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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
9804/1103
General Section Contents
Issue 1
CONTENTS CONTENTS
General
1-1
Metrication - S.I.Units
The following list gives the units and symbols to be found in technical publications. Quantity 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
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 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
9804/1103
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Issue 1
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 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
9804/1103
1-3
Issue 1
CONTENTS CONTENTS
General
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
9804/1103
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Issue 1
CONTENTS CONTENTS
General
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
9804/1103
1-5
Issue 1
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 - 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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CONTENTS CONTENTS
General
1-7
Hydraulic Formulae
Pump flow (litres/min) = Displacement (cm3/rev) x Speed (rev/min) 1000 Pump flow (UK gal/min) = Displacement (in3/rev) x Speed (rev/min) 277.4
Power output of Hydraulic Pump (kw) = Flow (litres/min) x Pressure (bar) 600 Power output of Hydraulic Pump (hp) = Flow (UK gal/min) x Pressure (Ibf/in2) 1430
Power output of Hydraulic Motor (kw) = Torque (Nm) x Speed (rev/min) 9550 Power output of Hydraulic Motor (hp) = Torque (Ibf ft) x Speed (rev/min) 5250
Cylinder Thrust (kgf) = pressure (bar) x piston area (mm2) 98 Cylinder Thrust (Ibf) = pressure (Ibf/in2) x piston area (in2)
9804/1103
1-7
Issue 1
CONTENTS
General
Torque Settings (for all machines except JS Range)

Use only where no torque setting is specified in the text. Values are for dry threads and may be within three percent of the figures stated. For lubricated threads the values should be REDUCED by one third. Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
UNF Grade 'S' Bolts Bolt Size in. 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
2-1
Issue 1
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
Issue 1
CONTENTS
General
Antifreeze Protection
The protection provided by JCB Universal Anti-freeze is shown below. If any other anti-freeze is used, refer to the manufacturers' instructions and ensure that a corrosion inhibitor is included. DO NOT use solutions of more than 60% or less than 50% or damage to the cooling system will occur. Solution 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
9804/1103
3-1
Issue 1
CONTENTS
General
Introduction to Hydraulic Schematic Symbols

Complex hydraulic components and circuits can be described to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used. There are many symbols in use and it would be impossible to include them all here. However it should be noted that most are only variations or refinements on the basic principles explained here. If more detailed information is required you are recommended to obtain a copy of BS2917 or IS01219. Once familiar with the symbols, the engineer can use hydraulic circuit diagrams as an aid to fault finding. It will be possible to see the complete hydraulic circuit and decipher the relationship between hydraulic components. 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
9804/1103
4-1
Issue 1
CONTENTS
General
Introduction to Hydraulic Schematic Symbols (continued)

Control Valves
Used to enclose several valves indicating that they are supplied as one unit
One way restrictor
3-Position, 4-Port spring centred pilot operated valve
High pressure selector (shuttle valve)
3-Position, 6-Port spring centred hand operated valve
Throttling orifice normally closed
3-Position, 4-Port spring centred solenoid & pilot pressure operated valve
Throttling orifice normally open
3-Position, 4-Port spring centred detent hand operated valve
Relief valve Non - return valve
Non - return valve with back pressure spring Variable restrictor
Pilot operated non - return valve
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Issue 1
CONTENTS
General

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
4-3
Issue 1
CONTENTS
General

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

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

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
9804/1103
4-6
Issue 1
CONTENTS
Backhoe Loaders
Contents i
2CX, 2DX, 210S, 212S and Variants Contents

Page No. * General Information -Lubricants and Capacities - 2CX from m/c no 655000 to 656500 - 210S from m/c no 655000 to 656500 - 2CX, 2CXL, 210S, 210SL from m/c no. 657001 - 2DX from m/c no. 659249 - 2CX from m/c no. 659598 - 2CX, 2DX from m/c no. 659599 (N. America to m/c no 659599) - 210S, 212S from m/c no. 762080 * -Statics Dimensions and Weight - 2CX, 210S from m/c no 655000 to 656500 - 2CX, 210S from m/c no. 657001 - 2CX, 210S with Extending Dipper from m/c no. 657001 - 2CX, 210SL from m/c no. 657001 - 2CX Airmaster from m/c no. 657001 - 2CX Farm Master from m/c no. 657001 - 2CXU, 210SU from m/c no. 657001 - 2DX, 212SU from m/c no. 659249 - 2DX, 212S with Extending Dipper from m/c no. 659249 * Data - Electrical - 2CX, 210S from m/c no. 655000 to 656500 - 2CX, 2CXL, 210S, 210SL from m/c no. 657001 - 2DX from m/c no. 659249 - 2CX, 2DX, 210S and Variants from m/c no. 657001 - 2CX from m/c no. 655030 to 656999 - 2DX from m/c no. 657001 - 2CX from m/c no. 659600 to 761891 - 2CX, 2DX, 210S, 212S from m/c no. 760841 - 212SU (N. Am) from m/c no. 657001 * 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
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*
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
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
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
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
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
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)
* 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
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
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)
ESEN-M2C 86A/B
ISO VG46
ISO VG32
Grease Points
---
JCB MPL Grease
---
JCB HP Grease (High Performance)
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
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)
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
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
API-GL4 API-GL4 ISO VG46 ISO VG32
Grease Points
---
JCB Moly EP#2 Grease
Lithium based, No. 2
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
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
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
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
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
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

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

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
YES: NO:
42
Are the synchroniser spring pins damaged?
YES: NO: YES: NO:
43
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.
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
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

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
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
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
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

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
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
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
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
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

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
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
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
Grease Points
---
JCB MPL Grease or JCB HP Grease Waxoyl
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
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
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
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
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
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
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
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
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
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

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

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

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

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

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

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

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
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
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
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
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
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
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).
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I'@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K ?3@@@@@@@@@@ ?I4@@@@@@@@6K? ?O&@@@@@@@@@ @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0M? ?J@@@@@@@@@@@@@@@@0Mhf?V+MeI4@@@@@@@@@@@@@@@@@L @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? ?N@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K ?N@@@@@@@@@@L? ?I4@@@@@@@@@@@@@@@@@@@@@@@6K ?O2@@@@@@@@@@@ @@@@@@@@ ?7@@@@@@@@@@@@@0M? I'@@@@@@@@@@@@@1 @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K? 3@@@@@@@@@)X I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@ @@@@@@@@ J@@@@@@@@@@@@(M? ?V'@@@@@@@@@@@@@ @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K? N@@@@@@@@@@1 ?I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@ @@@@@@@@ 7@@@@@@@@@@@(Y V4@@@@@@@@@@@@L? @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K? ?3@@@@@@@@@@L? ?I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@ @@@@@@@@ @@@@@@@@@@@(Y? I'@@@@@@@@@@1? @@@@@@@@@(M?he?I'@@@@@@@@@@(M?h?I'@@@@@@@@@@? @@@@@@@@@@@?I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K ?N@@@@@@@@@@1? ?@@@@@@@@@ @@@@@@@@ @@@@@@@@@@@H ?N@@@@@@@@@@@? @@@@@@@@@H N@@@@@@@@@@HhfN@@@@@@@@@@? @@@@@@@@@@5?eI4@@@@@@@@@@@@@@@@@@@@@@@@@@@@6X @@@@@@@@@@@L ?@@@@@@@@@ @@@@@@@@ @@@@@@@@@@5? 3@@@@@@@@@@L @@@@@@@@@? ?@@@@@@@@@@?hf?@@@@@@@@@@? @@@@@@@@@@H?fI4@@@@@@@@@@@@@@@@@@@@@@@@@@@)X? 3@@@@@@@@@@)X? ?@@@@@@@@@ @@@@@@@@ ?J@@@@@@@@@@H? V'@@@@@@@@@1 @@@@@@@@@? ?@@@@@@@@@@?hf?@@@@@@@@@@? @@@@@@@@@@heI4@@@@@@@@@@@@@@@@@@@@@@@@1? N@@@@@@@@@@@1? ?@@@@@@@@@ @@@@@@@@ ?7@@@@@@@@@5 ?N@@@@@@@@@@ @@@@@@@@@? ?@@@@@@@@@@?hf?@@@@@@@@@@? @@@@@@@@@@hfI4@@@@@@@@@@@@@@@@@@@@@@@? ?@@@@@@@@@@@@L ?@@@@@@@@@ @@@@@@@@ ?@@@@@@@@@@H @@@@@@@@@@ @@@@@@@@@? ?@@@@@@@@@@?hf?@@@@@@@@@@? @@@@@@@@@@ I4@@@@@@@@@@@@@@@@@@@@@? ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6?2@@@@@@@@@@@@@)X? ?@@@@@@@@@ @@@@@@@@ ?@@@@@@@@@@? @@@@@@@@@@ @@@@@@@@@? ?@@@@@@@@@@?hf?@@@@@@@@@@? @@@@@@@@@@ ?I4@@@@@@@@@@@@@@@@@@? J@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1? ?@@@@@@@@@ @@@@@@@@ ?@@@@@@@@@@? 3@@@@@@@@@ @@@@@@@@@? ?@@@@@@@@@@?hf?@@@@@@@@@@? @@@@@@@@@@ ?I4@@@@@@@@@@@@@@@@? @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? ?@@@@@@@@@ @@@@@@@@ ?@@@@@@@@@@? N@@@@@@@@@ @@@@@@@@@? ?@@@@@@@@@@?hf?@@@@@@@@@@? @@@@@@@@@@ ?I4@@@@@@@@@@@@@@? ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? ?@@@@@@@@@ @@@@@@@@ ?@@@@@@@@@@? ?@@@@@@@@@ @@@@@@@@@? ?@@@@@@@@@@?hf?@@@@@@@@@@? @@@@@@@@@@ ?W@@@@@@@@@@@@@? @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? ?@@@@@@@@@ @@@@@@@@ ?@@@@@@@@@@? ?@@@@@@@@@ @@@@@@@@@? ?@@@@@@@@@@?hf?@@@@@@@@@5? @@@@@@@@@@ O&@@@@@@@@@@@@@? N@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? ?@@@@@@@@@ @@@@@@@@ ?@@@@@@@@@@? J@@@@@@@@@ @@@@@@@@@? ?@@@@@@@@@@?hf?@@@@@@@@@H? @@@@@@@@@@ O2@@@@@@@@@@@@@@5? ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? ?@@@@@@@@@ @@@@@@@@ ?@@@@@@@@@@? 7@@@@@@@@@ @@@@@@@@@? ?@@@@@@@@@@?hf?@@@@@@@@@ @@@@@@@@@@ ?O2@@@@@@@@@@@@@@@@@H? ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? ?@@@@@@@@@ @@@@@@@@ ?@@@@@@@@@@? @@@@@@@@@@ @@@@@@@@@L ?@@@@@@@@@@?hf?@@@@@@@@@ @@@@@@@@@@ O2@@@@@@@@@@@@@@@@@@@@ ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? ?@@@@@@@@@ @@@@@@@@ ?3@@@@@@@@@L ?J@@@@@@@@@@ @@@@@@@@@1 J@@@@@@@@@@LhfJ@@@@@@@@@ @@@@@@@@@@hfO2@@@@@@@@@@@@@@@@@@@@@@ ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? ?@@@@@@@@@ @@@@@@@@ ?N@@@@@@@@@1 ?7@@@@@@@@@@ @@@@@@@@@@ 7@@@@@@@@@@1he?W&@@@@@@@@@ @@@@@@@@@@hO2@@@@@@@@@@@@@@@@@@@@@@@@@@ ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5? ?@@@@@@@@@ @@@@@@@@ @@@@@@@@@@L? J@@@@@@@@@@5 @@@@@@@@@@L?hf@@@@@@@@@@@@L?h?7@@@@@@@@@@ @@@@@@@@@@gO2@@@@@@@@@@@@@@@@@@@@@@@@@@@@ ?I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0Y? ?@@@@@@@@@ @@@@@@@@ @@@@@@@@@@)X ?W&@@@@@@@@@@H 3@@@@@@@@@)Xhe?J@@@@@@@@@@@@)Kh?@@@@@@@@@@@ @@@@@@@@@@e?O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5 ?I@M ?@@@@@@@@@ @@@@@@@@ @@@@@@@@@@@)X? O&@@@@@@@@@@@? N@@@@@@@@@@1heW&@@@@@@@@@@@@@@6KfO2@@@@@@@@@@@@ @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0Y ?@@@@@@@@@ @@@@@@@@ 3@@@@@@@@@@@)K O2@@@@@@@@@@@@5? ?@@@@@@@@@@@h?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5 @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0M ?@@@@@@@@@ @@@@@@@@ N@@@@@@@@@@@@@6K O2@@@@@@@@@@@@@@H? ?@@@@@@@@@@@@6K?fO&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@H ?J@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0M ?@@@@@@@@@ @@@@@@@@ ?3@@@@@@@@@@@@@@@@6X @@@@@@@@@@@@@@@@@@ ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0M? ?@@@@@@@@@ @@@@@@@@ ?N@@@@@@@@@@@@@@@@@1 @@@@@@@@@@@@@@@@@5 ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5? ?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0M ?@@@@@@@@@ @@@@@@@@ 3@@@@@@@@@@@@@@@@@ @@@@@@@@@@@@@@@@@H ?3@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@H? O&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0M ?@@@@@@@@@ @@@@@@@@ N@@@@@@@@@@@@@@@@@ @@@@@@@@@@@@@@@@5? ?N@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5 O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0M? ?@@@@@@@@@ @@@@@@@@ ?3@@@@@@@@@@@@@@@@ @@@@@@@@@@@@@@@@H? 3@@@@@@@@@@@@@@@@@@@@@@@@@@(?'@@@@@@@@@@@@@@@@@@@@@@@H O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0M? ?@@@@@@@@@ @@@@@@@@ ?N@@@@@@@@@@@@@@@@ @@@@@@@@@@@@@@@5 N@@@@@@@@@@@@@@@@@@@@@@@@@@H?N@@@@@@@@@@@@@@@@@@@@@@5? O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0M? ?@@@@@@@@@ @@@@@@@@ @@@@@@@@@@@@@@@5 @@@@@@@@@@@@@@(Y ?3@@@@@@@@@@@@@@@@@@@@@@@@5?e@@@@@@@@@@@@@@@@@@@@@(Y? ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0M ?@@@@@@@@@ @@@@@@@@ ?I'@@@@@@@@@@@@H @@@@@@@@@@@@@(Y? ?V'@@@@@@@@@@@@@@@@@@@@@@(Y?e?I'@@@@@@@@@@@@@@@@@0Y ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0M? ?@@@@@@@@@ @@@@@@@@L? V'@@@@@@@@@@@? @@@@@@@@@@@@0Y V'@@@@@@@@@@@@@@@@@@@@(YgV'@@@@@@@@@@@@@@(M ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0M ?@@@@@@@@@ @@@@@@@@@? ?V'@@@@@@@@@@? @@@@@@@@@@(M ?V'@@@@@@@@@@@@@@@@@@(Y?g?V4@@@@@@@@@@@@0Y? ?@@@@@@@@@@@@@@@@@@@@@@@@@@@0M ?@@@@@@@@@ @@@@@@@@H? V4@@@@@@@@@? @@@@@@@@@0Y? V4@@@@@@@@@@@@@@@@0YhfI4@@@@@@0M ?@@@@@@@@@@@@@@@@@@@@@@@@0M? ?@@@@@@@@@ @@@@@@@@ I4@@@@@@@? 3@@@@@@0M? I4@@@@@@@@@@@@0M ?@@@@@@@@@@@@@@@@@@@@@0M ?@@@@@@@@@ @@@@@@@@ I4@@@@@? V4@@0M I4@@@@@@@@0M ?@@@@@@@@@@@@@@@@@@@0M ?@@@@@@@@@ @@@@@@@@ ?I4@@? ?@@@@@@@@@@@@@@@@0M? ?@@@@@@@@@ @@@@@@@@ ?@@@@@@@@@@@@@0M ?@@@@@@@@@ @@@@@@@@ ?@@@@@@@@@@@0M ?@@@@@@@@@ @@@@@@@@ ?@@@@@@@@0M? ?@@@@@@@@@ @@@@@@@@ ?@@@@@0M ?@@@@@@@@@ @@@@@@@@L? ?@@@0M ?@@@@@@@@@ @@@@@@@@@? ?@@@@@@@@@ @@@@@@@@H? ?@@@@@@@@@ @@@@@@@@ ?@@@@@@@@@ @@@@@@@@ ?O2@@@@@@@@@@@@@@6K??O@K?O@KfO@K? @@@@@@@@6K?O26KO@KO@KO@KeO@K? ?O@K ?W2@@@@@@@@@@@@@@@@6?26K?O@K O26K O)X? O@K?eO@KO@K O@KO2@@@@@@@@@@@ W2@@@@@@6K ?@@@@@@@@@ @@@@@@@@L? @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6X @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@
! 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
From m/c no. 430001
Circuit Protection
The relays and fuses are located in the side console underneath cover A.
! CAUTION
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
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
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.
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
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
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
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
From m/c no. 400001
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
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
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
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
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
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

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
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

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

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 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
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
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
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
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
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
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
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
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)
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)
Pump/Transmission Stall Speed Combinations - AWS Machines, 12.2 Convertor, Gear Pump, 1000 Series Engine
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)
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
Low Emission Engine Stall Speed Combinations - 2WS Machines

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
Low Emission Engine Stall Speed Combinations - AWS Machines

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
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.
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.
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.
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
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.
Mechanical detent will not hold. 1) Broken detent shaft. 1) Remove detent & inspect.
Electrical detent will not hold. 1) Current broken. 1) Check current going into detent.
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
Is there noise when running with direction selector in neutral and ratio selector in 1st? Is there air in the hydraulic system?
Is pump pressure as specified?
10
11
Are the pump bushes worn?
12
13
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
16
Are clutch sealing rings damaged?
17
18
19
20
21
22
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
26
27
28
29
30
31
32
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
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
36
37
38
Are the synchroniser components damaged?
39
40
Are chips wedged between splines of shaft or gear?
41
42
43
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)
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
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)
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
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
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
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
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
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
Backhoe Loaders
15 - 15 - 01/7
From m/c no. 430001
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
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
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
Backhoe Loaders
15 - 15 - 01/10
From m/c no. 430001
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)
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
9804/1103
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
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
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
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

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

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

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

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
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
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
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
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

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
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
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
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
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
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
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
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
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

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

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

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*
INDEX
Loadalls
Contents iii
- 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
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
Issue 3*
INDEX
Loadalls
Contents v
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
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
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)
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
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)
13 (2.8) 2.0 (0.4)
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
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
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

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
Engine (Coolant)
23.5 (5.2)
JCB Universal Antifreeze/water ( See Coolant Mixtures) JCB Special Transmission Fluid
18.25 (4.0)
ESP-M2C 33G
17 (3.7) 2.0 (0.4)
18 (3.9) 0.75 (0.16)
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
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
Engine (Coolant)
4.4 (17)
JCB Universal Antifreeze/water (See Coolant Mixtures) JCB Special Transmission Fluid
5.7 (22)
ESP-M2C 33G
4.7 (18) 0.6 (2.0)
3.4 (13) 0.5 (2.0)
Hydraulic System
28.8 (110)
ISO VG46 ISO 32
Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. Coolant Mixtures % 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
Engine (Coolant)
4.7 (18)
4.8 (18.25)
ESP-M2C 33G
4.7 (18) 0.5 (2.0)
3.4 (13) 0.5 (2.0)
Hydraulic System
50.2 (190)
ISO VG46 ISO 32
Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. Coolant Mixtures % 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
Engine (Coolant)
6.2 (23.5)
4.8 (18.25)
ESP-M2C 33G
4.5 (17) 0.5 (2.0)
4.7 (18) 0.2 (0.75)
Hydraulic System
77.0 (292)
ISO VG46 ISO 32
Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. Coolant Mixtures % 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
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)
13 (2.8) 2.0 (0.4)
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
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:
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:
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)

9804/1103
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)
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

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)
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
* 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
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
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
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
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
Transmission Syncro Shuttle Powershift Front Axle Housing Hubs (x2) Rear Axle Housing Hubs (x2) Brake System
4.8 (18.25) 3.9 (15.0)
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
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
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)
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 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
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)
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 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)
ESP-M2C 33G
2.3 (9) 0.5 (2)
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
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
ESEN-M2C 86A/B
112 121
24.6 26.6 29.5 32.0
ISO VG46
ISO VG32
ISO VG46 ISO VG15
0.7
0.8
Lithium based
Wear Pad Runways
JCB Waxoyl
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
ESEN-M2C 86A/B
112 121
24.6 26.6 29.5 32.0
ISO VG46
ISO VG32
ISO VG46 ISO VG15
0.7
0.8
Lithium based
Wear Pad Runways
JCB Waxoyl
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 ()
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)
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)
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)
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
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
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
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
9804/1103
20 - 00 - 02/6
Issue 1
CONTENTS
Loadalls
20 - 00 - 02/7
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
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
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
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
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)
D E F G
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)
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)
D E F G
3590 mm (11ft 9in) 300 mm (1ft 0in) 1020 mm (3ft 9in) 4700 Kg (10,362lb)
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)
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
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)
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)
D E G
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
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

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

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

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)
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
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
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
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
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
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

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
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

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
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

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
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

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
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
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

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
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
9804/1103
20 - 05 - 02/9
3610 - E/1-1.5
Issue 5*
CONTENTS
Loadalls
20 - 05 - 02/10

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
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
9804/1103
20 - 05 - 02/10
Issue 2*
CONTENTS
Loadalls
20 - 05 - 02/11

* 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
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
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
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
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
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
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
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
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
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
508-40
Front
lbf/in2 58 Bar 4.0
Rear
510-40
Front
lbf/in2 65 Bar 4.48
Rear
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
525-50
Size 12.5 x 18 335/80 R18 Ply 10/12 10 Bar 4.0 4.5
Front
lbf/in2 58 65 Bar 4.0 4.5
Rear
lbf/in2 58 65
3620 - F/1-1.3
525-52
Size 405/70R20 16.0/70-20 Ply 10 14 Bar TBA TBA
Front
lbf/in2 TBA TBA Bar TBA TBA
Rear
lbf/in2 TBA TBA Type
3620 - F/1-1.3
506B, 506C
Size 15.5-25 1300-24 Ply 12 14 Bar 4.0 5.4
Front
lbf/in2 58 78 Bar 4.0 5.4
Rear
lbf/in2 58 78 Type Industrial Traction
3640U - F/1-4.3
506C (HL), 508C

Size 15.5-25 1300-24 Ply 12 14 Bar 4.0 5.4 lbf/in2 58 78 Bar 4.0 5.4 lbf/in2 58 78 Type Industrial Traction
3640U - F/1-4.3
Note Tires are not water/calcium chloride ballasted on 506C High Lift (HL) machines.
528-70, 506C
Size 13.0-24 15.5/80-24 Ply 14 12 Bar 5.4 4.0
Front
lbf/in2 78 58 Bar 5.4 4.0
Rear
lbf/in2 78 58
8450/192
528S
Size 17.5LR24 460/70R24 15.5/80-24 13.0-24 Ply Bar 3.7 3.7 4.0 5.4
Front
lbf/in2 54 54 58 78 Bar 3.7 3.7 4.0 5.4
Rear
lbf/in2 54 54 58 70
12 14
8450/192
9804/1103
20 - 05 - 04A/3
Issue 1
CONTENTS
Loadalls
20 - 05 - 04A/4
Note: The maximum pressure embossed on the tyre may differ from the pressure stated below. Inflate to pressures below, these are agreed with the tyre manufacturer/s in accordance with the European Tyre and Rim Technical Organisation (ETRTO) standards to satisfy machine stability performance. If the tyres fitted to your machine are not listed, then contact your JCB Distributor for advice, DO NOT guess tyre pressures.
530
Size 17.5 LR 24 15.5/80 x 24 15.5 - 25 12.00 R24 X MINE D2 Ply -10 12 -Bar 3.7 4.0 4.0 4.0
Front
lbf/in2 53 58 58 58 Bar 3.7 4.0 4.0 4.0
Rear
lbf/in2 53 58 58 58 Type Traction Sure Grip/Traction Industrial traction
* 535,
540
Ply 12 10 --Bar 4.0 4.0 4.0 4.0
Front
lbf/in2 58 58 58 58 Bar 4.0 4.0 4.0 4.0
Rear
lbf/in2 58 58 58 58 Type Industrial traction Sure Grip/Traction Traction
Size 15.5 - 25 15.5/80 x 24 445/70 R24 XM47 12.00 R24 X MINE D2
* 532 Size 15.5-25 15.5/80 x 24 16.5/85 x 24 15.5 R25 (L2/L3) 12.00 R24 (L5) Ply 12 12/16 14 Bar 4.0 4.0 4.0 4.5 5.8
Front
lbf/in2 Ballast litres/US gal 58 58 58 65 84 Bar 4.0 4.0 4.0 4.5 5.8
Rear
lbf/in2 Ballast litres/US gal 58 58 58 65 84 Type Industrial Traction Sure Grip/Traction
* 537 Size 15.5-25 16.5/85 x 24 17.5 -25 15.5/80 - 24 15.5 R25 (L2/L30
Front
Ply 12 14 12 16 Bar 4.0 4.0 4.0 4.0 4.5 lbf/in2 58 58 58 58 65 Bar 4.0 4.0 4.0 4.0 4.5
Rear
lbf/in2 58 58 58 58 65 Type Industrial Traction Sure Grip/Traction Sure Grip/Traction
* 550 Size 17.5-25
Front
Ply 12 Bar 4.0 lbf/in2 Ballast litres/US gal 58 288.5 (76.25) Bar 4.0
Rear
lbf/in2 Ballast litres/US gal 58 288.5 976.25) Type Industrial Traction
North America only (if applicable)
9804/1103
20 - 05 - 04A/4
Issue 1
CONTENTS
Loadalls
20 - 05 - 05/1
ALL MODELS Data - Transmission

TECHNICAL DATA Syncro Shuttle parking brake. Weight (dry) Torque Converter Dia. Torque Multiplication at Stall Gear Ratios 157 kg (345 lb) 279mm (11in.) 2.20:1 1st 2nd 3rd 4th bar 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 2.4 - 3.4 0.7 - 6.2 1.3 - 2.0 5.2 - 5.9 1.0 - 1.7 0 - 2.1 0.3 - 0.6 1.0 - 1.7 6.5 5.55:1 3.45:1 1.83:1 1.00:1 kgf/cm2 2.5 - 3.5 0.7 - 6.3 1.4 - 2.1 5.3 - 6.0 1.1 - 1.8 0 - 2.1 0.3 - 0.6 1.1 - 1.8 6.7
From m/c no. 567362
Combined torque converter, reverser, and gearbox unit with integral
Converter Pressures (in neutral) Converter In at 50 deg.C Converter In at 100 deg.C
lbf/in2 35 - 50 10 - 90 20 - 30 75 - 85 15 - 25 0 - 30.5 4.0 - 8.0 15 - 25 95
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
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 7.6 - 9.6 5.5 - 6.2 6.2 - 6.9 5.6 - 6.3 7.7 - 9.8 5.6 - 6.3 6.3 - 7.0 80 - 90 110 - 140 80 - 90 90 - 100
At 100 deg.C
9804/1103
20 - 05 - 05/1
Issue 4*
CONTENTS
Loadalls
20 - 05 - 05/2
ALL MODELS Data - Transmission

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
From m/c no. 567362
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
Cooler at 100 deg.C
Pump at 50 deg.C
520-55 Data - Transmission

As All Models.above except for the following: Weight (dry) Torque Converter Dia. Torque Multiplication at Stall Gear Ratios 157 kg (345 lb) 279mm (11in.) 2.20:1 1st 2nd 3rd 4th Engine Type AA50261 5.55:1 3.45:1 1.83:1 1.00:1 Rev/Min 1800
From m/c no. 277001
Minimum Engine Rev/Min at Converter Stall
* 520-5,
525-50, 525-52
From m/c no. 754000

3620 - F/1-2.3
Data - Transmission
As All Models above except for the following: Clutch Pressure (forward and reverse) bar 7.6 - 9.6 9.0 - 11.0 7.6 - 9.6 7.6 - 9.6 kgf/cm2 7.7 - 9.8 9.1 - 11.2 7.7 - 9.8 7.7 - 9.8
At 50C
lbf/in2 110 - 140 130 - 160 110 - 140 110 - 140
At 100 C
9804/1103
20 - 05 - 05/2
Issue 3*
CONTENTS
Loadalls
20 - 05 - 05/3
* 520,
526 from m/c no. 277001 528 from m/c no. 796000, 506, 508 Data - Transmission
Powershift Designation Weight (dry) Full electro-hydraulic transmission unit with input, reverse, layshaft, mainshaft and 4 wheel drive clutch packs. Torque converter and parking brake integral . PS740 (4 wheel drive) 107 kg (236 lb) Std Ratio Transfer Gear Layshaft Input Gear (4WD) Output Gear (4WD) 45 18 Std Ratio 1st 5.72:1 2nd 3.23:1 3rd 1.77:1 4th 1.00:1 279mm (11in.) 2.20:1 or 2.40:1 or 2.80:1 2.20:1 Ratio 2 (506/508-1) Purple 1 White bar 2.8 - 4.1 4.8 - 6.2 1.9 - 2.3 2.3 - 2.7 6.5 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 0.14 - 0.28 0.28 - 0.55 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 Low Ratio 46 16 Low Ratio 6.58:1 3.71:1 1.77:1 1.00:1 Extra Low Ratio (506, 508) 47 15 21 44 Extra Low Ratio (506, 508) 7.17:1 4.04:1 1.77:1 1.00:1
* Number of Teeth
* Gear Ratios
Torque Converter Dia. Torque Multiplication at Stall
* Torque Converter Colour Code Identification Colour Coded Dots
2.40:1 Ratio 2 Orange 1 (506/508-2) Green 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 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
2.80:1 Ratio 3 Brown
Converter Pressures (in neutral) Converter In at 50 deg.C Converter Out at 50 deg.C Converter Inlet Relief Valve Pressure (max.) Lubrication Pressures (in neutral) At 50 deg.C Mainline Pressure (in neutral) At 50 deg. C Flow Rates (in neutral) Cooler at 50 deg.C Pump at 50 deg.C
lbf/in2 40 - 60 70 - 90 27 - 33 33 - 39 95 lbf/in2 2.0 - 4.0 4.0 - 8.0 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
The following clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2): Input Clutch Pressure (high and low ratio) Reverse Clutch Pressure (high and low ratio) Layshaft Clutch Pressure Mainshaft Clutch Pressure 2/4 Wheel Drive Clutch Pressure * Note 1: For brand new gearboxes (i.e. under 100 hours service) or gear boxes that have been fully serviced the pressures will be slightly higher by approximately 0.7 - 1.0 bar (10 - 15 lbf/in2) than those shown. * Note 2: Using 2nd and 3rd gears in forward and reverse drive will ensure that ALL clutches are energised during the stall test refer to 'Torque Converter Stall Test'.
9804/1103
20 - 05 - 05/3
3610 - F/1-5.1
3650 - F/1-3.1 3640U - F/1-2.2
Issue 3*
CONTENTS
Loadalls
20 - 05 - 05/3A
520, 526 from m/c no. 277001 528 from m/c no. 796000 506, 508 Data - Transmission
Syncro Shuttle CAUTION: Before attempting to tow the machine read carefully the instructions, see Towing Procedure, this Section.
Syncro Shuttle
Combined torque converter, reverser, and gearbox unit Weight (dry) Torque Converter Dia. Torque Multiplication at Stall Gear Ratios 157 kg (345 lb) 279mm (11in.) 2.20:1 1st 2nd 3rd 4th AA/AR Builds (Nat Asp) 2290 rev/min 2000 rev/min 1589 rev/min bar 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 6.5 2.4 - 3.4 0.7 - 6.2 1.3 - 2.0 5.2 - 5.9 1.0 - 1.7 0 - 2.1 0.3 - 0.6 1.0 - 1.7 6.7 5.55:1 3.45:1 1.83:1 1.00:1 506, 508 AA/AB Builds 1650-1750/1830-1930
Stall Speeds Hydraulic only Converter only Hydraulics and Converter Converter Pressures (in neutral) Converter In at 50 deg.C Converter In at 100 deg.C Converter Out at 50 deg.C Converter Out at 100 deg.C
AK Build (Turbo) 2296 rev/min 2156 rev/min 1815 rev/min
kgf/cm2 2.5 - 3.5 0.7 - 6.3 1.4 - 2.1 5.3 - 6.0 1.1 - 1.8 0 - 2.1 0.3 - 0.6 1.1 - 1.8 95
lbf/in2 35 - 50 10 - 90 20 - 30 75 - 85 15 - 25 0 - 30.5 4.0 - 8.0 15 - 25
Converter Inlet Relief Valve Pressure (max.) Lubrication Pressures (in neutral) At 50 deg.C At 100 deg.C Main Line Pressure (in neutral) At 50 deg. C
0.2 - 0.3 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6
0.2 - 0.4 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6
3.0 - 5.0 6.0 - 10.0 2.0 - 3.0 4.0 - 8.0
9.3 - 10.3 10.7 - 11.7 9.3 - 10.3 9.3 - 10.3
9.5 - 10.5 10.9 - 12.0 9.5 - 10.5 9.5 - 10.5
135 - 150 155 - 170 135 - 150 135 - 150
At 100 deg.C Clutch Pressure (forward and reverse) At 50 deg. C
5.5 - 6.2 7.6 - 9.6 5.5 - 6.2 6.2 - 6.9 L/min
5.6 - 6.3 7.7 - 9.8 5.6 - 6.3 6.3 - 7.0
80 - 90 110 - 140 80 - 90 90 - 100
At 100 deg.C Flow Rates (in neutral) Cooler at 50 deg. C At 100 deg.C Pump at 50 deg. C
US gal/min UK 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 2.3 - 3.0 3.2 - 4.4 2.3 - 2.8 5.0 - 5.7 2.5 - 3.3 5.0 - 6.5
10.4 - 13.6 14.5 - 20.0 10.2 - 12.5 22.7 - 26.1 11.0 - 15.0 22.5 - 29.5
9804/1103
20 - 05 - 05/3A
36400 - F/1-1.2
3610 - F/1-4.2 3650 - F/1-2.2
Issue 1
CONTENTS
Loadalls
20 - 05 - 05/4
530, 532, 535, 537, 540, 550 Data - Transmission

Powershift Description Full electro-hydraulic transmission 4 or 5 speed (3 Germany) unit with input, layshaft, mainshaft, reverse, 5th gear (if applicable) and 4 wheel drive clutch packs. PS700 or PS750 2WD 4WD 157 kg (346 lb) 176 kg (388 lb) Extra Low Ratio 1.495 Input Gear Output Gear 4 Speed 279mm (11in) 2.20:1 Ratio 2 purple/1 White 21 44 5 Speed 310mm (12.2in) 2.24:1 Ratio 2 Blue Std Ratio 1.307 23 44
Designation Weight (dry)
2/4 Wheel Drive Ratio 4 Wheel Drive Number of Teeth
Torque Converter Dia. Torque Converter Colour Coded Dots
Converter Pressures (in neutral) Converter In at 50 deg.C
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 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 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 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 40 - 60 70 - 90 27 - 33 33 - 39 95 lbf/in2 2.0 - 4.0 4.0 - 8.0 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
Converter Relief (Safety) Valve Setting Lubrication Pressures (in neutral) At 50 deg.C
Mainline Pressure (in neutral) At 50 deg. C
Pump at 50 deg.C
All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2). Note: For new gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2 ).
9804/1103
20 - 05 - 05/4
3630 - F/1-1.5
Issue 3*
CONTENTS
Loadalls
*
20 - 05 - 05/5
532, 537, 550 Data - Transmission

Front Axle Type Brakes Steering Weight (approximate) Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction Rear Axle Type Brakes Steering Weight (approximate) Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction JCB SD80. Spiral bevel with epicyclic hub reduction Oil immersed multi-plate disc located in hubs 2 steer rams mounted on rear of axle 24.97:1 4.625:1 5.4:1 JCB SD80. Spiral bevel with epicyclic hub reduction Oil immersed multi-plate disc located in centre section 2 steer rams mounted on rear of axle 18.16:1 15.78:1 Germany 3.364:1 2.923 Germany 5.4:1
From m/c no. 767001
Colour Code: Blue Colour Code: Orange
Colour Code: Pink
3660 - F/1-2.1
* Pump/Transmission
Stall Speed Combinations - with 11 inch Converters
* The figures given below apply to bedded-in engines. ie. engines that have done a minimum of 250 working hours, therefore they should not be used for pre-delivery inspection (PDI) checks. They are intended to be used as guideline figures only and should not be considered as servicing parameters.
JCB Diesel Engine Build Codes AA/AB AK/AR
* Torque Converter Stall 106 hp Turbo (rpm) 76 hp NA (rpm) 102 hp Turbo (rpm) 80 hp NA (rpm) * Combined Stall 106 hp Turbo 76 hp NA 102 hp Turbo 80 hp NA
1965 100 1640 100 -
1950 100 1740 100
(rpm) (rpm) (rpm) (rpm)
1205 100 855 100 110 2.2:1
1490 100 960 100 110 2.2:1
Pump Size (l/min) Converter Type (W11)
Note: Combined stall tests are performed with the crowd service operated until the relief valve lifts. *
3660 - F/1-3.1
9804/1103
20 - 05 - 05/5
Issue 2*
CONTENTS
Loadalls
20 - 05 - 05/6
530, 532, 537, 540, 550 Data - Transmission

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
From m/c no. 767001
Colour Code: Blue
3630 - F/1-2.4
Pump/Transmission Stall Speed Combinations - 11 inch & 12.2 inch Converter

JCB Diesel Engines - Build Codes AM JCB Diesel Engines - Build Codes AA and AB Torque Converter Stall 106 hp Turbo (rpm) 76 hp NA (rpm) Combined Stall 106 hp Turbo 76 hp NA Torque Converter Stall 120 hp Turbo intercooled (rpm) Hydraulic Stall 120 hp Turbo intercooled (rpm) Combined Stall 120 hp Turbo intercooled (rpm) Pump Size (l/min) Pump Size (l/min) Converter Type (11in) 82 2.2:1 Converter Type (12.2in)
1980
1960 1685
2320
(rpm) (rpm)
1280 1185
1620 82 2.24:1
JCB Diesel Engines - Build Codes AK and AR Torque Converter Stall 102 hp Turbo (rpm) 80 hp NA (rpm) Hydraulic Stall 102 hp Turbo 80 hp NA Combined Stall 102 hp Turbo 80 hp NA Pump Size (l/min) Converter Type (11in)
1950 TBA
(rpm) (rpm)
2280 TBA
(rpm) (rpm)
1620 TBA 82 2.2:1
Note: Combined stall tests are performed with the crowd service operated until the relief valve is
3630 - F/1-3.4
9804/1103
20 - 05 - 05/6
Issue 2*
CONTENTS
Loadalls
20 - 05 - 07/1
525-58/67, 527-58/67, 530-67 & 535-67, 505-19/22 Data - Brakes

Service Brake Type Actuation Location Friction Plates (5 per brake pack) Outside Diameter Inside Diameter Nominal Facing Area Hydraulic Piston Diameter Master Cylinder Type Frenos Iruna Piston Diameter Parking Brake Type Disc Diameter Manually Adjusted Caliper 279.4 mm (11 in) JCB Oil-Immersed Disc Single Circuit Hydraulic, Direct Actuation Front Axle (2 Brake Packs)
From m/c no. 567362
35 mm (1.125 in)
530-95, 530-110, 506-36 Data - Brakes

Service Brake Type Actuation Location Friction Plates ( front axle 5 per brake pack) Outside Diameter Inside Diameter Nominal Facing Area Hydraulic Piston Diameter Master Cylinder Type Piston Diameter Parking Brake Type Disc Diameter Manually Adjusted Caliper 279.4 mm (11 in) Frenos Iruna 35 mm (1.125 in) JCB Oil-Immersed Discs Tandem Circuit Hydraulic, Direct Actuation Front Axle (2 Brake Packs)
From m/c no. 567362
9804/1103
20 - 05 - 07/1
Issue 3
CONTENTS
Loadalls
20 - 05 - 07/2
530-120, 537-120/130, 508-40, 510-40 Data - Brakes

Type Actuation Location
From m/c no. 567362
JCB Oil-Immersed Discs Tandem Circuit Hydraulic, Direct Actuation Front Axle (2 Brake Packs) Rear Axle (2 Brake Packs)
Friction Plates ( front axle 5 per brake pack and rear axle 3 per brake pack) Outside Diameter 220 mm (8.66 in) Inside Diameter 180 mm (7.10 in) Nominal Facing Area 12616 mm2 (19.3 in2) Hydraulic Piston Diameter 216 mm (8.5 in) Master Cylinder Type Piston Diameter Servo Unit Type Piston Diameter Exhauster Type Ratio Parking Brake Type Disc Diameter Manually Adjusted Caliper 279.4 mm (11 in) Clayton Dewandre H175 1.4 times engine speed driven off timing gear Frenos Iruna 203.2mm (8 in) Frenos Iruna Tandem Cylinder 38.1mm (1.50 in)
520-55 RS Data - Brakes

Service Brakes Type Actuation Location Master Cylinder Number of Cylinders Type Stroke Bore Parking Brake Type Location
From m/c no. 277001 to 279119
Single Circuit, Oil-Immersed Multi-Plate Disc Actuation Hydraulic Front Axle (2 Brake Packs)
1 Frenos compensated master cylinder 36 mm (1.4 in) 19.05 mm (0.75 in)
Manually Adjusted Disc, cable operated Top rear face of front axle drop box
3610-G/1-1.5
9804/1103
20 - 05 - 07/2
Issue 4*
CONTENTS
Loadalls
*
20 - 05 - 07/3
520-55 AWS Data - Brakes

Service Brakes Type Actuation Location Master Cylinder Number of Cylinders Type Stroke Bore Parking Brake Type Location 1 Frenos 35 mm (1.4 in) 25.4 (1.0 in)
From m/c no. 277001 to 279119
Single Circuit, Oil-Immersed Multi-Plate Disc Actuation Hydraulic Front Axle (2 Brake Packs), Rear Axle (2 Brake Packs)
Manually Adjusted Disc, cable operated Top rear face of front axle drop box
3610 - G/1-1.5
* 526-55, * 520-50
526, 526S from m/c no. 277467 to 280299 AWS from m/c no. 279120
Data - Brakes
Service Brakes Type Actuation Location Accumulator Pressure Brake Circuit Operating Pressure Cut-in Cut-out Parking Brake Type Location * 520-50, Manually Adjusted Disc, cable operated Top rear face of front axle drop box
3610 - G/1-1.5
JCB oil-immersed multi-plate disc high pressure brakes with hydraulic accumulators for emergency application. Hydraulic ON, spring OFF. Front Axle (2 Brake Packs), Rear Axle (2 Brake Packs) 25 bar (363 lbf/in2). 90 bar (1305 lbf/in2). 110 bar (1595 lbf/in2).
525-50, 525-52
From m/c no. 754000
Data - Brakes
Type Actuation Location * System Pressure Single Circuit, Oil-Immersed Multi-Plate Disc Hydraulic Front Axle (2 Brake Packs), Rear Axle (2 Brake Packs) 90 - 110 bar (1303 - 1595 lbf/in2)
3620 - G/1-1.2
9804/1103
20 - 05 - 07/3
Issue 3*
CONTENTS
Loadalls
20 - 05 - 07/4
526-55, 526, 526S & 520-55 4 Wheel Steer Data - Brakes

Service Brakes Type Actuation Location Accumulator Pressure Brake Circuit Operating Pressure Cut-in Cut-out Parking Brake Type Location Manually Adjusted Disc, cable operated Top rear face of front axle drop box
From m/c no. 2768611
JCB oil-immersed multi-plate disc high pressure brakes with hydraulic accumulators for emergency application. Hydraulic ON, spring OFF. Front Axle (2 Brake Packs), Rear Axle (2 Brake Packs) 25 bar (363 lbf/in2). 90 bar (1305 lbf/in2). 110 bar (1595 lbf/in2).
532, 537 Data - Brakes

Service Brakes Type Actuation Location Master Cylinder Type Piston diameter Stroke Servo Unit Type Vacuum cylinder diameter Hydraulic cylinder diameter Frenos vacuum assisted hydraulic valve 201 mm (7.9 in) 21.6 mm (0.85 in) Frenos master cylinder with remote servo unit 38.1 mm (1.5 in) 25 mm (1.0 in)
From m/c no. 2768611
Single Circuit, Oil-Immersed Multi-Plate Disc Hydraulic- vacuum servo assisted Front Axle Centre Mounted (2 Brake Packs), Rear Axle Hub Mounted (2 Brake Packs)
9804/1103
20 - 05 - 07/4
Issue 2*
CONTENTS
Loadalls
20 - 05 - 07/5
528-70 From m/c no. 796000 528S From m/c no. 796102 Data-Brakes
Service Brakes Type Actuation Location JCB oil-immersed multi-plate disc with inboard brakes Hydraulic Front axle centre mounted (2 brake packs)
Parking Brake Type Location Manually Adjusted Disc, cable operated Transmission output shaft
General Description The service brakes act on the front axle half shafts of all machines. The brakes are oil immersed, multi-disc types which are operated hydraulically by a single pedal and master cylinder arrangement. The brake cylinder reservoir is situated in front of the instrument panel in the cab. The cable operated parking brake acts on a disc which is mounted on the gearbox output shaft to the front axle.
9804/1103
20 - 05 - 07/5
3650 - G/1-1.2
Issue 1
CONTENTS
Loadalls
20 - 05 - 07/6
530, 535, 540 Data - Brakes

* Service Brakes Type Actuation Location * Master Cylinder Type
From m/c no. 767001
Single Circuit, Oil-Immersed Multi-Plate Disc 530 - Hydraulic 535, 540, 530FS Super, 540FS Super, 530 SXL, 540 SXL - Hydraulic, servo assisted All Machines - Front Axle Centre Mounted (2 Brake Packs)
Stroke
530 - master cylinder 535, 540, 530FS Super, 540FS Super, 530 SXL, 540 SXL - master cylinder with remote sservo unit 530 - 35 mm (1.38 in) 535, 540, 530FS Super, 540FS Super, 530 SXL, 540 SXL - 25 mm (1.0 in)
* Servo Unit Type Vacuum cylinder diameter Hydraulic cylinder diameter Vacuum assisted hydraulic valve 535, 540 - 135.5 mm (5.33 in) 535, 540, 530FS Super, 540FS Super, 530 SXL, 540 SXL - 19 mm (0.75 in)
9804/1103
20 - 05 - 07/6
3630 - G/1-1.4
Issue 2*
CONTENTS
Loadalls
20 - 05 - 07/7
506B, 506C, 506C(HL), 508C Data - Brakes

Service Brakes Type Actuation Location JCB Oil-Immersed Discs Tandem Circuit Hydraulic, Direct Actuation Front Axle (2 Brake Packs) Rear Axle (2 Brake Packs)
Master Cylinder Piston Diameter Parking Brake Type Disc Diameter Manually Adjusted Caliper 279.4 mm (11 in) 35 mm (1.125 in)
9804/1103
20 - 05 - 07/7
3640U-G/1-1.3
Issue 1
CONTENTS
Loadalls
20 - 05 - 08/1
ALL MODELS Data - Steering

System Type Tandem Steer/Fan Pump - Steer Section Type
From m/c no. 567362
Full power hydrostatic with selectable 2/4/crab steer
Sundstrand, gear type AFGP8L/12.5L-31207, double gear type litres/min 18.2 25.0 48 UK gal/min 4.0 5.5 10.5 US gal/min 4.8 6.6 12.7
Controlled Flow Steer, at 1000 engine rev/min and neutral pressure Fan, at max. engine rev/min at zero pressure Total Flow through tank return line at 2200 engine rev/min (pressure outlet blocked)
Note: The outer section of the pump (furthest from the timing case) drives the steering system. The inner section (nearest the timing case) drives the engine cooling fan. Single Priority Steer/Fan Pump (For 527-58, 527-67, 535-67 from machine serial No. 574296 only) Type Flow at max. engine rev/min at zero pressure steering at neutral flow out of EF port Control Unit (525-58, 67, 527-58, 67, 530-67, 535-67, 530-95, 110) (530-120) Relief Valve Pressure With priority steer/fan pump (527-58, 67, 535-67) Relief Valve Pressure Danfoss Orbitrol OSPV 160 Danfoss Orbitrol OSPB 200 138 bar 2000 lbf/in2 Danfoss Orbitrol OSPC 160 175 bar 2537.5 lbf/in2 Ultra 1PX090, Gear type litres/min 34.3 UK gal/min 7.5 US gal/min 9.0
Ram Dimensions (525-58, 67, 527-58, 67 and 530-67, 95, 110) Bore 50 mm (1.97 in) Rod Dia. 25 mm (0.98 in) Stroke 206 mm (8.11 in) Ram Dimensions (530-120 & 537-120, 130) Bore Rod Dia. Stroke
60 mm (23.62 in) 30 mm (1.18 in) 209.5 mm (8.25 in)
Note: 530-120 & 537-120, 130 machines from Serial Number 574481, the rams are supplied by an alternative source. The rams must all be the same type, DO NOT mix rams on a machine. The seal kits are also different.
520-55, 526-55, 526, 526S Data - Steering

System Type Pump Control Unit Type Relief Valve Operating Pressure Shock Relief Valve Operating Pressure Powered Track Rod Stroke for each side
From m/c no. 277001
Full power hydrostatic, powered track rod on rear axle (see Data - Hydraulics) OSPC 125LS 2 2 175 bar (178 kgf/cm ; 2500 lbf/in ) 2 235 bar (239 kgf/cm ; 3407 lbf/in2) 130 mm (5.11 in)
3610-H/1-1.3
9804/1103
20 - 05 - 08/1
Issue 5*
CONTENTS
Loadalls
20 - 05 - 08/1A
* ALL
MODELS
From m/c no. 773135
Data - Steering
System Type Fully hydraulic load sensing with selectable 2-wheel, 4-wheel and crab steer modes. Anti-cavitation valve on 540-170 and 5508 machines. On other machines, the anti-cavitation valve was discontinued from Serial No. 773135 Double acting cylinders on all wheels Pump Steering Valve Machines except 540-170, 5508 Displacement Relief Valve Operating Pressure Shock Relief Valve Operating Pressure 540-170, 5508 Machines Relief Valve Operating Pressure Shock Relief Valve Operating Pressure 200 cc/rev 2 2 175 bar (178 kgf/cm ; 2500 lbf/in ) 2 2 235 bar (239 kgf/cm ; 3407 lbf/in ) 95 cc/rev (2:1 ratio) 175 bar (178 kgf/cm2; 2500 lbf/in2) 2 2 235 bar (239 kgf/cm ; 3407 lbf/in ) Gear type (19cc/rev) with load sensing priority flow divider delivering 41 litres/min (9 UK Gal/min, 10.8 US Gal/min)
9804/1103
20 - 05 - 08/1A
3630 - H/1-2.3
Issue 1*
CONTENTS
Loadalls
20 - 05 - 08/2
* 520-50,
525 - 50, 525 - 52
From m/c no. 754000
Data - Steering
System Type Pump Control Unit Type Relief Valve Operating Pressure Shock Relief Valve Operating Pressure Powered Track Rod Stroke for each side Full power hydrostatic, powered track rod on rear axle (see Data - Hydraulics) OSPC 125LS 175 bar (178 kgf/cm2; 2500 lbf/in2) 235 bar (239 kgf/cm2; 3407 lbf/in2) 130 mm (5.11 in)
3620-H/1-1.1
530, 532, 537 Data - Steering

System Type 530 532, 537 Pump Control Unit Type 530 532, 537 Relief Valve Operating Pressure Shock Relief Valve Operating Pressure
From m/c no. 754000
Full power hydrostatic with selectable 2, 4 and crab steer Powered track rod on rear of axles Steer rams on rear of axles (see Data - Hydraulics) OSPV 160 LS OSPB 200 LS 2 2 175 bar (178 kgf/cm ; 2500 lbf/in ) 2 235 bar (239 kgf/cm ; 3407 lbf/in2)
9804/1103
20 - 05 - 08/2
Issue 3*
CONTENTS
Loadalls
20 - 05 - 08/3
528-70 from m/c no. 796000 528S from m/c no. 796102 Data-Steering
System Type Fully hydraulic load sensing with optional 2-wheel, 4-wheel and crab steer modes. Powered trackrods on both axles. Gear type (36 cc/rev) with load sensing priority flow divider. OSPC 125LS 175 bar (178 kgf/cm2; 2500 lbf/in2) 235 bar (239 kgf/cm2; 3407 lbf/in2)
Pump Control Unit Type Relief Valve Operating Pressure Shock Relief Valve Operating Pressure
9804/1103
20 - 05 - 08/3
3650 - H/1-1.2
Issue 1
CONTENTS
Loadalls
20 - 05 - 08/4
530, 535, 540 532, 537, 550 Data - Steering 530, 535, 540
System Type
From m/c no. 767001
Fully hydraulic load sensing with selectable 2-wheel, 4-wheel and crab steer modes. Anti-cavitation valve on Machines to Serial No. 773053. Powered track rod on both axles
Pump
Gear type (19cc/rev) with load sensing priority flow divider delivering 41 litres/min (9 UK Gal/min, 10.8 US Gal/min) OSPV 160 LS 175 bar (178 kgf/cm2; 2500 lbf/in2) 235 bar (239 kgf/cm2; 3407 lbf/in2)
3630 - H/1-1.3
Control Unit Type Relief Valve Pressure: Shock Relief Valve Pressure:
532, 537, 540

System Type Fully hydraulic load sensing with selectable 2-wheel, 4-wheel and crab steer modes. Anti-cavitation valve on Machines to Serial No. 773134. Double acting cylinders on all wheels Pump Gear type (19cc/rev) with load sensing priority flow divider delivering 41 litres/min (9 UK Gal/min, 10.8 US Gal/min)
Control Unit Type Relief Valve Pressure: Shock Relief Valve Pressure:
OSPB 200 LS 175 bar (178 kgf/cm ; 2500 lbf/in ) 235 bar (239 kgf/cm2; 3407 lbf/in2)
2 2
3660 - H/1-1.1
9804/1103
20 - 05 - 08/4
Issue 1
CONTENTS
Loadalls
20 - 05 - 08/5
506B, 506C, 506C(HL), 508C Data - Steering

System Type Full power hydrostatic with selectable 2/4/crab steer
506B
Tandem Steer/Fan Pump - Steer Section Type Controlled Flow Steer, at 1000 engine rev/min and neutral pressure Fan, at max. engine rev/min at neutral pressure Total Flow through tank return line at 2200 engine rev/min (pressure outlet blocked) Double gear type litres/min 12.5 18.8 27.5 UK gal/min 2.75 4.1 6.0 US gal/min 3.3 4.9 7.2
Note: The outer section of the pump (furthest from the timing case) drives the steering system. The inner section (nearest the timing case) drives the engine cooling fan. Control Unit Type Ram Dimensions Bore Rod Dia. Stroke OSPB 160
50 mm (1.97 in) 25 mm (0.98 in) 205.4 mm (8 in)
506C
Note: Hydraulic pressure supply from priority valve in main hydraulic circuit. Control Unit Type Relief Valve Pressure Ram Dimensions Bore Rod Dia. Stroke OSPC 160 175 bar (2500 lbf/in2)
50 mm (1.97 in) 25 mm (0.98 in) 205.4 mm (8 in)
506C (HL), 508C

Tandem Steer/Fan Pump - Steer Section Type Controlled Flow Steer, at 1000 engine rev/min and neutral pressure Fan, at max. engine rev/min at neutral pressure Total Flow through tank return line at 2200 engine rev/min (pressure outlet blocked) Double gear type litres/min 12.5 18.8 27.5 UK gal/min 2.75 4.1 6.0 US gal/min 3.3 4.9 7.2
Note: The outer section of the pump (furthest from the timing case) drives the steering system. The inner section (nearest the timing case) drives the engine cooling fan. Control Unit Type Ram Dimensions Bore Rod Dia. Stroke
9804/1103
OSPB 200
60 mm (2.36 in) 30 mm (1.18 in) 209.5 mm (8.25 in)
20 - 05 - 08/5
3640U - H/1-1.2 & H/1-2.2
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/1
ALL MODELS Circuit Diagram - Electrical
From m/c no. 567362
48
48
A
600
24 5
N
37 202 204 205 208

811
46 47 44 45
812 815
17 11
G/Y U 415 414 413A
27
26
49 50
51 52
53 54 59 60
414A 814 839 801 416 N G/Y U 805 806 807 400 600 841
403
405 404 406 407
203 206
34 42 43
55
412
408
409
413 414B 413B
21
402
56
10
804 803
32 36 40
842
210
212 211 213
214
57 41
808A 809
58
209
215
20 16 3 9 1 25
101 003 800 103A
23
802
31 30
803A 401
19
810
207
808
39
411 200
+
6
105 300
106A
100
61
15
800 100 200 842
103
104
106
A1
200
A2
A4
A5
A6
A7
A8
A9
B1
B2
004
103
000 000R 200 004 842
000 000R 200
A215190
9804/1103
20 - 15 - 01/1
Issue 2
CONTENTS
Loadalls
20 - 15 - 01/2
From m/c no. 567362
A
48
600
48
48
66 216 217 67 65
69 220 219 73 221

78C 78D 78E 78F
829P
78 225
78B
229 235 226 227 230

835 834 837 838
234 231 232 233
218 63
301 847
818
78A
831
99 B9 C1
816
62
844
72
817
821 822
823
848 826 824 825
829 830
86
B8
C2
68
410
77 83
B6
828
B7
112 833 836
71B 76 75 71
108 109 820
79
222
223
224
88
819 827 106D 855
93
832 110
80
81
82
87 B5 C4
B3
103 000 000R 200
B4
A215200
9804/1103
20 - 15 - 01/2
Issue 2
CONTENTS
Loadalls
20 - 15 - 01/3
From m/c no. 567362
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on page 20-15-01/1 and continued on page 20-15-01/2. WIRING DIAGRAM (All 527, 535 machines; 525-58/67, 530-95/110 from Serial No. 572168; 530-120 from Serial No. 572242) * For SLI system circuit for machines from serial No. 576404 and 537-120/130 see page 20-15-01/11 Note: Item A is Syncro Shuttle option. For Powershift option see page 10/10-14. Main Components 1 Battery 2 Starter Motor 3 Starter Solenoid 4 Starter Switch 5 Thermostart 6 Starter Relay 9 Safe Load Indicator Readout Box 10 Rear SLI Boss 11 Front SLI Boss 15 Heater Switch 16 Heater Resistor 17 Heater Motor 19 Seat Relay Swedish 20 Parking Brake Switch machines 21 Seat Switch only 23 Horn Push 24 Horn 25 Wash/Wipe Switch 26 Front Wiper Motor 27 Washer Pump 30 Hazard Switch 31 Indicator Relay 32 Indicator Switch 34 Fuel Shut-off Solenoid 36 Reverse Alarm Relay 37 Reverse Alarm 39 Forward/Reverse Selector Switch 40 Neutral Start Relay 41 Parking Brake Warning Relay 42 Reverse Relay 43 Forward Relay 44 Reverse Solenoid 45 Forward Solenoid 46 Transmission Dump Switch 47 Parking Brake Switch 48 Trailer Socket 49 Air Filter Switch 50 Engine Oil Pressure Switch 51 Transmission Oil Temperature Switch 52 Transmission Oil Pressure Switch 53 Water Temperature Switch Lamps 202 Trailer Indicator Warning 203 Hazard Warning 204 L.H. Indicators 205 R.H. Indicators 206 Indicator Warning 207 Hazard Indicator Warning 208 Reversing Lights 209 Parking Brake Warning 210 Air Filter Blocked Warning 211 Engine Oil Pressure Warning 212 Transmission Oil Temperature Warning 213 Transmission Oil Pressure Warning 214 Water Temperature Warning 215 Alternator Warning 216 Stabiliser Indicators 217 Interior Light 218 Beacon Warning 219 2 Wheel Drive Warning 220 L.H. Brake Lights 221 R.H. Brake Lights 222 4 Wheel Steer Warning 223 Crab Steer Warning 224 2 Wheel Steer Warning 225 Instrument Panel Illumination 226 L.H. Side Light 227 R.H. Side Light 229 Number Plate Light 230 Working Light Warning 231 Cab Working Light 232 Headlamp Dip Beam 233 Headlamp Main Beam 234 Headlamp Main Beam Warning 235 Inclinometer Illumination Fuses Fuses are numbered as shown on the fuse box in the cab. Cable Colour Code G N U Y Green Brown Blue Yellow
54 55 56 57 58 59 60 61 62 63 65 66 67 68 69 71 71B 72 73 75 76 77 78 78A 78B 78C 78D 78E 78F 79 80 81 82 83 86 87 88 93 99 100 101
Hourmeter Alternator Tachometer Fuel Gauge Water Temperature Gauge Fuel Gauge Sender Water Temperature Gauge Sender Warning Buzzer L. H. Stabiliser Switch R. H. Stabiliser Switch Interior Light Switch Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch Beacon Brake Switch Brake Switch Relay 2/4 Wheel Drive Switch (not fitted on permanent 4 wheel drive) 2 Wheel Drive Solenoid Front Axle Proximity Switch Rear Axle Proximity Switch Steering Mode Selector Switch Steer Mode Printed Circuit Board Relay 2 Relay 1 Relay 1 (latch) Relay 2 (unlatch) Relay 1 (unlatch) Relay 2 (latch) 4 Wheel/Crab Steer Solenoid 4 Wheel Steer Solenoid Crab Steer Solenoid 2 Wheel Steer Solenoid Side Lights Relay Working Light Switch Road Light Switch Headlamp Dip Switch Headlamp Flasher Radio (Optional) Transmission Dump Relay Transmission Dump Switch
Note: For machines without road lights a link is fitted (as shown) in place of Working Light Switch 86 and switch 87 operates the Working Lights.
9804/1103
20 - 15 - 01/3
Issue 4*
CONTENTS
Loadalls
20 - 15 - 01/4
* 520-55
(504B N. Am), 520-55 RS
From m/c no. 277001 to 277535

48
600
11 5
12 17 24 27 102 104 105
37 47 44 108 50 26 103
801 814 805 806
49
51 52
53 54 59 55
406 407 412
45
10 2
850
851
60
34 42
807
811
812
403 815 402 404
405
21
415 414 413 400
106
43
56
23
853
32
841 840 808A 809
110
112 111 113
114
36
40
842
41
109
401
57
115
58
19 116 3 9
101 800
839
20
16
802
31
803
804
30 25
114 808
810
39
411 113 200
1
003
15 135
104 102 300
107
105
106
13
813 107
61
100 200 842
46
103 106
A1
200
A2
A3
A4
A6
A7
A8
A9
000 001
B1
B2
004 000 001 000 001
200 004 842 102 829 103
200
200
102 829 103
A190160
9804/1103
20 - 15 - 01/4
3610 - C/41-2.1
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/5
* 520-55
(504B N. Am), 520-55 RS
From m/c no. 277001 to 277535

The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. 1 2 3 4 5 6 9 10 11 12 13 15 16 17 19 20 21 23 24 25 26 27 30 31 32 34 36 37 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 Battery Starter Motor Starter Solenoid Starter Switch Thermostart Starter Relay Safe Load Indicator Readout Box Rear Axle Transducer Trailer Hitch Diverter Valve Auxiliary Diverter Valve Transmission Dump Relay Heater Switch Heater Resistor Heater Motor Trailer Hitch Selector Switch Auxiliary Selector Switch Auxiliary Relay Horn Push Horn Wash/Wipe Switch Front Wiper Motor Washer Pump Hazard Switch Indicator Relay Indicator Switch Fuel Shut-off Solenoid Reverse Alarm Relay Reverse Alarm Forward/Reverse Switch Neutral Start Relay Parking Brake Warning Relay Reverse Relay Forward Relay Reverse Solenoid Forward Solenoid Transmission Dump Switches Parking Brake Switch Trailer Socket Air Filter Switch Engine Oil Pressure Switch Transmission Temperature Switch Transmission Oil Pressure Switch Water Temperature Switch Hourmeter 55 56 57 58 59 60 61 65 66 67 68 69 71 83 86 87 88 93 99 100 101 Alternator Tachometer Temperature Gauge Fuel Gauge Temperature Sender Fuel Sender Warning Buzzer Interior Light Switch Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch Beacon Brake Switch Side Lights Relay Working Light Switch Road Light Switch Headlamp Dip Switch Headlamp Flasher Radio (optional) Roof Wiper Switch Brake Light Relay 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 125 126 127 128 129 130 131 132 133 134 135 136 137 Trailer Indicator Hazard Warning L.H. Indicators R.H. Indicators Indicator Warning Hazard Indicator Warning Reversing Lights Parking Brake Warning Air Filter Blocked Warning Engine Oil Pressure Warning Transmission Temperature Warning Transmission Oil Pressure Warning Water Temperature Warning Alternator Warning Hitch Warning Interior Light Beacon Warning Roof Wiper Warning L.H. Brake Lights R.H. Brake Lights Instrument Panel Illumination L.H. Side Light R.H. Side Light Trailer Number Plate Working Light Warning Cab Working Lights Headlamp Dip Beam Headlamp Main Beam Headlamp Main Beam Warning Heater Switch Warning Road Light Warning Inclinometer Light
Fuses are numbered as shown on the fuse box in the cab.
9804/1103
20 - 15 - 01/5
3610 - C/41-1.5
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/6
* 520-55
(504B N. Am), 520-55 RS
From m/c no. 277001 to 277535
Circuit Diagrams - Electrical
48
600 600
48
48
69 117 65 67
120 121 137 125 126 127
129 131 128 132 133
134
66
844 816 301 849 829 830 831 834
835 837
838
86 68 101 130 B9 C1 118

855
99
100 119
B8 B6
828
C2
112 833 836
71 83
B7
88
108 827
93 87
832 110
136 B3 B4 B5 C3 C4
000 001
200
102 829 103
A190170
9804/1103
3610 - C/41-3.2
20 - 15 - 01/6
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/7
* 520-55
(from m/c no. 277536) * 526-55 (to m/c no. 278965) Circuit Diagram - Electrical
48
600
11 5
12 17 24 27 202 203 204 205
37 47 44 208 50 26
805 806
102
49
51 52
53 54 59 55
406 407 412 408
45
10 2
850
851
60
34 42
811
812
403 402 815 404
405
43
814
56
409
21
415A 414 413 400
106
807
23
841 853 839 801 840
32 36 40
842
210
107
212 211 213
214
41
209
809 401
57
215
58
19 216 3 9
101
20
16
802
31
803
804
30 25
800 114 808
810
39
411 200
1
003
15 235
104 102 300
207
105
106
46 61 13
100 200 842
103 106
A1
200
A2
A3
A4
A6
A7
A8
A9
000 001
B1
B2
004 810 000 001 000 001
200 004 842 102 829 103
200
200
102 829 103
A215620
9804/1103
20 - 15 - 01/7
3610 - C/41-5.1
Issue 2*
CONTENTS
Loadalls
20 - 15 - 01/8
* 520-55 * 526-55
(from m/c no. 277536) (to m/c no. 278965)

The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. * 1 2 3 4 5 6 9 10 11 12 13 15 16 17 19 20 21 23 24 25 26 27 30 31 32 34 36 37 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 Battery Starter Motor Starter Solenoid Starter Switch Thermostart Starter Relay Safe Load Indicator Readout Box Rear Axle Transducer Trailer Hitch Diverter Valve Solenoid Auxiliary Diverter Valve Solenoid Transmission Dump Relay Heater Switch Heater Resistor Heater Motor Trailer Hitch Selector Switch Auxiliary Selector Switch Auxiliary Relay Horn Push Horn Wash/Wipe Switch Front Wiper Motor Washer Pump Hazard Switch Indicator Relay Indicator Switch Fuel Shut-off Solenoid Reverse Alarm Relay Reverse Alarm Forward/Reverse Switch Neutral Start Relay Parking Brake Warning Relay Reverse Relay Forward Relay Reverse Solenoid Forward Solenoid Transmission Dump Switches Parking Brake Switch Trailer Socket Air Filter Switch Engine Oil Pressure Switch Transmission Temperature Switch Transmission Oil Pressure Switch Water Temperature Switch Hourmeter 55 56 57 58 59 60 61 65 66 67 68 69 71 83 86 87 88 93 99 99A 99B 99C 99D 100 101 102 Alternator Tachometer Temperature Gauge Fuel Gauge Temperature Sender Fuel Sender Warning Buzzer Interior Light Switch Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch Beacon 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 Trailer Indicator Hazard Warning L.H. Indicators R.H. Indicators Indicator Warning Hazard Indicator Warning Reversing Lights Parking Brake Warning (see note) Air Filter Blocked Warning Engine Oil Pressure Warning Transmission Temperature Warning Transmission Oil Pressure Warning Water Temperature Warning Alternator Warning Hitch Warning Interior Light Beacon Warning Roof Wiper Warning L.H. Brake Lights R.H. Brake Lights Instrument Panel Illumination L.H. Side Light R.H. Side Light Trailer Number Plate Working Light Warning Cab Working Lights Headlamp Dip Beam Headlamp Main Beam Headlamp Main Beam Warning Heater Switch Warning Road Light Warning Inclinometer Light Front Axle Alignment Indicator Rear Axle Alignment Indicator
Brake Switch Side Lights Relay Working Light Switch Road Light Switch Headlamp Dip Switch Headlamp Flasher Radio (optional) Machine 18 Pin Socket Radio 18 Pin Plug Aerial Speakers Roof Wiper Switch Brake Light Relay Hydraulic Low Pressure Switch (526-55 Only) 103 Front Proximity Switch (526-55 Only) 104 Rear Proximity Switch (526-55 Only) 105 Face Level Fan (if fitted)
Colour Code B Black R Red B/W Black/White S Slate G Green W/K White/Pink Fuses are numbered as shown on the fuse box in the cab. Note: On the 526-55 machines Warning lamp 209 also indicates Low Brake Pressure.
9804/1103
20 - 15 - 01/8
3610 - C/41-4.4
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/9
* 520-55 * 526-55
(from m/c no. 277536) (to m/c no. 278965)
48
600 600
48
48
69 217 65 67
220 221 239 238 225 226 227
229 231 228 232 233
234 105
601AG
66
844 816 834
835 837
838
99D
+ +
301 849 820 819 829 830
831
86 68 101 230 B9 C1 218

855 B S S S S W/K
100 219
B8 B6
828
C2
18 17 14 13
8 7
71 83
B7
18 17 14 13 8 7 3
99A 99B
112 115
833
836 B B/W R
88
108
99C 93
103
104
827
87
832
110
99
236 B3
810 000 001
B4
810
C3
C4
C5
200
102 829 103
A215630
9804/1103
3610- C/41-6.2
20 - 15 - 01/9
Issue 2*
CONTENTS
Loadalls
20 - 15 - 01/10
From m/c no. 567362
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on page 20-15-01/1 and continued on page 20-15-01/2. WIRING DIAGRAM (Powershift option) Main Components 1 Neutral Drive Relay 2 Forward Drive Relay 3 Forward High/Low Relay 4 Reverse High/Low Relay 5 Driveshaft Relay 6 Reverse Relay 7 Layshaft Solenoid 8 Mainshaft Solenoid 9 Reverse High Solenoid 10 Reverse Low Solenoid 11 Forward High Solenoid 12 Forward Low Solenoid Lamps 208 Reversing Lights 220 L.H. Brake Light 221 R.H. Brake Light 219 2 Wheel Drive Warning
13 14 39 40 41 46 47 71 71B 73 100
Column Gear Selector 2 Wheel Drive Switch Forward/Reverse Selector Switch Neutral Start Relay Parking Brake Warning Relay Transmission Dump Relay Parking Brake Switch Brake Switch Brake Switch Relay 2 Wheel Drive Solenoid Transmission Dump Relay
8 221 220 73 219

807
10 9 11
860 811 812
12
37 208
7
858 857
859
46
47
815
C9
816 818 863 863 865 862
71B 6 40
871 852
862
1 39
41
810 107
71
14
852
401
100
2 1 3 4 107
B4
000 000R 200 004
13
108
B1
B2
A215210
842
9804/1103
20 - 15 - 01/10
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/11

* WIRING DIAGRAM (530-120 from serial No. 576404 & all 537-120/130) Safe Load Indicator Circuit Safe Load Indicator Circuit 9 10 Safe Load Indicator Readout Box Transducer 9 10 11
From m/c no. 576404
* WIRING DIAGRAM (All machines from serial No. 576404 except 530-120 & 537-120/130 machines)
Safe Load Indicator Readout Box Rear SLI Boss Front SLI Boss
600
600
9
N
11
G/Y 414 413A 413 414B
414A
413 414
413B
N G/Y
10
10
101
9
101
A2
A221890
A2
A215191
9804/1103
20 - 15 - 01/11
Issue 2*
CONTENTS
Loadalls
20 - 15 - 01/12
* 520-55, * 526-55,
520S (from m/c no. 278966) 526S (526 N. Am) (from m/c no. 278966 to 280299)

The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on page 20-15-01/13 and continued on page 20-15-01/14. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 * 37 38 39 40 41 42 43 Battery 44 Battery Isolator 45 Fuse Links 46 Starter Motor 47 Starter Solenoid 48 Starter Switch 49 Thermostart 50 Starter Relay 51 Safe Load Indicator Readout Box 52 Rear Axle Transducer 53 Hitch/Auxiliary Selector Switch 54 Hitch Diverter Valve Solenoid 55 Auxiliary Circuit Selector Switch 56 Auxiliary Diverter Valve Solenoid 57 Heater Switch 58 Heater Resistor 59 Heater Motor 60 Wash/Wipe Switch 61 Washer Pump 62 Front Wiper Motor 63 Hazard Warning Switch 64 Indicator Relay 65 Trailer Socket 66 Indicator Switch 67 Fuel Shut-off Solenoid * 68 Reverse Alarm * 69 Neutral Start Relay * 70 Forward/Reverse Switch * 71 Reverse Relay 72 Reverse Solenoid 73 Transmission Dump Switches Transmission Dump Relay 74 Forward Relay 75 Forward Solenoid Parking Brake Switch 76 Parking Brake Warning Relay Accumulator Pressure Switch (if fitted) Air Filter Switch Engine Oil Pressure Switch Transmission Temperature Switch Transmission Oil Pressure Switch Water Temperature Switch Hourmeter Alternator * 100 Warning Buzzer 101 Tachometer 102 Temperature Sender 103 Temperature Gauge 104 Fuel Sender 105 Fuel Gauge 106 Interior Light Switch * 107 Roof Wiper Switch 108 Roof Wiper Motor and Parking Switch 109 Rear Wiper Motor and Switch Beacon Switch 110 Beacon 111 Brake Switch 112 Front Proximity Switch (526-55 Only) 113 Rear Proximity Switch (526-55 Only) 114 Horn Push 115 Horn 116 Side Lights Relay 117 Working Light Switch 118 Road Light Switch 119 Headlamp Dip Switch 120 Headlamp Flasher 121 Radio (optional) 122 N/A 123 N/A 124 N\A 125 N/A 126 Face Level Fan (optional) 127 Air Conditioning Compressor 128 Clutch Relay (optional) 129 Air Conditioning Thermostat (optional) 130 Air Conditioning Reciever Drier 131 Pressure Switch (optional) 132 Air Conditioning Compressor 133 Clutch (optional) Hitch/Aux. Warning Indicator Heater Indicator Trailer Direction Indicator Hazard Warning Indicator L.H. Indicators R.H. Indicators Direction Indicator Hazard Warning Indicator Reversing Lights Accumulator Pressure Warning (see note) Air Filter Blocked Warning Engine Oil Pressure Warning Transmission Temperature Warning Transmission Oil Pressure Warning Water Temperature Warning Alternator Warning Interior Light Roof Wiper Indicator Beacon Indicator L.H. Brake Lights R.H. Brake Lights Front Axle Alignment Indicator Rear Axle Alignment Indicator Instrument Panel Illumination L.H. Side Lights R.H. Side Lights Trailer Lights Number Plate Cab Working Lights Working Light Indicator Road Light Switch Indicator Headlamp Dip Beam Headlamp Main Beam Headlamp Main Beam Warning
Colour Code B Black R Red B/W Black/White S Slate G Green W/K White/Pink Fuses are numbered as shown on the fuse box in the cab. Note: On the 526-55 machines Warning lamp 109 also indicates Low Brake Pressure.
9804/1103
20 - 15 - 01/12
3610 - C/41-7.3
Issue 2*
CONTENTS
Loadalls
20 - 15 - 01/13
* 520-55, * 526-55,
23
601 600
12
14
17
19
102 20
103 104 105

806
26 25
105 807
108
30
34
35
37
38 39
40 41
404 405
42
43
7 10
414
850
851
839
400
805
811
812
815
44
406 407
402
403
200
27 106 16 24 A6
29
33
36
2 5
401
110 109 111
112 113
114 115
413
9 22
800 801 840 841 802 803 804
808
810
004 842
809
107
18 1 8 100 11 13 101
200 842 003 200 101 114 102 104 003
15
21
28
107
31 32
107
411
45
110
3 6
A1
B1
A9
B3
B5
C7
C6
A2
A4
B8
000R 001 810 200H 200G 829 100A 110 883
A248190
9804/1103
3610 - C/41-8.1
20 - 15 - 01/13
Issue 2*
CONTENTS
Loadalls
20 - 15 - 01/14
* 520-55, * 526-55,
23
600
600
116
412
48
50
54 51 53
61 56 119 120
814
123 124
127 125 126 128

831
133 131 132 72 76
46
829 830
834 834 838 838
75 67
409 408 301 849 854 844 816
52 117 47 49
55 118 60
112 828
129 63 C2 C1 C3 C4 74
121 57
122
833
836
62
108 819 820
66
827 103 829
58
59
73
115
65
832
106
810
130 B2 B7 64 B4
B6
C5
000R 102 810 200H 200G 829 100A 110 883
A248200
9804/1103
20 - 15 - 01/14
3610 - C/41-9.2
Issue 2*
CONTENTS
Loadalls
20 - 15 - 01/15
526-55, 526, 526 N.Am 526S (fitted with Powershift ECU gearbox control) Circuit Diagrams - Electrical
Component Key The complete electrical circuit is shown on pages 20-15-01/16 to 20-15-01/21. Fuses are numbered as shown on the fuse box in the cab. Component Key Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 * 47 48 49 50A 50B 50C 50D 51 52 Description Page 20-15-01/16 Battery Starter Motor Starter Solenoid Fusible Links 1 Thermostart Ignition Switch Neutral Start Relay Fusible Link 2 Ignition Solenoid Engine Shut Off Solenoid (ESOS) Reverse Light Reverse Alarm Reverse Light/Alarm Relay Auxiliary Solenoid Auxiliary Relay Hydraulic Hitch Solenoid Hydraulic Hitch Switch Load Indicator Transducer Load Indicator Page 20-15-01/17 Heater Switch Face Fan Air Conditioning Compressor Clutch (if fitted) Air Conditioning Relay (if fitted) Air Conditioning Switch (if fitted) Heater Fan Receiver Drier Switch (if fitted) Roof Wiper Roof Wiper Switch Front Wiper Rear Wiper Interior Light Beacon Switch Beacon Radio Power Page 20-15-01/18 Buzzer Instrument Panel Air Filter Switch Engine Oil Pressure Switch Transmission Oil Temperature Switch Water Temperature Switch Alternator Fuel Sender Water Temperature Sender Rear Axle Alignment Indicator Light Front Axle Alignment Indicator Light Front Proximity Axle Switch Rear Proximity Axle Switch Trailer Socket - L.H. Indicator Pin Trailer Socket - R.H. Indicator Pin Trailer Socket - Side Light Pin Trailer Socket - Brake Light Pin Page 20-15-01/19 Side Lights Relay Road Lights - Switch 53A 53B 54A 54B 55A 55B 56A 56B 56C 56D 57 57A 57B 57C 57D 58 59 60 61 62 63 64 65 66A 66B 67 67A 67B 67C 68 69 70 71 72 73 74 75 76 77 78 79 79 80 81A 81B 84 85 86 87 88 89 90 91
From m/c no. 280300 to 280576
L.H. Side Light - Front L.H. Indicator - Front L.H. Side Light - Rear L.H. Side Indicator - Rear L.H. Dip Beam L.H. Main Beam R.H. Dip Beam R.H. Main Beam R.H. Side Light - Front R.H. Indicator - Front Column Switch Dip/Main Beam Switch Indicator Switch Wiper Switch Washer Switch Washer Pump Page 20-15-01/20 L.H. Brake Lights R.H. Brake Lights Brake Lights - Switch Hazard Switch Flasher Relay Trailer Indicator - Cab Warning LIght Diode R.H. Indicator - Front R.H. Side Light Column Switch Forward/Reverse Switch Transmission Switch Horn Switch Horn Park Brake Switch Transmission ECU - Input Signal Connectors Transmission ECU - Output Signal Connectors Page 20-15-01/21 Transmission Oil Pressure Switch Transmission ECU Test Point Speed Sensor Mainshaft Solenoid Layshaft Solenoid Forward High Solenoid Forward Low Solenoid Reverse HI/LOW Relay Reverse High Solenoid Reverse Low Solenoid Work Light Work Light Number Plate Light Joy Stick Control (if fitted) Diode Pack (if fitted) Valve Block Solenoid (if fitted) Valve Block Solenoid (if fitted) Valve Block Solenoid (if fitted) Valve Block Solenoid (if fitted) Joystick Isolation Switch (if fitted)
3610 - C/41-10.2
9804/1103
20 - 15 - 01/15
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/16
526-55, 526, 526S (526 N.Am) (fitted with Powershift ECU gearbox control) Circuit Diagrams - Electrical (contd)
1 + 3 4 8 FA1 FA2 FA3 FA4 FA5 FA6 FA7 FA8 15 FA9 FB1 FB2 9 2
From m/c no. 280300 to 280576
6 7 13 17 18 19
10 11 12 14 16
A282270
9804/1103
20 - 15 - 01/16
3610 - C/41-11.1
Issue 2*
CONTENTS
Loadalls
20 - 15 - 01/17
From m/c no. 280300 to 280576
*
PHB3
20 21
PHB4 24
25 26 28
23
PHB5 30 33 29 31 32
PHB6
34
35
PHB6 36
A282280
9804/1103
20 - 15 - 01/17
3610 - C/41-12.1
Issue 2*
CONTENTS
Loadalls
20 - 15 - 01/18
From m/c no. 280300 to 280576
37
PHB8
38 39 40 41 42 43 44 45 46 47 48 49
A282290
9804/1103
20 - 15 - 01/18
3610 - C/41-13.1
Issue 2*
CONTENTS
Loadalls
20 - 15 - 01/19
526 55, 526, 526S (526 N.Am) (fitted with Powershift ECU gearbox control) Circuit Diagrams - Electrical (contd)
50A 50B
From m/c no. 280300 to 280576
PHB9
PHC1 51 52 53A
PHC2
50C
53B
54A 54B 55A
PHC3
55B
56A
PHC4 56B 56C 57 57A 57B 57C
56D
57D 58
A282300
9804/1103
20 - 15 - 01/19
3610 - C/41-14.1
Issue 2*
CONTENTS
Loadalls
20 - 15 - 01/20
From m/c no. 280300 to 280576
50D 59
61
PHC5
60
PHC6
PHC7 62 63
PHC8 65 64 PHC9 66A 66B 67 67A 67B 67C 68 69 70 71

R F A282310
9804/1103
20 - 15 - 01/20
3610 - C1-15.1
Issue 2*
CONTENTS
Loadalls
20 - 15 - 01/21
526-55, 526, 526S (526N.Am) (fitted with Powershift ECU gearbox control) Circuit Diagrams - Electrical (contd)
From m/c no. 280300 to 280576
72 73 74 75 76 77 78 79 80
81A
83
81B 84
86
85 87 88 89
A282320
90
91
9804/1103
20 - 15 - 01/21
3610 - C/41-16.1
Issue 2*
CONTENTS
Loadalls
20 - 15 - 01/22
520-55, 526, 526S (from m/c no. 280300) 520-55 (From m/c no. 281847) * (fitted with Syncro Shuttle Transmission) Circuit Diagrams - Electrical
Component Key Fuses are numbered as shown on the fuse box in the cab. * Component Key Sheet 1 Item 1 2 3 4 5 6 7 8 9 10 11 11A 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Description Battery isolator Battery Fuse links Starter motor Starter solenoid Key switch Thermostart Neutral start relay Fuse link Ignition relay Sender unit Cold start advance unit (see Note 1) Engine shut-off solenoid (ESOS) Rear work light Rear work light switch Front work lights Front worklights switch Brake lights Brake light switch Trailer brake lights connector Reverse alarm Reverse light Parkbrake switch Parkbrake relay Front axle alignment lamp Front axle proximity switch Rear axle alignment lamp Rear axle proximity switch Radio Load Moment Indicator (LMI) transducer Load Moment Indicator (LMI) Instrument panel Warning buzzer Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge sender Water temperature sender Alternator
Note 1: Cold start advance unit 11A is part of fuel injection pump.
9804/1103
20 - 15 - 01/22
3610 - C/41-17.2
Issue 3*
Loadalls
20 - 15 - 01/23
526, 526S (from m/c no. 280300) 520-55 (From m/c no. 281847) * (fitted with Syncro Shuttle Transmission) Circuit Diagrams - Electrical (contd)
*
40 38 39
33 34 35 36 37
31
32
29
28
30
24
26
22
25
20 21
23
27
19
18
17
15
16
13
14
12
11A
11
10
CONTENTS
9804/1103
20 - 15 - 01/23
3610 - C/41-18.2
F15
F12
F29
F17
F16
F6
F7
F18
F19 F20
F9 F10 F8 F11
Issue 3*
Loadalls
20 - 15 - 01/24
526, 526S From m/c no. 280300 520-55 (From m/c no. 281847 * (fitted with Syncro Shuttle Transmission) Circuit Diagrams - Electrical (contd)
79
77
76
73
74
75
78
71
72
69
70
66
68
67
63
65
64
61
62
60
57 58
59
55 56
54
53
52
47
44 46
48
49 50
51
CONTENTS
42
41
43
45
9804/1103
20 - 15 - 01/24
3610 - C/41-19.2
F22
F28
F23
F25
F21
F26
F30
F24
F27
F4 F1 F5 F2
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/25
526, 526S (From m/c no. 280300) 520-55 (From m/c no. 281847) * (fitted with Syncro Shuttle Transmission) Circuit Diagrams - Electrical (contd)
* Fuses are numbered as shown on the fuse box in the cab. * Component Key Sheet 2 Item 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 Description Rear indicator - right hand Rear side light - right hand Trailer light socket Number plate light Sidelights relay Front side light - left hand Front indicator - left hand Rear side light - left hand Rear indicators - left hand Trailer side light connection - left hand Road lights switch Dip beam - left hand Main beam - left hand Dip beam - right hand Main beam - right hand Front side lights - right hand Front indicators - right hand Fog lamp Fog light switch Steering column switch - right hand Trailer indicators Wash pump Roof wiper motor Roof wiper switch Front wiper motor Rear wiper motor Hazard warning lights switch Flasher relay Trailer indicator light Interior light Warning beacon Warning beacon switch Face level fan Air conditioning compressor Air conditioning relay Heater Receiver dryer Air conditioning switch Heater switch
9804/1103
20 - 15 - 01/25
3610 - C/41-20.2
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/26
526, 526S (From m/c no. 280300) 520-55 (From m/c no. 281847) * (fitted with Syncro Shuttle Transmission) Circuit Diagrams - Electrical (contd)
* Fuses are numbered as shown on the fuse box in the cab. * Component Key Sheet 3 Item 80 81 82 83 84 85 86 87 88 89 90 91 92 Description Column switch - left hand Horn Forward solenoid Forward relay Reverse solenoid Reverse relay Second auxiliary solenoid Second auxiliary relay Transmission dump relay Hitch solenoid Hitch switch Transmission dump switch (control lever) Transmission dump switch (gear change lever)
Single lever control (SLC) option: 93 94 95 96 97 98 99 100 Extend solenoid Auxiliary solenoid Retract solenoid Single lever control joystick Diodes Transmission dump switch (joystick) Auxiliary solenoid Lever isolation switch & auxiliary solenoid
9804/1103
20 - 15 - 01/26
3610 - C/41-21.2
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/27
526, 526S (From m/c no. 280300) 520 - 55(From m/c no. 281847) * (fitted with Syncro Shuttle Transmission) Circuit Diagrams - Electrical (contd)
*
100 99
94
95
96
98
SLC
93
91
92
89
87
88
90
97 81 80 83 85
82
84
86
9804/1103
20 - 15 - 01/27
3610 - C/41-21.2
F13
F14 F3
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/29
* (fitted
526, 526S with Powershift Transmission) Circuit Diagrams - Electrical
From m/c no. 280577
* Component Key Fuses are numbered as shown on the fuse box in the cab. Item 1 2 3 4 5 6 7 8 9 10 11 11A 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Description Battery isolator Battery Fuse links Starter motor Starter solenoid Key switch Thermostart Neutral start relay Ignition relay Fuse link Sender unit Cold start advance unit (see Note 1) Engine shut-off solenoid (ESOS) Rear work light Rear work light switch Front work lights Front worklights switch Brake lights Brake light switch Trailer brake lights connector Reverse alarm Reverse light Reverse 2 relay Parkbrake switch Parkbrake relay Front axle alignment lamp Front axle proximity switch Rear axle alignment lamp Rear axle proximity switch Radio Load Moment Indicator (LMI) Load Moment Indicator (LMI) transducer Instrument panel Warning buzzer Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge sender Water temperature sender Alternator
9804/1103
20 - 15 - 01/29
3610 - C/41-24.2
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/30
526, 526S * (fitted with Powershift Transmission) Circuit Diagrams - Electrical (contd)
*
41
From m/c no. 280577
39 40
34 35 36 37 38
31
29
30
32
33
27
25
21
23
22
24
26
28
19
20
18
17
16
15
13
12
14
11A
11
10
9804/1103
20 - 15 - 01/30
3610 - C/41-23.2
F18
F15
F29
F10 F12 F17 F7 F20 F19 F9 F16 F8 F11
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/31
526, 526S (fitted with Powershift Transmission) Circuit Diagrams - Electrical (contd)
Fuses are numbered as shown on the fuse box in the cab.
From m/c no. 280577
* Component Key Sheet 2 Item 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 Description Rear indicator - right hand Rear side light - right hand Trailer light socket Number plate light Sidelights relay Front side light - left hand Front indicator - left hand Rear side light - left hand Rear indicators - left hand Trailer side light - left hand Road lights switch Dip beam - left hand Main beam - left hand Dip beam - right hand Main beam - right hand Front side lights - right hand Front indicators - right hand Fog lamp Foglight switch Column switch - right hand Trailer indicators Wash pump Roof wiper motor Roof wiper switch Front wiper motor Rear wiper motor Hazard warning lights switch Flasher relay Trailer indicator light Interior light Warning beacon Warning beacon switch Face level fan Air conditioning compressor Air conditioning relay Heater Receiver dryer Air conditioning switch Heater switch
9804/1103
20 - 15 - 01/31
3610 - C/41-25.2
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/32
*
From m/c no. 280577
80
78
75
77
74
76
79
72
73
70
71
69
67
68
66
64
65
62
63
61
59
60
56 57 58
55
51
53
50
54
49
47
48
52
45
44
42
43
46
9804/1103
20 - 15 - 01/32
F24
F25
F21
F23
F22
F28
F30
F27
F26
3610 - C/41-26.2
F5
F4 F2 F1
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/33
Fuses are numbered as shown on the fuse box in the cab. * Component Key Sheet 3 Item 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 Description Column switch - left hand Horn Reverse low solenoid Reverse high solenoid Reverse high/low relay Diodes Reverse relay Forward solenoid Forward high solenoid Forward low solenoid Forward high/low solenoid Drive interlock Driveshaft relay Layshaft solenoid Mainshaft solenoid Second auxiliary solenoid Second auxiliary relay Transmission dump relay Hitch solenoid Hitch switch Transmission dump switch (control lever)
From m/c no. 280577
Single lever control (SLC) option: 102 103 104 105 106 107 108 109 Extend solenoid Auxiliary solenoid Retract solenoid Single lever control joystick Transmission dump switch (joystick) Diodes Auxiliary solenoid Single lever control isolation switch and auxiliary solenoid
9804/1103
20 - 15 - 01/33
3610 - C/41-28.2
Issue 3*
CONTENTS
Loadalls
20 - 15 - 01/34
* (fitted
526, 526S with Powershift Transmission) Circuit Diagrams - Electrical (contd)

109
From m/c no. 280577
*
108
103
104
105
106
SLC
102
101
99
96
97
98
100
95
94
90
89
88
91
84
86
83
82
81
85
87
92
93
9804/1103
20 - 15 - 01/34
3610 - C/41-27.2
F13
F3
107
F14
Issue 3*
CONTENTS
Loadalls
*
20 - 15 - 01/35
526, 526S (526 N.Am) (fitted with Powershift Gearbox) Circuit Diagrams - Electrical (contd)
From m/c no. 280577
14E 14F
72
73 79 79A
74 75 76 77
78
22 80 81
A282250
9804/1103
20 - 15 - 01/35
3610 - C/41-30.1
Issue 2*
CONTENTS
Loadalls
*
20 - 15 - 01/36
526, 526S (526 N, Am) (fitted with Powershift Gearbox) Circuit Diagrams - Electrical
From m/c no. 280577
83
84
86
87
82
82A
85
85A
A282260
9804/1103
20 - 15 - 01/36
3610 - C/41-31.1
Issue 2*
CONTENTS
Loadalls
20 - 15 - 01/37
528-70 With Syncro Shuttle Transmission Circuit Diagrams - Electrical Component Key 1
From m/c no. 796000
The complete electrical circuit is shown on pages 20-15-01/38 and 20-15-01/39. Fuses are numbered as shown on the fuse box in the cab.
Item 1 2 3 4 5 6 7 8 9 10 10A 11 12 13 14 15 16 17 18
Description Fuse links Battery Battery isolator Starter motor solenoid Starter motor Ignition switch Thermostart Ignition relay Safe Load Indicator (SLI) Auxiliary change-over switch Auxiliary solenoid Face level fan Heater switch Heater motor Hazard warning light switch Indicator relay Left hand indicators Indicator switch Indicator warning lamp
9804/1103
20 - 15 - 01/37
3650 - C/41-1.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/38
528-70 with Syncro Shuttle Transmission Circuit Diagrams - Electrical (contd)
To m/c no. 796000
11 10A 5 3
13
16
19
20 21
22
23
27
29
31
7 18
F17
26
28
30
9 4 15 17
25
2 8 1 10
12
14
24
32
F10
F11
F30
F12
9804/1103
F13
F7
F3
F2
F4
F1
20 - 15 - 01/38
3650- C/41-2.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/39
528-70 with Syncro Shuttle Transmission Circuit Diagrams - Electrical (contd)
From m/c no. 796000
54 35 36 37 38 39 41 42 43 48 49 52
55
57
62 59
65
66
67
68
70
71 73
76
F23
F24
47
Water Gauge
Fuel Gauge
Handbrake
Tacho
33
Hourmeter
46 72 51 58 53 61 60 69 74 63 75
44
34 40
F14 F18 F19 F29 F28 F27 F26 F20 F8 F6
9804/1103
F25
64
F22
F21
45
50
56
20 - 15 - 01 /39
3650- C/41-3.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/40
528-70 with Syncro Shuttle Transmission Circuit Diagrams - Electrical Component Key 2
From m/c no. 796000
The complete electrical circuit is shown on pages 20-15-01/38 and 20-15-01/39. Fuses are numbered as shown on the fuse box in the cab.
Item 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76
Description Instrument panel Buzzer Air filter switch Oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Alternator Water temperature sender Fuel sender Washer pump Wash/wipe switch Front wiper Roof wiper warning lamp Roof wiper Rear wiper Radio Interior light Rotating beacon switch Rotating beacon Brake light switch Left hand brake light Right hand brake light Fog light switch Fog light Horn push Horn Main beam flash Main lights relay Dip beam Road lights switch Dip beam switch Main beam Main bean warning lamp Instrument panel illumination Left hand side lights Front worklight relay Right hand side lights Number plate light Front work light switch and warning lamp Front work lights Rear work light relay Rear work light switch and warning lamp Rear worklight
9804/1103
20 - 15 - 01/40
3650 - C/41-4.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/41
528S With Powershift Transmission Circuit Diagrams - Electrical Component Key 1
From m/c no. 796102
The complete electrical circuit is shown on pages 20-15-01/42, 20-15-01/43 and 20-15-01/46. Fuses are numbered as shown on the fuse box in the cab. Item 1 2 3 4 5 6 7 8 9 10 11 11A 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Description Battery isolator Battery Fuse links Starter motor Starter solenoid Key switch Thermostart Neutral start relay Ignition relay Fuse link Sender unit Cold start advance unit (see Note 1) Engine shut-off solenoid (ESOS) Rear work light Rear work light switch Front work lights Front worklights switch Brake lights Brake light switch Trailer brake lights connector Reverse alarm Reverse light Reverse 2 relay Parkbrake switch Parkbrake relay Front axle alignment lamp Front axle proximity switch Rear axle alignment lamp Rear axle proximity switch Radio Load Moment Indicator (LMI) Load Moment Indicator (LMI) transducer Instrument panel Warning buzzer Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge sender Water temperature sender Alternator
9804/1103
20 - 15 - 01/41
3650 - C/41-5.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/42
528S with Powershift Transmission Circuit Diagrams - Electrical (contd)
From m/c no. 796102
11A 4 1 7 11
12
15
17 19 21 23 25 27 31 34 35 36 37 38 39 40
13
20
5 2 8 9
14
16
29 18 22 24 26 30 28 32 41
33 3 10
F11
F19
F20
F16
F8 F17
F15
F18
F29
9804/1103
F10
F7
F12
F9
20 - 15 - 01/42
3650 - C/41-6.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/43
528S With Powershift Transmission Circuit Diagrams-Electrical contd
From m/c no. 796102
78 42 43 44 45 47 48 49 51 50 53 55 54 56 57 58 59 62 63 64 66 67 69 72 71 70 74 75 77
46 52
60
61
65
68
73
76
79
80
F26
F27
F30
F22
F23
F21
F25
F24
F28
F5
F1
F2
9804/1103
20 - 15 - 01/43
3650 - C/41-7.1
F4
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/44
528S With Powershift Transmission Circuit Diagrams - Electrical (contd) Component Key 2
From m/c no. 796102
The complete electrical circuit is shown on pages 20-15-01/42, 20-15-01/43 and 20-15-01/46. Fuses are numbered as shown on the fuse boxc in the cab. Item 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 Description Rear indicator - right hand Rear side light - right hand Trailer light socket Number plate light Sidelights relay Front side light - left hand Front indicator - left hand Rear side light - left hand Rear indicators - left hand Trailer side light - left hand Road lights switch Dip beam - left hand Main beam - left hand Dip beam - right hand Main beam - right hand Front side lights - right hand Front indicators - right hand Fog lamp Foglight switch Column switch - right hand Trailer indicators Wash pump Roof wiper motor Roof wiper switch Front wiper motor Rear wiper motor Hazard warning lights switch Flasher relay Trailer indicator light Interior light Warning beacon Warning beacon switch Face level fan Air conditioning compressor Air conditioning relay Heater Receiver dryer Air conditioning switch Heater switch
9804/1103
20 - 15 - 01/44
3650 - C/41-8.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/45
528S With Powershift Transmission Circuit Diagram- Electrical (contd) Component Key 3
From m/c no. 796102
The complete electrical circuit is shown on pages 20-15-01/42, 20-15-01/43 and 20-15-01/46. Fuses are numbered as shown on the fuse boxc in the cab. Item 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 Description Column switch - left hand Horn Reverse low solenoid Reverse high solenoid Reverse high/low relay Diodes Reverse relay Forward solenoid Forward high solenoid Forward low solenoid Forward high/low solenoid Drive interlock Driveshaft relay Layshaft solenoid Mainshaft solenoid Second auxiliary solenoid Second auxiliary relay Transmission dump relay Hitch solenoid Hitch switch Transmission dump switch (control lever)
Single lever control (SLC) option: 102 103 104 105 106 107 108 109 Extend solenoid Auxiliary solenoid Retract solenoid Single lever control joystick Transmission dump switch (joystick) Diodes Auxiliary solenoid Single lever control isolation switch and auxiliary solenoid
9804/1103
20 - 15 - 01/45
3650 - C/41-9.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/46
528S with Powershift Transmission Circuit Diagrams - Electrical (contd)
From m/c no. 796102
SLC 83 82 84 89 90 94 96 95 99 101 102 103 104 108
81
86
109
88 85 87
91
97
98
100
105
106
92
93
F13
9804/1103
F14
F3
107
20 - 15 - 01/46
3650 - C/41-10.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/47
528S with Syncro Shuttle Transmission Circuit Diagrams-Electrical
From m/c no. 796102
11A 4 1 7 11
12
15 13
17 19 20 21 22 24 26 29 33 34 35 36 37 38 39
5 2 8
10
14 18 23 16
25
28 30 27 31 40
32 3 9
F11
F19 F20
F18
F16
F17
F12
F15
F29
F6
F7
F9 F10
F8
9804/1103
20 - 15 - 01/47
3650 - C/41-11.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/48
528S With Syncro Shuttle Transmission Circuit Diagrams - Electrical (contd) Component Key 1
From m/c no. 796102
The complete electrical circuit is shown on pages 20-15-01/47, 20-15-01/50 and 20-15-01/51. Fuses are numbered as shown on the fuse box in the cab. Item 1 2 3 4 5 6 7 8 9 10 11 11A 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Description Battery isolator Battery Fuse links Starter motor Starter solenoid Key switch Thermostart Neutral start relay Fuse link Ignition relay Sender unit Cold start advance unit (see Note 1) Engine shut-off solenoid (ESOS) Rear work light Rear work light switch Front work lights Front worklights switch Brake lights Brake light switch Trailer brake lights connector Reverse alarm Reverse light Parkbrake switch Parkbrake relay Front axle alignment lamp Front axle proximity switch Rear axle alignment lamp Rear axle proximity switch Radio Load Moment Indicator (LMI) transducer Load Moment Indicator (LMI) Instrument panel Warning buzzer Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge sender Water temperature sender Alternator
9804/1103
20 - 15 - 01/48
3650 - C/41-12.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/49
From m/c no. 796102
The complete electrical circuit is shown on pages 20-15-01/47, 20-15-01/50 and 20-15-01/51. Fuses are numbered as shown on the fuse box in the cab. Item 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 Description Rear indicator - right hand Rear side light - right hand Trailer light socket Number plate light Sidelights relay Front side light - left hand Front indicator - left hand Rear side light - left hand Rear indicators - left hand Trailer side light connection - left hand Road lights switch Dip beam - left hand Main beam - left hand Dip beam - right hand Main beam - right hand Front side lights - right hand Front indicators - right hand Fog lamp Fog light switch Steering column switch - right hand Trailer indicators Wash pump Roof wiper motor Roof wiper switch Front wiper motor Rear wiper motor Hazard warning lights switch Flasher relay Trailer indicator light Interior light Warning beacon Warning beacon switch Face level fan Air conditioning compressor Air conditioning relay Heater Receiver dryer Air conditioning switch Heater switch
9804/1103
20 - 15 - 01/49
3650 - C/41-13.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/50
528S With Syncro Shuttle Transmission Circuit Diagrams - Electrical (contd)
From m/c no. 796102
77 42 41 43 44 46 47 48 49 50 52 53 54 55 56 57 58 61 62 63 65 66 68 70 69 71 73 74 76
45
51
59
60
64
67
72
75
78
79
F24
F27
F21
F25
F26
F30
F22
F23
F28
F5
F1
F2
9804/1103
F4
3650 - C/41-14.1
20 - 15 - 01/50
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/51
528S With Syncro Shuttle Transmission Circuit Diagrams - Electrical (contd)
From m/c no. 796102
SLC 82 81 84 86 89 93 94 95 99
91 80 100
92
83
85
87
88
90
96
98
F13
F14
97
F3
9804/1103
20 - 15 - 01/51
3650 - C/41-15.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 01/52
From m/c no. 796102
The complete electrical circuit is shown on pages 20-15-01/47, 20-15-01/50 and 20-15-01/51. Fuses are numbered as shown on the fuse box in the cab. Item 80 81 82 83 84 85 86 87 88 89 90 91 92 Description Column switch - left hand Horn Forward solenoid Forward relay Reverse solenoid Reverse relay Second auxiliary solenoid Second auxiliary relay Transmission dump relay Hitch solenoid Hitch switch Transmission dump switch (control lever) Transmission dump switch (gear change lever)
Single lever control (SLC) option: 93 94 95 96 97 98 99 100 Extend solenoid Auxiliary solenoid Retract solenoid Single lever control joystick Diodes Transmission dump switch (joystick) Auxiliary solenoid Lever isolation switch & auxiliary solenoid
9804/1103
20 - 15 - 01/52
3650 - C/41-16.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/1
530 Without Neutral Start Relay Circuit Diagrams - Electrical
From m/c no. 767001 to 768836
601
601
601
601
600
600
601
600
601
600
601
601
601
601
601
600
601
600
601
601
600
600
600
600
600
601
601
48
411
856
400 856
58
601 601 601 601
840
600
601
43 24 27 37
883 885
45 50
601 601
M
841
65
848
601
12
14
18
32
825
47
60
66
5
800
61
59
824
2 8 17 6 1 16 28 33
39
M 41
44 23 26
57 52 56
901
105
M
926 925
49
1 2 3
100
55
911 854
917
9
106 600
120
51 15 21
M
38
(SLC)
31
120 102
34
884
22
25
003
851
829
F1
115 120
3
M +++
004
F2
101
F3
F4
F5
F6
F7
F8
104
F9
F11 F12 F13
000 200 001
000 200
914
414
19 29
853
30
413
46 36
886
54 53 62
1 2 3 4 5 6 7 8
109
42
826
601
35
40
11 20 13 10
907
819
820
801
64
1 2 823 3 4 822 821 5 6
Z X Y 63
9804/1103
20 - 15 - 02/1
3630 - C/26-1.5 3630 - C/25-1.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/2
530 Without Neutral Start Relay Circuit Diagram - Electrical (contd) Component Key 1
From m/c no. 767001 to 768836
To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. The complete electrical circuit is shown on pages 20 - 15 - 02/1 and 20 - 15 - 02/4 Key
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 Battery Battery isolator Starter motor Ignition switch Starting aid Auto relay High Speed Control relay Pump dump switch Single lever control Sway isolation relay Sway/Auxiliary change-over Auxiliary change-over valve 1 Sway isolation switch Auxiliary A solenoid Auxiliary A/B switch Auxiliary B relay Auxiliary A relay Auxiliary B solenoid Auxiliary change-over switch Auxiliary change-over relay Auxiliary change-over valve 2 Boom extend switch Extend relay Extend solenoid Boom retract switch Retract relay Retract solenoid Transmission dump switch Safe Load Indicator (SLI) SLI transducer Heater/air conditioning fan Heater/air conditioning unit Air conditioning switch Face level fan Air conditioning compressor Air conditioning relay Binary Switch Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/cassette Heater seat Digital clock Warning buzzer Trailer indicators Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Ignition relay ESOS Two wheel steer solenoid 59 60 61 62 Four-wheel/crab steer solenoid Four wheel steer solenoid Crab steer solenoid Steer Mode Control Unit W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front sensor Rear sensor Instrument panel
63
64 65 66
Steer Sensor Wiring: Terminal 1 2 3 Wire Code 820 or 819 600 or 601 810 or 109 Wire Colour Black Blue Brown Description Signal Earth Feed
9804/1103
20 - 15 - 02/02
3630 - C/25-2.4
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/3
530 Without Neutral Start Relay Circuit Diagram - Electrical (contd) Component Key 2
From m/c no. 767001 to 768836
To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. The complete electrical circuit is shown on pages 20 - 15 - 02/1 and 20 - 15 - 002/4.
68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111
Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Water temperature sender Alternator Fuel sender Water temperature switch Steering column switch Horn Reverse relay Powershift control unit Park brake Four wheel brake relay Foot brake Two wheel drive switch Brakelights Brakelights Trailer rear Reverse alarm Auxiliary power socket Rear worklight switch Rear worklight Sidelight relay Main light switch Primary fuse Right hand sidelights Trailer rear Left hand sidelights Trailer rear Left hand worklights Front worklight switch Right hand worklights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear foglight switch Trailer rear Steering column switch Screen wash pump Right hand indicators Trailer rear Left hand indicators Trailer rear
Note: Powershift control unit (78) only shows input connections from the mainframe harness. Refer to the ECU fault finding information in this section for control unit output connections.
9804/1103
20 - 15 - 02/3
3630 - C/25-3.4
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/4
530 Without Neutral Start Relay Circuit Diagrams - Electrical (contd)
To m/c no. 767001 to 768836
600
601
304
81
600 601 600
71 72
601
832 841
69 68 70
76
77 80
833
827
G
808 873 871
84 89 86
97 91
450
840
105 94 92 101 100 104 103 102 109 108
831
75 74
9 15 16 1 13 10 7 2 5 4 3 17 18 12 6
85
88 82
200
87
96
898
79
83
99
106
90 95
98
78
118 119 108
73
304
123
93
107 110
304
111
806 805 838 301 840 841 110 832
F18
838
F24
F25
F21
874
F22
F23
F26
F28
F15
F17
F19
F29
836
F14
F16
F30
A313920
9804/1103
20 - 15 - 02/4
3630 3630 - C/25-4.5 - C/26-1.5
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/5
530 With Neutral Start Relay and ECU Controlled Transmission Circuit Diagram - Electrical
49
411
From m/c to 768837 to 770053
601
601
601
600
600
601
600
600
601
600
601
601
601
601
601
601
601
601
600
601
600
600
600
600
600
600
601
400
856
17 14 19 25 28 33
856
59
601 601 601 601
825 600 601 601
840
44
M
841
46
48
61
51
601 601
38
883
66
848
67
6
800
62
60
824
2 9 16 7 1 18 29 34
M
925
40
M 42
45
58 53 57
901
24
27
105
926
M 1 2 3
854
50
100
56
917
10
106 600
120
911
901
52 15 22
M
104
39
(SLC)
32
120 102
35
884
003
23
26
851
109
43
826
820
801
65
004
810
F1
F11
F7
F8
F9
F2
F3
120
F4
101
115
F12
F5
F6
301
3
M
200 200
+++ 842
414
20 30
853
4 12
31
413
47 37
886
55 54 63
1 2 3 4 5 6 7 8
F13
874
601
36
41
819
21 13 11
907
1 2 823 3 4 822 821 5 6
Z X Y 64
A313890
9804/1103
20 - 15 - 02/5
3630 - C/26-1.5
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/6
530 From m/c no. 768837 to 770053 with Neutral Start Relay and ECU Controlled Transmission Circuit Diagrams - Electrical (contd) Component Key 1
To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. The complete electrical circuit is shown on pages 20-15-02/5 and 20-15-02/8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Battery Battery isolator Starter motor Neutral start Ignition switch Starting aid Auto relay High Speed Control relay Pump dump switch Single lever control Sway isolation relay Sway/Aux change-over Sway isolation switch Auxiliary change-over valve 1 Auxiliary A/B switch Auxiliary A relay Auxiliary A solenoid Auxiliary B relay Auxiliary B solenoid Auxiliary change-over switch Auxiliary change-over relay Auxiliary change-over valve 2 Boom extend switch Extend relay Extend solenoid Boom retract switch Retract relay Retract solenoid Transmission dump switch Safe Load Indicator (SLI) SLI Transducer Heater/air conditioning fan Air conditioning unit Air conditioning switch Face level fan Air conditioning compressor Air conditioning relay Binary switch Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/cassette Heated seat Digital clock Warning buzzer Trailer indicators Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Ignition relay 58 59 60 61 62 63 Engine Shut-Off Solenoid Two wheel steer solenoid Four-wheel/crab steer solenoid Four wheel steer solenoid Crab steer solenoid Steer Mode Control Unit W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front sensor Rear sensor Instrument panel
64
65 66 67
9804/1103
20 - 15 - 02/6
3630 - C/26-2.4
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/7
530 From m/c no. 768837 to 770053 with Neutral Start Relay and ECU Controlled Transmission Circuit Diagram - Electrical (contd) Component Key 2
To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. The complete electrical circuit is shown on pages 20-15-02/5 and 20-15-02/8.
69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Water temperature sender Alternator Fuel sender Water temperature switch Steering column switch Horn Reverse relay Powershift control unit Parkbrake Two wheel drive switch Four wheel drive brake switch Foot brake Brakelights Brakelights Trailer rear Reverse alarm Auxiliary power socket Rear worklight switch Rear worklights Sidelight relay Main light switch Primary fuse Right hand Sidelights Trailer rear Left hand sidelights Trailer rear Front worklight switch Left hand worklights Right hand worklights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear foglight switch Trailer rear Steering column switch Front wash/wipe motor Right hand indicators Trailer rear Left hand indicators Trailer rear
9804/1103
20 - 15 - 02/7
3630 - C/26-3.3
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/8
530 With Neutral Start Relay and ECU Controlled Transmission Circuit Diagram - Electrical (contd)
From m/c no 768837 to 770053
803
600 601
304
83
600 601 600
72 73
601
832 841
70 69 71
77
78 82
833
827
808 873 871
831
76 75
9 15 16 1 13 10 7 2 5 4 3 17 18 12 6
86
87
89 81
200
88
93
97
101 105 104 103
898
80
84
90
450
300
85
99 92 95 100 102 106
840
110 109
107
91 96
98
79
118 119 108
72
304 124 100 401 806 805 838 301 840 841 110 829
123
94
108 111
112
832
F18
F14
F16
F21
F22
F23
F24
F25
F26
F28
F30
810
874
F17
F15
F19
F29
836
803
A313900
9804/1103
20 - 15 - 02/8
3630 - C/26-4.4
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/9
530 with Relay Controlled Transmission, ECU not fitted Circuit Diagram - Electrical
From m/c no. 770054 to 770958
601
601
601
601
601
601
601
601
601
601
600
601
600
601
600
601
601
600
600
600
600
600
600
601
47
411 601
601
601
400
57
601 601 601 601
825 600 601 601
840
6 13 24
003
42 27 32
883
44
46
59
M
841
49
601 601
36
800
003
58
824
801
848
16
18
60
64
65
12 8
004
17 (PP)
M
925
38
40 43 56 51 55
826
901
23
26
31 41
M
901
200
105
4 15
926
48
1 2 3
100
54
854
11
50
106
14 9 2 20
600
30
102
33
840 884 841 110
22
25
851
829
104
37
109
820
63
810
F11
F5
F1
000 200 001 414
000 200
3 M
21 28
+++ 853
29
413
45
301
53 52 61
1 2 3 4 5 6 7 8
F13
874 842
F3
120
120
F2
F4
101
115
F6
F12
F8
F7
F9
810
601
10
917
35
886
34
39
819
19
1 2 823 3 4 822 821 5 6
Z X Y 62
A313870
9804/1103
20 - 15 - 02/9
3630 - C/27-1.5
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/10
530 with Relay Controlled Transmission, ECU not fitted Circuit Diagram - Electrical (contd) Component Key 1
The complete electrical circuit is shown on pages 20-15-02/9 and 20-15-02/12. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Battery Battery isolator Starter motor Neutral start relay Ignition switch Starting aid not used High Speed Control relay Ppump dump switch not used Sway/Auxiliary change-over Auxiliary A relay Auxiliary A solenoid Auxiliary A/B switch Auxiliary B relay Auxiliary B solenoid Auxiliary change-over relay 2 Auxiliary change-over valve 1 Auxiliary change-over relay Auxiliary change-over valve 2 Auxiliary change-over switch Boom extend switch Extend relay Extend solenoid Boom retract switch Retract relay Retract solenoid Safe Load Indicator (SLI) SLI transducer Heater/air conditioning fan Air conditioning switch Heater/air conditioning unit Face level fan Air conditioning compressor Air conditioning relay Binary switch (air con) Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/cassette Heated seat Digital clock Warning buzzer Trailer indicators Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Ignition relay Engine Shut-Off Solenoid Two wheel steer solenoid 58 59 60 61
From m/c no. 770054 to 770958
Four-wheel/crab steer solenoid Four wheel steer solenoid Crab steer solenoid Steer Mode Control Unit W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front sensor Rear sensor Instrument panel
62
63 64 65
9804/1103
20 - 15 - 02/10
3630 - C/27-2.4
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/11
530 with Relay Controlled Transmission, ECU not fitted Circuit Diagrams - Electrical (contd) Component Key 2
The complete electrical circuit is shown on pages 20-15-02/9 and 20-15-02/12. 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Steering column switch Alternator Fuel sender Water temperature switch Steering column switch Horn Reverse relay 2 Ignition relay 2 Transmission dump switch Pump dump relay Reverse 1 relay Forward relay Drive relay Parkbrake relay Reverse HI/LOW relay Reverse high solenoid Reverse low solenoid Forward HI/LOW relay Forward high solenoid Forward low solenoid Driveshaft relay Layshaft solenoid Mainshaft solenoid Two/four wheel drive solenoid Transmission oil temperature switch Parkbrake switch Footbrake switch Four wheel drive brake relay Two wheel drive switch Brakelights Brakelights Trailer rear Reverse alarm Auxiliary power socket Rear worklight switch Rear worklight Sidelight relay Main light switch Primary fuse Right hand sidelight Trailer rear Left hand sidelight Trailer rear Front work light switch Left hand work lights Right hand work lights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear fog light switch Rear fog light Steering column switch Front wash/wipe motor Right hand indicators Trailer rear Left hand indicators Trailer rear
From m/c no. 770054 to 770958
9804/1103
20 - 15 - 02/11
3630 - C/27-3.4
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/12
530 with Relay Controlled Transmission, ECU not fitted Circuit Diagram - Electrical (contd)
From m/c 770054 to 770958
803 601 601 601 601 600 600 601 601 809 300 600 601 600 601 856 807 601 600 600
73
808
85
72 76
827
67 68 69
70
89
96 114 107
450
601
811
863
859
80 81
600
100 94 97 99
600 108
121 110 117
808
84
86 88
105
200
115 112
871
852
600
601
82
861
87
812
91 93 104
874
71
857
601
98
872
75
890
119
79 83
304 124
103
106 109 118
125
600
90
111
119
815
601
807
401
118
806 805 838 301 840 841 110
F28
601
107
F16
F18
95 77
101
102
F21
F22
F23
F24
F25
815
F17
F15
F19
827
F26
F29
F30
124
123
3 SPEED ONLY
809
126
839 A313880
122 74
107
9804/1103
20 - 15 - 02/12
3630 - C/27-4.4
127
Issue 1
78
92
108
600 601
113
116
120
CONTENTS
Loadalls
20 - 15 - 02/13
530, 540 Sway Machines Circuit Diagrams - Electrical
From m/c no. 770959
601
601
601
601
601
600
600
600
600
600
600
600
600
601
601
601
601
600
600
601
601
601
601
44
411 400
11 15 20 18
5 7
23 29
840 851
55
601 601 601 601
825 600 601 601
13
39
801 800
41
43
57
M
841
46
601 601
33 24
853 883
58 56
824 848
62
63
M 35
925 932 004 935 934
37
40
54 48
200
28
901
53
105 109
931
17
21
882 933 926
38
M
45
1 2 3
100
51
854
52
12
14
19
22
901
47 27
102 120
810
850
9
451
30
884 840 841
301
16
114
110 829 829 810
106
34
826
820
61
810
F11
F7
F8
F5
F10
101
F3
F1
F4
115
F6
1
842
F9
10
F2
F12 F13
874 000 200 001 +++ 414
874 200
3 M 26
+++
25
413
42 32
886
50
301
601
31
36
49
59
8 819
1 2 823 3 4 822 821 5 6
Z X Y 60
A314050
9804/1103
20 - 15 - 02/13
3630 - C/28-1.5
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/14
530, 540 Sway Machines Circuit Diagram - Electrical (contd) Component Key 1
The complete electrical circuit is shown on pages 20-15-02/13 and 20-15-02/16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 Battery Battery isolator Starter motor Ignition switch Starting aid Neutral start relay not used HSC pump dump switch Auxiliary change-over valve 2 Sway/Auxiliary change-over switch Auxiliary change-over valve 1 Auxiliary A switch Auxiliary A solenoid Auxiliary B switch Auxiliary B solenoid Joystick isolation switch Single lever control - extend Extend solenoid Single lever control - retract Retract solenoid Auxiliary 2 A switch Auxiliary 2 B switch Auxiliary change-over valve 2 Auxiliary change-over relay Safe Load Indicator (SLI) SLI transducer Heater/air conditioning fan Air conditioning switch Heater/air conditioning unit Face level fan Air conditioning compressor Air conditioning relay Binary switch (air conditioning) Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/cassette Heated seat Digital clock Warning buzzer Trailer indicators Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Primary fuse Ignition relay Engine Shut-Off Solenoid Two wheel steer solenoid Four-wheel/crab steer solenoid Four wheel steer solenoid Crab steer solenoid
From m/c no. 770959
59
60
61 62 63
Steer Mode Control Unit W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front sensor Rear sensor Instrument panel
9804/1103
20 - 15 - 02/14
3630 - C/28-2.3
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/15
530, 540 Sway Machines circuit Diagram - Electrical (contd) Component Key 2
Component Key 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Steering column switch Alternator Fuel sender Water temperature switch Steering column switch Horn Reverse relay 2 Ignition relay 2 Transmission dump switch Transmission dump relay Reverse 1 relay Forward relay Drive relay Parkbrake relay Reverse HI/LOW relay Reverse high solenoid Forward HI/LOW relay Reverse low solenoid Forward high solenoid Forward low solenoid Driveshaft relay Layshaft solenoid Mainshaft solenoid Two/Four wheel drive solenoid Transmission oil temperature switch Parkbrake Four wheel drive brake relay Footbrake Two wheel drive switch Brakelights Brakelights Trailer rear Reverse alarm Auxiliary power socket Rear worklight switch Rear worklight Sidelight relay Primary fuse 3 Main light switch Primary fuse 2 Right hand sidelight Trailer rear Left hand sidelight Trailer rear Front work light switch Left hand work lights Right hand work lights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear fog light switch Trailer rear Steering column switch Front wash/wipe motor Right hand indicators Trailer rear 125 Left hand indicators 126 Trailer rear
From m/c no. 770959
9804/1103
20 - 15 - 02/15
3630 - C/28-3.4
Issue 2*
CONTENTS
Loadalls
20 - 15 - 02/16
530, 540 Sway Machines Circuit Diagram - Electrical (contd)
From m/c no. 770959
601
601
601
601
600
600 601
601
809
601
601
601
601
600
601
600
601 601
601
601
600
600
807
601
601
600
71 66 65 67
808
83
808
70 74
827
68
87
95
118
113 106
450
601
811
863
859
78 79
600
98 97 103
120 109 116
92
82
85 86
94
114 111
816
600
80 69
852
874
84
861
812
89 91
601
200
871
600
101 107 104

119 200
857
601
96
872
73
77 81
304 124
890
858 601
124
815
105
108
100
118
401 806 805 838 301 840 841 110 829
108
F28
809
107
F31
F32
F33
F34
F35
F16
F18
93
807
99
100
F21
F22
F23
F24
F25
815
F17
F15
F19
75
F26
F29
F30
601
123
122 121
3 SPEED ONLY
125
839
A314060
117
72
F14
832
107
9804/1103
20 - 15 - 02/16
3630 - C/28-4.4
600
88
118
126
Issue 1
76
90
110
600 601
102
112
115
119
300
807
601 600
600
CONTENTS
Loadalls
20 - 15 - 02/17
530, 540 Non-Sway Machines Circuit Diagram - Electrical
From m/c no. 770959
601
601
601
601
601
600
600
600
600
600
600
601
601
600
601
601
601
600
600
601
601
601
601
44
411 400
5 12 7 10 17
20
23 28
840 851
55
601 601 601 601
825 600 601 601
39
801 800
41
43
57
M
841
46
601 601
15
932 931
33 19
853 883
58 56
824 848
62
63
M 35
925 932 004
37
40
54 48
200
934
27
901
53
105 109
931
14
18
882 933 926
38
M
45
1 2 3
100
51
854
52
11
16
(DR)
21
901
47 26
102
810
120
30
884 840 841
301
451
13
22
829 114
110 829 810
106
34
826
820
61
810
F11
F7
F8
F5
F10
101
F3
F1
F4
115
F6
842
F13
F2
F9
F12
874 000 200 001 +++ 414
874 200
3 M 25
+++
24
413
42 32
886
50
301
601
31
36
49
59
8 819
1 2 823 3 4 822 821 5 6
Z X Y
60
A314070
9804/1103
20 - 15 - 02/17
3630 - C/26-1.5 3630 - C/29-1.3
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/18
530, 540 Non-Sway Machines Circuit Diagram - Electrical (contd) Component Key 1
The complete electrical circuit is shown on pages 20 - 15 - 02/17 and 20 - 15 - 02/20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 Battery Battery isolator Starter motor Ignition switch Starting aid Neutral start relay not used Pump dump switch Auxiliary A switch Auxiliary A solenoid Auxiliary B switch Auxiliary B solenoid Joystick isolation switch Boom extend switch Extend solenoid Boom retract switch Retract solenoid Auxiliary 2 A switch Auxiliary change-over relay Auxiliary change-over valve 2 Auxiliary 2 B switch Stabilizer isolation switch Auxiliary change-over valve 1 Safe Load Indicator (SLI) SLI transducer Heater/air conditioning fan Air conditioning switch Heater/air conditioning unit N/A Face level fan Air conditioning compressor Air conditioning relay Binary switch (air conditioning) Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/cassette Heated seat Digital clock Warning buzzer Trailer indicators Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Primary fuse Ignition relay Engine Shut-Off Solenoid Two wheel steer solenoid Four-wheel/crab steer solenoid Four wheel steer solenoid Crab steer solenoid
From m/c no. 770959
59
60
61 62 63
Steer Mode Control Unit W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front sensor Rear sensor Instrument panel
9804/1103
20 - 15 - 02/18
3630 - C/29-2.2
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/19
530, 540 Sway Machines circuit Diagram - Electrical (contd) Component Key 2
The complete electrical circuit is shown on pages 20-15-02/17 to 20-15-02/20. 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Steering column switch Alternator Fuel sender Water temperature switch Steering column switch Horn Reverse relay 2 Ignition relay 2 Transmission dump switch Transmission dump relay Reverse 1 relay Forward relay Drive relay Parkbrake relay Reverse HI/LOW relay Reverse high solenoid Forward HI/LOW relay Reverse low solenoid Forward high solenoid Forward low solenoid Driveshaft relay Layshaft solenoid Mainshaft solenoid Two/Four wheel drive solenoid Transmission oil temperature switch Parkbrake Four wheel drive brake relay Footbrake Two wheel drive switch Brakelights Brakelights Trailer rear Reverse alarm Auxiliary power socket Rear worklight switch Rear worklight Sidelight relay Primary fuse 3 Main light switch Primary fuse 2 Right hand sidelight Trailer rear Left hand sidelight Trailer rear Front work light switch Left hand work lights Right hand work lights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear fog light switch Trailer rear Steering column switch Front wash/wipe motor Right hand indicators 124 Trailer rear 125 Left hand indicators 126 Trailer rear
From m/c no. 770959
9804/1103
20 - 15 - 02/19
3630 - C/29-3.3
Issue 2*
CONTENTS
Loadalls
20 - 15 - 02/20
530, 540 Non-Sway Machines Circuit Diagram - Electrical (contd)
From m/c no. 770959
601
601
601
601
600
600 601
601
809 601 601 601 601
600
601
600
601 601
601
601
600
600
807
601
601
600
71 66 65 67
808
83
808
70 74
827
68
87
95
118
113 106
450
601
811
863
859
78 79
600
98 97 103
120 109 116
92
82
85 86
94
114 111
816
600
80 69
852 874
84
861
812
89 91
601
200
871
600
101 107 104

119 200
857
601
96
872
73
77 81
304 124
890
858 601
124
815
105
108
100 118 401 806 805 838 301 840 841 110 829 108
F28
809
107
F31
F32
F33
F34
F35
F16
F18
93
807 815
99
100
F21
F22
F23
F24
F25
F17
F15
F19
75
F26
F29
F30
601
123
122 121
3 SPEED ONLY
125
839 A314060
117
72
F14
832
107
9804/1103
20 - 15 - 02/20
3630 3630 - C/29-4.3 - C/26-1.5
600
88
118
126
Issue 1
76
90
110
600 601
102
112
115
119
300
807
601 600
600
CONTENTS
Loadalls
20 - 15 - 02/21
530, 540 From m/c no. 775402 535 From m/c no. 777362 all with Manual Auxiliary Controls Circuit Diagram - Electrical Component Key 1
The complete electrical circuit is shown on pages 20-15-02/22, 20-15-02/23 and 20-15-02/26
Key
1 2 3 4 5 5A 6 7 8 9 10 11 11A 12 12A 12B 13 13A 14 15 16 17 17A 18 19 19A 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Battery Battery isolator Starter motor Starter solenoid Ignition switch Fuse link 2 Starting aid Neutral start relay Ignition feed relay 1 Ignition feed relay 2 E.S.O.S. Rear work lamp switch Rear work lamp Front work lamps switch Front work lamps Auxiliary power connector 2/4WD brake relay Brake lamps Brake switch 2/4WD switch 2/4WD solenoid Reverse relay Reverse lamp Reverse alarm Park brake relay Park brake switch Heated seat Radio/cassette Digital clock Transducer - Load Moment Indicator (LMI) Instrument panel Warning buzzer Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge Water temperature gauge Alternator
* Optional fan reversing circuit shown at inset X 131 Fan reverse switch 132 Fan reverse solenoid 133 Fan reverse horn Note: All the items listed here are not necessarily fitted to all machines in the range.
9804/1103
20 - 15 - 02/21
3630 - C/30-1.3
Issue 2*
CONTENTS
Loadalls
20 - 15 - 02/22
530, 540 From m/c no. 775402 535 From m/c no. 777362 All with Manual Auxiliary Controls Circuit Diagram - Electrical (contd)
10 2 6 11A 12A 3 4 1 11 12 13 15 7 8 9 12B 13A
16 17A 26 27 28 29 30 18 19A 20 21 23
31
32
22 17 19 33 24 25 14
133
1840a 1840
601JR 601JM 601JN
132
5
131
5A
417050
160-02292-1
9804/1103
20 - 15 - 02/22
171
3630 - C/30-2.3
Issue 2*
CONTENTS
Loadalls
20 - 15 - 02/23
530, 540 From m/c no. 775402 535 From m/c no. 777362 all with Manual Auxiliary Controls Circuit Diagram - Electrical (contd)
54 35 36 38 39 41 43 44 45 46 47 48 49 53 55 58 40 37 34 42 50 51 52 59 63 64 56 57 60 61 62 65
34A
160-02292-2
9804/1103
20 - 15 - 02/23
3630 - C/30-3.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/24
530, 540 From m/c no. 775402 535 From m/c no. 777362 all with Manual Auxiliary Controls Circuit Diagram - Electrical Component Key 2
The complete electrical circuit is shown on pages 20-15-02/22, 20-15-02/23 and 20-15-02/26.
34 34A 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 Sidelight relay Fuse link 2 RH side lights LH side lights Main light switch RH/LH dip beam RH/LH main beam Rear fog light switch Rear fog lamp (optional) Column switch - RH LH indicators RH indicators Front washer pump Front wiper motor Rear wiper motor Roof/rear washer pump Roof wiper motor Rear wiper switch Roof wiper switch Hazard warning switch Hazard warning relay Trailer indicator warning light Interior light/switch Beacon switch Beacon lamp Face level fan Air conditioning relay Air conditioning - compressor motor Air conditioning - freeze switch Air conditioning - receiver drier Air conditioning switch Heater/heater fan switch Heater
Note: All the items listed here are not necessarily fitted to all machines in the range.
9804/1103
20 - 15 - 02/24
3630 - C/30-4.1
Issue 1
CONTENTS
Loadalls
20 - 05 - 02/25
530, 540 From m/c no, 775402 535 From m/c no. 777362 all with Manual Auxiliary Controls Circuit Diagram - Electrical (contd)
66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 Column switch - LH Horn Reverse Hi/Lo relay Reverse Lo relay Reverse Hi relay Diode pack (see Note below) Reverse relay Forward relay Forward Hi/Lo relay Forward Hi solenoid Forward Lo solenoid Drive interlock relay Drive shaft relay Layshaft solenoid Mainshaft solenoid Transmission dump relay 2nd auxiliary relay 2nd auxiliary solenoid Hitch/boom hydraulics solenoid Hitch switch Sway switch Sway diverter solenoid Sway valve Sway valve 2nd auxiliary push button Isolation switch Transmission dump push button Steer mode control unit A Four wheel/crab steer relay B Two wheel steer relay C Crab steer relay D Four wheel steer relay 94 Steer mode selector switch X Two wheel steer Y Crab Steer Z Four wheel steer 95 2WS solenoid 96 4WS solenoid 97 AWS solenoid 98 Crab steer solenoid 99 Proximity switch - front axle 100 Proximity switch - rear axle Note: All the items listed here are not necessarily fitted to all machines in the range. Note: Diode indicated () not fitted to 3-speed machines.
9804/1103
20 - 15 - 02/25
3630 - C/30-5.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/26
530, 540 From m/c no. 775402 535 From m/c no. 777362 all with Manual Auxiliary Controls Circuit Diagram - Electrical (contd)
95 69 67 75 76 79 80 83 84 87 88 89 98 71 86 66 90 94 92 91 68 72 73 74 77 78 81 82 85
Z X Y
70
96
97
99
100 93
160-02292-3
9804/1103
20 - 15 - 02/26
3630 - C/30-6./1
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/27
530, 540 From m/c no. 775402 535 From m/c no. 777362 All with Single Lever Controls (SLC) Circuit Diagram - Electrical
13 11A 12A
6 3 4 7 8 9 11 12
16
27 20 21 23 24 25
31 32 33 34 35
36 37
10
18
26 15 17 19 22 30
133
1840a
601JR 601JM 601JN
132
1840 171
28 29 14 5
131
5A
417050
160-02291-1
9804/1103
20 - 15 - 02/27
3630 - C/31-1.2
Issue 2*
CONTENTS
Loadalls
20 - 15 - 02/28
530, 540 From m/c no. 775402 535 From m/c no. 777362 all with Single Lever Controls (SLC) Circuit Diagram - Electrical (contd) Component Key 1
Key
1 2 3 4 5 5A 6 7 8 9 10 11 11A 12 12A 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Battery Battery isolator Starter motor Starter solenoid Ignition switch Fuse link 2 Starting aid Neutral start relay Ignition feed relay 1 Ignition reed relay 2 E.S.O.S. Rear work lamp switch Rear work lamp Front work lamp switch Front work lamps Auxiliary power connector Brake switch 2/4WD brake relay Brake lamps 2/4WD switch 2/4WD solenoid Reverse relay Reverse lamp Reverse alarm Park brake relay Park brake switch Heated seat Radio/cassette Digital clock Transducer - load moment indicator (LMI) Instrument panel Warning buzzer Alternator Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge Water temperature gauge
9804/1103
20 - 15 - 02/28
3630 - C/31-2.2
Issue 2*
CONTENTS
Loadalls
20 - 15 - 02/29
The complete electrical circuit is shown on pages 20-15-02/27, 20-15-02/30 and 20-15-02/31. 38 38A 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 Sidelight relay Fuse link 1 RH side lights LH side lights Main light switch RH/LH dip beam RH/LH main beam Rear fog light switch Rear fog lamp (optional) Column switch - RH LH indicators RH indicators Front washer pump Front wiper motor Rear wiper motor Rear wiper switch Rear/roof washer pump Roof wiper motor Roof wiper switch Hazard warning switch Hazard warning relay Interior light/switch Beacon switch Beacon lamp Face level fan Air conditioning relay Air conditioning - compressor motor Air conditioning - freeze switch Air conditioning - receiver drier Air conditioning switch Heater/heater fan switch Heater
9804/1103
20 - 15 - 02/29
3630 - C/31-3.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/30
530, 540 From m/c no. 775402 535 From m/c no. 777362 all with Single Lever Controls (SLC) Circuit Diagram - Electrical (contd)
39
40
42
43 45
47
48 49
50
51 53
54
57 58
61 60 63 64
65 68
38 41 44
46
56
59
62
66
67
52
55
160-02291-2
9804/1103
20 - 15 - 02/30
3630 - C/31-4.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/31
530, 540 From m/c no. 775402 535 From m/c no. 777362 all with Single Lever Controls (SLC) Circuit Diagram - Electrical (contd)
100 70 72 73 78 79 82 83 86 87 91 93 95 96 103 101 102
69 99
Z X Y
104
89 71 75 76 77 80 81 84 85 88 90 92 94 97 105 98
160-02291-3
9804/1103
20 - 15 - 02/31
3630 - C/31-5.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/32
The complete electrical circuit is shown on pages 20-15-02/27, 20-15-02/30 and 20-15-02/31. 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 Column switch - LH Horn Reverse Hi/Lo relay Reverse Lo Solenoid Reverse Hi solenoid Diode pack (see Note below) Reverse relay Forward relay Forward Hi/Lo relay Forward Hi solenoid Forward Lo solenoid Drive interlock relay Drive shaft relay Layshaft solenoid Mainshaft solenoid Transmission dump relay 2nd auxiliary relay 2nd auxiliary solenoid Hitch/boom hydraulics solenoid Hitch switch Joystick isolation switch/lamp 2nd auxiliary extend switch 2nd auxiliary extend solenoid 2nd auxiliary retract switch 2nd auxiliary retract solenoid Auxiliary A/B switch Auxiliary A solenoid Auxiliary B solenoid Transmission dump push button Steer mode control unit A Four wheel/crab steer relay B Two wheel steer relay C Crab steer relay D Four wheel steer relay Steer mode selector switch X Two wheel steer Y Crab steer Z Four wheel steer 2WS solenoid 4WS solenoid AWS solenoid Crab steer solenoid Proximity switch - front axle Proximity switch - rear axle
99
100 101 102 103 104 105
Note: All the items listed here are not necessarily fitted to all machines in the range. Note: Diode indicated () not fitted to 3-speed machines.
9804/1103
20 - 15 - 02/32
3630 - C/31-6.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/33
530, 535, 540 Circuit Diagram - Electrical

530FS Super, 540FS Super, 530 SXL, 540 SXL Component Key 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Battery Battery isolator Starter motor Starter solenoid Ignition switch Fuse link 2 Starting aid Neutral start relay Ignition feed relay 1 Ignition feed relay 2 Wax Thermostat E.S.O.S. Rear work lamp switch Rear work lamp Front work lamps switch Front work lamps Auxiliary power connector 2/4WD brake relay Brake lamps Brake switch 2/4WD switch 2/4WD solenoid Reverse relay Reverse lamp Reverse alarm Heated seat Radio/cassette Digital clock Tracker Transducer - Load Moment Indicator (LMI) Fuse link 1 Instrument panel Warning buzzer Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Water temperature switch Fuel gauge Water temperature gauge Alternator Air suspension seat
From m/c no. 767001
9804/1103
20 - 15 - 02/33
3630 - C/32-1.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/34

530FS Super, 540FS Super, 530 SXL, 540 SXL
From m/c no. 767001
601
601
601
601
601
601
601
601
601
601
601
601
600
601
601 601
601
601
601
601 601
600
600
601
601
600
600
601
30A
LEAD
7 11 12
004 200 200
14
904
16
831
17
19
866 816
24 22
818 807
25 26 27
413 414 824 838 804 826 825
34 3536
405A
37 38
39
601
41
402
403
404
406
412
408
401
3
+
8 1 4
LEAD
10
13
15
1 2 3
28
450
407
409
18
21
23
29
808 112 301
30B
101
40
151
601JR
000
105
123
829
906
119
816
118
842
003
810
000
100
124
806
106
805
411
829
32
133
1840a 1840
33
20
003 200 200
5 6
001 +++
108
28
30
11
12
18
25
16
17
15
19
29
31 32 33 34 35
106
131
31
171
000 001 100 300 301 304 804 805 806 808 810 824 825 826 827 829 838 401
A374060 160/13114-1
405A
417050
9804/1103
20 - 15 - 02/34
3630 - C/32 - 2.3
601JM
601JN
132
Issue 2*
CONTENTS
Loadalls
20 - 15 - 02/35

530FS Super, 540FS Super, 530 SXL, 540 SXL Component Key 2 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 Sidelight relay Fuse link 1 RH side lights LH side lights Main light switch RH/LH dip beam RH/LH main beam Rear fog light switch Rear fog lamp (optional) Column switch - RH LH indicators RH indicators Front washer pump Front wiper motor Rear wiper motor Roof/rear washer pump Roof wiper motor Rear wiper switch Roof wiper switch Hazard warning switch Hazard warning relay Trailer indicator warning light Interior light/switch Beacon switch Beacon lamp Face level fan Air conditioning relay Air conditioning - compressor motor Air conditioning - freeze switch Air conditioning - receiver drier Air conditioning switch Heater/heater fan switch Heater Sway switch Sway diverter solenoid Sway valve Sway valve Sway isolator relay Sway isolator proximity switch
9804/1103
20 - 15 - 02/35
3630 - C/32-4.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/36

601
600
601
600
600
601
600
601
600
601
601
600
600
600
600
601
601
600
601
600
601
600
601
601
601
601
601
601
601
601
600
600
600
63
50 44
828 830 829
67
M M
45
47
834 838
48
898
52
805
53
806
58
802 854
62
400
71 70
884 883 801 800 885 882
54 55
839 841 840
56
925 926
57
901 849 803
64
66
69
886
74 76
850
77
931
78
932
827
46
49
909
42
51
59
304 803 841 840 110
60
829 300
61
65
104 301 115
68
72
73
75
200
905
832
833
836
805 804
102
829
79
907
600
21
22
23
27
24
43
000 001 100 300 301 304 804 805 806 808 810 824 825 826 827 829 838 401
405A
000 001
301 304
808 810 824 825 826 829 401

405A
121
A374070 160/13114-2
9804/1103
20 - 15 - 02/36
3630 - C/32 - 3.1
Issue 1
600
80
CONTENTS
Loadalls
20 - 15 - 02/37

530FS Super, 540FS Super, 530 SXL, 540 SXL Component Key 3 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 Transmission oil pressure switch 5th gear solenoid Speed sensor Mainshaft solenoid Layshaft solenoid Forward high solenoid Forward low solenoid Reverse high solenoid Reverse low solenoid Speedometer Speedometer illumination Throttle switch Column switch - LH Electronic control unit Diagnostic port Horn Parkbrake switch 2nd auxiliary relay 2nd auxiliary solenoid Hitch switch Hitch/boom hydraulics solenoid Joystick isolation switch Diode pack 2nd auxiliary B push button Extend push button Extend solenoid 2nd auxiliary A push button Retract push button Retract solenoid Auxiliary A push button Auxiliary A solenoid Auxiliary B push button Auxiliary B solenoid Transmission dump push button Steer mode control unit A Four wheel/crab steer relay B Two wheel steer relay C Crab steer relay D Four wheel steer relay Steer mode selector switch X Two wheel steer Y Crab Steer Z Four wheel steer 2WS solenoid 4WS solenoid AWS solenoid Crab steer solenoid Proximity switch - front axle Proximity switch - rear axle
116
117 118 119 120 121 122
9804/1103
20 - 15 - 02/37
3630 - C/32-5.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 02/38

601
600
600
600
600
600
600
600
600
601
601 600
600
601
601
600
600
600
600
600
600
601
82 83 81
480
91
808 809 874
814
92
872
96
97 99
815 851
101 106
850 853
117 118 119

601
45 2 4 6 0
120
84
894 857 858
85
86 87 88 89 90
1807
109 111
113
405
812
893
859
811
860
R N
93
871
116
315
103
600J
B
873 933 929 934 930 932 931
823 822 821
1 3 5
Z X Y
819
121
820
107
4 5 6 7 8
94
12
15
18
29
28
27
26
25
24
23
7 8 9 10 11 12 13 15 16 17 18 20
102
104 105
107 108
110 112 114 122

D
98 100
114 451 120 856 10
115
109
000
14
001 301 304
001
470A 473 470 474
808 810 824 825 826 829 401

405A
95
824 825 826
A374080 160/13114-3
9804/1103
20 - 15 - 02/38
363s0 - C/32 - 6.1
Issue 1
13
CONTENTS
Loadalls
20 - 15 - 03/1
532, 537 without Neutral Start Relay Circuit Diagrams - Electrical Component Key 1
From m/c no. 767001 to 768956
To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. The complete electrical circuit diagram is shown on pages 20-15-03/2 and 20-15-03/3.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 Battery Battery isolator Starter motor Ignition switch Starting aid not used Sway isolation relay Sway/Aux change-over Sway/Aux 1 solenoid Sway isolation switch Auxiliary A relay Auxiliary B relay Aux A/B switch Auxiliary A solenoid Auxiliary B solenoid Stabilizer isolation valve Stabilizer isolation relay Stabilizer isolation switch Stabilizer isolation proximity switch Transmission dump switch Not applicable Safe Load Indicator (SLI) SLI transducer Heater/air conditioning switch Heater/air conditioning unit Air conditioning switch Face level fan Air conditioning compressor Air conditioning relay Binary switch (air conditioning) Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/Cassette Heated seat Digital clock Left hand stabilizer warning light Right hand stabilizer warning light Warning buzzer Hazard switch Indicator relay Interior light Rotating beacon switch Rotating beacon Primary fuse Ignition relay Engine Shut-Off Solenoid Two wheel steer solenoid All wheel steer solenoid Four wheel steer solenoid Crab steer solenoid 55 Steer Mode Control Unit W All wheel steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay
56
57 58 59
Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front steer sensor Rear steer sensor Instrument panel
9804/1103
20 - 15 - 03/1
3660 - C/21-1.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/2
532, 537 without Neutral Start Relay Circuit Diagrams - Electrical (contd)
From m/c no. 767001 to 768956
14
16 23 25
D C B F A
856
600
601
601
601
825
30
44
47
15 11
883
35 27
M M 32 M
54 53
58
601
38
59
42
45 51
52
57
848 826 824
820
2
910
34 19 26 28
36
M
39
913
1 7
8
105 882
912
43
46
49
109
12
851
21
37
40 41 48
100
18
911
31 20 22 24 29
33
RT
10
907
17 13
003
F1
004
F2
F3
F4
F5
F6
F7
F8
F9
874 000
F11 F12
874
3
M +++ 200
F13
601
55
8 819
819
50
1 2 823 3 4 822 821 5 6
Z X Y 57
A312010
9804/1103
20 - 15 - 03/2
3630 - C/26-1.5 3660 - C/21-2.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/3
532, 537 without Neutral Start Relay Circuit Diagrams - Electrical (contd)
From m/c no. 767001 to 768956
601
601
74
601 601 600
64 65
62 61 63
601
69
70 73
873
G
72
9 15 16 1 13 10 7 2 5 4 3 17 18 12 6
827
77 82 79
91 84
450
98 87 85 94 102 101
76 78
92 89 90 88
68 67
871
200
80 81
99 93 97 96
83
75
71
118 119 108
66
123
86
95
100 103
104
F18
F23
F24
F25
F15
F17
F19
F29
F21
F22
F26
F28
F14
F16
F30
A312020
9804/1103
20 - 15 - 03/3
3660 3630 - C/21-3.1 - C/26-1.5
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/4
532, 537 without Neutral Start Relay Circuit Diagrams - Electrical (contd) Component Key 2
From m/c no. 767001 to 768956
To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. The complete electrical circuit is shown on pages 20 - 15 - 03/2 and 20 - 15 - 03/3
61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Steering column switch Alternator Fuel sender Water temperature sender Steering column switch Horn Reverse relay Powershift control unit Parkbrake switch Two wheel drive brake relay Foot brake switch Two wheel drive switch Brakelights Brakelights Rear light harness Reverse alarm Auxiliary power socket Rear worklight switch Rear worklight Sidelight relay Main light switch Primary fuse Right hand front sidelight Right hand rear sidelight Left hand front sidelight Left hand rear sidelight Front worklight switch Left hand worklights Right hand worklights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear foglight switch Rear foglight Steering column switch Screen wash pump Right hand front indicator Right hand rear indicator Left hand front indicator Left hand rear indicator
Note: Powershift control unit (71) only shows input connections from the mainframe harness. Refer to the ECU fault finding information in this section for control unit output connections..
9804/1103
20 - 15 - 03/4
3660 - C/21-4.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/5
532, 537 From m/c no. 768957 to 770063 with Neutral Start Relay and ECU Controlled Transmission Circuit Diagrams - Electrical Component Key 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
Battery Battery isolator Starter motor Neutral start relay Ignition switch Starting aid not used Sway isolation relay Sway/Aux change-over switch Sway isolation switch Sway/Aux 1 solenoid Auxiliary A relay Auxiliary B relay Aux A/B switch Auxiliary A solenoid Auxiliary B solenoid Stabilizer isolation valve Stabilizer isolation relay Stabilizer isolation switch Stabilizer isolation proximity switch Transmission dump switch Not applicable Safe Load Indicator (SLI) SLI transducer Heater/air conditioning fan Air conditioning switch Heater/air conditioning unit Face level fan Air conditioning compressor Air conditioning relay Binary switch Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/Cassette Heated seat Digital clock Left hand stabilizer warning light Right hand stabilizer warning light Warning buzzer Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Ignition relay Engine Shut-Off Solenoid (ESOS) Two wheel steer solenoid Four wheel/crab steer solenoid Four wheel steer solenoid Crab steer solenoid
57
58
59 60 61
Steer Mode Control Unit (SMCU) W Four wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front steer sensor Rear steer sensor Instrument panel
9804/1103
20 - 15 - 03/5
3660 - C/22-1.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/6
532, 537 with Neutral Start Relay and ECU Controlled Transmission Circuit Diagrams - Electrical (contd)
From m/c no. 768957 to 770063
601
600
600
601
601
601
601
601
600
600
600
601
600
601
601
600
600
601
601
601
601
601
411
856
856
6 7
53
601 601 601 601
11
15
16
840 856
825 826 600 601 601
37 27
601 883
39
43
55
17 20
M
841
45
601 601 848
31
800
56
60
61
908
54
824
M
925
33
35
12
004
38 42
52 47 51
410
19
884
26
901
4 13
36
M
44
105 100 109
882
9
912
926
41
1 2 3
854
50
911
901
21
907
46
M
102 106
8 2
32 25 28
(SLC)
14
18
(SLC)
(SLC)
22
120
200
826
820
10
801
59
810
F11
874 000 200 001
F5
101
115
F6
F1
F2
F3
842
3 M
000 200 001 414 +++
23
24
413
40 30
886
49 48 57
1 2 3 4 5 6 7 8
F13
874
F4
301
F12
F7
F8
F9
601
29
34
819
1 2 823 3 4 822 821 5 6
Z X Y 58
A313830
9804/1103
20 - 15 - 03/6
3660 - C/22-2.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/7
532, 537 with Neutral Start Relay and ECU Controlled Transmission Circuit Diagrams - Electrical (contd)
From m/c no. 768957 to 770063
803 601 601
304 600 600 809 405
805 600 600 601 806 841
76
601
601
832
600
66 67
601
64 63 65
71
72 75
833 827
G
808 873 871
79 84 81
93 86
450
840
100 89 87 96 104 103
74
9 15 16 1 13 10 7 2 5 4 3 17 18 12 6
78 80
94 91 92 90
70 69
R N
200
82 83
101 95 99 98
85
77
73
118 119 108
68
304
123
88
97
836 803 110
102 105
106
832
401 806 805 838 301 840 841 110 829
F18
F14
F16
F21
F22
F23
F24
F25
F26
F28
F17
F15
F19
827
F29
F30
810
839
A313840
9804/1103
20 - 15 - 03/7
3660 - C/22-3.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/8
532, 537 From m/c no. 768957 to 770063 with Neutral Start Relay and ECU Controlled Transmission Circuit Diagrams - Electrical (contd) Component Key 2
63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Water temperature switch Alternator Fuel sender Water temperature sender Steering column switch Horn Reverse relay Powershift control unit Parkbrake switch Two wheel drive brake relay Footbrake switch Two wheel drive switch Brakelights Brakelights Reverse lights Reverse alarm Auxiliary power socket Rear worklight switch Rear worklight Sidelight relay Main light switch Fusible link 1 Right hand front sidelight Right hand rear sidelight Left hand front sidelight Left hand rear sidelight Front worklight switch Left hand worklights Right hand worklights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear foglight switch Rear foglight Steering column switch Front wash/wipe motor Right hand front indicator Right hand rear indicator Left hand front indicator Left hand rear indicator
9804/1103
20 - 15 - 03/8
3660 - C/22-4.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/9
532, 537 with Relay Controlled Transmission, ECU not fitted Circuit Diagrams - Electrical Component Key 1
From m/c no. 770064 to 770958
The complete electrical circuit is shown on pages 20-15-03/10 and 20-15-03/11.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 Battery Battery isolator Starter motor Neutral start relay Ignition switch Starting aid not used Sway isolation relay Sway/auxiliary change over Sway isolation proximity switch Auxiliary A relay Auxiliary A solenoid Auxiliary B relay Auxiliary B solenoid Auxiliary A/B switch Auxiliary change over relay 2 Sway/auxiliary solenoid Stabilizer isolation relay Stabilizer isolation valve Stabilizer isolation switch Stabilizer isolation proximity switch Not applicable Safe load indicator (SLI) SLI transducer Heater/air conditioning fan motor Air conditioning switch Heater/air conditioning unit Face level fan Air conditioning compressor Air conditioning relay Binary switch - air conditioning Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper motor Front wiper motor Radio/cassette Heated seat Digital clock Left hand stabilizer warning light Right hand stabilizer warning light Warning buzzer Hazard warning light Indicator relay Hazard diode Interior light Beacon switch Beacon Primary fuse Ignition relay Engine shut-off system (ESOS) Two-wheel steer solenoid Four-wheel/crab steer solenoid Four-wheel steer solenoid Crab steer solenoid 57 Steer mode control unit (SMCU) W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front steer sensor Rear steer sensor Instrument panel
58
59 60 61
9804/1103
20 - 15 - 03/9
3660 - C/23-1.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/10
532, 537 with Relay Controlled Transmission, ECU not fitted Circuit Diagrams - Electrical (contd)
From m/c no. 770064 to 770958
601
601
601
601
600
601
601
601
600
600
600
600
411
601
600
601
601
600
601
601
600
600
601
6 7
601
601
601
601
601
601
17
12
14
840
53 39 43 55
825 600 601 601
37 19 21
800 908
27
601 883
M
841
45
601 601
31
56 54
848
60
61
10
801
410
925
11
004
35
20 9 13
38 42
52 47
200
26
901
51
105 109
410
36
M
44
100
926
912
41
1 2 3
854
50
911
901
909
46
907
(SLC)
102
15
18
22
(SLC)
25
884
28
840 841 110 829 829 810
301
120
106
32
826
824
33
820
59
810
F7
F8
F9
F11
F5
F1
101
F2
F3
842
F4
115
F6
F12
3 M
414 +++
200 001 +++
23 16
24
413
40 30
886
49
301
F13
874 000
874
601
29
34
48
57
8 819
1 2 823 3 4 822 821 5 6
Z X Y 58
A313850
9804/1103
20 - 15 - 03/10
3660 - C/23-2.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/11
532, 537 with Relay Controlled Transmission, ECU not fitted Circuit Diagrams - Electrical (contd)
From m/c no. 770064 to 770958
601
601
601
601
600
600 601
601
809 601 601 601 601
807
69
808
601 600
81
600
68 72
827
63 64 65
66
85
94 109 103
450 118
601
811
863
859
76 77
600
96 95 101
117 106 113
90
808
80
82 84
93
111 108
600
601
852
78
861
83
812
87 89 100
200
871
600
874
67
857
601
92
119
872
71
75 79
304 124
99
102 105 114
890 601
121
600
86
115
815
100 118 401 806 805 838 301 840 841 110 829 108
F28
F31
F32
F33
F34
F35
F16
F18
91
807 815
97
98
F21
F22
F23
F24
F25
F17
F15
F19
73
F26
F29
F30
601
120
119 118
3 SPEED ONLY
122
839 A313860
70
F14
832
107
9804/1103
20 - 15 - 03/11
3660 - C/23-3.1
123
Issue 1
74
88
104
107
600 601
110
112
116
CONTENTS
Loadalls
20 - 15 - 03/12
532, 537 with Relay Controlled Transmission, ECU not fitted Circuit Diagrams - Electrical (contd) Component Key 2
The complete electrical circuit is shown on pages 20-15-03/10 and 20-15-03/11. 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Water temperature switch Alternator Fuel sender Water temperature sender Steering column switch Horn Reverse 2 relay Ignition relay 2 Transmission dump switch Transmission dump relay Reverse 1 relay Forward relay Drive relay Parkbrake relay Rev HI/LO relay Reverse high/low solenoid Reverse low solenoid Forward HI/LO relay Forward high solenoid Forward low solenoid Driveshaft relay Layshaft solenoid Mainshaft solenoid Two/four wheel drive solenoid Transmission oil temperature switch Parkbrake switch Two-wheel drive switch Two-wheel drive brake relay Footbrake switch Brake lights Brake lights Reverse lights Reverse alarm Auxiliary power socket Rear work light switch Rear work light Side light relay Main light switch Primary fuse Right hand front sidelight Right hand rear sidelight Left hand front sidelight Left hand rear sidelight Left hand worklight Front worklight switch Right hand worklights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear foglight switch Rear foglight Steering column switch Front wash/wipe motor Right hand front indicator
From m/c no. 770064 to 770958
121 Right hand rear indicator 122 Left hand front indicator 123 Left hand rear indicator
9804/1103
20 - 15 - 03/12
3660 - C/23-4.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/13
532, 535, 537 Circuit Diagrams - Electrical Component Key 1

The complete electrical circuit is shown on pages 20-15-03/14 and 20-15-03/15. 1 2 3 4 5 6 7 8 9 10 11 Battery Battery isolator Starter motor Ignition switch Starting aid Neutral start relay not used Sway isolation relay Sway/auxiliary change over switch Sway/auxiliary change-over valve Sway isolation proximity switch (Not N. American 532 or 550) 11A Link Harness (N. American 532 and 550 only) 12 Sway/auxiliary solenoid 13 Auxiliary A solenoid 14 Joystick isolation switch 15A Auxiliary A button 15B Auxiliary B button 16 Auxiliary B solenoid 17 Stabilizer isolation relay 18 Stabilizer isolation valve 19 Stabilizer isolation switch 20 Stabilizer isolation proximity switch 21 Safe load indicator (SLI) 22 SLI transducer 23 Heater/air conditioning fan motor 24 Heater/air conditioning unit 25 Air conditioning switch 26 Face level fan 27 Air conditioning compressor 28 Air conditioning relay 29 Binary switch - air conditioning 30 Rear wiper switch 31 Rear wiper motor 32 Roof wiper switch 33 Roof wash pump 34 Roof wiper motor 35 Front wiper motor 36 Heated seat 37 Radio/cassette 38 Digital clock 39 Left hand stabilizer warning light 40 Right hand stabilizer warning light 41 Warning buzzer 42 Hazard warning light 43 Indicator relay 44 Hazard diode 45 Interior light 46 Beacon switch 47 Beacon 48 Primary fuse 1 49 Fusible link 50 Ignition relay 51 Engine shut-off system (ESOS) 52 Two-wheel steer solenoid 53 Four-wheel/crab steer solenoid 54 Four-wheel steer solenoid 55 Crab steer solenoid 56
From m/c no. 770959
57
58 59 60
Steer mode control unit (SMCU) W All wheel steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front steer sensor Rear steer sensor Instrument panel
9804/1103
20 - 15 - 03/13
3660 - C/24-1.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/14
532, 535, 537 Circuit Diagrams - Electrical (contd)
From m/c no. 770959
600
600
600
24
10
12 16
18 36
800
52 54 22
825 600 601 601
601
601
29 4 13 25 26
M
935
43 35
M
47 49
41 45
53
200 824 820
M 31
848
34
55
59
60
58
51 38 42 46 50
105 109
27 9 20
882
37
926 1 2 3
39
100
15A 6 2 7 8
15B
30 21 14 17 23 28
32
40
RT
48
44
842
907
11
1 11A
451
120
826
33
810
F7
F8
F5
F6
F9
F11
000 200
F12 F13
F1
F2
F3
F4
200
19
601 +++ 1 2 3 4 5 6 7 8 819
56
1 2 823 3 4 822 821 5 6
Z X Y 57
A311990
9804/1103
20 - 15 - 03/14
3660 - C/24-2.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/15
532, 535, 537 Circuit Diagram - Electrical (contd)
From m/c no. 770959
601
601
600
600 601
601
601
601
601
601
68
808
601 600
80
600
67 71
827
62 63 64
65
84
93 109 103
450
863
601
811
859
75 76
600
95 89 92 94
600
117 106 113
808
79
81 83
100 104
111 108
871
600
601
77 66
852
82
861
812
86 88 99 101
857
601
91
119
872
70
74 78
304 124
98 121 122 120 105 102 114
890 601
815
F28
601
90
F31 F32 F33 F34 F35
96
F16
F18
97
F21
F22
F23
F24
F25
815
F15
F17
F19
72
F26
F29
F30
600
85
115
119 118
3 SPEED ONLY
69
F14
107
839 A312000
9804/1103
20 - 15 - 03/15
3660 - C/24-3.1
123
73
87
107
600 601
110
112
116
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/16
532, 535, 537 Circuit Diagrams - Electrical (contd) Component Key 2
From m/c no. 770959
Tthe complete electrical circuit diagram is shown on pages 20-15-03/14 and 20-15-03/15.
62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Water temperature switch Alternator Fuel sender Water temperature sender Steering column switch Horn Reverse 2 relay Ignition relay 2 Transmission dump switch Transmission dump relay Reverse 1 relay Forward relay Drive relay Parkbrake relay Rev HI/LO relay Reverse high/low solenoid Reverse low solenoid Forward HI/LO relay Forward high solenoid Forward low solenoid Driveshaft relay Layshaft solenod Mainshaft solenoid Two/Four wheel drive solenoid Transmission oil temperature switch Parkbrake switch Two-wheel drive switch Two-wheel drive brake relay Footbrake Brake lights Brake lights Reverse lights Reverse alarm Auxiliary power socket Rear work light switch Rear work light Side light relay Fusible link 3 Main light switch Fusible link 2 Right hand front sidelight Righ hand rear sidelight Left hand front sidelight Left hand rear sidelight Left hand worklight Front worklight switch Right hand worklights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear foglight switch Rear foglight Steering column switch Front wash/wipe motor Right hand front indicator Right hand rear indicator 122 Left hand front indicator 123 Left hand rear indicator
9804/1103
20 - 15 - 03/16
3660 - C/24-4.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 03/17
* 540-170,
532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402 5508 with Servo Controls to m/c no. 1004130 Circuit Diagrams - Electrical Component Key 1
The complete electrical circuit is shown on pages 20 - 15 - 03/18, 20-15-03/19, 20 - 15 - 03/22 and 20 - 15 - 03/23.
Key 1 2 3 4 5 5A 6 7 8 9 10 11 11A 12 12A 12B 13 13A 14 15 16 17 17A 18 19 19A 20 21 22 22A 23 24 25 26 27 28 29 30 31 32 33 34 35 Battery Battery isolator Starter motor Starter solenoid Ignition switch Fuse link 2 Starting aid Neutral start relay Ignition feed relay 1 Ignition feed relay 2 E.S.O.S. Rear work lamp switch Rear work lamp Front work lamp switch Front work lamps Auxiliary power connector 2/4WD brake relay Brake lamps Brake switch 2/4WD switch 2/4WD solenoid Reverse relay Reverse lamp Reverse alarm Park brake relay Park brake switch Heated seat Radio/cassette Digital clock Fuse link 1 Transducer - load moment indicator (LMI) Instrument panel Warning buzzer Alternator Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge Water temperature gauge LH stabiliser lamp switch RH stabiliser lamp switch
Note 1: All the items listed here are not necessarily fitted to all machines in the range. Note 2: 540-17- machines only. See page 20 - 15 - 03/23 for additional circuits. Note 3: Fuses 31 and 32 for 540-170 machines are shown on page 20 - 15 - 03/23.
9804/1103
20 - 15 - 03/17
3630 - C/25-1.4
Issue 3*
CONTENTS
Loadalls
20 - 15 - 03/18
532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402 540-170, 5508 with Servo Controls to m/c no. 1004130 Circuit Diagrams - Electrical (contd)
10 2 6
11A 12A 12B 13A 16
17A
18
34 32 27 28 29 30 31 33
35
19A 20 21
1828 410
23
See Sheet 4
35
3 34 7 1 26 24 25 14
See Note 2 540-170 (5508 N.Am) Only
410
11
12 13
15 17 19
22
5 5A 22A
160-02290-1
9804/1103
20 - 15 - 03/18
3660 - C/25-2.2
Issue 3*
CONTENTS
Loadalls
20 - 15 - 03/19
* 532, *
537, 550 with Manual Auxiliary Controls from m/c no. 775402 540-170, 5508 with Servo Controls to m/c no. 1004130 Circuit Diagrams - Electrical (contd)
37
38
40
41
45
46
43
47
48
49 50
51
55 56 58
59 61 62
63 66
36
39 42
44 52 53
54
57
60
64 65
36A
160-02290-2
9804/1103
20 - 15 - 03/19
3630 - C/26-1.5 3660 - C/25-3.1
Issue 3*
CONTENTS
Loadalls
20 - 15 - 03/20
* 540-170,
532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402 5508 with Servo Controls to m/c no. 1004130 Circuit Diagrams - Electrical (contd) Component Key 2
The complete electrical circuit is shown on pages 20-15-03/18, 20-15-03/19, 20-15-03/22 and 20-15-03/23. 36 36A 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 Sidelight relay Fuse link 1 RH side lights LH side lights Main light switch RH/LH dip beam RH/LH main beam Rear fog light switch Rear fog lamp (optional) Column switch - RH LH indicator lamps RH indicator lamps Front washer pump Front wiper motor Rear wiper motor Rear/roof washer pump Roof wiper motor Rear wiper switch Roof wiper switch Hazard warning switch Hazard warning relay Interior light/switch Beacon switch Beacon lamp Face level fan Air conditioning relay Air conditioning - compressor motor Air conditioning - freeze switch Air conditioning - receiver drier Air conditioning switch Heater/heater fan switch Heater
9804/1103
20 - 15 - 03/20
3660 - C/25-4.4
Issue 3*
CONTENTS
Loadalls
20 - 15 - 03/21
532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402 540-170, 5508 with Servo Controls to m/c no. 1004130 Circuit Diagrams - Electrical (contd) Component Key 3
The complete electrical circuit is shown on pages 20-15-03/18, 20-15-03/19, 20-15-03/22 and 20-15-03/23. Column switch - LH Horn Reverse Hi-Lo relay Reverse Lo solenoid Reverse Hi solenoid Diode pack (see Note below) Reverse relay Forward relay Forward Hi/Lo relay Forward Hi solenoid Forward Lo solenoid Drive interlock relay Drive shaft relay Layshaft solenoid Mainshaft solenoid Transmission dump relay Stabiliser isolation switch Stabiliser isolation relay Stabiliser isolation solenoid Stabiliser isolation switch Sway isolation switch Sway isolation relay Sway switch Sway diverter solenoid Sway solenoid Sway solenoid Transmission dump push button Steer mode control unit A Four wheel/crab steer relay B Two wheel steer relay C Crab steer relay D Four wheel steer relay 94 Steer mode selector switch X Two wheel steer Y Crab steer Z Four wheel steer 95 2WS solenoid 96 4WS solenoid 97 AWS solenoid 98 Crab steer solenoid 99 Proximity switch - front axle 100 Proximity switch - rear axle 67 68 69 70 71 71A 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93
Note: All the items listed here are not necessarily fitted to all machines in the range. Note: Diode indicated () not fitted to 3-speed machines.
9804/1103
20 - 15 - 03/21
3660 - C/25-5.4
Issue 3*
CONTENTS
Loadalls
20 - 15 - 03/22
* 540-170,
532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402 5508 with Servo Controls to m/c no. 1004130 Circuit Diagrams - Electrical (contd)
95 79 68 70 71 75 76 80 84 89 90 91 96 97 98
67
71A 88
A
94 69 72 73 74 77 78 81 82 83 85 86 87 92
B C Z X Y
99
100
D
93
160-02290-3
9804/1103
20 - 15 - 03/22
3660 3630 - C/25-6.2 - C/26-1.5
Issue 3*
1828
CONTENTS
540-170, 5508 with Servo Controls Circuit Diagrams - Electrical (contd)
Loadalls
To m/c no. 1004130
20 - 15 - 03/23
000 1823
F31
170
170F 601HS
EXT ISOL. SW.
102
601GM 601FL
EXT. RELAY
104
170B
601HZ
1833A 1825C 1833 1833
EXT INTERLOCK
601FN
1820
EXT. DIVERTER SOL.
1821 170L 1825A
601JB 1825 601TH
LIFT ISOL. RELAY LIFT UNLOADER SOL
170E
601HR
LIFT ISOL. SW.
1824 170C 1820
601FY 601FZ
STABILISER LIFT RELAY STAB LIFT UNLOADER SOL
170D
601FW
STAB. LIFT ISOL. SW.
1829A
1829B
1829
601HW
FULL LOCK SOL.
170J 170H
1830B
1830
601HX
CROWD LOCK SOL.
1830A
601HV
DUMP LOCK SOL.
601GA
F32
171
1822A 1822
601GB
BOOM WORKLIGHT
9804/1103
20 - 15 - 03/23
101 105 119 106 107 108 110 109 111 112 116 113 114
1830C
3660 - C/25-7.2
Issue 1
From Sheet 1
103
1825B
115
118
117
CONTENTS
Loadalls
20 - 15 - 03/24
540-170, 5508 with Servo Controls Circuit Diagrams - Electrical (contd)

Component Key 4 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 Extend isolation switch Extension relay Inner boom extension switch Extension interlock Extension diverter valve solenoid Lift/unloader solenoid Lift solenoid relay Lift solenoid switch Stabiliser lift unloader solenoid Stabiliser lift relay Stabiliser lift isolation solenoid Full lock solenoid Diode Lock solenoid - tilt back Lock solenoid - tilt forward Joystick isolation switch Boom worklight Boom worklight switch Diode
To m/c no. 1004130
9804/1103
20 - 15 - 03/24
3660 - C/25-8.3
Issue 2*
CONTENTS
Loadalls
20 - 15 - 03/25
* 540-170,
5508 with Servo Controls from m/c no. 1004130 Circuit Diagrams - Electrical Component Key 1
1 2 3 4 5 5A 6 7 8 9 10 11 11A 12 12A 12B 13 13A 14 15 16 17 17A 18 19 19A 20 21 22 22A 23 24 25 26 27 28 29 30 31 32 33 34 35 Battery Battery isolator Starter motor Starter solenoid Ignition switch Fuse link 2 Starting aid Neutral start relay Ignition feed relay 1 Ignition feed relay 2 E.S.O.S. Rear work lamp switch Rear work lamp Front work lamp switch Front work lamps Auxiliary power connector 2/4WD brake relay Brake lamps Brake switch 2/4WD switch 2/4WD solenoid Reverse relay Reverse lamp Reverse alarm Park brake relay Park brake switch Heated seat Radio/cassette Digital clock Fuse link 1 Transducer - load moment indicator (LMI) Instrument panel Warning buzzer Alternator Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge Water temperature gauge LH stabiliser lamp switch RH stabiliser lamp switch
9804/1103
20 - 15 - 03/25
3630 - C/26-1.4
Issue 1*
CONTENTS
Loadalls
20 - 15 - 03/26
* 540-170,
36 36A 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 Sidelight relay Fuse link 1 RH side lights LH side lights Main light switch RH/LH dip beam RH/LH main beam Rear fog light switch Rear fog lamp (optional) Column switch - RH LH indicator lamps RH indicator lamps Fornt washer pump Front wiper motor Rear wiper motor Rear/roof washer pump Roof wiper motor Rear wiper switch Roof wiper switch Hazard warning switch Hazard warning relay Interior light/switch Beacon switch Beacon lamp Face level fan Air conditioning relay Air conditioning - compressor motor Air conditioning - freeze switch Air conditioning - receiver drier Air conditioning switch Heater/heater fan switch Heater
9804/1103
20 - 15 - 03/26
3630 - C/2641.4
Issue 1*
CONTENTS
Loadalls
20 - 15 - 03/27
* 540-170,
67 68 69 70 71 71A 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93
Column switch - LH Horn Reverse Hi-Lo relay Reverse Lo solenoid Reverse Hi solenoid Diode pack Reverse relay Forward relay Forward Hi-Lo relay Forward Hi solenoid Forward Lo solenoid Drive interlock relay Drive shaft relay Layshaft solenoid Mainshaft solenoid Transmission dump relay Stabiliser isolation switch Stabiliser isolation relay Stabiliser isolation solenoid Stabiliser isolation switch Sway isolation switch Sway isolation relay Sway switch Sway diverter solenoid Sway solenoid Sway solenoid Transmission dump push button Steer mode control unit A Four wheel/crab steer relay B Two wheel steer relay C Crab steer relay D Four wheel steer relay 94 Steer mode selector switch X Two wheel steer Y Crab steer Z Four wheel steer 95 2WS solenoid 96 4WS solenoid 97 AWS solenoid 98 Crab steer solenoid 99 Proximity switch - front axle 100 Proximity switch - rear axle
9804/1103
20 - 15 - 03/27
3630 - C/26-5.4
Issue 1*
CONTENTS
Loadalls
20 - 15 - 03/28
* 540-170,
101 102 103 104 105 106 111 112 113 114 115 116 117 118 119 120 121 Right hand stabiliser relay Right hand stabiliser LED Left hand stabiliser relay Left hand stabiliser LED Inner boom extension switch Inner boom extension relay Lift/unloader solenoid Lift isolation switch Lift isolation relay Stabiliser left unloader solenoid Stabiliser lift relay Stabiliser lift isolation switch Fork lock solenoid Fork lock solenoid Joystick isolation switch Boom worklight Boom worklight switch
9804/1103
20 - 15 - 03/28
3630 - C/26-8.4
Issue 1*
CONTENTS
Loadalls
20 - 15 - 03/29
* 540-170,
5508 Machines from m/c no. 1004131 Circuit Diagrams - Electrical (contd)
601
30 31
27 28 29
601
601
601
601
601
601
601
600
6 01
601
601
601
601
601
600
601
601
601
601
601
601
601
601
601
601
600
601
601
410
10 2 6 22A
11A 12A 12B

831
17A 13A
816 866
19A 18 20 21
23A 32 33
16
818 807
825
401
403
404
405
838
406
200
904
826
407
200
004
414
402
8 15
413
824
3 M 7 1 + 4
11
12
13
15 1 2 3 17 19
22
450
000
100
842
000
810
123
003
105
816
401
856
118
112
829
119
124
808
301
906
101
805
806
106
411
25
14
003 106
200
108
12
18
25
16
17 15
19
29
28 30
200
11
33 34 35
5A
001
+++
000 000 001 100 300 301 304 804 805 806 808 810 824 825 826 827 829 160-13328 838 856
22A
9804/1103
20 - 15 - 03/29
829
24
106
106
22B
23
8 04
412
408
409
34
481
35
26
3660 - C/26-2.4
Issue 1*
CONTENTS
Loadalls
20 - 15 - 03/30
* 540-170,
37
38
40
41
45
46
43
47
48
49 50
51
55 56 58
59
61 62
63 66
36
39 42
44 52 53
54
57
60
64
65
36A
160-13328-2
9804/1103
20 - 15 - 03/30
3660 - C/26-3.4
Issue 1*
CONTENTS
Loadalls
20 - 15 - 03/31
* 540-170,
95 79 68 70 71 75 76 80 84 89 90 91 96 97 98
67
71A 88 A 94 Z X Y
69
72
73
74 77
78
81
82
83 85
86
87
92
B C
99
100 D 93
160-13328-3
9804/1103
20 - 15 - 03/31
3660 - C/26-6.4
Issue 1*
CONTENTS
Loadalls
20 - 15 - 03/32
* 540-170,
601HW
601FN
601JW
601HT
601HV
601FZ
601JA
601JS
601JY
601JY
601JX
108
110
1825 601JB
111
601FY
114
117
1830A
118
120
1825A
1833
601HR
601FW
1829
109
1820
104
1829B 1829A
1830C
1825B
1842
601GM
601HS
112
115
601FL
1830B
601GA
1833A
1833
315 0 45
105
1834A
1821
1824
119*
103
1834 1850
1834B
113
170K
116
1822A
106
1828
102 101
1823
170L
170C
106 410 170B 481 170 170F
F31
171 160-13328-4
107
170D
170E
170H
170J
121
1822
601GB
000 828
9804/1103
20 - 15 - 03/32
F36
3660 - C/26-7.4
Issue 1*
CONTENTS
Loadalls
20 - 15 - 04/1
506B Syncroshuttle Circuit Diagrams - Electrical (contd)

48 48
To m/c no. 578676
600
24 5
N
37 202 204 205 208

811
46 47 44 45
812 815
17 11
G/Y U 415 414 413A
27
26
49 50
51 52
53 54 59 60
414A 814 839 801 416 N G/Y U 805 806 807 400 600 841
403
405 404 406 407
203 206
34 42 43
55
412
408
409
413 414B 413B
21
402
56
10
804 803
32 36 40
842
210
212 211 213
214
57 41
808A 809
58
209
215
20 16 3 9 1 25
101 003 800 103A
23
802
31 30
803A 401
19
810
207
808
39
411 200
+
6
105 300
106A
100
61
15
800 100 200 842
103
104
106
A1
200
A2
A4
A5
A6
A7
A8
A9
B1
B2
004
103
000 000R 200 004 842
000 000R 200
9804/1103
20 - 15 - 04/1
3640U - C/10-1.2
Issue 1
CONTENTS
Loadalls
20 - 15 - 04/2
506B Syncroshuttle Circuit Diagrams - Electrical (contd) Component Key
To m/c no. 578676
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on pages 20-15-04/1 and 20-15-04/3. 1 2 3 4 5 6 9 10 11 15 16 17 19 20 21 23 24 25 26 27 30 31 32 34 36 37 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 Battery Starter Motor Starter Solenoid Starter Switch Thermostart Starter Relay Safe Load Indicator Readout Box Rear SLI Boss Front SLI Boss Heater Switch Heater Resistor Heater Motor Seat Relay Swedish Parking Brake Switch machines Seat Switch only Horn Push Horn Wash/Wipe Switch Front Wiper Motor Washer Pump Hazard Switch Indicator Relay Indicator Switch Fuel Shut-off Solenoid Reverse Alarm Relay Reverse Alarm Forward/Reverse Selector Switch Neutral Start Relay Parking Brake Warning Relay Reverse Relay Forward Relay Reverse Solenoid Forward Solenoid Transmission Dump Switch Parking Brake Switch Trailer Socket Air Filter Switch Engine Oil Pressure Switch Transmission Oil Temperature Switch Transmission Oil Pressure Switch Water Temperature Switch 54 55 56 57 58 59 60 61 62 63 65 66 67 68 69 71 71B 72 73 75 76 77 78 78A 78B 78C 78D 78E 78F 79 80 81 82 83 86 87 88 93 99 100 Hourmeter Alternator Tachometer Fuel Gauge Water Temperature Gauge Fuel Gauge Sender Water Temperature Gauge Sender Warning Buzzer L. H. Stabiliser Switch R. H. Stabiliser Switch Interior Light Switch Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch Beacon Brake Switch Brake Switch Relay 2/4 Wheel Drive Switch (not fitted on permanent 4 wheel drive) 2 Wheel Drive Solenoid Front Axle Proximity Switch Rear Axle Proximity Switch Steering Mode Selector Switch Steer Mode Printed Circuit Board Relay 2 Relay 1 Relay 1 (latch) Relay 2 (unlatch) Relay 1 (unlatch) Relay 2 (latch) 4 Wheel/Crab Steer Solenoid 4 Wheel Steer Solenoid Crab Steer Solenoid 2 Wheel Steer Solenoid Side Lights Relay Working Light Switch Road Light Switch Headlamp Dip Switch Headlamp Flasher Radio (Optional) Transmission Dump Relay Lamps 202 Trailer Indicator Warning 203 Hazard Warning 204 L.H. Indicators 205 R.H. Indicators 206 Indicator Warning 207 Hazard Indicator Warning 208 Reversing Lights 209 Parking Brake Warning 210 Air Filter Blocked Warning 211 Engine Oil Pressure Warning 212 Transmission Oil Temperature Warning 213 Transmission Oil Pressure Warning 214 Water Temperature Warning 215 Alternator Warning 216 Stabiliser Indicators 217 Interior Light 218 Beacon Warning 219 2 Wheel Drive Warning 220 L.H. Brake Lights 221 R.H. Brake Lights 222 4 Wheel Steer Warning 223 Crab Steer Warning 224 2 Wheel Steer Warning 225 Instrument Panel Illumination 226 L.H. Side Light 227 R.H. Side Light 229 Number Plate Light 230 Working Light Warning 231 Cab Working Light 232 Headlamp Dip Beam 233 Headlamp Main Beam 234 Headlamp Main Beam Warning 235 Inclinometer Illumination Fuses Fuses are numbered as shown on the fuse box in the cab. Cable Colour Code G N U Y Green Brown Blue Yellow
Note: For machines without road lights a link is fitted (as shown) in place of Working Light Switch 86 and switch 87 operates the Working Lights. On North American machines the Safe Load Indicator System is not normally fitted, items 9, 10 and 11.
9804/1103
20 - 15 - 04/2
3640U - C/10-2.2
Issue 1
CONTENTS
Loadalls
20 - 15 - 04/3
To m/c no. 578676
48
600
48
48
66 216 217 67 65
69 220 219 73 221

78C 78D 78E 78F
829P
78 225
78B
229 235 226 227 230

835 834 837 838
234 231 232 233
218 63
301 847
818
78A
831
99 B9 C1
816
62
844
72
817
821 822
823
848 826 824 825
829 830
86
B8
C2
68
410
77 83
B6
828
B7
112 833 836
71B 76 75 71
108 109 820
79
222
223
224
88
819 827 106D 855
93
832 110
80
81
82
87 B5 C4
B3
103 000 000R 200
B4
9804/1103
20 - 15 - 04/3
3630 -- C/10-3.1 C/26-1.5 3640U
Issue 1
CONTENTS
Loadalls
20 - 15 - 04/4
506B Syncroshuttle Circuit Diagrams - Electrical
From m/c no. 578677
14 6 10 2 5 12
16
19 25 28 29 32
9 3
11
26 15 7 30 1 18 13 17 21 22 8 23 24 20 27 31
A1 4
A2
A3
A4
A5
A6
A269320
9804/1103
20 - 15 - 04/4
3640U3630 C/10-4.2 - C/26-1.5
Issue 1
CONTENTS
Loadalls
20 - 15 - 04/5
506B Syncroshuttle Circuit Diagrams - Electrical (contd) Component Key
From m/c no. 578677
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on pages 20-15-04/4 and 20-15-04/6. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 19A 19B 19C 19D 19E 19F 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Battery Starter Motor Starter Solenoid Starter Switch Thermostart Fuel Shut-off Solenoid Neutral Start Relay Forward/Reverse Selector Switch Reverse Relay Reverse Solenoid Forward Relay Forward Solenoid Transmission Dump Relay Transmission Dump Switch Parking Brake Warning Relay Parking Brake Switch Rear Axle Proximity Switch Front Axle Proximity Switch Steer Mode Printed Circuit Board Relay 2 Relay 1 Relay 1 (latch) Relay 2 (unlatch) Relay 1 (unlatch) Relay 2 (latch) Steering Mode Selector Switch 4 Wheel/Crab Steer Solenoid 4 Wheel Steer Solenoid Crab Steer Solenoid 2 Wheel Steer Solenoid Heater Motor Heater Resistor Heater Switch Horn Front Wiper Motor Horn Push Wash/Wipe Switch Washer Pump Air Filter Switch Engine Oil Pressure Switch Transmission Oil Temperature Switch Transmission Oil Pressure Switch Water Temperature Switch Warning Buzzer Hourmeter Alternator Tachometer Fuel Gauge Fuel Gauge Sender Water Temperature Gauge Water Temperature Gauge Sender Reverse Alarm Working Light Switch Interior Light Switch 49 50 51 52 Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Beacon Switch
Lamps 80 Parking Brake Warning 81 4 Wheel Steer Warning 82 Crab Steer Warning 83 2 Wheel Steer Warning 84 Air Filter Blocked Warning 85 Engine Oil Pressure Warning 86 Transmission Oil Temperature Warning 87 Transmission Oil Pressure Warning 88 Water Temperature Warning 89 Alternator Warning 90 Instrument Panel Illumination 91 Cab Working Light 92 Working Light Warning 93 Interior Light 94 Beacon Warning 95 Beacon Fuses Fuses are numbered as shown on the fuse box in the cab.
9804/1103
20 - 15 - 04/5
3640U - C/10-5.2
Issue 1
CONTENTS
Loadalls
20 - 15 - 04/6
From m/c no. 578677
33 34
35 36
37
43
45
46 91
93 95 51 48 49 50
39
40
42 80 81 82 83 84 85 86 87 88 89 41
44
52
94
90
47
92
38
A7
A8
A9
B1
9804/1103
20 - 15 - 04/6
3640U - C/10-6.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 04/7
506C, 508C Syncroshuttle Circuit Diagrams - Electrical
To m/c no. 585396
6 5 2 10
14
16 17 20 21 24 25
26 27
28 29
30 32 33 36 38 39 88 89 41 35 37 42 43 90
12
3 9 7 11 15
18
80 81 22 23
82 83
84 85
86
34
44 87 40
19
13 8
31
45 4
9804/1103
20 - 15 - 04/7
3640U - C/10-7.2
Issue 1
CONTENTS
Loadalls
20 - 15 - 04/8
506C, 508C Syncroshuttle Circuit Diagrams - Electrical (contd) Component Key
To m/c no. 585396
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on page 20-15-04/7. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Battery Starter Motor Starter Solenoid Starter Switch Thermostart Fuel Shut-off Solenoid Neutral Start Relay Forward/Reverse Selector Switch Reverse Relay Reverse Solenoid Forward Relay Forward Solenoid Transmission Dump Relay Transmission Dump Switch Parking Brake Warning Relay Parking Brake Switch Heater Motor Heater Resistor Heater Switch Horn Front Wiper Motor Horn Push Wash/Wipe Switch Washer Pump Face Fan Air Filter Switch Engine Oil Pressure Switch Transmission Oil TemperatureSwitch Transmission Oil Pressure Switch Water Temperature Switch Warning Buzzer Hourmeter Alternator Tachometer Fuel Gauge Fuel Gauge Sender Water Temperature Gauge Water Temperature Gauge Sender Reverse Alarm Working Light Switch Auxiliary Earth Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch Ignition relay Lamps 80 Parking Brake Warning 81 Air Filter Blocked Warning 82 Engine Oil Pressure Warning 83 Transmission Oil Temperature Warning 84 Transmission Oil Pressure Warning 85 Water Temperature Warning 86 Alternator Warning 87 Instrument Panel Illumination 88 Cab Working Light 89 Interior Light and Switch 90 Beacon Fuses Fuses are numbered as shown on the fuse box in the cab.
9804/1103
20 - 15 - 04/8
3640U - C/10-8.2
Issue 1
CONTENTS
Loadalls
20 - 15 - 04/9
506C, 508C Syncroshuttle Circuit Diagram - Electrical Component Key
From m/c no. 585397
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on page 20-15-04/10. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Battery Starter Motor Starter Solenoid Starter Switch Thermostart Fuel Shut-off Solenoid Neutral Start Relay Forward/Reverse Selector Switch Reverse Relay Reverse Solenoid Forward Relay Forward Solenoid Transmission Dump Relay Transmission Dump Switch Parking Brake Warning Relay Parking Brake Switch Heater Motor Heater Resistor Heater Switch Horn Front Wiper Motor Horn Push Wash/Wipe Switch Washer Pump Face Fan Air Filter Switch Engine Oil Pressure Switch Transmission Oil TemperatureSwitch Transmission Oil Pressure Switch Water Temperature Switch Warning Buzzer Hourmeter Alternator Tachometer Fuel Gauge Fuel Gauge Sender Water Temperature Gauge Water Temperature Gauge Sender Reverse Alarm Working Light Switch Auxiliary Earth Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch Ignition relay Lamps 80 Parking Brake Warning 81 Air Filter Blocked Warning 82 Engine Oil Pressure Warning 83 Transmission Oil Temperature Warning 84 Transmission Oil Pressure Warning 85 Water Temperature Warning 86 Alternator Warning 87 Instrument Panel Illumination 88 Cab Working Light 89 Interior Light 90 Beacon Fuses Fuses are numbered as shown on the fuse box in the cab.
9804/1103
20 - 15 - 04/9
3640U - C/10-9.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 04/10
506C, 508C Syncroshuttle Circuit Diagram - Electrical (contd)
From m/c no. 585397
14 6 2 10 5 12
16 17 20 21 24 25
26 27
28 29
30 32 33 36 38 39 88 41 35 37 44 89 42 43 90
11
18
80 81
82 83
84 85
86
34
15 22 87
1 13
19
23
40
31 8 45 4
9804/1103
20 - 15-04/10
3640U - C/10-10.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 04/11
506C, 508C Powershift with 6 Transmission Relays Circuit Diagrams - Electrical
To m/c no. 585396
33 6 2 8 9 10 12 17 11 13 18 14 29 1 7 19 30 25 80 81 82 20 21 23 22 24 27 28 31 32 34
35 36
37 39 40 48 49 42 84 86 85 51 87 41 44 43 45 46 88 89 50 90
83
26 15 16 38
47
9804/1103
20 - 15 - 04/11
3640U - C/10-11.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 04/12
506C, 508C Powershift with 6 Transmission Relays Circuit Diagrams - Electrical (contd) Component Key
To m/c no. 585396
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on page 20-15-04/11. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 Battery Starter Motor Starter Solenoid Starter Switch Thermostart Fuel Shut-off Solenoid Transmission Dump Relay Transmission Dump Switch Parking Brake Warning Relay Parking Brake Switch Drive Shaft Relay Layshaft Solenoid Forward Relay Reverse Relay Forward/Reverse Selector Switch Ratio Selector Switch Forward High/Low Relay Neutral Start Relay Reverse High/Low Relay Forward High Solenoid Forward Low Solenoid Reverse High Solenoid Reverse Low Solenoid Heater Motor Heater Resistor Heater Switch Horn Front Wiper Motor Horn Push Wash/Wipe Switch Washer Pump Face Fan Air Filter Switch Engine Oil Pressure Switch Transmission Oil TemperatureSwitch Transmission Oil Pressure Switch Water Temperature Switch Warning Buzzer Hourmeter Alternator Tachometer Fuel Gauge Fuel Gauge Sender Water Temperature Gauge Water Temperature Gauge Sender Reverse Alarm Working Light Switch Auxiliary Earth Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch Lamps 80 Parking Brake Warning 81 Air Filter Blocked Warning 82 Engine Oil Pressure Warning 83 Transmission Oil Temperature Warning 84 Transmission Oil Pressure Warning 85 Water Temperature Warning 86 Alternator Warning 87 Instrument Panel Illumination 88 Cab Working Light 89 Interior Light and Switch 90 Beacon Fuses Fuses are numbered as shown on the fuse box in the cab.
9804/1103
20 - 15 - 04/12
3640U - C/10-12.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 04/13
506C, 508C Powershift with 7 Transmission Relays Circuit Diagram - Electrical Component Key
To m/c no. 585396
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on page 20-15-04/14. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 Battery Starter Motor Starter Solenoid Starter Switch Thermostart Fuel Shut-off Solenoid Transmission Dump Relay Transmission Dump Switch Parking Brake Warning Relay Parking Brake Switch Drive Interlock Relay Drive Shaft Relay Layshaft Solenoid Mainshaft Solenoid Forward Relay Reverse Relay Forward/Reverse Selector Switch Ratio Selector Switch Forward High/Low Relay Neutral Start Relay Reverse High/Low Relay Forward High Solenoid Forward Low Solenoid Reverse High Solenoid Reverse Low Solenoid Heater Motor Heater Resistor Heater Switch Horn Front Wiper Motor Horn Push Wash/Wipe Switch Washer Pump Face Fan Air Filter Switch Engine Oil Pressure Switch Transmission Oil TemperatureSwitch Transmission Oil Pressure Switch Water Temperature Switch Warning Buzzer Hourmeter Alternator Tachometer Fuel Gauge Fuel Gauge Sender Water Temperature Gauge Water Temperature Gauge Sender Reverse Alarm Working Light Switch Auxiliary Earth Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch Lamps 80 Parking Brake Warning 81 Air Filter Blocked Warning 82 Engine Oil Pressure Warning 83 Transmission Oil Temperature Warning 84 Transmission Oil Pressure Warning 85 Water Temperature Warning 86 Alternator Warning 87 Instrument Panel Illumination 88 Cab Working Light 89 Interior Light and Switch 90 Beacon Fuses Fuses are numbered as shown on the fuse box in the cab.
9804/1103
20 - 15 - 04/13
3640U - C/10-13.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 04/14
506C, 508C Powershift with 7 Transmission Relays Circuit Diagram - Electrical (contd)
To m/c no. 585396
8 6 2
10
11 13 14 19 22 23 25 15 16 20 27 24 26
29 33 34 30
35 36
37 38
39 41 42 45 47
48 88 50 44 46 89 51 52
90
12
80 81
82 83
84 85
86
43
3 31 32 1 7 21 87 53
28 17 18 40
49
9804/1103
20 - 15 - 04/14
3640U - C/10-14.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 04/15
506C, 508C Powershift Circuit Diagrams - Electrical
From m/c no. 585397
10 6 2 8
11 13 14 19 22 23 25 15 20 16 27 24 26
29 33 30 34
35 36
37 38
39 41 42 50 44 46 51 45 47 48 88 89 52 90
12
80 81
82 83
84 85
86
43
3 31 1 7 21 32 28 40 87 49 53
17
18
9804/1103
20 - 15 - 04/15
3640U - C/10-15.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 04/16
506C, 508C Powershift Circuit Diagrams - Electrical (contd)
From m/c no. 585397
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical circuit is shown on page 20-15-04/15. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 Battery Starter Motor Starter Solenoid Starter Switch Thermostart Fuel Shut-off Solenoid Transmission Dump Relay Transmission Dump Switch Parking Brake Warning Relay Parking Brake Switch Drive Interlock Relay Drive Shaft Relay Layshaft Solenoid Mainshaft Solenoid Forward Relay Reverse Relay Forward/Reverse Selector Switch Ratio Selector Switch Forward High/Low Relay Neutral Start Relay Reverse High/Low Relay Forward High Solenoid Forward Low Solenoid Reverse High Solenoid Reverse Low Solenoid Heater Motor Heater Resistor Heater Switch Horn Front Wiper Motor Horn Push Wash/Wipe Switch Washer Pump Face Fan Air Filter Switch Engine Oil Pressure Switch Transmission Oil TemperatureSwitch Transmission Oil Pressure Switch Water Temperature Switch Warning Buzzer Hourmeter Alternator Tachometer Fuel Gauge Fuel Gauge Sender Water Temperature Gauge Water Temperature Gauge Sender Reverse Alarm Working Light Switch Auxiliary Earth Roof Wiper Motor and Switch Rear Wiper Motor and Switch Beacon Switch Lamps 80 Parking Brake Warning 81 Air Filter Blocked Warning 82 Engine Oil Pressure Warning 83 Transmission Oil Temperature Warning 84 Transmission Oil Pressure Warning 85 Water Temperature Warning 86 Alternator Warning 87 Instrument Panel Illumination 88 Cab Working Light 89 Interior Light and Switch 90 Beacon Fuses Fuses are numbered as shown on the fuse box in the cab.
9804/1103
20 - 15 - 04/16
3640U - C/10-16.1
Issue 1
CONTENTS
Loadalls
20 - 15 - 05/1
* 533-105
Machines Circuit Diagrams - Electrical

Key 1 2 3 4 5 5A 6 7 8 9 10 11 11A 12 12A 12B 13 13A 14 15 16 17 17A 18 19 19A 20 21 22 22A 23 24 25 26 27 28 29 30 31 32 33 34 35 Battery Battery isolator Starter motor Starter solenoid Ignition switch Fuse link 2 Starting aid Neutral start relay Ignition feed relay 1 Ignition feed relay 2 E.S.O.S. Rear work lamp swich Rear work lamp Front work lamp switch Front work lamps Auxiliary power connector 2/4WD brake relay Brake lamps Brake switch 2/4WD switch 2/4WD solenoid Reverse relay Reverse lamp Reverse alarm Park brake relay Park brake switch Heated seat Radio/cassette Digital clock Fuse link 1 Transducer - load moment indicator (LMI) Instrument panel Warning buzzer Alternator Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge Water temperature gauge LH stabiliser lamp switch RH stabiliser lamp switch
Optional fan reversing circuit shown at X 131 Fan reverse switch 132 Fan reverse solenoid 133 Fan reverse horn
Note: all the items listed here are not necessarily fitted to all machines in the range.
9804/1103
20 - 15 - 05/1
3630 - C/33-2.2
Issue 1*
CONTENTS
Loadalls
20 - 15 - 05/2
533-105 Machine Circuit Diagrams - Electrical
10 2 6
11A 12A 12B 13A 16
17A
18
34 32 27 28 29 30 31 33
35
1828
23 19A 20 21
See Sheet 4
35
3 34 7 1
410
11
12 13
15 17 19
26 24 25 14
410
601JR
133
1840a 1840
5 5A 22A
See Note 2 540-170 (5508 N.Am) Only
131
171
417050
160-02290-1
9804/1103
20 - 15 - 05/2
601JM
601JN
22
132
3660 - C/33-1.2
Issue 1*
CONTENTS
Loadalls
20 - 15 - 05/3
* 533-105

Key 36 36A 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 Sidelight reelay Fuse link 1 RH side lights LH side lights Main light switch RH/LH dip beam RH/LH main beam Rear fog light switch Rear fog lamp Column switch - RH LH indicator lamps RH indicator lamps Front washer pump Front wiper motor Rear wiper motor Rear/roof washer pump Roof wiper motor Rear wiper switch Roof wiper switch Hazard warning switch Hazard warning relay Interior light/switch Beacon switch Beacon lamp Face level fan Air conditioning relay Air conditioning - compressor motor Air conditioning - freeze switch Air conditioning - receiver drier Air conditioning switch Heater/heater fan switch Heater
9804/1103
20 - 15 - 05/3
3630 - C/33-3.2
Issue 1*
CONTENTS
Loadalls
20 - 15 - 05/4
37
38
40
41
45
46
43
47
48
49 50
51
55 56 58
59 61 62
63 66
36
39 42
44 52 53
54
57
60
64 65
36A
160-02290-2
9804/1103
20 - 15 - 05/4
3660 - C/33-4.1
Issue 1*
CONTENTS
Loadalls
20 - 15 - 05/5
* 533-105

Key 67 68 69 70 71 71A 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93
Column switch - LH Horn Reverse Hi-Lo relay Reverse Lo solenoid Reverse Hi solenoid Diode pack Reverse relay Forward relay Forward Hi-Lo relay Forward Hi solenoid Forward Lo solenoid Drive interlock relay Drive shaft relay Layshaft solenoid Mainshaft solenoid Transmission dump relay Stabiliser isloation switch Stabiliser isolation relay Stabiliser isolation solenoid Stabiliser isolation switch Sway isolation switch Sway isolation relay Sway switch Sway diverter solenoid Sway solenoid Sway solenoid Transmission dump push button Steer mode control unit A Four wheel/crab steer relay B Two wheel steer relay C Crab steer relay D Four wheel steer relay 94 Steer mode selector switch X Two wheel steer Y Crab steer Z Four wheel steer 95 2WS solenoid 96 4WS solenoid 97 AWS solenoid 98 Crab steer solenoid 99 Proximity switch - front axle 100 Proximity switch - rear axle
9804/1103
20 - 15 - 05/5
3630 - C/33-6.1
Issue 1*
CONTENTS
Loadalls
20 - 15 - 05/6
95 79 68 70 71 75 76 80 84 89 90 91 96 97 98
67
71A 88
A
94 69 72 73 74 77 78 81 82 83 85 86 87 92
B C Z X Y
99
100
D
93
160-02290-3
9804/1103
20 - 15 - 05/6
3660 - C/33-5.1
Issue 1*
CONTENTS
Loadalls
527-58/67 530-95
20 - 20 - 02/1
* 525-58/67,
From m/c no. 567362 to 574295
Circuit Diagram - Hydraulics

35
12 34A 34B 34 13A 42 13
12A
11 36 15A 15 43 V P C 15B 10 10
10A 33 P V 14
10A
29 C
2P
2M
2K
2H
2Y
P2 31
S2 P3
2X 2 2A
30
S3
P1 F
S1
2Q
2N
2L
2J
P4
2G
2F 2W
2E 2V
2D 2U
2C 2T
2B 2S 2R
2X
1B 1A
32
40
F1 T
41
41 a b 41A b 2CC 2S
A166543
A166543
9804/1103
20 - 20 - 02/1
Issue 3*
CONTENTS
Loadalls
20 - 20 - 02/2
525-58/67, 527-58/67, 530-95 Circuit Diagram - Hydraulics

Note 1: Includes machines up to 567217 with TI 5/033 Revised Hydraulic Circuit incorporated. Component Key F P1 P2 P3 P4 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2CC 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 2Q 2Y 2R 2S 2T 2U 2V 2W 2X 10 10A 11 12 12A 13 13A 14 15 15A 15B 29 Filter Main pump Steering pump Cooling fan pump Supplementary pump (Farm Special Plus Only) Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Extension spool (Half motor spool type, 530-95 Only) Auxiliary spool see note 2 Tilt spool Auxiliary spool Sway spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) see note 3 Auxiliary relief valve (A.R.V) see note 3 Auxiliary relief valve (A.R.V) (530-95 Only) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test point Lift rams Lift ram check valves Displacement ram Extension ram Extension ram check valve Tilt ram Tilt ram check valve Non-return valve (525-58 Only) Sway ram (530-95) Sway ram check valve Optional Sway isolation valve Steering Anti-cavitation valve 30 31 32 33 34 34A 34B 35 36 40 41 41A 42 43
From m/c no. 567362 to 574295
Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steering mode valve Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan pressure test point Cooling fan motor (inset is for later machines) Cooling fan motor relief valve Auxiliary attachment ram Displacement ram isolation valve (530-95 Only)
Note 2: The circuit illustrated includes most of the services likely to be found on these machines. The exact order of the spools in the valve block may vary from machine to machine. Note 3: On later machines ARV's 2P and 2Q are not fitted.
9804/1103
20 - 20 - 02/2
Issue 2
CONTENTS
Loadalls
20 - 20 - 02/2A
527-58/67, 535-67 Circuit Diagram - Hydraulics
From m/c no. 574296
35
12 T 34A P 34B 42 13 13A
34C B A
34D
36 11 15B 15A 15
12A
10
10
33
33B
33B
10A 41 29 P
10A
C 33A
14
2M 16A 2X 33C P T LS P EF P2 2G P2B S1 P4 2W 2V 2F 2E P1 2X 2 16
2K
2H
2A
2N 2L 2J
2D 2U
2C
2B
1B 2T 2S 2R 1A
P2A
F S2 C F1
A230120
9804/1103
20 - 20 - 02/2A
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/2B
527-58/67, 535-67 Circuit Diagram - Hydraulics

Component Key C F F1 P1 P2 P4 S1 S2 T 1A 1B 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2R 2S 2T 2U 2V 2W 2X 10 10A 11 12 12A 13 13A 14 15 15A 15B 16 16A 29 Tank cap Filter Filter by-pass Main pump Steering/Cooling fan pump Supplementary pump (if fitted) Main pump suction line Steering/Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary 1 spool Tilt spool Auxiliary 2 spool Sway spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test points Lift rams Lift ram check valves Displacement ram Extension ram Extension ram check valve Tilt ram Tilt ram check valve Non-return valve (527-58) Sway ram Sway ram check valve Sway isolation valve Oil cooler (535-67 turbo machines only) Check valve (535-67 turbo machines only) Steering anti-cavitation valve 33 33A 33B 33C 34A 34B 35 36 41 42 Steering unit Steer valve Shock valves (option) Main relief valve Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan motor Auxiliary attachment ram
From m/c no. 574296
Note: The circuit illustrated includes most of the services likely to be found on these machines. The exact order of the spools in the valve block may vary from machine to machine.
9804/1103
20 - 20 - 02/2B
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/3
530-120 Circuit Diagram - Hydraulics

23A 35 18 13 21 T 34A 34 34C B A 34D 24A 11 16B 25 16C 16A 16D 16 10 V 36 22 24
42
From m/c no. 567362
19
23
13A
17 20
P 34B
10
C P
15B L 33 R 15 33B 33B 26 15A 10A 10A
14 29 33A C V
P 2X 33C P T 31
30 2P 2K 2H
P1 2 P2 2A 2Q
2L 2J
1B
32
1A 2G 40 P3
S3 S2 2Y 2Z 2E 2D
2C 2SS
2B
2CC 2S
S1
2W
2V
2U
2T
2S
2R
41 F 41A
A142773
9804/1103
20 - 20 - 02/3
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/4

Component Key F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2D 2E 2G 2Y 2Z 2H 2J 2K 2L 2P 2Q 2R 2S 2T 2U 2V 2W 2X 10 10A 11 13 13A 14 15 15A 15B 16 17 18 19 20 Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary spool Tilt spool Sway spool Stabiliser Spool Stabiliser Spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test point Lift rams Lift ram check valves Displacement ram Tilt ram Tilt ram check valve Non-return valve (530-110 Only) Sway ram (Optional on 530-110) Sway ram check valve Sway isolation valve Regenerative valve Inner extension ram check valve Inner extension ram Outer extension ram Regenerative circuit bleed point 21 22 23 23A 24 24A 25 26 29 30 31 32 33 34 34A 34B 35 36 40 41 41A 42
From m/c no. 567362
Right stabiliser ram Left stabiliser ram Right stabiliser ram check valve Right stabiliser weight on switch Left stabiliser ram check valve Left stabiliser weight on switch Right stabiliser ram isolation valve Left stabiliser ram isolation valve Steering Anti-cavitation valve Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steering mode valve (Machines without IP67 electrics) Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan pressure test point Cooling fan motor Cooling fan motor relief valve Displacement ram isolation valve
Note: The circuit illustrated includes most of the services likely to be found on these machines. The exact order of the spools in the valve block may vary from machine to machine. Note: 2CC is extension spool half motor type.
9804/1103
20 - 20 - 02/4
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/5
From m/c no. 567362
23A 35 18 13 21 T 34A 34 34C B A 34D 24A 11 16B 25 16C 16A 16D 16 10 V 36 22 24

42
19
23
13A
17 20
P 34B
10
C P
15B L 33 R 15 33B 33B 26 15A 10A 10A
14 29 33A C V
P 2X 33C P T 31
30 2P 2K 2H
P1 2 P2 2A F 2Q
2L 2J
1B
32
1A 2G 40 P3
S3 S2 2Y 2Z 2E 2D
2C 2SS
2B
2CC 2S
S1
2W
2V
2U
2T
2S
2R
41
41A
A166551
9804/1103
20 - 20 - 02/5
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/6

Component Key F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2D 2E 2G 2Y 2Z 2H 2J 2K 2L 2P 2Q 2R 2S 2T 2U 2V 2W 2X 10 10A 11 13 13A 14 15 15A 15B 16 17 18 19 20 Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary spool Tilt spool Sway spool Stabiliser Spool Stabiliser Spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test point Lift rams Lift ram check valves Displacement ram Tilt ram Tilt ram check valve Non-return valve (530-110 Only) Sway ram Sway ram check valve Sway isolation valve Regenerative valve Inner extension ram check valve Inner extension ram Outer extension ram Regenerative circuit bleed point 21 22 23 23A 24 24A 25 26 29 30 31 32 33 34 34A 34B 35 36 40 41 41A
From m/c no. 567362
Right stabiliser ram Left stabiliser ram Right stabiliser ram check valve Right stabiliser weight on switch Left stabiliser ram check valve Left stabiliser weight on switch Right stabiliser ram isolation valve Left stabiliser ram isolation valve Steering Anti-cavitation valve Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steering mode valve (Machines without IP67 electrics) Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan pressure test point Cooling fan motor Cooling fan motor relief valve
9804/1103
20 - 20 - 02/6
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/7
505-19 & 505-22 Circuit Diagram - Hydraulics

35
From m/c no. 567362 to 574295
12 34A 34B 34 13A 42 13
12A
11 36 15A 15
43
15B 10 V P C 10
10A 33 P V 14
10A
29 C
2P
2M
2K
2H
2Y
P2 31
S2 P3
2X 2 2A
30
S3
P1 F
S1
2Q
2N
2L
2J
P4
2G
2F 2W
2E 2V
2D 2U
2C
2B
2X 2R 1A
1B
2T
2S
32
40
F1 T
41
41 a b 41A b 2CC
A166543
2S
A166543
9804/1103
20 - 20 - 02/7
Issue 2
CONTENTS
Loadalls
20 - 20 - 02/8
505-19, 505-22 Circuit Diagram - Hydraulics

Component Key F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 2Q 2R 2S 2T 2U 2V 2W 2X 10 10A 11 12 12A 13 13A 14 15 15A 29 Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary spool Tilt spool Auxiliary spool Sway spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test point Lift rams Lift ram check valves Displacement ram Extension ram Extension ram check valve Tilt ram Tilt ram check valve Non-return valve (505-19 Only) Sway ram (Optional) Sway ram check valve Steering anti-cavitation valve (if fitted) 30 31 32 33 34 34A 34B 35 36 40 41 41A 42
From m/c no. 567362 to 574295
Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steering mode valve (Machines without IP67 electrics) Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan pressure test point Cooling fan motor Cooling fan motor relief valve Auxiliary attachment ram
Note: The circuit illustrated includes most of the services likely to be found on these machines. The exact order of the spools in the valve block may vary from machine to machine. The test point may be at the valve block or the hydraulic pump.
9804/1103
20 - 20 - 02/8
Issue 2
CONTENTS
Loadalls
20 - 20 - 02/8A

35
From m/c no.574296
12 T 34A P 34B 42 13 13A
34C B A
34D
36 11 15B 15A 15
12A
10
10
33
33B
33B
10A 41 29 P
10A
C 33A
14
2M 16A 2X 33C P T LS P EF P2 2G P2B S1 P4 2W 2V 2F 2E P1 2X 2 16
2K
2H
2A
2N 2L 2J
2D 2U
2C
2B
1B 2T 2S 2R 1A
P2A
F S2 C F1
A230120
9804/1103
20 - 20 - 02/8A
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/8B

Component Key C F F1 P1 P2 S1 S2 T 1A 1B 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2R 2S 2T 2U 2V 2W 2X 10 10A 11 12 12A 13 13A 14 15 15A 15B 29 Tank cap Filter Filter by-pass Main pump Steering pump/Cooling fan pump Main pump suction line Steering/Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary 1 spool Tilt spool Auxiliary 2 spool Sway spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test points Lift rams Lift ram check valves Displacement ram Extension ram Extension ram check valve Tilt ram Tilt ram check valve Non-return valve (505-19) Sway ram Sway ram check valve Sway isolation valve Steering anti-cavitation valve (if fitted) 33 33A 33B 33C 34A 34B 35 36 41 42
From m/c no. 574296
Steering unit Steering valve Shock valves (option) Main relief valve Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan motor Auxiliary attachment ram
9804/1103
20 - 20 - 02/8B
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/9

23A 35 18 13 21 T 34A 34 34C B A 34D 24A 11 16B 25 16C 16A 16D 16 10 V 36 22 24 42 P C P 34B 23 13A 17 20
From m/c no.567362
19
10
15B L 33 R 15 33B 33B 26 15A 10A 10A
14 29 33A C V
P 2X 33C P T 31
30
2P P1 2 P2
2K
2H
1B 2A
32
2Q
2L
2J
1A 2G 40 P3 S3 S2 S1 2Y 2W 2Z 2V 2E 2U
2D
2C 2SS
2B
2CC 2S
2T
2S
2R
41
41A
A166552
9804/1103
20 - 20 - 02/9
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/10

Component Key F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2D 2E 2Y 2Z 2H 2J 2K 2L 2R 2S 2T 2U 2V 2W 2X 10 10A 11 13 13A 14 16 17 18 19 20 21 22 23 23A 24 24A 25 26 Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary spool Tilt spool Stabilizer spool Stabilizer spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test point Lift rams Lift ram check valves Displacement ram Tilt ram Tilt ram check valve Non-return valve Regenerative valve Inner extension ram check valve Inner extension ram Outer extension ram Regenerative circuit bleed point Right stabilizer ram Left stabilizer ram Right stabilizer ram check valve Weight on switch Left stabilizer ram check valve Weight on switch Right stabilizer ram isolation valve Left stabilizer ram isolation valve 29 30 31 32 33 34 34A 34B 35 36 40 41 41A 42
From m/c no. 567362
Steering Anti-cavitation valve Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steering mode valve (Machines without IP67 electrics) Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan pressure test point Cooling fan motor Cooling fan motor relief valve Displacement ram isolation valve
9804/1103
20 - 20 - 02/10
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/11
From m/c no.567362
18 13 17 20 13A 34A 34B 34 15 15A 16B 16C
19
35
16A 16D 16
11 V 36
42
10 C P
10
10A
10A
33
29 14
2P
31 30
2M
2K
2H
P2 32
S2 P3
2X
2 2A
2Q 2N 2L 2J
P1 S1 2G 2F 2W 2E 2V 2D 2U 2C 2T
2B
40
F
S3
1B 2R
2CC 2S
2S
1A
41 41A
A142782
9804/1103
20 - 20 - 02/11
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/12

Component Key F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 2Q 2R 2S 2T 2U 2V 2W 2X 10 10A 11 13 13A 14 15 15A 16 17 18 19 20 Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary spool Tilt spool Auxiliary spool Sway spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test point Lift rams Lift ram check valves Displacement ram Tilt ram Tilt ram check valve Non-return valve Sway ram Sway ram check valve Regenerative valve Inner extension ram check valve Inner extension ram Outer extension ram Regenerative circuit bleed point 29 30 31 32 33 34 34A 34B 35 36 40 41 41A 42
From m/c no. 567362
Steering anti-cavitation valve Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steering mode valve (Machines without IP67 electrics) Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan pressure test point Cooling fan motor Cooling fan motor relief valve Displacement ram isolation valve
9804/1103
20 - 20 - 02/12
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/13

23A
From m/c no.567362
18 35 21 23 13 17 20 13A 34A 34B 34 24A 25 11
19
16
10 V 36 22 24
42
10
C P
15A 15 10A 10A
26 33 29 14
31
30
P2 32
S2
2X
P3 S1 40 F
2P
2K
2H
P1
2 2A
1B
S3
2Q
2L
2J
1A T 41 2G
2Y 2Z 2E 2D
2C
2B
2W
2V
2U
2T
2S
2R
41A
A154531
9804/1103
20 - 20 - 02/13
Issue 2
CONTENTS
Loadalls
20 - 20 - 02/14

Component Key F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2D 2E 2G 2Y 2Z 2H 2J 2K 2L 2P 2Q 2R 2S 2T 2U 2V 2W 2X 11 13 13A 14 16 17 18 19 20 21 22 23 23A 24 24A 25 26 Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary spool Tilt spool Sway spool Stabilizer spool Stabilizer spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Load hold check valve (L.H.C.V) Pressure test point Displacement ram Tilt ram Tilt ram check valve Non-return valve Regenerative valve Inner extension ram check valve Inner extension ram Outer extension ram Regenerative circuit bleed point Right stabilizer ram Left stabilizer ram Right stabilizer ram check valve Weight on switch Left stabilizer ram check valve Weight on switch Right stabilizer ram isolation valve Left stabilizer ram isolation valve 29 30 31 32 33 34 34A 34B 35 36 40 41 41A 42
From m/c no. 567362
Steering anti-cavitation valve Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steering mode valve (Machines without IP67 electrics) Steering mode valve Steering mode valve Front axle steering rams Rear axle steering rams Cooling fan pressure test point Cooling fan motor Cooling fan motor relief valve Displacement ram isolation valve
9804/1103
20 - 20 - 02/14
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/15
* 520-55
RS and 520-55 4 Wheel Steer
From m/c no. 277001 to 278610
Circuit Diagram-Hydraulics
5 7 7A 4 5B 8
5C
7B
8A 8B
5A a 3 a 3B 3B 6 b 9 b
9A 2 3A 9B
2K 1A 3C
2B
2K
2C
2K
2D
2E
14
12 2H 2A 2F
13
LS
EF
P1
2J P1C P1B P1A 1C A B A B
2G
15
A 17
B 18
16
C S1
1B
T 10 F 11
9804/1103
20 - 20- 02/15
3610 - E/2-2.5
Issue 4*
CONTENTS
Loadalls
20 - 20 - 02/16
* 520-55
RS and 520-55 4 Wheel Steer
From m/c no. 277001 to 278610
Circuit Diagram Component Key

C F P1 P1A P1B P1C S1 T 1A 1B 1C 2 2A 2B * 2C 2D * 2E 2F 2G 2H 2J 2K 3 3A 3B 3C 4 5 5A 5B 5C 6 7 7A 7B 8 8A 8B 9 9A 9B 10 11 12 13 14 15 16 * 17 * 18 Cap Filter Main pump assembly Pump Pressure test point Priority valve Main pump suction line Tank Neutral circuit feed line Neutral circuit return line Steer circuit return line Valve block Main relief valve (M.R.V.) Auxiliary spool Lift spool (see Note) Tilt spool Extension spool (see Note) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valves (L.H.C.Vs) Steer unit assembly Steer valve Shock valves (option) Main relief valve RS machine rear axle steer track rod AWS machine steer circuit Front axle steer track rod Rear axle steer track rod Steer alignment valve Auxiliary 1 circuit (standard all machines) Q Fit Carriage pin locking (option) Q Fit Carriage pin locking ram Q Fit Carriage manual diverter valve Auxiliary 2 circuit (option) Diverter valve Auxiliary 2 ram Hydraulic hitch (option) Diverter valve Hitch ram Lift ram check valve Lift ram Displacement ram Tilt ram Tilt ram check valve Extension ram check valve Extension ram Port restrictor Port restrictor
Note: On early machines spools 2C and 2E are half motor type.
9804/1103
20 - 20 - 02/16
3610 - E/2-1.5
Issue 4*
CONTENTS
Loadalls
20 - 20 - 02/17
* 520-55 * 526-55,
4 Wheel Steer From m/c 278611 526, 526S From m/c no. 277001 to 280299
*
5A 19
5D 5C A P B
5D
7 7A 18B 18A 18C 18A 8
18 7B 8A 8B 17C
5D L
5B 3 R
5D
17B 17
3B
3B 17A
9 6
9A 1A 2 3A 9B
2K
2B
2K
2C
2K
2D
2E
14
3C 12 2H 2A 2F 13
LS P
EF
P1
2J P1C P1B P1A 20 C S1 1B 1C A B A B
2G
15
A 22
B 23
16
T 10 F 11
9804/1103
20 - 20 - 02/17
3610 - E/2-4.3
Issue 3*
CONTENTS
Loadalls
20 - 20 - 02/18
* *
520-55 Wheel Steer From m/c no. 278611 526-55, 526, 526S From m/c no. 277001 to 280299 Circuit Diagram - Hydraulics Component Key
C F P1 P1A P1B P1C S1 T 1A 1B 1C 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 3 3A 3B 3C 5A 5B 5C 5D 6 7 7A 7B 8 8A 8B 9 9A 9B 10 11 12 13 14 15 16 17 17A 17B 17C 18 18A 18B 18C 19 20 21 22 23 Cap Filter Main pump assembly Pump Pressure test point Priority valve Main pump suction line Tank Neutral circuit feed line Neutral circuit return line Steer circuit return line Valve block Main relief valve (M.R.V.) Auxiliary spool Lift spool Tilt spool Extension spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valves (L.H.C.V's) Steer unit assembly Steer valve Shock valves (option) Main relief valve Front axle steer track rod Rear axle steer track rod Steer mode selector valve Brake packs Auxiliary 1 circuit (standard all machines) Q Fit Carriage pin locking (option) Q Fit Carriage pin locking ram Q Fit Carriage manual diverter valve Auxiliary 2 circuit (option) Diverter valve Auxiliary 2 ram Hydraulic hitch (option) Diverter valve Hitch ram Lift ram check valve Lift ram Displacement ram Tilt ram Tilt ram check valve Extension ram check valve Extension ram Brake circuit charge valve Main spool Relief valve Compensating valve (not used) Accumulator manifold Accumulator spheres Pressure/vent connector Brake pressure switch Brake valve Liquid/liquid cooler (not fitted) not fitted Port restrictor Port restrictor
* *
9804/1103
20 - 20 - 02/16
3610 - E/2-3.4
Issue 3*
CONTENTS
Loadalls
20 - 20 - 02/19
537-120, 537-130 Circuit Diagram - Hydraulics
From m/c no. 572900
35
T 34A
P 34B
23A
34C B A
34D 13 21 23
13A
18
19
17 20
36 25 24A L 33 R 11 16B 16C 16A 16D 16
10 33B 33B
12 V P C
10
22
24
15B 15A 15 33A 26 10A 10A
29 C V
33C
T
30
P 31
P2 32
S2
2X
2K
2L
P1 S1 40 P3
S3
2 2A F
2J 2M
1B
41
C
41A 2F T 2U 2T 2S 2R 2Q 2P 2N
2H 2G 2E 2D
1A 2C
2B
A229130
9804/1103
20 - 20 - 02/19
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/20
537-120, 537-130 Circuit Diagram - Hydraulics Component Key

C F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 2Q 2R 2S 2T 2U 2X 10 10A 11 12 13 13A 15 15A 15B 16 16A 16B 16C 16D 17 18 19 20 Tank cap Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Extension spool Auxiliary spool Tilt spool see note 1 Sway spool Stabiliser Spool Stabiliser Spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Load hold check valves (L.H.C.V.) Load hold check valves (L.H.C.V.) Load hold check valves (L.H.C.V.) Load hold check valves (L.H.C.V.) Load hold check valves (L.H.C.V.) Load hold check valves (L.H.C.V.) Load hold check valves (L.H.C.V.) Pressure test point Lift rams Lift ram check valves Displacement ram Displacement ram isolation valve Tilt ram Tilt ram check valve Sway ram Sway ram check valve (if fitted) Sway isolation valve Regenerative valve Hose burst check valve Relief valve Check valve Non return valve Inner extension ram check valve Inner extension ram Outer extension ram Regenerative circuit bleed point 21 22 23 23A 24 24A 25 26 29 30 31 32 33 33A 33B 33C 34A 34B 34C 34D 35 36 40 41 41A
From m/c no. 572900
Right stabiliser ram Left stabiliser ram Right stabiliser ram check valve Right stabiliser weight on switch Left stabiliser ram check valve Left stabiliser weight on switch Right stabiliser ram isolation valve Left stabiliser ram isolation valve Steering Anti-cavitation valve Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steer valve Shock valves (option) Main relief valve 2 Wheel steer solenoid 4 Wheel and crab steer solenoid 4 Wheel steer solenoid Crab steer solenoid Front axle steering rams Rear axle steering rams Cooling fan pressure test point Cooling fan motor Cooling fan motor relief valve
Note 1: The circuit illustrated includes most of the services likely to be found on these machines. The exact order of the spools in the valve block may vary from machine to machine.
9804/1103
20 - 20 - 02/20
Issue 1
CONTENTS
Loadalls
525-50, 525-52
20 - 20 - 02/21
* 520-50,
From m/c no. 754000
7 10 11 7A 21 20 22
14 13 24 F S 12 S1 15 24A 16 17A 1C 23 23 2 1B 1A 2F 2G 2H 2J 2A 3A A2 X 2E 2D 2K 2C 2K 2B 2K 2K 25 A 5C 5A 5D 5B 5D 3B 3B B 18 19 18 A1 T 3 3C P LS 17E 17C 17B 17D T LS P1 17 X C T
EF P F
5D
5D A234942
9804/1103
20 - 20 - 02/21
3620 - E/2-2.3
Issue 3*
CONTENTS
Loadalls
20 - 20 - 02/22
520-50, 525-50, 525-52 Circuit Diagram - Hydraulics Component Key Component Key
C F LS P1 S S1 T X 1A 1B 1C 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 3 3A 3B 3C 5A 5B 5C 5D 7 7A 10 11 12 13 14 15 16 17 17A 17B 17C 17D 17E 18 19 20 21 22 23 * 24 * 25 * 26 Cap Filter Load Sensing line Main pump Suction strainer Main pump suction line Tank Pressure test point Neutral circuit feed line Neutral circuit return line Steer circuit return line Valve block Main relief valve (M.R.V.) Auxiliary spool Lift spool Tilt spool Extension spool Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Load hold check valves (L.H.C.V's) Steer unit assembly Steer valve Shock valves (option) Relief valve Front steer ram Rear steer ram Steering alignment valve Brake packs Q Fit Carriage pin locking Q Fit Carriage manual diverter valve Lift ram check valve Lift ram Displacement ram Tilt ram Tilt ram check valve Extension ram check valve Extension ram Brake charge/priority valve Priority valve Distributor valve Pilot valve Relief valve Brake pressure switch Accumulator Brake valve Auxiliary 1 quick release couplings Electrical diverter valve (if fitted) Auxiliary 2 quick release couplings One-way restrictor Hydraulic Hitch (Option) Electrical Diverter Valve Trailer Brake Valve (Option)
From m/c no. 754000
9804/1103
20 - 20 - 02/22
3620 - E/2-1.2
Issue 3*
CONTENTS
Loadalls
20 - 20 - 02/23
520-55 RS and 520-55 4 Wheel Steer Circuit Diagram - Hydraulics Component Key
C F P1 P1A P1B P1C S1 T 1A 1B 1C 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 3 3A 3B 3C 4 5 5A 5B 5C 6 7 7A 7B 8 8A 8B 9 9A 9B 10 11 12 13 14 15 16 Cap Filter Main pump assembly Pump Pressure test point Priority valve Main pump suction line Tank Neutral circuit feed line Neutral circuit return line Steer circuit return line Valve block Main relief valve (M.R.V.) Auxiliary spool Lift spool, see note Tilt spool Extension spool, see note Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Load hold check valves (L.H.C.V's) Steer unit assembly Steer valve Shock valves (option) Main relief valve RS machine rear axle steer track rod AWS machine steer circuit Front axle steer track rod Rear axle steer track rod Steer alignment valve Auxiliary 1 circuit (standard all machines) Q Fit Carriage pin locking (option) Q Fit Carriage pin locking ram Q Fit Carriage manual diverter valve Auxiliary 2 circuit (option) Diverter valve Auxiliary 2 ram Hydraulic hitch (option) Diverter valve Hitch ram Lift ram check valve Lift ram Displacement ram Tilt ram Tilt ram check valve Extension ram check valve Extension ram
To m/c no. 278610
Note: On early machines spools 2C and 2E are half motor type.
9804/1103
20 - 20 - 02/23
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/24
520-55 RS and 520-55 4 Wheel Steer Circuit Diagram - Hydraulics (contd)

5 7 7A 4 5B 8
To m/c no. 278610
5C
7B
8A 8B
5A a 3 a 3B 3B 6 b 9 b
9A 2 3A 9B
2K 1A 3C
2B
2K
2C
2K
2D
2E
14
12 2H 2A 2F
13
LS
EF
P1
2J P1C P1B P1A 1C
2G
15
16 C S1
1B
T 10 F 11
A183561
9804/1103
20 - 20 - 02/24
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/25
520-55 4 Wheel Steer from Serial No. 278611 & 526-55, 526, 526S to Serial No. 280299 Circuit Diagram - Hydraulics Component Key
C F P1 P1A P1B P1C S1 T 1A 1B 1C 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 3 3A 3B 3C 5A 5B 5C 5D 6 7 7A 7B 8 8A 8B 9 9A 9B 10 11 12 13 14 15 16 17 17A 17B 17C 18 18A 18B 18C 19 20 21 Cap Filter Main pump assembly Pump Pressure test point Priority valve Main pump suction line Tank Neutral circuit feed line Neutral circuit return line Steer circuit return line Valve block Main relief valve (M.R.V.) Auxiliary spool Lift spool Tilt spool Extension spool Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Load hold check valves (L.H.C.V's) Steer unit assembly Steer valve Shock valves (option) Main relief valve Front axle steer track rod Rear axle steer track rod Steer mode selector valve Brake packs Auxiliary 1 circuit (standard all machines) Q Fit Carriage pin locking (option) Q Fit Carriage pin locking ram Q Fit Carriage manual diverter valve Auxiliary 2 circuit (option) Diverter valve Auxiliary 2 ram Hydraulic hitch (option) Diverter valve Hitch ram Lift ram check valve Lift ram Displacement ram Tilt ram Tilt ram check valve Extension ram check valve Extension ram Brake circuit charge valve Main spool Relief valve Compensating valve (not used) Accumulator manifold Accumulator spheres Pressure/vent connector Brake pressure switch Brake valve Liquid/liquid cooler (if fitted) Restrictor (526-55, 526 & 526S)
9804/1103
20 - 20 - 02/25
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/26
520-55 4 Wheel Steer from Serial No. 278611 & 526-55, 526, 526S to Serial No. 280299 Circuit Diagram - Hydraulics (contd)
5A 19
5D 5C A P B
5D
7 7A 18B 18A 18C 18A 8
18 7B 8A 8B 17C
5D L
5B 3 R
5D
17B 17
3B
3B 17A
9 6
9A 1A 2 3A 9B
2K
2B
2K
2C
2K
2D
2E
14
3C 12 2H 2A 2F 13
LS P
EF
P1
2J P1C P1B P1A 1C
2G
15
16 20 C S1 1B 21
T 10 F 11
A210540
9804/1103
20 - 20 - 02/26
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/27
526, 526S Machines with Dual Lever Control Circuit Diagram - Hydraulics Component Key
C F P1 P1A P1B P1C S1 1A 1B 1C 2 2A 2B 2C 2D 2E * 2F * 2G * 2H * 2J 2K *3 3A 3B 3C *4 * 4A * 4B 5A 5B 5C 6 *7 7A 7B * 7C * 7D *8 * 8A *9 * 9A * 9B * 9C * 9D * 10 11 12 13 * 14 * 15 16 19 19A * 19B 19C 19D 20 21 22 23 Cap Filter Main pump assembly Pump Pressure test point Priority valve Main pump suction line Return line to tank Steer circuit return line Trailer brake valve return line Valve block Main relief valve (MRV) Auxiliary spool Raise/lower spool Tilt spool Extend/retract spool Auxiliary relief valve (ARV) head side (Port A) Auxiliary relief valve (ARV) rod side (Port B) Auxiliary relief valve (ARV) (Port B) Auxiliary relief valve (ARV) (Port A) Load hold check valves (LHCVs) Steer unit assembly (with shock valves) Steer valve Main relief valve Shock valves (option) Steer unit assembly (without shock valves) Steer valve Main relief valve Front axle steer track rod Rear axle steer track rod Steer mode selector valve Auxiliary 1 circuit (standard all machines) Twin auxiliary option with hydraulic pin locking option Quickfit carriage locking pin ram Quickfit carriage manual diverter valve Solenoid diverter valve (boom mounted) Tool carrier locking pin ram Twin auxiliary option Solenoid diverter valve (boom mounted) Hydraulic pick-up hitch (option) Solenoid diverter valve (chassis mounted) Pick-up hitch cylinder Restrictor Quick release coupling Counter balance valve Lift ram Displacement ram Tilt ram Counter balance valve Counter balance valve Extension ram Trailer brake valve (option) Pilot valve Trailer brake valve Trailer brake coupling Brake circuit connection Liquid/liquid cooler (if fitted) Check valve Port restrictor (3.5 mm) Port restrictor (3.5 mm)
From m/c no. 280300
9804/1103
20 - 20 - 02/27
3610 - E/2-6.3
Issue 3*
CONTENTS
Loadalls
20 - 20 - 02/28
526, 526S Machines with Dual Lever Control Circuit Diagram - Hydraulics (contd) *
5A
P A B
To m/c no. 280300
2
B
23
Extend
15
16
2E 5C 5B 2D
T
Retract
12 2K
B
14
13
22
Crowd
2F
2G
Dump
3 L
3C
2K
B
21
Raise
10
11
2C
c d
Lower
6 3A 4A 2K
B
3B P
a
4B T
g a f g
2B
2H
2J
A P1 A D P2 C
7B
AUX1 B AUX2
7A
7D
Ls
f
2K 2A
c d
Ef
Ls
7C 19C P T
P1 D c d AUX2 P2 C AUX1 A B
P1B
P1C P1A
S
8A C S1
B R
19B
Y
P1 c D P2
AUX1 A B C
9D 9B
F
P
19A 19D 19
9C 9A
9804/1103
3610 - E/2-5.3
20 - 20 - 02/28
Issue 3*
CONTENTS
Loadalls
20 - 20 - 02/29
526, 526S Machines with Single Lever Control Option Circuit Diagrams - Hydraulics
The single lever control option provides servo operated boom extend/retract and auxiliary functions. The spools, 2F and 2G respectively, are solenoid operated from lever mounted switches which select the required function. The raise/lower spool 2D and tilt spool 2E are both mechanically operated with spring loading to the neutral (central) position. * Component C F P1 P1A P1B P1C S1 1A 1B 1C 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 3 3A 3B 3C 4 4A 4B 5A 5B 5C 6 7 7A 7B 7C 7D 8 8A 9 9A 9B 9C 9D 10 11 12 13
From m/c no. 280300
Key
14 15 16 19 19A 19B 19C 19D 21 22 23 24 Counterbalance valve Counterbalance valve Extension ram Trailer brake valve (option) Pilot valve Brake valve Trailer brake coupling Brake circuit connection Check valve Port restrictor (3.5mm) Port restrictor (3.5mm) Port restrictor (2.5mm)
Cap Filter Main pump assembly Pump Pressure test point Priority valve Main pump suction line Return line to tank Steer circuit return line Trailer brake valve return line Valve block Main relief valve (MRV) Pressure reducing valve (20 bar) Pressure maintaining valve (10 bar) Auxiliary spool Raise/lower spool Tilt spool Extend/retract spool Auxiliary relief valve (ARV) rod side (Port B) Auxiliary relief valve (ARV) head side (Port A) Auxiliary relief valve (ARV) (Port A) Auxiliary relief valve (ARV) (Port B) Load hold check valves LHCVs Accumulator Filter Steer unit assembly (with shock valves) Steer valve Main relief valve Shock valves (option) Steer unit assembly (without shock valves) Steer valve Main relief valve Front axle steer track rod Rear axle steer track rod Steer mode selector valve Auxiliary 1 circuit (standard all machines) Twin auxiliary option with hydraulic pin locking option Quickfit carriage locking pin ram Quickfit carriage manual diverter valve Solenoid diverter valve (boom mounted) Tool carrier locking pin ram Twin auxiliary option Solenoid diverter valve (boom mounted) Hydraulic pick-up hitch option Solenoid diverter valve (chassis mounted) Pickup hitch cylinder Restrictor Quick release coupling Counterbalance valve Lift ram Displacement ram Tilt ram
9804/1103
20 - 20 - 02/29
3610 - E/2-7.3
Issue 3*
CONTENTS
Loadalls
20 - 20 - 02/30
526, 526S Machines with Single Lever Control Option Circuit Diagram - Hydraulics (contd) *
5A
To m/c no. 280300
24
P B 5C A
15
16
2
A
T 5B 2M
2G B
12 22
14
13
b 2F 2H 2J
A B
3C
2M
21
A 2E 2M c 3A 4A 2D 2K 3B 2M 4B 2L A B B
10
11
6
d
7
P e Ls f T g 2P e f g 2N P 19C P1B P1C P1A S 1C 1A 1B P1 c P2 d 8A D C T 2B 2A 2C P1 c P2 d 7C A B C D
7B
7A
7D
P1
Ef
Ls
A B
S1 F
B P 19A N R 19B c P2 19D d P1
A D 9C C B
9D 9B
19
9A
9804/1103
3610 - E/2-8.3
20 - 20 - 02/30
Issue 3*
CONTENTS
Loadalls
20 - 20 - 02/31
528-70 from m/c no. 796000 528S from m/c no. 796102 Circuit Diagram - Hydraulics Component Key
C F F1 N1 N2 S S1 T 1 1A 1B 1C 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 3 3A 3B 3C 3D 3E 4 4A 4B 4C 5A 5B 5C 5D 6 7 8 8A 8B 8C 9 9A 10 10A 10B 10C 10D Pressure cap breather Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Main pump suction line Suction strainer Hydraulic tank Main pump assembly Pump Pressure test point Load sensing valve Valve block Main relief valve (MRV) Auxiliary spool Raise/lower spool Tilt spool Extend/retract spool Auxiliary relief valve (ARV) head side - Port A Auxiliary relief valve (ARV) rod side - Port B Auxiliary relief valve (ARV) - Port B Auxiliary relief valve (ARV) - Port A Load Hold Check Valve (LHCVs) Steer unit assembly (with shock valves) Steer valve Main relief valve Shock valves (option) Non-return valve Steer circuit return line Steer unit assembly (without shock valves) Steer valve Main relief valve Non-return valve Front axle steer track rod Rear axle steer track rod Steer mode selector valve (steer mode option only) AWS setting lever Single auxiliary connectors High flow auxiliary option Twin auxiliary option with hydraulic pin locking option Diverter valve - boom mounted Quick-fit carriage manual isolation valve Pin locking cylinder Twin auxiliary option Diverter valve - boom mounted Hydraulic pick up hitch option Diverter valve - chassis mounted Pickup hitch cylinder Restrictor Quick release coupling 11A 12 12A 12B 13 14 15 15A 15B 16 16A 16B 17 18 Counterbalance valve Tilt cylinder Counterbalance valve Port restrictor (3.5mm) Displacement cylinder Check valve Extension cylinder Counterbalance valve Port restrictor (3.5mm) Trailer brake valve (option) Trailer brake coupling Hydraulic hitch return line Hydraulic cooler: Liquid/liquid - 528-70 with high flow Aux option Hydraulic cooler: liquid/air blast - 528S
Note: Spools 2D and 2E are reversed on machines fitted with a placing control pattern.
11
Lift cylinder
9804/1103
20 - 20 - 02/31
3650 - E/2-1.2
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/32
528-70 From m/c no. 796000 528S From m/c no. 796102 Circuit Diagram - Hydraulics (contd)
5A
2 15B 15A
15
5B
5C 2E 5D 5B 13 2K 12B 12A 12
5A
2D 3 4 2K
2F
2G 14 11A 11
3C 2C 6 3A 4A 2K 7
3B 3D 4D
4B
2B 2K
2H
2J
8B
8C
1 16A
2A
8A
1B
3E 1C 1A 16B
9 17 N1 9A N2 T
B R
16
Y
10 18 10C 10D 10B
F S1
F1
10A
9804/1103
3650 - E/2-2.2
20 - 20 - 02/32
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/33
528S With Single Lever Controls (SLC) Circuit Diagram - Hydraulics
From m/c no. 796102
5A
2 15B 15A
15
5B
5C 2E 5D 5B 13 2K 12B 12A 12
5A
2D 3 4 2K
2F
2G 14 11A 11
3C 2C 6 3A 4A 2K 7
3B 3D 4D
4B
2B 2K
2H
2J
8B
8C
1 16A
2A
8A
1B
3E 1C 1A 16B
9 17 N1 9A N2 T
B R
16
Y
10 18 10C 10D 10B
F S1
F1
10A
9804/1103
20 - 20 - 02/33
3650 - E/2-3.1
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/34
528S With Single Lever Control (SLC) Circuit Diagram - Hydraulics (contd) Component Key
C F F1 N1 N1 S S1 T 1 1A 1B 1C 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 3 3A 3B 3C 3D 3E 4 4A 4B 4C 5A 5B 5C 5D 6 7 8 8A 8B 8C 9 9A 10 10A 10B 10C 10D Pressure Cap breather Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Main pump suction line Suction strainer Hydraulic tank Main pump assembly Pump Pressure test point Load sensing valve Valve block Main relief valve (MRV) Pressure reduction valve Accumulator Pressure maintaining valve Auxiliary spool Raise/lower spool Tilt spool Extend/retract spool Auxiliary relief valve (ARV) rod side - Port B Auxiliary relief valve (ARV) head side - Port A Auxiliary relief valve (ARV) - Port B Auxiliary relief valve (ARV) - Port A Load Hold Check-Valves (LHCVs) Steer unit assembly (with shock valves) Steer valve Main relief valve Shock valves (option) Non-return valve Steer circuit return line Steer unit assembly (without shock valves) Steer valve Main relief valve Non-return valve Front axle steer track rod Rear axle steer track rod Steer mode selector valve (steer mode option only) AWS setting lever Single auxiliary connectors High flow auxiliary option Twin auxiliary option with hydraulic pin locking option Diverter valve - boom mounted Quick-fit carriage manual isolation valve Pin locking cylinder twin auxiliary option Diverter valve - boom mounted Hydraulic pick up hitch option Diverter valve - chassis mounted Pick up hitch cylinder Restrictor Quick release coupling 11 11A 12 12A 12B 13 14 15 15A 15B 16 16A 16B 17 18
From m/c no. 796102
Lift cylinder Counterbalance valve Tilt cylinder Counterbalance valve Port restrictor (3.5mm) Displacement cylinder Check valve Extension cylinder Counterbalance valve Port restrictor (3.5mm) Trailer brake valve (option) Trailer brake coupling Hydraulic hitch return line Not fitted Hydraulic cooler: liquid/air blast
Note: Spools 2D and 2E are reversed on machines equipped with a placing control pattern.
9804/1103
20 - 20 - 02/34
3650 - E/2-4.1
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/35
530, 540 Agricultural Circuit Diagrams - Hydraulic Component Key

B F F1 F2 N1 N2 S T 1 1A 1B 1C 1D 1E 1F 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 3 3A 3B 3C 4 4A 5 8 8A 9 10 10A 11 11A 11B 11C 12 13 13A 13B 13C 13D 13E 14 14A 14B 14C 15 15A 15B 15D 15E Pressure cap breather (if fitted) Filter Filter by-pass See Note 1 Neutral circuit feed line Neutral circuit return line Pump suction line Tank Pump assembly - see Note 2 Main pump Fan pump Steer pump Priority valve Test points Test point (if fitted) Valve block Main relief valve (M.R.V.) Pressure reducing valve (20 bar) Pressure maintaining valve (10 bar) Lift spool Tilt spool Extension spool Auxiliary spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.)- see Note 3 Auxiliary relief valve (A.R.V.)- see Note 3 Load hold check valves (L.H.C.V's) Accumulator Steering unit Steer valve Shock valves (option) Main relief valve Cooling fan motor Cooling fan motor drain line (if fitted) Cooler (if fitted) Lift ram Lift ram check valve Displacement ram Tilt ram Tilt ram check valve Extension ram Extension ram check valve Auxiliary relief valve (A.R.V.) (540 only) Auxiliary relief valve (A.R.V.) (540 only) Auxiliary 1 boom quick release couplings Auxiliary 1 with trailer hitch option Diverter valve (chassis) - see Note 4 Trailer hitch ram Auxiliary 1 boom quick release couplings Trailer/Auxiliary quick release coupling Restrictor adaptor - See Note 5. Auxiliary 1 and 2 option Diverter valve (boom) - see Note 4 Auxiliary 2 boom quick release couplings Auxiliary 1 boom quick release couplings Auxiliary 1 and 2 with carriage pin locking option Diverter valve (boom) - see Note 4 Auxiliary 2 boom quick release couplings Manual change over valve Hydraulic pin locking ram 16 17 17A 17B 17C 17D 17E 18 19 19A 19B 19C 19D 20
From m/c no. 767001
Rear power track rod Steer mode valve 2 Wheel steer solenoid 4 Wheel and crab steer solenoid 4 Wheel steer solenoid Crab steer solenoid Steering anti-cavitation valve - See Note 6. Front power track rod Trailer brake valve assembly option Pilot valve Brake valve Trailer brake coupling Brake circuit connection Restricted non return valve
Note 1: Later machines have direct return to tank from the Filter F. Note 2: From machine S/N 771430 the positions of fan pump 1B and steer pump 1C of pump assembly 1 are reversed. Note 3: Early machines have auxiliary relief valves which incorporate check valves. Note 4: Ports B and C of items 13A, 14A and 15A were Ports A and D on machines prior to serial number 775468. Note 5: Restrictor adaptor 13E fitted to improve hitch control on machines fitted with a pickup hitch option. See Technical Information Bulletin 5/195 (E191). Note 6: Steering anti-cavitation valve 17E is by-passed via connector Y, as shown on inset Z, on machines from S/N 773054.
9804/1103
20 - 20-02/35
3630 - E/5-1.5
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/36
530, 540 Agricultural Circuit Diagrams - Hydraulics (contd)
From m/c no. 767001
17 17A 18 17B 17D 17E Y B3 3 17C 16 Z 17E
15 15D 15E 15B 15C 15A 14 14B 14C 14A
5 3 3B 4 4A 3A
19C
13 13C 2 T
13E
13D
13B 13A 12
19D A 2G
3C
B2 B1
19A
19B
2M 2K
B 2L A B 11B 11C 11A 11
19 2M 1F 1 1E 1D F 1C F1 B S T F2 N2 2N 2B 1B 2M
2F
A 2E 2H B 2J A 9 10
1A 2M
2D
B 20 2C 2A 10A
N1
8A
8
A293711
9804/1103
20 - 20 - 02/36
3620 - E/5-2.4
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/37
530 Construction Circuit Diagram - Hydraulic
From m/c no. 767001 to 770616
14 P1
A B C
14B
A 17 T 18 P 17B 17D 17E C V A 13G B P1

A C B
P2 14A
B 17C B 16 A 13
14C
17A
13C
P2
2K
5 L 3 3B 4 3A A 3C P T LS 2 2M 2G 2K A 2E 2M EF 1E 1 1E 2M 1D F F1 S 1C 1B A 1A N1 2M 2C 2N 2B T 2A P 2D B A 2F B 2H 2J B B T R
2L
13D 13B
13A
12 2L
10 9 11A 10A 11
LS
20
N2
8A 8
A259692
9804/1103
20 - 20 - 02/37
3630 - E/5-3.3
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/38
530 Construction Circuit Diagrams - Hydraulic (contd) Component Key

B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 3 3A 3B 3C 4 5 8 8A 9 10 10A 11 11A 12 13 13A 13B 13C 13D 13G 14 14A 14B 14C 16 17 17A 17B 17C 17D 17E 18 Pressure cap breather Filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction line Tank Pump assembly - see Note 1. Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (M.R.V.) Pressure reducing valve (20 bar) Pressure maintaining valve (10 bar) Lift spool Tilt spool Extension spool Auxiliary spool (open centre, see 13G) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) (Sway ram option A.R.V) Auxiliary relief valve (A.R.V.) (Sway ram option A.R.V) Load hold check valves (L.H.C.V's) Accumulator Steering unit Steer valve Shock valves (option) Main relief valve Cooling fan motor Cooler Lift ram Lift ram check valve Displacement ram Tilt ram Tilt ram check valve Extension ram Extension ram check valve Auxiliary 1 boom quick release couplings Auxiliary 1 with sway option Sway ram Sway ram check valve Auxiliary 1 boom quick release couplings Diverter valve (chassis) Sway/auxiliary spool (motor spool, see 2G) Auxiliary 1 and 2 option Diverter valve (boom) Auxiliary 2 boom quick release couplings Auxiliary 1 boom quick release couplings Rear power track rod Steer mode valve 2 Wheel steer solenoid 4 Wheel and crab steer solenoid 4 Wheel steer solenoid Crab steer solenoid Steering anti-cavitation valve Front power track rod 20
From m/c no. 767001 to 770616
Restricted non return valve
Note 1: From machine S/N 771430 the positions of fan pump 1B and steer pump 1C of pump assembly 1 are reversed.
9804/1103
20 - 20 - 02/38
3630 - E/5-4.3
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/39
530, 540 Construction with Single Lever Controls Circuit Diagrams - Hydraulics Component Key
B Pressure cap breather F Filter F1 Filter by-pass F2 See Note 1. N1 Neutral circuit feed line N2 Neutral circuit return line S Pump suction strainer T Tank 1 Pump assembly - see Note 2. 1A Main pump 1B Fan pump 1C Steer pump 1D Priority valve 1E Test points 2 Valve block 2A Main relief valve (M.R.V.) 2B Pressure reducing valve (20 bar) 2C Pressure maintaining valve (10 bar) 2D Lift spool 2E Extension spool 2F Tilt spool 2G Auxiliary spool 2H Auxiliary relief valve (A.R.V.) 2J Auxiliary relief valve (A.R.V.) 2K Auxiliary relief valve (A.R.V.) (Sway ram option A.R.V.) 2L Auxiliary relief valve (A.R.V.) (Sway ram option A.R.V.) 2M Load hold check valves (L.H.C.V's) 2N Accumulator 3 Steering unit 3A Steer valve 3B Shock valves (option) 3C Main relief valve 4 Cooling fan motor 5 Cooler (if fitted) 8 Lift ram 8A Lift ram check valve 9 Displacement ram 10 Tilt ram 10A Tilt ram check valve 11 Extension ram 11A Extension ram check valve 11B Auxiliary relief valve (A.R.V.) (540 only) 11C Auxiliary relief valve (A.R.V.) (540 only) 12 Auxiliary 1 boom quick release couplings 13 Auxiliary 1 with sway option (if fitted) 13A Sway ram (if fitted) 13B Sway ram check valve (if fitted) 13C Auxiliary 1 boom quick release couplings 13D Diverter valve (chassis) 13E Diverter valve 13G Sway/auxiliary spool 14 Auxiliary 1 and 2 option 14A Diverter valve (boom) - See Note 3. 14B Auxiliary 2 boom quick release couplings 14C Auxiliary 1 boom quick release couplings 15 Auxiliary 1 and 2 with hydraulic pin lock option 15A Diverter valve - See Note 3. 15B Auxiliary 1 boom quick release couplings 15C Auxiliary 2 boom quick release couplings 15D Hydraulic pin lock ram 15E Manual change over valve 16 16A 16B 16C 16D 16E 17 17A 17B 17C 17D 17E 18 19 19A 19B 19C 19D 20 21
From m/c no. 767001 to 770617
Auxiliary 1 with trailer hitch option Diverter valve (chassis) - See Note 3. Trailer hitch ram Auxiliary 1 boom quick release couplings Trailer/Auxiliary quick release coupling Restrictor adaptor - See Note 4. Steer mode valve 2 Wheel steer solenoid 4 Wheel and crab steer solenoid 4 Wheel steer solenoid Crab steer solenoid Steering anti-cavitation valve - See Note 5. Front power track rod Trailer brake valve assembly option Pilot valve Brake valve Trailer brake coupling Brake circuit connection Restricted non return valve Rear power track rod
Note 1: Later machines have direct return to tank from the filter F. Note 2: From machine S/N 771430 the positions of fan pump 1B and steer pump 1C of pump assembly 1 are reversed. Note 3: Ports B and C of items 14A, 15A and 16A were Ports A and D on machines prior to serial number 775468. Note 4: Restrictor adaptor 16E fitted to improve hitch control on machines fitted with a pickup hitch option. See Technical Information Bulletin 5/195 (E191). Note 5: Steering anti-cavitation valve 17E is by-passed, as shown on inset Z, on machines from S/N 773054.
9804/1103
20 - 20 - 02/39
3630 - E/5-5.5
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/40
530, 540 Construction with Single Lever Control Circuit Diagram - Hydraulic (contd)
From m/c no. 767001 to 770617
16 16C Z 17 17E 17A 18 17B 17D 17E 3 14 17C 21 Y 15A 15 16A
16E
16D
16B
15B 15C
15E 15D
14C
14B
14A 13 3 3B 19C 4 2 3A 19D 3C B2 B1 19 1 1E 2M 1D F 1C F1 1A N1 2M 20 B N2 2B T S F2 2N 8A 8

A293721
5 2M
13G 2K 2L 13A 13B 13D 13C 2G 2M 19A 19B 2F 2H 2M 2E 11B 11C 9 2D 2J 2K 2L 12 11A 11 13E
1B
10
10A
2C 2A
9804/1103
20 - 20 - 02/40
3620 - E/5-6.4
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/41
530 Construction with Single Lever Control Circuit Diagram - Hydraulic (contd)
16
16A 16C
From m/c no. 775402
15 18
17
16B 16D
15B 15A
15C 14D 14F 14E
14
L
14B
14C
3
3B
R A
14A
13 2
3A
LS
13B
13C
4
A
2G 2M 2K 2F 2L
13A
B
3C
P T
12
A B
11A
11
2M 2H
LS P EF
2J
A B
1
1E 2M 1C
2E
1D
10
A
F
F1
1B
1A
2D
2280 rev/min B
2M
19 B
2A
10A
S T
N1 8A N2
9804/1103
20 - 20 - 02/41
3630 - E/5-7.3
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/42
530 Construction with Manual Auxiliary Controls Circuit Diagrams - Hydraulics (contd) Component Key
B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 3 3A 3B 3C 4 8A 9 10 10A 11 11A 12 13 13A 13B 13C 14 14A 14B 14C 14D 14E 14F 15 16 16A 16B 16C 16D 17 18 19 Pressure cap breather Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (MRV) Lift spool Extension spool Tilt spool Auxiliary spool Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Load hold check valves (LHCVs) Steering unit Steer valve Shock valves (option) Main relief valve Cooling fan motor8 Lift ram Counter-balance valve Displacement ram Tilt ram Counter-balance valve Extension ram Counter-balance valve Auxiliary 1 boom quick release couplings Second auxiliary option Diverter valve (boom) Auxiliary 1 boom quick release couplings Auxiliary 2 boom quick release couplings Second auxiliary with hydraulic pin locking option Diverter valve (boom) Auxiliary 1 boom quick release couplings Auxiliary 2 boom quick release couplings Manual change-over valve Flow restrictor Hydraulic pin locking cylinder Sway option Steer mode valve - See Note 1. Two Wheel steer solenoid Four Wheel and crab steer solenoid Four Wheel steer solenoid Crab steer solenoid Front power track-rod Rear power track-rod Restricted non return valve
From m/c no. 775402
Note 1: Pump flow goes direct to the fan motor on non-sway machines. Note 2: Electrically operated steer mode valve shown. Manual version also available.
9804/1103
20 - 20 - 02/42
3630 - E/5-8.3
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/41A
530 Construction Machines with Manual Auxiliary Controls - fitted with 2-stage pump (From Serial No. TBA) Circuit Diagrams - Hydraulics
Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The two stage pump assembly comprises two sections each of which supplies oil to parts of the circuit as follows: 1A Steer/valve block/auxiliary options 1B Fan motor The main services pump 1A has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve, oil flows from the EF port to the control valve to provide loading auxiliary services. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 N1 N2 S T 1 1A 1B 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 3 3A 3B 3C 4 4A 5 5A 5B 8 8A 9 10 Pressure cap breather (if fitted) Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly Main pump Fan pump Priority valve Test points Valve block Main relief valve (MRV) Lift Spool Extension spool Tilt spool Auxiliary spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Load hold check valves (LHCVs) Steer unit assembly (Early type shown on main circuit at X, later type shown in inset Y) Steer valve Shock valves (option) Main relief valve Cooling fan motor (non-reversible) Relief valve - 190 bar (to M78434) Relief valve - 108 bar (from M78435) Reversible cooling fan motor option Relief valves Fan change-over solenoid Lift ram Counter-balance valve Displacement ram Tilt ram 10A 11 11A 12 Counter-balance valve Extension ram Counter-balance valve Auxiliary 1 boom quick release couplings (standard build) 13 Second auxiliary option 13A Diverter valve (boom) 13B Auxiliary 1 boom quick release couplings 13C Auxiliary 2 boom quick release couplings 14 Second auxiliary with hydraulic pin locking option 14A Diverter valve (boom) 14B Auxiliary 1 boom quick release couplings 14C Auxiliary 2 boom quick release couplings 14D Manual change-over valve 14E Flow restrictor 14F Hydraulic pin locking cylinder 15 Sway control valve option 15A One way restrictors 15B Pilot operated check-valve 15C Sway hydraulic cylinder 16 Steer mode valve - See Note 2 16A Two wheel steer solenoid 16B Four wheel and crab steer solenoid 16C Four wheel steer solenoid 16D Crab steer solenoid 17 Front power track rod 18 Rear power track rod 19 Restricted non return valve 20 Lift circuit with optional Smooth Ride System (SRS) 20A Solenoid valve 20B Solenoid valve 20C Accumulators 20D Pressure switch
Note 1: Pump flow goes directt to the fan motor on nonsway machines Note 2: Electrically operated steer mode valve shown. Manual version also available.
9804/1103
20 - 20 - 02/41A
3630 - E/5-9.5
Issue 1*
CONTENTS
Loadalls
20 - 20 - 02/42A
530 Construction Machines with Manual Auxiliary Controls - fitted with 2-stage pump Circuit Diagram - Hydraulic
16
16A 16C
From Serial No. TBA
15 18
17
16B 16D
15B 15A
4A
15C
B A
14D 14F 14E
3
L R
14
3C
A
14B
14C
14A
3A
13
13B
13C
LS
4
2G 2M 2K 2F 2L
A B
3B
T
3D
P
13A
12
A B
11A
11
1E
LS P EF
2M 2H 2E 2J
A B
1D
1B
1A
16 36
2M
10
2280 RPM
F
F1 2M
2D
B
19 B
2A
10A
8
8A
S T
N1
20
N2 8A
20D
20B
20A
4
20C
160-02300-4
9804/1103
20 - 20 - 02/42A
3660 - E/5-10.5
Issue 1*
CONTENTS
Loadalls
20 - 20 - 02/41B
530 Construction Machines with Manual Auxiliary Controls - fitted with 3-stage pump (From Serial No. 775402) Circuit Diagram - Hydraulics
Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The two stage pump assembly comprises two sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/auxiliary options 1B Fan motor 1C Steer valve The steer pump 1C has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve, oil returns back to the tank. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 3 3A 3B 3C 4 4A 5 5A 5B 8 8A 9 10 Pressure cap breather (if fitted) Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (MRV) Lift Spool Extension spool Tilt spool Auxiliary spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Load hold check valves (LHCVs) Steer unit assembly (Early type shown on main circuit at X, later type shown in inset Y) Steer valve Shock valves (option) Main relief valve Cooling fan motor (non-reversible) Relief valve - 190 bar (to M78434) Relief valve - 108 bar (from M78435) Reversible cooling fan motor option Relief valves Fan change-over solenoid Lift ram Counter-balance valve Displacement ram Tilt ram 10A 11 11A 12 Counter-balance valve Extension ram Counter-balance valve Auxiliary 1 boom quick release couplings (standard build) 13 Second auxiliary option 13A Diverter valve (boom) 13B Auxiliary 1 boom quick release couplings 13C Auxiliary 2 boom quick release couplings 14 Second auxiliary with hydraulic pin locking option 14A Diverter valve (boom) 14B Auxiliary 1 boom quick release couplings 14C Auxiliary 2 boom quick release couplings 14D Manual change-over valve 14E Flow restrictor 14F Hydraulic pin locking cylinder 15 Sway control valve option 15A One way restrictors 15B Pilot operated check-valve 15C Sway hydraulic cylinder 16 Steer mode valve - See Note 2 16A Two wheel steer solenoid 16B Four wheel and crab steer solenoid 16C Four wheel steer solenoid 16D Crab steer solenoid 17 Front power track rod 18 Rear power track rod 19 Restricted non return valve 20 Lift circuit with optional Smooth Ride System (SRS) 20A Solenoid valve 20B Solenoid valve 20C Accumulators 20D Pressure switch
Note 1: Pump flow goes directt to the fan motor on nonsway machines Note 2: Electrically operated steer mode valve shown. Manual version also available.
9804/1103
20 - 20 - 02/41B
3630 - E/5-8.5
Issue 1*
CONTENTS
Loadalls
20 - 20 - 02/42B
530 Construction Machines with Manual Auxiliary Controls - fitted with 3-stage pump Circuit Diagram - Hydraulic
16
16A 16C
From Serial No. 775402
15 18
17
16B 16D
15B 15A
4A
15C
B A
14D 14F 14E
a
L
Y
3
3C
b
R
a
L
X
3
3B
b
R
14
14B
14C
14A
13 2
3A
3A
LS
B
13B
13C
4
2G 2M 2K 2F 2L
LS
13A
B
3B
T
3D
P
3D
P
3C T
12
A
11A
11
c d
c
2M
d
LS P EF
2H
2J
A B
1
1E 2M 1C
2E
1D
10
A
P
16 19 32
F
F1
1B
1A
2D
2280 rev/min B
2M
19 B
2A
10A
8
8A
S T
N1 N2
20
20D
8A
20B
20A
4 160-02300-2
20C
9804/1103
20 - 20 - 02/42B
3660 - E/5-7.5
Issue 1*
CONTENTS
Loadalls
20 - 20 - 02/43
540 Construction with Manual Auxiliary Controls Circuit Diagrams - Hydraulics Component Key
B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 3 3A 3B 3C 4 8 8A 9 10 10A 11 11A 12 13 13A 13B 13C 14 14A 14B 14C 14D 14E 14F 15 16 16A 16B 16C 16D 17 18 19 Pressure cap breather Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (MRV) Lift spool Extension spool Tilt spool Auxiliary spool Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Load hold check valves (LHCVs) Steering unit Steer valve Shock valves (option) Main relief valve Cooling fan motor Lift ram Counter-balance valve Displacement ram Tilt ram Counter-balance valve Extension ram Counter-balance valve Auxiliary 1 boom quick release couplings Second auxiliary option Diverter valve (boom) Auxiliary 1 boom quick release couplings Auxiliary 2 boom quick release couplings Second auxiliary with hydraulic pin locking option Diverter valve (boom) Auxiliary 1 boom quick release couplings Auxiliary 2 boom quick release couplings Manual change-over valve Flow restrictor Hydraulic pin locking cylinder Sway option Steer mode valve - See Note 1. Two Wheel steer solenoid Four Wheel and crab steer solenoid Four Wheel steer solenoid Crab steer solenoid Front power track-rod Rear power track-rod Restricted non return valve
From m/c no. 775402
Note 1: Electrically operated steer mode valve shown. Manual version also available.
9804/1103
20 - 20 - 02/43
3630 - E/5-9.3
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/44
540 Construction with Manual Auxiliary Controls Circuit Diagrams - Hydraulic (contd)
16
16A 16C
From m/c no. 775402
17
16B 16D
18
14B 14C
14D 14E 14F
14
14A
13B
13C
13
L
3
3B
13A
2
3A
LS
4
A
12
2G
B
3C
P T
2P 2M 2F
B
11A 2N
A
11
2P 2K 2L
A B
1
1E 2P 1C 1D 1B 1A
2E
2H 2D
2280 rev/min
2J
A B
10 9
F B
F1 N2
2P
19
2A
10A
8 T S
N1 8A
9804/1103
3630 - E/5-10.3
20 - 20 - 02/44
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/43A
540 Construction Machines with Manual Auxiliary Controls - fitted with 3-stage pump (From Serial No. 775402) Circuit Diagram - Hydraulics
Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The two stage pump assembly comprises two sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/auxiliary options 1B Fan motor 1C Steer valve The steer pump 1C has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve, oil returns back to the tank. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 3 3A 3B 3C 4 4A 5 5A 5B 8 8A Pressure cap breather Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (MRV) Lift Spool Extension spool Tilt spool Auxiliary spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Load hold check valves (LHCVs) Steer unit assembly (Early type shown on main circuit at X, later type shown in inset Y) Steer valve Shock valves (option) Main relief valve Cooling fan motor (non-reversible) Relief valve - 190 bar (to M78434) Relief valve - 108 bar (from M78435) Reversible cooling fan motor option Relief valves Fan change-over solenoid Lift ram Counter-balance valve 9 Displacement ram 10 Tilt ram 10A Counter-balance valve 11 Extension ram 11A Counter-balance valve 12 Auxiliary 1 boom quick release couplings 13 Second auxiliary option 13A Diverter valve (boom) 13B Auxiliary 1 boom quick release couplings 13C Auxiliary 2 boom quick release couplings 14 Second auxiliary with hydraulic pin locking option 14A Diverter valve (boom) 14B Auxiliary 1 boom quick release couplings 14C Auxiliary 2 boom quick release couplings 14D Manual change-over valve 14E Flow restrictor 14F Hydraulic pin locking cylinder 15 Sway option 16 Steer mode valve - See Note 1 16A Two wheel steer solenoid 16B Four wheel and crab steer solenoid 16C Four wheel steer solenoid 16D Crab steer solenoid 17 Front power track rod 18 Rear power track rod 19 Restricted non return valve 20 Lift circuit with optional Smooth Ride System (SRS) 20A Solenoid valve 20B Solenoid valve 20C Accumulators 20D Pressure switch
Note 1: Electrically operated steer mode valve shown. Manual version also available.
9804/1103
20 - 20 - 02/43A
3630 - E/5-12.4
Issue 1*
CONTENTS
Loadalls
20 - 20 - 02/44A
540 Construction Machines with Manual Auxiliary Controls Circuit Diagram - Hydraulic
17
T
13
17C
B A T
17A
18
P
16
19C
13G 13F 13C

SA SB
17B
17D
13B
19D
Y
13E
150 BAR
13A 13D 15C 15B 15A
19 5B
R B
19B
5A
P1 P2 N
a
L
Y
3
3C
15D
b
R
a
L
X
3
3C
b
R
19A
P
20 12
c P1 P2 A B C D
20C
20D 20B
2
3A 3A
LS LS
d
20E
4A
A
20A 2G
2K
2L
21
3B
T
3D
P P
3D
3B
T
2M
c d e e
c
A
2F
25 24 23 22
d
2M
2H
2J
A LS P EF
1
1E 2M 1A 1B
16 19 32
2E
24A B
1D
1C
F
F1
2280 rev/min
2D 2M
28
27
26
B
2A
T S
F2
29
N1 N2
30 31
A343503 160/12719
9804/1103
20 - 20 - 02/44A
3660 - E/5-11.4
Issue 1*
CONTENTS
Loadalls
20 - 20 - 02/45
535-95 Circuit Diagrams - Hydraulic
From m/c no. 777362
17
T
13
17C
B A T
17A
18
P
16
19C 19D
Y
13G 13F 13C

SA SB
17B
17D
13B
13E
150 BAR
13A 13D 15C 15B 15A
19
19B
R B L
P1 P2
15D
19A
P
20 12
c P1 P2 A B C D
20C
20D 20B
4
3C 3A
A LS
2
d
20E
20A 2G 2M
A
3D
P
3B
T
2K
2L
21
2F 2M
25 24 23 22
2H
2J
A LS P EF
Extend 24A
1
1E 2M 1A 1B
16 19 32
2E
Retract
1D
1C
F
F1
2280 rev/min
2D 2M
28
Crowd
27
26
B
N2 N1 2A
Dump
T S
F2
T Dump
29
Lift
30 31
A343501
9804/1103
20 - 20 - 02/45
3630 - E/5-11.2
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/46
535-95 Circuit Diagrams - Hydraulic (contd) Component Key

B F F1 F2 S T N1 N2 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 3 3A 3B 3C 3D 4 12 13 13A 13B 13C 13D 13E 13F 13G 15A 15B 15C 15D 16 17 17A 17B 17C 17D 18 19 19A 19B 19C 19D 20 20A 20B 20C Pressure cap breather Return line filter Filter by-pass Direct return to tank Pump suction strainer Tank Neutral circuit feed line Neutral circuit return line Pump assembly Main pump Fan pump Steer pump Priority valve Test point Valve block Main relief valve (MRV) Lift spool Extend spool Tilt spool Auxiliary spool Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Load hold check valves (LHCVs) Steer unit assembly Steering valve Main relief valve Shock valves (option) Non return valve Cooling fan motor Auxiliary 1 boom quick release couplings (standard build) Sway control valve (option) Sway ram Pilot operated check valve One-way restrictor One-way restrictor Relief valve Diverter valve Sway valve spool Hydraulic pin lock ram Restrictor Manual changeover valve Auxiliary 2 boom quick release couplings Rear power track rod Steer mode valve (option) 2 wheel steer solenoid 4 wheel and grab steer solenoid 4 wheel steer solenoid Crab steer solenoid Front power track rod Trailer brake valve assembly (option) Pilot valve Brake valve Trailer brake coupling Brake circuit connection Pick-up hitch (option) Solenoid diverter valve (chassis mounted) Pick-up hitch ram Auxiliary 1 boom quick release couplings 20D 20E 21 22 23 24 24A 25 26 27 28 29 30 31
From m/c no. 777362
Trailer/Auxiliary quick release coupling Restrictor adaptor - see Note 2 High flow auxiliary (option) Inner extension ram Extension ram check/counter balance valve Outer extension ram Bleed point Regenerative valve Tilt ram Tilt check/counterbalance valve Displacement ram Displacement lift valve Lift ram Lift check/counterbalance valve
Note 1: The schematic shows sway and trailer brake options. Pump flow goes direct to fan motor if sway is not fitted. Note 2: Restrictor adaptor 20E is fitted to improve hitch control on machines fitted with pick-up hitch option. See Technical Information Bulletin 5/195 (E191).
9804/1103
20 - 20-02/46
3630 - E/5-12.2
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/45A
535-95 Machines - fitted with 3-stage pump (From Serial No. 777362) Circuit Diagram - Hydraulics
Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The two stage pump assembly comprises two sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/auxiliary options 1B Fan motor 1C Steer valve The steer pump 1C has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve, oil returns back to the tank. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 F2 S T N1 N2 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 3 3A 3B 3C 3D 4 4A 5 5A 5B 12 13 13A Pressure cap breather Return line filter Filter by-pass Direct return to tank Pump suction strainer Tank Neutral circuit feed line Neutral circuit return line Pump assembly Main services pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (MRV) Lift Spool Extension spool Tilt spool Auxiliary spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Steer unit assembly Steer valve Main relief valve Shock valves (option) Non-return valve Cooling fan motor (non-reversible) Relief valve - 190 bar (to M78434) Relief valve - 108 bar (from M78435) Reversible cooling fan motor option Relief valves (108 bar) Fan change-over solenoid Auxiliary 1 boom quick release couplings (standard build) Sway control valve (option) Sway ram 13B Pilot operated check valve 13C One-way restrictor 13D One-way restrictor 13E Relief valve 13F Diverter valve 13G Sway valve spool 15A Hydraulic pin lock ram 15B Restrictor 15C Manual changeover valve 15D Auxiliary 2 boom quick release couplings 16 Rear power track rod 17 Steer mode valve (option) 17A 2 wheel steer solenoid 17B 4 wheel and grab steer solenoid 17C 4 wheel steer solenoid 17D Crab steer solenoid 18 Front power track rod 19 Trailer brake valve assembly (option) 19A Pilot valve 19B Brake valve 19C Trailer brake coupling 19D Brake circuit connection 20 Pick-up hitch (option) 20A Solenoid diverter valve (chasis mounted) 20B Pick-up hitch ram 20C Auxiliary 1 boom quick release couplings 20D Trailer/Auxiliary quick release coupling 20E Restrictor adaptor 21 High flow auxiliary (option) 22 Inner extension ram 23 Extension ram check/counter balance valve 24 Outer extension ram 24A Bleed point 25 Regenerative valve 26 Tilt ram 27 Tilt check/counterbalance valve 28 Displacement ram 29 Displacement lift valve 30 Lift ram 31 Lift check/counterbalance valve
9804/1103
20 - 20 - 02/45A
3630 - E/5-13.2
Issue 1*
CONTENTS
Loadalls
20 - 20 - 02/46A
535-95 Machines - fitted with 3-stage pump Circuit Diagram - Hydraulic
17
T
13
17C
B A T
17A
18
P
16
19C
13G 13F 13C

SA SB
17B
17D
13B
19D
Y
13E
150 BAR
13A 13D 15C 15B 15A
19 5B
R B L
19B
5A 3
P1 P2
15D
19A
P
20 12
c P1 P2 A B C D
20C
20D 20B
3C 3A
2
d
20E
4A
A LS
20A 2G 2M
A
2K
2L
21
3D
P
3B
T
b b c
1E
LS P EF
d
2M
2F
25 24 23 22
2H
2J
d Y
c
LS P EF
X
1
1E 1D
P
Extend 24A
2E 2M 1A
Retract
1
1C 1B
16 19 32
1D
F
1B
16 36
1A
2280 rev/min
F1
2280 rev/min
2D
28
2M
27
26
B
N2 N1 2A
N1
T S
F2
29
30 31
A343502 A343502
9804/1103
20 - 20 - 02/46A
3660 - E/5-14.2
Issue 1*
CONTENTS
Loadalls
20 - 20 - 02/45B
535-95 Machines - fitted with 2-stage pump (From Serial No. TBA) Circuit Diagram - Hydraulics
Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The two stage pump assembly comprises two sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/auxiliary options 1B Fan motor 1C Steer valve The steer pump 1C has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve, oil returns back to the tank. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 F2 S T N1 N2 1 1A 1B 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 3 3A 3B 3C 3D 4 4A 5 5A 5B 12 Pressure cap breather Return line filter Filter by-pass Direct return to tank Pump suction strainer Tank Neutral circuit feed line Neutral circuit return line Pump assembly Main services pump Fan pump Priority valve Test points Valve block Main relief valve (MRV) Lift Spool Extend spool Tilt spool Auxiliary spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Steer unit assembly Steering valve Main relief valve Shock valves (option) Non-return valve Cooling fan motor (non-reversible) Relief valve - 108 bar Reversible cooling fan motor option Relief valves (108 bar) Fan change-over solenoid Auxiliary 1 boom quick release couplings (standard build) 13 Sway control valve (option) 13A Sway ram 13B Pilot operated check valve 13C One-way restrictor 13D One-way restrictor 13E Relief valve 13F Diverter valve 13G Sway valve spool 15A Hydraulic pin lock ram 15B Restrictor 15C Manual changeover valve 15D Auxiliary 2 boom quick release couplings 16 Rear power track rod 17 Steer mode valve (option) 17A 2 wheel steer solenoid 17B 4 wheel and grab steer solenoid 17C 4 wheel steer solenoid 17D Crab steer solenoid 18 Front power track rod 19 Trailer brake valve assembly (option) 19A Pilot valve 19B Brake valve 19C Trailer brake coupling 19D Brake circuit connection 20 Pick-up hitch (option) 20A Solenoid diverter valve (chasis mounted) 20B Pick-up hitch ram 20C Auxiliary 1 boom quick release couplings 20D Trailer/Auxiliary quick release coupling 20E Restrictor adaptor 21 High flow auxiliary (option) 22 Inner extension ram 23 Extension ram check/counter balance valve 24 Outer extension ram 24A Bleed point 25 Regenerative valve 26 Tilt ram 27 Tilt check/counterbalance valve 28 Displacement ram 29 Displacement lift valve 30 Lift ram 31 Lift check/counterbalance valve
9804/1103
20 - 20 - 02/45B
3630 - E/5-16.1
Issue 1*
CONTENTS
Loadalls
20 - 20 - 02/46B
535-95 Machines - fitted with 2-stage pump Circuit Diagram - Hydraulic
From Serial No. TBA
17
T
13
17C
B A T
17A
18
P
16
19C
13G 13F 13C

SA SB
17B
17D
13B
19D
Y
13E
150 BAR
13A 13D 15C 15B 15A
19 5B
R B
19B
5A
P1 P2 N
a
L
Y
3
3C
15D
b
R
a
L
X
3
3C
b
R
19A
P
20 12
c P1 P2 A B C D
20C
20D 20B
2
3A 3A
LS LS
d
20E
4A
A
20A 2G
2K
2L
21
3B
T
3D
P P
3D
3B
T
2M
c d e e
c
A
2F
25 24 23 22
d
2M
2H
2J
A LS P EF
1
1E 2M 1A 1B
16 19 32
2E
24A B
1D
1C
F
F1
2280 rev/min
2D 2M
28
27
26
B
2A
T S
F2
29
N1 N2
30 31
A343503 160/12719
9804/1103
20 - 20 - 02/46B
3660 - E/5-15.1
Issue 1*
CONTENTS
Loadalls
20 - 20 - 02/47
532 to m/c no. 770638 537, 550 to m/c no. 770613 Circuit Diagrams - Hydraulic
6 T 5 P 6B 6C 6E C 5 V 7 2Q A 2J 2 2Q 20A
C3
6A
6D
B A
7 T
A 2K B
22A
22
21A
21
L 3B
9 4 2Q 2G
2H A 20 B 2L 2F 2M A
C2 C4
C1
18 18A
19 16A 16
3A LS 2Q P 3C T 2E 2Q 2N
B 2P A B 15 A 13E 13B 17
13
2D LS P EF 1E 1 1E 1D 1C 1B 1A 2R 2B 2A N2 S F F1 P 2Q
B 13C 13D 2C 13A
14 11A 12 11
8A 8
N1
A260812
9804/1103
20 - 20 - 02/47
3660 - E/5-1.1
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/48
532 to m/c no. 770638 537, 550 to m/c no. 770613 Circuit Diagrams - Hydraulic (contd)
B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 2Q 2R 3 3A 3B 3C 4 5 6 6A 6B 6C 6D 6E 7 8 8A 9 11 11A 12 13 13A 13B 13C 13D 13E 14 15 16 16A 17 18 Pressure cap breather Filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction line Tank Pump assembly - see Note 1. Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (M.R.V.) Pressure reducing valve (20 bar) Pressure maintaining valve (10 bar) Lift spool Extension spool Tilt spool Sway/Auxiliary spool (motor spool with sway only) Unloader valve Right hand stabiliser spool Left hand stabiliser spool Auxiliary relief valve (A.R.V) (Sway ram option A.R.V.) Auxiliary relief valve (A.R.V) (Sway ram option A.R.V.) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valves (L.H.C.V's) Accumulator (only fitted with auxiliary circuit) Steering unit Steer valve Shock valves (option) Main relief valve Cooling fan motor Front steer rams Steer mode valve 2 Wheel steer solenoid 4 Wheel and crab steer solenoid 4 Wheel steer solenoid Crab steer solenoid Steering anti-cavitation valve Rear steer rams Lift ram Lift ram check valve Cooler Inner extension ram Inner extension ram check valve Outer extension ram Regenerative valve Hose burst check valve Relief Valve Check valve Non-return valve Non-return valve Regenerative circuit bleed valve Restricted non return valve Tilt ram Tilt ram check valve Displacement rams Sway ram 18A 19 20 20A 21 21A 22 22A Sway ram check valve Auxiliary 1 boom quick release couplings Diverter valve (chassis) Diverter valve - see Note 2. Right hand stabiliser ram Right hand stabiliser ram check valve Left hand stabiliser ram Left hand stabiliser ram check valve
Note 1: From machine S/N 771429 the positions of fan pump 1B and steer pump 1C of pump assembly 1 are reversed. Note 2: See FSI 5/151 (E164 N.Am) and 5/152 (E166 N.Am) for details of diverter valve 20A.
9804/1103
20 - 20 - 02/48
3660 - E/5-2.1
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/49
532 from m/c no. 770689 to 775401 537, 550 from m/c no. 770614 to 775401 Circuit Diagrams - Hydraulics
B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 2Q 2R 2S 3 3A 3B 3C 4 5 6 6A 6B 6C 6D 6E 7 8 8A 9 11 11A 12 13 13A 13B 13C 13D 13E 14 15 16 16A 17 Pressure cap breather Filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly -see Note 1. Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (M.R.V.) Pressure reducing valve (20 bar) Pressure maintaining valve (10 bar) Lift spool Extension spool Tilt spool Sway/Auxiliary spool Unloader valve Right hand stabiliser spool Left hand stabiliser spool Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Auxiliary relief valve (A.R.V) Load hold check valves (L.H.C.V's) Accumulator (only fitted with auxiliary circuit) Extension motor spool - see Note 2 Steering unit Steer valve Shock valves (option) Main relief valve Cooling fan motor Front steer rams Steer mode valve 2 Wheel steer solenoid 4 Wheel and crab steer solenoid 4 Wheel steer solenoid Crab steer solenoid Steering anti-cavitation valve - see Note 3. Rear steer rams Lift ram Lift ram check valve Cooler Inner extension ram Inner extension ram check valve Outer extension ram Regenerative valve Hose burst check valve Relief Valve Check valve Non-return valve Non-return valve Regenerative circuit bleed valve Restricted non return valve Tilt ram Tilt ram check valve Displacement rams 18 18A 18B 19 20 20A 21 21A 22 22A Sway ram Pilot check valve (sway ram) Sway function in-line restrictor Auxiliary 1 boom quick release couplings Diverter valve (chassis) Diverter valve (chassis) Right hand stabiliser ram Right hand stabiliser ram check valve Left hand stabiliser ram Left hand stabiliser ram check valve
Note 1: From machine S/N 771429 the positions of fan pump 1B and steer pump 1C of pump assembly 1 are reversed. Note 2: Revised extend spool fitted due to boom over-run on machines prior to S/N 772366. Note 3: Steering anti-cavitation valve 6E is by-passed via connector Y, as shown on inset Z, on machines from S/N 773135. The anti-cavitation valve is not fitted from machine S/N 773630.
9804/1103
20 - 20 - 02/49
3660 - E/5-3.1
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/50
532 from m/c no. 770639 to 775401 537, 550 from m/c no. 770614 to 775401 Circuit Diagrams - Hydraulic (contd)
6 6A 5 6B 6C 6E 5 7 21A 2 22A 2K 22 6D 7 T
2J 2Q 3 3B 9 2H 4 3A 2Q 3C 2F 1E 6E 1B 1D Y 1C 1A 2D 3 N2 2Q
13C 13D
21 20 20A 18B 2G 18A 18 2L 2M 19
2Q 1 1E 2E 2Q
2N 2P 17
16
15
13E
13 13B 14
16A
13A B T S P N1 F F1 2C 2R 2B 2A
12
11A
11
8A
8
A293731
9804/1103
20 - 20 - 02/50
3660 - E/5-4.1
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/51
532, 537, 550 with Manual Auxiliary Controls Circuit Diagrams - Hydraulics
19
19A 19C
From m/c no. 775402
18B 19B 19D
20
21
18A 18C
2K 2R
17A
B
17
17B 16A
2J
L
19
2R 2H
4 15
LS A
16
16B
2G
P T B
1E
2R 2N 1E 2P
A
1
1E 2R
2F
B
13
14A 2L 2M
14
1C 1D 1B 1A 2R 2E
A B
12
11
11B
2D N2
B
11C 11D 11A
10A
10
9A
B F
F1
2R
2A
8
8A
S T
N1
9804/1103
20 - 20 - 02/51
3660 - E/5-5.1
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/52
532, 537, & 550 Machines with Manual Auxiliary Controls Circuit Diagram - Hydraulics
Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The pump assembly comprises three sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/auxiliary options 1B Fan motor 1C Steer valve The pump is mounted on the rear face of the bevel box. The valve block is mounted under the cab on the inboard side The steer pump 1C has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve, oil returns back to the tank. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 2R 3 3A 3B 3C Pressure cap breather Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (M.R.V.) Lift spool Extension spool Tilt spool Auxiliary spool Unloader valve Right hand stabilizer Left hand stabilizer Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Load hold check-valves (LHCVs) Steering unit Steer valves Shock valves Main relief valve
4 Cooling fan motor (non-reversible) * 4A Reversible cooling fan motor option (from Serial No. 785165) 8 Lift ram 8A Counter balance valve 9 Inner extension ram 9A Counter balance valve 10 Outer extension ram 11 Regenerative valve 11A Hose burst check-valve (HBCV) 11B Relief valve 11C Check valve 11D Non-return valve 11E Non return valve 12 Restricted non-return valve 13 Displacement cylinders 14 Tilt ram 14A Counter-balance valve 15 Auxiliary 1 boom quick release couplings 16 Right hand stabilizer hydraulic cylinder 16A Stabilizer lock-out valve 16B Pressure switch (option) 17 Left hand stablizer hydraulic cylinder 17A Stabilizer lock-out valve 17B Pressure switch (option) 18 Sway control valve option 18A One-way restrictor 18B Pilot operated check-valve 18C Sway hydraulic cylinder * 18D relief valve (150 bar) 19 Steer mode valve - see Note 2 19A Two wheel steer solenoid 19B Four wheel and crab steer solenoid 19C Four wheel steer solenoid 19D Crab steer solenoid 20 Front steer cylinders 21 Rear steer cylinders
Note 1: Pump flows goes direct ro the fan motor on nonsway machines. Note 2: Electrically operated steer mode valve shown. Manual version also available.
9804/1103
20 - 20 - 02/52
3630 - E/5-6.2
Issue 2*
CONTENTS
Loadalls
20 - 20 - 02/53
506B Circuit Diagrams - Hydraulics Component Key
C F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2E 2F 2G 2L 2M 2N 2P 2Q 2R 2S 2T 2U 2V 2X 10 10A 11 12 13 13A 14 15 15A 16 17 18 29 30 31 32 33 34A 34B 35 36 41 42 43
Cap Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Auxiliary spool Tilt spool Extension spool (See Note 1) Sway spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Load hold check valve (L.H.C.V.) Load hold check valve (L.H.C.V.) Load hold check valve (L.H.C.V.) Load hold check valve (L.H.C.V.) Load hold check valve (L.H.C.V.) Pressure test point Lift cylinders Lift cylinder check valves Displacement cylinder Extension cylinder Tilt cylinder Tilt cylinder check valve Non-return valve Sway cylinder Sway cylinder check valve Regenerative valve Hose burst protection valve Combined load hold check and regenerative valve Steering anti-cavitation valve Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steering mode valve Steering mode valve Front axle steering cylinders Rear axle steering cylinders Cooling fan motor Auxiliary attachment cylinder In-line ARV (See Note 2)
Note 1 : Machines from serial number 572655 have a combined load hold check and regenerative valve 18 with a closed centre spool 2F fitted as standard. Some machines before 572655 may have valve 18 fitted. Check your machine. Note 2: An in-line ARV 43 is available for the boom retract service. See Technical Bulletin E193.
9804/1103
20 - 20 - 02/53
3640U - E/4-1.2
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/54
506B Circuit Diagrams - Hydraulics (contd)
12 12 16 35
16B 16C 16D 18B C2
18
C1
42 13
17
34A C2 34B P V2 T V2 V1 18A 18C
13A
11
36 15
15A 2F
10
33
P R P T 10A 10A
29
C V
14
2P A S2 2X B A B A B A B
2Q A B
2
P2 P3 S3
31
C
P1
43
S1 2G
2M
2N
2L
2A
30
2F 2V 2U
2E 2T
2C 2S
2B 2R 1A
1B
F 32 41
9804/1103
3640U - E/4-2.2
20 - 20 - 02/54
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/55
506C Circuit Diagrams - Hydraulics (contd)
35
P A B
34 13
T
16
12
13A
36
C2
18
18B
C1
11
33
R 18C
15
33A
15A
18A
10
V2 V1
33C See Note P T
10A
10A
29
C V
14
LS
EF 2W A B A B A B 2P A B 2Q A B
P1 2 C
P1C P1B P1A S3 S1
2A
42
2G
2M
2N
2L
2F 2V 2U
2E 2T
2C 2S
2B 2R
1B
P3 F 41 T
1A
9804/1103
20 - 20 - 02/55
3640U - E/4-3.2
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/56
506C Circuit Diagrams - Hydraulics (contd) Component Key

C Cap F Filter P1 Main pump assembly P1A Pump P1B Pressure test point P1C Priority valve P3 Cooling fan pump S1 Main pump suction line S3 Cooling fan pump suction line T Tank 1A Neutral circuit feed line 1B Neutral circuit return line 2 Valve block 2A Main relief valve (M.R.V.) 2B Lift spool 2C Auxiliary spool 2E Tilt spool 2F Extension spool 2G Sway spool 2L Auxiliary relief valve (A.R.V.) 2M Auxiliary relief valve (A.R.V.) 2N Auxiliary relief valve (A.R.V.) 2P Auxiliary relief valve (A.R.V.) 2Q Auxiliary relief valve (A.R.V.) 2R Load hold check valve (L.H.C.V.) 2S Load hold check valve (L.H.C.V.) 2T Load hold check valve (L.H.C.V.) 2U Load hold check valve (L.H.C.V.) 2V Load hold check valve (L.H.C.V.) 2W Auxiliary relief valve (A.R.V.) (See Note 2) 10 Lift cylinders 10A Lift cylinder check valves 11 Displacement cylinder 12 Extension cylinder 13 Tilt cylinder 13A Tilt cylinder check valve 14 Non-return valve 15 Sway cylinder 15A Sway cylinder check valve 16 Auxiliary attachment cylinder 18 Combined load hold check and regenerative valve 18A Retract load hold check valve 18B Regenerative check valve 18C Extend load hold check valve 29 Steering anti-cavitation valve (See Note 1) 33 Steering unit 33A Steer valve 33C Main relief valve 34 Steering mode selctor valve 35 Front axle steering cylinders 36 Rear axle steering cylinders 41 Cooling fan motor 42 In-line ARV (See Note 2) Note 1: Anti-cavitation valve (item 29) is not fitted to machines from serial number 585873. Note 2: An in-line ARV 42 is available for the boom retract service on machines prior to 585208. See Technical Bulletin E193. Machines after 585208 have an ARV 2W fitted within the valve block.
9804/1103
20 - 20-02/56
3640U - E/4-4.1
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/57
506C (HL), 508C Circuit Diagrams - Hydraulics Component Key

C F P1 P2 P3 S1 S2 S3 T 1A 1B 2 2A 2B 2C 2E 2F 2G 2L 2M 2N 2P 2Q 2R 2S 2T 2U 2V 2W 2X 10 10A 11 12 13 13A 15 15A 16 18 18A 18B 18C 29 30 31 32 33 33A 34 35 36 41 42 43 Cap Filter Main pump Steering pump Cooling fan pump Main pump suction line Steering pump suction line Cooling fan pump suction line Tank Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Auxiliary spool Tilt spool Extension spool Sway spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Load hold check valve (L.H.C.V.) Load hold check valve (L.H.C.V.) Load hold check valve (L.H.C.V.) Load hold check valve (L.H.C.V.) Load hold check valve (L.H.C.V.) Auxiliary relief valve (A.R.V.) Pressure test point Lift cylinders Lift cylinder check valves Displacement cylinder Extension cylinder Tilt cylinder Tilt cylinder check valve Sway cylinder Sway cylinder check valve Auxiliary attachment cylinder Combined load hold check and regenerative valve Retract load hold check valve Regenerative check valve Extend load hold check valve Steering anti-cavitation valve Steering flow control valve Steering pressure relief valve Steering pressure test point Steering unit Steer valve Steering mode selctor valve Front axle steering cylinders Rear axle steering cylinders Cooling fan motor In-line ARV (See Note 1) Non-return valve (See Note 2) Note 1: An in-line ARV 42 is available for the boom retract service on machines between 579569 and 585196. See Technical Bulletin E193. Machines after 585196 have an ARV 2W fitted within the valve block. Note 2: Non-return valve 43 fitted to 506C (HL) machines only.
9804/1103
20 - 20 - 02/57
3640U - E/4-5.2
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/58
506C (HL), 508C Circuit Diagrams - Hydraulic (contd)
35
P A B
34 16
T
13
12 36 11
C2 L
13A
18
18B
C1
33
R 15A
15
18A 33A V2 V1 10A P 18C
10
10A
29
C V
43
2W
2P
2Q
S2
2 31
P2 30 S1 2G 2F 2V 2U 2E 2T 2C 2S 2B 2R 1A 1B P3
C
S3
2X
P1 42
2M 2N
2L
2A
F 32 41 T
9804/1103
20 - 20 - 02/58
3640U - E/4-6.2
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/59
540-170, 5508 with Servo Controls Circuit Diagrams - Hydraulics

T
From m/c no. 780925
12
13B
SA
13A
SA
11
13B P A A 14A
13
7
11Q
11A
16
A
14
B
A 11B B 11Q
14B 15A
11C
L R
15 26 8 4
26B 26C T 2 P2 Ext Extr 11N 11P Retm P4 Ret Retr 16 33 41 P3 P2 P1 11Q 4 Low Lowr 11F 11Q Liftr 11G Crdm 11Q 24B
C2 V1
15B 11L 26A 11D 11Q 11M A B
26D
18
17
26E Extm
P1 11R
P LS 3 1 P EF
19
A B
17A
11E
20 21 23
3A
2
Lowm A B
P2
C D B A
22A
P1
22
9 1 2
P T
2 Lift T1 Crd 1 T2
Liftm
B
C1
24
Dumpm Dump 11K
11J
V2
24A
11H T
25 10
A 10A B 25A
10E A 10B B
10E
10C
9804/1103
20 - 20 - 02/59
3630 - C/26-1.5 3660 - E/52-1.2
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/60
540-170, 5508 with Servo Controls Circuit Diagrams - Hydraulic (contd) Component Key
T P P1 P2 P3 P4 1 2 3 4 5 6 7 8 Tank Pump Main services pump Steer pump Sway/fan pump Priority flow diverter Pressure cap breather Return line filter Steering valve Engine cooling fan motor Steer mode valve Front steering cylinders Rear steering cylinders Two axis servo hand controller: Port 1 Lift Port 2 Retract Port 3 Lower Port 4 Extend Single axis servo hand controller: Port 1 Crowd Port 2 Dump Two spool valve block Extension spool Lift spool MRV Port A (240 bar) Load hold check valves (LHCV) Six spool valve block Left hand stabiliser spool Right hand stabiliser spool Unloader section Tilt spool Auxiliary spool Extension spool Lift spool MRV (260 bar) Pressure maintaining valve (10 bar) Pressure reducing valve (20 bar) Tilt ARV Port B (330 bar) Tilt ARV Port A (276 bar) Auxiliary ARV Port B ( 138 bar) Auxiliary ARV Port A (138 bar) Load hold check valves (LHCV) Tilt isolator section Sway control valve Sway cylinder Pilot operated check valve One way restrictor Left hand stabiliser cylinder Stabiliser lockout valve Pressure switch (35 bar) Right hand stabiliser cylinder Stabiliser lockout valve Pressure switch (35 bar) Stabiliser isolation valve Tilt cylinder Counterbalance valve Displacement cylinders Restricted check-valve Auxiliary connectors, inner boom section Auxilliary high flow connectors, outer boom section (if fitted) Inner extension cylinder 22A 23 24 24A 24B 25 25A 26 26A 26B 26C 26D 26E 26F 26G 26H
From m/c no. 780925
Counterbalance valve Boom section diverter valve Outer telescopic extension cylinder Regeneration valve Pressure switch (100 bar) Lift cylinder Counterbalance valve Servo diverter valve Filter Check valve Test point Accumulator Control isolate valve Lift isolate valve Crowd isolate valve Dump isolate valve
10 10A 10B 10C 10E 11 11A 11B 11C 11D 11E 11F 11G 11H 11J 11K 11L 11M 11N 11P 11Q 11R 12 13 13A 13B 14 14A 14B 15 15A 15B 16 17 17A 18 19 20 21 22
9804/1103
20 - 20 - 02/60
3660 - C/52-2.2 3660 - E/52-3.2
Issue 1
CONTENTS
Loadalls
20 - 20 - 02/61
533-105 Machines (from serial No. 786756) Circuit Diagram - Hydraulics

Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The pump assembly comprises two sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/auxiliary options 1B Fan motor The pump has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve oil flows from the EF port to the control valve to provide loading services. Component Key B Pressure cap breather F Return line filter F1 Filter by-pass F2 Direct return to tank S Pump suction strainer T Tank N1 Neutral circuit feed line N2 Neutral circuit return line 1 Pump assembly 1A Main pump 1B Fan pump 1D Priority valve 1E Test point 2 Valve block 2A Main relief valve 2D Lift spool 2E Extend spool 2F Tilt spool 2G Auxiliary spool 2H Auxiliary relief valve (ARV) 2J Auxiliary relief valve (ARV) 2K Auxiliary relief valve (ARV) 2L Auxiliary relief valve (ARV) 2M Load hold check-valves (LHCVs) 3 Steer unit assembly 3A Steering valve 3B Main relief valve 3C Shock valves 3D Non return valve 4 Cooling fan motor (non-reversible) 4A Relief valve (108 bar) 5 Reversible cooling fan motor option 5A Relief valves (108 bar) 5B Fan reversing valve 10 Left stabilizer ram 10A Left stabilizer lock out valve 10B Pressure switch 11 Right stabilizer ram 11A Right stabilizer lock out valve 11B Pressure switch (optional) 12 Auxiliary 1 boom quick release couplings (standard build) 15A Hydraulic ram pin lock 15B Restrictor 15C Manual changeover valve 15D Auxiliary 2 boom quick release couplings 16 Rear power track rod 17 Steer mode valve 17A 2 wheel steer solenoid 17B 4 wheel and grab steer solenoid 17C 4 wheel steer solenoid 17D Crab steer solenoid 18 Front power track rod 21 High flow auxiliary (option) 22 Inner extension ram 23 Extension ram check/counter balance valve 24 Outer extension ram 24A Bleed point 25 Regenerative valve 26 Tilt ram 27 Tilt check/counterblance valve 28 Displacement ram 29 Displacement lift valve 30 Lift ram 31 Lift check/counterbalance valve
9804/1103
20 - 20 - 02/61
3630 - E/5-17.1
Issue 1*
CONTENTS
Loadalls
20 - 20 - 02/62
533-105 Machines Circuit Diagram - Hydraulic
17
18
2
A
10A 10
5 2M
B A
2Q
10B
5B 2P
A B
11A 11 11B 15C 15B 15A
5A 3
L R
2M 4
3C 2N 3A 4A
LS A
12
15D
2G 1E
LS P EF
2K
2L
3D P
3B
2M 2H 2J
A B
21 2F
1 2M 1A
25 24 23 22
1C 1B
16 36
2E
2280 RPM
2M
A
F 2M F1 S
2D
28
27
26
T F2 N1 N2
P
2A
T
29
30 31
160-13379
9804/1103
20 - 20 - 02/62
3660 - E/5-17.1
Issue 1*
CONTENTS
RTFL
Contents 1
926, 930 Contents

Page No. General Information - Fluids, Lubricants and Capacities (926, 930) - Fluids, Lubricants and Capacities - (926, 930, 940 N.Am) - Static Dimensions (926, 930) - Static Dimensions (926, 930, 940 N.Am) Data - Electrical - Hydraulic - Transmission - Brakes - Steering - Engine Fault Finding - Transmission
* Circuit Diagrams
95 - 00 - 01/1,2 95 - 00 - 01/3,4 95 - 00 - 02/1,2 95 - 00 - 02/3,4
95 - 05 - 01/1 to 5 95 - 05 - 02/1,2 95 - 05 - 03/1 95 - 05 - 04/1 95 - 05 - 05/1,2 95 - 05 - 06/1
95 - 10 - 01/1 to 3
- Electrical - Hydraulic
95 - 15 - 01/1 to 8 95 - 20 - 01/1,2
9804/1103
RTFL Contents - 1
Issue 2*
CONTENTS
RTFL
95 - 00 - 01/1
926 from m/c 602000 930 from m/c 607700 Fluids, Lubricants & Capacities (Type AA Engine Builds)
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Mutigrade oil. This oil should be drained after the first 100 hours of operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Mutigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM CAPACITY Litres (Gal) 88 (19.3) 10.5 (2.3) FLUID/LUBRICANT INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40 API CF4/SG SAE10W/30 API CF4/SG ASTM D3306-74
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)
Engine (Coolant)
17 (3.7)
Transmission (2WD) Transmission (4WD) Front Axle Rear Axle (4WD) Differential Hubs (x2) Brake System
17.3 (3.8) 18.3(4) 29.5 (6.5)
ESP-M2C 33G
JCB High Performance Gear Oil
ESEN-M2C 86A/B
15 (3.3) 1.3 (0.3)
JCB HD90 Gear Oil
API GL-5
JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID 64 (14) JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Special Hydraulic Fluid (Below 38 C, 100 F)
ISO VG15
Hydraulic System
ISO VG46
ISO VG32
Grease Points and Fork Pivot Pins Mast Chains
JCB HP Grease
JCB Chain Lubricant
Note: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Watch level sight glass when filling.
9804/1103
95 - 00 - 01/1
7576 - 108
Issue 1
CONTENTS
RTFL
95 - 00 - 01/2
926 from m/c 602000 930 from m/c 607700 Fluids, Lubricants & Capacities (Type AR Engine Builds)
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Mutigrade oil. This oil should be drained after the first 100 hours of operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Mutigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM CAPACITY Litres (Gal) 88 (19.3) 10.5 (2.3) FLUID/LUBRICANT INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40 API CF4/SG SAE10W/30 API CF4/SG ASTM D3306-74
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)
Engine (Coolant)
17 (3.7)
17.3 (3.8) 18.3(4) 29.5 (6.5)
ESP-M2C 33G
JCB High Performance Gear Oil
ESEN-M2C 86A/B
15 (3.3) 1.3 (0.3)
JCB HD90 Gear Oil
API GL-5
JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID 64 (14) JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Special Hydraulic Fluid (Below 38 C, 100 F)
ISO VG15
Hydraulic System
ISO VG46
ISO VG32
Grease Points and Fork Pivot Pins Mast Chains
JCB HP Grease
JCB Chain Lubricant
9804/1103
95 - 00 - 01/2
7576 - 109
Issue 1
CONTENTS
RTFL
95 - 00 - 01/3
926 (N. Am) from m/c 603110 to 605999 and from m/c 660300 930 (N. Am) from m/c 608300 to 609999 and from m/c 660300 940 (N. Am) from m/c 660001 Fluids, Lubricants & Capacities (Type AA Engine Builds)
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Mutigrade oil. This oil should be drained after the first 100 hours of operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Mutigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM CAPACITY FLUID/LUBRICANT US Gal (Liters) 23.25 (88) 2.8 (10.5) Diesel Oil (See Types of Fuel) JCB Super Multigrade 15W/40 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) 4.5 (17) JCB For Seasons Antifreeze And Summer Coolant (See Coolant Mixtures) JCB Special Transmission Fluid INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40 API CF4/SG SAE10W/30 API CD/SF SAE10W API CD/SF ASTM D3306-74
5.0 (18.9) 5.5 (20.8) 7.8 (29.5)
ESP-M2C 33G
ESEN-M2C 86A/B
4.0 (15) 0.4 (1.3)
JCB HD90 Gear Oil
API GL-5
JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID 16.9 (64) JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Special Hydraulic Fluid (Below 38 C, 100 F)
ISO VG15
Hydraulic System
ISO VG46
ISO VG32
Grease Points and Fork Pivot Pins Mast Sideshift Carrier Mast Chains
JCB HP Grease
JCB Waxoyl JCB Chain Lubricant
9804/1103
95 - 00 - 01/3
7591 - 107
Issue 1
CONTENTS
RTFL
95 - 00 - 01/4
926 (N. Am) from m/c 603110 to 605999 and from m/c 660300 930 (N. Am) from m/c 608300 to 609999 and from m/c 660300 940 (N. Am) from m/c 66001 Fluids, Lubricants & Capacities (Type AR Engine Builds)
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Mutigrade oil. This oil should be drained after the first 100 hours of operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Mutigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM CAPACITY FLUID/LUBRICANT US Gal (Liters) 23.25 (88) 2.8 (10.5) Diesel Oil (See Types of Fuel) JCB Super Multigrade 15W/40 14 F to 122 F (-10 C to 50 C) JCB Super Multigrade 10W/30 5 F to 104 F (-15 C to 40 C) Engine (Coolant) 4.5 (17) JCB Four Seasons Antifreeze And Summer Coolant (See Coolant Mixtures) 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
5.0 (18.9) 5.5 (20.8) 7.8 (29.5)
ESP-M2C 33G
ESEN-M2C 86A/B
4.0 (15) 0.4 (1.3)
JCB HD90 Gear Oil
API GL-5
JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID 16.9 (64) JCB High Performance Hydraulic Oil (Above 38 C, 100 F) JCB Special Hydraulic Fluid (Below 38 C, 100 F)
ISO VG15
Hydraulic System
ISO VG46
ISO VG32
Grease Points and Fork Pivot Pins Mast Sideshift Carrier Mast Chains
JCB HP Grease
JCB Waxoyl JCB Chain Lubricant
9804/1103
95 - 00 - 01/4
7591 - 108
Issue 1
CONTENTS
RTFL
95 - 00 - 02/1
926 from m/c 602000 930 from m/c 607700 Static Dimensions
H A G F C D E B
151800
9804/1103
95 - 00 - 02/1
7576 - 111
Issue 1
CONTENTS
RTFL
95 - 00 - 02/2
926 from m/c 602000 930 from m/c 607700 Static Dimensions (contd)
Note: Unless otherwise indicated the following data applies to both the 926 and 930 machines. A B C D E F Overall cab height Overall width (over tyres) Overall length to front carriage (industrial or bar) Inside width of cab Front track Wheel base (2 wheel drive) (4 wheel drive) Ground clearance (2 wheel drive) (4 wheel drive) Mast Closed Height 3.6 m mast 4.5 m mast 5.5 m mast 6.55 m mast Mast Open Height 3.6 m mast 4.5 m mast 5.5 m mast 6.55 m mast Free lift (4.5 m mast only) Mast Tilt Forwards Mast Tilt Backwards 2.57 m 2.20 m 3.60 m 1.16 m 1.80 m 2.07 m 2.13 m 0.37 m 0.37 m 2.95 m 2.41 m 2.95 m 3.32 m 4.78 m 5.41 m 6.61 m 7.67 m 1.46 m 18 10 (8 ft 5 in) (7 ft 3 in) (11 ft 10 in) (3 ft 10 in) (5 ft 11 in) (6 ft 10 in) (7 ft 0 in) (1 ft 2 in) (1 ft 2 in) (9 ft 8 in) (7 ft 10 in) (9 ft 8 in) (10 ft 11 in) (15 ft 8 in) (17 ft 9 in) (21 ft 8 in) (25 ft 2 in) (4 ft 10 in)
K L
Forklift Performance
Outside turning radius (2 wheel drive) (4 wheel drive) Departure angle - 926 machine (2 wheel drive) (4 wheel drive) Departure angle - 930 machine (2 wheel drive) (4 wheel drive) Obstruction angle (2 wheel drive) (4 wheel drive) Lift capacity Lift height 3.6 m 4.49 m 46 53 38 43 57 51 See Rating Plate (11 ft 10 in) (14 ft 9 in)
Weight (With Cab and 5.5 m Mast)

926 Machine 2 Wheel drive 4 Wheel drive 930 Machine 2 Wheel drive 4 Wheel drive 5880 kg 5910 kg (12966 lb) (13032 lb)
6310 kg 6380 kg
(13914 lb) (14068 lb)
Note: The above data is based on a standard fork size of 1067 mm x 100 mm x 50 mm (42 in x 4 in x 2 in)
9804/1103
95 - 00 - 02/2
7576 - 112
Issue 1
CONTENTS
RTFL
95 - 00 - 02/3
926 (N. Am) from m/c 603110 to 605999 and from m/c 660300 930 (N. Am) from m/c 608300 to 609999 and from m/c 660300 940 (N. Am) from m/c 660001 Static Dimensions
J L
H E F G
9804/1103
95 - 00 - 02/3
7576 - 110
Issue 1
CONTENTS
RTFL
95 - 00 - 02/4
926 (N. Am) from m/c 603110 to 605999 and from m/c 660300 930 (N. Am) from m/c 608300 to 609999 and from m/c 660300 940 (N. Am) from m/c 660001 Static Dimensions (contd)
926 A B C D E Height to top of cab Overall width (over tires) Inside width of cab Front track Wheel base (2-Wheel drive) (4-Wheel drive) Overall length to front tires Overall length to front of carriage Ground clearance (2-Wheel drive) (4-Wheel drive) WEIGHT (With Cab) 2- Wheel drive 4- Wheel drive 2- Wheel drive & 12 ft mast 4- Wheel drive & 12 ft mast 2- Wheel drive & 21 ft 6 in mast 4- Wheel drive & 21 ft 6 in mast FORKLIFT PERFORMANCE Outside turning radius, unbraked (2-Wheel drive) (4-Wheel drive) Lift capacity Lift height Mast tilt Maximum tilt forward (jobsite) Maximum tilt forward (transporting) Maximum tilt back See Rating Plate 12520 lb (5679 kg) 12860 lb (5834 kg) 13305 lb (6035 kg) 13645 lb (5989 kg) 8 ft 5 in (2.565 m) 7 ft 5 in (2.26 m) 3 ft 7 in (1.1 m) 6 ft 2 in (1.88 m) 6 ft 9 in (2.06 m) 7 ft 0 in (2.13 m) 11 ft 1 in (3.3 m) 11 ft 11 in (3.6 m) 0 ft 11 in (280 mm) 0 ft 11 in (280 mm) 930 8 ft 5 in (2.565 m) 7 ft 11 in (2.41 m) 3 ft 7 in (1.1 m) 6 ft 2 in (1.88 m) 6 ft 10 in (2.07 m) 7 ft 0 in (2.13 m) 11 ft 1 in (3.3 m) 11 ft 11 in (3.6 m) 1 ft 3 /4 in (400 mm) 0 ft 11 in (280 mm)
3
940 8 ft 5 in (2.565 m) 3 7ft 5 /4 in (2.279 m) 3 ft 7 in (1.1 m) 6 ft 2 in (1.88 m) 7ft 1 in (2.159 m) 7ft 21/2 in (2.197 m) 11 ft 1 in (3.3 m)
F G H
1ft 4 in (406 mm) 1 ft 01/2 in (318 mm)
15036 lb (6820 kg) 15991 lb (7253 kg)
14,740 lb (6,700kg)
11 ft 10 in (3.6 m) 3 14 ft 8 /4 in (4.49 m) 20 37 10
11 ft 10 in (3.6 m) 3 14 ft 8 /4 in (4.49 m) 20 37 10
12 ft 5 in (3.789 m) 14 ft 9 in (4.495 m) 20 42 9.5
K L M
9804/1103
95 - 00 - 02/4
7591 - 111
Issue 1
CONTENTS
RTFL
95 - 05 - 01/1
926, 930 Data - Electrical

System Type Battery Cranking Performance at - 18 C (0 F) Reserve capacity (minutes) for 25 amp load Alternator Starter Motor Light Bulbs Headlights Side/tail lights Stop lights Reversing light Direction indicators Number plate light Instruments Beacon 60/55 W H4 Halogen 5 W SBC 21 W SBC 21 W SBC 21 W SBC 10 W 3W 55 W Halogen 12 volt, negative earth 410 amps to 1.4 V.P.C. 180 Lucas A127-65, 65 amp maximum output Lucas M127
IP67 Electrics Machines from serial No. 602902 (926) and 608656 (930) are fitted with IP67 electrics which features different loom construction and method of attachment.
9804/1103
95 - 05 - 01/1
5100 - 10/1-1.2
Issue 1
CONTENTS
RTFL
95 - 05 - 01/2
926, 930 Data - Electrical Fuses
To m/c no. 602073 (926), 607717 (930)
The electrical circuits are protected by fuses. The fuses are located in a fuse box near the instrument panel. They are in two rows, labelled A and B. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one. Circuit Protection
Fuse Number A1 A2 A3 A4
Circuits
Fuse Rating (Amps) 10 10 10 10
Dip Beam - left hand Dip Beam - right hand Main Beam - left hand Main Beam - right hand Main Beam Warning Light Roof Wiper Rear Wiper Beacon Hazard Warning Lights Back-up Alarm Transmission Solenoids Parking Brake Buzzer Engine Shut Off Solenoid Sidelights - left hand Sidelights - right hand Heater Direction Indicators Gauges Parking Brake Light Instrument Panel Warning Lights Brake Lights Horn Washer Front Wiper Headlight Flasher
A5
10
A6 B1
10 10
B2 B3 B4
10 10 10
B5
10
B6
10
9804/1103
95 - 05 - 01/2
5100 - 10/1-2.2
Issue 1
CONTENTS
RTFL
95 - 05 - 01/3
From m/c no. 602074 (926), 607718 (930) & machines with IP67 Electrics
The electrical circuits are protected by fuses. The fuses are located in fuse boxes near the instrument panel. They are in three rows, labelled A, B and C. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one. Circuit Protection Fuse Number A1 A2 A3 A4 Circuits Fuse Rating (Amps) 10 10 10 10
Dip Beam - left hand Dip Beam - right hand Main Beam - left hand Main Beam - right hand Main Beam Warning Light Rear Wiper Beacon or as above plus Roof Wiper Hazard Warning Lights Forward/Reverse Solenoids via Relays Sidelights - left hand Sidelights - right hand Number Plate Light Heater Gauges Parking Brake Light Instrument Panel Warning Lights Brake Lights Horn Front Wiper Direction Indicators Engine Shut-Off Solenoid Back-Up Alarm Reversing Light Circuit Headlight Flasher
A5
10 15 10 10
A6 B1
B2 B3
10 10
B4 B5
10 10
B6
10
126820
C1 C2
5 5
C3
10
9804/1103
95 - 05 - 01/3
5100 - 10/1-3.3
Issue 1
CONTENTS
RTFL
95 - 05 - 01/3A

The electrical circuits are protected by fuses. The primary fuses are located in the engine bay adjacent to the battery. The individual circuit fuses are located in fuse boxes near the instrument panel. They are in two rows labelled A and B. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one. PRIMARY FUSES PR1 Feeding circuit fuses B1 - B4 PR2 Feeding circuit fuses A7 - A9, B5 - B7 PR3 Feeding ignition switch, circuit fuses A1 - A6 PR4 Feeding air conditioning
From m/c no. TBA
50A 60A 70A 60A
CIRCUIT FUSES Row A A1 Transmission A2 Instrumentation A3 Brake Lights A4 ESOS/Cold Start Advance A5 Rear/Roof Wiper, Face Fan (Option) A6 Front Wipe/Wash A7 Beacon A8 Hazard Warning Lights A9 Horn, Headlamp Flash A10 Thermostart Row B B1 Direction Indicators B2 Dip Beam B3 Worklamp B4 Heater Fan B5 Left Hand Sidelights B6 Right Hand Sidelights B7 Fog Light B8 Not used B9 Not used B10 Not used
7.5A 5A 7.5A 10A 10A(15A) 10A 7.5A 10A 15A 20A
PR1
50A 60A
PR2
7.5A 15A 10A 10A 5A 5A 5A
70A
817/17132
60A
PR3
PR4
A370770
9804/1103
95 - 05 - 01/3A
5100 - 10/1-6.1
Issue 1
CONTENTS
RTFL
95 - 05 - 01/4
926, 930 Data - Electrical Relay Location

The relays are located as follows: A B C D E F G Neutral start relay Flasher relay Reverse alarm relay Side lights relay Parking brake relay Forward relay Reverse relay
9804/1103
95 - 05 - 01/4
5100 - 10/1-4.1
Issue 1
CONTENTS
RTFL
95 - 05 - 01/5

The electrical circuits are protected by fusews. The fuses are located in fuse boxes near the instrument panel. They are in three rows, labelled A, B and C. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one. ROW A Circuit 1 2 3 4 5 6 Brake Light Rotation Beacon Laft hand sidelights Right hand sidelights Engine shut-off Solenoid (ESOS) Hazard Warning Lights Rating 7.5A 7.5A 5A 5A 5A 10A
From m/c 664290
Relay Location
A B C D E F G H Buzzer Flashers Parbrake lamp Ignition Neutral start Transmission dump Foeward Reverse
ROW B Circuit Heater Fan Warning Lights Dip beam Main beam Worklamp Direction Indicators Rating 15A 5A 15A 15A 7.5A 7.5A
1 2 3 4 5 6
ROW C Circuit Front wash/wipe Horn/headlamp flash Transmission Thermostart Rear/roof wiper - with fan level fan Main lighting Rating 7.5A 15A 10A 20A 10A 15A 25A
1 2 3 4 5 6
9804/1103
95 - 05 - 01/5
5100 - 10/1-5.1
Issue 1
CONTENTS
RTFL
95 - 05 - 02/1
926, 930 940 (N. Am. only) Data Hydraulic

Pump Type Flow at MRV pressure Control Valves Type build. Spool 1 Spool 2 Spool 3 Relief Valve Operating Pressures Main Relief Valve (M.R.V.) Carriage Lift A.R.V. (UK and Rest of World) - JCB 926, 3.6 m Mast - JCB 926, 4.5 m Free Lift Mast - JCB 926, 5.5 & 6.55 m Masts - JCB 930, 3.6 m Mast - JCB 930, 4.5 m Free Lift Mast - JCB 930, 5.5 & 6.55 m Masts Carriage Lift A.R.V. (North America Machines only) - 926, 144 Standard 2-rail Mast - 926, 171 Duplex 2-rail Mast - 926, 258 3-rail Mast - 930, All Masts - JCB 930, Sideshift 11 ft 9 in Duplex Mast - JCB 930, Sideshift 14 ft 9 in Free Lift Mast - JCB 930, Sideshift 21 ft 6 in Mast - JCB 930, 28 ft Mast - 940, All Masts Sundstrand gear AFGP25L27689 55 litres/min 12 UK gal/min 14 US gal/min
Kontak Unit 18 Sectional, two to four spools according to Double-acting, carriage lift. Double-acting, mast tilt. Double-acting, attachments as required. bar 220 kgf/cm@ 225 lbf/in@ 3200
138 207 193 152 234 172
141 211 197 155 239 176
2000 3000 2800 2200 3400 2500
110 131 134 128 145 234 207 162 155
113 134 137 130 148 239 211 165 159
1600 1900 1940 1850 2100 3400 3000/3050 2350 2250
Note: For North America machines with JCB masts, refer to UK and Rest of World A.R.V. settings. Multi-hitch A.R.V.'s (top & bottom) Other Attachments Sideshift A.R.V. (North America only) - Top Port - Bottom Port Deration Relief Valve - JCB 926, 5.5 m Mast - JCB 926, 6.55 m Mast - JCB 926, 6.55 m Mast (narrow track) - JCB 930, 5.5 m Mast - JCB 930, 6.55 m Mast - JCB 930, 6.55 m Mast (narrow track) 172 145 158 124 179/183 155/159 145/148 152/155 134/138 121/124 176 148 161 126 183/186 158/162 148/151 155/158 137/141 123/126 2500 2100 2300 1800 2600/2650 2250/2300 2100/2150 2200/2250 1950/2000 1750/1800
Tilt A.R.V. 69 70 1000 Note: All hydraulic pressure settings to be carried out at maximum engine revs and hydraulic oil hot at 40 C. Rams JCB 926 3.6 m Mast - Lift - Tilt 4.5 m Mast - Lift (outer) - Lift (centre) - Tilt 5.5 m Mast - Lift - Tilt 6.55 m Mast - Lift - Tilt
9804/1103
Bore mm in 60 2.3 70 2.8 60 2.3 82 3.2 70 2.8 60 2.3 70 2.8 60 2.3 70 2.8
Rod Dia mm in 50 1.9 40 1.6 50 1.9 80 3.1 40 1.6 50 1.9 40 1.6 50 1.9 40 1.6
Stroke mm in 1833 72.2 254 10.0 1525 60.0 725 28.5 254 10.0 1833 72.2 254 10.0 2172 85.5 254 10.0
5100 - 2/1-1.6
95 - 05 - 02/1
Issue 1
CONTENTS
RTFL
95 - 05 - 03/1
926, 930 940 (N. Am. only) Data Transmission

Syncro Shuttle Torque Converter Diameter. Torque Multiplication at Stall Minimum Engine Speed at Converter Stall Gear Ratios 1st 2nd 3rd 4th 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 Combined torque converter, reverser and gearbox unit with optional four wheel drive output. 279 mm (11 in) 2.2 : 1 1650 - 1750 rev/min 5.55 : 1 3.45 : 1 1.83 : 1 1.00 : 1 bar 2.4 - 3.4 5.9 - 7.9 1.3 - 2.0 5.2 - 5.9 1.0 - 1.7 2.1 - 3.1 0.3 - 0.6 1.0 - 1.7 7.9 kgf/cm2 2.5 - 3.5 6.0 - 8.1 1.4 - 2.1 5.3 - 6.0 1.1 - 1.8 2.1 - 3.2 0.3 - 0.6 1.1 - 1.8 8.1 lbf/in2 35 - 50 85 - 115 20 - 30 75 - 85 15 - 25 30 - 45 4-8 15 - 25 115
Converter Out at 50 deg C Converter Out at 100 deg C
Converter Inlet Protection Pressure (max.) Lubrication Pressures (in neutral) At 50 deg C 1000 rev/min 2000 rev/min 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
3-5 6 - 10 2-3 4-8
At 100 deg C
Main Line Pressure 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 8.3 - 9.0 9.0 - 10.0 8.3 - 9.0 8.3 - 9.0 l/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 11.4 - 13.6 20.5 - 22.7 10.2 - 12.5 22.7 - 26.1 11.0 - 15.0 22.5 - 29.5 8.4 - 9.1 9.1 - 10.2 8.4 - 9.1 8.4 - 9.1 UK gal/min 2.5 - 3.0 4.5 - 5.0 2.25 - 2.75 5.0 - 5.75 2.5 - 3.3 5.0 - 6.5 120 - 130 130 - 145 120 - 130 120 - 130 US gal/min 3.0 - 3.6 5.4 - 6.0 2.7 - 3.3 6.0 - 6.9 3.0 - 4.0 6.0 - 8.0
At 100 deg C
Flow Rates Cooler at 50 deg C Cooler at 100 deg C Pump at 50 deg C
9804/1103
95 - 05 - 03/1
5100 - 6/1-1.2
Issue 1
CONTENTS
RTFL
95 - 05 - 03/2
926, 930 940 (N. Am. only) Data Transmission (contd)

Drive Axle - Front Type Weight (approximate) Overall Gear Ratio Epicyclic 386 kg (852 lb) 18.16 : 1 24.975 : 1 German
Steering Axle - Rear (2WD) Weight with Steer Rams (but without wheels) Toe-in Camber Angle Castor Angle King-pin Angle Oscillation Steering Axle - Rear (4WD) Weight with Steer Rams (but without wheels) Overall Gear Ratio (JCB Syncro Shuttle) Crownwheel and Pinion Ratio Oscillation Castor Angle Camber Angle King-pin Inclination Toe-in Tyre Pressures Front 15.5/80 x 24 x 10 15.5 x 25 x 8 16.5/85 x 24 x 8 16.9 x 24 x 12 (926 only) Rear - JCB 926 9.00 x 16 x 8 10.5 x 18 x 10 11L x 16 x 10 12.5/80 x 18 x 8 12.5 x 18 x 10 12.5/80 x 18 x 10 14 x 17.5 x 10 (N. Am 4WD only) Rear - JCB 930 10.5 x 18 x 10 12.5/80 x 18 x 8 12.5 x 18 x 10 12.5/80 x 18 x 10 14 x 17.5 x 10 (N. Am 4WD only) 14.5/75 x 16.1 x 10 (N. Am 4WD only) Wheel Nut Torques Front lbf ft 500 Nm 678 lbf ft 500 Rear Nm 678 3.7 2.1 2.1 2.1 5.4 30 30 30 3.9 2.5 3.6 1.5 1.7 1.7 1.7 57 36 52 22 25 25 25 bar 3.0 3.0 3.0 2.0 lbf/in2 44 44 44 29 352 kg (776 lb) 18.6 : 1 3.44 : 1 9 2 2 Positive Zero Zero 278 kg (613 lb) Zero 3 Positive 2 Zero + 6
9804/1103
95 - 05 - 03/2
5100 - 7/1-1.3
Issue 1
CONTENTS
RTFL
95 - 05 - 04/1

Service Brakes Type Actuation Location Friction Plates (5 per brake pack) Outside Diameter Inside Diameter Nominal Facing Area Hydraulic Piston Diameter Master Cylinder, Single Brake Pedal Machines Piston diameter (each) Piston Area (each) Pedal Ratio Master Cylinder, Dual Brake Pedal Machines Total Stroke Parking Brake Type Disc Diameter Manually Adjusted Caliper 279.4 mm (11 in) 35 mm (1.4in) 28.58 mm (1.125 in) 641.4 mm (0.994 in2) 5.1 : 1 JCB Oil-Immersed Multi-plate Disc Hydraulic Front Axle 222 mm (8.74 in) 180 mm (7.10 in) 13266 mm2 (20 in2) 216 mm (8.5 in)
9804/1103
95 - 05 - 04/1
5100 - 8/1-1.5
Issue 1
CONTENTS
RTFL
95 - 05 - 05/1
926, 930 Data - Steering

System Type Pump Controlled Flow at 1300 engine rev/min and neutral pressure Total Flow through tank return line at 2200 engine rev/min (pressure outlet blocked) Relief Valve Operating Pressure Control Unit Ram Dimensions (2 Wheel Drive) Bore Rod Dia. Stroke Ram Dimensions (4 Wheel Drive) Bore Rod Dia. Stroke
To m/c nos. 602749 (926), 608299 (930)
Full power hydrostatic A12.5/29926, gear type litres/min UK gal/min 27.5 6.0 45.5 10.0 120 bar (123 kgf/cm2; 1750 lbf/in2) Danfoss Orbitrol OSPB 160 50.8 mm (2.0 in) 25.4 mm (1.0 in) 275 mm (10.83 in) 50.0 mm (1.97 in) 25.0 mm (0.98 in) 250 mm (9.84 in)
9804/1103
95 - 05 - 05/1
5100 - 9/1-1.2
Issue 1
CONTENTS
RTFL
95 - 05 - 05/2

System Type Pump Control Unit Type 2 Wheel Drive Control Unit Type 4 Wheel Drive Priority Valve Type Relief Valve Operating Pressure Shock Relief Valve Operating Pressure 2 Wheel Drive 4 Wheel Drive Ram Dimensions (2 and 4 Wheel Drive) Bore Rod Dia. Stroke
From m/c no. 602750 to 602797 (926), 608300 to 608418 (930)
Full power hydrostatic (see Data - Hydraulics) OSPC 160 OSPC 200 OLSB 80 150 bar (153 kgf/cm2; 2175 lbf/in2) 250 bar (255 kgf/cm2; 3625 lbf/in2) 240 bar (245 kgf/cm2; 3480 lbf/in2) 50.0 mm (1.97 in) 25.0 mm (0.98 in) 275 mm (10.83 in)

System Type Pump Control Unit Type 2 Wheel Drive Control Unit Type 4 Wheel Drive Priority Valve Type Relief Valve Operating Pressure Shock Relief Valve Operating Pressure 2 Wheel Drive 4 Wheel Drive Ram Dimensions (2 Wheel Drive) Bore Rod Dia. Stroke Ram Dimensions (4 Wheel Drive) Bore Rod Dia. Stroke
From m/c no. 602798 (926), 608419 (930)
Full power hydrostatic (see Data - Hydraulics) OSPC 160 OSPC 200 OLSB 80 150 bar (153 kgf/cm2; 2175 lbf/in2) 250 bar (255 kgf/cm2; 3625 lbf/in2) 240 bar (245 kgf/cm2; 3480 lbf/in2) 70.0 mm (2.75 in) 30.0 mm (1.18 in) 275 mm (10.83 in) 70.0 mm (2.75 in) 30.0 mm (1.18 in) 290 mm (11.42 in)
9804/1103
95 - 05 - 05/2
5100 - 9/1-2.2
Issue 1
CONTENTS
RTFL
95 - 05 - 06/1
926, 930 Data - Engine

Type Perkins 1000 Series 4 cylinder Engine AA - 50430, naturally aspirated AR - 50681, naturally aspirated (low emission) AA Build (76 HP) 100 mm (3.937 in) 127 mm (5.000 in) 4 litres (243 in3) 16.5:1 20-30 bar (300-450 lbf/in2) 1,3,4,2 0.20 mm (0.008 in) 0.45 mm (0.018 in) 750 rev/min 2000 rev/min 2420 rev/min AR Build (75 HP) 103 mm (4.055 in) 127 mm (5.000 in) 4.23 litres (258 in3) 18.5:1 25-35 bar (375-525 lbf/in2) 1,3,4,2 0.20 mm (0.008 in) 0.45 mm (0.018 in) 750 rev/min 2200 rev/min 2350 rev/min
Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance - Hot or Cold Idling Speed Max. Governed Speed Max. No Load Speed Fuel System Injection Pump Type Governing Injector Pump Setting Code Injection Timing Injector Setting Pressure Injector Codes
- Inlet - Exhaust
CAV DPA Mechanical DM55L/1000/1/2420 16 deg BTDC 220 atm HZ
Lucas DP203 Mechanical 2644G002RG/2350 3 deg BTDC Dynamic 290 atm KW
For further engine details see Engine Manual Publication No. 9806/0100 for AA Engine builds 9806/2140 for AR Engine builds
9804/1103
95 - 05 - 06/1
5100 - 5/1-1.4
Issue 1
CONTENTS
RTFL
95 - 10 - 01/1
926, 930 Fault Finding - Transmission

Before carrying out the checks listed the machine should, if possible, be operated to determine the fault area(s), and bring the systems to their normal working temperatures. Ensure that the correct quantity and grade of oil is used and that there are no obvious leaks. A 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 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
Is there noise when running with direction selector in neutral and ratio selector in 1st? Is there air in the hydraulic system?
Is pump pressure as specified? free
10
11
Are the pump bushes worn? restriction to flow.
12
YES: Check 16 NO: Check 13 YES: Stall test machine, Check 14 NO: Check 16
13 .
9804/1103
95 - 10 - 01/1
5100 - 6/4-1.1
Issue 1
CONTENTS
RTFL
95 - 10 - 01/2
926, 930 Fault Finding - Transmission (contd)
CHECK 14 Is 'converter in' pressure as specified?
ACTION YES: Check 15 NO: Inspect converter relief valve for damage. YES: Check pump pressure. NO: Renew damaged parts. YES: Tap pressure gauge into clutch feed lines to NO: Check clutch plates for damage.
15
16
Are clutch sealing rings damaged? monitor pressure.
17
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
18
19
20
21
22
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
26
27
28
29
30
31
32 .
9804/1103
95 - 10 - 01/2
5100 - 6/4-2.1
Issue 1
CONTENTS
RTFL
95 - 10 - 01/3
926, 930 Fault Finding - Transmission (contd)
CHECK 33 Are the selector rods worn or damaged?
ACTION YES: Renew. NO: Check 34 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 NO: Check 38
34
35
36
37
Are steel chips embedded in the bronze? bronze or be rejected.
38
Are the synchroniser components damaged? damage.
YES: Renew. NO: Check free running gears for seizure or
39
YES: Free or renew. NO: Check 40 YES: Remove chips. NO: Ensure that clutch is disengaged when dump
40
Are chips wedged between splines of shaft or gear? pedal is pressed. Are steel chips embedded in the bronze? bronze or be rejected.
41
YES: Continue using, chips will either embed below NO: Check 42
42
YES: Renew synchro. NO: Check 43 YES: Renew synchro. NO: Check blocker pins.
43
9804/1103
95 - 10 - 01/3
5100 - 6/4-3.1
Issue 1
CONTENTS
RTFL
95 - 15 - 01/1
926 to m/c 602902 930 to m/c 608656 Circuit Diagram - Electrical

Machines without IP67 electrics
9804/1103
95 - 15 - 01/1
5100 - 10/7-1.2
Issue 1
CONTENTS
RTFL
95 - 15 - 01/2
926 to m/c 602902 930 to m/c 608656 Circuit Diagrams -Electrical (contd)
Machines without IP67 electrical Main Components & Switches 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 50 51 52 53 54 55 56 57 Battery Starter Solenoid Starter Motor Starter Switch Thermostart Fuse B4 Heater Switch Resistor Heater Motor Fuse B6 Horn Push Horn Wash/Wiper Switch Washer Pump Front Wiper Hazard Warning Switch Indicator Relay Direction Indicator Switch Fuse A6 Fuse A5 Rear Wiper Roof Wiper Beacon Engine Stop Solenoid Fuse C1 Fuse C2 Back-up Alarm Relay Back-up Alarm Fuse B1 Forward/Reverse Switch Parking Brake Buzzer Relay Forward Relay Reverse Relay Diode Reverse Solenoid Forward Solenoid Dump Switch Parking Brake Switch Fuse B5 Brake Switch Fuel Gauge Fuel Gauge Sender Air Filter Switch Oil Pressure Switch Transmission Oil Temperature Switch Transmission Oil Pressure Switch Water Temperature Switch Diode Alternator Hourmeter Hourmeter Diode Bank Buzzer Fuse C3 Headlight Flasher Switch Dip Switch Fuse A4 Fuse A3 58 59 60 61 62 63 64 65 66 67 Fuse A2 Fuse A1 Fuse B3 Fuse B2 Road Lights Switch Side Lights Relay Diode Diode Neutral Start Relay Battery Isolator (optional)
Lights 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 Direction Indicator Warning Hazard Warning L.H. Front Indicator L.H. Rear Indicator R.H. Front Indicator R.H. Rear Indicator Rear Working R.H. Stop L.H. Stop Beacon Blocked Air Filter Warning Engine Oil Pressure Warning Transmission Oil Temperature Warning Transmission Oil Pressure Warning Engine Coolant Temperature Warning Alternator Warning Parking Brake Warning Fuel Gauge/Hourmeter Illumination L.H. Side L.H. Tail R.H. Side R.H. Tail Number Plate Light L.H. Dip Beam R.H. Dip Beam L.H. Main Beam R.H. Main Beam Main Beam Warning Hazard Warning Switch Repeater Front Working Light (fitted to later machines)
Cable Colour Code B Black G Green K Pink LG Light Green N Brown O Orange P Purple R Red S Slate U Blue W White Y Yellow Note: On machines from No. 602750 (926) and 608300 (930) the fuse A5, 20 for the rear wiper 21 and roof wiper
9804/1103
95 - 15 - 01/2
5100 - 10/7-2.4
Issue 1
CONTENTS
RTFL
95 - 15 - 01/3
926 from m/c 602903 to 664289 930 from m/c 608657 to 664289 Circuit Diagrams - Electrical (contd) Machines with IP67 electerics
9804/1103
95 - 15 - 01/3
5100 - 10/7-3.2
Issue 1
CONTENTS
RTFL
95 - 15 - 01/4
926 from m/c 602903 to 664289 930 from m/c 608657 to 66289 Circuit Diagrams -Electrical (contd)
Machines without IP67 electrical Main Components & Switches 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 50 51 52 53 54 55 56 57 58 59 60 Battery Starter Solenoid Starter Motor Starter Switch Thermostart Fuse B4 Heater Switch Resistor Heater Motor Fuse B6 Horn Push Horn Wash/Wiper Switch Washer Pump Front Wiper Hazard Warning Switch Indicator Relay Direction Indicator Switch Fuse A6 Fuse A5 Rear Wiper Roof Wiper Beacon Engine Stop Solenoid Fuse C1 Fuse C2 Back-up Alarm Relay Back-up Alarm Fuse B1 Forward/Reverse Switch Parking Brake Buzzer Relay Forward Relay Reverse Relay Diode Reverse Solenoid Forward Solenoid Dump Switch Parking Brake Switch Fuse B5 Brake Switch Fuel Gauge Fuel Gauge Sender Air Filter Switch Oil Pressure Switch Transmission Oil Temperature Switch Transmission Oil Pressure Switch Water Temperature Switch Diode Alternator Hourmeter Hourmeter Diode Bank Buzzer Fuse C3 Headlight Flasher Switch Dip Switch Fuse A4 Fuse A3 Fuse A2 Fuse A1 Fuse B3 61 Fuse B2 62 Road Lights Switch 63 Side Lights Relay 64 Diode 65 Diode 66 Neutral Start Relay 67 Battery Isolator (optional) Lights 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 Direction Indicator Warning Hazard Warning L.H. Front Indicator L.H. Rear Indicator R.H. Front Indicator R.H. Rear Indicator Rear Working R.H. Stop L.H. Stop Beacon Blocked Air Filter Warning Engine Oil Pressure Warning Transmission Oil Temperature Warning Transmission Oil Pressure Warning Engine Coolant Temperature Warning Alternator Warning Parking Brake Warning Fuel Gauge/Hourmeter Illumination L.H. Side L.H. Tail R.H. Side R.H. Tail Number Plate Light L.H. Dip Beam R.H. Dip Beam L.H. Main Beam R.H. Main Beam Main Beam Warning Hazard Warning Switch Repeater Front Working Light (fitted to later machines)
Cable Colour Code B G K LG N O P R S U W Y Black Green Pink Light Green Brown Orange Purple Red Slate Blue White Yellow
9804/1103
95 - 15 - 01/4
5100 - 10/7-4.3
Issue 1
CONTENTS
RTFL
95 - 15 - 01/5
926, 930 Circuit Diagram - Electrical (contd)

From m/c 664290
9804/1103
95 - 15 - 01/5
5100 - 10/7-6.1
Issue 1
CONTENTS
RTFL
95 - 15 - 01/6
926, 930 Circuit Diagrams -Electrical (contd)

Machines without IP67 electrical
From m/c 664290
*Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Battery Thermostart Starter Motor Starter Solenoid Neutral start relay Starter Switch Dump pedal Forward/reverse switch Forward Relay Forward solenoid Reverse relay Transmission dump relay Reverse solenoid Reverse alarm Reverse lights - right hand side Reverse lights - left hand side Ignition relay Parking brake buzzer relay Parking brake switch Buzzer Parkbrake warning lamp Water temperature warning lamp Water temperature switch Transmission oil temperature warning lamp Transmission oil temperature switch Engine oil pressure warning lamp Engine oil pressure switch Transmission oil pressure warning lamp Transmission oil pressure switch Alternator warning lamp Alternator diode Hourmeter Alternator Brake lights switch Brake light - right hand Brake light - left hand Fuel gauge Fuel sender Engine shut-off solenoid (ESOS) Heater Switch Heater resistor Heater Motor Front indicator - right hand Rear indicator - right hand Hazard warning lights switch 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 Indicator switch Indicator repeater Front indicator - left hand Rear indicator - left hand Flasher unit Beacon Beacon switch Rear wiper motor Roof wiper motor Face fan motor - optional Front wash/wipe switch Washer pump Front wiper motor Horn switch Horn Main beam indication lamp Main beam - right hand Headlight flash Main beam - left hand Dip beam - right hand Dip beam - left hand Side lights - left hand Road light switch Main beam/dip beam switch Rear light - left hand Number plate light - left hand Side light - right hand Rear light - right hand Number plate light - right hand Worklight switch Worklight
9804/1103
95 - 15 - 01/6
5100 - 10/7-5.1
Issue 2*
OFF
IGN
START
PRE HEAT
310L
15/54
17
50a
19
926, 930 Circuit Diagrams-Electrical
310D
305
310B
2
30
434B
415A
403A
404A
406A
803A 803B
5 17 18
805 803B 803A
806B
806A
805A
828 - 2 WAY BUSBAR IN FUSEBOX
9804/1103
2
123
CONTENTS
70A
PRI FUSE 3 50A
PRI FUSE 2 60A PRI FUSE 1 60A
PRI FUSE 4
THERMOSTART M
4 3
3 5 1
810A 810C 842 600V
STARTER MOTOR
310A
6 001A
5 001
004
4 2
4 7
8 9
003A 003
FUSE A10 F
809 810C 875 5
600AC
4 1 3
812 600BS
FORWARD RELAY FORWARD SOLENOID

600AD
100 100A
N R
5
FUSE A1
10
808
4 2
REVERSE RELAY
600BT
12
3
838 875A
1
811B
811
13
100B
5 3 1
REVERSE SOLENOID
600CD
6
811A
100C 815B
REVERSE ALARM
600H
14 15
811G
REVERSE LIGHT RHS

600G
11
811F 815
REVERSE LIGHT LHS

600CV
16
600BF
SHOWN WITH HANDBRAKE OFF
HANDBRAKE
810A
4 2 1 5 3
815A 815B
401H
17
401E
27
411B 411 411B 411
106E 106C
RTFL
FUSE A2

106AK 401E 401H
95 - 15 - 01/7
106AB 406 406B 106AC 404 404B 106AD 403 403B
406B
600CK
WATER TEMP SWITCH

404B 600C
TRANS OIL TEMP SWITCH

403B 600HH
19 21 23 25
415B 407 407A 434 407A
4 4 0 3
ENGINE OIL PRESS SWITCH

600BU
18 20 22 24 26 29
415 415B 434 434A
106AF
TRANS OIL PRESS SWITCH

600HS
106AA
HOURMETER
31
106D 407 200 200A 108 816C 816G
28
ALTERNATOR
30
600H
32
FUSE A3
RH BRAKE LIGHT
816F 600G
33 34
LH BRAKE LIGHT
35
408 106 V
S
36
600CE
FUEL SENDER
+ 830A 600JA 600HT
105B
COLD START ADVANCE
37 38
105
105A
600
FUSE A4
E.S.O.S.
39
600BD 103F
103
FUSE A5
103H
REAR WIPER
40 41
M
103N
600JF
ROOF WIPER M
600EG
FACE FAN (OPTIONAL)
42
110
839
600BG
FUSE A6
WASHER PUMP
43 44
600AK
840
FRONT WIPER
45
+8
106N 303G
-7 1
600DY
BEACON SWITCH
46
2 3
894
FUSE A7
2
701/60000
600AP
BEACON
600DX
HAZARD SWITCH
49
47
-10
200N
805E
600BC
48
FUSE A8
50
300
1
104
805F
600G
LH FRONT INDICATOR LH REAR INDICATOR

2 3
802
49 49a 31
600BL
FLASHER UNIT
54
FUSE B1
53
310G - 3 WAY BUSBAR IN FUSEBOX
805B
55
4 001A 310L 5 3 2 1 002
314
106F
+8
701/60005
51
806F
600H
RH REAR INDICATOR
52
806D
806E
600AZ 600W
RH FRONT INDICATOR IGNITION RELAY
56
314B
57
814
600B
FUSE A9
FRONT HORN
600DW
59
829C 829D
600AU
60
600G
FUSE B6
61
58
8+
829A
829E 830G 106K 310P
600BC
62
600AX
ROADLIGHTS SWITCH LH No PLATE LIGHT LH TAIL LIGHT LH SIDE LIGHT
63
1 2
-7
830B
600H
64
+3
828
FUSE B7
830A 830R 138
830D
600AZ
65
834A
600AZ
834B
600BC
66
FUSE B2
2
701/60004
832
834A 834B
RH No PLATE LIGHT RH TAIL LIGHT RH SIDE LIGHT RH DIP BEAM LH DIP BEAM
67
314A
837
837C 837A
600EK 600AZ
70
68
837B
600BC
MAIN BEAM IND RH MAIN BEAM LH MAIN BEAM
69
600N 106J 832A
+8 2
-7
FOGLIGHT SWITCH
72
FUSE B8
2
835
835A
600H
835B
LHS FOGLIGHT
600G
RHS FOGLIGHT
73
74
701/60000
71
106L
116
+8 2
-7
600CJ
WORKLIGHT SWITCH
75
600AR
FUSE B3
2
701/60000
855
WORKLIGHT
106R
+10 2
-7 1
600EB
HEATER SWITCH
102
SPLIT IF AIR CON FITTED.
87
800
600BH
HEATER MOTOR
76
5
77
78
4 6
800B
FUSE B4
102
102F
30/925403
2
701/60016
LINK
106AT
+8
1 2
-7 1
600FB
AIR CON SWITCH
81
800E
2 2
701/60001
800
600MY
HEATER MOTOR
3
All m/cs from May2001
5100 - 10/7-7.2
79
962
600JG
80
A370710
980
600MX
CONDENSER RELAY CONDENSER FAN
83
82
X
962A
963
961
95 - 15 - 01/7
COMPRESSOR CLUTCH
84
85
86
Issue 1
CONTENTS
RTFL
95 - 15 - 01/8
926, 930 Circuit Diagrams -Electrical (contd)

Component Key
All m/cs from May 2001
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Battery Thermostart Starter motor/solenoid Neutral start relay Starter switch Dump pedal Forward/reverse switch Forward relay Reverse relay Forward solenoid Transmission dump relay Reverse solenoid Reverse alarm Reverse lights - right hand side Reverse lights - left hand side Parking brake switch Parking brake buzzer relay Parkbrake warning lamp Water temperature switch Water temperature warning lamp Transmission oil temperature switch Transmission oil temperature warning lamp Engine oil pressure switch Engine oil pressure warning lamp Transmission oil pressure switch Transmission oil pressure warning lamp Buzzer Hourmeter Alternator warning lamp Alternator Alternator diode Brake lights switch Brake light - right hand Brake light - left hand Fuel gauge Fuel sender Cold start advance Engine shut-off solenoid (ESOS) Rear wiper motor Roof wiper motor
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87
Face fan (optional) Front wash/wipe switch Washer pump Front wiper motor Beacon switch Beacon Hazard warning lights switch Flasher unit Left hand front indicator Left hand rear indicator Right hand rear indicator Right hand front indicator Indicator repeater lamp Indicator switch Ignition relay Horn switch Horn Road lights switch Left hand number plate lamp Left hand tail light Left hand side light Right hand number plate Right hand tail light Right hand side light Right hand dip beam Left hand dip beam Main beam indicator lamp Right hand main beam Left hand main beam Main beam/dip beam switch/light flash Fog light switch Left hand fog light Right hand fog light Work light switch Work light Heater switch Heater resistor Heater motor Air conditioning switch Resistor switch - air conditioning Heater motor - air conditioning Condenser relay - air conditioning Condenser fan motor - air conditioning Thermostat - air conditioning Pressure switch - air conditioning Compressor clutch - air conditioning Link removed if air conditioning fitted
9804/1103
95 - 15 - 01/8
5100 - 10/7-8.1
Issue 1
CONTENTS
RTFL
95 - 20 - 01/1
926, 930 Circuit Diagrams - Hydraulics
1B
11 2E 2E
2 2D 2C
12
2F
1A
2G
2A
2X
10 S P1 13 F
14
15
16
A184641
9804/1103
95 - 20 - 01/21
5100 - 2/11 -1.2
Issue 1
CONTENTS
RTFL
95 - 20 - 01/2
926, 930 Circuit Diagrams - Hydraulics (contd)

Component Key F P P1 T S 1A 1B 2 2A 2C 2D 2E 2F 2G 2X 10 11 12 13 14 15 16 Filter Priority valve Pump Tank Combined steering unit and shock valve Neutral circuit feed line Neutral circuit return line Valve block Main relief valve (M.R.V.) Lift spool Tilt spool Auxiliary spool Load hold check valve (L.H.C.V) Auxiliary relief valves (A.R.V's) System pressure test point Lift rams Tilt rams Steer ram Flow regulator cartridge Hose burst protection valve Deration diverter valve Deration valve
9804/1103
95 - 20 - 01/2
5100 - 2/11 -2.2
Issue 1
CONTENTS
Excavators
Contents 1
* JS
70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180, 200, 200W, 210, 220, 240, 260, 300, 330, 450LC, 460
Contents
Page No. General Information Fluids, Lubricants and Capacities - JS 70 to m/c no. 695500 45 - 00 - 01/1 - JS 110, 130 to m/c no. 757999, 150LC 45 - 00 - 01/2 - JS 200LC to m/c no. 705000, 240LC to m/c no. 780500, 300LC, 450LC 45 - 00 - 01/3 - JS 130W, 150W 45 - 00 - 01/4 - JS 70 from m/c no. 695501 45 - 00 - 01/4A - JS130 from m/c no. 758000, JS160 from m/c no. 702000 45 - 00 - 01/5 - JS180 45 - 00 - 01/5A - JS130W frm m/c no. 716500, JS145W from m/c no. 810000, JS160W from m/c no. 718500 45 - 00 - 01/4B - JS200, 220 from m/c no. 705001, JS210 from m/c no. 705648,JS240 from m/c no.708001, * JS260 from m/c no. 708501 45 - 00 - 01/6 - JS200W from m/c no. 0802000 to 802999 45 - 00 - 01/6A & 45 - 00 - 01/6B - JS330 from m/c no. 712501, JS450 from m/c no. 714501, JS460 from m/c no. 714550 45 - 00 - 01/7 - JS200W from m/c no. 809000 45 - 00 - 01/6C & 45 - 00 - 01/6D Static Dimensions - JS 70 to m/c no. 695500 - JS 110 - JS 130 to m/c no. 757999 - JS 150LC - JS 200LC - JS 240LC - JS 300LC - JS 450LC - JS 130W - JS 150W - JS 70 from m/c no. 695501 - JS130 from m/c no. 758000 - JS160 from m/c no. 702000 - JS180 - JS200, 220 from m/c no. 705001 - JS210 - JS240, 260 from m/c no. 708501 - JS220LC Long reach (LR) from m/c no. 705001 - JS330 from m/c no. 712501 - JS450 from m/c no. 714501 - JS130W from m/c no. 0716500 - JS160W from m/c no. 0718500 - JS200W from m/c no. 0802000 to 802999 - JS200W from m/c no. 809000 - JS460 from m/c no. 714550 Shipping Weights - JS 70 to m/c no. 695500 - JS 110, 130, 150LC - JS 200LC to m/c no. 70500, 240LC to m/c no. 780500, 300LC, 450LC - JS 70 from m/c no. 695501 - JS130 from m/c no. 758000, JS160, 180 from m/c no. 702000 - JS200, 210, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 - JS330 from m/c no. 712501, JS450 from m/c no. 714501, JS460 from m/c no. 714550 - JS130W from m/c no. 0716501, JS160W from 0718501 - JS200W from m/c no. 0802000 to 802999
45 - 00 - 02/1 45 - 00 - 02/2 45 - 00 - 02/3 45 - 00 - 02/4 45 - 00 - 02/5 45 - 00 - 02/6 45 - 00 - 02/7 45 - 00 - 02/8 45 - 00 - 02/9 45 - 00 - 02/10 45 - 00 - 02/10A 45 - 00 - 02/11 45 - 00 - 02/12 45 - 00 - 02/12A 45 - 00 - 02/13 45 - 00 - 02/13A 45 - 00 - 02/14 45 - 00 - 02/15 45 - 00 - 02/16 45 - 00 - 02/16A 45 - 00 - 02/17 45 - 00 - 02/18 45 - 00 - 02/19 45 - 00 - 02/20 45 - 00 - 02/21
45 - 00 - 03/1 45 - 00 - 03/2 45 - 00 - 03/3 45 - 00 - 03/3A 45 - 00 - 03/4 45 - 00 - 03/4 45 - 00 - 03/4 45 - 00 - 03/5 45 - 00 - 03/6
9804/1103
Excavator Contents - 1
Issue 9*
CONTENTS
Excavators
Contents 2
* JS
70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180, 200, 200W, 210, 220, 240, 260, 300, 330, 450LC, 460
Contents
Data Electrical - JS 70 to m/c no. 695500 - JS 110, 130, 150LC - JS 200LC, 240LC, 300LC, 450LC - JS 130W, 150W - JS130 from m/c no. 758000, JS160 from m/c no. 702000 - JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 - JS130W from m/c no. 0716501, JS160W from m/c no. 0718501 * - JS70 from m/c no. 695501 - JS 200W from m/c no. 809000 * - JS330 from m/c no. 712501, JS450 from m/c no. 714501 JS460 from m/c 714550 - The A.M.S. System Data Hydraulic - JS 70 to m/c no. 695500 - JS 110 - JS 130 to m/c no. 757999 - JS 150 - JS 200LC to m/c no. 705000 - JS 240LC - JS 300LC - JS 450LC - JS 130W from m/c no. 0716501, JS145W from m/c no. 810000 - JS 70 from m/c no. 695501 - JS130 from m/c no. 758000 - JS160 from m/c no. 702000 - JS200, 220 from m/c no. 705001 - JS240, 260 from m/c no. 708501 * - JS 200W from m/c no. 809000 - JS330 from m/c no. 712501 - JS450 from m/c no. 714501, JS460 from m/c no. 714550 * Track Motor/Gearbox - JS130 from m/c no. 758000, JS160 from m/c no. 702000 - JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 - JS330 from m/c no. 712501, JS450 from m/c no. 714501 JS460 from m/c no 714550 Control Valve - JS 200W from m/c no. 809000 Drive Gearbox - JS 200W from m/c no. 809000 Front Axle - JS 200W from m/c no. 809000 - JS130W from m/c no. 716500 (SD70 PT) - JS130W from m/c no. 716500, JS160W from m/c no. 718500 (SD80PT) Rear Axle - JS 200W from m/c no. 809000 - JS130W from m/c no. 716500 (PD70) - JS130W from m/c no. 716500, JS160W from m/c no. 718500 (PD80) Engine - JS 70 to m/c no. 695500 - JS 110, 130, 150LC - JS 200LC, 240LC - JS 300LC, 450LC - JS 70 from m/c no. 695501 - JS 130W from m/c no. 785001, JS160W from m/c no. 702001
9804/1103
Page No. 45 - 05 - 01/1 45 - 05 - 01/2 45 - 05 - 01/3 45 - 05 - 01/4 & 45 - 05 - 01/5 45 - 05 - 01/6 45 - 05 - 01/6 45 - 05 - 01/7 45 - 05 - 01/8 45 - 05 - 01/9 & 45 - 05 - 01/10 45 - 05 - 01/11 45 - 05 - 01/12,13
45 - 05 - 02/1 45 - 05 - 02/2 45 - 05 - 02/3 45 - 05 - 02/4 45 - 05 - 02/5 45 - 05 - 02/6 45 - 05 - 02/7 45 - 05 - 02/8 45 - 05 - 02/9 to 45 - 05 - 02/10D 45 - 05 - 02/11 45 - 05 - 03/1 & 45 - 05 - 03/2 45 - 05 - 03/3 & 45 - 05 - 03/4 45 - 05 - 03/5 & 45 - 05 - 03/6 45 - 05 - 03/7 & 45 - 05 - 03/8 45 - 05 - 03/9 to 45 - 05 - 03/11 45 - 05 - 03/12 & 45 - 05 - 03/13 45 - 05 - 03/14
45 - 05 - 04/1 45 - 05 - 04/2 45 - 05 - 04/3 to 45 - 05 - 04/5
45 - 05 - 05/1 45 - 05 - 06/1 45 - 05 - 07/1 45 - 07 - 07/1A 45 - 07 - 07/1B 45 - 05 - 07/2 45 - 07 - 07/2A 45 - 07 - 07/2B 45 - 05 - 08/1 45 - 05 - 08/2 45 - 05 - 08/3 45 - 05 - 08/4 45 - 05 - 08/4A 45 - 05 - 08/5
Issue 7*
CONTENTS
Excavators
Contents 3
* JS
70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180, 200, 200W, 210, 220, 240, 260, 300, 330, 450LC, 460
Contents
* Engine (contd) Page No. - JS 330 from m/c no. 712501, JS450 from m/c no. 714501 45 - 05 - 08/6 JS460 from m/c no.714550 - JS460 Tier 2 45 - 05 - 08/6A - JS 130 from m/c no. 716501, JS160 from m/c no. 718501 45 - 05 - 08/7 - JS130W from m/c no. 716500, JS145 from m/c no. 810000 45 - 05 - 08/7A - JS175W from m/c no. 875000 45 - 05 - 08/8 JS160W from m/c no. 718500, - JS 200W from m/c no. 809000 45 - 05 - 08/9 - JS200, 220 from m/c no. 705001, JS210 from m/c no. 705648,JS240 from m/c no.708001, JS260 from m/c no. 708501 45 - 05 - 08/10 Track and Running Gear - JS330 from m/c no. 712501, JS450 from m/c no. 714501 Fault Finding Hydraulics - JS 70 to m/c no. 695500 - JS 110, 130 - JS 150LC - JS 200LC, 300LC - JS 240LC - JS 450LC - JS70 from m/c no. 695501 - JS 200W from m/c no. 809000 Track Gearbox - JS 110, 130, 150LC - JS 200LC, 240LC, 300LC, 450LC Swing Gearbox - JS70, 110, 130, 150LC, 200LC, 240LC, 300LC, 450LC - JS130W from m/c no. 716500, JS160W from m/c no. 718500 - JS200 from m/c no. 705001, JS240 from m/c no. 708501 - JS 200W from m/c no. 809000 * Pump/ Regulator - JS130 from m/c no. 758000, JS160 from m/c no. 702000 - JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 - JS330 from m/c no. 712501, JS450 from m/c no. 714501 - JS330 from m/c no. 712501, JS460 from m/c no. 714550 * Remote Control Valve - JS130 from m/c no. 758000, JS160 from m/c no. 702000 - JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501, JS 200W from m/c no. 809000 - JS330 from m/c no. 712501, JS450 from m/c no. 714501 JS460 from m/c no. 714550 Control Valve - JS70 from m/c no. 695501 Multiple Valve - JS70 from m/c no. 695501 Rams - JS70 from m/c no. 695501 - JS130 from m/c no. 758000, JS160 from m/c no. 702000 - JS130W from m/c no. 716500, JS160W from m/c no. 718500 - JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 Track Motor/Gearbox - JS70 from m/c no. 695501
9804/1103
45 - 05 - 09/1 & 45 - 05 - 09/2
45 - 10 - 01/1 to 45 - 10 - 01/3 45 - 10 - 01/4 to 45 - 10 - 01/8 45 - 10 - 01/9 to 45 - 10 - 01/13 45 - 10 - 01/14 to 45 - 10 - 01/19 45 - 10 - 01/20 45 - 10 - 01/21 to 45 - 10 - 01/23 45 - 10 - 01/24 & 45 - 10 - 01/25 45 - 10 - 01/26 to 45 - 10 - 01/31
45 - 10 - 02/1 & 45 - 10 - 02/2 45 - 10 - 02/3 & 45 - 10 - 02/4
45 - 10 - 03/1 45 - 10 - 03/6 45 - 10 - 03/2 to 45 - 10 - 03/3 45 - 10 - 03/6
45 - 10 - 05/1 to 45 - 10 - 05/2 45 - 10 - 06/1 to 45 - 10 - 06/2 45 - 10 - 06/3 & 45 - 10 - 06/4 45 - 10 - 06/5
45 - 10 - 07/1 45 - 10 - 07/1 45 - 10 - 07/1
45 - 10 - 07/2 & 45 - 10 - 07/3 45 - 10 - 07/4
45 - 10 - 08/1 to 45 - 10 - 08/5 45 - 10 - 08/1 to 45 - 10 - 08/5 45 - 10 - 08/1 to 45 - 10 - 08/5 45 - 10 - 08/1 to 45 - 10 - 08/5 45 - 10 - 09/1 to 45 - 10 - 09/3
Issue 7*
CONTENTS
Excavators
Contents 4
* JS
70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180, 200, 200W,210, 220, 240, 260, 300, 330, 450LC, 460
Contents
- JS130 from m/c no. 758000, JS160 from m/c no. 702000 - JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 - JS330 from m/c no. 712501, JS450 from m/c no. 714501 Fault Finding (contd) Slew Motor - JS70 from m/c no. 695501 - JS130 from m/c no. 758000, JS160 from m/c no. 702000 * - JS130W from m/c no. 716500, JS145W from m/c no. 810000 JS160W from m/c no. 718500, JS175W from m/c no. 875000 - JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501, JS 200W from m/c no. 809000 - JS330 from m/c no. 712501, JS450 from m/c no. 714504 JS460 from m/c no. 714550 Engine - JS70 from m/c no. 695501 Monitor Display - JS70 from m/c no. 695501 Operating Controls - JS70 from m/c no. 695501 Hydraulic Pump - JS70 from m/c no. 695501 Working Attachments - JS70 from m/c no. 695501 Travelling - JS70 from m/c no. 695501 Slewing - JS70 from m/c no. 695501 Hydraulic Rams - JS70 from m/c no. 695501 Electrics - JS330 from m/c no. 712501, JS450 from m/c no. 714501 JS460 from m/c no. 714550 Circuit Diagrams Electrical - JS70 to m/c no. 695500 - JS70 from m/c no. 695501 - JS110, 130 to m/c no. 757999 - JS150LC - JS200LC to m/c no. 705000 - JS240LC to m/c no. 780500 - JS300LC - JS450LC - JS130W, 150W (Common with JS130, JS150 Tracked Excavators) - JS130W, 150W (Additional to JS130, JS150 Tracked Excavators) - JS130W, 150W (Relay Box P.C.B.) - JS130W from m/c no. 716501, 160W from 718501 - JS130 from m/c no. 758000, JS160 from m/c no. 702000 * - JS200W from m/c no. 809000 - JS200, 220 from m/c no.705001, JS240 from m/c no. 708501 - JS330 from m/c no. 712501 - JS450 from m/c no. 714501 - JS330/JS460 (AMS) - JS460 Tier2
9804/1103
45 - 10 - 09/1 to 45 - 10 - 09/3 45 - 10 - 10/1 to 45 - 10 - 10/5 45 - 10 - 10/6 to 45 - 10 - 10/11 Page No. 45 - 10 - 03/4 & 45 - 10 - 03/5 45 - 10 - 11/1 to 45 - 10 - 11/2 45 - 10 - 11/1 to 45 - 10 - 11/2 45 - 10 - 11/1 to 45 - 10 - 11/2 45 - 10 - 11/3
45 - 10 - 12/1 45 - 10 - 13/1
45 - 10 - 13/2
45 - 10 - 13/2
45 - 10 - 13/2
45 - 10 - 13/3
45 - 10 - 13/3
45 - 10 - 13/3
45 - 10 - 14/1 to 45 - 10 - 14/19
45 - 15 - 01/1 & 45 - 15 - 01/2 45 - 15 - 01/2A & 45 - 15 - 01/2B 45 - 15 - 01/3 & 45 - 15 - 01/4 45 - 15 - 01/5 & 45 - 15 - 01/6 45 - 15 - 01/7 & 45 - 15 - 01/8 45 - 15 - 01/9 & 45 - 15 - 01/10 45 - 15 - 01/11 & 45 - 15 - 01/12 45 - 15 - 01/13 & 45 - 15 - 01/14 45 - 15 - 02/1 & 45 - 15 - 02/2 45 - 15 - 02/3 & 45 - 15 - 02/4 45 - 15 - 02/5 & 45 - 15 - 02/6 45 - 15 - 02/7 to 45 - 15 - 02/11 45 - 15 - 02/11A & 45 - 15 - 02/11B 45 - 15 - 02/12 & 45 - 15 - 02/13 45 - 15 - 02/13A & 45 - 15 - 02/13B 45 - 15 - 02/14 & 45 - 15 - 02/15 45 - 15 - 02/16 & 45 - 15 - 02/17 45 - 15 - 02/18 & 45 - 15 - 02/19 45 - 15 - 02/20 & 45 - 15 - 02/21
Issue 4*
CONTENTS
Excavators
Contents 5
JS 70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180,, 200, 200W, 210, 220, 240, 260, 300, 330, 450LC, 460
Contents
Hydraulic - JS70 (Standard Boom to m/c 695001) - JS70 (Offset Boom to m/c 695001) - JS70 (Standard Boom from m/c 695002 to m/c 695500) - JS70 (Offset Boom from m/c 695002 to m/c 695500) Circuit Diagrams Hydraulic (contd) - JS70 from m/c no. 695501 - JS110 (To m/c 697013) & 130 (To m/c 699036) - JS110 (From m/c 697014) & 130 (From m/c 699037 to m/c no. 757999) - JS150LC (To m/c 701044) - JS150LC (From m/c 701045) - JS200LC (To m/c 704074) - JS200LC (From m/c 704075 to m/c no. 705000) - JS240LC to m/c no. 780500 - JS300LC - JS450LC - JS130W from m/c no. 716501, JS145W from m/c no. 810000, 160W from m/c no. 718501, JS175W from m/c no. 875000 - JS160W from m/c no. 718501, JS175W from m/c no. 875000 - TAB Option - JS130W from m/c no. 716501, 160W from m/c no. 718501 - JS130 from m/c no. 758000 - JS160 from m/c no. 702000 - JS175W from m/c no. 875000 - JS200, 220 from m/c no. 705001 - JS240, 260 from m/c no. 708001 - JS330 from m/c no. 712501 - JS450 from m/c no. 714501 - JS460 from m/c no. 714550 - JS330/JS460 Tier2 - JS450/JS460 - Control Valve - JS460 Tier2 - Control Valve - JS460 Tier2 - Circuit Descriptions 45 - 20 - 01/1 & 45 - 20 - 01/2 45 - 20 - 01/3 & 45 - 20 - 01/4 45 - 20 - 01/5 & 45 - 20 - 01/6 45 - 20 - 01/7 & 45 - 20 - 01/8 Page No. 45 - 20 - 01/8A &45 - 20 - 01/8B 45 - 20 - 01/9 & 45 - 20 - 01/10 45 - 20 - 01/11 & 45 - 20 - 01/12 45 - 20 - 01/13 & 45 - 20 - 01/14 45 - 20 - 01/15 & 45 - 20 - 01/16 45 - 20 - 01/17 & 45 - 20 - 01/18 45 - 20 - 01/19 & 45 - 20 - 01/20 45 - 20 - 01/21 & 45 - 20 - 01/22 45 - 20 - 01/23 & 45 - 20 - 01/24 45 - 20 - 01/25 & 45 - 20 - 01/26 45 - 20 - 02/1 & 45 - 20 - 02/2 45 - 20 - 02/3 45 - 20 - 02/4 45 - 20 - 02/4A & 45 - 20 - 02/4B 45 - 20 - 02/4C & 45 - 20 - 02/4D 45 - 20 - 02/4E & 45 - 20 - 02/4F 45 - 20 - 02/6A & 45 - 20 - 02/6B 45 - 20 - 02/6C & 45 - 20 - 02/6D 45 - 20 - 02/7 & 45 - 20 - 02/8 45 - 20 - 02/9 & 45 - 20 - 02/10 45 - 20 - 02/11 & 45 - 20 - 02/12 45 - 20 - 02/13 & 45 - 20 - 02/14 45 - 20 - 02/15 45 - 20 - 02/16 45 - 20 - 02/17 to 45 - 20 - 02/42
9804/1103
Excavators Contents - 5
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 00 - 01/1
* JS
70 to m/c no. 695500
Lubricants & Capacities

Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
* Item ENGINE
Lubricant To Class API CD (see separate chart below) JCB HD90 Gear Oil
Capacity 6 litres (1.32 UK gal) 2 x 1.7 litres (2 x 0.37 UK gal) 6 litres (1.3 UK gal) 0.9 litres (0.18 UK gal)
TRACK GEARBOX
SWING GEARBOX
JCB HD90 Gear Oil *JCB HP Grease
TRACK ROLLERS AND IDLER WHEEL HYDRAULIC SYSTEM
Engine Oil JCB Hydraulic Fluid 46
92 litres (20.26 UK gal)
SWING RING - BEARINGS - GEAR TEETH
*JCB HP Grease *JCB HP Grease
3.2 kg (7.14 lb)
ALL OTHER GREASE POINTS COOLING SYSTEM
*JCB HP Grease 10.4 litres (2..29 UK gal) 130 litres (28.6 UK gal)
FUEL TANK
ENGINE LUBRICATION CHART
* -20 -10
Use according to ambient temperature (C) 0 10 20 30 40
JCB 15W/40 MULTIGRADE ENGINE OIL API CD MIL L-2104C JCB SUPER UNIVERSAL AGRICULTURAL (10W/30) API CD/SF
9804/1103
45 - 00 - 01/1
Issue 4*
CONTENTS CONTENTS
Excavators
45 - 00 - 01/2
JS 110, 130, 150LC Lubricants & Capacities

Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
Item
Lubricant JS110
Capacity JS130 13.8 litres (3 UK gal) 2 x 2.5 litres (2x 0.55 UK gal) 1.7 litres (0.37 UK gal) 0.47 litres JS150LC 13.8 litres (3 UK gal) 2 x 3 litres (2x0.55UK gal) 6 litres (1.32 UK gal) Not applicable
ENGINE
To Class API CD (see separate chart below) JCB HD90 Gear Oil JCB HD90 Gear Oil *JCB HP Grease (0.1 UK gal)
13.8 litres (3 UK gal) 2 x 2.5 litres (2 x 0.55 UK gal) 1.7 litres (0.37 UK gal) 0.47 litres (0.1 UK gal)
TRACK GEARBOX SWING GEARBOX
Engine Oil JCB Hydraulic Fluid 46
SWING RING - BEARINGS - GEAR TEETH
*JCB HP Grease *JCB HP Grease
10 kg (22 lb)
10 kg (22 lb)
13 kg (28.7 lb)
EXCAVATOR GREASE POINTS COOLING SYSTEM
*JCB HP Grease 17.8 litres (3.9 UK gal) 240 litres (52.8 UK gal) 17.8 litres (3.9 UK gal) 240 litres (52.8 UK gal) 17.8 litres (3.9 UK gal) 240 litres (52.8 UK gal)
FUEL TANK
Use according to ambient temperature (C) -20 -10 0 10 20 30 40
9804/1103
45 - 00 - 01/2
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 00 - 01/3
JS 200LC,240LC,300LC,450LC Lubricants & Capacities

Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently runin. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
Item
Lubricant JS200LC JS240LC
Capacity JS300LC 33 litres (7.26 UK gal) JS450LC 45 litres (9.9 UK gal)
ENGINE
To Class API CD (see separate chart) JCB HD90 Gear Oil
22.6 litres (5 UK gal)
TRACK GEARBOX
Serial Nos up to 2 x 3.3 litres 2 x 8.5 litres 2 x 7 litres 704597 (2 x 0.73 UK gal) 2 x 1.87 UK gal) (2 x 1.54 UK gal) 2 x 5.6 litres (2 x 1.23 UK gal) Serial Nos from 704598 on 2 x 3.5 litres (2 x 0.77 UK gal)
6 litres (2.4 UK gal) 0.9 litres 11 litres (3.9 UK gal) 14.5 litres (4 UK gal) 18 litres -
SWING GEARBOX
JCB HD90 Gear Oil (1.3 UK gal) JCB HP Grease (0.18 UK gal)
TRACK ROLLERS AND IDLER WHEEL Engine Oil HYDRAULIC SYSTEM JCB Hydraulic Fluid 46
350 litres (77 UK gal)
SWING RING - BEARINGS - GEAR TEETH ALL OTHER GREASE POINTS COOLING SYSTEM
JCB HP Grease JCB HP Grease
13 kg (28.6 lb)
22 kg (48.4 lb)
27 kg (59.4 lb)
31 kg (68.2 lb)
JCB HP Grease 25.8 litres (5.7 UK gal) 280 litres (61.6 UK gal) 25 litres (5.5 UK gal) 280 litres (61.6 UK gal) 34 litres (7.5 Uk gal) 500 litres (110 UK gal) 50 litres (11 UK gal) 500 litres (110 UK gal)
FUEL TANK
9804/1103
45 - 00 - 01/3
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 00 - 01/4
JS 130W, 150W Lubricants & Capacities

Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
Capacity Item Lubricant JS130W ENGINE To Class API CD (see separate chart) JCB HD90 Gear Oil JCB HP Grease 13.8 litres (3 UK gal) 1.7 litres (0.37 UK gal) 0.47 litres (0.1 UK gal) 157 litres (34.5 UK gal) JS150W 13.8 litres (3 UK gal) 6 litres (1.32 UK gal) Not Applicable 170 litres (37.4 UK gal)
SWING GEARBOX
HYDRAULIC SYSTEM
JCB Hydraulic Fluid 46
SWING RING - BEARINGS - GEAR TEETH PROPSHAFTS ALL OTHER GREASE POINTS COOLING SYSTEM
JCB HP Grease JCB HP Grease JCB HP Grease
10 kg (22lb)
13 kg (28.7 lb)
JCB HP Grease 17.8 litres (3.9 UK gal) 240 litres (52.8 UK gal) 17.8 litres (3.9 UK gal) 240 litres (52.8 UK gal)
FUEL TANK
FRONT AXLE - DIFFERENTIAL - HUB (x 2)
JCB Gear Oil LS JCB Gear Oil LS
9 litres (2 UK gal) 0.9 litres (0.2 UK gal)
9 litres (2 UK gal) 1.5 litres (0.33 UK gal)
REAR AXLE - DIFFERENTIAL - HUB (x 2)
JCB Gear Oil LS JCB Gear Oil LS
12 litres (2.64 UK gal) 0.9 litres (0.2 UK gal) 3.4 litres (0.8 gal)
12 litres (2.64 UK gal) 1.5 litres (0.33 UK gal) 3.4 litres (0.8 gal)
DRIVE GEARBOX
JCB 15W/40 Multigrade Oil
9804/1103
45 - 00 - 01/4
Issue 2
CONTENTS CONTENTS
Excavators
45 - 00 - 01/4A
JS 70 from m/c no. 695501 Lubricants & Capacities

Note: New engines DO NOT require a running-in period. The engine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
Item ENGINE
Fluid/Lubricant See separate chart
International Specification -
Capacity 6.8 litres (1.49 UK gal) 0.2 kg (0.44 lb) 2 x 1.7 litres (0.37 UK gal)
SLEW GEARBOX
JCB HP Grease
Lithium based, No. 2 consistency API-GL-5, MIL-L-2105C
TRACK GEARBOXES
JCB Gear Oil HD90
Engine Oil (see separate chart) JCB Special Hydraulic Fluid HP46
Vickers 35VQ25/V104C: Sundstrand, Denison and FZG Approval Tests
SLEW RING - BEARINGS - GEAR TEETH ALL OTHER GREASE POINTS COOLING SYSTEM
JCB HP Grease JCB HP Grease
Lithium based, No. 2 consistency Lithium based, No. 2 consistency ASTM D3306-74
3.2 kg (7.14 lb)
JCB HP Grease
10.1 litres (2.22 UK gal) 140 litres (30.8 UK gal)
FUEL TANK
ASTM D975-66T Nos 1D, 2D
Engine Lubrication Chart
* -20 -10
Use according to ambient temperature (C) 0 10 20 30 40
JCB SUPER 15W/40 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F JCB SUPER UNIVERSAL AGRICULTURAL (10W/30) API CE/SF MIL L-2104D
9804/1103
45 - 00 - 01/4A
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 01/4B
JS 130W from m/c no. 716500, JS160W from m/c no. 718500 Lubricants and Capacities
Item
Fluid/Lubricant
International Specification JS130W
Capacity JS160W 12.1 litres (2.7 UK gal) 5 litres (1.09 UK gal) 124 litres (27.3 UK gal)
ENGINE
See separate chart
12.1 litres (2.7 UK gal) API-GL-5: MIL-L-2105C 5 litres (1.09 UK gal) 124 litres (27.3 UK gal)
SLEW GEARBOX
JCB Gear Oil HD90
HYDRAULIC SYSTEM
JCB Special Hydraulic Fluid HP46
SLEW RING - BEARINGS - GEAR TEETH PROPSHAFTS
Lithium complex (NLGI) inc. extreme pressure additives Lithium complex (NLGI) inc. extreme pressure additives Lithium complex (NLGI) inc. extreme pressure additives ASTM D3306-74
17 kg (37.48 lb)
17 kg (37.48 lb)
JCB HP Grease See Coolant Mixtures
FUEL TANK
See Fuel System, Types of Fuel
FRONT AXLE - DIFFERENTIAL - HUB (x 2)
JCB Special Gear Oil Plus JCB Special Gear Oil Plus
API GL4: M2C-41B/134D, JD20C MGF M1135/M1141/ M1143
18 litres (3.9 Uk gal) 1.5 litres (0.33 UK gal)
18 litres (3.9 Uk gal) 1.5 litres (0.33 UK gal)
REAR AXLE - DIFFERENTIAL AND HUBS (x 2)
API GL4: M2C-41B/134D JD20C, MGF M1135/M1141/ M1143 API CF4/SG: MIL-L-2104F
17.7 litres (3.9 UK gal)
DRIVE GEARBOX
JCB Super 15W/40 Multigrade Engine Oil
Engine Lubrication Chart - All Machines

Use according to ambient temperature (C) -30 -20 -10 0 10 20 30 40 50
JCB SUPER 15W/40 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F JCB SUPER 10W/30 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F
9804/1103
45 - 00 - 01/4B
6980 - 127.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 01/5
JS 130 from m/c no. 758000, JS160 from m/c no. 702000
*
Lubricants and Capacities

International Item ENGINE Lubricant (see separate chart) Specification JS130 12.1 litres (2.7 UK gal) (3.2 US gal) API-GL-5, MIL-L-2105 2 x 3.0 litres (2 x 0.66 UK gal) (2 x 0.79 US gal) 5 litres (1.09 UK gal) (1.31 US gal) 1 litre (0.22 UK gal) (0.26 US gal) 124 litres (27.3 UK gal) (32.8 US gal) Capacity JS160 12.1 litres (2.7 UK gal) (3.2 US gal) 2 x 3.0 litres (2 x 0.66 UK gal) (2 x 0.79 US gal) 5 litres (1.09 UK gal) (1.31 US gal) 1 litre (0.22 UK gal) (0.26 US gal) 124 litres (27.3 UK gal) (32.8 US gal)
TRACK GEARBOX
JCB HD90 Gear Oil
SLEW GEARBOX
JCB HD90 Gear Oil JCB Special HP Grease
API-GL-5, MIL-L-2105 Lithium based No. 2 consistency API-GL-5, MIL-L-2105 Lithium based, No. 2 consistency ISO VG46
TRACK ROLLERS IDLER WHEEL RECOIL SPRING CYLINDER HYDRAULIC SYSTEM
JCB HD 90 Gear OIl JCB Special HP Grease JCB Hydraulic Fluid 46
SLEW RING - BEARING - GEAR TEETH ALL OTHER GREASE POINTS COOLING SYSTEM
JCB Special HP Grease JCB Special HP Grease
Lithium based No. 2 consistency Lithium based No. 2 consistency Lithium based No. 2 consistency -
11kg (24.25 lb)
17kg (37.48 lb)
JCB Special HP Grease see Coolant Mixtures
16.4 litres (3.6 UK gal) (4.3 US gal) 240 litres (52.8 UK gal) (63.4 US gal)
FUEL TANK
see Type of Fuel
ENGINE LUBRICATION CHART - ALL COUNTRIES EXCEPT NORTH AMERICAN -30 -20 Use according to ambient temperature (C) -10 0 10 20 30
JCB SUPER 15W/40 MULTIGRADE ENGINE OIL API CF4/SG JCB SUPER 10W/30 MULTIGRADE ENGINE OIL API CF4/SG ENGINE LUBRICATION CHART - NORTH AMERICAN Use according to ambient temperature (F) -22 -5 0 14 32 50 68 90
JCB 15W/40 MULTIGRADE ENGINE OIL API CF4/SG JCB 10W ENGINE OIL API CF4/SG
9804/1103
45 - 00 - 01/5
6410 - 3/1-1.2
Issue 3*
CONTENTS CONTENTS
Excavators
45 - 00 - 01/5A
* *
JS 180 from m/c no. 702132 Lubricants & Capacities

International Item ENGINE Lubricant (see separate chart) Specification Capacity JS180 12.1 litres (2.7 UK gal) (3.2 US gal) API-GL-5, MIL-L-2105 2 x 3.5 litres (2 x .77 UK gal) (2 x .92 US gal) 5 litres (1.09 UK gal) (1.31 US gal) -
TRACK GEARBOX
JCB HD90 Gear Oil
SLEW GEARBOX
JCB HD90 Gear Oil
API-GL-5, MIL-L-2105
JCB HD 90 Gear OIl
JCB Special HP Grease
Lithium complex (NLGI) inc. extreme pressure additives ISO VG46
124 litres (27.3 UK gal) (32.8 US gal)
SLEW RING - BEARING - GEAR TEETH
Lithium complex (NLGI) inc. extreme pressure additives Lithium complex (NLGI) inc. extreme pressure additives
17kg (37.48 lb)
ALL OTHER GREASE POINTS
Lithium complex (NLGI) inc. extreme pressure additives -
COOLING SYSTEM
see Coolant Mixtures
FUEL TANK
see Type of Fuel

Use according to ambient temperature (C)
JCB SUPER 15W/40 MULTIGRADE ENGINE OIL
9804/1103
45 - 00 - 01/5A
6950 - 88
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 00 - 01/6
* *
JS 200, 220 and variants from m/c no. 705001, JS 240, 260 from m/c no. 708501 Lubricants & Capacities
Capacity Item Lubricant International Specification
ENGINE
(see separate chart)
21.5 litres (4.72 UK gal) (5.67 US gal) API-GL-5, MIL-L-2105 2 x 3.5 litres (2 x 0.77 UK gal) (2 x 0.92 US gal) 5 litres (1.09 UK gal) (1.31 US gal) ---
TRACK GEARBOX
JCB HD90 Gear Oil
SLEW GEARBOX
JCB HD90 Gear Oil
TRACK ROLLERS AND IDLER WHEEL RECOIL SPRING CYLINDER
JCB HD90 Gear Oil
JCB Special HP Grease Lithium complex (NLGI) inc. extreme pressure additives
--
HYDRAULIC SYSTEM JCB Hydraulic Fluid 46
ISO VG46
203 litres (44.64 UK gal) (53.6 US gal)
SLEW RING - BEARING - GEAR TEETH
JCB Special HP Grease Lithium complex (NLGI) inc. extreme pressure additives JCB Special HP Grease Lithium complex (NLGI) inc. extreme pressure additives
-JS 200, JS 220 17 kg (37.48 lb) JS 240, JS 260 20 kg (44.10 lb)
ALL OTHER GREASE POINTS
JCB Special HP Grease Lithium complex (NLGI) inc. extreme pressure additives
--
COOLING SYSTEM
25.5 litres (5.6 UK gal) (6.7 US gal) 310 litres (68.19 UK gal)
FUEL TANK
Use according to ambient temperature (C)
9804/1103
45 - 00 - 01/6
6950 - 89
Issue 3*
CONTENTS
Excavators
45 - 00 - 01/6A
JS 200W from m/c no. 0802000 to 802999 Lubricants & Capacities

Item
Fluid/Lubricant
International Specification
Capacity JS200W
ENGINE
See separate chart
18.5 litres (4.0 UK gal) (4.9 US gal) API-GL-5: MIL-L-2105C 5 litres (1.09 UK gal) (1.31 US gal) 1 litre (0.22 UK gal) (0.26 US gal) 124 litres (27.3 UK gal) (32.7 US gal)
SLEW GEARBOX
JCB Gear Oil HD90
JCB HP Grease
HYDRAULIC SYSTEM
Lithium based, No. 2 consistency Lithium based, No. 2 consistency Lithium based, No. 2 consistency ASTM D3306-74
17 kg (37.48 lb)
JCB HP Grease See Coolant Mixtures
27 litres (5.9 UK gal) (7.1 US gal) 310 litres (68.2 UK gal) (81.2 US gal)
FUEL TANK
See Fuel System, Types of Fuel in Operator Handbook
FRONT AXLE - DIFFERENTIAL
JCB Gear Oil HD90
API GL-5: MIL-L-2105D
- HUB (x 2)
9.0 litres (1.98 UK gal) (2.37 US gal) 2.0 litres (0.44 UK gal) (0.52 US gal)
JCB Gear Oil HD90
17.0 litres (3.74 UK gal) (4.49 US gal)
DRIVE GEARBOX
API CF4/SG: MIL-L-2104F
9804/1103
45 - 00 - 01/6A
Issue 1
CONTENTS
Excavators
45 - 00 - 01/6B
JS 200W from m/c no. 0802000 to 802999 Lubricants & Capacities (contd)
Engine Lubrication Chart
Use according to ambient temperature (C) -30 20 -10 0 10 20 30 40 50
9804/1103
45 - 00 - 01/6B
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 01/6C
* *
JS 200W from m/c no. 809000 Lubricants & Capacities

Item
Fluid/Lubricant
International Specification
Capacity JS200W
ENGINE
See separate chart
18.5 litres (4.0 UK gal) (4.9 US gal) API-GL-5: MIL-L-2105C 5 litres (1.09 UK gal) (1.31 US gal) 124 litres (27.3 UK gal) (32.7 US gal)
SLEW GEARBOX
JCB Gear Oil HD90
HYDRAULIC SYSTEM
Lithium complex (NLGI) inc. extreme pressure additives Lithium complex (NLGI) inc. extreme pressure additives Lithium complex (NLGI) inc. extreme pressure additives ASTM D3306-74
17 kg (37.48 lb)
JCB HP Grease
27 litres (5.9 UK gal) (7.1 US gal) 310 litres (68.2 UK gal) (81.2 US gal)
FUEL TANK
See Fuel System, Types of Fuel in Operator Handbook
FRONT AXLE - DIFFERENTIAL
JCB Gear Oil HD90
- HUB (x 2)
9.0 litres (1.98 UK gal) (2.37 US gal) 2.0 litres (0.44 UK gal) (0.52 US gal)
JCB Gear Oil HD90
DRIVE GEARBOX
API CF4/SG: MIL-L-2104F
9804/1103
45 - 00 - 01/6C
6980 - 128
Issue 1
CONTENTS
Excavators
45 - 00 - 01/6D
JS 200W from m/c no. 809000 Lubricants and Capacities (contd)
Use according to ambient temperature (C) -30 20 -10 0 10 20 30 40 50
9804/1103
45 - 00 - 01/6D
6320 - 3/1-2.1
Issue 1
CONTENTS
Excavators
45 - 00 - 01/7
* JS
330 from m/c no. 712501, JS 450 from m/c no. 714501, JS 460 from m/c no. 714550 Lubricants & Capacities
Capacity Item Lubricant International Specification JS330 ENGINE (see separate chart) 34 litres (7.5 Uk gal) API-GL-5, MIL-L-2105 2 x 8.5 litres (2 x 1.9 UK gal) 14.5 litres (3.2 UK gal) JS450/JS460 34 litres (7.5 UK gal) 2 x 7.0 litres (2 x 1.5 UK gal) 18 litres (4 UK gal) -
TRACK GEARBOX
JCB HD90 Gear Oil
SLEW GEARBOX
JCB HD90 Gear Oil
JCB HD90 Gear Oil
Lithium based, No. 2 consistency ISO VG46
SLEW RNG - BEARING - GEAR TEETH
Lithium based, No. 2 consistency Lithium based, No. 2 consistency Lithium based, No. 2 consistency -
17 kg (34. 48 lb)
17 kg (34. 48 lb)
38 litres (8.4 UK gal) 580 litres (128 UK gal)
43 litres (9.5 UK gal) 650 litres (143 UK gal)
see Coolant Mixtures
FUEL TANK
see Type of Fuel
Use according to ambient temperature (C) -30 -20 -10 0 10 20 30 40
9804/1103
45 - 00 - 01/7
6420 - 3/1-1.2
Issue 3*
CONTENTS CONTENTS
*JS
Excavators
70 to m/c no. 695500
Static Dimensions
A B C D E F
Track length on ground Undercarriage - overall length Tail height Tailswing radius Tail length Superstructure width
2050 mm (6 ft 9 in) 2680 mm (8 ft 10 in) 760 mm (2 ft 6 in) 1600 mm (5 ft 3 in) 1600 mm (5 ft 3 in) 2200 mm (7 ft 3 in) 2550 mm (8 ft 4 in) 360 mm (1 ft 2 in) 1700 mm (5 ft 8 in) - 450 mm (18 in) shoes - 600 mm (24 in) shoes - 700 mm (28 in) shoes - standard boom - offset boom - standard boom - offset boom 2150 mm (7 ft 1 in) 2300 mm (7 ft 7 in) 2400 mm (7 ft 11 in) 5860 mm (19 ft 3 in) 5950 mm (19 ft 6 in) 2540 mm (8 ft 4 in) 2740 mm (9 ft 0 in) 620 mm (2 ft 0 in) 2250 mm (7 ft 5 in) 460 mm (1 ft 6 in) 480 mm (1 ft 7 in)
G Height over cab H J K Ground clearance Track gauge Track width
Transport length
M Transport height
N P R S
Track height Dozer blade width Dozer blade height Dozer blade reach in front of tracks
9804/1103
45 - 00 - 02/1
Issue 3*
CONTENTS CONTENTS
Excavators
45 - 00 - 02/2
JS 110 Static Dimensions
A B C D E F
Track length on ground Undercarriage - overall length Tail Height Tailswing radius Tail length Superstructure width
2610 mm (8 ft 7 in) 3380 mm (11 ft 1 in) 920 mm (3 ft 0 in) 2150 mm (7 ft 1 in) 2080 mm (6 ft 10 in) 2420 mm (7 ft 11 in) 2695 mm (8 ft 10 in) 460 mm (1 ft 6 in) 1990 mm (6 ft 6 in) 500 mm (20 in) shoes 600 mm (24 in) shoes 700 mm (28 in) shoes 850 mm (34 in) shoes 2490 mm (8 ft 2 in) 2590 mm (8 ft 6 in) 2690 mm (8 ft 10 in) 2840 mm (9 ft 4 in) 7320 mm (24 ft 0 in) 7340 mm (24 ft 1 in) 7380 mm (24 ft 3 in) 2600 mm (8 ft 6 in) 2660 mm (8 ft 9 in) 2630 mm (8 ft 8 in) 795 mm (2 ft 7 in)
Transport length
- 1.96 m dipper - 2.26 m dipper - 2.91 m dipper* - 1.96 m dipper - 2.26 m dipper - 2.91 m dipper*
M Transport height
Track height
*Dipper ram in transport position (as shown).
9804/1103
45 - 00 - 02/2
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 02/3
JS 130 Static Dimensions
A B C D E F
2780 mm (9 ft 1 in) 3550 mm (11 ft 8 in) 920 mm (3 ft 0 in) 2200 mm (7 ft 3 in) 2130 mm (7 ft 0 in) 2420 mm (7 ft 11 in) 2695 mm (8 ft 10 in) 460 mm (1 ft 6 in) 1990 mm (6 ft 6 in) 500 mm (20 in) shoes 600 mm (24 in) shoes 700 mm (28 in) shoes 850 mm (34 in) shoes 2490 mm (8 ft 2 in) 2590 mm (8 ft 6 in) 2690 mm (8 ft 10 in) 2840 mm (9 ft 4 in) 7660 mm (25 ft 2 in) 7690 mm (25 ft 3 in) 7700 mm (25 ft 4 in) 2550 mm (8 ft 4 in) 2650 mm (8 ft 8 in) 2540 mm (8 ft 4 in) 800 mm (2 ft 5 in)
Transport length
- 1.96 m dipper - 2.50 m dipper - 2.91 m dipper* - 1.96 m dipper - 2.50 m dipper - 2.91 m dipper*
M Transport height
Track height
*Dipper ram in transport position (as shown).
9804/1103
45 - 00 - 02/3
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 02/4
JS 150LC Static Dimensions
A B C D E F
3100 mm (10 ft 2 in) 3900 mm (12 ft 10 in) 1050 mm (3 ft 5 in) 2350 mm (7 ft 9 in) 2235 mm (7 ft 4 in) 2500 mm (8 ft 3 in) 2850 mm (9 ft 4 in) 460 mm (1 ft 6 in) 1990 mm (6 ft 6 in) - 500 mm (20 in) shoes - 600 mm (24 in) shoes - 700 mm (28 in) shoes - 2.70 m dipper - 3.15 m dipper* - 2.70 m dipper - 3.15 m dipper* 2490 mm (8 ft 2 in) 2590 mm (8 ft 6 in) 2690 mm (8 ft 10 in) 8320 mm (27 ft 4 in) 8380 mm (27 ft 6 in) 2850 mm (9ft 4 in) 2865 mm (9ft 5 in) 870 mm (2 ft 10 in)
Transport length
M Transport height
Track height
*Dipper ram in transport position.
9804/1103
45 - 00 - 02/4
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 02/5
A B C D E F
3640 mm (11 ft 11 in) 4440 mm (14 ft 7 in) 1065 mm (3 ft 6 in) 2850 mm (9 ft 4 in) 2800 mm (9 ft 2 in) 2650 mm (8 ft 8 in) 2850 mm (9 ft 4 in) 485 mm (1 ft 7 in) 2300 mm (7 ft 7 in) - 600 mm (24 in) shoes - 700 mm (28 in) shoes - 800 mm (32 in) shoes - 1.90 m dipper - 2.36 m dipper - 2.94 m dipper - 1.90 m dipper - 2.36 m dipper - 2.94 m dipper 2900 mm (9 ft 6 in) 3000 mm (9 ft 10 in) 3100 mm (10 ft 2 in) 9510 mm (31 ft 2 in) 9480 mm (31 ft 1 in) 9380 mm (30 ft 9 in) 3010 mm (9 ft 11 in) 3010 mm (9 ft 11 in) 2850 mm (9 ft 4 in) 910 mm (3 ft 0 in)
Transport length
M Transport height
Track height
9804/1103
45 - 00 - 02/5
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 02/6
A B C D E F
3850 mm (12 ft 8 in) 4710 mm (15 ft 5 in) 1155 mm (3 ft 9 in) 3040 mm (10 ft 0 in) 2930 mm (9 ft 7 in) 2700 mm (8 ft 10 in) 2987 mm (9 ft10 in) 475 mm (1 ft 7 in) 2590 mm (8 ft 6 in) - 600 mm (24 in) shoes - 700 mm (28 in) shoes - 800 mm (32 in) shoes 2.00 m dipper 2.41 m dipper 3.05 m dipper 3.51 m dipper 2.00 m dipper 2.41 m dipper 3.05 m dipper 3.51 m dipper 3190 mm (10 ft 6 in) 3290 mm (10 ft 10 in) 3390 mm (11 ft 2 in) 9980 mm (32 ft 9 in) 9960 mm (32 ft 8 in) 9870 mm (32 ft 5 in) 9920 mm (32 ft 7 in) 3200 mm (10 ft 6 in) 3230 mm (10 ft 7 in) 3040 mm (10 ft 0 in) 3300 mm (10 ft 10 in) 1016 mm (3 ft 4 in)
Transport length
M Transport height
Track height
9804/1103
45 - 00 - 02/6
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 02/7
A B C D E F
3910 mm (12 ft 10 in) 4840 mm (15 ft 11 in) 1225 mm (4 ft 0 in) 3350 mm (11 ft 0 in) 3250 mm (10 ft 8 in) 3140 mm (10 ft 4 in) 3020 mm (9 ft 11 in) 525 mm (1 ft 9 in) 2600 mm (8 ft 6 in) - 600 mm (24 in) shoes - 700 mm (28 in) shoes - 800 mm (32 in) shoes 2.21 m dipper 2.63 m dipper 3.23 m dipper 4.03 m dipper 2.21 m dipper 2.63 m dipper 3.23 m dipper 4.03 m dipper 3200 mm (10 ft 6 in) 3300 mm (10 ft 10 in) 3400 mm (11 ft 2 in) 11070 mm (36 ft 4 in) 10970 mm (36 ft 0 in) 10870 mm (35 ft 8 in) 10970 mm (36 ft 0 in) 3590 mm (11 ft 9 in) 3540 mm (11 ft 7 in) 3330 mm (10 ft 11 in) 3820 mm (12 ft 6 in) 1015 mm (3 ft 4 in)
Transport length
M Transport height
Track height
9804/1103
45 - 00 - 02/7
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 02/8
A B C D E F
4260 mm (14 ft 0 in) 5290 mm (17 ft 4 in) 1395 mm (4 ft 7 in) 3620 mm (11 ft 11 in) 3530 mm (11 ft 7 in) 3140 mm (10 ft 4 in) 3230 mm (10 ft 7 in) 585 mm (1 ft 11 in) 2740 mm (9 ft 0 in) - 600 mm (24 in) shoes - 760 mm (30 in) shoes 2.50 m dipper 3.36 m dipper 4.00 m dipper 4.76 m dipper 2.50 m dipper 3.36 m dipper 4.00 m dipper 4.76 m dipper 3400 mm (11 ft 2 in) 3500 mm (11 ft 6 in) 12100 mm (39 ft 8 in) 12060 mm (39 ft 7 in) 12070 mm (39 ft 7 in) 12160 mm (39 ft 11 in) 3530 mm (11 ft 7 in) 3430 mm (11 ft 3 in) 3460 mm (11 ft 4 in) 4060 mm (13 ft 4 in) 1150 mm (3 ft 9 in)
Transport length
M Transport height
Track height
9804/1103
45 - 00 - 02/8
Issue 1
CONTENTS
Excavators
JS 130W Static Dimensions
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N@5??@@? ?@@Hg?N@@@@H?g@@@Hg@@ ?@@?he?@@@?V'@)K 7@@Hhe?V4@@@)K N@@1e?@@L ?@@1?@@L ?I4@@@@@@@@@6K ?7@@@@1?g3@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6?2@@@@@@@@@@@6?2@@6K?eO2@@6K O&@? J@e?@@? ?@@Lh@@@@L?g@@@Lg@@ ?@@?he?3@@L?V'@@6X ?J@@@?hf?I'@@@6K ?3@@L??3@1 ?@@@?@@1 I4@@@@@@6K ?3@@@@5?gN@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6?2@@@@@@@@@@@6KO2@@@6?@K? 7@1??@@? J@@1h@@@@1?g@@@1g@@ ?@5?he?N@@1??V'@@)X? ?7@@5? V'@@@@6X ?N@@)X?N@@L? ?3@@?3@@ I4@@@@@@6K @@@@H?g?3@@@??I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K @@@??@@? 7@@5h@@@@@?g@@@5g@@ ?(Y?hf3@@LeV'@@)X ?@@(Y? ?V4@@@@)X? 3@@)K?@@1? ?N@@LN@@L? ?I4@@@@@6K ?7@@@@L?g?N@@@L I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6Kg@@@??@@? @@@?h@@@@@?g@@@Hg@@ N@@1e?V'@@)K? J@@H ?I4@@@)K V'@@@@@@@? 3@1?3@1? ?I4@@@@@6X ?@@@@@@?h3@@1 I4@0Y@@@@@@@@@@0M?I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@??@@? @@@@h@@@@5?g@@@?g@@ ?3@@fV'@@@6X? ?W&@5? ?I'@@@6X ?V'@@@@@@@6K N@@LN@@LhO2@@@@@@@@@@@@@@@@@@@6K? I'@@@)K? ?@@@@@heN@@@L? ?@@? I@M?f?I4@0MeI4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@??@@? @@@Hh@@@@h@@@?g@@ ?N@@L?e?V4@@@)K ?7@@H? V'@@@)K? V4@@@@@@@@@6K? ?@@1?@@)K??O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6Kh?V4@@@@6K? ?3@@@@)Kh?@@@)X ?3@? I'@@@??3@L @@@Lh@@@@1?g@@@Lg@@ @@1?f?I'@@@6X J@@5 ?V4@@@@6X? ?I4@@@@@@@@@6K ?@@@?3@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K?g?I'@@@@6X? ?N@@@@@@@@@@@@@@@@@@@)K? @? ?N@@@??N@1 @@@@g?J@@@@5?g@@@@g@@ 3@@LgV4@@@)X? 7@@H ?I'@@@)X I4@@@@@@@@@@6K ?3@@LN@@@@@@@@@@@@@@0Mh?I@M?I4@@@@@@@@@@@@@@6K?fV4@@@@)X @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6?26K O&@? @@@?e@@ 3@@Hg?@@@@@h@@@Hg@@ V'@1hI4@@)K ?J@@5? V4@@@)K? ?I4@@@@@@@@@@6K?h?N@@@?3@@@@@0M I4@@@@@@@@@@@@6KfI4@@@)X? I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6?2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6KO2@@@6K? @@@?e@@L? ?@@?g?N@@@@@?g@@@?g@@ ?N@@heI'@@@6X? W&@@H? I'@@@6X? @@@@@@@@@@@@6Kh3@H?N@@@ ?I4@@@@@@@6XfI'@@)X I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K? @@@??J@@1? 7@@Lh@@@@H?g@@@?g@@ @@L?h?V'@@@)X 7@@5 ?V'@@@)X 3@@@V4@@@@@@@@6Kg?@e?@@@ ?I4@@@@@@)X?e?V'@@)X? W26K?O2@@@@@@@@@@@6?2@@@6Kf?O26K? I'@@@?heI40?@MgI40MI4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?O&@@@? @@@1h3@@@h@@@?g@@ 3@1?heV'@@@)K? ?J@@@H V'@@@)X? N@@@fI4@@@@@@@6K??O&@L??3@@ I4@@@@)KfV'@@)X ?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6X ?N@@5? ?I@Mhf?I4@0MeI@M??I'@@(M?e?I4@@@@0M?eI4@@@@@0?4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K?@@@@ N@X?g?J@@@Lg@@ N@@?he?V4@@@@@6X ?7@@5? ?V'@@@)X ?@@@L?fI4@@@@@@@@@@@@1??N@@ I'@@@@6Xe?V'@@)X? ?7@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1 @@H? N@@H @@@? ?I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6X@)KgO&@@@)K?f@@ ?@@?hf?I4@@@@)K? ?@@(Y? V'@@@)K? ?3@@)Xg?I4@@@@@@@@@5?e@@L? ?V'@@@@)X?eV'@@)X ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@L? @@L? ?3@? @@@? ?I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@he'@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@? ?3@L ?I4@@@@6K? J@@H ?V4@@@@6K? ?V'@@)K?h?I4@@@@0Y?e3@)X V4@@@@)Ke?V'@@)K? ?3@@(M I@M?e?I40M?f?I4@@@@@@@1? @@1? ?N@? @@5? ?I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5heV4@0?'@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0M? ?N@)X?fW2@@@6X?fI'@@@@6X ?W&@5? ?I'@@@@6X? V'@@@6X? N@@1 ?I'@@@@6X?V'@@@@ ?N@@H? @@@? @@@? ?J@? @@ ?I4@@@@@@@@@@@@@0Y ?N@@@@ @@1?e?W&@@@@@)Xf?V'@@@@)K? ?7@@H? V4@@@@)X ?V'@@@)X ?@@@ V4@@@@)X?V'@@@L? ?J@@ @@@? @@@? ?7@? @@1? @@@@ 3@@Le?7@@@@@@@1gN@@@@@@6K? J@@5 I'@@@)K? V'@@@)X? ?@@@ I'@@@)X?V'@@)X ?7@@ @@@? @@@@@@@@6?2@@@@@@6KO2@@6K??O@KO@K??O26K?g?O2@@@@6?2@@6?@?2@@6?@K?hf?@@? ?J@@@? @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K @@@@ N@@1e?@@@@@@@@@g?@@@@@@@@6K? ?W&@(Y ?V4@@@@6X? ?V4@@@)X ?3@@L? ?V4@@@)K?V'@@)X? ?@@@ @@@? 3@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K O&@@5? @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6X @@@@ ?@@@e?@@Xe?@@@f?@@@@@@@@@@@@@6K ?7@@H? I'@@)K ?I'@@)X? ?N@@1? ?I'@@@6XV'@@1? ?@@@ @@@? V4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@H? @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1 3@@@ ?3@@L??@@)X?J@@@fJ@@@@@@@@@@@@@@@6K ?@@@ ?V'@@@6X V'@@)X 3@@? V'@@@)XV'@@L ?@@@ @@@? W2@@@@@? ?I'@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@e?@@?e@@@@@?@@@@hf?@@@e@@@@@@@@@(M?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5 @@(Me?I@M @@ N@@@ ?N@@1??3@@)?&@@5e?W&@@@(MeI4@@@@@@@@6K J@@5 V'@@@)K? ?V'@@)X? N@@L ?V'@@@)XN@@)X?hf?@@@ @@@? ?W&@@@@@@L N@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6KO2@@@@@@@@@@@@@@@@@Ye@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@f@@@@?@@@@@@?e?@@@@@@@e@@@@@@@@0Y ?J@@H? @@ ?@@5 3@@L?N@@@@@@@HeW&@@@(Y?f?@@@@@@@@@@6K? 7@@H ?V'@@@@6X? V'@@)X ?@@1 V'@@@)T@@@1?hf?@@@ @@@? O&@@@@@@@1 ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@(M? ?@@@ @@ ?@@H N@@1e3@@@@@5??W&@@@@Hg?@@@@@@@@@@@@@6X ?J@@5? V4@@@@)X ?V'@@1 ?3@@ ?V4@@@@R'@@?hf?@@@ @@@? W2@@@@@@@@@@@@ J@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@H ?N@@ @@ ?@@? ?3@@eV4@@@0Y?O&@@@@@?g?@@@@@@@@@@@@@@)K? W&@@H? I4@@@)K? V'@@L?hf?N@@L? ?I
Monoboom Dipper Lengths 1.96m 2.26m 2.5m 2.91m 1.96m
Articulated Dipper Lengths 2.26m 2.5m 2.91m
A B
3040 7680
3040 7680
3040 7700
3040 7700
3040 7540
3040 7550
3040 7570
3040 7590
Shipping Weights
Mach ne equ pped w h 2 26 m d ppe and 0 46m s anda d excava ng bucke
12350 o 14110 kg depend ng whe he s ab se s and o doze a e
ed
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JS 150W Static Dimensions
Monoboom Dipper Lengths 2.1m 2.7m 3.15m 2.1m
Articulated Dipper Lengths 2.7m 3.15m
A B
3060 8320
3060 8320
3060 8320
3060 8000
3060 8010
3060 8020
Shipping Weights
Machine equipped with 2.1 m dipper and 0.62m3 standard excavating bucket:
14150 to 16510 kg depending whether stabilisers and/or dozer are fitted.
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JS 70 from m/c no. 695501 Static Dimensions
L D E F
G R C S A B N H J K P
JS08420
A B C D E F G H J K
Tracked length on ground Undercarriage - overall length Tail height Tailswing radius Tail length Superstructure width Height over cab Ground clearance Track gauge Track width 450 mm (18 in) shoes 600 mm (24 in) shoes Standard boom (1.74 m dipper) Standard boom (2.18 m dipper) Offset Boom Standard boom (1.74 m dipper) Standard boom (2.18 m dipper) Offset Boom
2050 mm (6 ft 9 in) 2680 mm (8 ft 10 in) 760 mm (2 ft 6 in) 1740 mm (5 ft 9 in) 1740 mm (5 ft 9 in) 2200 mm (7 ft 3 in) 2560 mm (8 ft 5 in) 380 mm (1 ft 3 in) 1700 mm (5 ft 8 in) 2150 mm (7 ft 1 in) 2300 mm (7 ft 7 in) 6010 mm (19 ft 9 in) 5990 mm (19 ft 8 in) 5950 mm (19 ft 6 in) 2640 mm (8 ft 8 in) 2930 mm (9 ft 7 in) 2740 mm (9 ft 0 in) 660 mm (2 ft 2 in) 2250 mm (7 ft 5 in) 460 mm (1 ft 6 in) 480 mm (1 ft 7 in)
Transport length
Transport height
N P R S
Track height Dozer blade width Dozer blade height Dozer blade reach in front of tracks
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JS 130, from m/c no. 758000

*
Static Dimensions
J D E
Monoboom
K C
G A B H I
JS03463
ILLUSTRATION NOT AVAILABLE AT THIS TIME Dimensions in millimetres (ft. in) A Track length on ground B Undercarriage overall length C Counterweight clearance D Tailswing radius E Overall width of superstructure F Height over cab G Ground clearance H Track gauge I Width over tracks (500 mm shoes) I Width over tracks (600 mm shoes) I Width over tracks (700 mm shoes) I Width over tracks (850 mm shoes) J Transport length (2.10 m dipper) J Transport length (2.50 m dipper) J Transport length (3.00 m dipper) * K Transport height (2.10 m dipper) K Transport height (2.50 m dipper) K Transport height (3.00 m dipper) * L Track height * Machine in transport position.
J D E
MONOBOOM 2780 3550 910 2050 2410 2695 460 1990 2490 2590 2690 2840 7580 7600 7630 2695 2695 2695 815 (9ft 1 in) (11 ft 8 in) (3 ft 0 in) (6 ft 9 in) (7 ft 11 in) (8 ft 11 in) (1 ft 6 in) (6 ft 6 in) (8 ft 2 in) (8 ft 6 in) (8 ft 10 in) (9 ft 4 in) (24 ft 10 in) (24 ft 11 in) (25 ft 0 in) (8 ft 11 in) (8 ft 11 in) (8 ft 11 in) (2ft 8 in)
T.A. BOOM 2780 3550 910 2050 2410 2695 460 1990 2490 2590 2690 2840 7310 7650 7890 3040 3040 3040 815 (9ft 1 in) (11 ft 8 in) (3 ft 0 in) (6 ft 9 in) (7 ft 11 in) (8 ft 11 in) (1 ft 6 in) (6 ft 6 in) (8 ft 2 in) (8 ft 6 in) (8 ft 10 in) (9 ft 4 in) (24 ft 1 in) (25 ft 1 in) (25 ft 11 in) (11 ft 2 in) (11 ft 2 in) (11 ft 2 in) (2ft 8 in)
T.A. Boom
K C
G A B H I
JS03463
ILLUSTRATION NOT AVAILABLE AT THIS TIME
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JS 160 from m/c 702000 Static Dimensions
K F G
E I A B C D
JS03510
Dimensions in millimetres (ft. in) A Track length on ground B Undercarriage overall length C Track gauge 1990 (6 ft 6 in) D Width over tracks (500 mm shoes) D Width over tracks (600 mm shoes) D Width over tracks (700 mm shoes) D Width over tracks (800 mm shoes) D Width over tracks (900 mm shoes) E Counterweight clearance F Tailswing radius G Width of superstructure H Height over cab I Ground clearance J Track height Machine in transport position.
NLC 3090 (10 ft 2 in) 3940 (12 ft 11 in) 2200 (7 ft 3 in) 2490 (8 ft 2 in) 2590 (8 ft 6 in) 2690 (8 ft 10 in) 1050 (3 ft 5 in) 2350 (7 ft 9 in) 2500 (8 ft 2 in) 2840 (9 ft 4 in) 470 (1 ft 7 in) 880 (2 ft 11 in)
LC 3090 (10 ft 2 in) 3940 (12 ft 11 in) 2200 (7 ft 3in) 2700 (8 ft 10 in) 2800 (9 ft 2 in) 2900 (9 ft 6 in) 3000 (9 ft 10 in) 3100 (10 ft 2 in) 1050 (3 ft 5 in) 2350 (7 ft 9 in) 2500 (8 ft 2 in) 2840 (9 ft 4 in) 470 (1 ft 7 in) 880 (2 ft 11 in)
Dipper lengths K Transport length with Monoboom L Transport height with Monoboom
2.70 m 8310 (27 ft 3 in) 2790 (9 ft 2 in)
3.05 m 8400 (27 ft 7 in) 3095 (27 ft 2 in)
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K F G
E I A B C D
JS03511
Dimensions in millimetres (ft. in) A Track length on ground B Undercarriage overall length C Track gauge D Width over tracks (600 mm shoes) D Width over tracks (700 mm shoes) E Counterweight clearance F Tailswing radius G Width of superstructure * H Height over cab I J Ground clearance * Track height 3370 4170 2200 2800 2900 1066 2350 2500 2855 486 885 (11 ft 1 in) (13 ft 8 in) (7 ft 2 in) (9 ft 2 in) (9 ft 6 in) (3 ft 6 in) (7 ft 9 in) (8 ft 2 in) (9 ft 4 in) (1 ft 7 in) (2 ft 11 in)
* Machine in transport position.
Dipper lengths A Transport length B Transport height
2.25 m 8366 (27 ft 5 in) 8265 (9 ft 5 in)
2.70 m 8326 (27 ft 4 in) 2790 (9 ft 5 in)
3.05 m 8415 (27 ft 7 in) 3095 (10 ft 2 in)
9804/1103
45 - 00 - 02/12A
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 02/13
JS 200, 220 from m/c no. 705001 Static Dimensions

Note: The information given below applies also to all variants of the JS220 range, except the LR.
E J K
Monoboom
JS200LC
I M A B C D
JS03050
Dimensions in millimetres (ft. in) A Track length on ground B Undercarriage overall length C Track gauge D Width over tracks (500 shoes) D Width over tracks (600 shoes) D Width over tracks (700 shoes) D Width over tracks (800 shoes) D Width over tracks (900 shoes) Dipper lengths E Transport length with Monoboom F Transport height with Monoboom G Transport length with T.A. Boom H Transport height with T.A. Boom 2800 2900 3370 4170 2200
S (11ft 1 in) (13 ft 8 in) (7 ft 2 in) (9 ft 2 in) (9 ft 6 in) 1.91 m 9570 3055 9598 3128 (31 ft 5 in) (10 ft 0 in) (31 ft 6 in) (10 ft 3 in) 3370 4170 1990 2490 2590 2690
N (11 ft 1 in) (13 ft 8 in) (6 ft 6 in) (8 ft 2 in) (8 ft 6 in) (8 ft 10 in) 2.40 m 9560 3060 9573 3065 (31 ft 4 in) (10 ft 0 in) (31 ft 5 in) (10 ft 1 in) 9440 2860 9499 2913 2990 3090 3190 3290 3660 4460 2390
LC (12 ft 0 in) (14 ft 8 in) (7 ft 10 in) (9 ft 10 in) (10 ft 2 in) (10 ft 6 in) (10 ft 10 in) 3.0 m (31 ft 0 in) (9 ft 5 in) (31 ft 2 in) (9 ft 7 in)
Dimensions in millimetres (ft in) I Counterweight clearance J Tailswing radius K Width of superstructure* L Height over cab M Ground clearance N Track height
S/N/LC 1066 2770 2500 2886 486 885 (3 ft 6 in) (9 ft 1 in) (8 ft 2 in) (9 ft 6 in) (1 ft 7 in) (2 ft 11 in) * with cab handrail removed
G J K
T.A. Boom
H
JS200LC
I M A B C D
JS03060
9804/1103
45 - 00 - 02/13
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 02/13A
JS 130, from m/c no. 705001 Static Dimensions
E J K
I M A B C D
JS03051
JSO3051
Dimensions in millimetres (ft. in) A Track length on ground B Undercarriage overall length C Track gauge D Width over tracks (700 mm shoes) Dimensions in millimetres (ft. in) I Counterweight clearance F Tailswing radius G Width of superstructure * H Height over cab 2886 I Ground clearance J Track height * with cab handrail removed 1066 (3 ft 6 in) 2770 (9 ft 1 in) 2500 (8 ft 2 in) (9 ft 6 in) 486 (1 ft 7 in) 885 (2 ft 11 in) 3370 (11 ft 1 in) 4170 (13 ft 8 in) 2200 (7 ft 2 in) 2900 (9 ft 6 in)
Dipper lengths E Transport length with Monoboom F Transport height with Monoboom
1.91 m 9570 (31 ft 5 in) 3055 (10 ft 0 in)
2.40 m 9560 (31 ft 4 in) 3060 (10 ft 0 in)
3.0 m 9440 (31 ft 0 in) 2860 (9 ft 5 in)
9804/1103
45 - 00 - 02/13A
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 00 - 02/14
JS 240, 260 from m/c no 708501 Static Dimensions

Note: The information given below applies also to all variants of the JS260 range.
E J K
Monoboom
F
JS240LC
I M A B C D
JS03070
Dimensions in millimetres (ft. in) A Track length on ground B Undercarriage overall length C Track gauge D Width over tracks (600 shoes) D Width over tracks (700 shoes) D Width over tracks (800 shoes) D Width over tracks (900 shoes) Dipper lengths E Transport length with Monoboom F Transport height with Monoboom G Transport length with T.A. Boom H Transport height with T.A. Boom 3173 10449 3006 3460 4260 2390 2990 3090 3190 3290 2.00 m 10083
S (11ft 4 in) (14 ft 0 in) (7 ft 10 in) (9 ft 10 in) (10 ft 2 in) (10 ft 6 in) (10 ft 9 in) 3840 4640 2390 2990 3090 3190 3290 2.44 m 10060 3230 10424 3086
NLC (12 ft 7 in) (15 ft 83 in) (7 ft 10 in) (9 ft 10 in) (10 ft 2 in) (10 ft 6 in) (10 ft 9 in) 3.09 m 9960 (32 ft 8 in) 3050 (10 ft 0 in) 10386 (34 ft 1 in) 2950 (9 ft 8 in) 3220 3209 3840 4640 2590 3190 3290 3390 3490
LC (12 ft 7 in) (15 ft 3 in) (8 ft 6 in) (10 ft 6 in) (10 ft 9 in) (11 ft 1 in) (11 ft 5 in) 3.53 m 10010 (32 ft 10 in) (10 ft 7 in) (10 ft 6 in) 10373 (34 ft 0 in)
(33 ft 0 in) (10 ft 5 in) (34 ft 3 in) (9 ft 10 in)
(33 ft 0 in) (10 ft 7 in) (34 ft 2 in) (10 ft 1 in)
Dimensions in millimetres (ft in) I Counterweight clearance J Tailswing radius K Width of superstructure* L Height over cab M Ground clearance N Track height 1125 3000 2500 2920 486 940 (3 ft 8 in) (9 ft 10 in) (8 ft 2 in) (9 ft 10 in) (1 ft 7 in) (3 ft 1 in) * with cab handrail removed
G J K
T.A. Boom
JS240LC
I M A B C D
JS03080
9804/1103
45 - 00 - 02/14
Issue 1
CONTENTS
Excavators
45 - 00 - 02/15
JS 220LC Long Reach (LR) from m/c no. 705001 Static Dimensions
JS03821
With the exception of E and F detailed in the table below, the following dimensions are the same as those for the JS200/JS220 LC machine as listed on page 45 - 00 - 02/13, i.e. A, B, C, D (900 shoes), I, J, K, L, M, N.
Dimension E Transport length F Transport height 12520 mm (41 ft 1 in) 3000 mm (9 ft 10 in)
9804/1103
45 - 00 - 02/15
Issue 1
CONTENTS
Excavators
45 - 00 - 02/16

E H
F
JS240LC
G L A B C D
JS09740
Dimension in millimetres A Track length on ground B Undercarriage overall length C Track gauge D Width over tracks (600 shoes) D Width over tracks (700 shoes) D Width over tracks (800 shoes) D Width over tracks (900 shoes) E Transport length (2.21 m dipper) E Transport length (2.63 m dipper) E Transport length (3.23 m dipper) E Transport length (4.03 m dipper) F Transport height (2.21 m dipper) F Transport height (2.63 m dipper) F Transport height (3.23 m dipper) F Transport height (4.03 m dipper) G Counterweight clearance H Tailswing radius J Width of superstructure
LC 3910 (12 ft 10 in) 4810 (15 ft 9 in) 2600 (8 ft 6 in) 3200 (10 ft 6in) 3300 (10 ft 10 in) 3400 (11 ft 2 in) 3500 (11 ft 6 in) 11050 (36 ft 3 in) 10960 (35 ft 11 in) 10860 (35 ft 7 in) 10950 (35 ft 11 in) 3610 (11 ft 10 in) 3570 (11 ft 9 in) 3360 (11 ft 0 in) 3850 (12 ft 8 in) 1190 (3 ft 10 in) 3260 (10 ft 9 in) 2990 (9 ft 10 in) 3030 (10 ft 0 in) 500 (1 ft 7 in)
NLC 3910 (12 ft 10 in) 4810 (15 ft 9 in) 2390 (7 ft 10 in) 2990 (9 ft 9 in) 3090 (10 ft 2 in) 3190 (10 ft 6 in) 3290 (10 ft 10 in) 11050 (36 ft 3 in) 10960 (35 ft 11 in) 10860 (35 ft 7 in) 10950 (35 ft 11 in) 3610 (11 ft 10 in) 3570 (11 ft 9 in) 3360 (11 ft 0 in) 3850 (12 ft 8 in) 1190 (3 ft 10 in) 3260 (10 ft 9 in) 2990 (9 ft 10 in) 3030 (10 ft 0 in) 500 (1 ft 7 in)
K Height over cab L Ground clearance
9804/1103
45 - 00 - 02/16
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 02/16A

Note: The information given below applies also to all variants of the JS 450 range.
E H
G L A B C D
A296890
Dimensions in millimetres (ft. in) A Track length on ground B Undercarriage overall length C Track gauge D Width over tracks (600 shoes) E Transport length (3.36 m dipper) F Transport height (3.36 m dipper) G Counterweight clearance H Tailswing radius J Width of superstructure 4400 (14 ft 5 in) 5470 (17 ft 11 in) 2750 (9 ft 0 in) 3430 (11 ft 3 in) 11700 (38 ft 4 in) 3510 (11 ft 6 in) 1380 (4 ft 6 in) 3300 (10 ft 10 in) 2990 ( 9 ft 10 in) 3260 (10 ft 8 in) 550 (1 ft 10 in)
K Height over cab L Ground clearance
9804/1103
45 - 00 - 02/16A
Issue 1
CONTENTS
Excavators
45 - 00 - 02/17
JS 130W from m/c no. 0716500 Static Dimensions

2050 mm
A 1240 mm 498 mm 519 mm B
2410 mm
3040 mm
350 mm 1330 mm 2490 mm

JS08090
Monoboom Dipper Length (m) A (mm) B (mm) 2.10 3040 7580 2.50 3040 7600 3.00 3040 7630
Articulated Boom 2.10 3040 7310 2.50 3040 7650 3.00 3040 7890
9804/1103
45 - 00 - 02/17
Issue 1
CONTENTS
Excavators
45 - 00 - 02/18
JS 160W from m/c no. 0718500 Static Dimensions

2190 mm
A 1270 mm 498 mm 519 mm B
2500 mm
3070 mm
360 mm 1330 mm 2490 mm

JS08800
9804/1103
45 - 00 - 02/18
Issue 1
CONTENTS
Excavators
45 - 00 - 02/19
JS 200W from m/c no. 0802000 to 802999 Static Dimensions
2530 mm
1310 mm 556 mm 511 mm B
2500 mm
3200 mm
350 mm 1240 mm 2500 mm

JS08801
9804/1103
45 - 00 - 02/19
Issue 1
CONTENTS
Excavators
45 - 00 - 02/20
JS 200W from m/c no. 809000

*
Static Dimensions
2530 mm (8ft 3in)
A 1310 mm (4ft 3in)
556 mm (1ft 10in) 511 mm (1ft 8in)
2500 mm (8ft 2in)
3150 mm (10ft 4in)
350 mm (1ft 2in) 1240 mm (4ft 1in) 2500 mm (8ft 2in)

JS08801
Monoboom Dipper Length (m) A (mm) B (mm) 1.90 3360 (10ft 0in) 9450 (31ft 0in) 2.40 2985(9ft 9in) 9350(30ft 8in) 3.00 2875(9ft 5in) 9280(29ft 5in) 1.90 3290(10ft 9in) 9160(30ft 0in)
Articulated Boom 2.40 3290(10ft 9in) 9150(30ft 0in) 3.00 3120(10ft 3in) 9040(29ft 8in)
9804/1103
45 - 00 - 02/20
6980 - 144
Issue 2*
CONTENTS
Excavators
45 - 00 - 02/21
JS 460 from m/c no. 714550

*
Static Dimensions
E H
G L A B C D
JS09741
Dimension in millimetres A B C D E F G H J K L Track length on ground Undercarriage overall length Track gauge Width over tracks (600 shoes) Transport length (3.36 m dipper) Transport height (3.36 m dipper) Counterweight clearance Tailswing radius Width of superstructure Height over cab Ground clearance 4360 (14 ft 4 in) 5343 (17 ft 7 in) 2750 (9ft 0 in) 3430 (11 ft 3 in) 11700 (38 ft 4 in) 3510 (11 ft 6 in) 1380 (4 ft 6 in) 3300 (10 ft 10 in) 2990 (9ft 10 in) 3330 (10 ft 11 in) 590 (1 ft 11 in)
9804/1103
45 - 00 - 02/21
6950 - 149.2
Issue 1*
CONTENTS
Excavators
45 - 00 - 03/1
* JS
70 from m/c no. 695501
Shipping Weights
Machine equipped with Boom; 1.74 m (5 ft 8 in) Dipper Arm, Dozer Blade, Standard Excavating Bucket, operator and full fuel tank. * Standard
Boom
Operating Weight 6800 kg (14994 lb) 7000 kg (15435 lb) Ground Bearing Pressure 0.33 kgf/cm2 (4.69 lb/in2) 0.25 kgf/cm2 (3.56 lbf/in2)
Shoe Width 450 mm (18 in) 600 mm (24 in)
* Offset
Boom
Shoe Width 450 mm (18 in) 600 mm (24 in) Operating Weight 7300 kg (16060 lb) 7500 kg (16500 lb) Ground Bearing Pressure 0.35 kgf/cm2 (4.97 lb/in2) 0.27 kgf/cm2 (3.84 lbf/in2)
9804/1103
45 - 00 - 03/1
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 00 - 03/2
JS 110,130,150LC Shipping Weights MODEL JS110

Machine equipped with 4.35 m (14 ft 3 in) Boom, 2.26 m (7 ft 5 in) Dipper Arm, Standard Excavating Bucket, operator and full fuel tank. Shoe Width 500 mm (20 in) 600 mm (24 in) 700 mm (28 in) 850 mm (34 in) Operating Weight 11150 kg (24600 lb) 11325 kg (25000 lb) 11500 kg (25350 lb) 11780 kg (25970 lb) Ground Bearing Pressure 0.39 kgf/cm2 (5.55 lbf/in2) 0.33 kgf/cm2 (4.69 lbf/in2) 0.29 kgf/cm2 (4.12 lbf/in2) 0.24 kgf/cm2 (3.42 lbf/in2)
Basic machine weight, with 1860 kg (4100 lb) counterweight and 600 mm (24 in) shoes but no boom or dipper arm: 9300 kg (20500 lb)
MODEL JS130
Machine equipped with 4.35 m (14 ft 3 in) Boom, 2.26 m (7 ft 5 in) Dipper Arm, Standard Excavating Bucket, operator and full fuel tank. Shoe Width 500 mm (20 in) 600 mm (24 in) 700 mm (28 in) 850 mm (34 in) Operating Weight 12290 kg (27100 lb) 12480 kg (27500 lb) 12680 kg (28000 lb) 12970 kg (28600 lb) Ground Bearing Pressure 0.39 kgf/cm2 (5.55 lbf/in2) 0.33 kgf/cm2 (4.69 lbf/in2) 0.29 kgf/cm2 (4.12 lbf/in2) 0.24 kgf/cm2 (3.47 lbf/in2)
Basic machine weight, with 2560 kg (56448 lb) counterweight and 600 mm (24 in) shoes but no boom or dipper arm: 10000 kg (22050 lb).
MODEL JS150LC
Machine equipped with 5.15 m (16 ft 11 in) Boom; 2.7 m (8ft 10 in) Dipper Arm, Standard Excavating Bucket, operator and full fuel tank. Shoe Width 500 mm (20 in) 600 mm (24 in) 700 mm (28 in) Operating Weight 15870 kg (34990 lb) 16110 kg (35520 lb) 16360 kg (36070 lb) Ground Bearing Pressure 0.47 kgf/cm2 (6.70 lb//in2) 0.38 kgf/cm2 (5.60 lbf/in2) 0.33 kgf/cm2 (4.80 lbf/in2)
Basic machine weight, with 3000 kg (6615 lb) counterweight and 600 mm (24 in) shoes but no boom or dipper arm; 13460 kg (29680 lb)
9804/1103
45 - 00 - 03/2
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 03/3
JS 200LC,240LC,300LC,450LC Shipping Weights MODEL JS200LC

Machine equipped with 5.63 m (18 ft 6 in) Boom; 2.94 m (9 ft 8 in) Dipper Arm, Standard Excavating Bucket, operator and full fuel tank. Shoe Width 600 mm (24 in) 700 mm (28 in) 800 mm (32 in) Operating Weight 19610 kg (43240 lb) 19900 kg (43880 lb) 20180 kg (44500 lb) Ground Bearing Pressure 0.41 kgf/cm2 (5.83 lbf/in2) 0.36 kgf/cm2 (5.12 lbf/in2) 0.31 kgf/cm2 (4.41 lbf/in2)
Basic machine weight, with 3900 kg (8600 lb) counter weight and 600 mm (24 in) shoes but no boom or dipper arm; 15790 kg (34820 lb)
MODEL JS240LC
Machine equipped with 5.85 m (19 ft 2 in) Boom, 3.06 m (10 ft 0 in) Dipper Arm, Standard Excavating Bucket, operator and full fuel tank. Shoe Width 600 mm (24 in) 700 mm (28 in) 800 mm (32 in) Operating Weight 23900 kg (52700 lb) 24200 kg (53350 lb) 24500 kg (54000 lb) Ground Bearing Pressure 0.48 kgf/cm2 (6.881 lbf/in2) 0.43 kgf/cm2 (6.17 lbf/in2) 0.37 kgf/cm2 (5.30 lbf/in2)
Basic machine weight, with 4200 kg (9260 lb) counter weight and 600 mm (24 in) shoes but no boom or dipper arm; 18910 kg (41690 lb)
MODEL JS300LC
Machine equipped with 6.45 m (21 ft 2 in) boom, 3.23 m (10 ft 7 in) arm, standard bucket, operator and full fuel tank. Shoe Width 600 mm (24 in) 700 mm (28 in) 800 mm (32 in) Operating Weight 31000 kg (683401 lb) 31400 kg (69200 lb) 31750 kg (70000 lb) Ground Bearing Pressure 0.60 kgf/cm2 (8.61 lbf/in2) 0.52 kgf/cm2 (7.40 lbf/in2) 0.47 kgf/cm2 (6.72 lbf/in2)
Basic machine weight, with 6000 kg (13230 lb) counter weight and 600 mm (24 in) triple grouser track without boom or dipper 24400 kg (53800 lb).
MODEL JS450LC
Machine equipped with 7.10 m (23 ft 4 in) boom, 3.36 m (11 ft 0 in) dipper arm, standard bucket, operator and full fuel tank. Shoe Width 600 mm (24 in) 760 mm (30 in) Operating Weight 43530 kg (95961 lb) 44340 kg (97740 lb) Ground Bearing Pressure 0.79 kgf/cm2 (11.2 lbf/in2) 0.63 kgf/cm2 (8.96 lbf/in2)
Basic machine weight, with 9050 kg (19950 lb) counterweight and 600 mm (24 in) triple grouser shoes, without boom and dipper 34600 kg (76280 lb).
9804/1103
45 - 00 - 03/3
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 03/3A
JS 70 from m/c no. 695501 Shipping Weights

Machine equipped with Boom; 1.74 m (5 ft 8 in) Dipper Arm, Dozer Blade, Standard Excavating Bucket, operator and full fuel tank.
Standard Boom
Offset Boom
9804/1103
45 - 00 - 03/3A
Issue 1
CONTENTS
Excavators
45 - 00 - 03/4
JS 130, 160, 180, 200, 210 220, 240, 260, JS330, 450 Shipping Weights
Approximate weight when equipped with monoboom, medium length dipper, bucket, operator and full fuel tank.
JS130 from m/c no. 758000

Model 130 130 130 130 Track Shoe Width 500 mm 600 mm 700 mm 850 mm Weight 13210 kg 13400 kg 13600 kg 13890 kg

Model 220S 220LC 220N XD 220 LC LR 220S LC XD Track Shoe Width 600 mm 700 mm 500 mm 700 mm 700 mm 600 mm Weight 21310 kg 21990 kg 21430 kg 22590 kg 22490 kg 20560 kg

Model 160NLC 160 LC 160LC 160LC 160LC Track Shoe Width 500 mm 600 mm 700 mm 800 mm 900 mm Weight 16000 kg 16220 kg 16470 kg 16710 kg 16940 kg
220S XD
Machine eqipped with 15 metre long reach boom/dipper

Model 240S 240NLC Track Shoe Width 600 mm 600 mm 700 mm Weight 23750 kg 24270 kg 24620 kg

Model 180 180 Track Shoe Width 600 mm 700 mm Weight 18120 kg 18475 kg
240LC

Model 260S Track Shoe Width 600 mm 600 mm 700 mm 600 mm 600 mm 700 mm Weight 24750 kg 25270 kg 25620 kg 25250 kg 25770 kg 26120 kg

Model 200N 200S 200LC Track Shoe Width 500 mm 600 mm 700 mm Weight 19630 KG 20010 kg 20690 kg
260NLC 260LC 260S XD 220 NLC XD 220LC XD

Model 210 Track Shoe Width 700 mm Weight 21500 kg

Model 330 330 Track Shoe Width 600 mm 700 mm 800 mm 900 mm Weight 31900 kg 32250 kg 32600 kg 32850 kg

330 330
Machine weight without bucket/full tank of fuel

Machine weight without bucket/full tank of fuel
9804/1103
45 - 00 - 03/4
6950 - 150
Issue 4*
CONTENTS
Excavators
45 - 00 - 03/5
JS 130W from m/c no. 0716501, JS 160W from m/c no. 0718501 Shipping Weights JS130W
Basic Machine i.e. without dozer blade or stabilisers Monoboom 12700 kg Basic Machine Basic Machine with dozer blade with 2 stabilisers Basic Machine with dozer blade and 2 stabilisers Basic Machine with 4 stabilisers
13140 kg
13580 kg
14120 kg
14460 kg
Triple Articulated Boom
13200 kg
13640 kg
14080 kg
14620 kg
14960 kg
Machine equipped with 2.5 m dipper, 0.55 m3 standard excavating bucket and dual wheels. For single wheels subtract 400 kg.
JS160W
15850 kg
16290 kg
16830 kg
17170 kg
16010 kg
16450 kg
16890 kg
17430 kg
17770 kg
9804/1103
45 - 00 - 03/5
Issue 1
CONTENTS
Excavators
45 - 00 - 03/6
JS 200W from m/c no. 0802000 to 802999 Shipping Weight (Approximate)

19400 kg
19660 kg
20360 kg
20640 kg
19130 kg
19820 kg
20090 kg
20790 kg
21050 kg
9804/1103
45 - 00 - 03/6
Issue 1
CONTENTS CONTENTS
Excavators
45 - 00 - 03/7
JS 130W from m/c no. 716500, JS 160W from m/c no. 718500 JS200W from m/c no. 809000 Shipping Weight (Approximate) JS130W
13140 kg
13580 kg
14120 kg
14460 kg
13200 kg
13640 kg
14080 kg
14620 kg
14960 kg
JS160W
15850 kg
16290 kg
16830 kg
17170 kg
16010 kg
16450 kg
16890 kg
17430 kg
17770 kg
JS200W
19400 kg
19660 kg
20360 kg
20640 kg
19130 kg
19820 kg
20090 kg
20790 kg
21050 kg
9804/1103
45 - 00 - 03/7
6980 - 145
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 01/1
JS 70 to m/c no. 695500 Data - Electrical

System Battery Alternator Light Bulbs Working, Boom Mounted Working, Tank Mounted Cab Engine Compartment Beacon Fuse Box Circuits Radio/Cab Light Operation Control Switch/Travel Control Switch Heater Refuelling Pump (optional) Systems Control Monitor Idle Switch Working Lamps/Horn Windscreen Wiper/Washer Rating (Amps) 10 20 20 20 10 30 20 15 Fuse No. 1 2 3 4 5 6 7 8 12 Volt, negative earth 12 Volt Heavy Duty, 110 Ah 12 Volt, 50 Amp
55 Watts 55 Watts 10 Watts x 1 10 Watts 70 Watts
S267430
9804/1103
45 - 05 - 01/1
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 05 - 01/2
JS 110,130,150LC Data - Electrical

System Battery Alternator Starter Motor Light Bulbs Working, Boom Mounted Working, Tank Mounted Cab Engine Compartment Circuit Protection Circuits Controller Electric Control Horn/Working Light Windscreen Wiper Cab Light/Radio Oil Pressure Heater/Cooler (Optional) Spare Rating (Amps) 10 15 15 15 10 10 15 15 Fuse No. 1 2 3 4 5 6 7 8 24 Volt, negative earth 2 x 12 Volt Heavy Duty, 120Ah 24 Volt, 40 Amp 24 Volt, 3.5 or 4.5 kW, 30 secs.
70 Watt 55 Watt 10 Watt x 2 10 Watt
S26744-0
9804/1103
45 - 05 - 01/2
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 01/3
JS 200LC,240LC,300LC,450LC Data - Electrical

System (All Machines) Battery (All Machines) Alternator (JS 200, 240, 300LC) Alternator (JS 450LC) Starter Motor (JS 200, 240LC) Starter Motor (JS 300LC) Starter Motor (JS 450LC) Light Bulbs JS 200LC Working, Boom Mounted Working, Tank Mounted Cab Engine Compartment JS 300LC Working, Boom Mounted Working, Tank Mounted Cab Engine Compartment 80 Watt 80 Watt 10 Watt x 2 10 Watt 70 Watt 70 Watt 10 Watt x 2 10 Watt JS 240LC Working, Boom Mounted Working, Tank Mounted Cab Engine Compartment JS 450LC Working, Boom Mounted Working, Tank Mounted Working, Rear Mounted Cab Engine Compartment 80 Watt 80 Watt 80 Watt 10 Watt x 2 10 Watt 80 Watt 80 Watt 10 Watt x 2 10 Watt 24 Volt, negative earth 2 x 12 Volt Heavy Duty, 120Ah 24 Volt, 40 Amp 24 Volt, 25 Amp 24 Volt, 4.5 kW, 30 secs. 24 Volt, 5.5 kW, 30 secs. 24 Volt, 11 kW, 30 secs.
Circuit Protection Circuits Controller Electric Control Horn/Working Light Windscreen Wiper Cab Light/Radio Oil Pressure Heater/Air Conditioning (Optional) Spare Rating (Amps) 10 15 15 15 10 10 15 15 Fuse No. 1 2 3 4 5 6 7 8
S267450
9804/1103
45 - 05 - 01/3
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 01/4
JS 130W,150W Data - Electrical

System Battery Alternator Starter Motor Light bulbs Working (boom) Working (tank) Cab Interior Engine Compartment Beacon Headlights Indicator Lights Number Plate Light Brake Lights Reversing Lights Fog Lights Side Lights Circuit Protection The electrical circuits are protected by fuses. Some of the fuses are located in fuse box 1 on the inside face of the right console, others are located in fuse box 2 situated to the right of the seat (see Service Manual, page C/1 - 2). If a fuse blows, find out why before fitting a new one. Fuse Box 1 Fuse No. 1 2 3 4 5 6 7 8 Circuit(s) Protected Service Check Maintenance Monitor Engine Throttle, Redundant (Back-up) Switch Work Lamp, Horn, Travel Control Switch Windscreen Wiper/Washer Radio (plus 2A in-line fuse), Cab Light, Attachment Cushion Switch Operation Control Switch Heater, Air Conditioner (Optional) Feed to Relay Box, Refuelling Pump (Optional) Rating 10A 15A 15A 15A 10A 10A 15A 10A 70 W 55 W 2 x 10 W 10 W 70 W 75/70 W 21 W 5 W (Festoon) 21 W 21 W 21 W 10 W 24 Volt, negative earth 2 x 12 Volt Heavy Duty, 120Ah 24 Volt, 40 Amp 24 Volt, 4.5 kW, 30 secs.
Fuse Box 2
See next page
9804/1103
45 - 05 - 01/4
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 01/5
JS 130W,150W Data - Electrical (contd)

Fuse Box 2 Fuse No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Circuit(s) Protected Headlights Foglights Cigar Lighter Sidelights RH Left Stabiliser (Optional) Right Stabiliser (Optional) Triple Articulated Boom Axle Lock Relay Brake Inhibit Touch Sensitive Panel (switched) Brake Lights Reversing Lights Dozer Relay Park Brake Relay Range Change Relay Creep Speed Relay Grab Rotate/Hammer (Optional) Drive Isolator Relay Relays (switched) Hazard Relays (unswitched) Sidelights LH Touch Sensitive Panel (unswitched) Hazard (unswitched) Rating 10A 5A 5A 5A 5A 5A 5A 5A 5A 5A 5A 5A 5A 5A 5A 5A 5A 5A 5A 5A 5A 5A 5A 5A
9804/1103
45 - 05 - 01/5
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 01/6
JS 130 from m/c no. 758000, JS160 from m/c no. 702000, JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 Data - Electrical Circuit Protection; Fuse rating and circuit names
BACK UP 10A KEY SW. 10A AIRCON., HEATER 20A LAMP 15A LAMP (SPARE) 15A LAMP (SPARE) 15A LAMP (SPARE) 15A WIPER, WASHER 15A HORN, ROOM LAMP 10A RADIO, LIGHTER 10A COMPUTER P. 15A COMPUTER C. 10A SHUT DOWN 15A LEVER LOCK 10A LUBRICATOR 10A WARNING BEACON 10A OIL PUMP 20A CONDENSER MOTOR 15A SPARE 10A SPARE 10A
(A)
Fuse Replacement
See illustration on the right for location of Fuse Box (A).
1. Prepare the machine, stop the engine remove the starter key. 2. Prepare an appropriate fuse of the correct amperage, remove cover. Note: The fuse covers right corner is the grip. 3. Replace the blown fuse with a new one. 4. Install the fuse cover. Note: If the reason for the blown fuse is unknown or the fuse fails repeatedly, check the electrical circuit(s) concerned.
Lighting and Horn

Voltage Working light Boom Roof light Horn Cab Tank 24 V 24 V 24 V 24 V Wattage 70 W 70 W 10 W No. off 1 1 1 2
9804/1103
45 - 05 - 01/6
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 01/7
JS 130W from m/c no. 0716501, JS 160W from m/c no. 0718501 Data - Electrical Circuit Protection
The electrical circuits are protected by fuses. Some of the fuses are located in fuse box A on the rear console to the right behind the drivers seat. Others are located in fuse box B situated to the left rear of the seat. If a fuse blows, find out why before fitting a new one. Fuse Box A Fuse No. 1 2 3 4 5 6 7 * 8 9 10 11 12 13 14 15 16 17 18 19 20 Circuit(s) Protected Emergency Back-up Switch Ignition Switch Air Conditioning Blower (if fitted) Heater Working Lights Spare Optional Working Lights Spare Windscreen Wiper/Washer Horn Cab Light Radio Cigar Lighter Computer (Power) Computer (Control) Emergency Engine Stop Switch Servo Isolation Spare Flashing Beacon Re-fuelling Pump Air Conditioning Unit (if fitted) Load Indicator (optional) Spare 15 A 10 A 15 A 10 A 10 A 10 A 20 A 15 A 10 A 10 A
JS06070
Rating 10 A 10 A 20 A 15 A 15 A 15 A 15 A 10 A 10 A 10 A
1 2 3 4 5 6 7 8 9 0
A
10 10 20 15 15 15 15 10 10 10 15 10 15 10 10 10 20 15 10 10
! @ $ % ^ & * ( )
Fuse Box B Fuse No. 1 2 3 4 5 6 Circuit(s) Protected Lights - left side Lights - right side Stabilisers Park Brake Drive Isolator Solenoid Brake Lights Reverse Lights Rockbreaker Circuit (if fitted) Headlights, sidelights, indicators.
JS06080
Rating 10 A 10 A 5A 5A 5A 5A
1 2 3 4 5 6
10
10
9804/1103
45 - 05 - 01/7
Issue 2*
CONTENTS
Excavators
45 - 05 - 01/8
JS 70 from m/c no. 695501 Data - Electrical Circuit Protection; Fuse rating and circuit names ! CAUTION
8-3-3-5
Fuses
The electrical circuits are protected by fuses located in fuse box A on the front face of the right console (below the Right Excavator Joystick). If a fuse blows, find out why before fitting a new one. Fuse Box A Fuse No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Circuit(s) Protected Emergency Back-up Switch Ignition Switch Air Conditioning Blower (if fitted) Heater Working Lights Spare Working Lights (Optional) Spare Windscreen Wiper/Washer Horn Cab Light Radio Cigar Lighter Computer (Power) Computer (Control) Emergency Engine Stop Switch Servo Isolation Spare Flashing Beacon Re-fuelling Pump Air Conditioning Condenser (if fitted) Spare Spare 15 A 10 A 15 A 10 A 10 A 10 A 20 A 15 A 10 A 10 A
JS08750
Rating 10 A 10 A 20 A 15 A 15 A 15 A 15 A 10 A 10 A 10 A
1 2 3 4 5 6 7 8 9 0
A
10 10 20 15 15 15 15 10 10 10 15 10 15 10 10 10 20 15 10 10
! @ $ % ^ & * ( )
Lighting and Horn

Voltage Working light Boom Roof light Horn
9804/1103
Wattage 70 W 70 W 10 W
No. off 1 1 1 2
Tank
24 V 24 V
Cab
24 V 24 V
45 - 05 - 01/8
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 01/9
JS 200W from m/c no. 809000 Data - Electrical Circuit Protection Fuse Rating and Circuit Names ! CAUTION
8-3-3-5
Fuses
The electrical circuits are protected by fuses. Some of the fuses are located in fuse box A on the rear console to the right behind the drivers seat. Others are located in fuse box B situated to the left rear of the seat (see next page). If a fuse blows, find out why before fitting a new one. Fuse Box A Fuse No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Circuit(s) Protected Emergency Back-up Switch Ignition Switch Air Conditioning Blower (if fitted) Heater Working Lights Spare Optional Working Lights Spare Windscreen Wiper/Washer Horn Cab Light Radio Cigar Lighter Computer (Power) Computer (Control) Emergency Engine Stop Switch Servo Isolation Spare Flashing Beacon Re-fuelling Pump Air Conditioning Unit (if fitted) Load Indicator (optional) Spare 15 A 10 A 15 A 10 A 10 A 10 A 20 A 15 A 10 A 10 A 10 A 15 A 15 A 15 A 15 A 10 A 10 A
JS06070
A
1 2
Rating 10 A 10 A 20 A
3 4 5 6 7 8 9 0
10 10 20 15 15 15 15 10 10 10
15 10 15 10 10 10 20 15 10 10
! @ $ % ^ & * ( )
9804/1103
45 - 05 - 01/9
6320 - C/2-1.1
Issue 1
CONTENTS
Excavators
45 - 05 - 01/10
JS200W from m/c no. 809000 Data - Electrical (contd) Circuit Protection Fuse Rating and Circuit Names (contd) Fuses (contd) ! CAUTION
8-3-3-5
Fuse Box B Fuse No. Circuit(s) Protected 1 2 3 4 5 6 Lights - left side Lights - right side Stabilisers Park Brake Drive Isolator Solenoid Brake Lights Reverse Lights Rockbreaker Circuit (if fitted) Headlights, sidelights, indicators.
JS06080
Rating 10 A 10 A 5A 5A 5A 5A
10
10
9804/1103
45 - 05 - 01/10
3270 - 6320 - C/2-2.1
Issue 1
CONTENTS
Excavators
45 - 05 - 01/11
JS 330 from m/c no. 712501, JS 450 from m/c no. 714501 JS 460 from m/c no. 714550 Data - Electrical (contd) Circuit Protection; Fuse rating and circuit names
BACKUP 10A KEY SW. 10A AIRCON., HEATER 20A LAMP 15A LAMP (SPARE) 15A LAMP (SPARE) 15A LAMP (SPARE) 15A WIPER, WASHER 15A HORN, CAB LAMP 10A RADIO, LIGHTER 10A
COMPUTER P. 15A COMPUTER C. 10A SHUT DOWN 15A LEVER LOCK 10A LUBRICATOR 10A WARNING BEACON 10A OIL PUMP 20A CONDENSER MOTOR 15A SPARE 10A SPARE 10A
Fuse Replacement
See illustration on the right for location of Fuse Box (A). 1. Prepare the machine, stop the engine and remove the starter key. 2. Prepare and appropriate fuse of the correct amperage, remove cover. Note: The fuse covers right corner is the grip. 3. Replace the blown fuse with a new one. 4. Install the fuse cover. Note: If the reason for the blown fuse is unknown or the fuse fails repeatedly, check the elctrical circuit(s) concerned.
JS11030
Lighting and Horn

Voltage Working Light Boom Roof light Horn Cab Tank 24 V 24 V 24 V 24 V Wattage 70 W 70 W 10 W No. off 1 1 1 2
9804/1103
45 - 05 - 01/11
6420 - C/2-1.2
Issue 2*
CONTENTS
Excavators
45 - 05 - 01/12
Data - Electrical The A.M.S. System

The JCB A.M.S. system (Advanced Management System) is a whole machine electronic control system which replaces the CAPS II system. The system controls engine speed, pump power, transmission, excavator functions, lights, wiper, auxiliary circuits, warning lamps, etc. The AMS manual supplement 9803/6450 is an addition to the following JS XO Machine Service Manuals: Manual No. 9803/6410 Machine No. JS 130 JS 160/180 JS 130W JS 145W JS 160W JS 175W JS 200/210 JS 220 JS 240 JS 260 JS 200W JS 330 JS460 Serial No. 759561 703075 717027 810001 718966 875001 706966 706966 709004 709004 809056 712847 714550 AMS JS330/460 Tracked Machine
A296531
9803/6310
9803/6400
9803/6320 9803/6420
Note: Only those areas of the machines which detail the AMS system are covered in the supplement. For all other aspects refer to the above manuals.
9804/1103
45 - 05 - 01/12
6420 - C/1-1.1
Issue 1*
CONTENTS
Excavators
! CAUTION
45 - 05 - 01/13
Data - Electrical
8-3-3-5
Fuses - AMS Machines

The elctrical circuits are protected by fuses. Some of the fuses are located in fuse box A on the rear console to the right behind the drivers seat. If a fuse blows, find out why before fitting a new one. Fuse Box A Fuse Circuit(s) Protected A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6 C1 C2 C3 C4 C5 C6 D1 D2 D3 D4 D5 D6 Controller (std), Monitor, fascia switch panel Controller (std) outputs 1 ~ 6 Controller (std) outputs 7 ~ 12 Controller (std) outputs 13 ~ 16 Controller (std) outputs 17 ~ 22 Controller (std) outputs 23 ~ 28 Heater/air conditioner, auto fan Radio, lighter, room lamp Refuelling pump (if fitted), auxiliary, wiper Work lights, optional hydraulic circuits (if fitted) Key Switch Controller (std), monitor Spare Spare Spare Spare Spare Spare Not Used (Wheeled Machine Only) Not Used (Wheeled Machine Only) Not Used (Wheeled Machine Only) Not Used (Wheeled Machine Only) Unused Unused JS330 and JS460 R S T U V Pre-heat relay Main fuses Pre-heat resistor Battery isolator relay Safety relay Rating 2A 15A 15A 15A 10A 10A 20A 10A 20A 15A 10A 2A 336891 10A 10A 15A 15A 20A 2A
D C 10 10 15 15 20 2 B 20 10 20 15 10 2 A 2 15 15 15 10 10 1 2 3 4 5
A
A296853
R T S U
V
A370310
9804/1103
45 - 05 - 01/13
6420 - C/2-1A.1
Issue 1*
CONTENTS
Excavators
45 - 05 - 02/1
* JS
70 to m/c no. 695500
Data - Hydraulic
Pump Type Two variable displacement axial piston pumps. Integral gear servo pump. Manufactured in two halves and bolted together. Servo actuation of dipper, swing, blade and L.H. track (from Machine No 695002). Track mechanically actuated by lever/pedal prior to Machine No. 695002. Servo actuation of boom, bucket and R.H. track (from Machine No 695002). Track mechanically actuated by lever/pedal prior to Machine No. 695002. Mechanically actuated by pedal.
Control Valve Side A
Side B
Offset Boom Control Valve (if fitted)
Pressures - All pressure checks should be undertaken at maximum engine speed with the hydraulic fluid at 50 C 5 (3 to 4 LED's). bar Servo Main Relief Valve (MRV) Control Valve Mounted Auxiliary Relief Valve (ARV's) Boom Raise (Head Side) Boom Lower (Rod Side) Bucket Open/Close Dipper In/Out Dozer Blade raise Dozer Blade lower 294 5 245 5 294 5 294 5 206 5 294 5 300 5 250 5 300 5 300 5 210 5 300 5 4266 72.5 3555 72.5 4266 72.5 4266 72.5 2986 72.5 4266 72.5 39 + 5/ - 0 275 5 kgf/cm2 40 + 5/ - 0 280 5 lbf/in2 569 + 72.5/ - 0 3982 72.5
Component Mounted Relief Valves Swing Cross Line Relief Valves Offset Boom/Attachment Control Valve Ram Rod Side Ram Head Side 196 5 294 5 196 5 200 5 300 5 200 5 2844 72.5 4266 72.5 2844 72.5
Rams Boom Dipper Bucket Dozer Blade Offset Boom (if fitted) Motors Track Swing Two speed, axial piston type Fixed displacement, axial piston type Bore 100mm (3.93 in) 95mm (3.74 in) 85mm (3.34 in) 70mm (2.75 in) 100mm (3.93 in) Rod Dia. 65mm (2.55 in) 60mm (2.36 in) 55mm (2.16 in) 45mm (1.77 in) 45mm (1.77 in) Stroke 932mm (36.7 in) 900mm(35.43 in) 668mm (26.2 in) 180mm (7.08 in) 415mm (16.4 in)
9804/1103
45 - 05 - 02/1
Issue 3*
CONTENTS CONTENTS
Excavators
45 - 05 - 02/2
JS 110 Data - Hydraulic

Pump Type Variable displacement, two element piston pump in tandem. Integral gear servo pump. Manufactured in two halves and bolted together. Servo actuation of bucket, boom and right track (from Serial No 697014 on). Servo actuation of dipper, swing and left track (from Serial No 697014 on). Mechanical track actuation on earlier Serial Nos. * Pressures (All pressure checks should be undertaken at maximum speed in the 'S' mode with the hydraulic fluid at 50 C 5 (3 to 4 LED's illuminated).
* Control Valve Left Hand Valve
Right Hand Valve
bar Servo Main Relief Valve (M.R.V.) Control Valve MountedAuxiliary Relief Valves (ARV's) Boom Raise (Head Side) Boom Lower (Rod Side) Bucket Open (Rod Side) Bucket Close (Head Side) Dipper In (Head Side) Dipper Out (Rod Side) Component Mounted Relief Valves Swing Cross Line Relief Valves Track Cross Line Relief Valves Rams Boom (2 off) Dipper Bucket Motors Track Swing Bore 100mm (3.9in.) 110mm (4.3in.) 100mm (3.9in.) 211 5 323 5 245 5 206 5 255 5 255 5 255 5 255 5 39 + 5/ - 0 294 5
kgf/cm2 40 + 5/ - 0 300 5
lbf/in2 570 + 72.5/ - 0 4270 72.5
250 5 210 5 260 5 260 5 260 5 260 5
3555 72.5 2985 72.5 3700 72.5 3700 72.5 3700 72.5 3700 72.5
215 5 330 5
3057 72.5 4700 72.5
Rod Dia. 65mm (2.6in.) 75mm (3.0in.) 65mm (2.6in.)
Stroke 1043mm (41.1in.) 1282mm (50.5in.) 890mm (35.0in.)
Variable displacement, axial piston motor Fixed displacement, axial piston motor
9804/1103
45 - 05 - 02/2
Issue 2*
CONTENTS CONTENTS
Excavators
45- 05 - 02/3
* JS
130
to machine no. 757999
Data - Hydraulic
Pump Type Variable displacement, two element piston pump in tandem. Integral gear servo pump. Manufactured in two halves and bolted together. Servo actuation of bucket, boom and right track (from Serial No 699037 on). Servo actuation of dipper, swing and left track (from Serial No 699037 on). Mechanical track actuation on earlier Serial Nos. Pressures (All pressure checks should be undertaken at maximum speed in the 'S' mode with the hydraulic fluid at 50 C 5 (3 to 4 LED's illuminated). bar Servo Main Relief Valve (M.R.V.) Control Valve MountedAuxiliary Relief Valves (ARV's) Boom Raise (Head Side) Boom Lower (Rod Side) Bucket Open (Rod Side) Bucket Close (Head Side) Dipper In (Head Side) Dipper Out (Rod Side) Component Mounted Relief Valves Swing Cross Line Relief Valves Track Cross Line Relief Valves Rams Boom (2 off) Dipper Bucket Motors Track Swing Variable displacement, axial piston motor Fixed displacement, axial piston motor Bore 100mm (3.9in.) 110mm (4.3in.) 100mm (3.9in.) Rod Dia. 65mm (2.6in.) 75mm (3.0in.) 65mm (2.6in.) Stroke 1043mm (41.1in.) 1282mm (50.5in.) 890mm (35.0in.) 211 5 323 5 215 5 330 5 3057 72.5 4700 72.5 245 5 206 5 255 5 255 5 255 5 255 5 250 5 210 5 260 5 260 5 260 5 260 5 3555 72.5 2985 72.5 3700 72.5 3700 72.5 3700 72.5 3700 72.5 39 + 5/ - 0 294 5 kgf/cm2 40 + 5/ - 0 300 5 lbf/in2 570 + 72.5/ - 0 4270 72.5
Control Valve Left Hand Valve
Right Hand Valve
9804/1103
45 - 05 - 02/3
Issue 3*
CONTENTS CONTENTS
Excavators
45- 05 - 02/4

Pump Type Variable displacement, two element piston pump in tandem. Integral gear servo pump. Manufactured in two halves and bolted together. Servo actuation of bucket, boom and right track (from Serial No 701045 on). Servo actuation of dipper, swing and left track (from Serial No 701045 on). Mechanical track actuation on earlier Serial Nos. Pressures (All pressure checks should be undertaken at maximum speed in the 'S' mode with the hydraulic fluid at 50 C 5 (3 to 4 LED's illuminated). bar Servo Main Relief Valve (M.R.V.) Control Valve Mounted Auxiliary Relief Valves (ARV's) Boom Raise (Head Side) Boom Lower (Rod Side) Bucket Open (Rod Side) Bucket Close (Head Side) Dipper In (Head Side) Dipper Out (Rod Side) Swing 235 5 Component Mounted Relief Valves Swing Cross Line Relief Valves Track Cross Line Relief Valves Rams Boom (2 off) Dipper Bucket Motors Track Swing Variable displacement, axial piston motor Fixed displacement, axial piston motor Bore 120mm (4.7in.) 125mm (4.9in.) 110mm (4.3in.) Rod Dia. 80mm (3.1in.) 85mm (3.3in.) 70mm (2.8in.) Stroke 1184mm (46.6in.) 1448mm (57.0in.) 997mm (39.3in.) 226 5 294 5 230 5 300 5 3270 72.5 4266 72.5 275 5 206 5 275 5 275 5 275 5 275 5 240 5 280 5 210 5 280 5 280 5 280 5 280 5 3413 72.5 3980 72.5 3000 72.5 3980 72.5 3980 72.5 3980 72.5 3980 72.5 39 + 5/ - 0 294 5 kgf/cm2 40 + 5/ - 0 300 5 lbf/in2 570 + 72.5/ - 0 4266 72.5
Control Valve Left Hand Valve
Right Hand Valve
9804/1103
45 - 05 - 02/4
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 05 - 02/5
JS 200LC Data - Hydraulic

Pump Type Variable displacement, two element axial piston pump. Integral gear servo pump.
Control Valve Manufactured in two halves and bolted together. Side A Servo actuation of dipper and swing. Lever/pedal actuation of right track. Servo actuation of boom and bucket. Lever/pedal actuation of left track.
Side B
Pressures All pressure checks should be undertaken at maximum speed in the 'S mode' with the hydraulic fluid at 50 C 5 (3 to 4 LED's). bar Servo Main Relief Valve (MRV) A Main Relief Valve (MRV) B Control Valve Mounted Auxiliary Relief Valve (ARV's) Boom Raise (Head Side) Boom Lower (Rod Side) Bucket Open (Rod Side) Bucket Close (Head Side) Dipper In (Head Side) Dipper Out (Rod Side) Component Mounted Relief Valves Swing Cross Line Relief Valves Track Cross Line Relief Valves Hose Burst Check Valves Boom Dipper Rams Boom (2 off) Dipper Bucket Motors Track Swing Two speed, axial piston type Fixed displacement, axial piston type Bore 125mm (4.9 in.) 140mm (5.5 in.) 120mm (4.7 in.) Rod Dia. 85mm (3.4 in.) 95mm (3.7 in.) 80mm (3.0 in.) Stroke 1265mm (49.8 in.) 1515mm (60.0 in.) 1025mm (40.4 in.) 324 5 314 5 330 5 320 5 4693 72.5 4550 72.5 245 5 353 5 250 5 360 5 3555 72.5 5119 72.5 304 5 206 5 294 5 294 5 294 5 294 5 310 5 210 5 300 5 300 5 300 5 300 5 4408 72.5 2986 72.5 4266 72.5 4266 72.5 4266 72.5 4266 72.5 39 + 5 - 0 338 5 338 5 kgf/cm2 40 + 5/ - 0 345 5 345 5 lbf/in2 569 + 72.5/ - 0 4906.5 72.5 4906.5 72.5
9804/1103
45 - 05 - 02/5
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 02/6

Pump Type Variable displacement, two element axial piston pump in tandem. Integral gear servo pump.
Control Valve Manufactured in two halves and bolted together. Side A Side B Pressures All pressure checks should be undertaken at maximum speed in the 'S mode' with the hydraulic fluid at 50 C 5 (3 to 4 LED's). bar Servo Main Relief Valve (MRV) A Main Relief Valve (MRV) B Control Valve Mounted Auxiliary Relief Valves (ARV's) Boom Raise (Head Side) Boom Lower (Rod Side) Bucket Open (Rod Side) Bucket Close (Head Side) Dipper In (Head Side) Dipper Out (Rod Side) Swing Right Swing Left Component Mounted Relief Valves Swing Cross Line Relief Valves Track Cross Line Relief Valves Hose Burst Check Vlaves Boom Dipper Rams Boom (2 off) Dipper Bucket Motors Track Swing Two speed, axial piston type Fixed displacement, axial piston type Bore 130mm (5.1 in.) 150mm (5.9 in.) 130mm (5.1 in.) Rod Dia. Stroke 85mm (3.3 in.) 1253mm (49.3 in.) 105mm (4.1 in.) 1574mm (62.0 in.) 90mm (3.5 in.) 1125mm (44.3 in) 324 5 324 5 330 5 330 5 4693 72.5 4693 72.5 255 5 314 5 260 5 320 5 3697 72.5 4550 72.5 314 5 255 5 314 5 314 5 314 5 314 5 275 5 275 5 320 5 260 5 320 5 320 5 320 5 320 5 280 5 280 5 4550 72.5 3697 72.5 4550 72.5 4550 72.5 4550 72.5 4550 72.5 3982 72.5 3982 72.5 39 + 5/- 0 294 5 294 5 kgf/cm2 40 + 5/- 0 300 5 300 5 lbf/in2 569 + 72.5/- 0 4266 72.5 4266 72.5 Servo actuation of bucket, boom and right track. Servo actuation of dipper, swing and left track.
9804/1103
45 - 05 - 02/6
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 02/7

Control Valve Manufactured in two halves and bolted together. Side A Side B Pressures Checks of servo pressure and of MRV settings should be undertaken at maximum speed in the 'S mode'. Checks of ARV and cross line relief valve settings should be undertaken at maximum speed in the 'L mode'. In all cases the hydraulic fluid should be at 50 C 5 (3 to 4 LED's). bar Servo Main Relief Valve (MRV) A Main Relief Valve (MRV) B Control Valve Mounted Auxiliary Relief Valves (ARV's) Boom Lower (Rod Side) Bucket Open (Rod Side) Bucket Close (Head Side) Dipper In (Head Side) Dipper Out (Rod Side) Swing Right Swing Left Component Mounted Relief Valves Swing Cross Line Relief Valves Track Cross Line Relief Valves Hose Burst Check Valves Boom Dipper Rams Boom (2 off) Dipper Bucket Motors Track Swing Two speed, axial piston type Fixed displacement, axial piston type Bore 140mm (5.5 in.) 160mm (6.3 in.) 140mm (5.5 in.) Rod Dia. Stroke 100mm (3.9 in.) 1480mm (58.3 in.) 110mm (4.3 in.) 1733mm (68.2 in.) 95mm (3.7 in.) 1275mm (50.2 in.) 333 5 333 5 340 5 340 5 4835 72.5 4835 72.5 265 5 324 5 270 5 330 5 3839 72.5 4692 72.5 245 5 333 5 333 5 333 5 333 5 294 5 294 5 250 5 340 5 340 5 340 5 340 5 300 5 300 5 3555 72.5 4835 72.5 4835 72.5 4835 72.5 4835 72.5 4266 72.5 4266 72.5 44 + 5/-0 314 5 314 5 kgf/cm2 45 + 5/- 0 320 5 320 5 lbf/in2 640 + 72.5/- 0 4550 72.5 4550 72.5 Servo actuation of bucket, boom and right track. Servo actuation of dipper, swing and left track.
9804/1103
45 - 05 - 02/7
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 02/8

Control Valve Mono-block construction. A half B half Pressures Checks of servo pressure and of MRV settings should be undertaken at maximum speed in the 'S mode'. Checks of ARV and cross line relief valve settings should be undertaken at maximum speed in the 'L mode'. In all cases the hydraulic fluid should be at 50 C 5 (3 to 4 LED's). Servo actuation of bucket, boom and right track. Servo actuation of dipper, swing and left track.
bar Servo Main Relief Valve (MRV) Control Valve Mounted Auxiliary Relief Valve (ARV) Boom Lower (Rod Side) Bucket Open (Rod Side) Bucket Close (Head Side) Dipper In (Head Side) Dipper Out (Rod Side) Component Mounted Relief Valves Swing Cross Line Relief Valves Track Cross Line Relief Valves Holding Valve Boom Rams Boom (2 off) Dipper Bucket Motors Track Swing Bore 160mm (6.3 in.) 180mm (7.1 in.) 160mm (6.3 in.) 333 5 279 5 314 5 245 5 333 5 333 5 333 5 333 5 44 + 5/- 0 314 5
kgf/cm2 45 + 5/- 0 320 5
lbf/in2 640 + 72.5/- 0 4550 72.5
250 5 340 5 340 5 340 5 340 5
3555 72.5 4835 72.5 4835 72.5 4835 72.5 4835 72.5
285 5 320 5
4053 72.5 4550 72.5
340 5
4835 72.5
Rod Dia. Stroke 110mm (4.3 in.) 1580mm (62.2 in.) 130mm (5.1 in.) 1910mm (75.2 in.) 110mm (4.3 in.) 1306mm (51.4 in.)
Two speed, axial piston type Fixed displacement, axial piston type
9804/1103
45 - 05 - 02/8
Issue 1
CONTENTS
Excavators
45 - 05 - 02/9
* JS
130W from m/c no. 0716501, JS 160W from m/c no. 0718501
Data - Hydraulic (contd)

Pump Type Variable displacement, two element piston pumps in tandem. Integral gear servo pumps.
* Control Valve Manufactured in two halves and bolted together. Left Hand Valve (3 spool) Right Hand Valve (4 spool) Servo actuation of bucket, boom options/dozer. Servo actuation of dipper, swing, options and travel.
* Rams (JS130W) Boom (2 off) (mono boom only) Dipper Bucket Dozer (2 off) (optional) Stabilisers (optional) Axle Lock (2 off) Triple Articulated Boom (if fitted) Boom Raise/Lower Boom Position Bore 110 mm (4.3 in) 120 mm (4.7 in) 105 mm (4.1 in) 110 mm (4.3 in) 120 mm (4.7 in) 85 mm (3.3 in) 110 mm (4.3 in) 110 mm (4.3 in) Rod Diameter 70 mm (2.8 in) 80 mm (3.1 in) 65 mm (2.6 in) 60 mm (2.4 in) 65 mm (2.6 in) 85 mm (3.3 in) 70 mm (2.8 in) 70 mm (2.8 in) Stroke 1055 mm (41.5 in) 1282 mm (50.5 in) 890 mm (35.0 in) 192 mm (7.5 in) 476 mm (18.7 in) 160 mm (6.3 in) 835 mm (32.9 in) 815 mm (32.1 in)
* Rams (JS160W) Boom (2 off ) (mono boom only Dipper Bucket Dozer (2 off) (optional) Stabilisers (optional) Axle Lock (2 off) Triple Articulated Boom (if fitted) Boom Raise/Lower Boom Position 120 mm (4.7 in) 125 mm (4.9 in) 110 mm (4.3 in) 110 mm (4.3 in) 120 mm (4.7 in) 85 mm (3.3 in) 120 mm (4.7 in) 120 mm (4.7 in) 80 mm (3.1 in) 85 mm (3.3 in) 70 mm (2.8 in) 60 mm (2.4 in) 65 mm (2.6 in) 85 mm (3.3 in) 80 mm (3.1 in) 80 mm (3.1 in) 1184 mm (46.6 in) 1448 mm (57.0 in) 997 mm (39.3 in) 192 mm (7.5 in) 476 mm (18.7 in) 160 mm (6.3 in) 927 mm (36.5 in) 927 mm (36.5 in)
Motors Drive Swing Variable displacement, axial piston motor. Fixed displacement, axial piston motor.
9804/1103
45 - 05 - 02/9
Issue 2*
CONTENTS
Excavators
45 - 05 - 02/10
* JS
130W from m/c no. 0716501, JS 160W from m/c no. 0718501
Data - Hydraulic (contd)

* Pressures All pressure checks should be undertaken at maximum engine speed in the S mode. 2 Stage Main Relief Boom Raise Arm in/out Bucket open/close Standard Boost/F Mode Boom Service Relief - Boom Lower Stall Swing Service Relief (x 2) - Left/Right Stall Overload Relief - Boom/Arm/Bucket Hammer Service Relief (x 2) - Hammer/Auxiliary Stall Boom Position Ram Service Relief - TAB Stall Blade/Stabiliser Service Relief (x 2) - Service Stall Steer/Brakes Service Relief - Steer Stall Hand Steer Valve Overload - Steer Stall Grab Rotate Cross-line Relief (x 2) - Rotate Stall Negative Control - S Mode, Neutral, Maximum RPM Pilot Control Relief - Continuous Clutch Pilot Pressure - Continuous Service Brake Pressure - On Latch Park Brake Pressure - Clutch Residual Service Brake Charge - Cut In on Falling Pressure Service Brake Charge - Cut Out on Rising Pressure Hose Burst Check Valve Relief - Boom Ram Head Side Hose Burst Check Valve Relief - Position Ram Head Side Hose Burst Check Valve Relief - Arm Ram Rod Side 100% Swing Brake - Normal Residual Pressure Service Brake Accumulators (x 4) - Nitrogen Pre-charge Park Brake Accumulator - Nitrogen Pre-charge Service Brake Warning Lamp - Pressure Switch Falling Rear Brake Lights - Pressure Switch Rising Reverse Lights - Pressure Switch Rising Park Brake (Drive Inhibit and Alarm) - Pressure Switch Falling P22 Pump Signal - Drive at 90% Flow Pressure Sequence Valve - Clutch Priority Clutch Priority Accumulator - Nitrogen Pre-charge
9804/1103
JS 130W Bar (lbf/in2)
JS 160W Bar (lbf/in2)
312 (4524) 340 (4930) 295 (4227) 295 (4227) 365 (5292) 180 (2610) 365 (5292) 250 (3625) 175 (2538) 185 (2682) 150 (2175) 40 40 32 48 15 (580) (580) (464) (696) (218)
315 340 295 285 365 180 365 250 175 185 150 40 40 32 48 15 130 150 365 365 365 15 37 6 105 5 5 26 28 28 8
(4568) (4930) (4227) (4132) (5292) (2610) (5292) (3625) (2538) (2682) (2175) (580) (580) (464) (696) (218) (1885) (2175) (5292) (5292) (5292) (218) (536) (87) (1522) (72) (72) (377) (406) (406) (16)
Issue 2*
130 (1885) 150 (2175) 365 (5292) 365 (5292) 365 (5292) 13 37 6 (188) (536) (87)
105 (1522) 5 5 26 28 28 8 (72) (72) (377) (406) (406) (16)
45 - 05 - 02/10
CONTENTS
Excavators
45 - 05 - 02/11
JS 70 from m/c no. 695501 Data - Hydraulic (contd)
Pump
Type Displacement Volume Working Pressure Maximum Output Fixed Displacement Gear Pump Displacement Volume Working Pressure Maximum Output Total Dry weight 2 stage tandem, variable capacity swash plate type axial piston pump 36 cm3/rev x 2 (2.196 in3/rev x 2) 284.4 bar (4125 lbf/in2) 79 l/min (17 U.K. gal/min) Pilot 10.7 cm3/rev (0.65 in3/rev) 12.1 cm3/rev 39.2 bar ( 569 lbf/in2) 23 l/min (5 U.K. gal/min) 58kg (62 lb) Blade (0.74 in3/rev) 217 bar ( 3146 lbf/in2) 26 l/min (5.7 U.K. gal/min)
Control Valve (Main)

Type Operating System Main Relief Standard Pressure Rated Flow Oil Temperature Auxiliary Relief Valve Pressure Boom Raising, Dipper, Bucket Boom Lowering Pressure Function Dry Weight Hydraulic Pilot System Set pressure relief 279 - 284 bar (4046 - 4119 lb/in2) 79.2 l/min (17.4 gal/min) -25 C - 95 C (-13 F - 208 F) 304 - 314 bar (4409 - 4554 lb/in2) 255 - 265 bar (3698 - 3843 lb/in2) Travel priority, Slew priority, Boom and Dipper holding valves, Boom and Dipper 2-Speed internal confluence 66 kg (145.5 lb)
Control Valve (Blade)

Type Operating System Main Relief Auxiliary Relief Valve Pressure Dry Weight Hydraulic Pilot System Set pressure relief 221 - 231 bar (3205 - 3350 lb/in2) 250 - 260 bar (3626 - 3771 lb/in2) 4.5 kg (9.92 lb)
Slew Motor
Type Suction Capacity Working Pressure Work Flow Set Pressure Relief Reduction Gears Reduction Gear Ratio Slew Brake Brake Torque Brake Pressure Release Dry Weight Fixed displacement piston motor 45.5 cm3/rev (2.78in3/rev) 206 bar (2987 lbf/in2) 75.6 l/min (16.63 U.K. gal/min) 201 - 209 bar (2915 - 3031 lb/in2) Planetary gears with 2 gear reduction 19.464 : 1 More than 16.8 kgf m (121.5 lbf ft) (not including reduction gear) Min 32.3 bar (469 lbf/in2) 67 kg (148 lb)
9804/1103
45 - 05 - 02/11
Issue 1
CONTENTS
Excavators
45 - 05 - 02/12
JS 70 from m/c no. 695501 Data - Hydraulic (contd) Travel Equipment

Type Suction Capacity Working Pressure Working Flow Reduction Gear Ratio Parking Brake Brake Torque Brake Pressure Release Dry Weight Variable Displacement Piston Motor (automatic 2-speed change) 37.22/25.75 cm3/rev (2.27/1.57 in3/rev) 284.4 bar (4125 lbf/in2) 75.6 l/min (16.6 U.K. gal/min) 52.8 : 1 8.4 kgf/m (60.7 lbf ft) excluding reduction gear 4.5 bar (65.42 lbf/in2) 90 kg (198.4 lb)
Boom Ram
Cylinder Inside Diameter Rod Diameter Max Contracted Length Stroke Dry Weight 100 mm (3.94 in) 65 mm (2.56 in) 1383 mm (54.45 in) 927 mm (36.49 in) 85 kg (187.42 lb)
Dipper Ram
Cylinder Inside Diameter Rod Diameter Max Contracted Length Stroke Dry Weight 95 mm (3.74 in) 60 mm (2.36 in) 1364 mm (53.74 in) 878 mm (34.56 in) 81 kg (178.60 lb)
Bucket Ram
Cylinder Inside Diameter Rod Diameter Max Contracted Length Stroke Dry Weight 85 mm (3.35 in) 55 mm (2.16 in) 1050 mm (41.34 in) 688 mm (27.09 in) 52 kg (114 lb)
Offset Boom Ram

Cylinder Inside Diameter Rod Diameter Max Contracted Length Stroke Dry Weight 95 mm (3.74 in) 65 mm (2.56 in) 1255 mm (49.41 in) 788 mm (31.02 in) TBA
Blade Ram
Cylinder Inside Diameter Rod Diameter Max Contracted Length Stroke Dry Weight
9804/1103
70 mm (2.75 in) 45 mm (1.77 in) 496 mm (19.53 in) 180 mm (7.08 in) 20 kg (44.1 lb)
45 - 05 - 02/12
Issue 1
CONTENTS CONTENTS
Excavators
45- 05 - 03/1
JS 130 from m/c no 758000 Data - Hydraulic

Note: For full specification details see information in service manual
Pump
Type Displacement Volume Working Pressure Maximum Output Fixed Displacement Gear Pump Displacement Volume Working Pressure Maximum Output Dry weight 9.08 cm3/rev (0.55 in3/rev) 43 kgf/cm2 ( 612 lbf/in2) 20.2 l/min (4.5 gal/min) TBA 2 stage tandem, variable capacity swash plate type axial piston pump 55 cm3/rev x 2 (3.36 in3/rev x 2) 320 kgf/cm2 (4551 lbf/in2) 122.7 l/min (27 gal/min)
Control Valve
Type Operating System Main Relief Standard Pressure Maximum Pressure Overload Relief Pressure Boom Raising, Dipper, Bucket Boom Lowering Pressure Function Dry Weight Hydraulic Pilot System Set pressure relief 320 kgf/cm2 (4550 lbf/in2) at 91 l/min (20.02 gal/min) 350 kgf/cm2 (4977 lbf/in2) at 83 l/min (18.26 gal/min) 365 kgf/cm2 (5190.3 lbf/in2) at 30 l/min (6.6 gal/min) 300 kgf/cm2 (4266 lbf/in2) at 30 l/min (6.6 gal/min) Travel priority, Slew priority, Boom and Dipper holding valves, Boom and Dipper 2-Speed internal confluence 104 kg (229.3 lb)
Slew Motor
Type Suction Capacity Working Pressure Work Flow Set Pressure Relief Reduction Gears Reduction Gear Ratio Slew Brake Brake Torque Brake Pressure Release Dry Weight Fixed displacement piston motor 65 cm3/rev (3.97 in3/rev) 285 kgf/cm2 (4052 lbf/in2) 121 l/min (26.62 gal/min) 285 kgf/cm2 (4052 lbf/in2) at 107 l/min (23.54 gal/min) 275 kgf/cm2 (3953.2 lbf/in2) at 40 l/min (8.8 gal/min) Planetary gears with 2 gear reduction 17.03 : 1 More than 30 kgf m (217 lbf ft) (not including reduction gear) Min 30 kgf/cm2 (426 lbf/in2) 99 kg (218 lb)
9804/1103
45 - 05 - 03/1
Issue 1
CONTENTS
Excavators
45 - 05 - 03/2
JS 130 from m/c no 758000 Data - Hydraulic

Travel Equipment
Type Suction Capacity Working Pressure Working Flow Reduction Gear Ratio Parking Brake Brake Torque Brake Pressure Release Brake Valve Pressure Relief Dry Weight Fixed Displacement Piston Motor (automatic 2-speed change) 86.3 cm3/rev (5.27 in3/rev) 350 kgf/cm2 (4977 lbf/in2) TBA 39 : 1 26 kgf/m (188 lbf ft) including reduction gear > 10 kgf/cm2 (142 lbf/in2) TBA 165 kg (364 lb)
Boom Ram
Dipper Ram
* Cylinder Inside Diameter Rod Diameter Max Contracted Length Stroke Dry Weight 115 mm (4.53 in) 80 mm (3.15 in) 1714 mm (67.48 in) 1205 mm (47.44 in) 160 kg (353 lb)
Bucket Ram
9804/1103
45 - 05 - 03/2
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 05 - 03/3
JS 160 from m/c no 702000
Note: For full specification details see information in service manual
Pump Type Displacement Volume Working Pressure Maximum Output Fixed Displacement Gear Pump Displacement Volume Working Pressure Maximum Output Dry Weight Control Valve Type Operating System Main Relief Standard pressure Maximum pressure Overload Relief Pressure Boom Raising, Arm, Bucket Boom Lowering Pressure Function Dry Weight Slew Motor Type Suction Capacity Working Pressure Work Flow Set Pressure Relief Reduction Gears Reduction Gear Ratio Slew Brake Brake Torque Brake Pressure Release Dry Weight
2 stage tandem, variable capacity swash plate type axial piston pump 60 cm 3 /rev x 2 (3.66 in 3 /rev x 2) 320 kgf/cm 2 (4551 lbf/in 2 ) 139.8 l/min (30.75 gal/min) 9.08 cm 3 /rev (0.55 in 3 /rev) 43 kgf/cm 2 (612 lbf/in 2 ) 21.2 l/min (4.6 gal/min) TBA
Hydraulic Pilot System Set relief pressure 320 kgf/cm 2 (4550 lbf/in 2 ) at 91 l/min (20.02 gal/min) 350 kgf/cm 2 (4977 lbf/in 2 ) at 83 l/min (18.26 gal/min) 365 kgf/cm 2 (5190 lbf/in 2 ) at 30 l/min (6.6 gal/min) 300 kgf/cm 2 (4266 lbf/in 2 ) at 30 l/min (6.6 gal/min) Travel priority, Slew priority, Boom and Dipper holding valves, Boom and Dipper 2-Speed internal confluence 104 kg (229.3 lb)
Fixed displacement piston motor 151 cm 3 /rev (9.21 in 3 /rev) 285 kgf/cm 2 (4052.7 lbf/in 2 ) 138 l/min (36.5 gal/min) 285 kgf/cm 2 (4052.7 lbf/in 2 ) at 126 l/min (27.72 gal/min) 275 kgf/cm 2 (3910.5 lbf/in 2 ) at 40 l/min (8.8 gal/min) Planetary gears with 2 gear reduction 13.34 : 1 More than 68.5 kgf m (495.3 lbf ft) (Not including reduction gear) Min 32 kgf/cm 2 (455 lbf/in 2 ) 197 kg (434 lb)
9804/1103
45 - 05 - 03/3
Issue 2*
CONTENTS
Excavators
45 - 05 - 03/4
JS 160 from m/c no. 702000 Data - Hydraulic

Travel Equipment Motor Suction Capacity Working Pressure Working Flow Reduction Gear Ratio Parking Brake Brake Torque Brake Pressure Release Brake valve pressure relief Dry Weight Boom Rams Cylinder Inside Diameter Rod Diameter Max Contracted Length Stroke Dry Weight Dipper Ram Cylinder Inside Diameter Rod Diameter Max Contracted Length Stroke Dry Weight Bucket Ram Cylinder Inside Diameter Rod Diameter Max Contracted Length Stroke Dry Weight Fixed displacement piston motor (automatic 2-speed change) 104.8 cm 3 /rev (6.39 in 3 /rev) 350 kgf/cm 2 (4977 lb/in 2 ) TBA 48 : 1 26 kgf/m (188 lbf ft) including reduction gear > 11 kgf/cm 2 (156 lbf/in 2 ) TBA 225 kg (496 lb)
115 mm (4.53 in) 80 mm (3.15 in) 1689 mm (66.65 in) 1184 mm (46.61 in) 157 kg (346 lb)
9804/1103
45 - 05 - 03/4
Issue 2*
CONTENTS CONTENTS
Excavators
45- 05 - 03/4

Travel Equipment
Motor Suction Capacity Working Pressure Working Flow Reduction Gear Ratio Parking Brake Brake Torque Brake Pressure Release Brake valve pressure relief Dry Weight Fixed displacement piston motor (automatic 2-speed change) 104.8 cm3/rev (6.39 in3/rev) 350 kgf/cm2 (4977 lb/in2) TBA 48 : 1 26 kgf/m (188 lbf ft) including reduction gear > 11 kgf/cm2 (156 lbf/in2) TBA 225 kg (496 lb)
Boom Rams
Dipper Ram
Bucket Ram
9804/1103
45 - 05 - 03/4
Issue 1
CONTENTS CONTENTS
Excavators
45- 05 - 03/5
JS 200 & 220 from m/c no. 705001 Data - Hydraulic

Pump
Type Displacement Volume Working Pressure Maximum Output Fixed Displacement Gear Pump Displacement Volume Working Pressure Maximum Output Dry weight 10 cc/rev 40 kgf/cm2 (39.2 bar, 569 lb/in2) 20.5 litre/min (4.5 UK gal) 132 kg (291 lb) Twin variable displacement piston pump 96.6 (cc/rev) x2 350 kgf/cm2 (343 bar, 4977 lb/in2) 198.7 litre/min (43.7 UK gal)
Control Valve
Type Operating System Main Relief Pressure Standard Pressure Raising Overload Relief Pressure Boom Raising, Dipper, Bucket Boom Lowering Pressure Function Dry Weight Hydraulic Pilot System Set pressure relief 320 kgf/cm2 (309 bar, 4550 lb/in2) at 138 litre/min (30.3 UK gal) 350 kgf/cm2 (343 bar,4977 lb/in2) at 155 litre/min (34 UK gal) 370 kgf/cm2 (351 bar, 5161lb/in2) at 20 litre/min (4.4 UK gal) 250 kgf/cm2 (245 bar, 3555 lb/in2) at 20 litre/min (4.4 UK gal) Travel priority, Slew priority, Boom and Dipper Load Holding Valve, Boom and Dipper 2 Speed Confluence 165 kg (364 lb)
Slew Equipment
Type Suction Capacity Working Pressure Work Flow Set Pressure Relief Reduction Gear Ratio Slew Brake Brake Torque Brake Pressure Release Dry Weight Fixed displacement piston motor 151 cc/rev 285 kgf/cm2 (279 bar, 4052 lb/in2) 198.7 litre/min (43.6 gal/min) 285 kgf/cm2 (279 bar, 4053 lb/in2) at 155 litre/min (34 UK gal) 275 kgf/cm2 (269 bar, 3911 lb/in2) at 40 litre/min (8.8 UK gal) 16.757 : 1
More than 75.4 kgf m (739.4 Nm, 545 ft lbs) (not including reduction gear) Min 30 kgf/cm2 (29.4 bar, 426 lb/in2) 197 kg (434 lb)
9804/1103
45 - 05 - 03/5
Issue 1
CONTENTS CONTENTS
Excavators
45- 05 - 03/6

Travel Equipment
Type Suction Capacity Working Pressure Working Flow Reduction Gears Deceleration Ratio Parking Brake Brake Torque Brake Pressure Release Brake Valve Pressure Relief Dry Weight Fixed Displacement Piston Motor (automatic 2-speed change) 157.8/92.9 cc/rev 350 kgf/cm2 (338 bar, 4977 lb/in2) 199 litre/min (43.7 UK gal) 44.384 2135 kgf/m (20.9 kN/m) including reduction gear > 14 kgf/cm2 (6.8 bar, 101 lb/in2) 360 kgf/cm2 (348 bar, 5119 lb/in2) at 40 litre/min (8.8 UK gal) 270 kg (595 lb)
Boom Ram
Cylinder Inside Diameter Rod Diameter Max Contracted Length Stroke Dry Weight 125 mm 85 mm 1790 mm 1295 mm 176 kg (388 lb)
Dipper Ram
Bucket Ram
9804/1103
45 - 05 - 03/6
Issue 1
CONTENTS CONTENTS
Excavators
45- 05 - 03/7

Pump
Type Displacement Volume Working Pressure Maximum Output Fixed Displacement Gear Pump Displacement Volume Working Pressure Maximum Output Dry Weight Twin variable displacement piston pump 96.4 cc/rev x2 320 kgf/cm2 (309 bar, 4550lb/in2) 212.2 litre/min (46.6 UK gal) 10 cc/rev 40 kgf/cm2 (39.2 bar, 568lb/in2) 22.0 litre/min (4.8 UK gal) 132 kg (291 lb)
Control Valve
Type Operating System Main Relief Standard Pressure Raising Overload Relief Pressure Boom Raising, Arm, Bucket Boom Lowering Pressure Function Dry Weight Hydraulic Pilot System Set relief pressure 320 kgf/cm2 (309 bar, 4550 lb/in2) at 168 litre/min (37 UK gal) 350 kgf/cm2 (343 bar, 4977 lb/in2) at 155 litre/min (34 UK gal) 370 kgf/cm2 (351 bar, 5161 lb/in2) at 20 litre/min (4.4 UK gal) 250 kgf/cm2 (245 bar, 3555 lb/in2) at 20 litre/min (4.4 UK gal) Travel priority, Slew priority, Boom and Dipper Load Holding Valve, Boom and Dipper 2 Speed Confluence 165 kg (364 lb)
Slew Equipment
Type Suction Capacity Working Pressure Work Flow Set Pressure Relief Fixed displacement piston motor 151 cc/rev 285 kgf/cm2 (275 bar, 4052 lb/in2) 212.2 litre/min (46.6 gal/min) 285 kgf/cm2 (279 bar, 4052 lb/in2) at 188 litre/min (41.3 UK gal) 275 kgf/cm2 (269 bar, 3911 lb/in2) at 40 litre/min (8.8 UK gal) 22.097 : 1 More than 75.4 kgf m (739.4 Nm, 545 ft lbs) (Not including reduction gear) Min 30 kgf/cm2 (min 29.4 bar, 426 lb/in2) 325 kg (716 lb)
Reduction Gear Ratio Slew Brake Brake Torque Brake Pressure Release Dry Weight
9804/1103
45 - 05 - 03/7
Issue 1
CONTENTS CONTENTS
Excavators
45- 05 - 03/8

Travel Equipment
Motor Suction Capacity Working Pressure Working Flow Reduction Gears Deceleration Ratio Parking Brake Brake Torque Brake Pressure Release Brake valve pressure relief Dry Weight Fixed displacement piston motor (automatic 2-speed change) 164.4/98.1 cc/rev 350 kgf/cm2 (343 bar, 4977 lb/in2) 211 litre/min (46.4 UK UK gal) 44.384 2135 kgf/m (20.9 kNm, 15436 ft/lb) including reduction gear > 14 kgf/cm2 (13.5 bar, 199 lb/in2) 360 kgf/cm2 (348 bar, 5119l b/in2) at 40 litre/min (8.8 UK gal) 270 kg (595 lb)
Boom Rams
Dipper Ram
Bucket Ram
9804/1103
45 - 05 - 03/8
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 03/9
JS 200Wfrom m/c no. 809000 Data - Hydraulic

Pump Type Variable displacement, piston pump with integral gear servo pumps. 408 litre/min (90 U.K. gal/min) (108 U.S. gal/min) 32 l/min (7.0 U.K. gal/min) (8.4 U.S. gal/min)
Main pump max. flow Pilot pump max. flow
Rams (JS200W) Boom (2 off ) (mono boom only) Dipper Bucket Bore 125 mm (4.9 in) in) 135 mm (5.3 in) in) 120 mm (4.7 in) Rod Diameter 85 mm (3.3 in) 100 mm (3.9 in) 80 mm (3.1 in) Stroke 1295 mm (51.0 1580 mm (62.2 1012 mm (39.8in)
Motors Drive Max. Displacement Min Displacement Displacement Control Variable displacement, axial piston motor. 140cc/rev 75cc/rev Automatic - High pressure related Mounted with counterbalance valve size 25
Swing
Fixed displacement, axial piston motor.
9804/1103
45 - 05 - 03/9
6320 - E/1-1.1
Issue 1
CONTENTS
Excavators
45 - 05 - 03/10
JS200W from m/c no. 809000 Data - Hydraulics (contd)

Service Max Engine Speed, S Mode JS 200W Bar 2 Stage Main Relief Boom Raise ARV Arm in/out ARV Bucket open/close ARV Standard Boost/F Mode Boom Service Relief - Boom Lower Stall Swing Crossline Relief (x 2) - Left/Right Stall Overload Relief - Boom/Arm/Bucket Hammer Service Relief (x 2) - Hammer Stall Hammer Service Relief (x 2) - Auxiliary Stall Boom Position Ram Service Relief - TAB Stall Blade/Stabiliser Service Relief (x 2) - Service Stall Steer/Brakes Service Relief - Steer Stall Hand Steer Valve Overload - Steer Stall Grab Rotate Cross-line Relief (x 2) - Rotate Stall Servo Pressure - Continuous Clutch Pilot Pressure - Continuous Service Brake Pressure - On Latch Park Brake Pressure - Clutch Residual Service Brake Charge - Cut In on Falling Pressure Service Brake Charge - Cut Out on Rising Pressure Hose Burst Check Valve Relief - Boom Ram Head Side Hose Burst Check Valve Relief - Position Ram Head Side Hose Burst Check Valve Relief - Arm Ram Rod Side 100% Swing Brake - Normal Residual Pressure Service Brake Accumulators (x 4) - Nitrogen Pre-charge Park Brake Accumulator - Nitrogen Pre-charge Service Brake Warning Lamp - Pressure Switch Falling Rear Brake Lights - Pressure Switch Rising Reverse Lights - Pressure Switch Rising Park Brake (Drive Inhibit and Alarm) - Pressure Switch Falling Pressure Sequence Valve - Clutch Priority Clutch Priority Accumulator - Nitrogen Pre-charge Creep Speed Pilot Relief Valve Setting Boom Lower Pilot Relief Valve Setting Hammer Pilot Relief Valve Setting 320 350 245 230 360 190 360 360 250 175 185 200 35 32 65 15 120 150 355 TBA 370 15 61 8 105 5 6 26 26 8 15 19 19 (5366) (218) (885) (116) (1522) (72) (87) (377) (377) (116) (218) (275) (275) 10 1 2 1 10 1 1 3 2 1 1 1 1 (145) (14.5) (29) (14.5) (145) (14.5) (14.5) (43) (29) (14.5) (14.5) (14.5) (14.5) (4641) (5076) (3553) (3335) (5221) (2755) (2610) (5221) (3626) (2538) (2683) (2900) (507) (464) (943) (218) (1740) (2175) (5148) 5 5 5 5 5 10 10 5 5 5 5 5 3 2 2 1 5 5 5 (72) (72) (72) (72) (72) (145) (145) (72) (72) (72) (72) (72) (43) (29) (29) (14.5) (72) (72) (72) (lbf/in2) Tolerance Bar (lbf/in2)
9804/1103
45 - 05 - 03/10
6320 - E/1-2.1
Issue 1
CONTENTS
Excavators
45 - 05 - 03/11
JS 200W from m/c no. 809000 Data - Hydraulics (contd) Hydraulic Pump/Regulator
The pump/regulator consists of a variable displacement type axial piston pump (Pp) supplying pressurised oil to operate machine functions, plus two gear type pilot pumps, one (Pa) to provide pilot circuit pressure for operator control of machine functions. The other (Pb) to provide pressure for brake and steering functions. The Pump incorporates a regulator which adjusts the output flow rate according to system demand.
Axial Piston Pumps Maximum displacement cm3 (in3)/rev set Working pressure (travel) maximum Speed Maximum flow Maximum input torque Weight rpm l (gal)/min Nm (lbf ft) kg (lb)
JS 200W 190 (11.6) 319 bar (4551 lbf/in2 ,320 kgf/cm2) 343 bar (4978 lbf/in2 ,350 kgf/cm2) 1950 363 (79.8 UK gal) (95.9 US gal) 441 (325) 119 (262)
Gear pump Displacement cm3 (in3)/ rev Working pressure Maximum flow l (gal)/min Front Rear Front Rear 16.0 (0.97) 16.0 (0.97) 30 bar (435 lbf/in2, 30.6 kgf/cm2) 31.2 (6.86 UK gal) (8.24 US gal) 31.2 (6.86 UK gal) (8.24 US gal)
9804/1103
45 - 05 - 03/11
6320 - E/27-1.1
Issue 1
CONTENTS
Excavators
45 - 05 - 03/12
JS 330 from m/c no. 712501 Data Hydraulics
Pump
Type Displacement Volume Working Pressure Maximum Output Fixed Displacement Gear Pump Displacement Volume Working Pressure Maximum Output Dry Weight Twin variable displacement piston pump 134.6 cm3/rev (8.2 in3/rev ) 348 bar (355 kgf/cm2) 270 l/min x 2 (59 gal/min x 2) 12.4 cm3/rev (0.76 in3/rev) 44.1 bar (45 kgf/cm2) 24.8 l/min (5.5 gal/min) 220 kg (485 lb)
Control Valve
Type Operating System Main Relief Standard pressure Maximum pressure Overload Relief Pressure Boom Raising, Arm, Bucket Boom Lowering Pressure Function Dry Weight Hydraulic Pilot System Set pressure relief 319 bar (325 kgf/cm2) 348 bar (355 kgf/cm2) 363 bar (370 kgf/cm2) 245 bar (250 kgf/cm2) Travel priority, Slew priority, Boom and Dipper holding valves, Boom and Dipper 2-Speed internal confluence 180 kg (397 lb)
Slew Motor
Type Suction Capacity Working Pressure Work Flow Set Pressure Relief Reduction Gears Reduction Gear Ratio Slew Brake Brake Torque Brake Pressure Release Dry Weight Fixed displacement piston motor 210.1 cm3/rev (12.8 in3/rev) 279 bar (285 kgf/cm2) 276.1 l/min (60.7 gal/min) 279 bar (285 kgf/cm2) Planetary gear reduction 23.25 965 Nm (98 kgf m, 712 lbf ft) 34.5 bar (35.2 kgf/cm2) 410 kg (904 lb)
9804/1103
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6420 - E/1-1.2
Issue 1
CONTENTS
Excavators
45 - 05 - 03/13
JS 330 from m/c no 712501 Data Hydraulics (contd) Travel Equipment

Motor Suction Capacity Working Pressure Working Flow Reduction Gear Ratio Parking Brake Brake Torque Brake valve pressure relief Dry Weight Fixed displacement piston motor (automatic 2-speed change) 153.4/102.4 cm3/rev (9.4/6.25 in3/rev) 319 bar (326 kgf/cm2) 276 l/min (60.7 gal/min) 74.3 472 Nm (48.1 kgf m, 348 lbf ft) 324 bar (330 kgf/cm2) 360 kg (794 lb)
Boom Rams
Dipper Ram
Bucket Ram
9804/1103
45 - 05 - 03/13
6420 - E/1-2.2
Issue 1
CONTENTS
Excavators
45 - 05 - 03/14
JS 450 from m/c no. 714501 JS 460 from m/c no. 714550 Data - Hydraulic
Note: For full specification details see information in each section
Pump
Type Displacement Volume Working Pressure Maximum Output Fixed Displacement Gear Pump Displacement Volume Working Pressure Maximum Output Dry Weight Twin bariable displacement piston pump 170 cm3/rev (8.2 in3/rev) x 2 325 bar (331 kgf/cm2 348.5 l/min x 2 (77 gal/min x 2) 12.4 cm3/rev (0.76 in3/rev) 44.1 bar (45 kgf/cm2) 31.9 l/min (7.0 gal/min) 220 kg (485 lb)
Control Valve
Type Operating System Main Relief Standard Pressure Maximum Pressure Overload Relief Pressure Boom Raising, Arm, Bucket Boom Lowering Pressure Function Dry Weight Hydraulic Pilot System Set pressure relief 319 bar (325 kgf/cm2) 348 bar (355 kgf/cm2) 363 bar (370 kgf/cm2) 245 bar (250 kgf/cm2) Travel priority, Slew priority, Boom and Dipper holding valves, Boom and Dipper 2-Speed internal confluence 375 kg (826 lb)
Slew Motor
Type Suction Capacity Working Pressure Work Flow Set Pressure Relief Reduction Gears Reduction Gear Ration Slew Brake Brake Torque Brake Pressure Release Dry Weight Fixed Displacement Piston Motor 249.9 cm3 (15.2 in3/rev) 300 bar (305 kgf/cm2) 348.5 l/min (77 gal/min) 279 bar (285 kgf/cm2) Planetary gear reduction 27.14 1192 Nm (121.5 kgf m, 712 lbf ft) 18.6 bar (18.9 kgf/cm2) 583 kg (1285 lb)
9804/1103
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6420 - E/1-3.1
Issue 1*
CONTENTS CONTENTS
Wheeled Loaders
45 - 05 - 04/1
JS 130 from m/c no. 758000, JS160 Data - Track Motor/Gearbox
JS130 Reduction gear ratio Hydraulic motor Maximum stroke volume/rev Maximum rotational speed Maximum pressure 2-Speed switching pressure Parking brake Braking torque Release pressure Overall weight 9.8 bar (142 lbf/in2, 255 Nm (188 lbf ft, 26 kgf m) 10 kgf/cm2) 86.3 cc (5.27 in3) 2400 rpm 343 bar (4978 lbf/in2, 350 kgf/cm2) 39 : 1
JS160 48 : 1
104. 8 cc (6.39 in3) 2800 rpm
19.6 - 68.6 bar (284 - 296 lbf/in2, 20 - 70 kgf/cm2)
10.8 bar (156 lbf/in2, 11 kgf/cm2) 225 kg (496 lbs)
165 kg (364 lbs)
9804/1103
45 - 05 - 04/1
Issue 1
CONTENTS CONTENTS
Wheeled Loaders
45 - 05 - 04/2
JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 Data - Track Motor/Gearbox
JS200/220 Motor * cm3/rev Displacement Reduction gear, etc. value * cm3/rev Cross over relief Valve Double counter balance valve Cracking pressure Full flow pressure Plunger switch pressure Check valve cracking pressure Pilot pressure for 2-speed switch 2-speed switch valve 1 2 2 1 Reduction gear Parking brake Structure Speed Parking brake torque KNm {kgf/cm2} Release pressure Pressure MPa (kgf/cm2) 1st speed Supply flow L/min 2nd speed 1st speed Output torque kNm {kgf m} 2nd speed 1st speed Output revolutions rpm 2nd speed Normal Drain pressure Mpa {kgf/cm2} Maximum instant Oil temperature Total dry weight C kg less than 0.5 {5.0} -20 ~ +95 270 2139 less than 0.2 {2.0} 2161 0.507 {51.7} 1259 0.536 {54.7} 1291 198.7 0.862 {87.9} 212.2 0.898 {91.6} 198.7 Motionless Moving MPa (kgf/cm2) 1st 2nd MPa (kgf/cm2) MPa (kgf/cm2) MPa (kgf/cm2) MPa (kgf/cm2) MPa (kgf/cm2) MPa (kgf/cm2) MPa (kgf/cm2) 7004 4123 7297 4359 1st 2nd 157.8 92.9 JS240/260 164.4 98.2
31.1 {317} at 1.2 l/min 35.3 {360} at 40 l/min 0.6~1.3 {6~13} less than 0.03 {0.3} 3.9 {40} 23.2 {237} 25.3 {259} Planetary gear 3 step reduction gear 1/44.384 more than 20.94 {2135} more than 16.67 {1700} less than 1.4 {14} 34.3 {350} 212.2
9804/1103
45 - 05 - 04/2
Issue 1
CONTENTS
Excavators
45 - 05 - 04/3
JS 330 from m/c no. 712501 JS 450 from m/c no. 714501 Data - Track Motor/Gearbox
JS330 Reduction Gear Ratio Hydraulic Motor Maximum stroke volume/rev Maximum rotational speed Maximum pressure 2-Speed switching pressure Parking Brake Braking torque (stationary) Release Pressure Overall Weight 472 Nm (640 lbf ft, 48.1 kgf m) 14 bar (199 lbf/in2, 14 kgf/cm2) 360 kg (792 lb) 16.7 bar (242 lbf/in2, 17 kgf/cm2) 726 kg (1600 lb) 153.4 cc (9.36 in3) 2400 rpm 313 bar (4550 lbf/in2, 320 kgf/cm2) 44 bar (640 lbf/in2, 45 kgf/cm2) 104.8 cc (6.39 in3) 2800 rpm 74.3 : 1 JS450 59 : 1
Schematic (JS330, JS450)
9804/1103
45 - 05 - 04/3
6420 - F/2-1.1
Issue 1*
CONTENTS
Excavators
45 - 05 - 04/4
JS 460 from m/c no. 714550 Data - Traction Motor Component List
Item 1 2 3 4 4-1 4-2 5 6 7 7-1 7-2 -8 -9 10 - 11 11 - 1 11 - 2 - 12 - 13 - 14 - 15 16 17 18 19 20 21 22 23 24 25 26 27 28 - 29 - 30 - 31 31 - 1 31 - 2 31 - 3 31 - 4 31 - 5 31 - 6 31 - 7 31 - 8 31 - 9 31 - 10 31 - 11 31 - 12 31 - 13 31 - 14 31 - 15 31 - 16 31 - 17 32 Description Housing Screw Not Used Carrier Gear Circlip Washer Gear Carrier Gear Circlip Washer Gear Gear Carrier Gear Shaft Washer Seal Cover Bolt Screw Nut Washer Washer Washer Bearing Seal Hub Spacer Seal Spacer Beam Screw Seal Valve Brake Circlip Washer Circlip Bearing Hub Ring Seal Disc Disc Gasket Gasket Sleeve Piston Spring Spring Cover Circlip Seal Qty 1 1 2 5 5 1 1 1 3 3 1 1 1 1 3 3 1 1 1 12 2 1 1 2 3 2 1 1 1 1 1 1 2 3 1 1 1 2 1 1 1 2 10 9 1 1 1 1 14 14 1 1 1
9804/1103
45 - 05 - 04/4
6420 - F/7-10.1
Issue 1*
CONTENTS
Excavators
45 - 05 - 04/5
JS 460 from m/c no. 714550 Data - Traction Motor
4-1 4-2 7-1 7-2
11-1 11-2 10 5 4 6 7 32 29 30 28 27 11 12 8 13 14 9
25 31
21 15
16
31-16 26 24 31-10 31-15 31-14 31-13 31-12 31-6 31-11 31-6 31-8 31-9 31-7 31-5 31-2 31-3 23 20 18 22
31-17
31-4 31-2
21 19 17 31-1
374760
9804/1103
45 - 05 - 04/5
6420 - F/7-9.1
Issue 1*
CONTENTS CONTENTS
Excavators
45 - 05 - 05/1
JS 200W from m/c no. 809000 Data - Control Valve Technical Data
Rated flow - JS200W 400 l/min (88 UK gal/min) (105 US gal/min) 350 bar 356.9 kgf/cm2 (5076 lbf/in2) -20 to 80C (-4 to 176F) 100C (212 F) 35 bar 35.6 kgf/cm2 (507.6 lbf/in2) 3.1 to 21.8 bar 3.2 - 22 kgf/cm2 (45 - 316 lbf/in2) 11mm (0.43 in) Hydraulic pilot operation
Maximum pressure for normal use Oil temperature range Maximum oil temperature Pilot maximum allowable pressure Pilot operation pressure Spool stroke Control method Main relief valve Standard pressure setting Maximum pressure setting Overload relief valve Standard pressure setting (boom raise, dipper, bucket) Maximum pressure setting (boom lower) Options/dozer/stabiliser Spool Weight Function
320 bar 326.3 kgf/cm2 (4641 lbf/in2) 350 bar 356.9 kgf/cm2 (5076 lbf/in2)
360 bar 367.1 kgf/cm2 (5221 lbf/in2) 245 bar 249.8 kgf/cm2 (3553 lbf/in2) 250 bar 255 kgf/cm2 (3625 lbf/in2) Solid type 150 kg (330.7 lb) Travel priority, slew priority, boom/dipper with load holding, bucket, auxiliary
9804/1103
45 - 05 - 05/1
6320 - E/20-1.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 06/1
JS 200W from m/c no. 809000 Data - Drive Gearbox

Gearbox Installed position Brake Dry Weight 2HL-100, Two speed powershift transmission. Horizontal - Separate installation. Parking Brake 125 kg
9804/1103
45 - 05 - 06/1
6320 - F/4-1.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 07/1
JS 200W from m/c no. 809000 Data - Front Axle
Type Designation Installation Steering Weight Half (Axle) Shaft Braking Ratio: Overall Crown wheel and pinion Number of teeth: Crownwheel Pinion Hub reduction Input type Toe in Castor Angle Camber Angle King pin inclination Oscillation
Spiral bevel input with epicyclic hub reduction APL-B 765 Centre pivot Power track rod, integral cylinder 649 kg (1431 lb) 3 plate (each half shelf)
17.6 : 1 2.75 : 1
33 12 6.4 :1 Din 120 dia. 0 0 0 0 8
Service Brake Type Actuation Location Friction plates Outside diameter Inside diameter Hydraulic piston stroke Oil immersed multi plate disc, positive retraction Hydraulic Wheel hubs 3 per pack 232 mm (9.1 in) 154 mm (6 in) 2.4 - 2.8 mm (0.094 - 0.11in)
9804/1103
45 - 05 - 07/1
6320 - F/14-1.1
Issue 1
CONTENTS
Excavators
45 - 05 - 07/1A
JS 130 from m/c no. 716500 Data - Front Axle (SD 70PT)
Note: Earlier JS130W Wheeled Excavators are fitted with SD 70PT Front Axles. Later machines are fitted with SD 80PT Front Axles. SD70 with Power Track Rod Type Designation Installation Steering Weight Half (Axle) Shaft Braking Ratio: Overall Crown wheel and pinion Number of teeth: Crownwheel Pinion Hub reduction Input type Toe in Castor Angle Camber Angle King pin inclination Oscillation 15.78 : 1 2.923 : 1 ITL spiral bevel input with epicyclic hub reduction SD70PT Centre pivot Power track rod, integral cylinder 536 kg (1,182 lb) 4 plate (each half shaft)
38 13 5.4 : 1 1480 half yoke 0 0 1 0 5
Service Brake Type Actuation Location Friction plates Outside diameter Inside diameter Nominal facing area/plate Hydraulic piston diameter Oil immersed multi-plate disc, positive retraction Hydraulic Wheel hubs 4 per pack 220 mm (8.66 in) 160 mm (6.29 in) 17,900 mm2 (27.75 in2) 208 mm (8.18 in)
9804/1103
45 - 05 - 07/1A
6310 - F/14-1.1
Issue 1
CONTENTS
Excavators
45 - 05 - 07/1B
JS 130W from m/c no. 716500, JS 160 from m/c no. 718500 Data - Front Axle (SD 80PT)
Note: Earlier JS130W Wheeled Excavators are fitted with SD 70PT front axles. On later excavators both JS130W and JS160W machines are fitted with SD 80PT Front Axles. SD80 with Power Track Rod Type Designation Installation Steering Weight Half (Axle) Shaft Braking Ratio: Overall Crown wheel and pinion Number of teeth: Crownwheel Pinion Hub reduction Input type Toe in Castor Angle Camber Angle King pin inclination Oscillation 18.16 : 1 3.363 : 1 ITL spiral bevel input with epicyclic hub reduction SD80PT Centre pivot Power track rod, integral cylinder 540 kg (1,191 lb) 4 plate (each half shaft)
37 11 5.4 : 1 1480 half yoke 0 0 1 0 5
9804/1103
45 - 05 - 07/1B
6310 - F/30-1.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 07/2
JS 200W from m/c no. 809000 Data - Rear Axle Technical Data (JS200W)
Type Designation Installation Weight Half (Axle) Shaft Braking Ratio: Overall Crown wheel and pinion Number of teeth: Crownwheel Pinion Hub reduction Input type Toe in Castor Angle Camber Angle King pin inclination 17.6 : 1 2.75 : 1 Spiral bevel input with epicyclic hub reduction AP-765 Pad mounted 495 kg (1091 lb) 3 plate (each half shelf)
33 12 6.4 :1 Din 120 dia. 0 0 0 0
Service Brake Type Actuation Location Friction plates Outside diameter Inside diameter Hydraulic piston stroke Oil immersed multi plate disc, positive retraction Hydraulic Wheel hubs 3 per pack 232 mm (9.1 in) 154 mm (6 in) 2.4 - 2.8 mm (0.094 - 0.11in)
9804/1103
45 - 05 - 07/2
6320 - F/23-1.1
Issue 1
CONTENTS
Excavators
45 - 05 - 07/2A
JS 130 from m/c no. 716500 Data - Rear Axle (PD70)

Note: Earlier JS130W Wheeled Excavators are fitted with PD 70 Rear Axles. Later machines are fitted with PD 80 Rear Axles. Type Designation Installation Weight Half (Axle) Shaft Braking Ratio: Overall Crown wheel and pinion Number of teeth: Crownwheel Pinion Hub reduction Input type Toe in Castor Angle Camber Angle King pin inclination 15.78 : 1 2.923 : 1 ITL spiral bevel input with epicyclic hub reduction PD70 Pad mounted 386 kg (851 lb) approx. 4 plate (each half shaft)
38 13 5.4 : 1 1480 half yoke 0 0 1 0
9804/1103
45 - 05 - 07/2A
6310 - F/23-1.2
Issue 1
CONTENTS
Excavators
45 - 05 - 07/2B
JS 130W from m/c no. 716500, JS 160W from m/c no. 718500 Data - Rear Axle (PD80)
Note: Earlier JS130W Wheeled Excavators are fitted with PD 70 rear axles. On later excavators both JS130W and JS160W machines are fitted with PD 80 Rear Axles. Type Designation Installation Weight Half (Axle) Shaft Braking Ratio: Overall Crown wheel and pinion Number of teeth: Crownwheel Pinion Hub reduction Input type Toe in Castor Angle Camber Angle King pin inclination 18.16 : 1 3.363 : 1 ITL spiral bevel input with epicyclic hub reduction PD80 Pad mounted 386 kg (851 lb) approx. 4 plate (each half shaft)
37 11 5.4 : 1 1480 half yoke 0 0 1 0
9804/1103
45 - 05 - 07/2B
6310 - F/32-1.1
Issue 1
CONTENTS CONTENTS
*JS
Excavators
70 to m/c no. 695500
Data - Engine
Type Model Bore Stroke Swept Volume Compression Ratio Gross Power Net power at 2200 rev/min Firing Order Valve Clearance - Inlet - Exhaust Dry Weight (approximately) Fuel System Diesel Fuel Specification - Cetane Number (minimum) - Viscosity at 40 C (104 F) - Density - Sulphur (maximum) - Distillation at 350 C (662 F) Injection Timing (static) Injector Opening Pressure Induction System Air Cleaner Type For further details, see engine service manual, Publication No. 2 stage, dry element Isuzu 4JB1, 4 cylinder turbocharged, diesel 4JB1 PA-15 93 mm (3.7 in) 102 mm (4 in) 2771 cm3 (170 in3) 18.2 : 1 43 kW (57 hp) 41 kW (55 hp) 1,3,4,2 0.4 mm (0.016 in) 0.4 mm (0.016 in) 220 kg (485 lb)
45 2.5/4.5 cSt 0.836/0.866 kg/litre (1.046/1.084 lb/pint) 0.5% of mass 85% 17 BTDC 181.4 bar (2631 lbf/in2)
9803/6920
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately. Glazing of the cylinder bores resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming up without load).
9804/1103
45 - 05 - 08/1
Issue 3*
CONTENTS CONTENTS
Excavators
45 - 05 - 08/2
JS 110,130,150LC Data - Engine

Type Model - JS110 - JS130 - JS150LC Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately) Fuel System Max. Speed (No Load) - JS110 - JS130 - JS150LC Injection Timing (static) Injector Opening Pressure Induction System Air Cleaner Type For further details, see engine service manual, Publication No. 2 stage, dry element Isuzu 4BD1, 4 cylinder turbocharged 4BD1PTA-05 4BD1PTA-14 4BD1PTA-15 102 mm (4.016 in) 118 mm (4.646 in) 3856 cm3 (235.3 in3) 17.5 : 1 30 bar (440 lbf/in2) 1,3,4,2 0.4 mm (0,016 in) 0.4 mm (0.016 in) 350 kg
Less than 2230 rev/min Less than 2425 rev/min Less than 2550 rev/min 18 BTDC 180 bar (2630 lbf/in2)
9803/6910
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
9804/1103
45 - 05 - 08/2
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 08/3
JS 200LC,240LC Data - Engine

Machine Type Model Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately) Fuel System Max. Speed (No Load) Injection Timing (static) Injector Opening Pressure Induction System Air Cleaner Type 2 stage, dry element 2 stage, dry element Less than 2250 rev/min 16 BTDC 180 bar (2630 lbf/in2) Less than 2420 rev/min 13 BTDC 180 bar (2630 lbf/in2) JS200LC Isuzu 6 cylinder turbocharged 6BD1TLE-02 102 mm (4.016 in) 118 mm (4.646 in) 5785 cm3 (353 in3) 17.5 : 1 30 bar (440 lbf/in2) 1,5,3,6,2,4 0.4 mm (0,016 in) 0.4 mm (0.016 in) 470 kg (1036 lb) JS240LC Isuzu 6 cylinder turbocharged 6BG1TPC-01 105 mm (4.13 in) 125 mm (4.92 in) 6494cm3 (396 in3) 17 : 1 30 bar (440 lbf/in2) 1,5,3,6,2,4 0.4 mm (0,016 in) 0.4 mm (0,016 in) 470 kg (1036 lb)
For further details, see engine service manual, publication No.
9803/6910
9803/6910
9804/1103
45 - 05 - 08/3
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 08/4
JS 300LC,450LC Data - Engine

Machine Type Model Bore Stroke Swept Volume Compression Ratio Compression Pressure at 220 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately) Fuel System Max. Speed (No Load) Injection Timing (static) Injector Opening Pressure Induction System Air Cleaner Type 2 stage, dry element 2 stage, dry element Less than 2450 rev/min 18 BTDC 200 bar (2845 lbf/in2) Less than 2200 rev/min 18 BTDC 200 bar (2845 lbf/in2)) JS300LC Isuzu 6 cylinder turbocharged 6SD1TPB 120 mm (4.72 in) 145 mm (5.7 in) 9839 cm3 (600.2 in3) 16.5 : 1 28 bar (412 lbf/in2) 1,5,3,6,2,4 0.4 mm (0,016 in) 0.4 mm (0.016 in) 700 kg (1543 lb) JS450LC Isuzu 6 cylinder turbocharged 6RB1TPE-01 135 mm (5.31 in) 160 mm (6.30 in) 13741cm3 (838 in3) 16.5 : 1 28 bar (412 lbf/in2) 1,4,2,6,3,5 0.6 mm (0,024 in) 0.6 mm (0,024 in) 1085 kg (2392 lb)
For further details, see engine service manual, publication No.
9803/6930
9803/6940
9804/1103
45 - 05 - 08/4
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 08/4A
JS 70 from m/c no. 695501 Data - Engine Technical Data

Type Model Bore Stroke Swept Volume Compression Ratio Firing Order Valve Clearance - Inlet - Exhaust Dry Weight (approximately) Fuel System Injection Timing (static) Injector Opening Pressure Induction System Air Cleaner Type For further details see engine service manual, Publication No. 9803/6920 17 BTDC 185 bar (2630 lbf/in2) Isuzu 4JB1, 4 cylinder turbocharged,diesel 4JB1 PAA-04 93mm (3.7 in) 102 mm (4 in) 2771cm3 (170 in3) 18.2 :1 1-3-4-2 0.4mm (0.016 in) 0.4mm (0.016 in) 220 kg (486lb)
9804/1103
45 - 05 - 08/4A
Issue 1
CONTENTS
Excavators
45 - 05 - 08/5
* JS
130W from m/c no. 785001, JS 160W from m/c no. 702001 - Engine
Isuzu A4BG1T, 4 cylinder in-line, turbocharged, direct injection diesel. A4BG1T-S1 A4BG1T-S2 105 mm (4.13 in) 125 mm (4.92 in) 4329 cm3 (264.2 in3) 17.0 : 1 31 bar (450 lbf/in2) 1, 3, 4, 2 0.4 mm (0.016 in) 0.4 mm (0.016 in) 361 kg
* Data Type
Model - JS130W - JS160W Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately) Fuel System Max. Speed (No Load) - JS130W - JS160W Injector Timing (static) Injector Opening Pressure Induction System Air Cleaner Type For further details, see engine service manual, Publication No.
Less than 2570 rev/min Less than 2571 rev/min 12 BTDC 180 bar (2630 lbf/in2)
2 stage, dry element with in-cab warning indicator.
9803/6910
9804/1103
45 - 05 - 08/5
Issue 2*
CONTENTS
Excavators
45 - 05 - 08/6
JS 330 from m/c no. 712501 Data - Engine

Type Model - JS330 Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately) Fuel System Max. Speed (no load) - JS330 Injection Timing (Static) Injector Opening Pressure Induction System Air Cleaner Type Isuzu 6SD1, 6 cylinder turbo charged 6SD1TQB-02 120 mm (4.42 in) 145 mm (5.7 in) 9839 cm3 (600 in2) 15.7 : 1 30 bar (440 lbf/in2) 1, 5, 3, 6, 2, 4 0.4 mm (0.016 in) 0.4 mm (0.016 in) 700 kg 1540 lb)
2250 + 50 rev/min 12 BTDC 196 bar (2842 lbf/in2)

o
2 stage, dry element
For further details, see JS330 Engine Service Manual, Publication No. 9806/2160 For further details, see JS330 Tier 2 Engine Service Manual Publication No. 9806/2200
JS 450 from m/c no. 714501 JS 460 from m/c no. 714550
Type Model - JS450/460 Bore Stroke Swept volume Compression Ratio Compression Pressure at 220 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately) Fuel System Max. Speed (No Load) - JS 450/460 Injection Timing (static) Injector Opening Pressure Induction System Air Cleaner Type Isuzu 6RB1, 6 cylinder turbo charged 6RB1TQB-02 135 mm (5.32 in) 160 mm (6.30 in) 13741 cm3 (838 in2) 16.5 : 1 28.4 bar (412 lbf/in2) 1, 4, 2, 6, 3, 5 0.6 mm (0.024 in) 0.6 mm (0.024 in) 1076 kg (2375 lb)
2250 + 50 rev/min 17 BTDC 220 bar (3191 lbf/in2)

o
2 Stage, dry element
For further details, see JS450/460 Engine Service Manual, Publication No. 9806/2166 Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores resulting in excessive oil consumption, could occor if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming up without load).
9804/1103
45 - 05 - 08/6
6420 - K/1-1.2
Issue 2*
CONTENTS
Excavators
45 - 05 - 08/6A
JS460 Tier 2 Data - Engine

Type Model - JS460 Tier2 Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately) Fuel System Max. Speed (No Load) - JS460 Tier2 Injector Timing (static) Injector Opening Pressure Induction System Air Cleaner Type For further details, see engine service manual, Publication No. 2 stage, dry element with in-cab warning indicator. Isuzu AA 6SD1T, 6 cylinder turbo charged. AA 6SD1TQB-01 120 mm (4.72 in) 145 mm (5.7 in) 9839 cm3 (600 in3) 16.8 : 1 28 bar (411 lbf/in2) 1, 5, 3, 6, 2, 4 0.4 mm (0.016 in) 0.4 mm (0.016 in) 693 kg(1528 lb)
2300 + or _ 30 rev/min 7 BTDC 177 bar (2567 lbf/in2)
9806/2240
9804/1103
45 - 05 - 08/6A
36420 - K/1- 2.170 -6420
Issue 1
CONTENTS
Excavators
45 - 05 - 08/7
JS 130W from m/c no. 0716501, JS 160W from m/c no. 0718501 Data - Engine Technical Data
Type Model - JS130W - JS160W Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately) Fuel System Max. Speed (No Load) - JS130W - JS160W Injector Timing (static) Injector Opening Pressure Induction System Air Cleaner Type For further details, see engine service manual, Publication No. 2 stage, dry element. Isuzu A4BG1T, 4 cylinder in-line, turbocharged, direct injection diesel. A4BG1T-S1 A4BG1T-S2 105 mm (4.13 in) 125 mm (4.92 in) 4329 cm3 (264.2 in3) 17.0 : 1 31 bar (450 lbf/in2) 1, 3, 4, 2 0.4 mm (0.016 in) 0.4 mm (0.016 in) 361 kg
9803/6910
9804/1103
45 - 05 - 08/7
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 08/7A
JS 130 from m/c no. 758000, JS 160 from m/c no. 702000 Data - Engine
Type Model - JS130 - JS160 Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately) Fuel System Max. Speed (No Load) - JS130 - JS160 Injection Timing (static) Injector Opening Pressure Induction System Air Cleaner Type For further details, see engine service manual, Publication No. 2 stage, dry element with in-cab warning indicator. Isuzu A4BG1T, 4 cylinder in-line, turbocharged, direct injection diesel. A4BG1T-S1 A4BG1T-S2 105 mm (4.13 in) 125 mm (4.92 in) 4329 cm3 (264.2 in3) 17.0 : 1 31 bar (450 lbf/in2) 1, 3, 4, 2 0.4 mm (0.016 in) 0.4 mm (0.016 in) 361 kg
9806/2120
9804/1103
45 - 05 - 08/7A
6410 - K/1-1.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 08/8
JS 130W from m/c no. 716500, JS 160 from m/c no. 718500 Data - Engine
Type Model - JS130W - JS160W Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately) Fuel System Max. Speed (No Load) - JS130W - JS160W Injector Timing (static) Injector Opening Pressure Induction System Air Cleaner Type For further details, see engine service manual, Publication No. 2 stage, dry element with in-cab warning indicator. Isuzu A4BG1T, 4 cylinder in-line, turbocharged, direct injection diesel. A4BG1T-S1 A4BG1T-S2 105 mm (4.13 in) 125 mm (4.92 in) 4329 cm3 (264.2 in3) 17.0 : 1 31 bar (450 lbf/in2) 1, 3, 4, 2 0.4 mm (0.016 in) 0.4 mm (0.016 in) 361 kg
9803/6910
9804/1103
45 - 05 - 08/8
6310 - K/1-1.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 05 - 08/9
JS 200W from m/c no. 809000 Data - Engine

Type Model - JS200W Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately) Fuel System Max. Speed (No Load) - JS200W Injector Timing (static) Injector Opening Pressure Induction System Air Cleaner Type For further details, see engine service manual, Publication No. 2 stage, dry element with in-cab warning indicator. YH50727 100 mm (3.937 in) 127 mm (5.00 in) 5985 cm3 (365.2 in3) 17.25 : 1 31 bar (450 lbf/in2) 1, 5, 3, 6, 2, 4 0.4 mm (0.016 in) 0.4 mm (0.016 in) 480 kg YH 50727, 6 cylinder in-line, turbocharged, direct injection diesel.
Less than 2350 rev/min 12 BTDC 180 bar (2630 lbf/in2)
9806/2140
9804/1103
45 - 05 - 08/9
6320 - K/1-1.1
Issue 1
CONTENTS
Excavators
45 - 05 - 08/10
JS 200,220 from m/c no. 705001,JS 210 from m/c no.705648, JS 240 from m/c no. 708001, JS 260 from m/c no. 708501. Data - Engine
Type Model - JS200 - JS210 - JS220 - JS240 - JS260 Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately) Fuel System Max. Speed (No Load) - JS200 - JS210 - JS220 - JS240 - JS260 A-6BG1TQB-04 A-6BG1TQB-04 A-6BG1TQB-04 A-6BG1TQB-05 A-6BG1TQB-05 105 mm (4.13 in) 125 mm (4.92 in) 6,494 cm3 (396 in3) 17.5 : 1 31 bar (450 lbf/in2) 1, 5, 3, 6, 2, 4 0.4 mm (0.016 in) 0.4 mm (0.016 in) 458 kg (1007.6 lb.) Isuzu A4BG1T,6 cylinder in-line,turbocharged,direct injection diesel.
Less than 2100 rev/min Less than 2100 rev/min Less than 2100 rev/min Less than 2300 rev/min Less than 2100 rev/min
Injector Timing (static) Injector Opening Pressure Induction System Air Cleaner Type For further details, see engine service manual, Publication No.
12 BTDC 185 bar (2682.5 lbf/in2)
2 stage, dry element with in-cab warning indicator.
9806/2120
CONTENTS
Excavators
45 - 05 - 09/1
JS 330 from m/c no. 712501 JS 450 from m/c no. 714501 Data - Tracks and Running Gear - Torque Specifications
Component Drive Sprocket fastening Bolts Idler Wheels mounting Bolts Top Roller mounting bolts Bottom roller mounting bolts Grease cylinder mounting bolts Track Guard JS330 JS450 (STD) (HD) (STD) (HD) JS330 JS450 JS330 JS450 Nm 521 - 608 900 - 1051 267 - 312 kgf m 53 - 62 92 - 107 27.2 - 31.8 lbf ft 384 - 448 663 - 775 197 - 230
267 - 312 371 - 432 521 - 608 900 - 1051 267 - 312
27.2 - 31.8 38 - 44 53 - 62 92 - 107 27.2 - 31.8
197 - 230 273 - 318 384 - 448 606 - 775 197 - 230
521 - 608 900 - 1051 775 - 931 980 - 1180
53 - 62 92 - 107 77 - 95 100 - 120
384 - 448 663 - 775 557 - 687 723 - 871
Shoe Bolts
Note: Apply JCB Threadlocker and Sealer to the threads of the above bolts.
9804/1103
45 - 05 - 09/1
6420 - J/1-1.2
Issue 1*
CONTENTS
Excavators
45 - 05 - 09/2
JS 330 from m/c no. 712501 JS 450 from m/c no. 714501 Data - Tracks and Running Gear - Bottom Roller Wear Limits
Item Dimension Machine Standard Size mm in 180 210 20 25 100 200 250 70 90 70 90 82.5 93 20.5 24.6 7.09 8.27 0.79 0.98 3.94 7.87 9.84 2.76 3.54 2.76 3.54 3.25 3.66 0.81 0.97 Service Limit mm in 172 198 20 92 208 260 69 89 71.5 91 81.5 92 20 24 6.77 7.79 0.79 3.62 8.19 10.24 2.72 3.50 2.82 3.58 3.21 3.62 0.79 0.94 Action
Roller Diameter
JS330 JS450 JS330 JS450 JS330 JS450 JS330 JS450 JS330 JS450 JS330 JS450 JS330 JS450 JS330 JS450
Renew Renew Renew Renew Renew Renew Renew Renew Renew Renew Renew Renew Renew Renew Renew Renew
Inner flange width
Outer flange width
Shaft Diameter
Bushing diameter
Length
Collar
Inner Flange
Outer Flange
9804/1103
45 - 05 - 09/2
6420 - J/14-1.1
Issue 1*
CONTENTS
Excavators
45 - 10 - 01/1
*JS
70 to m/c no. 695500
Fault Finding - Hydraulics

Some problems which may occur in the hydraulic system are listed below, either for the system as a whole or for individual components. SYMPTOM 1. Hydraulic System a. The hydraulic system is defective or does not operate at all. 1. The pump is defective. Check pump pressure and renew if defective. Dismantle and clean the relief valve. POSSIBLE CAUSE ACTION
2. Dirt is clogging the inside of the relief valve. 3. The relief valve is defective. 4. A ram is worn. 5. Negative pressure is low. 6. A valve is cracked. 7. A spool is not operating over its full stroke. 8. The oil level in the tank is too low. 9. Circuit filters are clogged. 10. The circuit pipes are restricted. 2. Control Valve Oil temperature abnormally high.
Strip and check the relief valve. Repair or renew the ram. Check circuit pressure. Renew the valve. Check the movement of the spool or the operational linkage. Replenish the oil. Clean or renew filters. Check the piping.
a. A spool is sticking.
Check for correct fluid, see Lubricants and Capacities, page 45-00-01/1. 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.
2. The hydraulic fluid is dirty.
3. The service pipe connection is over tightened. 4. The valve housing was twisted during installation. 5. Pressure too high. 6. A control linkage is bent.
Loosen retaining bolts and tighten to correct torque figures. Check system pressure, see page 10 - 1. Disconnect the linkage, see page 25 - 5. Repair the linkage if possible, or fit a new one. Dismantle the control valve as detailed in the section starting on page 25 - 1. 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.
7. A spool is bent.
8. A return spring is broken. 9. A return spring or cap is out of alignment.
10. Temperature distribution within control valve not uniform. Note: refers to Service Manual.
9804/1103
45 - 10 - 01/1
Issue 2*
CONTENTS
Excavators
45 - 10 - 01/2
*JS
70 to m/c no. 695500
Fault Finding - Hydraulics (cont'd)

SYMPTOM 2. Control Valve (cont'd) 1. Dirt is clogging the inside of the valve. 2. A control linkage is bent or restricted. Remove the dirt by flushing out the valve. POSSIBLE CAUSE ACTION
b. A spool does not move over its full stroke.
Disconnect the linkage, see page 25 - 5. Repair the linkage, if possible, or replace it and/or remove the restriction. Consult JCB Service for repairs, or fit a new ram.
c. The dipper/boom falls under load with the spool in neutral.
1. Oil is leaking past the dipper/boom ram piston seals.
2. Oil is bypassing dipper/boom spool. 3. Oil is leaking past dipper/boom ARV.
Renew spool. Remove ARV and clean housing seat and relief valve seat. Refit ARV. Dismantle and check boom load hold check valve, see page 26 - 1. Replace faulty components. Dismantle and clean the boom load hold check valve, see page 26 - 1. Renew the poppet or smooth the poppet and seat with very fine emery cloth. Remove the seal and clean. Check circuit pressures, see page 10 - 1. 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.
4. Faulty boom load hold check valve.
d. The boom falls under load when the spool is moved to the 'raise' position.
1. Dirt is clogging the boom load hold check valve. 2. The boom load hold check valve seat is scratched or damaged. 1. Paint or dirt on the seal face. 2. The back pressure in the valve circuit is excessively high.
e. Leaking oil seal.
3. Spool damaged.
4. The seal is not secured.
5. The seal is cut or damaged. 3. Main Relief Valve a. System pressure does not rise at all. 1. The main poppet, check valve poppet or pilot poppet is sticking open, or dirt is caught in the valve seat.
Remove MRV and dismantle as detailed in the section starting on page 25 - 1. Inspect and clean all parts. Assemble MRV, ensuring that all parts slide freely. Refit the MRV. Remove MRV and dismantle as detailed in the section starting on page 25 - 1. Inspect and clean all parts. Renew damaged parts or remove scratches with very fine emery cloth. Assemble MRV, ensuring that all parts slide freely. Refit MRV. Reset MRV pressure, see page 10 - 2 and tighten the lock nut.
b. Relief pressure is unstable or incorrect.
1. The pilot poppet seat is scratched or the pilot piston is sticking with the main poppet. Parts worn.
2. The lock nut and adjusting screw are loose.
Note: refers to Service Manual.

9804/1103
45 - 10 - 01/2
Issue 2*
CONTENTS
Excavators
45 - 10 - 01/3
*JS
70 to m/c no. 695500
Fault Finding - Hydraulics (cont'd)

SYMPTOM 3. Main Relief Valve (cont'd) c. Oil leak 1. Worn 'O' rings, damaged seals, contamination. Remove and dismantle MRV. Check for scratches, dents and contamination. Renovate or replace damaged parts, and replace all 'O' rings and seals. Clean thoroughly. POSSIBLE CAUSE ACTION
4. Servo Hand Control Valves a. Low secondary pressure. 1. Servo pressure is low. Check servo pressure as detailed on page 10 - 1 and adjust as necessary. Renew spring. Renew spool and casing assembly
2. Spring 241 is damaged. 3. The clearance between the spools and casing is too large. 4. The handle unit is loose. b. Unstable secondary pressure. 1. Sliding parts are sticking.
Renew the handle unit. Dismantle and inspect as detailed in section starting on page 40 - 1. Repair or renew as necessary. Operate the valve several times to remove the air. Dismantle and inspect as detailed in section starting on page 40 - 1. Repair or renew as necessary.
2. Air is trapped in the pipes.
c. High secondary pressure.
1. Sliding parts are sticking.
9804/1103
45 - 10 - 01/3
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 10 - 01/4
JS 110,130 Fault Finding - Hydraulics (cont'd)

Some problems which may occur in the hydraulic system are listed below, either for the system as a whole or for individual components. SYMPTOM 1. Hydraulic System a. The hydraulic system is defective or does not operate at all. 1. The pump is defective. Check pump pressure and replace if defective. Dismantle and clean the relief valve. POSSIBLE CAUSE ACTION
2. Dirt is clogging the inside of the relief valve. 3. The relief valve is defective.
Strip and check the relief valve as detailed on page 21-1. Repair or replace the ram. Check circuit pressure. Replace the valve. Check the movement of the spool or the operational linkage. Replenish the oil. Clean or replace filters. Check the piping.
4. 5. 6. 7.
A ram is worn. Negative pressure is low. A valve is cracked. A spool is not operating over its full stroke.
8. The oil level in the tank is too low. 9. Circuit filters are clogged. 10. The circuit pipes are restricted. 2. Hydraulic Pump a. Oil is not discharged from the pump. 1. The tank strainer or intake pipe is blocked or closed. 2. The end of the inlet pipe is above the tank oil level. 3. One or more of the pump major components is damaged or the input shaft or coupling are defective.
Clean the strainer and open the intake pipe. Replenish the oil tank.
Dismantle and inspect pump as detailed on page 20-1. Renew damaged components and reassemble the pump. Renew shaft or coupling. Check hydraulic pump and control valve. Renew as required.
b. Pump output is low. Hydraulic pressure does not increase.
1. The pressure does not increase because of problems with the hydraulic pump or control valve. 2. Internal leakage within the hydraulic pump with excessive fluid drain from pump drain port.
Strip and inspect the hydraulic pump as detailed on page 20-1, paying particular attention to sliding surfaces. Repair or renew as necessary. Reassemble the pump. Check tank oil level and strainer for clogging. Correct as necessary. If OK, check tightness of pump inlet connection. Check correct oil . Check pump low pressure inlet pipe for collapse. Renew as required.
3. Air is being drawn into the pump from the inlet side.
4. Inlet resistance causing cavitation.
9804/1103
45 - 10 - 01/4
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/5

SYMPTOM 2. Hydraulic Pump (cont'd) c. The pump makes an abnormal noise. 1. Oil level is low and the pump is drawing in air. Check and replenish oil level. Run the pump under no load to bleed air from the hydraulic system. Clean strainer. If strainer is severely clogged, drain and flush hydraulic system. Check correct oil for ambient temperature, see Lubrication Chart, page 45-00-01/2. Check shaft run out. Check pump mounting bolts for tightness. Tighten as required. Dismantle and inspect pump, as detailed on page 20-1, paying particular attention to bearings and sliding surfaces. Adjust as necessary. Remove the regulator from the pump and check filter for blockage. Clean as necessary. If filter OK, dismantle and inspect regulator, see page 20-1. Dismantle and inspect pump as detailed on page 20-1, paying particular attention to sliding surfaces. Repair or renew as necessary. Reassemble the pump. Dismantle and inspect pump as detailed on page 20-1, paying particular attention to oil seals and sliding surfaces. Renew as necessary, ensuring that lips of oil seals are not damaged when installed. Inspect and renew as necessary. POSSIBLE CAUSE ACTION
2. Clogging of the tank strainer.
3. Oil temperature is too low or wrong oil specification. 4. Coupling defective. 5. The pump is resonating with external equipment. 6. Internal damage to pump.
d. Engine overload (engine speed very low or engine stalled).
1. Regulator torque set too high. 2. The servo flow within the regulator is blocked or internal components are seized.
3. Pump is seized or worn.
e. Oil leakage.
1. Internal leakage within the pump causing oil seal damage and oil leakage.
2. Damaged or blocked drain pipe. 3. Control Valve a. A spool is sticking. 1. Oil temperature abnormally high.
Check correct oil, see Lubrication Chart, page 45-00-01/2. Check oil cooler and grille for blockage. Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system. Check tightening torque.
2. The hydraulic oil is dirty.
3. The service pipe connection is overtightened. 4. The valve housing was twisted during installation. 5. Pressure too high.
Loosen retaining bolts and tighten to correct torque figures. Check system pressure, see page 10-1.
9804/1103
45 - 10 - 01/5
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/6

SYMPTOM 3. Control Valve (cont'd) 6. A spool is bent. Dismantle the control valve as detailed on page 25-1. 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. Remove the dirt (flush out the valve. POSSIBLE CAUSE ACTION
9. Temperature distribution within control valve not uniform. b. A spool does not move over its full stroke. c. The dipper/boom falls under load with the spool in neutral. 1. Dirt is clogging the inside of the valve. 1. Oil is leaking past the ram/ boom piston seals.
Renew piston seals.
Renew spool. Remove ARV and clean housing seat and relief valve seat. Refit ARV. Dismantle and clean the load hold check valve. Renew the poppet or smooth the poppet and seat with very fine emery cloth.
d. The dipper/boom falls under load when the spool is moved to a position higher than neutral. 4. Main Relief Valve
1. Dirt is clogging the load hold check valve. 2. The load hold check valve seat is scratched or damaged.
a. System pressure does not rise at all.
1. The main poppet, check valve poppet or pilot poppet is sticking open, or dirt is caught in the valve seat.
Remove MRV and dismantle as detailed on page 26-1. Inspect and clean all parts Assemble MRV, ensuring that all parts slide freely. Refit the MRV. Remove MRV and dismantle as detailed on page 26-1. Inspect and clean all parts. Renew damaged parts or remove scratches with very fine emery cloth. Assemble MRV, ensuring that all parts slide freely. Refit MRV. Tighten the lock nut and reset MRV pressure. Remove MRV and renew 'O' rings.
b. Relief pressure is unstable.
2. The lock nut and adjusting screw are loose. c. Oil leak 1. Worn 'O' rings.
9804/1103
45 - 10 - 01/6
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/7

SYMPTOM 5. Swing Motor a. Motor does not turn. 1. Internal damage to the motor. Measure the oil drain volume. If the supply volume approaches drain volume, dismantle and inspect as detailed on page 35-1. Repair or renew as necessary. Disconnect motor inlet and outlet ports and apply servo pressure of 19.6 bar (284 lb. in2) to the brake release port. Try to rotate shaft with a torque of approximately 4.8 9.8 Nm (3.6 - 7.2 ft. lbs.). If the shaft does not rotate smoothly, dismantle and inspect as detailed on page 35-1. Repair or renew as necessary. Fit a pressure gauge and measure load pressure, as detailed on page 10-1. Reset as necessary. Measure the oil drain volume. If the volume exceeds 5 litres/min, dismantle and inspect as detailed on page 35-1. Repair or renew as necessary. Reduce oil temperature. Disconnect motor inlet and outlet ports and apply servo pressure of 19.6 bar (284 lb. in2) to the brake release port. Try to rotate shaft with a torque of approximately 4.8 9.8 Nm (3.6 - 7.2 ft. lbs.). If the shaft does not rotate smoothly, dismantle and inspect as detailed on page 35-1. Repair or renew as necessary. Fit a pressure gauge and measure load pressure, as detailed on page 10-1. Reset as necessary. Check for metallic particles in the motor drain oil or drain filter. If particles found, dismantle and inspect as detailed on page 35-1. Repair or renew as necessary. Check the oil in the tank and motor casing. Bleed the system. Check pipe connections, mounting bolts for tightness. Retighten to specified torque. Check for metallic particles in the motor drain oil or drain filter. Also apply servo pressure of 19.6 bar (284 lb. in2) to the brake release port. Try to rotate the shaft with a torque of approximately 4.8 9.8 Nm (3.6 - 7.2 ft. lbs.). If particles found or the shaft does not rotate smoothly, dismantle and inspect as detailed on page 35-1. Repair or renew as necessary. POSSIBLE CAUSE ACTION
2. Internal damage to the motor.
3. Relief valve in the circuit not correctly set.
b. Large slip.
1. Wear or damage to the motor sliding surfaces or high pressure seal.
2. Oil hot and large leakage in the motor. c. Insufficient torque. 1. Wear or burning of the motor sliding
d. Abnormal noise.
2. Large amounts of air in the oil.
3. Loosening of bolts or connections.
e. Abnormal heating.
1. Burning of the motor sliding or turning parts.
9804/1103
45 - 10 - 01/7
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/8

SYMPTOM 5. Swing Motor (cont'd) f. Leaks from the oil seal. 1. Damage or wear to oil seal lip. Renew the oil seal, as detailed on page 35-1. Repair the problem or renew the motor assembly. Set the pressure in the casing to below 2.9 bar (43 lb. in2) and check drain volume. If drain volume large, dismantle and inspect as detailed on page 35-1. Renew the oil seal and, if possible, repair or renew other damaged parts. Renew 'O' ring. Repair seal face or renew. Check bolts and tighten to the specified torque. POSSIBLE CAUSE ACTION
2. Damage or wear to shaft seal.
3. Abnormal pressure in the casing.
g. Oil leaks from mating surface.
1. An 'O' ring is damaged. 2. The seal face is damaged. 3. Bolts are loose.
6. Hand Control Valves a. Low secondary pressure 1. Servo pressure is low. Check servo pressure as detailed on page 10-1 and adjust as necessary. Renew spring. Renew spool and casing assembly
2. Spring 241 is damaged. 3. The clearance between the spools and casing is too large. 4. The handle unit is loose. b. Unstable secondary 1. Sliding parts are sticking.
Renew the handle unit. Dismantle and inspect as detailed on page 40-1. Repair or renew as necessary. Operate the valve several times to remove the air. Dismantle and inspect as detailed on page 40-1. Repair or renew as necessary.
9804/1103
45 - 10 - 01/8
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/9
JS 150LC Fault Finding - Hydraulics (cont'd)

Some problems which may occur in the hydraulic system are listed below, either for the system as a whole or for individual components. SYMPTOM 1. Hydraulic System a. The hydraulic system is defective or does not operate at all. 1. The pump is defective. Check pump pressure and replace if defective. Dismantle and clean the relief valve. POSSIBLE CAUSE ACTION
Strip and check the relief valve as detailed on page 26-1. Repair or replace the ram. Check circuit pressure. Replace the valve. Check the movement of the spool or the operational linkage. Replenish the oil. Clean or replace filters. Check the piping.
4. 5. 6. 7.
A ram is worn. Negative pressure is low. A valve is cracked. A spool is not operating over its full stroke.
8. The oil level in the tank is too low. 9. Circuit filters are clogged. 10. The circuit pipes are restricted. 2. Hydraulic Pump a. Oil is not discharged from the pump. 1. The tank strainer or intake pipe is blocked or closed. 2. The end of the inlet pipe is above the tank oil level. 3. One or more of the pump major components is damaged or the input shaft or coupling are defective.
Clean the strainer and open the intake pipe. Replenish the oil tank.
Dismantle and inspect pump as detailed on page 20-1. Renew damaged components and reassemble the pump. Renew shaft or coupling. Check hydraulic pump and control valve. Renew as required.
b. Pump output is low. Hydraulic pressure does not increase.
1. The pressure does not increase because of problems with the hydraulic pump or control valve. 2. Internal leakage within the hydraulic pump with excessive fluid drain from pump drain port.
Strip and inspect the hydraulic pump as detailed on page 20-1, paying particular attention to sliding surfaces. Repair or renew as necessary. Reassemble the pump. Check tank oil level and strainer for clogging. Correct as necessary. If OK, check tightness of pump inlet connection. Check correct oil . Check pump low pressure inlet pipe for collapse. Renew as required.
3. Air is being drawn into the pump from the inlet side.
4. Inlet resistance causing cavitation.

9804/1103
45 - 10 - 01/9
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/10

SYMPTOM 2. Hydraulic Pump (cont'd) c. The pump makes an abnormal noise. 1. Oil level is low and the pump is drawing in air. Check and replenish oil level. Run the pump under no load to bleed air from the hydraulic system. Clean strainer. If strainer is severely clogged, drain and flush hydraulic system. Check correct oil for ambient temperature, see Lubrication Chart, page 45-00-01/1. Check shaft run out. Check pump mounting bolts for tightness. Tighten as required. Dismantle and inspect pump, as detailed on page 20-1, paying particular attention to bearings and sliding surfaces. Adjust as necessary. Remove the regulator from the pump and check filter for blockage. Clean as necessary. If filter OK, dismantle and inspect regulator, see page 20-1. Dismantle and inspect pump as detailed on page 20-1, paying particular attention to sliding surfaces. Repair or renew as necessary. Reassemble the pump. Dismantle and inspect pump as detailed on page 20-1, paying particular attention to oil seals and sliding surfaces. Renew as necessary, ensuring that lips of oil seals are not damaged when installed. Inspect and renew as necessary. POSSIBLE CAUSE ACTION
2. Clogging of the tank strainer.
3. Oil temperature is too low or wrong oil specification. 4. Coupling defective. 5. The pump is resonating with external equipment. 6. Internal damage to pump.
1. Regulator torque set too high. 2. The servo flow within the regulator is blocked or internal components are seized.
3. Pump is seized or worn.
e. Oil leakage.
1. Internal leakage within the pump causing oil seal damage and oil leakage.
2. Damaged or blocked drain pipe. 3. Control Valve a. A spool is sticking. 1. Oil temperature abnormally high.
Check correct oil, see Lubrication Chart, page 45-00-01/1. Check oil cooler and grille for blockage. Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system. Check tightening torque.
3. The service pipe connection is overtightened. 4. The valve housing was twisted during installation. 5. Pressure too high.
Loosen retaining bolts and tighten to correct torque figures. Check system pressure, see page 11-1.

9804/1103
45 - 10 - 01/10
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/11

SYMPTOM 3. Control Valve (cont'd) 6. A spool is bent. Dismantle the control valve as detailed on page 25-1. 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. Remove the dirt (flush out the valve). POSSIBLE CAUSE ACTION
9. Temperature distribution within control valve not uniform. b. A spool does not move over its full stroke. c. The dipper/boom falls under load with the spool in neutral. 1. Dirt is clogging the inside of the valve. 1. Oil is leaking past the ram/ boom piston seals. 2. Oil is bypassing dipper/boom spool. 3. Oil is leaking past dipper/boom ARV.
Consult JCB Service for repairs of fit new ram. Renew spool. Remove ARV and clean housing seat and relief valve seat. Refit ARV.
Dismantle and clean the load hold check valve. Renew the poppet or smooth the poppet and seat with very fine emery cloth.
Remove MRV and dismantle as detailed on page 21-1. Inspect and clean all parts. Assemble MRV, ensuring that all parts slide freely. Refit the MRV. Remove MRV and dismantle as detailed on page 21-1. Inspect and clean all parts. Renew damaged parts or remove scratches with very fine emery cloth. Assemble MRV, ensuring that all parts slide freely. Refit MRV. Tighten the lock nut and reset MRV pressure. Remove MRV and renew 'O' rings.

9804/1103
45 - 10 - 01/11
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/12

SYMPTOM 5. Swing Motor a. Motor does not turn. 1. The pressure does not rise because the relief valve is incorrectly set. 2. The relief valve plunger sticks. Set the relief valve to the correct setting, see page 11-1. Dismantle and inspect the relief valve, as detailed on page 26-1. Repair or renew as necessary. Dismantle and inspect the relief valve, as detailed on page 26-1.Clean or renew as necessary. Dismantle and inspect the relief valve, as detailed on page 26-1, paying particular attention to the valve seat. Renew the seat if abrasions or damage is found. Release the load. Dismantle and inspect the motor, as detailed on page 36-1. Repair or renew as necessary. Dismantle and check the brake, as detailed in Section F, page 11-1. Repair or renew as necessary. Dismantle and check the brake, as detailed in Section F, page 11-1. Renew as necessary. Dismantle and assemble as detailed on page 36-1. Fit pipes to correct positions. POSSIBLE CAUSE ACTION
3. The relief valve plunger choke is blocked.
4. The relief valve plunger seat is defective.
5. The load is too heavy. 6. The motor is thermally seized.
7. The brake piston is stuck.
8. The brake friction plate is thermally seized.
b. The direction of rotation is reversed.
1. Motor assembled incorrectly.
2. The inlet and outlet pipe connections are reversed. c. Motor speed low. 1. The oil flow rate is insufficient.
Check the hydraulic pump delivery rate and the circuit up to the motor. Check the oil cooler and grille for damage and blockage. Dismantle and inspect the motor, as detailed on page 36-1. Repair or renew as necessary. Check the motor drain flow. If the flow exceeds 500 cc/min., dismantle and inspect the motor, as detailed on page 36-1, paying particular attention to the sliding surfaces. Repair or renew as necessary. Set the relief valve to the correct setting, see page 11-1.
2. The oil temperature is high and leakage abnormally high. 3. The motor sliding surfaces are worn or damaged.
d. The superstructure over swings when neutral is selected.
1. High drainage rate within the pump.
2. The relief valve is incorrectly set.

9804/1103
45 - 10 - 01/12
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/13

SYMPTOM 5. Swing Motor (cont'd) 3. The relief valve plunger seat is defective. Dismantle and inspect the relief valve, as detailed on page 26-1, paying particular attention to the valve seat. Renew the seat if damage is found. Renew oil seal, as detailed on page 36-1. Renew shaft and oil seal , as detailed on page 36-1. Check drain line for damage or blocking. Clear or renew drain pipe. Dismantle and inspect, as detailed on page 36-1, and renew 'O' rings. Dismantle and inspect, as detailed on page 36-1, and repair as necessary. Check bolts and torque tighten to specified torque. POSSIBLE CAUSE ACTION
e. Oil leak at the oil seal.
1. Damage or wear to oil seal lip. 2. The shaft is damaged or worn.
3. Abnormal pressure in the casing.
f.
Oil leaks from mating face.
1. 'O' ring damaged or missing.
2. The seal face is damaged.
3. Bolts are loose.
6. Hand Control Valves a. Low secondary pressure 1. Servo pressure is low. Check servo pressure as detailed on page 10-1 and adjust as necessary. Renew spring. Renew spool and casing assembly
2. Spring 241 is damaged. 3. The clearance between the spools and casing is too large. 4. The handle unit is loose. b. Unstable secondary 1. Sliding parts are sticking.

9804/1103
45 - 10 - 01/13
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/14
JS 200LC,300LC Fault Finding - Hydraulics (cont'd)

Some problems which may occur in the hydraulic system are listed below, either for the system as a whole or for individual components.
SYMPTOM 1. Hydraulic System a. The hydraulic system is defective or does not operate at all.
POSSIBLE CAUSE
ACTION
1. The pump is defective.
Check pump pressure and renew if defective. Dismantle and clean the relief valve.
Strip and check the relief valve as detailed on page 25-1. Repair or renew the ram. Check circuit pressure. Renew the valve. Check the movement of the spool or the operational linkage. Replenish the oil. Clean or renew filters. Check the piping.
4. A ram is worn. 5. Negative pressure is low. 6. A valve is cracked. 7. A spool is not operating over its full stroke. 8. The oil level in the tank is too low. 9. Circuit filters are clogged. 10. The circuit pipes are restricted. 2. Hydraulic Pump a. The pump makes an abnormal noise. 1. Air in the system due to low oil level. 2. Pressure loss due to blocked filter. 3. Pressure loss due to high hydraulic oil viscosity in cold periods.
Check the hydraulic oil level and replenish if necessary. Check the filter elements, clean or renew filter if necessary. Check the temperature of oil and warm if necessary. Check type of hydraulic oil, renew with correct type if wrong type used. Check and readjust as necessary.
4. The speed of the input shaft is too high. 5. Mechanical damage to bearings.
Renew the damaged parts of the pump. Check pressures to find cause of overloading, readjust if necessary. Check hydraulic oil for contamination and flush the circuit or renew hydraulic oil.

9804/1103
45 - 10 - 01/14
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/15

SYMPTOM 2. Hydraulic Pump (cont'd) b. Insufficient flow rate. 1. The speed of the input shaft is too low. 2. Hydraulic oil temperature is too high. Check speed and readjust if necessary. Stop operation and check the oil temperature. Check the temperature and type of hydraulic oil used, renew if necessary. Check if the leakage occurs in a particular actuator only. Renew the actuator or selector valve. Check if the problem occurs in a particular pump only, if so renew the pump. Check if the locknuts are loose, reset and lock if necessary. Check the hydraulic oil level, replenish if necessary. Check the filter elements and clean or renew as necessary. Check the temperature of oil and warm if necessary. Check type of hydraulic oil, renew with correct type if wrong type used. Measure pressure and readjust if necessary. Check the operation of the secondary choke. Dismantle and clean. POSSIBLE CAUSE ACTION
3. Hydraulic oil viscosity is too low.
4. Leakage of the selector valves or actuators.
5. Low pump volumetric efficiency.
6. Power adjusting screw is loose.
7. Air in system due to low oil level.
8. Pressure loss due to blocked filter. 9. Pressure loss due to high hydraulic oil viscosity in cold periods.
10. The external command pressure exceeds the upper limit. 11. Power setting is low due to a change in the pressure reduction of the secondary choke. 12. Defective solenoid pressure reduction valve. c. No rise in pressure. 1. Relief valve is set too low.
Check and renew the valve if necessary.
Check pressure in the circuit, and readjust the relief valve as necessary. Check the operation of each actuator and valve and renew any which are defective. Check if the problem occurs in a particular pump only, if so renew the pump.
2. Selector valves or actuators leaking.

9804/1103
45 - 10 - 01/15
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/16

SYMPTOM 2. Hydraulic Pump (cont'd) d. Engine overload (engine speed very low or engine stalled). 1. Power setting is too high due to a change in the pressure reduction ratio of the secondary choke. Check the filter in the regulator cover, dismantle and clean or renew. Check operation of the secondary choke. Dismantle and clean. Check the command current and adjust if necessary. 2. Malfunction of the control equipment. Check if the sliding surfaces in the control equipment are sticking and repair or renew any damaged ones. Check for overheating of the housing or abnormal noises around the bearings. Renew as necessary. Renew the relief valve. Check for damage and repair or renew as necessary. Check the filters in the regulator cover. Dismantle and clean or renew. f. Pump overheats. Mechanical damage to bearings. Check for overheating of the housing or abnormal noises around the bearings. Repair or renew damaged parts. Locate the leaks and check for abnormally high pressure. Renew the seal and tighten. Check for scratching caused by foreign matter and check for abnormally high pressure. Renew the oil seal. Check for foreign matter and abnormally high pressure. Renew the pump. POSSIBLE CAUSE ACTION
3. Mechanical damage to bearings.
e. Low shaft speed.
1. Defective relief valve. 2. Poor response of the control equipment.
g. Oil leakage.
1. Damaged 'O' rings/packing or loose plugs. 2. Damaged oil seals.
3. Wear to the contact faces of the shaft oil seal.
3.
Control Valve 1. Oil temperature abnormally high. Check correct oil, see Lubrication Chart, page 45-00-01/3. Check oil cooler and grille for blockage. Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system.
a. A spool is sticking.
3. The service pipe connection is overtightened. 4. The valve housing was twisted during installation.
Check tightening torque.
Loosen retaining bolts and tighten to correct torque figures.

9804/1103
45 - 10 - 01/16
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/17

SYMPTOM 3. Control Valve (cont'd) 5. Pressure too high. Check system pressure, see page 10-1. POSSIBLE CAUSE ACTION
6. A spool is bent.
Dismantle the control valve as detailed on page 25-1. 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. Remove the dirt (flush out the valve).
9. Temperature distribution within control valve not uniform. b. A spool does not move over its full stroke. c. The dipper/boom falls under load with the spool in neutral. 1. Dirt is clogging the inside of the valve. 1. Oil is leaking past the ram/ boom piston seals.
Renew piston seals.
Renew spool. Remove ARV and clean housing seat and relief valve seat. Refit ARV. Dismantle and clean the load hold check valve. Renew the poppet or smooth the poppet and seat with very fine emery cloth.
Remove MRV and dismantle as detailed on page 25-1. Inspect and clean all parts. Assemble MRV, ensuring that all parts slide freely. Refit the MRV. Remove MRV and dismantle as detailed on page 25-1. Inspect and clean all parts. Renew damaged parts or remove scratches with very fine emery cloth. Assemble MRV, ensuring that all parts slide freely. Refit MRV. Tighten the lock nut and reset MRV pressure. Remove MRV and renew 'O' rings.

9804/1103
45 - 10 - 01/17
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/18

SYMPTOM 5. Swing Motor a. Motor does not turn. 1. Internal damage to the motor. Measure the oil drain volume. If the supply volume approaches drain volume, dismantle and inspect as detailed on page 35-1. Repair or renew as necessary. Disconnect motor inlet and outlet ports and apply servo pressure of 19.6 bar (284 lbf/ in2) to the brake release port. Try to rotate shaft with a torque of approximately 4.8 9.8 Nm (3.6 - 7.2 ft lb). If the shaft does not rotate smoothly, dismantle and inspect as detailed on page 35-1. Repair or renew as necessary. Fit a pressure gauge and measure load pressure, as detailed on page 10-1. Reset as necessary. Measure the oil drain volume. If the volume exceeds 5 litres/min (1.1 gal/min), dismantle and inspect as detailed on page 35-1. Repair or renew as necessary. Reduce oil temperature. Disconnect motor inlet and outlet ports and apply servo pressure of 19.6 bar (284 lbf/ in2) to the brake release port. Try to rotate shaft with a torque of approximately 4.8 9.8 Nm (3.6 - 7.2 ft lb). If the shaft does not rotate smoothly, dismantle and inspect as detailed on page 35-1. Repair or renew as necessary. Fit a pressure gauge and measure load pressure, as detailed on page 10-1. Adjust as necessary. Check for metallic particles in the motor drain oil or drain filter. If particles found, dismantle and inspect as detailed on page 35-1. Repair or renew as necessary. Check the oil in the tank and motor casing. Bleed the system. Check pipe connections, mounting bolts for tightness. Retighten to specified torque. Check for metallic particles in the motor drain oil or drain filter. Also apply servo pressure of 19.6 bar (284 lbf/ in2) to the brake release port. Try to rotate the shaft with a torque of approximately 4.8 9.8 Nm (3.6 - 7.2 lbf ft). If particles found or the shaft does not rotate smoothly, dismantle and inspect as detailed on page 35-1. Repair or renew as necessary. POSSIBLE CAUSE ACTION
b. Large slip.
1. Wear or damage to the motor sliding surfaces or high pressure seal.
2. Oil hot and large leakage in the motor. c. Insufficient torque. 1. Wear or burning of the motor sliding surfaces.
2. Circuit relief not correctly set.
d. Abnormal noise.
2. Large amounts of air in the oil.
3. Loosening of bolts or connections.
e. Abnormal heating.
1. Burning of the motor sliding or turning parts.

9804/1103
45 - 10 - 01/18
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/19

SYMPTOM 5. Swing Motor (cont'd) f. Leaks from the oil seal. 1. Damage or wear to oil seal lip. Renew the oil seal, as detailed on page 35-1. Repair or renew the motor assembly. Set the pressure in the casing to below 2.9 bar (43 lbf/ in2) and check drain volume. If drain volume large, dismantle and inspect as detailed on page 35-1. Renew the oil seal and repair or renew other damaged parts as necessary. Renew 'O' ring. Repair or renew seal face. Check bolts and tighten to the specified torque. POSSIBLE CAUSE ACTION
2. Damage or wear to shaft seal. 3. Abnormal pressure in the casing.
g. Oil leaks from mating surface.
1. An 'O' ring is damaged. 2. The seal face is damaged. 3. Bolts are loose.
6. Hand Control Valves a. Low secondary pressure. 1. Servo pressure is low. Check servo pressure as detailed on page 10-1 and adjust as necessary. Renew spring. Renew spool and casing assembly
9804/1103
45 - 10 - 01/19
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/20

SYMPTOM 1. Hand Control Valves a. Low secondary pressure.
POSSIBLE CAUSE
ACTION
1. Servo pressure is low.
Check servo pressure as detailed on page 10-5 and adjust as necessary. Renew spring. Renew spool and casing assembly
9804/1103
45 - 10 - 01/20
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/21

SYMPTOM 1. Hydraulic Pump a. The pump makes an abnormal noise.
POSSIBLE CAUSE
ACTION
1. Air in the system due to low oil level. 2. Pressure loss due to blocked filter. 3. Pressure loss due to high hydraulic oil viscosity in cold periods.
Check the hydraulic oil level and replenish if necessary. Check the filter elements, clean or renew filter if necessary. Check the temperature of oil and warm if necessary. Check type of hydraulic oil, renew with correct type if wrong type used. Check and readjust as necessary.
4. The speed of the input shaft is too high. 5. Mechanical damage to bearings.
Renew the damaged parts of the pump. Check pressures to find cause of overloading, readjust if necessary. Check hydraulic oil for contamination and flush the circuit or renew hydraulic oil.
b. Insufficient flow rate.
1. The speed of the input shaft is too low. 2. Hydraulic oil temperature is too high.
Check speed and readjust if necessary. Stop operation and check the oil temperature. Check the temperature and type of hydraulic oil used, renew if necessary. Check if the leakage occurs in a particular actuator only. Renew the actuator or selector valve. Check if the problem occurs in a particular pump only if so renew the pump. Check if the locknuts are loose, reset and lock if necessary. Check the hydraulic oil level, replenish if necessary. Check the filter elements and clean or renew as necessary. Check the temperature of oil and warm if necessary. Check type of hydraulic oil, renew with correct type if wrong type used. Measure pressure and readjust if necessary.
3. Hydraulic oil viscosity is too low.
4. Leakage of the selector valves or actuators.
6. Power adjusting screw is loose.
7. Air in system due to low oil level.
8. Pressure loss due to blocked filter. 9. Pressure loss due to high hydraulic oil viscosity in cold periods.
10. The external command pressure exceeds the upper limit.

9804/1103
45 - 10 - 01/21
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/22

SYMPTOM 1. Hydraulic Pump (cont'd) 11. Power setting is low due to a change in the pressure reduction of the secondary choke. 12. Defective solenoid pressure reduction valve. c. No rise in pressure. 1. Relief valve is set too low. Check the operation of the secondary choke. Dismantle and clean. POSSIBLE CAUSE ACTION
Check and renew the valve if necessary.
Check pressure in the circuit, and readjust the relief valve as necessary. Check the operation of each actuator and valve and renew any which are defective. Check if the problem occurs in a particular pump only if so renew the pump. Check the filter in the regulator cover, dismantle and clean or renew. Check operation of the secondary choke, Dismantle and clean. Check the command current and adjust if necessary.
2. Selector valves or actuators leaking.
1. Power setting is too high due to a change in the pressure reduction ratio of the secondary choke.
2. Malfunction of the control equipment.
Check if the sliding surfaces in the control equipment are sticking and repair or renew any damaged ones. Check for overheating of the housing or abnormal noises around the bearings. renew as necessary. Renew the relief valve. Check for damage and repair or renew as necessary. Check the filters in the regulator cover. Dismantle and clean or renew.
3. Mechanical damage to bearings.
e. Low shaft speed.
1. Defective relief valve. 2. Poor response of the control equipment.
f.
Pump overheats.
Mechanical damage to bearings.
Check for overheating of the housing or abnormal noises around the bearings. Repair or renew damaged parts. Locate the leaks and check for abnormally high pressure. Renew the seal and tighten. Check for scratching caused by foreign matter and check for abnormally high pressure. Renew the oil seal. Check for foreign matter and for abnormally high pressure. Renew the pump.
g. Oil leakage.
1. Damaged 'O' rings/packing or loose plugs. 2. Damaged oil seals.
3. Wear to the contact faces of the shaft oil seal.

9804/1103
45 - 10 - 01/22
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/23

SYMPTOM 2. Hand Control Valves a. Low secondary pressure. 1. Servo pressure is low. Check servo pressure as detailed on page 10-15 and adjust as necessary. Renew spring. Renew spool and casing assembly POSSIBLE CAUSE ACTION
9804/1103
45 - 10 - 01/23
Issue 1
CONTENTS
Excavators
45 - 10 - 01/24
JS 70 from m/c no. 695501 Fault Finding - Hydraulics (contd)

Hydraulic Pump As a first step towards locating a fault, carry out the following checks. 1 Check the hydraulic filter for the presence of excessive foreign materials. The nature of the foreign materials could yield a clue as to the source of damage or wear. Check the flow rate and condition of the oil drained from the pump. Check for abnormal sounds and vibration. Check the pressure at each of the pump pressure test points.
3 4
Symptom 1 Pump is producing abnormal noise. a
Possible cause Air is being drawn in due to low oil level in the hydraulic oil tank. Pump cavitation due to a clogged suction strainer.
Remedy Top up the hydraulic oil and bleed air from the system. Clean the strainer. If excessively clogged, flush the hydraulic system and/or renew the hydraulic oil. Check that the correct hydraulic oil for the ambient conditions is being used. If not, renew the oil. Adjust the rotation speed.
Excessively low oil temperature, or pump cavitation due to high oil viscosity. Input shaft rotation speed abnormally high. Component mechanically damaged, Bearing etc.
Replace the damaged parts Reset the pressure. Flush the circuit. Change the hydraulic oil. Adjust the rotation speed. Stop the operation and re-check after the oil temperature has dropped. Check that the correct hydraulic oil for the ambient conditions is being used. If not, renew the oil. Replace the switching valve and actuator. Replace the pump. Reset and lock. Top up the hydraulic oil and bleed air from the system. Clean the strainer. If excessively clogged, flush the hydraulic system and/or renew the hydraulic oil. Check that the correct hydraulic oil for the ambient conditions is being used. If not, renew the oil.
Insufficient flow.
a b
Input shaft rotation speed decrease. Oil temperature abnormally high.
Oil viscosity abnormally high.
d e f g
Switching valve or actuator leakage. Inadequate pump displacement. Power adjustment screw is loose. Air is being drawn in due to low oil level in the hydraulic oil tank. Pump cavitation due to a clogged suction strainer.
Excessively low oil temperature, or pump cavitation due to high viscosity.
9804/1103
45 - 10 - 01/24
Issue 1
CONTENTS
Excavators
45 - 10 - 01/25
JS 70 from m/c no. 695501 Fault Finding - Hydraulics (contd)

Hydraulic Pump (contd)
Symptom 3 Pressure does not increase. a b c 4 Overload at static load. a b
Possible cause Relief valve is set low. Switching valve or actuator leakage. Inadequate pump displacement. Pump horsepower settings Fault on control devise.
Remedy Reset the relief valve. Replace the switching valve actuator. Replace the pump. Reset the pump. Fix damage caused by foreign matter or replace the pump. Replace the damaged parts Reset the pressure. Flush the circuit. Change the hydraulic oil. Check for abnormal vibration of the circuit and measure pressure, if found replace the relief valve. Check for foreign matter clogging the servo line. If found remove the foreign matter.
Component mechanically damaged, Bearing etc.
Rotation speed low in dynamic load.
Peak pressure occurs due to decrease in responsiveness of the relief valve.
Decrease in responsiveness of the control device.
Check for debris on each sliding part of the control devices. Fix the damage caused by the foreign matter. Measure actuator speed, replace pump. Replace the damaged parts Reset the pressure. Flush the circuit/change the hydraulic oil. Replace damaged parts or pump.
Pump produces abnormal heat.
a b
Increase in pump leakage. Component mechanically damaged, Bearing etc.
Seizure or wear of pump internal parts. Damage to o-rings or seals, confirm the oil leakage points and measure for abnormal pressure. Damage to oil seal, check for damage due to foreign matter and measure for abnormal pressure. Wear of seal due to contact with input shaft. Loose plugs.
Oil leakage
Replace damaged seals.
Replace damaged seals.
Replace input shaft or pump.
Tighten plugs or replace seals.
9804/1103
45 - 10 - 01/25
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 01/26
JS130W from m/c no. 716500 JS 160W from m/c no. 718500 JS 200W from m/c no. 809000 Fault Finding - Hydraulics
Some problems which may occur in the hydraulic system are listed below, either for the system as a whole or for individual components Symptom 1 a Hydraulic System The hydraulic system is defective or does not operate at all. 1 The pump is defective. Check pump pressure and renew if defective. Dismantle and clean the relief valve. Strip and check the relief valve. Repair or renew the ram. Check circuit pressure. Renew the valve. Check the movement of the spool or the operational linkage. Replenish the oil. Clean or renew filters. Check the piping. Possible Cause Action
2 3 4 5 6 7 8 9
Dirt is clogging the inside of the relief valve. The relief valve is defective. A ram is worn. Negative pressure is low. A valve is cracked. A spool is not operating over its full stroke. The oil level in the tank is too low. Circuit filters are clogged.
10 The circuit pipes are restricted. 2 a Hydraulic Pump Oil is not discharged from the pump. 1 2 3 The tank strainer or intake pipe is blocked. The end of the inlet pipe is above the tank oil level. One or more of the pump major components is damaged or the input shaft or coupling are defective. The pressure does not increase because of problems with the hydraulic pump or control valve. 2 Internal leakage within the hydraulic pump with excessive fluid drain from pump drain port.
Clean the strainer and clean the intake pipe. Replenish the oil tank. Dismantle and inspect pump. Renew damaged components and reassemble the pump. Renew shaft or coupling. Check hydraulic pump and control Renew as required. Strip and inspect the hydraulic pump, paying particular attention to sliding surfaces. Repair or renew as Reassemble the pump.
b Pump output is low. valve. Hydraulic pressure does not increase.
necessary. 3 Air is being drawn into the pump from the inlet side. Check tank oil level and strainer for clogging. Correct as necessary. If OK, check tightness of pump inlet Check correct oil . Check pump low pressure inlet pipe for collapse. Renew as required. Check and replenish oil level. Run the pump under no load to bleed air from hydraulic system.
6320 - E/3-1.1
connection. 4 Inlet resistance causing cavitation.
c the
The pump makes an abnormal noise.
Oil level is low and the pump is drawing in air.
9804/1103
45 - 10 - 01/26
Issue 1
CONTENTS
Excavators
45 - 10 - 01/27
JS130W from m/c no. 716500 JS 160W from m/c no. 718500 JS 200W from m/c no. 809000 Fault Finding - Hydraulic (contd)
Symptom 2 Hydraulic Pump (cont'd) 2 Clogging of the tank strainer. Clean strainer. If strainer is severely clogged, drain and flush hydraulic system. Check correct oil for ambient temperature, see Fluids Lubricants and Capacities Check shaft run out. Check pump mounting bolts for tightness. Tighten as required. Dismantle and inspect pump, paying particular attention to bearings and sliding surfaces. Adjust as necessary. Remove the regulator from the pump and check filter for blockage. Clean as necessary. If filter OK, dismantle and inspect regulator. Dismantle and inspect pump, paying particular attention to sliding surfaces. Repair or renew as necessary. Reassemble the pump. Dismantle and inspect pump, paying particular attention to oil seals and sliding surfaces. Renew as necessary, ensuring that lips of oil seals are not damaged when installed. Inspect and renew as necessary. Possible Cause Action
Oil temperature is too low or wrong oil specification
4 5
Coupling defective. The pump is resonating with external equipment. Internal damage to pump.
Engine overload (engine speed very low or engine stalled).
1 2
Regulator torque set too high. The servo flow within the regulator is blocked or internal components are seized.
Pump is seized or worn.
Oil leakage.
Internal leakage within the pump causing oil seal damage and oil leakage.
2 3 a Control Valve A spool is sticking. 1
Damaged or blocked drain pipe.
Oil temperature abnormally high.
Check correct oil, see Fluids, Lubricants and Capacities. Check oil cooler and grille for blockage. Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system. Check tightening torque.
The hydraulic oil is dirty.
The service pipe connection is overtightened. The valve housing was twisted during installation. Pressure too high. A spool is bent.
Loosen retaining bolts and tighten to correct torque figures. Check system pressure. Renew the control valve section. Renew as necessary.
5 6
7 A return spring is broken.
9804/1103
45 - 10 - 01/27
6320 - E/3-2.1
Issue 1
CONTENTS
Excavators
45 - 10 - 01/28
JS 130W from m/c no. 716500 JS 160 from m/c no. 718500 JS 200W from m/c no. 809000 Fault Finding - Hydraulics (contd)
Symptom 3 Control Valve (cont'd) 8 A return spring or cap is out of alignment. Remove the cap, check that the spring is in the correct position. Refit cap and torque tighten bolts. Warm the entire system up before using service. Remove the dirt (flush out the valve). Possible Cause Action
Temperature distribution within control valve not uniform. Dirt is clogging the inside of the valve. Oil is leaking past the ram/ boom piston seals.
A spool does not move over its full stroke. The dipper/boom falls under load with the spool in neutral.
Renew piston seals.
2 3
Oil is bypassing dipper/boom spool. Oil is leaking past dipper/boom ARV.
Renew control valve section. Remove ARV and clean housing seat and relief valve seat. Refit ARV. Dismantle and clean the load hold check valve. Renew the poppet or smooth the poppet and seat with very fine emery cloth.
The dipper/boom falls under load when the spool is moved to a position higher than neutral. Main Relief Valve System pressure does not rise at all.
Dirt is clogging the load hold check valve. The load hold check valve seat is scratched or damaged.
4 a
The main poppet, check valve poppet or pilot poppet is sticking open, or dirt is caught in the valve seat.
Remove MRV and dismantle. Inspect and clean all parts. Assemble MRV, ensuring that all parts slide freely. Refit the MRV. Remove MRV and dismantle. Inspect and clean all parts. Renew damaged parts or remove scratches with very fine emery cloth. Assemble MRV, ensuring that all parts slide freely. Refit MRV. Tighten the lock nut and reset MRV pressure. Remove MRV and renew 'O' rings.
Relief pressure is unstable.
The pilot poppet seat is scratched or the pilot piston is sticking with the main poppet. Parts worn.
The lock nut and adjusting screw are loose. Worn 'O' rings.
c 5 a
Oil leak Slew Motor Motor does not turn.
Internal damage to the motor.
Measure the oil drain volume. If the supply volume approaches drain volume, dismantle and inspect. Repair or renew as necessary.
Disconnect motor inlet and outlet ports and apply servo pressure of 19.6 bar (284 lb. in2) to the brake release port. Try to rotate shaft with a torque of approximately 4.8 - 9.8 Nm (3.6 - 7.2 lbf ft.). If the shaft does not rotate smoothly, dismantle and inspect. Repair or renew as necessary.
9804/1103
45 - 10 - 01/28
6320 - E/3-3.1
Issue 1
CONTENTS
Excavators
45 - 10 - 01/29
JS 130W from m/c no. 716500 JS 160W from m/c no. 718500 JS 200W from m/c 809000 Fault Finding - Hydraulics (contd)
Symptom 5 a Slew Motor (cont'd) Motor does not turn. (contd) 3 Relief valve in the circuit not correctly set. Fit a pressure gauge and measure load pressure. Reset as necessary. Possible Cause Action
The pressure does not rise because the relief valve is incorrectly set. The relief valve plunger sticks.
Set the relief valve to the correct setting.
Dismantle and inspect the relief valve. Repair or renew as necessary. Dismantle and inspect the relief valve. Clean or renew as necessary. Dismantle and inspect the relief valve, paying particular attention to the valve seat. Renew the seat if abrasions or damage is found. Dismantle and inspect the motor.Repair or renew as necessary. Dismantle and check the brake. Repair renew as necessary. Dismantle and check the brake. Renew as necessary. Dismantle and assemble.
The relief valve plunger choke is blocked. The relief valve plunger seat is defective.
The motor is thermally seized.
The brake piston is stuck.
10 The brake friction plate is thermally seized. b The direction of rotation is reversed. 1 Motor assembled incorrectly.
The inlet and outlet pipe connections are reversed. The oil flow rate is insufficient.
Fit pipes to correct positions.
Motor speed low.
Check the hydraulic pump delivery rate and the circuit up to the motor. Check the oil cooler and grille for damage and blockage. Dismantle and inspect the motor. Repair or renew as necessary.
The oil temperature is high and leakage abnormally high. The motor sliding surfaces are worn or damaged.
The superstructure over swings when neutral is selected.
High drainage rate within the motor.
Check the motor drain flow. If the flow exceeds 500 cc/min., dismantle and inspect the motor, paying particular attention to the sliding surfaces. Repair or renew as necessary.
9804/1103
45 - 10 - 01/29
6320 - E/3-4.1
Issue 1
CONTENTS
Excavators
45 - 10 - 01/30
JS 130W from m/c no. 716500 JS 160W from m/c no. 718500 JS 200W from m/c no. 809000 Fault Finding - Hydraulic (contd)
Symptom 5 d Slew Motor (cont'd) The superstructure over swings when neutral is selected. (contd) 2
Possible Cause
Action
The A.R.V. is incorrectly set.
Set the relief valve to the correct setting.
The relief valve plunger seat is defective.
Dismantle and inspect the relief valve, paying particular attention to the valve seat. Renew the seat if damage is found. Measure the oil drain volume. If the volume exceeds 5 litres/min, dismantle and inspect. Repair or renew as necessary. Reduce oil temperature.
Large slip.
Wear or damage to the motor sliding surfaces or high pressure seal.
Oil hot and large leakage in the motor.
Insufficient torque.
Wear or burning of the motor sliding surfaces.
Disconnect motor inlet and outlet ports and apply servo pressure of 19.6 bar (284 lb. in2) to the brake release port. Try to rotate shaft with a torque of approximately 4.8 - 9.8 Nm (3.6 - 7.2 lbf ft). If the shaft does not rotate smoothly, dismantle and inspect Repair or renew as necessary. Fit a pressure gauge and measure load pressure, Reset as necessary.
ARV in the circuit not correctly set.
Abnormal noise.
Check for metallic particles in the motor drain oil or drain filter. If particles found, dismantle and inspect. Repair or renew as necessary. Check the oil in the tank and motor casing. Bleed the system. Check pipe connections, mounting bolts for tightness. Retighten to specified torque. Check for metallic particles in the motor drain oil or drain filter. Also apply servo pressure of 19.6 bar (284 lb. in2) to the brake release port. Try to rotate the shaft with a torque of approximately 4.8 9.8 Nm (3.6 - 7.2 lbf ft). If particles found or the shaft does not rotate smoothly, dismantle and inspect. Repair or renew as necessary.
Large amounts of air in the oil.
Loosening of bolts or connections.
Abnormal heating.
Burning of the motor sliding or turning parts.
9804/1103
45 - 10 - 01/30
6320-E/3-5.1
Issue 1
CONTENTS
Excavators
45 - 10 - 01/31
JS 130W from m/c no. 716500 JS 160W from m/c no. 718500 JS 200W from m/c no. 809000 Fault Finding - Hydraulics (contd)
Symptom 5 j Slew Motor (cont'd) Leaks from the oil seal. 1 2 Damage or wear to oil seal lip. Damage or wear to shaft seal. Renew the oil seal. Repair the problem or renew the motor assembly. Set the pressure in the casing to below 2.9 bar (43 lb in2) and check drain volume. If drain volume large, dismantle and inspect. Renew the oil seal and, if possible, repair or renew other damaged parts. Possible Cause Action
Abnormal pressure in the casing.
Oil leaks from mating surface.
1 2 3
An 'O' ring is damaged. The seal face is damaged. Bolts are loose.
Renew 'O' ring. Repair seal face or renew. Check bolts and tighten to the specified torque.
6 a
Remote Control Valves Low secondary pressure 1 Servo pressure is low. Check servo pressure and adjust as necessary. Renew spring. Renew spool and casing assembly. and casing is too large. Renew the handle unit. Dismantle and inspect. Repair or renew as necessary. Operate the valve several times to remove the air. Dismantle and inspect. Repair or renew as necessary.
2 3
Spring 14 is damaged. The clearance between the spools
4 b Unstable secondary 1
The handle unit is loose. Sliding parts are sticking.
Air is trapped in the pipes.
High secondary pressure.
Sliding parts are sticking.
9804/1103
45 - 10 - 01/31
6320 - E/3-6.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 02/1
JS 110,130,150LC Fault Finding - Track Gearbox

Motor Section Faults SYMPTOM 1. The motor does not run POSSIBLE CAUSE ACTION
1. Oil not reaching the motor 2. Motor excessively worn.
Check flow at control valve, pump etc. Renew excessively worn part. Remove damage and burrs from the surfaces and completely clean all parts. Renew or repair the gearbox.
3. Gearbox damaged. 4. Main relief valve blowing due to overload or incorrect setting.
Reduce the load and check relief valve setting.
2. Motor speed insufficient
1. Oil flow at motor not sufficient due to a fault in pump, control valve etc. 2. Motor efficiency low
Check flow at control valve, pump etc. Check internal oil leakage rate. If this is excessive, check motor pistons, bores, timing plate etc. for excessive wear. Renew if required.
3. Main relief valve leaking or set too low.
Check relief valve condition and reset.
3. Oil leakage
1. Oil seal damaged.
Renew the seal, taking care not to damage the lip of the seal. Note: On the JS110/130 gearbox, the maximum working temperature of the oil seal is 80 C (175 F).
2. Oil seal leaking due to excessive internal leakage.
Check leak-off pressure. Note: On the JS110/130 gearbox, the maximum pressure resistance of the oil seal is 4.8 bar (70 lbf/in2). Excessive leak-off pressure may be caused by back pressure due to dirt in the return lines. Renew gasket. Tighten fasteners. If leak continues, dismantle joint, renew gasket and re-assemble correctly. Dismantle joint, renew damaged parts, renew gasket and re-assemble correctly.
3. Gasket damaged or not installed. 4. Loose fasteners.
5. Damaged joint faces.
4. Abnormal noise and speed variation
1. Cavitation under over-run conditions.
Check brake valve setting. When correct and noise continues, dismantle motor and check for damaged parts.
9804/1103
45 - 10 - 02/1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 02/2
JS 110,130,150LC Fault Finding - Track Gearbox (cont'd)

Parking Brake Faults SYMPTOM 1. Braking force insufficient or uneven. POSSIBLE CAUSE ACTION
1. Brake plates worn.
Renew brake plates. Remove foreign materials and repair damaged areas. Renew brake springs. Remove foreign materials and repair damaged areas.
2.
Deformed brake springs.
2. Abnormal heat generation.
1. Brake not releasing correctly due to fluid leaks or clogged orifice.
Clean out the hydraulic components and renew seals.
9804/1103
45 - 10 - 02/2
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 02/3
JS 200LC,240LC,300LC,450LC Fault Finding - Track Gearbox (cont'd)

Motor Section Faults
SYMPTOM 1. The motor does not run
POSSIBLE CAUSE
ACTION
1. Oil not reaching the motor 2. Motor excessively worn.
Check flow at control valve, pump etc. Renew excessively worn part. Remove damage and burrs from the surfaces and completely clean all parts. Renew or repair the gearbox.
3. Gearbox damaged. 4. Main relief valve blowing due to overload or incorrect setting.
Reduce the load and check relief valve setting.
2. Motor speed insufficient
1. Oil flow at motor not sufficient due to a fault in pump, control valve etc. 2. Motor efficiency low
Check flow at control valve, pump etc. Check internal oil leakage rate. If this is excessive, check motor pistons, bores, timing plate etc. for excessive wear. Renew if required.
3. Main relief valve leaking or set too low.
Check relief valve condition and reset.
3. Oil leakage
Renew the seal, taking care not to damage the lip of the seal. Note: On the JS200LC gearbox, the maximum working temperature of the oil seal is 80 C (175 F).
2. Oil seal leaking due to excessive internal leakage.
Check leak-off pressure. Note: On the JS200LC/300LC gearbox, the maximum pressure resistance of the oil seal is 4.8 bar (70 lbf/in2). Excessive leak-off pressure may be caused by back pressure due to dirt in the return lines. Renew gasket. Tighten fasteners. If leak continues, dismantle joint, renew gasket and re-assemble correctly. Dismantle joint, renew damaged parts, renew gasket and re-assemble correctly.
3. Gasket damaged or not installed. 4. Loose fasteners.
4. Abnormal noise and speed variation
1. Cavitation under over-run conditions.
Check brake valve setting. When correct and noise continues, dismantle motor and check for damaged parts.
9804/1103
45 - 10 - 02/3
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 02/4
JS 200LC,240LC,300LC,450LC Fault Finding - Track Gearbox (cont'd)

Parking Brake Faults
SYMPTOM 1. Braking force insufficient or uneven.
POSSIBLE CAUSE
ACTION
1. Brake plates worn.
Renew brake plates. Remove foreign materials and repair damaged areas. Renew brake springs. Remove foreign materials and repair damaged areas.
2.
Deformed brake springs.
2. Abnormal heat generation.
1. Brake not releasing correctly due to fluid leaks or clogged orifice.
Clean out the hydraulic components and renew seals.
9804/1103
45 - 10 - 02/4
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 03/1
JS 70,110,130,150LC,200LC,240LC,300LC,450LC * JS 130W from m/c no. 716500, JS 160W from m/c no. 718500 Fluids, Lubricants & Capacities
SYMPTOM 1 A Output gear not turning Relief valve is blowing. 1. Overload. 2. Brake not releasing 1. Reduce the load. POSSIBLE CAUSE ACTION
2a. Check release pressure. 2b. Release brake and check brake condition. 3. Renew or repair the gearbox.
3. Gearbox damaged. B. Relief valve is not blowing. 1) Motor can be heard turning. 2) Motor cannot be heard turning. 1. Broken motor shaft. 2. Gearbox damaged. 1. Pump or valves defective.
1. 2. 1.
Renew motor. Renew or repair the gearbox. Check flow through pump, valves, etc.
2.
Oil leakage 1. Gasket damaged or not installed. 2. Loose fasteners. 1. Renew gasket.
A. Oil leaking from joints.
2a. Tighten fasteners. 2b. Dismantle joint, renew gasket and re-assemble correctly. 3. Dismantle joint, renew damaged parts, renew gasket and re-assemble correctly. Renew the seal.
B. Oil leaking at shaft.
1.
9804/1103
45 - 10 - 03/1
Issue 2*
CONTENTS
Excavators
45 - 10 - 03/2
JS 200 from m/c no. 705001, JS 240 from m/c no. 708501 Fault Finding - Swing Gearbox
Table 1. Symptom Cause Internal damage to the motor. External Inspection Measure the oil drain volume. Countermeasure High possibility of damage to the sliding surfaces if the supply volume is approximately equal to the drain volume. Dismantle and inspect. High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect. Reset to the prescribed setting. Leakage is too high if the oil drain volume exceeds 5 l/min (1.1 gal/min). Dismantle and inspect. Reduce the oil temperature. If metallic matter is discovered or the supply shaft does not rotate smoothly when torque is applied, there is a high possibility of internal damage to the motor. Dismantle and inspect. Refer to table 2. Repair Refer to Table 2.
Motor does not run
Open the motor inlet and outlet ports and apply 20 kg/cm2 (284.46 lbf/in2) pilot pressure to the brake release port. Try to rotate the shaft with a torque of approx. 39.32 Nm (29 lbf ft). Measure pressure. Measure the oil drain volume.
Replace damaged parts or renew the motor assembly.
Relief valve in circuit not set correctly. Excessive slip Wear or damage to the motor sliding surfaces or to the high-pressure seal. Oil hot and excessive leakage in the motor. Seizure of motor sliding parts or circuit.
Measure the oil temperature. Check for any metallic matter deposited in motor drain oil or drain filter. Apply a 30 kgf/cm2 (427 lbf/in2)pilot pressure to the brake release port and try to rotate the shaft with a torque of approx. 39.32 Nm (29 lbf ft).
Refer to table 2. Repair or renew the damaged parts. Renew the motor assembly.
Abnormal heating
Leakage from oil seals
Damage or wear to oil seal lip. Damage or wear of the shaft seal. Abnormal pressure in the casing. Check the pressure in the casing and measure the drain volume. Set the pressure in the casing below 3 kg/cm2 (43 lbf/in2) Disassemble and inspect if drain volume is excessive.
Renew the oil seals. Repair the problem or renew the motor assembly. Renew the oil seal. Repair or renew the damaged parts. Renew the motor assembly.
9804/1103
45 - 10 - 03/2
Issue 1
CONTENTS
Excavators
45 - 10 - 03/3
JS 200 from m/c no. 705001, JS 240 from m/c no. 708501 Fault Finding - Swing Gearbox (contd)
Symptom Cause Wear or seizure of the motor sliding surfaces. External Inspection Open motor inlet and outlet ports and apply 20 kgf/cm2 (284 lbf/in2) pilot pressure to the brake release port. Try to rotate the shaft with a torque of approx. 39.32 Nm (28.93 lbf ft). Measure relief pressure. Check if any metallic matter is deposited in the motor drain oil or drain filter. Check the oil in the tank and motor casing. Check if the piping connections, attachment mounting bolts, motor attachment bolts or other bolts are loose. Countermeasure High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect. Reset to the prescribed setting. High possibility of internal damage to the motor if metallic matter is discovered. Dismantle and inspect. Thoroughly bleed the air. Tighten to the specified torque. Repair or renew damaged parts. Renew the motor assembly. Repair Inspect the parts and bearing according to Table 2 a-e and renew any defective parts.
Insufficient torque
Relief valve in the circuit is not set correctly. Internal damage to the motor.
Abnormal noise
Large amount of air mixed in the oil. Loosening of bolts or pipes
O-ring is damaged Oil leakage from mating surfaces
Renew O-rings.
Seal face is damaged.
Repair seal face or renew. Check the bolt tightness. Tighten the bolts to the correct torque.
Bolts are loose.
Table 2. No. a b c d e f Part Inspected Wear of the sliding surface of balance plate 21. Damage to sliding surface of swash plate 6. Damage to sliding surface of the piston assemblies 8. External wear to the piston assemblies 8. Wear to piston bores in cylinder assembly 24. Damage to Teflon rings 19 or O-rings 52. Repair Repair or renew the part Repair the part or renew the motor. Repair the part or renew the motor. Repair the part or renew the motor. Renew the motor. Renew the part.
Note: refers to Service Manual
9804/1103
45 - 10 - 03/3
Issue 1
CONTENTS
Excavators
45 - 10 - 03/4
JS 70 from m/c no. 695501 Fault Finding - Swing Motor

Table 1.
Symptom
Cause Internal damage to the motor.
External Inspection Measure the oil drain volume.
Countermeasure High possibility of damage to the sliding surfaces if the supply volume is approximately equal to the drain volume. Dismantle and inspect. High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect. Reset to the prescribed setting. Leakage is too high if the oil drain volume exceeds 5 l/min (1.1 gal/min). Dismantle and inspect. Reduce the oil temperature. If metallic matter is discovered or the supply shaft does not rotate smoothly when torque is applied, there is a high possibility of internal damage to the motor. Dismantle and inspect.
Repair Refer to Table 2.
Motor does not run
Open the motor inlet and outlet ports and apply 40 kgf/cm2 (569lbf/in2) pilot pressure to the brake release port. Try to rotate the shaft with a torque of approx. 24.40 Nm (18 lbf ft). Measure pressure. Measure the oil drain volume.
Renew damaged parts or renew the motor assembly.
Relief valve in circuit not set correctly. Excessive slip Wear or damage to the motor sliding surfaces or to the high-pressure seal. Oil hot and excessive leakage in the motor. Seizure of motor sliding parts or circuit.
Refer to table 2.
Measure the oil temperature. Check for any metallic matter deposited in motor drain oil or drain filter. Apply a 40 kgf/cm2 (569 lbf/in2) pilot pressure to the brake release port and try to rotate the shaft with a torque of approx. 24.40 Nm (18 lbf ft).
Refer to table 2. Repair or renew the damaged parts. Renew the motor assembly.
Abnormal heating
Damage or wear to oil seal lip.
Renew the oil seals.
Damage or wear of the shaft seal.
Repair the problem or renew the motor assembly.
9804/1103
45 - 10 - 03/4
Issue 1
CONTENTS
Excavators
45 - 10 - 03/5
JS 70 from m/c no. 695501 Fault Finding - Swing Motor (contd)

Symptom Cause Wear or seizure of the motor sliding surfaces. External Inspection Open motor inlet and outlet ports and apply 40 kgf/cm2 (569 lbf/in2) pilot pressure to the brake release port.Try to rotate the shaft with a torque of approx. 24.40 Nm (18 lbf ft). Measure relief pressure. Check if any metallic matter is deposited in the motor drain oil or drain filter. Countermeasure High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect. Reset to the prescribed setting. High possibility of internal damage to the motor if metallic matter is discovered. Dismantle and inspect. Thoroughly bleed the air. Tighten to the specified torque. Repair or renew damaged parts. Renew the motor assembly. Repair Inspect the parts and bearing according to Table 2 a-e and renew any defective parts.
Insufficient torque
Abnormal noise
Check the oil in the tank and motor casing. Check if the piping connections, attachment mounting bolts, motor attachment bolts or other bolts are loose.
Renew O-rings.
Seal face is damaged. Bolts are loose. Check the bolt tightness. Tighten the bolts to the correct torque.
Repair seal face or renew.
Table 2. No. a b c d e f Part Inspected Wear of the sliding surface of balance plate 7. Damage to sliding surface of swash plate 20. Damage to sliding surface of the piston assemblies 18. External wear to the piston assemblies 18. Wear to piston bores in cylinder assembly 16. Damage to Teflon ring 13 . Repair Repair or renew the part Repair the part or renew the motor. Repair the part or renew the motor. Repair the part or renew the motor. Renew the motor. Renew the part.
Note: Refers to Service Manual.
9804/1103
45 - 10 - 03/5
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 03/6
JS 200W from m/c no. 809000 Fault Finding - Swing Gearbox

Symptom 1 a Output gear not turning Relief valve is blowing. 1 2 Overload. Brake not releasing. 1 Reduce the load. Possible cause Remedy
2a Check release pressure. 2b Release brake and check brake condition.
3 b Relief valve is not blowing. 1 Motor can be heard turning. 1 2 2 Motor cannot be heard turning. 1
Gearbox damaged.
Renew or repair the gearbox.
Broken motor shaft. Gearbox damaged. Pump or valves defective.
1 2 1
Renew motor. Renew or repair the gearbox. Check flow through pump, valves etc.
Oil Leakage a Oil leaking from joints. 1 2 Gasket damaged or not installed. Loose fasteners. 1 Renew gasket.
2a Tighten fasteners. 2b Dismantle joint, renew gasket and re-assemble correctly.
Damaged joint faces.
Dismantle joint, renew damaged parts, renew gasket and reassemble correctly. Renew the seal.
b Oil leaking at shaft.
Oil seal damaged.
9804/1103
45 - 10 - 03/6
6320-F/11-1.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 05/1
JS 130 from m/c no. 75800, JS 160 from m/c no. 702000 Fault Finding - Pump
As a first step towards locating a fault, carry out the following checks. 1 Check the hydraulic filter for the presence of excessive foreign materials. The nature of the foreign materials could yield a clue as to the source of damage or wear. Check the flow rate and condition of the oil drained from the pump. Check for abnormal sounds and vibration. Check the pressure at each of the pump pressure test points.
3 4
Symptom 1 No oil is delivered from the pump. a
Possible cause Suction strainer or suction line is blocked. The suction strainer is above the oil level of the tank. The pump itself is faulty.
Remedy Clean the suction strainer or clear the suction line. Top up the hydraulic oil tank and bleed air from the system. Dismantle and renew worn or damaged parts.
Low pump flow rate, or circuit pressure does not build-up.
Incorrect operation of various control valves or hydraulic motors served by the pump, causing low flow rate or loss of pressure. The sliding area of the pump is worn, allowing a large amount of pressurised oil to escape from the drain port. Air is being drawn into the pump.
Renew or inspect and repair the defective control valve or hydraulic motor.
Dismantle the pump and, if possible, polish or repair by lapping. If repair is not possible fit new parts. i Check the hydraulic connections for looseness and tighten if necessary. Check the hydraulic lines and seals for damage.
ii
The suction strainer is blocked or above the oil level of the tank.
Clean the suction strainer or, if necessary, renew. Top up the hydraulic oil tank and bleed air from the system. Check for abnormal oil temperature or viscosity, or other factors causing cavitation. Take the necessary remedial steps.
Excessive suction resistance.
9804/1103
45 - 10 - 05/1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 05/2
JS 130 from m/c no. 75800, JS 160 from m/c no. 702000 Fault Finding - Pump (continued)
Symptom 3 Pump is producing abnormal noise. a Possible cause Air is being drawn in due to low oil level in the hydraulic oil tank. Pump cavitation due to a clogged suction strainer. Remedy Top up the hydraulic oil and bleed air from the system. Clean the strainer. If excessively clogged, flush the hydraulic system and/or renew the hydraulic oil Check that the correct hydraulic oil for the ambient conditions is being used. If not, renew the oil. Check mounting bolts and tighten if necessary.
Excessively low oil temperature, or pump cavitation due to high viscosity. Resonance with external parts.
Engine overload - engine operates at extremely low speeds or stops.
The torque regulator is set too high. The filter incorporated in the pump is clogged.
Readjust the regulator.
Clean the filter. If excessively clogged, flush the hydraulic system and/or replace the hydraulic oil. Readjust the regulator. If no changes are observed, dismantle the regulator for inspection and repair.
The pilot oil passage and orifice inside the regulator are clogged, or some parts are thermally seized or damaged. Seizure or wear of pump internal parts.
Dismantle and renew worn or damaged parts.
Oil leakage.
Oil seal failure originating from an increased drain flow and raised pump internal pressure. Oil seal failure originating from restricted drain line and raised pump internal pressure.
Dismantle and renew the oil seal, taking particular care not to damage the lip when fitting the new oil seal. Change the drain lines so that pressure no higher than 3 bar (43 lb/in 2 ) is exerted on the oil seal. Renew the oil seal. (Take particular care not to damage the lip when fitting the new oil seal.)
9804/1103
45 - 10 - 05/2
Issue 1
CONTENTS
Excavators
45 - 10 - 06/1
JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 Fault Finding - Pump
Often the regulator and attendant valves or pump are combined which makes it very difficult to discover the reason for the trouble. Inspect the following categories which will assist in discovering the abnormal point. 1. Filter and Drain Oil Inspection. Inspect the filter element. Check to see whether there is an abnormally large amount of foreign matter. There will be a small amount of metallic powder due to wear of the shoe or cylinder, but if there is a large amount of metallic powder in the filter, it may be due to trouble with the shoe. Also check the drain oil in the pump casing. 2. Abnormal Vibration and Sound. Check to see if there is any abnormal vibration or sound in the pump main body. Check to see if it is like the regular frequency sound of the regulator's working or attendant valve relief working. If it is an abnormal vibration or sound, it is possible that there is damage or cavitation inside the pump. 3. Measure Pressure of Each Part. When it is a control problem, do not unnecessarily open ports for inspection purposes, measure the pressure for each section and find the abnormal item.
Prime Mover Overload

Cause 1. Are the revolutions - pressure higher than pre-determined values? 2. Is the regulator torque setting too high? 3. Seizure or damage of pumps internal parts 4. Wrong regulator hose connection. Treatment 1. Set to pre-determined value. Note
2. Re-inspect regulator.
2. Refer to regulator instructions.
3. Replace damaged parts.
3. Check the filter or drain oil for signs of abnormal wear.
4. Correct hose lines.
* When pump flow is extremely low, delivery pressures do not increase Cause 1. Regulator breakdown 2. Seizure or damage of pump internal parts. 3. Pump breakdown. Treatment 1. Repair the regulator 2. Replace damaged parts. Note 1. Refer to regulator instructions 2. Check filter, drain oil.
3. Replace damaged parts.
3. Remove pump and inspect shaft coupling.
4. Attendant valve breakdown. 5. Incorrect regulator hose connection.
4. Inspect attendant valve. 5. Correct hose lines.
9804/1103
45 - 10 - 06/1
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 10 - 06/2
JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 Fault Finding - Pump (continued)
Abnormal Sound and Vibration
Cause 1. Cavitation. Treatment 1. Prevent cavitation. Check to see if hydraulic oil is white and cloudy. Note 1.1. Boost pressure is low 1.2. Pump is broken. 1.3. Air is sucked by suction pipe. 1.4. Suction resistance is high.
2. Damage of shoe caulking part. 3. Crack in cylinder. 4. Bad installation of pump. 5. Relief valve bouncing.
2. Replace piston, shoe, shoe plate. 3. Replace cylinder. 4. Correct installation. 5. Repair relief valve. 5. Refer to relief valve instructions.
9804/1103
45 - 10 - 06/2
Issue 1
CONTENTS
Excavators
45 - 10 - 06/3
JS 330 from m/c no. 712501 JS 450 from m/c no. 714501 * JS 460 from m/c no. 714550 Fault Finding - Hydraulic Pump/Regulator
As a first step towards locating a fault, carry out the following checks. 1 2 3 4 Check the hydraulic filter for the presence of excessive foreign materials. The nature of the foreign materials could yield a clue as to the source of damage or wear. Check the flow rate and condition of the oil drained from the pump. Check for abnormal sounds and vibration. Check the pump pressure. Symptom 1 Abnormal noise. a Possible cause Air suction due to low hydraulic fluid level. Suction pressure drop increase due to filter clogging. Suction pressure drop increase due to increased viscosity of hydraulic fluid at low temperature. Input shaft rotation speed abnormally high. Bearing etc. mechanically. damaged Remedy Top-up hydraulic tank.
Clean or renew element.
Clean the cooler/fill with suitable fluid.
Adjust rotation speed.
Renew damaged parts or pump. Reset pressure. Flush the circuit. Change hydraulic fluid. Adjust rotation speed. Stop operation and recheck flow after fluid temperature has dropped. Fill with hydraulic fluid of suitable viscosity. Renew switching valve and actuator.
Insufficient flow amount.
a b
Input shaft rotation speed low. Hydraulic fluid temperature abnormally high. Viscosity abnormally high.
Switching valve, actuator leakage amount increase. Pump displacement efficiency low. Horsepower setting adjustment screw loose. Air suction due to low hydraulic fluid level. Suction pressure drop due to filter clogging. Suction pressure drop due to increased viscosity of hydraulic fluid at low temperature. External command pressure too high.
Renew pump.
Reset and lock.
Top-up hydraulic fluid.
Clean or renew element.
Clean the cooler/fill with suitable fluid.
Adjust external command pressure.
9804/1103
45 - 10 - 06/3
6420-E/12-1.2
Issue 2*
CONTENTS
Excavators
45 - 10 - 06/4
JS 330 from m/c no. 712501 JS 450 from m/c no. 714501 * JS 460 from m/c no. 714550 Fault Finding - Hydraulic Pump/Regulator (contd)
Symptom 3 Pressure does not increase. a b Possible cause Relief valve setting low. Switching valve, leakage increase. actuator Remedy Reset relief valve. Renew switching valve, actuator.
Pump displacement efficiency low. Pump horsepower increases. setting
Renew pump.
Overload at static load.
Adjust pump horsepower setting.
b c
Control device does not work. Bearing, etc. mechanically damaged. Peak pressure occurs due to failure of relief valve/control device.
Repair damage caused or renew. Renew damaged parts or the pump.
Rotation speed dynamic load.
falling
at
Renew relief valve/control device. Remove foreign matter. Repair damage caused by foreign matter or renew. Renew pump. Renew damaged parts or pump.
Overheating.
a b
Increase of pump leakage. Mechanical damage of the bearing etc. Seizure of sliding parts. Damage to O-ring, packing. Damage to oil seal. Wear to oil seal due to contact with input shaft. Looseness of plugs.
c 7 Oil leakage a b c
Renew damaged parts or pump. Renew seals. Renew seal. Renew input shaft or pump.
Tighten or renew seals.
9804/1103
45 - 10 - 06/4
6420-E/12-2.2
Issue 2*
CONTENTS
Excavators
45 - 10 - 06/5
JS 330, JS 460 Fault Finding - Hydraulic Regulator (contd) Regulator Trouble Shooting Engine Overloads
Put a load on each pump to determine if the front or rear pump is malfunctioning. If both pumps are abnormal, check 1 and 2. If only one pump is abnormal, begin with 3. 1 Check to see if the power shift command current value I is norrmal or not. Check the fluctuation of solenoid current. 2 Power shift pressure is too low Renew the proportional pressure reducing valve. 3 4 Disassemble and clean the compensatory piston, compensatory rod. Disassemble and clean the pin (898).
Maximum Flow Rate Is Not Achieved

1 2 3 4 Confirm that the pilot pressure Pi is normal or not. Disassemble and clean the pilot piston. Disassemble and clean the piston (648). Disassemble and clean the spool.
Note: If any of the parts shows wear of scratches replace it.
Checking the Proportional Solenoid Current Service Procedure Method 1 Refer to Self Test, Test Function, Pump Input Amperage.
Method 2 1 2 Switch engine off. Pull apart bullet connector on any of the two wires leading from the Proportional Solenoid on the Hydraulic Pump.
Note: Depending on which wire is disconnected will determine the polarity of the current reading. 3 4 5 6 Insert an appropriate Multimeter in series between the bullet connector and the wire that has been disconnected. Ensure that the Multimeter is scaled to mAmps not Amps. Switch engine on to maximum revs. Measure the current at the Proportional Solenoid.
9804/1103
45 - 10 - 06/5
6420 - E/21-1.1
Issue 1*
CONTENTS
Excavators
45 - 10 - 07/1
JS 130 from m/c no. 758001, JS160 from m/c no. 702000 JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 JS 200W from m/c no. 809000 JS 330 from m/c no. 712501, JS 450 from m/c no. 714501 * JS 460 from m/c no. 714550 Fault Finding - Remote Control Valve
Symptom 1 Low secondary pressure. a b c Possible cause Primary pressure is low. Spring is damaged. Clearance between the spool and seating is too large. The handle unit is loose. Remedy Apply the correct primary pressure. Renew the spring. Renew the remote control valve assembly. Dismantle, reassemble or renew the handle unit.
Unstable secondary pressure.
a b
Sliding parts are sticking. Fluctuations in the tank line pressure. Air is trapped in the piping.
Release the sticking part. Check return line and filter for blockage. Operate the valve several times to remove the air.
High secondary pressure.
The tank line pressure is too high. Sliding parts are sticking.
Check return line and filter for blockage. Release the sticking part.
9804/1103
45 - 10 - 07/1
6420 - E/42-1.3
Issue 3*
CONTENTS CONTENTS
Excavators
45 - 10 - 07/2
JS 70 from m/c no. 695501 JS 200, 220 from m/c no. 705001 JS 240, 260 from m/c no. 708501 Fault Finding - Control Valve
Symptoms Spool sticking Possible Causes 1. Oil temperature is abnormally high. 2. Hydraulic oil is dirty 3. Port connector is tightened too much 4. Valve housing is deformed due to Installation 5. Pressure is too high 6. Spool is bent 7. Return spring is damaged 8. Spring or cap is not on straight 9. Temperature inside valve is not even. Spool does not stroke Load cannot be maintained 1. Valve is clogged inside with dirt 1. Oil leakage from the ram 2. Oil is by-passing from the valve spool 3. Oil leakage from the port relief valve Countermeasures Remove the obstruction. Replace the hydraulic oil and clean the circuit at the same time. Check the torque. Loosen the installation bolt and check. Attach pressure gauge to pump port and ram port and check the pressure. Replace the valve assembly. Replace the damaged parts. Loosen the cap and after aligning, tighten. Warm up the circuit. Remove the dirt (flushing). Check the ram. Replace the valve assembly. Remove the port relief from the housing and clean the housing seat and relief valve seat. Disassemble the lock valve and clean the poppet seat and sleeve, plug seat. If the seat is damaged, replace the poppet, or lap the poppet and seat. Disassemble the check valve and clean.
4. Oil leakage from the lock valve
When the spool is selected from neutral to raise position, the load falls.
1. Foreign matter in load check valve
2. Check valve poppet or seat damaged
Replace the poppet or lap the poppet and seat part.
9804/1103
45 - 10 - 07/2
6020 - E/32-1.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 07/3
JS 70 from m/c no. 695501 JS 200, 220 from m/c no. 705001 JS 240, 260 from m/c no. 708501 Fault Finding - Control Valve (contd) Relief Valve
Symptoms Pressure does not rise at all Possible Causes 1. The main poppet, sleeve or pilot poppets are sticking open or foreign matter is in the valve seat. Countermeasures Check whether foreign matter is in each poppet. Check whether each part is sliding smoothly. Clean all the parts. Relief pressure is unstable 1. The pilot poppet seat is damaged. 2. The piston is sticking to the main poppet. Relief pressure is out of control 1. Wear due to foreign matter. 2. Lock nut and adjuster are loose. Oil leakage 1. Damaged seat or worn O-ring. Replace the damaged parts. Remove the surface scratches. Clean all the parts. Replace the worn parts Reset the pressure and tighten the lock nut to the rated torque. Replace damaged or worn parts. Check whether each part is sliding smoothly. Check for scratches, cuts or foreign matter. Clean all the parts.
2. Parts are sticking due to foreign matter.
Hydraulic System
Symptoms The hydraulic system is not working well or not at all Possible Causes 1. Pump problem. 2. Foreign matter clogging inside the relief valve. 3. Relief valve trouble. 4. Ram trouble. 5. Load is too heavy. 6. Crack in the valve. 7. Spool does not stroke fully. 8. Oil level too low. 9. Filters inside circuit are clogged. 10. Hose runs are kinked. Countermeasures Check the pressure or replace the pump. Disassemble the relief valve and clean. Check according to the maintenance procedures. Repair or replace. Check the circuit pressure. Replace the valve assembly. Check the spool movement and operation link. Replenish hydraulic oil. Clean filter or replace. Check the hoses.
9804/1103
45 - 10 - 07/3
6020 - E/32-2.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 07/4
JS 70 from m/c no. 695501 Fault Finding - Multiple Valve

Trouble Set pressure is high Causes Back pressure on port T. Small hole in the Poppet 4 is blocked. Spring setting 19 Small hole in the Poppet 4 is blocked. Malfunction of the poppet 4 Solutions Adjust the port T back pressure. Dismantle and clean valve, reassemble. Replace the spring or add shim. Dismantle and clean valve, reassemble. Dismantle and clean valve, repair/replace if any fault identified.
Relief Valve Check Valve
Set pressure is low
Does not relieve pressure
The leakage value from the ACC port P1 or P2 is more than normal. Does not return to neutral.
Damage to the check seat section 8 or contamination. Malfunction of the solenoid valve 2 Malfunction of the spool 18 Spring 9 defective
Dismantle and clean valve, Check the bearing, repair/replace. Refer to solenoid valve section. Dismantle and clean valve, repair/replace if any fault identified. Replace the spring.
Shut off Valve 2
Shut off Valve 1
Does not return to neutral.
Malfunction of the spool 16 Spring 7 defective
Dismantle and clean valve, repair/replace if any fault identified. Replace the spring.
During Operation Set pressure is low Pressure Reducing Valve 2
Low inlet pressure Malfunction of the spool 13 Spring 21 defective
Adjust the relief valve. Dismantle and clean valve, repair/replace if any fault identified. Replace the spring or add shim 1. Dismantle and clean valve, repair/replace if any fault identified. Adjust the port T back pressure. Refer to solenoid valve section.
Set pressure is high
Malfunction of the spool 13 Back pressure at port T Malfunction of the solenoid valve 2
During Locking No inlet pressure
Malfunction of the solenoid valve 2
Refer to solenoid valve section.
Shuttle Valve
The leakage value is more than normal.
Damage to the seat section or contamination.
Dismantle and clean valve, Check the bearing, repair/replace.
Defective operation Solenoid Valve
Low voltage Malfunction of the solenoid coil 20 Malfunction of the spools 23 and 24 Spring 6 defective
Ensure correct voltage. Replace coil Dismantle and clean valve, repair/replace if any fault identified. Replace the spring.
9804/1103
45 - 10 - 07/4
6020 - E/60-3.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 08/1
JS 70 from m/c no. 695501 JS 130 from m/c no. 75800, JS 160 from m/c no. 702000 * JS 130W from m/c no. 716500, JS 160W from m/c no. 718500 JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501
*
Fault Finding - Rams

The chart below lists some possible problems and suggested remedies. The types of problems fall into four main categories as follows:
Item 1 2 3 4
Symptoms Oil leakage from piston rod sliding part. Oil leakage from cylinder head joint. Oil leakage from pipe and cylinder tube welds. Faulty operation
Item Symptoms
Related Parts
Trouble On the sliding surface, there are scratches and rust that can be felt by the fingernail.
Treatment 1 Use an oil stone and remove the scratch and make the sliding surface smooth. If oil leakage continues even though the rod surface is made smooth, the scratch may have damaged the U-ring and other seals, so dismantle and inspect. 2 If the scratches and rust cover such a wide area that they cannot be repaired by an oil stone, renew the piston rod and U-ring, wiper ring and seals and the piston rod bearing member.
Piston rod
Piston rod sliding part oil leakage
The plating is peeling.
Re-plate or renew the piston rod. Also inspect the seal and piston rod bearing member and renew if damaged. Remove foreign matter. If there is damage to packing, renew it.
Foreign matter is biting into the inner and outer surfaces of the packing. Rod packing (Buffer ring U-ring) There is a scratch on the inner surface.
Renew.
The lip and groove parts are locally carbonised (burned).
Possibly due to burning caused by adiabatic compression from air remaining inside the ram. After renewing the packing, first operate the ram at low-pressure, low speed to sufficiently
9804/1103
45 - 10 - 08/1
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 10 - 08/2
*
Fault Finding - Rams (continued)
Item Symptoms
Related Parts
Trouble Packing rubber is perished.
Treatment The packing life or hydraulic oil deterioration and high temperature are possible reasons. 1 Renew hydraulic oil.
Rod packing (Buffer ring, U-ring)
2 Check the hydraulic oil temperature. (Below 80 C is advisable). 3 Check if high temperature locally. Lip is deficient all around. Renew. It is possible that abnormally high pressure is working on the packing. 1 Check the operation pressure, cushion pressure. 2 Part which is attached to the buffer ring may be abnormal. Inspect the buffer ring. The protrusion of the heel of the packing is excessive. As a rule, renew the rod packing at the same time. (It is desirable to renew parts which are attached to the buffer ring at the same time). It is possible that abnormally high pressure is the cause. Check the same as above (heel of packing protruding). Foreign matter is biting into the lip. The lip is damaged. There is also other abnormal damage. Remove the foreign matter.
Piston rod oil leakage
Back up ring
Wiper ring
Renew.
Bushing
Wear is excessive and the clearance Renew. with piston rod exceeds the *maximum permissible value. (*Refer to maintenance standards for maximum permissible value.) Large scratch on the sliding part. Renew. Also inspect the piston rod. Remove scratch, rust with oil stone. If it cannot be repaired, renew the cylinder head.
Cylinder head
Scratches, rust on the seal attachment parts.
9804/1103
45 - 10 - 08/2
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 10 - 08/3
*
Item Symptoms
Related Parts
Trouble Foreign matter on inner and outer diameters. O-ring damaged.
Treatment Remove foreign matter. Renew 'O'-ring if damaged. Inspect inside tube: if any scratches or rust, make surface smooth with oil stone. Inspect cylinder head 'O'-ring groove: if any scratches or rust, make surface smooth with oil stone. Inspect back up ring: if any deformation or protrusion, renew. Confirm the above and renew 'O'-ring. Renew, with the 'O'-ring. Dismantle cylinder head and inspect 'O'-ring and back up ring. Check tube and cylinder head thread for damage. If any damage, renew. After inspection, tighten to specified torque.
O-ring
Back up ring Oil leakage from cylinder head joint
Deformation, protrusion Looseness
Cylinder head
Bolt
Looseness, stretching, broken
Renew all bolts and tighten to specified torque. Replace with new parts. Oil leakage from connecting parts may be caused by abnormal pressure (including cushion pressure). Inspect the tube for bulges, deformation and check the circuit pressure.
Abnormal bulge
Cylinder tube
Crack in welding Oil leakage from pipe and cylinder tube welded seam
Replace with new parts. Cracks will develop into fractures. Fractures are very dangerous, so if any cracks are found, stop work immediately and replace with new parts. Welding on top of cracks will have no effect.
Cylinder tube pipe (hollow piston rod)
9804/1103
45 - 10 - 08/3
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 10 - 08/4
*
Item Symptoms Poor operation
Related Parts
Trouble Bending to more than the specified limit. (Bending distortion: refer to maintenance standards) Tube scored
Treatment Replace with new part. The seal and sliding part material may be damaged too, so inspect. If abnormal, renew. Replace with new part. As above, inspect the seal and sliding part material. Replace with new part. As above, inspect the seal and sliding part material. Remove foreign material. As above, inspect the seal and sliding part material. Replace with new part. Inspect the cylinder tube inner surface also. Remove the scratches, rust by honing or with an oil stone and make the surface smooth. If the scratch is deep and cannot be repaired, renew cylinder tube. Renew piston seal.
Piston rod cylinder tube
4-1 Movement not smooth
Cylinder tube
Piston rod cylinder rod sliding part
Abnormal wear, damage of sliding area Foreign matter intruding on piston and cylinder head sliding area
4-2 Inner oil leakage. Piston rod extends when work stops or lowers abnormally during work. Also, specified operating speed is not achieved.
Scratches, wear are present Piston seal
Scratches, rust on inside
Cylinder tube
Piston nut Valves
Loose nut Leak from valve
Tighten to specified torque. Inspect the valve leakage amount and service.
Note: Hydraulic oil expands and contracts due to changes in temperature and pressure. Accordingly, the ram also expands and this can be mistaken for internal leakage. When inspecting for internal leakage, do so at set conditions.
9804/1103
45 - 10 - 08/4
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 10 - 08/5
*
Item Symptoms 4-3
Related Parts
Trouble Air remaining inside ram. Operation is unsteady
Treatment Bleed the air. For rams that do not have an air bleeder, operate back and forth several times at low pressure and low speed to bleed the air. For rams with an air bleeder, remove the load to reduce the pressure then loosen the air bleeder and completely bleed the air. Note: The ram may expand if it is stopped suddenly. This is due to the compression of the hydraulic oil. This occurs especially with long stroke rams.
Air
4 4-4 Heavy shock loading when changing from extension to retraction and back 4-5 Noisy operation Pin bushing/pin Gap between mounting and pin bushing is too large. Measure the pin and pin bushing and renew parts if measurements exceed the specifications.
Oil supply Pin bushing/pin
Insufficient oil. Scuffing at connecting part.
Add oil. Replace with new part and add oil.
Note: If left in the state where operation is poor, the ram will no longer move and other parts will be affected adversely. Inspect early and carry out appropriate measures.
9804/1103
45 - 00 - 08/5
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 10 - 09/1
* *
JS 70 from m/c no. 695501 JS 130 from m/c no. 758000, JS 160 from m/c no. 702000 Fault Finding - Track Motor/Gearbox
Symptom 1 Motor does not start - no oil pressure present. Possible cause a Low relief valve set pressure. b Pump failure. Remedy Set correct pressure. Check operation of services other than travel. Repair pump if necessary. Check spool for damage. Repair if necessary. If spool or valve is thermally seized, repair or renew. Check hydraulic oil and renew if necessary. Dismantle reduction gear and renew broken parts. Remove load. Lap surfaces using wet stone or emery paper. Tighten bolts and recheck. Tighten plug. Dismantle reduction gear and renew damaged parts. Dismantle reduction gear and renew damaged parts. Dismantle reduction gear and renew damaged parts. Retighten bolt(s). Renew O-ring. Lap surface using wet stone or emery paper. Renew traction motor. Renew brake valve and/or rear flange.
c Direction switching valve failure.
2 Motor does not start - oil pressure present.
a Brake valve failure
b Hydraulic motor failure.
c Gear teeth are broken.
d Overloaded. 3 Oil leakage from mating surfaces. a Mating surface is scratched.
b Bolts loose. 4 Oil leakage from case. a Plug is loose. b Cracks caused by stone, etc.
5 Oil leakage from floating seal.
a Sliding surface is worn.
b Seepage past O-ring.
6 Oil leakage from hydraulic motor.
a Mounting bolts loose. b O-ring is damaged. c Seal surface is scratched.
7 Slips down on slope.
a Poor motor efficiency. b Excessive leakage inside brake valve. c Parking brake spring broken. d Parking brake friction plate worn.
Renew spring. Renew friction plate and/or other plate
9804/1103
45 - 10 - 09/1
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 10 - 09/3
* *
JS 70 from m/c no. 695501 JS 130 from m/c no. 758000, JS 160 from m/c no. 702000 Fault Finding - Track Motor/Gearbox
Symptom 8 High temperature of reduction gear case surface. a b c Possible cause Insufficient gear oil. Pitching is generated in bearing. Entry of hydraulic oil into gear case. Uneven delivery flow between right and left sides. Uneven motor drain leakage between right and left sides. Uneven delivery flow between right and left sides. Uneven motor drain between right and left sides. Non-uniform operation of right and left brake valves. Drop in relief pressure in right or left control valve. Pump regulator and/or related parts faulty. Leakage outside pump is excessive. Internal leakage is excessive. Motor or reduction gear is broken. Vibration of pipework. Faulty operation of high pressure selection check valve. Faulty operation of switching valve. Low pilot pressure. Faulty operation of 2-speed switching piston. Top up oil Dismantle and renew damaged parts. Renew oil seal. Remedy
9 Does not travel in a straight line at low speed.
Repair pump and/or regulator.
Dismantle motor/reduction gear and repair. Repair pump and/or regulator.
10 Does not travel in a straight line at high speed.
Dismantle motor/reduction gear and repair. Renew brake valve and/or rear flange.
Set correct pressure and/or renew relief valve. Repair regulator and/or related parts.
11 Does not speed up - pump delivery slow.
Repair or renew pump.
12 Does not speed up. 13 Abnormal sound.
a a
Dismantle reduction gear and repair. Dismantle motor and/or reduction gear and repair. Clamp pipework securely. Inspect and repair or renew if necessary. Check to see if spool is normal, and repair or renew if necessary. Set to specified pressure. Inspect and repair or renew if necessary.
b 14 Does not change from low speed to high speed. a
c d
9804/1103
45 - 10 - 09/2
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 10 - 09/3
* *
JS 70 from m/c no. 695501 JS 130 from m/c no. 758000, JS 160 from m/c no. 702000 Fault Finding - Track Motor/Gearbox (continued)
Symptom 15 Does not change from high speed to low speed. a Possible cause Faulty operation of switching valve. Faulty operation of 2-speed switching piston. Remedy Check for spool damage. Repair or renew if necessary. Inspect and repair or renew if necessary.
9804/1103
45 - 10 - 09/3
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 10 - 10/1
JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 Fault finding - Track Motor/Gearbox
Motor
Fault 1. Motor does not run
Possible cause 1. Device other than the piston motor or reduction gear may have malfunctioned.
Countermeasure or remedy Check whether or not the specified pressurised oil is delivered to the motor input side and then inspect each device and repair if necessary. Replace the excessively worn part. Remove scratches and burrs from the surface and completely clean all parts. Reassemble the parts. Disassemble and replace the damaged part. Completely clean all parts and reassemble.
2. Sliding area of motor is abnormally worn allowing the pressurised oil to escape.
3. Improper operation resulting from damage of important motor part. In this case, abnormal noise is heard from the motor itself. 4. Relief valve is activated because the motor is excessively loaded. 2. Motor revolution speed is insufficient 1. Oil not supplied to motor at specified rate due to problems in hydraulic pump, pressure control valve, etc. 2. Specified revolution speed cannot be achieved due to reduced volume efficiency of motor. 3. Motor revolution speed varies greatly 1. Pressurised oil escaping through the drain port due to wear on the sliding area of the motor. Also, revolution speed variation resulting from wear in the bearing. 2. Motor load is excessive and the automatic 2-speed function is working. 4. Oil leaks 1. Oil leaks due to damage of the oil seals or 'O'-rings.
Check the load state and operate the machine under a load which matches the relief pressure. Check whether the specified pressurised oil is delivered to the motor input side and then inspect each device and repair if necessary. After disassembly, check for abnormal wear of the sliding area and repair or replace worn parts. Disassemble and replace excessively worn parts. Completely clean all parts and reassemble them.
Check the load state and operate the machine under a load which matches the automatic 2-speed set pressure. Replace a broken oil seal or 'O'-ring with a new one. When inserting the oil seal, be careful not to damage the lip. Since the safe working temperature limit of the oil seal and 'O'-ring is up to 80C, it is necessary to take steps to prevent the hydraulic oil temperature from exceeding 80C.
9804/1103
45 - 10 - 10/1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 10/2
JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 Fault finding - Track Motor/Gearbox (continued)
Fault 4. Oil Leaks (continued) Possible cause 2. Motor case excessively pressurised resulting in oil leakage. Oil seal pressure resistance Ordinary 0.2 MPa {2 kgf/cm2} Maximum 0.5 MPa {5 kgf/cm2} 3. Due to clogging, etc. by foreign matter in drain pipe, pressure rises causing the oil seal to leak. Countermeasure or remedy Repair the motor and replace oil seal. When inserting new oil seal, be careful not to damage the lip.
Clean the clogged drain piping. There should not be more than 0.3 MPa {3 kgf/cm2} pressure on the oil seal. Renew oil seal. When inserting new oil seal, be careful not to damage the lip.
Oil seal pressure resistance Ordinary 0.2 MPa {2 kgf/cm2} Maximum 0.5 MPa {5 kgf/cm2} 5. Abnormal noise, excessive revolution variation and pressure variation due to cavitation. 1. When the motor works as a pump, when the closed circuit is used, when the boost pressure is low (standard: 0.4~0.5 MPa {4~5 kgf/cm2}) or when the double counterbalance valve operates incorrectly, negative pressure is generated on the suction side of the motor, resulting in cavitation. Recheck the hydraulic circuit and repair or replace the double counterbalance valve. Disassemble the motor and replace any abnormally worn or broken parts. After cleaning all parts, reassemble them.
Parking Brake Fault 1. Oil Leaks Possible cause 1. Disk is worn. Countermeasure or remedy Replace the disk. Completely remove foreign matter and repair damaged areas. After cleaning, reassemble. Grind and recondition the affected area. Reassemble after cleaning and replace if change in quality of the surface is excessive. Replace the spring. Completely remove foreign matter and reassemble after cleaning. Replace the broken 'O'-ring. Reassemble after cleaning.
2. Disk surface has changed in quality or the contact is incorrect.
3. Spring is deformed or damaged.
2. Abnormal heat generated from brake drag.
1. Brake release incorrect. 1) Oil leaks due to broken 'O'-ring. 2) Orifice is clogged.
9804/1103
45 - 10 - 10/2
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 10/3
JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 Fault Finding - Track Motor/Gearbox (continued)
* Relief Valve Fault I. Motor does not run or rotation speed is slow. Possible cause 1. Relief valve closing incorrectly. 1) Foreign matter is clogging components. Countermeasure or remedy Completely remove foreign matter, repair damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Replace the spring. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Replace relief valve sub assembly. After cleaning, reassemble.
2) Spring is broken
2. The cracking pressure of relief valve is low. 1) Spring is deformed 2) Poppet orifice is clogged II. Motor does not stop or stops slowly. 1. Relief valve closing incorrectly. 1) Foreign matter is clogging components.
2) Spring is broken.
Completely remove foreign matter, repair damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Replace the spring. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Replace relief valve sub assembly. After cleaning, reassemble.
2. The cracking pressure of relief valve is low. 1) Spring is deformed.
2) Poppet orifice is clogged.

III.Excessive shock when travel is stopped. 1. Shockless function does not work. 1) Foreign matter caught up in shockless piston section. Completely remove foreign matter, repair damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Replace the spring. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Readjust the relief valve set pressure.
2) Spring is deformed. 3) Relief pressure set too high.
9804/1103
45 - 10 - 10/3
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 10 - 10/4
JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 Fault Finding - Track Motor/Gearbox (continued)
* Double Counterbalance Valve Fault 1. Motor does not run or rotation speed is slow. Possible cause 1. Plunger is not switched 1) Pressurised oil from the pilot not there. 2) Foreign matter caught between plunger and body. Countermeasure or remedy Inspect the piping for damage. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Reassemble after cleaning. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Replace spring. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Assemble spring in specified position. Reassemble after cleaning. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Reassemble after cleaning. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Replace spring. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Replace if damage or leakage is excessive. Reassemble after cleaning. Replace dumper piston and cap. Completely remove foreign matter, repair the damaged part and reassemble after cleaning.
3) Orifice is clogged.
4) Foreign matter caught between dumper piston and cap.
2. Motor does not stop or stops slowly.
1. Plunger does not return. 1) Foreign matter is caught.
3) Spring is not assembled correctly. 4) Orifice is clogged.

3. Rotation varies. 1. Plunger does not return. 1) Foreign matter is caught.
4. Abnormal noise is heard. 1. Plunger does not return. 1) Foreign matter is caught.
5. Travel not linear. 1. Dumper piston or cap is abnormally worn.
9804/1103
45 - 10 - 10/4
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 10 - 10/5
JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 Fault finding - Track Motor/Gearbox (continued)
2-Speed Control Function
Fault 1. Travel is not linear Possible cause 1. Plunger is not switched 1) Foreign matter is caught between plunger and body. * 2) Spring is not assembled correctly. 3) Spring is broken. * 4) Foreign matter is trapped in spool galleries. 2. Pressurised oil leaks due to abnormal wear of 2-speed control piston 3. 2-speed control piston is not assembled correctly 4. Steel ball is abnormally worn. 5. Set pressure is rising due to abnormal wear of spools. 6. The orifice of the 2-speed piston cavity drain is incorrect. 7. The orifice of the 2-speed piston cavity drain is clogged. 8. Number of washers is different and set pressure is different on the left and right. 2.Will not go into 2nd. 1. Plunger is not switched 1) Foreign matter is caught between plunger and body. * 2) Foreign matter is trapped in spool galleries. 2. Pressurised oil leaks due to abnormal wear of 2-speed control piston. 3. 2-speed control piston is not assembled correctly. 4. The orifice of the 2-speed piston cavity drain is clogged. 3.Will not go into 1st. 1. Spring is not assembled correctly. 2. Spring is broken. Countermeasure or remedy Completely remove foreign matter, repair the damage and reassemble after cleaning. Replace if damage or leakage is excessive. Assemble spring in specified position. * Renew spring. Completely remove foreign matter, repair the damage and reassemble after cleaning. Replace if damage or leakage is large. Replace the 2-speed control piston. Completely remove foreign matter and reassemble after cleaning. Assemble 2-speed control piston to the specified position. Replace steel balls. Completely remove foreign matter and reassemble after cleaning. Replace spool. Completely remove foreign matter and reassemble after cleaning. Confirm orifice diameter. Reassemble after cleaning. Reassemble using correct number of washers.
Completely remove foreign matter, repair the damage and reassemble after cleaning. Replace if damage or leakage is excessive. Completely remove foreign matter, repair the damage and reassemble after cleaning. Replace if damage or leakage is excessive. Replace the 2-speed control piston. Completely remove foreign matter and reassemble after cleaning. Assemble 2-speed control piston to the specified position. Reassemble after cleaning. Assemble spring to specified position. Replace spring. Completely remove foreign matter, repair the damage and reassemble after cleaning. Replace if the damage or leakage is excessive. Replace spool. Completely remove foreign matter, repair the damage and reassemble after cleaning. Replace if the damage or leakage is excessive.
3. Set pressure is rising due to abnormal wear of spools.
9804/1103
45 - 10 - 10/5
Issue 1
CONTENTS
Excavators
45 - 10 - 10/6
JS 330 from m/c no. 712501, JS 450 from m/c no. 714501, JS460 from m/c no. 714550 Fault Finding - Track Motor/Reduction Gear
1 Traction Motor Symptom a Motor does not run. 1 Possible Cause Device external to the piston motor or reduction gear malfunctioning. Remedy Check that the specified pressurised oil is delivered to the motor input side. Inspect all associated devices and repair if necessary. Renew the excessively worn part. Remove scratches and burrs from the surface and completely clean all parts. Reassemble. Dismantle and renew the damaged part(s). Completely clean all parts and then reassemble. Check the load and only operate the machine with a suitable load. Check that the specified pressurised oil is delivered to the motor input side. Inspect all associated devices and repair if necessary. After dismantling, check for abnormal wear of the sliding area and repair or renew the worn parts. Dismantle and renew excessively worn parts. Clean all parts and reassemble. Renew motor bearings. Check the load and only operate the machine with a suitable load. Renew damaged oil seals or O-rings. When fitting an oil seal, be careful not to damage the lip. Check the system to ensure the running temperature does not exceed 80 C. Take the necessary steps to ensure the temperature remains within the acceptable range. Refer to a2 and/or c1. Clean the clogged drain piping. Recheck the piping system and reduce the passage resistance. Renew the oil seal taking care not to damage the lip. Recheck the hydraulic circuit and by remedying or renewing the double counterbalance valve, prevent the generation of negative pressure. Dismantle the motor and renew any abnormally worn or broken parts. After cleaning all parts, reassemble.
Issue 2*
Sliding area of motor is excessively worn, allowing pressurised oil to escape.
Malfunction resulting from damaged motor part(s), resulting in excessive noise.
Relief valve operating due to excessive motor loading. Oil not supplied to motor at specified rate due to problems in hydraulic pump, pressure control valve etc.
Motor speed low.
Volume efficiency of motor low.
Motor greatly.
speed
varies
Large amount of pressurised oil escapes and flows out of the drain port due to wear on the sliding area of the motor. Wear in the bearings. Motor load is excessive and automatic 2-speed function is operating. Oil leaks due to damaged oil seals or O-rings.
2 3
1 d Oil leaks.
2 3
Refer to a2 and/or c1. Clogging due to foreign matter in drain pipe or long, narrow pipes causing the oil seal to break.
1 e Abnormal noise, excessive speed and pressure variation due to cavitation.
When the motor works as a pump, when the closed circuit is used, when the boost pressure is low (standard: 0.4 ~5 kgf/cm2) or when the double counterbalance valve operates improperly, negative pressure is generated on the suction side of the motor, resulting in cavitation.
9804/1103
45 - 10 - 10/6
6420 - F/5-1.2
CONTENTS
Excavators
45 - 10 - 10/7
JS 330 from m/c no. 712501, JS 450 from m/c no. 714501, JS460 from m/c no. 714550 Fault Finding - Track Motor/Reduction Gear (contd)
2 Parking Brake Symptom a Braking force is low or insufficient. 1 Possible Cause Friction plates worn. Remedy Renew discs. Completely remove foreign matter and repair damaged areas. After cleaning, reassemble. Grind and recondition the affected area. Reassemble after cleaning. Renew plates if excessively damaged. Renew the spring. Completely remove foreign matter and reassemble after cleaning. b Abnormal heat generated from brake drag. 1 Brake not releasing. i ii Oil leaks due to broken O-ring. Orifice is clogged. Renew broken O-ring. Clean and reassemble.
Counter places surface damaged or making poor contact.
Spring is deformed or damaged.
9804/1103
45 - 10 - 10/7
6420 - F/5-2.2
Issue 3*
CONTENTS CONTENTS
Excavators
45 - 10 - 10/8
JS 330 from m/c no. 712501, JS 450 from m/c no. 714501 Fault Finding - Track Motor/Reduction Gear (contd)
3 Relief Valve Symptom a Motor does not run or rotation speed is slow. 1 Possible Cause Relief valve not closing fully: i Foreign matter clogging components. Completely remove foreign matter, repair damaged part and reassemble after cleaning. Renew if damage or leakage is excessive. Renew the spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive. Remedy
ii
Spring broken.
The cracking pressure of relief valve is low. i ii Spring is deformed. Poppet orifice is clogged. Renew relief valve sub-assembly. After cleaning, reassemble.
Motor does not stop or stops slowly.
Relief valve not closing fully. i Foreign matter clogging components. Completely remove foreign matter, repair damaged part(s) and reassemble after cleaning. Renew if damage or leakage is excessive. Renew the spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive. Refer to 3a 2.
ii
Spring broken.
2 c Motor does not run or rotation speed is slow. 1
Refer to 3a 2 Shockless function does not work. i Foreign matter in piston section.
Completely remove foreign matter, repair damaged part and reassemble after cleaning. Renew if damage or leakage is excessive. Renew the spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive. Adjust the relief valve set pressure.
ii
Spring broken.
iii Relief valve pressure set too high.
9804/1103
45 - 10 - 10/8
6420 - F/5-3.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 10/9
4 Counterbalance Valve Symptom a Motor does not run or rotation speed is slow. 1 Possible Cause Plunger not switching. i ii External pilot pressure not present. Foreign matter between plunger and body. Inspect the piping for damage. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive. Renew spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive. Remedy
iii Orifice clogged.
iv Foreign matter caught between dumper piston and cap.
Motor does not stop or stops slowly.
Plunger does not return. i Foreign matter between plunger and body. Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Renew if damage or leakage is excessive. Renew spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive. Fit spring in specified position. Reassemble after cleaning.
ii
Spring broken.
iii Spring not fitted. iv Orifice clogged. c Rotation varies. 1 Plunger does not move smoothly. i Foreign matter between plunger and body.
Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive. Reassemble after cleaning.
ii d Abnormal noise is heard. 1
Orifice clogged.
Plunger does not return. i Foreign matter between plunger and body. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive. Renew spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive. Reassemble after cleaning. Renew dumper piston and cap. Completely remove foreign matter, repair any damage and reassemble after cleaning.
ii
Spring broken.
iii Orifice clogged. e Travel not linear. 1 Dumper piston or cap is excessively worn.
9804/1103
45 - 10 - 10/9
6420 - F/5-4.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 10/10
4 Speed Range Changing Symptom a Travel is not linear. 1 Possible Cause Plunger not switching. i Foreign matter between plunger and body. Completely remove foreign matter, repair the damage and reassemble after cleaning. Replace if the damage or leakage is large. Install spring. Renew spring. Completely remove foreign matter, repair any damage, reassemble after cleaning. Renew if the damage or leakage is excessive. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if the damage or leakage is large. Renew the 2-speed control piston. Completely remove foreign matter and reassemble after cleaning. Install 2-speed control piston. Renew steel balls. Completely remove foreign matter and reassemble after cleaning. Renew the two spools. Completely remove foreign matter and reassemble after cleaning. Fit a new orifice of correct diameter. Reassemble after cleaning. Confirm number of washers. Remedy
ii
Spring not installed.
iii Spring broken.
iv Foreign matter is caught between the two spools.
Pressurised oil leaks due to excessive wear of 2-speed control piston. 2-speed control piston is not installed. Steel balls badly worn.
3 4
Set pressure is rising due to excessive spool wear. The orifice of the 2-speed piston compartment oil passage is incorrect. The orifice of the 2-speed piston compartment oil passage is clogged. Number of washers is different, making set pressure different between the left and right. Plunger not switching. i Foreign matter between plunger and body.
6 7 8 b Will not go into high speed. 1
Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if the damage or leakage is excessive. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if the damage or leakage is excessive. Renew 2-speed control piston. Completely remove foreign matter and reassemble after cleaning. Install the 2-speed control piston. Reassemble after cleaning.
ii
Foreign matter is caught between the two spools.
Pressurised oil leaking due to excessive wear of 2-speed control piston.
3 4
2-speed control piston not installed. The orifice of the 2-speed piston compartment oil passage is clogged.
9804/1103
45 - 10 - 10/10
6420 - F/5-5.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 10/11
4 Speed Range Changing (continued)
Symptom c Will not go into low speed. 1 2
Possible Cause Spring is not installed. Spring is broken. Install spring.
Remedy
Renew spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if the damage or leakage is excessive. Renew one or both spools. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if the damage or leakage is excessive.
Set pressure rising due to excessive wear of one or both spools.
9804/1103
45 - 10 - 10/11
6420 - F/5-6.1
Issue 1
CONTENTS
Excavators
45 - 10 - 11/1
JS 130 from m/c no. 75800, JS 160 from m/c no. 702000 130W from m/c no. 716500, JS 160W from m/c no. 718500 JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 * JS 200W from m/c no. 809000
* JS
Fault finding - Slew Motor
Table 1. Symptom Cause Internal damage to the motor. External Inspection Measure the oil drain volume. Countermeasure High possibility of damage to the sliding surfaces if the supply volume is approximately equal to the drain volume. Dismantle and inspect. High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect. Repair Refer to Table 2.
Motor does not run
Open the motor inlet and outlet ports and apply 20 kgf/cm 2 (284 lbf/in 2 ) pilot pressure to the brake release port. Try to rotate the shaft with a torque of approx. 39.32 Nm (29 lbf ft). Measure pressure.
Renew damaged parts or renew the motor assembly.
Relief valve in circuit not set correctly. Excessive slip Wear or damage to the motor sliding surfaces or to the high-pressure seal.
Reset to the prescribed setting. Leakage is too high if the oil drain volume exceeds 5 l/min (1.1 gal/min). Dismantle and inspect. Reduce the oil temperature. If metallic matter is discovered or the supply shaft does not rotate smoothly when torque is applied, there is a high possibility of internal damage to the motor. Dismantle and inspect. Refer to table 2.
Measure the oil drain volume.
Oil hot and excessive leakage in the motor. Seizure of motor sliding parts or circuit.
Measure the oil temperature. Check for any metallic matter deposited in motor drain oil or drain filter. Apply a 30 kgf/cm2 (427 lbf/in2 ) pilot pressure to the brake release port and try to rotate the shaft with a torque of approx. 39.32 Nm (29 lbf ft).
Refer to table 2.
Abnormal heating
Repair or renew the damaged parts. Renew the motor assembly.
Damage or wear to oil seal lip. Damage or wear of the shaft seal.
Renew the oil seals.
Repair the problem or renew the motor assembly. Check the pressure in the casing and measure the drain volume. Set the pressure in the casing below 3 kg/cm2 . (43 lbf/in2 ) Dismantle and inspect if drain the volume is excessive. Renew the oil seal. Repair or renew the damaged parts. Renew motor assembly.
Abnormal pressure in the casing.
9804/1103
45 - 10 - 11/1
Issue 2*
CONTENTS
Excavators
45 - 10 - 11/2
JS 130 from m/c no. 75800, JS 160 from m/c no. 702000 * JS 130W from m/c no. 716500, JS 160W from m/c no. 718500 JS 200, 220 from m/c no. 705001, JS 240, 260 from m/c no. 708501 * JS 200W from m/c no. 809000 Fault finding - Slew Motor (continued)
Symptom Cause Wear or seizure of the motor sliding surfaces. External Inspection Open motor inlet and outlet ports and apply 20 kgf/cm2 (284 lbf/in2) pilot pressure to the brake release port.Try to rotate the shaft with a torque of approx. 39.32 Nm (29 lbf ft). Measure relief pressure. Check if any metallic matter is deposited in the motor drain oil or drain filter. Countermeasure High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect. Reset to the prescribed setting. High possibility of internal damage to the motor if metallic matter is discovered. Dismantle and inspect. Thoroughly bleed the air. Tighten to the specified torque. Repair or renew damaged parts. Renew the motor assembly. Repair Inspect the parts and bearing according to Table 2 a-e and renew any defective parts.
Insufficient torque
Abnormal noise
Check the oil in the tank and motor casing. Check if the piping connections, attachment mounting bolts, motor attachment bolts or other bolts are loose.
Renew O-rings.
Seal face is damaged. Bolts are loose. Check the bolt tightness. Tighten the bolts to the correct torque.
Repair seal face or renew.
Table 2. No. a b c d e f Part Inspected Wear of the sliding surface of balance plate 21 . Damage to sliding surface of swash plate 6 . Damage to sliding surface of the piston assemblies 8 . External wear to the piston assemblies 8 . Wear to piston bores in cylinder assembly 24 . Damage to Teflon ring 19 or O-rings 52 . Repair Repair or renew the part Repair the part or renew the motor. Repair the part or renew the motor. Repair the part or renew the motor. Renew the motor. Renew the part.
Note: refers to Service Manual
9804/1103
45 - 10 - 11/2
Issue 3*
CONTENTS
Excavators
45 - 10 - 11/3
JS 330 from m/c no. 712501, JS 450 from m/c no. 714501, JS460 from m/c no. 714550 Fault Finding - Slew Motor
1 Motor Does Not Rotate Symptom a The pressure is low. 1 2 Possible Cause The relief valve is not set correctly. The relief balve does not work properly. i Plunger sticking. ii 3 b The pressure is correct but no rotation. 1 2 Plunger orifice contaminated. Remedy Set to the correct value.
Repair or renew the plunger. Dismantle and clean. Renew the plunger seat. Remove the cause of overload. Check and repair the piston/shoe, cylinder/valve plate, etc. Check and repair the circuit. Dismantle and clean/repair. Dismantle and renew the damaged parts.
Plunger not seating correctly. Overload protection operating The moving part is burnt
3 4 5
No release pressure acting on the brake. The brake piston is sticking. The brake friction plate is burnt and sticking to the counter plate.
Motor Rotates in the Reverse Direction Symptom Possible Cause 1 The motor has been incorrectly assembled. Remedy Check step 16 of the Assembly procedure to verify that the valve housing 303 and main housing 301 are in their correct relative positions. Rectify is necessary. Relocate hoses.
Reverse rotation
Inlet/outlet hose reversed.
Motor Speed is Low Symptom Possible Cause 1 The oil volume is low. Remedy Check the pump output and the circuit to the motor. Check the oil cooling circuit.
Slow rotation
The temperature is high and leakage is serious The sliding part are worn out or broken.
Renew suspect parts.
9804/1103
45 - 10 - 11/3
6420 - F/95-1.1
Issue 1*
CONTENTS
Excavators
45 - 10 - 12/1
JS 70 from m/c no. 695501 Fault Finding

To extend the service life and improve the operation of the machine, daily inspection and lubrication are necessary as well as immediately isolating any problem found and dealing with it. If the machine is operated with the problem uncorrected, it may lead to larger trouble and possibly to a big accident. If trouble occurs, search for the cause in the items below and make adjustments, repairs, etc. as necessary. If the cause cannot be isolated, contact your JCB Distributor. Indicates jobs which should be done by a specialist. Refer to Engine Service Manual.
Engine
Problem Cause
Defective starter switch (Starter does not run) Defective rotation of starter (Starter rotates slowly) Improper viscosity of engine oil Excessive cooling of engine (Cold weather) Engine does not start Possible seizure in engine Incomplete air bleeding of fuel system No fuel in fuel tank Fuel quality unsuitable Fuel filter clogged Low compression Defective fuel injection pump No fuel in fuel tank Fuel filter clogged Air is mixed in the fuel system Low oil Defective oil pressure switch Oil filter clogged Low oil viscosity Improper operation of oil pump Oil leakage at connections
Remedy
Connect, repair connection Discharged battery, starter problems, contaminated or loose wiring connection Inspect and replace as necessary Preheat with air heater Warm up the coolant (add hot water) Repair Completely bleed air Refill Inspect and replace as necessary Clean or replace Repair Repair Refill Clean and replace Retighten fuel pipe connections and bleed system Refill Replace Replace element Replace with oil of viscosity matching temperature Replace parts Tighten connections Disassemble and repair, replace parts Replace with correct oil Adjust Adjust or replace if necessary Disassemble and repair, replace parts Replace with correct fuel Adjust Adjust or replace if necessary Disassemble and repair, replace parts Clean or replace the element Adjust or replace if necessary Adjust or replace if necessary Adjust or replace if necessary Replace with correct fuel Disassemble and repair, replace parts Clean or replace element Drain oil to proper level Replace with oil of viscosity matching temperature Retighten and replace parts if necessary Disassemble and repair, replace parts Replace Replace
Engine stops during operation
Low oil pressure
Excessive oil consumption Excessively low oil viscosity Exhaust gas from engine Excessive cooling by radiator is white or blue Improper fuel injection timing Low compression Improper fuel Improper valve clearance Exhaust gas from engine Defective fuel injection pump is black or dark grey Low compression Insufficient air intake (air cleaner clogged) Defective fuel injection pump Improper spray from fuel injection nozzle Improper fuel injection timing Improper fuel Low compression Insufficient air intake Excessive oil Low oil viscosity Oil leakage Worn cylinder piston rings Bad fuel Damage inside muffler
Excessive fuel consumption
Excessive engine oil consumption
Abnormal noise.(Fuel or mechanical)
9804/1103
45 - 10 - 12/1
Issue 1
CONTENTS
Excavators
45 - 10 - 12/2
JS 70 from m/c no. 695501 Fault Finding (contd) Engine (contd)

Problem Cause
Low coolant Water leakage Elongated or oil dirtied belt Defective radiator Broken fan Incorrect mixture of anti-freeze solution Defective thermostat Defective water pump Defective water sensor Improper belt tension Wiring trouble Defective battery Defective regulator Defective alternator Refill Repair Clean or replace Repair or replace Replace Replace Replace Replace Replace Adjust Repair Replace Replace Replace
Remedy
Engine overheating (Water temperature reads too high)
Defective battery charge
9804/1103
45 - 10 - 12/2
Issue 1
CONTENTS
Excavators
45 - 10 - 13/1
JS 70 from m/c no. 695501 Fault Finding (contd) Monitor Display

Problem Cause
Water leakage Belt elongation, soiled with oil Defective radiator Broken fan Improper anti-freeze mixture Defective thermostat Defective water pump Dirty oil cooler (clogged) Dirty radiator (clogged) Defective dust protection net (clogged) Defective monitor Low Engine oil Oil leakage at connections Defective engine oil pressure sensor Engine oil viscosity low Defective engine oil pump Defective monitor Air filter element clogged Intake system clogged, foreign matter inside Fuel low Defective sensor Belt tension Wiring fault Defective battery Defective regulator Defective alternator Coolant low Defective sensor Engine oil dirty Defective sensor Short circuit, etc abnormalities Repair Clean or replace Repair or replace Replace Replace Replace Replace Clean Clean Clean Replace Refill Repair Replace Replace with oil of viscosity matching the temperature Adjust, clean, replace Replace Clean, replace Clean Refill Replace Adjust Repair Replace Replace Repair or replace Refill Replace Refill Replace Inspect, repair
Remedy
OVERHEAT
LOW OIL PRESSURE
AIR FILTER
LOW FUEL LEVEL
ALTERNATOR
LOW COOLANT
ENG. OIL FILTER
ELEC. PROBLEM
Indicates jobs which should be done by a specialist. Refer to Service Manual.
9804/1103
45 - 10 - 13/1
Issue 1
CONTENTS
Excavators
45 - 10 - 13/2
JS 70 from m/c no. 695501 Fault Finding (contd) Operating Controls

Problem
Operating controls hard to operate
Cause
Foreign matter caught on control valve spool Valve sticking Improper lubrication of lever link Lever link seizure
Remedy
Wash the control valve Repair or replace valve assembly Grease Grease
Hydraulic Pump
Problem Oil not delivered by
oil pump Low hydraulic oil Clogged suction filter Oil leakage inside hydraulic pump Air inside the hydraulic pump Main relief valve pressure set too low Cavitation resulting from deformed hose on the suction side or suction filter clogged Joint of the suction side is loose or hydraulic oil is low and air is being sucked in Cavitation resulting from excessively high viscosity of hydraulic oil Defective seal in hydraulic pump
Cause
Refill Repair
Remedy
Hydraulic pump does not build pressure
Replace hydraulic pump Refill oil or check hose on suction side Adjust pressure
Abnormal noise from hydraulic pump
Replace filter, replace hydraulic oil if dirty Retighten or grease the joints Check that oil is filled to proper level inside casing Replace with hydraulic oil of suitable viscosity Replace seal or hydraulic pump
Oil leakage from hydraulic pump
Working Attachments
Problem Cause
Insufficient engine output Function drops due to wear of hydraulic pump Defective main relief valve Low hydraulic oil Viscosity of hydraulic oil incorrect Suction filter clogged Hydraulic pump broken Hydraulic oil low Set pressure for main or port relief valve is low or incorrect Damaged hydraulic ram seals Damaged hydraulic ram, cylinder Damaged hydraulic ram, seals Damaged hydraulic ram, cylinder Oil leakage inside control valve Oil leakage inside holding valve Insufficient grease Connecting pin seizure
Remedy
Refer to Engine Service Manual Replace hydraulic pump Adjust the pressure or replace Refill Replace with hydraulic oil of proper viscosity Replace suction filter Replace hydraulic pump Replace suction filter Adjust pressure or replace relief valve Replace hydraulic ram seals Replace hydraulic ram/cylinder or the assembly Replace hydraulic ram seals Replace hydraulic ram/cylinder or the assembly Repair valve assembly, replace Repair valve assembly, replace Grease Replace the bushing and/or pin
Overall low power
Defective operations
Insufficient work power
Attachment sinks down
Abnormal noise from joints of the attachment
Indicates jobs which should be done by a specialist. Refer to service Manual.

9804/1103
45 - 10 - 13/2
Issue 1
CONTENTS
Excavators
45 - 10 - 13/3
JS 70 from m/c no. 695501 Fault Finding (contd) Travelling

Problem
Insufficient travel force
Cause
Pressure setting for main relief valve is too low Defective counterbalance valve Performance reduction of travel motor Swivel joint packing damage Performance reduction of hydraulic pump Excessively tightened track Stone or foreign matter caught in track Defective valve Performance reduction of travel motor Air in travel motor Left and right tracks are not equally tightened Performance reduction of hydraulic pump Performance reduction of travel motor Oil leakage inside control valve Swivel joint packing damage Loose lever link
Remedy
Adjust the pressure Replace the counterbalance valve Replace travel motor Replace swivel joint packing Replace hydraulic pump Adjust to proper tension Remove stone or foreign matter Repair valve or replace Replace travel motor Refill with oil Bleed air from left and right, adjust tracks to equal tension Replace hydraulic pump Replace travel motor Replace valve housing assembly Replace swivel joint packing Adjust
Rough travel
Crooked travel
Slewing
Problem
Insufficient slew force
Cause
Performance reduction of slew motor Thermal seizure of slew shaft Low setting of brake valve Clogged valve Performance reduction of slew motor Internal oil leakage of control valve Low setting of brake valve or port relief valve Clogged valve Performance reduction of slew motor Internal oil leakage of control valve Air in slew motor Insufficient greasing of slew bearing
Remedy
Replace slew motor Supply grease or replace the slew shaft Adjust the pressure Wash the valve Replace slew motor Repair or replace valve assembly Adjust the pressure Wash the valve Replace slew motor Repair or replace valve assembly Refill with oil Add grease
Poor braking performance
Poor stopping performance
Abnormal noise during slew
Hydraulic Rams
Problem
Insufficient force of hydraulic ram
Cause
Low pressure setting for the relief valve Oil leakage inside the hydraulic ram Damage of the hydraulic ram or rod Oil leakage inside the control valve Defective hydraulic ram seals Hydraulic cylinder rod damage
Remedy
Adjust the pressure Replace the ram seals Replace the hydraulic ram or rod Repair or replace the valve assembly Replace hydraulic ram seals Replace hydraulic ram rod
Oil leakage outside the hydraulic ram
Indicates jobs which should be done by a specialist. Refer to Service Manual.
9804/1103
45 - 10 - 13/3
Issue 1
CONTENTS
Excavators
45 - 10 - 14/1
JS 330, JS 450, JS 460 Fault Finding (contd) - Electrics (CAPS II)

This section is designed to simplify the task of Fault Finding. When a message is displayed the description of the fault is shown and the Problem No. is shown; this in turn then relates to the relevant page showing the problem No. Procedure Depending on the result of the inspection or measurement inside the box, continue on to either the YES or NO branch and onto the next box. Inside each box the inspection or measurement method or values are written. the necessary preparatory work, operations and values are listed. Make sure the preparatory work is carried out, that is checking the procedures and equipment as mistakes in judgements and procedures can seriously damage the equipment. Note: When removing or checking a piece of electrical equipment turn the key switch OFF.
9804/1103
45 - 10 - 14/1
6420 - C/9-1.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/2

This explains how to troubleshoot in the event that the message does not go out even though suitable measures are taken to check and clear the problem. !Mark ! Message Display Engine emergency stop Trouble Description Even though the emegency stop button is pressed, the message does not go out. Even though fuel is supplied, the message does not go out. Even though cooling water is suppplied, the message does not go out. Battery fluid sensor not fitted, fault should not be displayed. Even though filter is cleaned, the message does not go out. Even though the engine oil is correct, the message does not go out. Even though the engine oil filter is replaced and the engine oil is correct, the messge does not go out. Even though hydraulic oil temperature is less than 84 C and the engine cooling water temperature is less than 92 C, the message does not go out.
o o
Problem No. 1
! ! ! ! ! !
Refuel Refill coolant Replenish battery fluid Air cleaner clogged Engine oil pressure drop Engine filter clogged
2 3 4 5 6 7
Over heat
! !
Battery Charging Deficient
The message does not go out
9 10
Electric system abnormality The message does not go out.
This explains how to troubleshoot when an operation is not indicated on a message, but it does not operate normally. 1 Engine Control Area Trouble Description Electric system abnormality is indicated on monitor. Trouble No.
Engine does not start.
Refer to trouble No. 10. 11
Controlling engine rotation is not possible.
Engine rotation does not change with throttle volume.
12
9804/1103
45 - 10 - 14/2
6420 - C/9-2.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/3

Judgement Value 25-26 V -
Item 1. Fuel amount check 2. Inspection for fuel containment Lubricants Coolants 3. Hydraulic oil amount check 4. Inspection of hydraulic oil strainer 5. Inspection of oil amount for each reduction gear 6. Inspection of engine oil amount (amount in oil pan) 7. Coolant amount check 8. Dust indicator clogging check
Electrical Equipment
Measure Refuel Clean, drain Refill oil Clean, drain Refill oil Refill oil Refill water Clean or replace Tighten or replace Tighten or replace Tighten or replace Repair Repair Air bleeding Replacement Replensih or replace Replacement Repair Disconnect and dry
Start-up Inspection items
9. Inspection for looseness, corrosion of battery terminal and wiring 10. Inspection for looseness, corrosion of alternator terminal and wiring 11. Inspection for looseness, corrosion of starter terminal and wiring 12. Abnormal sound, smell check 13. Oil leakage check 14. Air bleeding 15. Battery voltage (engine stopped) check 16. Battery fluid sensor not fitted, fault should not be displayed
Other Inspection Items
Hydraulic Mechanical Equipment
Electricity Electric Equipment
17. Inspection for discolouration, burning, peeling of wiring 18. Inspection for wiring clamp removal, sagging 19. Inspection for wet wiring (special attention to wet connector and terminal) 20. Inspection for fuse breakage, corrosion 21. Alternator voltage check (engine revolution more than 1/2 throttle) (When battery insufficiently charged may be about 25 V soon after starting.( 22. Battery relay making noise (when starter switch is ON or OFF)
27.5~29.5 V
Replacement Replacement
Replacement
9804/1103
45 - 10 - 14/3
6420 - C/9-3.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/4

Emergency Engine Stop, Problem No.1 Note: Even if the emergency stop button is pressed the message does not go out. Prior Confirmation Items 1 2 3 The "MODE" of the mode display is not flashing. Confirm that the fuses in the fuse box are normal. The engine does not run.
Troubleshoot
Cause
Remedy
Key switch ON When CN11 connector is removed, does message go out? NO Remove CN2 connector and measure voltage of female side of LB. Is it within the range of 20~30V?
YES
Defective LW wiring from switch panel or switch panel defective.
Repair wiring or replace switch panel.
YES
Bad connection of CN2 connector or controller defect.
Clean CN2 connector terminal or replace controller.
NO
Measure voltage of LW with shut down relay 1 connector connected. Is it within the range of 20~30V. NO
YES
Breakage of LW wiring between shut off relay 1 and controller.
Repair LW wiring.
Remove shut off relay 1 connector and measure NO () resistance of 1 and 2 of relay side. Connect 1 to +, 2 to -. Is it 250 . YES
Defective shut off relay 1.
Replace shut off relay 1.
Breakage of LR wiring between shut off relay 1 and fuse.
Repair LR wiring.
9804/1103
45 - 10 - 14/4
6420 - C/9-4.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/5

Refuel, Problem No.2 Note: Message does not go out even if refuelled Prior Confirmation Items 1 2 The "MODE" of the mode display is not flashing. Fuel bar graph displays one.
Troubleshoot
Key switch ON Measure resistance value of sensor at self-check. Is it within the range of values in chart below? (Refer to resistance values in chart below.)
Cause
Remedy
YES
Controller defect
Replace controller.
Key switch OFF NO
NO
Remove sensor coupler and measure resistance on sensor side. Is it within the range of values in chart below? (Refer to resistance values in chart below.)
Fuel sensor defect
Replace sensor or inspect it.
YES
Remove CNE connector and measure resistance between male side terminal YR and GR. Is it within the range of values in chart below? (Refer to resistance values in chart below.)
NO
Bad connection of fuel sensor connector
Clean connector terminal.
YES
Remove CN10 connector and measure resistance between female side terminal YR and GR. Is it within the range of values in chart below? (Refer to resistance values in chart below.) YES
NO
Bad connection of CNE
Clean CNE connector terminal.
Controller defect or bad connection of CN10
Replace controller or clean CN10 connector terminal.
Note: When there is breakage in the wiring, the bar graph goes out completely. Resistance Value between YR and GR Monitor Resistance Value (OHM)
9804/1103
1 Refuel.
80~78
78~59
59~44 44~34 34~27
27~21 21~13 13~10

6420 - C/9-5.2
45 - 10 - 14/5
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/6

Coolant Refill, Problem No 3 Note: Message does not go out even if coolant is refilled Prior Confirmation Items 1 The "MODE" of the mode display is not flashing.
Troubleshoot
Key switch ON
Cause
Remedy
When reserve tank level switch connector is removed, does message go out?
YES
Reserve tank level switch defect
Replace reserve tank switch.
NO
When reserve tank level switch connector is removed, does message go out?
YES
Defective YW wiring between reserve tank level switch and CNB
Repair YW wiring.
YES
Defective YW wiring between CNB and CN7
Repair YW wiring.
NO
Controller
Replace controller.
9804/1103
45 - 10 - 14/6
6420 - C/9-6.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/7

Air Cleaner clogged, Problem No. 5 Note: Message does not go out even if the filter is renewed. Prior Confirmation Items 1 The "MODE" of the mode display is not flashing.
Troubleshoot
Key switch ON When spade terminal of air filter switch on YL side is removed, does message go out?
Cause
Remedy
YES
Air filter switch defect
Replace air filter switch.
NO
When CNB connector is removed, does message go out?
YES
Breakage or bad connection of BW wiring between CNB and air filter switch
Repair BW wiring.
NO
When CN7 connector is removed, does message go out?
YES
Breakage or bad connection of BW wiring between CNB and CN5
Repair BW wiring.
NO
Controller defect
Replace controller
9804/1103
45 - 10 - 14/7
6420 - C/9-7.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/8

Low Engine Oil Pressure. Problem No. 6 Note: Message does not go out even if engine oil is satisfactory. Prior Confirmation Items 1 The "MODE" of the mode display is not flashing.
Troubleshoot
Confirm after 12 seconds have passed after starting the engine. When oil pressure switch connector is removed, does message go out? YES
Cause
Remedy
Oil pressure switch defect
Replacement
NO
YES
Defective YG wiring between CNB and oil pressure switch
Repair YG wiring.
NO
YES
Defective YG wiring between CNB and oil pressure switch
Repair YG
NO
Controller defect
Replace controller
9804/1103
45 - 10 - 14/8
6420 - C/9-8.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/9

Engine Oil Filter Blocked, Problem No 7 Note: Message does not go out even if the engine oil filter is replaced and the oil is satisfactory. Prior Confirmation Items 1 The "MODE" of the mode display is not flashing.
Troubleshoot
Engine starts
Cause
Remedy
When oil filter connector is removed, does message go out?
YES
Oil filter switch defect
Replace switch.
NO
YES
Defective LB wiring between CNB and oil filter switch
Repair LB wiring.
NO
YES
Defective LB wiring between CN7 and CNB
Repair wiring.
NO
Controller defect
Replace controller.
9804/1103
45 - 10 - 14/9
6420 - C/9-9.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/10

Fluid Overheating, water, oil, Problem No 8 Note: Message does not go out even if the actual temperature is below the following; Hydraulic Oil Temperature 84C. Engine Coolant Temperature 92C. Prior confirmation Items 1 3 The "MODE" of the mode display is not flashing. 2. Each bar graph displays more than one graduation. Confirm that the water and oil temperature bar graph is lit at 8 graduations.
Troubleshoot
1. Water temperature bar graph lit at 8 graduations. Key switch ON Is thermo sensor (water) temperature abnormal at selfcheck? (comparison of actual and indicated temperature) Display water temperature with self-check Measure actual temperature YES When thermo switch (water) connector is removed, does message go out?
Cause
Remedy
Thermo switch (water) defect

YES
Replace switch
NO
Defective YR wiring between CNB and thermo switch

YES YES
Repair YR wiring
NO
When CNB connector is removed, does message go out? NO
Key switch OFF

Remove thermo sensor (water) connector and measure resistance of sensor side. Is it within the range of values in separate chart? (Refer to resistance values in separate chart)
When CN3 connector is removed, does message go out? NO
Defective YR wiring between CN3 and CNB Controller defect
Repair YR wiring. Replace controller Replace sensor. Clean sensor connector terminal Clean CNE connector terminal Replace controller or clean CN10 connector terminal
NO
Thermo switch (water) defect Bad connection of thermo (water) connector
YES
Remove CNE connector and measure resistance between male side terminal YB and GR. Is it within the range of values in separate chart? (Refer to resistance values in separate chart)
NO
YES
Remove CN10 connector and measure resistance between female side terminal YB and GR. Is it within the range of values in separate chart? (Refer to resistance values in separate chart)
NO
YES
Controller defect or bad connection CN10
Note: When there is breakage in the wiring, the bar graph goes out completely.
9804/1103
45 - 10 - 14/10
6420 - C/9-10.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/11

Fluid Overheating, water, oil, Problem No 8 (continued) Note: Message does not go out even if the actual Temperature is below the following:Hydraulic Oil Temperature 84C Engine Coolant Temperature 92C
Troubleshoot
1. Oil temperature bar graph lit at 8 graduations. Key switch ON Is thermo sensor (oil) temperature abnormal at self-check? (comparison of actual and indicated temperature) Display oil temperature with self-check Measure actual temperature YES NO When thermo switch (oil) connector is removed, does message go out? YES
Cause
Remedy
Thermo switch (oil) defect Defective Br wiring between CNB and thermo switch (oil)
YES YES
Replace switch
Repair Br wiring
NO
When CNB connector is removed, does message go out? NO
Key switch OFF

Remove thermo sensor (oil) connector and measure resistance of sensor side. Is it within the range of values in separate chart? (Refer to resistance values in separate chart)
When CN3 connector is removed, does message go out? NO
Defective Br wiring between CN3 and CNB Controller defect
Repair Br wiring. Replace controller Replace sensor. Clean sensor connector terminal Clean CNE connector terminal Replace controller or clean CN10 connector terminal
NO
Thermo switch (oil) defect Bad connection of thermo sensor (oil) connector
YES
Remove CNE connector and measure resistance between male side terminal BrW and GR. Is it within the range of values in separate chart? (Refer to resistance values in separate chart)
NO
YES
Remove CN10 connector and measure resistance between female side terminal BrW and GR.
NO
YES
Controller defect or bad connection CN10
Note: When there is breakage in the wiring, the bar graph goes out completely.
9804/1103
45 - 10 - 14/11
6420 - C/9-11.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/12

Battery Charging, Problem No 9 Note: Message does not go out. Prior Confirmation Items 1 The "MODE" of the mode display is not flashing.
Troubleshoot
Cause
Remedy
Does hour meter operate?
YES
Remove CN2 connector and measure voltage between female side terminal WR and ground? Is it more than 10V?
NO
Defective WR wiring between CN2 and CNC
Repair WR
NO
YES
Bad connection of CN2 or controller defect
Clean CN2 connector terminal or replace controller.
Remove spade terminal of alternator R and measure voltage between female side and ground. Is it more than 10V?
NO
Alternator defect
Replace alternator
YES Remove CNC connector and measure voltage between male side terminal WR and ground? Is it more than 10V? YES NO
Breakage of WR wiring between CNC and alternator or bad connection of alternator spade terminal
Repair WR wiring between CNC and alternator or clean spade terminal.
9804/1103
45 - 10 - 14/12
6420 - C/9-12.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/13

Electrical Systems, Message Fault, Problem No 10 Note: Message does not go out.
9804/1103
45 - 10 - 14/13
6420 - C/9-13.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/14

Electrical System, Message Fault, Problem No. 10 (continued) Note: Message does not go out. Troubleshoot
Key switch ON When transistor output is carried out with self-check, are any abnormal points found? YES When display solenoid valve YES connector is removed, does message go out? NO When electro magnetic proportional valve is removed, does message go out? NO When CNB connector is removed, does message go out? NO When CN8 connector is removed, does message go out? NO YES Defective BrB wiring between CNB and CN8 Controller defect Solenoid valve defect YES When CN7 connector is removed, does message go out? NO * When there are multiple abnormalities the smaller number is displayed and after it is repaired, the next number is displayed. When CN6 connector is also removed, does message go out? YES Reconnect CN6, CN7 connectors. NO Defective wiring between CNA and solenoid valve Defective wiring between CN6 and CNA Controller defect Repair wiring. Repair wiring. Replace controller. Repair BrB wiring. Replace controller. Replace solenoid valve. YES Defective BrB wiring between CNB and electro-magnetic proportional valve Electro-magnetic proportional valve defect or defective BrB wiring Replace electro magnetic proportional valve or repair BrB wiring Repair BrB wiring
Cause
Remedy
Does Clock display 0000?
NO
NO
YES
YES
For example when swing lock no. 11 is displayed (Display number explanation on separate sheet).
When CNA connector is removed, does message go out? NO
YES Is throttle motor out of step? Remove throttle motor connector, measure resistances between B and Br, B and R, B and O, B and Y. (Are they within NO range of 3.0~3.6 ?) YES Remove throttle motor connector. Is it continuous between W and L on NO throttle motor side? YES Remove CNI and measure resistances between male side terminals R and B, R and G, R and W, R and Y.. (Are they within range of 3.0~3.6 ?) Throttle motor or driver abnormality Continues to next page B YES
Throttle link system abnormality
Inspect and adjust throttle motor. (Automatic adjustment necessary) Replace throttle motor. (Automatic adjustment necessary) Replace throttle motor. (Automatic adjustment necessary) Repair wiring. Repair wiring.
NO NO Does throttle motor operate with redundancy?
Throttle motor abnormality (energising coil defect)
YES
Throttle motor abnormality (limit switch defect) Breakage or defective wiring between CNI and throttle motor Breakage or defective wiring between CNI and throttle motor
NO
NO Remove CNI. Is it continuous between male side terminal GL and LgR? YES Continues to next page A
9804/1103
45 - 10 - 14/14
6420 - C/9-14.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/15

Electrical System, Message Fault, Problem No.10 (continued) Note: Message does not go out. Troubleshoot B Continued from previous page A
YES Remove driver connector CN15 and measure resistances between female side terminals R and B, R AND G R and W, R and Y. Are they within the range of 3.0~3.6 .
Cause
Remedy
NO
Breakage or defective wiring between CNI and CN15
Repair wiring
Same work as *1 YES Remove driver connector CN15. Is it continuous between female side terminals GL and LgR? NO
Breakage or defective wiring between CNI and CN15
Repair wiring
Ignition switch YES Remove driver connector CN15 and measure voltage between female side terminals P and BG, connecting P to + and BG to -. Is it within the range of 20~30V?.
NO
Breakage of wiring P between CN15 and fuse box
Repair P wiring
* Ignition switch
YES Remove driver connector CN15 and measure voltage between female side terminals RY and BG, connecting RY to + and BG to -. Is it within the range of 20~30V? YES NO
Breakage of wiring RY between CN15 and key switch
Repair RY wiring
Driver defect
Replace driver
Redundancy switch OFF, ignition switch NO
Remove controller side connector CN8 and measure voltage between GY and ground. YES Is it 0V? Measure voltage between GR and ground. Control System Is it 5V?
Abnormalities
Controller defect
Replace controller
YES
Breakage of wiring GY or GR between controller CN8 and driver CN15
Repair GR or GY wiring
9804/1103
45 - 10 - 14/15
6420 - C/9-15.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/16

Engine Trouble, Problem No 11 Note: Engine does not start even though the message "electrical system abnormal" is not displayed. Prior Confirmation Items
G G G G G
No abnormalities in engine or fuel system. Fuse is not blown. The message "Engine emergency stop" is not displayed. Redundancy switch is OFF. Starter motor rotates and engine is cranking.
9804/1103
45 - 10 - 14/16
6420 - C/9-16.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/17

Engine Trouble, Problem No 11 (continued) Troubleshoot Cause Remedy
Key switch ON Is fuel cut lever on stop side YES
Engine system Abnormality
Inspect engine system.
NO Remove the stop motor connector and connect female side (cab side) to service connector (6 pin). Measure voltage between LR and ground, connecting LR to + and ground to -. Is it within the range of 20~30V. YES Remove the stop motor connector and attach service connector to female side. Confirm continuity between L and LW. Is the following true? Key switch ON: Continuity Key switch OFF:
NO
Breakage of LR wiring between stop motor connector and CND or between CND and fuse
Repair LR wiring.
YES
Stop motor defect
Replace stop motor.
NO
Measure voltage between shut down relay 1 connector L and ground, connecting L to + and ground to -. Is the following true? Emergency stop button ON: 0V Emergency stop button OFF: 20~30V
NO
Shut down relay defect
Replace shut down relay 1.
YES
Shut down relay 2 Defect or breakage of L wiring between shut down 1 and 2
To judge if relay is defective or not, interchanging the relay with one in the centralized relay is another method.
Replace shut down relay 2 or repair L wiring.
9804/1103
45 - 10 - 14/17
6420 - C/9-17.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/18

Engine Problem, Problem No 12 Note: Engine revolutions do not change with throttle volume control. Prior Confirmation Items 1 The message "Engine emergency stop" is not displayed
Troubleshoot
Key switch ON Change voltage moving throttle volume with self-check. Is it within the range of 0~4.5V? NO Without removing CN10 connector, change the voltage between GrR + and Gr - moving the throttle volume. Is it within the range of 0~4.5V? YES
Cause
Remedy
Controller defect or bad connection of CN10 connector
YES
NO Remove throttle volume connector, measure resistance between throttle volume side connector GrR and GrL. Is it within the range of 0~1 ? YES Remove throttle volume connector, measure resistance between throttle volume side connector GrR and Gr. Is it within the range of 0~1 ? YES NO
Replace controller or clean CN10 connector terminal. Replace throttle volume.
Throttle volume defect.
NO
Breakage or defective wiring GrL, GrR, Gr between CN10 and throttle volume
Repair of the GrL, GrR, Gr.
Check motor transmitted pulse by self-check. Is it within the range of 500~1023? NO Even though the throttle motor is moving.
YES
Controller defect
NO
Replace controller.
Remove controller CN4 and driver CN15. Is GL wiring continuous?
Breakage of GL wiring
Repair GL wiring
YES
Driver defect
Replace driver.
9804/1103
45 - 10 - 14/18
6420 - C/9-18.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 14/19
JS 330, JS 450, JS 460 Fault Finding (contd) - Electrics (CAPS II) Sensor Resistance Value
Water temperature (Oil temperature) 20C 30C 40C 50C 60C 70C 80C
Minimum 8.00k 5.35k 3.60k 2.50k 1.70k 1.20k 0.85k
Maximum 10.20k 6.50k 4.55k 3.10k 2.20k 1.55k 1.15k
9804/1103
45 - 10 - 14/19
6420 - C/9-19.2
Issue 1*
CONTENTS
Excavators
45 - 10 - 13/4
JS 200W from m/c no. 809000 Fault Finding - Hydraulic Rams

The chart below lists some possible problems and suggested remedies. The types of problems fall into four main categories as follows:
Item 1 2 3 4
Symptoms Oil leakage from piston rod sliding part. Oil leakage from cylinder head joint. Oil leakage from pipe and cylinder tube welds. Faulty operation
Item Symptoms
Related Parts
Trouble On the sliding surface, there are scratches and rust that can be felt by the fingernail.
Treatment 1 Use an oil stone and remove the scratch and make the sliding surface smooth. If oil leakage continues even though the rod surface is made smooth, the scratch may have damaged the U-ring and other seals, so dismantle and inspect. 2 If the scratches and rust cover such a wide area that they cannot be repaired by an oil stone, renew the piston rod and U-ring, wiper ring and seals and the piston rod bearing member.
Piston rod
Piston rod sliding part oil leakage
The plating is peeling.
Re-plate or renew the piston rod. Also inspect the seal and piston rod bearing member and renew if damaged. Remove foreign matter. If there is damage to packing, renew it. Renew. Possibly due to burning caused by adiabatic compression from air remaining inside the ram. After renewing the packing, first operate the ram at low-pressure, low speed to sufficiently bleed the air.
Foreign matter is biting into the inner and outer surfaces of the packing. Rod packing (Buffer ring U-ring) There is a scratch on the inner surface. The lip and groove parts are locally carbonized (burned).
9804/1103
45 - 10 - 13/4
6320 - E/46-1.1
Issue 1
CONTENTS
Excavators
45 - 10 - 13/5
JS 200W from m/c no. 809000 Fault Finding - Hydraulic Rams (contd)
Item Symptoms Related Parts Trouble Packing rubber is perished. Treatment The packing life or hydraulic oil deterioration and high temperature are possible reasons. 1 Renew hydraulic oil. Rod packing (Buffer ring, U-ring) Lip is deficient all around. 2. Check the hydraulic oil temperature. (Below 80 C is advisable). 3 Check if high temperature locally. Renew. It is possible that abnormally high pressure is working on the packing. 1 Check the operation pressure, cushion pressure. 2 Part which is attached to the buffer ring may be abnormal. Inspect the buffer ring. The protrusion of the heel of the packing is excessive. 1 Piston rod oil leakage Back up ring As a rule, renew the rod packing at the same time. (It is desirable to renew parts which are attached to the buffer ring at the same time). It is possible that abnormally high pressure is the cause. Check the same as above (heel of packing protruding). Wiper ring Foreign matter is biting into the lip. The lip is damaged. There is also other abnormal damage. Wear is excessive and the clearance with piston rod exceeds the maximum permissible value. (Refer to Maintenance Specifications for maximum permissible value.) Large scratch on the sliding part. Remove the foreign matter. Renew. Renew.
Bushing
Renew. Also inspect the piston rod. Remove scratch, rust with oil stone. If it cannot be repaired, renew the cylinder head.
Cylinder head
Scratches, rust on the seal attachment parts.
9804/1103
45 - 10 - 13/5
6320 - E/46-2.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 13/6
Item Symptoms Related Parts Trouble Foreign matter on inner and outer diameters. O-ring damaged. O-ring Treatment Remove foreign matter. Renew 'O'-ring if damaged. Inspect inside tube: if any scratches or rust, make surface smooth with oil stone. Inspect cylinder head 'O'-ring groove: if any scratches or rust, make surface smooth with oil stone. Inspect back up ring: if any deformation or protrusion, renew.
Confirm the above and renew 'O'-ring. Back up ring 2 Oil leakage from cylinder head joint Deformation, protrusion Looseness Cylinder head Bolt Looseness, stretching, broken Abnormal bulge Renew, with the 'O'-ring. Dismantle cylinder head and inspect 'O'-ring and back up ring. Check tube and cylinder head thread for damage. If any damage, renew. After inspection, tighten to specified torque.
Renew all bolts and tighten to specified torque. Replace with new parts. Oil leakage from connecting parts may be caused by abnormal pressure (including cushion pressure). Inspect the tube for bulges, deformation and check the circuit pressure.
Cylinder tube
Crack in welding Oil leakage from pipe and cylinder tube welded seam Cylinder tube pipe (hollow piston rod)
Replace with new parts. Cracks will develop into fractures. Fractures are very dangerous, so if any cracks are found, stop work immediately and renew the parts. Welding on top of cracks will have no effect.
9804/1103
45 - 10 - 13/6
6320 - E/46-3.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 13/7
Item Symptoms Poor operation Related Parts Piston rod cylinder tube Trouble Bending to more than the specified limit. (Bending distortion: refer to Maintenance Specifications) Tube scored Cylinder tube Abnormal wear, damage of sliding area Foreign matter intruding on piston and cylinder head sliding area Scratches, wear are present Piston seal Scratches, rust on inside Treatment Replace with new part. The seal and sliding part material may be damaged too, so inspect. If abnormal, renew. Replace with new part. As above, inspect the seal and sliding part material. Replace with new part. As above, inspect the seal and sliding part material. Remove foreign material. As above, inspect the seal and sliding part material. Replace with new part. Inspect the cylinder tube inner surface also. Remove the scratches, rust by honing or with an oil stone and make the surface smooth. If the scratch is deep and cannot be repaired, renew cylinder tube. Renew piston seal. Tighten to specified torque. Inspect the valve leakage amount and service.
4-1 Movement not smooth
Piston rod cylinder head sliding part
4-2 Inner oil leakage. Piston rod extends when work stops or lowers abnormally during work. Also, specified operating speed is not achieved.
Cylinder tube Piston nut Valves Loose nut Leak from valve
Note: Hydraulic oil expands and contracts due to changes in temperature and pressure. Accordingly, the ram also expands and this can be mistaken for internal leakage. When inspecting for internal leakage, do so at set conditions.
9804/1103
45 - 10 - 13/7
6320 - E/46-4.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 10 - 13/8
Item Symptoms 4-3 Related Parts Trouble Air remaining inside ram. Operation is unsteady Treatment Bleed the air. For rams that do not have an air bleeder, operate back and forth several times at low pressure and low speed to bleed the air. For rams with an air bleeder, remove the load to reduce the pressure then loosen the air bleeder and completely bleed the air.
Air
Note: The ram may expand if it is stopped suddenly. This is due to the compression of the hydraulic oil. This occurs especially with long stroke rams. 4 4-4 Heavy shock loading when changing from extension to retraction and back 4-5 Noisy operation Pin bushing/pin Gap between mounting and pin bushing is too large. Measure the pin and pin bushing and renew parts if measurements exceed the specifications.
Oil supply Pin bushing/pin
Insufficient oil. Scuffing at connecting part.
Add oil. Replace with new part and add oil.
Note: If left in the state where operation is poor, the ram will no longer move and other parts will be affected adversely. Inspect early and carry out appropriate measures.
9804/1103
45 - 10 - 13/8
6320 - E/46-5.1
Issue 1
CONTENTS CONTENTS
*JS 70 to m/c no. 695500 Circuit Diagrams - Electrical
CONTENTS CONTENTS
Excavators
45 - 15 - 01/2
*JS 70 to m/c no. 695500 Circuit Diagrams - Electrical Main Components

1 2 3 4A 4B 5 6 7 8 9 10 11 12 13 14 15 16A 16B 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Monitor Display Unit Systems Control Monitor System Control Solenoid 2-Speed Travel Solenoid Swing Parking Brake Solenoid Idle Switch Swing Pressure Sensing Switches Idle Solenoid Resistor Diode Unit Horn Refuelling Pump (optional) Working Lamp (Boom) Working Lamp (Tank) Filter Blocked Switch Fuel Level Sensor Hydraulic Oil Temperature Sensor Water Temperature Sensor Engine Engine Intake Heater Relay Safety Relay Battery Battery Relay Horn Switch Horn Relay Wiper Relay Working Lamp Switch Intermittent Wipe Relay Wiper Motor Idle Relay System Control Switch 2-Speed Travel Switch Wiper Switch Heater Motor Heater Switch Cab Lamp Switch Screen Washer Fuse Box Fuses Stop Motor Starter Switch Buzzer Off Switch Radio Aerial Radio Loudspeaker Radio Beacon Switch
Monitor Display and Monitor Controller Plug Pin Positions

Monitor Display 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 POWER (+12 V) GND HOUR METER BATTERY CHARGE LAMP FUEL LAMP FUEL METER WATER TEMPERATURE METER OVERHEAT LAMP HYDRAULIC OIL TEMPERATURE METER ENGINE OIL PRESSURE LAMP AIR FILTER LAMP BACK-UP LAMP SWING BRAKE LAMP IDLE LAMP CONTROL OFF LAMP BUZZER GLOW LAMP OPTION (1) LAMP OPTION (2) LAMP (No Connection)
Monitor Controller CN 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 POWER (+12V) GND GND BATTERY CHARGE FUEL METER (LAMP) FUEL METER WATER TEMPERATURE METER HYDRAULIC OIL TEMPERATURE METER ENGINE OIL PRESSURE SWITCH AIR FILTER SWITCH WORKING LAMP SWING PRESSURE SWITCH SWING BRAKE OUT IDLE SWITCH CONTROL OFF SWITCH BUZZER STOP SWITCH
CN 2 1 2 3 4 5 6 HEAT RELAY (IN) HEAT RELAY (OUT) OPTION (1) OPTION (2) IDLE RELAY (No Connection)
Cable Colour Code B Br G L Lg R V W Y Black Brown Green Blue Light Green Red Violet White Yellow
9804/1103
45 - 15 - 01/2
Issue 2*
CONTENTS
Excavators
45 - 15 - 01/2A
JS 70 from m/c no. 695501 Circuit Diagrams - Electrical
REFER TO THE SERVICE MANUAL FOR THIS ILLUSTRATION
9804/1103
45 - 15 - 01/2A
6020 - C/2-4.1
Issue 1
CONTENTS
Excavators
45 - 15 - 01/2B
JS 70 from m/c no. 695501 Circuit Diagrams - Electrical (contd) Main Components
1 2 3 4 5 6 7 8 9 10 11 12 13A 13B 13C 13D 13E 13F 13G 13H 13J 13K 13L 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Cigar Lighter Radio Aerial Lead Panel (LH) Limit Switch (Gate) Horn Button Panel (RH) Pressure Switch (Breaker) - Optional Switch (Breaker) - Optional Switch (2 Stage Travel) Monitor Motor Driver Switch - One Touch Idle Relay - Ran 1 Relay - Fan 2 Relay - Ran 3 Relay - Horn Relay - Plug (Glow) Relay - Washer Relay - Wiper Relay - Cab Light Relay - Working Lights (Boom Mounted) Relay - Engine Shutdown Relay - Lever Lock Cab - Wiper/Light Fuse Box Starter Switch Fuse Fuse Relay - Battery Battery Battery Relay - Safety Relay - Heating Washer - Tank Horn Working lights - House Mounted Stop Solenoid Sensor - Thermo Switch - Thermo (Hydraulic Oil) Engine Block Sensor - Fuel Level Valve Block Solenoid (Breaker) - Optional Over Heat Switch (Oil) Throttle Motor Radio Loudspeaker Working Lights - Boom Mounted Glow Plug KEY B W Br P V G O BLACK WHITE BROWN PINK VioLET GREEN ORANGE R Y Lg Sb L Gr RED YELLOW LIGHT GREEN SKY BLUE BLUE GREY
9804/1103
45 - 15 - 01/2B
6020 - C/2-3.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 15 - 01/4
JS 110,130 Circuit Diagrams - Electrical

Main Components
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Hourmeter Monitor Display Unit Proportional Solenoid 2-speed Travel Solenoid Swing Park Solenoid Free Swing Solenoid Swing Brake Pressure Switch Throttle Motor Engine Compartment Lamp Refuelling Pump (optional) Horn (110 dB) Horn (120 dB) Working Lamp, Boom Working Lamp, Tank Air Filter Vacuum Switch Fuel Reserve Tank Level Switch Fuel Level Sensor Hydraulic Fluid Temperature Sensor Alternator Low Oil Pressure Switch Filter Switch Engine Coolant Temperature Sensor Engine Intake Heater Starter Motor Engine Intake Heater Relay Horn Selector Switch Horn Relay Emergency By-pass Switch Resistor } CR Filter Condenser } Diode Resistor Resistor Controller Idle/F Selection Switch Mode Switch Throttle Switch Free Swing Switch Lamp Check Switch Buzzer Idle Switch (Hand Controller) Cushion Switch Emergency Throttle By-pass Switch Windscreen Wiper Switch Cab Heater Switch Working Lamp Switch Cab Heater Cab Lamp Control Switch (Servo Isolator) Beacon Switch 2-speed Travel Switch Horn Switch Limit Switch Engine Stop Relay Timer (Engine Stop) Intermittent Wipe Relay Windscreen Wiper Relay Cushion Valve Relay Windscreen Washer Windscreen Wiper Motor Shut-off Solenoid 61 62 63 64 65 66 67 68 69 70 71 Cushion Valve Solenoid Starter Switch Fuse Box Battery Relay Battery Sensor Batteries Speaker Aerial Radio Cab Fan Beacon
Fuses
1 - 8 See 45 - 00 - 01/2.
Cable Colour Code

B Br G GY L Lg O P R Sb V W Y Black Brown Green Grey Blue Light Green Orange Pink Red Sky Blue Violet White Yellow
Note : On the JS 110 (from Machine No. 697014) and 130 (from Machine No. 699037), sealed electrical connectors have been introduced on the throttle motor 8 and the swing brake pressure switch 7 (see below).
A183550
9804/1103
45 - 15 - 01/4
Issue 1
CONTENTS
JS 150LC Circuit Diagrams - Electrical
CONTENTS CONTENTS
Excavators
45 - 15 - 01/6

Main Components
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Hourmeter Monitor Display Unit Proportional Solenoid 2-speed Travel Solenoid Swing Park Solenoid Swing Brake Pressure Switch Throttle Motor Engine Compartment Lamp Refuelling Pump (optional) Horn (110 dB) Horn (120 dB) Working Lamp, Boom Working Lamp, Tank Air Filter Vacuum Switch Fuel Reserve Tank Level Switch Fuel Level Sensor Hydraulic Fluid Temperature Sensor Alternator Low Oil Pressure Switch Filter Switch Engine Coolant Temperature Sensor Engine Intake Heater Engine Intake Heater Relay Horn Selector Switch Horn Relay Emergency Throttle By-pass Switch Emergency By-pass Switch Resistor } CR Filter Condenser } Diode Resistor Resistor Controller Idle/F Selection Switch Mode Switch Throttle Switch Lamp Check Switch Buzzer Idle Switch (Hand Controller) 2-speed Travel Switch Control Switch Horn Switch Engine Stop Relay Timer (Engine Stop) Intermittent Wipe Relay Windscreen Wiper Relay Cushion Valve Relay Windscreen Wiper Motor Windscreen Washer Control Solenoid Cushion Valve Solenoid Starter Switch Beacon Switch Control Switch (Servo Isolator) Cushion Switch Windscreen Wiper Switch Heater Switch Working Lamp Switch Cab Lamp Cab Heater Fuse Box 61 62 63 64 65 66 67 68 69 Battery Relay Battery Sensor Batteries Speaker Aerial Radio Fan Starter Motor Beacon
Fuses
1 - 8 See 45 - 00 - 01/2.
Cable Colour Code

B Br G GY L Lg O P R Sb V W Y Black Brown Green Grey Blue Light Green Orange Pink Red Sky Blue Violet White Yellow
Note: From Machine No. 701045, sealed electrical connectors have been introduced on the throttle motor 7 and the swing brake pressure switch 6 (see below).
CN15
R R Br G Y W B B/L Br G Y W B L
TR1 R1 R3
TR2 R2 R4 TR4
LS1 LS2
R5
TR3
R6
Br/Y B Br/Y W B R Br G Y
A183550
9804/1103
45 - 15 - 01/6
Issue 1
CONTENTS
CONTENTS
Excavators

Main Components 1 Hourmeter 2 Monitor Display Assembly 3 Proportional Solenoid 4 2-speed Tracking Solenoid 5 Free Swing Solenoid 6 Swing Park Solenoid 7 Swing Brake Pressure Switch 8 Throttle Motor 9 Engine Compartment Lamp 10 Refuelling Pump 11 Horn (110dB) 12 Horn (120 dB) 13 Working Lamp, Boom 14 Working Lamp, Tank 15 Air Filter Vacuum Switch 16 Fuel Reserve Tank Level Switch 17 Fuel Level Sensor 18 Hydraulic Fluid Temperature Sensor 19 Alternator 20 Engine Low Oil Pressure Switch 21 Oil Filter Switch 22 Engine Coolant Temperature Sensor 23 Engine Intake Heater 24 Starter Motor 25 Engine Intake Heater Relay 26 Horn Selector Switch 27 Horn Relay 28 Emergency By-pass Switch 29 Resistor } CR Filter 30 Condenser } 31 Diode 32 Controller (see page 7-9 for plug pin connectors) 33 Idle/F Selector Switch 34 Mode Selector Switch 35 Throttle Selector Switch 36 Free Swing Switch 37 Buzzer Off/Lamp Check Switch 38 Idle Switch (Hand Controller) 39 Cushion Switch 40 Control Switch (Servo Isolator) 41 Throttle Emergency By-pass Switch 42 Windscreen Wiper Switch 43 Heater Switch 44 Working Lamp Switch 45 Cab Heater 46 Cab Lamp and Switch 47 Beacon Switch 48 2-speed Tracking Switch 49 Horn Switch 50 Limit Switch 51 Engine Stop Relay 52 Timer (Engine Stop) 53 Windscreen Wiper Relay 54 Intermittent Wipe Relay 55 Cushion Valve Relay 56 Timer (Boom Down) 57 Windscreen Washer 58 Windscreen Wiper Motor Boom Down Negative Control Delay Switch * 59 60 Cushion Valve Solenoid * 61 62 63 64 65 66 67 68 69 70 * 71 72 * 73 * 74 * 75 * 76 * 77 * 78 * 79 * * Fuses * 1-8 Servo Isolator Solenoid Boom Down Delay Solenoid Starter Switch Fuse Box Battery Relay Battery Sensor Batteries Speaker Aerial Radio Cab Fan Beacon Air Conditioner Unit Air Conditioner Panel Air Conditioning Drier Air Conditioning Compressor Auxiliary Circuit - Fuse Auxiliary Circuit - Relay Auxiliary Circuit - Flow Priority Valve Optional Only fitted to JS200LR (long reach) models
See page 45 - 05 - 01/3.
Cable Colour Code B Black Br Brown G Green GY Grey L Blue Lg Light Green O Orange P Pink R Red Sb Sky Blue V Violet W White Y Yellow Note: From Machine No. 704075, sealed electrical connectors have been introduced on the throttle motor 8 and the swing brake pressure switch 7 (see below).
CN15
TR1 R1 R3
TR2 R2 R4 TR4
LS1 LS2
R5
TR3
R6
A183550
9804/1103
45 - 15 - 01/8
Issue 2*
CONTENTS
CONTENTS
Excavators

Main Components 1 Hourmeter 2 Monitor Display Assembly 2-speed Tracking Solenoid *3 4 Free Swing Solenoid 5 Swing Park Solenoid 6 Proportional Solenoid 7 Swing Brake Pressure Switch 8 Throttle Motor 9 Engine Compartment Lamp 10 Refuelling Pump 11 Horn (110 dB) 12 Horn (120 dB) 13 Working Lamp, Boom 14 Working Lamp, Tank 15 Air Filter Vacuum Switch 16 Fuel Reserve Tank Level Switch 17 Fuel Level Sensor 18 Hydraulic Fluid Temperure Sensor 19 Alternator 20 Engine Low Oil Pressure Switch 21 Oil Filter Switch 22 Engine Coolant Temperature Sensor 23 Engine Intake Heater 24 Starter Motor 25 Engine Intake Heater Relay 26 Horn Selector Switch 27 Horn Relay 28 Emergency Throttle By-pass Switch 29 Emergency By-pass Switch 30 Resistor } CR Filter 31 Condenser } 32 Diode 33 Controller (see page 7-9 for plug pin positions) 34 Idle/F Selector Switch 35 Mode Switch 36 Throttle Switch 37 Free Swing Switch 38 Buzzer Off/Lamp Check Switch 39 Idle Switch (Hand Controller) 40 2-speed Tracking Switch 41 Limit Switch 42 Horn Switch 43 Engine Stop Relay 44 Timer (Engine Stop) 45 Windscreen Wiper Relay 46 Intermittent Wipe Relay 47 Cushion Valve Relay 48 Windscreen Washer 49 Windscreen Wiper Motor 50 Servo Isolator Solenoid 51 Cushion Valve Solenoid 52 Starter Switch 53 Beacon Switch 54 Control Switch (Servo Isolator) 55 Cushion Switch 56 Windscreen Wiper Switch 57 Cab Heater Switch 58 Working Lamp Switch 59 Cab Lamp and Switch 60 Cab Heater 61 62 63 64 65 66 67 68 69 Fuse Box Battery Relay Battery Sensor Batteries Speaker Aerial Radio Cab Fan (Optional) Beacon
Fuses * 1-8
See page 45 - 05 - 01/3.
Cable Colour Code B Black Br Brown G Green GY Grey L Blue Lg Light Green O Orange P Pink R Red Sb Sky Blue V Violet W White Y Yellow Note: From Machine No. 708040, sealed electrical connectors have been introduced on the throttle motor 8 and swing brake pressure switch 7 (see below).
A183550
9804/1103
45 - 15 - 01/10
Issue 2*
CONTENTS
CONTENTS
Excavators

Main Components 1 Controller 2 Proportional Solenoid 3 2-speed Tracking Solenoid 4 Swing Park Solenoid 5 Cushion Valve Solenoid 6 Free Swing Solenoid 7 Swing Brake Pressure Switch 8 Working Lamp (Tank) 9 Working Lamp (Boom) 10 Horn 11 Air Horn 12 Refuelling Pump 13 Engine Compartment Lamp 14 Throttle Motor 15 Hydraulic Tank Air Pressure Switch 16 Air Filter Vacuum Switch 17 Fuel Reserve Tank Level Switch 18 Fuel Level Sensor 19 Hydraulic Fluid Temperature Sensor 20 Alternator 21 Low Oil Pressure Switch 22 Oil Filter Switch 23 Engine Coolant Temperature Sensor 24 Engine Intake Heater 25 Starter Motor 26 Safety Relay 27 Engine Intake Heater Relay 28 Diode 29 Emergency By-pass Switch 30 Resistor } CR Filter 31 Condenser } 32 Diode 33 Swing Park Switch 34 Buzzer Off/Lamp Check Switch 35 Mode Switch 36 Throttle Switch 37 Emergency By-pass Throttle Switch 38 Beacon Switch 39 Horn Selector Switch 40 Horn Relay 41 Control Switch (Servo Isolator) 42 Cushion Switch 43 Idle Switch (Hand Controller) 44 Free Swing Switch 45 Hourmeter 46 Monitor Display Unit 47 Engine Stop Relay 48 Horn Switch 49 Timer (Engine Stop) 50 Limit Switch 51 Windscreen Wiper Relay 52 Intermittent Wipe Relay 53 Cushion Valve Relay 54 Windscreen Wiper Motor 55 2-speed Tracking Switch 56 Servo Isolator Solenoid 57 Windscreen Washer 58 Cab Lamp and Switch 59 Radio 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 Fuses * 1-8 Aerial Speaker Beacon Cab Fan Switch (Optional) Cab Fan (Optional) Fuse Box Starter Switch Working Lamp Switch Windscreen Wiper Switch Heater Switch Air Conditioning Compressor (Optional) Drier (Optional) Air Conditioner Panel (Optional) Air Conditioner Unit (Optional) Cab Heater Batteries Battery Sensor Battery Relay
See page 45 - 05 - 01/3.
Cable Colour Code B Black Br Brown G Green GY Grey L Blue Lg Light Green O Orange P Pink R Red Sb Sky Blue V Violet W White Y Yellow Note: From Machine No. 712020, sealed electrical connectors have been introduced on the throttle motor 14 and the swing brake pressure switch 7 (see below).
CN15
TR1 R1 R3
TR2 R2 R4 TR4
LS1 LS2
R5
TR3
R6
A183550
9804/1103
45 - 15 - 01/12
Issue 2*
CONTENTS
Excavators
CONTENTS
Excavators

Main Components 1 Controller 2 Proportional Solenoid 3 2-speed Tracking Solenoid 4 Swing Park Solenoid 5 Cushion Valve Solenoid 6 Free Swing Solenoid 7 Swing Brake Pressure Switch 8 Working Lamp (Tank) 9 Working Lamp (Boom) 10 Horn 11 Air Horn 12 Refuelling Pump 13 Rear Working Lamp 14 Engine Compartment Lamp 15 Throttle Motor 16 Hydraulic Tank Air Pressure Switch 17 Air Filter Vacuum Switch 18 Fuel Reserve Tank Level Switch 19 Fuel Level Sensor 20 Hydraulic Fluid Temperature Sensor 21 Alternator 22 Low Oil Pressure Switch 23 Engine Coolant Temperature Sensor 24 Air Intake Pre-heater 25 Magnetic Valve 26 Starter Motor 27 Safety Relay 28 Air Intake Heater Resistor 29 Heater Relay 30 Diode 31 Emergency By-pass Switch 32 Resistor { CR Filter 33 Condenser { 34 Idle/F Selector Switch 35 Buzzer Off/Lamp Check Switch 36 Mode Switch 37 Throttle Switch 38 Emerency Throttle By-pass Switch 39 Beacon Switch 40 Horn Selection Switch 41 Horn Relay 42 Control Switch (Servo Isolator) 43 Cushion Valve Switch 44 Idle Switch (Hand Controller) 45 Free Swing Switch 46 Hourmeter 47 Monitor Display Unit 48 Engine Stop Relay 49 Horn Switch 50 Limit Switch 51 Timer (Engine Stop) 52 Windscreen Wiper Relay 53 Intermittent Wipe Relay 54 Cushion Valve Relay 55 Windscreen Wiper Motor 56 2-speed Tracking Switch 57 Servo Isolator Solenoid 58 Windscreen Washer 59 Cab Lamp and Switch 60 Radio 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 Aerial Speaker Working Lamp Switch Windscreen Wiper Switch Heater Switch Air Conditioning Compressor Air Conditioning Drier Air Conditioning Panel Air Conditioning Unit Batteries Battery Sensor Battery Realy Cab Heater Seat Heater Seat Heater Switch Starter Switch Fuse Box
Fuses * 1 - 8 See page 45 - 05 - 01/3. Cable Colour Code B Black Br Brown G Green GY Grey L Blue Lg Light Green O Orange P Pink R Red Sb Sky Blue V Violet W White Y Yellow Note: From Machine No. 714004, sealed electrical connectors have been introduced on the throttle motor 15 and the swing brake pressure switch 7 (see below).
CN15
TR1 R1 R3
TR2 R2 R4 TR4
LS1 LS2
R5
TR3
R6
A183550
9804/1103
45 - 15 - 01/14
Issue 2*
CONTENTS
JS 130W,150W Circuit Diagrams - Electrical (Common with JS130, JS150 Tracked Excavators)
CONTENTS
Excavators
JS 130W,150W Circuit Diagrams - Electrical (Common with JS130, JS150 Tracked Excavator)
Main Components 1 Hourmeter 2 Monitor Display Unit 3 Proportional Solenoid 4 Gear Change Solenoid 5 Swing Park Solenoid 6 Swing Brake Pressure Switch 7 Throttle Motor 8 Engine Compartment Lamp 9 Refuelling Pump (optional) 10 Horn (110 dB) 11 Horn (120 dB) 12 Working Lamp, Boom 13 Working Lamp, Tank 14 Air Filter Vacuum Switch 15 Fuel Reserve Tank Level Switch 16 Fuel Level Sensor 17 Hydraulic Fluid Temperature Sensor 18 Alternator 19 Low Oil Pressure Switch 20 Filter Switch 21 Engine Coolant Temperature Sensor 22 Engine Intake Heater 23 Engine Intake Heater Relay 24 Horn Selector Switch 25 Horn Relay 26 Emergency Throttle By-pass Switch 27 Emergency By-pass Switch 28 Resistor } CR Filter 29 Condenser } 30 Diode 31 Resistor 32 Resistor 33 Controller 34 Idle/F Selection Switch 35 Mode Switch 36 Throttle Switch 37 Lamp Check Switch Buzzer 38 Idle Switch (Hand Controller) 39 Gearbox Ratio Change 40 Control Switch 41 Horn Switch 42 Engine Stop Relay 43 Timer (Engine Stop) 44 Intermittent Wipe Relay 45 Windscreen Wiper Relay 47 Windscreen Wiper Motor 48 Windscreen Washer 49 Control Solenoid 51 Starter Switch 52 Beacon Switch 53 Control Switch (Servo Isolator) 55 Windscreen Wiper Switch 56 Heater Switch 57 Working Lamp Switch 58 Cab Lamp 59 Cab Heater 60 Fuse Box 61 Battery Relay 62 Battery Sensor 63 Batteries 64 65 66 67 68 69 Speaker Aerial Radio Fan Starter Motor Beacon
Fuses See pages 45 - 05 - 01/4, 01/5. Note: Some cables are colour coded, others are numbered at intervals along their whole length. Cable Colour Code B Black Br Brown G Green GY Grey L Blue Lg Light Green O Orange P Pink R Red Sb Sky Blue V Violet W White Y Yellow
9804/1103
45 - 15 - 02/2
Issue 1
CONTENTS
JS 130W,150W Circuit Diagrams - Electrical (additional to JS130, JS150 Tracked Excavator)
CONTENTS
JS 130W,150W Circuit Diagrams - Electrical (additional to JS130, JS150 Tracked Excavator)

Key A B C D E F G H J K L M N P R S T U V W X Y Z Relay Box Brake Pressure Switch Low Accumulator Pressure Switch Steering Column Switch Assembly Light Cluster - Left Front Light Cluster - Right Front Dipper Side Light (optional) Hazard Light Switch Grab/Rockbreaker Left Switch (Joystick Mounted) Isolator Relay Batteries Binnacle and SCM Monitor Light Cluster - Left Rear Light Cluster - Right Rear Number Plate Lamp Pressure Switch - Drive Isolator Solenoid Cigar Lighter Ignition Switch Grab/Rockbreaker Right Switch (Joystick Mounted) Working Lights Switch Windscreen Wash/Wipe Switch Reverse Pressure Switch Gear Change Signal Wire Functions (cont'd) Wire No 013 014 015 016 017 018 020 021 022 024 025 026 027 028 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 049 050 051 200 201 202 203 205 Wire Functions (cont'd) Wire No 600 601 602 603 604 605 606 607 613 614 615 616 617 618 619 620 621 622 623 624 625 626 627 628 629 630 800 801 802 803 804 805 806 807 808 809 810 811 812 813 814
Solenoids SOL 3 SOL 4 SOL 5 SOL 6 SOL 7 SOL 8 SOL 9 SOL 10 SOL 13 SOL 14 SOL 15 SOL 16 SOL 17 SOL 18 SOL 19 SOL 20 SOL 21 SOL 22 SOL 23 Drive Motor Range Change Brake Inhibit Creep Speed Drive Isolator Triple Articulation - Down Triple Articulation - Up Creep Speed Creep Speed Boom/Dozer-Up Boom/Dozer-Down Axle Lock Stabiliser - Right Stabiliser - Left Gear Change Park Brake Grab Rotate - Left Grab Rotate - Right Rockbreaker/Auxiliary - Left Rockbreaker/Auxiliary - Right
Hazard Lights - Switched Drive Isolator Axle Lock Reverse Lights Creep Speed Binnacle - Switched Brake Inhibit Signal Grab/Rockbreaker Switch Feed Cigar Lighter Feed Ignition ON Signal Wash/Wipe Supply Headlights 24V, Switched Brake Switch Feed Full Flash Pressure Switch Feed to S Grab/Rockbreaker Feed Low Accumulator Switch Feed Headlights - Fused Side Fog Lights - Fused Side Cigar Lighter - Fused Side Stabiliser Left - Fused Side Stabiliser Right - Fused Side Triple Articulation - Fused Side Axle Lock - Fused Side Brake Inhibit - Fused Side Binnacle Switched - Fused Side Brake Lights - Fused Side Reversing Lights - Fused Side Dozer - Fused Side Park Brake - Fused Side Drive Motor Range Change - Fused Side Creep Speed - Fused Side Grab Rotate/Rockbreaker - Fused Side Drive Isolator - Fused Side Relays, Switched - Fused Side Hazard Lights, Switched- Fused Side Relays, Unswitched Sidelights, Right Binnacle, Unswitched Hazard Lights, Unswitched 24V, Unswitched
Cigar Lighter, Earth Wash/Wipe, Earth Earth Full Beam/Low Accumulator, Return Drive Isolator Solenoid, -ve Triple Articulation Solenoids, -ve Creep Speed Solenoids, -ve Boom/Dozer Solenoids, -ve Earth, Left Rear Light Cluster Earth, Right Rear Light Cluster Earth, Left Front Light Cluster Wash/Wipe Earth to Switch Earth, Right Front Light Cluster/Dipper Side (optional) Axle Lock Solenoid, -ve Stabiliser Right Solenoid, -ve Stabiliser Left Solenoid, -ve Rockbreaker Right Solenoid, -ve Grab Rotate Left Solenoid, -ve Grab Rotate Right Solenoid, -ve Rockbreaker Left, -ve Range Change Solenoid, -ve Brake Inhibit Solenoid, -ve Park Brake Solenoid, -ve Earth Battery -ve Vehicle Chassis Working Lights Supply Grab/Rockbreaker Switch Return Cigar Lighter Lamp Intermittent Wipe Output Continuous Wipe Output Screen Wash Output Axle Lock Axle Lock With Brake Stabiliser, Right Triple Articulation Stabiliser, Left Fog Light Creep Speed Park Brake Range Change
CONTENTS
JS 130W,150W Circuit Diagrams - Electrical (Relay Box P.C.B.)

Key Relays RL1 RL2 RL3 RL4 RL5 RL6 RL7 RL8 RL9 RL10 RL11 RL12 RL13 RL14 RL15 RL16 RL17 RL18 RL19 Test Points P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P20 Auxiliary Stabiliser, Left Stabiliser, Right Triple Articulation Creep Speed Timer Dozer Park Brake Drive Motor Range Change Fog Lights Headlights Intermittent Wipe Sidelights Brake/Axle Lock Continuous Wipe Working Lights Axle Lock Flasher Ignition Function 24V Unswitched 24V Switched Main Beam/Accummulator Low Return Earth Earth from TSP* 'Dozer' Switch Earth from TSP* 'Auxiliary' Switch Sidelights Relay Input Emergency Steer Warning Light Output Earth from TSP* 'Axle Lock/Brake' Switch Earth from TSP* 'Park Brake' Switch Earth from TSP* 'Stabiliser Left' Switch Earth from TSP* 'Range Change' Switch Earth from TSP* 'Fog Light' Switch Earth from TSP* 'Stabiliser Right' Switch Indicator Warning Light Main Beam Warning Light Indicator Warning Light Earth from TSP* 'Axle Lock' Switch Earth from TSP* 'Triple Articulation' Switch Earth from TSP* 'Headlights' Switch Test Points P34 P35 P36 P37 P38 P39 P40 P41 P42 P43 P44 P45 P46 P47 P48 P49 P50 P51 P52 P53 P54 P55 P56 P57 P58 P59 P60 P61 P62 P63 P64 P65 P66 P67 P68 P69 P70 P71 P72 P73 P74 P75 P76 P77 Function Binnacle Switch (to P83) Cigar Lighter (to P69) Relay P.C.B. Switch (to P69) Grab Rotate/Rockbreaker (to P86) Creep (to P75) Drive Motor Range Change (P85) Wiper Supply Ignition ON Signal to Ignition Relay Drive Isolator (to P87) Dozer (to P70) 24V Unswitched, Relay P.C.B. Triple Articulation (to P82) Stabiliser, Left (to P72) Stabiliser, Right (to P73) 24V Switched, from Ignition Switch 'C' Brake Inhibit (to P74) Park Brake (to P71) Right Toggle Switch, N/O Axle Lock (to P84) Sidelights, Right Sidelights, Left Supply to Working Lights Not used 24V Unswitched, Hazard Cigar Lighter Lamp Output 24V Switched, Headlights 24V Switched, Fog Lights 24V Switched, Hazard Switch 24V Switched, Brake Lights 24V Switched, Reverse Lights Screen Wash Output Cigar Lighter Output Continuous Wipe Output 24V Unswitched, Relay P.C.B. 24V Unswitched, Binnacle 24V Switched, Relay P.C.B. Switch 24V Switched, Dozer 24V Switched, Park Brake 24V Switched, Stabiliser Left 24V Switched, Stabiliser Right 24V Switched, Brake Inhibit 24V Switched, Creep Earth, Wash/Wipe Intermittent Wipe Output Test Points P91 P92 P93 P94 P95 P96 P97 P98 P99 P100 P101 P102 P103 P104 P105 P106 P107 P108 P109 P110 P111 P112 P113 P114 P115 P116 P117 P118 P119 P120 P121 P122 P123 P124 P125 P126 P127 P128 P129 P130 P131 P132 P133 P134 Function Axle Lock Solenoid, Return Grab Rotate Left Solenoid Return Stabiliser Right Solenoid, Return Grab Rotate Solenoid Right Return Stabiliser Left Solenoid Return Rockbreaker Left Solenoid Return Rockbreaker Right Solenoid Return Grab Rotate Left Solenoid Feed Grab Rotate Right Solenoid Feed Rockbreaker Left Solenoid Feed Rockbreaker Right Solenoid Feed Gearchange Pressure Switch Supply Range Change Solenoid, Return Brake Inhibit Solenoid Return Park Brake Solenoid Return Park Brake Solenoid Feed Range Change Solenoid Feed Gear Change Pressure Switch Return Brake Inhibit Solenoid Feed Right Brake Light Output Left Brake Light Output Fog Light Left Output Fog Light Right Output Reverse Light Left Output Reverse Light Right Output Sidelight, Rear Right Output Sidelight, Rear Left Output Left Rear Indicator Output Right Rear Indicator Output Earth, Left Rear Light Earth, Right Rear Light Sidelight, Front Right Output Full Beam Output, Right Right Front Indicator Output Dipped Beam Output, Right Earth, Right Front Lights Horn Output Left Toggle Switch, Common Left Toggle Switch, N/O 24V Switched, to Hazard Switch Hazard Switch Lamp 24V Unswitched to Hazard Switch Earth, Hazard Switch Flash Output to Hazard
CONTENTS
JS 130W,150W Circuit Diagrams - Electrical (Relay Box P.C.B.)
CONTENTS
Excavators
45 - 15 - 02/7
JS 130W from m/c no. 716501,160W from m/c no. 718501 Circuit Diagrams - Electrical
Component Key 1 2 3 4 6 7 8 10 11 12 13 14 15 16 17 18 19A 19B 19C 20A 20B 20C 20D 20E 20F 20G 20H 20J 20K 20L 20M 20N 21A 21B 22 23 24 25 26/28 30A 30B 31 32 33 34 35 36 37 38A 38B 38C 38D 39 40A 40B 41 42 43 44 45 46 Cigar Lighter Loudspeaker Radio Aerial Lead Radio (Standard) System Controller (Computer) Fuse Box Switch Panel - Left Hand (Standard) Limit Switch - Lever Lock (Gate) Limit Switch - Lever Lock (Console) Switch - Free Swing (Optional) Horn Push Switch Panel - Right Hand Switch - Speed Change Switch - One Touch Idle Monitor, Controller Driver Push-button - Breaker Pilot Pressure Push-button - Boom Pilot Pressure Push-button - Swing Pilot Pressure Relay - Fan 1 Relay - Fan 2 Relay - Fan 3 Relay - Horn Relay - Horn Volume Relay - Screenwasher Relay - Screenwiper Relay - Lamp (Boom) Relay - Auxiliary Lamps (Optional) Relay - Cab Working Light Relay - Lever Lock Relay - Engine Shutdown 1 Relay - Engine Shutdown 2 Wiper Motor Cab Light Air Conditioning Unit Cab Heater Starter Switch Motor - Engine Shut-down Batteries Fusible Link - Starter Switch/Back-up Fuses Fusible Link - Engine Shut-down Fuse Fusible Link - Fuse Box Relay - Battery Solenoid Valve Free Swing (Optional) Solenoid Valve Block Solenoid Valve - Swing Brake/Swing Lock Alternator Starter Motor Oil Pressure Sensor Oil Filter Pressure Sensor Water Temperature Sensor Engine Speed Sensor Glow Plugs Sensor - Water Temperature Sensor - Hydraulic Oil Temperature Warning Buzzer Air Conditioning - Drier Switch Air Conditioning - Compressor Magnetic Clutch Motor - Screen Washer Relay - Engine Glow Plugs Horn - Loud 47 48 49 50 51 52 53 54 57 58 59 60 61 62 63 64A 64B 64C 65 66 Horn - Standard Working Lights - Cab Mounted Working Lights - Boom Mounted Sensor - Fuel Level Switch - Hydraulic Oil Overheat Switch - Hydraulic Oil Tank Level Switch - Air Filter Blocked Control - Hydraulic Pump Pressure Switch - Upper Pilot Pressure Motor - Engine Throttle Solenoid - Breaker Pilot Pressure (Optional) Pressure Switch - Travel Pilot Pressure Pressure Switch - Angle Sensor (Optional) Controller - Optional Monitor - Optional Angle Sensor - Dipper (Optional) Angle Sensor - Bucket (Optional) Angle Sensor - Boom (Optional) Solenoid (3) - (Optional) Switch - Double (Optional)
Cable Colour Code B W Br P V G O R Y Lg Sb L Gr Black White Brown Pink Violet Green Orange Red Yellow Light Green Sky Blue Blue Grey
9804/1103
45 - 15 - 02/7
Issue 1
CONTENTS CONTENTS
Excavators
45 - 15 - 02/8
JS 130W from m/c no. 716501, JS 160W from m/c no. 718501 Circuit Diagrams - Electrical
*
25 13 18 20 32 29 39 36 11 3 4 5 6 7 14 15 27 16 23 28 30 32A 32B 32C 32D 39A 39C 39B 39E 39F 39G 39D 39K 39H 39J 39L 32E 32F 32G 33 34 35 26 37
12 17 8 19
24
22 2 10
21
31
38
70
40
67
54
56
66
57
41
40A
66A
66C 66E 66B 66D 68A 68B 68C 68D 68E 68F 68G
52
68 43C 43B 43D
55H 55E 55F 59
43E 43F 55G 51 47 50 55 46 50A 50J 55A 55B 63 58 55C 53
43A
43G 43H 43J 43K
43
45
49
50B
50C 50E 50G 50D 50F
50H 61 65
X Y 42 44 48 62 64
9804/1103
45 - 15 - 02/8
Issue 2*
CONTENTS
Excavators
45 - 15 - 02/9
Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Plug 1 Switch Box 1 Park Brake Solenoid Stabiliser Up Solenoid Stabiliser Down Solenoid Stabiliser Right Hand Side Stabiliser Left Hand Side Fuse 3 Plug 2 Switch Box 2 Lamp Box Left Hand Side Front Lights Lamp Box Left Hand Side Rear Lights Lamp Box Arm Sidelights - German Homologation Option Axle Lock Solenoid Dozer Solenoid Fuse 1 Fuse Box Brake Light Switch Fuse 5 Fuse Box Reverse Light Pressure Switch Fuse 6 Plug 3 Switch Box 3 Lamp Box Right Hand Side Front LIghts Lamp Box Right Hand Side Rear Lights Number Plate Lights Number Plate Lights Grab Clockwise Solenoid Grab Counter Clockwise Solenoid Low Flow Priority Valve - Option Fuse 2 Socket 1 Stabiliser Switch Panel A Left Hand Stabiliser Up B OV C Illumination Supply D Back Light Feed E Left Hand Stabiliser Down F Right Hand Stabiliser Up G Right Hand Stabiliser Down Dozer Switch Dozer Switch Hazard Switch Connections to Diagram 1 Horn Switch Socket 2 Column Switch A Continuous Wiper B Intermittent Wiper C Screen Wash D Horn E Earth F Headlight Return G Headlight In H Headlight Flash J Indicator Left K Indicator Right L Indicator Return Plug 4, Axle Lock with Brakes Signal Low Accumulator Pressure Switch 42 43 44 45 46 47 48 49 50 Battery Isolator (Item 32 on Diagram 1) X and Y indicate connection points to Diagram 1. Fuse Box Connections to Item 6 on Diagram 1 (CN6) Gear Change Solenoid P2 Solenoid Valve P1 Solenoid Valve Connections to Item 6 on Diagram 1 (CN5) Travel Pressure Switch Connections to Diagram 1 A Computer Control Fuse in Item 7 B Item 14 (CN14) C Item 20F D Item 20G E Item 20K F Item 20H G Item 14 on Diagram 1 (CN14) H Item 8 on Diagram 1 (CN11) J Item 14 on Diagram 1 (CN12) Grab Counter Clockwise Switch - Right Hand Control Machine Ignition Switch Grab Clockwise Switch - Right Hand Control Socket 3 Connections to Diagram 1 A Item 6 (CN3) B Item 6 (CN7) C Item 6 (CN5) E Item 6 (CN2) F Item 6 (CN5) G Item 6 (CN5) H Item 6 (CN5) Socket 4 Main Frame Earth Left Hand Hand Control Switch Hammer Relay 1 Reverse Lights Press Switch Hammer Solenoid Drive Isolator Relay Drive Isolator Switch Drive Isolator Solenoid Status Monitor A Main Beam B Indicators/Hazard C Low Accumulator Warning Light D Emergency Steer Warning Light E Dozer Select Plug 5 Sub Monitor A Headlights B Sidelights C Fog Light D Park Brake E Axle Lock with Brakes F Axle Lock G Creep Speed Wheel Controller
51 52 53 54 55
33 34 35 36 37 38 39
56 57 58 59 61 62 63 64 65 66
67 68
70
40 40A 41
9804/1103
45 - 15 - 02/9
Issue 1
CONTENTS
Excavators
45 - 15 - 02/10
Cable Colour Code R BL G Y W BK Red Blue Green Yellow White Black V O P T GY BN Violet Orange Pink Torquoise Grey Brown
9804/1103
45 - 15 - 02/10
Issue 1
CONTENTS
JS 70 (Standard Boom to m/c 695001) Circuit Diagrams - Hydraulic
CONTENTS
Excavators
45 - 15 - 02/11A
JS 130 from m/c no. 758000, JS 160 from m/c no. 702000 Circuit Diagrams - Electrical Main Components
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19A 19B 19C 20A 20B 20C 20D 20E 20F 20G 20H 20J 20K 20L 20M 20N 21 22 23 24 25 26/28 27/29 30A 30B 31 32 33 34 35 36 40A 40B 41 42 43 44 45 46 47 48 Cigar Lighter Loudspeaker Radio Aerial Lead Radio (Standard) Radio (AM/FM) (Optional) System Controller (Computer) Fuse Box Switch Panel - Left Hand (Standard) Switch Panel - Left Hand (Optional) Limit Switch - Lever Lock (Gate) Limit Switch - Lever Lock (Console) Switch - Free Swing (Optional) Horn Push Switch Panel - Right Hand Switch - Speed Change Switch - One Touch Idle Monitor, Controller Driver Push-button - Breaker Pilot Pressure Push-button - Boom Pilot Pressure Push-button - Swing Pilot Pressure Relay - Fan 1 Relay - Fan 2 Relay - Fan 3 Relay - Horn Relay - Horn volume Relay - Screen Washer Relay - Screen Wiper Relay - Lamp (Boom) Relay - Auxiliary Lamps (Optional) Relay - Cab Light Relay - Lever Lock Relay - Engine Shutdown 1 Relay - Engine shutdown 2 Indicator Lamp-wiper Motor Air Conditioning Unit Cab Heater Starter Switch Motor - Engine Shut-down Batteries - Standard Batteries - Heavy Duty (Optional) Fusible Link - Starter Switch/Back-up Fuses Fusible Link - Engine Shut-down Fuse Fusible Link - Fuse Box Relay - Battery Solenoid Valve Free Swing (Optional) Solenoid Valve Block Solenoid Valve - Swing Brake/Swing Lock Engine Block Sensor - Water Temperature Sensor - Hydraulic Oil Temperature Warning Buzzer Air Conditioning - Drier Switch Air Conditioning - Compressor Magnetic Clutch Motor - Screen Washer Relay - Engine Glow Plugs Horn - Loud Horn - Standard Working Lights - Cab Mounted 49 50 51 52 53 54 57 58 59 60 61 62 63 64A 64B 64C 65 66 67 Working Lights - Boom Mounted Sensor - Fuel Level Switch - Hydraulic Oil Overheat Switch - Hydraulic Oil Reserve Tank Level Switch - Air Filter Blocked Control - Hydraulic Pump Pressure Switch - Upper Pilot Pressure Motor - Engine Throttle Solenoid - Breaker Pilot Pressure (Optional) Pressure Switch - Travel Pilot Pressure Pressure Switch - Angle Sensor (Optional) Controller - Optional Monitor - Optional Angle Sensor - Dipper (Optional) Angle Sensor - Bucket (Optional) Angle Sensor - Boom (Optional) Solenoid (3) - Optional Switch - Double (Optional) Monitor - Optional
9804/1103
45 - 15 - 02/11A
6410 - C/2-3.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 15 - 02/11B
JS 130 from m/c no. 758000, JS 160 from m/c no. 702000 Circuit Diagrams - Electrical
9804/1103
45 - 15 - 02/11B
6410 - C/2-4.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 15 - 02/12
JS 200W from m/c no. 809000 Circuit Diagrams - Electrical Main Components
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 59 Headlamp (RH dip) Headlamp (LH dip) Number Plate Lamp Pressure Switch Coolant Overheat Switch Engine Oil Pressure Switch Refuelling Pump A/C Compressor Washer Heater Assembly Air Conditioning Assembly Battery Work Lamps Fuse Box Relay Oil Temperature Sensor Oil Overheat Switch Changeover Solenoid Valve Stabiliser Solenoid Valve Column Switch Horn Stabiliser Switch Panel Sub Monitor Wheel Controller Status Monitor Harness Harness Harness Harness Harness Controller Assembly Rear Lamp LH Rear Lamp RH Air Filter Switch A/C Pressure Switch Engine Speed Sensor Sensor - Water Temperature Sensor - Hydraulic Oil Temperature Proportional Solenoid Valve Low Flow (Grab) Transmission Valve Solenoid Valve Assembly Low Flow (W/Cut) Amplifier Low Accumulator Pressure Switch Brake Valve Pressure Switch Fuel Level Sensor Resistor Assembly Travel Pilot Pressure Switch Upper Pressure Switch Swing Solenoid Valve Battery Relay Throttle Motor Panel Switch Assembly LH Panel Switch Assembly RH Key Switch Throttle Driver Monitor
9804/1103
45 - 15 - 02/12
6320 - C/2-4.1
Issue 1
CONTENTS
Excavators
45 - 15 - 02/13
JS 200W from m/c no. 809000 Circuit Diagrams - Electrical (contd)
SEE SERVICE MANUAL
9804/1103
45 - 15 - 02/13
6320 - C/2-5.1
Issue 1
CONTENTS
Excavators
45 - 15 - 02/13A
JS 200, 220 from m/c no. 705001 JS 240 from m/c no. 708501 Circuit Diagrams - Electrical Main Components
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19A 19B 19C 20A 20B 20C 20D 20E 20F 20G 20H 20J 20K 20L 20M 20N 21 22 23 24 25 26/28 27/29 30A 30B 31 32 33 34 35 36 40A 40B 41 42 43 44 45 46 47 Cigar Lighter Loudspeaker Radio Aerial Lead Radio (Standard) Radio (AM/FM) (Optional) System Controller (Computer) Fuse Box Switch Panel - Left Hand (Standard) Switch Panel - Left Hand (Optional) Limit Switch - Lever Lock (Gate) Limit Switch - Lever Lock (Console) Switch - Free Swing (Optional) Horn Push Switch Panel - Right Hand Switch - Speed Change Switch - One touch Idle Monitor, Controller Driver Push-button - Breaker Pilot Pressure Push-button - Boom Pilot Pressure Push-button - Swing Pilot Pressure Relay - Fan 1 Relay - Fan 2 Relay - Fan 3 Relay - Horn Relay - Horn Volume Relay - Screenwasher Relay - Screenwiper Relay - Lamp (Boom) Relay - Auxiliary Lamps (Optional) Relay - Cab Light Relay - Lever Lock Relay - Engine Shutdown 1 Relay - Engine Shutdown 2 Indicator Lamp-wiper Motor Air Conditioning Unit Cab Heater Starter Switch Motor - Engine Shut-down Batteries - Standard Batteries - Heavy Duty (Optional) Fusible Link - Starter Switch/Back-up Fuses Fusible Link - Engine Shut-down Fuse Fusible Link - Fuse Box Relay - Battery Solenoid Valve Free Swing (Optional) Solenoid Valve Block Solenoid Valve - Swing Brake/Swing Lock Engine Block Sensor - Water Temperature Sensor - Hydraulic Oil Temperature Warning Buzzer Air Conditioning - Drier Switch Air Conditioning - Compressor Magnetic Clutch Motor - Screen Washer Relay - Engine Glow Plugs Horn - Loud Horn - Standard 48 49 50 51 52 53 54 57 58 59 60 61 62 63 64A 64B 64C 65 66 68 Working Lights - Cab Mounted Working Lights - Boom Mounted Sensor - Fuel Level Switch - Hydraulic Oil Overheat Switch - Hydraulic Oil Reserve Tank Level Switch - Air Filter Blocked Control - Hydraulic Pump Pressure Switch - Upper Pilot Pressure Motor - Engine Throttle Solenoid - Breaker Pilot Pressure (Optional) Pressure Switch - Travel Pilot Pressure Pressure switch - Angle Sensor (Optional) Controller - Optional Monitor - Optional Angle Sensor - Dipper (Optional) Angle Sensor - Bucket (Optional) Angle Sensor - Boom (Optional) Solenoid (3) - Optional Switch - Double (Optional) Monitor (Optional)
9804/1103
45 - 15 - 02/13A
6400 - C/2-3.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 15 - 02/13B
JS 200, 220 from m/c no. 705001 JS 240 from m/c no. 708501 Circuit Diagrams - Electrical (contd)
9804/1103
45 - 15 - 02/13B
6400 - C/2-?.?
Issue 1
CONTENTS
Excavators
45 - 15 - 02/14
JS 330 from m/c no. 712501 Circuit Diagrams - Electrical Main Components - JS330 (CAPS II)
1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 19 20 20A 21A 21B 21C 21D 21E 21F 21G 21J 21K 21L 21M 22 23 24 25 26A 26B 27 29 30 31 32 33 34 35 36 37 38A 38B 39 40 41 42 43 44 45 46 47 48 49 Cigar Lighter Speaker Antenna Cord Radio Set Controller (Computer) Fusebox Switch Panel - L(LH) Switch Switch (Option) Limit Switch (Gate) Limit Switch (Console) Horn Throttle Volume Switch Switch Panel (RH) Travel Switch One Touch Idle Switch Driver Pilot Pressure Switch (Boom Down) Option Relay - Beacon Relay - Boom Light Relay - Cab Light Relay - Windshield wiper Relay - Windshield washer Relay - Horn Relay - Fan 3 Relay - Fan 2 Relay - Fan 1 Relay - Engine Shutdown 1 Relay - Engine shutdown 2 Cab Light/Wiper Motor Air Conditioner (Unit) Starter Switch Battery Fusible Link - Starter Switch/Back-up Fuses Fusible Link - Engine Shut Down Fuse Fusible Link - Main Battery Relay Battery Safety Relay Solenoid Valve Solenoid Valve - Swing Brake/Lock Solenoid Valve Solenoid Valve - High Dump Diesel Engine Diesel Engine Water Temperature Sensor Hydraulic Oil Temperature Sensor Warning buzzer Relay - Heating (Engine Glow Plugs) Washer Tank Compressor Cooler Cooler/Drier Unit Horn (Air) Horn (Standard) Working Light (Cab) Working Light (Boom) Hydraulic Pump Control - Hydraulic Pump 50 51 52 53 54 55 56 57 59 60 61 62 63 64 65 Throttle Motor Fuel Sensor Thermo Switch (Hyd.) Level Switch (Reserve Tank) Air Filter Sensor Pressure Switch (Sump Tank) Pressure Switch (Upper Pilot) Pressure Switch (Travel Pilot) Pilot Pressure Switch (Boom Up) Solenoid Valve (Option) Solenoid Valve (Option) Switch Panel (LH) Switch Panel (RH) (Beacon) Switch (Option) Monitor
9804/1103
45 - 15 - 02/14
6420 - C/2-3.3
Issue 2*
CONTENTS
Excavators
45 - 15 - 02/15
JS 330 from m/c no. 712501 Circuit Diagrams - Electrical (contd)
SEE SERVICE MANUAL
9804/1103
45 - 15 - 02/15
6420 - C/2-4.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 15 - 02/16
JS 450 from m/c no. 714501 Circuit Diagrams - Electrical Main Components
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15A 15B 15C 15D 15E 15F 15G 15H 15J 15K 15L 15M 15N 16 17 18 19 20 21A 21B 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40A 40B 40C 41 42A 42B 43 Cigar Lighter Controller (Computer) Fuse Box Starter Switch Switch Panel (LH) High Dump Switch Limit Switch (Gate) Limit Switch (Console) Switch (Horn) Switch (Throttle Volume) Switch Panel (RH) Travel Switch Switch (One Touch Idle) Monitor Relay - Beacon Relay - Boom Light Relay - Cab Light Relay - Windshield Wiper Relay - Windshield Washer Relay - Horn Volume Relay - Horn Relay - Fan 3 Relay - Fan 2 Relay - Fan 1 Relay - Engine Shutdown 1 Relay - Engine Shutdown 2 Relay - Lever Lock Air conditioner (Unit) Cab Driver Engine Shutdown Motor Batteries Fuse - Key Switch Back-up Fuse - Shutdown Fuse - Main Battery Relay Solenoid Valve Safety Relay Valve (Swing Lock/Brake) Diesel Engine Solenoid Valve - High Dump Cooler/Drier Unit Compressor Cooler Washer Tank Relay - Heating (Engine Glow Plugs) Resistor (Air Heater) Horn (Air) Horn (Standard) Working Light (Cab) Working Light (Boom) Hydraulic Pump Pressure Switch (Upper Pilot) Pressure Switch (Swing Pilot) Pressure Switch (Boom Up) Pressure Switch (Boom Down) Pressure Switch (Travel Pilot) Thermo Sensor (Hyd) Thermo Sensor (Water) Fuel Sensor 44 45 46 47 48 49 Thermo Switch (Hyd) Level Switch (Reserve Tank) Air Filter Sensor Pressure Switch (Sump Tank) Throttle Motor Warning Buzzer
9804/1103
45 - 15 - 02/16
6420 - C/2-5.1
Issue 1
CONTENTS
Excavators
45 - 15 - 01/17
* JS
450 from m/c no. 714501
SEE SERVICE MANUAL
9804/1103
45 - 15 - 01/17
640 - C/-6.1
Issue 1
CONTENTS
Excavators
45 - 15 - 02/18
JS330/JS460 - AMS Circuit Diagrams - Electrical Main Components - JS330/JS460 - AMS

Refer to Service Manual Supplement 9803/6450 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Electronic Control Unit Electronic Monitor System Fascia Switch Panel Fuse Box Assembly Fuse Box Assembly Throttle Dial Key Switch Switch (Limp mode) Air Conditioner Heater Switch Body Switch Cap (Worklamp) Switch Cap (Boom Priority) Cigar Lighter Radio Cassette Limit Switch (Lever) Limit Switch (Console) Switch (Travel Change) Work Lamp Work Lamp Breaker Pilot Switch LH Lever Switch RH Lever Switch Relay (Radio) Relay (Stop Solenoid) Wiper Room Lamp Battery Relay Battery (JS330) Fuse Link (25A) Fuse Link (60A) Stop Solenoid Valve Solenoid Valve Solenoid Engine (JS330) Pilot Switch, Upper Pilot Switch, Travel Pilot Switch Throttle Position Sensor Engine Control Solenoid Travel Alarm Pump (JS330) Refuel Pump A/C Suppression LEad Beacon Air Con Compressor Air Con Binary Switch Horn Washer Pre Heat Relay Temperature Sensor Overheat Switch Fuel Level Sensor Coolant Level Switch Air FIlter Blocked Switch Overload Pressure Switch Electronic Control Unit LH Switch Panel 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 86 88 89 Switch Cap (Road Lamps) Switch Body Switch Cap (Fog Lamps) Switch Cap (Hazards) Column Switch Headlamp (RH Dip) Headlamp (LH Dip) Rear Lamp RH Rear Lamp LH Number Plate Lamp Arm Side Lamp Stabiliser Solenoid Assembly Transmission Valve Grab Rotate Valve Priority Valve Solenoid Valve Breaker Solenoid Valve Dig Isolate Solenoid Dozer Solenoid Valve Transmission Pressure Valve Pressure Switch Low Brake Pressure Switch Connector Switch Body Switch Harness Harness Harness Heater Switch Direction Control Valve Solenoid Valve
9804/1103
45 - 15 - 02/18
6420 - C/2-7.1
Issue 1*
CONTENTS
Excavators
- AMS
45 - 15 - 02/19
* JS330/JS460
Circuit Diagrams - Electrical (contd) Refer to Service Manual Supplement 9803/6450
SEE SERVICE MANUAL
9804/1103
45 - 15 - 02/19
640 - C/-4.2
Issue 1*
CONTENTS
Excavators
45 - 15 - 02/20
JS460 Tier 2 Circuit Diagrams - Electrical

The item numbers in the following list are identified on the wiring schematic. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 38 39 40 41 42 43 44 45 46 47 48 50 51 52 53 54 55 59 86 88 89 Electronic Control Unit (ECU) Electonic Montior System (EMS) Facia Switch Panel Fuse Box Assembly Throttle Dial Key Switch Switch (Redundancy) Air Conditioner Switch ( Air Conditioner) Switch Body (Work Lamp) Switch Cap (Work Lamp) Switch (Boom Priority) Cigar Lighter Radio Limit Switch (Lever) Limit Switch (Console) Switch (Travel Change) Work Lamp Work Lamp Breaker Pilot Switch Left Hand Lever Switch Right Hand Lever Switch Relay (Radio) Relay (Stop Solenoid) Wiper Room Lamp Battery Relay Battery Fuse Link (25A) Fuse Link (60A) Stop Solenoid Solenoid Valve Solenoid Valve Engine Pilot Switch, Upper Pilot Switch, Travel Throttle Position Sensor Engine Control Solenoid Travel Alarm Pump Refuel Pump A/C Suppression Lead Beacon Air Conditioning Compressor Air Conditioning Binary Switch Horn Washer Temperature Sensor Over Heat Switch Fuel Level Sensor Coolant Level Switch Air Filter Blocked Switch Over Load Pressure Switch Switch Body Heater Switch Direction Control Valve Solenoid Valve
9804/1103
45 - 15 - 02/20
6420 - C/2-8.1
Issue 1
25 21 22
5 6 7 8 0.5 BU 8 9 0.5 R 1 C108 C109 0.5 B 0.5 BU 0.5 WR 0.5 BU 0.5 R +12V RADIO SUPPLY 10 0.5 BU 0.5 BU 1 C107 8.5 R +24V IGNITION SUPPLY 0.5 BU 7 0.5 BO 0.5 BU 6 0.5 BO 1 4.5 W +24V BATT SUPPLY 5 0.5 BO
CAB ROOM LAMP ECU-STD,EMS BATT SUPPLY
CAB LH LAMP
CAB RH LAMP
C104
MAIN WIPER
15
C6
RH LEVER SWITCHES
9 10
0.5 BG
C114
M POWER UP SW ONE TOUCH IDLE SW GRAB CW SW GRAB CCW SW
LOCK LEVER SW
LH LEVER SWITCHES
EARTH HEADER 1
FUSE A
2A
15A
15A
15A
10A
10A
FUSE B
20A
10A
20A
15A
10A
2A
HORN S W
DOZER OFF SW
DOZER ON SW
HAM/BOOM PRIORITY SW
C7
32 40
C94
1 2 1 0.5 UG 0.5 B 2 0.5 UR 1 2 0.5 B 1 0.5 RG 0.5 B
- +
28
C56
- +
12V
8.5 W
NO
COM
NC
ALARM TRAVEL
SWING LOCK
0.5 B
0.5 B
1.0 B
0.5 B
1.0 B
0.5 B
0.5 B
0.5 B
1.0 B
C37
1 1 2 2 3 4 1 2 3 4 1 1 1 2 1 2 0.5 SB 2 0.5 OW 0.5 LGW 0.5 UW 5 0.5 UY
S
3 2
23
2 3 4 0.5 UW 1
C
0.5 LGW SWING SHUT OFF SOL V
TRAVEL CHANGE SOL V
HIGH SPEED TRAVEL
12V RADIO RELAY 0.5 OW MAX FLOW CONT SOL V 0.5 B 2
SWING BRAKE
C34
0.5 UY 0.5 UY 2 STAGE RELIEF SOL V
C33 C59
SAFETY RELAY
C32 C55
C171
C31
0.5 BU 0.5 BW 0.5 BU 0.5 UW 0.5 BU 0.5 UG 0.5 BU 0.5 G 0.5 BU 0.5 G 0.5 LGR 0.5 GY 0.5 BY 0.5 UR 0.5 BU 0.5 LGY 0.5 WU
C30
C29
C27
C26
C112
1 0.5 LGW 1
0.5 SB
NEG FLOW SOL V
C58
BOOM PRIORITY
0.5 BO
0.5 BW
0.5 BW
0.5 BW
0.5 BW
0.5 U
0.5 BG
0.5 GR
0.5 LG
0.5 G
0.5 RB
0.5 RY
0.5 GR
0.5 PG
0.5 PU
0.5 NU
0.5 BW
2 STAGE RELIEF
1.0 P
1.0 GB
1.0 N
1.0 RB
1.0 O
1.0 S
1.0 UG
1.0 LG
1.5 G
1.0 RG
0.5 RY
1.0 SR
1.0 R
NEG FLOW CONT
30
86
85
87
87A
1 0.5 YU 13 14 0.5 UB OIL FILTER SW OIL PRESSURE SW MERGED FLOW SOL V 0.5 UW 0.5 B 2 1 0.5 YG 0.5 GB 0.5 YU AIR FILTER SW 0.5 OG 1 0.5 YW RESERVE TANK SW 0.5 BG 2 0.5 SR SOFT/HARD SOL V
C117
0.5 SR 12 0.5 YW 0.5 UB 0.5 YG 0.5 GB 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 0.5 BW 0.5 BG 2.5 W 2.5 R 41 0.5 NW 0.5 B 42 43 44 2 1 45 46 1 47 2 3 4 5 6 0.5 GU AUX 0.5 NW BEACON 0.5 RG LAMP SUPPLY 0.5 RU CWT LAMP 0.5 NB 2 HYD OIL LEVEL 0.5 0 A/C BINARY SW 2 0.5 W A/C COMPRESSOR 0.5 G A/C BINARY SW 1 0.5 GW HORN 0.5 RW TOOLBOX WORKLAMP 0.5 RS BOOM WORKLAMP 0.5 WR ALTERNATOR SIGNAL 0.5 YR WINDOW WASHER 0.5 B 0.5 LG TRAVEL PILOT SW 2 0.5 NY SWING PILOT SW 0.5 OW 1 0.5 OB UPPER PILOT SW 0.5 UO BOOM UP PILOT SW 0.5 B 2 0.5 O BOOM LWR PILOT SW 0.5 UG BOOM PRIORITY SOL V 0.5 SR 1 0.5 NB PUMP PROP SOL V (OUT) 16 15
0.5 SG
4.5 R
12V RADIO 11 0.5 UB SWING LOCK SOL V 0.5 B 2
C38
0.5 UB
0.5 B
0.5 LG
0.5 R
GROUND
0.5 BW
LEVER LOCK
IGN SUPPLY
0.5 BW
C39
0.5 UG 0.5 O 0.5 UO 0.5 OB
0.5 SB
SWING SHUT OFF
C102
EARTH HEADER 3
0.5 LG
C103
C40
SOFT/ HARD
13
B R1 R2 Acc Br C
THROTTLE VOL DIAL 5 24

0.5 GW 0.5 G 0.5 W 0.5 O 0.5 GW 0.5 RU 8 7 3 2
6
0.5 RW
KEY SWITCH SHUTDOWN RELAY

0.5 RS
59 12
2.0 R
9 10
FACIA SW PANEL
0.5 WR
MAX FLOW CONT
0.5 BW
0.5 BW
0.5 BW
0.5 BW
0.5 BW
0.5 BW
0.5 BW
0.5 BW
0.5 BW
0.5 BW
30
86
85
BEACON
0.5 RG 0.5 BO 0.5 BO 3 0.5 BU 0.5 W 0.5 SG 0.5 SR 0.5 S 0.5 U 0.5 O 4 5 6
1 0.5 G 1 0.5 GU 2 30
CRANK
87
3 44
C22
0.5 NU
0.5 BU
0.5 BW
0.5 RY
0.5 RB
0.5 R
EMERG STOP
EMERG STOP
MRST-E (SPI)
SHLD
SCLK-E (SPI)
MTSR-E (SPI)
GND
IGNITION SUPPLY
GND
GND
IGNIION SUPPLY
REDUNDANCY
GND
BATT SUPPLY
SPARE
PROG (SPARE)
RS 232 RX (SPARE)
RS 232 TX (SPARE)
RS 232 SHIELD (SPARE)
CAN H
CAN L
CAN SHIELD
SHLD
MTSR-E (SPI)
MRST-E (SPI)
SCLK-E (SPI)
0.5 UK
0.5 U
0.5 OG
0.5 RW
0.5 LG
0.5 UG
0.5 B
1.0 B
1.0 B
1.0 P
1.0 PU
1.0 B
0.5 SR
0.5 R
0.5 U
0.5 RW
0.5 UG
0.5 OG
0.5 LG
0.5 P
0.5 RG
0.5 GU
0.5 GB
0.5 WU
0.5 BO
0.5 LGR
0.5 UR
1.0 P
1.0 PU
0.5 YR
0.5 BW
0.5 BG
1.0 PG
PREHEAT
0.5 B
0.5 SR
0.5 P
0.5 R
0.5 U
0.5 G
0.5 B
0.5 U
0.5 R
0.5 RB
0.5 P
0.5 B
0.5 UY
0.5 Y
0.5 P
0.5 P
0.5 RS
0.5 RW
C181
C49
0.5 P
0.5 B
0.5 RS
0.5 RW
0.5 SR
0.5 SR
0.5 NU
1.0 SR
1.0 O
1.0 PU
1.0 RB
1.0 RB
0.5 U
0.5 B
1.0 N
1.0 N
0.5 R
0.5 G
1.0 B
1.0 GB
1.0 GB
0.5 U
0.5 B
0.5 YW
0.5 YG
0.5 GW
0.5 UR
0.5 OB
0.5 YU
0.5 YR
0.5 WR
0.5 SG
0.5 LGR
0.5 RB
0.5 LGY
0.5 GR
0.5 UW
0.5 LG
0.5 UB
0.5 YB
0.5 NW
0.5 S
0.5 UO
0.5 NU
0.5 SB
0.5 PG
0.5 GY
0.5 O
0.5 GU
0.5 UY
0.5 SR
0.5 WY
0.5 U
0.5 PU
0.5 BW
0.5 NY
0.5 BY
0.5 Y
0.5 WG
0.5 RY
1.0 S
0.5 R
1.0 SR
1.0 B
0.5 OW
0.5 NB
0.5 UB
0.5 UR
0.5 RB
0.5 RY
0.5 LGW
0.5 YR
0.5 B
0.5 B
0.5 SG
0.5 UG
0.5 GW
0.5 UW
0.5 GR
0.5 RU
0.5 RW
0.5 R
0.5 NW
0.5 RG
0.5 PS
0.5 SR
0.5 UK
0.5 UY
0.5 K
0.5 YR
0.5 YB
0.5 YU
0.5 Y
0.5 YG
0.5 OG
0.5 SB
0.5 RS
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
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
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
CONNECTOR A C10
CONNECTOR B
CONNECTOR C
C8
C9
0.5 BR
O/P28 SOFT/HARD
O/P22 ENG SHUTDOWN
O/P24 2 STAGE RELIEF
O/P25 QUICK HITCH
O/P36 SPARE
O/P31 SHUTDOWN RELAY
O/P1A SPARE
O/P17 DOZER
O/P18 CW GRAB
O/P19 CCW GRAB
O/P20 LOW FLOW PRI
O/P21 LEVER LOCK
O/P23 NEG FLOW CONT
O/P34 SPARE
O/P29 BOOM LIGHT
I/P15 POWER UP
I/P28 BOOM LWR PILOT
I/P13 O/LOAD PRESS
I/P9 STD LAMPS
I/P8 THROTTLE VOL
I/P7 SPARE
SPARE
I/P17 ENG SPEED
I/P32 LEVER LOCK
I/P22 DOZER OFF
I/P16 KEY SW (CRANK)
I/P29 SWING PILOT
I/P14 ONE TOUCH IDLE
I/P10 OPT LAMPS
I/P6 THROTTLE LEVER
I/P5 ENGINE OVERHEAT
I/P3 ALTERNATOR
SUPPLY O/P17-22
SUPPLY O/P23-28
SPARE
RS232 RX
IGN
BATT
SUPPLY O/P13-16
SUPPLY O/P13-16
SPARE
RS232 TX
OV
SPARE
SUPPLY O/P7-12
SUPPLY O/P7-12
CAN Hi
PROG
GND I/P9-14
CAN SLD
SUPPLY O/P1-6
SUPPLY O/P1-6
CAN Lo
CHASSIS
GND I/P7,8,15,16
RS/SPI SHLD
+V REF
I/P20 HAMMER PILOT
I/P36 PREHEAT
I/P34 TRAVEL CHANGE
I/P24 HORN
I/P31 GRAB CCW
I/P27 TRAVEL PILOT
I/P12 OIL FILTER
I/P2 WATER TEMP
I/P1 HYD OIL TEMP
0V REF
I/P19 BOOM UP PILOT
I/P18 BOOM PRI/HAM
I/P33 AIR PRESS
I/P23 DOZER ON
O/P3 MAX FLOW CUT
O/P7 PUMP PROP
O/P8 SWING LOCK 1
O/P9 SWING BRAKE 2
O/P13 CAB LH LIGHT
O/P14 CAB RH LIGHT
O/P15 HIGH SPEED TRAVEL
O/P16 WASHER
GND
GND
O/P2 BOOMSPEED REG
O/P7A SPARE
O/P5 BOOM PRIORITY
O/P6 HORN
O/P11 LOWER WIPER
O/P10 SWING SHUT OFF 3
O/P12 WIPER
O/P33 CWT LIGHT
O/P35 SPARE
O/P30 TOOLBOX LAMP
O/P1 THROTTLE CONT
O/P4 BEACON
O/P26 TRAVEL ALARM
I/P21 LOWER WIPER
I/P37 RES TANK SW
I/P35 ENG OIL PRESS
I/P25 HYD OIL LEVEL
I/P30 GRAB CW
I/P26 UPPER PILOT
I/P11 AIR FILTER
I/P4 FUEL LEVEL
INPUTS
SYSTEM
OUTPUTS
O/P27 BREAKER
O/P32 HEAT RELAY
6420 - C/2-9.1
0.5 OG
0.5 NU
0.5 OG
9804/1103
4 CAB
EARTH HEADER 2
8.5 R
CONTENTS
JS460 Tier 2
MAIN FRAME
25A
19
A1
0.5 BO 0.5 BO 0.5 BO 0.5 BO
EARTH HEADER 4 ECU-STD,EMS, FASCIA IGN SUPPLY ECU-STD O/P 1-6 ECU-STD O/P 7-12 ECU-STD O/P 13-16 ECU-STD O/P 17-22 ECU-STD O/P 23-28 B6 B5 KEW SWITCH
4.5 W 2 8.5 R 4.5 WB 1 2 1
B1 B2 B3 B4 WORK LAMPS, OPT HYDS REFUEL PUMP , AUX, WIPER RADIO, LIGHTER, ROOM LAMP
HEATER/AIR CON, AUTO FAN
1 2 3 4 0.5 BU 4 3 2
A2 A3 A4 A5 A6
26
C92 C5 C105 C91
JOIN CONNECTORS TOGETHER FOR TRACKED MACHINES
29 27 30
60A
0.5 BG
C113
12V
C111
TRAVEL CHANGE SW
17
C57
0.5 UB 0.5 B 2
20
BREAKER PILOT SW
31
0.5 U 2.5 W 2.5 B A B C HOLD PULL
9 10
C1
AUX 1 AUX 2
C36
C35
C115
AUTO FAN
CONNECTOR A
33
C54 ISUZU ENGINE

60 B B
E N G STO P SOLENOID
C172
0.5 WR 0.5 BW
R
1
4.5 BW
4.5 BW
14
1 2 3 4 5 6 7 8 9 10 11 12 13 14 0.5 RG
6 7 8 9 10 0.5 UR SWING BRAKE SOL V 0.5 SB 1 0.5 OG

E
C
B
C174
STARTER MOTOR
C173
M
1.0 B 8.5 R 0.5 WR 0.5 BU E B 3 L 2 R 1
34
0.5 RG 0.5 BG LEVER LOCK SOL V (OUT) LEVER LOCK SOL V (RET)
TRAVEL ALARM
0.5 B
C25
0.5 BG 0.5 OG 0.5 UR
C60
C97 C98 C99 C84

0.5 YG 1
C61
0.5 Y
ALTERNATOR
BATT SUPPLY 0.5 NB
0.5 R
C62
49
HEAT RELAY
4.5 R
0.5 B
OIL PRESS
C85
0.5 UB
C63
C159
OIL FILTER
4.5 BW 0.5 BR 0.5 RG 2 1 0.5 RY
0.5 LG
CIGAR
LIGHTER 0.5 LG 0.5 YR
0.5 BW
AIR CONDITIONER BOOM PRIORITY SW
0.5 NY
C64
C86
0.5 YB 0.5 SG 1 2
C162
OVERHEAT SW
C41
50
C101 C87
0.5 WY 0.5 S 1 2
WATER TEMP SENSOR
AUTO IDLE
HEAT OFF IGN C21 C42

0.5 NW 2 0.5 UG 0.5 RG
WIPER
C66
0.5 B 1
41
0.5 RU 0.5 RG
C28
1 2
18
PUMP CONTROL SOL V C'WEIGHT LAMP
4.5 BW
ENG REV SENSOR
C100
WASHER
C43
C80
0.5 G 1
C88
A/C BINARY S W
0.5 0 1
47
0.5 B 1
GLOW PLUG
QUICK HITCH
46
C89
C74
0.5 GW 2
HORN
0.5 NW 0.5 SG
1 2
2
C20
1 0.5 UB
MONITOR (EMS)
50 38
C81
ISOLATOR
18
C166
BEACON
C163 C67
0.5 SG 0.5 WG 0.5 S 1 2 3 0.5 RG 0.5 RW 0.5 RG 1 2 0.5 NW 1
HYD OIL TEMP SENSOR
CUSHION
TOOLBOX LAMP
0.5 SG
HYD OIL OVERHEAT SW
51
C82
1 0.5 RS 2
O/LOAD
1 0.5 UB 0.5 UO 0.5 UW 1.0 UG 0.5 SG C D E F G H 0.5 BU 0.5 BW 0.5 YB 0.5 UB 0.5 WY 0.5 RY 0.5 SG 0.5 YR 0.5 NW 8 7 6 5 4 3 2 1 J K L M N P R 0.5 K 0.5 GU 0.5 G S T U V 2.5 R 2.5 W W 1 2 3.0 B 3 4 0.5 U B A 0.5 U 0.5 SG 0.5 S 0.5 R 0.5 R 2 3 4
C19 C2
CONNECTOR B
C23
48
18
C68
THROTTLE POSITION SENSOR BOOM LAMP
C75
0.5 YR 1
FUEL SENSOR
ENG CONT SOL (OUT) 0.5 S 2
SLEW BRAKE
ENG SHUT DOWN THROTTLE LEVER +V REF SENSOR 0V REF HAMMER PILOT SW 0.5 WG 0.5 BR 0.5 BU 0.5 BW 0.5 YB 0.5 WY 0.5 RY 0.5 SG 0.5 YR 0.5 NW 0.5 K 0.5 GU 0.5 G THROTTLE LEVER SIG HEAT RELAY KEY SW - BATT RELAY STARTER RELAY WATER TEMP SENSOR ENG REV SENSOR ENGINE OVERHEAT SENSOR +V REF FUEL SENSOR OIL TEMP SENSOR QUICK HITCH OVERLOAD FUEL PUMP 0.5 B 0.5 GU
C76
0.5 R 1 2 0.5 B
52 39
C79
0.5 YR 0.5 B 1 2
EMERG STOP
M
C118
0.5 S 0.5 UR 0.5 WG 0.5 BR
WASHER
48
M
C110
0.5 YW 0.5 B
1 2
RESERVE TANK LSW
53
C77
0.5 YU 1
C18
1 2 0.5 U
ENGINE CONTROL SOLV
0.5 B
AIR FILTER
54
7
5
A/C SW
4
18 17 16 15 14 13 12 11 10 9
9
6 7 8
C14 C17
A/C IND
2 0.5 U 1 0.5 UG
C15 C160
REDUNDANCY SW
C93
1 2 3 4
OPT HYDS SWITCH (SEE 2/2)
86
LAMP
55
0.5 OB 0.5 B STOP SOL SUPPLY 2.5 R 2.5 W STOP SOLENOID 0.5 LG 3.0 B EARTH
C69
1 2
35
OVERLOAD PRESSURE SW UPPER PILOT P SW
C90
0.5 W
A/C COMP
45 36
C70
1 0.5 B 2
OFF
2 DIAGNOSTIC CONNECTOR
43
C72
0.5 K 1
BLOWER SWITCH
C161
1 2 3 4 5 6 7 8
LO
ME C11
HI C13
C164
1 2
C157
0.5 B 2
C116
QUICK HITCH REFUEL PUMP
TRAVEL PILOT P SW
0.5 O 0.5 B
1 2
C71 C83 C4
0.5 YB 0.5 YU 0.5 Y 0.5 YG 0.5 PS 0.5 LG 1 2 3 4 5 6 0.5 G
BOOM LWR P I LOT P SW
37 42
M
0.5 UO 0.5 B 1 2
C16
0.5 UO
C73
0.5 NY 0.5 B 1 2
0.5 UB
0.5 UW
BOOM UP P I LOT P SW
SWING PILOT P SW
37
Excavators
45 - 15 - 02/21
1.0 P 0.5 BW
11 10
WORKLAMP SW
C180
0.5 P
0.5 SR
0.5 P
0.5 PU
0.5 SR
C24 C156
0.5 B
0.5 PU
0.5 R
0.5 B
0.5 UK
C155
0.5 U
0.5 R
0.5 U
0.5 U
0.5 UK 1 0.5 U 2 3 0.5 R
0.5 U
0.5 UW
0.5 UK
C12
0.5 UB
10
0.5 UW
0.5 UO
11
0.5 UB
0.5 UY
12
0.5 UO
0.5 Y
13
0.5 UY
14
0.5 Y
CAN LINK
A408460
45 - 15 - 02/21
Issue 1
CONTENTS CONTENTS
Excavators
45 - 20 - 01/2
JS 70 (Standard Boom to m/c 695001) Circuit Diagrams - Hydraulic

Component Key M P1 P2 1 2 3 4 5 6 7 8 9 9A 9B 9C 9D 9E 9F 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Engine Main pump elements Servo pump element Blade rams Track motors Rotary coupling Swing gearbox Swing motor Boom ram Boom holding valve Bucket ram Control valve Swing motor spool Dipper spools Boom spools Bucket spool Blade spool Track motor spools Return manifold Dipper ram Attachment control valve Oil cooler Tank air breather Servo hand control valves Return filter Hydraulic tank Relief valve Suction strainer Pressure switches Selector valve Manifold Solenoid valve block Accumulator Line filter Hydraulic pump Boom servo cushion valves Dipper servo cushion valve
9804/1103
45 - 20 - 01/2
Issue 1
CONTENTS
JS 70 (Offset Boom to m/c 695001) Circuit Diagrams - Hydraulic
CONTENTS
Excavators
45 - 20 - 01/4
JS 70 (Offset Boom to m/c 695001) Circuit Diagrams - Hydraulic

Component Key M P1 P2 1 2 3 4 5 6 7 8 9 9A 9B 9C 9D 9E 9F 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Engine Main pump elements Servo pump element Blade rams Track motors Rotary coupling Swing gearbox Swing motor Boom ram Boom holding valve Bucket ram Control valve Swing motor spool Dipper spools Boom spools Bucket spool Blade spool Track motor spools Return manifold Dipper ram Offset boom control valve Oil cooler Tank air breather Servo hand control valves Return filter Hydraulic tank Relief valve Suction strainer Pressure switches Selector valve Manifold Solenoid valve block Accumulator Line filter Hydraulic pump Boom offset check valves Offset boom ram
9804/1103
45 - 20 - 01/4
Issue 1
CONTENTS
Excavators
45 - 20 - 01/5
* JS
70 (Standard Boom from m/c 695002 to m/c 695500)
Circuit Diagrams - Hydraulic
9804/1103
45 - 20 - 01/5
Issue 2*
CONTENTS
* JS
Excavators
45 - 20 - 01/6
70 (Standard Boom from Machine No. 695002 to Machine No. 695500)

Component Key M P1 P2 P3 1 2 2A 2B 2C 2D 2E 2F 3 4 5 5A 5B 6 7 8 9 9A 9B 9C 9D 9E 9F 9G 9H 9J 9K 9L 9M 9N 9P 9R 9S 10 11 12 12A 13 14 15 16 17 18 19 20 21 22 22A 22B 22C 22D 22E 23 24 25 Engine No. 1 pump element No. 2 pump element Servo pump element Blade rams Track motors Counterbalance spool Brake release piston Brake release valve Cross line relief valves Speed selection spool Speed actuator Rotary coupling Swing gearbox Swing motor Cross line relief valves Counterbalance spool Boom ram Boom holding valve Bucket ram Control valve Swing motor spool Dipper spools Boom spools Bucket spool Blade spool Track motor spools MRV Blade rod side ARV Blade head side ARV Dipper rod side ARV Dipper head side ARV Boom rod side ARV Boom head side ARV Bucket rod side ARV Bucket head side ARV Straight ahead track valve Return manifold Dipper ram Attachments control valve Attachments relief valves Oil cooler Tank air breather Servo hand control valves Return filter (10) Hydraulic tank Filter by-pass relief valve (1.03 bar/14.9 lb in2) Suction strainer (150 Mesh) Pressure switches Manifold Solenoid valve block Servo relief valve Quick-heat valve Servo isolator solenoid Two speed tracking solenoid Swing brake solenoid Accumulator Line filter (10) Hydraulic pump 25A 25B 25C 26 27 28 29 30 Control piston Control spool Summator spool Boom servo cushion valves Dipper servo cushion valve Servo track control RH Servo track control LH Servo blade control
9804/1103
45 - 20 - 01/6
Issue 3*
CONTENTS
Excavators
JS 70 (Standard Boom from Machine No. 695002) Circuit Diagrams - Hydraulic

Component Key M P1 P2 P3 1 2 2A 2B 2C 2D 2E 2F 3 4 5 5A 5B 6 7 8 9 9A 9B 9C 9D 9E 9F 9G 9H 9J 9K 9L 9M 9N 9P 9R 9S 10 11 * 12 * 12A 13 14 15 16 17 18 19 20 21 22 22A 22B 22C 22D 22E 23 24 25 25A Engine No. 1 pump element No. 2 pump element Servo pump element Blade rams Track motors Counterbalance spool Brake release piston Brake release valve Cross line relief valves Speed selection spool Speed actuator Rotary coupling Swing gearbox Swing motor Cross line relief valves Counterbalance spool Boom ram Boom holding valve Bucket ram Control valve Swing motor spool Dipper spools Boom spools Bucket spool Blade spool Track motor spools MRV Blade rod side ARV Blade head side ARV Dipper rod side ARV Dipper head side ARV Boom rod side ARV Boom head side ARV Bucket rod side ARV Bucket head side ARV Straight ahead track valve Return manifold Dipper ram Attachments control valve Attachments relief valves Oil cooler Tank air breather Servo hand control valves Return filter (10) Hydraulic tank Filter by-pass relief valve (1.03 bar/14.9 lb in2) Suction strainer (150 Mesh) Pressure switches Manifold Solenoid valve block Servo relief valve Quick-heat valve Servo isolator solenoid Two speed tracking solenoid Swing brake solenoid Accumulator Line filter (10) Hydraulic pump Control piston 25B 25C 26 27 28 29 30 Control spool Summator spool Boom servo cushion valves Dipper servo cushion valve Servo track control RH Servo track control LH Servo blade control
9804/1103
45 - 20 - 01/6
Issue 2*
CONTENTS
* JS
Excavators
45 - 20 - 01/7
70 (Offset Boom from m/c 695002 to m/c 695500)
9804/1103
45 - 20 - 01/7
Issue 3*
CONTENTS
* JS70
Excavators
45 - 20 - 01/8
Circuit Diagrams - Hydraulic (Offset Boom from Machine No. 695002 to 695028) (from machine No. 695029 to 695500, see Note)
Component Key M P1 P2 P3 1 2 2A 2B 2C 2D 2E 2F 3 4 5 5A 5B 6 7 8 9 9A 9B 9C 9D 9E 9F 9G 9H 9J 9K 9L 9M 9N 9P 9R 9S 10 11 12 12A 13 14 15 16 17 18 19 20 21 22 22A 22B 22C 22D 22E 23 24 25 Engine No. 1 pump element No. 2 pump element Servo pump element Blade rams Track motors Counterbalance spool Brake release piston Brake release valve Cross line relief valves Speed selection spool Speed actuator Rotary coupling Swing gearbox Swing motor Cross line relief valves Counterbalance spool Boom ram Boom holding valve Bucket ram Control valve Swing motor spool Dipper spools Boom spools Bucket spool Blade spool Track motor spools MRV Blade rod side ARV Blade head side ARV Dipper rod side ARV Dipper head side ARV Boom rod side ARV Boom head side ARV Bucket rod side ARV Bucket head side ARV Straight ahead track valve Return manifold Dipper ram Offset boom control valve Offset boom, ARV's Oil cooler Tank air breather Servo hand control valves Return filter (10) Hydraulic tank Filter by-pass relief valve (1.03 bar/14.9 lb in2) Suction strainer (150 Mesh) Pressure switches Manifold Solenoid valve block Servo relief valve Quick-heat valve Servo isolator solenoid Two speed tracking solenoid Swing brake solenoid Accumulator Line filter (10) Hydraulic pump 25A 25B 25C 26 27 28 29 30 Control piston Control spool Summator spool Boom offset check valves (see Note) Offset boom ram Servo track control RH Servo track control LH Servo blade control
* Note: Machines from serial no. 695029 to 695500 are fitted with a different Offset Boom Control Valve (item 12) to earlier machines. The replacement Control Valve incorporates a different metering arrangement with the result that these machines are not fitted with Boom Offset Check Valves (item 26).
9804/1103
45 - 20 - 01/8
Issue 3*
CONTENTS
Excavators
45 - 20 - 01/8A
JS 70 from m/c no. 695501 Circuit Diagrams - Hydraulic
9804/1103
45 - 20 - 01/8A
6020 - E/3-2.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 20 - 01/8B
JS 70 from m/c no. 695501 Circuit Diagrams - Hydraulic (contd)

Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Blade Ram (Left) Blade Ram (Right) Traction Motor Rotary Coupling Line Filter Slew Motor Filter Radiator Control Valve Return Manifold Relief Valve Control Valve Stop Valve Relief Valve Manifold Line Filter Oil Tank Air Breather Relief Valve Return Filter Strainer Pressure Switch Cushion Valve Cushion Valve Cushion Valve Manifold Remote Control Valve Filter Remote Control Valve Remote Control Valve Valve Accumulator Line Filter Flat Flange Hydraulic Pump Bucket Ram Boom Ram Dipper Ram
9804/1103
45 - 20 - 01/8B
6020 - E/3-1.1
Issue 1
CONTENTS
JS 110 (To m/c 697013) & JS 130 (To m/c 699036) Circuit Diagrams - Hydraulic
@@
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O@K? ?@@? @@@@@? ?@@@1? ?@@@ @@ ?@@@ ?J@@@6?26?2@@@@@@@6?2@@@he@@@?eO2@@ @@@? ?@@@ @@@? ?@@5 @? W2@@@@@@@@@@@@@@@@g?@@@@@@@@@ ?@@? @@@@@? O2@@@@@L ?@@@ @@ ?@@@1? W&@@@@@@@@@@@@@@@@@@@@@@he@@@@@@@@@@ @@@? ?@@@ @@@? ?@@H @? @@@@@?7@@@@@@@@@@@@@@@@@g?@@@@@@@@@ @@@@@@@@@@@@@?g@@@@@@6Xf?@@? ?O2@@@@@@@@@f?@@@@@@@@@@@@?f?O2@@@@@@@@@gO26Kh@@@?e?@@@@@@@g@@@@@@@@@@@?f@@@@@@@@@1 ?@@@ @@ ?@@@@? 7@@@@@@@@@@@@@@@@@@@@@@@he@@@@@@@@@@ @@@? ?@@@ @@@? ?@@? @? @@@@@?@@@@@@@@@@@@@@@@@@g?@@@@@@@@@@@@@g?'@@@@@@@@@@@@(?g@@@@@@@@@@@@@?g@@@@@@@1f?@@?f@@@@@@@?f@@@@@@@@@@@@f?@@@@@@@@@@@@?f@@@@@@@@@@@@f?@@@@@@@g@@@?e?@@@@@@@g@@@@@@@@@@@?f@@@@@@@@@@ ?@@@ @@ ?@@@5? @Y@@0?4@@@@@@@@@@@@@@@@@he@@@@@@@@@@ @@@? ?@@@ @@@? ?@@? ?O2@@?hf@@@@@@@@@@@@@?3@@@@@(M ?V4@@@@@@@@@@0Y? @@@@f?@@?f@@@@h?I4@@@@@@@@@f?@@@@@@@@@@@@?f@@@@@@@@@@@@f?@@@@@@@W@e@@@@@?e?@@@@@@@g@@@@@@@@@@@?f@@@@@@@@@5 ?@@@ @@ ?@@@H? @?h?@@@@?f@@he@@@?e?@@@ @@@? ?@@@ @@@? ?@@? @@@@@@@@@@@@@@@@@@@@@?g@@@@@@@0M?fN@@@@@H? @@@@f?@@?f@@@5 ?I'@@@@@e@@@@@??@@@@@ @@@@@@@H ?@@@ @@ ?@@@ @?h?@@@@?f@@he@@@?e?@@@ @@@? ?@@@ @@@? ?@@? @@@@@@@@@@@@@@@@@@@? ?@@@@5 @@f?@@?f@@0Y N@@@@@L?@@@@@?J@@@@@ 3@@@@@5? ?@@@ @@ ?@@@ @?h?@@@5?f@@he@@5?f?@ @@@? ?@@@ @@@? ?@@? @@@@@@@@@@@@@@@@@@@? ?@@@(Y @@@@?@@@@?e@@@? ?@@@@@)X@@@@@W&@@(M? ?@@@@0Y? ?@@@ @@ ?@@@ @?h?@@@H? @0Y?f?@ @@@? ?@@@ @@@? ?@@? @@he@@@? ?@@@H? 3@@@?@@@@?e@@@? I'@@@@@@@@@@@@@H 7@@@ ?@@@ ?J@@ ?@@@ @?h?@@@ ?@ @@@? ?@@@ @@@? ?@@? @@@@he@@@? ?@@@ V'@@@@@@@@@@@@5? ?N@@@@@@@@@@@@@? @@@5 ?@@@ ?@@@ ?@@@ @?h?@@@ ?@ @@@? ?@@@ @@@? ?@@? @@@@he@@@? ?@@@ ?N@@@@@@@@@@@@H? @?'@@@@@@@(M @@@H ?@@@ ?N@@ ?@@@ ?@@@ ?@ @@@? ?@@@ @@@? ?@@?he?@@@@@@@@@@@@?f@@@? ?@@@ @@@@@@@@@@@@ V'@@@@@(Y? @@@@@? ?@@@ @@ ?@@@ W2@?h?@@@ ?@ @@@? ?@@@ ?@@?he?@@@@@@@@@@?g@@@? ?@@@ ?I'@@@@@0M ?N@@@@@H @@@? ?@@@ @@ ?@@@ 7@@?h?@@@L? ?@ @@@? ?@@@ ?@@?he?@@@@@@@@@@?g@@@? ?@@@ V4@@@? @@@@@? ?J@@5? ?@@@ @@ ?@@@ @@@?hJ@@@1? O@K?g?@ @@@? ?@@@ ?@@?he?@@@@@@@@@@?g@@@? ?@@@ ?@@? @@@? W&@@H? ?@@@ @@ ?@@@ @@@?h7@@@@?hf?@@@@@@@e?@@@ @@@? ?@@@ ?@@?he?@@@@@@@@@@?g@@@? ?@@@ ?@@? @@@? 7@@@ ?@@@
W2@@
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CONTENTS CONTENTS
Excavators
45 - 20 - 01/10
JS 110 (To m/c 697013) & JS 130 (To m/c 699036) Circuit Diagrams - Hydraulic
Component Key P1 P2 P3 M 1 2 2A 3 4 5 6 6A 6B 6C 6D 6E 7 8 9 10 11 11A 11B 11C 11D 11E 11F 11G 11H 11J 11K 11L 11M 11N 11O 11P 11R 11S 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Front Pump Element Rear Pump Element Servo Pump Engine Swing Park Brake Solenoid Valve Swing Motor Cross Line Relief Valves Dipper Ram Free Swing Restrictor Free Swing Solenoid Valve Track Motor LH Counterbalance Spool Cross Line Relief Valves Brake Release Piston Speed Selector Spool Speed Actuator Rotary Coupling Track Motor RH Bucket Ram Boom Rams Control Valve Main Relief Valve Track Spools Boom Spool Bucket Spool Dipper Boost Spool Dipper Spool Swing Spool Boom Boost Spool Straight Ahead Track Valve Boom Rod Side ARV Boom Head Side ARV Bucket Head Side ARV Bucket Rod Side ARV Dipper Rod Side ARV Dipper Head Side ARV Negative Control Pressure Relief Valves Swing Priority Valve Shuttle Valve Swing Brake Release Pressure Switch Cooler Cooler Check Valve (0.49 bar, 7.1 lb. in2) Breather Cooler Check Valve (2.9 bar, 42.7 lb. in2) Return Filter (10) Filter By-pass Relief Valve (0.98 bar, 14.2 lb. in2) Suction Strainer (150 ) Hydraulic Tank Drain Line Filter (10) Servo Hand Control Valve LH Servo Hand Control Valve RH Warm Up Filter (100 x 800 Mesh) Warm Up Restrictor Cushion Valve Solenoid Cushion Valve Servo/Drain Manifold Accumulator 31 32 33 34 35 36 36A 36B 36C 36D 36E 37 38 Servo Isolator Solenoid Valve Check Valve Servo Filter (10) Boom Holding Valve Auxiliary Control Valve Hydraulic Pump Proportional Solenoid Valve Swing Pump Control Summator Assembly Pump Control Spool Pump Control Actuators Servo Pump Relief Valve Speed Change Solenoid
Note: To aid the clarity of the diagram, some servo lines have been omitted. To assist in tracing these lines, an identification letter has been included where the line terminates, e.g. f. The component to which the line connects has been added after the letter, e.g. f(28). Therefore, reference f(28) means that the line connects to line f on component 28, the cushion valve.
9804/1103
45 - 20 - 01/10
Issue 1
CONTENTS
JS 110 (From m/c 697014) & JS 130 (From m/c 699037) Circuit Diagrams - Hydraulic
CONTENTS CONTENTS
Excavators
45 - 20 - 01/12
JS 110 (From m/c 697014) & JS 130 (From m/c 699037) Circuit Diagrams - Hydraulic
Component Key P1 P2 P3 M 1 2 2A 3 4 5 6 6A 6B 6C 6D 6E 7 8 9 10 11 11A 11B 11C 11D 11E 11F 11G 11H 11J 11K 11L 11M 11N 11O 11P 11R 11S 12 13 14 15 16 17 18 19 20 21 22 22A 23 24 25 26 27 28 29 30 Front Pump Element Rear Pump Element Servo Pump Engine Swing Park Brake Solenoid Valve Swing Motor Cross Line Relief Valves Dipper Ram Free Swing Restrictor Free Swing Solenoid Valve Track Motor LH Counterbalance Spool Cross Line Relief Valves Brake Release Piston Speed Selector Spool Speed Actuator Rotary Coupling Track Motor RH Bucket Ram Boom Rams Control Valve Main Relief Valve Track Spools Boom Spool Bucket Spool Dipper Boost Spool Dipper Spool Swing Spool Boom Boost Spool Straight Ahead Track Valve Boom Rod Side ARV Boom Head Side ARV Bucket Head Side ARV Bucket Rod Side ARV Dipper Rod Side ARV Dipper Head Side ARV Negative Control Pressure Relief Valves Swing Priority Valve Shuttle Valve Swing Brake Release Pressure Switch Cooler Cooler Check Valve (0.49 bar/7.1 lb in2) Breather Cooler Check Valve (2.9 bar/42.7 lb in2) Return Filter (10) Filter By-pass Relief Valve (0.98 bar/14.2 lb in2) Suction Strainer (150 ) Hydraulic Tank Drain Line Filter (10) Filter By-pass Relief Valve (0.6 bar/8.5 lb in2) Servo Hand Control Valve LH Servo Hand Control Valve RH Warm Up Filter (100 x 800 Mesh) Warm Up Restrictor Cushion Valve Solenoid Cushion Valve Servo/Drain Manifold Accumulator 31 32 33 33A 34 35 35A 35B 36 36A 36B 36C 36D 36E 37 38 39 40 41 Servo Isolator Solenoid Valve Check Valve (0.4 bar/5.7 lb in2) Servo Filter (10) Filter By-pass Relief Valve (1.0 bar/14.9 lb in2) Boom Holding Valve Auxiliary Control Valve Auxiliary Service ARV's Auxiliary Control Valve MRV Hydraulic Pump Proportional Solenoid Valve Swing Pump Control Summator Assembly Pump Control Spool Pump Control Actuators Servo Pump Relief Valve (39.2 bar/568.8 lb in2) Speed Change Solenoid Servo Track Control RH Servo Track Control LH Servo/Drain Manifold
Note: To aid the clarity of the diagram, some servo lines have been omitted. To assist in tracing these lines, an identification letter has been included where the line terminates, e.g. f. The component to which the line connects has been added after the letter, e.g. f(28). Therefore, reference f(28) means that the line connects to line f on component 28, the cushion valve.
9804/1103
45 - 20 - 01/12
Issue 1
CONTENTS
JS 150LC (To m/c 701044) Circuit Diagrams - Hydraulic
CONTENTS CONTENTS
Excavators
45 - 20 - 01/14

Component Key P1 P2 P3 M 1 2 3 3A 4 5 6 6A 6B 6C 6D 6E 6F 7 8 9 10 11 12 12A 12B 12C 12D 12E 12F 12G 12H 12J 12K 12L 12M 12N 12O 12P 12R 12S 12T 12U 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Front Pump Element Rear Pump Element Servo Pump Engine Swing Park Brake Solenoid Valve Shuttle Valve Swing Motor Cross Line Relief Valves Dipper Ram Dipper Hose Burst Check Valve Track Motor LH Counterbalance Spool Brake Release Piston Brake Release Valve Cross Line Relief Valve Speed Selection Spool Speed Actuator Rotary Coupling Track Motor RH Bucket Ram Boom Rams Boom Hose Burst Check Valves Control Valve Main Relief Valve Track Spools Boom Spool Bucket Spool Dipper Boost Spool Dipper Spool Swing Spool Boom Boost Spool Straight Ahead Track Valve Boom Rod Side ARV Boom Head Side ARV Bucket Rod Side ARV Bucket Head Side ARV Dipper Rod Side ARV Dipper Head Side ARV Swing Left ARV Swing Right ARV Negative Control Pressure Relief Valves Swing Priority Valve Swing Brake Release Pressure Switch Cooler Cooler Check Valve (0.49 bar, 7.1 lb. in2) Breather Cooler Check Valve (3.4 bar, 49.8 lb. in2) Return Filter (10) Filter By-pass Relief Valve (0.98 bar, 14.2 lb. in2) Suction Strainer (150 ) Hydraulic Tank Drain Line Filter (10) Servo Hand Control Valve LH Servo Hand Control Valve RH Warm Up Filter (100 x 800 Mesh) Warm Up Restrictor Cushion Valve Solenoid Cushion Valve Servo/Drain Manifold 30 31 32 33 34 35 35A 35B 35C 35D 35E 36 37 Accumulator Servo Isolator Solenoid Valve Check Valve Servo Filter (10) Auxiliary Control Valve Hydraulic Pump Proportional Solenoid Valve Swing Pump Control Summator Assembly Pump Control Spool Pump Control Actuators Servo Pump Relief Valve Speed Change Solenoid
Note: To aid the clarity of the diagram, some servo lines have been omitted. To assist in tracing these lines, an identification letter has been included where the line terminates, e.g. f. The component to which the line connects has been added after the letter, e.g. f(12). Therefore, reference f(12) means that the line connects to line f on component 12, the control valve.
9804/1103
45 - 20 - 01/14
Issue 1
CONTENTS
JS 150LC (From m/c 701045) Circuit Diagrams - Hydraulic
CONTENTS CONTENTS
Excavators
45 - 20 - 01/16

Component Key P1 P2 P3 M 1 2 3 3A 4 5 6 6A 6B 6C 6D 6E 6F 7 8 9 10 11 12 12A 12B 12C 12D 12E 12F 12G 12H 12J 12K 12L 12M 12N 12O 12P 12R 12S 12T 12U 13 14 15 16 17 18 19 20 21 22 22A 23 24 25 26 27 28 29 Front Pump Element Rear Pump Element Servo Pump Engine Swing Park Brake Solenoid Valve Shuttle Valve Swing Motor Cross Line Relief Valves Dipper Ram Dipper Hose Burst Check Valve Track Motor LH Counterbalance Spool Brake Release Piston Brake Release Valve Cross Line Relief Valve Speed Selection Spool Speed Actuator Rotary Coupling Track Motor RH Bucket Ram Boom Rams Boom Hose Burst Check Valves Control Valve Main Relief Valve Track Spools Boom Spool Bucket Spool Dipper Boost Spool Dipper Spool Swing Spool Boom Boost Spool Straight Ahead Track Valve Boom Rod Side ARV Boom Head Side ARV Bucket Rod Side ARV Bucket Head Side ARV Dipper Rod Side ARV Dipper Head Side ARV Swing Left ARV Swing Right ARV Negative Control Pressure Relief Valves Swing Priority Valve Swing Brake Release Pressure Switch Cooler Cooler Check Valve (0.49 bar, 7.1 lb in2) Breather Cooler Check Valve (3.4 bar, 49.8 lb in2) Return Filter (10) Filter By-pass Relief Valve (0.98 bar, 14.2 lb in2) Suction Strainer (150 ) Hydraulic Tank Drain Line Filter (10) Filter By-pass Relief Valve (0.6 bar/8.5 lb in2) Servo Hand Control Valve LH Servo Hand Control Valve RH Warm Up Filter (100 x 800 Mesh) Warm Up Restrictor Cushion Valve Solenoid Cushion Valve Servo/Drain Manifold 30 31 32 33 33A 34 34A 34B 35 35A 35B 35C 35D 35E 36 37 38 39 40 Accumulator Servo Isolator Solenoid Valve Check Valve (0.4 bar/5.7 lb in2) Servo Filter (10) Filter By-pass Relief Valve (1.03 bar/14.9 lb in2) Auxiliary Control Valve Auxiliary Services ARV's Auxiliary Control Valve MRV Hydraulic Pump Proportional Solenoid Valve Swing Pump Control Summator Assembly Pump Control Spool Pump Control Actuators Servo Pump Relief Valve Speed Change Solenoid Servo Track Control RH Servo Track Control LH Servo/Drain Manifold
Note: To aid the clarity of the diagram, some servo lines have been omitted. To assist in tracing these lines, an identification letter has been included where the line terminates, e.g. f. The component to which the line connects has been added after the letter, e.g. f(12). Therefore, reference f(12) means that the line connects to line f on component 12, the control valve.
9804/1103
45 - 20 - 01/16
Issue 1
CONTENTS
CONTENTS CONTENTS
Excavators
45 - 20 - 01/18

Component Key PS P1 P2 M 1 1A 2 3 3A 4 5 6 7 8 9 9A 9B 9C 9D 9E 10 11 12 13 14 15 15A 15B 15C 15D 15E 15F 15G 15H 15J 15K 15L 15M 15N 15P 15R 15S 15T 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Servo Pump No. 1 Pump Element No. 2 Pump Element Engine Swing Brake Release Solenoid Valve Swing Parking Brake Release Switch Shuttle Valve Swing Motor Cross Line Relief Valves Free Swing Restrictor Free Swing Solenoid Reverse Prevention Valve Dipper Ram Dipper Hose Burst Check Valve Track Motor LH Counterbalance Spool Brake Release Piston Cross Line Relief Valves Speed Selector Control Spool Speed Actuators Track Motor RH Rotary Coupling Bucket Ram Boom Rams Boom Hose Burst Check Valves Control Valves (A & B) Neative Control Pressure Relief Valves Track Left Spool Dipper Spool Swing Spool Track Right Spool Option Spool Bucket Spool Boom Spool Main Relief Valve (A) Main Relief Valve (B) Dipper Rod Side ARV Dipper Head Side ARV Bucket Rod Side ARV Bucket Head Side ARV Boom Head Side ARV Boom Rod Side ARV Logic Valves Restrictor Cooler Cooler Check Valve (0.5 bar/7.25 lb in2) Tank Breather Cooler Check Valve (1.96 bar/28.4 lb in2) Return Filter (10) Filter By-pass Relief Valve (0.98 bar/14.2 lb in2) Suction Strainer Warm Up Filter (100 x 800 Mesh) Hydraulic Tank Drain Filter (10) Servo Hand Control Valve LH Servo Hand Control Valve RH Cushion Valve Cushion Valve Solenoid Valve Servo/Drain Manifold Accumulator 33 34 35 36 36A 37 37A 37B 37C 38 39 Servo Isolator Solenoid Valve Check Valve Servo Filter Boom Down Negative Control Delay Solenoid Valve Boom Down Negative Control Delay Switch Hydraulic Pump Proportional Solenoid Valve Summator Assembly Pump Control (Swing Operation) Servo Pump Relief Valve Speed Change Solenoid Valve
9804/1103
45 - 20 - 01/18
Issue 1
CONTENTS
Excavators
CONTENTS CONTENTS
Excavators
45 - 20 - 01/20

Component Key PS P1 P2 M 1 1A 2 3 3A 4 5 6 7 8 9 9A 9B 9C 9D 9E 10 11 12 13 14 15 15A 15B 15C 15D 15E 15F 15G 15H 15J 15K 15L 15M 15N 15P 15R 15S 15T 16 17 18 19 20 21 22 23 24 25 26 26A 27 28 29 30 Servo Pump No. 1 Pump Element No. 2 Pump Element Engine Swing Brake Release Solenoid Valve Swing Parking Brake Release Switch Shuttle Valve Swing Motor Cross Line Relief Valves Free Swing Restrictor Free Swing Solenoid Reverse Prevention Valve Dipper Ram Dipper Hose Burst Check Valve Track Motor LH Counterbalance Spool Brake Release Piston Cross Line Relief Valves Speed Selector Control Spool Speed Actuators Track Motor RH Rotary Coupling Bucket Ram Boom Rams Boom Hose Burst Check Valves Control Valves (A & B) Neative Control Pressure Relief Valves Track Left Spool Dipper Spool Swing Spool Track Right Spool Option Spool Bucket Spool Boom Spool Main Relief Valve (A) Main Relief Valve (B) Dipper Rod Side ARV Dipper Head Side ARV Bucket Rod Side ARV Bucket Head Side ARV Boom Head Side ARV Boom Rod Side ARV Logic Valves Restrictor Cooler Cooler Check Valve (0.5 bar/7.25 lb in2) Tank Breather Cooler Check Valve (1.96 bar/28.4 lb in2) Return Filter (10) Filter By-pass Relief Valve (0.98 bar/14.2 lb in2) Suction Strainer Warm Up Filter (100 x 800 Mesh) Hydraulic Tank Drain Filter (10) Filter By-pass Relief Valve (0.6 bar/8.5 lb in2) Servo Hand Control Valve LH Servo Hand Control Valve RH Cushion Valve Cushion Valve Solenoid Valve 31 32 33 34 35 35A 36 36A 37 37A 37B 37C 38 39 40 41 42 Servo/Drain Manifold Accumulator Servo Isolator Solenoid Valve Check Valve (0.4 bar/5.7 lb in2) Servo Filter (10) Filter By-pass Relief Valve (1.1 bar/14.9 lb in2) Boom Down Negative Control Delay Solenoid Valve Boom Down Negative Control Delay Switch Hydraulic Pump Proportional Solenoid Valve Summator Assembly Pump Control (Swing Operation) Servo Pump Relief Valve (39 bar/565.5 lb in2) Speed Change Solenoid Valve Servo/Drain Manifold Servo Track Control RH Servo Track Control LH
9804/1103
45 - 20 - 01/20
Issue 1
CONTENTS
JS 240LC Circuit Diagrams - Hydraulic
CONTENTS CONTENTS
Excavators
45 - 20 - 01/22

Component Key PS P1 P2 M 1 2 3 4 4A 4B 4C 4D 4E 4F 4G 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20A 20B 20C 21 22 22A 22B 22C 22D 22E 22F 22G 22H 22J 22K 22L 22M 22N 22P 22R 22S 22T 22U 22V 22W 22X 23 23A 23B Servo Pump No. 1 Pump Element No. 2 Pump Element Engine Speed Change Solenoid Valve Rotary Coupling Track Motor LH Track Motor RH Counterbalance Spool Brake Release Piston Speed Change Spool Brake Release Valve Brake Release Pressure Control Cross Line Relief Valve Speed Actuator Servo Hand Control Valve LH Track Control LH Track Control RH Servo Hand Control Valve RH Hydraulic Swing Lock Valve Swing Brake Release Switch Cushion Valve Solenoid Valve Cushion Valve Dipper Ram Dipper Hose Burst Check Valve Bucket Ram Boom Rams Boom Hose Burst Check Valves Shuttle Valve Swing Brake Release Solenoid Valve Swing Motor Cross Line Relief Valve Swing Brake Release Piston Swing Anti- reversal Valves Free Swing Solenoid Valve Control Valves (A & B) Negative Control Pressure Relief Valves Dipper Boost Spool Option Spool Bucket Spool Boom Spool Track Right Spool Main Relief Valve (A) Dipper Spool Swing Spool Boom Boost Spool Track Left Spool Straight Ahead Track Valve Main Relief Valve (B) Bucket Head Side ARV Bucket Rod Side ARV Boom Rod Side ARV Boom Head Side ARV Dipper Rod Side ARV Dipper Head Side ARV Swing Left ARV Swing Right ARV Hydraulic Pump Negative Control Valves Swing Cut-off Valve 23C 24 25 26 27 28 29 30 31 32 33 34 35 36 Constant Power Valves Cooler Cooler Check Valve (1.96 bar/28.4 lb in2) Restrictor Servo Filter (10) Check Valve Accumulator Servo Isolator Valve Drain Filter (10) Return Filter (10) Filter By-pass Relief Valve (1.47 bar/21.3 lb in2) Suction Strainer (105) Hydraulic Tank Tank Breather
9804/1103
45 - 20 - 01/22
Issue 1
CONTENTS
Excavators
CONTENTS CONTENTS
Excavators
45 - 20 - 01/24

Component Key PS P1 P2 M 1 2 3 3A 3B 3C 3D 3E 3F 4 5 6 7 8 8A 8B 8C 8D 8E 8F 8G 8H 8J 8K 8L 8M 8N 8P 8R 8S 8T 8U 8V 8W 8X 9 10 10A 10B 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Servo Pump No. 1 Pump Element No. 2 Pump Element Engine Dipper Ram Track Motor LH Track Motor RH Counterbalance Spool Cross Line Relief Valves Speed Change Spool Speed Actuator Brake Release Piston Relief Valve Damping Rotary Coupling Bucket Ram Boom Rams Boom Holding Valve Control Valve (A & B) Negative Control Pressure Relief Valves Dipper Boost Spool Bucket Spool Boom Spool Option Spool Track Left Spool Main Relief Valve (A) Dipper Spool Swing Spool Boom Boost Spool Track Right Spool Straight Ahead Track Valve Main Relief Valve (B) Bucket Head Side ARV Bucket Rod Side ARV Boom Rod Side ARV Dipper Head Side ARV Dipper Rod Side ARV Swing Left ARV Swing Right ARV Logic Valve Shuttle Valve Swing Motor Cross Line Relief Valves Swing Brake Release Piston Free Swing Solenoid Valve Servo Foot Control Valve RH Servo Foot Control Valve LH Service Pedal (Optional) Manifold Servo Hand Control Valve LH Servo Hand Control Valve RH Cushion Valve Cushion Valve Solenoid Valve Swing Brake Release Solenoid Valve Speed Change Solenoid Valve Servo Isolator Solenoid Valve Accumulator Check Valve Servo Relief Valve Servo Filter 27 28 29 30 31 31A 31B 31C 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 Restrictor Swing Brake Release Switch Line Filter Restrictor Hydraulic Pump Proportional Solenoid Valve Summator Assembly Pump Control (Swing Operation) Check Valve Drain Valve Air Horn Safety Valve Air Tank Governor Reducing Valve Cooler Check Valve Cooler Check Valve Drain Filter (10) Tank Relief Valve (1.47 bar/21.3 lb in2) Pressure Switch Hydraulic Tank Drain Valve Suction Strainer (150 Mesh) Filter By-pass Relief Valve (1.47 bar/21.3 lb in2) Return Filter (10)
9804/1103
45 - 20 - 01/24
Issue 1
CONTENTS
CONTENTS CONTENTS
Excavators
45 - 20 - 01/26

Component Key PS P1 P2 M 1 2 3 4 5 5A 5B 5C 5D 5E 6 7 8 8A 8B 9 10 11 12 13 13A 13B 13C 13D 13E 13F 13G 13H 13J 13K 13L 13M 13N 13P 13R 13S 13T 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Servo Pump No. 1 Pump Element No. 2 Pump Element Engine Bucket Ram Boom Rams Holding Valve Track Motor RH Track Motor LH Counterbalance Valve Cross Line Relief Valves Speed Change Spool Speed Actuator Brake Release Piston Rotary Coupling Dipper Ram Swing Motor Cross Line Relief Valves Swing Brake Release Piston Shuttle Valve Manifold Free Swing Solenoid Restrictor Control Valve Swing Spool Dipper Spool Boom Boost Spool Option Spool Track Left Spool Pressure Maintenance Valve (Negayive Control) Dipper Boost Spool Boom Spool Bucket Spool Track Right Spool Straight Ahead Track Valve Main Relief valve Dipper Head Side ARV Dipper Rod Side ARV Boom Rod Side ARV Bucket Head Side ARV Bucket Rod Side ARV Servo Foot Control RH Servo Foot Control LH Service Pedal (Optional) Manifold Servo Hand Control RH Servo Hand Control LH Cushion Valve Line Filter Restrictor Cushion Valve Solenoid Valve Speed Change Solenoid Valve Swing Brake Release Solenoid Valve Servo Isolator Solenoid Valve Accumulator Check Valve Servo Relief Valve Servo Filter Swing Brake Release Switch 32 32A 32B 32C 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Hydraulic Pump Proportional Solenoid Valve Summator Assembly Pump Control (Swing Operation) Check Valve Drain Valve Air Horn Safety Valve Air Tank Governor Reducing Valve Cooler Check Valve (1.47 bar/21.3 lb in2) Cooler Check Valve Drain Filter (10) Tank Relief Valve (1.47 bar/21.3 lb in2) Pressure Switch Suction Strainer (150 Mesh) Hydraulic Tank Drain Valve Filter By-pass Relief Valve (1.47 bar/21.3 lb in2) Return Filter (10)
9804/1103
45 - 20 - 01/26
Issue 1
CONTENTS CONTENTS
Excavators
JS 130W (From m/c no. 716501), JS 160W (From m/c no. 718501) Circuit Diagrams - Hydraulic
*
67 1 4 6 8 7 8 68 9 11 11 12 3 2 69 68 69 5 68 25 17 18 56 24 17 16 14 26 17 15 10 13
29 39 28
30 32
31
38 33 34 20 21 17
71
19
35 45 65
36
37
17
B
23 22
27
C D
42 64 48
49 74 76 72
52
46
47
53
A B D A B C
73 43 43 13
44
59
54
57 62 63 61 55 60 55
58
50
66
9804/1103
45 - 20 - 02/1
Issue 2*
CONTENTS
Excavators
45 - 20 - 02/2
* JS
130W (From m/c no. 716501), JS 160W (From m/c no. 718501)

Component Key 1 2 Swing Motor Swing Brake Control: A Swing Lock Solenoid Valve B Swing Brake Solenoid Valve Arm Cylinder Arm Cylinder Hose Burst Check Valve (HBCV) Bucket Cylinder Boom Cylinder (Left) Boom Cylinder (Right) Hose Burst Check Valve - Boom Steering Control Valve and Steering Priority Valve 47 48 49 50 52 Accumulator Servo Control (Foot Operated, TAB) Transmission Control Valve Spool Valve (Servo Controls) Solenoid Valves: A Drive Isolate B Axle Lock 53 Solenoid Valves (Dozer/Stabiliser): A Stabiliser LHS B Stabiliser RHS C Stabiliser Down D Stabiliser Up 54 Rotary Coupling 55 Stabiliser Rams 56 Shuttle Valve 57 Logic Valve 58 Front Axle 59 Axle Lock Rams 60 Drive Motor 61 Transmission 62 Left Hand Dozer Ram 63 Right Hand Dozer Ram #64 Remote Control Valve (Hammer) #65 Control Valve (Hammer) 66 Rear Axle 67 Boom Position Ram (TAB) 68 Hose Burst Check Valve (TAB) 69 Boom Lift Rams #71 In-line Filter 72 Shuttle Valve 73 Dozer/Arm Control Solenoid Valve 74 Pressure Switch 75 Manifold (JS160W) 76 Pilot Shuttle Valve # Overload Warnings Grab Rotate Option Triple Articulated Boom Option Hammer Option Stabiliser Option
3 4 5 6 7 8 9 Unit 10 11 12 13 14 15 16 17 18 19
Brake Valve Accumulators Pressure Switch (Charge Warning) Pressure switch (Brake Light Warning) In-line Filter Manifold Hydraulic Pump Test Point Main Control Valve Solenoid Valves: A Drive B Swing Shut-off C 2 Stage Relief D Cushion Control E Boom Speed Control F Boom Down Delay G Maximum Flow Control H Servo Isolator 20 Accumulator 21 Accumulator 22 Transmission Control Valve: A P1 Flow Limiter B P2 Flow Limiter C Gear Change D Park Brake 23 In-line Filter 24 Pressure Switch (Overload Warning) 25 Pressure Switch 26 Relief Valve 27 Test Point 28 Oil Cooler 29 Return Manifold 30 In-line Filter 31 Nephron Group 32 Air breather 33 Sump Tank 34 Suction Strainer 35 Relief Valve 36 Return Line Filter 37 In-line Filter 38 Check Valve 39 Solenoid Valves: A Grab Lift B Grab Right 42 Servo Control Valve (Bucket/Boom) 43 Pressure Switch (Boom/Swing Control) 44 Shuttle Valve 45 Servo Control Valve (Swing/Arm) 46 Pressure Switch (Transmission Control)
Note: The diagram on page 45-20-02/1 is for the JS130W. The circuit for the JS160W is identical except for the TAB boom option (see page 45-20-02/3).
9804/1103
45 - 20 - 02/2
Issue 2*
CONTENTS
Excavators
45 - 20 - 02/3
JS 160W (From m/c 718501) JS 160W Boom Circuit (TAB Option)

For key see page 45 - 20 - 02/2
9804/1103
45 - 20 - 02/3
Issue 1
CONTENTS
Excavators
45 - 20 - 02/4
JS 130W (From m/c 716501), JS 160W (From m/c 718501) JS 130W and JS160W (Circuit to m/c TBA)
For complete circuit see page 45 - 20 - 02/1.
9804/1103
45 - 20 - 02/4
Issue 1
CONTENTS CONTENTS
Excavators
45 - 20 - 02/4A
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
MOTOR; SLEW RAM; DIPPER VALVE; ASSEMBLY MOTOR; TRACTION ROTARY COUPLING RAM; BUCKET RAM; BOOM (L) RAM; BOOM (R) VALVE; SHUTTLE VALVE; CONTROL VALVE; SOLENOID ORIFICE FILTER; LINE VALVE; CHECK VALVE; CHECK RADIATOR RADIATOR BREATHER; AIR TANK; SUMP FILTER; LINE STRAINER VALVE; RELIEF FILTER; RETURN VALVE; STOP NEPHRON FILTER VALVE; STOP VALVE; CHECK SWITCH; PRESS. VALVE; SOLENOID
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
VALVE; SHUTTLE ACCUMULATOR VALVE; CHECK FILTER; LINE PUMP; HYD VALVE; REMOTE CONT VALVE; REMOTE CONT VALVE; SHUTTLE SWITCH; PRESS VALVE; STOP CUSHION VALVE SWITCH PRESS. VALVE; STOP VALVE; SPL VALVE; RELIEF FILTER; LINE
9804/1103
45 - 20 - 02/4A
6410 - E/3-1.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 20 - 02/4B
9804/1103
45 - 20 - 02/4B
6410 - E/3-2.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 20 - 02/4C
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
VALVE; SHUTTLE ACCUMULATOR VALVE; CHECK FILTER; LINE PUMP; HYD VALVE; REMOTE CONT VALVE; REMOTE CONT VALVE; SHUTTLE SWITCH; PRESS VALVE; STOP CUSHION VALVE SWITCH PRESS. VALVE; STOP VALVE; SPL VALVE; RELIEF FILTER; LINE
9804/1103
45 - 20 - 02/4C
6410 - E/3-4.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 20 - 02/4D
9804/1103
45 - 20 - 02/4D
6410 - E/3-3.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 20 - 02/5
JS 200W from m/c no. 809000 Circuit Diagrams - Hydraulic

Component Key 1 2 3 4 4/1 5 5/2 5/16 6 7 8 8/3 8/4 9 10 11 12 13 13/5 13/6 13/7 13/8 13/9 13/10 13/11 13/12 13/13 14 15 15/17 15/18 15/19 15/20 16 17 18 18/14 18/15 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Sump tank Suction Strainer Breather Main Pump Pump Proportional Solenoid Proportional Valve Fine Mode Proportional Solenoid Boom Priority Solenoid Servo Filter Test Point Transmission Control Valve Park Brake Solenoid Gear Change Solenoid Clutch Accumulator Servo Accumulator Pressure Switch Park Brake Accumulator 9 Station Solenoid Valve Servo Isolator Solenoid Swing Shut Off Solenoid Drive Isolation Solenoid Axle Lock Solenoid Actuator Isolation Solenoid Boom Down Speed Regulation Solenoid Creep Speed Regulation Solenoid Hammer Speed Regulation Solenoid Boost Pressure Solenoid Manifold Stabiliser Control Valve Stabiliser Up Solenoid Stabiliser LHS Solenoid Stabiliser RHS Solenoid Stabiliser Down Solenoid Joystick RH Servo Valve Pedal Change Over Valve Arm/Dozer Solenoid TAB /Hammer - Aux Solenoid Joystick LH Shuttle Valve Pressure Switch Manifold Hose Burst Check Valve Manifold Tank Servo Drain Filter Bypass Filter Relief Valve Steering/Brake Filter Steer Valve Unit Brake Valve Pressure Switch Pressure Switch Brake Accumulator Stop Tap Oil Cooler Return Filter Pressure Switch Main Control Valve Swing Motor Swing Gearbox Swing Brake Valve 40/21 40/22 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 70/23 70/24 71 72 73 74 75 76 77 78 Swing Lock Solenoid Swing Brake Solenoid Bucket Ram Arm Ram Arm Hose Burst Check Valve Monoboom Boom Ram TAB Boom Ram Boom Hose Burst Check Valve Pressure Switch TAB Ram TAB Hose Burst Check Valve Change Over Valve Hammer Relief Hammer Filter Coupling Coupling Rotary Coupling Drive Motor Transmission Rear Axle Front Axle Axle Lock Ram Tank Manifold Left Hand Dozer Ram Right Hand Dozer Ram Logic Valve Stabiliser Ram Check Valve Relief Valve Check Valve TAB Section Valve Low Flow Valve Low Flow Option Solenoid Low Flow Option Solenoid Low Flow Valve Test Point Pressure Switch Drive Motor Manifold Tee Stabiliser Manifold Brake Manifold Tee Relief Valve
9804/1103
45 - 20 - 02/5
6410 - E/2-1.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 20 - 02/6
JS 200W from m/c no. 809000 Circuit Diagrams - Hydraulic (contd)
9804/1103
45 - 20 - 02/6
6320 - E/2-2.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 20 - 02/6A
JS 200, 220 from m/c no. 705001 Circuit Diagrams - Hydraulic
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
VALVE; SHUTTLE ACCUMULATOR VALVE; CHECK FILTER; LINE PUMP; HYD VALVE; REMOTE CONT VALVE; REMOTE CONT VALVE; SHUTTLE SWITCH; PRESS VALVE; STOP VALVE; SPL SWITCH PRESS. VALVE; STOP VALVE; SPL VALVE; RELIEF FILTER; LINE
9804/1103
45 - 20 - 02/6A
6400 - E/3-1.2
Issue 1
CONTENTS CONTENTS
Excavators
45 - 20 - 02/6B
JS 200, 220 from m/c no., 705001 Circuit Diagrams - Hydraulic (contd)
9804/1103
45 - 20 - 02/6B
6400 - E/3-2.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 20 - 02/6C
JS 240, 260 from m/c no. 708501 Circuit Diagrams - Hydraulics
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
MOTOR; SLEW RAM; DIPPER VALVE; ASSEMBLY MOTOR; TRACTION COUPLING; ROTARY RAM; BUCKET RAM; BOOM (L) RAM; BOOM (R) VALVE; SHUTTLE VALVE; CONTROL VALVE; SOLENOID ORIFICE FILTER; LINE VALVE; CHECK VALVE; CHECK RADIATOR RADIATOR BREATHER; AIR TANK; SUMP FILTER; LINE STRAINER VALVE; RELIEF FILTER; RETURN VALVE; STOP FILTER; NEPHRON VALVE; STOP VALVE; CHECK SWITCH; PRESS. VALVE; SOLENOID
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
VALVE; SHUTTLE ACCUMULATOR VALVE; CHECK FILTER; LINE PUMP; HYD VALVE; REMOTE CONT VALVE; REMOTE CONT VALVE; SHUTTLE SWITCH; PRESS VALVE; STOP VALVE; SPL SWITCH PRESS. VALVE; STOP VALVE; SPL VALVE; RELIEF FILTER; LINE
9804/1103
45 - 20 - 02/6C
6400 - E/3-4.2
Issue 1
CONTENTS CONTENTS
Excavators
45 - 20 - 02/6D
JS 240, 260 from m/c no., 708501 Circuit Diagrams - Hydraulic (contd)
9804/1103
45 - 20 - 02/6D
6400 - E/3-3.1
Issue 1
CONTENTS CONTENTS
Excavators
45 - 20 - 02/7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 Solenoid Valve (optional) Restrictor (optional) Slew Motor Slew Reduction Gears Dipper Ram Traction Motor Rotary Coupling Bucket Ram Left Boom Ram Right Boom Ram Control Valve Check Valve Solenoid Valve (optional) Solenoid Valve (optional) Pressure Switch (optional) Shuttle Valve (optional) Remote Control Valve Filter Filter (optional) Remote Control Valve (optional) Slew Valve Remote Control Valve Filter Solenoid Valve Pressure Switch Shuttle Valve Cushion Valve Solenoid Valve Check Valve Accumulator Relief Valve Line Filter Shuttle Valve Line Filter Pressure Switch Pressure Switch Hydraulic Pump Engine Stop Valve (optional) Stop Valve (optional) Relief Valve (optional) Line Filter (optional) Spool Valve (optional) Return Filter Relief Valve Suction Strainer Hydraulic Tank Drain Tap Hydraulic Tank Pressure Switch Relief Valve Line filter Check valve Check valve Reducing Valve Oil Cooler Isolating Cock Filter Governor Air Tank Check valve Safety Valve Check Valve (optional) Holding Valve (optional)
9804/1103
45 - 20 - 02/7
6420 - E/3-1.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/8
Refer to Service Manual
9804/1103
45 - 20 - 02/8
6420 - E/3-2.1
Issue 2*
CONTENTS CONTENTS
Excavators
45 - 20 - 02/9
JS 450 from m/c no. 714501 Circuit Diagrams - HydraulicS

1 2 3 4 5 6 6A 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Solenoid Valve (optional) Restrictor (optional) Slew Motor Slew Reduction Gears Dipper Ram Traction Motor Traction Reduction Gear Rotary Coupling Bucket Ram Left Boom Ram Right Boom Ram Control Valve Solenoid Valve (optional) Solenoid Valve (optional) Solenoid Valve (optional) Pressure Switch (optional) Shuttle Valve (optional) Remote Control Valve Filter Filter (optional) Remote Control Valve (optional) Slew Valve Remote Control Valve Filter Solenoid Valve Pressure Switch Shuttle Valve Cushion Valve Solenoid Valve Check Valve Accumulator Relief Valve Line Filter Shuttle Valve Line Filter Pressure Switch Pressure Switch Hydraulic Pump Engine Stop Valve (optional) Stop Valve (optional) Relief Valve (optional) Line Filter (optional) Spool Valve (optional) Return Filter Relief Valve Suction Strainer Hydraulic Tank Drain Tap Hydraulic Tank Pressure Switch Relief Valve Line filter Check valve Check valve Reducing Valve Oil Cooler Isolating Cock Filter Governor Air Tank Check valve 61 62 63 Safety Valve Check Valve (optional) Holding Valve (optional)
9804/1103
45 - 20 - 02/9
6420 - E/3-3.2
Issue 1
CONTENTS
Excavators
45 - 20 - 02/10
Refer to Service Manual
9804/1103
45 - 20 - 02/10
6420 - E/3-4.1
Issue 2*
CONTENTS
Excavators
45 - 20 - 02/11
JS460 from m/c no. 714550 Circuit Diagrams - Hydraulic (contd)

Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 Bucket Ram Left Boom Ram Right Boom Ram Track Motor Track Gearbox Rotary Coupling Dipper Ram Hose Burst Check Valve (optional) Hose Burst Check Valve (optional) Slew Motor Slew Gearbox Main Control Valve Solenoid Valve (optional) Shuttle Valve (optional) Pressure Switch 200 bar (optional) Pressure switch 10 bar (optional) Slew Brake Valve Remote Control Valve Remote Control Valve Nipple Remote Control Valve RH Manifold (optional) Filter Adaptor Remote Control Valve LH Pressure Switch 5 bar Multi Shuttle Block Cushion Valve 8 Stattion Solenoid Valve Pressure Switch Accumulator Servo Manifold Not Used Not Used Not Used Line Filter Pressure Switch 20 bar Not Used Merged Valve (optional) Nephron Filter Stop Valve Oil Cooler Check Valve Hydraulic Pump Engine Hammer Return Filter (optional) Not Used Hammer/Auxiliary Valve RH (optional) Hammer/Auxiliary Valve LH (optional) Stop Valve (optional) Low Flow Pump (optional) Air Tank Actuator Proportional Valve Quick Release Valve Coupling (optional) Check Valve Servo Return Filter Relief Valve Pressure Switch Strainer 60 61 62 63 Hydraulic Tank Directional Valve (optional) Relief Valve (optional) Return Filter (optional)
9804/1103
45 - 02 - 02/11
6420 - E/3-6.1
Issue 1*
CONTENTS
Excavators
45 - 20 - 02/10
Refer to Service Manual 9803/640
9804/1103
45 - 20 - 02/1
6420 - E/3-7.1
Issue 1*
CONTENTS
Excavators
45 - 20 - 02/13
JS330/JS460 Tier Circuit Diagrams - Hydraulic

The item numbers in the following list are identified on the Hydraulic schematic. Description Bucket Ram Boom Ram Left Hand Boom Ram Right Hand Track Motor Track Gearbox Rotary Coupling Dipper Ram Hose Burst Check Valve Hose Burst Check Valve Swing Motor Swing Gearbox Main Control Valve Solenoid Valve (Merged Valve) Shuttle Valve Pressure Switch (200 bar) Pressure Switch (10 bar) Swing Brake Valve Remote Control Valve (Travel) Remote Control Valve (Option) Adapter Filter Remote Control Valve Right Hand Manifold Adaptor Filter Remote Control Valve Left Hand Pressure Switch (5 bar) Multi Shuttle Valve Cushion Valve 8 Station Solenoid Valve Pressure Switch (12 bar) Accumulator Servo Manifold Servo Filter Filter Line Pressure Switch (20 bar) Plexus Filter Stop Valve Oil Cooler Check Valve Hydraulic Pump Engine Hammer Return Filter Hammer/Auxiliary Valve Right Hand Hammer/Auxiliary Valve Left Hand Stop Valve Low Flow Pump Actuator Proportional Valve Quick Release Coupling Servo Return Filter Strainer Hydraulic Tank Directional Valve Relief Valve Return Filter Part No. KTV 1021 KTV 0939 KTV 0937 50/100113 50/100058 JSA 0155 KTV 1063 928/60086 928/60087 20/925266 05/202400 25/221026 25/220536 KHJ 0579U-A 701/80198 JRR0076 25/220998 KSJ 2465 JRJ 0162 JHJ 0168 25/221904 JRJ0132 JHJ0168 25/221904 701/80824 25/220830 25/220042 928/60061 JHR 0185 JHJ0050 KHJ 0658 32/925214 KHJ 0568 JHR 0184 JHJ 0238 KHJ 0897 30/925506 KHJ 0982 20/925278 01/145166 JBJ0066 JSV 0328 JSV 0327 JSV 0352 20/925311 331/14519 928/60027 45/910400 KHJ0287 KTJ 1081Y-A 215/10658 JSJ 0083 928/60066 581/10866
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 35 36 39 40 41 42 43 44 45 47 48 49 50 52 53 54 56 59 60 61 62 63
9804/1103
45 - 20 - 02/13
6420 - E/3-8.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/14
JS330/JS460 Tier 2 Circuit Diagrams - Hydraulic (contd)

1
Z=15 Z=104 i=19.3 Z=104 i=19.3
7
C2
180-130-1910
2
Z=15
4
9
10
11
160-110-1306
12
160-110-1580
13
14
15
No.
16
Component BUCKET CYLINDER BOOM CYLINDER LH BOOM CYLINDER RH TRACK MOTOR TRACK GEARBOX CENTRE JOINT ARM CYLINDER HOSE BURST CHECK VALVE HOSE BURST CHECK VALVE SWING MOTOR SWING GEARBOX MAIN CONTROL VALVE VALVE SOLENOID VALVE SHUTTLE PRESSURE SWITCH 200 bar PRESSURE SWITCH 10 bar SWING BRAKE VALVE VALVE REMOTE CONTROL VALVE REMOTE CONTROL NIPPLE VALVE REMOTE CONTROL RH MANIFOLD ADAPTER FILTER VALVE REMOTE CONTROL LH PRESSURE SWITCH 5 bar MULTI SHUTTLE BLOCK VALVE CUSHION 8 STATION SOL VALVE PRESSURE SWITCH 12 bar ACCUMULATOR SERVO MANIFOLD SERVO FILTER
MIN L 1976
MA X S S X MB
2 8 1
MIN L 2230
3 8
MIN L 2580 107/160

CC/rev
1 2 3 4 5
107/160 325 bar at 40 / min

A B
CC/rev
i=121:1 PG DB 145.9
cc/rpm
325 bar at 40 / min
i=121:1
5
PG DB
145.9
cc/rpm
11
5
Bre
R/G
1
6
C2 C2
380 bar
PIL
6
T V2
I-12 L-2
Bre
R/G
4
V2 T PIL
380 bar
* *
E
380 bar
8 9 10 11 12
PIL
V2
B
280 bar l/min at 200 280 bar l/min at 200
B A Gri BP MB MA BP
T P L 7
L-1
L P T T PSW
I-13
10
Gri
D B M M A LEFT B RIGHT A LEFT B RIGHT BACKWARD LEFT FORWARD LEFT A
C
6
22
15
200 bar
* * * *
13 14 15 16 17 18
BACKWARD RIGHT FORWARD RIGHT
19 20
Pi
Dr
21
22 23 24 25
*
29 DIA
13
49
26 27
D
15bar
D-10
B A
SOL VALVE D MERGED VALVE (HYD TANK)
ps1
47 bar at 60 l/min
T3
T1
pc5
47 bar at 60 l/min
ps2
28 29 30
*
16
A C
q
pa11
DR1' DR1
pa10
D-3
31 32 33
17
pc1
H-3
B5
P T
18
v w h
A5
F-6 F-6
B9
OUT IN IN OUT
47
34 35 36 FILTER LINE PRESSURE SWITCH 20 bar
E
BACKWARD LEFT BACKWARD RIGHT FORWARD LEFT FORWARD RIGHT
pb5
A9
48
L-2
*
T
37 38 39
190 bar
ARM1
ON 10 bar OFF 8 bar
E
NEPHRON FILTER VALVE STOP OIL COOLER VALVE CHECK HYDRAULIC PUMP ENGINE DIESEL HAMMER RTN FILTER
363bar at20 /min
pb9 pa9
14
* *
J-3
g
L-2
pa5
t
I-1
ARM2
363 bar at20 /min
J-3
40
D
1
OPTION
2
19
5
pc4 B4 A4 pb4
OPTION
F-6
B A D T P T P
41 42 43
F-11
B8
OPEN CLOSE
F-13 E-3
A8 pb8 pa8
A B
F-6
44
H-3
* * * * *
3.5 bar
45 46 47 48 49 50 51 52 53
F
1
G-6
pa4
OPEN CLOSE
363 bar at 20 l/min 245 bar at20 /min
BUCKET
H-2
P
k
2
G-6
3
G-11
4
G-11
E-3
HAM/AUX VALVE RH HAM/AUX VALVE LH STOP VALVE LOW FLOW PUMP
DR2' DR2 pc2

s
A3 B3 pb3
L-1
A7 B7
L-1
20
r
DOWN
UP UP DOWN
10*
C A
pa3 B2
BOOM2
LEFT
pb7 pa7 B6 pb6 pa6

l f
L-1
13
L-1
ACTUATOR PROPORTIONAL VALVE QUICK REL COUPLING
24
BOOM1
23
21
23
J-1
A2 RIGHT pb2 DR3

J-1
SOL VALVE C HAMMER/AUX CHANGEOVER (UNDER CAB)
SWING
BACKWARD
FORWARDA6
I-12
45
54 55 56 57 58 59
G
SERVO RETURN FILTER
u
K-5
pa2 pc6 B1 A1 pb1

BACKWARD FORWARD
F-2
TRAVEL (R)
F-2
STRAINER HYDRAULIC TANK DIRECTIONAL VALVE RELIEF VALVE RETURN FILTER
SWING
4
IN
ARM
RIGHT LEFT
OUT
BUCKET
BOOM
F-1
12
60
CLOSE
a
F-11
OPEN
b
F-11
DOWN
UP
j
F-1
pa1
TRAVEL (L)
STRAIGHT TRAVEL
319 bar at 240 /min 348 bar at 220 /min
pr1
40
* * *
39 42 40
61 62 63
NOTES
1) UPPER VALUES SHOW THE CONNECTION POINTS AND LOWER VALUES SHOW THE ZONE NUMBER OF THIS DRAWING. 2) COMPONENTS MARKED THUS ARE OPTIONS
pr2 P2
P1
ON 5 bar 25 OFF 4 bar
PT
PA
PH
25 36
D-6
ON 20 bar OFF 15 bar
ON 12 bar OFF 9 bar
29
3.0 bar
t E-6
A1
S1
A2
LEFT
A3
UP
S2 S3 BOOM
A4
DOWN
A5
OUT
C9 ARM
C5 A6
IN
3
G-12
41
1
B-4
2
C-13
C8 RIGHT C7 C6 B1
c
I
56 28 43
SWING 0.6 bar 0.05bar 10 Pm2 Pi2

A
B2
d
B3 C1
C2 B4
s
G-10
B5 C3
n
F-10
C4 B6
p
F-10
30
B1
SOFT/HARD
T1
LEVER LOCK
GAS PRESS. 15 bar CAPACITY 300 cm

3
31
32
14
26
J
G-6
G-6
C4 C5 P
2-STAGE RELIEF MAX FLOW CUT
Dr3
63
0.5 bar
10 Pb2 Dr2 44 bar / min a4 at 26 A3
10
27
E F A B T
C3
C7
C4
C3
C2 C1
0.3 bar 150MESH

59
a2
60
1.03 bar
SWING SHUT OFF NEGATIVE FLOW CON.
A2 a3 164.7 CC/rev i=1.032 170.0 i=1.0

CC/rev
15
CC/rev
B3 B1 B 20
CC/rev
62
C2
C6
K
BOOM PRIORITY OVER SWING C5
Psv A1
44
61
*
54
2-STAGE TRAVEL
200 bar
C1
S
H-6
a1
u
M
Pb1 Pi1 D0
50
175 bar 200 bar T B
*
ISUZU 228 KW @ 2000rpm
E1
G BOOM DOWN
e
G-11
A1 ARM IN
G B-4 g E-6
D OUT
E-6
B2
T2
L
C-12
UP
f G-10 r G-6
35
3.0
Pm1
T
A P
52
53
A408440
10
11
12
13
14
15
16
9804/1103
45 - 20 - 02/14
6320 - E/3-9.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/15
JS450/JS460 Circuit Diagrams - Hydraulic Control Valve

4Ps T1 T2 5P.P2 5P 5Dr2 5Pa1 5Pb1 5Pa1 SWING 4A4 4T1 4B4 4Pb4 4Pa4 4A3 BL3 BOOM(1) 4P.P1 4Pb3' 4Pb3 4Pa3 4A2 4B2 4Pb2' 4Pb2 4Pa2 4A1 4B1 4Pb1 4Pa1 PG2 TRAVEL (L) TRAVEL (R) 5Pa5 5Pb5 5A5 5B5 5PS ARM(2) 5Pb1 5Pb2 5B1 5Pb2 5Pb2 5A2
ARM (1)
5T1
3B3 4Dr1
5B2 5Dr1 BOOM (2)
5A3 5B3 5P 5Pa4 5Pb4
5P.P1
OPTION
5A4 5B4
PG1
PG3 Pp 4P T4 4P.P3 T3 PG5 PG4
PG5
A357600
9804/1103
45 - 20 - 02/15
6420 - E/32-4.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/16
JS460 Tier 2 Circuit Diagrams - Hydraulic Control Valve
ps1
T3
T1 pc5
ps2
pa11 DR1' DR1 pc1 B5 A5 pb5 DIPPER 1
pa10
DHV
B9
a f
A9
pa5 pc4 B4 A4 pb4 OPTION pa4
DIPPER 2 pb9
SDV
pa9
B8 A8
BUCKET pb8
pa8
BHV
DR2' DR2 pc2 A7
A3 B3 pb3 BOOM2 pa3 pb2 DR3 pa2 pc6 B1 A1 pb1 pa1 pr1
R1 R3 R2 TRAVEL BPV SLEW
c h d i
B7
BOOM1 pb7
B2 A2
pa7 B6 A6
TRAVEL pb6
pa6
LINEAR TRAVEL
pr2 PH P2
P1
PT
PP
PA
A1
A2
A408690
9804/1103
45 - 20 - 02/16
6420 - E/32-5.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/17
JS460 Tier 2 - Neutral Circuit Circuit Diagrams - Hydraulic

With all the controls in the neutral position, flow from pump A1 enters the main control valve 12 at port P1 and flow from pump A2 enters the main control valve 12 at port P2. Oil is allowed to flow across all of the spools via the neutral gallery when all controls are in the neutral position. Oil from pump A1 exits port Ps1 and oil from pump A2 exits port Ps2 at the top of the main control valve. Both flows of oil meet a separate restrictor and relief valve. Some oil will pass through the restrictor and back to tank, creating back pressure in the line. Oil is exhausted across the relief valves at 40 bar. The back pressure is sensed at ports Ps1 and Ps2 and ports Pi1 and Pi2 of the pumps, holding the pumps on minimum flow. Flow from the servo pump enters the valve block at port Pp, where it meets 3 restrictors. These maintains the pressure on the input side at full servo pressure. Oil that crosses the restrictors, is allowed back to tank after passing over the neutral gallery of the spools. No pressure is created in this line whilst all controls are in neutral, allowing all pressure switches to remain in the open position. a b c d e f g h i j Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool
9804/1103
45 - 20 - 02/17
6420 - E/38-1.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/18
JS460 Tier 2 - Neutral Circuit Circuit Diagrams - Hydraulic (contd)
12
ps1 T3 T1 pc5 ps2
pa11 DR1' DR1 pc1 B5 A5 pb5

DIPPER 1 a
pa10
DHV
B9 A9
f DIPPER 2
pa5
Pm2 Pi2 Pb2 Dr2 a2 44 bar / min a4 at 26 A3 15 164.7 CC/rev i=1.032 170.0 i=1.0
CC/rev CC/rev
pb9 pa9
43
Dr3
SDV
pc4 B4 A4 pb4
10
b
OPTION
g BUCKET
B8 A8
pb8 pa8
A2
A2 a3 Psv A1
pa4
BHV
B3 B1 B 20
CC/rev
DR2' DR2 pc2 A7
A1
1.03 bar
A3 B3 pb3 BOOM2 c pa3 B2 A2 pb2 pa2 pc6 B1 A1

A
a1 D0
M
Pb1 Pi1
ISUZU 228 KW @ 2000rpm
h BOOM1 pb7 d
BPV
B7
52
A T P
SLEW
pa7
Pm1
DR3
TRAVEL
B6 A6
pb6
30
C5
pa6
31
Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up
0.5 bar
pb1 pa1 pr1
TRAVEL
LINEAR TRAVEL
C4
C3
C2 C1
R1 R3 P1 PT R2 PP PA PH P2
pr2
A408770
9804/1103
45 - 20 - 02/18
6420 - E/38-2.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/19
JS460 Tier 2 - Neutral Circuit Circuit Diagrams - Hydraulic (contd)
ps1
T3 T1 pc5
ps2
12 6
pa10
DIPPER 1 a
DHV
B9 A9
f
pa5 pc4 B4 A4
SDV
DIPPER 2
pb9
pa9
pb4 OPTION pa4
B8 A8
BUCKET
pb8
pa8
BHV
DR2' DR2 pc2
A3 B3 pb3
BOOM2
A7
BOOM1
4
MA X S S X MB
pa3 B2 A2 pb2
SLEW
B7 pb7 B6 A6 pb6
d
BPV
pa7
107/160
CC/rev
107/160 325 bar at 40 / min

A B
CC/rev
i=121:1
325 bar at 40 / min
i=121:1
DR3 pa2 pc6

R/G
i
TRAVEL
Bre
R/G
Bre
pa6
B1 A1 pb1
e
pa1 pr1 R1 R3 P1 PT R2 PP PA PH P2
TRAVEL
LINEAR TRAVEL
B Gri BP MB
A Gri MA BP
D A
pr2
36
29
A1 A2
A408790
9804/1103
45 - 20 - 02/19
6420 - E/38-3.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/20
JS460 Tier 22 - Straight Line Travel Circuit Diagrams - Hydraulic Control Valv
(Travel and exavator services selected) Refer to Travel Middle Speed for servo function of travel circuit and Boom Up for servo function of Boom up function. Servo pressure entering at port Pp on the main control valve 12 is blocked from tank by the Travel spools and the Boom (2) spool, this causes back pressure which selects the travel and excavator pressure switchs 36 and 29 and selects the Linear travel spool. Flow from pump A1 is available to the left hand Travel spool and the Linear travel spool which diverts the flow to the right hand Travel motor. Flow from pump A2 is available to all the other functions of the Main control valve 12 via the parrallel working galleries. If any excavator function is selected at slow speed and does not require the full flow from pump A2, then the extra flow is used in the travel circuit (as long as the travel circuit is working at a lower pressure) via the check valve at the right hand travel spool, a restrictor gives low priority to the travel circuit. If the Boom up is selected both Boom 1 and 2 spools are fed from the pump A2 through the left and right hand parrallel working gallery. When both Travel spools are selected, the loss of pressure in the neutral gallery is sensed at the pumps through ports Ps1 and Ps2 on the main controll valve 12 . The pumps come into full flow. a b c d e f g h i j Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool
9804/1103
45 - 20 - 02/20
6420 - E/38-4.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/21
JS460 Tier 22 - Travel - Middle Speed Circuit Diagrams - Hydraulic

When both tracks are selected, servo pressure from port 2 (LH travel lever),and port 4 (RH travel lever) 18 enters the main control valve 12 at Pb1 and Pa6 respectively, selecting the left and right hand travel spools. Flow from pump A1 is available at the Left hand travel spool and is directed to the Left hand travel motor via port A1 of the Main control valve 12, through the rotary coupling and in to port P1 on the LH travel motor. Exhaust oil from the motor enters the main control valve 12 at port B1 and is directed to the Left hand travel spool to the tank port. Flow from pump A2 is available at the Right hand travel spool and is directed to the Right hand travel motor via port A6 of the main control valve 12, through the rotary coupling and in to port P2 on the Right hand travel motor. Exhaust oil from the motor enters the Main control valve 12 at port B6 and is directed to the Right travel spool to the tank port. a b c d e f g h i j Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool
The servo oil flowing over restrictors R1 and R2 is available to tank causing the excavator pressure switch 36 to stay open and the straight line travel spool to remain un-selected. Pressure is lost on both negative control ports Ps1 and Ps2, which is sensed at the pumps which come into full flow.
9804/1103
45 - 20 - 02/21
6420 - E/38-5.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/22
JS460 Tier 2 - Travel - Middle Speed Circuit Diagrams - Hydraulic 12
ps1
T3 T1 pc5
ps2
B5 A5
pa11 DR1' DR1 pc1
pa10
DHV
B9
pb5 DIPPER 1
a f
A9
pa5 pc4 B4 A4
DIPPER 2
pb9
SDV
pa9
pb4 OPTION pa4
B8 A8
BUCKET
pb8
pa8
BHV
DR2' DR2 pc2 A7
A3 B3 pb3 B2 A2 pb2
BOOM2
c h d
BPV BOOM1
pa3
SLEW
B7 pb7 B6 A6 pb6
pa7
TRAVEL
DR3 pa2 pc6 B1 A1 pb1 pa1 pr1 R1 R3 R2 PP PA PH P2
i e
TRAVEL
pa6
LINEAR TRAVEL
18
pr2
4
MA X S S X MB
P1
PT
107/160
CC/rev
107/160 325 bar at 40 / min

A B
CC/rev
i=121:1
325 bar at 40 / min
i=121:1
A1
A2
Bre
R/G
Bre
R/G
B Gri BP MB
A Gri MA BP
D A
A408800
9804/1103
45 - 20 - 02/22
6320 - E/38-6.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/23
JS460 Tier 2 - Travel - Middle Speed Circuit Diagrams - Hydraulic
2
ps1 T3 T1 pc5 ps2
3 8
12
pa10

DIPPER 1 a
DHV
B9 A9
V2
PIL
380 bar
380 bar
PIL
V2
f
pa5 pc4 B4 A4
SDV
DIPPER 2
pb9
pa9
pb4 OPTION pa4
B8 A8
BUCKET
pb8
pa8
BHV
DR2' pc2 DR2 A7 B7

P T
A3 B3 pb3 pa3 B2 A2 pb2
21
c
BOOM2
BOOM1
27
T
SLEW
d
BPV
h i
pb7 pa7
DR3 pa2 pc6 B1 A1 pb1 TRAVEL pa1 pr1 R1 R3 P1 PT R2 PP PA PH P2
B6 A6 TRAVEL pb6 pa6

1
BUCKET OPEN CLOSE 3 2
UP
BOOM DOWN 4
E1
LINEAR TRAVEL
A1
25
pr2
A1 C8 RIGHT C7 C6 B1 B2 B3 C1 C2 B4 B5 C3 C4 B6 SWING S1 A2
LEFT
22
A3
UP
S2 S3 BOOM
A4
DOWN
A5
OUT
C9 ARM
C5 A6
IN
36
29
Key to Oil Flow & Pressure Full Pressure
A1 A2
Pressure Servo Neutral Exhaust Cavitation Lock Up
9804/1103
45 - 20 - 02/23
6420 - E/38-7.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/24
JS460 Tier 22 - Boom Up Circuit Diagrams - Hydraulic

Servo pressure from the handcontroller 21 enters the servo shuttle valve 26 at port A3 and is disributed to: 1 2 Boom up pressure switch 25 at port S2. Port B3 through the Cushion control valve 27 , the signal is then divided between the Boom 1 spool valve at port Pa7 and Boom(2) spool at port Pa3 on the main control valve 12.
Flow from pump A2 is stopped by the Boom(1) spool and is diverted via the parrallel working passage to the Boom(1) spool. The oil passes through the spool and merges with the flow from pump A1. Flow from pump A1 is stopped by the Boom(2) spool and is diverted via the parrallel working passage to the boom 2 spool.The oil passes through the spool and merges with the flow from pump A2. The pressure lifts the Boom holding valve BHV off its seat allowing oil to leave the main control valve at port A7 to enter the Hose Burst Protection valve (HBPV) 22 (if fitted) and the Boom rams 2 and 3. Exhaust oil enters the Main control valve 12 at port B7 and crosses the Boom 1 spool to tank. Pressure is lost on both negative control ports Ps1 and Ps2, which is sensed at the pumps, which comes into full flow. The Excavator pressure switch 29 is closed by back pressure resulting from Boom 2 spool closing the servo route to tank. The travel pressure switch 36 remains open.
a b c d e f g h i j
Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool
9804/1103
45 - 20 - 02/24
6420 - E/38-8.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/25
JS460 Tier 22 - Boom Down Circuit Diagrams - Hydraulic

Servo pressure from the Handcontroller enters the Servo Shuttle valve 26 at port A4 and is disributed to: 1 2 Port S3 to activate the Boom down pressure switch 25. Port C2 to the Main control valve 12 at port Pc2. The Boom holding spool valve is moved across allowing pressure at the top of the Boom Holding Valve BHV to exhaust to tank. Port B4 to port E of the Cushion control valve 27. The oil flows across the unrestricted part of the spool and out of port G to the main control valve 12 at port Pb7, moving the spool to the down position. Note. If HBCVs 12 are fitted a signal is also sent from port E1 of the Cushion control valve 27 to the P ports of the HBCVs to move the HBCV spool over and allow oil to return from the rams. Flow from pump A2 travels through the neutral gallery to the Boom 1 spool. The flow is restricted allowing a reduced pressure at port Ps2 which is sensed at Pm2 of the pump A2 which increases flow (less than full flow). Oil flow also passes through the parallel working gallery to the Boom(1) spool and is directed to the Boom rams 2 and 3 via port B7. Exhaust oil passes through the HBVCs 12 (if fitted) to the Main controll valve 12 at port A8, lifts the Boom Holding Valve BHV off its seat and passes through the Boom (1) spool and exhausts to tank. Exhaust oil passing through the spool can be regenerated into the feed side of the rams. A check valve in the spool (see Fig 1) allows oil to enter the pressure side of the spool if the returning oil is a a higher pressure, due to the wieght of the boom/load. The restrictor also creates back pressure so causing the check valve to open.
a b c d e f g h i j
9804/1103
45 - 20 - 02/25
6420 - E/38-9.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/26
ps1
T3 T1
ps2
12
pa10
pa11 DR1' DR1 pc1
DHV
B9 A9
f
pa5 pc4
SDV
DIPPER 2
pb9
C2 C2 C2 C2
Fig 1
pa9
pb4 OPTION pa4
B4 A4
B8 A8
BUCKET
pb8
V2
BL
BL
V2
pa8
BHV
DR2' pc2 DR2 A7
A3 B3 pb3 B2 A2 pb2
BOOM2
c h d
BPV BOOM1
pa3
SLEW
B7 pb7 B6 A6
pa7
DR3 pa2 pc6 Key to Oil Flow & Pressure B1 A1 Full Pressure pb1 TRAVEL Pressure Servo pa1
21
P T
B T
27
TRAVEL
pb6
pa6
LINEAR TRAVEL
1
BUCKET OPEN CLOSE 3 2
UP
BOOM DOWN 4
Neutral pr1 Exhaust Cavitation Lock Up

P1 PT R3 R2
R1
pr2 PA PH P2
E1
A1
PP
25 26
A1 A2
A1 C8 RIGHT C7
S1
A2
LEFT
A3
UP
S2 S3
DOWN
A4
A5
OUT
C9 ARM
C5 A6
IN
BOOM SWING
Pm2
C6 B1 B2 B3 C1 C2 B4 B5 C3 C4 B6
A408850
9804/1103
45 - 20 - 02/26
6320 - E/38-10.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/27
ps1
T3 T1 pc5
ps2
12
pa10
P BL E V2
T C2 C2
M
D D
pa11 DR1' DR1 pc1 B5 A5

DIPPER 1 a
DHV
B9 A9
pb5
f
pa5 pc4 B4 A4
DIPPER 2 SDV
pb9 pa9 B8 A8
pb4 OPTION pa4
BUCKET
pb8
pa8
BHV
DR2' pc2 DR2 A7 B7 pb7
A3 B3 pb3
P T
BOOM2
c h d
BPV BOOM1
27
24
pa3 B2 A2 pb2
SLEW
B T
pa7
DR3
LEFT 1 SWING RIGHT 2 ARM IN 3 OUT 4
B6 A6
TRAVEL
pa2 pc6 B1 A1 pb1 TRAVEL pa1 pr1
pb6
pa6
LINEAR TRAVEL
E1
A1
pr2
A1 C8 RIGHT C7 C6 B1
S1
A2
LEFT
A3
UP
S2 S3
DOWN
A4
A5
OUT
C9 ARM
C5 A6
IN
26
A1 A2
BOOM SWING
B2
B3 C1
C2 B4
B5 C3
C4 B6
A408910
9804/1103
45 - 20 - 02/27
6420 - E/38-11.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/28
JS460 Tier 22 - Dipper Out Circuit Diagrams - Hydraulic

Servo pressure from the Handcontroller 24 is sent to port A5 of the shuttle valve 26 and is disributed to: 1 Port C3 to port Pb9 of the Main control valve 12 to activate the Dipper 2 spool. Port B5 to port B of the Cushion valve 27, through the valve leaving at port D. The signal is sent to port P b 5 on the Main contol valve 12 activating the Dipper 1 spool. a b c d e f g h i j Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool
Flow from pump A1 is available at the Dipper 1 spool via the left hand neutral passage and the Linear travel spool via the parrallel working passage. Flow from pump A2 is diverted at the Dipper 2 spool and joins the flow from pump A1 after it has crossed the Dipper 1 spool. Exhaust oil from the ram enters the Main controll valve 12 at port A5 and has a path to tank via the Dipper 1 spool.
9804/1103
45 - 20 - 02/28
6420 - E/38-12.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/29
JS460 Tier 22 - Dipper In Circuit Diagrams - Hydraulic

Servo pressure from the Hand controller 24 is sent to port A6 of the servo shuttle valve 26 and is dritributed to: 1 Port C4 to port Pa9 on the Main controll valve 12 to the Dipper 2 spool. Port B6 to port A on the Cushion valve 27, through the valve leaving at port C (if machine is fitted with HBCV 11, pressure is also sent via port A1 to port P on the HBCV to allow trapped oil in the ram to exit). From port C to port Pa5 and port Pc1 on the Main controll valve 12 to select the Dipper Spool. Port C5 to select the Dipper Holding Valve DHV.
a b c d e f g h i j
Flow from pump A1 is avaiable at the Dipper spool via the left hand neutral gallery or after passing over the straight line travel spool via the parrallel working passage. At the Dipper 1 spool the flow is diverted to the Dipper ram 2. Pressure is sensed at the regeneration spool RGS and moves it to the lesser restricted position (Fig 2). Flow from pump A2 is blocked at the Dipper 1 spool and joins the flow of pump A1 after it has crossed the Dipper 1 spool. The pressure from both pumps is now cut off from the negative control ports Ps1 and Ps2. This reduced pressure is sensed at both pumps which now come into full flow. Exhaust oil from the ram passes (through the HBCV 11 if fitted) to the Main controll valve 12 at port B5 through the Dipper hold check valve DHV (that has been released by servo pressure) to the Dipper 1 spool. Exhaust oil from the Dipper ram 2 can be at a hgher pressure than the feed oil due to the effect of gravity on the dipper arm when first selected. This causes the regeneration check valve RG to open, feeding a proportion of exhaust oil into the feed side. The remaining exhaust oil returns to tank passing over the regeneration spool RGS. The regeneration spool has two restrictors, one more restricted than the other. The restrictors cause back pressure incouraging the regeneration check valve to open. As the return pressure drops the regeneration spool moves across to the less retricted position. When the feed pressure is greater than the exhaust pressure the regeneration check valve will close. Servo pressure travels over restrictors R2 and R3 and to tank via the unselected travel spools. Oil passing over R1 has no passage to tank, creating back pressure that selects the excavator pressure switch 36.
9804/1103
45 - 20 - 02/29
6420 - E/38-13.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/30
JS460 Tier 2 - Dipper In Circuit Diagrams - Hydraulic
T C2 C2
12
M
D
ps1
T3 T1 pc5
ps2
pa11 DR1' DR1 pc1 B5
pa10
DHV
BL E
V2
A5 pb5
B9
a
DIPPER 1
A9
f
pb9
SDV DIPPER 2
27
T
pa5 pc4
P T
pa9
24
pb4 OPTION pa4

S
B4 A4
B8 A8
BUCKET
pb8
pa8
BHV
DR2' DR2 pc2 A7
E1
A1
SWING LEFT RIGHT 1 2
ARM IN 3 OUT 4
A3 B3 pb3 B2 A2 pb2
BOOM2
c h d
BPV BOOM1
pa3
B7 pb7
26
LEFT
SLEW
pa7
A3
UP
S2 S3
DOWN
A4
A5
OUT
C9 ARM
C5 A6
IN
DR3 pa2 pc6 B1 A1 pb1 TRAVEL pa1 pr1 R1 R3 R2 PP PA PH P2
B6 A6
TRAVEL
pb6
BOOM
pa6
LINEAR TRAVEL
pr2
Fig 2
DHV
P1
PT
A5 pb5
36
A1
29
A2
a
DIPPER 1
A408850
pa5
A408920
9804/1103
45 - 20 - 02/30
6320 - E/38-14.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/31
JS460 Tier 2 - Bucket Opening Circuit Diagrams - Hydraulic
ps1
T3 T1
ps2
12

DIPPER 1 a
pa10
DHV
B9 A9
f
pa5 pc4 B4 A4
SDV
DIPPER 2
pb9 pa9 B8
pb4 OPTION pa4
b
BUCKET
g
pa8
BHV
A8 pb8
A3 B3 pb3 B2 A2 pb2
BOOM2
c h d
BPV BOOM1
pa3
SLEW
pa7
DR3 pa2 pc6
B6 A6
TRAVEL
21
P T
pb6
pa6
B1 A1 pb1 TRAVEL pa1 pr1
LINEAR TRAVEL
BUCKET CLOSE OPEN 3 1
BOOM DOWN UP 4 2
R1 R3
P P PP1
R2 PP PA PH P2
pr2
PT
36
PSW1
29
A2
A408940
9804/1103
45 - 20 - 02/31
6420 - E/38-15.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/32
JS460 Tier 22 - Bucket Opening Circuit Diagrams - Hydraulic

Servo pressure from port 1 of the Handcontroller 21 selects the bucket spool open position via port Pa8 of the Main control valve 12. Flow from pump A2 is avaiable to the Bucket spool via the parrallel working gallery. At the spool the flow is diverted to port A8 of the Main control valve 12 to the Bucket ram 1. Returning oil enters the Main control valve 12 at port A8 and is diverted by the Bucket spool to the tank port. Pressure in the neutral circuit drops after the selected Bucket spool, this is sensed at the port Ps2 and at the pump bringing it into full flow. Servo pressure entering the Main contol valve at port Pp is blocked by the bucket spool causing back pressure to the restrictor which activates the Excavator pressure switch 36. a b c d e f g h i j Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool
9804/1103
45 - 20 - 02/32
6420 - E/38-16.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/33
JS460 Tier 22 - Bucket Closing Circuit Diagrams - Hydraulic

Servo pressure from the handcontroller is sent from port 3 to port Pb8 of the Main control valve 12 and moves the Bucket spool into the bucket close position. Flow from pump A2 is avaible at the Bucket spool via the parrallel working gallery. Flow is dirverted to port B8 of the Main control valve to the Bucket ram 1. Returning oil from the Bucket ram enters the Main control valve at port A8 and is dirverted to tank by the Bucket spool. When returning oil from the Bucket ram enters the spool it crosses a restrictor which causes back pressure so preventing cavitation. Servo pressure entering the main contol valve at port Pp is blocked by the bucket spool causing back pressure to the restrictor which activates the Excavator pressure switch 29. a b c d e f g h i j Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool
9804/1103
45 - 20 - 02/33
6420 - E/38-17.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/34
JS460 Tier 2 - Bucket Closing Circuit Diagrams - Hydraulic
ps1
T3 T1 pc5
ps2
12
pa11 DR1' DR1 pc1 B5 A5 pb5 DIPPER 1
pa10
DHV
B9
a f
A9
pa5 pc4 B4 A4
DIPPER 2
pb9
SDV
pa9
B8 A8
pb4 OPTION pa4
g
BUCKET
pb8 pa8
BHV
DR2' DR2 pc2 A7
A3 B3 pb3 B2 A2 pb2
BOOM2
c h d
BPV BOOM1
pa3
SLEW
B7 pb7
pa7
DR3 pa2 pc6 B1 A1 pb1 TRAVEL pa1 pr1 R1 R3 P1 PT R2 PP PA PH P2
B6 A6
TRAVEL
pb6
pa6
LINEAR TRAVEL
pr2
21
P T
Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation
36
29
BUCKET CLOSE OPEN 3 1 BOOM DOWN 4
UP 2
Lock Up
A1
A2
A408930
9804/1103
45 - 20 - 02/34
6320 - E/38-18.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/35
JS460 Tier 2 - Priority Valves Circuit Diagrams - Hydraulic
SDV
26
LEFT
A3
UP
S2 S3 BOOM
A4
DOWN
A5
OUT
C9 ARM
C5 A6
IN
ps1
T3 T1 pc5
ps2
12

DIPPER 1 a
pa10
DHV
B9 A9
B
pa5 pc4 B4 A4
SDV
DIPPER 2
pb9
pa9
pb4 OPTION pa4
B8 A8
BUCKET
pb8
pa8
BHV
A3
28
SOFT/HARD
B1
T1
LEVER LOCK
B3 pb3 B2 A2 pb2
BOOM2
c h d
BPV BOOM1
C4 P
2-STAGE RELIEF MAX FLOW CUT
pa3
SLEW
pa7
C3
DR3
C7
B6 A6
TRAVEL
pa2 pc6 B1 A1 pb1 TRAVEL pa1 pr1
pb6
pa6
SWING SHUT OFF
C2
NEGATIVE FLOW CON.
C6
LINEAR TRAVEL
2-STAGE TRAVEL
C1
pr2
B2
T2
A408740
9804/1103
45 - 20 - 02/35
6420 - E/38-19.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/36
JS460 Tier 22 - Priority Valves Circuit Diagrams - Hydraulic

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

This is selected by the operator via EMS. When operated the Boom priorty solenoid on the 8 spool block 28 is energised sending a signal via port C5 to the Main control valve 12 at port Pc6. This selects the Boom over Slew priority. Oil now being fed to the Slew spool is restricted to give priority to the boom.
a b c d e f g h i j
9804/1103
45 - 20 - 02/36
6420 - E/38-20.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/37
JS460 Tier 22 - Slew Circuit Circuit Diagrams - Hydraulic

Servo pressure from the Handcontroller 24 enters the Servo shuttle valve 26 at port A2 and is disributed to: 1 2 Port C7 to port A on Slew brake valve 17. Port C8 to port Pc4 on Slew over Dipper priority s p o o l SDV in the Main control valve. Port S1 to the Slew pressure switch 25. Port B2 to the Slew spool at port Pa2 on the Main control valve 12 to move spool across. a b c d e f g h i j Dipper 1 spool Option spool Boom 2 spool Slew spool Travel (left) spool Dipper 2 spool Bucket spool Boom 1 spool Travel (Right) Linear Travel spool
3 4
Flow from pump A1 is stopped in the neutral gallery by the Swing spool. The flow passes through the Linear travel spool into the parrallel working passage over the unrestricted side of the Boom priority spool BPV and to the Slew spool. the flow is then directed via port A2 to the Slew motors 10. Exhaust oil enters the Main control valve at B2 to the Slew spool to the tank line.
9804/1103
45 - 20 - 02/37
6420 - E/38-21.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/38
JS460 Tier 2 - Slew Circuit Circuit Diagrams - Hydraulic

B1
SOFT/HARD
T1
LEVER LOCK
28
P
C4
2-STAGE RELIEF
MAX FLOW CUT
12
C7
C3
ps1
T3 T1 pc5
ps2
Dr
Dr
SWING SHUT OFF
NEGATIVE FLOW CON.
C2
C6
pa11 DR1' DR1 pc1 B5 A5 pb5 DIPPER 1 a
pa10
DHV
2-STAGE TRAVEL
C1
B9 A9
Mu
RIGHT
Mu
RIGHT
B2
T2
f
pa5 pc4 B4 A4
SDV
DIPPER 2
pb9
LEFT
LEFT
10
10
pa9
pb4 OPTION pa4
B8 A8
BUCKET
pb8
pa8
BHV
DR2' DR2 pc2 A7
A3 B3 pb3
BOOM2
c h
BOOM1
pa3 B2 A2
B7 pb7
d
DR3 SLEW pa2 pc6
BPV
pa7
17
A
A
pb2
B6 A6
TRAVEL
pb6
pa6
B1 A1 pb1 TRAVEL pa1 pr1
LINEAR TRAVEL
P
R3 P1 PT R2
R1
pr2 PA PH P2
PP
26
LEFT
24
Key to Oil Flow & Pressure Full Pressure
LEFT SWING RIGHT
A3
UP
S2 S3 BOOM
A4
DOWN
A5
OUT
C9 ARM
C5 A6
IN
A1
A2
Pressure Servo Neutral Exhaust Cavitation Lock Up

A408950
9804/1103
45 - 20 - 02/38
6320 - E/38-22.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/39
JS460 Tier 2 - Auxiliary Flow Merged Circuit Diagrams - Hydraulic
pa11 DR1' DR1 pc1 B5 A5 pa10 ps1 T3 T1 pc5 ps2
12
49
pb5
DHV
B9
DIPPER 1 a
48
B D T T A P
47
190 bar
D
A9
f
pa5
SDV
DIPPER 2
pb9
P B A
pc4 B4 pb4 A4
pa9
13
B C A
b
OPTION
B8 A8
BUCKET
pb8
10
3.5 bar
pa4
BHV
pa8 DR2' pc2

BOOM2
A3
45
B
B3 pb3 B2 A2 pb2
DR2 A7 B7 pb7
c h d
BPV BOOM1
pa3
A C
SLEW
pa7
DR3 pa2 pc6 B1 A1 pb1 TRAVEL pa1 pr1 R1 R3

T P
B6 A6
TRAVEL
pb6
pa6
LINEAR TRAVEL
1
OPTION
19
R2 PP PA PH P2
pr2
P1
PT
A1
A2
A408960
9804/1103
45 - 20 - 02/39
6420 - E/38-23.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/40
JS460 Tier 2 - Auxiliary Flow Circuit Diagrams - Hydraulic

An auxiliary circuit gives a bi-directional flow to the equipment being used. The Option pedal 19 can be selected back or forward depending on the direction the operator wants the equipment to move. Servo pressure from the pedal, enters the main control valve at either port Pa4 or Pb4 depending on the direction the pedal is selected. This in turn moves the spool in the selected direction. Oil from pump A1 is blocked at the option spool and is diverted to the parallel-working gallery via the linear travel spool, where it is available to the now selected option spool. Depending on the direction selected, the oil will exit the valve block through ports A4 or B4. In the example shown, oil flows from Port A4 to the direction valve, which is set in the auxiliary position. The oil travels across the valve and to the attachment fitted. In Auxiliary mode, solenoid 13 is energised allowing the change-over valves to vent to tank and select the auxiliary position. Returning oil again goes across the direction valve and back to the option spool via port B4 were it is diverted to the tank port. In Auxiliary the oil from pump A2 is in a neutral state. (See neutral circuit)
a b c d e f g h i j
JS460 Tier 2 - Merged

This option allows the flow of both pumps to come together where the attachment requires high oil flow. The operation is similar to auxiliary except, a shuttle valve 14 is placed between the direction hoses, which allows pressure from either side of the option pedal to be available to the merge solenoid 13. When the merged option is selected, using the auxiliary switch in the cab, the merge solenoid 13 is energised. Pressure from either side of the pedal crosses the solenoid and selects the Merge Spool at port Pa10 spool, which blocks the flow of oil to tank from pump A2. Oil from pump A2 is directed to merge with the flow of oil from pump A1 at the option spool.
9804/1103
45 - 20 - 02/40
6420 - E/38-24.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/41
JS460 Tier 2 - Hammer Circuit Circuit Diagrams - Hydraulic

The hammer function only works when the hammer pedal 19 is pressed in a forward direction. In this position pressure from the foot pedal is available to the hammer pressure switch 16, to reduce engine RPM to supply the required oil flow for the hammer. Servo pressure from the foot pedal enters the main control valve 12 at port Pa4 and selects the option spool. Oil from pump A1 is then blocked at the option spool and is diverted through the linear travel spool and into the parallel working gallery, where it is able to cross the now selected option spool and exit the valve block at port A4. On hammer only systems, the oil flow is will now go directly to the hammer. The pressure required to drive the hammer is set at the option spool ARV on the main valve block. Oil returning from the hammer flows through the hammer filter 45 and direct to tank. Note: When the machine is equipped for hammer only (not auxiliary) the hose from Port2 of the hammer pedal will be connected to the tank port of the cab manifold and the hose from Port Pb4 of the main control valve 12 will be connected to the tank manifold. When a machine that is fitted with a hammer/auxiliary combined option the ARV's in the valve block are set to the pressure required for the auxiliary system and not the hammer. In hammer mode oil flowing from the main control valve 12, has to cross the hammer /auxiliary change over valve 47. At the valve the flow is diverted in 2 directions: 1. To feed the hammer. 2. To the hammer ARV 47, so pressure going to the hammer can be regulated. Returning oil from the hammer enters the change over valve 48 and is diverted direct to tank via the hammer filter 45. The Hammer/auxiliary change over solenoid 13 is deenergised and allows a 40 bar servo pressure to cross and hold the change over valve 47 in the hammer position.
a b c d e f g h i j
9804/1103
45 - 20 - 02/41
6420 - E/38-25.1
Issue 1
CONTENTS
Excavators
45 - 20 - 02/42
JS460 Tier 2 - Hammer Circuit Circuit Diagrams - Hydraulic
12
ps1 T3 T1 pc5 ps2
49
B5 A5
pa11 DR1' DR1 pc1
pa10
DHV
B9
DIPPER 1 a
48
B D T T A P
47
190 bar
D
pb5
A9
f
pa5
SDV
DIPPER 2
pb9
P B A
pc4 B4 pb4 A4
pa9
13
B C A
b
OPTION
B8 A8
BUCKET
pb8
10
3.5 bar
pa4
BHV
pa8 DR2' pc2

BOOM2
45 13
B
A3 B3 pb3 B2 A2 pb2
DR2 A7 B7 pb7
c h d
BPV BOOM1
pa3
SLEW
pa7
DR3 pa2 pc6 B1 A1 pb1 TRAVEL pa1 pr1 R1 R3

T P
B6 A6
TRAVEL
pb6
pa6
LINEAR TRAVEL
2
OPTION
19
R2 PP PA PH P2
pr2
P1
PT
A1
A2
A408970
9804/1103
45 - 20 - 02/42
6320 - E/38-26.1
Issue 1
CONTENTS
Wheeled Loaders
Contents i
ALL MODELS Contents

Page No. General Information -Lubricants and Capacities - 406, 408 - 407, 409 - 407B ZX, 408B ZX, 409B ZX (1000 Series Engines) - 407B ZX, 408B ZX, 409B ZX (N. America) (1000 Series Engines) - 407B ZX, 408B ZX, 409B ZX (New 1000 Series Engines) - 407B ZX, 408B ZX, 409B ZX (N. America) (New1000 Series Engines) - 410B ZX, 411B ZX - 412S, 414S, 416S - Pre-Smoothshift Transmission - 412S, 414S, 416S - Smoothshift Transmission - 412S, 414S, 416S (N.America) - Pre- Smoothshift Transmission - 411, 416 * - 411, 416, 411B, 416B - 426, 436 - 426B, 436B, 446B - 426B, 436B. 446B (N. America) - 436B from m/c no. 533692 - 456B - 456 to m/c no. 539249 (N. America) * - 446 from m/c no. 540000, 456 from m/c no. 539250 * - 446 from m/c no. 540000, 456 from m/c no. 539250 (N. America) * - TM200, TM270 - TM200, TM270 (N. America) Static Dimensions and Wieghts - 406, 407, 408, 409 - 407B, 408B, 409B, 410B - 409TM - 411, 416 - 412S, 414S - 426, 436 - 426B - 436B to m/c n. 533691 - 436B from m/c no. 533692 - 446B - 456B to m/c no. 539249 - 456B from m/c no. 539250 - TM200 - TM270
50 - 00 - 01/1 50 - 00 - 1/2 50 - 00 - 01/6 50 - 00 - 01/6A 50 - 00 - 01/6B 50 - 00 - 01/6C 50 - 00 - 01/7,7A 50 - 00 - 01/5 50 - 00 - 01/5A 50 - 00 - 01/5B 50 - 00 - 01/3 50 - 00 - 01/3A 50 - 00 - 01/4 50 - 00 - 01/10 50 - 00 - 01/11 50 - 00 - 01/12 50 - 00 - 01/8 50 - 00 - 01/8A 50 - 00 - 01/8B 50 - 00 - 01/8C 50 - 00 -01/9,9A 50 - 00 - 01/9B 50 - 00 - 02/1 50 - 00 - 02/6 50 - 00 - 02/5 50 - 00 - 02/2 50 - 00 - 02/4 50 - 00 - 02/3 50 - 00 - 02/10 50 - 00 - 02/10 50 - 00 - 02/10A 50 - 00 - 02/11 50 - 00 - 02/7 50 - 00 - 02/7A 50 - 00 - 02/8 50 - 00 - 02/9
Data Electrical - 406, 407, 408, 409 - 407B, 408B, 409B,to serial no. 755182 - 407B, 408B, 409B from serial no. 755183 to 755490 - 410B ZX to m/c no 755490 - 407B ZX, 408B ZX, 409B ZX from m/c no. 755491 to 757399 - 407B ZX, 408B ZX, 409B ZX from m/c no. 7557400 - 410B ZX, 411B ZX from m/c no. 755491 - 411, 416 - 411 to m/c no. 527375, 416 to m/c no. 529431 - 411 from m/c no. 527400, 416 from m/c no. 529500 * - 411 from m/c no. 527850, 416 from m/c no. 530100 * - 411 from m/c no. 527850, 416 from m/c no. 530100 - 412S, 414S, 416S - 412S to m.c no. 535116 - 412S from m/c no. 535117 to 535349, 414S to m/c no. 537149 - 412S from m/c no. 535350, 414S from m/c no. 537150 - 416S from m/c no. 543000 - 412S from m/c no. 535500, 414S from m/c no. 537300, 416S from m/c no. 543100 - 426, 436 - 426B, 436B, 446B
9804/1103
50 - 05 - 01/1 50 - 05 - 01/9 50 - 05 - 01/10 50 - 05 - 01/11 50 - 05 - 01/11A 50 - 05 - 01/11B 50 - 05 - 01/11A 50 - 05 - 01/2 50 - 05 - 01/3 50 - 05 - 01/3A 50 - 05 - 01/3B 50 - 05 - 01/3C 50 - 05 - 01/6 50 - 05 - 01/7 50 - 05 - 01/8 50 - 05 - 01/8A 50 - 05 - 01/8B 50 - 05 - 01/8C 50 - 05 - 01/4 & 5 50 - 05 - 01/15
Issue 8*
Wheeled Loaders Contents - 1
CONTENTS
Wheeled Loaders
Contents ii
- 426B to serial no. 531064, 436B to serial no. 533069 - 426B from serial no. 531065, 436B from serial no. 533070 - 426B from serial no. 531300, 436B from serial no. 533300 - 446B from serial no. 540000 - 436B from m/c no. 533692 - 456B - TM200 - TM270 to m/c no. 787040 - TM270 from m/c no. 787041 Hydraulics - 406, 407 - 408, 409 - 407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX - 409TM - 411 - 412S, 414S, 416S - 416 - 426 - 436 - 426B - 436B, 446B - 456B - 426, 436 Smoothshift - TM200 - TM270 Transmission, Axles & Tyres - 406, 407, 408, 409 - 407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX - 411, 416 - 412S, 414S, 416S - 426, 436 - 426B, 436B, 446B - 456B - TM200, TM270 - TM200, TM270 Syncro Shuttle - TM200, TM270 Powershift - TM200, TM270 Transfer Gearbox Brakes - 406, 407, 408, 409 - 407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX - 411, 416 - 412S, 414S, 416S - 426, 436 - 426B, 436B, 446B - 456B - TM200, TM270 Steering - 406, 407, 408, 409 - 407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX - 411, 416, 426, 436 - 412S, 414S, 416S - 426B, 436B, 446B - 456B - TM200, TM270 Engine - 406, 407 - 408, 409 - 407B ZX, 408B ZX, 409B ZX, 410B ZX - 411B ZX - 407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX (Darwin Engines) - 411 - 412S - 414S - 412S, 414S, 416S
9804/1103
50 - 05 - 01/16 50 - 05 - 01/17 50 - 05 - 01/18 50 - 05 - 01/19 50 - 05 - 01/20, 21 50 - 05 - 01/12 50 - 05 - 01/13 50 - 05 - 01/14 50 - 05 - 01/14A 50 - 05 - 02/1 50 - 05 - 02/2 50 - 05 - 02/9,10 50 - 05 - 02/8 50 - 05 - 02/3 50 - 05 - 02/7 50 - 05 - 02/4 50 - 05 - 02/5 50 - 05 - 02/6 50 - 05 - 02/14 50 - 05 - 02/15 50 - 05 - 02/11 50 - 05 - 02/16 & 16A 50 - 05 - 02/12 50 - 05 - 02/13 50 - 05 - 03/1 to 3 50 - 05 - 03/7 50 - 05 - 03/4, 4A 50 - 05 - 03/6, 6A 50 - 05 - 03/5 50 - 05 - 03/14, 15 50 - 05 - 03/8 50 - 05 - 03/9, 10 50 - 05 - 03/11 50 - 05 - 03/12 50 - 05 - 03/13 50 - 05 - 05/1 50 - 05 - 05/5 50 - 05 - 05/2 50 - 05 - 05/4 50 - 05 - 05/3 50 - 05 - 05/8 50 - 05 - 05/6 50 - 05 - 05/7 50 - 05 - 06/1 50 - 05 - 06/4 50 - 05 - 06/2 50 - 05 - 06/3 50 - 05 - 06/7 50 - 05 - 06/5 50 - 05 - 06/6 50 - 05 - 07/1 50 - 05 - 07/2 50 - 05 - 07/8 50 - 05 - 07/8A 50 - 05 - 07/8B 50 - 05 - 07/3 50 - 05 - 07/6 50 - 05 - 07/7 50 - 05 - 07/7A
Issue 8*
Wheeled Loader Contents - 2
CONTENTS
Wheeled Loaders
Contents iii
Engine (continued) - 412S from m/c no. 535650 (RJ Build) - 416 - 411B, 416B - 416 from m/c no. 530350 (RJ Build) - 426, 436 * - 426 from m/c no. 532500 - 426B, 436B - 446B - 426B, 436B, 446B, (Darwin Engines) - 456B - TM200, TM270 - TM200, TM270 (Darwin Engines) Fault Finding Hydraulics - 407B, 408B, 409B, 410B - 426, 436 - 426B, 436B, 446B - 456B Circuit Diagrams Electrical - 406, 407, 408, 409, Syncro Shuttle Machines from serial no. 632700 - 406, 407, 408, 409 Powershift Machines from serial no. 632700 - 407B, 408B,409B to serial no. 755182 - 407B, 408B,409B from serial no. 755183 - 409TM - 410B ZX to m/c no. 755490 - 407B ZX, 408B ZX, 409B ZX from m/c no. 755491 to 757399 - 407B ZX, 408B ZX, 409B ZX from m/c no. 757400 - 410B ZX, 411B ZX from m/c no. 755491 - 411 to serial no. 527012, 416 to serial no. 529014 - 411 to serial no. 527013, 416 to serial no. 529015 - 411 from m/c no. 527400, 416 from m/c no. 529500 - 411, 411B from m/c no. 527850, 416, 416B from m/c no. 530100 - 412S to serial no. 535116 - 412S from serial no. 535117 - 412S from m/c no. 535375 - 414S from serial no. 537000 to 537193 - 414S from m/c no. 537194, 416S from m/c no. 543000 - 426, 436 - 426 m/cs from 532100, 436 m/cs from 533692 * - 426B to serial no. 531064, 436B to serial no. 533069 - 426B from serial no. 531065, 436B from serial no. 533070 - 426B from serial no. 531300, 436B from serial no. 533300 - 426B, 436B m/cs from March 1998 - 436B from m/c no. 533692 - 446B m/cs from March 1998 - 446B m/cs from no 540000 - 456B - TM200 - TM270 to m/c no. 787040 - TM270 from m/c no. 787041 Hydraulic - 406, 407, 408, 409 - 407B ZX, 408B ZX, 409B ZX Servo to m/c no. 757399 - 407B ZX, 408B ZX, 409B ZX Manual to m/c no. 757399 - 407B ZX, 408B ZX, 409B ZX from m/c no. 757400 - 410B ZX - 411B ZX - 411 - 412S, 414S - 416 to machine no. 529342 - 416 from m/c no. 529343 - 416S Circuit Diagrams (continued)
9804/1103
50 - 05 - 07/7B 50 - 05 - 07/4 50 - 05 - 07/10B 50 - 05 - 07/10C 50 - 05 - 07/5 50 - 05 - 07/5A 50 - 05 - 07/11 50 - 05 - 07/12 50 - 05 - 07/13 50 - 05 - 07/9 50 - 05 - 07/10 50 - 05 - 07/10A
50 - 10 - 01/2 to 9 50 - 10 - 01/1 50 - 10 - 01/11 50 - 10 - 01/10
50 - 15 - 01/1 to 4 50 - 15 - 01/5 to 8 50 - 15 - 04/2 to 5 50 - 15 - 05/1 to 4 50 - 15 - 04/1 50 - 15 - 06/1 to 4 50 - 15 - 06/5 to 8 50 - 15 - 06/8A to 8D 50 - 15 - 06/5 to 8 50 - 15 - 01/9 & 10 50 - 15 - 01/11 & 12 50 - 15 - 01/13 to 20 50 - 15 - 01/21 to 34 50 - 15 - 02/1 & 2 50 - 15 - 02/3 to 6 50 - 15 - 02/7 to 14 50 - 15 - 03/1 to 4 50 - 15 - 03/5 to 12 50 - 15 - 01/21, 22 50 - 15 - 10/45 to 58 50 - 15 - 10/1,2 50 - 15 - 10/3 to 6 50 - 15 - 10/7 to 10 50 - 15 - 10/15 to 22 50 - 15 - 10/31 to 44 50 - 15 - 10/23 to 30 50 - 15 - 10/11 to 14 50 - 15 - 07/1 to 4 50 - 15 - 08/1 to 4 50 - 15 - 09/1 to 4 50 - 15 - 09/5 to 8 50 - 20 - 01/1, 2 50 - 20 - 03/1, 2 50 - 20 - 03/3, 4 50 - 20 - 03/5, 6 50 - 20 - 04/1, 2 50 - 20 - 04/3, 4 50 - 20 - 01/3 & 4 50 - 20 - 02/1 & 2 50 - 20 - 01/5 & 6 50 - 20 - 01/6A, 6B 50 - 20 - 02/3, 4
Issue 6*
CONTENTS
Wheeled Loaders
Contents iv
* Hydraulic (continued) - 426 machines with 4-ram loader - 426 machines with Z-bar loader - 426B machines with Z-bar loader to serial no. 531203 - 426B machines with 4-ram loader from serial no. 531204 - 426B machines with Z-bar loader from serial no. 531204 - 426B machines 4-ram loader to serial no. 531203 - 436 machines with 4-ram loader - 436 machines with Z-bar loader - 436B machines with 4-ram loader to serial no. 533195 - 436B machines with Z-bar loader to serial no. 533195 - 436B machines with 4-ram loader from serial no. 533196 - 436B machines with Z-bar loader from serial no. 533196 - 446B ZX from m/c no. 540000 - 436B from m/c no.533692 - 456 to m/c no. 539249 - 456 from m/c no. 539250, 446 from m/c no. 540013 - TM200 - TM270 - TM270 from m/c no. 787118 50 - 20 - 01/7 & 8 50 - 20 - 01/9 & 10 50 - 20 - 08/3, 4 50 - 20 - 08/9, 10 50 - 20 - 08/11, 12 50 - 20 - 08/1, 2 50 - 20 - 01/11 & 12 50 - 20 - 01/13 & 14 50 - 20 - 08/5, 6 50 - 20 - 08/7, 8 50 - 20 - 08/13, 14 50 - 20 - 08/15, 16 50 - 20 - 08/15, 16 50 - 20 - 08/17, 18 50 - 20 - 05/1, 2 50 - 20 - 05/1A, 2A 50 - 20 - 06/1, 2 50 - 20 - 07/1, 2 50 - 20 - 07/3, 4
9804/1103
Issue 3*
CONTENTS
Wheeled Loaders
50 - 00 - 01/1
406,408 Fluids, Lubricants & Capacities

Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below.
ITEM
Engine Oil -18 to 0 C -10 to 50 C
CAPACITY
406 7.2 litres (1.6 UK gal) 408 10.7 litres (2.4 UK gal) Syncro Shuttle 19 litres (4.2 UK gal) Powershift 19 litres (4.2 UK gal) 1.3 litres (0.3 UK gal)
FLUID/LUBRICANT
JCB Torque Converter Fluid JCB 15W/40 Multigrade
SPECIFICATION
API CD MIL-L-2104C
Gearbox
JCB Special Transmission Fluid JCB Special Transmission Fluid JCB HD 90 Gear Oil
Ford ESN-M2C 33G Ford ESN-M2C 33G API-GL-5, MIL-L-2105C
Transfer box Axles - Hurth (406) Differential Housing Hubs (Individual) Axles - JCB
5.0 litres (1.1 UK gal) 0.2 litres (0.04 UK gal) 406 5.0 litres (1.1 UK gal) 408 16 litres (3.6 UK gal) 406 59 litres (13.2 UK gal) 408 63 litres (14.1 UK gal) 1.2 litres (0.27 UK gal)
Ford ESE-M2C 86B Ford ESE-M2C 86B
Hydraulic System Up to 38 C Above 38C
JCB Special Hydraulic Fluid JCB High Performance Hydraulic Fluid
ISO 32 ISO 46
Brake System
ISO 15
CAUTION: DO NOT USE ORDINARY BRAKE FLUID Cooling System 406 12.5 litres (2.8 UK gal) 408 15.5 litres (3.5 UK gal) 406 65 litres (14.5 UK gal) 408 90 litres (20.2 UK gal) Water/Anti-freeze ASTM D3306-74
Fuel System
Diesel Oil
ASTM D975-66T Nos. 1D, 2D.
Grease Points
JCB Special MPL Grease
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.
9804/1103
50 - 00 - 01/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 01/2

ITEM
Engine Oil -18 to 0 C -10 to 50 C Gearbox
CAPACITY
FLUID/LUBRICANT
SPECIFICATION
API CD MIL-L-2104C
Syncro Shuttle 19 litres (4.2 UK gal) Powershift 13 litres (2.9 UK gal) 1.3 litres (0.3 UK gal) 407 5.0 litres (1.1 UK gal) 409 16 litres (3.6 UK gal)
Transfer box Axles
Hydraulic System Up to 38 C Above 38C Brake System
JCB Special Hydraulic Fluid JCB High Performance Hydraulic Fluid JCB Light Hydraulic Fluid
ISO 32 ISO 46 ISO 15
CAUTION: DO NOT USE ORDINARY BRAKE FLUID Cooling System Fuel System Grease Points 15.5 litres (3.5 UK gal) 90 litres (20.2 UK gal) Water/Anti-freeze Diesel Oil JCB Special MPL Grease ASTM D3306-74 ASTM D975-66T Nos. 1D, 2D. Lithium based, No. 2 consistency
9804/1103
50 - 00 - 01/2
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 01/3

411
ITEM
Engine Oil -18 to 0 C -10 to 50 C Gearbox Axles Hydraulic System Brake System
CAPACITY
FLUID/LUBRICANT
JCB Torque Converter Fluid JCB 15W/40 Multigrade JCB Torque Converter Fluid JCB Special Gear Oil JCB HP32 Hydraulic Fluid JCB Light Hydraulic Fluid
SPECIFICATION
API CE, MIL-L-2104C/D API CE, MIL-L-2104C/D Ford ESE-M2C 86B ISO VG32 ISO 15
18 litres (4.1 UK gal) 25.0 litres (5.6 UK gal) 110 litres (24.8 UK gal) 0.7 litres (0.15 UK gal)
* 411 machines up to ser. no. 527163 ONLY Cooling System Fuel System Grease Points 26 litres (5.9 UK gal) 125 litres (28.1 UK gal)
CAUTION: DO NOT USE ORDINARY BRAKE FLUID Water/Anti-freeze Diesel Oil JCB HP Grease ASTM D3306-74 ASTM D975-66T Nos. 1D, 2D. Lithium based
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. * Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals.
416
ITEM
Engine Oil -18 to 0 C -10 to 50 C Gearbox Axles Hydraulic System Cooling System Fuel System Grease Points
CAPACITY
FLUID/LUBRICANT
JCB Torque Converter Fluid JCB 15W/40 Multigrade JCB Torque Converter Fluid JCB Special Gear Oil JCB HP32 Hydraulic Fluid Water/Anti-freeze Diesel Oil JCB HP Grease
SPECIFICATION
API CE, MIL-L-2104C/D API CE, MIL-L-2104C/D Ford ESE-M2C 86B ISO VG32 ASTM D3306-74 ASTM D975-66T Nos. 1D, 2D. Lithium based
19 litres (4.3 UK gal) 23.0 litres (5.2 UK gal) 125 litres (27.5 UK gal) 26 litres (5.9 UK gal) 140 litres (31.5 UK gal)
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. * Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals.
9804/1103
50 - 00 - 01/3
Issue 2*
CONTENTS
Wheeled Loaders
50 - 00 - 01/3A
* 411,
416, 411B, 416B
Fluids, Lubricants & Capacities

ITEM
Engine Oil (A) -18C to 0C -10C to 50C Engine Oil (B)
CAPACITY
FLUID/LUBRICANT
JCB Torque Converter Fluid JCB 15W/40 Multigrade JCB Super Multigrade 15W/40 -10C to +50C (14F to 122F) JCB Super Multigrade 15W/40 -15C to +40C (5F to 104F)
SPECIFICATION
API CE, MIL-L-2104C/D
CF-4/SG, SAE 15W/40 CF-4/SG, SAE 10W/30
Gearbox
411 18 litres (4.1 UK gal) 416 19 litres (4.3 UK gal) 411 24.0 litres (5.3 UK gal) 416 25.0 litres (5.6 UK gal) 4111 110 litres (24.2 UK gal) 414 125 litres (27.5 UK gal)
JCB Torque Converter Fluid JCB Torque Converter Fluid
API CE, MIL-L-2104C/D API CE, MIL-L-2104C/D
Axles
JCB Special Gear Oil Plus JCB Special Gear Oil Plus
API GL4 API GL4
Hydraulic System
JCB HP32 Hydraulic Fluid JCB HP32 Hydraulic Fluid
ISO VG32 ISO VG32
Brake System 0.7 litres (0.15 UK gal) 411 machines up to ser. no. 527163 ONLY Cooling System 26 litres (5.9 UK gal)
JCB Light Hydraulic Fluid ISO 15 CAUTION: DO NOT USE ORDNINARY BRAKE FLUID Water/Anti-feeze (see Coolant Mixture) ASTM D3306-74
Fuel System
411 125 litres (27.5 UK gal) 416 140 litres (30.8 UK gal)
Diesel Oil (see Types of Fuel) Diesel Oil (see Types of Fuel) JCB HP Grease
ASTM D975-66T Nos. 1D, 2D. ASTM D975-66T Nos. 1D, 2D. Lithium based
Grease Points
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals. Engine Oil (A) Engine Oil (B) 411 to serial number 527504, 416 to serial number 529618 411 from serial number 527505, 416 from serial number 529619
Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
9804/1103
50 - 00 - 05/3A
4150 - 3/1-1.7
Issue 1*
CONTENTS
Wheeled Loaders
50 - 00 - 01/4

ITEM
Engine Oil -18 to 0 C -10 to 50 C Gearbox 426 436 Front Axle 426 * 436 Rear Axle 426 * 436 Hydraulic System 426 436 Fuel System 426 436 Cooling System Grease Points
CAPACITY
FLUID/LUBRICANT
SPECIFICATION
23 litres (5.2 UK gal) 24 litres (5.4 UK gal)
JCB Torque Converter Fluid
26.0 litres (5.8 UK gal) 40.0 litres (9.0 UK gal)
JCB LS Gear Oil
API GL4, MIL-L-2105A
JCB LS Gear Oil
JCB HP32 Hydraulic Fluid
ISO VG32
212 litres (47.6 UK gal) 230 litres (51.7 UK gal) 50 litres (11.2 UK gal)
Diesel Oil
ASTM D975-66T Nos. 1D, 2D
Water/Anti-freeze JCB HP Grease
ASTM D3306-74 Lithium based
9804/1103
50 - 00 - 01/4
Issue 2*
CONTENTS
Wheeled Loaders
50 - 00 - 01/5
* 412S,
414S, 416S - Pre-Smoothshift Transmission
ITEM
CAPACITY
412S To Ser. No 535352 10.7 litres (2.4 UK gal) 414S To Ser. No 537160 16.0 litres (3.5 UK gal) 412S From Ser. No 535353 10.7 litres (2.4 UK gal) 414S From Ser. No 537161 16.0 litres (3.5 UK gal)
FLUID/LUBRICANT
SPECIFICATION
Engine Oil
JCB Super Multigrade 15w/40 -10C to +50C (14F to 122F) JCB Super Multigrade 10w/30 -15C to +40C (5F to 104F)
CF-4/SG, SAE 15w/40 CF-4/SG, SAE 10w/30
Gearbox
412S 18 litres (4.1 UK gal) 414S 23 litres (5.1 UK gal) 412S 24.0 litres (5.3 UK gal) 414S 23.0 litres (5.1 UK gal) 416S 25.0 litres (5.6 UK gal) 412S 110 litres (24.8 UK gal) 414S 125 litres (27.5 UK gal) 412S 26 litres (5.9 UK gal) 414S 412S 125 litres (27.5 UK gal) 414S 140 litres (30.8 UK gal)
API CE, MIL-L-2104C/D API CE, MIL-L-2104C/D
Axles
API GL4
Hydraulic System
ISO VG32
Cooling System
Water/Anti-freeze
ASTM D3306-74 50 litres (11 UK gal)
Fuel System 2D.
Diesel Oil
ASTM D975-66T Nos. 1D,
Diesel Oil
ASTM D975-66T Nos. 1D,
2D. Grease Points JCB HP Grease Lithium based
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be caried out at TEN (10) HOUR intervals. The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. A 75 litre (16.5 UK gal) auxiliary fuel tank is available as an option.
Note: Biodegradeable Hydraulic Fluid is a factory option ONLY. Replenish with JCB Biodegradeable Multigrade Hydraulic Fluid. For further information, contact Wheeled Loader Technical Service. Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
9804/1103
50 - 00 - 01/5
4170 - 3/1 - 1.4
Issue 3*
CONTENTS
Wheeled Loaders
50 - 00 - 01/5A
* 412S,
414S, 416S - Smoothshift Transmission

ITEM
Engine Oil -10C to 50C
CAPACITY
412S 10.7 litres (2.4 UK gal) 414S/416S 16.0 litres (3.5 UK gal) 24 litres (5.3 UK gal) 412S 24.0 litres (5.3 UK gal) 414S 23.0 litres (5.1 UK gal) 416S 25.0 litres (5.6 UK gal) 412S 110 litres (24.2 UK gal) 414S 125 litres (27.5 UK gal) 416S 125 litres (27.5 UK gal)
FLUID/LUBRICANT
JCB Extreme Performance Engine Oil 15W/40
SPECIFICATION
ACEA E3/B3/A3 API CH-4/A3
Gearbox Axles
JCB HP Universal ATF
ZF TE-MIL 09, 11, 12, 14
JCB Special HP Gear Oil JCB Special Gear Oil Plus JCB Special Gear Oil Plus
API GL4 API GL4 API GL4
Hydraulic System
JCB HP32 Hydraulic Fluid JCB Extreme Performance Multigrade Hydraulic Fluid 46 JCB HP32 Hydraulic Fluid
ISO VG32
ISO VG46 ISO VG32
Cooling System
412S 26 litres (5.7 UK gal) 414S/416S 50 litres (11.0 UK gal) 412S 125 litres (27.5 UK gal) 414S/416S 140 litres (30.8 UK gal)
Four Seasons Anti-freeze & Summer Coolant/Water
ASTM D3306, BS6580
Fuel System
Diesel Oil
Grease Points
JCB HP Grease
Lithium based
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals. The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. A 75 litre (16.5 UK gal)(412S), 110 litre (16.5 UK gal)(414S/416S) auxiliary fuel tank is available as an option. Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). Note: Biodegradable Hydraulic Fluid is a factory option ONLY. Replenish with JCB Biodegradable Multigrade Hydraulic Fluid. For further information, contact Earthmovers Technical Service. Note: Smoothshift machine serial numbers as follows: 412S from Serial No. 535500, 414S from Serial No. 537300, 416S from Serial No. 543100
9804/1103
50 - 00 - 05/5A
4170 - 3/1-2.4
Issue 2*
CONTENTS
Wheeled Loaders
50 - 00 - 01/5B
412S, 414S, 416S (N. America) - Pre-Smoothshift Transmission Fluids, Lubricants & Capacities
ITEM
CAPACITY
412S To Ser. No 535352 10.7 litres (2.8 US gal) 414S To Ser. No 537160 16.0 litres (4.2 US gal) 412S From Ser. No 535353 10.7 litres (2.8 US gal) 414S From Ser. No 537161 16.0 litres (4.2 US gal)
FLUID/LUBRICANT
JCB 10W or JCB 15W/40 JCB 30W
SPECIFICATION
MIL-L-2104E API CE
Engine Oil
JCB 15w/40 Engine Oil -10C to +50C (14F to 122F) JCB Engine Oil 10w -20C to +10C (-4F to 50F)
CF-4/SG, SAE 15w/40 CF-4/SG, SAE 10w
Gearbox
412S 18 litres (4.8 US gal) 414S 23 litres (6.1 US gal) 412S 24.0 litres (6.3 US gal) 414S 23.0 litres (6.1 US gal) 416S 25.0 litres (6.6 US gal) 412S 110 litres (29.1 US gal) 414S 125 litres (33.0 US gal) 26 litres (6.9 US gal)
JCB Torque Converter Fluid JCB Torque Converter Fluid
MIL-L-2104E
Axles
JCB GL-5 80w/90 or 85w/140 JCB GL-5 80w/90 or 85w/140 JCB GL-5 80w/90 or 85w/140
API GL-5
Hydraulic System
JCB HP32 Hydraulic Fluid JCB HP32 Hydraulic Fluid Water/Anti-freeze
ISO VG32
Cooling System
ASTM D3306-74
Fuel System
412S 125 litres (33.0 US gal) 414S 140 litres (37.0 US gal)
Diesel Oil Diesel Oil JCB MOLY EP # Grease
Grease Points
Lithium based, NO. 2
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be caried out at TEN (10) HOUR intervals. The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. A 75 litre (19.8 US gal) auxiliary fuel tank is available as an option.
Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). Above 32F (0C). In conditions below 32F (0C) use JCB HP32 Hydraulic Fluid (ISO VG32).
9804/1103
50 - 00 - 01/5B
4170-3/1-2.3
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 01/6
407B ZX, 408B ZX, 409B ZX Fluids, Lubricants & Capacities

ITEM
Engine Oil -18 to 0 C -10 to 50 C Axle Hubs (each) Front Differential Rear Differential/ Transfer Gearbox Hydraulic System Cooling System Fuel System Grease Points Brake System
CAPACITY
FLUID/LUBRICANT
JCB Torque Converter Fluid JCB 15W/40 Multigrade JCB Special Gear Oil Plus JCB Special Gear Oil Plus
SPECIFICATION
API CD MIL-L-2104C
API GL4 API GL4
7.0 litres (1.5 UK gal) 70 litres (15.4 UK gal) 15.5 litres (3.5 UK gal) 100 litres (22 UK gal)
JCB Special Gear Oil Plus JCB 10W/30 Multigrade Water/Anti-freeze Diesel Oil JCB HP Grease JCB Light Hydraulic fluid
API GL4 API CD MIL-L-2104C ASTM D3306-74 ASTM D975-66T Nos. 1D, 2D. Lithium based ISO 15
CAUTION: DO NOT USE ORDINARY BRAKE FLUID
9804/1103
50 - 00 - 01/6
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 01/6A
407B ZX, 408B ZX, 409B ZX (N. America)(1000 Series Engine) Fluids, Lubricants & Capacities
ITEM
Engine Oil -18 to 0 C -10 to 50 C Axle Hubs (each) Front Differential Rear Differential/ Transfer Gearbox Hydraulic System Cooling System Fuel System Grease Points Brake System
CAPACITY
*8 litres (2.2 US gal)
FLUID/LUBRICANT
JCB 10W or JCB 15W/40 JCB 30W JCB GL-5 80W/90 or JCB GL-5 85W/140 JCB GL-5 80W/90 or JCB GL-5 85W/140
SPECIFICATION
API CD, MIL-L-2104D API CD, MIL-L-2104D API-GL-5 API-GL-5
1.75 litres (0.5 US gal) 6.0 litres (1.6 US gal)
7.0 litres (1.8 US gal) 70 litres (18.5 US gal) 15.5 litres (4.1 US gal) 100 litres (26.4 US gal)
JCB GL-5 80W/90 or JCB GL-5 85W/140 JCB 10W/30 Multigrade Water/Anti-freeze Diesel Oil JCB Moly EP # 2 Grease Light Hydraulic fluid
API-GL-5 API CD MIL-L-2104C ASTM D3306-74 ASTM D975-66T Nos. 1D, 2D. Lithium based, No. 2 ISO VG15
CAUTION: DO NOT USE ORDINARY BRAKE FLUID
9804/1103
50 - 00 - 01/6A
4210 - 3/1 - 2 .2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 00 - 01/6B
407B ZX, 408B ZX, 409B ZX (New 1000 Series Engine) Fluids, Lubricants & Capacities
ITEM
Engine Oil (AS Build)
CAPACITY
FLUID/LUBRICANT
JCB Super Multigrade 15w/40 -10C to +50C (14F to 122F) JCB Super Multigrade 10w/30 -15C to +40C (5F to 104F) JCB Special Gear Oil Plus JCB Special Gear Oil Plus
SPECIFICATION
Axle Hubs (each) Front Differential Rear Differential/ Transfer Gearbox Hydraulic System Cooling System
API GL4 API GL4
7.0 litres (1.5 UK gal) 70 litres (15.4 UK gal) 15.5 litres (3.5 UK gal) 16.0 litres (3.52 UK gal) 100 litres (22 UK gal)
JCB Special Gear Oil Plus JCB 10w/30 Super Multigrade Water/Anti-freeze (see Coolant mixture) Diesel Oil (see Types of Fuel) JCB HP Grease
API GL4 CF-4/SG, SAE 10w/30 ASTM D3306-74
Fuel System Grease Points Braking System
ASTM D975-66T Nos. 1D, 2D. Lithium based
JCB Light Hydraulic Fluid ISO 15 CAUTION: DO NOT USE ORDINARY BRAKE FLUID
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). The figure quoted is the TOTAL system capacity. Use the MAX and MIN marks on the dipstick when refilling the system. 407 - 409B ZX, S/N. 757400 on.
9804/1103
50 - 00 - 01/6B
4210 - 3/1 - 4 .2
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 01/6C
407B ZX, 408B ZX, 409B ZX (N. America)(New 1000 Series Engine) Fluids, Lubricants & Capacities
ITEM
Engine Oil (AS Build)
CAPACITY
8.0 litres (2.2 US Gal)
FLUID/LUBRICANT
JCB 15w/40 Engine Oil -10C to +50C (14F to 122F) JCB Engine Oil 10w -20C to +10C (-4F to 50F) JCB GL-5 80w/90 or 85w/140 JCB GL-5 80w/90 or 85w/140
SPECIFICATION
Axle Hubs (each) Front Differential Rear Differential/ Transfer Gearbox Hydraulic System Cooling System
1.75 litres (0.5 US Gal) 6.0 litres (1.6 US Gal)
API GL-5 API GL-5
7.0 litres (1.8 US Gal) 70 litres (18.5 US Gal) 15.5 litres (4.1 US Gal)
JCB GL-5 80w/90 or 85w/140 JCB Engine Oil 10w Water/Anti-freeze (see Coolant mixture) Diesel Oil (see Types of Fuel) JCB HP Grease
API GL-5 CF-4/SG, SAE 10w ASTM D3306-74
Fuel System Grease Points Braking System
100 litres (26.4 US Gal)
ASTM D975-66T Nos. 1D, 2D. Lithium based, No. 2
Light Hydraulic Fluid ISO VG15 CAUTION: DO NOT USE ORDINARY BRAKE FLUID
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). The figure quoted is the TOTAL system capacity. Use the MAX and MIN marks on the dipstick when refilling the system.
9804/1103
50 - 00 - 01/6C
4210 - 3/1 - 5.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 01/7
410B ZX, 411B ZX Fluids, Lubricants & Capacities

ITEM
Engine Oil 410B ZX -18 to 0 C -10 to 50 C 411B ZX -18 to 0 C -10 to 50 C Front Axle Rear Axle/ Transfer Gearbox Hydraulic System Cooling System Fuel System Grease Points Brake System 410B ZX
CAPACITY
FLUID/LUBRICANT
SPECIFICATION
JCB Torque Converter Fluid JCB 15W/40 Multigrade JCB Torque Converter Fluid JCB 15W/40 Multigrade JCB Special Gear Oil Plus
API CD MIL-L-2104C
API CD MIL-L-2104C
API GL4
18.0 litres (4.0 UK gal) 130 litres (28.6 UK gal) 18.0 litres (4.0 UK gal) 110 litres (24 UK gal)
JCB Special Gear Oil Plus JCB 10W/30 Multigrade Water/Anti-freeze Diesel Oil JCB HP Grease JCB Light Hydraulic Fluid
API GL4 API CD MIL-L-2104C ASTM D3306-74 ASTM D975-66T Nos. 1D, 2D. Lithium based ISO 15
CAUTION: DO NOT USE ORDINARY BRAKE FLUID Inching System 411B ZX
ISO 15
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator.
9804/1103
50 - 00 - 01/7
4210 - 3/1 - 3 .2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 00 - 01/7A
410B ZX, 411B ZX Fluids, Lubricants & Capacities

ITEM
Engine Oil 410B ZX (AS Build)
CAPACITY
FLUID/LUBRICANT
SPECIFICATION
JCB Super Multigrade 15w/40 -10C to +50C (14F to 122F) JCB Super Multigrade 10w/30 -15C to +40C (5F to 104F) JCB Super Multigrade 15w/40 -10C to +50C (14F to 122F) JCB Super Multigrade 10w/30 -15C to +40C (5F to 104F) JCB Special Gear Oil Plus
411B ZX (AQ Build)
Front Axle Rear Axle/ Transfer Gearbox Hydraulic System
API GL4
JCB Special Gear Oil Plus JCB 10w/30 Super Multigrade -15C to 40C (5F to 104F)
API GL4 CF-4/SG, SAE 10w/30
Cooling System
Water/Anti-freeze (see Coolant mixture) Diesel Oil (see Types of Fuel) JCB HP Grease
ASTM D3306-74
Fuel System Grease Points Inching System
JCB Light Hydraulic Fluid ISO 15 CAUTION: DO NOT USE ORDINARY BRAKE FLUID
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). The figure quoted is the TOTAL system capacity. Use the MAX and MIN marks on the dipstick when refilling the system.
9804/1103
50 - 00 - 01/7A
4210 - 3/1 - 6.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 01/8
456B Fluids, Lubricants and Capacities

ITEM
Engine Oil -18 to 0 C -10 to 50 C Gearbox Axles Hydraulic System Cooling System Fuel System Grease Points
CAPACITY
FLUID/LUBRICANT
JCB Torque Converter Fluid JCB 15W/40 Multigrade JCB Torque Converter Fluid JCB Special Gear Oil Plus JCB HP32 Hydraulic Fluid Water/Anti-freeze Diesel Oil JCB HP Grease
SPECIFICATION
API CE, MIL-L-2104C/D API CE, MIL-L-2104C/D API GL4 ISO VG32 ASTM D3306-74 ASTM D975-66T Nos. 1D, 2D. Lithium based
28 litres (6.2 UK gal) 51 litres (11.2 UK gal) 215 litres (47.3 UK gal) 38 litres (8.4 UK gal) 325 litres (71.5 UK gal)
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals. The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.
9804/1103
50 - 00 - 01/8
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 01/8A
* 456
to Serial Number 539249
Fluids, Lubricants & Capacities - North America

Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). ENgines of new machies are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be usd for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below.
ITEM
Engine Oil 0 to 32C
CAPACITY
5.0 gal (18.9 liters)
FLUID/LUBRICANT
JCB Genuine Engine Oil SAE 15W/40
SPECIFICATION
MIL-L-2104C/D API CE APi CE, MIL-L-2104C/D API GL4, MIL-L-2105A ISO 46 ASTM D3306-74 ASTM D975-66T Nos. 1D, 2D Lithium based No. 2
Gearbox Axles Hydraulic System Cooling System Fuel System Grease Points
7.4 gal (28.0 liters) 13.5 gal (51.0 liters) 56.8 gal (215 liters) 10.1 gal (37 liters) 85.9 gal (325 liters)
JCB 10W Engine Oil JCB 80 - 90 JCB 46 AW Water/Anti-feeze (see Coolant Mixture) Diesel Oil (See Types of Fuel) JCB Molygrease EP2
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. Above 32F (0C). In conditions below 32F (0C) use JCB HP32 Hydraulic Fluid
9804/1103
50 - 00 - 05/8A
4180 - 3/1-3.3
Issue 1*
CONTENTS
Wheeled Loaders
50 - 00 - 01/8B
* 446
from Serial Number 540000 456 from Serial Number 539250

Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). ENgines of new machies are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be usd for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below.
ITEM
Engine Oil -10 to 50C
CAPACITY
FLUID/LUBRICANT
JCB Extreme Performance Engine Oil 15W/40 JCB HP Universal HTF JCB Gear Oil LS JCB HP32 Hydraulic Fluid Water/Anti-feeze (see Coolant Mixture) Diesel Oil (See Types of Fuel) JCB HP Grease
SPECIFICATION
ACEA E/3B/3A/3 API CH-4A3 ZF TE-ML 09, 11, 12, 14 API GL4, MIL-L-2105B ISO VG32 ASTM D3306-74 ASTM D975-66T Nos. 1D, 2D Lithium based
28 litres (6.2 UK gal) 51 litres (11.2 UK gal) 215 litres (47.3 UK gal) 38 litres (8.4 UK gal) 325 litres (71.5 UK gal)
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carriewd out at TEN (10) HOUR intervals. The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). If API CH-4 or ACEA E3/B3/A3 engine oil is not available, then the engine oil must be changed every 250 hours.
9804/1103
50 - 00 - 05/8B
4180 - 3/1-4.2
Issue 1*
CONTENTS
Wheeled Loaders
50 - 00 - 01/8C
* 446
from Serial Number 540000 456 from Serial Number 539250
Fluids, Lubricants & Capacities - North America

Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal qork cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil cinsumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oils should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation it is essential that the 10W/30 oil is replaced by the lubricant recommended below.
ITEM
Engine Oil 14 to 122F
CAPACITY
5.0 gal (18.9 liters)
FLUID/LUBRICANT
JCB Genuine Engine Oil SAE 15W/40
SPECIFICATION
ACEA E/3B/3A/3 API CH-4A3 ZF TE-ML 09, 11, 12, 14 API GL4, MIL-L-2105A ISO 46 ASTM D3306-74 ASTM D975-66T Nos. 1D, 2D Lithium based No. 2
7.4 gal (28.0 liters) 16.5 gal (51.0 liters) 56.8 gal (215 liters) 10.1 gal (38 liters) 85.9 gal (325 liters)
JCB MP Automatic Transmission Fluid JCB 80 - 90 JCB 46 AW Water/Anti-feeze (see Coolant Mixture) Diesel Oil (See Types of Fuel) JCB Molygrease EP2
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. Above 32F (0). In conditions below 32F (0C) use JCB HP32 Hydraulic FLuid (ISO VG32) Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). If API CH-4 or ACEA E3/B3/A3 engine oil is not available, then the engine oil must be changed every 250 hours.
9804/1103
50 - 00 - 05/8C
4180 - 3/1-5.2
Issue 1*
CONTENTS
Wheeled Loaders
50 - 00 - 01/9
TM200, TM270 (1000 Series Engines) Fluids, Lubricants & Capacities

ITEM
Engine Oil -18 to 0 C -10 to 50 C Gearbox Syncro Shuttle Powershift Transfer box Axles (TM 200) (TM 270) Hydraulic System (TM200) Up to 38 C Above 38C (TM270) Up to 38 C Above 38C Cooling System Fuel System Grease Points
CAPACITY
FLUID/LUBRICANT
SPECIFICATION
API CD MIL-L-2104C
19 litres (4.2 UK gal) 13 litres (2.9 UK gal) 1.3 litres (0.3 UK gal)
JCB Special Hydraulic Fluid JCB High Performance Hydraulic Fluid JCB Special Hydraulic Fluid JCB High Performance Hydraulic Fluid Water/Anti-freeze Diesel Oil JCB Special MPL Grease
ISO 32 ISO 46 ISO 32 ISO 46 ASTM D3306-74 ASTM D975-66T Nos. 1D, 2D. Lithium based, No. 2 consistency
Wear Pad Runways
JCB Waxoyl
9804/1103
50 - 00 - 01/9
4225 - 3/1 - 1 . 1
Issue 2
CONTENTS
Wheeled Loaders
50 - 00 - 01/9A
TM200, TM270 (New 1000 Series Engines) Fluids, Lubricants & Capacities
ITEM
Engine Oil
CAPACITY
FLUID/LUBRICANT
JCB Super Multigrade 15w/40 -10C to +50C (14F to 122F) JCB Super Multigrade 10w/30 -15C to +40C (5F to 104F) JCB Special Transmission Fluid JCB HD 90 Gear Oil
SPECIFICATION
Gearbox Transfer box Axles (TM200) (TM270) Hydraulic System (TM200) Up to 38 C Above 38C (TM270) Up to 38 C Above 38C Cooling System Fuel System Grease Points Wear Pad Runways
13 litres (2.9 UK gal) 1.3 litres (0.3 UK gal)
Ford ESN-M2C 33G API-GL-5, MIL-L-2105C
JCB Special Hydraulic Fluid JCB High Performance Hydraulic Fluid JCB Special Hydraulic Fluid JCB High Performance Hydraulic Fluid Water/Anti-freeze Diesel Oil JCB Special MPL Grease JCB Waxoyl
ISO 32 ISO 46 ISO 32 ISO 46 ASTM D3306-74 ASTM D975-66T Nos. 1D, 2D. Lithium based, No. 2 consistency
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. Note: Biodegradable Hydraulic Fluid is a factory option ONLY. Replenish with JCB Biodegradable Multigrade Hydraulic Fluid. For further information, contact Wheeled Loader Technical Service.
9804/1103
50 - 00 - 01/9A
4225 - 3/1 - 2.2
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 01/9B
TM200, TM270 (New 1000 Series Engines) (N. America) Fluids, Lubricants & Capacities
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. NORTH AMERICA
ITEM
Engine Oil
CAPACITY
FLUID/LUBRICANT
SPECIFICATION
10.7 litres (2.82 US gal) JCB 15w/40 Engline Oil -10C to +50C (14F to 122F) JCB Engine Oil 10w -20C to +10C (-4F to +50F) Gearbox Transfer box Axles (TM200) (TM270) Hydraulic System (TM200) Up to 38 C Above 38C (TM270) Up to 38 C Above 38C Cooling System Fuel System Grease Points Wear Pad Runways 13 litres (3.34 US gal) 1.3 litres (0.34 US gal) JCB Special Transmission Fluid JCB HD 90 Gear Oil
Ford ESN-M2C 33G API-GL-5, MIL-L-2105C
16 litres (4.2 US gal) 20 litres (5.28 US gal)
63 litres (16.6 US gal)
JCB Special Hydraulic Fluid JCB High Performance Hydraulic Fluid JCB Special Hydraulic Fluid JCB High Performance Hydraulic Fluid Water/Anti-freeze Diesel Oil JCB Special MPL Grease JCB Waxoyl
ISO VG32 ISO VG46 ISO VG32 ISO VG46 ASTM D3306-74 ASTM D975-66T Nos. 1D, 2D. Lithium based, No. 2 consistency
90 litres (23.78 USgal)
15.5 litres (4.1 US gal) 90 litres (23.78 US gal)
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. Note: Biodegradable Hydraulic Fluid is a factory option ONLY. Replenish with JCB Biodegradable Multigrade Hydraulic Fluid. For further information, contact Wheeled Loader Technical Service.
9804/1103
50 - 00 - 01/9B
4225 - 3/1 - 3.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 01/10
426B, 436B, 446B Fluids, Lubricants and Capacities

ITEM
CAPACITY
426, 436 16 litres (3.5 UK gal) 446 18.9 litres (4.2 UK gal)
FLUID/LUBRICANT
SPECIFICATION
Gearbox 426 436 Front Axle Rear Axle Hydraulic System 426 436 Fuel System 426 436, 446 Cooling System 426, 436 446 Grease Points
24 litres (5.3 UK gal) 23 litres (5.1 UK gal) 40.0 litres (8.8 UK gal) 38.0 litres (8.5 UK gal)
JCB LS Gear Oil JCB LS Gear Oil
API GL4, MIL-L-2105A API GL4, MIL-L-2105A
ISO VG32
Diesel Oil (see Types of Fuel)
Water/Anti-freeze (see Coolant mixture)
ASTM D3306-74
JCB HP Grease
Lithium based
9804/1103
50 - 00 - 01/10
4160 - 3/1 - 1.4
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 01/11
426B,436B, 446B (N. America) Fluids, Lubricants & Capacities

North American Capacities and Lubricant Equivalent

ITEM
Engine Oil -18 to 0C -10 to 50C
CAPACITY
426 To Ser. No. 531347 16 liters (4.2 US gal) 436 To Ser. No. 533408 16 liters (4.2 US gal) 446 18.9 liters (5.0 US gal) 426 From Ser. No. 531348 16 liters (4.2 US gal) 436 From Ser. No. 533409 16 liters (4.2 US gal)
FLUID/LUBRICANT
JCB 10W or JCB 15W/40 JCB 30W
SPECIFICATION
MIL-L-2104E API CD/CE
Engine Oil -20 to +10C (-4 to +50F) -10 to +50C (14 to 122F)
JCB 10W JCB 15W40
CF-4/SG, SAE 10W CF-4/SG, SAE 15W40
Gearbox 426 436 Front Axle Rear Axle Hydraulic System 426 436 $ Fuel System 426 436, 446 Cooling System 426, 436 446 Grease Points 24 liters (6.3 US gal) 23 liters (6.1 US gal) 40.0 liters (10.6 US gal) 38.0 liters (10.0 US gal) JCB 10W or JCB 15W/40 MIL-L-2104E
JCB LS Gear Oil JCB LS Gear Oil
MIL-L-2105A MIL-L-2105A
200 liters (52.8 US gal) 210 liters (55.5 US gal)
JCB Hydraulic Fluid
ISO VG46
Diesel Oil (see Types of Fuel)
Water/Anti-freeze (see Coolant mixture) JCB MOLY EP # Grease
ASTM D3306-74
Lithium based, No. 2
Above 32F (0C). In conditions below 32F (0C) use JCB HP32 Hydraulic Fluid (ISO VG32). $ Also 426 machines built after November 1998.
9804/1103
50 - 00 - 01/11
4160-3/1-2.3
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 01/12
436B Fluids, Lubricants & Capacities
From m/c no. 533692
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
Engine Oil
CAPACITY
FLUID/LUBRICANT
JCB Super Multigrade 15w/40 -10C to +50C (14F to 122F) JCB Super Multigrade 10w/30 -15C to +40C (5F to 104F)) Transmission Oil Auto 15
SPECIFICATION
Gearbox Axles
34 litres (7.5 UK gal) (Front) 39.0 litres (8.6 UK gal) (Rear) 37.0 litres (8.1 UK gal) 210 litres (46.2 UK gal) 50 litres (11.0 UK gal)
ATF Auto 15
JCB Gear Oil LS JCB Gear Oil LS JCB Special Hydraulic Fluid Four Seasons Anti-freeze & Summer Coolant/Water
API GL4, MIL-L-2105B API GL4, MIL-L-2105B ISO VG32 ASTM D3306, BS6580
Hydraulic System Cooling System
Fuel System Grease Points
Diesel Oil JCB HP Grease
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals. The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). Note: Biodegradable Hydraulic Fluid is a factory option ONLY. Replenish with JCB Biodegradable Multigrade Hydraulic Fluid. For further information, contact Earthmovers Technical Service.
9804/1103
50 - 00 - 01/12
4160-3/1-3.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 02/1
406,407,408,409 Static Dimensions

406/407
mm A B C D E F G H J K L Overall length (including standard shovel) Wheelbase Centre of gravity Minimum ground clearance (to transfer gearbox) Height over cab Width over tyres Load over height (maximum) Pin height Chassis oscillation Dump angle at full height Roll back angle at full height Articulation angle kg Unladen weight 4700 lb 10363 5090 1900 1253 398 2543 1745 2867 3100 ft 16 6 4 1 8 5 9 10 in 8 3 1 4 4 9 5 2 9 45 50 80 kg 5500 lb 12127
408/409
mm 5350 2200 1373 400 2530 1916 3013 3280 ft in
17 7 7 4 1 8 6 3 6 4 4 4
9 11 10 9
Note: Dimensions based on a machine equipped with the standard shovel and 14.5 - 20 tyres.
E D B J F
C A L
K G H
A199070
9804/1103
50 - 00 - 02/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 02/2
411,416 Static Dimensions

411
mm A B * C * D * E * F * G * H * J * K * L * M Overall length (including standard shovel) Wheelbase Centre of Gravity (No attachment fitted) Minimum ground clearance Height over cab Width (without plastic roof) (with plastic roof) (Over tyres- without bulge) (Maximum - Shovel Toeplate) 5965 2700 1666 400 3000 3108 2200 2250 3487 4427 2671 ft 19 8 5 1 in 7 10 6 4 mm 6080 2800 1749 438 3082 3190 2400 2330 3633 4605 2773 12.5 50 58 80 Kg Weight 7300 lb 16096 Kg 8600 lb 18963
416
ft 20 9 5 1 10 10 7 7 in 0 2 9 5 1 5 10 8
9 10 10 2 7 7 11 14 8 2 4 5 6 9
Pin height (maximum) Maximum height Dump height Axle oscillation Dump angle at full height Roll back angle at full height Articulation angle
11 11 15 9 1 1
Note: Dimensions based on a 411 machine equipped with the standard 1.1 m3 shovel and 15.5R25 tyres. Note: Dimensions based on a 416 machine equipped with the standard 1.3 m3 shovel and 17.5R25 tyres.
A M H
D B
K F
L J G
A203190
9804/1103
50 - 00 - 02/2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 00 - 02/3
50 00 02/3
426,436 Static Dimensions

426
mm A B C D E F G H J K L M Overall length (including standard shovel) Wheelbase Centre of gravity Minimum ground clearance Height over cab Width (Over tyres- without bulge) (Maximum - Shovel Toeplate) 6540 2900 1621 375 3245 2403 2498 3829 5027 2961 ft in 21 5 9 5 6 4
436
mm 6990 3000 1749 459 3340 2597 2700 3996 5310 3050 ft in 22 11 9 10 5 1 9 6
436Z
mm 6990 3000 1675 459 3340 2597 2700 3996 5310 3050 ft in 22 11 9 10 5 1 6 6
1 3 10 8 7 11 8 2 12 6 16 6 9 9
10 11 8 6 8 10 13 1 17 5 10 0
10 11 8 6 8 10 13 1 17 5 10 0
Pin height (maximum) Maximum height Dump height (at 45 Dump) Axle oscillation Dump angle at full height Roll back angle at full height Articulation angle
12.5 49 58 80 Kg lb 21134
3
12.5 49 58 80 Kg 13470 lb 29701 Kg
12.5 47 58 80 lb 30990
Unladen weight
10945
14060
Note: Dimensions based on a 426 machine equipped with the standard 1.8m shovel and 17.5R25 tyres. Note: Dimensions based on a 436/436Z machine equipped with the standard 2.3m3 shovel and 20.5R25 tyres.
E D B K F
A L H
M J G
A218290
9804/1103
50 - 00 - 02/3
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 02/4
412S, 414S Static Dimensions

412S mm A B C D E F G H J K L M Overall length (to front of Quickhitch) Wheelbase Centre of gravity (No attachment fitted) Minimum ground clearance Height over cab Width (Over tyres- without bulge) 5488 2700 1510 410 2843 2375 3635 4532 3429 ft in 18 0 8 10 4 11 1 4 9 7 4 9 414S mm 5797 2800 1493 410 2930 2375 3670 4663 3464 12.5 47.6 59 80 Kg Unladen weight lb Kg lb ft in 20 9 9 2
4 11 1 9 7 4 7 9
Pin height (maximum) Maximum height Load over Height Axle oscillation Dump angle at full height Roll back angle at full height Articulation angle
11 11 14 10 11 3
12 0 15 4 11 4
6660 14685
7340 16185
Note: Dimensions based on a machine equipped with the standard Quickhitch and 19.5LR24tyres.
E D B K F
A L
M G
S228720
9804/1103
50 - 00 - 02/4
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 02/5
409 Telemaster Static Dimensions STATIC DIMENSIONS
mm A B C D E F G H J Overall length to front of Quickhitch Overall length to front of tyres Wheelbase Centre of gravity Minimum ground clearance (to transfer gearbox) Height over cab Width over tyres Pin Height (Maximum) Chassis oscillation Articulation angle kg Unladen weight 5790 4755 4175 2200 1090 400 2550 1916 4620 9 80
ft 15 13 7 3 1 8 6 15
in 7 8 3 7 4 5 4 2
lb 12767
Note: Dimensions based on a machine equipped with Cone and Pin Quickhitch and 14.5 - 20 tyres.
F E D A C B J G
A227700
9804/1103
50 - 00 - 02/5
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 02/6
407B ZX, 408B ZX, 409B ZX, 410B ZX Static Dimensions

407B ZX
mm A B C D E F G H J K L Overall length to front of Quickhitch Wheelbase Centre of gravity Minimum ground clearance (to axle) Height over cab Width over tyres Load over height Pin height (Maximum) Chassis oscillation Dump angle at full height Roll back at full height Articulation angle kg Unladen weight 4293 4278 2000 1196 367 2597 1692 2901 3099 ft in 14 0 6 7
408B ZX
mm 4278 2000 1248 410 2640 1712 2944 3142 ft in 14 0 6 4 1 8 5 9 7 1 4 8 7 8
409B ZX
mm 4278 2000 1298 433 2663 1845 2967 3165 ft in 14 0 6 7 4 3 1 5 8 9 6 0 9 9 10 5 10 45 69 40 kg 4793 lb 10568
410B ZX
mm 4732 2250 383 2824 2017 3220 3470 ft in 15 6 7 5 1 3 9 3 6 7 10 7 11 5 10 45 65 40 kg 6860 lb 15125
3 11 1 8 5 9 2 6 7 6
10 2 10 45 69 40 lb 9446
10 4 10 45 69 40
kg 4493
lb 9907
Note: Dimensions based on a machine equipped with : 12.5 - 18 tyres. 12.5 - 20 tyres.
14.5 - 20 tyres. 405/70R24 tyres.
J D B
F A
L K H G
A243220
9804/1103
50 - 00 - 02/6
Issue 1
CONTENTS
Wheeled Loaders
STATIC DIMENSIONS
50 - 00 - 02/7
456B Static Dimensions
To m/c no. 539245
mm A B C D E F G H J K L M Overall length (including standard shovel) Wheelbase Centre of Gravity (No attachment fitted) Minimum ground clearance Height over cab Width (Over tyres- without bulge) (Maximum - Shovel Toeplate) 7558 3200 2083 450 3240 2702 2800 4107 5571 3039
ft
in
24 10 10 6 1 10 8 9 13 18 10 12.5 50 58 40 6 10 6 8 10 2 6 3 0
Kg Unladen Weight 18125
lb 39960
Note: Dimensions based on a 456B machine equipped with the standard 2.8 m3 shovel and 23.5R25 tyres.
E K C D B F
A M
H L J G
A260490
9804/1103
50 - 00 - 02/7
8210-153
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 02/7A
456 Static Dimensions
from m/c no. 539250
mm A B C D E F G H J K L M Overall length (including standard shovel) Wheelbase Centre of Gravity (No attachment fitted) Minimum ground clearance Height over cab Width (Over tyres- without bulge) (Maximum - Shovel Toeplate) 7908 3300 2200 450 3305 2702 2800 4107 5571 2950
ft in 26 2
10 10 7 1 3 6
10 10 8 9 13 18 9 12.5 45 67 40 10 2 6 3 8
Kg Unladen Weight 18600
lb 41005
Note: Dimensions based on a 456 machine equipped with the standard 3.0 m3 shovel and 23.5R25 L3 tyres.
E K A M C D B F
H L J G
A260490
9804/1103
50 - 00 - 02/7A
8570-153
Issue 1
CONTENTS
Wheeled Loaders
mm 5119 1069 2500 1420 440 5169 1148 2240 1836 2660 5724 2314 4545 ft in
50 - 00 - 02/ 9
TM 270 Static Dimensions

A B C D E F G H I J K Overall length to front of carriage Axle to pivot point Wheelbase Axle to counterweight face Minimum ground clearance (to transfer gearbox) Pin Height (Maximum) Width over cab Width over tyres Wheel track Height over cab Overall operating height Inside radius Maximum radius Articulation angle kg Front axle weight Rear axle weight Total weight 2600 3940 6540 16 10 3 8 4 1 17 3 7 6 8 18 7 6 2 8 5 0 9 4 0 9 9 7
14 11
80 ( 40) lb 5733 8688 14421
Note: Dimensions based on a machine equipped with Cone and Pin Quickhitch 17.5 x 24 X M27 tyres and ROPS/FOPS cab.
G K F J
E I B C A D H
A272460
9804/1103
50 - 00 - 02/9
8470-153.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 02/10
426B, 436B, 446B Static Dimensions

426B HT
mm A B C D E F G H J K L M Overall length (including standard shovel) 6540 Wheelbase Centre of gravity Minimum ground clearance Height over cab Width (Over tyres- without bulge) (Maximum - Shovel Toeplate) 2900 1621 375 3155 2403 2498 3839 5027 2961 ft in 21 5 9 5 6 4
426B ZX
mm 6540 2900 1621 375 3155 2403 2498 3839 5027 2961 ft in 21 5 9 5 1 6 4 3
436B HT
mm 6990 3000 1749 459 3250 2597 2700 3996 5310 3050 ft in 22 11 9 10 5 1 9 6
436B ZX
mm 6990 3000 1749 459 3250 2597 2700 3996 5310 3050 ft in 22 11 9 10 5 1 9 6
1 3 10 4 7 11 8 2 12 7 16 6 9 9
10 4 7 11 8 2 12 7 16 6 9 9
10 8 8 6 8 10 13 1 17 5 10 0
10 8 8 6 8 10 13 1 17 5 10 0
Pin height (maximum) Maximum height Dump height (at 45 Dump) Axle oscillation Roll back angle at full height Dump angle at full height Articulation angle
12.5 58 49 40 Kg lb 21134 Kg
12.5 52 46 40 lb Kg
12.5 58 49 40 lb 29701 Kg
12.5 58 47 40 lb 30990
Unladen weight
10945
11060 24380
13470
14060
Note: Dimensions based on a 426BHT/426BZX machine equipped with the standard 1.8m3 shovel and 17.5R25 tyres. Note: Dimensions based on a 436BHT/436BZX machine equipped with the standard 2.3m3 shovel and 20.5R25 tyres.
E D B K F
A L H
M J G
A218290
9804/1103
50 - 00 - 02/10
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 02/ 10A
From m/c no. 533692
436HT
mm A B C D E F G H J K L M Overall length (including standard shovel) 6920 Wheelbase Centre of gravity Minimum ground clearance Height over cab Width (Over tyres- without bulge) (Maximum - Shovel Toeplate) 3000 1736 459 3315 2597 2700 3996 5310 3050 ft in 22 8 9 10 5 1 8 6
436ZX
mm 7140 3000 1670 459 3315 2597 2700 3996 5310 3050 ft in 23 5 9 10 5 1 5 6
10 10 8 6 8 10 13 1 17 5 10 0
10 10 8 6 8 10 13 1 17 5 10 0
12.5 43 50 40 Kg lb Kg
12.5 58 45 40 lb
Unladen weight
13923 30695
14232 31376
Note: Dimensions based on a 436HT/436ZX machine equipped with the standard 2.4m3 shovel and 20.5R25 tyres.
E D B K F
A L H
M J G
A218290
9804/1103
50 - 00 - 02/10A
8450-153.2
Issue 1
CONTENTS
Wheeled Loaders
50 - 00 - 02/11
426B, 436B, 446B Static Dimensions 446B

mm A B C D E F G H J K L M Overall length (including standard shovel) Wheelbase Centre of gravity Minimum ground clearance Height over cab Width (Over tyres- without bulge) (Maximum - Shovel Toeplate) HT ZX 7300 3000 1769 1734 430 3215 2597 2700 3996 5399 2900 12.5 58 47 40 Kg Unladen weight HT ZX 14880 15179 lb 32810 33470 ft in 23 11 9 10 5 10 5 8 1 5
10 7 8 6 8 10 13 1 17 9 9 6
Note: Dimensions based on a 446B machine equipped with the standard 2.6m3 shovel and 20.5R25 tyres.
E D B K F
A L
M J G
A218290
9804/1103
50 - 00 - 02/11
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/1
406,407,408,409 Data - Electrical

System Battery Cranking Performance at -18 deg. C (0 deg. F) Reserve Capacity (minutes) for 25 amp load Alternator Starter Motor Light Bulbs Side Stop/Tail Direction Indicators Head Number Plate Interior Rear Working/Reversing Fog Instrument/Warning Beacon (optional) Circuit Protection Fuses Circuit Rating (Amps) Fuse No. 10 10 5 5 10 10 10 15 20 A1 A2 A3 A4 A5 A6 A7 A8 A9 Flasher Neutral Start Buzzer Drive Start C1 C2 C3 C4 D1 5 W SBC 5/21 W SBC 21 W SBC 60/55 W H4 5 W MCC 10 W Festoon 55 W H3 Halogen 21 W SBC 1.2 W Capless 55 W H3 Halogen Relays Transmission Dump Rear Working Light Forward High/Low Forward Parking Brake Front Working Light Reverse High/Low Reverse A1 A2 A3 A4 B1 B2 B3 B4 12 volt, negative earth 410 amps to 1.4 V.P.C. 180 Lucas A127, 65 amp max. output Lucas M127/2.A
Headlamp Main Beam and Warning Light Headlamp Dipped Beam and Rear Fog Light Side/Tail Light LH Side/Tail Light RH and Instrument Panel Front Working Lights Rear Working Lights Reverse Lights Hazard Switch and Stop Lights Road Lights LH Column Switch (Power Shift only) and Dump Switch Neutral Start Relay Interior Light, Beacon and Radio Heater Rear Wash/Wipe Engine Shut-off System (ESOS) Blank Blank Blank Buzzer Hazard Lights (permanent feed) Instrument Panel Blank RH Column Switch and Switch Illumination Blank Blank Blank Blank
10 20 10 10 10 5 10 10 5 25 -
B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9
9 8 7 6 5 4 3 2 1 A B C
A4
B4
C4
A3
B3
C3
A2
B2
C2
A1
B1
C1
D1
D3
D2
A199600
9804/1103
50 - 05 - 01/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/2
411,416 Data - Electrical

System Type Battery Cold Crank Amps for 1 minute to 1.4VPC at -18 C (0 F) Reserve Capacity (minutes) for 25 Amp load Alternator Starter Motor Light Bulbs Headlights - main Headlights - dip Indicators Indicator repeater Instruments Work lights Number plate light Tail lights Front sidelights Interior lights Stop lights Beacon Rear fog Warning lights 410 Amps 180 12 Volts, negative earth
Lucas A127-65, 65 Amp maximum output Lucas M127 Rating (Watts) 65 W 60 W 21 W 5W 1.2 W 55 W Halogen 5W 5W 4W 10 W 21 W 55 W Halogen 21 W 1.2 W
9804/1103
50 - 05 - 01/2
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/ 3
* *
411 to m/c no. 527375 416 to m/c no. 529431 Data - Electrical (continued) Fuses
The electrical circuits are protected by fuses. The fuses are located in a fuse box underneath the oddments tray in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one. Fuse Circuit No. A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 Fuse Rating (Amps) 5 10 5 10 10 20 10
Relays
A1 A2 A3 A4 A5 B1 B2 B3 B4 Neutral Start Rear Work Lights/Reverse Lights Reverse Alarm Hazard Seat Warning (Optional) Start Front Work Lights Buzzer Transmission Timer
Direction Indicators Right Sidelights and Gauge Illumination Rear Fog Light Reverse Alarm/Dump Switch Brake Lights, Loader Arm and Bucket Reset Warning lights, Heater Fan and Gauges Main Beam Blank Blank Hazard Warning Lights Dip Beam Rear Work Lights/Reversing Lights Rear Wash/Wipe Interior Light and Beacon Engine shut off system (ESOS) Air Conditioning (Optional) Blank Blank Left Sidelights Front Work Lights Transmission Blank Horn and Front Wash/Wipe Blank Blank Blank Blank
10 10 10 10 10 5 10
A1
B1
A2
B2
C1 * C2 C3 C4 C5 C6 C7 C8 C9
10 25 10 10 -
A3
B3
A4
B4
A5
2 3 4 5 6 7 8 9
9804/1103
50 - 05 - 01/3
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 01/ 3A
411 from m/c no. 527400 416 from m/c no. 529500 Data - Electrical ( continued )
Fuses The electrical circuits are protected by fuses. The fuses are located in a fuse box underneath the armrest in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one. Relays 1 2 3 4 5 6 7 8 9 10 11 12 Direction Indicators Intermittent Wipers Computer Feed Engine Shut Down Start Inhibit ACCS (If fitted) Blank Heater Fan Front Work Lights Anti-stall (if fitted) Reverse Alarm Rear Work Lights
! CAUTION
8-3-3-5
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 C6 C7 C8 C9
Circuit
Fuse Rating (Amps)

3 6 9 12
Hazard Warning Lights and Direction Indicators 5 Right Side/Tail Lights and Switch Illumination 5 Rear Fog Light 5 Anti-stall (if fitted) 5 Brake Lights, Float, Lift and Shovel Reset 10 Computer Feed Relay Solenoid 1 Main Beam 15 EMS Battery Feed 1 Blank Hazard Warning Lights (Battery Feed) Dip Beam Rear Work Lights and Reverse Alarm Rear Wash/Wipe Radio, Under Bonnet Lights, Interior Light and Beacon Engine shut off system (ESOS) Air Conditioning Thermostart Blank Left Side/Tail Lights and No. Plate Lights Front Work Lights EMS and ZF Computer Feed Blank Horn and Front Wash/Wipe Heater Blower and Cigar Lighter Hydraulic Dump Valve ACCS Road Lights 10 10 15 10 10 5 10 15 5 25 10 10 25 5 5 25
2 3 4
11
5 6 7
10
A270230
8 9
9804/1103
50 - 05 - 01 / 3A
4150-C/1 - 3.2
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/ 3B
411 from m/c no. 527850 416 from m/c no. 530100 Data - Electrical (continued) Fuses
The electrical circuits are protected by fuses. The fuses are located in a fuse box to the rear of the side console. If a fuse ruptures, find out why and recitfy the fault before fitted a new one. D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 EMS (Ignition Feed) ZF COmputer (Ignition Feed) Front Work Lights Dipped Beam Main Beam Rear Fog Lights Blank Thermostart Dump Relay Ignition Relays 3 7.5 5 5 5 10 7.5 7.5
! CAUTION
8-3-3-5
Fuse Circuit No. A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 Rear Work Lights Road Lights Front Work Lights Dipped Beam Main Beam Rear Fog Lights Blank Thermostart Dump Relay Ignition Relays
Fuse Rating (Amps)

3 2 1
10 9 8 7 6 5 4 3 2 1
A B
13
10 15 20 10 10 5 30 3 3 3 3 10 3 7.5 10 7.5 10 15 5 3 10 7.5 10 10 5 15 5 15
14
C D
15
12
11
10
Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and No. Plate Lights 12 Volt Trailer Electrics (Option) EMS (Battery Feed) ZF Computer (Battery Feed) Hazard Warning Beacon and Interior Light Radio (24 Volt) Headlight Flash Side Lights Starter Relay Solenoid Cigar Lighter (24 Volt) See Note Blank Rear Wash/Wipe Front Wash/Wipe and Horn Heated Seat/Mirrors and Air Suspension Seat (Option) Air Conditioning (Option) Heater Blower Direction Indicators Heated Rear Screen
Y
A336170
Note: To gain access to the underside of the fuse/relay panel. Remove the securing screw and unhook the rear of the panel. Manipulate the panel until it is clear. Make sure the panel is refitted securely.
Note: Not fitted if in-cab 24/12 Volt converter fittted.
9804/1103
50 - 05 - 01/3B
4180 - C/1-4.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 05 - 01/ 3C
411 from m/c no. 527850 416 from m/c no. 530100 Data - Electrical ( continued ) Primary Fuses
The primary fuses are located in a fuse box attached to the battery positive terminal. If a new fuse ruptures, find out why and recitfy the fault before fitting a new one. Fuse No. PF1 Front Work Lights Rear Work Lights Main Beam Dip Beam Fog Lights PF2 RH Side/Tail Lights & Switch Illumination LH Side/Tail Lights & No. Plate Lights Headlight Flash Radio (24 Volt) Beacon and Interior Light Hazard Warning EMS (Battery Feed) ZF Computer (Battery Feed) 12 Volt Trailer Electrics PF3 Starter Solenoid Thermostart Heater Blower Air Conditioning Direction Indicators Heated Seat, Mirrors and Air Suspension Seat Heated Rear Screen Ignition Relays PF4 EMS (Ignition Feed) ZF Computer (Ignition Feed) Rear Wash/Wipe Front Wash/Wipe and Horn Cigar Lighter (24 Volt) ESOS and Cold Start Advance Reverse Alarm/Lights Headlight Flash Brake Lights Shovel and Arm Reset CCTV In-Cab 24/12 Volt Converter 50
10 9 8 7 6 5 4 3 2 1
3 2 1
Relays
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Heated Rear Screen Ignition 2 Flasher Front Work Lights Lights Reverse Alarm/Lights Dump Air Conditioning Blank ESOS Ignition 1 Ignition 3 Wash/Wipe Interval Timer Start Blank
Circuits
Fuse Rating (Amps) 40
40
Diagnostic Connectors
X Y ZF Transmission EMS
40
PF4 PF3
PF2 PF1
A B
13
14
C D
15
12
11
10
Y
A336170
9804/1103
50 - 05 - 01 / 3C
4150-C/1 - 5.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 05 - 01/ 6
412S, 414S, 416S Data - Electrical

System Type Battery Cold Crank Amps for 1 minute to 1.4VPC at -18 C (0 F) Reserve Capacity (minutes) for 25 Amp load Alternator Starter Motor 12 Volts, negative earth
410 Amps 180
Lucas A127-65, 65 Amp maximum output Lucas M127
Bulbs
Bulb Headlights - main Headlights - dip Indicators Indicator repeater Instruments Work lights Number plate light Tail lights Front sidelights Interior lights Stop lights Beacon Rear fog Warning lights Master Warning Light Rating (Watts) 65 W 60 W 21 W 5W 1.2 W 55 W Halogen 5W 5W 4W 10 W 21 W 55 W Halogen 21 W 1.2 W 5W
9804/1103
50 - 05 - 01/6
4170-C/1-1.2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 01/ 7
412S Data - Electrical (continued) Fuses

The electrical circuits are protected by fuses. The fuses are located in a fuse box underneath the oddments tray in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one.
*To m/c no. 535116
Relays
! CAUTION
8-3-3-5
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 * C6 C7 C8 C9
Circuit
Fuse Rating (Amps) 5 10 5 10 10 20 10 10 10 10 10 10 5 10 10 25 10 10 -
A1
B1
A2
B2
A3
B3
A4
B4
A5
9804/1103
50 - 05 - 01 / 7
4170-C/1 - 2.2
2 3 4 5 6 7 8 9
A200630
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 01/ 8
* 412S * 414S
From m/c no. 535117 to 535349 to m/c no. 537149
Data - Electrical ( continued ) Fuses

The electrical circuits are protected by fuses. The fuses are located in a fuse box underneath the oddments tray in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one. !CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage.
8-3-3-5
Relays
1 2 3 4 5 6 7 8 9 10 11 12 Hazard Blank Transmission Timer Neutral Start Start Blank Blank Transmission Disconnect Front Work Lights Blank Reverse Alarm Rear Work Lights
Fuse Circuit Fuse Rating No. (Amps) A1 Direction Indicators 5 A2 Right Sidelights and Switch/Panel Illumination 10 A3 Fog Lights 5 A4 Reverse Alarm/Dump Switch 10 A5 Brake Lights, Loader Arm, Shovel Reset and Tow Hitch Solenoids 10 A6 Warning Lights, Heater Fan, Gauges, Cigar Lighter, Transmission Disconnect Relay, Timer and Hourmeter 20 A7 Main Beam 10 A8 Blank A9 Blank B1 Hazard Warning Lights and Clock 10 B2 Dip Beam 10 B3 Reversing Lights 10 B4 Rear Wash/Wipe 10 B5 Interior Light, Beacon and Radio (Optional) 10 B6 Engine shut off system (ESOS) 5 B7 Air Conditioning (Optional) 10 B8 Blank B9 Blank C1 Left Sidelights and Number Plate Lights 10 C2 Work Lights 25 C3 Transmission 10 C4 Blank C5 Horn and Front Wash/Wipe 10 C6 Blank C7 Hydraulic Dump Valve 5 C8 Blank Blank -
10
C
11
A B
12
1 2 3 4 5 6 7 8 9
A248620 4170-C/1-3.1
9804/1103
50 - 05 - 01 / 8
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 01/ 8A
412S From m/c no. 535350 414S From m/c no. 537150 Data - Electrical ( continued ) Fuses
The electrical circuits are protected by fuses. The fuses are located in a fuse box underneath the armrest in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one.
Relays
1 2 3 4 5 6 7 8 9 10 11 12 Direction Indicators Intermittent Wipers Computer Feed Engine Shut Down Start Inhibit ACCS (if fitted) Blank Heater Fan Front Work Lights Anti-stall (if fitted) Reverse Alarm Rear Work Lights
! CAUTION
8-3-3-5
Circuit
Fuse Rating (Amps) A B 5 5
Hazard Warning Lights and Direction Indicators Right Side/Tail Lights and Switch Illumination Rear Fog Light Anti-stall (if fitted) Brake Lights, Float, Lift and Shovel Reset Computer Feed Relay Solenoid Main Beam EMS Battery Feed Blank Hazard Warning Lights (Battery Feed) Dip Beam Rear Work Lights and Reverse Alarm Rear Wash/Wipe Radio, Under Bonnet Lights, Interior Light and Beacon Engine shut off system (ESOS) Air Conditioning Thermostart Blank Left Side/Tail Lights and No. Plate Lights Front Work Lights EMS and ZF Computer Feed Blank Horn and Front Wash/Wipe Heater Blower and Cigar Lighter Hydraulic Dump Valve ACCS Road Lights
5 5 5 5 5 5 10 5 1 1 15 10 1 1 - 1 10 10 15 10 5 10 10 10
1 2
12
3 4
11
5 6 7
10
10 10 5 5 10 10 15 30 5 25 10 10 25 5 5 25 5 15 10 10 20 5 5 15
A270230
8 9
Column A - To Ser. No. 535374 (412S) 537193 (414S) Column B - From Ser. No. 535375 (412S) 537194 (414S)
9804/1103
50 - 05 - 01 / 8A
4170 - C/1 - 4.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/ 8B

The electrical circuits are protected by fuses. The fuses are located in a fuse box underneath the armrest in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one.
From m/c no. 543000
Relays
1 2 3 4 5 6 7 8 9 10 11 12 Direction Indicators Intermittent Wipers Computer Feed Engine Shut Down Start Inhibit ACCS (if fitted) Blank Heater Fan Front Work Lights Anti-stall (if fitted) Reverse Alarm Rear Work Lights
! CAUTION
8-3-3-5
Circuit
Fuse Rating (Amps)
Hazard Warning Lights and Direction Indicators Right Side/Tail Lights and Switch Illumination Rear Fog Light Anti-stall (if fitted) Brake Lights, Float, Lift and Shovel Reset Computer Feed Relay Solenoid Main Beam EMS Battery Feed Blank Hazard Warning Lights (Battery Feed) Dip Beam Rear Work Lights and Reverse Alarm Rear Wash/Wipe Radio, Under Bonnet Lights, Interior Light and Beacon Engine shut off system (ESOS) Air Conditioning Thermostart Blank Left Side/Tail Lights and No. Plate Lights Front Work Lights EMS and ZF Computer Feed Blank Horn and Front Wash/Wipe Heater Blower and Cigar Lighter Hydraulic Dump Valve ACCS Road Lights
5 5 5 5 5 1 10 1 1 5 10 10 10 10 5 10 30 5 15 10 10 20 5 5 15
1 2
12
3 4
11
5 6 7
10
A270230
8 9
9804/1103
50 - 05 - 01 / 8B
4170 - C/1-5.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/8C
* 412S
from m/c no. 535500 414S from m/c no. 537300 416S from m/c no. 543100 Data Electrical Primary Fuses
The primary fuses are located in a fuse box attached to the battery positive terminal. If a fuse ruptures, find out why and rectify the fault before fitting a new one. Fuse No. PF1 Front Work Lights Rear Work Lights Main Beam Dip Beam Fog Lights PF2 RH Side/Tail Lights & Switch Illumination LH Side/Tail Lights & No. Plate Lights Headlight Flash Radio (24 Volt) Beacon & Interior Light Hazard Warning EMS (Battery Feed) ZF Computer (Battery Feed) 12 Volt Trailer Electrics PF3 Starter Solenoid Thermostart Heater Blower Air Conditioning Direction Indicators Heated Seat, Mirrors & Air suspension Seat Heated Rear Screen Ignition Relays PF4 EMS (Ignition Feed) ZF Computer (Ignition Feed) Rear Wash/Wipe Front Wash/Wipe & Horn Cigar Lighter (24 Volt) ESOS & Cold Start Advance Reverse Alarm/Lights Headlight Flash Brake Lights Shovel and Arm Reset CCTV In-cab 24/12 Volt Converter 50 40 40 Circuits Fuse Rating (Amps) 40
Relays
10 9 8 7 6 5 4 3 2 1
3 2 1
A B
13
14
PF4 PF3
PF2 PF1
C D
15
12
11
10
X
A336180
Y
A336170
9804/1103
50 - 05 - 01/8C
4170 - C/1-6.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/4
426,436 Data - Electrical

System Type Battery (Two 12 Volt batteries in series) Cold Crank Amps for 1 minute to 1.4VPC at -18 C (0 F) Reserve Capacity (minutes) for 25 Amp load * Alternator Starter Motor 24 Volts, negative earth
410 Amps 180
BUTEC A5524, 65 Amp maximum output S115 24-7
Light Bulbs Bulb Headlights - main Headlights - dip Indicators Indicator repeater Instruments Work lights Number plate light Tail lights Front sidelights Interior lights Stop lights Beacon Rear fog Warning lights Master warning light Rating (Watts) 75 W 70 W 21 W 5W 1.2 W 70 W Halogen 10 W 5W 5W 10 W 21 W 70 W Halogen 21 W 1.2 W 5W
9804/1103
50 - 05 - 01/4
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 01/5
426,436 Data - Electrical (continued)

Fuses The electrical circuits are protected by fuses. The fuses are located in a fuse box underneath the oddments tray in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one. Fuse No. A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9 Circuit Fuse Rating (Amps) 5 10 5 10 10 20 10 10 10 10 10 10 5 10 10 20 10 10 Relays A1 A2 A3 A4 A5 B1 B2 B3 B4 Neutral Start Rear Work Lights/Reverse Lights Reverse Alarm Hazard Seat Warning (Optional) Start Front Work Lights Buzzer Transmission Timer
A1
B1
A2
B2
A3
B3
A4
B4
A5
2 3 4 5 6 7 8 9
A200630
9804/1103
50 - 05 - 01/5
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/6
412S, 414S Data - Electrical

System Type Battery Cold Crank Amps for 1 minute to 1.4VPC at -18 C (0 F) Reserve Capacity (minutes) for 25 Amp load Alternator Starter Motor 410 Amps 180 12 Volts, negative earth
Lucas A127-65, 65 Amp maximum output Lucas M127
Bulbs
Bulb Headlights - main Headlights - dip Indicators Indicator repeater Instruments Work lights Number plate light Tail lights Front sidelights Interior lights Stop lights Beacon Rear fog Warning lights Master Warning Light Rating (Watts) 65 W 60 W 21 W 5W 1.2 W 55 W Halogen 5W 5W 4W 10 W 21 W 55 W Halogen 21 W 1.2 W 5W
9804/1103
50 - 05 - 01/6
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/7

Relays
! CAUTION
8-3-3-5
Circuit
Fuse Rating (Amps) 5 10 5 10 10 20 10 10 10 10 10 10 5 10 10 25 10 10 -
A1
B1
A2
B2
A3
B3
A4
B4
A5
2 3 4 5 6 7 8 9
A200630
9804/1103
50 - 05 - 01/7
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/8

Relays
1 2 3 4 5 6 7 8 9 10 11 12 Hazard Blank Transmission Timer Neutral Start Start Blank Blank Transmission Disconnect Front Work Lights Blank Reverse Alarm Rear Work Lights
! CAUTION
8-3-3-5
Fuse No. A1 A2 A3 A4 A5 A6
Circuit
Fuse Rating (Amps) 5
A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9
Direction Indicators Right Sidelights and Switch/Panel Illumination Fog Lights Reverse Alarm/Dump Switch Brake Lights, Loader Arm, Shovel Reset and Tow Hitch Solenoids Warning Lights, Heater Fan, Gauges, Cigar Lighter, Transmission Disconnect Relay, Timer and Hourmeter Main Beam Blank Blank Hazard Warning Lights and Clock Dip Beam Reversing Lights Rear Wash/Wipe Interior Light, Beacon and Radio (Optional) Engine shut off system (ESOS) Air Conditioning (Optional) Blank Blank Left Sidelights and Number Plate Lights Work Lights Transmission Blank Horn and Front Wash/Wipe Blank Hydraulic Dump Valve Blank Blank
1
10 5 10 10
20 10 10 10 10 10 10 5 10 10 25 10 10 5 -
10
C
11
A B
12
1 2 3 4 5 6 7 8 9
A248620
9804/1103
50 - 05 - 01/8
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/9
407B ZX, 408B ZX, 409B ZX, 410B ZX Data - Electrical

System Type Battery Cold Crank Amps for 1 minute to 1.4VPC at -18 C (0 F) Reserve Capacity (minutes) for 25 Amp load Alternator Starter Motor Bulbs Bulb Headlights - main Headlaights - dip Indicators Instruments Work lights Number plate light Side lights Tail lights Interior lights Stop lights Beacon Rear fog Warning lights Switch illumination Circuit Protection to Serial No. 755182 Fuse No. A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9 Circuit Fuse Rating (Amps) 10 10 5 5 5 10 10 5 10 10 5 10 10 10 5 10 20 5 10 10 10 5 15 10 A
To m/c no. 755182
12 Volts, negative earth JCB 708/00300 410 Amps 180 Lucas A127-65, 65 Amp maximum output Lucas M127 Relays Rating (Watts) 60 W 55 W 21 W 1.7 W 55 W Halogen 5W 5W 5W 10 W 21 W 55 W Halogen 21 W 3W 1.2 W 1 2 3 4 5 6 7 8 9 10 11 12 Front Work Lights Lights Indicator Flasher Buzzer Forward Reverse Parking Brake Light Dump Ignition 2 Ignition 1 Neutral Start 2 Neutral Start 1
Relay Not Shown 13 Hydraulic Oil Cooler Fan (Located adjacent to brake fluid reservoir).
Brake Lights Warning Lights; Buzzer LH side/tail lights; LH No. Plate Light RH side/tail lights; RH No. Plate Light Rear Wash/Wipe Hazard Warning Beacon; Clock and Front Wiper Radio; Interior Light Front Wash/Wipe; Head Light Flasher; Horn Junction Box Engine shut off system (ESOS) Dip Beam Main Beam Front Work Lights Directional Indicators Servo Control Lever Switches Heater Motor/Air Conditioning Hydraulic Cooler Fan Relay Rear Work/Reverse Light Speed Control Unit; Servo Cut-off Solenoid Forward/Reverse Relay; Reverse Alarm Fog Light Thermostart Cigar Lighter Blank Blank Blank
4 5
7
C
8 12 11 10 9
A242480
Note: The 30 Amp inline fuse controlling the hydraulic cooler fan is located with its relay.
9804/1103
50 - 05 - 01/9
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 01/10
407B ZX, 408B ZX, 409B ZX Data - Electrical (continued)

System Type Battery Cold Crank Amps for 1 minute to 1.4VPC at -18 C (0 F) Reserve Capacity (minutes) for 25 Amp load Alternator Starter Motor Bulbs Bulb Headlights - main Headlaights - dip Indicators Instruments Work lights Number plate light Side lights Tail lights Interior lights Stop lights Beacon Rear fog Warning lights Switch illumination Circuit Protection from Serial No. 755183 Fuse No. A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9 Circuit Fuse Rating (Amps) Brake Lights 10 Warning Lights; Buzzer 10 LH side/tail lights; LH No. Plate Light 5 RH side/tail lights; RH No. Plate Light 5 Rear Wash/Wipe 5 Hazard Warning 10 Beacon; Clock 10 Radio; Interior Light 5 Front Wash/Wipe; Head Light Flasher; Horn 10 Junction Box Engine shut off system (ESOS) Dip Beam Main Beam Front Work Lights Directional Indicators Servo Control Lever Switches Heater Motor Thermostart Reverse Light Speed Control Unit; Servo Cut-off Solenoid Forward/Reverse Relay; Reverse Alarm Fog Light Blank Blank Blank Blank Blank 10 5 10 10 10 5 10 20 15 10 10 10 5 A
12 Volts, negative earth JCB 708/00300 410 Amps 180 Lucas A127-65, 65 Amp maximum output Lucas M127 Relays Rating (Watts) 60 W 55 W 21 W 1.7 W 55 W Halogen 5W 5W 5W 10 W 21 W 55 W Halogen 21 W 3W 1.2 W 1 2 3 4 5 6 7 8 9 10 11 12 Front Work Lights Lights Indicator Flasher Buzzer Forward Reverse Dump Ignition 2 Ignition 1 Neutral Start 2 Neutral Start 1 Speed Control
Relay Not Shown 13 Hydraulic Oil Cooler Fan (Located adjacent to brake fluid reservoir).
4 5
7
C
8 12 11 10 9
A242480
Note: The 30 Amp inline fuse controlling the hydraulic cooler fan is located with its relay.
9804/1103
50 - 05 - 01/10
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 01/11
* 410B
ZX
To m/c no. 755490
Data - Electrical (continued)

System Type Battery Cold Crank Amps for 1 minute to 1.4VPC at -18 C (0 F) Reserve Capacity (minutes) for 25 Amp load Alternator Starter Motor Bulbs Bulb Headlights - main Headlaights - dip Indicators Instruments Work lights Number plate light Side lights Tail lights Interior lights Stop lights Beacon Rear fog Warning lights Switch illumination Circuit Protection - 410B ZX
1 2 3 4 5 6 7 8 9
12 Volts, negative earth JCB 708/00300 410 Amps 180 Lucas A127-65, 65 Amp maximum output Lucas M127 Relays Rating (Watts) 60 W 55 W 21 W 1.7 W 55 W Halogen 5W 5W 5W 10 W 21 W 55 W Halogen 21 W 3W 1.2 W 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Front Work Lights Lights Indicator Flasher Buzzer Parking Brake Light Forward Reverse Aux 1 Aux 2 Ignition 2 Ignition 1 Dump Neutral Start Speed Control
1 2 3 4 5
Circuit
Fuse Rating (Amps) Brake Lights 10 Warning Lights; Buzzer 7.5 LH side/tail lights; LH No. Plate Light 5 RH side/tail lights; RH No. Plate Light; Front Work Light Relay 5 Rear Wash/Wipe 7.5 Hazard Warning 10 Beacon; Clock; Front Wiper Park 10 Radio; Interior Light 5 Front Wash/Wipe; Head Light Flasher; Horn 20 Junction Box Engine shut off system (ESOS) Dip Beam Main Beam Front Work Lights Directional Indicators Servo Control Lever Switches Heater Motor Hydraulic Oil Cooler Relay (when fitted) Thermostart Speed Control Unit; Servo Cut-off Solenoid Forward/Reverse Relay; Reverse Alarm Rear Fog Light Rear Work Lights Blank Blank Blank Blank 10 5 15 15 15 5 10 20 5 15 10 10 5 15 -
7
B
14
13
12
11
10
A277350
Fuse Box Decal
10A 7.5A
5A
5A
7.5A 10A
10A
5A
20A
10A
5A
15A
15A
15A
5A
10A
20A
5A
15A
10A
10A
5A
15A
5A
10A
15A
A277360
9804/1103
50 - 05 - 01/11
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 01/11A
407B ZX, 408B ZX, 409B ZX from m/c no. 755491 to 757399 410B ZX, 411B ZX from m/c no. 755491 Data - Electrical
System Type Battery Cold 12 Volts, negative earth JCB 708/00300 Crank Amps for 1 minute to 1.4VPC at -18 C (0 F) Reserve Capacity (minutes) for 25 Amp load 410 Amps 180 Lucas A127-65, 65 Amp maximum output Lucas M127 Relays 1 Front Work Lights 2 Lights 3 Indicator Flasher 4 Buzzer 5 Parking Brake Light 6 Forward 7 Reverse 8 Aux 1 9 Aux 2 10 Ignition 2 11 Ignition 1 12 Dump 13 Neutral Start 14 Speed Control
Alternator Starter Motor Bulbs Bulb Headlights - main Headlaights - dip Indicators Instruments Work lights Number plate light Side lights Tail lights Interior lights Stop lights Beacon Rear fog Warning lights Switch illumination Circuit Protection Fuse Circuit No. A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9
Rating (Watts) 60 W 55 W 21 W 1.7 W 55 W Halogen 5W 5W 5W 10 W 21 W 55 W Halogen 21 W 3W 1.2 W
Fuse Rating (Amps)

A
Brake Lights Warning Lights; Buzzer LH side/tail lights; LH No. Plate Light RH side/tail lights; RH No. Plate Light; Front Work Light Relay Rear Wash/Wipe Hazard Warning Beacon; Clock; Front Wiper Park Radio; Interior Light Front Wash/Wipe; Head Light Flasher; Horn Junction Box Engine shut off system (ESOS) Dip Beam Main Beam Front Work Lights Directional Indicators Servo Control Lever Switches Heater Motor Hydraulic Oil Cooler Relay (when fitted) Thermostart Speed Control Unit; Servo Cut-off Solenoid Forward/Reverse Relay; Reverse Alarm Rear Fog Light Rear Work Lights Blank Blank Blank Blank
10 7.5 5 5 7.5 10 10 5 20 10 5 15 15 15 5 10 20 5 15 10 10 5 15 -
7
B
14
13
12
11
10
Fuse Box Decal
A277350
10A 7.5A
5A
5A
7.5A 10A
10A
5A
20A
10A
5A
15A
15A
15A
5A
10A
20A
5A
15A
10A
10A
5A
15A
5A
10A
15A
A277360
9804/1103
50 - 05 - 01/11A
4210-C/1-5.2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 01/11B
407B ZX, 408B ZX, 409B ZX Data - Electrical

System Type Battery Cold 12 Volts, negative earth JCB 708/00300 Crank Amps for 1 minute to 1.4VPC at -18 C (0 F) = 410 Amps Reserve Capacity (minutes) for 25 Amp load = 180 Lucas A127-65, 65 Amp maximum output Lucas M127 C1 C2 C3 C4 C5 C6 C7 C8 C9
From m/c no. 757400
Alternator Starter Motor
Thermostart Servo Cut-off Solenoid Forward/Reverse Relay; Reverse Alarm Rear Fog Light Rear Work Lights Speed Control Unit Blank Blank Blank
15 5 10 5 15 5 -
Bulbs
Bulb Headlights - main Headlaights - dip Indicators Instruments Work lights Number plate light Side lights Tail lights Interior lights Stop lights Beacon Rear fog Warning lights Switch illumination Rating(Watts) 60 W 55 W 21 W 1.7 W 55 W Halogen 5W 5W 5W 10 W 21 W 55 W Halogen 21 W 3W 1.2 W
Relays
1 2 3 4 5 6 7 8 9 Front Work Lights Lights Indicator Flasher Buzzer Parking Brake Parking Brake Light Forward Reverse Neutral Start 10 11 12 13 14 15 16 17 Dump Aux 1 Aux 2 Not used Not used Ignition 1 Ignition 2 Not used
1 A
Fuses
The electrical circuits are protected by fuses. The fuses are located in a fuse box below the loader control console. If a fuse ruptures, find out why and rectify the fault before fitting a new one.
7
B
9 10
! CAUTION
11 12
8-3-3-5
17
16
15
14 13
Fuse No. A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9
Circuit
Fuse Rating (Amps) 10 7.5 5 5 7.5 10 10 5 20 10 5 15 15 15 5 10 20 5
A370790
Brake Lights Warning Lights; Buzzer LH side/tail lights; LH No. Plate Light RH side/tail lights; RH No. Plate Light; Front Work Light Relay Rear Wash/Wipe Hazard Warning Beacon; Clock; Front Wiper Park Radio; Interior Light Front Wash/Wipe; Head Light Flasher; Horn Junction Box Engine shut off system (ESOS) Dip Beam Main Beam Front Work Lights Directional Indicators Servo Control Lever Switches Heater Motor Hydraulic Oil Cooler Relay (when fitted)
Fuse Box Decal
9804/1103
50 - 05 - 01/11B
4210-C/1-6.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/12
456 Data - Electrical

System Type Battery Cold Crank Amps for 1 minute to 1.4VPC at -18 C (0 F) 410 Amps Reserve Capacity (minutes) 180 for 25 Amp load Alternator Starter Motor Bulbs Headlights - main Headlights - dip Indicators Indicator repeater Instruments Work lights Number plate light Tail lights Front sidelights Interior lights Stop lights Beacon Rear fog Warning lights Master Warning Light Fuse No. A1 A2 A3 A4 A6 A7 A8 A9 B1 B2 B3 B4 B5 * B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9 Circuit Fuse Rating Hazard Warning Lights and Direction Indicators RH Side/Tail Lights and Switch Illumination Rear Fog Lights Blank Brake Lights, Float, Lift and Shovel Reset ZF Computer Feed Relay Solenoid Main Beam EMS Battery Feed Parking Brake Hazard Warning Lights (Battery Feed) Dip Beam Rear Work Lights and Reverse Alarm Rear Wash/Wipe Radio, Under Bonnet Lights, Interior Light and Beacon Engine shut off system (ESOS Hold Coil) Air Conditioning Engine shut off system (ESOS Pull Coil) Blank LH Side/Tail Lights and No. Plate Lights Front Work Lights EMS and ZF Computer Feed Hydraulic Mode Switch Horn and Front Wash/Wipe Heater Blower and Cigar Lighter Grid Heater Relay and Hydraulic Dump Valve ACCS 5 Blank (Amps) 5 5 5 A5 5 1 10 1 5 5 10 10 10 10 5 10 30 5 15 10 5 10 20 5 A B C
24 Volts, negative earth
BOSCH 0120-488-206 DELCO REMY 42-MT/400 Rating (Watts) 75 W 70 W 21 W 5W 1.2 W 70 W Halogen 5W 5W 4W 10 W 21 W 70 W Halogen 21 W 1.2 W 5W Relays 1 Direction Indicators 2 Intermittent Wipers 3 Computer Feed 4 Engine Shut Down 5 Start Inhibit 6 ACCS 7 Blank 8 Heater Fan 9 Front Work Lights 10 Blank 11 Reverse Alarm 12 Rear Work Lights
1 2
12
3 4
11
5 6 7
10
A270230
8 9
9804/1103
50 - 05 - 01/12
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 01/ 13
TM200, TM270 Data - Electrical TM200

System Battery Cranking Performance at - 18 deg. C (0 deg. F) Reserve capacity (minutes) for 25 amp load 180 * Alternator * Starter Motor Bulbs Bulb Headlights - main Headlights - dip Indicators Instruments Work lights Number plate light Side lights Tail lights Interior lights Stop lights Beacon Rear fog Warning lights Switch illumination Circuit Protection Fuse Circuit No. A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9 Fuse Rating (Amps) 10 5 5 5 10 10 7.5 5 15 10 5 10 10 20 10 10 20 10 15 15 5 5 7.5 5 Rating (Watts) 60 W 55 W 21 W 1.7 W 55 W Halogen 5W 5W 5W 10 W 21 W 55 W Halogen 21 W 3W 1.2 W Relays 1 Reverse 2 Forward 3 Reverse Lights 4 5 6 7 8 9 10 11 12 13 14 15 * 16 Neutral Start Parking Brake Flasher Road Lights Ignition 2 Ignition 1 Front and Rear Work Lights Transmission Dump Buzzer Forward Hi/Low (P/S Only) Reverse Hi/Low (P/S Only) Layshaft (P/S Only) Mainshaft (P/S 6-Solenoid gearboxes only) 12 volt, negative earth 410 amps to 1.4 V.P.C A127, 65 amp max. output M127/2.A
Brake lights Instruments/Instrument illumination; Buzzer LH side/tail lights RH side/tail lights Rear Wash/Wipe Hazard Warning Lights Beacon; Front Wiper Park Interior Light/Radio Front Wash/Wipe; Horn; Flasher Auxiliary Plug Engine shut off system (ESOS) Dip Beam Main Beam Work lights Direction Indicators Auxiliary 1; Auxiliary 2 (Hyd.) Heater Boom Extend/Retract Thermostart Transmission; Transmission Dump Relay Blank Fog Light Blank Load Indicator Tow Hitch Speed Sensor Blank
9 8 7 6 5 4 3 2 1 A B C
10
11
12
13
14
15
16
A274141
9804/1103
50 - 05 - 01/13
4225-C/1-3.1
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 01/ 14
TM200, TM270 Data - Electrical (continued) TM270 to m/c no. 787040

System 12 volt, negative earth Battery Cranking Performance at - 18 deg. C (0 deg. F) Reserve capacity (minutes) for 25 amp load Alternator Starter Bulbs Bulb Headlights - main Headlights - dip Indicators Instruments Work lights Number plate light Side lights Tail lights Interior lights Stop lights Beacon Rear fog Warning lights Switch illumination Reversing Light Circuit Protection Fuse Circuit Fuse Rating No. (Amps) A1 Brake lights 10 A2 Warning lights/Buzzer 5 A3 LH side/tail lights 5 A4 RH side/tail lights 5 A5 Rear Wash/Wipe 7.5 A6 Hazard Warning Lights 10 A7 Beacon and clock; Front Wiper Park 10 A8 Interior Light/Radio 5 A9 Front Wash/Wipe; Horn; Head Light Flasher 15 B1 Cab junction box 10 B2 Engine shut off solenoid (ESOS) 5 B3 Dip Beam 10 B4 Main Beam 10 B5 Front Work lights 10 B6 Direction Indicators 5 (with trailer indication) (7.5) B7 Joystick switches, Boom solenoids 10 B8 Heater Motor 20 (with optional Air conditioning) (20) B9 Joystick switches, Auxiliary solenoids 10 C1 Rear work lights 10 C2 Drive solenoids, Layshaft FWD HI/LO, REV HI/LO 10 C3 Drive controls relays, Dump neutral start park brake lights 5 C4 Rear Fog Light 5 C5 Thermostart 15 C6 Load Indicator 5 C7 Servo cut off solenoid 5 (with Tow Hitch Solenoid) 7.5 C8 Speedometer 5 C9 Blank Rating (Watts) 60 W 55 W 21 W 1.7 W 55 W Halogen 5W 5W 5W 10 W 21 W 55 W Halogen 21 W 3W 1.2 W 21 W Relays 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Layshaft Front work lights Road Lights Indicator/Flasher Buzzer Forward Hi/Low Reverse Hi/Low Forward Reverse Parking Brake Dump Relay Ignition 2 relay Ignition 1 relay Neutral start relay 410 amps to 1.4 V.P.C 180 A127 12V 65A M127 12V
A277210
9804/1103
50 - 05 - 01/14
4225-C/1-3.1
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 01/ 14A
TM200, TM270 Data - Electrical (continued) TM270 from m/c no. 787041
System Battery Cranking Performance at - 18 deg. C (0 deg. F) Reserve capacity (minutes) for 25 amp load Alternator Starter Motor 12 volt, negative earth 410 amps to 1.4 V.P.C 180 A127 12V 65A M127 12V
Bulbs
Bulb Headlights - main Headlights - dip Indicators Instruments Work lights Number plate light Side lights Tail lights Interior lights Stop lights Beacon Rear fog Warning lights Switch illumination Reversing Light Rating (Watts) 60 W 55 W 21 W 1.7 W 55 W Halogen 5W 5W 5W 10 W 21 W 55 W Halogen 21 W 3W 1.2 W 21 W
Relays
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Layshaft Front work lights Road Lights Indicator/Flasher Buzzer Mainshaft Forward Hi/Low Reverse Hi/Low Forward Reverse Parking Brake Dump Relay Ignition 2 relay Ignition 1 relay Neutral start relay
Circuit Protection
Fuse Circuit No. A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9 Fuse Rating (Amps) 10 5 5 5 7.5 10 10 5 15 10 5 10 10 10 5 (7.5) 10 20 (20) 10 10 10 5 5 15 5 5 7.5 5 -
Brake lights Warning lights/Buzzer LH side/tail lights RH side/tail lights Rear Wash/Wipe Hazard Warning Lights Beacon and clock; Front Wiper Park Interior Light/Radio Front Wash/Wipe; Horn; Head Light Flasher Cab junction box Engine shut off solenoid (ESOS) Dip Beam Main Beam Front Work lights Direction Indicators (with trailer indication) Joystick switches, Boom solenoids Heater Motor (with optional Air conditioning) Joystick switches, Auxiliary solenoids Rear work lights Drive solenoids, Layshaft FWD HI/LO, REV HI/LO Drive controls relays, Dump neutral start park brake lights Rear Fog Light Thermostart Load Indicator Servo cut off solenoid (with Tow Hitch Solenoid) Speedometer Blank
6 7
8
B C 1 2 3 4 5 6 7 8 9
9 10
15
14
13
12 11
A310330
9804/1103
50 - 05 - 01/14A
4225-C/1-3.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/15
426B, 436B, 446B Data - Electrical

System Type Battery (Two 12 Volt batteries in series) Cold Crank Amps for 1 minute to 1.4VPC at -18 C (0 F) Reserve Capacity (minutes) for 25 Amp load Alternator 426, 436 446 Starter Motor 426, 436 446 24 Volts, negative earth
410 Amps 180
Butec A5524, 65 Amp maximum output BOSCH 0120-488-206
S115 24-7 DELCO REMY 42-MT/400
Light Bulbs Bulb Headlights - main Headlights - dip Indicators Indicator repeater Instruments Work lights Number plate light Tail lights Front sidelights Interior lights Stop lights Beacon Rear fog Warning lights Master warning light Rating (Watts) 75 W 70 W 21 W 5W 1.2 W 70 W Halogen 10 W 5W 5W 10 W 21 W 70 W Halogen 21 W 1.2 W 5W
9804/1103
50 - 05 - 01/15
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/16
426B, 436B, 446B Data - Electrical (continued)

Fuses Fuse No. A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9 Circuit Fuse Rating (Amps) 5 10 5 10 10 20 10 10 10 10 10 10 5 10 10 25 10 10 Relays A1 A2 A3 A4 A5 B1 B2 B3 B4
m/cs to 531064 (426B) m/cs to 533069 (436B)
Neutral Start Rear Work Lights/Reverse Lights Reverse Alarm Hazard Seat Warning (Optional) Start Front Work Lights Buzzer Transmission Timer
A1
B1
A2
B2
A3
B3
A4
B4
A5
2 3 4 5 6 7 8 9
A200630
9804/1103
50 - 05 - 01/16
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/17

Fuses Fuse No. A1 A2 A3 A4 A5 A6 Circuit Fuse Rating (Amps) 5 10 5 10 10 Relays 1 2 3 4 5 6 7 8 9 10 11 12
m/cs from 531065 (426B) m/cs from 533070 (436B)
A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9
Direction Indicators Right Sidelights and Gauge Illumination Rear Fog Light Reverse Alarm, Dump Switch, Anti-Stall Relay and Solenoid Valve Brake Lights, Loader Arm and Bucket Reset Warning lights, Heater Fan, Gauges, Cigar Lighter, Transmission Disconnect Relay, Timer and Hourmeter Main Beam Blank Blank Hazard Warning Lights and Clock Dip Beam Rear Work Lights/Reversing Lights Rear Wash/Wipe Interior Light, Beacon and Radio (Optional) Engine shut off system (ESOS) Air Conditioning (Optional) Blank Blank Left Sidelights and Number Plate Lights Front Work Lights Transmission Blank Horn and Front Wash/Wipe Blank Hydraulic Dump Valve Blank Blank
Hazard Blank Transmission timer Neutral Start Start Blank Blank Transmission Disconnect Front Work Lights Anti-Stall Reverse Alarm Rear Work Lights/Reverse Lights
20 10 10 10 10 10 10 5 10 10 25 10 10 5 -
10
C
11
A B
12
1 2 3 4 5 6 7 8 9
A248620
9804/1103
50 - 05 - 01/17
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/18

Fuses Fuse No. A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9 Circuit Fuse Rating (Amps) Relays 1 2 3 4 5 6 7 8 9 10 11 12
Hazard Warning Lights and Direction Indicators 5 Right Side/Tail Lights and Switch Illumination 5 Rear Fog Light 5 Anti-stall (if fitted) 5 Brake Lights, Float, Lift and Shovel Reset 10 Computer Feed Relay Solenoid 1 Main Beam 15 EMS Battery Feed 1 Blank Hazard Warning Lights (Battery Feed) Dip Beam Rear Work Lights and Reverse Alarm Rear Wash/Wipe Radio, Under Bonnet Lights, Interior Light and Beacon Engine shut off system (ESOS) Air Conditioning Thermostart Blank Left Side/Tail Lights and No. Plate Lights Front Work Lights EMS and FZ Computer Feed Blank Horn and Front Wash/Wipe Heater Blower and Cigar Lighter Hydraulic Dump Valve Blank Blank 10 10 15 10 10 5 10 15 5 25 10 10 25 5 -
Direction Indicators Blank Computer Feed Engine Shut Down Start Inhibit ACCS (If fitted) Blank Heater Fan Front Work Lights Anti-stall (if fitted) Reverse Alarm Rear Work Lights
1 2
12
3 4
11
5 6 7
10
A270230
8 9
9804/1103
50 - 05 - 01/18
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/19

Fuses Fuse Circuit No. A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9 Fuse Rating (Amps) Relays 1 2 3 4 5 6 7 8 9 10 11 12
m/cs from 540000 (446B)
Hazard Warning Lights and Direction Indicators 5 Right Side/Tail Lights and Switch Illumination 5 Rear Fog Lights 5 Blank Brake Lights, Float, Lift and Shovel Reset 5 Computer Feed Relay Solenoid 1 Main Beam 10 EMS Battery Feed 1 Blank Hazard Warning Lights (Battery Feed) Dip Beam Rear Work Lights and Reverse Alarm Rear Wash/Wipe Radio, Under Bonnet Lights, Interior Light and Beacon Engine shut off system (ESOS Hold Coil) Air Conditioning Engine shut off system (ESOS Pull Coil) Blank Left Side/Tail Lights and No. Plate Lights Front Work Lights EMS and ZF Computer Feed Blank Horn and Front Wash/Wipe Heater Blower and Cigar Lighter Grid Heater Relay and Hydraulic Dump Valve ACCS Blank 5 10 10 10 10 1 10 30 5 15 10 10 20 5 5 -
Direction Indicators Intermittent Wipers Computer Feed Engine Shut Down Start Inhibit ACCS Blank Heater Fan Front Work Lights Blank Reverse Alarm Rear Work Lights
1 2
12
3 4
11
5 6 7
10
A270230
8 9
9804/1103
50 - 05 - 01/19
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 01/20
426B, 436B, 446B Data - Electrical (continued) Fuses

The electrical circuits are protected by fuses. The fuses are located in a fuse box to the rear of the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one. D1 D2 D3 D4 D5 D6 D7 D8 D9 D10
m/cs from 533692 (436B)
! CAUTION
8-3-3-5
EMS (Ignition Feed) ZF Computer (Ignition Feed) CCTV (Option) Blank ESOS and Cold Start Advance Reverse Lights and Alarm In-cab 24/12 Volt Converter (Option) Blank Brake Lights Float, Lift and Shovel Reset and 4th Spool
3 7.5 5 5 5 10 7.5 7.5
Fuse Circuit No. A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 C1 C2 C3 C4 C5 C6 Rear Work Lights Road Lights Front Work Lights Dipped Beam Main Beam Rear Fog Lights Blank Thermostart Dump Relay Ignition Relays
Fuse Rating (Amps) 10 15 20 10 10 5 30 3 3 3 3 10 3 7.5 10 7.5 10 15 5 3 10 7.5 10 10 5 15 5 15
10 9 8 7 6 5 4 3 2 1
3 2 1
A B
13
14
C D
15
Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and No. Plate Lights 12 Volt Trailer Electrics (Option) EMS (Battery Feed) ZF Computer (Battery Feed) Hazard Warning Beacon and Interior Light Radio (24 Volt) Headlight Flash Side Lights
12
11
10
A336170
Starter Relay Solenoid Cigar Lighter (24 Volt) See Note Blank Rear Wash/Wipe Front Wash/Wipe and Horn Heated Seat/Mirrors and Air Suspension Seat (Option) C7 Air Conditioning (Option) C8 Heater Blower C9 Direction Indicators C10 Heated Rear Screen Note: Not fitted if in-cab 24/12 Volt converter fitted.
Note: To gain access to the underside of the fuse/relay panel, remove the securing screw and unhook the rear of the panel. Manipulate the panel until it is clear. Make sure the panel is refitted securely.
9804/1103
50 - 05 - 01/20
4160-C/1-6.2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 01/21
426B, 436B, 446B Data - Electrical (continued) Primary Fuses

The primary fuses are located in a fuse box attached to the battery positive terminal. If a fuse ruptures, find out why and rectify the fault before fitting a new one. Fuse No. PF1 Front Work Lights Rear Work Lights Main Beam Dip Beam Fog Lights PF2 40 RH Side/Tail Lights & Switch Illumination LH Side/Tail Lights & No. Plate Lights Headlight Flash Radio (24 Volt) Beacon & Interior Light Hazard Warning EMS (Battery Feed) ZF Computer (Battery Feed) 12 Volt Trailer Electrics 426 - 40 436 - 50 Starter Solenoid Thermostart Heater Blower Air Conditioning Direction Indicators Heated Seat, Mirrors & Air suspension Seat Heated Rear Screen Ignition Relays 50 EMS (Ignition Feed) ZF Computer (Ignition Feed) Rear Wash/Wipe Front Wash/Wipe & Horn Cigar Lighter (24 Volt) ESOS & Cold Start Advance Reverse Alarm/Lights Headlight Flash Brake Lights Shovel and Arm Reset CCTV In-cab 24/12 Volt Converter Circuits Fuse Rating (Amps) 40
M/cs from 533692 (436B)
Relays
* PF3
PF4
10 9 8 7 6 5 4 3 2 1
3 2 1
A B
13
14
C D
15
PF4 PF3
PF2
12 11 10
PF1
X Y
A336180
A336170
9804/1103
50 - 05 - 01/21
4160-C/1-7.2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 02/1
406,407 Data - Hydraulic

Pump Type Flow at 2000 rev/min and186 bar (2700lbf/in2) Main Relief Valve Operating Pressure Sundstrand AFGP 28L-30442 (gear type) 56 litres/min 12.3 UK gal/min 14.8 US gal/min bar 186 kgf/cm2 190 lbf/in2 2700
Auxiliary Relief Valves Operating Pressures Shovel Ram Rod Side Shovel Ram Head Side Filter By-pass pressure Ram Torque Settings Piston Head (all rams except steer ram) End Cap (all rams except steer ram) Piston Head (steer ram) End Cap (steer ram) Ram Dimensions [mm (in.)] Steering Ram (to m/c 631796) Steering Ram (from m/c 631797) Shovel Ram (to m/c 631796) Shovel Ram (from m/c 631797) Lift Ram (to m/c 631796) Lift Ram (from m/c 631797) Quick Hitch (Twin piston cylinder) Bore 60 (2.36) 60 (2.36) 100 (3.94) 100 (3.94) 100 (3.94) 100 (3.94) 60 (2.36) 1.05 Nm 405 678 300 450 Stroke 245.5 (9.67) 245.5 (9.67) 387.5 (15.26) 387.5 (15.26) 715.0 (28.15) 715.0 (28.15) 54.0 (2.13) 1.07 kgf m 41.3 69.2 30.6 45.9 Rod Dia. 30 (1.18) 30 (1.18) 60 (2.36) 60 (2.36) 60 (2.36) 60 (2.36) 44.4 (1.75) 15.0 lbf ft 300 500 221 332 Piston Head A/F 40 45 75 75 75 75 Cap A/F 50 55 95 85 95 85 73 158 227 160 230 2300 3300
9804/1103
50 - 05 - 02/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 02/2
408,409 Data - Hydraulic

Pump Type Flow at 2000 rev/min and 207 bar (3000lbf/in2) Sundstrand AFGP 36L-31805 (gear type) 72 litres/min 15.8 UK gal/min
19 US gal/min
Main Relief Valve Operating Pressure
bar 207
kgf/cm2 211
lbf/in2 3000
Auxiliary Relief Valves Operating Pressures Shovel Ram Rod Side Shovel Ram Head Side Filter By-pass pressure Ram Torque Settings Piston Head (all rams) End Cap (all rams) Ram Dimensions [mm (in.)] Steering Ram Shovel Ram (to m/c 631870) Shovel Ram (from m/c 631871) Lift Ram (to m/c 631870) Lift Ram (from m/c 631871) Quick Hitch (Twin piston cylinder) Bore 70 (2.76) 100 (3.94) 100 (3.94) 110 (4.33) 110 (4.33) 60 (2.36) Nm 405 678 Stroke 246 (9.69) 397 (1563) 397 (1563) 708 (27.87) 708 (27.87) 54 (2.13) kgf m 41.3 69.2 Rod Dia. 40 (1.58) 60 (2.36) 60 (2.36) 60 (2.36) 60 (2.36) 44.4 (1.75) lbf ft 300 500 Piston Head A/F 55 75 75 75 85 Cap A/F 65 95 85 95 95 73 1.05 1.07 15.0 172 228 175 233 2494 3306
9804/1103
50 - 05 - 02/2
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 02/3
411 Data - Hydraulics

Pump Type Pump 1 flow at 2200 engine rev/min Flow at 200 bar Pump 2 flow at 2200 engine rev/min Flow at 200 bar Ultra 2PRO332PRO23 Fixed Displacement Gear Double Pump 45.5 l/min 37.0 l/min 65.3 l/min 60.0 l/min 10.0 gal/min 8.1 gal/min 14.4 gal/min 13.2 gal/min
- Minimum acceptable flow rate for a worn pump. Relief Valve Operating Pressres Main Relief Valve (P1) Main Relief Valve (P2) Auxiliary Releif Valve - Shovel Ram Head Side - Shovel Ram Rod Side - Lift Ram Head Side Unloader Servo From machine No. 527210 Rams Bore mm 80 90 60 in 3.1 3.5 2.4 Rod Dia. mm in 50 1.9 50 1.9 30 1.2 Stroke mm in 927 36.5 742 29.2 312 12.3 bar 220 195 150 240 345 170 38 kgf/cm2 224 194 153 245 352 173 38.8 lbf/in2 3190 2755 2175 3480 5002 2465 551
Shovel Ram Lift Ram Steer Ram Filter Filtration Size By pass Setting Suction Strainer Size
10 Micron 1.5 bar 140 Micron
20 - 05 - 02/3
4160 - E/1-1.3
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 02/4
416 Data - Hydraulic

Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure (220 bar) Loader Valve Type Ref Services Operated Spool 1 (LV1) * Spool 2 (LV2) Spool 3 (LV3) Spool 4 (LV4) Relief Valve Operating Pressures System pressure (pump relief valve) Standby pressure (pump relief valve) Auxiliary Relief Valves (A.R.V.) Steering priority Lift ram, head side * Shovel ram, head side (1st stage) * Shovel, head side (2nd stage) * Shovel ram, rod side Servo Brake (non-adjustable) By-pass Pressures Filter Oil Cooler Tank Capacities Rexroth, stacked directional control, model MP18. 4 spool 3 spool Loader arms Shovel Quickhitch (optional) Auxiliary (optional) bar 220 27 175 350 80 220 248 30 60 bar 1.5 3.0 Litres 125 82 70 Bore mm 90 100 70 kgf/cm2 224 27.5 178.5 357 81.6 224 253 30.6 61.2 kgf/cm2 1.53 3.06 UK gall 27.5 18 15.4 lbf/in2 3190 391.5 2537.5 5075 1160 3190 3596 435 870 lbf/in2 22 44 US gall 33 21.7 18.5 Stroke mm in 927 36.5 740 29.1 312 12.3 Rexroth. Variable displacement axial piston AV10VO 71DFR 1/31 RPS C2 NOO 5.0 litres/min 1.1 UK gal/min 156.0 litres/min 34.3 UK gal/min 5.0 litres/min 1.1 UK gal/min
1.3 US gal/min 41.2 US gal/min 1.3 US gal/min
2 spool
Rams in 3.5 3.9 2.8 Rod Dia. mm in 50 1.9 60 2.4 40 1.6
9804/1103
50 - 05 - 02/4
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 02/5

Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure (220 bar) Loader Valve Type Services Operated Spool 1 (LV1) Spool 2 (LV2) Spool 3 (LV3) (optional) Spool 4 (LV4) (optional) Relief Valve Operating Pressures System pressure (pump relief valve) Standby pressure (pump relief valve) Auxiliary Relief Valves (A.R.V.) Lift ram, head side Shovel ram, head side (1st stage)* Shovel ram, head side (2nd stage) Shovel ram, rod side Servo Brake (non-adjustable)(max) Steer relief pressure (at ram) Steer relief pressure (at pump) * Not fitted on Z-bar machines By-pass Pressures Filter Oil Cooler Capacities Hydraulic tank Rams Bore mm 100 110 80 in 3.9 4.3 3.1 Rod Dia. mm in 60 2.4 60 2.4 50 2.0 Stroke mm in 1056 41.6 821 32.3 312 12.3 bar 1.5 3.0 Litres 164 kgf/cm2 1.53 3.06 UK gal 36.1 lbf/in2 22 44 US gal 43.4 Rexroth, stacked directional control, model MP-22. Rexroth. Variable displacement axial piston AV10VO 100DFR 1/3R-PSC 12NOO-50420 5 litres/min 1.1UK gal/min 220 litres/min 48.4 UK gal/min 210 litres/min 46.2 UK gal/min
Loader arms Shovel Auxiliary (Quickhitch) Auxiliary (Clam) bar 220 27 345 80 225 248 27-35 80 175 190 kgf/cm2 224 27.5 352 81.6 230 253 27.5-35.6 61.2 178.5 193.8 lbf/in2 3190 391.5 4985 1160 3262 3596 391.5-508 870 2537.5 2755
* * * *
9804/1103
50 - 05 - 02/5
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 02/6

Primary Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure (220 bar) Secondary Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure Loader Valve Type Services Operated Spool 1 (LV1) Spool 2 (LV2) Spool 3 (LV3) (optional) Spool 4 (LV4) (optional) Relief Valve Operating Pressures * * * * System pressure (main pump relief valve) Standby pressure (main pump relief valve) System pressure (secondary pump return valve) Standby pressure (secondary pump Auxiliary Relief Valves (A.R.V.) Lift ram, head side Shovel ram, head side (1st stage)* Shovel ram, head side (2nd stage) Shovel ram, rod side Servo Brake (non-adjustable) Steer relief pressure (at ram) Steer relief pressure (at pump) * Not fitted on Z-bar machines By-pass Pressures Filter Oil Cooler Capacities Hydraulic tank Rams Bore mm Shovel Ram Lift Ram Steer Ram Filter Filtration Size By pass Setting Suction Strainer Size
9804/1103
Rexroth. Variable displacement axial piston AV10VO 71DFR 1/31 RPS C2 NOO 5 litres/min 1.1 UK gal/min 1.3 US gal/min 156 litres/min 34.3 UK gal/min 41.2 US gal/min 5 litres/min 1.1 UK gal/min 1.3 US gal/min
Rexroth. Variable displacement axial piston AA10VO 45OFR 1/50L PSC 11NOO-50420 3 litres/min 0.7 UK gal/min 0.8 US gal/min 99 litres/min 21.8 UK gal/min 26.1 US gal/min 94 litres/min 20.7 UK gal/min 24.8 US gal/min
Rexroth, stacked directional control, model MP-22.
Loader arms Shovel Auxiliary (Quickhitch) Auxiliary (Clam) bar 220 27 220 25 345 80 225 248 27-35 80 175 190 kgf/cm2 224 27.5 224 25.5 352 81.6 230 253 27.5-35.6 61.2 178.5 193.8 lbf/in2 3190 391.5 3190 362.5 4985 1160 3262 3596 391.5-508 870 2537.5 2755
* * * *
bar 1.5 3.0 Litres 181
kgf/cm2 1.53 3.06 UK gal 39.8
lbf/in2 22 44 US gal 47.9 Rod Dia. mm in 60 2.4 70 2.8 50 2.0 Stroke mm in 1056 41.6 814 32.0 312 12.3
in 4.3 5.1 3.1
110 130 80
50 - 05 - 02/6
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 02/7
412S, 414S, 416S Data - Hydraulics

Pump 412S Type Pump 1 flow at 2200 engine rev/min Flow at 200 bar Pump 2 flow at 2200 engine rev/min Flow at 200 bar Ultra 2PRO33/2PRO23 Fixed Displacement Gear Double Pump 45.5 l/min 37.0 l/min 65.3 l/min 60.0 l/min 10.0 gal/min 8.1 gal/min 14.4 gal/min 13.2 gal/min
* 414S/416S Type Pump 1 flow at 2200 engine rev/min Flow at 200 bar Pump 2 flow at 2200 engine rev/min Flow at 200 bar
Ultra 2PRO41/2PRO29 Fixed Displacement Gear Double Pump 63.8 l/min 51.0 l/min 90.2 l/min 72.0 l/min 14.0 gal/min 11.2 gal/min 19.8 gal/min 15.8 gal/min
- Minimum acceptable flow rate for a worn pump. Relief Valve Operating Pressures Main Relief Valve (P1) Main Relief Valve (P2) Auxiliary Relief Valve - Shovel Ram Head Side - Shovel Ram Rod Side - Lift Ram Head Side Unloader Servo Rams Bore m in 80 3.1 90 3.5 60 2.4 Rod Dia. mm in 50 1.9 50 1.9 30 1.2 Stroke mm 927 742 312 bar 220 195 150 240 345 170 38 kgf/cm 2 224 194 153 224 352 173 38.8 lbf/in 2 3190 2755 2175 3190 5002 2465 551
in 36.5 29.2 12.3
20 - 05 - 02/7
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 02/8
409 Telemaster Data - Hydraulic

Pump Type Flow at 2250 rev/min and 207 bar (3000lbf/in2) Sundstrand AFGP 36L-31805 (gear type) 81 litres/min 17.8 UK gal/min
21.4 US gal/min
Main Relief Valve Operating Pressure
bar 207
kgf/cm2 211
lbf/in2 3000
Auxiliary Relief Valves Operating Pressures Forward Tilt (G) Backward Tilt (F) Filter By-pass pressure Ram Torque Settings Piston Head (all rams) End Cap (all rams) Ram Dimensions [mm (in.)] Steering Ram Tilt Ram Compensating Ram Lift Ram Extending Ram Quickhitch (Twin piston cylinder) Bore 70 (2.76) 120 (4.73) 70 (2.76) 110 (4.33) 70 (2.76) 40 (1.58) Nm 405 678 Stroke 246 (9.69) 285 (11.23) 630 (24.82) 842 (33.18) 1,200 (47.28) 40 (1.58) kgf m 41.3 69.2 Rod Dia. 40 (1.58) 70 (2.76) 40 (1.58) 60 (2.36) 40 (1.58) 30 (1.18) lbf ft 300 500 Piston Head A/F 55 95 55 85 55 Cap A/F 65 105 65 95 65 1.05 1.07 15.0 280 280 286 286 4060 4060
9804/1103
50 - 05 - 02/8
Issue 1
CONTENTS
Wheeled Loaders
410B ZX, 411B ZX
50 - 05 - 02/9
407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX Data - Hydraulics 407B ZX, 408B ZX, 409B ZX
Transmission Pump Type Frame size Charge pressure setting Variable displacement axial piston 55 (55 cc/rev displacement) 56 (56 cc/rev displacement) 24 bar (24.5 kgf/cm2, 348 lbf/in2) 28 bar (28.5 kgf/cm2, 406 lbf/in2) (minimum) 14 cc/rev 11 cc/rev 470 bar (479.4 kgf/cm2, 6817 lbf/in2) 468 bar (477 kgf/cm2, 6786 lbf/in2) 470 bar (479.4 kgf/cm2, 6817 lbf/in2) 468 bar (477 kgf/cm2, 6786 lbf/in2) Clockwise
Variable displacement axial piston 75 (75 cc/rev displacement) 28 bar (28.6 kgf/cm2, 406 lbf/in2)
Charge pump displacement High pressure setting port A High pressure setting port B Rotation Main Hydraulic Pump Type Flow at 2200 rev/min (no load) Max. cont. pressure Flow at 2150 rev/min (full load)
17 cc/rev 440 bar (448.8 kgf/cm2, 6382 lbf/in2) 440 bar (448.8 kgf/cm2, 6382 lbf/in2) Clockwise
Fixed displacement gear pump 70.4 lpm (15.5 UK gal/min, 18.6 US gal/min) 72.6 lpm (16 UK gal/min, 19.2 US gal/min) 240 bar (245 kgf/cm2, 3480 lb/in2) 68.8 lpm (15.1 UK gal/min, 18.2 US gal/min) 71 lpm (15.7 UK gal/min, 18.8 US gal/min)
Fixed displacement gear pump (41 cc/rev) 90 lpm (19.8 UK gal/min, 23.8 US gal/min) 250 bar (255 kgf/cm2, 3625 lb/in2) 88.2 lpm (19.4 UK gal/min, 23.3 US gal/min)
Fan Pump Type Flow at 2000 rev/min (zero pressure) Flow at 2000 rev/min (system pressure)
Fixed displacement gear pump 14.1 lpm (3.1 UK gal/min, 3.7 US gal/min) 13.5 lpm (2.9 UK gal/min, 3.5 US gal/min) 10 cc/rev pump 18.3 lpm (4 UK gal/min, 4.8 US gal/min) 12 cc/rev pump 21.9 lpm (4.8 UK gal/min, 5.8 US gal/min)
Fixed displacement gear pump (10 cc/rev) 22 lpm (4.8 UK gal/min, 5.8 US gal/min) 21 lpm (4.6 UK gal/min, 5.5 US gal/min)
Steer Pump Type Flow at 2200 rev/min Max. cont. pressure Fan Motor Type Max. fan speed
Fixed displacement gear pump (17 cc/rev) 37.4 lpm (8.2 UK gal/min, 9.9 US gal/min) 210 bar (215 kgf/cm2, 3045 lb/in2)
Fixed displacement gear motor 1710 rev/min 2150 rev/min
Fixed displacement gear motor 3500 rev/min
Transmission Motor Type Frame size
Bent axis 110 (110 cc/rev displacement) 107 (107 cc/rev displacement)
Bent axis 160 (161 cc/rev displacement)
407B ZX, 408B ZX, 409B ZX, to S/N. 757399. 407B ZX, 408B ZX, 409B ZX, S/N. 757400 on.
9804/1103
20 - 05 - 02/9
4210 - E/1-1.6
Issue 3*
CONTENTS
Wheeled Loaders
50 - 05 - 02/10
407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX Data - Hydraulics (continued) 407B ZX, 408B ZX, 409B ZX
Valve Block Type Ref Husco International AR1325-001 (4-spool, servo) AR1325-004 (3-spool, servo) AR1325-005 (4-spool, manual) AR1325-006 (3-spool, manual) 63 litres/min Crowd Lift Auxiliary (Quickhitch) Auxiliary Priority Steer
410B ZX, 411B ZX

Commercial Hydraulics KA18 346 9204 166 (4-spool, servo) KA18 346 9203 192 (3-spool, servo)
Max. flow Services Operated Spool 1 (S1) Spool 2 (S2) Spool 3 (S3) Spool 4 (S4) * Spool PS1
90 litres/min Crowd Lift Auxiliary 1 Auxiliary 2
Relief Valve Operating Pressures bar kgf/cm Main Relief Valve, B - 407B Main Relief Valve, B - 408B Main Relief Valve, B - 409B Auxiliary Relief Valve Crowd ram, A Crowd ram, B Lift ram, B Priority steer, B
2
kgf/cm2
2
lbf/in2 233 250 3335 3553
bar
lbf/in 220 230 240 250 250 260 138
223 233 243 253 253 264 140
3190 3335 3480 3625 3625 3770 2001
410B ZX 230 411B ZX 245
260 260 270
264 264 275
3770 3770 3916
By-pass Pressures Filter Capacities Hydraulic system Rams Crowd Ram Lift Ram Steer Ram
bar 3.0 Litres 70 Bore mm in 90 3.5 80 3.1 50 2.0
kgf/cm2 3.06 UK gall 15.4 Rod Dia. mm in 50 2.0 50 2.0 30 1.2
lbf/in2 44 US gall 18.5 Stroke mm in 515 20.3 530 20.9 305 12.0 Litres 130 Bore mm in 110 4.3 90 3.5 60 2.4 UK gall 28.6 Rod Dia. mm in 60 2.4 60 2.4 30 1.2 US gall 34.3 Stroke mm in 520 20.5 60.5 23.8 305 12
411B ZX with optional Volvo style Quick-hitch

Bore mm in 120 4.7 Rod Dia. mm in 65 2.6 Stroke mm in 520 20.5
Crowd Ram
9804/1103
20 - 05 - 02/10
4210 - E/1 - 2.3
Issue 3*
CONTENTS
Wheeled Loaders
50 - 05 - 02/11
456B Data - Hydraulic

Primary Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure (220 bar) Secondary Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure Loader Valve Type Services Operated Spool 1 (LV1) Spool 2 (LV2) Spool 3 (LV3) (optional) Spool 4 (LV4) (optional) Relief Valve Operating Pressures System Control Pressure (pressure control valve) System control pressure (main pump relief valve) Standby pressure (main pump relief valve) System pressure (secondary pump relief valve) Standby pressure (secondary pump) Auxiliary Relief Valves (A.R.V.) Lift ram, head side Shovel ram, head side Shovel ram, rod side Servo Brake (non-adjustable) Steer relief pressure (at ram) Steer relief pressure (at pump) By-pass Pressures Filter Oil Cooler Capacities Hydraulic tank Rams Bore mm 180 160 90 in 7.1 6.3 3.5 Rod Dia. mm in 90 3.5 80 3.1 50 2.0 Stroke mm 560 727 312 in 22.05 28.6 12.3 Rexroth, stacked directional control, model MP-22. Rexroth. Variable displacement axial piston A 10VS0 45DFR 1/50L PSC 11NOO-50420 3 litres/min 0.7 UK gal/min 99 litres/min 21.8 UK gal/min 3 litres/min 0.7 UK gal/min Rexroth. Variable displacement axial piston A 10VS0 100DFR 1/31 RPS C12 NOO 5 litres/min 1.1 UK gal/min 220 litres/min 48.4 UK gal/min 5 litres/min 1.1 UK gal/min
Loader arms Shovel Auxiliary (Quickhitch) Auxiliary (Clam) bar 190 220 27 190 25 345 225 248 27-35 80 175 190 bar 1.5 3.0 Litres 181 kgf/cm2 194 224 27.5 194 25.5 352 230 253 27.5-35.6 81.6 178.5 193.8 kgf/cm2 1.53 3.06 UK gal 39.8 lbf/in2 2755 3190 391.5 2755 362.5 4985 3262 3596 391.5-508 1160 2537.5 2755 lbf/in2 22 44 US gal 47.9
Shovel Ram Lift Ram Steer Ram Filter Filtration Size By pass Setting
10 Micron 1.5 bar
9804/1103
50 - 05 - 02/11
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 02/12
TM200, TM270 Data - Hydraulics

TM200 Pump Type Flow at 2250 rpm Relief Valve Operating Pressure * Main Relief Valve Auxiliary Relief Valves Forward Tilt (G) Backward Tilt (F) Servo Pressure Filter Filtration Size By-pass Pressure Ram Dimensions Steering Tilt Compensating Lift Extension Quickhitch Hydraulic Tank Capacity
Sunstrand AFGP 36L - 31805 (gear type) 81 litres/min 17.80 UK gal/min bar 207 280 280 30 kgf/cm 2 211 286 286 30
21.4 US gal/min lbf/in 2 3000 4060 4060 435
25 microns 1.05 Bore 70 120 70 110 70 40
1.07 Rod Dia 40 70 40 60 40 30
15 Stroke 246 285 630 842 1200 40
63 litres
13.9 UK gal
16.6 US gal
9804/1103
20 - 05 - 02/12
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 02/13
TM200, TM270 Data - Hydraulics (continued)

TM270
Pump Main Pump Flow at 2200 rpm Auxiliary Pump Flow at 2200 rpm Relief Valve Operating Pressure Main Relief Valve Auxiliary Relief Valves Forward Tilt Backward Tilt Unloader Valve Servo Pressure Filter Filtration Size By-pass Pressure Ram Dimensions Steering Tilt Compensating Lift Extension Quickhitch Hydraulic Tank Capacity
79 litres/min 42 litres/min bar 210 230 230 150 30
17.4 UK gal/min 9.2 UK gal/min kg/cm2 214 235 235 153 30
21.0 US gal/min 11.0 US gal/min lbf/in2 3045 3335 3335 2175 435
25 microns 1.05 Bore 60 130 60 120 80 40
1.07 Rod Dia 30 75 35 70 50 30
15 Stroke 288 342 600 1040 1275 40
90 litres
19.8 UK gal
23.8 US gal
9804/1103
50 - 05 - 02/13
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 02/14
426B, 436B, 446B Data - Hydraulics 426 Machines

Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure (220 bar) Loader Valve Type Services Operated Spool 1 (LV1) Spool 2 (LV2) Spool 3 (LV3) (optional) Spool 4 (LV4) (optional) Relief Valve Operating Pressures bar Rexroth, stacked directional control, model MP-22. Rexroth. Variable displacement axial piston AV10VO 100DFR 1/3R-PSC 12NOO-50420 5 litres/min 1.1UK gal/min 220 litres/min 48.4 UK gal/min 5 litres/min 1.1UK gal/min
Loader arms Shovel Auxiliary (Quickhitch) Auxiliary (Clam) kgf/cm2 lbf/in2
System control pressure (pump relief valve) 220 224 3190 Standby pressure (pump relief valve) 27 27.5 391.5 Auxiliary Relief Valves (A.R.V.) Lift ram, head side 345 352 4985 Shovel ram, head side (1st stage) 80 81.6 1160 Shovel ram, head side (2nd stage) 225 230 3262 Shovel ram, rod side 248 253 3596 Servo 27-35 27.5-35.6 391.5-508 Brake (non-adjustable)(max) 80 81.6 1160 Steer relief pressure (at ram) 175 178.5 2537.5 Steer relief pressure (at pump) 190 193.8 2755 Idle control pressure 140 142.8 2030 (up to 1150-1250 rev/min) Not fitted on Z-bar machines By-pass Pressures Filter Oil Cooler Capacities Hydraulic tank Rams Bore mm 100 110 80 in 3.9 4.3 3.1 Rod Dia. mm in 60 2.4 60 2.4 50 2.0 Stroke mm in 1056 41.6 821 32.3 312 12.3 bar 1.5 3.0 Litres 164 kgf/cm2 1.53 3.06 UK gal 36.1 lbf/in2 22 44 US gal 43.4
9804/1103
20 - 05 - 02/14
4160 - E/1-1.3
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 02/15
426B, 436B, 446B Data - Hydraulics (continued) 436, 446 Machines

Primary Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure (220 bar) Secondary Pump Type Ref Standby flow Fullflow at 2200 rev/min Flow at max. pressure Loader Valve Type Services Operated Spool 1 (LV1) Spool 2 (LV2) Spool 3 (LV3) (optional) Spool 4 (LV4) (optional) Relief Valve Operating Pressures System control pressure (main pump relief valve) Standby pressure (main pump relief valve) System pressure (secondary pump return valve) Standby pressure (secondary pump) Auxiliary Relief Valves (A.R.V.) Lift ram, head side Shovel ram, head side (1st stage) Shovel ram, head side (2nd stage) * Shovel ram, rod side (HT) * Shovel ram, rod side (ZX) Servo Brake (non-adjustable) Steer relief pressure (at ram) Steer relief pressure (at pump) Idle control pressure Not fitted on Z-bar machines By-pass Pressures Filter Oil Cooler Capacities Hydraulic tank Rams Bore mm 110 130 140 80 in 4.3 5.1 5.5 3.1 Rod Dia. mm in 60 2.4 70 2.8 75 2.9 50 2.0 Stroke mm in 1056 41.6 814 32.0 814 32.0 312 12.3 bar 1.5 3.0 Litres 181 kgf/cm2 1.53 3.06 UK gal 39.8 lbf/in2 22 44 US gal 47.9 Rexroth, stacked directional control, model MP-22. Loader arms Shovel Auxiliary (Quickhitch) Auxiliary (Clam) bar 245 - 255 27 155 - 165 25 345 80 225 248 125 27 - 35 80 175 190 25 kgf/cm2 250 - 260 27.5 158 - 168 25.5 352 81.6 230 253 127 27.5 - 35.6 81.6 178.5 193.8 25.5 lbf/in2 3552 - 3697 391.5 2247 - 2392 362.5 4985 1160 3262 3596 1813 391.5 - 508 1160 2537.5 2755 362.5 (Secondary pump remains at standby up to 1150-1250 rev/min) Rexroth. Variable displacement axial piston AA10VO 45OFR 1/50L PSC 11NOO-50420 3 litres/min 0.7 UK gal/min 99 litres/min 21.8 UK gal/min 3 litres/min 0.7 UK gal/min Rexroth. Variable displacement axial piston AV10VO 71DFR 1/31 RPS C2 NOO 5 litres/min 1.1 UK gal/min 156 litres/min 34.3 UK gal/min 5 litres/min 1.1 UK gal/min
Shovel Ram Lift Ram Lift Ram (446) Steer Ram Filter Filtration Size By pass Setting
9804/1103
10 Micron 1.5 bar
50 - 05 - 02/15
4160 - E/1-2.5
Issue 2
CONTENTS
Wheeled Loaders
50 - 05 - 02/16
Smoothshift Machines Data - Hydraulics (continued) 426 Machines from serial number 532100 436 Machines from serial number 533692
Pump Type Ref Pump 1 Standby flow Full flow at 2200 rev/min Flow at max. pressure (220 bar) Pump 2 Standby flow Full flow at 2200 rev/min Flow at max. pressure (160 bar) Loader Valve Type Services Operated Spool 1 (SV) Spool 2 (LV1) Spool 3 (LV2) Spool 4 (LV3) Spool 5 (LV4) Relief Valve Operating Pressures Pump 1 Standby pressure (pump compensator valve) System control pressure (pump relief valve) Pump 2 Standby pressure (pump compensator valve) System control pressure (pump relief valve) Auxiliary Relief Valves (A.R.V.) Lift ram, head side HT Shovel ram, head side ZX Shovel ram, head side Shovel ram, rod side Servo Brake (non-adjustable) Steer relief pressure (at ram) Steer relief pressure (at pump) Idle control pressure By-pass Pressures Filter Oil Cooler Capacities Hydraulic tank Hydraulic Tank (446) Rexroth, stacked directional control, model MP-22. Rexroth. Tandem variable displacement axial piston A20VO60 DFR1/10R-NSD24K01-S1296 litres/min 5 132 5 UK gal/min 1.1 29.0 1.1 US gal/min 1.3 34.8 1.3
5 132 5
1.1 29.0 1.1
1.3 34.8 1.3
Priority Steer Loader arms Shovel Auxiliary (Quickhitch) Auxiliary (Clam) (optional) bar kgf/cm2 lbf/in2
27 245 - 255 25 155 - 165
27.5 250 - 260 25.5 158 - 168
391.5 3552 - 3697 362.5 2247 - 2394
345 125 125 260 27-35 80 175 190 25 bar 1.5 3.0 Litres 181 173
352 127 127 265 27.5-35.6 81.6 178.5 193.8 25.5 kgf/cm2 1.53 3.06 UK gal 39.8 38.0
4985 1812 1812 3770 391.5-508 1160 3262 2755 362.5) lbf/in2 22 44 US gal 47.9 45.8
9804/1103
50 - 05 - 02/16
4160 - 3/1-3.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 05 - 02/16A
Smoothshift Machines Data - Hydraulics (continued) 426 Machines from serial number 532100 436 Machines from serial number 533692
Rams Bore mm in 100 3.9 110 4.3 130 5.1 160 6.3 130 5.1 130 5.1 140 6.3 80 3.1 Rod Dia. mm in 60 2.4 65 2.6 70 2.8 80 3.1 70 70 75 50 2.8 2.8 3.1 2.0 Stroke mm in 1056 41.6 1056 41.6 575 22.6 530 20.9 814 814 744 312 32.0 32.0 29.3 12.3
Shovel Ram (HT 426) Shovel Ram (HT 436) Shovel Ram (ZX 426) Shovel Ram (ZX 436, 446) Lift Ram (426) Lift Ram (436) Lift Ram (446) Steer Ram
Filter Filtration Size By pass Setting Suction Strainer Size 10 Micron 1.5 bar 140 Micron
9804/1103
50 - 05 - 02/16A
4160 - 3/1- 4.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 05 - 03/1
406,407,408,409 Data - Transmission, Axles & Tyres

Syncro Shuttle brake. Weight (dry) Torque Converter Dia. Torque Multiplication at Stall Minimum Engine Speed at Converter Stall Gear Ratios 1st 2nd 3rd 4th Combined torque converter, reverser and gearbox unit with integral parking 406/407 157 kg (345 lb) 279 mm (11 in) 2.45:1 D3.152 (CE build) 2160 rev/min 5.55:1 3.45:1 1.83:1 1.00:1 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 95 408/409 185 kg (408 lb) 279 mm (11 in) 2.83:1 1004-LR (AA build) 2040 rev/min
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
Converter Inlet Protection Pressure (max.) Lubrication Pressures (in neutral) At 50 deg.C At 100 deg.C 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min
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 L/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/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 5.6-6.3 7.0-7.7 5.6-6.3 6.3-7.0 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 80-90 100-110 80-90 90-100 UK gal/min 2.3-3.0 3.2-4.4 5.0-5.7 5.0-5.7 2.5-3.3 5.0-6.5
At 100 deg.C
Cooler at 100 deg.C
Pump at 50 deg.C
9804/1103
50 - 05 - 03/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 03/2
406,407,408,409 Data - Transmission, Axles & Tyres (continued)

Drive Axles - Front & Rear 406/407 Machines with Hurth axle Type Weight (dry, less wheels; approx.) Overall Gear Ratio Crownwheel & Pinion Ratio Hub Reduction Mounting Spiral bevel with epicyclic hub reduction 170 kg (375 lb) 21.857:1 5.143:1 4.25:1 Direct to front and rear frames
406/407 Machines with JCB axle Type Weight (dry, less wheels; approx.) Overall Gear Ratio Crownwheel & Pinion Ratio Hub Reduction Mounting 408/409 Machines Type Weight (dry, less wheels; approx.) Overall Gear Ratio Crownwheel & Pinion Ratio Hub Reduction Mounting PD55 Rigid 280 kg (618 lb) 20.925:1 3.875:1 5.4:1 Direct to front and rear frames PD 40 - Spiral bevel with epicyclic hub reduction 195 kg (430 lb) 21.82:1 3.636:1 6:1 Direct to front and rear frames
Tyre Sizes and Pressures 406/407 Industrial Front Axle bar 2.2 Rear Axle bar 2.2
lbf/in2 32.0
lbf/in2 32.0
12.5 x 18MPT x 10ply Continental 14.5 x 20MPT x 10ply Continental 405/70 R20 XM27 1 Star Michelin
2.8
45.0
2.0
29.0
2.5
36.5
1.6
23.0
406/407 Farm
Front Axle bar 2.2
lbf/in2 32.0
Rear Axle bar 2.2
lbf/in2 32.0
12.5/80 x 18 x 10ply Continental 12.5/80 x 18 x 10ply Goodyear 335/80 R18 XM27 1 Star Michelin
2.2
32.0
2.2
32.0
2.5
36.5
1.6
23.0
9804/1103
50 - 05 - 03/2
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 03/3
406,407,408,409 Data - Transmission, Axles & Tyres (continued)

Tyre Sizes and Pressures (contd) 408/409 Industrial Front Axle bar 2.2 Rear Axle bar 1.5
lbf/in2 32.0
lbf/in2 21.8
12.5 x 20MPT x 10ply Goodyear 14.5 x 20MPT x 10ply Continental
2.8
40.0
1.5
21.8
408/409 Farm
Front Axle bar 2.5
lbf/in2 36.3
Rear Axle bar 1.5
lbf/in2 21.8
12.5/80 x 20 x 10ply Continental 12.5/80 x 18 x 10ply Goodyear 405/70 R20 XM27 1 Star Michelin
2.8
40.0
1.5
21.8
2.5
36.3
1.5
21.8
9804/1103
50 - 05 - 03/3
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 03/4
411, 416 Data - Transmission, Axles & Tyres

CAUTION: Before attempting to tow the machine, read carefully Towing Procedure in the Service Manual. 411 280mm (11in.) 2.63:1 Forward 1st 2nd 3rd 4th 416 280mm (11in.) 2.45:1 Reverse 4.516:1 2.333:1 1.042:1 0.686:1
Torque Converter Dia. Torque Multiplication at Stall Gear Ratios
1st 4.516:1 2nd 2.333:1 3rd 1.042:1 Not Applicable
Charge pump flow Oil Temperature STALL TESTING
55 l/min (12.4 gal/min) at 2200 rev/min. 82 to 93C (180 to 200F
Note: Switch off transmission dump (transmission disconnect); the switch on the cab roof panel should not be illuminated. Engage the parking brake and apply the foot brake. Select Forward Drive, keep brake pedal pushed down, push the accelerator pedal down fully and record the engine speed. To stall hydraulic system, operate shovel crowd to blow off Main Relief Valve. Maximum engine speed (rev/min) at: - Converter stall only - Combined converter and hydraulic system stall 416 Machines Only If combined converter and hydraulic system stall result is outside the figures given, before rejecting the torque converter, carry out the following procedure * Set the shovel head side A.R.V. (2nd Stage) pressure to 200 bar (204 kgf/cm 2 )(2090 lbf/in 2 ) see page E/36-3, Service Manual 9803/4150 Note: Shovel head side A.R.V. (2nd Stage) pressure is normally 220 bar (224 kgf/cm 2 )(3190 lbf/in 2 ) and should be returned to this setting when the procedure is complete. * Check pump maximum pressure is set at 220 (224 kgf/cm 2 )(3190 lbf/in 2 ) see page E/36-1, Service Manual 9803/4150 Operate the service, maximum engine speed (rev/min) should be 1950 to 2100. If the result is lower, the possible cause is low engine power. Drive Axle -Front and Rear Type slipdifferential Crownwheel & Pinion Ratio Hub Ratio Overall Axle Ratio Tyre Sizes and Pressures 411 Front 15.5 - 25 15.5 R25 Rear 15.5 - 25 15.5 R25 12 ply 1.75 bar (25 lbf/in2) 1.75 bar (25 lbf/in2) 17.5 - 25 17.5 R25 12 ply 1.75 bar (25 lbf/in2) 1.75 bar (25 lbf/in2) 12 ply 2.5 bar (36 lbf/in2) 2.25 bar (33 lbf/in2) 17.5 - 25 17.5 R25 12 ply 2.5 bar (36 lbf/in2) 2.25 bar (33 lbf/in2) 416 411 JCB Epicyclic (PD70), standard or limited slip differential 3.36:1 3.36:1 5.4:1 6.0:1 18.16:1 416 JCB Epicyclic (PD90), standard or limited 411 2050 50 1500 50 416 2190 50 2140 50
20.18:1
9804/1103
20 - 05 - 03/4
Issue 3*
CONTENTS
Wheeled Loaders
50 - 05 - 03/4A
* 411,
416
Data - Transmission
WG - 110 Pump Flow @ 2000 r.p.m. System Pressure Torque Converter - input pressure (max) - output pressure (max) - output temperature (max) - continuous - short duration Inductive Transmitters (engine, turbine central geartrain) Resistance @ 20C (68F) Temperature range Torque limit - securing bolts Speed Sensor Output Temperature range Working range Supply Voltage Proportional valves in control valve Resistance @ 20C (68F) current (mA) Pressure range Stall Data Engine Idle Engine max no-load Transmission Hydraulic Combined - transmission/hydraulic 501 (11.0 UK gal, 13.2 US gal) 16+2 bar (232+29 lb/in2)
9 bar (130 lb/in2) 3.5 bar (51lb/in2) 100C (212F) 120C (248F)
1050+105 ohms -40C (-40F) - 150C (302F) 30 Nm (22lbf ft, 3 kgf m)
-40C (-40F) - 150C (302F) 2 Hz - 5 kHz 24V
19+1.9 ohms 100 - 500 0.8 - 8.3 bar 11.6 - 120lb/in2)
780+20 r.p.m. 2360+20 r.p.m. 2220+20 r.p.m. 2330+20 r.p.m. 2040+20 r.p.m.
9804/1103
50 - 05 - 03/4A
4150 - F/1-3.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 05 - 03/5
426,436 Data - Transmission, Axles & Tyres

Transmission CAUTION: Before attempting to tow the machine, read carefully Towing Procedure, in the Service Manual. 426 Type Torque Converter Dia. Torque Multiplication at Stall ZF Powershift Type WG-150 300mm (11in.) 2.91:1 Forward 1st 4.222:1 2nd 2.296:1 3rd 0.984:1 4th 0.629:1 Reverse 1st 4.222:1 2nd 2.296:1 3rd 0.984:1 Not Applicable 436 ZF Powershift Type WG-200 300mm (11in.) 2.66:1 Forward 1st 4.278:1 2nd 2.368:1 3rd 1.126:1 4th 0.648:1 Reverse 1st 4.278:1 2nd 2.368:1 3rd 1.126:1 Not Applicable
Gear Ratios
Charge pump flow Oil Temperature Drive Axle - Front
25 l/min (5.6 gal/min) @ 1000 rev/min 82 to 93C (180 to 200F)
Type Crownwheel & Pinion Ratio 3.909:1 Hub Ratio 5.167:1 Overall Axle Ratio 20.197:1 Drive Axle - Rear Type Crownwheel & Pinion Ratio 3.909:1 Hub Ratio 5.167:1 Overall Axle Ratio 20.197:1 Tyre Sizes and Pressures 426 Standard Front 17.5 - 25 17.5 R25 Rear 17.5 - 25 17.5 R25 Optional Front 20.5 - 25 20.5 R25 Rear 20.5 - 25 20.5 R25 436
16 ply -
2.75 bar (40 lbf/in2) 2 3.75 bar (54 lbf/in )
20.5 - 25 20.5 R25
12 ply -
2.75 bar (40 lbf/in2) 2.75 bar (40 lbf/in2)
16 ply -
20.5 - 25 20.5 R25
12 ply -
12 ply -
12 ply -
9804/1103
50 - 05 - 03/5
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 03/6
412S, 414S Data - Transmission, Axles & Tyres

Torque Converter Dia. Torque Multiplication at Stall Gear Ratios 2nd 3rd 4th Charge pump flow - 412S Charge pump flow - 414S Oil Temperature Clutch Pressure STALL TESTING *Note: Switch off transmission dump at the cab roof panel (with this switch off, the transmission is disconnected and there is no engine braking; maximum power is thus used for tearing out etc.).Engage the parking brake and apply the foot brake. Select Forward Drive (4) keep brake pedal pushed down, push the accelerator pedal down fully and record the engine speed. To stall hydraulic system, operate shovel crowd to blow off Main Relief Valve. Maximum engine speed (rev/min) at: - Converter stall only - Combined converter and hydraulic system stall Drive Axle - Front and Rear Type (Standard or limited slip differentials) Crownwheel & Pinion Ratio Hub Ratio Overall Axle Ratio Tyre Sizes and Pressures 412S Front 15.5/80 - 24 10 ply 17.5LR24 19.5 LR24 Rear 15.5/80 - 24 10 ply 1.75 bar (25 lbf/in2) 17.5LR24 - 1.75 bar (25 lbf/in2) 19.5 LR24 - 1.75 bar (25 lbf/in2) 17.5 LR24 19.5 LR24 1.5 bar (22 lbf/in2) 1.2 bar (17 lbf/in2) 2.25 bar (33 lbf/in2) - 2.5 bar (36 lbf/in2) - 2.0 bar (29 lbf/in2) 17.5 LR24 19.5 LR24 1.8 bar (26 lbf/in2) 1.4 bar (20 lbf/in2) *414S/416S 412S 2000 - 2050 1800 - 1850 412S JCB Epicyclic (PD70) 3.36:1 5.4:1 18.16:1 *414S/416S 2100 - 2130 1910 - 1940 414S JCB Epicyclic (PD90) 3.909:1 5.167:1 20.197:1 412S 280mm (11in.) 2.63:1 Forward 1st 4.516:1 2.333:1 1.042:1 0.686:1 414S/416S 300mm (12in.) 2.91:1 Reverse 1st 4.222:1 2nd 2.296:1 3rd 0.984:1 Not Applicable
55 l/min (12.4 gal/min) at 2200 rev/min. 25 l/min (5.6 gal/min) at 1000 rev/min. 82 to 93C (180 to 200F) 16 to 18 bar (232 to 261 lb/in 2 )
9804/1103
50 - 05 - 03/6
4170 -F/1-1.1 4170 - F/1-2.1
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 03/6A
412S, 414S, 416S Data - Transmission

WG - 110 (412S) Pump Flow@ 2000 r.p.m. System pressure Torque converter - input pressure (max) -output pressure (max) -output temperature (max) -continuous -short duration Inductive transmitters (engine, turbine, central geartrain) Resistance @ 20C (68F) Temperature range Torque limit - securing bolts Speed sensor output Temperature range Working range Supply voltage Proportional valves in control valve Resistance @ 20C (68F) Current (mA) 100 - 500 Pressure range Stall data 412S Engine idle Engine max no-load Transmission Hydraulic Combined - transmission/hydraulic 780 20 r.p.m. 236020 r.p.m. 222020 r.p.m. 233020 r.p.m. 204020 r.p.m. 414S 780 10 r.p.m. 230020 r.p.m. 210020 r.p.m. 227020 r.p.m. 190020 r.p.m. 416S 78020 r.p.m. 232020 r.p.m. 214020 r.p.m. 231020 r.p.m. 212020 r.p.m. WG - 160 (414S/416S)
50 l (11.0 UK gal, 13.2 US gal) 80 l (17.6 UK gal, 21 US gal) 412S/414S/416S 16+2 bar (232+29lb/in2)
9 bar (130 lb/in2) 3.5 bar (51 lb/in2) 100C (212F) 120C (248F)
1050 105 ohms -40C (-40F) - 150C (302F) 30Nm (22lbf ft, 3 kgf m)
-40C (-40F) - 150C (302F) 2Hz - 5kHz 24V
19 1.9 ohms. 0.8 - 8.3 bar (11.6 - 120lb/in2)
9804/1103
50 - 05 - 03/6A
4170 - F/1-3.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 03/7
407B ZX, 408B ZX, 409B ZX, 411B ZX Data - Transmission, Axles & Tyres
407B ZX , 408B ZX , 409B ZX Axles Crownwheel & Pinion Ratio Hub Ratio Overall Axle Ratio Transmission Pump Type Displacement Axial piston, variable displacement. 55 cc/rev 56 cc/rev 4.375:1 3.67:1 16:04:1 3:1 5.4:1 16.2:1 410B ZX, 411B ZX
75 cc/rev
Transmission Motor Type Displacement Bent axis 110 cc/rev 107 cc/rev
161 cc/rev
Transfer Box Type Gear Ratio Tyre Sizes 407B ZX 408B ZX 409B ZX 410B ZX 411B ZX 12.5 x 18 12.5 x 20 14.5 x 20 405/70 R24 405/80 R25 Single-speed, directly driving rear axle and driving front axle via propshaft 2.217:1 2.217:1
407B ZX, 408B ZX, 409B ZX, to S/N. 757399. 407B ZX, 408B ZX, 409B ZX, S/N. 757400 on.
9804/1103
50 - 05 - 03/7
4210 - F/1-1.4
Issue 3*
CONTENTS
Wheeled Loaders
50 - 05 - 03/8
456B Data - Transmission Axles

(Available with Standard or Limited Slip Differential) Drive Axle - Front Type Crownwheel & Pinion Ratio Hub Ratio Overall Axle Ratio Graziano 10/908800 (S) 10/909000 (LS) 4.77:1 5.16:1 24.65:1 Drive Axle - Rear Type Crownwheel & Pinion Ratio Hub Ratio Overall Axle Ratio Graziano 10/908900 (S) 10/909100 (LS) 4.77:1 5.16:1 24.65:1
Note: Front and rear axles can have Standard Differential (S) or Limited Slip Differential (LS). Tyre Sizes and Pressures Standard 23.5 R25 XTLA.TL Optional 23.5 R25 XHA.TL Maximum inflation pressure 3.5 bar
Transmission
Type Torque Converter Dia. Torque Multiplication at Stall ZF Powershift Type 4WG-200 300mm (11 in) 2.55:1 Forward 1st 4.278:1 2nd 2.368:1 3rd 1.126:1 4th 0.648:1 Reverse 1st 4.278:1 2nd 2.368:1 3rd 1.126:1 Not Applicable
Gear Ratios
Charge pump flow Oil Temperature Stall Testing
Note: Switch off transmission dump (transmission disconnect); the switch on the cab roof panel should not be illuminated. Engage the parking brake and apply the foot brake. Select Forward Drive, keep brake pedal pushed down, push the accelerator pedal down fully and record the engine speed. To stall hydraulic system, operate shovel crowd to blow off Main Relief Valve. Maximum engine speed (rev/min) at: - Converter stall only - Combined converter and hydraulic system stall
2165 - 2115 2130 - 2080
9804/1103
50 - 05 - 03/8
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 03/9
TM200, TM270 Data - Transmission TM200 Front and Rear Axles

Note : It is essential that the correct ratio axle in relationship to the gearbox ratio is fitted to the machine. Do not fit a new axle with a different ratio to the axle being replaced. Designation Installation Weight (dry and without wheels) Half (Axle) Shaft Braking/Type Input Type Hub Reduction Ratios Overall Crownwheel and Pinion Number of Teeth Crownwheel Pinion PD55 Rigid pad mount 280 kg (618 lb) approx. 3 friction plate, 4 counter plate (each half shaft) Yoke 5.4:1 16.2:1 3.0:1 33 13
TM270
Note : It is essential that the correct ratio axle in relationship to the gearbox ratio is fitted to the machine. Do not fit a new axle with a different ratio to the axle being replaced.
Front Axle
Type Designation Installation Weight (dry and without wheels) Half (Axle) Shaft Braking/Type Input Type Hub Reduction Ratios Overall Crownwheel and Pinion Number of Teeth Crownwheel Pinion 3 piece, JCB spiral bevel input with epicyclic hub reduction, and inboard braking PD70 Rigid pad mount 386 kg (851 lb) approx. 5 friction plate, 6 counter plate (each half shaft) Yoke 5.4:1 13.7:1 2.538:1 33 13
Rear Axle
Type Designation Installation Weight (dry and without wheels) Input Type Hub Reduction Ratios Overall Crownwheel and Pinion Number of Teeth Crownwheel Pinion 3 piece, JCB spiral bevel input with epicyclic hub reduction. PD70 Rigid pad mount 386 kg (851 lb) approx. Yoke 5.4:1 13.7:1 2.538:1 33 13
9804/1103
50 - 05 - 03/9
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 03/10
TM200, TM270 Data - Transmission (continued) Tyre Pressures

Note : If the tyres fitted to your machine are not listed, then contact JCB for advice, DO NOT guess tyre pressures.
TM200
Item Size x Ply Type Make bar 1 2 3 4 5 14.5 x 20 x 10PR 14.5 x 20 x 10PR 405/70 R20 425/75 R20 9.00 R20 IND CONTINENTAL CONTINENTAL MICHELIN MICHELIN MICHELIN 2.8 2.8 2.5 2.8 2.8 Front Pressure lbf/in2 41 41 36 41 41 bar 1.5 1.5 1.5 1.5 1.5 Rear Pressure lbf/in2 22 22 22 22 22
TM270
6 7 8 15.5 x 24 17.5 x 24 17.5LR x 24 XM27 TRAC GOODYEAR MICHELIN GOODYEAR 3.5 3.5 3.5 51 51 51 2.0 2.0 2.0 29 29 29
9804/1103
50 - 05 - 03/10
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 03/11
TM200, TM270 Data - Transmission (continued) Syncro Shuttle

Description Weight (dry) Gear Ratios 1st 2nd 3rd 4th Torque Converter Torque Converter Dia. Torque Converter Identification Torque Multiplication at Stall Torque Converter Colour Coded Dots Combined torque converter, reverser, and gearbox unit with integral parking brake. 157 kg (346 lb) STD Ratio Low Ratio 5.56:1 6.56:1 3.45:1 4.06:1 1.83:1 1.90:1 1.00:1 1.00:1 310 mm (12.2 in.) 12.2 - D 12.2 - P 2.82:1 2.54:1 2 Purple 2 Orange 1 Yellow 1 Yellow 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 C 1000 rev/min 2000 rev/min Converter In at 100 C 1000 rev/min 2000 rev/min Converter Out at 50 C 1000 rev/min 2000 rev/min Converter Out at 100 C 1000 rev/min 2000 rev/min Converter Inlet Relief Valve Pressure (max.) Lubrication Pressures (in neutral) At 50 C 1000 rev/min 2000 rev/min At 100 C 1000 rev/min 2000 rev/min Main Line Pressure (in Neutral) At 50 C At 100 C
Clutch Pressures Flow Rates (in neutral) Cooler at 50 C Cooler at 100 C Pump at 50 C
All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (lbf/in2) l/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 10.4 - 13.6 14.5 - 20.0 10.2 - 12.5 22.7 - 26.1 11.0 - 15.0 22.5 - 29.5 US gal/min 2.8 - 3.6 3.8 - 5.3 2.7 - 3.3 6.0 - 6.9 2.9 - 4.0 6.0 - 7.8 UK gal/min 2.3 - 3.0 3.2 - 4.4 2.3 - 2.8 5.0 - 5.7 2.5 - 3.3 5.0 - 6.5
Note : For gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 (lbf/in2)
9804/1103
50 - 05 - 03/11
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 03/12
TM200, TM270 Data - Transmission (continued) Powershift

Description Full electro-hydraulic transmission unit with input, reverse, layshaft and mainshaft clutch packs. Torque converter and parking brake integral. 220 kg (484 lb) STD Ratio Low Ratio 5.72:1 6.58:1 3.23:1 3.71:1 1.77:1 1.77:1 1.00:1 1.00:1 310 mm (12.2 in) 12.2 - D 12.2 - P 2.82:1 2.54:1 2 Purple 2 Orange 1 Yellow 1 Yellow 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 bar 9.7 - 12.8 11.4 - 14.1 11.4 - 12.8 11.4 - 13.4 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 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
Weight (dry) Gear Ratios 1st 2nd 3rd 4th Torque Converter Torque Converter Dia. Torque Converter Identification Torque Multiplication at Stall Torque Converter Colour Coded Dots
Converter Pressures (in neutral) Converter In at 50 C 1000 rev/min 2000 rev/min Converter Out at 50 C 1000 rev/min 2000 rev/min
Converter Inlet Relief Valve Pressure (max.) Lubrication Pressures (in neutral) At 50 C 1000 rev/min 2000 rev/min Main Line Pressure (in Neutral) At 50 C At 100 C Clutch Pressures
All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2)
Flow Rates (in neutral) Cooler at 50 C Pump at 50 C
litres/min 10.4 - 13.6 14.5 - 20.0 11.0 - 15.0 22.5 - 29.5
US gal/min 2.8 - 3.6 3.8 - 5.3 2.9 - 4.0 6.0 - 7.8
UK gal/min 2.3 - 3.0 3.2 - 4.4 2.5 - 3.3 5.0 - 6.5
Note : For new gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 (lbf/in2)
9804/1103
50 - 05 - 03/12
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 03/13
TM200, TM270 Data - Transmission (continued) Transfer Gearbox

Type Installation Weight (dry) Ratio Drop Dimension Oil Type Oil Capacity Nominal Rating Maximum Input Speed Input and Output Drive ITL helical gears 3 bolt mounting 67 kg (147 lb) 1.1 (Permanently engaged) 300 mm Mobil HD90 1 litre 56.7 kW (76 bhp) 3000 rpm 1480 Half Yoke
9804/1103
50 - 05 - 03/13
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 03/14
426B, 436B, 446B Data - Transmission

Drive Axle - Front Type Crownwheel & Pinion Ratio Hub Ratio Overall Axle Ratio Tyre Sizes and Pressures * 426 (to Ser. No 531762) Standard Front 17.5 - 25 17.5 R25 Rear 17.5 - 25 17.5 R25 3.909:1 5.167:1 20.197:1 Drive Axle - Rear Type Crownwheel & Pinion Ratio Hub Ratio Overall Axle Ratio 3.909:1 5.167:1 20.197:1
436, 446 (See Note $)
16 ply -
20.5 - 25 20.5 R25 555/70 R25 20.5 - 25 20.5 R25 * 555/70 R25
12 ply 12 ply -
2.75 bar (40 lbf/in2) 2.75 bar (40 lbf/in2) 2.00 bar (29lbf/in2) 1.75 bar (25 lbf/in2) 1.75 bar (25 lbf/in2) 2.00 bar (29lbf/in2)
16 ply -
Optional Front 20.5 - 25 20.5 R25 Rear 20.5 - 25 20.5 R25 *
12 ply 2.0 bar (29 lbf/in2) - 2.0 bar (29 lbf/in2)
12 ply 1.75 bar (25 lbf/in2) - 1.75 bar (25 lbf/in2)
Note $: Also 426 (USA machines) built after November 1998. 426 From Serial No. 532100
FRONT
REAR
Model 426 426 426 426 426
Size 17.5 - 25 17.5R25 20.5 - 25 20.5 R25 555/70R25
Ply 16 12 -
Bar 2.75 3.75 2.50 2.50 3.25
lbf/in2 40 55 36 36 47
Bar 1.75 1.75 1.75 1.75 1.75
lbf/in2 25 25 25 25 25
Note: If the tyres fitted to your machine are not listed, then contact your JCB Distrubutor for advice, DO NOT guess tyre pressures.
9804/1103
50 - 05 - 03/14
4160 - F/1-1.5
Issue 3*
CONTENTS
Wheeled Loaders
50 - 05 - 03/15
426B, 436B, 446B Data - Transmission (continued)

Transmission * Model Torque Converter Dia. Torque Multiplication at Stall 426 WG-150 300mm (11in.) 2.91:1 Forward 1st 4.222:1 2nd 2.296:1 3rd 0.984:1 4th 0.629:1 Reverse 1st 4.222:1 2nd 2.296:1 3rd 0.984:1 Not Applicable 436 WG-200 300mm (11in.) 2.66:1 Forward 1st 4.278:1 2nd 2.368:1 3rd 1.126:1 4th 0.648:1 Reverse 1st 4.278:1 2nd 2.368:1 3rd 1.126:1 Not Applicable 446 WG-200 340 (13in.) 2.879:1 Forward 1st 4.278:1 2nd 2.368:1 3rd 1.126:1 4th 0.648:1 Reverse 1st 4.278:1 2nd 2.368:1 3rd 1.126:1 Not Applicable
Gear Ratios
Oil Temperature
82 to 93C (180 to 200F)
82 to 93C (180 to 200F)
82 to 93C (180 to 200F)
426 (From S/N 532100) Model Torque Converter Dia. Torque Multiplication at Stall WG-160 300mm (11in) 2.549:1 Forward 1st 4.012:1 2nd 2.024:1 3rd 1.088:1 4th 0.619:1 Reverse 3.424:1 1.919:1 1.031:1 Not Applicable
436 (From S/N. 533692) WG-190 340mm (13in.) 2.873:1 Forward 1st 3.745:1 2nd 2.089:1 3rd 1.072:1 4th 0.636:1 Reverse 1st 3.745:1 2nd 2.089:1 3rd 1.072:1 Not Applicable
Gear Ratios
Oil Temperature Stall Testing
82 to 93 C (180 to 200F)
82 to 93C (180 to 200F)
Note: Switch off transmission dump (transmission disconnect); the switch on the cab roof panel should not be illuminated. Engage the parking brake and apply the foot brake. Select Forward Drive, keep brake pedal pushed down, push the accelerator pedal down fully and record the engine speed.
426 Maximum engine speed (rev/min) at: - Converter stall only 2290 - 2240 426 (From S/N 532100) 2207
436 2165 - 2115 436 (From S/N. 533692) 2146
446 2184
9804/1103
50 - 05 - 03/15
4160-F/1-2.2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 03/16
426B, 436B, 446B Technical Data

WG - 160 (426) Pump Flow @ 2000 r.p.m. Ststem pressure Torque converter - input pressure (max) - output pressure (max) - output pressure (max) - continuous - short duration 80 I (17.6 UK gal, US gal) 16+2 bar (232+29lb/in2) WG - 190 (436) 105 I (23 UK gal, 28 US gal) 16+2 bar (232+29lb/in2)
Inductive transmitters (engine, turbine, central geartrain) Resistance @ 20C (68F) 1050 105 ohms Temperature range -40C (-40F) - 150C (302F) Torque limit - securing bolts 30Nm (22lbf ft, 3 kgf m)
1050 105 ohms -40C (-40F) - 150C (302F) 30Nm (22lbf ft, 3 kf m)
Speed sensor output Temperature range Working Range Supply voltage
-40C (-40F) - 150C (302F) 2Hz - 5kHz 24V
-40C (-40F) - 150C (302F) 2Hz - 5kHz 24V
Proportional valves in control valve Resistance @ 20C (68F) Current (mA) Pressure range
19 1.9 ohms. 100 - 500 0.8 - 8.3 bar (11.6 - 120lb/in2)
19 1.9 ohms. 100 - 500 0.8 - 8.3 bar (11.6 - 120lb/in2)
Stall data Engine idle Engine max no-load Transmission Hydraulic Combined - transmission/hydraulic
78020 r.p.m. 234020 r.p.m. 2200 r.p.m. 2330 r.p.m. 2180 r.p.m.
85010 r.p.m. 234020 r.p.m. 200 r.p.m. 2330 r.p.m. 2180 r.p.m.
9804/1103
50 - 05 - 03/16
4160 - F/1-3.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 05/1
406,407,408,409 Data - Brakes

406 Machines with Hurth Axles Service Brake Type Actuation Location Friction Plates Outside Dia. Inside Dia. Nominal Facing Area/Plate Master Cylinder Type Piston Dia. Parking Brake Type Disc Dia. Manually Adjusted Caliper, cable operated, acting on disc at transmission output 279.4 mm (11.0 in) Girling CV single 25.4 mm (1 in) Oil-immersed Multi-plate Disc Hydraulic Half shaft mounted within intermediate axle housings 5 per brake (ie) 10 per axle 155 mm (6.10 in) 115 mm (4.53 in) 0.017m2 (26.25 in2)
Machines with JCB Axles Service Brake Type Actuation Location Friction Plates Outside Dia. Inside Dia. Nominal Facing Area/Plate Master Cylinder Type Piston Dia. Parking Brake Type Disc Dia. Manually Adjusted Caliper, cable operated, acting on disc at transmission output 279.4 mm (11.0 in) Frenos Iruna Single Circuit 31.75 mm (1.25 in) Oil-immersed Multi-plate Disc Hydraulic Outboard - Axle Hub 3 per brake (ie) 6 per axle 220 mm (8.66 in) 180 mm (7.09 in) 0.025 m2 (38.75 in2)
9804/1103
50 - 05 - 05/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 05/2

411 Service Brakes Type Actuation Location Master Cylinder Type Stroke Bore Parking Brake Type Location 416 Service Brakes Type Actuation Location Brake Valve Type Rexroth Compact Type LT13 Parking Brake Type Location Oil-Immersed Multi-Plate Disc Actuation Hydraulic, Vacuum Servo Assisted Front and Rear Axle (2 Brake Packs each axle)
Frenos Iruna Dual Diaphragm 39 mm (1.5 in) 38.1 mm (1.5 in)
Manually Adjusted Disc, cable operated Front face of transmission
Oil-Immersed Multi-Plate Disc Actuation Dual Circuit, Full Hydraulic with compact valve and pressure accumulators Front and Rear Axle (2 Brake Packs each axle)
9804/1103
50 - 05 - 05/2
Issue 3*
CONTENTS
Wheeled Loaders
50 - 05- 05/3
426,436 Data - Brakes

Service Brakes Type Actuation Location Accumulator Capacity (per circuit) Pre-charge Charge Valve - cut in - cut out Parking Brake Type Location Manually Adjusted Disc, cable operated Front face of transmission 0.75 litre 57 bar 164 bar 200 bar 1.3 pint 826 lbf/in2 2378 lbf/in2 2900 lbf/in2 Oil-Immersed Multi-Plate Disc Actuation Dual Circuit, Full Hydraulic with compact valve and pressure accumulators Front and Rear Axle (4 plates per hub)
9804/1103
50 - 05 - 05/3
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 05/4
* 412S,
414S, 416S
Data - Brakes
Service Brakes Type Actuation Location Brake Valve Type Piston Diameter (each) Piston Area (each) Controlled Pressure to Brake Piston Charge Valve Type Ultra Hydraulics Modulating Valve 25.4 mm (1 in) 507 mm 2 (0.79 in 2 ) 50 bar (725 lbf/in 2 ) Oil-Immersed Multi-Plate Disc Actuation Hydraulic Front and Rear Axle (2 Brake Packs each axle)
Ultra Hydraulics Accumulator Charge Valve 412S to Ser. No. 535112 412S from Ser. No. 535113 and 414S 90 bar (1305 lbf/in 2 ) 110 bar (1595 lbf/in 2 )
Cut-in Pressure Cut-out Pressure Parking Brake Type Location
160 bar (2320 lbf/in 2 ) 200 bar (2900 lbf/in 2 )
9804/1103
50 - 05 - 05/4
4170 - G/1-1.3
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 05/5
407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX Data - Brakes All except 411B ZX
Service Brake Type Actuation Location Disc dia. Parking Brake Type Disc dia. Location Disc dia. * Stilfreni Caliper 2/60 EOPM Cable 280 mm (11in) 280 mm (11 in) Stilfreni Caliper 2/60 Hydraulic Attached to transfer gearbox 280 mm (11 in)
411B ZX only
Service Brake Type Actuation Location Friction Plates Outside Diameter Inside Diameter Nominal Facing Area per Plate Parking Brake Type Disc dia. Manually Adjusted Calliper, cable operated, mounted on transmission output 280 mm (11 in.) JCB Oil-immersed Multi-Plate Disc Hydraulic Front and Rear Axle Hubs 2 per brake (i.e.) 4 per Axle 220 mm (8.66 in) 180 mm (7.09 in) 0.025 m2 (38.75 in2)
9804/1103
50 - 05 - 05/5
4210 - G/1-1.3
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 05/6
456B Data - Brakes

System Type Rexroth Full Hydraulic with Compact valve and pressure accumulators. These operating on integral axle mounted, oil immersed service brakes and a single transmission parking brake. Hydraulic supply is from a main, engine driven pump. See Data - Hydraulic Rexroth Compact.
Pump Control Valve Type Pressure Regulator Setting Cut-in Cut-out Service Brake Operating Pressure Parking Brake Operating Pressure Pressure Switch Operating Pressure Low pressure warning on Parking brake warning off Stop lamp on Accumulator Gas Accumulator Gas Pressure Parking Brake
150 bar (2175 lbf/in2) 125 bar (1812.5 lbf/in2) 80 bar (1160 lbf/in2) 80 bar (1160 lbf/in2)
105 bar (1522.5 lbf/in2) 65 bar (942.5 lbf/in2) 3 bar (43.5 lbf/in2) Nitrogen. 65 bar (942.5 lbf/in2) Hydraulically released, fail safe design, operating on the transmission propeller shaft. Operating warning system to indicate brake position with vehicle unattended.
9804/1103
50 - 05 - 05/6
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 05/7
TM200, TM270 Data - Brakes TM200

Service Brake Type Actuation Location Friction Plates Outside Diameter Inside Diameter Nominal Facing Area per Plate Parking Brake Type Disc Diameter JCB Oil-Immersed Multi-Plate Disc Hydraulic Front and Rear Axle Hubs 3 per brake (ie) 6 per Axle 220 mm (8.66 in) 180 mm (7.09 in) 0.025 m2 (38.75 in2)
Manually Adjusted Calliper, cable operated, mounted on transmission output 279.4 mm (11 in)
TM270
Service Brake Type Actuation Location Friction Plates Outside Diameter Inside Diameter Nominal Facing Area per Plate Hydraulic Piston Diameter Parking Brake Type Disc Diameter JCB Oil-Immersed Multi-Plate Disc Hydraulic Front Axle Centre Casing (2 brake packs) 3 per brake (ie) 6 per Axle 220 mm (8.66 in) 180 mm (7.09 in) 0.025 m2 (38.75 in2) 216 mm (8.5 in)
Manually Adjusted Calliper, cable operated, mounted on transmission output 279.4 mm (11 in)
Note: Because the service brakes are located in the axles, instructions for dismantling and assembly are shown in the Transmission Section.
9804/1103
50 - 05 - 05/7
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 05/8
426B, 436B, 446B Data - Brakes

Service Brakes Type Actuation Location Accumulator Capacity (per circuit) Pre-charge Charge Valve - cut in - cut out Parking Brake Type Location Manually Adjusted Disc, cable operated Front face of transmission 0.75 litre 57 bar 164 bar 200 bar 1.3 pint 826 lbf/in2 2378 lbf/in2 2900 lbf/in2 Oil-Immersed Multi-Plate Disc Actuation Dual Circuit, Full Hydraulic with compact valve and pressure accumulators Front and Rear Axle (4 plates per hub)
9804/1103
50 - 05 - 05/8
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 06/1
406,407,408,409 Data - Steering

406 Machines with Hurth Axles System Type Pump Control Unit Priority Valve Full Power Hydrostatic (pivot steer) (see Section 2) Danfoss Orbitrol type OSPC 160 LS Danfoss type OLSB 80 with 4 bar (58 lbf/in2) standby pressure
Relief Valve Operating Pressure Shock Valve Operating Pressure Ram Dimensions - Bore - Stroke - Rod Dia. - Piston Head A/F - Cylinder Cap A/F
175 bar 250 bar mm 60.0 245.5 30 40 50
2535 lbf/in2 3625 lbf/in2 in 2.36 9.67 1.18 -
Machines with JCB Axles System Type Pump Control Unit Priority Valve Full Power Hydrostatic (pivot steer) (see Section 2) Danfoss Orbitrol type OSPC 200 LS Danfoss Ref. HN 29CA 02
Relief Valve Operating Pressure Shock Valve Operating Pressure Ram Dimensions - Bore - Stroke - Rod Dia. - Piston Head A/F - Cylinder Cap A/F
175 bar 240 bar mm 70.0 246 40 55 65
2535 lbf/in2 3480 lbf/in2 in 2.756 9.685 1.575 -
9804/1103
50 - 05 - 06/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 06/2
411,416,426,436 Data - Steering

Pump Supply from hydraulic system. See section 50 - 0 5 - 02. Steering Valve Type Eaton Steering Control Unit ABV. 411/416 Relief Valve Operating Pressures Priority Shock valve(s) bar 175 235 kgf/cm2 178 240 lbf/in2 2537 3407 bar 176 426/436 kgf/cm2 180 lbf/in2 2550
Ram Dimensions 411 mm(in) 60(2.4) 30(1.2) 305(12.0) 416 mm(in) 70(2.8) 40(1.6) 312(12.3) 426/436 mm(in) 80(3.1) 50(2.0) 312(12.3)
Bore Rod Dia. Stroke
9804/1103
50 - 05 - 06/2
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 06/3
412S, 414S, 416S Data - Steering

Pump Supply from hydraulic system. Refer to page 50-05-02/7 Steering Valve Type Eaton Steering Control Unit ABV. 412S Relief Valve Operating Pressures bar kgf/cm2 lbf/in2 bar 414S/416S kgf/cm2 lbf/in2
* Priority * Shock valves Ram Dimensions
175 235
178 240
2537 3407
220 272
224 277
3191 3945
Bore Rod Dia. Stroke
412S mm 60 30 305
414S/416S mm 70 40 312
9804/1103
50 - 05 - 06/3
4170 - H/1-1.2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 06/4
407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX Data - Steering
407B ZX, 408B ZX, 409B ZX System Details Pump * Steer valve * Priority valve * Relief valve setting 410B ZX, 411B ZX
See Data-Hydraulics OSPC 200 LS Integral with valve block bar kgf/cm2 lbf/in2 138 140.7 2001
See Data-Hydraulics 263-4339-002 bar 175 kgf/cm2 lbf/in2 178.5 2538
Turns, Lock-to-Lock Left-to-right Right-to-left Ram dimensions Bore Stroke Rod dia. * Steering Valve Type
5.75 4.75
5 5
50 mm (2.0 in) 305 mm (12.0 in) 30 mm (1.2 in)
60 mm (2.4 in) 305 mm (12.0 in) 30 mm (1.2 in) two off
Load sensing (295 cc/rev)
9804/1103
50 - 05 - 06/4
4210 - H/1-1.4
Issue 3*
CONTENTS
Wheeled Loaders
50 - 05 - 06/5
456B Data - Steering

Pump Supply from hydraulic system. See Data - Hydraulics. Steering Valve Type Relief Valve Operating Pressure Eaton Steering Control Unit ABV. bar 176 Ram Dimensions Bore Rod Dia. Stroke mm 90 50 312 in 3.5 2.0 12.3 kgf/cm2 180 lbf/in2 2550
General Description Steering is hydraulically controlled. Two rams, one either side of a centre pivot articulate the front chassis in the required direction. Hydraulic oil is delivered from the pump via a steering priority valve to the steering valve. When the steering is turned the steering valve is actuated and a pressure demand signal sent to the priority valve spool. The spool moves and directs pressurised oil from the pump to the steering valve and then the steering rams. Pressurised oil enters the ram cylinders (rod side first ram and head side second ram) and causes the rams to extend or retract to turn the machine in the required direction. A pressure relief valve is fitted to guard against shock steering loads. A gearbox driven emergency steer pump may be fitted which provides pressure for steering in the event of hydraulic pump or engine failure.
9804/1103
50 - 05 - 06/5
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 06/6
TM200, TM270 Data - Steering TM200

System Type Hydraulic Supply Control Unit Priority Valve Relief Valve Operating Pressure Shock Valve Operating Pressure Full Power Hydrostatic (pivot steer) From Main Hydraulic Pump via Priority Valve Danfoss Orbitrol type OSPC 200 LS Danfoss Ref. HN 29CA 02 175 bar 240 bar 2535 lbf/in2 3480 lbf/in2
TM270
System Type Hydraulic Supply Control Unit Relief Valve Operating Pressure Shock Valve Operating Pressure Full Power Hydrostatic (pivot steer) From Main Hydraulic Pump via Priority Valve Eaton Load Sensing Steer Valve 175 bar 235 bar 2535 lbf/in2 3408 lbf/in2
9804/1103
50 - 05 - 06/6
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 06/7
426B, 436B, 446B Data - Steering

Pump Supply from hydraulic system. Steering Valve Type Relief Valve Operating Pressure Shock valve Ram Dimensions Bore Rod Dia. Stroke mm 80 50 312 in 3.1 2.0 12.3 Eaton Steering Control Unit ABV. bar 176 kgf/cm2 180 lbf/in2 2550
General Description Steering is hydraulically controlled. Two rams, one either side of a centre pivot articulate the front chassis in the required direction. Hydraulic oil is delivered from the pump via a steering priority valve to the steering valve. When the steering is turned the steering valve is actuated and a pressure demand signal sent to the priority valve spool. The spool moves and directs pressurised oil from the pump to the steering valve and then the steering rams. Pressurised oil enters the ram cylinders (rod side first ram and head side second ram) and causes the rams to extend or retract to turn the machine in the required direction. A pressure relief valve is fitted to guard against shock steering loads. A gearbox driven emergency steer pump provides pressure for steering in the event of hydraulic pump or engine failure.
9804/1103
50 - 05 - 06/7
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 07/1
406,407 Data - Engine

Type Number of cylinders Bore and Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance - Cold Oil Pressure (Hot) at maximum speed Fuel System Injection Pump Type Injection Pump Setting Codes C.A.V., D.P.A., mechanically governed Original: TW48E/800/2/2470 CAV/ISO: TW49L/800/2/2470 Perkins/ISO: 36960TW/2/2470 2250 rev/min 2470 rev/min 750 rev/min 20 BTDC (equivalent to 0.192in. displacement) Engine Angle 27 (checked at TDC compression) Fuel Pump Angle 37 170 atm 185 atm Perkins D3.152 naturally aspirated 3 91.44 mm (3.60 in) x 127.0 mm (5.00 in) 2500 cm3 (152.7 in3) 18.5:1 17-31 bar (250-450 lbf/in2) [maximum variation between cylinders; 3.5 bar (50 lbf/in2)] 1,2,3 0.30 mm (0.012 in) 2.1-4.1 bar (30-60 lbf/in2)
Maximum Governed Speed Maximum No-load Speed Idling Speed Injection Timing Static
Injectors - Working Pressure - Setting Pressure Cooling System Coolant Pressure Coolant Temperature (normal) Temperature Warning Light operates at
0.48 bar (7 lbf/in2) 80-85 deg C 98 deg C
For further details see engine manual, Publication No. 9806/0052
9804/1103
50 - 05 - 07/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 07/2

Model Type Number of cylinders Bore and Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance (hot or cold) - Inlet - Exhaust Max. Speed (No Load) Governed Speed Idling Speed Fuel System Injection Pump Type Injection Pump Setting Code Governing 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 Cooling Temperature (normal) Temperature Warning Light operates at 0.48 bar (7 lbf/in2) 80 to 85 deg C 98 deg C Eccentric rotor 2.0 bar (30 lbf/in2) (minimum) 2 stage, dry element 635 mm (25 in) H20 CAV DPA 2643C621/HM46L/850/7/2160 Mechanical 16 2 BTDC 250 atm AC Diaphragm Perkins 1004 - 4LR2, naturally aspirated (AA) 4 100 mm (3.937 in) x 127 mm (5 in) 3990 cm3 (243.5 in3) 16.5 : 1 20 to 34 bar (290 to 493 lbf/in2) [max. variation between cylinders of 3.5 bar (50 lbf/in2)] 1, 3, 4, 2 0.20 mm (0.008 in) 0.45 mm (0.018 in) 2160 rev/min 2000 rev/min 820 rev/min
For further details see engine manual, Publication No. 9806/0100
9804/1103
50 - 05 - 07/2
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 07/3
411 Data - Engine

Type Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance - Cold or Hot - Inlet 0.20mm (0.008 in) - Exhaust 0.45mm (0.018 in) * Idling Speed * Maximum Governed Speed Maximum No-load Speed Fuel System Injection Pump Type Governing Injector Pump Setting Code Injector Timing Injector Setting Pressure 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: 0.69 bar (10 lbf/in2) 80-85 C (176-185 F) 98C (208F) Eccentric rotor 2.07 bar (30 lbf/in2) 2 stage, dry element 635mm (25 in H2O) C.A.V. Mechanical GM 58L 1000/2/2420 19.5 BTDC 220 atm Perkins 1004-4TLR 1000 Series, 4 cylinder, water cooled AB - Turbocharged (84 HP Gross - SAE J1349) 100mm (3.937 in) 127mm (5.000 in) 4 litres (243 in3) 16.5:1 20-30 bar (240-493 lbf/in2) 1,3,4,2
880 - 920 rev/min 2360 - 2400 rev/min 2420 rev/min
9804/1103
50 - 05 - 07/3
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 07/4
416 Data - Engine

Type Perkins 1004-4THR3 1000 Series, 4 cylinder, water cooled AB - Turbocharged (106 HP Gross - SAE J1349) 100mm (3.937 in) 127mm (5.000 in) 4 litres (243 in3) 16.5:1 20-30 bar (240-493 lbf/in2) 1,3,4,2
Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance - Cold or Hot - Inlet 0.20mm (0.008 in) - Exhaust 0.45mm (0.018 in) * Idling Speed * Maximum Governed Speed Maximum No-load Speed Fuel System Injection Pump Type Governing Injector Pump Setting Code Injector Timing Injector Setting Pressure 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:
880-920 rev/min 2360-2400 rev/min 2420 rev/min
C.A.V. Mechanical T.B.A. 12 BTDC 250 atm
2 stage, dry element 635mm (25 in H2O)
Eccentric rotor 2.07 bar (30 lbf/in2)
0.69 bar (10 lbf/in2) 80-85 C (176-185 F) 98C (208F)
9804/1103
50 - 05 - 07/4
Issue 2*
CONTENTS
Wheeled Loaders
50 - 05 - 07/5

426 Type Number of Cylinders Capacity Bore (nominal) Stroke Compression Ratio Power Output @ 1000mm barometric, 25C Max Nett Torque Idling Speed Maximum Governed Speed Maximum No-load Speed Fuel System Injection Pump Type Injector Pump Setting Code Injector Timing Injector Setting Pressure Lift Pump Type Induction System Air Cleaner Type Maximum Air Cleaner Restriction Lubrication System Oil Pressure Oil Cooler Max. Oil Temperature Cooling system Coolant Pressure Coolant Temperature (Normal) Coolant Temperature (Max) Temperature warning light operates at: 0.7 bar (10 lbf/in2) 80-85 C (176-185 F) 103 C (217.4 F) 98C (208F) 0.7 bar (10 lbf/in2) 80-85 C (176-185 F) 103 C (217.4 F) 98C (208F) 2.07 bar (30 lbf/in2) Integral Plate Cooler 125C (257F) 2.07 bar (30 lbf/in2) Integral Plate Cooler 125C (257F) 2 stage, dry element 635mm (25 in H2O) 2 stage, dry element 635mm (25 in H2O) Lucas DPA rotary KK75L 1100/1/2420 18 BTDC 250 atm Mechanical Diaphragm 2641A070 Lucas DPA rotary RK90L1100/3/2310 17 BTDC 250 atm Mechanical Diaphragm 2641A070 Perkins 1006-6T7 4 Stroke, direct injection 6 in-line vertical 6.0 litres (365 in3) 100mm (3.937 in) 127mm (5.000 in) 16:1 93kW 5% @ 2200 rev/min 404.9Nm @ 2200 rev/min 750 rev/min 2200 rev/min 2420 rev/min 436 Perkins 1006-6T4 4 Stroke, direct injection 6 in-line vertical 6.0 litres (365 in3) 100mm (3.937 in) 127mm (5.000 in) 16:1 122kW 5% @ 2200 rev/min 629.5Nm @ 2200 rev/min 750 rev/min 2200 rev/min 2420 rev/min
9804/1103
50 - 05 - 07/5
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 07/5A
426 Data - Engine

Type Number of Cylinders Capacity Bore (nominal) Stroke Compression Ratio Power Output @ 1000 mm barometric, 25 C Max Nett Torque Idling Speed Maximum Governed Speed Maximum No-load Speed BTAA5.9 - C/50 18487 Tier 2 4 Stroke, direct injection 6 in-line vertical 6.0 litres (365 in3) 100mm (3.937 in) 127mm (5.000 in) 16:1 93kW 5% @ 2200 rev/min 404.9 Nm @ 2200 rev/min 750 rev/min 2200 rev/min 2420 rev/min
from m/c no. 532500
Fuel System Injection Pump Type Injector Pump Setting Code Injector Timing Injector Setting Pressure Lift Pump Type Lucas DPA rotary KK75L 1100/1/2420 18 BTDC 250 atm Mechanical Diaphragm 2541A070
Induction System Air Cleaner Type Maximum Air Cleaner Restriction 2 stage, dry element 635mm (25 in H2O)
Lubrication System Oil Pressure Oil Cooler Max. Oil Temperature 2.07 bar (30 lbf/in2) Integral Plate Cooler 125 C (257 F)
Cooling system Coolant Pressure Coolant Temperature (Normal) Coolant Temperature (Max) Temperature warning light operates at: 0.7 bar (10 lbf/in2) 80-85 C (176-185 F) 103 C (217.4 F) 98C (208F)
9804/1103
50 - 05 - 07/5A
4160 - K/1-4/1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 05 - 07/6
412S Data - Engine

Type Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance - Cold or Hot - Inlet - Exhaust Idling Speed Maximum Governed Speed Maximum No-load Speed Fuel System Injection Pump Type Governing Injector Pump Setting Code Injector Timing Injector Setting Pressure 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: 0.69 bar (10 lbf/in2) 80-85 C (176-185 F) 98C (208F) Eccentric rotor 2.07 bar (30 lbf/in2) 2 stage, dry element 635mm (25 in H2O) C.A.V. Mechanical GM 58L 1000/2/2420 19.5 BTDC 220 atm Perkins 1004-4TLR 1000 Series, 4 cylinder, water cooled AB - Turbocharged (84 HP Gross - SAE J1349) 100mm (3.937 in) 127mm (5.000 in) 4 litres (243 in3) 16.5:1 20-30 bar (240-493 lbf/in2) 1,3,4,2 0.20mm (0.008 in) 0.45mm (0.018 in) 700-750 rev/min 2200 rev/min 2420 rev/min
For further engine details see Engine Manual Publication No. 9806/0100.
9804/1103
50 - 05 - 07/6
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 07/7
414S Data - Engine

Type Bore (nominal) Stroke Swept Volume Compression Ratio Power Output @ 1000 mm barometric, 25C Max Nett Torque Idling Speed Maximum Governed Speed Maximum No-load Speed Fuel System Injection Pump Type Lift Pump Type Injector Pump Setting Code Engine Check Angle Pump Mark Angle Injector Setting Pressure Induction System Air Cleaner Type Maximum Air Cleaner Restriction Lubrication System Oil Cooler Oil Pressure Max Oil Temp Cooling system Coolant Pressure Coolant Temperature (Normal) Temperature warning light operates at: Coolant Temperature (Max) 0.7 bar (10 lbf/in2) 80-85 C (176-185 F) 98C (208F) 103C (217F) Integral plate cooler 208 kNm2 125C (257F) 2 stage, dry element 635mm (25 in H2O) Stanadyne Mechanical diaphragm 2641A070 JL 325 334.5 250 atm Perkins 1006-6T7 1000 Series, 6 cylinder, water cooled 4 stroke, direct injection 100mm (3.937 in) 127mm (5.000 in) 6 litres (365 in3) 16:1 93 kW 5% @ 2200 rev/min 404.9 Nm @ 2200 rev/min 750 rev/min 2200 rev/min 2420 rev/min
For further engine details see Engine Manual Publication No. 9806/0100.
9804/1103
50 - 05 - 07/7
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 07/7A
412S, 414S, 416S Data - Engine

Type New 1000 Series, 4 cylinder, water cooled, direct injection 412S AM50684 build Bore (nominal) Stroke Cylinder Capacity Gross Power Output at 2200 rev/min Compression Ratio Idling Speed Rated Speed (Full Load) Max. No-Load Speed Max. Net Torque at 1400 rev/min 100mm (3.937 in) 127mm (5.000 in) 4 litres (243 in3) 85.3 kW (115 HP) 17.25:1 900 rev/min 2200 rev/min 2310 rev/min 448.5 Nm (331 lbf ft) 414S/416S YH50605 build 100mm (3.937 in) 127mm (5.000 in) 4 litres (243 in3) 113.1 kW (151 HP) 17.25:1 800 rev/min 2200 rev/min 2400 rev/min 620 Nm (457 lbf ft)
Fuel System Injection Pump Type Governing ISO Setting Code Injector Setting Pressure C.A.V. Rotary Distributor Mechanical 2644F404 FG/1/2350 250 atm C.A.V. Rotary Distributor Mechanical 2644K606 FH/1/2370 290 atm
Induction System Air Cleaner Type Maximum Air Cleaner Restriction 2 stage, dry element 635 mm (25 in) H2O
Lubrication System Oil Pump Type Oil Pressure at maximum speed Oil Temperature Oil Capacity Cooling System Coolant Pressure Coolant Temperature (Normal) Capacity 0.8 bar (11.6 lbf/in2) 80-90 C (176-194 F) 15.5 litres (3.5 UK galls) Eccentric rotor 2.8 bar (40 lbf/in2) (min) 125C (52F)(Continuous), 135C (58F) (Intermittent) 5000 cm3 (305 in3)(min), 6500 cm3 (396 in3) (max)
50 - 05 - 07/7A
4170 - K/1-3.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 07/7B
412S Data - Engine

Type
From m/c no. 535650 (RJ Build)
1104C-44TA to Power Curve T2174 412S From Serial No. 535650 (RJ Build) 105 mm (4.133 in) 127 mm (5.000 in) 4.4 litres (268 in3) 121 hp @ 2200 rev/min (90.23 kW) 19.3 : 1 850 rev/min 2200 rev/min 2370 rev/min 434 Nm @ 1400 rev/min (320 lbf ft)
Bore (nominal) Stroke Cylinder Capacity Gross Power Output at 2200 rev/min Compression Ratio Idling Speed Rated Speed (Full Load) Max. No-Load Speed Max. Net Torque at 1400 rev/min
Fuel System Injection Pump Type Governing ISO Setting Code Injection Timing Injector Setting Pressure Delphi mechanical DP210, rotary Mechanical Not Used N/A Dynamically timed only 290 bar +8, -0 (286 +7, -0 atm)
Induction System Air Cleaner Type Maximum Air Cleaner Restriction Restriction Indicator 2 stage, dry element 635 mm (25 in) H2O Vacuum switch on air cleaner inlet
Lubrication System Oil Pump Type Oil Pressure at maximum speed Oil Temperature Oil Capacity Without/With Filter Concentric gear 300 KPa (45.5 lbf/in2) Anything up to 125C max, depending on load, speed and ambient conditions 9.4 litre / 10.9 litre (2.1 UK gal / 2.4 UK gal)
Cooling System Coolant Pressure Coolant Temperature (Normal) Capacity 95 KPa (13.8 lbf/in2) 82 C - 110C (179-203 F) 23 litres (5.5 UK gal)
50 - 05 - 07/7B
4170 - K/1-4.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 05 - 07/8
407B ZX, 408B ZX, 409B ZX, 410B ZX Data - Engine

Type 1000 Series, 4 cylinder, water cooled, direct injection, naturally aspirated. 407B ZX & 408B ZX Perkins 1004-4LR2 409B ZX Perkins 1004-4HR 410B ZX Perkins 1004-4 100mm (3.937 in) 127mm (5.000 in) 4 litres (243 in3) 407B ZX & 408B ZX 409B ZX 410B ZX 47.4 kW (65 HP) 53 kW (71 HP) 59 kW (80 HP) 16.5:1 407B ZX, 408B ZX, 409B ZX 410B ZX 820 - 850 rev/min 700 - 750 rev/min 2000 rev/min 407B ZX, 408B ZX, 409B ZX 410B ZX 2160 rev/min 2150 rev/min 4LR - 246.1 Nm (181.5 lbf ft), 4HR - 286.5 Nm (211.3 lbf ft)
Bore (nominal) Stroke Cylinder Capacity Power Output at 2000 rev/min
Compression Ratio Idling Speed Rated Speed (Full load) Maximum No-load Speed Maximum Net Torque at 1200 rev/min
Fuel System Tank Capacity Injection Pump Type Governing ISO Setting Code Injector Timing Injector Setting Pressure Lift Pump Induction System Air Cleaner Type Maximum Air Cleaner Restriction Lubrication System Oil Pump Type Oil Pressure at maximum speed Oil Temperature (Intermittent) Oil Capacity Cooling system Coolant Pressure Coolant Temperature (Normal) Capacity 407B ZX, 408B ZX, 409B ZX 410B ZX 0.8 bar (11.6 lbf/in2) 80-90 C (176-194 F) 15.5 litres (3.5 UK galls) 18 litres (3.96 UK galls) Eccentric rotor 2.0 bar (30 lbf/in2) (min) 125C (52F)(Continuous), 135C (58F) 2 stage, dry element 635 mm (25 in) H2O 407B ZX & 408B ZX 409B ZX & 410B ZX 407B ZX & 408B ZX 409B ZX 407B ZX, 408B ZX, 409B ZX 410B ZX 100 litres (22 UK Gal) 110 litres (24.2 UK Gal) C.A.V. Rotary Distributor Mechanical DSA685 DSA626 16 2 BTDC 16.5 2 BTDC 250 atm Engine mounted, mechanical Diaphragm
5000 cm3 (305 in3)(min), 6500 cm3 (396 in3) (max)
9804/1103
50 - 05 - 07/8
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 07/8A
411B ZX Data - Engine

Type Bore (nominal) Stroke Cylinder Capacity Power Output at 2200 rev/min Compression Ratio Idling Speed High Idling Speed Torque at 1200 rev/min Sump Oil Capacity Perkins TN440 (1004 - 4 TLR2) Build No. AH50613 100 mm (3.937 in) 127 mm (5.000 in) 4 litres (243 in3) 67.5 kW (90.5 HP) 16:1 750 rev/min 2420 rev/min 300 Nm (221.3 lbf ft) Max. 9.4 litres Min. 7.6 litres Add 1.5 litres (includes filter)
Total Engine Capacity
9804/1103
50 - 05 - 07/8A
4210 - K/1-2.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 07/8B
407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX Data - Engine
Type New 1000 Series, 4 cylinder, water cooled, direct injection 407B ZX/408B ZX/409B ZX AS50693 build Bore (nominal) Stroke Cylinder Capacity Power Output at 2000 rev/min Compression Ratio Idling Speed Rated Speed (Full Load) Max. No-Load Speed Max. Net Torque at 1200 rev/min Fuel System Tank Capacity Injection Pump Type Governing ISO Setting Code Injector Timing Injector Setting Pressure Induction System Air Cleaner Type Maximum Air Cleaner Restriction Lubrication System Oil Pump Type Oil Pressure (min) at maximum speed Oil Temperature Oil Capacity Cooling System (407-409B ZX) Coolant Pressure Coolant Temperature (Normal) Capacity 0.8 bar (11.6 lbf/in ) 80-90 C (176-194 F) 15.5 litres (3.5 UK galls)
2
410B ZX AS50675 build 103mm (4.055 in) 127mm (5.000 in) 4.23 litres (258 in3) 60 kW (80 HP) 18.5:1 700 - 750 rev/min 2200 rev/min 2420 rev/min 285 Nm (210 lbf ft)
411B ZX AQ50697 build 100mm (3.937 in) 127mm (5.000 in) 4 litres (243 in3) 68.5 kW (92 HP) 17.25:1 750 rev/min 2200 rev/min 2420 rev/min 350 Nm (258 lbf ft)
103mm (4.055 in) 127mm (5.000 in) 4.23 litres (258 in3) 57.5 kW (77 HP) 18.5:1 820 - 850 rev/min 2000 rev/min 2150 rev/min 285 Nm (210 lbf ft)
100 litres (22 UK Gal) C.A.V. Rotary Distributor Mechanical 2644G525 YG/1/2180 4 2 BTDC 250 atm
100 litres (22 UK Gal) C.A.V. Rotary Distributor Mechanical 2644G521 YG/1/2350 3 2 BTDC 250 atm
100 litres (22 UK Gal) C.A.V. Rotary Distributor Mechanical 2644C707 FG/1/2180 1 2 BTDC 250 atm
2 stage, dry element 635 mm (25 in) H2O
2 stage, dry element 635 mm (25 in) H2O
2 stage, dry element 635mm (25m) H2o
Eccentric rotor 2.1 bar (30 lbf/in2) (min)

3
Eccentric rotor 2.1 bar (301bf/in2)

3 3
Eccentric rotor 2.1 bar (301bf/in2)

3
125C (52F)(Continuous), 135C(58F)(Intermittent) 5000 cm (305 in )(min), 6500 cm (396 in ) (max)
0.8 bar (11.6 lbf/in ) 80-90 C (176-194 F) 15.5 litres (3.5 UK galls)
0.8 bar (11.6 lbf/in ) 80-90 C (176-194 F) 15.5 litres (3.5 UK galls)
9804/1103
50 - 05 - 07/8B
4210 - K/1-3.1 4210 - K/1-4.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 07/9
456B Data - Engine

Type Model Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately) HP @ 2200 rev/min Fuel System Max. Speed (No Load) Injection Timing (static) Injector Opening Pressure Fuel Pump Induction System Air Cleaner Type Electrical Alternator Starter Motor Cummings C Series, 6 cylinder diesel, turbocharged, water cooled. C8.3-C205
1, 5, 3, 6, 2, 4
153 kW (205 bhp)
Bosch MW
Bosch 24 V 40 A Delco Remy 42MT Type 400
For further details, see engine service manual. Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
9804/1103
50 - 05 - 07/9
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 07/10
TM200, TM270 Data - Engine TM200

Type Engine Build List Number Bore (nominal) Stroke Swept Volume Compression Ratio Max variation in compression pressure between cylinders Injection Sequence Valve Clearance - Cold Oil Pressure (hot) at maximum speed Maximum Air Cleaner Restriction Perkins 1000 Series 4 cylinder turbocharged Engine AB50541 - 71.5kw (96bhp) 100mm (3.937 in) 127mm (5.000 in) 4 litres (243 in3) 16.0:1 3.5 bar 1,3,4,2 - Inlet 0.20mm (0.008 in) - Exhaust 0.45mm (0.018 in) 2.6 bar (40 lbf/in2) 559mm (22 in H2O)
Injection System Details - Refer to Perkins Manual, publication number 9806/0100. Idling Speed Maximum Governed Speed Maximum No-load Speed (High Idle) Cooling System Coolant Pressure Coolant Temperature (Normal) Temperature Warning Light operates at: 750 rev/min 2200 rev/min 2420 rev/min
0.48 bar (7 lbf/in2) 80-85 C (176-185 F) 98 C (208 F)
TM270
Type Engine Build List Number Bore (nominal) Stroke Swept Volume Compression Ratio Max variation in compression pressure between cylinders Injection Sequence Valve Clearance - Cold Oil Pressure (hot) at maximum speed Maximum Air Cleaner Restriction Perkins 1000 Series 4 cylinder turbocharged Engine AB50630 - 79kw (106bhp) 100 mm (3.937 in) 127 mm (5.000 in) 4 litres (243 in3) 16.0:1 3.5 bar 1,3,4,2 - Inlet 0.20 mm (0.008 in) - Exhaust 0.45 mm (0.018 in) 2.6 bar (40 lbf/in2) 559 mm (22 in H2O)
Injection System Details - Refer to Perkins Manual, publication number 9806/0100. Idling Speed Maximum Governed Speed Maximum No-load Speed (High Idle) Cooling System Coolant Pressure Coolant Temperature (Normal) Temperature Warning Light operates at: 750 rev/min 2200 rev/min 2420 rev/min
0.48 bar (7 lbf/in2) 80-85 C (176-185 F) 98 C (208 F)
9804/1103
50 - 05 - 07/10
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 07/10A
TM200, TM270 Data - Engine (continued)

Type New 1000 Series, 4 cylinder, water cooled, direct injection, turbo charged TM200 AK50753 build Bore (nominal) Stroke Cylinder Capacity Power Output at 2200 rev/min Compression Ratio Idling Speed Rated Speed (Full Load) Max. No-Load Speed Max. Net Torque at 1200 rev/min 100mm (3.937 in) 127mm (5.000 in) 4.0 litres (243 in3) 68.5 kW (92 HP) 17.25:1 750 - 800 rev/min 2200 rev/min 2350 rev/min 350 Nm (258 lbf ft) TM270 AK50729 build 100mm (3.937 in) 127mm (5.000 in) 4.0 litres (243 in3) 76.6 kW (100 HP) 17.25:1 750 - 800 rev/min 2200 rev/min ? 2350 rev/min 350 Nm (258 lbf ft)
Fuel System Tank Capacity Injection Pump Type Governing ISO Setting Code Injector Timing Injector Setting Pressure 75 litres (16.5 UK Gal) C.A.V. Rotary Distributor Mechanical 2644F30//CG/1/2350 Pre-set 250 atm 90 litres (19.8 UK Gal) C.A.V. Rotary Distributor Mechanical 2644C705 BG/1/2350 Pre-set 250 atm
Induction System Air Cleaner Type Maximum Air Cleaner Restriction 2 stage, dry element 635 mm (25 in) H2O 2 stage, dry element 635 mm (25 in) H2O
Lubrication System Oil Pump Type Oil Pressure at maximum speed Oil Temperature Oil Capacity Cooling System Coolant Pressure Coolant Temperature (Normal) Capacity 0.8 bar (11.6 lbf/in2) 80-90 C (176-194 F) 15.5 litres (3.5 UK galls) 0.8 bar (11.6 lbf/in2) 80-90 C (176-194 F) 15.5 litres (3.5 UK galls) Eccentric rotor 2.1 bar (30 lbf/in2) (min) Eccentric rotor 2.1 bar (30 lbf/in2) (min)
125C (52F)(Continuous), 135C (58F) (Intermittent) 5000 cm3 (305 in3)(min), 6500 cm3 (396 in3) (max)
50 - 05 - 07/10A
4225 - K/1-2.1 4225 - K/1-2.2
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 07/10B
411B, 416B Data - Engine

Type New 1000 Series, 4 cylinder, water cooled, direct injection 411 AK50646 build Bore (nominal) Stroke Cylinder Capacity Power Output at 2200 rev/min Compression Ratio Idling Speed Rated Speed (Full Load) Max. No-Load Speed Max. Net Torque at 1200 rev/min 100mm (3.937 in) 127mm (5.000 in) 4.0 litres (243 in3) 60 kW (80 HP) 17.25:1 900+20 rev/min 2200 rev/min 2360+20 rev/min 359.6 Nm (265.2 lbf ft) 416B AM50684 build 100mm (3.937 in 127mm (5.000 in) 4.0 litres (243 in3) 68.5 kW (92 HP) 17.25:1 900+20 rev/min 2200 rev/min 2360+20 rev/min 439.9 Nm (324.4 lbf ft)
Fuel System Injection Pump Type Governing ISO Setting Code Injector Setting Pressure C.A.V. Rotary Distributor Mechanical 2644F304 CG/1/2350 250 atm C.A.V. Rotary Distributor Mechanical 2644F404 FG/1/2350 250 atm
Induction System Air Cleaner Type Maximum Air Cleaner Restriction 2 stage, dry element 635 mm (25 in) H2O
Lubrication System Oil Pump Type Oil Pressure at maximum speed Oil Temperature Oil Capacity Cooling System Coolant Pressure Coolant Temperature (Normal) Capacity 0.8 bar (11.6 lbf/in2) 80-90 C (176-194 F) 15.5 litres (3.5 UK galls) Eccentric rotor 2.8 bar (40 lbf/in2) (min) 125C (52F)(Continuous), 135C (58F) (Intermittent) 5000 cm3 (305 in3)(min), 6500 cm3 (396 in3) (max)
9804/1103
50 - 05 - 07/10B
4150 - K/1-3.1
Issue 1*
Wheeled Loaders
416 Data - Engine
Type 1104C-44TA to Power Curve T2174 416 From Serial No. 535650 (RJ Build) 105 mm (4.133 in) 127 mm (5.000 in) 4.4 litres (268 in3) 121 hp @ 2200 rev/min (90.23 kW) 19.3 : 1 850 rev/min 2200 rev/min 2370 rev/min 434 Nm @ 1400 rev/min (320 lbf ft)
50 - 05 - 07/10C
From m/c no. 530350 (RJ Build)
Bore (nominal) Stroke Cylinder Capacity Gross Power Output at 2200 rev/min Compression Ratio Idling Speed Rated Speed (Full Load) Max. No-Load Speed Max. Net Torque at 1400 rev/min
Fuel System Injection Pump Type Governing ISO Setting Code Injection Timing Injector Setting Pressure Delphi mechanical DP210, rotary Mechanical Not Used N/A Dynamically timed only 290 bar +8, -0 (286 +7, -0 atm)
Induction System Air Cleaner Type Maximum Air Cleaner Restriction Restriction Indicator 2 stage, dry element 635 mm (25 in) H2O Vacuum switch on air cleaner inlet
Lubrication System Oil Pump Type Oil Pressure at maximum speed Oil Temperature Oil Capacity Without/With Filter Concentric gear 300 KPa (45.5 lbf/in2) Anything up to 125C max, depending on load, speed and ambient conditions 9.4 litre / 10.9 litre (2.1 UK gal / 2.4 UK gal)
Cooling System Coolant Pressure Coolant Temperature (Normal) Capacity 95 KPa (13.8 lbf/in2) 82 C - 110C (179-203 F) 23 litres (5.5 UK gal)
50 - 05 - 07/10C
4150 - K/1-4.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 05 - 07/11
426B, 436B, 446B Data - Engine

426 Type Number of Cylinders Capacity Bore (nominal) Stroke Compression Ratio Power Output @ 1000mm barometric, 25C Max Nett Torque Idling Speed Maximum Governed Speed Maximum No-load Speed Fuel System Injection Pump Type Injector Pump Setting Code Injector Timing Injector Setting Pressure Lift Pump Type Induction System Air Cleaner Type Maximum Air Cleaner Restriction Lubrication System Oil Pressure Oil Cooler Max. Oil Temperature Cooling system Coolant Pressure Coolant Temperature (Normal) Coolant Temperature (Max) Temperature warning light operates at: 0.7 bar (10 lbf/in2) 80-85 C (176-185 F) 103 C (217.4 F) 98C (208F) 0.7 bar (10 lbf/in2) 80-85 C (176-185 F) 103 C (217.4 F) 98C (208F) 280kNm2 Integral Plate Cooler 125C (257F) 280kNm2 Integral Plate Cooler 125C (257F) 2 stage, dry element 635mm (25 in H2O) 2 stage, dry element 635mm (25 in H2O) Lucas DPA rotary KK75L 1100/1/2420 18 BTDC 250 atm Mechanical Diaphragm 2641A070 Lucas DPA rotary RK90L1100/3/2310 17 BTDC 250 atm Mechanical Diaphragm 2641A070 Perkins 1006-6T7 4 Stroke, direct injection 6 in-line vertical 6.0 litres (365 in3) 100mm (3.937 in) 127mm (5.000 in) 16:1 93kW 5% @ 2200 rev/min 404.9Nm @ 2200 rev/min 780 - 820 rev/min 2200 rev/min 2370 - 2410 rev/min 436 Perkins 1006-6T4 4 Stroke, direct injection 6 in-line vertical 6.0 litres (365 in3) 100mm (3.937 in) 127mm (5.000 in) 16:1 122kW 5% @ 2200 rev/min 629.5Nm @ 2200 rev/min 780 - 820 rev/min 2200 rev/min 2240 - 2280 rev/min
9804/1103
50 - 05 - 07/11
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 07/12
426B, 436B, 446B Data - Engine (continued)

446 Type Model Power Bore Stroke Displacement Compression Ratio Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately) Fuel System Injection Timing (static) Injector Opening Pressure Induction System Air Cleaner Type For further details, see engine service manual. Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the cylinder bores resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). 2 stage, dry element Cummings C Series, 6 cylinder turbocharged diesel, water cooled 6CT 8.3 - 170 170 hp @ 2200 rpm governed speed 114 mm (4.49 in) 135 mm (5.32 in) 8.3 litres (504.5 in3) 17.3:1 1, 5, 3, 6, 2, 4 0.3 mm 0.61 mm 590 kg BOSCH MW/RSV 16 BTDC 207-210 bar
9804/1103
50 - 05 - 07/12
Issue 1
CONTENTS
Wheeled Loaders
50 - 05 - 07/13
426B, 436B, 446B Data - Engine (continued)

426B Type 1006-6T New 1000 Series YK50598 build Bore (nominal) Stroke Cylinder Capacity Power Output at 2200 rev/min Compression Ratio Idling Speed Rated Speed (Full Load) Max. No Load Speed Peak Torque at 1400 rev/min Fuel System Injection Pump Type Governing ISO Setting Code Injector Setting Pressure Induction System Air Cleaner Type Maximum Air Cleaner Restriction 2 stage, dry element 635 mm (25 in) H2O 2 stage, dry element 635 mm (25 in) H2O C.A.V. Rotary Distributor Mechanical 2644K206 BH/1/2350 250 atm C.A.V. Rotary Distributor Mechanical 2644K504 DH//1/2350 250 atm 100mm (3.937 in) 127 mm (5.000 in) 6 litres (365 in3) 107.4 kW (144 HP) 17.25:1 80020 rev/min 2200 rev/min 2350 rev/min 588 Nm (433.6 lbf ft) 436B 1006-TW New 1000 Series YK50559 build 100mm (3.937 in) 127mm (5.000 in) 6 litres (365 in3) 119.3 kW (160HP) 17.25:1 85010 rev/min 2200rev/min 2350 rev/min 439.9 Nm (324.4 lbf ft)
Lubrication System Oil Pump Type Oil Pressure at maximum speed Oil Temperature Oil Capacity Cooling System Coolant Pressure Coolant Temperature (Normal) Capacity 0.8 bar (11.6 lbf/in2) 80-90C (176-194 F) 15.5 litres (3.5UK galls) 0.8 bar (11.6 lbf/in2) 80-90C (176-194 F) 15.5 litres (3.5UK galls) Eccentric rotor 2.8 bar (40 lbf/in2) (min) Eccentric rotor 2.8 bar (40 lbf/in2) (min)
125C (52F)(Continuous), 135C (58F) (Intermittent) 5000 cm3 (305in3)(min), 6500 cm3 (396in3) (max)
9804/1103
50 - 05 - 07/13
4160 - K/1-3.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 10 - 01/1
426,436 Fault Finding - Hydraulics

Fault
1
Probable Cause
Action
Check for leaks and top up as required. Check hoses, replace as required. Check engine performance. Check and adjust as required. Check for external leaks, replace seals. Check priority valve. Replace pump.
Lack of power in all hydraulic functions. Insufficient hydraulic fluid. Hydraulic leaks in system. Engine performance. M.R.V. setting incorrect. Low pump flow. Priority valve sticking.
All hydraulic rams slow to operate.
Neutral circuit or low pressure lines leaking, damaged, trapped or kinked. M.R.V setting incorrect. Low pump flow
Check pipe lines, replace as required.
Check and adjust as required. Check pump flow. Check for external leaks, replace seals. Check for priority valve sticking. Replace pump.
One hydraulic service fails to operate or is slow to operate.
Associated service pipe lines leaking, damaged, trapped or kinked. Associated ram leaking. A.R.V. setting incorrect. Associated valve block section leaking or not operating.
Check hoses, replace as required.
Replace seals. Check and adjust as required. Check for leaks, rectify as required. Check that the control lever is operating the spool, rectify as required.
Associated check valve not opening to allow return of oil to tank. Diverter not opening.
Check electrical power supply and valve operation, rectify as required.
The engine tends to stall when hydraulics are under load.
M.R.V setting incorrect.
Check and adjust as required.
Engine performance.
Check engine performance.
Ram creep.
Associated ram or pipe lines from ram leaking. Check valve.
Check operation, rectify as required.
9804/1103
50 - 10 - 01/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 10 - 01/2
407B ZX, 408B ZX, 409B ZX, 410B ZX Fault Finding - Hydraulics - Hydrostatic Pump
Neutral difficult or impossible to find
CHECK CONTROL LINKAGE
OK
INSPECT CONTROL VALVE
OK
REPLACE PUMP
DEFECTIVE
DEFECTIVE
REPAIR OR REPLACE
REPLACE CONTROL VALVE
A246030
9804/1103
50 - 10 - 01/2
Issue 1
CONTENTS
Wheeled Loaders
50 - 10 - 01/3
407B ZX, 408B ZX, 409B ZX, 410B ZX Fault Finding - Hydraulics - Hydrostatic Pump (continued)
Transmission operates in one direction only
CHECK INPUT SIGNAL
OK
INSPECT PCOR AND RELIEF VALVES
OK
DEFECTIVE
DEFECTIVE
REPAIR OR REPLACE CONTROL VALVE
REPAIR OR REPLACE
INSPECT LOOP FLUSHING VALVE
OK
DEFECTIVE
DEFECTIVE
REPLACE LOOP FLUSHING VALVE
A246040
9804/1103
50 - 10 - 01/3
Issue 1
CONTENTS
Wheeled Loaders
50 - 10 - 01/4
System response sluggish
CHECK CHARGE PRESSURE
OK
OK
INSPECT BYPASS VALVE
OK
REPLACE PUMP AND MOTOR
DEFECTIVE
DEFECTIVE
REPAIR OR REPLACE
TOO LOW IN NEUTRAL
TOO LOW IN FORWARD AND REVERSE
TOO LOW IN NEUTRAL AND FORWARD OR REVERSE
INSPECT PUMP CHARGE PRESSURE RELIEF VALVE
INSPECT MOTOR PURGE PRESSURE RELIEF VALVE
OK
INSPECT INLET FILTER
OK
INSPECT CHARGE PUMP
DEFECTIVE
DEFECTIVE
DEFECTIVE
CLOGGED
DEFECTIVE
REPAIR OR REPLACE
REPAIR OR REPLACE
REPAIR OR REPLACE
REPLACE
REPAIR OR REPLACE
A246050
9804/1103
50 - 10 - 01/4
Issue 1
CONTENTS
Wheeled Loaders
50 - 10 - 01/5
System will not operate in either direction
CHECK HYDRAULIC OIL LEVEL
OK
OK
INSPECT BYPASS VALVE
OK
OK
TOO LOW
DEFECTIVE
DEFECTIVE
FILL TO PROPER LEVEL
REPAIR OR REPLACE
REPAIR OR REPLACE
TOO LOW IN NEUTRAL, FORWARD OR REVERSE
TOO LOW IN NEUTRAL
TOO LOW IN FORWARD OR REVERSE
OK
INSPECT CHARGE PUMP
OK
INSPECT INLET FILTER
OK
INSPECT MOTOR PURGE PRESSURE RELIEF VALVE
DEFECTIVE
CLOGGED
DEFECTIVE
DEFECTIVE
REPAIR OR REPLACE
REPLACE
REPAIR OR REPLACE
REPAIR OR REPLACE
OK
OK
INSPECT PCOR
OK
CHECK SYSTEM PRESSURE
DEFECTIVE
DEFECTIVE
REPAIR OR REPLACE
REPAIR OR REPLACE
A246060
9804/1103
50 - 10 - 01/5
Issue 1
CONTENTS
Wheeled Loaders
50 - 10 - 01/6
407B ZX, 408B ZX, 409B ZX, 410B ZX Fault Finding - Hydraulics - Hydrostatic Motor
System response sluggish
CHECK OIL LEVEL IN RESERVOIR
OK
CHECK SYSTEM RELIEF VALVE PRESSURE SETTINGS
OK
CHECK PUMP INLET PRESSURE
OK
CHECK PUMP SPEED
LOW
DEFECTIVE
LOW
LOW
OK
FILL TO CORRECT LEVEL
ADJUST OR REPLACE
INSPECT INLET FILTER AND REPLACE IF NECESSARY
ADJUST
OK
CHECK SYSTEM INTERNAL LEAKAGE
OK
CHECK CHARGE AND CONTROL PRESSURES
HIGH
INCORRECT
REPAIR AS REQUIRED
REPAIR AS REQUIRED
A246070
9804/1103
50 - 10 - 01/6
Issue 1
CONTENTS
Wheeled Loaders
50 - 10 - 01/7
407B ZX, 408B ZX, 409B ZX, 410B ZX Fault Finding - Hydraulics - Hydrostatic Motor (continued)
System operating hot
OK
INSPECT OIL COOLER
OK
OK
LOW
DEFECTIVE
INCORRECT
LOW
OK
CLEAN, REPAIR OR REPLACE
REPAIR AS REQUIRED
OK
CHECK SYSTEM PRESSURE
OK
CHECK FOR INTERNAL SYSTEM LEAKAGE
OK
CHECK SYSTEM RELIEF PRESSURE SETTINGS
HIGH
HIGH
LOW
REDUCE LOAD ON TRANSMISSION
REPAIR AS REQUIRED
ADJUST OR REPLACE
A246090
9804/1103
50 - 10 - 01/7
Issue 1
CONTENTS
Wheeled Loaders
50 - 10 - 01/8
Motor operates normally in one direction only
OK
CHECK PUMP CONTROL SYSTEM
OK
INTERCHANGE SYSTEM RELIEF VALVES AND/OR CHARGE CHECK VALVES
OK
DECAYS IN ONE DIRECTION (FORWARD OR REVERSE) ONLY
DEFECTIVE
PROBLEM CHANGES DIRECTION
INSPECT AND REPAIR LOOP FLUSHING VALVE
REPAIR OR REPLACE
REPAIR OR REPLACE APPROPRIATE VALVE
A246100
Excessive noise and/or vibration
OK
AIR IN SYSTEM
OK
OK
INSPECT SHAFT COUPLINGS
OK
INSPECT SHAFT ALIGNMENT
LOW
LOOSE FITTINGS
LOW
DEFECTIVE
DEFECTIVE
FILL TO PROPER LEVEL
PURGE AIR AND TIGHTEN FITTINGS
REPAIR OR REPLACE
ALIGN SHAFTS
A246080
9804/1103
50 - 10 - 01/8
Issue 1
CONTENTS
Wheeled Loaders
50 - 10 - 01/9
Low torque output
CHECK MOTOR INLET PRESSURE
OK
CHECK MOTOR OUTLET PRESSURE
OK
MOTOR AT INCORRECT (MINIMUM) DISPLACEMENT
OK
REPAIR OR REPLACE MOTOR
LOW
HIGH/LOW
INCORRECT
CORRECT SYSTEM
CORRECT SYSTEM
CHECK CONTROL SUPPLY PRESSURE AND/OR REPAIR DISPLACEMENT CONTROL
A246110
Output speed incorrect
OK
OK
CHECK PUMP OUTPUT FLOW
OK
CHECK MOTOR DISPLACEMENT
LOW
INCORRECT
INCORRECT
INCORRECT
OK
REPAIR CHARGE SYSTEM
REPAIR PUMP CONTROL AND/OR PUMP
CHECK AND REPAIR CONTROL SYSTEM AND DISPLACEMENT CONTROLS (PUMP AND MOTOR)
REPAIR OR REPLACE MOTOR
A246120
9804/1103
50 - 10 - 01/9
Issue 1
CONTENTS
Wheeled Loaders
50 - 10 - 01/10
456B Fault Finding - Hydraulics

To use this section, look for the fault in the list below and refer to the probable causes and actions required listed against the fault. Remember safety must always be the first priority, refer to the 'Care and Safety' section for a reminder on safety practices.
Fault
1
Probable Cause
Action
Check for leaks and top up as required. Check hoses, replace as required. Check engine performance. Check and adjust as required. Check for external leaks, replace seals. Check priority valve.
Lack of power in all hydraulic functions. Insufficient hydraulic fluid. Hydraulic leaks in system. Engine performance. Pump control setting incorrect. Low pump flow. Priority valve sticking.
All hydraulic rams slow to operate.
Neutral circuit or low pressure lines leaking, damaged, trapped or kinked. Pump control setting incorrect. Low pump flow
Check pipe lines and replace as required.
Check and adjust as required. Check pump flow. Check for external leaks, replace seals. Check for priority valve sticking.
Check electrical power supply and valve operation, rectify as required. Check and adjust as required.
Pump control setting incorrect.
Engine performance. 5 Ram creep. Ram seals.
Check engine performance. Check and rectify as required.
A.R.V.
50 - 10 - 01/10
4180-E/90-1.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 10 - 01/11
426B, 436B, 446B Fault Finding - Hydraulics

To use this section, look for the fault in the list below and refer to the probable causes and actions required listed against the fault. Remember safety must always be the first priority, refer to the 'Care and Safety' section for a reminder on safety practices.
Fault
1
Probable Cause
Action
Check for leaks and top up as required. Check hoses, replace as required. Check engine performance. Check and adjust as required. Check for external leaks, replace seals. Check priority valve.
Lack of power in all hydraulic functions. Insufficient hydraulic fluid. Hydraulic leaks in system. Engine performance. Pump control setting incorrect. Low pump flow. Priority valve sticking.
2 All hydraulic rams slow to operate. required.
Neutral circuit or low pressure lines leaking, damaged, trapped or kinked. Pump control setting incorrect. Low pump flow
Check pipe lines and replace as
Check and adjust as required. Check pump flow. Check for external leaks, replace seals. Check for priority valve sticking.
Check electrical power supply and valve operation, rectify as required. Check and adjust as required.
Pump control setting incorrect.
Engine performance. 5 Ram creep. Ram seals. A.R.V.

9804/1103
Check engine performance. Check and rectify as required.
50 - 10 - 01/11
4160 - E/90-1.2
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/1
406, 407, 408, 409 Circuit Diagrams - Electrical

Main Components and Switches 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Battery Starter Motor Solenoid and Motor Start Relay Thermostart Starter Switch Dump Relay Hand Dump Switch (Gear Lever) Hand Dump Switch (Loader Control) Forward Solenoid Forward Relay Reverse Solenoid Reverse Relay Forward/Reverse Switch Horn Push Parking Brake Relay Parking Brake Switch Horn Headlight Dip Switch Headlight Flash Switch Direction Indicator Switch Wiper Motor Front Wiper Switch Front Washer Motor Front Washer Switch Front Speed Transducer Speedometer Hourmeter Water Temperature Sender Water Temperature Gauge Fuel Gauge Sender Fuel Gauge Diode Buzzer Transmission Oil Temperature Switch Water Temperature Switch Air Filter Switch Alternator Engine Oil Pressure Switch Transmission Oil Pressure Switch Flasher Unit Hazard Switch Brake Light Switch Road Light Switch Front Work Light Relay Front Work Light Switch Rear Work Light Relay Rear Work Light Switch Reverse Alarm Engine Shut Off Solenoid Heater Motor Heater Resistor Heater Switch Fog Light Switch Beacon Motor Beacon Switch Washer Motor Rear Wash/Wipe Switch Rear Wiper Motor Rear Interior Light Switch Radio Carrier Lamps 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
Syncro Shuttle m/c's from 632700
Dipped Beam Main Beam LH Indicators RH Indicators Transmission Oil Temperature Warning Water Temperature Warning Air Filter Warning Indicator Warning Main Beam Warning Hazard Warning Alternator Warning Engine Oil Pressure Warning Transmission Oil Pressure Warning Parking Brake Warning Panel Illumination Hazard Switch Stop Lights RH Side/Tail Lights LH Side/Tail Lights Road Light Switch Illumination Front Work Lights Front Work Light Switch Illumination Rear Work Lights Rear Work Light Switch Illumination Fog Light Fog Light Switch Illumination Heater Switch Illumination Beacon Beacon Switch Illumination Interior Light Rear Wash/Wipe Switch Illumination
9804/1103
50 - 15 - 01/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/2
Syncro Shuttle m/cs from 632700
16 4 9 11 17 2 10 12 21
M
65
66
67
68
23
M
1
+
14 6 13
A2
A1
19 7 8 3 15 18 20 22
24
B1 5
B2
C5
A214050
9804/1103
50 - 15 - 01/2
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/3
Syncro Shuttle m/cs from 632700
34
37 39 35 36 81 38 49 92
M
59 56 48 82 83 85 87 50
M
25
28
30
89
94
54 42 27 40 78 26 29 31 69 70 71 72 73 74 76 75 77 79 44 46 51
M
58
60
32 A3 80 A4 43 45 84 52 C3 C1 86 47 88 53 90 57 93 55 B3 B5 95
33
41
91
A8
C2
A9
A5
A6
A7
B6
B4
A214060
9804/1103
50 - 15 - 01/3
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/6
Powershift m/cs from 632700
13 3 6 2 14 9
18 19
22 23 80 81 82 83 32 24 31
M M
26 11 12 16 17
A1
+
A2
8 21 10 7 4 15 20 25 27 28 29 30
B1 5
B2
C5
A201710
9804/1103
50 - 15 - 01/6
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/7
Powershift m/cs from 632700
42 35 38 40 43
45 46 44
67 47 65 99 100 101 102 105 57 106 56 63

M M
60
104
108
66 50 37 39 84 88 85 86 90 92 94 53 87 89 91 93 49 55 59 68
M
34
36
33 52 97 41 95 48 51 96 58 62 54 98 103 107 61 64
C3
C1
A8
C2
A9
A5
A6
A7
B6
B4
B3
B5
A201720
9804/1103
50 - 15 - 01/7
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/8

Main Components and Switches 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 Battery Starter Motor Solenoid Starter Motor Start Relay Starter Switch Thermostart Hand Dump Switch(Loader Control) Dump Relay Drive Relay Neutral Start Relay Reverse Relay Forward Relay Layshaft Solenoid Mainshaft Solenoid Parking Brake Relay Forward High/Low Relay Reverse High/Low Relay Forward Low Solenoid Forward High Solenoid Forward/Reverse Switch Gear Selector Switch Reverse High Solenoid Reverse Low Solenoid Parking Brake Switch Horn Push Horn Headlight Dip Switch Headlight Flash Switch Direction Indicator Switch Front Wash/Wipe Switch Front Wiper Motor Front Washer Motor Diode Speedometer Speed Transducer Hourmeter Water Temperature Gauge Water Temperature Gauge Sender Fuel Gauge Fuel Gauge Sender Buzzer Transmission Oil Temperature Switch Water Temperature Switch Air Filter Switch Alternator Engine Oil Pressure Switch Transmission Oil Pressure Switch Hazard Warning Switch Flasher Unit Brake Light Switch Road Light Switch Front Working Light Switch Front Working Light Relay Rear Working Light Switch Rear Working Light Relay Reverse Alarm Engine Shut Off Solenoid Heater Switch Heater Resistor Heater Motor Fog Light Switch Beacon Switch 63 64 65 66 67 68
Powershift m/c's from 632700
Beacon (Socket) Rear Wash/Wipe Switch Rear Washer Motor Rear Wiper Motor Interior Light Switch Radio Carrier
Lamps 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 Dipped Beam Main Beam LH Indicators RH Indicators Transmission Oil Temperature Warning Water Temperature Warning Air Filter Warning Indicator Warning Main Beam Warning Hazard Warning Alternator Warning Engine Oil Pressure Warning Transmission Oil Pressure Warning Parking Brake Warning Panel Illumination Hazard Switch Road Light Switch Illumination Front Work Light Switch Illumination Rear Work Light Switch Illumination Stop Lights RH Side/Tail Lights LH Side/Tail Lights Front Working Lights Fog Light Switch Illumination Fog Light Rear Working Lights Beacon Rear Wash/Wipe Switch Illumination Interior Light
9804/1103
50 - 15 - 01/8
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/9
411, 416 Circuit Diagrams - Electrical

Main Components 1 2 3 4 5 6 7 8 9 9A 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 54A 55 55A 56 Battery Starter Switch Thermo Coil Start Relay Starter Solenoids Starter Motor Neutral Start Relay Parking Brake Switch Reverse Alarm Relay Reverse Alarm Reverse Light Relay Dump Pressure Switch Dump Switch Reverse Light Switch Transmission Solenoid Switches (Y1 (M1), Y2 (M2), Y3 (M3), Y4 (M4), Y5 (M5)) Transmission Automatic Control Transmission Hand Control Output Speed Sensor Throttle Switch Water Temperature Gauge Fuel Gauge Speedometer Timer Relay Diode Buzzer Test Button Clutch Pressure Switch Engine Oil Pressure Switch Water Temperature Switch Vacuum Switch Transmission Oil Temperature Switch Brake Pressure Switch Alternator Hourmeter Heater Switch Resistor Heater Blower Cigar Lighter Changeover Switch Lift Arm Reset Bucket Ram Reset Clock Brake Switch Hazard Relay Hazard Switch Column Switch Sidelight Switch Column Switch Fog Light Switch Work Light Switch Work Light Relay Interior Light Switch Front Wiper Switch Front Wiper Motor Front Washer Switch Front Wash Motor Horn Push Horn Rear Wash/Wipe Switch 56A 56B 57 58 Lamps 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 Fuses A1 A2 A4 A5 A6 A7 B1 B2 B3 B4 B5 B6 C1 C2 C3 C5 Rear Wiper Motor Rear Washer Motor E.S.O.S. Brake Dump Valve
411 m/cs to 527012 416 m/cs to 529014
Parking Brake Warning Light Reverse Light (Left Hand) Reverse Light (Right Hand) Master Warning Light Transmission Pressure Light Engine Oil Pressure Light Water Temperature Light Air Filter Light Transmission Oil Temperature Light Brake Pressure Light Alternator Warning Light Indicator Warning Light Brake Light (Left Hand) Brake Light (Right Hand) Indicator (Front Left Hand) Indicator (Rear Left Hand) Indicator (Front Right Hand) Indicator (Rear Right Hand) Hazard Warning LIght Sidelight (Right Hand) Sidelight (Left Hand) Rear Fog Light Dipped Beam Main Beam Work Light (Front) Interior Light Beacon
Direction Indicators Right Sidelights and Gauge Illumination Gear Selection Brake Lights, Loader Arm and Bucket Reset Warning Lights, Heater Fan and Gauges Main Beam Hazard Warning Lights Dipped Beam Rear Work Lights Rear Wash/Wipe Interior Light and Beacon E.S.O.S. Left Sidelights Front Work Lights Forward/Reverse Select Horn, Wash/Wipe (Front)
Note: For bulb and fuse ratings see pages 50 - 05 - 01/2, 01/3. Note: For manual transmission machines, Item 18 (Throttle Switch) is not fitted. Wires 9508 and 9508A are linked.
9804/1103
50 - 15 - 01/9
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/10
411 m/cs to 527012 416 m/cs to 529014
55A 9A 71 72 14
420 420 414 413
56B
27 26 28
29 30
31
33
37
82 83
84 85 86 87
89 90 91 92 93
801 802 812 806 807
94 95 96 54A
810 304E
846B 835E 836G 846A 835D 836F
56A
844B 844C
32
861
852
851
48 42
803C
19
826G 844
20
21
408 405 416 400 411 422 418
36 38 39 40
104C 104H 104G 104B
17 18
9508A 9508 106C
81
104A 838
88
A2 C1
800B 800 804
A7 53 B2
805 304C 818 817 819 816A 815 814
10
22
25
839
835
9588A
9588
813
16
7 8 1 2
50
45 23
23 74
406
845 9584
3 4 6 5 9434 9442 9430 9464 9524 9528 9512 9536 9504
41
837 822 106S 104 8360 8358
47
52
9438 9446 9460 003
49
802
8
101
54 55
56 56
13
33 15 32 14 31 27 17 8 26 23 25 19 24
35
9658 9674 820
57
800 803
306
004
421
11
840
302A
15 58
5 29 18 9666 420 9678
23
75 76 77 78 79 80 34
106A 100 300B 838 300 837A
51
22
1 9650
2 9654
35
44 46
304D 105 102
12 3
302 200 200E
9600
24
73
9612
106B
106
107
100A
A4
002B 002A
B3
200K
C3
A6
200 & 200A
B6
A5
A1
000A
B1
200H
70
43
200F 304
C5
B4
000F
000C
001
000
2 C2
2000 200S 200M
B5
A211591
9804/1103
50 - 15 - 01/10
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/11
411 m/cs from 527013 416 m/cs from 529015
55A 9A 71 72 14 6
844B 844C 414 420 420 413
56B
27 26 28
29 30
31
33
37
82 83
84 85 86 87
89 90 91 92 93
801 802 812 806 807
94 95 96 54A
810 304E
846B 835E 836G 846A 835D 836F
56A
62
862
17A
32 36
408 405 416 400 411 422 418
861
852
851
19
826G 844
20
21
38 39
104G 104B
42 40
104C 104H 104A 838
17 18
9508A 9508 106C
81
88
A2 C1
800B 800
A3
A7 53 B2
805 804 304C 818 817 819 816A 815 814 862
61
10
22
25
839
835
9588A
9588
813
16
7 8 1 2
50
45 23
48
803C
23 74
406
60 47 52
863
845 9584
3 4 6 5 9434 9442 9430 9474 9464 9524 9536
41
837 822 106S 104 8360 8358
003
11
840
9438 9446 9470 9460 9528 9512 9504
49
802
54 55
56 56
13
33 15 32 14 31 9 34 27 17 8 26 23 25 19 24
35
9658 9674 820
63
800 803
306
004
421 101
12
302A
4 64
15
101M
5 29 18 9666 420 9678
59 51
23
75 76 77 78 79 80 34
106A 100 300B 838 300 837A
57
9600A
22 9600
1 9650
2 9654
35
44 46
304D 105 102 100
24 58
9536A 106B 106
73
3
200 200E
101H 9612A 302 9612
107
100A
70 A4
002B 200K 002A
B3
C3
A6
200 & 200A
B6
A5
A1
000A
B1
200H
43
200F 304
C5
B4
B7
000F
000C
000
001
000
2 C2
2000 200S 200M
B5
A217091
9804/1103
50 - 15 - 01/11
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/12

Main Components 1 2 3 4 5 6 7 8 9 9A 10 11 12 13 14 15 16 17 17A 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 54A 55 55A 56 56A 56B 57 58 59 60 Battery Starter Switch Thermo Coil Start Relay Starter Solenoids Starter Motor Neutral Start Relay Parking Brake Switch Reverse Alarm Relay Reverse Alarm Reverse Light Relay Dump Pressure Switch Dump Switch Reverse Light Switch Transmission Solenoid Switches (Y1 (M1), Y2 (M2), Y3 (M3), Y4 (M4), Y5 (M5)) Transmission Automatic Control Transmission Hand Control Output Speed Sensor Turbine Sensor Throttle Switch Water Temperature Gauge Fuel Gauge Speedometer Timer Relay Diode Buzzer Test Button Clutch Pressure Switch Engine Oil Pressure Switch Water Temperature Switch Vacuum Switch Transmission Oil Temperature Switch Brake Pressure Switch Alternator Hourmeter Heater Switch Resistor Heater Blower Cigar Lighter Changeover Switch Lift Arm Reset Bucket Ram Reset Clock Brake Switch Hazard Relay Hazard Switch Column Switch Sidelight Switch Column Switch Fog Light Switch Work Light Switch Work Light Relay Interior Light Switch Front Wiper Switch Front Wiper Motor Front Washer Switch Front Wash Motor Horn Push Horn Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Motor Dump Switch (Loader Control) Kickdown Switch (Loader Control) Air Conditioning Switch Air Conditioning Thermostat 61 62 63 64 Lamps 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 Fuses A1 A2 A3 A4 A5 A6 A7 B1 B2 B3 B4 B5 B6 B7 C1 C2 C3 C5
411 m/cs from 527013 416 m/cs from 529015
Air Conditioning Pressure Switch Compressor Clutch Field Coil E.S.O.S. Brake Dump Valve
Parking Brake Warning Light Reverse Light (Left Hand) Reverse Light (Right Hand) Master Warning Light Transmission Pressure Light Engine Oil Pressure Light Water Temperature Light Air Filter Light Transmission Oil Temperature Light Brake Pressure Light Alternator Warning Light Indicator Warning Light Brake Light (Left Hand) Brake Light (Right Hand) Indicator (Front Left Hand) Indicator (Rear Left Hand) Indicator (Front Right Hand) Indicator (Rear Right Hand) Hazard Warning Light Sidelight (Right Hand) Sidelight (Left Hand) Rear Fog Light Dipped Beam Main Beam Work Light (Front) Interior Light Beacon
Direction Indicators Right Sidelights and Gauge Illumination Rear Fog Light Gear Selection Brake Lights, Loader Arm and Bucket Reset Warning Lights, Heater Fan and Gauges Main Beam Hazard Warning Lights Dipped Beam Rear Work Lights Rear Wash/Wipe Interior Light and Beacon E.S.O.S. Air Conditioning Left Sidelights Front Work Lights Forward/Reverse Select Horn, Wash/Wipe (Front)
Note: For bulb and fuse ratings see pages 50 - 05 - 01/2, 01/3. Note 2: For manual transmission machines, Item 18 (Throttle Switch) is not fitted. Wires 9508 and 9508A are linked. Note 3: For Germany ONLY, Wire 9588 is not connected to Item 10 (Reverse Light Relay).
9804/1103
50 - 15 - 01/12
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/13

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 Starter Switch Battery Isolator Starter Relay Starter Solenoids Starter Motor Hydraulic Dump Valve Thermostart Coil Shut down Relay E.S.O.S. Electronic Monitoring system (EMS) Computer Feed Relay ZF Computer Transmission Solenoids Turbine Speed Sensor Output Speed Sensor Throttle Switch Kickdown Switch Hand Controller Relays Forward/Reverse Control Relays Hand Controller Forward/Reverse Switch Reverse Alarm Relay Reverse Alarm Reverse Lights Switch Reverse Lights Relay ACCS Relay ACCS Override Switch ACCS Solenoid Valve Lamps 110 111 112
411 m/cs from 527400 416 m/cs from 529500
LH Reverse Light RH Reverse Light ACCS Operating Indication Light
Fuses 6A 8A 3B 6B 8B 3C 7C 8C Computer Feed Relay Solenoid EMS Battery Feed Reverse Alarm and Rear Work Lights Engine Shut Off System (ESOS) Thermostart EMS and ZF Computer Feed Hydraulic Dump Valve (416 Only) ACCS
Note 1: For fuse ratings see Fuses, Relays in Technical Data.
Note: Arrows marked indicate remote connection (not shown), ie. B5 goes to connection B5 on EMS (Item 11).
50 - 15 - 01/13
4150 - C/6-5.2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 01/14

2 3 5 4 1 7C 7 8 10
411 m/cs from 527400 416 m/cs from 529500
8B 6B
9 8A 11
3C 6A
12
13 15 14 17
16
19
20
18
21 23 3B 25
22 24
26 110 111 28 29 112
27 8C
A298570 4150 - C/6-6.2
9804/1103
50 - 15 - 01/14
Issue 3*
CONTENTS
Wheeled Loaders
50 - 15 - 01/15
411, 416 Circuit Diagram - Electrical

Main Components 1 11 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 Starter Switch Electronic Monitoring system (EMS) Warning Light Test Button Buzzer Fuel Contents Sender Water Temperature Sender Transmission Oil Temperature Sender Hydraulic Oil Temperature Sender Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Engine Oil Level Sensor Coolant Level Sensor Transmission Oil LevelSensor Hydraulic Oil Level Sensor Emergency Steer Switch Water in Fuel Sensor Parking Brake Switch Alternator Heater Switch Heater Relay Heater Blower Cigar Lighter Air Conditioning Switch Air Conditioning Temperature Switch Air Conditioning Pressure Switch Air Conditioning Compressor Clutch Lamps 113
411 m/cs from 527400 416 m/cs from 529500
Master Warning Light
Fuses 8A 7B 6C EMS Battery Feed Air Conditioning Heater Blower and Cigar Lighter
Note: Arrows marked indicate remote connection (not shown), ie. 3C goes to Fuse 3C via. Relay (Item 12).
9804/1103
50 - 15 - 01/15
4150 - C/6-7.2
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/16
411,416 Circuit Diagrams - Electrical

1
411 m/cs from 527400 416 m/cs from 529500
30 113 31 32 33
8A
34 35 36 11 37 38 39 40 41 42 43 44 45 46 47
48 50 51 6C 49
52 7B 53 54 55 56
9804/1103
50 - 15 - 01/16
4150 - C/6 - 8.2
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/17

Main Components 1 57 58 59 60 61 62 63 64 65 66 Starter Switch Hazard Relay Hazard Warning Switch Column Switch Diode Road Light Switch Head Light Flasher Switch Fog Light Switch Front Work Lights Switch Front Work Lights Inhibit Relay (Italy Only) Front Work Lights Relay Lamps 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128
411 m/cs from 527400 416 m/cs from 529500
On all machines other than Italy, relay 65 is not fitted and wires 853A and 808A are connected Note: Arrows marked indicate remote connection (not shown), ie. B4 goes to connection B4 on EMS (Item 11). B6 goes to connection B6 on EMS (Item 11). B10 goes to connection B10 on EMS (Item 11). B11 goes to connection B11 on EMS (Item 11). B12 goes to connection B12 on EMS (Item 11). B16 goes to connection B16 on EMS (Item 11). B17 goes to connection B17 on EMS (Item 11). B18 goes to connection B18 on EMS (Item 11).
LH Front Indicator LH Rear Indicator RH Front Indicator RH Rear Indicator RH Front Side Light RH Tail Light LH Front Side Light LH Tail Light RH Number Plate Light LH Number Plate Light Dipped Beam Main Beam Fog Lights LH Front Work Lights RH Front Work Lights
Fuses 1A 2A 3A 1B 2B 1C 2C 9C Hazard Warning Lights and Direction Indicators RH Side/Tail Lights and Switch/Panel Illumination Fog Lights Hazard Battery Feed Dip Beam LH Side/Tail Lights and Number Plate Lights Front Work Lights Road Lights
9804/1103
50 - 15 - 01/17
4150 - C/6 - 9.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/18

1
411 m/cs from 527400 416 m/cs from 529500
1A 1B 58
114 115
57
59
116 117
60
118 2A 119
120 121 1C 122 123
2B
124
61
9C
62 7A 125
63
3A
126
127
65 64 2C 66 128
9804/1103
50 - 15 - 01/18
4150 -C/6 - 10.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/19

Main Components 1 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 Starter Switch Lift Ram Proximity Switch Detent Coil (Lift Arm Reset) Shovel Ram Proximity Switch Detent Coil (Shovel Ram Reset) Detent Coil (Float) Brake Light Switch Heated Mirror Switch LH Heated Mirror RH Heated Mirror Heated Seat Switch Heated Seat Heated Seat Thermostat Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Pump Horn Front Wiper Motor Column Switch Intermittent Wiper Relay Front Washer Pump Beacon Switch Interior Light Radio (Option) Under Bonnet Lights Switch Lamps 129 130 131 132 133 134
411 m/cs from 527400 416 m/cs from 529500
LH Brake Light RH Brake Light Beacon Interior Light LH Under Bonnet Light RH Under Bonnet Light
Fuses 5A 4B 5B 4C 5C Brake Lights, Float, Lift and Shovel Reset Rear Wash/Wipe Beacon, Interior Light, Radio and Under Bonnet Lights Heated Mirror and Heated Seat Front Wash/Wipe and Horn
9804/1103
50 - 15 - 01/19
4150 - C/6 - 11.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/20
411 m/cs from 527400 416 m/cs from 529500
1 67 68 69 5A 71
70
72
129 130
74 73 75 4C 76 77 78
4B
79
80
81 82 83
5C
84 85
86 87 131
5B
132 89
88
133 90 134
9804/1103
50 - 15 - 01/20
4150 - C/6 - 12.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/21

Main Components 1 2 3 4 5 6 7 8 9 9A 10 11 12 13 14 15 16 17 17A 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 54A 55 55A 56 56A Battery Starter Switch Thermo Coil Start Relay Starter Solenoids Starter Motor Neutral Start Relay Parking Brake Switch Reverse Alarm Relay Reverse Alarm Reverse Light Relay Dump Pressure Switch Dump Switch Reverse Light Switch Transmission Solenoid Switches (Y1 (M1), Y2 (M2), Y3 (M3), Y4 (M4), Y5 (M5)) Transmission Automatic Control Transmission Hand Control Output Speed Sensor Turbine Sensor Throttle Switch Water Temperature Gauge Fuel Gauge Speedometer Timer Relay Diode Buzzer Test Button Clutch Pressure Switch Engine Oil Pressure Switch Water Temperature Switch Vacuum Switch Transmission Oil Temperature Switch Brake Pressure Switch Alternator Hourmeter Heater Switch Resistor Heater Blower Cigar Lighter Changeover Switch Lift Arm Reset Bucket Ram Reset Clock Brake Switch Hazard Relay Hazard Switch Column Switch Sidelight Switch Column Switch Fog Light Switch Work Light Switch Work Light Relay nterior Light Switch Front Wiper Switch Front Wiper Motor Front Washer Switch Front Wash Motor Horn Push Horn Rear Wash/Wipe Switch Rear Wiper Motor 60 61 62 63 64 Air Conditioning Thermostat Air Conditioning Pressure Switch Compressor Clutch Field Coil E.S.O.S. Brake Dump Valve
Lamps 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 Parking Brake Warning Light Reverse Light (Left Hand) Reverse Light (Right Hand) Master Warning Light Transmission Pressure Light Engine Oil Pressure Light Water Temperature Light Air Filter Light Transmission Oil Temperature Light Brake Pressure Light Alternator Warning Light Indicator Warning Light Brake Light (Left Hand) Brake Light (Right Hand) Indicator (Front Left Hand) Indicator (Rear Left Hand) Indicator (Front Right Hand) Indicator (Rear Right Hand) Hazard Warning Light Sidelight (Right Hand) Sidelight (Left Hand) Rear Fog Light Dipped Beam Main Beam Work Light (Front) Interior Light Beacon
Fuses A1 Direction Indicators A2 Right Sidelights and Gauge Illumination A3 Rear Fog Light A4 Gear Selection A5 Brake Lights, Loader Arm and Bucket Reset A6 Warning Lights, Heater Fan and Gauges A7 Main Beam B1 Hazard Warning Lights B2 Dipped Beam B3 Rear Work Lights B4 Rear Wash/Wipe B5 Interior Light and Beacon B6 E.S.O.S. B7 Air Conditioning C1 Left Sidelights C2 Front Work Lights C3 Forward/Reverse Select C5 Horn, Wash/Wipe (Front) Note 1: For bulb and fuse ratings see pages 50 - 05 - 01/4, 01/5. Note 2: For manual transmission machines, Item 18 (Throttle Switch) is not fitted. Wires 9508 and 9508A are linked. Note 3: For Germany ONLY, Wire 9588 is not connected to Item 10 (Reverse Light Relay).
9804/1103
50 - 15 - 01/21
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/22
55A 9A 71 72 14
420 420 414 413
56B
27 26 28
29 30
31
33
37
82 83
84 85 86 87
89 90 91 92 93
801 802 812 806 807
94 95 96 54A
810 304E
846B 835E 836G 846A 835D 836F
56A 62
862
844B 844C
32 36
408 405 416 400 411 422 418
861
852
851
48 42
803C
19
826G 844
20
21
38 39
104G 104B
17 18
9508A 9508 106C
40
104C 104H 104A
81
838
88
A2 C1
8008 800 804
A7 53 B2
805 304C 818 817 819 816A 815 814 862
61
10
22
25
839
835
9588A
9588
813
16
7 8 1 2
50
45 23 60 41
837 822 106S 104 8360 8358 863
23 74
406
845 9584
3 4 6 5 9434 9442 9430 9464 9524 9528 9512 9536 9504
47
52
+
1
003
8
101
11
840
9438 9446 9460
49
802 306
54 55
56 56
13
33 15 32 14 31 27 17 8 26 23 25 19 24
35
9658 9674
+
4
004
421
63
820 800 803
12 64
101M
302A
15
5 29 18 9666 420 9678
23
75 76 77 78 79 80 34
106A 100 300B 838 300 837A
59 51
22
1 9650
2 9654
35
44 46
304D 105 102 100
57 3
200 200E 9600A 101H 302
9600
24
73
70 A4
002B 002
9612
106B
106
107
100A
B3
200K
C3
A6
200 & 200A
B6
A5
000H
A1
000A
B1
200H
43
200F 304
C5
B4
B7
000F
000C
000
001
000
2 C2
200D 200S 200M
B5
9804/1103
50 - 15 - 01/22
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 01/ 21
411, 411B from m/c no. 527850 416, 416B from m/c no. 530100 Circuit Diagram - Electrical Main Components
1 2 3 4 5 6 7 8 9 Battery Isolator Light Relay Road Light Switch Fog Light Switch Column Switch Front Work Light Relay Front Work Light Switch Rear Work Light Switch
Lamps
120 121 122 123 124 Fog Lights Dipped Beam Main Beam Front Work Lights Rear Work Lights
Fuses
A1 A2 A3 A4 A5 A6 B1 B2 P1 Rear Work Lights Road Lights Front Work Lights Dipped Beam Main Beam Rear Fog Lights Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and Number Plate Lights Front Work Lights Rear Work Lights Main Beam Dip Beam Fog Lights
Note: Items marked $ indicate remote connections (not shown), i.e. $1 $2 $3 $4 $5 $6 From EMS A23 To EMS B6 To EMS B12 To EMS B11 To EMS B10 To EMS B5
9804/1103
50 - 05 - 01/21
4150 - C/6-13.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 15 - 01/ 22
411, 411B from m/c no. 527850 416, 416B from m/c no. 530100 Circuit Diagram - Electrical
1 1 2
B1 B2
See C/6-16 See C/6-16 $2 To EMS B6
LH 812D
812A
3
See C/6-18
132A 201 005
See C/6-16
303
800
A2
120 803B
812C
A6
812
812B
120
RH
806C 803 806A
$3 To EMS B12
LH
6 P1
See C/6-16
305
804
A4 A5
806
121
806B RH
805
807
807A
LH
807B 807C
122
RH
$4 To EMS B11 $5 To EMS B10
810E
201A
006
A3
122 122A
122B
810
810A LH 810B
See C/6-24
$1 From EMS A23 808
123
810C RH 810D
813C
LH
A1
121
124
813 813A 813D RH
813B
$6 To EMS B5
9804/1103
50 - 05 - 01/22
4150 - C/6-14.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 15 - 01/ 23
1 2 10 11 12 13 14 15 16 Battery Isolator Electronic Monitoring System (EMS) ZF Computer Hazard Warning Switch Hazard Warning Relay Column Switch Beacon Switch 24 Volt Radio
Lamps
125 126 127 128 129 130 131 132 133 134 135 Left Front Indicator Left Rear Indicator Right Front Indicator Right Rear Indicator Beacon Interior Light Right Front Side Light Right Rear Side Light Left Front Side Light Left Rear Side Light Number Plate Lights
Note : Items marked $ indicate remote connections (not shown), i.e. $7 $8 $9 $10 $11 $12 12 Volt Trailer Electrics To EMS B18 To EMS B16 Headlight Flash Switch Illumination To EMS B18
Fuses
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 C9 P2 Rigth Side/Tail Lights and Switch Illumination Left Side/Tail Lights and Number Plate Lights 12 Volt Trailer Electrics (Option) EMS (Battery Feed) ZF Computer (Battery Feed) Hazard Warning Beacon and Interior Light 24 Volt Radio Headlight Flash Side Lights Direction Indicators Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and Number Plate Lights Headlight Flash Radio (24 Volt) Beacon and Interior Light Hazard Warning EMS (Battery Feed) ZF Computer (Battery Feed) 12 Volt Trailer Electrics
9804/1103
50 - 05 - 01/23
4150 - C/6-15.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 15 - 01/ 24
1 1 2
B3
$7 12 Volt Trailer Electrics
B4
301
10
See C/6-42
B5
9832
11
9836
See C/6-40
202A
C9
See C/6-20
835C 100 835A 835
$8 To EMS B18
P2
202
B6
12
300 838 30 49 15
125
835D
LH FRONT
14
126 127
LH REAR
13
837A 49A
L R
835B 836 836B
836A
RH FRONT
836D 837 836C
RH REAR
128
$9 To EMS B16
304E
15
823
129
B7
304
304D
130 B8 16
309
B9
802D 305
$11 Switch Illumination
$10 Headlight Flash See C/6-14

802C
$12 To EMS B18
802A
131 132 133 134
B1 B10 4
303 800
802
802B
B2
801
801A
See C/6-14
120 803B
801B
801C
See C/6-14
801D
LH
135
801E
RH
9804/1103
50 - 05 - 01/24
4150 - C/6-16.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 15 - 01/ 25
1 2 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Battery Isolator Starter Solenoids Starter Motor Start Relay Starter Switch Not Applicable Start-up Dump Solenoid Thermostart Resistor Thermostart Not Applicable Dump Relay Heater Speed Switch Heater Blower Air Conditioning Switch Air Conditioning Temperature Switch Air Conditioning Pressure Switch Air Conditioning Compressor Heated Mirror Switch Heated Mirrors Heated Seat Switch Seat Heating Elements Air Suspension Switch Air Suspension Compressor Heated Rear Screen Switch Heated Rear Screen Relay Heated Rear Screen Lights Relay Solenoid Ignition Relay Solenoid 1 Ignition Relay Solenoid 2 Ignition Relay Solenoid 3
Lamps
136 Road Light Switch Illumination
Fuses
A7 A8 A9 A10 C1 C6 C7 C8 C9 C10 P3 Blank Thermostart Dump Relay Ignition Relays Starter Relay Solenoid Heated Seat/Mirrors and Air Suspension Seat (Option) Air Conditioning (Option) Heater Blower Direction Indicators Heated Rear Screen Starter Solenoid Thermostart Heater Blower Air Conditioning Direction Indicators Heated Seat, Mirrors and Air Suspension Seat Heated Rear Screen Ignition Relays
Note : Items marked $ indicate remote connections (not shown), i.e. $13 $14 $15 $16 To EMS A34 Indicators To EMS A24 To EMS B4
9804/1103
50 - 05 - 01/25
4150 - C/6-17.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 15 - 01/ 26
1 1 2
001
203A
17
+
19 C1
127
18
128
P3
20
203 1
$13 To EMS 34 See C/6-24

7 2 8 9
002
A7
111
21 22
6 5
A8
113
23
24 25
000
A9
129
C8 26
27
112
28
822 821 820
C7
109
29
863
30
862
31
862A
32
33
119A
873A 873 873
34
830
C6
119
35
872
36
119B
37
38
C9
100
$14 Indicators See C/6-16
39
103A 826 834
$16 To EMS B4 See C/6-24
C10
103
$15 To EMS A24 See C/6-24
841
40 42 43 44 45 136
41
132A
000A
A10
132
132C
132D
132E
132F
9804/1103
50 - 05 - 01/26
4150 - C/6-18.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 15 - 01/ 27
1 2 10 11 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 Battery Isolator Electronic Monitoring System (EMS) ZF Computer Ignition Relay 1 Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Pump Horn Ignition Relay 2 Coluumn Switch Front Wiper Motor Intermittent Wiper Relay Front Washer Pump 24 Volt Cigar Lighter Shutdown Relay E.S.O.S. Reverse Relay Reverse Alarm Ignition Relay 3 Brake Light Switch Changeover Switch Changeover Solenoid Lift Ram Proximity Switch Detent Coil (Lift Ram Reset) Shovel Ram Proximity Switch Detent Coil (Shovel Ram Reset) Detent Coil (Float)
Lamps
137 138 139 140 Left Fog Light Right Fog Light Left Brake Light Right Brake Light
Fuses
C2 C3 C4 C5 D1 D2 D3 D5 D6 D7 D8 D9 D10 P4 24 Volt Cigar Lighter Blank Rear Wash/Wipe Front Wash/Wipe and Horn EMS (Ignition Feed) ZF Computer (Ignition Feed) CCTV (Option) E.S.O.S. and Cold Start Advance Reverse Lights and Alarm In-cab 24/12 Volt Converter (Option) Blank Brake Lights Float, Lift and Shovel Reset and 4th Spool EMS (Ignition Feed) ZF COmputer (Ignition Feed) Rear Was/Wipe Front Wash/Wipe Cigar Lighter (24 Volt) E.S.O.S. and Cold Start Advance Reverse Alarm/Lights Headlight Flash Brake Lights Shovel and Arm Reset CCTV In-cab 24/12 Volt Converter
Note : Items marked $ indicate remote connections (not shown), i.e. $17 $18 $19 $20 CCTV Spare To EMS A11 To CCTV
9804/1103
50 - 05 - 01/27
4150 - C/6-19.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 15 - 01/ 28
+
D3 46
See C/6-20
132C 204 008
118
+
$17 CCTV See C/6-26
125
D1 D2
10 11
See C/6-40
102B
See C/6-24
9916A
47 C4
102 102A
827
48
815
C3
$18 Spare
816
814
49 50
105B
53
817 818
51
See C/6-18
132D 204B 007
829
C5
105
105A
52
831 105C 828 819B
54
819
819A
55
C2
811
124
57
809
56 58 60
844 844A
P4
204A
D5

107
59 D6
See C/6-22
115 9916J
137 138
844D
844B
204C
61
009
D7
108
$20 To CCTV See C/6-26
See C/6-26
See C/6-18
132E
D8
$18 Spare
D9
126
62
847
847A
139 140
847B
63
104G
861
64
D10
65
104 104C
852
67
66
104B
851
68
104H
69
9804/1103
50 - 05 - 01/28
4150 - C/6-20.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 15 - 01/ 29
70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 Gear Box Controller Unit Torque Converter Out Temperature Sensor Reverse Relay Solenoid Load Suspension Solenoid Load Suspension On/Off Switch Parking Brake On/Off Switch (411 to 446) Parking Brake On/Off Switch (456) Auto/Manual Switch On/Off Switch Pressure Switch Transmission Disconnect Switch Parking Brake Solenoid Internal Gear Chain Speed Sensor Turbine Speed Sensor Engine Speed Sensor Output Speed Sensor Forward Reverse Rocker Switch Hand Controller Transmission Kick Down Button ZF Diagnostic Port ZF Display Plug
Fuses
B5 D2 ZF Computer (Battery Feed) ZF Computer (Ignition Feed)
Note : Items marked $ indicate remote connections (not shown), i.e. $21 $22 CAN-BUS to EMS To EMS A30 (456 Only)
9804/1103
50 - 05 - 01/29
4150 - C/6-21.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 15 - 01/ 30
70
VSP1 TEMP 8 TEMP 9 Y1 1 9430 56 AIP1 Y2 2 9434 10 AIP2 Y3 3 9438 32 AIP3 Y4 4 9442 55 AIP4 Y5 5 9446 09 AIP5 51 AIP6 Y6 6 9450 12 VPS1
$21 CAN-BUS to EMS See C/6-24
$22 To EMS A30 (456 Only)
7 9454 9904 9908 13 VPS1
9462A 9574 9570
421
71
439 438
9458 39 ER1
9462 46 VMGA2
9916J
72
25
9808
ADM2
CANF-H CANF-L
07
438B 438A 9856 9920 9852
26 27
9916M
73
897
CANF-T 05 VM2
02
9916H
74
01
896
VM1 30
9916F
75
9820B
848
57
76
9916D 9820
9820A
81
ED10
21
11
893
9900
9916G
77 78 79
840 9816B
08
9824
29
ED11 03 42 VMG1 EF3
9424
9420
9916A
82
9414
9410
80
9916B 9816A 9916
41
9816
ED9
EF2
83
9404 9400
66
D2
See C/6-20
9916A
45
VPI
19
EF1
84
9836
68
VPE2
14
B5
See C/6-16
9832
23 EF4 62
VPE1 ED13 VMG2 04 9500 ED8 44 ED3 20 ED4 43 ED6 67 ED5 64 ED1 63 ED2 65 ED7 22
15 18
31
9504
9532A
9508
85
2 3
880 2
882 3
881 9548 9544 9528 9524 9540 4
9536A
86
9532
1 F N R B1 B2
9864 9648 9644 9652
KD
9536
87 88
4 3 2
9598
9594
9916K
9640
89
9590
90
9804/1103
50 - 05 - 01/30
4150 - C/6-22.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 15 - 01/ 31
1 2 10 91 92 93 94 95 96 97 98 99 100 101 102 103 104 Battery Isolator Electronic Monitoring System (EMS) EMS Diagnostic Port Buzser Fuel Level Sender Water Temperature Sender Transmission Oil Temperature Sender Engine Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Emergency Steer Switch Shutdown Relay Coil Front Work Light Relay Coil Heated Rear Screen Relay Coil Alternator
Fuses
B4 D1 EMS (Battery Feed) EMS (Ignition Feed)
Note : Items marked $ indicate remote connections (not shown), i.e. $21 $23 $24 $25 $26 $27 $28 $29 $30 $31 $32 $33 $34 CAN-BUS to EMS From Fuse A6 From Fuse A4 From Fuse A5 From Front Work Light Switch From Rear Work Light Switch From LH Indicator Feed From RH Indicator Feed From Side Light Feed From Heated Rear Screen Switch From ZF Computer (Park Brake Status-456 Only) From Start Relay Coil 120 ohm Resistor
9804/1103
50 - 05 - 01/31
4150 - C/6-23.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 15 - 01/ 32
1 1 2
91
4 125A 425 A26 3 423 A2
2 5 600BX A35 A13 600G 600DU 420
+
1 424 A3
139 92 93 94 95
B4
See C/6-16
301
A25
A12
420A 431 415 401
D1
See C/6-20
B7 125 A36
10
B14 B1
$23 From Fuse A6 $24 From Fuse A4 $25 From Fuse A5 $26 From Front Work Light Switch $27 From Rear Work Light Switch $28 From LH Indicator Feed $29 From RH Indicator Feed $30 From Side Light Feed $31 From Heated Rear Screen Switch
812D 806C 807C 810E 813B 835C 836C 802C 826
B6 B12 B11 B10 B5 B18 B16 B18 B4 A16 A4 A15 A6 408 400 412 422 432
96 97 98 99 100
A18
A11
811
101 102 103
$32 From ZF Computer (Park Brake Status-456 Only)
A23 421 A30 A34 A24
808
128
834
B3
418
A27
B15 438E
B9 439E
650
$34 120 ohm Resistor
$21 CAN-BUS To EMS See C/6-22
104
9804/1103
50 - 05 - 01/32
4150 - C/6-24.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 15 - 01/ 33
1 2 105 106 107 108 109 110 Battery Isolator 24/12 Volt Converter 12 Volt Radio 12 Volt Cigar Lighter 12 Volt Auxiliary Plug Closed Circuit Television Display (CCTV) CCTV Camera
Fuses
D3 D7 CCTV (Option) In-cab 24/12 Volt Converter (Option)
Note : Items marked $ indicate remote connections (not shown), i.e. $35 $36 Reverse Light/Alarm RFeed From Side Light Feed
9804/1103
50 - 05 - 01/33
4150 - C/6-25.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 15 - 01/ 34
1 1 2
600DZ 308A
106
603A
D7
See C/6-20
108
105
308
308B
107
603B
308C
108
603C
603
$35 Reverse Light/Alarm Feed See C/6-20 See C/6-20
844D
D3
118
109
$36 From Side Light Feed
802M
110
9804/1103
50 - 05 - 01/34
4150 - C/6-26.1
Issue 1*
CONTENTS
Wheeled Loaders
50 - 15 - 02/1
412S Circuit Diagrams - Electrical Main Components

1 2 3 4 5 6 7 8 9 9A 10 11 12 13 14 15 16 17 17A 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 54A 55 55A 56 56A 56B Battery Starter Switch Thermo Coil Start Relay Starter Solenoids Starter Motor Neutral Start Relay Parking Brake Switch Reverse Alarm Relay Reverse Alarm Reverse Light Relay Dump Pressure Switch Dump Switch Reverse Light Switch Transmission Solenoid Switches (Y1 (M1), Y2 (M2), Y3 (M3), Y4 (M4), Y5 (M5)) Transmission Automatic Control Transmission Hand Control Output Speed Sensor Turbine Sensor Throttle Switch Water Temperature Gauge Fuel Gauge Speedometer Timer Relay Diode Buzzer Test Button Clutch Pressure Switch Engine Oil Pressure Switch Water Temperature Switch Vacuum Switch Transmission Oil Temperature Switch Brake Pressure Switch Alternator Hourmeter Heater Switch Resistor Heater Blower Cigar Lighter Changeover Switch Lift Arm Reset Bucket Ram Reset Clock Brake Switch Hazard Relay Hazard Switch Column Switch Sidelight Switch Column Switch Fog Light Switch Work Light Switch Work Light Relay Interior Light Switch Front Wiper Switch Front Wiper Motor Front Washer Switch Front Wash Motor Horn Push Horn Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Motor 57 58 59 60 61 62 63 64
m/cs to 535116
Dump Switch (Loader Control) Kickdown Switch (Loader Control) Air Conditioning Switch Air Conditioning Thermostat Air Conditioning Pressure Switch Compressor Clutch Field Coil E.S.O.S. Brake Dump Valve
Lamps
70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 Parking Brake Warning Light Reverse Light (Left Hand) Reverse Light (Right Hand) Master Warning Light Transmission Pressure Light Engine Oil Pressure Light Water Temperature Light Air Filter Light Transmission Oil Temperature Light Brake Pressure Light Alternator Warning Light Indicator Warning Light Brake Light (Left Hand) Brake Light (Right Hand) Indicator (Front Left Hand) Indicator (Rear Left Hand) Indicator (Front Right Hand) Indicator (Rear Right Hand) Hazard Warning Light Sidelight (Right Hand) Sidelight (Left Hand) Rear Fog Light Dipped Beam Main Beam Work Light (Front) Interior Light Beacon
Fuses
A1 A2 A3 A4 A5 A6 A7 B1 B2 B3 B4 B5 B6 B7 C1 C2 C3 C5 Direction Indicators Right Sidelights and Gauge Illumination Rear Fog Light Gear Selection Brake Lights, Loader Arm and Bucket Reset Warning Lights, Heater Fan and Gauges Main Beam Hazard Warning Lights Dipped Beam Rear Work Lights Rear Wash/Wipe Interior Light and Beacon E.S.O.S. Air Conditioning Left Sidelights Front Work Lights Forward/Reverse Select Horn, Wash/Wipe (Front)
Note 1: For fuse and bulb ratings see pages 50-05-01/6&7 Note 2 For Germany ONLY, Wire 9588 is not connected to Item 10 (Reverse Light Relay).
9804/1103
50 - 15 - 02/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 02/2
412S Circuit Diagrams - Electrical
To m/c no. 535116
55A 9A 71 72 14 6
844B 844C 414 420 420 413
56B
27 26 28
29 30
31
33
37
82 83
84 85 86 87
89 90 91 92 93
801 802 812 806 807
94 95 96 54A
810 304E
846B 835E 836G 846A 835D 836F
56A
62
862
17A
32 36
408 405 416 400 411 422 418
861
852
851
19
826G 844
20
21
38 39
104G 104B
42 40
104C 104H 104A 838
17 18
9508A 9508 106C
81
88
A2 C1
800B 800
A3
A7 53 B2
805 804 304C 818 817 819 816A 815 814 862
61
10
22
25
839
835
9588A
9588
813
16
7 8 1 2
50
45 23
48
803C
23 74
406
60 47 52
863
845 9584
3 4 6 5 9434 9442 9430 9474 9464 9524 9536
41
837 822 106S 104 8360 8358
003
11
840
9438 9446 9470 9460 9528 9512 9504
49
802
54 55
56 56
13
33 15 32 14 31 9 34 27 17 8 26 23 25 19 24
35
9658 9674 820
63
800 803
306
004
421 101
12
302A
4 64
15
101M
5 29 18 9666 420 9678
59 51
23
75 76 77 78 79 80 34
106A 100 300B 838 300 837A
57
9600A
22 9600
1 9650
2 9654
35
44 46
304D 105 102 100
24 58
9536A 106B 106
73
3
200 200E
101H 9612A 302 9612
107
100A
70 A4
002B 200K 002A
B3
C3
A6
200 & 200A
B6
A5
A1
000A
B1
200H
43
200F 304
C5
B4
B7
000F
000C
000
001
000
2 C2
2000 200S 200M
B5
A217091
9804/1103
50 - 15 - 02/2
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 02/3
From m/c no. 535117
17 7 2
850 855 826G
102
103 24
414
39 38 40
41 42
43
45
49
10
844B 844C
25
415
431
413
44 50 46
408 405 416 400 411 422 862A
13 5 3 8 11 14 31
844
32
33
26 27
9508A 9508 106C
18
22
34
37
839
35
51
9588A
9588
813
30
8 7 4 3
35 103
406
862
845 9584
101L
9520
2 1 6 5
52
106S 863
9516
003
C7
15
421 9600C 9600B 9600A
9434 9442 9430 9474 9464 9524
9536B
9438 9446 9470 9460 9528 9512 9504
+
002B 004 002C
23
33 15 32 14 31 8 26 23 25
9536 19 24
47
9658 9674
822
421B 421A
19 16
840 302A
4
107 307 308
21
28
5 29 18 9666 9678
106B 420
35
420A 420B
105
107
109 110
820
53
101
106F 101C
20
101M 101A
22 9600
1 9650
2 9654
35
106 104
106M
108
48
106A 109
36 29
106D 9536A
9
200 200E
12
9612A 106 101H 302 9612
B6
002 001 00H
A6
A4
B3
C3
106 200 & 200A
B7
000K
000G
000B
000L
000S
002A
000
6
200D 202
A251550
9804/1103
50 - 15 - 02/3
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 02/4
From m/c no. 535117
Main Components
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 Battery Starter Motor Starter Solenoids Start Relay Hydraulic Dump Valve Starter Switch Glow Plug 1 Glow Plug 1 Relay 60A Fuse Glow Plug 2 Glow Plug 2 Relay 60A Fuse E.S.O.S. Neutral Start Relay Park Brake Switch Park Brake Transmission Disconnect Reverse Alarm Reverse Alarm Relay Dump Pressure Switch Dump Switch Dump Switch (Loader Control) Reverse Light Relay Rear Work Light Switch Transmission Solenoids (Y1 (M1), Y2 (M2), Y3 (M3), Y4 (M4), Y5 (M5) Turbine Sensor Output Speed Sensor Throttle Switch Transmission Automatic Control Kickdown Switch (Loader Control) Transmission Hand Control Water Temperature Gauge Fuel Gauge Speedometer Timer Diode Buzzer Test Button Clutch Pressure Switch Engine Oil Pressure Switch Water Temperature Switch Vacuum Switch Transmission Oil Temperature Switch Brake Pressure Switch Alternator Hourmeter Heater Blower Resistor Heater Switch Cigar Lighter Air Conditioning Compressor Air Conditioning Pressure Switch Air Conditioning Temperature Switch Air Conditioning Switch
Lamps
101 102 103 104 105 106 107 108 109 110 Parking Brake Warning Light Reverse Light (Left Hand) Reverse Light (Right Hand) Master Warning Light Engine Oil Pressure Light Water Temperature Light Air Filter Light Transmission Oil Temperature Light Brake Pressure Light Alternator Warning Light
Fuses
A4 Reverse Alarm/Dump Switch A6 Warning Lights, Heater Fan Gauges, Cigar Lighter, Transmission Disconnect Relay, Timer and Hourmeter B3 Reversing Lights B6 E.S.O.S. B7 Air Conditioning (Optional) C3 Transmission C7 Hydraulic Dump Valve
Note 1: For fuse and bulb ratings see pages C1-1 and C1 - 2. Note 2 For Germany ONLY, Wire 9588 is not connected to Item 22 (Reverse Light Relay).
9804/1103
50 - 15 - 02/4
4170 - C/6 - 5.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 02/5

Main Components 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 Clock Column Switch Hazard Switch Hazard Relay Sidelight Switch Column Switch Fog Light Switch Work Light Relay Work Light Switch Detent Coil (Lift Arm) Proximity Switch (Lift Arm) Detent Coil (Shovel Ram) Proximity Switch (Shovel Ram) Detent Coil (Float) Brake Light Switch Tow Hitch Solenoids Tow Hitch Switch Rear Wiper Motor Rear Wash/Wipe Switch Rear Washer Motor Front Washer Motor Front Washer Switch Horn Horn Push Front Wiper Motor Front Wiper Switch Interior Light Switch Radio Fuses A1 A2 A3 A5 A7 B1 B2 B4 B5 C1 C2 C5
From m/c no. 535117
Directions Indicators Right Sidelights and Switch/Panel Illumination Fog Lights Brake Lights, Loader Arm, Shovel Reset and Tow Hitch Solenoids Main Beam Hazard Warning Lights and Clock Dip Beam Rear Wash/Wipe Interior Light, Beacon and Radio (Optional) Left Sidelights and Number Plate Lights Work Lights Horn and Front Wash/Wipe
Lamps 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 Indicator (Trailer Left Hand) Indicator (Front Left Hand) Indicator (Rear Left Hand) Indicator (Front Right Hand) Indicator (Rear Right Hand) Indicator (Trailer Right Hand) Indicator Warning Hazard Warning Light Indicator (Trailer Warning) Sidelight (Front Right Hand) Sidelight (Rear Right Hand) Trailer Light Sidelight (Front Left Hand) Sidelight (Rear Left Hand) Numberplate Light (Right Hand) Numberplate Light (Left Hand) Trailer Light Dipped Beam (Left Hand) Dipped Beam (Right Hand) Main Beam (Left Hand) Main Beam (Right Hand) Main Beam Warning Fog Lights Fog Lights (Trailer) Work Lights (Left Hand) Work Lights (Right Hand) Brake Light (Left Hand) Brake Light (Right Hand) Brake Light (Trailer) Beacon Interior Light
9804/1103
50 - 15 - 02/5
4170 - C/6-5.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 02/6
From m/c no. 535117
111 113 112
115 116
121 120
802A 802B
123
125
127 128
806A
129
131 130
807A
133 134
812B 812A 812D
135
136 63 65 67
137 138
139 69 78
863 846D 846B 864
114
122
124
801C 801A
126
132
807C 807B
835B 835E 836G 835D 836F 836J
801H 801E
806B
810A 810C
810B
810D 852 851
846A
140 70
802
141
81
117
118
801 806 807 812
104F
71
73
74 76
817 818
68
810
80
64
104B
66
104C 104H 104E
815
814
819
816
A2 55 35
C1
8008
B2
804 805
A7
A3
812C
79 61 72 75 77
304C
304E
304B
304D
60 59 54
837 8360 8358 802N 800A 306 800 104 102 105 304 803B 808
62
119
300B
803
56
100 300 838 837A
58
A1
000A
B1 57
200H 200F
C2
200S
A5
000E
B4
000C
C5
000F
B5
200M
A251560
9804/1103
50 - 15 - 02/6
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 02/7

Main Components 1 2 3 4 5 6 7A 7B 8A 8B 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Starter Switch Battery Isolator Starter Relay Starter Solenoids Starter Motor Glow Plug 1 Relay Glow Plug 2 Relay Glow Plug 1 Glow Plug 2 Shut down Relay E.S.O.S. Electronic Monitoring system (EMS) Computer Feed Relay ZF Computer Transmission Solenoids Turbine Speed Sensor Output Speed Sensor Throttle Switch Kickdown Switch Hand Controller Relays Forward/Reverse Control Relays Hand Controller Forward/Reverse Switch Reverse Alarm Relay Reverse Alarm Reverse Lights Switch Reverse Lights Relay ACCS Relay ACCS Override Switch ACCS Solenoid Valve Lamps 110 111 112
From m/c no. 535375
Fuses
6A 8A 3B 6B 8B 3C 8C Computer Feed Relay Solenoid EMS Battery Feed Reverse Alarm and Rear Work Lights Engine Shut Off System (ESOS) Thermostart EMS and ZF Computer Feed ACCS
Note: For fuse ratings see Fuses, Relays in Technical Data.
9804/1103
50 - 15 - 02/7
4170 - C/6 - 11.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 02/8

2 5 4 1 3
From m/c no. 535375
7A 8A 7B 8B
6B
10
8A 11
3C 6A
12
14 15 13
17
16 19 20
18
21 23 3B 25 27 8C 28 29
22 24
26 110 111
112
9804/1103
50 - 15 - 02/8
4170 - C/6 - 12.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 02/9

Main Components 1 11 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 Starter Switch Electronic Monitoring system (EMS) Warning Light Test Button Buzzer Fuel Contents Sender Water Temperature Sender Transmission Oil Temperature Sender Hydraulic Oil Temperature Sender Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Engine Oil Level Sensor Coolant Level Sensor Transmission Oil LevelSensor Hydraulic Oil Level Sensor Emergency Steer Switch Water in Fuel Sensor Parking Brake Switch Alternator Heater Switch Heater Relay Heater Blower Cigar Lighter Air Conditioning Switch Air Conditioning Temperature Switch Air Conditioning Pressure Switch Air Conditioning Compressor Clutch Lamps 113 Master Warning Light
From m/c no. 535375
9804/1103
50 - 15 - 02/9
4170 - C/6 - 13.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 02/10
412S Circuit Diagram - Electrical

1
From m/c no 535375
30 113 31 32 33
8A
34 35 36 11 37 38 39 40 41 42 43 44 45 46 47
48 50 51 6C 49
52 7B 53 54 55 56
50 - 15 - 02/10
4170 - C/6-14.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 02/11

Main Components 1 57 58 59 60 61 62 63 64 65 66 Starter Switch Hazard Relay Hazard Warning Switch Column Switch Diode Road Light Switch Head Light Flasher Switch Fog Light Switch Front Work Lights Switch Front Work Lights Inhibit Relay (Italy Only) Front Work Lights Relay Lamps 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134
From m/c no 535375
Trailer Indicator Warning LH Trailer Indicator LH Front Indicator LH Rear Indicator RH Front Indicator RH Rear Indicator RH Trailer Indicator RH Front Side Light RH Tail Light Trailer Switch/Panel Illumination LH Front Side Light LH Tail Light RH Number Plate Light LH Number Plate Light Trailer Dipped Beam Main Beam Fog Lights Trailer Fog Light LH Front Work Lights RH Front Work Lights
9804/1103
50 - 15 - 02/11
4170 - C/6-15.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 02/12

1
From m/c no 535375
115 1A 1B 58 116 117 57 59 118 119
114
60
120
2A
121 122 123
124 125 126 127 128
1C
2B 129 61
9C
62 7A 130
63
3A
131 132
133 65 64 2C 66 134
9804/1103
50 - 15 - 02/12
4170-C/6-16.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 02/13

Main Components 1 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 Starter Switch Lift Ram Proximity Switch Detent Coil (Lift Arm Reset) Shovel Ram Proximity Switch Detent Coil (Shovel Ram Reset) Detent Coil (Float) Brake Light Switch Tow Hitch Switch Tow Hitch Solenoids Heated Mirror Switch LH Heated Mirror RH Heated Mirror Heated Seat Switch Heated Seat Heated Seat Thermostat Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Pump Horn Front Wiper Motor Column Switch Intermittent Wiper Relay Front Washer Pump Beacon Switch Interior Light Radio (Option) Under Bonnet Lights Switch Lamps 135 136 137 138 139 140 LH Brake Light RH Brake Light Beacon Interior Light LH Under Bonnet Light RH Under Bonnet Light
From m/c no 535375
Fuses 5A 4B 5B 4C 5C Brake Lights, Float, Lift and Shovel Reset Rear Wash/Wipe Beacon, Interior Light, Radio and Under Bonnet Lights Heated Mirror and Heated Seat Front Wash/Wipe and Horn
9804/1103
50 - 15 - 02/13
4170-C/6-17.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 02/14

1 67 68 69 70 5A 71
From m/c no 535375
135 72 136 73 74 76 75 4C 78 79 80 77
81 4B 82
83 84
85
5C
86 87
88 89 137
5B 138 90
91
139 140
92
9804/1103
50 - 15 - 02/14
4170-C/6-18.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 03/1
From m/c no. 537000 to 537193
17
102
103 24
414
39 38 40
41 42
43
45
49
844B
844C
25
415
431
413
44 50 46
408 405 416 400 411 422 862A
13 31
826G 844
32
33
26 27
9508A 9508 106C
14
18
22
34
37
839
35
51
002C 9588A 9588 813
30
8 7 4 3
35 103
406
862
845 9584
101L
9520
2 1 6 5
52
106S 863
9516
003
C7
15
421 9600C 9600B 9600A
9434 9442 9430 9474 9464 9524
9536B
9438 9446 9470 9460 9528 9512 9504
+
002B 004
23
33 15 32 14 31 8 26 23 25
9536 19 24
47
9658 9674
822
421B 421A
19 16
840 302A
4
107
21
28
5 29 18 9666 9678
106B 420
35
420A 420B
105
107
109 110
820
53
101
106F 101C
20
101M 101A
22 9600
1 9650
2 9654
35
106 104
106M
108
48
106A 109
36 29
106D 9536A
9612A 106 200 200E 101H 302 9612
B6
002 001 00H
A6
A4
B3
C3
106 200 & 200A
B7
000K
000G
000B
000L
000S
002A
000
6
200D
9804/1103
50 - 15 - 03/1
3270 - E/6-2.4
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 03/2

Main Components 1 Battery 2 Starter Motor 3 Starter Solenoids 4 Start Relay 5 Hydraulic Dump Valve 6 Starter Switch 7 Thermostart 13 E.S.O.S. 14 Neutral Start Relay 15 Park Brake Switch 16 Park Brake Transmission Disconnect 17 Reverse Alarm 18 Reverse Alarm Relay 19 Dump Pressure Switch 20 Dump Switch 21 Dump Switch (Loader Control) 22 Reverse Light Relay 23 Rear Work Light Switch 24 Transmission Solenoids (Y1 (M1), Y2 (M2), Y3 (M3), Y4 (M4), Y5 (M5) 25 Turbine Sensor 26 Output Speed Sensor 27 Throttle Switch 28 Transmission Automatic Control 29 Kickdown Switch (Loader Control) 30 Transmission Hand Control 31 Water Temperature Gauge 32 Fuel Gauge 33 Speedometer 34 Timer 35 Diode 36 Buzzer 37 Test Button 38 Clutch Pressure Switch 39 Engine Oil Pressure Switch 40 Water Temperature Switch 41 Vacuum Switch 42 Transmission Oil Temperature Switch 43 Brake Pressure Switch 44 Alternator 45 Hourmeter 46 Heater Blower 47 Resistor 48 Heater Switch 49 Cigar Lighter 50 Air Conditioning Compressor 51 Air Conditioning Pressure Switch 52 Air Conditioning Temperature Switch 53 Air Conditioning Switch
*From m/c no 537000 to 537193
Lamps 101 Parking Brake Warning Light 102 Reverse Light (Left Hand) 103 Reverse Light (Right Hand) 104 Master Warning Light 105 Engine Oil Pressure Light 106 Water Temperature Light 107 Air Filter Light 108 Transmission Oil Temperature Light 109 Brake Pressure Light 110 Alternator Warning Light Fuses A4 A6 A7 B3 B6 B7 C3 C7 Reverse Alarm/Dump Switch Warning Lights, Heater Fan,Gauges, Cigar Lighter, Transmission Disconnect Relay, Timer and Hourmeter Main Beam Reversing Lights E.S.O.S. Air Conditioning (Optional) Transmission Hydraulic Dump Valve
Note 1: For fuse and bulb ratings see pages 50-05-01/6&8 Note 2 For Germany ONLY, Wire 9588 is not connected to Item 22 (Reverse Light Relay).
50 - 15 - 03/2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 03/3

Main Components 54 Clock 55 Column Switch 56 Hazard Switch 57 Hazard Relay 58 Sidelight Switch 59 Column Switch 60 Fog Light Switch 61 Work Light Relay 62 Work Light Switch 63 Detent Coil (Lift Arm) 64 Proximity Switch (Lift Arm) 65 Detent Coil (Shovel Ram) 66 Proximity Switch (Shovel Ram) 67 Detent Coil (Float) 68 Brake Light Switch 69 Tow Hitch Solenoids 70 Tow Hitch Switch 71 Rear Wiper Motor 72 Rear Wash/Wipe Switch 73 Rear Washer Motor 74 Front Washer Motor 75 Front Washer Switch 76 Horn 77 Horn Push 78 Front Wiper Motor 79 Front Wiper Switch 80 Interior Light Switch 81 Radio Lamps 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 Indicator (Trailer Left Hand) Indicator (Front Left Hand) Indicator (Rear Left Hand) Indicator (Front Right Hand) Indicator (Rear Right Hand) Indicator (Trailer Right Hand) Indicator Warning Hazard Warning Light Indicator (Trailer Warning) Sidelight (Front Right Hand) Sidelight (Rear Right Hand) Trailer Light Sidelight (Front Left Hand) Sidelight (Rear Left Hand) Numberplate Light (Right Hand) Numberplate Light (Left Hand) Trailer Light Dipped Beam (Left Hand) Dipped Beam (Right Hand) Main Beam (Left Hand) Main Beam (Right Hand) Main Beam Warning Fog Lights Fog Lights (Trailer) Work Lights (Left Hand) Work Lights (Right Hand) Brake Light (Left Hand) Brake Light (Right Hand) Brake Light (Trailer) Beacon Interior Light Fuses A1 A2 A3 A5 A7 B1 B2 B4 B5 C1 C2 C5
*From m/c no 537000 to 537193
Direction Indicators Right Sidelights and Switch/Panel Illumination Fog Lights Brake Lights, Loader Arm, Shovel Reset and Tow Hitch Solenoids Main Beam Hazard Warning Lights and Clock Dip Beam Rear Wash/Wipe Interior Light, Beacon and Radio (Optional) Left Sidelights and Number Plate Lights Work Lights Horn and Front Wash/Wipe
Note 1: For fuse and bulb ratings see pages 50-05-01/6&8
9804/1103
50 - 15 - 03/3
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 04/1
409 Telemaster Circuit Diagrams - Electrical
1
22A B A C
950
647E
4 D
B7
+12v
22
951
647D
4
647G
7
1 -ve 2 +ve
2
A B 957 4 2
3
22B 5 1 3
952
647C
3 451 452 450
5 C
954 647F
452A
452B
2
A 2 1 B 955 4 2
3
6 22C 22D 5 1 3
953
647B
956 5
6
647A
647
A233140
Main Components and Switches 1 2 3 4 5 6 7 C D Solenoid Control Switch - Boom Extend/Retract Solenoid Control Switch - Auxiliary Service Solenoid Relays Solenoids - Boom Extend/Retract Valve Solenoids - Auxiliary Valve Safe Load Indicator Strain Gauge Connections to Auxiliary Solenoid Control Valve C Connections to Boom Extend/Retract
9804/1103
50 - 15 - 04/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 03/5
414S From m/c no. 537194 416S From m/c no. 543000 Circuit Diagram - Electrical
Main Components 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 Starter Switch Battery Isolator Starter Relay Starter Solenoids Starter Motor Not Used Thermostart Coil Shut down Relay E.S.O.S. Electronic Monitoring system (EMS) Computer Feed Relay ZF Computer Transmission Solenoids Turbine Speed Sensor Output Speed Sensor Throttle Switch Kickdown Switch Hand Controller Relays Forward/Reverse Control Relays Hand Controller Forward/Reverse Switch Reverse Alarm Relay Reverse Alarm Reverse Lights Switch Reverse Lights Relay ACCS Relay ACCS Override Switch ACCS Solenoid Valve Lamps 110 111 112 LH Reverse Light RH Reverse Light ACCS Operating Indication Light
Fuses 6A 8A 3B 6B 8B 3C 8C Computer Feed Relay Solenoid EMS Battery Feed Reverse Alarm and Rear Work Lights Engine Shut Off System (ESOS) Thermostart EMS and ZF Computer Feed ACCS
9804/1103
50 - 15 - 03/5
4170-C/6-19.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 03/6
2 2 3 5 4 1 8B 8 6
6B
10
8A 11
3C 6A
12
15
14 13
17
16
19
20
18
21
22 24 23
3B 25
26 110
27 8C 28 29
111
112
9804/1103
50 - 15 - 03/6
4170-C/6-20.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 03/7
Main Components 1 11 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 Starter Switch Electronic Monitoring system (EMS) Warning Light Test Button Buzzer Fuel Contents Sender Water Temperature Sender Transmission Oil Temperature Sender Hydraulic Oil Temperature Sender Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Engine Oil Level Sensor Coolant Level Sensor Transmission Oil LevelSensor Hydraulic Oil Level Sensor Emergency Steer Switch Water in Fuel Sensor Parking Brake Switch Alternator Heater Switch Heater Relay Heater Blower Cigar Lighter Air Conditioning Switch Air Conditioning Temperature Switch Air Conditioning Pressure Switch Air Conditioning Compressor Clutch Lamps 113 Master Warning Light
9804/1103
50 - 15 - 03/7
4170-C/6-21.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 03/8
1
30 113 31 32 33
8A
34 35 36 11 37 38 39 40 41 42 43 44 45 46 47
48 50 51 6C 49
52 7B 53 54 55 56
9804/1103
50 - 15 - 03/8
4170-C/6-22.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 03/9
Main Components 1 57 58 59 60 61 62 63 64 65 66 Starter Switch Hazard Relay Hazard Warning Switch Column Switch Diode Road Light Switch Head Light Flasher Switch Fog Light Switch Front Work Lights Switch Front Work Lights Inhibit Relay (Italy Only) Front Work Lights Relay Lamps 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 Trailer Indicator Warning LH Trailer Indicator LH Front Indicator LH Rear Indicator RH Front Indicator RH Rear Indicator RH Trailer Indicator RH Front Side Light RH Tail Light Trailer Switch/Panel Illumination LH Front Side Light LH Tail Light RH Number Plate Light LH Number Plate Light Trailer Dipped Beam Main Beam Fog Lights Trailer Fog Light LH Front Work Lights RH Front Work Lights
9804/1103
50 - 15 - 03/9
4170-C/6-23.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 03/10
414S From m/c no. 537194 416S From m.c no. 543000 Circuit Diagram - Electrical
1
115 1A 1B 58 116 117 57 59 118 119
114
60
120
2A
121 122 123
124 125 126 127 128
1C
2B 129 61
9C
62 7A 130
63
3A
131 132
133 65 64 2C 66 134
9804/1103
50 - 15 - 03/10
4170-C/6-24.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 03/11
Main Components 1 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 Starter Switch Lift Ram Proximity Switch Detent Coil (Lift Arm Reset) Shovel Ram Proximity Switch Detent Coil (Shovel Ram Reset) Detent Coil (Float) Brake Light Switch Tow Hitch Switch Tow Hitch Solenoids Heated Mirror Switch LH Heated Mirror RH Heated Mirror Heated Seat Switch Heated Seat Heated Seat Thermostat Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Pump Horn Front Wiper Motor Column Switch Intermittent Wiper Relay Front Washer Pump Beacon Switch Interior Light Radio (Option) Under Bonnet Lights Switch Lamps 135 136 137 138 139 140 LH Brake Light RH Brake Light Beacon Interior Light LH Under Bonnet Light RH Under Bonnet Light
Fuses 5A Brake Lights, Float, Lift and Shovel Reset
4B Rear Wash/Wipe 5B Beacon, Interior Light, Radio and Under Bonnet Lights 4C 5C Heated Mirror and Heated Seat Front Wash/Wipe and Horn
9804/1103
50 - 15 - 03/11
4170-C/6-25.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 03/12
1 67 68 69 70 5A 71 135 72 136 73 74 76 75 4C 78 79 80 77
81 4B 82
83 84
85
5C
86 87
88 89 137
5B 138 90
91
139 140
92
9804/1103
50 - 15 - 03/12
4170-C/6-26.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 04/1
409 Telemaster Circuit Diagrams - Electrical
1
22A B A C
950
647E
4 D
B7
+12v
22
951
647D
4
647G
7
1 -ve 2 +ve
2
A B 957 4 2
3
22B 5 1 3
952
647C
3 451 452 450
5 C
954 647F
452A
452B
2
A 2 1 B 955 4 2
3
6 22C 22D 5 1 3
953
647B
956 5
6
647A
647
A233140
Main Components and Switches 1 2 3 4 5 6 7 C D Solenoid Control Switch - Boom Extend/Retract Solenoid Control Switch - Auxiliary Service Solenoid Relays Solenoids - Boom Extend/Retract Valve Solenoids - Auxiliary Valve Safe Load Indicator Strain Gauge Connections to Auxiliary Solenoid Control Valve C Connections to Boom Extend/Retract
9804/1103
50 - 15 - 04/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 04/2
407B ZX, 408B ZX, 409B ZX Circuit Diagrams - Electrical Main Components
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Battery Thermostart Starter Motor Starter Solenoid Neutral Start Relay 1 Starter Switch Ignition Relay 1 Forward Relay Forward/Reverse Switch Forward Solenoid Transmission Dump Relay Reverse Solenoid Reverse Relay Diode Diode Reverse Alarm Speed Control Relay Speed Control Switch Diode Speed Control Unit Neutral Start Relay 2 Parking Brake Switch Parking Brake Light Relay Servo Cut-off Solenoid Servo Arm Switch Servo Cut-off Switch Junction Box E.S.O.S. Hazard Warning Light Switch Direction Indicator Switch Diode Flasher Unit Trailer Indicator Alarm (option) Water Temperature Sender Water Temperature Gauge Hydraulic Oil Temperature Sender Hydraulic Oil Temperature Gauge Fuel Sender Fuel Gauge Hourmeter Alternator Buzzer Warning Light Panel Water Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Filter Blockage Switch Hydraulic Filter Blockage Switch
m/cs to 755182
Lamps
104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 Servo Cut-off Switch LH Trailer Indicator LH Front Indicator LH Rear Indicator Hazard Switch RH Trailer Indicator RH Front Indicator RH Rear Indicator Water Temperature Gauge Hydraulic Oil Temperature Gauge Fuel Gauge Indicator Warning Master Warning Master Warning Master Warning Master Warning Alternator Warning Water Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Filter Blockage Warning Hydraulic Filter Blockage Warning Main Beam Warning
Fuses
A2 A6 B1 B2 B6 C2 C3 C5 Warning Lights and Buzzer Hazard Warning Junction Box E.S.O.S. Direction Indicators Speed Control Unit and Servo Cut-off Solenoid Forward/Reverse Relay and Reverse Alarm Thermostart
Note 1: For fuse and bulb ratings see page 50-05-01/9
9804/1103
50 - 15 - 04/2
Issue 1
CONTENTS
Wheeled Loaders
50-15-04/3
407B ZX, 408B ZX, 409B ZX Circuit Diagram - Electrical (continued)
m/cs to 755182
10 2 3 4
12
16
22 24 28 23
105 107
109 111 34 36 38 41 44 46 48 45 47
17 8 13 18 14 15
20
106 27 25 21 30
110
33
43 42 31 35
112
37
113
39 40
114
116 118 120 122 124 126 115 117 119 121 123 125
1 5 9 19
26 104 29
32
11 C5 C3 6 7 C2 B1 B2
108
B6
A6
A2
A244950
9804/1103Issue 1
50-15-04/3
CONTENTS
Wheeled Loaders
50-15-04/4
407B ZX, 408B ZX, 409B ZX Circuit Diagram - Electrical (continued)
m/cs to 755182
129 130 128 49 51 56 131 58 60 61 135 133 136 137
139 140 138 141
143 144 145 68 148 150 73 152 75 76 154
77
85 90 82 86 91
79
80 87
B4 134 63 55 50 52 57 62 132 59 C4 64
142 B3 A3 65 A4
146 69 78
88
92 149 151 72 74 153 89 83 155
147 66
71
C6 70
127
156 84 C1 81 93
157
B5 A1 A5 A9
53 B7
A7 67 54
A8
B9
94 B8
A244960
9804Issue 1
50-15-04/4
CONTENTS
Wheeled Loaders
50 - 15 - 04/5
407B ZX, 408B ZX, 409B ZX Circuit Diagrams - Electrical (continued) Main Components
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 Loader Auxiliary 1 Solenoids Loader Auxiliary 1 Switch Loader Auxiliary 2 Solenoids Loader Auxiliary 2 Switch Auxiliary 2 Hydraulics Switch Ignition Relay 2 Brake Light Switch Rear Wiper Rear Wash/Wipe Switch Front Washer Pump Front Wash/Wipe Switch Front Wiper Motor Horn Horn Switch Fog Light Switch Head Light Flasher Dipswitch Road Lights Switch Road Lights Relay Cigar Lighter Clock Front Work Lights Relay Front Work Lights Switch Rear Work Lights Switch Beacon Beacon Switch Interior Light Radio (option) LH Speaker RH Speaker Hydraulic Cooler Fan Switch Hydraulic Cooler Fan Motor Hydraulic Cooler Fan Relay
m/cs to 755182
Lamps
127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 Auxiliary 2 Hydraulics Switch LH Brake Light LH Trailer Brake Light RH Trailer Brake Light RH Brake Light Rear Wash/Wipe Switch Fog Light Fog Light Switch LH Main Beam RH Main Beam LH Dip Beam RH Dip Beam LH Trailer Light LH Number Plate Light LH Tail Light LH Side Light RH Trailer Light RH Number Plate Light RH Tail Light RH Side Light Road Lights Switch Front Work Lights Front Work Lights Switch Rear Work/Reverse Light Rear Work/Reverse Light Switch Beacon Beacon Switch Interior Light Air Conditioning Switch
Machines with Air Conditioning 156 Heater Switch
Machines with Air Conditioning 82 83 84 85 86 87 88 89 90 Heater Motor Heater Resistor Heater Switch High Pressure Switch Low Pressure Switch Freeze Valve Air Condioning Relay Air Conditioning Switch Air Conditioning Compressor Clutch
Machines with Heater 157 Heater Switch
Fuses
A1 A3 A4 A5 A7 A8 A9 B3 B4 B5 B7 B8 B9 C1 C4 C6 94 Brake Lights LH Side/Tail Lights and LH Number Plate Light RH Side/Tail Lights and RH Number Plate Light Rear Wash/Wipe Beacon, Clock and Front Wiper Radio and Interior Light Front Wash/Wipe, Headlight Flasher and Horn Dip Beam Main Beam Front Work Lights Servo Control Lever Switches Air Conditioning and Heater Hydraulic Cooler Fan Relay Rear Work/Reverse Light Fog Light Cigar Lighter In-line Fuse (Hydraulic Cooler Fan)
Machines with Heater 91 92 93 Heater Motor Heater Resistor Heater Switch
9804/1103
50 - 15 - 04/5
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 05/1
407B ZX, 408B ZX, 409B ZX Circuit Diagrams - Electrical Main Components
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Battery Thermostart Starter Motor Starter Solenoid Neutral Start Relay 1 Starter Switch Ignition Relay 1 Forward Relay Forward/Reverse Switch Forward Solenoid Transmission Dump Relay Reverse Solenoid Reverse Relay Diode Diode Reverse Alarm Speed Control Relay Speed Control Switch Speed Control Unit Neutral Start Relay 2 Parking Brake Switch Servo Cut-off Solenoid Servo Arm Switch Servo Cut-off Switch Junction Box E.S.O.S. Hazard Warning Light Switch Direction Indicator Switch Diode Flasher Unit Water Temperature Sender Water Temperature Gauge Hydraulic Oil Temperature Sender Hydraulic Oil Temperature Gauge Fuel Sender Fuel Gauge Hourmeter Alternator Buzzer Warning Light Panel Water Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Filter Blockage Switch
m/cs from 755183
Lamps
104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 Servo Cut-off Switch LH Trailer Indicator LH Front Indicator LH Rear Indicator Hazard Switch RH Trailer Indicator RH Front Indicator RH Rear Indicator Water Temperature Gauge Hydraulic Oil Temperature Gauge Fuel Gauge Indicator Warning Parking Brake Warning Parking Brake Warning Parking Brake Warning Parking Brake Warning Alternator Warning Water Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Filter Blockage Warning Hazard Warning Main Beam Warning
Fuses
A2 A6 B1 B2 B6 B9 C2 C3 Warning Lights and Buzzer Hazard Warning Junction Box E.S.O.S. Direction Indicators Thermostart Speed Control Unit and Servo Cut-off Solenoid Forward/Reverse Relay and Reverse Alarm
9804/1103
50 - 15 - 05/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 06/1
410B ZX Circuit Diagrams - Electrical

Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Battery Thermostart Starter Motor Starter Solenoid Neutral Start Relay 1 Starter Switch Ignition Relay 1 Forward Relay Forward/Reverse Switch Forward Solenoid Transmission Dump Relay Reverse Solenoid Reverse Relay Brake Assist Switch Diode Reverse Alarm Speed Control Relay Speed Control Switch Speed Control Unit Park Brake Light Relay Parking Brake Switch Servo Cut-off Solenoid Servo Arm Switch Servo Cut-off Switch Junction Box E.S.O.S. Hazard Warning Light Switch Direction Indicator Switch Diode Flasher Unit Water Temperature Sender Water Temperature Gauge Hydraulic Oil Temperature Sender Hydraulic Oil Temperature Gauge Fuel Sender Fuel Gauge Hourmeter Alternator Buzzer Warning Light Panel Water Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Filter Blockage Switch Lamps 102 103 104 105 106 107 107A 108 109 110 111 111A 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 Fuses A2 A6 B1 B2 B6 B9 C1 C2 C3
*To m/c no. 755490
Forward Indicator Light Reverse Indicator Light Servo Cut-off Switch LH Trailer Indicator LH Front Indicator LH Rear Indicator LH Reverse Light Hazard Switch RH Trailer Indicator RH Front Indicator RH Rear Indicator RH Reverse Light Water Temperature Gauge Hydraulic Oil Temperature Gauge Fuel Gauge Indicator Warning Master Warning - Park Brake Master Warning - Park Brake Master Warning - Park Brake Master Warning - Park Brake Alternator Warning Water Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Filter Blockage Warning Hazard Warning Main Beam Warning
Warning Lights and Buzzer Hazard Warning Junction Box E.S.O.S. Direction Indicators Hydraulic Oil Cooler Relay (when fitted) Thermostart Speed Control Unit and Servo Cut-off Solenoid Forward/Reverse Relay and Reverse Alarm
9804/1103
50 - 15 - 06/1
Issue 2*
CONTENTS
Loadalls
50 - 15 - 06/2
410B ZX Circuit Diagrams - Electrical (continued)
*To m/c no. 755490
800AC
102
812H
3 4 21
10
811H
103 107A 16 12 111A
105 107 22 26
109 111 31 33 35 38 41 43 42 44
800AD
811
106 19 25
805
110
800FA
800
842
815
812
461
408
409
407
13
107E
17 23
868
406
404
403
806
40 39
107B 808 809 815A
14
870 888 979 105
28
7 10
29 30
802
32
112
34
113
36 37
114
116 118 120 122 124 126 115 117 119 121 123 125
20 1 5
824A 810 912
18 9
24
5 9
104 27
803 7 1 3
6 830
15
824 107M 107N
11
108
101 10 5 8 104 2 300
123
004
C1 6
824 003
107
C3
002
C2
B1
B2
002
B6
A6
A2
7
948A 001
200
402
A276890
9804/1103
50 - 15 - 06/2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 06/3
410B ZX Circuit Diagram - Electrical (continued)
*To m/c no. 755490
800KM
800GE
600HX
600HY
600KN
800GF
800FU
800FF
129 130 128 131 59

M M
139 133A 62 61
M
133
135
137 140
143 144 145 148 148A 72

M
76 74 75 152
602
971
972
50
52
136
837
138
834
141
829
81
M
814
816
103
839
50A
50B
B4 134
836
142 B3
833
830
57A
57
150 146 69
855 855 894
860
77
958
959
64
863 862 840 841 868
A3 A4
828
51
125
56
864
60 132 58 63
65
832 110
66
C4
149 147 71
117
149A 71A
116
82 73 151
67
009 200
830
830
941
108
70
103 110
153 83 C5
127
B5
54 B7
A1
A5
A9
007
A7 68
A8 B8
55
A276900
9804/1103
50 - 15 - 06/3
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 06/4
410B ZX Circuit Diagrams - Electrical (continued)

Main Components 50 50A 50B 51 52 53 54 55 56 57 57A 58 59 60 61 62 63 64 65 66 67 68 69 70 71 71A 72 73 74 75 76 77 78 79 80 81 82 83 Loader Auxiliary 1 Solenoids Auxiliary 1 Relay Auxiliary 2 Relay Loader Auxiliary 1 Switch Loader Auxiliary 2 Solenoids Auxiliary 2 Hydraulics Switch Ignition Relay 2 Brake Light Switch Rear Wiper Rear Washer Pump Rear Wash/Wipe Switch Front Washer Pump Front Wash/Wipe Switch Front Wiper Motor Horn Horn Switch Fog Light Switch Head Light Flasher Dipswitch Road Lights Switch Road Lights Relay Clock Front Work Lights Relay Front Work Lights Switch Rear Work Lights Switch Beacon Beacon Switch Interior Light Radio (option) LH Speaker RH Speaker Hydraulic Cooler Fan Switch Hydraulic Cooler Fan Motor Hydraulic Cooler Fan Relay Heater Motor Heater Resistor Heater Switch Lamps 127 128 129 130 131 132 133 133A 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 148A 149 149A 150 151 152 153 * Fuses A1 A3 A4 A5 A7 A8 A9 B3 B4 B5 B7 B8 C4 C5
*To m/c no 755490
Auxiliary 2 Hydraulics Switch LH Brake Light LH Trailer Brake Light RH Trailer Brake Light RH Brake Light Rear Wash/Wipe Switch RH Fog Light LH Fog Light Fog Light Switch LH Main Beam RH Main Beam LH Dip Beam RH Dip Beam LH Trailer Light LH Number Plate Light LH Tail Light LH Side Light RH Trailer Light RH Number Plate Light RH Tail Light RH Side Light Road Lights Switch Front Work Lights Rear Work Lights Front Work Lights Switch Rear Work Lights Switch Beacon Beacon Switch Interior Light Heater Switch
Brake Lights LH Side/Tail Lights and LH Number Plate Light RH Side/Tail Lights and RH Number Plate Light/ Front Work Lights Relay Rear Wash/Wipe Beacon, Clock and Front Wiper Radio and Interior Light Front Wash/Wipe, Headlight Flasher and Horn Dip Beam Main Beam Front Work Lights Servo Control Lever Switches and Auxiliary Solenoids Heater Motor Fog Light Rear Work Lights
84
In-line Fuse (Hydraulic Cooler Fan) (Option - may be fitted)
9804/1103
50 - 15 - 06/4
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 06/5
407B ZX, 408B ZX, 409B ZX from m/c no. 755491 to 757399 410B ZX, 411B ZX from m/c no. 755491 Circuit Diagrams - Electrical Main Components
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Battery Thermostart Starter Motor Starter Solenoid Neutral Start Relay Key Switch Parkbrake Switch Parkbrake Light Relay Ignition Relay 1 Forward Relay Forward/Reverse Switch Forward Solenoid Transmission Dump Relay Reverse Solenoid Reverse Relay Reverse Alarm Speed Control Relay Brake Assist Switch Speed Control Switch Speed Control Unit Servo Cut-off Solenoid Servo Arm Switch Servo Cut-off Switch Junction Box Engine Shut-off Solenoid Indicator Switch Hazard Switch Flasher Unit Water Temperature Sender Water Temperature Gauge Hydraulic Oil Temperature Sender Hydraulic Oil Temperature Gauge Fuel Sender Fuel Gauge Hourmeter Alternator Warning Buzzer Brake Malfunction Switch Water Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Filter Blockage Switch Warning Light Panel
Lamps
100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 Forward Indicator Light Reverse Indicator Light LH Reversing Light RH Reversing Light Speed Control Servo Cut-off LH Trailer Indicator LH Front Indicator LH Rear Indicator Hazard Warning RH Trailer Indicator RH Front Indicator RH Rear Indicator Water Temperature Gauge Hydraulic Oil Temperature Gauge Fuel Gauge Turn Signal Master Warning Master Warning Alternator Warning Hydraulic Oil Pressure Warning Brake Malfunction Warning Water Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Filter Blockage Warning Hazard Warning Main Beam Warning
Fuses
A2 A6 B1 B2 B6 C1 C2 C3 Warning Lights and Buzzer Hazard Warning Junction Box Engine Shut-off Solenoid Direction Indicators Thermostart Speed Control Unit and Servo Cut-off Forward, Reverse and Transmission Dump Relays
9804/1103
50 - 15 - 06/5
4210 - C/6-13.2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 06/6
407B ZX, 408B ZX, 409B ZX from m/c no. 755491 to 757399 410B ZX, 411B ZX from m/c no. 755491 Circuit Diagrams - Electrical (continued)
100
101 102 103
106
108
110
112
3 4
16 12 14 20 10 15 17 24 26 18 21 25 107 111
36 29 31 33
38 40 42 39 41
43 30 32 113 34 35 114 115 37 117 119 121 123 125 127 116 118 120 122 124 126
22 8 19 11 5 13 109 C1 6 9 C3 C2 B1 B2 B6 104 23 105 27
28
A6
A2
A296120
9804/1103
50 - 15 - 06/6
4210 - C/6-14.2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 06/7
407B ZX, 408B ZX, 409B ZX from m/c no. 755491 to 757399 410B ZX, 411B ZX from m/c no. 755491 Circuit Diagrams - Electrical (continued)
130 44 45 46 47 129 131 53 132

M
135 134 55
M M
141 137 140 142 143
145 146 147 148 150 151 153 154 69

M
73
58 56
M
138 139
72 156 71
75
77
M
78
M
52
144 60 136 B4 B3
68
2 B A
158
74
978 977
48
51
57 54 133 C4 59
61
62 A3 63
A4 152 149 66 67 155
79
70 157
65 128 49 B7 64 50 A7 A8 A1 A5 A9 B5 C5 76
80 159
128
160 B8
001
A296130
9804/1103
50 - 15 - 06/7
4210 - C/6-15.2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 06/8
407B ZX, 408B ZX, 409B ZX from m/c no. 755491 to 757399 410B ZX, 411B ZX from m/c no. 755491 Circuit Diagrams - Electrical (continued) Main Components
44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 Loader Auxiliary 1 Solenoids Loader Auxiliary 1 Relay 1 Loader Auxiliary 1 Relay 2 Loader Auxiliary 2 Solenoids Joystick Switch Auxiliary 1 Loader Auxiliary 2 Hydraulics Switch Ignition Relay 2 Brake Lights Switch Rear Washer Pump Rear Wiper Rear Wash/wipe Switch Front Washer Pump Front Wiper Front Wash/wipe Switch Horn Horn Switch Fog Light Switch Headlight Flasher Switch Dipped Headlight Switch Road Lights Switch Road Lights Relay Front Work Lights Relay Front Work Lights Switch Rear Work Lights Switch Clock Beacon Beacon Switch Interior Light Switch Radio (if fitted) LH Speaker (if fitted) RH Speaker (if fitted) Oil Cooler Fan Switch (407B ZX, 408B ZX, 409B ZX) Oil Cooler Relay (407B ZX, 408B ZX, 409B ZX) Oil Cooler Fan Motor (407B ZX, 408B ZX, 409B ZX) Heater Motor Heater Resistor Heater Switch
Lamps
128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 Loader Auxiliary 2 Hydraulics Switch LH Brake Light LH Trailer Brake Light RH Trailer Brake Light RH Brake Light Rear Wash/wipe Switch Light LH Fog Light RH Fog Light Fog Light Switch LH Main Beam RH Main Beam LH Dip Beam RH Dip Beam LH Trailer Light LH Number Plate Light LH Tail Light LH Side Light RH Trailer Light RH Number Plate Light RH Tail Light RH Side Light Road Lights Switch Front Work Light Front Work Light Front Work Light Switch Rear Work Light Rear Work Light Rear Work Light Switch Beacon Beacon Switch Interior Light Heater Switch
Fuses
A1 A3 A4 A5 A7 A8 A9 B3 B4 B5 B7 B8 C4 C5 160 Brake Lights LH Side/tail and Number Plate Lights RH Side/tail and Number Plate Lights Rear Wash/wipe Beacon Interior Light and Radio Front Wash/wipe, Horn and Headlight Flasher Dip Beam Main Beam Front Work Lights Auxiliary Hydraulics Heater Fog Lights Rear Work Lights In-line Fuse, Oil Cooler (407B ZX, 408B ZX, 409B ZX)
9804/1103
50 - 15 - 06/8
4210-C/6-16.2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 06/8A
407B ZX, 408B ZX, 409B ZX Circuit Diagrams - Electrical (continued)
From m/c no. 757400
Main Components
1 2 3 4 5 6 7 8 9 10 11 12 13 14 14A 15 16 17 17A 18 18A 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Battery Thermostart Starter Motor Starter Solenoid Neutral Start Relay Key Switch Parkbrake Switch Parkbrake Light Relay Ignition Relay 1 Forward Relay Forward/Reverse Switch Forward Solenoid Transmission Dump Relay Pump Reverse Solenoid Motor Reverse Solenoid Reverse Relay Reverse Alarm Low Speed Solenoid Creep Speed Solenoid Brake Assist Switch Transmission Pressure Switch Speed Control Switch Speed Control Unit Servo Cut-off Solenoid Servo Arm Switch Servo Cut-off Switch Junction Box Engine Shut-off Solenoid Indicator Switch Hazard Switch Flasher Unit Water Temperature Sender Water Temperature Gauge Hydraulic Oil Temperature Sender Hydraulic Oil Temperature Gauge Fuel Sender Fuel Gauge Hourmeter Alternator Warning Buzzer Brake Malfunction Switch Water Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Filter Blockage Switch Warning Light Panel
Lamps
100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 Forward Indicator Light Reverse Indicator Light LH Reversing Light RH Reversing Light Speed Control Servo Cut-off LH Trailer Indicator LH Front Indicator LH Rear Indicator Hazard Warning RH Trailer Indicator RH Front Indicator RH Rear Indicator Water Temperature Gauge Hydraulic Oil Temperature Gauge Fuel Gauge Turn Signal Master Warning Master Warning Alternator Warning Hydraulic Oil Pressure Warning Brake Malfunction Warning Water Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Filter Blockage Warning Hazard Warning Main Beam Warning
Fuses
A2 A6 B1 B2 B6 C1 C2 C3 C6 Warning Lights and Buzzer Hazard Warning Junction Box Engine Shut-off Solenoid Direction Indicators Thermostart Speed Control Unit and Servo Cut-off Forward, Reverse and Transmission Dump Relays Speed Control Unit
9804/1103
50 - 15 - 06/8A
4210 - C/6 - 17.1
Issue 1
CONTENTS
824
824A
3
407B ZX, 408B ZX, 409B ZX
100
F 809 107
107A/G
5
14
107M
4 3
9804/1103
1
600
C1
123
003
5 3 4
3 4 5
004 842
2
6
1
967
600W
9 7 8
4 2
600BF
815
600FR
810
002
824
946A
001
Circuit Diagrams - Electrical (continued)
200
10
600AC
812H
11
N
600BX
600BS
C3
812 812
12
R 875
13
107N 815A
811H
600AD
101
600CA
600BT
809 811
875A
600NE
811J
19 15
113C
969C
600JV
811F
102
18
Wheeled Loaders
50 - 15 - 06/8B
811G
600JL
113E 969E
14A 103
600CD
811A
16
18A
969D
113D 113B
600NF
969
3
969B
7 5 1
17A
C6
113A
8 6 4
600ND
1805
969A
2 10 9
20
1805A
600HN
22
17 21
104
600JR
C2
124
106Y
979
10 9
980
600JS
23 105
101
24
600CC
B1 B2
804 803
803
25
600
105
600DX
107
109
106 108 110 112
002 104
805
600G
106F
26
805B 10
7 803A 806B 1 805 5 3 8 6 804A 49a 31 803
27
802
49
111
600H
806
600BL
B6 A6
824 200
300
28
30
S
29
806H 106D
409
106X
+ 830W
600JC 600HW
113
S
31
32
461
106W
+ 830V
600JB
600HV
114
S
34
408
106V
33
+
830U
600JA
600HT
115 35
1 2
4 4 0 3
600HS
36
407
824
37
106E
4210 - C/6 - 18.1

5 12 106B
117 119 121 123 125 127 116 118 120 122 124 126
A2
11
10
38
14
13
600EK
458
9
600CK
406
8
600C
404
7
39 41
403
6
600CF
40 42
402
804
3 2
600EK
43
600
946A
837D
106
200
001
007
830
From m/c no. 757400
A370910
50 - 15 - 06/8B
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 06/8C
407B ZX, 408B ZX, 409B ZX Circuit Diagrams - Electrical (continued)
From m/c no. 757400
600
130
600KM
600HX
600HY
600KN
600GE
600FF
600GF
600BG
600AK
600AK
600BJ
600FU
600BP
600BD
600LV
600AK
600LV
600FJ
135 134
600G
600H
600?
600?
600?
600?
600?
600?
600?
141
145
601
44
971
131
972
137
835
45
2 1
47 129
816D
1 2
53
103
859
55
M
140 142 139 143

834 829
146 147 148

830
150
153 72 69
M
73 75
M
860
132 52
816E
M M
58
837 814
77
M
78
156
602
138 B3
144
151
154 71 158 68
S-839
125F
125G
958
959
816
863A
836
833
855
840
841
862
868
304
978
816
125B
864
54
828
C4
832
5 10 1
10
149 63
3 2 9 5 9 5 9
800B
800A
51
125
982 981 837D
110
133
59
152
009 200 116 117
155
157
800
83 159
600FB B5
830
830
941A
941
946A
110
126A
L1 64 A7
200
81
102D
007
007
+8
A8
B9
001
50
001
B8
200 106
200 106
A370920
9804/1103
50 - 15 - 06/8C
4210 - C/6 - 19.1
102DF
82
102D
701/60001
A1
A5
A9
009
126
B7
125A
49
102DA
10
303
B5
C5
102DA
128
108A
80
116B
108
103
B1
-7 1
1
800E
65
B4
A3
C1
600GR
66
10
67
10
70
10
977
48
861
894
51A
136 61 57
A3A4 62
79
600FB
5 3
4 3
46
56
60
1 10
B4
74
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 06/8D
407B ZX, 408B ZX, 409B ZX Circuit Diagrams - Electrical (continued) Main Components
44 45 46 47 48 49 50 51 51A 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 Loader Auxiliary 1 Solenoids Loader Auxiliary 1 Relay 1 Loader Auxiliary 1 Relay 2 Loader Auxiliary 2 Solenoids Joystick Switch Auxiliary 1 Loader Auxiliary 2 Hydraulics Switch Ignition Relay 2 Brake Lights Switch Brake Lights Relay Rear Washer Pump Rear Wiper Rear Wash/wipe Switch Front Washer Pump Front Wiper Front Wash/wipe Switch Horn Horn Switch Fog Light Switch Headlight Flasher Switch Dipped Headlight Switch Road Lights Switch Road Lights Relay Front Work Lights Relay Front Work Lights Switch Rear Work Lights Switch Clock Beacon Beacon Switch Interior Light Switch Radio (if fitted) LH Speaker (if fitted) RH Speaker (if fitted) Oil Cooler Fan Switch Oil Cooler Relay Oil Cooler Fan Motor Heater Motor Heater Resistor Heater Switch Removeable Link (removed if air conditioning is fitted) Air Conditioning Switch (if fitted) Air Conditioning Plug (if fitted)
From m/c no. 757400
Lamps
128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 Loader Auxiliary 2 Hydraulics Switch LH Brake Light LH Trailer Brake Light RH Trailer Brake Light RH Brake Light Rear Wash/wipe Switch Light LH Fog Light RH Fog Light Fog Light Switch LH Main Beam RH Main Beam LH Dip Beam RH Dip Beam LH Trailer Light LH Number Plate Light LH Tail Light LH Side Light RH Trailer Light RH Number Plate Light RH Tail Light RH Side Light Road Lights Switch Front Work Light Front Work Light Front Work Light Switch Rear Work Light Rear Work Light Rear Work Light Switch Beacon Beacon Switch Interior Light Heater Switch
Fuses
A1 A3 A4 A5 A7 A8 A9 B3 B4 B5 B7 B8 B9 C4 C5 L1 Brake Lights LH Side/tail and Number Plate Lights RH Side/tail and Number Plate Lights Rear Wash/wipe Beacon Interior Light and Radio Front Wash/wipe, Horn and Headlight Flasher Dip Beam Main Beam Front Work Lights Auxiliary Hydraulics Heater/Air Conditioning Oil Cooler Fan Motor Switch Relay Fog Lights Rear Work Lights In-line Fuse, Oil Cooler Fan Motor
9804/1103
50 - 15 - 06/8D
4210 - C/6 - 20.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 07/1
456B Circuit Diagrams - Electrical

Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56A 56B 56C 100 Isolator Battery Starter Motor Starter Solenoids Starter Relay Grid Heater Grid Heater Relay Hydraulic Dump Valve Starter Switch E.S.O.S. Pull Coil (25 Amp) E.S.O.S. Hold Coil (0.2 Amp) Shut Down Relay Alternator Electronic Monitoring system (EMS) Buzzer Fuel Contents Sender Water Temperature Sender Transmission Oil Temperature Sender Hydraulic Oil Temperature Sender Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Engine Oil Level Sensor Coolant Level Sensor Transmission Oil Level Sensor Hydraulic Oil Level Sensor Emergency Steer Pressure Switch Water in Fuel Sensor Parking Brake Switch Transmission Disconnect Switches Transmission Solenoids ZF Transmission Computer Computer Feed Relay Turbine Speed Sensor Output Speed Sensor Throttle Switch Transmission Hand Control Kick Down Switch Reverse Alarm Reverse Alarm Relay Rear Work Lights Relay Rear Work Lights Switch ACCS Solenoid Valve ACCS Override Switch ACCS Relay Heater Relay Heater Switch Heater Blower Cigar Lighter Air Conditioning Compressor Clutch Air Conditioning Pressure Switch Air Conditioning Temperature Switch Air Conditioning Switch High Flow/Normal Pressure Solenoid Low Flow/High Pressure Solenoid Hydraulic Mode Changeover Switch Changeover Switch (Hydraulic Mode/Transmission Dump) Lamps 109 110 111 112
From m/c no. 755491
Mode Switch Illumination Master Warning Light Rear Work Lights ACCS Operating Indication Light
Fuses 6A 8A 3B 6B 7B 8B 3C 4C 6C 7C 8C Computer Feed Relay Solenoid EMS Battery Feed Reverse Alarm and Rear Work Lights E.S.O.S. Hold Coil Air Conditioning E.S.O.S. Pull Coil EMS and ZF Computer Feed Hydraulic Mode Switch Heater Blower and Cigar Lighter Grid Heater Relay and Hydraulic Dump Valve ACCS
9804/1103
50 - 15 - 07/1
4180-C/6-1.2
Issue 2*
CONTENTS
Wheeled Loaders
456B Circuit Diagrams - Electrical (continued)
6 1 3 7
8 16 10 11 15 110 17 19 20 22 24 26 28 30 33
9438A 9446A 9434A 9422A 9430A 111A 113 9508 600DU 420 431 411 839 405 412 402 404 432 421 600G 419 415 401 408 400 422 403 406 407 9584 9430B 9446B 9442B 9438B 9434B 9520 9516
41 18 56 21 23 25 27 29 31
826G
111
112
844B
844C
50 38 42 43 45
51
52
111B
809
39
3 6 5 8 7 4 2 1
9588A
9588
813A
896A
896B
862A
13 12
813
111
409 418
44
896 115A 115C 115B
825
53 48
112B 862
+
7C 2
002B 002C A1
9536B 9678 9438 9446 9674 9658 9524 9504 9666 9434 9422 9430 9508A 9528 9512 9536 B3 A13 A12 A28 A15 A17 A5 A18 A30 A20 A33 A10 A31 B7 B2 A23 B14 B1 A14 A35 A16 A4 A6 A29 A19 A7 A8 A9 A21 413 9600C 9600B 9600A A34 B10 B6 B11 B12 B17 B16 B4 B18 B5 A25 A3 A2 A26 A36 840 1 2 9 34 27 17 13 897 9600 18 35 11 22 33 15 32 14 31 29 25 5 8 26 23 19 24 9536A
46
895
822
821 820
54
863
8B
811
+
003 A11
14
A24
34
40
47
112C 112A
49
55
32
9612A 9612A 9650 9654 9470 9474 9460 9464 115 103 112 109
9612D 004 002 107 810C 812D 807C 806C 836E 836D 835C 813B 301 UART/ UART/ TxD RxD MODA/ MODB 9612B
5 6B
001 000H
9612E 9612
36 35
37 3B
000L
8A
200P 302 106
8C
000M
6C
000P
7B
000K
3C
000
6A
200N 000G
9
200E
813B 835C 836D 836E
200W & 200X
200 & 220A 806C 807C 812D 810C
A261140
9804/1103
50 - 15 - 07/2
Issue 1
CONTENTS
Wheeled Loaders
68 114 113 116 117 119 121 123 124 125 126 127
806B 806A 807A 807B 812A 812B 810A 810C 810B 810D
129 128 66 70 72 74
846A
130 79 76
846B
131 81 78 82 83 132
829 823
86
830
133 134
115
802A
118 120
802B 801A 801C
122
801H 801E
85
835E 836G 835D 836F
824A
824B
898A 898B 899A 899B 835C 836E 802 801 806 807 812
852
851
87
2A 57 58
837 836E 8358
1C
800B
2B
804
7A
805
3A
812C 810 898
827 899 846
815
814 816
105B
105C 819B 819A
824
71 69
73 75
102B
84 77
818 102A 817 813 828 819 304E 304D 304B
88
304C
63 64
803B
89
808
104D
104B
104C
104H
104E
62
803
80
894
65
808A
59
100 300 838 800 837A 306 108 105
67
104
102
105A
304
1A
000A
1B
200H
60
61
2C
9A
5A
4B
5C
5B
200F
200S
000N
000E
000C
000F
200M
835C 836D 836E 802C 806C 807C 812D 810C
A261150
9804/1103
50 - 15 - 07/3
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 07/3
68 114 113 116 117 119 121 123 124 125 126 127
806B 806A 807A 807B 812A 812B 810A 810C 810B 810D
129 128 66 70 72 74
846A
130 79 76
846B
131 81 78 82 83 132
829 823
86
830
133 134
115
802A
118 120
802B 801A 801C
122
801H 801E
85
835E 836G 835D 836F
824A
824B
898A 898B 835C 836E 802 801 806 807 812
899A 899B
852
851
87
2A 57 58
837 836E 8358
1C
800B
2B
804
7A
805
3A
812C 810
827 899 846
815
814 816
105B
105C 819B 819A
824
71 69
898 104D 104B
73 75
104C 104H 104E 102B
84 77
818 102A 817 813 828 819 304E 304D 304B
88
304C
63 64
803B
62
808 803
80
65
808A
59
100 300 838 800 837A 306 108 105
67
104
102
105A
304
1A
000A
1B
200H
60
61
2C
9A
5A
4B
5C
5B
200F
200S
000N
000E
000C
000F
200M
835C 836D 836E 802C 806C 807C 812D 810C
A261150
9804/1103
50 - 15 - 07/3
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 07/4
456B Circuit Diagrams - Electrical Main Components

57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 * 89 Column Switch Diode Hazard Warning Switch Hazard Relay Road Light Switch Head Light Flasher Switch Fog Light Switch Front Work Lights Relay Front Work Lights Switch Parking Brake Solenoids Parking Brake Switch Float Coils Float Pressure Switch Detent Coil (Lift Ram Reset) Lift Ram Proximity Switch Detent Coil (Shovel Ram Reset) Shovel Ram Proximity Switch Detent Coil (Float) Brake Light Switch Rear Wiper Motor Rear Wash/Wipe Switch Rear Washer Pump Horn Column Switch Front Wiper Motor Intermittent Wiper Relay Front Washer Pump Beacon Switch Interior Light Interior Light Door Switch Radio (Option) Under Bonnet Lights Switch Parking Brake Controller
From m/c no. 755491
Lamps
113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 LH Front Indicator LH Rear Indicator RH Front Indicator RH Rear Indicator RH Side Light RH Tail Light Switch Illumination LH Side Light LH Tail Light RH Number Plate Light LH Number Plate Light Dip Beam Main Beam Fog Lights LH Front Work Lights RH Front Work Lights LH Brake Light RH Brake Light Beacon Interior Light LH Under Bonnet Light RH Under Bonnet Light
Fuses
1A 2A 3A 5A 7A 9A 1B 2B 4B 5B 1C 2C 5C Hazard Warning Lights and Direction Indicators RH Side/Tail Lights and Switch/Panel Illumination Fog Lights Brake Lights, Float, Lift and Shovel Reset Main Beam Parking Brake Hazard Battery Feed Dip Beam Rear Wash/Wipe Beacon, Interior Light, Radio and Under Bonnet Lights LH Side/Tail Lights and Number Plate Lights Front Work Lights Front Wash/Wipe and Horn
9804/1103
50 - 15 - 07/4
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 08/1
TM200, TM270 Circuit Diagrams - Electrical TM200

Main Components and Switches 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Battery Thermostart Starter Switch Neutral Start Relay 1 Starter Solenoid Starter Motor Ignition Relay 1 Neutral Start Relay 2 Park Brake Switch Diode Forward/Reverse Switch Forward Relay Reverse Relay Forward Solenoid Reverse Solenoid Dump Relay Reverse Alarm Speed Control Switch Speed Control Relay Speed Control Unit Servo Cut-off Switch Servo Arm Switch Servo Cut-off Solenoid Junction Box E.S.O.S. Hazard Switch Flasher Relay Direction Indicator Switch Water Temperature Gauge Water Temperature Sender Oil Temperature Gauge Oil Temperature Sender Fuel Gauge Fuel Sender Hourmeter Alternator Warning Buzzer Water Temperature Switch Transmissions Oil Temperature Switch Engine Oil Pressure Switch Air Filter Vacuum Switch Lamps 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 Reverse Light LH Trailer Indicator LH Front Indicator LH Rear Indicator RH Trailer Indicator RH Front Indicator RH Rear Indicator Turn Signal Park Brake Warning Light Park Brake Warning Light Park Brake Warning Light Park Brake Warning Light Alternator Warning Light Water Temperature Warning Light Transmission Oil Temperature Warning Light Engine Oil Pressure Warning Light Air Filter Warning Light Hazard Warning Light Main Beam Warning Light
9804/1103
50 - 15 - 08/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 08/2
TM200, TM270 Circuit Diagrams - Electrical (continued) TM200
100 9 6 2 5 13 12 14 15
17 20 19 23 25
101
104 103 106 30 32 34 36 39 102 105 41 38 40
24
10
18
10 22 28 37 27 29 31 33 108 110 112 114 116 118 107 109 111 113 115 117
1 4
8 10
35
21 16 26
11
3 7
A282070
9804/1103
50 - 15 - 08/2
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 08/3
TM200, TM270 Circuit Diagrams - Electrical (continued) TM200
Manual
120 121 125 124
128 127 126 129 130
132 133 134 135 136 137 65 67 69 70 73
122 119 43 45 50
123 52 53 56 55
131
66 59 60 63 72
42
44
48 49
51
58 54
62
64
61 68 46
71
57 47
A282080
9804/1103
50 - 15 - 08/3
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 08/4
TM 200, TM270 Circuit Diagrams - Electrical (continued)

Main Components and Switches 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 Joystick Switch Auxiliary 1 Loader Auxiliary 1. Solenoids Joystick Switch Auxiliary 2 Loader Auxiliary 2. Solenoids Auxiliary 2. Hydraulics Switch Ignition Relay 2 Brake Lights Switch Rear Wash/Wiper Switch Rear Wiper Motor Front Wash/Wiper Switch Front Washer Pump Front Wiper Motor Horn Switch Front Horn Fog Light Switch Road Lights Relay Road Lights Switch Head Light Flasher Switch Head Light Dip Switch Front Work Lights Relay Front Work Lights Switch Clock Beacon Switch Beacon Interior Light/Switch Radio Oil Cooler Relay Oil Cooler Fan Switch Oil Cooler Fan Motor Heater Switch Heater Resistor Heater Motor Lamps 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 LH Brake Light LH Trailer Brake Light RH Trailer Brake Light RH Brake Light Fog Light LH Main Beam RH Main Beam LH Dip Beam RH Dip Beam LH Trailer Light LH Number Plate Light LH Tail Light LH Side Light RH Trailer Light RH Number Plate Light RH Tail Light RH Side Light Front Work Light Front Work Light
9804/1103
50 - 15 - 08/4
4225-C/30-4.1
Issue 1
CONTENTS
Wheeled Loaders
- Electrical (continued) Lamps
100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 Reverse Light LH Trailer Indicator LH Front Indicator LH Rear Indicator RH Trailer Indicator RH Front Indicator RH Rear Indicator Turn Signal Master Warning Lights Master Warning Lights Brake Malfunction Alternator Water Temperature Transmission Oil Temperature Engine Oil Pressure Air Filter Transmission Oil Pressure Main Beam Hazard
50 - 15 - 09/1
TM200, TM270
* Diagrams
TM270 to m/c no. 787040 Main Components and Switches

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 * 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Battery Thermostart Starter Switch Neutral Start Relay Starter Solenoid Starter Motor Parking Brake/Handbrake Relay Handbrake Switch Dump Switch Diode Layshaft Relay Layshaft Solenoid Ignition Relay Transmission Dump Relay Forward Relay Forward Hi/Low Relay Forward Solenoid - Low Column Switch Forward Solenoid - High Reverse Hi/Low Relay Reverse Solenoid - High Reverse Solenoid - Low Reverse Relay Reverse Alarm Front Horn Joystick Auxiliary 1. Solenoid Auxiliary 2. Solenoid Boom Out Solenoid Boom In Solenoid Servo Cut-off Solenoid Servo Cut-off Switch Arm Rest Switch Auxiliary Solenoid Switch Hydraulic Tow Hitch Solenoid Safe Load Indicator (SLI) Unit Junction Box E.S.O.S Hazard Switch Direction Indicator Switch Flasher Unit Speed Transducer Transducer Resistor Speedometer Water Temperature Gauge Water Temperature Sender Fuel Gauge Fuel Sender Hourmeter Alternator Warnings Buzzer Brake Pressure Switch Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Air Filter Vacuum Switch Transmission Oil Pressure Switch (Blocked Oil Filter)
9804/1103
50 - 15 - 09/1
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 09/2
TM200, TM270 Circuit Diagrams - Electrical (continued) * TM270 to m/c no. 787040
24 100 6 8 9 12 17 19 5 11 10 23 15 33 36 16 20 25 21 22 27 28 29 30 31 35 37 38
101 103
104
43 50 52 53 54 55 56 57
46 106 102 105 42
48
10
40 41 108 110 112 114 116 118 51 44 45 47 49 107 109 111 113 115 117
1 14 4 7 18
26
32
34
39
10 13
A282090
9804/1103
50 - 15 - 09/2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 09/3
TM200, TM270 Circuit Diagrams - Electrical (continued) * TM270 to m/c no. 787040
120 123 121 119 122 61

M
129 125 127 128 130 131
133 134 135 136
137
139 75
M
85
M
84
63
M
124 64
M
126
138
140
77 80
M
132 65 68 69 70
76
83 82
72
73
74 79
59 60 67 62 71
81
78
66 58
A282100
9804/1103
50 - 15 - 09/3
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 09/4
TM 250, TM270 Circuit Diagrams - Electrical (continued)

*
TM270 to m/c 787040 Main Components and Switches

58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 Ignition Relay 2. Brake Lights Switch Rear Wash/Wiper Switch Rear Wiper Motor Front Wash/Wiper Switch Washer Pump Front Wiper Motor Fog Light Switch Road Lights Relay Road Lights Switch Headlight Flasher Switch Dip Switch Clock Front Work Lights Relay Front Work Lights Switch Rear Work Lights Switch Beacon Switch Beacon Interior Light/Switch Radio Heater Switch Heater Resistor Heater Motor Air Conditioning Switch Air Conditioning Relay Freeze Valve Switch Air Conditioning Fan motor Pressure Switch
Lamps
119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 LH Brake Light LH Trailer Brake Light RH Trailer Brake Light RH Brake Light Trailer Fog Light Fog Light LH Main Beam RH Main Beam LH Dip Beam RH Dip Beam LH Trailer Light LH Number Plate Light LH Tail Light LH Side Light RH Trailer Light RH Number Plate Light RH Tail Light RH Side Light Front Work Light Front Work Light Rear Work Light Rear Work Light
9804/1103
50 - 15 - 09/4
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 09/5
TM 200, TM270 Circuit Diagrams - Electrical (continued) TM270 From m/c no. 787041
Main Components and Switches 1 2 3 4 5 6 7 8 9 10 11 11A 12 12A 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Battery Thermostart Starter Switch Neutral Start Relay Starter Solenoid Starter Motor Parking Brake/Handbrake Relay Handbrake Switch Dump Switch Diode Layshaft Relay Mainshaft Relay Layshaft Solenoid Mainshaft Solenoid Ignition Relay Transmission Dump Relay Forward Relay Forward Hi/Low Relay Forward Solenoid - Low Column Switch Forward Solenoid - High Reverse Hi/Low Relay Reverse Solenoid - High Reverse Solenoid - Low Reverse Relay Reverse Alarm Front Horn Joystick Auxiliary 1. Solenoid Auxiliary 2. Solenoid Boom Out Solenoid Boom In Solenoid Servo Cut-off Solenoid Servo Cut-off Switch Arm Rest Switch Auxiliary Solenoid Switch Hydraulic Tow Hitch Solenoid Safe Load Indicator (SLI) Unit Junction Box E.S.O.S Hazard Switch Direction Indicator Switch Flasher Unit Speed Transducer Transducer Resistor Speedometer Water Temperature Gauge Water Temperature Sender Fuel Gauge Fuel Sender Hourmeter Alternator Warnings Buzzer Brake Pressure Switch Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Air Filter Vacuum Switch Transmission Oil Pressure Switch (Blocked Oil Filter) Lamps 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 Reverse Light LH Trailer Indicator LH Front Indicator LH Rear Indicator RH Trailer Indicator RH Front Indicator RH Rear Indicator Turn Signal Master Warning Lights Master Warning Lights Brake Malfunction Alternator Water Temperature Transmission Oil Temperature Engine Oil Pressure Air Filter Transmission Oil Pressure Main Beam Hazard
9804/1103
50 - 15 - 09/5
4225-C/30-9.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 09/6
TM200, TM270 Circuit Diagrams - Electrical (continued) TM270 from m/c no. 787041
24 100 6 8 9 12A 12 17 19
851
21
101 27 28 29 30 31 35 37 25 102 38 103
104
43 50 52 53 54 55 56 57
22
46 106 105 42
48
5 10 10
11A
11
16
20
23 15
857
36 33 40 41 108 110 112 114 116 118 51 44 45 47 49

106D
107 109 111 113 115 117
1 14 4 7
26
830
817
18
10 13
858
32
34
39
A311630
9804/1103
4225-C/30-10.1
50 - 15 - 09/6
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 09/7
TM200, TM270 Circuit Diagrams - Electrical (continued) TM270 from m/c no. 787041
120 123 121 119 122 61

M
129 125 127 128 130 131
133 134 135 136
137
139 76
M
64
M
124 65
M
126
138
140
78 81
M
62
132 66 69 70 71
77
103H
73
74
75 80
600FB
59 60 68 63 72
84
600FB
830
830
102DA
79
800E
600GR
83
1 2 102DF
82
102D 102D
67 58
A311640
9804/1103
50 - 15 - 09/7
4225-C/30-11.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 09/8
TM 200, TM270 Circuit Diagrams - Electrical (continued) TM270 From m/c no. 787041
Main Components and Switches 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 Ignition Relay 2. Brake Lights Switch Rear Wash/Wiper Switch Roof Wiper Motor Rear Wiper Motor Front Wash/Wiper Switch Washer Pump Front Wiper Motor Fog Light Switch Road Lights Relay Road Lights Switch Headlight Flasher Switch Dip Switch Clock Front Work Lights Relay Front Work Lights Switch Rear Work Lights Switch Beacon Switch Beacon Interior Light/Switch Radio Heater Switch Heater Resistor Heater Motor Link (Remove when Air Conditioning is fitted) Air Conditioning Switch (optional) Air Conditioning Plug (optional)
Lamps 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 LH Brake Light LH Trailer Brake Light RH Trailer Brake Light RH Brake Light Trailer Fog Light Fog Light LH Main Beam RH Main Beam LH Dip Beam RH Dip Beam LH Trailer Light LH Number Plate Light LH Tail Light LH Side Light RH Trailer Light RH Number Plate Light RH Tail Light RH Side Light Front Work Light Front Work Light Rear Work Light Rear Work Light
9804/1103
50 - 15 - 09/8
4225-C/30-12.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/1
426B, 436B, 446B Circuit Diagrams - Electrical Main Components

1 2 3 4 5 6 7 8 9 9A 10 11 12 13 14 15 16 17 17A 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 54A 55 55A 56 56A 56B Battery Starter Switch Thermo Coil Start Relay Starter Solenoids Starter Motor Neutral Start Relay Parking Brake Switch Reverse Alarm Relay Reverse Alarm Reverse Light Relay Dump Pressure Switch Dump Switch Reverse Light Switch Transmission Solenoid Switches (Y1 (M1), Y2 (M2), Y3 (M3), Y4 (M4), Y5 (M5)) Transmission Automatic Control Transmission Hand Control Output Speed Sensor Turbine Sensor Throttle Switch Water Temperature Gauge Fuel Gauge Speedometer Timer Relay Diode Buzzer Test Button Clutch Pressure Switch Engine Oil Pressure Switch Water Temperature Switch Vacuum Switch Transmission Oil Temperature Switch Brake Pressure Switch Alternator Hourmeter Heater Switch Resistor Heater Blower Cigar Lighter Changeover Switch Lift Arm Reset Bucket Ram Reset Clock Brake Switch Hazard Relay Hazard Switch Column Switch Sidelight Switch Column Switch Fog Light Switch Work Light Switch Work Light Relay Interior Light Switch Front Wiper Switch Front Wiper Motor Front Washer Switch Front Wash Motor Horn Push Horn Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Motor 57 58 59 60 61 62 63 64
m/cs to 531064 (426B) m/cs to 533069 (436B)

Dump Switch (Loader Control) Kickdown Switch (Loader Control) Air Conditioning Switch Air Conditioning Thermostat Air Conditioning Pressure Switch Compressor Clutch Field Coil E.S.O.S. Brake Dump Valve
Lamps
70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 Parking Brake Warning Light Reverse Light (Left Hand) Reverse Light (Right Hand) Master Warning Light Transmission Pressure Light Engine Oil Pressure Light Water Temperature Light Air Filter Light Transmission Oil Temperature Light Brake Pressure Light Alternator Warning Light Indicator Warning Light Brake Light (Left Hand) Brake Light (Right Hand) Indicator (Front Left Hand) Indicator (Rear Left Hand) Indicator (Front Right Hand) Indicator (Rear Right Hand) Hazard Warning Light Sidelight (Right Hand) Sidelight (Left Hand) Rear Fog Light Dipped Beam Main Beam Work Light (Front) Interior Light Beacon
Fuses
A1 A2 A3 A4 A5 A6 A7 B1 B2 B3 B4 B5 B6 B7 C1 C2 C3 C5 Direction Indicators Right Sidelights and Gauge Illumination Rear Fog Light Gear Selection Brake Lights, Loader Arm and Bucket Reset Warning Lights, Heater Fan and Gauges Main Beam Hazard Warning Lights Dipped Beam Rear Work Lights Rear Wash/Wipe Interior Light and Beacon E.S.O.S. Air Conditioning Left Sidelights Front Work Lights Forward/Reverse Select Horn, Wash/Wipe (Front)
* Note 1: For fuse and bulb ratings see pages 50-05-01/16 to 20 * Note 2: For manual transmission machines, Item 18 (Throttle Switch) is not fitted. Wires 9508 and 9508A are linked. * Note 3: For Germany ONLY, Wire 9588 is not connected to Item 10 (Reverse Light Relay).
9804/1103
50 - 15 - 10/1
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 10/2
426B, 436B, 446B Circuit Diagrams - Electrical (continued)
m/cs to 531064 (426B) m/cs to 533069 (436B)
55A 9A 71 72 14
420 420 414 413
56B
27 26 28
29 30
31
33
37
82 83
84 85 86 87
89 90 91 92 93
801 802 812 806 807
94 95 96 54A
810 304E
846B 835E 836G 846A 835D 836F
56A 62
862
844B 844C
32 36
408 405 416 400 411 422 418
861
852
851
48 42
803C
19
826G 844
20
21
38 39
104G 104B
17 18
9508A 9508 106C
40
104C 104H 104A
81
838
88
A2 C1
8008 800 804
A7 53 B2
805 304C 818 817 819 816A 815 814 862
61
10
22
25
839
835
9588A
9588
813
16
7 8 1 2
50
45 23 60 41
837 822 106S 104 8360 8358 863
23 74
406
845 9584
3 4 6 5 9434 9442 9430 9464 9524 9528 9512 9536 9504
47
52
+
1
003
8
101
11
840
9438 9446 9460
49
802 306
54 55
56 56
13
33 15 32 14 31 27 17 8 26 23 25 19 24
35
9658 9674
+
4
004
421
63
820 800 803
12 64
101M
302A
15
5 29 18 9666 420 9678
23
75 76 77 78 79 80 34
106A 100 300B 838 300 837A
59 51
22
1 9650
2 9654
35
44 46
304D 105 102 100
57 3
200 200E 9600A 101H 302
9600
24
73
70 A4
002B 002
9612
106B
106
107
100A
B3
200K
C3
A6
200 & 200A
B6
A5
000H
A1
000A
B1
200H
43
200F 304
C5
B4
B7
000F
000C
000
001
000
2 C2
200D 200S 200M
B5
A221980
9804/1103
50 - 15 - 10/2
Issue 1
CONTENTS
Wheeled Loaders
Lamps
101 102 103 104 105 106 107 108 109 110 142
50 - 15 - 10/3

1 2 3 4 5 6 7 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 82 83 84 Battery Starter Motor Starter Solenoids Start Relay Hydraulic Dump Valve Starter Switch Thermostart E.S.O.S. Neutral Start Relay Park Brake Switch Park Brake Transmission Disconnect Reverse Alarm Reverse Alarm Relay Dump Pressure Switch Dump Switch Dump Switch (Loader Control) Reverse Light Relay Rear Work Light Switch Transmission Solenoids (Y1 (M1), Y2 (M2), Y3 (M3), Y4 (M4), Y5 (M5) Turbine Sensor Output Speed Sensor Throttle Switch Transmission Automatic Control Kickdown Switch (Loader Control) Transmission Hand Control Water Temperature Gauge Fuel Gauge Speedometer Timer Diode Buzzer Test Button Clutch Pressure Switch Engine Oil Pressure Switch Water Temperature Switch Vacuum Switch Transmission Oil Temperature Switch Brake Pressure Switch Alternator Hourmeter Heater Blower Resistor Heater Switch Cigar Lighter Air Conditioning Compressor Air Conditioning Pressure Switch Air Conditioning Temperature Switch Air Conditioning Switch A.C.C.S. Solenoid Valve (Optional 436 Only) A.C.C.S. Override Switch (Optional 436 Only) A.C.C.S. Relay (Optional 436 Only)
Parking Brake Warning Light Reverse Light (Left Hand) Reverse Light (Right Hand) Master Warning Light Engine Oil Pressure Light Water Temperature Light Air Filter Light Transmission Oil Temperature Light Brake Pressure Light Alternator Warning Light A.C.C.S. Switch Light (Optional 436 Only)
Fuses
A4 A6 A7 B3 B6 B7 C3 C7 C8 Reverse Alarm/Dump Switch Warning Lights, Heater Fan,Gauges, Cigar Lighter, Transmission Disconnect Relay, Timer and Hourmeter Main Beam Reversing Lights E.S.O.S. Air Conditioning (Optional) Transmission Hydraulic Dump Valve A.C.C.S. (Optional 436 Only))
* Note 1: For fuse and bulb ratings see pages 50-05-01/16 to 20 * Note 3: For Germany ONLY, Wire 9588 is not connected to Item 22 (Reverse Light Relay).
9804/1103
50 - 15 - 10/3
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 10/4
17
102
103 24
414
39 38 40
41 42
43
45
49
844B
844C
25
415
431
413
44 50 46
408 405 416 400 411 422 862A
13 31
826G 844
32
33
26 27
9508A 9508 106C
14
18
22
34
37
839
35
51
002C 9588A 9588 813
30
8 7 4 3
35 103
406
862
845 9584
101L
9520
2 1 6 5
52
106S 863
9516
003
C7
15
421 9600C 9600B 9600A
9434 9442 9430 9474 9464 9524
9536B
9438 9446 9470 9460 9528 9512 9504
+
002B 004
23
33 15 32 14 31 8 26 23 25
9536 19 24
47
9658 9674
822
421B 421A
19 16
840 302A
4
107
21
28
5 29 18 9666 9678
106B 420
35
420A 420B
105
107
109 110
820
53
101
106F 101C
20
101M 101A
22 9600
1 9650
2 9654
35
106 104
106M
108
48
106A 109
36 29
106D 9536A
9612A 106 200 200E 101H 302 9612
B6
002 001 00H
A6
A4
B3
C3
106 200 & 200A
B7
000K
000G
000B
000L
000S
002A
000
6
200D
A251570
9804/1103
50 - 15 - 10/4
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/5
111 113 112
115 116
121 120
802A 802B
123
125
127 128
806A
129
131 130
807A
133 134
812B 812A 812D
135
136 63 65 67
137 138
139 69 78
863 846D 846B 864
114
122
124
801C 801A
126
132
807C 807B
835B 835E 836G 835D 836F 836J
801H 801E
806B
810A 810C
810B
810D 852 851
846A
140 70
802
141
81
117
118
801 806 807 812
104F
71
73
74 76
817 818
68
810
80
64
104B
66
104C 104H 104E
815
814
819
816
A2 55 35
C1
8008
B2
804 805
A7
A3
812C
79 61 72 75 77
304C
304E
304B
304D
60 59 54
837 8360 8358 802N 800A 306 800 104 102 105 304 803B 808
62
119
300B
803
56
100 300 838 837A
58
A1
000A
B1 57
200H 200F
C2
200S
A5
000E
B4
000C
C5
000F
B5
200M
A251580
9804/1103
50 - 15 - 10/5
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/6

Main Components 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 Clock Column Switch Hazard Switch Hazard Relay Sidelight Switch Column Switch Fog Light Switch Work Light Relay Work Light Switch Detent Coil (Lift Arm) Proximity Switch (Lift Arm) Detent Coil (Shovel Ram) Proximity Switch (Shovel Ram) Detent Coil (Float) Brake Light Switch Tow Hitch Solenoids Tow Hitch Switch Rear Wiper Motor Rear Wash/Wipe Switch Rear Washer Motor Front Washer Motor Front Washer Switch Horn Horn Push Front Wiper Motor Front Wiper Switch Interior Light Switch Radio Fuses
A1 Direction Indicators A2 Right Sidelights and Switch/Panel Illumination A3 Fog Lights A5 Brake Lights, Loader Arm, Shovel Reset and Tow Hitch Solenoids A7 Main Beam B1 Hazard Warning Lights and Clock B2 Dip Beam B4 Rear Wash/Wipe B5 Interior Light, Beacon and Radio (Optional) C1 Left Sidelights and Number Plate Lights C2 Work Lights C5 Horn and Front Wash/Wipe * Note1: For fuse and bulb ratings see pages 50-05-01/16 to 20
Lamps 111 Indicator (Trailer Left Hand) 112 Indicator (Front Left Hand) 113 Indicator (Rear Left Hand) 114 Indicator (Front Right Hand) 115 Indicator (Rear Right Hand) 116 Indicator (Trailer Right Hand) 117 Indicator Warning 118 Hazard Warning Light 119 Indicator (Trailer Warning) 120 Sidelight (Front Right Hand) 121 Sidelight (Rear Right Hand) 122 Trailer Light 123 Sidelight (Front Left Hand) 124 Sidelight (Rear Left Hand) 125 Numberplate Light (Right Hand) 126 Numberplate Light (Left Hand) 127 Trailer Light 128 Dipped Beam (Left Hand) 129 Dipped Beam (Right Hand) 130 Main Beam (Left Hand) 131 Main Beam (Right Hand) 132 Main Beam Warning 133 Fog Lights 134 Fog Lights (Trailer) 135 Work Lights (Left Hand) 136 Work Lights (Right Hand) 137 Brake Light (Left Hand) 138 Brake Light (Right Hand) 139 Brake Light (Trailer) 140 Beacon 141 Interior Light
9804/1103
50 - 15 - 10/6
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 10/7
426B, 436B, 446B Fault Finding - Electrical Main Components

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 Isolator Battery Starter Motor Starter Solenoids Starter Relay Thermostart Resistor Anti-Stall Solenoid Hydraulic Dump Valve Starter Switch Thermostart Coil E.S.O.S. Shut Down Relay Alternator Electronic Monitoring system (EMS) Buzzer Fuel Contents Sender Water Temperature Sender Transmission Oil Temperature Sender Hydraulic Oil Temperature Sender Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Engine Oil Level Sensor Coolant Level Sensor Transmission Oil Level Sensor Hydraulic Oil Level Sensor Emergency Steer Switch Water in Fuel Sensor Parking Brake Switch Transmission Disconnect Switches Transmission Solenoids ZF Transmission Computer Computer Feed Relay Turbine Speed Sensor Output Speed Sensor Throttle Switch Transmission Hand Control Kick Down Switch Reverse Alarm Reverse Alarm Relay Rear Work Lights Relay Rear Work Lights Switch ACCS Solenoid Valve ACCS Override Switch ACCS Relay Heater Relay Heater Switch Heater Blower Cigar Lighter Air Conditioning Compressor Clutch Air Conditioning Pressure Switch Air Conditioning Temperature Switch Air Conditioning Switch
m/cs from 531300 (426B) m/cs from 533300 (436B) Lamps

110 111 112 Fuses 6A 8A 3B 6B 7B 8B 3C 6C 7C 8C Computer Feed Relay Solenoid EMS Battery Feed Reverse Alarm and Rear Work Lights E.S.O.S. Air Conditioning Thermostart EMS and ZF Computer Feed Heater Blower and Cigar Lighter Hydraulic Dump Valve ACCS Master Warning Light Rear Work Lights ACCS Operating Indication Light
* Note 1: For fuse ratings see pages 50-05-01/16 to 20
9804/1103
50 - 15 - 10/7
Issue 2*
CONTENTS
Wheeled Loaders
50 - 15 - 10/8
8 16 1 3 10 11 7 15 110
111A
41 18 17 56 21 22 23 24 25 26 27 28 29 30 33
9438A 9446A 9434A 9442A 9430A 9508 600DU 420 431 411 839 405 412 402 404 432 421 600G 419 415 401 408 400 422 403 406 407 9584 9430B 9446B 9442B 9438B 9434B 9520 9516
111
112
31
826G 844B 844C
19 20
50 38 42 43 45
51
52
4 6
809
809
39
3 6 5 8 7 4 2 1
9588A
9588
813A
896A
896B
862A
13 12 56
813
111
113
409 418
44
896 115A 115C 115B
825
53 48
112B 862
865 864
9536B 9678 9438 9446 9674 9658 9524 9504 9666 9434 9442 9430 9508A 9528 9512 9536 B3 A13 A12 A28 A15 A17 A5 A18 A30 A20 A33 A10 A31 B7 B2 A23 B14 B1 A14 A35 A16 A4 A6 A29 A19 A7 A8 A9 A21 A1 413 9600C 9600B 9600A A34 B10 B6 B11 B12 B17 B16 B4 B18 B5 A25 A3 A2 A26 A36 840 1 2 9 34 27 17 13 897 9600 18 35 11 22 33 15 32 14 31 29 25 5 8 26 23 19 24 9536A
46
895
822
821 820
54
863
7C
8B
002C
811
002B
+
2
003
A22 A11
14
A24
34
40
47
112C 112A
49
55
+
004 002 107 114 810C 812D 807C 806C 836E 836D 835C 813B 301 UART/ UART/ TxD RxD MODA/ MODB 9612D
32
9612A 9612A 9650 9654 9470 9474 9460 9464 115 103 112 109
9612B
5 6B
001 000H
9612E 9612
36 35
37 3B
000L
4A
000B
8A
200P 302 106
8C
000M
6C
000P
7B
000K
3C
000
6A
200N 000G
9
200E
813B 835C 836D 836E
200W & 200X
200 & 220A 806C 807C 812D 810C
A282620
9804/1103
50 - 15 - 10/8
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/9
114 113
116
117
119
121
123
124
125
126 127 128 70

810A 810C 810B 810D
129
130 79 76 81 78 82 83
131 85
86
830
133 134
115
802A
118 120
802B 801A 801C
122
801H 801E 806A 806B 807A 807B 812A 812B
835E 836G 835D 836F
72
74
846A 846B
824A
824B
852 835C 836E 802 801 806 807 812
851 829 823
132
87
2A 57 58
837 836E 8358
1C
800B
2B
804
7A
805
3A
812C 810
827 846
815
814 816
105B
105C 819B 819A
824
71
73 75
102B
84 77
818 102A 817 813 828 819 304E 304D 304B
88
304C
63 64
803B 104B 104C 104H
104E
62
808 803
80
65
808A 104 102 105A 304
59
100 300 838 800 837A 306 105
1A
000A
1B
200H
60
61
2C
5A
4B
5C
5B
200F
200S
000E
000C
000F
200M
835C 836D 836E 802C 806C 807C 812D 810C
A282630
9804/1103
50 - 15 - 10/9
Issue 1
CONTENTS
Wheeled Loaders
Lamps 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 LH Front Indicator LH Rear Indicator RH Front Indicator RH Rear Indicator RH Side Light RH Tail Light Switch Illumination LH Side Light LH Tail Light RH Number Plate Light LH Number Plate Light Dip Beam Main Beam Fog Lights LH Front Work Lights RH Front Work Lights LH Brake Light RH Brake Light Beacon Interior Light LH Under Bonnet Light RH Under Bonnet Light
50 - 15 - 10/10

Main Components 56 57 58 59 60 61 62 63 64 65 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 Anti-Stall Relay Column Switch Diode Hazard Warning Switch Hazard Relay Road Light Switch Head Light Flasher Switch Fog Light Switch Front Work Lights Relay Front Work Lights Switch Detent Coil (Lift Ram Reset) Lift Ram Proximity Switch Detent Coil (Shovel Ram Reset) Shovel Ram Proximity Switch Detent Coil (Float) Brake Light Switch Rear Wiper Motor Rear Wash/Wipe Switch Rear Washer Pump Horn Column Switch Front Wiper Motor Intermittent Wiper Relay Front Washer Pump Beacon Switch Interior Light Interior Light Door Switch Radio (Option) Under Bonnet Lights Switch
m/cs to 531300 (426B) m/cs to 533300 (436B)
Fuses 1A 2A 3A 5A 7A 9A 1B 2B 4B 5B 1C 2C 5C Hazard Warning Lights and Direction Indicators RH Side/Tail Lights and Switch/Panel Illumination Fog Lights Brake Lights, Float, Lift and Shovel Reset Main Beam Blank Hazard Battery Feed Dip Beam Rear Wash/Wipe Beacon, Interior Light, Radio and Under Bonnet Lights LH Side/Tail Lights and Number Plate Lights Front Work Lights Front Wash/Wipe and Horn
Note 1: For fuse ratings see pages 50-05-01/16 to 20.
9804/1103
50 - 15 - 10/10
4160-C/6-10.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/11
426B, 436B, 446B Circuit Diagrams - Electrical

Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 Isolator Battery Starter Motor Starter Solenoids Starter Relay Grid Heater Grid Heater Relay Hydraulic Dump Valve Starter Switch E.S.O.S. Pull Coil (25 Amp) E.S.O.S. Hold Coil (0.2 Amp) Shut Down Relay Alternator Electronic Monitoring system (EMS) Buzzer Fuel Contents Sender Water Temperature Sender Transmission Oil Temperature Sender Hydraulic Oil Temperature Sender Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Engine Oil Level Sensor Coolant Level Sensor Transmission Oil Level Sensor Hydraulic Oil Level Sensor Emergency Steer Pressure Switch Water in Fuel Sensor Parking Brake Switch Transmission Disconnect Switches Transmission Solenoids ZF Transmission Computer Computer Feed Relay Turbine Speed Sensor Output Speed Sensor Throttle Switch Transmission Hand Control Kick Down Switch Reverse Alarm Reverse Alarm Relay Rear Work Lights Relay Rear Work Lights Switch ACCS Solenoid Valve ACCS Override Switch ACCS Relay Heater Relay Heater Switch Heater Blower Cigar Lighter Air Conditioning Compressor Clutch Air Conditioning Pressure Switch Air Conditioning Temperature Switch Air Conditioning Switch Lamps 110 111 112
m/cs from 540000 (446B)
Master Warning Light Rear Work Lights ACCS Operating Indication Light
Fuses 6A 8A 3B 6B 7B 8B 3C 6C 7C 8C Computer Feed Relay Solenoid EMS Battery Feed Reverse Alarm and Rear Work Lights E.S.O.S. Hold Coil Air Conditioning E.S.O.S. Pull Coil EMS and ZF Computer Feed Heater Blower and Cigar Lighter Grid Heater Relay and Hydraulic Dump Valve ACCS
Note 1: For fuse ratings see pages 50-05-01/16 to 20.
Note: 56 is not used.
9804/1103
50 - 15 - 10/11
4160-C/6-11.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/12
m/cs from 540000 (446B)
6 1 3 7
8 16 10 11 15 110 17 19 20 22 24 26 28 30 33
9438A 9446A 9434A 9422A 9430A 111A 113 9508 600DU 420 431 411 839 405 412 402 404 432 421 600G 419 415 401 408 400 422 403 406 407 9584 9430B 9446B 9442B 9438B 9434B 9520 9516
41 18 56 21 23 25 27 29 31
826G
111
112
844B
844C
50 38 42 43 45
51
52
111B
809
39
3 6 5 8 7 4 2 1
9588A
9588
813A
896A
896B
862A
13 12
813
111
409 418
44
896 115A 115C 115B
825
53 48
112B 862
+
7C 2
002B 002C A1
9536B 9678 9438 9446 9674 9658 9524 9504 9666 9434 9422 9430 9508A 9528 9512 9536 B3 A13 A12 A28 A15 A17 A5 A18 A30 A20 A33 A10 A31 B7 B2 A23 B14 B1 A14 A35 A16 A4 A6 A29 A19 A7 A8 A9 A21 413 9600C 9600B 9600A A34 B10 B6 B11 B12 B17 B16 B4 B18 B5 A25 A3 A2 A26 A36 840 1 2 9 34 27 17 13 897 9600 18 35 11 22 33 15 32 14 31 29 25 5 8 26 23 19 24 9536A
46
895
822
821 820
54
863
8B
811
+
003 A11
14
A24
34
40
47
112C 112A
49
55
32
9612A 9612A 9650 9654 9470 9474 9460 9464 115 103 112 109
9612D 004 002 107 810C 812D 807C 806C 836E 836D 835C 813B 301 UART/ UART/ TxD RxD MODA/ MODB 9612B
5 6B
001 000H
9612E 9612
36 35
37 3B
000L
8A
200P 302 106
8C
000M
6C
000P
7B
000K
3C
000
6A
200N 000G
9
200E
813B 835C 836D 836E
200W & 200X
200 & 220A 806C 807C 812D 810C
9804/1103
4160-C/6-12.1
50 - 15 - 10/12
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/13
m/cs from 540000(446)
114 113
116
117
119
121
123
124
125
126 127 128 70

810A 810C 810B 810D
129
130 79 76 81 78 82 83
131 85
86
830
133 134
115
802A
118 120
802B 801A 801C
122
801H 801E 806A 806B 807A 807B 812A 812B
835E 836G 835D 836F
72
74
846A 846B
824A
824B
852 835C 836E 802 801 806 807 812
851 829 823
132
87
2A 57 58
837 836E 8358
1C
800B
2B
804
7A
805
3A
812C 810
827 846
815
814 816
105B
105C 819B 819A
824
71
73 75
102B
84 77
818 102A 817 813 828 819 304E 304D 304B
88
304C
63 64
803B 104B 104C 104H
104E
62
808 803
80
65
808A 104 102 105A 304
59
100 300 838 800 837A 306 105
1A
000A
1B
200H
60
61
2C
5A
4B
5C
5B
200F
200S
000E
000C
000F
200M
835C 836D 836E 802C 806C 807C 812D 810C
9804/1103
50 - 15 - 10/13
4160-C/6-13.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/14

57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 Column Switch Diode Hazard Warning Switch Hazard Relay Road Light Switch Head Light Flasher Switch Fog Light Switch Front Work Lights Relay Front Work Lights Switch Not Used Not Used Not Used Not Used Detent Coil (Lift Ram Reset) Lift Ram Proximity Switch Detent Coil (Shovel Ram Reset) Shovel Ram Proximity Switch Detent Coil (Float) Brake Light Switch Rear Wiper Motor Rear Wash/Wipe Switch Rear Washer Pump Horn Column Switch Front Wiper Motor Intermittent Wiper Relay Front Washer Pump Beacon Switch Interior Light Interior Light Door Switch Radio (Option) Under Bonnet Lights Switch
m/cs from 540000 (446)
Lamps
113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 LH Front Indicator LH Rear Indicator RH Front Indicator RH Rear Indicator RH Side Light RH Tail Light Switch Illumination LH Side Light LH Tail Light RH Number Plate Light LH Number Plate Light Dip Beam Main Beam Fog Lights LH Front Work Lights RH Front Work Lights LH Brake Light RH Brake Light Beacon Interior Light LH Under Bonnet Light RH Under Bonnet Light
Fuses
1A 2A 3A 5A 7A 1B 2B 4B 5B Lights 1C 2C 5C Hazard Warning Lights and Direction Indicators RH Side/Tail Lights and Switch/Panel Illumination Fog Lights Brake Lights, Lift and Shovel Reset Main Beam Hazard Battery Feed Dip Beam Rear Wash/Wipe Beacon, Interior Light, Radio and Under Bonnet LH Side/Tail Lights and Number Plate Lights Front Work Lights Front Wash/Wipe and Horn
Note 1: For fuse ratings see pages 50-05-01/16 to 20
9804/1103
50 - 15 - 10/14
4160-C/6-14.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/15

1 2 3 4 5 6 7 8A 8B 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Starter Switch Battery Isolator Starter Relay Starter Solenoids Starter Motor Hydraulic Dump Valve Thermostart Restistor Thermostart Coil Shut down Relay E.S.O.S. Electronic Monitoring system (EMS) Computer Feed Relay Transmission Disconnect ZF Computer Transmission Solenoids Turbine Speed Sensor Output Speed Sensor Throttle Switch Kickdown Switch Hand Controller Relays Forward/Reverse Control Relays Hand Controller Forward/Reverse Switch Reverse Alarm Relay Reverse Alarm Reverse Lights Switch Reverse Lights Relay ACCS Relay ACCS Override Switch ACCS Solenoid Valve
m/cs from March98 (426B, 436B)
Lamps
110 111 112 LH Reverse Light RH Reverse Light ACCS Operating Indication Light
Fuses
6A 8A 3B 6B 8B 3C 7C 8C Computer Feed Relay Solenoid EMS Battery Feed Reverse Alarm and Rear Work Lights Engine Shut Off System (ESOS) Thermostart EMS and ZF Computer Feed Hydraulic Dump Valve (416 Only) ACCS
Note : For fuse ratings see pages 50-05-01/16 to 20
9804/1103
50 - 15 - 10/15
4160-C/6-15.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/16

2 2
3 5 4 1 7C 8A 10 7 8B 6
8B 6B
9 8A 11
13 3C 6A 12
14 16 15 18
17
20
21
19
22 24 3B 26
23 25
27 110 111 29 30 112
28 8C
9804/1103
50 - 15 - 10/16
4160-C/6-16.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/17

Main Components 1 11 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 Starter Switch Electronic Monitoring system (EMS) Warning Light Test Button Buzzer Fuel Contents Sender Water Temperature Sender Transmission Oil Temperature Sender Hydraulic Oil Temperature Sender Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Engine Oil Level Sensor Coolant Level Sensor Transmission Oil LevelSensor Hydraulic Oil Level Sensor Emergency Steer Switch Water in Fuel Sensor Parking Brake Switch Alternator Heater Switch Heater Relay Heater Blower Cigar Lighter Air Conditioning Switch Air Conditioning Temperature Switch Air Conditioning Pressure Switch Air Conditioning Compressor Clutch Lamps 115
Note: Arrows marked indicate remote connection (not shown), ie. 3C goes to Fuse 3C via Relay (Item 12).
9804/1103
50 - 15 - 10/17
4160-C/6-17.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/18

1
35 115 36 37 38
8A
39 40 41 11 42 43 44 45 46 47 48 49 50 51 52
53 55 56 6C 54
57 7B 58 59 60 61
9804/1103
50 - 15 - 10/18
4160-C/6-18.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/19

9804/1103
50 - 15 - 10/19
4160-C/6-19.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/20

1
1A 1B 67
120 121
66
68
122 123
69
124 2A 125
126 127 1C 128 129
2B
130
70
9C
71 7A 131
72
3A
132
133
74 73 2C 75 134
9804/1103
50 - 15 - 10/20
4160-C/6-20.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/21

9804/1103
50 - 15 - 10/21
4160-C/6-21.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/22

1 80
81 82 5A 84
83
85
140 141
87 86 88 4C 89 90 91
4B
92
93
94 95 96
5C
97 98
99 100 142
5B
143 102
101
144 103 145
9804/1103
50 - 15 - 10/22
4160-C/6-22.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/23

Main Components 1 2 3 4 5 6 7A 7B 8 9 10A 10B 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Starter Switch Battery Isolator Starter Relay Starter Solenoids Starter Motor Grid Heater Solenoid Grid Heater Hydraulic Dump Valve Shut down Relay E.S.O.S. Pull Coil (25 Amp) E.S.O.S. Hold Coil (0.2 Amp) Electronic Monitoring system (EMS) Computer Feed Relay Transmission Disconnect ZF Computer Transmission Solenoids Turbine Speed Sensor Output Speed Sensor Throttle Switch Kickdown Switch Hand Controller Relays Forward/Reverse Control Relays Hand Controller Forward/Reverse Switch Reverse Alarm Relay Reverse Alarm Reverse Lights Switch Reverse Lights Relay ACCS Relay ACCS Override Switch ACCS Solenoid Valve Lamps 110 111 112
m/cs from March98 (446B)
Fuses 6A 8A 3B 6B 8B 3C 7C 8C Computer Feed Relay Solenoid EMS Battery Feed Reverse Alarm and Rear Work Lights Engine Shut Off System (ESOS) Thermostart EMS and ZF Computer Feed Hydraulic Dump Valve (416 Only) ACCS
9804/1103
50 - 15 - 10/23
4160-C/6-23.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/24

2 2
3 5 4 6
1 7C 8B 6B 9 8A 11
7A 8
7B
10A 10B
13 3C 6A 12
14 16 15 18
17
20
21
19
22 24 3B 26
23 25
27 110 111 29 30 112
28 8C
9804/1103
50 - 15 - 10/24
4160-C/6-24.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/25

Main Components 1 11 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 Starter Switch Electronic Monitoring system (EMS) Warning Light Test Button Buzzer Fuel Contents Sender Water Temperature Sender Transmission Oil Temperature Sender Hydraulic Oil Temperature Sender Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Engine Oil Level Sensor Coolant Level Sensor Transmission Oil Level Sensor Hydraulic Oil Level Sensor Emergency Steer Switch Water in Fuel Sensor Parking Brake Switch Alternator Heater Switch Heater Relay Heater Blower Cigar Lighter Air Conditioning Switch Air Conditioning Temperature Switch Air Conditioning Pressure Switch Air Conditioning Compressor Clutch Lamps 115
Note: Arrows marked indicate remote connection (not shown), ie. 3C goes to Fuse 3C via Relay (Item 12).
9804/1103
50 - 15 - 10/25
4160-C/6-25.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/26

1
35 115 36 37 38
8A
39 40 41 11 42 43 44 45 46 47 48 49 50 51 52
53 55 56 6C 54
57 7B 58 59 60 61
9804/1103
50 - 15 - 10/26
4160-C/6-26.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/27

9804/1103
50 - 15 - 10/27
4160-C/6-27.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/28

1
1A 1B 67
120 121
66
68
122 123
69
124 2A 125
126 127 1C 128 129
2B
130
70
9C
71 7A 131
72
3A
132
133
74 73 2C 75 134
9804/1103
50 - 15 - 10/28
4160-C/6-28.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/29

Note 1: For fuse ratings see pages50-05-01/16 to 20
9804/1103
50 - 15 - 10/29
4160-C/6-29.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/30

1 80
81 82 5A 84
83
85
140 141
87 86 88 4C 89 90 91
4B
92
93
94 95 96
5C
97 98
99 100 142
5B
143 102
101
144 103 145
9804/1103
50 - 15 - 10/30
4160-C/6-30.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/31
426B, 436B, 446B Circuit Diagrams - Electrical

Main Components Lamps
1 2 3 4 5 6 7 8 9 Battery Isolator Light Relay Road Light Switch Fog Light Switch Column Switch Front Work Light Relay Front Work Light Switch Rear Work Light Switch 120 121 122 123 124 Fog Lights Dipped Beam Main Beam Front Work Lights Rear Work Lights
m/cs from 533692 (436B)
Fuses
Note: Items marked $ indicate remote connections (not shown), ie. $1 $2 $3 $4 $5 $6 From EMS A23 To EMS B6 To EMS B12 To EMS B11 To EMS B10 To EMS B5
Note 1: for Fuse ratings, see pages 50-05-01/16 to 20
9804/1103
50 - 15 - 10/31
4160-C/6-31.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/32

1 1
m/cs from 533692 (436B)
3
See C/6-36
132A 201 005
See C/6-34 303
A2
120 803B
4
800
B1
See C/6-34
+
5
803
B2
See C/6-34 $2 To EMS B6
LH
812D
812A
812C
A6
120
812 812B RH
806C 806A
$3 To EMS B12
LH
6 P1
See C/6-34
305
804
A4 A5
121
806 806B RH
805
807
807A
LH
122
807B 807C RH
810E
7
201A 006
A3
122 122A
122B
810
810A LH 810B
$1 From EMS A23 808 See C/6-42
123
810C RH 810D
813C
LH
A1
121
124
813 813A 813D RH
813B
$6 To EMS B5
9804/1103
50 - 15 - 10/32
4160-C/6-32.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/33

Main Components
1 2 10 11 12 13 14 15 16 Battery Isolator Electronic Monitoring System (EMS) ZF Computer Hazard Warning Switch Hazard Warning Relay Column Switch Beacon Switch 24 Volt Radio
m/cs from 533692 (436B)
Lamps
125 126 127 128 129 130 131 132 133 134 135 Left Front Indicator Left Rear Indicator Right Front Indicator Right Rear Indicator Beacon Interior Light Right Front Side Light Right Rear Side Light Left Front Side Light Left Rear Side Light Number Plate Lights
Note: Items marked $ indicate remote connections (not shown), ie. $7 $8 $9 $10 $11 $12 12 Volt Trailer Electrics To EMS B18 To EMS B16 Headlight Flash Switch Illumination To EMS B18
Fuses
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 C9 P2 Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and Number Plate Lights 12 Volt Trailer Electrics (Option) EMS (Battery Feed) ZF Computer (Battery Feed) Hazard Warning Beacon and Interior Light 24 Volt Radio Headlight Flash Side Lights Direction Indicators Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and Number Plate Lights Headlight Flash Radio (24 Volt) Beacon and Interior Light Hazard Warning EMS (Battery Feed) ZF Computer (Battery Feed) 12 Volt trailer Electrics
9804/1103
50 - 15 - 10/33
4160-C/6-33.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/34

1 1
m/cs from 533692 (436B)
B3
B4
301
10
See C/6-42
9832
B5
9836
11
See C/6-40
202A
835C
C9
See C/6-38
$8 To EMS B18
100 835A
LH FRONT
P2
202
B6
12
300 838 30 49 15
125
835D
835
14
LH REAR
126 13
837A 49A L R 835B 836A
RH FRONT
127
836D
836
836B
RH REAR
837 836C
128
$9 To EMS B16
304E
15
823
129
B7
304
304D
130 B8 16
309
B9
802D 305
$10 Headlight Flash See C/6-32

802C
$12 To EMS B18
802A
131
B1 4
303 800
802
802B
132
B10
B2
801
801A
133
See C/6-32
120 803B
801B
801C
134
See C/6-32
801D
LH
135
801E
RH
9804/1103
50 - 15 - 10/34
4160-C/6-34.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/35

Main Components
1 2 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Battery Isolator Starter Solenoids Starter Motor Start Relay Starter Switch Not Applicable Start-up dump Solenoid Thermostart Resistor Thermostart Not Applicable Dump Relay Heater Speed Switch Heater Blower Air Conditioning Switch Air Conditioning Temperature Switch Air Conditioning Pressure Switch Air Conditioning Compressor Heated Mirror Switch Heated Mirrors Heated Seat Switch Seat Heating Elements Air Suspension Switch Air Suspension Compressor Heated Rear Screen Switch Heated Rear Screen Relay Heated Rear Screen Lights Relay Solenoid Ignition Relay Solenoid 1 Ignition Relay Solenoid 2 Ignition Relay Solenoid 3
m/cs from 533692 (436B)
Lamps
Fuses
A7 A8 A9 A10 C1 C6 Blank Thermostart Dump Relay Ignition Relays
Starter Relay Solenoid Heated Seat/Mirrors and Air Suspension Seat (Option) C7 Air Conditioning (Option) C8 Heater Blower C9 Direction Indicators C10 Heated Rear Screen P3 Starter Solenoid Thermostart Heater Blower Air Conditioning Direction Indicators Heated Seat, Mirrors and Air Suspension Seat Heated RearScreen Ignition Relays
Note 1: for Fuse ratings, pages 50-05-01/16 to 20
Note: Items marked $ indicate remote connections (not shown), ie. $13 $14 $15 $16 To EMS A34 Indicators To EMS A24 To EMS B4
9804/1103
50 - 15 - 10/35
4160-C/6-35.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/36

1 1
m/cs from 533692 (436B)
001
203A
17
+
19 C1
127
18
128
20 P3
203 1
$13 To EMS 34 See C/6-42

7
002
A7
111
21 22
2 8 9 6 5
A8
113
23
24 25
000
A9
129
27 C8
822 112 821 820
28
26
C7
109
29
863
30
862
31
862A
32
873A
33
119A
873 873
34
830
C6
119
35
872
36
119B
37
38
C9
100
$14 Indicators See C/6-34
39
103A 826 834 841
$16 To EMS B4 See C/6-42
C10
103
40 42 43 44 45 136
41
132A
000A
A10
132
132C
132D
132E
132F
9804/1103
50 - 15 - 10/36
4160-C/6-36.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/37

1 2 10 11 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 Battery Isolator Electronic Monitoring System (EMS) ZF Computer Ignition Relay 1 Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Pump Horn Ignition Relay 2 Column Switch Front Wiper Motor Intermittent Wiper Relay Front Washer Pump 24 Volt Cigar Lighter Shutdown Relay E.S.O.S. Reverse Relay Reverse Alarm Ignition Relay 3 Brake Light Switch Changeover Switch Changeover Solenoid Lift Ram Proximity Switch Detent Coil (Lift Ram Reset) Shovel Ram Proximity Switch Detent Coil (Shovel Ram Reset) Detent Coil (Float) 137 138 139 140 Left Fog Light Right Fog Light Left Brake Light Right Brake Light
m/cs from 533692 (436B)
Fuses
C2 C3 C4 C5 D1 D2 D3 D5 D6 D7 D8 D9 D10 P4 24 Volt Cigar Lighter Blank Rear Wash/Wiipe Front Wash/Wipe and Horn EMS (Ignition Feed) ZF Computer (Ignition Feed) CCTV (Option) ESOS and Cold Start Advance Reverse Lights and Alarm In-cab 24/12 Volt Converter (Option) Blank Brake Lights Float, Lift and Shovel Reset and 4th Spool EMS (Ignition Feed) ZF Computer (Ignition Feed) Rear Wash/Wipe Front Wash/Wipe and Horn Cigar Lighter (24 Volt) ESOS and Cold Start Advance Reverse Alarm/Lights Headlight Flash Brake Lights Shovel and Arm Reset CCTV In-cab 24/12 Volt Converter
Note: Items marked $ indicate remote connections (not shown), ie. $17 $18 $19 $20 CCTV Spare To EMS A11 To CCTV
Note 1: for Fuse ratings, pages 50-05-01/16 to 20
9804/1103
50 - 15 - 10/37
4160-C/6-37.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/38

1 1
m/cs from 533692 (436B)
+
D3 D1 46
See C/6-38
132C 204 008
118
+
$17 CCTV See C/6-44
125
10 11
See C/6-40
102B
See C/6-42
D2
9916A
827
47 C4
102 102A 815
48
C3
$18 Spare
816
814
49 50
105B
53
817 818
51
See C/6-36
132D 204B 007
829
C5
105
105A
52
831 105C 828 819B
54
819
819A
55
C2
124
P4
204A
D5

107
811
57
809
56 58
59 D6
See C/6-40
115 9916J 844 844A
60 137 138
844D
844B
61
204C 009
D7
108
$20 To CCTV See C/6-44
See C/6-44
See C/6-36
132E
D8
$18 Spare
D9
126
62
847
847A
139 140
847B
63
104G
861
64
D10
65
104 104C
852
67
66
104B
851
68
104H
69
9804/1103
50 - 15 - 10/38
4160-C/6-38.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/39

Main Components
70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 Gear Box Controller Unit Torque Converter Out Temperature Sensor Reverse Relay Solenoid Load Suspension Solenoid Load Suspension On/Off Switch Parking Brake On/Off Switch(411 to 446) Parking Brake On/Off Switch (456) Auto/Manual Switch On/Off Switch Pressure Switch Transmission Disconnect Button Parking Brake Solenoid Internal Gear Chain Speed Sensor Turbine Speed Sensor Engine Speed Sensor Output Speed Sensor Forward/Reverse Rocker Switch Hand Controller Transmission Kick Down Button ZF Diagnostic Port ZF Display Plug
m/cs from 533692 (436B)
Fuses
B5 D2
ZF Computer (Battery Feed) ZF Computer (Ignition Feed)
Note 1: for Fuse ratings, see pages 50-05-01/16 to 20.
Note: Items marked $ indicate remote connections (not shown), ie. $21 CAN-BUS To EMS $22 To EMS A30 (456 Only)
9804/1103
50 - 15 - 10/39
4160-C/6-39.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/40
m/cs from 533692 (436B)
70
$21 CAN-BUS to EMS See C/6-42
7 9454 9904 9908 13 VPS1
9462A 9574 9570
421
71
438 439
9458 39 ER1
9462 46 VMGA2
9916J
72
25
9808
ADM2
CANF-H CANF-L CANF-T
07
438B 438A 9856 9920 9852
26 27
9916M
73
897
05 02 01
VM2
9916H
74
VM1 896
30
9916F
75
9820B
848
57
76
9916D 9820
9820A
81
21
ED10
11
893
9900
08
9916G
77
9824
29
ED11 VMG1 9424

03
78
9916A 840
79
9816B
EF3
9420
42
82
9414
9410
80
9916B 9816A
41
9816
ED9
EF2
66
83
9404 9400
D2
See C/6-38
9916A
9916
45
VPI
19
EF1
84
14
9836
68
VPE2
B5
See C/6-34
9832
23 EF4 62 2
15
VPE1
ED13 VMG2 04 9500 1 ED8 44 ED3 20 ED4 43 ED6 67 ED5 64 ED1 63 ED2 65 ED7 22
18
31
9504
9532A
9508
85
880
882
881
3 9540 9548 9544 9528 9524 2 3 4 9532
9536A
86
1 F N R B1 B2
9864 9648 9652 9644
KD
9536
87
9916K
9598
9594
88
4 3 2
9640
89
9590
9804/1103
50 - 15 - 10/40
4160-C/6-40.1
90
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/41

Main Components
1 2 10 91 92 93 94 95 96 97 98 99 100 101 102 103 104 Battery Isolator Electronic Monitoring System (EMS) EMS Diagnostic Port Buzzer Fuel Level Sender Water Temperature Sender Transmission Oil Temperature Sender Engine Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Emergency Steer Switch Shutdown Relay Coil Front Work Light Relay Coil Heated Rear Screen Relay Coil Alternator
m/cs from 533692 (436B)
Fuses
Note: Items marked $ indicate remote connections (not shown), ie. $21 $23 $24 $25 $26 $27 $28 $29 $30 $31 $32 $33 $34 CAN-BUS To EMS From Fuse A6 From Fuse A4 From Fuse A5 From Front Work Light Switch From RearWork Light Switch From LH Indicator Feed From RH Indicator Feed From Side Light Feed From Heated Rear Screen Switch From ZF Computer (Park Brake Status-456 Only) From Start Relay Coil 120 ohm Resistor
9804/1103
50 - 15 - 10/41
4160-C/6-41.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/42

1 1
m/cs from 533692 (436B)
91
4 125A 425 3 423
2 5 600BX
+
1 424
A26
A2
A3 A35
600G
A13
600DU
420
139 92 93 94 95
B4
See C/6-34
301
A25
A12
420A
D1
See C/6-38
B7 125 A36
431 415
10
B14
B1
401
812D
B6 B12 A16 A4 408
806C
96 97 98 99 100
807C 810E
B11 B10
400 412
813B 835C
B5 B18
A15 A6
422 432
836C 802C
B16
A18
B18 B4
826
A11
811
101 102 103
A23 421 A30 A34 A24
808
128
834
B3
418
A27
B15 438E
B9 439E
650
$21 CAN-BUS To EMS See C/6-40
104
9804/1103
50 - 15 - 10/42
4160-C/6-42.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/43

Main Components
1 2 105 106 107 108 109 110 Battery Isolator 24/12 Volt Converter 12 Volt Radio 12 Volt Cigar Lighter 12 Volt Auxiliary Plug Closed Circuit Television Display (CCTV) CCTV Camera
m/cs from 533692 (436B)
Fuses
D3 D7 CCTV (Option) In-cab24/12 Volt Converter (Option)
Note 1: for Fuse ratings, see pages 50-05-01/16 to 26.
Note: Items marked $ indicate remote connections (not shown), ie. $35 Reverse Light/Alarm Feed $36 From Side Light Feed
9804/1103
50 - 15 - 10/43
4160-C/6-43.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 15 - 10/44

1 1
m/cs from 533692 (436B)
600DZ 308A
106
603A
D7
See C/6-38
108
105
308
308B
107
603B
308C
108
603C
603
$35 Reverse Light/Alarm Feed See C/6-38
844D
D3
See C/6-38
802M
118
109
110
9804/1103
50 - 15 - 10/44
4160-C/6-44.1
Issue 1
CONTENTS CONTENTS
Wheeled Loaders
50 - 15 - 10/45
426, 436 Circuit Diagrams - Electrical (continued)

Main Components
1 2 3 4 5 6 7 8 9 Battery Isolator Light Relay Road Light Switch Fog Light Switch Column Switch Front Work Light Relay Front Work Light Switch Rear Work Light Switch
426 m/cs from 532100 436 m/cs from 533692

Lamps
120 121 122 123 124 Fog Lights Dipped Beam Main Beam Front Work Lights Rear Work Lights
Fuses
Note: Items marked $ indicate remote connections (not shown), ie. $1 $2 $3 $4 $5 $6 From EMS A23 To EMS B6 To EMS B12 To EMS B11 To EMS B10 To EMS B5
Note 1: for Fuse ratings, see Fuses 50-05-01/20
9804/1103
50 - 15 - 10/45
4160-C/6 - 31.2
Issue 1*
CONTENTS CONTENTS
Wheeled Loaders
50 - 15 - 10/46

1 1
426 m/cs from 532100 436 m/cs from 533692

2
B1 B2
See 50 - 15 - 10/48 See C/6-34
See50 C/6-34 See - 15 - 10/48 $2 To EMS B6

LH
3
See 50See - 15 C/6-36 - 10/50
132A 201
See 50See - 15 C/6-34 - 10/48 303

005
800
812D
812A
A2
120 803B
812C
A6
812
812B
120
RH
806C 803 806A
$3 To EMS B12
LH
6 P1
C/6-34 See See 50-15-10/48
305
804
A4 A5
806
121
806B RH
805
807
807A
LH
807B 807C
122
RH
810E
201A
006
A3
122 122A
122B
810
810A LH 810B
See C/6-42 See 50-15-10/56
$1 From EMS A23 808
123
810C RH 810D
813C
LH
A1
121
124
813 813A 813D RH
813B
$6 To EMS B5
9804/1103
50 - 15 - 10/46
4160-C/6 - 32.2
Issue 1*
CONTENTS CONTENTS
Wheeled Loaders
50 - 15 - 10/47

1 2 10 11 12 13 14 15 16 Battery Isolator Electronic Monitoring System (EMS) ZF Computer Hazard Warning Switch Hazard Warning Relay Column Switch Beacon Switch 24 Volt Radio 125 126 127 128 129 130 131 132 133 134 135
426 m/cs from 532100 436 m/cs from 533692
Note: Items marked $ indicate remote connections (not shown), ie. $7 $8 $9 $10 $11 $12 12 Volt Trailer Electrics To EMS B18 To EMS B16 Headlight Flash Switch Illumination To EMS B18
Left Front Indicator Left Rear Indicator Right Front Indicator Right Rear Indicator Beacon Interior Light Right Front Side Light Right Rear Side Light Left Front Side Light Left Rear Side Light Number Plate Lights
Fuses
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 C9 P2 Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and Number Plate Lights 12 Volt Trailer Electrics (Option) EMS (Battery Feed) ZF Computer (Battery Feed) Hazard Warning Beacon and Interior Light 24 Volt Radio Headlight Flash Side Lights Direction Indicators Right Side/Tail Lights and Switch Illumination Left Side/Tail Lights and Number Plate Lights Headlight Flash Radio (24 Volt) Beacon and Interior Light Hazard Warning EMS (Battery Feed) ZF Computer (Battery Feed) 12 Volt trailer Electrics
9804/1103
50 - 15 - 10/47
4160-C/6 - 33.2
Issue 1*
CONTENTS CONTENTS
Wheeled Loaders
50 - 15 - 10/48

1 1
426 m/cs from 532100 436 m/cs from 533692

2
B3
B4
301
10
See See C/6-42 50-15-10/56
B5
9832
11
9836
See 50-15-10/54 See C/6-40
202A
See 50 - 15 - C/6-38 10/52 See
C9 12
835C 100 835A 835
$8 To EMS B18
P2
202
B6
125
835D
LH FRONT
300 838
30 49 15
14
126 127
LH REAR
13
837A 49A
L R
835B 836 836B
836A
RH FRONT
836D 837 836C
RH REAR
128
$9 To EMS B16
304E
15
823
129
B7
304
304D
130 B8 16
309
B9
802D 305
$10 Headlight Flash See SeeC/6-32 50 - 15 - 10/46
802C
$12 To EMS B18
802A
131 132 133 134
B1 B10 4
303 800
802
802B
B2
801
801A
See See 50 - 15 - C/6-32 10/46
120 803B
801B
801C
See SeeC/6-32 50 - 15 - 10/46

801D
LH
135
801E
RH
9804/1103
50 - 15 - 10/48
4160-C/6 - 34.2
Issue 1*
CONTENTS CONTENTS
Wheeled Loaders
50 - 15 - 10/49

1 2 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 32A 33 34 35 36 37 38 39 40 41 42 43 44 45 Battery Isolator Starter Solenoids Starter Motor Start Relay Starter Switch Not Applicable Start-up dump Solenoid Thermostart Resistor Thermostart Not Applicable Dump Relay Heater Speed Switch Heater Blower Air Conditioning Switch Air Conditioning Temperature Switch Air Conditioning Pressure Switch Air Conditioning Compressor Air Conditioning Relay Heated Mirror Switch Heated Mirrors Heated Seat Switch Seat Heating Elements Air Suspension Switch Air Suspension Compressor Heated Rear Screen Switch Heated Rear Screen Relay Heated Rear Screen Lights Relay Solenoid Ignition Relay Solenoid 1 Ignition Relay Solenoid 2 Ignition Relay Solenoid 3
426 m/cs from 532100 436 m/cs from 533692
Fuses
A7 A8 A9 A10 C1 C6 Blank Thermostart Dump Relay Ignition Relays
Starter Relay Solenoid Heated Seat/Mirrors and Air Suspension Seat (Option) C7 Air Conditioning (Option) C8 Heater Blower C9 Direction Indicators C10 Heated Rear Screen P3 Starter Solenoid Thermostart Heater Blower Air Conditioning Direction Indicators Heated Seat, Mirrors and Air Suspension Seat Heated RearScreen Ignition Relays
Note: Items marked $ indicate remote connections (not shown), ie. $13 $14 $15 $16 To EMS A34 Indicators To EMS A24 To EMS B4
9804/1103
50 - 15 - 10/49
4160-C/6 - 35.2
Issue 1*
CONTENTS CONTENTS
Wheeled Loaders
50 - 15 - 10/50

1 1
426 m/cs from 532100 436 m/cs from 533692

2
001
203A
17
+
19 C1
127
18
128
$13 To EMS 34
P3
20
203 1
002
A7
111
21 22
See C/6-42 See 50-15-10/56
7 2 8 9 6 5
A8
113
23
24 25
000
A9
129
C8
27
112
28
822 821 820
26 32A C7 29 30 31
873A 873 873
862
32
109
863 863B
863A
862
825
600BY
33
119A
34
830
C6
119
35
872
36
119B
37
38
C9
100
$14 Indicators See SeeC/6-34 50-15-10/48
39
103A 826 834
$16 To EMS B4 See C/6-42 See 50-15-10/56
C10
$15 To EMS A24

103
See C/6-42 See 50-15-10/56
841
40 42 43 44 45 136
41
132A
000A
A10
132
132C
132D
132E
132F
9804/1103
50 - 15 - 10/50
4160-C/6 - 36.2
Issue 1*
CONTENTS CONTENTS
Wheeled Loaders
50 - 15 - 10/51

Main Components
1 2 10 11 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 Battery Isolator Electronic Monitoring System (EMS) ZF Computer Ignition Relay 1 Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Pump Horn Ignition Relay 2 Column Switch Front Wiper Motor Intermittent Wiper Relay Front Washer Pump 24 Volt Cigar Lighter Shutdown Relay E.S.O.S. Reverse Relay Reverse Alarm Ignition Relay 3 Brake Light Switch Changeover Switch Changeover Solenoid Lift Ram Proximity Switch Detent Coil (Lift Ram Reset) Shovel Ram Proximity Switch Detent Coil (Shovel Ram Reset) Detent Coil (Float)
426 m/cs from 532100 436 m/cs from 533692

Lamps
137 138 139 140 Left Fog Light Right Fog Light Left Brake Light Right Brake Light
Fuses
C2 C3 C4 C5 D1 D2 D3 D5 D6 D7 D8 D9 D10 P4 24 Volt Cigar Lighter Blank Rear Wash/Wiipe Front Wash/Wipe and Horn EMS (Ignition Feed) ZF Computer (Ignition Feed) CCTV (Option) ESOS and Cold Start Advance Reverse Lights and Alarm In-cab 24/12 Volt Converter (Option) Blank Brake Lights Float, Lift and Shovel Reset and 4th Spool EMS (Ignition Feed) ZF Computer (Ignition Feed) Rear Wash/Wipe Front Wash/Wipe and Horn Cigar Lighter (24 Volt) ESOS and Cold Start Advance Reverse Alarm/Lights Headlight Flash Brake Lights Shovel and Arm Reset CCTV In-cab 24/12 Volt Converter
Note: Items marked $ indicate remote connections (not shown), ie. $17 $18 $19 $20 CCTV Spare To EMS A11 To CCTV
9804/1103
50 - 15 - 10/51
4160-C/6 - 37.2
Issue 1*
CONTENTS CONTENTS
Wheeled Loaders
50 - 15 - 10/52

1 1
426 m/cs from 532100 436 m/cs from 533692

2
+
D3 46
See C/6-38 See 50-15-10/52
132C 204 008
118
+
$17 CCTV See C/6-44 See 50-15-10/58
125
D1 D2
10 11 See See C/6-40 50-15-10/54

102B
See 50-15-10/56 See C/6-42
9916A
47 C4
102 102A
827
48
815
C3
$18 Spare
816
814
49 50
105B
53
817 818
51
See C/6-36
132D 204B 007
829
C5
105
105A
52
831 105C 828 819B
54
819
819A
55
C2
811
124
57
809
56 58 60
844 844A
P4
204A
D5
$19 To EMS A11 See C/6-42 See 50-15-10/56

107
59 D6
See C/6-40 See 50-15-10/54
115 9916J
137 138
844D
844B
204C
61
009
D7
$20 To CCTV See C/6-44 See 50-15-10/58
108
See SeeC/6-44 50-15-10/58
See C/6-36 See 50-15-10/50
132E
D8
$18 Spare
D9
126
62
847
847A
139 140
847B
63
104G
861
64
D10
65
104 104C
852
67
66
104B
851
68
104H
69
9804/1103
50 - 15 - 10/52
4160-C/6 - 38.2
Issue 1*
CONTENTS CONTENTS
Wheeled Loaders
50 - 15 - 10/53

Main Components
70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 Gear Box Controller Unit Torque Converter Out Temperature Sensor Reverse Relay Solenoid Load Suspension Solenoid Load Suspension On/Off Switch Parking Brake On/Off Switch(411 to 446) Parking Brake On/Off Switch (456) Auto/Manual Switch On/Off Switch Pressure Switch Transmission Disconnect Button Parking Brake Solenoid Internal Gear Chain Speed Sensor Turbine Speed Sensor Engine Speed Sensor Output Speed Sensor Forward/Reverse Rocker Switch Hand Controller Transmission Kick Down Button ZF Diagnostic Port ZF Display Plug
426 m/cs from 532100 436 m/cs from 533692

Fuses
B5 D2
ZF Computer (Battery Feed) ZF Computer (Ignition Feed)
Note: Items marked $ indicate remote connections (not shown), ie. $21 CAN-BUS To EMS $22 To EMS A30 (456 Only)
9804/1103
50 - 15 - 10/53
4160-C/6 - 39.2
Issue 1*
CONTENTS CONTENTS
Wheeled Loaders
50 - 15 - 10/54

70
426 m/cs from 532100 436 m/cs from 533692
$21 CAN-BUS to EMS C/6-42 See See 50-15-10/56
7 9454 9904 9908 13 VPS1
9462A 9574 9570
421
71
438 439
9458 39 ER1
9462 46 VMGA2
9916J
72
25
9808
ADM2
CANF-H CANF-L
07
438B 438A 9856 9920 9852
26 27
9916M
73
897
CANF-T 05 VM2
02
9916H
74
01
896
VM1 30
9916F
75
9820B
848
57
76
9916D 9820
9820A
81
ED10
21
11
893
9900
9916G
77 78 79
840 9816B
08
9824
29
ED11 03 42 VMG1 EF3
9424
9420
9916A
82
9414
9410
80
9916B 9816A 9916
41
9816
ED9
EF2
83
9404 9400
66
D2
See C/6-38 See 50-15-10/52
9916A
45
VPI
19
EF1
84
9836
68
VPE2
14
B5
See C/6-34 See 50-15-10/48
9832
23 EF4 62
VPE1 ED13 VMG2 04 9500 ED8 44 ED3 20 ED4 43 ED6 67 ED5 64 ED1 63 ED2 65 ED7 22
15 18
31
9504
9532A
9508
85
2 3
880 2
882 3
881 9548 9544 9528 9524 9540 4
9536A
86
9532
1 F N R B1 B2
9864 9648 9652 9644
KD
9536
87 88
4 3 2
9598
9594
9916K
9640
89
9590
90
9804/1103
50 - 15 - 10/54
4160-C/6 - 40.2
Issue 1*
CONTENTS CONTENTS
Wheeled Loaders
50 - 15 - 10/55

Main Components
1 2 10 91 92 93 94 95 96 97 98 99 100 101 102 103 104 Battery Isolator Electronic Monitoring System (EMS) EMS Diagnostic Port Buzzer Fuel Level Sender Water Temperature Sender Transmission Oil Temperature Sender Engine Oil Pressure Switch Air Filter Blockage Switch Steer Pressure Switch Brake Pressure Switch Emergency Steer Switch Shutdown Relay Coil Front Work Light Relay Coil Heated Rear Screen Relay Coil Alternator
426 m/cs from 532100 436 m/cs from 533692

Fuses
Note: Items marked $ indicate remote connections (not shown), ie. $21 $23 $24 $25 $26 $27 $28 $29 $30 $31 $32 $33 $34 CAN-BUS To EMS From Fuse A6 From Fuse A4 From Fuse A5 From Front Work Light Switch From RearWork Light Switch From LH Indicator Feed From RH Indicator Feed From Side Light Feed From Heated Rear Screen Switch From ZF Computer (Park Brake Status-456 Only) From Start Relay Coil 120 ohm Resistor
9804/1103
50 - 15 - 10/55
4160-C/6 - 41.2
Issue 1*
CONTENTS CONTENTS
Wheeled Loaders
50 - 15 - 10/56

1 1
426 m/cs from 532100 436 m/cs from 533692

2
91
4 125A 425 A26 3 423 A2
2 5 600BX A35 A13 600G 600DU 420
+
1 424 A3
139 92 93 94 95
B4
See 50-15-10/48 See C/6-34
301
A25
A12
420A 431 415 401
D1
See C/6-38 See 50-15-10/52
B7 125 A36
10
B14 B1
812D 806C 807C 810E 813B 835C 836C 802C 826
B6 B12 B11 B10 B5 B18 B16 B18 B4 A16 A4 A15 A6 408 400 412 422 432
96 97 98 99 100
A18
A11
811
101 102 103
A23 421 A30 A34 A24
808
128
834
B3
418
A27
B15 438E
B9 439E
650
$21 CAN-BUS To EMS See 50-15-10/54 C/6-40
104
9804/1103
50 - 15 - 10/56
4160-C/6 - 42.2
Issue 1*
CONTENTS CONTENTS
Wheeled Loaders
50 - 15 - 10/57

Main Components Fuses
1 2 105 106 107 108 109 110 Battery Isolator 24/12 Volt Converter 12 Volt Radio 12 Volt Cigar Lighter 12 Volt Auxiliary Plug Closed Circuit Television Display (CCTV) CCTV Camera D3 D7
426 m/cs from 532100 436 m/cs from 533692
CCTV (Option) In-cab24/12 Volt Converter (Option)
Note: Items marked $ indicate remote connections (not shown), ie. $35 Reverse Light/Alarm Feed $36 From Side Light Feed
9804/1103
50 - 15 - 10/57
4160-C/6 - 43.2
Issue 1*
CONTENTS CONTENTS
Wheeled Loaders
50 - 15 - 10/58

1 1
426 m/cs from 532100 436 m/cs from 533692

2
600DZ 308A
106
603A
D7
See 50-15-10/52 See C/6-38
108
105
308
308B
107
603B
308C
108
603C
603
$35 Reverse Light/Alarm Feed See 50-15-10/52 C/6-38 See
844D
D3
See 50-15-10/52 See C/6-38

802M
118
109
110
9804/1103
50 - 15 - 10/58
4160-C/6 - 44.2
Issue 1*
CONTENTS
Wheeled Loaders
50 - 20 - 01/1
406, 407, 408, 409 Circuit Diagrams - Hydraulic

1 2 2A 2B 2C Steering Priority Valve Loader Control Valve Main Relief Valve Pressure Test Point Quick Hitch Control Spool 2D 2E 2F 2G 2H Lift Control Spool Shovel Control Spool Auxiliary Control Spool Auxiliary Relief Valve Auxiliary Relief Valve 3 3A 3B 4 5 Orbitrol Steering Unit Steering System Relief Valve Steering Shock Valves Filter Tank 6 7 8 9 10 Pump Shovel Ram Lift Ram Quick Hitch Ram Steering Ram
10
3 3B 2 2B
2F
2C
2D
2E
3A 2G
2A 2H 1
A216700
9804/1103
50 - 20 - 01/1
Issue 2*
CONTENTS
Wheeled Loaders
50 - 20 - 01/5
416 Circuit Diagrams - Hydraulic

6 4 2 1 5
*To m/c no. 529342
34 9 17 16 21
11
10
13
12
32
15
14
31
7 36 37 36 37 33 36 37 36
22
19 37 30
18
20
40
41
26 24
28 23 27 25 28 35 38
39
29
9804/1103
4150 - E/2-3.3
50 - 20 - 01/5
Issue 2*
CONTENTS
Wheeled Loaders
50 - 20 - 01/6

Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Inlet Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valves Controls Isolator Valve Steer Priority Relief Valve. Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. (2 Stage) Shovel Ram Rod Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather
*To m/c no. 529342
9804/1103
50 - 20 - 01/6
Issue 2*
CONTENTS
Wheeled Loaders
50 - 20 - 01/6A

Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Not Used Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Inlet Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valves Controls Isolator Valve Steer Priority Relief Valve. Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. (2 Stage) Shovel Ram Rod Side A.R.V. Not Used Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Engine Driven Gear Pump
9804/1103
50 - 20 - 01/6A
4150-E/2-5.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 01/6B

6 4 2 1 5
9 17 16 21
11
10
13
12
32
15
14
31
7 36 37 36 37 33 36 37 36
22
19 37 30 42 18
20
40
41
26 24
28 23 27 25 28 35 38
39
29
A211071
9804/1103
4150 - E/2-6.1
50 - 20 - 01/6B
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 01/7
426 Machines with 4-Ram Loader Circuit Diagrams - Hydraulic

Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. (2 Stage) Shovel Ram Rod Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump
9804/1103
50 - 20 - 01/7
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 01/8

6 4 2 1 5
42
41 9 17 16
33
21
11
10
13
12
31
15
14
30
7 35 36 35 36 32 35 36 35 36 18
22
19
20
39
40
24
38 23 28 27 25 34 26 29
A220352 A220352
37
9804/1103
50 - 20 - 01/8
Issue 2
CONTENTS
Wheeled Loaders
50 - 20 - 01/9
426 Machines with Z-Bar Loader Circuit Diagrams - Hydraulic

6 4 2 1 5
42
41 9 17 16
33
21
11
10
13
12
31
15
14
30
7 35 36 35 36 32 35 36 35 36 18
22
19
20
39
40
24
38 23 28 27 25 34 26 29
A220342 A220342
37
9804/1103
50 - 20 - 01/9
Issue 2
CONTENTS
Wheeled Loaders
50 - 20 - 01/10

Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Shovel Ram Head Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump
9804/1103
50 - 20 - 01/10
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 01/12

Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Main Pump Control Piston Main Pump Stroking Piston Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. (2 Stage) Shovel Ram Rod Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump
9804/1103
50 - 20 - 01/12
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 01/13

6 5 4 2 1
46
25 45 26 9 23 11 10 13 12 35 15 14 34 17 16 24 7 39 40 39 40 36 39 40 39 40 37 8
21 22 18 19
20
28
43
44
27
32 31 29 38 30 33 41
A220372 A220372
42
9804/1103
50 - 20 - 01/13
Issue 2
CONTENTS
Wheeled Loaders
50 - 20 - 01/14

Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Main Pump Control Piston Main Pump Stroking Piston Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Shovel Ram Head Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump
9804/1103
50 - 20 - 01/14
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 02/1
412S, 414S Circuit Diagrams - Hydraulic

Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 * 36 * 37 Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Charge Valve Accumulators Pump P1 M.R.V. Pump P2 M.R.V. Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Unloader Valve Servo Filter Steer Relief Valve Lift Spool Shovel Spool Quickhitch Spool Auxiliary Spool Pump P1 Pump P2 Changeover Valve Servo Control Valve Controls Isolator Valve Steer Valve Steer Rams Oil Cooler and By-pass Tank Steer Priority Valve Steer Shock Valves Suction Strainer Return Filter/Diffuser Filler/Breather Lift Ram Head Side A.R.V. Pressure Reducing Valve Brake Valve Brakes Trailer Brake Option Trailer Hitch Option
9804/1103
50 - 20 - 02/1
4170-E/2-1.3
Issue 2*
CONTENTS
Wheeled Loaders
50 - 20 - 02/2
412S, 414S Circuit Diagrams - Hydraulic

36 6
1 34
35
37
5 9 10 32
12 33
7 15 8 13 14
18
17
16 11 19
27
30 23 21 20 25 28 24 28
31
29
22
26
9804/1103
4170 - E/2-2.4
50 - 20 - 02/2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 20 - 02/3
416S Circuit Diagram - Hydraulics
27
40
41
28
35 39 38
24 42 8 23 25 29 21 26
22 37 11 36 13 37 36 32 31 15 30 37 36 33 17 36 18 7 10 12 14 16 9 6 20 37 37 19
3 34
6 4 2 1
9804/1103
50 - 20- 02/3
4170-E/2-3.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 02/4
416S Circuit Diagrams - Hydraulic

Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Servo Filter with Bypass Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Inlet Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valves Controls Isolator Valve Steer Priority Relief Valve. Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Emergency Steer Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Engine Driven Gear Pump
9804/1103
50 - 20 - 02/4
4170-E/2-4.1
Issue 1
CONTENTS CONTENTS
Wheeled Loaders
50 - 20 - 03/1
* 407B
Zx, 408B ZX, 409B ZX - Servo
To m/c no. 757399

Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14A 14B 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Steer Ram Steer Valve Steer Shock Valves Brake Fluid Reservoir Brake Valve Brake Caliper Hydrostatic Pump Hydrostatic System Charge Pump Inching Valve Forward/Reverse Valve FBA Amplifier Valve Loop Relief Valve Loop Relief Valve Hydrostatic Pump Case Drain Hydrostatic Motor Case Drain Sequence Valve Purge and Relief Valve Brake Pressure Defeat Valve Proportional Solenoid Valve Hi/Low Range Valve Hydrostatic Motor Transmission Oil Cooler Filler/Breather Hydraulic Return Line Filter Hydraulic Tank Cooling Fan Pump Cooling Fan Motor Main Hydraulic Pump Steering Priority Valve Main Relief Valve Steering Relief Valve Shovel Spool Lift Spool Auxiliary 1 Spool Auxiliary 2 Spool Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Lift Ram Head Side A.R.V. Servo Control Isolator Valve Servo Control Valve Shovel Ram Lift Rams Quickhitch Locking Ram Power Diverter Valve Auxiliary 1 Circuit Quick Release Couplings Auxiliary 2 Circuit Quick Release Couplings Hose Burst Check Valve (option) Hose Burst Check Valve (option) Hose Burst Check Valve (option) Balancing Valve (A to G) Test Points
9804/1103
50 - 20 - 03/1
4210-E/2-1.1
Issue 2*
CONTENTS
Wheeled Loaders
50 - 20 - 03/2
407B ZX, 408B ZX, 409B ZX - Servo Circuit Diagrams - Hydraulic
To m/c no. 757399
50D 50B 1 4 10 50C 3 50A 5 12 2 6 21 7 8 13 14B 14A 46 40 18 50F 19 17 15 9 11 50E 16 20
47 49 41 23 25 24 27 42 50G
CONTENTS
22
30 26 29
35
36 37 38
39
48
43 44
28
31
32
33
34
45
9804/1103
50 - 20 - 03/2
4210 - E/2 - 2.2
Issue 2*
CONTENTS CONTENTS
Wheeled Loaders
50 - 20 - 03/3
* 407B ZX, 408B ZX, 409B ZX - Manual Circuit Diagrams - Hydraulic
To m/c no. 757399
48D 48B 1 4 10 48C 3 48A 5 12 2 6 21 7 8 13 14B 14A 44 38 18 48F 19 17 15 9 11 48E 16 20
45 47 39 23 25 24 27 40 48G 28 31 32 33 34 41 42 26 29 30 35 36 37 46
22
43
9804/1103
50 - 20 - 03/3
4210 - E/2 - 3.1
Issue 2*
CONTENTS CONTENTS
Wheeled Loaders
50 - 20 - 03/4
* 407B
ZX, 408B ZX, 409B ZX - Manual
To m/c no. 757399
Circuit Diagrams - Hydraulics (continued) Component Key

1 2 3 4 5 6 7 8 9 10 11 12 13 14A 14B 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Steer Ram Steer Valve Steer Shock Valves Brake Fluid Reservoir Brake Valve Brake Caliper Hydrostatic Pump Hydrostatic System Charge Pump Inching Valve Forward/Reverse Valve FBA Amplifier Valve Loop Relief Valve Loop Relief Valve Hydrostatic Pump Case Drain Hydrostatic Motor Case Drain Sequence Valve Purge and Relief Valve Brake Pressure Defeat Valve Proportional Solenoid Valve Hi/Low Range Valve Hydrostatic Motor Transmission Oil Cooler Filler/Breather Hydraulic Return Line Filter Hydraulic Tank Cooling Fan Pump Cooling Fan Motor Main Hydraulic Pump Steering Priority Valve Main Relief Valve Steering Relief Valve Shovel Spool Lift Spool Auxiliary 1 Spool Auxiliary 2 Spool Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Lift Ram Head Side A.R.V. Shovel Ram Lift Rams Quickhitch Locking Ram Power Diverter Valve Auxiliary 1 Circuit Quick Release Couplings Auxiliary 2 Circuit Quick Release Couplings Hose Burst Check Valve (option) Hose Burst Check Valve (option) Hose Burst Check Valve (option) Balancing Valve (A to G) Test Points
9804/1103
50 - 20 - 03/4
4210-E/2-4.1
Issue 2*
CONTENTS
Wheeled Loaders
50 - 20 - 03/5
407B ZX, 408B ZX, 409B ZX Circuit Diagrams - Hydraulics (continued) Component Key
1 2 3 4 5 6 7 8 9 10 11 12 13 14A 14B 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 Steer Ram Steer Valve Steer Shock Valves D/A Valve Pump Control Piston Thermostatic Valve Hydrostatic Pump Hydrostatic System Charge Pump Inching Valve Forward/Reverse Solenoid Charge Relief Valve Loop Relief Valve Loop Relief Valve Hydrostatic Pump Case Drain Hydrostatic Motor Case Drain Travel Direction Valve Purge and Relief Valve Brake Pressure Defeat Valve Pressure Override Valve Hi/Low Range Valve Hydrostatic Motor Transmission Oil Cooler Filler/Breather Hydraulic Return Line Filter Hydraulic Tank Cooling Fan Pump Cooling Fan Motor Main Hydraulic Pump Steering Priority Valve Main Relief Valve Steering Relief Valve Shovel Spool Lift Spool Auxiliary 1 Spool Auxiliary 2 Spool Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Lift Ram Head Side A.R.V. Servo Control Isolator Valve Servo Control Valve Shovel Ram Lift Rams Quickhitch Locking Ram Power Diverter Valve Auxiliary 1 Circuit Quick Release Couplings Auxiliary 2 Circuit Quick Release Couplings Hose Burst Check Valve (option) Hose Burst Check Valve (option) Hose Burst Check Valve (option) Creep Speed Kit (option) (A to H) Test Points Brake Valve Brake Caliper Brake Reservoir Hydrostatic Motor Control Piston Loop Flushing Valve Smooth Ride System (option)
From m/c no. 757400
9804/1103
50 - 20 - 03/5
4210-E/2-5.2
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 03/6
407B ZX, 408B ZX, 409B ZX Circuit Diagrams - Hydraulic (continued)
From m/c no. 757400
1 53 10 14A
9 50 15 54 19 13 11 52 14B 50 18 20 56
12 2 3 51 7 5
4 8 55
16
49 6 46 21 40
47
41 22 48 23 25 24 27 42 31 50 32 33 34 44 43 26 29 38 30 37 35 36 39 41
45
A370780
9804/1103
50 - 20 - 03/6
4210 - E/2 - 6.2
Issue 1
CONTENTS CONTENTS
Wheeled Loaders
50 - 20 - 04/1
410B ZX Circuit Diagrams - Hydraulic Component Key

1A 1B 2 3 4 5 6 7 8 9 10 11 12 13 14A 14B 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 Steer Ram Steer Ram Steer Valve Steer Shock Valves Steer Pump Thermostatic Valve Hydrostatic Pump Hydrostatic System Charge Pump Inching Valve Forward/Reverse Valve FBA Amplifier Valve Loop Relief Valve Loop Relief Valve Hydrostatic Pump Case Drain Hydrostatic Motor Case Drain Sequence Valve Purge and Relief Valve Brake Pressure Defeat Valve Proportional Solenoid Valve Hi/Low Range Valve Hydrostatic Motor Transmission Oil Cooler Filler/Breather Hydraulic Return Line Filter Hydraulic Tank Cooling Fan Pump Cooling Fan Motor Main Hydraulic Pump Steering Priority Valve Main Relief Valve Steering Relief Valve Shovel Spool Lift Spool Auxiliary 1 Spool Auxiliary 2 Spool Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Lift Ram Head Side A.R.V. Servo Control Isolator Valve Servo Control Valve Shovel Ram Lift Rams Quickhitch Locking Ram Power Diverter Valve Auxiliary 1 Circuit Quick Release Couplings Auxiliary 2 Circuit Quick Release Couplings Hose Burst Check Valve (option) Hose Burst Check Valve (option) Hose Burst Check Valve (option) (A to H) Test Points Brake Valve Brake Caliper Brake Reservoir Low Range Pressure Switch Pressure Differential Valve
9804/1103
50 - 20 - 04/1
4210-E/2 - 8.2
Issue 2*
CONTENTS CONTENTS
Wheeled Loaders
50 - 20 - 04/2
410B ZX Circuit Diagrams - Hydraulic (continued)
53 1A
54 50D 50B 9 11
M9 A XA XB L2 M4 M3 M1
1B 55 52 3 2 51 6
LS
X6
50E
X13
16 10
M3.1
20
50A
M11 M1 M5 M4 A
50C 17 12
15
19
M5
8 7
B
18
X1 M7 L1
M2
50F
21
M2
13
B L2
14B 46 40
L1
14A
47
22
28
EF
CF
LS
30 23
P T
35 29 36
37 38
50H
39 41 48
5 24 27 25 26 50G
31
32
33
34
2 4 1 3
T P
42
43 44
45
A275630
9804/1103
4210 - E/2 - 7.2
50 - 20 - 04/2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 20 - 04/3
411B ZX Circuit Diagrams - Hydraulic

Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 Steer Rams Load Sensing Steer Valve Steer Shock Valves Filler/Breather Return Line Filter Axle Brakes Brake Modulating Valve Accumulator Block Steering/Accumulator Charge Valve Steering Pressure Relief Valve Steer Pump Service Pump Fan Pump Fan Motor Brake Reservoir Inching Pedal Thermostatic Valve Oil Cooler Inching Valve Forward/Reverse Solenoid Transmission Pump Charge Relief Valve Feedback Amplifier Loop Relief Valves 4 Spool Valve Block Main Relief Valve Auxiliary Relief Valves (Shovel Ram) Auxiliary Relief Valve (Lift Rams) Shovel Spool Lift Spool Auxiliary 1 Spool Auxiliary 2 Spool Servo Cut Off Valve Servo Control Valve Sequence Valve Brake Pressure Defeat Valve Proportional Solenoid Valve Purge and Relief Valve Hi/Low Range Valve Transmission Motor Hose Burst Check Valves Quickhitch Rams Quickhitch Diverter Valve Shovel Ram Lift Rams Auxiliary 1 Quick Release Couplings Auxiliary 2 Quick Release Couplings
9804/1103
50 - 20 - 04/3
4210-E/2-9.1
Issue 2*
CONTENTS
Wheeled Loaders
50 - 20 - 04/4
411B ZX Circuit Diagrams - Hydraulics (continued)
15 6
19 23
16 7 2 3
20
38 35 40
36 8 17 21 22 24 37 18
39
41
9 10 4 5 25
1B 1A 2B 2A 3B 3A 4B 4A
44 41
45 34 41
26 11 12 13 14
27
28 33
42 30 29 31 32
43
46
47
A296150
9804/1103
4210 - E/2-10.1
50 - 20 - 04/4
Issue 2*
CONTENTS
Wheeled Loaders
50 - 20 - 05/ 1
456 to m/c no. 539249 Circuit Diagrams - Hydraulic

Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Auxiliary Ram Shovel Ram Lift Rams Brake Valve Service Brake Accumulators Parking Brake Accumulator Parking Brake Valve Loader Valve Emegency Steer Valve Emergency Steer Pump Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Start Up Valve Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Main Pump Control Piston Main Pump Stroking Piston Shuttle Valve Priority Valve Return Filter/Diffuser Filler/Breather Suction Strainer Tank Oil Cooler and By-Pass Steer Valve Steer Shock Vlave Steer rams Servo Control Accumulator Controls Isolator Valve Servo Control Valve Servo Pressure Regulating Valve Auxiliary Circuit Spool Shovel Circuit Spool Lift Circuit Spool Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Head Side Float Solenoid Rod Side Float Solenoid Surge Protection Valve Hydraulic Mode Valve, P2 Disconnect Hydraulic Mode Valve, P1 Pressure Control
* Note: 446 machines from serial no. 540000 to 540012 use the same hydraulic circuit as 436 machines. For these machines refer to hydraulic diagram on pages 50 - 20 - 01/13 and 14
9804/1103
50 - 20 - 05/1
4180 - E/3-7.4
Issue 2*
CONTENTS
Wheeled Loaders
50 - 20 - 05/2
456 to m/c no. 539249 Circuit Diagrams - Hydraulic (continued)

5 4 2 1 3 6 7
10
11 8 40 39 41 9 12
13 37
33 34
38 35
36
42 43 44 15
14
20
20
20 16 20 21 18 3 19 17
32
22
23
28 29 30 26 27 31 25
9804/1103 A263630
24
50-20-05/2
Issue 2*
CONTENTS
Wheeled Loaders
50 - 20 - 05/ 1A
456 from m/c no. 539250 446 from m/c no. 540013 Circuit Diagrams - Hydraulic
Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 Lift Rams Shovel Rams Quickhitch Ram Quickhitch Isolator Brake Valve Brake Accumulators Filter and Bypass Valve (446 to 540009; 456 to 539399) Cooling Fan Motor (446 from 540050; 456 from 539400) Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Main Pump Control Piston Main Pump Stroking Piston Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Not Used Oil Cooler and By-Pass Primary Shuttle Valve Secondary Shuttle Valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump Clipper Valve Engine Driven Gear Pump and Charge Valve Parking Brake Valve Parking Brake Parking Brake Accumulator and Check Valve (Germany Only)
9804/1103
50 - 20 - 05/1A
4180 - E/3-10.3
Issue 1*
CONTENTS
Wheeled Loaders
50-20-05/2A
456 from m/c no. 539250, 446 from m/c no. 540013 Circuit Diagrams - Hydraulic (continued)
EF
A2 A1
S2
48
IN
27
29 28
S1 T OUT
33 5 9 35 40 39 39 40 36 39 40 34 39 18 11 10 13 12 15 14 17 16 38 40 40 47 50
B
49
A C
51
43
41
44 42
4 21 22 20 2 3 1 19
30 32 31 45 23 46 25 26 24
A352802
9804/1103
50-20-05/2A
4180 - E/3-9.3
Issue 1*
CONTENTS
Wheeled Loaders
50 - 20 - 06/1
TM200, TM270 Circuit Diagrams - Hydraulic TM200

1 2 2A 2B 2C 2D 2E 2F 2G 3 3A 3B 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Servo Control Lever Loader Control Valve Main Relief Valve Tilt Control Spool Lift Control Spool Auxiliary Control Spool Extension Control Spool Auxiliary Relief Valve Auxiliary Relief Valve Orbitrol Steering Unit Steering System Relief Valve Steering Shock Valves Servo Pressure Reducing Valve Brake Valve Steer Priority/Charge Valve Tilt Ram Compensating Ram Lift Ram Quick Hitch Rams Extension Ram Steer Ram Pump Quickhitch lock/Auxiliary Diverter Valve Quick Release Couplings Accumulator Pressure Test Point Filter Breather Sealed Cap Brakes Hydraulic Tank Check Valve
9804/1103
50 - 20 - 06/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 06/2
TM200, TM270 Circuit Diagrams - Hydraulic (continued) TM200
17 4 12 1 7 8 3 3B 17 11 9 10 14 3A 15 2 2F 2G 17 6 17 16 21 5
2B 2A
2C
2D
2E
17 13 20 18 22 19
A240271 A240271
9804/1103
50 - 20 - 06/2
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 07/1
3 3A 10
12
11
2 4 1 3
7 15
8
S LS
16
2F 2E 2G
4 1
17 4
23
17
EF P G
5 13
18
2A
2B
2C
2D 2 6 14 21 19 22
20
18
A277190
9804/1103
50 - 20 - 07/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 07/2

1 2 2A 2B 2C 2D 2E 2F 2G 3 3A 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Servo Control Lever Loader Control Valve Auxillary Control Spool Extension Control Spool Tilt Control Spool Lift Control Spool Main Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Eaton Load Sensing/Steer Valve Steering Shock Valves Brake modulating Valve Accumulator Charge Valve Unloader Valve Quickhitch Rams Extension Ram Tilt Ram Lift Ram Compensating Rams Steer Rams Main Pump Auxillary Pump Quickhitch lock/Auxiliary Diverter Valve Quick Release Couplings Accumulator Pressure Test Point Filter Breather Sealed Cap Hydraulic Tank Front Axle Brakes
9804/1103
50 - 20 - 07/2
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 07/3
TM200, TM270 Circuit Diagrams - Hydraulic (continued)

1 2 2A 2B 2C 2D 2E 2F 2G 3 3A 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Servo Control Lever Loader Control Valve Auxillairy Conrol Spool Extension Control Spool Tilt Control Spool Lift Control Spool Main Relif Valve Auxiliary Releif Valve Auxiliary Releif Valve Load Sensing Steer Valve Steering Shock Valves Brake Modulating Valve Accumulator Charge Valve Unloader Valve Quickhitch Rams Extension Ram Tilt Ram Lift Ram Compensating Rams Steer Rams Main Pump Auxiliary Pump Quickhitch Lock/Auxiliary Diver Valve Quick Release Couplings Accumulator Block Pressure Test Point Filter Breather Sealed Cap Hydraulic Tank Front Axle Brakes Servo Cut-off Valve Pressure Reducing Valve Hydraulic Tow Hitch (Option) Oil Cooler
TM270 from m/c no. 787118
9804/1103
50 - 20 - 07/3
4225-E/26-1.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 07/4
TM200, TM270 Circuit Diagrams - Hydraulics (continued)

11
TM270 from m/c no. 787118
16
15
10
26
1 2F 2G 2B 25 24 18 17 5 23 19 13 2E 4 12 27 21 3A 3 20 22 2C
4225-E/26-2.1
2D
9804/1103
50 - 20 - 07/4
14
2A
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 08/1
426B, 436B, 446B Circuit Diagrams - Hydraulics 426 Machines with 4-Ram Loader
Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. (2 Stage) Shovel Ram Rod Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump
m/cs to 531203
9804/1103
50 - 20 - 08/1
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 08/2
426B, 436B, 446B Circuit Diagrams - Hydraulic (continued) 426 Machines with 4-Ram Loader
6 4 2 1 5
m/cs to 531203
42
41 9 17 16
33
21
11
10
13
12
31
15
14
30
7 35 36 35 36 32 35 36 35 36 18
22
19
20
39
40
24
38 23 28 27 25 34 26 29
A220352
37
9804/1103
50 - 20 - 08/2
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 08/3
426B, 436B, 446B Circuit Diagrams - Hydraulic 426 Machines with Z-Bar Loader
4 2 1 5
m/cs to 531203
42
41 9 17 16
33
21
11
10
13
12
31
15
14
30
7 35 36 35 36 32 35 36 35 36 18
22
19
20
39
40
24
38 23 28 27 25 34 26 29
A220342
37
9804/1103
50 - 20 - 08/3
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 08/4
426B, 436B, 446B Circuit Diagrams - Hydraulics (continued) 426 Machines with Z-Bar Loader
Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Shovel Ram Head Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump
m/cs to 531203
9804/1103
50 - 20 - 08/4
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 08/5
426B, 436B, 446B Circuit Diagrams - Hydraulics 436 Machines with 4-Ram Loader
Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Main Pump Control Piston Main Pump Stroking Piston Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. (2 Stage) Shovel Ram Rod Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump
m/cs to 533195
9804/1103
50 - 20 - 08/5
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 08/6
6 5 4 3 2 1
m/cs to 533195
46
25 45 26 9 23 11 10 13 12 35 15 14 34 17 16 24 7 39 40 39 40 36 39 40 39 40 37 8
21 22 18 19
20
28
43
44
27
32 31 29 38 30 33
A220362
42
41
9804/1103
50 - 20 - 08/6
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 08/7
426B, 436B, 446B Circuit Diagrams - Hydraulic (continued) 436 Machines with Z-Bar Loader
6 5 4 2 1
m/cs to 533195
46
25 45 26 9 23 11 10 13 12 35 15 14 34 17 16 24 7 39 40 39 40 36 39 40 39 40 37 8
21 22 18 19
20
28
43
44
27
32 31 29 38 30 33
A220372
42
41
9804/1103
50 - 20 - 08/7
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 08/8
Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Start Up Valve Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Main Pump Control Piston Main Pump Stroking Piston Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Shuttle Valve Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump
m/cs to 533195
9804/1103
50 - 20 - 08/8
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 08/9
426B, 436B, 446B Circuit Diagrams - Hydraulic 426 Machines with 4-Ram Loader
Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Not Used Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. (2 Stage) Shovel Ram Rod Side A.R.V. Not Used Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump Clipper Valve Engine Driven Gear Pump
m/cs from 531204
9804/1103
50 - 20 - 08/9
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 08/10
6 4 2 1 5
m/cs from 531204
42
41 9 17 16 21
11
10
13
12
31
15
14
30
7 35 36 35 36 32 35 36 35 36 43 18
22
19
44
20
39
40
24
38 23 28 27 25 34 26 29
A220353
37
9804/1103
50 - 20 - 08/10
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 08/11
6 4 2 1 5
m/cs from 531204
42
41 9 17 16 21
11
10
13
12
31
15
14
30
7 35 36 35 36 32 35 36 35 36 43 18
22
19
44
20
39
40
24
38 23 28 27 25 34 26 29
A220343
37
9804/1103
50 - 20 - 08/11
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 08/12
Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Not Used Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Pump Control Piston Pump Stroking Piston Pump Standby Pressure Relief Valve Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Shovel Ram Head Side A.R.V. Not Used Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump Clipper Valve Engine Driven Gear Pump
m/cs from 531204
9804/1103
50 - 20 - 08/12
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 08/13
426B, 436B, 446B Circuit Diagrams - Hydraulic 436 Machines with 4-Ram Loader
Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Not Used Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Main Pump Control Piston Main Pump Stroking Piston Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. (2 Stage) Shovel Ram Rod Side A.R.V. Not Used Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump Clipper Valve Engine Driven Gear Pump
m/cs from 533196
9804/1103
50 - 20 - 08/13
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 08/15
426B, 436B, 446B Circuit Diagrams - Hydraulics (continued) 436 and 446 Machines with Z-Bar Loader
6 5 4 2 1
m/cs from 533196 (436B ZX) m/cs from 540000 (446B ZX)
46
25 45 26 9 23 11 10 13 12 35 15 14 34 17 16 24 7 39 40 39 40 36 39 40 39 40 47 21 22 18 19 48
20
28
43
44
27
32 31 29 38 30 33
A220373
42
41
9804/1103
50 - 20 - 08/15
Issue 2*
CONTENTS
Wheeled Loaders
50 - 20 - 08/16
426B, 436B, 446B Circuit Diagrams - Hydraulic (continued) 436 and 446 Machines with Z-Bar Loader
Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Lift Rams Shovel Rams Quickhitch Ram Auxiliary Rams Brake Valve Brake Accumulators Servo Pressure Regulating Valve Not Used Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Main Pump Control Piston Main Pump Stroking Piston Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Shovel Ram Head Side A.R.V. Not Used Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump Clipper Valve Engine Driven Gear Pump
m/cs from 533196 (436B ZX) m/cs from 540000 (446B ZX)
9804/1103
50 - 20 - 08/16
Issue 2*
CONTENTS
Wheeled Loaders
50 - 20 - 08/17
426B, 436B, 446B Circuit Diagram - Hydraulic (continued) 436 Machines with 4-Ram Loader
Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Lift Rams Shovel Rams Quickhitch Ram Quickhitch Isolator Brake Valve Brake Accumulators Not Used Not Used Loader Valve Auxiliary Circuit Compensator Spool Auxiliary Circuit Spool Quickhitch Circuit Compensator Spool Quickhitch Circuit Spool Shovel Circuit Compensator Spool Shovel Circuit Spool Lift Circuit Compensator Spool Lift Circuit Spool Priority Valve Main Pump Control Piston Main Pump Stroking Piston Main Pump Standby Pressure Relief Valve Main Pump System Pressure Relief Valve Secondary Pump Control Piston Secondary Pump Stroking Piston Secondary Pump Standby Pressure Relief Valve Secondary Pump System Pressure Relief Valve Changeover Valve (4-spool only) Servo Control Valve Servo Control Accumulator Steer Valve Steer Rams Steer Shock Valve Controls Isolator Valve Lift Ram Head Side A.R.V. Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Not Used Oil Cooler and By-pass Primary Shuttle Valve Secondary Shuttle valve Tank Suction Strainer Return Filter/Diffuser Filler/Breather Emergency Steering Valve Emergency Steering Pump Clipper Valve Engine Driven Gear Pump
From m/c no. 533692
9804/1103
50 - 20 - 08/17
4160-E/3-23.1
Issue 1
CONTENTS
Wheeled Loaders
50 - 20 - 08/18
426B, 436B, 446B Circuit Diagrams - Hydraulics (continued) 436 Machines with 4-Ram Loader
From m/c no. 533692
6 5 48 27 29 28
33
43
41
47 40 39 39 40 39 40 39 18 11 10 13 12 15 14 17 16 40 40
44 42
38
21
22 20
2 3
19
30 32 31 45 23 46 25 26 24
9804/1103
4160 - E/3-24.1
50 - 20 - 08/18
Issue 1
INDEX CONTENTS
Fastrac
Contents 1
ALL MODELS Contents

Page No. General Information Fluids, Lubricants and Capacities - 125, 135, 145, 150, 155 (not N. Am. machines) - 125, 135, 145, 150, 155 (N. Am. machines) - 185 (not N. Am. machines) - 185 (N. Am. machines) - 1115 & 1135 - 2000 Series Machines - 2000 Series Machines (N. America) - 3155 - 3155 (N. America) - 3185 - 3185 (N. America) - Engine Oil (All 2000, 3000 Series Machines) Static Dimensions and Weights - 125, 135, 145, 150, 155 to m/c no. 636000 - 125, 135, 145, 150, 155 from m/c no. 636001 to 636368 - 125, 135, 145, 150, 155, 185 from m/c no. 636369 - 1115 & 1135 - 2000 Series Machines - 3000 Series Machines Data Electrical - General - 125, 135, 145, 150, 155, 185, 1115 & 1135 - 2000 Series Machines - 3000 Series Machines - Fuses - 125, 135, 145, 150, 155 UK machines to serial no. 635329 - 125, 135, 145, 150, 155 UK machines from m/c no. 635330 to 636000 - 125, 135, 145, 150, 155 Export machines to m/c no. 636000 - 125, 135, 145, 150, 155, 185 from m/c no. 636001 - 1115 & 1135 - 2000 & 3000 Series Machines * - Relay Identification - 125, 135, 145, 150, 155 to m/c no. 636000 - 125, 135, 145, 150, 155, 185 from m/c no. 636001 to 637739 - 155, 185 from m/c no. 637740 - 1115 & 1135 to m/c no. 736577 - 1115 and 1135 from m/c no. 736578 - 2000 & 3000 Series Machines External Hydraulics - 125, 135, 145, 150, 155, 185, 1115 & 1135 - 2000 & 3000 Series Machines Front Axle - 125, 135, 145, 150, 155, 185, 1115 & 1135 Rear Axle - 125, 135, 145, 150, 155, 185, 1115 & 1135 Clutch Gearboxes - 125, 135, 145, 150, 155, 185, 1115 & 1135 - 2000 & 3000 Series Machines Transmission - 2000 & 3000 Series Machines Tyre Pressures, Speeds and Loads - 125, 135, 145, 150, 155, 185 - 1115 & 1135 - High Traction Tyres - 2000 Series Machines - 3000 Series Machines
60 - 00 - 01/1 60 - 00 - 01/2 60 - 00 - 01/3 60 - 00 - 01/3A 60 - 00 - 01/4 60 - 00 - 01/5 60 - 00 - 01/6 60 - 00 - 01/7 60 - 00 - 01/8 60 - 00 - 01/9 60 - 00 - 01/10 60 - 00 - 01/11
60 - 00 - 02/1 60 - 00 - 02/2 60 - 00 - 02/3 & 60 - 00 - 02/4 60 - 00 - 02/5 & 60 - 00 - 02/6 60 - 00 - 02/7 & 60 - 00 - 02/8 60 - 00 - 02/9 & 60 - 00 - 02/10
60 - 05 - 01/1 60 - 05 - 01/1A 60 - 05 - 01/1B 60 - 05 - 01/2 60 - 05 - 01/3 60 - 05 - 01/3 60 - 05 - 01/4 & 60 - 05 - 01/5 60 - 05 - 01/6 60 - 05 - 01/6A, 6B 60 - 05 - 01/7 60 - 05 - 01/8 & 60 - 05 - 01/9 60 - 05 - 01/9A 60 - 05 - 01/10 & 60 - 05 - 01/11 60 - 05 - 01/11A & 60 - 05 - 01/11B 60 - 05 - 01/12 & 60 - 05 - 01/13 60 - 05 - 02/1 60 - 05 - 02/1A 60 - 05 - 02/2 60 - 05 - 02/2 60 - 05 - 02/2 60 - 05 - 04/1 60 - 05 - 04/2 60 - 05 - 04/3 60 - 05 - 06/1 60 - 05 - 06/2 60 - 05 - 06/3 60 - 05 - 06/4 60 - 05 - 06/5
9804/1103
Fastrac Contents - 1
Issue 11*
INDEX CONTENTS
Fastrac
Contents 2
ALL MODELS Contents

Data (continued) Brakes -125, 135, 145, 150, 155, 185 -1115, 1135 - 2000 & 3000 Series Machines Steering - 125, 135, 145, 150, 155, 185 - 1115, 1135 - 2000 & 3000 Series Machines Suspension - 125, 135, 145, 150, 155, 185 - 1115, 1135 - 2000 & 3000 Series Engine (Perkins) - 125, 135, 145, 150, 155, 185 - 2000 Series Machines - 3000 Series Machines Selectronic System Air Conditioning System - 2115 & 2150 Fault Finding Electronic Draft Control - 125, 135, 145, 150, 155, 185 to m/c no. 637733 - 125, 135, 145, 150, 155, 185 from m/c no. 637734, 1115, 1135, 2000 & 3000 Series (E.C.U.s Type D+ and Type B) Vehicle Electrics - 2000 Series, 3000 Series Electronic Management System - 2000 & 3000 Series Machines Complete Transmission Wet Master Clutch - 2000 & 3000 Series Machines PTO Clutches 2/4 Wheel Drive NoSPIN Differential (Front Axle) Differential Lock (Rear Axle) - 125, 135, 145, 150, 155, 185 - 1115, 1135, 2115, 2125, 2135, 2150 - 2000 Series, 3000 Series Brakes - 125, 135, 145, 150, 155, 185 - 1115 & 1135 - 2000 Series, 3000 Series Steering - 125, 135, 145, 150, 155, 185 - Fastrac 1115, 1135, 2115, 2125, 2135, 2150 - 2000 Series (Front Axle) - 2115, 2125, 2135 (Rear Axle, 4WS) - 3000 Series Page No. 60 - 05 - 10/1 60 - 05 - 10/3 60 - 05 - 10/3A 60 - 05 - 10/1 60 - 05 - 10/4 60 - 05 - 10/4A 60 - 05 - 10/2 60 - 05 - 10/5 60 - 05 - 10/5A 60 - 05 - 15/1 60 - 05 - 15/2 & 60 - 05 - 15/3 60 - 05 - 15/4 60 - 05 - 16/1 60 - 05 - 17/1
60 - 10 - 04/1 to 60 - 10 - 04/3 60 - 10 - 05/1 to 60 - 10 - 05/5A 60 - 10 - 05/6 to 60 - 10 - 05/9 60 - 10 - 05/10 to 60 - 10 - 05/23 60 - 10 - 06/1 60 - 10 - 06/2 60 - 10 - 07/1 & 60 - 10 - 07/2 60 - 10 - 08/1 60 - 10 - 10/1 60 - 10 - 11/1 60 - 10 - 11/2 60 - 10 - 11/3 60 - 10 - 15/1 to 60 - 10 - 15/3 60 - 10 - 15/4 to 60 - 10 - 15/7 60 - 10 - 15/8 to 50 - 10 - 15/10 60 - 10 - 16/1 & 60 - 10 - 16/2 60 - 10 - 17/1 & 60 - 10 - 17/2 60 - 10 - 18/1 & 60 - 10 - 18/2 60 - 10 - 18/3 to 60 - 10 - 18/7 60 - 10 - 19/1 & 60 - 10 - 19/2
9804/1103
Issue 8*
INDEX CONTENTS
Fastrac
Contents 3
ALL MODELS Contents

* Circuit Diagrams Electrical - 125, 135, 145, 150, 155, 185 to m/c no. 635329 - 125, 135, 145, 150, 155, 185 from m/c no. 635330 and all export machines to 636000 - 2000 Series, 3000 Series - Introduction - Main Connectors - Connector Terminals - Splice Identification - Wiring Diagrams, Contents - Wiring Diagrams, Component Key - Wiring Diagrams, Alphabetical Index - Wiring Diagrams
60 - 15 - 01/1 & 60 - 15 - 01/2 60 - 15 - 01/3 & 60 - 15 - 01/4 60 - 15 - 01/5 & 60 - 15 - 01/6 60 - 15 - 01/7 60 - 15 - 01/7 to 60 - 15 - 01//9 60 - 15 - 01/10 60 - 15 - 01/11 60 - 15 - 01/12 60 - 15 - 01/13 60 - 15 - 01/14 to 60 - 15 - 01/56
Hydraulic - 125, 135, 145, 150, 155, 185 to m/c no. 637733 - 125, 135, 145, 150, 155, 185 from m/c no. 637734 - Fastrac 1115, 1135, 2115, 2125, 2135, 2150 - 2000 Series Machines - 3000 Series Machines
60 - 20 - 02/1 60 - 20 - 02/2 & 60 - 20 - 02/3 60 - 20 - 03/1 & 60 - 20 - 03/2 60 - 20 - 03/3 & 60 - 20 - 03/4 60 - 20 - 03/5 & 60 - 20 - 03/6
9804/1103
Issue 4*
CONTENTS CONTENTS
Fastrac
60 - 00 - 01/1
125, 135, 145, 150, 155 (not N. Am. machines) Fluids, Lubricants and Capacities
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately. DO NOT use a special running-in oil but use the oil recommended below from new.
ITEM
CAPACITY FLUID/LUBRICANT Litres (UK Gal) 16.5 (3.6) JCB Super Multigrade 15W/40 -10 C to 50 C (14 F to 122 F) JCB Super Universal Agricultural -15 C to 30 C (5 F to 86 F) SEE Note ABOVE
INTERNATIONAL SPECIFICATION SAE15W/40, API CF4/SG SAE10W/30 API CE/SF
Engine Oil
Coolant (to 636000) (from 636001)
28 (6.2) 34 (7.5)
JCB Four Seasons Antifreeze & Summer Coolant/water (See Coolant Mixtures) JCB Super Universal Agricultural
ASTM D3306, BS6580
PTO and Range Boxes (to 636000) Speed Box (to 636000) PTO/Speed/Range Box (combined from 636001) Front Axle Housing Hubs (x2) Rear Axle Brake System Front Rear
20 (4.49)
10 (2.2)
JCB HD90 Gear Oil
API-GL-5, MIL-L-2105C
38 (8.4)
JCB Super Universal Agricultural
11.5 (2.6) 1.5 (0.34) 21 (4.6)
JCB HD90 Gear Oil
JCB HD90 Gear Oil JCB Universal Brake Fluid
API-GL-5, MIL-L-2105C SAE J1703 DOT 4
0.75 (0.17) 0.75 (0.17)
! CAUTION
Do not use ordinary hydraulic fluid in the brake or clutch systems.
13-3-1-13
Clutch System Hydraulic System
0.5 (0.11) 75 (16.5)
JCB Universal Brake Fluid JCB Special Hydraulic Fluid HP46 (Above 38 C, 100 F) JCB Special Hydraulic Fluid HP32 (Below 38 C, 100 F) JCB HP Grease
SAE J1703 DOT 4 ISO VG46 ISO VG32
Grease Points
---
Lithium complex NLGI No. 2 consistency including extreme pressure additives
Front PTO Transfer Box (optional) Air Conditioning System - Refrigerant - Compressor Lubricant
3.0 (0.67)
JCB HD90 Gear Oil
0.9 kg (2 lb) 0.24 (0.05)
HFC 134c Polyalkalineglycol
CH2 FC F3 PAG SP20
Note: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank.
9804/1103
60 - 00 - 01/1
8000 - 3/1-1.11
Issue 5*
CONTENTS
Fastrac
60 - 00 - 01/2
* 125,
135, 145, 150, 155 (N. Am. machines)

Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately. DO NOT use a special running-in oil but use the oil recommended below from new.
ITEM
CAPACITY FLUID/LUBRICANT US Gal (Liters) 4.36 (16.5) JCB Engine Oil 15W/40 14 F to 122 F (-10 C to 50 C) JCB Engine Oil 10W/30 5 F to 104 F (-15 C to 40 C) SEE Notice
Engine (Oil)
SAE15W/40, API CF4SG SAE10W/30, API CE/SF
ABOVE ASTM D3306-74
Coolant
9.0 (34)
JCB Permanent Antifreeze/water (See Coolant Mixtures)
PTO, Speed and Range Boxes (combined) Front Axle Housing Hubs (x2) Rear Axle
10.0 (38)
JCB AG-Transmission Fluid
3.04 (11.5) 0.40 (1.5) 5.55 (21)
JCB GL5 80W/90 Gear Oil
Brake System Front Rear
JCB Universal Brake Fluid 0.20 (0.75) 0.20 (0.75)
SAE J1703 DOT 4
Do not use ordinary hydraulic oil in the brake or clutch systems.

13-3-1-13
! CAUTION
Clutch System Hydraulic System Grease Points
0.13 (0.5) 19.82 (75) ---
JCB Universal Brake Fluid JCB Special Hydraulic Fluid HP46 JCB HP Grease
SAE J1703 DOT 4 ISO VG46 Lithium complex NGLI # 2 consistency including extreme pressure additives
0.80 (3.0)
2 lb (0.9 kg) 0.05 (0.24)
CH2 FC F3 PAG SP20
Notice: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank.
9804/1103
60 - 00 - 01/2
8000 - 3/1-1A.2
Issue 3*
CONTENTS * 185
Fastrac
60 - 00 - 01/3
(not N. Am. machines)

Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately. DO NOT use a special running-in oil but use the oil recommended below from new. While 15W/40 oil is recommended for most climates, limited use of low viscosity oils such as 10W/30 is permitted to provide easier starting and sufficient oil flow at ambient temperatures below -5 C (23 F). Continued use of low viscosity oils can decrease engine life.
ITEM Engine (Oil)
CAPACITY FLUID/LUBRICANT Litres (UK Gal) 15 (3.3) JCB Super Multigrade 15W/40 -10 C to 50 C (14 F to 122 F) JCB Super Multigrade 10W/30 -25 C to 20 C (-13 F to 68 F) SEE Note ABOVE
INTERNATIONAL SPECIFICATION SAE15W/40, API CF4/SG SAE10W/30, API CF4/SG ASTM D3306, BS6580
Coolant
33 (7.3)
PTO, Speed and Range Boxes (combined) Front Axle Housing Hubs (x2) Rear Axle Brake System Front Rear
38 (8.4)
11.5 (2.6) 1.5 (0.34) 27 (6)
JCB HD90 Gear Oil
JCB HD90 Gear Oil JCB Universal Brake Fluid
API-GL-5, MIL-L-2105C SAE J1703 DOT 4
0.75 (0.17) 0.75 (0.17)
! CAUTION
13-3-1-13
0.5 (0.11) 75 (16.5)
JCB Universal Brake Fluid JCB Special Hydraulic Fluid HP46 (Above 38 C, 100 F) JCB Special Hydraulic Fluid HP32 (Below 38 C, 100 F) JCB HP Grease
SAE J1703 DOT 4 ISO VG46 ISO VG32
Grease Points
---
Lithium complex NLGI No 2 consistency including extreme pressure additives
3.0 (0.67)
JCB HD90 Gear Oil
0.9 kg (2 lb) 0.24 (0.05)
CH2 FC F3 PAG SP20
9804/1103
60 - 00 - 01/3
8000 - 3/1-2.5
Issue 3*
CONTENTS
Fastrac
60 - 00 - 01/3A
* 185
(N. Am. machines)

Notice: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately. DO NOT use a special running-in oil but use the oil recommended below from new. While 15W/40 oil is recommended for most climates, limited use of low viscosity oils such as 10W/30 is permitted to provide easier starting and sufficient oil flow at ambient temperatures below 23 F (-5 C). Continued use of low viscosity oils can decrease engine life. ITEM CAPACITY FLUID/LUBRICANT US Gal (Liters) 3.96 (15) JCB Engine Oil 15W/40 14 F to 122 F (-10 C to 50 C) JCB Permanent Antifreeze/water (See Coolant Mixtures) SEE Notice ABOVE INTERNATIONAL SPECIFICATION SAE15W/40, API CF4/SG
Engine (Oil)
Coolant
8.7 (33)
ASTM D3306-74
10.0 (38)
JCB Ag-Transmission Fluid
3.04 (11.5) 0.40 (1.5) 7.13 (27)
SAE J1703 DOT 4
Do not use ordinary Hydraulic oil in the brake or clutch systems.

13-3-1-13
! CAUTION
Clutch System
0.13 (0.5)
JCB Universal Brake Fluid
SAE J1703 DOT 4
Hydraulic System
19.82 (75)
JCB Hydraulic Fluid HP46 (Above 100 F, 38 C ambient) JCB Hydraulic Fluid HP32 (Below 100 F, 38 C ambient)
ISO VG46
ISO VG32
Grease Points
---
JCB HP Grease
Lithium complex NGLI # 2 consistency including extreme pressure additives
0.80 (3.0)
JCB HD90 Gear Oil
0.9 kg (2 lb) 0.24 (0.05)
CH2 FC F3 PAG SP20
9804/1103
60 - 00 - 01/3A
8000 - 3/1-2A.3
Issue 1
CONTENTS
* 1115
Fastrac
60 - 00 - 01/4
& 1135

* Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately. DO NOT use a special running-in oil but use the oil recommended below from new. ITEM Fuel Engine (Oil) CAPACITY FLUID/LUBRICANT Litres (UK Gal) 220 (48) 16.5 (3.6) Diesel Oil (See Types of Fuel) JCB Super Multigrade 15W/40 -10 C to 50 C (14 F to 122 F) SEE JCB Super Universal Agricultural -15 C to 30 C (5 F to 86 F) Note ABOVE JCB Torque Converter Fluid -18 C to 0 C (0 F to 32 F) Engine (Coolant) 20 (4.4) JCB Four seasons Antifreeze & Summer Coolant/water (See Coolant Mixtures) JCB Super Universal Agricultural SAE10W, API CD/SF ASTM D3306, BS6580 SAE10W/30, API CE/SF INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D SAE15W/40, API CF4/SF
PTO, Speed and Range Boxes (combined) Front Axle Housing Hubs (x2) Rear Axle (2WS) Rear Axle (4WS) Housing Hubs (x2) Brake System (Machines to Serial No. 737000)
38 (8.4)
7 (1.56) 1.9 (0.4) 23 (5.0) 17 (3.7) 2.0 (0.4)
JCB HD90 Gear Oil JCB HD90 Gear Oil JCB HD90 Gear Oil Supplied from main hydraulic system (see below) JCB Universal Brake Fluid
API-GL-5, MIL-L-2105C API-GL-5, MIL-L-2105 API-GL-5, MIL-L-2105C
Brake System (Machines from Serial No. 737001) Front 0.75 (0.17) Rear 0.75 (0.17)
SAE J1703 DOT 4

13-3-1-13
! CAUTION
0.5 (0.11) 75 (16.5)
JCB Universal Brake Fluid JCB Special Hydraulic Fluid HP46 (Above 38 C, 100 F) JCB Special Hydraulic Fluid HP32 (Below 38 C, 100 F)
SAE J1703 DOT 4 ISO VG46 ISO VG32 Lithium complex NLGI No. 2 consistency including extreme pressure additives
Grease Points
---
JCB HP Grease
Air Conditioning System - Refrigerant (Machines to Serial No. 736115) 1.15 kg (2 lb 4 oz) HFC 134c (Machines from Serial No. 736116) 0.9 kg (2 lb) HFC 134c - Compressor Lubricant 0.24 (0.05) Polyalkalineglycol Front PTO Transfer Box (optional) 3.0 (0.67) JCB HD90 Gear Oil
CH2 FC F3 CH2 FC F3 PAG SP20 API-GL-5, MIL-L-2105C
9804/1103
60 - 00 - 01/4
8010 - 3/1-1.4
Issue 2*
CONTENTS
Fastrac
60 - 00 - 01/4A
* 1115
& 1135 (N. American Machines)

Notice: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately. DO NOT use a special running-in oil but use the oil recommended below from new. ITEM Fuel Engine (Oil) CAPACITY FLUID/LUBRICANT US Gal (Liters) 57.6 (220) 4.3 (16.5) Diesel Oil (See Types of Fuel) JCB Engine Oil 15W/40 14 F to 122 F (-10 C to 50 C) JCB Engine Oil 10W/30 5 F to104 F (-15 C to 40 C) Engine (Coolant) PTO, Speed and Range Boxes (combined) Front Axle Housing Hubs (x2) Rear Axle (2WS) Rear Axle (4WS) Housing Hubs (x2) Brake System (Machines to Serial No. 737000) Brake System (Machines from Serial No. 737001) Front 0.2 (0.75) Rear 0.2 (0.75) 5.3 (20.0) JCB Permanent Antifreeze/water (See Coolant Mixtures) JCB AG Transmission Fluid SEE Notice ABOVE INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D
SAE10W, API CF4/SG ASTM D3306-74
10 (38.0)
1.8 (7.0) 0.5 (1.9) 6.1 (23.0) 4.5 (17.0) 0.5 (2.0)
JCB GL5 80W/90 Gear Oil JCB GL5 80W/90 Gear Oil JCB GL5 80W/90 Gear Oil Supplied from main hydraulic system (see below) JCB Universal Brake Fluid
API-GL-5, MIL-L-2105C API-GL-5, MIL-L-2105C API-GL-5, MIL-L-2105C
! CAUTION
SAE J1703 DOT 4
Do not use ordinary hydraulic oil in the brake or clutch systems.

13-3-1-13
Clutch System Hydraulic System Grease Points
0.13 (0.5) 19.8 (75.0) ---
JCB Universal Brake Fluid JCB Special Hydraulic Fluid HP46 JCB HP Grease
ISO VG15 ISO VG46 Lithium complex NGLI # 2 consistency including extreme pressure additives
Air Conditioning System - Refrigerant (Machines to Serial No. 736115) 2 lb 4 oz (1.15 kg) HFC 134c (Machines from Serial No. 736116) 2 lb (0.9 kg) HFC 134c - Compressor Lubricant 0.05 (0.24) Polyalkalineglycol Front PTO Transfer Box (optional) 0.8 (3.0) JCB GL5 80W/90 Gear Oil
CH2 FC F3 CH2 FC F3 PAG SP20 API-GL-5, MIL-L-2105C
9804/1103
60 - 00 - 01/4A
8010 - C/1-1A.1
Issue 1
CONTENTS
Fastrac
60 - 00 - 01/5
2000 SERIES MACHINES Fluids, Lubricants and Capacities

ITEM Fuel 2115, 2125, 2135 2150 Engine (Oil) 220 (48) 350 (77) 16.5 (3.6) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D CAPACITY FLUID/LUBRICANT Litres (UK Gal) MINIMUM INTERNATIONAL SPECIFICATION
See Engine Oil (All 2000, 3000 Series Machines) on page 60-00-01/11
Engine (Coolant)
34 (7.5)
ASTM D3306, BS6580
PTO, Speed and Range Boxes (combined) Front Axle Housing Hubs (x2) Rear Axle (2WS) Rear Axle (4WS) Housing Hubs (x2) Brake System Front Rear
38 (8.4) 42 (9.3) 7 (1.56) 1.9 (0.4) 23 (5.0) 17 (3.7) 2.0 (0.4) 0.75 (0.17) 0.75 (0.17)
JCB HD90 Gear Oil JCB HD90 Gear Oil JCB HD90 Gear Oil JCB Universal Brake Fluid
API-GL-5, MIL-L-2105C API-GL-5, MIL-L-2105C API-GL-5, MIL-L-2105C SAE J1703 DOT 4
Do not use ordinary hydraulic fluid in the brake system.

13-3-2-6
! CAUTION
Clutch System Hydraulic System - see Note 1
--82 (18.0) 120 (26.4)
JCB Light Hydraulic Fluid - see Note 2 JCB High Performance Hydraulic Oil JCB Hydraulic Fluid HP32 (Below 38 C, 100 F)
ISO VG15 ISO VG46 (Above 38 C, 100 F) ISO VG32 Lithium complex NLGI No. 2 consistency including extreme pressure additives
Grease Points
---
JCB HP Grease
Air Conditioning System - Refrigerant 0.9 kg (2 lb) - Compressor Lubricant 0.24 (0.05) Front PTO Transfer Box (optional) 3.0 (0.67)
HFC R134a Polyalkalineglycol JCB HD90 Gear Oil
CH2 FC F3 PAG SP20 API-GL-5, MIL-L-2105C
Note 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank. Note 2: It is essential that the correct specification fluid is used. Contact your JCB Distributor for further information. 2000 Series to S/N 739999 2000 Series from S/N 740000
9804/1103
60 - 00 - 01/5
8020 - 3/1-2.7
Issue 4*
CONTENTS CONTENTS
Fastrac
60 - 00 - 01/6
2000 SERIES MACHINES (N. America) Fluids, Lubricants and Capacities

ITEM Fuel 2115, 2125, 2135 2150 Engine (Oil) 57.6 (220) 92.5 (350) 4.3 (16.5) Diesel Oil (See Types of Fuel) See Engine Oil (All 2000, 3000 Series Machines) on page 60-00-01/11 JCB PermanentAntifreeze/water (See Coolant Mixtures) JCB AG Transmission Fluid ASTM D3306-74 ASTM D975-66T Nos. 1D, 2D CAPACITY FLUID/LUBRICANT US Gal (Liters) MINIMUM INTERNATIONAL SPECIFICATION
Engine (Coolant) PTO, Speed and Range Boxes (combined) Front Axle Housing Hubs (x2) Rear Axle (2WS) Rear Axle (4WS) Housing Hubs (x2) Brake System Front Rear
9.0 (34.0)
10 (38.0) 11.2 (42.0) 1.8 (7.0) 0.5 (1.9) 6.1 (23.0) 4.5 (17.0) 0.5 (2.0) 0.2 (0.75) 0.2 (0.75)
JCB GL5 80W/90 Gear Oil JCB GL5 80W/90 Gear Oil JCB GL5 80W/90 Gear Oil JCB Universal Brake Fluid
API-GL-5, MIL-L-2105C API-GL-5, MIL-L-2105C API-GL-5, MIL-L-2105C SAE J1703 DOT 4
! CAUTION
Do not use ordinary hydraulic oil in the brake system.
13-3-2-6
Clutch System Hydraulic System - see Notice 1 Grease Points
--21.7 (82.0) 31.7 (120) ---
JCB Light Hydraulic Fluid - see Notice 2 JCB High Performance Hydraulic Oil
ISO VG15 ISO VG46
JCB HP Grease
Lithium complex NLGI No. 2 consistency including extreme pressure additives CH2 FC F3 PAG SP20
Air Conditioning System - Refrigerant 2 lb (0.9 kg) * - Compressor Lubricant 0.06 (0.24) Front PTO Transfer Box (optional)
HFC R134a Polyalkalineglycol
0.8 (3.0)
Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank. Notice 2: It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information. 2000 Series to S/N 739999 2000 Series from S/N 740000
9804/1103
60 - 00 - 01/6
8020 - 3/1-3.7
Issue 4*
CONTENTS
Fastrac
60 - 00 - 01/7
FASTRAC 3155 Fluids, Lubricants and Capacities

ITEM CAPACITY FLUID/LUBRICANT Litres (UK Gal) 350 (77) 16.5 (3.6) Diesel Oil (See Types of Fuel) See Engine Oil (All 2000, 3000 Series Machines) on page 60-00-01/11 JCB Four Seasons Antifreeze & Summer Coolant/water (See Coolant Mixtures) JCB Super Universal Agricultural ASTM D3306, BS6580 MINIMUM INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D
Fuel Engine (Oil)
Engine (Coolant)
34 (7.5)
38 (8.4) 42 (9.3)
20 (4.4) 2.5 (0.55) 21 (4.6)
JCB HD90 Gear Oil
JCB HD90 Gear Oil
SAE J1703 DOT 4

13-3-2-6
! CAUTION
82 (18.0) 120 (26.4)
JCB Light Hydraulic Fluid - see Note 2 JCB High Performance Hydraulic Oil
ISO VG15 ISO VG46 (Above 38 C, 100 F) ISO VG32
JCB Hydraulic Fluid HP32 (Below 38 C, 100 F) Grease Points --JCB HP Grease
Air Conditioning System - Refrigerant 0.9 kg (2 lb) - Compressor Lubricant 0.24 (0.05) Front PTO Transfer Box (optional)
CH2 FC F3 PAG SP20
3.0 (0.67)
JCB HD90 Gear Oil
Note 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank. Note 2: It is essential that the correct specification fluid is used. Contact your JCB Distributor for further information. 3000 Series to S/N 641999 3000 Series from S/N 642000
9804/1103
60 - 00 - 01/7
8020 - 3/1-4.6
Issue 4*
CONTENTS
Fastrac
60 - 00 - 01/8
FASTRAC 3155 (N. America) Fluids, Lubricants and Capacities

ITEM Fuel 92.5 (350) Engine (Oil) 4.3 (16.5) Diesel Oil (See Types of Fuel) See Engine Oil (All 2000, 3000 Series Machines) on page 60-00-01/11 JCB Permanent Antifreeze/water (See Coolant Mixtures) JCB AG Transmission Fluid ASTM D3306-74 ASTM D975-66T Nos. 1D, 2D CAPACITY FLUID/LUBRICANT US Gal (Liters) MINIMUM INTERNATIONAL SPECIFICATION
Engine (Coolant) PTO, Speed and Range Boxes (combined) Front Axle Housing Hubs (x2) Rear Axle (2WS) Brake System Front Rear
9 (34.0)
10.1 (38.0) 11.2 (42.0) 5.3 (20.0) 0.66 (2.5) 7.1 (27.0)
JCB GL5 80W/90 Gear Oil JCB GL5 80W/90 Gear Oil JCB Universal Brake Fluid
API-GL-5, MIL-L-2105C API-GL-5, MIL-L-2105C SAE J1703 DOT 4
0.2 (0.75) 0.2 (0.75)
! CAUTION
13-3-2-6
--21.7 (82.0) 31.7 (120) ---
JCB Light Hydraulic Fluid - see Notice 2 JCB High Performance Hydraulic Oil
ISO VG15 ISO VG46
JCB HP Grease
Lithium complex NLGI No. 2 consistency including extreme pressure additives CH2 FC F3 PAG SP20 API-GL-5, MIL-L-2105C
Air Conditioning System - Refrigerant 2 lb (0.9 kg) - Compressor Lubricant 0.06 (0.24) Front PTO Transfer Box (optional) 0.8 (3.0)
HFC R134a Polyalkalineglycol JCB GL5 80W/90 Gear Oil
Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank. Notice 2: It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information.
3000 Series to S/N 641999 3000 Series from S/N 642000
9804/1103
60 - 00 - 01/8
8020 - 3/1-5.6
Issue 4*
CONTENTS
Fastrac
60 - 00 - 01/9
FASTRAC 3185 Fluids, Lubricants and Capacities

ITEM CAPACITY FLUID/LUBRICANT Litres (UK Gal) 350 (77) 15 (3.3) Diesel Oil (See Types of Fuel) See Engine Oil (All 2000, 3000 Series Machines) on page 60 - 00 - 01/11 JCB Four Seasons Antifreeze & Summer Coolant/water (See Coolant Mixtures) ASTM D3306, BS6580 MINIMUM NTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D
Fuel Engine (Oil)
Engine (Coolant)
33 (7.3)
38 (8.4) 42 (9.3)
JCB Super Universal Agricultural
20 (4.4) 2.5 (0.55) 27 (6.0)
JCB HD90 Gear Oil
JCB HD90 Gear Oil
SAE J1703 DOT 4

13-3-2-6
! CAUTION
82 (18.0) 120 (26.4)
JCB Light Hydraulic Fluid - see Note 2 JCB High Performance Hydraulic Oil
ISO VG15 ISO VG46 (Above 38 C, 100 F) ISO VG32
JCB Hydraulic Fluid HP32 (Below 38 C, 100 F) Grease Points --JCB HP Grease
Air Conditioning System - Refrigerant 0.9 kg (2 lb) - Compressor Lubricant 0.24 (0.05) Front PTO Transfer Box (optional)
CH2 FC F3 PAG SP20
3.0 (0.67)
JCB HD90 Gear Oil
Note 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank. Note 2: It is essential that the correct specification fluid is used. Contact your JCB Distributor for further information.
9804/1103
60 - 00 - 01/9
8020 - 3/1-6.6
Issue 4*
CONTENTS
Fastrac
60 - 00 - 01/10
FASTRAC 3185 (N. America) Fluids, Lubricants and Capacities

ITEM Fuel 92.5 (350) Engine (Oil) 4 (15) Diesel Oil (See Types of Fuel) See Engine Oil (All 2000, 3000 Series Machines) on page 60 - 00 - 01/11 JCB Permanent Antifreeze/water (See Coolant Mixtures) JCB AG Transmission Fluid ASTM D3306-74 ASTM D975-66T Nos. 1D, 2D CAPACITY FLUID/LUBRICANT US Gal (Liters) MINIMUM INTERNATIONAL SPECIFICATION
Engine (Coolant) PTO, Speed and Range Boxes (combined) Front Axle Housing Hubs (x2) Rear Axle Brake System Front Rear
8.77 (33.0)
10 (38.0) 11.2 (42.0) 5.3 (20.0) 0.66 (2.5) 7.1 (27.0)
JCB GL5 80W/90 Gear Oil JCB GL5 80W/90 Gear Oil JCB Universal Brake Fluid
API-GL-5, MIL-L-2105C API-GL-5, MIL-L-2105C SAE J1703 DOT 4
0.2 (0.75) 0.2 (0.75)
! CAUTION
13-3-2-6
--21.7 (82.0) 31.7 (120) ---
JCB Light Hydraulic Fluid - see Notice 2 JCB High Performance Hydraulic Oil JCB HP Grease
ISO VG15 ISO VG46 Lithium complex NLGI No. 2 consistency including extreme pressure additives CH2 FC F3 PAG SP20 API-GL-5, MIL-L-2105C
Air Conditioning System - Refrigerant 2 lb (0.9 kg) - Compressor Lubricant 0.06 (0.24) Front PTO Transfer Box (optional) 0.8 (3.0)
HFC R134a Polyalkalineglycol JCB GL5 80W/90 Gear Oil
Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank. Notice 2: It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information.
9804/1103
60 - 00 - 01/10
8020 - 3/1-7.3
Issue 3*
CONTENTS
Fastrac
60 - 00 - 01/11
FASTRAC 3185 (N. America) Fluids, Lubricants and Capacities Engine Oil New Engines
New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately. DO NOT use a special running-in oil but use the oil recommended below from new.
Engine Oil Specification

Recommended Oil JCB Extreme Performance Engine Oil SAE 15W/40 API CH-4 or ACEA E3/B3A3 IMPORTANT NOTE: IF SAE 15W/40, API CH-4 OR ACEA E3/B3A3 ENGINE OIL IS NOT AVAILABLE, THEN THE ENGINE OIL MUST BE CHANGED AT 250 HOURS. Alternative Oil If the oil recommended above is not available then the alternatives listed below should be used according to the ambient temperature. Note: (3185 machines only). While 15W/40 oil is recommended for most climates, limited use of low viscosity oils such as 10W/30 is permitted to provide easier starting and sufficient oil flow at ambient temperatures below -5 C (23 F). Continued use of low viscosity oils can decrease engine life. JCB Super Multigrade 15W/40 SAE15W/40, API CF4/SG -10 C to 50 C (14 F to 122 F) JCB Super Multigrade 10W/30 SAE10W/30, API CF4/SG -15 C to 40 C (5 F to 104 F) The temperature range for 3185 machines is - 20 C to 20 C (-4 F to 68 F).
Engine Oil Specification (N. America)

Recommended Oil JCB Genuine Engine Oil SAE 15W/40, Grade CH-4/SJ IMPORTANT NOTICE: IF SAE 15W/40, GRADE CH-4/SJ ENGINE OIL IS NOT AVAILABLE, THEN THE ENGINE OIL MUST BE CHANGED AT 250 HOURS. Alternative Oil If the oil recommended above is not available then the alternatives listed below should be used according to the ambient temperature. Notice: (3185 machines only). While 15W/40 oil is recommended for most climates, limited use of low viscosity oils such as 10W/30 is permitted to provide easier starting and sufficient oil flow at ambient temperatures below -5 C (23 F). Continued use of low viscosity oils can decrease engine life. JCB 15W/40 Engine Oil SAE15W/40, API CF4/SG -10 C to 50 C (14 F to 122 F) JCB Engine Oil 10W/30 SAE10W/30, API CE/SF -15 C to 40 C (5 F to 104 F) The temperature range for 3185 machines is -4 F to 68 F (- 20 C to 20 C).
9804/1103
60 - 00 - 01/11
8020 - 3/1-1.6
Issue 1
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CONTENTS
Fastrac
60 - 00 - 02/1
* 125,
135, 145, 150, 155
To m/c no. 636000
Static Dimensions
D C K
J E F G H
A170051
With 495/70 R 24 Tyres With 480/70 R 30 Tyres mm in mm in A Height to top of Cab 2781 109.5 2881 113.5 B Height to top of Exhaust 2765 109 2865 113 C Overall Width 2270 89.4 2490 98 D Track Width 1879 74 2015 79 E Minimum Ground Clearance 390 15.4 490 19.3 Note: The position of the minimum ground clearance varies according to machine specification. When a clevis drawbar is fitted, the clearance is reduced by 60 mm (2.4 in) F Wheelbase 3006 118 3006 118 G Overall Length (less Front Linkage) 4923 193.8 4923 193.8 H Overall Length (with Front Linkage) 5523 217 5523 217 J Height to Trailer Coupling (Adjustable) 540-1010 21.3-39.3 640-1110 25.2-43.3 K Length of Load Deck 1572 61.9 1572 61.9 Turning Radius (Kerb to kerb with 1829 mm/72 in track) 7050 277.5 7050 277.5 Unladen Weights Total with Oil and Coolant On Front Axle On Rear Axle kg 6378 2812 3566 lb 14060 6199 7861 kg 6458 2852 3606 lb 14237 6287 7950
9804/1103
60 - 00 - 02/1
Issue 4*
W2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K?h ?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@h
?7@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@L?g ?7@(M? I'@@L?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1?g ?@@H ?N@@1?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@? @@@?g ?@@?e?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W2@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>)?&R1?*>1?7R1?*>1?7R1?*>)T&>)?&R)?&R)?&R)?&R1?7R1?*>)T&>)?&R)?&R1?7R1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@9V@@@@@@LV'@?@@@?S@@X@@@LV'@@R@@@@@@@@@@@@@@@@@@X@@@LV'@@R@@@@@@@@@@X@@@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S@@@@@@@@)XN@@@@@@@8S@@@@)XN@@W@@@@@@@@?@@@@@@@?S@@@@)XN@@W@@@@@@@@?S@@@@)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@X@@@@)X@@@V'@@W&U@@@@1?@@@R'X@@@X@?@@@V'X@?*U@@@@1?@@@R'X@@@X@?7@@V'@1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LN@@XI4@XI4@@@@@LV'@@R'@@@@@?@@@LV'@@V4@X@@@?V@@LV'@@@@@?@@@LV'@@V4@T@@@?V@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X@@)X?S)X?W@@?S)XN@@LN@@?@@@@@S)XN@@L?S@@@@@@@@)XN@@?@@@@@S)XN@@L?S@>@@@@@V)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>@@@V1?*>)T&@@?*>1?@@1?@@@@@?@@@>1?@@1?*U@@@@@@@>1?@@@@@?@@@>1?@@1?*>@R'@@@@@1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@@@@@LN@@@R'@LV4@X@@@X@@@T@@@@V4@X@@@LV'@@V4@XI4@X@@@T@@@@V4@X@@@LV'@LV4@X@@@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?W@@@V)X@@@LN@)K?V@@?S@@@S@U@@@L?S@@@S)XN@@??V)K?S@@@S@U@@@L?S@@@S)XN@)K?V@@@>)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@@@@@>1?3@@@@@@?*U@@@>@@@@1?*U@@@>1?@@@@@@@@@U@@@>@@@@1?*U@@@>1?3@@@@@@V'>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@@@@@XI4@LV4@@@@@LV4@@V4@T@@@LV4@@V4@T@@@@@@@@V4@@V4@T@@@LV4@@V4@LV4@@@@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?W@X?S)X?S)X?W@X?S)X?W@L?S@U?S)X?W@L?S@U?W@X?W@L?W@L?S@U?S)X?W@L?S)X?W@X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?S)K?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?W2@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@>@@@U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@W&@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@V@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5?g ?@@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@@?@@5?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@(Y?g I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0Yh
CONTENTS
Fastrac
* M/c
60 - 00 - 02/2
* 125,
135, 145, 150, 155
nos. 636001 to 636368
Static Dimensions
D C K
B J E F G H
A194480
With 495/70 R 24 Tyres With 480/70 R 30 Tyres mm in mm in A Height to top of Cab 2905 114.3 2973 117.0 B Deck Height 1587 62.5 1655 65.2 C Overall Width 2370 93.3 2485 97.8 D Track Width 1875 73.8 2015 79.3 E Minimum Ground Clearance 458 18 558 22 Note: The position of the minimum ground clearance varies according to machine specification. When a clevis drawbar is fitted, the clearance is reduced by 60 mm (2.4 in) F Wheelbase 3006 118 3006 118 G Overall Length (less Front Linkage) 5008 197 5008 197 H Overall Length (with Front Linkage) 5608 221 5608 221 J Height to Trailer Coupling (Adjustable) 540-1010 21.3-39.3 640-1110 25.2-43.3 K Length of Load Deck 1572 61.9 1572 61.9 Turning Radius (Kerb to kerb with 1829 mm/72 in track) 7050 277.5 7050 277.5 Unladen Weights (excluding front hitch & trailer coupling) Total with Oil and Coolant On Front Axle On Rear Axle
kg 6199 3362 2837
lb 13666 7412 6254
kg 6279 3402 2877
lb 13843 7500 6343
9804/1103
60 - 00 - 02/2
Issue 3*
CONTENTS
Fastrac
60 - 00 - 02/3
125, 135, 145, 150, 155, 185 Static Dimensions
From m/c no. 636369
D C K
B J E F G H
A194481
With 495/70 R 24 Tyres With 520/70 R 30 Tyres mm in mm in A Height to top of Cab - Fastrac 185 2965 117 3040 120 - All other models 2905 114 2980 117 B Deck Height 1425 56 1496 59 C Overall Width 2370 93 2535 100 D Track Width 1875 74 2015 79 E Minimum Ground Clearance 400 16 493 19 Note: The position of the minimum ground clearance varies according to machine specification. When a clevis drawbar is fitted, the clearance is reduced by 60 mm (2.4 in) F Wheelbase 3006 118 3006 118 G Overall Length (less Front Linkage) 5157 203 5157 203 H Overall Length (with Front Linkage) 5757 227 5757 227 J Height to Trailer Coupling (Adjustable) 540-1010 21.3-39.3 640-1110 25.2-43.3 K Length of Load Deck 1572 61.9 1572 61.9
Turning Radius (Kerb to kerb with 1829 mm/72 in track) 7050
277.5
7050
277.5
9804/1103
60 - 00 - 02/3
Issue 2
I'@@L?g ?N@@1?g @@@?g
W2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K?h ?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@h ?7@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@L?g ?7@(M? ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1?g ?@@H ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@? ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W-X?W2@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@?e?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?S)X?W@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??@?*>1?*>)?&R1?*>1?7R1?*>1?7R1?*>)T&>)?&R)?&R)?&R)?&R1?7R1?*>)T&>)?&R)?&R1?7R1?*>1?*U@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??3LV4@9V@@@@@@LV'@?@@@?S@@X@@@LV'@@R@@@@@@@@@@@@@@@@@@X@@@LV'@@R@@@@@@@@@@X@@@LV4@LN@@@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??S)X?S@@@@@@@@)XN@@@@@@@8S@@@@)XN@@W@@@@@@@@?@@@@@@@?S@@@@)XN@@W@@@@@@@@?S@@@@)X?S)X@W@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??*>1?*U@@@X@@@@)X@@@V'@@W&U@@@@1?@@@R'X@@@X@?@@@V'X@?*U@@@@1?@@@R'X@@@X@?7@@V'@1?*>@@@U@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g ?@@??V4@LN@@XI4@XI4@@@@@LV'@@R'@@@@@?@@@LV'@@V4@X@@@?V@@LV'@@@@@?@@@LV'@@V4@T@@@?V@@LV4@@V@@@?g ?@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?g 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CONTENTS
Fastrac
60 - 00 - 02/4
*125, 135, 145, 150, 155, 185 Unladen Weights

With 495/70 R 24 Tyres kg lb Basic Machine with rear linkage and rear PTO On Front Axle On Rear Axle Total Machine Machine with front linkage and front PTO On Front Axle On Rear Axle Total Machine
From m/c no. 636369
With 520/70 R 30 Tyres kg lb
3400 2974 6374
7495 6556 14051
3510 3014 6524
7740 6644 14384
3700 2920 6620
8157 6437 14594
3740 2960 6700
8245 6525 14770
Load Capacities
Front 3-point Linkage Rear Pick-up Hitch (Maximum vertical down-load) Rear 3-point Linkage (load on hook end) with 80 mm lift cylinders with 85 mm lift cylinders Rear Load Deck Trailer Coupling and Ladder 3000 6613 3000 6613
3000
6613
3000
6613
6000 7000 2500
13227 15432
6000 7000
13227 15432 5511
5511 2500 Refer to data plates on the components
Laden Weights
Maximum permissible laden weights are in some cases governed by legislation which varies from country to country. You must not exceed the total mass and load figures shown on the machine identification plate.
Note 1: The maximum load on the rear load deck is permitted only if placed over the centre-line of the rear axle. For advice on loads in other positions, consult JCB Landpower. Note 2: In some cases, maximum permissible tyre loadings may be less than the stated loadings given above (see Tyres and Wheels in MAINTENANCE section). You must never exceed either of these limits. Note that the figures quoted on the Tyres and Wheels page are the maximum loads per tyre. If in doubt, refer to the tyre supplier or JCB Landpower.
! CAUTION
The Fastrac has to comply with certain braking regulations which in some countries control weight distribution between front and rear axles. Travelling on the road with implements or weights carried on the front when no implement is on the rear may break the law. In this case you should transfer the front mounted equipment to the rear linkage. It is the operator's responsibility to know and observe the laws in the country concerned.
13-2-2-5
! WARNING
The machine must never be loaded such that less than 20% of the unladen vehicle weight is carried on the front axle.
13-1-1-11
9804/1103
60 - 00 - 02/4
Issue 2*
CONTENTS
Fastrac
60 - 00 - 02/5
FASTRAC 1115 & 1135 Static Dimensions
E F G
H D C
A230380
1115
Dimensions on 480/70 R28 Tyres mm A B C D E F G H Height to top of Cab Deck Height Overall Width Track Width Minimum Ground Clearance Wheelbase Overall Length Width between Tyres Turning Circle (Kerb to kerb) on 16.9 R28 tyres on 480/70 R28 tyres 2800 1471 2310 1830 465 2782 5164 1350 in 110 58 91 72 18 110 203 53
1135
Dimensions on 480/70 R30 Tyres mm 2830 1500 2310 1830 495 2782 5164 1350 in 111 59 91 72 19 110 203 53
12.75m (41.8 ft) 13.13m (43.1 ft)
on 480/70 R30 tyres 13.4m (43 ft 11 in)
9804/1103
60 - 00 - 02/5
Issue 1
W2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K?h ?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@h
CONTENTS
Fastrac
60 - 00 - 02/6
FASTRAC 1115 & 1135 Unladen Weights

kg Basic Machine with rear linkage and rear PTO On Front Axle On Rear Axle Machine with front linkage and front PTO On Front Axle On Rear Axle 2720 2580 lb 5996 5688
3700 2920
8157 6437
Load Capacities
Front 3-point Linkage (total load on hook ends) Rear Pick-up Hitch Rear 3-point Linkage (total load on hook ends) with 75 mm lift cylinders with 80 mm lift cylinders Rear Load Deck Trailer Coupling and Ladder 2500 3000 5511 6613
5250 6000
11574 13227
Laden Weights
Note 1: The maximum load on the rear load deck is permitted only if placed over the centre-line of the rear axle. For advice on loads in other positions, consult JCB Landpower. Note 2: In some cases, maximum permissible tyre loadings may be less than the stated loadings given above. You must never exceed either of these limits. Note that the figures quoted on the Tyres and Wheels page are the maximum loads per tyre. If in doubt, refer to the tyre supplier or JCB Landpower.
! CAUTION
13-2-2-5
! WARNING
The machine must never be loaded such that less than 20% of the unladen vehicle weight is carried on the front axle.
13-1-1-11
9804/1103
60 - 00 - 02/6
Issue 1
CONTENTS
Fastrac
60 - 00 - 02/7
2000 SERIES MACHINES Static Dimensions
E F G
H D C
A262630
Fastrac 2115, 2125, 2135 Dimensions on 480/70 R28 Tyres A B C D E F G H Height to top of Cab Deck Height Overall Width Track Width Minimum Ground Clearance Wheelbase Overall Length Width between Tyres mm 2825 1500 2310 1830 400 2782 5080 1350 in 112 59 91 72 16 110 200 53
Fastrac 2150 Dimensions on 480/70 R30 Tyres mm in 2950 116 1524 60 2310 91 1830 72 385 15 3006 118 5150 203 1350 53
Turning Circle (Kerb to kerb) on 16.9 R28 tyres on 480/70 R28 tyres
12.75m (41 ft 7 in) 13.13m (43 ft 1 in)
on 480/70 R30 tyres
13.4m (43 ft 11 in)
9804/1103
60 - 00 - 02/7
Issue 1
CONTENTS
Fastrac
60 - 00 - 02/8
2000 SERIES MACHINES Unladen Weights

Fastrac 2115, 2125, 2135 480/70 R28 Tyres kg Basic Machine with rear linkage and rear PTO Front Axle Rear Axle Machine with front linkage and front PTO Front Axle Rear Axle Maximum design load Front Axle Rear Axle Maximum gross vehicle weight 3080 2850 lb 6790 6283 Fastrac 2150 480/70 R30 Tyres kg 3248 3117 lb 7160 6871
3320 2845
7319 6272
3498 3102
7712 6839
4400 5300 9000
9700 11684 19841
4400 5300 9000
9700 11684 19841
Load Capacities
Front 3-point Linkage (total load on hook ends) Rear Pick-up Hitch Rear 3-point Linkage (total load on hook ends) with 75 mm lift cylinders with 80 mm lift cylinders with 85 mm lift cylinders Rear Load Deck Trailer Coupling and Ladder 2500 3000 5511 6613
5250 6000 7000
11574 13227 15432
Laden Weights
! CAUTION
13-2-2-5 13-1-1-11/1
! WARNING
The machine must never be loaded such that less than 20% of the vehicle weight is carried on the front axle.
9804/1103
60 - 00 - 02/8
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 00 - 02/9
* 3000
Series
Static Dimensions
D C
E F G
A303791
Dimensions
With 495/70 R 24 Tyres With 520/70 R 30 Tyres mm in mm in A Height to top of Exhaust 3075 121 3150 124 B Deck Height 1475 58 1550 61 C Overall Width 2370 93 2535 100 D Track Width 1875 74 2015 79 E Minimum Ground Clearance 320 12 395 15 Note: The position of the minimum ground clearance varies according to machine specification. F Wheelbase 3006 118 3006 118 G Overall Length (less Front Linkage) 5157 203 5157 203 H Overall Length (with Front Linkage) 5757 227 5757 227 J Height to Trailer Coupling (Adjustable) 540-1010 21.3-39.3 640-1110 25.2-43.3
9804/1103
60 - 00 - 02/9
1371 - 171-2
Issue 2*
CONTENTS
Fastrac
60 - 00 - 02/10
FASTRAC 3155 & 3185 Unladen Weights

With 495/70 R 24 Tyres kg lb Basic Machine with rear linkage and rear PTO On Front Axle On Rear Axle Total Machine Machine with front linkage and front PTO On Front Axle On Rear Axle Total Machine With 520/70 R 30 Tyres kg lb
3598 3103 6701
7933 6842 14775
3688 3193 6881
8132 7040 15172
3848 3088 6936
8484 6809 15293
3938 3178 7116
8683 7007 15690
Load Capacities
Front 3-point Linkage Rear Pick-up Hitch (Maximum vertical down-load) Rear 3-point Linkage (load on hook end) with 80 mm lift cylinders with 85 mm lift cylinders Rear Load Deck Trailer Coupling and Ladder 3000 6613 3000 6613
3000
6613
3000
6613
6000 7000 2500
13227 15432
6000 7000
13227 15432 5511
Laden Weights
! CAUTION
13-2-2-5 13-1-1-11/1
! WARNING
The machine must never be loaded such that less than 20% of the vehicle weight is carried on the front axle.
9804/1103
60 - 00 - 02/10
Issue 1
I'@@L?g ?N@@1?g @@@?g
CONTENTS
Fastrac
60 - 05 - 01/1
*125, 135, 145, 150, 155, 185, 1115 & 1135

*
Data - Electrics (125, 135, 145, 150, 155, 185)

System Type Batteries Cold crank amps for 1 minute to 1.4 Volts per cell at -18 deg C (0 deg F) Reserve capacity (minutes) for 25 Amp load 12 Volts, negative earth Two batteries, each 12 Volts, in parallel 800, each battery 200, each battery
* Alternator Maximum output at maximum engine speed
Lucas A133: 80 Amps Magneti Marelli: 85 Amps Bosch: 85 Amps Lucas M127/2.8 Lucas M127/2.8
Starter Motor Starter motor Light Bulbs Headlights main/dip Working lamps Front side lamps Tail lamps Stop lamps Indicator lamps Indicator side repeater lamps Reversing lamps Number plate lamps Fog lamps Interior lamps Panel/Warning lamps Beacon
60W/55W (Halogen) 55W (Halogen) 4W 10W 21W 21W 5W 21W 10W 21W 10W 1.7W 55W (Halogen)
Data - Electrics (1115 & 1135)

System Type Battery Cold crank amps for 1 minute to 1.4 Volts per cell at -18 deg C (0 deg F) Reserve capacity (minutes) for 25 Amp load Alternator Maximum output at maximum engine speed Starter motor Light Bulbs Headlights main/dip Working lamps Front side lamps Tail lamps Stop lamps Indicator lamps Indicator side repeater lamps Reversing lamps Number plate lamps Fog lamps Interior lamps Panel/Warning lamps Beacon 12 Volts, negative earth
800 200
65 Amps Lucas M127/2.8
60W/55W (Halogen) 55W (Halogen) 4W 10W 21W 21W 5W 21W 10W 21W 10W 1.7W 55W (Halogen)
9804/1103
60 - 05 - 01/1
Issue 4*
CONTENTS
Fastrac
60 - 05 - 01/1A
* 2000 SERIES MACHINES Data - Electrics
System Type Battery Cold crank amps for 1 minute to 1.4 Volts per cell at -18 deg C (0 deg F) Reserve capacity (minutes) for 25 Amp load Alternator Starter motor Light Bulbs (12V rated unless specified otherwise) Headlights main/dip Working lamps Front side lamps Tail lamps Stop lamps Indicator lamps Indicator side repeater lamps Reversing lamps Number plate lamps Fog lamps Interior lamps Panel/Warning lamps Beacon 4WS Quadtronic control panel
800 200 100 Amps Lucas M127/2.8
60W/55W (Halogen) 55W (Halogen) 4W 10W 21W 21W 5W 21W 10W 21W 10W 1.7W 55W (Halogen) 14 volts 18 volts
See Electronic Control Unit, Bulb Renewal for further details.
Note: This machine is fitted with a CAN-BUS system which links certain Electronic Control Units (ECUs) on the vehicle. This stands for Controlled Area Network and uses a special cable in the vehicle harness which carries two (2) twisted signal wires. These carry digital messages and are covered by a metal foil casing called a screen to help prevent corruption from electrical interference. The CAN-BUS is used to send text and fault codes from the transmission controller to the instrument cluster as well as to share information between each other, such as vehicle set-up.
9804/1103
60 - 05 - 01/1A
Issue 2*
CONTENTS
Fastrac
60 - 05 - 01/1B
* 3000 SERIES MACHINES Data - Electrics
System Type Battery Cold crank amps for 1 minute to 1.4 Volts per cell at -18 deg C (0 deg F) Reserve capacity (minutes) for 25 Amp load Alternator Starter motor Light Bulbs (12V rated unless specified otherwise) Headlights main/dip Working lamps Front side lamps Tail lamps Stop lamps Indicator lamps Indicator side repeater lamps Reversing lamps Number plate lamps Fog lamps Interior lamps Panel/Warning lamps Beacon 4WS Quadtronic control panel
800 200 100 Amps Lucas M127/2.8
60W/55W (Halogen) 55W (Halogen) 4W 10W 21W 21W 5W 21W 10W 21W 10W 1.7W 55W (Halogen) 14 volts 18 volts
See Electronic Control Unit, Bulb Renewal for further details.
Note: This machine is fitted with a CAN-BUS system which links certain Electronic Control Units (ECUs) on the vehicle. This stands for Controlled Area Network and uses a special cable in the vehicle harness which carries two (2) twisted signal wires. These carry digital messages and are covered by a metal foil casing called a screen to help prevent corruption from electrical interference. The CAN-BUS is used to send text and fault codes from the transmission controller to the instrument cluster as well as to share information between each other, such as vehicle set-up.
9804/1103
60 - 05 - 01/1B
Issue 2*
CONTENTS
* 125,
h h g g g g g g g g g g g g g g g g g g g g g g g g g g g g g g g g h
Fastrac
60 - 05 - 01 2
135, 145, 150, 155
UK Machines to Serial No 635329
Data - Fuses
The electrical circuits are protected by fuses. The fuses are located in a fuse box on the side of the switch console. If a fuse blows, find out why and rectify the fault before fitting a new one. Fuse No. Circuit Fuse Rating (Amps) 10 15 20 20 10 10 30 10 30 10 15 5 5 7.5 7.5 10
Note: The draft control, screenwipers, speedometer and radio are each protected by more than one fuse. The auxiliary sockets each have an individual 10 amp in-line fuse in addition to fuse B7. The in-line fuses are located behind the electronic linkage control panel.
Fuse No. A1 A2 A3 A4 A5 A6 A7 A8 Circuit Fuse Rating (Amps) 10 15 10 5 15 30 10
Spare Brake lights Rear wash/wipe, radio, draft control Front wash/wipe, horn Engine shut-off solenoid Beacon Powered windows 2WD, front & rear PTO solenoids (including PTO brakes), differential lock solenoid A9 Spare
B1 Radio memory, interior lights, darft control memory B2 Hazard warning light B3 Front working lights B4 Rear working lights B5 Headlight flasher B6 Dip beam B7 Auxiliary sockets B8 Tachograph (when fitted) B9 Air conditioning and heater system C1 Reverse lights, neutral start switch, air conditioning and heater relay C2 Direction Indicators C3 Front wiper: park, intermittent relay C4 Instrument cluster, buzzer, switch position lights, speedometer C5 LH side light, rear fog light and number plate light C6 RH side light, front working light relay C7 Main Beam C8 Spare C9 Spare
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160780
9804/1103
60 - 05 - 01/2
Issue 3*
CONTENTS
* 125,
Fastrac
60 - 05 - 01 3
135, 145, 150, 155
Data - Fuses
The electrical circuits are protected by fuses. The fuses are located in a fuse box on the side of the switch console. If a fuse blows, find out why and rectify the fault before fitting a new one. Fuse No. B1 B2 B3 B4 B5 B6 B7 * B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9
UK Machines from 635330 to 636000 All Export Machines to 636000

Fuse Rating (Amps) Radio memory, interior light 10 Hazard warning lights 15 Front working lights 20 Rear working lights 20 Headlight flasher 10 Dip beam 10 Auxiliary socket 30 Speedometer/tachograph 7.5 Air conditioning and heater system 30 Reverse lights, air conditioning and heater relay 10 Direction Indicators 15 Front wiper: park, intermittent relay 5 Instrument cluster, buzzer, switch position lights, speedometer 5 LH side light, instrument panel illumination, front and rear working light relays 7.5 RH side light, number plate lights, radio illumination, outline marker lights 7.5 Main Beam 10 Rear fog lights 5 Electronic draft control (permanent feed) 5 Circuit
Note: The draft control, screenwipers, speedometer and radio are each protected by more than one fuse. The auxiliary socket has a 10 amp in-line fuse in addition to fuse B7. The in-line fuse is located behind the electronic linkage control panel.
Fuse No. A1 A2 A3 A4 A5 A6 A7 A8 Fuse Rating (Amps) Neutral Start Circuit 5 Brake lights 10 Rear wash/wipe, radio, draft control 15 Front wash/wipe, horn 10 Engine shut-off solenoid 5 Electronic draft control (starter switch feed) 5 Spare 2WD, front & rear PTO solenoids (including PTO brakes), differential lock solenoid, 4WD engaged 10 Speedometer/tachograph 7.5 Circuit
* A9
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170030
9804/1103
60 - 05 - 01/3
Issue 4*
I'@@L?g ?N@@1?g @@@?g
CONTENTS
Fastrac
60 - 05 - 01/4
125, 135, 145, 150, 155, 185 Data - Fuses

The electrical circuits are protected by fuses. The main fuse block A contains 27 fuses. It is located, together with an inline fuse W, under switch panel B. Machines with Anti-lock Braking System (ABS) for trailers have the additional fuses X, Y and Z. There are also six lighting circuit fuses behind a panel to the left of the steering column and some enginemounted fuses on Perkins 160TW (Euro 1) and Cummins engines (see next page). Note: When a priority flow service is fitted, a 5 Amp in-line fuse V is fitted inside the switch console. If a fuse blows, find out why and rectify the fault before fitting a new one. To gain access to the main fuse block and fuses X, Y and Z, remove screws C and carefully lift panel B. Fuse No. Circuit Fuse Rating (Amps) Fuse No. B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 Circuit
Fuse Rating (Amps)
A1 Clutch depressed start circuit, Selectronic range change solenoids (when fitted) A2 Brake lights. A3 Rear wash/wipe, air conditioning relay. A4 Front wash/wipe, horn. A5 Engine shut-off solenoid. A6 Electronic draft control (starter switch feed). A7 Powersplit. A8 2WD, front & rear PTO solenoids (including PTO brakes), differential lock solenoid, 4WD engaged. A9 Tachograph IGN feed. Also (from m/c no 636369) Selectronic IGN feed and speedometer
5 10 10 10 5 5 7.5
C5 C6 C7 C8 C9 W X Y Z
10 7.5
Radio memory, interior lights, beacon socket, digital clock 7.5 Hazard warning lights 15 Front working lights 20 Rear working lights 20 Headlight flasher 15 Radio/cassette power feed 7.5 Auxiliary socket 20 Tachograph (battery feed). Also (from m/c no 636369) Selectronic anti-surge 7.5 Air conditioning and heater system 30 Reverse lights 10 Direction Indicators 7.5 Cold start system 15 Speedometer to m/c no 636368 only, Instrument cluster, buzzer, switch position lights, delay relay for transmission oil pressure warning, cigar lighter 15 Selectronic range change solenoids (when fitted) 3 Starter solenoid 20 13 Pin trailer socket (charging circuit) 10 13 Pin trailer socket (permanent feed) 15 Electronic draft control (permanent feed) 3 Feed to main side and head light switch. 40 ABS solenoids 25 ABS electronics 5 ABS bulbs 3
S193072
9804/1103
60 - 05 - 01/4
Issue 5*
CONTENTS
Fastrac
60 - 05 - 01 5
125, 135, 145, 150, 155, 185 Data - Fuses (continued) Fuses from m/c no. 636001 (continued)
To ga n access o he s x gh ng c cu s acken sc ew A and open he pane Fuse No C rcu uses s ed be ow
All Machines from 636001
Fuse Ra ng Amps 15 15 10 75 75 5
D1 D2 D3 D4 D5 D6
Ma n beam D p beam Rea og gh s LH s de gh ns umen pane um na on RH s de gh cab oo um na on Aux a y gh e ays
Eng ne moun ed Fuses Perk ns 160TW Euro 1 on y E F G Eng ne Shu o Sys em ESOS Man o d Hea e on Man o d Hea e ea 40 60 60
* Eng ne moun ed Fuses Cumm ns To ga n access o he eng ne moun ed uses pu o he e evan p as c cove as shown The man o d hea e uses ed om mach ne numbe 637635 on a e each e a ned by wo nu s L H J K Eng ne Shu o sys em ESOS Man o d Hea e s a e mach nes Man o d Hea e s a e mach nes 40 100 100
O2@@@@@@@@@@6K O2@@@@@@@@@@@@@@@@6K ?W2@@@@@@@0Me?I4@@@@@@@6X W&@@@@@@(Mg?I4@@@@@@)X? ?W&@@@@@@0Y?h?I4@@@@@)K O&@@@@0M ?I4@@@@@6X W2@@@@0M ?I4@@@@)K? ?W&@@@(M ?I'@@@@6K? W&@@@(Y? V'@@@@@6X? ?O&@@@(Y ?V4@@@@@)K ?W2@@@@(Y? ?@@6X?g?I4@@@@@@6X? O&@@@@0Y ?3@@)Xh?I'@@@@@)X W2@@@@(M ?N@@@1heV'@@@@@)K? ?W&@@@@0Y? 3@@@L?h?N@@@@@@@6X? ?O@?@K W&@@@(M? N@@@1?h?J@@@@@@@@)Khf?O2@@@@@@@@@@@6Kg?O@K ?W&@@@(Y ?3@@@LhW&@@@@@@@@@@6Xe?O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K O&@@@(Y? ?@@6X??V'@@1g?W&@@@@@@@@@@@@)?2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K W2@@@@(Y ?@@@)XeN@@@L?f?7@@@@(MI4@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K? ?W&@@@@0Y? ?3@@@1e?@@@)Xf?@@@@(Y?e?@@@@@@@@@@0M?I@M?hI@M?I@MI'@@@@@@@@@@@@@@6K? W&@@@(M? ?N@@@@e?3@@@1f?3@@@?f?@@@@@@0M? N@@@@@@@@@@@@@@@@@6X ?O&@@@0Y 3@@@L??V'@@@L?e?N@@@1f?@@@@(M? ?3@@@@@@@@@@@@@@@@@)K? ?W2@@@(M V'@@)XeN@@@)Xf3@@@L?e?@@@@? ?V'@@@@@@@@@@@@@@@@@@6X? O&@@@(Y? ?V'@@1e?3@@@1fV'@@)Xe?3@@@1 N@@@@@@@@XeI4@@@@@@)K W2@@@@(Y N@@@L??V'@@@L?e?N@@@)X??V'@@@L? ?3@@@@@@@1fI4@@@@@@6X ?W&@@@@(Y? ?3@@1?eN@@@1?f3@@@1?eN@@@1? ?V'@@@@@@@L?f?I'@@@@)X? W&@@@@0Y ?N@@@Le?@@@@LfN@@@@?e?3@@@L N@@@@@@@)XgV'@@@@)X ?W&@@@(M 3@@1e?3@@@)X?e?3@@@Le?N@@@1 ?3@@@@@@@1g?V'@@@@)X? W&@@@(Y? N@@@L??V'@@@1?e?N@@@1f3@@@L? ?N@@@@@@@@L?gV'@@@@1? ?W&@@@0Y ?3@@)XeN@@@@Lf3@@@L?eN@@@)X 3@@@@@@@1?g?V4@@@@L O&@@(M ?V'@@1e?3@@@1fV'@@)Xe?3@@@1 V'@@@@@@@Lhe@@@1 W2@@@(Y? N@@@L??V'@@@L?e?N@@@)X??N@@@@ ?N@@@@@@@1he3@@@L? ?O&@@@(Y ?3@@1?eV'@@)Xf@@@@1?e3@@@L? @@@@@@@@heN@@@)X ?W2@@@@(Y? ?N@@@Le?N@@@)X?e3@@@@LeN@@@1? 3@@@@@@@he?3@@@1 O&@@@@0Y 3@@)X?e3@@@1?eV'@@@1e?3@@@L V'@@@Xhf?N@@@@L? W2@@@@(M N@@@)XeN@@@@?e?N@@@@L??V'@@)X? ?N@@@1 3@@@)X ?W&@@@@(Y? ?3@@@1e?3@@@Lf3@@@1?eN@@@1? 3@@@L?hfV'@@@)X? W&@@@@0Y ?V'@@@e?N@@@)X?eV'@@@Le?3@@@L N@@@1?hf?V'@@@1? ?W&@@@(M N@@@L?e3@@@1?e?V'@@1e?V'@@1 ?3@@@L N@@@@L W&@@@(Y? ?3@@)XeV'@@@LfN@@@L?eN@@@L? ?V'@@1 ?3@@@)X? ?W&@@@(Y ?V'@@)X??N@@@)X?e?3@@)Xe?3@@1? N@@@L?hf?N@@@@)X W&@@@(Y? N@@@1?e3@@@1?e?N@@@1e?N@@@L ?3@@)X 3@@@@)K? ?O&@@@0Y ?@@@@LeN@@@@?f3@@@L?e@@@)X? ?N@@@1 N@@@@@@6X? ?O2@@@(M ?3@@@1e?3@@@LfN@@@1?e3@@@1? O@K?f@@@@ ?3@@@@@@)K ?W2@@@@(Y? ?V'@@@L??N@@@)X?e?3@@@LeV'@@@L O2@6?2@@@@@@@@@?@@@@gO@K?f?V'@@@@@@@@6X? W&@@@@(Y V'@@1?e3@@@1?e?V'@@1e?V'@@)X?h?O2@@@@@@@@@@@@@@@@?hW2@@@@6KfN@@@@@@@@@)X ?W&@@@@(Y? ?N@@@LeV'@@@LfN@@@L?eN@@@1?gO2@@@@@@@@@@@@@@@@@@5?h&@@@@@@@6?@K?@@@@@@@@@@)K? W&@@@@0Y 3@@)X??N@@@)X?e?3@@)Xe?3@@@Le?O2@@@@@@0M?heW@U?he?I'@@@@@@@@@@@@@@V4@@@@6K? ?O&@@@(M N@@@1?e3@@@1?e?N@@@1e?N@@@)KO2@@@@@@0M?hO2@@@R@@@@@@@6?@K?eV@@@@@@@@@@@@@@??I'@@@@6X? ?W2@@@@0Y? ?3@@@LeV'@@@Lf3@@@L?e3@@@@@@@@(M?hO2@@@@@@@@@@@@@@@@@@@6?2@@@@@@@@@@@@@@@LeV4@@@@)X W&@@@(M? ?N@@@)X??N@@@1fN@@@1?eN@@@@@@@0YgO@?2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1fI4@@@)K? ?W&@@@(Y 3@@@1?e3@@@L?e?3@@@Le?3@@@@g?O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@gI'@@@6K? O&@@@(Y? V'@@@LeN@@@)Xe?V'@@1e?V'@@@L?e?O2@@@@@@@@@0MhfI'@@@@@@@@@@@@@@@@@@@@@@g?V'@@@@6X? W2@@@@(Y ?N@@@1e?3@@@1fN@@@L?eN@@@1??W2@@@@@@0M? ?N@@@@@@@@@@?I4@@@@@@@@@L?gV'@@@@)X ?W&@@@@(Y? 3@@@L??V'@@@L?e?@@@)Xe?3@@@?O&@@@@@0M? 3@@@@?@@@@fI4@@@@@@)Kg?V4@@@@)K? W&@@@@(Y N@@@1?eN@@@)Xe?3@@@)X??N@@@@@@@@@0M? V'@@@W@@@@L?fI4@@@@@@6Xg?I'@@@@6X? ?W&@@@@0Y? ?3@@@Le?3@@@1e?V'@@@1?e3@@@@@@(M? ?N@@@@Y@@@1?g?I'@@@@)X??@6XeV4@@@@)K W&@@@(M? ?N@@@)X??N@@@@fN@@@@LeN@@@@@(Y 3@@@@@@@@LhV4@@@@)K?@@)X?eI4@@@@6X ?W&@@@(Y 3@@@1?e3@@@L?e?3@@@1e?3@@@@H? N@@@@@@@@)X?hI'@@@@@@@@)Xf?@@@@)K? O&@@@0Y? V'@@@LeN@@@)Xe?N@@@@L??N@@@@L? ?3@@@@@@@@1?h?N@@@@@@@@@1f?@@@@@@6K? W2@@@(M? ?N@@@1e?3@@@1f3@@@1?e3@@@1? ?N@@@@@@@@@Lhe@@@@@@@@@@L?fI4@@@@@6X? ?W&@@@(Y 3@@@L??V'@@@L?eV'@@@LeV'@@@L 3@@@@@@@@1he@@@@@@@@@@1?gI4@@@@)X O&@@@(Y? V'@@)XeN@@@1?e?N@@@1e?N@@@)X? V'@@@@?@@@hf@@@@@@@@@LhI'@@@)K? W2@@@@(Y ?N@@@1e?3@@@Lf3@@@L?e3@@@)X ?N@@@@W@@@@@he3@@@@?@@@)X?g?V4@@@@6K? ?O&@@@@(Y? @@@@L??V'@@)X?eV'@@1?eN@@@@1 3@@@@Y@@@@heN@@@@?@@@@)Xh?I'@@@@6X? @@@@@@0Y 3@@@)XeN@@@1?e?N@@@Le?3@@@@ N@@@@W@@@@L?h?3@@@@@@@@@1heV'@@@@)X ?J@@@@(M V'@@@1e?@@@@Lf3@@)X??N@@@@L? ?3@@@@Y@@@1?h?N@@@@@@@@@@L?h?V4@@@@)K? W&@@@(Y? ?V'@@@e?3@@@1fN@@@1?e3@@@1? ?N@@@@@@@@@Lhe3@@@@@@@@@1?he?I'@@@@6X? ?O&@@@0Y N@@@L??V'@@@L?e?3@@@LeV'@@@L 3@@@@W@@@1heV'@@@@@@@@@LhfV'@@@@)X ?W2@@@(M ?3@@)XeN@@@)Xe?N@@@1e?N@@@1 N@@@@@Y@@@L?h?N@@@@@@@@@)X?he?V4@@@@)K? W&@@@(Y? ?N@@@1e?3@@@)X?e3@@@L?e3@@@L? ?3@@@@?@@@)Xhe@@@@@@@@@@1?hf?I'@@@@6X? ?W&@@@(Y 3@@@L??V'@@@1?eV'@@1?eN@@@)X ?V'@@@@@@@@1he3@@@@@@@@@@L V4@@@@)K O&@@@(Y? N@@@)XeN@@@@?e?N@@@Le?3@@@1 N@@@@@@@@@heV'@@@@@@@@@1 I4@@@@6X O2@@@@0Y ?3@@@1e?3@@@Lf@@@)X??V'@@@L? ?3@@@@@@@@L?h?N@@@@@@@@@@L? I'@@@)K? W2@@@@(M ?V'@@@e?N@@@)X?e3@@@1?eN@@@)X ?V'@@@V'@@1?he3@@@@@@@@@)X ?V4@@@@6K? ?W&@@@@0Y? N@@@L?e3@@@1?eV'@@@Le?3@@@1 N@@@LN@@@LheN@@@@@@@@@@)X? ?I'@@@@6X? W&@@@(M? ?3@@)XeV'@@@Le?N@@@)X??V'@@@L? ?3@@)X@@@)X?h?3@@@@@@@@@@)K V4@@@@)X ?W&@@@(Y ?V'@@1e?N@@@1f3@@@1?eN@@@1? O26Xg?N@@@@@@@@)Kh?N@@@@@@@@@@@@6K I'@@@)K? O&@@@0Y? N@@@L?e3@@@L?eN@@@@Le?@@@@LhfO2@@@@@@@1h@@@@@@@@@@@@@@@6K?e3@@@@@?@@@@@@@6X ?V'@@@@6X? W2@@@(M? ?@@@)XeV'@@1?e?3@@@1e?3@@@1heO2@@@@@@@@@@heI4@@@@@@@@@@@@@6K?V@@@@@W@@@@@@@@)X? V4@@@@)X ?@6K ?W&@@@(Y ?3@@@1e?N@@@Le?N@@@@L??V'@@@L?f?O2@@@@@@@@@0M I4@@@@@@@@@@@@@@@@@@@Y@@@@@@@@)K I'@@@)K? ?@@@6X ?7@@@(Y? ?V'@@@L?e@@@)X?e3@@@)XeN@@@)Xe?W2@@@@@@@@0M? ?I4@@@@@@@@@@@@@@@@@@@@@@@@@@@@6X? ?V'@@@@6K? ?3@@@)K? ?@@@(Y N@@@1?e3@@@1?eV'@@@1e?3@@@1e?7@@@@(Mhe?O2@@@@@@@@@@6K?h@@@@@@@@@@@@V'@@@@@@@@@@)X V4@@@@@6K? ?V4@@@@6K? O2@@@(Y? ?3@@@LeV'@@@Le?V'@@@e?N@@@@e?@@@@0Y?fO2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@LV'@@@@@@@@@@)K? I'@@@@@6X? ?I4@@@@6K? W2@@@@(Y ?V'@@)X??N@@@)X?eN@@@L?e3@@@L??@@0M?e?O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1?N@@@@XI4@@@@@6K? ?V4@@@@@)K ?I4@@@@@6X ?W&@@@@0Y? N@@@1?e3@@@1?e?3@@)XeN@@@)XgW2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@??3@@@1eI4@@@@@6X? ?I4@@@@@6X I'@@@)K? W&@@@(M? ?@@@@LeV'@@@Le?N@@@1e?3@@@)X?e?O&@@@@@@@@@0Mhf?@@@@@f@@@@@@@@@@@@@@@L?V'@@@L?eI'@@@@)X ?I'@@@@)K? ?V4@@@@6X? ?W&@@@0Y ?3@@@)X??N@@@1f3@@@L??V'@@@1??W2@@@@@@@@@0M ?3@@@@L??J@??I4@@@@@@@@@@1eN@@@1?e?V4@@@@)K? V4@@@@@6X? ?I'@@@)K W&@@(M ?V'@@@1?e3@@@L?eN@@@)XeN@@@@L?*@@@@@(M? ?V'@@@1??7@LgI4@@@@@@e?@@@@Lf?I'@@@@6X? I4@@@@)K V4@@@@@@@@@6K? ?W&@@(Y? V'@@@?eN@@@1?e?3@@@1e?3@@@1?N@@@@0Y N@@@@L?@@)X?gI4@@@@@6T@@@@)X?fV'@@@@)K I'@@@@6X W&K?hf?@@@@@@@@@@@@6K? O&@@(Y ?N@@@Le?3@@@Le?V'@@@e?V'@@@L?@@0M ?@@@@)X@@@1?h?I'@@@@R'@@@1?f?V4@@@@@6X ?V'@@@@)X? 7@@6X?heJ@@@@@@@@@@@@@@6K? W2@@@(Y? 3@@)X??N@@@)X?eN@@@L?eN@@@1? ?@@@@@@@@@@LheV'@@@LV'@@@Lg?I'@@@@)X? 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V'@@@5 I4@@@@6K W&@@@(Y? ?V'@@)X??N@@@1fN@@@L?eN@@@L? 3@@)X@@@@?he?3@@@@@@@@@Lhf?I'@@@@)X?fV'@@@@6XfV4@@@@@6X? @@@H I4@@@@6K ?O&@@@(Y V'@@1?e3@@5f?@@@)Xe?3@@)X N@@@@@@@@?he?V'@@@@@@@@1 V4@@@@)Kf?V4@@@@)K?fI'@@@@)K ?7@@5?hf@6X?hfI4@@@@@6K? ?W2@@@@0Y? ?N@@@LeV40Yf?3@@@)X??N@@@)K? ?3@@@@@@@@@?heV'@@@@@@@@L? I'@@@@6Xf?I'@@@@6X?e?V'@@@@@6X J@@(Y?hf@@1? I4@@@@@6K? O&@@@(M? @@@1he?V'@@@1?e@@@@@@@@@@@@@@6K ?N@@@?@@@@@Lhe?N@@@@@@@@1? ?V'@@@@)K?fV4@@@@)KfV4@@@@@)K? 7@@H @@@? I4@@@@@6K? ?@@@@@(Y 3@@@L?heN@@@@L?J@@@@@@@@@@@@@@@@@@@6K? 3@@@@@@@@1hf3@@@@@@@@L V4@@@@@6K?fI'@@@@6Xf?I'@@@@6X? ?J@@5? @@@? I4@@@@@6K? J@@@@(Y? V'@@1?he?3@@@)?&@@@@@@@@@@@@@@@@@@@@@6K?hfV'@@@@@@@@L?heN@@@@@@@@)X? I4@@@@@6X?e?V4@@@@)K?fV'@@@@)K ?7@@H? 3@@L I4@@@@@6X? ?O&@@@0Y ?N@@@Lhe?N@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6Xhe?N@@@@V'@@1?he?3@@@@@@@@1? I'@@@@)Kf?I'@@@@6X?e?V'@@@@@6X ?@@5 V'@)X? I4@@@@)K ?W2@@@(M 3@@)X?he3@@@@@@@@0M?h?I4@@@@@@@@)K?he@@@@LN@@@Lhe?N@@@@@@@@@L ?V'@@@@@6XfV'@@@@)XfV'@@@@@)X? J@@H ?N@@1? 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J@@@@@gO&@@@@ ?7@@ @@@@ @@@?f?@@@@? ?I4@@@@@@@@@@@5?g@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@ @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5? ?W&@@@@@@(Y? 7@@@@@@@@@@@@@@@@@ ?@@@ @@@@ @@@?f?@@@@? ?@@@H?g@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@ @@@@@@@@@@0?4@@@@@@@0M I40MeI4@0MI40MI4@@0?4@@@@@0Y? ?7@@@@@@(Y 3@@@@@@@@@@@@@@@@@ ?@@@ @@@@ @@@?f?@@@@? ?@@@h@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@0MI4@@@@0M?eI40M ?I'@@@@@@@@? J@@@@@@(Y? V4@@@@@@@@@@@@@@@@ ?@@@ @@@@ @@@?f?@@@@? ?@@@h@@@@@(M? 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D6 D5 D4 D3 D2 D1
S193081
9804/1103
60 - 05 - 01/5
Issue 3*
W2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6K?h ?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@h
CONTENTS
Fastrac
60 - 05 - 01/6
FASTRAC 1115 & 1135 Data - Fuses Fuses

The electrical circuits are protected by fuses. The main fuse block A contains 27 fuses. It is located, together with an inline fuse W, under switch panel B. There are also six lighting circuit fuses D1 - D6 behind a panel to the left of the steering column. If a fuse blows, find out why and rectify the fault before fitting a new one. To gain access to the main fuse block, remove screws C and carefully lift panel B. Fuse No. Circuit Fuse Rating (Amps)
A1 A2 A3 A4 A5 A6 A7 A8
A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4
C5 C6 C7 C8 C9 W D1 D2 D3 D4 D5 D6
Clutch depressed start circuit, Selectronic range change solenoids Brake lights. Rear wash/wipe, air conditioning relay Front wash/wipe, horn Engine shut-off solenoid. Electronic draft control (starter switch feed). Powershift 2WD, front & rear PTO solenoids (including PTO brakes), differential lock solenoid, 4WD engaged Selectronic IGN feed and speedometer Radio memory, interior lights, beacon socket, digital clock. Hazard warning lights. Front working lights. Rear working lights. Headlight flasher. Radio/cassette power feed. Auxiliary socket. Selectronic anti-surge. Air conditioning and heater system. Reverse lights. Direction indicators. Cold start system Instrument cluster, buzzer, switch position lights, delay relay for transmission oil pressure warning, cigar lighter. Selectronic range change solenoids Starter solenoid 13 Pin trailer socket (charging circuit). 13 Pin trailer socket (permanent feed). Electronic draft control (permanent feed). Maxifuse - Feed to main side and head light switch. Main beam. Dip beam. Rear fog lights. LH sidelight, instrument panel illumination. RH sidelight, cab roof illumination. Auxiliary light relays.
5 10 10 10 5 5 7.5
10 7.5 7.5 15 20 20 15 7.5 20 7.5 30 10 7.5 15
15 3 20 10 15 3 40 15 15 10 7.5 7.5 5
D6 D5 D4 D3 D2 D1
A229261
9804/1103
60 - 05 - 01/6
Issue 3
CONTENTS
Fastrac
60 - 05 - 01/6A
2000 & 3000 SERIES MACHINES Data - Fuses

* Fuses The electrical circuits are protected by fuses. The main fuse block A contains 27 fuses. It is located, together with fuses E, F, W and X (Series 2000 only), under switch panel B. To gain access, disconnect the battery, remove screws C and carefully lift panel B. There are also six lighting circuit fuses D1 - D6 behind a panel to the left of the steering column. If a fuse blows, find out why and rectify the fault before fitting a new one.
Fuse No. A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 Fuse Rating (Amps) Clutch start. 5 Brake lights. 10 Rear wash/wipe, suspension seat, 2WD dump relay, fuse E3. 15 Front wash/wipe, horn. 10 ESOS start relay (3185 only), ESOS, Waxstat. 7.5 EDC IGN. 5 Transmission controller. 15 2WD, front & rear PTO, differential lock solenoids, PTO brake relay. 15 Cab heater (3000 series only), ACU, compressor clutch, 30 Radio memory, interior light, beacon socket, AG panel illumination. Hazard warning lamps. Front work lights. Rear work lights. Headlight flasher. Radio/cassette power supply. Auxiliary socket. Cigar lighter. EDC battery, instrument cluster battery. 13 pin trailer socket reverse lights supply (2000 Series to S/N 738748, 3000 Series to S/N 640777) Reverse lights ( 2000 Series from S/N 738749, 3000 Series from S/N 640778) Direction indicators. Thermostart (all except 3185), starter heater relays (3185 only) Instrument cluster, lights switch illumination, speedometer sender, diagnostic connector, differential lock cut-out switch, fuse C5, warning bleeper. Radar, fuel flow meter. Starter motor solenoid. 13 Pin trailer socket ignition supply (2000 Series to S/N 738748, 3000 Series to S/N 640777). Auxiliary socket ignition supply (2000 Series from S/N 738749, 3000 Series from S/N 640778) 13 Pin trailer socket battery supply (2000 Series to S/N 738748, 3000 Series to S/N 640777). Auxiliary socket battery supply (2000 Series from S/N 738749, 3000 Series from S/N 640778) 7.5 15 30 20 15 7.5 20 10 3 Circuit C9 D1 D2 D3 D4 D5 D6 E1 E2 E3 E4 E5 * F1 * F2 * F3 * F4 W *X Air drier, gearbox neutral start. Main beam Dipped beam Rear fog lights LH sidelights RH sidelights Auxiliary lights switching (3000 series) Not used (2000 series) ABS trailer socket ABS trailer socket Flow divider 4 wheel steer (2000 series, except 2150) Not used Tractor ABS Tractor ABS Tractor ABS Tractor ABS 10 15 15 10 7.5 7.5 5 25 5 5 5 3 10 10 5
Maxifuse - Feed to side and headlight switch 40 Steering control system (4WS) (2000 Series only) 5
Engine-mounted Fuses (3185 machines) To gain access to the engine-mounted fuses, pull off the relevant plastic cover as shown. The manifold heater fuses are each retained by two nuts J.
F G H Engine Shut-off System (ESOS) Manifold Heaters (Megafuse) Manifold Heaters (Megafuse) 40 Amps 100 Amps 100 Amps
* Refer to appropriate schematic for Fuse Functions.
5 10 7.5 30
C1 C2 C3 C4
C5 C6 C7
7.5 3 20
10
C7
5 15
C8 C8
20
9804/1103
60 - 05 - 01/6A
8020 - C/1-2.5
Issue 3*
CONTENTS
Fastrac
60 - 05 - 01/6B
2000 & 3000 SERIES MACHINES Data - Fuses (continued)

*
E
1 2
W
2 3 4 5 6 7 8
3 4
1 A B C
X B
1 3 5
0
IG N H HS
G H J
2 4 6
A286502
D2 D3 D4 D5 D1 D5 D4 D3 D2 D1
2000 Series
9804/1103
A302640
D6
A302650
3000 Series
60 - 05 - 01/6B
8020-C/1-2A.3
Issue 3*
CONTENTS
*
Fastrac
60 - 05 - 01 7
125, 135, 145, 150, 155 Data - Relay Identification

Although some relays look similar, internally they can be different, for example, they can be single contact or double contact; normally closed or normally open. Make sure the correct relay part number is used, otherwise the machine electrical circuits will not function properly. All the relays shown at A or B are housed in the front console behind access panel X. In addition, the two neutral start relays are positioned to the right of the steering column. The rear wiper relay is positioned near the rear wiper switch.
To Machine number 636000
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O&@@ ?N@?e?@ V4@)K?eV4@@@6K?heO2@@@0M? ?W2@@@(Y ?J(Yhe?W&(Y? ? 7H ?@@@ ?I4@@@@@@@@6K? ?O2@0M?W20M? W2@< @?e?@ I4@@6Ke?I4@@@@@@@@@@@@@@@@(M? W&@@@0Y? W&H?he?7(Y ? @? ?@@@ I4@@@@@@@6K? ?W2@(MeW.M? ?W&@@? ?@ I4@@@@6Kf@@@@@@@@@@@@0Y ?O&@@@ 75hfJ@H? ? ?J5? ?@@@ I4@@@@@@@6K? O&@0Y?e.Y O&(M ?@ ?I4@@@@@@@@@@@@@@@@0M? ?W2@@@@@ ?J(Yhe?W&5 ? ?7H? ?@@@ ?I4@@@@@@6K? O2@0M??O.? W2@0Y? ?I4@@@@@0M O&@@@(M? W.Y?he?7(Y ? ?@ ?@@@ I4@@@@@@@6K? W2@(M??W20Y? ?W&(M? ?@@@@@0Y 7HhfJ@H? ? ?@ ?@@@ /K ?I4@@@@@@?@@@@@@6K ?O&@0Ye?.M? O&0Y ?@@@(M ?J5?he?W&5 ? ?@@@ V'6X ?O2@0MeW. W2@< W2@@@(Y? W&H?he?7@H ? @? ?@@@ W2@@@6XV'1 I4@@@@@6K? ?W2@(Me?O.Y ?W&@@? ?O&@@@0Y 75hfJ@5? ? @? ?@@@ ?W&@@@@@)XV'L? ?I4@@? O&@0Y??O20Y? O&(M ?W2@@@(M ?J(Yhe?W&(Y? ? @? ?@@@ ?7(Me?I'1?N1? W2@(M??W20M? W2@0Y? W&@@@0Y? W&H?he?7@H ? ?@@@ ?@H?fN@L?@? ?W&@0YeW.M? ?O&(M? ?W&? ?O&@@(M? 75hfJ@5? ? ?@ ?@@@ ?@?W&KO.?31?@? ?@6K O&0Mf.Y ?W2@0Y W&@? ?W2@@@0Y ?J(Yhe?W&(Y? ? J5 ?@@@ ?@?&@@@U?N@?@? I'6K @@(Me?O.? W&(M ?W.M O&@@@? W&H?he?7(Y ? 7H ?@@@ ?@fI/e@@5? ?V4@6Xh/X @(Y??W20Y? ?W&(Y? W.Y? W2@@@@@? 75hfJ@H? ? @? ?@@@ ?3=?f?J@@H? ?I4)K?gV/ ?O2@0YeO.M? O&0Y ?O.Y ?W&@@@(M ?J(Yhe?W&5 ? @? ?@@@ ?N@@@?eW&@5 ?I4@6Xg?@6X ?O2@0MeW20Y W2(M ?W20Y? W&@@@0Y? W&H?he?7(Y ? ?@@@ @@@??O&@0Y ?I4)K?gI/ ?O2@0Mf.M ?O&0Y? O.M? ?O&@@(M? 75hfJ(Y? ? ?@ ?@@@ ?I4@@@0M ?I'6K?g?@6X ?W2@(Me?W.? ?W2(M? W2(Y ?W2@@@0Y ?J(Yhe?W&H ? ?@ ?@@@ V4@6X?gI/K? O&@(Y?eO.Y? W&(Y ?W&(Y? O&@@@? W&H?he?7@? ? J5 ?@@@ I4)Kg?V46K? W2@@0YeO20Y ?W&0Y? O&0Y W2@@@@@? 75hfJ@5? ? 7H ?@@@L? I'6Kg?I46K? ?O&@0MeW2(M O.M? ?@(M ?O&@@@(M ?J(Yhe?W&(Y? ? @? ?@@@1? ?V4@6Xg?I'6K? ?W2@(Mf7(Y? W2(Y C(Y? @@@@@0Y? W&H?he?7(Y ? @? ?@@@@? ?I4)K?gV4@6K? O&@0Y?f(Y ?O&0Y? W2(Y ?W&? @@@(M? 75hfJ@H? ? ?@@@@@@@@@@@6K ?I'@6Xg?I4@6X W2@(M? ?W2(M? ?W&(Y? W&5? ?W2@@@(Y ?J(Yhe?W&5 ? ?@@@(Me?I4@@@@@@@6K V4@)K?g?I')X? ?O&@0Y W&(Y W&0Y ?W&(Y? O&@@@0Y? ?7H?he?7(Y ? ?@ ?@@@H?h?I4@@@@@@@6K I4@6K?gV4)Khf?O2@0M ?O&0Y? ?O.M W&(Y W2@@@(M? J5hfJ(Y? ? ?@ ?@@@ ?I4@@@@@@@6K I'@6X?gI4@@he@@(M ?W2(M? ?W2(Y? 7(Y? ?W&@@@0Y ?W&Hhe?W&H ? J5 ?@@@ I4@@@@@@@6K? ?O26K? ?V4@)KhI@he@0Y? W&(Y W&(Y ?J@H O&@@@? W&5?he?7@? ? 7H ?@@@ I4@@@@@@@@6K ?O2@@@@6K? ?I4@6K ?O&0Y? ?O&0Y? W&5? W2@@@@@? 7(Y?he?@5? ? @? ?@@@ ?I4@@@@@@@@6K? ?W2@@@@XI4@@ ?I4@6Xhf@? ?W2(M? ?W2(M? ?W&(Y? ?W&@@@(M ?J(YhfJ(Y? ? ?J5? ?@@@ I4@@@@@@@@@6K? W&@@@@@)K?I'L? ?I'1 W&(Y W&(Y ?7(Y W&@@@0Y? W&H?he?W.Y ? ?7H? ?@@@ ?O@K I4@@@@@@@@@6K? ?W&(M?eI4@@?N)X V' ?O&0Y? ?W&0Y? J(Y? ?O&@@(M? ?W&5hfW&H? ? ?@ ?3@@ ?W2@@@@@@@@@6K ?I4@@@@@@@@6K? ?7@H?W26X?W@L?31 ?W2(M? O.M? ?W.Y ?W2@@@(Y ?7(Yhe?W&5 ? ?@ ?N@@ O&@(M??I4@@@@@@@6K I4@@@@@@@6K? ?@5?W&@@)?&@1?N@ W&(Y W2(Y W.Y? O&@@@(Y? J@H?he?7(Y ? @@ O2@@@YhI4@@@@@@@@@@6K ?I4@@@@@@@@6K? ?@H?&@@@@@@@@L?@ ?O&0Y? ?W&(Y? ?W.Y W2@@@@0Y ?W&5hfJ(Y? ? @? @@ ?@@@@@@@@@@6K?hfI4@@@@@@@6K? ?I4@@@@@@@@6K? ?@eV+M??@@@@)X@ ?W.? ?W2(M? O&(Y W&H? ?O&@@@(M ?7@Hhe?W&H ? @? @@ ?@@?eI4@@@@@@@@@6K?he?I4@@@@@@@@6K? ?I4@@@@@@@@6K? ?@L?fJ@@@@@@@ W.Y? O&0Y W2@0Y? ?W&@ ?W2@@@@0Y? J@5?heW&5? ? ?J5? @@ ?@@?he?I4@@@@@@@@6K?hf?I4@@@@@6K ?I4@@@@@@@@6K? ?31?f'@e@@@5 7He?W.? W2(M ?W&(M? ?.M? O&@@@(M? 7(Y?he7@H? ? ?7H? @@ ?@@? I4@@@@@@@@@6K?hfI4@@@@@6K? ?I4@@@@@@@6K ?V'LfV'e@@(Y ?J@?eW&H? ?W&(Y? W&(Y ?@@@@@0Y ?J(Yhe?J@5 ? ?@ @@ ?@@? ?I4@@@@@@@@6K?hfI4@@@@@@ ?I@MI4@@@@6K N)?@f?C@0Y? ?75?e75 O&0Y ?O&0Y? ?O.? ?@@@(M W&H?heW&(Y ? J5 @@ ?@@? ?I4@@@@@@@@6K? @@@@@6K? ?I4@@@@@@@@6K? ?@@@f@(M? J(Y??J(Y W2(M ?W2(M? @(Y? W2@@@(Y? ?W&5hf7@H? ? 7H @@ ?@@? ?I4@@@@@@@6K ?I4@@@6K ?I4@@@@@@@6K I4@@e(Y 7He?7H? ?W&(Y? W&(Y ?J(Y ?O&@@@0Y ?7(Yhf@5 ? @? @@ ?@@? I4@@@@@@@@6K I4@@@@6K ?I4@@@@@@@6K ?J@?eJ@ O&0Y ?W&(Y? W.Y? ?W2@@@(M J@H?he?J(Y ? @? @@ ?@@? I4@@@@@@@@6KhfI4@@@@@@6K ?I4@@@@@@@6K W&5??W&5 W2(M W&0Y ?W.Y W&@@@0Y? ?W&5hfW&H? ? @@ ?@@? I4@@@@@@@6K?he?I4@@@@@@@6K ?I4@@@@@@@6K 7(Y??7@H ?W&(Y? ?O&< ?W.?f?.Y? ?W&@@@ ?7@Hhe?W&5 ? ?@ @@ ?@@? ?I4@@@@@@@@6K?he?I4@@@@@@@ ?I4@@@@@@@6K ?J@HeJ@5? O&0Y ?W2@@? W.Y? O&@@@@ J@5?he?7(Y ? ?@ @@ ?@@? I4@@@@@@@6K?hf?@@@@@@@6K ?I4@@@@@@@6K ?75?e7(Y? W2(M W&(M ?W.Yf?@ W2@@@(M? 7(Y?heJ@H? ? J@ @@ ?@@? ?I4@@@@@@@6Khf?I4@@@@@@6K? I4@@@@@@@@6K J@H??J@H ?W&(Y? ?W&(Y? W.Y?fJ5 ?W&@@@(Y ?J(Yhf75 ? 75 @@ ?@@? ?I4@@@@@@@6Khf?I4@@@@@@6K? ?I4@@@@@@@@6K? ?W&5e?75? O&0Y O&0Y ?W.Yf?W.Y O&@@@0Y? W&H?he?C(Y ? @H @@ ?@@? ?I4@@@@@@@@6K?he?I4@@@@@@@ ?I4@@@@@@@@@6K ?7(Ye?@H? W2(M W2(M W&H?fW.Y? W2@@@(M? 75hf@@H? ? ?J@? @@ ?@@? ?I4@@@@@@@6K @@@? ?I4@@@@@@@@@6K ?W2@@@6X ?@H?eJ5 ?W&(Y? ?W&(Y? ?W&5g.Y ?O&@@@(Y ?J(Yhf@5 ? ?75? @@ ?@@? ?I4@@@@@@@6K ?I4@@@@@@@@6K? W&@@@@@)K? J5e?W&H O&0Y O&(Y ?&0Y ?W2@@@@0Y? W&H?he?J(Y ? ?@H? @@ J@@? I4@@@@@@@@6K ?@ ?W@@@@@@@@@@@@6K ?W&@@@e?I'6X? ?W&He?75? W2(M W2@0Y? ?W&? W&@@@(M? ?W&5hfW&H? ? ?@ @@ 7@@? ?I4@@@@@@@6K O&@0M?fI4@@@@@@@6K? W&@@@@@6X?V'1? ?75?eJ(Y?hf?W&(Y? ?W&(M? ?W.?f?75? ?W&@@@(Y ?7@Hhe?W&5 ? ?@ @@ @@@? I4@@@@@@@6K? W2@(M?he?I4@@@@@@@6K ?W&0M??I4@)X?V'L J@H?e7H O&0Y W&(Yhf@?hW.Y?fJ(Y? O&@@@0Y? J@5?he?7(Y ? @@ @@@? ?I4@@@@@@@@6K?hfO.f?W&@0Y I4@@@@@@@@6K W&<?f?I')X?N1 75e?J5?hfW2(M ?W&0Y?h?W.?h?W.Yf?W.Y W2@@@(M? ?W&(Y?heJ@H? ? @? @@ @@@? I4@@@@@@@@6KgO2(YfW&(M ?I4@@@@@@@@6K? 75hV')X?@ ?J(YeW&H?he?O&0Y? O.M?he?.Y?hW.Y?fW.Y? ?O&@@@0Y W&(Yhe?W&5 ? @? @@ @@@? I4@@@@@@@@@@H?f7@H? ?I4@@@@@@@6K @Hf?@@@?V'1?@ W&H?e75he?W2(M? W2(Y ?W.Yf?W.Y ?W2@@@@? 7@H?he?7(Y ? ?J5? @@ @@@? ?I4@@@@@f?J@5 I4@@@@@@@@6K @??W26T@@@eN@?@ 75e?J@HheW&(Y ?W&(Y? ?.Y?fW.Y? W&@@@@@? @5hfJ@H? ? ?7H? @@ @@@? ?I'@f?7@H I4@@@@@@@6K? @??&@@0MI@e?@?@ ?J@He?75?h?O&0Y? O&0YheO. ?W.Y ?O&@@@@@@@6K ?J(Yhe?W&5 ? ?@ @@ @@@? N@f?@@? I4@@@@@@@@6K @?he?@@@ ?75?eJ(Y?g?W2(M? W2(MheW2(Yhe?@(?fW.Y? ?W2@@@(MeI4@@@@6K W&H?he?7(Y ? J5 ?J@@ @@@? ?@f?@@? ?I4@@@@@@@6K 3Lhe?@@@ J(Y?e.YhW&(Y ?W&(Y?he7(Y?heJ(Y?f7H W&@@@(Y?f?I4@@@@6K? ?W&5hfJ@H? ? 7H ?7@@ @@@? ?@f?3@? ?I4@@@@@@6K? N)X?@@gJ@V@ ?W&Hhf?O&0Y? O&(Yhf(Yhe?W.Yf?C5? ?O&@@@0Yhe?I4@@@6K ?7(Yhe?W&5 ? @? ?3@@ @@5? ?@f?N@? I4@@@@@@@@@6X? ?3)Xe?'@(e7@ ?7@?he?W2(M? ?@@(Y?hW2(?hfW.Y?f@(Y? ?W2@@@(M I4@@@6K? J(Y?he?7(Y ? @? @@ @@H? ?@g@? ?I4@@@)?'@6K ?V')X??V'Y?J@@L? J@5?heW&(Y ?@(Yh?W&(Y?he?W.Yf?J(Y W&@@@(Y? ?I4@@@6K 7Hhf?@H? ? ?7@@ @@ ?@L?f@L V4@@@@@@6K V')KfO&@@@? 7(Y?h?O&0Y? W2@0Y?hO&(YhfW&H?fO.Y? ?O&@@@0Yhf?@6KheI4@@@6K? ?C5?hfJ5 ? ?3@@ @@ ?@1?f@1 ?I4@@@@@@@6Khf?V4@@@@@@@0M (Yh?W2(M? ?@ ?W&(M?hW2@0Y?he?W&5f?@(Y ?W2@@@(M I4@@@6K?h?I4@@@@6K? @@H?he?W.Y ? ?@ ?N@@ @@ ?@@?f@@ ?I4@@@@@@@6Kh?I4@@0M? O&(Y W&(Yh?W&@ ?7(YfJ(Y? W&@@@(Y? ?I4@@@6KheI4@@@@6K ?J@5hfW&H? ? ?@ @@ @@ ?@@?f@@ I4@@@@@@@@6K W2@0Y? ?O&0Y?hW&@@ C(Y?e?W&H ?O&@@@0Y I4@@@6K?heI4@@@6K? W&(Yhf75 ? @@ @@ ?@@?f@@ ?I4@@@@@@@@@6K ?O&(M? ?W2(M?h?W&(M?hf?@(YfW&5? ?W2@@@(M ?I4@@@@6K?h?I4@@@6K ?W&@H?he?J(Y ? @? @@ @@ ?3@?f@@ ?I4@@@@@@@@6K? ?O2@(Y W&(YheW&(Y J(Y?e?W&(Y? W&@@@(Y? ?I4@@@6KheI4@@@6K? ?7@5hfW&H? ? @? @@ @@ ?N@?f3@ ?I4@@@@@@@6K ?O2@@0Y? ?W&0Y?h?O&(Y?hf?W.YfW&(Y ?O&@@@0Y I4@@@6K?h?I4@@@6K ?@(Yhf75 ? @@ @@ @?fN@ ?I4@@@@@@@@@6KgO2@@@0M? W&<?h?W2@0Y W&H?f7(Y? ?W2@@@(M ?I4@@@6XheI4@@@6K? J(Y?he?J(Y ? @@ @@ @?f?@ I4@@@@@@@@@@@@@@@0M? ?W&5heW&(M ?W&5f?J(Y W&@@@0Y? I4@)T&K?heI4@@6K ?W&HhfW&H? ? @@ @@ @Lf?@ I4@@@@@0M? O&0Yh?W&(Y? W&0YfW&H? ?O&@@(M? ?I4@@@6Khe?I4@@6K? ?&@?he?W&5 ? @@ @@ @1f?@ W2(MheW&(Y 7<f?W&5 ?W2@@@0Y I4@@@6K?h?I4@@@6K ?7(Y ? @@ @@ @@f?@ ?O&(Y?h?O&(Y? ?J5?fW&(Y W&@@@? I4@@6Khe?I4@@6X? ?@H? ? @@ @@ @@f?@ ?@ ?W2@0Yh?W2@(Y W.Y?e?W&(Y? ?O&@@@@? ?I4@@@hfI4)K J5 ? @? @@ @@ 3@f?@L? ?@ W&(MheO&@0Y? ?W.YfW&(Y ?W2@@@(M ?@@@heI46X ?W.Y ? @@ @@ N@f?31? ?@ ?O&0Y?hW2@0M? W.Y?e?W&(Y? O&@@@0Y? I/K? W.Y? ? @@ @@ ?@f?N@? ?@ ?W2(M?h?W&(M? ?W.YfW&(Y W2@@@(M? ?N@@ 7H ? @@ @@ ?@g@? ?@ W&(YheW&(Y W&H?f7@H? ?W&@@@(Y 3@L? ?J5? ? @@ @@ ?@g@? ?@ ?O&0Y?h?O&(Y? 75f?J@@ O&@@@0Y? V'1? W&H? ? @@ @@ ?@g@? ?W2@<?h?W2@(Y ?J(YfW.M? W2@@@(M? ?N@?e@?h?W&5 ? @@ @@ ?@g@? W&@@heW&@(Y? W.Y?e?W&H ?W&@@@(Y @?e@?h?7(Y ? @@ @@ ?@g@? @? ?W&(M?h?W&@0Y ?O.YfW&@? O&@@@0Y? @?e@?hJ(Y? ? @@ @@ ?3L?f@? @?e@? W&(YheO&(M @(Y?f.M W2@@@(M? @?e@?h7H ? @@ @@ ?N1?f@L @?e@? ?W&0Y?hW2@(Y? ?J(Y ?W&@@@(Y @?e@?g?J@? ? @@ @@ @?f@1 @?e@? W&H?fO. O&@@@0Y? @?e@?gW&5? ? @@ @5 @?f@@ @?e@? W2O.M?h?W&@0Y
X
174790
View A - UK Machines to serial No. 635329 C D E F G H Buzzer Front wiper intermittent Air conditioning Front working lights Rear working lights Flasher Unit
C D E
H G F
174800
View B - UK Machines from Serial No. 635330 to 636000 and all Export Machines to 636000 J K L M N P 4WD Engaged light Front wiper intermittent Air conditioning Front working lights Rear working lights Buzzer
J K L
P N M
Note: When a second trailer flasher warning is fitted, the flasher unit is mounted on the fuse block, behind panel Y.
B
9804/1103
174810
60 - 05 - 01/7
Issue 3*
CONTENTS
Fastrac
60 - 05 - 01/8
* 125,
135, 145, 150, 155, 185
From Machine number 636001
Data - Relay Indentification
S198891
9804/1103
60 - 05 - 01/8
Issue 3*
CONTENTS * 125,
Fastrac
60 - 05 - 01/9
135, 145, 150, 155, 185
From m/no. 636001 to 637739
Data - Relay Identification (continued)

Note: Relays which form part of the JCB Selectronic control circuit are identified by an alpha/numeric suffix, e.g. (PR5). This suffix is also used on the wiring diagram for the Selectronic system. Relays - Cab mounted 1 Neutral Start (2 relays) 2 Buzzer/Timer Latching (PR5) 3 High (H4) 4 Medium (H5) 5 Buzzer Earth (PR15) 6 Splitter Dump Latching ( H3) 7 Selectronic Splitter Dump (H1) 8 4WD Engaged Light 9 Air Conditioning 10 Powersplit 2 (Low) 11 Front Working Light 12 Timer Circuit Anti-surge (PR16) - early position 12A Timer Circuit Anti-surge (PR16) - later position 13 Rear Work Light 14 Intermittent Rear Wiper 15 Powersplit 1 (High) 16 Low (H6) 17 Rev (H7) 18 Speed Inhibit (H2) 19 Main Beam 20 Dipped Beam 21 RH Side Light Machines with auxiliary head 22 LH Side Light lights only. 23 LH Direction Indicator 24 RH Direction Indicator 25 Time Delay - Transmission Warning Light 26 Intermittent Front Wiper 27 Flasher 28 Differential Lock/Area Cut-out 29 Neutral Select (PR18) - from machine no. 636369 30 Buzzer Other JCB Selectronic Components 31 Buzzer/Timer Unit 32 Diodes - Range Warning Lights - Splitter Latching. Relays - Engine Mounted (160TW Euro 1 Engine only) * A ESOS B Manifold Heater C Manifold Heater Relays - Engine Mounted (185 from Machine No. 637635) D Manifold Heater E Manifold Heater Relays - Engine Mounted (185 from Machine No. 637635) D Manifold Heater E Manifold Heater Relays - Electronic Draft Control (135, 155 and 185 from Machine No. 637734) Some 135, 155 and 185 machines may be fitted in service with an additional relay in the Alternator Signal line. See T.I. 10/100 (C45/N.Am) for details.
A B C
198880
A277260
9804/1103
60 - 05 - 01/9
8000 - C/1-8.5
Issue 3*
CONTENTS
Fastrac
60 - 05 - 01/9A
* 155,
185
From m/no. 637740
Data - Relay Identification (continued)

Note: The illustration on page 60 - 05 - 01/8 is still generally applicable, see the illustrations on this page for the alterations. Relays - Cab mounted (Selectronic Transmission) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 29 33 34 35 Neutral Start (2 relays) Buzzer/Timer Latching (PR5) High (H4) Medium (H5) Buzzer Earth (PR15) Splitter Dump Latching ( H3) Selectronic Splitter Dump (H1) 4WD Engaged Light Air Conditioning Powersplit 2 (Low) Brakelights Timer Circuit Anti-surge (PR16) Rear Work Light Intermittent Rear Wiper Powersplit 1 (High) Low (H6) Rev (H7) Speed Inhibit (H2) Neutral Select (PR18) Front Work Lights Clutch Buzzer and Clutch Buzzer Delay (2 relays) Reverse Lights
S198891A
Other JCB Selectronic Components 31 Buzzer/Timer Unit 32 Diodes - Range Warning Lights - Splitter Latching
Relays - Cab mounted (Manual Transmission) 1 7 8 9 10 11 13 14 15 33 34 35 Neutral Start (2 relays) Selectronic Splitter Dump (H1) 4WD Engaged Light Air Conditioning Powersplit 2 (Low) Brakelights Rear Work Light Intermittent Rear Wiper Powersplit 1 (High) Front Work Lights Clutch Buzzer and Clutch Buzzer Delay (2 relays) Reverse Lights
S198891B
9804/1103
60 - 05 - 01/9A
8000 - C/1-9.1
Issue 1
CONTENTS
Fastrac
60 - 05 - 01/10
* 1115
& 1135
To m/no. 736577
* Data - Relay Identification
130 71 29 129 63 108B 108A
A234891
9804/1103
60 - 05 - 01/10
8010 - C/1-3
Issue 5*
CONTENTS
* 1115
Fastrac
60 - 05 - 01/11
& 1135 (2WS)
From m/no. 736577
Data - Relay Identification (continued) (2WS machines to No. 736577)

Note 1: The component identification key numbers listed below correspond with those used on the wiring diagrams. Note 2: Relays which form part of the JCB Selectronic circuit are identified by an alpha/numeric suffix , e.g. (PR5). This suffix is also used on the Selectronic system wiring diagram. * Note 3: Some machines may be fitted in service with an additional relay in the Alternator Signal line (Part of the Electronic Draft Control). See T.I. 10/100 (C45/N.Am) for details.
Wiring Diagram Key No. 7 8 22 23 29 32 33 37 43 53 63 71 75 81 108A 108B 113 129 130 153 (H4/H) 153 (H5/M) 153 (H6/L) 153 (H7/R) 154 (H2) 157 158 159 161 162 167 Other Components 36
Description
Wiring Diagram Page No. 12 - 3 12 - 3 12 - 5, 12 - 26 12 - 5 12 - 7 12 - 11 12 - 11 12 - 11 12 - 12 12 - 12 12 - 15 12 - 15 12 - 16 12 - 17 12 - 23 12 - 23 12 - 26 12 - 29 12 - 29 12 - 33 12 - 33 12 - 33 12 - 33 12 - 33 12 - 35 12 - 35 12 - 35 12 - 33 12 - 36 12 - 38
Inhibit start 1 Inhibit start 2 Air conditioning (Ignition switched) Intermittent rear wiper Intermittent front wiper Powersplit 1 (High) Powersplit 2 (Low) Neutral dump (H1) 4WD engaged light 2WD dump First trailer turn relay Second trailer turn relay Front work light Rear work light Main beam Dipped beam Air conditioning (compressor clutch) Buzzer Time delay - transmission warning light Range select - High (H4) Range select - Medium (H5) Range select - Low (H6) Range select - Rev (H7) Speed inhibit (H2) Buzzer/timer latching (PR5) Buzzer earth (PR15) Neutral dump latching (H3) (PR11) Neutral select (PR18) Timer circuit anti-surge (PR16) Area/diff. lock cut-out
Diode connector packs
12 - 11, 12 - 33, 12 - 35, 12 - 36
Alternative items, fitted according to purchaser specification. Fitted only on machines with auxiliary headlights. To identify a specific diode connector pack, cross check the wire numbers from the mating connectors against the wiring diagrams.
9804/1103
60 - 05 - 01/11
8010 - C/1- 4.4
Issue 3*
CONTENTS
Fastrac
60 - 05 - 01/11A
1115 & 1135 (2WS) Data - Relay Identification (continued)
From m/c no. 736578
130 71 29 129 63 108B 108A
A234891
EE
EE
EE
FF
DD J R X S Y T Z U K V L W M N P
AA BB CC
A249151
9804/1103
60 - 05 - 01/11A
8010 - C/1-5.2
Issue 1
CONTENTS
Fastrac
60 - 05 - 01/11B
1115 & 1135 2WS machines from No. 736578, all 4WS Machines Data - Relay Identification (continued)
Note 1: The component identification key numbers listed below correspond with those used on the wiring diagrams. Note 2: Relays which form part of the JCB Selectronic circuit are identified by an alpha/numeric suffix , e.g. (PR5). This suffix is also used on the Selectronic system wiring diagram. Note 3: Some 2WS machines may be fitted in service with an additional relay in the Alternator Signal line (Part of the Electronic Draft Control). See T.I. 10/100 (C45/N.Am) for details. Item Colour Wiring Diagram Key No. 7 8 162 161 53 175 167 C16 C8 158 159 37 43 113 176 157 153 (H4/H) 153 (H5/M) 22 33 75 154 153(H7/R) 153 (H6/L) 32 23 81 167 122A 29 63 71 108A 108B 130 Description
A B C D E F G (2WS) G (4WS) H J K L M N P R S T U V W X Y Z AA BB CC DD FF
Black Black Blue Green Green Green Green
Blue Blue Green Green Green Blue Black Blue Green Green Blue Green Blue Green Green Green Green Black Blue Green
Inhibit start 1 Inhibit start 2 Selectronic anti-surge (PR16) Neutral select (PR18) 2WD Dump Clutch warning Area/diff. lock cut-out (2WS machines only) - located at position DD on 4WS Diff. lock cut-out (4WS machines only) Alternator signal (4WS machines only) Buzzer earth (PR15) Neutral dump latching (H3) (PR11) Neutral dump (H1) 4WD Engaged Air conditioning (compressor clutch) Clutch warning delay relay (CR42) Buzzer/timer latching (PR5) Range select - High Range select - Medium Air conditioning (Ignition switched) Powersplit 2 (low) Front work light Speed inhibit Range select - Reverse Range select - Low Powersplit 1 (high) Intermittent rear wiper Rear work light Area/diff. lock cut out (4WS machines only) - located at position G on 2WS Reversing lights relay (CR11) Intermittent front wiper First trailer turn relay Second trailer turn relay Main beam Dipped beam Time delay - transmission warning light
Other Components EE
36
Diode connector packs
129 Buzzer (service malfunction) Alternative items, fitted according to purchaser specification. Fitted only on machines with auxiliary headlights. To identify a specific diode connector pack, cross check the wire numbers from the mating connector against the wiring diagrams.
9804/1103
60 - 05 - 01/11B
8010 - C/1-6.3
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 05 - 01/12
2000 & 3000 SERIES MACHINES

*
Data - Relay Identification (Front of Cab)
M J L E F K C D G H A B
With Auxiliary Lights
A C E
B D F E F C D A B
Without Auxiliary Lights

A303131
2000 Series
3000 Series
Item A B C D E F G H J K L M
Colour Blue Blue Blue Green Green Green Green Green Green Green
Description Brake lights A post work lights Fog lights Intermittent front wiper Single trailer turn Warning buzzer Auxiliary lights Auxiliary lights Auxiliary lights Auxiliary lights Auxiliary lights Auxiliary lights
Installation Standard - all machines Optional - all machines Standard - all machines Standard - all machines Optional - all machines Standard - all machines Optional - 3000 Series Optional - 3000 Series Optional - 3000 Series Optional - 3000 Series Optional - 3000 Series Optional - 3000 Series
9804/1103
60 - 05 - 01/12
8020 - C/1-3.4
Issue 2*
CONTENTS
Fastrac
60 - 05 - 01/13
2000 & 3000 SERIES MACHINES Data - Relay Identification (continued) Relay Identification (Rear of Cab)
*
N S P T R U
A1 B1 C1 D1 E1 F1
4 3 2 1 8 7 6 5
A303122
Item N P R S T U
Colour Blue Green Blue Green Black Blue
Description Air conditioning unit compressor clutch 2WD dump Start inhibit 2 Diff. lock cut-out Intermittent rear wiper Start inhibit 1
Installation
Standard - all machines Standard - all machines Standard - all machines Standard - all machines Standard - all machines Standard - all machines
* Machines with Dry Clutch Transmission
V W X
Blue Green Green
13 - pin trailer socket reverse lights relay Rear PTO drive cut-out relay 4WS diff. lock cut-out relay
Optional - all machines Optional - all machines Optional - 2115, 2125, 2135 only
* Machines with Wet Clutch Transmission A1 B1 C1 D1 E1 F1 Blue Green Green Black Green Green Reverse lights relay Splitter safety dump Rear PTO drive cut-out relay Tractor ABS Tractor ABS 4WS diff. lock-out relay Standard - all machines Standard - all machines Standard - all machines ABS Machines ABS Machines Optional - 2115, 2125, 2135 only
* * *
9804/1103
60 - 05 - 01/13
8020 - C/1-4.6
Issue 3*
CONTENTS
Fastrac
60 - 05 - 02/1
125, 135, 145, 150, 155, 185, 1115 & 1135 Data - External Hydraulics
Pump Type on * Pump Flow at Maximum System Pressure All models except 1115 & 1135 to m/c no. 636000 at 2600 engine rev/min.
Front section (P3) of gear type double pump (triple pump 4WS machines), driven by PTO gearbox.
61 litres/min (13.4 UKgal/min, 16.1 US gal/min) 57 litres/min (12.5 UK gal/min,15.6 US gal/min) 73 litres/min (16 UK gal/min, 20 US gal/min)
All later machines - Standard pump at 2400 engine rev/min All later machines - Optional pump at 2400 engine rev/min Main Relief Valve Pressure - External Hydraulics bar At 2400 rev/min 210 kgf/cm2 214 lbf/in2 3045
Control Valve * Husco Valve (all models except 1115 and 1135 to Serial No. 637733 2115, 2125, 2135, 2150) Spool I 4-position, double acting spool with hydraulic kick-out and float. For single/double acting rams or motors. 3-position, double acting spool without detent. For single double acting rams. Note: On some machines these spools are double acting with hydraulic kick-out and float. 4-position, double acting spool with hydraulic kick-out and float. For 3-point linkage operation.
Spool II and III
Spool III
* Bosch Valve (all 1115 & 1135 machines from m/c no. 637734) Two-spool valve - spool I Three-spool valve - spools I and II Four-spool valve - spools I and II Two-spool valve - spool II Three-spool valve - spool III motors. Four-spool valve - spool III Four-spool valve - spool IIII Fixed flow, 4-position, double acting spools with hydraulic kick-out and float. For single/double acting rams or Variable flow, 3-position, double acting spools with hydraulic kick-out. For single/double acting rams or motors.
Fixed flow, 4-position, double acting spools with hydraulic kick-out and float. For front 3-point linkage operation.
9804/1103
60 - 05 - 02/1
8010 - E/1-1.4
Issue 7*
CONTENTS
Fastrac
60 - 05 - 02/1A
2000 & 3000 SERIES MACHINES * Data - External Hydraulics

Pump Type Type 1 Flow at Maximum System Pressure Standard pump at 2400 engine rev/min Optional pump at 2400 engine rev/min Type 1 Main Relief Valve Pressure At 2400 rev/min Early machines - non adjustable Later machines - adjustable Type 1 Control Valve Two-spool valve - spool I Three-spool valve - spools I and II Four-spool valve - spools I and II Two-spool valve - spool II Three-spool valve - spool III Four-spool valve - spool III Four-spool valve - spool IIII 77 litres/min (17 UK gal/min; 20.3 US gal/min) 96 litres/min (21 UK gal/min; 25.4 US gal/min) Front section (P3) of gear type double pump (triple pump on 4WS machines), driven by PTO gearbox.
bar 210 210 + 0/-5
kgf/cm2 214 214 + 0/-5
lbf/in2 3045 3045 + 0/-72.5
Variable flow, 3-position, double acting spools with hydraulic kick-out. For single/double acting rams or motors. Fixed flow, 4-position, double acting spools with hydraulic kick-out and float. For single/double acting rams or motors. Fitted with zero leak check valve. Fixed flow, 4-position, double acting spools with hydraulic kick-out and float. For front 3-point linkage operation. Fitted with zero leak check valave.
Type 2 Flow at Maximum System Pressure At 1500 engine rev/min Type 2 Main Relief Valve Pressure at 1500 rev/min Type 2 Control Valve Two-spool valve - spool I Three-spool valve - spools I and II or motors. Four-spool valve - spools I and II Two-spool valve - spool II Three-spool valve - spool III Four-spool valve - spool III Four-spool valve - spool IIII Variable flow, 4-position, double acting spools with hydraulic kick-out and float. For single/double acting rams Fitted with zero leak check valve. Fixed flow, 4-position, double acting spools with hydraulic kick-out and float. For single/double acting rams or motors. Fitted with zero loak check valve. Fixed flow, 4-position, double acting spools with hydraulic kick-out and float. For front 3-point linkage operation. Fitted with zero leak check valave. bar 210 + 0/-5 kgf/cm2 214 + 0/-5 lbf/in2 3045 + 0/-72.5 60 litres/min (13.2 UK gal/min; 15.9 US gal/min)
2000 Series to S/N 739999, 3000 Series to S/N 641999 2000 Series from S/N 740000, 3000 Series from S/N 642000
DO NOT EXCEED STATED PRESSURE
Other Hydraulic Circuits

Note: For technical data of other hydraulic systems, refer to the following pages: Transmission: 60 - 05 - 04/3 Steering: 60 - 05 - 10/4A Suspension: 60 - 05 - 10/5A
9804/1103
60 - 05 - 02/1A
8020-E/1-1.4
Issue 4*
CONTENTS
* 125,
Fastrac
60 - 05 - 02/2
135, 145, 150, 155, 185, 1115, 1135
Data - Axles
Front Axle Model Type Weight (approximate) Differential (from machine no. 636001) (to machine no. 636000) SD55 Crown wheel and pinion primary reduction with epicyclic hub reduction 510 kg (1124 lb) Optional Maxtrac NoSPIN standard NoSPIN standard
Rear Axle Model Type Weight (approximate) Brakes PD70 except Fastrac 185 (has PD90) Crown wheel and pinion primary reduction with epicyclic hub reduction 590 kg (1300 lb) Single caliper solid disc on each hub
Control Valve (from machine no. 636000) Type Remote, chassis-mounted control valve. Incorporates pressure maintenance valve, check valve and solenoid valves. Incorporates Differential Lock Control. 13.5 bar (195 lbf/in2) 1.5 bar (22 lb/in2) 12V dc, 3 position, 4-way 1 - 2 bar (14.5 - 29 lbf/in2)
Pressure Maintenance Valve Setting Check Valve Cracking Pressure Solenoid Valves Lubrication Pressure at 1500 rev/min
Differential Lock Control Valve (from machine no. 636001) Type Pressure Maintenance Valve Setting at maximum engine speed Solenoid and pressure maintenance valve for 'soft-engage' diff. lock mounted in suspension valve block 38 bar (550 lbf/in2)
Pump Type Flow Rate at 13.5 bar (195 lbf/in2) to machine no. 636000 from machine no. 636001 Rear section (P4) of gear type double pump, driven by P.T.O. gearbox. 16.4 litres/min (3.7 UK gal/min) at 2600 rev/min 28.8 litres/min (6.5 UK gal/min) at 2400 rev/min
Data - Main Clutch

Type Nominal Diameter Cover Plate: Diaphragm sprung with live drive for P.T.O. Box. Driven Plate: Spring centre, non-asbestos single dry plate. 350 mm (14 in)
9804/1103
60 - 05 - 02/2
Issue 3*
CONTENTS
* 125,
Fastrac
60 - 05 - 04/1
135, 145, 150, 155, 185, 1115 & 1135
Data - Gearboxes
Power Take Off Gearbox Type Output to machine no. 636000 Output from machine no. 636001 Power Take Off Clutches Live drive from engine; constant mesh with sliding sleeve non-synchromesh. 540 PTO rev/min at 1894 Engine rev/min or 1000 PTO rev/min at 2428 Engine rev/min 540 PTO rev/min at 2118 Engine rev/min or 1000 PTO rev/min at 2196 Engine rev/min Electro-hydraulic engagement. Multi-plate oil-immersed clutches with yoke output connections.
JCB Powersplit from machine no. 636001 Type Low Clutch Direct Drive High Clutch, Indirect Drive - early machines - later machines Clutch Pressure at 1500 rev/min Speed Gearbox Type Note: Where local legislation demands, the speed gearbox may be limited to 5 speeds by the addition of a stop in the remote control housing to prevent engagement of 6th speed. Range Gearbox Type 4 Wheel Drive Clutch High, medium, low and reverse ranges, all synchromesh. Yoke output to front axle. Flange output to rear axle. Spring-engaged, multi-plate, oil-immersed clutch. Electro-hydraulic disengagement to select 4WD. 6 speed (all forward) synchromesh Low and High Splitter Clutches in PTO/Splitter Box 1 : 1 Ratio 1.27 : 1 Ratio 1.225 : 1 Ratio 13.5 bar (195 lbf/in2)
Pump Type Flow Rate at 13.5 bar (195 lbf/in2) to machine no. 636000 from machine no. 636001 Control Valve Type Remote, chassis-mounted control valve. Incorporates pressure maintenance valve, check valve and solenoid valves. Incorporates Differential Lock Control to machine no. 636000. 13.5 bar (195 lbf/in2) 1.5 bar (22 lbf/in2) 12V dc, 3 position, 4-way 1 - 2 bar (14.5 - 29 lbf/in2) Rear section (P4) of gear type double pump, driven by PTO gearbox 16.4 litres/min (3.68 UK gal/min) at 2600 rev/min 28.8 litres/min (6.47 UK gal/min) at 2400 rev/min
Pressure Maintenance Valve Setting Check Valve Cracking Pressure Solenoid Valves Lubrication Pressure at 1500 rev/min Differential Lock Control Valve (from machine no. 636001 and 736001) Type Pressure Maintenance Valve Setting at maximum engine speed
Solenoid and pressure maintenance valve for 'soft-engage' diff. lock mounted in suspension valve block 38 bar (550 lbf/in2)
9804/1103
60 - 05 - 04/1
Issue 5*
CONTENTS
Fastrac
60 - 05 - 04/2

*
Data - Gearboxes
Main Clutch (Dry Clutch Transmission ) Type Cover Plate: Diaphragm sprung with live drive for P.T.O. Box. Driven Plate: Spring centre, non-asbestos single dry plate. 350 mm (14 in)
Nominal Diameter Master Clutch (Wet Clutch Transmission ) Type
Multiplate oil-immersed hydraulically actuated (pressure on to engage). Clutch drum/drum carrier transmit a live drive for P.T.O. box. Actuating hydraulic pressure measured at the control valve test point (TPE) at 1500 rev/min: Minimum - Clutch disengaged (pedal fully down) 0.7 - 1.4 bar (10 - 20 lbf/in2). Maximum - Clutch engaged (pedal fully up) 12 - 13 bar (175 - 190 lbf/in2).
Power Take Off Gearbox Type Live drive from engine; constant mesh with sliding sleeve - non synchromesh. 540 PTO rev/min at 2118 Engine rev/min. or 1000 PTO rev/min at 2196 Engine rev/min. Electro-hydraulic engagement. Multi-plate oil-immersed
Output
Power Take Off Clutches clutches with yoke output connections.
JCB Powershift Type Clutch Pressure at 1500 rev/min Clutch Pack End Float Low, medium and High Splitter Clutches in PTO/Splitter Box 13.5 bar (195 lbf/in2) 2 - 3 mm (when refitting used plates) 1.75 - 2.5 mm (when fitting new plates) Operating Pressure at 1500 rev/min - 13.5 bar (195 lbf/in2)
Transmission brake (wet clutch machine only) Speed Gearbox Type
6 speed (all forward) synchromesh
Range Gearbox Type High, medium, low and reverse ranges, all synchromesh. Flange outputs to front and rear axles. Spring-engaged, multi-plate, oil-immersed clutch. Electro-hydraulic dis-engagement to select 2WD.
4 Wheel Drive Clutch
9804/1103
60 - 05 - 04/2
8020 - F/1-1.3
Issue 2*
CONTENTS
Fastrac
60 - 05 - 04/3

*
Data - Transmission
Pump (Dry Clutch Transmission ) Type Rear section (P4) of gear type double pump (triple pump on 4WS machines), driven by PTO gearbox. 28.5 litres/min (6.3 UK gal/min; 7.6 US gal/min) at 2400 rev/min
Flow Rate at 13.5 bar (195 lbf/in2) Pump (Wet Clutch Transmission ) Type
Rear section (P4) of gear type double pump (triple pump on 4WS machines), driven by PTO gearbox. 28.5 litres/min (6.3 UK gal/min; 7.6 US gal/min) at 1500 rev/min.
Flow Rate at 13.5 bar (195 lbf/in2)
Control Valve (Dry Clutch Transmission ) Type Remote, chassis-mounted control valve. Incorporates pressure maintenance valve, check valve and solenoid valves. 13.5 bar (195 lbf/in2) 1.5 bar (22 lbf/in2) 12V dc, 3 position, 4-way 1 - 2 bar (14.5 - 29 lbf/in2)
Pressure Maintenance Valve Setting Check Valve Cracking Pressure Solenoid Valves Lubrication Pressure at 1500 rev/min.
Control Valve (Wet Clutch Transmission) Type Remote, chassis-mounted control valve. Incorporates pressure maintenance valve, check valve and solenoid valves. 13.5 bar (195 lbf/in2)
Pressure Maintenance Valve Setting (CT1) Check Valve Cracking Pressure CT2 CT3 CT4 Solenoid Valves Low Pressure Lubrication (LPL) at 1500 rev/min.
2 bar (29 lbf/in2) 5 bar (72.5 lbf/in2) 2 bar (29 lbf/in2) 12V dc, 3 position, 4-way 1 - 2 bar (14.5 - 29 lbf/in2)
9804/1103
60 - 05 - 04/3
8020 - F/1-2.3
Issue 2*
CONTENTS
Fastrac
60 - 05 - 04/4
2000 & 3000 SERIES MACHINES Data - Transmission

Differential Lock Control Valve Type Solenoid and pressure maintenance valve for 'soft-engage' diff. lock mounted in suspension valve block 38 bar (550 lbf/in2) at 2400 rev/min.
Pressure Maintenance Valve Setting
Front Axle Model SD55 (2000 Series) SD70 (3000 Series) Crown wheel and pinion primary reduction with epicyclic hub reduction 3 leading link control arms and Panhard rod SD55 - 510 kg (1124 lb) SD70 - TBA SD55 - NoSPIN (standard) Maxtrac (optional) SD70 - Soft engaged differential lock with electro - hydraulic control
Type
Mounting Weight (approximate)
Differential
Rear Axle Model PD70 (all 2WS machines except 3185) PD90 (3185 machines only) SD70 (4WS machines) Crown wheel and pinion primary reduction with epicyclic hub reduction 2 trailing link control arms and 'V' link PD70 - 590 kg (1300 lb) PD90 - 555 kg (1224 lb) SD70 - TBA Single caliper solid disc on each hub Soft-engaged differential lock with electro-hydraulic control
Type
Brakes Differential
Note: For technical data on wheels and tyres, see Routine Maintenance, Section 3.
9804/1103
60 - 05 - 04/4
8020 - F/1-3.1
Issue 1
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CONTENTS
Fastrac
60 - 05 - 06/1
* 125,
135, 145, 150, 155, 185
Data - Tyre Pressures, Speeds and Loads

The versatility of the JCB Fastrac dictates a range of tyre types which may be operated at differing loads and widely differing speeds. Agricultural type tyres are designated according to both their load carrying ability and their ability to operate at certain speeds. Generally, the speed at which a given tyre can operate depends upon inflation pressure and the load carried. The table below gives the load carrying capacity per tyre at varying pressures and speeds. All tyres supplied as original equipment may be operated over the full speed range of the vehicle provided the pressure is correct and their loading is no higher than that given below. Note 1: Whatever the loading, it is desirable to inflate rear tyres to 0.3 bar (4.4 lbf/in2) higher than the pressures given which are for the front tyres. This results in improved handling. Note 2: It is recommended that tyres larger than 495 mm section width are not used on machines fitted with a NoSPIN Differential except for special applications as agreed with JCB Landpower. HIGH SPEED TYRES Tyre Size Speed Designation Max Speed Pressure bar lbf/in2 Max load per tyre at speed of 30 kph (19 mph) 40 kph (25 mph) 70 kph (44 mph)
! WARNING
Running tyres outside recommended guidelines may result in failure of the tyres which at high speeds may endanger life. BE WARNED.
13-3-1-6
! WARNING
High traction tyres available as optional equipment have maximum permitted speeds below the maximum speed of the vehicle. Brake efficiency is slightly reduced and stopping distance is increased when these tyres are fitted. They will suffer damage if operated at speeds higher than those recommended and may endanger life.
13-3-1-5
! WARNING
Wheels are heavy. Handle and store with care to ensure that they cannot fall and cause injury.
13-3-1-7
445/70 R 24 G 90 kph (56 mph) It is unsafe to operate this tyre at this speed and pressure.
1.0 1.8 2.6 3.5 1.0 1.8 2.6 3.5
15 26 38 51 15 26 38 51
1675 kg (3693 lb) 2510 kg (5533 lb) 3350 kg (7385 lb) 4310 kg (9502 lb) 1890 kg (4167 lb) 2650 kg (5842 lb) 3415 kg (7529 lb) 4350 kg (9590 lb)
1540 kg (3395 lb) 2310 kg (5093 lb) 2167 kg (4777 lb) 3080 kg (6790 lb) 2707 kg (5968 lb) 3970 kg (8752 lb) 3285 kg (7242 lb) 1725 kg (3803 lb) 2450 kg (5401 lb) 3180 kg (7011 lb) 4000 kg (8818 lb) 1659 kg (3657 lb) 2301 kg (5073 lb) 2943 kg (6488 lb) 3665 kg (8080 lb)
495/70 R 24
90 kph (56 mph)
HIGH TRACTION TYRES Tyre Size Speed Designation Max Speed Pressure bar lbf/in2 Max load per tyre at speed of 30 kph (19 mph) 40 kph (25 mph) 65 kph (40 mph)
16.9 R 30 A8 30 kph (19 mph) It is unsafe to operate this tyre above 30 kph (25 mph). 480/70 R 30 D 65 kph (40 mph)
0.6 1.2 1.6 0.6 1.2 1.6 2.4 0.6 1.2 1.6 2.1 0.6 1.3 1.6 2.4
9 17 23 9 17 23 35 9 17 23 35 9 19 23 35
1605 kg (3538 lb) 2035 kg (4486 lb) 2460 kg (5423 lb) 1820 kg (4012 lb) 2380 kg (5247 lb) 2755 kg (6074 lb) 3800 kg (8377 lb) 2030 kg (4475 lb) 2680 kg (5908 lb) 3100 kg (6834 lb)
1700 kg (3748 lb) 2225 kg (4905 lb) 2575 kg (5677 lb) 3550 kg (7826 lb)
520/70 R 30
65 kph (40 mph)
1900 kg (4189 lb) 2500 kg (5511 lb) 2900 kg (6393 lb) 2505 kg (5522 lb) 3550 kg (7826 lb) 3075 kg (6779 lb) 1580 kg (3483 lb) 2245 kg (4949 lb) 2640 kg (5820 lb) 3750 kg (8267 lb)
540/65 R 30
65 kph (40 mph)
2000 kg (4409 lb) 2300 kg (5071 lb) 3250 kg (7165 lb)

Issue 4
9804/1103
60 - 05 - 06/1
CONTENTS
Fastrac
60 - 05 - 06/2
1115 & 1135 Data - Tyre Pressures, Speeds and Loads General
The versatility of the JCB Fastrac dictates a range of tyre types which may be operated at differing loads and widely differing speeds. Agricultural type tyres are designated according to both their load carrying ability and their ability to operate at certain speeds. Generally, the speed at which a given tyre can operate depends upon inflation pressure and the load carried. The table below gives the load carrying capacity per tyre at varying pressures and speeds. All tyres supplied as original equipment may be operated over the full speed range of the vehicle provided the pressure is correct and their loading is no higher than that given below. Note 1: Whatever the loading, it is desirable to inflate rear tyres to 0.3 bar (4.4 lbf/in2) higher than the pressures given which are for the front tyres. This results in improved handling. Note 2: It is recommended that tyres larger than 495 mm section width are not used on machines fitted with a NoSPIN Differential except for special applications as agreed with JCB Landpower.
! WARNING
Running tyres outside recommended guidelines may result in failure of the tyres which at high speeds may endanger life. BE WARNED.
13-3-1-6
! WARNING
Certain tyres fitted as after-market equipment may have maximum permitted speeds below the maximum speed of the vehicle. Brake efficiency is slightly reduced and stopping distance is increased when these tyres are fitted. They will suffer damage if operated at speeds higher than those recommended and may endanger life.
13-3-2-5
! WARNING
Wheels are heavy. Handle and store with care to ensure that they cannot fall and cause injury.
13-3-1-7
Pressures, Speeds and Loads

HIGH TRACTION TYRES Tyre Size Speed Designation Max Speed Pressure bar lbf/in2 Max load per tyre at speed of 30 kph (19 mph) 40 kph (25 mph) 50 kph (31 mph)
16.9 R 28
A8/B
50 kph (31 mph)
1.0 1.3 1.5 1.7
15 19 22 24
480/70 R 28
A8/B
50 kph (31 mph)
1.0 1.3 1.5 1.7 2.0
15 19 22 24 29
2130 kg (4695 lb) 2410 kg ((5313 lb) 2590 kg (5709 lb) 2680 kg (5908 lb)
1810 kg (3990 lb) 2050 kg (4519 lb) 2200 kg (4850 lb) 2300 kg (5070 lb) 2900 kg (6393 lb)
540/65 R 28
A8/B
50 kph (31 mph)
1.0 1.3 1.5 1.7
15 19 22 24
1840 kg (4056 lb) 2070 kg (4563 lb) 2300 kg (5070 lb)
1680 kg (3704 lb) 1900 kg (4189 lb) 2120 kg (4674 lb)
480/70 R 30
50 kph (31 mph)
0.6 1.2 1.6 2.4
9 17 23 35
9804/1103
60 - 05 - 06/2
Issue 1
CONTENTS
Fastrac
60 - 05 - 06/3
1115 & 1135 Data - Tyre Pressures, Speeds and Loads (continued) Pressures, Speeds and Loads
HIGH TRACTION TYRES Tyre Size 16.9 R 30 Speed Designation A8/B Pressure lbf/in2 9 12 17 23 15 19 22 24 9 17 23 29 35 9 17 23 35 9 17 23 35 9 17 23 Max load per tyre at speed of 40 kph (25 mph) 50 kph (31 mph) 1500 kg (3306 lb) 1660 kg (3660 lb) 1980 kg (4365 lb) 2300 kg (5070 lb) 1640 kg (3615 lb) 1850 kg (4078 lb) 1990 kg (4387 lb) 2060 kg (4541 lb) 1780 kg (3924 lb) 2375 kg (5236 lb) 2680 kg (5908 lb) 2940 kg (6481 lb) 3175 kg (7000 lb) 1690 kg (3725 lb) 2225 kg (4905 lb) 2575 kg (5677 lb) 3550 kg (7826 lb) 1580 kg (3483 lb) 2125 kg (4685 lb) 2640 kg (5820 lb) 3750 kg (8267 lb) 1720 kg (3792 lb) 2320 kg (5115 lb) 2900 kg (6393 lb) 1400 kg (3086 lb) 1540 kg (3395 lb) 1830 kg (4034 lb) 2120 kg (4673 lb) 1490 kg (3285 lb) 1690 kg (3726 lb) 1820 kg (4012 lb) 1900 kg (4189 lb) 1705 kg (3759 lb) 2280 kg (5026 lb) 2570 kg (5665 lb) 2820 kg (6217 lb) 3045 kg.(6713 lb) 1540 kg (3395 lb) 2030 kg (4475 lb) 2360 kg (5202 lb) 3230 kg (7121 lb) 1460 kg (3219 lb) 1955 kg (4310 lb) 2425 kg (5346 lb) 3400 kg (7496 lb) 1590 kg (3505 lb) 2130 kg (4696 lb) 2650 kg (5842 lb)
bar 0.6 0.8 1.2 1.6 1.0 1.3 1.5 1.7 0.6 1.2 1.6 2.0 2.4 0.6 1.2 1.6 2.4 0.6 1.2 1.6 2.4 0.6 1.2 1.6
30 kph (19 mph) 1600 kg (3527 lb) 1770 kg (3902 lb) 2120 kg (4674 lb) 2460 kg (5423 lb) 1760 kg (4036 lb) 1980 kg (4365 lb) 2140 kg (4718 lb) 2210 kg (4872 lb) 1870 kg (4123 lb) 2495 kg (5500 lb) 2815 kg (6206 lb) 3090 kg (6812 lb) 3335 kg (7352 lb) 1820 kg (4012 lb) 2380 kg (5247 lb) 2755 kg (6074 lb) 3800 kg (8377 lb) 1705 kg (3759 lb) 2270 kg (5004 lb) 2820 kg (6217 lb) 4010 kg (8840 lb) 1840 kg (4012 lb) 2500 kg (5511 lb) 3100 kg (6834 lb)
420/70 R28
A8
480/70 R 28
A8/B
480/70 R 30
A8/D
540/65 R 30
A8/D
580/70 R 26
Adjustable Track Width

The standard wheels provide a track width of 72 in (1829 mm). To obtain an alternative track of 76 in (1930 mm), move the wheels from one side of the machine to the other and reverse the wheels on the hubs. The 'V' of the tyre tread pattern must always point forward when at the top of the wheel .
Lock Stops
To prevent the tyres from fouling on the vehicle chassis, lock stops must be fitted to the inside of each steering axle swivel. The correct size of lock stop is fitted at the factory to suit the tyre and wheel configuration supplied as original equipment. If a different tyre and wheel configuration is to be used, consult JCB Landpower about the need to change the lock stops.
Checking Wheel Nut Torques

On a new machine check the wheel nut torques every ten hours until they stay correct. If a wheel has been removed and refitted, check the wheel nut torques every ten hours until they stay correct. Do not apply oil to the wheel nut threads. Wheel nut torque setting Nm 500 kgf m 51.0 lbf ft 370
9804/1103
60 - 05 - 06/3
Issue 2*
CONTENTS
Fastrac
60 - 05 - 06/4
2000 SERIES MACHINES Data - Tyre Pressures, Speeds and Loads

* Tyre Size 16.9 R24 (1) Speed Designation D Rolling Pressure Max load per tyre at speed of Circumference bar lbf/in2 10 kph (6 mph) 40 kph (25 mph) 50 kph (31 mph) 3.933 m 1.5 2.1 2.7 3.0 1.0 1.2 1.4 1.6 1.5 2.3 2.6 2.9 1.0 1.2 1.4 1.6 1.5 2.1 2.5 2.9 0.6 1.2 1.6 2.4 0.6 1.2 1.6 2.4 1.5 1.9 2.1 2.4 0.6 1.2 1.6 2.1 0.6 1.2 1.6 2.1 0.6 1.2 1.6 2.4 0.6 1.2 1.6 2.4 0.6 1.2 1.6 2.4 0.6 1.0 1.2 1.6 0.6 1.2 1.6 2.4 22 30 39 43 14 17 20 23 22 33 38 42 14 17 20 23 22 30 36 42 9 17 23 35 9 17 23 35 22 28 30 35 9 17 23 30 9 17 23 30 9 17 23 35 9 17 23 35 9 17 23 35 9 14 17 23 9 17 23 35 (4) 2470 kg 2690 kg 2910 kg 3120 kg 2950 kg 3740 kg 4200 kg 4630 kg 1870 kg 2495 kg 2815 kg 3335 kg 1810 kg 2380 kg 2760 kg 3480 kg 4130 kg 4410 kg 4830 kg 2030 kg 2680 kg 3100 kg 2250 kg 3020 kg 3540 kg 4580 kg 1500 kg 2245 kg 2745 kg 2750 kg 3320 kg 3890 kg 5030 kg 1545 kg 2315 kg 2830 kg 2880 kg 3490 kg 3800 kg 4410 kg 1545 kg 2315 kg 2830 kg 2410 kg 2620 kg 2830 kg 3040 kg 2200 kg 2790 kg 3300 kg 3530 kg 1770 kg 1930 kg 2080 kg 2240 kg 2360 kg 2180 kg 3450 kg 3765 kg 1950 kg 2120 kg 2290 kg 2460 kg 2360 kg 2990 kg 3360 kg 3705 kg 1780 kg 2375 kg 2680 kg 3175 kg 1690 kg 2230 kg 2580 kg 3075 kg 2780 kg 3300 kg 3530 kg 3860 kg 1900 kg 2500 kg 2900 kg 3550 kg 1600 kg 2250 kg 2690 kg 3560 kg 1425 kg 2140 kg 2610 kg 3560 kg 1870 kg 2550 kg 2770 kg 3670 kg 1470 kg 2205 kg 2685 kg 3670 kg 2260 kg 2570 kg 2800 kg 3250 kg 1470 kg 2205 kg 2685 kg 3670 kg 2070 kg 2620 kg 3100 kg 3250 kg 1640 kg 1780 kg 1920 kg 2060 kg 2220 kg 2990 kg 3240 kg 3550 kg 1820 kg 1980 kg 2140 kg 2300 kg 2220 kg 2810 kg 3160 kg 3450 kg 1705 kg 2280 kg 2570 kg 3045 kg 1540 kg 2030 kg 2360 kg 2800 kg 2610 kg 3100 kg 3320 kg 3550 kg 1730 kg 2280 kg 2650 kg 3230 kg 1520 kg 2120 kg 2510 kg 3310 kg 1370 kg 2050 kg 2505 kg 3415 kg 1830 kg 2460 kg 2670 kg 3520 kg 1410 kg 2115 kg 2580 kg 3520 kg 2110 kg 2390 kg 2590 kg 3000 kg 1410 kg 2115 kg 2580 kg 3520 kg
16.9 R28 (1)
4.305 m
16.9 R28
4.222 m
16.6 R30
4.398 m
16.9 R30
4.398 m
480/70 R28 (1)
4.240 m
480/70 R30
4.395 m
520/65 R30
4.430 m
520/70 R30 (2)
4.615 m
540/65 R28 (1)
4.230 m
540/65 R28
4.230 m
540/65 R30
4.432 m
540/65 R30
4.432 m
580/70 R26 (3)
4.300 m
600/65 R28 (3)
4.415 m
Notes: (1) Not approved for 2150 machines. (2) Approved for 2150 machines only. (3) Front AXLE load must not exceed 4700 kg (10360 lb).
9804/1103
Whatever the loading, it is desirable to inflate rear tyres to 0.3 bar (4.4 lbf/in2) higher than the pressures given which are for the front tyres. This results in improved handling.
8020-3/12-2.6 Issue 2*
60 - 05 - 06/4
CONTENTS
Fastrac
60 - 05 - 06/5
3000 SERIES MACHINES Data - Tyre Pressures, Speeds and Loads

* Tyre Size Speed Designation Rolling Pressure Circumference bar lb/in2 10 kph (6 mph) 2950 kg 3740 kg 4200 kg 4630 kg 1810 kg 2380 kg 2760 kg Max load per tyre at speed of 40 kph 65 kph 70 kph (25 mph) (40 mph) (44 mph) 2360 kg 2990 kg 3360 kg 3705 kg 1690 kg 2230 kg 2580 kg 3550 kg 1550 kg 2110 kg 2860 kg 3890 kg 2780 kg 3300 kg 3530 kg 3860 kg 1900 kg 2500 kg 2900 kg 3550 kg 1470 kg 2205 kg 2685 kg 3670 kg 1650 kg 2320 kg 2770 kg 3670 kg 2370 kg 2880 kg 3140 kg 3650 kg 1645 kg 2465 kg 3015 kg 4110 kg 2370 kg 2880 kg 3140 kg 3650 kg 2060 kg 2610 kg 2935 kg 3250 kg 90 kph (60 mph)
16.9 R30
4.398 m
1.5 2.1 2.5 2.9 0.6 1.2 1.6 2.4 1.0 1.6 2.4 3.5 1.5 1.9 2.1 2.4 0.6 1.2 1.6 2.1 0.6 1.2 1.6 2.4 0.6 1.2 1.6 2.4 0.6 1.0 1.2 1.5 0.6 1.2 1.6 2.4 0.6 1.0 1.2 1.6
22 30 36 42 9 17 23 35 14 23 35 50 22 28 30 35 9 17 23 30 9 17 23 35 9 17 23 35 9 14 17 23 9 17 23 35 9 14 17 23
480/70 R30
4.395 m
2255 kg 3075 kg 1440 kg 1970 kg 2660 kg 3620 kg 2430 kg 2880 kg 3085 kg 3350 kg
2055 kg 2800 kg 1350 kg 1840 kg 2490 kg 3390 kg
495/70 R24
3.913 m
2430 kg 3310 kg 4480 kg 6090 kg 3480 kg 4130 kg 4410 kg 4830 kg 2030 kg 2680 kg 3100 kg
520/65 R30
4.430 m
520/70 R30
4.615 m
2505 kg 3075 kg
2280 kg 2800 kg
540/65 R30
4.432 m
1545 kg 2315 kg 2830 kg
2460 kg 3350 kg
2240 kg 3075 kg
540/65 R30
4.432 m
2460 kg 3320 kg 3890 kg 5030 kg 2880 kg 3490 kg 3800 kg 4410 kg 1730 kg 2590 kg 3165 kg
2410 kg 3350 kg
580/70 R26 (1)
4.300 m
600/65 R28
4.415 m
2750 kg 3750 kg
2505 kg 3450 kg
620/70 R26
4.469 m
3230 kg 3920 kg 4270 kg 4960 kg
Notes: (1) Approved for 3155 machines only. (2) Whatever the loading, it is desirable to inflate rear tyres to 0.3 bar (4.4 lbf/in2) higher than the pressures given which are for the front tyres. This results in improved handling.
9804/1103
60 - 05 - 06/5
8020 - 3/12-3.5
Issue 2*
CONTENTS
Fastrac
60 - 05 - 10/1
125, 135, 145, 150, 155, 185 Data - Brakes

Operating Pressure (Air) Parking Brake Minimum Lining Thickness (at renewal) Disc Thickness - New - Minimum after Skimming Foot (Service) Brake Minimum Lining Thickness (at renewal) Front Disc Thickness - New - Minimum after Skimming Rear Disc Thickness - New - Minimum after Skimming 3 mm (0.125 in) 3 mm (0.125 in) 8 bar (120 lbf/in2)
9.5 mm 8.9 mm
(0.374 in) (0.350 in)
22 mm 19.8-20.2 mm
(0.866 in) (0.780-0.795 in)
16 mm 14.3-14.7 mm
(0.630 in) (0.563-0.579 in)
Data - Steering
Pump Type Controlled Flow at 2600 rev/min and system pressure Rear section (P2) of gear type double pump, driven by engine. 14 litres/min (3 UK gal/min)
Relief Valve Pressure * At engine speed of 1500 rev/min To machine no. 636371 From machine no. 636372
bar
kgf/cm2
lbf/in2
140 135
143 138
2030 1958
IMPORTANT: The steering pressure must not be set above the specified figure under any circumstances.
9804/1103
60 - 05 - 10/1
Issue 4*
CONTENTS
Fastrac
60 - 05 - 10/2
* 125,
135, 145, 150, 155, 185
Data - Suspension
Pump Type Front section (P1) of gear type double pump, driven by engine.
Maximum Flow To machine no. 636000, at 2600 rev/min and system pressure From machine no. 636001, at 2400 rev/min and system pressure
10 litres/min (2.2 UK gal/min) 9.2 litres/min (2.0 UK gal/min)
bar Pressure Maintaining Valve Cut out pressure Cut in pressure Accumulator Charge Pressure Gas Spring Charge Pressure To machine no 636323 (except when fitted with 45 mm suspension cylinders) From machine no. 636324 and all machines with 45 mm suspension cylinders
kgf/cm2
lbf/in2
200 180 75
204 184 76
2900 2610 1088
37 35
38 36
537 508
Note: The 35 bar gas springs may be fitted to earlier machines but only in complete sets of four.
9804/1103
60 - 05 - 10/2
Issue 2*
CONTENTS
* FASTRAC
Fastrac
60 - 05 - 10/3
1115, 1135
Data - Brakes
Operating Pressure (hydraulic) (to machine no. 737000) Operating Pressure (hydraulic) (from machine no. 737001) Parking Brake Minimum Permissible Lining Thickness - Outboard Liner - Inboard Liner Maximum Lining Thickness (i.e. New Liners) - Outboard Liner - Inboard Liner Disc Thickness - New - Minimum after Skimming Foot (Service) Brake Minimum Lining Thickness (at renewal) Front Disc Thickness - New - Minimum after Skimming Rear Disc Thickness - New - Minimum after Skimming Hydraulic Accumulator Pressure - front and rear (from machine no. 737000 only) 3 mm (0.125 in) 140 - 160 bar 8 bar (2030 - 2320 lbf/in2) (120 lbf/in2)
1 mm 3.4 mm
(0.04 in) (0.13 in)
3 mm 5.4 mm
(0.12 in) (0.21 in)
9.5 mm 8.9 mm
(0.374 in) (0.350 in)
22 mm 19.8-20.2 mm
(0.866 in) (0.780-0.795 in)
16 mm 14.3-14.7 mm
(0.630 in) (0.563-0.579 in)
40 bar
(580 lbf/in2)
9804/1103
60 - 05 - 10/3
Issue 3*
CONTENTS
Fastrac
60 - 05 - 10/3A
2000 & 3000 Series Machines Data - Brakes

Brake System Operating Pressure (air) Parking Brake Minimum Permissible Lining Thickness Disc Thickness - New - Minimum after Skimming Foot (Service) Brake Minimum Lining Thickness (at renewal) Front Disc Thickness - New - Minimum after Skimming Rear Disc Thickness - New - Minimum after Skimming 3 mm (0.125 in) 3 mm (0.12 in) 8 bar (120 lbf/in2)
9.5 mm 8.9 mm
(0.374 in) (0.350 in)
22 mm 19.8-20.2 mm
(0.866 in) (0.780-0.795 in)
16 mm 14.3-14.7 mm
(0.630 in) (0.563-0.579 in)
9804/1103
60 - 05 - 10/3A
Issue 1
CONTENTS
Fastrac
60 - 05 - 10/4
2000 & 3000 SERIES MACHINES Data - Transmission

Differential Lock Control Valve Type Solenoid and pressure maintenance valve for 'soft-engage' diff. lock mounted in suspension valve block 38 bar (550 lbf/in2) at 2400 rev/min.
Pressure Maintenance Valve Setting
Front Axle Model SD55 (2000 Series) SD70 (3000 Series) Crown wheel and pinion primary reduction with epicyclic hub reduction 3 leading link control arms and Panhard rod SD55 - 510 kg (1124 lb) SD70 - TBA SD55 - NoSPIN (standard) Maxtrac (optional) SD70 - Soft engaged differential lock with electro - hydraulic control
Type
Differential
Rear Axle Model PD70 (all 2WS machines except 3185) PD90 (3185 machines only) SD70 (4WS machines) Crown wheel and pinion primary reduction with epicyclic hub reduction 2 trailing link control arms and 'V' link PD70 - 590 kg (1300 lb) PD90 - 555 kg (1224 lb) SD70 - TBA Single caliper solid disc on each hub Soft-engaged differential lock with electro-hydraulic control
Type
Brakes Differential
Note: For technical data on wheels and tyres, see Routine Maintenance, Section 3.
9804/1103
60 - 05 - 10/4
8020 - F/1-3.1
Issue 1
CONTENTS
Fastrac
60 - 05 - 10/4A

*
Data - Steering 2WS (Front Axle) Circuit (Fastrac 2000 and 3000 Series)
Pump (Type 1) Type Controlled Flow at 2400 rev/min and system pressure Pump Relief Valve Pressure (at 1500 r.p.m. engine speed) Fastrac 2000 Series Fastrac 3000 Series 200 bar (2900 lb/in2) 135 bar (1958 lb/in2) Rear section (P2) of gear type double pump, driven by engine. 18.2 litres/min (4 UK gal/min; 4.8 US gal/min)
IMPORTANT: The steering pump relief valve pressure must not be set above the specified figure under any circumstances. Steering Unit Relief Valve Pressure (Fastrac 2000 Series) 180 bar (2610 lb/in2)
4WS (Rear Axle ) Circuit (Fastrac 2115, 2125, 2135 only)

Pump Type PTO Flow rate @ 100 bar (1450 lbf/in2) and *1500 rev/min Centre section (P5) of gear type triple pump, driven by gearbox 43 litres/min (9.5 UK gal/min; 11.4 US gal/min)
4WS Main Relief Valve Pressure At 1500 r.p.m. engine speed 4WS Dump Valve Pressure At 1500 r.p.m. engine speed * Air Pressure Regulator
100 bar (1450 lbf/in2)
10 bar (145 lbf/in2) 7 bar (100 lbf/in2)
9804/1103
60 - 05 - 10/4A
8020 - H/1-1.4
Issue 2*
CONTENTS
Fastrac
60 - 05 - 10/5
FASTRAC 1115, 1135 Data - Suspension

Pump Type Front section (P1) of gear type double pump, driven by engine. 9.2 litres/min (2.0 UK gal/min)
Maximum Flow
Pressures bar Pressure Maintaining Valve (Machines to Serial No. 737000) Cut out pressure Cut in pressure Pressure Maintaining Valve (Machines from Serial No. 737001) Cut out pressure Cut in pressure Accumulator Charge Pressure Machines to Serial No. 737000 Machines from Serial No. 737001 Gas Spring Charge Pressure kgf/cm2 lbf/in2
160 140
163 143
2320 2030
200 180
204 184
2900 2610
40 75 26
41 76.5 27
580 1087 377
9804/1103
60 - 05 - 10/5
Issue 2*
CONTENTS
Fastrac
60 - 05 - 10/5A
2000 & 3000 SERIES MACHINES Data - Suspension

Pump Type by Maximum Flow Front section (P1) of gear type double pump, driven engine. 9.2 litres/min (2.0 UK gal/min; 2.4 US gal/min)
Pressures bar Pressure Maintaining Valve Cut-out pressure Cut-in pressure Accumulator Charge Pressure * Gas Spring Charge Pressure Fastrac 2115, 2125, 2135 (1 x) (1 x) Fastrac 2150 and 3000 Series (2 x) kgf/cm2 lbf/in2
200 180 75
204 184 76.5
2900 2610 1087
26 35 35
27 36 36
377 508 508
9804/1103
60 - 05 - 10/5A
8020 - S/1-1.3
Issue 2*
CONTENTS
* 125,
Fastrac
60 - 05 - 15/1
135, 145, 150, 155, 185, 1115, 1135
Data - Engine Perkins Engines

GENERAL Model Bore Stroke Swept Volume Compression Ratio - Naturally aspirated 1000 Series - Turbocharged 1000 Series - Turbocharged New 1000 Series Compression Pressure Firing Order Valve Clearance (hot or cold) - Inlet - Exhaust Oil Pressure (hot) at maximum speed - Naturally aspirated 1000 Series - Turbocharged 1000 Series - Turbocharged New 1000 Series Idling Speed Perkins 1000 Series or New 1000 Series, 6 cylinder, water cooled, 100 mm (3.937 in) 127 mm (5 in) 5985 cm3 (365.2 in3) 16.5 : 1 16.0 : 1 17.25 : 1 20 to 34 bar (290 to 500 lbf/in2) with maximum variation between cylinders of 3.5 bar (50 lbf/in2) 1, 5, 3, 6, 2, 4 0.20 mm (0.008 in) 0.45 mm (0.018 in) 2.1 bar (30 lbf/in2) minimum 2.8 bar (40 lbf/in2) minimum 4.0 bar (58 lbf/in2) minimum 750 rev/min
FUEL SYSTEM Engine Type Rating 1006-6 1006-6 1006-6LR4 1006-6T 1006-6T 1006-6T 1006-6T4 1006-6T4 1006-6T HR5 1006-6T HR5 1006-6T HR5 145T 145T 160T 160T 160TW 1941/2300 1929/2300 1947/2300 1930/2300 Engine No. Prefix Pump Type Setting Code Max Governed speed Max No Load Speed
YA50347 YA50474 YA50532 YB50375 YB50431 YB50436 YB50472 YB50477 YB50473 YB50478 YB50558 YB50400 YB50437 YB50403 YB50438 YD50494 YH50595 YH50596 YH50597 YH50600
CAV CAV CAV CAV CAV CAV CAV CAV Stanadyne Stanadyne CAV Bosch (rotary) Bosch (rotary) Bosch (rotary) Bosch (rotary) Bosch (in-line) CAV CAV CAV CAV
FK59L/750/1/2860 FK59L/750/4/2640 2643 D805/MK/3/2570 AK77L/800/1/2860 2643M010AK/1/2860 AK77L/800/1/2860 RK90L/1100/3/2520 RK90L/1100/3/2520 JL JL 2643 U610/JL/1/2660 2643J605 CK/1/2960 2643J605 CK/1/2960 2643J601 EK/1/2960 2643J601 EK/1/2960 PL 2644 D106/EH/-/2460 2644 D102/BH/-/2460 2644 D109/FH/-/2460 TBA
2600 rev/min 2400 rev/min 2400 rev/min 2600 rev/min 2600 rev/min 2600 rev/min 2400 rev/min 2400 rev/min 2400 rev/min 2400 rev/min 2400 rev/min 2600 rev/min 2600 rev/min 2600 rev/min 2600 rev/min 2400 rev/min 2300 rev/min 2300 rev/min 2300 rev/min 2200 rev/min
2830 rev/min 2540/2640 rev/min 2470/2520 rev/min 2830 rev/min 2830 rev/min 2860 rev/min 2470/2520 rev/min 2470/2520 rev/min 2520/2620 rev/min 2520/2620 rev/min 2470/2520 rev/min 2930 rev/min 2930 rev/min 2930 rev/min 2930 rev/min 2736 rev/min 2460 50 rev/min 2460 50 rev/min 2460 50 rev/min 2530 50 rev/min
For further details, see engine service manual, publication No. 9806/0100 Note: New engines DO NOT require a running-in period. The engine should be used in a normal work cycle immediately; glazing of the cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
9804/1103
60 - 05 - 15/1
Issue 6*
CONTENTS
* 2000
9804/1103
Data - Engine Perkins Engines
General
Fastrac 2115 Model Turbocharged/intercooled, water cooled Rating Bore Stroke Swept Volume Compression Ratio Compression Pressure - Permitted range - Maximum variation between cylinders Firing Order Valve Clearance (hot or cold) - Inlet - Exhaust Oil Pressure (hot) at maximum speed 1941/2300 100 mm (3.937 in) 127 mm (5 in) 5985 cm3 (365.2 in3) 17.25 : 1 water cooled 1929/2300 100 mm (3.937 in) 127 mm (5 in) 5985 cm3 (365.2 in3) 17.25 : 1 water cooled 1947/2300 100 mm (3.937 in) 127 mm (5 in) 5985 cm3 (365.2 in3) 17.25 : 1 6 cylinder, water cooled 1930/2200 100 mm (3.937 in) 127 mm (5 in) 5985 cm3 (365.2 in3) 17.25 : 1 Perkins New 1000 Series, Turbocharged, 6 cylinder, Fastrac 2125 Perkins New 1000 Series, Turbocharged, 6 cylinder, Fastrac 2135 Perkins New 1000 Series, Turbocharged, 6 cylinder, Fastrac 2150 Perkins New 100 Series
CONTENTS
SERIES MACHINES
Fastrac
20-34 bar (290-500 lbf/in2) 3.5 bar (50 lbf/in2) 1, 5, 3, 6, 2, 4
60 - 05 - 15/2
Issue 3*
0.20 mm (0.008 in) 0.45 mm (0.018 in)
0.20 mm (0.008 in) 0.45 mm (0.018 in)
0.20 mm (0.008 in) 0.45 mm (0.018 in)
0.20 mm (0.008 in) 0.45 mm (0.018 in)
4 bar (58 lbf/in2)
4 bar (58 lbf/in2)
4 bar (58 lbf/in2)
4 bar (58 lbf/in2)
Idling Speed
750 rev/min
750 rev/min
750 rev/min
750 rev/min
60 - 05 - 15/2
CONTENTS CONTENTS
Fastrac
60 - 05 - 15/3
2000 SERIES MACHINES Data - Engine (continued) Perkins Engines Fuel System
Engine Rating 1941/2300 1929/2300 1947/2300 1930/2200 Engine No. Prefix Pump Type Setting Code Max Governed speed Max No Load Speed
YH50595 YH50596 YH50597 YK50600
CAV CAV CAV CAV
2644 D106/EH/-/2460 2644 D102/BH/-/2460 2644 D109/FH/-/2460
2460 50 rev/min 2460 50 rev/min 2460 50 rev/min 2530 50 rev/min
For further details, see engine service manual, publication No. 9806/2140 (Perkins New 1000 Series). Note: New engines DO NOT require a running-in period. The engine should be used in a normal work cycle immediately; glazing of the cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
9804/1103
60 - 05 - 15/3
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 05 - 15/4
3000 SERIES MACHINES Data - Engine General

Fastrac 3155 Model 1000 Series, Turbocharged, 6-cylinder, water cooled. 1702/2400 100 mm (3.937 in) 127 mm (5 in) 5985 cm3 (365.2 in3) Fastrac 3185 Cummins 6 BTA, Turbocharged, 6-cylinder, water cooled, after cooled. 102 mm (4.02 in) 120 mm (4.72 in) 5880 cm3 (359 in3)
Rating Bore Stroke Swept Volume Compression Pressure - permitted range - maximum variation between cylinders Compression Ratio Firing Order Valve Clearance Inlet Exhaust Oil Pressure at idle (minimum allowable) Oil Pressure at maximum speed (minimum allowable) Idling Speed Governor Run-out Speed Boost Pressure at rated speed Injector Type Working Pressure
20 - 34 bar (290 - 500 lbf/in2) 3.5 bar (50 lbf/in2) 16.0 : 1 1, 5, 3, 6, 2, 4
16.5 : 1 1, 5, 3, 6, 2, 4
0.20 mm (0.008 in) 0.45 mm (0.018 in) 2.8 bar (40 lbf/in2) 750 rev/min -
0.25 mm (0.010 in) 0.51 mm (0.020 in) 0.7 bar (10 lbf/in2) 2.1 bar (30 lbf/in2) 750 rev/min 2550 - 2650 rev/min
1.37 bar (19.9 lbf/in2) JL 253 bar (3847 lbf/in2)
Note: Injectors supplied from new are set at 7 to 10 bar (106 to 152 lbf/in2) higher than working pressure.
Fuel System
Fastrac 3155 Engine Type 1006 - 6T4 1006 - 6T4 Engine No. Prefix YB 50694 YB50695 Pump Type CAV CAV Setting Code RK90L/1100/3/2520 RK90L/1100/3/2520 Max. Governed Speed 2400 rev/min 2400 rev/min Max. No Load Speed 2470/2520 rev/min 2470/2520 rev/min
For further information, see engine service manual, publication number 9806/0100 (Fastrac 3155) or 9806/1170 (Fastrac 3185).
9804/1103
60 - 05 - 15/4
8020 - T/1-3.3
Issue 1
CONTENTS
Fastrac
60 - 05 - 16/1
ALL MODLES Data - Selectronic System (125, 135, 145, 150, 155, 185
Pneumatic Cylinders Type CQ2B40 - 40 +40 XC10 Piston Bore and Stroke Maximum Operating Pressure Microswitches Reed Switch Type Solenoid Valves Type Maximum Operating Pressure 4 Station Manifold1 Supply Voltage Pressure Regulator Type Pressure Setting
40mm (1.58 in) x 40mm (1.58 in) 9.6 bar (140 lbf/in 2 ) 500 mA
Double Solenoid Valve - VZ3220-60-115 6.8 bar (99lbf/in 2 ) WSZ3-20-041 12V DC (-15% to +10%)
Pressure Reducing Valve RV-1 5.5 bar (80lbf/in 2 )
Data - Selectronic System (Fastrac 1115, 1135, 2000 Series, 3000 Series)
Pneumatic Cylinders * Piston Bore and Stroke (Dry Clutch) * Piston Bore and Stroke (Wet Clutch) Maximum Operating Pressure Microswitches Reed Switch Type Solenoid Valves Maximum Operating Pressure Supply Voltage Pressure Regulator and Filter Type Pressure Setting 2000 Series to S/N 739999, 3000 Series to S/N 641999 2000 Series from S/N 740000, 3000 Series from S/N 642000 7.0 bar (102 lbf/in 2 ) 4.5 bar (65 lbf/in 2 ) Pressure Reducing Valve 7.0 bar (102 lbf/in 2 ) 12V DC ( -15% to +10%) 500 mA 32 mm (1.26 in) x 50 mm (1.97 in) 40 mm (1.57 mm) x 50 mm (1.97 in) See Pressure Regulator and Filter Pressure Setting
9804/1103
60 - 05 - 16/1
8020 - D/1-1.3
Issue 6*
CONTENTS CONTENTS
Fastrac
60 - 05 - 17/1
* FASTRAC
2000 Series, 3000 Series
Data - Air Conditioning System

Refrigerant Refrigerant Type Refrigerant Charge Weight Compressor Lubricant - Type - Quantity Switch Pressures Low Pressure Switch - Cut in - Cut out High Pressure Switch - Cut in - Cut out
HFC R134a 0.9 kg (2 lb) PAG SP20 240 c.c. (0.05 UK gal)
> 2.35 bar (> 34 lb/in2) < 0.4 bar (< 6 lb/in2)
< 19.3 bar (< 280 lb/in2) > 27.6 bar (> 400 lb/in2)
9804/1103
60 - 05 - 17/1
8020 - B/1-1.1
Issue 2*
CONTENTS
Fastrac
60 - 10 - 05/1
* 125,
135, 145, 150, 155, 185 from 637734, 1115, 1135, 2000 & 3000 Series
Fault Finding - Electronic Draft Control

Introduction The Electronic Draft Control System is self-monitoring for faults. These are identified by error codes indicated by a diagnostic LED. Refer to Interpreting the Diagnostic LED under Fault Diagnosis. Experience has shown that faults are unlikely to lie within the electronic components. Understand how the system works before attempting rectification (see Introduction , System Activation Procedure and Operation to ensure that all controls are set to allow full linkage movement). Note: If you are unable to diagnose a fault by following the fault finding procedure or by visual examination, contact JCB Landpower Service for further assistance.
9804/1103
60 - 10 - 05/1
Issue 4*
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CONTENTS
Fastrac
60 - 10 - 05/2
* 125, 135, 145, 150, 155, 185 from 637734, 1115, 1135, 2000 & 3000 Series Fault Finding - Electronic Draft Control (continued)
Functional Test of Control Valve

If the rear lift arms do not function correctly carry out the following tests. Note: In order to test the control valve, draft links must be loaded to approximately 800 kg (1700 lb). 3 1 2 Start engine. When button A on the control valve is pressed, the lift arms should lower to their lowest position. When button B on the control valve is pressed, the lift arms should rise to their highest position. If the functions at steps 2 and 3 operate correctly, the fault is electrical. If the arms do not raise or lower smoothly at steps 2 and 3, the fault is hydraulic. Use the Fault Finding table on the next page to identify the fault.
! WARNING
The procedure below must be carried out with the engine running. Apply the parking brake, chock the wheels and ensure that no-one enters the cab.
SUS 1-1
A
227140
9804/1103
60 - 10 - 05/2
Issue 3*
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CONTENTS
Fastrac
60 - 10 - 05/3
* 125, 135, 145, 150, 155, 185 from 637734, 1115, 1135, 2000 & 3000 Series Fault Finding - Electronic Draft Control (continued)
Arms Cannot be Raised or Lowered

Run engine at tickover CHECK 1 Do hydraulics move when control valve solenoids are pressed manually? Are the relevant fuses intact? YES: NO: YES: NO: YES: NO: ACTION Check 2. Check 3. Check Diagnostic LED indication. Renew fuses. Renew defective control valve. Check and adjust MRV/overhaul pump.
Are pump P3 flow and MRV settings correct?
Arms Cannot be Lowered

Run engine at tickover, adjust setpoint control to fully lowered. CHECK 1 Is rate of drop control on minimum rate setting? YES: NO: YES: NO: ACTION Move to mid position. Check 2. Check Diagnostic LED indication. Renew defective control valve.
Do arms move when control valve solenoids are pressed manually?
Arms Cannot be Raised

Run engine at tickover, set height limitation control to maximum height. ACTION CHECK 1 Do arms move when control valve solenoids are pressed manually? YES: NO: Check Diagnostic LED indication. Renew defective control valve.
9804/1103
60 - 10 - 05/3
Issue 3*
CONTENTS CONTENTS
Fastrac
60 - 10 - 05/4
125, 135, 145, 150, 155, 185 from 637734, 1115, 1135, 2000 & 3000 Series Fault Finding - Electronic Draft Control (continued) Fault Diagnosis
The faults indicated by the flashing diagnostic LED (see Interpreting the Diagnostic LED) are classified in three categories, see Error Codes , and the control unit reacts accordingly. 1 Major Fault As a result of such a fault the draft control is inhibited and locked up. The control unit shuts down to protect its output stages. Until the fault is cleared, control will remain inhibited and the diagnostic LED will flash every time an attempt is made to activate draft control. Once the fault has been cleared, draft control can be resumed by switching the ignition from OFF to ON and then carrying out the System Activation Procedure. Moderate Fault Moderate faults cause the same reaction as for major faults except that the control unit does not automatically shut down. Once the fault has been cleared, draft control can be resumed, with the ignition already ON, by carrying out the System Activation Procedure. 3 Minor Faults Draft control is maintained, but the diagnostic LED operates. Wherever draft control is activated, the LED will operate until the fault has been rectified.
Interpreting the Diagnostic LED All fault codes consist of two digits. The LED flashes the same number of times as the digit, e.g. six flashes for the number 6. It is therefore necessary to count the flashes following a long pause and then count the flashes following a short pause in order to decipher the digits, e.g. error code 36, shows as: long pause - three flashes - short pause - six flashes. The LED keeps on repeating the two digit code. Note: Some of the error codes utilise the same two digits, e.g. 13 and 31. To avoid confusion, remember that the first digit follows a long pause, the second digit follows a short pause. Refer to Error Codes for fault details.
* Error
Codes (E.C.U. Type D+)
All 125, 135, 145, 150, 155, 185 Machines from S/N 637734 All 1115, 1135 Machines All 2000 Series machines to S/N 738694 2000 Series machines with radar from S/N 738695 All 3000 Series machines to S/N 640709 3000 Series machines with radar from S/N 640710 Major Faults Error Code 11 Fault No output (raise circuit) Control Unit pin no. 37 i ii iii i ii iii Possible Cause Raise solenoid output stage faulty. Open circuit solenoid lead to pin 35. No voltage at pin 29 - check fuse C9. Lower solenoid output stage faulty. Open circuit solenoid lead to pin 35. No voltage at pin 29 - check fuse C9. Short circuit between pins 35 and 19 or pins 35 and 37. Possible solenoid short circuit. i ii iii 9 i ii Open circuit in lead(s) from pins 19, 37, 35 to solenoids. Possible solenoid fault (open circuit). No voltage at pin 29 - check fuse C9. Open circuit from pin 9 to button feeds. Faulty button(s). Stabilised supply faulty. Poor earth connection Check battery. Check continuity between control unit and control panel.
8020 - C/55-1.1
12
No output (lower circuit)
19
13
Short circuit (raise/lower circuit). Excessive current at pin 35.
35
14
Open circuit (raise/lower circuit). No current at pin 35 when solenoid actuated.
35
15
Rear button(s) not working.
16
Control unit supplies faulty.
2 20 29 21
17 18
Battery non-switched voltage. Control lever A inoperative
9804/1103
60 - 10 - 05/4
Issue 4*
CONTENTS CONTENTS
Fastrac
60 - 10 - 05/5
125, 135, 145, 150, 155, 185 from 637734, 1115, 1135, 2000 & 3000 Series Fault Finding - Electronic Draft Control (continued)
*
Error Codes (E.C.U. Type D+) (continued)

Moderate Faults Error Code 22 Fault Control Unit pin no. 6 i ii iii Possible Cause
Position sensor signal faulty.
Sensor open circuit or not connected. Possible short circuit or short to earth. Position sensor needs adjusting. Potentiometer open circuit or not connected.
23
Set command control D potentiometer signal faulty. Upper limit control E potentiometer signal faulty.
22
24
Potentiometer open circuit or not connected.
Minor Faults Error Code 31 32 33 34 Fault Control Unit pin no. 26 7 24 23 Possible Cause
Right force-sensing pin signal faulty. Left force-sensing pin signal faulty. Battery switched voltage below 11.5V. Lowering control C potentiometer signal faulty. Mix control H potentiometer signal faulty. Hitch fails to lift with active current at pin 37.
i ii iii
Sensor open circuit or not connected. Possible short circuit or short to earth. Possible overload of force sensing pin. Check battery. Potentiometer open circuit or not connected.
36 37
4 37 i ii 10 i ii
Potentiometer open circuit or not connected. If engine running: No oil pressure. Valve seized. Sensor open circuit or not connected. Possible short circuit or short to earth.
41
Radar signal absent, transmission signal present with Differential Lock selected. Transmission signal absent, radar signal present with Differential Lock selected.
42
11
i ii
Sensor open circuit or not connected. Possible short circuit or short to earth.
9804/1103
60 - 10 - 05/5
8020 - C/55-2.1
Issue 4*
CONTENTS CONTENTS
Fastrac
60 - 10 - 05/5A
125, 135, 145, 150, 155, 185 from 637734, 1115, 1135, 2000 & 3000 Series Fault Finding - Electronic Draft Control (continued) Error Codes (E.C.U. Type B)
Only available on 2000 Series machines not fitted with radar from S/N 738695 Only available on 3000 Series machines not fitted with radar from S/N 640710 Major Faults Error Code 11 Fault Control Unit pin no. 2 i ii i ii Possible Cause
No output (raise circuit)
Raise solenoid output stage faulty. Open circuit solenoid lead to pin 6. Lower solenoid output stage faulty. Open circuit solenoid lead to pin 6. Short circuit between pins 6 and 2 or pins 6 and 14. Possible solenoid short circuit.
12
No output (lower circuit)
14
13
Short circuit (raise/lower circuit) Excessive current at pin 6.
14
Rear up button not working
10
i ii i ii
Open circuit from pin 10 to button feed. Faulty button. Open circuit from pin 20 to button feed. Faulty button. Supply faulty. Poor earth connection. Check continuity between control unit and control panel.
15
Rear down button not working.
20
16
Control unit supply faulty
12
18
Control lever A inoperative
Moderate Faults Error Code 22 Fault Control Unit pin no. 19 i ii iii Possible Cause
Position sensor signal faulty.
Sensor open circuit or not connected. Possible short circuit or short to earth. Position sensor needs adjusting. Potentiometer open circuit or not connected.
23
Set command control D potentiometer signal faulty. Upper limit control E potentiometer signal faulty.
16
24
22
Minor Faults Error Code 31 32 34 Fault Control Unit pin no. 18 17 24 Possible Cause
Right force-sensing pin signal faulty. Left force-sensing pin signal faulty Lowering control C potentiometer signal faulty. Mix control H potentiometer signal faulty.
i ii iii
Sensor open circuit or not connected. Possible short circuit or short to earth. Possible overload of force sensing pin. Potentiometer open circuit or not connected.
36
9804/1103
60 - 10 - 05/5A
8020 - C/55-3.1
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 10 - 05/6
2000 Series, 3000 Series Fault Finding - Vehicle Electrics Starting Circuit
Circuit Description With the 6-speed gearbox lever set to neutral and starter switch A turned to 'IGN', the battery supply is fed via fuse Ca and the 6-speed gearbox neutral switch C (now closed as shown on the diagram) to the solenoids of the two inhibit start relays D and E. To eliminate the need to select neutral in the 6-speed gearbox, an alternative supply route to the solenoids of the start inhibit relays is provided via Ba the clutch depressed switch H (see Note ). With the front and rear power take off (PTO) switches F and G turned to the braking position, as shown in the diagram, an earth return is provided for the inhibit start relay solenoids, causing them to energise. When the starter switch is turned to the start ('HS') position, the battery supply is fed via fuse Bb and the relay contacts of the inhibit start relays D and E to the starter solenoid J, which energises and connects the battery supply to the starter motor K. Note: The clutch operating system is power assisted when the engine is running. With the engine switched off considerably greater effort than normal is required to depress the clutch pedal.
Ca
G
IGN
C H
Ba
HS
A
Bb
J1
J2
J
K1
+ K -
K2
A297190
9804/1103
60 - 10 - 05/6
8020 - C/21-1.3
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 10 - 05/7
2000 Series, 3000 Series Fault Finding - Vehicle Electrics (contd) Starting Circuit (contd)
Testing The following test procedure covers the starter motor, starter solenoid and battery. Before carrying out the voltmeter tests, check the condition of the battery (see Battery - Specific Gravity) and ensure that all connections are clean and tight. 3 To prevent the engine from starting during the tests ensure that the engine shut off solenoid is disconnected. Check the readings in the following sequence using a voltmeter (+ or - in the text indicates which voltmeter lead to use at the particular test point). Unless otherwise stated, the readings must be taken with the starter switch in the 'HS' position, the 6-speed gearbox gear lever set to nuetral and the front and rear PTO switches turned to the ' brake' positions. 1 Connect the voltmeter across the battery terminals. With starter switch in 'HS' position and starter motor running, the voltage reading should be approximately 10 volts. A low reading probably indicates a fault in the starter motor. Connect the voltmeter between the starter motor main terminal K1 (+) and the starter motor earth connection K2 (-). With starter switch in 'HS' position and starter motor running, the voltage reading should not be more than 0.5 volt below the reading in Test 1. If the voltage reading is significantly more than 0.5 volt below the reading in Test 1, the starter solenoid contacts may be 4 faulty or a poor connection may exist between the battery and the starter solenoid, or between the starter solenoid and the main terminal K1. Connect the voltmeter between the solenoid terminal J1 (+) and a good earth. Minimum reading with starter switch in 'HS' position should be 8.0 Volts. Connect the voltmeter between starter motor earth connection K2 (+) and battery negative. The voltage reading with the starter switch in position 'HS' should be practically zero. If the reading is appreciably above zero, a high resistance in the earth lead or connections is indicated. Connect the voltmeter between battery positive (+) and the starter motor main terminal K1 (-). With the starter switch 'OFF', the voltmeter should indicate battery voltage, but it should fall to practically zero when the switch is turned to position 'HS'. If the reading is appreciably above zero, a high resistance is present in the insulated lead or in the solenoid. Connect the voltmeter between the battery positive (+) and solenoid connection D. If the voltmeter now reads zero with the switch closed, the fault is in the solenoid.
Finally, reconnect the engine shut off solenoid.
Ca
G
IGN
C H
Ba
HS
A
Bb
J1
J2
J
K1
+ K -
K2
A297190
9804/1103
60 - 10 - 05/7
8020 - C/21-2.3
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 10 - 05/8
2000 Series, 3000 Series Fault Finding - Vehicle Electrics (contd) Charging Circuit Test
Note: The illustration below shows the battery location on Fastrac 2115, 2125 and 2135 machines. On Fastrac 2150 machines, the battery is on the left hand side of the machine and on 3000 Series machines the battery is in the cab. Before doing the following test, make sure that the battery and alternator connections are in good condition and that the fan belt is correctly adjusted. If the battery is in a fully charged condition, switch on the working lights for 3 minutes before commencing the test. Alternatively, operate the starter for a few moments with fuse A5 removed. Disconnect the positive lead from battery terminal A. Install a 100 Amp open-type shunt between the positive lead and the battery positive terminal A. Connect a multimeter positive lead to vehicle side of the shunt and negative lead to battery side of the shunt. Connect the leads to the meter and set the meter to the relevant range as follows: AVO 2002 Red lead to volts (middle) socket on meter. Black lead to negative on meter. RH slider to DC voltage. LH slider as illustrated below. Red lead to amps socket (marked A) on meter. Black lead to negative on meter. RH slider to DC voltage. LH slider to 200 Shunt. Red lead to volts socket (marked V ) on meter. Black lead to COM socket on meter. Set dial to mV. Start the engine and run at maximum speed (see Technical Data, Section T). Meter should show the maximum alternator output in Amps (see Technical Data, in this section). Note: The meter reading should be taken as soon as possible after starting the engine, as the charging current will fall rapidly. A zero reading indicates failure of the alternator and may be caused by one of the following conditions. These are listed in the order of probability. a b c d e f Defective suppression capacitor. Dirty sliprings or worn brushes. Defective regulator. Defective rectifier. Open or short-circuited field (rotor) windings. Open or short-circuited power (stator) windings.
To check for fault a, disconnect the capacitor and repeat the charging test. Renew the capacitor if necessary. To check for faults b and c, remove the regulator and brush box assembly. Check the condition of the brushes and, if necessary, clean the sliprings using extra-fine glasspaper. The regulator may only be checked by substitution. Faults d, e, and f may be checked only by removing and dismantling the alternator for further testing.
AVO 2003
FLUKE 85
A290400
9804/1103
60 - 10 - 05/8
8020 - C/22-1.3
Issue 1
CONTENTS
Fastrac
60 - 10 - 05/9
2000 Series, 3000 Series Fault Finding - Vehicle Electrics (contd) Tachometer Feed Test
Use the hand throttle to set the engine speed to a value higher than idling speed, so that the charge lamp is extinguished. Using a pointer type (analogue) multimeter set to DC 10 volts range, measure the voltage at the small stud on the alternator with respect to the alternator casing. The voltage reading should be between 6 volts and 8 volts.
9804/1103
60 - 10 - 05/9
8020 - C/22-2.2
Issue 1
CONTENTS
Fastrac
60 - 10 - 05/10
2000 Series, 3000 Series Fault Finding - Electronic Management System Diagnostic Error Code Tables
Error codes are able to identify individual faults within the system. It is unlikely that individual error codes will be generated erroneously by either the EMS or Transmission ECU. In the unlikely event that either of these units should fail, there will be a major failure. Before any diagnostic work is carried out, it is recommended that the initial start up sequence is watched closely to ensure that the both the EMS and the Transmission ECU are functioning correctly. To check both units, turn the starter key to ON. For a period of approximately 3 seconds the display is tested. Ensure that each of the display segments on the EMS display are functioning. Check that all of the display lamps are also illuminated. Ensure that the external buzzer sounds following display test; if not check the buzzer. If any of this does not happen, suspect a fault within the EMS. Reprogramming the EMS may cure this; if this fails, change the EMS. Following directly on from this, the centre display will display HELLO (dry clutch transmission) or HI THERE (wet clutch transmission) for approximately 2 seconds. This is done to inform the operator that the data link between the Transmission ECU and the EMS has been established correctly. If this does not happen, suspect the Transmission ECU is disconnected, or has an internal fault. Check all connections between the EMS and Transmission ECU, particularly the CAN bus. Turn the ignition off and on again to retest; if the fault persists, change the Transmission ECU. The dashboard will then revert back to its normal operation mode. * Non-displayable Fault Codes There are certain fault codes (D224 - D236 and T230) that are used for datalogging purposes but are not displayed to the driver. This is because these codes represent abuse information as opposed to an actual failure of the vehicle electrical system. E.g. If the oil pressure warning lamp is on for more than 10 seconds of engine running a fault code will be generated inside the EMS for datalogging purposes. The driver does not see this code as it is already supported by the warning lamp. Remember that the codes are historical data and oil levels, etc., may have been corrected since the faults were recorded In the following tables, the possible causes for each error code are listed in order of probability, and should always be checked in the order given.
Instrument Cluster Internal Error Codes Code Description Possible Cause EMS internal fault. Action and Remedy Reprogram EMS using updated software. Change EMS if problem persists. Switch off ignition and switch on. This should clear code. Change EMS. Check CAN Bus link for short or open circuit. (continued)
D001 EMS ROM memory error.
D002 EMS EPROM memory error.
May occur once after updating EMS software or setup values. EMS internal fault.
D003 EMS CAN Bus switched off.
EMS has detected a problem with the CAN Bus link.
9804/1103
60 - 10 - 05/10
8020 - C/40-1.3
Issue 2*
CONTENTS
Fastrac
60 - 10 - 05/11
2000 Series, 3000 Series Fault Finding - Electronic Management System (contd) Diagnostics Error Code Tables (continued)
* Code D010 Description Datalog memory full. Instrument Cluster Internal Error Codes Possible Cause The Datalog memory has reached capacity and can no longer store new error codes. Note: This code was removed at new software introduction JCBV0400.HEX. Handbook warning icon now illuminates if datalog becomes full. D020 Speed sensor present line disconnected. Speed sensor supply fuse ruptured. Speed sensor disconnected. Poor continuity of speed sensor supply line and present line. Action and Remedy Download Datalog memory, investigate codes and erase Datalog memory. If required, update EMS software to latest version.
Check speed sensor supply fuse. Check speed sensor connected. With the ignition turned on, check for the presence of +12V at present line input to EMS. Check function and operation of the speed sensor using a multimeter or the diagnostics function of the PSION Workabout.
D021
Speed sensor is assumed to have failed.
This error is an ASSUMPTION, as the tractor appears to have been driven, but the EMS has not received any signals from the speed sensor. May be caused by repeatedly operating the Selectronic range change with the tractor stationary and the park brake off. Damaged wiring.
Advise operator of cause to prevent further recurrences.
Check continuity of signal line from speed sensor to the EMS.
Note: If this error occurs, the EMS sets the speed triggers to illegal settings which make the tractor usable but safe, causing error code T060, and disabling Selectronic High and Medium ranges. D030 Radar sense line disconnected. Radar supply fuse ruptured. Radar disconnected. Poor continuity of radar supply line and present line. This code is deleted from JCBV0301 onwards, replaced by flashing radar symbol and non-displayed code D236. D031 No Bosch slip point signal. Break in wiring between EMS and Bosch Hitchtronic ECU. Options connectors have been joined on tractor without option package fitted (radar and fuel meters). Faulty Bosch ECU, or wrong type of Bosch ECU fitted. Check integrity of wiring from EMS to the Bosch ECU. Disconnect options connectors; refer to wiring diagrams. Check radar supply fuse. Check radar connected. With the ignition turned on, check for the presence of +12V at present line input to EMS.
Check Bosch ECU part number is correct for options package fitted or change ECU. (continued)
9804/1103
60 - 10 - 05/11
8020 - C/40 - 2.2
Issue 2*
CONTENTS
Fastrac
60 - 10 - 05/12
2000 Series, 3000 Series Machines Fault Finding - Electronic Management System (contd) Diagnostic Error Code Tables (contd)
Instrument Cluster Internal Error Codes Code D032 Description No fuel meter return signal. Possible Cause Air in fuel lines means meter is not turning. (Can occur briefly in return line when first starting engine; from JCB V0500 software, condition must persist for 20 seconds). Fuel meter is sticking. Options connectors have been joined on tractor without option package fitted (radar and fuel meters). Damaged wiring. Action and Remedy Check fuel lines and check Datalog to see engine rpm when fault recorded.
D033
No fuel meter feed signal.
Check fuel meter function and operation. Disconnect options connectors; refer to wiring diagrams.
Check integrity of wiring from fuel meter to the EMS. Check connections, referring to wiring diagrams. Update EMS software. Check Datalog to ensure that engine rpm was zero when code was logged. Advise operator of need to switch engine off before changing PTO speed. Check integrity of wiring from PTO selector to the EMS and operation of both switches . Check fuel injection pump; refer to engine manual. Check for signs of overspeeding; refer to engine manual. Check calibration figures in EMS setup. Check supply voltage. Only use 12V battery for jump start. Check sensor for operation and function. Check continuity of wiring from sensor to the EMS. Check sensor for correct operation and function. Check integrity of wiring from sensor to the EMS. Update EMS software.
D034
Fuel meter signal lines appear to have been swapped over. Both PTO 1000 and PTO 540 selected.
This code was used in JCBV0301 only.
D040
Sometimes occurs when changing PTO speed selector if ignition is on, as the two switches are close to each other and lever has short travel. Damaged wiring or short circuit switch.
D041
Engine rpm over 2850 rpm.
Tampering with fuel injection pump settings.
Engine over sped by, for example, travelling downhill. EMS calibration figures incorrectly set up. D042 Over voltage detected (>16V) Faulty alternator/voltage regulator. Jump start attempted from 24V battery. D050 Coolant temperature sensor open circuit (after 20 minutes running). Coolant temperature sensor short circuit. Faulty sensor. Damaged wiring.
D051
Faulty sensor.
Damaged wiring.
D052
Fuel tank level sensor short circuit.
Sometimes occurs when fuel tank filled. This code deleted from JCBV0200 onwards.
9804/1103
60 - 10 - 05/12
8020 - C/40 - 3.3
Issue 2*
CONTENTS
Fastrac
60 - 10 - 05/13
2000 Series, 3000 Series Machines Fault Finding - Electronic Management System (contd) Diagnostic Error Code Tables (continued)
* Notes for Non-displayable Fault Codes: Fault must be present for 10 seconds with the engine running before the code is logged. Fault must be present for 1 minute before the code is logged. Code will be logged if the vehicle has been moving at > 1 kph and the fault present for 5 seconds.
Non-displayable Fault Codes Code Description Possible Cause Low engine oil pressure. Action and Remedy Check engine oil pressure; refer to engine service manual for causes of low oil pressure. Check pressure switch for correct operation. Check integrity of wiring from switch to EMS. Check transmission oil pressure.
D224 Engine oil pressure low.
Faulty engine oil pressure switch. Damaged wiring. D225 Transmission oil pressure low. Low transmission oil pressure.
Faulty transmission oil pressure switch. Damaged wiring between switch and Transmission ECU.
Check pressure switch for correct operation. Check integrity of wiring from transmission oil pressure switch to Transmission ECU, noting that one pressure switch pin connects to two ECU pins; refer to wiring diagrams. Check integrity of warning light wiring from Transmission ECU to EMS; refer to wiring diagrams. Change filter.
Damaged wiring between Transmission ECU and EMS.
D226 Transmission oil filter blocked.
Blockage in transmission oil filter.
Note: It is important also to investigate the cause of the filter blockage. Faulty blockage switch. Check pressure switch for correct operation. Check integrity of wiring from switch to EMS. Change the outer air filter and also the inner filter if required. Check pressure switch for correct operation. Check integrity of wiring from switch to EMS. Investigate trailer system. (continued)
Damaged wiring. D227 Air filter blocked Blockage in air filter.
Faulty blockage switch.
Damaged wiring. D228 Trailer ABS fault Signal from trailer ABS system.
9804/1103
60 - 10 - 05/13
8020 - C/40 - 4.2
Issue 2*
CONTENTS
Fastrac
60 - 10 - 05/14
Non-displayable Fault Codes (contd) Code D229 Description Alternator No Charge warning. Possible Cause Slack or worn alternator drive belts. Action and Remedy Check alternator drive belt tension and condition. Check alternator output and operation. Check level of fluid on both brake fluid reservoirs. Check operation of switches by pressing test buttons on switch body. Check for leaks, etc. Check air pressure switch fo correct operation and function. Check operation of circuit protection valve. Check integrity of wiring from switch to EMS.
Internal alternator fault. D230 Brake fluid level low. Low brake fluid level in one or both actuator reservoirs. Faulty fluid level switch.
D231
Air tank 1 pressure low. Air tank 2 pressure low.
Low pressure in air tank. Faulty air pressure switch.
D232
Air tank not charging. D233 Air tank 3 pressure low. Damaged wiring.
D234
Handbrake on when Driving before handbrake is released. moving. Faulty air pressure switch.
Check air pressure switch for correct operation and function. Check integrity of wiring from switch to EMS.
Damaged wiring. The code will be logged if the vehicle has been moving at > 3 kph for 10 seconds and: (i) instantly the handbrake is applied(up to JCBV0400) (ii) the handbrake has been on for 10 seconds (from JCBV0500) D235 Engine coolant over temperature. Excessive datalogging by older versions of EMS software.
Check version of software. Update to current version. Check radiator and grille for blockage.
Blocked radiator. Note: From JCBV0400 on, Insufficient coolant in radiator. Fault must be present for 1 minute Slack or worn drive belts before it is logged. Faulty thermostat. Faulty temperature switch. Damaged wiring.
Check operation of thermostat. Check operation of temperature switch. Check integrity of wiring from temperature switch to EMS. (continued)
9804/1103
60 - 10 - 05/14
8020 - C/40 - 5.3
Issue 2*
CONTENTS
Fastrac
60 - 10 - 05/15
Non-displayable Fault Codes (contd) Code D236 Description Radar not connected. Possible Cause Options connectors have been joined on tractor without option package fitted (radar and fuel meters). Action and Remedy Disconnect options connectors; refer to wiring diagrams.
(Radar symbol also Break in wiring between radar unit and EMS. flashes). Note: This code replaces D030 from JCBV0301 on.
Check integrity of wiring from radar unit to EMS.
Transmission ECU Internal Error Codes Code T000 Description Possible Cause Action and Remedy Check fuse and power supply Check connections Check integrity of insulation with multimeter Check CAN Bus resistors; refer to wiring
No CAN Alive Power supply to Transmission ECU failed signals from the Transmission ECU Open circuit in CAN Bus wiring arriving at the EMS Short circuit in CAN Bus wiring Faulty resistor in CAN Bus wiring diagram Transmission ECU faulty
Change Transmission ECU Change Transmission ECU
T001
EPROM memory not working Suspect data in EPROM memory EPROM memory continually busy Factory default values not valid Wet clutch calibration values out of range
Transmission ECU internal fault
T002
Change Transmission ECU
T003
T004
T005
Wet clutch not calibrated or calibrated incorrectly
Re-calibrate the clutch. See Powershift and Master Clutch Calibration
9804/1103
60 - 10 - 05/15
8020 - C/40 - 6.2
Issue 2*
CONTENTS
Fastrac
60 - 10 - 05/16
Powershift Error Codes Code T010 Description Snail solenoid open circuit Possible Cause Internal breakdown of solenoid coil Action and Remedy Check solenoid for continuity
Damaged wiring
Check continuity of wiring from solenoid to both Transmission ECU and earth; refer to wiring diagram Check solenoid resistance, which should be 5 ohms Check for short circuit to earth in wiring between solenoid and Transmission ECU
T011
Snail solenoid short
Solenoid coil faulty internally circuit Damaged wiring
T012
Snail solenoid driver over temperature
Caused by abnormally high current drawn from Transmission ECU (the driver is inside the ECU and is not serviceable) Solenoid coil faulty internally Check solenoid resistance, which should be 5 ohms Check for short circuit or low resistance to earth in wiring between solenoid and Transmission ECU Check solenoid for continuity
Damaged wiring
T013
Tortoise solenoid open circuit
Internal breakdown of solenoid coil
Damaged wiring
Check continuity of wiring from solenoid to both Transmission ECU and earth; refer to wiring diagram Check solenoid for continuity
T014
Tortoise solenoid short circuit
Damaged wiring
Check for short circuit to earth in wiring between solenoid and Transmission ECU
T015
Tortoise solenoid driver over temperature
Caused by abnormally high current drawn from Transmission ECU (the driver is inside the ECU and is not serviceable) Solenoid coil faulty internally Check solenoid resistance, which shoiuld be 5 ohms Check for short circuit or low resistance to earth in wiring between solenoid and Transmission ECU Check solenoid for continuity
Damaged wiring
T016
Hare solenoid open circuit
Damaged wiring
Check continuity of wiring from solenoid to both Transmission ECU and earth; refer to wiring diagram (continued)
9804/1103
60 - 10 - 05/16
8020 - C/40 - 7.2
Issue 2*
CONTENTS
Fastrac
60 - 10 - 05/17
Powershift Error Codes (contd) Code T017 Description Hare solenoid short Possible Cause Solenoid coil faulty internally circuit Damaged wiring Action and Remedy Check solenoid resistance, which should be 5 ohms Check for short circuit to earth in wiring between solenoid and Transmission ECU
T018
Hare solenoid driver over temperature
Caused by abnormally high current drawn from Transmission ECU (the driver is inside the ECU and is not serviceable) Solenoid coil faulty internally Check solenoid resistance, which shoiuld be 5 ohms Check for short circuit or low resistance to earth in wiring between solenoid and Transmission ECU
Damaged wiring
Wet Clutch Lubrication Error Codes Code T019 Description Clutch lubrication solenoid open circuit Possible Cause Solenoid coil faulty internally Action and Remedy Check solenoid for continuity
Damaged wiring
Check for short circuit to earth in wiring between solenoid and Transmission ECU Check solenoid resistance, which should be 5 ohms Check for short circuit to earth in wiring between solenoid and Transmission ECU
T020
Clutch lubrication circuit
Solenoid coil faulty internally solenoid short Damaged wiring
T021
Clutch lubrication solenoid driver over temperature
Caused by abnormally high current drawn from Transmission ECU (the driver is inside the ECU and is not serviceable) Solenoid coil faulty internally Check solenoid resistance, which should be 5 ohms Check for short circuit or low resistance to earth in wiring between solenoid and Transmission ECU
Damaged wiring
9804/1103
60 - 10 - 05/17
8020 - C/40 - 8.3
Issue 2*
CONTENTS
Fastrac
60 - 10 - 05/18
* Reverse Lamp Error Codes - Dry Clutch Machines only Code T022 Description Possible Cause Action and Remedy Check reversing light bulbs and relay (if fitted); refer to wiring diagrams.
Reversing lamp open For this circuit to be open, both reversing circuit. bulbs and the trailer reverse light relay (if fitted) must all have failed open circuit. Damaged wiring
Check continuity of wiring from Transmission ECU to reversing lights and trailer reverse lights relay (if fitted); refer to wiring diagram.
T023
Reversing lamp short Trailer reversing light bulb or relay short circuit. Check reversing light bulbs and relay. circuit. Damaged wiring Check integrity of wiring from Transmission ECU to reversing lights and trailer reverse lights relay (if fitted); refer to wiring diagram. Reversing lamp driver over temperature. Caused by abnormally high current drawn from Transmission ECU (the driver is inside the ECU and is not serviceable). Internal failure of the relay. Damaged wiring Check relay for function. Check for short circuit or low resistance to earth in wiring from ECU to reversing lights and trailer reverse lights relay (if fitted); refer to wiring diagram. Check bulbs and replace as necessary.
T024
Incorrect wattage bulbs fitted.
Selectronic Air Solenoid Error Codes Code T025 Description Possible Cause Action and Remedy Check individual solenoid for continuity, as guided by the individual fault code. Check supply and return wiring between Transmission ECU and relevant solenoid(s); refer to wiring diagram. Note: If either all four neutral solenoids or all four engage solenoids are showing failures, it is likely to be a supply fault. If there is only one solenoid failure, it is likely to be an individual solenoid return.
L ram neutral air Internal breakdown of a solenoid coil. solenoid open circuit. R ram engage air Wiring fault. solenoid open circuit. M ram engage air solenoid open circuit. H ram neutral air solenoid open circuit. L ram engage air solenoid open circuit. R ram neutral air solenoid open circuit. M ram neutral air solenoid open circuit. H ram engage air solenoid open circuit.
T026
T027
T028
T029
T030
T031
T032
9804/1103
60 - 10 - 05/18
8020 - C/40 - 9.2
Issue 2*
CONTENTS
Fastrac
60 - 10 - 05/19
Selectronic Air Solenoid Error Codes Code T033 Description One air solenoid has short circuit. Possible Cause Internal solenoid failure. Action and Remedy Check solenoid resistance, which should be 75 to 80 ohms. Determine which solenoid has failed by sequencing through all Selectronic gear changes. Check that the common air valve supply lines from the Transmission ECU are not shorting to earth; refer to wiring diagrams.
T034
Air solenoid valve block 12V supply line short circuit. Air solenoid valve block 12V supply over temperature.
Damaged wiring.
T035
Caused by abnormally high current drawn from Transmission ECU (the driver is inside the ECU and is not serviceable). Internal solenoid failure. Check all air solenoid resistances, which should each be 75 to 80 ohms. Check for short circuit or low resistance to earth in common supply from Transmission ECU to air solenoids.
Damaged wiring.
T040
REV engage.
All these switches appear to be OPEN and should be CLOSED. These codes can also result from attempting Check air pressure and operation of to use Selectronic with insufficient air pressure, cylinders. causing insufficient cylinder movement to operate the switches normally, or air cylinder Check for air cylinder leaks. leaks which also cause slow or weak air cylinder movement. Failed switch (open circuit). Check switch operation using a magnet and multimeter, or by using the diagnostics function of the Psion Workabout. Check supply and return wiring between Transmission ECU and switches; refer to wiring diagram.
T041
LOW engage.
T042
MED engage.
T043
HIGH engage.
T044
REV neutral. Wiring faulty.
T045
LOW neutral.
T046
MED neutral.
T047
HIGH neutral.
9804/1103
60 - 10 - 05/19
8020 - C/40 - 10.3
Issue 2*
CONTENTS
Fastrac
60 - 10 - 05/20
Selectronic Air Solenoid Error Codes Code Description Possible Cause Action and Remedy
T050
REV engage.
All these switches appear to be CLOSED and should be OPEN . These codes can also result from attempting Check air pressure and operation of to use Selectronic with insufficient air pressure, cylinders. causing insufficient cylinder movement to operate the switches normally, or air cylinder Check for air cylinder leaks. leaks which also cause slow or weak air cylinder movement. Failed switch. Check switch operation using a magnet and multimeter, or by using the diagnostics function of the Psion Workabout. Check supply and return wiring between Transmission ECU and switches; refer to wiring diagram.
T051
LOW engage.
T052
MED engage.
T053
HIGH engage.
T054
REV neutral. Wiring faulty.
T055
LOW neutral.
T056
MED neutral.
T057
HIGH neutral.
Illegal Speed Trigger Error Codes Code T060 Description Triggers <1, <3 and >20 kph. Possible Cause Action and Remedy
The EMS sets the speed triggers to these Check for error codes D020 or D021. values if it detects a speed sensor fault. These settings make the tractor systems safe but useable; for example, Quadtronic is forced to 2WS. Break in 20 kph signal line from EMS to Transmission ECU. Check continuity of 20 kph line, referring to wiring diagrams. Check continuity of 3 kph and/or 20 kph lines, referring to wiring diagrams. Check continuity of 1 kph line, referring to wiring diagrams. Check continuity of 1 kph line, referring to wiring diagrams. Check for short on 3 kph line, referring to wiring diagrams.
T061
Triggers >1, <3 and >20 kph. Triggers <1, >3 and >20 kph. Triggers <1, >3 and <20 kph.
Break in 3 kph and/or 20 kph line from EMS to Transmission ECU. Break in 1 kph line from EMS to Transmission ECU. Break in 1 kph line from EMS to transmission ECU. Short to 12V on 3 kph line from EMS to Transmission ECU.
T062
T063
9804/1103
60 - 10 - 05/20
8020 - C/40 - 11.2
Issue 2*
CONTENTS
Fastrac
60 - 10 - 05/21
Clutch Switch Error Codes *(Dry clutch transmission) Code T070 Description Possible Cause Action and Remedy Check both switches for correct operation and function.
Clutch switches show One of clutch pedal switches is faulty or clutch pedal both jammed. fully up and fully down at the same time.
Wet Clutch Transmission Error Codes Code T071 Description Transmission brake solenoid open circuit Possible Cause Solenoid coil faulty internally Action and Remedy Check solenoid for continuity
Damaged wiring
Check for short circuit to earth in wiring between solenoid and Transmission ECU Check solenoid resistance, which should be 5 ohms Check for short circuit to earth in wiring between solenoid and Transmission ECU
T072
Transmission brake circuit
Solenoid coil faulty internally solenoid short Damaged wiring
T073
Transmission brake solenoid driver over temperature
Caused by abnormally high current drawn from Transmission ECU (the driver is inside the ECU and is not serviceable) Solenoid coil faulty internally Check solenoid resistance, which should be 5 ohms Check for short circuit or low resistance to earth in wiring between solenoid and Transmission ECU Check and correct oil level Clean or renew cooler Renew sensor unit, check potentiometer operation Service clutch Low transmission oil level Lubrication oil supply failure Check and correct oil level Check clutch lubrication oil pressures Check clutch control valve operation, potentiometer operation. Service clutch
Damaged wiring
T077
Transmission oil over temperature *Note: The low transmission oil pressure light will flash when this fault is present
Low transmission oil level Blocked or damaged oil cooler Faulty sensor unit
T078
Wet clutch over temperature *Note: The low transmission oil pressure light will flash when this fault is present
Excessive clutch slip
T079
Oil temperature sensor fault
Faulty sensor unit Damaged wiring
Renew sensor Check for short circuit or low resistance to earth in wiring between sensor and Transmission ECU
9804/1103
60 - 10 - 05/21
8020 - C/40 - 12.1
Issue 2*
CONTENTS
Fastrac
60 - 10 - 05/22
2000 Series, 3000 Series Machines Fault Finding - Electronic Management System (contd)
Column Switch Connection Error Codes Code T080 Description Possible Cause Action and Remedy Check switch for correct operation and function, using a multimeter or the diagnostics function of the PSION Workabout. Check integrity of wiring from column switch to both the EMS and the Transmission ECU.
Low and reverse Faulty column switch. appear both selected.
T081
Low and medium Damaged wiring. appear both selected. Low and high appear both selected. High and reverse appear both selected. Medium and reverse appear both selected. Medium and high appear both selected. Wet Clutch Control Error Codes
T082
T083
T084
T085
Code T100
Description Wet clutch solenoid open circuit
Possible Cause Solenoid coil faulty internally Faulty inching resistor
Action and Remedy Check solenoid for continuity Check resistance of inching resistor, which should be 4.7 ohms Check for open circuit in wiring between solenoid and Transmission ECU Check solenoid resistance, which should be 7 to 14 ohms Check resistance of inching resistor, which should be 4.7 ohms Check for short circuit to earth in wiring between solenoid and Transmission ECU
Damaged wiring
T101
Wet Clutch solenoid short circuit
Solenoid coil faulty internally
Faulty inching resistor
Damaged wiring
T102
Wet Clutch solenoid driver over temperature
Caused by abnormally high current drawn from Transmission ECU (the driver is inside the ECU and is not serviceable) Solenoid coil faulty internally Damaged wiring Check solenoid resistance Check for short circuit or low resistance to earth in wiring between solenoid and Transmission ECU Check solenoid for continuity Check resistance of inching resistor, which should be 4.7 ohms. Check for open circuit in wiring between solenoid and transmission ECU. Check ECU supply wiring.
8020 - C/40 - 13.1
T103
Not enough wet clutch solenoid valve current when clutch pedal up.
Solenoid coil faulty internally. Faulty inching resistor.
Damaged wiring.
Low ECU supply voltage.

9804/1103
60 - 10 - 05/22
Issue 2*
CONTENTS
Fastrac
60 - 10 - 05/23
Wet Clutch Control Error Codes (contd) Code T114 Description Clutch pedal is fully down but clutch switch has not operated Possible Cause Clutch pedal not adjusted correctly Faulty clutch switch Damaged wiring T115 Clutch pedal is fully up but clutch down switch has not released Faulty clutch switch Damaged wiring Action and Remedy Adjust pedal Check switch operation Check for open circuit Check switch operation Check for short circuit
T120
Clutch potentiometer Faulty potentiometer or installation calibrated position is too high Clutch potentiometer See code T120 calibrated position is too low Clutch potentiometer See code T120 above calibrated limits Clutch potentiometer See code T120 below calibrated limits Clutch potentiometer Faulty potentiometer is above electrical limits Faulty wiring Clutch potentiometer Faulty potentiometer is below electrical limits Faulty wiring Clutch pedal calibrated range too small Splitter safety dump relay does not operate when clutch pedal is fully depressed. Splitter safety dump relay operates even though clutch pedal released. Clutch operation not calibrated correctly
Check potentiometer mounting and operation
T121
See code T120
T122
See code T120
T123
See code T120
T124
Check potentiometer operation Check related wires for damage Check potentiometer operation Check related wires for damage Calibrate clutch
T125
T126
T130
Relay faulty Relay wiring faulty
Check relay Check wiring.
T131
Relay faulty Relay wiring faulty
Check relay Check wiring
9804/1103
60 - 10 - 05/23
8020 - C/40 - 14.1
Issue 2*
CONTENTS
Fastrac
60 - 10 - 05/24
Non-displayable Fault Codes Code T230 Description Limp Home mode activated. Note: This mode is not available on Transmission ECU Part Number 704/33700. Possible Cause Driver used Limp Home mode. Action and Remedy Find reason for use of this mode and rectify any faults. Check integrity of wiring from switch to EMS.
Damaged wiring.
9804/1103
60 - 10 - 05/24
8020 - C/40 - 15.1
Issue 2*
CONTENTS
Fastrac
60 - 10 - 06/1
ALL MODELS
*
Fault Finding - Complete Transmission Complete Transmission

If the problem is noise rather than loss of drive start at check 7. CHECK 1 Is drive being transmitted to the road wheels? ACTION YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: 9 Isolate noise source to range box or rear axle or front axle by disconnecting relevant drive shafts. Is transmission oil level low? YES: Check 7. Check 2. Check 3. Check clutch actuation. See Note 2 below. Examine and repair clutch. See Note 2 below. Check 4. Check 5. Engage gear/check gearchange linkages. Check 6. Remove and examine 6-speed gearbox. Check rear axle. Check range gearbox. Check 8. Check 10. Examine speed gearbox for worn/damaged components. Check 9. Examine relevant transmission element for worn/damaged components. Fill to correct level.
Is the clutch actuation system functioning?
Is the clutch slipping?
Are range and speed gearboxes both in gear?
Is 6-speed gearbox heard to drive with the range gearbox in neutral? Does rear axle driveshaft rotate with both gearboxes in gear? Is fault noise rather than loss of drive?
Is transmission noisy with speed gearbox in gear and range gearbox in neutral?
10
Note 1: When carrying out fault finding on the transmission always check for any error codes that may have been generated by the electronic management system. See Fault Finding (Electronic Management System) Section C. Note 2: For machines fitted with a wet master clutch transmission see Fault Finding - Wet Master Clutch.
9804/1103
60 - 10 - 06/1
8020 - F/5-1.2
Issue 2*
CONTENTS
Fastrac
60 - 10 - 06/2
2000 AND 3000 SERIES MACHINES

* Fault
Finding - Wet Master Clutch
Symptom A Clutch fails to engage. Clutch slips. Clutch engages erratically. CHECK 1 2 3 4 Is the transmission oil level low? Is the pressure maintenance valve set correctly? Is the clutch pedal potentiometer faulty? Is the clutch hydraulic pressure low? ACTION YES: NO: YES: NO: YES: NO: YES: Fill to correct level. Check 2. Check 3. Set the valve to the correct pressure. Renew the potentiometer. Check 4. Recheck 2, check related external pipework for leaks. Check 5. Check 5. Check 6. Renew the valve. Check 7. Re-calibrate pedal Renew piston seals, see the Note below. Check 8.
NO: 5 *6 *7 Is the clutch control valve operating correctly? Is pedal calibration correct? Are the clutch piston seals leaking? YES: NO: YES: NO: YES: NO:
Note: The following checks can only be carried out after the complete gearbox assembly has been removed from the machine. Make sure that all other checks have been carried out correctly before contemplating removal of the gearbox. *8 *9 * 10 Is the clutch piston check valve faulty? Are the clutch friction plates worn? Are steps visible in the drive tangs on the clutch drum? YES: YES: YES: Renew the check valve. Renew the plates. Renovate or renew the drum as required.
Symptom B Clutch fails to disengage correctly when machine is in motion (clutch drag). CHECK 1 2 3 4 *5 Is the transmission oil level too high? Is the clutch external return line pipework damaged? Is the clutch pedal potentiometer faulty? Is the clutch control valve operating correctly? Is pedal calibration correct? ACTION YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: Adjust oil level, check for oil contamination. Check 2. Renew pipes as required. Check 3. Renew the potentiometer. Check 4. Check 5. Renew the valve. Check 6. Re-calibrate pedal.
Note: The following checks can only be carried out after the complete gearbox assembly has been removed from the machine. Make sure that all other checks have been carried out correctly before contemplating removal of the gearbox. *6 *7 *8 Is the clutch piston check valve faulty? Are steps visible in the drive tangs on the clutch drum? Are the clutch return springs worn or broken? YES: YES: YES: NO: Renew the check valve. Renovate or renew the drum as required. Renew the springs. Always renew the springs even if they appear serviceable.
9804/1103
60 - 10 - 06/2
8020 - F/5-2.2
Issue 2*
CONTENTS
Fastrac
60 - 10 - 06/3
2000 AND 3000 SERIES MACHINES

*
Fault Finding - Wet Master Clutch (contd)
Symptom C Clutch fails to disengage correctly when selecting a gear with the machine stationary (clutch drag). CHECK 1 2 ACTION
Carry out checks 1 to 4 for symptom B then carry out check 2 below. Is the transmission brake hydraulic pressure low? YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: Check 3. Check 5. Fill to correct level. Check 4. Check 5. Set the valve to the correct pressure. Check 5. Renew the valve. Renew piston seals, see the Note below. Check 7.
Is the transmission oil level low?
Is the pressure maintenance valve set correctly?
Is the brake solenoid valve operating correctly?
Are the brake piston seals leaking?
Note: The following checks can only be carried out after the complete gearbox assembly has been removed from the machine. Make sure that all other checks have been carried out correctly before contemplating removal of the gearbox. 7 Are the brake friction plates worn? YES: NO: Renew the plates. Check 8.
Carry out checks 5 to 7 for symptom B.
9804/1103
60 - 10 - 06/3
8020 - F/5-3.1
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 10 - 07/1
ALL MODELS Fault Finding - Power Take Off Clutches

If the problem is a partial or complete lack of drive to PTO drive lines start at check 1. If the problem is that the PTO shaft continues to rotate when selector switch is in the 'brake' position, start at check 12.
CHECK 1 Are both front and rear PTO drive lines fitted? YES: NO: YES: NO: YES: NO:
ACTION Check 2. Check 3. Check 3. Check 4. Rectify fault in PTO gearbox. Rectify cable/selector mechanism and engage gear.
Has drive been lost to both shafts?
Is the PTO speed selector lever engaged and cable/selector mechanism intact?
Note: Checks from 4 onwards refer to either front or rear PTO operating mechanism. 4 Is PTO drive line intact? YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: Check 5. Repair as necessary. Rectify leak. Check 6. Check 7. Adjust pressure. Replace filter element. Check 8. Check 9. Check 10. Replace the defective solenoid. Check 10. Check 11. Replace PTO selector switch. Free off or renew valve. Remove and dismantle PTO clutch pack and inspect condition. Check 13. Check 14. Rectify leak. Check 14. Check 15. Adjust pressure. Replace filter element. Check 16. Check 17. Check 18.
Is there a leak in the extended pipework to the PTO drive clutch? Is the transmission hydraulic circuit pressure correct?
Is the transmission hydraulic circuit pressure filter blocked? Is current reaching the PTO drive solenoid?
Is the PTO drive solenoid defective?
10
Is the PTO selector switch passing current in the PTO 'drive' position? Is the PTO drive solenoid spool sticking?
11
12
Does the PTO shaft continue to rotate when the PTO selector switch is in the 'brake' position? Is there a leak in the external pipework to the PTO brake? Is the transmission hydraulic circuit pressure correct?
13
14
15
Is the transmission hydraulic circuit pressure filter blocked? Is current reaching the PTO brake solenoid?
16
9804/1103
60 - 10 - 07/1
CONTENTS CONTENTS
Fastrac
60 - 10 - 07/2
ALL MODELS Fault Finding - Power Take Off Clutches (continued)
CHECK 17 Is the PTO brake solenoid defective? YES: NO: YES: NO: YES: NO:
ACTION Replace solenoid. Check 18. Check 19. Replace PTO selector switch. Free off or renew valve. Dismantle and examine PTO brake assembly.
18
Is the PTO selector switch passing current in the PTO 'brake' position? Is the PTO brake solenoid spool sticking?
19
9804/1103
60 - 10 - 07/2
CONTENTS CONTENTS
Fastrac
60 - 10 - 08/1
ALL MACHINES 2/4 Wheel Drive - Fault Finding
No four-wheel drive but all gears functioning in two-wheel drive. CHECK 1 Is the front axle drive train intact? YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: ACTION Check 2. Repair as required. Replace 2WD dump switch. Check 3. Dismantle/renew valve. Check 4. Renew 2/4WD switch. Check 5. Renew 2/4WD drive relay. Dismantle 4WD clutch and inspect condition.
Is 2WD dump switch permanently closed with parking brake on? Is the 2/4WD solenoid spool sticking?
Put the starter switch in "IGN" position. Select 4WD. Is there a voltage reading at the 4WD relay? Put the starter switch in"'IGN" position. Select 4WD. Is there a voltage reading at the 2/4WD solenoid socket?
Two-wheel drive cannot be engaged (or four-wheel drive will not disengage). CHECK 1 Is there a leak in the external pipework to the 2/4WD clutch? Is the transmission hydraulic circuit pressure correct? YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: ACTION Rectify leak. Check 2. Check 3. Adjust pressure. Replace filter element. Check 4. Check 5. Check 6. Renew 2/4WD dump switch. Dismantle 4WD clutch and check condition, particularly the piston seals. Replace the defective solenoid. Check 7. Check 8. Renew 2/4WD selector switch. Free off or renew valve.
Is the transmission hydraulic circuit pressure filter blocked? Is current reaching the 2/4WD solenoid when the starter switch is in "IGN" position and 2WD is selected'? Is the 2WD dump switch permanently open, even with the park brake disengaged?
Is the 2/4WD solenoid defective?
YES: NO: YES: NO: YES:
Is the 2/4WD selector switch passing current in the 2WD position? Is the 2/4WD solenoid spool sticking?
9804/1103
60 - 10 - 08/1
8020 - F/7-1.1
Issue 1
CONTENTS
Fastrac
125, 135, 145, 150, 155, 185 Fault Finding - Differential Lock (rear axle)
Differential lock will not engage.

CHECK 1 Is there a leak in the external pipework to the differential lock? Is the transmission hydraulic circuit pressure correct? YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: ACTION Rectify leak. Check 2. Check 3. Adjust pressure. Replace filter element. Check 4. Check 5. Check 6. Replace the defective solenoid. Check 7. Check 7. Replace 4WD drive/differential lock selector switch. Free off or renew valve. Dismantle differential lock mechanism and check condition of drive dogs and piston seals.
Is the transmission hydraulic circuit pressure filter blocked? Is current reaching the 4WD/differential lock solenoid?
Is the 4WD/differential lock solenoid defective?
Is the 4WD/differential lock selector switch passing current in the 4WD and diff. lock position? Is the 4WD/differential lock solenoid spool sticking?
Differential lock will not disengage.

CHECK 1 Put the starter switch in "IGN" position. Is current reaching the 4WD/differential lock solenoid when only 4WD is selected? Is the 4WD/differential lock solenoid spool sticking? YES: NO: ACTION Renew 4WD/differential lock selector switch. Check 2.
YES: NO:
Free off or renew valve. Dismantle 4WD/differential lock mechanism and check condition of release spring and piston for sticking.
9804/1103
60 - 10 - 11/1
Issue 3
CONTENTS
Fastrac
* FASTRAC 1115, 1135, 2115, 2125, 2135, 2150 Fault Finding - Differential Lock
Differential lock will not engage.

CHECK 1 Is there a leak in the external pipework to the differential lock? Is the transmission hydraulic circuit pressure correct? YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: ACTION Rectify leak. Check 2. Check 3. Adjust pressure. Replace filter element. Check 4. Check 5. Check 6. Replace the defective solenoid. Check 7. Check 7. Replace 4WD drive/differential lock selector switch. Free off or renew valve. Dismantle differential lock mechanism and check condition of drive plates and piston seals.
Is the transmission hydraulic circuit pressure filter blocked? Is current reaching the differential lock solenoid?
Is the differential lock solenoid defective?
Is the 4WD/differential lock selector switch passing current in the 4WD and diff. lock position? Is the differential lock solenoid spool sticking?

CHECK 1 Put the starter switch in "IGN" position. Is current reaching the differential lock solenoid when only 4WD is selected? Is the differential lock solenoid spool sticking? YES: NO: ACTION Renew 4WD/differential lock selector switch. Check 2.
YES: NO:
Free off or renew valve. Dismantle differential lock mechanism and check condition of release spring and piston for sticking.
9804/1103
60 - 10 - 11/2
Issue 2*
CONTENTS CONTENTS
Fastrac
60 - 10 - 11/3
2000 Series, 3000 Series Fault Finding - Differential Lock Differential lock will not engage.
CHECK 1 Is there a leak in the external pipework to the differential lock? Is the transmission hydraulic circuit pressure correct? YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: ACTION Rectify leak. Check 2. Check 3. Adjust pressure. Replace filter element. Check 4. Check 5. Check 6. Replace the defective solenoid. Check 7. Check 7. Replace 4WD drive/differential lock selector switch. Free off or renew valve. Dismantle differential lock mechanism and check condition of drive plates and piston seals.
Is the transmission hydraulic circuit pressure filter blocked? Is current reaching the differential lock solenoid?
Is the differential lock solenoid defective?
Is the 4WD/differential lock selector switch passing current in the 4WD and diff. lock position? Is the differential lock solenoid spool sticking?

CHECK 1 Put the starter switch in "IGN" position. Is current reaching the differential lock solenoid when only 4WD is selected? Is the differential lock solenoid spool sticking? YES: NO: ACTION Renew 4WD/differential lock selector switch. Check 2.
YES: NO:
Free off or renew valve. Dismantle differential lock mechanism and check condition of release spring and piston for sticking.
9804/1103
60 - 10 - 11/3
3820 - F/8-1.1
Issue 1
CONTENTS
* 125,
Fastrac
135, 145, 150, 155, 185
Fault Finding - Brakes
Introduction
For diagnostic purposes the air brake system is fitted with five test points, one on each 'dry' tank and two on the output side of the footbrake valve. Diagnosis of system faults requires the use of suitable gauges (three are usually sufficient). A service kit of gauges, hoses and fittings is available as JCB Service Tool 892/00311. The brake system air pressure should be 8 bar (120 lbf/in ).
2
Safety Precautions
Before working on or around the brake system, always observe the following precautions: 1 2 Stop the engine and chock all four wheels. When the air system is being exhausted, keep hands away from the parking brake actuator pushrod and caliper, as they may move and trap your fingers. Take care if disconnecting an air hose containing pressure as it may whip as air escapes. Never remove or dismantle a component until air pressure has been exhausted and you have read and understood the recommended procedures. Wear safety glasses when working with air pressure.
! WARNING
General air leaks are usually audible with the engine stopped. For smaller air leaks on valves, soak the valve in soap solution and watch for the formation of bubbles. The illustration below will aid identification of the components mentioned in the fault finding procedure.
BRAK 8-3/1
Component Key A B C E F G1 G2 G3 L Feed from Compressor Unloader Valve Wet Tank Schrader valve Circuit Protection Valve Front Circuit Reservoir Rear Circuit Reservoir Trailer and Parking Brake Reservoir Trailer Brake Air Valve *M Air/hydraulic Actuators * Note: To machine no. 636000, the front actuator feeds the rear brakes and the rear actuator feeds the front brakes. From machine no. 636001 the front actuator feeds the front brakes and the rear actuator feeds the rear brakes. S Non-return Valve * TP1 Test Point, Front Circuit * TP2 Test Point, Rear Circuit * TP3 Test Point, Trailer and Parking Brake Circuit Note: Test point TP3(1) is alternative to TP3(2). Test points TP4 and TP5 are on the footbrake valve (see circuit diagram) Z(f) Threshold Valve (front) - if fitted
S162623
9804/1103
60 - 10 - 15/1
Issue 3*
CONTENTS
*
Fastrac
125, 135, 145, 150, 155, 185 Fault Finding - Brakes (continued)
Low Pressure Warning Lights On

CHECK 1 Are all three warning lights on? YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: ACTION Check 2. Check 4. Rectify leak. Check 3. Renew defective unloader valve. Strip and examine compressor. Renew defective low pressure switch. Check 5. Renew circuit protection valve. System now OK.
Is there a leak between the compressor and the circuit protection valve? Is air continually pumping from unloader valve exhaust?
If only one light is on, pressure test relevant tank. Is pressure OK? Drain air from complete system. Recharge. Does fault still exist?
Service Brakes Poor

CHECK 1 Do disc pads have a minimum of 3 mm (0.12 in) friction material? Do both brake fluid reservoirs have adequate fluid? YES: NO: YES: NO: YES: NO: YES: NO: ACTION Check 2. Renew pads (in complete axle sets). Check 3. Top up and check for leaks. Check 4. Bleed brakes. Check 5 Strip and inspect footbrake valve
Have brakes been bled?
Fit gauges first to TP1 and TP4 and then to TP2 and TP5. Do the gauges indicate that the footbrake valve is functioning? Are air/hydraulic actuators functioning?
YES: NO: .
Bleed brakes. Strip and inspect actuator(s).
Poor Front Brakes, Good Rear Brakes

CHECK 1 Fit gauges to TP1 and TP4. Charge system. Does TP1 reach system pressure? YES: NO: YES: NO: YES: NO: ACTION Check 2. Check for leaks or faulty circuit protection valve. Check 3. Check footbrake valve. Check air/hydraulic actuator. Bleed front hydraulic circuit.
2 3
Operate footbrake. Does TP4 reach TP1? Has the front hydraulic circuit been bled?
9804/1103
60 - 10 - 15/2
Issue 3*
CONTENTS
*
Fastrac
125, 135, 145, 150, 155, 185 Fault Finding - Brakes (continued)
Poor Rear Brakes, Good Front Brakes

CHECK 1 Fit gauges to TP2 and TP5. Charge system. Does TP2 reach system pressure? YES: NO: ACTION Check 2. Check for leaks or faulty circuit protection valve.
Operate footbrake. Does TP5 reach TP2?
YES: NO: YES: NO:
Check 3. Check footbrake valve. Check air/hydraulic actuator. Bleed rear hydraulic circuit.
Has the rear hydraulic circuit been bled?
Trailer Brakes Poor

CHECK 1 Fit gauge to TP3. Charge system. Is tank up to system pressure? Drain air from complete system. Recharge. Is tank up to system pressure? Fit gauges to trailer tappings TS and TC . Is TS at system pressure? Operate footbrake. Is TC at system pressure? YES: NO: YES: NO: YES: NO: YES: NO: ACTION Check 3. Check 2. System now OK. Renew circuit protection valve. Check 4. Defective trailer brake valve. Fault on trailer brakes. Defective trailer brake valve.
Park Brake Not Holding

CHECK 1 Do disc pads have a minimum of 3 mm (0.12 in) friction material? Are pads adjusted correctly? YES: NO: YES: NO: YES: NO: ACTION Check 2. Renew pads. Check 3. Adjust. Suspect fault in rear axle. Suspect fault in spring brake actuator.
Is caliper clamping on disc?
Park Brake Not Releasing

CHECK 1 Fit gauge to TP3 and TP4. Charge system. Is pressure OK? Is there a leak between the trailer brake valve and the park brake actuator? YES: NO: YES: NO: YES: NO: ACTION Check 3. Check 2. Rectify leak. Defective park brake valve. Suspect fault in spring brake actuator. Adjust.
Are pads adjusted correctly?
9804/1103
60 - 10 - 15/3
Issue 3*
CONTENTS
Fastrac
Safety Precautions
Before working on the air system, always observe the following precautions: 1 2 Stop the engine and chock all four wheels. Take care if disconnecting an air hose containing pressure as it may whip as air escapes. Never remove or dismantle a component until air pressure has been exhausted and you have read and understood the recommended procedures. Wear safety glasses when working with air pressure.
FASTRAC 1115 & 1135 Introduction

For diagnostic purposes the air system is fitted with a test point up-stream of the trailer brake reservoir. Diagnosis of system faults requires the use of suitable gauges. A service kit of gauges, hoses and fittings is available as JCB Service Tool 892/00311. The system air pressure should be 8 bar (120 lbf/in2). General air leaks are usually audible with the engine stopped. For smaller air leaks on valves, soak the valve in soap solution and watch for the formation of bubbles. The illustration below will aid identification of the components mentioned in the fault finding procedure.
! WARNING
BRAK-8-9
Component Key C D E F G H K P R T Unloader Valve Silencer Low air pressure switch Test Point Wet Tank (Trailer Brake Reservoir) Auto-drain Valve Circuit Protection Valve Dry Tank (Tractor Supplies Reservoir) Manual Drain Valve Alcohol Injector
9804/1103
60 - 10 - 15/4
Issue 1
CONTENTS
Fastrac
FASTRAC 1115 & 1135 Fault Finding - Brakes (continued)
Service Brakes - Low Pressure Warning Lights On

CHECK 1 Are both warning lights (1 and 2) on? YES: NO: NO: ACTION All the time. Check 2. Check 4. But intermittently when the foot brake in pressed. Check the acumulator(s) on the faulty circuit(s). Mend the leak. Check 3. Check pressure switch(es) and circuits. Remove valve. Fit new O rings and check for debris inside. Clean and reset valve to correct pressure.
Is there a leak between the steer/suspension pump and the pressure maintenance valve? Install a pressure gauge into the pressure maintenance valve (brakes, suspension, differential lock). Does the gauge indicate the correct pressure (see Data)?
YES: NO: YES: NO:
Note: If the correct pressure cannot be achieved, check the pump flow and pressure
Are the oil pipes from the foot brake valve to the pressure maintenance valve broken/leaking?
YES: NO:
Carry out remedial work. Check the pressure switch.
Trailer Brakes - Low Pressure Warning Light On

CHECK 1 Is the low air pressure warning light (3) on? YES: NO: YES: NO: YES: NO: YES: NO: ACTION Check 2. Check 4. Rectify leak. Check 3. Renew defective unloader valve. Strip and examine compressor. Renew circuit protection valve. System now OK.
Is there a leak between the compressor and the circuit protection valve? Is air continually pumping from unloader valve exhaust?
Drain air from complete system. Does the trailer brake air tank fail to re-charge?
Service Brakes Poor

CHECK 1 Do disc pads have a minimum of 3 mm (0.12 in) friction material? Is the brake pressure correct at pressure maintenance valve? Have brakes been bled? YES: NO: YES: NO: YES: NO: YES: NO: ACTION Check 2. Renew pads (in complete axle sets). Check 3. Adjust valve. Check 4. Bleed brakes. Check 5 Replace the footbrake valve
Fit a pressure gauge in place of the bleed screw into one caliper on the front and rear axles. Press the foot pedal. Is full pressure being seen? Are the accumulators faulty? (See Service Manual Section S, Gas Spring and Accumulators, Testing for procedure.)
YES: NO:
Replace faulty accumulator(s). Bleed brakes.
9804/1103
60 - 10 - 15/5
Issue 1
CONTENTS
Fastrac

CHECK 1 Are disc pads within wear limits? YES: NO: YES: NO: YES: NO: ACTION Check 2. Renew pads. Check 3. Adjust. Suspect fault in rear axle. Check and adjust linkage.
Are pads adjusted correctly?
Is caliper clamping on disc?

CHECK 1 Check condition of front brake pads/discs. Are they serviceable? Have the brakes been bled? YES: NO: YES: NO: YES: NO: YES: NO: ACTION Check 2. Replace pads/discs as required. Check 3. Bleed brakes. Check 4. Adjust valve. Check to see if the caliper pistons have seized. If necessary, carry our repairs. Check the hydraulic foot brake valve.
Is the pressure setting of the pressure maintenance valve correct? Fit a pressure gauge in place of the bleed screw in one of the front calipers. With the foot brake pedal fully depressed, is fuel system pressure indicated?
Poor Rear Brakes, Good Front Brakes

CHECK 1 Check condition of rear brake pads/discs. Are they serviceable? Have the brakes been bled? YES: NO: YES: NO: YES: NO: YES: NO: ACTION Check 2. Replace pads/discs as required. Check 3. Bleed brakes. Check 4. Adjust valve. Check to see if the caliper pistons have seized. If necessary, carry our repairs. Check the hydraulic foot brake valve.
Is the pressure setting of the pressure maintenance valve correct? Fit a pressure gauge in place of the bleed screw in one of the rear calipers. With the foot brake pedal fully depressed, is fuel system pressure indicated?
9804/1103
60 - 10 - 15/6
Issue 1
CONTENTS
Fastrac
Trailer Brakes Poor

CHECK 1 Fit a pressure gauge to the air system test point. Is the reading correct? YES: NO: ACTION Check 2. Check for air leaks, the unloader valve or the compressor. Check 3. Check the coupling and the pipework feeding it. Trailer brakes faulty. Check 4. Check 5. Rectify the fault. The trailer brake valve is faulty. Check the pilot circuit pipework and the shuttle valve.
Fit a gauge to trailer coupling TS. Is the gauge reading system pressure? Fit the gauge to trailer coupling TC. With the foot brake pedal pressed, is the gauge reading system pressure? Are the tractor service brakes operating correctly?
YES: NO: YES: NO: YES: NO: YES: NO:
Is there hydraulic pressure at the pilot port of the trailer brake valve?
9804/1103
60 - 10 - 15/7
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 10 - 15/8
2000 Series, 3000 Series Fault Finding - Brakes Introduction

Note: The illustration below shows the component layout on the right side of Fastrac 2115, 2125 and 2135 machines. On Fastrac 2150 and 3000 series machines the components are on the left side and are a mirror image of the layout below. For diagnostic purposes the air brake system is fitted with five test points, one on each brake circuit reservoir (TP1, TP2) one on the trailer/parking brake reservoir (TP3) and two on the foot brake air valve (TP4, TP5). Diagnosis of system faults requires the use of suitable gauges (three are usually sufficient). A service kit of gauges, hoses and fittings is available as JCB Service Tool 892/00311. The brake system air pressure should be 8 bar (120 lbf/in2). General air leaks are usually audible with the engine stopped. For smaller air leaks on valves, soak the valve in soap solution and watch for the formation of bubbles. The illustration below will aid identification of the components mentioned in the fault finding procedure. Component Key C D E F G1 G2 G3 K1 K2 Air Dryer/Unloader Valve System Reservoir Schrader Valve Circuit Protection Valve Front Circuit Reservoir Rear Circuit Reservoir Trailer/Parking Brake Reservoir Front Brake Air/Hydraulic Actuator Rear Brake Air/Hydraulic Actuator
Safety Precautions
Before working on or around the brake system, always observe the following precautions: 1 2 Stop the engine and chock all four wheels. When the air system is being exhausted, keep hands away from the parking brake actuator pushrod and caliper, as they may move and trap your fingers. Take care if disconnecting an air hose containing pressure as it may whip as air escapes. Never remove or dismantle a component until air pressure has been exhausted and you have read and understood the recommended procedures. Wear safety glasses when working with air pressure.
! WARNING
3 4
BRAK 8-3/1
Pressure Reducing Valve (Failure Conscious) Trailer Brake Air Valve Tractor Services Reservoir Non-return Valve Test Point, Front Circuit (not shown) (on rear of G1) Test Point, Rear Circuit (not shown) (on rear of G2) Test Point, Trailer and Parking Brake Circuit (not shown) (on rear of G3) TP4 Test Point, Front Circuit TP5 Test Point, Rear Circuit Note: For positions of TP4 and TP5 see Foot Brake Air Valve Removal and Replacement. F
N P U V TP1 TP2 TP3
K2 K1
C P E
D G3
G2
A258160
G1
9804/1103
60 - 10 - 15/8
8020 - G/3-1.3
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 10 - 15/9
2000 Series, 3000 Series Fault Finding - Brakes (contd) Low Pressure Warning Lights On
CHECK 1 2 3 4 5 Are all three warning lights on? Is there a leak between the compressor and the circuit protection valve? Is air continually pumping from air dryer/unloader valve exhaust? If only one light is on, pressure test relevant tank. Is pressure OK? Drain air from complete system. Recharge. Does fault still exist? YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: ACTION Check 2. Check 4. Rectify leak. Check 3. Renew defective air dryer/unloader valve. Strip and examine compressor. Renew defective low pressure switch. Check 5. Renew circuit protection valve. System now OK.
Service Brakes Poor

CHECK 1 2 Do disc pads have a minimum of 3 mm (0.12 in) friction material? Do both brake fluid reservoirs have adequate fluid? YES: NO: YES: NO: YES: NO: YES: NO: ACTION Check 2. Renew pads (in complete axle sets). Check 3. Top up and check for leaks. Check 4. Bleed brakes. Check 5 Check that air system pressure is reaching the circuit protection valve. If not check for a leak in the circuit from the compressor. If pressure is reaching the circuit protection valve check the valve for faults. Check 6. Strip and inspect actuator(s). Fit a new valve. Bleed brakes.
3 4
Have brakes been bled? Fit a gauge first to TP1 and then to TP2 . Does the gauge indicate that air system pressure is reaching the footbrake valve.
5 6
Are air/hydraulic actuators functioning? Is there evidence of oil leakage at the failure conscious pressure relief valve?
YES: NO: YES: NO: .

CHECK 1 Fit a gauge to TP1. Charge system. Does TP1 reach system pressure? Operate footbrake. Does the front air/hydraulic actuator function? Is there evidence of oil leakage at the failure conscious pressure relief valve? Has the front hydraulic circuit been bled? YES: NO: YES: NO: YES: NO: YES: NO: ACTION Check 2. Check for leaks or faulty circuit protection valve. Check 3. Check footbrake valve. Fit a new valve. Check 4. Check operation of the caliper and serviceability of the brake friction pads. Bleed front hydraulic circuit.
3 4
9804/1103
60 - 10 - 15/9
8020 - G/3-2.1
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 10 - 15/10
2000 Series, 3000 Series Fault Finding - Brakes (contd) Poor Rear Brakes, Good Front Brakes
CHECK 1 2 3 4 Fit a gauge to TP2. Charge system. Does TP2 reach system pressure? Operate footbrake. Does the rear air/hydraulic actuator function? Is there evidence of oil leakage at the failure conscious pressure relief valve? Has the rear hydraulic circuit been bled? YES: NO: YES: NO: YES: NO: YES: NO: ACTION Check 2. Check for leaks or faulty circuit protection valve. Check 3. Check footbrake valve. Fit a new valve. Check 4. Check operation of the calipers and serviceability of the brake friction pads. Bleed rear hydraulic circuit.
Trailer Brakes Poor

CHECK 1 2 3 4 Fit gauge to TP3. Charge system. Is tank up to system pressure? Drain air from complete system. Recharge. Is tank up to system pressure? Fit gauges to trailer tappings TS and TC . Is TS at system pressure? Operate footbrake. Is TC at system pressure? YES: NO: YES: NO: YES: NO: YES: NO: ACTION Check 3. Check 2. System now OK. Renew circuit protection valve. Check 4. Defective trailer brake valve. Fault on trailer brakes. Defective trailer brake valve.

CHECK 1 2 3 Do disc pads have a minimum of 3 mm (0.12 in) friction material? Are pads adjusted correctly? Is caliper clamping on disc? YES: NO: YES: NO: YES: NO: ACTION Check 2. Renew pads. Check 3. Adjust. Suspect fault in rear axle. Suspect fault in spring brake actuator.
Park Brake Not Releasing

CHECK 1 2 3 Fit gauge to TP1 and TP3. Charge system. Is pressure OK? Is there a leak between the trailer brake valve and the park brake actuator? Are pads adjusted correctly? YES: NO: YES: NO: YES: NO: ACTION Check 3. Check 2. Rectify leak. Defective park brake valve. Suspect fault in spring brake actuator. Adjust.
9804/1103
60 - 10 - 15/10
8020 - G/3-3.1
Issue 1
CONTENTS
* 125,
Fastrac
135, 145, 150, 155, 185
Fault Finding - Steering
Introduction
Before assuming that the steering box or the pump is the cause of a steering problem, ensure that all other steering system faults have been rectified. Carry out the following checks before using the fault finding procedure: 1 2 3 Question the driver and drive the machine to establish the exact nature of the fault. Check that the hydraulic oil level is correct and that there are no signs of oil leakage from the circuit. Check that the steering box mountings and all linkages are correctly tightened.
Heavy Steering
CHECK 1 Is the front axle overloaded? YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: ACTION Reduce load. Check 2. Check 3. Replace / inflate tyres. Check 4. Lubricate and free off. Check 5. Clean out debris. Check for dirt at relief valve. Check 6. Check for flow control valve sticking and check 11. Check 7. Check 8. Free off / check universal joint phasing. Check 9. Adjust. Check 10. Renew parts as required. Renew seals. Check 11. Check cooler and pipework for free flow. Suspect fault in steering box.
Are the correct tyres fitted and correctly inflated?
Are the steering swivels free?
Is the oil cooler free of air blockage?
Is the pump relief valve pressure too low?
Is the pump flow rate too low?
Is the steering column turning freely?
Is front wheel alignment correct?
Are suspension and steering geometry correct?
10
Is steering box leaking oil?
11
Is oil temperature high?
9804/1103
60 - 10 - 16/1
Issue 3*
CONTENTS
* 125,
Fastrac
135, 145, 150, 155, 185
Fault Finding - Steering (continued)
Steering Wander or Free Play

If the fault is wander, start at check 1. If the fault is free play, start at check 4. CHECK 1 Is the rear axle overloaded? ACTION YES: Reduce load. NO: Check 2. YES: Check 3. NO: Replace / inflate tyres. YES: Check 4. NO: Adjust. YES: Tighten or renew. NO: Check 5. YES: Check 6. NO: Check condition of flow control. YES: Bleed out air (see Service Manual). NO: Suspect fault in steering box.
Is the front wheel alignment correct?
Are the column or steering linkages worn or loose?
Is the pump flow correct?
Is air trapped in the hydraulic oil?
9804/1103
60 - 10 - 16/2
Issue 4*
CONTENTS CONTENTS
Fastrac
60 - 10 - 17/1
* FASTRAC 1115, 1135, 2115, 2125, 2135, 2150 Fault Finding - Steering
Introduction
Before assuming that the steering control unit or the pump is the cause of a steering problem, ensure that all other steering system faults have been rectified. Carry out the following checks before using the fault finding procedure: 1 2 3 Question the driver and drive the machine to establish the exact nature of the fault. Check that the hydraulic oil level is correct and that there are no signs of oil leakage from the circuit. Check that the steering box mountings and all linkages are correctly tightened.
Heavy Steering
CHECK 1 Is the front axle overloaded? YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: YES: NO: ACTION Reduce load. Check 2. Check 3. Replace / inflate tyres. Check 4. Lubricate and free off. Check 5. Clean out debris. Check for dirt at relief valve. Check 6. Check for flow control valve sticking and check 10. Check 7. Check 8. Free off / check universal joint phasing. Check 9. Adjust. Check 10. Renew parts as required. Check cooler and pipework for free flow. Suspect fault in steering control unit.
10
9804/1103
60 - 10 - 17/1
Issue 2*
CONTENTS CONTENTS
Fastrac
60 - 10 - 17/2
* FASTRAC 1115, 1135, 2115, 2125, 2135, 2150 Fault Finding - Steering (continued)

If the fault is wander, start at check 1. If the fault is free play, start at check 4. CHECK 1 Is the rear axle overloaded? ACTION YES: Reduce load. NO: Check 2. YES: Check 3. NO: Replace / inflate tyres. YES: Check 4. NO: Adjust. YES: Tighten or renew. NO: Check 5. YES: Check 6. NO: Check condition of flow control. YES: Bleed out air (see Service Manual). NO: Suspect fault in steering control unit.
9804/1103
60 - 10 - 17/2
Issue 2*
CONTENTS CONTENTS
Fastrac
60 - 10 - 18/1
2000 Series Fault Finding - Steering (Front Axle)
Introduction
Before assuming that the steering control unit or the pump is the cause of a steering problem, ensure that all other steering system faults have been rectified. Follow the fault finding procedure on the next page but first carry out the following checks: 1 Question the driver and drive the machine to establish the exact nature of the fault. Check that the hydraulic oil level is correct and that there are no signs of oil leakage from the circuit. Check that the steering linkages are correctly tightened.
9804/1103
60 - 10 - 18/1
8020 - H/3-1.2
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 10 - 18/2
2000 Series Fault Finding - Steering (Front Axle) (contd)
Heavy Steering
CHECK 1 Is the front axle overloaded? ACTION YES: Reduce load. NO: Check 2. YES: Check 3. NO: Replace / inflate tyres. YES: Check 4. NO: Lubricate and free off. YES: Check 5. NO: Clean out debris. YES: Check for dirt at relief valve. NO: Check 6. YES: Check for flow control valve sticking and check 10. NO: Check 7. YES: Check 8. NO: Free off / check universal joint phasing. YES: Check 9. NO: Adjust. YES: Check 10. NO: Renew parts as required. YES: Check cooler and pipework for free flow. NO: Suspect fault in steering control unit.
10

If the fault is wander, start at check 1. If the fault is free play, start at check 4. CHECK 1 Is the rear axle overloaded? ACTION YES: Reduce load. NO: Check 2. YES: Check 3. NO: Replace / inflate tyres. YES: Check 4. NO: Adjust. YES: Tighten or renew. NO: Check 5. YES: Check 6. NO: Check condition of flow control. YES: Bleed out air. NO: Suspect fault in steering control unit.
9804/1103
60 - 10 - 18/2
8020 - H/3-2.2
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 10 - 18/3
2115, 2125, 2135 Fault Finding - Steering (Front Axle, 4WS) Introduction
Panel Self-Test When the ignition is first switched on, all the indicator lamps should light and the buzzer should sound for half a second as a test. Replace any faulty lamps and rectify an inoperative buzzer. During operation, if the red cross X lights up or if the buzzer sounds continually, a steering system fault is indicated. Only if the green tick Y is lit, as an indication that the system is functioning correctly, should the machine be used. Fuses The circuits associated with the 4WS system are covered by the following fuses. (For locations see Section C.) 4WS Main Supply Alternator Supply Axle Lock Switch Supply Axle lock air solenoid valve Sprayer or implement override 1 kph and 20 kph signal from instrument cluster Draft control override
Fuse X (5 Amp)
Fuse C4 (15 Amp) Fuse A6 (5 Amp)
If the fault continues, use the table below to trace and rectify the cause.
Diagnosis
FAULT 1 2WS selected but rear wheels remain off-centre when the machine is driven above 1 kph. ACTION 1 This is likely to be an electrical fault. To get the machine going the rear wheels can be centralised and locked manually as follows: 1.1 Make sure that there is no air pressure to the axle lock. Air pressure should normally be released when the 2WS button is pressed but if air pressure fails to release, disconnect the electrical supply from the air solenoid valve. 1.2 Disconnect the electrical supply from the each of the two 4WS hydraulic valve solenoids. 1.3 Start the engine and set to low idle.
! WARNING
Keep clear of the rear wheels when the engine is running as you could be injured by unexpected wheel movement.
HYD ST 5-5
1.4 Operate the 4WS hydraulic valve by pushing a suitable piece of rod or a small screwdriver into either access hole in the solenoid valves until the rear wheels steer to the centre and the lock is heard to click into place. (Trial and error will determine which solenoid is the correct one.) 1.5 Once the rear wheels are locked, the machine can be driven safely on the road and used to perform normal duties in 2WS until the 4WS system can be repaired.
9804/1103
60 - 10 - 18/3
8020 - H/4-1.1
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 10 - 18/4
2115, 2125, 2135 Fault Finding - Steering (Rear Axle, 4WS) (contd)
FAULT 2 Red X lights up and buzzer sounds
ACTION 2 This indicates a fault in either a front or rear 4WS sensor (potentiometer), or in the sensor wiring harness. 4WS will not work when the red X is showing. If the fault is intermittent, the warning can be cleared by turning the ignition switch off and on. The system will then operate normally until the fault re-occurs. To trace the fault: 2.1 Disconnect the front axle sensor from the wiring harness swivel connector. Substitute a known sensor and manually turn to approximately half way. Switch on the ignition (no need to start the engine). If the green tick is now showing, the original front axle sensor is at fault and should be renewed. Note: When a sensor has been changed the system must be re-calibrated (see Sensors, Section C). 2.2 Repeat step 2.1 for the rear axle sensor. 2.3 If both sensors are functional and the fault remains, there is a fault in the wiring harness. Remove the Electronic Control Unit (ECU) from the B post and disconnect the machine wiring harness. Trace the fault by simple continuity tests from this point down to the swivel connectors at the sensors. 2.4 If both sensors and wiring harness are OK then the fault must be in the ECU. This cannot be serviced and must be renewed as a complete unit. Note: A fault in the ECU is extremely unlikely and the unit should not be renewed unless it is absolutely certain that it is at fault.
Note: A buzzer may be heard (without the red cross showing) if a foot is resting on the clutch pedal. This is a warning of operator malpractice and should not be confused with a machine fault indication.
9804/1103
60 - 10 - 18/4
8020 - H/4-2.1
Issue 1
CONTENTS
CONTENTS
Fastrac
60 - 10 - 18/5
2115, 2125, 2135 Fault Finding - Steering (Rear Axle, 4WS) (contd)
FAULT 3 4WS Fails to engage, rear axle remains locked in 2WS ACTION 3 Check the Diagnostic LEDs
3.1 Remove the 4WS control panel to reveal the diagnostic LEDs (see Diagnostic LEDs). 3.2 When the ignition switch is turned on, LEDs 2 and 3 should be on, indicating the rear axle is locked and the machine is stationary. 3.3 When the engine is started, LEDs 2, 3 and 5 should be on (LED 5 indicates engine running.) 3.4 When an attempt to select 4WS is made, LED 6 should come on (air solenoid valve signal) and LEDs 7 and 8 should cycle off in turn. Check each of the 4WS modes and crab steer in turn. If each of the LEDs operates in the sequence shown above, then check for the following faults: a) Rear axle power track rod lock failed to release. b) Rear axle power track rod switch has failed. c) 4WS electronics out of calibration. d) The rear axle sensor mechanical linkage has developed backlash. a a1 a2 a3 Rear axle power track rod lock failed to release. Check that air pressure is present at the power track rod feed. In 2WS there should be no pressure. As 4WS is selected, pressure should be present to unlock the axle. If no pressure is detected, check the air solenoid valve (inside cab) is operating correctly. Rear axle power track rod switch has failed. If the power track rod lock has released but the switch has failed to signal the ECU, the rear wheels will be seen to dither ( slowly oscillate from side to side) while the 4WS selection is being made. The switch may be out of adjustment and can be checked by removing the copper washer fitted behind the switch. If the switch still fails to operate, a replacement is required. Be sure to replace the copper washer if a new switch is fitted. If the unit still fails to operate, check the wiring harness continuity. 4WS electronics out of calibration. As 4WS selection is attempted, observe LEDs 7 and 8. The LEDs should cycle on and off in turn. If there is a bias towards one of the LEDs or if one of the LEDs remains lit continually, then the 4WS electronic panel is out of calibration. Calibration is normally needed only after sensors or control unit have been dismantled. If frequent calibration is needed, the rear axle sensor has probably developed backlash. The rear axle sensor mechanical linkage has developed backlash. Remove sensor (potentiometer) top cover. Check the sensor linkage for backlash by fitting an open ended spanner over the spindle where it protrudes above the sensor. Apply moderate pressure in each direction. There should be no detectable backlash.
b) b1
b2
b3
b4 c) c1
d)
9804/1103
60 - 10 - 18/5
8020 - H/4-3.2
Issue 2*
CONTENTS CONTENTS
Fastrac
60 - 10 - 18/6
2115, 2125, 2135 Fault Finding - Steering (Rear Axle, 4WS) (contd) Diagnostic LEDs
O/R
X
O/R 2
Fm
4
T
4
SP P5
A A
BP
TP P CT1
5
CT3 B CT2
AWS
1.75
AD
AE Q
A243471
2
9804/1103
8
8020 - H/5-1.1
A249140
60 - 10 - 18/6
Issue 1
CONTENTS
CONTENTS
Fastrac
60 - 10 - 18/7
2115, 2125, 2135 Fault Finding - Steering (Rear Axle, 4WS) (contd) Diagnostic LEDs (contd)
Eight diagnostic LEDs can be found by removing the front panel of the Electronic Control Unit as shown on page 60 - 10 - 18/6. LED Number 1 LED Name Draft Control or Sprayer Override a) OR b) Indication when ON On when linkage override button 2 (illustration X) is pressed and linkage is down.
On when linkage override button (2) is pressed and sprayer or implement remote switch is closed. Note: Active 2WS is operative when LED is on.
Rear axle lock signal
On when rear axle is locked in 2WS.
20 kph Override
On at forward speeds under 20 kph. Goes off at speeds over 20 kph.
1 kph Override
On at forward speeds over 1 kph. Goes off at speeds less than 1 kph.
Not Used
Rear axle unlock - Air solenoid valve signal
On when air solenoid valve (AE) is energised to unlock the rear axle.
Hydraulic solenoid valve signal
On when the proportional valve (SP) is energised to turn the rear wheels to the left. Note: In 4WS steer mode (not crab) the machine will turn to the right.
Hydraulic solenoid valve signal
On when the proportional valve (SP) is energised to turn the rear wheels to the right. Note: In 4WS steer mode (not crab) the machine will turn to the left.
9804/1103
60 - 10 - 18/7
8020 - H/5-2.2
Issue 2*
CONTENTS CONTENTS
Fastrac
60 - 10 - 19/1
3000 Series Fault Finding - Steering
Introduction
Before assuming that the steering box or the pump is the cause of a steering problem, ensure that all other steering system faults have been rectified. Follow the fault finding procedure on the next page but first carry out the following checks: 1 Question the driver and drive the machine to establish the exact nature of the fault. Check that the hydraulic oil is clean and to the correct and that there are no signs of oil leakage from the circuit. Check that the steering box mountings and all steering and suspension linkages are correctly tightened.
9804/1103
60 - 10 - 19/1
8020 - H/31-1.1
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 10 - 19/2
3000 Series Fault Finding - Steering (contd) Heavy Steering

CHECK 1 Is the front axle overloaded? ACTION YES: Reduce load. NO: Check 2. YES: Check 3. NO: Replace / inflate tyres. YES: Check 4. NO: Lubricate and free off. YES: Check 5. NO: Clean out debris. YES: Check for dirt at relief valve. NO: Check 6. YES: Check for flow control valve sticking and check 11. NO: Check 7. YES: Check 8. NO: Free off / check universal joint phasing. YES: Check 9. NO: Adjust. YES: Check 10. NO: Renew parts as required. YES: Renew seals. NO: Check 11. YES: Check cooler and pipework for free flow. NO: Suspect fault in steering box.
10
Is steering box leaking oil?
11

If the fault is wander, start at check 1. If the fault is free play, start at check 4. CHECK 1 Is the rear axle overloaded? ACTION YES: Reduce load. NO: Check 2. YES: Check 3. NO: Replace / inflate tyres. YES: Check 4. NO: Adjust. YES: Tighten or renew. NO: Check 5. YES: Check 6. NO: Check condition of flow control. YES: Bleed out air. NO: Suspect fault in steering box.
9804/1103
60 - 10 - 19/2
8020 - H/31-2.1
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 15 - 01/1
* 125,
135, 145, 150, 155, 185
UK Machines to serial No. 635329
Electrical Circuit - Component Key

1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 Battery 1 Battery 2 Beacon Switch Illumination Rear Working Light Switch Illumination Left Hand Window Switch Illumination Right Hand Window Switch Illumination Side & Head Lights Switch Illumination Alternator Starter Switch Thermostart Starter Motor Starter Solenoid Inhibit Start Relay 1 Inhibit Start Relay 2 Neutral Start Switch Fuse A5 Engine Shut Off Solenoid Rear Power Take Off Switch Front Power Take Off Switch 2-Wheel Drive/Diff Lock Switch Rear Power Take Off Drive Solenoid Rear Power Take Off Brake Solenoid Front Power Take Off Drive Solenoid Front Power Take Off Brake Solenoid Diff Lock Solenoid 2-Wheel Drive Solenoid Fuse A8 2-Wheel Drive Dump Switch Instrument Cluster Fuse C4 Buzzer Tachometer Feed Alternator Warning Feed Blocked Air Filter Switch Handbrake Switch Test Button Diff Locked Switch Engine Oil Pressure Switch Fuel Level Sender Low Air Tank 1 Switch Low Air Tank 2 Switch Low Air Tank 3 Switch Water Temperature Sender Brake Front Reservoir Switch Brake Rear Reservoir Switch Transmission Oil Filter Switch Transmission Low Oil Pressure Switch Fuse A2 Left Hand Brake Light Switch Right Hand Brake Light Switch 52 53 54 55 56 57 58 59 60 61 62 63 65 66 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 Left Hand Brake Light Right Hand Brake Light Trailer Socket, Brake Light Speedometer Speedometer Illumination Speed Transducer Left Hand Reversing Light Right Hand Reversing Light Reversing Light Switch Fuse C1 Fuse A6 Beacon Switch Beacon Light Beacon Motor Flasher Unit Hazard Switch Fuse C2 Fuse B2 L H Direction Indicator, Front L H Direction Indicator, Rear L H Direction Indicator, Repeater Trailer Socket, L H Direction Indicator R H Direction Indicator, Front R H Direction Indicator, Rear R H Direction Indicator, Repeater Trailer Socket, R H Direction Indicator Direction Indicator Switch Fuse A7 Window Switch, Right Hand Window Motor, Right Hand Window Switch, Left Hand Window Motor, Left Hand Compressor Low Pressure Switch High Pressure Switch Heater Air Conditioner Air Conditioner Relay Fuse B9 Fuse B7 In Line Fuse 1 In Line Fuse 2 In Line Fuse 3 Auxiliary Socket 1 Auxiliary Socket 2 Auxiliary Socket 3 Front Work Light Switch Illumination Rear Fog Light Switch Illumination Fuse A3 Radio (Optional) Radio Illumination (Optional) Left Hand Speaker (Optional) Right Hand Speaker (Optional) Front Left Hand Side Light 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 Rear Left Hand Side Light Left Hand Number Plate Light Right Hand Number Plate Light Fuse C5 Road Lights Switch Left Hand Rear Fog Lamp Right Hand Rear Fog Lamp Trailer Socket, Fog Lamp Fog Lamps Switch Trailer Socket, L H Side Light Trailer Socket, R H Side Light Front Right Hand Side Light Rear Right Hand Side Light Fuse C6 Front Work Light Relay Front Work Light Switch Fuse B3 Left Hand Front Work Light Right Hand Front Work Light Rear Wiper Intermittent Relay Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Motor Fuse B1 Electronic Draft Control Connector Left Hand Interior Light Right Hand Interior Light Left Hand Door Switch Right Hand Door Switch Trailer Socket, Battery Negative Left Hand Dip Beam Right Hand Dip Beam Fuse B6 Dip Switch Left Hand Main Beam Right Hand Main Beam Fuse C7 Head Light Flasher Fuse B5 Rear Work Light Relay Rear Work Light Switch Fuse B4 Left Hand Rear Work Light Right Hand Rear Work Light Horn Horn Push Front Wiper Intermittent Relay Front Wiper Motor Front Wiper Switch Fuse A4 Front Washer Motor Front Washer Push Fuse C3
9804/1103
60 - 15- 01/1
Issue 3*
CONTENTS CONTENTS
* 125,
Fastrac
60 - 15 - 01 2
135, 145, 150, 155, 185

? ? ?@@? ?@@?
UK Machines to serial no. 635329

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Electrical Circuit
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W@@@@@H?hf@? ?@@? ?@H?hf?@@@(M I4@@0M ?@@?he@@@@@@hf?N@@@@@@@@@@@@@@@(Y?he@@ @@ ?@@? @@ J@ @@ ?7@? @? @? @? @@ ?@@? @@ @? @5 ?@ 3@ @? @?@? @? ?@ 7@ @?he?O2@?@@@@@6Xhe?W2@@@@@@@@6K? @@ @5 @@ ?@@??@@? @@ @H ?@6K @? @5 ?@@? @@ ?7@? @? ?@@? ?@ @@ ?@@@6X @? @? @? ?@@? @@ @1 @@ ?@@? @? @? ?@@? J@ 3@ @??J@1 ?3@? @? ?3@@@1 @? @? ?@5? @@ ?3@? @? @? ?@5? @@ ?S5?O&@@ @? ?N@@@@ ?J@? @? @@ @@ @@ 7@ ?@?J@@L? @??'@? @? @? ?@H? N@ he?J@@@@@@@@@@@@@@)X ? ?7@@@@5? @@ ?@ 7@ ?7H? @? @@@@@6X? W&@L @? @? @)X??@H? ?@L? ?J@@L? O&@@)K@@ @5 @L @? ?@L? ?@ @@@@6X @L ?@@?he?7@@@@@@@@@@@@@@@1 @? J@@@@@H? @@ 3@ O2@@@@@6X? ?@L? @? ?@@?3@@@@@)X ?O&@@)K? @? ?W2@@@)X ?@@? O&@@)K W2@@@@@@6K ?S5? ?7U? ?O2@@)K? @? ?@1? ?@ W2@ @? N@@@@@@)X? ?W2@@@@@@6K? @? O&@@@@@)K? ?@H? W2@@@@@@6X@? @1 ?W2@@@@@@6K? @? ?@5? ?@ ?@ ? @H ?N@@(Y I@ B@@H 3@ @? @? @? ?@ ?@ @? @? ?@ @@ @? @? @? 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'@H @@ ?@
9804/1103
60 - 15 - 01/2
Issue 3*
CONTENTS CONTENTS
Fastrac
60 - 15 - 01/4
* 125,
135, 145, 150, 155, 185
Electrical Circuit - Component Key
UK Machines from 635330 to 636000 All Export Machines to 636000
Note: The item numbers on this page correspond to the large numbers on the diagram. The small numbers and letters on the diagram identify terminals and connections. 104 Front Work Light Switch 51 Speedometer Transducer 1 Battery 1 105 Fuse B3 52 Left Hand Reversing Light 2 Battery 2 106 L H Front Work Light, Inner 53 Right Hand Reversing Light 3 Rear Working Light Switch 107 R H Front Work Light, Inner 54 Reversing Light Switch Illumination 108 L H Front Work Light, Outer 55 Fuse C1 4 Side & Head Lights Switch 109 R H Front Work Light, Outer 56 Fuse A6 Illumination 110 Rear Wiper Intermittent Relay 57 Fuse C9 5 Alternator 111 Rear Wash/Wipe Switch 58 Electronic Draft Control 6 Starter Switch 112 Rear Wiper Motor Connector 7 Thermostart 113 Rear Washer Motor 59 Flasher Unit 8 Starter Motor 114 Fuse B1 60 Hazard Switch 9 Starter Solenoid 115 Rear Wiper Switch Illumination 61 Fuse C2 10 Inhibit Start Relay 1 116 Interior Light 62 Fuse B2 11 Inhibit Start Relay 2 117 Left Hand Door Switch 63 L H Direction Indicator, Front 12 Neutral Start Switch 119 Trailer Socket, Battery Negative 64 L H Direction Indicator, Rear 13 Fuse A5 120 Left Hand Dip Beam 65 L H Direction Indicator, Repeater 14 Engine Shut Off Solenoid 121 Right Hand Dip Beam 66 Trailer Socket, L H Direction 15 Rear Power Take Off Switch 122 Fuse B6 Indicator 16 Front Power Take Off Switch 123 Dip Switch 67 R H Direction Indicator, Front 17 2-Wheel Drive/Diff Lock Switch 124 Left Hand Main Beam 68 R H Direction Indicator, Rear 18 Rear Power Take Off Drive 125 Right Hand Main Beam 69 R H Direction Indicator, Repeater Solenoid 126 Fuse C7 70 Trailer Socket, R H Direction 19 Rear Power Take Off Brake 132 Head Light Flasher Indicator Solenoid 133 Fuse B5 71 Direction Indicator Switch 20 Front Power Take Off Drive 134 Rear Work Light Relay 72 Compressor Solenoid 135 Rear Work Light Switch 73 Low Pressure Switch 21 Front Power Take Off Brake 136 Fuse B4 74 High Pressure Switch Solenoid 137 Rear Work Light 1 75 Heater 22 Diff Lock Solenoid 138 Rear Work Light 2 76 Air Conditioner 23 2-Wheel Drive Solenoid 139 Rear Work Light 3 77 Air Conditioner Relay 24 Fuse A8 140 Rear Work Light 4 78 Fuse B9 25 2-Wheel Drive Dump Switch 141 Horn 79 Fuse B7 26 Instrument Cluster 142 Horn Push 80 Auxiliary Socket 27 Fuse C4 143 Front Wiper Intermittent Relay 81 Front Work Light Switch 28 Alternator Warning Feed 144 Front Wiper Motor Illumination 29 Blocked Air Filter Switch 145 Front Wiper Switch 82 Rear Fog Light Switch Illumination 30 Handbrake Switch 146 Fuse A4 83 Fuse A3 31 Test Button 147 Front Washer Motor 84 Radio (Optional) 32 Diff Lock Switch 148 Front Washer Switch 85 Radio Illumination (Optional) 33 Engine Oil Pressure Switch 149 Fuse C3 86 Left Hand Speaker (Optional) 34 Fuel Level Sender 150 Fuse B8 87 Right Hand Speaker (Optional) 35 Low Air Tank 1 Switch 151 Fuse A9 88 Front Left Hand Side Light 36 Low Air Tank 2 Switch (when 152 Tachograph (if fitted) 89 Rear Left Hand Side Light fitted) 153 Panel Light 1 90 L H Number Plate Light 37 Low Air Tank 3 Switch 154 Panel Light 2 91 R H Number Plate Light 38 Water Temperature Sender 155 Panel Light 3 92 Fuse C5 39 Brake Front Reservoir Switch 156 Panel Light 4 93 Road Lights Switch 40 Brake Rear Reservoir Switch 157 Air Tank Gauge Illumination (If 94 L H Rear Fog Lamp 41 Transmission Oil Filter Switch fitted) 95 R H Rear Fog Lamp 42 Transmission Low Oil Pressure 158 L H Marker Light 96 Trailer Socket, Fog Lamp Switch 159 R H Marker Light 97 Fog Lamps Switch 43 Fuse A2 160 Fuse C8 98 Trailer Socket, Left Hand Side 44 Left Hand Brake Light Switch 161 Buzzer Light 45 Right Hand Brake Light Switch 162 Fuse A1 99 Trailer Socket, Right Hand Side 46 Left Hand Brake Light 163 4WD Warning Light Relay Light 47 Right Hand Brake Light 164 Second Trailer Direction Indicator 100 Front Right Hand Side Light 48 Trailer Socket, Brake Light Warning Light 101 Rear Right Hand Side Light 49 Speedometer 165 Tachometer Feed 102 Fuse C6 50 Speedometer Illumination 103 Front Work Light Relay Note: Item 50 is for the analogue speedo. The optional digital speedo does not have separate illumination but in other respects is wired as the analogue speedo.
9804/1103
60 - 15 - 01/4
Issue 4*
CONTENTS CONTENTS
Fastrac
60 - 15 - 01/5
2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams Introduction
As an aid to fault finding and repair of wiring, the sectional diagrams show every wire and wire number on the machine together with all the harness connectors and the pins to which each wire is connected. In order to show this amount of detail the sectional diagrams are spread over a series of figures (12-1 to 12-42), details of which are listed under Contents. The first figure shows the main feed from the batteries to the starter motor, alternator and fuses etc. The second figure shows the common earth returns to the battery. The remaining figures show fused circuits, usually starting from the relevant fuse. The key for the diagrams is listed under Component Key. The page should be used in conjunction with the sectional diagrams. The diagram extracts on page 60-15-01/6 show examples of the way various items are identified on individual diagrams, as follows: i The item numbers shown in large bold type correspond to the numbers in the component key, e.g. Item 131 denotes Trailer Socket Reverse Light Relay (view A). Fuses are denoted by alpha-numeric annotations in bold type, e.g. C1 (view A). Wire numbers are shown in smaller plain type alongside the lines representing wires on the diagram. The wire number is followed by a number in brackets indicating the wire size. e.g. 877 (0.6) (view A ). Where lines representing wires intersect, there is no electrical joint unless a solid black circle is shown at the point of intersection (view B). Where a cross reference is required from one figure to another, an arrow is shown on the diagram, followed by the number of the figure where the information is continued or, for clarity, repeated e.g. 12-22 (view B). Relays are shown by the conventional relay symbol (e.g. 131) as well as the relay base (view A). The diagrams cover both 2000 Series and 3000 Series machines, except where specified otherwise. Where such a circuit differs from one series to the other (e.g. view C) the wires are shown as broken lines with an appropriate identification, i.e. 2000 SERIES and 3000 SERIES. Such an identification indicates that all machines in the range are wired in this way. If only a single model from one of the series is wired as shown, a specific identification is given, e.g. 2150 or 3155 (view D). Connectors Some connectors are featured on a number of diagrams. These and other important connectors are identified under Main Connectors. Terminal details of large connectors to the Instrument Cluster, the two Electronic Control Units (ECUs) and the Electronic Draft Control (EDC) Control Panel are given under Connector Terminals. Bulkhead and other connectors which join two harnesses are shown on the diagrams in two parts (i.e. the plug and the socket) linked by dotted lines. Each part of the connector is denoted by one or more letters (to identify the harness to which it is fitted) followed by a number, e.g. C5 denotes Chassis harness connector 5 and CR1 denotes Cab Roof harness connector 1 (view A). Pin letters and numbers are shown on the connectors to indicate the wire positions. Some other connectors on the diagrams may not be labelled. These can usually be found close to the components which they are feeding. Splices Individual harnesses incorporate splices, i.e. points where two or more wires are joined within the harness. Splices are denoted on the wiring diagrams by rectangles containing code letters, e.g. CRES3 (view A). In the majority of cases the first or first and second letters indicate the harnesses containing the splice, e.g. C = Chassis harness, CR = Cab Roof harness. Subsequent letters or letters and numbers describe the electrical function of the splice, e.g. CRES3 = earth splice 3 in the Cab Roof harness. Other codes do not include a harness reference, but simply refer to the electrical function, e.g. ASS = Alternator Supply splice, RS = raise splice. The splices are not visible without dismantling the harnesses but they are shown on the diagrams to act as cross reference points between one figure and another. The same splice may therefore appear on more than one figure to provide continuity when following a circuit. For a full list of splices refer to Splice Identification. vi
ii
iii
iv
9804/1103
60 - 15 - 01/5
8020 - C/7-1.2
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 15 - 01/6
2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams Introduction (contd)
Examples of Component Identification
131
C1
A309750
1A
12-22
2000 SERIES
11
1A
3000 SERIES
A307150
11A
A307160
D
3185 3185 2000 3155 SERIES
137
2150
138
9804/1103
60 - 15 - 01/6
8020 - C/7-2.1
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 15 - 01/7
2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams Main Connectors
Connector A2 ABS1 ABS2 AHL1 AHL2 C1 (14-pin) C1 (10-pin) C2 C4 C5 C28 CP1 CP2 CP3 CR1 Description Rear bulkhead ABS trailer socket Rear bulkhead Auxiliary lights connector Auxiliary lights connector Trailer socket Control module Control module 4WS interconnect - if fitted (2000 Series) Rear bulkhead Front bulkhead Control module Control module Control module Rear bulkhead Mating Connector ABS 2 --A2 ------CP3 CP2 CR64 CR1 CR51 --C2 C1 (10-pin) C5 Connector CR43 CR49 CR50 CR51 CR64 CR65 CR66 CR73 CR74 CR87 CR89 E1 E2 E4 E15 E16 Mating Connector Column switch --Powershift ECU 1 (Black) --Powershift ECU 2 (Red) --Front bulkhead C28 4WS option (2000 Series) C4 Instrument cluster 1 (Black) --Instrument cluster 2 (Red) --Panel - auxiliary light interconnect --Panel - auxiliary light interconnect --Vansco instrument cluster E4 Diagnostic connector --EDC ECU --Control panel --Vansco instrument cluster CR87 Bulkhead E16 Bulkhead E15 Description
Connector Terminals
Instrument Cluster CR65 (Black) Terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
9804/1103
Instrument Cluster CR66 (Red) Function Low air pressure - 2 Low brake fluid level Low air pressure - 3 Low transmission oil pressure Terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Wire 479B 512 502 414A 410 411 500A 517 423 898 485 505 484 859G 483 478B 403A 510 516 486 508 416 514F 515F 501 497 412A 513 300B 160B 710C 626 Function High range selected Fuel feed signal Fuel return signal Transmission speed signal Engine water temperature Fuel level Radar speed signal RS232 RX Buzzer out <20 kph speed trigger >3 kph speed trigger Increase wheel slip output High range Left turn signal Medium range Medium range selected Alternator charge Wheel slip setpoint RS232 TX >1 kph speed trigger Decrease wheel slip output Differential lock cut-out CANL CANH Radar presence signal Transmission speed sensor presence
Wire 406 409 408 434 899A 415 482 473 476 474 420 880B 511 402 405 444 445 440 481 857B 477B 475 861G 418 419 417 496 407 400A 404 480B 848B 509B
Differential lock solenoid Area cut-out Low range Auto Snail Hare 2WD selected Side lights Option present Low engine oil pressure Transmission oil filter blocked 540 PTO range selected 1000 PTO range selected Trailer ABS warning Reverse range Rear PTO drive selected Low range selected Tortoise Right turn signal Main beam 2nd trailer turn signal 1st trailer turn signal 4WS tracking (2000 Series - if fitted) Low air pressure - 1 Park brake ON Air filter blocked Reverse range selected Front PTO drive selected EDC lower signal
Engine rpm Program + 12V Battery + 12V ignition Battery earth Chassis earth
8020 - C/8-1.1
60 - 15 - 01/7
Issue 1
CONTENTS
Fastrac
60 - 15 - 01/8
2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams (contd) Connector Terminals (contd)
* Powershift - Electronic Control Unit (ECU) Dry Clutch Transmission CR49 (Black) Terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Wire 514 810B 400C 877 Link 1 900 435A 901 660J 125B 515 434 450 898B 476 475 474 473 660H 125A Link 2 Link 2 413 470 471 472 412B Link 1 625 447 435B 902 Function CANL Clutch down Handbrake on Reverse lamps Link to terminal 32 Snail clutch solenoid Transmission oil pressure Tortoise clutch solenoid Battery negative + 12v ignition CANH Transmission oil pressure warning Bleeper <20 kph speed trigger Snail indicator Tortoise indicator Hare indicator Auto indicator Battery negative + 12v ignition Link to terminal 26 Link to terminal 25 Accelerator pedal up Up shift switch Down shift switch Auto mode Engine rpm signal Link to terminal 7 Chassis ground Transmission oil pressure switch Transmission oil pressure switch Hare clutch solenoid * Powershift - Electronic Control Unit (ECU) Dry Clutch Transmission CR50 (Red) Terminal Wire 1 477A 2 478A 3 479A 4 480A 5 495 6 485 7 8 126 9 10 489 11 660N 12 125C 13 14 437 15 442 16 436 17 438 18 443 19 441 20 446 21 439 22 492 23 24 25 486, 486A 26 481 27 484 28 483 29 482 30 491 31 490 32 493 33 488 34 487 35 494 36 629 Function Low range selected Medium range selected High range selected Reverse range selected Clutch up >3 kph speed trigger + 12v output (air valve) Medium range neutral solenoid Battery negative + 12v ignition Low range engaged switch Medium range neutral switch Reverse range engaged switch Medium range engaged switch High range neutral switch Low range neutral switch Reverse range neutral switch High range engaged switch Low range engage solenoid
> 1 kph speed trigger Reverse range indicator High range indicator Medium range indicator Low range indicator Reverse range engage solenoid High range neutral solenoid Medium range engage solenoid Low range neutral solenoid Reverse range neutral solenoid High range engage solenoid Can bus screen
9804/1103
60 - 15 - 01/8
8020 - C/8-2.2
Issue 2*
CONTENTS
Fastrac
60 - 15 - 01/8A
Powershift - Electronic Control Unit (ECU) Wet Clutch Transmission CR49 (Black) Terminal Wire 1 514 2 3 810B 4 400C 5 820 6 822 7 823 8 900 9 821A 10 901 11 660J 12 125B 13 14 515 15 434 16 450 17 898, 898B 18 816 19 20 21 22 523 23 660H 24 125A 25 522 26 521 27 413 28 470A 29 471A 30 472A 31 412B 32 33 625 34 35 36 902 Function CANL Clutch down Handbrake Wet clutch solenoid Wet clutch lubrication solenoid Transmission brake solenoid Snail clutch solenoid Wet clutch current sense resistor Tortoise clutch solenoid Battery negative + 12v ignition CANH Transmission oil pressure warning Buzzer 20 kph speed trigger Reversing lamps relay coil Clutch pedal potentiometer return Battery negative + 12v ignition Clutch pedal potentiometer wiper Clutch pedal potentiometer supply Throttle deceleration switch Up shift switch Down shift switch Auto mode switch Engine rpm signal EMC ground Hare clutch solenoid Powershift - Electronic Control Unit (ECU) Wet Clutch Transmission CR50 (Red) Terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Wire 477A 478A 479A 480A 435 485 526 126 524A 489 660N 125C 525 437 442 436 438 443 441 446 439 492 524B 486, 486A 491 490 493 488 487 494 629 Function Low range selected Medium range selected High range selected Reverse range selected Transmission oil pressure switch 3 kph speed trigger Transmission temperature sender 2 return Ram solenoid 12V supply Link to CN2 pin 24 Medium range neutral solenoid Battery negative +12 V ignition Transmission temperature sender 1 return Low range neutral switch Medium range neutral switch Reverse range engage switch Medium range engage switch High range neutral switch Low range neutral switch Reverse range neutral switch High range engage switch Low range engage switch Transmission oil temperature senders (link to CN2 pin 9) 1 kph speed trigger Reverse range engage solenoid High range neutral solenoid Medium range engage solenoid Low range neutral solenoid Reverse range neutral solenoid High range engage solenoid Can bus screen
9804/1103
60 - 15 - 01/8A
8020 - C/8-2A.1
Issue 2*
CONTENTS CONTENTS
Fastrac
60 - 15 - 01/9
Electronic Draft Control - Electronic Control Unit (ECU) (Type D+) E1 All 2000 Series machines to S/N 738694 2000 Series machines with radar from S/N 738695 All 3000 Series machines to S/N 640709 3000 Series machines with radar from S/N 640710 Terminal Wire 1 725 2 506 3 427 4 431 5 505 6 424 7 425 8 518 9 930 10 500B 11 414B 12 13 403B 14 15 16 509 17 922 18 19 504/504A 20 507 21 428 22 429 23 430 24 135 25 26 426 27 28 660GA 29 300A 30 31 433 32 33 34 510 35 924 36 928 37 503/503A 38 715 39 920 40 41 508 42-55 Function Draft sensor earth Control panel supply Raise limit signal Draft/position mix signal Slip setpoint increase Position sensor signal Left draft sensor signal Slip setpoint decrease Remote raise/lower switch-common Radar signal Transmission speed signal Alternator charge signal
Electronic Draft Control (EDC) (Type D+) - Control Panel E2 All 2000 Series machines to S/N 738694 2000 Series machines with radar from S/N 738695 All 3000 Series machines to S/N 640709 3000 Series machines with radar from S/N 640710 Terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Wire 431 506 507 429 428 430 504A 503A 427 433 508 Function Draft/position mix signal Power supply in Earth Setpoint level signal Control lever signal Lower speed signal Control valve lower signal Control valve raise signal Raise limit signal Diagnostic LED (+ve) Diagnostic LED (-ve)
Lower signal out Remote switch raise signal Control valve lower signal Control panel earth Control lever signal Setpoint level signal Lower speed signal +12v ignition Right draft sensor signal Battery earth +12v battery Diagnostic LED (+ve)
Slip setpoint feedback signal Control valve common Remote switch lower signal Control valve raise signal Position sensor earth Position/draft sensor supply Diagnostic LED (-ve)
9804/1103
60 - 15 - 01/9
8020 - C/8-3.1
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 15 - 01/9A
Electronic Draft Control - Electronic Control Unit (ECU) (Type B) E1 2000 Series machines not fitted with radar from S/N 738695 3000 Series machines not fitted with radar from S/N 640710 Terminal Wire 1 508/660GA 2 503/503A 3 507 4 431 5 403B 6 924 7 8 428 9 433 10 922 11 509 12 506/930 13 920 14 504/504A 15 715/725 16 429 17 425 18 426 19 424 20 928 21 22 427 23 24 430 25 135 Function Battery 0v Control valve raise signal Control panel earth Draft/position mix signal Alternator charge signal Control valve common Control lever signal Diagnostic LED+ Fender raise switch Lowered signal (area cut-out) Fender switch, control panel common Position/draft sensor supply Control valve lower signal Position/draft sensor earth Setpoint level signal Left draft sensor signal Right draft sensor signal Position sensor signal Fender lower switch Top end position signal Lower speed signal +12 v ignition 4WS - Electronic Control Module C1 - Inputs Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 C2 - Outputs Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 Pin 13 Pin 14
+12V ignition (main) Earth (main) +12V sidelights Not used +12V > 1 kph + 12V < 20 kph +12V EDC power override +12V axle locked +12V sprayer override - audible warning Not used
Left steering valve solenoid Right steering valve solenoid Axle unlock signal Front axle sensor (potentiometer)
Rear axle sensor (potentiometer) Differential lock cut-out signal Not used
Electronic Draft Control (EDC) (Type B) - Control Panel E2 2000 Series machines not fitted with radar from S/N 738695 3000 Series machines not fitted with radar from S/N 640710 Terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Wire 431 506 common 507 429 428 430 504A 503A 427 433 508 Function Draft/position mix signal Fender switch, control panel
Control panel earth Setpoint level signal Control lever signal Lower speed signal Control valve lower signal Control valve raise signal Top end position signal Diagnostic LED+ Battery 0v
9804/1103
60 - 15 - 01/9A
8020 - C/8 - 3A.2
Issue 1
CONTENTS CONTENTS
Fastrac
60 - 15 - 01/10
2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams (contd) Splice Identification
Splice ABSSS ADBS ADCOS ALES ALSS AMBS APWLS ASS ASSS AWS BATS BLS BMS CANHS CANLS CDS CES CRES CRPFS CRSIS C9CS DBS DSSS EDCES EDCS ELSS FDES FDSS FLES FLS FPDS FWLSS HSS IGNS IFWLS IRWLS ISRS LHIS LHSLS LS LSLS MBS OCES Description ABS supply splice Auxiliary dipped beam splice Area differential lock cut-out splice Auxiliary lights earth splice Auxiliary lights supply splice Auxiliary main beam splice A post work lights splice Alternator signal splice Autoshift switch splice Alternator W splice Battery splice Brake lights splice Brakes malfunction splice CAN high splice CAN low splice Clutch down splice Chassis earth splice Cab roof earth splice Cab roof permanent feed splice Cab roof start inhibit splice Fuse C9 chassis splice Dipped beam splice Downshift switch splice Electronic draft control earth splice Electronic draft control splice EDC lower signal splice Flow divider earth splice Flow divider supply splice Front lights earth splice Fog lights splice Front PTO drive splice Front working lights supply splice Hare solenoid splice Ignition splice Inner front working light supply splice Inner rear working light supply splice Inching solenoid resistor splice Left hand indicator splice Left hand side lights splice Lower splice Left side lights splice Main beam splice Option-chassis earth splice Splice OCSS OFWLS ORWLS PES PFS PHS PIS PLIS PRSFS PRHS PRIS PRLS PRMS PRRS PSSS RHIS RHSLS RLSS RPBS RPCOS RPDS RS RSLS RSS RWLSS SA SD SES SFS * SSS * SSS * SSS * SSS SWFS * TAES * TAIS TOPS * TOTS * TSS * USSS VSS 1KSS 2WDDS Description Option-chassis supply splice Outer front working lights splice Outer rear working lights splice Panel earth splice Permanent feed splice Panel headlights splice Panel ignition splice Panel left indicator splice Power range solenoid feed splice Power range high splice Panel right indicator splice Power range low splice Power range medium splice Power range reverse splice Powershift supply splice Right hand indicator splice Right hand side lights splice Reverse lights switching splice Rear PTO brake splice Rear PTO cut-out splice Rear PTO drive splice Raise splice Right side lights splice Radar signal splice Rear working lights supply splice 4WS ignition splice 4WS earth splice Starter motor earth splice Solenoid feed splice Speed signal splice (Fig. 12 - 34) Solenoid supply splice (Fig. 12 - 9) Sensor supply splice (Fig. 12 - 10) Snail solenoid splice (Fig. 12 - 13A) Switched feed splice Tractor ABS earth splice Tractor ABS ignition splice Transmission oil pressure splice Transmission oil temperature splice Tortoise solenoid splice Upshift switch splice Valve supply splice 1 kph signal splice 2WD dump splice
9804/1103
60 - 15 - 01/10
8020 - C/8-4.2
Issue 2*
CONTENTS
Fastrac
60 - 15 - 01/11
2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams (contd)
Figure No. 12 - 1 12 - 2 12 - 3 Supply Circuit Earth Circuit Fuse A1 - Neutral Start (Clutch) Fuse C6 - Starter Solenoid Fuse C9 - Air Drier; Neutral Start (Gearbox) Fuse A2 - Brake Lights Fuse A3 - Rear Wash/Wipe Fuse A4 - Front Wash/Wipe; Horn Fuse A4 (contd) Fuse A5 - Engine Shut-Off Solenoid (E.S.O.S.) (2000 Series, 3155 Dry Clutch Transmission) Fuse A5 - Engine Shut-Off Solenoid (E.S.O.S.) (2000 Series, 3155 Wet Clutch Transmission) Fuse A5 - Engine Shut-Off Solenoid (E.S.O.S.) (3185 only) - E.S.O.S. Maxifuse Fuse A6 - Electronic Draft Control (EDC) D +, Ignition Cab Side. Fuse B9 - Electronic Draft Control (EDC) D +, Battery Cab Side Fuse A6 - Electronic Draft Control (EDC) B, Ignition Cab Side. Fuse B9 - Electronic Draft Control (EDC) B, Battery Cab Side Fuse A6 - Electronic Draft Control (EDC) D+ and B, Ignition Chassis Side Fuse B9 - Electronic Draft Control (EDC) D+ and B, Battery Chassis Side Fuse A7 - Powershift ECU - 3-Speed Splitter (Dry Clutch Transmission) Fuse A7 (contd) - Powershift ECU - Selectronic (Dry Clutch Transmission) Fuse A7 - Powershift ECU - Selectronic (Wet Clutch Transmission) Fuse A7 (contd) - Powershift ECU - Selectronic (Wet Clutch Transmission) Fuse A7 (contd) - Wet Clutch Control (Wet Clutch Transmission) Fuse A7 (contd) - Powershift ECU - Selectronic Fuse A8 - Front/Rear PTO; 2WD and Differential Lock Solenoids; Rear PTO Cut-Out Rear PTO Cut-Out Option Fuse A9 - Air Conditioning Circuit Fuse B1 - Interior Lights; Radio/Cassette; Beacon Socket Fuse B2 - Hazard Warning LIghts Fuse C2 - Direction Indicators Fuse B3 - Front Work Lights Fuse B4 - Rear Work Lights Fuse B5 - Headlight Flash Fuse W (Maxifuse) - Main Lights Fuse D1 - Main Beam Fuse D2 - Dipped Beam Fuse D3 - Rear Fog Lights Fuse D4 - Side Lights (Left Side) Fuse D5 - Side Lights (Right Side) Auxiliary Lights Switching (2000 Series) Fuse D6 - Auxiliary Lights Switching (3000 Series) Fuse B6 - Radio Cassette Fuse B7 - Auxiliary Jack-Plug Socket Fuse B8 - Cigar Lighter Fuse C1 - Trailer Socket Reverse Light (Dry Clutch Transmission) Fuse C1 - Reverse Lights (Wet Clutch Transmission) Fuse C3 - Thermostart Fuse C4 - Lights Switch Illumination; Bleeper; Instrument Cluster; Differential Lock Cut-Out; Diagnostic Supply Connector; Speedo Sensor; Fuse C5 (Dry Clutch Transmission) Fuse C4 (Dry Clutch Transmission ) (contd) Fuse C4 - Lights Switch Illumination; Bleeper; Instrument Cluster; Differential Lock Cut-Out; Diagnostic Supply Connector; Speedo Sensor; Fuse C5 (Wet Clutch Transmission) Fuse C4 (Wet Clutch Transmission) (contd) Fuse C4 (contd) - Canbus; Diagnostic Connector Fuse C5 - Fuel Flow Sensor; Ground Speed Radar Sensor (Dry Clutch Transmission) Fuse C5 - Fuel Flow Sensor; Ground Speed Radar Sensor (Wet Clutch Transmission) Fuse C7 - 13-pin Trailer Socket (Ignition) Fuse C8 - 13-pin Trailer Socket (Battery) Fuses E1, E2 - Trailer ABS Fuses F1, F2, F3, F4 - Tractor ABS Fuse E3 - Flow Divider Fuse E4 - Four Wheel Steer (4WS) Circuit Trailer Sockets
12 - 4 12 - 5 12 - 6 12 - 7 12 - 8 12 - 8A 12 - 9 12 - 10 12 - 10A 12 - 11 12 - 12 12 - 13 12 - 13A 12 - 13B 12 - 13C 12 - 14 12 - 15 12 - 16 12 - 17 12 - 18 12 - 19 12 - 20 12 - 21 12 - 22 12 - 23 12 - 24 12 - 25 12 - 26 12 - 27 12 - 28 12 - 29 12 - 30 12 - 31 12 - 32 12 - 32A 12 - 33 12 - 34 12 - 35 12 - 35A 12 - 35B 12 - 36 12 - 37 12 - 37A 12 - 38 * 12 - 39 12 - 40 12 - 41 12 - 42
9804/1103
60 - 15 - 01/11
8020 - C/8-5.3
Issue 3*
Sectional Diagrams Component Key

* 67 68 69 70 71 71a
9804/1103
CONTENTS
71b 72 73 74 75 76 77 78 79 80 81 82 83 165 166 167 168 169 170 171 172 173 174
1 1A 2 3 4 5 5A 5B 6 7 8 9 9A 10 10A 11 11A 12 13 14 15 16 17 18 19 20 21 22 23 24 24A 25 26 27 27A 175 176 177 178 179 180 181 182 183 184 185 186 187 102 * * * * * * * * * * * * * 188 189 190 191 192 193 194 195 196 197 198 199 200 84 85 86 87 88 89 90 91 92 93 94 95A 95B 96 97 98 99 100 101
149A 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164
Fastrac
Electrical Circuit - Sectional Wiring Diagrams (contd) Wiring Diagrams - Component Key
60 - 15 - 01/12
48A 49 49A 50 51 52 53
8020 - C/8-6.5
28 29 30 31 32 33 33A 34 35 36 37 38 39 40 41 42L 42R 43 44A 44B 45A 45B 46 47 48
Battery (all machines) Second Battery (3000 Series only) Ignition Switch Starter Motor Alternator Trailer ABS Socket Tractor ABS Supply (if fitted) Tractor ABS Return (if fitted) Ignition Relay Worklights Relay Heater Unit (3000 Series) Auxiliary Connector Auxiliary Power Socket (if fitted) Air Conditioning Connector (2000 Series) Air Conditioning Connector (3000 Series) Auxiliary Lights Earth Connector (2000 Series) Auxiliary Lights Supply Connector (3000 Series) Suspension Seat/Flow Divider Connector Horn Connector Start Inhibit Relay 1 Start Inhibit Relay 2 Clutch Start Micro-switch Diode Connector Front PTO Switch Rear PTO Switch Brake Lights Switch Brake Lights Relay Rear Wiper Motor Rear Wash/Wipe Switch Connector - Rear Washer Pump (2000 Series) Connector - Rear Washer Pump (3000 Series) Rear Intermittent Wipe Relay Rear Wiper Connectors Front Washer Pump Connector (2000 Series) Front Washer Pump Connector (3000 Series) Horn Washer/Horn Switch Front Wiper Motor Front Intermittent Wipe Relay Front Wiper Switch Cold Advance Switch (2000 Series only) Waxstat E.S.O.S. (2000 Series, 3155) E.S.O.S. Relay (3185 only) E.S.O.S. (3185 only) Timer (3185 only) Area Cut-out Switch (EDC) Connector - EDC Unit Pin position identification for 39 Raise/Lower Switch (EDC) (In cab) Draft Pin (EDC) (Left Hand) Draft Pin (EDC) (Right Hand) Position Sensor (EDC) Raise Push-Button (EDC) (RH Fender) Raise Push-Button (EDC) (LH Fender) Lower Push-Button (EDC) (RH Fender) Lower Push-Button (EDC) (LH Fender) Raise Solenoid (EDC) Lower Solenoid (EDC) Gear Lever Powershift Switches a Down b Up c Auto Duplicate Powershift Switches (if fitted) Powershift Solenoids a Snail b Tortoise c Hare Splitter Dump Relay Accelerator Pedal Switch
Rear Brake Reservoir Level (ABS) Transmission Oil Pressure Switch Speedometer Pick-up Engine Oil Pressure Switch Canbus Cable Screen RF Ground Diagnostic Connector 4WS Interconnecting Connector Non-4WS Connector Fuel Flow Sensor Radar Speed Sensor ABS Trailer Socket Suspension Seat Connector Flow Divider Switch Flow Divider Valve Connector Rear Axle Ram Lock Switch (closed when locked) Rear Axle Ram Lock Valve Steer Valve (RH) Steer Valve (LH) Front Potentiometer (4WS) Rear Potentiometer (4WS) 4WS Differential Lock Cut-Out Relay Trailer Socket (7-pin) Trailer Socket (13-pin) 4WS Jack Socket Wheel Slip Enable Switch (machines with optional software package only) (2000 Series from serial no. 788376; 3000 Series from serial no. 640305) Inching Solenoid Resistor - 4.7 ohm Column Switch Button Clutch Potentiometer Transmission Oil Temperature Sensor 1 Transmission Oil Temperature Sensor 2 (clutch housing oil sump) Clutch Lubrication Solenoid Transmission Brake Solenoid Clutch Control Solenoid Cab Auxiliary Supply Connector Cab Auxiliary Battery Supply - Terminal Ports Cab 3-pin Auxiliary Power Socket (battery and ignition supplies) Cab Auxiliary Power Convenience Socket (Option - N.Am. machines) Ignition Switched Relay (supplied with item 186) ABS Diagnostic Interconnect Tractor Diagnostic Interconnect Tractor ABS Diagnostic Relay Diagnostic Switch Tractor ABS Ignition Relay ABS Speed Sensor (Front RH) ABS Speed Sensor (Front LH) ABS Speed Sensor (Rear RH) ABS Speed Sensor (Rear LH) ABS Pressure Modulating Valve (Front) ABS Pressure Modulating Valve (Rear LH) ABS Pressure Modulating Valve (Rear RH) Tractor ABS ECU Connectors
54 55 56 57 58 59 60 61 62 63 64 65 66
Issue 4*
Column Switch Powershift Range Neutral Solenoid Connector Powershift Range Engaged Solenoid Connector 4WS Option Connector Clutch Warning/Selectronic Bleeper Powershift Low/Reverse Air Ram Powershift Medium/High Air Ram 2WD/Differential Lock Switch Rear PTO Switch Front PTO Switch Differential Lock Switch Differential Lock Cut-Out Relay 2WD Dump Relay 2WD Solenoid Differential Lock Solenoid Rear PTO Brake Solenoid
60 - 15 - 01/12
103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 120A 121 121A 122 123 124 125 126 127 128A 128B 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149
Front PTO Brake Solenoid Rear PTO Drive Solenoid Front PTO Drive Solenoid Park Brake Switch Rear PTO Cut-Out Connector Rear PTO Termination Connector (machines without rear PTO cut-out option) Rear PTO Interconnecting Connector (machines with rear PTO cut-out option) Diode Connector (E21) (PTO Cut-Out) PTO Cut-Out Push-Button (LH Fender) PTO Cut-Out Push Button (RH Fender) Air Conditioning Blower Switch (2000 Series only) Air Conditioning Switch (2000 Series only) Heater Unit (3000 Series only) Air Conditioning Unit Air Conditioning Compressor Switch Air Conditioning Compressor Clutch Air Conditioning Compressor Pressure Switch (High) Air Conditioning Compressor Pressure Switch (Low) Air Conditioning Compressor Clutch Relay Radio/Cassette Interior LIght (RH) Interior Light (LH) Door Switch (LH) Beacon Switch Beacon Socket Hazard Switch Single Trailer Turn Relay Second Trailer Turn Relay Outer Indicator Lights (RH) Outer Indicator Lights (LH) Auxiliary Lights Connector (In) Auxiliary Lights Connector (Out) Side Repeater (LH) (3000 Series only) Side Repeater (RH) (3000 Series only) Trailer Socket Rear Light Cluster (LH) Connector Rear Light Cluster (RH) Connector Front Light Cluster (RH) Connector (3000 Series only) Front Light Cluster (LH) Connector (3000 Series only) Front Worklights Switch A Post Worklights Relay Front Working Light (RH outer) Front Working Light (RH inner) Front Working Light (LH inner) Front Working Light (LH outer) Front Working Light (RH A post) Front Working Light (LH A post) Rear Worklights Switch Rear Working Light (RH outer) Rear Working Light (RH inner) Rear Working Light (LH inner) Rear Working LIght (LH outer) Main Lights Switch Rear Fog Lights Switch Rear Fog LIghts Relay Column Lights Switch (Main/Dip/Flash) Headlight Connector (LH) (3000 Series) Sidelight Connector (LH) (2000 Series) Headlight Connector (RH) (3000 Series) Sidelights Connector (RH (2000 Series) Air Gauge Illumination Lamp Number Plate Lamp (LH) Number Plate Lamp (RH) Auxiliary Lights Switch (3000 Series) Auxiliary Headlights (RH) Auxiliary Headlights (LH) Speaker (LH) Speaker (RH) Auxiliary Socket Cigar Lighter Trailer Socket Reverse Light Relay Mega Fuses - Thermostart (3185 only) Thermostart Heater Relay 1 (3185 only) Thermostart Heater Relay 2 (3185 only) Thermostart Heater 1 (3185 only) Thermostart Heater 2 (3185 only) Thermostart 1 (2000 Series, 3155) Thermostart 2 (2150 only) Buzzer Relay Clutch Up Switch Water Temperature Sender Air Pressure Switch - Tank 1 Air Pressure Switch - Tank 2 Air Pressure Switch - Tank 3 Fuel Level Sender Transmission Oil Filter Switch Air Filter Switch Front Brake Reservoir Level Rear Brake Reservoir Level
CONTENTS
Fastrac
60 - 15 - 01/13
2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams (contd) Wiring Diagrams - Alphabetical Index
Fuses A1 A2 A3 A4 * A5 A6 12-11 * A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 12-11 * C1 C2 C3 * C4 * C5 C6 C7 C8 C9 D1 D2 D3 D4 D5 D6 E1 E2 E3 E4 W Figure No. 12-3 12-4 12-5 12-6 & 12-7 12-8, 12-8A & 12-9 12-10, 12-10A & 12-12, 12-13 ,12-13A,12-13B 12-13C & 12-14 12-15 12-17 12-18 12-19 12-20 12-21 12-22 12-29 12-30 12-31 12-10, 12-10A & 12-32 & 12-32A 12-19 12-33 12-34, 12-35,12-35A 12-35B & 12-36 12-37 & 12-37A 12-3 12-38 12-38 12-3 12-23 12-23 12-24 12-25 12-26 12-28 12-39 12-39 12-40 12-41 12-22 Item Air Conditioning Air Dryer Alternator Auxiliary Lights Switching Area Cut-out Switch Auxiliary Jack Plug Socket Battery Beacon Socket Bleeper Brake Lights Cigar Lighter Diagnostic Supply Connector Differential Lock Cut-out Direction Indicators Earth Circuit Electronic Draft Control system * ESOS Flow Divider Fog Lights - Rear Four Wheel Steer (if fitted) * Fuel Flow Sensor * Ground Speed Radar Sensor Hazard Warning Lights Head Lights Horn Instrument Cluster Interior Lights Light Switch Illumination Main Lights Maxifuse (W) Neutral Start (Clutch & Gearbox) Powershift ECU - 3-Speed Splitter * Powershift ECU - Selectronic Figure No.
12-17 12-3 12-1 12-27 & 12-28 12-10 12-30 12-1 12-18 12-34 12-4 12-31 12-36 12-15 12-19 12-2 12-10 & 12-11 12-8, 12-8A & 12-9 12-40 12-24 12-41 12-37, 12-37A 12-37, 12-37A 12-19 12-22 & 12-23 12-6 12-34 12-18 12-34 12-22 12-22 12-3 12-12 12-13, 12-13A, 12-13B 12-13C & 12-14 PTO - Front 12-15 PTO - Rear 12-15 & 12-16 Radio/Cassette 12-29 Side Lights - LH 12-25 Side Lights - RH 12-26 Solenoid - Two Wheel Drive 12-15 Solenoid - Differential Lock 12-15 * Speedometer Sensor 12-35, 12-35A & 12-35B Starter Solenoid 12-3 Supply Circuit 12-1 Thermostart 12-33 Trailer ABS Socket 12-39 * Trailer Socket Reverse Lights 12-32 &12-32A Trailer Sockets 12-38 &12-42 * Transmission Oil Pressure Switch 12-35, 12-35A & 12-35B Two Wheel Drive Solenoid 12-15 Wash/Wipe-front 12-6 & 12-7 Wash/Wipe-rear 12-6 * Wet Clutch Control 12-13C * Wheelslip Enable Switch 12-37 &12-37A Work Lights - Front 12-20 Work Lights - Rear 12-21
9804/1103
60 - 15 - 01/13
8020 - C/8-7.3
Issue 2*
CONTENTS
9804/1103
*
12-39
Electrical Circuit - Sectional Wiring Diagrams (contd) Wiring Diagrams
A1 A2 A3 A4 A5 A6 A7
12-3 12-4 12-5 12-6 12-8 12-10 12-12 12-15 12-17 12-18 12-19 12-20 12-21 12-22 12-29 12-30 12-31 12-10 12-32 12-19 12-33 12-34 12-37 12-3 12-38 12-38 12-3
A307153
A8 A9
12-26
B1 B2 B3 B4 B5 B6 B7
Fastrac
60 - 15 - 01/14
12-39
7 5A
B8 B9 C1 C2 C3
W
21
12-22 12-3
C4 C5 C6 C7
8020 - C/12-1.4
1
12-4
1A
C8 C9
60 - 15 - 01/14
FIG. 12-1 SUPPLY CIRCUIT: BATTERY TO STARTER MOTOR; ALTERNATOR; FUSES A1 - A9, B1 - B9, C1 - C9, W (Maxifuse); TRAILER ABS CONNECTOR, TRACTOR ABS CONNECTOR
Issue 4*
Fastrac
60 - 15 - 01/15
2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams (contd) Wiring Diagrams (contd)
13
3185
12
1A
2000 SERIES
3000 SERIES
11A
11
A307162
12-9
12-4
5B
9A
CONTENTS
*
9804/1103
60 - 15 - 01/15
12-39A
8020 - C/12-2.3
10A
10
3000 SERIES
FIG12-2 EARTH CIRCUIT

2000 SERIES
Issue 3*
CONTENTS
9804/1103
856B (0.6)
181 (4.0)
CES7
*
CR4-C
C
Electrical Circuit - Sectional Wiring Diagrams (contd) Wiring Diagrams (contd)
C6 +12V 180 (4.0)
6 854 (0.6) 8
C 6
C8
181 (4.0)
C 4
CRES3
660B (0.6)
14
2 5 856A (0.6)
C5
856A (0.6) CR8 180 (4.0)

3
C 2
3 A 2/4 B C B C A D
18
1 BRAKE 854 (0.6)
+12V IGN
A1
105 (0.6)
CRSIS 810A (0.6) 856 (0.6) 810 (0.6) CDS 810C (0.6)
856C (0.6)
CR86
17
2 1 4 3 1 2 3 4
3 A B C
660C (0.6)
B C CR7
A D
12-13A
2/4 1
19
15
2 5 8
855 (0.6) 182 (4.0) 182 (4.0) C41
CR36
CR4-D 182 (4.0)
Fastrac
36 35 34 33 32 31 30 29 28 27 26 25
TH2
1 2
C9CS
CR49
1 2 3 4 8 9 14 15 16 17 24 30 31 38 44 48 37 43 47 23 29 36 42 46 22 28 35 41 45 21 27 34 40 7 13 20 26 33 39 6 12 19 25 32 5 11 18
1 5 11 18 19 25 32 33 39 40 41 45 46 47 48 42 43 44 34 35 36 37 38 26 27 28 29 30 31 20 21 22 23 24 12 13 14 15 16 17 6 7 8 9 10 2 3 4
195B (0.6) 811 (0.6)

M N O X W V H U G F S T U T S V H W X J B C D O
+12V IGN
C9
195 (1.4)
10
K L C D P
195B (0.6)
195 (1.4)
195A (1.4)
B J A E
L M N
G A F E R Q P
Q R
C5 CR1 C72 TH1
A309863
811 (0.6)
24 23 22 21 20 19 18 17 16 15 14 13
811 (0.6)
60 - 15 - 01/16
12 11 10 9
16
810B (0.6) 855 (0.6)
D D8
hh
bb
aa bb
aa
B A E L K S W V R D J P
1
D 4
A D J K R V
ff
B E L S W
ee
2
F M T U G N
dd cc
2 cc
G N U M T F
1 hh
C H
D 6
D5
856B (0.6) 181 (4.0)
C H P
gg
D 2
4 ee
3 ff
C6
640K (1.4)
dd
gg
2 4 1 3
CR51
C28
8020 - C/12-3.4
60 - 15 - 01/16
FIG12-3 FUSE A1 - NEUTRAL START (CLUTCH); FUSE C6 - STARTER SOLENOID; FUSE C9 - AIR DRIER, NEUTRAL START (GEARBOX)
Issue 4*
CONTENTS
Fastrac
60 - 15 - 01/17
A307170
CONTENTS
A2
20
21
9804/1103
60 - 15 - 01/17
8020 - C/12-4.1
FIG. 12-4 FUSE A2 - BRAKE LIGHTS

12-42
Issue 1
hh
P J
gg 3 4 W ee
V
aa 1
bb 2
cc
dd
ff
CONTENTS
Fastrac
60 - 15 - 01/18
A307180
26
26
25
12-25
CONTENTS
A3
2000 SERIES
hh
24A
gg
aa 1
4 W ee
bb 2
ff
cc
9804/1103
60 - 15 - 01/18
dd
24
8020 - C/12-5.1
Issue 1
FIG. 12-5 FUSE A3 - REAR WASH/WIPE

23
12-15
22
12
3000 SERIES
12-40
CONTENTS
Fastrac
60 - 15 - 01/19
28
29
hh
gg
aa 1
27
4 W ee
bb 2
ff
A307190
12-7
A4
12-7
CONTENTS
27A
9804/1103
60 - 15 - 01/19
8020 - C/12-6.1
FIG. 12-6 FUSE A4 - FRONT WASH/WIPE; HORN

G
12-7
3000 SERIES
cc
dd
2000 SERIES
Issue 1
CONTENTS
Fastrac
60 - 15 - 01/20
31
32
A307200
hh
gg
aa 1
12-6
CONTENTS
30
9804/1103
60 - 15 - 01/20
cc
dd
4 W ee
bb 2
ff
8020 - C/12-7.1
FIG. 12-7 FUSE A4 (CONTD) - FRONT WASH/WIPE

Issue 1
Fastrac
60 - 15 - 01/21
2000 Series, 3000 Series Electrical Circuit - Sectional Wiring Diagrams (contd)
CONTENTS
9804/1103
60 - 15 - 01/21
8020 - C/12-8.2
FIG. 12-8 *FUSE A5 - ENGINE SHUT-OFFF SOLENOID (ESOS) (2000 SERIES, 3155) - DRY CLUTCH TRANSMISSION
34
2000 SERIES
A5
33
Issue 2*
CONTENTS
9804/1103
Electrical Circuit - Sectional Wiring Diagrams (contd)
A5
Fastrac
60 - 15 - 01/21A
3155 ONLY
8020 - C/12-8A.1
(2000)
(3155)
34
2000 SERIES ONLY
33
WAXSTAT
A353910
60 - 15 - 01/21A
FIG. 12-8A FUSE A5 - ENGINE SHUT OFF SOLENOID (ESOS) (2000 SERIES, 3155 - WET CLUTCH TRANSMISSION)
Issue 1
CONTENTS
Fastrac
60 - 15 - 01/22
A309870
37
36
CONTENTS
A5
9804/1103
60 - 15 - 01/22
8020 - C/12-9.1
FIG. 12-9 FUSE A5 - ENGINE SHUT-OFF SOLENOID (ESOS) (3185 ONLY) ESOS MAXIFUSE
35
Issue 1
ESOS (40A)
CONTENTS
9804/1103
42L 39 12-34 42R 12-37 40 12-37
860RB (0.6)
Wiring Diagrams (contd)
CONTENTS
Fastrac
60 - 15 - 01/23
8020 - C/12-10.3
38
A6 B9
3000 SERIES
2000 SERIES
41 12-11
12-41
All 2000 Series machines to S/N 738694 2000 Series machines with radar from S/N 738695 All 3000 Series machines to S/N 640709 3000 Series machines with radar from S/N 640710
A307222
60 - 15 - 01/23
FIG. 12-10 ELECTRONIC DRAFT CONTROL (EDC) TYPE D+ FUSE A6 - IGNITION CAB SIDE FUSE B9 - BATTERY CAB SIDE
Issue 1
CONTENTS
9804/1103
42L 42R 39 40
CONTENTS
Fastrac
60 - 15 - 01/24
A6 B9
3000 SERIES 2000 SERIES
12-41 41 12-11
2000 Series machines not fitted with radar from S/N 738695 3000 Series machines not fitted with radar from S/N 640710
8020 - C/12-10A.1
A343740
60 - 15 - 01/24
FIG. 12-10A ELECTRONIC DRAFT CONTROL (EDC) TYPE B FUSE A6 - IGNITION CAB SIDE FUSE B9 - BATTERY CAB SIDE
Issue 1
CONTENTS
Fastrac
60 - 15 - 01/25
44B 44A 45A 45B
46
47
A307250
CONTENTS
9804/1103
60 - 15 - 01/25
8020 - C/12-11.2
FIG. 12-11 ELECTRONIC DRAFT CONTROL (EDC) TYPES D+ AND B FUSE A6 - IGNITION CHASSIS SIDE FUSE B9 - BATTERY CHASSIS SIDE
Issue 1
43
Fastrac
60 - 15 - 01/26
50
154
A307240
CONTENTS
9804/1103
60 - 15 - 01/26
48
49
8020 - C/12-12.2
FIG. 12-12 *FUSE A7 - POWERSHIFT ECU - 3 SPEED SPLITTER (DRY CLUTCH TRANSMISSION)
C P J
aa 1
3 dd 4 W ee
V
bb 2
A7
cc
ff
Issue 2*
Fastrac
60 - 15 - 01/27
A307260
54
CONTENTS
9804/1103
60 - 15 - 01/27
8020 - C/12-13.2
FIG 12-13 *FUSE A7 (CONTD) - POWERSHIFT ECU - SELECTRONIC (DRY CLUTCH TRANSMISSION)
52 53
2000 SERIES
12-3 12-34 51
55
Issue 2*
CONTENTS
9804/1103
660ZB (0.6)
CR95
660ZC (0.6)
815 (1.0)
*
810D (0.6) 125 (2.0) CDS 810C (0.6) 4 6 660L (0.6) 660ZA (0.6) 660X (1.0) +12V IGN UP CRES3 660N (1.0)
12-3
CRES3 660H (1.0)
660J (1.0)
2 CR97
125C (1.0)
12 11 10
24 23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25
CR50
49A
A7
TSS 901A (0.6)
PSSS 900A (0.6) 900 (0.6) 901B (0.6) HSS 125B (1.0)
12 11 10 9 8 7 6 5 4 3 2 1
CR62 625 (1.0)
901 (0.6)
154
SSS CR49
A D
B C
B C
A D
470B (0.6)
48A
DOWN CR96
471B (0.6) 472B (0.6) 472 (0.6)
902 (0.6)
902A (0.6) 127 (2.0)
125A (1.0)
24 23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25
ASSS
472A (0.6) DSSS 471A (0.6)
413 (0.6) 902B (0.6)
CR61
50
1 2
A B 471 (0.6) 470 (0.6)
2 1 3 3
1 3
USSS
AUTO C21
470A (0.6) 720E (0.6) 127 (2.0) PES3
DOWN
a b 48 c
UP
1 2 3 4
1
Fastrac
901B (0.6)
5 11 12 18 19 20 25 26 27 33 34 35 40 41 42 45 46 47 39
gg hh aa bb
900 (0.6)
900 (0.6)
W X J B C D O X B C D O P J A E W V H U G F S T
412A
(0.6)
60 - 15 - 01/27A
TH5
2 1
4
2 3 7 8 9 10 16 17 24 23 29 30 31 38 44 48 37 43 36 15 22 28 14 21 13 6
900B (0.6)
AUTO
4 3
1
32
A D J K R V
ff
B E L S W
ee
2
F M T U G N
dd cc
902B (0.6)
C H P
640B (1.4)
CRES3 412 (0.6) 412B (0.6)
4
AWS
660ZD (0.6) 1 CR102 4 8 5 2 6 9 10 3 7
CES7
CR51 471 (1.4) 472 (1.4)

1 5 2 6 12 19 25 32 33 39 40 41 45 46 47 42 43 44 48 34 35 36 37 38 26 27 28 29 30 31 20 21 22 23 24 13 14 15 16 17 dd 4
W V
CR1 514H (0.6) 631 (1.0)

12 11 10 9 8 7 6 5 4 3 2 1
12-36
1 2
470 (1.4)
515H (0.6) 125 (2.0) 810D (0.6)
24 23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25
bb 3 7 8 9 10
N U
aa
B A E L K S R D J P
49
11 18
2 4 cc
G M T F
1 hh
C H
TH7
1 2
815A (0.6) 815B (0.6)
V H U
L M N M N
SDS
T S
G A F E R Q P
CR66
TORTOISE MEDIUM
SNAIL LOW HARE HIGH
gg 3 ff
Q R
3 7 C50 W 10 412 (1.4) 6
2 5 9
1 4 8 +12v SUPPLY 7
3 6 10
2 5 9
1 4 8 C'DOWN SPLICE
8020 - C/12-13A.2
TH4
1 2
815C (0.6)
C5 815 (1.0) 901 (0.6) 902 (0.6) TH1 C72 815 (1.0) 901 (0.6) 902 (0.6)
C28
ee
CAN L CAN H P'SHIFT SUPPLY MH1 CAN SCRN
60 - 15 - 01/27A
A353921
FIG 12-13A FUSE A7 (CONTD) - POWERSHIFT ECU - SELECTRONIC (WET CLUTCH TRANSMISSION)
Issue 3*
Fastrac
60 - 15 - 01/27B
54
A353940
CONTENTS
9804/1103
60 - 15 - 01/27B
8020 - C/12-13B.1
FIG 12-13B FUSE A7 (CONTD) - POWERSHIFT ECU - SELECTRONIC (WET CLUTCH TRANSMISSION)
52 53
2000 SERIES
12-3 12-35A 51
55
Issue 1
CONTENTS
9804/1103
24 23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25
820 (0.6)
L K B C D O P
640N (0.6)
J A E
V H U G F S T
V H U T S G F
J A E
K B C D
L M N O
499 (0.6) 498 (0.6) CR99 821 (0.6) 820 (0.6) CR1
1
821 (0.6)
C72
Q R
R QP
175
1 2 2 1
TH1 C5
5 6 7 8 9 10 16 15 22 23 24 30 29 36 37 38 44 48 43 47 42 46 28 35 41 45 14 21 27 34 40 13 20 26 33 39 12 19 25 32 11 18 2 3 4
1 5 11 18 19 25 32 33 39 40 41 45 46 47 48 42 43 44 34 35 36 37 38 26 27 28 29 30 31 20 21 22 23 24 12 13 14 15 16 17 6 7 8 9 10 2 3
4R7 821A (0.6)
ISRS
31
524D (0.6)
821B (0.6)
17
526 (0.6)
524D (0.6)
640M (0.6)
640N (0.6)
526 (0.6)
823 (0.6)
CRES3
660A (0.6)
822 (0.6) 823 (0.6) 823 (0.6)
822 (0.6)
821 (0.6)
640M (0.6)
820 (0.6)
*
CR98 CR66
176
2 1 1 2
TH3 CES7
179
2 1
12 11 10
Fastrac
524C (0.6)
60 - 15 - 01/27C
8020 - C/12-13C.3
822 (0.6) CR49 524 (0.6)

CLUTCH PEDAL DOWN 5K RT
525 (0.6)
D.O.R.
12 11 10
TOTS2
RP 1K
24 23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25
CLUTCH PEDAL UP
177
1 2 3
CR53
524D (0.6)
526 (0.6)
523 (0.6) 522 (0.6) 521 (0.6) TH9 TH8 C71 TH6
524B (0.6) 524A (0.6) TOTS1 526 (0.6) 524 (0.6)
182
1 2
178
1 2
181
1 2
180
1 2
525 (0.6)
12 11 10 9 8 7 6 5 4 3 2 1
A353892
24 23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25
CR50
60 - 15 - 01/27C
FIG 12-13C FUSE A7 (CONTD) - WET CLUTCH CONTROL (WET CLUTCH TRANSMISSION)
Issue 3*
CONTENTS
Fastrac
60 - 15 - 01/28
A309580
CONTENTS
9804/1103
60 - 15 - 01/28
8020 - C/12-14.1
FIG. 12-14 FUSE A7 (CONTD) - POWERSHIFT ECU - SELECTRONIC (CONTD)

56 57 Issue 1
CONTENTS
9804/1103
64
65
66
67
68
70 58 69
Fastrac
60 - 15 - 01/29
A8
59 63
12-34
60 12-26 12-34 12-3 61 71a 71 71b 12-16 62 12-34
8020 - C/12-15.3
A309591
* Wire 400A only fitted on later machines
60 - 15 - 01/29
FIG. 12-15 FUSE A8 - FRONT/REAR PTO; 2WD AND DIFFERENTIAL LOCK SOLENOIDS; REAR PTO CUT-OUT
Issue 2*
CONTENTS
Fastrac
60 - 15 - 01/30
A309950
73
74
CONTENTS
72
71b
9804/1103
60 - 15 - 01/30
8020 - C/12-16.1
FIG. 12-16 REAR PTO CUT-OUT OPTION

Issue 1
CONTENTS
Fastrac
60 - 15 - 01/31
A309620
82
80
79
81
83
2000 SERIES
2000 SERIES
77
A9
CONTENTS
75
2000 SERIES
9804/1103
60 - 15 - 01/31
76
8020 - C/12-17.1
FIG. 12-17 FUSE A9 - AIR CONDITIONING CIRCUIT

78
2000 SERIES 3000 SERIES 3000 SERIES 3000 SERIES 3000 SERIES
3000 SERIES
2000 SERIES
Issue 1
CONTENTS
Fastrac
60 - 15 - 01/32
2000 SERIES
A309630
86
CONTENTS
B1
9804/1103
60 - 15 - 01/32
8020 - C/12-18.1
FIG. 12-18 FUSE B1 - INTERIOR LIGHTS; RADIO/CASSETTE; BEACON SOCKET

87
3000 SERIES
84
85
88
89
Issue 1
CONTENTS
CONTENTS
9804/1103
C2 B2
3000 SERIES
94
95B
95A
cc
bb 2
G F M U T
B E L S W
aa 1
D C J R P
hh
H
3000 SERIES
93
3000 SERIES
dd
4 ee
gg
3 ff
96
97
3000 SERIES
Fastrac
60 - 15 - 01/33
8020 - C/12-19.2
98 90
99 51 92 91 100
3000 SERIES
101
3000 SERIES
102
A309601
60 - 15 - 01/33
FIG. 12-19 FUSE B2 - HAZARD WARNING LIGHTS FUSE C2 - DIRECTION INDICATORS
Issue 2*
CONTENTS
Fastrac
60 - 15 - 01/34
108
110
3000 SERIES
107
2000 SERIES
A309640
CONTENTS
B3
103
9804/1103
60 - 15 - 01/34
104
8020 - C/12-20.1
FIG. 12-20 FUSE B3 - FRONT WORK LIGHTS

Issue 1
109
105
106
2000 SERIES
CONTENTS
Fastrac
60 - 15 - 01/35
A309650
114
115
CONTENTS
B4
111
9804/1103
60 - 15 - 01/35
8020 - C/12-21.1
FIG. 12-21 FUSE B4 - REAR WORK LIGHTS

Issue 1
112
113
CONTENTS
Fastrac
60 - 15 - 01/36
119
12-23
12-23
12-24
12-25
12-26
D1
D2
D3
D4
D5
D6
12-27
A309660
12-34
CONTENTS
116
9804/1103
60 - 15 - 01/36
117
8020 - C/12-22.1
FIG. 12-22 FUSE B5 - HEADLIGHT FLASH FUSE W (MAXIFUSE) - MAIN LIGHTS

118
3000 SERIES
Issue 1
B5
CONTENTS
9804/1103
CONTENTS
D1
D2
2000 SERIES 3000 SERIES 2000 SERIES 2000 SERIES 2000 SERIES 3000 SERIES 3000 SERIES
120
95A
95B 60 - 15 - 01/37
cc
N
3000 SERIES
3000 SERIES
3000 SERIES
121
Fastrac
bb 2
G M U T F
B E L S
aa 1
D C J R P
hh
H
dd
4 W ee
gg
8020 - C/12-23.1
3 ff
A309670
60 - 15 - 01/37
FIG. 12-23 FUSE D1 - MAIN BEAM FUSE D2 - DIPPED BEAM
Issue 1
CONTENTS
Fastrac
60 - 15 - 01/38
100
98
99
A309680
hh
gg
aa 1
CONTENTS
D3
9804/1103
60 - 15 - 01/38
cc
dd
4 W ee
bb 2
ff
8020 - C/12-24.1
FIG. 12-24 FUSE D3 - REAR FOG LIGHTS

Issue 1
CONTENTS
Fastrac
60 - 15 - 01/39
98
100
A309690
3000 SERIES
95A
2000 SERIES
CONTENTS
121A
9804/1103
60 - 15 - 01/39
D5
2000 ES SERI
8020 - C/12-25.1
FIG. 12-25 FUSE D4 - SIDE LIGHTS (LEFT SIDE)

123 12-29 12-41 12-15 12-10 124 12-31 12-1
Issue 1
121
95B
3000 SERIES
CONTENTS
Fastrac
60 - 15 - 01/40
98
100
A309690
3000 SERIES
95A
2000 SERIES
CONTENTS
121A
9804/1103
60 - 15 - 01/40
D5
2000 ES SERI
8020 - C/12-26.1
FIG. 12-26 FUSE D5 - SIDE LIGHTS (RIGHT SIDE)

123 12-29 12-41 12-15 12-10 124 12-31 12-1
Issue 1
121
95B
3000 SERIES
CONTENTS
Fastrac
60 - 15 - 01/41
127
126
12-23 12-25
12-19
12-23
12-26
12-19
95B
A309710
CONTENTS
12-25
95A
9804/1103
60 - 15 - 01/41
12-19
12-26 12-19
12-23 12-23
8020 - C/12-27.1
FIG. 12-27 AUXILIARY LIGHTS SWITCHING (2000 SERIES)

Issue 1
125
CONTENTS
Fastrac
60 - 15 - 01/42
126 127
12-23
95B
12-26
12-19 12-19
12-23 12-25
A309700
11A
CONTENTS
D6
125
12-25
95A
9804/1103
60 - 15 - 01/42
12-19
12-26 12-19
12-23 12-23
8020 - C/12-28.1
FIG. 12-28 FUSE D6 - AUXILIARY LIGHTS SWITCHING (3000 SERIES)

Issue 1
CONTENTS
Fastrac
60 - 15 - 01/43
128B
12-18
A309720
CONTENTS
B6
84
9804/1103
60 - 15 - 01/43
12-26
8020 - C/12-29.1
FIG. 12-29 FUSE B6 - RADIO/CASSETTE

Issue 1
128A
CONTENTS
Fastrac
60 - 15 - 01/44
129
CR30
A309730
CONTENTS
9804/1103
60 - 15 - 01/44
8020 - C/12-30.1
FIG. 12-30 FUSE B7 - AUXILIARY JACK-PLUG SOCKET

680 (3)
B7
+12V BAT
330 (3)
Issue 1
CONTENTS
Fastrac
60 - 15 - 01/45
A309740
12-26
CONTENTS
9804/1103
60 - 15 - 01/45
B8
8020 - C/12-31.1
FIG. 12-31 FUSE B8 - CIGAR LIGHTER

Issue 1
130
Fastrac
60 - 15 - 01/46
A309750
CONTENTS
9804/1103
60 - 15 - 01/46
8020 - C/12-32.2
FIG. 12-32 *FUSE C1 - TRAILER SOCKET REVERSE LIGHTS (DRY CLUTCH TRANSMISSION)
131 C1 98 100 99
Issue 2*
Fastrac
60 - 15 - 01/46A
A354000
CONTENTS
9804/1103
60 - 15 - 01/46A
8020 - C/12-32A.1
FIG. 12-32A *FUSE C1 - TRAILER SOCKET REVERSE LIGHTS (WET CLUTCH TRANSMISSION)
C1 100 99
Issue 2*
131
CONTENTS
Fastrac
60 - 15 - 01/47
A309760
135
136
CONTENTS
132
C3
9804/1103
60 - 15 - 01/47
8020 - C/12-33.1
FIG. 12-33 FUSE C3 - THERMOSTART

137
2000 3155 SERIES 2150
133
134
138
3185 3185
Issue 1
CONTENTS
CONTENTS
3000 SERIES
9804/1103
C4
55
140 12-22 12-36 12-15
C5
12-15
139
2000 SERIES
Fastrac
60 - 15 - 01/48
12-41
2000 SERIES
2000 SERIES
12-35(C28)
2000 SERIES
12-10
8020 - C/12-34.3
12-15
A309771
60 - 15 - 01/48
FIG. 12-34 FUSE C4 - LIGHTS SWITCH ILLUMINATION; BLEEPER; INSTRUMENT CLUSTER; DIFFERENTIAL LOCK CUT-OUT; DIAGNOSTIC SUPPLY CONNECTOR; SPEEDO SENSOR; FUSE C5 (DRY CLUTCH TRANSMISSION)
Issue 3*
Fastrac
60 - 15 - 01/49
148
149
A309780
144
CONTENTS
141
145
147
9804/1103
60 - 15 - 01/49
8020 - C/12-35.2
150
FIG. 12-35 FUSE C4-DRY CLUTCH TRANSMISSION (CONTD)

151 152
Issue 2*
143
142
12-34(CR51)
hh
gg
aa 1
cc
dd
4 W ee
bb 2
ff
146
CONTENTS
9804/1103
C4
55
12-22 12-36 12-15
C5
12-15
139
2000 SERIES
3000 SERIES
Fastrac
60 - 15 - 01/49A
8020 - C/12-35A.1
12-41
2000 SERIES
2000 SERIES
12-35B(C28)
2000 SERIES
12-10
12-15
A353980
60 - 15 - 01/49A
FIG. 12-35A FUSE C4 - LIGHTS SWITCH ILLUMINATION; BLEEPER; INSTRUMENT CLUSTER; DIFFERENTIAL LOCK CUT-OUT; DIAGNOSTIC SUPPLY CONNECTOR; SPEEDO SENSOR; FUSE C5 (WET CLUTCH TRANSMISSION)
Issue 1
CONTENTS
9804/1103
640L (0.6)
*
C52 406 (0.6) 650F (0.6) CES9 1
C34 2 650D (0.6)
141
143
CES9 C33 1 2
410 (0.6) C8
bb aa
B F M U T W L S V E K R A D J P
407 (0.6)
650C (0.6)
640H (0.6)
408 (0.6)
12 - 35A (CR51)
1 hh
C H
142
640C (0.6) CES7
2 cc
G N
C28
C3
A B
144
CES7 C20
dd 4 3 ff
gg
405 (0.6)
640A (0.6) C54

2 1 1 2
411 (0.6)
ee
C14
145
146
409A (0.6)
640F (0.6)
148
C9 409 (0.6) CES9 404 (0.6) BMS 409B (0.6) 1 2 640G (0.6) CES7
147
C49/C50 W
650G (0.6)
149
C31 409C (0.6) 650E (0.6) CES9 1 C73 402 (0.6)
1 2
640P (0.6)
412 (1.4) 403 (1.4)
Fastrac
IND
149A
60 - 15 - 01/49B
8020 - C/12-35B.2
4
2 1
C5 435 (0.6)
B A 32 33 39 40 41 45 46 47 48 42 43 44 34 35 36 37 38 18 19 25 26 27 28 29 30 31 1 5 11 12 13 20 21 22 23 24 14 15 16 17 6 7 8 9 10 2 3 4
710P (1.4)
414 (1.4)
160E (1.4)
C55
150
152
C72
TH1 414 (0.6)

W V H U U T S V H
L M N O
K B C D P
X J A E
X J B
K C D
TH10
L M N O
G F S
G A F E R Q P
2 1 4 3 710P (0.6) 160E (0.6)
Q R
151
497 (1.4)
497 (0.6)
A353951
60 - 15 - 01/49B
FIG. 12-35B FUSE C4-WET CLUTCH TRANSMISSION (CONTD)

Issue 2*
CONTENTS
9804/1103
189
515D (1.0) 1 2 3 4 5 6 7 8 A15
513 (0.6)
155
4 3 2 1 515D (0.6) SCRN (0.6)
R1
8 7 6 5
514D (0.6)
515B (0.6)
514B (0.6)
515A (0.6)
660Y (1.0)
514D (1.0)
R1
514E (0.6)
12 11 10
514A (0.6)
*
631 (1.0) 1 4 8 5 2 6 9 10 3 7 514H (0.6)
CONTENTS
153
CR102
515H (0.6)
515C (0.6) 515E (0.6) 515 or (515B) (0.6) 515A (0.6) 3000 SERIES CANHS2 515 (0.6) 7 14 3 6 2 5 9 13 12 1
C2
CANHS3 660Y (0.6)
4 8
CRES3
11 10
514A (0.6) 514 (0.6) 514 or (514B) (0.6) CANLS2 R1
153
PISC4
160F (0.6)
CR89
Fastrac
CANLS3 514C (0.6)
24 23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25
J H
561 (1.0)
A16 1 2
517 (0.6)
516 (0.6)
515F (0.6)
514F (0.6)
515 (1.0)
626 (1.0) 560 (1.0)

G F
A J B C D K N
M L E
154
CR64
153
627 (1.0)
R1
A309791
514 (1.0)
60 - 15 - 01/50
8020 - C/12-36.2
CANHS1
160F (1.0)
SCRN (1.0)
D C E
CR49
1 4 5 8
2 6
3 7
CANHS1
CANLS1
560(1.0)
12 11 10
24 23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25
515C (0.6)
C4
A14
156
CR50
188
A17
153
12 11 10 9 8 7 6 5 4 3 2 1
629 (1.0) 1 2 5 8 6 9 10 3 7
12 - 39A
561 (1.0) A2
1
2 1
CR66 3 7 10 6 9 2 5 8 2000 SERIES 1 4
157
24 23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25
CR83
2000 SERIES
514C (0.6)
9 10
CANLS1
515G (0.6)
514G (0.6)
60 - 15 - 01/50
FIG. 12-36 FUSE C4 (CONTD) - CANBUS; DIAGNOSTIC CONNECTOR
Issue 2*
CONTENTS
9804/1103
12-34(CR66)
39
C5
40
EDCIS
161C (0.6)
Fastrac
60 - 15 - 01/51
158
161D (0.6) 432 (0.6) +8 1 +3 4 6
12-10
660RB (0.6)
8020 - C/12-37.4
174
-7
5 660GJ (0.6) 660GK (0.6)
159
A309801
60 - 15 - 01/51
FIG. 12-37 FUSE C5 - FUEL FLOW SENSOR; GROUND SPEED RADAR SENSOR WHEELSLIP ENABLE SWITCH (DRY CLUTCH TRANSMISSION)
Issue 2*
Fastrac
60 - 15 - 01/51A
40
A353960
CONTENTS
12-35A
C5
9804/1103
60 - 15 - 01/51A
8020 - C/12-37A.1
159
FIG. 12-37A FUSE C5 - FUEL FLOW SENSOR; GROUND SPEED RADAR SENSOR WHEELSLIP ENABLE SWITCH (WET CLUTCH TRANSMISSION)
12-10 174 Issue 1
39
CONTENTS
Fastrac
60 - 15 - 01/52
A309810
C7
CONTENTS
C8
9804/1103
60 - 15 - 01/52
8020 - C/12-38.2
FIG. 12-38 FUSE C7 - 13 PIN TRAILER SOCKET (IGNITION) FUSE C8 - 13 PIN TRAILER SOCKET (BATTERY) * (2000 SERIES TO S/N 738748, 3000 SERIES TO S/N 640777)
98
C1
Issue 2*
CONTENTS
CONTENTS
+12V BAT
355 (3.0) 191 (1.0) 685 (3.0)
CR94 A B C
183
A B C APS1 191 (1.0) 685 (3.0)
355 (3.0)
PFSC8
+12V IGN
5A C7
185
PSES
355C (3.0)
82
355D (3.0)
186
4 6
191A (1.0) 191 (1.0)
187
191A (1.0) 4 191 (1.0) 8 2 6 355D (3.0) 685D (1.0) 192 (3.0)
APS5
192 (3.0)
685D (1.0)
9804/1103
355A (3.0) 191 (1.0) 20A C8 355B (3.0)
APS2 RED BLACK 685A (3.0)
184
APS3
15/30 31
685B (3.0)
Fastrac
APS4
3
60 - 15 - 01/52A
8020 - C/12-38A.1
685C (3.0)
60 - 15 - 01/52A
A370430
FUSE C7 - AUXILIARY SOCKET (IGNITION SUPPLY) FUSE C8 - AUXILIARY SOCKET (BATTERY SUPPLY) (2000 SERIES FROM S/N 738749, 3000 SERIES FROM S/N 640778)
Issue
CONTENTS
9804/1103
BROWN (1.0)
2 153 (1.0) 4 5 8 6 883 (1.4) A13
20C (1.0)
F4
12 - 2
153A (1.0) CR101 A9 A B C C B A
190
2 8 5
449 (1.0)
A B
465 (1.0)
191
A A11
6
200
1 7 1
BLACK (1.0)
BLACK (1.0)
A8
BROWN (1.0)
BLACK (1.0)
ABS5
7 1
BLACK (1.0)
TAIS
F3
BROWN (1.0)
ABS6
7
5B
448 (1.0) 665A (3) 665B (3)
12
12
12
448 (1.0) 665A (3) 665B (3) TAES 440 (1.4) 015J (1.0) A B D C +12V BAT 260 (3) 270 (3) A17 A3
1 2 1
ABS4 665C (2.0) 665D (2.0) 152 (2.0) 151 (2.0)
200
1807 (1.4) 1808 (1.4)
200
1802 (1.4) 1801 (1.4) 1800 (1.4) 1804 (1.4) 1803 (1.4) 1805 (1.4)
BROWN (1.0)
*
2 4 5 8 6 +12V IGN CR100 +12V BAT B A C D +12V BAT 265A (2.0) 265B (2.0) 2 8 20 (4) 20B (2.0) 20A (2.0) A7
192
A9 15K (1.0) A5 F1 154 (0.6) 4 6 A12 665E (0.6) TAES A6 F2 ABS10
1 2
12 - 1
883D (0.6)
A B D C
193
ABS11
194
ABS9
1 2
195
ABS8
1 2
196
1 2
5A
Fastrac
30 29 28 27 26 25
6 5 4 3 2 1
30 29 28 27 26 25
6 5 4 3 2 1 7 6 5 4 3
17 16 15 14 13
17 16 15 14 13
605 (1.4) 615 (6.0)
A2
ABS2 1807 (1.4) 1806 (1.4) 1808 (1.4)
H G F M E
AP1
160
370A (3) 370 (6) 440 (1.4) 150 (1.4)
1803 (1.4) 1800 (1.4) 1801 (1.4) 1805 (1.4)

1 2 3
CR66
CR65
1 3 2
1802 (1.4)
12 - 39
ABSSS
1 2
370B (3) AP2
1804 (1.4) AP4 AP3
60 - 15 - 01/53
36 35 34 33 32 31
BAT -VE
CR47
A1 +12V IGN
560 (1.0)
B A C D +12V BAT
370B (3) 370A (3)
E1
151 (2.0)
152 (2.0)
440 (0.6)
665C (2.0)
665D (2.0)
561 (1.0) 465 (1.0) 883 (1.4) 1806 (1.4)
12 - 1
A4
E2
150 (1.0)
ABS7
12 - 36
24 23 22 21 20 19 18 12 11 10 9 8 7 36 35 34 33 32 31 24 23 22 21 20 19 18 12 11 10 9 8 7 1 2
2 1
1 561(1.0) 560(1.0) A J B C D K 2 N L E H M G F G F E 2 D H M N L K 1 A J B C
A J H B K M G L D F E
A K B C D
8020 - C/12-39.2
197
198
A387670
199
60 - 15 - 01/53
FIG. 12-39 FUSES E1, E2 - TRAILER ABS * FUSES F1, F2, F3, F4 (TRACTOR ABS)
Issue 2*
CONTENTS
Fastrac
60 - 15 - 01/54
163
162
A309830
CONTENTS
9804/1103
60 - 15 - 01/54
161
12
8020 - C/12-40.1
FIG. 12-40 FUSE E3 - FLOW DIVIDER

Issue 1
E3
CONTENTS
Fastrac
60 - 15 - 01/55
12-15
12-15
167
168
169
58
12-26
12-34
12-34
12-13
12-36
12-36 12-34
12-1
166
E4
153
A309840
CONTENTS
9804/1103
60 - 15 - 01/55
173
8020 - C/12-41.1
FIG. 12-41 FUSE E4 - FOUR WHEEL STEER (4WS) CIRCUIT

170 156 54 153 12-36
164 165
Issue 1
CONTENTS
9804/1103
CONTENTS
171
Fastrac
60 - 15 - 01/56
6 5
7 4
8 1 2 3
9 10 11 12
98 172
13
8020 - C/12-42.2
A309851
60 - 15 - 01/56
FIG. 12-42 TRAILER SOCKETS
Connector C1 (98) Pin Functions

1 2 3 4 LH Direction Indicator (see Fig. 12 - 19) Rear Fog Light (see Fig. 12 - 24) Earth for pins 1 to 8 RH Direction Indicator (see Fig. 12 - 19) 5 6 7 8 RH Side Light (see Fig. 12 - 26) Brake Lights (see Fig. 12 - 4) LH Side Light (see Fig. 12 - 25) Rev. Lights (see Fig. 12 - 32) 9 Battery Feed (see Fig. 12 - 38) 10 IGN Feed (see Fig. 12 - 38) 11/12/14 Spare 13 Earth for Pins 9 to 12 (see Fig. 12 - 38)
Issue 1
CONTENTS CONTENTS
125, 135, 145, 150, 155, 185 to machine no. 637733

* Hydraulic
Circuit
R V
N
X
N
S D
T P B
D1
P3
P4
6
1A
B1 2 TH 2A
P1
P2
CONTENTS CONTENTS
Fastrac
60 - 20 - 02/2
125, 135, 145, 150, 155, 185 from machine no. 637734 Hydraulic Circuit
Component Key A A1 B B1 CS D D1 F G H N P1 P2 P3 P4 R RR S SB T V X External Hydraulics/Draft Control Valve Main Relief Valve Hydraulic Trailer Brake Valve (optional) Feed to Hydraulic Trailer Brake Connector TH Steering Circuit Cooler Flow Regulator Valve (optional) Flow Regulator Valve Auxiliary Output Circuit Main Filter Front Auxiliary Circuit (optional) Rear Auxiliary Circuits Ride Height Corrector Valves Suspension Pump Steering Pump External Hydraulics Pump Transmission Pump Front Lift Rams Rear Lift Rams Suspension Cylinders Steering Box Tank Suspension Pressure Maintenance Valve Differential Lock
9804/1103
60 - 20 - 02/2
Issue 2
CONTENTS
125, 135, 145, 150, 155, 185 from machine no. 637734 Hydraulic Circuit
X
N
P3
P4
1A
B1 2 TH
1
P1
P2
2A
CONTENTS
* FASTRAC
Fastrac
60 - 20 - 03/1
1115, 1135, 2115
Circuit Diagrams- Hydraulic

Description The diagram shows the hydraulic circuits of the machine to clarify the way in which they relate to each other. The circuits each have their own pump section: P1 P2 P3 P4 P5 Suspension/Rear Axle Differential Lock Steering (front axle) (2WS/4WS) External Hydraulic Services/Draft Control Transmission Steering (rear axle) (4WS) (if fitted) Component Key A AA AB AC AD AE AE1 AWS A1 B CS Fm G H M N P1 P2 P3 P4 P5 Q R RR S SP SU T V X Y External Hydraulics/Draft Control Valve Steering Rams (front axle) Steering Pump Relief Valve Feed to Hydraulic Trailer Brake Connector TH Power Track Rod (rear wheel steering) (optional) Flow Regulator Valve (optional) Flow Regulator Valve Auxiliary Output Circuit Four-wheel Steer Valve (optional) Main Relief Valve Hydraulic Trailer Brake Valve (optional) Steering Circuit Cooler Main Filter Front Auxiliary Circuit (Optional) Rear Auxiliary Circuits Accumulator - Ride Height Adjustment Ride Height Corrector Valves Pump - Suspension/Rear Axle Differential Lock Pump - Steering (front axle) Pump - External Hydraulics/Draft Control Pump - Transmission Pump - Steering (rear axle) (optional) Pilot Feed from Front Brakes Hydraulic Brake Fluid Line Front Lift Rams (Optional) Rear Lift Rams Suspension Cylinders Proportional Solenoid Valve (optional) Steering Unit Tank Suspension Pressure Maintenance/Differential Lock Valve Rear Axle Differential Lock Differential Lock Relief Valve
P1 and P2 are the two sections of the engine-driven pump. P3, P4 and P5 (if fitted) are the sections of the gearboxdriven pump. The external hydraulics and draft control circuits are described in detail in this section of the manual. More details on the other circuits are given in the relevant sections of the manual. When a machine is fitted with provision for hydraulic trailer brakes, line 1 from the pump feeds the hydraulic trailer brake valve B and line 1A is not fitted. When there is no hydraulic trailer brake valve, line 1A is fitted to give a direct feed to control valve A which controls feeds to the external services by means of spools l, ll and lll. A four spool control valve is illustrated but two and three spool valves are also available to the same general design. When the four spool valve is fitted, spool llll feeds the front linkage lift rams R. When the machine is fitted with the optional Flow Regulator Valve AE, line 2A is not required, the oil flow to External Hydraulics/Draft Control Valve A coming from port B of valve AE . Flow Regulator Valve AE provides the means of adjusting flow to external implements from 5 to 55 l (1 to 12 UK gal/min). Control valve A incorporates the main relief valve A1. It also incorporates a draft control section which feeds the rear lift rams RR. Exhaust oil returns from control valve A to tank through filter Fm.
Note: Certain ports of valve A are identified by the letters a and b cast into the valve block. These identifications are included in the schematic opposite but do not relate to the letters A and B on the control lever decal or the quick release coupling decals.
9804/1103
60 - 20 - 03/1
Issue 2*
CONTENTS
Fastrac
* FASTRAC 1115, 1135 Circuit Diagrams - Hydraulic

N M
TP1 S1
RR
R Y
T D
R1
T
b 0 F 1 2 a
IIII
SP
Fm
1A
AD
P A A CT1 BP T TP P R N B
AC
0 F 1 2
1.2 b a
III
1.2
Fm
b
CT3 B CT2
a 2
T
Y
II
AWS
T
Q CS P1 P2
Fm
1.2
2A
Fm
0 1 2
1 AB AE P3 P5 P4
Fm
a
T P
AE1
B 1.2
Z
A1
R2 P
Fm
B A B A B A
3 3A b
AA
II
III
A249311
SU
9804/1103
60 - 20 - 03/2
Issue 2*
CONTENTS
* 2000 *
Fastrac
60 - 20 - 03/3
SERIES MACHINES (TYPES 1 AND 2)

Description The diagram shows the hydraulic circuits of the machine to clarify the way in which they relate to each other. Note that later machines are fitted with a different External Hydraulics/Draft Control Valve A (Type 2). Be sure to refer to the correct circuit diagram, Circuit DiagramsHydraulic,2000 Series Machines (Type 1) or Circuit Diagrams-Hydraulic, 2000 Series Machines (Type 2) as applicable. The circuits each have their own pump section: P1 P2 P3 P4 P5 Suspension/Rear Axle Differential Lock Steering (front axle) (2WS/4WS) External Hydraulic Services/Draft Control Transmission Steering (rear axle) (4WS) (if fitted) Component Key A AA AB AC AD AE AE1 AWS A1 B CS Fm G H M N P1 P2 P3 P4 P5 Q R RD RR S SP SU T V X Y External Hydraulics/Draft Control Valve Steering Rams (front axle) Steering Pump Relief Valve Feed to Hydraulic Trailer Brake Connector TH Power Track Rod (rear wheel steering) (optional) Flow Regulator Valve (optional) Flow Regulator Valve Auxiliary Output Circuit Four-wheel Steer Valve (optional) Main Relief Valve Hydraulic Trailer Brake Valve (optional) Steering Circuit Cooler Main Filter Front Auxiliary Circuit (Optional) Rear Auxiliary Circuits Accumulator - Ride Height Adjustment Ride Height Corrector Valves Pump - Suspension/Rear Axle Differential Lock Pump - Steering (front axle) Pump - External Hydraulics/Draft Control Pump - Transmission Pump - Steering (rear axle) (optional) Pilot Feed from Front Brakes Hydraulic Brake Fluid Line Front Lift Rams (Optional) Drop Flow Control Valve (front lift rams) (optional) Rear Lift Rams Suspension Cylinders Proportional Solenoid Valve (optional) Steering Unit Tank Suspension Pressure Maintenance/Differential Lock Valve Rear Axle Differential Lock Differential Lock Relief Valve
P1 and P2 are the two sections of the engine-driven pump. P3, P4 and P5 (if fitted) are the sections of the gearboxdriven pump. The external hydraulics and draft control circuits are described in detail in this section of the manual. More details on the other circuits are given in the relevant sections of the manual. When a machine is fitted with provision for hydraulic trailer brakes, line 1 from the pump feeds the hydraulic trailer brake valve B and line 1A is not fitted. When there is no hydraulic trailer brake valve, line 1A is fitted to give a direct feed to control valve A which controls feeds to the external services by means of spools l, ll and lll. A four spool control valve is illustrated but two and three spool valves are also available to the same general design. When the four spool valve is fitted, spool llll feeds the front linkage lift rams R. The optional lift ram drop flow control valve RD can be fitted when extra control is required while lowering front attachments, especially heavy attachments. When the machine is fitted with the optional Flow Regulator Valve AE, line 2A is not required, the oil flow to External Hydraulics/Draft Control Valve A coming from port B of valve AE . Flow Regulator Valve AE provides the means of adjusting flow to external implements. Note 1: The optional Flow Regulator Valve AE is shown in outline only. For the internal details see page 60-20-03/7. Control valve A incorporates the main relief valve A1. It also incorporates a draft control section which feeds the rear lift rams RR. Exhaust oil returns from control valve A to tank through filter Fm.
Note 2: Certain ports of valve A are identified by the letters a and b cast into the valve block. These identifications are included in the schematic opposite but do not relate to the letters A and B on the control lever decal or the quick release coupling decals. Note 3: Machines with Type 2 External Hydraulics/Draft Control Valves use colour codes on the relevant control and hydraulic coupling decals. The valve spools correspond with the colour code as follows: Valve Spool Colour Code Green Blue Brown Orange
I II III IIII
The above colour code key only relates to the Type 2 circuit diagram. Do not relate the key to the Type 1 circuit.
9804/1103
60 - 20 - 03/3
8020 - E/2-1.4
Issue 3*
CONTENTS
Fastrac
* 2000 SERIES MACHINES (TYPE 1) * Circuit Diagrams Hydraulic (contd)

N M
TP1 S1
RR
RD R Y
T D
R1
T
b 0 F 1 2 a
IIII
SP
Fm
1A
AD
AC
0 F 1 2
1.2 b a
III
1.2
Fm
b
CT3 B CT2
a 2
T
Y
II
AWS
T
Q CS P1 P2
Fm
1.2
2A
Fm
0 1 2
1 AB P3 P5
b c
AE1
d 1.2
P4
Fm
AE
R2 P
A1
Fm
B A B A B A
3 3A b
AA
a
II
III
SU
H
A249312
9804/1103
60 - 20 - 03/4
8020 - E/2-2.4
Issue 2*
CONTENTS
Fastrac
60 - 20 - 03/4A
2000 SERIES MACHINES (TYPE 2) Circuit Diagrams Hydraulic (contd)

N M
TP1 S1
RR
a R1
Y
T D
1 0 2 F b a
SP
1.2
1A
AD
AC
1 0 2 F
II
1.2
Fm
b a
Fm
1 0 2 F
CT3 B CT2
T
Y
III
1.2
AWS
T
Fm
I
b a
Q CS P1 P2
Fm
1 0 2 F
II
III
2A
Fm
1 AB P3 P5
b c
IIII
1.2
AE1
d
P4
Fm
RD
R1
AE
R2
3 3A b
AA
a
SU
T
A358860
9804/1103
60 - 20 - 03/4A
8020 - E/2-3.3
Issue 1
CONTENTS
* 3000 *
Fastrac
60 - 20 - 03/5
SERIES MACHINES (TYPES 1 AND 2)

Description The diagrams show the four hydraulic circuits of the machine to clarify the way in which they relate to each other. Note that later machines are fitted with a different External Hydraulics/Draft Control Valve A (Type 2). Be sure to refer to the correct circuit diagram, Circuit Diagrams - Hydraulic, 3000 Series Machines (Type 1 ) or Circuit Diagrams Hydraulic, 3000 Series Machines (Type 2 ) as applicable. The four circuits each have their own pump section: P1 P2 P3 P4 Suspension Steering External Hydraulic Services Transmission Component Key A A1 B B1 CS D D1 F G H N P1 P2 P3 P4 R RD RR S SB External Hydraulics/Draft Control Valve Main Relief Valve Hydraulic Trailer Brake Valve (optional) Feed to Hydraulic Trailer Brake Connector TH Steering Circuit Cooler Flow Regulator Valve (optional) Flow Regulator Valve Auxiliary Output Circuit Main Filter Front Auxiliary Circuit (optional) Rear Auxiliary Circuits Ride Height Corrector Valves Pump - Suspension Pump Pump - Steering Pump Pump - External Hydraulics Pump Pump - Transmission Pump Front Lift Rams Drop Flow Control Valve (front lift rams ) (optional) Rear Lift Rams Suspension Cylinders Steering Box
P1 and P2 are the two sections of the engine-driven pump. P3, P4 are the two sections of the gearbox-driven pump. The external and draft control circuits are described in detail in this section of the manual. More details on the other circuits are given in the relevant sections of the manual. When a machine is fitted with provision for hydraulic trailer brakes, line 1 from the pump feeds the hydraulic trailer brake valve B and line 1A is not fitted. When there is no hydraulic trailer brake valve, line 1A is fitted to give a direct feed to the main control valve A which controls feeds to the external services by means of spools l, ll and lll. A four spool control valve is illustrated but two and three spool valves are also available to the same general design. When the four spool valve is fitted, spool llll feeds the front linkage lift rams R. The optional lift ram drop flow control valve RD can be fitted when extra control is required while lowering front attachments, especially heavy attachments. When the machine is fitted with the optional Flow Regulator Valve D , line 2A is not required, the oil flow to External Hydraulics Control Valve A coming from port B of valve D. Flow Regulator Valve D provides the means of adjusting flow to external tools. Note 1: The optional Flow Regulator Valve D is show in outline only. For the internal details see page 60 - 20 - 03/7. The main control valve also incorporates the main relief valve A1. The neutral circuit continues through the control valve via line 3 to draft control valve C which feeds the rear lift rams RR. Exhaust oil returns via lines 4, 5, 6 and 8 to tank where it passes through filter F.
Note 2: Certain ports of valve A are identified by the letters a and b cast into the valve block. These identifications are included in the schematic opposite but do not relate to the letters A and B on the control lever decal or the quick release coupling decals. Note 3: Machines with Type 2 External Hydraulics/Draft Control Valves use colour codes on the relevant control and hydraulic coupling decals. The valve spools correspond with the colour code as follows: Valve Spool Colour Code Green Blue Brown Orange
I II III IIII
The above colour code key only relates to the Type 2 circuit diagram. Do not relate the key to the Type 1 circuit.
9804/1103
60 - 20 - 03/5
8020 - E/2-4.3
Issue 2*
CONTENTS
Fastrac
60 - 20 - 03/6
* 3000 SERIES MACHINES (TYPE 1) * Circuit Diagrams - Hydraulic (contd)
RR
N
a
RD X
N
R1
T
b 0 F 1 2 a
IIII
F
1.2 b 0 F 1 2 a
III
1.2
P3
P4
b 0 1 2 a
II
1A
1.2
B1 2 TH
1 0 2
b a
P1
P2
2A
D1
1.2
SB
,,,, ,,,, ,,,, ,,,,

CS
A1
R2 P
F
B A B A B A
II
III
T
a
A243311
9804/1103
60 - 20 - 03/6
8020 - E/2-5.1
Issue 3*
CONTENTS
Fastrac
60 - 20 - 03/6A
* 3000 SERIES MACHINES (TYPE 2) * Circuit Diagrams - Hydraulic (contd)
X
a
RR N
R1
b a 1 0 2 F
I
1.2
1
1 0 2 F
P3
P4
II
1.2
Fm
b a
1A
III
B 1.2
B1 2 TH
Fm
I
b a
II
III
P1
P2
2A
D1
IIII
1.2
RD
SB T
R1 R2 P M
CS
A360010
9804/1103
60 - 20 - 03/6A
8020 - E/2-6.1
Issue 1
CONTENTS
* 2000 *
Fastrac
60 - 20 - 03/7
SERIES & 3000 SERIES
Circuit Diagrams- Hydraulic Flow Regulator Valves
A343830
55 litre Flow Regulator Valve
CT2 a CT1 c
CT3
CT4
A343840 d b
90 litre Flow Regulator Valve
9804/1103
60 - 20 - 03/7
8020 - E/2-7.1
Issue 1
CONTENTS
* * 2000
9804/1103
Dry Clutch Transmission
Pump P4 feeds the PTO clutches, the 4WD clutch, the splitter solenoid valve, the main drive clutch booster and the lubrication circuit. The circuit is selfcontained, using transmission oil. Note: Pump P4 is the rear section of a pump which is driven by the PTO gearbox. The front section(s) of the pump supply the external hydraulic services and 4WS (if fitted), and use hydraulic oil. The sections of the pump are separated by oil seals. Transmission oil is drawn from the range gearbox RB by pump P4 and delivered first to the cooler CT. Oil from the cooler flows via filter F1 to the solenoid valve block TS which contains a pressure maintenance valve and three solenoids 1, 2 and 3. Solenoid 2 is only fitted to machines having the optional front PTO. Port A2 of this solenoid pressurises the front PTO clutch pack in the main PTO gearbox PB . Port B2 pressurises the front PTO brake. Solenoid 3 supplies the rear PTO clutch in the same way. Port A1 of solenoid 1 pressurises the 4WD clutch W in the range gearbox. Port B1 is not used.
Each end of the solenoid valve block has a port marked P. The one on the end of the block nearest the right side of the machine is for the feed from the pump via filter F1. Port P on the opposite end of the block feeds the splitter solenoid valve S (port L of which provides lubrication feeds to the PTO clutches and the gearbox bearings) and the main drive clutch booster X which is actuated from the clutch pedal via port X1 to operate the clutch mechanism via port X2. Additional pipework provides air balance and lubrication links between the PTO, speed and range gearboxes which all use the same oil. Note: Special adapters with restrictor orifices are fitted to certain lubrication inlets on the gearboxes and it is essential that the correct size restrictors are fitted as follows. A Front PTO clutch housing (both with and without a front PTO fitted) - 1/2 inch BSP male x 3/8 inch BSP female with 2.5 mm restrictor. Rear PTO clutch housing - 1/2 inch BSP male x 3/8 inch BSP female with 2.5 mm restrictor.
Key A-F CH CL CM CT F1 LH, LM PB P1 P4 RB S TS W X Restrictors Splitter clutch - high Splitter clutch - low Splitter clutch - medium Transmission oil cooler Transmission oil filter Restrictors PTO gearbox Pump - differential lock/suspension circuits Pump - transmission circuit Range gearbox Splitter solenoid valve Solenoid valve block-transmission 4WD clutch Main drive clutch booster
Fastrac
60 - 20 - 03/8
8020 - E/13-2.4
C and D Speed gearbox - 3/8 inch BSP male x 1/4 inch BSP male with 2 mm restrictor. E Range gearbox front bearing - 1/2 inch BSP male x 1 / 4 inch BSP male with 1.5 mm positional restrictor (see Range Gearbox Removal and Replacement for fitting instructions). Range gearbox rear bearing - 7/ 16 inch UNF x 1 / 4 inch BSP male with 1 mm restrictor.
60 - 20 - 03/8
Issue 1
CONTENTS
* 2000 *
Fastrac
60 - 20 - 03/9
Circuit Diagrams- Hydraulic Dry Clutch Transmission (contd)
F1
TS
A3
B1
B3
B2
A2
A1
RB
X2
CM
CH
P4
CL
LH LMLL
PB
AC
X1
TPM
CT
9804/1103
60 - 20 - 03/9
8020 - E/13-1.5
TPH
TPL
S
Issue 1
A293504
CONTENTS
9804/1103
2000 SERIES & 3000 SERIES
Pump P4 feeds the PTO clutches, the 4WD clutch, the splitter solenoid valve and the lubrication circuit. The circuit is self-contained, using transmission oil. Note: Pump P4 is the rear section of a pump which is driven by the PTO gearbox. The front section(s) of the pump supply the external hydraulic services and 4WS (if fitted), and use hydraulic oil. The sections of the pump are separated by oil seals. Note that the Wet master clutch, PTO/Splitter, speed and range gearboxes all use the same oil. Transmission oil is drawn from the range gearbox RB by pump P4 and delivered first to the cooler CT. Oil from the cooler flows via filter F1 to the solenoid valve block TS which contains a pressure maintenance valve and three solenoids 1, 2 and 3. A pressure switch PS is fitted to activate a low oil pressure warning in the cab. Solenoid 2 is only fitted to machines having the optional front PTO. Port A2 of this solenoid pressurises the front PTO clutch pack in the main PTO gearbox PB. Port B2 pressurises the front PTO brake. Solenoid 3 supplies the rear PTO clutch in the same way. Port A1 of solenoid 1 pressurises the 4WD clutch W in the range gearbox. Port P2 on the solenoid valve block is for the feed from the pump via filter F1. Port P1 on the opposite end of the block feeds the splitter and transmission brake solenoid control valves VCL, VCM, VCH and VTB. Note that the valves are mounted on a valve block SB that is an integral part of the PTO/Splitter gearbox housing. A feed is also provided for the wet clutch control valve VWC.
The solenoid control valve block TS also incorporates feeds for lubrication circuits from ports HPL and LPL. High pressure lubrication (HPL) and low pressure lubrication (LPL) feeds are connected to wet clutch lubrication valve VL. When the clutch is slipped by the operator the valve supplies high pressure lubrication to the clutch plates. Note that the valve is mounted on the wet clutch housing integral valve block CB. Sensors S1 and S2 warn of overheating transmission oil. S2 is fitted to the clutch housing oil sump. S1 is fitted in the pipe next to the transmission oil filter. Low pressure lubrication oil from port LPL is supplied to clutches and bearings throughout the transmission. Many of these lubrication connections incorporate restrictors inside special adaptors. It is essential that the correct restrictors are fitted as follows: Lubrication Restrictors Wet Clutch A High flow lubrication B Low flow lubrication PTO/Splitter Gearbox C 200 psi engagement feed D 2 bar lube - Splitter clutch H E 2 bar lube - Splitter clutch M F 2 bar lube - Splitter clutch L G Input/Idler gear mesh H Idler shaft J Intermediate shaft K Front PTO pod or blanking plate L Rear PTO pod Speed Gearbox M Front restrictor N Rear restrictor Range Box P Top shaft front feed (angled) R Top shaft rear feed (in plate) S Output shaft front feed T Output shaft rear feed
Key A-T CH CL CM CT F1 PB P4 PS RB S1 S2 SB TB TS VCH VCM VCL VL VTB VWC W Restrictors Splitter clutch - high Splitter clutch - low Splitter clutch - medium Transmission oil cooler Transmission oil filter PTO gearbox Pump - transmission circuit Pressure Switch Range gearbox Transmission oil temperature sensor 1 Transmission oil temperature sensor 2 Splitter solenoid valve block (integral with PTO/Splitter gearbox housing) Transmission brake Solenoid valve block-transmission Splitter clutch control valve - high Splitter clutch control valve - medium Splitter clutch control valve - low Wet clutch lubrication control valve Transmission brake control valve Wet clutch control valve 4WD clutch
Wet Clutch Transmission
Fastrac
60 - 20 - 03/10
8020 - F/13-4.1
3.0 mm dia 3.0 mm dia
3.0 mm dia
1.0 mm dia 1.0 mm dia 1.0 mm dia 2.5 mm dia 2.5 mm dia
Pressure Test Points TP Clutch engagement feed TPB Transmission Brake TPE Master clutch TPL Low splitter Clutch TPM Medium splitter clutch TPH High splitter Clutch TPG Low pressure lubrication
1.5 mm dia 1.5 mm dia
60 - 20 - 03/10
1.5 mm dia No restrictor 1.0 mm dia 1.0 mm dia
Issue 1
CONTENTS
* 2000 *
Fastrac
60 - 20 - 03/11
Circuit Diagrams- Hydraulic Wet Clutch Transmission (contd)

TP PS
F1
S1
TS
A3
B3
B2
TPG
RB
A2
A1
CM
CH
CL
VCM
AC
PB
G H J
D E
TB
VTB
VCH
VCL
CB
VL
SB
VWC
CT
S2
9804/1103
60 - 20 - 03/11
8020 - F/13-3.1
B
Issue 1
A
TPE
TPH TPM TPB TPL
AC
P4
A358460
DRAIN P1 CT1
T CT3 CT4 CT2 P2 HPL LPL
CONTENTS INDEX
Skidsteer Range
ROBOT 185, 1105 Contents

Page No. General Information Fluids, Lubricants and Capacities General Specification Tyre Specification Static Dimensions 70 - 00 - 01/1A 70 - 00 - 01/2 70 - 00 - 01/2 70 - 00 - 02/3,4
Data Electrical Hydraulics from m/c no. 746001 to 804423 Hydraulics from m/c no. 804424 Engine - Standard and High-flow Machines to m/c no. 746805 Engine - High-flow Machines from m/c no. 746806 Circuit Diagrams Electrical from m/c no. 746001 to 746216 Electrical from m/c no. 746217 Hydraulic Standard Machines from m/c no. 746001 to 746998 - Single Lever Drive Control Hydraulic - High-flow Machines from m/c no. 746001 to 746998 - Single Lever Drive Control Hydraulic - Standard Machines - Dual Lever Drive Control from m/c no. 746001 to 746998 Hydraulic - High-flow Machines - Dual Lever Drive Control from m/c no. 746001 to 746998 Hydraulic - Standard Machines - Single Lever Drive Control from m/c no. 746999 to 804423 Hydraulic - High-flow Machines - Single Lever Drive Control from m/c no. 746999 to 804423 Hydraulic - Standard Machines - Dual Lever Drive Control from m/c no. 746999 to 804423 Hydraulic - High-flow Machines - Dual Lever Drive Control from m/c no. 746999 tp 804423 Hydraulic - Standard Machines - Single Lever Drive Control from m/c no. 804424 Hydraulic - High-flow Machines - Single Lever Drive Control from m/c no. 804424 Hydraulic - Standard Machines - Dual Lever Drive Control from m/c no. 804424 Hydraulic - High-flow Machines - Dual Lever Drive Control from m/c no. 804424
70 - 05 - 01/1 & 4 70 - 05 - 03/1-3 20 - 05 - 03/2B, 2C 70 - 05 - 05/1 70 - 05 - 05/2
70 - 15 - 02/1-4 70 - 15 - 02/5-8 70 - 20 - 02/1,2 70 - 20 - 02/3,4 70 - 20 - 02/5,6 70 - 20 - 02/7,8 70 - 20 - 02/9, 10 70 - 20 - 02/11, 12 70 - 20 - 02/13, 14 70 - 20 - 02/15, 16 70 - 20 - 02/17, 18 70 - 20 - 02/19, 20 70 - 20 - 02/21, 22 70 - 20 - 02/23, 24
9804/1103
Skidsteer Contents - 1
Issue7*
INDEX
Skidsteer Range
*ROBOT 160, 170, 170HF Contents

Page No General Information Fluids Capacities and Lubricants General Specification Tyre Specification Static Dimensions Data Electrical Hydraulic Engine from m/c no. 680001 to 681290 Engine from m/c no. 681291 Circuit Diagrams Electrical up to m/c no. 681290 Electrical from m/c no. 681291 Hydraulic Single Lever Drive Control Standard Servo Machine High-flow Servo Machine Hydraulic Dual Lever Drive Control Standard Servo Machine High-flow Servo Machine Manual Machines Standard Circuit High-flow Circuit
70 - 00 - 01/1B 70 - 00 - 01/3 70 - 00 - 01/3 70 - 00 - 02/5,6
70 - 05 - 01/1 & 5 70 - 05 - 03/3 70 - 05 - 06/1 70 - 05 - 06/2
70 - 15 - 3/1, 2 70 - 15 - 3/3, 4 70 - 20 - 01/15,16 70 - 20 - 01/17,18 70 - 20 - 01/19,20 70 - 20 - 01/21,22 70 - 20 - 03/5, 6 70 - 20 - 03/7, 8
9804/1103
Issue 8*
INDEX
Skidsteer Range
150, 165
* ROBOT
Contents
Fault Finding Go to the CD Contents, select Problem Solving, then Robot. Circuit Diagrams Electrical Hydraulic - Standard Servo Machines - High Flow Servo Machine - Standard Manual Machine - High Flow Manual Machine General Information Lubricants and Capacities General Specification Tyre Specification Static Dimensions Data Electrical Hydraulics to m/c no. 677000 Hydraulics from m/c no. 677001 to 677999 Hydraulics from m/c no. 678000 Engine to m/c no. 677000 (Peugeot) Engine from m/c no. 677001 (Perkins) Circuit Diagrams Electrical from m/c no. 675001 to 675357 Electrical from m/c no. 675358 to 677000 Electrical, Basic Canopy - Servo Controls from m/c no. 677001 Electrical, Cab and Options - Servo Controls from m/c no. 677001 Electrical, Basic Canopy - Manual Controls from m/c no. 677001 Electrical, Cab and Options - Manual Controls from m/c no. 677001 Hydraulic from m/c no. 675001 to 675573 Hydraulic from m/c no. 675574 to 677000 Hydraulic from m/c no. 677001 to 677999 Single Lever Drive Control Dual Lever Drive Control Manual Control Hydraulic from m/c no. 678000 Servo machines Standard Circuit High Flow Circuit Manual Controls Standard Circuit High Flow Circuit
70 - 15 - 03/1
70 - 20 - 03/1,2 70 - 20 - 03/3,4 70 - 20 - 03/5,6 70 - 20 - 03/7,8
70 - 00 - 01/1 70 - 00 - 01/2 70 - 00 - 01/2 70 - 00 - 01/1,2
70 - 05 - 01/1-3 70 - 05 - 02/1 70 - 05 - 02/4 70 - 05 - 02/6 70 - 05 - 04/1 70 - 05 - 04/2
70 - 15 - 01/1,2 70 - 15 - 01/3,4 70 - 15 - 01/5,6 70 - 15 - 01/7,8 70 - 15 - 01/9,10 70 - 15 - 01/11,12 70 - 20 - 01/1,2 70 - 20 - 01/3,4 70 - 20 - 01/5,6 70 - 20 - 01/7,8 70 - 20 - 01/9,10
70 - 20 - 01/11 70 - 20 - 01/12 70 - 20 - 01/13 70 - 20 - 01/14
9804/1103
Issue1
CONTENTS
Skidsteer Range
70 - 00 - 01/1
ROBOT 150,165 Lubricants & Capacities

ITEM Engine Oil Peugeot XUD Perkins 104 Hydraulic System CAPACITY FLUID/LUBRICANT
From m/c no. 675001
SPECIFICATION
5 litres (1.32 US gal) JCB 15W/40 Multigrade 8.2 litres (2.17 US gal) JCB 10W/30 Multigrade 65 litres (17.2 US gal) JCB 15W/40 Multigrade JCB 10W/30 Multigrade
API CE 15W 40 API CE 10W 30 API CE 15W 40 API CC 10W 30
Cooling System Peugeot XUD Total coolant cap. Antifreeze Perkins 104 Total coolant cap. Antifreeze Fuel System Grease Points
11 litres (2.9 US gal) Water/Anti-freeze (see Coolant Mixtures) 5.5 litres (1.45 US gal) 11 litres (2.9 US gal) JCB Universal Antifreeze/water 5.5 litres (1.45 US gal) (see Coolant Mixtures) 60 litres (15.8 US gal) Diesel oil (see Types of Fuel) JCB Special HP Grease or JCB Special MPL Grease Engine Oil
Inhibited Ethanediol AL - 39
ASTM D3306-74
ASTM D975-66T Nos. 1D, 2D Lithium based, No. 2 consistency
Chain Case
Fill to level plug
API CE 15W 40 or API CC 10W 30
9804/1103
70 - 00 - 01/1
Issue 5*
CONTENTS
Skidsteer Range
70 - 00 - 01/1A
ROBOT 185, 1105 Fluids, Capacities and Lubricants
To m/c no. 746537
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently runin. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without a load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below.
ITEM
Engine Oil
CAPACITY
FLUID/LUBRICANT
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)
SPECIFICATION
CF-4/SG, SAE15W/40
CF-4/SG, SAE10W/30
Hydraulic System Hydraulic Tank Cooling System Antifreeze Total coolant mixture Fuel System Grease Points
JCB Super Multigrade 10W/30 CF-4/SG, SAE10W/30 JCB Super Multigrade 15W/40 (top up only) CF-4/SG, SAE15W/40
5.5 litres (9.7 UK pints) 11 litres (19.4 UK pints) 99 litres (21.8 UK gal) -
JCB Universal Antifreeze/water (see Coolant Mixtures) Diesel oil (see Types of Fuel) JCB Special HP Grease or JCB Special MPL Grease Engine Oil
ASTM D3306-74
Chain Case
Fill to level plug
North American Capacities and Lubricant Equivalents

ITEM
Engine Oil
CAPACITY
10.7 litres (2.8 US gal)
FLUID/LUBRICANT
JCB 15W/40 Engine Oil 14 F to 122 F (-10 C to +50 C) JCB Engine Oil 10W -4 F to +50 F (-20 C to +10 C)
SPECIFICATION
CF-4/SG, SAE 15W/40
CF-4/SG, SAE 10W
Hydraulic System Hydraulic Tank Cooling System Antifreeze Total coolant mixture Fuel System Grease Points Chain Case
70 litres (18.5 US gal) 58 litres (15.3 US gal)
JCB 10W JCB 15W/40 (top up only)
MIL-L-2104D MIL-L-2104D
5.5 litres (11.6 US pints) 11 litres (23 US pints) 99 litres (26 US gal) Fill to level plug
JCB Universal Antifreeze/water (see Coolant Mixtures) Diesel oil (see Types of Fuel) JCB Moly EP #2 Grease Engine Oil
ASTM D3306-74
ASTM D975-66T Nos. 1D, 2D Lithium based, No. 2
9804/1103
70 - 00 - 01/1A
Issue 2*
CONTENTS
Skidsteer Range
70 - 00 - 01/1B
ROBOT 160, 170, 170HF
From m/c no. 680002
Fluids, Capacities and Lubricants - except North America

ITEM
* Engine Oil To machine no. 681290: From machine no. 681291: * Hydraulic System
CAPACITY
8.2 litres (1.8 UK gal) 10.5 litres (2.3 UK gal) 26 litres (5.7 UK gal)
FLUID/LUBRICANT
JCB High Performance 15W/40
SPECIFICATION
ACEA E2:B2:A2, API CF4/SG
JCB High Performance 10W/30 JCB High Performance 15W/40 (top up only) JCB Four Seasons Antifreeze & Summer Coolant/Water (see Coolant Mixtures) Diesel oil (see Types of Fuel) JCB Special HP Grease
ACEA E2:B2:A2, API CF4/SG ACEA E2:B2:A2, API CF4/SG
* Cooling System Total Coolant Antifreeze * Fuel System * Grease Points
ASTM D3306, BS6580
8 litres (1.8 UK gal) 4 litres (0.9 UK gal) 80 litres (17.6 UK gal)
ASTM D975-66T Nos. 1D, 2D Lithium complex NLGI No. 2 consistency including extreme pressure additives. Lithium based NLGI No. 2 consistency including extreme pressure additives.
or JCB Special MPL-EP Grease
* Chain Case
Engine Oil
Fluids, Capacities and Lubricants - North America

ITEM
* Engine Oil To machine # 681290: From machine # 681291: * Hydraulic System
CAPACITY
FLUID/LUBRICANT
SPECIFICATION
2.16 US gal (8.2 liters) 2.8 US gal (10.5) 6.8 US gal (26 liters)
JCB Genuine Engine Oil 15W/40
CH-4/SJ, SAE 15W/40
JCB Genuine Engine Oil 10W/30 JCB Genuine Engine Oil 15W/40 (top up only)
CH-4/SJ, SAE 15W/40 CH-4/SJ, SAE 15W/40
* Cooling System Total coolant cap. Antifreeze * Fuel System * Grease Points
2.2 US gal (8 liters) 1.1 US gal (4 liters) 21.1 US gal (80 liters)
Permanent Antifreeze
ASTM D3306-74
Diesel oil (see Types of Fuel) JCB Moly EP #2 Grease
ASTM D975-66T Nos. 1D, 2D Lithium based NLGI # 2 consistency including extreme pressure additives.
* Chain Case
7.0 US gal (27 liters)
Engine Oil
9804/1103
70 - 00 - 01/1B
8520 - 3/1-1.6
Issue 3*
CONTENTS
* ROBOT
Skidsteer Range
*
150,165,185, 1105
From m/c no. 675001
General Specification
* Robot 150 kg (lb) Rated lifting capacity SAE tipping load Total weight (inc. standard shovel and driver) Weight distribution (unloaded) front/rear % 500 (1102) 1000 (2205) Robot 165 kg (lb) 650 (1433) 1300 (2866) Robot 185 kg (lb) 850 (1874) 1700 (3748) Robot 1105 kg (lb) 1050 (2314) 2100 (4628)
2300 (5071)
2430 (5358)
3240 (7143)
3455 (7615)
30/70
30/70
30/70
30/70
Tyre Specification
* Robot 150 Pneumatic tyres Goodyear (tubed) or Dico/Armstrong (tubeless) Goodyear or Dico/Armstrong (tubeless) Michelin XZM (tubeless) Non-inflatable tyres (on special rim) Airboss Solid Robot 165 Pneumatic tyres Goodyear or Dico/Armstrong (tubeless) Michelin XZM (tubeless) Non-inflatable tyres (on special rim) Airboss Solid Robot 185, 1105 Pneumatic tyres Dico/Armstrong (tubeless) Dico/Armstrong HD 2000 (tubeless) Michelin X MINE D2 (tubeless) Galaxy (tubeless) - (Robot 1105 only) Non-inflatable tyres (on special rim) Segmented - standard and heavy duty Solid - standard and heavy duty
9804/1103
size 27 x 8.5 x 15 10 x 16.5 700 x R15
pressure - bar (lbf/in2) 3.5 (50) 2.4 (35) 3.0 (43)
10 x 16.5 & 7.5 x 15 7.00 x 15 - 5.5
size 10 x 16.5 700 x R15
pressure - bar (lbf/in2) 2.4 (35) 3.0 (43)
10 x 16.5 & 7.5 x 15 7.00 x 15 - 5.5
size 12 x 16.5 12 x 16.5 7.50 x 15 33 x 15.5 x 16.5
pressure - bar (lbf/in2) 3.5 (50) 3.5 (50) 3.5 (50) 4.0 (60)
70 - 00 - 01/2
Issue 2
CONTENTS
Skidsteer Range
70 - 00 - 01/3
ROBOT 160, 170, 170HF
From m/c no. 680001
General Specification
Robot 160 - kg (lb) Rated operating capacity with standard bucket with JCB approved fork carrier and forks SAE tipping load with standard bucket with JCB approved fork carrier and forks Total weight (inc. standard bucket) Weight distribution (unloaded) front/rear %
Robot 170 - kg (lb)
600 (1325) 495 (1090)
700 (1545) 555 (1225)
1200 (2650) 990 (2180)
1400 (3090) 1110 (2450)
2410 (5315)
2510 (5535)
30/70
30/70
Tyre Specification
Pneumatic tyres Solideal Solideal Galaxy - North America only Solideal Solideal Galaxy- North America only Non-inflatable tyres (on special rim) Airboss Solids
size 10 x 16.5, 6 Ply 10 x 16.5, 8 Ply 10 x 16.5, 8 Ply 7.00 x 15, 6 Ply 7.00 x 15, 14 Ply 31.5/1300 x 16.5, 10 Ply
pressure - bar (lbf/in2) 3.1 (45) 3.1 (45) 3.1 (45) 4.1 (60) 4.1 (60) 4.1 (60)
10 x 16.5 & 7.50 x 15 6.50 x 16, 7.50 x 15 & 7.50 x 16
9804/1103
70 - 00 - 01/3
4300 - 131
Issue 1
CONTENTS
Skidsteer Range
70 - 00 - 01/5
ROBOT 160, 170, 170H Static Dimensions
From m/c no. 680001
Robot 160 A B C D E Overall length (including Quickhitch) Overall length (including standard shovel) Height to cab roof Height to loader tower Width over tyres (7 x 15) Width over tyres (10 x 16.5) F G H J K L M N O P Q Ground clearance Wheel base Maximum pin height Shovel roll back angle (from horizontal) Shovel dump angle at maximum height Shovel maximum lift height Shovel dump height at maximum dump angle Shovel reach at maximum dump angle Shovel reach at ground level Shovel reach at maximum height Shovel width (standard) 2530 mm (99.6 in) 3210 mm (126.4 in) 1929 mm (76.0 in) 1606 mm (63.2 in) 1372 mm (54 in) 1524 mm (60 in) 169 mm (6.7 in) 980 mm (38.6 in) 2800 mm (110.2 in) 30 40 2645 mm (104.1 in) 2158 mm (85.0 in) 562 mm (22.1 in) 870 mm (34.3 in) 852 mm (33.5 in) 1430 mm (56.0 in)
Robot 170 2583 mm (101.7 in) 3264 mm (128.5 in) 1938 mm (76.3 in) 1615 mm (63.6 in) 1372 mm (54 in) 1524 mm (60 in) 178 mm (7 in) 1033 mm (40.7 in) 2929 mm (115.3 in) 30 40 2775 mm (109.3 in) 2288 mm (90.1 in) 470 mm (18.5 in) 857 mm (33.8 in) 759 mm (29.9) 1580 mm (62.0 in)
9804/1103
70 - 00 - 01/5
4300 - 132
Issue 1
CONTENTS
Skidsteer Range
70 - 00 - 01/6
ROBOT 160, 170, 170H Static Dimensions (contd)
From m/c no. 680001
N M P C D
J O G A B F
332751
9804/1103
70 - 00 - 01/6
4300 - 133
Issue 1
CONTENTS
Skidsteer Range
From m/c no. 675001
ROBOT 150, 165 Static Dimensions

Robot 150 A B C D E F G H Overall length (including standard shovel) Height to cab roof Width over tyres Ground clearance at sides Ground clearance at centre Wheel base Rear overhang Maximum pin height Standard shovel J - roll back angle (from horizontal) K - dump angle at maximum height L - dump height at maximum dump angle - reach at maximum dump angle * - width 39 45 2366 mm (93.10 in) 570 mm (22.50 in) 1430 mm (56.30 in) 3010 mm (118.50 in) 1850 mm (72.80 in) 1363 mm (53.70 in) 165 mm (6.50 in) 255 mm (10.00 in) 988 mm (38.90 in) 942 mm (37.10 in) 2980 mm (117.30 in)
Robot 165 3060 mm (120.50 in) 1860 mm (73.20 in) 1500 mm (59.00 in) 175 mm (6.90 in) 265 mm (10.40 in) 1043 mm (41.10 in) 915 mm (36.00 in) 2976 mm (117.20 in)
39 45 2345 mm (92.32 in) 690 mm (27.20 in) 1580 mm (62.20 in)
D F A G
E C
S174470
9804/1103
70 - 00 - 02/1
Issue 3*
CONTENTS
Skidsteer Range
*
From m/c no. 675001
9804/1103
70 - 00 - 02/2
Issue 2*
CONTENTS
Skidsteer Range
From m/c no. 746001

* Robot 185 A Overall length (including standard shovel) B Height to cab roof C Width over tyres D Ground clearance at centre E Wheel base F Maximum pin height Standard shovel G - roll back angle (from horizontal) H - dump angle at maximum height J - dump height at maximum dump angle - reach at maximum dump angle - width 39 45 2645 mm (8 ft 7 in) 650 mm (2 ft 1 in) 1800 mm (5 ft 11 in)
Robot 1105
3406 mm (11 ft 2 in) 2020 mm (6 ft 6 in) 1700 mm (5 ft 7 in) 255 mm (10 in) 1130 mm (3 ft 7 in) 3315 mm (10 ft 9 in)
3412 mm (12 ft 10 in) 2020 mm (6 ft 6 in) 1700 mm (5 ft 7 in) 255 mm (10 in) 1130 mm (3 ft 7 in) 3315 mm (10 ft 9 in)
39 45 2645 mm (8 ft 7 in) 650 mm (2 ft 1 in) std. 1800 mm (5 ft 11 in) opt. 1950 mm (6 ft 5 in)
9804/1103
70 - 00 - 02/3
Issue 2*
CONTENTS
* ROBOT
Skidsteer Range
From m/c no. 746001
185, 1105
Static Dimensions
D E A C
A225940
F J
G
A225950
9804/1103
70 - 00 - 02/4
Issue 2*
CONTENTS CONTENTS
Skidsteer Range
70 - 05 - 01/2
ROBOT 150,165 Data - Electrical (cont) Fuses

The electrical circuits are protected by fuses. The fuses are located towards the rear of the switch/warning indicator panel as shown in the illustration.
From m/c no. 675001 to 675367
Relays
Indicator Flasher Unit Door Open/Close Switch Alarm Buzzer Harness Plugs Cover Glow Plugs Relay Auxiliary Isolation Relay A B C D E F
D A Y X B F C
S174431
Y
7 8 9
S174511
X
1
Fuse Number 1 2 3 4 5 6 7 8 9
A174431
Note: The canopy machine has only fuse board X fitted, the standard cab machine and the cab machine with options have both fuse boards X and Y fitted.
Canopy Machine Spare Spare Pressure reducing solenoid valve Interlock relay Auxiliary hydraulics ESOS, warning lights and buzzer Horn Low water warning Spare Spare Spare
Cab Machine / Options Interior light Front work lights Beacon Rear work light Pressure reducing solenoid valve Interlock relay Auxiliary hydraulics ESOS, warning lights and buzzer Horn Low water warning Indicators, Sidelights, Dip and Number plate Wipers and Washer Heater/Blower Reverse Alarm
Fuse Size
10 amp 10 amp 10 amp 10 amp 5 amp 10 amp
10 amp 10 amp 10 amp
9804/1103
70 - 05 - 01/2
Issue 2
CONTENTS
Skidsteer Range
70 - 05 - 01/1
ROBOT 150,165 From m/c no. 675001 Data - Electrical

System Type Battery Cold Crank Amps for 1 minute to 1.4 VPC at -18 C (0 F) Reserve capacity (minutes) for 25 Amp load Alternator Peugeot Engines Perkins Engines Starter Motor Peugeot Engines Perkins Engines 12 Volts, negative earth
420 to 585 170 to 230
according to battery type
Lucas A127-65, 65 Amp maximum output Lucas A127-55, 55 Amp maximum output Lucas M127/2.8 Mitsubishi M002T54091, 2Kw
Light Bulbs
Working Lights Indicator Lights Interior Light Warning Light Beacon (if fitted) Side Lights * ROBOT 55W (Halogen) 21W 10W 1.2W 70W 5W
185, 1105 From m/c no. 746001

System Type Battery Cold Crank Amps for 1 minute to 1.4 VPC at -18 C (0 F) Reserve capacity (minutes) for 25 Amp load Alternator Starter Motor
420 to 585 170 to 230
Magneti Marelli A127-65, 65 Amp maximum output Magneti Marelli M127
Light Bulbs
Working Lights Indicator Lights Interior Light Warning Light Beacon (if fitted) Side Lights * Robot 55W (Halogen) 21W 10W 1.2W 70W 5W
160, 170, 170HF From m/c no. 680001

12 Volts, negative earth 420 to 585 170 to 230 535 135 55 Amp maximum output according to battery type
System Type Battery up to machine number 680579 Cold Crank Amps for 1 minute to 1.4 VPC at -18 C (0 F) Reserve capacity (minutes) for 25 Amp load Battery from machine number 680580 Cold Crank Amps for 1 minute to 1.4 VPC at -18 C (0 F) Reserve capacity (minutes) for 25 Amp load Alternator
Light Bulbs
Working Lights Headlights Indicator Lights Brake Lights Interior Light Warning Lights Beacon (if fitted) Side Lights
9804/1103
55W (Halogen) 55/60W (Halogen) 21W 21W 10W 1.2W 55W 5W
70 - 05 - 01/1
Issue 5*
CONTENTS
Skidsteer Range
From m/c no. 675358
ROBOT 150,165 Data - Electrical (cont)

*
Fuses - later machines

The electrical circuits are protected by fuses. The fuses are located towards the rear of the switch/warning indicator panel as shown in the illustration.
Relays - later machines

Relays (A) Indicator Flasher Unit Door Open/Close Switch Alarm Buzzer Auxiliary Isolation Relay Glow Plug Relay B The Glow Plug Relay for Perkins engines is visually different but in the same location. Relay type PC MF (Blue relay) PD PS (Black relay)
S201900
* Note: Depending on the number of options specified, the machine may be fitted with either one fuse board X or both fuse boards X and Y.
S174511
* Fuse Number 1 2 3
Machine with fuse board X only Interior light, Beacon Front and rear working lights Interlock relay, Brake solenoid, Operational solenoid (servo only), Reverse alarm Auxiliary hydraulics (servo only), High-flow solenoid
Fuse Size
Machine with fuse boards X and Y Interior light, Roadlights Beacon Interlock relay, Brake solenoid, Operational solenoid (servo only)
Fuse Size
10 amp 15 amp 5 amp
15 amp 10 amp 10 amp
5 amp (10 High-flow) 5 amp
Heated seat, Auxiliary hydraulics (servo only)
10 amp
ESOS, warning lights and buzzer, Hour meter, Float solenoid (servo only)
ESOS, warning lights and buzzer, Hour meter, High-flow solenoid, Float solenoid (servo only) Horn, Front working lights, Brake lights Hazard lights Wipers and Washer Heater/Blower, Reverse Alarm Rear working light, Indicators L.H. Sidelights, Number plate light R.H. Sidelights
5 amp (10 High-flow)
6 7 8 9 10 11 12
9804/1103
Horn Not used Not used Not used Not used Not used Not used
15 amp
10 amp 10 amp 10 amp 10 amp 10 amp 5 amp 5 amp

Issue 3
70 - 05 - 01/3
CONTENTS
Skidsteer Range
From m/c no. 746001
ROBOT 185 Data - Electrical (cont) Relays

Relay Indicator Flasher Unit * Interlock Relay Alarm Buzzer Auxiliary Isolation Relay Horn Relay Two Speed Relay Position at A PC (Black) MF (Blue) PD (Black) PS (Black) PZ (Blue) TS (Blue)
* Deleted from machine no. 746218 (Sept. 96)
Fuses
The electrical circuits are protected by fuses. The fuses are located towards the rear of the switch/warning indicator panel as shown in the illustration. Note: The canopy machine has only fuse board X fitted, the standard cab machine and the cab machine with options have both fuse boards X and Y fitted.
S236102
Fuse Number 1 2 3 4 5 6 7 8 9 10 11 12
Standard Machine Interior light Beacon (Sequence unit up to m/c no. 746217) Parking brake, Front working lights (Interlock relay up to m/c no. 746217) Auxiliary hydraulics ESOS, warning lights and buzzer 2 speed switch Horn, 2 speed solenoid Spare Spare Spare Spare Spare Spare
Machine with Options Interior light, Roadlights Beacon (Sequence unit up to m/c no. 746217) Parking brake, Front working lights (Interlock relay up to m/c no. 746217) Auxiliary hydraulics ESOS, warning lights and buzzer, 2 speed switch Float solenoid, Hi-flow solenoid Brake lights, Horn, 2 speed solenoid Hazard lights Wipers and Washer, Indicators Reverse Alarm, Wiper Rear working lights, Heater/Blower L.H. Sidelights, Number plate light R.H. Sidelights
Fuse Size 15 amp 10 amp
15 amp 5 amp 10 amp 10 amp 10 amp 10 amp 5 amp 15 amp 5 amp 5 amp
9804/1103
70 - 05 - 01/4
Issue 3
CONTENTS
Skidsteer Range
Primary Fuses
70 - 05 - 01/5
ROBOT 160, 170, 170H Data - Electrical (contd) Fuses

The electrical circuits are protected by fuses. The fuses are located behind a cover on the right hand side of the cab as shown at X. Note: Depending on the number of options specified, some fuses may not be fitted. Fuse No. Circuits Protected A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 Spool Lock, Restraint Switch, Cut-off Solenoid (Servo) Junction Box Ignition Circuits ESOS Front Work Lights Rear Work Light Reverse Alarm Float Circuit Horn Beacon, Interior Light Right Hand Side and Tail Lights Left Hand Side and Tail Lights, Number Plate Light Head Light Dip Beam Indicators High Flow Hydraulics Heater Blower Wipers and Washers Brake Lights Self Level Circuit Hazard Warning
From m/c no. 680001
To further protect the machine wiring harnesses and electrical circuits, a primary fuse box is fitted to the battery positive terminal as shown at A. Remember to check the main fuses as well as the primary fuses shown below. 1 2 3 4 5 Starter switch, all ignition switched circuits Beacon, horn, road lights, indicators Not used Not used Ignition relay 60 Amp 30 Amp 30 Amp 80 Amp 40 Amp
Size
10 Amp 10 Amp 5 Amp 5 Amp 15 Amp 7.5 Amp 5 Amp 5 Amp 5 Amp 7.5 Amp 5 Amp 5 Amp 15 Amp 5 Amp 5 Amp 10 Amp 10 Amp 5 Amp 5 Amp 10 Amp 60A 40A
2
30A
3
30A
MAIN
A
80A
326590
B
5 5 15 5 5 10 10 5 5 10
A
10 10 5 5 15 7.5 5 5 5 7.5
@ ! 0 9 8 67
Relays
The relays are located under fuse cover X on the right hand side of the cab as shown in the illustration. 6 Parking Brake 10 Float 7 Horn 11 High-flow 8 Neutral Start 12 Indicator Flasher Unit 9 Ignition Note: Relay 7 is located behind relay 6. Relays 10, 11 and 12 are for optional circuits and are only fitted as required.
332851
9804/1103
70 - 05 - 01/5
8520 - C/1-2.2
Issue 1
CONTENTS
Skidsteer Range
*
ROBOT 150,165 Data - Hydraulics

Auxiliary Pump - Standard Type Displacement Maximum Working Pressure Maximum Speed Maximum Input Torque Auxiliary Pump - High-Flow Type Displacement - Front Section Displacement - Rear Section Maximum Working Pressure Maximum Speed Maximum Input Torque Main Pump (2-off) up to machine no. 676354 * Type Displacement Control Maximum Working Pressure Maximum Speed Maximum Input Torque Charge Pressure (oil temperature at 50 C) Main Pump (2-off) from machine no. 676355 * Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50 C) Loader & Transmission Joysticks Type Maximum Working Pressure Output Characteristics - all 4 positions
From m/c no. 675001 to 677000
Sauer Sundstrand SP2 250/16.0, gear type 48 l/min (10.5 UK gal, 12.7 US gal/min) at 3000 rev/min 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 3200 rev/min 121 Nm (89 lbf ft, 12 kgf m)
Sauer Sundstrand AJJ 0100 16/28LC 57 l/min (12.5 UK gal, 15 US gal/min) at 3600 rev/min 90 l/min (19.8 UK gal, 23.8 US gal/min) at 3600 rev/min 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 3600 rev/min 121 Nm (89 lbf ft, 12 kgf m)
Sauer Sundstrand tandem axial piston Series 40 M35 35 cc/rev (2.13 in3/rev) Servo non-feedback proportional, 18 bar (261 lbf/in 2) to give max pump displacement. 280 bar (4060 lbf/in2) 3600 rev/min 121 Nm (89 lbf ft, 12 kgf m) 6 bar (87 lbf/in2) at engine idle; 18 bar (261 lbf/in2) at 3000 rev/min
Sauer Sundstrand tandem axial piston Series 42 M28 28 cc/rev (1.71 in3/rev) Servo non-feedback proportional, 15 bar (218 lbf/in 2) to give max pump displacement. 350 bar (5076 lbf/in2) 3900 rev/min 7.5 bar (109 lbf/in2) at engine idle; 19.5 bar (283 lbf/in2) at 3000 rev/min
Vickers HRC4 - J1Q - 1 - 30 24 bar (348 lbf/in2) 3.3 to 3.7 bar (48 to 53 lbf/in2) at 15% stroke. 14.5 to 16.5 bar (210 to 234 lbf/in2) at 95% stroke.
Hydraulic Motors up to machine no. 676354 Type Displacement Maximum Working Pressure Maximum Speed Maximum Flow Hydraulic Motors from machine no. 676355 Type Displacement Maximum Working Pressure Maximum Speed Maximum Flow Rexroth MCR03 328 cc/rev (20 in3/rev) 414 bar (6000 lbf/in2) continuous 237 rev/min continuous 84 l/min (18.5 gal/min, 24 US gal/min) continuous Danfoss OMT 400 FX 410.9 cc/rev (25 in3/rev) 280 bar (4061 lbf/in2) continuous 306 rev/min continuous 125 l/min (27.5 gal/min, 33 US gal/min) continuous
9804/1103
70 - 05 - 02/1
Issue 4*
CONTENTS
Skidsteer Range
*
ROBOT 150,165 Data - Hydraulics (cont)

Loader Valve Block to machine no. 675573 Type Maximum Working Pressure * Maximum Return Pressure Services Operated: - Spool 1 - Spool 2 - Spool 3 (Optional) Maximum Leakage (all spools) Loader Valve Block from machine No. 675574 Type Maximum Working Pressure * Maximum Return Pressure Services Operated: - Spool 1 - Spool 2 - Spool 3 (Optional) Maximum Leakage (all spools) High-Flow Valve Block Type Maximum Working Pressure * Maximum Return Pressure Maximum Leakage Relief Valve Operating Pressures (at normal working temperature) Main Relief Valve: at 1500 rev/min (24 litres/min) Auxiliary Relief Valve - Spool 1 - Spool 2 - Spool 3 A.R.V. ports tapped and plugged Pressure Reducing Solenoid Valve Maximum Inlet Pressure Regulated Pressure Minimum Rated Flow Maximum Leakage Oil Temperature Range Solenoid Valve (including Diodes) Reducing Valve Electrics
From m/c no. 675001 to 677000
Husco 5000 C824 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 20 bar (290 lbf/in2, 20 kgf/cm2) Boom Ram - Hydraulic Servo Crowd Raise Lower - Hydraulic Servo Auxiliary - Electrical Solenoid 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)
Husco 5000 B815 (2 spool), C842 (3 spool) 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 20 bar (290 lbf/in2, 20 kgf/cm2) Crowd Raise Lower - Hydraulic Servo Boom Ram - Hydraulic Servo Auxiliary - Electrical Solenoid 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)
Husco 6000 (single acting spool) 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 20 bar (290 lbf/in2, 20 kgf/cm2) 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)
bar 185 - 192 230 - 237 230 - 237
lbf/in2 2683 - 2785 3335 - 3436 3335 - 3436
kgf/cm2 188 - 196 234 - 242 234 - 242
185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 24 bar (348 lbf/in2, 24 kgf/cm2) 10 l/min (2.2 gal/min) 25 cc/min (1.5 in3/min) at 210 bar (3045 lbf/in2) and 10 cSt - 40 C to +106 C 3 Position, 3 Port Cartridge Valve Cartridge Type 12 Volt
Filter Type Main Hydraulic * High-Flow * * Suction Strainer High Pressure Spin - On 5 micron 17 micron 125 micron
9804/1103
70 - 05 - 02/2
Issue 4*
CONTENTS
Skidsteer Range
From m/c no. 675001

Rams Boom Lift Crowd Compensating Bore mm 70 80 100 60 50 Nm in 2.75 3.15 3.94 2.36 1.97 Rod Dia mm in 40 1.57 40 1.57 50 1.97 30 1.18 25 0.98 lbf ft
(80 x 40) (100 x 50) (60 x 30) (50 x 25)
Stroke mm 677 233 234 264 288 Kg fm
in 26.65 9.17 9.21 10.39 11.32
Ram Torque Settings Piston Head: Boom Lift Crowd
(80 x 40) (100 x 50) Compensating (60 x 30) (50 x 25)
405 405 405 300 250
299 299 299 221 184
41.3 41.3 41.3 30.6 25.5
End Cap: Boom Lift Crowd
(80 x 40) (100 x 50) Compensating (60 x 30) (50 x 25)
678 678 678 450 400
500 500 500 331 295
69.2 69.2 69.2 45.9 40.8
* General
Description
The main components of the hydraulic circuit are the tank, pumps, drive motors, control valves, filters, cooler and rams. Two types of control system are used, servo and manual. On servo machines, hydraulic joystick controls are used to operate the loader and drive functions. The pumps are driven by the engine and are mounted in tandem. they deliver pressurised oil to the valves and motors. Servo Machines When a drive control is operated, oil is fed from the joystick to the transmission pump servo-controls. The pump swashplate moves to vary or change the flow direction to the motors and hence the speed or direction of rotation. When a loader control is operated, servo oil is fed from the joystick to a loader valve spool which then moves to direct pressurised oil to operate the appropriate ram. Relief valves in the loader and transmission circuits prevent system pressure from rising too far. On machines prior to serial number 678000, hydraulic pressure for the joysticks is regulated by the Pressure Reducing Solenoid Valve which, together with its associated electrical circuitry, is designed to ensure that the controls cannot be operated without the operator being seated correctly, with the Safety Restraint Bar in the operating position and the door closed and latched. On machines from serial number 678000, hydraulic pressure for the joysticks is regulated by the transmission pump charge valve and is fed to the joysticks via the solenoid operated Brake Valve. The Brake Valve, together with its associated electrical circuitry, is designed to ensure that the controls cannot be operated without the operator being seated correctly, with the Safety Restraint Bar in the operating position and the door closed and latched. Manual Machines The control levers are mechanically connected to the transmission pump and to the loader valve block. When a drive control is operated, the pump swashplate is moved to change or reverse the flow direction to the motors. When a loader control is operated, the loader valve spool moves to direct pressurised oil to operate the appropriate ram. Relief valves in the loader and transmission circuits prevent system pressure from rising too far. As an option on machines after serial number 678000, the loader functions can be controlled by dual foot pedals. A mechanical interlock prevents the controls from being moved unless the Safety Restraint is in the operating position. In addition, on machines after serial number 678000, solenoid operated lockout valves also prevent the boom service from being operated until the operator is seated correctly in his seat, with the door closed and latched.
9804/1103
70 - 05 - 02/3
Issue 3*
CONTENTS
Skidsteer Range
*
ROBOT 150,165 Data - Hydraulics

Auxiliary Pump - Standard Type Displacement Maximum Working Pressure Maximum Speed Auxiliary Pump - High-Flow Type Displacement - Front Section Displacement - Rear Section Maximum Working Pressure Maximum Speed Main Pump (2-off) - Servo Machines * Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50 C) Main Pump (2-off) - Manual Machines Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50 C) Servo Joysticks Type Maximum Working Pressure * Output Characteristics - Transmission control spools * Output Characteristics - Loader control spools
From m/c no. 677001 to 677999
Sauer Sundstrand SP2 250/16.0, gear type 48 l/min (10.5 UK gal, 12.7 US gal/min) at 3000 rev/min 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 3000 rev/min
Sauer Sundstrand AJJ 0100 16/28LC 48 l/min (10.5 UK gal, 12.7 US gal/min) at 3000 rev/min 106 l/min (23.3 UK gal, 28 US gal/min) at 3000 rev/min 207 bar (3002 lbf/in2, 211 kgf/cm2) 3000 rev/min
Sauer Sundstrand tandem axial piston Series 42 M28 28 cc/rev (1.71 in3/rev) Servo non-feedback proportional, 18 bar (261 lbf/in 2) to give max pump displacement. 414 bar (6004 lbf/in2) 3000 rev/min 7.5 bar (109 lbf/in2) at 800 rev/min; 19.5 bar (283 lbf/in2) at 3000 rev/min
Sauer Sundstrand tandem axial piston Series 40 M35 35 cc/rev (2.14 in3/rev) Direct Displacement Manual Control 345 bar (5003 lbf/in2) 3000 rev/min 17 bar (246 lbf/in2)
Vickers HRC4 - J1Q - 1 - 30 24 bar (348 lbf/in2) 5 bar (72 lbf/in2) at 15% stroke. 15 bar (217 lbf/in2) at 100% stroke. 3.3 to 3.7 bar (48 to 53 lbf/in2) at 15% stroke. 14.5 to 16.5 bar (210 to 239 lbf/in2) at 95% stroke.
Hydraulic Motors - Servo Machines Type Displacement Maximum Working Pressure * Maximum Speed * Maximum Flow Hydraulic Motors - Manual Machines Type Displacement Maximum Working Pressure Maximum Speed Maximum Flow Rexroth MCR3 400 cc/rev (24.4 in3/rev) 414 bar (6003 lbf/in2) continuous 305 rev/min continuous 122 l/min (26.8 gal/min, 32 US gal/min) Rexroth MCR3 328 cc/rev (20 in3/rev) 414 bar (6000 lbf/in2) continuous 305 rev/min continuous 100 l/min (22 gal/min, 26 US gal/min)
9804/1103
70 - 05 - 02/4
Issue 3*
CONTENTS
Skidsteer Range
*

Loader Valve Block - Servo Machines Type Maximum Working Pressure * Maximum Return Pressure Services Operated: - Spool 1 - Spool 2 - Spool 3 (Optional) Maximum Leakage (all spools) Loader Valve Block - Manual Machines Type Maximum Working Pressure Maximum Return Pressure Services Operated: - Spool 1 (Optional) - Spool 2 - Spool 3 Maximum Leakage (all spools) High-Flow Valve Block Type Maximum Working Pressure * Maximum Return Pressure Maximum Leakage Relief Valve Operating Pressures (at normal working temperature) Main Relief Valve: at 1500 rev/min (24 litres/min) Auxiliary Relief Valve - Lift Service - Shovel Service - Auxiliary Service A.R.V. ports plugged Pressure Reducing Solenoid Valve - Servo Machines Maximum Inlet Pressure Regulated Pressure Minimum Rated Flow Maximum Leakage Oil Temperature Range Solenoid Valve (including Diodes) Reducing Valve Electrics
From m/c no. 677001 to 677999
Commercial Hydraulic KA18 207 bar (3002 lbf/in2, 211 kgf/cm2) 20 bar (290 lbf/in2, 20 kgf/cm2) Shovel Ram - Hydraulic Servo Boom Ram - Hydraulic Servo Auxiliary - Electrical Solenoid 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)
Commercial Hydraulic KA10 207 bar (3002 lbf/in2, 211 kgf/cm2) 30 bar (435 lbf/in2, 31 kgf/cm2) Auxiliary - Manually operated Shovel Ram - Manually operated Boom Ram - Manually operated 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)
Husco 6000 (single acting spool) 185 bar (2683 lbf/in2, 188 kgf/cm2) 20 bar (290 lbf/in2, 20 kgf/cm2) 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)
bar 185 3.5 230 - 237 230 - 237
lbf/in2 2683 50 3335 - 3436 3335 - 3436
kgf/cm2 188 3.57 234 - 242 234 - 242
185 bar (2683 lbf/in2, 188 kgf/cm2) 24 bar (348 lbf/in2, 24 kgf/cm2) 10 l/min (2.2 gal/min) 25 cc/min (1.5 in3/min) at 210 bar (3045 lbf/in2) and 10 cSt - 40 C to +106 C 3 Position, 3 Port Cartridge Valve Cartridge Type 12 Volt
* Filter Type Main Hydraulic High-Flow Suction Strainer High Pressure Spin - On 5 micron 17 micron 125 micron
9804/1103
70 - 05 - 02/5
Issue 2*
CONTENTS
Skidsteer Range
*

* Auxiliary Pump - Standard Type Displacement Maximum Working Pressure Maximum Speed * Auxiliary Pump - High-Flow Type Displacement - Front Section Displacement - Rear Section Maximum Working Pressure Maximum Speed * Main Pump (2-off) - Servo Machines Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50 C) * Main Pump (2-off) - Manual Machines Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50 C) * Servo Joysticks Type Maximum Working Pressure Output Characteristics - Transmission control spools Output Characteristics - Loader control spools
From m/c no. 678000
Sauer Sundstrand SP2 250/16.0, gear type 54 l/min (11.9 UK gal, 14.2 US gal/min) at 3000 rev/min 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 3200 rev/min
Sauer Sundstrand AJJ 0100 16/28LC 54 l/min (11.9 UK gal, 14.2 US gal/min) at 3000 rev/min 106 l/min (23.3 UK gal, 28 US gal/min) at 3000 rev/min 207 bar (3002 lbf/in2, 211 kgf/cm2) 3200 rev/min
Sauer Sundstrand tandem axial piston Series 42 M28 28 cc/rev (1.71 in3/rev) Servo non-feedback proportional, 18 bar (261 lbf/in 2) to give max pump displacement. 414 bar (6004 lbf/in2) 3000 rev/min 7.5 bar (109 lbf/in2) at 800 rev/min; 19.5 bar (283 lbf/in2) at 3000 rev/min
Sauer Sundstrand tandem axial piston Series 40 M35 35 cc/rev (2.14 in3/rev) Direct Displacement Manual Control 385 bar (5584 lbf/in2) 3100 rev/min 11 bar (160 lbf/in2) non adjustable
Vickers HRC4 - J1Q - 1 - 30 24 bar (348 lbf/in2) 5 bar (72 lbf/in2) at 15% stroke. 15 bar (217 lbf/in2) at 100% stroke. 3.3 to 3.7 bar (48 to 53 lbf/in2) at 15% stroke. 14.5 to 16.5 bar (210 to 239 lbf/in2) at 95% stroke.
* Hydraulic Motors - Servo Machines Type Displacement Maximum Working Pressure Maximum Speed Maximum Flow * Hydraulic Motors - Manual Machines Type Displacement Maximum Working Pressure Maximum Speed Maximum Flow Rexroth MCR3 400 cc/rev (24.4 in3/rev) 414 bar (6000 lbf/in2) continuous 305 rev/min continuous 122 l/min (27 UK gal/min, 32 US gal/min) Rexroth MCR3 328 cc/rev (20 in3/rev) 414 bar (6000 lbf/in2) continuous 305 rev/min continuous 100 l/min (22 UK gal/min, 32 US gal/min)
9804/1103
70 - 05 - 02/6
Issue 2*
CONTENTS
Skidsteer Range
From m/c no. 678000

Loader Valve Block - Servo Machines Type Maximum Working Pressure Maximum Return Pressure Services Operated: - Spool 1 - Spool 2 - Spool 3 (Optional) Maximum Leakage (all spools) Loader Valve Block - Manual Machines Type Maximum Working Pressure Maximum Return Pressure Services Operated: - Spool 1 (Optional) - Spool 2 - Spool 3 Maximum Leakage (all spools) High-Flow Valve Block Type Maximum Working Pressure Maximum Return Pressure Maximum Leakage Relief Valve Operating Pressures (at normal working temperature) Main Relief Valve: at 1500 rev/min (24 litres/min) Auxiliary Relief Valve - Lift Service - Shovel Service - Auxiliary Service A.R.V. ports plugged Solenoid Brake Valve Type - Servo Machines - Manual Machines Electrics Filter Type Main Hydraulic High-Flow Suction Strainer High Pressure Spin - On 5 micron 17 micron 125 micron
Commercial Hydraulic KA18 207 bar (3002 lbf/in2, 211 kgf/cm2) 20 bar (290 lbf/in2, 20 kgf/cm2) Shovel Ram - Hydraulic Servo Boom Ram - Hydraulic Servo Auxiliary - Manually operated 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)
Commercial Hydraulic KA10 207 bar (3002 lbf/in2, 211 kgf/cm2) 20 bar (290 lbf/in2, 20 kgf/cm2) Auxiliary - Manually operated Shovel Ram - Manually operated Boom Ram - Manually operated 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)
Husco 6000 (single acting spool) 185 bar (2683 lbf/in2, 188 kgf/cm2) 20 bar (290 lbf/in2, 20 kgf/cm2) 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)
bar 185 3.5 230 - 237 230 - 237
lbf/in2 2683 50 3335 - 3436 3335 - 3436
kgf/cm2 188 3.57 234 - 242 234 - 242
3 Position, 4 way Directional Control 2 Position, 4 way Directional Control 12 Volt
9804/1103
70 - 05 - 02/7
Issue 1
CONTENTS
Skidsteer Range
*
70 - 05 - 03/1
ROBOT 185, 1105 Data - Hydraulics

* To machine no. 804434 Note: System Cleanliness is to be to ISO 16/13. * Auxiliary Pump Type Displacement Maximum Working Pressure * High-Flow Pump (up to June 1997) Type Displacement Maximum Working Pressure * High-Flow Pump (from July 1997) Type Displacement Maximum Working Pressure * Main Pump (2-off) Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50 C) Charge Pump Flow * Loader Joystick - Single lever drive control Output Characteristics - Forward/Reverse positions - Left/Right positions
From m/c no. 746001 to 804423
SP2 250/36.0, gear type 75 litres (16.5 UK gal; 19.8 US gal) per min. at 2200 rev/min 220 - 227 bar (3190 - 3292 lbf/in2, 223 - 232 kgf/cm2)
16 cc/rev 65 litres (14.3 UK gal; 17.2 US gal) per min. at 2200 engine rev/min 205 - 212 bar (2973 - 3074 lbf/in2, 208 - 216 kgf/cm2)
12.8 cc/rev 45 litres (9.8 UK gal; 11.8 US gal) per min. at 2200 engine rev/min 205 - 212 bar (2973 - 3074 lbf/in2, 208 - 216 kgf/cm2)
Tandem axial piston Series 40 M35 35 cc/rev Servo non-feedback proportional, 18 bar (261 lbf/in2) to give max pump displacement. 414 bar (6003 lbf/in2) 2400 rev/min 20 - 30 bar (290 - 435 lbf/in2) at 2200 rev/min 38 - 40 litres (8.4 - 8.8 UK gal; 10.0 - 10.5 US gal) per min. at 2200 rev/min
5 bar (72.5 lbf/in2) at 15% stroke, 19 bar (275 lbf/in2) at 100% stroke. 1 bar (14.5 lbf/in2) at 15% stroke, 15 bar (217.5 lbf/in2) at 100% stroke.
* Transmission Joystick - Single lever drive control Output Characteristics - Forward/Reverse positions - Left/Right positions 5 bar (72.5 lbf/in2) at 15% stroke, 19 bar (275 lbf/in2) at 100% stroke. 1 bar (14.5 lbf/in2) at 15% stroke, 25 bar (363 lbf/in2) at 100% stroke.
* Servo Joysticks - Dual lever drive control Output Characteristics - Transmission control spools Output Characteristics - Loader control spools 5 bar (72.5 lbf/in2) at 15% stroke, 15 bar (217.5 lbf/in2) at 100% stroke. 3.5 bar (51 lbf/in2) at 15% stroke, 15 bar (217.5 lbf/in2) at 100% stroke.
9804/1103
70 - 05 - 03/1
8510 - E/1-1.6
Issue 6*
CONTENTS
Skidsteer Range
* From
70 - 05 - 03/2
ROBOT 185, 1105 Data - Hydraulics (cont)

* To machine no. 804423 Hydraulic Motors Displacement Maximum Working Pressure Maximum Speed Maximum Flow Loader Valve Block Maximum Working Pressure Maximum Return Pressure Services Operated: - Spool 1 - Spool 2 - Spool 3 (Optional) Maximum Leakage (all spools) High-Flow Valve Block Maximum Working Pressure Maximum Return Pressure * Relief Valve Operating Pressures (at normal working temperature) Main Relief Valve (at maximum rev/min) Auxiliary Relief Valve - Spool 1 - Spool 2 - Spool 3 A.R.V. ports tapped and plugged High-flow Relief Valve * Pressure Reducing Solenoid Valve * To machine no. 746998 Maximum Inlet Pressure Regulated Pressure Minimum Rated Flow Maximum Leakage Oil Temperature Range Solenoid Valve (including Diodes) Reducing Valve Electrics * Solenoid Brake Valve (from machine no. 746999) Type Electrics Filter Type Main Hydraulic High-Flow Suction Strainer
m/c no. 746001 to 804423
520 cc/rev (32 in3/rev) 414 bar (6003 lbf/in2) continuous 310 rev/min continuous 80 litres (17.6 gal; 21.1 US gal) per min. continuous
220 - 227 bar (3190 - 3292 lbf/in2, 223 - 232 kgf/cm2) 12 bar (174 lbf/in2, 12 kgf/cm2) Crowd/Raise/Lower - Hydraulic Servo Boom Ram - Hydraulic Servo Auxiliary - Electrical Solenoid 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)
205 - 212 bar (2973 - 3074 lbf/in2, 208 - 216 kgf/cm2) 12 bar (174 lbf/in2, 12 kgf/cm2)
bar 220 - 227 250 - 257 250 - 257 205 - 212
lbf/in2 3190 - 3292 3625 - 3756 3625 - 3756 2973 - 3074
kgf/cm2 223 - 232 253 - 262 253 - 262 208 - 216
220 - 227 bar (3190 - 3292 lbf/in2, 223 - 232 kgf/cm2) 25 bar (363 lbf/in2, 25.5 kgf/cm2) 10 l/min (2.2 gal/min) 25 cc/min (1.5 in3/min) at 210 bar (3045 lbf/in2) and 10 cSt - 40 C to +106 C 3 Position, 3 Port Cartridge Valve Cartridge Type 12 Volt
3-position, 4-way directional control 12 volt
High Pressure Spin - On 5 micron 17 micron 125 micron
9804/1103
70 - 05 - 03/2
8510 - E/1-2.6
Issue 5*
CONTENTS
Skidsteer Range
70 - 05 - 03/2A
Robot 185, 1105 Data - Hydraulics (contd)

To machine no. 804423 Rams Boom Lift Crowd Compensating (80 x 50) (110 x 50) (60 x 30) Bore mm 80 110 60 Nm in 3.14 4.33 2.36
From m/c no. 746001 to 804423
Rod Dia mm in 50 1.97 50 1.97 30 1.18 lbf ft
Stroke mm 688.5 233 331 Kg fm
in 27.1 9.17 13.03
Ram Torque Settings Piston Head: Boom Lift (80 x 50) Crowd (110 x 50) Compensating (60 x 30) End Cap: Boom Lift (80 x 50) Crowd (110 x 50) Compensating (60 x 30)
405 405 405
299 299 299
41.3 41.3 41.3
678 678 678
500 500 500
69.2 69.2 69.2
9804/1103
70 - 05 - 03/2A
8510 - E/1-3.4
Issue 1
CONTENTS
Skidsteer Range
70 - 05 - 03/2B
Robot 185, 1105 Data - Hydraulics

Note: System Cleanliness is to be to ISO 16/13.
From m/c no. 804424
Auxiliary Pump Type Displacement Maximum Working Pressure High-Flow Pump Type Displacement Maximum Working Pressure Main Pump (2-off) Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50 C) Loader Joystick - Single lever drive control Type Output Characteristics - All 4 spools Rexroth 3.5 bar (51 lbf/in2) at 15% stroke, 20 - 30 bar (290 - 435 lbf/in2) at 100% stroke. Sauer Sundstrand tandem axial piston Series 42 M35 35 cc/rev Servo non-feedback proportional, 18 bar (261 lbf/in2) to give max pump displacement. 414 bar (6003 lbf/in2) 2400 rev/min 20 - 30 bar (290 - 435 lbf/in2) at 2200 rev/min Sauer Sundstrand gear type 50 litres (11 UK gal; 13.2 US gal) per min. at 2350 engine rev/min 205 - 212 bar (2973 - 3074 lbf/in2, 208 - 216 kgf/cm2) Sauer Sundstrand gear type 90 litres (19.8 UK gal; 23.8 US gal) per min. at 2350 rev/min 220 - 227 bar (3190 - 3292 lbf/in2, 223 - 232 kgf/cm2)
Transmission Joystick - Single lever drive control Type Output Characteristics - Forward/Reverse spools - Left/Right spools Rexroth 3.5 bar (51 lbf/in2) at 15% stroke, 20 - 30 bar (290 - 435 lbf/in2) at 100% stroke. 5.5 bar (80 lbf/in2) at 15% stroke, 20 - 30 bar (290 - 435 lbf/in2) at 100% stroke.
Servo Joysticks - Dual lever drive control Type Output Characteristics - Transmission control spools Output Characteristics - Loader control spools Vickers 5 bar (72.5 lbf/in2) at 15% stroke, 20 - 30 bar (290 - 435 lbf/in2) at 100% stroke. 3.5 bar (51 lbf/in2) at 15% stroke, 20 - 30 bar (290 - 435 lbf/in2) at 100% stroke.
Hydraulic Motors Displacement Maximum Working Pressure Maximum Speed Maximum Flow 520 cc/rev (32 in3/rev) 414 bar (6003 lbf/in2) continuous 310 rev/min continuous 80 litres (17.6 gal; 21.1 US gal) per min. continuous
9804/1103
70 - 05 - 03/2B
8510 - E/1-4.3
Issue 1
CONTENTS
Skidsteer Range
70 - 05 - 03/2C
Robot 185, 1105 Data - Hydraulics (contd)

Loader Valve Block Maximum Working Pressure Maximum Return Pressure Services Operated: - Spool 1 - Spool 2 - Spool 3 (Optional) Maximum Leakage (all spools) High-Flow Valve Block Maximum Working Pressure Maximum Return Pressure Relief Valve Operating Pressures (at normal working temperature) Main Relief Valve (at maximum rev/min) Auxiliary Relief Valve - Spool 1 - Spool 2 - Spool 3 A.R.V. ports tapped and plugged High-Flow Relief Valve Solenoid Brake Valve Type Electrics Filter Type Main Hydraulic High-Flow Suction Strainer Rams Boom Lift Crowd Compensating (80 x 50) (110 x 50) (60 x 30) High Pressure Spin - On 5 micron 17 micron 125 micron Bore mm 80 110 60 Nm Rod Dia mm in 50 1.97 50 1.97 30 1.18 lbf ft
From m/c no. 804424
220 - 227 bar (3190 - 3292 lbf/in2, 223 - 232 kgf/cm2) 12 bar (174 lbf/in2, 12 kgf/cm2) Crowd Raise Lower - Hydraulic Servo Boom Ram - Hydraulic Servo Auxiliary - Electrical Solenoid 35 cc/min at 207 bar (2 in3/min at 3001 lbf/in2)
205 - 212 bar (2973 - 3074 lbf/in2, 208 - 216 kgf/cm2) 12 bar (174 lbf/in2, 12 kgf/cm2)
bar 220 - 227 250 - 257 250 - 257
lbf/in2 3190 - 3292 3625 - 3756 3625 - 3756
kgf/cm2 223 - 232 253 - 262 253 - 262
205 - 212 bar (2973 - 3074 lbf/in2, 208 - 216 kgf/cm2)
3 Position, 4 way Directional Control 12 Volt
in 3.14 4.33 2.36
Stroke mm 688.5 233 331 Kg fm
in 27.1 9.17 13.03
Ram Torque Settings Piston Head: Boom Lift (80 x 50) Crowd (110 x 50) Compensating (60 x 30) End Cap: Boom Lift (80 x 50) Crowd (110 x 50) Compensating (60 x 30)
405 405 405
299 299 299
41.3 41.3 41.3
678 678 678
500 500 500
69.2 69.2 69.2
9804/1103
70 - 05 - 03/2C
8510 - E/1-5.1
Issue 1
CONTENTS
Skidsteer Range
70 - 05 - 03/3
ROBOT 160, 170, 170H Data - Hydraulics

Note: System Cleanliness is to be ISO 16/13
From m/c no. 680001
Loader Pump - Standard Type Maximum displacement at 205 bar (2972 lbf/in2) - Robot 160 - Robot 170 Loader Pump - High-Flow Type Maximum displacement at 150 bar (2175 lbf/in2) - Front Section - Rear Section Priority Valve setting Transmission Pump - Servo Machines Type Displacement Control Charge Pressure (oil temperature at 50 C) - Standard Machines - High-flow Machines High Pressure Loop Valve Pressure Transmission Pump - Manual Machines Type Displacement Control Charge Pressure (oil temperature at 50 C) - Standard Machines - High-flow Machines High Pressure Loop Valve Pressure Hydraulic Motors Type Displacement Loader Valve Block - Servo Machines Services Operated: - Spool 1 - Spool 2 - Spool 3 (Optional) Geroter 395 cc/rev (24 in3/rev) Tandem axial piston Series 40 44 cc/rev (2.68 in3/rev) Direct Displacement Manual Control 19 - 22 bar (275 - 319 lbf/in2) at max. rev/min 19 - 22 bar (275 - 319 lbf/in2) at max. rev/min (controlled by priority valve) 385 bar (5582 lbf/in2) Tandem axial piston Series 42 41 cc/rev (2.5 in3/rev) Servo non-feedback proportional. 19 - 22 bar (275 - 319 lbf/in2) at max. rev/min 19 - 22 bar (275 - 319 lbf/in2) at max. rev/min (controlled by priority valve) 385 bar (5582 lbf/in2) Tandem gear with integral priority valve 54 l/min (11.9 UK gal/min, 14.2 US gal/min) 61 l/min (13.4 UK gal/min, 16.1 US gal/min) 19 l/min (4.2 UK gal/min, 5 US gal/min) at 20 bar (290 lbf/in2) Gear 55 l/min (12.1 UK gal/min, 14.5 US gal/min) 60 l/min (13.2 UK gal/min, 15.8 US gal/min)
Boom Lift - Hydraulic Servo with Solenoid Spool Lock Quickhitch Tilt - Hydraulic Servo with Solenoid Spool Lock Auxiliary - Manually operated
Loader Valve Block - Manual Machines Services Operated: - Spool 1 - Spool 2 - Spool 3 (Optional)
Boom Lift - Manually operated with Solenoid Spool Lock Quickhitch Tilt - Manually operated with Solenoid Spool Lock Auxiliary - Manually operated
9804/1103
70 - 05 - 03/3
8520 - E/1-1.3
Issue 1
CONTENTS
Skidsteer Range
70 - 05 - 03/4
ROBOT 160, 170, 170H Data - Hydraulics

Relief Valve Operating Pressures (at normal working temperature) * Main Relief Valve: at max. rev/min (see Note 1) * Tilt Ram Head Side Auxiliary Relief Valve (see Note 2) * Note 1: Test point will show both M.R.V. and Transmission Pump Charge Pressure. * Note 2: Fitted to all machines from Jan 2001. Should be fitted to earlier machines whenever breaker is used. Self Level Valve (optional) Type bar 180 230 lbf/in2 2610 3335
From m/c no. 680001
Solenoid controlled in line, adjustable split flow, level to lift only
High-Flow Valve Block (optional) Type Relief Valve Setting Filter Type Main Hydraulic High-flow Rams Boom Lift Crowd Ram Torque Settings Piston Head: Boom Lift Crowd End Cap: Boom Lift Crowd Hydraulic Tank Tank pressurised to: Loader Cycle Times (average) at normal working temperature, unladen and at max. rev/min 160 Standard machine Boom Lift Boom Lower Bucket Crowd Bucket Dump High-flow machine Boom Lift Boom Lower Bucket Crowd Bucket Dump 3.7 secs 2.9 secs 1.6 secs 1.9 secs 170 3.9 secs 3.0 secs 1.7 secs 2.0 secs 0.31 to 0.38 bar (4.5 to 5.5 lbf/in2) High Pressure Spin - On Charge pressure filtration Return oil filtration Bore mm in 75 2.95 90 3.54 Nm Rod Dia mm in 50 1.97 40 1.57 lbf ft Stroke mm in 898 35.35 324 12.75 Ventable relief valve 185 bar (2683 lbf/in2)
405 450
299 332
678 678
500 500
3.7 secs 2.9 secs 1.6 secs 2.0 secs
3.9 secs 3.0 secs 1.7 secs 2.0 secs
9804/1103
70 - 05 - 03/4
8520 - E/1-2.3
Issue 2*
CONTENTS
Skidsteer Range
From m/c no. 675001 to 677000
ROBOT 150,165 Data - Peugeot Engine

* Type Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure (Measured with warm engine turned by the starter) Injection Sequence Valve Clearance - Cold - Inlet Exhaust Maximum Air Cleaner Restriction Maximum Back Pressure (Exhaust) Speeds Model Robot 150 Robot 165 Robot 165 High-flow Idling Speed Fuel System Injection Pump Type Governing Pump Setting Code Static Timing Injector Codes Injector Setting Pressure Cooling System Fan Type Coolant Pressure Temperature Warning Light operates at Loaded Max. rev/min 2630 2630 3600
4 cylinder in-line, overhead camshaft, compression ignition, naturally aspirated. 83 mm (3.268 in) 88 mm (3.465 in) 1905 cm3 (116.24 in3) 23.5 : 1 25 - 30 bar (363 - 435 lbf/in2, 25.5 - 33 kgf/cm2) Maximum variation between cylinders 5 bar (72.5 lbf/in2, 5.1 kgf/cm2) 1,3,4,2 0.15 - 0.20 mm (0.0059 - 0.0078 in) 0.30 - 0.35 mm (0.0118 - 0.0138 in) 20 mbar (0.29 lbf/in2, 0.02 kgf/cm2) at 3600 rev/min 140 mbar (2.03 lbf/in2, 0.143 kgf/cm2) at 3600 rev/min
No. Load Max. rev/min 3000 3000 3860
Oil Pressure (hot) (at loaded speeds) 110 C (230 F) 3.6 bar (52.2 lbf/in2, 3.7 kgf/cm2) 3.7 bar (53.7 lbf/in2, 3.8 kgf/cm2) 3.8 bar (55.1 lbf/in2, 3.9 kgf/cm2)
880 - 920 rev/min
Lucas CAV DPC R84 43 Mechanical 063 16 1 BTDC RDN O5DC 6730 115 5 bar (1667.5 72.5 lbf/in2, 117 5.1 kgf/cm2)
Mechanical 1 bar (14.5 lbf/in2, 1.02 kgf/cm2) 105 2 C (221 35.6 F)
Note: If at anytime during the life of a machine it is necessary to fit a new engine, then after the first 50 operating hours a new engine oil filter must be fitted and the engine oil changed. Failure to complete this could damage the engine. Note: Should further details be required for the refitting of the engine refer to Engine Service Manual 9803/8600.
9804/1103
70 - 05 - 04/1
Issue 2*
CONTENTS
Skidsteer Range
From m/c no. 677001
ROBOT 150,165 Data - Perkins Engine

Type Bore (nominal) Stroke Swept Volume Compression Ratio Injection Sequence Valve Clearance - Cold - Inlet and Exhaust Oil Pressure * Speeds 150 up to machine serial number 677999 and 165 Rated Speed Idling Speed 150 from machine serial number 678000 Rated Speed Idling Speed Fuel System Injection Pump Type Governing Static Timing Injector Codes Injector Setting Pressure Cooling System Fan Type Coolant Pressure Thermostat operating temperature Temperature Warning Light operates at Mechanical 1 bar (14.5 lbf/in2, 1.02 kgf/cm2) 82 - 94 C (180 - 200 F) 97 - 103 C (207 - 217 F) Bosch 104135-4010 Mechanical 19 BTDC Bosch 105148-1170 147 bar (2133 lbf/in2, 150 kgf/cm2)
4 cylinder in-line, compression ignition, naturally aspirated. 84 mm (3.31 in) 100 mm (3.94 in) 2216 cm3 (135.2 in3) 22 : 1 1,3,4,2 0.2 mm (0.0078 in) 2.6 - 3.5 bar (38 - 52 lbf/in2, 2.7 - 3.6 kgf/cm2)
2800 rev/min 850 - 950 rev/min 2600 rev/min 890 - 910 rev/min
Note: If at anytime during the life of a machine it is necessary to fit a new engine, then after the first 50 operating hours a new engine oil filter must be fitted and the engine oil changed. Failure to complete this could damage the engine. Note: Should further details be required, refer to Engine Service Manual 9806/2100.
9804/1103
70 - 05 - 04/2
Issue 2*
CONTENTS
* ROBOT
Skidsteer Range
*
70 - 05 - 05/1
185, 1105 (Standard, High-flow machines)
To m/c no. 746805
Data - Engine
Type Build Number - 185 Build Number - 1105 Number of cylinders Bore Stroke Swept Volume Compression Ratio Compression Pressure Maximum variation between cylinders Injection Sequence Valve Clearance - Hot or Cold - Inlet - Exhaust Maximum Speed (no load) Governed Speed Idling Speed Fuel System - Robot 185 Injection Pump Type Governing Pump Setting Code Static Timing Injector Code Injector Setting Pressure Fuel System - Robot 1105 Injection Pump Type Governing Pump Setting Code Static Timing Injector Code Injector Setting Pressure Induction System Air Cleaner Type Maximum Restriction (at which warning light operates) Lubrication System Oil Pump Type Oil Pressure (hot) at maximum speed Cooling System Coolant Pressure Coolant Temperature (normal) Temperature Warning Light operates at 0.48 bar (7 lbf/in2) 80 - 85 C (176 - 185 F) 98 C (209 F) Eccentric Rotor 2.0 bar (30 lbf/in2) (minimum) 2 stage, dry element 635 mm (25 in) H2O Lucas CAV DPA 334B F790 Mechanical 059 16 1 BTDC JB 253 bar (3675 lbf/in2, 258 kgf/cm2) Lucas CAV DPC R84 43 Mechanical 063 16 1 BTDC NJ 223 bar (3234 lbf/in2, 227 kgf/cm2) Perkins 1004-4HR naturally aspirated AA50530 AA50688 4 100 mm (3.937 in) 127 mm (5.00 in) 3990 cm3 (243.5 in3) 16.5 : 1 20 - 34 bar (240 - 493 lbf/in2) 3.5 bar (50 lbf/in2) 1,3,4,2 0.20 mm (0.008 in) 0.45 mm ( 0.018 in) 2400-2420 rev/min 2200 rev/min 700-750 rev/min
Note: For further details of the engine refer to Engine Service Manual 9806/0100.
9804/1103
70 - 05 - 05/1
Issue 4*
CONTENTS
* ROBOT
Skidsteer Range
*
70 - 05 - 05/2
185, 1105 (High-flow machines)
From m/c no. 746806
Data - Engine
Robot 185 Type Build Number Number of cylinders Bore Stroke Swept Volume Compression Ratio Compression Pressure Maximum variation between cylinders Injection Sequence Valve Clearance - Hot or Cold - Inlet - Exhaust Maximum Speed (no load) Governed Speed Idling Speed Fuel System Injection Pump Type Governing Pump Setting Code Static Timing Injector Code Injector Setting Pressure Induction System Air Cleaner Type Maximum Restriction (at which warning light operates) Lubrication System Oil Pump Type Oil Pressure (hot) at maximum speed Cooling System Coolant Pressure Coolant Temperature (normal) Temperature Warning Light operates at 0.48 bar (7 lbf/in2) 80 - 85 C (176 - 185 F) 98 C (209 F) 0.48 bar (7 lbf/in2) 80 - 85 C (176 - 185 F) 98 C (209 F) Eccentric Rotor 2.0 bar (30 lbf/in2) (minimum) Eccentric Rotor 2.0 bar (30 lbf/in2) (minimum) 2 stage, dry element 635 mm (25 in) H2O 2 stage, dry element 635 mm (25 in) H2O Lucas DP 203 Mechanical 2644G002RG/1/2350 3 BTDC Dynamic KW 294 bar (4263 lbf/in2, 4182 kgf/cm2) Lucas DP 203 Mechanical 2644G601PG/1 /2460 2 BTDC Dynamic KW 294 bar (4263 lbf/in2, 4182 kgf/cm2) Perkins 1004-42AR (75hp) naturally aspirated AR50679 4 103 mm (4.055 in) 127 mm (5.00 in) 4230 cm3 (258 in3) 18.5 : 1 25 - 35 bar (375 - 525 lbf/in2) 3.5 bar (50 lbf/in2) 1,3,4,2 0.20 mm (0.008 in) 0.45 mm ( 0.018 in) 2350 rev/min 2200 rev/min 750 rev/min Robot 1105 Perkins 1004-42AR (80hp) naturally aspirated AR50674 4 103 mm (4.055 in) 127 mm (5.00 in) 4230 cm3 (258 in3) 18.5 : 1 25 - 35 bar (375 - 525 lbf/in2) 3.5 bar (50 lbf/in2) 1,3,4,2 0.20 mm (0.008 in) 0.45 mm ( 0.018 in) 2460 rev/min 2200 rev/min 750 rev/min
Note: For further details of the engine refer to Engine Service Manual 9806/2140.
9804/1103
70 - 05 - 05/2
Issue 2*
CONTENTS
Skidsteer Range
70 - 05 - 06/1
ROBOT 160,170, 170HF Data - Engine

Type Bore (nominal) Stroke Swept Volume Compression Ratio Injection Sequence Valve Clearance - Cold - Inlet and Exhaust Oil Pressure Speeds Robot 160 Rated Speed Idling Speed Robot 170 Rated Speed Idling Speed Fuel System Governing Static Timing Injector Codes Injector Setting Pressure Cooling System Fan Type Coolant Pressure Thermostat operating temperature Temperature Warning Light operates at Mechanical 19 BTDC 105148-1170 147 bar (2133 lbf/in2)
*From m/c no. 680001 to 681290
4 cylinder in-line, compression ignition, naturally aspirated. 84 mm (3.31 in) 100 mm (3.94 in) 2216 cm3 (135.2 in3) 22 : 1 1,3,4,2 0.2 mm (0.0078 in) 2.6 - 3.5 bar (38 - 52 lbf/in2)
2600 rev/min 890 - 910 rev/min 2800 rev/min 850 - 950 rev/min
Mechanical 1 bar (14.5 lbf/in2) 82 - 94 C (180 - 200 F) 97 - 103 C (207 - 217 F)
9804/1103
70 - 05 - 06/1
8520-K/1-1.2
Issue 2*
CONTENTS
Skidsteer Range
From m/c no. 681291
ROBOT 160, 170, 170H Data - Engine

Type Bore (nominal) Stroke Swept Volume Compression Ratio Injection Sequence Valve Clearance - Cold - Inlet and Exhaust Oil Pressure Speeds Robot 160 Rated Speed Idling Speed Robot 170 Rated Speed Idling Speed Fuel System Governing Static Timing Injector Codes Injector Setting Pressure Cooling System Fan Type Coolant Pressure Thermostat operating temperature - opens at: - fully open at: Temperature Warning Light operates at Mechanical 1 bar (14.5 lbf/in2) 82 C (180 F) 95 C (202 F) 97 - 103 C (207 - 217 F) Mechanical 19 - 21 BTDC 131 406 360 147 bar (2133 lbf/in2)
400 Series 4 cylinder in-line, compression ignition, naturally aspirated. 84 mm (3.31 in) 100 mm (3.94 in) 2216 cm3 (135.2 in3) 23.3 : 1 1,3,4,2 0.2 mm (0.0078 in) 1 bar (15 lbf/in2) min
2600 rev/min 900 25 rev/min 2800 rev/min 900 25 rev/min
9804/1103
70 - 05 - 06/2
8520 - K/1 - 2.1
Issue 1
CONTENTS CONTENTS
Skidsteer Range
70 - 15 - 01/1
ROBOT 150,165 Circuit Diagrams - Electrical Main Components

Option 1 2 3 4 5 6 7 8 8A 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 Battery Glow Plugs Glow Plugs Glow Plugs Glow Plugs Pre-heat Timer Relay Starter Switch Starter Solenoid Starter Motor Interior Light Switch Auxiliary Neutral Start Relay Front Work Light Switch Rear Work Light Switch Beacon Interlock Relay Brake Switch Brake Solenoid on Pressure Reducing Operational Solenoid Solenoid Valve Door Switch Restraint Switch Auxiliary Attachments Control Switch Auxiliary Attachments Detent Switch Auxiliary Hydraulics - Forward Solenoid Auxiliary Hydraulics - Reverse Solenoid High-flow Hydraulics Switch High-flow Hydraulics Solenoid Valve Warning Buzzer Alternator Hourmeter Diodes Engine Oil Pressure Switch Engine Water Temperature Switch Air Cleaner Warning Switch Low Fuel Warning Switch Charge Pump Pressure Switch Hydraulic Oil Temperature Switch Engine Shut Off Solenoid Horn Push Horn Low Water Float Switch Later Machines only Low Water E.C.U. Flasher Relay Indicator Switch Side Lights Switch Rear Wash/Wipe Switch Rear Wash/Wipe Motor Windscreen Wiper Switch Windscreen Wiper Motor Windscreen Washer Motor Switch Windscreen Washer Motor Heater Blower Switch Heater Blower Resistor Heater Blower Motor Reverse Alarm Switch 1 Reverse Alarm Switch 2 Reverse Alarm Buzzer Brake Light Pressure Switches 1 1 1 1 1 1 1 1 1 3 1 3 3 3 1 1 1 1 1 1 1 1 1 1 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3/4 3/4 3/4 4 4 2 2 2 2 2 2 2 3 3 3 4 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
From m/c no. 675001 to 675357
Lamps
Option Pre-heat Warning Interior Light Right Hand Front Work Light Left Hand Front Work Light Work Light Switches Illumination (Front) Rear Work Light Work Light Switches Illumination (Rear) Beacon Lamp Brake Switch Illumination Auxiliary Attachments Detent Switch Illumination Alternator Warning Oil Pressure Warning Water Temperature Warning Air Cleaner Warning Low Fuel Warning Charge Pump Pressure Hydraulic Oil Temperature Warning Indicator Repeater Left Hand Indicator (Front) Left Hand Indicator (Rear) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Sidelight (Rear) Right Hand Side Light (Rear) Left Hand Side Light (Front) Right Hand Side Light (Front) Number Plate Side Light Warning Left Hand Dip Beam Right Hand Dip Beam Left Hand Brake Light Right Hand Brake Light 1 3 3 3 3 3 3 3 1 1 1 1 1 1 1 1 1 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 4 3/4 3/4 3/4 4 4
Fuses
110 111 112 113 114 115 116 117 118 Interior/Front Work Lights Beacon/Rear Work Light Pressure Reducing Solenoid Valve Auxiliary Hydraulics ESOS/Warning Lights and Buzzer Horn, Low Water ECU Indicators/Dip/Sidelights and Number Plate Wipers and Washer Heater/Blower plus Reverse Alarm 3 3 1 1 1 1 3/4 2 2 3
Note: See pages 70-05-01/1 for bulb ratings and page 70-05-01/2 for fuse ratings.
Equipment Options
Standard Cab Standard Optional Homologation 1 2 3 4
9804/1103
70 - 15 - 01/1
Issue 2
9804/1103
10 607
CONTENTS CONTENTS
1 17
2 3 4 5
70
ROBOT 150,165
3 208 642 30 EARTH SPLICES 606, 623, 624, 625 410 608
16
10
14
8 8A
204 42 203
626
205
611
110
71
26
72
11
800 801 827 802 201 204
601
73
600 602 603
74
200
75
12
804 803 202
76
Skidsteer Range
70 - 15 - 01/2
111 13
206
612
29
77
14 15
830
112
20 23 829
634
78
16 17
831
632 633
18
22 21 838
19
24
631 640
29 22
29
832 834
113
25
79
21
837
635
20
835
23
836
839
641
29
29
29
25
24
39
27
G 3 403 605
26
400
28
114
9 11
402
80
405
401 7 404
30
29
408 412
81
401
409
31
29 29 29
82
411 413 414 415
32 33
83 84
416 417 418
628 610
34
85
420 419 426
629
86
424 406
35 36
407
609
115
6 209
805
604
38
37
28 29
39
639 425 15 637
40 116
207
41
813 824 14
87 88
818
616
89
618
91
90
815
42
620
92 93
807
43 97 98 44
12 8
94
826
95
96
99
45
117 50
47
810 27 13
52
51
811 18 422
46
613
812
48
49
M
809
614 615
118
421
622
53
54
55
100
A167872
101
56
56
70 - 15 - 01/2
From m/c no. 675001 to 675357
Issue 2
CONTENTS CONTENTS
Skidsteer Range
70 - 15 - 01/3
ROBOT 150,165 Circuit Diagrams - Electrical
From m/c no. 675358
18
608 642 626 611 612 628 610 634 632 633 640 635 605 629 609 602
73
75
92 34
637 616
94
95 96 97
57
614 615
641
24
850
851
81
16
17
82
403
27
28
29
30 31
32
33
98 101 48 51 60
2
409 411 416 417 420
35
426
800
802
7 70
410
72 71
74
849
76
15 13 14
15 15
19
20
23 15
407
91
93 47 100
801 803
50
M
56
856
1
17
858
857
847
805
848
8 111
838
830
829
211
878
78
607
839
10 80
831
85 83
7
87 86 88
89 90
853 425 425
77
21 15
837
25 84
401
854
3
205 824 208 206
827
37
804
36
46 52
810 811 422
12
832 23 834
836
43
408 415 419 406 28 29
44
201
16
45
31 12 8
400
203
32
201
424
210
10
15 11 113
200 24 204
15 38
6 401 412 413 414 418
204
852
39 53
18
110
22 26
20 25
642
835
404
40
42
812
112
41
42
99
49
809
421
79
402
639
855
55
54
5
42 3
405
15
15
15
11
15
209 209 13
58 59
873
120
34
121
14
26
14
27
114
115
116
117
118
119
A206390
9804/1103
70 - 15 - 01/3
Issue 1
CONTENTS
Skidsteer Range
*
ROBOT 150,165 Circuit Diagrams - Electrical Main Components

Option 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 * 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Battery Glow Plugs Pre-heat Timer Relay Starter Switch Auxiliary Neutral Start Relay Starter Solenoid Starter Motor Interior Light Switch Side Lights Switch Beacon Interlock Relay Brake Switch Brake Solenoid on Pressure Reducing Operational Solenoid Solenoid Valve Diodes Restraint Switch Door Switch Sequence E.C.U. (See Note 2) Auxiliary Hydraulics - Forward Solenoid Auxiliary Hydraulics - Reverse Solenoid Auxiliary Attachments Detent Switch Auxiliary Attachments Control Switch High-flow Hydraulics Switch High-flow Hydraulics Solenoid Valve Alternator Warning Buzzer Hourmeter Engine Oil Pressure Switch Engine Water Temperature Switch Air Cleaner Warning Switch Low Fuel Warning Switch Charge Pump Pressure Switch Hydraulic Oil Temperature Switch Engine Shut Off Solenoid Horn Horn Push Low Water Float Switch Low Water E.C.U. Hazard Warning Switch Flasher Relay Indicator Switch Brake Light Pressure Switches Front Work Light Switch Rear Work Light Switch Windscreen Wiper Switch Rear Wash/Wipe Switch Rear Wash/Wipe Motor Windscreen Wiper Motor Windscreen Washer Motor Switch Windscreen Washer Motor Heater Blower Motor Heater Blower Resistor Heater Blower Switch Reverse Alarm Switch 1 Reverse Alarm Switch 2 Reverse Alarm Buzzer Float Solenoid Float Switch Heated Seat Switch Heated Seat 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 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
From m/c no. 675358 to 677000
Lamps
Option Pre-heat Warning Interior Light Left Hand Side Light (Rear) Right Hand Side Light (Rear) Left Hand Side Light (Front) Right Hand Side Light (Front) Number Plate Side Light Warning Left Hand Dip Beam Right Hand Dip Beam Beacon Lamp Brake Switch Illumination Auxiliary Attachments Detent Switch Illumination Alternator Warning Oil Pressure Warning Water Temperature Warning Air Cleaner Warning Low Fuel Warning Charge Pump Pressure Hydraulic Oil Temperature Warning Indicator Repeater Left Hand Indicator (Front) Left Hand Indicator (Rear) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Right Hand Front Work Light Left Hand Front Work Light Work Light Switches Illumination (Front) Rear Work Light Work Light Switches Illumination (Rear) 1 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 1 1 1 2 2
Fuses
110 111 112 * 113 114 115 116 117 118 119 120 121 Interior/Headlights/Sidelights and Number Plate Left Hand Sidelights Right Hand Sidelights Beacon/Sequence E.C.U. (See Note 2) Pressure Reducing Solenoid Valve Auxiliary Hydraulics ESOS/Warning Lights & Buzzer/Float/High Flow Horn/Low Water ECU/Front Work Lights Indicators Rear Work Lights/Hazard Warning Wipers and Washers Heater/Blower/Reverse Alarm
* Note: For fuse ratings see pages 70-05-01/2. For bulb ratings see page 70-05-01/1. * Note 2: The Sequence E.C.U. was deleted from machines manufactured after May 1996.
Equipment Options
Standard Optional 1 2
Issue 2*
9804/1103
70 - 15 - 01/4
CONTENTS
Skidsteer Range
From m/c no. 677001
ROBOT 150,165 Basic Canopy - Servo Controls Circuit Diagrams - Electrical Main Components
Option 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Battery Starter Solenoid Starter Motor Auxiliary Neutral Start Relay Starter Switch Glow Plug Relay Glow Plugs Beacon Motor Front Work Light Switch Rear Work Light Switch Reverse Alarm Switches Reverse Alarm Buzzer Operational Solenoid Brake Solenoid Brake Switch Interlock Relay Door Switch Restraint Switch High-Flow Hydraulics Solenoid Valve High-Flow Hydraulics Switch Warning Buzzer Alternator Hourmeter Charge Pump Pressure Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Engine Water Temperature Switch Air Cleaner Warning Switch Low Fuel Warning Switch Engine Shut Off Solenoid Float Solenoid Pressure Switch Latching Relay Float Switch Horn Push Horn Engine Earth 1 1 1 1 1 1 1 0 0 0 0 0 1 1 1 1 1 1 0 0 1 1 1 1 1 1 1 1 1 1 0 0 0 0 1 1 1 60 61 62 63 64 65 66 67 68 69 70
Lamps
Option Beacon Lamp Interior Light Front Work Lights Rear Work Light Alternator Warning Charge Pump Pressure Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Water Temperature Warning Air Cleaner Warning Low Fuel Warning 0 0 0 0 1 1 1 1 1 1 1
Note: For fuse ratings see pages 70-05-01/2. For bulb ratings see page 70-05-01/1.
Equipment Options
9804/1103
70 - 15 - 01/5
Issue 1
9804/1103
BATTERY AUX/NEUTRAL START RELAY
CONTENTS
4
START SOLENOID GLOW PLUG RELAY
2
STARTER SOLENOID STARTER MOTOR
3
AUX. NEUTRAL START RELAY GLOW PLUGS
ROBOT 150,165 Basic Canopy - Servo Controls
STARTER SWITCH
5 6 60
BEACON
8
INTERIOR LIGHT
61
Skidsteer Range
70 - 15 - 01/6
FRONT WORK LIGHT SWITCH
9 62
REAR WORK LIGHT
FRONT WORK LIGHTS
REAR WORK LIGHT
10 11
INTERLOCK RELAY
63 12
WORK LIGHT WARNING
REVERSE ALARM
11 13
OPERATIONAL SOLENOID BRAKE SOLENOID
15
BRAKE SWITCH DOOR SWITCH
14 18
16 17 20
RESTRAINT SWITCH
DOOR/RESTRAINT SWITCH
HIGH FLOW SOLENOID
19
ALTERNATOR
21 64 65 66 67 68 69
22 24 25 26 28 29
23
HOURMETER ALTERNATOR FAILURE CHARGE PUMP PRESSURE HYDRAULIC OIL TEMP. ENGINE OIL PRESSURE
27
WATER TEMP. SWITCH AIR CLEANER LOW FUEL
EQUIPMENT OPTIONS
OPTIONAL
70
STANDARD 246/90901
30
FLOAT SOLENOID
E.S.O.S..
31
PRESS. SWITCH
32
34
FLOAT SWITCH
FLOAT SOLENOID
LATCHING RELAY
33 35
36
HORN
ENGINE EARTH
37
From m/c no. 677001
Issue 1
CONTENTS
Skidsteer Range
From m/c no. 677001
ROBOT 150,165 Cab & Options - Servo Controls Circuit Diagrams - Electrical Main Components
Option 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Battery Starter Solenoid Starter Motor Auxiliary Neutral Start Relay Starter Switch Glow Plug Relay Glow Plugs Road Light Switch Beacon Motor Brake Switch Interlock Relay Operational Solenoid Brake Solenoid Restraint Switch Door Switch High-Flow Hydraulics Solenoid Valve High-Flow Hydraulics Switch 1 1 1 1 1 1 1 0Y 0Y 1 1 1 1 1 1 0Y 0Y 70 71 72 73 74 75 76 77 78 79 80 Interior Light L.H. Dip Beam (Italian) R.H. Dip Beam (Italian) L.H. Dip Beam (German) R.H. Dip Beam (German) L.H. Rear Light No. Plate Light L.H. Side Light R.H. Rear Light R.H. Side Light Beacon Lamp
Lamps
Option 1Y 0Y 0Y 0Y 0Y 0Y 0Y 0Y 0Y 0Y 0Y
Note: For fuse ratings see page 70-05-01/2. For bulb ratings see page 70-05-01/1.
Equipment Options
Standard Optional Cab Optional Canopy 1 0 Y
9804/1103
70 - 15 - 01/7
Issue 1
9804/1103
CONTENTS
BATTERY
ROBOT 150,165 Cab and Options - Servo Controls
Skidsteer Range
70 - 15 - 01/8
AUX/NEUTRAL START RELAY STARTER SWITCH
4
START SOLENOID
2
AUX. NEUTRAL START RELAY
GLOW PLUG RELAY
GLOW PLUGS
5 6 70 72 73 8 75 77
ROAD LIGHT SWITCH
7
INTERIOR LIGHT LH DIP BEAM
71 74 76 78 79
ITALIAN RH DIP BEAM
LH DIP BEAM GERMAN RH DIP BEAM LH TAIL LIGHT NO. PLATE LIGHT LH SIDE LIGHT RH TAIL LIGHT RH SIDE LIGHT
80
9 10
BEACON
12
OPERATIONAL SOLENOID
INTERLOCK RELAY
EQUIPMENT OPTIONS STANDARD OPTIONS CAB OPTIONS CANOPY 246/91001

1 OF 2
BRAKE SOLENOID
13 14
DOOR SWITCH
11 17
15
RESTRAINT SWITCH
HIGH FLOW SOLENOID
16
From m/c no. 677001
Issue 1
9804/1103
BATTERY
CONTENTS
aa 2
AUX/NEUTRAL/ST. RELAY
ROBOT 150,165 Basic Canopy - Manual Controls
4
STARTER SOLENOID
GLOW PLUGS
6 5
7
STARTER SWITCH GLOW PLUG RELAY
40
8 41
Skidsteer Range
70 - 15 - 01/9
FRONT WORK LIGHT SW. REAR WORK LIGHT SW.
BEACON
INTERIOR LIGHT
9
FRONT WORK LIGHTS
42
10
REAR WORK LIGHT
43 12
WORK LIGHT WARNING
REVERSE ALARM
INTERLOCK RELAY
11
23A
BRAKE SWITCH
11
23B 600JS
13
23C
600JR
LIFT CUTOUT SWITCHES
15
BRAKE SOLENOID
14
16 17 19 20 23
18 21
DOOR/RESTRAINT SWITCHES
HIGH FLOW SOLENOID
HOURMETER
ALTERNATOR
22
BUZZER
44
ALTERNATOR FAILURE
24
45 46 47 48
CHARGE PUMP PRESSURE
25 26 27
HYDRAULIC OIL TEMP. OPTIONAL STANDARD 246/91401 ENGINE OIL PRESSURE WATER TEMP. SWITCH
49
28
Skidsteer Range
EQUIPMENT OPTIONS
AIR CLEANER
50 30
PRESS. SWITCH
FLOAT SOLENOID
29 31
LOW FUEL E.S.O.S..
FLOAT SOLENOID
32
34
FLOAT SWITCH
LATCHING RELAY
33 36 37
35
ENGINE EARTH
HORN
From m/c no. 677001
Issue 1
CONTENTS
Skidsteer Range
From m/c no. 677001
ROBOT 150,165 Basic Canopy - Manual Controls Circuit Diagrams - Electrical Main Components
Option 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Battery Starter Solenoid Starter Motor Auxiliary Neutral Start Relay Glow Plugs Glow Plug Relay Starter Switch Beacon Motor Front Work Light Switch Rear Work Light Switch Reverse Alarm Switches Reverse Alarm Buzzer Lift Cutout Switches Brake Solenoid Brake Switch Interlock Relay Door Switch Restraint Switch High-Flow Hydraulics Solenoid Valve High-Flow Hydraulics Switch Hourmeter Alternator Warning Buzzer Charge Pump Pressure Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Engine Water Temperature Switch Air Cleaner Warning Switch Low Fuel Warning Switch Engine Shut Off Solenoid Float Solenoid Pressure Switch Latching Relay Float Switch Horn Horn Push Engine Earth 1 1 1 1 1 1 1 0 0 0 0 0 1 1 1 1 1 1 0 0 1 1 1 1 1 1 1 1 1 1 0 0 0 0 1 1 1 40 41 42 43 44 45 46 47 48 49 50
Lamps
Option Beacon Lamp Interior Light Front Work Lights Rear Work Light Alternator Warning Charge Pump Pressure Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Water Temperature Warning Air Cleaner Warning Low Fuel Warning 0 0 0 0 1 1 1 1 1 1 1
Note: Link wire aa is not used when High-Flow circuit is fitted. Note: For fuse ratings see page 70-05-01/2. For bulb ratings see page 70-05-01/1.
Equipment Options
9804/1103
70 - 15 - 01/10
Issue 1
CONTENTS
Skidsteer Range
From m/c no. 677001
ROBOT 150,165 Cab & Options - Manual Controls Circuit Diagrams - Electrical Main Components
Option 1 2 3 4 5 6 7 8 9 10 11 11A 12 13 14 15 16 17 18 19 Battery Starter Solenoid Starter Motor Auxiliary Neutral Start Relay Starter Switch Glow Plug Relay Glow Plugs Road Light Switch Beacon Motor Lift Cutout Switches Brake Switch Brake Solenoid Interlock Relay Door Switch Restraint Switch Heated Seat Heated Seat Switch High-Flow Hydraulics Solenoid Valve High-Flow Hydraulics Switch Engine Shut Off Relay 1 1 1 1 1 1 1 0Y 0Y 1 1 1 1 1 1 0 0 0Y 0Y 1 60 61 62 63 64 65 66 67 68 69 70 Interior Light L.H. Dip Beam (Italian) R.H. Dip Beam (Italian) L.H. Dip Beam (German) R.H. Dip Beam (German) L.H. Rear Light No. Plate Light L.H. Side Light R.H. Rear Light R.H. Side Light Beacon Lamp
Lamps
Option 1Y 0Y 0Y 0Y 0Y 0Y 0Y 0Y 0Y 0Y 0Y
Note: Link wire aa is not used when High-Flow circuit is fitted. Note: For fuse ratings see page 70-05-01/2. For bulb ratings see page 70-05-01/1.
Equipment Options
Standard Optional Cab Optional Canopy 1 0 Y
9804/1103
70 - 15 - 01/11
Issue 1
9804/1103
BATTERY
CONTENTS
aa 2
ROBOT 150,165 Cab and Options - Manual Controls
AUX/NEUTRAL/ST. RELAY
4
STARTER SOLENOID
GLOW PLUGS
6 7
5
STARTER SWITCH GLOW PLUG RELAY
Skidsteer Range
70 - 15 - 01/12 60 61 62 63 64
ROADLIGHT SWITCH
INTERIOR LIGHT
LH DIP BEAM ITALIAN RH DIP BEAM LH DIP BEAM GERMAN RH DIP BEAM
8 65 67 68 69
23B 23A 23C
LH TAIL LIGHT
66
NO. PLATE LIGHT LH SIDE LIGHT RH TAIL LIGHT RH SIDE LIGHT
70
BEACON
600JS
10
600JR
LIFT CUTOUT SWITCHES
INTERLOCK RELAY
11 11A
BRAKE SWITCH
BRAKE SOLENOID
14
DOOR SWITCH
12 16
13
EQUIPMENT OPTIONS STANDARD OPTIONS CAB OPTIONS CANOPY 246/91501

1 OF 2
RESTRAINT SWITCH
HEATED SEAT
15
HEATED SEAT SWITCH
17
HIGH FLOW SOLENOID
18
E.S.O.S. RELAY
19
From m/c no. 677001
Issue 1
PRIMARY FUSE BOX
9804/1103
003E BATTERY
CONTENTS
GLOW PLUGS
BATTERY LEAD BATTERY LEAD
30A
120
ROBOT 160, 170, 170HF
60A 80A START PRE HEAT IGN OFF
30A
40A
301A
30 1 2 2 3 1 4 5
001B
STARTER MOTOR
301B
NEUTRAL START RELAY

5
842
004
2
5 6 3 4 7 8 9
15/54 17 50 19
STARTER SWITCH
310A 310B
STARTER SOLENOID
600V
6 4
310D
6 Y
310L 001A 810A 810
NEUTRAL START RELAY PARK BRAKE LIGHT (Italian only)
79
FUSE A1
1
122A
810
4 2
10A 122B 865 815C

3 5
122 600CL
815
815B 600CP
SPOOL LOCK SOLENOID 1 SPOOL LOCK SOLENOID 2 RESTRAINT SWITCH
121 X
SPOOL LOCK RELAY
-7 2
7
F RESTRAINT SWITCH
9
600HB
10
+3
10a
5 6
LOADER CUT OFF SWITCH (GERMAN AND ITALIAN ONLY)
11
001B 101 408 FUEL GAUGE 830L HOURMETER

2 1
FUSE A2 10A
5
600CC
JUNCTION BOX
12
122 13
600CE 600JA 600HT 600HS
FUEL SENDER FUEL GAUGE FUEL GAUGE ILLUMINATION HOURMETER

407
Skidsteer Range
70 - 15 - 03/1
106D
3
14
15
407A
200 200A 106C FUSE A3 106AA 106 106AB 5A BUZZER ALTERNATOR WATER TEMP. 411
ALTERNATOR
16
DIODE PACK
17
18
434
415A 403C 414A 406A 434B 406
19 20
COOLANT TEMP. SWITCH

HYD. OIL TEMP. 414 600JT
80 81 82 83 84 85
123
106AC 106AD 106AE 106AF FUSE A4 5A
HYD. OIL TEMP. SWITCH

ENGINE OIL PRESS. AIR FILTER CHARGE PUMP PRESS. 403 402 415 X
ENGINE OIL PRESS. SWITCH

600CF 600CS
AIR FILTER SWITCH CHARGE PUMP PRESS. SWITCH
21 22 23
24
124
855C
-7
105
X 600CJ
E.S.O.S. FRONT WORKLIGHT SWITCH
8520-C/4-2.4
FUSE A5 15A FUSE A6 10A
86
106M 116
8+ 2
855A
+3
600AR
RH FRONT WORKLIGHT
125
855
5 6
855B
600AS
LH FRONT WORKLIGHT
87
88
117
861
2
861
600AY
REAR WORKLIGHT
126
127
25
REVERSE SWITCHES 807A
807B
600CD
REVERSE ALARM
26
26
27
127
+9 1
600LX FLOAT SWITCH 106AN 142 142A

3 4 6
600HD
1 -10 2 5
901 600LX 901B 900C

2 -7 +8
900B 902A PRESSURE SWITCH
29
900
128
18
900A
31
9
901A 1 5 3
600HE 142A 902 903 600HZ
FLOAT SOLENOID
30
28
5A FUSE A9
34
312
312B 312A
LATCHING RELAY 871

7
600EY 870
10 8
FRONT HORN
600GZ
129
+8
HORN RELAY
-7
32
HORN SWITCH
33
600DY 106N
1
310G
10A FUSE A10
BEACON SWITCH ILLUM.

2
303
303B
894
600AP M
BEACON
35
BEACON SWITCH
130
303A
90
89
001A
810A
310L
310E
830L
37
310L
310L 001A
855C
8 6
106S 106K 310P FUSE B3 15A 138
600AJ 830L
INTERIOR LIGHT
W
LINK WHEN ROADLIGHTS ARE NOT FITTED 855C 600DW 830B 828M
8+ -7 1 2 +3
17 36
ROADLIGHT SWITCH
5 6 2
131
FUSE B1 5A FUSE B2 828
830 829
830D 829C 829D
600H 600AV 600G
ROADLIGHT SWITCH RH SIDE LIGHT RH TAIL LIGHT No. PLATE LIGHT
92 94 96
132
5A 834
829E 834B
91 93 95 97
133
106B
2
834A
134
FUSE B4 5A FUSE B10 10A 300
HAZARD SWITCH ILLUM.

-10 1 2
104
31 49a 49
802
3
FLASHER UNIT
1
600DX 600LA 600BL
98
HAZARD SWITCH
5 17
10 2
805
803A
805E 805C
-7 6 +3
600G
FLASHER UNIT LH FRONT INDICATOR LH REAR INDICATOR
38
99
135
FUSE B5 5A IGN. RELAY
5
803
18
100
106F
806P
+8
803A
2
806B
805B
39
INDICATOR SWITCH
806E
17
806C 810A 810A 877A

+8
600H
101
40
136
106AK 129
106AK 129
-7 1
877B
2 3
600DD
1
600CU 874 877C

5 6
600CU 877
5 3
877E
600DH
HI-FLOW HYDRAULICS
41
LATCHING RELAY 002

2 4 +10 2
HI-FLOW SWITCH
600DE
42
600W 106R 106R 600EB

-7 1 2 3
44
FUSE B6 10A
1 3
FUSE B7 10A
137
56
800B
4
FAST
43
5
45
102
102
800
6 2
HEATER SWITCH
SLOW
800JD HEATER RESISTOR

10 -7
600BH
M
600GR
600GR
HEATER MOTOR
600ED
1 2 4 1
138
103 103 841 FRONT WASH WIPE SWITCH 106P 106P 103C
600JF 840 M
2
600JF 600AK FRONT WIPER MOTOR

3 5
FRONT AND REAR WASH WIPE
47
6 2 +8
841
103C
46
48
839
10 -7
600BG WASHER MOTOR

1 1 2 4 1 3
FUSE B8 5A 127B
139
127C 600AW
3 4
103B
864
862
600EF 600BD M
2
102
816L
869A
816
2 1
816D
600G
REAR WIPER MOTOR

5
10 SEC. TIMER
50
864
51
53
BRAKE SWITCHES
53
49
6
816E
600H
106H
REAR WASH WIPE SWITCH 106H
103F
2 +8
52
139
103
103F FUSE B8 127C 127B

3 4
863
600BK WASHER MOTOR 600AW M
10 SEC. TIMER
53
5A
BRAKE LIGHT TIMER UNIT
52
57
5
53
816L BRAKE SWITCHES
869A 127D
914
1 2
600MJ
2
BRAKE LIGHT TIMER RELAY

816
1 4
102
816D
600G
LH BRAKE LIGHT
103
816E BRAKE LIGHT TIMER RELAY
-7
321202
600H
RH BRAKE LIGHT
FUSE B9 5A
140
106AM 141
+8 2
600LW
1 2 1
SELF LEVEL SWITCH ILLUM.

893
3
600LV
SELF LEVEL SOLENOID
Z 55
54
70 - 15 - 03/1
SELF LEVEL SWITCH
Up to m/c no. 681290
Issue 1
CONTENTS
Skidsteer Range
70 - 15 - 03/2
ROBOT 160,170, 170HF Circuit Diagrams - Electrical (contd) Main Components

1 2 3 4 5 6 7 8 9 10 10a 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Battery Starter Switch Glow Plugs Starter Motor Starter Solenoid Neutral Start Relay Spool Lock Relay Spool Lock Solenoid 1 Spool Lock Solenoid 2 Restraint Switch Loader Cut Off Switch (German and Italian only) Junction Box Fuel Gauge Sender Fuel Gauge Hourmeter Alternator Diode Pack Diode Warning Buzzer Engine Water Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Cleaner Warning Switch Charge Pump Pressure Switch Engine Shut Off Solenoid Work Light Switch Reverse Switches Reverse Alarm Float Solenoid Pressure Switch Latching Relay Float Switch Horn Relay Horn Switch Front Horn Beacon Switch Road Lights Switch Flasher Unit Hazard Switch Indicator Switch Latching Relay High-Flow Hydraulics Solenoid Valve High-Flow Hydraulics Switch Heater Blower Switch Heater Blower Resistor Heater Blower Motor Front Wiper Motor Front Wash/Wipe Switch Front Washer Motor Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Motor 10 Second Timer Brake Light Switches Self Level Solenoid Self Level Switch Ignition Relay Brake Light Timer Relay (from July 2000 on)
Lamps
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 W X Y Z Park Brake Warning (Italian only) Alternator Warning Water Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Cleaner Warning Charge Pump Pressure Right hand Front Worklight Left hand Front Worklight Rear Worklight Beacon Lamp Interior Light Right Hand Side Light Right Hand Tail Light Number Plate Light Left Hand Tail Light Left Hand Side Light Left Hand Dip Beam Right Hand Dip Beam Left Hand Indicator (Front) Left Hand Indicator (Rear) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Link when road lights are not fitted Link Wire (except German and Italian) Wire fitted up to machine no. 680076 except High-flow Wire 893 was connected to terminal 3 of switch 55 up to machine no. 680077.
Fuses
120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 Primary Fuse Box (On Battery) Spool Lock, Restraint Switch, Cut-off Solenoid (Servo) Junction Box Ignition Circuits ESOS Front Work Lights Rear Work Light Reverse Alarm Float Circuit Horn Beacon, Interior Light Right Hand Side and Tail Lights Left Hand Side and Tail Lights, Number Plate Light Head Light Dip Beam Indicators Hazard Warning High Flow Hydraulics Heater Blower Wipers and Washers Brake Lights Self Level Circuit
Note 1: Diagram A shows brake light timer circuit prior to July 2000
9804/1103
Note 2: For fuse ratings see page70-05-01/5. For bulb ratings see page 70-05-01/1.
8520 - C/4-1.4
70 - 15 - 03/2
Issue 1
CONTENTS
Skidsteer Range
70 - 15 - 03/4
ROBOT 160,170, 170HF 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 Battery Starter Switch Glow Plugs Starter Motor Starter Solenoid Neutral Start Relay Spool Lock Relay Spool Lock Solenoid 1 Spool Lock Solenoid 2 Loader Cut Off Switch (German and Italian only) Restraint Switch Junction Box Fuel Gauge Sender Fuel Gauge Hourmeter Alternator Diode Pack Diode Warning Buzzer Engine Water Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Cleaner Warning Switch Charge Pump Pressure Switch Engine Shut Off Solenoid Work Light Switch Reverse Switches Reverse Alarm Float Solenoid Pressure Switch Latching Relay Float Switch Horn Relay Horn Switch Front Horn Beacon Switch Road Lights Switch Flasher Unit Hazard Switch Indicator Switch High-Flow Hydraulics Solenoid Valve High-Flow Hydraulics Switch Heater Blower Switch Heater Blower Resistor Heater Blower Motor Front Wiper Motor Front Washer Motor Front Wash/Wipe Switch 10 Second Timer Brake Light Switches Brake Light Timer Relay Self Level Solenoid Self Level Switch Ignition Relay
From m/c no. 681291
Lamps
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 W X Park Brake Warning (Italian only) Alternator Warning Water Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Cleaner Warning Charge Pump Pressure Right hand Front Worklight Left hand Front Worklight Rear Worklight Beacon Lamp Interior Light Right Hand Side Light Right Hand Tail Light Number Plate Light Left Hand Tail Light Left Hand Side Light Left Hand Dip Beam Right Hand Dip Beam Left Hand Indicator (Front) Left Hand Indicator (Rear) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Link when road lights are not fitted Link Wire (except German and Italian)
Fuses
9804/1103
70 - 15 - 03/4
8520 - C/4-4.1
Issue 1
CONTENTS
* ROBOT
Skidsteer Range
*
185, 1105
From m/c no. 746001 to 746216

*
Main Components
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Battery Thermostat Starter Motor Starter Solenoid Starter Switch Auxiliary Neutral Start Relay Front Work Light Switch Interlock Relay Parking Brake Switch Operational Solenoid Brake Solenoid Sequence Module Restraint Switch Door Switch Road Light Switch Road Light Connector (German only) Hazard Light Switch Indicator Switch Flasher Unit Windscreen Wiper Switch Windscreen Washer Pump Windscreen Wiper Motor Beacon Switch
Lamps
80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 L.H. Front Work Light R.H. Front Work Light Front L.H. Sidelight Rear L.H. Sidelight Number Plate Light Rear R.H. Sidelight Front R.H. Sidelight R.H. Dip Beam L.H. Dip Beam Interior Light L.H. Rear Indicator L.H. Front Indicator R.H. Rear Indicator R.H. Front Indicator Rotating Beacon
Fuses
110 111 112 113 114 115 116 117 Front Working Lights, Interlock Relay Beacon, Sequence Unit Interior Light, Road Lights L.H. Sidelights, Number Plate Light R.H. Sidelights Hazard Lights Wipers, Washers, Indicators Reverse Alarm, Wiper
Note: See pages 70-05-01/1 for bulb ratings and page 7005-01/4 for fuse ratings.
9804/1103
70 - 15 - 02/1
Issue 2*
CONTENTS
* ROBOT
Skidsteer Range
*
185, 1105
From m/c no. 746001 to 746216

203
1
10 15
2 3
14
5
3 2 877 32
4 6
646
80
4 215 801 802 803 608 810
110
20
219
81
653
9
24 830 829
10 11
634 633
831 401 632
13
200 213 212 216 878 214 208 22 21 218
111
206
12
652
14
850
203A
824 847
113 114
848
82 83 851 84
850
646 645 646 645 674
15
201
851 848 880
85
112
27 207 827 602 205
879 880
86 87 88
646
16 89
881
611
637
115
209 43
818
90 91 92 93
673 648 645 674 616
17
816 210 861 870 869 3 860 815
18
252 44 841 211 840
116
28 853 8
19
1 2
20
809
21
853
22
805 16 806 662 12 18 853
117 23
990 991 890
94
853
5 205 204 401 877
18
C234283
9804/1103
70 - 15 - 02/2
Issue 2*
CONTENTS CONTENTS
* ROBOT
Skidsteer Range
*
185, 1105
From m/c no. 746001 to 746216
401
204 205
877
5 18
28
845 839 835 836 837 832 834 9 838 846 641
27 29
640
118 26 30
899 898 845 868
119
35 874 200 39 9A 201
31
11 202 205 603
33
206 207 208 604
32
204 203
34
605
35
875 45 876
606
601
36
44
36
40 41 38
38
863
39
890 42
39
691 675
37 120
41A 864 220 6 655 39A 36
38A 42
654
40
41
37 607
43 44
422
44
421 673
45 24
43
24
802
1 3
4 2
891
628 652
95 96
674
46
862
673
25
994 995 39 41 40 997 998 681 663
47
48
662
49
50
29A 31 803 804 674
121
97
827
401
45 204 205
13
51
810 811 867 812 615
52
845
53
C234292
9804/1103
70 - 15 - 02/3
Issue 2*
CONTENTS
* ROBOT
Skidsteer Range
*
185, 1105
From m/c no. 746001 to 746216

* Main 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 38A 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55
Components (contd)
56 57 58 59 60 61 62 63 * Hydraulic Oil temperature Switch Engine Oil Pressure Switch Water Temperature Switch Air Cleaner Blocked Switch Low Fuel Switch Charge Pressure Switch Alternator Hour Meter
Brake Light Pressure Switches Auxiliary Ouput Plug Auxiliary Hydraulic Switch Joystick Auxiliary Hydraulic Switch Forward Solenoid Reverse Solenoid Diodes E.S.O.S. (Engine Shut Off Solenoid) Hydraulic Float Switch Hydraulic Float Pressure Switch Hydraulic Float Relay Hydraulic Float Solenoid Pressure Switches (fitted up to October 1995) 2 Speed Switch 2 Speed Relay Diode (fitted from November 1995) Pressure Switches 2 Speed Solenoid Horn Relay Horn switch Horn Pressure Switches Reverse Alarm Breka Light timer Plug High-flow Switch High-flow Solenoid Rear Work Light Switch Heater Blower Switch Resistor Heater Blower Motor Warning Buzzer Diode Gate
Lamps (contd)
95 96 97 98 99 100 101 102 103 104 105 L.H. Brake Light R.H. Brake Light Rear Working Light Hydraulic Oil Pressure Warning Light Engine Oil Pressure Warning Light Water Temperature Warning Light Air Cleaner Blocked Warning Light Low Fuel Warning Light Charge Pressure Alternator Failure Warning Park Brake Master Warning LIght
Fuses (contd)
118 119 120 121 Auxiliary Hydraulics E.S.O.S., Float Solenoid, 2 Speed, High-flow 2 Speed Switch, Brake Lights, Horn Rear Work Light, Heater Blower
Note: For fuse ratings see page 70-05-01/2. For bulb ratings see page 70-05-01/1.
401
45 405
204 205
400
55 54
7 406 415 419 404 408
98 99 100 101 102 103

45
424
407 409
56 57 58 59 60
629 601
414 418
411
802 628 610 609
416 417 444 420
61
104 105
413
402
62
605 403 204 205
401
C234302
661
63
9804/1103
70 - 15 - 02/4
Issue 2*
CONTENTS
Skidsteer Range
From m/c no. 746217
ROBOT 185, 1105 Circuit Diagrams - Electrical Main Components

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Battery Thermostart Starter Motor Neutral Start Relay Starter Switch Diodes Auxiliary Hydraulic Switch Joystick Switches Forward Solenoid (Front) Reverse Solenoid (Front) Output Plug High-flow Solenoid High-flow Switch Restraint Switch Door Switch Park Brake Switch Operational Solenoid Park brake Solenoid Front Worklight Switch Hourmeter Alternator Warning buzzer Diode Gate Hydraulic Oil Temperature Sender Engine OIl Pressure Sender Engine Water Temperature Sender Air Filter Switch Low Fuel Switch Charge Pressure Switch E.S.O.S. (Engine Shut Off Solenoid) Float Switch Pressure Switch Latching Relay Float Solenoid
Lamps
80 81 82 83 84 85 86 87 88 89 90 L.H. Front Work Light R.H. Front Work Light Park Brake Warning Lights Engine Pre-heat Alternator Failure Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Water Temperature Warning Air Cleaner Blocked Warning Low Fuel Warning Charge Pressure Warning
Fuses
110 Auxiliary Hydraulics 111 Operation and Park Brake Solenoids, Front Worklights 112 E.S.O.S. Warning Lights and Buzzer, 2 Speed Switch, Float Solenoid, High-flow Solenoid, Spare Circuit Note: For fuse ratings see page 70-05-01/2. For bulb ratings see page 70-05-01/1.
9804/1103
70 - 15 - 02/5
Issue 1
CONTENTS
Skidsteer Range
70 - 15 - 02/6
ROBOT 185, 1105 Circuit Diagrams - Electrical

203
From m/c no. 746217
1
10 15
2 3
14
5
3 2 877 32
4 6
646
80
4 215 801 802 803 608 810
110
20
219
81
653
9
24 830 829
10 11
634 633
831 401 632
13
200 213 212 216 878 214 208 22 21 218
111
206
12
652
14
850
203A
824 847
113 114
848
82 83 851 84
850
646 645 646 645 674
15
201
851 848 880
85
112
27 207 827 602 205
879 880
86 87 88
646
16 89
881
611
637
115
209 43
818
90 91 92 93
673 648 645 674 616
17
816 210 861 870 869 3 860 815
18
252 44 841 211 840
116
28 853 8
19
1 2
20
809
21
853
22
805 16 806 662 12 18 853
117 23
990 991 890
94
853
5 205 204 401 877
18
C234283
9804/1103
70 - 15 - 02/6
Issue 1
CONTENTS
Skidsteer Range
70 - 15 - 02/7
ROBOT 185, 1105 Circuit Diagrams - Electrical
From m/c no. 746217
41 39 44 9A FUSE PE 6 864 38
41A
2 3 5 4 1
35
2 SPEED SWITCHES
40
863 42
37
890
37 38
691 675
113
39A 220
2 SPEED RELAY 2 SPEED SOLENOID
36
BRAKE LIGHT SWITCHES
43
802
40
1 4
628 862 852
39
39 41
10 SECOND 891 3 TIMER 2
91 92
BRAKE LIGHT TIMER UNIT L.H. BRAKE LIGHT R.H. BRAKE LIGHT FRONT HORN HORN RELAY HAZARD SWITCH ILLUM. L.H. FRONT INDICATOR L.H. REAR INDICATOR
673 674 607 654
6 36
4 3
37 655
42 43
860
853
INDICATOR SWITCH
7
93 94
637 645 673
870 869 840
HAZARD SWITCH
10 7
252 44
815
45
210 816 211
49a 49 31
44 114
27 207 FUSE PH 1 FUSE PH 2 43 44A 209
8 6 2 5 3 1
841
10 9
818 861
95 96
646 674 616
46
8
R.H. FRONT INDICATOR R.H. REAR INDICATOR FLASHER UNIT WASHER MOTOR FRONT WIPER MOTOR WASH/WIPE SWITCH ILLUM.
115
FLASHER UNIT
WASH/WIPE SWITCH
2 7 4
809 805
48 49
614 609 662
16 29 FUSE PH 3
9 10
47
806 421 12
12 18
BEACON SWITCH REVERSE SWITCHES
116
200
50 97
673 672
51
422 990
51
690
REVERSE ALARM BEACON BEACON SWITCH ILLUM. L.H. DIP BEAM R.H. DIP BEAM NO. PLATE LIGHT L.H. TAIL LIGHT L.H. SIDE LIGHT R.H. TAIL LIGHT R.H. SIDE LIGHT ROADLIGHT SWITCH ILLUM. INTERIOR LIGHT
117
FUSE PE 2
206
52
991
10
881 827
3
879 880 TO TUV ROOF FUSE PH 5 MTD DIP BEAM 824 848
880 850 851 850 849 851
203A
118
FUSE PE 1
201
6 2
53
9 10
120 121
FUSE PH 6 847
98 99 100 101 102 103 104
645 646 672 673 645 674 646 602 611
ROADLIGHTS SWITCH INTERIOR LIGHT
205
105
HEATER SWITCH
29A
FUSE PH 4
13
54
3
1 5
810 811
SLOW
FAST
119
55
867
9 10
812
56
615 645
HEATER MOTOR HEATER SWITCH ILLUM. REAR WORKLIGHT REAR W/LIGHT SWITCH ILLUM. 852/90103-2
REAR W/LIGHT SWITCH
31 804
803
106
674 627
57
9 10
9804/1103
70 - 15 - 02/7
Issue 1
CONTENTS
Skidsteer Range
From m/c no. 746217
ROBOT 185, 1105 Circuit Diagrams - Electrical Main Components (contd)

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 2 Speed Switch 2 Speed Relay 2 Speed Switches 2 Speed Solenoid Brake Light Switches Brake Light Timer Horn Relay Horn Horn Switch Hazard Switch Direction Indicator Switch Flasher Unit Wash/Wipe Switch Washer Motor Front Wiper Motor Reverse Alarm Reverse Switches Beacon Switch Roadlights Switch Heater Blower Switch Resistor Heater Blower Motor Rear Worklight Switch
Lamps
91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 L.H. Brake Light R.H. Brake Light L.H. Front Indicator L.H. Rear Indicator R.H. Front Indicator R.H. Rear Indicator Rotating Beacon L.H. Dip Beam R.H. Dip Beam Number Plate Light L.H. Tail Light L.H. Sidelight R.H. Tail Light R.H. Sidelight Interior Light Rear Worklight
Fuses
113 114 115 116 117 118 119 120 121 2 Speed Solenoid, Brake Lights, Front Horn Wipers, Washers, Indicators Hazard Lights Reverse Alarm Beacon Roadlights, Interior Light Heater, Rear Working Light L.H. Sidelight, L.H. Tail Light, Number Plate Light R.H. Sidelight, R.H. Tail Light
9804/1103
70 - 15 - 02/8
Issue 1
PRIMARY FUSE BOX
9804/1103
003E BATTERY
GLOW PLUGS
BATTERY LEAD BATTERY LEAD
30A
120
CONTENTS
ROBOT 160, 170, 170HF
60A 80A START PRE HEAT IGN OFF
30A
40A
301A
30 1 2 2 3 1 4 5
001B
STARTER MOTOR
301B
NEUTRAL START RELAY

5
842
004
2
5 6 3 4 7 8 9
15/54 17 50 19
STARTER SWITCH
310A 310B
STARTER SOLENOID
600V
6 4
310D
6 Y
310L 001A 810A 810
NEUTRAL START RELAY PARK BRAKE LIGHT (Italian only)
79
FUSE A1
1
122A
810
4 2
10A 122B 865 815C 600CL

3 5
122
815
815B 600CP
SPOOL LOCK SOLENOID 1 SPOOL LOCK SOLENOID 2 RESTRAINT SWITCH
121 X
SPOOL LOCK RELAY
-7 2
7
F RESTRAINT SWITCH
9
600HB
10
+3
10a
5 6
LOADER CUT OFF SWITCH (GERMAN AND ITALIAN ONLY)
11
001B 101 408 FUEL GAUGE 830L HOURMETER

2 1
FUSE A2 10A
5
600CC
JUNCTION BOX
12
122 13
600CE 600JA 600HT 600HS
FUEL SENDER FUEL GAUGE FUEL GAUGE ILLUMINATION HOURMETER
Skidsteer Range
70 - 15 - 03/1
106D
3
407
14
407A
15
200 200A 106C 411
ALTERNATOR
16
DIODE PACK
17
18
FUSE A3 BUZZER ALTERNATOR WATER TEMP. 106AA 106 106AB 5A
434
415A 403C 414A 406A 434B 406
19 20
COOLANT TEMP. SWITCH

414 600JT
80 81 82 83 84 85
123
106AC 106AD 106AE 106AF FUSE A4 5A
HYD. OIL TEMP. ENGINE OIL PRESS. AIR FILTER CHARGE PUMP PRESS.

403 402 415 X
ENGINE OIL PRESS. SWITCH

600CF 600CS
AIR FILTER SWITCH CHARGE PUMP PRESS. SWITCH
21 22 23
24
124
855C
-7
8520-E/4-1
105
X 600CJ
E.S.O.S. FRONT WORKLIGHT SWITCH
86
106M 116
8+ 2
855A
+3
600AR
RH FRONT WORKLIGHT
125
855
5 6
855B
600AS
LH FRONT WORKLIGHT
87
88
117
861
2
861
600AY
REAR WORKLIGHT
126
127
25
807B
600CD
REVERSE ALARM
26
26
27
127
+9 1
600LX FLOAT SWITCH 106AN 142 142A

3 4 6
600HD
1 -10 2 5
901 600LX 901B 900C

2 -7 +8
900B 902A PRESSURE SWITCH
29
900
128
900A
18
901A 1 5
31
9
600HE 142A
FLOAT SOLENOID
3
902
903
600HZ
30
28
5A FUSE A9
34
312
312B 312A
LATCHING RELAY 871

7
600EY 870
10 8
FRONT HORN
600GZ
129
+8
HORN RELAY
-7
32
HORN SWITCH
33
600DY 106N
1
310G
10A FUSE A10

2
303
303B
894
600AP M
BEACON
35
BEACON SWITCH
130
303A
90
89
001A
810A
310L
310E
830L
37
310L
310L 001A
855C
8 6
106S 106K 310P FUSE B3 15A 138
600AJ 830L
INTERIOR LIGHT
W
LINK WHEN ROADLIGHTS ARE NOT FITTED 855C 600DW 830B 828M
8+ -7 1 2 +3
17 36
ROADLIGHT SWITCH
5 6 2
131
FUSE B1 5A FUSE B2 828
830 829
830D 829C 829D
600H 600AV 600G
92 94 96
132
5A 834
829E 834B
ROADLIGHT SWITCH RH SIDE LIGHT RH TAIL LIGHT No. PLATE LIGHT LH TAIL LIGHT LH SIDE LIGHT
91 93 95 97
133
106B
2
834A
134
FUSE B4 5A FUSE B10 10A 300
HAZARD SWITCH ILLUM.

-10 1 2
104
31 49a 49
802
3
FLASHER UNIT
1
600DX 600LA 600BL
98
HAZARD SWITCH
5 17
10 2
805
803A
805E 805C
-7 6 +3
600G
FLASHER UNIT LH FRONT INDICATOR LH REAR INDICATOR
38
99
135
FUSE B5 5A IGN. RELAY
5
803
18
100
106F
806P
+8
803A
2
806B
805B
39
INDICATOR SWITCH
806E
17
806C 810A 810A 877A

+8
600H
101
40
136
106AK 129
106AK 129
-7 1
877B
2 3
600DD
1
600CU 874 877C

5 6
600CU 877
5 3
877E
600DH
HI-FLOW HYDRAULICS
41
LATCHING RELAY 002

2 4 +10 2
HI-FLOW SWITCH
600DE
42
600W 106R 106R 600EB

-7 1 2 3
44
FUSE B6 10A
1 3
FUSE B7 10A
137
56
800B
4
FAST
43
5
45
102
102
800
6 2
HEATER SWITCH
SLOW
800JD HEATER RESISTOR

10 -7
600BH
M
600GR
600GR
HEATER MOTOR
600ED
1 2 4 1
138
103 103 841 FRONT WASH WIPE SWITCH 106P 106P 103C
600JF 840 M
2
600JF 600AK FRONT WIPER MOTOR

3 5
FRONT AND REAR WASH WIPE
47
6 2 +8
841
103C
46
48
839
10 -7
600BG WASHER MOTOR

1 1 2 4 1 3
FUSE B8 5A 127B
139
127C 600AW
3 4
103B
864
862
600EF 600BD M
2
102
816L
869A
816
2 1
816D
600G
REAR WIPER MOTOR

5
10 SEC. TIMER
50
864
51
53
BRAKE SWITCHES
53
49
6
816E
600H
106H
REAR WASH WIPE SWITCH 106H
103F
2 +8
52
139
103
103F FUSE B8 127C 127B

3 4
863
600BK WASHER MOTOR 600AW M
10 SEC. TIMER
53
5A
52
57
5
53
816L BRAKE SWITCHES
869A 127D
914
1 2
600MJ
2
BRAKE LIGHT TIMER RELAY

816
1 4
102
816D
600G
LH BRAKE LIGHT
103
816E BRAKE LIGHT TIMER RELAY
-7
321202
600H
RH BRAKE LIGHT
FUSE B9 5A
140
106AM 141
+8 2
600LW
1 2 1
SELF LEVEL SWITCH ILLUM.

893
3
600LV
SELF LEVEL SOLENOID
Z 55
54
70 - 15 - 03/1
SELF LEVEL SWITCH
From m/c no. 680001
Issue 1
CONTENTS
Skidsteer Range
70 - 15 - 03/2
ROBOT 16 0,170, 170HF Circuit Diagrams - Electrical (contd) Main Components

1 2 3 4 5 6 7 8 9 10 10a 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Battery Starter Switch Glow Plugs Starter Motor Starter Solenoid Neutral Start Relay Spool Lock Relay Spool Lock Solenoid 1 Spool Lock Solenoid 2 Restraint Switch Loader Cut Off Switch (German and Italian only) Junction Box Fuel Gauge Sender Fuel Gauge Hourmeter Alternator Diode Pack Diode Warning Buzzer Engine Water Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Cleaner Warning Switch Charge Pump Pressure Switch Engine Shut Off Solenoid Work Light Switch Reverse Switches Reverse Alarm Float Solenoid Pressure Switch Latching Relay Float Switch Horn Relay Horn Switch Front Horn Beacon Switch Road Lights Switch Flasher Unit Hazard Switch Indicator Switch Latching Relay High-Flow Hydraulics Solenoid Valve High-Flow Hydraulics Switch Heater Blower Switch Heater Blower Resistor Heater Blower Motor Front Wiper Motor Front Wash/Wipe Switch Front Washer Motor Rear Wash/Wipe Switch Rear Wiper Motor Rear Washer Motor 10 Second Timer Brake Light Switches Self Level Solenoid Self Level Switch Ignition Relay Brake Light Timer Relay (from July 2000 on)
From m/c no. 680001
Lamps
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 W X Y Z Park Brake Warning (Italian only) Alternator Warning Water Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Cleaner Warning Charge Pump Pressure Right hand Front Worklight Left hand Front Worklight Rear Worklight Beacon Lamp Interior Light Right Hand Side Light Right Hand Tail Light Number Plate Light Left Hand Tail Light Left Hand Side Light Left Hand Dip Beam Right Hand Dip Beam Left Hand Indicator (Front) Left Hand Indicator (Rear) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Link when road lights are not fitted Link Wire (except German and Italian) Wire fitted up to machine no. 680076 except High-flow Wire 893 was connected to terminal 3 of switch 55 up to machine no. 680077.
Fuses
Note 1: Diagram A shows brake light timer circuit prior to July 2000
9804/1103
8520 - E/4-2.3
70 - 15 - 03/2
Issue 1
CONTENTS CONTENTS
Skidsteer Range
70 - 20 - 01/1
ROBOT 150,165 Circuit Diagrams - Hydraulic

Component Key Standard Circuit C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 3 4 5 5A 6 7 8 9 10 Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Loader Joystick Main Loader Valve Block Lift Spool Crowd Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Pressure Test Points/Hand Pump Connectors Check Valve (5 bar) Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Drive Control Joystick Pressure Reducing Solenoid Valve Filter By-pass and Oil Cooler Relief Valve
From m/c no. 675001 to 675573
Optional High-flow Circuit F2 S2 11 12 12A 13 14 High-flow Filter High-flow Pump Suction Strainer High-flow Pump High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor
Note: Neutral Circuit shown in bold line
9804/1103
70 - 20 - 01/1
Issue 3
CONTENTS CONTENTS
Skidsteer Range
70 - 20 - 01/2
From m/c no. 675001 to 675573
5A 2E 2F 2G 2H 2J T 7 6 2
2X
5 2A 2B 2C 2D
10 F1 1
14
2X
13 12
P3
2X 12A
8 P1 M1 2X F2 C P2 M2 4 11
S1
S2 T
A167843
9804/1103
70 - 20 - 01/2
Issue 3
CONTENTS
Skidsteer Range
*
From m/c no. 675574 to 677000
2K 5A 2E 2F 2G 2H 2J T 7 6 2
2X
5 2A 2B 2C 2D
10 F1 1
14
2X
13 12
P3
2X 12A
8 P1 M1 2X F2 C P2 M2 4 11
S1
S2 T
70 - 20 - 01/3
A167845
9804/1103
Issue 3*
CONTENTS CONTENTS
Skidsteer Range
70 - 20 - 01/4

Standard Circuit C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 5A 6 7 8 9 10 Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Loader Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) One-way Restrictor Pressure Test Points Check Valve (8 bar) Oil Cooler By-pass Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Drive Control Joystick Pressure Reducing Solenoid Valve Filter By-pass and Oil Cooler Relief Valve
From m/c no. 675574 to 677000
Optional High-flow Circuit F2 S2 11 12 12A 13 14 High-flow Filter High-flow Pump Suction Strainer High-flow Pump High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor
9804/1103
70 - 20 - 01/4
Issue 2
CONTENTS
Skidsteer Range
*

Component Key - Servo machines Single Drive Lever Control Standard Circuit C1 F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 5A 6 7 8 9 10 Cooler (see note 2) Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Loader Joystick Main Loader Valve Block Auxiliary Spool Lift Spool Crowd Spool Main Relief Valve (MRV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) One-way Restrictor Pressure Test Points Drive Control Joystick Check Valve (8 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Pressure Reducing Solenoid Valve Check Valve (2 bar) Filter By-pass and Oil Cooler Relief Valve
From m/c no. 677001 to 677999
Optional High-flow Circuit C2 F2 S2 11 12 12A 13 14 Cooler High-flow Filter High-flow Pump Suction Strainer High-flow Pump High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor
Note 1: Neutral Circuit shown in bold line Note 2: On High-flow machines, the line to cooler C1 is blanked off at the main pump.
9804/1103
70 - 20 - 01/5
Issue 2*
CONTENTS
Skidsteer Range
From m/c no. 677001
2K 5 2E 2F 2G 2H 2J 2 T 2D 6 7
5A
2A
2B
2C
10 F1 1 2X
2X
14 4 3 13 12 2X 12A
P3
C2
M1
P1 P2
M2 11
2X C1
F2
S1
S2 T
A257392
9804/1103
70 - 20 - 01/6
Issue 2*
CONTENTS
Skidsteer Range
From m/c no. 677001
2K 5 2E 2F 2G 2H 2J 2 T 2D 6 7
5A
2A
2B
2C
10 F1
2X
14 4
2X 1 3
13 12 2X 12A
P3
C2
M1
P1 P2
M2 11
2X C1
F2
S1
S2 T
A257372
9804/1103
70 - 20 - 01/7
Issue 2*
CONTENTS
Skidsteer Range
*

Component Key - Servo machines Dual Drive Lever Control Standard Circuit C1 F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 5A 6 7 8 9 10 Cooler (see note 2) Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Left Hand Joystick Main Loader Valve Block Auxiliary Spool Lift Spool Crowd Spool Main Relief Valve (MRV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) One-way Restrictor Pressure Test Points Drive Control Joystick Check Valve (8 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Pressure Reducing Solenoid Valve Check Valve (2 bar) Filter By-pass and Oil Cooler Relief Valve
From m/c no. 677001 to 677999
Optional High-flow Circuit C2 F2 S2 11 12 12A 13 14 Cooler High-flow Filter High-flow Pump Suction Strainer High-flow Pump High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor
9804/1103
70 - 20 - 01/8
Issue 2*
CONTENTS
Skidsteer Range
*

* Component Key - Manual machines Standard Circuit C1 F1 P1 P2 P3 M1 M2 S1 T 1 *2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 3 4 5 6 7 8 Cooler (see note 2) Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Brake Valve Main Loader Valve Block Lift Spool Crowd Spool Auxiliary Spool Main Relief Valve (MRV) Anti-cavitation Valve Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valves (if required) Pressure Test Points One-way Restrictor Lift Ram Compensating Ram Crowd Ram Filter By-pass and Oil Cooler Relief Valve Check Valve (2 bar)
From m/c no. 677001 to 677999
Optional High-flow Circuit C2 F2 S2 9 10 11 11A 12 Cooler High-flow Filter High-flow Pump Suction Strainer High-flow Pump High-flow Control Valve High-flow Valve High-flow Circuit Relief Valve Attachment Motor
9804/1103
70 - 20 - 01/9
Issue 2*
CONTENTS
Skidsteer Range
From m/c no. 677001
3 2F 4 2E 2D 2G 2H 2J 2J
2A 7
2B
2C 12
F1
2X
2X
10 11 P3 2X 11A
C2 M1 P1 P2 2X C1 M2 9
F2
S1
S2 T
A257152
9804/1103
70 - 20 - 01/10
Issue 2*
CONTENTS
Skidsteer Range
Servo machines from m/c no. 678000
ROBOT 150, 165 Circuit Diagrams - Hydraulic
Component Key - Standard Circuit
2K 5 4 2E 2F 2G 2H 2J 2 T 2D 6 7
2A
2B
2C
10 F1 1 2X
2X
C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 6 7 8 9 10
Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Loader Joystick Main Loader Valve Block Auxiliary Spool Lift Spool Crowd Spool Main Relief Valve (MRV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) One-way Restrictor Pressure Test Points Drive Control Joystick Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Brake Valve Check Valve (2 bar) Filter By-pass and Oil Cooler Relief Valve
Note 1: Neutral Circuit shown in bold line
P3 8 M1 P1 P2
CONTENTS
M2
2X
C S1 T
A257393-1
9804/1103
70 - 20 - 01/11
Issue 1
CONTENTS
Skidsteer Range
Servo machines from m/c no. 678000

Component Key - High-flow Circuit C F1 F2 P1 P2 P3 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 6 7 8 9 10 11 12 12A 13 14 Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Pump Suction Strainer Tank Loader Joystick Main Loader Valve Block Auxiliary Spool Lift Spool Crowd Spool Main Relief Valve (MRV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) One-way Restrictor Pressure Test Points Drive Control Joystick Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Brake Valve Check Valve (2 bar) Filter By-pass High-flow Pump High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor
2K 5 4 2E 2F 2G 2H 2J 2 T 2D 6 7
2A
2B
2C
10 F1 1 2X
2X
14
3 13 12 2X 12A
P3 8 M1 P1 P2 M2 11
2X
F2
9 S1 S2 T
A257393-2
9804/1103
70 - 20 - 01/12
Issue 1
CONTENTS
Skidsteer Range
Manual machines from m/c no. 678000
3 6 5 3 2E 2D 2E 2F 2G 2H 2J 2 4
Component Key - Standard Circuit C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 3 4 5 6 7 8 Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Brake Valve Main Loader Valve Block Auxiliary Spool Crowd Spool Lift Spool Main Relief Valve (MRV) Attachment Auxiliary Relief Valves (if required) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Anti-cavitation Valve Pressure Test Points Cutout Valve Lift Ram Compensating Ram Crowd Ram Filter By-pass and Oil Cooler Relief Valve Check Valve (2 bar)
2A 7 F1
2B
2C
2X
2X
P3
M1
P1
P2
M2
2X
C S1 T
A257153-1
9804/1103
70 - 20 - 01/13
Issue 1
CONTENTS
Skidsteer Range
Manual machines from m/c no. 678000
Component Key - High-flow Circuit C F1 F2 P1 P2 P3 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 3 4 5 6 7 8 9 10 11 11A 12 Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Pump Suction Strainer Tank Brake Valve Main Loader Valve Block Auxiliary Spool Crowd Spool Lift Spool Main Relief Valve (MRV) Attachment Auxiliary Relief Valves (if required) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Anti-cavitation Valve Pressure Test Points Cutout Valve Lift Ram Compensating Ram Crowd Ram Filter By-pass Check Valve (2 bar) High-flow Pump High-flow Control Valve High-flow Valve High-flow Circuit Relief Valve Attachment Motor
3 6 5 3 2E 2D 2E 2F 2G 2H 2J 2 4
2A 7 F1
2B
2C
2X
12
2X
10 11 1 P3 2X 11A
C M1 P1 P2 M2 9 2X F2 8 S1 S2 T
A257153-2
9804/1103
70 - 20 - 01/14
Issue 1
CONTENTS
Skidsteer Range
70 - 20 - 01/15
ROBOT 160, 170, 170H Circuit Diagrams - Hydraulic (contd) Standard Servo Machine - Single Lever Control
Component Key C F1 P1 P2 P3 M1 M1a M2 M2a S1 T X1 X2 Y Z 1 2 2a 2b 2c 2d 2e 3 3a 3b 3c 3d 4 4a 4b 4c 4d 4e 4f 4g 5 6 7 8 9 10 11 12 13 14 15 16 17 Cooler Filter Transmission Pump Run in Tandem Transmission Pump Loader Gear Pump Left Hand (upper) Drive Motor Left Hand Motor Shuttle Valve Right Hand (lower) Drive Motor Right Hand Motor Shuttle Valve Suction Strainer Tank Pressure Test Point Pressure Test Point Plan View of Pump showing Servo Connections Plan View of Valve Block showing Servo Connections Oil Cooler By-pass Valve (3 bar [see note 2]) Drive Servo Control Valve Forward Right Left Reverse Shuttle Valves Loader Servo Control Valve Crowd (joystick in) Tip (joystick out) Lift (joystick back) Lower (joystick forward) Loader Valve Block Main Relief Valve (MRV) Lift Spool Tilt Spool Auxiliary Spool One Way Restrictor Anti-cavitation Valve Auxiliary Relief and Anti-cavitation Valve (see note 3) Auxiliary Couplings Tilt Ram Levelling Valve (Optional) Float Valve (Optional) Lift Ram Manual Load Lower Valve Suction Manifold Cut Off Valve (see note 4) Charge Pressure Swtich Hydraulic Oil Temperature Switch Reverse Alarm Pressure Switches (Optional) Brake Light Pressure Switches (Optional) Float Pressure Switch (Optional) Note 1: Neutral Circuit shown in bold line Note 2: Machines manufactured prior to July 2000 were fitted with a 2 bar by-pass valve. The 3 bar valve may be fitted to earlier machines. Note 3: When machine is fitted with a breaker, item 4g is used instead of 4f. Note 4: This valve was fitted on production from machine no. 681091. Some earlier machines may also be fitted with the valve.
* * * * *
9804/1103
70 - 20 - 01/15
8520 - E/15 - 1.5
Issue 2*
CONTENTS
Skidsteer Range
ROBOT 160, 170, 170H Circuit Diagrams - Hydraulic (contd) Standard Servo Machine - Single Lever Control
14
RIGHT HAND (LOWER) MOTOR
T B REV B
M2
Y SERVO CONNECTIONS
ENGINE M4 A M5 B
M1 MOTOR
T
LEFT HAND (UPPER)
DRIVE SERVO CONTROL VALVE
PLAN VIEW OF PUMP SHOWING
P2
FRONT PUMP
P1 REAR PUMP
2a FWD
P
REV
2b
RIGHT
2c
LEFT
C M5 M4
2d
REV
M2a
A FWD A D FWD
M1a
A
C COOLER
M5 M4 M5 M4 A C B D
2e 15 16 16 15
FLOAT VALVE (OPTIONAL)
X1 F1 FILTER
D
7 9
LIFT RAM
LEVELLING VALVE (OPTIONAL)
12
CUT OFF VALVE
17
A
6
TILT RAM
13
C B
5
AUX. COUPLINGS
FEMALE MALE
10
MANUAL LOWER VALVE
B1 A1 A2 B2
3 LOADER SERVO CONTROL VALVE

3a CROWD
(JOYSTICK LEFT) LIFT (JOYSTICK BACK)
B3
A3
4
LOADER VALVE BLOCK
T S1
TANK
4e 4b
LOWER
4d 4c
TIP
3c
11
P3
GEAR PUMP
LOWER (JOYSTICK FORWARD) TIP (JOYSTICK RIGHT) 1
3d
X2
4a
LIFT CROWD
3b
4f
A1 P B1
A2 T B2
4g
PLAN VIEW OF VALVE BLOCK SHOWING SERVO CONNECTIONS
321234
9804/1103
70 - 20 - 01/16
8520 - E/15 - 2.5
Issue 2*
CONTENTS
Skidsteer Range
ROBOT 160, 170, 170H Circuit Diagrams - Hydraulic (contd) High - flow Servo Machine - Single Lever Control
17
M2
Y SERVO CONNECTIONS
ENGINE M4 A M5 B

T
M1 MOTOR
T REV B
LEFT HAND (UPPER)

B
P2
FRONT PUMP
P1 REAR PUMP
C REV B
2a FWD
P
2b
RIGHT
2c
LEFT
2d
C M5 M4 D REV
M2a
A FWD A D FWD A
M1a
2e
M5 M4 M5 M4 A C B D
C2
HIGH-FLOW COOLER
18 19 19
18
X1 F1
FILTER
9
LIFT RAM
7
20
A

D
15
CUT OFF VALVE
16
6
TILT RAM
C B FEMALE
T
TANK
S1 P3
GEAR PUMP
10
MANUAL LOWER VALVE
5
AUX. COUPLINGS
MALE

3a CROWD
(JOYSTICK LEFT)
1 PRIORITY VALVE
B1
A1
A2
B2
B3
A3
4
LOADER VALVE BLOCK
4e 4b
LOWER
3
LIFT (JOYSTICK BACK)
11
4d 4c
TIP T
3c
A1 P
A2 T
12
HIGH-FLOW FILTER
P4
HIGH-FLOW GEAR PUMP
HPCO
B1
B2
14 ATTACHMENT MOTOR
LOWER (JOYSTICK FORWARD) TIP (JOYSTICK RIGHT) T P
3d
X2
4a
LIFT CROWD
3b
1
2 3 4 1
4f
4g
C1
COOLER
13
HIGH-FLOW VALVE
T
TANK 321254
9804/1103
70 - 20 - 01/17
8520 - E/15 - 3.5
Issue 2*
CONTENTS
Skidsteer Range
70 - 20 - 01/18
ROBOT 160, 170, 170H Circuit Diagrams - Hydraulic (contd) High - flow Servo Machine - Single Lever Control
Component Key C1 C2 F1 P1 P2 P3 P3 M1 M1a M2 M2a S1 T X1 X2 Y Z 1 2 2a 2b 2c 2d 2e 3 3a 3b 3c 3d 4 4a 4b 4c 4d 4e 4f 4g 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Cooler High-flow Cooler Filter Transmission Pump Run in Tandem Transmission Pump Loader Gear Pump High-flow Pump Left Hand (upper) Drive Motor Left Hand Motor Shuttle Valve Right Hand (lower) Drive Motor Right Hand Motor Shuttle Valve Suction Strainer Tank Pressure Test Point Pressure Test Point Plan View of Pump showing Servo Connections Plan View of Valve Block showing Servo Connections Charge Pressure Priority Valve Drive Servo Control Valve Forward Right Left Reverse Shuttle Valves Loader Servo Control Valve Crowd (joystick in) Tip (joystick out) Lift (joystick back) Lower (joystick forward) Loader Valve Block Main Relief Valve (MRV) Lift Spool Tilt Spool Auxiliary Spool One Way Restrictor Anti-cavitation Valve Auxiliary Relief and Anti-cavitation Valve (see note 2) Auxiliary Couplings Tilt Ram Levelling Valve (Optional) Float Valve (Optional) Lift Ram Manual Load Lower Valve Suction Manifold High-flow Filter High-flow Control Valve Attachment Motor Cut Off Valve (see note 3) Charge Pressure Swtich Hydraulic Oil Temperature Switch Reverse Alarm Pressure Switches (Optional) Brake Light Pressure Switches (Optional) Float Pressure Switch (Optional) Note 1: Neutral Circuit shown in bold line Note 2: When machine is fitted with a breaker, item 4g is used instead of 4f. Note 3: This valve was fitted on production from machine no. 681091. Some earlier machines may also be fitted with the valve.
* * * * *
9804/1103
70 - 20 - 01/18
8520 - E/15 - 4.5
Issue 2*
CONTENTS
Skidsteer Range
70 - 20 - 01/19
ROBOT 160, 170, 170H Circuit Diagrams - Hydraulic (contd) Standard Servo Machine - Dual Lever Control
Component Key C F1 P1 P2 P3 M1 M1a M2 M2a S1 T X1 X2 Y Z 1 2 2a 2b 2c 2d 3 3a 3b 3c 3d 4 4a 4b 4c 4d 4e 4f 4g 5 6 7 8 9 10 11 12 13 14 15 16 17 Cooler Filter Transmission Pump Run in Tandem Transmission Pump Loader Gear Pump Left Hand (upper) Drive Motor Left Hand Motor Shuttle Valve Right Hand (lower) Drive Motor Right Hand Motor Shuttle Valve Suction Strainer Tank Pressure Test Point Pressure Test Point Plan View of Pump showing Servo Connections Plan View of Valve Block showing Servo Connections Oil Cooler By-pass Valve (3 bar) Left Hand Joystick Forward Drive Reverse Drive Lift Arm Lower Lift Arm Raise Right Hand Joystick Forward Drive Reverse Drive Shovel Tip Shovel Crowd Loader Valve Block Main Relief Valve (MRV) Lift Spool Tilt Spool Auxiliary Spool One Way Restrictor Anti-cavitation Valve Auxiliary Relief and Anti-cavitation Valve (see note 2) Auxiliary Couplings Tilt Ram Levelling Valve (Optional) Float Valve (Optional) Lift Ram Manual Load Lower Valve Suction Manifold Cut Off Valve (see note 3) Charge Pressure Swtich Hydraulic Oil Temperature Switch Reverse Alarm Pressure Switches (Optional) Brake Light Pressure Switches (Optional) Float Pressure Switch (Optional) Note 1: Neutral Circuit shown in bold line Note 2: When machine is fitted with a breaker, item 4g is used instead of 4f. Note 3: This valve was fitted on production from machine no. 681091. Some earlier machines may also be fitted with the valve.
* * * * *
9804/1103
70 - 20 - 01/19
8520 - E/15 - 5.2
Issue 2*
CONTENTS
Skidsteer Range
ROBOT 160, 170, 170H Circuit Diagrams - Hydraulic (contd) Standard Servo Machine - Dual Lever Control
14
M2
Y SERVO CONNECTIONS
ENGINE M4 L.H. 3 M5 L.H. 1

T B REV B
M1
T
LEFT HAND (UPPER) MOTOR
LEFT HAND JOYSTICK
P2
FRONT PUMP
P1 REAR PUMP
REV
2a FORWARD 2c LOWER
R.H. 1 M5 M4
R.H. 3
2d LIFT
M2a
A FWD A D FWD
M1a
2b
A 2 3 4 1 REVERSE T P
COOLER
M5 M4 M5 M4
15 16 16
15
X1 F1
12
CUT OFF VALVE
7 9
LIFT RAM

D
FILTER
17
A
6
TILT RAM
13
C B
5
AUX. COUPLINGS
FEMALE MALE
10
MANUAL LOWER VALVE
B1 A1 A2 B2
RIGHT HAND JOYSTICK
B3
A3
4
LOADER VALVE BLOCK
3a FORWARD 3c TIP
T S1
TANK
4e 4b
LOWER
4d 4c
TIP
3d CROWD 3b
REVERSE
11
P3
GEAR PUMP
L.H. 4
R.H. 2
X2
4a
LIFT CROWD
4f
A1 P B1
A2 T B2
4g
L.H. 2
R.H. 4
387221
9804/1103
70 - 20 - 01/20
8520 - E/15 - 6.2
Issue 2*
CONTENTS
Skidsteer Range
ROBOT 160, 170, 170H Circuit Diagrams - Hydraulic (contd) High - flow Servo Machine - Dual Lever Control
17
M2
Y
PLAN VIEW OF PUMP SHOWING SERVO CONNECTIONS
ENGINE M4 L.H. 3 M5 L.H. 1

T B REV B
M1 MOTOR
T
LEFT HAND (UPPER)
LEFT HAND JOYSTICK
P2
FRONT PUMP
P1 REAR PUMP
C REV B
2a FORWARD 2c LOWER
2d LIFT
R.H. 1 M5 M4 R.H. 3
M2a
A FWD A D FWD A
M1a
2b
REVERSE 2 M5 M4 M5 M4 3 4 1 T P
C2
HIGH-FLOW COOLER
18 19 19
18
X1 F1
15
CUT OFF VALVE
9
LIFT RAM
7
20
A

D
FILTER
16
6
TILT RAM
T
TANK
3 10
MANUAL LOWER VALVE
C B FEMALE
RIGHT HAND JOYSTICK
S1 P3
GEAR PUMP
5
AUX. COUPLINGS
MALE
3a FORWARD 3c TIP
1 PRIORITY VALVE
B1
A1
A2
B2
B3
A3
4
LOADER VALVE BLOCK
4e 4b
LOWER
11
4d 4c
TIP T
3d CROWD 3b
12
HIGH-FLOW FILTER
P4
HIGH-FLOW GEAR PUMP
HPCO 2 3 4 1
REVERSE T P
14 ATTACHMENT MOTOR
X2
4a
LIFT CROWD
4f
4g
L.H. 4
R.H. 2
C1
COOLER
13
HIGH-FLOW VALVE
P B1 B2 A1 A2

T
T
TANK
L.H. 2
R.H. 4
387231
9804/1103
70 - 20 - 01/21
8520 - E/15 - 7.2
Issue 2*
CONTENTS
Skidsteer Range
70 - 20 - 01/22
ROBOT 160, 170, 170H Circuit Diagrams - Hydraulic (contd) High - flow Servo Machine - Dual Lever Control
Component Key C1 C2 F1 P1 P2 P3 P3 M1 M1a M2 M2a S1 T X1 X2 Y Z 1 2 2a 2b 2c 2d 3 3a 3b 3c 3d 4 4a 4b 4c 4d 4e 4f 4g 5 6 7 8 9 10 11 12 13 14 15 * 16 * 17 * 18 * 19 * 20 Cooler High-flow Cooler Filter Transmission Pump Run in Tandem Transmission Pump Loader Gear Pump High-flow Pump Left Hand (upper) Drive Motor Left Hand Motor Shuttle Valve Right Hand (lower) Drive Motor Right Hand Motor Shuttle Valve Suction Strainer Tank Pressure Test Point Pressure Test Point Plan View of Pump showing Servo Connections Plan View of Valve Block showing Servo Connections Charge Pressure Priority Valve Left Hand Joystick Forward Drive Reverse Drive Lift Arm Lower Lift Arm Raise Right Hand Joystick Forward Drive Reverse Drive Shovel Tip Shovel Crowd Loader Valve Block Main Relief Valve (MRV) Lift Spool Tilt Spool Auxiliary Spool One Way Restrictor Anti-cavitation Valve Auxiliary Relief and Anti-cavitation Valve (see note 2) Auxiliary Couplings Tilt Ram Levelling Valve (Optional) Float Valve (Optional) Lift Ram Manual Load Lower Valve Suction Manifold High-flow Filter High-flow Control Valve Attachment Motor Cut Off Valve (see note 3) Charge Pressure Swtich Hydraulic Oil Temperature Switch Reverse Alarm Pressure Switches (Optional) Brake Light Pressure Switches (Optional) Float Pressure Switch (Optional) Note 1: Neutral Circuit shown in bold line Note 2: When machine is fitted with a breaker, item 4g is used instead of 4f. Note 3: This valve was fitted on production from machine no. 681091. Some earlier machines may also be fitted with the valve.
9804/1103
70 - 20 - 01/22
8520 - E/15 - 8.2
Issue 2*
CONTENTS
Skidsteer Range
*
70 - 20 - 02/1
From m/c no. 746001 to 746998
12 2F 2G 2E 2K 2H 2J 4 T 7 6
2X
5A
2 2D 2A 2B 2C
F1 10 T
2X 9 P4
11 4
8 P3
B A X Z Z X A B
8A
8B 8C
8D C
P1 M1
L2 L1
P3
P2 M2
L1 L2
d
2 4
3 b c a
S2
S1 T
70 - 20 - 02/1
9804/1103
Issue 3*
CONTENTS CONTENTS
Skidsteer Range
*
70 - 20 - 02/2

Component Key Standard machines with single lever drive control C1 F1 P1 P2 P3 P4 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 2 5 5A 6 7 8 8A 8B 8C 8D 9 10 11 12 Cooler Filter Main Pump Run in Tandem Main Pump Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Suction Strainer Tank Loader Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Anti-cavitation Check Valve Pressure Test Points/Hand Pump Connectors Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Pressure Reducing Solenoid Valve Filter By-pass Valve 2-speed Control Float Solenoid Valve (optional)
From m/c no. 746001 to 746998
Motor Ports A B L1 L2 X Z Main Port Main Port Motor Flush In Motor Flush Out 2- Speed Port Brake Port
9804/1103
70 - 20 - 02/2
Issue 3*
CONTENTS CONTENTS
Skidsteer Range
*
70 - 20 - 02/3

Component Key High-flow machines with single lever drive control C1 F1 P1 P2 P3 P4 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 5A 6 7 8 8A 8B 8C 8D 9 10 11 12 13 14 14A 14B 15 Cooler Filter Main Pump Run in Tandem Main Pump Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Suction Strainer Tank Loader Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Anti-cavitation Check Valve Pressure Test Points/Hand Pump Connectors Check Valve (5 bar) Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Pressure Reducing Solenoid Valve Filter By-pass Valve 2-speed Control Float Solenoid Valve (optional) High-flow Pump High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor
From m/c no. 746001 to 746998
Motor Ports A B L1 L2 X Z Main Port Main Port Motor Flush In Motor Flush Out 2 Speed Port Brake Port
Note: Neutral Circuit shown in bold line Note: Line X is the feed to the High-flow valve on machines up to serial number 746105. Line Y is the High-flow feed from machine serial number 746106.
9804/1103
70 - 20 - 02/3
Issue 3*
CONTENTS CONTENTS
Skidsteer Range
*
70 - 20 - 02/4
From m/c no. 746001 to 746998
12 2F 2G 2E 2K 2H 2J 4 T 7 6
2X
5A
2 2D 2A 2B 2C
F1 10 T
14
2X 9 P4
14A
14B 15
3 11 4
F2
X
T 8D 13
8 P3
B A X Z Z X A B
8A
8B 8C
P1 M1
L2 L1
P3
P2 M2
L1 L2
d
2 4
3 b c a
S2
S1 T
9804/1103
70 - 20 - 02/4
Issue 3*
CONTENTS CONTENTS
Skidsteer Range
* From
70 - 20 - 02/5

Component Key Standard machines with dual lever drive control C1 F1 P1 P2 P3 P4 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 4 5 5A 6 7 8 9 10 11 12 Cooler Filter Main Pump Run in Tandem Main Pump Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Suction Strainer Tank Left Hand Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Anti-cavitation Check Valve Pressure Test Points/Hand Pump Connectors Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Drive Control Joystick Pressure Reducing Solenoid Valve Filter By-pass Valve 2-speed Control Float Solenoid Valve (optional)
m/c no. 746001 to 746998
9804/1103
70 - 20 - 02/5
Issue 2*
CONTENTS CONTENTS
Skidsteer Range
* From
70 - 20 - 02/6
m/c no. 746001 to 746998
12 2F 2G 2E 2K 2H 2J 4 T 7 6
2X
5A
2 2D 2A 2B 2C
F1 10 T
2X
P4 11 4
P3
B A X Z Z X A B
9 C
P1 M1
L2 L1
P3
P2 M2
L1 L2
S2
S1 T
A275690A
9804/1103
70 - 20 - 02/6
Issue 2*
CONTENTS CONTENTS
Skidsteer Range
* From
70 - 20 - 02/7
m/c no. 746001 to 746998
12 2F 2G 2E 2K 2H 2J 4 T 7 6
2X
5A
2 2D 2A 2B 2C
14
F1 10 T
14A
14B 15
2X 3 P4 11 4 F2
T P3
B A X Z Z X A B
9 13 C
P1 M1
L2 L1
P3
P2 M2
L1 L2
S2
S1
A275690
T
9804/1103
70 - 20 - 02/7
Issue 2*
Skidsteer Range
* From
70 - 20 - 02/8

Component Key High-flow machines with dual lever drive control C1 F1 F2 P1 P2 P3 P4 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 5A 6 7 8 9 10 11 12 13 14 14A 14B 15 Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Suction Strainer Tank Left Hand Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Anti-cavitation Check Valve Pressure Test Points/Hand Pump Connectors Check Valve (5 bar) Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Drive Control Joystick Pressure Reducing Solenoid Valve Filter By-pass Valve 2-speed Control Float Solenoid Valve (optional) High-flow Pump Hifh-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor
m/c no. 746001 to 746998
9804/1103
70 - 20 - 02/8
8510-E/30-8.2
Issue 2*
Skidsteer Range
70 - 20 - 02/9

Component Key Standard machines with single lever drive control. C F1 P1 P2 P3 P4 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 4 5 5A 6 7 8 8A 8B 8C 8D 9 10 11 12 Cooler Filter Main Pump Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Suction Strainer Tank Loader Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Anti-cavitation Check Valve Pressure Test Points/Hand Pump Connectors Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Solenoid Brake Valve Filter By-pass Valve 2-speed Control Float Solenoid Valve (optional)
From m/c no. 746999 to 804423
Motor Ports A Main Port B Main Port L1 Motor Flush In L2 Motor Flush Out X 2 Speed Port Z Brake Port
9804/1103
70 - 20 - 02/9
8510-E/30-9.2
Issue 1
CONTENTS
Skidsteer Range
70 - 20 - 02/10
From m/c no. 746999 to 804423
12 2F 2G 2E 2K 2H 2J 5A T 7 6
2X
2 2D 2A 2B 2C
2X F1 10
P4 T
LJ BL
9
P TJ
T BR
11
8 P3
B A X Z Z X A B
8A
8B 8C
8D
P1 M1
L2 L1
P3
P2 M2
L1 L2
d
2 4
3 b c a
S2
S1 T
9804/1103
70 - 20 - 02/10
8510 - E/30-10
Issue 1
CONTENTS
Skidsteer Range
70 - 20 - 03/1
ROBOT 160, 170, 170HF Circuit Diagrams - Hydraulic Standard Servo Machine
*
M2
Y SERVO CONNECTIONS
ENGINE M4 A M5 B RIGHT
From m/c no. 680001

T B REV B
M1 MOTOR
T
LEFT HAND (UPPER)
P2
FRONT PUMP
P1 REAR PUMP
2a FWD
P
REV
2b 2c
LEFT
C M5 M4
2d
REV
M2a
A FWD A D FWD
M1a
A
2e
COOLER
M5 M4 M5 M4 A C B D
X1 F1
FILTER
7 9
LIFT RAM

D
6
A
TILT RAM
C
5
AUX. COUPLINGS
FEMALE MALE
10
MANUAL LOWER VALVE
B1 A1 A2 B2

3a CROWD
(JOYSTICK IN) LIFT (JOYSTICK BACK)
B3
A3
4
LOADER VALVE BLOCK
T S1
TANK
4e 4b
LOWER
4d 4c
TIP
3c
11
P3
GEAR PUMP
4 3
LOWER (JOYSTICK FORWARD)
3d
X2
4a
LIFT CROWD
3b TIP
4f
4g
(JOYSTICK OUT)
A1 P B1
A2 T B2
321232
INCREASED BY 130%
9804/1103
70 - 20 - 03/1
8520 - E/5-2.3
Issue 2*
CONTENTS
Skidsteer Range
70 - 20 - 02/11

Component Key High-flow machines with single lever drive control. C F1 F2 P1 P2 P3 P4 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 5A 6 7 8 8A 8B 8C 8D 9 10 11 12 13 14 14A 14B 15 Cooler Filter High-flow Filter Main Pump Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Suction Strainer Tank Loader Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Anti-cavitation Check Valve Pressure Test Points/Hand Pump Connectors Check Valve (5 bar) Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Solenoid Brake Valve Filter By-pass Valve 2-speed Control Float Solenoid Valve (optional) High-flow Pump High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor
From m/c no. 746999 to 804423
9804/1103
70 - 20 - 02/11
8510-E/30-12.2
Issue 1
CONTENTS
Skidsteer Range
70 - 20 - 02/12
From m/c no. 746999 to 804423
12 2F 2G 2E 2K 2H 2J 5A T 7 6
2X
2 2D 2A 2B 2C
2X F1 10
14
P4 T 14A 14B 15
LJ BL
9
P
3
TJ
F2
T BR
11 T 8
P3
B A X Z Z X A B
8A
8B 8C
8D 13
P1 M1
L2 L1
P3
P2 M2
L1 L2
d
2 4
3 b c a
S2
S1 T
9804/1103
70 - 20 - 02/12
8510 - E/30-11
Issue 1
CONTENTS
Skidsteer Range
70 - 20 - 02/13

Component Key Standard machines with dual lever drive control. C F1 P1 P2 P3 P4 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 4 5 5A 6 7 8 9 10 11 12 Cooler Filter Main Pump Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Suction Strainer Tank Left Hand Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Anti-cavitation Check Valve Pressure Test Points/Hand Pump Connectors Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Right Hand Joystick Solenoid Brake Valve Filter By-pass Valve 2-speed Control Float Solenoid Valve (optional)
From m/c no. 746999 to 804423
9804/1103
70 - 20 - 02/13
8510-E/30-13.2
Issue 1
CONTENTS
Skidsteer Range
70 - 20 - 02/14
From m/c no. 746999 to 804423
12 2F 2G 2E 2K 2H 2J 5A T 7 6
2X
2 2D 2A 2B 2C
2X F1 10 T
P4
11
P3
B A X Z Z X A B P
LJ
BL
C
TJ
P1 M1
L2 L1
P3
P2 M2
L1 L2
BR
S2
S1 T
9804/1103
70 - 20 - 02/14
8510 - E/30-14
Issue 1
CONTENTS
Skidsteer Range
70 - 20 - 02/15

Component Key High-flow machines with dual lever drive control. C F1 F2 P1 P2 P3 P4 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2X 3 4 5 5A 6 7 8 9 10 11 12 13 14 14A 14B 15 Cooler Filter High-flow Filter Main Pump Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Suction Strainer Tank Left Hand Joystick Main Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Anti-cavitation Check Valve Pressure Test Points/Hand Pump Connectors Check Valve (5 bar) Check Valve (2 bar) Lift Ram Manually Operated Dump Valve Compensating Ram Crowd Ram Right Hand Joystick Solenoid Brake Valve Filter By-pass Valve 2-speed Control Float Solenoid Valve (optional) High-flow Pump High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor
From m/c no. 746999 to 804423
9804/1103
70 - 20 - 02/15
8510-E/30-16.2
Issue 1
CONTENTS
Skidsteer Range
70 - 20 - 02/16
From m/c no. 746999 to 804423
12 2F 2G 2E 2K 2H 2J 5A T 7 6
2X
2 2D 2A 2B 2C
14
2X F1 10
14A T P4
14B 15
F2
11
T P3
B A X Z Z X A B P
LJ
BL
TJ
13 C
P1 M1
L2 L1
P3
P2 M2
L1 L2
BR
S2
S1 T
9804/1103
70 - 20 - 02/16
8510 - E/30-15
Issue 1
CONTENTS
Skidsteer Range
70 - 20 - 02/17

Component Key - Standard machines with single lever drive control. C F1 P1 P2 P3 Pa M1 M2 S1 T 1 2 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 3K 4 5 6 7 8 9 10 10A 10B 10C 10D 11 12 X Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Charge Pump (disabled) Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Charge Pressure Priority Valve Pressure Test Points Main Loader Valve Block Main Relief Valve (MRV) Crowd Spool Lift Spool Auxiliary Spool Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Anti-cavitation Check Valve Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Crowd Ram Compensating Ram Lift Ram Float Solenoid Valve (optional) Emergency Lower Valve 2-speed Control Drive Control Joystick Forward Spool Right Turn Spool Left Turn Spool Reverse Spool Solenoid Brake Valve Loader Joystick Plan of Main Pump showing joystick connections
From m/c no. 804424
9804/1103
70 - 20 - 02/17
8510-E/30-17.1
Issue 1
CONTENTS
Skidsteer Range
70 - 20 - 02/18
From m/c no. 804424
T T T 1 D B
10A 10B
4 2
10
P T
M2
C
M4 M5
Pa P2 P1
M1
E
3
10C 10D
M5
M4
D
A B C A D C
M5
M4 M5
M4
BR
6 5 4 7 F1 S1 1 3 C 3A P3
B1 A1 A2 B2 B3 A3
9 8 2
T P
11
CT1 CT2 TJ
T
T LJ BL
T 3E 3F 3G
3H 3J
3K T
12 3B 2
1 3
3C
3D
361600
9804/1103
70 - 20 - 02/18
8510 - E/30-18.1
Issue 1
CONTENTS CONTENTS
Skidsteer Range
70 - 20 - 02/19

Component Key High-flow machines with single lever drive control. C F1 F2 P1 P2 P3 P4 Pa M1 M2 S1 S2 T 1 2 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 3K 4 5 6 7 8 9 10 10A 10B 10C 10D 11 12 13 14 14A 14B 15 X Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump High-flow Pump Charge Pump (disabled) Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Suction Strainer Tank Charge Pressure Priority Valve Pressure Test Points Main Loader Valve Block Main Relief Valve (MRV) Crowd Spool Lift Spool Auxiliary Spool Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Anti-cavitation Check Valve Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Crowd Ram Compensating Ram Lift Ram Float Solenoid Valve (optional) Emergency Lower Valve 2-speed Control Drive Control Joystick Forward Spool Right Turn Spool Left Turn Spool Reverse Spool Solenoid Brake Valve Loader Joystick Check Valve (10 bar) High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor Plan of Main Pump showing joystick connections
From m/c no. 804424
9804/1103
70 - 20 - 02/19
8510-E/30-20.1
Issue 1
CONTENTS
Skidsteer Range
70 - 20 - 02/20
From m/c no. 804424
T T T 1 D B
10A 10B
4 2
10
P T
M2
C
M4 M5
Pa P2 P1
M1
E
3
10C 10D
M5
M4
A D C
M5
M4 M5
M4
BR
6 5 4 T 7 F1 T S2 C 13 P3 S1 1 3 3A
B1 A1 A2 B2 B3 A3
9
P
CT1
CT2
11
TJ
8 2
T T LJ BL
3E
3F 3G
3H 3J
3K T
3B F2 P4 2
3C
3D
12
15
P2 P1 T P
14
14A
T
14B
361610
9804/1103
70 - 20 - 02/20
8510 - E/30-19.1
Issue 1
CONTENTS
Skidsteer Range
70 - 20 - 02/21

Component Key Standard machines with dual lever drive control. C F1 P1 P2 P3 Pa M1 M2 S1 T 1 2 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 3K 4 5 6 7 8 9 10 10A 10B 10C 10D 11 12 12A 12B 12C 12D X Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Charge Pump (disabled) Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Charge Pressure Priority Valve Pressure Test Points Main Loader Valve Block Main Relief Valve (MRV) Crowd Spool Lift Spool Auxiliary Spool Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Anti-cavitation Check Valve Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Crowd Ram Compensating Ram Lift Ram Float Solenoid Valve (optional) Emergency Lower Valve 2-speed Control Left Hand Control Joystick Left Hand Motor Forward Spool Arm Lower Spool Arm Raise Spool Left Hand Motor Reverse Spool Solenoid Brake Valve Right Hand Control Joystick Right Hand Motor Forward Spool Bucket Crowd Spool Bucket Tip Spool Right Hand Motor Reverse Spool Plan of Main Pump showing joystick connections
From m/c no. 804424
9804/1103
70 - 20 - 02/21
8510-E/30-21.1
Issue 1
CONTENTS
Skidsteer Range
70 - 20 - 02/22
From m/c no. 804424
T T T
10A M1
1
10
P2 T
M2
C
M4 M5
Pa P2 P1
10B
4 2
P1
10C
3
M5
M4
D
A B C A
10D
X Z
M5
M4 M5
M4
BR
6 5 4 7 F1 S1 1 3 C 3A P3
B1 A1 A2 B2 B3 A3
9 8 2
T P
11
CT1 CT2 TJ
T
T LJ BL
T 3E 3F 3G
3H 3J
3K T
3B 2
3C
3D 12
P2
12B
2
12A
1
12D
3
12C
T P1
361620
9804/1103
70 - 20 - 02/22
8510 - E/30-22.1
Issue 1
CONTENTS CONTENTS
Skidsteer Range
70 - 20 - 02/23

Component Key High-flow machines with dual lever drive control. C F1 F2 P1 P2 P3 P4 Pa M1 M2 S1 S2 T 1 2 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 3K 4 5 6 7 8 9 10 10A 10B 10C 10D 11 12 12A 12B 12C 12D 13 14 14A 14B 15 X Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump High-flow Pump Charge Pump (disabled) Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Suction Strainer Tank Charge Pressure Priority Valve Pressure Test Points Main Loader Valve Block Main Relief Valve (MRV) Crowd Spool Lift Spool Auxiliary Spool Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Anti-cavitation Check Valve Attachment Auxiliary Relief Valve (if required) Attachment Auxiliary Relief Valve (if required) Crowd Ram Compensating Ram Lift Ram Float Solenoid Valve (optional) Emergency Lower Valve 2-speed Control Left Hand Control Joystick Left Hand Motor Forward Spool Arm Lower Spool Arm Raise Spool Left Hand Motor Reverse Spool Solenoid Brake Valve Right Hand Control Joystick Right Hand Motor Forward Spool Bucket Crowd Spool Bucket Tip Spool Right Hand Motor Reverse Spool Check Valve (10 bar) High-flow Valve High-flow Circuit Relief Valve High-flow Control Valve Attachment Motor Plan of Main Pump showing joystick connections
From m/c no. 804424
9804/1103
70 - 20 - 02/23
8510-E/30-24.1
Issue 1
CONTENTS
Skidsteer Range
70 - 20 - 02/24
From m/c no. 804424
T T T
10A M1
1
10
P2 T
M2
C
M4 M5
Pa P2 P1
10B
4 2
P1
10C
3
M5
M4
10D
X Z
M5
M4 M5
M4
BR
6 5 4 T 7 F1 T S2 C 13 P3 S1 1 3 3A
B1 A1 A2 B2 B3 A3
9
P
CT1
CT2
11
TJ
8 2
T T LJ BL
3E
3F 3G
3H 3J
3K T
3B F2 P4 2
3C
3D
P2
12
12B
2
12A
1 3
12D
15
P2 P1
14
12C
T P1
14A
T
14B
361630
9804/1103
70 - 20 - 02/24
8510 - E/30-23.1
Issue 1
CONTENTS
Skidsteer Range
70 - 20 - 03/2
ROBOT 160,170, 170HF Circuit Diagrams - Hydraulic (Contd) Standard Servo Machine
Component Key C F1 P1 P2 P3 * M1 M1a * M2 M2a S1 T X1 X2 1 *2 * 2a * 2b * 2c * 2d * 2e *3 * 3a * 3b * 3c * 3d *4 * 4a * 4b * 4c * 4d * 4e * 4f * 4g 5 6 7 8 9 10 11 Cooler Filter Transmission Pump Run in Tandem Transmission Pump Loader Gear Pump Left Hand (upper) Drive Motor Left Hand Motor Shuttle Valve Right Hand (lower) Drive Motor Right Hand Motor Shuttle Valve Suction Strainer Tank Pressure Test Point Pressure Test Point Oil Cooler By-pass Valve (3 bar [see Note 2]) Drive Servo Control Valve Forward Right Left Reverse Shuttle Valves Loader Servo Control Valve Crowd (joystick in) Tip (joystick out) Lift (joystick back) Lower (joystick forward) Loader Valve Block Main Relief Valve (MRV) Lift Spool Tilt Spool Auxiliary Spool One Way Restrictor Anti-cavitation Valve Auxiliary Relief and Anti-cavitation Valve (see Note 3) Auxiliary Couplings Tilt Ram Levelling Valve (Optional) Float Valve (Optional) Lift Ram Manual Load Lower Valve Suction Manifold
From m/c no. 680001
Note 1: Neutral Circuit shown in bold line Note 2: Machines manufactured prior to July 2000 were fitted with a 2 bar by-pass valve. The 3 bar valve may be fitted to earlier machines. * Note 3: When machine is fitted with a breaker, item 4g is used instead of item 4f.
9804/1103
70 - 20 - 03/2
8520 - E/15-1.3
Issue 2*
CONTENTS
Skidsteer Range
70 - 20 - 03/3
ROBOT 160, 170, 170HF Circuit Diagram - Hydraulic High Flow Servo Machine
*
M2 Y SERVO CONNECTIONS
ENGINE M4 A M5 B RIGHT
From m/c no. 680001

T
M1 MOTOR
T REV B
LEFT HAND (UPPER)

B
P2
FRONT PUMP
P1 REAR PUMP
C REV B
2a FWD
P
2b 2c
LEFT
2d
C M5 M4 D REV
M2a
A FWD A D FWD A
M1a 2e
M5 M4 M5 M4 A C B D
C2
HIGH-FLOW COOLER
X1 F1 FILTER
9
LIFT RAM

D
6
A
T
TANK
TILT RAM
C
S1 P3
GEAR PUMP
10
MANUAL LOWER VALVE
B FEMALE
5
AUX. COUPLINGS
MALE
3 LOADER SERVO CONTROL VALVE 3a CROWD

(JOYSTICK IN)
1 PRIORITY VALVE
B1
A1
A2
B2
B3
A3
4
LOADER VALVE BLOCK
4e 4b
LOWER
3
LIFT (JOYSTICK BACK)
11
4d 4c
TIP T
3c
A1 P
A2 T
12
HIGH-FLOW FILTER
P4
HIGH-FLOW GEAR PUMP
HPCO
B1
B2
14 ATTACHMENT MOTOR
LOWER (JOYSTICK FORWARD)
3d
X2
4a
LIFT CROWD
3b TIP
2 1
2 3 4 1
4f
4g
(JOYSTICK OUT)
C1
COOLER
13
HIGH-FLOW VALVE
T
TANK
321252
INCREASED BY 130%
9804/1103
70 - 20 - 03/3
8520 - E/15-3.3
Issue 2*
CONTENTS
Skidsteer Range
70 - 20 - 03/4
ROBOT 160,170, 170HF Circuit Diagrams - Hydraulic (Contd) High Flow Servo Machines
Component Key C1 C2 F1 P1 P2 P3 P3 M1 M1a M2 M2a S1 T X1 X2 1 2 2a 2b 2c 2d 2e 3 3a 3b 3c 3d 4 4a 4b 4c 4d 4e 4f 4g 5 6 7 8 9 10 11 12 13 14 Cooler High-flow Cooler Filter Transmission Pump Run in Tandem Transmission Pump Loader Gear Pump High-flow Pump Left Hand (upper) Drive Motor Left Hand Motor Shuttle Valve Right Hand (lower) Drive Motor Right Hand Motor Shuttle Valve Suction Strainer Tank Pressure Test Point Pressure Test Point Charge Pressure Priority Valve Drive Servo Control Valve Forward Right Left Reverse Shuttle Valves Loader Servo Control Valve Crowd (joystick in) Tip (joystick out) Lift (joystick back) Lower (joystick forward) Loader Valve Block Main Relief Valve (MRV) Lift Spool Tilt Spool Auxiliary Spool One Way Restrictor Anti-cavitation Valve Auxiliary Relief and Anti-cavitation Valve (see Note 2) Auxiliary Couplings Tilt Ram Levelling Valve (Optional) Float Valve (Optional) Lift Ram Manual Load Lower Valve Suction Manifold High-flow Filter High-flow Control Valve Attachment Motor
From m/c no. 680001
* *
* * * * * * * * * * * * * * * * * **
* Note 1: Neutral Circuit shown in bold line. * Note 2: When machine is fitted with a breaker, item 4g is used instead of item 4f.
9804/1103
70 - 20 - 03/4
8520 - E/15-4.3
Issue 2*
CONTENTS
Skidsteer Range
70 - 20 - 03/5
ROBOT 160, 170, 170HF Circuit Diagrams - Hydraulic Standard Manual Machine
*
From m/c no. 680001
M2

T B REV B
11
M1 MOTOR
T
LEFT HAND (UPPER)
P2
FRONT PUMP
P1 REAR PUMP
REV
M2a C COOLER
A FWD A D FWD A
M1a
X1 F1
FILTER
6 FLOAT VALVE (OPTIONAL)

10
7
LIFT RAM
5
12

D
4
A
TILT RAM
C
3
AUX. COUPLINGS
FEMALE MALE
8
MANUAL LOWER VALVE
B1 A1 A2 B2
T S1
2
TANK LOADER VALVE BLOCK
B3
A3
2e 2b
LOWER TIP
2d 2c
T
P3
GEAR PUMP
X2
2a
LIFT CROWD
2f 2g
321243
9804/1103
70 - 20 - 03/5
8520 - E/16-2.4
Issue 3*
CONTENTS
Skidsteer Range
70 - 20 - 03/6
ROBOT 160,170, 170HF Circuit Diagrams - Hydraulic (Contd) Standard Manual Machine
Component Key - Standard Manual Machine C F1 P1 P2 P3 M1 M1a M2 M2a S1 T X1 X2 1 2 2a 2b 2c 2d 2e 2f 2g 3 4 5 6 7 8 9 * 10 * 11 * 12 Cooler Filter Transmission Pump Run in Tandem Transmission Pump Loader Gear Pump Left Hand (upper) Drive Motor Left Hand Motor Shuttle Valve Right Hand (lower) Drive Motor Right Hand Motor Shuttle Valve Suction Strainer Tank Pressure Test Point Pressure Test Point Oil Cooler By-pass Valve (3 bar [see Note 2]) Loader Valve Block Main Relief Valve (MRV) Lift Spool Tilt Spool Auxiliary Spool One Way Restrictor Anti-cavitation Valve Auxiliary Relief and Anti-cavitation Valve (see Note 3) Auxiliary Couplings Tilt Ram Levelling Valve (Optional) Float Valve (Optional) Lift Ram Manual Load Lower Valve Suction Manifold Charge Pressure Switch Hydraulic Oil Temperature Switch Float Pressure Switch (Optional)
From m/c no. 680001
Note 1: Neutral Circuit shown in bold line Note 2: Machines manufactured prior to July 2000 were fitted with a 2 bar by-pass valve. The 3 bar valve may be fitted to earlier machines. Note 3: When machine is fitted with a breaker, item 2g is used instead of item 2f.
9804/1103
70 - 20 - 03/6
8520 - E/16-1.4
Issue 4*
CONTENTS
Skidsteer Range
70 - 20 - 03/7
ROBOT 160, 170, 170HF Circuit Diagrams - Hydraulic High Flow Manual Machine
*
From m/c no. 680001
M2

T B REV B
14
M1 MOTOR
T
LEFT HAND (UPPER)
P2
FRONT PUMP
P1 REAR PUMP
REV
C2
HIGH-FLOW COOLER
M2a
A FWD A D FWD A
M1a
X1 F1
FILTER
13
6 FLOAT VALVE (OPTIONAL)
5 7 T S1 P3
GEAR PUMP TANK LIFT RAM

D
15
A
4
TILT RAM
1
PRIORITY VALVE
8
MANUAL LOWER VALVE
C B
3
AUX. COUPLINGS
FEMALE MALE
B1
A1
A2
B2
B3
A3
10
HIGH-FLOW FILTER
2 P4
HIGH-FLOW GEAR PUMP
12 ATTACHMENT MOTOR
LOADER VALVE BLOCK
2e 2b 2c
TIP
2d
LOWER
C1
COOLER
11
HIGH-FLOW VALVE
HPCO
X2 T
TANK
2a
LIFT CROWD
2f 2g
321263
9804/1103
70 - 20 - 03/7
8520 - E/16-3.4
Issue 3*
CONTENTS
Skidsteer Range
70 - 20 - 03/8
ROBOT 160,170, 170HF Circuit Diagram - Hydraulic (Contd) High Flow Manual Machine
Component Key C1 C2 F1 P1 P2 P3 P4 M1 M1a M2 M2a S1 T X1 X2 1 2 2a 2b 2c 2d 2e 2f 2g 3 4 5 6 7 8 9 10 11 12 * 13 * 14 * 15 Cooler High-flow Cooler Filter Transmission Pump Run in Tandem Transmission Pump Loader Gear Pump High-flow Pump Left Hand (upper) Drive Motor Left Hand Motor Shuttle Valve Right Hand (lower) Drive Motor Right Hand Motor Shuttle Valve Suction Strainer Tank Pressure Test Point Pressure Test Point Charge Pressure Priority Valve Loader Valve Block Main Relief Valve (MRV) Lift Spool Tilt Spool Auxiliary Spool One Way Restrictor Anti-cavitation Valve Auxiliary Relief and Anti-cavitation Valve (see Note 2). Auxiliary Couplings Tilt Ram Levelling Valve (Optional) Float Valve (Optional) Lift Ram Manual Load Lower Valve Suction Manifold High-flow Filter High-flow Control Valve Attachment Motor Charge Pressure Switch Hydraulic Oil Temperature Switch Float Pressure Switch (Optional)
From m/c no. 680001
Note 1: Neutral Circuit shown in bold line. Note 2: When machine is fitted with a breaker, item 2g is used instead of item 2f.
9804/1103
70 - 20 - 03/8
8520-E/16-4.4
Issue 4*
INDEX
Skidsteer Range
1CX (208S) Contents

Page No. General Information Lubricants and Capacities Static Dimensions & Specification Data Electrical From m/c no. 727000 From m/c no. 727000 to 751599 To m/c no. 752370 From m/c no. 752371 Hydraulics To m/c no. 752462 From m/c no. 752463 Engine (XUD) * Engine (100 and 400 Series) * Circuit Diagrams Electrical To m/c no. 751599 To m/c no. 752370 From m/c no. 752371 to 752675 From m/c no. 752676 Hydraulic Standard Machine - Single Lever Drive Control To m/c no. 751011 From m/c no. 751012 to 752462 From m/c no 752463 Standard Machine - Dual Lever Drive Control From m/c no. 751012 to 752462 From m/c no. 752463 High-flow Machine - Single Lever Drive Control To m/c no. 751001 From m/c no. 751012 to 752462 From m/c no. 752463 High-Flow Machone - Dual Lever Drive Control From m/c no. 751012 to 752462 From m/c no. 752463 Optional Hand Tool Circuit
75 - 00 - 01/1 75 - 00 - 02/2
75 - 05 - 01/1 75 - 05 - 01/2 75 - 05 - 01/3 75 - 05 - 01/4 75 - 05 - 02/1 75 - 05 - 02/3 75 - 05 - 03/1 75 - 05 - 03/2-3
75 - 15 - 01/1 75 - 15 - 01/3 75 - 15 - 01/5 75 - 15 - 01/7
75 - 20 - 01/1 75 - 20 - 01/3 75 - 20 - 01/5 75 - 20 - 01/7 75 - 20 - 01/9 75 - 20 - 01/11 75 - 20 - 01/13 75 - 20 - 01/15 75 - 20 - 01/17 75 - 20 - 01/19 75 - 20 - 01/21
9804/1103
Skidsteer Range Contents - 1
Issue 5*
CONTENTS
Skidsteer Range
75 - 00 - 01/1
1CX (208S) Fluids, Lubricants & Capacities - except North America

ITEM CAPACITY FLUID/LUBRICANT
From m/c no. 727000
SPECIFICATION
Engine Oil * XUD 5 litres * 100 Series up to m/c no. 807552 8.2 litres * 400 Series from m/c no. 807553 10.5 litres Hydraulic System 45 litres
JCB High Performance 15W/40 (See note)
JCB High Performance 10W/30 JCB High Performance 15W/40 (top up only)
Cooling System * XUD Total coolant cap. Antifreeze * 100 and 400 Series Total coolant cap Antifreeze
11 litres 5.5 litres 11 litres 5.5 litres
Water/Anti-freeze (see Coolant Mixtures) JCB Four Seasons Antifreeze and Summer Coolant/Water (see Coolant Mixtures) Diesel oil (see Types of Fuel) JCB Special HP Grease
Inhibited Ethanediol AL - 39 11
ASTM D3306, BS6580
45 litres -
ASTM D975-66T Nos. 1D, 2D Lithium complex NLGI, No. 2 consistency including extreme pressure additives Lithium based NLGI No. 2 consistency including extreme pressure additives
or JCB Special MPL-EP Grease
Chain Case Slew Oil up to m/c 807225 Slew Oil from m/c no. 807226
Fill to level plug Fill to level mark Fill to level plug
Engine Oil JCB HD90 Gear Oil JCB High Performance 10W/30 API GL 5 ACEA E2:B2:A2, API CF4/SG
Note: From machine number 807553, providing the above specified oil is used, the engine oil may be changed at 500 hour intervals. On earlier machines, or if a lower specification oil is used, the engine oil must be changed at 250 hours.
9804/1103
75 - 00 - 01/1
8550 - 3/1-1 . 6
Issue 6*
CONTENTS
Skidsteer Range
75 - 00 - 01/1A
1CX (208S) Fluids, Lubricants & Capacities - North America

ITEM CAPACITY FLUID/LUBRICANT
From m/c no. 727000
SPECIFICATION
Engine Oil * XUD 1.32 US gal * 100 Series up to m/c no. 807552 2.17 US gal * 400 Series from m/c no. 807553 2.8 US gal Hydraulic System 11.89 US gal
JCB 15W/40 (See note)
JCB 30W JCB 15W/40 (top up only)
Cooling System * XUD Total coolant cap. Antifreeze * 100 and 400 Series Total coolant cap Antifreeze Fuel System Grease Points
2.9 US gal 1.45 US gal 2.9 US gal 1.45 US gal 11.89 US gal -
Water/Anti-freeze (see Coolant Mixtures) Permanent Antifreeze
Inhibited Ethanediol AL - 39 11
ASTM D3306, BS6580
Diesel oil (see Types of Fuel) JCB Moly EP #2 Grease Grease
ASTM D975-66T Nos. 1D, 2D Lithium complex NLGI #2 consistency including extreme pressure additives
Chain Case Slew Oil up to m/c 807225 Slew Oil from m/c no. 807226
Fill to level plug Fill to level mark Fill to level plug
Engine Oil Gear Oil EP90 JCB 30W API GL 5 ACEA CD/CE
Note: From machine number 807553, providing the above specified oil is used, the engine oil may be changed at 500 hour intervals. On earlier machines, or if a lower specification oil is used, the engine oil must be changed at 250 hours.
9804/1103
75 - 00 - 01/1A
8550 - 3/1-2 . 3
Issue 3
CONTENTS CONTENTS
Skidsteer Range
75 - 00 - 01/2
1CX (208S) Static Dimensions & Specification
From m/c no. 727000
F G A H
E D C
203860
Dimensions A B C D E F G H J Overall length (including standard shovel) Height to cab roof Width over tyres Width over shovel Ground clearance under stabilisers Ground clearance at centre Wheel base Rear overhang Height to top of backhoe
3400 mm (11ft 2in) 2252 mm (7ft 4in) 1556 mm (5ft 1in) 1580 mm (5ft 2in) 258 mm (10in) 323mm (1ft 0in) 1070 mm (3ft 6in) 977 mm (3ft 2in) 2209 mm (7ft 3in)
Weight Total SAE (inc. standard shovel, bucket and driver) Tyres Pneumatic - size - pressure - manufacturer
2780 kg (6120 lb)
bar (lbf/in2)
10 x 16.5 7 x 15 3.1(45) 4.1 (60) Goodyear (tubeless) Dico/Armstrong (tubed) Airboss
Non-inflatable (on special rim)
9804/1103
75 - 00 - 01/2
Issue 1
CONTENTS
Skidsteer Range
From m/c no. 727000
1CX (208S) Data - Electrical

System Type Battery Cold crank amps for 1 minute to 1.4 VPC at -18 C (0 F) Reserve capacity (minutes) for 25 Amp load * Alternator XUD Engines 100 and 400 Series Engines 12 Volts, negative earth
420 to 585 170 to 230
12V, 50 Amp output 12V, 55 Amp output
Light Bulbs
Working Lights Indicator Lights Warning Lights Beacon (if fitted) Interior Light (if fitted) Side Lights (if fitted) 55W (Halogen) 21W 1.2W 70W 10W 5W
Relays up to machine no. 751599

Overheat Delay Relay Alarm Buzzer Indicator Flasher Relay Neutral Start Relay Loader Isolation Relay Horn Relay Glow Plug Relay A B C D E F G
C D
203821
202800
9804/1103
75 - 05 - 01/1
8550 - C/1-1 . 5
Issue 3*
CONTENTS
Skidsteer Range
*
1CX (208S) Data - Electrical (cont) Fuses

The electrical circuits are protected by fuses. The fuses are located behind the panel A as shown in the illustration.
From m/c no. 727000 to 751599
Fuse Number 1
Service
Fuse Size
Beacon Side lights and headlights Front worklights (see note) Interlock relay Pressure reducing solenoid valve Auxiliary hydraulics Rear worklights Warning lights and buzzer ESOS Horn Low coolant warning Stabiliser warning Hazard warning Rear wiper Interior light Front wiper Washer bottle Direction indicators Heater Heated seat Reverse alarm Brake light unit R. H. front & rear sidelights L. H. front & rear sidelights
10 amp 10 amp
2 3
5 amp
10 amp
203810
5 amp
15 amp
10 amp
10 amp
10 amp
10
10 amp 5 amp 5 amp

203802
11 12
Note: Fuse 2 also supplies, where fitted, Hydraulic Float, Brake Lights and High-flow Hydraulics. If any or all of these are fitted, the fuse rating is increased to 15 amps.
9804/1103
75 - 05 - 01/2
Issue 2*
CONTENTS
Skidsteer Range
75 - 05 - 01/3
1CX (208S) Data - Electrical Circuit Protection

Fuses The electrical circuits are protected by fuses. The fuses are located behind panel H. A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 Parkbrake Auxiliary Hydraulics High-flow Hydraulics Instrumentation Front / Rear Horn Hazard Indicators Direction Indicators Engine Shut-off Solenoid Front Wash/wipe, Rear Wiper Heater Motor Dip Beam L.H. Side Lights R.H. Side Lights Front Work Lights Rear Work Lights Reverse Alarm, Brake Lights Hand Held Attachments, Float Hydraulics Face Level Fan Junction Box Beacon, Interior Light
* To m/c no. 752370
S203811
2
5
3
5
4
10
5
10
6
10
7
10
8
15
9
10
10
10
10
Fuse Colour Code Orange 5 amp Red 10 amp Blue 15 amp
15
10
10
15
Relays
1 2 3 4 5 6 7 8 Work Light Park Brake Ignition Isolator Horn Neutral Start Indicator Flasher Alarm Buzzer
8
S262020
9804/1103
75 - 05 - 01/3
Issue 2*
CONTENTS
Skidsteer Range
75 - 05 - 01/4
1CX (208S) Data - Electrical Circuit Protection

Fuses The electrical circuits are protected by fuses. The fuses are located behind panel H. A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 Park Brake Auxiliary Hydraulics High-flow Hydraulics Instrumentation Engine Shut-off Solenoid Float Hydraulics Rear Wiper Front / Rear Horn Beacon, Interior Light Hazard Indicators Dip Beam L.H. Side Lights R.H. Side Lights Front Work Lights Rear Work Lights Junction Box Heater Motor Front Wash/wipe Reverse Alarm, Brake Lights Direction Indicators
From m/c no. 752371
S203811
Fuse Colour Code Orange 5 amp Red 10 amp Blue 15 amp
Relays
The relays are located behind panel H. 1 2 3 4 5 6 Neutral Start Isolator Ignition Park Brake Alarm Buzzer Indicator Flasher
SS262021
9804/1103
75 - 05 - 01/4
Issue 1
CONTENTS
Skidsteer Range
75 - 05 - 02/1
1CX (208S) Data - Hydraulic

Note: System Cleanliness is to be to ISO 16/13.
Auxiliary Pump - Standard Type Displacement Maximum Working Pressure Maximum Speed Maximum Input Torque Auxiliary Pump - High-Flow Type Displacement - Front Section Displacement - Rear Section Maximum Working Pressure Maximum Speed Maximum Input Torque Main Pump (2-off) up to machine no. 751011 Type Displacement Control Maximum Working Pressure Maximum Speed Maximum Input Torque Charge Pressure (oil temperature at 50 C) Main Pump (2-off) from machine no. 751012 Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50 C) * Servo Joysticks Type Output Characteristics - Transmission control spools Output Characteristics - Loader control spools
* To m/c no. 752462
Gear 48 l/min (10.5 UK gal/min, 12.7 US gal/min) at 3000 rev/min 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 3200 rpm 121 Nm (89 lbf ft, 12 kgf m)
Tandem gear 90 l/min (19.8 UK gal/min, 23.8 US gal/min) at 3600 rev/min 57 l/min (12.5 UK gal/min, 15 US gal/min) at 3600 rev/min 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 3600 rpm 121 Nm (89 lbf ft, 12 kgf m)
Sauer Sundstrand tandem axial piston Series 40 M35 35 cc/rev (2.13 in3/rev) Servo non-feedback proportional, 18 bar (261 lbf/in2) to give max pump displacement. 280 bar (4060 lbf/in2) 3600 rpm 121 Nm (89 lbf ft, 12 kgf m) 6 bar (87 lb/in2) at engine idle; 18 bar (261 lb/in2) at 3000 rev/min
Sauer Sundstrand tandem axial piston Series 42 M28 28 cc/rev (1.71 in3/rev) Servo non-feedback proportional, 15 bar (218 lbf/in2) to give max pump displacement. 350 bar (5076 lbf/in2) 3900 rpm 7.5 bar (109 lb/in2) at engine idle; 19.5 bar (283 lb/in2) at 3000 rev/min
Vickers 5 bar (72 lb/in2) at 15% stroke. 15 bar (217.5 lb/in2) at 95% stroke. 3.3 - 3.7 bar (48 - 53 lb/in2) at 15% stroke. 14.5 - 16.5 bar (210 - 239 lb/in2) at 95% stroke.
Hydraulic Motors up to machine no. 751011 Type Displacement Maximum Working Pressure Maximum Speed Maximum Flow Hydraulic Motors from machine no. 751012 Type Displacement Maximum Working Pressure Maximum Speed Maximum Flow Rexroth MCR03 328 cc/rev (20 in3/rev) 414 bar (6000 lbf/in2) continuous 237 rpm continuous 84 l/min (18.5 UK gal/min, 24 US gal/min) continuous Danfoss OMT 400 FX 410.9 cc/rev (25 in3/rev) 280 bar (4061 lbf/in2) continuous 306 rpm continuous 125 l/min (27.5 UK gal/min, 33 US gal/min) continuous
9804/1103
75 - 05 - 02/1
Issue 5*
CONTENTS
Skidsteer Range
75 - 05 - 02/3
1CX (208S) Data - Hydraulic (contd)

Note: System Cleanliness is to be to ISO 16/13. Auxiliary Pump - Standard Type Displacement Maximum Working Pressure Maximum Speed Maximum Input Torque Auxiliary Pump - High-Flow Type Displacement - Front Section Displacement - Rear Section Maximum Working Pressure Maximum Speed Maximum Input Torque Main Pump (2-off) Type Displacement Control Maximum Working Pressure Maximum Speed Charge Pressure (oil temperature at 50 C) up to machine number 807734 from mahcine number 807735
From m/c no. 752463
Gear 48 l/min (10.5 UK gal/min, 12.7 US gal/min) at 3000 rev/min 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 3200 rpm 121 Nm (89 lbf ft, 12 kgf m)
Tandem gear 90 l/min (19.8 UK gal/min, 23.8 US gal/min) at 3600 rev/min 57 l/min (12.5 UK gal/min, 15 US gal/min) at 3600 rev/min 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) 3600 rpm 121 Nm (89 lbf ft, 12 kgf m)
Sauer Sundstrand tandem axial piston Series 42 M28 28 cc/rev (1.71 in3/rev) Servo non-feedback proportional, 15 bar (218 lbf/in2) to give max pump displacement. 350 bar (5076 lbf/in2) 3900 rpm 7.5 bar (109 lb/in2) at engine idle; 19.5 bar (283 lb/in2) at 3000 rev/min 11.5 bar (167 lb/in2) at engine idle 23.5 - 24 bar (340 - 348 lb/in2) at 3000 rev/min
Note: When the charge pressure is set correctly it is not possible to move the lift arms when the engine is idling.
Servo Joysticks Type Output Characteristics - Transmission control spools Output Characteristics - Loader control spools Hydraulic Motors Type Displacement Maximum Working Pressure Maximum Speed Maximum Flow Rexroth MCR03 328 cc/rev (20 in3/rev) 414 bar (6000 lbf/in2) continuous 237 rpm continuous 84 l/min (18.5 UK gal/min, 24 US gal/min) continuous Vickers 5 bar (72 lb/in2) at 15% stroke. 15 bar (217.5 lb/in2) at 95% stroke. 3.3 - 3.7 bar (48 - 53 lb/in2) at 15% stroke. 14.5 - 16.5 bar (210 - 239 lb/in2) at 95% stroke.
9804/1103
75 - 05 - 02/3
8550 - E/1-3 . 3
Issue 3*
CONTENTS
Skidsteer Range
75 - 05 - 02/4

Relief Valve Operating Pressures Main Relief Valve (M.R.V.) at 1500 rev/min Auxiliary Relief Valves (A.R.V.) Loader Shovel Crowd Shovel Dump Lift Ram Raise Excavator Slew Rams Boom Raise Boom Lower Dipper In Dipper Out Bucket Crowd Bucket Dump Auxiliary Spool (optional) - both ports (see note) Optional Hand Tool Circuit bar 207 kgf/cm2 211
From m/c no. 752463
lbf/in2 3006
235 100-103 235 241 241 241 241 241 241 241 241 138
240 102-105 240 246 246 246 246 246 246 246 246 141
3410 1450-1494 3410 3500 3500 3500 3500 3500 3500 3500 3500 2001
Note: The return line auxiliary A.R.V. should be set to zero when a Rockbreaker is fitted (Refer to Technical Information 1/011). The A.R.V. must be returned to the correct setting when the Rockbreaker is removed. Solenoid Brake Valve Type Electrics Filter Type Suction Strainer Rams Lift Shovel Boom Dipper Bucket Stabiliser (60 x 30) (60 x 30) (70 x 40) (70 x 40) (70 x 40) (Long and Short Dipper) (60 x 30) High Pressure Spin On - 5 micron 125 micron Bore mm 60 60 70 70 70 60 Nm in 2.36 2.36 2.75 2.75 2.75 2.36 Rod Dia mm in 30 1.18 30 1.18 40 1.57 40 1.57 40 1.57 30 1.18 lbf ft Stroke mm 500 500 600 500 400 500 Kgf m in 19.69 19.69 23.62 19.69 15.75 19.69 3 position, 4 way Directional Control 12 Volt
Ram Torque Settings Piston Head Lift Rams Shovel Rams (Crowd) 6-in-1 Shovel Boom Ram Stabiliser Rams Dipper Ram Bucket Ram End Cap Lift Rams Shovel Rams 6-in-1 Shovel Boom Ram Stabiliser Rams Dipper Ram Bucket Ram
300 300 405 405 300 405 405 450 450 678 678 450 678 678
222 222 300 300 222 300 300 332 332 500 500 332 500 500
30.7 30.7 41.5 41.5 30.7 41.5 41.5 45.9 45.9 69.2 69.2 45.9 69.2 69.2
9804/1103
75 - 05 - 02/4
8550 - E/1-4 . 2
Issue 2*
CONTENTS
Skidsteer Range
75 - 05 - 02/2

* Relief Valve Operating Pressures bar kgf/cm2
* To m/c no. 752462
lbf/in2
Main Relief Valve (M.R.V.) at 1500 rev/min 207 211 3006 Auxiliary Relief Valves (A.R.V.) Loader Shovel Crowd 235 240 3410 Shovel Dump 100-103 102-105 1450-1494 Lift Ram Raise 235 240 3410 Excavator 241 246 3500 Slew Rams 241 246 3500 Boom Raise 241 246 3500 Boom Lower 241 246 3500 Dipper In 241 246 3500 Dipper Out 241 246 3500 Bucket Crowd 241 246 3500 Bucket Dump 241 246 3500 Auxiliary Spool (optional) - both ports (see note) 138 141 2001 Optional Hand Tool Circuit Note: The return line auxiliary A.R.V. should be set to zero when a Rockbreaker is fitted (Refer to Technical Information 1/011). The A.R.V. must be returned to the correct setting when the Rockbreaker is removed. * Pressure Reducing Solenoid Valve Maximum Inlet Pressure Regulated Pressure Minimum Rated Flow Maximum Leakage Oil Temperature Range Solenoid Valve (including Diodes) Reducing Valve Electrics * Filter Type Suction Strainer * Rams Lift Shovel Boom Dipper Bucket Stabiliser (60 x 30) (60 x 30) (70 x 40) (70 x 40) (70 x 40) (Long and Short Dipper) (60 x 30) High Pressure Spin On - 5 micron 125 micron Bore mm 60 60 70 70 70 60 Rod Dia mm in 30 1.18 30 1.18 40 1.57 40 1.57 40 1.57 30 1.18 Stroke mm 500 500 600 500 400 500 207 Bar (3006 lbf/in2, 211 kgf/cm2) 24 Bar (348 lbf/in2, 24.47 kgf/cm2) 10 l/min (2.2 UK gal/min, 2.64 US gal/min) 25 cc/min (1.52 in3/min) at 210 Bar (3045 lbf/in2) and 10 cSt - 40 C to +106 C 3 Position, 3 Port Cartridge Valve Cartridge Type 12 Volt
in 2.36 2.36 2.75 2.75 2.75 2.36
in 19.69 19.69 23.62 19.69 15.75 19.69
* Ram Torque Settings Piston Head Lift Rams Shovel Rams (Crowd) Boom Ram Stabiliser Rams Dipper Ram Bucket Ram End Cap Lift Rams Shovel Rams Boom Ram Stabiliser Rams Dipper Ram Bucket Ram
Nm
lbf ft
Kgf m
300 300 405 300 405 405 450 450 678 450 678 678
222 222 300 222 300 300 332 332 500 332 500 500
30.7 30.7 41.5 30.7 41.5 41.5 45.9 45.9 69.2 45.9 69.2 69.2
9804/1103
75 - 05 - 02/2
Issue 4*
CONTENTS
Skidsteer Range
75 - 05 - 03/1
1CX (208S)
* Technical Type Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure (Measured with warm engine turned by the starter) Injection Sequence Valve Clearance - Cold - Inlet Exhaust Maximum Air Cleaner Restriction Maximum Back Pressure (Exhaust) Speeds Maximum Loaded Maximum No Load - standard machines Maximum No Load - High-flow machines Idling Speed Oil Pressure at 110 C (230 F) at loaded speed Fuel System Injection Pump Type Governing Pump Setting Code Static Timing Injector Codes Injector Setting Pressure Cooling System Fan Type Coolant Pressure Temperature Warning Light operates at Mechanical 1 bar (14.5 lbf/in2, 1.02 kgf/cm2) 105 +/- 2 C (221 +/- 3.6 F) 2630 rev/min 3000 rev/min 3500 rev/min 880 - 920 rev/min 3.6 bar (52.2 lbf/in2, 3.7 kgf/cm2)
From m/c no. 727000
Data - XUD Engine

4 cylinder in-line, overhead camshaft, compression ignition, naturally aspirated. 83 mm (3.268 in) 88 mm (3.465 in) 1905 cm3 (116.24 in3) 23.5 : 1 25 - 30 bar (363 - 435 lbf/in2, 25.5 - 33 kgf/cm2) Maximum variation between cylinders 5 bar (72.5 lbf/in2, 5.1 kgf/cm2) 1,3,4,2 0.15 - 0.20 mm (0.0059 - 0.0078 in) 0.30 - 0.35 mm (0.0118 - 0.0138 in) 20 mbar (0.29 lbf/in2, 0.02 kgf/cm2) at 3600 rev/min 140 mbar (2.03 lbf/in2, 0.143 kgf/cm2) at 3600 rev/min
Lucas CAV DPC R84 43 Mechanical 063 16 +/- 1 BTDC RDN O5DC 6730 115 +/- 5 bar (1667.5 +/- 72.5 lbf/in2, 117
+/-
5.1 kgf/cm2)
Note: If at anytime during the life of a machine it is necessary to fit a new engine, then after the first 50 operating hours a new engine oil filter must be fitted and the engine oil changed. Failure to complete this could damage the engine. Note: Should further details be required for the refitting of the engine refer to Engine Service Manual 9803/8600.
9804/1103
75 - 05 - 03/1
8550 - K/1-1 . 4
Issue 4*
CONTENTS
Skidsteer Range
75 - 05 - 03/2
1CX (208S)
* Technical
Data - 100 Series Engine

4 cylinder in-line, compression ignition, naturally aspirated. 84 mm (3.31 in) 100 mm (3.94 in) 2216 cm3 (135.2 in3) 22 : 1 1,3,4,2 0.2 mm (0.0078 in) 2.6 - 3.5 bar (38 - 52 lbf/in2, 2.7 - 3.6 kgf/cm2)
* Type Bore (nominal) Stroke Swept Volume Compression Ratio Injection Sequence Valve Clearance - Cold - Inlet and Exhaust Oil Pressure Speeds Rated Speed Idling Speed Fuel System Governing Static Timing Injector Codes Injector Setting Pressure Cooling System Fan Type Coolant Pressure Thermostat operating temperature Temperature Warning Light operates at
2800 rev/min 850 - 950 rev/min
Mechanical 19-21 BTDC PN: 130506140 150-162 bar (2175-2350 lbf/in2, 153-165 kgf/cm2)
Mechanical 1 bar (14.5 lbf/in2, 1.02 kgf/cm2) 82 - 94 C (180 - 200 F) 97 - 103 C (207 - 217 F)
9804/1103
75 - 05 - 03/2
8550 - K/1-2 . 4
Issue 4*
CONTENTS
Skidsteer Range
75 - 05 - 03/3
1CX (208S)
* Technical
From m/c no. 807553
Data - 400 Series Engine

4 cylinder in-line, compression ignition, naturally aspirated. 84 mm (3.31 in) 100 mm (3.94 in) 2216 cm3 (135.2 in3) 22 : 1 1,3,4,2 0.2 mm (0.0078 in) 1 bar (15 lbf/in2) min
* Type Bore (nominal) Stroke Swept Volume Compression Ratio Injection Sequence Valve Clearance - Cold - Inlet and Exhaust Oil Pressure Speeds Rated Speed Idling Speed Fuel System Governing Static Timing Injector Codes Injector Setting Pressure Cooling System Fan Type Coolant Pressure Thermostat operating temperature Temperature Warning Light operates at
2800 rev/min 900 + 25 rev/min
Mechanical 19-21 BTDC 131 406 360 147 bar (2133 lbf/in2)
Mechanical 1 bar (14.5 lbf/in2) 82 C (180 F) 97 - 103 C (207 - 217 F)
Note: If at anytime during the life of a machine it is necessary to fit a new engine, then after the first 50 operating hours a new engine oil filter must be fitted and the engine oil changed. Failure to complete this could damage the engine. Note: Should further details be required, refer to Engine Service Manual TBA.
9804/1103
75 - 05 - 03/3
8550 - K/1-3 . 2
Issue 2*
CONTENTS
Skidsteer Range
*
1CX (208S) Circuit Diagrams - Electrical Main Components

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 Battery Glow Plugs Glow Plugs Glow Plugs Glow Plugs Pre-heat Timer Relay Starter Switch Starter Solenoid Starter Motor Neutral Start Relay Side Lights Switch Head Lights Switch Beacon Motor Beacon Switch Front Worklight Switch Interlock Relay Park Brake Switch Operational Solenoid Park Brake Solenoid Seat Switch Override Switch Auxiliary Attachments Control Switch Auxiliary Attachments Detent Switch Auxiliary Hydraulics - Forward Solenoid Auxiliary Hydraulics - Reverse Solenoid Rear Worklight Switch Alternator Hourmeter Warning Buzzer Engine Oil Pressure Switch Engine Coolant Temperature Switch Air Cleaner Warning Switch Charge Pump Pressure Switch Hydraulic Oil Temperature Switch L. H. Stabiliser Switch R. H. Stabiliser Switch Engine Shut Off Solenoid Brake Pressure Switch Horn Pushbutton Low Coolant E.C.U. Low Coolant Float Switch Horn Relay Front Horn Rear Horn Hazard Warning Switch Flasher Relay Indicator Switch & Warning Light Wash/Wipe Switch & Warning Light Rear Wiper Switch Front Wiper Motor Rear Wiper Motor Washer Bottle Interior Light Switch Heater Blower Switch Heater Blower Restrictor Heater Blower Heated Seat Reverse Alarm Reverse Alarm Switches Heated Seat Switch Brake Light Switches 62 63 64 65 66 67 68
From m/c no. 727000 to 751599
Brake Light Timer Hydraulic Float Switch Hydraulic Float Pressure Switch Hydraulic Float Relay Hydraulic Float Solenoid High-flow Hydraulic Solenoid High-flow Hydraulic Switch
Lamps
80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 Pre-heat Warning Number Plate Light R. H. Rear Side Light L. H. Front Side Light L. H. Rear Side Light L. H. Front Side Light R. H. Headlight Dip L. H. Headlight Dip Beacon Light Left Hand Front Worklight Right Hand Front Worklight Worklight Warning Park Brake Warning Auxiliary Hydraulic Warning Left Hand Rear Worklight Right Hand Rear Worklight Rear Worklight Warning Alternator Warning Engine Oil Pressure Warning Engine Coolant Temperature Warning Air Cleaner Warning Charge Pump Pressure Warning Hydraulic Oil temperature Warning Stabiliser Warning L. H. Rear Direction Indicator L. H. Front Direction Indicator R. H. Rear Direction Indicator R. H. Front Direction Indicator Interior Light L. H. Rear Brake Light R. H. Rear Brake Light High-flow Hydraulic Warning
Fuses
210 Beacon, Sidelights, Headlights 211 Front Worklights, Brake Lights, Hydraulic Float, Highflow Hydraulics 212 Interlock Relay, Pressure Reducing Solenoid Valve 213 Auxiliary Hydraulics, Rear Worklights 214 Engine Shut Off Solenoid, Warning Lights and Buzzer 215 Horn, Low Coolant E.C.U., Stabiliser Warning 216 Hazard Warning, Rear Wiper, Interior Light 217 Front Wiper/Washer, Direction Indicators 218 Heater, Heated seat 219 Reverse Alarm, Rear Brake Lights 220 R. H. Front/Rear Sidelights 221 L. H. Front/Rear Sidelights Note: See page 75-05-01/1 for bulb ratings and page 75-0501/2 for fuse ratings.
9804/1103
75 - 15 - 01/1
Issue 2*
CONTENTS CONTENTS
Skidsteer Range
75 - 15 - 01/2
1CX (208S) Circuit Diagram - Electrical
From m/c no. 727000
660
601
649
655
655
654
654
604
660
604
661 997 206
610
653
654
654
655
654
655
648
647
645
602
632
613
612
607
635
608
655
609
605
600
614
651
649
603
605
616
644
643
627
603
611
663
606
5
604
4 3 2 80
37 81 9 82 83 84 85 86 87 88 89 90 91 20 92 19
831
44 43
637
104
106 107
855 860
110 109
66
67
93 95
96 28
403
105
854 855 861
108 57 50 51 52
M M M
58
873
208
30
31
32
33
34 35 36
56
M
650
804
648
18
21 24
828
25 94
840 841
850
221
642
865
868
867
891
890
843
842
869
827
416
402
409
830
829
23
425
639
834
835
601
415
408
411
419
420
407
866
838
839
208
410
217
851
252
49
849
854
13 220
863 864
55
810
856
42
805 218
809
27
406
49 47 46
213
53 59 62 61
216 204
65
17
605
17
22
842
23
400 832 837 836 803
401
426
23
871
859
32
219
220
207
39 601 216
206
201
202
35
31
10
10 214
405 813 427 11
24
200
20
43 6
210
203
210
42
211
218
212
25
213
214
45
215
216
217
218
219
204 2 200 4 9
26
26
14
14
27
36
201
209
50
13
211
63
A204781
9804/1103
75 - 15 - 01/2
Issue 1
41
11
12
33
16
40
215
30
16 22
26
853
14
15
29
45
48
54
112
68
995
28
38
29
412
413
414
39
212
811
46
221
404
208
424
41
60 59 61
205
97
98
99
100
101 102
103
64
996
662
111
BATTERY
1CX
1 4
THERMOSTART
9804/1103
GLOW PLUGS
5 3 2 6
NEUTRAL START RELAY STARTER SOLENOID
N/START RELAY
CONTENTS
STARTER MOTOR
7 SWITCH
OPERATIONAL SOLENOID PARKBRAKE SOLENOID
BRAKE 8 P. RELAY
P. BRAKE
9 10
FUSE A1
11OVERRIDE SWITCH
FUSE A2
SEAT
14
AUX. SWITCH
ISOLATOR RELAY AUX. HYD. FWD (FRONT)
13 16
JOYSTICK
12 ISOLATION RELAY
15
AUX. HYD. REV (FRONT)
Skidsteer Range
75 - 15 - 01/3
17 18
HI FLOW SWITCH SEAT SWITCH
20 21 19 LATCHING RELAY
HOURMETER HI-FLOW HYDRAULICS
FUSE A3
22
BUZZER
23 24
ALTERNATOR
FUSE A4
100
ALTERNATOR
WATER TEMP. HYD. OIL TEMP. ENGINE OIL PRESS. AIR FILTER CHARGE PUMP PRESS.
ENGINE WATER TEMP. HYD. OIL TEMP. ENGINE OIL PRESSURE AIR FILTER
FUSE A8
101 102 103 104 105
25 26 27 28 29 30 33 31 32
CHARGE PUMP PRESSURE E.S.O.S. REAR HORN FRONT HORN
FUSE A5
34
FUSE B10
BEACON SWITCH
INTERIOR LIGHT
35 36 106 107
FUSE B1
ROAD LIGHT SWITCH
INTERIOR LIGHT BEACON
37
IGN. RELAY
108 39 109
FUSE B2
110 111
FUSE B3
WORKING LIGHT RELAY
112 113 38
FRONT WORKLIGHT
L.H. DIP BEAM R.H. DIP BEAM NO. PLATE LIGHT L.H. TAIL LIGHT L.H. SIDE LIGHT R.H. TAIL LIGHT R.H. SIDE LIGHT
FUSE B4
114 40 115
FUSE B5
L.H. FRONT WORK LIGHT R.H. FRONT WORK LIGHT
116 41 117
REAR WORKLIGHT
L.H. REAR WORK LIGHT R.H. REAR WORK LIGHT
118
INDICATOR SWITCH
42
HAZARD SWITCH
119 44 120
FUSE A7
L.H. FRONT INDICATR L.H. REAR INDICATOR
121
FUSE A6
R.H. FRONT INDICATR R.H. REAR INDICATOR FLASHER UNIT
43 FLASHER UNIT
WASH/WIPE SWITCH
46 48
FUSE A9
HEATER MOTOR
47
WASHER MOTOR FRONT WIPER MOTOR
49 50
FUSE A10
REAR WIPER MOTOR
51
FAST SLOW
53 52
FUSE B6
HEATER MOTOR
55
55 54
REVERSE ALARM BRAKE LIGHT TIMER UNIT

10 SECOND TIMER
122 56 45
FUSE B7
56
57 123 58
H/H ATTACHMENT SOLENOID FLOAT SWITCH PRESS. SWITCH
L.H. BRAKE LIGHT R.H. BRAKE LIGHT HAND HELD ATTACHMENT SOLENOID
59 61 60
LATCHING RELAY
62
FLOAT SOLENOID
FUSE B8
63 65
FUSE B9
852/95001/1
FACE LEVEL FAN
* To m/c no. 752370
Issue 2*
66
64
JUNCTION BOX
CONTENTS
Skidsteer Range
75 - 15 - 01/4

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Battery Starter Switch Neutral Start Relay Glow Plugs Starter Motor Starter Solenoid Park Brake Switch Park Brake Relay Operational Solenoid Park Brake Solenoid Override Switch Isolator Relay Auxiliary Attachments Switch Seat Switch Joystick Switch Auxiliary Hydraulics - Forward Solenoid Auxiliary Hydraulics - Reverse Solenoid High-flow Hydraulic Switch Latching Relay Seat Switch High-flow Hydraulic solenoid Hourmeter Alternator Warning Buzzer Engine Coolant Temperature Switch Hydraulic Oil temperature switch Engine Oil Pressure Switch Air Cleaner Warning Switch Charge Pump Pressure Switch Engine Shut Off Solenoid Rear Horn (when fitted) Front Horn Horn Relay Horn Pushbutton Interior Light and Switch Beacon switch Ignition Relay Working Light Relay road Lights Switch Front Worklight Switch Rear Worklight Switch Hazard Warning Switch Flasher Unit Indicator Switch & Warning Light Wash/Wipe Switch & Warning Light Washer Motor Front Wiper Motor Rear Wiper Motor Rear Wiper Switch Heater Blower Switch Heater Blower Restrictor Heater Blower Reverse Alarm Reverse Alarm Switches Brake Light Switches Brake Light Timer Hand Held Attachment Switch & Warning Light Hand Held Attachment Solenoid Hydraulic Float Switch 61 62 63 64 65 66
* To m/c no. 752370
Hydraulic Float Pressure Switch Latching Relay Hydraulic Float Solenoid Face Level Fan Face Level Fan Switch Junction Box
Lamps
100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 Alternator Warning Engine Coolant Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Cleaner Warning Charge Pump Pressure Warning Beacon Light L. H. Headlight Dip R. H. Headlight Dip Number Plate Light L. H. Rear Side Light L. H. Front Side Light R. H. Rear Side Light R. H. Front Side Light Left Hand Front Worklight Right Hand Front Worklight Left Hand Rear Worklight Right Hand Rear Worklight L. H. Front Direction Indicator L. H. Rear Direction Indicator R. H. Front Direction Indicator R. H. Rear Direction Indicator L. H. Rear Brake Light R. H. Rear Brake Light
Fuses
Note: For fuse applications and ratings, see page 70-0501/2; for bulb ratings, see page 70-05-01/1.
9804/1103
75 - 15 - 01/4
Issue 2*
CONTENTS
Skidsteer Range
75 - 15 - 01/5

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Battery Glow Plugs Starter Motor Starter Solenoid Neutral Start Relay Starter Switch Park Brake Relay Park Brake Switch Operational Solenoid Park Brake Solenoid TUV Seat Switch (German machines only) Override Switch Seat Switch Isolator Relay Auxiliary Attachments Switch Joystick Switch Auxiliary Hydraulics - Forward Solenoid (Front) Auxiliary Hydraulics - Reverse Solenoid (Front) High-flow Hydraulic Solenoid Latching Relay Seat Switch High-flow Hydraulic Switch Diode Ignition Relay Hourmeter Engine Speed Indicator Unit Warning Buzzer Alternator Engine Coolant Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Cleaner Warning Switch Charge Pump Pressure Switch Engine Shut Off Solenoid Hydraulic Float Pressure Switch Hydraulic Float Switch Latching Relay Hydraulic Float Solenoid Rear Wiper Motor Road Lights Switch Front Worklight Switch Rear Worklight Switch Indicator Switch & Warning Light Hazard Warning Switch Flasher Unit Horn Switch Front Horn Rear Horn (when fitted) Beacon Switch Junction Box Heater Blower Switch Heater Blower Resistor Heater Blower Washer Motor Wiper Motor Wash/Wipe Switch & Warning Light Reverse Alarm Switches Reverse Alarm Brake Light Timer Brake Light Switches
*From m/c no. 752371 to 752675
Lamps
80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 Alternator Warning Engine Coolant Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Cleaner Warning Charge Pump Pressure Warning L. H. Headlight Dip R. H. Headlight Dip Number Plate Light L. H. Tail Light L. H. Side Light R. H. Tail Light R. H. Side Light Left Hand Front Worklight Right Hand Front Worklight Left Hand Rear Worklight Right Hand Rear Worklight L. H. Front Direction Indicator L. H. Rear Direction Indicator R. H. Front Direction Indicator R. H. Rear Direction Indicator Interior Light and Switch Beacon Light L. H. Rear Brake Light R. H. Rear Brake Light
Fuses
Note: For fuse applications and ratings, see page 75-05-01/4 for bulb ratings, see page 75-05-01/1
9804/1103
75 - 15 - 01/5
Issue 2*
1CX
9804/1103
003E
BATTERY
THERMOSTART
2
GLOW PLUGS STARTER MOTOR
CONTENTS
19 17 50a 004 5 3 842 200B 200C 30
N/START RELAY
STARTER SOLENOID
6
810 600V 4 2 1 15/54
NEUTRAL START RELAY OPERATION SOLENOID PARK BRAKE SOLENOID P/BRAKE SWITCH ILLUM.
9
600GV 600CP
P/BRAKE RELAY
P/BRAKE SWITCH
7 1 938A 938B 5
FUSE A1
122 122A 1 815 5
10
122B 4 2 600GN
9 815A
10
7
866A
TUV SEAT SWITCH (GERMAN BUILD ONLY)
11
810 125E 5 1 3 600HB F 865B 600HC
ISOLATION RELAY
OVERRIDE SWITCH SEAT POSITION SWITCH
FUSE A2
125 125D 4 865 865A 2 886
12 13
14
15
7 125B 5 3 1 B 873A 972 887 8 A 971
600HX
AUX. HYD. FWD. (FRONT)
17
001
JOYSTICK
C 600HY
16
6 2 10 9
AUX. HYD. REV. (FRONT)
18
600JU
23
810A 810C 810B 877A
Skidsteer Range
75 - 15 - 01/6
20
HIGH-FLOW SWITCH
4 877C 2 7 3 002 001A 4 2 106T 1 1 877D 9 10 874 877B
AUX. SWITCH ILLUM.
SEAT SWITCH
881 4
600DD
600CU
22
21
FUSE A3 IGN. RELAY

205A 5 3 129 5
1 5
877
877E
600DH
HIGH-FLOW HYDRAULICS
19
LATCHING RELAY
600DE 600W 2 600HR
IGNITION RELAY ENGINE SPEED INDICATOR UNIT

ENGINE SPEED INDICATOR UNIT 3 412 600HS
23
24
106D
26
2 1 407 'W'
HOURMETER
25
28
HOURMETER
106C
407B 407A 411
200 200A
ALTERNATOR
27
23
80
FUSE A4
106
106AA
BUZZER ALTERNATOR 434A

106AB
434
434B
415A 403C 414A
29
WATER TEMP.
106AC
406
ENGINE WATER TEMP. SWITCH

HYD. OIL TEMP.
106AD 106AE 414B 414 600JT
30 31 32 33
83 84 85
106AF
81 82

ENGINE OIL PRESS. AIR FILTER CHARGE PUMP PRESS. FUSE A5
403B 402 415B 415 403 X 600CF 600CS
ENGINE OIL PRESS. SWITCH AIR FILTER SWITCH CHARGE PUMP PRESS. SWITCH
34
105
E.S.O.S.
FUSE A6 FLOAT SWITCH
101AR 1 7 2 6 8 9 10 3
FLOAT SWITCH ILLUM.
35
LATCHING RELAY
2 4 5 1 3
PRESSURE SWITCH
36 37
FLOAT SOLENOID
38
FUSE A7
114
600BD
REAR WIPER MOTOR
39
FUSE B1
834
86
834B
LH DIP BEAM
87
834A
40
3 6 205D 2 828 828M 106K 9 10 833 855C
RH DIP BEAM
88
829C
NO. PLATE LIGHT

FUSE B2
89
829
829D 829E
LH TAIL LIGHT
90
LH SIDE LIGHT
FUSE B3
91
830
830B 830D
RH TAIL LIGHT
92
600DW
RH SIDE LIGHT ROADLIGHT SWITCH

FUSE B4
116 106L 5 9 1 10 855 855B 855A 600AS
93 94
LH FRONT WORKLIGHT
600AR
RH FRONT WORKLIGHT
41
600CJ
FRONT WORKLIGHT SWITCH

FUSE B5
95
117 106M
5 9
1 10
861
861B 861A
600AY
LH REAR WORKLIGHT
96
600AV
RH REAR WORKLIGHT
42 97
805E 803 803A 106F 7 10
600CK 600DX
REAR WORKLIGHT SWITCH
IND. SWITCH
5
1 805B 7
805C
600G
HAZARD SWITCH ILLUM. LH FRONT INDICATOR LH REAR INDICATOR
98
806B
43
44
1 3 805 806P
9 803B
10 805G 806H 806E 808C
99
600H
FUSE B10
104 300
5 8 2
100
802
49a 49 31
600BL
FLASHER UNIT
45
FUSE A10 FUSE A8

312
47
HAZARD SWITCH
FLASHER UNIT
HORN SWITCH
303A 205B
46
871B 871 871A
600EY 600EL
FRONT HORN REAR HORN
48
INTERIOR LIGHT FUSE A9
600AJ 303 303G 106N 5 9 1 10 894
INTERIOR LIGHT
101 102
600AP
BEACON
600DY
49
50
FUSE B8
101
BEACON SWITCH
1 800B
800CC FAST
JUNCTION BOX
FUSE B7
102 3 106R 8
53
5 10
800
SLOW
52
800D
600BH
800GR
HEATER MOTOR
HEATER RESISTOR
600EB
51
54
HEATER SWITCH FUSE B8

103
WASH/WIPE SWITCH
4 2 5 7 840 839
600BG 800AK
WASHER MOTOR WIPER MOTOR
55
106H
10
600ED
W/WIPE SWITCH ILLUM.
56
58
FUSE B9
REVERSE SWITCHES
127A 807A
807B
600CD
REVERSE ALARM
57
57
127C 127B
600AW

BRAKE SWITCHES
816L 869A
10 SEC. TIMER
103
816D 816 816E
LH BRAKE LIGHT
104
60
60
59
75 - 15 - 01/6
From m/c no. 752371 to 752675
Issue 2*
RH BRAKE LIGHT
CONTENTS
Skidsteer Range
75 - 15 - 01/7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 Battery Glow Plugs Starter Motor Starter Solenoid Neutral Start Relay Starter Switch Park Brake Relay Park Brake Switch Operational Solenoid Park Brake Solenoid TUV Seat Switch (German machines only) Override Switch Seat Switch Isolator Relay Auxiliary Attachments Switch Joystick Switch Auxiliary Hydraulics - Forward Solenoid (Front) Auxiliary Hydraulics - Reverse Solenoid (Front) High-flow Hydraulic Solenoid Latching Relay Seat Switch High-flow Hydraulic Switch Diode Ignition Relay Hourmeter Engine Speed Indicator Unit Warning Buzzer Alternator Engine Coolant Temperature Switch Hydraulic Oil Temperature Switch Engine Oil Pressure Switch Air Cleaner Warning Switch Charge Pump Pressure Switch Engine Shut Off Solenoid Hydraulic Float Pressure Switch Hydraulic Float Switch Latching Relay Hydraulic Float Solenoid Rear Wiper Motor Road Lights Switch Front Worklight Switch Rear Worklight Switch Indicator Switch & Warning Light Flasher Unit Hazard Warning Switch Horn Switch Front Horn Rear Horn (when fitted) Beacon Switch Junction Box Heater Blower Switch Heater Blower Resistor Heater Blower Wiper Motor Washer Motor Wash/Wipe Switch & Warning Light Reverse Alarm Switches Reverse Alarm Brake Light Timer Brake Light Switches Brake Light Timer Relay
From m/c no. 752676
Lamps
80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 Alternator Warning Engine Coolant Temperature Warning Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Air Cleaner Warning Charge Pump Pressure Warning L. H. Headlight Dip R. H. Headlight Dip Number Plate Light L. H. Tail Light L. H. Side Light R. H. Tail Light R. H. Side Light Left Hand Front Worklight Right Hand Front Worklight Left Hand Rear Worklight Right Hand Rear Worklight L. H. Front Direction Indicator L. H. Rear Direction Indicator R. H. Front Direction Indicator R. H. Rear Direction Indicator Interior Light and Switch Beacon Light L. H. Rear Brake Light R. H. Rear Brake Light
Fuses
Note: For fuse applications and ratings, see page 75-05-01/4 for bulb ratings, see page 75-05-01/1.
9804/1103
75 - 15 - 01/7
8550-C/6-8.1
Issue 2
1
THERMOSTART
414A
403C
415A
406A
9804/1103
003E BATTERY
GLOW PLUGS
3
STARTER MOTOR
CONTENTS
1CX (208S)
19 17 N/START RELAY
200B 200C 50a 004 5 3 1 842 810
30
6 4
4 2 600V 15/54
STARTER SOLENOID
106AK
600GN P/BRAKE SWITCH P/BRAKE RELAY
NEUTRAL START RELAY P/BRAKE SWITCH ILLUM OPERATION SOLENOID PARKBRAKE SOLENOID
+8
FUSE A1 122 122A 3 815

2 3
5 1 936A 600CP
-7 1
936B 600GV
122B
4 2
10
7
2
866A
TUV SEAT SWITCH (GERMAN BUILD ONLY)
11
810 ISOL RELAY O/R 865B 600HC
14
12
125E 5 3 1 600HB SEAT FUSE A2 125 125D
OVERRIDE SWITCH SEAT POSITION SWITCH AUX SWITCH ILLUM AUX HYD FWD (FRONT)
13
4 865 865A 600JU F
2 866
15
AUXILIARY SWITCH
106AR
10 1
001 971
-7 1
600HX
125B
2
17
3 4
A 873A B JOYSTICK C
16
125C
5 6 +8 2
972 867
600HY
AUX HYD REV (FRONT)
18
810A 810C 810B 877A
Skidsteer Range
75 - 15 - 01/8
23
HI FLOW SWITCH
20
877D
877B 881
2
+8 -7 1
SEAT SWITCH 4 5 2 1
FUSE A3 129
600DD 877 877E
600CU 600DH
HI FLOW HYDRAULICS
874
21
22
19
IGN RELAY
5
200D 002
2
5 1
877C
3 LATCHING RELAY
600DE
001A 4 2
600W
IGNITION RELAY
2 600HR 3
24
106T 1 106D
ENGINE SPEED INDICATOR UNIT
26
23
1 4
ENGINE SPEED INDICATOR UNIT 2 4 0 3
412 600HS
HOURMETER
407 W
25
28
HOURMETER
407B
200 200A 106C BUZZER
X 407A 411
ALTERNATOR
27
434 106AA ALTERNATOR 434A
23
23
80
FUSE A4
434B
29
81 82
106AB 106AC 106AD 106AE
WATER TEMP
406 HYD OIL TEMP ENGINE OIL PRESS AIR FILTER 414B 403B 414 403 402 415B 106AF CHARGE PUMP PRESS 415
ENGINE WATER TEMP SWITCH

600JT
HYD. OIL TEMP SWITCH

X 600CF 600CS
ENGINE OIL PRESS SWITCH AIR FILTER SWITCH CHARGE PUMP PRESS SWITCH
30 31 32 33
83 84 85
34
FUSE A5
105
E.S.O.S. FLOAT SWITCH ILLUM

FUSE A6 FLOAT SWITCH 101AR 1 7 2 8 10 9 4 5 3 2 1 6 LATCHING RELAY 3
36 35
PRESSURE SWITCH
37
23
38
FLOAT SOLENOID
39
FUSE A7
114
600BD
REAR WIPER MOTOR

600DW 834B 106K
8+
ROADLIGHT SWITCH
86
-7
LH DIP BEAM
FUSE B1 834 834A
87
200N
5 6
RH DIP BEAM
833 200F
2 +3 2
88
829C
No PLATE LIGHT
89
828
FUSE B2
829
829D
LH TAIL LIGHT
40
ROADLIGHT SWITCH
90
828M
829E
LH SIDE LIGHT
23
855C
FUSE B3
91
830
830B 830D 106L FUSE B4 116

+8 2 -7 1
RH TAIL LIGHT
92
600CJ
RH SIDE LIGHT FRONT WORKLIGHT SWITCH
93
855
855B
600AS 855A 600AR
LH FRONT WORKLIGHT
FRONT WORKLIGHT SWITCH
RH FRONT WORKLIGHT
94
41
2
106M FUSE B5 117
+8 2
-7
600CK
95
861B
3
861
600AY
LH REAR WORKLIGHT
861A 600AV
RH REAR WORKLIGHT
96
42
2
600DX
49 31 49a 600BL
HAZARD SWITCH ILLUM
44
FLASHER UNIT
FUSE B10 104 300 FUSE A10
5 17 18 1 3 2 -10 2
600LA
805E
97
802
803B
IND SWITCH
106AP
8 1 -7 +1
FLASHER UNIT INDICATOR SWITCH LH FRONT INDICATOR

805C 803A
2
600G
LH REAR INDICATOR
98
805 803 806P

+8
+3
805B 806B
43
2
99
45
106F
806E
HAZARD SWITCH
106AP
100
806C
600H

871B FUSE A8 600EY
47
312
871
FRONT HORN
46
HORN SWITCH FUSE A9 205B
871A
600EL
REAR HORN
48
101
INTERIOR LIGHT 303 303A
600AJ
INTERIOR LIGHT
106N
303G
+8 2 3 1 -7
600DY
BEACON SWITCH ILLUM

894 M 600AP
BEACON
BEACON SWITCH
50
102
49
2
FUSE B6
101
600CC
JUNCTION BOX
51
106R FUSE B7 102
+10 2
-7 1 3
600BH
102A HEATER SWITCH

5 4
52
800 102A
2 6
HEATER RESISTOR
800D M 600EB 600GR
SLOW
HEATER MOTOR
53
800B FAST
1 -7 1
600ED FUSE B8 103

840A
W/WIPE SWITCH ILLUM

2 3
From m/c no. 752676
8550-C/6-7.1
347380
840
600AK
WIPER MOTOR
56
WASH/WIPE SWITCH 5
106H
+8 2
54
839
600BG
WASHER MOTOR
55
57
57
FUSE B9
127A
807B
600CD
REVERSE ALARM
58
127C
600AW
60
60
127B
59
10 SEC TIMER 816L 869A BRAKE SWITCHES
103
816D 816 816E
75 - 15 - 01/8
Issue 1
LH BRAKE LIGHT
104
RH BRAKE LIGHT
CONTENTS
Skidsteer Range
*
75 - 20 - 01/1
1CX (208S)
Standard Machine up to m/c no. 751011 - Single Lever Drive Control
* Component C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 8A 8B 8C 8D 9 11 12 30 32 33 34 35
Key
36 37 38 50 51 Boom Ram Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor
Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Loader Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (5 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Pressure Reducing Solenoid Valve Filter By-pass Valve (3 bar) Auxiliary Feeds Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram
Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.
9804/1103
75 - 20 - 01/1
Issue 3*
CONTENTS
1CX (208S) Schematic Diagram
Skidsteer Range
75 - 20 - 01/2
* Standard Machine up to m/c. no. 751011 - Single Lever Drive Control
32 5 2 2F 2E 2G 2J 2D T 4K 4B 2A 2B 2C 50 4M 4C 34 F1 1 11 3 4D 35 4L 12 2H 6 4A 7 4 36 4J 51 37 38
2X
4N 2Y 9 P3 4F 8 2Z 8A 8B 8C 8D 4G 4R 4S 33 4P 4Q 4E
P1 M1
P2 4T M2 C 4H 30
S1
A204773A A204773A
9804/1103
70 - 20 - 01/2
Issue 3*
CONTENTS
52 5 2 2F 2E 2G 2J 2D T 12 2H 6 4A 7
Skidsteer Range
75 - 20 - 01/3
* Standard Machine from m/c. no. 751012 to 752462 - Single Lever Drive Control
32 37 4 36 4J 51 38
4K 4B 2A 2B 2C 50 4M 4C 34 4L
2X
F1 1 11 3 4D 35
4N 2Y 9 P3 4F 8 2Z 8A 8B 8C 8D 10 4G 4R 4S 33 4P 4Q 4E
P1 M1
P2 4T M2 4H C 30
S1
A243002A A243002A
9804/1103
75 - 20 - 01/3
Issue 3*
CONTENTS
Skidsteer Range
*
75 - 20 - 01/4
1CX (208S)
Standard Machine from m/c no. 751012 to 752462 - Single Lever Drive Control
* Component C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 8A 8B 8C 8D 9 10 11 12 30
Key
32 33 34 35 36 37 38 50 51 52 Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor One-way Restrictor
Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Loader Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Pressure Reducing Solenoid Valve Check Valve (2 bar) Filter By-pass Valve (3 bar) Auxiliary Feeds Hydraclamp
9804/1103
75 - 20 - 01/4
Issue 3*
CONTENTS
Skidsteer Range
*
75 - 20 - 01/5
1CX (208S)
Standard Machine from m/c no. 752463 - Single Lever Drive Control
* Component C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 8A 8B 8C 8D 9 10 11 12 30
Key
32 33 34 35 36 37 38 50 51 52 *X Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor One-way Restrictor Return line fitted from machine no. 807226
Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Loader Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Brake Valve Check Valve (2 bar) Filter By-pass Valve (3 bar) Auxiliary Feeds Hydraclamp
9804/1103
75 - 20 - 01/5
8550 - E/30-6 . 3
Issue 3*
CONTENTS
52 5 2 2F 2E 2G 2J 2D T 12 2H 6 4A 7
Skidsteer Range
75 - 20 - 01/6
* Standard Machine from m/c. no. 752463 - Single Lever Drive Control
32 37 4 36 4J 51 38
4K 4B 2A 2B 2C 50 4M 4C 34 4L
2X
F1 1 11 3 4D 35
4N 2Y 4E
P3 4F 8
4P 4Q
2Z
8A
8B
8C
8D
10 4G
4R 4S
33
P1 M1
P2 4T M2 4H C 30
S1
316740
9804/1103
75 - 20 - 01/6
Issue 3*
CONTENTS
52 5 2 2F 2E 2G 2J 2D T 12 2H 6 4A 7
Skidsteer Range
75 - 20 - 01/7
* Standard Machine from m/c. no. 751012 to 752462 - Dual Lever Drive Control
32 37 4 36 4J 51 38
4K 4B 2A 2B 2C 50 4M 4C 34 4L
2X
F1 3 1 11 8 4D 35
2Y
4N 4E
9 P3 4F
4P 4Q
4R 2Z 4S 4G
33
10 P1 M1 P2 M2 C 4H 30 4T
S1
A243003A
9804/1103
75 - 20 - 01/7
Issue 3*
CONTENTS
Skidsteer Range
75 - 20 - 01/8
1CX (208S)
* Standard Machine from m/c no. 751012 to 752462 - Dual Lever Drive Control Key
37 38 50 51 52 Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor One-way Restrictor
* Component C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 9 10 11 12 30 32 33 34 35 36
Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Left Hand Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Right Hand Joystick Pressure Reducing Solenoid Valve Check Valve (2 bar) Filter By-pass Valve (3 bar) Auxiliary Feeds Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram
9804/1103
75 - 20 - 01/8
Issue 3*
CONTENTS
Skidsteer Range
75 - 20 - 01/9
1CX (208S)
* Standard Machine from m/c no. 752463 - Dual Lever Drive Control Key
37 38 50 51 52 *X Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor One-way Restrictor Return line fitted from machine no. 807226
* Component C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 9 10 11 12 30 32 33 34 35 36
Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank Left Hand Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Right Hand Joystick Brake Valve Check Valve (2 bar) Filter By-pass Valve (3 bar) Auxiliary Feeds Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram
9804/1103
75 - 20 - 01/9
8550 - E/31-3 . 2
Issue 2*
CONTENTS
52 5 2 2F 2E 2G 2J 2D T 12 2H 6 4A 7
Skidsteer Range
75 - 20 - 01/10
* Standard Machine from m/c. no. 752463 - Dual Lever Drive Control
32 37 4 36 4J 51 38
4K 4B 2A 2B 2C 50 4M 4C 34 4L
2X
F1 3 1 11 8 4D 35
2Y
4N 4E
4P P3 9 4F 4Q
4R 2Z 4S 4G
33
10 P1 M1 P2 M2 C 4H 30 4T
S1
316760
9804/1103
75 - 20 - 01/10
Issue 2*
CONTENTS
Skidsteer Range
75 - 20 - 01/11
* High-flow Machine up to m/c. no. 751011 - Single Lever Drive Control
32 5 2 2F 2E 2G 2J 2D T 4K 4B 2A 2B 2C 50 4M 4C 34 F1 1 11 3 14 F2 14A 2Y 9 4P P3 4F 8 2Z 8A 8B 8C 8D C 4G 4R 4S 33 4Q 4E 13 4N 14C 15 4D 35 14B 4L 12 2H 6 4A 7 4 36 4J 51 37 38
2X
P1 M1
P2 4T M2 4H 30
S1
S2
A204773B
9804/1103
75 - 20 - 01/11
Issue 2*
CONTENTS
Skidsteer Range
75 - 20 - 01/12
1CX (208S)
* High-flow Machine up to m/c no. 751011 - Single Lever Drive Control Key
13 14 14A 14B 14C 15 30 32 33 34 35 36 37 38 50 51 High-flow Pump High-flow Valve High-flow Pilot Valve High-flow Control Valve High-flow Circuit Relief Valve Attachment Motor Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor
* Component C F1 F2 P1 P2 P3 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 8A 8B 8C 8D 9 11 12
Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Pump Suction Strainer Tank Loader Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (5 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Pressure Reducing Solenoid Valve Filter By-pass Valve (3 bar) Auxiliary Feeds
9804/1103
75 - 20 - 01/12
Issue 2*
CONTENTS
Skidsteer Range
75 - 20 - 01/13
1CX (208S)
High-flow Machine from m/c no. 751012 to 752462 - Single Lever Drive Control
Component Key
C F1 F2 P1 P2 P3 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2W 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 8A 8B 8C 8D 9 10 11 12 Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Pump Suction Strainer Tank Loader Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (High-flow Relief Valve) Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Pressure Reducing Solenoid Valve Check Valve (2 bar) Filter By-pass Valve (3 bar) Auxiliary Feeds 13 14 14A 14B 14C 15 30 32 33 34 35 36 37 38 50 51 52 High-flow Pump High-flow Valve High-flow Pilot Valve High-flow Control Valve High-flow Circuit Relief Valve Attachment Motor Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor One-way Restrictor
9804/1103
75 - 20 - 01/13
Issue 1
CONTENTS
Skidsteer Range
75 - 20 - 01/14
High-flow Machine from m/c. no. 751012 to 752462 - Single Lever Drive Control
52 5 2 2F 2E 2G 2J 2D T 4K 4B 2A 2B 2C 50 4M 2W F1 1 11 3 14 F2 14A 2Y 9 4P P3 4F 8 2Z 8A 8B 8C 8D C 4G 4R 4S 4Q 4E 13 4N 14C 15 4D 14B 4C 4L 12 2H 6 4A 7 4 36 4J 51
32 37 38
2X
34
35
33
P1 M1
P2 4T M2 4H 10 30
S1
S2
A243000B A243000B
9804/1103
75 - 20 - 01/14
Issue 1
CONTENTS
52 5 2 2F 2E 2G 2J 2D T 12 2H 6 4A 7
Skidsteer Range
75 - 20 - 01/15
High-flow Machine from m/c. no. 752463 - Single Lever Drive Control
32 37 4 36 4J 51 38
4K 4B 2A 2B 2C 50 4M 2W 4C 34 14B 1 3 14 F2 14A 4N 4E 13 14C 15 4D 35 4L
2X
F1
11
2Y
4P 9 P3 4F 8 2Z 8A 8B 8C 8D C 4G 4R 4S 33 4Q
P1 M1
P2 4T M2 4H 10 30
S1
S2
316750
9804/1103
75 - 20 - 01/15
Issue 1
CONTENTS
Skidsteer Range
75 - 20 - 01/16
1CX (208S)
High-flow Machine from m/c no. 752463 - Single Lever Drive Control
Component Key
C F1 F2 P1 P2 P3 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2W 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 8A 8B 8C 8D 9 10 11 12 Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Pump Suction Strainer Tank Loader Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (High-flow Relief Valve) Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Drive Control Joystick Reverse Spool Left Turn Spool Forward Spool Right Turn Spool Brake Valve Check Valve (2 bar) Filter By-pass Valve (3 bar) Auxiliary Feeds 13 14 14A 14B 14C 15 30 32 33 34 35 36 37 38 50 51 52 *X High-flow Pump High-flow Valve High-flow Pilot Valve High-flow Control Valve High-flow Circuit Relief Valve Attachment Motor Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor One-way Restrictor Return line fitted from machine no. 807226
9804/1103
75 - 20 - 01/16
8550 - E/32-6 . 2
Issue 2
CONTENTS
Skidsteer Range
75 - 20 - 01/17
1CX (208S)
High-flow Machine from m/c no. 751012 to 752462 - Dual Lever Drive Control
Component Key
C F1 F2 P1 P2 P3 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2W 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 9 10 11 12 Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Pump Suction Strainer Tank Left Hand Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (High-flow Relief Valve) Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Right Hand Joystick Pressure Reducing Solenoid Valve Check Valve (2 bar) Filter By-pass Valve (3 bar) Auxiliary Feeds 13 14 14A 14B 14C 15 30 32 33 34 35 36 37 38 50 51 52 High-flow Pump High-flow Valve High-flow Pilot Valve High-flow Control Valve High-flow Circuit Relief Valve Attachment Motor Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor One-way Restrictor
9804/1103
75 - 20 - 01/17
Issue 1
CONTENTS
52 5 2 2F 2E 2G 2J 2D T 12 2H 6 4A 7
Skidsteer Range
75 - 20 - 01/18
High-flow Machine from m/c. no. 751012 to 752462 - Dual Lever Drive Control
32 37 4 36 4J 51 38
4K 4B 2A 2B 2C 50 4M 4C 34 4L
2X
F1 3 1 11 8 4D 35
2Y 2W 14B 9 P3 14 14C 15 14 14A F2
4N 4E
4P 4Q 4F
4R 2Z 13 4S 4G
33
P1 M1
P2 M2 10
4T C 4H 30
S1
S2
A243004
9804/1103
75 - 20 - 01/18
Issue 1
CONTENTS
52 5 2 2F 2E 2G 2J 2D T 12 2H 6 4A 7
Skidsteer Range
75 - 20 - 01/19
High-flow Machine from m/c. no. 752463 - Dual Lever Drive Control
32 37 4 36 4J 51 38
4K 4B 2A 2B 2C 50 4M 4C 34 4L
2X
F1 3 1 11 8 4D 35
2Y 2W 14B 14 P3 9 14C 15 14 14A F2
4N 4E
4P 4Q 4F
4R 2Z 13 4S 4G
33
P1 M1
P2 M2 10
4T C 4H 30
S1
S2
316770
9804/1103
75 - 20 - 01/19
Issue 1
CONTENTS
Skidsteer Range
75 - 20 - 01/20
1CX (208S)
High-flow Machine from m/c no. 752463 - Dual Lever Drive Control
Component Key
C F1 F2 P1 P2 P3 M1 M2 S1 S2 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2W 2X 2Y 2Z 3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8 9 10 11 12 Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Pump Suction Strainer Tank Left Hand Joystick Loader Valve Block Crowd Spool Lift Spool Auxiliary Spool Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Pressure Test Point (High-flow Relief Valve) Pressure Test Point (Main Relief Valve) Pressure Test Point (Transmission Charge Pressure) Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Auxiliary Spool Hydraclamp Valve Slew ARV Slew ARV Boom Ram Head Side ARV Boom Ram Rod Side ARV Dipper Ram Rod Side ARV Dipper Ram Head Side ARV Bucket Ram Rod Side ARV Bucket Ram Head Side ARV Auxiliary ARV Auxiliary ARV Crowd Rams Manually Operated Dump Valve Lift Rams Right Hand Joystick Brake Valve Check Valve (2 bar) Filter By-pass Valve (3 bar) Auxiliary Feeds 13 14 14A 14B 14C 15 30 32 33 34 35 36 37 38 50 51 52 *X High-flow Pump High-flow Valve High-flow Pilot Valve High-flow Control Valve High-flow Circuit Relief Valve Attachment Motor Hydraclamp Stabiliser Ram Stabiliser Ram Slew Ram Slew Ram Boom Ram Dipper Ram Bucket Ram Bi-restrictor Bi-restrictor One-way Restrictor Return line fitted from machine no. 807226
9804/1103
75 - 20 - 01/20
8550 - E/33-4 . 2
Issue 2
CONTENTS
Skidsteer Range
75 - 20 - 01/21
1CX (208S)
Optional Hand Tool Circuit

Description The oil supply for the optional hand tool circuit is taken from the excavator valve auxiliary circuit feed lines. When the auxiliary circuit is selected by the foot pedal, oil is fed via the Manual Valve 2 to the Flow Regulator Valve 3 . Flow Regulator Spool 3a controls the flow to the hand tool circuit 4, dumping excess oil back to tank via the return line of the excavator auxiliary circuit. Return oil from the hand tool is fed directly back to tank. Relief Valve 3b prevents pressure in the hand tool circuit from rising too far. Manual Valve 2 is turned off to isolate the hand tool circuit when the excavator auxiliary circuit is to be used for other applications. Component Key
2 3a 3 4 3b
5
T 1 2 3 3a 3b 4 5 Tank Excavator Valve Block Auxiliary Lines Manual Valve Flow Regulator Valve Flow Regulator Spool Relief Valve Hand Tool Connection Return Line from Brake Valve
T
303930
9804/1103
75 - 20 - 01/21
Issue 1
INDEX
Teletruk
All Models Contents

Page No. General Information Fluids, Lubricants and Capacities Static Dimensions Weights and Lifting Capacities Data Electrical Hydraulic Transmission Hydraulics Tyres Steering Brakes Engine - Diesel - LPG
80 - 00 - 01/1 80 - 00 - 02/1 80 - 00 - 02/2
80 - 05 - 01/1 to 80 - 05 - 01/3 80 - 05 - 02/1 80 - 05 - 03/1 80 - 05 - 03/1 80 - 05 - 04/1 80 - 05 - 04/1 80 - 05 - 05/1 80 - 05 - 05/1
* Circuit Diagrams
Electrical All Models to m/c no. 788000 All Models (Diesel Engine, Single Pedal) from m/c no. 788001 to 788643 All Models (Diesel Engine, Single Pedal) from m/c no. 788644 All Models (Diesel Engine, Twin Pedal) from m/c no. 788001 to 788643 All Models (Diesel Engine, Twin Pedal) from m/c no. 788644 All Models (LPG Engine, Single Pedal) from m/c no. 788001 to 788643 All Models (LPG Engine, Single Pedal) from m/c no. 788644 All Models (LPG Engine,Twin Pedal) from m/c no. 788001 to 788643 All Models (LPG Engine, Twin Pedal) from m/c no. 788644 All Models (Diesel Engine - TCR) from m/c no. 788001 All Models (2 Speed Option - Intelligent Transmission) from m/c no. 788644 All Models (2 Speed/Traction Control Option - Intelligent Transmission) from m/c no. 788644 Hydraulic All Models to m/c no. 788390 All Models to m/c no. 788390 - Transmission Circuit All Models from m/c no. 788391 All Models from m/c no. 788391 - Transmission and Valve Circuit
80 - 15 - 01/1 to 80 - 15 - 01/3 80 - 15 - 01/4 to 80 - 15 - 01/6 80 - 15 - 01/6A to 80 - 15 - 01/6C 80 - 15 - 01/7 to 80 - 15 - 01/9 80 - 15 - 01/09A to 80 - 15 - 01/9C 80 - 15 - 01/10 to 80 - 15 - 01/12 80 - 15 - 01/12A to 80 - 15 - 01/12C 80 - 15 - 01/13 to 80 - 15 - 01/15 80 - 15 - 01/15A to 80 - 15 - 01/15C 80 - 15 - 01/16 to 80 - 15 - 01/18 80 - 15 - 01/19
80 - 15 - 01/20 80 - 20 - 01/1 to 80 - 20 - 01/2 80 - 20 - 01/3 80 - 20 - 0/4 to 80 - 20 - 01/5 80 - 20 - 01/6
9804/1103
Teletruk Contents - 1
Issue 2*
CONTENTS
Teletruk
80 - 00 - 01/1
All Models Fluids, Lubricants and Capacities

ITEM CAPACITY FLUID/LUBRICANT SPECIFICATION
SAE 10W/30 API CF4/SG API CC 10W 30 API CE 15W 40 API CC 10W 30
Engine Oil Diesel Hydraulic System
8.2 litres 55 litres
JCB 10W/30 Multigrade JCB 15W/40 Multigrade JCB 10W/30 Multigrade
Cooling System Diesel Total coolant cap. 11 litres Antifreeze 5.5 litres Fuel System Grease Points 90 litres -
JCB Universal Antifreeze/water
ASTM D3306-74
Diesel oil JCB Special HP Grease or JCB Special MPL Grease
Boom Runways
Waxoyl
9804/1103
80 - 00 - 01/1
Issue 2*
CONTENTS
Teletruk
80 - 00 - 02/1
All Models Static Dimensions Dimensions

A Overall length to fork face B Overall machine width C Height of overhead guard standard container Height - boom extended D Wheelbase Ground clearance E at centre of wheelbase F at lowest point
2.0/2.5
2625 mm 1175 mm
3.0
2750 mm 1280 mm
2190 mm 2090 mm 4580 mm 1700 mm
2195 mm 2095 mm 4625 mm 1700 mm
135 mm 105 mm
160 mm 130 mm
F E B D A
A286920
9804/1103
80 - 00 - 02/1
Issue 2*
CONTENTS
Teletruk
80 - 00 - 02/2
Models To S/N 0788000 Weight and Lifting Capacity

Weight
Unladen TLT20D Diesel engine TLT20G LPG engine TLT25D Diesel engine TLT25G LPG engine 4100 kg 4160 kg 4400 kg 4460 kg
Lifting Capacity
TLT20D TLT20G TLT25D TFL25G 2000 kg 2000 kg 2500 kg 2500 kg
Models - S/N 0788001 Onwards
Weight
Unladen Diesel engine LPG engine
2.0/2.5
4220 kg 4280 kg
3.0
4850 kg 5010 kg
Lifting Capacity
TLT 20D TLT 20G TLT 25D TLT 25G TLT30D TLT 30G 2000 kg 2000 kg 2500 kg 2500 kg 3000 kg 3000 kg
9804/1103
80 - 00 - 02/2
Issue 1
CONTENTS
Teletruk
80 - 05 - 01/1
All Models Data - Electrical General

The electrical system is a 12 volt DC system with a negative earth. * Main
Fuses to m/c no. 788643
The main fuse box is situated on the left side of the dash. The fuses and their respective circuits are shown below. Fuse A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 Load Moment Indicator (from m/c S/NO788001 onwards) Reverse Alarm, Rear Worklight Engine Stop (E.S.O.S.) Transmission Control Box Parking Brake Solenoid Rear Worklight Information Display Centre (Switched) Rocker Switch Warning Lights Horn IDC Buzzer (Low Pressure. Low Fuel. High Temperatures) Front Worklights Beacon (Optional) Rear Wiper (Optional) Front Wiper (Optional) Interior Light (Optional) Radio (Optional) Heater (Optional) Face Fan (Optional) Information Display Centre (Un-switched Clock Memory) Low Fuel Switch Electrical Ancillaries (Optional Not Used Hazard Switch (Un-switched) (Optional) Brake Lights (Optional) Hazard Switch (Switched) (Optional) Headlight Main Beam (Optional) Headlight Dip Beam (Optional Left Hand Sidelights Right Hand Sidelights Not Used Not Used Not Used Circuit Rating 5 amp 3 amp 10 amp 5 amp 10 amp 5 amp 5 amp 5 amp 10 amp 10 amp 5 amp 10 amp 10 amp 5 amp 5 amp 15 amp 15 amp 3 amp 10 amp 10 amp
Bulbs
In the event of a bulb failure, change the bulb. The specification for each bulb is given below: Note: These bulbs fitted to your machine will be dependant on which options were selected during manufacture. Headlights (Main/Dip) Worklights Front Sidelights Stop/Tail Lights Turn Indicators Interior Light Beacon 60/55 W 55 W 5W 21/5 W 21 W 10 W 55 W
Fuses
Various fuses are installed in the machine to protect the electrical circuits. If a circuit fails to operate, change the relevant fuse and then test the circuit for operation. If a fuse continually blows, there will probably be a fault in the circuit that will require rectification.
Primary Fuses
The primary fuse box is mounted on the battery. The fuses and their respective circuits are shown below. Circuit 1 Roadlights Relay Supply (optional) 2 Ignition Relay 1 Supply 3 Ignition Switch 4 Ignition Relay 2 Supply 5 Not Used Rating 60 amp 30 amp 40 amp 30 amp
10 amp 5 amp 10 amp 15 amp 15 amp 5 amp 5 amp
A 4 5 1 2
S245110
9804/1103
80 - 05 - 01/1
3400 - C/1-1.2
Issue 3*
CONTENTS
Teletruk
80 - 05 - 01/2
All Machines Data - Electrical (contd) Main Fuses Torque Convertor Response
The main fuse box is situated on the left side of the dash. The fuses and their respective circuits are shown below. Fuse A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 Circuit Rating 3 amp 10 amp 5 amp 10 amp 5 amp 5 amp
From m/c no. 788644
Relays Torque Convertor Response

1 2 3 4 5 6 7 8 Parking Brake Neutral Start Ignition 1 Not Used Reverse Ignition 2 Direction Indicators Headlights
Load Moment Indicator Reverse Alarm, Rear Worklight Engine Stop (E.S.O.S.) Transmission Control Box Parking Brake Solenoid Rear Worklight Information Display Centre (Switched) Rocker Switch Warning Lights 5 amp Horn, Warning Buzzer (Low Pressure. Low Fuel. High Temperatures) 10 amp Front Worklights 10 amp Beacon (Optional) 5 amp Rear Wiper (Optional) Front Wiper (Optional) Interior Light (Optional) Radio (Optional) Heater (Optional) Face Fan (Optional) Differential Lock (Optional) Low Fuel Switch Electrical Ancillaries (Optional) Man Platform Option Hazard Switch (Un-switched) (Optional) Brake Lights (Optional) Hazard Switch (Switched) (Optional) Headlight Main Beam (Optional) Headlight Dip Beam (Optional) Left Hand Sidelights Right Hand Sidelights Not Used Not Used Front Working Lights (Optional)
A
5A 10A
B
10A 10A 10A 5A 15A 15A 5A 5A 10A 10A
C
10A
10 9 8
10 amp 10 amp 5 amp 5 amp 15 amp 15 amp 5 amp 10 amp 10 amp 10 amp 10 amp 5 amp 10 amp 15 amp 15 amp 5 amp 5 amp
1 2 3
FNR
STOP
10A 5A 5A 5A 10A 5A 10A
5A 5A 15A 15A 10A 5A 10A
7 6 5 4 3 2 1
817/17019
3A
8
371300
10 amp
1 2 3
4 5 67 8
281321 281321
9804/1103
80 - 05 - 01/2
3400 - C/1-2.1
Issue 1
CONTENTS
Teletruk
80 - 05 - 01/3
All Machines Data - Electrical (contd) Main Fuses Intelligent Transmission

The main fuse box is situated on the left side of the dash. The fuses and their respective circuits are shown below. Fuse A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 Circuit Rating 3 amp 10 amp 5 amp 10 amp 5 amp 5 amp
From m/c no. 788644
Relays Intelligent Transmission

1 2 3 4 5 6 7 8 9 Engine Shut Off Solenoid Neutral Start Ignition 1 Reverse Ignition 2 Direction Indicators Headlights Main Beam Hazard Warning Lights
Load Moment Indicator Reverse Alarm, Rear Worklight Engine Stop (E.S.O.S.) Transmission Control Box Parking Brake Solenoid Rear Worklight Information Display Centre (Switched) Rocker Switch Warning Lights 5 amp Horn, Warning Buzzer (Low Pressure. Low Fuel. High Temperatures) 10 amp Front Worklights 10 amp Beacon (Optional) 5 amp Rear Wiper (Optional) Front Wiper (Optional) Interior Light (Optional) Radio (Optional) Heater (Optional) Face Fan, Differential Lock (Optional) Not Used Low Fuel Switch Electrical Ancillaries (Optional) Man Platform Option Hazard Switch (Un-switched) (Optional) Brake Lights (Optional) Hazard Switch (Switched) (Optional) Headlight Main Beam (Optional) Headlight Dip Beam (Optional) Left Hand Sidelights Right Hand Sidelights Not Used Not Used Front Working Lights (Optional)
1
STOP
A
5A
B
10A 10A 10A
C
10A
10 9 8
2 3
10A 10A 5A 5A 5A FNR

STOP
10 amp 10 amp 5 amp 5 amp 15 amp 10 amp 10 amp 10 amp 10 amp 10 amp 5 amp 10 amp 15 amp 15 amp 5 amp 5 amp
5A 15A 15A 5A 5A 10A 10A 5A 15A 15A 10A 5A 10A
7 6 5 4 3 2 1
10A 5A 10A
817/04894
3A
8 9
371310
10 amp
1 2 3 8 4 5 679
281321 281321
9804/1103
80 - 05 - 01/3
3400 - C/1-3.1
Issue 1
CONTENTS
Teletruk
80 - 05 - 02/1
All Models Data - Hydraulics Description

The main components of the hydraulic circuit are the tank, pumps, control valve, filter, cooler, rams and unloader valve. The pumps are driven by the engine and are mounted in tandem. The tranmission pump is electronically operated via the drive controls and delivers pressurised oil to the wheel motors. The main pump delivers pressurised oil to the control valve. When a valve is operated by a control lever, it delivers the oil to one end of the appropriate ram. The pressurised oil forces the rams piston along the bore of the ram. Relief valves prevent system pressure from rising too far. The steering pump delivers pressurised oil to the steering ram via the orbitrol steering unit. The unloader valve dumps flow back to tank when pressure from the valve block increases above a preset level due to the load on the circuit, e.g. lifting a heavy weight on the forks. This reduces the load on the engine.
Relief Valve Operating Pressures (Oil temperature at 50 C)

Main Relief Valve (at 2800 rev/min) Auxiliary RElief Valves Brake Pressure Reducing Valve Unloader Valve 2.5 tonne 3.0 tonne Check Valve Steering Orbitrol Unit 245 bar (3553 lbf/in2) 255 bar (3698 lbf/in2) 25 bar (363 lbf/in2) At idle 80 bar (1160 lbf/in2) At max RPM 110-120 bar (1595-1740 lbf/in2) At idle 95 bar (1377 lbf/in2) At max RPM 190 bar (2755 lbf/in2) 3 bar (43.5 lbf/in2) 150 bar (2175 lbf/in2)
Pressure Tapping Points

Four hydraulic tapping points are provided on the Teletruk for maintenance, these are listed in the table below: Position Gauge Pressure bar 30 (max.) 150 Main Use bar Charge pressure
1 Transmission pump 2 Hydraulic pump 3 Steering Pump
40
400
Unloader pressure
400
245 150 17 - 18 25 17
MRV at full lift During turning At idle At full lift At idle
4 Brake
40
Note: Hydraulic oil temperature should be at 50 degrees C.
Attachments
2.0/2.5
3.0
Working Pressure Oil Flow OR Working Pressure Oil Flow
110 bar 70 litres/min 245 bar 31 litres
110 bar 70 litres/min 245 bar 31 litres/min
9804/1103
80 - 05 - 02/1
Issue 2*
CONTENTS
Teletruk
80 - 05 - 03/1
All Models Data - Transmission Hydraulics

Description The transmission pump and motor are combined in a system that provides an infinitely variable speed range between zero and maximum in both forward and reverse. The variable displacement pump has a parallel axial piston/slipper design in conjunction with a tiltable cradle swashplate to vary the pumps displacement. Reversing the direction of tilt of the swashplate reverses the flow of oil from the pump and thus the direction of rotation of the motor output. The pump is controlled by an electrical input signal. Two multi-function valves are included in the pump design to provide the check valve, pressure limiter, high pressure relief and bypass functions. The fixed displacement motors also use the parallel axial piston slipper design in conjunction with a fixed displacement swashplate. The motors include a multiple disc brake pack, held on by spring force and released by hydraulic pressure. Note: JCB recommends that only minor repairs and replacements be carried out on the transmission pump and drive motors. Should anything more be required a reconditioned or new replacement unit should be fitted. The procedures in this section reflect this policy.
Data - Tyres
General The Teletruk may be fitted with either pneumatic tyres or solid tyres. This section describes the maintenance procedures for both types of tyre. Specification 2.0/2.5 Models up to S/N 0788000 Type Semi solid or pneumatic Standard size front rear Pressure (pneumatic) front 7.00 x 12 rear 6.00 x 9
!WARNING
Do not fit pneumatic tyres on a wheel made for a solid tyre. Do not fit a solid tyre on a wheel made for a pneumatic tyre. If you are unsure of the correct specification for your machine, contact your local JCB Distributor or a trained specialist.
12-6-1-1
7.00 x 12 6.00 x 9
9 bar 8.5 bar
Models S/N0788001 Onwards
!CAUTION
The wheels and tyres are heavy. Take care when lifting or moving them.
12-6-1-2
2.0/2.5
3.0
Type - Semi solid or pneumatic standard size front 7.00 x 12 rear 6.00 x 9 Pressure (pnuematic) Front 7.00 x 12 Crossply Watts Radial Michelin Front 27 x 10 x 12 Radials Continential Radials Michelin Rear 6.00 x 9 Crossply Watts Rear 6.5 x 10 Radials Continential Radials Michelin
27 x 10 x 12 6.5 x 10
9.5 bar (137.75 lbf/ in2) 7.0 bar (101.5 lbf/ in2) 10.0 bar (140.5 lbf/in2) 7.5 bar (108.75 lbf/in2)
8.5 bar (123.25 lbf/in2) 10.0 bar (140.lbf/in2) 9.0 bar (130.5 lb/ in2)
9804/1103
80 - 05 - 03/1
Issue 2
CONTENTS
Teletruk
80 - 05 - 04/1
All Models Data - Steering

Description Steering is hydraulically controlled by a power track rod. Hydraulic oil is delivered from the steering pump via the flow/relief valve section to the steering unit. When the steering is turned the steering valve is actuated and a pressure demand signal sent to the priority inlet spool. The spool moves and directs pressurised oil from the pump to the steering valve and then the power track rod. Pressurised oil enters the power track rod and causes the ram to move to turn the wheels in the required direction. Shock valves are fitted to guard against shock steering loads. The steering pump and circuit is included in the Circuit Diagrams - Hydraulics.
Data - Brakes
The brake circuit is included in Circuit Diagrams - Hydraulic.
9804/1103
80 - 05 - 04/1
Issue 1
CONTENTS
Teletruk
80 - 05 - 05/1
All Models Data - Engine Technical Data - Diesel engine

Type Bore (nominal) Stroke Swept Volume Compression Ratio Injection Sequence Valve Clearance - Cold - Inlet and Exhaust Oil Pressure Manf. type Speeds Rated Speed Idling Speed Fuel System Injection Pump Type Governing Static Timing Injector Codes Injector Setting Pressure Cooling System Fan Type Coolant Pressure Thermostat operating temperature Temperature Warning Light operates at Mechanical 1 bar (14.5 lbf/in2, 1.02 kgf/cm2) 82 - 94 C (180 - 200 F) 97 - 103 C (207 - 217 F) Bosch 104135-4010 Mechanical 19 BTDC Bosch 105148-1170 147 bar (2133 lbf/in2, 150 kgf/cm2) 4 cylinder in-line, compression ignition, naturally aspirated. 84 mm (3.31 in) 100 mm (3.94 in) 2216 cm3 (135.2 in3) 22 : 1 1,3,4,2 0.2 mm (0.0078 in) 2.6 - 3.5 bar (38 - 52 lbf/in2, 2.7 - 3.6 kgf/cm2) Perkins 104 2.2 2800 rev/min 850 - 950 rev/min
Note: Should further details be required, refer to Engine Service Manual 9806/2100.
Technical Data - LPG engine

Type Bore (nominal) Stroke Swept Volume Compression Ratio Firing Sequence Valve Clearance - Cold - Inlet Exhaust Maximum Air Cleaner Restriction Maximum Back Pressure (Exhaust) Manf. type Speeds Rated Speed Idling Speed Fuel System LPG Carburettor, vapouriser and water heated filter. Cooling System Fan Type Coolant Pressure Thermostat operating temperature Temperature Warning Light operates at Mechanical 1 bar (14.5 lbf/in2, 1.02 kgf/cm2) 82 - 94 C (180 - 200 F) 97 - 103 C (207 - 217 F) 4 cylinder in-line, spark ignition, naturally aspirated. 101.6 mm (4 in) 91.44 mm (3.6 in) 2966.59 cm3 (181 in3) 9.25 : 1 1,3,4,2 Refer to Engine Service Manual 9806/2150
GM 3.0 L4 3000 rev/min 850 - 900 rev/min
Note: Should further details be required for the refitting of the engine refer to Engine Service Manual 9806/2150
9804/1103
80 - 05 - 05/1
Issue 2
CONTENTS
Teletruk
80 - 15 - 01/1
All Models up to S/N 0788000 Circuit Diagrams - Electrical

Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 13A 14 15 16 16A 17 18 19 20 21 22 23 24 25 26 27A 27B 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 44A 45 46 47 48 49 50 51 52 53 54 55 56 Battery Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valv Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Solenoid Key Switch Glow Plugs Glow Plugs Glow Plugs Glow Plugs Starter Solenoid Starter Motor Neutral Start Relay Starter Relay Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Reverse Relay Reverse Alarm Buzzer Engine Shut Off Solenoid - Relay Engine Shut Off Solenoid Electronic Brake Control Unit Park Brake Switch EDC (Pump Swash Operation) Susmic 12 PPU (Pump Speed Sensor) Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal SAS Actuator (Engine Revs) Clock (IDC Internal) Hourmeter (IDC Internal) Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Low Fuel Oil Level Air Filter Vacuum Switch Filter Bypass IDC Buzzer Head Light LED Mini Relay Alternator Alternator Resister Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch Beacon Switch Beacon Motor Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Flasher Unit Brake Light Switch Ignition Relay 2 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 Rear Wash/Wipe Switch Rear Washer Motor Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Head Light Flash Switch Road Lights Relay Road Lights Switch Dip Switch Interior Light Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor
Lamps 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 Rear Work Light Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Low Fuel Level Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam Warning LED Indicator Warning LED Right Hand Front Work Light Left Hand Front Work Light Beacon Lamp Left Hand Indicator (Rear) Hazard Switch Warning LED Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light
Primary Fuses F1 Roadlights Relay Supply (optional) F2 Ignition Relay 1 Supply F3 Key Switch F4 Starter Relay 2 Supply Note: F or bulb and fuse ratings see page 80-05-01/1 (LEDS not service parts)
9804/1103
80 - 15 - 01/1
Issue 2*
CONTENTS
Teletruk
80 - 15 - 01/2
All Models up to S/N 0788000 Circuit Diagram - Electrical (continued)
600
600
21 4
981
7
982
9 10 12
13A 19 13 22
25
11 80 16 16A
G
971
972
125B
125D
14
18
20
24
416E
417E
416F
125C
125A
17 A1 8 15
001K RED
GREEN
23
A2 A6
A3 A5
BLACK
27A
27B 30
31
32 33
A4 26
29 28
F2 F3
B9
417F
424
425
A283260
9804/1103
80 - 15 - 01/2
Issue 2*
CONTENTS
Teletruk
80 - 15 - 01/3
All Models up to S/N 0788000 Circuit Diagram - Electrical (continued)
38 40 36 37 39 44 47 92 41 91 50 93 96 94 53 98 100 97 99 57 59 60 63 35 64 42 34 82 84 86 88 90 45 81 83 85 87 89 46 51 55 71 48 49 52 54 62 102 101 104 105 103 106 107 108

860
70B 68 73 69
602
76
109
70A
67
58 61 66 72 75
43
B8 A9 A7 B7 A8 A10
95 C2 C3 C1 56 B1 B2 65 B3 B4
74
001K
B5 F4 F1
B6
A283270
9804/1103
80 - 15 - 01/3
Issue 2
CONTENTS
Teletruk
* M/c
80 - 15 - 01/4
All Models Circuit Diagrams Electrical Main Components (Diesel Engine, Single Pedal)
1 2 3 4 5 6 7 8 9 10 11 12 13 13A 14 15 16 16A 17 18 19 20 21 22 23 24 25 26 27A 27B 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 44A 45 46 47 48 49 50 51 52 53 54 55 56 Battery Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Solenoid Key Switch Glow Plugs Glow Plugs Glow Plugs Glow Plugs Starter Solenoid Starter Motor Neutral Start Relay Starter Relay Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Reverse Relay Reverse Alarm Buzzer Engine Shut Off Solenoid - Relay Engine Shut Off Solenoid Electronic Brake Control Unit Park Brake Switch EDC (Pump Swash Operation) Susmic 12 PPU (Pump Speed Sensor) Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal SAS Actuator (Engine Revs) Clock (IDC Internal) Hourmeter (IDC Internal) Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Low Fuel Oil Level Air Filter Vacuum Switch Filter Bypass IDC Buzzer Head Light LED Mini Relay Alternator Alternator Resister Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch Beacon Switch Beacon Motor Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Flasher Unit Brake Light Switch Ignition Relay 2 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76
nos. 788001 to 788643
Rear Wash/Wipe Switch Rear Washer Motor Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Head Light Flash Switch Road Lights Relay Road Lights Switch Dip Switch Interior Light Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor
Lamps
80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 Rear Work Light Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Low Fuel Level Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam Warning LED Indicator Warning LED Right Hand Front Work Light Left Hand Front Work Light Beacon Lamp Left Hand Indicator (Rear) Hazard Switch Warning LED Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light
Primary Fuses
F1 Roadlights Relay Supply (optional) F2 Ignition Relay 1 Supply F3 Key Switch F4 Starter Relay 2 Supply Note: For bulb and fuse ratings see page 80 - 05 - 01/1. (LEDs not service part)
9804/1103
80 - 15 - 01/4
3400 - C/3-2.4
Issue 4*
CONTENTS
*
Teletruk
* M/c
80 - 15 - 01/5
All Models Circuit Diagrams - Electrical Main Components (Diesel Engine, Single Pedal
nos. 788001 to 788643
600 9 11 13A 13 10 12 80 16 16A 22 19 21 25 401
18 1 14
20
24
17 A1 8 15 F2 A6 A5 F3 A4 A2 A3
23 27A 27B 26 29 28 30
31
32 33
002 108 001K
9804/1103
80 - 15 - 01/5
Issue 2*
CONTENTS
*
Teletruk
* M/c
80 - 15 - 01/6
All Models Circuit Diagrams - Electrical Main Components (Diesel Engine, Single Pedal
nos. 788001 to 788643
600 36 401
37 39 41 38 40 44 47 94 91 92 50 93 96 53 98 99 99 100 57 59 62 63 107 105 106 68 108 109 69 73 70 76 3 6
104 101 103 102
35 42 34 82 84 86 88 90 81 83 85 87 89 45 46 51 71 43 B8 A7 B7 95 A8 A9 A10 C3 C1 56 F4 F1 B1 B2 C2 65 B3 B4 74 48 49 72 52 54 55 58 61 75 2 5
B5
B6 B9
002 108 001K
9804/1103
80 - 15 - 01/6
Issue 2*
1
600 BATTERY
Circuit Diagrams - Electrical Main Components (Diesel Engine, Single Pedal)
9804/1103
003
310A
CONTENTS
40A
1
All Models
MAIN FUSE BOX DETAILS
F1
KEY SWITCH
F2
2
6 5
310B
9 4 3 7
F3
GLOW PLUGS
60A 30A 40A
30A
F4
F3
80A
004 842 001
STARTER MOTOR STARTER SOLENOID

NEUTRAL START RELAY
F5
9
IGNITION RELAY 1
30A
11
002
F2 10
S.L.I. UNIT FUSE A1 974 IGNITION RELAY 1
001A
S.L.I.
A1
463 464
13
A6
80 - 15 - 01/6A
12
009 861
FUSE A6
TRANSDUCER
Teletruk
14
3
861A
REAR WORKLIGHT
2
1
1 8
15
807 FUSE A2 107E REVERSE RELAY
16
807
REVERSE ALARM
FUSE A3 105
A2
E.S.O.S RELAY
17
18
E.S.O.S
A3
FUSE A5
19
122
122 600JY 418 420 417J 416J
ELECTRONIC BRAKE CONTROL UNIT
1 2 3 4 5 6
FUSE A4 600HG 600HJ 416 417 808 401 HANDBRAKE SWITCH 418
A5 A4
130
HANDBRAKE EARTH
22
130A
1 +BATTERY 2 -BATTERY 3 CHASSIS 4 -SENSOR 5 +SENSOR
21
A B
20 24
6 BID OUT 1
419 401J 809E 842B 130B
7 BID OUT 2 8 DIG INP 1.2 9 DIG INP 1.0 10 +BATTERY
PPU
23
RED
F N R
3 1 4
BLACK
808 GREEN
431 130C 416A
11 PPU/IN 0 12 IGNITION 13 SENSOR-
ELEVATION
421 422
14 PPU/IN 1 15 DIG INP 1.3
SUSMIC 12
25
16 RXD
423
17 TXD
28
AUX
27 29
TILT
424
18 AN.IN ACHO
26
423 422 429
425 426 427 416B 417A 417B 428 429 808F 430
19 AN.IN ACH1 20 D OUT 0 21 D OUT 1 22 SENSOR 23 SENSOR + 24 SENSOR + 25 AN.IN ACH3 26 RS232 GND 27 DIG.INP1.1 28 AN.IN ACH2
ACCELERATOR PEDAL INCH/BRAKES PEDAL
RS232 DIAGNOSTIC CONNECTOR ON PSION UNIT
1 2 3 4 5 6 7 8 9
30
3400 - C/3-3A.1
A B C
B W R
31
417G 428 416G 426 427
C B A
SAS
32
ACTUATOR
1 2 3 4 5 6
002 108 001K
600 401
80 - 15 - 01/6A
From m/c no. 788644
Issue 1
33
1 3 2
FUSE B8 106V
Circuit Diagrams - Electrical Main Components (Diesel Engine, Single Pedal) (contd)
9804/1103
HOURS COUNTER
FUSE A7
MASTER W/LIGHT
CONTENTS
All Models
310A HORN SWITCH (COLUMN)
B8
106
34
A7
MASTER W/LIGHT
35
401 406
ALTERNATOR
HAND BRAKE WATER TEMP
WATER TEMP SWITCH TRANS OIL TEMP SWITCH ENGINE OIL PRESS SWITC LOW FUEL LEVEL AIR FILTER VAC. SWITCH FILTER BYPASS
600
TRANS OIL TEMP
404 403 408 402 413
ENGINE OIL PRES LOW FUEL LEVEL AIR FILTER FILTER BYPASS MAIN BEAM
43 45 47
TURN SIGNAL
37 39 40 42 36 38 41
44 46 48
WARNING LIGHTS
407
HEADLIGHT LED RELAY
50 49 52
411 411B 106 887
ENGINE SHUT DOWN
51
ALTERNATOR
53
80 - 15 - 01/6B
FUSE A8
54
814 HORN SWITCH (BUTTON) 855
55
A8
110J 116
1
FRONT HORN
57 58
FUSE A9
Teletruk
FUSE A10 303

1
A9
885
56
3 2
2
8 7
F/W/L SWITCH 894
A10 59
BEACON SWITCH
BEACON
60
3 2
2
837
001A
106 310 106F HAZARD SWITCH

8 10
001K
HAZARD SWITCH LH REAR INDICATOR

805
65 64
LH FRONT INDICATOR
62
INDICATOR SWITCH
DIR.IND LED RELAY
63
61
17
803
67
RH FRONT INDICATOR
5
68
FUSE C3 300 FUSE C1 FUSE C2 108D

3
C3
104
66
804
18 49a 1 31
806 802
2
RH REAR INDICATOR
49 C2
FLASHER UNIT
71
BRAKE LIGHT
816 BRAKE LIGHTS SWITCH
C2 C1
70
72
BRAKE LIGHT
F4
30A
IGNITION RELAY 2
IGNITION RELAY 2
84 85
82
F1 60A
ROAD LIGHTS RELAY
F4
69
78
FUSE B2
007
6 6
75
FUSE B1
B1
103
74
863
3 2 1
2 2
ROOF WASHER AND REAR WASHER PUMP M

862 REAR W/W SWITCH
8 7
REAR WIPER
73
6 6
864 103
B2
110
77
839
3 2 1
2
FRONT WASHER PUMP M

840 FRONT W/W SWITCH
8 7
FRONT WIPER
76
841 303
LIGHTS RELAY
83
C4
79
8
2
H/LIGHT FLASH
837
LH MAIN BEAM
81
836 106 833
FUSE C4
RH MAIN BEAM 6 5
FUSE C5 009 832 828 DIP SWITCH
LH DIP BEAM
C5
829
86
834
RH DIP BEAM 2
FUSE C6
1
C6C7
ROAD LIGHTS SWITCH 310
80
3
830
7
FUSE C7
87
LH TAIL LIGHT
88 89 90
LH SIDE LIGHT
RH TAIL LIGHT RH SIDE LIGHT LIGHT SWITCH
3400 - C/3-3C.1
001A FUSE B5 FUSE B6 FUSE B9
FUSE B3
92
FUSE B4
B3
303A 304
91
601 859 SPEAKER
INTERIOR LIGHT
RADIO
B4
B5
102 106
93
5 2 4
95
96
800
800B
3
HEATER SWITCH
2
HEATER MOTOR
94
8
HEATER RESISTOR
From m/c no. 788644
B6
114E M
800B
99
600EG
FACE FAN
97
98
FACE FAN SWITCH
80 - 15 - 01/6B
B9
001K 114E
125A
971
100
125C
101
AUX BUTTON 1
125B
AUX SOLENIOD 1 SOL1
102
972
103
AUX BUTTON 2
AUX SOLENIOD 2
125D
104
105
Issue 1
SOL1
CONTENTS
Teletruk
80 - 15 - 01/6C
All Models Circuit Diagrams - Electrical Main Components (Diesel Engine, Single Pedal) (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 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Battery Key Switch Glow Plugs Glow Plugs Glow Plugs Glow Plugs Starter Solenoid Starter Motor Neutral Start Relay Ignition 1 Relay Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Rear Work Light Reverse Relay Reverse Alarm Buzzer Engine Shut Off Solenoid - Relay Engine Shut Off Solenoid Electronic Brake Control Unit Park Brake Switch Electric Displacement Control (Pump Swash Operation) Susmic S1X Pluse Pick-up (Pump Speed Sensor) Forward/Reverse Selector Switch Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal Throttle Motor Actuator (Engine Revs) Hourmeter Master Warning LED Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Low Fuel Level Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Low Fuel Level Air Filter Vacuum Switch Filter Bypass Information Display Centre Buzzer Head Light LED Mini Relay Alternator Engine Shut Down Solenoid Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch Right Hand Front Work Light 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105
From m/c no. 788644
Left Hand Front Work Light Beacon Switch Beacon Motor/Light Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Left Hand Indicator (Rear) Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Flasher Unit Ignition Relay 2 Brake Light Switch Left Hand Brake Light Right Hand Brake Light Rear Wash/Wipe Switch Roof and Rear Washer Pump Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Road Lights Relay Road Lights Switch Head Light Flash Switch Dip Switch Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light and Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor Auxiliary 1 Valve Switch Auxiliary 1 Valve Relay Auxiliary 1 Valve Solenoid Auxiliary 2 Valve Switch Auxiliary 2 Valve Relay Auxiliary 2 Valve Solenoid
Primary Fuses
F1 Roadlights Relay Supply (optional) F2 Ignition Relay 1 Supply F3 Key Switch F4 Starter Relay 2 Supply Note: For bulb and fuse ratings see pages 80 - 05 - 01/1 and 80 - 05 - 01/2. (LEDs not service part)
9804/1103
80 - 15 - 01/6C
3400 - C/3-3B.1
Issue 1
CONTENTS
Teletruk
* M/c 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 77A 78 78A Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Head Light Flash Switch Road Lights Relay Road Lights Switch Dip Switch Interior Light Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor Reverse Relay Reverse Microswitch Forward Relay Forward Microswitch
80 - 15 - 01/7
* All
Models Circuit Diagrams - Electrical Main Components (Diesel Engine, Twin Pedal)
1 2 3 4 5 6 7 8 9 10 11 12 13 13A 14 15 16 16A 17 18 19 21 22 23 24 25 26 27A 27B 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 44A 45 46 47 48 49 50 51 52 53 54 55 56 57 58 Battery Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Solenoid Key Switch Glow Plugs Glow Plugs Glow Plugs Glow Plugs Starter Solenoid Starter Motor Neutral Start Relay Starter Relay Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Reverse Alarm Relay Reverse Alarm Buzzer Engine Shut Off Solenoid Electronic Brake Control Unit Park Brake Switch EDC (Pump Swash Operation) Susmic 12 PPU (Pump Speed Sensor) Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal SAS Actuator (Engine Revs) Clock (IDC Internal) Hourmeter (IDC Internal) Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Low Fuel Oil Level Air Filter Vacuum Switch Filter Bypass IDC Buzzer Head Light LED Mini Relay Alternator Alternator Resister Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch Beacon Switch Beacon Motor Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Flasher Unit Brake Light Switch Ignition Relay 2 Roof and Rear Screen Washer Motor Rear Wash/Wipe Switch
Nos. 788001 to 788643
Lamps
80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 Rear Work Light Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Low Fuel Level Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam Warning LED Indicator Warning LED Right Hand Front Work Light Left Hand Front Work Light Beacon Lamp Left Hand Indicator (Rear) Hazard Switch Warning LED Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light
Primary Fuses
9804/1103
80 - 15 - 01/7
3400 - C/3-5.2
Issue 4*
CONTENTS
*
Teletruk
* M/c
80 - 15 - 01/8
All Models Circuit Diagrams - Electrical Main Components (Diesel Engine, Twin Pedal)
Nos. 788001 to 788643
600 21 9 11 13A 13 10 12 16 16A 19 22 25 401
1 14
18
24
23 78 27A 27B 29 A4 77A 78A 26 28 30 31 32 33
17 8 15 F2 A1 A6 A5 F3 A2 A3
77
9804/1103
80 - 15 - 01/8
3400 - C/3-4.1
Issue 2*
CONTENTS
*
Teletruk
* M/c
80 - 15 - 01/9
All Models Circuit Diagrams - Electrical Main Components (Diesel Engine, Twin Pedal)
no.s 788001 to 788643
37 39 41 36 38 40 53 91 44 47 92 50 94 93 96 C4 35 44A 34 42 82 84 86 88 90 81 83 85 87 89 45 46 51 48 49 52 54 55 58 61 66 71 43 B8 A7 B7 95 A8 A9 A10 C3 C2 C1 56 B5 F1 B6 B9 B1 B2 65 B3 B4 74 64 2 5 C6 67 C7 72 75 C5 98 97 99 100 57 60 62 63 101 103 102 104 105 106 108 70 107 68 73 69 109 3 6 76 4 7
9804/1103
80 - 15 - 01/9
3400 - C/3-6.1
Issue 2*
1
600 BATTERY
Circuit Diagrams - Electrical Main Components (Diesel Engine, Twin Pedal)
9804/1103
003
310A
CONTENTS
All Models
1 9
F1
F2
2 7
KEY SWITCH
40A F3
6 5 3
GLOW PLUGS
60A
310B
30A 30A
40A
7 8
F4
80A
004 842 001
F3 F5
10
NEUTRAL START RELAY
1(6) 2(7)
30A
002
IGNITION RELAY 1
11
F2
IGNITION RELAY 1 S.L.I. UNIT FUSE A1 974
001A
4(9)
5(10)
3(8)
MICRORELAY BASE CONNECTIONS
S.L.I.
A1
463 464
13
80 - 15 - 01/9A
2
A6 12
009 861
FUSE A6
TRANSDUCER
Teletruk
14
3
861A
REAR WORKLIGHT
2
1
1 8
15
807 FUSE A2 107E
REVERSE RELAY 807
16
REVERSE HORN
FUSE A3 105
A2 A3
122 122 FUSE A5
17
E.S.O.S
A5 19
122F 897
3 2 4 1 5
22
600JY 418 420 417J 808 842B 416J
1 2 3 4 5 6
REVERSE MICROSWITCH REVERSE RELAY

122G 896
8 6 9 10 7
FOWARD MICROSWITCH
AUX
18
600AB
HANDBRAKE EARTH
600AC 809E 817 130A 600HG
20
FUSE A4 130 401
25
1 +BATTERY
21
FOWARD RELAY
2 -BATTERY
600HJ 416 417 808 418
HANDBRAKE SWITCH
3 CHASSIS
23
4 -SENSOR 5 +SENSOR
A B
6 BID OUT 1
24
419 401J 809E 130B 431 RED GREEN BLACK 416A 130C
7 BID OUT 2
PPU
A4
3 1 4
8 DIG INP 1.2 9 DIG INP 1.0 10 +BATTERY 11 PPU/IN 0 12 IGNITION 13 SENSOR-
26 29 31
ELEVATION
421 422 423
14 PPU/IN 1 15 DIG INP 1.3
27
16 RXD
TILT
30 28
423 422 429
17 TXD
424 425 426 427 416B 417A 417B 428 429 808F 430
18 AN.IN ACHO 19 AN.IN ACH1 20 D OUT 0 21 D OUT 1 22 SENSOR 23 SENSOR + 24 SENSOR + 25 AN.IN ACH3 26 RS232 GND 27 DIG.INP1.1 28 AN.IN ACH2
3400 - C/3-6A.1 Issue 1
1 2 3 4 5 6 7 8 9
ACCELERATOR
32
PEDAL
A B C
33
INCH/BRAKES PEDAL
C B C A
34
SAS ACTUATOR
417G 428 416G 426 427
From m/c n. 788644
1 2 3 4 5 6
80 - 15 - 01/9A
35
1 3 2
FUSE B8 106V
Circuit Diagrams - Electrical Main Components (Diesel Engine, Twin Pedal)
9804/1103
HOURS COUNTER
FUSE A7
MASTER W/LIGHT
CONTENTS
All Models
B8
106
36 37
A7
MASTER W/LIGHT ALTERNATOR HAND BRAKE
401 406
WATER TEMP
600
TRANS OIL TEMP
404 403 408 402 413 407
ENGINE OIL PRES LOW FUEL LEVEL AIR FILTER FILTER BYPASS MAIN BEAM TURN SIGNAL
47 49 51 48 50 52
WARNING LIGHTS
HEADLIGHT LED RELAY
39 42 40 45 41 43 44 46 53 38
411 411B
54
106 887
56
ENGINE SHUT DOWN
55
ALTERNATOR
57
80 - 15 - 01/9B
FUSE A8
58
59
A8
110J 116
1
FRONT HORN
61
FUSE A9
62
Teletruk
FUSE A10 303

1
A9 60
3 2
2
885
8
F/W/L SWITCH
894
BEACON
64
A10
BEACON SWITCH
63
3 2
2
837
001A
106 310 HAZARD SWITCH

8 10 17 5
001K FUSE C3 300 FUSE C1

3
HAZARD SWITCH
68
106F
LH REAR INDICATOR
69
805
LH FRONT INDICATOR
66
INDICATOR SWITCH
DIR.IND LED RELAY
67
65
804
18
803
70
RH FRONT INDICATOR
C3
104
71
806
49a 1 31
RH REAR INDICATOR
72
802
2
49 C2
FLASHER UNIT
75
C1
FUSE C2 108D BRAKE LIGHTS SWITCH 816
BRAKE LIGHT
73
76
BRAKE LIGHT
F4
30A
IGNITION RELAY 2
IGNITION RELAY 2
74
F1 60A
007
6 6
FUSE B1
FUSE B2
2
B1
103
863
3 2 1
2 2
79 78
862 REAR W/W SWITCH

8 7
REAR WIPER
77
864 103
6 6
B2
110 ROAD LIGHTS RELAY
1
839
3 2 1 8 7
FRONT WASHER PUMP M

82 81
FRONT WIPER
80
841 303
LIGHTS RELAY
87
C4
84
8
2
H/LIGHT FLASH
837
LH MAIN BEAM
83
836
FUSE C4
RH MAIN BEAM
86
106
833
88 89
009
832
DIP SWITCH
FUSE C5
LH DIP BEAM
C5
85
90
828
829
834
RH DIP BEAM 2 7
FUSE C6 830
3400 - C/3-6C.1
007 001A
C6 C7
FUSE C7
91 92 94 93
FUSE B3
96
FUSE B4
B3
303A
95
INTERIOR LIGHT
B4
304 601
RADIO
98
859
97
5 2 4
FUSE B5
102
103
101
FUSE B6
106
FUSE B9
B5
102 106
SPEAKER
6
M
100
800
800B
3
HEATER SWITCH
2
HEATER MOTOR
99
HEATER RESISTOR
From m/c n. 788644
B6
114E M
800B
600EG FACE FAN SWITCH
FACE FAN
80 - 15 - 01/9B
B9
001K 114E
FACE FAN
125A 971
105
104
125C
AUX BUTTON 1
125B
AUX SOLENIOD 1 SOL1
108
972
107
AUX BUTTON 2
125D
109
Issue 1
AUX SOLENIOD 2 SOL1
CONTENTS
Teletruk
80 - 15 - 01/9C Fromm m/c no. 788644
All Models Circuit Diagrams Electrical Main Components From No. 788644 (Diesel Engine, Twin Pedal)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Battery Key Switch Glow Plugs Glow Plugs Glow Plugs Glow Plugs Starter Solenoid Starter Motor Neutral Start Relay Ignition 1 Relay Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Rear Work Light Reverse Alarm Relay Reverse Alarm Buzzer Engine Shut Off Solenoid Reverse Microswitch Reverse Relay Forward Microswitch Forward Relay Electronic Brake Control Unit Park Brake Switch Electric Displacement Control (Pump Swash Operation) Susmic 12 Pulse Pick-up (Pump Speed Sensor) Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal Throtle Motor Actuator (Engine Revs) Hourmeter Master Warning LED Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Low Fuel Level Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam Warning LED Indicator Warning LED Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Low Fuel Level Air Filter Vacuum Switch Filter Bypass Information Display Centre Buzzer Head Light LED Mini Relay Alternator Engine Shut Down Solenoid Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109
Right Hand Front Work Light Left Hand Front Work Light Beacon Switch Beacon Motor/Light Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Left Hand Indicator (Rear) Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Flasher Unit Brake Light Switch Ignition Relay 2 Left Hand Brake Light Right Hand Brake Light Rear Wash/Wipe Switch Rear and Roof Washer Motor Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Head Light Flash Switch Road Lights Relay Road Lights Switch Dip Switch Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light and Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor Auxiliary 1 Valve Switch Auxiliary 1 Valve Relay Auxiliary 1 Valve Solenoid Auxiliary 2 Valve Switch Auxiliary 2 Valve Relay Auxiliary 2 Valve Solenoid
Primary Fuses
F1 Roadlights Relay Supply (optional) F2 Ignition Relay 1 Supply F3 Key Switch F4 Starter Relay 2 Supply Note: For bulb and fuse ratings see pages 80 - 05 - 01/1 and 80 - 05 - 01/2. (LEDs not service part).
3400 - C/3-6B.1
9804/1103
80 - 15 - 01/9C
Issue 1
CONTENTS
* All
Teletruk
*
80 - 15 - 01/10
Models
58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76
M/c Nos. 788001 to 788643
Circuit Diagrams - Electrical Main Components (LPG Engine, Single Pedal)

1 2 3 4 5 6 7 8 9 10 13 13A 14 15 16 16A 17 18 19 20 22 23 24 25 26 27A 27B 28 29 30 31 32 33 34 35 36 37 38 40 41 42 43 44 44A 45 46 47 48 49 50 51 52 53 54 55 56 57 Battery Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Solenoid Key Switch Distributor Ignition Coil Starter Solenoid Starter Motor Neutral Start Relay Starter Relay Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Reverse Relay Reverse Alarm Buzzer Coil Relay Electronic Brake Control Unit Park Brake Switch EDC (Pump Swash Operation) Susmic 12 PPU (Pump Speed Sensor) Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal SAS Actuator (Engine Revs) Clock (IDC Internal) Hourmeter (IDC Internal) Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Air Filter Vacuum Switch Filter Bypass IDC Buzzer Head Light LED Mini Relay Alternator Alternator Resister Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch Beacon Switch Beacon Motor Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Flasher Unit Brake Light Switch Ignition Relay 2 Roof and Rear Screen Washer Motor Rear Wash/Wipe Switch Rear Washer Motor Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Head Light Flash Switch Road Lights Relay Road Lights Switch Dip Switch Interior Light Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor
Lamps
80 81 82 83 84 85 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 Rear Work Light Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam Warning LED Indicator Warning LED Right Hand Front Work Light Left Hand Front Work Light Beacon Lamp Left Hand Indicator (Rear) Hazard Switch Warning LED Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light
Primary Fuses
9804/1103
80 - 15 - 01/10
3400 - C/3-8.2
Issue 2*
CONTENTS
*
Teletruk
* M/c
80 - 15 - 01/11
All Models Circuit Diagrams - Electrical Main Components (LPG Engine, Single Pedal)
nos. 788001 to 788643
9 13A 13 80 16 16A 19 10 22
25
18 1 14
20
24
23 17 A1 8 15 A6 A5 A4 A2 A3 26 27A 27B 30 31 32 33
29 28
9804/1103
3400 - C/3-7.1
80 - 15 - 01/11
Issue 2*
CONTENTS
* All
Teletruk
* M/c
80 - 15 - 01/12
Models
nos. 788001 to 788643
Circuit Diagrams - Electrical Main Components (LPG Engine, Single Pedal)
37 41 36 38 40 94 50 93 96 53 99 98 97 100 57 60 62 63 101 103 102 104 105 107 68 106 108 109 69 70 35 44A 34 82 84 88 90 81 83 85 87 89 42 45 46 51 48 49 52 54 55 58 61 66 71 95 A8 A7 B7 43 A9 A10 C3 C2 C1 56 F4 F1 B1 B2 65 B3 B4 74 64 C8 C7 67 72 75 73 76
44
47
91 92
B5
B6
B9
9804/1103
3400 - C/3-9.1
CONTENTS
80 - 15 - 01/12
Issue 2*
CONTENTS
Teletruk
80 - 15 - 01/12A
All Models Circuit Diagrams - Electrical Main Components (LPG Engine, Single Pedal)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 Battery Key Switch Ignition 1 Relay Neutral Start Relay Starter Solenoid Starter Motor Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Rear Work Light Reverse Relay Reverse Alarm Buzzer Coil Relay Ignition Coil Distributor To Ignition Module To Tachometer To Ignition Module Electronic Brake Control Unit Park Brake Switch Electric Display Centre (Pump Swash Operation) Susmic 12 Forward/Reverse Selector Pulse Pick-up (Pump Speed Sensor) Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal Throttle Motor Actuator (Engine Revs) Hourmeter Master Warning LED Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Low Fuel Level Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam LED Direction Indicator LED Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Low Fuel Level Air Filter Vacuum Switch Filter Bypass Information Display Centre Buzzer Head Light LED Mini Relay Alternator Engine Shut Down Solenoid Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch Right Hand Front Work Light Left Hand Front Work Light Beacon Switch 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107
From m/c no. 788644
Beacon Motor/Light Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Left Hand Indicator (Rear) Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Flasher Unit Ignition Relay 2 Brake Light Switch Left Hand Brake Light Right Hand Brake Light Rear Wash/Wipe Switch Roof and Rear Washer Pump Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Road Lights Relay Road Lights Switch Head Light Flash Switch Dip Switch Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light and Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor Auxiliary 1 Valve Switch Auxiliary 1 Valve Relay Auxiliary 1 Valve Solenoid Auxiliary 2 Valve Switch Auxiliary 2 Valve Relay Auxiliary 2 Valve Solenoid
Primary Fuses
F1 Roadlights Relay Supply (optional) F2 Ignition Relay 1 Supply F3 Key Switch F4 Starter Relay 2 Supply Note: For bulb and fuse ratings see page 80 - 05 - 01/1 and 80 - 05 - 01/2. (LEDs not service part)
9804/1103
80 - 15 - 01/12A
3400 - C/3-9B.1
Issue 1
1
600 BATTERY
Circuit Diagrams - Electrical (contd) Main Components (LPG Engine, Single Pedal)
9804/1103
310A
CONTENTS
1 9 4 3
KEY SWITCH
All Models
F1
2 6 5 7
F2
40A F3
2
310B
60A 30A 40A
30A
5 6
F4
80A
004 842 001
F3
STARTER MOTOR
F5
STARTER SOLENOID
3
NEUTRAL START RELAY
3400 - C/3-9A.1
30A
002
IGNITION RELAY 1
F2
001A IGNITION RELAY 1 S.L.I. UNIT FUSE A1 974
S.L.I.
A1
463 464 REAR WORKLIGHT SWITCH
A6 8
2
009 861
FUSE A6
TRANSDUCER
Teletruk
10
3
861A
REAR WORKLIGHT
2
1
1 8
7
807
80 - 15 - 01/12B
11
FUSE A2 107E REVERSE RELAY 807 FUSE A3 105
12
REVERSE ALARM
A2 16
COIL RELAY
17
SECONDARY
DISTRIBUTOR
13
18
TO IGN MODULE TO TACHO TO IGN MODULE APPLIED
PRIMARY
15
14
IGNITION COIL
A3
FUSE A5
19
122
122 600JY 418 420 417J 416J
1 2 3 4 5 6
FUSE A4 600HG 600HJ 416 417 808 401 HANDBRAKE SWITCH 418
PPU
24
A5 A4
130
HANDBRAKE EARTH
22
130A
1 +BATTERY 2 -BATTERY 3 CHASSIS 4 -SENSOR 5 +SENSOR 6 BID OUT 1
21
A B
20 23
RED GREEN BLACK
419 401J 809E 842B 808 130B 431 130C 416A
7 BID OUT 2 8 DIG INP 1.2 9 DIG INP 1.0 10 +BATTERY 11 PPU/IN 0
F N R
3 1 4
12 IGNITION 13 SENSOR-
ELEVATION
421 422
14 PPU/IN 1 15 DIG INP 1.3 16 RXD
SUSMIC 12
25
423
17 TXD
28
AUX
27 29
TILT
424 425 426 427 416B 423 422 417A 417B 428 429 429 808F 430
18 AN.IN ACHO
26
ACCELERATOR
30
PEDAL INCH/BRAKES PEDAL

31 32
1 2 3 4 5 6 7 8 9
A B C C B A
417G 428
SAS
416G 426 427
From m/c no. 788644
ACTUATOR
1 2 3 4 5 6
Issue 1
80 - 15 - 01/12B
FUSE B8 106V BULKHEAD CONNTR
1 3 2
33
HOURS COUNTER
B8
Circuit Diagrams - Electrical (contd) Main Components (LPG Engine, Single Pedal)
9804/1103
FUSE A7
MASTER W/LIGHT
CONTENTS
All Models
106
34
A7
MASTER W/LIGHT
35 36
401
ALTERNATOR
45
WATER TEMP SWITCH
37
406
46
TRANS OIL TEMP
38
404
TRANS OIL TEMP SWITCH ENGINE OIL PRESS SWITC LOW LPG FUEL AIR FILTER VAC. SWITCH FILTER BYPASS
600
39 47
403 408
ENGINE OIL PRES
40
LOW FUEL LEVEL AIR FILTER
WARNING LIGHTS
48 49
41
402
50
42
413 407
3400 - C/3-9C.1
FILTER BYPASS
43 44
MAIN BEAM TURN SIGNAL
HEADLIGHT LED RELAY
52 54
106 411 411B
ENGINE SHUT DOWN
51
887
53
ALTERNATOR
55
FUSE A8
57
56
A8
110J 116
1
FRONT HORN
59
FUSE A9
60
Teletruk
A9 58
885
80 - 15 - 01/12C
3 2
2
8
F/W/L SWITCH
FUSE A10 303

1
894
BEACON
62
A10
BEACON SWITCH
61
3 2
2
837
001A
106 310 HAZARD SWITCH

8 10 17 5
001K FUSE C3 FUSE C1 300

3
HAZARD SWITCH
66
106F
LH REAR INDICATOR
67
805
LH FRONT INDICATOR
64
INDICATOR SWITCH
DIR.IND LED RELAY
65
63
803
68
RH FRONT INDICATOR
C3
104
69
804
18 49a 1 31
806 802
2
RH REAR INDICATOR
70
49 C2
FLASHER UNIT
73
C1
FUSE C2 108D 816
BRAKE LIGHT
C2
BRAKE LIGHTS SWITCH
72
74
BRAKE LIGHT
F4
30A
IGNITION RELAY 2
IGNITION RELAY 2
71
007
6 6
FUSE B1
FUSE B2
B1
103
76
863
3 2 1
2 2
77
862 REAR W/W SWITCH

8 7
REAR WIPER
75
864 103
6 6
B2
110
79
839
3 2 1
2
FRONT WASHER PUMP M
80

8
FRONT WIPER
30
78
841 303
LIGHTS RELAY
85
C4
H/LIGHT FLASH
837
LH MAIN BEAM
81
8
2
86
836 106 833
83 84
FUSE C4
RH MAIN BEAM 6 5
FUSE C5 009 832 DIP SWITCH
87
LH DIP BEAM
C5
88
82
F1 60A
828
829
834
RH DIP BEAM 2
ROAD LIGHTS RELAY
1
FUSE C6 830
FUSE C7
89 90 91 92
FUSE B3
FUSE B4 001A
B3
303A
93
INTERIOR LIGHT
B4
304 602
94
RADIO
601
96
860
859
5 2 4
FUSE B5
101
100
FUSE B6
104
FUSE B9
B5
102 106
RH SPEAKER
LH SPEAKER
6
800
800B
95
95
M
98
3
HEATER SWITCH
2
HEATER MOTOR
97
HEATER RESISTOR
From m/c no. 788644
B6
114E M
800B
600EG
FACE FAN
99
FACE FAN SWITCH
FACE FAN
80 - 15 - 01/12C
B9
001K 114E
103
102
125A 125C
971
AUX BUTTON 1
125B
AUX SOLENIOD 1 SOL1
106
972
105
AUX BUTTON 2
125D
107
AUX SOLENIOD 2 SOL1
Issue 1
CONTENTS
Teletruk
* M/c
80 - 15 - 01/13
* All
Models
nos. 788001 to 788043
Circuit Diagrams - Electrical Main Components (LPG Engine, Twin Pedal)

1 2 3 4 5 6 7 8 9 10 13 13A 14 15 16 16A 17 18 19 22 23 24 25 26 27A 27B 28 29 30 31 32 33 34 35 36 37 38 40 41 42 43 44 44A 45 46 47 48 49 50 51 52 53 54 55 56 57 58 Battery Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Solenoid Key Switch Distributor Ignition Coil Starter Solenoid Starter Motor Neutral Start Relay Starter Relay Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Reverse Alarm Relay Reverse Alarm Buzzer Electronic Brake Control Unit Park Brake Switch EDC (Pump Swash Operation) Susmic 12 PPU (Pump Speed Sensor) Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal SAS Actuator (Engine Revs) Clock (IDC Internal) Hourmeter (IDC Internal) Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Air Filter Vacuum Switch Filter Bypass IDC Buzzer Head Light LED Mini Relay Alternator Alternator Resister Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch Beacon Switch Beacon Motor Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Flasher Unit Brake Light Switch Ignition Relay 2 Roof and Rear Screen Washer Motor Rear Wash/Wipe Switch 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 77A 78 78A Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Head Light Flash Switch Road Lights Relay Road Lights Switch Dip Switch Interior Light Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor Reverse Relay Reverse Microswitch Forward Relay Forward Microswitch
Lamps
80 81 82 83 84 85 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 Rear Work Light Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam Warning LED Indicator Warning LED Right Hand Front Work Light Left Hand Front Work Light Beacon Lamp Left Hand Indicator (Rear) Hazard Switch Warning LED Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light
Primary Fuses
9804/1103
80 - 15 - 01/13
3400 - C/3-11.2
Issue 2*
CONTENTS
*
Teletruk
*
80 - 15 - 01/14
All Models Circuit Diagrams - Electrical Main Components (LPG Engine, Twin Pedal)
M/c nos. 788001 to 788643
25 13A 13 80 16 16A 10 19 9 22
1 14
24 18
17 8 15
77
23 78 27A 27B 30 31 32 33
26 77A 78A
29 28
9804/1103
3400 - C/3-10.2
80 - 15 - 01/14
Issue 2*
CONTENTS
*
Teletruk
* M/c
80 - 15 - 01/15
nos. 788001 to 788643
41 37 36 38 40 53 91 44 47 92 50 94 93 96 98 100 97 99 57 60 62 63 101 103 102 104 107 105 68 106 108 109 73 69 76 3 6 70 4 7
35 44A 42 82 84 88 90 81 83 85 87 89 34 46 45 48 49 67 95 52 54 55 58 61 66 71 51 43 65 74 64 75 2 5 72
56
9804/1103
3400 - C/3-12.2
80 - 15 - 01/15
Issue 2*
CONTENTS
Teletruk
80 - 15 - 01/15A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Battery Key Switch Ignition 1 Relay Neutral Start Relay Starter Solenoid Starter Motor Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Rear Work Light Reverse Relay Reverse Alarm Buzzer Ignition Coil Distributor To Ignition Module To Tachometer To Ignition Module Electronic Brake Control Unit Park Brake Switch Electric Display Centre (Pump Swash Operation) Susmic Reverse Microswitch Reverse Relay Forward Microswitch Forward Relay Pulse Pick-up (Pump Speed Sensor) Lift Sensor Lower Sensor Auxiliary Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal Throttle Motor Actuator (Engine Revs) Hourmeter Master Warning LED Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Low Fuel Level Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam LED Direction Indicator LED Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Low Fuel Level Air Filter Vacuum Switch Filter Bypass Information Display Centre Buzzer Head Light LED Mini Relay Alternator Engine Shut Down Solenoid Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109
From m/c no. 788644
Right Hand Front Work Light Left Hand Front Work Light Beacon Switch Beacon Motor/Light Hazard Switch Indicator Switch Directional Indicator LED Mini Relay Left Hand Indicator (Rear) Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Flasher Unit Ignition Relay 2 Brake Light Switch Left Hand Brake Light Right Hand Brake Light Rear Wash/Wipe Switch Roof and Rear Washer Pump Rear Wiper Motor Front Wash/ Wipe Switch Front Wash Motor Front Wiper Motor Road Lights Relay Road Lights Switch Head Light Flash Switch Dip Switch Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light and Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor Auxiliary 1 Valve Switch Auxiliary 1 Valve Relay Auxiliary 1 Valve Solenoid Auxiliary 2 Valve Switch Auxiliary 2 Valve Relay Auxiliary 2 Valve Solenoid
Primary Fuses
F1 Roadlights Relay Supply (optional) F2 Ignition Relay 1 Supply F3 Key Switch F4 Starter Relay 2 Supply Note: For bulb and fuse ratings see pages 80 - 05 - 01/1 and 80 - 05 - 01/2. (LEDs not service part)
3400 - C/3-12B.1
9804/1103
80 - 15 - 01/15A
Issue 1
1
600 BATTERY 003
Circuit Diagrams - Electrical (contd) Main Components (LPG Engine, Twin Pedal)
9804/1103
310A
CONTENTS
1 9 7 6 5 3
KEY SWITCH
All Models
F1
2
F2
40A F3
2
310B
60A 30A 40A
30A
5 6
F4
80A
004 842 001
F3
STARTER MOTOR
F5
STARTER SOLENOID
3
NEUTRAL START RELAY
3400 - C/3-12A.1
1(6) 2(7)
30A
002
IGNITION RELAY 1
F2
A1
S.L.I. UNIT
001A IGNITION RELAY 1 FUSE A1 974
4(9)
5(10)
3(8)
MICRORELAY BASE CONNECTIONS
S.L.I.
463
464
A6 8
2
009 861
FUSE A6
TRANSDUCER
Teletruk
10
3
861A
REAR WORKLIGHT
2
1
1 8
7
807
80 - 15 - 01/15B
11
FUSE A2 107E REVERSE RELA Y 807
12
REVERSE HORN
DISTRIBUTOR
SECONDARY
FUSE A3 105
A2
TO IGN MODULE TO TACHO TO IGN MODULE APPLIED
16
15 17
PRIMARY
13
14
A3
FUSE A5
18
122
122 600JY 418 600AB 808 842B 420 417J 416J
23
1 2 3 4 5 6
REVERSE MICROSWITCH
1 4
FOWARD MICROSWITCH
6
AUX
A5 22
122F 897
3 2 5
REVERSE RELAY
HANDBRAKE EARTH
600AC
24
122G 896
8 10 7 9
21
809E 817
130A 600HG
1 +BATTERY 2 -BATTERY
FOWARD RELAY
HANDBRAKE SWITCH
25
600HJ
3 CHASSIS
19
808
416 417 418
4 -SENSOR 5 +SENSOR
A B
20
FUSE A4 130 401
6 BID OUT 1
419 401J 809E 130B 431
7 BID OUT 2
PPU 1
4
26
A4
8 DIG INP 1.2 9 DIG INP 1.0 10 +BATTERY 11 PPU/IN 0
RED GREEN BLACK 416A 130C
12 IGNITION 13 SENSOR-
ELEVATION
421 422
14 PPU/IN 1 15 DIG INP 1.3 16 RXD
27
423
17 TXD
29
30 31
TILT
424
18 AN.IN ACHO
28
423 422 429
425 426 427 416B 417A 417B 428 429 808F 430
ACCELERATOR
32
PEDAL INCH/BRAKES PEDAL

33 34
1 2 3 4 5 6 7 8 9
A B C C B A
417G 428
SAS
416G 426 427
From m/c no. 788644
ACTUATOR
1 2 3 4 5 6
Issue 1
80 - 15 - 01/15B
Circuit Diagrams - Electrical (contd) Main Components (LPG Engine, Twin Pedal)
9804/1103
35
FUSE B8
1 3 2
CONTENTS
All Models
106V
HOURS COUNTER
FUSE A7
MASTER W/LIGHT
B8
106
36
A7
MASTER W/LIGHT
37 38
401
ALTERNATOR
47
39
406
600
48
40
404 403
TRANS OIL TEMP
3400 - C/3-12C.1
41 42
408
49
ENGINE OIL PRES
50
LOW FUEL LEVEL AIR FILTER
WARNING LIGHTS
51
43
402
44
413 407
52
FILTER BYPASS
46
TURN SIGNAL
45
MAIN BEAM
HEADLIGHT LED RELAY
56
54
106 411
411B
ENGINE SHUT DOWN
53
887
55
ALTERNATOR
57
Teletruk
FUSE A8
59
58
814 855
A8
110J HORN SWITCH (BUTTON)
FRONT HORN
61
80 - 15 - 01/15C
FUSE A9 116
1
62
FUSE A10 303

1
A9 60
3 2
2
885
8
F/W/L SWITCH
894
BEACON
64
A10
3 8
63
2
837
001A
106 310
10 5
001K FUSE C3 FUSE C1 300

3
BEACON SWITCH
7 HAZARD SWITCH
68
106F
LH REAR INDICATOR
69
HAZARD SWITCH
805 INDICATOR SWITCH

8
LH FRONT INDICATOR
66
DIR.IND LED RELAY
67
803
65
17
70
RH FRONT INDICATOR
C3
104
71
804
18 49a 1 31
806 802
2
RH REAR INDICATOR
72
49 C2
FLASHER UNIT
75
C1
FUSE C2 108D 816
BRAKE LIGHT
C2
BRAKE LIGHTS SWITCH
74
76
BRAKE LIGHT
F4
30A
IGNITION RELAY 2
IGNITION RELAY 2
73
007
6 6
FUSE B1
FUSE B2
2
B1
103
78
863
3 2 1
2 2
79
862 REAR W/W SWITCH

8 7
REAR WIPER
77
864 103
6 6
B2
110
81
839
3 2 1 8 7
FRONT WASHER PUMP M
82
FRONT WIPER
80
841 303
LIGHTS RELAY
87
C4
83
8
2
H/LIGHT FLASH 836 106 833
837
LH MAIN BEAM
88
85 86
FUSE C4
RH MAIN BEAM 6 5
F1 60A
ROAD LIGHTS RELAY
89
009
832 828
DIP SWITCH
FUSE C5
LH DIP BEAM
C5
829
90
834
RH DIP BEAM 2
FUSE C6
1
C6 C7
84
3
830
7
FUSE C7
91 92 93 94
FUSE B3
FUSE B4 007 001A
B3
303A
95
INTERIOR LIGHT
B4
304
96
RADIO
601 859
98
5 2 4
FUSE B5
102
103
FUSE B6
106
FUSE B9
B5
102 106
SPEAKER
6
M
97
100
800
800B
3
HEATER SWITCH
2
HEATER MOTOR
99
HEATER RESISTOR
From m/c no. 788644
B6
114E
101
FACE FAN SWITCH
800B
600EG FACE FAN
FACE FAN
80 - 15 - 01/15C
B9
001K 114E
104
125A
105
971
AUX BUTTON 1
125B
AUX SOLENIOD 1 SOL1
107
125C
108
972
AUX BUTTON 2
125D
109
Issue 1
AUX SOLENIOD 2 SOL1
CONTENTS
Teletruk
80 - 15 - 01/16
All Models S/N 0788001 Onwards Circuit Diagrams - Electrical Main Components (Diesel Engine - TCR)
1 2 3 4 5 6 7 8 9 10 11 12 13 13A 14 15 16 16A 17 18 19 20 21 22 23 24 25 26 * 27 * 27A * 27B 28 29 30 31 32 33 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 54 55 56 58 Battery Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Auxiliary Valve Switch Auxiliary Valve Relay Auxiliary Valve Solenoid Key Switch Glow Plugs Glow Plugs Glow Plugs Glow Plugs Starter Solenoid Starter Motor Neutral Start Relay Starter Relay Moment Load Indicator Moment Load Indicator - Transducer Rear Work Light Switch Reverse Relay Reverse Alarm Buzzer Engine Shut Off Solenoid - Relay Engine Shut Off Solenoid Park Brake Solenoid Park Brake Switch Proportional Pressure Reducing Valve Susmic 12 PPU (Pump Speed Sensor) 2 Speed/Traction Control Selector Switch 2 Speed/Traction Control Solenoid 2 Speed/Traction Control Pressure Switch Relay FNR Switch Tilt Switch Diagnostic Connector - Psion Accelerator Pedal Brake Pedal Auxiliary Connector Hourmeter Water Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Low Fuel Oil Level Air Filter Vacuum Switch Filter Bypass IDC Buzzer Head Light LED Mini Relay Alternator Horn Switch - Column Horn Switch - Push Horn Front Work Light Switch Beacon Switch Beacon Motor Hazard Switch Indicator Switch Flasher Unit Brake Light Switch Ignition Relay 2 Rear Wipe Switch 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 Rear Wiper Motor Front Wipe Switch Front/Rear Wash Switch Front Wiper Motor Head Light Flash Switch Road Lights Relay Road Lights Switch Dip Switch Interior Light Switch Radio Speaker Heater Blower Switch Heater Blower Resistor Heater Blower Motor Face Fan Blower Switch Face Fan Resistor Face Fan Motor
Lamps
80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 Rear Work Light Alternator Warning LED Hand Brake Warning LED Water Temperature Warning LED Transmission Oil Temperature Warning LED Engine Oil Pressure Warning LED Low Fuel Level Warning LED Air Filter Warning LED Hydraulic Oil Filter Bypass Warning LED Main Beam Warning LED Indicator Warning LED Right Hand Front Work Light Left Hand Front Work Light Beacon Lamp Left Hand Indicator (Rear) Hazard Switch Warning LED Left Hand Indicator (Front) Right Hand Indicator (Front) Right Hand Indicator (Rear) Left Hand Brake Light Right Hand Brake Light Left Hand Main Beam Right Hand Main Beam Left Hand Dip Beam Right Hand Dip Beam Left Hand Tail Light Left Hand Side Light Right Hand Tail Light Right Hand Side Light Interior Light Master Work Light Master Work Light
Primary Fuses
9804/1103
80 - 15 - 01/16
3400 - C/3-14.2
Issue 2*
1
600 BATTERY
Circuit Diagrams - Electrical Main Components (Diesel Engine, TCR)
9804/1103
003
CONTENTS
10
310A
40A
1
KEY SWITCH
11
F1
2
F2
F3
6 5
9 4 3 7
GLOW PLUGS
60A
310B
30A
12
30A
40A
13
F4
80A
004 842 001
13A
F3 F5
15
NEUTRAL START RELAY
14
All Models S/N 0788001 Onwards
3400 - C/3-13.2
30A
IGNITION RELAY 1
002 S.L.I. UNIT FUSE A1 974
16
F2
IGNITION RELAY 1
001A
S.L.I.
A1
463 464 REAR WORKLIGHT SWITCH
A6 17
009 861
16A
FUSE A6
TRANSDUCER
80
Teletruk
4 3
861A
80 - 15 - 01/17
2
1 1 8
REAR WORKLIGHT
19
807 FUSE A2 107E REVERSE RELAY 807
REVERSE ALARM
A3
FUSE A3 105 FUSE A5 122 808 842 FUSE A4 960
A2
444
HANDBRAKE RELAY
18 21
E.S.O.S
22
HANDBRAKE SOLENOID
A5
HANDBRAKE SWITCH 401 130
27A
20
918
23
FLOW DIVIDER SOLENOID
25
S1X ECU 42 PIN

416 809E 808F
A4
1 - SENSOR
PRESSURE SWITCH RELAY
28
2 D IG INP 0 3 D IG INP 1
R
449 959
F N R
1
995 401A 426
4 D IG INP 2 5 D IG INP 3
918
27B
6 3 8
RED WHITE
6 H IGH CURRENT 0 (+)
5
419 421
7 H IGH CURRENT 1 (+) 8 H IGH CURRENT 0 FB (-)
2
2
9 H IGH CURRENT 1 FB (-)
24
27
10 L OW CURRENT 0 FB(-)
NFPE VALVES
11 H IGH CURRENT 1 FB (-) 12 N C
PPU
26
BLACK GREEN UNUSED

429 417 600 431 448
A B C D
13 R S232 GROUND 14 S ENSOR (+) 15 B ATTERY (-) 16 P PU INPUT 0 17 P PU INPUT 1 18 N C 19 N C

423 422 423 422
20 R S232 TXD 21 R S232 RXD 22 H IGH CURRENT 4 (+)

429 418
23 N C 24 H IGH CURRENT 5 (+) 25 N C 26 N C 27 N C

130A
BRAKE PEDAL
1 2 3 4 5 6 7 8 9
30
28 B ATTERY (+)
600
29 B ATTERY (-) 30 N C
425
31 A NALOGUE INPUT 0 32 A NALOG INPUT 1 33 NC 34 NC 35 NC
32
416 425 417 130B FUSE B8
36 NC 37 NC 38 NC 39 NC 40 NC 41 NC 42 BATTERY ( +)
S1X ECU 42 PIN
B8
80 - 15 - 01/17
106V
Issue 2*
35
Circuit Diagrams - Electrical Main Components (Diesel Engine, TCR)
9804/1103
106
CONTENTS
111
A7 36
401 406 404 403 408 402 413
WATER TEMP SWITCH TRANS OIL TEMP SWITCH ENGINE OIL PRESS SWITCH LOW FUEL LEVEL AIR FILTER VAC SWITCH FILTER BYPASS
600
37 39
38 40
83 85 87 110 81 82 84 86 88 90
All Models S/N 0788001 Onwards
3400 - C/3-15.2
41
89
407 411B 106 411
ENGINE SHUT DOWN
42
44
ALTERNATOR
45
310A
47
FRONT HORN
46
814
A8
110J 855 116
1
91
80 - 15 - 01/18
A9
805 806
Teletruk
92
48
2
50
M
894 303
1
BEACON
A10 49
2
93
310
837
106
001K 001A
68
109
B3
303A 304
INTERIOR LIGHT
RADIO
601
69
B4
106F
859
70
HAZARD SWITCH
94
LH REAR INDICATOR
95 51
805
LH FRONT INDICATOR
94
96 97
803
52
RH FRONT INDICATOR
C3
104 802 300
806
RH REAR INDICATOR FLASHER UNIT
54
C1
BRAKE LIGHT
99
108D
816
C2
55
100
56 F4
007
BRAKE LIGHT IGNITION RELAY 2
103
REAR WIPER
58
60
B1 61 B2
110
2
59
M
839 M 840
FRONT & REAR WASHER PUMP FRONT WIPER
63
841 303
101
LIGHTS RELAY
65
2
64
837
LH MAIN BEAM
C4
836 106 009 833 832
102
RH MAIN BEAM
103
C5
LH DIP BEAM
66
C6 C7 67
828
1
F1
001A 102
829 830
834
RH DIP BEAM
104 105
LH TAIL LIGHT
43
310
LH SIDE LIGHT
106 108
107
71 73
M
B5
2
800 106
800B
HEATER MOTOR
72
B6
114E
M
76
600EG 800B
74
125A 004B
FACE FAN
75
971
AUX SOLENOID 1
80 - 15 - 01/18
A355400
B9 5
125C
1258
972 1250
AUX SOLENOID 2
Issue 2*
CONTENTS
Teletruk
80 - 15 - 01/19
All Models Circuit Diagrams - Electrical Main Components (2 Speed Option - Intelligent Transmission)
1 2 3 4 5 6 7 Susmic Mode Selector Switch Forward/Reverse Selector Switch Neutral Isolation Relay Fixed Resistor Relay Brake Pedal Differential Solenoid
From m/c no. 788644
007M
10A FUSE
19 ANALOG INPUT
A4
B6
13 SENSOR -
158
130
STANDARD SUSMIC ECU
23 SENSOR +
10A FUSE
3
F N
918
417A
416A
425
7 600A
2
DIFF LOCK SWITCH
8 6
100
10k
100
416F
417F
425
425A
959
842B
5
960B
C B A
6
600C
600B
417K
STANDARD BRAKE PEDAL FIXED VALUE RESISTOR NETWORK
2.3K
2.7K
416K
443
960
959A
960A
DIFF LOCK SOLENOID 600D
7
A371960
9804/1103
80 - 15 - 01/19
3400 - C/3-16.1
Issue 1
CONTENTS
Teletruk
80 - 15 - 01/20
All Models Circuit Diagrams - Electrical Main Components (2 Speed/Traction Control Option - Intelligent Transmission)
1 2 3 4 5 6 7 Susmic Mode Selector Switch Forward/Reverse Selector Switch Neutral Relay Fixed Resistor Relay Brake Pedal Differential Solenoid
From m/c no. 788644
007M
10A FUSE
19 ANALOG INPUT
B6
13 SENSOR -
A4
158
130
STANDARD SUSMIC ECU
23 SENSOR +
10A FUSE
3
F N
918
417A
416A
425
7 600A
2
DIFF LOCK SWITCH
8 6
100
10k
100
416F
417F
425
425A
959
842B
5 6
600C 960B
C B A
600B
417K
STANDARD BRAKE PEDAL
FIXED VALUE RESISTOR NETWORK
2.3K
2.7K
416K
443
960
959A
960A DIFF LOCK SOLENOID 600D
A371970
9804/1103
80 - 15 - 01/20
3400 - C/3-17.1
Issue 1
CONTENTS
Teletruk
80 - 20 - 01/1
Models to machine No M788390 Circuit Diagrams - Hydraulic

Component Key (To Machine Number M788390) 1 2 3A 3B 4A 4B 4C 4D 5A 5B 5C 6 7 8 9 9A 9B 9C 9D 9E 9F 9G 9H 9J 9K 9L 9M 9N 9P 10A 10B 10C 10D 11 12A 12B 13A 13B 14A 14B 14C 14D 15 16 17 18 19 20 20A 20B 20C 20D 21A 21B 22 Filler/Breather Tank Suction Strainer - Main/Steering Pumps Suction Strainer - Transmission Demand Pump Main Pump Steering Priority Valve Steering Pressure Relief Valve Test Point Test Point Test Point Unloader Valve Steering Ram Hydraulic Steering Unit Valve Block Main Relief Valve Tilt/Crowd Spool Lift Spool Extension Spool Auxiliary 1 Spool Auxiliary 2 Spool Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Tilt/Crowd Ram Tilt/Crowd Ram Hose Burst Check Valve Hose Burst Check Valve Compensation Ram Lift Ram Hose Burst Check Valve Extension Ram Hose Burst Check Valve Quick Release Hoses (If fitted) Quick Release Hoses (If fitted) Quick Release Hoses (If fitted) Quick Release Hoses (If fitted) Auxiliary Ram 1 (If fitted) Auxiliary Ram 2 (If fitted) Cooler Check Valve - 3 Bar Filter Transmission Pump Assembly Pump Charge Valve Forward/Reverse Direction Control Multi-Function Valves Drive Motor and Brake Drive Motor and Brake Park Brake Valve
9804/1103
80 - 20 - 01/1
Issue 2*
CONTENTS
Teletruk
80 - 20 - 01/2
Models to Machine S/N M788390 Circuit Diagram - Hydraulic (continued)
7 1 8 2
S
19
D E X3
5B
20 20A 20B
M3
3A
3B 18
T LS P L2
M4 M5
10C
10D
11 20C
M2
M1
6 5C 4A 4D 4B
EF LS P 4 1 3 2
17 10A 10B 12A 12B

A B L1
20D
22
4C 13B 5A 9
B A B A B A B A B A
13A
P BR
14A 9G 9H 9A 9K 9J 9L 9M 9P 14C 9N 14B
15
21A
16
21B 14D 9B 9C 9D 9E 9F
9804/1103
80 - 20 - 01/2
Issue 2*
CONTENTS
Teletruk
80 - 20 - 01/3
Models to Machine S/N M788390 Circuit Diagram - Hydraulic (continued) Transmission Circuit
IMAGE NOT AVAILABLE AT THIS TIME
9804/1103
80 - 20 - 01/3
Issue 1
CONTENTS
Teletruk
80 - 20 - 01/4
Models from Machine No M788391 Circuit Diagrams - Hydraulic

Transmission and Valve Hydraulic Circuit Component Key The transmission circuit is on page 80-20-01/3 and the valve block circuit is on page 80-20-01/5. Some components have been duplicated, this is to enable the reader to appreciate how the various components fit into the circuit. 1 2 3A 3B 4A 4B 4C 4D 5A 5B 5C 5D 6 7 8 9 9A 9B 9C 9D 9E 9F 9G 9H 9J 9K 9L 9M 9N 9P 10A 10B 10C 10D 11 12A 12B 13A 13B 14A 14B 14C 14D 15 16 17 18 19 Filler/Breather Tank Suction Strainer - Main/Steering Pumps Suction Strainer - Transmission Demand Pump Main Pump Steering Priority Valve Steering Pressure Relief Valve Test Point Test Point Test Point Test Point Unloader Valve Steering Ram Hydraulic Steering Unit Valve Block Main Relief Valve Tilt/Crowd Spool Extension Spool Lift Spool Auxiliary 1 Spool Auxiliary 2 Spool Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Auxiliary Relief Valve Tilt/Crowd Ram Tilt/Crowd Ram Hose Burst Check Valve Hose Burst Check Valve Compensation Ram Lift Ram Hose Burst Check Valve Extension Ram Hose Burst Check Valve Quick Release Hoses (If fitted) Quick Release Hoses (If fitted) Quick Release Hoses (If fitted) Quick Release Hoses (If fitted) Auxiliary Ram 1 (If fitted) Auxiliary Ram 2 (If fitted) Cooler Check Valve - 3 Bar Filter 20 20A 20B 20C 20D 21A 21B 22 Transmission Pump Assembly Pump Charge Valve Forward/Reverse Direction Control Multi-Function Valves Drive Motor and Brake Drive Motor and Brake Park Brake Valve
9804/1103
80 - 20 - 01/4
Issue 1
CONTENTS
Teletruk
80 - 20 - 01/5
Models from Machine S/N M788391 Circuit Diagram - Hydraulic (continued)
9804/1103
80 - 20 - 01/5
Issue 1
CONTENTS
Teletruk
80 - 20 - 01/6
Models from Machine No M788391 Circuit Diagrams - Hydraulic (Contd)

TRANSMISSION & VALVE HYDRAULIC CIRCUIT The schematic below refers to the TCR transmission, see pages 80 - 20 - 01/4 and 80 - 20 - 01/5 for the remainder of the hydraulic circuit. Component Key - TCR 5B 19 20 20A 20B 20C 20D Charge Pressure Test Point Filter Transmission Pump Assembly Pump Charge Valve Proportional Pressure Reducing Valve Multi Function Valves
9804/1103
80 - 20 - 01/6
Issue 1
INDEX
714 and 718 Contents

Page No. General Information Fluids, Lubricants and Capacities General Specification Tyre Specification Static Dimensions Data Electrical Hydraulics Transmission Brakes Fault Finding Hydraulics Transmission * Suspension Circuit Diagrams Electrical Hydraulic 90 - 00 - 01/1 90 - 00 - 01/2 90 - 00 - 01/2 90 - 00 - 01/3,4
90 - 05 - 01/1 90 - 05 - 02/1 90 - 05 - 03/1 90 - 05 - 04/1
90 - 10 - 02/1 90 - 10 - 03/1 90 - 10 - 04/1
90 - 15 - 01/1 90 - 20 - 01/1
9804/1103
Articulated Dump Truck Contents - 1
Issue 2*
CONTENTS
90 - 00 - 01/1
714 and 718 Fluids, Capacities and Lubricants

Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately. Glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10/ 30W Multigrade oil. This should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grades as shown in the lubrication chart. JCB 10W/30 Multigrade should be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended.
* ADT 714 Machine

ITEM Engine Oil -10 to 50 C (14 to 122 F) Transmission Axles Housings (x2) Hubs (x4) Propshaft Centre Bearing Hydraulic Tank Cooling System 16.3 litres (3.58 UK gal) (including filter) 35 Litres (7.7 UK gal) JCB Extreme Performance Engine Oil 15W/40 JCB HP Universal ATF ACEA E3/B3A3 API CH-4/A3 CAPACITY FLUID/LUBRICANT SPECIFICATION
21 Litres (4.6 UK gal) 6 Litres (1.3 UK gal) 3.3 litres (0.73 UK gal)
JCB LS Gear Oil
JCB 15W/40 Multigrade
SAE 15W/40, API CF4/SG
88 litres (19.3 UK gal) 30 Litres (6.6 UK gal)
JCB Hydraulic Fluid HP32 JCB Four Seasons Antifreeze & Summer Coolant & Water (see Coolant Mixture) Diesel Oil (see Types of Fuel) JCB HP Grease
ISO VG32 ASTM D3306-74, BS6580
* *
Fuel System Grease Points 200 litres (44 UK gal)
ASTM D975-66T Nos. 1D, 2D Lithium based
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals. Note: The figure quoted is the service capacity. Use the MAX and MIN marks on the dipstick when refilling the system. Note: If API CH-4 or ACEA E3/B3A3 engine oil is not available, then the engine oil must be changed at 250 hours. Note: JCB Biodegradable Multigrade Hydraulic Fluid is a factory option ONLY. Replenish with JCB Biodegradable Multigrade Fluid. For further information, contact ADT Technical Service.
9804/1103
90 - 00 - 01/1
7160 - 3/27-1 . 2
Issue 2
CONTENTS
90 - 00 - 01/1A
714 and 718 Fluids, Capacities and Lubricants ADT 718 Machine
ITEM Engine Oil -10 to 50 C (14 to 122 F) Transmission Axles Housings (x2) Hubs (x4) Propshaft Centre Bearing Hydraulic Tank Cooling System 16.3 litres (3.58 UK gal) (including filter) 37 Litres (8.1 UK gal) 22 Litres (4.8 UK gal) 7 Litres (1.5 UK gal) 3.3 litres (0.73 UK gal) 88 litres (19.3 UK gal) 33 Litres (7.3 UK gal) JCB 15W/40 Multigrade JCB Hydraulic Fluid HP32 JCB Four Seasons Antifreeze & Summer Coolant & Water (see Coolant Mixture) Diesel Oil (see Types of Fuel) JCB HP Grease SAE 15W/40, API CF4/SG ISO VG32 ASTM D3306-74, BS6580 JCB Extreme Performance Engine Oil 15W/40 JCB HP Universal ATF JCB LS Gear Oil API GL4, MIL-L-2105A ACEA E3/B3A3 API CH-4/A3 CAPACITY FLUID/LUBRICANT SPECIFICATION
ASTM D975-66T Nos. 1D, 2D Lithium based
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals. Note: The figure quoted is the service capacity. Use the MAX and MIN marks on the dipstick when refilling the system. Note: If API CH-4 or ACEA E3/B3A3 engine oil is not available, then the engine oil must be changed at 250 hours. Note: JCB Biodegradable Multigrade Hydraulic Fluid is a factory option ONLY. Replenish with JCB Biodegradable Multigrade Fluid. For further information, contact ADT Technical Service.
9804/1103
90 - 00 - 01/1A
7160 - 3/27-2 . 1
Issue 1
CONTENTS
90 - 00 - 01/2
714 General Specification

Total - Unladen Weight 10140 Kg (22308 lb) Front Axle Rear Axle 6370 kg (14014 lb) 3770 kg (8294 lb) Total - Laden Weight 23140 Kg (50908 lb) 8973 kg (19740 lb) 14167 kg (31167 lb
Note: All the weights given above are with 20.5R25 tyres, fitted, a full fuel tank and the operator in the cab. All rated capacities are based on the criteria of the machine being level and on a firm supporting ground. When the machine is operated in conditions that deviate from these criteria (e.g. on soft or uneven ground, on a slope or when subject to side loads), these conditions shall be taken into account by the operator.
Tyre Pressures
Note: The maximum pressure embossed on the tyre may differ from the pressure stated below. Inflate to pressures below. These are agreed with the tyre manufacturer/s in accordance with the European Tyre and Rim Organisation (ETRTO) standards to satisfy machine stability performance.
FRONT Size 20.5 R25 (Bridgestone) 20.5 R25 (Michelin) 660/55 R25 (Michelin) Ply Bar 2.0 2.1 2.1 lbf/in2 30 31 31 Bar 4.0 3.4 3.4
REAR lbf/in2 59 50 50
Note: If the tyres fitted to your machine are not listed, then contact your JCB Distributor for advice. DO NOT guess the tyre pressures.
9804/1103
90 - 00 - 01/2
7160 - 95
Issue 1
CONTENTS
90 - 00 - 01/3
5 , ) *
. /
4 2
!""'#
9804/1103
90 - 00 - 01/3
7160 - 97
Issue 1
CONTENTS
90 - 00 - 01/4

714 mm A B C D E F G H J K L M N P R S T Overall length Axle to front bumper Wheelbase Axle to end of body Axle to pivot point Wheel track Overall width Height over Cab Load over height Overall operating height Clearance - Body tipped Minimum ground clearance Turning radius (centre wheel) Clearance radius Articulation angle Front clearance angle Body tip angle 6620 2010 3650 960 1250 1955 2500 3180 2340 4275 1000 490 7070 7315 ft 21 6 11 3 4 6 8 10 7 14 3 1 23 24 36 28.5 70 in 8 7 11 2 1 5 2 5 8 3 7 2 -
9804/1103
90 - 00 - 01/4
7160 - 96
Issue 1
CONTENTS
90 - 05 - 01/1
714 and 718 Data - Electrical Fuses

The electrical circuits are protected by fuses. The majority of the fuses are located in the main fuse box CAB REAR to the right of the operators seat, rearward of the right console. The lighting fuse box CAB FRONT is located directly in front of the operators left knee. A set of five primary fuses are located in the battery compartment. For details of how to gain access to the fuses and relays, refer to Accessing the Fuse Locations Operator Handbook . If a fuse ruptures, find out why and rectify the fault before fitting a new one.
+)* 4-)4
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! " # $ % & '
+)* .4 6 + ! " # $
8
+)* 4-)4
.75-5
9
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! CAUTION
Always replace fuses with ones of correct ampere rating to avoid electrical system damage.
8-3-3-5
4- );5
4 4"
4 4#
4! 4$
4%
4&
4' 4
!""$
Primary Fuse Box 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 C9 Circuit Ignition Relay Engine Stop Engine Start Pre-Heat EMS Ignition EMS Battery Back-up Beacon Front Work Lights Tipper Work Light Brake Lamps Reverse Lamp/Alarm Front Wash/Wipe Rear Wash/Wipe Heater/Air Conditioning Radio/Interior Lighting 12-24V Convertor 7.5 Rear Camera Park Brake Transmission Control System Ignition Horn Heated Mirrors Transmission Control System Battery Accessory/Suspension Seat Radio/Cigar Lighter Hydraulic Suspension (ADT 718 machine only) Fuse Rating (Amps) 5 10 25 30 5 5 10 15 7.5 5 5 15 10 30 7.5 10 10 7.5 15 10 7.5 10 10 15
4 4
ADT 714 Machine - Fuse and Relay Layout Decal
CAB REAR
718
A 1 2 3 4 5 6 7 8 9
CAB FRONT C 1 2 3 4 5 6
V
CAB REAR
W
FUSES RELAYS CAB FRONT
R1 R2 R3 R4 R5 R6
R7 R8 R13 R14 R15 R9 R10 R11 R12 R16 R17 R18
Y
354680
ADT 718 Machine - Fuse and Relay Layout Decal Key V W X Y Cab Rear - Fuses Cab Front - Fuses Cab Rear - Relays Cab Front - Relays
Lighting Fuse Box - CAB FRONT Fuse No. C1 C2 C3 C4 C5 C6 Circuit Hazard Lights Direction Indicators Left Sidelights Right Sidelights Dip Beam Main Beam Fuse Rating (Amps) 10 10 10 10 10 10
9804/1103
90 - 05 - 01/1
7160 - C/1-2 . 3
Issue 3*
CONTENTS
90 - 05 - 01/2
714 and 718 Data - Electrical

Pre-heat Fuses (ADT 718 Machine Only) The ADT 718 machine has a set of pre-heat fuses mounted on the right hand side of the engine, just below the starter motor. Fuse No. P1 P2 Circuit Fuse Rating (Amps) 100 100 Primary Fuse Box Fuse No. 1 2 3 4 5 Circuit Fuse Rating (Amps) 50 40 40 80 50
Pre-heat Fuse Pre-heat Fuse
Cab Ancillaries Instrument Cluster Radio/Beacon Alternator Ignition Switch
" # !
2
2
!#"&
!#""!
9804/1103
90 - 05 - 01/2
7160 - C/1-3 . 2
Issue 3
CONTENTS
90 - 05 - 01/3
714 and 718 Data - Electrical Relays - 714 Machine

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R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12
Air Conditioning Blank Blank Start Inhibit Ignition Alarm Mute Hazard Warning Lights Reverse Alarm Latch Relay Shut Down Park Inhibit Lights
%"
! " # $ % & '
+)* .4 6 + ! " # $
8
+)* 4-)4
.75-5
9
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4- );5
4 4"
4 4#
4! 4$
4%
4&
4' 4
!""$
Relays - 718 Machine

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 Key V W X Y Cab Rear - Fuses Cab Front - Fuses Cab Rear - Relays Cab Front - Relays Blank Blank Left Hand Raise Right Hand Lower Left Hand Lower Right Hand Raise Start Inhibit Air Conditioning Ignition Blank Alarm Mute Blank Hazard Warning Lights Reverse Alarm Latch Relay Shut Down Park Inhibit Lights
4 4
CAB REAR
718
A 1 2 3 4 5 6 7 8 9
CAB FRONT C 1 2 3 4 5 6
V
CAB REAR
W
R1 R2 R3 R4 R5 R6
R7 R8 R13 R14 R15 R9 R10 R11 R12 R16 R17 R18
Y
354680
9804/1103
90 - 05 - 01/3
7160 - C/1-4 . 1
Issue 2
CONTENTS
90 - 05 - 01/3A

Accessing the Relay Locations There are two blocks of relays. One block is located in the lighting fuse book CAB FRONT (refer to Accessing the Fuse Locations for details on how to access the lighting fuse box in Operator Handbook). The other block is located in a compartment at the rear of the cab behind the operators seat CAB REAR. To access the rear relay block compartment, proceed as follows: Note: This compartment also provides access to the transmission system diagnostic tool communications port. 1 Stop the engine and remove the ignition key. Isolate the battery by turning the isolator key anti-clockwise. Move the operators seat as far forward as possible. If greater access is required, remove the operators seat completely. Remove the three screws F and lift off the cover G. ADT 714 Fuse and Relay Layout Decal
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8
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9
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4- );5
4 4"
4 4#
4! 4$
4%
4&
4' 4
!""$
4 4
Refer to the Technical Data pages and the Fuse and Relay Layout Decals for details of the relay locations and functions. Replacement is the reverse of removal.
CAB REAR
718
A 1 2 3 4 5 6 7 8 9
CAB FRONT C 1 2 3 4 5 6
. .
/ .
V
CAB REAR
W
R1 R2 R3 R4 R5 R6
R7 R8 R13 R14 R15 R9 R10 R11 R12 R16 R17 R18
X
!#""
Y
354680
ADT 718 Fuse and Relay Layout Decal Key V W X Y Cab Rear - Fuses Cab Front - Fuses Cab Rear - Relays Cab Front - Relays
9804/1103
90 - 05 - 01/3A
7160 - C/20 - 3.1
Issue 1
CONTENTS
90 - 05 - 01/4

System Type
Battery ADT 714 Machine ADT 718 Machine Alternator Starter Motor ADT 714 Machine ADT 718 Machine Batteries (x 2) Batteries (x2) 410 Amps 425 Amps 22SI 24V/70A
28MT Type 171 37-MT/300
Bulbs Bulb Headlights - main Headlights - dipped Indicators Work Lights Number plate light Tail lights Front sidelights Stop lights Beacon Rear Fog Rating (Watts) 70W 70W 21W 70W 5W 6W 14W 24W 70W 21W
9804/1103
90 - 05 - 01/14
7160 - C/1-1.2
Issue 1
CONTENTS
90 - 05 - 01/5

Remove and Replace the Pre-heat Fuses (ADT 718 Machine Only) 1 Stop the engine and remove the ignition key. Isolate the battery by turning the isolator key anti-clockwise. Remove the relevant cover E. Remove the nuts A, washers B (2 off) and the cable ends C and D from the fuse P1 and/or P2 as required. Withdraw the fuse P1 and/or P2.
2 3
Replacement is the reverse of removal. Ensure that the covers E are replaced securely.
+
2
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9804/1103
90 - 05 - 01/5
7160 - C/20 - 2A.1
Issue 1
CONTENTS
90 - 05 - 02/1
714 and 718 Data - Hydraulics

Primary Pump ADT 714 Machine Type Flow at 2200 rev/min. * ADT 718 Machine Type Flow at 2500 rev/min. Secondary Pump ADT 714 Machine Type Flow at 2200 rev/min. * ADT 718 Machine Type Flow at 2500 rev/min. Control Valve Spool 1 Main Relief Valve Operating Pressure * ADT 714 Machine * ADT 718 Machine Steer Relief Valve Operating Pressure ADT 714 Machine * ADT 718 Machine Steering Stand-by Pressure Body Tip bar 175 2 210 bar 175 2 210 bar 14 2 Bore mm 110 110 80 80 80 kgf/cm2 183.5 2.1 214 kgf/cm2 183.5 2.1 214 kgf/cm2 14.7 2.1 Rod Dia. mm in 60 2.36 60 2.36 50 1.97 40 1.57 80 3.15 lbf/in2 2500 29 3050 lbf/in2 2500 29 3050 lbf/in2 203 29 Stroke mm 980 1061 312 312 140
Gear Type 114 L/min. (25 UK gal/min.; 30 US gal/min.)
Gear Type 130 L/min. (28.6 UK gal/min.; 34.3 US gal/min
Gear Type 17.6 L/min. (4 UK gal/min.; 5 US gal/min.)
Gear Tpye 20 L/min. (4.4 UK gal/min; 5.32 UDS gal/min.)
Rams Lift Ram (up to machine serial no. 830032) Lift Ram (from machine serial no. 830033) Steer Ram (ADT 714 machine) (ADT 718 machine) Suspension Ram (ADT 718 machine only) Filter (Return Line) Filtration Size
in 4.3 4.3 3.15 3.15 3.15
in 38.6 41.8 12.3 12.3 5.5
10 Micron
9804/1103
90 - 05 - 02/1
7160 - E/1-1.2
Issue 2
CONTENTS
90 - 05 - 03/1
714 and 718 Data - Transmission

*
Axles
Note: Both the front and rear axles have limited slip differentials fitted as standard. ADT 714 Machine Type Drive Head Ratio Hub Reduction Ratio Overall Reduction ADT 718 Machine Type Drive Head Ratio Hub Reduction Ration Overall Reduction Tyres Standard Pressure Drive Axle - Front Beam with hub reduction 1 : 3.909 1 : 5.167 1 : 21.197 Drive Axle - Front Benam with hub reduction 1 : 4.555 1 : 5.167 1 : 23.538 ADT 714 Machine 20.5 R 25 Bridgestone Front: 2 bar Rear: 4 bar 20.5 R 25 Michelin Front: 2.1 bar Rear: 3.4 bar 660/55 R25 Michelin Front: 2.1 bar Rear: 3.4 bar 750/55 X 26.5 Front: 3.2 bar Rear: 4.0 bar Drive Axle - Rear Beam with hub reduction 1 : 3.909 1 : 5.167 1 : 21.197 Drive Axle - Rear Beam with hub reduction 1 : 4.555 1 : 5.167 1 : 23.538 ADT 718 Machine 650/65 R25 Michelin Front: 3.0 Rear: 4.0 850/45 x 30.5 Trelleborg Front: 2.0 Rear: 3.5 750/55 x 26.5 Nokian Front: 2.25 Rear: 4.0
Options Pressure
Pressure
Pressure
Speed limited to 40 kph. * Transmission Type Torque Convertor Dia. Torque Multiplication Gear Ratios ADT 714 Machine 6 speed powershift 300 mm (11.8 in) 1.9 : 1 Forward 1st: 2nd 3rd 4th 5th 6th ADT 718 Machine 6 speed powershift 340 mm (13.4 in) with lock-up 1.9 : 1 Reverse 1st 4.939 : 1 2nd 2.078 : 1 3rd 0.895 : 1
5.202 : 1 3.367 : 1 2.191 : 1 1.418 : 1 0.944 : 1 0.611 : 1
Stall Testing Engage the parking brake and apply the foot brakes. Select the forward manual fifth gear. Press the accelerator pedal to maximum. Record the engine rpm. Note: do not carry out this test for more than 2 minutes. * Stall Speed ADT 714 Machine ADT 718 Machine 1750 - 1800 rpm 1780 - 1880 rpm
9804/1103
90 - 05 - 03/1
7160 - F/1-1.2
Issue 2
CONTENTS
90 - 05 - 04/1
* 714
and 718
Data - Brakes
System Type
Full power brakes with accumulator back-up. Two independent circuits operating outboard dry discs.
Pressure Regulator Setting Cut-in Cut-out Service Brake Operating Pressure Low Pressure Warning Switch Operating Pressure Accumulator Gas * Accumulator Pre-charge Pressure Parking Brake
140 bar (2030 lbf/in2) 175 bar (2537.5 lbf/in2) 120 bar (1740 lbf/in2)
120 bar (1740 lbf/in2) Nitrogen 80 bar (1160 lbf/in2) Spring applied hydraulic release fail safe type mounted on the front axle.
9804/1103
90 - 05 - 04/1
7160 - G/1-1.2
Issue 2*
CONTENTS
90 - 10 - 02/1
714 and 718 Fault Finding - Hydraulics

To use this section, look for the fault in the list below and refer to the probable causes and actions required listed against the fault. Remember, safety must always be the first priority. Refer to Section 2, Care and Safety section for a reminder on safety practices.
Fault 1 Lack of power
Probable Cause Insufficient hydraulic fluid Hydraulic leaks in the system Engine performance MRV setting incorrect Low pump flow
Action Check for leaks and top up as required Check hoses and replace as required Check engine performance Check and adjust as required Check for external leaks. Replace seals Priority valve Sticking Replace pump
Hydraulic rams slow to operate
Neutral circuit or low pressure lines leaking, damaged, trapped or kinked MRV setting incorrect Low pump flow
Check pipe lines and replace as required
Check and adjust as required Check pump flow Check for external leaks. Replace seals Check for priority valve sticking Replace pump
One hydraulic service fails to operate or is slow to operate
Associated service pipe lines leaking, damaged, trapped or kinked Associated ram leaking Associated valve block section leaking or not operating
Check hoses. Replace as required
Replace seals Check for leaks and rectify as required. Check that the control lever is operating the spool. Rectify as required Check and rectify as required
Associated check valve not opening to allow return of oil to tank 4 The engine tends to stall when hydraulics are under load MRV setting incorrect Engine performance 5 Ram creep Associated ram or pipe lines from ram are leaking Check valve
Check and adjust as required Check engine performance Check and rectify as required
Check operation and rectify as required
9804/1103
90 - 10 - 02/1
7160 - E/90-1.2
Issue 2
CONTENTS
90 - 10 - 03/1
714 Fault Finding - Transmission Error Codes

In the event of a fault developing in the transmission system the Electronic Monitoring System (EMS) will display an error code. The code will be displayed on the top line of the operators EMS display panel in the format: ZFCB ERROR xx. Note: TCU = Transmission Control Unit Fault Code 11 Fault Detected Possible Causes Action
Logical error at gear range signal
G G
Cable from shift lever to TCU is broken Cable is defective and is contacted to battery voltage or earth Shift lever is defective Cable from shift lever to TCU is broken Cable is defective and is contacted to battery voltage or earth Shift lever is defective Cable is defective and is contacted to battery voltage Cable has no connection to TCU Temperature sensor has an internal defect Connector pin is contacted to battery voltage or is broken Cable is defective and is contacted to vehicle ground Temperature sensor has an internal defect Connector pin is contacted to vehicle ground Cable is defective and is contacted to battery voltage Cable has no connection to TCU Temperature sensor has an internal defect Connector pin is contacted to battery voltage or is broken Cable is defective and is contacted to vehicle ground Temperature sensor has an internal defect Connector pin is contacted to vehicle ground Cable is defective and is contacted to battery voltage Cable has no connection to TCU Speed sensor has an internal defect Connector pin is contacted to battery voltage or is broken
G G
Check cables from TCU to shift lever Check signal combinations of shift lever positions for gear range
12
Logical error at direction select signal
G G
G G
Check cables from TCU to shift lever Check signal combinations of shift lever positions F-N-R
25
Short circuit to battery voltage or open circuit at transmission sump temperature sensor input
G G G G
G G G
Check the cable from the TCU to the sensor Check the connectors Check the temperature sensor
26
Short circuit to earth at transmission sump temperature sensor input
G G G
G G G
27
Short circuit to battery voltage or open circuit at converter output temperature sensor input
G G G G
G G G
28
Short circuit to earth at converter output temperature sensor input
G G G
G G G
31
Short circuit to battery voltage or open circuit at engine speed input
G G G G
G G G
Check the cable from the TCU to the sensor Check the connectors Check the speed sensor
9804/1103
90 - 10 - 03/1
7160 - F/10-1.1
Issue 1
CONTENTS
90 - 10 - 03/2
714 Fault Finding - Transmission

Fault Code 32 Fault Detected Possible Causes Action
Short circuit to earth at engine speed input
G G
Cable/connector is defective and is contacted to vehicle earth Speed sensor has an internal defect Cable/connector is defective and is contacted to vehicle earth Speed sensor has an internal defect Sensor gap is the wrong size Cable is defective and is contacted to battery voltage Cable has no connection to TCU Speed sensor has an internal defect Connector pin is contacted to battery voltage or has no contact Cable/connector is defective and is contacted to vehicle earth Speed sensor has an internal defect Cable/connector is defective and is contacted to vehicle earth Speed sensor has an internal defect Sensor gap is the wrong size Cable is defective and is contacted to battery voltage Cable has no connection to TCU Speed sensor has an internal defect Connector pin is contacted to battery voltage or has no contact Cable/connector is defective and is contacted to vehicle earth Speed sensor has an internal defect Cable/connector is defective and is contacted to vehicle earth Speed sensor has an internal defect Sensor gap is the wrong size Cable is defective and is contacted to battery voltage Cable has no connection to TCU Speed sensor has an internal defect Connector pin is contacted to battery voltage or has no contact
G G G G G G G G G G
Check the cable from the TCU to the sensor Check the connectors Check the speed sensor Check the cable from the TCU to the sensor Check the connectors Check the speed sensor Check the sensor gap Check the cable from the TCU to the sensor Check the connectors Check the speed sensor
33
Logical error at engine speed input
G G G
34
Short circuit to battery voltage or open circuit at turbine speed input
G G G G
35
Short circuit to earth at turbine speed input
G G
G G G G G G G G G G
36
Logical error at turbine speed input
G G G
37
Short circuit to battery voltage or open circuit at internal speed input
G G G G
38
Short circuit to earth at internal speed input
G G
G G G G G G G G G G
39
Logical error at internal speed input
G G G
3A
Short circuit to battery voltage or open circuit at output speed input
G G G G
9804/1103
90 - 10 - 03/2
7160 - F/10-2.1
Issue 1
CONTENTS
90 - 10 - 03/3

Fault Code 3B Fault Detected Possible Causes Action
Short circuit to earth at output speed input
G G
Cable/connector is defective and is contacted to vehicle earth Speed sensor has an internal defect Cable/connector is defective and has bad contact Speed sensor has an internal defect Sensor gap is the wrong size Speed sensor has an internal defect Sensor gap is the wrong size
G G G G G G G G G G
Check the cable from the TCU to the sensor Check the connectors Check the speed sensor Check the cable from the TCU to the sensor Check the connectors Check the speed sensor Check the sensor gap Check the cable from the TCU to the sensor Check the sensor signal of the output speed sensor Check the sensor gap of the output speed sensor Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox
3C
Logical error at output speed input
G G G
3E
Output speed zero does not fit to other speed signals
G G
71
Short circuit to battery voltage at clutch K1
G G
Cable/connector is defective and has contact to battery voltage Cable/connector is defective and has contact to another regulator output of the TCU Regulator has an internal defect
G G G G
72
Short circuit to earth at clutch K1
G G
Cable/connector is defective and is contacted to vehicle earth Regulator has an internal defect
G G G G
73
Open circuit at clutch K1
G G
Cable/connector is defective and has no contact to TCU Regulator has an internal defect
G G G G
74
G G
G G G G
9804/1103
90 - 10 - 03/3
7160 - F/10-3.1
Issue 1
CONTENTS
90 - 10 - 03/4

G G
G G G G
Check the cable from TCU to the gearbox Check the connectorss from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox
76
G G
G G G G
77
G G
G G G G
78
G G
G G G G
79
G G
G G G G
81
G G
G G G G
82
G G
G G G G
9804/1103
90 - 10 - 03/4
7160 - F/10-4.1
Issue 1
CONTENTS
90 - 10 - 03/5

Open circuit to clutch K4
G G
G G G G
Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox
84
Short circuit to battery voltage at clutch KV
G G
G G G G
85
Short circuit to earth at clutch KV
G G
G G G G G
86
Open circuit at clutch KV
G G
G G G G
87
Short circuit battery voltage at clutch KR
G G
G G G G
88
Short circuit to earth at clutch KR
G G
G G G G
89
Open circuit at clutch KR
G G
G G G G
9804/1103
90 - 10 - 03/5
7160 - F/10-5.1
Issue 1
CONTENTS
90 - 10 - 03/6

Short circuit to earth at the reverse warning alarm relay
G G G
Cable is defective and is contacted to vehicle earth Backup alarm device has an internal defect Connector pin is connected to vehicle earth Cable is defective and is contacted to battery voltage Backup alarm device has an internal defect Connector pin is connected to battery voltage Cable is defective and has no connection to the TCU Backup alarm device has an internal defect Connector has no connection to TCU Cable is defective and is contacted to vehicle earth Difflock solenoid has an internal defect Connector pin is connected to vehicle earth Cable is defective and is contacted to battery voltage Difflock solenoid has an internal defect Connector pin is connected to battery voltage Cable is defective and has no connection to the TCU Difflock solenoid has an internal defect Connector has no connection to TCU Cable is defective and is contacted to vehicle earth Warning device has an internal defect Connector pin is connected to vehicle earth Cable is defective and has no connection to the TCU Warning device has an internal defect Connector has no connection to TCU
G G G
Check the cable from TCU to the backup alarm device Check the connectors from the backup alarm device to the TCU Check the resistance of the backup alarm device Check the cable from TCU to the backup alarm device Check the connectors from the backup alarm device to the TCU Check the resistance of the backup alarm device Check the cable from TCU to the backup alarm device Check the connectors from the backup alarm device to the TCU Check the resistance of the backup alarm device Check the cable from TCU to the difflock solenoid Check the connectors from the difflock solenoid to the TCU Check the resistance of the difflock solenoid Check the cable from TCU to the difflock solenoid Check the connectors from the difflock solenoid to the TCU Check the resistance of the difflock solenoid Check the cable from TCU to the diff solenoid Check the connectors from the difflock solenoid to the TCU Check the resistance of the difflock solenoid Check the cable from TCU to the warning device Check the connectors from the warning device to the TCU Check the resistance of the warning device Check the cable from TCU to the warning device Check the connectors from the warning device to the TCU Check the resistance of the warning device
92
Short circuit to battery voltage at the reverse warning alarm relay
G G G
G G G
93
Open circuit at the reverse warning alarm relay
G G G
G G G
A1
Short circuit to earth at difflock solenoid
G G G
G G G
A2
Short circuit to battery voltage at difflock solenoid
G G G
G G G
A3
Open circuit at difflock solenoid
G G G
G G G
A4
Short circuit to ground at warning signal output
G G G
G G G
A5
Open circuit at warning signal output
G G G
G G G
9804/1103
90 - 10 - 03/6
7160 - F/10-6.1
Issue 1
CONTENTS
90 - 10 - 03/7

Fault Code A6 Fault Detected Possible Causes Action
Short circuit to battery voltage at warning signal output
G G G
Cable is defective and is contacted to battery voltage Difflock solenoid has an internal defect Connector pin is connected to battery voltage Low pressure at clutch K1 Low main pressure Wrong signal at internal speed sensor Wrong signal at output speed sensor Wrong size of the sensor gap Clutch is defective
G G G
Check the cable from TCU to the warning device Check the connectors from the warning device to the TCU Check the resistance of the warning device Check pressure at clutch K1 Check main pressure in the system Check sensor gap at internal speed sensor Check sensor gap at output speed sensor Check signal at internal speed sensor Check signal at output speed sensor Replace clutch Check pressure at clutch K2 Check main pressure in the system Check sensor gap at internal speed sensor Check sensor gap at output speed sensor Check signal at internal speed sensor Check signal at output speed sensor Replace clutch Check pressure at clutch K3 Check main pressure in the system Check sensor gap at internal speed sensor Check sensor gap at output speed sensor Check signal at internal speed sensor Check signal at output speed sensor Replace clutch
B1
Slippage at clutch K1
G G G G G G
G G G G G G G
B2
G G G G G G
Low pressure at clutch K2 Low main pressure Wrong signal at internal speed sensor Wrong signal at output speed sensor Wrong size of the sensor gap Clutch is defective
G G G G G G G
B3
G G G G G G
G G G G G G G
9804/1103
90 - 10 - 03/7
7160 - F/10-7.1
Issue 1
CONTENTS
90 - 10 - 03/8

Fault Code B4 Fault Detected Possible Causes Action
G G G G G G
G G G G G G G
Check pressure at clutch K4 Check main pressure in the system Check sensor gap at internal speed sensor Check sensor gap at output speed sensor Check signal at internal speed sensor Check signal at output speed sensor Replace clutch Check pressure at clutch KV Check main pressure in the system Check sensor gap at internal speed sensor Check sensor gap at turbine speed sensor Check signal at internal speed sensor Check signal at turbine speed sensor Replace clutch Low pressure at clutch KR Check main pressure in the system Check sensor gap at internal speed sensor Check sensor gap at turbine speed sensor Check signal at internal speed sensor Check signal at turbine speed sensor Replace clutch Cool down machine Check oil level Check temperature sensor Cool down machine Check oil level Check temperature sensor
B5
Slippage at clutch KV
G G G G G G
Low pressure at clutch KV Low main pressure Wrong signal at internal speed sensor Wrong signal at turbine speed sensor Wrong size of the sensor gap Clutch is defective
G G G G G G G
B6
G G G G G G
Slippage at clutch KR Low main pressure Wrong signal at internal speed sensor Wrong signal at turbine speed sensor Wrong size of the sensor gap Clutch is defective
G G G G G G G
B7
Excessively hot sump
Measured temperature of oil in the sump is above allowed maximum Measured temperature of the retarder oil is above allowed maximum
G G G G G G
B8
Excessively hot retarder
B9 BA
Overspeed engine Differential pressure oil filter
Not used
G G
Oil filter is polluted Cable/connector is broken or cable/connector is contacted to battery voltage or vehicle ground Differential pressure switch is defective
G G G
Check oil filter Check wiring from TCU to differential pressure switch Check differential pressure switch (measure resistance)
9804/1103
90 - 10 - 03/8
7160 - F/10-8.1
Issue 1
CONTENTS
90 - 10 - 03/9

Fault Code D1 Fault Detected Possible Causes Action
Short circuit to battery voltage at power supply for sensors
The TCU measures more than 6V at the pin AU1 (5V sensor supply)
Check cables and connectors to sensors, which are supplied from AU1 Check the power supply at the pin AU1 (should be appx. 5V) Check cables and connectors to sensors, which are supplied from AU1 Check the power supply at the pin AU1 (should be appx. 5V) Check power supply battery Check cables from batteries to TCU Check connectors from batteries to TCU Check power supply battery Check cables from batteries to TCU Check connectors from batteries to TCU Check fuse Check cables from gearbox to TCU Check connectors from gearbox to TCU Replace TCU
D2
Short circuit to earth at power supply for sensors
The TCU measures less than 4V at the pin AU1 (5V sensor supply)
D3
Low power at battery
Measured voltage at power supply is less than 24V
G G G
D4
High power at battery
Measured voltage at power supply is more than 24V
G G G
D5
Error at switch 1 for valve power supply VPS1
G G
Cable or connectors are defect and are contacted to battery voltage Cable or connectors are defect and are contacted to vehicle ground Permanent power supply KL30 missing TCU has an internal defect Cable or connectors are defective and are contacted to battery voltage Cable or connectors are defective and are contacted to vehicle ground Permanent power supply KL30 missing TCU has an internal defect TCU is defective Interference during saving data on non volatile memory TCU is brand new or from another vehicle Something in the application is wrong One of the AEB values is out of limit
G G G G
D6
Error at switch 2 for valve power supply VPS2
G G G
Check fuse Check cables from gearbox to TCU Check connectors from gearbox to TCU Replace TCU
F1 F2
General EEPROM fault Configuration lost
G G G
G G
Replace TCU Reprogram the correct configuration for the vehicle (e.g. with cluster controller,...)
F3
Application error
Replace TCU
F5
Clutch failure
Check clutch
9804/1103
90 - 10 - 03/9
7160 - F/10-9.1
Issue 1
CONTENTS
90 - 10 - 03/10

Fault Code F6 Fault Detected Possible Causes Action
Clutch adjustment data lost
G G
Interference during saving data on non volatile memory TCU is brand new or from another vehicle
Execute AEB
9804/1103
90 - 10 - 03/10
7160 - F/10-10.1
Issue 1
CONTENTS
90 - 10 - 04/1
718 Fault Finding - Suspension

Error Codes In the event of a fault developing in the hydraulic suspension system the Electronic Monitoring System (EMS) will display an error code. The code will be displayed on the top line of the operators EMS display panel in the format: FAULT xx. IMPORTANT: When any errors in the hydraulic suspension system are detected, the hydraulic suspension system will shutdown and drain down to the hydraulic tank. The machine will lower onto the bump stops.
! WARNING
Do not attempt to drive the machine in this condition. Stop the machine as soon as it is safe to do so and switch off the engine.
0080
Fault Code S1
Fault Detected
Possible Causes
Action
No signal is detected from the self levelling suspension switches to the EMS
! Cable from self levelling ! suspension switches to the EMS is broken ! Cable is defective and is ! contracted to earth ! Self levelling suspension switch is defective ! Self levelling suspension switches are defective ! Self levelling suspension rods are incorrectly adjusted ! Hydraulic system is defective ! Suspension solenoids are defective ! ! !
Check cables and connectors from self levelling suspension switches to the EMS Check signals generated by self levelling suspension switches over a range of positions of the suspension Check self levelling suspension switches Check self levelling suspension rod adjustment Check the hydraulic system for leaks, loose pipework and/or blockages Check suspension solenoids
S2
Out of range or incorrect signal received from the self levelling suspension switches
S3
Suspension system is not adjusting to changes in the suspension loading (signals from the self levelling suspension switches are outside the dead band in excess of the set time)
9804/1103
90 - 10 - 04/1
7160 -S/90 - 1.1
Issue 1
CONTENTS
Articulated Dump Truck
90 - 15 - 01/1
714 Circuit Diagrams - Electrical Main Components

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Battery Isolator Battery Starter Motor Alternator Starter Switch Starter Relay Ignition Relay Start Inhibit Relay Shutdown Relay Pre-heater Body Up Switch Diagnostic Tool Connector Instrument Cluster and Monitoring System Air Cleaner Blockage Switch Brake Accumulator Pressure Sensor Steer Pressure Sensor Engine Oil Pressure Sensor Emergency Steering Pressure Sensor Fuel Level Sensor
Fuses
P1 P2 P3 P4 P5 A1 A2 A3 A4 A5 A6 Cab Auxiliaries (50A) Instrument Cluster/Work Lights/Transmission Controller (40A) Radio/Beacon/24 to 12V Converter Lights (40A) Alternator (80A) Ignition Switch (50A) Ignition Relay Engine Stop Engine Start Pre-Heat EMS Ignition EMS Battery Backup
9804/1103
90 - 15 - 01/1
7160 - C/6-1.1
Issue 1
CONTENTS
90 - 15 - 01/2
714 Circuit Diagrams - Electrical (contd)

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9804/1103
90 - 15 - 01/2
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7160 - C/6-2.1
Issue 1
CONTENTS
90 - 15 - 01/3
714 Circuit Diagrams - Electrical (contd) Main Components

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Hazard Warning Switch Indicator Switch Brake Light Switch Beacon Switch Beacon Motor Front Work Light Switch Horn Switch Horn Body Lamp Switch Side Lights Switch Side Light Relay Dip/Main Beam Switch Fog Lamp Switch Reversing Warning Horn Mute Relay Reversing Warning Horn Latch Relay Reversing Light Relay Reversing Warning Horn Reversing Warning Mute Switch
Lamps
100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 Front Indicator Light (LH) Rear Indicator Light (LH) Display Panel Repeater Lamp (LH) Front Indicator Light (RH) Rear Indicator Light (RH) Display Panel Repeater Lamp (RH) Rear Stop Light (RH) Rear Stop Light (LH) Beacon Light Inner Light (RH) Inner Light (LH) Outer Light (RH) Outer Light (LH) Body Lamp Front Side Light (LH) Rear Side Light (LH) Number Plate Light (LH) Front Side Light (RH) Rear Side Light (RH) Number Plate Light (RH) Main Beam Light (RH) Main Beam Light (LH) Dip Beam Light (RH) Dip Beam Light (LH) Fog Lamp Reversing Light
Fuses
A7 A8 A9 B1 B2 C1 F1 F2 F3 F4 F5 F6 Beacon Front Work Lights Body Lamp Brake Lamps Reverse Lamp/Reverse Alarm Horn Hazard Lights Direction Indicator Lights LH Side Lights RH Side Lights Dip Beam Main Beam
9804/1103
90 - 15 - 01/3
7160 - C/6-4.1
Issue 1
714
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90 - 15 - 01/5

38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 79 80 81 Wiper Switches Front Wiper Motor Front Screen Washer Pump Switch Front Screen Washer Pump Rear Wiper Relay Front Wiper Relay Rear Wiper/Screen Washer Switch Rear Wiper Motor Rear Screen Washer Pump Switch Air Conditioning Blower Switch Air Conditioning Switch Air Conditioning Blower Motor Air Conditioning Relay Air Conditioning Low Pressure Switch Air Conditioning High Pressure Switch 24V/12V Convertor Radio/Cassette Player Speakers Cigar Lighter Element Interior Light Switch Interior Light Door Switch Rear View Monitor Rear View Camera Park Brake Switch Park Brake Solenoid Park Brake Solenoid Air Conditioning Compressor Clutch Solenoid Heated Mirrors Switch Heated Mirrors Suspension Seat Compressor Motor
Lamps
126 Interior Light
Fuses
B3 B4 B5 B6 B7 B8 B9 C2 C3 C4 C5 Front Wash/Wipe Rear Wash/Wipe Heater/AC Radio/Interior Light/24 to 12 Convertor Rear Camera Park Brake Transmission Control System Ignition Heated Mirrors Transmission Control System Battery Suspension Seat Radio/Cigar Lighter (12V)
9804/1103
90 - 15 - 01/5
7160 - C/6-5.1
Issue 1
CONTENTS
90 - 15 - 01/6
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7160 - C/6-6.1
Issue 1
CONTENTS
90 - 15 - 01/7

65 66 67 68 69 70 71 72 73 74 75 76 77 78 Transmission Diagnostic Tool Connector Transmission Shift Lever Transmission Control Unit Front Axle Connect Solenoid Front Axle Connected Switch Front Axle Connect Switch Convertor Oil Temperature Sensor Blocked Filter Switch Engine Speed Sensor Turbine Speed Sensor Gear Chain Speed Sensor Output Shaft Speed Sensor Transmission Control Module Sump Oil Temperature Sensor
9804/1103
90 - 15 - 01/7
7160 - C/6-8.1
Issue 1
CONTENTS
90 - 15 - 01/8
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9804/1103
90 - 15 - 01/8
7160 - C/6-7.1
Issue 1
CONTENTS
90 - 20 - 01/1
714 and 718 Circuit Diagrams - Hydraulic Components Key

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 * X Ground Driven Pump Emergency Steer Valve Priority Steer Valve Load Sensing Steer Valve Steer Rams Tipping Valve Block Front and Rear Chassis Umbilical Main Body Lift Rams Main Return Filter Brake Modulating Valve Front Axle Brake Piston Rear Axle Brake Piston Service Brake Accumulator Accumulator Charge Valve Park Brake Valve Propshaft Mounted Disc Park Brake Accumulator Main Tank Return Manifold Tank Strainers Secondary Supply Pump Main Supply Pump ADT 718 machine hydraulic suspension circuit insert. Refer to Hydraulic Suspension Circuit - ADT 718 Machine Only.
9804/1103
90 - 20 - 01/1
7160 - E/3-7.2
Issue 2
CONTENTS
90 - 20 - 01/2
714 and 718 Circuit Diagrams - Hydraulic (contd)
4
LS CF
P
LS
P EF
2
GP
3
T
6 13
ACC A1
1B 1A
14
S
22
A2 ACC
21
EF
13
G P2 P1 T1
10
X
PS
15
P
5 2 5
B2
B1
BR
16 12
7 11
17 19
ACC
18
20
344961
9804/1103
90 - 20 - 01/2
7160 - E/3-8.2
Issue 2
CONTENTS
CONTENTS
90 - 20 - 01/3
714 and 718 Circuit Diagrams - Hydraulic Hydraulic Suspension Circuit - ADT 718 Machine only 26 X
P C
28
23
P
24 27
S P C
29
30 31 T T
T
25
354711
* Note: All other areas of the ADT 718 machines hydraulic circuit are as the other machines as shown on the other pages.
Hydraulic Suspension Circuit Component Key - ADT 718 Machine Only

23 24 25 26 27 28 29 * 30 * 31 T X Main Suspension Control Valve Right Hand Suspension Control Valve Left Hand Suspension Control Valve Right Hand Suspension Accumulators Left Hand Suspension Accumulators Right Hand Suspension Hydraulic Cylinder Left Hand Suspension Hydraulic Cylinder Accumulator Cooler To tank return manifold Connection from the Accumulator Charge Valve
9804/1103
90 - 20 - 01/3
7160 - E/3-9 . 2
Issue 2*
CONTENTS
90 - 20 - 01/4
714 up to Machine Serial No. 830153 718 up to Machine Serial No. 832019 Circuit Diagrams - Hydraulic
Component Key 1 2 3 4 5 6 6A Ground Driven Pump Emergency Steer Valve Priority Steer Valve Load Sensing Steer Valve Steer Rams Tipping Valve Block Tipping Valve Block (with ARV) (ADT 714 from machine serial no. 830107; ADT 718 from machine serial no. 832012) Front and Rear Chassis Umbilical Main Body Lift Rams Main Return Filter Brake Modulating Valve Front Axle Brake Piston Rear Axle Brake Piston Service Brake Accumulator Accumulator Change Valve Park Brake Valve Propshaft Mounted Disc Park Brake Accumulator Main Tank Return Manifold Tank Strainers Secondary Supply Pump Main Supply Pump Over Centre Valve ADT 718 machine hydraulic suspension circuit insert. Refer to Hydraulic Suspension Circuit - ADT 718 Machine Only.
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 X
9804/1103
90 - 20 - 01/4
7160 - E/3-7.3
Issue 1*
CONTENTS
90 - 20 - 01/5
714 up to Machine Serial No. 830153 718 up to Machine Serial No. 832019 Circuit Diagrams - Hydraulic (contd)
L R
4
LS CF
P
LS
P EF
2
GP
3
T
6 13
ACC A1
1B 1A
14
S
22
23
A2 ACC
6A 10
P2 P1 T1
1A 1B
21
EF
13
G
X
PS
15
P
5 2 5
B2
B1
BR
16 12
7 11
17 19
ACC
18
20
!""'$
9804/1103
90 - 20 - 01/5
7160 - E/3 - 8.3
Issue 1*
CONTENTS
90 - 20 - 01/6
714 from Machine Serial No. 830154 718 from Machine Serial No. 832020 Circuit Diagrams - Hydraulic (contd)
L R
4
LS CF
P
LS
P EF
2
GP
3
T P T
6 13
ACC A1
1A 1B
14
S
22
23
A2 ACC
21
EF
13
G P2 P1 T1
10
P T
2 1
X
2
PS
25
3 B2 B1
15
P
5 2 5
BR
16 12
24 7 11 8
17 19
ACC
18
20
354890
9804/1103
90 - 20 - 01/6
7160 - E/3 - 8A.1
Issue 1*
CONTENTS
90 - 20 - 01/7
714 from Machine Serial No. 830154 718 from Machine Serial No. 832020 Circuit Diagrams - Hydraulic
Component Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 X Ground Driven Pump Emergency Steer Valve Priority Steer valve Load Sensing Steer Valve Steer Rams Tipping Valve Block (with ARV) Front and Rear Chassis Umbilical Main Body Lift Rams Main Return Filter Brake Modulating Valve Front Axle Brake Piston Rear Axle Brake Piston Service Brake Accumulator Accumulator Charge Valve Park Brake Valve Propshaft Mounted Disc Park Brake Accumulator Main Tank Return Manifold Tank Strainers Secondary Supply Pump Main Supply Pump Over Centre Valve Servo Controller Pressure Reducing Valve ADT 718 machine hydraulic suspension circuit insert. Refer to Hydraulic Suspension Circuit - ADT 718 Machine Only.
9804/1103
90 - 20 - 01/7
7160 - E/3-8B . 1
Issue 1*

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RETURN

Introduction General Information Backhoe Loaders

Service Data Book 1992 on

Loadalls RTFL Excavators Wheeled Loaders Fastrac Skidsteer Range Teletruk

Articulated Dump Trucks

Publication No. 9804/1103

1992 Data Book

Page number example:

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

B Subject classification Data, Fault Finding, etc

C Number to suit detail variation within subject

General Section Contents

Area Capacity Electric

Flow Force Length

Mass Moment of force Pressure Speed Temperature Time

Mass Moment of force

Conversion Tables - Capacity

Conversion Tables - Length

Conversion Tables - Pressure

Conversion Tables - Temperature

Torque Settings (for all machines except JS Range)

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

Nm 7 12 28 56 98 244 476 822 1633 2854

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

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

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

Introduction to Hydraulic Schematic Symbols

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

Variable capacity motor two directions of flow

Double acting with damping at rod area end

Introduction to Hydraulic Schematic Symbols (continued)

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

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

Introduction to Hydraulic Schematic Symbols (continued)

Reservoir - return line above fluid level

Pilot control Reservoir - return line below fluid level

Pressure sealed tank

Accumulator Crossing lines

Line plugged, also pressure test point