Jcb 214 Service Manual

Page 1

General information 1 care & safety 2 routine maintenance 3 attachments a body & framework b electrics c controls d hydraulics e transmission f brakes g steering h engine k service manual 3cx, 4cx, 214e, 214, 215, 217 & variants backhoe loader from m/c no. 930000 onwards from m/c no. 903000 onwards ...

Page 3: Www.Workshopmanuals.Co.Uk

Colour coding the following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout jcb service publications. 9803/3280 issue 1 a390940 full pressure pressure generated from operation of a service. Depending on application this may be an...

Page 5: General Information

Machine identification plate your machine has an identification plate mounted on the loader tower. The serial numbers of the machine and its major units are stamped on the plate. The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the se...

Page 7: General Information

2 - 1 torque settings use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be reduced by one third. Unf grade 's' bolts bolt size hexagon (a/f) torque settings in (mm) in...

Page 9: General Information

3 - 2 892/00282 shunt 4 - 4 892/00283 tool kit case 4 - 4 892/00284 tachometer 4 - 4 892/00285 hydraulic oil temperature probe 4 - 4 892/00286 surface temperature probe 4 - 4 892/00293 connector pipe 4 - 6 892/00294 connector pipe 4 - 6 892/00298 fluke meter 4 - 4 892/00301 flow test adapter 4 - 10 ...

Page 11: General Information

Folding stand for holding glass - essential for preparing new glass prior to installation. Jcb part number - 892/00843 s186280 12v mobile oven - 1 cartridge capacity - required to pre-heat adhesive prior to use. It is fitted with a male plug (703/23201) which fits into a female socket (715/04300). J...

Page 13: General Information

Long knife - used to give extended reach for normally inaccessible areas. Jcb part number - 892/00844 braided cutting wire - consumable heavy duty cut-out wire used with the glass extraction tool (above). Jcb part number - 892/00849 (approx 25 m length) s186330 4 - 3 section 1 general information 98...

Page 15: General Information

4 - 5 section 1 general information 9803/3280 section 1 4 - 5 issue 1 service tools (cont'd) section c - electrics 1 electrical repair kit 2a :7212/0002 2 way pin housing 2b :7212/0004 2 way pin retainer 2c :7212/0003 2 way socket retainer 2d :7212/0001 2 way socket connector 3a :7213/0002 3 way pin...

Page 17: General Information

Male adapters - bsp x npt (usa only) 816/00439 3/8 in. X 1/4 in. 816/00440 1/2 in. X 1/4 in. 816/15007 3/8 in. X 3/8 in. 816/15008 1/2 in. X 3/8 in. Hand pump equipment 892/00223 hand pump 892/00137 micro-bore hose 1/4 in bsp x 3 metres 892/00274 adapter 1/4 in m bsp x 3/8 in m bsp taper 892/00262 1...

Page 19: General Information

S216250 892/00334 ram seal fitting tool 4 - 9 section 1 general information 9803/3280 section 1 4 - 9 issue 1 service tools (cont'd) section e - hydraulics ram seal protection sleeves 892/01016 for 25 mm rod diameter 892/01017 for 30 mm rod diameter 892/01018 for 40 mm rod diameter 892/01019 for 50 ...

Page 21: General Information

892/00224 impulse extractor set for hub bearing seals 892/00225 adapter - impulse extractor small 17mm to 25mm medium 25mm to 45mm large 45mm to 80mm 993/59500 adapter - impulse extractor (syncro shuttle and powershift transmission) s197070 4 - 11 section 1 general information 9803/3280 section 1 4 ...

Page 23: General Information

4 - 13 section 1 general information 9803/3280 section 1 4 - 13 issue 1 service tools (cont'd) section f - transmission 892/01077 synchro shuttle gearbox - selector shaft lock screw a395350 synchro shuttle gearbox - setting ring socket spanners a396590 a396600 892/01078 synchro shuttle gearbox - mai...

Page 25: General Information

4 - 15 section 1 general information 9803/3280 section 1 4 - 15 issue 1 service tools (cont'd) section f - transmission 1 6 8, 9 7 6 5 a396950 3 4 a396580 a396930 a396960 a396940 www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 27: General Information

4 - 17 892/01083 powershift - assembly tool, transfer gear. 892/01084 powershift - transfer gear, bearing assembly. 892/01085 powershift - seal fitting tool powershift - support plates, for use with transmission jack, manufacture locally, for details see section f, service tools. 892/01082 - powersh...

Page 29: General Information

4 - 19 section 1 general information 9803/3280 section 1 4 - 19 issue 1 service tools (cont'd) section k - engine 892/00836 lifting wire assembly (for engine removal) s219080 892/00041 de-glazing tool for cylinder bores (to assist bedding-in of new piston rings) s192390 for details of other engine s...

Page 31: Care & Safety

I section 2 care & safety 9803/3280 section 2 i issue 1 contents page no. Safety notices 1 - 1 general safety 2 - 1 operating safety 3 - 1 maintenance safety 4 - 1 www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 33: Care & Safety

2 - 1 all construction and agricultural equipment can be hazardous. When a jcb machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. Do not work with t...

Page 35: Danger

4 - 1 maintenance safety ! Warning repairs do not try to do repairs or any other type of maintenance work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer. Gen-1-5 ! Warning modifications and welding non-approved modifications can cause injury and damag...

Page 37: Care & Safety

4 - 3 maintenance safety (cont'd) ! Warning hydraulic hoses damaged hoses can cause fatal accidents. Inspect the hoses regularly for: - damaged end fittings - chafed outer covers - ballooned outer covers - kinked or crushed hoses - embedded armouring in outer covers - displaced end fittings. Int-3-3...

Page 39: Routine Maintenance

Contents page no. Engine oil and filter checking the oil level 13 - 1 changing the oil and filter 13 - 1 engine cooling system checking the coolant 14 - 1 changing the coolant 14 - 1 adjusting the fan belt 14 - 2 cleaning the cab heater filter 14 - 2 fuel system types of fuel 15 - 1 fuel standards 1...

Page 41: Routine Maintenance

2 - 1 it is most important that you read and understand this information and the publications referred to. Make sure all your colleagues who are concerned with lubricants read it too. Hygiene jcb lubricants are not a health risk when used properly for their intended purposes. However, excessive or p...

Page 43: Routine Maintenance

3 - 2 pre-start cold checks operation 10 50 †100 500 1000 2000 service points and fluid levels hr hr hr hr hr hr hydraulic oil cooler - clean ! ! ! Hydraulic oil strainer - clean ! Hydraulic tank filler cap (with integral filter) - change ! Hydraulic pump drive shaft - examine/grease ! ! ! ! Brakes ...

Page 45: Routine Maintenance

4 - 1 installing install the loader arm safety strut as detailed below before working underneath raised loader arms. ! Warning raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut. 2-1-1-6 1 empty the shovel and raise...

Page 47: Routine Maintenance

6 - 1 park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the attachments to the ground and stop the engine. Clean the machine using water and/or steam. Do not allow mud, debris etc to build upon the machine, pay particular attention to the foll...

Page 49: Routine Maintenance

8 - 1 checking the seat belt condition and security ! Warning when a seat belt is fitted to your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident. Fit a new seat belt every three years. 2-3-1-7/1 inspect the seat belt for signs of f...

Page 51: Routine Maintenance

9 - 2 backhoe & quickhitch 22 grease points note: figure shows a typical boom and dipper arrangement. Section 3 routine maintenance 9803/3280 section 3 9 - 2 issue 1 greasing 2 1 3 4 @ 6 £ $ ) * ^ % ¤ ( & a340900 ⁄ 8 7 9 ! 5 0 www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 53: Routine Maintenance

9 - 4 section 3 routine maintenance 9803/3280 section 3 9 - 4 issue 1 greasing front axle (all wheel steer machines) 5 grease points rear axle (all wheel steer machines) 4 grease points note: grease point 5 is a remote grease point mounted on the side of the front nose (near the left front wheel). 1...

Page 55: Routine Maintenance

9 - 6 section 3 routine maintenance 9803/3280 section 3 9 - 6 issue 1 greasing stabilisers (centremount machines) 3 grease points on each stabiliser - total 6 grease points loader quickhitch 2 grease points each end - total 4 grease points s089961 s259390 1 2 3 4 5 6 3 2 1 6 - in - 1 clamshovel 3 gr...

Page 57: Routine Maintenance

9 - 8 section 3 routine maintenance 9803/3280 section 3 9 - 8 issue 1 greasing knuckle (if fitted) refer to backhoe greasing for the boom and dipper grease points. Total 2 grease points. 2 1 s256440 backhoe quickhitch (hydraulic) ! Caution waxoyl contains turpentine substitute, which is inflammable....

Page 59: Routine Maintenance

11 - 1 parking brake adjustment 1 disengage the parking brake (lever horizontal). 2 turn handle grip e clockwise, half a turn. 3 test the parking brake, see section g, service procedures . 4 if the brake fails the test, repeat steps 1 , 2 and 3 . If there is no more adjustment and pin f is at the en...

Page 61: Routine Maintenance

13 - 1 checking the oil level 1 make sure the park brake is engaged and the transmission set to neutral. Lower the loader arms and backhoe to the ground, switch off the engine and remove the starter key. 2 open the bonnet, see engine panels, opening and closing the bonnet. 3 check that the oil level...

Page 63: Routine Maintenance

14 - 2 adjusting the fan belt ! Warning make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5 1 park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Raise and block the loader arms. Lower the backhoe to the groun...

Page 65: Routine Maintenance

15 - 2 filling the tank ! Warning lower the loader arms and switch off the engine before refuelling. Do not permit operation of the machine controls while refuelling. 2-3-3-9 at the end of every working day, fill the tank with the correct type of fuel. This will prevent overnight condensation from d...

Page 67: Routine Maintenance

16 - 1 checking the oil level 1 make sure the park brake is engaged and the transmission set to neutral. Lower the loader arms and backhoe to the ground, switch off the engine and remove the starter key. 2 open the bonnet, see engine panels, opening and closing the bonnet. 3 switch off the engine an...

Page 69: Routine Maintenance

17 - 2 section 3 routine maintenance 9803/3280 section 3 17 - 2 issue 1 powershift gearbox changing the oil and filter when draining jcb 760 series powershift gearboxes it is recommended that the oil is drained through the cover plate a to make sure that the debris collected in the transmission sump...

Page 71: Routine Maintenance

18 - 2 changing the filter element ! Warning fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardbo...

Page 73: Routine Maintenance

19 - 1 checking the differential oil level ! Warning make the machine safe before getting beneath it. Lower the attachments to the ground; engage the parking brake; remove the starter key, disconnect the battery. 2-3-2-2 ! Caution the axle oil level must be checked with the machine level, otherwise ...

Page 75: Routine Maintenance

19 - 3 the front axle procedures are the same as described on the previous pages (all wheel steer machines). Refer to the following procedures for checking and changing the oil on the rear axle. Checking the oil level ! Caution the axle oil level must be checked with the machine level, otherwise a f...

Page 77: Routine Maintenance

21 - 2 ! Warning batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery carefully to preven...

Page 79: Routine Maintenance

23 - 1 cleaning the tubes/fins the hydraulic oil cooler is in front of the engine radiator. If the hydraulic oil cooler tubes/fins get clogged (by dirt and flies etc) the radiator and cooler will be less efficient. 1 park the machine on firm level ground, engage the parking brake and set the transmi...

Page 81: Routine Maintenance

26 - 1 ! Warning the air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person. You can be severely frostbitten or injured by escapin...

Page 83: Routine Maintenance

Item capacity fluid/lubricant international litres uk gal specification fuel tank 150 33 diesel oil astm d975-66t nos. 1d, 2d engine (oil) ! 2 wheel steer machines - build ar 11.0 2.4 jcb super multigrade 15w/40 sae15w/40 - build ak 10 2.2 -10°c to +50°c (14°f to 122°f) cf-4/sg 4 wheel steer machine...

Page 85: Attachments

I section a attachments 9803/3280 section a i issue 1 contents page no. Www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 87: Body & Framework

Ii section b body & framework 9803/3280 section b ii issue 2* contents page no. Loader arms - removal and replacement 35 - 1 stabiliser legs - removal and replacement 36 - 1 kingpost - removal and replacement 37 - 1 boom & dipper - removal and replacement 38 - 1 hydraulic tank - removal and replacem...

Page 89: Body & Framework

Wire starter - used to access braided cutting wire (below) through original polyurethane seal. Jcb part number - 892/00848 braided cutting wire - consumable heavy duty cut-out wire used with the glass extraction tool (above). Jcb part number - 892/00849 (approx 25 m length) glass extractor (handles)...

Page 91: Body & Framework

5 fit the ' slide hammer' , item f , onto the slide bar as shown. 6 finally, fit another end stop, item c , at the end of the slide bar, as shown. The slide hammer kit is now ready to use. 7 to extract the pivot pin, slide the hammer along the bar until it contacts end stop c . Repeat this step unti...

Page 93: Body And Framework

2 - 1 section b body and framework 9803/3280 section b 2 - 1 issue 1 technical data air conditioning (option) binary pressure switch settings low pressure 1.96 bar (2.0 kgf/cm 2 28.4 lbf/in 2 ) high pressure 27.5 bar (28 kgf/cm 2 400 lbf/in 2 ) thermostatic switch settings cut out -0.6 °c (33.0 °f) ...

Page 95: Body & Framework

3 - 2 section b body & framework 9803/3280 section b 3 - 2 issue 1 basic operation x d y a b c a401390 e g h j f to operate the air conditioning, press switch f to switch the system on. Press switch g to operate the 3-speed heater fan. Rotate h to select the desired temperature. Control j enables th...

Page 97: Body & Framework

3 - 4 7 when checking the state of the refrigerant at the receiver drier sight glass, it is necessary to run the engine with the side panel removed and the bonnet raised. Extreme care must be taken to avoid moving engine parts such as fans, pulleys and belts. 8 use caution when working near exposed ...

Page 99: Body & Framework

10 - 2 air conditioning (cont’d) no air conditioning check action 1 are the controls set correctly, i.E. Air conditioning yes: check 2 selected, thermostat switch set to coldest position no: reset controls and retest. And blower switched on? 2 is the air conditioning (evaporator) blower working? Yes...

Page 101: Body & Framework

10 - 4 air conditioning - system diagnosis (cont'd) low r-134a charge gauge readings: low side gauge - low. High side gauge - low. Other symptoms: sight glass - bubbles continuously visible. Diagnosis: system slightly low on r- 134a, due to leak or incorrect charge. Correction: 1. Leak test system. ...

Page 103: Body & Framework

10 - 6 air conditioning - system diagnosis (cont'd) air in system gauge readings: low side gauge - high. High side gauge - high. Other symptoms: sight glass - bubbles visible during system operation. Pipes - low pressure pipes are hot to the touch. Diagnosis: air is present in the system, possibly f...

Page 105: Body & Framework

Air conditioning (cont'd) wiring continuity checks use the illustration below to complete continuity checks on the hvac/air conditioning system and heater harness wires.The harness connects to the main machine harness via connector 1 . Refer also to the main machine circuit diagram in section c elec...

Page 107: Body & Framework

20 - 2 air conditioning - refrigerant charging and discharging note: the procedures for refrigerant charging and discharging must only be carried out by qualified service personel who have received specialist training on the air conditioning system. ! Warning the air conditioning system is a closed ...

Page 109: Body & Framework

20 - 4 section b body & framework 9803/3280 section b 20 - 4 issue 1 service procedures electronic vacuum gauge the cps vg100 vacuum gauge is an electronic type using led’s to indicate various states of vacuum. It is used in place of or to supplement the gauge on the vacuum pump. Before connecting i...

Page 111: Body & Framework

20 - 6 air conditioning - refrigerant charging and discharging note: the procedures for refrigerant charging and discharging must only be carried out by qualified service personel who have received specialist training on the air conditioning system. ! Warning the air conditioning system is a closed ...

Page 113: Body & Framework

20 - 8 air conditioning condenser matrix it is likely that over a period of time, because of the machine' s working environment, the airflow around the condenser matrix will become restricted due to a build up of airborne particles. If the build up of particles is severe, heat dissipation from the r...

Page 115: Body & Framework

20 - 10 air conditioning compressor drive belt - adjusting 1 park the machine on firm level ground. Raise and block the loader arms. Lower the backhoe to the ground and stop the engine. 2 remove the starter key. ! Warning make sure the engine cannot be started. Disconnect the battery before doing th...

Page 117: Body & Framework

21 - 2 direct glazing (cont'd) removing the broken glass and old sealant (cont'd) 1 position the machine on level ground and apply the parking brake. Stop the engine. Put protective covers over the cab seat and control pedestals. 2 a laminated glass - leave installed until the old sealant has been c...

Page 119: Body & Framework

21 - 4 direct glazing (cont'd) preparing the new glass ! Caution the laminated front screen must be handled with extra care to prevent breakage. Wherever possible, store and handle it in a vertical attitude. When placing or lifting the screen in a horizontal attitude it must be supported over its wh...

Page 121: Body & Framework

21 - 6 direct glazing (cont'd) installing the new glass (cont'd) 3 make the inside seal smooth: a wearing surgical gloves, dip your finger in a soapy water solution. B use your finger to make the inside seal smooth. 4 all exposed edges must be sealed using black polyurethane sealant (see sealing and...

Page 123: Body & Framework

23 - 1 engine panels - removing and fitting instructions for removing and fitting the engine panels are described in the routine maintenance section, refer to section 3 routine maintenance - engine panels . Section b body & framework 9803/3280 section b 23 - 1 issue 1 service procedures www.Workshop...

Page 125: Body And Framework

25 - 1 extending dipper - wear pad adjustment the extradig dipper wear pads are bolt-on replaceable items. They support and guide the inner dipper section during extension and retraction. The following procedures explain how to inspect, and where applicable, adjust the pads. There is a front and rea...

Page 127: Body & Framework

26 - 1 section b body & framework 9803/3280 section b 26 - 1 issue 1 service procedures sideshift - hydraclamp clearance setting if the kingpost clearance d is not set correctly leaks may occur or the seal could become dislodged, use the procedure below to set the clearance. 1 park the machine on fi...

Page 129: Body & Framework

26 - 3 removal 1 park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the loader arms to the ground. 2 position the carriage centrally and rest the bucket on the ground, remove the starter key. 3 undo and remove nuts b . 4 remove split pins d and...

Page 131: Body & Framework

30 - 2 section b body & framework 9803/3280 section b 30 - 2 issue 1 air conditioning hvac/air conditioning unit - removal and replacement note: before removing the hvac/air conditioning unit, discharge the system. Refer to service procedures, air conditioning - refrigerant charging and discharging....

Page 133: Body & Framework

30 - 4 section b body & framework 9803/3280 section b 30 - 4 issue 1 air conditioning blower unit - removal and replacement the blower w is located inside the hvac/air conditioning unit and can be removed without having to remove the hvac unit from the machine. The only user-serviceable part is the ...

Page 135: Body & Framework

30 - 6 binary pressure switch - removal and replacement the pressure switch is located adjacent to the expansion valve s on the hvac/air conditioning unit, beneath the right hand side console. ! Warning goggles and rubber gloves must be worn when pressure switches are removed or fitted. A small amou...

Page 137: Body & Framework

35 - 2 removal and replacement removal 1 park the machine on firm level ground. Engage the parking brake and set the transmission to neutral. 2 remove loader end attachment (such as a shovel) if fitted. If the attachment is hydraulically operated, disconnect attachment hoses and plug/cap immediately...

Page 139: Danger

36 - 2 removal and replacement - (centremount machines) removal 1 park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the backhoe and loader end to the ground and stop the engine. 2 lower the stabiliser legs to the ground. Danger hydraulic press...

Page 141: Body & Framework

36 - 4 removal and replacement - (sideshift machines) removal 1 park the machine on firm level ground. Engage the parking brake and set the transmission to neutral. 2 lower the loader shovel to the ground. 3 make sure that the backhoe assembly is set central to the mainframe as shown. If necessary '...

Page 143: Body & Framework

37 - 2 removal and replacement removal 1 slew the kingpost to the centre and remove the boom and dipper. ! Warning hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses....

Page 145: Danger

38 - 2 boom - removal and replacement removal the procedures describe the removal of the boom with the boom and dipper rams still installed. If required, these items can be removed separately before removing the boom, refer to the appropriate removal and replacement procedure. 1 remove the backhoe b...

Page 147: Danger

38 - 4 dipper - removal and replacement removal the procedures describe the removal of the dipper with the extradig (if fitted) and the bucket ram still installed. If required, these items can be removed separately before removing the dipper, refer to the appropriate removal and replacement procedur...

Page 149: Body & Framework

40 - 1 removal and replacement removal 1 park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the loader arms to the ground. 2 position the carriage in the central protruding travel position at 150 mm (6 in) from end of the rail, rest the bucket ...

Page 151: Body and Framework

51 - 1 section b body and framework 9803/3280 section b 51 - 1 issue 1 cab panels removal and replacement front/steering console removal 1 park the machine on firm level ground, apply the parking brake. Lower the loader arms and excavator to the ground, switch off the engine and remove the starter k...

Page 153: Electrics

Ii section c electrics 9803/3280 section c ii issue 3* contents page no. Alternator removal and replacement 30 - 1 starter motor removal and replacement 40 - 2 inspection 40 - 2 dismantling and assembly 40 - 2 earth points 145 - 1 harness data drawings 150 - 1 harness interconnection 150 - 1 * www.W...

Page 155: Electrics

2 - 1 general electrical data system type 12 volt, negative earth battery (heavy duty) - cold crank amps for 1 minute to 1.4 volts per cell at -18 deg c (0 deg f) 550 - reserve capacity (minutes) for 25 amp load 220 battery (temperate) - cold crank amps for 1 minute to 1.4 volts per cell at -18 deg ...

Page 157: Electrics

2 - 2 fuses and relays fuses ! Caution always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5 the relays and fuses are located in the side console underneath cover a . If a fuse melts, find out why and rectify the fault before fitting a new one. The fuses ...

Page 159: Electrics

Electrics basic system operation section c section c 9803/3280 issue 3* 4 - 1 4 - 1 r a d io 861 h a za r d w a r n in g fr o n t w/l tu r n s ig n a l front console instruments w a te r te m p s e n d e r 18 - p r im a r y fu s e 3 tr a n s o il p r e s e .S .O .S . 10 a l te r n a t o r w a te r t...

Page 161: Electrics

4 - 3 main components: 59 cigar lighter 60 face level fan 61 face level fan switch 62 heated seat 63 heated seat switch 64 rear washer/wiper switch 65 rear wiper motor 66 rear washer motor 67 front washer/wiper switch 68 front washer motor 69 front wiper intermittent electronic control unit 70 front...

Page 163: Electrics

3 6 10 fo r / r e v 7 9 4 3 2 fo r / r e v s witc h tr a n s d u mp r e la y 1 f r 812 1 2 n 4 to fuse a5 mission & steer mode options 10 2 7 5 tr a n s m is s io n e a r th 5 r e v e r s e a la r m 8 8 1 m a in s h a ft s o le n o id 850 fo r w a r d h ig h s o le n o id d u m p s witc h (lo a d e ...

Page 165: Electrics

4 - 7 circuit schematics - options steer mode - 4cx and 3cx super (4x4x4) 1 front axle proximity switch 2 rear axle proximity switch 3 steer mode selector switch 4 steer mode printed circuit board 5 crab relay 6 crab/4 wheel steer relay 7 2 wheel steer relay 8 4 wheel steer relay 9 4 wheel steer/cra...

Page 167: Electrics

854 933 8 4wd s witc h 1 2 3 4 4wd s o le n o id 9 6 6 illu m in a tio n 922 101 107 829 816 830 5 3 7 10 a u t o 2wd r e la y r h b r a k e lig h t 107 4wb r e la y 4th s p e e d p /s h ift fe e d lh b r a k e lig h t a u t o 2wd r e la y 858 7 5 877 b r a k e lig h ts s witc h 974 illu m in a tio ...

Page 169: Electrics

4 - 11 circuit schematics - options hand held tools 1 selector switch 2 indicator lamp 3 roadbreaker solenoid dedicated quickhitch 1 hitch enable switch 2 quick-hitch relay 3 warning buzzer 4 lever ‘hold-in’ button 5 lever ‘hold-in’ button 6 quick-hitch solenoid pole planter 1 selector switch 2 grab...

Page 171: Electrics

Electrics basic system operation section c section c 9803/3280 issue 2* 4 - 13 4 - 13 10 7 106 922 8 6 p a r k b r a k e r e la y 10 n e u tr a l s ta r t r e la y 6 7 from parkbrake warning light 3rd g e a r 120 ohm resistor r e v e r s e a la r m r e la y d ia g n o s tic s p /b r a k e s witc h 1...

Page 173: Electrics

4 - 15 section c electrics 9803/3280 section c 4 - 15 issue 1 basic system operation main components: 1 thermostart 2 battery 3 starter switch 4 neutral start relay 5 starter solenoid 6 starter motor 7 ignition relay ‘1’ 8 transmission dump relay 9 forward/reverse selector lever 10 forward relay 11 ...

Page 175: Electrics

Electrics basic system operation section c section c 9803/3280 issue 1 4 - 17 4 - 17 8 011 401 402 engine oil pres s tr o b e li g h t s k t ha nd b ra ke 830 tr a ns o il t em p s wi tch fuse c6 2 861 2 a ir fi lt er f/ w/ l s wi tch 4 106 412 011 7 7 116 405 r /w/ l s wi tch a lt erna tor fuse b1 ...

Page 177: Electrics

19 - 1 electrical testing methods - using a multimeter these instructions are intended to cover the use of the recommended multimeters. 1 make sure that the test leads are plugged into the correct sockets. The black test lead should be plugged into the black socket (sometimes, this socket is also ma...

Page 179: Electrics

19 - 3 electrical testing methods - using a multimeter 1 measuring dc voltage a on the fluke 85 turn the switch to position b . B on the av0 2003 move the right slider switch to position a , and the left hand slider switch to the appropriate range. C on an analogue meter turn the dial to the appropr...

Page 181: Electrics

19 - 5 electrical testing methods - using a multimeter 4 testing a diode or a diode wire a diode wire is a diode with male connector fitted on one end and a female connector fitted on the other end. The diode is sealed in heatshrink sleeving. A on the fluke 85 turn the switch to position d . Press t...

Page 183: Electrics

20 - 2 section c electrics 9803/3280 section c 20 - 2 issue 1 service procedures battery (cont’d) testing this test is to determine the electrical condition of the battery and to give an indication of the remaining useful ‘life’. Before testing ensure that the battery is at least 75% charged (sg of ...

Page 185: Electrics

Starter motor starting circuit test before carrying out the voltmeter tests, check the battery condition (see battery testing) and ensure that all connections are clean and tight. To prevent the engine starting during the tests ensure that the engine stop fuse is removed, (refer to fuse identificati...

Page 187: Electrics

23 - 1 wiring harness introduction instances do occur where it is necessary to incorporate auxiliary electrical components into existing electrical circuits and, although unlikely with present wiring harnesses, repair or replace specific individual wires within a harness. This will also apply to oth...

Page 189: Electrics

E turn the red ring d to the right (in the direction of the plus sign) in order to turn on the gas. Important: before turning the heater on, make sure that the cartridge is not hotter than the reflector element. This may occur if the cartridge is held in the hand for a long time. The temperature dif...

Page 191: Electrics

40 - 1 section c electrics 9803/3280 section c 40 - 1 issue 1 starter motor s02043c www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 193: Electrics

145 - 1 earth points section c electrics 9803/3280 section c 145 - 1 issue 1 harness data a405010 dr2 e2 mb f f1 f2 f nj e a c47 e f a e1 e g fb1 h dr2 www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 195: Electrics

Harness interconnection the harness number refers to and corresponds with the annotations in the schematic drawing on the adjacent page. Harness no. Issue remarks page 1 front console 721/10940 1 4 speed powershift / synchro shuttle 151 - 1 721/10937 3 6 speed powershift (shiftmaster) 151 - 3 2 side...

Page 197: Electrics

Electrics harness data section c section c 9803/3280 issue 2* 151 - 1 151 - 1 721/10940_1 key to connectors: fa bulkhead plug fb front cab earth fc steer mode unit fd forward relay forward h.L fe reverse relay reverse h/l ff drive relay interlock relay fg transmission dump blank fh 4ws auto 2wd fj l...

Page 199: Electrics

Electrics electrics harness data harness data section c section c 9803/3280 issue 1 151 - 3 151 - 3 a721/10937_1 harness drawing - front console, 6 speed powershift (shiftmaster) page 1 of 2 - cad 721/10937 issue 1 key to connectors: fa bulkhead plug fb front cab earth fc steer mode unit fg transmis...

Page 201: Electrics

Electrics harness data section c section c 9803/3280 issue 2* 153 - 1 153 - 1 721/10936_1 harness drawing - side console, page 1 of 4 * - cad 721/10936 issue 1 (machines up to serial no. 933756) www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 203: Electrics

Electrics electrics harness data section c section c 9803/3280 issue 2* 153 - 3 153 - 3 721/10936_3 harness drawing - side console, page 3 of 4 - cad 721/10936 issue 1 (machines up to serial no. 933756) www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 205: Electrics

Electrics electrics harness data harness data section c section c 9803/3280 issue 1 153 - 5 153 - 5 721/10970_1 harness drawing - side console, page 1 of 5 - cad 721/10970 issue 2 (machines from serial no. 933757) www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 207: Electrics

Harness drawing - side console, page 3 of 5 - cad 721/10970 issue 2 (machines from serial no. 933757) 153 - 7 section c electrics 9803/3280 section c 153 - 7 issue 1 harness data key to connectors: cb cab link cu ignition switch (cu1) cv instrument panel cw fuel gauge cwa fuel gauge illium cx water ...

Page 209: Electrics

Electrics electrics har ness data har ness data section c section c 9803/3280 issue 1 153 - 9 153 - 9 7 2 1 /1 0 9 7 0 _ 3 har ness drawing - side console, page 5 of 5 - cad 721/10970 issue 2 (machines from serial no. 933757) www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 211: Tri

155 - 2 s e c tio n c e le c tri c s 9803/ 3280 s e c tio n c 155 - 2 issue 1 ha rne ss d a ta harness drawing - cab roof (usa only) page 2 of 2 - cad 721/10966 issue 1 721/10966_2 key to connectors: c5 lh worklight c10 beacon socket c15 lh front indicators c20 rh worklight c25 lh headlights c30 rh ...

Page 213: Tri

155 - 4 s e c tio n c e le c tri c s 9803/ 3280 s e c tio n c 155 - 4 issue 1 ha rne ss d a ta harness drawing - cab roof (not usa) page 2 of 2 - cad 721/10965 issue 1 c30 5 c40 8 c25 1 721/10965_2 key to connectors: c5 lh worklight c10 beacon socket c20 rh worklight c25 lh headlights c30 rh headlig...

Page 215: Tri

157 - 1 s e c tio n c e le c tri c s 9803/ 3280 s e c tio n c 157 - 1 issue 1 ha rne ss d a ta harness drawing - steer controls, page 1 of 1- cad 721/10968 issue 1 721/10968_1 key to connectors: ma 2ws md 4ws me cab connector mf rear proximity switch sa steer mode feed sm steer mode feed www.Worksho...

Page 217: Tri

160 - 1 s e c tio n c e le c tri c s 9803/ 3280 s e c tio n c 160 - 1 issue 1 ha rne ss d a ta harness drawing - transmission, page 1 of 2 - cad 721/10943 issue 1 37 49 13 721/10943_1 key to connectors: la front console harness lb side console harness lc gearbox ld transmission oil temperature switc...

Page 219: Tri

160 - 3 s e c tio n c e le c tri c s 9803/ 3280 s e c tio n c 160 - 3 issue 1 ha rne ss d a ta harness drawing - transmission, page 1 of 2 - cad 721/10942 issue 1 36 60 48 31 37 49 25 13 30 24 12 36 60 48 37 49 13 30 24 12 13mm wide (nom) red tape (2 posn) front console harness side console harness ...

Page 221: Tri

160 - 5 s e c tio n c e le c tri c s 9803/ 3280 s e c tio n c 160 - 5 issue 1 ha rne ss d a ta harness drawing - transmission, page 1 of 2 - cad 721/10941 issue 1 solenoid identification hsg id function id char c20 forward high c30 forward low c40 mainshaft c50 layshft c60 reverse low c70 reverse hi...

Page 223: Electrics

Harness drawing - transmission - sychro shuttle, page 1 of 1 - cad 721/10938 issue 2 * 1.0 dest ga 4 c dest 1.0 ga 3 reverse solenoid type gc 1.0 term sa 2 600bt wire 811 size 1 type forward solenoid type size 1.0 405 gb d e,f wire 1.0 600bu xmsn oil press sw gf 2 1.0 wire 812 term 600bu c 600bs a s...

Page 225: Electrics

Harness drawing - engine mainframe, page 1 of 2 - cad 721/10935 issue 2 * 721/10935_1 165 - 1 section c electrics 9803/3280 section c 165 - 1 issue 2* har ness data www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 227: Electrics

Harness drawing - rear lights / hydraclamp - sideshift, page 1 of 1 - cad 721/10944 issue 1 721/19044 key to connectors: la cab plug lb hydraclamp lc rh rear lights ld lh rear lights sa earth sb brake lights 165 - 3 section c electrics 9803/3280 section c 165 - 3 issue 2* har ness data * www.Worksho...

Page 229: Electrics

165 - 5 section c electrics 9803/3280 section c 165 - 5 issue 1 har ness data harness drawing - rear horn / alarm - centre mount page 1 of 1 - cad 721/10947 issue 1 1 size 847a wire c,d 600cd 2 s10 term 1.0 a,b c50 type reverse alarm reverse alarm c103 c,d dest 1.0 1 size 835 wire c,d 600bj 2 s10 te...

Page 231: Controls

Contents page no. Steering column removal and replacement 30 - 1 dismantling and assembly 30 - 1 shovel reset (214e machines) 31 - 1 return to dig operation 33 - 1 adjustment 33 - 1 precision control (servo) machines up to serial no. 931159 basic system operation - component location 35 - 1 - compon...

Page 233: Controls

A396921 30 - 1 section d controls 9803/3280 section d 30 - 1 issue 2* steering column g a b r d n c h c b l f f b b e j h h m p t g s h www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 235: Controls

2065mm a320510 31 - 1 section d controls 9803/3280 section d 31 - 1 issue 1 shovel reset h e b g f h a j l m k c www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 237: Controls

33 - 1 section d controls 9803/3280 section d 33 - 1 issue 1 return to dig a374040 1 2 x www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 239: Controls

35 - 1 section d controls 9803/3280 section d 35 - 1 issue 1 precision control (servo) a402030 v p r h p g f s j m u k a c l s e q d t n u u u u b basic system operation component location www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 241: Controls

Full pressure servo exhaust key to oil flow & pressure 1h 3h 3h 4j 4h 4 1 4 2 pl pr tr tl tp t p 3 1 2 3 p t p t 2h 2j 2j 1h s1b s2b s3b s4b s3b s2b s2a iso + sae + sae + s3a s1a s2a s3a s4a 4j 1j 3j h h j j a n g b d d z q l k r f e a402070 m t 4 t p 1 2 3 q e g f s tp pl p tr tl pr t tl 2 t p 3 4 ...

Page 243: Controls

1 2 1 2 1 2 1 4 2 3 1 6 2 5 3 4 6 1 5 2 4 3 5 4 6 3 7 2 8 1 4 5 3 6 2 7 1 8 5 4 6 3 7 2 8 1 4 5 3 6 2 7 1 8 5 4 6 3 7 2 8 1 4 5 3 6 2 7 1 8 5 4 6 3 7 2 8 1 4 5 3 6 2 7 1 8 hh 4 1 3 2 hf hg sb sc sh ta a1 dr2 cm cp sd sa ha ctg ctb hb hd hc he 3 5 875 101bg 101ag 875b 600hx 1805f 101y 600kh 921 929 9...

Page 245: Controls

37 - 1 fault finding introduction the fault finding procedures are given in the form of flow charts. There are a number of charts, each one dedicated to a particular fault. The charts are designed to identify possible causes by performing checks and where applicable, specific tests. Having identifie...

Page 247: Controls

37 - 3 section d controls 9803/3280 section d 37 - 3 issue 1 precision control (servo) no yes no yes yes no yes is the pilot supply valve oil filter blocked? Start is the pilot oil pressure low? Are the joystick linkages worn? Check the condition of the universal joints and actuator plates on the pi...

Page 249: Controls

37 - 5 section d controls 9803/3280 section d 37 - 5 issue 1 precision control (servo) yes no yes yes no no is the relevant wiring damaged? Start check for damage and carry out continuity checks. Repair as applicable. Test and renew switch if applicable. Does the system operate with the operator sea...

Page 251: Controls

38 - 2 section d controls 9803/3280 section d 38 - 2 issue 1 precision control (servo) a402430 a c b f d e d d www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 253: Controls

38 - 4 service procedures seat arms control lever - adjustment in some instances it may be necessary to adjust the operation of the arms raise/lower control lever 1 . When the button 2 is depressed upwards fully, the arms are released for raise/lower. If the arms are not released, or release but re-...

Page 255: Controls

40 - 2 pilot control valves removal and replacement note that the procedure shows the right hand control valve. The removal and replacement procedure for the left hand valve is identical. Before attempting to remove a pilot control valve the pilot circuit accumulator pressure must be vented. 1 stop ...

Page 257: Controls

40 - 4 section d controls 9803/3280 section d 40 - 4 issue 1 precision control (servo) pilot control valves dismantling, inspection and assembly note that the procedure shows the right hand control valve. The procedure for the left hand valve differs only in the location of one way restrictors 4 and...

Page 259: Controls

41 - 2 electrical switches joystick mounted microswitches, removal and replacement note that the procedure shows the right hand joystick. The procedure is very similar for the left hand joystick. Note that where the joysticks incorporate more than one switch, all switches must be renewed as a comple...

Page 261: Controls

45 - 2 basic system operation component identification a right hand joystick controller b left hand joystick controller c operator seat d servo pressure supply valve e isolation valve solenoid f accumulator g servo pressure regulating valve h servo pressure relief valve j loader valve block k excava...

Page 263: R.H.

T ls p b a b a b a full pressure servo exhaust key to oil flow & pressure 1 1 3 3 s1a s2a s5a s6a s2b s5b s5a sae+ iso+ iso+ s2a s1b s2b s5b s6b l.H. A404990 3 1 4 2 r.H. 3 1 4 2 l.H. A b a b a b a b a b a b a b t1 ls p m p t t3 c 4 1 3 2 p t 4 3 2 1 p t 1h 1h s3a s3b s4a s4b s7a s7b 2 1 p 4 t 3 p2 ...

Page 265: Controls

45 - 6 basic system operation electrical operation - joystick controller there are two solenoid actuated isolation valves incorporated in the servo pressure supply valve block, which when energised direct servo pressure to enable the r.H. And l.H. Joystick controllers. Each valve solenoid is control...

Page 267: Controls

45 - 8 section d controls 9803/3280 section d 45 - 8 issue 1 precision control (servo) a404750 hydraulic symbol pv p2 t p1 basic system operation servo pressure supply valve - description the servo pressure supply valve is fitted with a pressure regulating valve 1 , a pressure relief valve 2 and two...

Page 269: Controls

47 - 2 section d controls 9803/3280 section d 47 - 2 issue 1 precision control (servo) yes yes no start no yes no yes a405600 does the system operate if the seat is locked in the opposite facing position? Check that the arm rests are raised forward (i.E. Not pushed back) check the function of the se...

Page 271: Controls

47 - 4 section d controls 9803/3280 section d 47 - 4 issue 1 precision control (servo) yes no yes start a405690 no inspect the associated joystick controller valve capsule for signs of wear, damage or contamination. Is the valve in good working order? Clean and renew components as applicable. Refer ...

Page 273: Controls

50 - 1 section d controls 9803/3280 section d 50 - 1 issue 1 precision control (servo) joystick controllers removal and replacement ! Danger hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pres...

Page 275: Controls

Joystick controllers dismantling and assembly dismantling the illustration shown on the opposite page is intended as a guide to dismantling. Be sure to note the location of all components when dismantling. Although some components may appear to be identical they are not interchangeable. Make sure th...

Page 277: Controls

1 2 3 4 2b 2a 5 6 7 a404760 servo pressure supply valve dismantling and assembly 51 - 2 section d controls 9803/3280 section d 51 - 2 issue 1 precision control (servo) www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 279: Controls

A404500 60 - 1 section d controls 9803/3280 section d 60 - 1 issue 1 control rods and linkages x b a k c d j e g h f dismantling and assembly loader valve controls locking pin a404660 k www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 281: Controls

A404810 61 - 1 section d controls 9803/3280 section d 61 - 1 issue 1 control rods and linkages dismantling and assembly excavator valve controls (jcb + pattern) a j b d c e f g h h k l locking pin www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 283: Controls

A404491 0 1 2 - 3- - 70 - 1 section d controls 9803/3280 section d 70 - 1 issue 1 control cables s x z r d c x e removal and replacement cab heater controls r t y www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 285: Controls

71 - 1 section d controls 9803/3280 section d 71 - 1 issue 1 control cables removal and replacement stabiliser controls a404730 a404700 h d b e c f g www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 287: Controls

A404510 72 - 1 section d controls 9803/3280 section d 72 - 1 issue 1 control cables a394410 removal and replacement boom lock cable b a c 6 4 2 5 1 3 a405180 x d www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 289: Controls

73 - 1 section d controls 9803/3280 section d 73 - 1 issue 1 control cables removal and replacement engine throttle cable a404690 a404670 a404680 d g j k k e f e c www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 291: Controls

74 - 1 section d controls 9803/3280 section d 74 - 1 issue 1 control cables removal and replacement auxiliary footpedal cable the auxiliary footpedal control a is mounted in the cab floor as shown. The cable operates the auxiliary control valve located adjacent to the excavator valve. The cable is a...

Page 293: Hydraulics

Ii section e hydraulics 9803/3280 section e ii issue 4* contents page no. Loader valve - variable flow operation 7 - 1 priority inlet section operation 7 - 2 auxiliary spool 7 - 4 loader shovel spool 7 - 5 loader lift spool 7 - 6 shuttle valve signal network 7 - 7 excavator valve manual control - ne...

Page 295: Hydraulics

Iv section e hydraulics 9803/3280 section e iv issue 4* contents page no. Excavator valve removal and replacement manual control 60 - 1 variable flow 60 - 4 precision control (servo) 60 - 6 dismantling and assembly manual control 61 - 1 - auxiliary relief valves (arv’s) 61 - 3 - hydraclamp valve (si...

Page 297: Hydraulics

1 - 1 section e hydraulics 9803/3280 section e 1 - 1 issue 1 service tools hydraulic circuit pressure test kit 892/00253 pressure test kit :892/00201 replacement gauge 0-20 bar (0-300 lbf/in 2 ) :892/00202 replacement gauge 0-40 bar (0-600 lbf/in 2 ) :892/00203 replacement gauge 0-400 bar (0-6000 lb...

Page 299: Hydraulics

1 - 3 section e hydraulics 9803/3280 section e 1 - 3 issue 1 service tools hexagon spanners for ram pistons and end caps 992/09300 55mm a/f 992/09400 65mm a/f 992/09500 75mm a/f 992/09600 85mm a/f 992/09700 95mm a/f 992/09900 115mm a/f 992/10000 125mm a/f female cone blanking plug 892/00055 1/4 in. ...

Page 301: Hydraulics

2 - 1 hydraulic pumps fixed flow model/reference double pump/4070h mounting gearbox theoretical displacement: cc/rev cu in/rev pump section 1 (mounting flange end) 33 2.01 pump section 2 23 1.40 flow at 2200 rev/min and system pressure (90% min displacement): litres/min uk gal/min us gal/min pump se...

Page 303: Hydraulics

2 - 3 hydraulic pumps variable flow type variable displacement reference a10vo - 978753 mounting gearbox load sense pressure (in neutral position) maximum permitted - 5 bar; 72.5 lbf/in 2 load sense pressure relief valve (if fitted) 230 bar; 3335 lbf/in 2 stand-by pressure 20 bar; 290 lbf/in 2 maxim...

Page 305: Hydraulics

2 - 5 section e hydraulics 9803/3280 section e 2 - 5 issue 3* technical data component key: 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 8 unloader solenoid 9 auxiliary relief valve 10 tank port...

Page 307: Hydraulics

2 - 7 section e hydraulics 9803/3280 section e 2 - 7 issue 2* technical data relief valve pressures loader valve - variable flow bar kgf/cm 2 lbf/in 2 priority relief valve† 170 - 176 173 - 179 2450 - 2550 auxiliary relief valves (a.R.V.) @ 0.5gal/min (1.9 litres/min) shovel ram head side 170 - 174 ...

Page 309: Hydraulics

2 - 10 section e hydraulics 9803/3280 section e 2 - 10 issue 3* technical data relief valve pressures excavator valve - precision control (servo) (machines up to serial no. 931159) component key: 1 bucket 2 dipper 3 stabiliser 4 stabiliser 5 boom 6 slew 7 auxiliary relief valve 8 tank port 9 pilot o...

Page 311: Hydraulics

2 - 11 relief valve pressures auxiliary valve - fixed flow bar kgf/cm 2 lbf/in 2 extradig ram head side 138 - 145 141 - 148 2000 - 2100 extradig ram rod side 207 - 214 211 - 218 3000 - 3100 jaw bucket ram head side 138 - 145 141 - 148 2000 - 2100 jaw bucket ram rod side 207 - 214 211 - 218 3000 - 31...

Page 313: Dra

H y dra u lic s 9803/ 3280 issue 1 3 - 1 3 - 1 b a sic s yst e m o p e ra tio n s e c tio n e s e c tio n e a401400 26 t 1c 6 13 4 3 p 7 1b component location www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 315: Dra

H y dra u lic s 9803/ 3280 issue 1 3 - 3 3 - 3 b a sic s yst e m o p e ra tio n s e c tio n e s e c tio n e 5 a401420 p2 p1 7 1b 13 62 6 26 1c t 3 4 5 component location www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 317: Dra

H y dra u lic s 9803/ 3280 issue 1 3 - 7 3 - 7 b a sic s yst e m o p e ra tio n s e c tio n e s e c tio n e 5 a401430 26 6 t 3 4 1a 13 p component location www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 319: Hydraulics

Pumps & motors 3 - 10 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...

Page 321: Hydraulics

3 - 12 introduction to hydraulic schematic symbols (cont'd) energy transmissions and conditioning section e hydraulics 9803/3280 section e 3 - 12 issue 1 basic system operation a189720 a189710 pilot control drain lines flexible pipe line junction crossing lines air bleed line plugged, also pressure ...

Page 323: Hydraulics

3 - 14 introduction to hydraulic schematic symbols (cont'd) control valves control valves are usually represented by one or more square boxes. Fig. 1 shows a control valve represented by three boxes. The number of boxes indicates the number of possible valve operating positions, (4 boxes - 4 positio...

Page 325: Hydraulics

3 - 20 3cx, 4cx, 214, 215, 217 & ‘s’ series machines 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 ...

Page 327: Hydraulics

Hydraulics circuit schematics - fixed flow section e section e 9808/3280 issue 1 3 - 22 3 - 22 3cx ‘s’ series & 4cx gear pump options this c irc uit sho w s t he ex t end ing dip p er and po w er sideshift, for the main hydraulic circuit see pages e/3-20 and e/3-21. Component key hpco high pressure ...

Page 329: Hydraulics

3 - 24 214e machines component key: a hydraulic tank b return filter c hydraulic oil cooler d hydraulic pump e twin check valve f shovel rams g quick release couplings h lift rams j loader valve block j1 main relief valve j2 auxiliary spool j3 lift spool j4 shovel spool k flow regulator valve (optio...

Page 331: Hydraulics

Hydraulics circuit schematics - variable flow section e section e 9803/3280 issue 1 3 - 26 3 - 26 38 36 39 37 40 41 a b a b a b a b a b a b a b a b a b a b p ls t 26 28 27 29 15 15a 17 18 25 17 18 17 18 17 18 17 18 17 18 17 18 16a 16 34 16 15 33 32 31 15 15 30 28 16 16 p t a b r l 45 48 46 47 ls p t...

Page 333: Hydraulics

3 - 28 4cx, 4cx super machines (6 spool with high/low flow options) 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 res...

Page 335: Hydraulics

3 - 30 4cx, 4cx super machines hand held tools option component key p pump variable flow t hydraulic tank x main circuit connection 1 pressure flow regulator 2 high pressure flow spool 3 relief valve (2000 lb/in 2 - 138 bar - 146 kgf/cm 2 ) 4 load sense solenoid 5 hand held tool 6 shuttle valve 9 ex...

Page 337: Hydraulics

4 4g 4f 4e 4d 4c 4b 4a 4s 4t 4r 4q 4p 4n 17 18 19 20 21 22 23 24 4m 4l 4k 4j 4h 4u 5 6 7 9 3e 3f 3g 3h 11 12 13 14 15 16 1 1a 1b 1c 2a 2 8 3a 3 3m 3q 3n 3p 3l 3b 3c 3d 10 hydraulics circuit schematics section e section e 9803/3280 issue 2* 3 - 32 3 - 32 a396210 precision control (servo) (machines up...

Page 339: Hydraulics

3 - 34 section e hydraulics 9803/3280 section e 3 - 34 issue 1 basic system operation hydraulic circuit schematic precision control (servo) (machines from january 2003) the schematic shows the main system hydraulics for precision control (servo) machines. For the pilot circuit refer to relevant page...

Page 341: Hydraulics

Hydraulics circuit schematics section e section e 9803/3280 issue 1 3 - 36 3 - 36 b2 t a4 b a3 4 pv a1 1 p2 p a7 t 2 b4 b t a 2 1 c p2 t3 b3 1 a2 a a b6 p 2 1 b a t a6 3 t 1 p a p 2 4 b p1 t a5 a t b7 b 2 b a m b1 b p t2 ls t1 p b5 3 30 31 32 33 34 4 35 19 22 26 25 23 24 20 27 21 a405700 precision c...

Page 343: Hydraulics

P2 b d c a p1 a a396380 hydraulics 9803/3280 issue 1 5 - 2 5 - 2 circuit descriptions section e section e a b full pressure pressure servo neutral exhaust cavitation lock up a390630 key to oil flow & pressure www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 345: Hydraulics

5 - 4 section e hydraulics 9803/3280 section e 5 - 4 issue 1 circuit descriptions 13 p ls t a p 4 11 6 5 12 10 9 3 2 1 8 7 neutral circuit pressure pressure generated by operation of a service trapped oil exhaust a275730 www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 347: Hydraulics

5 - 6 section e hydraulics 9803/3280 section e 5 - 6 issue 1 circuit descriptions 13 p ls 2 1 8 7 4 3 t a p 11 6 5 12 10 9 neutral circuit pressure pressure generated by operation of a service trapped oil exhaust a275740 www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 349: Hydraulics

5 - 8 section e hydraulics 9803/3280 section e 5 - 8 issue 1 circuit descriptions 13 p ls t a p 4 11 6 5 12 10 9 3 2 1 8 7 neutral circuit pressure pressure generated by operation of a service trapped oil exhaust a275750 www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 351: Hydraulics

Hydraulics 9803/3280 issue 1 6 - 1 6 - 1 circuit descriptions section e section e loader valve - neutral circuit component key: b parallel gallery c gallery d drilling t tank port 1a pump inlet (section p1) 1b high pressure carry over 1c pump inlet (section p2) 3b main relief valve 3c lift ram spool...

Page 353: Hydraulics

Hydraulics 9803/3280 issue 1 6 - 3 6 - 3 circuit descriptions section e section e 3m 3l 3p 3c c 3d 3e 3q t 3j 3n 1c(p2) 1a(p1) w a401170 full pressure pressure servo neutral exhaust cavitation lock up a390630 key to oil flow & pressure www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co....

Page 355: Hydraulics

Hydraulics 9803/3280 issue 1 6 - 5 6 - 5 circuit descriptions section e section e loader valve - load hold check valves component key: 1a pump inlet b parallel gallery d service line 3c lift ram spool 3j load hold check valve 33 lift ram 34 lift ram operation 1 the illustration shows 'arms raise' be...

Page 357: Hydraulics

Hydraulics 9803/3280 issue 1 6 - 7 6 - 7 circuit descriptions section e section e 33 b 1a 34 3c 3j d c e a396390 33 34 3c a a a396400 full pressure pressure servo neutral exhaust cavitation lock up a390630 key to oil flow & pressure www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 359: Hydraulics

Hydraulics 9803/3280 issue 1 6 - 9 6 - 9 circuit descriptions section e section e loader valve - a.R.V. Operation component key: 1a pump inlet 3c lift ram spool 3d shovel ram spool 3f arv - head side 3g arv - rod side 31 shovel ram 32 shovel ram under normal operating conditions, with the shovel in ...

Page 361: Hydraulics

Hydraulics 9803/3280 issue 1 6 - 11 6 - 11 circuit descriptions section e section e b e a d c 3b 3d 1a a h d g f 1a 2 d c a e f 1a 3 1 a401180 full pressure pressure servo neutral exhaust cavitation lock up a390630 key to oil flow & pressure www.Workshopmanuals.Co.Uk purchased from www.Workshopmanua...

Page 363: Hydraulics

7 - 1 loader valve - variable flow operation the loader valve is mounted on the chassis frame, right hand side (when viewed from rear). It is a stack type, directional control valve that is configured for closed centre operation. The valve block comprises two or three service valve sections and a pr...

Page 365: Hydraulics

7 - 3 loader valve - variable flow priority inlet section operation service selected (no steering demand) if the steering is not selected, there will be no pressure demand signal in chamber c . Pump pressure is ‘dead ended’ at the steer unit, this pressure is felt in chamber f via priority port pr a...

Page 367: Hydraulics

Loader valve - variable flow loader shovel spool the loader shovel spool operates in the same manner as the auxiliary spool, refer to auxiliary spool . The shovel valve section also houses auxiliary relief valves (items 30 and 30a ). Under normal operating conditions, with the shovel in the ' carry'...

Page 369: Hydraulics

Loader valve - variable flow shuttle valve signal network each control valve section has two shuttle valves. Each valve compares two pressure signals. One of the shuttles is the primary 18 and the other is the secondary 17 . The p rimary shut t le 18 c omp ares t he p ressure signal between the two ...

Page 371: Hydraulics

Hydraulics 9803/3280 issue 1 8 - 2 8 - 2 circuit descriptions section e section e 4a 4b a 4c 4d 4e 4f c b a401190 full pressure pressure servo neutral exhaust cavitation lock up a390630 key to oil flow & pressure www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 373: Hydraulics

Hydraulics 9803/3280 issue 1 8 - 4 8 - 4 circuit descriptions section e section e component key: b parallel gallery d service line 4b spool 4s load hold check valve excavator valve - load hold check valves operation 1 flow to the service via a typical solid spool 4b is controlled by the load hold ch...

Page 375: Hydraulics

Hydraulics 9803/3280 issue 1 8 - 6 8 - 6 circuit descriptions section e section e c 4h 4j 4a d b a401220 e a396350 full pressure pressure servo neutral exhaust cavitation lock up a390630 key to oil flow & pressure www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 377: Hydraulics

Hydraulics 9803/3280 issue 1 8 - 8 8 - 8 circuit descriptions section e section e componet key: 4a slew spool 4e dipper spool 4f bucket spool 4h arv 4j arv 4m arv 4n arv 4p arv 4q arv (option) excavator valve - slew a.R.V. And anti- cavitation operation the spool 4a is in neutral but the momentum of...

Page 379: Hydraulics

Hydraulics 9803/3280 issue 1 8 - 10 8 - 10 circuit descriptions section e section e g b a 1 k f e d c b a 3 k e l d c a 2 k f e j h a390480 full pressure pressure servo neutral exhaust cavitation lock up a390630 key to oil flow & pressure www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals....

Page 381: Hydraulics

Excavator valve precision control (servo) (machines up to serial no. 931159) component key: a inlet port b outlet port c centering spring d integral load sensing valves (isolator compensator spools) e bypass compensator valve f load sense drain regulator and relief valve g hydra-clamp solenoid valve...

Page 383: Hydraulics

8 - 15 section e hydraulics 9803/3280 section e 8 - 15 issue 1 circuit descriptions a402770 t e1 2 e 5 r 1 3 p pump = 20 bar load = 100 bar 20 bar ls = 0 bar s a402780 pump = 40 bar ls = 20 bar load = 100 bar 20 bar e1 2 e t 5 r 1 3 h u 4 p s a402790 full pressure pressure servo exhaust lock up key ...

Page 385: Hydraulics

Excavator valve precision control (servo) (machines up to serial no. 931159) hydraclamp valve operation when the backhoe is being used for excavating duties, the kingpost assembly must be 'clamped' to the sideshift rearframe. The hydraclamp control valve assembly (items g , d and c ) is positioned i...

Page 387: Hydraulics

Excavator valve precision control (servo) (continued) (machines from january 2003) load sense - pressure compensator valves operation no service selected (all spools in neutral) with the spools in the neutral position oil from the pump p flows to each service spool s and is dead ended. This generate...

Page 389: Hydraulics

8 - 21 section e hydraulics 9803/3280 section e 8 - 21 issue 1 circuit descriptions a405050 bucket actuation pc ls p1 p2 a405060 ls bucket actuation boom actuation pc full pressure pressure servo neutral exhaust cavitation lock up a390630 key to oil flow & pressure www.Workshopmanuals.Co.Uk purchase...

Page 391: Dra

H y dra u lic s 9803/ 3280 issue 1 10 - 1 10 - 1 cir c uit d e sc rip tio ns s e c tio n e s e c tio n e smooth ride system 1 1 2 3 4 t a391100 4 3a 3b 3c 3d 3e 3f 3g 3h 3j 1 1 3j 3j t acc p1 p2 3 2 s307310 www.Workshopmanuals.Co.Uk purchased from www.Workshopmanuals.Co.Uk.

Page 393: Hydraulics

11 - 1 hose burst protection valve boom & dipper operation the small letter annotations a , b, x , and y are stamped on the valve. Operation 1 - load raise when 'dipper out' is selected, oil from the excavator valve block is fed to port b , the oil opens check valve c against spring d and passes thr...

Page 395: Hydraulics