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Service Data Book 1992 on SEPTEMBER 2003 PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB

Service Data Book 1992 on

SEPTEMBER 2003

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

Publication No. 9804/1103

Introduction

General Information

Backhoe Loaders

Loadalls

RTFL

Excavators

Wheeled Loaders

Fastrac

Skidsteer Range

Robot

1CX

Teletruk

Articulated Dump Trucks

INDEX
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
A
location of pages. Page number example: 20 - 05 - 02/1 A BC Machine Range e.g.
location of pages. Page number example: 20 - 05 - 02/1 A BC Machine Range e.g.

BC

Machine Range e.g. Backhoe Loader, Loadall etc.

Subject classification Data, Fault Finding, etc

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.

CONTENTS INDEX
CONTENTS
INDEX

General

Contents

Metric Units

1 -

1

Conversion Factors Conversion Tables

1 - 2

- Capacity

1 - 3

- Length

1 - 4

- Pressure

1 - 5

- Temperature

1 - 6

Hydraulic Formulae Torque Settings Antifreeze Protection Hydraulic Circuit Symbols

1 - 7 2 - 1 3 - 1 4 - 1

CONTENTS

CONTENTS

General

1

- 1

Metrication - S.I.Units

The following list gives the units and symbols to be found in technical publications.

Quantity

Name of Unit

Unit Symbol

Angle

second

"

minute

'

degree

0

Area

square millimetre

mm 2

Capacity

litre

l

Electric

— Current

Ampere

A

Resistance

ohm

Tension

Volt

V

Flow

litre per minute

l/m

Force

Newton

N

Length

millimetre

mm

metre

m

kilometre

km

Mass

kilogram

kg

Moment of force

Newton metre

Nm

Pressure

bar

bar

Speed

kilometre per hour

km/h

Temperature

 

degree Celsius

°C

Time

second

s

minute

min

hour

h

day

d

Volume

cubic millimetre

mm 3

cubic centimetre

cm 3

cubic metre

m 3

9804/1103

1

- 1

Issue 1

CONTENTS

CONTENTS

General

1 - 2

Conversion Factors

Imperial to S.l. Units

To convert imperial units to Sl multiply by the conversion factor.

To convert Sl units to imperial divide by the conversion factor.

Quantity

Area

Capacity

Flow

Force

Length

Mass

Moment of force

Pressure

Speed

Volume

Imperial

in 2

ft 2

yd 2

pints—UK

pints—US

gallon—UK

gallon—US

gal/min—UK

gal/min—US

Ibf

in

mile

Ib

Ibf in

Ibf ft

Ibf ft

Ibf/in

Ibf/in

2

2

ft/s

mile/h

in 3

yd 3

Metric

mm 2

m

m

2

2

I

I

I

l

l/min

I/min

N

mm

km

kg

Nm

Nm

kgf m

bar

kgf/cm 2

m/s

km/h

cm 3

m 3

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

CONTENTS

CONTENTS

General

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

UK gallon

Litres

UK gallon

1.201

1

0.833

4.546

1

0.219

2.402

2

1.665

9.092

2

0.440

3.603

3

2.498

13.638

3

0.659

4.804

4

3.331

18.184

4

0.879

6.005

5

4.163

22.730

5

1.099

7.206

6

4.996

27.276

6

1.319

8.407

7

5.829

31.822

7

1.539

9.608

8

6.661

36.368

8

1.759

10.809

9

7.494

40.914

9

1.979

12.010

10

8.327

45.461

10

2.199

18.014

15

12.490

68.191

15

3.299

24.019

20

16.653

90.922

20

4.399

30.024

25

20.815

113.652

25

5.499

36.029

30

24.980

136.383

30

6.599

42.033

35

29.143

159.113

35

7.699

48.038

40

33.307

181.844

40

8.799

54.043

45

37.470

204.574

45

9.898

60.047

50

41.634

227.305

50

10.998

66.052

55

45.797

250.035

55

12.098

72.057

60

49.960

272.766

60

13.198

78.062

65

54.124

295.496

65

14.298

84.067

70

58.287

318.227

70

15.398

90.071

75

62.450

340.957

75

16.498

96.076

80

66.614

363.688

80

17.598

102.081

85

70.777

386.418

85

18.697

108.086

90

74.940

409.149

90

19.797

114.090

95

79.104

431.879

95

20.897

120.095

100

83.267

454.610

100

21.997

CONTENTS

CONTENTS

General

1 - 4

Conversion Tables - Length

Fractions of an inch to decimals of an inch and millimetres.

 

Inch

Millimetre

1/64

0.015 625

0.396 875

1/32

0.031 250

0.793 750

1/16

0.062 500

1.587 500

1/8

0.125 000

3.175 000

3/16

0.187 500

4.762 500

1/4

0.250 000

6.350 000

5/16

0.312 500

7.937 500

3/8

0.375 000

9.525 000

7/16

0.437 500

11.112 500

1/2

0.500 000

12.700 000

9/16

0.562 500

14.287 500

5/8

0.625 000

15.875 000

11/16

0.687 500

17.462 500

3/4

0.750 000

19.050 000

13/16

0.812 500

20.637 500

7/8

0.875 000

22.225 000

15/16

0.937 500

23.812 500

1

1.000 000

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

Millimetres

Feet

Metres

0.039

1

25.4

3.281

1

0.3048

0.078

2

50.8

6.562

2

0.6096

0.118

3

76.2

9.843

3

0.9144

0.157

4

101.6

13.124

4

1.2192

0.197

5

127.0

16.405

5

1.5240

0.236

6

152.4

19.686

6

1.8288

0.275

7

177.8

22.967

7

2.1336

0.315

8

203.2

26.248

8

2.4384

0.354

9

228.6

29.529

9

2.7432

0.394

10

254.0

32.810

10

3.0480

0.590

15

381.0

49.215

15

4.5720

0.787

20

508.0

65.620

20

6.0960

0.984

25

635.0

82.025

25

7.6200

1.181

30

762.0

98.430

30

9.1440

1.378

35

889.0

114.835

35

10.668

1.574

40

1016.0

131.240

40

12.192

1.772

45

1143.0

147.645

45

13.716

1.968

50

1270.0

164.050

50

15.240

2.165

55

1397.0

180.455

55

16.764

2.362

60

1524.0

196.860

60

18.288

2.559

65

1651.0

213.265

65

19.812

2.756

70

1778.0

229.670

70

21.336

2.953

75

1905.0

246.075

75

22.860

3.149

80

2032.0

262.480

80

24.384

3.346

85

2159.0

278.885

85

25.908

3.543

90

2286.0

295.290

90

27.432

3.740

95

2413.0

311.695

95

28.956

3.937

100

2540.0

328.100

100

30.480

CONTENTS

CONTENTS

General

1 - 5

Conversion Tables - Pressure

Ibf/in 2 to kgf/cm 2 and Bar

Select the known pressure from the centre column and read off the required conversion.

Ibf/in 2

kgf/cm 2

Ibf/in 2

Bar

142.233

10

0.703

145.038

10

0.690

284.466

20

1.406

290.076

20

1.379

426.699

30

2.109

435.114

30

2.069

568.932

40

2.812

580.152

40

2.758

711.165

50

3.516

725.190

50

3.448

853.398

60

4.219

870.228

60

4.137

995.631

70

4.922

1015.266

70

4.827

1137.864

80

5.625

1160.304

80

5.516

1280.097

90

6.328

1305.342

90

6.206

1422.330

100

7.031

1450.380

100

6.895

2844.660

200

14.062

2900.760

200

13.790

4266.990

300

21.093

4351.140

300

20.685

5689.320

400

28.124

5801.520

400

27.580

7111.650

500

35.155

7251.900

500

34.475

8533.980

600

42.186

8702.280

600

41.370

9956.310

700

49.217

10152.660

700

48.265

11378.640

800

56.248

11603.040

800

55.160

12800.970

900

63.279

13053.420

900

62.055

14223.300

1000

70.310

14503.800

1000

68.950

28446.600

2000

140.620

29007.600

2000

137.900

42669.900

3000

210.930

43511.400

3000

206.850

CONTENTS

CONTENTS

General

1 - 6

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

- 25

- 13.0

87.8

190

374

- 28.9

- 20

- 4.0

90.6

195

383

- 26.1

- 15

5.0

93.3

200

392

- 23.3

- 10

14.0

96.1

205

401

- 20.6

- 5

23.0

98.9

210

410

- 17.8

0

32.0

101.7

215

419

- 15.0

5

41.0

104.4

220

428

- 12.2

10

50.0

107.2

225

437

- 9.4

15

59.0

110.0

230

446

- 6.7

20

68.0

112.8

235

455

- 3.9

25

77.0

115.6

240

464

- 1.1

30

85.0

118.3

245

473

1.7

35

95.0

121.1

250

482

4.4

40

104.0

123.9

255

491

7.2

45

113.0

126.7

260

500

10.0

50

122.0

129.4

265

509

12.8

55

131.0

132.2

270

518

15.6

60

140.0

135.0

275

527

18.3

65

149.0

137.8

280

536

21.1

70

158.0

140.6

285

545

23.9

75

167.0

143.3

290

554

26.7

80

176.0

146.1

295

563

29.4

85

185.0

148.9

300

572

32.2

90

194.0

35.0

95

203.0

37.8

100

212.0

40.6

105

221.0

43.3

110

230.0

46.1

115

239.0

48.9

120

248.0

51.7

125

257.0

54.4

130

266.0

57.2

135

275.0

60.0

140

284.0

62.8

145

293.0

65.6

150

302.0

68.3

155

311.0

71.1

160

320.0

73.9

165

329.0

76.7

170

338.0

79.4

175

347.0

82.2

180

356.0

85.0

185

365.0

CONTENTS

CONTENTS

General

1 - 7

Hydraulic Formulae

Pump flow (litres/min) = Displacement (cm 3 /rev) x Speed (rev/min)

1000

Pump flow (UK gal/min) = Displacement (in 3 /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/in 2 )

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 (mm 2 )

98

Cylinder Thrust (Ibf) = pressure (Ibf/in 2 ) x piston area (in 2 )

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

Hexagon (A/F)

Torque Settings

in.

(mm.)

in.

Nm

kgf m

lbf ft

1/4

(6.3)

7/16

14

1.4

10

5/16

(7.9)

1/2

28

2.8

20

3/8

(9.5)

9/16

49

5.0

36

7/16

(11.1)

5/8

78

8.0

58

1/2

(12.7)

3/4

117

12.0

87

9/16

(14.3)

13/16

170

17.3

125

5/8

(15.9)

15/16

238

24.3

175

3/4

(19.0)

1.1/8

407

41.5

300

7/8

(22.2)

1.5/16

650

66.3

480

1

(25.4)

1.1/2

970

99.0

715

1.1/4

(31.7)

1.7/8

1940

198.0

1430

1.1/2

(38.1)

2.1/4

3390

345.0

2500

Metric Grade 8.8 Bolts

 

Bolt Size

Hexagon

Torque Settings

No.

(mm.)

mm.

Nm

kgf m

lbf ft

M5

(5)

8

7

0.7

5

M6

(6)

10

12

1.2

9

M8

(8)

13

28

3.0

21

M10

(10)

17

56

5.7

42

M12

(12)

19

98

10

72

M16

(16)

24

244

25

180

M20

(20)

30

476

48

352

M24

(24)

36

822

84

607

M30

(30)

46

1633

166

1205

M36

(36)

55

2854

291

2105

Metric Socket-head Capscrews

 
 

Torque Settings

Bolt Size No.

(mm)

Nm

kgfm

lbf ft

M5

(5)

11

1.1

8

M6

(6)

19

2.0

12

M8

(8)

46

4.8

34

M10

(10)

91

9.5

67

M12

(12)

159

16

120

M16

(16)

395

40

290

M20

(20)

770

79

570

M24

(24)

1332

135

980

CONTENTS

General

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

RIVET NUT BOLTS/SCREWS

Bolt Size

Torque Settings (for steel rivet nuts)

 

(mm)

Nm

kgf m

lbf ft

M3

(3)

1.2

0.12

0.9

M4

(4)

3.0

0.3

2.0

M5

(5)

6.0

0.6

4.5

M6

(6)

10

1.0

7.5

M8

(8)

24

2.5

18.0

M10

(10)

48

4.9

35.5

M12

(12)

82

8.4

60.5

HOSE & PIPEWORK CONNECTIONS USING 'O' RING FACE SEALS (ORFS)

CONNECTIONS USING 'O' RING FACE SEALS (ORFS) Note: Adapters A always have a UNF thread for

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

Nominal Diameter

of UNF Thread

Torque Settings

of Metric ThreadTorque Settings

(inches)

Nm

kgf m

lbf ft

(mm)

Nm

kgf m

lbf ft

7/16

20

2.1

15

8

10

1.1

7

9/16

35

3.6

26

10

20

2.1

15

3/4

81

8.3

60

12

35

3.6

26

7/8

108

11.1

80

14

45

4.7

33

11/16

183

18.7

135

16

55

5.8

41

15/16

298

30.5

220

18

70

7.1

52

15/8

380

38.8

280

20

80

8.2

59

17/8

488

50

360

22

100

10

74

 

27

170

17

125

33

310

32

229

42

330

34

243

48

420

43

310

60

500

51

369

ORFS Hydraulic Hose Connections (Item B above)

Nominal Thread

Torque Settings

 

Diameter (inches)

Nm

kgf m

lbf ft

9/16

24

2.5

18

11/16

33

3.3

24

13/16

44

4.8

35

1

58

6.0

43

13/16

84

8.6

62

1 7/16

115

11.8

85

111/16

189

19.4

140

2

244

24.9

180

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

Protects against damage down to

deg C

deg F

deg C

deg F

55%

-36

-33

-41

-42

The strength of the anti-freeze solution must be checked at least once a year, preferably at the beginning of the cold period.

It is an advantage to leave the anti-freeze in all the year round as it gives continued protection against corrosion. Always renew the anti-freeze every two years.

A 50% anti-freeze mixture must be used even if frost protection is not needed. This gives protection against corrosion and raises

the coolant's boiling point.

! WARNING

Antifreeze can be harmful. Obey the manufacturer's instructions when handling neat or diluted antifreeze.

7-3-4-4

CONTENTS

General

Introduction to Hydraulic Schematic Symbols

Complex hydraulic components and circuits can be described Pumps & Motors to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used.

brief description for some of the more common symbols used. Fixed capacity pump one direction of

Fixed capacity pump one direction of flow

Fixed capacity pump two directions of flowsymbols used. Fixed capacity pump one direction of flow Variable capacity pump one direction of flow

direction of flow Fixed capacity pump two directions of flow Variable capacity pump one direction of

Variable capacity pump one direction of flowdirection of flow Fixed capacity pump two directions of flow There are many symbols in use

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)

Springcomponents. General (Basic & Functional Symbols) Flow restriction affected by viscosity Direction of flow

Flow restrictioncomponents. General (Basic & Functional Symbols) Spring affected by viscosity Direction of flow Indication of

affected by viscosity(Basic & Functional Symbols) Spring Flow restriction Direction of flow Indication of rotation Indication of

Direction of flowSymbols) Spring Flow restriction affected by viscosity Indication of rotation Indication of direction and paths of

Indication of rotationFlow restriction affected by viscosity Direction of flow Indication of direction and paths of flow Variable

Indication of direction and paths of flow and paths of flow

of rotation Indication of direction and paths of flow Variable capacity pump two directions of flow

Variable capacity pump two directions of flow two directions of flow

paths of flow Variable capacity pump two directions of flow Fixed capacity motor one direction of

Fixed capacity motor one direction of flowpaths of flow Variable capacity pump two directions of flow Fixed capacity motor two directions of

of flow Fixed capacity motor one direction of flow Fixed capacity motor two directions of flow

Fixed capacity motor two directions of flowof flow Fixed capacity motor one direction of flow Variable control Rams Variable capacity motor one

Variable controlof flow Fixed capacity motor two directions of flow Rams Variable capacity motor one direction of

Rams

capacity motor two directions of flow Variable control Rams Variable capacity motor one direction of flow

Variable capacity motor one direction of flowcapacity motor two directions of flow Variable control Rams Single acting Double acting Double ended Double

Single acting Double acting Double ended Double acting with damping at rod area end
Single acting
Double acting
Double ended
Double acting with
damping at rod area end

Variable capacity motor two directions of flow two directions of flow

CONTENTS

General

Introduction to Hydraulic Schematic Symbols (continued)

Control Valves

Used to enclose several valves indicating that they are supplied as one unit

    3-Position, 4-Port
   
    3-Position, 4-Port
    3-Position, 4-Port

3-Position, 4-Port

   
   

spring centred pilot operated valve

  3-Position, 6-Port
  3-Position, 6-Port
  3-Position, 6-Port
 

3-Position, 6-Port

 
  spring centred hand

spring centred hand

   
 

operated valve

3-Position, 4-Port spring centred solenoid & pilot pressure operated valve
3-Position, 4-Port spring centred solenoid & pilot pressure operated valve
3-Position, 4-Port spring centred solenoid & pilot pressure operated valve

3-Position, 4-Port spring centred solenoid & pilot pressure operated valve

 
3-Position, 4-Port
3-Position, 4-Port

3-Position, 4-Port

spring centred detent

 

hand operated valve

Non - return valvespring centred detent   hand operated valve Non - return valve with back pressure spring Pilot

Non - return valve with back pressure spring back pressure spring

Pilot operated non - return valve non - return valve

One way restrictor High pressure selector (shuttle valve)
One way restrictor
High pressure selector
(shuttle valve)
One way restrictor High pressure selector (shuttle valve) Throttling orifice - normally closed Throttling orifice -
One way restrictor High pressure selector (shuttle valve) Throttling orifice - normally closed Throttling orifice -

Throttling orifice - normally closed normally closed

Throttling orifice - normally open normally open

- normally closed Throttling orifice - normally open Relief valve Variable restrictor 9804/1103 4 - 2

Relief valve

Variable restrictorvalve) Throttling orifice - normally closed Throttling orifice - normally open Relief valve 9804/1103 4 -

CONTENTS

General

Introduction to Hydraulic Schematic Symbols (continued)

Energy Transmissions and Conditioning

 

Working line, return or feed

Pilot control

Drain lines

Flexible pipe

Flexible pipe

Line junction

Line junction

feed Pilot control Drain lines Flexible pipe Line junction Crossing lines Air bleed Line plugged, also
Crossing lines

Crossing lines

Drain lines Flexible pipe Line junction Crossing lines Air bleed Line plugged, also pressure test point
Air bleed

Air bleed

Line plugged, also pressure test point

Line plugged, also pressure test point

Line plugged with take off line
Line plugged with take off line

Line plugged with take off line

pressure test point Line plugged with take off line Quick release couplings - connected Quick release

Quick release couplings - connected

Quick release couplings - disconnected

Reservoir - return line above fluid levelcouplings - connected Quick release couplings - disconnected Reservoir - return line below fluid level Header

Reservoir - return line below fluid level- disconnected Reservoir - return line above fluid level Header tank Pressure sealed tank Accumulator Filter

Header tank above fluid level Reservoir - return line below fluid level Pressure sealed tank Accumulator Filter or

Pressure sealed tanklevel Reservoir - return line below fluid level Header tank Accumulator Filter or strainer Water trap

line below fluid level Header tank Pressure sealed tank Accumulator Filter or strainer Water trap indication
line below fluid level Header tank Pressure sealed tank Accumulator Filter or strainer Water trap indication

Accumulator

Filter or strainerfluid level Header tank Pressure sealed tank Accumulator Water trap indication of coolant flow Cooler -

Water traptank Pressure sealed tank Accumulator Filter or strainer indication of coolant flow Cooler - with no

indication of coolant flowsealed tank Accumulator Filter or strainer Water trap Cooler - with no Cooler - indicating direction

Cooler - with no

Cooler - indicating direction of coolant flowAccumulator Filter or strainer Water trap indication of coolant flow Cooler - with no Heater 9804/1103

Heatertrap indication of coolant flow Cooler - with no Cooler - indicating direction of coolant flow

CONTENTS

General

Introduction to Hydraulic Schematic Symbols (continued)

Control Mechanisms

Rotating shaft-one directionHydraulic Schematic Symbols (continued) Control Mechanisms Rotating shaft-two directions Detent Locking device Over

Rotating shaft-two directions(continued) Control Mechanisms Rotating shaft-one direction Detent Locking device Over centre device Simple linkage

DetentRotating shaft-one direction Rotating shaft-two directions Locking device Over centre device Simple linkage General

Locking deviceshaft-one direction Rotating shaft-two directions Detent Over centre device Simple linkage General control Push

Over centre deviceRotating shaft-two directions Detent Locking device Simple linkage General control Push button operated Lever

Simple linkagedirections Detent Locking device Over centre device General control Push button operated Lever operated Pedal

General controlDetent Locking device Over centre device Simple linkage Push button operated Lever operated Pedal operated Stem

Push button operateddevice Over centre device Simple linkage General control Lever operated Pedal operated Stem operated Spring operated

Lever operateddevice Simple linkage General control Push button operated Pedal operated Stem operated Spring operated Roller operated

Pedal operatedlinkage General control Push button operated Lever operated Stem operated Spring operated Roller operated Roller trip

Stem operatedcontrol Push button operated Lever operated Pedal operated Spring operated Roller operated Roller trip operated (one

Spring operatedbutton operated Lever operated Pedal operated Stem operated Roller operated Roller trip operated (one directional)

Roller operatedLever operated Pedal operated Stem operated Spring operated Roller trip operated (one directional) Solenoid one winding

Roller trip operated (one directional)Pedal operated Stem operated Spring operated Roller operated Solenoid one winding Solenoid two winding Electric motor

Solenoid one windingRoller operated Roller trip operated (one directional) Solenoid two winding Electric motor operated Internal

Solenoid two windingRoller trip operated (one directional) Solenoid one winding Electric motor operated Internal pressure pilot operated

Electric motor operated(one directional) Solenoid one winding Solenoid two winding Internal pressure pilot operated External pressure pilot

one winding Solenoid two winding Electric motor operated Internal pressure pilot operated External pressure pilot

Internal pressure

pilot operated

External pressure

pilot operated

Pressure operated

spring release

Pilot operated by solenoid pilot valvepressure pilot operated Pressure operated spring release Pilot operated by a solenoid or separate pilot valve

Pilot operated by a solenoid or separate pilot valve or separate pilot valve

Pressure gaugeby solenoid pilot valve Pilot operated by a solenoid or separate pilot valve Pressure switch 9804/1103

valve Pilot operated by a solenoid or separate pilot valve Pressure gauge Pressure switch 9804/1103 4

Pressure switch

CONTENTS

General

Introduction to Hydraulic Schematic Symbols (continued)

Control Valves

Control valves are usually represented by one or more square boxes.

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.

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

FIG 1

Position 1

Position 2

Position 3

FIG 2

port FIG 1 Position 1 Position 2 Position 3 FIG 2 Port 1 Port 3 FIG
port FIG 1 Position 1 Position 2 Position 3 FIG 2 Port 1 Port 3 FIG
port FIG 1 Position 1 Position 2 Position 3 FIG 2 Port 1 Port 3 FIG
Port 1 Port 3 FIG 3
Port 1
Port 3
FIG 3
1 Position 2 Position 3 FIG 2 Port 1 Port 3 FIG 3 Port 2 Port
Port 2 Port 4 FIG 4
Port 2
Port 4
FIG 4

FIG 5

1 Position 2 Position 3 FIG 2 Port 1 Port 3 FIG 3 Port 2 Port

CONTENTS

General

Introduction to Hydraulic Schematic Symbols (continued)

Example of Schematic Circuit

Some of the symbols described on the preceding pages have been arranged into a simple schematic circuit shown below.

Hydraulic tank A is a pressurised tank with an internally mounted strainer B on the suction line to the fixed displacement pump C. System pressure is limited to the setting of relief valve D.

Valve spool E is an open-centre spool that is in neutral position; flow from the pump passes through the spool and returns to the hydraulic tank.

Example Circuit Key

A Hydraulic Tank

B Strainer

C Fixed Displacement Pump

D Relief Valve

E Spool

F One Way Valve

G Double Acting Hydraulic Ram

If the lever operated spool is moved away from neutral position hydraulic fluid is directed to either head side or rod side of hydraulic ram G. Notice that the fluid must first open one way valve F before flowing to the ram.

A B C G D E F
A
B
C
G
D
E
F
CONTENTS Backhoe Loaders Contents i
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

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

- 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

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

- 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

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

- 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

10 - 05 - 02/1 10 - 05 - 02/2 10 - 05 - 02/3

- 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

10 - 05 - 03/1 10 - 05 - 03/1 10 - 05 - 03/1

- 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

10 - 05 - 04/1 10 - 05 - 04/1 10 - 05 - 04/1

- 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

10 - 05 - 05/1

- 2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL from m/c no. 657001

- 2CXAM from m/c no. 657001

10 - 05 - 05/2,3 10 - 05 - 05/4

- Tyre Sizes and Pressures