slide Lubricant

ISO VG46 ISO VG32

Grease Points Wear Pad Runways Boom Hoses

Lithium based, No. 2 consistency

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 % 55 Antifreeze 9.35 litres (2.04 gal) Starts to Freeze -36 C (-33 F)

9804/1103

20 - 00 - 01/7

Issue 2

CONTENTS

Loadalls

20 - 00 - 01/8

520-55 RS 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 * Fuel Tank Up to serial No. 279000 From serial No. 279001 * Engine (Oil) CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal 120 160 10 26.4 35.2 2.2 31.7 42.2 Diesel Oil (See Types of Fuel) JCB High Performance Engine Oil -10 C to 50 C (14 F to 122 F) 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) 2.6 NORTH AMERICA JCB 15W/40 Engine Oil 14F to 122F (-10C to 50C) JCB 10W Engine Oil -4F to 50 F (-20C to 10C) * Engine (Coolant) 55% Antifreeze 20 11 4.4 2.4 JCB Four Seasons Antifreeze And Summer Coolant Starts to freeze -36 C (-33 F) 5.3 2.9 * Syncro Shuttle Transmission * Front Axle Housing Hubs (x2) * Rear Axle Housing Hubs (x2) * Hydraulic Tank (1) Up to serial No. 279000 From serial No. 279001 17 3.7 4.5 NORTH AMERICA Permanent Antifreeze Starts to freeze -33 F (-36 C) JCB High Performance Transmission Fluid JCB High performance Gear Oil Plus INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40 API CF4/SG (ACEA E2:B2:A2) SAE10W/30 API CD/SF SAE10W API CD/SF SAE 15W/40 API CF4/SG SAE 10W API CF4/SG ASTM D3306-74

ASTM D3306-74 JCB: 4000/0900 Friction modified oils MUST NOT be used (eg Dexron ATF type). JCB: 4000/2200 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).

9.7 0.6

2.1 0.1

2.5 0.16

5.0 1.5 100 110

1.1 0.3 22.0 24.2

1.3 0.4 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 26.4 29.0 NORTH AMERICA (All Machines) JCB Hydraulic Fluid JCB HP Grease JCB Special MPL-EP Grease ISO VG46 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.

Up to serial No. 279000 From serial No. 279001 * Grease Points (2)

* Wear Pad Runways * Boom Hoses * Note 1: * Note 2:

JCB Waxoyl JCB Special Slide Lubricant

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. 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 * Fuel Tank Up to serial No. 279000 From serial No. 279001 * Engine (Oil) CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal 120 160 10 26.4 35.2 2.2 31.7 42.2 Diesel Oil (See Types of Fuel) JCB High Performance Engine Oil -10 C to 50 C (14 F to 122 F) JCB Super Universal -15 C to 30 C (5 F to 86 F) JCB Torque Converter Fluid -18 C to 0 C (0 F to 32 F) 2.6 NORTH AMERICA JCB 15W/40 Engine Oil 14F to 122F (-10C to 50C) JCB 10W Engine Oil -4F to 50 F (-20C to 10C) * Engine (Coolant) 55% Antifreeze 20 11 4.4 2.4 JCB Four Seasons Antifreeze And Summer Coolant Starts to freeze -36 C (-33 F) 5.3 2.9 * Syncro Shuttle Transmission * Front Axle Housing Hubs (x2) * Rear Axle Housing Hubs (x2) * Hydraulic Tank (1) Up to serial No. 279000 From serial No. 279001 17 3.7 4.5 NORTH AMERICA Permanent Antifreeze Starts to freeze -33 F (-36 C) JCB High Performance Transmission Fluid JCB High performance Gear Oil Plus SAE10W API CD/SF SAE 15W/40 API CF4/SG SAE 10W API CF4/SG ASTM D3306-74 INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40 API CF4/SG (ACEA E2:B2:A2) SAE10W/30 Agricultural API CD/SF

ASTM D3306-74 JCB: 4000/0900 Friction modified oils MUST NOT be used (eg Dexron ATF type). JCB: 4000/2200 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).

5.5 1.5

1.2 0.3

1.4 0.4

5.0 1.5 100 110

1.1 0.3 22.0 24.2

1.3 0.4 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 26.4 29.0 NORTH AMERICA (All Machines) JCB Hydraulic Fluid JCB HP Grease JCB Special MPL-EP Grease ISO VG46 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.

Up to serial No. 279000 From serial No. 279001 * Grease Points (2)

* Wear Pad Runways * Boom Hoses * Note 1: * Note 2:

JCB Waxoyl JCB Special Slide Lubricant

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.

9804/1103

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 Fuel Tank 160 Engine (Oil) 10 35.2 2.2 42.2 Diesel Oil (See Types of Fuel) JCB High Performance Engine Oil -10 C to 50 C (14 F to 122 F) JCB High Performance Engine Oil ASTM D975-66T Nos. 1D, 2D SAE15W/40 API CF4/SG (ACEA E2:B2:A2) SAE10W/30 -15 C to 40 C (5 F to 104 F) API CF4/SG (ACEA E2:B2:A2) SAE 15W/40 API CF4/SG SAE 10W API CF4/SG ASTM D3306-74 CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal INTERNATIONAL SPECIFICATION

2.6

NORTH AMERICA JCB 15W/40 Engine Oil 14F to 122F (-10C to 50C) JCB 10W Engine Oil -4F to 50 F (-20C to 10C)

Engine (Coolant) 55% Antifreeze

20 11

4.4 2.4

JCB Four Seasons Antifreeze And Summer Coolant Starts to freeze -36 C (-33 F) 5.3 2.9 NORTH AMERICA Permanent Antifreeze Starts to freeze -33 F (-36 C) JCB High Performance Transmission Fluid JCB High Performance Gear Oil Plus

ASTM D3306-74 JCB 4000/0900 Friction modified oils MUST NOT be used (eg Dexron ATF type). JCB 4000/2200 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).

Syncro Shuttle Transmission Front Axle Housing Hubs (x2) Rear Axle Housing Hubs (x2) Hydraulic Tank (1)

17

3.7

4.5

5.5 1.5 5.0 1.5 110

1.2 0.3 1.1 0.3 24.2

1.4 0.4 1.3 0.4

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 29.0 NORTH AMERICA (All Machines) JCB Hydraulic Fluid JCB HP Grease JCB Special MPL-EP Grease

ISO VG46 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.

Grease Points (2)

Wear Pad Runways Boom Hoses * Note 1: * Note 2:

JCB Waxoyl JCB Special Slide Lubrican

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.

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 Fuel Tank Up to serial No. 279000 From serial No. 279001 Engine (Oil) CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal 120 160 10 26.4 35.2 2.2 31.7 42.2 Diesel Oil (See Types of Fuel) JCB High Performance Engine Oil -10 C to 50 C (14 F to 122 F) JCB Super Universal Agricultural -15 C to 30 C (5 F to 86 F) API CD/SF JCB Torque Converter Fluid -18 C to 0 C (0 F to 32 F) 2.6 NORTH AMERICA JCB 15W/40 Engine Oil 14F to 122F (-10C to 50C) JCB 10W Engine Oil -4F to 50 F (-20C to 10C) Engine (Coolant) 55% Antifreeze 20 11 4.4 2.4 JCB Four Seasons Antifreeze And Summer Coolant Starts to freeze -36 C (-33 F) 5.3 2.9 Syncro Shuttle Transmission Front Axle Housing Hubs (x2) Rear Axle Housing Hubs (x2) Brake System From serial No. 280300 Hydraulic Tank (1) Up to serial No. 279000 From serial No. 279001 100 110 22.0 24.2 17 3.7 4.5 NORTH AMERICA Permanent Antifreeze Starts to freeze -33 F (-36 C) JCB High Performance Transmission Fluid JCB High performance Gear Oil Plus SAE10W API CD/SF SAE 15W/40 API CF4/SG SAE 10W API CF4/SG ASTM D3306-74 INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40 API CF4/SG (ACEA E2:B2:A2) SAE10W/30

ASTM D3306-74

Fr us

JCB 4000/0900 Friction modified oils MUST NOT be used (eg Dexron ATF type). JCB 4000/2200 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).

9 2 8.4 2

1.98 0.44 1.85 0.44

2.4 0.5 2.2 0.5

JCB Light Hydraulic Fluid Do not use ordinary brake fluid 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 26.1 29.0 NORTH AMERICA (All Machines) JCB Hydraulic Fluid JCB HP Grease JCB Special MPL-EP Grease

ISO VG15 ISO VG46 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.

Up to serial No. 279000 From serial No. 279001 Grease Points (2)

Wear Pad Runways Boom Hoses * Note 1: * Note 2:


9804/1103

JCB Waxoyl JCB Special Slide Lubricant

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 Fuel Tank 160 Engine (Oil) 10 35.2 2.2 42.2 Diesel Oil (See Types of Fuel) JCB High Performance Engine Oil -10 C to 50 C (14 F to 122 F) JCB High Performance Engine Oil ASTM D975-66T Nos. 1D, 2D SAE15W/40 API CF4/SG (ACEA E2:B2:A2) SAE10W/30 -15 C to 40 C (5 F to 104 F) API CF4/SG (ACEA E2:B2:A2) SAE 15W/40 API CF4/SG SAE 10W API CF4/SG ASTM D3306-74 CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal INTERNATIONAL SPECIFICATION

2.6

NORTH AMERICA JCB 15W/40 Engine Oil 14F to 122F (-10C to 50C) JCB 10W Engine Oil -4F to 50 F (-20C to 10C)

Engine (Coolant) 55% Antifreeze

20 11

4.4 2.4

JCB Four Seasons Antifreeze And Summer Coolant Starts to freeze -36 C (-33 F) 5.3 2.9 NORTH AMERICA Permanent Antifreeze Starts to freeze -33 F (-36 C) JCB High Performance Transmission Fluid JCB High Performance Gear Oil Plus

ASTM D3306-74 JCB 4000/0900 Friction modified oils MUST NOT be used (eg Dexron ATF type). JCB 4000/2200 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).

Syncro Shuttle Transmission Front Axle Housing Hubs (x2) Rear Axle Housing Hubs (x2) Hydraulic Tank (1)

17

3.7

4.5

9.0 2.0 8.4 2.0 110

1.98 0.44 1.85 0.44 24.2

2.4 0.5 2.2 0.5

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 29.0 NORTH AMERICA (All Machines) JCB Hydraulic Fluid JCB HP Grease JCB Special MPL-EP Grease

ISO VG46 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.

Grease Points (2)

Wear Pad Runways Boom Hoses * Note 1: * Note 2:

JCB Waxoyl JCB Special Slide Lubricant

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.

9804/1103

20 - 00 - 01/10A

3610 - 3/1-6.2

Issue 2*

CONTENTS

Loadalls
*

20 - 00 - 01/11

* 520-50

(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 * * Fuel Tank * Engine (Oil) CAPACITY FLUID/LUBRICANT US Gal (Liters) 23.8 (90) 2.6 (10) Diesel Oil (See Types of Fuel) JCB 15W/40 Engine Oil - 14 F to 122 F (10 C to 50 C) JCB 10W Engine Oil - 5 F to 86 F(15 C to 30 C) * Engine (Coolant) 55% Antifreeze * Gearbox 5.3 (20) 2.9 (11) 4.6 (17.5) JCB Universal Antifreeze/water Starts to freeze -33 F (-36 C) JCB Special Transmission Fluid INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40, API CF4/SG SAE10W/30, API CF4/SG ASTM D3306-74

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). ISO VG46 ISO VG32

* Hydraulic Tank

18.5 (70)

JCB High Performance Hydraulic Oil (Above 100 F, 38 C) JCB Special Hydraulic Fluid (Below 100 F, 38 C) JCB HP Grease JCB Waxoyl

* Grease Points * Wear Pad Runways

Lithium based, No. 2 consistency

* 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*

CONTENTS

Loadalls

20 - 00 - 01/12

528-70, 528S Fluids, Lubricants and Capacities


ITEM CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal

From m/c no. 796000

INTERNATIONAL SPECIFICATION

Fuel Tank 160 Engine (Oil) 10 35.2 2.2 42.2 Diesel Oil (See Types of Fuel) JCB Super 15W/40 Multigrade -10C to 50C (14F to 122F) JCB Super 10W/30 Multigrade -15C to 40C (5F to 104F) Engine (Coolant) 55% Antifreeze 20 11 4.4 2.4 JCB Four Seasons Antifreeze & Summer Coolant Starts to freeze -36 C (-33 F) 4.5 JCB Special Transmission Fluid ASTM D975-66T Nos. 1D, 2D SAE15W/40 API CF4/SG SAE10W/30 API CF4/SG ASTM D3306-74

Transmission Syncro Shuttle & Powershift Front Axle Housing Hubs (x2)

17

3.7

JCB 4000/0900 Friction modified oils MUST NOT be used (eg Dexron ATF type). JCB 4000/2200 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).

9 2

1.98 0.44

2.4 0.5

JCB High Performance Gear Oil Plus

Rear Axle Housing Hubs (x2) Hydraulic Tank

8.4 2 110

1.85 0.44 24.2

2.2 0.5

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

ISO VG32

Grease Points

JCB HP Grease

JCB Special MPL-EP Grease

Lithium complex NLGI No. 2 consistency including extreme pressure additives. Lithium based NGLI No. 2 consistency including extreme pressure additives.

Wear Pad Runways Boom Hoses

JCB Waxoyl JCB Special Slide Lubricant

Note: Note:

This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check 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 FIFTY (50) HOUR intervals

9804/1103

20 - 00 - 01/12

8450/147

Issue 1

CONTENTS

Loadalls

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) 23.7 (90) 2.6 (10) Diesel Oil (See Types of Fuel) JCB 15W/40 Engine Oil 14F to 122F (-10C to 50C) JCB 10W Engine Oil -4F to 50F (-20C to 10C) Engine (Coolant) 6.2 (23.5) Permanent Antifreeze (See Coolant Mixtures) INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE 15W/40 API CF4/SG SAE 10W API CF4/SG ASTM D3306-74

Fuel Tank Engine (Oil)

Transmission Syncro Shuttle Powershift Front Axle Housing Hubs (x2) Rear Axle Housing Hubs (x2) Brake System

4.8 (18.25) 3.9 (15.0)

JCB Special Transmission Fluid

ESP-M2C 33G Friction modified oils must not be used (eg. Dexron ATF type)

4.7 (18) 0.5 (2.0)

JCB Special High performance Gear Oil

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 DO NOT USE ORDINARY BRAKE FLUID ISO VG15

Hydraulic Tank 506C, 506C 506C, 508C Grease Points Wear Pad Runways Boom Hoses Boom Chains

32.0 (121) 48.0 (181)

JCB High Performance Hydraulic Oil (Above 100 F, 38 C) JCB Moly EP #2 Grease JCB Waxoyl JCB Special Slide Lubricant JCB Chain Lubricant

ISO VG46

Lithium based, No. 2 consistency

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 % 55 Antifreeze 3.4 gal (12.92 litres) Starts to Freeze -36 C (-33 F)

9804/1103

20 - 00 - 01/13

3640U - 3/1-1.3 & 3/1-2.3

Issue 1

CONTENTS

Loadalls

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) 90 (20) 10 (2.2) FLUID/LUBRICANT INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40 API CF4/SG (ACEA E2:B2:A2) SAE10W/30 API CD/SE SAE10W API CD/SE ASTM D3306-74

Fuel Tank Engine (Oil)

Diesel Oil (See Types of Fuel) JCB High Performance Engine Oil -10C to 50C (14F to 122F) JCB Super Universal Agricultural -15C to 30C (5F to 86F) JCB Torque Converter Fluid -18C to 0C (0F to 32F)

Coolant Capacity 55% Concentration

20 (4.4) 9.4 (2.0)

JCB Four Seasons Antifreeze And Summer Coolant ( See Coolant Mixtures) JCB High Performance Transmission Fluid

Gearbox

17.5 (3.8)

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) Hydraulic Tank ()

4.0 (0.88) 8.8 (1.94) 8.8 (1.94) 1.0 (0.22) 1.8 (0.4) 1.8 (0.4) 70 (15.4)

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 ISO VG46 (Above 38C, 100F) JCB High Performance Hydraulic Fluid 32 ISO VG32 (Below 38C, 100F) JCB HP Grease Lithium complex NLGI No. 2 consistency including extreme pressure additives. Lithium based NLGI No. 2 consistency including extreme pressure

Grease Points ()

JCB Special MPL-EP Grease 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

CONTENTS

Loadalls

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) 90 (20) 10 (2.2) FLUID/LUBRICANT INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40 API CF4/SG (ACEA E2:B2:A2) SAE10W/30 API CF4/SG (ACEA E2:B2:A2) ASTM D3306-74

Fuel Tank Engine (Oil)

Diesel Oil (See Types of Fuel) JCB High Performance Engine Oil -10C to 50C (14F to 122F) JCB High Performance Engine Oil -15C to 40C (5F to 104F)

Coolant Capacity 55% Concentration

20 (4.4) 9.4 (2.0)

JCB Four Seasons Antifreeze And Summer Coolant ( See Coolant Mixtures) JCB High Performance Transmission Fluid

Gearbox

17.5 (3.8)

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) Hydraulic Tank ()

4.0 (0.88) 8.8 (1.94) 8.8 (1.94) 1.0 (0.22) 1.8 (0.4) 1.8 (0.4) 70 (15.4)

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 ISO VG46 (Above 38C, 100F) JCB High Performance Hydraulic Fluid 32 ISO VG32 (Below 38C, 100F) JCB HP Grease Lithium complex NLGI No. 2 consistency including extreme pressure additives. Lithium based NLGI No. 2 consistency including extreme pressure

Grease Points ()

JCB Special MPL-EP Grease 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

CONTENTS

Loadalls

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) 31.7 (120) 12 (2.2)

FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE 15W/40 API CF4/SG SAE 10W API CF4/SG ASTM D3306-74

Fuel Tank Engine Oil

Diesel Oil (See Types of Fuel) JCB 15W/40 Engine Oil 14F to 122F (-10C to 50C) JCB 10W Engine Oil -4F to 50F (-20C to 10C)

Engine (Coolant)

5.2 (20)

Permanent Antifreeze (See Coolant Mixtures)

Transmission Syncro Shuttle Powershift Front Axle Housing Hubs (x2) Rear Axle Housing Hubs (x2) Brake System From Serial No. 280300 Hydraulic Tank

4.4 (17) 4.0 (15.5)

JCB Special Transmission Fluid

ESP-M2C 33G

2.3 (9) 0.5 (2)

JCB Special Gear Oil Plus

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 29.0 (110) JCB Hydraulic Fluid (Above 100 F (38 C) JCB HP Grease JCB Waxoyl JCB Special Slide Lubricant ISO VG15

ISO VG46

Grease Points Wear Pad Runways Boom Hoses

Lithium based, No. 2 consistency

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

CONTENTS

Loadalls

20 - 00 - 01/17

530, 535, 540 Fluids, Lubricants and Capacities

ITEM Litres Fuel Tank Engine (Oil) 125 10

CAPACITY UK Gal US gal 27.5 (2.2) 30

FLUID/LUBRICANT

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

Diesel Oil

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) 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 ASTM D3306-74

2.6

* Engine (Coolant) Except AM Engine AM Engine only

23 23.5

5.0 5.2

6.0 6.2

ASTM D3306-74

Transmission (See Note 1) Axles Housing Hubs (x4) Housing Hubs (x4) Hydraulic Tank (See Note 2) 530, 540 535 530, 540 535 Braking System

21 23

4.6 5.0

5.5 6.0

JCB Special Transmission Fluid ESP-M2C 33G

18 2.0

3.9 0.4 4.6 0.48

JCB High Performance Gear Oil API GL4 NORTH AMERICA JCB Special Gear Oil

ESEN-M2C 86A/B

112 121

24.6 26.6 29.5 32.0

JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Special Hydraulic Fluid (Below 38 C, 100 F) NORTH AMERICA JCB Hydraulic oil JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID JCB HP Grease NORTH AMERICA JCB Moly EP 2 Grease

ISO VG46

ISO VG32

ISO VG46 ISO VG15

0.7

0.8

Grease Points (See Note 3)

Lithium based

Lithium based No. 2 constituency

Wear Pad Runways

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*

CONTENTS

Loadalls

20 - 00 - 01/17A

530, 533, 535, 540 Fluids, Lubricants and Capacities Type AA and AB Engines
ITEM Litres Fuel Tank Engine (Oil) 125 10 CAPACITY UK Gal US gal 27.5 (2.2) 30 FLUID/LUBRICANT

From m/c no. 767001

INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40 API CF4/SG SAE10W/30, API CD/SE, SAE 10W, API CD/SE

Diesel Oil 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) 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) JCB Four Seasons Antifreeze and Summer Coolant

2.6

SAE15W/40 API CF4/SG SAE10W/30 API CD/SE SAE10W API CD/SE ASTM D3306-74

Engine (Coolant)

23

5.0

6.0

NORTH AMERICA Permanent Antifreeze

ASTM D3306-74

Transmission (See Note 1) Axles Housing Hubs (x4) Housing Hubs (x4) Hydraulic Tank (See Note 2) 530, 540 535, 533 530, 540 535, 533 Braking System

21 23

4.6 5.0

5.5 6.0

JCB Extreme Performance Transmission Oil

JCB: 4000/2501

18 2.0

3.9 0.4 4.6 0.48

JCB High Performance Gear Oil API GL4 NORTH AMERICA JCB Special Gear Oil

ESEN-M2C 86A/B

112 121

24.6 26.6 29.5 32.0

JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Special Hydraulic Fluid (Below 38 C, 100 F) NORTH AMERICA JCB Hydraulic oil JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID JCB HP Grease NORTH AMERICA JCB Moly EP 2 Grease

ISO VG46

ISO VG32

ISO VG46 ISO VG15

0.7

0.8

Grease Points (See Note 3)

Lithium based

Lithium based No. 2 constituency

Wear Pad Runways

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*

CONTENTS

Loadalls

20 - 00 - 01/17B

530, 533, 535, 540 Fluids, Lubricants and Capacities Type AR, AK and AB Engines
ITEM Litres Fuel Tank Engine (Oil) 125 10 CAPACITY UK Gal US gal 27.5 (2.2) 30 FLUID/LUBRICANT

From m/c no. 767001

INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40 API CF4/SG SAE10W/30, API CD/SE, SAE 10W, API CD/SE

Diesel Oil 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) 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) JCB Four Seasons Antifreeze and Summer Coolant

2.6

SAE15W/40 API CF4/SG SAE10W/30 API CD/SE SAE10W API CD/SE ASTM D3306-74

Engine (Coolant)

23

5.0

6.0

NORTH AMERICA Permanent Antifreeze

ASTM D3306-74

Transmission (See Note 1) Axles Housing Hubs (x4) Housing Hubs (x4) Hydraulic Tank (See Note 2) 530, 540 535, 533 530, 540 535, 533 Braking System

21 23

4.6 5.0

5.5 6.0

JCB Extreme Performance Transmission Oil

JCB: 4000/2501

18 2.0

3.9 0.4 4.6 0.48

JCB High Performance Gear Oil API GL4 NORTH AMERICA JCB Special Gear Oil

ESEN-M2C 86A/B

112 121

24.6 26.6 29.5 32.0

JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Special Hydraulic Fluid (Below 38 C, 100 F) NORTH AMERICA JCB Hydraulic oil JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID JCB HP Grease NORTH AMERICA JCB Moly EP 2 Grease

ISO VG46

ISO VG32

ISO VG46 ISO VG15

0.7

0.8

Grease Points (See Note 3)

Lithium based

Lithium based No. 2 constituency

Wear Pad Runways

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*

CONTENTS

Loadalls

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 CAPACITY Litres (Gal) 125 (27.5) FLUID/LUBRICANT INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40 API CF4/SG SAE10W/30 API CF4/SG SAE10W/30 API CD/SE SAE10W API CD/SE ASTM D3306-74

Fuel Tank Engine (Oil) Engine Type: AA, AB, AR & AK Builds Engine Type: AA & AB Builds Only

Diesel Oil (See Types of Fuel) 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) 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)

10 (2.2)

Engine (Coolant)

23 (5.0)

JCB Four Seasons Antifreeze And Summer Coolant (See Coolant Mixtures) JCB Special Transmission Fluid

Gearbox Wet fill Dry fill Axles Housing Hubs (x4)

21 (4.6) 23 (5.0) JCB High Performance Gear Oil 18 (3.9) 2.0 (0.4)

ESP-M2C 33G Friction modified oils MUST NOT be used (eg. Dexron ATF type). API GL4 Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). ISO VG15

Brake System

JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID 131 (28.8) JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Special Hydraulic Fluid (Below 38 C, 100 F) JCB HP Grease

Hydraulic Tank ()

ISO VG46 ISO VG32

Grease Points ()

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. 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

CONTENTS CONTENTS

Loadalls

20 - 00 - 02/1

525-58, 525-67, 527-58, 527-67 Static Dimensions and Weights

From m/c no. 567362

H D B K E F G
A122340

DESCRIPTION 525-58, 527-58 A B C Overall height Overall width Inside width of cab (between windows) Track Wheelbase Overall length to front tyres Overall length to front of Q-Fit carriage Ground clearance Centre of gravity (unladen) 2.59 m (8 ft 6 in) 2.34 m (7 ft 8 in)

DIMENSION 525-58FS, 527-58FS 2.57 m (8 ft 5 in) 2.35 m (7 ft 8 in) 525-67, 527-67 2.59 m (8 ft 6 in) 2.34 m (7 ft 8 in) 525-67FS, 527-67FS 2.57 m (8 ft 5 in) 2.35 m (7 ft 8 in)

0.93 m (3 ft 0 in) 1.90 m (6 ft 3 in) 2.38 m (7 ft 10 in) 3.87 m (12 ft 8 in)

0.93 m (3 ft 0 in) 1.90 m (6 ft 3 in) 2.38 m (7 ft 10 in) 3.87 m (12 ft 8 in)

0.93 m (3 ft 0 in) 1.90 m (6 ft 3 in) 2.49 m (8 ft 2 in) 4.05 m (13 ft 3 in)

0.93 m (3 ft 0 in) 1.90 m (6 ft 3 in) 2.49 m (8 ft 2 in) 4.05 m (13 ft 3 in)

D E F G

4.46 m (14 ft 7 in) 0.42 m (1 ft 5 in) 1.21 m (3 ft 11 in) 6300 kg (13,860 lb)

4.46 m (14 ft 7 in) 0.40 m (1 ft 4 in) 1.21 m (3 ft 11 in) 6300 kg (13,860 lb)

4.79 m (15 ft 8 in) 0.42 m (1 ft 5 in) 1.34 m (4 ft 3 in) 6422 kg (14,128 lb)

4.79 m (15 ft 8 in) 0.40 m (1 ft 4 in) 1.34 m (4 ft 3 in) 6422 kg (14,128 lb)

H K

Weight (unladen)

9804/1103

20 - 00 - 02/1

Issue 3*

CONTENTS

Loadalls

20 - 00 - 02/2

530-95 Static Dimensions and Weights

From m/c no. 567362

A H K D B E F G
DESCRIPTION DIMENSION
A198790

A B C

Overall height Overall width Inside width of cab (between windows) Track Wheelbase Overall length to front tyres Overall length to front of Q-Fit carriage Ground clearance Boom overhang

2.59 m (8 ft 6 in) 2.35 m (7 ft 8 in)

0.94 m (3 ft 1 in) 1.90 m (6 ft 3 in) 2.49 m (8 ft 2 in) 4.78 m (15 ft 8 in)

D E F G

5.60 m (18 ft 4 in) 0.4 m (1 ft 4 in) 0.54 m (1 ft 8 in) 7960 kg (17,550 lbs) Approximately

H J

Weight (unladen)

9804/1103

20 - 00 - 02/2

Issue 1

CONTENTS

Loadalls

20 - 00 - 02/3

530-110 Static Dimensions and Weights

From m/c no. 567362

H D B K E F G
*A122430 DESCRIPTION DIMENSION

* A * B C

Overall height Overall width Inside width of cab (between windows) Track Wheelbase Overall length to front tyres Overall length to front of Q-Fit carriage Ground clearance Centre of gravity (unladen, stabilisers raised)

2.59 m (8 ft 6 in) 2.35 m (7 ft 8 in)

0.94 m ( 3 ft 1 in) 1.90 m (6 ft 3 in) 2.49 m (8 ft 2 in) 4.78 m (15 ft 8 in)

D E * F * G

5.60 m (18 ft 4 in) 0.4 m ( 1 ft 4 in)

* H * K

1.36 m (4 ft 6 in) 7960 kg (17,550 lbs) Approximately

Weight (unladen)

9804/1103

20 - 00 - 02/3

8190/151

Issue 2*

CONTENTS

Loadalls

20 - 00 - 02/3A

530-110 Performance Data Forklift Performance


Lift capacity to full height Lift capacity at full reach Lift height Reach at maximum lift height Maximum forward reach Placing height 3000 kg (6,614 lb) 950 kg (2,095 lb) 10.95 m (36 ft 1 in) 1.55 m (5 ft 5 in) 6.85 m (23 ft 0 in) 10.3 m (33 ft 9 1/2 in)

From m/c no. 567362

Based on 500 mm (20 in) Load Centre. See Load Charts.

Loader Performance (Standard GP Bucket)


Bucket rated capacity Maximum dump height at 45 degrees Maximum dump height Maximum loadover height Placing height 1.0 m3 (35 cu ft) TBA 10.65 m (35 ft 1 in) 10.80 m (35 ft 5 in) TBA

9804/1103

20 - 00 - 02/3A

8190/152

Issue 1

CONTENTS

Loadalls

20 - 00 - 02/4

530-120, 537-130 Static Dimensions and Weights

From m/c no. 567362

H K D E F B
DESCRIPTION DIMENSION

G
S140100

A B C

Overall height Overall width Inside width of cab (between windows) Track Wheelbase Overall length to front tyres Overall length to front of Q-Fit carriage Ground clearance

2.56 m (8 ft 5 in) 2.364 m (7 ft 9 in)

0.94 m ( 3 ft 1 in) 1.90 m (6 ft 3 in) 2.49 m (8 ft 2 in) 4.44 m (14 ft 6 in)

D E F G H

5.30 m (17 ft 5 in) 0.38 m ( 1 ft 3 in) 8730 kg (19,250 lbs) Approximately

Weight (unladen)

9804/1103

20 - 00 - 02/4

Issue 1

CONTENTS

Loadalls

20 - 00 - 02/5

505-19, 505-22 Static Dimensions and Weights

From m/c no. 567362

H D B K E F G
A122340

DESCRIPTION 505-19 A B C Overall height Overall width Inside width of cab (between windows) Track Wheelbase Overall length to front tires Overall length to front of Q-Fit carriage Ground clearance

DIMENSION 505-22 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)

3 ft 2.5 in (0.92 m) 6 ft 3 in (1.90 m) 7 ft 10 in (2.38 m) 12 ft 8 in (3.86 m)

3 ft 2.5 in (0.92 m) 6 ft 3 in (1.90 m) 8 ft 2 in (2.49 m) 13 ft 3 in (4.04 m)

D E F G

14 ft 7 in (4.45 m) 1 ft 4.5 in (0.42 m) 13,960 lbs (6300 kg)

15 ft 8 in (4.77 m) 1 ft 41/2 in (0.42 m) 15,345 lbs (6960 kg)

Weight (unladen)

Notice: Dimensions are based on a machine with 15.5-25 tires fitted.

9804/1103

20 - 00 - 02/5

Issue 1

CONTENTS

Loadalls

20 - 00 - 02/6

506-36 Static Dimensions and Weights

From m/c no. 567362

H D B

E F G
S157670

DESCRIPTION A Overall height B Overall width C Inside width of cab (between windows) D Track E Wheelbase F Overall length to front tires G Overall length to front of Q-Fit carriage H Ground clearance Weight (unladen)

DIMENSION 8 ft 6 in (2.59 m) 7 ft 6 in (2.29 m)

3 ft 21/2 in (0.92 m) 6 ft 3 in (1.90 m) 7 ft 10 in (2.38 m) 12 ft 8 in (3.86 m)

14 ft 7 in (4.45 m) 1 ft 41/2 in (0.42 m) 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

CONTENTS

Loadalls

20 - 00 - 02/7

508-40 Static Dimensions and Weights

From m/c no. 567362

A H

E F

B
DESCRIPTION A Overall height B Overall width C Inside width of cab (between windows) D Track E Wheelbase F Overall length to front tires G Overall length to front of Q-Fit carriage H Ground clearance Weight (unladen) DIMENSION 8 ft 6 in (2.59 m) 8 ft 1 in (2.46 m)

G
S141370

3 ft 1 in (0.94 m) 6 ft 8 in (2.03 m) 9 ft 2 in (2.80 m) 16 ft 1 in (4.90 m)

19 ft 2 in (5.86 m) 1 ft 31/2 in (0.39 m) 24,458 lbs (11,094 kg) Approximately

9804/1103

20 - 00 - 02/7

Issue 1

CONTENTS

Loadalls

20 - 00 - 02/8

510-40 Static Dimensions and Weights

From m/c no. 567362

E F

G
S140100

DESCRIPTION A Overall height B Overall width C Inside width of cab (between windows) D Track E Wheelbase F Overall length to front tires G Overall length to front of Q-Fit carriage H Ground clearance Weight (unladen)

DIMENSION 8 ft 6 in (2.59 m) 8 ft 0 in (2.44 m)

3 ft 1 in (0.94 m) 6 ft 3 in (1.90 m) 9 ft 2 in (2.80 m) 16 ft 1 in (4.91 m)

19 ft 1 in (5.81 m) 1 ft 4 in (0.4 m) 26,808 lbs (12,160 kg)

9804/1103

20 - 00 - 02/8

Issue 1

CONTENTS

Loadalls

20 - 00 - 02/9

520-55, 520S Static Dimensions and Weights

From m/c no. 567362

A H D B E F G
DESCRIPTION A B C D E F G H Overall height Overall width Inside width of cab Front track Wheelbase Overall length to front tyres Overall length to front of Q-Fit carriage Ground clearance Weight (unladen) DIMENSION 7 ft 5 in (2.26 m) 7 ft 11/2 in (2.17 m) 2 ft 11 in (0.88 m) 6 ft 2 in (1.87 m) 7 ft 5 in (2.25 m) 12 ft 4 in (3.76 m) 14 ft 6 in (4.42 m) 1 ft 1 in (0.32 m) 10745 lb (4875 kg)
8020/191 A245130

Note: The above figures are based on a machine fitted with 12.5/80 X 18" tyres.

* Performance

Dimensions

Forklift Performance
Lift capacity to full height Lift capacity at full reach Lift height Maximum forward reach Placing height * Based on 24 in (610 mm) Load Centre. See Load Charts. 4500 lb (2041 kg) 2000 lb (907 kg ) 18 ft 0 in (5.50 m) 10 ft 6 in (3.20 m) 15 ft 61/2 in (4.74 m)
8020/193

9804/1103

20 - 00 - 02/9

Issue 3*

CONTENTS

Loadalls

20 - 00 - 02/10

526-55, 526, 526S Static Dimensions and Weights

From m/c no. 277001

H D B E F G
A195450

DESCRIPTION DIMENSION 526-55 7 ft 61/2 in (2.30 m) 7 ft 31/4 in (2.23 m) 2 ft 11 in (0.88 m) 6 ft 0 in (1.85 m) 7 ft 5 in (2.26 m) 12 ft 51/2 in (3.80 m) 14 ft 6 in (4.42 m) 1 ft 2 in (0.36 m) 12122 lb (5500 kg) DIMENSION 526 7 ft 61/2 in (2.30 m) 7 ft 31/4 in (2.23 m) 2 ft 11 in (0.88 m) 5 ft 11 in (1.81 m) 7 ft 7 in (2.33 m) 12 ft 91/2 in (3.90 m) 14 ft 10 in (4.52 m) 1 ft 51/2 in (0.45 m) 12171 lb (5520 kg) DIMENSION 526S 7 ft 81/2 in (2.38 m) 7 ft 31/4 in (2.23 m) 2 ft 11 in (0.88 m) 5 ft 11 in (1.81 m) 7 ft 7 in (2.33 m) 12 ft 91/2 in (3.90 m) 14 ft 10 in (4.52 m) 1 ft 51/2 in (0.45 m) 12877 lb (5840 kg)
8020/192

A B C D E F G H

Overall height Overall width Inside width of cab Front track Wheelbase Overall length to front tyres Overall length to front of Q-Fit carriage Ground clearance Weight (unladen)

Performance Dimentional Forklift Performance


Lift capacity to full height Lift capacity at full reach Lift height Maximum forward reach Placing height 5730 lb (2600 kg) 2204 lb (1000 kg) 18 ft 2 in (5.54 m) 10 ft 0 in (3.05 m) 15 ft 8 in (4.78 m)

Based on 24 in (610 mm) Load Centre. See Load Charts.

8020/193

9804/1103

20 - 00 - 02/10

Issue 3*

CONTENTS

Loadalls

20 - 00 - 02/11

537-120 Static Dimensions and Weights

From m/c no. 567362

A H K D E F B
DESCRIPTION A Overall height B Overall width C Inside width of cab (between windows) D Track E Wheelbase F Overall length to front tyres G Overall length to front of Q-Fit carriage H Ground clearance K Centre of gravity (unladen, stabilisers raised) Weight (unladen) DIMENSION 2.59 m (8 ft 6 in) 2.46 m (8 ft 1 in)

G
S141370

0.94 m (3 ft 1 in) 1.98 m (6 ft 6 in) 2.80 m (9 ft 2 in) 4.91 m (16 ft 1 in)

5.87 m (19 ft 3 in 0.4 m (1 ft 4 in)

1.28 m (4 ft 2 in) 11,100 kg (24,458 lbs) Approximately

9804/1103

20 - 00 - 02/11

Issue 1

CONTENTS

Loadalls

20 - 00 - 02/12

530-67, 535-67 Static Dimensions and Weights

From m/c no. 567362

D B

H K E F G
A214860

DESCRIPTION A B C Overall height Overall width Inside width of cab (between windows) Track Wheelbase Overall length to front tyres Overall length to front of Q-Fit carriage Ground clearance Centre of gravity (unladen)

DIMENSION 2.57 m (8 ft 5 in) 2.36 m (7 ft 9 in)

0.94 m (3 ft 1 in) 1.90 m (6 ft 3 in) 2.49 m (8 ft 2 in) 4.23 m (13 ft 11 in)

D E F G

4.96 m (16 ft 3 in) 0.40 m (1 ft 4 in) 1.44 m (4 ft 9 in) 7170 kg (15,770 lb)

H K

Weight (unladen)

9804/1103

20 - 00 - 02/12

Issue 1

CONTENTS

Loadalls

20 - 00 - 02/13

* 520-50, * Static

525-50, 525-52

From m/c no. 754000

Dimensions and Weight

H D B K E F G
A234930

DESCRIPTION

DIMENSION 520-50 2120 mm (6ft 11in) 1985 mm (6ft 6in) 1800 mm (5ft 11in)

DIMENSION 525-50 2190 mm (7ft 2in) 2055 mm (6ft 9in) 1820 mm (6ft 0in)

DIMENSION 525-52 2250 mm (7ft 5in) 2115 mm (6ft 11in) 1880 mm (6ft 2in)

Standard overall height Low cab option Overall width Inside width of cab (between windows) Track Wheelbase Overall length to front tyres Overall length to front of carriage Ground clearance Centre of gravity (unladen)

B C

830 mm (2ft 7in) 1530 mm (5ft 0in) 2000 mm (6ft 7in) 3080 mm (10ft 1 in)

830 mm (2ft 7in) 1490 mm (4ft 11in) 2000 mm (6ft 7in) 3130 mm (10ft 3in)

830 mm (2ft 7in) 1490 mm (4ft 11in) 2000 mm (6ft 7in) 3130 mm (10ft 3in)

D E F G

3590 mm (11ft 9in) 300 mm (1ft 0in) 1020 mm (3ft 9in) 4700 Kg (10,362lb)

3620 mm (11ft 11in) 360 mm (1ft 2in) 1020 mm (3ft 9in) 5400 Kg (11,905lb)

3620 mm (11ft 11in) 420 mm (1ft 4in) 1020 mm (3ft 9in) 5400 Kg (11,905lb)

H K

Weight (unladen)

* Note: Only 520-50 machines are available in N. America.

9804/1103

20 - 00 - 02/13

8170/151

Issue 2*

CONTENTS

Loadalls

20 - 00 - 02/13A

520-50, 525-50, 525-52 Performance Dimensions

From m/c no. 754000

Forklift Performance (except N. America)


520-50 Lift capacity to full height Lift capacity at maximum reach Maximum lift height Reach at maximum lift height Maximum forward reach Reach with 1 tonne load Placing height, 2 tonne load Based on 500 mm (20 in) Load Centre. 2000 Kg (4,410 lb) 700 Kg (1,543 lb) 5000 mm (16ft 4in) 500 mm (1ft 6in) 2820 mm (9ft 2 in) 2255 mm (7ft 3in) 4600 mm (15ft 0in) 525-50 2500 Kg (5,511 lb) 1000 Kg (2,205 lb) 5000 mm (16ft 4in) 500 mm (1ft 6in) 2820 mm (9ft 2in) 2820 mm (9ft 2in) 4600 mm (15ft 0in) 525-52 2500 Kg (5,511 lb) 1000 Kg (2,205 lb) 5200 mm (17ft 1in) 500 mm (1ft 6in) 2820 mm (9ft 2in) 2820 mm (9ft 2in) 4600 mm (15ft 0in)
8170/152

Forklift Performance (N. America)


Lift capacity to full height Lift capacity at maximum reach Maximum lift height Reach at maximum lift height Maximum forward reach Reach with 2,200 lb load Placing height, 4,400 lb load 4,400 lb. (1998 kg) 1,650 lb. (749 kg) 16 ft 4 in (5000 mm) 1 ft 10 in (559 mm) 9 ft 6 in (2896 mm) 8 ft 5 in (2565 mm) 15 ft 0 in (4572 mm)
8185/152

Based on 24 in (609 mm) Load Center.

Loader Performance (Standard GP Bucket)


520-50 Bucket rated capacity Maximum dump height at 45 bucket angle 0.7 m3 (24 cu ft) 4.07 m (13ft 3in) 525-50 0.9 m3 (32 cu ft) 4.11 m (13ft 6in) 525-52 0.95 m3 (33 cu ft) 4.17 m (13ft 8in)

8170/152

9804/1103

20 - 00 - 02/13A

Issue 1

CONTENTS

Loadalls
*

20 - 00 - 02/14

530, 540 Static Dimensions and Weights

From m/c no. 767001

A H E F G

D B

A264240

DESCRIPTION

DIMENSION 530

DIMENSION 540 2490 mm (8ft 2in) 2290 mm (7ft 6in)

A B C

Overall height Overall width Inside width of cab (between windows) Track Wheelbase Overall length to front tyres Overall length to front of carriage Ground clearance Centre of gravity (unladen) Weight (unladen)

2480 mm (8ft 1 in) 2230 mm (7ft 1 in)

940 mm (3ft 1in) 1794 mm (5ft 10in) 2750 mm (9ft 0in) 4380 mm (14ft 4in)

940 mm (3ft 1in) 1870 mm (6ft 2in) 2750 mm (9ft 0in) 4380 mm (14ft 4in)

D E F G

4940 mm (16ft 2in) 390 mm (1ft 2in) 1420 mm (4ft 8in) 6475 kg (14,277 lb)

4990 mm (16ft 4in) 400 mm (1ft 4in) 7400 kg (16,314 lb)

H K

9804/1103

20 - 00 - 02/14

8130/151

Issue 2*

CONTENTS

Loadalls

20 - 00 - 02/14A

535 Static Dimensions and Weights


C

From m/c no. 767001

A1 N W 15 115 D B M G L F H1 K E P H2 X H3

A2

A345760

R1/R2

R3 U1/U2 V

R4

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) P R1 R2 R3 R4 S T U1 U2 V W X

DIMENSION 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.

9804/1103

20 - 05 - 02/14A

8130/152

Issue 1

CONTENTS

Loadalls

20 - 00 - 02/15

530, 540 Performance Dimensions


* Forklift

From m/c no. 767001

Performance

530
3000 kg (6,615 lb) 2500 kg (5,512 lb) 1250 kg (2,756 lb) 7000 mm (22ft 9in) 480 mm (1ft 6in) 3700mm (12ft 2in) 3700mm (12ft 2in)

535
3500 kg (7,716 lb) 1750 kg (3,858 lb) 600 kg (1,323 lb) 9500 mm (31 ft 2 in) 2430 mm (7 ft 11 in) 6520 mm (12 ft 2 in) 5290 mm (17 ft 4 in)

540
4000 kg (8,818 lb) 3000 kg (6,614 lb) 1500 kg (3,307 lb) 7000 mm (22ft 8in) 480 mm (1ft 7in) 3700 mm (12ft 2in) 3700 mm (12ft 2in)

Maximum lift capacity Lift capacity to full height Lift capacity at maximum reach Maximum lift height Reach at maximum lift height Maximum forward reach Reach with 1 tonne load * 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 Static Dimensions and Weights

From m/c no. 767001

A H K

D B

E F G
A264250

DESCRIPTION

DIMENSION 532

DIMENSION 537 2580 mm (8ft 5in) 2350 mm (7ft 8in)

DIMENSION 550 2590 mm (8ft 6in) 2350 mm (7ft 8in)

A B C

Overall height Overall width Inside width of cab (between windows) Track Wheelbase Overall length to front tyres Overall length to front of carriage Ground clearance Centre of gravity (unladen) Weight (unladen)

2580 mm (8ft 5in) 2350 mm (7ft 8in)

940 mm (3ft 1in) 1900 mm (6ft 2in) 2750 mm (9ft 0in) 4830 mm (15ft 10in)

940 mm (3ft 1in) 1900 mm (6ft 2in) 2900 mm (9ft 5in) 5180 mm (17ft 0in)

940 mm (3ft 1in) 1900 mm (6ft 2in) 2900 mm (9ft 5in) 5180 mm (17ft 0in)

D E F G

5800mm (19ft 0in) 390 mm (1ft 2in) 1380 mm (4ft 6in) 9430 kg (20,793 lbs)

6190 mm (20ft 3in) 390 mm (1ft 2in) 1660 mm (5ft 5in) 10,600 kg (23,373 lbs)

6230 mm (20ft 5in) 400 mm (1ft 4in) 11,300 kg (24,912 lbs)

H K

9804/1103

20 - 00 - 02/16

Issue 2*

CONTENTS

Loadalls
*

20 - 00 - 02/17

532, 537, 550 Performance Dimensions Forklift Performance*


Maximum lift capacity Lift capacity to full height Lift capacity at maximum reach Maximum lift height Reach at maximum lift height Maximum forward reach Reach with 1 tonne load Placing height, 2 tonne load * Based on 500 mm (20 in) Load Centre.

From m/c no. 767001

532
3200 kg (7,056 lb) 3200 kg (7,056 lb) 1250 kg (2,756 lb) 12000 mm (39ft 4 in) 1450 mm (4ft 9 in) 8010 mm (26ft 3in) 8010 mm (26ft 3in) -

537
3700 kg (8158 lb) 3700 kg (8158 lb) 1500 kg (3,307 lb) 13500 mm (44ft 3in) 1680 mm (5ft 5in) 9250 mm (30ft 3in) 9250 mm (30ft 3in) -

550
4536 kg (10,00 0 lb) 4536 kg (10,000 lb) 1134 kg (2,500 lb ) 13500 mm (44ft 3in) 1680 mm (5ft 6in) 9250 mm (30ft 4in) -

9804/1103

20 - 00 - 02/17

Issue 2*

CONTENTS

Loadalls

20 - 00 - 02/18

506, 506 (HL), 508 (N. America) Static Dimensions and Weights

H D B
DESCRIPTION 506 A B C Overall height Overall width Inside width of cab (between windows) Track Wheelbase Overall length to front of Q-Fit carriage Ground clearance Weight (unladen) 8 ft 8 in (2.67 m) 7 ft 8 in (2.13 m) DIMENSION 506 (HL) 8 ft 8 in (2.67 m) 8 ft 1 in (2.46 m) 508 8 ft 8 in (2.67 m) 8 ft 1 in (2.46 m)

E G
A196390

3 ft 0 in (0.93 m) 6 ft 3 in (1.92 m) 9 ft 1 in (2.78 m)

3 ft 0 in (0.93 m) 6 ft 7 in (2.01 m) 9 ft 10 in (3.00 m)

3 ft 0 in (0.93 m) 6 ft 7 in (2.01 m) 9 ft 10 in (3.00 m)

D E G

17 ft 6 in (5.34 m) 1 ft 3 in (0.38 m) 21,040 lbs (9,540 kg)

20 ft 1 in (6.12 m) 1 ft 4 in (0.41 m) 22,150 lbs (10,069 kg)

20 ft 1 in (6.12 m) 1 ft 4 in (0.41 m) 25,225 lbs (11,440 kg)

Notice: Dimensions are based on a machine with 15.5-25 tires fitted.

9804/1103

20 - 00 - 02/18

8205/171

Issue 1

CONTENTS

Loadalls

20 - 00 - 02/19

506, 506 (HL), 508 (N. America) Performance Data Forklift Performance
506 Lift capacity to full height Lift capacity at full reach Lift height Reach at maximum lift height Maximum forward reach Placing height 6,000 lb (3000 kg) 2,000 lb (900 kg) 36 ft 1 in (11.0 m) 5 ft 5 in (1.65 m) 23 ft 5 in (7.1 m) 33 ft 10 in (10.31 m) 506 (HL) 6,000 lb (3000 kg) 1,500 lb (681 kg) 42 ft 0 in (12.8 m) 5 ft 11 in (1.80 m) 27 ft 4 in (8.33 m) 508 8,000 lb (3628 kg) 1,800 lb (816 kg) 42 ft 0 in (12.8 m) 5 ft 11 in (1.80 m) 27 ft 4 in (8.33 m) -

Based on 24 in (610 mm) Load Center. See Load Charts.

9804/1103

20 - 00 - 02/19

8205/172

Issue 1

CONTENTS

Loadalls

20 - 00 - 02/20

526 (N. America) Static Dimensions and Weights

A H E F G
A245130

D B

DESCRIPTION A B C D E F G H Overall height Overall width Inside width of cab Front track Wheelbase Overall length to front tires Overall length to front of Q-Fit carriage Ground clearance Weight (unladen)

DIMENSION 7 ft 81/2 in (2.38 m) 7 ft 31/4 in (2.23 m) 2 ft 11 in (0.88 m) 5 ft 11 in (1.81 m) 7 ft 7 in (2.33 m) 12 ft 91/2 in (3.90 m) 14 ft 10 in (4.52 m) 1 ft 51/2 in (0.45 m) 12877 lb (5840 kg)

Performance Dimensions Forklift Performance


Lift capacity to full height Lift capacity at full reach Lift height Maximum forward reach Placing height 5730 lb (2600 kg) 2204 lb (1000 kg) 18 ft 2 in (5.54 m) 10 ft 0 in (3.05 m) 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

CONTENTS

Loadalls

20 - 00 - 02/21

528-70, 528S Static Dimensions and Weights

A H D B E F G

A314940

DESCRIPTION

DIMENSION 528-70 8 ft 11 in (2.46 m) 7 ft 6 in (2.29 m) 2 ft 11 in (0.88 m) 6 ft 2 in (1.88 m) 8 ft 10 in (2.70 m) 14 ft 7 in (4.45 m) 16 ft 11 in (5.15 m) 1 ft 7 in (0.48 m) 13800 lb (6260 kg) 11 ft 9 in (3.58 m)

DIMENSION 528S 8 ft 11 in (2.46 m) 7ft 7 in (2.31 m) 2 ft 11 in (0.88 m) 6 ft 2 in (1.88 m) 8 ft 10 in (2.70 m) 14 ft 7 in (4.45 m) 16 ft 11 in (5.15 m) 1 ft 7 in (0.48 m) 14575 lb (6610 kg) TBA

A B C D E F G H

Overall height Overall width Inside width of cab Front track Wheelbase Overall length to front tyres Overall length to front of Q-Fit carriage Ground clearance Weight (unladen) Turn radius over tyres (4WS)

9804/1103

20 - 00 - 02/21

8450/191

Issue 1

CONTENTS

Loadalls

20 - 00 - 02/22

528-70, 528S Performance Dimensions Forklift Performance


Lift capacity to full height Lift capacity at full reach Lift height Maximum forward reach Placing height

528-70
5292 lb (2400 kg) 2756 lb (1250 kg) 22 ft 2 in (6.75 m) 12 ft 3 in (3.73 m) 20 ft 0 in (6.1 m)

528S
5071 lb (2300 kg) 2756 lb (1250 kg) 22 ft 2 in (6.75 m) 12 ft 3 in (3.73 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

20 - 05 - 01/1

ALL MODELS Data - Electrical


System Type Battery Cold Crank amps for 1 minute to * 1.4 VPC at -18C (0F) * Reserve capacity (minutes) for 25 amp load * Alternator Starter Motor 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 12 volts, negative earth

From m/c no. 567362

410 to 585 170 to 230 Lucas A127-65, 65 amp maximum output Lucas M127/2.8

45W/40W or 60/55W (halogen) 55W (Halogen) 5W 21W/5W/21W 21W 10W 21W 18W 1.2W 55W (Halogen)

9804/1103

20 - 05 - 01/1

Issue 2*

CONTENTS

Loadalls

20 - 05 - 01/2

ALL MODELS Data - Electrical

From m/c no. 567362

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 Fuse Rating 1 2 3 4 5 Circuit Rating Fuse Row B Circuit Rating Fuse Row C Circuit

Starter relay Safe load indicator Brake lock (USA) Heater Seat/parking brake warning (if fitted) Horn Indicators

1 1

Reversing lights, panel warning light

1 5 2

L.H. Main beam R.H. main beam, main beam warning light Cooling fan solenoid (if fitted) Radio (if fitted)

7.5

2 5 15

Forward/reverse switch, transmission dump switch (if fitted), manual gearbox 7.5 powershift gearbox 15 Interior lights, roof wiper (if fitted) beacon (if fitted) or as above plus rear wiper Brake lights Steer circuit (without IP67) (with IP67) Panel illumination, L.H. sidelights R.H. sidelights, number plate light, one working light, or above but with two working lights L.H. dipped beam R.H. dipped beam

7.5

15 1

4 10 20 7.5 4 5 5 3

6 7 8 9

10 15

Note: The radio fuse may need to be replaced by one of a higher rating as specified in radio fitting instructions. 5 Servo control Headlamp flasher (if fitted) 10 15

Hazard warning lights 15 Engine shut-off solenoid (ESOS)

7.5 6 5 7.5

*9

Reverse alarm (powershift) 5

7.5

10 15 7.5 7.5

8 9

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*

CONTENTS

Loadalls

20 - 05 - 01/3

ALL MODELS Data - Electrical


Location The relays are located in front of the steering wheel, to gain access remove the panel. Non servo machines

From m/c no. 567362

Basic servo machines (525-58, 525- 67, 505-19 & 505-22)

A F E D
S167140

A B F E J G
A B C D E F G

B C

S167142

A B C D E F

Steer mode PCB relay Reverse alarm relay Buzzer relay Flasher relay Sidelights relay Hand brake warning relay

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 FC G
A B C D E F G H J 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
S167142

9804/1103

20 - 05 - 01/3

Issue 1

CONTENTS

Loadalls

20 - 05 - 01/4

ALL MODELS Data - Electrical


Machines with IP67 electrics (All except 530-120 up to serial No. 572168, 530-120 up to serial No. 572242)

From m/c no. 567362

Machines with transmission dump relay (All except 530-120 from serial No. 572169, 530-120 from serial No. 572243)

K L M K E D C B F G

E H D C B G F

S172170

S215940

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

A B C D E F G H J K L M N

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

9804/1103

20 - 05 - 01/4

Issue 2

CONTENTS

Loadalls

20 - 05 - 01/5

ALL MODELS Data - Electrical


Machines with Powershift option

From m/c no. 567362

P N M J D C B

K E F

H R

G Q S

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

CONTENTS

Loadalls

20 - 05 - 01/6

* 520-55,

520S, 520-55 RS (504B N. Am), 526-55, 526, 526S (526 N. Am)

Data - Electrical
* Fuse Identification

From m/c no. 277001

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 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 Row B 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 Row C 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

8 9

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 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 1 10 15 15 15 7.5 5 5

Fuse 1 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

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

Machines with syncro shuttle transmission.

Fuse links 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

1 2 3 4 5

4 5

3
S245110 S192451 3610-C/1-4.2

9804/1103

20 - 05 - 01/6

Issue 4*

CONTENTS

Loadalls

20 - 05 - 01/7

* 520-55,

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

% 1 4 2 5 3 6 $

7 0

8 !

S192450

9804/1103

20 - 05 - 01/7

3610 - C/1-2.6

Issue 3*

CONTENTS

Loadalls

20 - 05 - 01/8

* 520-50,

525-50, 525-52

From m/c no. 754000

Data - Electrical
Battery Cold Crank amps for 1 minute to 1.4 VPC at -18C (0F) Reserve capacity (minutes) for 25 amp load 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 12 volts, negative earth 410 to 58 170 to 230 Lucas A127-65, 65 amp maximum output Lucas M127/2.8 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 5 9

2 6 0

3 7 !

4 8 @

S239200

9804/1103

20 - 05 - 01/8

3620-C/1-1.1

Issue 2*

CONTENTS

Loadalls

20 - 05 - 01/9

* 520-50,

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 Fuse 1 2 3 4 5 6 7 8 9 Row B Circuit 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 Rating Row C Fuse Circuit 1 2 3 4 5 6 7 8 9 Spare Safe load indicator Forward/reverse switch, transmission dump relay Spare Thermostart Spare Spare Spare Spare

15 5 10 10 15 10 5 5 15

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 Circuit 1 2 3 4 5 Starter relay Tracker, Radio, Hazard lights, Wipers Lights relay Starter switch Not used Rating 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*

CONTENTS

Loadalls

20 - 05 - 01/10

* 520-55,

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

% 1 4 2 5 3 6 $

7 0

8 !

S192450

9804/1103

20 - 05 - 01/10

Issue 2*

CONTENTS

Loadalls

20 - 05 - 01/11

* 526,

526S (526 N.Am)

Data - Electrical (contd) Relay Identification (contd)


* 526, 526S (526 N.Am) - Powershift Transmission * From M/c Serial No 280577 Onwards The relay configuration for machines with powershift transmission is shown at A. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 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 * 526, 526S (526 N.Am) - Syncro Shuttle Transmission * From M/c Serial No 280574 Onwards 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 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 3

58

6 9 ! @

A
1 2 4 7 0 5 8 ! $ ^

6 9 @ %

A282130

9804/1103

20 - 05 - 01/11

3610-C/1-3.3

Issue 2*

CONTENTS

Loadalls

20 - 05 - 01/12

* 520-55,

526-55, 526, 526S (526 N.Am)

From m/c no. 279000 to 280299

Data - Electrical (contd) 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. Row A Circuit 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 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

Fuse 1 2 3 4 5 6 7 8 9
+

Rating

Fuse 1 2 3 4 5 6 7 8 9

Rating 1 10 15 15 15 7.5 5 5

Fuse 1 2 3 4 5 6 7 8 9

Rating 15 7.5 10 10 10 15 10

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

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

3
S245110 S192451

9804/1103

20 - 05 - 01/1

Issue 2*

CONTENTS

Loadalls

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 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

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

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

Rating 40 40

4 5

1 3

40

40 80 *
3610-C/1-5.2

20 - 05 - 01/1

Issue 2*

CONTENTS

Loadalls

20 - 05 - 01/14

* 530, * Data

535, 540 - Electrical

*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

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 -

1 2 3

90

56 !@ %^ 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 -

A335670

NOTE : ECU deletion cut-in numbers are transmission dependant. Transmission Part Number 449/06100 449/06200 449/06300 449/06400 449/06500 449/06600 Serial Number of cut-in 770055 770065 770053 770069 770063 770093

9804/1103

20 - 05 - 01/14

3630 - C/1-2.4

Issue 2*

CONTENTS

Loadalls

20 - 05 - 01/14A

530, 535, 540 Data - Electrical Relay Identification (contd) 530, 540 Fitted with smooth Ride System (SRS)

From m/c no. 767001

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

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

18 19

10 11

20 21

12 13

22 23

5
A335680

14 15

24 25

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 (contd) 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 -

12 13

14 15

10 11

16 17
A372461

9804/1103

20 - 05 - 01/14B

3630 - 3/1-6.2

Issue 1

CONTENTS

Loadalls

20 - 05 - 01/15

530, 535, 540 Data - Electrical (contd)


* Relay

From m/c no. 767001

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 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

1 1 2 2 3 3 4 4

7 7

16 & 17 ^

18 ( 19 8 9 9 8 *

21 10 ! 11 ) 20 21 0 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 Data - Electrical (contd) 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

From m/c no. 767001

14 15

10 11

16 17

12 13

18 19

360940

9804/1103

20 - 05 - 01/15A

3630 - C/1-4.4

Issue 1

CONTENTS

Loadalls

20 - 05 - 01/16

530, 535, 540 Data - Electrical (contd) 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. 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
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

From m/c no. 767001

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

21 22 23 24 25 26 27 28 29 30

31 32 33 34 35 36 37 38 39 40

A348080

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 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 Smooth Ride System (if fitted) SPARE SPARE Air suspension seat (if fitted) SPARE BLANK BLANK BLANK BLANK BLANK 10 10 10 10 10 5 10 5 15 5

B A D E
Fuse Links S/N 767000 to 770053 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

C
S245111

A B C D E

15

Fuse Links S/N 770054 onwards 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
3630 - C/1-5.1 3630 - C/1-6.1

Rating 40 40 40 40 80
Issue 3*

A B C D E

9804/1103

20 - 05 - 01/16

CONTENTS

Loadalls

20 - 05 - 01/17

532, 537, 550 Data - Electrical (contd) 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 m/c no. 767001

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 -

Note : ECU deletion cut-in numbers are transmission dependant. Transmission Part Number 449/06100 449/06200 449/06300 449/06400 449/06500 449/06600 Serial Number of cut-in 770055 770065 770053 770069 770063 770093

9804/1103

20 - 05 - 01/17

3660 - C/1-2.1

Issue 2*

CONTENTS

Loadalls

20 - 05 - 01/18

532, 537, 550, 5508 Data - Electrical (contd) Relay Identification (contd)
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 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 -

From m/c no. 767001

1 1 2 2 3 3 4 4

7 7

16 & 17 ^
Note: ECU cut-in numbers are transmission dependent (see page 20 - 05 - 01/17 for transmission details).

18 ( 19 8 9 9 8 * 10 ! 11 ) 20 ( 21 0

22 23 23 22 12 13 @

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 (contd) Relay Identification (contd)
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 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

From m/c no. 767001

14 15

10 11

16 17

12 13

18 19
A361560

* 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 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

8 9

10 11

16 17

12 13

18 19

14 15

20 21
A361561

9804/1103

20 - 05 - 01/18A

3660 - C/1-4.3

Issue 2*

CONTENTS

Loadalls

20 - 05 - 01/18B

532, 537, 540-170, 550, 5508 Data - Electrical (contd) Relay Identification (contd)
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

From m/c no. 767001

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

16 17

* 540-170/5508 Machines from S/N 1004131 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 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

8 9

18 19

10 11

20 21

12 13

22 23

14 15

24 25

A361140

9804/1103

20 - 05 - 01/18B

3660 - C/1-5.4

Issue 2*

CONTENTS

Loadalls

20 - 05 - 01/19

* 532,

537, 540-170, 550, 5508

From m/c no. 767001

Data - Electrical (contd) 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. 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 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 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 Hydraulics (540-170/5508 only) Boom work light (540-170/5508 only) SPARE Air Suspension Seat (if fitted) SPARE EMPTY EMPTY EMPTY EMPTY EMPTY Rating 7.5 10 5 15 15 15 5 7.5 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

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

5 5 7.5 15 5 10 10 10 10 7.5 7.5

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

B A D E C
S245111

10 10 10 10 10 5 10 5 15 15 5 15

Fuse Links S/N 768700 to 770053 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

A B C D E

Fuse Links S/N 770054 onwards 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
3660 - C/1-6.2 3660 - C/1-7.1

Rating 40 40 40 40 80
Issue 3*

A B C D E

9804/1103

20 - 05 - 01/19

*
CONTENTS

Loadalls

20 - 05 - 01/20

528-70 Data - Electrical (contd) Syncro Shuttle Transmission Fuse Identification


Circuit 1 2 3 4 5 6 7 8 9 10 Rating

From m/c no. 796000

Relay Identification
A B C D E F G H J K L M Buzzer Neutral start Ignition Sidelights Park brake Rear work light Spare Front work light Transmission dump Flasher Forward Reverse

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

5 5 10 10 5 7.5 15 7.5 5 15

A B C

D G E H F J K 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

CONTENTS

Loadalls

20 - 05 - 01/21

528S Data - Electrical (contd) Fuse Identification


Circuit 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 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 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 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 15 7.5 5 15

From m/c no. 796102

A B C

D G E H F J K 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 - 01/21

3650 - C/1-3.2

Issue 1

CONTENTS

Loadalls

20 - 05 - 01/22

528S Data - Electrical (contd) Relay Identification Power Shift Transmision


The relay configuration for machines with Powershift Transmission is shown at A. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 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

From m/c no. 796102

Syncro Shuttle Transmission


The relay configuration for machines with Syncroshuttle Transmission is shown at B. 1 2 3 4 5 6 7 8 9 10 11 12 Buzzer Neutral start Ignition Side lights Parking brake Auxiliary 2 change over Air conditioning Spare Transmission dump Flasher Forward Reverse

B
1 4 7

5 8

6 9 ! @

A
1 4 7 0

5 8 ! $

6 9 @ %

A282130

9804/1103

20 - 15 - 01/22

3650 - C/1-4.1

Issue 1

CONTENTS

Loadalls

20 - 05 - 01/23

528-70, 528S Data - Electrical (contd) Fuse Links


Circuit 1 2 3 4 5 Rating

From m/c no. 796000

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

S245110

A308110

9804/1103

20 - 15 - 01/23

3650 - C/1-5.1

Issue 1

*
CONTENTS

Loadalls

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 Steer mode PCB relay Forward relay Reverse relay Transmission dump relay Parkbrake warning Neutral start relay Buzzer Ignition Relay (506C & 508C only - not shown)

A B G F C D 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

Later Machines

P D C K B M G H B D

P Q M C

R X G 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 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

1 2 3 4 5 6 7 8 9

ROW B Circuit Rating Interior light, roof wiper, rear wiper & beacon 10 Ignition relay 1 3-9 Not used
S269270

1 2

ROW C Circuit Not used Rating

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 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

From m/c no. 567362

23.2 US gal/min 22.2 US 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 Rams 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) Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Fan Motor Type Max fan speed at Max engine rev/min mm 110 110 70 70 110 110 70 110 110

5.3 US gal/min 4.8 US gal/min

Kontak, parallel service, double acting spools. Boom Raise & Lower Boom Extend & Retract Auxiliary (see note) Carriage Tilt Auxiliary (see note) Auxiliary (see note) bar 220 138 138 275 96 172 131 165 kgf/cm2 224 140 140 281 98 176 133 168 lbf/in2 3200 2000 2000 4000 1400 2500 1900 2400

Bore 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

Partial flow ('spin on') 25 microns (0.001 in) 0.17 bar 125 microns (0.005 in)

NAT ASP engine TURBO engine

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 Data - Hydraulics


Pump Type Flow at max. engine rev/min at zero pressure at system pressure Control Valves Type Services Operated Spool 1 Spool 2 Spool 3 Spool 4 Spool 5 Spool 6 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 Sway, head side Sway, rod side Note: On later machines the sway ARVs are not fitted Rams Boom Lift Boom Extension Tilt Ram Displacement Sway * Sway Ram (later machines) Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Fan Motor * Type Max fan speed at Max engine rev/min NAT ASP engine TURBO engine Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in) mm 110 100 120 120 110 110 Sundstrand SP/230/40, gear type 88.0 litres/min 84.0 litres/min

From m/c no. 567362

19.4 UK gal/min 18.5 UK gal/min

23.2 US gal/min 22.2 US gal/min

Kontak, parallel service, double acting spools. Boom Raise & Lower Boom Extend & Retract Auxiliary (see note) Carriage Tilt Auxiliary (see note) Sway bar 220 138 138 275 131 165 kgf/cm2 225 140 140 281 133 168 lbf/in2 3200 2000 2000 4000 1900 2400

Bore 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

Sundstrand TFU 200/8, gear type / Ultra 1MR 084C 8784 40 C ambient temp. zone 1800 1800 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 Data - Hydraulics


Pump Type Flow at max. engine rev/min at zero pressure at system pressure Control Valves Type Services Operated Spool 1 Spool 2 Spool 3 Spool 4 Spool 5 Spool 6 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 Rams Boom Lift Boom Outer Extension Boom Inner Extension Tilt Ram Displacement Stabiliser Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Fan Motor * Type Max fan speed at Max engine rev/min NAT ASP engine TURBO engine Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in) mm 110 110 90 120 120 100 Sundstrand SP/230/40, gear type 88.0 litres/min 84.0 litres/min

From m/c no. 567362

19.4 UK gal/min 18.5 UK gal/min

23.2 US gal/min 22.2 US gal/min

Kontak, parallel service, double acting spools. Boom Raise & Lower Boom Extend & Retract Auxiliary Carriage Tilt Stabiliser Stabiliser bar 241 138 138 275 Bore in 4.3 4.3 3.5 4.7 4.7 3.9 kgf/cm2 245 140 140 281 lbf/in2 3500 2000 2000 4000 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

Sundstrand TFU 200/8, gear type / Ultra 1MR 084C 8784 40 C ambient temp. zone 1800 1800 46 C ambient temp. zone 2100 2100

9804/1103

20 - 05 - 02/3

Issue 2*

CONTENTS

Loadalls

20 - 05 - 02/4

530-120 Data - Hydraulics


Pump * Type Flow at max. engine rev/min at zero pressure at system pressure Control Valves Type Services Operated Spool 1 Spool 2 Spool 3 Spool 4 Spool 5 Spool 6 Spool 7 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 Sway, head side Sway, rod side * Note: On later machines the sway ARVs are not fitted Rams Boom Lift Boom Outer Extension Boom Inner Extension Tilt Ram Displacement Stabiliser Sway Sway Ram (later machines) On machines from serial number 567736 Tilt Ram Displacement Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Fan Motor * Type Max fan speed at Max engine rev/min NAT ASP engine TURBO engine Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in) mm 120 120 100 130 130 110 110 110

From m/c no. 567362

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

Kontak, parallel service, double acting spools. Boom Raise & Lower Boom Extend & Retract Auxiliary Carriage Tilt Stabiliser Stabiliser Sway bar 241 138 138 275 131 165 kgf/cm2 245 140 140 281 133 168 lbf/in2 3500 2000 2000 4000 1900 2400

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

2.5 2.5

695 500

27.3 19.6

Sundstrand TFU 200/8, gear type or Ultra 1MR 084C 8784 40 C ambient temp. zone 1800 1800 46 C ambient temp. zone 2500 2500

9804/1103

20 - 05 - 02/4

Issue 2*

CONTENTS

Loadalls

20 - 05 - 02/5

505-19, 505-22 Data - Hydraulics


Pump Type Flow at max. engine rev/min at zero pressure at system pressure Control Valves Type Services Operated Spool 1 Spool 2 Spool 3 Spool 4 Spool 5 Spool 6 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 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 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) Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Fan Motor Type Max fan speed at Max engine rev/min Sundstrand TFU 200/8, gear type 18 inch fan 40 C ambient temp. zone 2100 2100 Partial flow ('spin on') 25 microns (0.001 in) 0.17 bar 125 microns (0.005 in) mm 110 110 70 70 110 110 70 110 110 Sundstrand SP/230/40, gear type 88.0 litres/min 19.4 UK gal/min 84.0 litres/min 18.5 UK gal/min

From m/c no. 567362

23.2 US gal/min 22.2 US gal/min

Kontak, parallel service, double acting spools. Boom Raise & Lower Boom Extend & Retract Auxiliary (see note) Carriage Tilt Auxiliary (see note) Auxiliary (see note) bar 220 138 138 275 96 172 131 165 kgf/cm2 224 140 140 281 98 176 133 168 lbf/in2 3200 2000 2000 4000 1400 2500 1900 2400

Bore 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

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

NAT ASP engine TURBO engine

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 Data - Hydraulics


Pump Type Flow at max. engine rev/min at zero pressure at system pressure Control Valves Type Services Operated Spool 1 Spool 2 Spool 3 Spool 4 Spool 5 Spool 6 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 Rams Boom Lift Boom Outer Extension Boom Inner Extension Tilt Ram Displacement Stabilizer Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Fan Motor Type Max fan speed at Max engine rev/min NAT ASP engine TURBO engine Sundstrand TFU 200/8, gear type 40 C ambient temp. zone 1800 1800 46 C ambient temp. zone 2100 2100 Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in) Sundstrand SP/230/40, gear type 88.0 litres/min 84.0 litres/min

From m/c no. 567362

19.4 UK gal/min 18.5 UK gal/min

23.2 US gal/min 22.2 US gal/min

Kontak, parallel service, double acting spools. Boom Raise & Lower Boom Extend & Retract Auxiliary Carriage Tilt Stabiliser Stabiliser bar 241 138 138 275 Bore mm 110 110 90 120 120 100 kgf/cm2 245 140 140 281 lbf/in2 3500 2000 2000 4000 Rod Dia. mm 60 60 60 65 65 60 Stroke mm 1020 2560 2690 495 495 380

in 4.3 4.3 3.5 4.7 4.7 3.9

in 2.3 2.3 2.3 2.5 2.5 2.3

in 40.1 100.7 105.9 19.4 19.4 15

9804/1103

20 - 05 - 02/6

Issue 1

CONTENTS

Loadalls

20 - 05 - 02/7

508-40 Data - Hydraulics


Pump Type Flow at max. engine rev/min at zero pressure at system pressure Control Valves Type Services Operated Spool 1 Spool 2 Spool 3 Spool 4 Spool 5 Spool 6 Spool 7 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 Sway, head side Sway, rod side Sundstrand SP/230/50, gear type 110.0 litres/min 105.0 litres/min

From m/c no. 567362

24.2 UK gal/min 23.0 UK gal/min

29.0 US gal/min 27.6 US gal/min

Kontak, parallel service, double acting spools. Boom Raise & Lower Boom Extend & Retract Auxiliary Carriage Tilt Stabiliser Stabiliser Sway bar 241 138 138 275 131 165 kgf/cm2 245 140 140 281 133 168 lbf/in2 3500 2000 2000 4000 1900 2400

Rams Boom Lift Boom Outer Extension Boom Inner Extension Tilt Ram Displacement Sway On machines from serial number 567736 Tilt Ram Displacement Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Fan Motor Type Max fan speed at Max engine rev/min TURBO engine

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

130 130

5.1 5.1

65 65

2.5 2.5

695 500

27.3 19.6

Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)

Sundstrand TFU 200/8, gear type 40 C ambient temp. zone 2300 46 C ambient temp. zone 2900

9804/1103

20 - 05 - 02/7

Issue 1

CONTENTS

Loadalls

20 - 05 - 02/8

510-40 Data - Hydraulics


TECHNICAL DATA (510-40 Only) Pump * Type Flow at max. engine rev/min at zero pressure at system pressure Control Valves Type Services Operated Spool 1 Spool 2 Spool 3 Spool 4 Spool 5 Spool 6 Spool 7 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 Sway, head side Sway, rod side Note: On later machines the sway ARVs are not fitted 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 Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Fan Motor Type Max fan speed at Max engine rev/min TURBO engine Sundstrand TFU 200/8, gear type 40 C ambient temp. zone 2600 46 C ambient temp. zone 2900 Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in) mm 120 120 100 130 130 110 110 110

From m/c no. 567362

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

Kontak, parallel service, double acting spools. Boom Raise & Lower Boom Extend & Retract Auxiliary Carriage Tilt Stabilizer Stabilizer Sway bar 241 138 138 275 131 165 kgf/cm2 245 140 140 281 133 168 lbf/in2 3500 2000 2000 4000 1900 2400

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

2.5 2.5

695 500

27.3 19.6

9804/1103

20 - 05 - 02/8

Issue 2*

CONTENTS

Loadalls

20 - 05 - 02/9

520-55, 526-55, 520S, 526, 526S Data - Hydraulics


Pump Type Flow at 2200 engine rev/min at zero pressure at system pressure Control Valves Type Powermaster 2PR 036, gear type 79.0 litres/min 75.0 litres/min 17.4 UK gal/min 16.5 UK gal/min

From m/c no. 567362

21.0 US gal/min 20.0 US gal/min

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

Spool 1 Spool 2 Spool 3 Spool 4

Auxiliary Boom Raise & Lower Carriage Tilt Boom Extend & Retract

Mechanical Mechanical Mechanical Mechanical

Pilot Mechanical Mechanical Pilot

* Relief Valve Operating Pressures

bar 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 241 193 144 250 276

kgf/cm2 245 196 144 255 281

lbf/in2 3500 2798 2080 3625 4002

Rams

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 Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer

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

Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)

9804/1103

20 - 05 - 02/9

3610 - E/1-1.5

Issue 5*

CONTENTS

Loadalls

20 - 05 - 02/10

537-120 Data - Hydraulics


Pump * Type Flow at max. engine rev/min at zero pressure at system pressure Control Valves Type Services Operated Spool 1 Spool 2 Spool 3 Spool 4 Spool 5 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 Rams Boom Lift Boom Outer Extension Boom Inner Extension Tilt Ram Displacement Stabiliser Sway Ram Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Fan Motor Type Max fan speed at Max engine rev/min NAT ASP engine TURBO engine Ultra 1MR 084C 8784 40 C ambient temp. zone 1800 1800 Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in) mm 120 120 100 130 130 110 110

From m/c no. 567362

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

Kontak, parallel service, double acting spools. Boom Raise & Lower Boom Extend & Retract Auxiliary Carriage Tilt Sway bar 241 138 138 275 Bore in 4.7 4.7 3.9 5.1 5.1 4.3 4.3 kgf/cm2 245 140 140 281 lbf/in2 3500 2000 2000 4000 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

46 C ambient temp. zone 2500 2500

9804/1103

20 - 05 - 02/10

Issue 2*

CONTENTS

Loadalls

20 - 05 - 02/11

537-130 Data - Hydraulics


* Pump Type Flow at max. engine rev/min at zero pressure at system pressure Control Valves Type Services Operated Spool 1 Spool 2 Spool 3 Spool 4 Spool 5 Spool 6 Spool 7 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 Rams Boom Lift Boom Outer Extension Boom Inner Extension Tilt Ram Displacement Stabiliser Sway Ram Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Fan Motor Type Max fan speed at Max engine rev/min NAT ASP engine TURBO engine Ultra 1MR 084C 8784 40 C ambient temp. zone 1800 1800 Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in) mm 120 120 100 130 130 110 110

From m/c no. 567362

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

Kontak, parallel service, double acting spools. Boom Raise & Lower Boom Extend & Retract Auxiliary Carriage Tilt Stabiliser Stabiliser Sway bar 241 138 138 275 Bore in 4.7 4.7 3.9 5.1 5.1 4.3 4.3 kgf/cm2 245 140 140 281 lbf/in2 3500 2000 2000 4000 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

46 C ambient temp. zone 2500 2500

9804/1103

20 - 05 - 02/11

Issue 2*

CONTENTS

Loadalls

20 - 05 - 02/12

520-50, 525-50, 525-52 Data - Hydraulics


Pump Type Flow at 2200 engine rev/min at zero pressure at system pressure Control Valves Type Services Operated Spool 1 Spool 2 Spool 3 Spool 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 Crowd, head side Carriage Tilt Dump, rod side Rams Boom Lift Boom Extension Tilt Displacement Hitch Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Hydraulic Tank Capacity 70 litres (15.4 gals) Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in) Kontak, parallel service, double acting spools. Auxiliary Boom Raise & Lower Carriage Tilt Boom Extend & Retract bar 241 185 185 250 275 Bore mm in 110 4.3 70 2.7 120 4.7 70 2.7 50 1.9 kgf/cm2 245 188 188 255 280 Rod Dia. mm in 60 2.3 50 1.9 70 2.75 40 1.5 25 0.9 lbf/in2 3500 2683 2683 3625 3987 Stroke mm in 1020 40.1 1700 66.0 334 13.1 503 19.8 254 9.8 Powermaster 2PR 036, gear type 79.0 litres/min 75.0 litres/min 17.4 UK gal/min 16.5 UK gal/min

From m/c no. 754000

21.0 US gal/min 20.0 US gal/min

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

9804/1103

20 - 05 - 02/12

3620-E/1-1.2

Issue 3*

CONTENTS

Loadalls

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 Services Operated Spool 1 Spool 2 Spool 3 Spool 4 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) Rams Boom Lift Boom Extension Tilt Displacement Hitch Sway Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Hydraulic Tank Capacity 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 112 litres (24.6 UK gals) Partial flow ('spin on') 10 microns (0.0004 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in) Parallel service, double acting spools.

Boom Raise & Lower Carriage Tilt Boom Extend & Retract (electro/servo operated) Auxiliary (electro/servo operated) bar 10 - 20 10 - 30 bar 241 138 (220) 138 138 275 Bore mm in 130 5.1 70 2.7 110 4.3 120 4.7 50 1.9 110 4.3 kgf/cm2 10.2 - 20.4 10.2 - 30.6 kgf/cm2 245 140 (223) 140 140 280 Rod Dia. mm in 70 2.7 50 1.9 50 1.9 60 2.3 25 0.9 50 1.9 lbf/in2 145 - 290 145 - 435 lbf/in2 3500 2000 (3190) 2000 2000 3987 Stroke mm in 753 29.6 2470 97.2 474 18.6 294 11.5 429 16.8 136 5.4 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

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*

CONTENTS

Loadalls

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 * Control Valves Type Services Operated Spool 1 Spool 2 Spool 3 Spool 4 * 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 Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Hydraulic Tank Capacity 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 112 litres (24.6 UK gals) Partial flow ('spin on') 10 microns (0.0004 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in) Parallel service, 4 double acting spools. 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)

Boom Raise & Lower Boom Extend & Retract Carriage Tilt Auxiliary/Sway (electro/servo operated) bar 10 - 20 10 - 30 bar 260 138(220) 138 138 275 241 241 Bore mm in 140 5.5 70 2.7 110 4.3 120 4.7 50 1.9 kgf/cm2 10.2 - 20.4 10.2 - 30.6 kgf/cm2 263 140(223) 140 140 280 245 245 Rod Dia. mm in 75 2.9 50 1.9 50 1.9 60 2.3 25 0.9 lbf/in2 145 - 290 145 - 435 lbf/in2 3770 2000(3190) 2000 2000 3987 3500 3500 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

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*

CONTENTS

Loadalls

20 - 05 - 02/14A

540 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 Control Valves Type Services Operated Spool 1 Spool 2 Spool 3 Spool 4 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 Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Hydraulic Tank Capacity Fan Motor Oil Flow Max fan speed at Max engine rev/min 112 litres (24.6 UK gals) Partial flow ('spin on') 10 microns (0.0004 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in) Parallel service, 4 double acting spools.

From m/c no. 767001

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)

Boom Raise & Lower Carriage Tilt Boom Extend & Retract (electro/servo operated) Auxiliary (electro/servo operated) bar 10 - 20 10 - 30 bar 260 138(220) 138 138 275 241 241 Bore mm in 140 5.5 70 2.7 110 4.3 120 4.7 50 1.9 kgf/cm2 10.2 - 20.4 10.2 - 30.6 kgf/cm2 263 140(223) 140 140 280 245 245 Rod Dia. mm in 75 2.9 50 1.9 50 1.9 60 2.3 25 0.9 lbf/in2 145 - 290 145 - 435 lbf/in2 3770 2000(3190) 2000 2000 3987 3500 3500 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

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

CONTENTS

Loadalls

20 - 05 - 02/14B

540 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 Control Valves Type Services Operated Spool 1 Spool 2 Spool 3 Spool 4 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 Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Hydraulic Tank Capacity Fan Motor Oil Flow Max fan speed at Max engine rev/min 112 litres (24.6 UK gals) Partial flow ('spin on') 10 microns (0.0004 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in) Parallel service, 4 double acting spools.

From m/c no. 767001

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)

Boom Raise & Lower Boom Extend & Retract Carriage Tilt Auxiliary/Sway (electro/servo operated) bar 10 - 20 10 - 30 bar 260 138(220) 138 138 275 241 241 Bore mm in 140 5.5 70 2.7 110 4.3 120 4.7 50 1.9 kgf/cm2 10.2 - 20.4 10.2 - 30.6 kgf/cm2 263 140(223) 140 140 280 245 245 Rod Dia. mm in 75 2.9 50 1.9 50 1.9 60 2.3 25 0.9 lbf/in2 145 - 290 145 - 435 lbf/in2 3770 2000(3190) 2000 2000 3987 3500 3500 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

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

CONTENTS

Loadalls

20 - 05 - 02/14C

535 Data - Hydraulics 535 Machines


Triple Pump Type gal/min) Main pump 2PR036 Fan pump 1PX160 Steer pump 2PR019 Priority valve 2VP-EAF-JIJ2V1-00-00-56 Control Valves Type Services Operated Spool 1 Spool 2 Spool 3 Spool 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, rod side (A port) Carriage Tilt Crowd, head side (B port) Parallel service, 4 double acting spools.

From m/c no. 767001

82.0

litres/min

(18.0

UK

36.5 litres/min (8.0 UK gal/min) 43.3 litres/min (9.5 UK gal/min)

Boom Raise & Lower Boom Extend & Retract Carriage Tilt Auxiliary bar 240 220 220 250 275 kgf/cm2 244 224 224 255 280 lbf/in2 3480 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 Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Hydraulic Tank Capacity 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 121 litres (26.6 UK gals) Partial flow ('spin on') 10 microns (0.0004 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in) 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

9804/1103

20 - 05 - 02/4C

3630 - E/1-5.4

Issue 1

CONTENTS

Loadalls

20 - 05 - 02/15

532 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

From m/c no. 567362

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 Servo Pressure Range M/c nos. to 771428 M/c nos. from 771429 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 (A port) Carriage Tilt Dump, rod side (B port) Rams Boom Lift Boom Extension Outer Boom Extension Inner Tilt Displacement Stabiliser Sway Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Hydraulic Tank Capacity Fan Motor Oil Flow * Max fan speed at Max engine rev/min 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) 131 litres (28.8 gals) Partial flow ('spin on') 12 microns (0.0005 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in) 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 bar 10-20 10-30 bar 241 138 138 330 275 Bore mm in 130 5.1 120 4.7 100 3.9 130 5.1 90 3.5 110 4.3 110 4.3 kgf/cm2 10.2-20.4 10.2-30.6 kgf/cm2 245 140 140 336 280 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 lbf/in2 145-290 145-435 lbf/in2 3500 2000 Sway ram option A.R.V. 2000 Sway ram option A.R.V. 4785 3987 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

9804/1103

20 - 05 - 02/15

3630 - E/1-1.2

Issue 3*

CONTENTS

Loadalls

20 - 05 - 02/16

537, 550 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

From m/c no. 767001

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 Servo Pressure Range M/c nos. to 771428 M/c nos. from 771429 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 (A port) Carriage Tilt Dump, rod side (B port) Rams Boom Lift Boom Extension Outer Boom Extension Inner Tilt Displacement Stabiliser Sway Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Hydraulic Tank Capacity Fan Motor Oil Flow * Max fan speed at Max engine rev/min 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) 131 litres (28.8 gals) Partial flow ('spin on') 12 microns (0.0005 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in) 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 bar 10-20 10-30 bar 241 138 138 330 275 Bore mm in 160 6.2 130 5.1 110 4.3 140 5.5 90 3.5 110 4.3 110 4.3 kgf/cm2 10.2-20.4 10.2-30.6 kgf/cm2 245 140 140 336 280 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 lbf/in2 145-290 145-345 lbf/in2 3500 2000 Sway ram option A.R.V. 2000 Sway ram option A.R.V. 4785 3987 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

9804/1103

20 - 05 - 02/16

3630 - E/1-2.2

Issue 3*

CONTENTS

Loadalls

20 - 05 - 02/17

528-70, 528S Data - Hydraulics


Pump Type Displacement Flow at 2200 engine rev/min: at zero pressure at system pressure Control Valves Type Loading Pattern: Services Operated Mode of Operation 528-70 Mechanical Mechanical Mechanical Mechanical lbf/in2 145 - 435 Parallel service, double acting spools. 79.0 litres/min 75.0 litres/min 17.4 UK gal/min 16.5 UK gal/min Gear type 36 cc/rev

From m/c no. 796000

21.0 US gal/min 20.0 US gal/min

Spool 1 Spool 2 Spool 3 Spool 4

Auxiliary Boom Raise & Lower Carriage Tilt Boom Extend & Retract bar 10 - 30 kgf/cm2 10.2 - 30.6

528S Servo operated Mechanical Mechanical Servo operated

Servo Pressure:

Note: Spools 3 and 4 are reversed on 528-70 machines fitted with a placing control pattern. Relief Valve Operating Pressures bar 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 Weight kg 94 91 63 71 30 240 193 193 250 276 kgf/cm2 244 196 196 254 280 Rod Dia. mm in 60 50 70 75 40 2.3 1.9 2.7 2.9 1.5 lbf/in2 3480 2798 2798 3625 4000 Stroke mm in 1163 2300 384 334 750 45.7 90.5 15.1 13.1 29.5 Open centre mm in 2666 4885 1126 1026 1745 104.9 192.3 44.3 40.4 68.7 Closed centre mm in 1503 2585 742 692 995 59.1

Bore mm in 110 70 120 130 70 4.3 2.7 4.7 5.1 2.7

Boom Lift Boom Extension 101.7 Tilt Ram (528-70) Tilt Ram (528S) Displacement Filter Return Filter Type Filtration Size Relief Valve Setting Suction Strainer Type Filtration Size

29.2 27.2 39.1

Partial flow 5 microns (0.00025 in) 3 bar 'spin on' 125 microns (0.005 in)

9804/1103

20 - 05 - 02/17

3650 - E/1-1.2

Issue 1

CONTENTS

Loadalls

20 - 05 - 02/18

506B, 506C Data - Hydraulics


Pump Type Displacement Flow at 2200 engine rev/min at zero pressure at system pressure 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. 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 506B Gear type 40 cc/rev 88.0 litres/min (23.2 US gal/min) 85.0 litres/min (22.5 US gal/min) 506C Gear Type 41 cc/rev 90.2 litres (23.8 US gal/min) 87.0 litres (23.0 US gal/min)

Services Operated Spool 1 Spool 2 Spool 3 Spool 4 Spool 5 Anti-cavitation check valves fitted to all services Relief Valve Operating Pressures Main Relief Valve (M.R.V.) 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) From m/n serial no. 585208 Boom extend (Port A) Boom retract (Port B) Rams Boom Lift Boom Extension Tilt Ram Displacement Sway Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Fan Motor Type Ambient temperature zone Max fan speed at Max engine rev/min

bar 238

kgf/cm2 241

lbf/in2 3450

bar 238

kgf/cm2 241

lbf/in2 3450

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

Bore mm in 110 4.3 110 4.3 120 4.7 120 4.7 110 4.3

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

230 2193 Bore mm 110 110 120 120 110

233 196 Rod Dia. mm in 70 2.7 70 2.7 65 2.5 65 2.5 50 1.9

3335 2800 Stroke mm in 102040.1 2625103.3 422 16.6 335 13.2 178 7.0

in 4.3 4.3 4.7 4.7 4.3

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 40C to 46C 2400 rev/min

Gear type (15 cc/rev) 20 in. fan 40C to 46C 2400 rev/min

9804/1103

20 - 05 - 02/18

3640U - E/1-1.3 & E1/1-2.3

Issue 1

CONTENTS

Loadalls

20 - 05 - 02/19

506C (HL), 508C Data - Hydraulics


Pump Type Displacement Flow at 2200 engine rev/min at zero pressure at system pressure Control Valves Type Services Operated Spool 1 Spool 2 Spool 3 Spool 4 Spool 5 Anti-cavitation check valves fitted to all services Relief Valve Operating Pressures Main Relief Valve (M.R.V.) 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) From machine serial number 585196: Boom Extend (Port A) Boom Retract (Port B) Rams Boom Lift Boom Extension Tilt Ram Displacement Sway Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Fan Motor Type Ambient temperature zone Max fan speed at Max engine rev/min Gear type (8.4 cc/rev) 20 in. fan 40C to 46C 2600 rev/min Partial flow ('spin on') 25 microns (0.001 in) 2 bar 125 microns (0.005 in) mm 120 110 120 120 110 230 207 Bore in 4.7 4.3 4.7 4.7 4.3 206 210 2944 3000 Rod Dia. mm in 75 3.0 75 3.0 65 2.5 65 2.5 50 1.9 Stroke mm 1020 3,187 422 335 178 in 40.1 125.5 16.6 13.2 7.0 bar 238 kgf/cm2 241 lbf/in2 3450 Parallel service, double acting spools, except for sway which is a motor spool. Boom Raise & Lower Auxiliary Service Tilt Forwards and Backwards Boom Extend and Retract Sway Gear type 50 cc/rev 110.0 litres/min 105.0 litres/min 29.0 US gal/min 27.6 US gal/min

138 138 138 241 193 207

140 140 140 246 196 210

2000 2000 2000 3500 2800 3000

9804/1103

20 - 05 - 02/19

3640U - E/1-3.3

Issue 1

CONTENTS

Loadalls

20 - 05 - 02/20

540-170, 5508 with Servo Controls Data - Hydraulics


Triple Pump Type Main pump 2PR041 Steer pump 2PR033 Fan pump 1PX160

From m/c no. 780925

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 Servo Pressure Range Parallel service, 6 spools.

Boom Raise & Lower Boom Extend & Retract Carriage Tilt Auxiliary Right Hand Stabiliser Left Hand Stabiliser bar 10 - 30 kgf/cm2 10.2 - 30.6 kgf/cm2 265 140 140 280 336 lbf/in2 145 - 435 lbf/in2 3770 2000 2000 4000 4785

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, rod side (A port) Carriage Tilt Crowd, head side (B port) Remote Control Valve Type Servo Operation Spool 1 Spool 2 Servo Pressure Range

bar 260 138 138 276 330

Parallel service, 2 spools.

Boom Raise & Lower Boom Extend bar 10 - 30 kgf/cm2 10.2 - 30.6 kgf/cm2 245 lbf/in2 145 - 435 lbf/in2 3481

Relief Valve Operating Pressures Main Relief Valve (M.R.V.) Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Hydraulic Tank Capacity Fan Motor Oil Flow Max fan speed at Max engine rev/min
9804/1103

bar 240

Partial flow ('spin on') 10 microns (0.0004 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in)

180 litres (40 UK gals) approx.

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

CONTENTS

Loadalls

20 - 05 - 03/1

ALL MODELS Data - Engine


Type

From m/c no. 567362

Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance - Cold Oil Pressure (Hot) at maximum speed Maximum Air Cleaner Restriction Fuel System

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) AA Build (76 HP) C.A.V. D.P.A. Mechanical DM55L/1000/1/2420 16.5 BTDC 850 rev/min 900 rev/min 2200 rev/min 2420 rev/min HZ 220 atm AB (94.5 HP) Build C.A.V. D.P.A. Mechanical CM78L/1100/1/2420 15.5 BTDC 850 rev/min 900 rev/min 2200 rev/min 2420 rev/min JG 230 atm AB (102 HP) Build C.A.V. D.P.A. Mechanical AM77L/800/1/2420 19.5 BTDC 850 rev/min 900 rev/min 2200 rev/min 2420 rev/min JF 250 atm

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 Cooling System Coolant Pressure Coolant Temperature (Normal) Temperature Warning Light operates at: Steer/Fan Pump - Fan section Type Flow at max. engine rev/min at zero pressure Fan Motor

0.48 bar (7 lbf/in2) 80-85 C (176-185 F) 98 C (208 F)

Sundstrand, gear type 25 litres/min 5.5 UK gal/min 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

20 - 05 - 03/2

520-55, 526-55,526, 526S Data - Engine


Type * Build Codes:

From m/c no. 277001

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 Induction System Air Cleaner Type Maximum Air Cleaner Restriction * Lubrication System Oil Pump Type Oil Pressure (Hot) at maximum 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

2 stage, dry element 635 mm (25 in H2O)

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 - 185F) 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

Loadalls

20 - 05 - 03/3

* 520-50, * Data Type:

525-50, 525-52

From m/c no. 754000

- Engine
JCB diesel engine, 4 cylinder, water cooled

Build Codes: 520-50, 525-50 525-52 Bore (nominal) AA, AK builds AR builds Stroke Swept Volume AA, AK builds Compression Ratio AA builds AR builds AK builds Compression Pressure Injection Sequence Valve Clearance - Cold or Hot - Inlet - Exhaust Idling Speed Maximum Governed Speed Maximum No-load Speed AA builds AR builds AK builds

AA 50550- naturally aspirated (76 HP) AR 50690 - naturally aspirated, low emission (75 HP) AK - turbocharged, low emission (100 HP)

100mm (3.937 in) 103mm (4.055 in) 127mm (5.000 in)

4 litres (243 in3)

16.5:1 17.25:1 18.5:1 20-30 bar (300-450 lbf/in2) 1,3,4,2

0.20mm (0.008 in) 0.45mm (0.018 in) 750 rev/min 2000 rev/min

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 Lubrication System Oil Pump Type Oil Pressure (Hot) at maximum speed 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) Eccentric rotor 2.1 bar (30 lbf/in2) 2 stage, dry element 635mm (25 in H2O)

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

20 - 05 - 03/4

530, 535, 540 532, 537, 550 Data - Engine


Type

From m/c no. 767001

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 Stroke Swept Volume AA, AB, AK Builds AR Builds Compression Ratio AA, AB Builds AR Builds AK Builds Compression Pressure Injection Sequence Valve Clearance - Cold

100mm (3.937 in) 103 mm (4.055 in) 127mm (5.000 in)

4 litres (243 in3) 4.23 litres (258 in3)

16.5 : 1 17.25 : 1 18.5 : 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) 750 rev/min (AA/AB) 800 rev/min (AR/AK) 2200 rev/min

Idling Speed

Maximum Governed Speed Maximum No-load Speed AA/AB Build AR/AK Build Injection System Details 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:

2420 rev/min 2350 rev/min - refer to appropriate Engine Service Manual (see below)

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) AA - naturally aspirated (76 HP) AB - turbo charged (96 hp) AR - naturally aspirated (low emission) 80 hp AK - turbo charged (low emission) 100 hp AR - naturally aspirated (low emission) 80 hp AB - turbo charged (96 hp) AK - turbo charged (low emission) 100 hp

506C:

506C(HL): 508C:

Bore (nominal) AA, AK builds AR builds Stroke Swept Volume AA, AK builds AR builds Compression Ratio

3.937 in (100mm) 4.055 in (103mm) 5.000 in (127mm)

243 in3 (4 litres) 258 in3 (4.23 litres) AA Builds 16.5:1 AR Builds 17.25:1 AK Builds 18.5:1

Compression Pressure Variance between cylinders Injection Sequence Valve Clearance - Cold or Hot - Inlet - Exhaust Idling Speed

300-500 lbf/in2 (20 to 35 bar) typical 3.5 bar (50 lbf/in2) maximum 1,3,4,2 0.008 in (0.20mm) 0.018 in (0.45mm) AA, AB Builds 750 rev/min (2) 2200 rev/min 2420 rev/min 2350 rev/min AR, AK Builds 800 rev/min (25)

Maximum Governed Speed High Idle Speed (AA, AB Builds) High Idle Speed (AR, AK Builds) Induction System Air Cleaner Type Maximum Air Cleaner Restriction Lubrication System Oil Pump Type Oil Pressure (Hot) at maximum speed

2 stage, dry element 635mm (25 in H2O)

Eccentric rotor AA Builds 30 lbf/in2 (2.1 bar) AB, AK Builds 2.6 bar (40 lbf/in2) AR Builds 2.0 bar (30 lbf/in2)

Cooling system Coolant Pressure Coolant Temperature (Normal) Temperature Warning Light operates at Fan Speed (506) Fan Speed (506HL, 508)

0.48 bar (7 lbf/in2) 80-85C (176-185F) 98C (208F) 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

CONTENTS

Loadalls

20 - 05 - 04/1

525-58/67, 527-58/67, 530-67/95 & 535-67, 505-19, 505-22 Data - Axles


FRONT AXLE Type Weight (approximate) Overall Gear Ratio Crownwheel & Pinion Ratio Hub Reduction 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 490 kg (1100 lb) 18.16:1 (Germany 13.7:1) 3.36:1 (Germany 2.54:1) 5.4:1

From m/c no. 567362

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 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 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

530-110, 506-36
FRONT AXLE Type Weight (approximate) Overall Gear Ratio Crownwheel & Pinion Ratio Hub Reduction 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 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

9804/1103

20 - 05 - 04/1

Issue 3

CONTENTS

Loadalls

20 - 05 - 04/2

Data - Axles
*

520-55 RS Machines from m/c no. 277001


Front Axle Type Axle Reduction Drop Box Location Reduction ratio Rear Axle Type Axle Reduction Steer angle Toe in Rigid, 2 wet brake packs, standard or limited slip differential 10.667:1

Rear face of front axle, housing parking brake, 2/4 wheel disconnect (if fitted) 1.178:1

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 Drop Box Location Reduction ratio 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

Rear face of front axle, housing parking brake, 2/4 wheel disconnect (if fitted) 1.178:1

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

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

9804/1103

20 - 05 - 04/2

3610 - F/1-1.5

Issue 5*

CONTENTS

Loadalls

20 - 05 - 04/3

* 520-50,

526-55, 526, 526S

Data - Axles
* All

526-55 Machines, 526 & 526S Machines to Serial No. 280299


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

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

3610 - F/1-2.4

* 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) 35 13 6 :1 0 0 1 0 330kg (728lb) approx 16.2 : 1 3:1 33 11 5.4 : 1 0 0 1 0

From m/c no. 754000

3610 - F/1-1.3

526S

From m/c no. 280300

Front Axle Type Brakes Steering Weight (approximate) Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction 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 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

Colour Code: Blue

3610 - F/1-2.4

9804/1103

20 - 05 - 04/3

Issue 5*

CONTENTS

Loadalls

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 Drop Box Drop Box Ratio Drop Box Ratio (Germany) Rear Axle Type Steering Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction Tyres and Pressures 528-70 Size 1300-24 15.5/80-24 Ply 15 12 528S Size 17.5LR24 Ply lbf/in2 54.0 Bar 3.7 lbf/in2 78 58.0 Bar 5.4 4.0 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 1.547:1 1.184:1 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

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 506C (HL) & 508C 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

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 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) 24.98:1 4.63:1 5.4:1 10 0 1 Zero Zero

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*

CONTENTS

Loadalls

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 Ply 10 12 Bar 3.0 3.0 2.45

Front
lbf/in2 43.5 43.5 35.5 Bar 3.0 3.0 2.45

Rear
lbf/in2 43.5 43.5 35.5 Manufacturer/Type Michelin/Traction Sure Grip/Traction Industrial Traction

525-67, 527-67
Size 17.5 - LR 24 15.5/80 - 24 15.5-25 Ply 10 12 Bar 3.7 4.0 4.0

Front
lbf/in2 54 58 58 Bar 3.7 4.0 4.0

Rear
lbf/in2 54 58 58 Manufacturer/Type Michelin/Traction Sure Grip/Traction Industrial Traction

530-67
Size 17.5 - LR 24 15.5/80 - 24 15.5-25 Ply 10 12 Bar 3.7 4.0 4.0

Front
lbf/in2 54 58 58 Bar 3.7 4.0 4.0

Rear
lbf/in2 54 58 58 Manufacturer/Type Michelin/Traction Sure Grip/Traction Industrial Traction

535-67
Size 15.5/80 - 24 15.5-25 Ply 10 12 Bar 4.0 4.0

Front
lbf/in2 58 58 Bar 4.0 4.0

Rear
lbf/in2 58 58 Manufacturer/Type Sure Grip/Traction Industrial Traction

530-95
Size 17.5 - LR 24 Ply 12 Bar 4.0

Front
lbf/in2 58 Bar 4.0

Rear
lbf/in2 58 Manufacturer/Type Sure Grip/Traction

505-19
Size 15.5-25 Ply 12 Bar 2.45

Front
lbf/in2 35.5 Bar 2.45

Rear
lbf/in2 35.5 Manufacturer/Type Firestone

505-22
Size 15.5-25 Ply 12 Bar 3.9

Front
lbf/in2 57 Bar 3.9

Rear
lbf/in2 57 Manufacturer/Type Firestone

530-110
Size 17.5 - LR 24 15.5-25 15.5 R25 Ply 10 12 Bar 4.0 4.0 4.0

Front
lbf/in2 58 58 58 Bar 4.0 4.0 4.0

Rear
lbf/in2 58 58 58 Manufacturer/Type Sure Grip/Traction Industrial Traction Michelin/Traction

506-36

Front
lbf/in2 58 Bar 4.0

Rear
lbf/in2 58 Manufacturer/Type Firestone

Size Ply Bar 15.5-25 12 4.0 Note: All tyres are water/calcium choride ballasted.

530-120
Size 15.5-25 15.5/80 - 24 Ply 12 12 Bar 4.0 4.0

Front
lbf/in2 58 58 Bar 4.0 4.0

Rear
lbf/in2 58 58 Manufacturer/Type Industrial Traction Sure Grip/Traction

9804/1103

20 - 05 - 04A/1

Issue 1

CONTENTS

Loadalls

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 Ply 14 Bar 4.0

Front
lbf/in2 58 Bar 4.0

Rear
lbf/in2 58 Type Industrial Traction

537-130
Size 15.5-25 Ply 14 Bar 4.0

Front
lbf/in2 58 Bar 4.0

Rear
lbf/in2 58 Type Industrial Traction

508-40

Front
lbf/in2 58 Bar 4.0

Rear
lbf/in2 58 Type Industrial Traction

Size Ply Bar 15.5-25 12 4.0 Note: All tyres are water/calcium choride ballasted.

510-40

Front
lbf/in2 65 Bar 4.48

Rear
lbf/in2 65 Type Industrial Traction

Size Ply Bar 17.5-25 14 4.48 Note: All tyres are water/calcium choride ballasted.

520-55
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 Ply 10 10 10 Bar 3.5 3.0 3.5 4.0 3.5 4.0

Front
lbf/in2 51 44 51 58 51 58 Bar 3.5 3.0 3.5 4.0 3.5 4.0

Rear
lbf/in2 51 44 51 58 51 58
3610 - F/1-3.2

526-55 & 526


Size 405 x 70 x R20 375 x 75 x R20 16.0/20-70 Ply 10 Bar 4.0 4.0 2.9

Front
lbf/in2 58 58 42 Bar 4.0 4.0 2.9

Rear
lbf/in2 58 58 42

3610 - F/1-3.2

3610 - F/1-3.2

526S (526 N.Am)


Size 15.5/80-24 17.5LR 24 Ply 10 Bar 3.0 3.0

Front
lbf/in2 44 44 Bar 3.0 3.0

Rear
lbf/in2 44 44

520-50
Size 10.5/80 x 80 10.5/18 MPT 15.0/55-17 Ply 10 10 10 Bar 3.0 4.0 3.5

Front
lbf/in2 44 58 51 Bar 3.0 4.0 3.5

Rear
lbf/in2 44 58 51

3620 - F/1-1.3

3620 - F/1-1.3

9804/1103

20 - 05 - 04A/2

Issue 1

CONTENTS

Loadalls

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 (ETRT