Electrics
Electrics
Electrics
                                              Service Manual - 3DX / 4DX Backhoe Loader
                                                          Section 1 - General Information
                                                           Section 2 - Operator’s Manual
                                                                 Section A - Attachments
                                                        Section B - Body and Framework
                                                                    Section C - Electrics
                                                                     Section D - Controls
                                                                   Section E - Hydraulics
                                                                Section F - Transmission
                                                                      Section G - Brakes
                                                                     Section H - Steering
                                                                      Section K - Engine
                                                                            Publication No.
                                                                           9813/2050-3
                                                                                                                                                                                      World Class
                                                                                                                                                                                    Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
                                      electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
     Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
                       Section C - Electrics
Notes:
      Circuit Schematics
         Electrical Circuit .......................................................................................    1-13
         Electrical Circuit .......................................................................................    1-14
         Maxi Fuses Harness ................................................................................           1-15
         Electrical Harness ....................................................................................       1-16
         Cab Harness - 2WD ................................................................................            1-17
         Panel Harness 4WD ................................................................................            1-18
      Fuses
         ................................................................................................................ 1-19
C-i                                                                                                                                   C-i
                                                                                     Section 1 - Electrics
                                         Service Procedure
                                                Using a Multimeter
                                                                 TC-002
Fig 1. FLUKE 85
c On an analogue meter.
          If there is continuity in the circuit, the beeper will    5     Touch or connect the red probe to the frequency
          sound. If there is no continuity (open circuit), the            source to be measured. Press and hold button if an
          beeper will not sound.                                          average reading is required.
c On an analogue meter.
A diode wire is a diode with male connector fitted on one                    i    Select the Ohms 1000s (1k) range.
end and a female connector fitted on the other end. The
diode is sealed in heatshrink sleeving.                                           Connect the black probe to the end of the
                                                                                  diode marked with a band, or to the male
1     To test a Diode or a Diode Wire                                             connector of the diode wire, the red probe
                                                                                  should be connected to the other end of the
      a   On the FLUKE 85.                                                        diode or diode wire. The meter should read
                                                                                  20-400 kΩ, if it reads more than this the diode
          i    Turn the switch to position 1-D.                                   is faulty.
          ii   Press the HOLD button and check that the H                    ii   Select the Ohms 100s range.
               sign appears at the top right hand side of the
               display window.                                                    Connect the red probe to the end of the diode
                                                                                  marked with a band, or to the male connector
          iii Connect the black probe to the end of the                           of the diode wire, the black probe should be
              diode with a band or to the male connector of                       connected to the other end of the diode or
              the diode wire. Connect the red probe to the                        diode wire. The meter should read 300-400Ω,
              other end of the diode or diode wire. If the                        if it reads less than this the diode is faulty.
              beeper does not sound the diode or diode wire
              is faulty.
                                                        Battery
                                                               TC-001_5
Maintenance                                                                                  !MWARNING
To ensure that the battery provides optimum performance                   Batteries give off an explosive gas. Do not smoke
the following steps should be observed:                                   when handling or working on the battery. Keep the
                                                                          battery away from sparks and flames.
1     Make sure that the electrical connections are clean
      and tight. Smear petroleum jelly on connectors to                   Battery electrolyte contains sulphuric acid. It can burn
      prevent corrosion.                                                  you if it touches your skin or eyes. Wear personal
                                                                          protective equipment (PPE). Handle the battery
2     When applicable - never allow the electrolyte level to              carefully to prevent spillage. Keep metallic items
      fall below the recommended level - 6 mm (1/4 in)                    (watches, rings, zips etc) away from the battery
      above the plates. Use only distilled water for topping              terminals. Such items could short the terminals and
      up.                                                                 burn you.
3     Keep the battery at least three quarters charged,                   Set all switches to OFF before disconnecting and
      otherwise the plates may become sulphated                           connecting the battery. When disconnecting the
      (hardened) - this condition makes recharging the                    battery, take off the earth (-) lead first.
      battery very difficult.
                                                                          Re-charge the battery away from the machine, in a well
Extra precautions must be taken when bench charging                       ventilated area. Switch the charging circuit off before
maintenance free batteries, they are more prone to                        connecting or disconnecting the battery. When you
damage by overcharging than the standard type of battery:                 have installed the battery in the machine, wait five
                                                                          minutes before connecting it up.
    – Never boost-charge a maintenance free battery (if
      fitted).                                                            When reconnecting, fit the positive (+) lead first.
                                                                          5-3-4-12_2
    – Never charge a battery at a voltage in excess of 15.8
      Volts.
                                                                          Testing
    – Never continue to charge a battery after it begins to
      gas.
                                                                          This test is to determine the electrical condition of the
                                                                          battery and to give an indication of the remaining useful
                                                                          'life'.
Note: Do not hold the switch in the LOAD position for more
than 10 seconds.
Specific Gravity Testing                                         Readings should be as tabulated and should not vary
                                                                 between cells by more than 0.04. A greater variation
The specific gravity of the electrolyte gives an idea of the     indicates an internal fault on that particular cell.
state of charge of the battery. Readings should be taken
using a hydrometer, when the electrolyte temperature is          If the electrolyte temperature is other than 15°C (60°F) a
15°C (60°F). If the battery has recently been on charge,         'correction factor' must be applied to the reading obtained.
wait approximately one hour (or slightly discharge the           Add 0.07 per 10°C (18°F) if the temperature is higher than
battery) to dissipate the surface charge before testing.         15°C (60°F) and subtract the same if the temperature is
                                                                 lower.
                                                         Alternator
                                                                   TC-006_2
Servicing is restricted to periodic inspection of slip ring                   4    Start the engine; all warning lights should extinguish
brushes. Bearings are 'sealed for life'.                                           rapidly.
Service Precautions                                                                If the 'No charge' warning light remains ON, K Check
                                                                                   2 ( T 1-9).
1     Ensure that the battery negative terminal               is
      connected to the earthing cable.                                             If the oil pressure warning remains on stop engine
                                                                                   Immediately and investigate the engine lubrication
2     Never make or break connections to the battery or                            system.
      alternator, or any part of the charging circuit whilst the
      engine is running. Disregarding this instruction will                   Check 1
      result in damage to the regulator or rectifying diodes.
                                                                              With start switch 'ON' try the heater motor and screen
3     Main output cables are 'live' even when the engine is                   wiper.
      not running. Take care not to earth connectors in the
      moulded plug if it is removed from the alternator.                      If they operate normally, check the warning light bulb/LED
                                                                              is not defective.
4     During arc welding on the machine, protect the
      alternator by removing the moulded plug (or if                          Simultaneous failure of all items indicates a fault at the
      separate output cables fitted, remove the cables).                      start switch. Check for cable disconnection before
                                                                              condemning the switch itself.
5     If jump starting starting is necessary, connect the
      second battery in parallel without disconnecting the                    If the 'No charge' warning bulb/LED is in good order,
      vehicle battery from the charging circuit. The second                   withdraw the triple plug from the back of the alternator.
      battery may then be safely removed after a start has                    Make a temporary connection between the SMALL
      been obtained. Take care to connect batteries                           terminal in the plug and earth as shown below. If the 'No
      positive to positive, negative to negative.                             charge' warning bulb/LED still fails to light, check the cable
                                                                              for continuity. If the bulb/LED now lights, check the
                                                                              alternator for a defective regulator. K Alternator
                                                                              Charging Test ( T 1-9).
Fig 5.
Check 2
c Defective regulator.
d Defective rectifier.
                                                       Starter Motor
                                                                    TC-005
Starting Circuit Test                                                            than 0.5V below the reading obtained in Step 1.
                                                                                 Minimum permissible reading in 'start' position 9.0V.
Before carrying out the voltmeter tests, check the battery
condition and ensure that all connections are clean and                          If the reading is within this limit, continue to Step 3. If
tight.                                                                           the reading is outside the limit, proceed to Step 4 and
                                                                                 Step 5.
To prevent the engine starting during the tests ensure that
the engine stop fuse is removed, (refer to Fuse
Identification page).
2    Connect the voltmeter between the starter main                              a   If the reading is less than specified, connect the
     terminal 9-A and the commutator end bracket 9-B. In                             voltmeter between the neutral start relay terminal
     the 'start' position, the reading should not be more                            11-D and earth. An increase in reading to 8.0V
                                                                                     indicates a fault in the wiring from the start relay to
                                                                                     the solenoid.
Fig 13.
Fig 14.
Fig 12.
                        Circuit Schematics
                         Electrical Circuit - 3DX
Fig 15.
Fig 16.
                                                                                                                                                                                             Section 1 - Electrics
                                                                                                                                                                        Circuit Schematics
1-15
                                                                                                        D070880-01
                                                                    Fig 17. 334/Y7150 sheet 1
                                       Section 1 - Electrics
                                             Circuit Schematics
                     Electrical Circuit - 3DX Xtra, 3DX Super and 4DX
                                               D070880-02
                                                            Fig 18. 334/Y7150 sheet 2
1-16   9813/2050-3                                                                      1-16
                                       Section 1 - Electrics
                                             Circuit Schematics
                     Electrical Circuit - 3DX Xtra, 3DX Super and 4DX
                                                   D070880-03
                                                                Fig 19. 334/Y7150 sheet 3
1-17   9813/2050-3                                                                          1-17
                                       Section 1 - Electrics
                                             Circuit Schematics
                     Electrical Circuit - 3DX Xtra, 3DX Super and 4DX
                                                         D070880-04
                                                                      Fig 20. 334/Y7150 sheet 4
1-18   9813/2050-3                                                                                1-18
                                       Section 1 - Electrics
                                             Circuit Schematics
                     Electrical Circuit - 3DX Xtra, 3DX Super and 4DX
                                                  D070880-05
                                                               Fig 21. 334/Y7150 sheet 5
1-19   9813/2050-3                                                                         1-19
                                       Section 1 - Electrics
                                             Circuit Schematics
                     Electrical Circuit - 3DX Xtra, 3DX Super and 4DX
                                                           D070880-06
                                                                        Fig 22. 334/Y7150 sheet 6
1-20   9813/2050-3                                                                                  1-20
                                       Section 1 - Electrics
                                             Circuit Schematics
                     Electrical Circuit - 3DX Xtra, 3DX Super and 4DX
                                                    D070880-07
                                                                 Fig 23. 334/Y7150 sheet 7
1-21   9813/2050-3                                                                           1-21
                                       Section 1 - Electrics
                                             Circuit Schematics
                     Electrical Circuit - 3DX Xtra, 3DX Super and 4DX
                                                        D070880-08
                                                                     Fig 24. 334/Y7150 sheet 8
1-22   9813/2050-3                                                                               1-22
                                             Section 1 - Electrics
                                                Circuit Schematics
                                                   Harness Data - 3DX
Fig 25.
Fig 28.
Fig 29.
               Chassis Harness
 9813/2050-3
                                                                                                                                                                                   Section 1 - Electrics
                                                                                                                                                              Circuit Schematics
                                                                                                    D070870-01
                                                                      Fig 31. 334/Y4606
1-29
                                                                     Section 1 - Electrics
                                                                           Circuit Schematics
                                                       Harness Data - 3DX Xtra, 3DX Super and 4DX
                      D070870-02
                                   Fig 32. 334/Y4607
Panel Harness
1-30            9813/2050-3                                                                 1-30
                                                                      Section 1 - Electrics
                                                                            Circuit Schematics
                                                        Harness Data - 3DX Xtra, 3DX Super and 4DX
       D070870-06
                                                                                             D070870-07
                    Fig 33. 334/Y7355 (3DX Xtra Base)
                                 Fig 21.
1-19    9813/2050-3                         1-19
                                       Section 1 - Electrics
                                                      Fuses