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Servicio de JCB, 1992 PDF
Servicio de JCB, 1992 PDF
Introduction
General Information
Backhoe Loaders
Loadalls
Service
Data RTFL
Book Excavators
1992 on
Wheeled Loaders
JUNE 2003
Fastrac
Robot
Skidsteer Range
1CX
Teletruk
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; ©
ROCESTER, STAFFORDSHIRE, ST14 5LS,
ENGLAND
Articulated Dump Trucks
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
The JCB Service Data Book is compiled in sections as listed on the main title page at the front of the book. The section names
on the title page register with the tabs of the section divider cards to promote rapid reference to the relevant machine ranges.
The General Section is applicable to all machine ranges, covering such subjects as conversion tables, torque settings etc.
The various machine range sections contain information on current or recent machines as detailed in their respective contents
pages. Information on earlier machines is contained in the previous Data Book, publication no. 9804/1102.
The page numbering in each section is not continuous. This is to allow for additional pages to be inserted as they are issued.
A basic explanation of the page number system is given below to enable correct location of pages.
A B C
When locating pages, refer to the page number in the sequence A, followed by B, followed by C.
The service data book is not intended as a substitute for service manuals which should be consulted for all further details.
Contents
Metrication - S.I.Units
The following list gives the units and symbols to be found in technical publications.
Capacity litre l
Force Newton N
Length millimetre mm
metre m
kilometre km
Mass kilogram kg
Time second s
minute min
hour h
day d
Conversion Factors
Length in mm 25.4
mile km 1.6093
Mass Ib kg 0.4536
Select the known capacity from the centre column and read off the required conversion.
Inch Millimetre
Select the known length from the centre column and read off the required conversion.
Select the known pressure from the centre column and read off the required conversion.
Select the known temperature from the centre column and read off:
Hydraulic Formulae
Power output of Hydraulic Pump (hp) = Flow (UK gal/min) x Pressure (Ibf/in2)
1430
Power output of Hydraulic Motor (hp) = Torque (Ibf ft) x Speed (rev/min)
5250
Use only where no torque setting is specified in the text. Values are for dry threads and may be within three percent of the
figures stated. For lubricated threads the values should be REDUCED by one third.
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
Torque Settings
Bolt Size No. (mm) Nm kgfm lbf ft
M5 (5) 11 1.1 8
M6 (6) 19 2.0 12
M8 (8) 46 4.8 34
M10 (10) 91 9.5 67
M12 (12) 159 16 120
M16 (16) 395 40 290
M20 (20) 770 79 570
M24 (24) 1332 135 980
HOSE & PIPEWORK CONNECTIONS USING 'O' RING FACE SEALS (ORFS)
Note: Adapters A always have a UNF thread for the ORFS hose connection B but the thread A on the opposite end of the
adapter may be either UNF or metric. Measure the thread diameter carefully before choosing the relevant torque setting table.
9/16 24 2.5 18
11/16 33 3.3 24
13/16 44 4.8 35
1 58 6.0 43
13/16 84 8.6 62
1 7/16 115 11.8 85
111/16 189 19.4 140
2 244 24.9 180
Antifreeze Protection
The protection provided by JCB Universal Anti-freeze is shown below. If any other anti-freeze is used, refer to the
manufacturers' instructions and ensure that a corrosion inhibitor is included.
DO NOT use solutions of more than 60% or less than 50% or damage to the cooling system will occur.
The strength of the anti-freeze solution must be checked at least once a year, preferably at the beginning of the cold period.
It is an advantage to leave the anti-freeze in all the year round as it gives continued protection against corrosion. Always renew
the anti-freeze every two years.
A 50% anti-freeze mixture must be used even if frost protection is not needed. This gives protection against corrosion and raises
the coolant's boiling point.
! WARNING
Antifreeze can be harmful. Obey the manufacturer's instructions when handling neat or diluted antifreeze.
7-3-4-4
Complex hydraulic components and circuits can be described Pumps & Motors
to the engineer by using graphical symbols. The following
pages illustrate and give a brief description for some of the
more common symbols used.
Fixed capacity pump
There are many symbols in use and it would be impossible to one direction of flow
include them all here. However it should be noted that most
are only variations or refinements on the basic principles
explained here. If more detailed information is required you
are recommended to obtain a copy of BS2917 or IS01219.
Fixed capacity pump
Once familiar with the symbols, the engineer can use two directions of flow
hydraulic circuit diagrams as an aid to fault finding. It will be
possible to see the complete hydraulic circuit and decipher
the relationship between hydraulic components.
Variable capacity pump
General (Basic & Functional Symbols) one direction of flow
Spring
Direction of flow
Fixed capacity motor
one direction of flow
Indication of rotation
Variable control
Double acting
Double ended
Control Valves
3-Position, 6-Port
spring centred hand Throttling orifice -
operated valve normally closed
3-Position, 4-Port
spring centred solenoid &
pilot pressure operated valve
Throttling orifice -
normally open
3-Position, 4-Port
spring centred detent
hand operated valve
Relief valve
Non - return valve
Pilot operated
non - return valve
Pilot control
Accumulator
Crossing lines
Filter or strainer
Quick release
couplings - connected Heater
Quick release
couplings - disconnected
Control Mechanisms
Detent
M Electric motor operated
Locking device
Internal pressure
pilot operated
Over centre device
External pressure
pilot operated
Simple linkage
Pressure operated
spring release
General control
Pressure gauge
Pedal operated
Spring operated
Roller operated
Control Valves
FIG 1
Control valves are usually represented by one or more
square boxes.
Position 1 Position 2 Position 3
Fig. 1 shows a control valve represented by three boxes. The
number of boxes indicates the number of possible valve
operating positions, (4 boxes - 4 positions etc).
If the valve spool was moved to Position 3, movement of the Port 1 Port 3
spool would connect Port 1 to Port 4, and Port 3 to Port 2.
FIG 3
It must be noted that not all spools are of the same type.
Their operating designs can be seen by following the path the
flow arrows take in their respective operating squares.
Three typical JCB style spools are known as 'D' spools, 'F'
spools and 'N' spools.
Fig 4 - 'F' spools are often shown as four position spools with
the three normal positions for neutral and service control; and
the forth position, which has a detent, connects both sides of
the ram together to allow the service to 'float'. FIG 4
FIG 5
Some of the symbols described on the preceding pages have Example Circuit Key
been arranged into a simple schematic circuit shown below.
A Hydraulic Tank
Hydraulic tank A is a pressurised tank with an internally B Strainer
mounted strainer B on the suction line to the fixed C Fixed Displacement Pump
displacement pump C. System pressure is limited to the D Relief Valve
setting of relief valve D. E Spool
F One Way Valve
Valve spool E is an open-centre spool that is in neutral G Double Acting Hydraulic Ram
position; flow from the pump passes through the spool and
returns to the hydraulic tank.
A
B
C G
D
E
F
* Data - Electrical
- 2CX, 210S from m/c no. 655000 to 656500 10 - 05 - 01/1
- 2CX, 2CXL, 210S, 210SL from m/c no. 657001 10 - 05 - 01/2
- 2DX from m/c no. 659249 10 - 05 - 01/3
- 2CX, 2DX, 210S and Variants from m/c no. 657001 10 - 05 - 01/4
- 2CX from m/c no. 655030 to 656999 10 - 05 - 01/5
- 2DX from m/c no. 657001 10 - 05 - 01/6
- 2CX from m/c no. 659600 to 761891 10 - 05 - 01/6
- 2CX, 2DX, 210S, 212S from m/c no. 760841 10 - 05 - 01/7
- 212SU (N. Am) from m/c no. 657001 10 - 05 - 01/8
* Data - Hydraulics
-Machine Hydraulics
- 2CX, 210S from m/c no. 655000 to 656500 10 - 05 - 02/1
- 2CX, 2CXL, 210S, 210SL from m/c no. 657001 to 658960 10 - 05 - 02/2
- 2CX, 2DX from m/c no. 658961 10 - 05 - 02/3
-Steer Hydraulics
- 2CX, 210S from m/c no. 655000 to 656500 10 - 05 - 03/1
- 2CX, 2CXL, 210S, 210SL from m/c no. 657001 to 658960 10 - 05 - 03/1
- 2CX, 2CXL, 2DX, 210S, 210SL from m/c 658961 10 - 05 - 03/1
* Data - Transmission
- Front and Rear Axles
- 2CX, 210S from m/c no. 655000 to 656500 10 - 05 - 04/1
- 2CX, 210S from m/c no. 657001 10 - 05 - 04/1
- 2CXAM, 2CXL, 210FM, 210SL, 2DX from m/c no. 657001 10 - 05 - 04/1
- Syncro Shuttle
- 2CX, 210S from m/c no. 655000 to 656500 10 - 05 - 05/1
- 2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL from m/c no. 657001 10 - 05 - 05/2,3
- 2CXAM from m/c no. 657001 10 - 05 - 05/4
- Tyre Sizes and Pressures
- 2CX, 210S from m/c no. 655000 to 656500 10 - 05 - 06/1
- 2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL from m/c no. 657001 10 - 05 - 06/2
Data - Brakes
- 2CX, 210S from m/c no. 655000 to 656500 10 - 05 - 07/1
- 2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL from m/c no. 657001 10 - 05 - 07/1
* Data Engine
- 2CX, 210S from m/c no. 655000 to 656500 10 - 05 - 08/1
- 2DX Range from m/c no. 659249 (including 212S to m/c no. 762079) 10 - 05 - 08/2
Fault Finding
- Syncro Shuttle - Mechanical
- 2CX, 2DX, 210S, 212S from m/c no. 655000 10 - 10 - 01/1,2,3
- Syncro Shuttle - Hydraulics
- 2CX, 210S from m/c no. 655000 10 - 10 - 01/4,5
- Parking Brake
- 2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL from m/c no. 657001 10 - 10 - 02/1
- Pneumatics
- 2CXAM from m/c no. 657001 10 - 10 - 03/1
- Air Conditioning
- 2CX, 2DX, 210S, 212S 10 - 10 - 04/1,2
Data
-Electrical (3CX, 4CX - 200 Series)
- General (from m/c no. 400001) 15 - 05 - 01/1
- Circuit Protection (from m/c no. 400001 to 430000) 15 - 05 - 01/2
- Circuit Protection (from m/c. no. 430001) 15 - 05 - 01/3
- Relay Identification - Syncro Shuttle m/c's (from m/c. no. 400001 to 430000) 15 - 05 - 01/4
- Relay Identification - Powershift m/c's (from m/c. no. 400001 to 430000) 15 - 05 - 01/5
- Relay Identification - All Machine Models (from m/c. no. 430001) 15 - 05 - 01/6
-Electrical (2DX, 212 Servo Machines and Variants (except 2CX) from m/c no. 400001
- General 15 - 05 - 01/10
- Fuses 15 - 05 - 01/11
- Bulbs 15 - 05 - 01/11
- Relay Identification 15 - 05 - 01/12,13
- Pin Identification
- Logic Box 15 - 05 - 01/14
- RH Joystick 15 - 05 - 01/15
- LH Joystick 15 - 05 - 01/15
- Harness Identification 15 - 05 - 01/16,17
-Electrical (3CX, 4CX and Variants from m/c no. 460001)
- General 15 - 05 - 01/19
- Fuse Identification 15 - 05 - 01/20,20A,23,24,25
- Link Box Fuses 15 - 05 - 01/21
- Bulbs 15 - 15 - 01/21
- Relay Identification 15 - 05 - 01/22,23,24,25,26
- Harness Identification 15 - 05 - 01/27,28,29
-Hydraulic (3CX, 4CX Standard Machines)
- Machine Hydraulics (from m/c no. 400001) 15 - 05 - 02/1,2,3,4,5
- Steer Hydraulics (AWS) (from m/c no. 400001) 15 - 05 - 02/6
- Steer Hydraulics (2WS) (from m/c no. 400001) 15 - 05 - 02/6
-Hydraulic (3CXE (214E) Machines)
- Machine Hydraulics 15 - 05 - 02/7
-Hydraulic 2DX, 212 Servo Machines and Variants (except 2CX) from m/c no. 400001)
- Machine Hydraulics 15 - 05 - 02/8,9,10
-Hydraulic Pumps (3CX, 4CX and Variants from m/c no. 460001) 15 - 05 - 02/11,11A,12
-Loader Valve (3CX, 4CX and Variants from m/c no. 460001) 15 - 05 - 02/13,14,15,16
-Backhoe Valve (3CX, 4CX and Variants from m/c no. 460001) 15 - 05 - 02/17,18
Contents (continued)
Data (continued) Page No.
-Transmission
- Front Axle (2DX, 212 and Variants (except 2CX ) from m/c no. 400001) 15 - 05 - 03/1
- Rear Axle (3CX, 4CX and Variants from m/c no. 460001) 15 - 05 - 04/1
- Tyre Sizes and Pressures (3CX, 4CX from m/c no. 400001) 15 - 05 - 05/1
- Tyre Sizes and Pressures (3CX, 4CX and Variants from m/c no. 460001) 15 - 05 - 05/2,3
- Syncro Shuttle (3CX, 4CX from m/c no. 400001) 15 - 05 - 06/1,2
- Powershift (3CX, 4CX from m/c no. 400001) 15 - 05 - 07/1,2
- Syncro Shuttle (3CX, 4CX and Variants from m/c no. 460001) 15 - 05 - 07/2A,2B
- Stall Figures - 3CX, 4CX AWS Machines from m/c no. 400001 15 - 05 - 07/3
- Stall Figures - 3CX, 4CX 2WS Machines from m/c no. 400001 15 - 05 - 07/4
- Stall Figures (3CX, 4CX and Variants from m/c no. 460001) 15 - 05 - 07/5,6,7,8,9
-Brakes
- Standard Machines (All Models (except 2CX) from m/c no. 400001) 15 - 05 - 08/1
- Servo Machines (All Models (except 2CX) from m/c no 400001) 15 - 05 - 08/1
- 3CX, 4CX and Variants from m/c no. 460001 15 - 05 - 08/2
-Engine
- All Models (except 2CX) from m/c no. 400001 15 - 05 - 09/1
- 3CX, 4CX and Variants from m/c no. 460001 15 - 05 - 09/2
Fault Finding
-Electrical (3CX, 4CX and Variants from m/c no. 460001) 15 - 10 - 01/1,2
-Hydraulic (Standard Machines) (All Models (except 2CX) from m/c no. 400001)
- Introduction 15 - 10 - 02/1
- Diagnosis 15 - 10 - 02/1,2,3,4
-Hydraulic (Servo Machines) (All Models (except 2CX) from m/c no. 400001) 15 - 10 - 03/1
-Variable Flow Hydraulics (All Models (except 2CX) from m/c no. 460001) 15 - 10 - 03/2,3
-Syncro Shuttle (All Models (except 2CX) from m/c no. 400001)
- Gearbox 15 - 10 - 06/1,2,3
- 2/4 Wheel Drive Clutch - 'Spring-on to 4WD' (3CX, 4CX from m/c. no. 400077 to 415011) 15 - 10 - 06/4
- 2/4 Wheel Drive Clutch - 'Pressure-on to 4WD' (3CX, 4CX from m/c. no. 415012) 15 - 10 - 06/5,6
- 2/4 Wheel Drive Clutch (3CX, 4CX and Variants from m/c no. 460001) 15 - 10 - 6/7,8
-Powershift Gearbox (All Models (except 2CX) from m/c no. 400001
- Introduction and Index 15 - 10 - 07/1
- Diagnosis 15 - 10 - 07/2,3
- Powershift Transmission (3CX, 4CX and Variants from m/c no. 460001)
- Introduction and Index 15 - 10 - 07/4
- Diagnosis 15 - 10 - 07/5,6,7,8
-Brakes All Models (except 2CX) from m/c no. 400001) 15 - 10 - 08/1,2,3,4
-Steering (3CX, 4CX and Variarts from m/c no. 460001) 15 - 10 - 09/1,2,3
Fuel Tank 64 (14) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Front Axle
Housing 4 (0.88) JCB HD90 Gear Oil API-GL-5
Hubs (x2) 1 (0.22) JCB HD90 Gear Oil MIL-L-2105
Rear Axle
Housing 4 (0.88) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 1 (0.22) JCB Special Gear Oil
Hydraulic System 70 (15.4) JCB High Performance Hydraulic Oil ISO VG46
(including tank) (Above 38 °C, 100 °F) †
† Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level
indicator on hydraulic tank.
Fuel Tank 16.81 (64) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Syncro Shuttle 5.04 (19.0) JCB Special Transmission Fluid ESP-M2C 33G
Front Axle
Housing 1.05 (4.0) JCB HD90 Gear Oil API-GL-5
Hubs (x2) 0.26 (1.0) JCB HD90 Gear Oil MIL-L-2105
Rear Axle
Housing 1.05 (4.0) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 0.26 (1.0) JCB Special Gear Oil
Hydraulic System 18.49 (70.0) JCB High Performance Hydraulic Oil ISO VG46
(including tank) (Above 100° F, 38° C) †
† Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level
indicator on hydraulic tank.
Fuel Tank 83.2 18.3 22.0 Diesel Oil ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 10.7 2.4 2.9 JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B,
-10 °C to 50 °C (14 °F to 122 °F) API CE/SF, MIL-L-2104D
Syncro Shuttle 17.5 3.8 4.6 JCB Special Transmission Fluid ESP-M2C 33G
Hydraulic System † 77 17 20.4 JCB High Performance Hydraulic Oil ISO VG46
(including tank) (Above 38 °C, 100 °F)
† Note:The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level
indicator on hydraulic tank.
Fuel Tank 83.2 18.3 22 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 11.1 2.5 2.9 JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B,
-10 °C to 50 °C (14 °F to 122 °F) API CD/SE, MIL-L-2104D
JCB Super Universal Agricultural SAE10W/30, MIL-L-2105,
-15 °C to 30 °C (5 °F to 86 °F) API CD/SE, MIL-L-2104C
MIL-L-46152
JCB Torque Converter Fluid SAE10W, MIL-L-46152,
-18 °C to 0 °C (0 °F to 32 °F) API CD/SE, MIL-L-2104D
Engine (Coolant) 12.0 2.6 3.2 JCB Universal Antifreeze/water ASTM D3306-74
(See Coolant Mixtures)
Syncro Shuttle 17.5 3.8 4.6 JCB Special Transmission Fluid ESP-M2C 33G
Axles (SD55)
Housing 8.8 1.94 2.3 JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x4) 1.8 0.4 0.5 JCB Special Gear Oil
Hydraulic System* 82 18.04 21.7 JCB High Performance Hydraulic Oil ISO VG46
(including tank) (Above 38 °C, 100 °F)
JCB Special Hydraulic Fluid ISO VG32
(Below 38 °C, 100 °F)
* Note:The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level
indicator on hydraulic tank.
Fuel Tank 83.2 18.3 22.0 Diesel Oil ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 10.7 2.4 2.9 JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B,
-10 °C to 50 °C (14 °F to 122 °F) API CE/SF, MIL-L-2104D
Syncro Shuttle 17.5 3.8 4.6 JCB Special Transmission Fluid ESP-M2C 33G
Hydraulic System † 77 17 20.4 JCB High Performance Hydraulic Oil ISO VG46
(including tank) (Above 38 °C, 100 °F)
† Note:The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level
indicator on hydraulic tank.
Fuel Tank 83.2 18.3 22 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 11.1 2.5 2.9 JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B,
-10 °C to 50 °C (14 °F to 122 °F) API CD/SE, MIL-L-2104D
JCB Super Universal Agricultural SAE10W/30, MIL-L-2105,
-15 °C to 30 °C (5 °F to 86 °F) API CD/SE, MIL-L-2104C
MIL-L-46152
JCB Torque Converter Fluid SAE10W, MIL-L-46152,
-18 °C to 0 °C (0 °F to 32 °F) API CD/SE, MIL-L-2104D
Engine (Coolant) 12.0 2.6 3.2 JCB Universal Antifreeze/water ASTM D3306-74
(See Coolant Mixtures)
Syncro Shuttle 17.5 3.8 4.6 JCB Special Transmission Fluid ESP-M2C 33G
Axles
Housing (SD55) 8.8 1.94 2.3 JCB Special Gear Oil API-GL4
Housing (SD40) 4.0 0.88 1.0 JCB Special Gear Oil API-GL4
Hubs (x4 - SD55) 1.8 0.4 0.5 JCB Special Gear Oil API-GL4
Hubs (x4 - SD40) 1.0 0.22 0.25 JCB Special Gear Oil API-GL4
Hydraulic System† 82 18.04 21.7 JCB High Performance Hydraulic Oil ISO VG46
(including tank) (Above 38 °C, 100 °F)
JCB Special Hydraulic Fluid ISO VG32
(Below 38 °C, 100 °F)
† Note:The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level
indicator on hydraulic tank.
Fuel Tank 22 83.2 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 2.9 11.1 JCB 15W/40 Engine Oil CF-4/SG, SAE15W/40
-10 °C to 50 °C (14 °F to 122 °F)
Syncro Shuttle 4.6 17.5 JCB Special Transmission Fluid ESP-M2C 33G
Axles
Housing (SD55) 2.3 8.8 JCB Special Gear Oil API-GL4
Hubs (x4 - SD55) 0.5 1.8 JCB Special Gear Oil API-GL4
Hydraulic System† 21.7 82 JCB High Performance Hydraulic Oil ISO VG46
(including tank) (Above 38 °C, 100 °F)
JCB Special Hydraulic Fluid ISO VG32
(Below 38 °C, 100 °F)
Grease Points --- JCB Moly EP#2 Grease Lithium based, No. 2
† Note:The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level
indicator on hydraulic tank.
➄ !WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl.
Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the
affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not
breathe the fumes. Apply in a well-ventilated area.
GEN-1-3
➅ Note: AWS axles with limited slip differential must use JCB Special Gear Oil.
S136710
Note: Dimensions based on standard tyres fitted (12.5 x 18, 10 PR traction). For Backhoe and Loader dimensions contact
your JCB Distributor.
B C
F E
D
G
A
A182671
Note: Dimensions based on standard tyres fitted (12.5 x 18, 10 PR traction). For Backhoe and Loader dimensions contact
your JCB Distributor.
B
C
F E
D
G
A208661
Note: Dimensions based on standard tyres fitted (12.5 x 18, 10 PR traction). For Loader dimensions contact your JCB
Distributor.
D C
A
A198341
1.92m
(6ft 3in)
4.90m
(16ft 1in)
2.49m
(8ft 2in)
1.80m
1.37m
(5ft 11in)
(4ft 6in)
Note: Dimensions based on standard tyres fitted (405/70 R 20, XM27). For Loader dimensions contact your JCB Distributor.
C
D
A
A220291
The 2CXU machine must have either an implement or counterweight attached to the three point hitch before the machine is
used to its full loader capabilities.
Maximum rated operating load with a 0.07 m3 (2.50 ft3) general purpose shovel - with counterweight 2150 Kg (4740 lbs)
without counterweight 1400 Kg (3087 lbs)
Lift capacity, bottom hitch links at ball end H when fully lowered 3000 Kg (3 tonne)
Maximum load on each axle 5500 Kg (5.5 tonne)
When an implement is attached, the weight on the front axle should be greater than or equal to 0.2 the gross weight of the
machine. However do no exceed the maximum load of the rear axle.
Note: Dimensions based on standard tyres fitted (12.5 x 18, 10 PR traction). For Backhoe and Loader dimensions contact
your JCB Distributor.
D
G
A A182672
Note: Dimensions based on standard tyres fitted (12.5 x 20, 10 PR traction). For Backhoe and Loader dimensions contact
your JCB Distributor.
D A B
A227680
Note: Dimensions based on standard tyres fitted (12.5x20 industrial traction). For Backhoe and Loader dimensions contact
your JCB Distributor.
D A B
A279700
S136670
A201931
R1 R2 R7 R8 S227260
R3 R4 R9 R10
R5 R6 R11 R12
R13 R14
9 10 10
A
15
8 5 20 R15 R16
7 10 5
R17 R18
6 10 5
10
5 5 10 15 R19 R20
4 5 10 5
3 5 10 10
2 5 5 5
1 5 15 10
5
A230370
A B C
2CX, 2DX, 210S, 212S and Variants From m/c no. 657001
Data - Electrical
The electrical circuits are protected by fuses. The fuses are located in the front console, underneath cover A. If a fuse ruptures,
find out why and rectify the fault before fitting a new one.
The fuses are identified using column letters (A, B and C) and row numbers (1 to 9). Note that all the fuses are shown (including
optional equipment fuses). Your machine may not be equipped with all the fuses shown on these pages.
A201931
S181851
A R1 R2 R7 R8
R3 R4 R9 R10
R5 R6 R11 R12
9 10 10
R13 R14
A
15
8 5 20 R15 R16
7 10 5
R17 R18
6 10 5
10
5 10 10 15 R19 R20
4 5 10 5
3 5 10 10
2 5 5 5
1 5 15 10
5
A B C
A230371 S227260
A R1 R2 R7 R8
R3 R4 R9 R10
R5 R6 R11 R12
A
9 R13 R14
8
7 R15 R16
6
R17 R18
5
4
R19 R20
3
2
R21 R22
1
A B C
A300850 S227260
B1 Attachments socket 10
B2 Engine shut off system 5
B3 Dipped beam 15
B4 Main beam 15
B5 Front work lights 10
B6 Direction indicators 5
B7 Parking brake 5
B8 Heater motor; air conditioning 15
B9 Blank 15
R1 R2
9
8
R3 R4
7
A
6
R5 R6
5
4
3 R7 R8
2
1 R9 R10
A B C
A300870 S227260
Type 550
Flow at 2250 rev/min and system pressure 56.25 litres/min 12.38 UK gal/min (14.87 US gal/min)
Excavator
Slew Ram Head Side (pilot-operated) 241 246 3500
Slew Ram Rod Side (pilot-operated) 241 246 3500
Boom Ram Head Side (pilot-operated) 241 246 3500
Boom Ram Rod Side (direct acting) 262 267 3800
Dipper Ram Head Side (pilot-operated) 241 246 3500
Dipper Ram Rod Side (direct acting) 241 246 3500
Bucket Ram Head Side (direct acting) 241 246 3500
Piston Head
Lift Ram 405 41.5 300
Shovel Ram 405 41.5 300
Slew Ram 405 41.5 300
Boom Ram 405 41.5 300
Stabiliser Ram 405 41.5 300
Dipper Ram 405 41.5 300
Bucket Ram 405 41.5 300
Hydraclamp Ram 405 41.5 300
End Cap
Lift Ram 450 45.9 332
Shovel Ram 450 45.9 332
Slew Ram 450 45.9 332
Boom Ram 450 45.9 332
Stabiliser Ram 450 45.9 332
Dipper Ram 450 45.9 332
Bucket Ram 450 45.9 332
Hydraclamp Ram 450 45.9 332
Model/Reference Single-Priority/3939
Rotation Clockwise
Mounting Engine Timing Case (with adapter)
Flow at 2000 rev/min and system pressure litres/min UK gal/min US gal/min
58 12.76 15.32
Hydraulic Pump (from machine serial number 657448)
Model/Reference Single-Priority/4506
Rotation Clockwise
Mounting Engine Timing Case (direct - no adapter required)
Flow at 2000 rev/min and system pressure litres/min UK gal/min US gal/min
58 12.76 15.32
Piston Head
Lift Rams 405 41.5 300
Shovel Rams 405 41.5 300
Slew Rams 405 41.5 300
Boom Ram 405 41.5 300
Stabiliser Rams 405 41.5 300
Dipper Ram 405 41.5 300
Bucket Ram 405 41.5 300
Clam Shovel Ram 405 41.5 300
End Cap
Lift Rams 678 69.2 500
Shovel Rams 678 69.2 500
Slew Rams 678 69.2 500
Boom Ram 678 69.2 500
Stabiliser Rams 678 69.2 500
Dipper Ram 678 69.2 500
Bucket Ram 678 69.2 500
Clam Shovel Ram 450 45.9 332
Model/Reference Single/5910P
Rotation Clockwise
Mounting Engine Timing Case (with adapter)
Flow at 2000 rev/min and system pressure litres/min UK gal/min US gal/min
58 12.76 15.32
Auxiliary Hydraulic Pump (2DX only)
Model/Reference Single/4240J
Rotation Anti-Clockwise
Mounting Auxiliary Take-Off
Flow at 2000 rev/min and system pressure litres/min UK gal/min US gal/min
28 6.16 7.39
Note: Relief valve settings for the 2CX range of machines remain as shown on page 10 - 05 - 02/2.
Piston Head
Lift Rams 405 41.5 300
Shovel Rams 405 41.5 300
Slew Rams 405 41.5 300
Boom Ram 405 41.5 300
Stabiliser Rams 405 41.5 300
Dipper Ram 405 41.5 300
Bucket Ram 405 41.5 300
Clam Shovel Ram 405 41.5 300
End Cap
Lift Rams 678 69.2 500
Shovel Rams 678 69.2 500
Slew Rams 678 69.2 500
Boom Ram 678 69.2 500
Stabiliser Rams 678 69.2 500
Dipper Ram 678 69.2 500
Bucket Ram 678 69.2 500
Clam Shovel Ram 450 45.9 332
At 100 deg.C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
2000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
Cooler at 50 deg.C 1000 rev/min 10.4 - 13.6 2.8 - 3.6 2.3 - 3.0
2000 rev/min 14.5 - 20.0 3.8 - 5.3 3.2 - 4.4
Cooler at 100 deg.C 1000 rev/min 10.2 - 12.5 2.7 - 3.3 2.3 - 2.8
2000 rev/min 22.7 - 26.1 6.0 - 6.9 5.0 - 5.7
Pump at 50 deg.C 1000 rev/min 11.0 - 15.0 2.9 - 4.0 2.5 - 3.3
2000 rev/min 22.5 - 29.5 6.0 - 7.8 5.0 - 6.5
2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL From m/c no. 657001
Data - Synchro Shuttle
Syncro Shuttle Combined torque converter, reverser, and gearbox unit with
integral parking brake.
Type SS400
Drive Output 4 wheel-drive, double yoke
Weight (dry) 150 kg (330 lb)
Gear Ratios 30 kph (18 mph) 20 kph (12 mph)
1st 4.27:1 6.31:1
2nd 2.50:1 3.70:1
3rd 1.18:1 1.75:1
4th 0.70:1 1.03:1
Torque Converters
Stall Figures
2 Converter + MRV
max. r.p.m. 1825 1825 1490 1848 1825 N/A
min. r.p.m. 1725 1725 1400 1748 1725 N/A
Build Specification
Engine Size 65 bhp ● ● ● ●
74 bhp ● ●
Fan Ratio 1 to 1 ● ● ●
1 to 1.25 ● ● ●
Converter Out (measure at 50 deg.C and 2000 rev/min) 3.4 3.5 50 max
2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL From m/c no. 657001
Data - Synchro Shuttle (cont'd)
Lubrication Pressures (in neutral)
At 100 deg.C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
2000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
At 100 deg.C 1000 rev/min 7.6 - 9.7 7.7 - 9.8 110 - 140
2000 rev/min 7.6 - 9.7 7.7 - 9.8 110 - 140
† Note: The forward and reverse clutch pressures should always be the same as the mainline pressure less (a maximum of)
1.7bar (25lbf/in2; 1.8kgf/cm2). If the mainline pressure is in the lower part of the tolerance band, then the forward and reverse
clutch pressures should also be in the lower part of the tolerance band and vice versa.
Cooler at 50 deg.C 1000 rev/min 10.4 - 13.6 2.3 - 3.0 2.8 - 3.6
2000 rev/min 14.5 - 20.0 3.2 - 4.4 3.8 - 5.3
Cooler at 100 deg.C 1000 rev/min 10.2 - 12.5 2.3 - 2.8 2.7 - 3.3
2000 rev/min 22.7 - 26.1 5.0 - 5.7 6.0 - 6.9
Pump at 50 deg.C 1000 rev/min 11.0 - 15.0 2.5 - 3.3 2.9 - 4.0
2000 rev/min 22.5 - 29.5 5.0 - 6.5 6.0 - 7.8
Torque Converter
Ratio 2.83:1
Colour Coded Dots 2 Yellow, 1 Orange
Engine Rev/Min at Converter Stall 2027 - 2127
Engine Rev/Min at Converter Stall + MRV Operating 1725 - 1825
† Note: The forward and reverse clutch pressures should always be the same as the mainline pressure less (a maximum of)
1.7bar (25lbf/in2; 1.8kgf/cm2). If the mainline pressure is in the lower part of the tolerance band, then the forward and reverse
clutch pressures should also be in the lower part of the tolerance band and vice versa.
Front
Rear
Type Size Ply Pressure (Normal Duty) † Pressure (Heavy Duty) †††
bar lbf/in2 bar lbf/in2
† These tyre pressures are recommended for road travel and normal working conditions.
†† These tyre pressures are recommended when handling heavy or palletised loads.
††† These tyre pressures are recommended when using a rock breaker or patch planer.
Radial Ply
Front
Type Size Pressure
bar lbf/in2
Rear
Type Size Pressure
bar lbf/in2
2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL From m/c no. 657001
Data - Tyre Sizes & Pressures
Note: Wheel fixing on SD40 axle was changed from 8 stud to 4 stud at machine serial number 657150. Wheel fixing on SD40
Limited Slip Differential axle was changed from 8 stud to 4 stud at machine serial number 657159. The first machine fitted with
SD55 axles (5 stud fixing) was serial number 657628.
FRONT
REAR
Type Size Ply Pressure (Normal Duty) † Pressure (Heavy Duty) †††
bar lbf/in2 bar lbf/in2
† These tyre pressures are recommended for road travel and normal working conditions.
†† These tyre pressures are recommended when handling heavy or palletised loads.
††† These tyre pressures are recommended when using a rock breaker or patch planer.
Note: If the tyres fitted to your machine are not listed, then contact your JCB Distributor for advice, DO NOT guess tyre
pressures.
Master Cylinder
Parking Brake
2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL From m/c no. 657001
Data - Brakes
Service Brakes
Type JCB oil-immersed multi-plate disc high pressure brakes with hydraulic
accumulators for emergency application.
Actuation Hydraulic ON, spring OFF.
Location Front and rear axle hubs.
Friction Plates 2 per brake pack, i.e., 8 per machine.
Counter Plates 3 per brake pack, i.e., 12 per machine.
Accumulator Pressure 25 bar (363 lbf/in2).
Brake Circuit Operating Pressure
Cut-in 90 bar (1305 lbf/in2).
Cut-out 110 bar (1595 lbf/in2).
Parking Brake
Fuel System
Injection Pump Type C.A.V., D.P.A., mechanically governed
Injection Pump Setting Code Perkins/ISO 36960TW/2/2470
Maximum Governed Speed 2250 rev/min
Maximum No-load Speed 2470 rev/min
Idling Speed 750 rev/min
Injection Timing Static 20° BTDC (equivalent to 0.192 in displacement)
Cooling System
Coolant Pressure 0.48 bar (7 lbf/in2)
Coolant Temperature (normal) 80-85 deg C
Temperature Warning Light operates at 98 deg C
Injection Sequence 1, 3, 4, 2
Valve Clearance - Hot or Cold
Fuel System
Injection Pump Type C.A.V., D.P.A., mechanically governed
Injection Pump Setting Code 2643C621/HM46L/850/7/2160
Injection Timing 16° ± 2° BTDC
Injection Setting Pressure 250 atm
Lift Pump Type AC Diaphragm
Induction System
Air Cleaner Typ 2 stage, dry element
Max. Restriction (at which warning
light operates) 635 mm (25 in) H 2 0
Lubrication System
Oil Pump Type Eccentric rotor
Oil Pressure (hot) at maximum speed 2.0 bar (30 lbf/in 2 ) (minimum)
Cooling System
Coolant Pressure 0.48 bar (7 lbf/in 2 )
Coolant Temperature (normal) 80-85 °C (176 - 185 °F)
Temperature Warning Light operates at 98 °C (209 °F)
* Note: For further details of the engine refer to Engine Service Manual 9806/0100
Injection Sequence 1, 3, 4, 2
Valve Clearance - Hot or Cold
- inlet 0.20 mm (0.008 in)
- exhaust 0.45 mm (0.018 in)
Maximum Speed (no load) 2320 - 2420 rev/min
Governed Speed 2200 rev/min
Idling Speed 750 rev/min
Fuel System
Induction System
Lubrication System
Cooling System
Note: For further details of the engine refer to Engine Service Manual 9806/0100
Performance
Rated F.A.D. at full output to ISO 1217 73.2 Itr/sec (4.4 m3/min, 155 ft3/min)
Compressor
CHECK ACTION
3 Is there air in the hydraulic system? YES: Continue running to expel air.
NO: Check 4
13 Is the transmission not pulling in both YES: Stall test machine, Check 14.
Forward and Reverse? NO: Check 16
16 Are clutch sealing rings damaged? YES: Tap pressure gauge into clutch feed
lines to monitor pressure.
18 Is the start switch in the run position and supplying YES: Check 19
current to the neutral start relay? NO: Rectify.
19 Is the fault only when the transmission is hot? YES: Dismantle solenoid and check
components.
NO: Check microswitches, relay and wiring
loom.
20 Is the noise a growl, hum or grinding? YES: Check gears for damage or wear.
NO: Check 21
21 Is the noise a hiss, thump or bumping? YES: Check bearings for damage or wear.
NO: Check 22
22 Is the noise a squeal? YES: Check free running gears for seizure.
NO: Check 23
24 Is the countershaft or its bearings worn or damaged? YES: Renew damaged parts.
NO: Check 25
25 Is there excessive backlash in the gears? YES: Adjust by checking shaft end float.
NO: Check 26
28 Are the sliding gear teeth worn or damaged? YES: Renew gears.
NO: Check 29
30 Are the selector fork pads or grooves in gears worn? YES: Renew worn parts.
NO: Check 31
34 Are the selector fork pads out of position? YES: Reposition or renew (check interlock).
NO: Check 35
37 Are steel chips embedded in the bronze? YES: Continue using, chips will either embed
below bronze or be rejected.
NO: Check 38
39 Are the sliding gears tight on the splines? YES: Free or renew.
NO: Check 40
41 Are steel chips embedded in the bronze? YES: Continue using, chips will either
embed below bronze or be rejected.
NO: Check 42
LACK OF POWER
Possible Cause Remedy
1 Poor engine condition. 1 Check and if necessary repair engine.
2 Low oil level. 2 Top up system.
3 Worn pump. 3 Check flow and if necessary repair or renew pump.
4 Torque converter damage. 4 Check and if necessary repair or renew torque converter.
5 Low mainline pressure. 5 See fault 'Low Mainline Pressure'.
6 Clutches slipping. 6 See fault 'Low Clutch Pressure'.
7 Internal leakage. 7 a) Check internal cored galleries and casting for porosity.
b) Check condition of seals.
8 High stall speeds. 8 See fault 'High Stall Speeds'.
9 Low stall speeds. 9 See fault 'Low Stall Speeds'.
10 Overheating. 10 See fault 'Overheating'.
OVERHEATING
Possible Cause Remedy
1 Low oil level. 1 Top up system.
2 High oil level. 2 Drain oil to correct level.
3 Trapped or kinked hoses in cooler system. 3 Renew or repair hoses.
4 Low converter out pressure and flow rate. 4 Repair or renew the converter relief valve.
5 Oil cooler blocked. 5 Clean cooler.
6 Operating in wrong gear range. 6 Select correct gears to suit working conditions.
7 Water system overheating. 7 Rectify water system problems, eg radiator, cooler lines,
low water level etc.
8 Oil aerated (foaming). 8 See fault 'Low Mainline Pressure', item 4.
9 Clutch piston(s) sticking on return stroke. 9 Check and repair clutch piston(s) and seal(s).
10 Cored galleries on front housing pump mounting 10 Replace front housing (or rectify existing housing).
face wrong depth (indicated by excessively low
pressure and flow on converter out cooling line).
11 Leakage across pump mounting face and front case. 11 Check for damaged surface on both components and
loose pump mounting bolts.
Check Action
2 Is the parking brake solenoid spool sticking? YES: Free off or renew valve.
NO: Check 3.
3 Put the starter switch in 'IGN' position. Disengage the YES: Dismantle parking brake and check condition.
parking brake, is there a voltage reading at the parking NO: Check 4.
brake feed wire?
4 Put the starter switch in 'IGN' position. Is there a voltage YES: Renew parking brake relay.
reading at the parking brake solenoid feed wire? NO: Check switch and wiring.
Check Action
1 Is the parking brake solenoid spool sticking? YES: Free off or renew valve.
NO: Check 2.
2 Put the starter switch in 'IGN' position. Disengage the YES: Check 4.
parking brake, is there a voltage reading at the parking NO: Check 3.
brake feed wire?
3 Put the starter switch in 'IGN' position. Is there a voltage YES: Check 4.
reading at the parking brake solenoid feed wire? NO: Check switch and wiring.
4 Has the parking brake been dismantled recently? YES: Dismantle and check for correct build.
NO: Check 5.
6 Is the main line pressure correct with the parking brake YES: Dismantle parking brake and check condition.
circuit isolated? NO: See Transmission Fault Finding.
Compressor fails to build up to a Choked air intake filter a Change air intake filter element
working pressure
b Suction unloader valve stuck on seat b Inspect and release valve through
unloader air intake
c Faulty blow down valve c Overhaul or change blow down valve
d Faulty gauge d Overhaul or change gauge
Compressor fails to off-load a Suction unloader valve stuck open a Inspect and release valve through
(safety valve blowing) unloader air intake
b Suction unloader/compressor joint leak b Tighten or renew joint
c Punctured diaphragm on pressure c Inspect and renew
regulator or unloader piston
d Safety valve faulty d Inspect and rectify
e Air/oil separator faulty e Clean or change element
Plant not operating at correct a Speed control faulty a Reset speed control
minimum or maximum speed
b Engine fault b Refer to engine Service Manual
Excessive compressor oil a Receiver scavenge oil restrictor a Clean oil restrictor
consumption choked
b Air/oil separator faulty b Clean or change element
c Incorrect grade of oil c Drain and refill with correct grade of oil
Shut down due to high air a Machine not standing level or sited a Level machine or resite for maximum air
delivery temperature badly flow
b Air receiver level low b Top up air receiver oil
c Incorrect grade of compressor oil c Drain and refill with correct grade of oil
d Air/oil separator choked d Clean or change element
e External surface of oil cooler clogged e Clean external surface of oil cooler
f Clogging of compressor oil circulating f Drain, flush and refill oil circulating
system system
g Faulty temperature switch or circuit g Check circuit and/or change faulty
switch(es)
Compressor drive will not a Parking brake not applied, a Engage parking brake, put transmission
engage transmission not in neutral in neutral
b Power take-off solenoid fuse (A8) b Change fuse
blown
c Power take-off solenoid faulty c Check circuit and change solenoid if
necessary
Use the harness illustration below to complete continuity checks on the air conditioning harness wires.The harness connects to
the mainframe harness via connector A, located behind the side console panel.
ITEM DESCRIPTION
WIRE DESCRIPTION
20 Controls to Power
21 Controls to Compressor
685 Power to Splice
686
687
Controls to Pressure Switch
Pressure Switch to Splice
E
688 Pressure Switch to Pressure Switch
689 Controls to Splice
D C
A201500
CHECK ACTION
1 Are the controls set correctly, i.e. air conditioning YES: Check 2
selected, thermostat switch set to coldest position NO: Reset controls and retest.
and blower switched on?
4 Is the air conditioning fuse (B8) blown? YES: Renew fuse and retest.
NO: Check 5.
7 Does the compressor clutch engage with YES: Renew high pressure switch and retest.
HP switch bypassed? NO: Check 8.
(See Pressure Switch Testing)
8 Does the compressor clutch engage with YES: Renew low pressure switch and retest.
LP switch bypassed? NO: Charge check required by refrigeration engineer.
(See Pressure Switch Testing)
9 Does the clutch engage with thermostat switch YES: Renew thermostat switch and retest.
bypassed? NO: Check all electrical connections.
10 Are blower switch and wiring OK? YES: Renew blower motor.
NO: Renew switch or wiring.
13 Is evaporator air flow blocked? YES: Clean filter and, if necessary the evaporator.
NO: Call in refrigeration engineer.
153201
22
200
817 3 251 9 10 6 256 7
C7 C2 C6
203
4
10
205
258
226
807
8
C1 C5 C4
4
A9 A7 B8 B6 A6 B1
803
804
415
882 A1 B2 A2 A8 B7 B9 C3
17 16
880
219
224
806
97
254
211
830
838
223
217
883
21
2
18
16
225
79 71 57 45 7
81 23 805
233 826
99
232
812
11
861
229
230
827
412
414
855
865
257 6
100
841
884
856
B3 B4 101
237
236
410
238
825
248
98
209
80 41 19 18 15 8
810
243
221
239 32 681
245
244
227
70 67 66 63 62 48 42 413
56
1/2
249
249
228 9
46 40 37 36 35 34 33
234
833
212
49 +
808
800
863
862
218
207
1
859
857
255
247 -
82 250 A5
411
78 50
96 68 65
231
102
400
242
246
253
39 38
842
A4 A3 B5 64 61 55 47 3
241
409
814
836
213
850
849
14 10 5
235
216
44 43 401
408
404
252
844/845
214
820
866
222
851
853
811
802
801
60 25 24
416
848
847
846
215
819
822
821
818
886
839
837
832
831
835
834
816
815
853
860
407
406
402
405
403
20 12 11
93 91 89 87 86 84 75 74 72 59 53 51
809
95 77 31 30 29 28 27 26 4
94 92 90 88 85 83 76 73 69 58 54 52
13
607
646/647
605
684
619
680
651
624
660
658
638
649
661
659
637
637
637
639
648
623
652
633
639
638
637
638
648
649
614
604
642
669
654
656
653
643
639
649
637
633
627
644
657
637
640
664
603
618
637
637
602
636
622
631
620
682
621
630
631
668
655
639
648
638
612
617
A183041 A183040-1
19 28
13
69 73 121 123 125 127 129 131 133
176 14
66 16
120 122 124 126 128 130 132
1
25
170 18 22 23 24
62
65
A1
67
178 68
173
72
70
C5 C3 B7 C2 B1 B6 A6
61
172
CONTENTS
9804/1103 10 - 15 - 01/5 3270 - C/18-1.3 Issue 2*
CONTENTS
CONTENTS
Backhoe Loaders 10 - 15 - 01/6
180 ➂ 140 93 48
153 145 149 151 152
36 38 146 41
150 40 47 50
34
97
37
33 35
32 44
B3 42 183
B4
100
88 89 A3 A4
31 96
46 49
85
128 135 130 137 83 84 86 92
134 133 131 136 138 C4
90
87 91 95
94
99
B5 C1
B2 A2 B9 A5 A9
A7 A8
B8
181
182
C3 2
7 9
A8 6
10
11
12
13
14
15
16
17
C2
18 A212850
2
3
5 8
7
9
10
11
12
13
6 14
15
16
17
18
A252070
26 27 79 81
10 111 112 114 117 82
79
78 29
116 118 75 77
3 5 6 7 154 14
2 63 71 74 76
8 17 115 119
9
64 20
110 113
4
11 12
174 175 177 185
171 179
184 28
2
13 19 25
73 22
176 16 121 123 125 127 130 132
69
120 122 124 126 128129 131 133
66
1 23 24
170 18
62 21
173
65 178
72
67 68
70
61
172
600
119
7 9 75
117 78
2 3 114 32
5 6 8 118 79 74 76 77
116 26 27
30 115
4 64 63
16
174 175
19
73
18 22 23 24
176
121 127 122 124 125 130
1 28
133 120 123 126 131
62
25
65
31
173 72
66
176
61
172
001
830Y
837C
200
160AH
600
49
93 44
100
89
88
70 90
85
178
86
84 91 92
87
99
181
001
830Y
837C
200
160AH
FUSE P4
FUSE P1
FUSE P2
FUSE P3
FUSE C7
9804/1103
BATTERY
CONTENTS
IGNITION
SWITCH BATTERY
6
3
NEUTRAL START RELAY STARTER MOTOR
1
5
200B
004
8
2
200C 842 STARTER SOLENOID
2
6
4
9 8 7 3 4 5 6
NEUTRAL START RELAY
IGNITION RELAY 1
810
FORWARD RELAY
9
FUSE C9
FOR / REV
3
2CX, 2DX and Variants
8
SWITCH
6
809
2
FUSE A5 F FORWARD RELAY
2
N
002 107 812
10
FORWARD SOLENOID
4
200
8
5
Circuit Diagram - Electrical
IGNITION R
8
REVERSE RELAY
7
10
RELAY 1
808
4
6
811
1
912
REVERSE SOLENOID
2
PARKBRAKE REVERSE RELAY
12 13
REVERSE ALARM
3
5
RELAY
11
15
14
8
TRANS DUMP
10
RELAY
001
011
7
6
200G/200L
200E/200R
200D/200M
401
9
934 DUMP SWITCH (GEAR)
16
17
934
7
18
10 - 15 - 01/22
6
967
2
PARKBRAKE
122 936
8
FUSE A4
9
10
Backhoe Loaders
19
953
COMPRESSOR COMPRESSOR
121
CONNECTOR CONNECTOR
FUSE A6
BRAKE LIGHTS
SWITCH LH BRAKE LIGHT
21
FUSE B6 FUSE A8
23
105 E.S.O.S.
FUSE A2 REAR WASH/
WIPE SWITCH
5
M
863
24 25
27
1
M
FUSE B5
2
103 864
8
7
829
BATTERY FEED
28
INTERIOR LIGHT
303
30
M
FRONT WIPER
32
33
FRONT
W/W SWITCH
840
841
34
303
JUNCTION BOX
JUNCTION BOX
101
36
FUSE A1
HAZARD SWITCH
803
LH FRONT INDICATOR
INDICATOR
SWITCH LH REAR INDICATOR
41
8
38
10
828
42
806
39
FLASHER
RELAY
RH FRONT INDICATOR
18
2
17
104 49a
1
31
FUSE A3
4
802
2
6
49
FLASHER UNIT
300 C2
3
FUSE C4
43
401
+ FUEL GAUGE
47
TACHOMETER
TACHOMETER
48
HOURMETER
49
9 9 9 9 9 9
7110 - C/7-16.1
ILLUMINATION
011
007
829
830
106
828
401
110
804
806
805
407
412
50
From m/c no. 489724
10 - 15 - 01/22
Issue 1
110
011
007
829
830
804
806
106
828
401
805
407
412
9804/1103
CONTENTS
200G/200L
200E/200R
200D/200M
11
51
MASTER
INSTRUMENTS
WARNING
FRONT CONSOLE
LIGHTS
12
2 W STEER
TURN SIGNAL
5
4
52
SIDE LIGHRS
2CX, 2DX and Variants
3
53
MAIN BEAM
2
54
HAZARD WARNING
6
55
REAR W/L
8
56
FRONT W/L
7
57
REAR FOG
Circuit Diagram - Electrical (cont’d)
9
58
16
ALTERNATOR
7
3
HAND BRAKE
458 BRAKE PRESS SWITCH
18
WATER TEMP
406 WATER TEMP SWITCH
12
TRANS OIL TEMP
BATTERY FEED
404
9
TRANS OIL TEMP SWITCH
10 - 15 - 01/23
ENGINE OIL PRES
SIDE CONSOLE
403 ENGINE OIL PRESS SWITCH
INSTRUMENTS
11
TRANS OIL PRES
405 TRANS OIL PRESS SWITCH
10
60 61 62 63 64 65
59
AIR FILTER
402 AIR FILTER VAC. SWITCH
17
66
Backhoe Loaders
411
407
106
FUSE
B1
67
BUZZER
68
W
ALTERNATOR
RADIO SOCKET
69
304
FUSE
C6
8
7
71
70
3
118
1
FUSE
B3
REAR HORN SWITCH
114
73
POWER SOCKET
72
5
FUSE
8
B4
24
6
IGNITION RELAY 2
F/W/L SWITCH
IGNITION
RELAY 2
5
76
6
6
2
3
011
2
855
8
7
310
74
FUSE
B9
4
6
4
6
011 861
2
1
8
78
117
2
FUSE 861
B7
7
77
79
8
BEACON SWITCH
R/W/L SWITCH
8
7
BEACON
80
FUSE
81
M
B10
3
894
2
314
1
8
7
FOG LIGHT
82
83
H/LIGHT
FUSE C1
3
FLASH 835
2
862
1
84
FOG LT SWITCH
LIGHTS RELAY
ROAD LIGHTS
RELAY
834 RH DIP BEAM
88
85
5
FUSE C2
2
5
837
89 90
311
87
DIP/MAIN
FUSE BEAM SWITCH 837 RH MAIN BEAM
C3
91
86
LIGHTS
SWITCH FUSE A9
829 LH SIDE LIGHT
93
830
FUSE A10
DIPPER SOCKET
7110 - C/7-18.1
RH TAIL LIGHT
94
830
95
RH SIDE LIGHT
From m/c no. 489724
10 - 15 - 01/23
Issue 1
CONTENTS
Backhoe Loaders 10 - 15 - 01/24
9804/1103
1
010 003 THERMOSTART
CONTENTS
FUSE P4
FUSE P1
FUSE P2
FUSE P3
FUSE C7
2
BATTERY
IGNITION
SWITCH BATTERY
5
4
6
3
NEUTRAL START RELAY STARTER MOTOR
1
5
200B
004
8
2
200C 842 STARTER SOLENOID
2
6
4
9 8 7 3 4 5 6
NEUTRAL START RELAY
IGNITION RELAY 1
892
967
FORWARD RELAY
9
FUSE C9 FOR / REV
SWITCH
3
5
6
809
8
2
F FORWARD RELAY
Circuit Diagram - Electrical
FUSE A5
2
N
002 107 812
10
FORWARD SOLENOID
4
200
8
5
R
7
8
IGNITION REVERSE RELAY
10
RELAY 1
808
4
6
811
1
REVERSE SOLENOID
12
912
2
11
REVERSE RELAY
13
PARKBRAKE
REVERSE ALARM
3
5
810
RELAY
14
15
TRANS DUMP
8
10
RELAY
001
011
200G
7
200E/200R
200D/200M
9
411 824
16
10 - 15 - 01/25
936
1
5
18
122
FUSE A4 936
6
2
815 PARKBRAKE
Backhoe Loaders
10
PARKBRAKE
SWITCH
4
19
5
6
1
2
3
20
8
JUNCTION BOX
22
101
FUSE A1 BRAKE LIGHTS
24
LH BRAKE LIGHT
SWITCH FUSE A8
126 933 816 RH BRAKE LIGHT
25
FUSE B6
23
105 E.S.O.S.
FUSE A2
27
M
863
26 28
REAR WASH/
1
M
FUSE B5
3
103 864
BATTERY FEED
8
7
829
30
HEATER SWITCH
1
2
33
32
102
HEATER RESISTOR HEATER FAN MOTOR
4
FUSE C8
5
M
800 HEATER
6
800B
7
8
34
INTERIOR LIGHT
303
35
M
FRONT WIPER
37
38
840
841
303
HAZARD SWITCH
803
LH FRONT INDICATOR
INDICATOR
SWITCH LH REAR INDICATOR
42
10
45
828
41
806
5
46
RH FRONT INDICATOR
18
2
804 806
47
RH REAR INDICATOR
17
104 49a
1
31
FUSE A3 802
4
6
49
FLASHER UNIT
300 C2
3
FUSE C4
FLASHER
43
RELAY
7110 - C/7-19.1
411
110
011
007
829
804
806
828
411
805
From m/c no. 489724
10 - 15 - 01/25
Issue 1
212SU
110
011
007
829
804
806
828
411
805
9804/1103
CONTENTS
200G
200E/200R
CONTENTS
200D/200M
U 409 WATER TEMP SENDER
48
+ WATER TEMP GAUGE
49
-
50
+ FUEL GAUGE
51
-
CONTENTS
TACHOMETER
TACHOMETER
HOURMETER
9 9 9 9 9 9
52 53
Circuit Diagram - Electrical (cont’d)
ILLUMINATION
411
407
412
TURN SIGNAL
5
4
HAZARD WARNING
3
1
MAIN BEAM
2
MASTER WARNING
55 56 57 58
LIGHTS
BATTERY FEED
10 - 15 - 01/26
54
10
ALTERNATOR
12
11
HAND BRAKE
458 BRAKE PRESS SWITCH
13
Backhoe Loaders
WATER TEMP
406 WATER TEMP SWITCH
9
TRANS OIL TEMP
404
8
TRANS OIL TEMP SWITCH
ENGINE OIL PRES
INSTRUMENTS
403 ENGINE OIL PRESS SWITCH
17
FRONT CONSOLE
TRANS OIL PRES
405 TRANS OIL PRESS SWITCH
14
AIR FILTER
402 AIR FILTER VAC. SWITCH
6
59 60 61 62 63 64 65
411
407
106
FUSE
B1
BUZZER
67
66
W
ALTERNATOR
8
RADIO SOCKET
68
7
304
FUSE
C6
8
24
6
IGNITION RELAY 2
F/W/L SWITCH
IGNITION
69
5
RELAY 2
6
011
2
72
855
8
310
3
FUSE 855
B9
70
7
71
4
6
4
6
011
75
861
2
1
117
2
FUSE 861
73
B7
7
74
8
BEACON SWITCH
R/W/L SWITCH
8
7
76
BEACON
77
FUSE M
B10
3
894
2
314
1
8
7
FOG LIGHT
78
79
FUSE C1
3
835
H/LIGHT
2
862
1
FLASH
FOG LT SWITCH
80
LIGHTS RELAY
ROAD LIGHTS
RELAY RH DIP BEAM
84
81
FUSE C2
5
833 834
2
LH DIP BEAM
85
FUSE B8 832
6
127
312 836 837
4
LH MAIN BEAM
86
FUSE C10
2
DIP/MAIN
3
83
FUSE
C3
7
82
ROAD
LIGHTS
SWITCH 828 829 LH TAIL LIGHT
88
FUSE A9
829 LH SIDE LIGHT
89
830
7110 - C/7-21.1
FUSE A10
DIPPER SOCKET
90
RH TAIL LIGHT
91
830
92
RH SIDE LIGHT
From m/c no. 489724
10 - 15 - 01/26
Issue 1
CONTENTS
CONTENTS
Backhoe Loaders 10 - 15 - 01/27
+
-
50 Direction Indicator Light
51 Right Hand Indicator Light - Front
1
52 Right Hand Indicator Light - Rear C6
53 Left Hand Indicator Light - Front
101AL
54 Left Hand Indicator Light - Rear 2
203
10
69 Rear Brake Lights
70 Rear Brake Light Switch
103 Trailer Brake Lights B6 A6 A1
101AM
922
104 Trailer Indicator Warning Buzzer
105 Right Hand Trailer Indicator Light
223
217
106 Left Hand Trailer Indicator Light
211
107 Diverter Switch † 107
108 Diverter Solenoid Valve † 45
237
236
238
operate the hitch ram.
239
243
600GC
48
46
49 255
50
455
410
253
108
47
850
849
815
816
851
853
805K
806L
600GD
816J
853
104 69
53 51
106
600GE
105
649
648
54 52
639
649
633
103
648
638
637
DIPPER SOCKET
REAR WORKING
RH MAIN BEAM
LH MAIN BEAM
LIGHTS RELAY
RH SIDE LIGHT
LH SIDE LIGHT
RH TAIL LIGHT
LH TAIL LIGHT
RH DIP BEAM
LIGHTS
LH DIP BEAM
LIGHTS
12 14
11 13 16 19
17
834
837
829
830
3 6
834
837
15 18
834
837
FUSE C10
FUSE C2
861
855
861
855
833
836
829
830
TO INST PANEL
TO FOG LT SW
FUSE A10
FUSE A9
6 3 7 TO INST PANEL
F/W/L SWITCH
2 4 6 1 3 7
BEAM SWITCH
R/W/L SWITCH
DIP/MAIN
5 2
116
5 2 8
5 10
117
832
828
4 2 5 4 2 5
1 4 4 6 3 7
SWITCH
6 8 6 8
LIGHTS
ROAD
011
011
TO HAZARD SW 5 2 9
TO INST PANEL
SW ILUMINATION
TO INST PANEL
311
FLASH
H/LIGHT
127
309
310
ON GERMAN/ITALIAN
LINK NOT REQUIRED
ROAD LIGHTS
5 2 4
BUILDS
7
FUSE
RELAY
FUSE
B7
B9
3 1
110 FEED
FUSE B8
FUSE C3
FUSE P4
FUSE P1
A363450
AIR CON.
HEATER
HEATER
8
HIGH PRESS
SWITCH
HEATER FAN MOTOR
965
3 M 9
7 M
LOW PRESS
4
SWITCH
M
961
964
2 1 3
6
HEATER RESISTOR
2 4 5
800B
963
800B
FREEZE
AIR CON
VALVE
RELAY
RESISTOR
3 5
HEATER
800
962
7 3 1
1 3 4 6 7
SWITCH
AIR CON
HEATER SWITCH
1 8 2
2
800B
800A
800
2 5
8
800E
B4 B3 A4 C1
B5
B1
SWITCH
HEATER
1
102
829
600
102
829
600
FUSE C8
FUSE C8
A363460 A363470
COMPRESSOR
COMPRESSOR
TEMP SENDER
AIR FILTER SW
AIR RECIEVER
HOURMETER
TEMP SW
TEMP SW
AIR DELIVERY
TEMP GAUGE
SOLENOID
RADIO
12
7
602
2
511
4
3
6
2
1
8
U
-
952
860
9 10 11
952
10 7 9
COMPRESSOR
1
INTERLOCK
RELAY
5
8 6
955
459
459
459
859
951
4 2 5
COMPRESSOR
SHUTDOWN
RELAY
4
2
601
1 3
3
5 2 4
COMPRESSOR
3
RELAY
START
3 1
959
BUTTON
157
START
1
953
600
600
304
STOP/START
SWITCH
121
PARKBRAKE
LIGHTS RELAY
FUSE A6
FUSE C6
A363490
A363480
TOOLS SOLENOID
HAND HELD
HYDROCLAMP
SOLENOID
HAMMER
SOLENOID
2
2
801
3
801
966
1 3 7
899
1 3 7
1
1 2 8
2 8
HAMMER
RELAY
1
FEED SKT
AUXILIARY
FEED SKT
101
829
600
AUXILIARY
101
829
600
101
600
FUSE A1
FUSE A1
FUSE A1
S9808/9047-1
20
26
11 27
21
1 4
4W
5 4A 4H
10
19 28
22
R L
19
9B 3
2 4W
4B 4J
4L
7
3A 19
24 3E 3F 4W
8
3J 4C 4K
6 LS
9
6A 9A 4W 30 31
P T 4D
3B
29
3J 4E 4W
4N
13 3C 19
15 17 25 4W
4F 4M
3G 3H 4R
3J
3D
16 18 4W
14
23 4P 27
8 4S 4T
14
8 12
12 32
4V
4U 1
4G
33
12
A210610
1 Hydraulic Tank
2 Pump
3 Loader Valve Block
4 Filter
5 Excavator Valve Block
6 B.H.T.M.A. Class 'C' Quick Release Couplings
7 Auxiliary Tool Switch
8 Priority Flow Divider
9 Hi-flow Return Line
1
5
9
2
6
A173420
A173420
26
27
10
R L
1 9B 4
8
5 20 4W
2A 4A 4H
36 35
19 28
22 21
11
19
3
LS 4W
9 4B 4J
4L
7
2 9A 3A 19
P T
8
24 3E 3F 4W
G1 S 13 3J 4C 4K
6
6A 4W 30 31
4D
3B
G2 16 29
3J 4E 4W
4N
EF P T LS A1 A2
3C 19
25 4W
15 4F 4M
3G 3H
8
17 3J
3D
14
23 4P 27
14
18
4G
8 34
33A
33
33B
12 32
CONTENTS
9804/1103 10 - 20 - 02/2 7110 - E/2-2.6 Issue 4*
CONTENTS
CONTENTS
Backhoe Loaders 10 - 20 - 02/3
40
V C
20
P 21
5
10
11
1
22
R L
9B 3
2
7
3A
24 3E 3F
8
3J
6 LS
9
6A 9A
P T
3B
3J
13 3C
15 17 25
3G 3H
3J
3D
16 18
14
23
8
14
8
A221000
A221000
29
4A
4E
4G
28 4B
4G
27
4F 4C
40 4G
V C 26
4D
P
10 4G
31 32
5 30
1
22
L R
9B 3
2
7
3A
24 3E 3F
8
3J
6 LS
9
6A 9A
P T
3B
3J
13 3C
15 17 25
3G 3H
3J
3D
16 18
14
23
8
14
8
11
20 21
T Tank
S Suction Line
P Pump
2 Priority Valve
5 Suction Strainer
6 Filter
6A Filter By-pass Valve
7 Cooler
8 Pressure Test Connector (prior to Machine No. 655604)
8A Pressure Test Connector (from Machine No. 655604)
40 Front Steer Ram
41 Rear Steer Ram
42 Counterbalance Valve
43 Steering Control Valve
43A Shock Valve
43B Relief Valve
43C Non-return Valve
S9808/9002-2
1 Air Reciever
2 Hose
3 Oil Cooler
4 Hose
5 Oil Filter
6 Hose
7 Compressor
8 Hose
6 2
5 4 3
A213330
Syncro Shuttle (2WD) ➁ 15.75 3.5 JCB Special Transmission Fluid ESP-M2C 33G
Syncro Shuttle (4WD) ➁ 16.25 3.6
(machines up to serial number 431230)
Syncro Shuttle (2WD) ➁ 13.0 2.9 JCB Special Transmission Fluid ESP-M2C 33G
Syncro Shuttle (4WD) ➁ 14.0 3.1
(machines from serial number 431230)
Rear Axle (2WS) 23 5.0 JCB Special Gear Oil ESEN-M2C 86A/B
Slew Gearbox 4.3 0.9 JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Brake System
- Standard 1.2 0.26 JCB Light Hydraulic Fluid ISO VG15
Hydraulic System ➂ 135 29.7 JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
Boom Lock 1.0 0.22 JCB Light Hydraulic Fluid ISO VG15
.............continued
9804/1103 15 - 00 - 01/1 Issue 3
CONTENTS
CONTENTS
Backhoe Loaders 15 - 00 - 01/2
Electrical --- As a corrosion and moisture inhibitor all exposed connections should be
connections coated liberally with petroleum jelly.
➀ Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is
gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up
without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be
drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the
lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or
reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is
replaced by the lubricant recommended. The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on
the dipstick when filling the system. Figures quoted within ±0.5 litre (0.11 U.K. gal).
➁ Note: The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system.
Figures quoted within ±1.0 litre (0.22 U.K. gal).
➂ Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level
indicator on hydraulic tank.
➃ Note: JCB HP Grease is a high specification grease, in certain applications this grease must be used, for instance
transmission bearings during an overhaul.
➄ ! WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl.
Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the
affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe
the fumes. Apply in a well-ventilated area.
GEN-1-3
➅ Note: AWS axles with limited slip differential must use JCB Special Gear Oil.
†Fuel Tank (with toolbox) 110 24.2 Diesel Oil ASTM D975-66T Nos. 1D, 2D
†Fuel Tank (without toolbox) 150 33 Diesel Oil ASTM D975-66T Nos. 1D, 2D
Fuel Tank (All later m/c’s) 130 28.6 Diesel Oil ASTM D975-66T Nos. 1D, 2D
†Initial build machines only, all machines built after Feb. 1997 have a 130 litre (28.6 gal.) capacity tank.
Engine (Coolant) 23.0 5.1 JCB Four Seasons Antifreeze ASTM D3306, BS6580
& Summer Coolant/Water
(see Coolant Mixtures)
Syncro Shuttle (2WD) ➁ 14.4 3.2 JCB Special Transmission Fluid ESP-M2C 33G
Syncro Shuttle (4WD) ➁ 15.4 3.4 Friction modified oils MUST NOT be used (eg. Dexron ATF type)
Front Axle (4WD) JCB HD90 Gear Oil (without LSD) API-GL-5
Housing (2WS) 13 2.86 JCB Special Gear Oil Plus (with LSD) API-GL-4
Housing (4WS) ➅ 18 3.96 Must be suitable for use with limited slip differentials (LSD).
Hubs (x2) 2.0 0.44
Brake System
- Standard 1.2 0.26 JCB Light Hydraulic Fluid ISO VG15
Hydraulic System ➂ 130 28.6 JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
Electrical --- As a corrosion and moisture inhibitor all exposed connections should be
connections coated liberally with petroleum jelly.
➀ Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is
gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up
without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be
drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in
the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or
reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is
replaced by the lubricant recommended. The figure quoted is TOTAL system capacity. Use the MIN and MAX marks
onthe dipstick when filling the system. Figures quoted within ±0.5 litre (0.11 U.K. gal).
➁ Note: The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system.
Figures quoted within ±1.0 litre (0.22 U.K. gal).
➂ Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch
level indicator on hydraulic tank.
➃ Note: JCB HP Grease is a high specification grease, in certain applications this grease must be used, for instance
transmission bearings during an overhaul.
➄ !WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl.
Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the
affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not
breathe the fumes. Apply in a well-ventilated area.
GEN-1-3
➅ Note: AWS axles with limited slip differential must use JCB Special Gear Oil.
214, 214E, 215, 215E, 217 (N. America) From m/c no. 460001
Fluids, Lubricants and Capacities
†Fuel Tank (with toolbox) 29 110 Diesel Oil ASTM D975-66T Nos. 1D, 2D
†Fuel Tank (without toolbox) 39.6 150 Diesel Oil ASTM D975-66T Nos. 1D, 2D
Fuel Tank (All later m/c’s) 34.3 130 Diesel Oil ASTM D975-66T Nos. 1D, 2D
Engine (Oil) ➀
2 Wheel Steer Machines
- Build AA 2.6 9.7 JCB 10W or JCB 15W/40 † API CF4/SG,
- Build AA (Hot Climate) 2.9 11.0 Below 32 °F (0°C) † MIL-L-2104F
- Build AB 2.7 10
JCB 30W or JCB 15W/40 † Note: spec given for 15W/40
4 Wheel Steer Machines Above 32 °F (0°C)
- Build AB 2.7 10.0
Syncro Shuttle (2WD) ➁ 3.2 14.4 JCB Special Transmission Fluid ESP-M2C 33G
Syncro Shuttle (4WD) ➁ 3.4 15.4
Rear Axle (2WS) 6.1 23 JCB Special Gear Oil Plus API-GL-4
Brake System
- Standard 0.32 1.2 Light Hydraulic Fluid ISO VG15
Electrical --- As a corrosion and moisture inhibitor all exposed connections should be
connections coated liberally with petroleum jelly.
†Initial build machines only, all machines built after Feb. 1997 have a 34.3 gal. (130 liter) capacity tank.
Continued.......
214, 214E, 215, 215E, 217 (N. America) From m/c no. 460001
Fluids, Lubricants and Capacities (Cont’d)
➀ Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is
gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up
without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be
drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in
the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or
reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is
replaced by the lubricant recommended. The figure quoted is TOTAL system capacity. Use the MIN and MAX marks
onthe dipstick when filling the system. Figures quoted within ±0.5 litre (0.11 U.K. gal).
➁ Note: The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the
system.
Figures quoted within ±1.0 litre (0.22 U.K. gal).
➂ Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch
level indicator on hydraulic tank.
➃ Note: JCB HP Grease is a high specification grease, in certain applications this grease must be used, for instance
transmission bearings during an overhaul.
➄ !WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl.
Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the
affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not
breathe the fumes. Apply in a well-ventilated area.
GEN-1-3
➅ Note: AWS axles with limited slip differential must use JCB Special Gear Oil.
Fuel Tank 34.3 130 Diesel Oil ASTM D975-66T Nos. 1D, 2D
Engine (Oil) !
2 Wheel Steer Machines
- Build AR 2.6 9.7 JCB 15W/40 CF 4/SG, SAE 15W/40
-10°C to + 50°C (14°F to 122°F)
JCB 10W CF 4/SG, SAE 10W
-20°C to + 10°C (-4°F to 50°F)
Syncro Shuttle (2WD) " 3.8 14.4 JCB Special Transmission Fluid ESP-M2C 33G
Syncro Shuttle (4WD) " 4.0 15.4
Front Axle
Housing (2WS) 3.4 13 JCB GL-5 80W/90 API-GL-5
Hubs (x2) 0.5 2.0
Brake System
- Standard 0.32 1.2 Light Hydraulic Fluid ISO VG15
- Servo 0.37 1.4 ! CAUTION: DO NOT USE ORDINARY BRAKE FLUID
Electrical --- As a corrosion and moisture inhibitor all exposed connections should be
connections coated liberally with petroleum jelly.
! Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is
gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up
without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be
drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in
the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or
reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is
replaced by the lubricant recommended. The figure quoted is TOTAL system capacity. Use the MIN and MAX marks
onthe dipstick when filling the system. Figures quoted within ±0.5 litre (0.11 U.K. gal).
" Note: The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the
system.
Figures quoted within ±1.0 litre (0.22 U.K. gal).
# Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch
level indicator on hydraulic tank.
*% Note: JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing must
be carried out more frequently.
Continued.......
9804/1103 15 - 00 - 01/7 3270 - 3/1-6.2 Issue 2*
CONTENTS
CONTENTS
Backhoe Loaders 15 - 00 - 01/8
➄ !WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl.
Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the
affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not
breathe the fumes. Apply in a well-ventilated area.
GEN-1-3
➅ Note: AWS axles with limited slip differential must use JCB Special Gear Oil.
Engine (Oil) ➀
2 Wheel Steer Machines
- Build AR 11.0 2.4 JCB Super Multigrade 15W/40 SAE15W/40
- Build AK 10 2.2 -10°C to +50°C (14°F to 122°F) CF-4/SG
Engine (Coolant) 23.0 5.1 JCB Four Seasons Antifreeze ASTM D3306, BS6580
& Summer Coolant/Water
(see Coolant Mixtures)
Front Axle (4WD) JCB HD90 Gear Oil (without LSD) API-GL-5
Housing (2WS) 13 2.86 JCB Special Gear Oil Plus (with LSD) API-GL-4
Housing (4WS) ➅ 18 3.96 Must be suitable for use with limited slip differentials (LSD).
Hubs (x2) 2.0 0.44
Brake System 1.4 0.3 JCB Light Hydraulic Fluid ISO VG15
! CAUTION: DO NOT USE ORDINARY BRAKE FLUID
Hydraulic System ➂ 130 28.6 JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
Grease Points --- JCB HP Grease Lithium based NLGI No.2 consistency
including extreme pressure additives
or JCB Special MPL-EP Grease ➃ Lithium based NLGI No.2 consistency
including extreme pressure additives
Electrical --- As a corrosion and moisture inhibitor all exposed connections should be
connections coated liberally with petroleum jelly.
➀ Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is
gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up
without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be
drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in
the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or
reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is
replaced by the lubricant recommended. The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on
the dipstick when filling the system. Figures quoted within +0.5 litre (0.11 UK gal).
➁ Note: The figure quoted us TOTAL system capacity. Use the MIN and MAX amrks on the dipstick when filling the
system. Figures quoted within +1.0 litre (0.22 UK gal)
➂ Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level
indicator on hydraulic tank.
➃ Note: JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing must
be carried out more frequently
➄ !WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl.
Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the
affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not
breathe the fumes. Apply in a well-ventilated area.
GEN-1-3
➅ Note: 4WS alxes with liited slup differential must use JCB Special Gear Oil Plus
Coolant Mixtures
! WARNING
Antifreeze can be harmful. Obey the manufacturer’s instructions when handling neat or diluted antifreeze.
7-3-4-4
The protection provided by JCB Four Seasons Antifreeze and Summer Coolant is shown below. If any other antifreeze is used
refer to the manufacturer’s instructions and ensure that a corrosion inhibitor is included. DO NOT use solutions of more than
60% or less than 50% or damage to the cooling system will occur.
55% Solution - Maintains circulation down to -36°C (-33°F), protects agains damage down to -41°C (-42°F)
The strength of the antifreeze solution must be checked at least once a year, preferably at the beginning of the cold period. It
is an advantage to leave the antifreeze in all year round as it gives continued protection against corrosion. Always renew the
antifreeze every two years. A 50% antifreeze mixture must be used even if frost protection is not needed. This gives
protection against corrosion and raises the coolant’s boiling point.
It should be noted that serious damage to the cooling system can occur if corrosion inhibitors are not used.
D Wheelbase
C
H
F E
J D
A
G
A163130
B
A163130
D Wheelbase
C
H
F E
J D
A
G
B
A163140
D Wheelbase
C
H
F E
J D
A
G
B
A163140
D Wheelbase
C
H
F E
J D
A
G
B
A163150
D Wheelbase
C
H
F E
G J D
A163160
D Wheelbase
C
H
F E
J D
A
G
A166290
D Wheelbase
C
H
F E
J D
A
G
A163130
B
A163130
D Wheelbase
- 4WD
C
H
F E
J D
A
G
B
A163140
C
H
F E
J D
A
G
B
A162830
C
H
F E
D
A
G
A170890
C
H
F E
D
A
G
A170890
F E
D
A
G
B
A171020
C
H
F E
G J D
A162850
C
H
F E
J D
A
G
A170771
C
H
F E
J D
A
G
B
A165850
B
C
H
F E
J D
A
A229150
C
H
F E
G J D
A162850
D Wheelbase
Note: Dimensions based on following tyres fitted -rear: 18.4 x 26 industrial; front: 10.5/80 x 18PR.
F E
D
A
G
A257120
B
C
F E
G
G D
B Overall height
- standard backhoe fitted 3.52 - - -
- extending dipper fitted 3.60 3.60 3.60 3.60
Dimensions in metres and are based on standard tyres fitted. For Backhoe and Loader dimensions contact your JCB
Distributor.
B
C
F E
G
G D
B Overall height
- standard backhoe fitted 3.59 - - -
- extending dipper fitted 3.67 3.67 3.92 3.96
Dimensions in metres and are based on standard tyres fitted. For Backhoe and Loader dimensions contact your JCB
Distributor.
B
C
F E
G
G D
A270000
Dimensions in metres and are based on standard tyres fitted. For Backhoe and Loader dimensions contact your JCB
Distributor.
B
C
F E
G
G D
B Overall height
- standard backhoe fitted 3.43 - 3.43
- extending dipper fitted 3.53 3.53 -
D Wheelbase
- 2WD 2.21 2.21 2.21
- 4WD 2.28 2.26 2.26
Dimensions in metres and are based on standard tyres fitted. For Backhoe and Loader dimensions contact your JCB
Distributor.
B
C
F E
D
A
G
B Overall height
- standard backhoe fitted 3.43 -
- extending dipper fitted 3.53 3.53
Dimensions in metres and are based on standard tyres fitted. For Backhoe and Loader dimensions contact your JCB
Distributor.
B
C
F E
D G
A
G
A260770
B Overall height
- standard backhoe fitted 3.89 3.89 3.89
- extending dipper fitted 3.91 3.91 3.91
Dimensions in metres and are based on standard tyres fitted. For Backhoe and Loader dimensions contact your JCB
Distributor.
Light Bulbs
Head lights - main/dip 45/37.5W
Work lights 55W Halogen (front & rear)
Front side lights 5W
Tail/stop lights 5/21W
Fog light 21W
Direction turn indicators 21W (front & rear)
Instruments 1.2W
Warning lights 3W
† Number plate light 2 x 5W
Interior light 10W
† Beacon 70W Halogen
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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).
! CAUTION
Fuses
Always replace fuses with ones of correct ampere rating
to avoid electrical system damage.
8-3-3-5
COLUMN 'C'
1 Rear work lights. 10 Amp
2 Steering solenoids, proximity switches ††. 5 Amp
3 2/4 WD switch & relay, forward relay and
solenoid, reverse relay and solenoid.
! CAUTION
Fuses
Always replace fuses with ones of correct ampere rating
to avoid electrical system damage.
8-3-3-5
Fuse Identification
* If a fuse melts, find out why and rectify the fault before fitting
a new one. The fuses are identified using column letters (A,
B and C) and row numbers (1 to 9). Note that all the fuses
are shown (including optional equipment fuses). Your
machine may not be equipped with all the fuses shown on
this page.
S247030
All the relays on your machine (except items T & U) are housed in the front console as shown. Items T & U are secured to the
parking brake mounting bracket, as shown in the inset.
Note † : From machine serial number 406613 the hydraulic speed control circuit is operated with a single relay, not two relays
as shown.
Note ††: The parkbrake dump relay is only applicable on machines from serial number 413772.
DC
E B
F G
H J
K L
U R
S V
Note †: From machine serial number 406613 the hydraulic speed control circuit is operated with a single relay, not two relays
as shown.
Note ††: The parkbrake dump relay is only applicable on machines from serial number 413772.
E A
D C
B
F G
R S
K L
H M
U P
Q
J V
N S215400
Relay Identification * Note 3: On 3CX 4x4x4 machines, the neutral relay (item 24)
is moved to a single relay base located on the left hand side
1 Ignition
of the fuse base. Positions 23 and 24 then house 2 wheel
2 Neutral Start steer and 4 wheel steer select relays respectively (see inset
3 Indicators X).
4 Ignition
* 5 5-Speed
6 Transmission Dump
* 7 Hydraulic Speed Control (HSC) - see Note 1
8 Forward Drive
9 Buzzer
10 Parking Brake
11 Reverse Drive
12 Reverse Horn
13 Auxiliary Attachment (Jaw)
14 Heater
15 Lights - see Note 1
16 Worklights (Italian Requirement Only)
17 Hammer Circuit
18 All Wheel Braking
19 Forward High/Low Ratio ➀
20 2 Wheel Drive ➁
21 Reverse High/Low Ratio ➀
22 Drive (Layshaft/Mainshaft) ➀
* 23 -
* 24 Neutral ➀ - see Notes 2 & 3 A
S247490
X
23 24
1 4 7 10 13 16 19 21
2 5 8 11 14 17 20 22
3 6 9 12 15 18 23 24
S247020
General
System Type 12V, negative earth
* Note: Logic control boxes from February 1994 are designed to isolate the excavator and
loader control relays when the joysticks are in the neutral position. This neutral position
switch will activate almost immediately the joystick is left in neutral.
† These are nominal values proportional to the supply input voltage, i.e. 25 to 75% of the
battery voltage
Fuses Bulbs
The electrical circuits are protected by fuses. The fuses are Bulbs Bulb Rating
located in a fuse box to the right of the steering pedestal. If a Headlights - main/dip 45/37.5 W
fuse melts, find out why and rectify the fault before fitting a
Work lights 55 W Halogen (front & rear)
new one. The fuses are identified using column letters (A, B
and C) and row numbers (1 to 9). Front Side lights 5W
Tail/stop lights 5/21 W
Fog light 21 W
! CAUTION
Indicators 21 W (front & rear)
Fuses
Always replace fuses with ones of correct ampere rating Instruments 1.2 W
to avoid electrical system damage. Warning lights 3W
8-3-3-5
Number plate light 2x5W
COLUMN 'A' Fuse Rating Interior light 10 W
A1 4WD/Brakes, Stop Lights 10 Amp Beacon 70 W Halogen
A2 Instruments, Reverse Alarm† 5 Amp
A3 Left Hand Sidelights 5 Amp
A4 Right Hand Sidelights 5 Amp
A5 Rear Wiper, Rear Wash† 5 Amp
A6 Hazard Warning Lights 10 Amp
A7 Beacon, Interior Light 10 Amp
A8 Radio† 5 Amp
A9 Horn, Front Wash/Wiper 10 Amp
COLUMN 'B'
B1 Hydraulic Options 10 Amp
B2 Fuel Pump solenoid (Engine Stop) 5 Amp
B3 Dipped Beam 10 Amp
B4 Main Beam 10 Amp
B5 Front Work Lights 10 Amp
B6 Indicators 5 Amp
B7 Dump Relay Feed 10 Amp
B8 Heater 15 Amp
B9 Hand Dump, Buzzer 5 Amp
COLUMN 'C'
C1 Rear Work Lights. 10 Amp
C2 Steering solenoids, proximity switches. 5 Amp
C3 Gearbox Control, 2 Wheel Drive 10 Amp
C4 Fog light† 5 Amp
C5 Heated seat, clock & cigar lighter† 15 Amp
C6 Servo Controls 20 Amp
S190050
4 3 2 1
5 6
7 8
9 10
16 15 14 13 12 11
22
21
23 20
25 24
S193280
17 18 19
9804/1103 15 - 05 - 01/12 Issue 1
CONTENTS
CONTENTS
Backhoe Loaders 15 - 05 - 01/13
Relay Identification
Relays 1 to 16 are housed in the front console, at the side of the steering pedestal. Relays 17 to 25 are housed behind the
side console panel.
Relay Description
1 Ignition
2 Neutral Start
3 Reverse Alarm
4 Buzzer
5 Road Lights
6 Parking Brake
7 2/4WD Brake
8 2WD Select
9 Flasher
10 Transmission Dump
11 Neutral (Powershift)
12 Drive (Layshaft/Mainshaft)
13 Reverse Drive
14 Forward Drive
18 Steering
19 Loader
20 Backhoe
21 Hammer
22 Hydraclamp
23 Horn
25 Jaw (aux)
A244360
A A A
M B M B M B
L U N C L U N C L U N C
K T V P D K T V P D K T V P D
J S R E J S R E J S R E
H H H
G F G F G F
A
B M
C N L
P U
D V K
R T
E S J
F
G H
A244100
Harness
Connector
H
G L
K
6
8 5
7
F
3 D
C
E
B A
1
S193310
Harness Identification
Key
1 Mainframe Harness
2 Cab Harness
3 Panel Harness
4 Seat Harness
Note: The routing of the rear light extension harnesses will vary depending on whether the machine is a sideshift or
centremount type. The centremount routing is shown in dotted line form, the sideshift routing shown in solid line form.
8 Logic Box
! CAUTION
Always replace fuses with ones of correct ampere rating
to avoid electrical system damage.
8-3-3-5
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.
10 9 8 7 6 5 4 3 2 1
4W
A
3A 3A 3A 5A 20A 10A 7.5A 7.5A 5A 10A
R A
B
25A 20A 25A 10A 5A 15A 7.5A 15A 5A
0
C A333470
A276790
0 1 0 4 7 0
P
0 2 5 8 !
F R
3 6 9 @
R
A265070
B
S254320
1 2
3 4 A254310
The relays and fuses are located in the side console 3CXE, 214E only
underneath cover A. Note that all the relays are shown B Ignition
(including optional equipment relays). Your machine may not C Neutral Start
be equipped with all the relays shown on this page. D Indicators
E Ignition
All Models (Except 3CXE, 214E) F Front Work Lights
1 Ignition G Transmission Dump
2 Neutral Start H Rear Work Lights
3 Indicators J Forward Drive
4 Ignition K Buzzer
5 Heater L Parking Brake
6 Transmission Dump M Reverse Drive
N Reverse Horn
7 Hydraulic Speed Control (HSC)
8 Forward Drive
9 Buzzer
10Parking Brake 0 0
11Reverse Drive P
12Reverse Horn B E H L
13Front Work Lights
14
15
Worklights (Italian, German requirement only)
Lights
0
F R
C F J M
16Rear Work Lights
17Intermittent Wash/Wipe R
18All Wheel Braking (standard machines) D G K N
18Reverse alarm (autoshift machines)
19Forward High/Low Ratio ! A265070
25 26 27 1 4 7 10 19 22
13 16
0 0
P F R
28 29 30 8 11 14 17
2 5 20 23
0
F R D
9 12 15 18 21 24
3 6
R 4W N AUTO
R
A260440
R11 R10 R8 R9
R13 R12 R6 R7
A R15 R14 R4 R5
R17 R16 R2 R3
R1
BUZZER
10
2
3
4
5
6
7
8
9
1
A B C
4W 4W
D E F
10 9 8 7 6 5 4 3 2 1
4W
A
A G H J
3A
3A 3A 5A
5A 3A 10A
10A 7.5A
7.5A 5A 5A
5A 5A
B
B
K L
10A 25A 20A
10A 25A 15A 20A
20A 25A 10A 15A 15 5A
15A 5A
1 1
M N
C
15A 3A 30A 20A 1A 10A 15A
15A 3A 7.5A 15A
15A 7.5A 15A 2 2
345740 345741
817/16774
9804/1103 15 - 05 - 01/24 3270 - C/1-6.2 Issue 1
CONTENTS
Backhoe Loaders 15 - 05 - 01/25
Q R S T U
G F E D C B A
A356072
A357830
A356071 21 22 23 24 25 26 27 28 29 30
4WD
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4
5 6 7 8
A359330
A333470
1 4 7 0 £ ^
2 5 8 ! $ &
1 2
3 6 9 @ % * 3 4
A334100 A357840
3 4
1
7 5
ITEM DESCRIPTION
Note: The illustration shows a typical machine.
1 Mainframe Harness
2 Panel Harness
3 Cab Harness
4 Cab Roof Harness
5 Solenoid Harness
6 Rear Light Harnesses
7 Engine Shut Off Harness
Item Description
1 Seat
2 Loader Valve Block
3 Auxiliary Valve Block
4 Excavator Valve Block
5 Manifold Block
Item Description
1 Chassis Harness
2 Cab Panel Harness
3 Cab Roof Harness
4 Powershift Transmission Harness (not shown)
5 Rear Cab (Sideshift) Harness
6 Rear Lights (Sideshift) Harness
7 Auxiliary Harness
8 Head Lights Harness (not shown)
9 Powershift Relay Harness
10 Steer Mode Harness
11 Air Conditioning Harness (not shown)
12 Power Tool Extension Harness
13 Servo Auxiliary Chassis Harness
14 3CX Link Connector (not shown)
16 Strap Earth
Note: The applicability chart is intended as a guide only, make sure that you check the pump data plate (mounted on the
pump) to determine exactly which type of pump is fitted to your machine.
Note: The applicability chart is intended as a guide only, make sure that you check the pump data plate (mounted on the
pump) to determine exactly which type of pump is fitted to your machine.
214 215 216 217 S/Master 214S 215S 216S 217S S/Master
190906
190706
190705
190606
Note: The applicability chart is intended as a guide only, make sure that you check the pump data plate (mounted
on the pump) to determine exactly which type of pump is fitted to your machine.
Note: The applicability chart is intended as a guide only, make sure that you check the pump data plate (mounted on the pump) to
determine exactly which type of pump is fitted to your machine.
Main Relief Valve (M.R.V.) @ 1500 RPM 228 - 240 233 - 245 3300 - 3500
† When setting 'Hamworthy' Loader Valve A.R.V.'s using a hand pump, set 15 bar (220 lbf/in2) below nominal figure shown.
† When setting 'Husco' Loader Valve A.R.V.'s using a hand pump, set to the figure shown above.
Note: Later type loader valves are produced by a different manufacturer (Husco). When appropriate, the loader valve will be
identified using the manufacturer's name, (Hamworthy - earlier type, or Husco - later type). In some instances, there will be no
need to differentiate (e.g., descriptions of operation - the valves operate in the same manner).
Main Relief Valve (M.R.V.) @ 1500 RPM 228 - 240 233 - 245 3300 - 3500
2B 4
3
A248220
Fig 1
Machine Hydraulics
Hydraulic Pumps See Page E/1-2, in Service Manual 9803/3260
Loader Valve
Electric Supply Logic Box
Metering Characteristics Closed Centre Load Sensed
Section Designation
- Loader, Shovel, Clam PVG 32
Auxilary Relief Valve Pressures Bar kgf/cm2 lbf/in2
- Shovel Ram Head Side 165 - 179 168 - 183 2400 - 2600
- Shovel Ram Rod Side 303 - 317 309 - 323 4400 - 4600
Main Relief Valve Pressure - see Note 1
* - machines up to serial no. 419307 260 265 3770
* - machines from serial no. 419308 230 235 3335
Valve Block Identification Refer to Fig 1 (view shown as fitted on machine)
- Spool 1 Loader Arms Service
- Spool 2 Shovel Service
-A Head Side
-B Rod Side
-C Load Sense Line Connection Port
-D Pump
-E Tank
-F Pressure Test Point (plugged - use test point on backhoe valve)
- Spool 3 (Optional) Clam Service
-A Rod Side
-B Head Side
Output Descriptions Operation Port Neutral Full Deflection - see Note 2
- Loader Arm Lift A 6V 4.2V
Lower B 6V 7.8V
* Float - 6V 9V (with ‘Float Enable’ selected)
- Shovel Dump A 6V 3V
Crowd B 6V 9V
* Return-to Dig B 6V 9V (with ‘RTD Enable’ selected)
- Clam Open A 6V 3V
Close B 6V 9V
A 1
On machines from serial number 419308 only the loader B
valve houses a main relief valve (a blanking plug is fitted in
the backhoe valve). The MRV in the loader valve is set at
A
230 bar and controls the hydraulic system pressure. B 2
A193570
Machine Hydraulics
Backhoe Valve
Electric Supply Logic Box
Metering Characteristics Open Centre Load Sensed
Section Designation
- Bucket, Slew, Steering PVG 32
- Boom, Dipper PVG 120
Auxilary Relief Valve Pressures Bar kgf/cm2 lbf/in2
* - Boom Ram Head Side 266 - 280 271 - 285 3850 - 4060
* - Boom Ram Rod Side 341 - 355 348 - 362 4945 - 5148
* - Bucket Ram Head Side 303 - 317 309 - 323 4400 - 4600
* - Bucket Ram Rod Side 241 - 255 246 - 260 3500 - 3700
- Dipper Ram Head Side 241 - 255 246 - 260 3500 - 3700
- Dipper Ram Rod Side 241 - 255 246 - 260 3500 - 3700
* - Slew Left and Right 241 - 255 246 - 260 3500 - 3700
Main Relief Valve Pressure - see Note 1
* - machines up to serial no. 419307 260 265 3770
* - machines from serial no. 419308 230 235 3335
Valve Block Identification Refer to FIG 2, (view shown as fitted on machine)
- Spool 1 Boom
* A Rod Side
* B Head Side
- Spool 2 Dipper
- Spool 3 Bucket
* A Head Side
* B Rod Side
- Spool 4 Slew
* A&B Slew Cylinders
- Spool 5 Steering
* A Port ‘P’ Steer Mode Valve, Port ‘L’ Orbitrol Unit
* B Front Steer Rams - LH rod side & RH head side, Port ‘R’ Orbitrol Unit
* - Port C Load Sense Line Connection Port
* - Port D Pump
* - Port E Tank
* - Item F Pressure Test Point
* - Item G Valve Sections Interface
FIG 2 A193580
Machine Hydraulics
Backhoe Valve (continued)
Output Descriptions (ISO + Pattern) Operation Port Neutral Full Deflection
- Boom Lift A 6V 3V
Lower B 6V 9V
- Dipper Lift B 6V 9V
Lower A 6V 3V
- Bucket Dump B 6V 9V
Crowd A 6V 3V
- Slew Left B 6V 3V
Right A 6V 9V
Auxiliary Valve
Relief Valve Pressures Bar kgf/cm2 lbf/in2
- Main 227 231.5 3300
- Auxiliary
Head 138 - 145 141-148 2000-2100
Rod Side 207 - 214 211 - 218 3000 - 3100
Slew Motion Control Valve - see Note 1
Relief Valve Pressures Bar kgf/cm2 lbf/in2
- Slew Left and Right 235 238.5 3408
Unloader Valve
Relief Valve Pressures Bar kgf/cm2 lbf/in2
- Unloader 207 211 3000
Note 1: ServoPlus machines from serial number 420485 are not fitted with a slew motion control valve. Instead, new type
spools are fitted on the slew service of the excavator valve block; these spools are also able to fine control the slewing motion
of the backhoe. In addition to the spools, new relief valves are fitted on the slew services. Technical Bulletin 2/148 also refers.
Note 2: On later machines the ‘pop-up’ visual indicator is deleted from the specification of the hydraulic filter. Make sure that
the filters are changed at the recommended interval.
Hydraulic Pumps
S273090
† Note: It is not possible to test full pump flow at system pressure, figures quoted give a ‘snapshot’ indication of pump
performance.
S273090
Weight:
TBA kg (TBA lbs)
Weight:
TBA kg (TBA lbs)
Weight
25kg (55lbs)
1 2 3
7
9
8
@ @ @
6
5 $ £
0 !
@ @ @
4
A262160
Weight:
8kg (17.6lbs)
A262420
Note: The pressure testing and adjustment MUST be carried out as detailed on pages E/13-1 to E/13-8.
Weight:
10 kg (22 lbs)
A313430
† Note: Steer circuit pressure is controlled by a relief valve housed in the orbitrol unit (see section H). The priority relief valve
housed in the loader valve must be set at 2500 lb/in2, this will ensure it does not interfere with the operation of the relief valve
housed in the orbitrol unit.
Weight:
2 Spool - TBA kg (TBA lbs)
3 Spool - TBA kg (TBA lbs)
A273670
Weight:
44 kg (97 lbs) - Centremount
46 kg (101 lbs) - Sideshift
† System shown is for JCB plus pattern and JCB diagonal pattern. For ISO system, the boom and dipper spools change
position, i.e. boom is position 2 and dipper is position 5. The bottom ARV from spool 5 will also be swapped with the bottom
ARV from spool 2.
1 2 3 4 5 6
7 7 7
8
0 0 0 0 0 0
9
! ! ! ! ! !
@
0 0 0 0 0 0
FIG SHOWS A 7 7 7 7
CENTREMOUNT VALVE A262520
2DX, 212 and Variants (except 2CX) From m/c no. 460001
Data Transmission
Front Axle
Note: It is essential that the correct ratio axle in relation to the gearbox ratio is fitted to the machine. Do not fit a new axle with
a
different ratio to the axle being replaced.
* Note: From 1st April 1999 the hub is splined and not doweled. Machine serial number TBA.
Front - 4WD
† Industrial 14 x 17.5 10 3.8 55
Traction 10.5 x 18 10 3.8 55
Industrial (Firestone) 12.0 x 18 12 3.5 50
Industrial (Olympic) 12.0 x 18 12 4.5 65
Radial 335/80 x R18 XM27 3.5 50
Industrial 12.5/80 x 18 10 4.25 61 * (see WARNING below)
† Radial 335/80 - R20 XM27 3.0 43.5
† Radial 12.5 - R20 XM27 3.0 43.5
Industrial 12.5/12.0 x 18 12 3.5 50
Note: 12 ply tyres must be fitted on rear wheels when any backhoe attachment is used. For the correct pressure see the table
above. The front wheels from machine serial number 400001 are made from a stronger construction than front wheels fitted
prior to 400001. Wheels fitted to Backhoe Loaders prior to 400001 must not be used on the new Backhoe Loaders.
† Steering lock restriction stops must be fitted to 4 wheel drive machines that have this type of tyre fitted, consult your JCB
Distributor for advice.
WARNING: Tyres indicated above with an asterix (*) are not recommended or approved for use on 5-speed machines. DO
NOT use these tyres on 5-speed machines.
Front Wheels
AWS/4WD MACHINES
Item Size x Ply Type Make Remarks Pressure
bar lbf/in2
1 16.9x24x12 IND ARMSTRONG TUBELESS 2.6 38
2 16.9x24x12 IND GOODYEAR TUBELESS 2.6 38
3 15.5x25 XTLA MICHELIN TUBELESS 2.5 36
4 16.9x28x12 IND ARMSTRONG TUBELESS 2.6 38
5 16.9x28x12 IND GOODYEAR TUBELESS 2.6 38
6 16.9x28x10 IND GOODYEAR TUBELESS 2.2 32
7 16.9x28 XM27 MICHELIN TUBELESS 2.7 39
8 16.9x28x14 IND NOKIA TUBE 2.6 38
9 16.9x24x12 IND GOODYEAR TUBELESS 2.6 38
10 16.9x28x12 TRAC OLYMPIC TUBELESS 2.6 38
11 16.9x28x12 IND OLYMPIC TUBE 2.6 38
12 14.9x24x12 IND GOODYEAR TUBELESS 2.75 40
13 16.9x28 IND GOODYEAR TUBELESS 2.5 36
2WS/2WD MACHINES
21 11.0x16x12 RIB ARMSTRONG TUBELESS 4.4 64
22 11.0x16x12 RIB GOODYEAR TUBELESS 4.2 61
23 11Lx16x12 IND ARMSTRONG TUBELESS 4.4 64
24 10.5x18x10 IND FIRESTONE TUBELESS 3.8 55
25 12.0x18x12 IND FIRESTONE TUBELESS 3.5 51
2WS/4WD MACHINES
31 14x17.5x10 IND ARMSTRONG TUBELESS 3.8 55
32 14x17.5x10 IND GOODYEAR TUBELESS 3.8 55
34 12.0x18x12 IND FIRESTONE TUBELESS 3.5 51
35 12.0x18x12 IND OLYMPIC TUBELESS 4.25 62
36 335 x18 XM27 MICHELIN TUBELESS 3.5 51
37 12.5x18x10 IND GOODYEAR TUBELESS 4.25 62
38 335 x20 XM27 MICHELIN TUBE 3.0 43.5
39 340 x18 IND GOODYEAR TUBELESS 3.2 46
Items 4, 5, 6, 7,8, 9, 10, 11, 13, 38 must have steering lock restriction stops fitted.
AWS MACHINES
Item Size x Ply Type Make Remarks Pressure
bar lbf/in2
1 16.9x24x12 IND ARMSTRONG TUBELESS 2.6 38
2 16.9x24x12 IND GOODYEAR TUBELESS 2.6 38
3 15.5x25 XTLA MICHELIN TUBELESS 2.5 36
4 16.9x28x12 IND ARMSTRONG TUBELESS 2.6 38
5 16.9x28x12 IND GOODYEAR TUBELESS 2.6 38
6 16.9x28x10 IND GOODYEAR TUBELESS 2.2 32
7 16.9x28 XM27 MICHELIN TUBELESS 2.7 39
8 16.9x28x14 IND NOKIA TUBE 2.6 38
9 16.9x24x12 IND GOODYEAR TUBELESS 2.6 38
10 16.9x28x12 TRAC OLYMPIC TUBELESS 2.6 38
11 16.9x28x12 IND OLYMPIC TUBE 2.6 38
12 14.9x24x12 IND GOODYEAR TUBELESS 2.75 40
13 16.9x28 IND GOODYEAR TUBELESS 2.5 36
2WS MACHINES
21 16.9x24x10 IND ARMSTR0NG TUBELESS 2.2 32
22 16.9x24x12 IND GOOOYEAR TUBELESS 2.2 32
23 19.5x24x10 IND ARMSTRONG TUBELESS 1.9 28
24 19.5x24x12 IND ARMSTRONG TUBELESS 2.3 33
25 21L x24x12 IND GOODYEAR TUBELESS 2.2 32
26 18.4x26x12 TRAC GOODYEAR TUBELESS 2.5 36
27 18.4x26x12 TRAC OLYMPIC TUBELESS 2.4 35
28 18.4x26x12 IND GOODYEAR TUBELESS 2.0 29
29 16.9x28x12 TRAC OLYMPIC TUBELESS 2.2 32
30 16.9x28x12 TRAC FIRESTONE TUBE 2.2 32
31 16.9x28x12 IND GOODYEAR TUBELESS 2.2 32
32 16.9x28 XM27 MICHELIN TUBELESS 2.5 36
33 18.4x30x14 IND GOODYEAR TUBE 2.0 29
34 16.9x28 IND GOODYEAR TUBELESS 2.5 36
Note: 12 ply tyres must be fitted on rear wheels when any backhoe attachment is used. For the correct pressure see the table
above.
Items 4, 5, 6, 7,8, 9, 10, 11, 13 must have steering lock restriction stops fitted.
Torque Converter Colour Code Identification 2.20:1 Ratio 2.40:1 Ratio 2.80:1 Ratio
Colour Coded Dots 2 purple 2 Orange 3 Brown
1 White 1 Green
Minimum Engine Rev/Min at Converter Stall See pages 15 - 05 - 07/3 and 07/4
Converter Out at 100 deg.C 1000 rev/min 0.3 - 0.6 0.3 - 0.6 4.0 - 8.0
2000 rev/min 1.0 - 1.7 1.1 - 1.8 15 - 25
At 100 deg.C 1000 rev/min 0.1 - 0.2 0.1 - 0.2 2.0 - 3.0
2000 rev/min 0.3 - 0.6 0.3 - 0.6 4.0 - 8.0
.....cont'd
At 100 deg.C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
2000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
At 100 deg.C 1000 rev/min 8.3 - 9.0 8.4 - 9.1 120 - 130
2000 rev/min 8.3 - 9.0 8.4 - 9.1 120 - 130
Cooler at 100 deg.C 1000 rev/min 10.2 - 12.5 2.7 - 3.3 2.3 - 2.8
2000 rev/min 22.7 - 26.1 6.0 - 6.9 5.0 - 5.7
Pump at 50 deg.C 1000 rev/min 11.0 - 15.0 2.9 - 4.0 2.5 - 3.3
2000 rev/min 22.5 - 29.5 6.0 - 7.8
Torque Converter Colour Code Identification 2.20:1 Ratio 2.40:1 Ratio 2.80:1 Ratio
Colour Coded Dots 2 Purple 2 Orange 3 Brown
1 White 1 Green
Minimum Engine Rev/Min at Converter Stall See pages 15-05-07/3 & 15-05-07/4
Pump at 50 deg.C 1000 rev/min 11.0 - 15.0 2.9 - 4.0 2.5 - 3.3
The following clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2):
Clutch Pressures † All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2)
† Note: For gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be slightly
higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2 ).
Clutch Pressures † All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2)
† Note: For new gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be
slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2 ).
2 Converter + MRV
max. r.p.m. 1795 1770 1685 1660 1640
min. r.p.m. 1700 1670 1575 1550 1530
Build Specification
Engine Size N.A. (74 bhp)
T2 (90 bhp)
T3 (96 bhp) ● ● ● ● ●
W11 (2.2:1)
34 gal ● ● ●
Fan Ratio 1 to 1 ● ●
1 to 1.25 ● ●
1 to 1.36 ●
CONTENTS
Stall Figures
Note: All tests conducted with single pump option selected unless specified thus #, then tests to be conducted with double pump option selected.
3CX 3CX 214 3CXT 3CXT 3CXT+ 3CXT+ 3CXT 3CXT 214T 215 217
N.Am. option option N.Am. N.Am. N.Am.
Nordic South
Iceland Africa
Backhoe Loaders
1 Convertor Only max r.p.m. 1755 1735 2215# 1900 1875 1890 1870 1880 1860 2070 2065 1915
min r.p.m. 1695 1670 2145# 1830 1810 1820 1800 1810 1790 2000 1995 1840
2 Convertor + MRV max r.p.m. 1360 1340 1830# 1525 1510 1515 1495 1380 1365 1730 1675 1465
15 - 05 - 07/4
min r.p.m. 1260 1245 1730# 1420 1405 1410 1390 1220 1200 1630 1570 1345
Build Specification
Fan Ratio 1 to 1 ● ● ● ●
1 to 1.25 ● ● ● ● ● ● ●
1 to 1.36 ●
15 - 05 - 07/4
Issue 1
9804/1103 CONTENTS
CONTENTS
Note. On all double pump options the test is to be carried out with single pump option selected.
3CXE 3CX 3CXT 3CXT 3CXT 3CXT 3CXT 3CXT 214E 214 214T/215E 214T/215E 215/217 215/217
N. Am. N. Am. N. Am. N. Am. N. Am. N. Am.
2.Convertor + M.R.V.
Max.r.p.m. 1100 1465 1575 1550 1475 1445 1655 1635 1345 1650 1745 1720 1630 1620
Min.r.p.m. stall 1365 1430 1405 1310 1270 1560 1545 1140 1575 1620 1580 1540 1540
Build specification.
Backhoe Loaders
Engine size.
N.A. (75hp) (56kw) ● ● ● ●
T2 (91hp) (68kw) ● ● ● ● ● ●
15 - 05 - 07/5
T3 (96hp) (72kw) ● ● ● ●
Convertor type.
12.2D (2.82) ● ● ● ●
12.2P (2.54) ● ● ● ● ● ● ● ● ● ●
Pump size.
50cc ● ●
33/23cc ● ●
36/26cc ● ●
41/26cc ● ● ● ● ● ●
41/29cc ● ●
Fan Ratio.
1 to 0.85 ● ● ● ● ● ● ● ●
3270 - F/1-7.1
Air Conditioning
None (Europe) ● ● ● ● ●
15 - 05 - 07/5
None (R.O.W.) ● ● ● ● ● ● ● ● ●
Europe ● ● ●
Europe (Hot) ● ● ●
Isssue 1
R.O.W. ● ● ● ● ●
9804/1103 CONTENTS
CONTENTS
Note. On all double pump options the test is to be carried out with single pump option selected.
3CXSuper 3CXSuper 4CX 4CX 4C/4CN 4C/4CN 4C/4CN 214S 214S 215S/217S 215S/217S
N. Am. N. Am. N. Am. N. Am.
2.Convertor + M.R.V.
Max.r.p.m. 1575 1550 1655 1635 1650 1630 1620 1655 1635 1630 1620
Min.r.p.m. 1430 1405 1560 1545 1560 1540 1530 1560 1545 1540 1530
Build specification.
Backhoe Loaders
Engine size.
N.A. (75hp) (56kw)
T2 (91hp) (68kw) ● ●
● ● ● ● ● ● ● ● ●
15 - 05 - 07/6
T3 (96hp) (72kw)
Convertor type
12.2D (2.82)
12.2P (2.54) ● ● ● ● ● ● ● ● ● ● ●
Pump size.
50cc
33/23cc
36/26cc ● ●
41/26cc ● ● ● ●
41/29cc ● ● ● ● ●
Fan Ratio.
1 to 0.85 ● ● ● ●
3270 - F/1-8.1
Air Conditioning
None (Europe) ● ● ●
15 - 05 - 07/6
None (R.O.W.) ● ● ● ● ● ●
Europe ● ● ● ●
Europe (Hot) ●
Issue 1
R.O.W. ● ● ● ● ●
CONTENTS
9804/1103
CONTENTS
4CX 4CX 4CXSuper 4CXSuper 4CXSuper
Build specification.
Engine size.
N.A. (75hp) (56kw)
T2 (91hp) (68kw)
T3 (96hp) (72kw) ● ● ● ● ●
Backhoe Loaders
Convertor type
12.2D (2.82)
12.2P (2.54) ● ● ● ● ●
15 - 05 - 07/7
Pump size.
74 Variable ● ● ● ● ●
Fan Ratio.
1 to 0.85 ● ●
1 to 1.06 ● ●
1 to 1.16 ●
Air Conditioning
None (Europe) ● ●
None (R.O.W.) ● ●
Europe ● ●
Europe (Hot) ● ●
R.O.W. ● ●
3270 - F/1-9.2
CONTENTS
Note. On all double pump options the test is to be carried out with single pump option selected.
3CX 3CXT 3CXT 3CXT 3CXT 3CX 3CX 214E 214e 214 214e.T 215E 215E 215
214T 214T 217
Std lift Std lift Hi. lift Hi. lift Contractor Contractor N. Am. N. Am. N. Am. N. Am. N. Am. N. Am. N. Am.
2.Convertor + M.R.V.
Max.r.p.m. 1520 1735 1720 1675 1660 1770 1760 1415 1555 1770 1745 1890 1875 1760
Min.r.p.m. 1380 1615 1600 1545 1530 1660 1650 stall 1280 1625 1580 1760 1745 1645
Build specification.
Backhoe Loaders
Engine size.
N.A. (75hp) (56kw) ● ● ● ●
T1 (80hp (60kw) ●
● ● ● ● ● ●
15 - 05 - 07/8
T2 (91hp) (68kw)
T3 (100hp) (74kw) ● ● ●
Convertor type.
SSL11(2.83) ● ●
12.2D (2.82) ● ● ● ● ●
12.2P (2.54) ● ● ● ● ● ● ●
Pump size.
50cc ● ● ●
33/23cc ● ●
36/26cc ● ●
41/26cc ● ● ● ● ● ●
41/29cc ●
3270 - F/1-10.2
15 - 05 - 07/8
Air Conditioning ● ●
None ● ● ● ● ● ● ● ● ● ●
Europe ● ● ●
Issue 1
ROW ● ● ●
CONTENTS
9804/1103
CONTENTS
Note. On all double pump options the test is to be carried out with single pump option selected.
3CXS 3CXS 3CXS 3CXS 4CX 4CX 4CXS/4C 4CXS/4C 4CXS 4CXS 214S 215S/217S
Std lift Std lift Hi. lift Hi. lift 4CX 4CX N. Am. N. Am.
2.Convertor + M.R.V.
Max.r.p.m. 1735 1720 1675 1660 1770 1760 1770 1760 1760 1760
Min.r.p.m. 1615 1600 1545 1530 1660 1650 1660 1645 1650 1645
Build specification.
Backhoe Loaders
Engine size.
N.A. (75hp) (56kw)
T2 (91hp) (68kw) ● ● ● ●
T3 (100hp) (74kw) ● ● ● ● ● ● ● ●
15 - 05 - 07/9
Convertor type
12.2D (2.82)
12.2P (2.54) ● ● ● ● ● ● ● ● ● ● ● ●
Pump size.
50cc
33/23cc
36/26cc ● ●
41/26cc ● ● ● ● ●
41/29cc ● ● ●
74 Variable ● ●
Fan Ratio.
3270 - F/1-11.1
Air Conditioning ● ●
15 - 05 - 07/9
None (Europe) ● ● ● ● ●
None ● ●
Europe ● ● ● ● ●
Issue 1
Europe (Hot)
R.O.W. ● ● ● ● ●
CONTENTS
CONTENTS
Backhoe Loaders 15 - 05 - 08/1
STANDARD MACHINES
Service Brake
Type JCB Oil-Immersed Multi-Plate Disc
Actuation Hydraulic - vacuum servo assisted for machines powered by model
AB turbocharged engine
Location Rear Axle Centre Casing (2 brake packs)
Exhauster
Type Frenos Iruna
Parking Brake
Type Manually Adjusted Caliper, cable operated, mounted on transmission
output
Disc Diameter 279.4 mm (11 in)
SERVO MACHINES
Service Brake
Type As 'Standard Machines'
Actuation As 'Standard Machines'
Location As 'Standard Machines'
Master Cylinder
Number of Cylinders 3 (two front and one rear)
Type
Front Frenos compensated master cylinder with integral servo unit
Rear Frenos master cylinder with remote mounted servo unit
Piston Diameter
Front (each) 22.22 mm (0.875 in)
Rear 28.575mm (1.125 in)
Exhauster
Type As 'Standard Machines'
Parking Brake
Type As 'Standard Machines'
Disc Diameter As 'Standard Machines'
Parking Brake
Type Manually Adjusted Caliper, cable operated, mounted on transmission output
Disc Diameter 279.4 mm (11 in)
Note: Because the service brakes are located in the rear axle, instructions for dismantling and assembly are shown in the
Transmission Section (Rear Axle Brakes).
Fuel System
Injection System Details
Cooling System
Coolant Pressure 0.48 bar (7 lbf/in2)
Coolant Temperature (Normal) 80-85 °C (176-185 °F)
Temperature Warning Light operates at: 98 °C (208 °F)
Note: When removing the engine from the machine the following points must be noted:
iii Special lifting wires must be used to lift the engine see 'General Information', Section 1, in the Service Manual
(publication number 9803/3260).
iii The torque convertor can be left on the transmission (flexi plate removed from flywheel).
iv The alternator, starter motor and hydraulic pump can be left on the engine.
Engine Build List Number AA50608 - AR50656, AR50654, AR50678 - 56kw (75bhp), AK50745 60kw (80bhp)
AA50606 - 56kw (75bhp)
AB50607 - 67.5 kw (90.5bhp), AK50628 - 68.5 kw (92bhp)
AB50609 - 71.5kw (96bhp), AK50640 - 74.6 kw (100bhp) AM50647 85.5 kw (115bhp)
Bore
AA, AB, AK, AM 100mm (3.937 in)
AR 103mm (4.055 in)
Stroke 127mm (5.000 in)
Swept Volume AB, AA, AK, AM 4 litres (243 in3)
AR 4.23 litres (258 in3)
Compression Ratio AB 16.0:1
AA 16.5:1
AK, AM 17.25:1
AR 18.5:1
Compression Pressure 28 bar (400 lbf/in2)
[maximum variation between cylinders 3.5 bar (50 lbf/in2)]
Injection Sequence 1,3,4,2
Valve Clearance - Cold - Inlet 0.20mm (0.008 in)
- Exhaust 0.45mm (0.018 in)
Oil Pressure (hot) at maximum speed - AA 2.1 bar (30 lbf/in2)
- AB, AK, AM 2.6 bar (40 lbf/in2)
- AR 2.0 bar (30 lbf/in2)
Maximum Air Cleaner Restriction 559mm (22 in H2O)
Cooling System
Coolant Pressure 0.48 bar (7 lbf/in2)
Coolant Temperature (Normal) 80-85 °C (176-185 °F)
Temperature Warning Light operates at: 98 °C (208 °F)
ECU mainframe connector loose. Check connector is mating correctly with ECU.
Gear twist switch not in neutral. Gear switch must be in neutral on power up
before a gear can be selected.
No 4th gear Faulty speed signal Check speed sensor and wiring.
(4 speed machine only) Check speed sensor installation.
..... continued
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.
Intermittent 4 wheel drive Faulty 4 wheel drive input Check 4 wheel drive switch and wiring.
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.
Reverse will not operate Speed too fast to reverse direction Slow machine.
Psion will not communicate Faulty connecting lead. Check lead connection.
All hydraulic rams slow to operate 15 - 10 - 02/2 To help identify circuits, valves, rams etc mentioned in the
fault finding procedures, refer to the hydraulic schematic
One hydraulic service fails to operate or is diagrams.
slow to operate 15 - 10 - 02/2
1 Before you begin fault finding, read the Safety
The engine tends to stall when the information at the beginning of the Service Manual.
hydraulics are under load 15 - 10 - 02/2
2 Make simple checks before say, stripping a major
A spool is sticking 15 - 10 - 02/3 component.
Leaking Oil Seal (Control Valves) 15 - 10 - 02/3 3 Make sure that the hydraulic fluid is at correct working
temperature (50 °C, 122 °F).
Ram creep 15 - 10 - 02/3
4 What ever the fault, check the condition of the hydraulic
Hydraulic oil becomes too hot 15 - 10 - 02/4 fluid. Drain and replace if necessary.
Steering fails to operate or 5 Make any relevant electrical checks before moving on to
is stiff to operate 15 - 10 - 02/4 the hydraulics.
1 Lack of power in all hydraulic functions. Insufficient hydraulic fluid. Check for leaks and top up as required.
..... continued
5 A spool is sticking. Oil temperature abnormally high. Check for correct fluid, see Lubricants and
Capacities. Check oil cooler and grille for
blockage.
The hydraulic fluid is dirty. Clean the tank strainer. If strainer badly
clogged, drain and flush hydraulic system
Fill with clean hydraulic fluid.
The valve housing was twisted Loosen retaining bolts and tighten to
during installation. correct torque figures.
A return spring or cap is out of Remove the cap, check that the spring is
alignment. in the correct position. Refit cap and
torque tighten bolts
6 Leaking Oil Seal (Control Valves) Paint or dirt on the seal face. Remove the seal and clean.
The back pressure in the valve Check circuit pressures. Adjust if possible.
circuit is excessively high. Otherwise investigate thoroughly.
The seal is not secured. Clean the seal and tighten the retaining
bolts to the correct torque.
7 Ram creep. Associated ram or pipe lines from Check and rectify as required.
ram leaking.
..... continued
8 Hydraulic oil becomes too hot Oil cooler obstructed Remove debris from cooler fins
9 Steering fails to operate or Tyres not inflated to Inflate tyres to correct pressure
is stiff to operate correct pressure
Leaks in the relevant hoses or Check hoses and connections for leaks
component connections
Steer relief valve set Check pressure setting of steer unit relief
incorrectly valve, adjust as required.
Steer mode valve not operating Check if spools sticking, rectify as required
correctly
Check if solenoids operating, replace
solenoids as required
10 Steering fails to respond to Selector switch faulty Check selector switch, replace as required
selected mode
Proximity switches not operating Check setting of proximity switches, reset
correctly or replace switches as required.
Steer mode valve not operating Check if spools sticking, rectify as required
correctly
Check if solenoids operating, replace
solenoids as required.
Leaks in the relevant hoses or Check hoses and connections for leaks
component connections
If there appears to be a fault with the machine, eliminate the obvious and easiest tasks first before doing any detailed fault
finding:
The following descriptions identify briefly some possible problems that may occur, and the associated remedial checks.
2 Seat Rear and Seat Forward Functions Mixed Up. 12 Float Inoperative
Check that proximity switches are connected correctly Check wiring to switch. Check that hose burst check
valves are not fitted on the loader arm circuit
3 System Is Completely Dead
Check that fuse C6 has not blown 13 RTD Inoperative
Check shovel reset switch. Check wiring to switch
4 LH Joystick is Inoperative
Check feed from control box at wire 423. Remember 14 Loader Valve Block Inoperative
when seat is forwards that LH joystick is inoperative Check relay and wiring. Check wire 440 to control box
Pressure or flow obtained at one port only 15 - 10 - 03/3 2 Make simple checks before say, stripping a major
component.
No pressure or flow at either port 15 - 10 - 03/3
3 Make sure that the hydraulic fluid is at correct working
High work port leakage 15 - 10 - 03/3 temperature (50 °C, 122 °F).
Leaks between sections 15 - 10 - 03/4 4 What ever the fault, check the condition of the hydraulic
fluid. Drain and replace if necessary.
Sticking spool 15 - 10 - 03/4
5 Make any relevant electrical checks before moving on to
Detent will not hold 15 - 10 - 03/4 the hydraulics.
Electrical detent will not hold 15 - 10 - 03/4 6 Be sure to remove ALL contamination and if possible
identify its origin. It may be part of a component from
Poor performance, slow operating speed and/or elsewhere in the circuit.
low maximum stall speed 15 - 10 - 03/4
7 Replace any seals such as 'O' rings before re-
assembling hydraulic components.
....continued
PROBLEM: Poor performance, slow operating speed and/or low maximum stall speed.
POSSIBLE CAUSE: 1) Blocked flow regulator spool.
CORRECTIVE ACTION: 1) Flow check, remove and clean flow regulator valve, see page E/10-36.
Ensure that the correct quantity and grade of oil is used and that there are no obvious leaks.
CHECK ACTION
3 Is there air in the hydraulic system? YES: Continue running to expel air.
NO: Check 4
13 Is the transmission not pulling in both YES: Stall test machine, Check 14.
Forward and Reverse? NO: Check 16
16 Are clutch sealing rings damaged? YES: Tap pressure gauge into clutch feed lines to monitor
pressure.
NO: Check clutch plates for damage.
18 Is the start switch in the run position and supplying YES: Check 19
current to the neutral start relay? NO: Rectify.
19 Is the fault only when the transmission is hot? YES: Dismantle solenoid and check components.
NO: Check microswitches, relay and wiring loom.
20 Is the noise a growl, hum or grinding? YES: Check gears for damage or wear.
NO: Check 21
21 Is the noise a hiss, thump or bumping? YES: Check bearings for damage or wear.
NO: Check 22
22 Is the noise a squeal? YES: Check free running gears for seizure.
NO: Check 23
24 Is the countershaft or its bearings worn or damaged? YES: Renew damaged parts.
NO: Check 25
25 Is there excessive backlash in the gears? YES: Adjust by checking shaft end float.
NO: Check 26
28 Are the sliding gear teeth worn or damaged? YES: Renew gears.
NO: Check 29
30 Are the selector fork pads or grooves in gears worn? YES: Renew worn parts.
NO: Check 31
9804/1103
15 - 10 - 06/2 Issue 1
CONTENTS
CONTENTS
Backhoe Loaders 15 - 10 - 06/3
ALL MODELS (EXCEPT 2CX) From m/c no. 400001
Fault Finding - Syncro Shuttle Gearbox (continued)
CHECK ACTION
34 Are the selector fork pads out of position? YES: Reposition or renew (check interlock).
NO: Check 35
37 Are steel chips embedded in the bronze? YES: Continue using, chips will either embed below bronze
or be rejected.
NO: Check 38
39 Are the sliding gears tight on the splines? YES: Free or renew.
NO: Check 40
41 Are steel chips embedded in the bronze? YES: Continue using, chips will either embed below bronze
or be rejected.
NO: Check 42
In normal operation the 2/4 wheel drive clutch is spring loaded and therefore engaged to give 4 wheel drive. The clutch must
be pressurised to give 2 wheel drive. Before starting the more detailed fault finding procedures - eliminate the obvious:
If the fault is not rectified after eliminating the obvious, check the following:
Possible Cause Remedy
7 Low mainline pressure 7 Identify if the fault is related to the 2/4WD disconnect:
(Minimum pressure required to disengage 2/4WD clutch 7.1 Disconnect the external pipework to the 2/4WD
is 8.6 bar; 125 lb/in2). clutch. Cap and plug open orifices.
8.1 2/4WD solenoid spool sticking. 8.1 Strip, clean and re-assemble solenoid valve, renew
valve if required.
8.2 2/4WD solenoid permanently energised. 8.2 Check the 2/4WD relay and select switch, replace
as necessary.
8.4 Clutch shaft sealing rings leaking. 8.4 Renew clutch shaft sealing rings.
8.5 Excessive clutch shaft end float. 8.5 Rectify fault, renew parts as required, reset end float
(should not exceed 0.03 mm; 0.001 in)
8.6 Wrong type clutch piston fitted. 8.6 Fit correct type clutch piston (ie, without bleed hole).
8.7 Clutch piston O-ring failed. 8.7 Replace clutch piston O-ring.
9.1 Worn pressure plate 9.1 Inspect pressure plate, renew as required.
9.2 Worn actuating sleeve. 9.2 Measure length of actuating sleeve and renew as
required, sleeve length should be 60.70 mm; 2.390
inches
9.3 Incorrect clutch pack end float. 9.3 Measure clutch pack end float (should be 0.75 - 1.5
mm; 0.030 - 0.059 inches). Correct as required.
If the fault is not rectified after eliminating the obvious, check the following:
8.1 2/4WD solenoid spool sticking. 8.1 Strip, clean and re-assemble solenoid valve,
renew valve if required.
8.3 Clutch shaft sealing rings leaking. 8.3 Renew clutch shaft sealing rings.
8.4 Excessive clutch shaft end float. 8.4 Rectify fault, renew parts as required, reset
end float (should not exceed 0.03 mm; 0.001
in)
8.5 Wrong type clutch piston fitted. 8.5 Fit correct type clutch piston (ie, without bleed
hole).
8.6 Clutch piston O-ring failed. 8.6 Replace clutch piston O-ring.
9.2 Mechanical failure of 4WD unit 9.2 Strip and inspect 4WD unit. Check that the
electrical and hydraulic circuits are functioning
correctly.
9.3 Incorrect clutch pack end float. 9.3 Measure clutch pack end float (should be 1.0
to 2.3 mm). Correct as required.
No pressure is required to engage 2WD(spring loaded). Check that the solenoid spool is not sticking (in the 4WD position),
then see below.
11 Non-return valve faulty (noticeable because 2WD 11 Check the non-return valve.
cannot be engaged).
Note: NOT fitted on Powershift machines.
12 2/4WD solenoid permanently energised. 12 Check the 2/4WD relay and select switch, replace
as necessary.
In normal operation the 2/4 wheel drive clutch is spring loaded off and therefore disengaged to give 2 wheel drive. The clutch
must be pressurised to give 4 wheel drive. Before starting the more detailed fault finding procedures - eliminate the obvious:
If the fault is not rectified after eliminating the obvious, check the following:
8.1 2/4WD solenoid spool sticking. 8.1 Strip, clean and re-assemble solenoid valve,
renew valve if required.
8.3 Clutch shaft sealing rings leaking. 8.3 Renew clutch shaft sealing rings.
8.4 Excessive clutch shaft end float. 8.4 Rectify fault, renew parts as required, reset
end float (should not exceed 0.03 mm; 0.001
in)
8.5 Wrong type clutch piston fitted. 8.5 Fit correct type clutch piston (ie, without bleed
hole).
8.6 Clutch piston O-ring failed. 8.6 Replace clutch piston O-ring.
9.2 Mechanical failure of 4WD unit 9.2 Strip and inspect 4WD unit. Check that the
electrical and hydraulic circuits are functioning
correctly.
9.3 Incorrect clutch pack end float. 9.3 Measure clutch pack end float (should be 1.0
to 2.3 mm). Correct as required.
No pressure is required to engage 2WD(spring loaded). Check that the solenoid spool is not sticking (in the 4WD position),
then see below.
11 Non-return valve faulty (noticeable because 2WD 11 Check the non-return valve.
cannot be engaged).
Note: NOT fitted on Powershift machines.
12 2/4WD solenoid permanently energised. 12 Check the 2/4WD relay and select switch, replace
as necessary.
Page No.
Lack of Power 15 - 10 - 07/2
Low Mainline Pressure 15 - 10 - 07/2
High Stall Speeds (On All Clutches) 15 - 10 - 07/2
Low Stall Speeds (On All Clutches) 15 - 10 - 07/2
Low Converter Out Pressure 15 - 10 - 07/2
Low Pump Flow 15 - 10 - 07/2
High Converter Out Pressure 15 - 10 - 07/3
Low Lubrication Pressure 15 - 10 - 07/3
* Low Clutch Pressure and/or Clutch Slipping 15 - 10 - 07/3
Overheating 15 - 10 - 07/3
OVERHEATING
S154080
Introduction
The Powershift fault finding procedures concern themselves
with general problems normally associated with this type of
transmission system, and so the layout is a 'Possible Cause
and Remedy' type.
LACK OF POWER
Possible Cause Remedy
1 Poor engine condition. 1 Check and if necessary repair engine.
2 Low oil level. 2 Top up system.
3 Worn pump. 3 Check and if necessary repair or renew pump.
4 Torque converter damage. 4 Check and if necessary repair or renew torque converter.
5 Low mainline pressure. 5 See fault 'Low Mainline Pressure'.
6 Clutches slipping. 6 Check clutch pressures, check clutch piston rings.
7 Internal leakage. 7 Check internal cored galleries and the casting for porosity.
8 High stall speeds. 8 See fault 'High Stall Speeds (on ALL clutches)'.
9 Low stall speeds. 9 See fault 'Low Stall Speeds (on ALL clutches)'.
10 Overheating 10 See fault 'Overheating'.
11 Converter safety relief valve faulty. 11 Check and if necessary repair safety relief valve.
OVERHEATING
Possible Cause Remedy
1 Low oil level. 1 Top up system.
2 High oil level. 2 Drain oil to correct level.
3 Trapped or kinked hoses in cooler system. 3 Renew or repair hoses.
4 Low converter out pressure and flow rate. 4 Repair or renew the converter relief valve.
5 Oil cooler blockage. 5 Clean cooler.
6 Operating in wrong gear range usage. 6 Select correct gears to suit working conditions.
7 Water system overheating. 7 Rectify water system problems, eg radiator, cooler lines,
low water level etc.
8 Oil aerated (foaming). 8 See fault 'Low Mainline Pressure', item 4.
9 Clutch piston(s) sticking on return stroke. 9 Check and repair clutch piston(s) and seal(s).
10 Cored galleries on front housing pump mounting 10 Replace front housing (or rectify existing housing).
face wrong depth (indicated by an excessively low pressure
and flow on the converter out cooling line).
11 Leakage across pump mounting face and front case. 11 Check for damaged surface on both components and loose
pump mounting bolts.
In normal operation the 2/4 wheel drive clutch is spring loaded off and therefore disengaged to give 2 wheel drive. The clutch
must be pressurised to give 4 wheel drive. Before starting the more detailed fault finding procedures - eliminate the obvious:
If the fault is not rectified after eliminating the obvious, check the following:
No pressure is required to engage 2WD(spring loaded). Check that the solenoid spool is not sticking (in the 4WD position),
then see below.
11 2/4WD solenoid permanently energised. 11 Check the 2/4WD relay and select switch, replace
as necessary.
12 Piston ball valve blocked. 12 Replace piston or rectify as required.
Carefully inspect the transmission oil for signs of water contamination. Contaminated oil will contain water droplets or be visibly
emulsified. Water droplets may be visible on the dipstick or inside the filler tube. For oil analysis purposes, the maximum
permissible water content of the oil is 0.10%.
If the transmission oil has been contaminated with water, faults or damage to the gearbox may be apparent as a result. Before
remedying, thoroughly investigate and rectify the cause of the water contamination.
4 Oil cooler failure. Remove, inspect, test oil cooler. Renew if applicable.
Carry out flushing procedure.
Refill with JCB Special Transmission Fluid.
Gearbox faults caused typically by water contamination and other factors related to the transmission oil:
Gearbox over filled with oil. Drain the oil level to the correct level,
see Routine Maintenance - Checking
Transmission Oil Level.
3 Clutch Failure - Clutch Piston Water ingress causing nylon Carry out flushing procedure.
Seizing. components to swell and stick Refill with JCB Special Transmission Fluid.
when hot. Note: If after a period of service without
water contamination seizing still occurs,
renew piston.
A One or both brakes do not apply. 1 Check master fault 1 Check master cylinder in
(Brake travel not excessive,
brakes not pulling to one side) 2 Friction/counter plate distortion. 2 Check friction/counterplates.
C Applying one brake (pedals 1 Valve stem seal inside (non-active) 1 Renew master cylinder position.
unlocked) also partially engages master cylinder piston not sealing.
the other brake.
E Pedals touch floor under constant 1 Master cylinder fault. 1 Check master cylinder in single
pressure - no fluid loss and coupled pedal modes to
identify fault area, service as
required.
F Pedals touch floor under constant 1 External fluid leaks. 1 Visually Check brake circuit for
pressure - and fluid loss fluid loss, service as required.
G Pulling to one side when pedals 1 Compensating feature not working. 1 Inspect master cylinder
locked together. compensating. Check if blockage
in bridging pipe. Service as
required.
H Poor braking (not pulling to one 1 Friction plates worn beyond limits 1 Renew friction/counter plates -
side). or distorted on one side. BOTH sides.
6 Annular brake piston(s) binding in 6.1 Check that the correct brake fluid
axle. has been used (incorrect fluid
could swell the annular brake
piston seals).
K Poor braking when hot. 1 Moisture in system vapourizing when 1 Strip axle and clean annular piston to
axle is hot. remove moisture. Remove master
cylinders and check for corrosion,
service as required. Flush hydraulic
brake system.
L Excessive brake noise in operation. 1 Deterioration of axle oil or wrong 1 Change axle oil.
type of axle oil.
Note: Due to the metal to metal contact
of oil immersed brakes, limited noise can 2 Axle oil loss. 2 Refill axle with correct oil and check
be heard which is consistent with this for leaks.
type of design - this is normal.
3 Friction plates worn beyond limits. 3 Renew friction/counter plates.
M Fluid loss when machine standing, 1 Slight cut or nick in the brake piston 1 Strip axle, replace seal.
for instance - overnight (see note). seal, see 'Brake Piston Seal Leakage
Test' page 15-10-08/4.
Note: Confirm fault is as indicated by
checking that the pedals DO NOT touch
floor under constant pressure.
!WARNING
Before working on the brake system make sure the
machine is on level ground and chock all four wheels.
BRAK 1-4
!WARNING
Do not drive the machine with any part of its brake
system disconnected. When the following test has been
completed reconnect all brake pipes and bleed the brake
system using the recommended procedure.
BRAK 2-1
Note 2: The tube must be kept vertical during the test, use
tape to attach the tube to the side of the machine.
4.3 Using a suitable pen, mark the level line of the brake
fluid on the tube, as shown at C.
Steering wheel turns on its own 15 - 10 - 09/2 To help identify circuits, valves, rams etc mentioned in the
fault finding procedures, refer to the hydraulic schematic
Machine will not turn when the diagrams (near the beginning of the Hydraulics Section).
steering wheel turned. 15 - 10 - 09/2
1 Before you begin fault finding, read the Safety
Steering fails to respond to information at the beginning of this manual.
selected mode (4WS Machines only) 15 - 10 - 09/3
2 Make simple checks before say, stripping a major
component.
1 Steering wheel difficult to turn. Tyres not inflated to Inflate tyres to correct
correct pressure pressure
....... continued
Check if solenoids
operating, replace
solenoids as required
2 Steering wheel turns on its own. Dirt in the steer control unit Clean and inspect unit.
(causing sleeves to stick open)
3 Machine will not turn when the Insufficient hydraulic fluid. Check for leaks and top
steering wheel turned. up as required.
Check if solenoids
operating, replace solenoids
as required
Check if solenoids
operating, replace
solenoids as required.
600G
600AD 600BN 600BG 600AZ 600G 604A
600H 600CB 600BL 600AJ 600AX
600AZ 600G 600BC 600BM 600H
600AC 600AP 600AK 600AZ 600AU 604
600BT 600DF
600Y 600BS
600CE 600C 600BU
34 600H 600BC
52 600DY
600BC 600DW
600T 600P
600BF
600V
10 13 16 600CF 32 600AS 600AV
89
600CK
600CD
600BD 600B 63 78 81 600AR 600AY 600BJ
75
600S 816D
816E
600 43 44 45 50
811
18 21 23 M 62 83 71
812
14 53
77 600AA
600AB
600BK 61 85
815
816
40 834A
67 861B
3 36
804
M 79 84 82
8 12 837A
834B
861A
M
20 22 24 853
894 837B
855A
867B
4 912 912A 807
35
303A 57 855B
M 46 55 603
809 808A
5 M
M
839
76 806 805 841 80 855
877A
38 119
003 15 17 125 47 834 B5 88
877 56 840 829 830
831
837
108 600BH
864
804A 600N
842 808 863 69
F N R 909
862
41
48
- 31 853B 103A 803 56 830D
+ 815
802
800B 58 836
A4 101A
6 7 11 11A
814
866 865
810C 810A 404 405 49
838 401
412 407
102A
60
107M 107N 406 403 402
004
200 42 303F
868A 120
868
200A 110A
39 110B 59 908 C4
103E 907
100A 28 108 104B 110C 64 87
9 9A 30 103 303
100
105 104A 300 70 861
106
37 102 110 832B 828B
101P
19
111A
104C
600BE 90
B7 29 B2
832
101
103C
A2 107
A1 A5 A6 B8 A7 A9
B9 000D
411
B6 000B 200H 72
002K 001D
107D
001C
001E
001F
200J
002H
000A 65 B1
000E
C3 002C 002D 002G
002L 002B 002A 000C 000F
302
111 001B
002J 200E 104C
103B
002F
C2
2
601
602
C1
200G 859 860
A8 54
200K 304 600R
A214640
A214640
2 Starter Switch
110 Front Proximity Switch
111 Rear Proximity Switch
112 Steer Mode Select Switch
113 Steer Mode Printed Circuit Board
114 Crab/4 Wheel Steer Solenoid
115 4 Wheel Steer Solenoid 600L
822 823
821
112
820
115 116 117
600BW
110 111
109E
109A 109B
2
002E 109
C2
002B
A2
A216990
600BN
6 813
810A 11
810C
140 107F
152 107B 153 107E
401
883B
808A
30
884B 884C
809
A2
7
R F 2 4 3 1
N
838A 29
9A
- 150
111A 852
1
+ 600W
2
107
100 C3
001A
151
B9 B7
200C 002
200D
A216980
600AB
600BR 600AD 600BN A216960
600AC
32 600Y 600BS
600BT
600BF
600V
10 13
853
811
812
600AA 14
815
8 12
816
107B 107E
809 808A
35
853A
854 818
36
F N R
852
108B
877
815
37
6 7 11
810C 810A
838 401
107D
31
108
100A
9 9A 30
100
A1 106
111A
19
B7 107
A2 29
B9 000D
411
C3
000E
C3
2 A216950 2 111 001B
600BP
600C 600BU
600CF
21 23 25
600CK
85
20 22 24
89
867A
410 101A
86
88 867B
867
88
866A
101C
866
404 405
87
101A
A2 19
29
101
2
2 B9 B1
A216970 A216940
19 20 73 74 75 76 77
143 145
60 61 7 8
3 5 140
6 9 141 10 11 12 13 14 15 142 144
1
68
63
72 24
21 22 23
69 147 149 151 153 155 156
146 148 150 152 154 155
65
110 115 17
62
67 18
112 66 70
71
64
111
A228951
(CAD 852/35036 - 1/4)
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
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
163 166 89
168 171 173 174
33 35 37 42
39
27 29 31 36 41
26
34 90
28 30 32
40
84 95
25
86
82
94
158 153 160 78 79 87 88
157
156 154 159 161
80 91
83
93
121
92
81
119 120
85
A228960 A2289611
(CAD 852/35036 - 2/4)
CONTENTS
8
43 45 48
9
3 5
61 63 44 46 47
102
1
16 16
Backhoe Loaders
4 123
126 16
16 101
15 - 15 - 01/11
116 53
115
125 127
16
113 114
124
16
110
16
16
16
49
100
175 176 177 178
16 50 51 52
112
62
96 64
97
FUSE C6
15 - 15 - 01/11
111 119
A228972
A228972
Issue 2
CONTENTS
CONTENTS
Note: Except for the transmission and steer circuits
(shown above), the AWS electrical circuit is the
same as shown on Page15-15-01/7 to 15-15-01/10.
Backhoe Loaders
44 Layshaft Solenoid 124 Auto 2 Wheel Drive Relay
45 Forward Low Solenoid 125 Drive Relay (Layshaft & Mainshaft)
46 Forward High Solenoid 126 Forward High/Low Relay
15 - 15 - 01/12
Switches
Note: Fuse C6 is only fitted on machines from serial
*
CONTENTS
and Steer Circuit for 3CX 4x4x4 Machines
8 140 43 45 48
9
5
3
61 63 141 44 46 47
1
Backhoe Loaders
123
129 130
116 126
4
15 - 15 - 01/13
115
125 127
113 114
16
110 65
147 16
16
16
100
50
112
62
64 52 177 178
97
98 99
15 - 15 - 01/13
FUSE C2
Issue 2
CONTENTS
Powershift Transmission - 2WS Machines Only - and Steer Circuit for 3CX 4x4x4 Machines
9804/1103
CONTENTS
Note: Except for the transmission circuit (shown
above), the 2WS electrical circuit is the same as
shown on Pages 15-15-01/7 to 15-15-01/10.
Backhoe Loaders
44 Layshaft Solenoid 125 Drive Relay (Layshaft & Mainshaft)
45 Forward Low Solenoid 126 Forward High/Low Relay
46 Forward High Solenoid 127 Reverse High/Low Relay
15 - 15 - 01/14
15 - 15 - 01/14
fuse C3.
Issue 2
CONTENTS
CONTENTS
Backhoe Loaders 15 - 15 - 01/15
60 61 19 20 73 75 77
74 76 106
143 145
63 B B
3 5 140 13 14 15 142 144
9 10 57 11 12
1 8
62
71
64
111
The basic circuit shows a standard 3CX (214) machine fitted with syncro shuttle transmission and 2 wheel steer.Pages
15 - 15 - 01/19 to 15 - 15 - 01/31 show machine circuits that differ from the ‘basic’. Note that ONLY the differences are shown.
..... continued
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
30 32 90
95
26
40
84
25
78 79 86 94
86 87
80
157 158 154 160
156 153 159 161
83
82 88
85
121
91 93
132 133
92
81
120
119
63
16 61
12
43 44 68
5
3
8 140
1 9 16 102
136 134
112 53
141
114 46 47 48
45 117
102
101
4 115 135 116
124
67
127
113 100
110 114
98 99
2 111
119
63
43 44 61 12
5 49
3
1 140 112 68
124 126
100 175
50
62 64
52 177 178
131
97 99 98
111
119
TO PAGE
C/18 - 11
19 20 73 75 77
74 76
143 145
5 60 7
3 6 140 15 142 144
9 10
1 8
61
141
63
113 114
4
118
37 16 54
71
64
A274310
(CAD 852/30213)
2 111
FROM PAGE
C/18 - 9
173 174
35
26
25
87
132 133
119
A274320
(CAD 852/30213)
19 20
143 145
35
5 60 7 8 40
3 140 37 13 142 144
6 9 10 58
1 31 33
61
141
32 34
113
41 97
4
72
114 116
17
80 82
115 96
83 25
110 92 22 23 21
62
112
64
71
111
2
74 76
59
73 75 77 173 174
39
60
26
29
54
87
78
88
24
147 149 151
146 148 150 152
28 18
132
133
119
4 5
3
70
90 71
50
72
73 7
8
51
9
52
53 10
54
11
16 12
13
55 14
77
15
180D
17
74
18
56 75 19
57
76
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
4 5
3
70
90 71
50
72
73 6
51
9
52
53 10
54
11
12
16
13
14
55 15
17
74
18
56 75 19
57
76
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
63
16 61 12
43 44 68
5
3
8 140
1 9
112 53
141
136 48
102
46 45 134
47 117
116
4 135
115 124 126 101
67
127
142 113 114 100
110 16
16
64 175 176 177 178
49
97
96
62 50 51 52
16
98 99
2
111 119
63 12
3 16 43 44 49 61
5
1 140 112 68
124 126
16 100 50
178
16
62 52
64
16 177
129
97 99 98
2
111
119
Powershift (PS750) 2/4WD Powered On 2WD (Germany) Power Sideshift with Hammer Circuit
446
446
1
010 003 THERMOSTART
9804/1103
2
BATTERY
BATTERY ISOLATOR
CONTENTS
BATTERY
CONTENTS
6
7
NEUTRAL START RELAY STARTER MOTOR
200
8
2
004
200 842 STARTER SOLENOID
Basic Machine
KEY SWITCH
4
PRIMARY
4
NEUTRAL START RELAY
FUSE 4
810
5
200 ALTERNATOR
8
3CX, 4CX and Variants
FROM NEUTRAL
9
SELECT
001
IGNITION RELAY 1
Circuit Diagrams - Electrical
FUSE C7
6
4
407
412
133 FUSE A5
11
002 107
2
13
200
8
WAXSTAT
PRIMARY TO GEARBOX
IGNITION
14
CONTROL FEED COLD START ADVANCE
FUSE 3 RELAY 1 10
105 E.S.O.S.
12
FUSE A2
6
4
133 IGNITION RELAY 2
8
200
15
IGNITION
RELAY 2
007
HAZARD SWITCH
15 - 15 - 03/1
19
LH FRONT INDICATOR
INDICATOR
SWITCH LH REAR INDICATOR ROOF-USA
21
002
8
10
805
18
22
830
3
16
806
Backhoe Loaders
B/O
5
23
RH FRONT INDICATOR
18
804 806
24
RH REAR INDICATOR
17
104 49a
1
31
FUSE A3 802
25
2
49
RH FRONT INDICATOR ROOF-USA
300 C2
3
26
17
FUSE 1 UNIT
FLASHER UNIT
200
U 409 WATER TEMP SENDER
27
FUSE B1 -
U 408
28
FUEL SENDER
+ FUEL GAUGE
30
CLOCK
DIRECT EARTH CLOCK
617
31
FUSE C4
HOURMETER
4 4 0 3
33
HOURMETER
35
ALTERNATOR
HAND BRAKE
WATER TEMP
406 WATER TEMP SWITCH
402
36 37 38 39 40 41
53 54 55 56 57
ILLUMINATION
42
INSTRUMENT PANEL
BUZZER
43
411
45
MASTER
45
805
WARNING
806
45
LIGHTS
45
TURN SIGNAL
46
SIDE LIGHTS
WARNING CLUSTER
47
HAZARD WARNING
804
48
MAIN BEAM
44
49
LH
RH
SPEAKER
SPEAKER
REAR W/L
INSTRUMENTS
FRONT CONSOLE
50
FRONT W/L
51
601
602
860
59
60
REAR FOG
859
52
3270 - C/19_1.1
304A
RADIO
001
133
002
007
200
830
837
861
855
835
401
407
58
EARTH
From m/c no. 495455
15 - 15 - 03/1
Issue1
CONTENTS
CONTENTS
Backhoe Loaders 15 - 15 - 03/2
Main Components
9804/1103
CONTENTS
CONTENTS
114
CIGAR LIGHTER
61
FUSE B4 830
63
62
Basic Machine (cont’d)
HEATED SEAT
65
64
Circuit Diagrams - Electrical
5
M
REAR 863
68
REAR WASHER PUMP
6
WASH/
WIPE
1
M
SWITCH 862 REAR WIPER
67
3
103 864
66
8
7
FUSE B5
839
M
FRONT WASHER PUMP
70
FRONT WIPER
72
69
982
15 - 15 - 03/3
110
73
841
984
ECU
71
840
INTERMITTENT
H/LIGHT
FLASH
74
75
8
7
FOG LIGHT
829 FOG LIGHT SWITCH
76
78
ITALY, GERMAN ONLY ITALY, GERMAN ONLY
3
835
77
868
79
FUSE C1 LIGHTS RELAY
B/U B LH MAIN BEAM
83
ROAD LIGHTS
RELAY DIP FUSE C10
1133
4
SWITCH
836 837 B/U B
10
RH MAIN BEAM
80
5
832
6
82
833 834
127 B/Y B
7
LH DIP BEAM
84 85
6
2
FUSE C9
FUSE 2
3
PRIMARY
829
7
830
ROAD
LIGHTS
311
SWITCH
828
FUSE A10
FUSE C1
81
LH TAIL LIGHT
87
DIPPER SOCKET
89
No PLATE LIGHT
90
RH TAIL LIGHT
91
LIGHT SWITCH
ENGINE RUNING
RELAY
3
93 5
407
2
1133
1853
96
F/W/L SWITCH
5
94
855
4
116
98
2
3
310 855
8
4
7
FUSE B10
5
6
6
4
1
117
2
309
8
861
99
FUSE B8
97
95
8
861
R/W/L SWITCH
303 INTERIOR LIGHT
100
FUSE C3
BEACON SWITCH
8
7
101
3
M
894 BEACON
2
102
8
M
935 HEATER
102
105
HEATER RESISTOR
FUSE C7 800
6
4
HEATER SWITCH
3270 - C/19-4.1
106
HEATER RELAY
103
8
7
108
2
From m/c no. 495455
15 - 15 - 03/3
Issue1
AIR-CON COMPRESSOR
9
1
13
9804/1103
CONTENTS
401 401
START RELAY
TO NEUTRAL
10
8
810
CONTENTS
TO FUSE A5
6
815 815
9
3
810
934 934 815 P/BRAKE SWITCH
TRANS DUMP
RELAY
3CX, 4CX and Variants
4
8
DUMP SWITCH (LOADER)
3
5
5 6
107 FORWARD RELAY DUMP SWITCH (GEARLEVER)
Transmission and Steering
1
2
Circuit Diagrams - Electrical
4
812
10
FORWARD SOLENOID
809
3
5
852
7
F
N
107 FORWARD/REVERSE RELAY
R
REVERSE RELAY
FOR / REV
10
8
SWITCH
808
7
12
811 REVERSE SOLENOID
6
11
811 847
14
REVERSE ALARM
15 - 15 - 03/5
1
9
Backhoe Loaders
14
401
START RELAY
TO NEUTRAL
810
TO FUSE A5
2
815
3
810
934 815 P/BRAKE SWITCH
TRANS DUMP
RELAY
4
5
3
5
107
10
FORWARD RELAY
13
INTERLOCK 851
1
1
RELAY
2
4
4
1
1
15
809 850
3
5
LAYSHAFT SOLENOID
852
11
7
3
3
5
F
N
107 TRANSMISSION EARTH
12
R
REVERSE RELAY
883
FOR / REV
10
SWITCH
808
7
16
883
18
POWER SHIFT
GEAR SELECTOR REVERSE 849 REVERSE LOW SOLENOID
H/L RELAY
9
1
6
7
856
10
19
107 3
17
4
858
21
6
7
20
FRONT PROX SW
1
PROXIMITY SWITCHES
6
FUSE A4
5
820 CRAB/4WS
REAR PROX SW RELAY
7
822
2WS RELAY
8
12
P.C.B.
4WS SOLENOID
826
STEER MODE
13
2WS/4WS
14
3270 - C/19-5.1
16
2WS SOLENOID
825
(SIDE CONSOLE)
17
Issue1
(FRONT CONSOLE)
CONTENTS
CONTENTS
Backhoe Loaders 15 - 15 - 03/6
2
SELECTOR
9804/1103
854
Options
CONTENTS
107
FUSE A5
8
CONTENTS
10
4
5
AUTO 2WD RELAY 2WD/2WB
BRAKE LIGHTS 2WD/4WB
SWITCH
3
853 4WD/4WB SOLENOID
1
126 933 BR MODE SW
6
FUSE B6 922 4 WB RELAY
3CX, 4CX and Variants
5
877
3
FUSE A8
7
4WB RELAY LH BRAKE LIGHT
Circuit Diagrams - Electrical
8
816 RH BRAKE LIGHT
FUSE A7
2
ILLUNINATION
8
7
830
6
4
4WD SWITCH
FUSE A5 AUTO 2WD RELAY
3
10
922
2
5
107
6
15 - 15 - 03/7
AUTO 2WD RELAY
1
2
BRAKE LIGHTS 877 4WB RELAY
5
818
SWITCH FUSE A8
7
3
8
1
858 FUSE B6 816 RH BRAKE LIGHT
TH FUSE A7
FROM 4 GEAR
SELECTOR
5
JAW RELAY
1
3
5
875
2
873
7
874
1
JAW SOLENOID
4
7
8
ILLUMINATION
829
1
FUSE A1
2
101 872
2
5
6
6
898
8
HAMMER RELAY
101
1830
HYDRACLAMP SWITCH
7
8
4
2
3
9
5
1
FUSE C4
304
FUSE A5
107
SPEEDO
FUSE A10
830
3
3270 - C/19-8.1
From m/c no. 495455
15 - 15 - 03/7
Issue1
CONTENTS
CONTENTS
Backhoe Loaders 15 - 15 - 03/8
ROTATION SOLENOID
HAND HELD TOOLS
4WD/AWB SOLENOID
GRAB SOLENOID
QUICK HITCH
4 WB RELAY
2WD/2WB
2WD/4WB
4WD/4WB
QUICK-HITCH
SOLENOID
7
932
ROADBREAKER
SOLENOID
3
QUICK-HITCH
RELAY
6
853
931
2
2 3
2 4 10
AUTO 2WD RELAY
7
1855
930
972
801
801
877
107
854
ROADBREAKER
BR MODE SW
4
SWITCH
1
3
3
FUSE A8
FUSE A5
2 1
929
858
114
FEED SWITCH
QUICK-HITCH
933
114
1
BRAKE LIGHTS
SWITCH
1
FUSE B4
101
FUSE B4
126
FUSE A1
A370070
Powershift 4WD
Auto 2WD In 4th
Powered on 2WD German Hand Held Tools Dedicated Quick Hitch Pole Planter
1 Brake Light Switch 1 Rockbreaker Switch 1 Hitch Enable Switch 1 Selector Switch
2 4 Wheel Brake Relay 2 Indicator Lamp 2 Indicator Lamp 2 Grab Solenoid
3 Brake Mode Selector 3 Rockbreaker Solenoid 3 Alarm 3 Rotation Solenoid
4 Auto 2WD Relay 4 Push Button
5 4WD/AWB Solenoid 5 Push Button
6 Quick Hitch Relay
7 Quick Hitch Solenoid
H.S.C. SOLENOID
ACCUMULATOR
H.S.C. RELAY
LEVER 'HOLD'
SOLENOID
SOLENOIDS
867
3
6 10
4
H.S.C. RELAY
2
844
9 7 8
PROXIMITY SWITCH
1857
866
865
CROWD RAM
2
1 6
H.S.C. SWITCH
7 3 4
1801
1851
7 3 7 3
SHOVEL RESET
8 2 5
2
SWITCH
SWITCH
SRS
1 1
1856
829
8 2 8 2
H.S.C. BUTTON
3
830
829
FUSE A9
818
GEAR
SELECTOR
TH
FROM 4
132
132
101
FUSE A1
FUSE B7
A378770
1
IGN
1808
SW
200V
1816
107
D3 D4
12V
101AB
+VE SERVO
FUSE 15A
FUSE 10A
FUSE 3A
FEED BUZZER FROM
TRANS DUMP
6 7
101
931
RELAY
37 844 D10 LH 17 4
1821 1851
R1 R7 5 AMPLIFIER
PUMP DUMP
1808
EXISTING FUSE 3A 3 2 1
1826
5 6 7
MODE
+VE FEED
STAB
2
AUTO DUMP
012 TO HORN
S2
R
131
929
RELAY
3 6
8 9
830 8
SWEEPER PROPORTIONAL
934
L2
12 SWITCH.
921
BLOWER
1825
1823
1846
1822
1840
1839
1827
7 2 8 2 5 LH STAB,
SERVO L3 SWITCH AUX.OPT.
1857
SWITCH
112
ECU
8
2 3 7 6 7 2 FEED 16
1804
S3
1809
18
1824
1805
RTD 1813
4k
934
0.5k 0.5k
930
FUSE 1A
875
1814 D6
1811
0V 1V 9V 10V
TO HSC
1806
TRANS DUMP
RELAY
11 RTD
REAR HORN
D1
AUX
FROM TACHO ILLUMINATION
1805 D7 14 16 D9
1824
13 15
D8
6 7
RH
19 4
D5
1812 1833 1850
D2
5 AMPLIFIER
1810 D11
FUSE 3A 3 2 1
R2 R3 R4 R5 1807
PROPORTIONAL
SWITCH.
1841
1843
1842
1807 CLAM, AUX,
HAMMER RH STAB.
SOLENOID FEED
870
20
1844 0.5k 4k 0.5k
1838 1845
1834
1849 1832
1847
1807
947
1829 1848
FUSE 5A
FUSE 5A
1837
1836
1831
1802
1828
960
956
1803
CLAM CLAM
959
957
955
954
EXT
958
953
ARMS/BOOM SHOVEL/BUCKET
CHANGEOVER VALVE LOADER VALVE AUX VALVE GROUND
CHANGEOVER VALVE EXCAVATOR VALVE LH LH/RH AUX VALVE
PILOT PILOT
PRESSURE PRESSURE
VALVE VALVE
Main Components
R20 Stabiliser Lower Changeover
1 Starter Switch
R21 Stabiliser Raise Changeover
2 Return To Dig Switch
R22 Stabiliser Lower Mode Changeover
3 Servo Enable Switch R23 Stabiliser Raise Mode Changeover
4 Sweeper Blower Switch
5 Shovel Limit Switch On the illustration:
6 Forward Seat Proximity Switch B = Bottom
7 Rearward Seat Proximity Switch T = Top
8 Mode Changeover Switch H = Head
9 Stabiliser Switch R = Rod
10 Float Electro Magnetic Latch Coil
11 Return To Dig Electro Magnetic Latch Coil
12 Hydraulic Speed Control Switch
13 Transmission Dump Switch
14 Auxiliary Switch
15 Rear Horn
16 Quick Hitch Switch
17 Left Hand Amplifier
18 Left Hand Proportional Rocker Switch
19 Right Hand Amplifier
20 Right Hand Proportional Rocker Switch
21/22 Manifold Arms/Boom Changeover Solenoid
23/24 Manifold Shovel/Bucket Changeover Solenoid
25/26 Loader Solenoid
27/28 Auxiliary Solenoid
29/30 Excavator Left Hand Stabiliser Solenoid
31/32 Excavator Right Hand Stabiliser Solenoid
33 Manifold Left Hand Pilot Pressure Valve
34 Manifold Left/Right Hand Pilot Pressure Valve
35/36 Auxiliary Option Solenoid
37 Alarm
Relays
R1 Ignition
R2 Front Seat
R3 Front Mode Changeover
R4 Rear Seat
R5 Rear Mode Changeover
R6 Spare
R7 Dump Interlink (autoshift only)
R8 Front Auxiliary Supply
R9 Hammer Interlink
R10 Stabiliser Isolator
R11 Spare
R12 Sweeper/Clam Changeover
R13 Pilot Valve Changeover
R14 Auxiliary/Clam 2 Changeover
R15 Auxiliary/Clam 1 Changeover
R16 Stabiliser/Clam 2 Changeover
R17 Stabiliser/Clam 1 Changeover
R18 Stabiliser/Auxiliary 1 Changeover
R19 Stabiliser/Auxiliary 2 Changeover
62A 54
62 4
35
4G
T
31 4X 61
33
6 C2
4R 4H 58
E
P
6A C2 4A
E 1B
T V2
P
4S 4J
3 59
S
66 T V2 4K
65 65
4B
3E
P2 P1 4T 52 55 51
4L
C
25 3K
3G 64
56
4C
V2 3D
V1 V
4U 61
3F
3J C2
E
4D
T V2 P
3C
4V
64
26 4M 57 T V2
P 3H
E
C2 1A
4E
66 3M
13 3Q 4W 4N
1A 3L 59
4P
2A
4F
3B 3N 3P
34 32
3A
36 EF
P
53
7B P2A
CF
9808/9555-2
PP 7
9808/9555-2
Circuit Variations
The hydraulic schematic diagram shown on page 15 - 20 - 02/2 shows the latest machine hydraulic circuit. The purpose of this
page is to identify 'older' circuit variations, where possible the machine serial numbers will be given to help identify the machine
range(s).
4K Component Key
C2
V2
4 Excavator Valve Block
V1 4S Load Hold Check Valve
C1 4K Boom Ram Rod Side A.R.V.
4L 52 4L Boom Ram Head Side A.R.V.
4B Boom Spool
52 Boom Ram
61 Hose burst Protection Valve (Optional)
A196780
P1
A197090
The illustration shows the manual type hydraclamp control valve. Machines from serial number 430001 have the hydraclamp
valve operated by a switch (and solenoid).
Component Key
T Tank
1B Neutral Circuit Line
1B T
4 Excavator Valve Block
4
4A Slew Spool
4G Hydraclamp Valve 62
4H Slew A.R.V.
4R Load Hold Check Valve 4G
4X Make-up Check Valve
4X
62 Hydraclamps (Sideshift Machines Only)
4R 4H
4A
A217690
Note: Hydraulic component port identification letters are shown in parenthesis, e.g. (LS). The same letters will be stamped on
the actual component.
T
6
43 (L) (R) 9 10
42 (T) (P)
(LS)
P2 P1
8
(P) 44 (T)
(CF)
(P)
7
P2A
12 11
9808/9510-3
Note: Hydraulic component port identification letters are shown in parenthesis, e.g. (LS). The same letters will be stamped on
the actual component.
T
6
43 (L) (R)
10
S 9
42
(LS)
P2 P1
(P) 44 (T)
(CF)
(LS)
(P)
7
P2A
9808/9545-1
LS
EF
LS
LS
FIG 1 FIG 2
LS
EF
LS
LS
FIG 1 FIG 2
31
10
16
40
LS
33 15
4D
37
48
3 36 4W
35 4C
3H
39
3M 38
4D
17
9B
4T
9 4C 44
3H
9A
3F 3L
4D 46
3E 3J L 8 R
8A
4R
3H 45
4E 4S
3G
3K
3G LS 4H
3J 42
41 43
8B 4Z 4J
34 3C
P T
P
LS
EF P2A
32 3B P 4D 18
CF
3D 4N 4P 4Q 18
4G
3A T
47
LS 7 14
30
T
HPCO T
TA 4D
4K 4L 4M
4G
5 P
5C C 12F
4X
6 4A
S 5A 4B
P1A
P2 P1 5B 12E
T
4 MA P
12D 12C
1 2 11
12A 49
1A
13
12B
50
P 12
A193291
9804/1103 Issue 2
15 - 20 - 03/2 15 - 20 - 03/2
CONTENTS
CONTENTS
Backhoe Loaders 15 - 20 - 03/3
31
10
40
B
LS
33 A 15
4D
37
3 48
36 4X
35 4C
B
3H
B
39
A 4W
3M 38
4D
A 17
9B
4U 4V
9 4C 44
B 3H
3F 9A
B
A 3L
4T 46
4D A
3E 3J L 8 R
8A
3H 4R
B
4E 45
4S
A
3G
3K
3G LS 4H
3J 42
41 43
8B 4Z 4J
34 3C
P T
P
LS B
A
EF P2A
32 3B P 4D 18
CF
3D 4N 4P 4Q 18
4G
3A T
47
LS 7 14
30 B
T A
HPCO T
TA 4D
4K 4L 4M
4G
5 P
5C C 12F
4Y
6
S 5A 4B
P1A
P2 P1 5B 12E
T
4 MA P
12D 12C
1 2 11
12A 49
1A
13
12B
50
P 12
A245980
9804/1103 Issue 1
15 - 20 - 03/3 15 - 20 - 03/3
CONTENTS
CONTENTS
Backhoe Loaders 15 - 20 - 03/4
3CX, 4CX, 214, 215, 217, “S” Series From m/c no. 460001
Circuit Diagrams - Hydraulic (cont’d)
C 35
1B
31
4
T 62 54
4G
6 33 4H
6B 4A
6A 40 4J
S 3
59 65
39 4B 4K
3E
4L 56
3F 38 52
3D 41 4C
P2 P1
3J 3G 55
3C 4D
43
34 66 57
3B 3J 3A 4M
P1 P2 15 42 4E
2A 4N
3M 59 51
26 3Q 44
T ACC 4F
JJ
3L JJ
4P T
16
3N 7 53
8 10
13
32 11
12 14
36 P2A
9
1A
5A 5B M
5C
CONTENTS
9804/1103 15 - 20 - 04/2 3270 - E/6-2.6 Issue 3*
CONTENTS
CONTENTS * Backhoe Loaders 15 - 20 - 04/3
Component Key
A Hydraulic Tank K Flow Regulator Valve BB Dipper Ram
B In Tank Filter L Pressure Test Point CC Bucket Ram
C Hydraulic Oil Cooler N Steer Valve DD Suction Strainer
D Single Stage Hydraulic Pump Q Priority Valve EE Stabilizer Check Valve
E One Way Restrictor S Excavator Valve Block FF Filter
F Shovel Rams W Stabiliser Rams Fitted from m/c no. 475518
G Quick Release Couplings Y One Way Restrictor or see bulletin 2/218
H Lift Rams Z Slew Rams GG Tank Cap
J Loader Valve Block AA Boom Ram
CONTENTS
9804/1103 15 - 20 - 04/3 3270 - E/7-1.2 Issue 3*
CONTENTS
CONTENTS * Backhoe Loaders 15 - 20 - 04/4
GG
S W
F
A
EE
SLEW
B DD
H
2WS FRONT
POWER TRACK ROD
SHOVEL
J4
BOOM
ENGINE F
Y Y
D
LOADER J3 Z
STABILISER
L R
BB CC
N
AA
AUX J2 STABILISER
Z
C
Y
P LS T DIPPER
MRV
J1 J LS
EF P
CF
Q BUCKET
PP
H EE
FF H.P.C.O.
E
W
F
HAMMERMASTER HAMMERMASTER HAMMERMASTER
260L 280 360
B
L
A
G G
NEUTRAL CIRCUIT / TANK RETURN K M
HAMMER RETURN
HAMMER FEED
Component Key
J2 Auxiliary Spool Q Priority Valve FF Filter
A Hydraulic Tank J3 Lift Spool S Excavator Valve Block Fitted from machine serial number
B In-tank Filter J4 Shovel Spool W Stabiliser Rams 475518 or see bulletin 2/218.
C Hydraulic Oil Cooler K Flow Regulator Valve (Option) Y One Way Restrictor GG Tank Cap
D Single Stage Hydraulic Pump L Pressure Test Point Z Slew Rams
E Twin Check Valve M Auxiliary Valve Block (Option) AA Boom Ram
F Shovel Rams Either option K or M can be fitted but not BB Dipper Ram
G Quick Release Couplings both. CC Bucket Ram
H Lift Rams N Steer Valve DD Suction Strainer
J Loader Valve Block P Auxiliary Rams EE Stabiliser Check Valve
J1 Main Relief Valve
CONTENTS
9804/1103 15 - 20 - 04/4 3270 - E/7-2.2 Issue 2*
CONTENTS
CONTENTS
Backhoe Loaders 15 - 20 - 04/4A
GG
1
P
S W
F
A 2
S1 EE
SLEW
B DD
H
SHOVEL
J4 S2 BOOM
ENGINE
L R
Y Y
D 3
LOADER J3 S3 Z
STABILISER
BB CC HH
N
S4 AA
AUX J2 STABILISER
Z
C
Y
P LS T S5 DIPPER
MRV
J1 J LS
EF P
CF
L Q J4 BUCKET
PP
H EE
FF H.P.C.O.
E
W
F
HAMMERMASTER HAMMERMASTER HAMMERMASTER
260L 280 360
B
L
A
G G
NEUTRAL CIRCUIT / TANK RETURN K M
HAMMER RETURN
HAMMER FEED
Component Key
J2 Auxiliary Spool Q Priority Valve W Stabiliser Rams FF Last Chance Filter
A Hydraulic Tank J3 Lift Spool S Excavator Valve Block Y One Way Restrictor GG Tank Cap
B Return filter J4 Shovel Spool S1 Slew Spool Z Slew Rams HH Extending Dipper
C Hydraulic Oil Cooler K Flow Regulator Valve (Option) S2 Boom Spool AA Boom Ram 1 Front Power Track Rod
D Single Stage Hydraulic Pump L Pressure Test Point S3 Stabiliser Spool BB Dipper Ram 2 Rear Power Track Rod
E Twin Check Valve M Auxiliary Valve Block (Option) S4 Stabiliser Spool CC Bucket Ram 3 Steer Control Valve
F Shovel Rams Either option K or M can be fitted but not S5 Dipper Spool DD Suction Strainer 4 Steer Selector Valve
G Quick Release Couplings both. S6 Bucket Spool EE Stabiliser Check Valve
H Lift Rams N Steer Valve
J Loader Valve Block P Auxiliary Rams A356640
J1 Main Relief Valve
69 69
75
77
11 11
10
HPCO
76
HPCO 76
72 72
74 T 74
M T
M
M
73
73
Component Key
69
77
11
HPCO 76
M
M
49
7 T LS 25 P
50 54
P
8 26
L R 18 49
3 17
P T 45
B
48 15
S 27 B
T B
5 6 A 53
P A 15A
46
4 LS 51
52
L 28
17 18
L1
47
16
29 B
36
P T A
16
43
T 28
17 18
37
P PRLS LS T
1 15
9 30 B
11
17
10 A
2 15
PR
20
17 18
21 44
19 17
22 31 B
18
12 38
A
B
17 18
A
17 32 B 39
19
18 A
13
15 17 18 40
B
A 15
33 B
24 15
T ACC A
23 17 16
19
18
14 17 18
41
22 P1 P2
B 16
34 B
21
A
20 LS A
16A
4CXE, 4CX Super - Variable Flow Hydraulics From m/c no. 460001
(7 - Spool with High Flow Options)
Circuit Diagrams - Hydraulic
Component Key
T Hydraulic Tank
1 By-pass Filter
2 Suction Line
P Pump Variable Flow 38 Stabiliser Ram
3 Stroking Piston 39 Stabiliser Ram
4 Control Piston 40 Dipper Ram
5 System Pressure Spool 41 Bucket Ram
6 Stand-by Pressure Spool 42 Accumulator
7 Hydraclamp Valve 43 Oil Cooler
8 Hydraclamps 44 Load Sense Relief Valve
9 Loader Valve Block 45 Steer Unit Assembly
10 Priority Inlet Section 46 Steer Valve
11 Relief Valve † 47 Relief Valve
12 Auxiliary Service Spool 48 Shock Valves
13 Shovel Service Spool 49 Quick release Couplings
14 Lift Service Spool 50 Isolation Valve
15 Auxiliary Relief Valves (anti-cavitation) 51 Extending Dipper Isolation Valve
15A ARV item 16 if Rockerbreaker Application 52 Foot Valve
16 Auxiliary Relief Valves (direct acting) 53 Extending Dipper Ram
16A ARV Only Fitted For Rockbreaker Application 54 Hammer
17 Secondary Shuttle Valve
18 Primary Shuttle Valve † Note: Steer circuit pressure is controlled by a relief valve
19 Load Hold Check Valve housed in the orbitrol unit (see section H). The priority relief
20 Auxiliary Rams valve housed in the loader valve must be set at 2500 lb/in2
21 Shovel Rams (173 bar, 176 kgf/cm2) this will ensure it does not interfere
22 Lift Rams with the operation of the relief valve housed in the orbitrol
23 Smooth Ride Selector Valve unit.
24 Smooth Ride Accumulator
25 Backhoe Loader Valve Block
26 Extradig Priority Valve
27 Extradig Service Spool
28 Compensator Valves
29 Slew Service Spool
30 Boom Service Spool
31 Stabiliser Service Spool
32 Stabiliser Service Spool
33 Dipper Service Spool
34 Bucket Service Spool
35 Extradig Ram
36 Slew Rams
37 Boom Ram
4CXE, 4CX Super - Variable Flow Hydraulics From m/c no. 460001
(6 - Spool with High/Low Flow Options)
Circuit Diagrams - Hydraulic
Component Key
T Hydraulic Tank
1 By-pass Filter
2 Suction Line
P Pump Variable Flow 38 Stabiliser Ram
3 Stroking Piston 39 Stabiliser Ram
4 Control Piston 40 Dipper Ram
5 System Pressure Spool 41 Bucket Ram
6 Stand-by Pressure Spool 42 Accumulator
7 Hydraclamp Valve 43 Oil Cooler
8 Hydraclamps 44 Load Sense Relief Valve
9 Loader Valve Block 45 Steer Unit Assembly
10 Priority Inlet Section 46 Steer Valve
11 Relief Valve † 47 Relief Valve
12 Auxiliary Service Spool 48 Shock Valves
13 Shovel Service Spool 49 Quick release Couplings
14 Lift Service Spool 50 Isolation Valve
15 Auxiliary Relief Valves (anti-cavitation) 54 Hammer
16 Auxiliary Relief Valves (direct acting) 55 Load Sense Isolation Valve
16A ARV Only Fitted For Rockbreaker Application
17 Secondary Shuttle Valve † Note: Steer circuit pressure is controlled by a relief valve
18 Primary Shuttle Valve housed in the orbitrol unit (see section H). The priority relief
19 Load Hold Check Valve valve housed in the loader valve must be set at 2500 lb/in2
20 Auxiliary Rams (173 bar, 176 kgf/cm2) this will ensure it does not interfere
21 Shovel Rams with the operation of the relief valve housed in the orbitrol
22 Lift Rams unit.
23 Smooth Ride Selector Valve
24 Smooth Ride Accumulator
25 Backhoe Loader Valve Block
28 Compensator Valves
29 Slew Service Spool
30 Boom Service Spool
31 Stabiliser Service Spool
32 Stabiliser Service Spool
33 Dipper Service Spool
34 Bucket Service Spool
36 Slew Rams
37 Boom Ram
4CXE, 4CX Super - Variable Flow Hydraulics From m/c no. 460001
(6 - Spool with High/Low Flow Options)
Circuit Diagrams - Hydraulics
49
7 50
54
P
8
L R 49
3
P T 45 55
B
48
S
T B
5 6
P A
T LS P
46 25
4 LS
L X 28
17 18
L1
47
16
29 B
36
P T A
16
43
T 28
17 18
37
P PRLS LS T
1 15
9 30 B
11
17
10 A
2 15
PR
20
17 18
21 44
19 17
22 31 B
18
12 38
A
B
17 18
A
17 32 B 39
19
18 A
13
15 17 18 40
B
A 15
33 B
24 15
T ACC A
23 17 16
19
18
14 17 18
41
22 P1 P2
B 16
34 B
21
A
20 LS A
16A
4CXE, 4CX Super - Variable Flow Hydraulics From m/c no. 460001
Circuit Diagrams - Hydraulic
Hand Held Tools Option
2
3
LS
4
9 25
LS LS
5
T
P
6
A322650
Component Key
1
4
3
6
5
8
A198310
1 7
12
4
3
2
11
6
5
10
A194220
ALL MODELS
Contents
Page No.
General Information
Fluids, Lubricants and Capacities
- 525-58, 525-67, 527-58, 527-67, 530-95 20 - 00 - 01/1
- 530-110 20 - 00 - 01/2
- 530-10 (AK/AR Builds) 20 - 00 - 01/2A
- 530-120, 537-120, 537-130 20 - 00 - 01/3
- 505-19, 505-22 20 - 00 - 01/4
- 506-36 20 - 00 - 01/5
- 508-40 & 510-40 20 - 00 - 01/6
- 525-58 FS Plus, 530-67, 535-67 20 - 00 - 01/7
- 520-55 RS 20 - 00 - 01/8
- 520-55 AWS (AA/AB Builds) 20 - 00 - 01/9
- 520-55 AWS (AK/AR Builds) 20 - 00 - 01/9A
- 526-55, 526, 526S (AA/AB Builds) 20 - 00 - 01/10
- 526-55, 526, 526S (AK/AR Builds) 20 - 00 - 01/10A
- 520-50 (N. America) 20 - 00 - 01/11
- 528-70, 528S 20 - 00 - 01/12
- 506B, 506C, 506C (HL), 508C 20 - 00 - 01/13
- 520-50, 525-50 (AA Build) 20 - 00 - 01/14
- 520-50, 525-50, 525-52 (AK/AR Builds) 20 - 00 - 01/15
- 526 (N.America) 20 - 00 - 01/16
- 530, 535, 540 20 - 00 - 01/17
* - 530, 533, 535, 540 20 - 00 - 01/17A & 17B
- 532, 537, 550 20 - 00 - 01/18.
Data - Electrical
ALL MODELS
Contents (continued)
Page No.
Data - Electrical (cont’d)
520-55, 526-55, 526, 526S (526 N.Am) From m/c no. 279000 to 280299
Relay Identification 20 - 05 - 01/10
Fuse Identification 20 - 05 - 01/12
Data Hydraulics
- 525-58, 525-67, 527-58, 527-67, 535-67 From m/c no. 567362 20 - 05 - 02/1
- 530-95 From m/c no. 567362 20 - 05 - 02/2
- 530-110 From m/c no. 567362 20 - 05 - 02/3
- 530-120 From m/c no. 567362 20 - 05 - 02/4
- 505-19 & 505-22 From m/c no. 567362 20 - 05 - 02/5
- 506-36 From m/c no. 567362 20 - 05 - 02/6
- 508-40 From m/c no. 567362 20 - 05 - 02/7
- 510-40 From m/c no. 567362 20 - 05 - 02/8
- 520-55, 526-55, 520S, 526, 526S from m/c no. 567362 20 - 05 - 02/9
- 537-120 From m/c no. 567362 20 - 05 - 02/10
- 537-130 From m/c no. 567362 20 - 05 - 02/11
- 520-50, 525-50, 525-52 From m/c no. 754000 20 - 05 - 02/12
- 530 Agricultural 20 - 05 - 01/13
- 530 Construction 20 - 05 - 02/14
- 540 Agricultural From m/c no. 767001 20 - 05 - 02/14A
- 540 Construction From m/c no. 767001 20 - 05 - 02/14B
- 535 From m/c no. 767001 20 - 05 - 02/14C
- 532 from m/c no. 567362 20 - 05 - 02/15
- 537, 550 From m/c no. 767001 20 - 05 - 02/16
- 528-70, 528S From m/c no. 796000 20 - 05 - 02/17
- 506B, 506C 20 - 05 - 02/18
- 506C (HL), 508C 20 - 05 - 02/19
- 540-170, 5508 with Servo Controls from m/c no. 780925 20 - 05 - 02/20
Data Engine
- All models from m/c no. 567362 20 - 05 - 03/1
- 520-55, 526-55, 526, 526S From m/c no.277001 20 - 05 - 03/2
- 520-50, 525-50, 525-52 From m/c no. 754000 20 - 05 - 03/3
- 530, 535, 540 and 532, 537, 550 From m/c no. 767001 20 - 05 - 03/4
ALL MODELS
Contents (continued)
* Page No.
Axles
- 525-58, 67, 527-58, 67, 530-67, 95, 535-67, 505-19 & 22 From m/c no. 567362 20 - 05 - 04/1
- 530-120, 537-120, 130, 508-40 & 510-40 From m/c no. 567362 20 - 05 - 04/1
- 530-110 & 506-36 From m/c no. 567362 20 - 05 - 04/1
- 520-55 RS From m/c 277001 20 - 05 - 04/2
- 520-55 4 Wheel Steer to m/c no. 2768610 20 - 05 - 04/2
- 520-55 4 Wheeled Steer from m/c no. 2768611 20 - 05 - 04/2
- 526-55, 526, 526S to m/c no. 280999 20 - 05 - 04/2
- 526-55, 526, 526S to m/c no. 280299 20 - 05 - 04/3
- 520-50, 525-50 from m/c no. 754000, 20 - 05 - 04/3
- 526, 526S from m/c no. 280300 20 - 05 - 04/3
- 528-70 from m/c no. 796000 20 - 05 - 04/4
- 528S from m/c no. 796102 20 - 05 - 04/4
- 506B, 506C, 506C (HL),508C 20 - 05 - 04/5
Data-Tyres
- All models, except 530, 532, 535, 537, 540, 550 20 - 05 - 04A/1
- 530, 532, 535, 537, 550, 540 20 - 05 - 04A/4
Data Transmission
- Syncro Shuttle, All models from m/c no. 567362 20 - 05 - 05/1, 2
- 520-55 Syncro Shuttle from m/c no. 277001 20 - 05 - 05/2
- 520-50, 525-50, 525-52 from m/c no. 754000 20 - 05 - 05/2
- 520, 526 Powershift from m/c no. 277001 20 - 05 - 05/3
- 528 Powershift from m/c no. 796000 20 - 05 - 05/3
- 506, 508 Powershift 20 - 05 - 05/3
- 520, 526 Syncro Shuttle from m/c no. 277001 20 - 05 - 05/3A
- 528 Syncro Shuttle from m/c no. 796000 20 - 05 - 05/3A
- 506, 508 Syncro Shuttle 20 - 05 - 05/3A
- 530, 532, 535, 537, 540, 550 Powershift 20 - 05 - 05/4
- 532, 537, 550, Axles and Stall Speeds from m/c no. 767001 20 - 05 - 05/5
- 530, 535, 540 Axles and Stall Speeds from m/c no. 767001 20 - 05 - 05/6
Data-Brakes
- 525-58/67, 527-58/67, 530-67, 535-67, 505-19/22 From m/c no. 567362 20 - 05 - 07/1
- 530-95/110, 506-36 from m/c no. 567362 20 - 05 - 07/1
- 530-120, 537-120/130, 508-40, 510-40 from m/c no. 567362 20 - 05 - 07/2
- 520-55 RS from m/c no. 277001 to 279119 20 - 05 - 07/2
- 520-55 AWS from m/c no. 277001 to 279119 20 - 05 - 07/3
- 526-55, 526, 526S from m/c no. 277467 to 280299 20 - 05 - 07/3
- 520-55 AWS from m/c no. 279120 20 - 05 - 07/3
- 520-50, 525-50, 525-52 20 - 05 - 07/3
- 526-55, 526, 526S, 520-55 4WS, from m/c no. 2768611 20 - 05 - 07/4
- 532, 537 from m/c no. 2768611 20 - 05 - 07/4
- 528-70 from m/c no. 796000 20 - 05 - 07/5
- 528S from m/c no. 796102 20 - 05 - 07/5
- 530, 535, 540 from m/c no. 767001 20 - 05 - 07/6
- 532, 537, 550 fromm/c no. 767001 20 - 05 - 07/6
- 506B, 506C, 506C(HL), 508C 20 - 05 - 07/7
ALL MODELS
Contents (contunued)
Page No.
Data-Steering
- All models from m/c no. 567362 20 - 05 - 08/1
- 520-55, 526-55, 526, 526S from m/c no. 277001 20 - 05 - 08/1
* -All models from m/c no. 773135 20 - 05 - 08/1A
- 520-50, 525-50, 525-52 from m/c no. 754000 20 - 05 - 08/2
- 530, 532, 537 from m/c no 754000 20 - 05 - 08/2
- 528-70 from m/c no. 796000 20 - 05 - 08/3
- 528S from m/c no. 796102 20 - 05 - 08/3
- 530, 535, 540 from m/c no. 767001 20 - 05 - 08/4
- 532, 537, 550 from m/c no. 767001 20 - 05 - 08/4
- 506B, 506C, 506C (HL), 508C 20 - 05 - 08/5
Circuit Diagrams-Electrical
- All models from m/c no. 567362 20 - 15 - 01/1 to 3
- 520-55 (504B N. Am), 520-55 RS from m/c no. 277001 to 277535 20 - 15 - 01/4 to 6
- 520-55 from m/c no. 277536 20 - 15 - 01/7 to 9
- 526-55 to m/c no. 278965 20 - 15 - 01/7 to 9
- All models from 567362 (Powershift option) 20 - 15 - 01/10
- Safe Load Indicator Circuit from m/c no. 576404 20 - 15 - 01/11
- 520-55, 520S from m/c no. 278966 20 - 15 - 01/12 to 14
- 526-55, 526S (526 N.Am) from m/c no. 278966 to 280299 20 - 15 - 01/12 to 14
- 526-55, 526, 526S (526 N.Am)(Powershift ECU) from m/c no. 280300 to 280576 20 - 15 - 01/15 to 21
- 526-55, 526, 526S (526 N. Am) (Syncroshuttle) from m/c no. 280300 20 - 15 - 01/22 to 27
- 520-55 (Syncro Shuttle) from m/c no. 281847 20 - 15 - 01/22 to 27
- 526, 526S (526 N. Am) (Powershift) from m/c no. 280577 20 - 15 - 01/29 to 34
- 528-70 (Syncro Shuttle) from m/c no. 796000 20 - 15 - 01/37 to 40
- 528S (Powershift) from m/c no. 796102 20 - 15 - 01/41 to 46
- 528S (Syncro Shuttle) from m/c no. 796102 20 - 15 - 01/47 to 52
- 530 Without Neutral Start Relay from m/c no. 767001 to768836 20 - 15 - 02/1 to 4
- 530 With Nuetral Start Relay/ECU from m/c no. 768837 to 770053 20 - 15 - 02/5 to 8
- 530 With Relay Controlled Transmission (ECU not fitted) from m/c no. 770054 to 770958 20 - 15 - 02/9 to 12
- 530, 540 Sway Machines from m/c no. 770959 20 - 15 - 02/13 to 16
- 530, 540 Non-Sway Machines from m/c no. 770959 20 - 15 - 02/17 to 20
- 530, 540 With Manual Auxiliary Controls from m/c no. 775402 20 - 15 - 02/21 to 26
- 535 With Manual Auxiliary Controls from m/c no. 777362 20 - 15 - 02/21 to 26
- 530, 540 With Single Lever Controls from m/c no. 775402 20 - 15 - 02/27 to 32
- 535 With Single Lever Controls from m/c no. 777362 20 - 15 - 02/27 to 32
- 530, 535, 540 from m/c no. 7670001/530 FS Super, 540 FS Super, 530SXL, 540 SXL 20 - 15 - 02/33 to 38
- 532, 537 Without Neutral Start Relay from m/c no. 767001 to 768956 20 - 15 - 03/1 to 4
- 532, 537 With Neutral Start Relay/ECU from m/c no. 768957 to 770063 20 - 15 - 03/5 to 8
- 532, 537 With Relay Controlled Transmission (ECU not fitted) from m/c no. 770064 to 770958 20 - 15 - 03/9 to 12
- 532, 537, 550 from m/c no. 770959 20 - 15 - 03/13 to 16
- 532, 537, 550 With Manual Auxiliary Controls from m/c no. 775402 20 - 15 - 03/17 to 22
* - 540-170, 5508 with Servo Controls to m/c no. 1004130 20 - 15 - 03/17 to 24
* - 540-170, 5508 with Servo Controls from m/c no. 1004131 20 - 15 - 03/25 to 32
- 506B (Syncro Shuttle) to m/c no. 578676 20 - 15 - 04/1 to 3
- 506B (Syncro Shuttle) from m/c no. 578677 20 - 15 - 04/4 to 6
- 506C, 508C (Syncro Shuttle) to m/c no. 585396 20 - 15 - 04/7 & 8
- 506C, 508C (Syncro Shuttle) from m/c no. 585397 20 - 15 - 04/9 & 10
- 506C, 508C (Powershift with 6 Transmission Relays) to m/c no. 585396 20 - 15 - 04/11 & 12
- 506C, 508C (Powershift with 7 Transmission Relays) to m/c no. 585396 20 - 15 - 04/13 & 14
- 506C, 508C(Powershift) from m/c no. 585397 20 - 15 - 04/15 & 16
* - 533-105 Machines 20 - 15 - 05/1 to 6
ALL MODELS
Contents (continued)
Page No.
Circuit Diagrams - Hydraulics
- 525-58/67, 527-58/67, 530-95 from m/c no. 567362 to 574295 20 - 20 - 02/1, 2
- 527-58/67, 535-67 from m/c no. 574296 20 - 20 - 02/2A, 2B
- 530-120 from m/c no. 567362 20 - 20 - 02/3, 4
- 530-110 from m/c no. 567362 20 - 20 - 02/5, 6
- 505-19 & 505-22 from m/c no 567362 to 574295 20 - 20 - 02/7, 8
- 505-19 & 505-22 from m/c no. 574296 20 - 20 - 02/8A, 8B
- 506-36 from m/c no. 567362 20 - 20 - 02/9, 10
- 508-40 from m/c no. 567362 20 - 20 - 02/11,12
- 510-40 from m/c no. 567362 20 - 20 - 02/13, 14
- 520-55 RS, 520-55 4 Wheel Steer from m/c no. 277001 to 278610 20 - 20 - 02/15, 16
- 520-50 4 Wheel Steer from m/c no. 278611 20 - 20 - 02/17, 18
- 526-55, 526, 526S from m/c no 277001 to 280299 20 - 20 - 02/17, 18
- 537-120, 537-130 from m/c no. 572900 20 - 20 - 02/19, 20
- 520-50, 525-50, 525-52 from m/c no. 754000 20 - 20 - 02/21, 22
- 520-55 RS, 520-55 4WS from 278610 20 - 20 - 02/23, 24
- 520-55 4WS from m/c no. 278611 20 - 20 - 02/25, 26
- 526-55, 526, 526S to m/c no. 280299 20 - 20 - 02/25, 26
- 526, 526S with Dual Lever Control from m/c no. 280300 20 - 20 - 02/27, 28
- 526, 526S with Single Lever Control Option from m/c no.280300 20 - 20 - 02/29, 30
- 528-70 from m/c. 796000 20 - 20 - 02/31, 32
- 528S from m/c no. 796102 20 - 20 - 02/31, 32
- 528S with Single Lever Controls from m/c no. 796102 20 - 20 - 02/33, 34
- 530, 540 Agricultural from m/c no. 767001 20 - 20 - 02/35, 36
- 530 Construction from m/c no. 767001 to 770616 20 - 20 - 02/37, 38
- 530, 540 Construction with Single Lever Control from m/c no. 767001 to 770617 20 - 20 - 02/39, 40
- 530 Construction with Manual Auxiliary Controls from m/c no. 775402 20 - 20 - 02/41, 42
* - 530 Construction with Manual Auxiliary Controls from m/c no. TBA 20 - 20 - 02/41A, 42A
(fitted with 2-stage pump)
* - 530 Construction with Manual Auxiliary Controls from m/c no. 775402 20 - 20 - 02/41B, 42B
(fitted with 3-stage pump)
- 540 Construction with Manual Auxiliary Controls from m/c no 775402 20 - 20 - 02/43, 44
* - 540 Construction with Manual Auxiliary Controls from m/c no. 775402 20 - 20 - 02/43A, 44A
(fitted with 3-stage pump)
- 535-95 from m/c no. 777362 20 - 20 - 02/45, 46
* - 535-95 Machines (fitted with a 3-stage pump) from m/c no. 777362 20 - 20 - 02/45A, 46A
* - 535-95 Machines (fitted with a 2-stage pump) from m/c no. TBA 20 - 20 - 02/45B, 46B
- 532 to m/c no. 770638 20 - 20 - 02/47, 48
- 537, 550 to m/c no. 770613 20 - 20 - 02/47, 48
- 532 from m/c no 770639 to 775401 20 - 20 - 02/49, 50
- 537, 550 from m/c no. 770614 to 775401 20 - 20 - 02/49, 50
- 532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402 20 - 20 - 02/51, 52
- 506B 20 - 20 - 02/53, 54
- 506C 20 - 20 - 02/55, 56
- 506C (HL), 508C 20 - 20 - 02/57, 58
- 540-170 with Servo Controls from m/c no. 780925 20 - 20 - 02/59, 60
* - 533-105 Machines from serial no. 786756 20 - 20 - 02/61, 62
Fuel Tank 90 (20) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Gearbox
Syncro Shuttle 18.25 (4.0) JCB Special Transmission Fluid ESP-M2C 33G
* Powershift ††15.0 (3.3) ††JCB Special Transmission Fluid ESP-M2C 33G
Front Axle
Housing 18 (3.9) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 2.0 (0.4) JCB Special Gear Oil ESEN-M2C 86A/B
Rear Axle
Housing 13 (2.8) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 2.0 (0.4) JCB Special Gear Oil ESEN-M2C 86A/B
* Hydraulic System †152 (33.5) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
JCB Special Hydraulic Fluid ISO VG32
(Below 38 °C, 100 °F)
Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency
* † Note: : This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill
with all rams closed. Watch level sight glass when filling.
* †† Note: This is a system capacity. Use the 'MIN' and 'MAX' marks on the dipstick when refilling the system.
Fuel Tank 90 (20) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Syncro Shuttle 18.25 (4.0) JCB Special Transmission Fluid ESP-M2C 33G
Front Axle
Housing 18 (3.9) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 2.0 (0.4) JCB Special Gear Oil ESEN-M2C 86A/B
Rear Axle
Housing 13 (2.8) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 2.0 (0.4) JCB Special Gear Oil ESEN-M2C 86A/B
Hydraulic System †190 (41.8) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
JCB HP32 ISO 32
(Below 38 °C, 100 °F)
JCB Light Hydraulic Fluid ISO VG15
(For Iceland, Norway, Sweden
and Finland ONLY)
Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency
† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with
all rams closed. Watch level sight glass when filling.
530-110
AK and AR Engine Builds
Fluids, Lubricants and Capacities
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently
run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first
100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB
10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to
the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended
below.
Fuel Tank 90 (20) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Front Axle
Housing 18 (3.9) JCB High Performance JCB 4000/2200
Hubs (x2) 2.0 (0.4) Gear Oil Plus Must be suitable for use with oil
immersed brakes and limited slip
Rear Axle Differentials (LSD).
Housing 13 (2.8)
Hubs (x2) 2.0 (0.4)
Hydraulic Tank † 190 (41.8) JCB High Performance Hydraulic Fluid 46 ISO VG46
(Above 38 °C, 100 °F)
JCB High Performance Hydraulic Fluid 32 ISO VG32
(Below 38 °C, 100 °F)
† Note 1: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check
with all rams closed. Watch level sight glass when filling.
†† Note 2: If JCB MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals; all
500 hour greasing operations must be carried out at 50 HOUR intervals.
Fuel Tank 90 (20) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Syncro Shuttle 18.25 (4.0) JCB Special Transmission Fluid ESP-M2C 33G
Front Axle
Housing 17 (3.7) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 2.0 (0.4) JCB Special Gear Oil ESEN-M2C 86A/B
Rear Axle
Housing 18 (3.9) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 0.75 (0.16) JCB Special Gear Oil ESEN-M2C 86A/B
Hydraulic System †292 (64.3) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
JCB HP32 ISO 32
(Below 38 °C, 100 °F)
Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency
† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with
all rams closed. Watch level sight glass when filling.
Fuel Tank 24.8 (93) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Syncro Shuttle 5.7 (22) JCB Special Transmission Fluid ESP-M2C 33G
Front Axle
Housing 4.7 (18) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 0.6 (2.0) JCB Special Gear Oil ESEN-M2C 86A/B
Rear Axle
Housing 3.4 (13) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 0.5 (2.0) JCB Special Gear Oil ESEN-M2C 86A/B
Hydraulic System †28.8 (110) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
JCB HP32 ISO 32
(Below 38 °C, 100 °F)
Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency
† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with
all rams closed. Watch level sight glass when filling.
Fuel Tank 23.7 (90) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Syncro Shuttle 4.8 (18.25) JCB Special Transmission Fluid ESP-M2C 33G
Front Axle
Housing 4.7 (18) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 0.5 (2.0) JCB Special Gear Oil ESEN-M2C 86A/B
Rear Axle
Housing 3.4 (13) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 0.5 (2.0) JCB Special Gear Oil ESEN-M2C 86A/B
Hydraulic System †50.2 (190) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
JCB HP32 ISO 32
(Below 38 °C, 100 °F)
Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency
† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with
all rams closed. Watch level sight glass when filling.
Fuel Tank 23.7 (90) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Syncro Shuttle 4.8 (18.25) JCB Special Transmission Fluid ESP-M2C 33G
Front Axle
Housing 4.5 (17) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 0.5 (2.0) JCB Special Gear Oil ESEN-M2C 86A/B
Rear Axle
Housing 4.7 (18) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 0.2 (0.75) JCB Special Gear Oil ESEN-M2C 86A/B
Hydraulic System †77.0 (292) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
JCB HP32 ISO 32
(Below 38 °C, 100 °F)
Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency
† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with
all rams closed. Watch level sight glass when filling.
Fuel Tank 90 (20) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Gearbox
Syncro Shuttle 18.25 (4.0) JCB Special Transmission Fluid ESP-M2C 33G
Powershift †15.0 (3.3) JCB Special Transmission Fluid ESP-M2C 33G
Front Axle
Housing 18 (3.9) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 2.0 (0.4) JCB Special Gear Oil ESEN-M2C 86A/B
Rear Axle
Housing 13 (2.8) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 2.0 (0.4) JCB Special Gear Oil ESEN-M2C 86A/B
Hydraulic Tank ††152 (34.5) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
JCB Special Hydraulic Fluid ISO VG32
(Below 38 °C, 100 °F)
Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency
†† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with
all rams closed. Watch level sight glass when filling.
† Note: This is a system capacity. Use the 'MIN' and 'MAX' marks on the dipstick when refilling the system.
* Note 1: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used.
Fill with all rams closed. Watch level sight glass when filling.
* Note 2: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR
intervals. All 500 hour greasing operations must be carried out at 50 HOUR intervals.
* Note 1: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill
with all rams closed.
* Note 2: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR
intervals. All 500 hour greasing operations must be carried out at 50 HOUR intervals.
* Fuel Tank 23.8 (90) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
* Axles
Housing 2.3 (8.8) JCB Special Gear Oil Plus API GL4
Hubs (x4) 0.47 (1.8) Must be suitable for use with oil
immersed brakes and limited slip
differentials (LSD).
* Hydraulic Tank †18.5 (70) JCB High Performance Hydraulic Oil ISO VG46
(Above 100 °F, 38 °C)
JCB Special Hydraulic Fluid ISO VG32
(Below 100 °F, 38 °C)
* † Notice: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all
rams closed. Watch level sight glass when filling.
* †† Notice: If JCB MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All
500 hour greasing operations must be carried out at 50 HOUR intervals.
Fuel Tank
160 35.2 42.2 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill
and check with all rams closed.
†† Note: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR
intervals. All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals
Fuel Tank 23.7 (90) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 2.6 (10) JCB 15W/40 Engine Oil SAE 15W/40
14°F to 122°F (-10°C to 50°C) API CF4/SG
Front Axle
Housing 4.7 (18) JCB Special High performance API GL4
Hubs (x2) 0.5 (2.0) Gear Oil MUST be suitable for use with
oil immersed brakes and limited-slip
Rear Axle differentials (LSD)
Housing 3.4 (13)
Hubs (x2) 0.5 (2.0)
Hydraulic Tank
506C, 506C †32.0 (121) JCB High Performance Hydraulic Oil ISO VG46
506C, 508C †48.0 (181) (Above 100 °F, 38 °C)
†Notice: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and
check with all cylinders closed. Watch level sight glass when filling.
IF JCB MPL-EP or MPL-Moly grease is used all 50 hour greasing operations must be carried out at 10 HOUR intervals, All
500 hour greasing operations must be carried out at 50 HOUR intervals.
520-50, 525-50
AA Engine Build
Fluids, Lubricants and Capacities
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently
run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first
100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB
10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to
the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended
below.
Fuel Tank 90 (20) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Axles
Housing (520-50) 4.0 (0.88) JCB High Performance JCB 4000/2200
Housing (525-50) 8.8 (1.94) Gear Oil Plus
Housing (525-52) 8.8 (1.94) Must be suitable for use with
Hubs (x4 - 520-50) 1.0 (0.22) oil immersed brakes and limited slip
Hubs (x4 - 525-50) 1.8 (0.4) differentials (LSD).
Hubs (x4 - 525-52) 1.8 (0.4)
Hydraulic Tank (†) 70 (15.4) JCB High Performance Hydraulic Fluid 46 ISO VG46
(Above 38°C, 100°F)
JCB High Performance Hydraulic Fluid 32 ISO VG32
(Below 38°C, 100°F)
†Note: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check
with all rams closed. Watch level sight glass when filling.
††Note: If JCB MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals; all 500
hour greasing operations must be carried out at 50 HOUR intervals.
Fuel Tank 90 (20) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Axles
Housing (520-50) 4.0 (0.88) JCB High Performance JCB 4000/2200
Housing (525-50) 8.8 (1.94) Gear Oil Plus
Housing (525-52) 8.8 (1.94) Must be suitable for use with
Hubs (x4 - 520-50) 1.0 (0.22) oil immersed brakes and limited slip
Hubs (x4 - 525-50) 1.8 (0.4) differentials (LSD).
Hubs (x4 - 525-52) 1.8 (0.4)
Hydraulic Tank (†) 70 (15.4) JCB High Performance Hydraulic Fluid 46 ISO VG46
(Above 38°C, 100°F)
JCB High Performance Hydraulic Fluid 32 ISO VG32
(Below 38°C, 100°F)
†Note: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check
with all rams closed. Watch level sight glass when filling.
††Note: If JCB MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals; all 500
hour greasing operations must be carried out at 50 HOUR intervals.
Notice: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently
run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first
100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB
10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to
the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended
below.
Fuel Tank 31.7 (120) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Transmission
Syncro Shuttle 4.4 (17) JCB Special Transmission Fluid ESP-M2C 33G
Powershift 4.0 (15.5)
Front Axle
Housing 2.3 (9) JCB Special Gear Oil Plus API GL4
Hubs (x2) 0.5 (2) Must be suitable for oil immersed
brakes and Limited Slip Differentials
Rear Axle (LSD).
Housing 2.2 (8.4)
Hubs (x2) 0.5 (2)
† Notice: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and
check with all cylinders closed.
†† Notice: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR
intervals; all 500 hour greasing operations must be carried out at 50 HOUR intervals.
Fuel Tank 125 27.5 30 Diesel Oil ASTM D975-66T Nos. 1D, 2D
NORTH AMERICA
2.6 JCB 15W/40 Engine Oil CF4/SG, SAE15W/40
14 °F to 122 °F (-10 °C to +50 °C)
JCB Engine Oil 10W CF4/SG, SAE10W
-4 °F to +50 °F (-20 °C to +10 °C)
Axles
Housing 18 3.9 JCB High Performance Gear Oil API GL4
Hubs (x4) 2.0 0.4
NORTH AMERICA
Housing 4.6 JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x4) 0.48
Braking System 3 0.7 0.8 JCB Light Hydraulic Fluid ISO VG15
DO NOT USE ORDINARY
BRAKE FLUID
Note 1: Wet fill capacity, eg. at fluid change 21 litres, dry fill capacity eg. after rebuild 23 litres.
Note 2: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check
with all rams closed.
Note 3: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals.
All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals.
Fuel Tank 125 27.5 30 Diesel Oil ASTM D975-66T Nos. 1D, 2D
NORTH AMERICA
2.6 JCB 15W/40 Multigrade SAE15W/40
14 °F to 122 °F (-10 °C to +50 °C) API CF4/SG
10W/30 Multigrade SAE10W/30
-4 °F to +50 °F (-20 °C to +10 °C) API CD/SE
JCB 10W SAE10W
-18 °C to 0 °C (0 °F to 32 °F) API CD/SE
Axles
Housing 18 3.9 JCB High Performance Gear Oil API GL4
Hubs (x4) 2.0 0.4
NORTH AMERICA
Housing 4.6 JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x4) 0.48
Braking System 3 0.7 0.8 JCB Light Hydraulic Fluid ISO VG15
DO NOT USE ORDINARY
BRAKE FLUID
Note 1: Wet fill capacity, eg. at fluid change 21 litres, dry fill capacity eg. after rebuild 23 litres.
Note 2: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check
with all rams closed.
Note 3: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals.
All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals.
9804/1103 20 - 00 - 01/17A 3630 - 3/1-2.6 Issue 1*
CONTENTS
Loadalls 20 - 00 - 01/17B
Fuel Tank 125 27.5 30 Diesel Oil ASTM D975-66T Nos. 1D, 2D
NORTH AMERICA
2.6 JCB 15W/40 Multigrade SAE15W/40
14 °F to 122 °F (-10 °C to +50 °C) API CF4/SG
10W/30 Multigrade SAE10W/30
-4 °F to +50 °F (-20 °C to +10 °C) API CD/SE
JCB 10W SAE10W
-18 °C to 0 °C (0 °F to 32 °F) API CD/SE
Axles
Housing 18 3.9 JCB High Performance Gear Oil API GL4
Hubs (x4) 2.0 0.4
NORTH AMERICA
Housing 4.6 JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x4) 0.48
Braking System 3 0.7 0.8 JCB Light Hydraulic Fluid ISO VG15
DO NOT USE ORDINARY
BRAKE FLUID
Note 1: Wet fill capacity, eg. at fluid change 21 litres, dry fill capacity eg. after rebuild 23 litres.
Note 2: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check
with all rams closed.
Note 3: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals.
All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals.
9804/1103 20 - 00 - 01/17B 3630 - 3/1-3.6 Issue 1*
CONTENTS
Loadalls 20 - 00 - 01/18
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently
run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first
100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB
10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to
the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended
below.
Fuel Tank 125 (27.5) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Hydraulic Tank (†) 131 (28.8) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
JCB Special Hydraulic Fluid ISO VG32
(Below 38 °C, 100 °F)
†Note: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check
with all rams closed.
††Note: If JCB MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals; all 500
hour greasing operations must be carried out at 50 HOUR intervals.
D K
B E
F
G
A122340
DESCRIPTION DIMENSION
A Overall height 2.59 m (8 ft 6 in) 2.57 m (8 ft 5 in) 2.59 m (8 ft 6 in) 2.57 m (8 ft 5 in)
B Overall width 2.34 m (7 ft 8 in) 2.35 m (7 ft 8 in) 2.34 m (7 ft 8 in) 2.35 m (7 ft 8 in)
F Overall length to front tyres 3.87 m (12 ft 8 in) 3.87 m (12 ft 8 in) 4.05 m (13 ft 3 in) 4.05 m (13 ft 3 in)
H Ground clearance 0.42 m (1 ft 5 in) 0.40 m (1 ft 4 in) 0.42 m (1 ft 5 in) 0.40 m (1 ft 4 in)
K Centre of gravity (unladen) 1.21 m (3 ft 11 in) 1.21 m (3 ft 11 in) 1.34 m (4 ft 3 in) 1.34 m (4 ft 3 in)
Weight (unladen) 6300 kg (13,860 lb) 6300 kg (13,860 lb) 6422 kg (14,128 lb) 6422 kg (14,128 lb)
K
J
D E
B F
G A198790
DESCRIPTION DIMENSION
D K
B E
F
G
*A122430
DESCRIPTION DIMENSION
Forklift Performance †
Lift capacity to full height 3000 kg (6,614 lb)
D E
B G
S140100
DESCRIPTION DIMENSION
D K
B E
F
G
A122340
DESCRIPTION DIMENSION
505-19 505-22
Weight (unladen) 13,960 lbs (6300 kg) 15,345 lbs (6960 kg)
D
E
B
F
G
S157670
DESCRIPTION DIMENSION
D Track 6 ft 3 in (1.90 m)
E Wheelbase 7 ft 10 in (2.38 m)
D E
B G
S141370
DESCRIPTION DIMENSION
D Track 6 ft 8 in (2.03 m)
E Wheelbase 9 ft 2 in (2.80 m)
D E
B G
S140100
DESCRIPTION DIMENSION
D Track 6 ft 3 in (1.90 m)
E Wheelbase 9 ft 2 in (2.80 m)
D E
B F
G A245130
DESCRIPTION DIMENSION
E Wheelbase 7 ft 5 in (2.25 m)
* Performance Dimensions †
Forklift Performance
Lift capacity to full height 4500 lb (2041 kg)
D E
B F
G
A195450
ø
DESCRIPTION DIMENSION DIMENSION DIMENSION
526-55 526 526S
F Overall length to front tyres 12 ft 51/2 in (3.80 m) 12 ft 91/2 in (3.90 m) 12 ft 91/2 in (3.90 m)
Weight (unladen) 12122 lb (5500 kg) 12171 lb (5520 kg) 12877 lb (5840 kg)
8020/192
* Performance Dimentional
Forklift Performance†
Lift capacity to full height 5730 lb (2600 kg)
D E
B G
S141370
DESCRIPTION DIMENSION
K Centre of gravity
(unladen, stabilisers raised) 1.28 m (4 ft 2 in)
H
K
D E
B F
G
A214860
DESCRIPTION DIMENSION
D K
B E
G
A234930
A Standard overall height 2120 mm (6ft 11in) 2190 mm (7ft 2in) 2250 mm (7ft 5in)
Low cab option 1985 mm (6ft 6in) 2055 mm (6ft 9in) 2115 mm (6ft 11in)
B Overall width 1800 mm (5ft 11in) 1820 mm (6ft 0in) 1880 mm (6ft 2in)
D Track 1530 mm (5ft 0in) 1490 mm (4ft 11in) 1490 mm (4ft 11in)
E Wheelbase 2000 mm (6ft 7in) 2000 mm (6ft 7in) 2000 mm (6ft 7in)
F Overall length to front tyres 3080 mm (10ft 1 in) 3130 mm (10ft 3in) 3130 mm (10ft 3in)
H Ground clearance 300 mm (1ft 0in) 360 mm (1ft 2in) 420 mm (1ft 4in)
K Centre of gravity (unladen) 1020 mm (3ft 9in) 1020 mm (3ft 9in) 1020 mm (3ft 9in)
Lift capacity to full height 2000 Kg (4,410 lb) 2500 Kg (5,511 lb) 2500 Kg (5,511 lb)
Lift capacity at maximum reach 700 Kg (1,543 lb) 1000 Kg (2,205 lb) 1000 Kg (2,205 lb)
Maximum lift height 5000 mm (16ft 4in) 5000 mm (16ft 4in) 5200 mm (17ft 1in)
Reach at maximum lift height 500 mm (1ft 6in) 500 mm (1ft 6in) 500 mm (1ft 6in)
Maximum forward reach 2820 mm (9ft 2 in) 2820 mm (9ft 2in) 2820 mm (9ft 2in)
Reach with 1 tonne load 2255 mm (7ft 3in) 2820 mm (9ft 2in) 2820 mm (9ft 2in)
Placing height, 2 tonne load 4600 mm (15ft 0in) 4600 mm (15ft 0in) 4600 mm (15ft 0in)
8170/152
† Based on 500 mm (20 in) Load Centre.
Bucket rated capacity 0.7 m3 (24 cu ft) 0.9 m3 (32 cu ft) 0.95 m3 (33 cu ft)
Maximum dump height at 45° bucket angle 4.07 m (13ft 3in) 4.11 m (13ft 6in) 4.17 m (13ft 8in)
8170/152
H
K
D E
B F
G
A264240
530 540
F Overall length to front tyres 4380 mm (14ft 4in) 4380 mm (14ft 4in)
A1 A2
W
15 H1 H2 X H3
115 K
D L E P
B F
M G
M A345760
T
S R1/R2
R3
U1/U2
R4
DIMENSION DIMENSION
Maximum lift capacity 3000 kg (6,615 lb) 3500 kg (7,716 lb) 4000 kg (8,818 lb)
Lift capacity to full height 2500 kg (5,512 lb) 1750 kg (3,858 lb) 3000 kg (6,614 lb)
Lift capacity at maximum reach 1250 kg (2,756 lb) 600 kg (1,323 lb) 1500 kg (3,307 lb)
Maximum lift height 7000 mm (22ft 9in) 9500 mm (31 ft 2 in) 7000 mm (22ft 8in)
Reach at maximum lift height 480 mm (1ft 6in) 2430 mm (7 ft 11 in) 480 mm (1ft 7in)
Maximum forward reach 3700mm (12ft 2in) 6520 mm (12 ft 2 in) 3700 mm (12ft 2in)
Reach with 1 tonne load 3700mm (12ft 2in) 5290 mm (17 ft 4 in) 3700 mm (12ft 2in)
H
D K
E
B
F
G
A264250
A Overall height 2580 mm (8ft 5in) 2580 mm (8ft 5in) 2590 mm (8ft 6in)
B Overall width 2350 mm (7ft 8in) 2350 mm (7ft 8in) 2350 mm (7ft 8in)
D Track 1900 mm (6ft 2in) 1900 mm (6ft 2in) 1900 mm (6ft 2in)
E Wheelbase 2750 mm (9ft 0in) 2900 mm (9ft 5in) 2900 mm (9ft 5in)
F Overall length to front tyres 4830 mm (15ft 10in) 5180 mm (17ft 0in) 5180 mm (17ft 0in)
H Ground clearance 390 mm (1ft 2in) 390 mm (1ft 2in) 400 mm (1ft 4in)
Weight (unladen) 9430 kg (20,793 lbs) 10,600 kg (23,373 lbs) 11,300 kg (24,912 lbs)
Lift capacity to full height 3200 kg (7,056 lb) 3700 kg (8158 lb) 4536 kg (10,000 lb)
Lift capacity at maximum reach 1250 kg (2,756 lb) 1500 kg (3,307 lb) 1134 kg (2,500 lb )
Maximum lift height 12000 mm (39ft 4 in) 13500 mm (44ft 3in) 13500 mm (44ft 3in)
Reach at maximum lift height 1450 mm (4ft 9 in) 1680 mm (5ft 5in) 1680 mm (5ft 6in)
Maximum forward reach 8010 mm (26ft 3in) 9250 mm (30ft 3in) 9250 mm (30ft 4in)
Reach with 1 tonne load 8010 mm (26ft 3in) 9250 mm (30ft 3in) -
D E
B G
A196390
DESCRIPTION DIMENSION
Weight (unladen) 21,040 lbs (9,540 kg) 22,150 lbs (10,069 kg) 25,225 lbs (11,440 kg)
Lift capacity to full height 6,000 lb (3000 kg) 6,000 lb (3000 kg) 8,000 lb (3628 kg)
Lift capacity at full reach 2,000 lb (900 kg) 1,500 lb (681 kg) 1,800 lb (816 kg)
H
D E
B F
G
A245130
DESCRIPTION DIMENSION
E Wheelbase 7 ft 7 in (2.33 m)
Performance Dimensions
Forklift Performance †
Lift capacity to full height 5730 lb (2600 kg)
528-70, 528S
Static Dimensions and Weights
H
D E
B F
G
A314940
528-70, 528S
Performance Dimensions
Forklift Performance † 528-70 528S
Lift capacity to full height 5292 lb (2400 kg) 5071 lb (2300 kg)
Lift capacity at full reach 2756 lb (1250 kg) 2756 lb (1250 kg)
Note: Lift capacity to full height is reduced to 5071 lb (2300 kg) for 528S machines fitted with 17.5LR24 tyres.
Light Bulbs
6 Panel illumination,
L.H. sidelights 7.5
7 R.H. sidelights,
number plate light,
one working light, 10
or above but with
two working lights 15
Note: Machines not fitted with road lights should not have fuses fitted at positions A7, A8, B8, B9, C1 and C2.
S112251
Non servo machines Basic servo machines (525-58, 525- 67, 505-19 & 505-22)
A
A
F F
B E B
E
C J C
D D
G
S167142
S167140
E
H D B
J
FC
G S167142
(All except 530-120 up to serial No. 572168, 530-120 up to (All except 530-120 from serial No. 572169, 530-120 from
serial No. 572242) serial No. 572243)
K
L
L K
N H
M
E J J E
H D
F
D C
F G
C B
B
G
A
A
S172170 S215940
A Steer mode printed circuit board A Steer mode printed circuit board
B Reverse alarm relay B Reverse alarm relay
C Buzzer relay C Buzzer relay
D Forward relay D Forward relay
E Flasher relay E Flasher relay
F Sidelights relay F Sidelights relay
G Hand brake warning relay G Hand brake warning relay
H Ignition relay H Ignition relay
J Parking brake relay J 4 Wheel drive/brake relay
K Neutral start relay K Neutral start relay
L Reverse relay L Reverse relay
M Transmission dump relay
N Diode gate
P
K
N H
M E
R
J F
D
C G
B Q S
S215930
The electrical circuits are protected by fuses. The fuses are located in a fuse box inside the door. They are in three rows,
labelled A, B and C. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one.
Note: The radio fuse may need to be replaced by one of a higher rating as specified in radio fitting instructions.
520-55, 526-55, 520-55RS (504B N.Am) From Machine Serial Number 277001 to 278965 (279014 504B)
Row A Row B Row C
526, 526S (526 N.Am) With Powershift Transmission From Machine Serial Number 278966 to 280576
526, 526S (526 N.Am) With Syncro Shuttle Transmission From Machine Serial Number 278966 to 280573
520-55, 520S From Machine Serial Number 278966 Onwards
Row A Row B Row C
Fuse Circuit Rating Fuse Circuit Rating Fuse Circuit Rating
Fuse links
Circuit Rating
1 Horn, Hazard warning lights, Beacon, Interior light 40
2 Road lights, Working lights 40
3 Not used
4 ESOS, Forward/reverse switch, Brake lights 40
5 Diverter valve, SLI, Heater, Wipers, Radio, Instruments 80
2
4 1
5
3
S245110
S192451
* Relay Identification
520-55, 526-55, 520-55RS (504B N.Am) From Machine Serial Number 277001 to 278965 (279014 504B)
1 Indicator relay 4 Side lights relay 7 Buzzer relay 10 Brake light relay
2 Forward relay 5 Parking brake relay 8 Reverse alarm relay 12/13 Starter relay
3 Reverse relay 6 Dump switch relay 9 Auxiliary solenoid relay 11/14 Neutral start relay
Note: Relays 13 and 14 can be fitted either way round, to identify them the Neutral Relay has an ‘I’ on it. On later machines
relay 13 is on the main board 12 and diode 15 is fitted in its place. Diode 15 links the handbrake warning light and transmission
dump to disconnect the drive when the handbrake is applied. Also, relay 14 is on the main board 12.
520-55, 520S, 526-55 From Machine Serial Number 278966 (279015 504B) onwards
1 Indicator relay 4 Side lights relay 7 Buzzer relay 10 Air conditioning relay
2 Forward relay 5 Parking brake relay 8 Spare 11 Neutral start relay
3 Reverse alarm relay 6 Dump switch relay 9 Spare 12 Starter relay
526, 526S (526 N.Am) From Machine Serial Number 280300 to 280576 (Powershift Transmission)
1 Indicator relay 4 Side lights relay 7 Buzzer relay 10 Air conditioning relay
2 Spare 5 Spare 8 Spare 11 Neutral start relay
3 Reverse relay 6 Spare 9 Auxiliary solenoid relay 12 Starter relay
526, 526S (526 N.Am) From Machine Serial Number 280300 to 280573 (Syncro Shuttle Transmission)
1 Indicator relay 4 Side lights relay 7 Buzzer relay 10 Air conditioning relay
2 Forward relay 5 Parking brake relay 8 Spare 11 Neutral start relay
3 Reverse alarm relay 6 Dump switch relay 9 Auxiliary solenoid relays 12 Starter relay
1 2 3
5 6
4
£ $
7 8 9
0 ! @
S192450
Relay Identification
Relays are used in the electrical circuits for a variety of reasons. The most usual application is to protect components like
switches etc. from being overloaded. A relatively small current (from the switch) energises the relay coil, this causes internal
contacts to open or close which controls a larger current in another circuit.
Although relays look similar, internally they can be different, for example, they can be single or double contact; normally closed
or open. Make sure you fit the correct type of relay, otherwise the machine electrical circuits will not function correctly. The
relays are identified as follows:
1 2 3 4
5 6 7 8
9 0 ! @
S239200
Note: The radio fuse may need to be replaced by one of a higher rating as specified in radio fitting instructions.
Fuse links
Circuit Rating
1 Starter relay 60 1
2 Tracker, Radio, Hazard lights, Wipers 30 3
3 Lights relay 40 2
4 Starter switch 30 5
5 Not used 80 4
S245110
S239200
Although relays look similar, internally they can be different, for example, they can be single or double contact; normally closed
or open. Make sure you fit the correct type of relay, otherwise the machine electrical circuits will not function correctly. The
relays are identified as follows:
1 2 3
5 6
4
£ $
7 8 9
0 ! @
S192450
The relay configuration for machines with powershift The relay configuration for machines with syncro shuttle
transmission is shown at A. transmission is shown at B.
1 4 7
2 58 0
3 6 9 ! @
1 4 7 0 £
2 5 8 ! $ ^
3 6 9 @ %
A282130
Fuse links
Circuit Rating
1 Horn, Hazard warning lights, Beacon, Interior light 40
2 Road lights, Working lights 40
3 Not used
4 ESOS, Forward/reverse switch, Brake lights 40
5 Diverter valve, SLI, Heater, Wipers, Radio, Instruments 80
2
4 1
5
3
S245110
S192451
1 Audible alarm
2 Reverse lights 2 56 !@ %^
3 Starter
4 Hazard warning lights
5 Side lights
6 Air conditioning 3 78 £$ &*
7 Sway isolation
8 Auxiliary change-over
9 Auxiliary A
10 Auxiliary B
11 -
12 -
13 Retract
14 Extend
15 -
16 2 Wheel drive brake
17 -
18 -
1 Audible alarm
2 Neutral start
3 Starter
4 Hazard warning lights A335670
5 Side lights
6 Air conditioning
7 Sway isolation NOTE: ECU deletion cut-in numbers are transmission
8 Auxiliary change-over dependant.
9 Auxiliary A
10 Auxiliary B Transmission Part Number Serial Number of cut-in
11 -
12 - 449/06100 770055
13 Retract 449/06200 770065
14 Extend 449/06300 770053
15 Reverse 449/06400 770069
16 2 Wheel drive brake 449/06500 770063
17 - 449/06600 770093
18 -
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
7 Hazard warning lights
8 Sidelights
9 Air conditioning
10 Forward relay
11 Reverse 1
12 Reverse 2
13 2 wheel drive brake
14 -
15 -
16 Auxiliary change-over
17 Sway isolation
18 Forward HI/LO
19 Reverse HI/LO
20 Drive
21 Driveshaft
22 Neutral
23 Dump
24 -
25 SRS relay
1 7 16 17
2 8 9 18 19
3 10 11 20 21
4 12 13 22 23
5 6 14 15 24 25
A335680
1 5
2 6 7 12 13
3 8 9 14 15
4 10 11 16 17
A372461
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
7 Hazard warning lights
8 Sidelights
9 Air conditioning
10 Auxiliary change-over 2
11 Auxiliary change-over
12 Forward relay
13 Reverse 1
14 Reverse 2
15 2 wheel drive brake
16 Auxiliary A
17 Auxiliary B
18 -
19 -
20 Retract
21 Extend
22 Forward HI/LO
23 Reverse HI/LO
24 Drive
25 Driveshaft
1
1 7
7 ^
16 &
17
2
2 8
8 9
9 *
18 (
19
3
3 0
10 !
11 ) 21
20 21
4
4 @
12 £
13 22 23
22 23
5
5 6
6 $
14 %
15 24
24 25
A335680
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
7 Hazard warning lights
8 Sidelights
9 Air conditioning
10 Forward relay
11 Reverse 1
12 Reverse 2
13 Two wheel drive brake relay
14 Auxiliary change-over
15 Sway isolation
16 Forward HI/LO
17 Reverse HI/LO
18 Drive
19 Driveshaft
2 7
3 8 9 14 15
4 10 11 16 17
5 6 12 13 18 19
360940
Fuse Identification
This illustration shows a typical fuse installation.
11 Starter relay 5
12 Engine shut-off solenoid (ESOS) 5
13 Steer mode selector 7.5
14 Powershift 15
15 2/4 Wheel drive selector 5
2/4 Wheel drive selector with trailer electrics (530) 10
16 Auxiliary socket 10
17 Brake lights 10
18 Rear work light 7.5 B A
19 Reverse lights, reverse alarm 7.5
20 BLANK
D
21
22
Right hand side lights
Left hand side lights
10
10
C
23 Dip beam lights 10 E
24 Main beam lights 10
25 Front working light 10 S245111
26 Rear fog light 5
27 BLANK Fuse Links S/N 767000 to 770053
28 Horn, Headlight flash 10
29 Warning beacon, Interior light, Radio 5 Circuit Rating
30 Hazard lights 15 A Horn, Hazard warning lights, Beacon,
Interior light 30
31 Smooth Ride System (if fitted) 5 B Road lights, Working lights 30
32 SPARE C Not used
33 SPARE D ESOS, Forward/reverse switch, Brake lights 40
34 Air suspension seat (if fitted) 15 E SLI, Heater, Wipers, Radio, Instruments 80
35 SPARE
36 BLANK Fuse Links S/N 770054 onwards
37 BLANK
38 BLANK Circuit Rating
39 BLANK A Horn, Hazard warning lights, Beacon,
40 BLANK Interior light 40
B Road lights, Working lights 40
C SLI, Heater, Wipers, Radio, Instruments 40
D ESOS, Forward/reverse switch, Brake lights 40
E Not used 80
1 Audible alarm
2 Reverse lights and alarm
3 Starter
4 Hazard warning lights
5 Side lights
6 Air conditioning
7 Sway isolation
8 Stabiliser isolation
9 Auxiliary A
10 Auxiliary B
11 -
12 -
13 -
14 -
15 -
16 2 Wheel drive brake
17 -
18 -
1 Audible alarm
2 Neutral start
3 Starter
4 Hazard warning lights
5 Side lights
6 Air conditioning Note: ECU deletion cut-in numbers are transmission
7 Sway isolation dependant.
8 Stabiliser isolation
9 Auxiliary A Transmission Part Number Serial Number of cut-in
10 Auxiliary B
11 Reverse 449/06100 770055
12 - 449/06200 770065
13 - 449/06300 770053
14 - 449/06400 770069
15 - 449/06500 770063
16 2 Wheel drive brake 449/06600 770093
17 -
18 -
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
7 Hazard warning lights
8 Sidelights
9 Air conditioning
10 Sway isolation
11 Stabilizer isolation
12 Forward relay
13 Reverse 1
14 Reverse 2
15 2 wheel drive brake
16 Auxiliary A
17 Auxiliary B
18 Auxiliary change-over 2
19 -
20 Forward HI/LO
21 Reverse HI/LO
22 Drive
23 Driveshaft
24 -
25 -
1
1 7
7 ^
16 &
17
3
3 0
10 !
11 )
20 (
21
4
4 @
12 £
13 22 23
22 23
5
5 6
6 $ 15 24 25
14 % 25
A343330
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
7 Hazard warning lights
8 Sidelights
9 Air conditioning
10 Sway isolation
11 Stabilizer isolation
12 Forward relay
1 13 Reverse 1
14 Reverse 2
15 2 wheel drive brake
2 7 16 Forward HI/LO
17 Drive
18 Reverse HI/LO
3 8 9 14 15 19 EMPTY
4 10 11 16 17
5 6 12 13 18 19
A361560
* 532/537/550
(from S/N 770959 onwards)
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
7 Hazard warning lights
8 Sidelights
9 Air conditioning
10 Sway isolation
11 Stabilizer isolation
12 Forward
13 Reverse
1 7
14 Reverse alarm/light
15 2 wheel drive/brakelights
16 EMPTY
2 8 9
17 Pump dump
18 Forward HI/LO
19 Reverse HI/LO
3 10 11 16 17 20 Drive
21 Driveshaft
4 12 13 18 19
5 6 14 15 20 21
A361561
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
7 Hazard warning lights
8 Sidelights
9 Air conditioning
10 Sway isolation
11 Stabilizer isolation
12 Forward relay
13 Reverse 1
14 Reverse Alarm/light
15 2 wheel drive/brake lights
16 Forward HI/LO
17 Reverse HI/LO
18 Drive relay
19 Driveshaft relay
20 EMPTY
21 EMPTY
22 Inner boom extend interlock (if fitted)
23 Lift isolation
24 Stabiliser lift unloader
25 Inner boom extend
1 Audible alarm
2 Neutral start
2 8 9 18 19 3 IGN Feed 1
4 IGN Feed 2
5 Dump
3 10 11 20 21 6 Parkbrake
7 Hazard warning lights
8 Sidelights
9 Air conditioning
4 12 13 22 23 10 Sway isolation
11 Stabiliser isolation
12 Forward relay
13 Reverse 1
5 6 14 15 24 25 14 Reverse alarm/light
15 2 wheel drive/brake lights
16 Left stabiliser
17 Right stabiliser
A361140 18 Forward HI/LO
19 Reverse HI/LO
20 Drive relay
21 Driveshaft relay
22 Extension boost
23 Lift isolation
24 Stabiliser lift unloader
25 Inner boom extend
Fuse Identification
This illustration shows a typical fuse installation.
CONTENTS
Loadalls 20 - 05 - 01/20
B E H K
C F J L M
1 11 21
2 12 22
3 13 23
4 14 24
5 15 25
6 16 26
7 17 27
8 18 28
9 19 29
10 20 30
321000
1 Indicators 7.5
2 Face level fan
Air conditioning compressor (if fitted) 10
3 Auxiliary 2
Hitch hydraulics (if fitted) 10
4 Heater 15
5 Windscreen washers & wipers 15
6 Safe Load Indicator/Load Moment Indicator 1
7 Instrument panel 5
8 Spare
9 Spare
10 Spare
1 Buzzer 1 Buzzer
2 Neutral star 2 Neutral start
3 Ignition 3 Ignition
4 Side lights 4 Side lights
5 Parking brake 5 Parking brake
6 Auxiliary 2 change over 6 Auxiliary 2 change over
7 Air conditioning 7 Air conditioning
8 Reverse alarm & light 8 Spare
9 Dump switch 9 Transmission dump
10 Reverse high/low 10 Flasher
11 Forward high/low 11 Forward
12 Drive 12 Reverse
13 Reverse
14 Forward
15 Driveshaft
16 Flasher
1 4 7
2 5 8 0
3 6 9 ! @
A
1 4 7 0 £
2 5 8 ! $ ^
3 6 9 @ %
A282130
S245110
A308110
CONTENTS
Loadalls 20 - 05 - 01/24
Location
F E
S167142
ROW A
Circuit Rating
1 Engine shut-off solenoid (ESOS) 5
2 Transmission 7.5
3 Spare (Max. 10A)
4 Heater 7.5
5 Washers, wipers & horn 15
6 Face fan 10
7 Instrument panel 5
8 Reverse alarm 5
9 Work lights 10
ROW B
Circuit Rating
1 Interior light, roof wiper, rear wiper & beacon 10
2 Ignition relay 1
Circuit Rating
Not used
525-58, 525-67, 527-67, 527-58, 530-67 & 535-67 From m/c no. 567362
Data - Hydraulics
Pump
Type Sundstrand SP/230/40, gear type
Flow at max. engine rev/min
— at zero pressure 88.0 litres/min 19.4 UK gal/min 23.2 US gal/min
— at system pressure 84.0 litres/min 18.5 UK gal/min 22.2 US gal/min
Control Valves
Type Kontak, parallel service, double acting spools.
Services Operated
— Spool 1 Boom Raise & Lower
— Spool 2 Boom Extend & Retract
— Spool 3 Auxiliary (see note)
— Spool 4 Carriage Tilt
— Spool 5 Auxiliary (see note)
— Spool 6 Auxiliary (see note)
Filter
Filter Type Partial flow ('spin on')
Filtration Size 25 microns (0.001 in)
Relief Valve Setting 0.17 bar
Suction Strainer 125 microns (0.005 in)
Fan Motor
Type Sundstrand TFU 200/8, gear type / Ultra 1MR 084C 8784
Max fan speed at Max engine rev/min 18 inch fan 20 inch fan
40° C ambient 46° C ambient 40° C ambient 46° C ambient
temp. zone temp. zone temp. zone temp. zone
NAT ASP engine 2100 2500
TURBO engine 2100 2100 2300 2600
Note: The function of spools 3, 5 & 6 (where fitted) will vary from machine to machine but may include the following: Hydraulic
Tow Hitch, Sway Control and Auxiliary Attachment Control.
Control Valves
Filter
Fan Motor
* Type Sundstrand TFU 200/8, gear type / Ultra 1MR 084C 8784
Max fan speed at Max engine rev/min 40° C ambient 46° C ambient
temp. zone temp. zone
NAT ASP engine 1800 2100
TURBO engine 1800 2100
Note: The function of spools 3, 5 (where fitted) will vary from machine to machine but may include the following: Hydraulic
Tow Hitch, and Auxiliary Attachment Control.
Control Valves
Filter
Fan Motor
* Type Sundstrand TFU 200/8, gear type / Ultra 1MR 084C 8784
Max fan speed at Max engine rev/min 40° C ambient 46° C ambient
temp. zone temp. zone
NAT ASP engine 1800 2100
TURBO engine 1800 2100
Control Valves
Filter
Fan Motor
* Type Sundstrand TFU 200/8, gear type or Ultra 1MR 084C 8784
Max fan speed at Max engine rev/min 40° C ambient 46° C ambient
temp. zone temp. zone
NAT ASP engine 1800 2500
TURBO engine 1800 2500
Control Valves
Filter
Fan Motor
Max fan speed at Max engine rev/min 18 inch fan 505-19 ONLY 20 inch fan
40° C ambient 46° C ambient 40° C ambient 46° C ambient
temp. zone temp. zone temp. zone temp. zone
NAT ASP engine 2100 2500
TURBO engine 2100 2100 2300 2600
Note: The function of spools 3, 5 & 6 (where fitted) will vary from machine to machine but may include the following: Hydraulic
Tow Hitch, Sway Control and Auxiliary Attachment Control.
Control Valves
Filter
Fan Motor
Max fan speed at Max engine rev/min 40° C ambient 46° C ambient
temp. zone temp. zone
NAT ASP engine 1800 2100
TURBO engine 1800 2100
Control Valves
Filter
Fan Motor
Max fan speed at Max engine rev/min 40° C ambient 46° C ambient
temp. zone temp. zone
TURBO engine 2300 2900
Pump
Control Valves
Filter
Fan Motor
Max fan speed at Max engine rev/min 40° C ambient 46° C ambient
temp. zone temp. zone
TURBO engine 2600 2900
Control Valves
Filter
Control Valves
Filter
Fan Motor
Max fan speed at Max engine rev/min 40° C ambient 46° C ambient
temp. zone temp. zone
NAT ASP engine 1800 2500
TURBO engine 1800 2500
Control Valves
Filter
Fan Motor
Max fan speed at Max engine rev/min 40° C ambient 46° C ambient
temp. zone temp. zone
NAT ASP engine 1800 2500
TURBO engine 1800 2500
Control Valves
Filter
Hydraulic Tank
530 Agricultural
Data - Hydraulics
* Triple Pump
* Control Valves
Services Operated
— Spool 1 Boom Raise & Lower
— Spool 2 Carriage Tilt
— Spool 3 Boom Extend & Retract (electro/servo operated)
— Spool 4 Auxiliary (electro/servo operated)
Filter
Hydraulic Tank
Fan Motor
Oil Flow 30.0 litres/min (6.6 UK gal/min) at 190 bar (2760 lbf/in2)
Max fan speed at Max engine rev/min 2200
† Machines with pick-up hitch. Since this ARV also controls the pressure to the boom auxiliary service, ensure that this
pressure will not cause damage to attachments used with the machine.
530 Construction
Data - Hydraulics
* Triple Pump
* Control Valves
Services Operated
— Spool 1 Boom Raise & Lower
— Spool 2 Boom Extend & Retract
— Spool 3 Carriage Tilt
— Spool 4 Auxiliary/Sway (electro/servo operated)
Filter
Hydraulic Tank
Fan Motor
Oil Flow 30.0 litres/min (6.6 UK gal/min) at 190 bar (2760 lbf/in2)
Max fan speed at Max engine rev/min 2200
† Machines with pick-up hitch. Since this ARV also controls the pressure to the boom auxiliary service, ensure that this
pressure will not cause damage to attachments used with the machine.
Control Valves
Services Operated
— Spool 1 Boom Raise & Lower
— Spool 2 Carriage Tilt
— Spool 3 Boom Extend & Retract (electro/servo operated)
— Spool 4 Auxiliary (electro/servo operated)
Filter
Hydraulic Tank
Fan Motor
Oil Flow 30.0 litres/min (6.6 UK gal/min) at 190 bar (2760 lbf/in2)
Max fan speed at Max engine rev/min 2200
† Machines with pick-up hitch. Since this ARV also controls the pressure to the boom auxiliary service, ensure that this
pressure will not cause damage to attachments used with the machine.
Control Valves
Services Operated
— Spool 1 Boom Raise & Lower
— Spool 2 Boom Extend & Retract
— Spool 3 Carriage Tilt
— Spool 4 Auxiliary/Sway (electro/servo operated)
Filter
Hydraulic Tank
Fan Motor
Oil Flow 30.0 litres/min (6.6 UK gal/min) at 190 bar (2760 lbf/in2)
Max fan speed at Max engine rev/min 2200
† Machines with pick-up hitch. Since this ARV also controls the pressure to the boom auxiliary service, ensure that this
pressure will not cause damage to attachments used with the machine.
Control Valves
Services Operated
— Spool 1 Boom Raise & Lower
— Spool 2 Boom Extend & Retract
— Spool 3 Carriage Tilt
— Spool 4 Auxiliary
Note: Since the auxiliary ARV also controls the pressure to the boom auxiliary service, ensure that this pressure will not cause
damage to attachments used with the machine.
Filter
Hydraulic Tank
Fan Motor
Oil Flow 30.0 litres/min (6.6 UK gal/min) at 190 bar (2760 lbf/in2)
Max fan speed at Max engine rev/min 2200
Control Valves
Services Operated
— Spool 1 Boom Raise & Lower
— Spool 2 Boom Extend & Retract
— Spool 3 Carriage Tilt
— Spool 4 Auxiliary/Sway (electro/servo operated from m/c no. 767001)
Unloader section
— Spool 5 Right Hand Stabiliser
— Spool 6 Left Hand Stabiliser
Filter
Hydraulic Tank
Fan Motor
Oil Flow 30.0 litres/min (6.6 gall/min) at 190 bar (2760 lbf/in2)
* Max fan speed at Max engine rev/min 2200 (to machine S/N 785165)
1800 nominal (from machine S/N 785166)
Control Valves
Services Operated
— Spool 1 Boom Raise & Lower
— Spool 2 Boom Extend & Retract
— Spool 3 Carriage Tilt
— Spool 4 Auxiliary/Sway (electro servo operated from m/c no. 767001)
Unloader section
— Spool 5 Right Hand Stabiliser
— Spool 6 Left Hand Stabiliser
Filter
Hydraulic Tank
Fan Motor
Oil Flow 30.0 litres/min (6.6 gall/min) at 190 bar (2760 lbf/in2)
* Max fan speed at Max engine rev/min 2200 (to machine S/N 785165)
1800 nominal (from machine S/N 785166)
Control Valves
Loading Pattern:
528-70 528S
— Spool 1 Auxiliary Mechanical Servo operated
— Spool 2 Boom Raise & Lower Mechanical Mechanical
— Spool 3 Carriage Tilt Mechanical Mechanical
— Spool 4 Boom Extend & Retract Mechanical Servo operated
Note: Spools 3 and 4 are reversed on 528-70 machines fitted with a placing control pattern.
Rams Weight Bore Rod Dia. Stroke Open centre Closed centre
kg mm in mm in mm in mm in mm in
Boom Lift 94 110 4.3 60 2.3 1163 45.7 2666 104.9 1503 59.1
Boom Extension 91 70 2.7 50 1.9 2300 90.5 4885 192.3 2585
101.7
Tilt Ram (528-70) 63 120 4.7 70 2.7 384 15.1 1126 44.3 742 29.2
Tilt Ram (528S) 71 130 5.1 75 2.9 334 13.1 1026 40.4 692 27.2
Displacement 30 70 2.7 40 1.5 750 29.5 1745 68.7 995 39.1
Filter
506B, 506C
Data - Hydraulics
Pump 506B 506C
Control Valves
Type Parallel service, double acting spools, except for sway, which is a
motor spool. On 506B extension spool is a half motor spool to
m/c no. 572655.
Services Operated
— Spool 1 Boom Raise & Lower Boom Raise & Lower
— Spool 2 Auxiliary Service Auxiliary Service
— Spool 3 Tilt Forwards and Backwards Tilt Forwards and Backwards
— Spool 4 Boom Extend and Retract Boom Extend and Retract
— Spool 5 Sway Sway
Relief Valve Operating Pressures bar kgf/cm2 lbf/in2 bar kgf/cm2 lbf/in2
Main Relief Valve (M.R.V.) 238 241 3450 238 241 3450
Filter
Filter Type Partial flow ('spin on') Partial flow ('spin on')
Filtration Size 25 microns (0.001 in) 25 microns (0.001 in)
Relief Valve Setting 1.05 bar 1.05 bar
Suction Strainer 125 microns (0.005 in) 125 microns (0.005 in)
Fan Motor
Type Gear type (8.4 cc/rev) 18 in. fan Gear type (15 cc/rev) 20 in. fan
Ambient temperature zone 40°C to 46°C 40°C to 46°C
Max fan speed at Max engine rev/min 2400 rev/min 2400 rev/min
Control Valves
Type Parallel service, double acting spools, except for sway which is a
motor spool.
Services Operated
— Spool 1 Boom Raise & Lower
— Spool 2 Auxiliary Service
— Spool 3 Tilt Forwards and Backwards
— Spool 4 Boom Extend and Retract
— Spool 5 Sway
Filter
Fan Motor
Triple Pump
Servo Operation
— Spool 1 Boom Raise & Lower
— Spool 2 Boom Extend & Retract
— Spool 3 Carriage Tilt
Manual Operation
— Spool 4 Auxiliary
— Spool 5 Right Hand Stabiliser
— Spool 6 Left Hand Stabiliser
Servo Operation
— Spool 1 Boom Raise & Lower
— Spool 2 Boom Extend
Filter
Hydraulic Tank
Fan Motor
Oil Flow 30.0 litres/min (6.6 UK gal/min) at 190 bar (2760 lbf/in2)
Max fan speed at Max engine rev/min 2200 rev/min
Fuel System AA Build (76 HP) AB (94.5 HP) Build AB (102 HP) Build
Cooling System
For further engine details see Engine Manual Publication No. 9806/0100
Induction System
Cooling System
For further engine details see Engine Manual Publication No. 9806/0100 (AA and AB Builds), 9806/2140 (AR and AK Builds).
Build Codes:
520-50, 525-50 AA 50550- naturally aspirated (76 HP)
AR 50690 - naturally aspirated, low emission (75 HP)
525-52 AK - turbocharged, low emission (100 HP)
Bore (nominal)
AA, AK builds 100mm (3.937 in)
AR builds 103mm (4.055 in)
Swept Volume
AA, AK builds 4 litres (243 in3)
Compression Ratio
AA builds 16.5:1
AR builds 17.25:1
AK builds 18.5:1
Induction System
Lubrication System
Cooling system
For further engine details see Engine Manual Publication No. 9806/0100 (AA builds), 9806/2140 (AR and AK builds).
Data - Engine
Type JCB diesel engine, 4 cylinder, water cooled
AA - 50590, naturally aspirated 76HP
AB - 50592, turbocharged 96HP
AB - 50645, turbocharged 106HP 85A Alternator
AB - 50591, turbocharged 106HP 65A Alternator
AR - 50659, naturally aspirated, 80HP
AK - 50667, turbocharged, 102HP 65A Alternator
AK - 50671, turbocharged, 102HP 85A Alternator
Bore (nominal):
AA, AB, AK Builds 100mm (3.937 in)
AR Builds 103 mm (4.055 in)
Swept Volume
AA, AB, AK Builds 4 litres (243 in3)
AR Builds 4.23 litres (258 in3)
Compression Ratio
AA, AB Builds 16.5 : 1
AR Builds 17.25 : 1
AK Builds 18.5 : 1
Injection System Details - refer to appropriate Engine Service Manual (see below)
Lubrication System
Oil Pump type Eccentric rotor
Oil Pressure (Hot) at maximum speed:
AA Builds 2.1 bar (30 lbf/in2)
AB, AK Builds 2.6 bar (40 lbf/in2)
AR Builds 2.0 bar (29 lbf/in2)
Cooling System
* Fan Speed 2200 rev/min (to machine S/N 785165)
1800 rev/min nominal (from machine S/N 785166)
Coolant Pressure 1 bar (14.5 lbf/in2)
Coolant Temperature (Normal) 80-85 °C (176-185 °F)
Temperature Warning Light operates at: 98 °C (208 °F)
For further engine details see Engine Service Manual, Publication No. 9806/0100 (AA and AB builds), 9806/2140 (AR and AK
builds).
Bore (nominal)
AA, AK builds 3.937 in (100mm)
AR builds 4.055 in (103mm)
Swept Volume
AA, AK builds 243 in3 (4 litres)
AR builds 258 in3 (4.23 litres)
Induction System
Air Cleaner Type 2 stage, dry element
Maximum Air Cleaner Restriction 635mm (25 in H2O)
Lubrication System
Oil Pump Type Eccentric rotor
Cooling system
Coolant Pressure 0.48 bar (7 lbf/in2)
Coolant Temperature (Normal) 80-85°C (176-185°F)
Temperature Warning Light operates at 98°C (208°F)
Fan Speed (506) 2400 rev/min
Fan Speed (506HL, 508) 2600 rev/min
For further engine details see Engine Manual Publication No. 9806/0100 (AA builds), 9806/2140 (AR and AK builds).
525-58/67, 527-58/67, 530-67/95 & 535-67, 505-19, 505-22 From m/c no. 567362
Data - Axles
FRONT AXLE
Type JCB Spiral bevel with epicyclic hub reduction
Weight (approximate) 490 kg (1100 lb)
Overall Gear Ratio 18.16:1 (Germany 13.7:1)
Crownwheel & Pinion Ratio 3.36:1 (Germany 2.54:1)
Hub Reduction 5.4:1
REAR AXLE
Type JCB Spiral bevel with epicyclic hub reduction
Weight (approximate) 352 kg (776 lb)
Overall Gear Ratio 23.625:1 (Germany 18.6:1)
Crownwheel and Pinion Ratio 4.38:1 (Germany 3.44:1)
Hub Reduction 5.4:1
Oscillation ± 9°
Castor Angle 2°
Camber Angle 2° Positive
King-pin Inclination Zero
Toe-in Zero
REAR AXLE
530-110, 506-36
FRONT AXLE
REAR AXLE
Data - Axles
* 520-55 RS Machines from m/c no. 277001
Front Axle
Type Rigid, 2 wet brake packs, standard or limited slip differential
Axle Reduction 10.667:1
Drop Box
Location Rear face of front axle, housing parking brake, 2/4 wheel disconnect (if fitted)
Reduction ratio 1.178:1
Rear Axle
Type Steer, non braked, standard or limited slip differential, hydraulic track rod
Axle Reduction 10.667:1
Steer angle 50° non adjustable
Toe in 0°
Drop Box
Location Rear face of front axle, housing parking brake, 2/4 wheel disconnect (if fitted)
Reduction ratio 1.178:1
Rear Axle
Type Steer, 2 wet brake packs, standard or limited slip differential, hydraulic track rod
Axle Reduction 10.667:1
Steer angle 40° non adjustable
Toe in 0°
Drop Box
Location Rear face of front axle, housing parking brake
Reduction ratio 1.545:1
Front Axle
Rear Axle
3610 - F/1-2.4
Front Axle
Drop Box
Rear Axle
528-70
528S
IMPORTANT: A different load chart is needed if the 17.5LR24 tyre is fitted as a replacement for the 15.5/80-24 tyre. Contact
your JCB Distributor for advice.
Note: If the tyres fitted to your machine are not listed, then contact your JCB Distributor for advice, DO NOT guess tyre
pressures.
Rear Axle
506B & 506C
Type JCB Spiral bevel with epicyclic hub reduction
Weight (approximate) 352 kg (776 lb)
Overall Gear Ratio 24.98:1
Crownwheel and Pinion Ratio 4.63:1
Hub Reduction 5.4:1
Oscillation ± 10°
Castor Angle 0°
Camber Angle 1°
King-pin Inclination Zero
Toe-in Zero
3610 - F/1-3.2
526S (526 N.Am) Front Rear
Size Ply Bar lbf/in2 Bar lbf/in2
15.5/80-24 10 3.0 44 3.0 44
17.5LR 24 - 3.0 44 3.0 44
Note Tires are not water/calcium chloride ballasted on 506C High Lift (HL) machines.
Syncro Shuttle Combined torque converter, reverser, and gearbox unit with integral
parking brake.
Weight (dry) 157 kg (345 lb)
Torque Converter Dia. 279mm (11in.)
Torque Multiplication at Stall 2.20:1
At 100 deg.C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
2000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
Cooler at 50 deg.C 1000 rev/min 10.4 - 13.6 2.8 - 3.6 2.3 - 3.0
2000 rev/min 14.5 - 20.0 3.8 - 5.3 3.2 - 4.4
Cooler at 100 deg.C 1000 rev/min 10.2 - 12.5 2.7 - 3.3 2.3 - 2.8
2000 rev/min 22.7 - 26.1 6.0 - 6.9 5.0 - 5.7
Pump at 50 deg.C 1000 rev/min 11.0 - 15.0 2.9 - 4.0 2.5 - 3.3
2000 rev/min 22.5 - 29.5 6.0 - 7.8 5.0 - 6.5
* Torque Converter Colour Code Identification 2.20:1 Ratio 2.40:1 Ratio 2.80:1 Ratio
Colour Coded Dots 2 (506/508-1) 2 Orange 3 Brown
Purple 1 (506/508-2)
1 White Green
Pump at 50 deg.C 1000 rev/min 11.0 - 15.0 2.9 - 4.0 2.5 - 3.3
2000 rev/min 22.5 - 29.5 6.0 - 7.8 5.0 - 6.5
The following clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2):
* Note 1: For brand new gearboxes (i.e. under 100 hours service) or gear boxes that have been fully serviced the pressures will
be slightly higher by approximately 0.7 - 1.0 bar (10 - 15 lbf/in2) than those shown.
* Note 2: Using 2nd and 3rd gears in forward and reverse drive will ensure that ALL clutches are energised during the stall test -
refer to 'Torque Converter Stall Test'.
Syncro Shuttle
Combined torque converter, reverser, and gearbox unit
Stall Speeds AA/AR Builds (Nat Asp) AK Build (Turbo) 506, 508 AA/AB Builds
*
Hydraulic only 2290 rev/min 2296 rev/min 1650-1750/1830-1930
Converter only 2000 rev/min 2156 rev/min
Hydraulics and Converter 1589 rev/min 1815 rev/min
At 100 deg.C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
2000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
Cooler at 50 deg. C 1000 rev/min 10.4 - 13.6 2.8 - 3.6 2.3 - 3.0
2000 rev/min 14.5 - 20.0 3.8 - 5.3 3.2 - 4.4
At 100 deg.C 1000 rev/min 10.2 - 12.5 2.7 - 3.3 2.3 - 2.8
2000 rev/min 22.7 - 26.1 6.0 - 6.9 5.0 - 5.7
Pump at 50 deg. C 1000 rev/min 11.0 - 15.0 2.9 - 4.0 2.5 - 3.3
2000 rev/min 22.5 - 29.5 6.0 - 7.8 5.0 - 6.5
4 Speed 5 Speed
Torque Converter Dia. 279mm (11in) 310mm (12.2in)
Torque Converter 2.20:1 Ratio 2.24:1 Ratio
Colour Coded Dots 2 purple/1 White 2 Blue
Pump at 50 deg.C 1000 rev/min 11.0 - 15.0 2.9 - 4.0 2.5 - 3.3
2000 rev/min 22.5 - 29.5 6.0 - 7.8 5.0 - 6.5
All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2).
Note: For new gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be
slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2 ).
Rear Axle
* The figures given below apply to ‘bedded-in’ engines. ie. engines that have done a minimum of 250 working hours, therefore
they should not be used for pre-delivery inspection (PDI) checks. They are intended to be used as guideline figures only and
should not be considered as servicing parameters.
* Combined Stall
106 hp Turbo (rpm) 1205 ±100 -
76 hp NA (rpm) 855 ±100 -
102 hp Turbo (rpm) - 1490 ±100
80 hp NA (rpm) - 960 ±100
Note: Combined stall tests are performed with the crowd service operated until the relief valve lifts.
*
3660 - F/1-3.1
Rear Axle
Hydraulic Stall
102 hp Turbo (rpm) 2280
80 hp NA (rpm) TBA
Combined Stall
102 hp Turbo (rpm) 1620
80 hp NA (rpm) TBA
Note: Combined stall tests are performed with the crowd service operated until the relief valve is
3630 - F/1-3.4
525-58/67, 527-58/67, 530-67 & 535-67, 505-19/22 From m/c no. 567362
Data - Brakes
Service Brake
Master Cylinder
Parking Brake
Master Cylinder
Parking Brake
Friction Plates ( front axle 5 per brake pack and rear axle 3 per brake pack)
Outside Diameter 220 mm (8.66 in)
Inside Diameter 180 mm (7.10 in)
Nominal Facing Area 12616 mm2 (19.3 in2)
Hydraulic Piston Diameter 216 mm (8.5 in)
Master Cylinder
Servo Unit
Exhauster
Parking Brake
Master Cylinder
Number of Cylinders 1
Type Frenos compensated master cylinder
Stroke 36 mm (1.4 in)
Bore 19.05 mm (0.75 in)
Parking Brake
3610-G/1-1.5
Master Cylinder
Number of Cylinders 1
Type Frenos
Stroke 35 mm (1.4 in)
Bore 25.4 (1.0 in)
Parking Brake
Data - Brakes
Service Brakes
Parking Brake
3620 - G/1-1.2
526-55, 526, 526S & 520-55 4 Wheel Steer From m/c no. 2768611
Data - Brakes
Service Brakes
Type JCB oil-immersed multi-plate disc high pressure brakes with hydraulic
accumulators for emergency application.
Actuation Hydraulic ON, spring OFF.
Location Front Axle (2 Brake Packs), Rear Axle (2 Brake Packs)
Accumulator Pressure 25 bar (363 lbf/in2).
Brake Circuit Operating Pressure
Cut-in 90 bar (1305 lbf/in2).
Cut-out 110 bar (1595 lbf/in2).
Parking Brake
Service Brakes
Master Cylinder
Servo Unit
Service Brakes
Parking Brake
General Description
The service brakes act on the front axle half shafts of all machines. The brakes are oil immersed, multi-disc types which are
operated hydraulically by a single pedal and master cylinder arrangement.
The brake cylinder reservoir is situated in front of the instrument panel in the cab.
The cable operated parking brake acts on a disc which is mounted on the gearbox output shaft to the front axle.
* Master Cylinder
* Servo Unit
Master Cylinder
Parking Brake
Note: The outer section of the pump (furthest from the timing case) drives the steering system. The inner section (nearest the
timing case) drives the engine cooling fan.
Single Priority Steer/Fan Pump (For 527-58, 527-67, 535-67 from machine serial No. 574296 only)
Control Unit
(525-58, 67, 527-58, 67, 530-67, 535-67, 530-95, 110) Danfoss Orbitrol OSPV 160
(530-120) Danfoss Orbitrol OSPB 200
Relief Valve Pressure 138 bar 2000 lbf/in2
With priority steer/fan pump (527-58, 67, 535-67) Danfoss Orbitrol OSPC 160
Relief Valve Pressure 175 bar 2537.5 lbf/in2
Note: 530-120 & 537-120, 130 machines from Serial Number 574481, the rams are supplied by an alternative source. The
rams must all be the same type, DO NOT mix rams on a machine. The seal kits are also different.
3610-H/1-1.3
System Type Fully hydraulic load sensing with selectable 2-wheel, 4-wheel and
crab steer modes. Anti-cavitation valve on 540-170 and 5508
machines. On other machines, the anti-cavitation valve was
discontinued from Serial No. 773135
Pump Gear type (19cc/rev) with load sensing priority flow divider delivering
41 litres/min (9 UK Gal/min, 10.8 US Gal/min)
Steering Valve
System Type Full power hydrostatic, powered track rod on rear axle
Pump (see Data - Hydraulics)
Control Unit Type OSPC 125LS
Relief Valve Operating Pressure 175 bar (178 kgf/cm2; 2500 lbf/in2)
Shock Relief Valve Operating Pressure 235 bar (239 kgf/cm2; 3407 lbf/in2)
Powered Track Rod 3620-H/1-1.1
Stroke for each side 130 mm (5.11 in)
Data - Steering
System Type Full power hydrostatic with selectable 2, 4 and crab steer
530 Powered track rod on rear of axles
532, 537 Steer rams on rear of axles
System Type Fully hydraulic load sensing with optional 2-wheel, 4-wheel and crab
steer modes. Powered trackrods on both axles.
Pump Gear type (36 cc/rev) with load sensing priority flow divider.
Relief Valve Operating Pressure 175 bar (178 kgf/cm2; 2500 lbf/in2)
Shock Relief Valve Operating Pressure 235 bar (239 kgf/cm2; 3407 lbf/in2)
System Type Fully hydraulic load sensing with selectable 2-wheel, 4-wheel and
crab steer modes. Anti-cavitation valve on Machines to Serial No.
773053.
Pump Gear type (19cc/rev) with load sensing priority flow divider delivering
41 litres/min (9 UK Gal/min, 10.8 US Gal/min)
Pump Gear type (19cc/rev) with load sensing priority flow divider delivering
41 litres/min (9 UK Gal/min, 10.8 US Gal/min)
506B
Tandem Steer/Fan Pump - Steer Section
Note: The outer section of the pump (furthest from the timing case) drives the steering system. The inner section (nearest the
timing case) drives the engine cooling fan.
Control Unit
Ram Dimensions
Bore 50 mm (1.97 in)
Rod Dia. 25 mm (0.98 in)
Stroke 205.4 mm (8 in)
506C
Note: Hydraulic pressure supply from priority valve in main hydraulic circuit.
Control Unit
Ram Dimensions
Bore 50 mm (1.97 in)
Rod Dia. 25 mm (0.98 in)
Stroke 205.4 mm (8 in)
Note: The outer section of the pump (furthest from the timing case) drives the steering system. The inner section (nearest the
timing case) drives the engine cooling fan.
Control Unit
Ram Dimensions
Bore 60 mm (2.36 in)
Rod Dia. 30 mm (1.18 in)
Stroke 209.5 mm (8.25 in)
48 48 A
600
46
24 37
47 49 51 53
17 27 26
5 11 44 45 59 60
202 204 205 208 54
N
G/Y
U 50 52
415 811 812 815
414A 403 405 408 409
414 55
413A 814 203 34
413 839 841 402 404 406
2 414B 21
412
413B 801 42 43
407 56
416 400 600 206
N G/Y U
805 806 807
803
808A 809
20 23
31 803A
16 802 401
3 103A
30
810
25 19
9 207
808 39
800
- 101 411 200
1
+ 003
6 105 106A
100
300 61
15 103 104
800
100 106
200 842
A1 A2 A4 A5 A6 A7 A8 A9 B1 B2 004
200
103
000 000
4
000R 000R
200 200
004
842
A215190
48 48 48
600
66 69
216 229 234
220 219 78
73 225 226 227 231 232 233
235
217 67 221
78B
78C 78D
230
65 78E 78F
218 818 835 838
829P 834 837
63 78A
301
831
847 99
B9 C1
62
816 72 821 823 848 829 830 B8 C2
822 826 824 825 86
844
817
68 77 B6 B7
112
828
833 836
410
83
71B 79 222 223 224
820
76
88
75 819
93
855
106D 827
71 80 81 82 832
110
108 109
87
B3 B4 B5 C4
103
000
000R
200
A215200
WIRING DIAGRAM
(All 527, 535 machines; 525-58/67, 530-95/110 from Serial No. 572168; 530-120 from Serial No. 572242)
* For SLI system circuit for machines from serial No. 576404 and 537-120/130 see page 20-15-01/11
Note: Item A is Syncro Shuttle option. For Powershift option see page 10/10-14.
Note: For machines without road lights a link is fitted (as shown) in place of Working Light Switch 86 and switch 87 operates
the Working Lights.
48
600
37
11 12
47 49 51 53
17 27
5 44 45
102 104 105 108 54
24 50 52
26 59 60
850 851
10 811 812 403 405
55
103 805 806 34 815
402 404 406
2 412
801 814 42 43
407 56
21 106
415
414 807
400
413
110 112 114
32 57 58
23 841
36 40 842 41
853
109 111 113 115
839 840
19 808A 809 401
116 16 31 804
9 20 802 803
3 30 810
101 25 808 39
800
- 114
107 106
411 200
1 15
113
+ 003
6 105 13
300 61
135
104
813
102 107
46
100
103
200 842 106
A1 A2 A3 A4 A6 A7 A8 A9 B1 B2
200
004
004
842
102 102
829 829
103 103
A190160
48 48 48
600 600
128
66 835 838
844 834 837
816
831
301
849
86 99
829 830
100 68 101
119 130
B9 C1
118 855
B8 C2
71 B6 B7
112
828
833 836
83
88
108
93
827
87 832 110
136
B3 B4 B5 C3 C4
000
001
200
102
829
103
A190170
48
600
37
11 12
47 102 49 51 53
17 27
5 44 45
202 203 204 205 208 54
24 50 52
26 59 60
850 851
10 811 812 403 405
55
805 806 34
402 404 406 408
2 42 43 412
814 815
407 56 409
21 106
415A
414 807
400
413
210 212 214
23 32 107
57 58
841
36 40 842 41
853 209 211 213 215
839 840
19 809 401
801
216 16 31 804
9 20 802 803
3 30 810
101 25 808 39
800
- 114
207 106
411 200
1 15
+ 003 46
6 105
300 61
235
104
13
102
100
103
200 842 106
A1 A2 A3 A4 A6 A7 A8 A9 B1 B2
200
004
810
004
842
102 102
829 829
103 103
A215620
Colour Code
B Black R Red
B/W Black/White S Slate
G Green W/K White/Pink
Note: On the 526-55 machines Warning lamp 209 also indicates Low Brake Pressure.
48 48 48
600 600
228
66 835 838
844 834 837 99D
816
- + - +
831
301
849
86
820 819 829 830
100 68 101
219 230
B S S S S W/K
B9 C1
218 855
B8 C2 18 17 14 13 8 7 3
99A
71 B6 B7
828 18 17 14 13 8 7 3
99B
833 836
83
B R
112 115
B/W
B
88 G S
99C
108
93
827
103 104
87 832 110
99
236
810
B3 B4 C3 C4 C5
810
000
001
200
102
829
103
A215630
8 10 12
7 9 11
221 37 208
858 860 859
46 47
220 73 219 857 811 812
5 4 3
807
815
C9
816 818
2
865 862
863
863
71B 862
6 1 41
40 871 852
39
810
107
852 401
71 14
100
2 3
1 4 107
B4 13 B1 B2
108
000
000R
200
004
A215210
842
600
600
11
9
N
G/Y
414A
414
413A
413
414B
413 413B
414
N G/Y
10
10
101
9
101
A2
A221890
A2
A215191
Colour Code
B Black R Red
B/W Black/White S Slate
G Green W/K White/Pink
Note: On the 526-55 machines Warning lamp 109 also indicates Low Brake Pressure.
23
601
600
12 14 17 19 26 108 35 37 38 40 42 43
102 103 30 34
104 105 25 39 41
4 7 20 44
850 851 839 400 805 806 105 807 811 812 815 200
402 403 404 405 406 407
27 29 33 36
10
2
414
106 A6
401
110 112 114
5 413
16 24
109 111 113 115
9 808 810 004 842 809 107
22
800 801 840 841 802 803 804
28
18 21
1 11 15 107 31
8 100 13 32
101
411
200 842 003 200 101 104 003 107
114 102
45
110
3
A1 B1 A9 B3 B5 C7 C6 A2 A4 B8
6
000R
001
810
200H
200G
829
100A
110
883
A248190
23
600 600
75
67
409 408 301 849 854 844 816
52 55 129
63 74
117 118
47 49 60
C2 C1 C3 C4
112
121 122 828
57 833 836
62
108 819 820
66 73
58 59 65
827
832 115
103 829
106 810
130
B6 C5 B2 B7 B4
64
000R
102
810
200H
200G
829
100A
110
883
A248200
526-55, 526, 526 N.Am 526S From m/c no. 280300 to 280576
(fitted with Powershift ECU gearbox control)
Circuit Diagrams - Electrical
Component Key
Component Key
Item Description
Page 20-15-01/16 53A L.H. Side Light - Front
1 Battery
2 Starter Motor 53B L.H. Indicator - Front
3 Starter Solenoid 54A L.H. Side Light - Rear
4 Fusible Links 1 54B L.H. Side Indicator - Rear
5 Thermostart 55A L.H. Dip Beam
6 Ignition Switch 55B L.H. Main Beam
7 Neutral Start Relay 56A R.H. Dip Beam
8 Fusible Link 2 56B R.H. Main Beam
9 Ignition Solenoid 56C R.H. Side Light - Front
10 Engine Shut Off Solenoid (ESOS) 56D R.H. Indicator - Front
11 Reverse Light 57 Column Switch
12 Reverse Alarm 57A Dip/Main Beam Switch
13 Reverse Light/Alarm Relay 57B Indicator Switch
14 Auxiliary Solenoid 57C Wiper Switch
15 Auxiliary Relay 57D Washer Switch
16 Hydraulic Hitch Solenoid 58 Washer Pump
Page 20-15-01/20
17 Hydraulic Hitch Switch 59 L.H. Brake Lights
18 Load Indicator Transducer 60 R.H. Brake Lights
19 Load Indicator 61 Brake Lights - Switch
Page 20-15-01/17
20 Heater Switch 62 Hazard Switch
21 Face Fan 63 Flasher Relay
23 Air Conditioning Compressor Clutch (if fitted) 64 Trailer Indicator - Cab Warning LIght
24 Air Conditioning Relay (if fitted) 65 Diode
25 Air Conditioning Switch (if fitted) 66A R.H. Indicator - Front
26 Heater Fan 66B R.H. Side Light
28 Receiver Drier Switch (if fitted) 67 Column Switch
29 Roof Wiper 67A Forward/Reverse Switch
30 Roof Wiper Switch 67B Transmission Switch
31 Front Wiper 67C Horn Switch
32 Rear Wiper 68 Horn
33 Interior Light 69 Park Brake Switch
34 Beacon Switch 70 Transmission ECU - Input Signal Connectors
35 Beacon 71 Transmission ECU - Output Signal
36 Radio Power Connectors
Page 20-15-01/18 Page 20-15-01/21
37 Buzzer 72 Transmission Oil Pressure Switch
38 Instrument Panel 73 Transmission ECU Test Point
39 Air Filter Switch 74 Speed Sensor
40 Engine Oil Pressure Switch 75 Mainshaft Solenoid
41 Transmission Oil Temperature Switch 76 Layshaft Solenoid
42 Water Temperature Switch 77 Forward High Solenoid
43 Alternator 78 Forward Low Solenoid
44 Fuel Sender 79 Reverse HI/LOW Relay
45 Water Temperature Sender 79 Reverse High Solenoid
46 Rear Axle Alignment Indicator Light 80 Reverse Low Solenoid
* 47 Front Axle Alignment Indicator Light 81A Work Light
48 Front Proximity Axle Switch 81B Work Light
49 Rear Proximity Axle Switch 84 Number Plate Light
50A Trailer Socket - L.H. Indicator Pin 85 Joy Stick Control (if fitted)
50B Trailer Socket - R.H. Indicator Pin 86 Diode Pack (if fitted)
50C Trailer Socket - Side Light Pin 87 Valve Block Solenoid (if fitted)
50D Trailer Socket - Brake Light Pin 88 Valve Block Solenoid (if fitted)
Page 20-15-01/19 89 Valve Block Solenoid (if fitted)
51 Side Lights Relay
52 Road Lights - Switch 90 Valve Block Solenoid (if fitted)
91 Joystick Isolation Switch (if fitted)
1 -
+
3
5
6
7
4
8
FA1 9
10
FA2
FA3
FA4
FA5
13
11
FA6
FA7
12
FA8
15
14
FA9
16
17
18
19
FB1
FB2
A282270
PHB3
20
21
PHB4
24
25
23
26
28
PHB5
30
29
31
32
33
PHB6
34
35
PHB6
36
A282280
37
PHB8
38
39
40
41
42
43
44
45
46
47
48
49
A282290
50A
50B
PHB9
PHC1
51
52
53A
PHC2
50C
53B
54A
54B
55A
PHC3
55B
56A
PHC4
56B
56C
56D
57
57A
57B
57C
57D
58
A282300
50D
59
61
PHC5
60
PHC6
PHC7
62
63
PHC8
65
64
PHC9
66A
66B
67
67A
R
F
67B
67C
68
69
70
71
A282310
72
73
74
75
76
77
78
79
80
81A
83
81B
84
86
85
87
88
89
A282320
90
91
* Component Key
Sheet 1
Item Description
1 Battery isolator
2 Battery
3 Fuse links
4 Starter motor
5 Starter solenoid
6 Key switch
7 Thermostart
8 Neutral start relay
9 Fuse link
10 Ignition relay
11 Sender unit
11A Cold start advance unit (see Note 1)
12 Engine shut-off solenoid (ESOS)
13 Rear work light
14 Rear work light switch
15 Front work lights
16 Front worklights switch
17 Brake lights
18 Brake light switch
19 Trailer brake lights connector
20 Reverse alarm
21 Reverse light
22 Parkbrake switch
23 Parkbrake relay
24 Front axle alignment lamp
25 Front axle proximity switch
26 Rear axle alignment lamp
27 Rear axle proximity switch
28 Radio
29 Load Moment Indicator (LMI) transducer
30 Load Moment Indicator (LMI)
31 Instrument panel
32 Warning buzzer
33 Air filter blocked switch
34 Engine oil pressure switch
35 Transmission oil temperature switch
36 Transmission oil pressure switch
37 Water temperature switch
38 Fuel gauge sender
39 Water temperature sender
40 Alternator
F10
F9
33 34 35 36 37
F8
F7
32
31
F6
29
30
28
F29
27
26
24
25
22
23
20 21
F17
19
18
F16
17
F20
16
F19
15
F18
13
14
F15
12 F12
11A
11
F11
10
9
CONTENTS
7
7
5
4
2
1
3
9804/1103 20 - 15 - 01/23 3610 - C/41-18.2 Issue 3*
Loadalls 20 - 15 - 01/24
526, 526S From m/c no. 280300
520-55 (From m/c no. 281847
* (fitted with Syncro Shuttle Transmission)
Circuit Diagrams - Electrical (cont’d)
79
F4
78
77
76
75
74
73
F2
71
72
F28
70
69
F1
67
68
66
F30
65
63
64
F5
62 61
F27
60
F26
F24
57 58
59
F25
55 56
F21
54
F23
53
52
51
50
49
48
47
44 46
F22
CONTENTS
45
43
42
41
9804/1103 20 - 15 - 01/24 3610 - C/41-19.2 Issue 3*
CONTENTS
Loadalls 20 - 15 - 01/25
* Component Key
Sheet 2
Item Description
* Component Key
Sheet 3
Item Description
93 Extend solenoid
94 Auxiliary solenoid
95 Retract solenoid
96 Single lever control joystick
97 Diodes
98 Transmission dump switch (joystick)
99 Auxiliary solenoid
100 Lever isolation switch & auxiliary solenoid
100
99 F14
98
95
94
96
97
93
SLC
92
91
90
89
88
87
F3
86
84
85
83
82
81
80
F13
Item Description
1 Battery isolator
2 Battery
3 Fuse links
4 Starter motor
5 Starter solenoid
6 Key switch
7 Thermostart
8 Neutral start relay
9 Ignition relay
10 Fuse link
11 Sender unit
11A Cold start advance unit (see Note 1)
12 Engine shut-off solenoid (ESOS)
13 Rear work light
14 Rear work light switch
15 Front work lights
16 Front worklights switch
17 Brake lights
18 Brake light switch
19 Trailer brake lights connector
20 Reverse alarm
21 Reverse light
22 Reverse 2 relay
23 Parkbrake switch
24 Parkbrake relay
25 Front axle alignment lamp
26 Front axle proximity switch
27 Rear axle alignment lamp
28 Rear axle proximity switch
29 Radio
30 Load Moment Indicator (LMI)
31 Load Moment Indicator (LMI) transducer
32 Instrument panel
33 Warning buzzer
34 Air filter blocked switch
35 Engine oil pressure switch
36 Transmission oil temperature switch
37 Transmission oil pressure switch
38 Water temperature switch
39 Fuel gauge sender
40 Water temperature sender
41 Alternator
41
39 40
F10
F9
34 35 36 37 38
F8
F7
33
32
31
30
29
F29
28
27
26
25
24
23
21
22
F17
20
19
18
F16
17
16
F20
F19
15
F18
13
F15
12
14
F12
11A
11
F11
10
8
7
6
5
4
1
* Component Key
Sheet 2
Item Description
80
F4
79
78
77
75
76
74
F2
72
73
F28
71
70
F1
69
68
67
F30
66
65
64
F5
63
62
61
F27
F26
F24
59
60
F25
56 57 58
F21
55
F23
54
53
51
50
52
49
48
47
F22
45
46
44
43
42
* Component Key
Sheet 3
Item Description
109
108
F14
106
104
103
105
107
102
SLC
101
100
99
98
97
96
F3
95
93
94
92
90
91
89
88
87
86
84
85
83
82
81
F13
14E
14F
72
73
74
75
76
77
78
22
79
79A
80
81
A282250
83 84 86 87
82 82A 85 85A
A282260
The complete electrical circuit is shown on pages 20-15-01/38 and 20-15-01/39. Fuses are numbered as shown on the fuse
box in the cab.
Item Description
1 Fuse links
2 Battery
3 Battery isolator
4 Starter motor solenoid
5 Starter motor
6 Ignition switch
7 Thermostart
8 Ignition relay
9 Safe Load Indicator (SLI)
10 Auxiliary change-over switch
10A Auxiliary solenoid
11 Face level fan
12 Heater switch
13 Heater motor
14 Hazard warning light switch
15 Indicator relay
16 Left hand indicators
17 Indicator switch
18 Indicator warning lamp
11 13 16 19 20 22 23 27 29 31
10A 21
5 7
3
26 28 30
18
F17
9 25
15 17
4
14 24
2 12
8 10
1 32
F10
F11
F30
F12
F13
F7
F1
F3
F2
F4
54 55 57 62 65 66 67 68 70 71 73 76
59
35 36 37 38 39 41 42 52
43 48 49
50 56
45
F23
F21
F24
F22
47
Water Gauge
Fuel Gauge
Handbrake
64
F25
Hourmeter
33
Tacho
46
72 75
63
51
44 58
53
61 69 74
60
34
40
F18
F14
F19
F20
F29
F28
F26
F27
F8
F6
Item Description
33 Instrument panel
34 Buzzer
35 Air filter switch
36 Oil pressure switch
37 Transmission oil temperature switch
38 Transmission oil pressure switch
39 Water temperature switch
40 Alternator
41 Water temperature sender
42 Fuel sender
43 Washer pump
44 Wash/wipe switch
45 Front wiper
46 Roof wiper warning lamp
47 Roof wiper
48 Rear wiper
49 Radio
50 Interior light
51 Rotating beacon switch
52 Rotating beacon
53 Brake light switch
54 Left hand brake light
55 Right hand brake light
56 Fog light switch
57 Fog light
58 Horn push
59 Horn
60 Main beam flash
61 Main lights relay
62 Dip beam
63 Road lights switch
64 Dip beam switch
65 Main beam
66 Main bean warning lamp
67 Instrument panel illumination
68 Left hand side lights
69 Front worklight relay
70 Right hand side lights
71 Number plate light
72 Front work light switch and warning lamp
73 Front work lights
74 Rear work light relay
75 Rear work light switch and warning lamp
76 Rear worklight
Item Description
1 Battery isolator
2 Battery
3 Fuse links
4 Starter motor
5 Starter solenoid
6 Key switch
7 Thermostart
8 Neutral start relay
9 Ignition relay
10 Fuse link
11 Sender unit
11A Cold start advance unit (see Note 1)
12 Engine shut-off solenoid (ESOS)
13 Rear work light
14 Rear work light switch
15 Front work lights
16 Front worklights switch
17 Brake lights
18 Brake light switch
19 Trailer brake lights connector
20 Reverse alarm
21 Reverse light
22 Reverse 2 relay
23 Parkbrake switch
24 Parkbrake relay
25 Front axle alignment lamp
26 Front axle proximity switch
27 Rear axle alignment lamp
28 Rear axle proximity switch
29 Radio
30 Load Moment Indicator (LMI)
31 Load Moment Indicator (LMI) transducer
32 Instrument panel
33 Warning buzzer
34 Air filter blocked switch
35 Engine oil pressure switch
36 Transmission oil temperature switch
37 Transmission oil pressure switch
38 Water temperature switch
39 Fuel gauge sender
40 Water temperature sender
41 Alternator
Note 1: Cold start advance unit 11A is part of fuel injection pump.
11A 12 15 17
4 21 23 25 27 34 35 36 37 38 39 40
19
1 7 31
11 13 20
29
5 14 16 18 22 24 26
2 8 9 30
28 32 41
33
F11
3 10
F16
F19
F20
F8
F9
F12
F17
F10
F15
F18
F29
F7
9804/1103 20 - 15 - 01/42 3650 - C/41-6.1 Issue 1
20 - 15 - 01/43
CONTENTS
Loadalls
528S From m/c no. 796102
With Powershift Transmission
Circuit Diagrams-Electrical cont’d
78
42 47 49 53 55 64 66 67 74 75
44 59 62 63 70
51
69 77
43 45 48 50 54 56 57 58 72
71
46 60 61 65 68 73 76 79
52
80
F26
F27
F30
F28
F22
F23
F21
F25
F24
F5
F1
F2
F4
9804/1103 20 - 15 - 01/43 3650 - C/41-7.1 Issue 1
CONTENTS
Loadalls 20 - 15 - 01/44
Item Description
Item Description
SLC
83 89 94
96
82 84 90 99 102 103 104 108
95
101
109
81 86
85 87
92 93
107
F13
F14
F3
Circuit Diagrams-Electrical
11A 15 17
12
4 13 19 20 21 22 24 26 33 34 35 36 37 38
1 7 29 39
11
28
5 10 14 25
18
2 23 30
40
8 16 27 31
32
F11
3 9
7
F19
F20
F10
F18
F8
F9
F16
F17
F29
F12
F15
F6
F7
9804/1103 3650 - C/41-11.1 Issue 1
20 - 15 - 01/47
CONTENTS
Loadalls 20 - 15 - 01/48
The complete electrical circuit is shown on pages 20-15-01/47, 20-15-01/50 and 20-15-01/51. Fuses are numbered as shown
on the fuse box in the cab.
Item Description
1 Battery isolator
2 Battery
3 Fuse links
4 Starter motor
5 Starter solenoid
6 Key switch
7 Thermostart
8 Neutral start relay
9 Fuse link
10 Ignition relay
11 Sender unit
11A Cold start advance unit (see Note 1)
12 Engine shut-off solenoid (ESOS)
13 Rear work light
14 Rear work light switch
15 Front work lights
16 Front worklights switch
17 Brake lights
18 Brake light switch
19 Trailer brake lights connector
20 Reverse alarm
21 Reverse light
22 Parkbrake switch
23 Parkbrake relay
24 Front axle alignment lamp
25 Front axle proximity switch
26 Rear axle alignment lamp
27 Rear axle proximity switch
28 Radio
29 Load Moment Indicator (LMI) transducer
30 Load Moment Indicator (LMI)
31 Instrument panel
32 Warning buzzer
33 Air filter blocked switch
34 Engine oil pressure switch
35 Transmission oil temperature switch
36 Transmission oil pressure switch
37 Water temperature switch
38 Fuel gauge sender
39 Water temperature sender
40 Alternator
Note 1: Cold start advance unit 11A is part of fuel injection pump.
The complete electrical circuit is shown on pages 20-15-01/47, 20-15-01/50 and 20-15-01/51. Fuses are numbered as shown
on the fuse box in the cab.
Item Description
77
42 47 53 55 56
41 49 54 63 65 66 73
44 46 48 52 57 58 62 69 74
43 50 61
68 76
71
70
45 51 59 60 64 67 72 75 78 79
F27
F24
F30
F26
F21
F25
F23
F28
F22
F2
F5
F1
F4
9804/1103 20 - 15 - 01/50 3650 - C/41-14.1 Issue 1
CONTENTS
Loadalls 20 - 15 - 01/51
SLC
82 84 86 89 93 94 95 99
81
91
80 100
92
83 85 87 88 90 96 98
97
F13
F14
F3
Item Description
93 Extend solenoid
94 Auxiliary solenoid
95 Retract solenoid
96 Single lever control joystick
97 Diodes
98 Transmission dump switch (joystick)
99 Auxiliary solenoid
100 Lever isolation switch & auxiliary solenoid
48
601
601
601
601
600
600
601
600
601
600
601
601
601
601
600
601
601
600
601
601
601
600
601
600
600
600
600
411
856
400
856
58
825
601
601
601
601
12 14 18 32 60
840
47
600
601
601
45
43
24 27 M
50
601
601
37 65
841
66
848
883
885
5 61
800
59
7 801
64
820
2 M 39 M 41
824
826
8 44 57
52
17
33 56
6 23 26
901
1 16 42
105
109
28 M 49
55
100
1 2 3
926
925
911
854
120
917
9 51
106
104
15 M 38
600
(SLC)
31 34
21
22 25
102
120
884
003
4
851
829
F1 F7 F8 F9 F11 F12
115
F5 F6
101
120
F2 F3 F4
004
19
29 30 46 54
601
853
413
36 35 40 1 2 3 4 5 6 7 8
11 53 62
886
20
819
1
Z
2
13 823 3
X
Y
10 907
4
W X Y Z
822 5
821 6 63
601
304
81
832
600
601
600
601
71
841
69 76 833
72 77 840
84 97
827
68 70 G 105
91
80
450
83 89
808
79 94 101 109
99
898
873
871
75 85 86
9 15 16 1 13 87 92 100 108
10 7 96
831
106
200
74 2
4 5
88 90 98 104
3
17 18 12 6 82
78 95
103
118
119
108
123
73 93
102 107 111
304
110
304
806
805
838
301
840
841
110
832
F18
F30
F16
F14
838
836
F28
F24
F25
F26
F21 F22 F23
F29
874
F19
F17
F15
A313920
49
601
601
601
600
600
601
600
600
601
600
601
601
601
601
601
601
600
601
601
601
600
600
601
600
600
600
600
411
856
17
400
856
59
825
601
601
601
601
19 33 61
840
48
14
600
601
601
46
44
25 28 M
51
601
601
38 66
841
67
848
883
6 62
800
60
8 801
65
820
2 M 40 M 42
824
826
925
9 45 58
53
16
34 57
7 24 27
901
1 18 43
105
109
29 M 50
926
56
100
1 2 3
901
911
854
120
917
10 52
39
106
104
15 M
600
(SLC)
32 35
22
003
23 26
102
5
120
884
851
810
004
F1
F11
F7
F8
F9
F12
301
F5
F6
115
F2
F3
F4
101
120
874
F13
3
M 200 200
+++
414
842
20
30 31 47 55
4 601
853
413
37 36 41 1 2 3 4 5 6 7 8
12 54 63
886
21
819
1
Z
2
13 823 3
X
Y
11 907
4
W X Y Z
822 5
821 6 64
A313890
Note: Powershift control unit (79) only shows input connections from the mainframe harness.
Refer to the ECU fault finding information in this section for control unit output connections.
803
600
601
304
83
832
600
601
600
601
72
841
70 73 77 833
78 99
840
85
827
69 71 G 106
92
300
82
450
84 90
808
80 95 102 110
100
898
873
871
76 86 87
9 15 16 1 13 88 93 101 109
10 7 97
831
107
200
75 2
4 5
89 91 98 105
3
17 18 12 6 81
79 96
104
118
119
108
123
72 94
103 108 112
304
124
111
803
100
401
806
805
838
301
840
841
110
829 832
810
F18
F30
F16
F14
F21
F22
F28
F23
F24
F25
F26
836
F29
874
F17
F19
F15
A313900
47
601
601
601
601
601
601
600
601
601
601
600
601
601
600
601
600
601
600
601
601
600
600
600
600
411
601
601
601
400
57
825
601
601
601
601
6 59
840
46
600
601
601
44
13 42
24 27 M
49
32
601
601
64
003
36 60
841
16 18 65
848
883
003
800
58
801
5 63
820
12 17 (PP) M 38 M 40
824
826
925
8 43 56
51
31 55
004
7 23 26
901
200
41
105
109
4 48
M
54
100
926
15 1 2 3
901
11
854
50
37
106
104
M
600
14
9 30 33
20
22 25
102
840
2 884 841
110
851
829
810
810
F11
F12
F8
F9
F7
F5
F6
115
101
F4
F2
F3
120
120
F1
874
F13
842
000 000
200 200
3 001
M
414
21
28 29 45 53
601
853
+++
413
10 35 34 39 1 2 3 4 5 6 7 8
301
52 61
886
19
917
819
1
Z
2
823 3
X
4
Y
W X Y Z
822 5
821 6 62
A313870
803
601
601
601
601
600
600
601
601
600
601
600
809
300
600
601
601
600
856
807
73 85 96
89
70
67 68 114
827
72
808
107 121
100
601
811
600
80 94
450
859
863
69 76 97
808 81 84 86 110 117
88 99 105 115
600
108
871
112
200
91
812
82 87 116
852
601
600
104 113 120
601
600
874 93
71 861
92
78 108
857
127
G 90 111 119
601
600
98 106
79 103
119
75 890
872
109
118
125
126
83 601
815
124
304
124
807
118
401
806
805
838
301
840
841
110
F28
601
F30
95 101 102
107
F18
F16
F21
F22
F23
F24
F25
F29
F26
77
815
F17
F19
F15
827
123
3 SPEED
ONLY
809
839
122
74
107
A313880
601
601
601
601
601
601
600
600
600
601
600
600
600
600
600
600
600
601
601
601
44
601
601
601
11 23
411
400
5 55
29 825
20
601
601
601
601
15 57
840
43
600
601
601
7 41
851
13 18 39
801
800
M
46
601
601
33 58 62
841
63
24
848
853
4 56
883
61
820
M 35 M
824
826
37
925
932
40 54
48
004
935
28
200
934
53
931
901
6
17 21 38
105
109
882 M 45
933
51 52
100
926
1 2 3
901
12 14 19 22
854
47
34
106
27 M
810
850
120
30
102
2 9
301
884 840
841
451
114
16 110
829 829
810 810
F11
F12
10
F7
F8
F9
1
F5
F6
F10
115
101
F3
F4
F1
F13
F2
842
874 874
000
3 200 200
001
M +++
414
26 25 42 50
601
413
301
+++
8 32 31 36 1 2 3 4 5 6 7 8
49 59
886
819
1
Z
2
823 3
X
4
Y
W X Y Z
822 5
821 6 60
A314050
601
601
601
601
600
600
601
601
600
601
600
809
601
601
601
601
807
600
601
600
601
601
601
601
600
600
300
71 83 95
807
601
601
600
87
66 68 113
827
70
808
106 120
118
65 98
601
811
600
78 92
863
450
859
67 74 94
808 79 82 85 109 116
86 97 103 114
600
871
111
200
816
601
89
812
80 84 115
600
102 112 119
601
600
874 91
101
852
69 861
90
76 107
110
857
126
G 88 118
601
600
96
200
104
77
119
73 890
872
858
117
124
125
81 601 108
815
105
123
304
124
100
118
108
401
806
805
838
301
840
841
110
829
F28
F30
601
93 99 100
809
107
F18
F31
F32
F33
F34
F35
F16
F21
F22
F23
F24
F25
807
F29
F26
75
815
F17
F19
F15
122
3 SPEED
ONLY
121
839
832
72
F14
107
A314060
601
601
601
601
601
601
600
600
600
601
600
600
600
600
600
601
601
600
601
601
44
601
601
601
20 23
411
400
5 55
28 825
17
601
601
601
601
12 57
840
43
600
601
601
41
851
7 10 39
801
800
M
46
601
601
15 33 58 62
841
63
19
848
932
931
853
4 56
883
61
820
M 35 M
824
826
37
925
932
40 54
48
004
27
934
200
53
931
901
6
14 18 38
105
109
882
M 45
933
51 52
100
926
1 2 3
901
9 11 16 21
854
(DR) 47
34
106
26 M
810
120
30
102
2 301
884 840
841
451
13 22 110
829 829
810 810
114
F11
F12
F7
F8
F9
1
F5
F6
F10
115
101
F3
F4
F1
F13
F2
842
874 874
000
3 200 200
001
M +++
414
25 24 42 50
601
413
8 32 301
+++ 31 36 1 2 3 4 5 6 7 8
49 59
886
819
1
Z
2
823
X
3
4
Y
W X Y Z
822 5
821 6 60
A314070
1 Battery
2 Battery isolator
3 Starter motor 59 Steer Mode Control Unit
4 Ignition switch W Four-wheel/crab steer relay
5 Starting aid X Two wheel steer relay
6 Neutral start relay Y Crab steer relay
7 not used Z Four wheel steer relay
8 Pump dump switch 60 Steer mode switch
9 Auxiliary A switch X Two wheel steer select
10 Auxiliary A solenoid Y Crab steer select
11 Auxiliary B switch Z Four wheel steer select
12 Auxiliary B solenoid 61 Front sensor
13 Joystick isolation switch 62 Rear sensor
14 Boom extend switch 63 Instrument panel
15 Extend solenoid
16 Boom retract switch
17 Retract solenoid Steer Sensor Wiring:
18 Auxiliary 2 A switch
19 Auxiliary change-over relay Terminal Wire Code Wire Colour Description
20 Auxiliary change-over valve 2 1 820 or 819 Black Signal
21 Auxiliary 2 B switch 2 600 or 601 Blue Earth
22 Stabilizer isolation switch 3 810 or 109 Brown Feed
23 Auxiliary change-over valve 1
24 Safe Load Indicator (SLI)
25 SLI transducer
26 Heater/air conditioning fan
27 Air conditioning switch
28 Heater/air conditioning unit
29 N/A
30 Face level fan
31 Air conditioning compressor
32 Air conditioning relay
33 Binary switch (air conditioning)
34 Rear wiper switch
35 Rear wiper motor
36 Roof wiper switch
37 Roof wash pump
38 Roof wiper
39 Front wiper
40 Radio/cassette
41 Heated seat
42 Digital clock
43 Warning buzzer
44 Trailer indicators
45 Hazard switch
46 Indicator relay
47 Hazard diode
48 Interior light
49 Rotating beacon switch
50 Rotating beacon
51 Primary fuse
52 Primary fuse
53 Ignition relay
54 Engine Shut-Off Solenoid
55 Two wheel steer solenoid
56 Four-wheel/crab steer solenoid
57 Four wheel steer solenoid
58 Crab steer solenoid
601
601
601
601
600
600
601
601
600
601
600
809
601
601
601
601
807
600
601
600
601
601
601
601
600
600
300
71 83 95
807
601
601
600
87
66 68 113
827
70
808
106 120
118
65 98
601
811
600
78 92
863
450
859
67 74 94
808 79 82 85 109 116
86 97 103 114
600
871
111
200
816
601
89
812
80 84 115
600
102 112 119
601
600
874 91
101
852
69 861
90
76 107
110
857
126
G 88 118
601
600
96
200
104
77
119
73 890
872
858
117
124
125
81 601 108
815
105
123
304
124
100
118
108
401
806
805
838
301
840
841
110
829
F28
F30
601
93 99 100
809
107
F18
F31
F32
F33
F34
F35
F16
F21
F22
F23
F24
F25
807
F29
F26
75
815
F17
F19
F15
122
3 SPEED
ONLY
121
839
832
72
F14
107
A314060
Key
1 Battery
2 Battery isolator
3 Starter motor
4 Starter solenoid
5 Ignition switch
5A Fuse link 2
6 Starting aid
7 Neutral start relay
8 Ignition feed relay 1
9 Ignition feed relay 2
10 E.S.O.S.
11 Rear work lamp switch
11A Rear work lamp
12 Front work lamps switch
12A Front work lamps
12B Auxiliary power connector
13 2/4WD brake relay
13A Brake lamps
14 Brake switch
15 2/4WD switch
16 2/4WD solenoid
17 Reverse relay
17A Reverse lamp
18 Reverse alarm
19 Park brake relay
19A Park brake switch
20 Heated seat
21 Radio/cassette
22 Digital clock
23 Transducer - Load Moment Indicator (LMI)
24 Instrument panel
25 Warning buzzer
26 Air filter blocked switch
27 Engine oil pressure switch
28 Transmission oil temperature switch
29 Transmission oil pressure switch
30 Water temperature switch
31 Fuel gauge
32 Water temperature gauge
33 Alternator
Note: All the items listed here are not necessarily fitted to all
machines in the range.
10 16
31 32
2 6 17A 19A
18 23
13A
26
27
28
29
30
11A 12A 12B
20 21 X
3
4 7 8 9 22
601JM
601JN
601JR
1
11 12 13 15 17 19 132
33 133
1840a
1840
24
25
14
5
131
171
5A
417050
160-02292-1
54
35 36 38 39 41 43 44 57 60 62
45 65
46 47 48 49 53 55 61
58
40 42 56
37 50
34 51 52 59 64
63
34A
160-02292-2
The complete electrical circuit is shown on pages 20-15-02/22, 20-15-02/23 and 20-15-02/26.
34 Sidelight relay
34A Fuse link 2
35 RH side lights
36 LH side lights
37 Main light switch
38 RH/LH dip beam
39 RH/LH main beam
40 Rear fog light switch
41 Rear fog lamp (optional)
42 Column switch - RH
43 LH indicators
44 RH indicators
45 Front washer pump
46 Front wiper motor
47 Rear wiper motor
48 Roof/rear washer pump
49 Roof wiper motor
50 Rear wiper switch
51 Roof wiper switch
52 Hazard warning switch
53 Hazard warning relay
54 Trailer indicator warning light
55 Interior light/switch
56 Beacon switch
57 Beacon lamp
58 Face level fan
59 Air conditioning relay
60 Air conditioning - compressor motor
61 Air conditioning - freeze switch
62 Air conditioning - receiver drier
63 Air conditioning switch
64 Heater/heater fan switch
65 Heater
Note: All the items listed here are not necessarily fitted to all machines in the range.
66 Column switch - LH
67 Horn
68 Reverse Hi/Lo relay
69 Reverse Lo relay
70 Reverse Hi relay
71 Diode pack (see Note below)
72 Reverse relay
73 Forward relay
74 Forward Hi/Lo relay
75 Forward Hi solenoid
76 Forward Lo solenoid
77 Drive interlock relay
78 Drive shaft relay
79 Layshaft solenoid
80 Mainshaft solenoid
81 Transmission dump relay
82 2nd auxiliary relay
83 2nd auxiliary solenoid
84 Hitch/boom hydraulics solenoid
85 Hitch switch
86 Sway switch
87 Sway diverter solenoid
88 Sway valve
89 Sway valve
90 2nd auxiliary push button
91 Isolation switch
92 Transmission dump push button
93 Steer mode control unit
A Four wheel/crab steer relay
B Two wheel steer relay
C Crab steer relay
D Four wheel steer relay
94 Steer mode selector switch
X Two wheel steer
Y Crab Steer
Z Four wheel steer
95 2WS solenoid
96 4WS solenoid
97 AWS solenoid
98 Crab steer solenoid
99 Proximity switch - front axle
100 Proximity switch - rear axle
Note: All the items listed here are not necessarily fitted to all machines in the range.
95
69 70 96
67 97
75 76 79 80 83 84 87 88 89
98
71
86
66 90
94
Z
92 X
91 Y 99
68 72 73 74 77 78 81 82 85
100
93
160-02292-3
10 18
36
37
31
32
33
34
35
13 27
16
2 6 20 23
11A 12A
24 25
3
21 X
4 7 8 9 26
1
601JM
601JN
601JR
11 12 15 17 19 22 30
132
133
28
1840a
1840
29
14
131
5A
171
417050
160-02291-1
Key
1 Battery
2 Battery isolator
3 Starter motor
4 Starter solenoid
5 Ignition switch
5A Fuse link 2
6 Starting aid
7 Neutral start relay
8 Ignition feed relay 1
9 Ignition reed relay 2
10 E.S.O.S.
11 Rear work lamp switch
11A Rear work lamp
12 Front work lamp switch
12A Front work lamps
13 Auxiliary power connector
14 Brake switch
15 2/4WD brake relay
16 Brake lamps
17 2/4WD switch
18 2/4WD solenoid
19 Reverse relay
20 Reverse lamp
21 Reverse alarm
22 Park brake relay
23 Park brake switch
24 Heated seat
25 Radio/cassette
26 Digital clock
27 Transducer - load moment indicator (LMI)
28 Instrument panel
29 Warning buzzer
30 Alternator
31 Air filter blocked switch
32 Engine oil pressure switch
33 Transmission oil temperature switch
34 Transmission oil pressure switch
35 Water temperature switch
36 Fuel gauge
37 Water temperature gauge
Note: All the items listed here are not necessarily fitted to all machines in the range.
The complete electrical circuit is shown on pages 20-15-02/27, 20-15-02/30 and 20-15-02/31.
38 Sidelight relay
38A Fuse link 1
39 RH side lights
40 LH side lights
41 Main light switch
42 RH/LH dip beam
43 RH/LH main beam
44 Rear fog light switch
45 Rear fog lamp (optional)
46 Column switch - RH
47 LH indicators
48 RH indicators
49 Front washer pump
50 Front wiper motor
51 Rear wiper motor
52 Rear wiper switch
53 Rear/roof washer pump
54 Roof wiper motor
55 Roof wiper switch
56 Hazard warning switch
57 Hazard warning relay
58 Interior light/switch
59 Beacon switch
60 Beacon lamp
61 Face level fan
62 Air conditioning relay
63 Air conditioning - compressor motor
64 Air conditioning - freeze switch
65 Air conditioning - receiver drier
66 Air conditioning switch
67 Heater/heater fan switch
68 Heater
Note: All the items listed here are not necessarily fitted to all machines in the range.
39 40 42 43 47 48 61
50 51 53 54 57 65
45 60
49 68
58 63 64
38 46 56 59 62 66 67
41 44
52 55
160-02291-2
100
83 87 102
70 72 73 78 79 101
91 93 95 96
82 86 103
69
99
Z
X
Y 104
89
105
71 75 76 77 80 81 84 85 88 90 92 94 97
98
160-02291-3
69 Column switch - LH
70 Horn
71 Reverse Hi/Lo relay
72 Reverse Lo Solenoid
73 Reverse Hi solenoid
74 Diode pack (see Note below)
75 Reverse relay
76 Forward relay
77 Forward Hi/Lo relay
78 Forward Hi solenoid
79 Forward Lo solenoid
80 Drive interlock relay
81 Drive shaft relay
82 Layshaft solenoid
83 Mainshaft solenoid
84 Transmission dump relay
85 2nd auxiliary relay
86 2nd auxiliary solenoid
87 Hitch/boom hydraulics solenoid
88 Hitch switch
89 Joystick isolation switch/lamp
90 2nd auxiliary extend switch
91 2nd auxiliary extend solenoid
92 2nd auxiliary retract switch
93 2nd auxiliary retract solenoid
94 Auxiliary A/B switch
95 Auxiliary A solenoid
96 Auxiliary B solenoid
97 Transmission dump push button
98 Steer mode control unit
A Four wheel/crab steer relay
B Two wheel steer relay
C Crab steer relay
D Four wheel steer relay
99 Steer mode selector switch
X Two wheel steer
Y Crab steer
Z Four wheel steer
100 2WS solenoid
101 4WS solenoid
102 AWS solenoid
103 Crab steer solenoid
104 Proximity switch - front axle
105 Proximity switch - rear axle
Note: All the items listed here are not necessarily fitted to all machines in the range.
1 Battery
2 Battery isolator
3 Starter motor
4 Starter solenoid
5 Ignition switch
6 Fuse link 2
7 Starting aid
8 Neutral start relay
9 Ignition feed relay 1
10 Ignition feed relay 2
11 Wax Thermostat
12 E.S.O.S.
13 Rear work lamp switch
14 Rear work lamp
15 Front work lamps switch
16 Front work lamps
17 Auxiliary power connector
18 2/4WD brake relay
19 Brake lamps
20 Brake switch
21 2/4WD switch
22 2/4WD solenoid
23 Reverse relay
24 Reverse lamp
25 Reverse alarm
26 Heated seat
27 Radio/cassette
28 Digital clock
29 Tracker
30 Transducer - Load Moment Indicator (LMI)
31 Fuse link 1
32 Instrument panel
33 Warning buzzer
34 Air filter blocked switch
35 Engine oil pressure switch
36 Transmission oil temperature switch
37 Water temperature switch
38 Fuel gauge
39 Water temperature gauge
40 Alternator
41 Air suspension seat
Note: All the items listed here are not necessarily fitted to all
machines in the range.
601
601
601
601
601
601
601
601
601
601
601
600
601
601
601
601
601
601
600
601
601
600
600
601
601
600
601
601
30A
2 7 25 34 37 38 39 M
24
LEAD
14 16 19 3536 41
11 12 17 22 *
26 27 X
405A
004
200
200
904
831
866
816
818
807
413
414
804
824
826
825
838
401
402
403
404
406
407
412
408
409
M
3
8 9 10 13 15 28
-
450
1 1 2 3
601JM
601JN
601JR
+
4 18 21 23
29 30B 40
132
151
133
LEAD
32
842
003
810
000
100
000
105
123
829
906
119
816
118
124
808
112
301
101
805
806
106
411
829
1840a
1840
33
20
003
106
108
5
200
200
11
12
18
25
16
17
15
19
29
28
30
31
32
33
34
35
7
8
6 131
001 31
171
+++
000
001
100
417050
300
301
304
804
805
806
808
810
824
825
826
827
829
838
401
A374060 405A
160/13114-1
Note: All the items listed here are not necessarily fitted to all
machines in the range.
601
600
601
600
601
601
600
600
600
600
601
601
600
601
600
601
600
600
601
600
601
601
601
601
601
601
601
600
601
601
600
600
600
600
600
63
67
50
M M M M M 58 62 400 M M 71
44 45 47 48 52 53 66 69 74
54 55 56 57 64 70 76 77 78
828
830
829
834
838
898
805
806
839
840
841
925
926
901
849
854
802
803
886
884
883
885
882
801
800
850
931
932
46
827
49
42 51 59 60 61 68 72 73 75
65
909
200
905
832
833
836
304
803
841
840
110
829
300
805
804
104
301
115
102
829
79
907
80
121
21
22
23
27
24
1
43
000 000
001 001
100
300
301 301
304 304
804
805
806
808 808
810 810
824 824
825 825
826 826
827
829 829
838 A374070
160/13114-2
401 401
405A 405A
Note: All the items listed here are not necessarily fitted to all
machines in the range.
600
600
600
600
600
600
600
600
601
601
600
600
601
601
600
600
600
600
600
600
601
117
82 83 91 96 101
97 118
81 92
808
809
874
814
120
601
119
84 85 86 87 88 89 90 99 106 109 111 113
872
480
894
1807
405
858
857
812
859
860
815
851
850
853
893
811
R N F
871
93 A
116
315
45
0
1 2 Z
103 823
3 4 X
819
822
B 121
600J
821
5 6 Y
873
933
929
934
930
932
931
820
C
107
4 3 2 1 1 2 3 4 5 6 7 102
5 8 104 105 107 108 110 112 114
6 9
7 10 122
8 11 98 100 D
94 12
13 115
114
451
120
856
109
15
10
12 16
2
17
13
18
15 18 29 28 27 26 25 24 23 20
000
14
001 001
301
470A
473
470
474
304
A374080
808 95 160/13114-3
810
824 824
825 825
826 826
829
401
405A
To check if a neutral start relay is fitted, try starting the engine with the transmission in gear.
The complete electrical circuit diagram is shown on pages 20-15-03/2 and 20-15-03/3.
1 Battery 55 Steer Mode Control Unit
2 Battery isolator W All wheel steer relay
3 Starter motor X Two wheel steer relay
4 Ignition switch Y Crab steer relay
5 Starting aid Z Four wheel steer relay
6 not used
7 Sway isolation relay
8 Sway/Aux change-over 56 Steer mode switch
9 Sway/Aux 1 solenoid X Two wheel steer select
10 Sway isolation switch Y Crab steer select
11 Auxiliary A relay Z Four wheel steer select
12 Auxiliary B relay 57 Front steer sensor
13 Aux A/B switch 58 Rear steer sensor
14 Auxiliary A solenoid 59 Instrument panel
15 Auxiliary B solenoid
16 Stabilizer isolation valve
17 Stabilizer isolation relay
18 Stabilizer isolation switch
19 Stabilizer isolation proximity switch
20 Transmission dump switch
21 Not applicable
22 Safe Load Indicator (SLI)
23 SLI transducer
24 Heater/air conditioning switch
25 Heater/air conditioning unit
26 Air conditioning switch
27 Face level fan
28 Air conditioning compressor
29 Air conditioning relay
30 Binary switch (air conditioning)
31 Rear wiper switch
32 Rear wiper motor
33 Roof wiper switch
34 Roof wash pump
35 Roof wiper
36 Front wiper
37 Radio/Cassette
38 Heated seat
39 Digital clock
40 Left hand stabilizer warning light
41 Right hand stabilizer warning light
42 Warning buzzer
43 Hazard switch
44 Indicator relay
45 Interior light
46 Rotating beacon switch
47 Rotating beacon
48 Primary fuse
49 Ignition relay
50 Engine Shut-Off Solenoid
51 Two wheel steer solenoid
52 All wheel steer solenoid
53 Four wheel steer solenoid
54 Crab steer solenoid
856
5 9 14 16
38
600
601
601
23
25
D F 44 47
30 M
601
601
825
54 58
C B A 35 59
15 53
42 52
11 27 45 57 820
M 32 M
883
2 M 51
34
848
826
824
36 50
910
819
19
26 28 M 39
43 46 49
6
913
912
8
1
105
109
12 21 37 40 41
882
7
100
48
851
18 31 33
24 29
911
RT
907 20 22
10
17
13
003
F1 F2 F3 F4 F5 F6 F7 F8 F9
F11 F12
004
874 874
3 000
M 200 F13
+++
601
1 2 3 4 5 6 7 8
55
819
1
Z
2
823 3
X
4
Y
W X Y Z
822 5
821 6 57
A312010
601
74
601
601
600
601
64
62 65 69 70
77 91
827
61 63 G 98
84
73
450
76 82 94
72 87 102
873 92
871
68 78 79
9 15 16 1 13 80 85 101
10 7 89 99
200
67 2
4 5 93
81 83 90 97
3
17 18 12 6 75
71 88 96
118
119
108
123
66 86
95 100 104
103
F18
F30
F14 F16
F28
F23
F24
F25
F26
F21 F22
F29
F19
F17
F15
A312020
Note: Powershift control unit (71) only shows input connections from the mainframe harness.
Refer to the ECU fault finding information in this section for control unit output connections..
601
600
600
601
601
601
600
601
601
600
411
601
600
601
600
601
601
600
600
601
601
601
601
856 856
6 53
11 16 825
15
601
601
601
601
55 826
840
43
600
601
601
39
7 37
856
M
17 27 45
601
601
848
20 31 56 60
841
61
601
883
800
54
5 801
10
908
59
820
M 33 M
824
826
35
925
38 52
12
47
19 42
004
26 51
901
884
200
4 36
410
13 M 44
50
105
109
100
926
9 41
882
1 2 3
912
901
854
911
46
21
32
106
8
907
M
22 25
(SLC)
28
(SLC)
14 18
102
2
(SLC)
120
810
F11
F12
F7
F8
F9
F5
F6
101
115
301
F1
F2
F3
F4
842
874 874
F13
000 000
3
200 200
M 001 001
414
+++
23 24 40 49
601
413
30 29 34 1 2 3 4 5 6 7 8
48 57
886
819
1
Z
2
823 3
X
4
Y
W X Y Z
822 5
821 6 58
A313830
803
601
601
304 805
76
600
600
809
405
832 806
600
600
601
601
601
600
601
66
841
64 833
67 71 72 840
79 93
827
63 65 G 100
86
75
450
78 84
808
74 89 96 104
873 94
871
70 80 81
9 15 16 1 13 82 87 103
10 7 91 101
200
69 2
4 5 95
83 85 92 99
3
N
R
17 18 12 6 77
73 90 98
118
119
108
123
68 88
97 102 106
304
836
803
110
832
105
839
401
806
805
838
301
840
841
110
829
810
F18
F30
F16
F14
F21
F22
F23
F24
F25
F26
F28
F29
827
F17
F19
F15
A313840
To check if a neutral start relay is fitted, try starting the engine with the transmission in gear.
The complete electrical circuit is shown on pages 20-15-03/6 and 20-15-03/7.
Note: Powershift control unit (73) only shows input connections from the mainframe harness.
Refer to the ECU fault finding information in this section for control unit output connections.
601
601
601
601
600
600
601
601
601
600
600
600
411
601
600
601
601
600
601
601
600
600
601
601
601
6 53
17 12 14 825
601
601
601
601
55
840
43
600
601
601
7 39
37
19 27 M
45
601
601
21 31 60
56
841
601
883
61
848
800
5 801 54
10
908
59
820
M 33 M
824
410
826
11 35
925
38 52
20 47
004
26 42
200
51
9
901
4
36
13
410
105
109
M 44
50
100
926
41
912
1 2 3
901
911
854
46
909
8 32
907
106
22 25 M
(SLC)
15 18 28
102
2 301
884 840
(SLC)
841
110
829 829
120
810 810
F7
F8
F9
F11
F12
1
F5
F6
115
101
F1
F2
F3
F4
842
874 874
000
F13
3 200
M 001
+++
414
+++ 23 24 40 49
601
413
301
16 30 29 34 1 2 3 4 5 6 7 8
48 57
886
819
1
Z
2
823 3
X
4
Y
W X Y Z
822 5
821 6 58
A313850
601
601
601
601
600
600
601
601
600
601
600
809
601
601
601
601
807
69 81 94
85
66
63 64 109
827
68
808
103 117
118
96
601
811
600
76 90
863
450
859
65 72 93
808 77 80 82 106 113
84 95 101 111
600
871
108
200
87
812
78 83 112
601
600
100 110 116
852
601
600
874 89
67 861
88
74 104
107
857
123
G 86 115
601
600
92 102
75 99
119
71 890
872
105
114
121
122
79 601
815
120
304
124
100
118
108
401
806
805
838
301
840
841
110
829
F28
F30
601
91 97 98
F18
F31
F32
F33
F34
F35
F16
F21
F22
F23
F24
F25
807
F29
F26
73
815
F17
F19
F15
119
3 SPEED
ONLY
118
839
832
70
F14
107
A313860
24
600
600
600
5 12 52
10 18 825
54
16 36
600
601
601
22
800
43 47
29 M
601
601
35 55 59
4 34 60
848
13 25 M 41 49
53
26 45
200
M 31 M 58
820
M
824
33
826
51
935
27 38
42 46 50
20
9
882
105
109
37 39
926
100
15A 15B
1 2 3
6
30 32
7 28 40 RT 48
2 8 23
21
44
17
14
451
842
907
11
1
11A
120
810
F7
F8
F9
F5
F6
F11
F12
F1
F2
F3
F4
000
F13
3
200 200
19
601
1 2 3 4 5 6 7 8
+++ 56
819
1
Z
2
823 3
X
4
Y
W X Y Z
822 5
821 6 57
A311990
601
601
600
600
601
601
600
601
600
601
601
601
601
68 80 93
84
65
62 63 109
827
67
808
103 117
95
863
601
811
600
75 89
450
859
64 71 92
808 76 79 81 106 113
83 94 100 111
600
871 104 108
86
812
77 82 112
601
600
99 101 110 116
601
600
88
852
66 861
87
73 107
857
123
G 85 115
601
600
91
74 98
119
70 890
872
105
114
121
122
78 601
815
102
120
304
124
F28
601
F30
90 96 97
F31
F32
F33
F34
F35
F18
F16
F21
F22
F23
F24
F25
F29
F26
72
815
F19
F17
F15
119
3 SPEED
ONLY
118
839
69
F14
107
A312000
Tthe complete electrical circuit diagram is shown on pages 20-15-03/14 and 20-15-03/15.
532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402
* 540-170,5508 with Servo Controls to m/c no. 1004130
Circuit Diagrams - Electrical
Component Key 1
The complete electrical circuit is shown on pages 20 - 15 - 03/18, 20-15-03/19, 20 - 15 - 03/22 and
20 - 15 - 03/23.
Key
1 Battery
2 Battery isolator
3 Starter motor
4 Starter solenoid
5 Ignition switch
5A Fuse link 2
6 Starting aid
7 Neutral start relay
8 Ignition feed relay 1
9 Ignition feed relay 2
10 E.S.O.S.
11 Rear work lamp switch
11A Rear work lamp
12 Front work lamp switch
12A Front work lamps
12B Auxiliary power connector
13 2/4WD brake relay
13A Brake lamps
14 Brake switch
15 2/4WD switch
16 2/4WD solenoid
17 Reverse relay
17A Reverse lamp
18 Reverse alarm
19 Park brake relay
19A Park brake switch
20 Heated seat
21 Radio/cassette
22 Digital clock
22A Fuse link 1
23 Transducer - load moment indicator (LMI)
24 Instrument panel
25 Warning buzzer
26 Alternator
27 Air filter blocked switch
28 Engine oil pressure switch
29 Transmission oil temperature switch
30 Transmission oil pressure switch
31 Water temperature switch
32 Fuel gauge
33 Water temperature gauge
34 LH stabiliser lamp switch
35 RH stabiliser lamp switch
Note 1: All the items listed here are not necessarily fitted to all machines in the range.
Note 2: 540-17- machines only. See page 20 - 15 - 03/23 for additional circuits.
Note 3: Fuses 31 and 32 for 540-170 machines are shown on page 20 - 15 - 03/23.
532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402
540-170, 5508 with Servo Controls to m/c no. 1004130
Circuit Diagrams - Electrical (cont’d)
See
23
1828
10 34 35 Sheet 4
11A 17A 18
2 6 19A 32 33
12A 13A
28
29
30
31
27
12B 16 35
20 21
3
34
7 8 9 11 12 13 15 22
1
4 17 19
410
410
26
24
25
14
See Note 2
5 540-170
(5508 N.Am) Only
22A
5A
160-02290-1
* 532,
537, 550 with Manual Auxiliary Controls from m/c no. 775402
*
540-170, 5508 with Servo Controls to m/c no. 1004130
Circuit Diagrams - Electrical (cont’d)
37
38
40
41
45
46
43 47 48 49 50 51 55 59 61 63
66
56 58
62
36 39 44 54 57 60 64
42 52
53 65
36A
160-02290-2
532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402
* 540-170,5508 with Servo Controls to m/c no. 1004130
Circuit Diagrams - Electrical (cont’d)
Component Key 2
The complete electrical circuit is shown on pages 20-15-03/18, 20-15-03/19, 20-15-03/22 and 20-15-03/23.
36 Sidelight relay
36A Fuse link 1
37 RH side lights
38 LH side lights
39 Main light switch
40 RH/LH dip beam
41 RH/LH main beam
42 Rear fog light switch
43 Rear fog lamp (optional)
44 Column switch - RH
45 LH indicator lamps
46 RH indicator lamps
47 Front washer pump
48 Front wiper motor
49 Rear wiper motor
50 Rear/roof washer pump
51 Roof wiper motor
52 Rear wiper switch
53 Roof wiper switch
54 Hazard warning switch
55 Hazard warning relay
56 Interior light/switch
57 Beacon switch
58 Beacon lamp
59 Face level fan
60 Air conditioning relay
61 Air conditioning - compressor motor
62 Air conditioning - freeze switch
63 Air conditioning - receiver drier
64 Air conditioning switch
65 Heater/heater fan switch
66 Heater
Note: All the items listed here are not necessarily fitted to all machines in the range.
532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402
540-170, 5508 with Servo Controls to m/c no. 1004130
Circuit Diagrams - Electrical (cont’d)
Component Key 3
The complete electrical circuit is shown on pages 20-15-03/18, 20-15-03/19, 20-15-03/22 and 20-15-03/23.
67 Column switch - LH
68 Horn
69 Reverse Hi-Lo relay
70 Reverse Lo solenoid
71 Reverse Hi solenoid
71A Diode pack (see Note below)
72 Reverse relay
73 Forward relay
74 Forward Hi/Lo relay
75 Forward Hi solenoid
76 Forward Lo solenoid
77 Drive interlock relay
78 Drive shaft relay
79 Layshaft solenoid
80 Mainshaft solenoid
81 Transmission dump relay
82 Stabiliser isolation switch
83 Stabiliser isolation relay
84 Stabiliser isolation solenoid
85 Stabiliser isolation switch
86 Sway isolation switch
87 Sway isolation relay
88 Sway switch
89 Sway diverter solenoid
90 Sway solenoid
91 Sway solenoid
92 Transmission dump push button
93 Steer mode control unit
A Four wheel/crab steer relay
B Two wheel steer relay
C Crab steer relay
D Four wheel steer relay
94 Steer mode selector switch
X Two wheel steer
Y Crab steer
Z Four wheel steer
95 2WS solenoid
96 4WS solenoid
97 AWS solenoid
98 Crab steer solenoid
99 Proximity switch - front axle
100 Proximity switch - rear axle
Note: All the items listed here are not necessarily fitted to all machines in the range.
532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402
* 540-170,5508 with Servo Controls to m/c no. 1004130
Circuit Diagrams - Electrical (cont’d)
95
79 80 90 91
96
68 70 71 75 76 84 89 97
98
67 71A
88
A
94
Z
73 74 77 92 X
69 72 78 81 82 83 85 86 87 B Y 99
C
100
D
93
160-02290-3
From
Sheet 1
1823
000
1828
F31
CONTENTS
170
101
170F
601HS EXT ISOL. SW.
601GM
102
601FL EXT. RELAY
170B
104
103
601HZ EXT INTERLOCK
1833A
1825B
119
107
108
170E
601HR LIFT ISOL. SW.
110
111
170D
601FW STAB. LIFT ISOL. SW.
112
116
113
114
1830C
1830A 601HV
DUMP LOCK SOL.
115
601GA
118
117
1822A
F32
171 1822 601GB
BOOM WORKLIGHT
31
28
29
27
30
601
601
601
601
601
601
601
601
601
601
6 01
601
601
600
601
601
601
601
600
601
601
600
601
601
601
601
601
601
601
410
481
10 23A
11A 17A 19A
2 6 22A 32 33
12A 13A 18
12B 16
20 21
34 35
401
200
904
831
818
825
838
403
404
405
406
407
200
816
807
826
409
004
8 15
414
402
408
866
413
824
412
8 04
3 M
7 8 9 11 12 13 15 22
-
450
1 1 2 3
+
4 17 19
22B 23 26
106
106
000
100
842
000
856
003
810
105
123
816
401
112
829
906
119
118
808
301
124
101
24
411
829
106
805
806
25
14
003
106
108
200
200
12
18
25
16
17
15
19
29
28
30
33
34
35
11
8
22A
5A
001
+++
000
000
001
100
300
301
304
804
805
806
808
810
824
825
826
827
829
838
160-13328
856
47 55
37
38
40
41
45
46
43 48 49 50 51 59 61 63
66
56 58
62
36 39 44 54 57 60 64
42 52
53 65
36A
160-13328-2
95
79 80 90 91
96
68 70 71 75 76 84 89 97
98
67 71A
88
A
94
Z
69 72 73 74 77 78 81 82 83 85 86 87 92 X
B Y 99
100
D
93
160-13328-3
601HW
601FN
601JW
601HT
601HV
601FZ
601JA
601JS
601JY
601JY
601JX
601GB
108 110 111 114 117 118
120
1825
601FY
601JB
1830A
104
1820
109
1829
1825A
1833
601FW
601HR
1829B 1830C
1825B
1829A
1830B
1842
112 115
601GM
601HS
601FL
601GA
1822
1833A
1833
315
1824
1821
0
45
105
119*
103
1834A
1834 1834B
113 116
1850
170K
1822A
106
1828
170C
170L
102
101
1823
121
170H
170J
170D
170E
106
107
171
410
170B
170F
481
170
F31
F36
000
828
160-13328-4
600
46
24 37
47 49 51 53
17 27 26
5 11 44 45 59 60
202 204 205 208 54
N
G/Y
U 50 52
415 811 812 815
414A 403 405 408 409
414 55
413A 814 203 34
413 839 841 402 404 406
2 414B 21
412
413B 801 42 43
407 56
416 400 600 206
N G/Y U
805 806 807
803
808A 809
20 23
31 803A
16 802 401
3 103A
30
810
25 19
9 207
808 39
800
- 101 411 200
1
+ 003
6 105 106A
100
300 61
15 103 104
800
100 106
200 842
A1 A2 A4 A5 A6 A7 A8 A9 B1 B2 004
200
103
000 000
4
000R 000R
200 200
004
842
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers.
When a cable identification number has a suffix number, for clarity, the suffix number is not shown.
The complete electrical circuit is shown on pages 20-15-04/1 and 20-15-04/3.
1 Battery 54 Hourmeter Lamps
2 Starter Motor 55 Alternator 202 Trailer Indicator Warning
3 Starter Solenoid 56 Tachometer 203 Hazard Warning
4 Starter Switch 57 Fuel Gauge 204 L.H. Indicators
5 Thermostart 58 Water Temperature Gauge 205 R.H. Indicators
6 Starter Relay 59 Fuel Gauge Sender 206 Indicator Warning
9 Safe Load Indicator Readout Box 60 Water Temperature Gauge 207 Hazard Indicator Warning
10 Rear SLI Boss Sender 208 Reversing Lights
11 Front SLI Boss 61 Warning Buzzer 209 Parking Brake Warning
15 Heater Switch 62 L. H. Stabiliser Switch 210 Air Filter Blocked Warning
16 Heater Resistor 63 R. H. Stabiliser Switch 211 Engine Oil Pressure Warning
17 Heater Motor 65 Interior Light Switch 212 Transmission Oil Temperature
19 Seat Relay Swedish 66 Roof Wiper Motor and Switch Warning
20 Parking Brake Switch machines 67 Rear Wiper Motor and Switch 213 Transmission Oil Pressure
21 Seat Switch only 68 Beacon Switch Warning
23 Horn Push 69 Beacon 214 Water Temperature Warning
24 Horn 71 Brake Switch 215 Alternator Warning
25 Wash/Wipe Switch 71B Brake Switch Relay 216 Stabiliser Indicators
26 Front Wiper Motor 72 2/4 Wheel Drive Switch (not fitted 217 Interior Light
27 Washer Pump on permanent 4 wheel drive) 218 Beacon Warning
30 Hazard Switch 73 2 Wheel Drive Solenoid 219 2 Wheel Drive Warning
31 Indicator Relay 75 Front Axle Proximity Switch 220 L.H. Brake Lights
32 Indicator Switch 76 Rear Axle Proximity Switch 221 R.H. Brake Lights
34 Fuel Shut-off Solenoid 77 Steering Mode Selector Switch 222 4 Wheel Steer Warning
36 Reverse Alarm Relay 78 Steer Mode Printed Circuit Board 223 Crab Steer Warning
37 Reverse Alarm 78A Relay 2 224 2 Wheel Steer Warning
39 Forward/Reverse Selector Switch 78B Relay 1 225 Instrument Panel Illumination
40 Neutral Start Relay 78C Relay 1 (latch) 226 L.H. Side Light
41 Parking Brake Warning Relay 78D Relay 2 (unlatch) 227 R.H. Side Light
42 Reverse Relay 78E Relay 1 (unlatch) 229 Number Plate Light
43 Forward Relay 78F Relay 2 (latch) 230 Working Light Warning
44 Reverse Solenoid 79 4 Wheel/Crab Steer Solenoid 231 Cab Working Light
45 Forward Solenoid 80 4 Wheel Steer Solenoid 232 Headlamp Dip Beam
46 Transmission Dump Switch 81 Crab Steer Solenoid 233 Headlamp Main Beam
47 Parking Brake Switch 82 2 Wheel Steer Solenoid 234 Headlamp Main Beam Warning
48 Trailer Socket 83 Side Lights Relay 235 Inclinometer Illumination
49 Air Filter Switch 86 Working Light Switch
50 Engine Oil Pressure Switch 87 Road Light Switch Fuses
51 Transmission Oil Temperature 88 Headlamp Dip Switch Fuses are numbered as shown on the
Switch 93 Headlamp Flasher fuse box in the cab.
52 Transmission Oil Pressure Switch 99 Radio (Optional)
53 Water Temperature Switch 100 Transmission Dump Relay Cable Colour Code
G Green
N Brown
U Blue
Y Yellow
Note: For machines without road lights a link is fitted (as shown) in place of Working Light Switch 86 and switch 87 operates the
Working Lights. On North American machines the Safe Load Indicator System is not normally fitted, items 9, 10 and 11.
48 48 48
600
66 69
216 229 234
220 219 78
73 225 226 227 231 232 233
235
217 67 221
78B
78C 78D
230
65 78E 78F
218 818 835 838
829P 834 837
63 78A
301
831
847 99
B9 C1
62
816 72 821 823 848 829 830 B8 C2
822 826 824 825 86
844
817
68 77 B6 B7
112
828
833 836
410
83
71B 79 222 223 224
820
76
88
75 819
93
855
106D 827
71 80 81 82 832
110
108 109
87
B3 B4 B5 C4
103
000
000R
200
19
14 16 25 28 29 32
6
10 12
2
5
9 11
3
26
15
31
7
30
1 20
27
18
13
17
21 22 23 24
A1 A2 A4 A5 A6
A3
4
A269320
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers.
When a cable identification number has a suffix number, for clarity, the suffix number is not shown.
The complete electrical circuit is shown on pages 20-15-04/4 and 20-15-04/6.
33 35 37 43 45 46 93
95
91 51
34 36
48 49 50
39
40
42 44
41
80 81 82 83 84 85 86 87 88 89
52 94
90
47 92
38
A7 A8 A9 B1
14 16 26 28 30
6 36 38 39
17 32
5 20 21 24 25 88
27 29 90
10 12
2 33 89 42 43
41
35 37
80 82 84 86 34
3 18
9 11
81 83 85
7 15
22 44
23 87
1 19
40
13 31
8
45
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers.
When a cable identification number has a suffix number, for clarity, the suffix number is not shown.
The complete electrical circuit is shown on page 20-15-04/7.
1 Battery Lamps
2 Starter Motor 80 Parking Brake Warning
3 Starter Solenoid 81 Air Filter Blocked Warning
4 Starter Switch 82 Engine Oil Pressure Warning
5 Thermostart 83 Transmission Oil Temperature Warning
6 Fuel Shut-off Solenoid 84 Transmission Oil Pressure Warning
7 Neutral Start Relay 85 Water Temperature Warning
8 Forward/Reverse Selector Switch 86 Alternator Warning
9 Reverse Relay 87 Instrument Panel Illumination
10 Reverse Solenoid 88 Cab Working Light
11 Forward Relay 89 Interior Light and Switch
12 Forward Solenoid 90 Beacon
13 Transmission Dump Relay
14 Transmission Dump Switch Fuses
15 Parking Brake Warning Relay Fuses are numbered as shown on the fuse box in the cab.
16 Parking Brake Switch
17 Heater Motor
18 Heater Resistor
19 Heater Switch
20 Horn
21 Front Wiper Motor
22 Horn Push
23 Wash/Wipe Switch
24 Washer Pump
25 Face Fan
26 Air Filter Switch
27 Engine Oil Pressure Switch
28 Transmission Oil TemperatureSwitch
29 Transmission Oil Pressure Switch
30 Water Temperature Switch
31 Warning Buzzer
32 Hourmeter
33 Alternator
34 Tachometer
35 Fuel Gauge
36 Fuel Gauge Sender
37 Water Temperature Gauge
38 Water Temperature Gauge Sender
39 Reverse Alarm
40 Working Light Switch
41 Auxiliary Earth
42 Roof Wiper Motor and Switch
43 Rear Wiper Motor and Switch
44 Beacon Switch
45 Ignition relay
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers.
When a cable identification number has a suffix number, for clarity, the suffix number is not shown.
The complete electrical circuit is shown on page 20-15-04/10.
1 Battery Lamps
2 Starter Motor 80 Parking Brake Warning
3 Starter Solenoid 81 Air Filter Blocked Warning
4 Starter Switch 82 Engine Oil Pressure Warning
5 Thermostart 83 Transmission Oil Temperature Warning
6 Fuel Shut-off Solenoid 84 Transmission Oil Pressure Warning
7 Neutral Start Relay 85 Water Temperature Warning
8 Forward/Reverse Selector Switch 86 Alternator Warning
9 Reverse Relay 87 Instrument Panel Illumination
10 Reverse Solenoid 88 Cab Working Light
11 Forward Relay 89 Interior Light
12 Forward Solenoid 90 Beacon
13 Transmission Dump Relay
14 Transmission Dump Switch Fuses
15 Parking Brake Warning Relay Fuses are numbered as shown on the fuse box in the cab.
16 Parking Brake Switch
17 Heater Motor
18 Heater Resistor
19 Heater Switch
20 Horn
21 Front Wiper Motor
22 Horn Push
23 Wash/Wipe Switch
24 Washer Pump
25 Face Fan
26 Air Filter Switch
27 Engine Oil Pressure Switch
28 Transmission Oil TemperatureSwitch
29 Transmission Oil Pressure Switch
30 Water Temperature Switch
31 Warning Buzzer
32 Hourmeter
33 Alternator
34 Tachometer
35 Fuel Gauge
36 Fuel Gauge Sender
37 Water Temperature Gauge
38 Water Temperature Gauge Sender
39 Reverse Alarm
40 Working Light Switch
41 Auxiliary Earth
42 Roof Wiper Motor and Switch
43 Rear Wiper Motor and Switch
44 Beacon Switch
45 Ignition relay
14 16 26 28 30
6 17 36 38 39
32
20 21 24 25 27 29 88 89 90
10 42 43
12
2 33
5
41
35 37
9 11 18 80 82 84 86 34
44
81 83 85
3 7 15
22
87
1 19
23 40
13
31
8
45
33 35 37
6 8 10 12 31 43 45
22 27 39
24 34 36 46 88 89 90
32 50
20 21
2 17 28 40
5 9 11 23 48
49
13
42 44
18 25 80 82 84 86 41
14 81 83 85
3
51
29
30 87
7 19
1
26
47
15 16 38
1 Battery Lamps
2 Starter Motor 80 Parking Brake Warning
3 Starter Solenoid 81 Air Filter Blocked Warning
4 Starter Switch 82 Engine Oil Pressure Warning
5 Thermostart 83 Transmission Oil Temperature Warning
6 Fuel Shut-off Solenoid 84 Transmission Oil Pressure Warning
7 Transmission Dump Relay 85 Water Temperature Warning
8 Transmission Dump Switch 86 Alternator Warning
9 Parking Brake Warning Relay 87 Instrument Panel Illumination
10 Parking Brake Switch 88 Cab Working Light
11 Drive Shaft Relay 89 Interior Light and Switch
12 Layshaft Solenoid 90 Beacon
13 Forward Relay
14 Reverse Relay Fuses
15 Forward/Reverse Selector Switch Fuses are numbered as shown on the fuse box in the cab.
16 Ratio Selector Switch
17 Forward High/Low Relay
18 Neutral Start Relay
19 Reverse High/Low Relay
20 Forward High Solenoid
21 Forward Low Solenoid
22 Reverse High Solenoid
23 Reverse Low Solenoid
24 Heater Motor
25 Heater Resistor
26 Heater Switch
27 Horn
28 Front Wiper Motor
29 Horn Push
30 Wash/Wipe Switch
31 Washer Pump
32 Face Fan
33 Air Filter Switch
34 Engine Oil Pressure Switch
35 Transmission Oil TemperatureSwitch
36 Transmission Oil Pressure Switch
37 Water Temperature Switch
38 Warning Buzzer
39 Hourmeter
40 Alternator
41 Tachometer
42 Fuel Gauge
43 Fuel Gauge Sender
44 Water Temperature Gauge
45 Water Temperature Gauge Sender
46 Reverse Alarm
47 Working Light Switch
48 Auxiliary Earth
49 Roof Wiper Motor and Switch
50 Rear Wiper Motor and Switch
51 Beacon Switch
29 35 37 39 90
8 10 11 48
6 13 14 24
33 41 45 47
26 36 38 88 89
34 52
22 23
2 19 30
5 9 12 42
25 50
51
15
44 46
20 80 82 84 86 43
16 27
81 83 85
3
31 53
32
21 87
1 7
28 49
17 18 40
10 29 35 37 39
11
6 8 13 14 33 45 47
24 41
26 30 36 38 48 88 89 90
34 52
22 23
2 19 42
5 9 12
25 50 51
15
44 46
20 27 80 82 84 86 43
16
81 83 85
3
31 53
21 87
1 7
32 49
28
40
17 18
The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers.
When a cable identification number has a suffix number, for clarity, the suffix number is not shown.
The complete electrical circuit is shown on page 20-15-04/15.
1 Battery Lamps
2 Starter Motor 80 Parking Brake Warning
3 Starter Solenoid 81 Air Filter Blocked Warning
4 Starter Switch 82 Engine Oil Pressure Warning
5 Thermostart 83 Transmission Oil Temperature Warning
6 Fuel Shut-off Solenoid 84 Transmission Oil Pressure Warning
7 Transmission Dump Relay 85 Water Temperature Warning
8 Transmission Dump Switch 86 Alternator Warning
9 Parking Brake Warning Relay 87 Instrument Panel Illumination
10 Parking Brake Switch 88 Cab Working Light
11 Drive Interlock Relay 89 Interior Light and Switch
12 Drive Shaft Relay 90 Beacon
13 Layshaft Solenoid
14 Mainshaft Solenoid Fuses
15 Forward Relay Fuses are numbered as shown on the fuse box in the cab.
16 Reverse Relay
17 Forward/Reverse Selector Switch
18 Ratio Selector Switch
19 Forward High/Low Relay
20 Neutral Start Relay
21 Reverse High/Low Relay
22 Forward High Solenoid
23 Forward Low Solenoid
24 Reverse High Solenoid
25 Reverse Low Solenoid
26 Heater Motor
27 Heater Resistor
28 Heater Switch
29 Horn
30 Front Wiper Motor
31 Horn Push
32 Wash/Wipe Switch
33 Washer Pump
34 Face Fan
35 Air Filter Switch
36 Engine Oil Pressure Switch
37 Transmission Oil TemperatureSwitch
38 Transmission Oil Pressure Switch
39 Water Temperature Switch
40 Warning Buzzer
41 Hourmeter
42 Alternator
43 Tachometer
44 Fuel Gauge
45 Fuel Gauge Sender
46 Water Temperature Gauge
47 Water Temperature Gauge Sender
48 Reverse Alarm
49 Working Light Switch
50 Auxiliary Earth
51 Roof Wiper Motor and Switch
52 Rear Wiper Motor and Switch
53 Beacon Switch
Note: all the items listed here are not necessarily fitted to all machines in the range.
533-105 Machine
Circuit Diagrams - Electrical
See
23
1828
10 34 35 Sheet 4
11A 17A 18
2 6
12A 13A
19A 32 33 X
28
29
30
31
27
12B 16 35
20 21
3
34
22
601JM
601JN
601JR
7 8 9 11 12 13 15
1
4 17 19 132
410
410
26 133
1840a
1840
24
25
14
See Note 2
5 540-170
(5508 N.Am) Only
131
22A
5A
171
417050
160-02290-1
Note: all the items listed here are not necessarily fitted to all machines in the range.
533-105 Machine
Circuit Diagrams - Electrical
37
38
40
41
45
46
43 47 48 49 50 51 55 59 61 63
66
56 58
62
36 39 44 54 57 60 64
42 52
53 65
36A
160-02290-2
Note: all the items listed here are not necessarily fitted to all machines in the range.
533-105 Machine
Circuit Diagrams - Electrical
95
79 80 90 91
96
68 70 71 75 76 84 89 97
98
67 71A
88
A
94
Z
73 74 77 92 X
69 72 78 81 82 83 85 86 87 B Y 99
C
100
D
93
160-02290-3
35
12
34A
13
34B 42
34
13A
12A
11
36 15B
15A 10 10
15
V C
P
43
10A 10A
33
P
29
14
C V
2P 2M 2K 2H 2Y
S2 2X
P2 P3 2
31
2A
P1 S1 2Q 2N 2L 2J
S3
30
F
P4
2G 2F 2E 2D 2C 2B
2X 1B
2W 2V 2U 2T 2S 2R
1A
F1
32 40
T
41 41
a
a b
41A b
2CC
A166543
A166543
2S
Component Key
35
12
T P
34A 34B
13
34D 42 13A
34C
B A
12A
36
11
15B
15A 10 10
15
L 33 R
33B 33B
10A 10A
41
29 P
C V
14
33A
2M 2K 2H
16A
2X
2
33C P1 16
2X 2A
P T 2N 2L 2J
LS P EF P2
2G 2F 2E 2D 2C 2B
1B
P2B
2W 2V 2U 2T 2S 2R
P4 1A
S1
P2A
F
S2
C
F1
A230120
23A
35
18
19
13
21 23 17
20
T P
13A
34A 34B
34
34C 34D 25
16C
B A 24A
16A
11 16
16B 16D
10 10
V C
P
36 42
22 24
15B
L 33 R
15A
15
10A 10A
33B 33B
26
14
29
33A
C V
2X
33C
2P 2K 2H
P T P1
31
2 1B
30
P2 2A
32 2Q 2L 2J
1A
2G 2Y 2Z 2E 2D 2C 2B 2CC
40 2S
S1 2W 2V 2U 2T 2SS 2S 2R
P3 S3 S2
41
F
41A
C
A142773
23A
35
18
19
13
21 23 17
20
T P
13A
34A 34B
34
34C 34D 25
16C
B A 24A
16A
11 16
16B 16D
10 10
V C
P
36 42
22 24
15B
L 33 R
15A
15
10A 10A
33B 33B
26
14
29
33A
C V
2X
33C
2P 2K 2H
P T P1
31
2 1B
30
P2 2A
32 F 2Q 2L 2J
1A
2G 2Y 2Z 2E 2D 2C 2B 2CC
40 2S
S1 2W 2V 2U 2T 2SS 2S 2R
P3 S3 S2
41
41A
C
A166551
35
12
34A
13
34B 42
34
13A
12A
11
36 15B
15A 10 10
15
V C
P
43
10A 10A
33
P
29
14
C V
2P 2M 2K 2H 2Y
S2 2X
P2 P3 2
31
2A
P1 S1 2Q 2N 2L 2J
S3
30
F
P4
2G 2F 2E 2D 2C 2B
2X 1B
2W 2V 2U 2T 2S 2R
1A
F1
32 40
T
41 41
a
a b
41A b
2CC
A166543
A166543
2S
35
12
T P
34A 34B
13
34D 42 13A
34C
B A
12A
36
11
15B
15A 10 10
15
L 33 R
33B 33B
10A 10A
41
29 P
C V
14
33A
2M 2K 2H
16A
2X
2
33C P1 16
2X 2A
P T 2N 2L 2J
LS P EF P2
2G 2F 2E 2D 2C 2B
1B
P2B
2W 2V 2U 2T 2S 2R
P4 1A
S1
P2A
F
S2
C
F1
A230120
23A
35
18
19
13
21 23 17
20
T P
13A
34A 34B
34
34C 34D 25
16C
B A 24A
16A
11 16
16B 16D
10 10
V C
P
36 42
22 24
15B
L 33 R
15A
15
10A 10A
33B 33B
26
14
29
33A
C V
2X
33C
2P 2K 2H
P T P1
31
2 1B
30
P2 2A
32 F 2Q 2L 2J
1A
2G 2Y 2Z 2E 2D 2C 2B 2CC
40 2S
S1 2W 2V 2U 2T 2SS 2S 2R
P3 S3 S2
41
41A
C
A166552
18
19
35 13
17
20
13A
34A 16C
15A
34 15 16A
34B 16B 16
16D
11 10 10
V C
P
36 42
10A 10A
33
29
14
2P 2M 2K 2H
31
30
P2 2X 2
32 2A
S2 2Q 2N 2L 2J
P3 P1
S1
40 2G 2F 2E 2D 2C 2B 1B 2CC
F
2S
2W 2V 2U 2T 2S 2R
S3 1A
41
41A
A142782
23A
18
19
13
35
21
23
17
20
13A
34A
34B
34
24A
25
11
16
10 10
V
C
36
P
42
22
24
15A
15
10A
10A
26
33
29 14
31
30
P2
2X
32
S2
2P
2K
2H
P3
P1
S1
40
F
2
1B
2A
S3
2L
2J
2Q
1A
2G
2Y
2Z
2E
2D
2C
2B
T
41 2W 2V 2U 2T 2S 2R
41A
A154531
* 520-55 RS and 520-55 4 Wheel Steer From m/c no. 277001 to 278610
Circuit Diagram-Hydraulics
5 7
7A
4 5B 8
5C 7B 8A
8B
5A
a b
3
a b 9
3B 3B
6
9A
9B
2
3A
2K 2B 2K 2C 2K 2D 2E 14
1A
3C
12 13
2H 2F
LS P EF P1 2A
2J 2G 15
P1C
P1B 1C
P1A
A B A B A B A B 16
17 18
C 1B
S1
10
F
11
Circuit Diagram
Component Key
C Cap
F Filter
P1 Main pump assembly
P1A Pump
P1B Pressure test point
P1C Priority valve
S1 Main pump suction line
T Tank
1A Neutral circuit feed line
1B Neutral circuit return line
1C Steer circuit return line
2 Valve block
2A Main relief valve (M.R.V.)
2B Auxiliary spool
* 2C Lift spool (see Note)
2D Tilt spool
* 2E Extension spool (see Note)
2F Auxiliary relief valve (A.R.V)
2G Auxiliary relief valve (A.R.V)
2H Auxiliary relief valve (A.R.V)
2J Auxiliary relief valve (A.R.V)
2K Load hold check valves (L.H.C.V’s)
3 Steer unit assembly
3A Steer valve
3B Shock valves (option)
3C Main relief valve
4 RS machine rear axle steer track rod
5 AWS machine steer circuit
5A Front axle steer track rod
5B Rear axle steer track rod
5C Steer alignment valve
6 Auxiliary 1 circuit (standard all machines)
7 Q Fit Carriage pin locking (option)
7A Q Fit Carriage pin locking ram
7B Q Fit Carriage manual diverter valve
8 Auxiliary 2 circuit (option)
8A Diverter valve
8B Auxiliary 2 ram
9 Hydraulic hitch (option)
9A Diverter valve
9B Hitch ram
10 Lift ram check valve
11 Lift ram
12 Displacement ram
13 Tilt ram
14 Tilt ram check valve
15 Extension ram check valve
16 Extension ram
* 17 Port restrictor
* 18 Port restrictor
5D 5D
7
5C A P B
7A
8
18B 18C
18A 18A
T
18
7B 8A
5B 17B 8B
5D 5D 17 17C
L 3 R
3B 3B 9
6
17A
9A
1A 9B
2
3A
2K 2B 2K 2C 2K 2D 2E 14
3C
12 13
2H 2F
LS P EF P1 2A
2J 2G 15
P1C
P1B 1C
P1A
A B A B A B A B 16
20
22 23
C
1B
S1
10
F
11
35
23A
T P
34A 34B
18
34C 34D 19
B A 13
21 23 17
20
13A
36
25 16C
16A
24A 16
16B 16D
11
L 33 R
10 10
V C
33B 33B
P
12
22 24
15B
15A
15
10A 10A
33A
26
29
C V
33C
P
P T
31
30
P2 2X
32
S2
2K 2L
P1
S1
P3 2 1B
40
2A
S3
41 F 2J 2M
C 1A
41A
2F 2H 2G 2E 2D 2C 2B
T
2U 2T 2S 2R 2Q 2P 2N
A229130
20 22
7
10
21
11 7A
14
C
13
T
24 F
S
12
S1
15 P1
24A
17
16 X
17A
1C 17D
EF F T
23 23 2 1B P
T 3 P
1A F LS
3C LS
17E 17C
2F 2H
2A 17B
2G 2J
3A
A2 A1
X
2E 2D 2C 2B 18 18
2K 2K 2K 2K 3B 3B 19
25 A B
5C
5A 5B
5D 5D
5D 5D
A234942
Component Key
Component Key
C Cap
F Filter
LS Load Sensing line
P1 Main pump
S Suction strainer
S1 Main pump suction line
T Tank
X Pressure test point
1A Neutral circuit feed line
1B Neutral circuit return line
1C Steer circuit return line
2 Valve block
2A Main relief valve (M.R.V.)
2B Auxiliary spool
2C Lift spool
2D Tilt spool
2E Extension spool
2F Auxiliary relief valve (A.R.V's)
2G Auxiliary relief valve (A.R.V's)
2H Auxiliary relief valve (A.R.V's)
2J Auxiliary relief valve (A.R.V's)
2K Load hold check valves (L.H.C.V's)
3 Steer unit assembly
3A Steer valve
3B Shock valves (option)
3C Relief valve
5A Front steer ram
5B Rear steer ram
5C Steering alignment valve
5D Brake packs
7 Q Fit Carriage pin locking
7A Q Fit Carriage manual diverter valve
10 Lift ram check valve
11 Lift ram
12 Displacement ram
13 Tilt ram
14 Tilt ram check valve
15 Extension ram check valve
16 Extension ram
17 Brake charge/priority valve
17A Priority valve
17B Distributor valve
17C Pilot valve
17D Relief valve
17E Brake pressure switch
18 Accumulator
19 Brake valve
20 Auxiliary 1 quick release couplings
21 Electrical diverter valve (if fitted)
22 Auxiliary 2 quick release couplings
23 One-way restrictor
* 24 Hydraulic Hitch (Option)
* 25 Electrical Diverter Valve
* 26 Trailer Brake Valve (Option)
7A
4 5B 8
5C 7B 8A
8B
5A
a b
3
a b
3B 3B 9
6
9A
9B
2
3A
2K 2B 2K 2C 2K 2D 2E 14
1A
3C
12 13
2H 2F
LS P EF P1 2A
2J 2G 15
P1C
P1B 1C
P1A
16
C 1B
S1
10
F
11
A183561
520-55 4 Wheel Steer from Serial No. 278611 & 526-55, 526, 526S to Serial No. 280299
Circuit Diagram - Hydraulics
Component Key
C Cap
F Filter
P1 Main pump assembly
P1A Pump
P1B Pressure test point
P1C Priority valve
S1 Main pump suction line
T Tank
1A Neutral circuit feed line
1B Neutral circuit return line
1C Steer circuit return line
2 Valve block
2A Main relief valve (M.R.V.)
2B Auxiliary spool
2C Lift spool
2D Tilt spool
2E Extension spool
2F Auxiliary relief valve (A.R.V's)
2G Auxiliary relief valve (A.R.V's)
2H Auxiliary relief valve (A.R.V's)
2J Auxiliary relief valve (A.R.V's)
2K Load hold check valves (L.H.C.V's)
3 Steer unit assembly
3A Steer valve
3B Shock valves (option)
3C Main relief valve
5A Front axle steer track rod
5B Rear axle steer track rod
5C Steer mode selector valve
5D Brake packs
6 Auxiliary 1 circuit (standard all machines)
7 Q Fit Carriage pin locking (option)
7A Q Fit Carriage pin locking ram
7B Q Fit Carriage manual diverter valve
8 Auxiliary 2 circuit (option)
8A Diverter valve
8B Auxiliary 2 ram
9 Hydraulic hitch (option)
9A Diverter valve
9B Hitch ram
10 Lift ram check valve
11 Lift ram
12 Displacement ram
13 Tilt ram
14 Tilt ram check valve
15 Extension ram check valve
16 Extension ram
17 Brake circuit charge valve
17A Main spool
17B Relief valve
17C Compensating valve (not used)
18 Accumulator manifold
18A Accumulator spheres
18B Pressure/vent connector
18C Brake pressure switch
19 Brake valve
20 Liquid/liquid cooler (if fitted)
21 Restrictor (526-55, 526 & 526S)
520-55 4 Wheel Steer from Serial No. 278611 & 526-55, 526, 526S to Serial No. 280299
Circuit Diagram - Hydraulics (contÕd)
5A 19
5D 5D
7
5C A P B
7A
8
18B 18C
18A 18A
T
18
7B 8A
5B 17B 8B
5D 5D 17 17C
L 3 R
3B 3B 9
6
17A
9A
1A 9B
2
3A
2K 2B 2K 2C 2K 2D 2E 14
3C
12 13
2H 2F
LS P EF P1 2A
2J 2G 15
P1C
P1B 1C
P1A
16
20
C
1B 21
S1
10
F
11
A210540
526, 526S Machines with Dual Lever Control From m/c no. 280300
Circuit Diagram - Hydraulics
Component Key
C Cap
F Filter
P1 Main pump assembly
P1A Pump
P1B Pressure test point
P1C Priority valve
S1 Main pump suction line
1A Return line to tank
1B Steer circuit return line
1C Trailer brake valve return line
2 Valve block
2A Main relief valve (MRV)
2B Auxiliary spool
2C Raise/lower spool
2D Tilt spool
2E Extend/retract spool
* 2F Auxiliary relief valve (ARV) head side (Port A)
* 2G Auxiliary relief valve (ARV) rod side (Port B)
* 2H Auxiliary relief valve (ARV) (Port B)
* 2J Auxiliary relief valve (ARV) (Port A)
2K Load hold check valves (LHCVs)
*3 Steer unit assembly (with shock valves)
3A Steer valve
3B Main relief valve
3C Shock valves (option)
*4 Steer unit assembly (without shock valves)
* 4A Steer valve
* 4B Main relief valve
5A Front axle steer track rod
5B Rear axle steer track rod
5C Steer mode selector valve
6 Auxiliary 1 circuit (standard all machines)
*7 Twin auxiliary option with hydraulic pin locking option
7A Quickfit carriage locking pin ram
7B Quickfit carriage manual diverter valve
* 7C Solenoid diverter valve (boom mounted)
* 7D Tool carrier locking pin ram
*8 Twin auxiliary option
* 8A Solenoid diverter valve (boom mounted)
*9 Hydraulic pick-up hitch (option)
* 9A Solenoid diverter valve (chassis mounted)
* 9B Pick-up hitch cylinder
* 9C Restrictor
* 9D Quick release coupling
* 10 Counter balance valve
11 Lift ram
12 Displacement ram
13 Tilt ram
* 14 Counter balance valve
* 15 Counter balance valve
16 Extension ram
19 Trailer brake valve (option)
19A Pilot valve
* 19B Trailer brake valve
19C Trailer brake coupling
19D Brake circuit connection
20 Liquid/liquid cooler (if fitted)
21 Check valve
22 Port restrictor (3.5 mm)
23 Port restrictor (3.5 mm)
526, 526S Machines with Dual Lever Control To m/c no. 280300
Circuit Diagram - Hydraulics (cont’d)
5A 16
2 15
23
P B Extend
A
B 2E A Retract
5C T 12 13
14
2K 22
5B
B Crowd
a b a b 2D 2F 2G A Dump
3 L R 4 21 11
3C 10
2K
B Raise
2C A Lower
c
6
d
3A 4A 2K
B
3B 4B 7D
2B A 7A
2H 2J 7B
P Ls T P1 A
2K D AUX1
a f g a f g c
P2 B
C
d
2A AUX2
P Ef Ls
7C
19C P T
P1B P1C P1 8
A
D AUX2
c B
P1A P2 C
S d AUX1
8A
C S1
B R
19B AUX1 9D 9
P1
Y A
D 9B
F N c B
19A P2
C
19D d 9C
P
19 9A
526, 526S Machines with Single Lever Control Option From m/c no. 280300
* Component Key
C Cap 14 Counterbalance valve
F Filter 15 Counterbalance valve
P1 Main pump assembly 16 Extension ram
P1A Pump 19 Trailer brake valve (option)
P1B Pressure test point 19A Pilot valve
P1C Priority valve 19B Brake valve
S1 Main pump suction line 19C Trailer brake coupling
1A Return line to tank 19D Brake circuit connection
1B Steer circuit return line 21 Check valve
1C Trailer brake valve return line 22 Port restrictor (3.5mm)
2 Valve block 23 Port restrictor (3.5mm)
2A Main relief valve (MRV) 24 Port restrictor (2.5mm)
2B Pressure reducing valve (20 bar)
2C Pressure maintaining valve (10 bar)
2D Auxiliary spool
2E Raise/lower spool
2F Tilt spool
2G Extend/retract spool
2H Auxiliary relief valve (ARV) rod side (Port B)
2J Auxiliary relief valve (ARV) head side (Port A)
2K Auxiliary relief valve (ARV) (Port A)
2L Auxiliary relief valve (ARV) (Port B)
2M Load hold check valves LHCVs
2N Accumulator
2P Filter
3 Steer unit assembly (with shock valves)
3A Steer valve
3B Main relief valve
3C Shock valves (option)
4 Steer unit assembly (without shock valves)
4A Steer valve
4B Main relief valve
5A Front axle steer track rod
5B Rear axle steer track rod
5C Steer mode selector valve
6 Auxiliary 1 circuit (standard all machines)
7 Twin auxiliary option with hydraulic pin locking option
7A Quickfit carriage locking pin ram
7B Quickfit carriage manual diverter valve
7C Solenoid diverter valve (boom mounted)
7D Tool carrier locking pin ram
8 Twin auxiliary option
8A Solenoid diverter valve (boom mounted)
9 Hydraulic pick-up hitch option
9A Solenoid diverter valve (chassis mounted)
9B Pickup hitch cylinder
9C Restrictor
9D Quick release coupling
10 Counterbalance valve
11 Lift ram
12 Displacement ram
13 Tilt ram
526, 526S Machines with Single Lever Control Option To m/c no. 280300
Circuit Diagram - Hydraulics (cont’d)
*
5A
16
15
24
P
B 5C A 2
A
2G
T B
12 13
14
5B 2M 22
a b A
a b 2F
2H 2J B
3 L 3C R 4 2M
21 10 11
A
2E
B
2M
c
3A 4A A 6
d
2D
B
2K 2L
2M
3B 4B
7D
7 7B 7A
2C
P Ls T
P1 A
e f g 2P D
e f g 2B 2A c B
P2
C
2N d
P1 P Ef Ls
P T 7C
19C
P1B 1B
P1C
P1 A 8
D
P1A c B
P2 C
S
1C
d
1A
8A
C S1
F
B R 19B 9D 9
P1
A
c D 9B
P B
P2
19A 9C C
19D d
N
19
9A
11 Lift cylinder
5A
2
15
15A
15B
5B 5C
2E
5D 5B 13 12
2K 12A
12B
5A
2D 2F 2G
11
3 4 2K 14 11A
3C
2C
6
3A 4A 2K 7
3B 4B 8C 8
2B 2H 2J 8B
3D 4D
2K
1 2A
8A
16A
1B 3E 9
1C
17
1A N1
16B
9A
C S N2
10
T B R 16
Y 18 10D
10B
F F1 N
S1 10C
10A
P
5A
2
15
15A
15B
5B 5C
2E
5D 5B 13 12
2K 12A
12B
5A
2D 2F 2G
11
3 4 2K 14 11A
3C
2C
6
3A 4A 2K 7
3B 4B 8C 8
2B 2H 2J 8B
3D 4D
2K
1 2A
8A
16A
1B 3E 9
1C
17
1A N1
16B
9A
C S N2
10
T B R 16
Y 18 10D
10B
F F1 N
S1 10C
10A
P
528S With Single Lever Control (SLC) From m/c no. 796102
Circuit Diagram - Hydraulics (cont’d)
Component Key
C Pressure Cap breather
F Return line filter 11 Lift cylinder
F1 Filter by-pass 11A Counterbalance valve
N1 Neutral circuit feed line 12 Tilt cylinder
N1 Neutral circuit return line 12A Counterbalance valve
S Main pump suction line 12B Port restrictor (3.5mm)
S1 Suction strainer 13 Displacement cylinder
T Hydraulic tank 14 Check valve
1 Main pump assembly 15 Extension cylinder
1A Pump 15A Counterbalance valve
1B Pressure test point 15B Port restrictor (3.5mm)
1C Load sensing valve 16 Trailer brake valve (option)
2 Valve block 16A Trailer brake coupling
2A Main relief valve (MRV) 16B Hydraulic hitch return line
2B Pressure reduction valve 17 Not fitted
2C Accumulator 18 Hydraulic cooler:
2D Pressure maintaining valve liquid/air blast
2E Auxiliary spool
2F Raise/lower spool Note: Spools 2D and 2E are reversed on machines equipped
2G Tilt spool with a placing control pattern.
2H Extend/retract spool
2J Auxiliary relief valve (ARV) rod side - Port B
2K Auxiliary relief valve (ARV) head side - Port A
2L Auxiliary relief valve (ARV) - Port B
2M Auxiliary relief valve (ARV) - Port A
2N Load Hold Check-Valves (LHCVs)
3 Steer unit assembly (with shock valves)
3A Steer valve
3B Main relief valve
3C Shock valves (option)
3D Non-return valve
3E Steer circuit return line
4 Steer unit assembly (without shock valves)
4A Steer valve
4B Main relief valve
4C Non-return valve
5A Front axle steer track rod
5B Rear axle steer track rod
5C Steer mode selector valve (steer mode option only)
5D AWS setting lever
6 Single auxiliary connectors
7 High flow auxiliary option
8 Twin auxiliary option with hydraulic pin locking option
8A Diverter valve - boom mounted
8B Quick-fit carriage manual isolation valve
8C Pin locking cylinder
9 twin auxiliary option
9A Diverter valve - boom mounted
10 Hydraulic pick up hitch option
10A Diverter valve - chassis mounted
10B Pick up hitch cylinder
10C Restrictor
10D Quick release coupling
17 15
Z
17A 17C 15D
17E 15E
18 16
15B
17B 17D
15C
Y 15A
17E
B3 14
14B
3
14C
14A
4 2 13B
T
13A
4A
3A 19D
A 12
2G
B
3C B2 19A 19B 2M
11A 11
2K 2L
B1 A
19 2F
B
2M
1F 11B 11C
A
1 2E
1E 2H B
2M
1B 2J 10
1D A 9
F 2D
1C 1A B
F1 2M
20 10A
B 2C
S N2 2B 2A
T 2N
N1 8
F2 8A
A293711
14
P1 B
14B
A
C
A D
P2
B 14C
17
14A
T 17A 17C B
18 16
P A
17B 17D
13
17E
P1 B 13C
C V A
C
A D
P2
13G
B
13A
2K 2L 13D
13B
5
L R
3 3B
4
T
3A
A
12
LS 2G
3C B
2 2M 2L
P T 2K
A
2E 2J 10
2H B
9
2M 11
A 11A
1E
LS P EF 1 2F 10A
1E B
2M
1D 1B
A
F 1C 2D
1A B
F1 N1 2M
20
S 2C
N2
B 2N
2B 2A
T P 8A
8
A259692
16 16E 16D
16C
16B
16A
Z
17 15
17E
17A 17C 15E
15B
18 21 15D
15C
17B 17D Y
15A
17E
3 14 14C 14B
14A
13
5 13G
3
3B 2M
19C 2K 2L
4
13A
2 13B
3A
13D 13C 13E
19D 2G
3C 12 11
2M 2K 2L 11A
B2 19A 19B
2F
B1 2H 2J
2M
19
1 2E
1E
2M 11B 11C
1B 10
1D 9
F 2D
1C 1A
N1 2M
F1
20 10A
B N2 2C
2B 2A
T
2N
S
F2 8A 8
A293721
16
15
16A 16C
17 18
15A
15C
14D
14F
14E
14 14B 14C
L 3 R
3B
A 14A
13
B
2
13B 13C
3A
4
A
LS
2G 13A
B
3C
2M 12 11
P T 11A
2K 2L
A
2F
B
2M
2H 2J
A
LS P EF 1 2E
B
1E
2M
1C 10
1D P
A 9
F 2D
1B 1A B
2280
rev/min
F1 2M
19 10A
B
2A
S N1
T 8A 8
N2
The diagram shows all the machine circuits to clarify the way 10A Counter-balance valve
in which they relate to each other. 11 Extension ram
11A Counter-balance valve
The two stage pump assembly comprises two sections each 12 Auxiliary 1 boom quick release couplings
of which supplies oil to parts of the circuit as follows: (standard build)
13 Second auxiliary option
1A Steer/valve block/auxiliary options 13A Diverter valve (boom)
1B Fan motor 13B Auxiliary 1 boom quick release couplings
13C Auxiliary 2 boom quick release couplings
The main services pump 1A has a priority valve 1D which 14 Second auxiliary with hydraulic pin locking option
always gives priority demand to the steer valve 3A. When 14A Diverter valve (boom)
there is no demand from the steer valve, oil flows from the 14B Auxiliary 1 boom quick release couplings
EF port to the control valve to provide loading auxiliary 14C Auxiliary 2 boom quick release couplings
services. 14D Manual change-over valve
14E Flow restrictor
The schematic shows a number of options, check your 14F Hydraulic pin locking cylinder
machine to see which options apply. 15 Sway control valve option
15A One way restrictors
Component Key 15B Pilot operated check-valve
15C Sway hydraulic cylinder
B Pressure cap breather (if fitted) 16 Steer mode valve - See Note 2
F Return line filter 16A Two wheel steer solenoid
F1 Filter by-pass 16B Four wheel and crab steer solenoid
N1 Neutral circuit feed line 16C Four wheel steer solenoid
N2 Neutral circuit return line 16D Crab steer solenoid
S Pump suction strainer 17 Front power track rod
T Tank 18 Rear power track rod
1 Pump assembly 19 Restricted non return valve
1A Main pump 20 Lift circuit with optional Smooth Ride System (SRS)
1B Fan pump 20A Solenoid valve
1D Priority valve 20B Solenoid valve
1E Test points 20C Accumulators
2 Valve block 20D Pressure switch
2A Main relief valve (MRV)
2D Lift Spool
2E Extension spool Note 1: Pump flow goes directt to the fan motor on non-
2F Tilt spool sway machines
2G Auxiliary spool
2H Auxiliary relief valve (A.R.V.) Note 2: Electrically operated steer mode valve shown.
2J Auxiliary relief valve (A.R.V.) Manual version also available.
2K Auxiliary relief valve (A.R.V.)
2L Auxiliary relief valve (A.R.V.)
2M Load hold check valves (LHCVs)
3 Steer unit assembly (Early type shown on main circuit at
X, later type shown in inset Y)
3A Steer valve
3B Shock valves (option)
3C Main relief valve
4 Cooling fan motor (non-reversible)
4A Relief valve - 190 bar (to M78434)
Relief valve - 108 bar (from M78435)
5 Reversible cooling fan motor option
5A Relief valves
5B Fan change-over solenoid
8 Lift ram
8A Counter-balance valve
9 Displacement ram
10 Tilt ram
530 Construction Machines with Manual Auxiliary Controls - fitted with 2-stage pump From Serial No. TBA
Circuit Diagram - Hydraulic
16 15
16A 16C
17 18
15A
4A
15C
B A
14D
14F
T P 14E
3
14 14B 14C
L R
3C
A 14A
3A 13
2 B
13B 13C
LS
4 A
2G 13A
3B 3D B
T P 2M 12 11
11A
2K 2L
A
2F
B
1E
2M
LS P EF 1
2H 2J
A
2E
B
1D 1A 2M
1B 16 36 10
2280 RPM A 9
F 2D
B
F1 2M
19 10A
B
2A
8A
S N1
T 20 20D
N2 8
8A
20B
20A
4
160-02300-4
20C
The diagram shows all the machine circuits to clarify the way 10A Counter-balance valve
in which they relate to each other. 11 Extension ram
11A Counter-balance valve
The two stage pump assembly comprises two sections each 12 Auxiliary 1 boom quick release couplings
of which supplies oil to parts of the circuit as follows: (standard build)
13 Second auxiliary option
1A Valve block/auxiliary options 13A Diverter valve (boom)
1B Fan motor 13B Auxiliary 1 boom quick release couplings
1C Steer valve 13C Auxiliary 2 boom quick release couplings
14 Second auxiliary with hydraulic pin locking option
The steer pump 1C has a priority valve 1D which always 14A Diverter valve (boom)
gives priority demand to the steer valve 3A. When there is 14B Auxiliary 1 boom quick release couplings
no demand from the steer valve, oil returns back to the tank. 14C Auxiliary 2 boom quick release couplings
14D Manual change-over valve
The schematic shows a number of options, check your 14E Flow restrictor
machine to see which options apply. 14F Hydraulic pin locking cylinder
15 Sway control valve option
Component Key 15A One way restrictors
15B Pilot operated check-valve
B Pressure cap breather (if fitted) 15C Sway hydraulic cylinder
F Return line filter 16 Steer mode valve - See Note 2
F1 Filter by-pass 16A Two wheel steer solenoid
N1 Neutral circuit feed line 16B Four wheel and crab steer solenoid
N2 Neutral circuit return line 16C Four wheel steer solenoid
S Pump suction strainer 16D Crab steer solenoid
T Tank 17 Front power track rod
1 Pump assembly 18 Rear power track rod
1A Main pump 19 Restricted non return valve
1B Fan pump 20 Lift circuit with optional Smooth Ride System (SRS)
1C Steer pump 20A Solenoid valve
1D Priority valve 20B Solenoid valve
1E Test points 20C Accumulators
2 Valve block 20D Pressure switch
2A Main relief valve (MRV)
2D Lift Spool
2E Extension spool Note 1: Pump flow goes directt to the fan motor on non-
2F Tilt spool sway machines
2G Auxiliary spool
2H Auxiliary relief valve (A.R.V.) Note 2: Electrically operated steer mode valve shown.
2J Auxiliary relief valve (A.R.V.) Manual version also available.
2K Auxiliary relief valve (A.R.V.)
2L Auxiliary relief valve (A.R.V.)
2M Load hold check valves (LHCVs)
3 Steer unit assembly (Early type shown on main circuit at
X, later type shown in inset Y)
3A Steer valve
3B Shock valves (option)
3C Main relief valve
4 Cooling fan motor (non-reversible)
4A Relief valve - 190 bar (to M78434)
Relief valve - 108 bar (from M78435)
5 Reversible cooling fan motor option
5A Relief valves
5B Fan change-over solenoid
8 Lift ram
8A Counter-balance valve
9 Displacement ram
10 Tilt ram
530 Construction Machines with Manual Auxiliary Controls - fitted with 3-stage pump From Serial No. 775402
Circuit Diagram - Hydraulic
16
15
16A 16C
17 18
16B 16D
15B
15A
4A
15C
B A
14D
14F
T P 14E
a Y b a X b 14 14B 14C
L 3 R L 3 R
3B
3C A 14A
13
B
2
3A 13B 13C
3A
4 A
LS
LS 2G 13A
B
3B 3D 3D 3C
2M 12 11
T P P T 11A
2K 2L
A
2F
B
c c
2M
d d 2H 2J
A
LS P EF 1 2E
B
1E
2M
1C 10
1D P
16 19 32 A 9
F 2D
1B 1A B
2280
rev/min
F1 2M
19 10A
B
2A
8A
S N1
T 20
N2 20D
8
8A
20B
20A
160-02300-2
4
20C
B Pressure cap breather Note 1: Electrically operated steer mode valve shown.
F Return line filter Manual version also available.
F1 Filter by-pass
N1 Neutral circuit feed line
N2 Neutral circuit return line
S Pump suction strainer
T Tank
1 Pump assembly
1A Main pump
1B Fan pump
1C Steer pump
1D Priority valve
1E Test points
2 Valve block
2A Main relief valve (MRV)
2D Lift spool
2E Extension spool
2F Tilt spool
2G Auxiliary spool
2H Auxiliary relief valve (ARV)
2J Auxiliary relief valve (ARV)
2K Auxiliary relief valve (ARV)
2L Auxiliary relief valve (ARV)
2M Auxiliary relief valve (ARV)
2N Auxiliary relief valve (ARV)
2P Load hold check valves (LHCVs)
3 Steering unit
3A Steer valve
3B Shock valves (option)
3C Main relief valve
4 Cooling fan motor
8 Lift ram
8A Counter-balance valve
9 Displacement ram
10 Tilt ram
10A Counter-balance valve
11 Extension ram
11A Counter-balance valve
12 Auxiliary 1 boom quick release couplings
13 Second auxiliary option
13A Diverter valve (boom)
13B Auxiliary 1 boom quick release couplings
13C Auxiliary 2 boom quick release couplings
14 Second auxiliary with hydraulic pin locking option
14A Diverter valve (boom)
14B Auxiliary 1 boom quick release couplings
14C Auxiliary 2 boom quick release couplings
14D Manual change-over valve
14E Flow restrictor
14F Hydraulic pin locking cylinder
15 Sway option
16 Steer mode valve - See Note 1.
16A Two Wheel steer solenoid
16B Four Wheel and crab steer solenoid
16C Four Wheel steer solenoid
16D Crab steer solenoid
17 Front power track-rod
18 Rear power track-rod
19 Restricted non return valve
16
16A 16C
14D
17 18
14E
14F
16B 16D
14B 14C
14
14A
13B 13C
13
L 3 R 13A
3B
3A 4
12
LS A
2G
B
3C
P T 2P 11A
11
2M 2N
A
2F
B
2P
2K 2L
A
1 2E
B
1E
2P
1C 10
1D 2H 2J
A 9
2D
1B 1A B
2280
F rev/min 2P
B
F1 19 10A
2A
N2
T S N1 8A
The diagram shows all the machine circuits to clarify the way 9 Displacement ram
in which they relate to each other. 10 Tilt ram
10A Counter-balance valve
The two stage pump assembly comprises two sections each 11 Extension ram
of which supplies oil to parts of the circuit as follows: 11A Counter-balance valve
12 Auxiliary 1 boom quick release couplings
1A Valve block/auxiliary options 13 Second auxiliary option
1B Fan motor 13A Diverter valve (boom)
1C Steer valve 13B Auxiliary 1 boom quick release couplings
13C Auxiliary 2 boom quick release couplings
The steer pump 1C has a priority valve 1D which always 14 Second auxiliary with hydraulic pin locking option
gives priority demand to the steer valve 3A. When there is 14A Diverter valve (boom)
no demand from the steer valve, oil returns back to the tank. 14B Auxiliary 1 boom quick release couplings
14C Auxiliary 2 boom quick release couplings
The schematic shows a number of options, check your 14D Manual change-over valve
machine to see which options apply. 14E Flow restrictor
14F Hydraulic pin locking cylinder
Component Key 15 Sway option
16 Steer mode valve - See Note 1
B Pressure cap breather 16A Two wheel steer solenoid
F Return line filter 16B Four wheel and crab steer solenoid
F1 Filter by-pass 16C Four wheel steer solenoid
N1 Neutral circuit feed line 16D Crab steer solenoid
N2 Neutral circuit return line 17 Front power track rod
S Pump suction strainer 18 Rear power track rod
T Tank 19 Restricted non return valve
1 Pump assembly 20 Lift circuit with optional Smooth Ride System (SRS)
1A Main pump 20A Solenoid valve
1B Fan pump 20B Solenoid valve
1C Steer pump 20C Accumulators
1D Priority valve 20D Pressure switch
1E Test points
2 Valve block
2A Main relief valve (MRV) Note 1: Electrically operated steer mode valve shown.
2D Lift Spool Manual version also available.
2E Extension spool
2F Tilt spool
2G Auxiliary spool
2H Auxiliary relief valve (A.R.V.)
2J Auxiliary relief valve (A.R.V.)
2K Auxiliary relief valve (A.R.V.)
2L Auxiliary relief valve (A.R.V.)
2M Auxiliary relief valve (A.R.V.)
2N Auxiliary relief valve (A.R.V.)
2P Load hold check valves (LHCVs)
3 Steer unit assembly (Early type shown on main circuit at
X, later type shown in inset Y)
3A Steer valve
3B Shock valves (option)
3C Main relief valve
4 Cooling fan motor (non-reversible)
4A Relief valve - 190 bar (to M78434)
Relief valve - 108 bar (from M78435)
5 Reversible cooling fan motor option
5A Relief valves
5B Fan change-over solenoid
8 Lift ram
8A Counter-balance valve
540 Construction Machines with Manual Auxiliary Controls From Serial No. 775402
Circuit Diagram - Hydraulic
17 13
T
17A 17C T
B
F
18 16 13G
A
P 13F
P 13C
17B 17D 19C 13B
SA
5 19D
SB
Y
13E
13A
150 BAR
19 13D 15C
19B
B A
5B 15B
15A
5A R P1
T P
P2
15D
a Y b a X b B
L 3 R L 3 R N 19A 20
3C 4 P 12 20C
3C P1 A 20D
c
B D 20B
P2
2 C
20E
d
3A
3A 4A
20A
A
LS
LS 21
2G 2K 2L B
3B 3D 3D 3B
T P P T 2M
c c
A
25
2F 2H 2J B
d d
2M 24 23 22
e e A
LS P EF 1 24A
2E B
1E
2M
1C
1D P
1A
A
1B 16 19 32
F 2D
2280 B
rev/min 28 26
F1 2M 27
B
2A
P T 29
T
N1
S
F2 N2
30
31
A343503
160/12719
17 13
T
17A 17C T
B
F
18 16 13G
A
P 13F
P 13C
17B 17D 19C 13B
SA
19D
SB
Y
13E
13A
150 BAR
19 13D 15C
19B
15B
15A
R P1
P2
15D
B
L 3 R N 19A 20
P 12 20C 20D
P1 A
4 B 20B
c D
3C P2
2 C
20E
d
3A
20A
A
LS 2G 21
2K 2L B
3D 3B
P T 2M
A
25
2F 2H 2J B
2M 24 23 22
A Extend
LS P EF 1 24A
2E B Retract
1E
2M
1C
1D P
1A
A
1B 16 19 32
F 2D
2280 B
rev/min 28 26
F1 2M 27
Crowd
B
N2 N1 2A
Dump
P T 29
T
S
Dump
F2
Lift
30
31
A343501
The diagram shows all the machine circuits to clarify the way 13B Pilot operated check valve
in which they relate to each other. 13C One-way restrictor
13D One-way restrictor
The two stage pump assembly comprises two sections each 13E Relief valve
of which supplies oil to parts of the circuit as follows: 13F Diverter valve
13G Sway valve spool
1A Valve block/auxiliary options 15A Hydraulic pin lock ram
1B Fan motor 15B Restrictor
1C Steer valve 15C Manual changeover valve
15D Auxiliary 2 boom quick release couplings
The steer pump 1C has a priority valve 1D which always 16 Rear power track rod
gives priority demand to the steer valve 3A. When there is 17 Steer mode valve (option)
no demand from the steer valve, oil returns back to the tank. 17A 2 wheel steer solenoid
17B 4 wheel and grab steer solenoid
The schematic shows a number of options, check your 17C 4 wheel steer solenoid
machine to see which options apply. 17D Crab steer solenoid
18 Front power track rod
Component Key 19 Trailer brake valve assembly (option)
19A Pilot valve
B Pressure cap breather 19B Brake valve
F Return line filter 19C Trailer brake coupling
F1 Filter by-pass 19D Brake circuit connection
F2 Direct return to tank 20 Pick-up hitch (option)
S Pump suction strainer 20A Solenoid diverter valve (chasis mounted)
T Tank 20B Pick-up hitch ram
N1 Neutral circuit feed line 20C Auxiliary 1 boom quick release couplings
N2 Neutral circuit return line 20D Trailer/Auxiliary quick release coupling
1 Pump assembly 20E Restrictor adaptor
1A Main services pump 21 High flow auxiliary (option)
1B Fan pump 22 Inner extension ram
1C Steer pump 23 Extension ram check/counter balance valve
1D Priority valve 24 Outer extension ram
1E Test points 24A Bleed point
2 Valve block 25 Regenerative valve
2A Main relief valve (MRV) 26 Tilt ram
2D Lift Spool 27 Tilt check/counterbalance valve
2E Extension spool 28 Displacement ram
2F Tilt spool 29 Displacement lift valve
2G Auxiliary spool 30 Lift ram
2H Auxiliary relief valve (A.R.V.) 31 Lift check/counterbalance valve
2J Auxiliary relief valve (A.R.V.)
2K Auxiliary relief valve (A.R.V.)
2L Auxiliary relief valve (A.R.V.) Note 1: The schematic shows sway and trailer brake
2M Auxiliary relief valve (A.R.V.) options. Pump flow goes direct to fan motor if sway is not
3 Steer unit assembly fitted.
3A Steer valve
3B Main relief valve Note 2: Restrictor adaptor 20E is fitted to improve hitch
3C Shock valves (option) control on machines fitted with pick-up hitch option. See
3D Non-return valve Technical Information Bulletin 5/195 (E191).
4 Cooling fan motor (non-reversible)
4A Relief valve - 190 bar (to M78434)
Relief valve - 108 bar (from M78435)
5 Reversible cooling fan motor option
5A Relief valves (108 bar)
5B Fan change-over solenoid
12 Auxiliary 1 boom quick release couplings
(standard build)
13 Sway control valve (option)
13A Sway ram
535-95 Machines - fitted with 3-stage pump From Serial No. 777362
Circuit Diagram - Hydraulic
17 13
T
17A 17C T
B
F
18 16 13G
A
P 13F
P 13C
17B 17D 19C 13B
SA
5 19D
SB
Y
13E
13A
150 BAR
19 13D 15C
19B
B A 5B 15B
15A
5A R P1
T P
P2
15D
B
L 3 R N 19A 20
4 P 12
P1 A
20C 20D
c
B D 20B
3C P2
2 C
20E
d
3A 4A
20A
A
LS 2G 21
2K 2L B
3D 3B
P T 2M
A
b d 25
2F 2H 2J B
b c 2M 24 22
d 23
X A Extend
c
1E Y LS P EF 1
2E
24A
B Retract
1E
LS P EF 1
2M
1C
1D P
1A
A
1B 16 19 32
1D P F 2D
2280 B
1B 16 36 rev/min e 28 26
1A F1 a 2M 27
2280
rev/min
a e B
N2 N1 2A
N1
P T 29
T
S
F2
30
31
A343502
A343502
The diagram shows all the machine circuits to clarify the way 13B Pilot operated check valve
in which they relate to each other. 13C One-way restrictor
13D One-way restrictor
The two stage pump assembly comprises two sections each 13E Relief valve
of which supplies oil to parts of the circuit as follows: 13F Diverter valve
13G Sway valve spool
1A Valve block/auxiliary options 15A Hydraulic pin lock ram
1B Fan motor 15B Restrictor
1C Steer valve 15C Manual changeover valve
15D Auxiliary 2 boom quick release couplings
The steer pump 1C has a priority valve 1D which always 16 Rear power track rod
gives priority demand to the steer valve 3A. When there is 17 Steer mode valve (option)
no demand from the steer valve, oil returns back to the tank. 17A 2 wheel steer solenoid
17B 4 wheel and grab steer solenoid
The schematic shows a number of options, check your 17C 4 wheel steer solenoid
machine to see which options apply. 17D Crab steer solenoid
18 Front power track rod
Component Key 19 Trailer brake valve assembly (option)
19A Pilot valve
B Pressure cap breather 19B Brake valve
F Return line filter 19C Trailer brake coupling
F1 Filter by-pass 19D Brake circuit connection
F2 Direct return to tank 20 Pick-up hitch (option)
S Pump suction strainer 20A Solenoid diverter valve (chasis mounted)
T Tank 20B Pick-up hitch ram
N1 Neutral circuit feed line 20C Auxiliary 1 boom quick release couplings
N2 Neutral circuit return line 20D Trailer/Auxiliary quick release coupling
1 Pump assembly 20E Restrictor adaptor
1A Main services pump 21 High flow auxiliary (option)
1B Fan pump 22 Inner extension ram
1D Priority valve 23 Extension ram check/counter balance valve
1E Test points 24 Outer extension ram
2 Valve block 24A Bleed point
2A Main relief valve (MRV) 25 Regenerative valve
2D Lift Spool 26 Tilt ram
2E Extend spool 27 Tilt check/counterbalance valve
2F Tilt spool 28 Displacement ram
2G Auxiliary spool 29 Displacement lift valve
2H Auxiliary relief valve (A.R.V.) 30 Lift ram
2J Auxiliary relief valve (A.R.V.) 31 Lift check/counterbalance valve
2K Auxiliary relief valve (A.R.V.)
2L Auxiliary relief valve (A.R.V.)
2M Auxiliary relief valve (A.R.V.) Note 1: The schematic shows sway and trailer brake
3 Steer unit assembly options. Pump flow goes direct to fan motor if sway is not
3A Steering valve fitted.
3B Main relief valve
3C Shock valves (option) Note 2: Restrictor adaptor 20E is fitted to improve hitch
3D Non-return valve control on machines fitted with pick-up hitch option. See
4 Cooling fan motor (non-reversible) Technical Information Bulletin 5/195 (E191).
4A Relief valve - 108 bar
5 Reversible cooling fan motor option
5A Relief valves (108 bar)
5B Fan change-over solenoid
12 Auxiliary 1 boom quick release couplings
(standard build)
13 Sway control valve (option)
13A Sway ram
535-95 Machines - fitted with 2-stage pump From Serial No. TBA
Circuit Diagram - Hydraulic
17 13
T
17A 17C T
B
F
18 16 13G
A
P 13F
P 13C
17B 17D 19C 13B
SA
5 19D
SB
Y
13E
13A
150 BAR
19 13D 15C
19B
B A
5B 15B
15A
5A R P1
T P
P2
15D
a Y b a X b B
L 3 R L 3 R N 19A 20
3C 4 P 12 20C
3C P1 A 20D
c
B D 20B
P2
2 C
20E
d
3A
3A 4A
20A
A
LS
LS 21
2G 2K 2L B
3B 3D 3D 3B
T P P T 2M
c c
A
25
2F 2H 2J B
d d
2M 24 23 22
e e A
LS P EF 1 24A
2E B
1E
2M
1C
1D P
1A
A
1B 16 19 32
F 2D
2280 B
rev/min 28 26
F1 2M 27
B
2A
P T 29
T
N1
S
F2 N2
30
31
A343503
160/12719
T 6A 6D B
7
5
T
P A
6B 6C
6E A
22A 22
C V 2K
B
5 7 2Q
A 21A 21
2J
B
2 2Q
20A
C3
2H C1
9
3 L R
3B A 18
20
4 2G B C2 C4
18A
2Q 2M
2L 19
3A A 16A
2F
LS 2N B
16
2Q 2P 17
3C
P T A
2E
B
13E
2Q 15 13
13B
A
2D
1E B 14
LS P EF 1 13C
2Q
1E 13D
11A
1D 1B 13A
2C 12 11
1C 2R
1A
2B
2A
8A
N2 8
S F
F1 P
B
T A260812
N1
6
6A 6D 7
5
T
2
6B 6C
22A
6E
2K
22
5 7
21A
2J
2Q
21
3 9 20 20A
3B
2H
4 18B
3A 2G 18A
18
2Q
2L 2M 19
3C
2F
2N
2Q 16
1E 17
1 2P
6E 1E
2E
1B
1D 2Q 15 13E 13
16A
Y 1A 13B
1C
2D 14
13C
3 2Q
N2 13D
11A
12 11
13A
B 2C
F F1 2R
2B 2A
T
S
8A 8
P
N1 A293731
19
19A 19C
18B
19B 19D
20 21 2 18A
18C
A
2K 17A
B
2R
A 17
2J 17B
L 19 B
L
16A
2R
2H
4 16
16B
15
LS A
2G
P T B
1E 2R
2N 2P
A
2F 14
1E 13
1 B
1E 14A
2R
1C 2L 2M
A
1D 12 11
2E
1B B 11B
1A
2R
10A
A 11C
2D 10 9
N2 B 11D
9A
B 2R
11A
F F1
2A
8
S
T 8A
N1
532, 537, & 550 Machines with Manual From Serial No. 775402
Auxiliary Controls
Circuit Diagram - Hydraulics
Description
The diagram shows all the machine circuits to clarify the way 4 Cooling fan motor (non-reversible)
in which they relate to each other. * 4A Reversible cooling fan motor option (from Serial No.
785165)
The pump assembly comprises three sections each of which 8 Lift ram
supplies oil to parts of the circuit as follows: 8A Counter balance valve
9 Inner extension ram
1A Valve block/auxiliary options 9A Counter balance valve
1B Fan motor 10 Outer extension ram
1C Steer valve 11 Regenerative valve
11A Hose burst check-valve (HBCV)
The pump is mounted on the rear face of the bevel box. 11B Relief valve
11C Check valve
The valve block is mounted under the cab on the inboard 11D Non-return valve
side 11E Non return valve
12 Restricted non-return valve
The steer pump 1C has a priority valve 1D which always 13 Displacement cylinders
gives priority demand to the steer valve 3A. When there is 14 Tilt ram
no demand from the steer valve, oil returns back to the tank. 14A Counter-balance valve
15 Auxiliary 1 boom quick release couplings
The schematic shows a number of options, check your 16 Right hand stabilizer hydraulic cylinder
machine to see which options apply. 16A Stabilizer lock-out valve
16B Pressure switch (option)
Component Key 17 Left hand stablizer hydraulic cylinder
17A Stabilizer lock-out valve
B Pressure cap breather 17B Pressure switch (option)
F Return line filter 18 Sway control valve option
F1 Filter by-pass 18A One-way restrictor
N1 Neutral circuit feed line 18B Pilot operated check-valve
N2 Neutral circuit return line 18C Sway hydraulic cylinder
S Pump suction strainer * 18D relief valve (150 bar)
T Tank 19 Steer mode valve - see Note 2
1 Pump assembly 19A Two wheel steer solenoid
1A Main pump 19B Four wheel and crab steer solenoid
1B Fan pump 19C Four wheel steer solenoid
1C Steer pump 19D Crab steer solenoid
1D Priority valve 20 Front steer cylinders
1E Test points 21 Rear steer cylinders
2 Valve block
2A Main relief valve (M.R.V.)
2D Lift spool Note 1: Pump flows goes direct ro the fan motor on non-
2E Extension spool sway machines.
2F Tilt spool
2G Auxiliary spool Note 2: Electrically operated steer mode valve shown.
2H Unloader valve Manual version also available.
2J Right hand stabilizer
2K Left hand stabilizer
2L Auxiliary relief valve (ARV)
2M Auxiliary relief valve (ARV)
2N Auxiliary relief valve (ARV)
2P Auxiliary relief valve (ARV)
2R Load hold check-valves (LHCVs)
3 Steering unit
3A Steer valves
3B Shock valves
3C Main relief valve
506B
Circuit Diagrams - Hydraulics
Component Key
506B
Circuit Diagrams - Hydraulics (cont’d)
12
12
16
C2 18 C1
42
35 16C
16D
16B 13
18B
17 13A
34A
18A 18C
C2
34B
P 11
V2 V1
T V2
36
15A
15
2F 10
L
33
P R
10A 10A
P
29 14
T
C V
2P 2Q
A B A B A B A B A B
S2 2
2X
31 P2 P3 S3 C
P1 2M 2N 2L
43 2A
30
S1
2G 2F 2E 2C 2B 1B
2V 2U 2T 2S 2R 1A
F
32
41
T
35
P
A B
34 16
13
12
13A
36
C2 18 C1
11
18B
L 33 R
18C
15A 18A
15
33A 10
V2 V1
LS P EF
P1 2W 2P 2Q
A B A B A B A B A B
2
C
P1C
S1
P1B 2A
S3 2M 2N 2L
P1A 42
2G 2F 2E 2C 2B 1B
P3 2V 2U 2T 2S 2R
1A
F
41
506C
Circuit Diagrams - Hydraulics (cont’d)
Component Key
C Cap
F Filter
P1 Main pump assembly
P1A Pump
P1B Pressure test point
P1C Priority valve
P3 Cooling fan pump
S1 Main pump suction line
S3 Cooling fan pump suction line
T Tank
1A Neutral circuit feed line
1B Neutral circuit return line
2 Valve block
2A Main relief valve (M.R.V.)
2B Lift spool
2C Auxiliary spool
2E Tilt spool
2F Extension spool
2G Sway spool
2L Auxiliary relief valve (A.R.V.)
2M Auxiliary relief valve (A.R.V.)
2N Auxiliary relief valve (A.R.V.)
2P Auxiliary relief valve (A.R.V.)
2Q Auxiliary relief valve (A.R.V.)
2R Load hold check valve (L.H.C.V.)
2S Load hold check valve (L.H.C.V.)
2T Load hold check valve (L.H.C.V.)
2U Load hold check valve (L.H.C.V.)
2V Load hold check valve (L.H.C.V.)
2W Auxiliary relief valve (A.R.V.) (See Note 2)
10 Lift cylinders
10A Lift cylinder check valves
11 Displacement cylinder
12 Extension cylinder
13 Tilt cylinder
13A Tilt cylinder check valve
14 Non-return valve
15 Sway cylinder
15A Sway cylinder check valve
16 Auxiliary attachment cylinder
18 Combined load hold check and regenerative valve
18A Retract load hold check valve
18B Regenerative check valve
18C Extend load hold check valve
29 Steering anti-cavitation valve (See Note 1)
33 Steering unit
33A Steer valve
33C Main relief valve
34 Steering mode selctor valve
35 Front axle steering cylinders
36 Rear axle steering cylinders
41 Cooling fan motor
42 In-line ARV (See Note 2)
35
P
A B
34
16
T 13
12
13A
36
11
C2 18 C1
L 33 R
18B
15A
15
18A 18C 10
33A
V2 V1
P T 10A 10A
P
29 43
C V
2W 2P 2Q
A B A B A B A B A B
S2
2
2X
C
31 P3
S3 P1
P2 2M 2N 2L 2A
42
30 S1
2G 2F 2E 2C 2B 1B
F 2V 2U 2T 2S 2R 1A
32
41
13B 13A
SA
5 SA
T B
11 13
13B
P A
A 14A
11A
6 7 B
11Q
16 14
A
A T B
11B 14B
B
11Q 15A
11C
L R 15
26 15B
1 11L 11M A
8
26A 11D
4 B
26B 18
26D 11Q 17
26C
T
26E P1
2
P2 11R 17A
T Extm 19
P
3 Ext
LS P EF Extr
3 P 11N 11P A
1 Retm 20
11E
Ret B
3A P4 Retr 21
2 11Q
16 33 41
Lowm 23
P3 P2 P1 4 22A
Low A P2
C
D
Lowr 11F B 22
B P1 A
9 2 Liftm
1 11Q
2 Lift
Liftr
P
T1 V1
11G
B
T Crdm
Crd
C1
24
11Q
T 1
24B
T2
C2
Dumpm 11J
V2
24A
Dump 11K
11H
T
25
10 25A
A
10A B
10E
A
10B
B
10E
10C
533-105 Machines
(from serial No. 786756)
Circuit Diagram - Hydraulics
Description
The diagram shows all the machine circuits to clarify the way 15A Hydraulic ram pin lock
in which they relate to each other. 15B Restrictor
15C Manual changeover valve
The pump assembly comprises two sections each of which 15D Auxiliary 2 boom quick release couplings
supplies oil to parts of the circuit as follows: 16 Rear power track rod
17 Steer mode valve
1A Valve block/auxiliary options 17A 2 wheel steer solenoid
1B Fan motor 17B 4 wheel and grab steer solenoid
17C 4 wheel steer solenoid
The pump has a priority valve 1D which always gives priority 17D Crab steer solenoid
demand to the steer valve 3A. When there is no demand 18 Front power track rod
from the steer valve oil flows from the EF port to the control 21 High flow auxiliary (option)
valve to provide loading services. 22 Inner extension ram
23 Extension ram check/counter balance valve
Component Key 24 Outer extension ram
24A Bleed point
B Pressure cap breather 25 Regenerative valve
F Return line filter 26 Tilt ram
F1 Filter by-pass 27 Tilt check/counterblance valve
F2 Direct return to tank 28 Displacement ram
S Pump suction strainer 29 Displacement lift valve
T Tank 30 Lift ram
N1 Neutral circuit feed line 31 Lift check/counterbalance valve
N2 Neutral circuit return line
1 Pump assembly
1A Main pump
1B Fan pump
1D Priority valve
1E Test point
2 Valve block
2A Main relief valve
2D Lift spool
2E Extend spool
2F Tilt spool
2G Auxiliary spool
2H Auxiliary relief valve (ARV)
2J Auxiliary relief valve (ARV)
2K Auxiliary relief valve (ARV)
2L Auxiliary relief valve (ARV)
2M Load hold check-valves (LHCVs)
3 Steer unit assembly
3A Steering valve
3B Main relief valve
3C Shock valves
3D Non return valve
4 Cooling fan motor (non-reversible)
4A Relief valve (108 bar)
5 Reversible cooling fan motor option
5A Relief valves (108 bar)
5B Fan reversing valve
10 Left stabilizer ram
10A Left stabilizer lock out valve
10B Pressure switch
11 Right stabilizer ram
11A Right stabilizer lock out valve
11B Pressure switch (optional)
12 Auxiliary 1 boom quick release couplings (standard
build)
17 B
T
18 P A
2 10A
10
A
5 2Q B
10B
2M
11A
B A 5B A
2P B 11
5A T P
3 2M 11B
L R
4 15C 15B
3C 15A
2N 12 15D
3A
A
4A
2G
LS 2K 2L B
3D P 2M 21
3B T
1E
2H 2J A
LS P EF 1 2F B
25
2M 24 23 22
1A
A
1C
1B 16 36
2E B
2280 RPM
2M
B F 2D B
28 27 26
2M
F1
S
T 2A 29
F2 N1 P T
30 160-13379
N2 31
926, 930
Contents
Page No.
General Information
- Fluids, Lubricants and Capacities (926, 930) 95 - 00 - 01/1,2
- Fluids, Lubricants and Capacities
- (926, 930, 940 N.Am) 95 - 00 - 01/3,4
- Static Dimensions (926, 930) 95 - 00 - 02/1,2
- Static Dimensions (926, 930, 940 N.Am) 95 - 00 - 02/3,4
Data
- Electrical 95 - 05 - 01/1 to 5
- Hydraulic 95 - 05 - 02/1,2
- Transmission 95 - 05 - 03/1
- Brakes 95 - 05 - 04/1
- Steering 95 - 05 - 05/1,2
- Engine 95 - 05 - 06/1
Fault Finding
- Transmission 95 - 10 - 01/1 to 3
* Circuit Diagrams
- Electrical 95 - 15 - 01/1 to 8
- Hydraulic 95 - 20 - 01/1,2
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently
run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
Engines of new machines are filled at the factory with JCB 10W/30 Mutigrade oil. This oil should be drained after the first 100
hours of operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB
10W/30 Mutigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to
the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended
below.
Fuel Tank 88 (19.3) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Transmission (2WD) 17.3 (3.8) JCB Special Transmission Fluid ESP-M2C 33G
Front Axle 29.5 (6.5) JCB High Performance Gear Oil ESEN-M2C 86A/B
Hydraulic System †64 (14) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
†Note: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and
check with all rams closed. Watch level sight glass when filling.
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently
run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
Engines of new machines are filled at the factory with JCB 10W/30 Mutigrade oil. This oil should be drained after the first 100
hours of operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB
10W/30 Mutigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to
the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended
below.
Fuel Tank 88 (19.3) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Transmission (2WD) 17.3 (3.8) JCB Special Transmission Fluid ESP-M2C 33G
Front Axle 29.5 (6.5) JCB High Performance Gear Oil ESEN-M2C 86A/B
Hydraulic System †64 (14) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
†Note: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and
check with all rams closed. Watch level sight glass when filling.
926 (N. Am) from m/c 603110 to 605999 and from m/c 660300
930 (N. Am) from m/c 608300 to 609999 and from m/c 660300
940 (N. Am) from m/c 660001
Fluids, Lubricants & Capacities (Type AA Engine Builds)
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently
run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
Engines of new machines are filled at the factory with JCB 10W/30 Mutigrade oil. This oil should be drained after the first 100
hours of operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB
10W/30 Mutigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to
the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended
below.
Fuel Tank 23.25 (88) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Coolant) 4.5 (17) JCB For Seasons Antifreeze ASTM D3306-74
And Summer Coolant
(See Coolant Mixtures)
Transmission (2WD) 5.0 (18.9) JCB Special Transmission Fluid ESP-M2C 33G
Front Axle 7.8 (29.5) JCB Special Gear Oil Plus ESEN-M2C 86A/B
Hydraulic System †16.9 (64) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
†Note: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and
check with all rams closed. Watch level sight glass when filling.
926 (N. Am) from m/c 603110 to 605999 and from m/c 660300
930 (N. Am) from m/c 608300 to 609999 and from m/c 660300
940 (N. Am) from m/c 66001
Fluids, Lubricants & Capacities (Type AR Engine Builds)
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently
run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
Engines of new machines are filled at the factory with JCB 10W/30 Mutigrade oil. This oil should be drained after the first 100
hours of operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB
10W/30 Mutigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to
the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended
below.
Fuel Tank 23.25 (88) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Coolant) 4.5 (17) JCB Four Seasons Antifreeze ASTM D3306-74
And Summer Coolant
(See Coolant Mixtures)
Transmission (2WD) 5.0 (18.9) JCB Special Transmission Fluid ESP-M2C 33G
Front Axle 7.8 (29.5) JCB Special Gear Oil Plus ESEN-M2C 86A/B
Hydraulic System †16.9 (64) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
†Note: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and
check with all rams closed. Watch level sight glass when filling.
Static Dimensions
K L
H
A
G
F D
E
C B
151800
Forklift Performance
Outside turning radius
(2 wheel drive) 3.6 m (11 ft 10 in)
(4 wheel drive) 4.49 m (14 ft 9 in)
Departure angle - 926 machine
(2 wheel drive) 46°
(4 wheel drive) 53°
Departure angle - 930 machine
(2 wheel drive) 38°
(4 wheel drive) 43°
Obstruction angle
(2 wheel drive) 57°
(4 wheel drive) 51°
Lift capacity † †
Lift height † †
930 Machine
2 Wheel drive 6310 kg (13914 lb)
4 Wheel drive 6380 kg (14068 lb)
Note: The above data is based on a standard fork size of 1067 mm x 100 mm x 50 mm (42 in x 4 in x 2 in)
926 (N. Am) from m/c 603110 to 605999 and from m/c 660300
930 (N. Am) from m/c 608300 to 609999 and from m/c 660300
940 (N. Am) from m/c 660001
Static Dimensions
K M B
J
D
L
E
F
926 (N. Am) from m/c 603110 to 605999 and from m/c 660300
930 (N. Am) from m/c 608300 to 609999 and from m/c 660300
940 (N. Am) from m/c 660001
Static Dimensions (cont’d)
926 930 940
WEIGHT
(With Cab)
2- Wheel drive 15036 lb (6820 kg) 14,740 lb (6,700kg)
4- Wheel drive 15991 lb (7253 kg)
FORKLIFT PERFORMANCE
926, 930
Data - Electrical
System Type 12 volt, negative earth
Battery
Cranking Performance at - 18 °C (0 °F) 410 amps to 1.4 V.P.C.
Reserve capacity (minutes) for 25 amp load 180
Alternator Lucas A127-65, 65 amp maximum output
Starter Motor Lucas M127
Light Bulbs
IP67 Electrics
Machines from serial No. 602902 (926) and 608656 (930) are fitted with IP67 electrics which features different loom
construction and method of attachment.
Circuit Protection
A5 Roof Wiper 10
Rear Wiper
Beacon
B1 Back-up Alarm 10
Transmission Solenoids
Parking Brake Buzzer
Engine Shut Off Solenoid
B4 Heater 10
Direction Indicators
B5 Gauges 10
Parking Brake Light
Instrument Panel
Warning Lights
Brake Lights
B6 Horn 10
Washer
Front Wiper
Headlight Flasher
926, 930 From m/c no. 602074 (926), 607718 (930) & machines with IP67 Electrics
Data - Electrical
Fuses
The electrical circuits are protected by fuses. The fuses are located in fuse boxes near the instrument panel. They are in three
rows, labelled A, B and C. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one.
Circuit Protection
A5 Rear Wiper 10
Beacon
or as above plus Roof Wiper 15
B1 Forward/Reverse Solenoids 10
via Relays
B4 Heater 10
B5 Gauges 10
Parking Brake Light
Instrument Panel
Warning Lights
Brake Lights
B6 Horn 10
Front Wiper
Direction Indicators 126820
C2 Back-Up Alarm 5
Reversing Light Circuit
C3 Headlight Flasher 10
PRIMARY FUSES
PR1 Feeding circuit fuses B1 - B4 50A
PR2 Feeding circuit fuses A7 - A9, B5 - B7 60A
PR3 Feeding ignition switch, circuit fuses A1 - A6 70A
PR4 Feeding air conditioning 60A
CIRCUIT FUSES
Row A
A1 Transmission 7.5A
A2 Instrumentation 5A
A3 Brake Lights 7.5A
A4 ESOS/Cold Start Advance 10A
A5 Rear/Roof Wiper, Face Fan (Option) 10A(15A)
A6 Front Wipe/Wash 10A
A7 Beacon 7.5A
A8 Hazard Warning Lights 10A
A9 Horn, Headlamp Flash 15A
A10 Thermostart 20A
PR1 PR2
926, 930
Data - Electrical
Relay Location
The relays are located as follows:
ROW B
Circuit Rating
1 Heater Fan 15A
2 Warning Lights 5A
3 Dip beam 15A
4 Main beam 15A
5 Worklamp 7.5A
6 Direction Indicators 7.5A
ROW C
Circuit Rating
1 Front wash/wipe 7.5A
2 Horn/headlamp flash 15A
3 Transmission 10A
4 Thermostart 20A
5 Rear/roof wiper 10A
- with fan level fan 15A
6 Main lighting 25A
926, 930
940 (N. Am. only)
Data Hydraulic
Pump
Control Valves
Type Kontak Unit 18 Sectional, two to four spools according to
build.
Spool 1 Double-acting, carriage lift.
Spool 2 Double-acting, mast tilt.
Spool 3 Double-acting, attachments as required.
Note: For North America machines with JCB masts, refer to UK and Rest of World A.R.V. settings.
926, 930
940 (N. Am. only)
Data Transmission
Syncro Shuttle Combined torque converter, reverser and gearbox unit
with optional four wheel drive output.
Torque Converter Diameter. 279 mm (11 in)
Torque Multiplication at Stall 2.2 : 1
Minimum Engine Speed at Converter Stall 1650 - 1750 rev/min
At 100 deg C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
2000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
At 100 deg C 1000 rev/min 8.3 - 9.0 8.4 - 9.1 120 - 130
2000 rev/min 8.3 - 9.0 8.4 - 9.1 120 - 130
Cooler at 50 deg C 1000 rev/min 11.4 - 13.6 2.5 - 3.0 3.0 - 3.6
2000 rev/min 20.5 - 22.7 4.5 - 5.0 5.4 - 6.0
Cooler at 100 deg C 1000 rev/min 10.2 - 12.5 2.25 - 2.75 2.7 - 3.3
2000 rev/min 22.7 - 26.1 5.0 - 5.75 6.0 - 6.9
Pump at 50 deg C 1000 rev/min 11.0 - 15.0 2.5 - 3.3 3.0 - 4.0
2000 rev/min 22.5 - 29.5 5.0 - 6.5 6.0 - 8.0
926, 930
940 (N. Am. only)
Data Transmission (cont’d)
Drive Axle - Front
Type Epicyclic
Weight (approximate) 386 kg (852 lb)
Overall Gear Ratio 18.16 : 1
24.975 : 1 German
Weight with Steer Rams (but without wheels) 278 kg (613 lb)
Toe-in Zero
Camber Angle 3° Positive
Castor Angle 2°
King-pin Angle Zero
Oscillation + 6°
Weight with Steer Rams (but without wheels) 352 kg (776 lb)
Overall Gear Ratio (JCB Syncro Shuttle) 18.6 : 1
Crownwheel and Pinion Ratio 3.44 : 1
Oscillation ± 9°
Castor Angle 2°
Camber Angle 2° Positive
King-pin Inclination Zero
Toe-in Zero
Tyre Pressures
15.5/80 x 24 x 10 3.0 44
15.5 x 25 x 8 3.0 44
16.5/85 x 24 x 8 3.0 44
16.9 x 24 x 12 (926 only) 2.0 29
9.00 x 16 x 8 3.9 57
10.5 x 18 x 10 2.5 36
11L x 16 x 10 3.6 52
12.5/80 x 18 x 8 1.5 22
12.5 x 18 x 10 1.7 25
12.5/80 x 18 x 10 1.7 25
14 x 17.5 x 10 (N. Am 4WD only) 1.7 25
Front Rear
lbf ft Nm lbf ft Nm
500 678 500 678
926, 930
Data - Brakes
Service Brakes
Parking Brake
926, 930 From m/c no. 602750 to 602797 (926), 608300 to 608418 (930)
Data - Steering
System Type Full power hydrostatic
Pump (see Data - Hydraulics)
Control Unit Type 2 Wheel Drive OSPC 160
Control Unit Type 4 Wheel Drive OSPC 200
Priority Valve Type OLSB 80
Relief Valve Operating Pressure 150 bar (153 kgf/cm2; 2175 lbf/in2)
Shock Relief Valve Operating Pressure
2 Wheel Drive 250 bar (255 kgf/cm2; 3625 lbf/in2)
4 Wheel Drive 240 bar (245 kgf/cm2; 3480 lbf/in2)
Ram Dimensions (2 and 4 Wheel Drive)
Bore 50.0 mm (1.97 in)
Rod Dia. 25.0 mm (0.98 in)
Stroke 275 mm (10.83 in)
926, 930
Data - Engine
Fuel System
For further engine details see Engine Manual Publication No. 9806/0100 for AA Engine builds
9806/2140 for AR Engine builds
926, 930
Fault Finding - Transmission
Before carrying out the checks listed the machine should, if possible, be operated to determine the fault area(s), and bring the
systems to their normal working temperatures.
Ensure that the correct quantity and grade of oil is used and that there are no obvious leaks.
CHECK ACTION
3 Is there air in the hydraulic system? YES: Continue running to expel air.
NO: Check 4
13 Is the transmission not pulling in both YES: Stall test machine, Check 14
. Forward and Reverse? NO: Check 16
926, 930
Fault Finding - Transmission (cont’d)
CHECK ACTION
16 Are clutch sealing rings damaged? YES: Tap pressure gauge into clutch feed lines to
monitor pressure.
NO: Check clutch plates for damage.
18 Is the start switch in the run position and supplying YES: Check 19
current to the neutral start relay? NO: Rectify.
19 Is the fault only when the transmission is hot? YES: Dismantle solenoid and check components.
NO: Check microswitches, relay and wiring loom.
20 Is the noise a growl, hum or grinding? YES: Check gears for damage or wear.
NO: Check 21
21 Is the noise a hiss, thump or bumping? YES: Check bearings for damage or wear.
NO: Check 22
22 Is the noise a squeal? YES: Check free running gears for seizure.
NO: Check 23
24 Is the countershaft or its bearings worn or damaged? YES: Renew damaged parts.
NO: Check 25
25 Is there excessive backlash in the gears? YES: Adjust by checking shaft end float.
NO: Check 26
28 Are the sliding gear teeth worn or damaged? YES: Renew gears.
NO: Check 29
30 Are the selector fork pads or grooves in gears worn? YES: Renew worn parts.
NO: Check 31
926, 930
Fault Finding - Transmission (cont’d)
CHECK ACTION
34 Are the selector fork pads out of position? YES: Reposition or renew (check interlock).
NO: Check 35
37 Are steel chips embedded in the bronze? YES: Continue using, chips will either embed below
bronze or be rejected.
NO: Check 38
39 Are the sliding gears tight on the splines? YES: Free or renew.
NO: Check 40
41 Are steel chips embedded in the bronze? YES: Continue using, chips will either embed below
bronze or be rejected.
NO: Check 42
1 Battery 61 Fuse B2
2 Starter Solenoid 62 Road Lights Switch
3 Starter Motor 63 Side Lights Relay
4 Starter Switch 64 Diode
5 Thermostart 65 Diode
6 Fuse B4 66 Neutral Start Relay
7 Heater Switch 67 Battery Isolator (optional)
8 Resistor
9 Heater Motor Lights
10 Fuse B6
11 Horn Push 70 Direction Indicator Warning
12 Horn 71 Hazard Warning
13 Wash/Wiper Switch 72 L.H. Front Indicator
14 Washer Pump 73 L.H. Rear Indicator
15 Front Wiper 74 R.H. Front Indicator
16 Hazard Warning Switch 75 R.H. Rear Indicator
17 Indicator Relay 76 Rear Working
18 Direction Indicator Switch 77 R.H. Stop
19 Fuse A6 78 L.H. Stop
20 Fuse A5 79 Beacon
21 Rear Wiper 80 Blocked Air Filter Warning
22 Roof Wiper 81 Engine Oil Pressure Warning
23 Beacon 82 Transmission Oil Temperature Warning
24 Engine Stop Solenoid 83 Transmission Oil Pressure Warning
25 Fuse C1 84 Engine Coolant Temperature Warning
26 Fuse C2 85 Alternator Warning
27 Back-up Alarm Relay 86 Parking Brake Warning
28 Back-up Alarm 87 Fuel Gauge/Hourmeter Illumination
29 Fuse B1 88 L.H. Side
30 Forward/Reverse Switch 89 L.H. Tail
31 Parking Brake Buzzer Relay 90 R.H. Side
32 Forward Relay 91 R.H. Tail
33 Reverse Relay 92 Number Plate Light
34 Diode 93 L.H. Dip Beam
35 Reverse Solenoid 94 R.H. Dip Beam
36 Forward Solenoid 95 L.H. Main Beam
37 Dump Switch 96 R.H. Main Beam
38 Parking Brake Switch 97 Main Beam Warning
39 Fuse B5 98 Hazard Warning Switch Repeater
40 Brake Switch 99 Front Working Light (fitted to later machines)
41 Fuel Gauge
42 Fuel Gauge Sender Cable Colour Code
43 Air Filter Switch
44 Oil Pressure Switch B Black
45 Transmission Oil Temperature Switch G Green
46 Transmission Oil Pressure Switch K Pink
47 Water Temperature Switch LG Light Green
48 Diode N Brown
49 Alternator O Orange
50 Hourmeter P Purple
50 Hourmeter R Red
51 Diode Bank S Slate
52 Buzzer U Blue
53 Fuse C3 W White
54 Headlight Flasher Switch Y Yellow
55 Dip Switch
56 Fuse A4
57 Fuse A3
58 Fuse A2
59 Fuse A1
60 Fuse B3
*Component Key
9804/1103
CONTENTS
926, 930
2
123
THERMOSTART
70A
60A
60A
50A
PRI FUSE 3
PRI FUSE 2
PRI FUSE 1
PRI FUSE 4
M
4
STARTER MOTOR
PRE
OFF
IGN
START
3
HEAT
004 5
310A 1 5 001
1 842
30
310B 2 6 001A
305
810A
310L
310D
15/54
810C 4 2 600V
17
4
50a
8 003A 600AC
7
003 FUSE A10
19
9
809 2
FORWARD RELAY
F 4
100 100A 810C 1 812 600BS
5
N
875 5 FORWARD SOLENOID
FUSE A1 R 3
Machines without IP67 electrics
10
600AD
9
REVERSE RELAY
Circuit Diagrams-Electrical
808 4 2
12
1 811B 811 600BT
3 838 875A 5 REVERSE SOLENOID
100B 5 3
13
1
811A 600CD
6
100C 4 2 815B REVERSE ALARM
14
811G 600H
REVERSE LIGHT RHS
15
811F 600G
11
REVERSE LIGHT LHS
815 600CV
HANDBRAKE
SHOWN WITH HANDBRAKE OFF
16
810A 4 2 600BF
1
401H 5
3 815A
815B
401E
17
27
411B
411
106E 106C 411B 411
FUSE A2
401E
RTFL
106AK 401H
95 - 15 - 01/7
434B
404A
415A
403A
406A
406
106AB 406B 406B 600CK
WATER TEMP SWITCH
18 20 22 24 26 29
106AA 434A 434 407A 407A 600HS
4 4 0 3
HOURMETER
31
28
106D
407
ALTERNATOR
200
30
200A
816F 600G
LH BRAKE LIGHT
35
36
33 34
408 600CE
S
106 V FUEL SENDER
+ 600JA
-
830A 600HT
105B
COLD START ADVANCE
37
38
103N 600EG
M FACE FAN
(OPTIONAL)
42
840 600AK
M FRONT WIPER
45
106N +8 -7 600DY
1
BEACON SWITCH
303G 2
46
3 894 600AP
FUSE A7 M BEACON
2
701/60000
600DX
HAZARD SWITCH
805E 600BC
49
47
LH FRONT INDICATOR
-10 805F 600G
48
200N
FUSE A8 1 2
300 LH REAR INDICATOR
50
2 802 49 600BL
104 3 31 FLASHER UNIT
49a
54
FUSE B1
803B
803A
806A
805 806B
5
17 803B 803A
18
53
701/60005
51
805A
806F 600H
RH REAR INDICATOR
001A 4 2
52
600AU
LH No PLATE LIGHT
829D 600G
60
58
LH SIDE LIGHT
830G 600AX
62
106K 8+ -7
1 RH No PLATE LIGHT
63
830B 600H
310P 2 RH TAIL LIGHT
828 - 2 WAY
BUSBAR IN
FUSEBOX
828
FUSE B7
64
834A
138 5
RH DIP BEAM
834A 834B 600BC
6 832 834B LH DIP BEAM
FUSE B2
66
2
67
106J +8 -7 600N
1
FOGLIGHT SWITCH
832A 2
72
701/60000
73
74
71
106L -7 600CJ
+8
1
WORKLIGHT SWITCH
116 2
75
3 855 600AR
FUSE B3 WORKLIGHT
2
701/60000
HEATER MOTOR
76
SPLIT IF AIR 4
5
77
78
106AT +8 -7 600FB
1
1 AIR CON SWITCH
2
3 800E
81
1 800 600MY
2
M
HEATER MOTOR
2
701/60001
3
962 600JG
5100 - 10/7-7.2
79
CONDENSER RELAY
80
980 600MX
A370710
M
CONDENSER FAN
83
82
COMPRESSOR CLUTCH
84
85
86
All m/c’s from May2001
95 - 15 - 01/7
Issue 1
CONTENTS
RTFL 95 - 15 - 01/8
926, 930
Circuit Diagrams - Hydraulics
1B
11 2 12
2E 2E 2D 2C
2F 1A
2G 2A
2X
10
S
P1
13
F
14
15 16
A184641
926, 930
Circuit Diagrams - Hydraulics (cont’d)
Component Key
F Filter
P Priority valve
P1 Pump
T Tank
S Combined steering unit and shock valve
1A Neutral circuit feed line
1B Neutral circuit return line
2 Valve block
2A Main relief valve (M.R.V.)
2C Lift spool
2D Tilt spool
2E Auxiliary spool
2F Load hold check valve (L.H.C.V)
2G Auxiliary relief valves (A.R.V's)
2X System pressure test point
10 Lift rams
11 Tilt rams
12 Steer ram
13 Flow regulator cartridge
14 Hose burst protection valve
15 Deration diverter valve
16 Deration valve
Contents
Page No.
General Information
Fluids, Lubricants and Capacities
- JS 70 to m/c no. 695500 45 - 00 - 01/1
- JS 110, 130 to m/c no. 757999, 150LC 45 - 00 - 01/2
- JS 200LC to m/c no. 705000, 240LC to m/c no. 780500, 300LC, 450LC 45 - 00 - 01/3
- JS 130W, 150W 45 - 00 - 01/4
- JS 70 from m/c no. 695501 45 - 00 - 01/4A
- JS130 from m/c no. 758000, JS160 from m/c no. 702000 45 - 00 - 01/5
- JS180 45 - 00 - 01/5A
- JS130W frm m/c no. 716500, JS145W from m/c no. 810000,
JS160W from m/c no. 718500 45 - 00 - 01/4B
* - JS200, 220 from m/c no. 705001, JS210 from m/c no. 705648,JS240 from m/c no.708001,
JS260 from m/c no. 708501 45 - 00 - 01/6
- JS200W from m/c no. 0802000 to 802999 45 - 00 - 01/6A & 45 - 00 - 01/6B
- JS330 from m/c no. 712501, JS450 from m/c no. 714501,
JS460 from m/c no. 714550 45 - 00 - 01/7
- JS200W from m/c no. 809000 45 - 00 - 01/6C & 45 - 00 - 01/6D
Static Dimensions
- JS 70 to m/c no. 695500 45 - 00 - 02/1
- JS 110 45 - 00 - 02/2
- JS 130 to m/c no. 757999 45 - 00 - 02/3
- JS 150LC 45 - 00 - 02/4
- JS 200LC 45 - 00 - 02/5
- JS 240LC 45 - 00 - 02/6
- JS 300LC 45 - 00 - 02/7
- JS 450LC 45 - 00 - 02/8
- JS 130W 45 - 00 - 02/9
- JS 150W 45 - 00 - 02/10
- JS 70 from m/c no. 695501 45 - 00 - 02/10A
- JS130 from m/c no. 758000 45 - 00 - 02/11
- JS160 from m/c no. 702000 45 - 00 - 02/12
- JS180 45 - 00 - 02/12A
- JS200, 220 from m/c no. 705001 45 - 00 - 02/13
- JS210 45 - 00 - 02/13A
- JS240, 260 from m/c no. 708501 45 - 00 - 02/14
- JS220LC Long reach (LR) from m/c no. 705001 45 - 00 - 02/15
- JS330 from m/c no. 712501 45 - 00 - 02/16
- JS450 from m/c no. 714501 45 - 00 - 02/16A
- JS130W from m/c no. 0716500 45 - 00 - 02/17
- JS160W from m/c no. 0718500 45 - 00 - 02/18
- JS200W from m/c no. 0802000 to 802999 45 - 00 - 02/19 -
- JS200W from m/c no. 809000 45 - 00 - 02/20
* - JS460 from m/c no. 714550 45 - 00 - 02/21
Shipping Weights
- JS 70 to m/c no. 695500 45 - 00 - 03/1
- JS 110, 130, 150LC 45 - 00 - 03/2
- JS 200LC to m/c no. 70500, 240LC to m/c no. 780500, 300LC, 450LC 45 - 00 - 03/3
- JS 70 from m/c no. 695501 45 - 00 - 03/3A
- JS130 from m/c no. 758000, JS160, 180 from m/c no. 702000 45 - 00 - 03/4
- JS200, 210, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 45 - 00 - 03/4
- JS330 from m/c no. 712501, JS450 from m/c no. 714501,
JS460 from m/c no. 714550 45 - 00 - 03/4
- JS130W from m/c no. 0716501, JS160W from 0718501 45 - 00 - 03/5
- JS200W from m/c no. 0802000 to 802999 45 - 00 - 03/6
Data
Hydraulic
- JS 70 to m/c no. 695500 45 - 05 - 02/1
- JS 110 45 - 05 - 02/2
- JS 130 to m/c no. 757999 45 - 05 - 02/3
- JS 150 45 - 05 - 02/4
- JS 200LC to m/c no. 705000 45 - 05 - 02/5
- JS 240LC 45 - 05 - 02/6
- JS 300LC 45 - 05 - 02/7
- JS 450LC 45 - 05 - 02/8
- JS 130W from m/c no. 0716501, JS145W from m/c no. 810000 45 - 05 - 02/9 to 45 - 05 - 02/10D
- JS 70 from m/c no. 695501 45 - 05 - 02/11
- JS130 from m/c no. 758000 45 - 05 - 03/1 & 45 - 05 - 03/2
- JS160 from m/c no. 702000 45 - 05 - 03/3 & 45 - 05 - 03/4
- JS200, 220 from m/c no. 705001 45 - 05 - 03/5 & 45 - 05 - 03/6
- JS240, 260 from m/c no. 708501 45 - 05 - 03/7 & 45 - 05 - 03/8
* - JS 200W from m/c no. 809000 45 - 05 - 03/9 to 45 - 05 - 03/11
- JS330 from m/c no. 712501 45 - 05 - 03/12 & 45 - 05 - 03/13
- JS450 from m/c no. 714501, JS460 from m/c no. 714550 45 - 05 - 03/14
Track Motor/Gearbox
* - JS130 from m/c no. 758000, JS160 from m/c no. 702000 45 - 05 - 04/1
- JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 45 - 05 - 04/2
- JS330 from m/c no. 712501, JS450 from m/c no. 714501 45 - 05 - 04/3 to 45 - 05 - 04/5
JS460 from m/c no 714550
Control Valve
- JS 200W from m/c no. 809000 45 - 05 - 05/1
Drive Gearbox
- JS 200W from m/c no. 809000 45 - 05 - 06/1
Front Axle
- JS 200W from m/c no. 809000 45 - 05 - 07/1
- JS130W from m/c no. 716500 (SD70 PT) 45 - 07 - 07/1A
- JS130W from m/c no. 716500, JS160W from m/c no. 718500 (SD80PT) 45 - 07 - 07/1B
Rear Axle
- JS 200W from m/c no. 809000 45 - 05 - 07/2
- JS130W from m/c no. 716500 (PD70) 45 - 07 - 07/2A
- JS130W from m/c no. 716500, JS160W from m/c no. 718500 (PD80) 45 - 07 - 07/2B
Engine
- JS 70 to m/c no. 695500 45 - 05 - 08/1
- JS 110, 130, 150LC 45 - 05 - 08/2
- JS 200LC, 240LC 45 - 05 - 08/3
- JS 300LC, 450LC 45 - 05 - 08/4
- JS 70 from m/c no. 695501 45 - 05 - 08/4A
- JS 130W from m/c no. 785001, JS160W from m/c no. 702001 45 - 05 - 08/5
9804/1103 Issue 7*
CONTENTS
Excavators Contents 3
* JS 70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180, 200, 200W, 210, 220, 240, 260,
300, 330, 450LC, 460
Contents
*
Engine (cont’d) Page No.
- JS 330 from m/c no. 712501, JS450 from m/c no. 714501 45 - 05 - 08/6
JS460 from m/c no.714550
- JS460 Tier 2 45 - 05 - 08/6A
- JS 130 from m/c no. 716501, JS160 from m/c no. 718501 45 - 05 - 08/7
- JS130W from m/c no. 716500, JS145 from m/c no. 810000 45 - 05 - 08/7A
- JS175W from m/c no. 875000 45 - 05 - 08/8
* JS160W from m/c no. 718500,
- JS 200W from m/c no. 809000 45 - 05 - 08/9
- JS200, 220 from m/c no. 705001, JS210 from m/c no. 705648,JS240 from m/c no.708001,
JS260 from m/c no. 708501 45 - 05 - 08/10
Fault Finding
Hydraulics
- JS 70 to m/c no. 695500 45 - 10 - 01/1 to 45 - 10 - 01/3
- JS 110, 130 45 - 10 - 01/4 to 45 - 10 - 01/8
- JS 150LC 45 - 10 - 01/9 to 45 - 10 - 01/13
- JS 200LC, 300LC 45 - 10 - 01/14 to 45 - 10 - 01/19
- JS 240LC 45 - 10 - 01/20
- JS 450LC 45 - 10 - 01/21 to 45 - 10 - 01/23
- JS70 from m/c no. 695501 45 - 10 - 01/24 & 45 - 10 - 01/25
- JS 200W from m/c no. 809000 45 - 10 - 01/26 to 45 - 10 - 01/31
Track Gearbox
- JS 110, 130, 150LC 45 - 10 - 02/1 & 45 - 10 - 02/2
- JS 200LC, 240LC, 300LC, 450LC 45 - 10 - 02/3 & 45 - 10 - 02/4
Swing Gearbox
- JS70, 110, 130, 150LC, 200LC, 240LC, 300LC, 450LC 45 - 10 - 03/1
- JS130W from m/c no. 716500, JS160W from m/c no. 718500 45 - 10 - 03/6
- JS200 from m/c no. 705001, JS240 from m/c no. 708501 45 - 10 - 03/2 to 45 - 10 - 03/3
- JS 200W from m/c no. 809000 45 - 10 - 03/6
*
Pump/ Regulator
- JS130 from m/c no. 758000, JS160 from m/c no. 702000 45 - 10 - 05/1 to 45 - 10 - 05/2
- JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 45 - 10 - 06/1 to 45 - 10 - 06/2
- JS330 from m/c no. 712501, JS450 from m/c no. 714501 45 - 10 - 06/3 & 45 - 10 - 06/4
- JS330 from m/c no. 712501, JS460 from m/c no. 714550 45 - 10 - 06/5
*
Remote Control Valve
- JS130 from m/c no. 758000, JS160 from m/c no. 702000 45 - 10 - 07/1
- JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501,
JS 200W from m/c no. 809000 45 - 10 - 07/1
- JS330 from m/c no. 712501, JS450 from m/c no. 714501 45 - 10 - 07/1
JS460 from m/c no. 714550
Control Valve
- JS70 from m/c no. 695501 45 - 10 - 07/2 & 45 - 10 - 07/3
Multiple Valve
- JS70 from m/c no. 695501 45 - 10 - 07/4
Rams
- JS70 from m/c no. 695501 45 - 10 - 08/1 to 45 - 10 - 08/5
- JS130 from m/c no. 758000, JS160 from m/c no. 702000 45 - 10 - 08/1 to 45 - 10 - 08/5
- JS130W from m/c no. 716500, JS160W from m/c no. 718500 45 - 10 - 08/1 to 45 - 10 - 08/5
- JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 45 - 10 - 08/1 to 45 - 10 - 08/5
Track Motor/Gearbox
- JS70 from m/c no. 695501 45 - 10 - 09/1 to 45 - 10 - 09/3
9804/1103 Excavator Contents - 3 Issue 7*
CONTENTS
Excavators Contents 4
* JS 70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180, 200, 200W,210, 220, 240, 260, 300,
330, 450LC, 460
Contents
- JS130 from m/c no. 758000, JS160 from m/c no. 702000 45 - 10 - 09/1 to 45 - 10 - 09/3
- JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 45 - 10 - 10/1 to 45 - 10 - 10/5
- JS330 from m/c no. 712501, JS450 from m/c no. 714501 45 - 10 - 10/6 to 45 - 10 - 10/11
Engine
- JS70 from m/c no. 695501 45 - 10 - 12/1
Monitor Display
- JS70 from m/c no. 695501 45 - 10 - 13/1
Operating Controls
- JS70 from m/c no. 695501 45 - 10 - 13/2
Hydraulic Pump
- JS70 from m/c no. 695501 45 - 10 - 13/2
Working Attachments
- JS70 from m/c no. 695501 45 - 10 - 13/2
Travelling
- JS70 from m/c no. 695501 45 - 10 - 13/3
Slewing
* - JS70 from m/c no. 695501 45 - 10 - 13/3
Hydraulic Rams
- JS70 from m/c no. 695501 45 - 10 - 13/3
Electrics
- JS330 from m/c no. 712501, JS450 from m/c no. 714501 45 - 10 - 14/1 to 45 - 10 - 14/19
JS460 from m/c no. 714550
Circuit Diagrams
Electrical
- JS70 to m/c no. 695500 45 - 15 - 01/1 & 45 - 15 - 01/2
- JS70 from m/c no. 695501 45 - 15 - 01/2A & 45 - 15 - 01/2B
- JS110, 130 to m/c no. 757999 45 - 15 - 01/3 & 45 - 15 - 01/4
- JS150LC 45 - 15 - 01/5 & 45 - 15 - 01/6
- JS200LC to m/c no. 705000 45 - 15 - 01/7 & 45 - 15 - 01/8
- JS240LC to m/c no. 780500 45 - 15 - 01/9 & 45 - 15 - 01/10
- JS300LC 45 - 15 - 01/11 & 45 - 15 - 01/12
- JS450LC 45 - 15 - 01/13 & 45 - 15 - 01/14
- JS130W, 150W (Common with JS130, JS150 Tracked Excavators) 45 - 15 - 02/1 & 45 - 15 - 02/2
- JS130W, 150W (Additional to JS130, JS150 Tracked Excavators) 45 - 15 - 02/3 & 45 - 15 - 02/4
- JS130W, 150W (Relay Box P.C.B.) 45 - 15 - 02/5 & 45 - 15 - 02/6
- JS130W from m/c no. 716501, 160W from 718501 45 - 15 - 02/7 to 45 - 15 - 02/11
* - JS130 from m/c no. 758000, JS160 from m/c no. 702000 45 - 15 - 02/11A & 45 - 15 - 02/11B
- JS200W from m/c no. 809000 45 - 15 - 02/12 & 45 - 15 - 02/13
- JS200, 220 from m/c no.705001, JS240 from m/c no. 708501 45 - 15 - 02/13A & 45 - 15 - 02/13B
- JS330 from m/c no. 712501 45 - 15 - 02/14 & 45 - 15 - 02/15
- JS450 from m/c no. 714501 45 - 15 - 02/16 & 45 - 15 - 02/17
- JS330/JS460 (AMS) 45 - 15 - 02/18 & 45 - 15 - 02/19
- JS460 Tier2 45 - 15 - 02/20 & 45 - 15 - 02/21
JS 70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180,, 200, 200W, 210, 220, 240, 260,
300, 330, 450LC, 460
Contents
Hydraulic
- JS70 (Standard Boom to m/c 695001) 45 - 20 - 01/1 & 45 - 20 - 01/2
- JS70 (Offset Boom to m/c 695001) 45 - 20 - 01/3 & 45 - 20 - 01/4
- JS70 (Standard Boom from m/c 695002 to m/c 695500) 45 - 20 - 01/5 & 45 - 20 - 01/6
- JS70 (Offset Boom from m/c 695002 to m/c 695500) 45 - 20 - 01/7 & 45 - 20 - 01/8
Circuit Diagrams Page No.
Hydraulic (cont’d)
- JS70 from m/c no. 695501 45 - 20 - 01/8A &45 - 20 - 01/8B
- JS110 (To m/c 697013) & 130 (To m/c 699036) 45 - 20 - 01/9 & 45 - 20 - 01/10
- JS110 (From m/c 697014) & 130 (From m/c 699037 to m/c no. 757999) 45 - 20 - 01/11 & 45 - 20 - 01/12
- JS150LC (To m/c 701044) 45 - 20 - 01/13 & 45 - 20 - 01/14
- JS150LC (From m/c 701045) 45 - 20 - 01/15 & 45 - 20 - 01/16
- JS200LC (To m/c 704074) 45 - 20 - 01/17 & 45 - 20 - 01/18
- JS200LC (From m/c 704075 to m/c no. 705000) 45 - 20 - 01/19 & 45 - 20 - 01/20
- JS240LC to m/c no. 780500 45 - 20 - 01/21 & 45 - 20 - 01/22
- JS300LC 45 - 20 - 01/23 & 45 - 20 - 01/24
- JS450LC 45 - 20 - 01/25 & 45 - 20 - 01/26
- JS130W from m/c no. 716501, JS145W from m/c no. 810000,
160W from m/c no. 718501, JS175W from m/c no. 875000 45 - 20 - 02/1 & 45 - 20 - 02/2
- JS160W from m/c no. 718501, JS175W from m/c no. 875000 - TAB Option 45 - 20 - 02/3
- JS130W from m/c no. 716501, 160W from m/c no. 718501 45 - 20 - 02/4
- JS130 from m/c no. 758000 45 - 20 - 02/4A & 45 - 20 - 02/4B
- JS160 from m/c no. 702000 45 - 20 - 02/4C & 45 - 20 - 02/4D
- JS175W from m/c no. 875000 45 - 20 - 02/4E & 45 - 20 - 02/4F
- JS200, 220 from m/c no. 705001 45 - 20 - 02/6A & 45 - 20 - 02/6B
- JS240, 260 from m/c no. 708001 45 - 20 - 02/6C & 45 - 20 - 02/6D
- JS330 from m/c no. 712501 45 - 20 - 02/7 & 45 - 20 - 02/8
- JS450 from m/c no. 714501 45 - 20 - 02/9 & 45 - 20 - 02/10
- JS460 from m/c no. 714550 45 - 20 - 02/11 & 45 - 20 - 02/12
- JS330/JS460 Tier2 45 - 20 - 02/13 & 45 - 20 - 02/14
- JS450/JS460 - Control Valve 45 - 20 - 02/15
- JS460 Tier2 - Control Valve 45 - 20 - 02/16
- JS460 Tier2 - Circuit Descriptions 45 - 20 - 02/17 to 45 - 20 - 02/42
SWING RING
- BEARINGS *JCB HP Grease -
- GEAR TEETH *JCB HP Grease 3.2 kg (7.14 lb)
*
Use according to ambient temperature (°C)
-20 -10 0 10 20 30 40
TRACK GEARBOX JCB HD90 Gear Oil 2 x 2.5 litres 2 x 2.5 litres 2 x 3 litres
(2 x 0.55 UK gal) (2x 0.55 UK gal) (2x0.55UK gal)
SWING GEARBOX JCB HD90 Gear Oil 1.7 litres 1.7 litres 6 litres
(0.37 UK gal) (0.37 UK gal) (1.32 UK gal)
*JCB HP Grease 0.47 litres 0.47 litres Not applicable
(0.1 UK gal) (0.1 UK gal)
HYDRAULIC SYSTEM JCB Hydraulic Fluid 46 157 litres 157 litres 170 litres
(34.5 UK gal) (34.5 UK gal) (37.4 UK gal)
SWING RING
- BEARINGS *JCB HP Grease - - -
- GEAR TEETH *JCB HP Grease 10 kg (22 lb) 10 kg (22 lb) 13 kg (28.7 lb)
EXCAVATOR GREASE
POINTS *JCB HP Grease
-20 -10 0 10 20 30 40
JS 200LC,240LC,300LC,450LC
Lubricants & Capacities
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-
in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
TRACK GEARBOX JCB HD90 Gear Oil Serial Nos up to 2 x 3.3 litres 2 x 8.5 litres 2 x 7 litres
704597 (2 x 0.73 UK gal) 2 x 1.87 UK gal) (2 x 1.54 UK gal)
2 x 5.6 litres
(2 x 1.23 UK gal)
Serial Nos from
704598 on
2 x 3.5 litres
(2 x 0.77 UK gal)
SWING GEARBOX JCB HD90 Gear Oil 6 litres 11 litres 14.5 litres 18 litres
(1.3 UK gal) (2.4 UK gal) (3.9 UK gal) (4 UK gal)
JCB HP Grease 0.9 litres - - -
(0.18 UK gal) - - -
HYDRAULIC SYSTEM JCB Hydraulic Fluid 46 233 litres 350 litres 320 litres 450 litres
(51.3 UK gal) (77 UK gal) (68.4 UK gal) (99 UK gal)
SWING RING
- BEARINGS JCB HP Grease - - - -
- GEAR TEETH JCB HP Grease 13 kg (28.6 lb) 22 kg (48.4 lb) 27 kg (59.4 lb) 31 kg (68.2 lb)
FUEL TANK 280 litres 280 litres 500 litres 500 litres
(61.6 UK gal) (61.6 UK gal) (110 UK gal) (110 UK gal)
-20 -10 0 10 20 30 40
JS 130W, 150W
Lubricants & Capacities
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is
gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up
without load).
Capacity
Item Lubricant
JS130W JS150W
SWING RING
- BEARINGS JCB HP Grease - -
- GEAR TEETH JCB HP Grease 10 kg (22lb) 13 kg (28.7 lb)
FRONT AXLE
- DIFFERENTIAL JCB Gear Oil LS 9 litres 9 litres
(2 UK gal) (2 UK gal)
- HUB (x 2) JCB Gear Oil LS 0.9 litres 1.5 litres
(0.2 UK gal) (0.33 UK gal)
REAR AXLE
- DIFFERENTIAL JCB Gear Oil LS 12 litres 12 litres
(2.64 UK gal) (2.64 UK gal)
- HUB (x 2) JCB Gear Oil LS 0.9 litres 1.5 litres
(0.2 UK gal) (0.33 UK gal)
DRIVE GEARBOX JCB 15W/40 Multigrade Oil 3.4 litres 3.4 litres
(0.8 gal) (0.8 gal)
-20 -10 0 10 20 30 40
TRACK GEARBOXES JCB Gear Oil HD90 API-GL-5, MIL-L-2105C 2 x 1.7 litres
(0.37 UK gal)
SLEW RING
- BEARINGS JCB HP Grease Lithium based, No. 2 -
- GEAR TEETH JCB HP Grease consistency 3.2 kg (7.14 lb)
*
Use according to ambient temperature (°C)
-20 -10 0 10 20 30 40
JS 130W from m/c no. 716500, JS160W from m/c no. 718500
Lubricants and Capacities
Note: New engines DO NOT require a running-in period. The engine should be used in a normal work cycle immediately;
glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no
circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
International Capacity
Item Fluid/Lubricant Specification
JS130W JS160W
SLEW GEARBOX JCB Gear Oil HD90 API-GL-5: MIL-L-2105C 5 litres 5 litres
(1.09 UK gal) (1.09 UK gal)
HYDRAULIC SYSTEM JCB Special Hydraulic Vickers 35VQ25/V104C: 124 litres 124 litres
Fluid HP46 Sundstrand, Denison and (27.3 UK gal) (27.3 UK gal)
FZG Approval Tests
SLEW RING
- BEARINGS JCB HP Grease Lithium complex (NLGI) inc. - -
- GEAR TEETH JCB HP Grease extreme pressure additives 17 kg (37.48 lb) 17 kg (37.48 lb)
COOLING SYSTEM See Coolant Mixtures ASTM D3306-74 16.4 litres 17.2 litres
(3.6 UK gal) (3.78 UK gal)
FUEL TANK See Fuel System, ASTM D975-66T 240 litres 240 litres
Types of Fuel Nos 1D, 2D (52.8 UK gal) (52.8 UK gal)
FRONT AXLE
- DIFFERENTIAL JCB Special Gear API GL4: M2C-41B/134D, 18 litres 18 litres
Oil Plus JD20C (3.9 Uk gal) (3.9 Uk gal)
- HUB (x 2) JCB Special Gear MGF M1135/M1141/ 1.5 litres 1.5 litres
Oil Plus M1143 (0.33 UK gal) (0.33 UK gal)
REAR AXLE
- DIFFERENTIAL JCB Special Gear API GL4: M2C-41B/134D 17.7 litres 17.7 litres
AND HUBS (x 2) Oil Plus JD20C, (3.9 UK gal) (3.9 UK gal)
MGF M1135/M1141/
M1143
DRIVE GEARBOX JCB Super 15W/40 API CF4/SG: MIL-L-2104F 3.8 litres 3.8 litres
Multigrade Engine Oil (0.83 UK gal) (0.83 UK gal)
JS 130 from m/c no. 758000, JS160 from m/c no. 702000
* Lubricants and Capacities
Capacity
International
Item Lubricant
Specification JS130 JS160
TRACK GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 2 x 3.0 litres 2 x 3.0 litres
(2 x 0.66 UK gal) (2 x 0.66 UK gal)
(2 x 0.79 US gal) (2 x 0.79 US gal)
SLEW GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 5 litres 5 litres
(1.09 UK gal) (1.09 UK gal)
(1.31 US gal) (1.31 US gal)
JCB Special HP Grease Lithium based No. 2 1 litre 1 litre
consistency (0.22 UK gal) (0.22 UK gal)
(0.26 US gal) (0.26 US gal)
HYDRAULIC SYSTEM JCB Hydraulic Fluid 46 ISO VG46 124 litres 124 litres
(27.3 UK gal) (27.3 UK gal)
(32.8 US gal) (32.8 US gal)
SLEW RING
- BEARING JCB Special HP Grease Lithium based No. 2
consistency - -
- GEAR TEETH JCB Special HP Grease Lithium based No. 2
consistency 11kg (24.25 lb) 17kg (37.48 lb)
Capacity
International
Item Lubricant
Specification JS180
TRACK GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 2 x 3.5 litres
(2 x .77 UK gal)
(2 x .92 US gal)
SLEW RING
- BEARING JCB Special HP Grease Lithium complex (NLGI) inc.
extreme pressure additives -
- GEAR TEETH JCB Special HP Grease Lithium complex (NLGI) inc.
extreme pressure additives 17kg (37.48 lb)
Capacity
TRACK GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 2 x 3.5 litres
(2 x 0.77 UK gal)
(2 x 0.92 US gal)
SLEW RING
- BEARING JCB Special HP Grease Lithium complex (NLGI) inc. --
extreme pressure additives
JS 200, JS 220
- GEAR TEETH JCB Special HP Grease Lithium complex (NLGI) inc. 17 kg (37.48 lb)
extreme pressure additives JS 240, JS 260
20 kg (44.10 lb)
International Capacity
Item Fluid/Lubricant Specification
JS200W
SLEW RING
- BEARINGS JCB HP Grease Lithium based, No. 2 -
- GEAR TEETH JCB HP Grease consistency 17 kg (37.48 lb)
FRONT AXLE
- DIFFERENTIAL JCB Gear Oil HD90 API GL-5: MIL-L-2105D 9.0 litres
(1.98 UK gal)
(2.37 US gal)
- HUB (x 2) 2.0 litres
(0.44 UK gal)
(0.52 US gal)
REAR AXLE
- DIFFERENTIAL JCB Gear Oil HD90 API GL-5: MIL-L-2105D 17.0 litres
AND HUBS (x 2) (3.74 UK gal)
(4.49 US gal)
DRIVE GEARBOX JCB Super 15W/40 API CF4/SG: MIL-L-2104F 3.8 litres
Multigrade Engine Oil (0.836 UK gal)
(1.0 US gal)
-30 20 -10 0 10 20 30 40 50
International Capacity
Item Fluid/Lubricant Specification
JS200W
SLEW RING
- BEARINGS JCB HP Grease Lithium complex (NLGI) inc. -
- GEAR TEETH JCB HP Grease extreme pressure additives 17 kg (37.48 lb)
FRONT AXLE
- DIFFERENTIAL JCB Gear Oil HD90 API GL-5: MIL-L-2105D 9.0 litres
(1.98 UK gal)
(2.37 US gal)
- HUB (x 2) 2.0 litres
(0.44 UK gal)
(0.52 US gal)
REAR AXLE
- DIFFERENTIAL JCB Gear Oil HD90 API GL-5: MIL-L-2105D 17.0 litres
AND HUBS (x 2) (3.74 UK gal)
(4.49 US gal)
DRIVE GEARBOX JCB Super 15W/40 API CF4/SG: MIL-L-2104F 3.8 litres
Multigrade Engine Oil (0.836 UK gal)
(1.0 US gal)
-30 20 -10 0 10 20 30 40 50
Capacity
Item Lubricant International Specification
JS330 JS450/JS460
TRACK GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 2 x 8.5 litres 2 x 7.0 litres
(2 x 1.9 UK gal) (2 x 1.5 UK gal)
SLEW GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 14.5 litres 18 litres
(3.2 UK gal) (4 UK gal)
HYDRAULIC SYSTEM JCB Hydraulic Fluid 46 ISO VG46 320 litres 450 litres
(70.5 UK gal) (99 UK gal)
SLEW RNG
- BEARING JCB Special HP Grease Lithium based, No. 2
consistency - -
- GEAR TEETH JCB Special HP Grease Lithium based, No. 2
consistency 17 kg (34. 48 lb) 17 kg (34. 48 lb)
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