Section C: Service Manual - Side Engine Loadalls

Section C
Electrics
Service Manual - Side Engine Loadalls
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section D - Controls
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine
Publication No.
9803/3630-14
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
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C-0 9803/3630-14 C-0

Contents Page No.

Technical Data
General Electrical Data ............................................................................ C - 1
Relay Identification .................................................................................. C - 2
Series I Machines ............................................................................... C - 2
Series II Machines ............................................................................ C - 16
Fuse Identification ................................................................................. C - 20
Introduction ....................................................................................... C - 20
Series I Machines ............................................................................. C - 21
Fuse Links ........................................................................................ C - 23
Schematic Circuits
Applicable Machines .............................................................................. C - 25
Series I Machines ............................................................................. C - 25
Schematics ............................................................................................ C - 28
530-70 .............................................................................................. C - 28
530-70 .............................................................................................. C - 32
530-70 .............................................................................................. C - 36
530-70, 540-70 ................................................................................. C - 40
530-70, 540-70 ................................................................................. C - 44
530-70, 535-95, 540-70 .................................................................... C - 48
530-70, 535-95, 540-70 .................................................................... C - 53
530 FS Super, 530 SXL, 540 FS Super, 540 SXL ............................ C - 58
532-120, 533-105, 537-135, 540-170, 550, 5508 ............................. C - 63
532-120, 537-135 ............................................................................. C - 70
532-120, 537-135 ............................................................................. C - 74
532-120, 537-135 ............................................................................. C - 78
532-120, 537-135, 550 ..................................................................... C - 82
540-170, 5508 .................................................................................. C - 86
All Series II Machines ....................................................................... C - 92
Service Procedures
Using a Multimeter ............................................................................... C - 112
Measuring DC Voltage ................................................................... C - 113
Measuring Resistance .................................................................... C - 113
Measuring Continuity ...................................................................... C - 114
Measuring Frequency ..................................................................... C - 114
Testing a Diode or a Diode Wire ..................................................... C - 115
Battery ................................................................................................. C - 116
Maintenance ................................................................................... C - 116
First Aid - Electrolyte ...................................................................... C - 116
Testing ............................................................................................ C - 117
Specific Gravity Testing .................................................................. C - 118
Alternator ............................................................................................. C - 119
General Description ........................................................................ C - 119
Service Precautions ....................................................................... C - 119
Charging Circuit Test ...................................................................... C - 119
Alternator Charging Test ................................................................. C - 120
Starter Motor ........................................................................................ C - 122
Starting Circuit Test ........................................................................ C - 122
Wire and Harness Number Identification ............................................. C - 124
Introduction ..................................................................................... C - 124
Wire Numbers and Functions ......................................................... C - 125
C-i C-i
Contents
Contents Page No.

Wiring Harness Repair ........................................................................ C - 126
Introduction ..................................................................................... C - 126
Repair Procedure ........................................................................... C - 126
Alternator
Removal and Replacement ................................................................. C - 129
Removal ......................................................................................... C - 129
Replacement .................................................................................. C - 129
Dismantling and Assembly .................................................................. C - 130
Lucas Type ..................................................................................... C - 130
Magneti Marelli Type ...................................................................... C - 132
Starter Motor
Removal and Replacement ................................................................. C - 134
Removal ......................................................................................... C - 134
Replacement .................................................................................. C - 134
Dismantling, Inspection and Assembly ................................................ C - 135
Dismantling ..................................................................................... C - 135
Inspection ....................................................................................... C - 135
Assembly ........................................................................................ C - 135
C - ii C - ii
Technical Data
General Electrical Data
Battery 12 volts, negative earth

- Cold Crank amps for 1 minute to
- 1.4 VPC at -18°C (0°F) 410 to 58
- Reserve capacity (minutes) for 25 amp load 170 to 230
Alternator A127-65, 65 amp maximum output
Starter Motor M127 12 volt
Light Bulbs
- Headlights main/dip 45W/40W or 60/55W (halogen)
- Working lamps 55W (Halogen)
- Front side lamps 5W
- Stop/tail lamps/reverse 21W/5W/21W
- Indicator lamps 21W
- Number plate lamp 10W
- Fog lamp 21W
- Interior lamp 18W
- Panel/warning lamps 1.2W
- Beacon 55W
C-1 9803/3630-14 C-1

Technical Data
Relay Identification
Series I Machines Machine Model and Serial Number

K 540-70 SN 770959 to 1016739 ( T C-6)
Relays are used in the electrical circuits for a variety of
reasons. The most usual application is to protect K 540-70 with SRS Up to SN 1016740 ( T C-7)
components like switches etc. from being overloaded. A K 540FS Super (Series I only) ( T C-8)
relatively small current (from the switch) energises the
K 550 SN 770959 to August 1999 ( T C-12)
relay coil, this causes internal contacts to open or close
which controls a larger current in another circuit. K 550 From August 1999 ( T C-13)
K 5508 SN 780925 to 1004130 ( T C-14)
Although relays look similar, internally they can be
K 5508 From SN 1004131 ( T C-15)
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 ECU Deletion Cut-In Numbers
circuits will not function correctly.
ECU deletion cut-in numbers are transmission dependant.
Quick Reference Chart K Table 1. ECU deletion cut-in numbers ( T C-2).
Use the following cross references to view the relevant Table 1. ECU deletion cut-in numbers
Relay Identification page for the machine concerned: Transmission Part Serial Number of cut-in
Number
Machine Model and Serial Number 449/06100 770055
K 530-70 SN 767001 to 768836 ( T C-3) 449/06200 770065
K 530-70 SN 768837 to 770053 ( T C-4) 449/06300 770053
K 530-70 SN 770054 to 770958 ( T C-5) 449/06400 770069
K 530-70 SN 770959 to 1016568 ( T C-6) 449/06500 770063
K 530-70 with SRS Up to SN 1016568 ( T C-7) 449/06600 770093
K 530FS Super (Series I only) ( T C-8)

K 532-120 SN 767001 to 768956 ( T C-9)
K 532-120 SN 768957 to 770063 ( T C-10)
K 532-120 SN 770064 to 770958 ( T C-11)
K 532-120 SN 770959 to August 1999 ( T C-12)
K 532-120 From August 1999 ( T C-13)
K 533-105 Up to SN 1036560 ( T C-6)
K 535-95 Up to SN 1036554 ( T C-6)
K 537-135 SN 767001 to 768956 ( T C-9)
K 537-135 SN 768957 to 770063 ( T C-10)
K 537-135 SN 770064 to 770958 ( T C-11)
K 537-135 SN 770959 to August 1999 ( T C-12)
K 537-135 From August 1999 ( T C-13)
K 540-170 SN 780925 to 1004130 ( T C-14)
K 540-170 From SN 1004131 ( T C-15)
C-2 9803/3630-14 C-2

Technical Data
530-70
K Quick Reference Chart ( T C-2)
Applicability:
– 530-70 SN 767001 to 768836
Note: Machines do not have Neutral Start.
Note: ECU deletion cut-in numbers are transmission

dependant. K ECU Deletion Cut-In Numbers ( T C-2).
1 Audible alarm
2 Reverse lights
3 Starter
4 Hazard warning lights
5 Side lights
6 Air conditioning
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 - Fig 1. From SN 767001 to SN 768836
18 -
C-3 9803/3630-14 C-3

Technical Data
530-70
Applicability:
– 530-70 SN 768837 to 770053
Note: Machines with Neutral Start.

1 Audible alarm
2 Neutral start
3 Starter
5 Side lights
6 Air conditioning
7 Sway isolation
9 Auxiliary A
10 Auxiliary B
11 -
12 -
13 Retract
14 Extend
15 Reverse
17 - Fig 2. From SN 767001 to SN 768836
18 -
C-4 9803/3630-14 C-4

Technical Data
530-70
Applicability:
– 530-70 SN 770054 to 770958

1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
8 Sidelights
9 Air conditioning
10 Auxiliary change-over 2
12 Forward relay
13 Reverse 1
14 Reverse 2
15 2 wheel drive brake
16 Auxiliary A
17 Auxiliary B
18 -
19 -
20 Retract
Fig 3. From SN 770054 to 770958
21 Extend
22 Forward HI/LO
23 Reverse HI/LO
24 Drive
25 Driveshaft
C-5 9803/3630-14 C-5

Technical Data
530-70, 533-105, 535-95, 540-70
Applicability:
– 530-70 SN 770959 to 1016568

– 533-105 Up to SN 1036560
– 535-95 Up to SN 1036554
– 540-70 SN 770959 to 1016739
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
8 Sidelights
9 Air conditioning
10 Forward relay
11 Reverse 1
12 Reverse 2
13 Two wheel drive brake relay
15 Sway isolation
16 Forward HI/LO
17 Reverse HI/LO
18 Drive
19 Driveshaft
Fig 4.
C-6 9803/3630-14 C-6

Technical Data
530-70, 540-70 fitted with Smooth Ride System
(SRS)
Applicability:
– 530-70 with SRS Up to SN 1016568

– 540-70 with SRS Up to SN 1016740
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
8 Sidelights
9 Air conditioning
10 Forward relay
11 Reverse 1
12 Reverse 2
14 -
15 -
17 Sway isolation
18 Forward HI/LO
19 Reverse HI/LO
20 Drive
21 Driveshaft
Fig 5. Series I - 530-70, 540-70 fitted with SRS
22 Neutral(1)
23 Dump(1)
24 - (1)
25 SRS relay(1)
(1) Smooth Ride System
C-7 9803/3630-14 C-7

Technical Data
530FS Super, 540FS Super Machines
Applicability:
– 530FS Super (Series I only)

– 540FS Super (Series I only)
Note: Machines with Five Speed Powershift Transmission
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
6 Sidelights
7 Air conditioning
9 Sway isolation
10 Reverse 2
12 Neutral relay(1)
13 Dump relay(1)
14 - (1)
15 SRS relay(1)
16 -
17 -
(1) Smooth Ride System Fig 6. Series I - 530FS Super, 540FS Super Machines
C-8 9803/3630-14 C-8

Technical Data
532-120, 537-135
Applicability:
– 532-120 SN 767001 to 768956

– 537-135 SN 767001 to 768956
Note: Machines do not have Neutral Start.
1 Audible alarm
2 Reverse lights and alarm
3 Starter
5 Side lights
6 Air conditioning
7 Sway isolation
8 Stabiliser isolation
9 Auxiliary A
10 Auxiliary B
11 -
12 -
13 -
14 -
15 -
17 -
18 -
Fig 7. SN 767001 to 768956
C-9 9803/3630-14 C-9

Technical Data
532-120, 537-135
Applicability:
– 532-120 SN 768957 to 770063

– 537-135 SN 768957 to 770063
Note: Machines with Neutral Start.
1 Audible alarm
2 Neutral start
3 Starter
5 Side lights
6 Air conditioning
7 Sway isolation
9 Auxiliary A
10 Auxiliary B
11 Reverse
12 -
13 -
14 -
15 -
17 -
18 -
Fig 8. From SN 768957 to 770063
C - 10 9803/3630-14 C - 10
Technical Data
532-120, 537-135
Applicability:
– 532-120 SN 770064 to 770958

– 537-135 SN 770064 to 770958
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
8 Sidelights
9 Air conditioning
10 Sway isolation
12 Forward relay
13 Reverse 1
14 Reverse 2
16 Auxiliary A
17 Auxiliary B
18 auxiliary change-over 2
19 -
20 Forward HI/LO
21 Reverse HI/LO
22 Drive
Fig 9. From SN 770064 to 770958
23 Driveshaft
24 -
25 -
C - 11 9803/3630-14 C - 11
Technical Data
532-120, 537-135, 550
Applicability:
– 532-120 SN 770959 to August 1999

– 537-135 SN 770959 to August 1999
– 550 SN 770959 to August 1999
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
8 Sidelights
9 Air conditioning
10 Sway isolation
12 Forward relay
13 Reverse 1
14 Reverse 2
16 Forward HI/LO
17 Drive
18 Reverse HI/LO
19 Empty
Fig 10.
C - 12 9803/3630-14 C - 12
Technical Data
532-120, 537-135, 550
Applicability:
– 532-120 From August 1999

– 537-135 From August 1999
– 550 From August 1999
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
8 Sidelights
9 Air conditioning
10 Sway isolation
12 Forward relay
13 Reverse 1
14 Reverse alarm/light
15 2 wheel drive/brakelights
16 Empty
17 Pump Dump Drive
18 Forward HI/LO
19 Reverse HI/LO
20 Drive
21 Driveshaft
Fig 11.
C - 13 9803/3630-14 C - 13
Technical Data
540-170, 5508
Applicability:
– 540-170 SN 780925 to 1004130

– 5508 SN 780925 to 1004130
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
8 Sidelights
9 Air conditioning
10 Sway isolation
12 Forward relay
13 Reverse 1
14 Reverse Alarm/light
15 2 wheel drive/brake lights
16 Spare
17 Pump dump (option)
18 Forward HI/LO
19 Reverse HI/LO
20 Drive relay
21 Driveshaft relay
22 Extension boost
Fig 12. From SN 780925 to 1004130
23 Lift isolation
24 Stabiliser lift unloader
25 Inner boom extend
C - 14 9803/3630-14 C - 14
Technical Data
540-170, 5508
Applicability:
– 540-170 From SN 1004131

– 5508 From SN 1004131
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
8 Sidelights
9 Air conditioning
10 Sway isolation
12 Forward relay
13 Reverse 1
14 Reverse Alarm/light
15 2 wheel drive/brake lights
16 Left stabiliser
17 Right stabiliser
18 Forward HI/LO
19 Reverse HI/LO
20 Drive relay
21 Driveshaft relay
22 Extension boost
Fig 13. From SN 1004131
23 Lift isolation
24 Stabiliser lift unloader
25 Inner boom extend
C - 15 9803/3630-14 C - 15
Technical Data
Series II Machines Quick Reference Chart
Relays are used in the electrical circuits for a variety of Use the following cross references to view the relevant
reasons. The most usual application is to protect Relay Identification page for the machine concerned:
components like switches etc. from being overloaded. A
relatively small current (from the switch) energises the Machine Model and Serial Number
relay coil, this causes internal contacts to open or close
which controls a larger current in another circuit. K 530-70 From SN 1016569 (3 and 4 speed
only) ( T C-17)
Although relays look similar, internally they can be K 530-70 FS Super (5 speed only) ( T C-18)
different, for example, they can be single or double K 532-120 From SN 1036631 ( T C-17)
contact; normally closed or open. Make sure you fit the
correct type of relay, otherwise the machine electrical K 533-105 From SN 1036561 ( T C-17)
circuits will not function correctly. K 535-125 ( T C-17)
K 535-140 ( T C-17)
The relays A are located in a fuse box inside the door.
They are seperated into banks. Each relay position in each K 535-60 (3 and 4 speed only) ( T C-17)
bank is numbered. K 535-60 FS Super (5 speed only) ( T C-18)
K 535-95 From SN 1036555 ( T C-17)
To access the relays, unscrew the two fasteners and
remove cover B. K 537-135 From SN 1036631 ( T C-17)
K 540-140 ( T C-17)
K 540-170 From SN 1037581 ( T C-19)
K 540-70 From SN 1016740 ( T C-17)
K 540-70 FS Super (5 speed only) ( T C-18)
K 550 From SN 1036474 ( T C-17)
K 550-140 ( T C-17)
K 550-170 ( T C-19)
K 5508 From SN 1037581 ( T C-17)
Fig 14.
C - 16 9803/3630-14 C - 16
Technical Data
Series II Relay Configuration 1 A1 Audible alarm
Applicability: A2 Neutral start

A3 IGN Feed relay 5
– 530-70 From SN 1016569 (3 and 4 speed only)
A4 IGN Feed relay 1
– 532-120 From SN 1036631
A5 IGN Feed relay 3
– 533-105 From SN 1036561
A6 Rear worklights
– 535-60 (3 and 4 speed only)
A7 Parkbrake warning light
– 535-95 From SN 1036555
B4 Forward relay
– 535-125
– 535-140 B5 IGN Feed relay 4
– 537-135 From SN 1036631 B6 Front worklights
– 540-70 From SN 1016740 B7 Transmission dump
– 540-140 C1 Reverse relay
– 550 From SN 1036474 C2 Driveshaft relay
– 550-140 C3 Forward HI/LO
– 5508 From SN 1037581 C4 Sway isolation
C5 Roadlights
C6 Boom worklight
A B C D E F
C7 Neutral relay(1)
R C8
C9
Blank(1)
Blank(1)
D D1 IGN Feed relay 2
D2 Drive relay
F R
D3 Reverse HI/LO
D4 2 wheel drive
F D5 2nd auxiliary
D6 Brake lights
D7 Dump relay(1)
: D8
D9
Smooth Ride System relay(1)
Blank(1)
E1 Parkbrake
E2 Stabiliser Isolation (raise/lower)
E3 Blank
F1 Engine running relay
F2 2 wheel drive brake
F3 Blank
Fig 15.
X Flasher (not panel mounted)
Note: All the relays are shown (including optional
equipment relays). Your machine may not be equipped (1) Machines with Smooth Ride System Only
with all the relays shown.
C - 17 9803/3630-14 C - 17
Technical Data
Series II Relay Configuration 2 C3 Road lights
C4 Boom worklight
Applicability:
C5 Smooth ride system (SRS)(1)
– 530-70 FS Super (5 speed only) C6 Blank(1)
– 540-70 FS Super (5 speed only)
C7 Blank(1)
– 535-60 FS Super (5 speed only)
D1 IGN Feed relay 2
D2 2 wheel drive
A B C D E F D3 2nd auxiliary
D4 Brake lights
R D5 Smooth ride system (SRS)(1)
D6 Smooth ride system (SRS)(1)
D7 Blank(1)
AUX.2
(1) Machines with Smooth Ride System Only
Fig 16.

equipment relays). Your machine may not be equipped
A1 Audible alarm
A2 Neutral start
A3 IGN Feed relay 5
A4 IGN Feed relay 1
A5 IGN Feed relay 3
A6 Rear worklights
B4 Engine running relay
B5 IGN Feed relay 4
B6 Front worklights
C1 Reverse alarm
C2 Sway isolation
C - 18 9803/3630-14 C - 18
Technical Data
Series II Relay Configuration 3 B6 Front worklights
B7 Transmission dump
Applicability:
C1 Reverse relay
– 540-170 From SN 1037581 C2 Driveshaft relay
– 550-170 C3 Forward HI/LO
C4 Sway isolation
C5 Roadlights
A B C D E F
C6 Boom worklight
R C7
C8
Left hand stabiliser
Extension boost valve
D D1 IGN Feed relay 2

D2 Drive relay
>57
D3 Reverse HI/LO
F R
D4 2 wheel drive
F D5
D6
2nd auxiliary
Brake lights
D7 Right hand stabiliser
D8 4th boom extension
E1 Parkbrake
: E2 Stabiliser Isolation (raise/lower)
E3 Boom interlock
F1 Engine running relay
F2 2 wheel drive brake
F3 Stabiliser isolation (raise)
Fig 17.

equipment relays). Your machine may not be equipped
A1 Audible alarm
A2 Neutral start
A3 IGN Feed relay 5
A4 IGN Feed relay 1
A5 IGN Feed relay 3
A6 Rear worklights
A7 Parkbrake warning light
B4 Forward relay
B5 IGN Feed relay 4
C - 19 9803/3630-14 C - 19
Technical Data
Fuse Identification
Fuse Identification
Introduction
The electrical circuits are protected by fuses. The fuses are
located in a fuse box, as shown. If a fuse blows, find out
why before fitting a new one.
K Series I Machines ( T C-21)

K Series II Machines ( T C-22)
The radio fuse may have a higher rating, depending on the

type of radio fitted. Check radio fitting instructions.
Note: Additional fuse links are fitted at the battery positive

terminal. K Fuse Links ( T C-23).
C - 20 9803/3630-14 C - 20
Technical Data
Fuse Identification
Series I Machines Circuit Rating

30 Hazard lights 15
terminal. K Fuse Links ( T C-23). 31 Smooth Ride System 5
Hydraulics(2) 15
Circuit Rating 32 Boom work light(2) 5
1 Boom isolator 7.5 33 SPARE
2 Joystick controls (1) 10 34 Air Suspension Seat(1) 15
Auxiliary controls (up to 775402 only) 10 35 SPARE
3 Load Moment Indicator (LMI) 5 36 EMPTY
4 Heater 15 37 EMPTY
5 Air conditioning, face fan 15 38 EMPTY
6 Wipers 15 39 EMPTY
7 Radio, clock & heated seat 5 40 EMPTY
8 Instrument panel 7.5
9 Direction Indicators 10 (1) If fitted
(2) 540-170/5508 only
10 EMPTY
11 Starter relay & road light switch 5
illumination
12 Engine shut-off solenoid (ESOS) 5
13 Steer mode selector 7.5
14 Powershift 15
15 2/4 Wheel drive selector, or Brake 5
lights(2)
2/4 Wheel drive with trailer electrics(1) 10
16 Auxiliary socket 10
17 Brake lights 10
2-Wheel drive relay coil (2) 10
18 Rear work light 7.5
Fig 18. Series I Machines
19 Reverse lights & Reverse Alarm 7.5
20 EMPTY
21 Right hand side light 10
22 Left hand side light 10
23 Dip beam lights 10
24 Main beam lights 10
25 Front working light 10
26 Rear fog light 5
27 EMPTY
28 Horn, Headlight flash 10
29 Warning beacon, Interior light 5
C - 21 9803/3630-14 C - 21
Technical Data
Fuse Identification
Series II Machines Circuit Rating

35 Front worklights 25
terminal. K Fuse Links ( T C-23). 36 Rear worklights 15
37 Spare -
Circuit Rating 38 Seat 20
1 Sway hydraulics 7.5 39 Electric mirrors 10
2 Auxiliary hydraulics 15 40 Heated windows 25
3 Spare -
4 Face fan 5
5 Heater, Air conditioning 30
6 Indicators 10
7 Load Moment Indicator (LMI) 3
8 Instrument panel 7.5
9 Steer mode selector 10
10 Reversing lights/alarm 10
11 Roof/rear wiper 20
12 Front wiper 15
13 Fog light 3
14 Dipped beam 15
15 Main beam 20
16 Left hand sidelights 7.5
17 Right hand sidelights 5
18 Mobile phone/cigarette lighter 15
19 Smooth Ride System 10
20 Reverse fan 5
21 Starter relay 3
22 Engine shut-off solenoid (ESOS) 7.5
23 Powershift relays/ECU 5
Fig 19. Series II Machines
24 Powershift solenoids 20
25 Brake lights 10
26 Side lights 10
27 Headlight flasher, horn 25
28 Warning beacon 7.5
29 Interior light, radio, clock 10
30 Hazard lights 20
31 Neutral start 30
32 Thermostart 25
33 Boom worklight 25
34 Roadlights 20
C - 22 9803/3630-14 C - 22
Technical Data
Fuse Identification
Fuse Links
Series I Machines
Table 2. Fuse Links from SN 768700 - 770053

Circuit Rating
A Horn, Hazard warning lights, Beacon, 30
Interior light
B Road lights, Working lights 30
C Not used
D ESOS, Forward/reverse switch, Brake 40
lights
E SLI, Heater, Wipers, Radio, Instruments 80
Table 3. Fuse Links SN 770054 onwards

Circuit Rating
A Horn, Hazard warning lights, Beacon, 40
Interior light
B Road lights, Working lights 40
C SLI, Heater, Wipers, Radio, Instruments 40
D ESOS, Forward/reverse switch, Brake 40
lights
E Not used 80
C - 23 9803/3630-14 C - 23
Technical Data
Fuse Identification
Series II Machines Machines fitted with "R" Series Engines
An additional in-line fuse is located in the engine bay.

K Fig 20. ( T C-24).
Fig 20.
Table 5. Additional Fuse link for "R" Series Engines

Table 4. Fuse Links Series II Machines
Circuit Rating
Circuit Rating
X Glow plug relay 60
1 Horn, Sidelights, Hazard warning lights, 50
Beacon, Interior light
2 Road lights, Working lights, Boom light 80
3 Sway, Auxiliary, Heater 60
4 SRS, Starting circuit, Transmission, Brake 70
lights
5 SLI, Heater, Wipers, Radio, Instruments(1) 60
6 Seat, Electric mirrors, Heated glass(1) 60
(1) Fuse links 5 and 6 may not be in the same relative

position in all machines. Identify by wire number; fuse
link 5 connects to wire number 204, fuse link 6
connects to wire number 203.
C - 24 9803/3630-14 C - 24
Schematic Circuits
Applicable Machines
Schematic Circuits
Applicable Machines
Series I Machines
530-70 Machines (and Variants)
K 530-70 (Without Neutral Start Relay) From SN 767001 to 768836. ( T C-28).

K 530-70 (With Neutral Start Relay and ECU Controlled Transmission) From SN 768837 to 770053. ( T C-32).
K 530-70 (With Relay Controlled Transmission, ECU Not Fitted) From SN 770054 to 770958. ( T C-36).
K 530-70 (Series I Sway Machines) From SN 770959. ( T C-40).
K 530-70 (Series I Non-Sway Machines) From SN 770959. ( T C-44)
K 530-70 (Series I Machines with Manual Auxiliary Controls) From SN 775402. ( T C-48)
K 530-70 (Series I Machines with Single Lever Controls) From SN 775402. ( T C-53)
K 530 FS Super (Series I). ( T C-58)
K 530 SXL (Series I). ( T C-58)
532-120 Machines
K 532-120 (Without Neutral Start Relay) From SN 767001 to 768956. ( T C-70)

K 532-120 (With Neutral Start Relay and ECU Controlled Transmission) From SN 768957 to 770063. ( T C-74)
K 532-120 (With Relay Controlled Transmission, ECU Not Fitted) From SN 770064 to 770958. ( T C-78)
K 532-120 From SN 770959 to 775401. ( T C-82)
K 532-120 (With Manual Auxiliary Controls) From SN 775402. ( T C-63)
533-105 Machines
K 533-105 (Series I Machines). ( T C-63)
535-95 Machines
537-135 Machines
K 537-135 (Without Neutral Start Relay) From SN 767001 to 768956. ( T C-70)

K 537-135 (With Neutral Start Relay and ECU Controlled Transmission) From SN 768957 to 770063. ( T C-74)
K 537-135 (With Relay Controlled Transmission, ECU Not Fitted) From SN 770064 to 770958. ( T C-78)
K 537-135 From SN 770959 to 775401. ( T C-82)
C - 25 9803/3630-14 C - 25
Schematic Circuits
Applicable Machines
K 537-135 (With Manual Auxiliary Controls) From SN 775402. ( T C-63)
540-70 Machines (and Variants)
K 540-70 (Series I Sway Machines) From SN 770959. ( T C-40).

K 540-70 (Series I Non-Sway Machines) From SN 770959. ( T C-44)
K 540 FS Super (Series I). ( T C-58)
K 540 SXL (Series I). ( T C-58)
540-170 Machines
K 540-170 (With Servo Controls) To SN 1004130. ( T C-63)

K 540-170 From SN 1004131. ( T C-86)
550 Machines
K 550 From SN 770959 to 775401. ( T C-82)

K 550 (With Manual Auxiliary Controls) From SN 775402. ( T C-63)
5508 Machines
K 5508 (With Servo Controls) To SN 1004130. ( T C-63)

K 5508 From SN 1004131. ( T C-86)
C - 26 9803/3630-14 C - 26
Schematic Circuits
Applicable Machines
Series II Machines
K 530-70 From SN 1016569 ( T C-92)

K 532-120 From SN 1036631 ( T C-92)
K 533-105 From SN 1036561 ( T C-92)
K 535-60 ( T C-92)
K 535-95 From SN 1036555 ( T C-92)
K 535-125 ( T C-92)
K 535-140 ( T C-92)
K 537-135 From SN 1036631 ( T C-92)
K 540-70 From SN 1016740 ( T C-92)
K 540-140 ( T C-92)
K 540-170 From SN 1037581 ( T C-92)
K 550 From SN 1036474 ( T C-92)
K 550-140 ( T C-92)
K 550-170 ( T C-92)
K 5508 From SN 1037581 ( T C-92)
C - 27 9803/3630-14 C - 27
Schematics
C - 28
530-70 16 Auxiliary B relay 45 Heater seat

17 Auxiliary A relay 46 Digital clock
Applicability
18 Auxiliary B solenoid 47 Warning buzzer
– 530-70 (Without Neutral Start Relay) From SN 19 Auxiliary change-over switch 48 Trailer indicators
767001 to 768836. 20 Auxiliary change-over relay 49 Hazard switch
Note: To check if a neutral start relay is fitted, try 21 Auxiliary change-over valve 2 50 Indicator relay
starting the engine with the transmission in gear. 22 Boom extend switch 51 Hazard diode
23 Extend relay 52 Interior light
Component Key
24 Extend solenoid 53 Rotating beacon switch
– Items 1 to 67: K Fig 21. ( T C-30) 25 Boom retract switch 54 Rotating beacon
– Items 68 to 111: K Fig 22. ( T C-31) 26 Retract relay 55 Primary fuse
27 Retract solenoid 56 Ignition relay
Note: Refer to the ECU fault finding information in this
9803/3630-14
section for control unit output connections. 28 Transmission dump switch 57 ESOS
29 Safe Load Indicator (SLI) 58 Two wheel steer solenoid
1 Battery 30 SLI transducer 59 Four-wheel/crab steer solenoid
2 Battery isolator 31 Heater/air conditioning fan 60 Four wheel steer solenoid
3 Starter motor 32 Heater/air conditioning unit 61 Crab steer solenoid
4 Ignition switch 33 Air conditioning switch 62 Steer Mode Control Unit
5 Starting aid 34 Face level fan W Four-wheel/crab steer relay
6 Auto relay 35 Air conditioning compressor X Two wheel steer relay
7 High Speed Control relay 36 Air conditioning relay Y Crab steer relay
8 Pump dump switch 37 Binary Switch Z Four wheel steer relay
9 Single lever control 38 Rear wiper switch 63 Steer mode switch
Schematic Circuits
10 Sway isolation relay 39 Rear wiper motor X Two wheel steer select
11 Sway/Auxiliary change-over 40 Roof wiper switch Y Crab steer select
12 Auxiliary change-over valve 1 41 Roof wash pump Z Four wheel steer select
13 Sway isolation switch 42 Roof wiper 64 Front sensor
Schematics
14 Auxiliary A solenoid 43 Front wiper 65 Rear sensor
C - 28
15 Auxiliary A/B switch 44 Radio/cassette 66 Instrument panel

C - 29
68 Air filter blocked switch 100 Right hand dip beam

69 Engine oil pressure switch 101 Left hand dip beam
70 Transmission oil temp switch 102 Right hand main beam
71 Water temperature sender 103 Left hand main beam
72 Alternator 104 Rear foglight switch
73 Fuel sender 105 Trailer rear
74 Water temperature switch 106 Steering column switch
75 Steering column switch 107 Screen wash pump
76 Horn 108 Right hand indicators
77 Reverse relay 109 Trailer rear
78 Powershift control unit(1) 110 Left hand indicators
79 Park brake 111 Trailer rear
80 Four wheel brake relay
81 Foot brake (1) Powershift control unit only shows input
connections from the mainframe harness.
82 Two wheel drive switch
9803/3630-14
83 Brakelights
84 Brakelights
85 Trailer rear
86 Reverse alarm
87 Auxiliary power socket
88 Rear worklight switch
89 Rear worklight
90 Sidelight relay
91 Main light switch
92 Primary fuse
Schematic Circuits
93 Right hand sidelights
94 Trailer rear
95 Left hand sidelights
96 Trailer rear
Schematics
97 Left hand worklights
C - 29
98 Front worklight switch

99 Right hand worklights
C - 30
9803/3630-14
Schematic Circuits
Fig 21. 530-70 From SN 767001 to 768836 (Sheet 1 of 2)
K Component Key ( T C-28)
Schematics
K Fig 22. ( T C-31), for Sheet 2 of 2.
C - 30
C - 31
600
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
9803/3630-14
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
Fig 22. 530-70From S N 767001 to 768836 (Sheet 2 of 2)
Schematic Circuits
Schematics
C - 31
530-70
C - 32
18 Auxiliary A relay 50 Hazard switch

19 Auxiliary B solenoid 51 Indicator relay
Applicability
20 Auxiliary change-over switch 52 Hazard diode
– 530-70 (With Neutral Start Relay and ECU 21 Auxiliary change-over relay 53 Interior light
Controlled Transmission) From SN 768837 to 22 Auxiliary change-over valve 2 54 Rotating beacon switch
770053.
23 Boom extend switch 55 Rotating beacon
Note: To check if a neutral start relay is fitted, try 24 Extend relay 56 Primary fuse
starting the engine with the transmission in gear.
25 Extend solenoid 57 Ignition relay
Component Key 26 Boom retract switch 58 ESOS
27 Retract relay 59 Two wheel steer solenoid
– Items 1 to 67: K Fig 23. ( T C-34)
28 Retract solenoid 60 Four-wheel/crab steer solenoid
– Items 68 to 112: K Fig 24. ( T C-35)
29 Transmission dump switch 61 Four wheel steer solenoid
Note: Refer to the ECU fault finding information in this 30 Safe Load Indicator (SLI) 62 Crab steer solenoid
section for control unit output connections. 31 SLI transducer 63 Steer Mode Control Unit
32 Heater/air conditioning fan W Four-wheel/crab steer relay
9803/3630-14
1 Battery
33 Heater/air conditioning unit X Two wheel steer relay
2 Battery isolator
34 Air conditioning switch Y Crab steer relay
3 Starter motor
35 Face level fan Z Four wheel steer relay
4 Neutral start
36 Air conditioning compressor 64 Steer mode switch
5 Ignition switch
37 Air conditioning relay X Two wheel steer select
6 Starting aid
38 Binary Switch Y Crab steer select
7 Auto relay
39 Rear wiper switch Z Four wheel steer select
8 High Speed Control relay
40 Rear wiper motor 65 Front sensor
9 Pump dump switch
41 Roof wiper switch 66 Rear sensor
10 Single lever control
42 Roof wash pump 68 Instrument panel
11 Sway isolation relay
Schematic Circuits
43 Roof wiper 69 Air filter blocked switch
12 Sway/Auxiliary change-over
44 Front wiper 70 Engine oil pressure switch
13 Auxiliary change-over valve 1
45 Radio/cassette 71 Transmission oil temp switch
14 Sway isolation switch
46 Heater seat 72 Water temperature sender
Schematics
15 Auxiliary A solenoid
47 Digital clock 73 Alternator
16 Auxiliary A/B switch
C - 32
48 Warning buzzer 74 Fuel sender

17 Auxiliary B relay
49 Trailer indicators 75 Water temperature switch
C - 33
76 Steering column switch 108 Screen wash pump

77 Horn 109 Right hand indicators
78 Reverse relay 110 Trailer rear
79 Powershift control unit(1) 111 Left hand indicators
80 Park brake 112 Trailer rear
81 Four wheel brake relay
82 Foot brake (1) Powershift control unit only shows input
84 Brakelights
85 Brakelights
86 Trailer rear
87 Reverse alarm
90 Rear worklight
9803/3630-14
91 Sidelight relay
93 Primary fuse
94 Right hand sidelights
95 Trailer rear
96 Left hand sidelights
97 Trailer rear
Schematic Circuits
101 Right hand dip beam
102 Left hand dip beam
103 Right hand main beam
104 Left hand main beam
Schematics
105 Rear foglight switch
C - 33
106 Trailer rear

107 Steering column switch
C - 34
9803/3630-14
Schematic Circuits
Schematics
C - 34
C - 35
9803/3630-14
Schematic Circuits
Schematics
C - 35
530-70
C - 36
24 Extend solenoid 56 Engine Shut-Off Solenoid

25 Boom retract switch 57 Two wheel steer solenoid
Applicability
26 Retract relay 58 Four-wheel/crab steer solenoid
– 530-70 (With Relay Controlled Transmission, 27 Retract solenoid 59 Four wheel steer solenoid
ECU Not Fitted) From SN 770054 to 770958. 28 Safe Load Indicator (SLI) 60 Crab steer solenoid
Component Key 29 SLI transducer 61 Steer Mode Control Unit

30 Heater/air conditioning fan W Four-wheel/crab steer relay
– Items 1 to 66: K Fig 25. ( T C-38), 31 Air conditioning switch X Two wheel steer relay
– Items 67 to 127: K Fig 26. ( T C-39),
32 Heater/air conditioning unit Y Crab steer relay
1 Battery 33 Face level fan Z Four wheel steer relay
2 Battery isolator 34 Air conditioning compressor 62 Steer mode switch
3 Starter motor 35 Air conditioning relay X Two wheel steer select
4 Neutral start relay 36 Binary switch (air con) Y Crab steer select
5 Ignition switch 37 Rear wiper switch Z Four wheel steer select
6 Starting aid 38 Rear wiper motor 63 Front sensor
9803/3630-14
7 not used 39 Roof wiper switch 64 Rear sensor

8 High Speed Control relay 40 Roof wash pump 65 Instrument panel
9 Pump dump switch 41 Roof wiper 67 Air filter blocked switch
10 not used 42 Front wiper 68 Engine oil pressure switch
11 Sway/Auxiliary change-over 43 Radio/cassette 69 Transmission oil temp switch
12 Auxiliary A relay 44 Heated seat 70 Steering column switch
13 Auxiliary A solenoid 45 Digital clock 71 Alternator
14 Auxiliary A/B switch 46 Warning buzzer 72 Fuel sender
47 Trailer indicators 73 Water temperature switch
16 Auxiliary B solenoid 48 Hazard switch 74 Steering column switch
Schematic Circuits
17 Auxiliary change-over relay 2 49 Indicator relay 75 Horn
18 Auxiliary change-over valve 1 50 Hazard diode 76 Reverse relay 2
19 Auxiliary change-over relay 51 Interior light 77 Ignition relay 2
20 Auxiliary change-over valve 2 52 Rotating beacon switch 78 Transmission dump switch
Schematics
21 Auxiliary change-over switch 53 Rotating beacon 79 Pump dump relay
C - 36
22 Boom extend switch 54 Primary fuse 80 Reverse 1 relay

23 Extend relay 55 Ignition relay 81 Forward relay
C - 37
82 Drive relay 114 Left hand work lights

83 Parkbrake relay 115 Right hand work lights
84 Reverse HI/LOW relay 116 Right hand dip beam
85 Reverse high solenoid 117 Left hand dip beam
86 Reverse low solenoid 118 Right hand main beam
87 Forward HI/LOW relay 119 Left hand main beam
88 Forward high solenoid 120 Rear fog light switch
89 Forward low solenoid 121 Rear fog light
90 Driveshaft relay 122 Steering column switch
91 Layshaft solenoid 123 Front wash/wipe motor
92 Mainshaft solenoid 124 Right hand indicators
93 Two/four wheel drive solenoid 125 Trailer rear
94 Transmission oil temperature switch 126 Left hand indicators
95 Parkbrake switch 127 Trailer rear
96 Footbrake switch
9803/3630-14
97 Four wheel drive brake relay

99 Brakelights
100 Brakelights
101 Trailer rear
102 Reverse alarm
105 Rear worklight
106 Sidelight relay
Schematic Circuits
108 Primary fuse
109 Right hand sidelight
110 Trailer rear
Schematics
111 Left hand sidelight
C - 37
112 Trailer rear

113 Front work light switch
C - 38
9803/3630-14
Schematic Circuits
Schematics
K Fig 26. ( T C-39), or Sheet 2 of 2.
C - 38
C - 39
9803/3630-14
Schematic Circuits
Schematics
C - 39
530-70, 540-70
C - 40
22 Auxiliary 2 B switch 54 Engine Shut-Off Solenoid

23 Auxiliary change-over valve 2 55 Two wheel steer solenoid
Applicability
24 Auxiliary change-over relay 56 Four-wheel/crab steer solenoid
– 530-70 (Series I Sway Machines) From SN 25 Safe Load Indicator (SLI) 57 Four wheel steer solenoid
770959. 26 SLI transducer 58 Crab steer solenoid
– 540-70 (Series I Sway Machines) From SN
27 Heater/air conditioning fan 59 Steer Mode Control Unit
770959.
28 Air conditioning switch W Four-wheel/crab steer relay
Component Key 29 Heater/air conditioning unit X Two wheel steer relay
30 Face level fan Y Crab steer relay
– Items 1 to 63: K Fig 27. ( T C-42),
31 Air conditioning compressor Z Four wheel steer relay
– Items 64 to 126: K Fig 28. ( T C-43),
32 Air conditioning relay 60 Steer mode switch
1 Battery
33 Binary switch (air conditioning) X Two wheel steer select
2 Battery isolator
34 Rear wiper switch Y Crab steer select
3 Starter motor
35 Rear wiper motor Z Four wheel steer select
4 Ignition switch
36 Roof wiper switch 61 Front sensor
9803/3630-14
5 Starting aid
37 Roof wash pump 62 Rear sensor
6 Neutral start relay
38 Roof wiper 63 Instrument panel
7 not used
39 Front wiper 65 Air filter blocked switch
8 HSC pump dump switch
40 Radio/cassette 66 Engine oil pressure switch
41 Heated seat 67 Transmission oil temp switch
10 Sway/Auxiliary change-over switch
42 Digital clock 68 Steering column switch
43 Warning buzzer 69 Alternator
12 Auxiliary A switch
44 Trailer indicators 70 Fuel sender
45 Hazard switch 71 Water temperature switch
14 Auxiliary B switch
46 Indicator relay 72 Steering column switch
15 Auxiliary B solenoid
Schematic Circuits
47 Hazard diode 73 Horn
16 Joystick isolation switch
48 Interior light 74 Reverse relay 2
17 Single lever control - extend
49 Rotating beacon switch 75 Ignition relay 2
18 Extend solenoid
50 Rotating beacon 76 Transmission dump switch
Schematics
19 Single lever control - retract
51 Primary fuse 77 Transmission dump relay
20 Retract solenoid
C - 40
52 Primary fuse 78 Reverse 1 relay

21 Auxiliary 2 A switch
53 Ignition relay 79 Forward relay
C - 41
80 Drive relay 112 Front work light switch

81 Parkbrake relay 113 Left hand work lights
82 Reverse HI/LOW relay 114 Right hand work lights
83 Reverse high solenoid 115 Right hand dip beam
84 Forward HI/LOW relay 116 Left hand dip beam
86 Forward high solenoid 118 Left hand main beam
87 Forward low solenoid 119 Rear fog light switch
88 Driveshaft relay 120 Trailer rear
89 Layshaft solenoid 121 Steering column switch
90 Mainshaft solenoid 122 Front wash/wipe motor
91 Two/Four wheel drive solenoid 123 Right hand indicators
92 Transmission oil temperature switch 124 Trailer rear
93 Parkbrake 125 Left hand indicators
94 Four wheel drive brake relay 126 Trailer rear
9803/3630-14
95 Footbrake
97 Brakelights
98 Brakelights
99 Trailer rear
100 Reverse alarm
103 Rear worklight
104 Sidelight relay
Schematic Circuits
105 Primary fuse 3
107 Primary fuse 2
Schematics
109 Trailer rear
C - 41

111 Trailer rear
C - 42
9803/3630-14
Schematic Circuits
Fig 27. 530-70, 540-70 Series I Sway Machines From SN 770959 (Sheet 1 of 2)
Schematics
C - 42
C - 43
9803/3630-14
Schematic Circuits
Fig 28. 530-70, 540-70 Series I Sway Machines From SN 770959 (Sheet 2 of 2)
Schematics
K Fig 27. ( T C-42), For Sheet 1 of 2.
C - 43
530-70, 540-70
C - 44
22 Stabilizer isolation switch 54 Engine Shut-Off Solenoid

23 Auxiliary change-over valve 1 55 Two wheel steer solenoid
Applicability
24 Safe Load Indicator (SLI) 56 Four-wheel/crab steer solenoid
– 530-70 (Series I Non-Sway Machines) From SN 25 SLI transducer 57 Four wheel steer solenoid
770959. 26 Heater/air conditioning fan 58 Crab steer solenoid
– 540-70 (Series I Non-Sway Machines) From SN
27 Air conditioning switch 59 Steer Mode Control Unit
770959.
28 Heater/air conditioning unit W Four-wheel/crab steer relay
Component Key 29 N/A X Two wheel steer relay
– Items 1 to 63: K Fig 29. ( T C-46),
– Items 64 to 126: K Fig 30. ( T C-47),
1 Battery
33 Binary switch (air conditioning) X Two wheel steer select
2 Battery isolator
3 Starter motor
4 Ignition switch
36 Roof wiper switch 61 Front sensor
9803/3630-14
5 Starting aid
37 Roof wash pump 62 Rear sensor
38 Roof wiper 63 Instrument panel
7 not used
39 Front wiper 65 Air filter blocked switch
8 Pump dump switch
9 Auxiliary A switch
41 Heated seat 67 Transmission oil temp switch
42 Digital clock 68 Steering column switch
11 Auxiliary B switch
43 Warning buzzer 69 Alternator
44 Trailer indicators 70 Fuel sender
45 Hazard switch 71 Water temperature switch
14 Boom extend switch
46 Indicator relay 72 Steering column switch
15 Extend solenoid
Schematic Circuits
47 Hazard diode 73 Horn
16 Boom retract switch
48 Interior light 74 Reverse relay 2
17 Retract solenoid
49 Rotating beacon switch 75 Ignition relay 2
18 Auxiliary 2 A switch
50 Rotating beacon 76 Transmission dump switch
Schematics
19 Auxiliary change-over relay
51 Primary fuse 77 Transmission dump relay
C - 44

21 Auxiliary 2 B switch
53 Ignition relay 79 Forward relay
C - 45
80 Drive relay 112 Front work light switch

81 Parkbrake relay 113 Left hand work lights
82 Reverse HI/LOW relay 114 Right hand work lights
83 Reverse high solenoid 115 Right hand dip beam
84 Forward HI/LOW relay 116 Left hand dip beam
87 Forward low solenoid 119 Rear fog light switch
88 Driveshaft relay 120 Trailer rear
89 Layshaft solenoid 121 Steering column switch
91 Two/Four wheel drive solenoid 123 Right hand indicators
92 Transmission oil temperature switch 124 Trailer rear
93 Parkbrake 125 Left hand indicators
94 Four wheel drive brake relay 126 Trailer rear
9803/3630-14
95 Footbrake
97 Brakelights
98 Brakelights
99 Trailer rear
100 Reverse alarm
103 Rear worklight
104 Sidelight relay
Schematic Circuits
105 Primary fuse 3
107 Primary fuse 2
Schematics
109 Trailer rear
C - 45

111 Trailer rear
C - 46
9803/3630-14
Schematic Circuits
Schematics
Fig 29. 530-70, 540-70 Series I Non-Sway Machines From SN 770959 (Sheet 1 of 2)
C - 46
K Component Key ( T C-44) K Fig 30. ( T C-47), for Sheet 2 of 2.

C - 47
9803/3630-14
Schematic Circuits
Fig 30. 530-70, 540-70 Series I Non-Sway Machines From SN 770959 (Sheet 2 of 2)
Schematics
C - 47

530-70, 535-95, 540-70
C - 48
12B Auxiliary power connector 40 Rear fog light switch

13 2/4WD brake relay 41 Rear fog lamp (optional)
Applicability
13A Brake lamps 42 Column switch - RH
– 530-70 (Series I Machines with Manual Auxiliary 14 Brake switch 43 LH indicators
Controls) From SN 775402. 15 2/4WD switch 44 RH indicators
– 535-95 (Series I Machines with Manual Auxiliary
16 2/4WD solenoid 45 Front washer pump
Controls) From SN 777362.
17 Reverse relay 46 Front wiper motor
– 540-70 (Series I Machines with Manual Auxiliary
Controls) From SN 775402. 17A Reverse lamp 47 Rear wiper motor
18 Reverse alarm 48 Roof/rear washer pump
Component Key
19 Park brake relay 49 Roof wiper motor
– Items 1 to 33: K Fig 32. ( T C-50), 19A Park brake switch 50 Rear wiper switch
– Items 34 to 65: K Fig 33. ( T C-51), 20 Heated seat 51 Roof wiper switch
– Items 66 to 100: K Fig 34. ( T C-52), 21 Radio/cassette 52 Hazard warning switch
– Items 131 to 133: K Fig 31. ( T C-49) 22 Digital clock 53 Hazard warning relay
23 Transducer - Load Moment Indicator (LMI) 54 Trailer indicator warning light
9803/3630-14
Note: All the items listed here are not necessarily

fitted to all machines in the range. 24 Instrument panel 55 Interior light/switch
25 Warning buzzer 56 Beacon switch
1 Battery 26 Air filter blocked switch 57 Beacon lamp
2 Battery isolator 27 Engine oil pressure switch 58 Face level fan
3 Starter motor 28 Transmission oil temperature switch 59 Air conditioning relay
4 Starter solenoid 29 Transmission oil pressure switch 60 Air conditioning - compressor motor
5 Ignition switch 30 Water temperature switch 61 Air conditioning - freeze switch
5A Fuse link 2 31 Fuel gauge 62 Air conditioning - receiver drier
6 Starting aid
32 Water temperature gauge 63 Air conditioning switch
7 Neutral start relay 33 Alternator 64 Heater/heater fan switch
Schematic Circuits
8 Ignition feed relay 1 34 Sidelight relay 65 Heater
9 Ignition feed relay 2 34A Fuse link 2 66 Column switch - LH
10 E.S.O.S. 35 RH side lights 67 Horn
11 Rear work lamp switch 36 LH side lights 68 Reverse Hi/Lo relay
Schematics
11A Rear work lamp 37 Main light switch 69 Reverse Lo relay
C - 48
12 Front work lamps switch 38 RH/LH dip beam 70 Reverse Hi relay

12A Front work lamps 39 RH/LH main beam 71 Diode pack(1)
C - 49
72 Reverse relay 97 AWS solenoid

73 Forward relay 98 Crab steer solenoid
74 Forward Hi/Lo relay 99 Proximity switch - front axle
75 Forward Hi solenoid 100 Proximity switch - rear axle
76 Forward Lo solenoid 131 Fan reverse switch(2)
77 Drive interlock relay 132 Fan reverse solenoid(2)
78 Drive shaft relay 133 Fan reverse horn(2)
79 Layshaft solenoid
80 Mainshaft solenoid (1) Diode indicated () not fitted to 3-speed machines.
(2) Optional fan reversing circuit.
81 Transmission dump relay
82 2nd auxiliary relay
83 2nd auxiliary solenoid
84 Hitch/boom hydraulics solenoid
85 Hitch switch
86 Sway switch
9803/3630-14
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
Fig 31. Optional fan reversing circuit
Schematic Circuits
D Four wheel steer relay
94 Steer mode selector switch
X Two wheel steer
Y Crab Steer
Schematics
Z Four wheel steer
C - 49
95 2WS solenoid
96 4WS solenoid
C - 50
9803/3630-14
Schematic Circuits
Fig 32. 530-70, 540-70 (Series I Machines with Manual Auxiliary Controls) From SN 775402, 535-95 (Series I Machines with Manual Auxiliary Controls) From
SN777362. (Sheet 1 of 3)
Schematics
C - 50

C - 51
9803/3630-14
Schematic Circuits
Fig 33. 530-70, 540-70 (Series I Machines with Manual Auxiliary Controls) From SN 775402, 535-95 (Series I Machines with Manual Auxiliary Controls) From
SN777362. (Sheet 2 of 3)
Schematics
C - 51

C - 52
9803/3630-14
Schematic Circuits
Fig 34. 530-70, 540-70 (Series I Machines with Manual Auxiliary Controls) From SN 775402, 535-95 (Series I Machines with Manual Auxiliary Controls) From SN
777362. (Sheet 3 of 3)
Schematics
C - 52

530-70, 535-95, 540-70
C - 53
13 Auxiliary power connector 44 Rear fog light switch

14 Brake switch 45 Rear fog lamp (optional)
Applicability
15 2/4WD brake relay 46 Column switch - RH
– 530-70 (Series I Machines with Single Lever 16 Brake lamps 47 LH indicators
Controls) From SN 775402. 17 2/4WD switch 48 RH indicators
– 535-95 (Series I Machines with Single Lever
18 2/4WD solenoid 49 Front washer pump
Controls) From SN 777362.
19 Reverse relay 50 Front wiper motor
– 540-70 (Series I Machines with Single Lever
Controls) From SN 775402. 20 Reverse lamp 51 Rear wiper motor
21 Reverse alarm 52 Rear wiper switch
Component Key
22 Park brake relay 53 Rear/roof washer pump
– Items 1 to 37: K Fig 36. ( T C-55), 23 Park brake switch 54 Roof wiper motor
– Items 38 to 68: K Fig 37. ( T C-56), 24 Heated seat 55 Roof wiper switch
– Items 69 to 105: K Fig 38. ( T C-57), 25 Radio/cassette 56 Hazard warning switch
– Items 131 to 133: K Fig 35. ( T C-54) 26 Digital clock 57 Hazard warning relay
27 Transducer - load moment indicator (LMI) 58 Interior light/switch
9803/3630-14

fitted to all machines in the range. 28 Instrument panel 59 Beacon switch
29 Warning buzzer 60 Beacon lamp
1 Battery 30 Alternator 61 Face level fan
2 Battery isolator 31 Air filter blocked switch 62 Air conditioning relay
3 Starter motor 32 Engine oil pressure switch 63 Air conditioning - compressor motor
4 Starter solenoid 33 Transmission oil temperature switch 64 Air conditioning - freeze switch
5 Ignition switch 34 Transmission oil pressure switch 65 Air conditioning - receiver drier
5A Fuse link 2 35 Water temperature switch 66 Air conditioning switch
6 Starting aid
36 Fuel gauge 67 Heater/heater fan switch
7 Neutral start relay 37 Water temperature gauge 68 Heater
Schematic Circuits
8 Ignition feed relay 1 38 Sidelight relay 69 Column switch - LH
9 Ignition reed relay 2 38A Fuse link 1 70 Horn
10 E.S.O.S. 39 RH side lights 71 Reverse Hi/Lo relay
11 Rear work lamp switch 40 LH side lights 72 Reverse Lo Solenoid
Schematics
11A Rear work lamp 41 Main light switch 73 Reverse Hi solenoid
C - 53
12 Front work lamp switch 42 RH/LH dip beam 74 Diode pack(1)

12A Front work lamps 43 RH/LH main beam 75 Reverse relay
C - 54
76 Forward relay 101 4WS solenoid

77 Forward Hi/Lo relay 102 AWS solenoid
78 Forward Hi solenoid 103 Crab steer solenoid
79 Forward Lo solenoid 104 Proximity switch - front axle
80 Drive interlock relay 105 Proximity switch - rear axle
81 Drive shaft relay 131 Fan reverse switch(2)
82 Layshaft solenoid 132 Fan reverse solenoid(2)
83 Mainshaft solenoid 133 Fan reverse horn(2)
85 2nd auxiliary relay (1) Diode indicated () not fitted to 3-speed machines.
88 Hitch switch
89 Joystick isolation switch/lamp
90 Extend switch
9803/3630-14
91 Extend solenoid
92 Retract switch
93 Retract solenoid
97 Transmission dump push button
Schematic Circuits
C Crab steer relay
99 Steer mode selector switch
X Two wheel steer
Schematics
Y Crab steer
C - 54
Z Four wheel steer

100 2WS solenoid
C - 55
9803/3630-14
Schematic Circuits
Fig 36. 530-70, 540-70 (Series I Machines with Single Lever Controls) From SN 775402, 535-95 (Series I Machines with Single Lever Controls) From SN 777362.
(Sheet 1 of 3)
Schematics
C - 55

C - 56
9803/3630-14
Schematic Circuits
(Sheet 2 of 3)
Schematics
C - 56

C - 57
9803/3630-14
Schematic Circuits
(Sheet 3 of 3)
Schematics
C - 57

530 FS Super, 530 SXL, 540 FS Super,
C - 58
16 Front work lamps 47 RH/LH dip beam

540 SXL 17 Auxiliary power connector 48 RH/LH main beam
18 2/4WD brake relay 49 Rear fog light switch
Applicability
19 Brake lamps 50 Rear fog lamp (optional)
– 530 FS Super (Series I). 20 Brake switch 51 Column switch - RH
– 530 SXL (Series I). 21 2/4WD switch 52 LH indicators
– 540 FS Super (Series I). 22 2/4WD solenoid 53 RH indicators
– 540 SXL (Series I). 23 Reverse relay 54 Front washer pump
Component Key 24 Reverse lamp 55 Front wiper motor

25 Reverse alarm 56 Rear wiper motor
– Items 1 to 41: K Fig 40. ( T C-60), 26 Heated seat 57 Roof/rear washer pump
– Items 42 to 80: K Fig 41. ( T C-61),
27 Radio/cassette 58 Roof wiper motor
– Items 81 to 122: K Fig 42. ( T C-62),
28 Digital clock 59 Rear wiper switch
– Items 131 to 133: K Fig 39. ( T C-59)
29 Tracker 60 Roof wiper switch
Note: All the items listed here are not necessarily 30A Load Moment Indicator (LMI) - Transducer 61 Hazard warning switch
9803/3630-14
fitted to all machines in the range. 30B LMI Readout Unit 62 Hazard warning relay
31 Fuse link 1 63 Trailer indicator warning light
1 Battery
32 Instrument panel 64 Interior light/switch
2 Battery isolator
33 Warning buzzer 65 Beacon switch
3 Starter motor
34 Air filter blocked switch 66 Beacon lamp
4 Starter solenoid
35 Engine oil pressure switch 67 Face level fan
5 Ignition switch
36 Transmission oil temperature switch 68 Air conditioning relay
6 Fuse link 2
37 Water temperature switch 69 Air conditioning - compressor motor
7 Starting aid
38 Fuel gauge 70 Air conditioning - freeze switch
39 Water temperature gauge 71 Air conditioning - receiver drier
9 Ignition feed relay 1
Schematic Circuits
40 Alternator 72 Air conditioning switch
10 Ignition feed relay 2
41 Air suspension seat 73 Heater/heater fan switch
11 Wax Thermostat
42 Sidelight relay 74 Heater
12 E.S.O.S.
43 Fuse link 1 75 Sway switch
Schematics
13 Rear work lamp switch
44 RH side lights 76 Sway diverter solenoid
14 Rear work lamp
C - 58
45 LH side lights 77 Sway valve

15 Front work lamps switch
46 Main light switch 78 Sway valve
C - 59
79 Sway isolator relay 111 Auxiliary A solenoid

80 Sway isolator proximity switch 112 Auxiliary B push button
81 Transmission oil pressure switch 113 Auxiliary B solenoid
82 5th gear solenoid 114 Transmission dump push button
83 Speed sensor 115 Steer mode control unit
84 Mainshaft solenoid A Four wheel/crab steer relay
85 Layshaft solenoid B Two wheel steer relay
86 Forward high solenoid C Crab steer relay
87 Forward low solenoid D Four wheel steer relay
88 Reverse high solenoid 116 Steer mode selector switch
89 Reverse low solenoid X Two wheel steer
90 Speedometer Y Crab Steer
91 Speedometer illumination Z Four wheel steer
92 Throttle switch 117 2WS solenoid
93 Column switch - LH 118 4WS solenoid
9803/3630-14

94 Electronic control unit 119 AWS solenoid
95 Diagnostic port 120 Crab steer solenoid
96 Horn 121 Proximity switch - front axle
97 Parkbrake switch 122 Proximity switch - rear axle
98 2nd auxiliary relay 131 Fan reverse switch(1)
99 2nd auxiliary solenoid 132 Fan reverse solenoid(1)
100 Hitch switch 133 Fan reverse horn(1)
103 Diode pack
Schematic Circuits
104 2nd auxiliary B push button
105 Extend push button
106 Extend solenoid
107 2nd auxiliary A push button
Schematics
108 Retract push button
C - 59
109 Retract solenoid

110 Auxiliary A push button
C - 60
9803/3630-14
Schematic Circuits
Fig 40. 530 FS Super, 530 SXL, 540 FS Super, 540 SXL Series I Machines (Sheet 1 of 3)
Schematics
C - 60

C - 61
9803/3630-14
Schematic Circuits
Schematics
C - 61

C - 62
9803/3630-14
Schematic Circuits
Schematics
C - 62

532-120, 533-105, 537-135, 540-170,
C - 63
9 Ignition feed relay 2 34 LH stabiliser lamp switch

550, 5508 10 E.S.O.S. 35 RH stabiliser lamp switch
11 Rear work lamp switch 36 sidelight relay
Applicability
11A Rear work lamp 36A Fuse link 1
– 532-120 (With Manual Auxiliary Controls) From 12 Front work lamp switch 37 RH side lights
SN 775402.
12A Front work lamps 38 LH side lights
– 533-105 (Series I Machines).
12B Auxiliary power connector 39 Main light switch
– 537-135 (With Manual Auxiliary Controls) From
SN 775402. 13 2/4WD brake relay 40 RH/LH dip beam
– 540-170 (With Servo Controls) To SN 1004130. 13A Brake lamps 41 RH/LH main beam
– 550 (With Manual Auxiliary Controls) From SN 14 Brake switch 42 Rear fog light switch
775402. 15 2/4WD switch 43 Rear fog lamp (optional)
– 5508 (With Servo Controls) To SN 1004130. 16 2/4WD solenoid 44 Column switch - RH
17 Reverse relay 45 LH indicator lamps
Component Key
17A Reverse lamp 46 RH indicator lamps
– Items 1 to 35: K Fig 44. ( T C-65), 18 Reverse alarm 47 Front washer pump
9803/3630-14
– Items 36 to 66: K Fig 45. ( T C-66), 19 Park brake relay 48 Front wiper motor
– Items 67 to 100: K Fig 46. ( T C-67),
19A Park brake switch 49 Rear wiper motor
– Items 101 to 119 (540-170, 5508): K Fig
20 Heated seat 50 Rear/roof washer pump
47. ( T C-68),
– Items 131 to 133 (Optional fan reversing circuit): 21 Radio/cassette 51 Roof wiper motor
K Fig 43. ( T C-64) 22 Digital clock 52 Rear wiper switch
22A Fuse link 1 53 Roof wiper switch
fitted to all machines in the range. 23 Transducer - load moment indicator (LMI) 54 Hazard warning switch
24 Instrument panel 55 Hazard warning relay
1 Battery 25 Warning buzzer 56 Interior light/switch
2 Battery isolator 26 Alternator 57 Beacon switch
Schematic Circuits
3 Starter motor 27 Air filter blocked switch 58 Beacon lamp
4 Starter solenoid 28 Engine oil pressure switch 59 Face level fan
5 Ignition switch 29 Transmission oil temperature switch 60 Air conditioning relay
5A Fuse link 2 30 Transmission oil pressure switch 61 Air conditioning - compressor motor
Schematics
6 Starting aid 31 Water temperature switch 62 Air conditioning - freeze switch
C - 63
7 Neutral start relay 32 Fuel gauge 63 Air conditioning - receiver drier

8 Ignition feed relay 1 33 Water temperature gauge 64 Air conditioning switch
C - 64
65 Heater/heater fan switch C Crab steer relay 132 Fan reverse solenoid(3)
66 Heater D Four wheel steer relay 133 Fan reverse horn(3)
67 Column switch - LH 94 Steer mode selector switch
68 Horn X Two wheel steer (1) Diode indicated () not fitted to 3-speed machines.
(2) On later machines, extend isolation switch
69 Reverse Hi-Lo relay Y Crab steer removed, but interlock relay retained to allow
70 Reverse Lo solenoid Z Four wheel steer correct operation of the extend diverter valve.
71 Reverse Hi solenoid 95 2WS solenoid (3) Optional fan reversing circuit.
71A Diode pack(1) 96 4WS solenoid

72 Reverse relay 97 AWS solenoid
73 Forward relay 98 Crab steer solenoid
74 Forward Hi/Lo relay 99 Proximity switch - front axle
75 Forward Hi solenoid 100 Proximity switch - rear axle
76 Forward Lo solenoid 101 Extend isolation switch (if fitted)
77 Drive interlock relay 102 Extension relay
78 Drive shaft relay 103 Inner boom extension switch
9803/3630-14
79 Layshaft solenoid 104 Extension interlock(2)

80 Mainshaft solenoid 105 Extension diverter valve solenoid
81 Transmission dump relay 106 Lift/unloader solenoid
82 Stabiliser isolation switch 107 Lift solenoid relay
83 Stabiliser isolation relay 108 Lift solenoid switch
84 Stabiliser isolation solenoid 109 Stabiliser lift unloader solenoid
85 Stabiliser isolation switch 110 Stabiliser lift relay
86 Sway isolation switch 111 Stabiliser lift isolation solenoid Fig 43. Optional fan reversing circuit
87 Sway isolation relay 112 Full lock solenoid
88 Sway switch 113 Diode
Schematic Circuits
89 Sway diverter solenoid 114 Lock solenoid - tilt back
90 Sway solenoid 115 Lock solenoid - tilt forward
91 Sway solenoid 116 Joystick isolation switch
92 Transmission dump push button 117 Boom worklight
Schematics
93 Steer mode control unit 118 Boom worklight switch
C - 64
A Four wheel/crab steer relay 119 Diode

B Two wheel steer relay 131 Fan reverse switch(3)
C - 65
9803/3630-14
Fig 44. 532-120, 537-135, 550 (With Manual Auxiliary Controls) From SN 775402, 533-105 Series I Machines, 540-140, 5508 (With Servo Controls) To SN 1004130
(Sheet 1 of 4)
Schematic Circuits
Schematics
K Fig 47. ( T C-68), for Sheet 4 of 4 and Item A (540-
140, 5508 Only).
C - 65
C - 66
9803/3630-14
(Sheet 2 of 4)
Schematic Circuits
Schematics
140, 5508 Only).
C - 66
C - 67
9803/3630-14
(Sheet 3 of 4)
Schematic Circuits
Schematics
140, 5508 Only).
C - 67
C - 68
9803/3630-14
Schematic Circuits
Fig 47. 540-170, 5508 (with Servo Controls) To Machine SN 1004130 Only (Sheet 4 of 4)
Schematics
C - 68

Schematic Circuits
Schematics
C - 69 9803/3630-14 C - 69
532-120, 537-135
C - 70
15 Auxiliary B solenoid 47 Rotating beacon

16 Stabilizer isolation valve 48 Primary fuse
Applicability
17 Stabilizer isolation relay 49 Ignition relay
– 532-120 (Without Neutral Start Relay) From SN 18 Stabilizer isolation switch 50 Engine Shut-Off Solenoid
767001 to 768956. 19 Stabilizer isolation proximity switch 51 Two wheel steer solenoid
– 537-135 (Without Neutral Start Relay) From SN
20 Transmission dump switch 52 All wheel steer solenoid
767001 to 768956.
21 Not applicable 53 Four wheel steer solenoid
Note: To check if a neutral start relay is fitted, try 22 Safe Load Indicator (SLI) 54 Crab steer solenoid
starting the engine with the transmission in gear.
23 SLI transducer 55 Steer Mode Control Unit
Component Key 24 Heater/air conditioning switch W All wheel steer relay
– Items 1 to 59: K Fig 48. ( T C-72),
26 Air conditioning switch Y Crab steer relay
– Items 61 to 104: K Fig 49. ( T C-73),
27 Face level fan Z Four wheel steer relay
Note: All the items listed here are not necessarily 28 Air conditioning compressor 56 Steer mode switch
fitted to all machines in the range. 29 Air conditioning relay X Two wheel steer select
9803/3630-14
Note: Refer to the ECU fault finding information in this 30 Binary switch (air conditioning) Y Crab steer select
section for control unit output connections. 31 Rear wiper switch Z Four wheel steer select
32 Rear wiper motor 57 Front steer sensor
1 Battery 33 Roof wiper switch 58 Rear steer sensor
2 Battery isolator 34 Roof wash pump 59 Instrument panel
3 Starter motor 35 Roof wiper 61 Air filter blocked switch
4 Ignition switch 36 Front wiper 62 Engine oil pressure switch
5 Starting aid 37 Radio/Cassette 63 Transmission oil temp switch
6 not used
38 Heated seat 64 Steering column switch
7 Sway isolation relay 39 Digital clock 65 Alternator
8 Sway/Aux change-over
Schematic Circuits
40 Left hand stabilizer warning light 66 Fuel sender
9 Sway/Aux 1 solenoid 41 Right hand stabilizer warning light 67 Water temperature sender
10 Sway isolation switch 42 Warning buzzer 68 Steering column switch
11 Auxiliary A relay 43 Hazard switch 69 Horn
Schematics
12 Auxiliary B relay 44 Indicator relay 70 Reverse relay
13 Aux A/B switch
C - 70
45 Interior light 71 Powershift control unit(1)

14 Auxiliary A solenoid 46 Rotating beacon switch 72 Parkbrake switch
C - 71

74 Foot brake switch (1) Powershift control unit only shows input
76 Brakelights
77 Brakelights
78 Rear light harness
79 Reverse alarm
82 Rear worklight
83 Sidelight relay
85 Primary fuse
86 Right hand front sidelight
87 Right hand rear sidelight
9803/3630-14
88 Left hand front sidelight

89 Left hand rear sidelight
Schematic Circuits
98 Rear foglight
100 Screen wash pump
101 Right hand front indicator
Schematics
102 Right hand rear indicator
C - 71
103 Left hand front indicator

104 Left hand rear indicator
C - 72
9803/3630-14
Schematic Circuits
Fig 48. 532-120, 537-135 From SN 767001 to 768956 (Sheet 1 of 2)
Schematics
C - 72
C - 73
9803/3630-14
Fig 49. 532-120, 537-135 From SN 767001 to 768956 (Sheet 2 of 2)
Schematic Circuits
Schematics
C - 73
532-120, 537-135
C - 74
13 Auxiliary B relay 45 Indicator relay

14 Aux A/B switch 46 Hazard diode
Applicability
15 Auxiliary A solenoid 47 Interior light
– 532-120 (With Neutral Start Relay and ECU 16 Auxiliary B solenoid 48 Rotating beacon switch
Controlled Transmission) From SN 768957 to 17 Stabilizer isolation valve 49 Rotating beacon
770063.
18 Stabilizer isolation relay 50 Primary fuse
– 537-135 (With Neutral Start Relay and ECU
Controlled Transmission) From SN 768957 to 19 Stabilizer isolation switch 51 Ignition relay
770063. 20 Stabilizer isolation proximity switch 52 Engine Shut-Off Solenoid (ESOS)
21 Transmission dump switch 53 Two wheel steer solenoid
Note: To check if a neutral start relay is fitted, try
starting the engine with the transmission in gear. 22 Not applicable 54 Four wheel/crab steer solenoid
23 Safe Load Indicator (SLI) 55 Four wheel steer solenoid
Component Key
24 SLI transducer 56 Crab steer solenoid
– Items 1 to 61: K Fig 50. ( T C-76), 25 Heater/air conditioning fan 57 Steer Mode Control Unit (SMCU)
– Items 63 to 106: K Fig 51. ( T C-77), 26 Air conditioning switch W Four wheel/crab steer relay
9803/3630-14

fitted to all machines in the range. 28 Face level fan Y Crab steer relay
Note: Refer to the ECU fault finding information in this
section for control unit output connections.
31 Binary switch X Two wheel steer select
1 Battery 32 Rear wiper switch Y Crab steer select
2 Battery isolator 33 Rear wiper motor Z Four wheel steer select
3 Starter motor 34 Roof wiper switch 59 Front steer sensor
4 Neutral start relay 35 Roof wash pump 60 Rear steer sensor
5 Ignition switch 36 Roof wiper 61 Instrument panel
6 Starting aid 37 Front wiper 63 Air filter blocked switch
Schematic Circuits
7 not used 38 Radio/Cassette 64 Engine oil pressure switch
8 Sway isolation relay 39 Heated seat 65 Transmission oil temperature switch
9 Sway/Aux change-over switch 40 Digital clock 66 Water temperature switch
10 Sway isolation switch 41 Left hand stabilizer warning light 67 Alternator
Schematics
11 Sway/Aux 1 solenoid 42 Right hand stabilizer warning light 68 Fuel sender
C - 74
12 Auxiliary A relay 43 Warning buzzer 69 Water temperature sender

44 Hazard switch 70 Steering column switch
C - 75
71 Horn 103 Right hand front indicator

72 Reverse relay 104 Right hand rear indicator
73 Powershift control unit(1) 105 Left hand front indicator
74 Parkbrake switch 106 Left hand rear indicator
76 Footbrake switch (1) Powershift control unit only shows input
78 Brakelights
79 Brakelights
80 Reverse lights
81 Reverse alarm
84 Rear worklight
85 Sidelight relay
9803/3630-14

87 Fusible link 1
Schematic Circuits
Schematics
100 Rear foglight
C - 75

102 Front wash/wipe motor
C - 76
9803/3630-14
Schematic Circuits
Fig 50. 532-120, 537-135 (With Neutral Start Relay and ECU Controlled Transmission) From SN 768957 to 770063 (Sheet 1 of 2)
Schematics
C - 76
C - 77
9803/3630-14
Fig 51. 532-120, 537-135 (With Neutral Start Relay and ECU Controlled Transmission) From SN 768957 to 770063 (Sheet 2 of 2)
Schematic Circuits
Schematics
C - 77
532-120, 537-135
C - 78
19 Stabilizer isolation valve 51 Ignition relay

20 Stabilizer isolation switch 52 Engine shut-off system (ESOS)
Applicability
21 Stabilizer isolation proximity switch 53 Two-wheel steer solenoid
– 532-120 (With Relay Controlled Transmission, 22 Not applicable 54 Four-wheel/crab steer solenoid
ECU Not Fitted) From SN 770064 to 770958. 23 Safe load indicator (SLI) 55 Four-wheel steer solenoid
– 537-135 (With Relay Controlled Transmission,
24 SLI transducer 56 Crab steer solenoid
ECU Not Fitted) From SN 770064 to 770958.
25 Heater/air conditioning fan motor 57 Steer mode control unit (SMCU)
Component Key 26 Air conditioning switch W Four-wheel/crab steer relay
– Items 1 to 61: K Fig 52. ( T C-80),
– Items 63 to 123: K Fig 53. ( T C-81),
Note: All the items listed here are not necessarily 30 Air conditioning relay 58 Steer mode switch
fitted to all machines in the range.
31 Binary switch - air conditioning X Two wheel steer select
1 Battery
9803/3630-14
2 Battery isolator
34 Roof wiper switch 59 Front steer sensor
3 Starter motor
35 Roof wash pump 60 Rear steer sensor
36 Roof wiper motor 61 Instrument panel
5 Ignition switch
37 Front wiper motor 63 Air filter blocked switch
6 Starting aid
7 not used
39 Heated seat 65 Transmission oil temperature switch
40 Digital clock 66 Water temperature switch
9 Sway/auxiliary change over
41 Left hand stabilizer warning light 67 Alternator
10 Sway isolation proximity switch
42 Right hand stabilizer warning light 68 Fuel sender
11 Auxiliary A relay
43 Warning buzzer 69 Water temperature sender
Schematic Circuits
44 Hazard warning light 70 Steering column switch
45 Indicator relay 71 Horn
46 Hazard diode 72 Reverse 2 relay
47 Interior light 73 Ignition relay 2
16 Auxiliary change over relay 2
Schematics
48 Beacon switch 74 Transmission dump switch
17 Sway/auxiliary solenoid
C - 78
49 Beacon 75 Transmission dump relay

18 Stabilizer isolation relay
C - 79
77 Forward relay 109 Left hand worklight

78 Drive relay 110 Front worklight switch
79 Parkbrake relay 111 Right hand worklights
80 Rev HI/LO relay 112 Right hand dip beam
81 Reverse high/low solenoid 113 Left hand dip beam
83 Forward HI/LO relay 115 Left hand main beam
84 Forward high solenoid 116 Rear foglight switch
85 Forward low solenoid 117 Rear foglight
86 Driveshaft relay 118 Steering column switch
87 Layshaft solenoid 119 Front wash/wipe motor
88 Mainshaft solenoid 120 Right hand front indicator
89 Two/four wheel drive solenoid 121 Right hand rear indicator
90 Transmission oil temperature switch 122 Left hand front indicator
91 Parkbrake switch 123 Left hand rear indicator
9803/3630-14
92 Two-wheel drive switch

93 Two-wheel drive brake relay
94 Footbrake switch
95 Brake lights
96 Brake lights
97 Reverse lights
98 Reverse alarm
100 Rear work light switch
101 Rear work light
Schematic Circuits
102 Side light relay
104 Primary fuse
Schematics
C - 79

C - 80
9803/3630-14
Schematic Circuits
Fig 52. 532-120, 537-135 (With Relay Controlled Transmission, ECU Not Fitted) From SN 770064 to 770958. (Sheet 1 of 2)
Schematics
C - 80

C - 81
9803/3630-14
Schematic Circuits
Fig 53. 532-120, 537-135 (With Relay Controlled Transmission, ECU Not Fitted) From SN 770064 to 770958. (Sheet 2 of 2)
Schematics
C - 81

532-120, 537-135, 550
C - 82
16 Auxiliary B solenoid 48 Primary fuse 1

17 Stabilizer isolation relay 49 Fusible link
Applicability
18 Stabilizer isolation valve 50 Ignition relay
– 532-120 From SN 770959 to 775401. 19 Stabilizer isolation switch 51 Engine shut-off system (ESOS)
– 537-135 From SN 770959 to 775401. 20 Stabilizer isolation proximity switch 52 Two-wheel steer solenoid
– 550 From SN 770959 to 775401. 21 Safe load indicator (SLI) 53 Four-wheel/crab steer solenoid
22 SLI transducer 54 Four-wheel steer solenoid
Component Key
23 Heater/air conditioning fan motor 55 Crab steer solenoid
– Items 1 to 61: K Fig 54. ( T C-84), 24 Heater/air conditioning unit 56 Steer mode control unit (SMCU)
– Items 63 to 123: K Fig 55. ( T C-85), 25 Air conditioning switch W All wheel steer relay
Note: All the items listed here are not necessarily 26 Face level fan X Two wheel steer relay
fitted to all machines in the range. 27 Air conditioning compressor Y Crab steer relay
28 Air conditioning relay Z Four wheel steer relay
1 Battery 29 Binary switch - air conditioning 57 Steer mode switch
2 Battery isolator 30 Rear wiper switch X Two wheel steer select
9803/3630-14
3 Starter motor 31 Rear wiper motor Y Crab steer select

4 Ignition switch 32 Roof wiper switch Z Four wheel steer select
5 Starting aid 33 Roof wash pump 58 Front steer sensor
6 Neutral start relay 34 Roof wiper motor 59 Rear steer sensor
7 not used 35 Front wiper motor 60 Instrument panel
8 Sway isolation relay 36 Heated seat 62 Air filter blocked switch
9 Sway/auxiliary change over switch 37 Radio/cassette 63 Engine oil pressure switch
10 Sway/auxiliary change-over valve 38 Digital clock 64 Transmission oil temperature switch
11 Sway isolation proximity switch (Not N.
39 Left hand stabilizer warning light 65 Water temperature switch
American 532 or 550)
40 Right hand stabilizer warning light 66 Alternator
11A Link Harness (N. American 532 and 550
Schematic Circuits
only) 41 Warning buzzer 67 Fuel sender
12 Sway/auxiliary solenoid 42 Hazard warning light 68 Water temperature sender
13 Auxiliary A solenoid 43 Indicator relay 69 Steering column switch
14 Joystick isolation switch 44 Hazard diode 70 Horn
Schematics
15A Auxiliary A button 45 Interior light 71 Reverse 2 relay
C - 82
15B Auxiliary B button 46 Beacon switch 72 Ignition relay 2

47 Beacon 73 Transmission dump switch
C - 83
74 Transmission dump relay 106 Righ hand rear sidelight

75 Reverse 1 relay 107 Left hand front sidelight
76 Forward relay 108 Left hand rear sidelight
77 Drive relay 109 Left hand worklight
78 Parkbrake relay 110 Front worklight switch
79 Rev HI/LO relay 111 Right hand worklights
80 Reverse high/low solenoid 112 Right hand dip beam
81 Reverse low solenoid 113 Left hand dip beam
82 Forward HI/LO relay 114 Right hand main beam
84 Forward low solenoid 116 Rear foglight switch
85 Driveshaft relay 117 Rear foglight
86 Layshaft solenod 118 Steering column switch
88 Two/Four wheel drive solenoid 120 Right hand front indicator
9803/3630-14
89 Transmission oil temperature switch 121 Right hand rear indicator

90 Parkbrake switch 122 Left hand front indicator
91 Two-wheel drive switch 123 Left hand rear indicator
92 Two-wheel drive brake relay
93 Footbrake
94 Brake lights
95 Brake lights
96 Reverse lights
97 Reverse alarm
Schematic Circuits
99 Rear work light switch
100 Rear work light
101 Side light relay
102 Fusible link 3
Schematics
C - 83
104 Fusible link 2

C - 84
9803/3630-14
Schematic Circuits
Fig 54. 532-120, 537-135, 550 From SN 770959 to 775401. (Sheet 1 of 2)
Schematics
C - 84
C - 85
9803/3630-14
Schematic Circuits
Fig 55. 532-120, 537-135, 550 From SN 770959 to 775401. (Sheet 2 of 2)
Schematics
C - 85
540-170, 5508
C - 86
17 Reverse relay 45 LH indicator lamps

17A Reverse lamp 46 RH indicator lamps
Applicability
18 Reverse alarm 47 Front washer pump
– 540-170 From SN 1004131. 19 Park brake relay 48 Front wiper motor
– 5508 From SN 1004131. 19A Park brake switch 49 Rear wiper motor
20 Heated seat 50 Rear/roof washer pump
Component Key
21 Radio/cassette 51 Roof wiper motor
– Items 1 to 35: K Fig 56. ( T C-88), 22 Digital clock 52 Rear wiper switch
– Items 36 to 66: K Fig 57. ( T C-89), 22A Fuse link 1 53 Roof wiper switch
– Items 67 to 100: K Fig 58. ( T C-90), 23 Transducer - load moment indicator (LMI) 54 Hazard warning switch
– Items 101 to 119: K Fig 59. ( T C-91), 24 Instrument panel 55 Hazard warning relay
1 Battery 25 Warning buzzer 56 Interior light/switch
2 Battery isolator 26 Alternator 57 Beacon switch
3 Starter motor 27 Air filter blocked switch 58 Beacon lamp
4 Starter solenoid 28 Engine oil pressure switch 59 Face level fan
9803/3630-14
5 Ignition switch 29 Transmission oil temperature switch 60 Air conditioning relay

5A Fuse link 2 30 Transmission oil pressure switch 61 Air conditioning - compressor motor
6 Starting aid 31 Water temperature switch 62 Air conditioning - freeze switch
7 Neutral start relay 32 Fuel gauge 63 Air conditioning - receiver drier
8 Ignition feed relay 1 33 Water temperature gauge 64 Air conditioning switch
9 Ignition feed relay 2 34 LH stabiliser lamp switch 65 Heater/heater fan switch
10 E.S.O.S. 35 RH stabiliser lamp switch 66 Heater
11 Rear work lamp switch 36 sidelight relay 67 Column switch - LH
11A Rear work lamp 36A Fuse link 1 68 Horn
12 Front work lamp switch 37 RH side lights 69 Reverse Hi-Lo relay
Schematic Circuits
12A Front work lamps 38 LH side lights 70 Reverse Lo solenoid
12B Auxiliary power connector 39 Main light switch 71 Reverse Hi solenoid
13 2/4WD brake relay 40 RH/LH dip beam 71A Diode pack
13A Brake lamps 41 RH/LH main beam 72 Reverse relay
Schematics
14 Brake switch 42 Rear fog light switch 73 Forward relay
C - 86
15 2/4WD switch 43 Rear fog lamp (optional) 74 Forward Hi/Lo relay

16 2/4WD solenoid 44 Column switch - RH 75 Forward Hi solenoid
C - 87
76 Forward Lo solenoid 101 Right hand stabiliser relay

77 Drive interlock relay 102 Right hand stabiliser LED
78 Drive shaft relay 103 Left hand stabiliser relay
79 Layshaft solenoid 104 Left hand stabiliser LED
80 Mainshaft solenoid 105 Inner boom extension switch
81 Transmission dump relay 106 Inner boom extension relay
82 Stabiliser isolation switch 107 Boost isolation switch
83 Stabiliser isolation relay 108 Extension diverter solenoid
84 Stabiliser isolation solenoid 109 Extension boost relay
85 Stabiliser isolation switch 110 Extension boost solenoid
86 Sway isolation switch 111 Lift/unloader solenoid
87 Sway isolation relay 112 Lift isolation switch
88 Sway switch 113 Lift isolation relay
89 Sway diverter solenoid 114 Stabiliser lift unloader solenoid
90 Sway solenoid 115 Stabiliser lift relay
9803/3630-14
91 Sway solenoid 116 Stabiliser lift isolation switch

92 Transmission dump push button 117 Full lock solenoid
93 Steer mode control unit 118 Fork lock solenoid
A Four wheel/crab steer relay 119 Joystick isolation switch(1)
B Two wheel steer relay 120 Boom worklight
C Crab steer relay 121 Boom worklight switch
94 Steer mode selector switch (1) Not fitted to 5508 machines
X Two wheel steer
Y Crab steer
Schematic Circuits
Z Four wheel steer
95 2WS solenoid
96 4WS solenoid
97 AWS solenoid
Schematics
98 Crab steer solenoid
C - 87
99 Proximity switch - front axle

100 Proximity switch - rear axle
C - 88
9803/3630-14
Schematic Circuits
Fig 56. 540-170, 5508 From SN 1004131 (Sheet 1 of 4)
K Component Key ( T C-86) K Fig 59. ( T C-91), or Sheet 4 of 4 and Item A.
Schematics
C - 88

C - 89
9803/3630-14
Schematic Circuits
K Component Key ( T C-86) K Fig 59. ( T C-91), or Sheet 4 of 4 and Item A.
Schematics
C - 89

C - 90
9803/3630-14
Schematic Circuits
K Fig 59. ( T C-91), or Sheet 4 of 4 and Item A.
Schematics
C - 90
C - 91
9803/3630-14
Schematic Circuits
Schematics
C - 91

All Series II Machines Diagram Key
C - 92
Applicability K Basic Circuit ( T C-93), for a `standard' machine.
– 530-70 From SN 1016569 The following pages in this section show machine
circuit s that differ from the `standard' machine.
– 532-120 From SN 1036631
– 533-105 From SN 1036561 Note: Only the differences are shown.
– 535-60
– 535-95 From SN 1036555 K Manual and Single Lever Hydraulic
– 535-125 Controls ( T C-99)
– 535-140 K Sway Hydraulic Controls ( T C-100)
– 537-135 From SN 1036631 K Stabiliser and Sway Hydraulic
– 540-70 From SN 1016740 Controls ( T C-101)
– 540-140 K Sway Hydraulic Controls ( T C-100)
– 540-170 From SN 1037581 K Air Conditioning and Two-speed
– 550 From SN 1036474 Wiper ( T C-102)
– 550-140 K Seat Options, Heated Glass, Mobile Phone,
9803/3630-14
Cigar Lighter ( T C-103)

– 550-170
K Smooth Ride System (SRS), Reversing
– 5508 From SN 1037581
Fan ( T C-104)
K Powershift (4-Speed) ( T C-105)
K Powershift (5-Speed) ( T C-107)
K Servo Controls (540-170, 5508) ( T C-109)
Schematic Circuits
Schematics
C - 92
Basic Circuit
C - 93
26 Tracker Connection Refer to:

27 Wax thermostat K K Fig 67. ( T C-102)
Component Key (Items 1 to 37)
28 Fuel shut off solenoid L K Fig 68. ( T C-103)
K Fig 60. ( T C-94). 28A Fuel lift pump (R series engines) Q K Fig 71. ( T C-108)
29 (2) Washer pump
1 Battery
30 Wash/wipe switch
2 Battery isolator
31 Front wiper
3 Starter motor
32 Roof wiper
4 Starter solenoid
33 Roof wiper switch
34 Roof/rear washer pump
6A Thermostart (A series engines)
35 Rear wiper
6B Glow plugs (R series engines)
36 Rear wiper switch
6C Glow plug relay (R series engines)
37 Ignition relay 4
7 Ignition relay 1
8 Ignition relay 2 (1) Standard heater, without air conditioning. For air
9803/3630-14
9 Ignition relay 3 conditioning option, see J.

(2) Single speed, standard option. For two speed
10 Ignition switch
option, see K.
11 Load Moment Indicator (LMI) Readout Unit
12 LMI Transducer Table 6. Connections
Connection Refer to:
13 Face level fan
A K Fig 68. ( T C-103)
14 Heater switch
B K Fig 68. ( T C-103)
15 Heater speed control resistor(1)
K Fig 69. ( T C-104)
16 Heater fan motor(1)
C K Fig 70. ( T C-106)
17 Hazard switch
K Fig 71. ( T C-108)
18 Indicator relay
G K Fig 63. ( T C-99)
19 Trailer indicator warning lamp
Schematic Circuits
K Fig 64. ( T C-99)
20 Trailer indicator (left)
K Fig 65. ( T C-100)
21 Turn indicators (left)
K Fig 66. ( T C-101)
22 Trailer indicator (right)
H K Fig 63. ( T C-99)
Schematics
23 Turn indicators (right)
K Fig 64. ( T C-99)
24 Indicator warning lamp
C - 93
J K Fig 67. ( T C-102)

25 Indicator switch
Schematic Circuits
Schematics
Fig 60. Basic Circuit 1
K Component Key (Items 1 to 37) ( T C-93).

C - 94 9803/3630-14 C - 94
C - 95
C Crab steer relay
K Fig 61. ( T C-96) D Four wheel steer relay

52 2WS solenoid
Note: All the items listed here are not necessarily 53 4WS solenoid
54 AWS solenoid
38 Warning light cluster 55 Crab steer solenoid
a Parking brake on light 56 Steer mode selector switch
b Air filter blocked warning light 57 Proximity switch - front axle
c Oil pressure low warning light 58 Proximity switch - rear axle
d Transmission oil temperature high warning Table 7. Connections

light
e Transmission oil pressure low warning light
D K Fig 70. ( T C-106)
f Coolant temperature high warning light
K Fig 71. ( T C-108)
g Battery not charging warning light
S K Fig 71. ( T C-108)
h Two wheel steer engaged light
9803/3630-14
j Four wheel steer engaged light

k Crab steer engaged light
39 Air filter blocked switch
40 Oil pressure switch
41 Transmission oil temperature switch
42 Transmission oil pressure switch
43 Coolant temperature switch
44 Alarm buzzer
45 Tachometer/hourmeter
46 Water temperature gauge
Schematic Circuits
47 Water temperature sender
48 Fuel gauge
49 Fuel sender
50 Alternator
Schematics
C - 95

Schematic Circuits
Schematics

C - 96 9803/3630-14 C - 96
C - 97
83 Road light switch
K Fig 62. ( T C-98) 84 Trailer sidelight (left)

85 Sidelights (left)
Note: All the items listed here are not necessarily 86 Front worklights relay
87 Sidelights (right)
59 Clock 88 Trailer sidelight (right)
60 Radio 89 Numberplate light
60A Speaker (left) 90 Trailer numberplate light
60B Speaker (right) 91 Worklight switch
61 Interior light 92 Front worklights
62 Beacon 93 Rear worklights relay
63 Beacon switch 94 Rear worklights
64 Brake light relay 95 Boom worklight switch
65 Footbrake proximity switch 96 Boom worklight relay

97 Boom worklights
9803/3630-14
66 Brakelights (left)
67 Trailer brake lights (left) 98 Engine running relay
68 Brakelights (right) Table 8. Connections

69 Trailer brake lights (right) Connection Refer to:
70 2 wheel drive relay E K Fig 70. ( T C-106)
71 2 wheel drive switch K Fig 71. ( T C-108)
72 2 wheel drive solenoid F K Fig 71. ( T C-108)
73 Fog light switch P K Fig 71. ( T C-108)
74 Fog light R K Fig 71. ( T C-108)
75 Horn
76 Horn push button
Schematic Circuits
77 Headlight flasher switch
78 Road light relay
79 Headlight dip switch
80 Dipped beam lights
Schematics
81 Main beam lights
C - 97
82 Main beam warning light

Schematic Circuits
Schematics

C - 98 9803/3630-14 C - 98
Schematic Circuits
Schematics
Manual and Single Lever Hydraulic Controls
Component Key
Note: All the items listed here are not necessarily fitted to
all machines in the range.

9 Boom/hitch hydraulics switch
10 Boom/hitch hydraulics solenoid
12 2nd auxiliary/extend switch
13 Diodes
14 Extend solenoid Fig 63. Single Lever Hydraulic Controls
15 2nd auxiliary/retract switch
16 Retract solenoid
17 Auxiliary 'A'/Auxiliary `B' switch
18 Auxiliary `A' solenoid
19 Auxiliary `B' solenoid
22 Boom/hitch hydraulics switch
23 Boom/hitch hydraulics solenoid
25 2nd auxiliary button
Table 9. Connections
Fig 64. Manual Hydraulic Controls
G K Fig 60. ( T C-94)
H K Fig 60. ( T C-94)
C - 99 9803/3630-14 C - 99
Schematic Circuits
Schematics
Sway Hydraulic Controls
Component Key
15 Sway switch
19 Sway solenoid
20 Sway solenoid

G K Fig 60. ( T C-94)
Fig 65. Sway Hydraulic Controls
C - 100 9803/3630-14 C - 100

Schematic Circuits
Schematics
Stabiliser and Sway Hydraulic Controls
Fig 66. Stabiliser and Sway Hydraulic Controls
Component Key 30 Sway valve

31 Sway valve
21 Stabiliser warning lights
22 Stabiliser warning light switches
23 Stabiliser isolation switch Note: Items 21 to 26, 533-105 machines only
24 Stabiliser isolation relay
25 Stabiliser isolation solenoid Connection Refer to:
26 Stabiliser isolation switch H K Fig 60. ( T C-94)
28 Sway switch
C - 101 9803/3630-14 C - 101

Schematic Circuits
Schematics
Air Conditioning and Two-speed Wiper
Component Key
1 Heater switch
2 Fan speed control resistor
3 Fan motor
4 Air conditioning switch
5 Thermostat
6 Binary switch
7 Air conditioning compressor
8 Two-speed wash/wipe switch
9 Intermittent wipe timer
10 Front washer pump
11 Front wiper

J K Fig 60. ( T C-94)
K K Fig 60. ( T C-94)
Fig 67. Air Conditioning and Two-speed Wiper
C - 102 9803/3630-14 C - 102

Schematic Circuits
Schematics
Seat Options, Heated Glass, Mobile Phone, Cigar
Lighter
Component Key
12 Ignition relay 5
13 Heated seat
14 Heated seat micro switch
15 Air suspension compressor
16 Heated glass switch
17 Heated right hand glass
18 Heated rear glass
19 Mobile phone charger/cigar lighter

A K Fig 60. ( T C-94)
B K Fig 60. ( T C-94)
L K Fig 60. ( T C-94)
Fig 68. Seat Options, Heated Glass, Mobile Phone,

Cigar Lighter
C - 103 9803/3630-14 C - 103

Schematic Circuits
Schematics
Smooth Ride System (SRS), Reversing Fan
Fig 69. Smooth Ride System (SRS), Reversing Fan
Component Key 28 Drain solenoid

29 SRS active warning light
20 SRS switch
30 Reversing fan switch
21 Pressure switch
31 Reversing fan solenoid
22 SRS relay
32 Reversing fan buzzer
23 Lift/lower micro switch
24 Neutral relay Table 14. Connections
25 Dump relay Connection Refer to:
26 Crowd/dump micro switch B K Fig 60. ( T C-94)
27 Accumulator solenoid
C - 104 9803/3630-14 C - 104

Powershift (4-Speed)
C - 105

D K Fig 61. ( T C-96)
Component Key
E K Fig 62. ( T C-98)
K Fig 70. ( T C-106). F K Fig 62. ( T C-98)
1 Forward/reverse switch
2 Reverse alarm
3 Reversing light
4 Reversing light
5 Trailer reversing light
6 Loader transmission dump
8 Parkbrake proximity switch
9 Parkbrake relay
10 Reverse relay
9803/3630-14
11 Forward relay
12 Parkbrake warning light relay
13 Parkbrake 2-wheel drive relay
14 Gearchange lever
15 Drive relay
16 Reverse high/low relay
17 Forward high/low relay
18 Driveshaft relay
19 Reverse high solenoid
20 Reverse low solenoid
21 Forward high solenoid
Schematic Circuits
22 Forward low solenoid
24 Mainshaft solenoid
Schematics
C - 105

C K Fig 60. ( T C-94)
Schematic Circuits
Schematics
Fig 70. Powershift (4-Speed)
K Component Key ( T C-105).

C - 106 9803/3630-14 C - 106
Powershift (5-Speed) Table 16. Connections
C - 107

Component Key C K Fig 60. ( T C-94)
K Fig 71. ( T C-108). D K Fig 61. ( T C-96)
E K Fig 62. ( T C-98)
1 Electronic control unit (ECU) F K Fig 62. ( T C-98)
2 Diagnostic port P K Fig 62. ( T C-98)
3 Reverse relay Q K Fig 60. ( T C-94)
4 Reverse alarm R K Fig 62. ( T C-98)
5 Reversing lights S K Fig 61. ( T C-96)
6 Trailer reversing light
7 Transmission oil pressure switch
8 5th speed solenoid
9 Speed sensor
10 Mainshaft solenoid
9803/3630-14
12 Forward high solenoid
13 Forward low solenoid
14 Reverse high solenoid
15 Reverse low solenoid
16 Speedometer
17 Throttle switch
18 Left hand column switch
18A Kick down switch (if fitted)
19 Loader transmission dump
20 Parkbrake proximity switch
Schematic Circuits
Schematics
C - 107
Schematic Circuits
Schematics
304B
816
Fig 71. Powershift (5-Speed)

C - 108 9803/3630-14 C - 108
Servo Controls (540-170, 5508)
C - 109
Component Key
K Fig 72. ( T C-110).
1 LH stabiliser switch
2 RH stabiliser switch
3 RH stabiliser LED
4 RH stabiliser relay
5 LH stabiliser relay
6 LH stabiliser LED
7 4th extension relay
8 Boost isolation switch
9 4th extension switch
10 Extension diverter solenoid
9803/3630-14
11 Extension boost relay

12 Extension boost solenoid
13 Lift unloader solenoid
14 Lift isolation relay
15 Lift isolation switch
16 Stabiliser lift relay
17 Stabiliser lift unloader solenoid
18 Stabiliser lift isolation switch
20 Boom and fork isolation solenoid
21 Fork isolation solenoid
Schematic Circuits
Schematics
C - 109
C - 110 9803/3630-14 C - 110
000
FUSE 2
170M
1
2
3
481
410
410A 601JY
170
410E 601JW
481B 601JX
170N

4
1850
6
5
481A 601KF
1828
601HS
601GM
7
601FL
170B
9
-7
+8
1834
829AW
10
1834A
1 +3
1833 601FN
1842
4
170F
1823
5
6
8
11
601JA
1834B
1841 601JS
170K
12
1825B
1821 601JB
1825A 1825 601HT

170L
13
14
170E
601HR
Fig 72. Servo Controls (540-170, 5508)
15
16
1824 601FY
1820 601FZ
170C
17
170D
601FW
18
1829A 1829 601HW

1829B
20
1830C
170J 1830B
170H
21
0
45
315
19
1830A 601HV
Schematics
Schematic Circuits
Schematic Circuits
Schematics
C - 111 9803/3630-14 C - 111

Service Procedures
Using a Multimeter
TC-002
In order to obtain maximum benefit from the fault finding

information contained in Section C it is important that the
technician fully understands the approach to fault finding
and the use of the recommended test equipment, in this
case a FLUKE 85 or AVO 2003 digital multimeter, or a
moving pointer (analogue) multimeter. The approach is
based on a fault finding check list. In tracing the fault from
the symptoms displayed you will be directed to make
measurements using a multimeter.
These instructions are intended to cover the use of the

recommended multimeters.
Fig 74. AVO 2003
Fig 73. FLUKE 85
Fig 75. A Typical Analogue Meter
C - 112 9803/3630-14 C - 112

Service Procedures
Using a Multimeter
1 Make sure that the test leads are plugged into the Measuring Resistance
correct sockets. The black test lead should be
plugged into the black socket (sometimes, this socket 1 Make sure there is no power to the part of the circuit
is also marked by a "-", or "E" or marked as you are about to measure.
"COMMON" or "COM"). The red test lead should be
plugged into the red socket marked with "+", "V" or 2 Connect one probe at one end of the component or
"Ω". wire to be checked and the other probe at the other
end. It does not matter which way round the two
2 When making measurements ensure that the test probes are placed.
probes have a good clean contact with bare metal,
free from grease, dirt, and corrosion as these can 3 Select the correct range on the multimeter.
cause a false reading.
a On the FLUKE 85.
3 When measuring voltage: Make sure that the correct
range is selected, that is set the selector to a value i Turn the switch to position 73-C and check
equal to or greater than that you are about to that the W sign at the right hand side of the
measure. e.g. If asked to measure 12 Volts, set the display window is on. If the F sign is on
selector to the 12V range. If there is no 12V range, set instead, press the blue button 73-G to change
the selector to the next range higher, 20V for the reading to Ω. Touch the meter lead probes
instance. If the meter is set to a range that is too low, together and press the REL3 key on the meter
it may be damaged. e.g. setting to the 2V range to to eliminate the lead resistance from the meter
measure 12V. reading.
Measuring DC Voltage b On the AV0 2003.
1 Select the correct range on the multimeter. i Move the right hand slider switch to position
74-B, and the left hand slider switch to the
a On the FLUKE 85. appropriate Ohms (Ω) range.
Turn the switch to position 73-B. c On an analogue meter.
Move the dial to the appropriate Ohms (Ω)

b On the AV0 2003.
i
range.
Move the right slider switch to position 74-A, and
the left hand slider switch to the appropriate
range.
c On an analogue meter.
Turn the dial to the appropriate DC Volts range.
2 Connect the black probe to the nearest available

suitable earth point, usually this will be the starter
motor earth, the battery negative, or the chassis.
Connect the red probe to the wire or contact from
which you are measuring the voltage.
C - 113 9803/3630-14 C - 113

Service Procedures
Using a Multimeter
Measuring Continuity Measuring Frequency

1 Make sure there is no power to the part of the circuit The AVO 2003 and the analogue meter are not capable of
you are checking for continuity. measuring frequency, therefore a Fluke 85 digital
multimeter must be used.
2 Connect one probe to one end of the component or
wire to be checked and the other probe to the other 1 Insert the black plug into the COM socket on the
end. It does not matter which way round the two meter and attach the probe to the nearest suitable
probes are placed. earth point on the chassis, for example, the battery
negative terminal.
3 Select the correct range on the multimeter.
2 Insert the red probe into socket 73-J.
a On the FLUKE 85.
3 Turn the selector switch to position 73-A and depress
Turn the switch to position 73-C and check that 73-G repeatedly until 73-F is highlighted on the top
the beeper symbol appears at the left hand side of row of the display.
the display window. If the F sign is on instead,
press the button labelled 73-F in the meter 4 Press button 73-H once.
drawing.
5 Touch or connect the red probe to the frequency
If there is continuity in the circuit, the beeper will source to be measured. Press and hold button if an
sound. If there is no continuity (open circuit), the average reading is required.
beeper will not sound.
b On the AV0 2003.
Move the right hand slider switch to position 74-B,

and the left hand slider switch to position 74-C.
If there is continuity (i.e. very low resistance)

between two points the buzzer will sound.
c On an analogue meter.
Turn the dial to the lowest Ohms (Ω) range.
If there is continuity (i.e. very low resistance)

between two points the needle will move across
fully (or almost fully) to the right hand side of the
scale.
C - 114 9803/3630-14 C - 114

Service Procedures
Using a Multimeter
Testing a Diode or a Diode Wire c On an analogue meter.
A diode wire is a diode with male connector fitted on one i Select the Ohms 1000s (1k) range.
end and a female connector fitted on the other end. The
diode is sealed in heatshrink sleeving. Connect the black probe to the end of the
diode marked with a band, or to the male
1 To test a Diode or a Diode Wire connector of the diode wire, the red probe
should be connected to the other end of the
a On the FLUKE 85. diode or diode wire. The meter should read
20-400 kΩ, if it reads more than this the diode
i Turn the switch to position 73-D. is faulty.
ii Press the HOLD button and check that the H ii Select the Ohms 100s range.
sign appears at the top right hand side of the
display window. Connect the red probe to the end of the diode
marked with a band, or to the male connector
iii Connect the black probe to the end of the of the diode wire, the black probe should be
diode with a band or to the male connector of connected to the other end of the diode or
the diode wire. Connect the red probe to the diode wire. The meter should read 300-400Ω,
other end of the diode or diode wire. If the if it reads less than this the diode is faulty.
beeper does not sound the diode or diode wire
is faulty.
iv Connect the red probe to the end of the diode

of the diode wire, the black probe should be
connected to the other end of the diode or
diode wire. If the beeper sounds or the meter
does not read O.L., the diode or diode wire is
faulty.
v Press the HOLD button and check that the H

sign disappears from the right hand side of the
display window.
b On the AV0 2003.
i Move the right hand slider to position 74-A,

and the left hand slider switch to position 74-C.
ii Connect the black probe to the end of the

diode marked with a band, or to the male
connector of the diode wire, the red probe
should be connected to the other end of the
diode or diode wire. If the Avometer does not
buzz the diode is faulty.
iii Connect the red probe to the end of the diode

of the diode wire, the black probe should be
connected to the other end of the diode or
diode wire. If the Avometer does not read "1"
the diode is faulty.
C - 115 9803/3630-14 C - 115

Service Procedures
Battery
Battery
TC-001_3
Maintenance !MWARNING
To ensure that the battery provides optimum performance Batteries give off an explosive gas. Do not smoke
the following steps should be observed: when handling or working on the battery. Keep the
battery away from sparks and flames.
1 Make sure that the electrical connections are clean
and tight. Smear petroleum jelly on connectors to Battery electrolyte contains sulphuric acid. It can burn
prevent corrosion. you if it touches your skin or eyes. Wear goggles.
Handle the battery carefully to prevent spillage. Keep
2 When applicable - never allow the electrolyte level to metallic items (watches, rings, zips etc) away from the
fall below the recommended level - 6 mm (1/4 in) battery terminals. Such items could short the
above the plates. Use only distilled water for topping terminals and burn you.
up.
Set all switches in the cab to OFF before
3 Keep the battery at least three quarters charged, disconnecting and connecting the battery. When
otherwise the plates may become sulphated disconnecting the battery, take off the earth (-) lead
(hardened) - this condition makes recharging the first.
battery very difficult.
Re-charge the battery away from the machine, in a well
Extra precautions must be taken when bench charging ventilated area. Switch the charging circuit off before
maintenance free batteries, they are more prone to connecting or disconnecting the battery. When you
damage by overcharging than the standard type of battery: have installed the battery in the machine, wait five
minutes before connecting it up.
– Never boost-charge a maintenance free battery.
When reconnecting, fit the positive (+) lead first.
– Never charge a maintenance free battery at a voltage
in excess of 15.8 Volts.
First Aid - Electrolyte
– Never continue to charge a maintenance free battery
after it begins to gas.
Do the following if electrolyte:
GETS INTO YOUR EYES
Immediately flush with water for 15 minutes, always get

medical help.
IS SWALLOWED
Do not induce vomiting. Drink large quantities of water or

milk. Then drink milk of magnesia, beaten egg or vegetable
oil. Get medical help.
GETS ONTO YOUR SKIN
Flush with water, remove affected clothing. Cover burns

with a sterile dressing then get medical help.
5-3-4-3_1
C - 116 9803/3630-14 C - 116

Service Procedures
Battery
Testing 5 Set the CHECK/LOAD switch 76-A to LOAD and hold

down for 5-10 seconds until the meter reading
This test is to determine the electrical condition of the stabilises. The reading should be at least 9 volts.
battery and to give an indication of the remaining useful
`life'. Note: Do not hold the switch in the LOAD position for more
than 10 seconds.
Before testing ensure that the battery is at least 75%
charged (SG of 1.23 to 1.25 for ambient temperature up to 6 K Table 17. Fault Diagnosis ( T C-117), if the
27°C). foregoing tests are unsatisfactory.
Ensure that the battery is completely disconnected from

the vehicle.
Connect up the battery tester as follows:
1 Set the CHECK/LOAD switch 76-A to OFF.
2 Set rocker switch 76-B to the battery voltage (12V).
3 Connect the red flying lead to the battery positive (+)

terminal and the black flying lead to the battery
negative (-) terminal.
Fig 76. Battery Tester
4 Set the CHECK/LOAD switch 76-A to CHECK to read
the battery no-load voltage which should be at least
12.4 volts.
Table 17. Fault Diagnosis

Battery Tester Readings Remedy
1 CHECK: 0 - 12.6 Volts Renew battery
LOAD: less than 6 Volts

2 CHECK: 6 - 12.4 Volts Recharge and re-test. If tests still unsatisfactory renew
battery.
LOAD: less than 9 Volts and falls steadily but remains
in yellow zone.
3 CHECK: less than 10 Volts Indicates battery has been over-discharged and unlikely to
recover. Renew battery.
LOAD: less than 3 Volts
4 CHECK: more than 11 Volts Charge battery which will probably recover.
LOAD: 6 - 10 Volts steady
C - 117 9803/3630-14 C - 117

Service Procedures
Battery
Specific Gravity Testing Readings should be as tabulated and should not vary
between cells by more than 0.04. A greater variation
The specific gravity of the electrolyte gives an idea of the indicates an internal fault on that particular cell.
state of charge of the battery. Readings should be taken
using a hydrometer, when the electrolyte temperature is If the electrolyte temperature is other than 15°C (60°F) a
15°C (60°F). If the battery has recently been on charge, 'correction factor' must be applied to the reading obtained.
wait approximately one hour (or slightly discharge the Add 0.07 per 10°C (18°F) if the temperature is higher than
battery) to dissipate the surface charge before testing. 15°C (60°F) and subtract the same if the temperature is
lower.
Table 18. Specific Gravity at 15°C (60°F)

Fully Charged Half Discharged Fully Discharged
Ambient temperature up to 27°C (80°F) 1.270 - 1.290 1.190 - 1.210 1.110 - 1.130
Ambient temperature above 27°C (80°F) 1.240 - 1.260 1.170 - 1.190 1.090 - 1.110
C - 118 9803/3630-14 C - 118

Service Procedures
Alternator
Alternator
TC-006
General Description Charging Circuit Test

The alternator is a three phase generator having a rotating 1 Ensure that all battery and alternator connections are
field winding and static power windings. in place, secure and making good metal - to - metal
contact, especially the 'earth' connections to chassis
When the start switch is turned on, current from the battery and engine.
flows by way of the 'No Charge' warning light to the field
winding. This creates a magnetic field which supplements 2 Adjust the alternator drive belt tension if necessary
the residual magnetism in the rotor poles. As the engine is and make sure that the battery is well charged.
started, the fan belt drives the rotor and alternating current
is generated in the power windings as they are cut by the 3 Turn the start switch to the ON position.
rotating magnetic field. Output is controlled by a solid state
regulator which varies the field current in accordance with 'Oil pressure' and 'No charge' warning lights should
electrical demand. glow. If any light fails, K Check 1 ( T C-119).
Servicing is restricted to periodic inspection of slip ring 4 Start the engine; all warning lights should extinguish
brushes. Bearings are 'sealed for life'. rapidly.
Service Precautions If the 'No charge' warning light remains ON, K Check
2 ( T C-120).
1 Ensure that the battery negative terminal is
connected to the earthing cable. If the oil pressure warning remains on stop engine
Immediately and investigate the engine lubrication
2 Never make or break connections to the battery or system.
alternator, or any part of the charging circuit whilst the
engine is running. Disregarding this instruction will Check 1
result in damage to the regulator or rectifying diodes.
With start switch 'ON' try the heater motor and screen
3 Main output cables are 'live' even when the engine is wiper.
not running. Take care not to earth connectors in the
moulded plug if it is removed from the alternator. If they operate normally, check the warning light bulb for
blown filament.
4 During arc welding on the machine, protect the
alternator by removing the moulded plug (or if Simultaneous failure of all items indicates a fault at the
separate output cables fitted, remove the cables). start switch. Check for cable disconnection before
condemning the switch itself.
5 If slave starting is necessary, connect the second
battery in parallel without disconnecting the vehicle If the 'No charge' warning bulb is in good order, withdraw
battery from the charging circuit. The slave battery the triple plug from the back of the alternator. Make a
may then be safely removed after a start has been temporary connection between the SMALL terminal in the
obtained. Take care to connect batteries positive to plug and earth as shown below. If the 'No charge' warning
positive, negative to negative. bulb still fails to light, check the cable for continuity. If the
bulb now lights, check the alternator for a defective
regulator. K Alternator Charging Test ( T C-120).
C - 119 9803/3630-14 C - 119

Service Procedures
Alternator
Alternator Charging Test
Fig 77.
Check 2
Note: The following checks should be made using an

analogue (moving pointer) type meter.
1 Stop the engine and turn the starter switch to OFF.
2 Withdraw the alternator plug and connect the test Fig 79.
meter between the large terminals and 'earth'. With
the meter set to measure 12V DC, the meter should 1 Ensure that all battery and alternator connections are
show battery voltage. If the reading is zero, check the in place, secure and making good metal - to - metal
cables for continuity, particularly at the starter contact, especially the 'earth' connections to chassis
terminals. and engine.
2 Make sure that the alternator drive belt tension is

correctly adjusted.
3 If the battery is in a fully charged condition, switch on

the working lights for 3 minutes before commencing
the test. Alternatively, operate the starter for a few
moments with the engine shut off solenoid (ESOS)
fuse removed (See Fuse Identification).
4 Install a 100 amp open - type shunt between the

battery positive lead and the battery positive terminal.
Fig 78.
5 Connect a multimeter positive lead to machine side of
If the voltage is correct, check the alternator. the shunt and negative lead to battery side of the
K Alternator Charging Test ( T C-120). shunt.
6 Connect the leads to the meter and set the meter to

the relevant range as follows.
C - 120 9803/3630-14 C - 120

Service Procedures
Alternator
11 Faults d, e, and f may be checked only by removing
AVO 2002 – Red lead to volts (middle) socket on
and dismantling the alternator for further testing.
meter.
– Black lead to negative on meter.
– RH slider to DC voltage.
– LH slider. K Fig 79. ( T C-120).
AVO 2003 – Red lead to amps socket (marked A) on
the meter.
– Black lead to negative on meter.
– RH slider to DC voltage
– LH slider to 200 Shunt
FLUKE 85 – Red lead to volts socket (marked V ) on
meter.
– Black lead to COM socket on meter.
– Set dial to mV.
7 Start the engine and run at maximum speed (see

Technical Data). Meter should show maximum
alternator output in Amps (see Technical Data).
Note: The meter reading should be taken as soon as

possible after starting the engine, as the charging current
will fall rapidly.
8 A zero reading indicates failure of the alternator and

may be caused by one of the following conditions.
These are listed in the order of probability.
a Defective suppression capacitor.
b Dirty slip rings or worn brushes.
c Defective regulator.
d Defective rectifier.
e Open or short - circuited field (rotor) windings.
f Open or short - circuited power (stator) windings.
9 To check for fault a, disconnect the capacitor and

repeat the charging test. Renew the capacitor if
necessary.
10 To check for faults b and c, remove the regulator and

brush box assembly. Check the condition of the
brushes and, if necessary, clean the slip rings using
extra-fine glass paper. The regulator may only be
checked by substitution.
C - 121 9803/3630-14 C - 121

Service Procedures
Starter Motor
Starter Motor
TC-005
Starting Circuit Test than 0.5V below the reading obtained in Step 1.
Minimum permissible reading in 'start' position 9.0V.
Before carrying out the voltmeter tests, check the battery
condition and ensure that all connections are clean and If the reading is within this limit, continue to Step 3. If
tight. the reading is outside the limit, proceed to Step 4 and
Step 5.
To prevent the engine starting during the tests ensure that
the engine stop fuse is removed, (refer to Fuse
Identification page).
Check the readings in the following sequence using a

voltmeter. Unless otherwise stated, the readings must be
taken with the starter switch held in the 'start' position ('HS')
and the transmission forward/reverse selector in neutral.
Note: Do not operate the starter motor for more than 20

seconds at one time. Let the starter motor cool for at least
two minutes between starts.
1 Connect the voltmeter across the battery terminals.

K Fig 80. ( T C-122). Reading in 'start' position:
10.0V approximately. Minimum permissible reading in Fig 81.
'start' position 9.5V.
3 Connect the voltmeter between the solenoid terminal
A low reading probably indicates a fault in the starter 82-C and a good earth. Minimum permissible reading
motor. in 'start' position: 8.0V.
Fig 80. Fig 82.
2 Connect the voltmeter between the starter main a If the reading is less than specified, connect the
terminal 81-A and the commutator end bracket 81-B. voltmeter between the neutral start relay terminal
In the 'start' position, the reading should not be more 83-D and earth. An increase in reading to 8.0V
indicates a fault in the wiring from the start relay to
the solenoid.
C - 122 9803/3630-14 C - 122

Service Procedures
Starter Motor
b If the reading between terminal 83-D and earth is 5 Connect the voltmeter between battery positive and
below 8.0V, connect the voltmeter between the starter main terminal 85-A. With the starter switch
terminal 83-E and earth. An increase in the 'off', the voltmeter should indicate battery voltage, but
reading to 8.0V indicates either a faulty start relay it should fall to practically zero when the switch is
or a fault in the feed from the transmission turned to the 'on' position, maximum permissible
selector switch to the relay solenoid. Check also reading 0.25V.
the solenoid earth connection.
If the reading between 83-E and earth is less than

8.0V, the fault must be in either the starter switch
or in the wiring between the solenoid, starter
switch, and the start relay.
Fig 85.
If the reading is above 0.25V, a high resistance is

present in the insulated lead or in the solenoid.
Connect the voltmeter between the battery positive
and solenoid connection 86-H. If the voltmeter now
reads zero with the switch closed, the fault is in the
Fig 83. solenoid.
4 Connect the voltmeter between battery negative and
starter earth connection 84-B. The reading in the
'start' position should be practically zero, maximum
permissible reading 0.25V.
If the reading is above 0.25V, a high resistance in the

earth lead or connections is indicated.
Fig 86.
6 Finally refit the engine stop fuse.
Fig 84.
C - 123 9803/3630-14 C - 123

Service Procedures
Wire and Harness Number Identification

TC-003
Introduction
This section details the allocation of wire numbers and the
identification of wires in the wiring harness.
Fig 87. Typical Wire and Harness Number
K Fig 87. ( T C-124) shows a typical connector and wires. The number stamped on the wire shown in K Fig
Each wire has an individual identification number 87. ( T C-124) identifies the following:
permanently marked on it, at regular intervals along it's
length.
Table 19. Wire and Harness Number Identification

Ident. No. Description
B If applicable - The colour of the flying lead that the harness wire should mate with. For instance, if wire 819
from harness 719/37100 mated with a flying lead coloured black (colour code B) then the number printed
on the wire would be B-819 9/371.
819 The wire's unique identification number. The wire functions and numbers allocated to them are consistent
through out the JCB range of products.
9/371 The part number of the harness that the wire originates from. If the harness part number is 719/37100, the
number printed on the harness wires will be 9/371 (71 and 00 are common numbers and therefore deleted).
C - 124 9803/3630-14 C - 124

Service Procedures
Wire Numbers and Functions Wires 800-999
Wires 000-199 These numbers are reserved for switched supplies to

electrical loads, i.e. to lights, etc.
These numbers are reserved for ignition feeds, heater start
circuits and start circuits. These can be further categorised Wires In Splices
by:
The main input wire is allocated with a wire number and a
– Wires 000 - 099 are allocated to unfused ignition suitable description, i.e. Wire 640 earth splice to earth. The
feeds. additional wires in the splice are allocated the same wire
number and a postfix, i.e. 640A, 640B, etc.
– Wires 100 - 199 are allocated to fused ignition feeds.
Note: The letters I, O, Q and S are not used.
Note: Feeds via ignition relays are classed as ignition
feeds.
General Points
Wires 200-399
1 Wires continue to have the same number even after
passing through a connector block to another
These numbers are reserved for battery feeds, They can
harness.
be further categorised by:
2 If all the numbers in a category have been allocated,
– Wires 200 - 299 are allocated to unfused battery
then the category is re-used with an additional prefix
feeds.
'1', i.e. 1832.
– Wires 300 - 399 are allocated to fused battery feeds.
Wires 400-599
These numbers are reserved for instruments, i.e.

alternators to tachos, temperature switches to warning
lights, etc. and signal wires used in electronic systems.
Wires 600-799
These numbers are used for earth wires. When the

number is printed onto a wire 88-A it is prefixed by the
Earth symbol 88-B. This symbol is printed onto the wire, it
may however be omitted from harness drawings.
Fig 88.
Where a load is switched negative, the wire number from

the load to the switch shall be different to that of the wire
from the switch to the earth.
C - 125 9803/3630-14 C - 125

Service Procedures
Wiring Harness Repair

TC-004
Introduction !MCAUTION
Instances do occur where it is necessary to incorporate When the heater is in use, the reflector and the air
auxiliary electrical components into existing electrical coming out are extremely hot. Keep away to avoid
circuits and, although unlikely with present wiring accidental burns. Do not touch the reflector until it has
harnesses, repair or replace specific individual wires within had time to cool down after switching off. If flame
a harness. This will also apply to other machines in reappears at the reflector when the heater is in use, the
addition to those of manufacture. catalytic element is damaged or used up. Stop work
immediately and replace the heater.
To ensure that either the inclusion of an auxiliary electrical ELEC-2-3
component or a repair within a harness is completed to an
acceptable standard it is strongly recommended that the Repair Procedure
following tools, equipment and procedures are always
used. Note that JCB harnesses have an International Table 20. Tools Required
Protection rating of 67 (I.P.67). Part No. Description Qty
892/00350 Butane Heater assembly 1
The sheath covering of the recommended splice is heat
shrunk onto the original wire insulation. This results in a 892/00349 Crimp tool 1
seal and corresponding joint to IP 67 specifications. 892/00351 Splice 0.5-1.5 mm (Red) 50
892/00352 Splice 1.5-2.5 mm (Blue) 50
!MCAUTION 892/00353 Splice 3.0-6.0 mm (Yellow) 50
When installing Auxiliary Electrical Components
always ensure that the additional load rating is 1 Cut the wire and remove the protective insulation for
suitable for that particular circuit. It is unacceptable to a suitable distance dependent upon the size of wire
simply increase the fuse rating as this can cause and splice to be used. For the splices detailed in
overloading and consequential failure of wiring, along K Table 20. ( T C-126), the dimension is 7mm.
with failure of integral circuit components, which the
fuse is protecting.
ELEC-2-1
!MWARNING
In addition to the warnings incorporated into this
procedure, extreme care should be taken when
handling the gas heating tool to ensure that the flame
does not damage or set fire to any items in the vicinity
of the repair, i.e. other wires, floor panels, floor mats,
sound proofing, paintwork, etc. This tool should not
be used in any restricted location prohibiting the use
of "Naked Flames" or where risk of explosive gas or
similar safety parameters apply. No other heat source
should be used to attempt a sealed joint. Fig 89.
ELEC-2-2
2 Using the correct sized splice, attach the new section
of wire required or auxiliary flying lead to the existing
harness and secure using the crimp tool. K Fig
89. ( T C-126). Note that each of the splices detailed
is colour-coded to make size and range readily
C - 126 9803/3630-14 C - 126

Service Procedures
visible. They are secured using the corresponding
size and matching colour-coded jaws of the crimp tool
to ensure joint security. This tool also incorporates a
ratchet closing mechanism which will not release until
the splice is fully closed to the correct compression
size.
3 With the Butane heater assembly, seal the

connection. K Fig 90. ( T C-127).
a Remove the cap 91-A from the end of the

disposable gas cartridge 91-B.
Fig 92.
d Turn the small ring 93-E so that the air holes at 93-
F are completely closed.
Fig 90.
b Before assembling the gas cartridge to the

reflector element 92-C, turn the red ring 92-D to
the left, (in the direction of the minus sign marked
on the ring).
Fig 93.
e Turn the red ring 94-D to the right (in the direction
of the plus sign) in order to turn on the gas.
Fig 91.
Important: Before turning the heater on, make sure that
c Position the tube hanging down from inside the
the cartridge is not hotter than the reflector element. This
reflector assembly into the hole at the top of the
may occur if the cartridge is held in the hand for a long
gas cartridge. Then press the gas cartridge up
time. The temperature difference between the cartridge
into the reflector assembly as far as possible until
and the reflector element may cause long yellow flames to
the two elements are clasped firmly together.
appear on ignition.
K Fig 92. ( T C-127). A click will be heard.
C - 127 9803/3630-14 C - 127

Service Procedures
i Side wings 96-G down, reflector head
completely open. In this mode the infra-red
heat waves are dominant (recommended for
the light coloured plastic splices).
Fig 94.
f Hold the heater vertically and, using a match or

cigarette lighter, light the gas as shown.
Fig 96.
Hold the heater vertically for 1 to 2 minutes until
the catalytic reaction occurs. This is indicated ii Side wings 97-G up, reflector head opening
when the blue flame fades and the ceramic reduced. In this mode the heating is done only
element glows red. Then turn the small ring 95-E by the hot gas (use for dark coloured plastic
until the air holes at 95-F are completely open. splices).
The tool is ready for use.
Note: The fact that the sound of liquid cannot be heard

when the cartridge is shaken does not mean it is empty. No
sound will be heard even when the cartridge is full.
Fig 97.
h To switch off the heater, turn the red ring 97-D to

the left (in the direction of the minus sign).
Fig 95.
g The heater can be used in two modes:
C - 128 9803/3630-14 C - 128

Alternator
Removal and Replacement
TC-008
Removal
Disconnect cables from rear of alternator, remove bolts 98-
A, 98-B and 98-C and withdraw unit from machine.
Fig 99.
Replacement
Replacement is the reversal of Removal.
Set the fan belt tension. See Adjusting the Fan Belt
Tension, Section 3.
Fig 98.
C - 129 9803/3630-14 C - 129

Alternator
Dismantling and Assembly
Lucas Type
TC-007
Fig 100.
C - 130 9803/3630-14 C - 130

Alternator
When Dismantling When Assembling
Important: Dismantling the alternator is not recommended Reverse the dismantling procedure, but note the following:
except to check the condition of the suppressor, brushes
and commutator and the regulator. If none of these items Ensure that spacers 100-14, 100-16, and 100-18 are
are faulty a new or exchange unit should be obtained and correctly positioned as shown.
fitted.
Ensure that the slip rings 100-J are clean and smooth,
Remove suppressor 100-2 (if fitted) by removing nut 100- using extra fine glasspaper to rectify slight imperfections.
1 and disconnecting lead 100-E from terminal 100-F.
Ensure that insulation bushes 100-9 and washers 100-5
Unscrew bolts 100-3 and disconnect lead 100-G from are positioned as shown.
terminal 100-H to remove the brush box and regulator
assembly 100-4. If the brush length is less than 5mm (0.2 Take care not to damage the brushes when fitting the
in.), new length 17mm (0.67 in.), or if spring pressure is brush box and regulator assembly.
less than 1.3N the brush box and regulator assembly must
be renewed. Table 21. Torque Settings
Item Nm kgf m lbf ft
Remove nuts and washers 100-5, bolts 100-6 and nuts
100-3 2.7 0.28 2.0
100-7. Remove slip ring end bracket 100-8.
100-5 4.1 0.4 13.0
Carefully remove rectifier 100-10 and stator 100-11 as an 100-6 3.4 0.35 2.5
assembly.
100-7 5.4 0.55 4.0
Note: JCB do not recommend further dismantling of the 100- 60.0 6.10 44.2
starter motor. 12
C - 131 9803/3630-14 C - 131

Alternator
Magneti Marelli Type
Fig 101.
C - 132 9803/3630-14 C - 132

Alternator
When Dismantling When Assembling
Important: Dismantling the alternator is not recommended Reverse the dismantling procedure, but note the following:
except to check the condition of the suppressor, brushes
and commutator, rectifier and the regulator. If none of Ensure that slip ring faces are clean and smooth, using
these items are faulty a new or exchange unit should be very fine glasspaper if required. Do not use emery cloth.
obtained and fitted.
Ensure that stator connecting wires will not touch against
Remove nuts 101-1 and cover 101-2. the rotor.
Check the protruding length of the brushes 101-A. If this is Lightly polish side faces of brushes to ensure free
less than 10 mm (0.4 in), the brushes must be renewed. movement in brush box.
This will involve renewal of the regulator and brush box
assembly 101-6 as the brushes are not available Table 22. Torque Settings
separately. Item Nm kgf m lbf ft
101-1 3.0-4.0 0.3-0.4 26-36
Un-clip slip-ring shroud 101-3. Remove screw 101-4 and
nuts 101-5 to remove regulator and brush box assembly 101-4 2.0-2.5 0.2-0.25 18-21
101-6. 101-5 1.7-2.3 0.2-0.23 15-20
(M5)
Do not separate the rectifier 101-7 from the slip-ring end
101-5 3.6-5.1 0.4-0.5 32-45
bracket 101-8 as the gasket between them and its jointing
(M6)
paste provide a special heat conducting path which must
not be disturbed. 101-9 70-90 7.2-9.1 52-66
Note: JCB do not recommend further dismantling of the

starter motor.
C - 133 9803/3630-14 C - 133

Starter Motor
Removal and Replacement
Removal
Disconnect cables and remove battery. Remove cables
from main starter terminal and solenoid terminal. Using
special tool 825/00410 (and adapter 825/99833 if required)
unscrew three securing nuts and remove starter motor.
Replacement
Replace by reversing the removal sequence.
C - 134 9803/3630-14 C - 134

Starter Motor
Dismantling, Inspection and Assembly

TC-009
Dismantling dimension 102-D. Adjust to 0.13-1.14mm (0.005-0.045in.)

by slackening locknut 103-17 and rotating eccentric pin
Important: Dismantling of a starter motor is not 103-18 as necessary. Re-tighten locknut.
recommended except to check the condition of the
solenoid, brushes and commutator. If none of these items
are faulty, a new or exchange unit should be obtained and
fitted.
Using a slotted steel tube, displace ring 103-23 to permit

withdrawal of ring 103-22.
Allow brake shoes 103-28 to remain in the end plate 103-

11 unless requiring renewal.
Inspection Fig 102.

Renew brushes 103-14 and 103-14A if their length is less
than 8mm (0.3in.).
Clean the commutator 103-A. If individual copper bars are

burned or eroded the armature has broken windings and
must be renewed. Otherwise polish with fine grade glass
paper (not emery). Renew armature if commutator
diameter is 38mm (1.5in.) or less.
Check the field windings for open circuits by connecting a

multimeter set to measure resistance between the stud
terminal 103-B and each positive brush 103-14A in turn. A
high or infinity reading indicates an open circuit. Similarly,
connect the meter between brushes 103-14A and the
motor yoke 103-15. Any reading other than infinity
indicates a short circuit between the coils and the yoke.
Check bronze bushes 103-32 and 103-34 for wear.
Assembly
Align crosspin 103-C with the notches in the brake shoes
103-28 before assembling brush carrier and back plate to
motor yoke. Ensure that brushes 103-14A are correctly
located in the insulated brush boxes.
Smear drive shaft splines and operating collar bearing

surface with JCB MPL Grease before assembly. Assemble
operating fork 103-19 with curved face toward the
armature.
Set the movement of drive pinion 103-24 by connecting a

6v battery and switch as shown. Operate switch and check
C - 135 9803/3630-14 C - 135

Starter Motor
Fig 103.
C - 136 9803/3630-14 C - 136

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Section C

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C-0 9803/3630-14 C-0

Contents Page No.

Contents Page No.

Battery 12 volts, negative earth

Alternator A127-65, 65 amp maximum output

Starter Motor M127 12 volt

C-1 9803/3630-14 C-1

Series I Machines Machine Model and Serial Number

Machine Model and Serial Number 449/06100 770055

K 530-70 SN 767001 to 768836 ( T C-3) 449/06200 770065

K 530-70 SN 768837 to 770053 ( T C-4) 449/06300 770053

K 530-70 SN 770054 to 770958 ( T C-5) 449/06400 770069

K 530-70 SN 770959 to 1016568 ( T C-6) 449/06500 770063

K 530-70 with SRS Up to SN 1016568 ( T C-7) 449/06600 770093

K 530FS Super (Series I only) ( T C-8)

C-2 9803/3630-14 C-2

K Quick Reference Chart ( T C-2)

– 530-70 SN 767001 to 768836

Note: Machines do not have Neutral Start.

Note: ECU deletion cut-in numbers are transmission

C-3 9803/3630-14 C-3

K Quick Reference Chart ( T C-2)

– 530-70 SN 768837 to 770053

Note: Machines with Neutral Start.

Note: ECU deletion cut-in numbers are transmission

C-4 9803/3630-14 C-4

K Quick Reference Chart ( T C-2)

– 530-70 SN 770054 to 770958

Note: ECU deletion cut-in numbers are transmission

C-5 9803/3630-14 C-5

K Quick Reference Chart ( T C-2)

– 530-70 SN 770959 to 1016568

C-6 9803/3630-14 C-6

K Quick Reference Chart ( T C-2)

– 530-70 with SRS Up to SN 1016568

(1) Smooth Ride System

C-7 9803/3630-14 C-7

K Quick Reference Chart ( T C-2)

– 530FS Super (Series I only)

Note: Machines with Five Speed Powershift Transmission

C-8 9803/3630-14 C-8

K Quick Reference Chart ( T C-2)

– 532-120 SN 767001 to 768956

Note: Machines do not have Neutral Start.

C-9 9803/3630-14 C-9

K Quick Reference Chart ( T C-2)

– 532-120 SN 768957 to 770063

Note: Machines with Neutral Start.

K Quick Reference Chart ( T C-2)

– 532-120 SN 770064 to 770958

K Quick Reference Chart ( T C-2)

– 532-120 SN 770959 to August 1999

K Quick Reference Chart ( T C-2)

– 532-120 From August 1999

K Quick Reference Chart ( T C-2)

– 540-170 SN 780925 to 1004130