Section C
Section C
Electrics
i
i
Contents
Page No.
Technical Data
General Electrical Data
Fuse Identification (Except 3CXE, 214E)
Relay Identification (Except 3CXE, 214E)
Fuse Identification - 3CXE, 214E
Relay Identification - 3CXE, 214E
Fuse Identification - Servo Command
Relay Identification - Servo Command
Fuse Identification - 214Se
Relay Identification - 214Se
Fuse Identification - From Serial No. 495455
Relay Identification - From Serial No. 495455
Relay Identificatioon - Autoshift only
Relay Identificatiom - Powershift transmission - From Serial No. 495455
Relay Identification - Syncro shuttle transmission - From Serial No. 495455
Link Box Fuses
Bulbs
1-1
1-2
1-3
1-4
1-4
1-5
1-5
1-6
1-6
1-7
1-7
1-8
1-8
1-8
1-9
1-9
Test Methods
Use of Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
How to Test a Diode or Diode Wire
2-1
2-3
2-3
2-3
2-4
Psion Workabout
Introduction of Autoshift Transmission
Loading JCB Supplied Psion Software Onto The Workabout
- Downloading Psion Programs To The Workabout
- Starting Link From The Psion Command Processor
- Disabling Link
- Psion Connection To The Information Display Centre
- Powershift Auto Diagnostic And Fault Finding
Fault Finding
Servo Command Fault Finding
* Brake Light Switch
Adjustment
5-1
5-1
5-2
5-3
5-5
6-1
7-1
9-1
Parking Brake Switch
Adjustment
10 - 1
Speed Sensor
- Testing
11 - 1
Servo Command
Fuse and Relay Panel - Removal and Replacement
12 - 1
Circuit Diagrams & Component Lists
Basic Machine (2WS)
Circuit Options and Variations
- Powershift (PS700) Transmission & Steer Circuit (AWS Machines Only)
- Powershift (PS700) Transmission (2WS Machines Only)
- Steer Circuit for 3CX 4x4x4 Machines
- 3CXE (214E Series 3) Machines Only
- 214e Series 4 Machines Only
9803/3270
4-1
18 - 1
18 - 5
18 - 7
18 - 7
18 - 9
18 - 12
Issue 9*
Section C
Section C
Electrics
ii
ii
Contents
Page No.
- Autoshift Transmission (2WS Machines Only)
- Autoshift Transmission (AWS Machines Only)
- Powershift (PS750) Transmission & Steer Circuit (AWS Machines Only)
- Powershift (PS750) Transmission (2WS Machines Only)
- Steer Circuit for 3CX 4x4x4 Machines
Auxiliary Electrical Options
- Hand Held Tools
- Dedicated Quick Hitch
- Pole Planter
- Smooth Ride System (SRS)
- Hammer
- Hand Held Tools (Variable Flow Pump)
- Powershift (PS750) 2/4WD Powered ON (Germany)
- Power Sideshift with Hammer Circuit
- Servo Command Pilot Circuit
* Basic Machine From Serial Number 495455 To 499999 And From 920000
Transmission And Steering From Serial Number 495455
Options From Serial Number 495455
Autoshift Transmission From Serial Number 495455
Auxiliary Electrical Options From Serial Number 495455
Servo Command Pilot Circuit From Serial Number 495455
9803/3270
18 - 15
18 - 17
18 - 19
18 - 21
18 - 21
18 - 23
18 - 23
18 - 23
18 - 23
18 - 24
18 - 24
18 - 25
18 - 25
18 - 26
19 - 1
19 - 5
19 - 7
19 - 9
19 - 11
19 - 13
Batteries
Safety
Specific Gravity Test
Battery Testing
20 - 1
20 - 2
20 - 2
Wiring Harness Repair
Harness Repair Introduction
Tools Required
Procedure
25 - 1
25 - 1
25 - 1
Starter Motor
Starting Circuit Test
Removal and Replacement
Dismantling
Service and Renewal
Assembly
38 - 1
38 - 4
38 - 4
38 - 4
38 - 4
Alternator
General Description
Service Precautions
Charging Test
Removal and Replacement
Dismantling and Assembly
Dismantling and Assembly (Magneti Marelli Type)
39 - 1
39 - 1
39 - 1
39 - 2
39 - 2
39 - 4
Harness Location
Cab and Chassis
Servo Command
Cab and Chassis - All Later Machines
40 - 1
40 - 2
40 - 3
Issue 6*
Electrics
Section C
Section C
Technical Data
1-1
1-1
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 C (0 deg F)
410
- Reserve capacity (minutes) for 25 amp load
170
Electronic Control Unit
Shift points Hz
449/05401
2nd to 3rd
3rd to 4th
693
1467
4th to 3rd
1304
3rd to 2nd
2nd to 1st
570
326
Note: The part number and ECU settings can be verified and checked on the Psion Workabout.
* Alternator
2WS
65 Amp nominal output
4WS
72 Amp nominal output
4WS (air conditioning or ServoPlus builds)
85 Amp nominal output
90
85
80
75
Max load
70
65
60
55
50
Output
amps
45
40
35
30
25
20
15
10
5
0
85A
500
Tick over
0
1000
1500
2000
2500
3000
Engine speed
rpm
65A
72A
A323770
A323770
9803/3270
Issue 3*
Electrics
Section C
Section C
Technical Data
1-2
1-2
! CAUTION
Always replace fuses with ones of correct ampere rating
to avoid electrical system damage.
8-3-3-5
The relays and fuses are located in the side console
underneath cover A.
If a fuse melts, find out why and rectify the fault before fitting
a new one. The fuses are identified using column letters (A, B
and C) and row numbers (1 to 9). Note that all the fuses are
shown (including optional equipment fuses). Your machine
may not be equipped with all the fuses shown on this page.
Fuse Identification (Except 3CXE, 214E)
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
25 Amp
10 Spare
COLUMN 'C'
1
Fog light
2
Main lights
3
Hazard lights
4
Beacon, interior light
5
Radio
6
Thermostart
7
Heater
8
Ignition relay coils
9
Main Beam
10 Dip Beam
9803/3270
Fuse Rating
3 Amp
7.5 Amp
15 Amp
10 Amp
5 Amp
20 Amp
30 Amp
3 Amp
15 Amp
15 Amp
10
9
8
7
6
5
4
3
2
1
5A
10A
4W
3A
3A
3A
A
5A
20A 10A 7.5A 7.5A
R
B
25A 20A 25A 10A
5A
15A 7.5A 15A
5A
0
15A 15A
C
3A
30A 20A
5A 10A 15A 7.5A 3A
A276790
A
A333470
Issue 3
Section C
Section C
Electrics
Technical Data
1-3
1-3
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.
Relay Identification (Except 3CXE, 214E)
* 21 Auto Hydraulic Speed Control (HSC)
1
Ignition
2
Neutral Start
22
Reverse High/Low Ratio ➀
3
Indicators
23
Drive (Layshaft/Mainshaft) ➀
Driveshaft Interlock ➀
4
Ignition
* 24
5
Heater
25
4 Wheel Steer ➂
6
Transmission Dump
26
2 Wheel Steer ➂
7
Hydraulic Speed Control (HSC)
27
Hammer Circuit
8
Forward Drive
28
Steer Relay 1 ➂
9
Buzzer
29
Steer Relay 2 ➂
10
Parking Brake
30
Auxiliary Attachment (Jaw)
11
Reverse Drive
12
Reverse Horn
13
Front Work Lights
14
Worklights (Italian, German requirement only)
15
Lights
16
Rear Work Lights
17
Intermittent Wash/Wipe
18
All Wheel Braking (standard machines)
18
Reverse alarm (autoshift machines)
19
Forward High/Low Ratio ➀
20
2 Wheel Drive ➁
fi
fl
‡
°
·
‚
➀
➁
➂
Powershift Machines Only
All Wheel Steer Machines Only
3CX 4x4x4 Machines Only - not applicable to N.Am.
1
4 7
0
£
2
5 8
!
$
3
6 9
@
%
¤
^
(
&
)
‹
*
⁄
›
AUTO
R
A260443
9803/3270
Issue 4*
Section C
Section C
Electrics
Technical Data
1-4
1-4
Fuse Identification - 3CXE, 214E
Relay Identification - 3CXE, 214E
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
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
Ignition
Neutral Start
Indicators
Ignition
Front Work Lights
Transmission Dump
Rear Work Lights
Forward Drive
Buzzer
Parking Brake
Reverse Drive
Reverse Horn
COLUMN 'B'
Fuse Rating
1
Instruments, buzzer
5 Amp
2
Front horn, front wiper/washer
15 Amp
3
Rear horn
7.5 Amp
4
Heated seat, cigar lighter, face level fan
15 Amp
5
Rear wiper/washer
5 Amp
6
Brake switch
10 Amp
7
Rear work lights
25 Amp
8
Headlights
20 Amp
9
Front work lights
12 Amp
10 Spare
COLUMN 'C'
1
Fog light
2
Main lights
3
Hazard lights
4
Beacon, interior light
10
9
8
7
6
Fuse Rating
3 Amp
7.5 Amp
15 Amp
10 Amp
5
4
3
2
1
4W
3A
3A
3A
A
5A
20A 10A 7.5A 7.5A
5A
10A
A
R
B
25A 20A 25A 10A
5A
15A 7.5A 15A
5A
0
15A 15A
C
3A
30A 20A
A333470
5A 10A 15A 7.5A 3A
A276790
0 1
0 4
0 2
5
3
6
7
0
8
!
9
@
P
F R
R
A265070
9803/3270
Issue 3
Electrics
Section C
Section C
Technical Data
1-5
1-5
Fuse Identification - Servo Command
Relay Identification - Servo Command
The relays and fuses are located in the side console
underneath cover A.
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
1
2
*3
*4
5
6
7
8
9
10
Spare
Spare
Left Amplifier
Right Amplifier
Right hand pilot valve
Left hand pilot valve
Return to dig
Main feed
Servo isolation switch
Change over solenoids
A
Fuse Rating
5 Amp
5 Amp
5 Amp
5 Amp
1 amp
10 Amp
3 Amp
15 Amp
Ignition
Front seat
Front mode changeover
Rear seat
Rear mode changeover
Right hand joystick proportional switch supply
Right hand amplifier supply
Front auxiliary supply
Hammer interlink
Stabiliser isolate
Left hand amplifier supply
Sweeper/Clam changeover
Pilot valves changeover
Auxiliary/Clam 2 changeover
Auxiliary/Clam 1 changeover
Stabiliser/Clam 2 changeover
Stabiliser/Clam 1 changeover
Stabiliser/Auxiliary 1 changeover
Stabiliser/Auxiliary 2 changeover
Stabiliser lower changeover
Stabiliser raise changeover
Stabiliser lower/mode changeover
Stabiliser raise/mode changeover
Dump interlink (autoshift only)
Spare
R11
R10
R8
R9
R13
R12
R6
R7
R15
R14
R4
R5
R17
R16
R2
R3
BUZZER
R1
10
9
8
7
6
5
4
3
2
1
R18
R20
R22
R24
R19
R21
R23
R25
A334090
9803/3270
Issue 3*
Section C
Section C
Electrics
Technical Data
1-6
Fuse Identification - 214Se
1-6
Relay Identification 214Se
COLUMN 'A'
1
Hydraulic auxiliary
2
Fuel pump solenoid (engine stop)
3
Turn signals
4
Spare
5
Gearbox control, Transmission
6
Spare
7
4WD (automatic brake)
8
Brake lights
9
Right hand sidelights
10 Left hand sidelights
Fuse Rating
5 Amp
5 Amp
7.5 Amp
COLUMN 'B'
1
Instruments, buzzer
2
Front horn, front wiper/washer
3
Spare
4
Auxiliary power socket
5
Rear wiper/washer
6
Brake switch
7
Rear work lights
8
Headlights
9
Front work lights
10 Beacon
Fuse Rating
5 Amp
15 Amp
COLUMN 'C'
1
Spare
2
Dip beam
3
Lights
4
Hazard
5
Face level fan
6
Radio
7
Thermostart
8
Heater
9
Ignition relay coils
10 Main beam
Fuse Rating
A
B
C
D
E
F
G
H
J
K
L
M
N
10 Amp
3 Amp
5 Amp
3 Amp
3 Amp
4 Wheel brake
Lights
Turn signals
Reverse drive
Forward drive
Front work lights
Parking brake
Transmission dump
Rear work lights
Neutral start
Ignition 1
Buzzer
Ignition 2
20 Amp
15 Amp
10 Amp
25 Amp
20 Amp
25 Amp
10 Amp
15 Amp
7.5 Amp
15 Amp
10 Amp
1 Amp
20 Amp
30 Amp
3 Amp
15 Amp
A
B
C
D
E
F
G
H
J
4W
4W
10
9
8
7
6
5
4
3
2
1
4W
A
A
3A 3A
3A
5A
5A 3A
10A
10A
7.5A
7.5A
5A 5A
5A
5A
K
B
B
10A
15A 20A
10A 25A
25A 20A
20A 25A 10A 15A
L
15 5A
5A
15A
1
M
1
N
C
15A
15A 3A
3A 30A 20A 1A 10A 15A
15A 7.5A
7.5A 15A
15A
2
345740
9803/3270
817/16774
2
345741
Issue 2
Section C
Technical Data
1-7
Fuse Identification - From Serial No. 495455
Fuse Rating
* COLUMN ‘A’
1
2
3
4
5
6
7
8
9
10
Hydraulic auxiliary
Fuel pump solenoid (engine stop)
Direction indicators
Steer mode proximity switch
Gearbox control, Transmission
Spare
Brake lights
4 wheel drive (automatic brakes)
Left hand side lights
Right hand side lights
10 Amp
5 amp
7.5 amp
7.5 Amp
10 Amp
5 Amp
3 Amp
5 Amp
5 Amp
* COLUMN ‘B’
1
2
3
4
5
6
7
8
9
10
Section C
Electrics
Instruments, Buzzer
Front horn, Front washer/wiper
Rear horn
Heated seat, Cigar lighter, Face level fan
Rear wiper/wash
Brake switch
Return to dig enable
Rear working lights
Headlights
Front working lights
5 Amp
15 Amp
7.5 Amp
15 Amp
10 Amp
10 Amp
5 Amp
25 Amp
20 Amp
25 Amp
1-7
* Relay Identification - From Serial 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
* COLUMN ‘C’
1
2
3
4
5
6
7
8
9
10
Lights
Hazard light
Beacon, Interior light
Radio
Thermostart
Heater
Ignition relay coils
Main beam
Fog light
Dip beam
7.5 Amp
15 Amp
10 Amp
5 Amp
20 Amp
30 Amp
3 Amp
15 Amp
3 Amp
15 Amp
P
Q
M
N
S
R
G
F
K
L
H
U
T
E
J
D
C
B
A
A356072
A357830
A356071
10 9 8
7 6 5
4 3 2 1
4WD
A
C
B
10 9 8
9803/3270
7 6 5
4 3 2 1
10 9 8
7 6 5
4 3 2 1
Issue 3*
Electrics
Section C
Technical Data
1-8
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
Section C
Ignition
Neutral Start
Indicators
Ignition
Heater
Parking Brake
Hydraulic Speed Control
Auxiliary Attachment (Jaw)
Buzzer
Auto Hydraulic Speed Control
Hammer
Reverse Horn
Front Working Lights
Working Lights (Italian, German requirement only)
Lights
Rear Working Lights
Intermittent Wash/Wipe
Reverse Alarm
1-8
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)
2
6
1
5
3
7
4
8
A359330
Relay Identification - Syncro Shuttle
* Transmission From Serial No. 495455
1
2
3
4
A
Transmission dump
Forward drive
Spare
Reverse drive
A333470
1
4
7
0
£
^
2
5
8
!
$
&
3
6
9
@
%
*
A334100
9803/3270
1
3
2
4
A357840
Issue 2*
Electrics
Section C
Section C
Technical Data
1-9
Link Box Fuses
1-9
Bulbs
To further protect the machine wiring harnesses and
electrical circuits, a fuse link box is fitted to the battery, as
shown at B. Remember to check the main circuit fuses as
well as the link box fuses shown on this page.
Head lights - main/dip †
45/37.5W
Front Lights ††
55W Halogen
Work lights
55 Halogen (front & rear)
Front side lights †
5W
1
Hazard warning lights, Beacon, Lights
30 Amp
Tail/stop lights
5/21W
2
Wash/Wipe, Transmission, Indicators
50 Amp
Fog light †
21W
3
Work lights, Fog Lights, Brake lights
50 Amp
Direction turn indicators
21W (front & rear)
Instruments
1.2W
4
Ignition, Heater, Thermostart
50 Amp
Warning lights
3W
Number plate light †
1 x 5W
Interior light
10W
Beacon †
70W Halogen
† Note: These items are not applicable to North America
†† Note: These items are applicable to North America only
B
S254320
1
2
3
4
9803/3270
A254310
Issue 1
Electrics
Section C
Section C
Test Methods
2-1
2-1
Use of Multimeter
These instructions are intended to cover the use of the recommended multimeters.
A
OFF
V/A
A
V/A
C
B
C
A171900
S153070
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 marked by a " – ", or "E" or marked as "COMMON" or "COM"). The red test lead
should be plugged into the red socket marked with "+", "V" or " ".
2
When making measurements ensure that the test probes have a good clean contact with bare metal, free from grease,
dirt, and corrosion as these can cause a false reading.
3
When measuring voltage:
Make sure that the correct range is selected, that is set the selector to a value equal to or greater than that you are about
to measure.
e.g. If asked to measure 12 Volts, set the selector to the 12V range. If there is no 12V range, set the selector to the next
range higher, 20V for instance.
If the meter is set to a range that is too low, it may be damaged.
e.g. setting to the 2V range to measure 12V.
9803/3270
Issue 1
Section C
2-2
Electrics
Section C
Test Methods
2-2
S153070
9803/3270
Issue 1
Section C
2-3
Electrics
Section C
Test Methods
2-3
Measuring DC Voltage
On the FLUKE 85
Turn the switch to position B.
On the AV0 2003
Move the right slider switch to position A, and the left hand slider switch to the appropriate range.
On an analogue meter
Turn the dial to the appropriate DC Volts range.
Connect the black probe to the nearest available suitable earth point, usually this will be the starter motor earth, the battery
negative, or the chassis.
Connect the red probe to the wire or contact from which you are measuring the voltage.
Measuring Resistance
Make sure there is no power to the part of the circuit you are about to measure.
Connect one probe at one end of the component or wire to be checked and the other probe at the other end. It does not
matter which way round the two probes are placed.
On the FLUKE 85
Turn the switch to position C and check that the sign at the right hand side of the display window is on. If the F sign is on
instead, press the blue button G to change the reading to .
Touch the meter lead probes together and press the REL ³ key on the meter to eliminate the lead resistance from the meter
reading.
On the AV0 2003
Move the right hand slider switch to position B, and the left hand slider switch to the appropriate Ohms ( ) range.
On an analogue meter
Move the dial to the appropriate Ohms ( ) range.
Measuring Continuity
Make sure there is no power to the part of the circuit you are checking for continuity.
Connect one probe to one end of the component or wire to be checked and the other probe to the other end. It does not
matter which way round the two probes are placed.
On the FLUKE 85
Turn the switch to position C and check that the beeper symbol appears at the left hand side of the display window. If the F
sign is on instead, press the button labelled F in the meter drawing.
If there is continuity in the circuit, the beeper will sound. If there is no continuity (open circuit), the beeper will not sound.
On the AV0 2003
Move the right hand slider switch to position B, and the left hand slider switch to position C.
If there is continuity (i.e. very low resistance) between two points the buzzer will sound.
On an analogue meter
Turn the dial to the lowest Ohms ( ) range.
If there is continuity (i.e. very low resistance) between two points the needle will move across fully (or almost fully) to the right
hand side of the scale.
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Issue 1
Section C
2-4
Electrics
Test Methods
Section C
2-4
How to Test 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.
On the FLUKE 85
Turn the switch to position D.
Press the HOLD button and check that the H sign appears at the top right hand side of the display window.
Connect the black probe to the end of the diode with a band or to the male connector of the diode wire. Connect the red
probe to the other end of the diode or diode wire. If the beeper does not sound the diode or diode wire is faulty. Connect the
red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be
connected to the other end of the diode or diode wire. If the beeper sounds or the meter does not read O.L., the diode or
diode wire is faulty.
Press the HOLD button and check that the H sign disappears from the right hand side of the display window.
On the AV0 2003
Move the right hand slider to position A, and the left hand slider switch to position C.
Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe
should be connected to the other end of the diode or diode wire. If the Avometer does not buzz the diode is faulty.
Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe
should be connected to the other end of the diode or diode wire. If the Avometer does not read "1" the diode is faulty.
On an analogue meter
Select the Ohms 1000s (1k) range.
Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe
should be connected to the other end of the diode or diode wire. The meter should read 20-400 K , if it reads more than this
the diode is faulty.
Select the Ohms 100s range.
Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe
should be connected to the other end of the diode or diode wire. The meter should read 300-400 , if it reads less than this the
diode is faulty.
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Issue 1
Electrics
Section C
Section C
Psion Workabout
4-1
4-1
INTRODUCTION OF AUTOSHIFT TRANSMISSION
1)
INTRODUCTION:
The Autoshift system comprises a Powershift gearbox controlled by an Electronic Control Unit (E.C.U.). This provides the
operator with an automatic gear change in 3rd and 4th when roading and 1st, 2nd and 3rd manual gear selection, for onsite work. In addition, a kickdown function has been incorporated. This allows the operator to temporarily select a lower
gear during site work or to select 2nd gear on the road if conditions demand this.
2)
KEY COMPONENTS:
Gearbox:
The existing 4 speed, 40 kph Powershift gearbox has a speed sensor fitted to detect the speed of rotation of the output
shaft. This information provides road speed information to the E.C.U. (see below).
E.C.U.:
The E.C.U. is a new component. It is a Solid State, microprocessor-based, electronics "black box", mounted inside the
cab under the right-hand-side mouldings. Based upon data supplied from the column switch, kickdown button, foot
throttle (see Controls/Instrumentation below), parkbrake switch, transmission dump switch and the speed sensor, the
E.C.U. controls the gear selection solenoid valves on the gearbox.
Controls/Instrumentation:
The gear selection is selected on the Forward, Neutral, Reverse (FNR) lever rotary switch but the "4" position is changed
to "A" for "Automatic" mode. Positions "1", "2" and "3" remain as current, manually selecting those gears.
A micro-switch is operated by the foot throttle pedal. This tells the E.C.U. whether throttle is selected or not.
A foot-operated kickdown button is located on the cab floor to the left of the brake pedal. When in a manually-selected
gear, if the kickdown is pressed, the next lowest gear is selected. By pressing kickdown again, the gearbox will revert to
the previous higher gear. When in automatic mode at slow speeds, pressing kickdown will engage 2nd gear. 3rd gear is
re-engaged either by a second press of the kickdown button or automatically when the machine reaches the preprogrammed speed for a 2nd to 3rd gear change.
The warning buzzer and red warning light on the front instrument panel will be activated if a gear selection is made which
is not allowed by the E.C.U. software (see System Logic). This comprises a double-bleep which will continue either until
the selection conditions are met, or the request is de-selected. For a non-allowed kickdown request, the buzzer will
double-bleep only once, at the time of the request. In the case of a speed sensor failure when in Automatic mode, the
buzzer will double-bleep continuously until the ignition is turned off. When the machine is re-started, the E.C.U. will be in
a "get you home" mode (see System Logic,).
3)
SYSTEM LOGIC
There are two modes of operation, Automatic and Manual. Automatic mode is selected via the FNR lever rotary switch
"A" position, and Manual mode by selecting a specific gear, "1", "2" or "3". The E.C.U. will not allow gear changes to
occur in either Automatic or Manual modes if outside the pre-programmed conditions. The following description explains
the system logic.
Automatic mode:
• When position "A" is selected, the transmission will change gear between 3rd and 4th automatically according to
road speed. This mode is recommended for roading only. On-site, manual gear selection is recommended.
Note: The system does not sense load on the transmission.
•
•
•
•
A change in direction can be made at any time. However, 4th gear in reverse is not available.
The foot throttle switch prevents the transmission changing from 3rd to 4th when travelling downhill with foot off the
throttle, providing engine braking. Note that if the transmission is already in 4th gear, the throttle switch has no effect.
If 4WD has been selected for the machine, 4WD is disengaged automatically in Automatic mode, except when 2nd
gear is engaged by kickdown, then 4WD is enabled for improved traction.
When braking, 4WD is engaged automatically. On the 3CX, this may be cancelled via the brake mode switch if 2
wheel braking has been selected.
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Issue 1
Section C
Electrics
Section C
Psion Workabout
4-2
4-2
Manual mode:
• 1st, 2nd and 3rd gears are selected in the normal way on the column switch.
• The E.C.U. does not allow downshifts above certain speeds. If attempted, a double-bleep will sound and the
transmission remains in its current gear until the speed has reduced sufficiently to allow a downshift to occur.
Upshifting is not speed limited.
• A change in direction can be made at any time.
• If 4WD is selected for the machine, 4WD is maintained in all 3 gears.
Kickdown facility - Manual mode
• When in 2nd or 3rd gear manual mode, pressing the kickdown button will result in a gear change to the next lowest
gear.
• Kickdown operation is subject to the same pre-programmed speed limits as downshifts. If a non-allowed kickdown is
requested, kickdown will not occur. The buzzer will sound a double-bleep. Note that the E.C.U. does not retain the
kickdown request in its memory, so kickdown will have to be re-selected once the machine speed has reduced.
• The transmission will revert to the original gear either by selecting a directional change on the FNR lever or by
pressing the kickdown button again.
Kickdown facility - Automatic mode
• When in 3rd gear automatic at slow speed, pressing the kickdown button will result in a gear change into 2nd. In 4th
gear automatic, kickdown is not allowed and pressing the kickdown button will not sound the warning buzzer.
• Kickdown operation is subject to the same pre-programmed speed limit as manual downshift 3rd to 2nd gear. If a
non-allowed kickdown is requested, kickdown will not occur. The buzzer will sound a double-bleep. Note that the
E.C.U. does not retain the kickdown request in its memory, so kickdown will have to be re-selected once the machine
speed has reduced.
• The transmission will change back up to 3rd gear when the machine speed reaches the pre-programmed limit. This
speed has been set near maximum speed in 2nd gear so that 3rd gear is not selected too early, for example during a
hill climb. The operator can reselect 3rd gear himself, overriding the automatic speed setting, by pressing the
kickdown button.
Note: Care is to be taken when downshifting, either by kickdown or manual selection on the column switch. It is
recommended that downshifting is not requested at high speed, relying on the downshift protection system to avoid
sudden deceleration. The downshift protection system is to reduce loads on the transmission, thereby improving its life,
and is not to be used as a means of pre-selecting a downshift when slowing down. If the speed sensor fails, (see "Get
you home" facility), downshift protection will not be available.
Warning buzzer/light:
• A double-bleep will sound for the following reasons;
Kickdown or manual downshift selected when machine speed is above the pre-programmed limit.
Failure of the speed sensor when in Automatic mode. In this case the buzzer will double-bleep continuously.
"Get you home" facility:
• If the speed sensor fails whilst roading in Automatic mode, the buzzer will start to double-bleep continuously and the
transmission will remain in the current gear, irrespective of machine speed. The machine must be brought to a stop as
soon as it is safe to do so and the ignition turned off. On starting the machine again, the buzzer will not sound and
only 3rd gear and kickdown to 2nd gear will be available in Automatic mode. In Manual mode, all three gears will be
available with kickdown. Note that there will be no downshift speed protection. Care is to be taken when
downshifting with either kickdown or gear selection on the column switch.
•
If the speed sensor fails whilst in Manual mode, the buzzer will not sound. All three gears will be available with
kickdown but there will be no downshift speed protection. If Automatic mode is selected, only 3rd gear and
kickdown to 2nd gear will be available. Again, there will be no downshift speed protection. Care is to be taken
when downshifting with either kickdown or gear selection on the column switch.
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Electrics
Section C
Psion Workabout
4-3
Section C
4-3
Diagnostics facility:
• A Sumitomo connector is provided within the right-hand side console to allow connection by the service engineer to
the on-board E.C.U. fault diagnostics system.
! WARNING
If you intend to use the Psion Tester while the
machine is in motion you must take all
precautions to ensure the safety of yourself
and others. Do not use the test equipment on
the public highway.
Elec 1-2
Do not use the machine with a defective or damaged speed sensor or the wrong gear will be indicated when 4th gear is
selected. If the ECU has a 4th gear/speed sensor activation feature, 4th gear will not be selected, this is to prevent the
operator continuing to operate the machine without downshift protection.
The safety start for a machine is normally obtained from the machine relays. However, if the ECU is powered up in gear,
neutral will have to be selected before drive can be obtained.
The Neutral, Handbrake and Dump are input selection signals to the ECU and are shown on the Psion UNIT STATUS
screen A. The ECU selections to the gearbox are displayed on screen B.
The example screen A shows FORWARD, LEVER 2 (2nd gear) selected and on screen B the ECU is selecting Neutral
because the DUMP switch is being operated.
A
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B
Issue 1
Electrics
Section C
Section C
Psion Workabout
5-1
5-1
Loading JCB-supplied Psion Software onto the Workabout
Install PsiWin application on the Dealership PC (PsiWin Users Guide)
Connect the Docking Holster to the PC (Refer Psion Workabout User Guide)
Insert Workabout into Docking Holster (Refer Psion Workabout User Guide)
A
Downloading Psion Programs to the Workabout
Run Link program on Workabout from: Command Processor screen refer step 2
Run the PsiWin Psion Manager on the PC (Refer Psion Workabout User Guide)
Select the ‘Copy...’ option from the ‘File’ menu
Specify the ‘From’ and ‘To’ drives as follows:
‘From’
Press ‘Browse’
In the ‘Computer’ window, select ‘PC’
In the ‘Drives’ window, select:
‘D:’ if installing from CD-ROM
‘A:’ if installing from floppy disk
(note that drive assignments may differ on your machine)
In the ‘Directories’ window, double-click on the ‘psion’ folder and then double-click on the required language
directory (ie ‘english’, ‘french’, ‘german’, ‘spanish’, ‘italian’, or ‘portuguese’)
In ‘File Name’ window, type ‘*.img’
Click on ‘OK’ to set this as the drive to read the program files from
‘To’
Press ‘Browse’
In the ‘Computer’ window, select ‘PSION’
In the ‘Drives’ window, select ‘Internal [RAMDRIVE]’
In ‘File Name’ window, type ‘*.*’
Click on ‘OK’ to select this as the drive to write program files to
Click on ‘OK’ to copy files between the PC and the Psion
If asked ‘Confirm File Replace’, click on ‘Yes to All’
When all programs are loaded. at ‘M>’ prompt (on Psion) press ‘Menu’ select ‘Remote Link’ (press Enter) and
using left or right arrow keys switch to ‘Off’. (This disables Link on Workabout, refer step 3)
B
Starting Link from the Psion Command Processor
1
After connecting the Psion
Press
On/Esc
The Psion display should be the System Screen.
If not, then press
Ctrl
Del
at the same time.
This resets the Psion and takes approximately 5 seconds.
Press
2
Menu
Select Command processor option using
Press
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Enter
Issue 1
Electrics
Section C
Psion Workabout
5-2
3
5-2
Display shows M> prompt.
Press
4
Section C
Menu
Select Special using
Select Remote link using
Press
5
Enter
Remote link settings screen: Off
Select Remote Link option using
To set Remote link On use
To activate Remote link press
Enter
Note: If a beep is sounded there is an error. Check all connections.
6
Remote link settings screen: On
After all programs have been copied ‘Disable Link’ see below.
C
Disabling Link
1
Navigate to Remote link screen as described in procedure B.
Set Remote link OFF using
Press
2
Enter
This screen is displayed when the Remote link is Off.
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Issue 1
Electrics
Section C
Psion Workabout
5-3
D
Psion Connection to the Information Display Centre (IDC)
1
After connecting the Psion
Press
Section C
5-3
On/Esc
The Psion display should be the System Screen.
If not, then press
Ctrl
Del
at the same time.
This resets the Psion and takes approximately 5 seconds.
Press
2
Select Command processor option using
Press
3
Menu
Enter
Display shows M> prompt.
Type ‘IDC’ or ‘idc’
Press
4
Enter
This will run the IDC program, then press any key.
At the next screen pressMenu
to display options.
Service
Perform Service
Turns OFF service indicator spanner and updates service history in IDC when
dealer and Engineer codes are entered.
Save History To Disc
Retrieves machine service history and saves to Psion internal drive.
Restore History From Disc
View saved history file.
PDI
Stores PDI information: Entered at PDI.
Dealer Account number.
Engineer identification number.
Installation
Stores installation information: Entered when machine is Installed.
Dealer Account number
Engineer identification number
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Issue 1
Section C
5-4
Electrics
Psion Workabout
Section C
5-4
View
VIN
Displays machine VIN number (eg. SLP3CXTSVE0469999 (17 digits))
PIN
History
Displays machine PIN number (eg. 0469999 (7 digits))
Displays machine history
Ex works date
PDI date
Installation date
Details of last two services
Displays machine hours.
Displays number of Services carried out.
Displays IDC product information.
Engine Hours
No Of Services
Product Information
Commissioning
IMPORTANT NOTE: Service mode must be set prior to entering VIN number.
Time
*VIN
*Engine Hours
*No Of Services
Service Params
†Service Mode
Allows time to be set from Psion Workabout internal clock without using buttons
(Refer Psion Workabout user guide to reset internal clock).
VIN number already entered by JCB production on new machines. When a new IDC
unit is fitted in the field the VIN number can be entered by dealer personnel. Number
must be entered twice to prevent errors (once it has been accepted it can not be
removed/replaced.)
Sets engine hours, can only be set once from zero.
Allows number of services to be set, can only be set once from zero.
Disabled for service personnel.
To change method of turning OFF service indicator light.
ENABLE (Dumb IDC) - Allow service indicator light to be turned OFF using clock
buttons. Select clock to 24 hour and key 0348 to extinguish light.
DISABLE (Intelligent IDC) - Service indicator light can only be turned OFF using
Psion.
* used only when a new IDC unit is fitted to replace the original IDC unit.
† replacement IDC’s are supplied as ‘Dumb’ units, use ‘service mode’ to disable.
Special
Delete History File
Delete All Histories
EXIT
9803/3270
Deletes service history file from Psion Workabout internal drive.
Deletes all history files on Psion Workabout internal drive
Quits IDC program.
Issue 2
Electrics
Section C
Psion Workabout
5-5
E
Section C
5-5
Powershift Auto Diagnostic and Fault Finding
If the Psion should lock up at any time during the use of the software, exit the
program by pressing
Ctrl at the same time.
1
After connecting the Psion
Press
On/Esc
The Psion display should be the System Screen.
If not, then press
Ctrl
Del
at the same time.
This resets the Psion and takes approximately 5 seconds.
Press Menu
2
Select Command processor option using
Press
3
Enter
Display shows M> prompt.
Type ‘AUTOPS’ or ‘autops’
This will run the AUTOPS program.
Press
4
Enter
This screen allows the user to verify that the correct ECU and Psion
software are being used.
Turn the ignition switch to ON
Press
5
Enter
If this screen appears:
Check wiring from Psion to ECU
Check power is on to the ECU
Check the remote link is OFF, see B steps 5 and 6.
Press On/Esc to QUIT the program.
6
ECU displays its details.
Allows the user to know which ECU is fitted without having to physically
inspect the ECU label.
Press
9803/3270
Enter
to Continue or On/Esc
to Exit program.
Issue 1
Electrics
Section C
Psion Workabout
5-6
7
5-6
This screen is displayed if the ECU and software being used are
incompatible.
Press On/Esc
8
Section C
to Exit program.
This screen shows the ECU software settings but does not allow the user
to make any changes.
These settings determine the downshift protection, gear lever set up, any
kickdown timer used and autoshift speeds.
This information can be useful for diagnosing any suspected faults.
Press
9
Enter
to Continue or On/Esc
to Exit program.
The ECU can detect faults with solenoids and wiring and only displays
this screen if a fault is found. On this screen example the ‘Reverse High’
is highlighted.
The Psion can detect either an open or short circuit in the solenoid or
electrical connections to the solenoid.
Check wiring to the solenoids
Check solenoids
Press
10
Enter
to Continue or On/Esc
to Exit program.
If ‘Continue’ is selected from the window at step 9 and the fault has not
been rectified this warning message is displayed.
This may result in missing gears.
Press
11
to Continue.
If the fault is rectified the highlighting disappears.
Press
12
On/Esc
Enter
to Continue or On/Esc
to Exit program.
If Continue is selected at step 11 and the fault has been rectified this
screen is displayed.
Press
9803/3270
On/Esc
to Continue.
Issue 1
Electrics
Section C
Psion Workabout
5-7
13
Section C
5-7
This is the next screen to be displayed, if there are no solenoid
connection faults this screen would be displayed after step 8.
This is the main diagnostic screen and is the final destination of the
software. The previous screens can not be recalled, exit the program and
restart if they are required again.
In this example the input lever/switch selection is FORWARD and LEVER
1, the ECU is selecting Forward 1st.
Press
On/Esc
to Exit the program.
Operating the various controls in the cab will change the display accordingly.
Some examples are shown below.
EXAMPLE 1
This example shows the input selection is FORWARD and 4th gear
automatic has been selected on the twist switch LEVER 3 and LEVER 4.
The THROTTLE switch signal must be highlighted to allow automatic
change up at the pre-determined SPEED FREQUENCY. This feature
prevents higher gears being selected when the machine is going downhill
and gathering speed.
EXAMPLE 2
This example shows the input selection is NEUTRAL, forward/reverse
lever in the neutral position, and LEVER 1, 1st gear selected on the twist
switch and the ECU is selecting Neutral.
EXAMPLE 3
This example shows the input selection is FORWARD and LEVER 2, 2nd
gear selected on the twist grip but the ECU is selecting Neutral as the
momentary DUMP switch is being pressed.
EXAMPLE 4
This example shows the input selection is FORWARD and LEVER 2, 2nd
gear selected on the twist grip but the ECU is selecting Neutral as the
HANDBRAKE is applied.
This condition will result in the machine warning alarm sounding a
continuous tone.
EXAMPLE 5
This example shows the input selection is FORWARD and LEVER 2, 2nd
gear selected on the twist grip but the ECU is selecting Forward 1st as
the KICKDOWN has been activated by pressing the momentary
kickdown switch.
9803/3270
Issue 1
Electrics
Section C
Section C
Fault Finding
6-1
Fault Finding Contents
Introduction
Page No.
Introduction
No drive on power up
No drive and continuous warning buzzer
No drive
Missing gears
No 4th gear (4 speed machines only)
Downshift protection not operating
No dump
No 4 wheel drive
Intermittent 4 wheel drive
Transmission will not downshift
Lower gear than switch selected engaged
Kickdown not operating
Reverse will not select
Psion unit will not operate
Fault
No drive on power-up.
6-1
6-1
6-1
6-1
6-1
6-1
6-1
6-2
6-2
6-2
6-2
6-2
6-2
6-2
6-2
6-2
The purpose of this section is to help you trace electrical
faults to a faulty unit. Once you have traced the faulty unit,
refer to the appropriate dismantling, inspecting and test
instructions given elsewhere in the Service Manual.
To help identify circuits, refer to the electrical schematic
diagrams.
Refer to Section F, Fault Finding also as this section will deal
with the mechanical aspect.
1
Before you begin fault finding, read the Safety
information at the beginning of this manual.
2
Make simple checks before say, stripping a major
component.
3
Make any relevant electrical checks before commencing
work.
Probable Cause
Action
Blown ECU fuse.
Check ECU fuse A5
ECU mainframe connector loose.
Check connector is mating correctly with
Gear twist switch not in neutral.
Gear switch must be in neutral on power up
before a gear can be selected.
ECU.
No drive and continuous
warning buzzer.
Attempting to select drive with the
handbrake engaged.
Release handbrake.
No drive.
Faulty gear switch.
Check switches and wiring.
Handbrake sticking.
Check handbrake assembly.
Faulty gearbox harness.
Check gearbox harness and connector for
continuity.
Faulty dump input.
Check dump switch and wiring.
Faulty solenoid(s)
Check solenoid(s) and wiring.
Fault gear switch
Check switch and wiring
Low oil pressures
Check clutch pack pressures, see Section F.
Check mainline pressure, see Section F.
Mechanical failure
See Section F.
Faulty speed signal
Check speed sensor and wiring.
Check speed sensor installation.
Missing gears
No 4th gear
(4 speed machine only)
..... continued
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Issue 1
Section C
Electrics
Section C
Fault Finding
6-2
Fault
6-2
Probable Cause
Action
Downshift protection not operating
Faulty speed signal
Check speed sensor and wiring.
Check speed sensor installation.
No dump selection
Faulty dump input
Check dump switch and wiring.
No 4 wheel drive (if fitted)
Faulty 4 wheel drive input
Check 4 wheel drive switch and wiring.
Faulty 4 wheel drive solenoid
Check solenoid and wiring.
Faulty 4 wheel drive input
Check 4 wheel drive switch and wiring.
2/4 wheel drive brake switch
operating
Check brake switch and wiring.
Intermittent 4 wheel drive
Transmission will not downshift
Speed too fast for selected downshift Slow the machine.
Lower gear engaged than selected
Kickdown engaged
Check kickdown switch and wiring.
Kickdown not operating
Speed too fast to engage lower gear
Slow the machine.
Faulty kickdown input
Check kickdown switch and wiring.
Reverse will not operate
Speed too fast to reverse direction
Slow machine.
Psion will not communicate
Faulty connecting lead.
Check lead connection.
No power to ECU
Turn ignition ON.
Check fuse A5.
Check power supply to ECU.
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Issue 1
Electrics
Section C
Servo Command Fault Finding
7-1
Fault Finding Contents
Introduction
Servo controls fail to operate
Controls from joystick fail to operate
but mode switch operates
Changeover from loader to
excavator controls fails to operate
Left hand controls fail to operate
Right hand rocker switch fails to operate
(clam, extending dipper, auxilary)
Left hand rocker switch fails to operate
(stabiliser, auxilary)
Stabilisers fail to operate
Stabiliser changeover logic fails to operate
Fault
Servo controls fail to operate
Controls from joystick fail to operate
but mode switch operates
Changeover from loader to
excavator controls fails to operate
Left hand controls fail to operate
Right hand rocker switch fails
to operate
(clam, extending dipper, auxilary)
7-1
Introduction
Page No.
9803/3270
Section C
7-1
7-1
7-1
7-1
7-1
7-1
7-1
7-2
7-2
The purpose of this section is to help you trace electrical
faults to a faulty unit. Once you have traced the faulty unit,
refer to the appropriate dismantling, inspecting and test
instructions given elsewhere in the Service Manual.
To help identify circuits, refer to the electrical schematic
diagrams.
Refer to Section E, Fault Finding also as this section will deal
with the hydraulic aspect.
1
Before you begin fault finding, read the Safety
information at the beginning of this manual.
2
Make simple checks before say, stripping a major
component.
3
Make any relevant electrical checks before commencing
work.
Probable Cause
Action
Blown servo fuse
Check fuses 5, 6, 8 and 9
No electrical power to left or right
pilot solenoid valves
Check enable switch and wiring for continuity
Check relay R1
No hydraulic pilot pressure
See Servo Command Hydraulic Fault Finding
Faulty front or rear seat proximity
switch
Check adjustment and operation.
Note: The indicator LED in the enable switch
illuminates as the seat switches operate.
Faulty relay
Check relay R2 and R4
Blown fuse to changeover solenoid
Check fuse 10
Faulty relay
Check relay R3 and R5
No electrical power to changeover
valves
Check wiring for continuity
Faulty changeover solenoid
Replace as required
Blown fuse
Check fuse 6
No hydraulic pilot pressure
See Servo Command Hydraulic Fault Finding
Blown fuse to right hand amplifier
Check fuse 4
Check supply to amplifier
Note: LED on amplifier illuminates green
to indicate supply
Faulty wiring between joystick
and amplifier
Check signal to amplifier
Note: LED on amplifier illuminates orange for
signal and red for fault
Faulty wiring between amplifier and
proportional solenoid on valve block
Check signal to solenoid valve
The signal is a pulse width modulated 12 volt
output and varies from 0 to 1.6 amps.
Issue 1
Electrics
Section C
Section C
Servo Command Fault Finding
7-2
Fault
Left hand rocker switch fails to
operate (stabiliser, aux)
Probable Cause
Blown fuse left hand amplifier
7-2
Action
Check fuse 3
As right hand rocker switch fails to operate
Stabilisers fail to operate
Stabiliser changeover logic
fails to operate
9803/3270
As, right hand rocker switch fails
to operate
Faulty relay
Check relays R16 to R23
Issue 1
Electrics
Section C
Brake Light Switch
9-1
Section C
9-1
Adjustment
An improved footbrake switch has been introduced on all
Backhoe machines from serial number 495500. It can be
identified by a white coloured terminal block and
supercedes the old switch with a green terminal block.
A firmer return spring has also been introduced to eliminate
brake pedal bounce.
1
With the brake pedal in the return position, screw the
switch A in fully until the body touches the brake pedal
lever.
2
Screw out one full turn to ensure the brake pedal lever
can only engage the switch plunger and not foul the
body.
3
Secure in position by tightening locknuts B.
4
Check the correct operation of the brake lights.
A
B
B
9803/3260
Issue 1
Section C
10 - 1
Electrics
Section C
Parking Brake Switch
10 - 1
Adjustment
Note: Depending on machine type, the parking brake switch
may be mounted as shown at A or B.
Select the starter switch to the ON position, do not start the
engine.
Select either forward or reverse.
Raise the handbrake to the ON position.
Screw the parking brake switch C in a clockwise direction
until the audible alarm sounds and the visual warning is
illuminated.
Lock switch C in position with lock nuts D.
Release the parking brake and the audible alarm should
cease and the visual alarm extinguish.
For adjustment of the Parking Brake, see Section G,
'Parking Brake Caliper'.
A
C
D
D
B
D
D
C
S218320
9803/3270
Issue 1
Electrics
Section C
Section C
Speed Sensor
11 - 1
11 - 1
Testing
Powershift machines fitted with an electronic control unit
(ECU) or a speedometer have a speed sensor A fitted. The
speed sensor detects the speed of rotation of the output
shaft and relays this information to the ECU.
See Powershift - Assembly, SECTION F for spacer
selection according to output gear ratios, number of teeth.
Because the ECU requires a speed signal in order to
determine the operating speed of the machine, certain gear
selections will not be permitted unless the speed signal is
being relayed, ie. downshift at too high a speed.
TA
B
TB
A
Note: The ECU is designed to inhibit 4th gear selection if the
speed sensor fails to relay a signal.
So that the speed sensor can be tested without removing, a
test lamp (part No. 892/00940) has been introduced.
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. Switch OFF the
engine and remove the starter key.
2
Connect the test lamp B as shown. Secure the wires
clear of the driveshaft and other moving components,
in a position where the light emitting diode (LED) can be
seen while operating the machine.
3
Turn the engine ON and drive the machine forward
approximately 5 feet, make sure it is clear in front.
Alternatively raise the wheels off the ground. If the
sensor is operating correctly the LED will illuminate
when a gear tooth passes the sender, as the speed
increases the light will flash, lighting continuously at
higher speeds.
4
If the LED fails to illuminate, remove the sender from
the transmission, placing a clean container underneath
to catch the oil.
5
With the ignition ON place a steel object such as a spanner against the sensor:
Does the LED now illuminate?
check
9803/3270
YES
NO
S308630
- Too large a gap, check correct spacer is fitted.
- Check damage to sensor from gear contact, renew as required and
the correct spacer is fitted.
- Check for battery voltage at pin 1 and an earth at pin 3. If the pins in the
harness and connector are OK, fit a new sensor and check if OK.
- If the fault is still apparent carry out a continuity check between the
connector and ECU.
- Repair or replace the harness as required.
- Check the ECU, replace as required.
Issue 1
Electrics
Section C
Section C
Servo Command
12 - 1
12 - 1
Fuse and Relay Panel
Removal
Replacement
1
Dissconnect the battery.
Replacement is a reversal of the removal procedure.
2
Remove parking brake gaiter A. Disconnect the parking
brake switch electrical connector J to prevent damage
to connector when removing the console.
Reconnect the battery and check the electrical circuits for
correct operation.
3
Remove screws B and lift off forward console C.
4
Undo screws D and raise the panel to gain access to
electrical connectors on the underside.
5
Release electrical connectors E and F, disconnect
panel illumination G and earth lead H.
6
The fuse and relay panel can now be removed.
J
A
C
B
G
D
F
E
H
9803/3270
352730
Issue 1
Electrics
Section C
Section C
Circuit Diagrams and Component Lists
18 - 1
18 - 1
Basic Machine
TO PAGE C/18-4
19
61
60
143
63
5
3
9
8
1
112
140
10
116 141
6
11
57
12
13 14
15
73
20
145
B
B
142
144
B/N
B/O
74
75
76
77
106
68
56
7
4
114
113
54
16
118
105
117
69
72
146
65
17
110
66
23
21
155
24
18
67
115
22
147 149 151 175
148 150 152
70
62
71
64
111
2
A273991
(CAD 852/30214-sheet 1 issue 5)
9803/3270
Issue 3
Electrics
Section C
18 - 2
Section C
Circuit Diagrams and Component Lists
18 - 2
Basic Machine
Refer to pages C/18-1 and C18-4.
The basic circuit shows a standard 3CX (214) machine fitted with syncro shuttle transmission and 2 wheel steer. The remaining
pages in section C/18 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 Technical Data pages at the beginning of Section C
for further fuse details and ratings.
..... continued
9803/3270
Issue 2*
Electrics
Section C
18 - 3
Circuit Diagrams and Component Lists
Section C
18 - 3
Basic Machine
Refer to pages C/18-1 and C18-4.
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
* Cable Colour Code
B
Black
N Brown
S
Slate
G Green
O Orange
U Blue
K
Pink
P
Purple
W White
LG Light Green
R
Red
Y
Yellow
Lights
140 LH Brake Light
141 RH Brake Light
142 LH Front Indicator
143 LH Rear Indicator
144 RH Front Indicator
145 RH Rear Indicator
146 Alternator Warning Indicator Light
147 Park Brake Indicator Light
148 Water Temperature Indicator Light
149 Transmission Temperature Indicator Light
150 Engine Oil Pressure Indicator Light
151 Transmission Oil Pressure Indicator Light
152 Air Filter Blocked Indicator Light
153 Hazard Warning Indicator Light
154 Main Beam Warning Indicator Light
155 Gauge Illumination
156 Turn Signal Indicator Light
157 Master Warning Lights
158 Side Lights Indicator Light
159 Rear Work Lights Indicator Light
160 Front Work Lights Indicator Light
161 Rear Fog Light Indicator Light
162 Rear Fog Light
163 LH Main Beam Light
164 RH Main Beam Light
165 LH Dip Beam Light
166 RH Dip Beam Light
167 LH Number Plate Light
168 LH Tail Light
169 LH Side Light
170 RH Number Plate Light
171 RH Tail Light
172 RH Side Light
173 Front Working Lights
174 Rear Working Lights
175 Brake Fluid Low Level Warning Light
9803/3270
Issue 3*
Electrics
Section C
Section C
Circuit Diagrams and Component Lists
18 - 4
18 - 4
Basic Machine
FROM PAGE C/18-1
35
34
162
164 165
163
27
29
167 169 170 172
168
173
171
174
42
89
33
31
30
166
37
36
39
41
90
32
95
26
40
84
25
78 79
157
158
156
86
86
94
87
80
160
154
159
161
153
83
82
88
85
121
132
81
93
91
133
92
120
119
A274000
(CAD 852/302142 sheet 2 iss 5)
9803/3270
Issue 3
Electrics
Section C
Section C
Circuit Diagrams and Component Lists
18 - 5
18 - 5
Powershift (PS700) Transmission & Steer Circuit - AWS Machines Only
63
16
61
5
3
12
68
43 44
8
1
140
9
136
141
134
46
114
102
4
135
115
102
16
112
47
53
48
45
117
101
116
124
127
100
113
110
67
114
64
96
176
175
49
97
50
51
177 178
52
62
98
2
111
119
9803/3270
99
A274010 (CAD 852/30214-2/6 iss 3
Issue 3
Electrics
Section C
Circuit Diagrams and Component Lists
18 - 6
* Powershift
Section C
18 - 6
Transmission (PS700) & Steer Circuit - AWS Machines Only
Refer to page C/18-5
Note: Except for the transmission and steer circuits (shown
opposite), the AWS electrical circuit is the same as shown
on Page C/18-1 to C/18-4.
It should be noted that some of the options shown may not
be fitted on all machine models.
Main Components
1
Battery
2
Starter Switch
3
Thermostart
4
Starter Solenoid
5
Starter Motor
8
Reverse Alarm
9
2/4 Wheel Drive Solenoid
12 Hydraulic Speed Control Solenoid
16 Diode
43 Mainshaft solenoid
44 Layshaft Solenoid
45 Forward Low Solenoid
46 Forward High Solenoid
47 Reverse High Solenoid
48 Reverse Low Solenoid
49 Crab/4 Wheel Steer Solenoid
50 4 Wheel Steer Solenoid
51 Crab Solenoid
52 2 Wheel Steer Solenoid
53 Steer Mode Printed Circuit Board
Switches
61 Transmission Dump Switch (Loader)
62 Forward/Reverse Switch
63 Park Brake Switch
64 Brake Light Switch
67 Hydraulic Speed Control Switch
68 Hydraulic Speed Control Switch
96 4 Wheel Drive Switch
97 Powershift Column Switch
98 Front Proximity Switch
99 Rear Proximity Switch
100 Steer Mode Select Switch
101 4 WS/Crab Selector (part of PCB - item 53)
102 2 WS/4 WS Selector (part of PCB - item 53)
9803/3270
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
Issue 3*
Electrics
Section C
18 - 7
Circuit Diagrams and Component Lists
Section C
18 - 7
* Powershift
Transmission (PS700) - 2WS Machines Only
and Steer Circuit for 3CX 4x4x4 Machines
Refer to page C/18-8
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 C/18-1 to C/18-4.
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
9803/3270
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 1
* 132 Steer Relay 2
134 Auto Hydraulic Speed Control Relay
* 135 Driveshaft Interlock 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
Issue 4*
Section C
18 - 8
Electrics
Section C
Circuit Diagrams and Component Lists
Powershift Transmission (PS700) - 2WS Machines
18 - 8
Steer Circuit for 3CX 4x4x4 Machines
132
A274021 (CAD 852/30214-6/6 issue 3)
9803/3270
Issue 4
Electrics
Electrics
Circuit Diagrams and Component Lists
Circuit Diagrams and Component Lists
Section C
18 - 9
Section C
18 - 9
* 3CXE (214E Series 3) Machines Only
A274310
9803/3270
Issue 2*
Electrics
Section C
18 - 10
* 3CXE
Section C
Circuit Diagrams and Component Lists
18 - 10
(214E Series 3) Machines 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
9803/3270
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 Technical Data pages at the beginning of Section C
for further fuse details and ratings.
Issue 2*
Electrics
Section C
Circuit Diagrams and Component Lists
18 - 11
* 3CXE
Section C
18 - 11
(214E Series 3) Machines Only
FROM PAGE
C/18 - 9
173
174
35
26
25
87
156
153
159 160
88
83
132
133
119
A274320
(CAD 852/30213)
A274320
9803/3270
Issue 2*
Electrics
Electrics
Circuit Diagrams and Component Lists
Circuit Diagrams and Component Lists
Section C
18 - 12
Section C
18 - 12
214e Series 4 Machines Only
19
35
7 8
60
5
3
6
140
9
1
40
37
10
13
58
31
143
142
20
145
144
33
61
141
32
34
113
41
4
97
72
116
114
17
80
82
96
115
110
92
25
83
22
23
21
62
112
64
71
111
2
A313490 (CAD 852/30219
9803/3270
Issue 2
Section C
18 - 13
Electrics
Section C
Circuit Diagrams and Component Lists
18 - 13
214e Series 4 Machines Only
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
13 Hydraulic Auxiliary Connector
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
28 Clock
29 Face Level Fan
31 Rear Washer Motor
32 Rear Wiper Motor
33 Washer Motor
34 Front Wiper Motor
35 Horn (Front)
37 Beacon/Strobe Light Socket
39 Radio
40 Heater Motor
41 Heater Resistor
58 Hammer Solenoid
59 Psion Electrical Connector
60 Cab Auxiliary Power Socket
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
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
173 Front Working Lights
174 Rear Working Lights
Fuses
A1 - A10
B1 - B10
C1 - C10
Refer to Technical Data pages at the beginning of Section C
for further fuse details and ratings.
Switches
60 Transmission Dump Switch (Gear)
61 Transmission Dump Switch (Loader)
62 Forward/Reverse Switch
63 Park Brake Switch
64 Brake Light Switch
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
80 Rear Washer/Wiper Switch
82 Front Washer/Wiper Switch
83 Horn Push (Front)
87 Front Working Lights Switch
88 Rear Working Lights Switch
92 Heater Switch
9803/3270
Issue 2
Section C
18 - 14
Electrics
Electrics
Circuit Diagrams and Component Lists
Circuit Diagrams and Component Lists
Section C
18 - 14
214e Series 4 Machines Only
74
76
59
73
75
77
26
174
173
39
60
29
54
87
78
88
24
147 149 151
146 148 150 152
28
18
132
133
119
A313410
9803/3270
Issue 2
9803/3270
9 8 7
1
2
2
1
FUSE P3
FUSE P2
FUSE P1
FUSE P4
FUSE P1 40A
FUSE P2 50A
FUSE P3 50A
FUSE P4 60A
4
3 4 5 6
6
126
2
8
5
2
6
5
7
6
1
3
111
1
8
65
1
3
2
8
67
1
8
6
1
3
8
83
1
10
7
8
5
18
17
4
22
1
71
1
1
3
9
9
9
9
9
M
ILLUMINATION
23
1
9
408
TACHOMETER
20
1
HOURMETER
FUEL SENDER
19
TACHOMETER
FUEL GAUGE
Circuit Diagrams and Component Lists
-
Circuit Diagrams and Component Lists
U
17
1
WATER TEMP SENDER
145
1
409
FLASHER UNIT
RH REAR INDICATOR
RH FRONT INDICATOR
LH REAR INDICATOR
LH FRONT INDICATOR
HAZARD SWITCH
FRONT HORN
FRONT WIPER
Electrics
-
6
401
806
805
144
1
WATER TEMP GAUGE
806
814
841
FRONT WASHER PUMP
HAMMER
WHEEL ALIGN SWITCH
RAER PROXIMITY SWITCH
FACE LEVEL FAN
INTERIOR LIGHT
REAR WIPER
REAR WASHER PUMP
HEATER RELAY
HEATER
E.S.O.S.
RH BRAKE LIGHT
LH BRAKE LIGHT
4WD SWITCH
4WD SOLENOID
P/BRAKE RELAY
P/BRAKE WARNING RELAY
REVERSE ALARM
Electrics
+
2
C2
2
U
72
1
+
82 7
1
49
2
3
802
5
31
1
49a
840
HEATER FAN MOTOR
870
34
1
FLASHER
RELAY
SUPER BRIGHT LED
HAMMER FOOT SWITCH
195
INDICATOR
SWITCH
839
8
142
1
804
7
66
1
7
805
2
977
864
3
HAMMER ISOL.
SWITCH
862
M
FRONT HORN SWITCH
2
820
863
HEATER RESISTOR
33
1
300
4
58
1
FUSE C4
3
35
1
143
1
104
80
29
1
803
8
1
5
78
1
REAR PROXIMITY SWITCH
800B
816
61
1
FUSE A3
64
1
92
1
HAZARD SWITCH
8
32
1
110
1
116
31
1
FUSE B2
115
1
8
110
6
FUSE A8
40
1
FRONT
WASH/
WIPE
SWITCH
6
303
4
7 10
101
10
9
800
933
140
1
FUSE A1
7
7
REAR WASH/
WIPE SWITCH
2
117
41
1
FUSE C5
9
853
61
1
M
103
105
3
10
1
FUSE B5
62
1
114
141
1
102
4
6
HEATER SWITCH
8
9
PARKBRAKE SWITCH
7 1
8
1
FUSE C8
2
7
63
1
4 WB
RELAY
1
REVERSE SOLENOID
REVERSE RELAY
FORWARD SOLENOID
FORWARD RELAY
DUMP SWITCH (LOADER)
DUMP SWITCH (GEAR)
214Se Machines & 214e From Serial No.
FUSE A2
3
10
REVERSE RELAY
9
1
BRAKE LIGHTS
SWITCH
5
811
812
6
1
877
815
113
PARKBRAKE
RELAY
808
4
R
3
N
809
60
1
FUSE B6
401
112
2
810
110
1
F
6
IGNITION RELAY 1
NEUTRAL START RELAY
STARTER SOLENOID
STARTER MOTOR
BATTERY
THERMOSTART
18 - 14A
FOR / REV
SWITCH
912
8
107
FORWARD RELAY
4
1
5
IGNITION
RELAY 1
002
842
BATTERY
1
200
FUSE A5
2
934
5
TRANS DUMP
RELAY
NEUTRAL START RELAY
003
5
1
FUSE C9
004
FUSE C7
3
1
200C
200B
IGNITION
SWITCH
010
Section C
Section C
18 - 14A
4
M
412
407
M
401
7
25
1
21 24
1
1
828
2
106
830
828
829
007
001
011
200D/200M
BATTERY FEED
200E/200R
200G
A347341
CAD 331/17034 sheet iss2
Issue 2
Electrics
Section C
18 - 14B
Section C
Circuit Diagrams and Component Lists
18 - 14B
* 214Se Machines & 214e From Serial No.
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
13 Hydraulic Auxiliary Connector
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
29 Face Level Fan
31 Rear Washer Motor
32 Rear Wiper Motor
33 Front Washer Motor
34 Front Wiper Motor
35 Horn (Front)
37 Beacon/Strobe Light Socket
39 Radio
40 Heater Motor
41 Heater Resistor
58 Hammer Solenoid
60 Cab Auxiliary Power Socket
61 Interior Light/Switch
62 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 Rear Steer Proximity Switch
66 Steer Alignment Switch
67 Hammer Isolation Switch
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
80 Rear Washer/Wiper Switch
82 Front Washer/Wiper Switch
83 Horn Push (Front)
9803/3270
87
88
92
93
94
95
Front Working Lights Switch
Rear Working Lights Switch
Heater Switch
Dip/main Light Switch
Road lights Switch
Hammer Foot Switch
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 4 Wheel Drive Relay
119 Ignition Relay ‘2’
132 Front Working lights Relay
133 Rear Working lights Relay
134 Road 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
173 Front Working Lights
174 Rear Working Lights
175 Front Dip and Main Lights
176 LH Tail and Side lights
177 RH Tail and Side lights
Fuses
A1 - A10
B1 - B10
C1 - C10
Refer to Technical Data pages at the beginning of Section C
for further fuse details and ratings.
Option - Smooth Ride System (SRS)
1
Selector Switch
2
Accumulator Switch
Issue 2*
9803/3270
BATTERY FEED
5
2
8
4
119
6
6
8
5
6
88
2
7
93
2
2
8
5
8
134
4
6
1
94
828
2
828
3
832
3
7
2
6
3
5
FUSE A9
8
'SRS'
SWITCH
837
834
ACCUMULATOR
SOLENOIDS
FUSE C10
FUSE C2
W
1801
830
829
17
FUSE A10
836
833
WATER TEMP SWITCH
LIGHT SWITCH
RH SIDE LIGHT
RH TAIL LIGHT
DIPPER SOCKET
LH SIDE LIGHT
LH TAIL LIGHT
RH MAIN BEAM
LH MAIN BEAM
LH DIP BEAM
RH DIP BEAM
STROBE LIGHT SKT
LIGHTS RELAY
REAR WORKING LIGHTS
FRONT WORKING LIGHTS
IGNITION RELAY 2
POWER SOCKET
RADIO SOCKET
ALTERNATOR
AIR FILTER VAC. SWITCH
TRANS OIL PRESS SWITCH
ENGINE OIL PRESS SWITCH
TRANS OIL TEMP SWITCH
Electrics
Electrics
Circuit Diagrams and Component Lists
Circuit Diagrams and Component Lists
3
2
95
600
4
1
DIP/MAIN
SWITCH
401
176
829
5
861
175
101
132
6
ROAD
LIGHTS
SWITCH
2
861
407
311
4
127
5
7
R/W/L SWITCH
117
76
FUSE
C3
011
312
007
3
ROAD LIGHTS
RELAY
106
6
894
4
855
855
39
FUSE
B10
18
87
011
146 147 148 149 150 151 152
116
62
309
SIDE CONSOLE
INSTRUMENTS
011
411
FUSE
B7
310
10
F/W/L SWITCH
412
FUSE
B9
114
26
IGNITION
RELAY 2
FUSE
B4
11
402
77
304
407
BUZZER
9
405
75
173
FUSE B8
829
403
74
AIR FILTER
12
TRANS OIL PRES
73
ENGINE OIL PRES
18
404
406
18 - 14C
FUSE
C6
106
7
FUSE
B1
3
TRANS OIL TEMP
16
WATER TEMP
HAND BRAKE
ALTERNATOR
Section C
Section C
18 - 14C
214Se Machines Only
OPTIONS
174
177
60
37
61
7
8
133
7
2
830
5
8
'SRS'
SMOOTH RIDE
SYSTEM
200D/200M
200E/200R
200G
Issue 3
Electrics
Section C
Section C
Circuit Diagrams and Component Lists
18 - 15
18 - 15
Autoshift Transmission - 2WS Machines Only
1
2
5
4
3
70
71
90
50
72
6
73
7
8
51
9
52
53
54
10
11
12
16
13
55
14
77
15
180D
74
17
18
56
19
75
57
76
A299420
(CAD 852/30214 sheet 5 iss 5
9803/3270
Issue 2
Electrics
Section C
18 - 16
Circuit Diagrams and Component Lists
Section C
18 - 16
Autoshift Transmission - 2WS Machines Only
Refer to page C/18-15
Except for the circuits shown opposite the 2WS Autoshift
electrical circuit is the same as shown on pages C/18-1 to
C/18-4.
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 Technical Data pages at the beginning of Section C
for further fuse details and ratings.
9803/3270
Issue 2*
Electrics
Section C
Section C
Circuit Diagrams and Component Lists
18 - 17
18 - 17
Autoshift Transmission - AWS Machines Only
1
2
4
5
3
70
71
90
50
72
6
73
7
8
51
9
52
53
10
54
11
12
16
13
14
55
15
17
74
18
75
56
76
19
57
A316310
9803/3270
Issue 1
Electrics
Section C
18 - 18
Circuit Diagrams and Component Lists
Section C
18 - 18
Autoshift Transmission - AWS Machines Only
Refer to page C/18-17
Except for the circuits shown opposite the AWS Autoshift
electrical circuit is the same as shown on pages C/18-1 to
C/18-4.
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 Technical Data pages at the beginning of Section C
for further fuse details and ratings.
9803/3270
Issue 1
Electrics
Section C
Circuit Diagrams and Component Lists
18 - 19
* Powershift
Section C
18 - 19
Transmission (PS750) & Steer Circuit - AWS Machines Only
Refer to page C/18-20
Note: Except for the transmission and steer circuits (shown
opposite), the AWS electrical circuit is the same as shown
on Page C/18-1 to C/18-4.
It should be noted that some of the options shown may not
be fitted on all machine models.
Main Components
1
Battery
2
Starter Switch
3
Thermostart
4
Starter Solenoid
5
Starter Motor
8
Reverse Alarm
9
2/4 Wheel Drive Solenoid
12 Hydraulic Speed Control Solenoid
16 Diode
43 Mainshaft solenoid
44 Layshaft Solenoid
45 Forward Low Solenoid
46 Forward High Solenoid
47 Reverse High Solenoid
48 Reverse Low Solenoid
49 Crab/4 Wheel Steer Solenoid
50 4 Wheel Steer Solenoid
51 Crab Solenoid
52 2 Wheel Steer Solenoid
53 Steer Mode Printed Circuit Board
Switches
61 Transmission Dump Switch (Loader)
62 Forward/Reverse Switch
63 Park Brake Switch
64 Brake Light Switch
67 Hydraulic Speed Control Switch
68 Hydraulic Speed Control Switch
96 4 Wheel Drive Switch
97 Powershift Column Switch
98 Front Proximity Switch
99 Rear Proximity Switch
100 Steer Mode Select Switch
101 4 WS/Crab Selector (part of PCB - item 53)
102 2 WS/4 WS Selector (part of PCB - item 53)
9803/3270
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
Issue 2
Section C
Section C
Electrics
Circuit Diagrams and Component Lists
18 - 20
18 - 20
Powershift (PS750) Transmission & Steer Circuit - AWS Machines Only
63
16
5
3
61
12
68
43 44
8
1
9
140
112
53
141
48
136
46
4
45
115
124
113
134
126
101
127
142
117
116
135
110
102
47
114
67
100
16
16
64
62
97
96
176
175
49
50
51
177 178
52
16
98
99
2
111
9803/3270
119
A325210
(CAD 852/30214 sheet 3 iss 5
Issue 1
Section C
Section C
Electrics
Circuit Diagrams and Component Lists
18 - 21
18 - 21
Steer Circuit for 3CX 4x4x4 Machines
Powershift Transmission (PS750) - 2WS Machines
12
63
3
61
49
43 44
16
5
112
140
1
68
141
125
8
65
117
46
45
48
132
47
131
134
4
135
115
116
63
126
124
110
114
113
147
67
127
130
16
50
100
178
16
62
52
64
16
177
129
97
99
98
2
111
119
A325220
(CAD 852/30214 sheet 4 issue 5)
9803/3270
Issue 1
Electrics
Section C
18 - 22
Circuit Diagrams and Component Lists
Section C
18 - 22
Powershift Transmission (PS750) - 2WS Machines Only
and Steer Circuit for 3CX 4x4x4 Machines
Refer to page C/18-21
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 C/18-1 to C/18-4.
It should be noted that some of the options shown may not
be fitted on all machine models.
Main Components
1
Battery
2
Starter Switch
3
Thermostart
4
Starter Solenoid
5
Starter Motor
8
Reverse Alarm
12 Hydraulic Speed Control Solenoid
16 Diode
43 Mainshaft Solenoid
44 Layshaft Solenoid
45 Forward Low Solenoid
46 Forward High Solenoid
47 Reverse High Solenoid
48 Reverse Low Solenoid
49 Drive/Brake Solenoid
50 4 Wheel Steer Solenoid
52 2 Wheel Steer Solenoid
Switches
61 Transmission Dump Switch (Loader)
62 Forward/Reverse Switch
63 Park Brake Switch
64 Brake Light Switch
65 Brake/Drive Select Switch
67 Hydraulic Speed Control Switch
68 Hydraulic Speed Control Switch
97 Powershift Column Switch
98 Front Proximity Switch
99 Rear Proximity Switch
100 Steer Mode Select Switch
9803/3270
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
Issue 1
Electrics
Section C
Section C
Circuit Diagrams and Component Lists
18 - 23
18 - 23
Auxiliary Electrical Options
6
3
2
5
2
2
3
4
1
4
1
3
1
2
1
Fuse B4
A308350
CAD 852/30214
Fuse A1
Fuse A1
Fuse A1
Hand Held Tools
(Gear Pump)
1
2
3
Switch
Indicator Lamp
Solenoid
9803/3270
Dedicated Quick Hitch
Pole Planter
Smooth Ride System (SRS)
1
2
3
4
5
6
1
2
3
1 Selector Switch/LED
2 Accumulator Solenoids
Hydraulic Enable Switch
Indicator Lamp
Warning Buzzer
Operator Switches
Relay
Solenoid
Selector Switch
Grab Solenoid
Rotation Solenoid
Issue 1
Electrics
Section C
Section C
Circuit Diagrams and Component Lists
18 - 24
18 - 24
(M)
600
Auxiliary Electrical Options (continued)
4
4
(M)
870
3
(P)
600
898
(P)
3
2
801
(M)
899
2
1
101
(P)
10A
(M)
101
1
Fuse A1
Fuse A1
Hammer
Hand Held Tools (Variable Flow Pump)
1
2
3
4
1
2
3
4
Micro Switch
Relay
Panel Switch
Hammer Solenoid
9803/3270
Switch
Indicator Lamp
Solenoid (normally open)
Solenoid
Issue 1
Section C
18 - 24A
Electrics
Circuit Diagrams and Component Lists
Section C
18 - 24A
Auxiliary Electrical Options (continued)
Hammer and Jaw Changeover Circuit
1 Foot Pedal Switch
2 Hammer Relay
3 Excavator Lever Switch
4 Jaw Relay
5 Panel Switch
6 Hammer Solenoid
7/8 Jaw Solenoid
9803/3270
Issue 1
Electrics
Section C
Section C
Circuit Diagrams and Component Lists
18 - 25
18 - 25
Auxiliary Electrical Options (continued)
5
5
7
920
6
8
870
4
3
1830
4
600
898
3
101
2
899
2
10A
101
101
1
1
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
9803/3270
Fuse A1
* 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
Issue 2*
Electrics
Section C
18 - 26
Section C
Circuit Diagrams and Component Lists
18 - 26
Servo Command Up To Serial No. 495454
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 Contol Switch
13
Transmission Dump Switch
14
Auxiliary Switch
15
Rear Horn
16
Quick Hitch Switch
17
Left Hand Amplifier
18
Left Hand Proportional Rocker Switch
19
Right Hand Amplifier
20
Right Hand Proportional Rocker Switch
21/22 Manifold Arms/Boom Changeover Solenoid
23/24 Manifold Shovel/Bucket Changeover Solenoid
25/26 Loader Solenoid
27/28 Auxiliary Solenoid
29/30 Excavator Left Hand Stabiliser Solenoid
31/32 Excavator Right Hand Stabiliser Solenoid
33
Manifold Left Hand Pilot Pressure Valve
34
Manifold Left/Right Hand Pilot Pressure Valve
35/36 Auxiliary Option Solenoid
37
Alarm
R20
R21
R22
R23
Stabiliser Lower Changeover
Stabilser Raise Changeover
Stabiliser Lower Mode Changeover
Stabiliser Raise Mode Changeover
On the illustration:
B = Bottom
T = Top
H = Head
R = Rod
Relays
R1 Ignition
R2 Front Seat
R3 Front Mode Changeover
R4 Rear Seat
R5 Rear Mode Changeover
R6 Spare
R7 Dump Interlink (autoshift only)
R8 Front Auxiliary Supply
R9 Hammer Interlink
R10 Stabiliser Isolator
R11 Spare
R12 Sweeper/Clam Changeover
R13 Pilot Valve Changeover
R14 Auxiliary/Clam 2 Changeover
R15 Auxiliary/Clam 1 Changeover
R16 Stabiliser/Clam 2 Changeover
R17 Stabiliser/Clam 1 Changeover
R18 Stabiliser/Auxiliary 1 Changeover
R19 Stabiliser/Auxiliary 2 Changeover
9803/3270
Issue 1
Electrics
Section C
Section C
Circuit Diagrams and Component Lists
18 - 27
18 - 27
Servo Command Pilot Circuit Up To Serial No. 495454
+12V
1816
1
1808
2
1813
1806
1811
RTD
1805
11
12 13 14 15
D7
931
1V
D5
10V
18
1833
19
7
6
1850
D11
D2
R5
0.5k
9V
D8
16
1823
1825
1822
0V
FUSE 5A
5
RH
AMPLIFIER
3
1807
2
4
1
D10
PROPORTIONAL
SWITCH.
CLAM, AUX,
RH STAB.
1842
1807
1841
HAMMER
SOLENOID FEED
R4
4k
0.5k
1843
R3
R2
4
1
D9
1812
1810
2
PROPORTIONAL
SWITCH.
LH STAB,
AUX.OPT.
1821
1824
17
LH
AMPLIFIER
1826
921
934
D6
D1
FROM TACHO ILLUMINATION
PUMP DUMP
FUSE 1A
1814
AUX
FEED
1827
STAB
10 FLOAT
REAR HORN
S3
MODE
R
F
S2
4
7
FROM
HSC
RELAY
934
6
5
3
EXISTING
+VE FEED
TO HORN
875
7
1840
3
L3
TO
AUTO
ECU
8 9
1804
112
2
7
603
RTD
5
6
SWEEPER
BLOWER
SWITCH
1805
S1
3
8
2
6
1809
L1
8
SERVO
ENABLE
SWITCH
1839
L2
2
3
8
1846
7
5
131
012
830
R7
7
6
1851
FUSE 5A
929
1808
AUX
R1
FROM
TRANS DUMP
RELAY
930
AUTO DUMP
RELAY
844
TRANS DUMP
FUSE 15A
FUSE 3A
FUSE 10A
D4
SERVO
BUZZER
QUICK HITCH SWITCHES
D3
101AB
12V
+VE
FEED
107
200V
IGN
SW
870
870
R10
R9
R13
R12
R14
4k
0.5k
1844
R8
R15
R16
R18
R17
0V
R19
1V
0.5k
9V
10V
20
1845
1838
1834
1832
1849
1847
1807
947
1848
R22
R23
21
22
ARMS/BOOM
CHANGEOVER VALVE
23
24
SHOVEL/BUCKET
CHANGEOVER VALVE
25 H
T
26B
LOADER VALVE
R
27
R
28
AUX VALVE
H
29 T
H
30
B
R
31 T
EXCAVATOR VALVE
H
32 B
R
33
LH
PILOT
6
34
FUSE 5A
AUX
OPTION
1802
R.STAB
1803
R.STAB
955
L.STAB
956
953
L.STAB
954
AUX
EXT
DIP
958
AUX
EXT
DIP
959
CLAM
960
CLAM
957
1836
5
LH/RH
PILOT
AUX
OPTION
35
1831
R21
1828
R20
FUSE 5A
1837
1829
36
AUX VALVE
GROUND
A352750
(CAD 852/30214 sheet 8 iss 1
9803/3270
Issue 3
9803/3270
001
8
2
6
15
8
HAZARD SWITCH
10
002
16
18
1
3
4
U
200
29
13
U
-
30
31
32
0
35
34
36 37 38 39 40 41
42
BUZZER
45
45
45
33
806
45
46
43
47
48
49
50
RH FRONT INDICATOR ROOF-USA
RH REAR INDICATOR ROOF-USA
DIRECT EARTH
FUEL SENDER
RADIO
WARNING CLUSTER
INSTRUMENT PANEL
AIR FILTER VAC. SW
TRANS OIL PRESS SWITCH
ENGINE OIL PRESS SWITCH
TRANS OIL TEMP SWITCH
WATER TEMP SWITCH
HOURMETER
TACHOMETER
CLOCK
WATER TEMP SENDER
FLASHER UNIT
RH REAR INDICATOR
RH FRONT INDICATOR
LH FRONT INDICATOR ROOF-USA
LH REAR INDICATOR ROOF-USA
LH FRONT INDICATOR
LH REAR INDICATOR
HAZARD SWITCH
REAR HORN
Electrics
53 54 55 56 57
RH
SPEAKER
412
51
304A
402
405
403
404
406
408
409
B/O
B/N
LH
SPEAKER
REAR FOG
FRONT W/L
REAR W/L
MAIN BEAM
411
HAZARD WARNING
SIDE LIGHTS
TURN SIGNAL
LIGHTS
617
112
WARNING
MASTER
ILLUMINATION
AIR FILTER
TRANS OIL PRES
ENGINE OIL PRES
TRANS OIL TEMP
WATER TEMP
HAND BRAKE
ALTERNATOR
3
TACHOMETER
CLOCK
FUEL GAUGE
HOURMETER
4
-
WATER TEMP GAUGE
18
+
C2
FLASHER
UNIT
49
806
805
871
19 - 1
804
2
28
304
830
17
+
17
27
FUSE C4
5
25
106
8
24
26
FUSE B1
830
802
31
806
921
23
300
49a
4
22
804
INDICATOR
SWITCH
111
21
104
803
118
IGNITION RELAY 2
E.S.O.S.
IGNITION RELAY 1
ALTERNATOR
NEUTRAL START RELAY
STARTER SOLENOID
STARTER MOTOR
BATTERY
THERMOSTART
COLD START ADVANCE
20
FUSE C2
4
19
FUSE A3
14
FUSE B3
6
007
11
WAXSTAT
113
PRIMARY
FUSE 1
4
2
12
IGNITION
RELAY 2
9
105
200
BATTERY ISOLATOR
2
10
200
6
133
4
TO GEARBOX
CONTROL FEED
5
FUSE A2
810
107
FUSE A5
6
IGNITION
RELAY 1
002
8
W
200
2
FROM NEUTRAL
SELECT
842
8
133
NEUTRAL START RELAY
BATTERY
3
FUSE C7
004
003
7
PRIMARY
FUSE 3
PRIMARY
FUSE 4
KEY SWITCH
FUSE C5
1
200
200
010
Section C
Section C
Circuit Diagrams and Component Lists
19 - 1
Basic Machine From Serial Number 495455 To 499999 And From 920000
60
859
EARTH
601
860
602
59
58
407
805
44
407
FRONT CONSOLE
INSTRUMENTS
401
SIDE CONSOLE
INSTRUMENTS
52
835
855
861
837
830
200
007
002
133
001
A370020
Issue 2
Electrics
Section C
19 - 2
Circuit Diagrams and Component Lists
Section C
19 - 2
Basic Machine From Serial Number 495455 To 499999 And From 920000
Refer to pages C/19-1 and C19-4.
The basic circuit shows a standard machine. The remaining pages in section C/19 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
49
50
Thermostart
Battery Isolator
Battery
Starter Switch
Neutral Start Relay
Starter Solenoid
Starter Motor
Alternator
From Neutral Selector
Cold Start Advance
Cold advance switch
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
Main Beam Warning Indicator Light
Rear Working Light Indicator
9803/3270
51
52
53
54
55
56
57
58
59
60
111
112
113
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
Rear Horn Switch
Rear Horn Relay
Rear Horn
Issue 3
Electrics
Section C
19 - 3
Circuit Diagrams and Component Lists
Section C
19 - 3
* Basic Machine From Serial Number 495455 To 499999 And From 920000 (cont)
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
110
Cigar Lighter
Face Level Fan
Face level Fan Switch
Heated Seat
Heated Seat Switch
Rear Washer/Wiper Switch
Rear Wiper Motor
Rear Washer Motor
Front Washer/Wiper Switch
Front Washer Motor
Front Wiper Intermittent Electronic Control Unit
Front Wiper Motor
Head Light Flasher Switch
Horn (Front) Push Switch
Horn (Front)
Rear Fog Light Switch
Rear Fog Light
Removed For Territories - Italy, Germany
Fitted For Territories - Italy, Germany
Road Lights Relay
Road Lights Switch
Head Light Dip Switch
LH Main Beam Light
RH Main Beam Light
LH Dip Beam Light
RH Dip Beam Light
LH Tail Light
LH Side Light
Socket (Dipper Light)
Number Plate Light
RH Tail Light
RH Side Light
Engine Running Relay
Front Working Lights Relay
Rear Working Lights Relay
Front Working Lights Switch
Rear Working Lights Switch
Front Working Lights
Rear Working Lights
Interior Light
Beacon Switch
Beacon
Heater Switch
Heater Relay
Heater Motor
Heater Resistor
Air Conditioning Switch
Air Conditioning Pressure Switch
Air Conditioning Pressure Switch
Air Conditioning Compressor
9803/3270
Fuses
A1 - A10
B1 - B10
C1 - C10
Refer to Technical Data pages at the beginning of Section C
for further fuse details and ratings.
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
Issue 2*
200
9803/3270
73
10
80
8
7
6
78
855
861
93 5
3
1
4
6
5
2
4
8
6
3
2
97
94
8
837
8
95
800
1
2
7
7
8
3
101
904
B/P
B/Y
B/Y
B/U
B/G
1042
8
903
HEATER RESISTOR
B
B
2
2
AIR-CONDITIONING
HEATER RELAY
HEATER
BEACON
INTERIOR LIGHT
REAR WORKING LIGHTS
FRONT WORKING LIGHTS
LIGHT SWITCH
RH SIDE LIGHT
RH TAIL LIGHT
No PLATE LIGHT
DIPPER SOCKET
LH SIDE LIGHT
LH TAIL LIGHT
RH DIP BEAM
LH DIP BEAM
B
RH MAIN BEAM
B
LH MAIN BEAM
LIGHTS RELAY
B
B
FOG LIGHT
FRONT HORN
Electrics
Circuit Diagrams and Component Lists
86
4
7
8
107
AIR-CON COMPRESSOR
105
106
HEATER FAN MOTOR
935
102
902
7
894
861
861
855
855
FUSE C9
M
AIR-CON SWITCH
4
6
100
HEATER RELAY
4
102
828
BEACON SWITCH
7
R/W/L SWITCH
5
HEATER SWITCH
81
117
FUSE A10
830
829
834
837
B/U
91
FUSE C7
835
3
303
ROAD
LIGHTS
SWITCH
6
99
FUSE C3
2
96
309
5
98
FUSE B8
3
89
310
6
87
FUSE B10
110
116
79
FUSE A9
82
88
F/W/L SWITCH
2
833
3
FUSE C10
76
836
7
DIP
SWITCH
835
84 85
90
1133
830
FOG LIGHT SWITCH
814
FRONT WIPER
FRONT WASHER PUMP
REAR WIPER
REAR WASHER PUMP
HEATED SEAT
FACE LEVEL FAN
CIGAR LIGHTER
19 - 4
407
74
832
8
FUSE C1
868
67
TERRITORIAL OPTION
ITALY, GERMAN ONLY
71
83
ENGINE RUNING
RELAY
829
69
FRONT HORN SWITCH
INTERMITTENT
ECU
311
8
841
840
77
FUSE C1
3
M
127
1
1133
66
984
M
75
ROAD LIGHTS
RELAY
6
7
982
64
983
M
REMOVED FOR TERRITORIES
ITALY, GERMAN ONLY
2
839
70
H/LIGHT
FLASH
5
864
862
M
110
65
863
68
FRONT W/W SWITCH
63
HEATED SEAT SWITCH
407
FUSE B5
REAR
WASH/
WIPE
SWITCH
830
72
FUSE B9
133
62
103
114
61
FUSE B2
007
FUSE B4
Section C
Section C
19 - 4
Basic Machine From Serial Number 495455
92
110
M
109
108
6
3
2
829
103
2
1853
001
PRIMARY
FUSE 2
A370020
Issue 1
13
9803/3270
TO FUSE A5
TO FUSE A5
14
7
1
810
6
1
2
TO NEUTRAL
START RELAY
2
2WS WRNG LIGHTS
3
11
12
4
4WS WRNG LGHT
13
2WS/4WS
MODE SELECTOR
STEER MODE P.C.B.
PROXIMITY SWITCHES
FORWARD HIGH SOLENOID
FORWARD LOW SOLENOID
REVERSE HIGH SOLENOID
REVERSE LOW SOLENOID
REVERSE ALARM
TRANSMISSION EARTH
LAYSHAFT SOLENOID
MAINSHAFT SOLENOID
Electrics
14
15
16
17
(FRONT CONSOLE)
825
9
2WS SOLENOID
(SIDE CONSOLE)
5
4WS/CRAB
MODE SELECTOR
812
848
811
849
4
CRAB WRNG LGHT
824
826
2WS RELAY
5
CRAB SOLENOID
6
8
4WS SOLENOID
20
4WS RELAY
7
845
8
CRAB RELAY
6
823
6
10
CRAB/4WS SOLENOID
17
7
822
9
CRAB/4WS
RELAY
10
106
852
8
FORWARD
H/L RELAY
883
STR MODE SW
821
REVERSE
H/L RELAY
3
820
8
6
21
REAR PROX SW
819
3
10
858
12
856
5
7
FRONT PROX SW
5
9
4
852
3
19
FUSE B1
3
1
5
3
2
2
18
007
4
847
16
2
6
15
FUSE A4
9
DUMP SWITCH (LOADER)
P/BRAKE SWITCH
Powershift Transmission
109
1
1
8
850
851
3
107
810
1
883
7
808
4
11
REVERSE RELAY
10
1
POWER SHIFT
GEAR SELECTOR
9
DRIVE RELAY
12
2
R
11
4
FOR / REV
SWITCH
TO NEUTRAL
START RELAY
5
INTERLOCK
RELAY
13
N
2
809
8
1
FORWARD RELAY
1
815
3
934
10
REVERSE ALARM
19 - 5
002
7
REVERSE SOLENOID
FORWARD/REVERSE RELAY
FORWARD SOLENOID
DUMP SWITCH (LOADER)
DUMP SWITCH (GEARLEVER)
P/BRAKE SWITCH
Manual Transmission
107
4
TRANS DUMP
RELAY
847
10
815
811
811
812
815
14
401
3
REVERSE RELAY
5
F
3
808
809
FORWARD RELAY
934
815
401
5 6
107
9
810
4
5
R
6
1
FOR / REV
SWITCH
8
934
2
N
F
10
TRANS DUMP
RELAY
815
401
8
107
107
810
Section C
Section C
Circuit Diagrams and Component Lists
19 - 5
Transmission And Steering From Serial Number 495455
Steer Mode - 4CX and 3CX Super (4x4x4)
22
STEER MODE
P.C.B.
10
7
18
A370040
Issue 1
Electrics
Section C
19 - 6
Section C
Circuit Diagrams and Component Lists
19 - 6
Transmission And Steering From Serial
Number 495455
Manual Transmission
Steer Mode - 4CX and 3CX Super (4x4x4)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
To wire 401 on page C/19-1
Parking Brake Relay
Parking Brake Switch
Transmission Dump Relay
Dump Switch on Loader Lever
Dump switch on Gear lever
Forward/Reverse Selector Lever
Forward Relay
To Neutral Start Relay on page C/19-1
Forward Solenoid
Reverse Relay
Reverse Solenoid
To Fuse A5 on page C/19-1
Reverse Alarm
Powershift Transmission
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
To wire 401 on page C/19-1
Parking Brake Relay
Parking Brake Switch
Transmission Dump Relay
Dump Switch on Loader Lever
Gear Selector Switch
Forward/Reverse Selector Lever
Forward Relay
To Neutral Start Relay on page C/19-1
Interlock Relay
Drive Relay
Reverse Relay
Mainshaft Solenoid
To Fuse A5 on page C/19-1
Layshaft Solenoid
Reverse Alarm
Reverse High/Low Relay
Reverse Low Solenoid
Reverse High Solenoid
Forward High/Low Relay
Forward Low Solenoid
Forward High Solenoid
9803/3270
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
Issue 1
Electrics
Section C
19 - 7
Section C
Circuit Diagrams and Component Lists
19 - 7
Options From Serial Number 495455
2 Wheel Steer/Brake Mode
Auxiliary and Hydraclamp Hydraulics
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
From 4th Gear Selector
Auto 2 Wheel Drive Relay
4 Wheel Braking Relay
Brake mode Selector Switch
4 Wheel Drive/4 Wheel Brake Solenoid
Brake Light Switch
LH Brake Light
RH Brake Light
All Wheel Steer/Brake Mode
1
2
3
4
5
6
7
8
From 4th Gear Selector
4 Wheel Drive Selector Switch
Brake Light Switch
Auto 2 Wheel Drive Relay
4 Wheel Braking Relay
4 Wheel Drive Solenoid
LH Brake Light
RH Brake Light
9803/3270
Excavator Lever Push Button Selector Switch
Auxiliary Selector Switch
Floor Push Button Selector Switch
Hydraclamp Selector Switch
Jaw Relay
Hammer Relay
Jaw Solenoid
Hammer Solenoid
Hydraclamp Solenoid
Speedometer Option
1
2
3
Speed Sensor
Speedometer
Illumination
Issue 1
9803/3270
1
2
2
6
1
5
3
101
7
4
2
4
5
830
3
107
8
FUSE A10
7
3
8
304
6
10
FUSE A5
1
7
SPEEDO
SPEED SENSOR
Auxiliary and Hydraclamp Hydraulics
FUSE C4
8
974
9
SPEED
SENSOR
HYDRACLAMP SOLENOID
8
920
5
7
109
4
HAMMER RELAY
8
HAMMER SOLENOID
7
870
5
JAW SOLENOID
874
RH BRAKE LIGHT
19 - 8
FUSE A4
2
HYDRACLAMP SWITCH
6
899
898
3
AUX HYD SWITCH
3
5
872
816
5
101
873
JAW RELAY
FUSE A7
LH BRAKE LIGHT
4WB RELAY
4WD SOLENOID
AUTO 2WD RELAY
RH BRAKE LIGHT
LH BRAKE LIGHT
4 WB RELAY
2WD/2WB
2WD/4WB
4WD/4WB SOLENOID
AUTO 2WD RELAY
All Wheel Steer/Brake Mode
FUSE A1
2
829
2
4WB RELAY
853
8
ILLUMINATION
3
875
8
3
FROM 4
GEAR
SELECTOR
8
933
1
126
5
877
2
FUSE A8
5
FUSE B6
6
BRAKE LIGHTS
SWITCH
10
AUTO 2WD RELAY
BR MODE SW
6
858
7
4
922
9
4WD SWITCH
922
853
7
TH
6
4WB RELAY
3
107
1
816
2
FUSE A5
8
3
830
6
877
10
FUSE A7
FUSE A8
9
AUTO 2WD RELAY
854
2 Wheel Steer/Brake Mode
ILLUNINATION
933
818
2
126
BRAKE LIGHTS
SWITCH
107
858
4
FUSE B6
FUSE A5
TH
1
FROM 4
GEAR
SELECTOR
Section C
Electrics
Section C
Circuit Diagrams and Component Lists
19 - 8
Options From Serial Number 495455
Speedometer
1
2
3
1
818
1830
A370080
Issue 1
Section C
19 - 9
Electrics
Circuit Diagrams and Component Lists
Section C
19 - 9
Autoshift Transmission From Serial Number 495455
A378770
9803/3270
Issue 1
Electrics
Section C
19 - 10
Circuit Diagrams and Component Lists
Section C
19 - 10
Autoshift Transmission From Serial
Number 495455
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 C/19-1
From Ignition Relay 1, see item 14 page C/19-1
From Parking Brake Relay, see item 36 page C/19-1
To Neutral Start Relay, see item 5 page C/19-1
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 C/19-8
4 Wheel Drive Selector Switch
2 Wheel Steer machines Only
Brake Mode Selector Switch
From Brake Switch, see item 3 page C/19-8
2 Wheel Braking Relay
Alarm
To Hydraulic Speed Control Switch, see item 2 page
C/19-12
Forward Low Solenoid
Forward High Solenoid
Mainshaft Solenoid
Layshaft Solenoid
Reverse Low Solenoid
Reverse High Solenoid
4 Wheel Drive Solenoid
Psion Diagnostic Connector
9803/3270
Issue 1
Electrics
Section C
Section C
Circuit Diagrams and Component Lists
19 - 11
19 - 11
ROADBREAKER
SWITCH
929
114
858
ROTATION SOLENOID
1
101
FUSE A1
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
FUSE B4
854
FUSE B4
BRAKE LIGHTS
SWITCH
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
9803/3270
3
1
126
1
4
2
933
FUSE A5
BR MODE SW
107
877
FUSE A8
3
1
801
5
801
4
3
972
8
2
114
6
930
1
OPERATOR HOLD-IN SWITCHES
1855
7
10
QUICK-HITCH
FEED SWITCH
4
AUTO 2WD RELAY
2
2
6
931
853
3
QUICK-HITCH
RELAY
ROADBREAKER
SOLENOID
932
7
GRAB SOLENOID
5
QUICK-HITCH
SOLENOID
QUICK HITCH
HAND HELD TOOLS
AUTO 2WD RELAY
4WD/4WB
2WD/4WB
2WD/2WB
4 WB RELAY
4WD/AWB SOLENOID
Auxiliary Electrical Options
A370070
Pole Planter
1 Selector Switch
2 Grab Solenoid
3 Rotation Solenoid
Issue 1
Electrics
Section C
Section C
Circuit Diagrams and Component Lists
19 - 12
19 - 12
H.S.C. RELAY
H.S.C. SOLENOID
LEVER 'HOLD'
SOLENOID
ACCUMULATOR
SOLENOIDS
Auxiliary Electrical Options
867
5
3
4
10
6
H.S.C. RELAY
865
2
4
5
H.S.C. BUTTON
2
8
1 6
3
1856
8
2
8
3
132
132
TH
FROM 4
GEAR
SELECTOR
818
FUSE A9
829
2
830
8
1
H.S.C. SWITCH
1
3
7
829
SRS
SWITCH
7
SHOVEL RESET
SWITCH
3
7
866
CROWD RAM
PROXIMITY SWITCH
1851
1801
2
7
9
1857
844
2
1
FUSE B7
FUSE A1
101
A370071
Smooth Ride System
(SRS)
1 Selector Switch
2 Accumulator Solenoids
9803/3270
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
Issue 1
Electrics
Section C
19 - 13
Section C
Circuit Diagrams and Component Lists
19 - 13
Servo Command Pilot Circuit From Serial
Number 495455
The circuit shown refers to the Servo option only, for the
remainder of the circuit see the appropriate additional
circuit.
Main Components
1
Starter Switch
2
Return To Dig Switch
3
Servo Enable Switch
4
Sweeper Blower Switch
5
Shovel Limit Switch
6
Forward Seat Proximity Switch
7
Rearward Seat Proximity Switch
8
Mode Changeover Switch
9
Stabiliser Switch
10
Float Electro Magnetic Latch Coil
11
Return To Dig Electro Magnetic Latch Coil
12
Hydraulic Speed Control Switch
13
Transmission Dump Switch
14
Auxiliary Switch
15
Rear Horn
16
Quick Hitch Switch
17
Left Hand Amplifier
18
Left Hand Proportional Rocker Switch
19
Right Hand Amplifier
20
Right Hand Proportional Rocker Switch
21/22 Manifold Arms/Boom Changeover Solenoid
23/24 Manifold Shovel/Bucket Changeover Solenoid
25/26 Loader Solenoid
27/28 Auxiliary Solenoid
29/30 Excavator Left Hand Stabiliser Solenoid
31/32 Excavator Right Hand Stabiliser Solenoid
33
Manifold Left Hand Pilot Pressure Valve
34
Manifold Left/Right Hand Pilot Pressure Valve
35/36 Auxiliary Option Solenoid
37
Alarm
R20
R21
R22
R23
Stabiliser Lower Changeover
Stabiliser Raise Changeover
Stabiliser Lower Mode Changeover
Stabiliser Raise Mode Changeover
On the illustration:
B = Bottom
T = Top
H = Head
R = Rod
Relays
R1 Ignition
R2 Front Seat
R3 Front Mode Changeover
R4 Rear Seat
R5 Rear Mode Changeover
R6 Spare
R7 Dump Interlink (autoshift only)
R8 Front Auxiliary Supply
R9 Hammer Interlink
R10 Stabiliser Isolator
R11 Spare
R12 Sweeper/Clam Changeover
R13 Pilot Valve Changeover
R14 Auxiliary/Clam 2 Changeover
R15 Auxiliary/Clam 1 Changeover
R16 Stabiliser/Clam 2 Changeover
R17 Stabiliser/Clam 1 Changeover
R18 Stabiliser/Auxiliary 1 Changeover
R19 Stabiliser/Auxiliary 2 Changeover
9803/3270
Issue 1
Electrics
Section C
Section C
Circuit Diagrams and Component Lists
19 - 14
19 - 14
Servo Command Pilot Circuit From Serial Number 495455 To 499999 And From 920000
+12V
1
IGN
SW
1816
1805
17
1851
1826
1825
1823
10V
7
6
RH
AMPLIFIER
4
1
2
D10
1842
PROPORTIONAL
SWITCH.
CLAM, AUX,
RH STAB.
1841
1843
1807
20
R9
R10
R13
R12
R18
R17
R16
R15
R14
4k
0.5k
1844
870
5
3
870
R8
0.5k
9V
1821
19
1850
1807
R2
HAMMER
SOLENOID FEED
1V
1833
16
15
1822
1827
921
929
D5
D2
R5
4
1
4k
0V
FUSE 5A
R4
2
0.5k
D11
R3
7
6
LH
AMPLIFIER
PROPORTIONAL
SWITCH.
LH STAB,
AUX.OPT.
D8
1812
1810
5
18
D9
930
875
14
13
D7
1824
REAR HORN
1806
11 RTD
D1
FROM TACHO ILLUMINATION
TO HSC
RELAY
AUX
D6
1811
1814
AUX
FEED
TRANS DUMP
FUSE 1A
16
QUICK HITCH SWITCHES
934
TO
AUTO
ECU
934
1805
1824
1813
FUSE 5A
3
EXISTING
+VE FEED
TO HORN
AUTO DUMP
RELAY
PUMP DUMP
10 FLOAT
2
S3
12
1809
7
9
931
101
4
6
7
RTD
FROM
TRANS DUMP
RELAY
R7
1857
8
SWEEPER
BLOWER
SWITCH
L3
STAB
F
R
MODE
7
6
1804
1839
5
1840
1846
2
6
S2
131
112
3
8
SERVO
ENABLE 3
SWITCH
S1
2
5
3
8
L2
2
L1
844
1808
012
830
8
D4
SERVO
BUZZER
FUSE 15A
FUSE 3A
FUSE 10A
R1
7
D3
37
101AB
12V
+VE
FEED
107
200V
1808
0V
R19
1V
0.5k
9V
10V
1845
1838
1834
1832
1849
1847
1807
947
1848
21
2
22
ARMS/BOOM
CHANGEOVER VALVE
9803/3270
24
SHOVEL/BUCKET
CHANGEOVER VALVE
H
25
T
B
26
LOADER VALVE
R
27
R
AUX VALVE
T
29
H
B
R
T
31
30
EXCAVATOR VALVE
H
B
R
33
LH
PILOT
PRESSURE
VALVE
1831
AUX
OPTION
5
6
32
AUX
OPTION
1802
R.STAB
R8
1803
R.STAB
955
L.STAB
956
953
L.STAB
H
28
954
AUX
EXT
DIP
958
959
AUX
EXT
DIP
4
3
23
CLAM
960
CLAM
1
957
1836
1828
R23
R22
FUSE 5A
R21
FUSE 5A
1837
1829
R20
35
34
LH/RH
PILOT
PRESSURE
VALVE
36
AUX VALVE
GROUND
A370081
CAD 852/30231 sheet 7 iss 3
Issue 2
Electrics
Section C
Section C
Batteries
20 - 1
Safety
20 - 1
! 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 prevent spillage. Keep metallic items
(watches, rings, zips etc) away from the battery terminals.
Such items could short the terminals and burn you.
Set all switches in the cab to OFF before disconnecting and
connecting the battery. When disconnecting the battery,
take off the earth (-) lead first.
When reconnecting, fit the positive (+) lead first.
Re-charge the battery away from the machine, in a well
ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you have
installed the battery in the machine, wait five minutes before
connecting it up.
First Aid - Electrolyte
Do the following if electrolyte:
GETS INTO YOUR EYES
Immediately flush with water for 15 minutes, always get
medical help.
Maintenance
To ensure that the battery provides optimum performance
the following steps should be observed:
1
Make sure that the electrical connections are clean and
tight. Smear petroleum jelly on connectors to prevent
corrosion.
2
When applicable - never allow the electrolyte level to
fall below the recommended level - 6 mm (1/4 in) above
the plates. Use only distilled water for topping up.
3
Keep the battery at least three quarters charged,
otherwise the plates may become sulphated (hardened)
- this condition makes recharging the battery very
difficult.
Extra precautions must be taken when bench charging
maintenance free batteries, they are more prone to damage
by overcharging than the standard type of battery:
-
NEVER boost-charge a maintenance free battery.
-
NEVER charge a maintenance free battery at a
voltage in excess of 15.8 Volts.
-
NEVER continue to charge a maintenance free
battery after it begins to gas.
IS SWALLOWED
Do not induce vomiting. Drink large quantities of water or
milk. Then drink milk of magnesia, beaten egg or vegetable
oil. Get medical help.
GETS ONTO YOUR SKIN
Flush with water, remove affected clothing. Cover burns with
a sterile dressing then get medical help.
5-3-4-3/1
9803/3270
Issue 1
Section C
20 - 2
Electrics
Section C
Batteries
20 - 2
Testing - Specific Gravity
The specific gravity of the electrolyte gives an idea of the
state of charge of the battery. Readings should be taken
using a hydrometer, when the electrolyte temperature is 15
°C (60 °F). If the battery has recently been on charge, wait
approximately one hour (or slightly discharge the battery) to
dissipate the surface charge before testing.
Readings should be as tabulated and should not vary
between cells by more than 0.04. A greater variation
indicates an internal fault on that particular cell.
If the electrolyte temperature is other than 15 °C (60 °F) a
'correction factor' must be applied to the reading obtained.
Add 0.07 per 10 °C (18 °F) if the temperature is higher than
15 °C (60 °F) and subtract the same if the temperature is
lower.
Specific Gravity at 15 °C (60 °F)
Ambient temperature up to 27 °C (80 °F)
Ambient temperature above 27 °C (80 °F)
Fully Charged
Half Discharged
Fully Discharged
1.270 - 1.290
1.240 - 1.260
1.190 - 1.210
1.170 - 1.190
1.110 - 1.130
1.090 - 1.110
Battery 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 1.23 to 1.25 for ambient temperature up to
27°C).
Ensure that the battery is completely disconnected from the
vehicle.
5
Set the CHECK/LOAD switch A to LOAD and hold down
for 5 - 10 seconds until the meter reading stabilises. The
reading should be at least 9 volts.
Note: Do not hold the switch in the LOAD position for more
than 10 seconds.
6
If the foregoing tests are unsatisfactory, consult Fault
Diagnosis below.
Connect up the battery tester (part no. 993/85700) as
follows:
1
Set the CHECK/LOAD switch A to OFF.
2
Set rocker switch B to the battery voltage (12V).
3
Connect the red flying lead to the battery positive (+)
terminal and the black flying lead to the battery negative
(-) terminal.
Set the CHECK/LOAD switch A to CHECK to read the
battery no-load voltage which should be at least 12.4
volts.
Fault Diagnosis
Battery Tester Readings
A
B
4
239510
Remedy
1
CHECK: 0 - 12.6 Volts
LOAD: less than 6 Volts
2
CHECK: 6 - 12.4 Volts
LOAD: less than 9 Volts and falls steadily but remains
in yellow zone.
Recharge and re-test. If tests still unsatisfactory renew
battery.
3
CHECK: less than 10 Volts
LOAD: less than 3 Volts
Indicates battery has been over-discharged and unlikely
to recover. Renew battery.
4
CHECK: more than 11 Volts
LOAD: 6 - 10 Volts steady
Charge battery which will probably recover.
9803/3270
Renew battery
Issue 1
Electrics
Section C
Section C
Wiring Harness Repair
25 - 1
25 - 1
Harness Repair Introduction
Tools Required
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 other machines in addition to those of
JCB manufacture.
892/00350
892/00349
892/00351
892/00352
892/00353
To ensure that either the inclusion of an auxiliary electrical
component or a repair within a harness is completed to an
acceptable standard it is strongly recommended that the
following tools, equipment and procedures are always used.
Note that JCB harnesses have an International Protection
rating of 67 (I.P.67).
The sheath covering of the recommended splice is heat
shrunk onto the original wire insulation. This results in a seal
and corresponding joint to IP 67 specifications.
ELEC 2 - 1
! WARNING
1
1
50
50
50
Procedure
1
Cut the wire and remove the protective insulation for a
suitable distance dependent upon the size of wire and
splice to be used. For the splices detailed above, the
dimension is 7mm.
2
Using the correct sized splice, attach the new section
of wire required or auxiliary flying lead to the existing
harness and secure using the crimp tool X, part number
892/00349.
Note that each of the splices detailed is colour-coded
to make size and range readily visible. They are
secured using the corresponding size and matching
colour-coded jaws of the crimp tool to ensure joint
security. This tool also incorporates a ratchet closing
mechanism which will not release until the splice is
fully closed to the correct compression size.
! CAUTION
When installing Auxiliary Electrical Components always
ensure that the additional load rating is suitable for that
particular circuit. It is unacceptable to simply increase
the fuse rating as this can cause overloading and
consequential failure of wiring, along with failure of
integral circuit components, which the fuse is protecting.
Butane Heater assembly
Crimp tool
Splice 0.5-1.5 mm (Red)
Splice 1.5-2.5 mm (Blue)
Splice 3.0-6.0 mm (Yellow)
3
With the Butane heater assembly, 892/00350, seal the
connection using the procedure on the next page.
....continued
In addition to the warnings incorporated into the
procedure, extreme care should be taken when handling
the gas heating tool to ensure that the flame does not
damage or set fire to any items in the vicinity of the
repair, i.e. other wires, floor panels, floor mats, sound
proofing, paintwork. etc. This tool should not be used in
any restricted location prohibiting the use of "Naked
Flames' or where risk of explosive gas or similar safety
parameters apply. No other heat source should be used
to attempt a sealed joint .
7
ELEC 2 - 2
!!!! CAUTION
When the heater is in use, the reflector and the air
coming out are extremely hot. Keep away to avoid
accidental burns. Do not touch the reflector until it has
had time to cool down after switching off. If flame
reappears at the reflector when the heater is in use, the
catalytic element is damaged or used up. Stop work
immediately and replace the heater.
X
ELEC 2-3
S189530
9803/3270
Issue 1
Section C
25 - 2
Electrics
Section C
Wiring Harness Repair
25 - 2
Procedure (cont'd)
With the Butane Heater assembly 892/00350, seal the
connection using the following procedure.
A
3.1 Remove the cap A from the end of the disposable gas
cartridge B.
B
S189490/1
3.2 Before assembling the gas cartridge to the reflector
element C, turn the red ring D to the left, (in the
direction of the minus sign marked on the ring).
C
D
S189490/2
3.3 Position the tube hanging down from inside the reflector
assembly into the hole at the top of the gas cartridge.
Then press the gas cartridge up into the reflector
assembly as far as possible until the two elements are
clasped firmly together. A click will be heard.
S189490/3
3.4 Turn the small ring E so that the air holes at F are
completely closed.
F
E
S189490/4
9803/3270
Issue 1
Section C
25 - 3
Electrics
Section C
Wiring Harness Repair
25 - 3
Procedure (cont'd)
3.5 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 difference between the cartridge and the
reflector element may cause long yellow flames to appear on
ignition.
D
S189490/5
3.6 Hold the heater vertically and, using a match or
cigarette lighter, light the gas as shown.
Note: The fact that the sound of liquid cannot be heard when
the cartridge is shaken does not mean it is empty. No sound
will be heard even when the cartridge is full.
F
E
Hold the heater vertically for 1 to 2 minutes until the
catalytic reaction occurs. This is indicated when the
blue flame fades and the ceramic element glows red.
Then turn the small ring E until the air holes at F are
completely open. The tool is ready for use.
S189490/6
The heater can be used in two modes:
3.7 Side wings G down, reflector head completely open. In
this mode the infra-red heat waves are dominant
(recommended for the light coloured plastic splices).
G
Side wings G up (see fig at step 3.8), reflector head
opening reduced. In this mode the heating is done only
by the hot gas (use for dark coloured plastic splices).
S189490/7
3.8 To switch off the heater, turn the red ring D to the left (in
the direction of the minus sign).
G
D
S189490/8
9803/3270
Issue 1
Electrics
Section C
Section C
Starter Motor
38 - 1
38 - 1
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 identification
page).
Test 3
Connect the voltmeter between the solenoid terminal C and
a good earth. Minimum permissible reading in 'start'
position: 8.0V.
Check the readings in the following sequence using a
voltmeter. Unless otherwise stated, the readings must be
taken with the starter switch held in the 'start' position ('HS')
and the transmission forward/reverse selector in neutral.
C
Note: Do not operate the starter motor for more than 20
seconds at one time. Let the starter motor cool for at least
two minutes between starts.
Test 1
Connect the voltmeter across the battery terminals. Reading
in 'start' position: 10.0V approximately. Minimum
permissible reading in 'start' position 9.5V.
S151010
A low reading probably indicates a fault in the starter motor.
Test 3a
If the reading is less than specified, connect the voltmeter
between the neutral start relay terminal D and earth. An
increase in reading to 8.0V indicates a fault in the wiring
from the start relay to the solenoid.
S151000
Test 2
Connect the voltmeter between the starter main terminal A
and the commutator end bracket B. In the 'start' position,
the reading should not be more than 0.5V below the reading
obtained in Test 1. Minimum permissible reading in 'start'
position 9.0V.
If the reading is within this limit, continue to Test 3. If the
reading is outside the limit, proceed to Tests 4 and 5.
F
N
R
810C
842
H
C
600V
D
004
E
+
A
B
B
A
S151030
9803/3270
-
A215660
Issue 1
Electrics
Section C
Section C
Starter Motor
38 - 2
38 - 2
Starting Circuit Test (cont'd)
Test 3b
Test 5
If the reading between terminal D and earth is below 8.0V,
connect the voltmeter between terminal E and earth. An
increase in the reading to 8.0V indicates either a faulty start
relay or a fault in the feed from the transmission selector
switch to the relay solenoid. Check also the solenoid earth
connection.
Connect the voltmeter between battery positive and the
starter main terminal A. With the starter switch 'off', the
voltmeter should indicate battery voltage, but it should fall to
practically zero when the switch is turned to the 'on'
position, maximum permissible reading 0.25V.
If the reading between E and earth is less than 8.0V, the fault
must be in either the starter switch or in the wiring between
the solenoid, starter switch, and the start relay.
Test 4
Connect the voltmeter between battery negative and starter
earth connection B. The reading in the 'start' position should
be practically zero, maximum permissible reading 0.25V.
A
S151050
Test 5a
B
S151040
If the reading is above 0.25V, a high resistance is present in
the insulated lead or in the solenoid. Connect the voltmeter
between the battery positive and solenoid connection H. If
the voltmeter now reads zero with the switch closed, the
fault is in the solenoid.
If the reading is above 0.25V, a high resistance in the earth
lead or connections is indicated.
H
Finally refit the engine stop fuse.
9803/3270
Issue 1
Section C
38 - 3
Electrics
Starter Motor
Section C
38 - 3
S02043C
9803/3270
Issue 1
Electrics
Section C
Starter Motor
38 - 4
Section C
38 - 4
Removal and Replacement
Disconnect cables and remove battery. Remove cables from
main starter terminal and solenoid terminal. Using special
tool 825/00410 (and adapter 825/99833 if required) unscrew
three securing nuts and remove starter motor.
* On the 214Se machine, for access remove the engine oil
dipstick tube E and throttle cable bracket F.
Assembly
Replace by reversing the removal sequence.
Dismantling
Note: Dismantle only to item 34 unless the field windings are
to be renewed. Test the windings electrically before
removing them from the motor yoke 15.
Using a slotted steel tube, displace ring 23 to permit
withdrawal of ring 22.
Allow brake shoes 28 to remain in the end plate 11 unless
requiring renewal.
Servicing and Renewal
Align crosspin C with the notches in the brake shoes 28
before assembling brush carrier and back plate to motor
yoke. Ensure that brushes 14A are correctly located in the
insulated brush boxes.
Smear drive shaft splines and operating collar bearing
surface with JCB MPL Grease before assembly. Assemble
operating fork 19 with curved face toward the armature.
Set the movement of drive pinion 24 by connecting a 6v
battery and switch as shown. Operate switch and check
dimension D. Adjust to 0.13-1.14mm (0.005-0.045in.) by
slackening locknut 17 and rotating eccentric pin 18 as
necessary. Re-tighten locknut.
Renew brushes 14 and 14A if their length is less than 8mm
(0.3in.).
Clean the commutator A. If individual copper bars are
burned or eroded the armature has broken windings and
must be renewed. Otherwise polish with fine grade glass
paper (not emery). Renew armature if commutator diameter
is 38mm (1.5in.) or less.
Check the field windings for open circuits by connecting a
multimeter set to measure resistance (see page C/2-2)
between the stud terminal B and each positive brush 14A in
turn. A high or infinity reading indicates an open circuit.
Similarly, connect the meter between brushes 14A and the
motor yoke 15. Any reading other than infinity indicates a
short circuit between the coils and the yoke. Renew the coils
as necessary, removing screws 36 with a pole shoe
screwdriver C50 (obtainable from Lucas dealers).
D
S02303A
Check bronze bushes 32 and 34 for wear.
F
E
A359370
9803/3270
Issue 2*
Section C
Electrics
Section C
39 - 1
Alternator
39 - 1
General Description
AVO 2002
Red lead to volts (middle) socket on meter.
Black lead to negative on meter.
RH slider to DC voltage.
LH slider as shown in the illustration.
AVO 2003
Red lead to amps socket (marked A) on the
meter.
Black lead to negative on meter.
RH slider to DC voltage
LH slider to 200 Shunt
FLUKE 85
Red lead to volts socket (marked V )on
meter.
Black lead to COM socket on meter.
Set dial to mV.
The alternator is a three phase generator having a rotating
field winding and static power windings.
When the start switch is turned on, current from the battery
flows by way of the 'No Charge' warning light to the field
winding. This creates a magnetic field which supplements
the residual magnetism in the rotor poles. As the engine is
started, the fan belt drives the rotor and alternating current is
generated in the power windings as they are cut by the
rotating magnetic field. Output is controlled by a solid state
regulator which varies the field current in accordance with
electrical demand.
Servicing is restricted to periodic inspection of slip ring
brushes. Bearings are 'sealed for life'.
Service Precautions
Start the engine and run at maximum speed (see Technical
Data). Meter should show maximum alternator output in
Amps (see Technical Data).
a
Ensure that the battery negative terminal is connected
to the earthing cable.
Note: The meter reading should be taken as soon as
possible after starting the engine, as the charging current
will fall rapidly.
b
Never make or break connections to the battery or
alternator, or any part of the charging circuit whilst the
engine is running. Disregarding this instruction will
result in damage to the regulator or rectifying diodes.
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.
c
Main output cables are 'live' even when the engine is
not running. Take care not to earth connectors in the
moulded plug if it is removed from the alternator.
d
e
During arc welding on the machine, protect the
alternator by removing the moulded plug (or if separate
output cables fitted, remove the cables).
If slave starting is necessary, connect the second
battery in parallel without disconnecting the vehicle
battery from the charging circuit. The slave battery may
then be safely removed after a start has been obtained.
Take care to connect batteries positive to positive,
negative to negative.
Charging Test
Ensure that all battery and alternator connections are in
place, secure and making good metal - to - metal contact,
especially the 'earth' connections to chassis and engine.
a
Defective suppression capacitor.
b
Dirty slip rings or worn brushes.
c
Defective regulator.
d
Defective rectifier.
e
Open or short - circuited field (rotor) windings.
f
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 slip rings 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.
Make sure that the alternator drive belt tension 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 the
engine shut off solenoid (ESOS) fuse removed (refer to fuse
identification pages).
Install a 100 amp open - type shunt between the battery
positive lead and the battery positive terminal.
Connect a multimeter positive lead to machine 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.
9803/3270
S08346
Issue 1
Section C
Electrics
Section C
39 - 2
Alternator
39 - 2
9803/3270
Issue 1
Section C
Electrics
Section C
39 - 3
Alternator
39 - 3
Removal and Replacement
Disconnect cables from rear of alternator, remove bolts A, B
and C and withdraw unit from machine.
Replace by reversing the removal sequence. Position the
alternator until belt deflection is approximately 10mm (3/8 in)
before tightening bolts B and C. It may be necessary to
slacken bolt D to allow full movement of alternator. Tighten
bolt A last of all.
A
B
Dismantling and Assembly
When Dismantling
Remove suppressor 2 (if fitted) by removing nut 1 and
disconnecting lead E from terminal F.
Unscrew bolts 3 and disconnect lead G from terminal H to
remove the brush box and regulator assembly 4. If the brush
length is less than 5mm (0.2 in.), new length 17mm (0.67 in.),
or if spring pressure is less than 1.3N the brush box and
regulator assembly must be renewed.
Remove nuts and washers 5, bolts 6 and nuts 7. Remove
slip ring end bracket 8.
Carefully remove rectifier 10 and stator 11 as an assembly.
Unsolder the interconnecting wires at X, Y, and Z only if
renewing either of these components.
S099850A
Remove nut and washer 12 using an 8mm Allen key in the
shaft hexagon hole to prevent rotation. If necessary, use a
press to remove rotor 19 from the drive end bracket 17.
Check the rotor poles and the inner faces of the stator for
signs of rubbing, which indicates worn bearings. The drive
end bearing is part of bracket 17 and cannot be removed
separately. If requiring renewal, needle roller bearing 20
should be pressed out in the direction of the arrow.
When Assembling
Reverse the dismantling procedure, but note the following:
Ensure that spacers 14,16, and 18 are correctly positioned
as shown.
Ensure that the slip rings J are clean and smooth, using
extra fine glasspaper to rectify slight imperfections.
Ensure that insulation bushes 9 and washers 5 are
positioned as shown.
Take care not to damage the brushes when fitting the brush
box and regulator assembly.
Torque Settings
Item
3
5
6
7
12
Nm
2.7
4.1
3.4
5.4
60.0
9803/3270
kgf m
0.28
0.41
0.35
0.55
6.10
lbf ft
2.0
3.0
2.5
4.0
44.2
C
D
S099850B
Issue 1
Section C
Electrics
Section C
39 - 4
Alternator
39 - 4
5
A
4
1
2
3
5
6
£
@
7
8
!
0
9
B
216870
9803/3270
Issue 1
Section C
Electrics
Section C
39 - 5
Alternator
39 - 5
Dismantling and Assembly - Magneti
Marelli Type
When Dismantling
When Assembling
Remove nuts 1 and cover 2.
Reverse the dismantling procedure, but note the following:
Check the protruding length of the brushes A. If this is less
than 10 mm (0.4 in), the brushes must be renewed. This will
involve renewal of the regulator and brush box assembly 6
as the brushes are not available separately.
Ensure that slip ring faces are clean and smooth, using very
fine glasspaper if required. Do not use emery cloth.
Un-clip slip-ring shroud 3. Remove screw 4 and nuts 5 to
remove regulator and brush box assembly 6.
Do not separate the rectifier 7 from the slip-ring end bracket
8 as the gasket between them and its jointing paste provide
a special heat conducting path which must not be disturbed.
If further dismantling is required, note the positions of the six
leads B and unsolder them from their locating tags on the
rectifier.
Using special socket 892/00882, remove nut 9, washer 10
and pulley 11. If necessary, press the drive end bearing,
complete with the rotor 12, out of the bracket and stator
assembly 13.
9803/3270
Ensure that stator connecting wires will not touch against
the rotor.
Lightly polish side faces of brushes to ensure free movement
in brush box.
Torque Settings
Item
1
4
5 (M5)
5 (M6)
Nm
3.0-4.0
2.0-2.5
1.7-2.3
3.6-5.1
Kgf m
0.3-0.4
0.2-0.25
0.2-0.23
0.4-0.5
lbf in
26-36
18-21
15-20
32-45
Item
Nm
Kgf m
lbf ft
9
70-90
7.2-9.1
52-66
Issue 1
Electrics
Section C
Section C
Harness Location
40 - 1
40 - 1
Cab and Chassis
3
4
2
6
7
ITEM
DESCRIPTION
1
2
3
4
5
6
7
Mainframe Harness
Panel Harness
Cab Harness
Cab Roof Harness
Solenoid Harness
Rear Light Harnesses
Engine Shut Off Harness
9803/3270
5
1
Note: The illustration shows a typical machine.
Issue 2
Section C
Electrics
Harness Location
40 - 2
Section C
40 - 2
Servo Command
Item
1
2
3
4
5
Description
Seat
Loader Valve Block
Auxiliary Valve Block
Excavator Valve Block
Manifold Block
9803/3270
Issue 1
Electrics
Section C
Harness Location
40 - 3
Section C
40 - 3
Cab and Chassis - All Later Machines
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
9803/3270
Issue 1