9813-1400-1 535-125jcbbrazil Cesto

Service Manual
535-125 HiViz and 535-140 HiViz

Personnel Platform
(Supplement)
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K Introduction ( T 1)
K Service Procedures ( T 29)
K Electrics ( T 51)
K Hydraulics ( T 159)
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Publication No.
9813/1400-1
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
Notes:
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0 9813/1400-1 0
Contents Page No.
Introduction
General Information ....................................................................................... 1
System Overview ........................................................................................... 2
Safety Notices
Introduction .................................................................................................... 1
Important Information .................................................................................... 2
Safety Check List ........................................................................................... 3
Safety Decals .............................................................................................. 16
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General Procedures
Introduction .................................................................................................... 1
Related Topics ............................................................................................... 3
Parking the Machine and Making it Safe ....................................................... 4
Boom Safety Strut (P1) .................................................................................. 6
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Boom Safety Strut (P2) .................................................................................. 9
Venting the Hydraulic Pressure ................................................................... 12
Venting the Brake System Pressure ............................................................ 14
Connecting/Disconnecting Hydraulic Hoses ................................................ 15
Quick Release Couplings ............................................................................ 16
Hydraulic Contamination ............................................................................. 18
Battery Disconnection/Connection .............................................................. 20
Battery Charging System Precautions ......................................................... 21
Removing and Replacing Components ....................................................... 22
Hydraulic Rams ........................................................................................... 24
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Gas Hydraulic Bladder Accumulators .......................................................... 26
Service Procedures
Introduction .................................................................................................. 29
RCU Engine Start Procedure ....................................................................... 30
Fault Finding ................................................................................................ 31
Servicemaster Tools .................................................................................... 34
Loadall Machine Diagnostics - User Guide ................................................. 35
Manplatform Calibration - User Guide ......................................................... 36
Manplatform Enable - Machines with LLMC or MC ..................................... 49
Electrics
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Fuses and Relays ........................................................................................ 51

Schematic Circuits ....................................................................................... 55
Component Location ................................................................................... 76
Manplatform ECU Power and Earth Connections ....................................... 80
Engine Start Operation - Cabin Mode .......................................................... 81
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Engine Start Operation - Remote Mode ...................................................... 83

Machine Operation - Remote Mode ............................................................ 92
Longitudinal Load Moment Indicator (LLMI) Operation ............................... 99
Longitudinal Load Moment Control (LLMC) Operation .............................. 101
Control Valve Operation ............................................................................ 104
Joystick Operation ..................................................................................... 109
Stabiliser Lever Operation ......................................................................... 117
Rear Axle Lock (RAL) Operation ............................................................... 119
Emergency Pump Operation ..................................................................... 122
Emergency Boom Operation ..................................................................... 123
Harness Drawings ..................................................................................... 125
Removal and Replacement ....................................................................... 145
1 1
Contents Page No.
Hydraulics
Specifications ............................................................................................ 159
Component Location ................................................................................. 162
Hydraulic Operation and Schematics ........................................................ 164
Test Procedures ......................................................................................... 184
Removal and Replacement ....................................................................... 190
Dismantle and Assemble ........................................................................... 200
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2 2
Introduction
General Information
Machine Model
This manual supplement provides information for the JCB
Work Platform, compatible with the following models in the
JCB machine range:
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– 535-125 HiViz with Manplatform
– 535-140 HiViz with Manplatform
About this Supplement
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This manual is a supplement to the JCB Loadall Service
Manual. The information covers the machines specified
fitted with the JCB Personnel Platform.
For Platform operation details and safety information refer

to the applicable Machine Operator Supplement: 9821/
2250.
Only those areas of the machine which are different from

the standard Loadall are dealt with here. For all other
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information refer to the applicable Loadall Service Manual:
– 9813/0950 for machines with Tier 3 Engine.
Unless specified otherwise, all references to 'Service

Manual' in this supplement are to be taken as meaning the
Service Manual specific to the standard machine.
Read the standard Service Manual and this supplement

completely to familiarise yourself with the machine before
carrying out any servicing procedures.
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1 9813/1400-1 1
Introduction
System Overview
System Overview
For details of systems and components refer to the The LMI transducer measures the load exerted on the rear
applicable topic: axle and sends a signal to the JCB electronic control unit
(ECU). When the machine is near its maximum working
– K Electrics ( T 51) limit (when it could tip forward), the JCB ECU prevents
– K Hydraulics ( T 159) forward reach of the platform (extending and lowering).
Note: When the system is operated in remote mode a

Introduction
safety system monitors operation of the remote control unit
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(RCU). If the unit is not operated during a 10 minute period
The JCB personnel platform fits to the machine using the
the engine automatically stops. If necessary the engine
JCB Q-Fit design attachment. Loadalls become classed as
can be re-started by use of the RCU.
MEWPs (Mobile Elevating Work Platforms) when this type
of system is installed.
Emergency Operation
The system enables safe access to elevated positions
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during building/maintenance work. In case of emergency, (engine failure for example) an
independent electrically driven hydraulic pump is provided.
Important: It is not permitted for persons to enter or exit The pump allows the platform to be safely lowered to the
the platform once it has been raised above 500 mm (20 in) ground from the platform or the cab.
from the ground.
Pressing the machine isolation push button stops the
engine and hydraulic system in an emergency. The
Controls
Platform also has an emergency stop (isolation) button.
Control of the boom is via a servo control lever in the cab
or a remote control unit (RCU) from the JCB platform. Both Longitudinal Load Moment Control
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control systems operate the same servo control valve. (LLMC) (if fitted)
A safety key system prevents operation of the boom by the The LLMC system is active with the boom retracted on
cab control lever and RCU at the same time. When the machines with Personnel Platforms. On standard
machine is operated from the cab it is in Cabin Mode. machines the LLMC system is not active when the boom is
When the machine is operated from the RCU it is in fully retracted.
Remote Mode.
LLMC is always active when the JCB personnel platform is
All the control signals are processed by the JCB ECU operated by the remote control unit (RCU).
located under the operator’s seat.
The LLMC system automatically reduces the speed of the
Remote Servo Control boom hydraulic services. When the machine is nearing its
maximum working limit (when it could tip forward) an
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The JCB work platform system enables remote control of intermittent audible alarm sounds. When the machine is at
the boom lift, lower, extend, retract, tilt and engine speed its maximum working limit forward reach of the platform is
functions by an operator located in the platform. The prevented. A continuous audible alarm sounds.
control of these functions is achieved through a remote
control unit (RCU) radio transmitter and radio receiver. For information about the LLMC system refer to the
machine Operator Manual or Service Manual. K About
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Before remote operation is enabled, there are safety

interlocks which require the machine’s park brake to be on this Supplement ( T 1)
and the stabilizer legs to be down. Switches and sensors
indicate the status of the park brake and stabilizers.
The stabiliser and sway systems are isolated when the

machine is in Remote Mode.
2 9813/1400-1 2
Introduction
System Overview
Component Location and Identification

For details of components and locations refer to the
applicable topic:
– K Electrics ( T 51)
– K Hydraulics ( T 159)
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3 9813/1400-1 3
Introduction
System Overview
System Operation Note: The RCU must be correctly “Docked” in the platform.
If the RCU is not correctly “Docked” it will not operate.
Interlocks are fitted to ensure correct operation of cabin
mode and remote mode. The table explains the operating Note: When docking the RCU on the platform make sure
logic. not to depress the RCU emergency stop button. The RCU
will not operate if this emergency stop is depressed.
Note: An overload switch is fitted to the platform. If the
platform exceeds the specified weight the switch informs Note: Make sure all emergency stop buttons are not
the ECU. The ECU isolates all platform operations. This is depressed.
indicated by a Yellow light illuminating on the RCU.
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Table 1.
Function Cabin Mode Remote Mode
Engine start z z (1)
Stabilisers z (2)
Sway z (3)
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Boom raise z z
Boom lower z z
Boom extend z z
Boom retract z z
Tilt z z (4)
Auxiliary hydraulics z
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Platform slew (if fitted) z
LLMC z z (5)
Engine speed control z z

Automatic engine speed control z
Engine stop z z (6)
Engine stop (after safety time period) z (7)
Emergency stop (cab isolation button) z

Emergency stop (platform isolation button) z
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Emergency boom operation z (8)

z (8)
(1) Stabilisers must be down and the park brake must be on before engine will start.
(2) Stabiliser service is isolated. Control must be switched back to cabin mode to re-activate stabiliser service.
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(3) Sway service is isolated. Control must be switched back to cabin mode to re-activate sway service.
(4) Only when boom angle is below 10º.
(5) LLMC operates at all times when in Remote Mode, even with the boom fully retracted.
(6) If the engine is running when remote mode is selected, the engine will stop. The engine must be re-started by use of
the remote control unit (RCU).
(7) If the remote control unit (RCU) is not operated during a 10 minute period the engine automatically stops. If necessary
the engine can be re-started by use of the RCU.
(8) Enables the emergency electric hydraulic pump. Only boom lower and retract services operate. The system will not
enable boom operation in the event of control valve failure.
4 9813/1400-1 4
Section 2-1 - Care and Safety
Safety Notices
Introduction
In this publication and on the machine, there are safety

notices. Each notice starts with a signal word. The signal
word meanings are given below.
!MDANGER
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Denotes an extreme hazard exists. If proper
precautions are not taken, it is highly probable that the
operator (or others) could be killed or seriously
injured.
INT-1-2-1
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!MWARNING
Denotes a hazard exists. If proper precautions are not
taken, the operator (or others) could be killed or
seriously injured.
INT-1-2-2
!MCAUTION
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Denotes a reminder of safety practices. Failure to
follow these safety practices could result in injury to
the operator (or others) and possible damage to the
machine.
INT-1-2-3
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2-1-1 2-01-06 Issue 01 2-1-1

Safety Notices
Important Information
Important Information
T1-042
The Operator Manual Safety Warnings
!MWARNING This safety alert system identifies

important safety messages in this
You and others can be killed or seriously injured if you manual. When you see this symbol, be
operate or maintain the machine without first studying alert, your safety is involved, carefully
the Operator Manual. You must understand and follow read the message that follows, and inform
the instructions in the Operator Manual. If you do not
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other operators.
understand anything, ask your employer or JCB
dealer to explain it.
In this publication and on the machine, there are safety
INT-1-4-2
notices. Each notice starts with a signal word. The signal
word meanings are given below.
Do not operate the machine without an Operator Manual,
or if there is anything on the machine you do not
!MDANGER
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understand.
Treat the Operator Manual as part of the machine. Keep it Denotes an extreme hazard exists. If proper
clean and in good condition. Replace the Operator Manual precautions are not taken, it is highly probable that the
immediately if it is lost, damaged or becomes unreadable. operator (or others) could be killed or seriously
injured.
INT-1-2-1
!MWARNING
Denotes a hazard exists. If proper precautions are not
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taken, the operator (or others) could be killed or
seriously injured.
INT-1-2-2
!MCAUTION
Denotes a reminder of safety practices. Failure to
follow these safety practices could result in injury to
the operator (or others) and possible damage to the
machine.
INT-1-2-3
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2-1-2 2-01-06 Issue 01 2-1-2

Safety Notices
Safety Check List
Safety Check List
Safety - Yours and Others For more information about cleanliness requirements and
INT-1-3-1_3
fuel types refer to Section 1 - General Information.
All machinary can be hazardous. When a machine is
correctly operated and properly maintained, it is a safe
machine to work with. But when it is carelessly operated or
!MCAUTION
poorly maintained it can become a danger to you (the Do not allow dirt to enter the fuel system. Before
operator) and others. disconnecting any part of the fuel system, thoroughly
clean around the connection. When a component has
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In this manual and on the machine you will find warning been disconnected, for example a fuel pipe, always fit
messages. Read and understand them. They tell you of protective caps and plugs to prevent dirt ingress.
potential hazards and how to avoid them. If you do not fully
understand the warning messages, ask your employer or Failure to follow these instruction will lead to dirt
JCB distributor to explain them. entering the fuel system. Dirt in the fuel system will
seriously damage the fuel injection equipment and
could be expensive to repair.
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But safety is not just a matter of responding to the
warnings. All the time you are working on or with the ENG-1-7
machine you must be thinking what hazards there might be
and how to avoid them.
Do not work with the machine until you are sure that you
can control it.
Do not start any job until you are sure that you and those
around you will be safe.
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If you are unsure of anything, about the machine or the job,
ask someone who knows. Do not assume anything.
Remember
BE CAREFUL
BE ALERT
BE SAFE
Common Rail (SE/SH/DH/SL Engine)

Specific
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In addition to the general safety notices and general good

workshop practices issued in this section and throughout
the manual, there are specific points to note when
completing maintenance on engine equipment:
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Diesel Fuel Quality
Important: The potential for engine damage due to the

use of incorrect or contaminated fuel is much greater with
common rail injection technology than with mechanical
injection systems.
2-1-3 2-01-06 Issue 01 2-1-3

Safety Notices
Safety Check List
Effects of Contamination Common Rail Safety Checklist
Once inside the system, fuel circuit contaminants greatly The following safety checklist is intended to help remind
effect the performance and life of the fuel injection you of safety procedures and practices relating to a
equipment. For example, contaminants in the fuel pump common rail engine.
will develop internal wear to cause internal leakage and
hence lower discharges. Use of poor quality fuels and poor SAFETY IS YOUR RESPONSIBILITY
maintenance could also lead to contaminants entering the
fuel injectors. There is a possibility of catastrophic – Do make sure the engine and surrounding area has
equipment failure if debris should prevent the injectors been thoroughly cleaned prior to completing any
from fully closing. The main contaminants can be classified maintenance tasks.
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as follows: These contaminations can appear during – Do complete all work in accordance with the Service
manufacture. assembly and operation. Manual procedures.
– Do disconnect both the battery positive (+) and
– Solid Particles - sand, fibres, metallic particles,
battery negative (-) cables prior to completing any
welding scale, sealing materials and wear particles
welding on the machine.
etc.
– Do use the recommended grade of fuel (EN590). The
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– Liquid - usually water and incompatible oils and
fuel injection pump, injector or other parts of the fuel
gases.
system can be damaged if you use a fuel or fuel
– Gases - Air, sulphur dioxide etc. which can create additives not recommended by JCB. Refer to Section
corrosive compounds if dissolved in the fluid. 1 - Acceptable and Unacceptable Fuels.
– Do make sure all the necessary new parts are
It is critical that the machine is thoroughly cleaned prior to
available before starting any maintenance work.
completing any maintenance work. The main filter is rated
at 2 micron = 0.002 mm (0.0007874 in). – Do not `crack' the injector high pressure fuel lines to
bleed the fuel system. The system operates at
Listed are a few typical comparisons of micron size: pressures in excess of 1200 bar (17400lbs/in2).
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– Do not steam clean the electronic control unit (ECU)
– Red Blood Cell = 8 microns (0.008 mm, 0.000315 in). or the ECU connectors.
– Human Hair = 70 microns (0.07 mm, 0.00275 in). – Do not touch the ECU connector pins, this will
– Grain of Salt = 100 microns (0.1 mm, 0.00394 in). eliminate the possibility of damage caused by
electrostatic discharge.
– The smallest particle visible to the naked eye is 40
microns (0.00157 in) approximately. – Do not leave any fuel connections òpen' for any
extended period of time.
– Do not open any new parts packaging until the part is
ready to be fitted. Unnecessary exposure will
increase the risk of contamination.
– Do not reuse high pressure fuel pipes. Reusing the
pipes will lead to potential fuel leaks.
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– Do not attempt to remove and replace the rail

pressure sensor or high pressure valve. It is not
possible to refit these components without the risk of
fuel leaks. If the valve or sensor is diagnosed as faulty
then a new common rail assembly must be fitted.
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Safety Notices
Safety Check List
General Safety
T1-043
!MWARNING
!MWARNING Feeling Unwell
Do not attempt to operate the machine if you are
To operate the machine safely you must know the feeling unwell. By doing so you could be a danger to
machine and have the skill to use it. You must abide by yourself and those you work with.
all relevant laws, health and safety regulations that 8-1-2-4
apply to the country you are operating in. The
Operator Manual instructs you on the machine, its
controls and its safe operation; it is not a training
!MWARNING
manual. If you are a new operator, get yourself trained Mobile Phones
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in the skills of using a machine before trying to work Switch off your mobile phone before entering an area
with it. If you don't, you will not do your job well, and with a potentially explosive atmosphere. Sparks in
you will be a danger to yourself and others. such an area could cause an explosion or fire
INT-1-4-1
resulting in death or serious injury.
!MWARNING Switch off and do not use your mobile phone when
refuelling the machine.
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Care and Alertness INT-3-3-9
All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always be
alert for hazards.
!MWARNING
INT-1-3-5
Lifting Equipment
You can be injured if you use incorrect or faulty lifting
!MWARNING equipment. You must identify the weight of the item to

be lifted then choose lifting equipment that is strong
Clothing enough and suitable for the job. Make sure that lifting
You can be injured if you do not wear the proper equipment is in good condition and complies with all
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clothing. Loose clothing can get caught in the local regulations.
machinery. Wear protective clothing to suit the job. INT-1-3-7_2
Examples of protective clothing are: a hard hat, safety
shoes, safety glasses, a well fitting overall, ear-
protectors and industrial gloves. Keep cuffs fastened.
!MWARNING
Do not wear a necktie or scarf. Keep long hair Raised Equipment
restrained. Remove rings, watches and personal Never walk or work under raised equipment unless it
jewellery. is supported by a mechanical device. Equipment
INT-1-3-6_2
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails or if
!MWARNING the control is operated (even with the engine stopped).
Alcohol and Drugs Make sure that no-one goes near the machine while
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It is extremely dangerous to operate machinery when you install or remove the mechanical device.
under the influence of alcohol or drugs. Do not 13-2-3-7_3
consume alcoholic drinks or take drugs before or
while operating the machine or attachments. Be aware
of medicines which can cause drowsiness.
!MWARNING
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INT-1-3-9_2
Raised Machine
NEVER position yourself or any part of your body
under a raised machine which is not properly
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be
killed.
INT-3-3-7_1
2-1-5 2-01-06 Issue 01 2-1-5

Safety Notices
Safety Check List
!MDANGER
Lightning
Lightning can kill you. Do not use the machine if there
is lightning in your area.
5-1-1-2
!MWARNING
Machine Modifications
This machine is manufactured in compliance with
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legislative and other requirements. It should not be
altered in any way which could affect or invalidate any
of these requirements. For advice consult your JCB
Distributor.
INT-1-3-10_2
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2-1-6 2-01-06 Issue 01 2-1-6

Safety Notices
Safety Check List
Operating Safety !MWARNING

!MWARNING You could be killed or seriously injured if you operate
a machine with a damaged or missing ROPS/FOPS. If
Machine Condition the Roll Over Protection Structure (ROPS)/Falling
A defective machine can injure you or others. Do not Objects Protection Structure (FOPS) has been in an
operate a machine which is defective or has missing accident, do not use the machine until the structure
parts. Make sure the maintenance procedures in this has been renewed. Modifications and repairs that are
manual are completed before using the machine. not approved by the manufacturer may be dangerous
INT-2-1-2_2
and will invalidate the ROPS/FOPS certification.
INT-2-1-9_6
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!MWARNING !MWARNING
Machine Limits
Operating the machine beyond its design limits can Work Sites
damage the machine, it can also be dangerous. Do not Work sites can be hazardous. Inspect the site before
operate the machine outside its limits. Do not try to working on it. Look for potholes, weak ground, hidden
rocks etc. Check for utilities such as electric cables
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upgrade the machine performance with unapproved
modifications. (overhead and underground), gas and water pipes etc.
INT-2-1-4
Mark the positions of the underground cables and
pipes. Make sure that you have enough clearance
!MWARNING beneath overhead cables and structures.

INT-2-2-1
Engine/Steering Failure
If the engine or steering fails, stop the machine as
quickly as possible. Do not operate the machine until
!MWARNING
the fault has been corrected. Communications
Bad communications can cause accidents. Keep
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INT-2-1-5
people around you informed of what you will be doing.
!MWARNING If you will be working with other people, make sure any
hand signals that may be used are understood by
The engine has exposed rotating parts. Switch OFF the everybody. Work sites can be noisy, do not rely on
engine before working in the engine compartment. Do spoken commands.
not use the machine with the engine cover open. INT-2-2-3
5-2-6-5
!MWARNING
!MWARNING Parking
Exhaust Gases An incorrectly parked machine can move without an
Breathing the machine exhaust gases can harm and operator. Follow the instructions in the Operator
possibly kill you. Do not operate the machine in closed Manual to park the machine correctly.
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spaces without making sure there is good ventilation. INT-2-2-4_2

If possible, fit an exhaust extension. If you begin to
feel drowsy, stop the machine at once and get into
fresh air.
!MWARNING
Banks and Trenches
INT-2-1-10_2
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Banked material and trenches can collapse. Do not

work or drive too close to banks and trenches where
there is danger of collapse.
INT-2-2-5
2-1-7 2-01-06 Issue 01 2-1-7

Safety Notices
Safety Check List
!MWARNING !MWARNING
Ramps and Trailers Practice
Water, mud, ice, grease and oil on ramps or trailers can You or others can be killed or seriously injured if you
cause serious accidents. Make sure ramps and trailers do unfamiliar operations without first practising them.
are clean before driving onto them. Use extreme Practise away from the work site on a clear area. Keep
caution when driving onto ramps and trailers. other people away. Do not perform new operations
INT-2-2-6 until you are sure you can do them safely.
INT-2-1-1
!MWARNING
!MWARNING
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Safety Barriers
Unguarded machines in public places can be Reversing
dangerous. In public places, or where your visibility is Reversing at high speeds can cause accidents. Do not
reduced, place barriers around the work area to keep reverse in a high gear with full throttle. Always drive at
people away. a safe speed to suit working conditions.
INT-2-2-8 INT-2-2-9_1
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!MDANGER !MWARNING
Sparks Airborne particles of light combustible material such
Explosions and fire can be caused by sparks from the as straw, grass, wood shavings, etc. must not be
exhaust or the electrical system. Do not use the allowed to accumulate within the engine compartment
machine in closed areas where there is flammable or in the propshaft guards (when fitted). Inspect these
material, vapour or dust. areas frequently and clean at the beginning of each
INT-2-2-10 work shift or more often if required. Before opening
the engine cover, ensure that the top is clear of debris.
!MWARNING 5-3-1-12_3
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Hazardous Atmospheres
This machine is designed for use in normal out door
!MWARNING
atmospheric conditions. It should not be used in an Keep the machine controls clean and dry. Your hands
enclosed area without adequate ventilation. Do not and feet could slide off slippery controls. If that
use the machine in a potentially explosive happens you could lose control of the machine.
atmosphere, i.e. combustible vapours, gas or dust, 2-2-3-6
without first consulting your JCB Distributor.
INT-2-1-14
!MWARNING
!MCAUTION Visibility
Accidents can be caused by working in poor visibility.
Regulations Use your lights to improve visibility. Keep the road
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Obey all laws, work site and local regulations which lights, windows and mirrors clean.
affect you and your machine.
INT-1-3-3 Do not operate the machine if you cannot see clearly.
5-1-4-7
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Safety Notices
Safety Check List
!MWARNING !MWARNING
Electrical Power Cables Fires
You could be electrocuted or badly burned if you get If your machine is equipped with a fire extinguisher,
the machine or its attachments too close to electrical make sure it is checked regularly. Keep it in the correct
power cables. machine location until you need to use it.
You are strongly advised to make sure that the safety Do not use water to put out a machine fire, you could
arrangements on site comply with the local laws and spread an oil fire or get a shock from an electrical fire.
regulations concerning work near electric power lines. Use carbon dioxide, dry chemical or foam
extinguishers. Contact your nearest fire department as
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Before you start using the machine, check with your quickly as possible. Firefighters should use self-
electricity supplier if there are any buried power contained breathing apparatus.
cables on the site. INT-3-2-7_2
There is a minimum clearance required for working

beneath overhead power cables. You must obtain
!MWARNING
details from your local electricity supplier. Should the machine start to roll over, you can be
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2-2-5-4 crushed if you try to leave the cab. If the machine
starts to roll over, do not try and jump from the cab.
!MCAUTION Stay in the cab, with your seat belt fastened.
INT-2-1-12
If you have an attachment which is not covered in the
Operator Manual do not install it, use it or remove it
until you have obtained, read and understood the
!MCAUTION
pertinent information. Install attachments only on the Fork Spacing
machines for which they were designed. Loads can fall off incorrectly spaced forks. Always
5-5-1-1_2 space the forks correctly for the load. Make sure the
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forks are completely under the load before lifting.
!MWARNING 5-1-4-2
Use only the JCB approved attachments that are

specified for your machine. Operating with non-
!MCAUTION
specified attachments can overload the machine, One-Fork Lifting
causing possible damage and machine instability A load lifted on one fork can slip off. Never lift a load
which could result in injury to yourself or others. with one fork.
5-1-4-3
The use of non-approved attachments could invalidate
your warranty.
2-4-5-2_1
!MCAUTION
Unloading
!MWARNING
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Never unload the forks by stopping the machine

suddenly. Follow the procedures in the Operator
Controls Manual for unloading.
You or others can be killed or seriously injured if you 5-1-4-4_2
operate the control levers from outside the machine.
!MCAUTION
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Operate the control levers only when you are correctly

seated.
0179_2 Uneven Ground
Loads stacked on uneven ground can topple. Never
stack loads on uneven ground.
5-1-4-5
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Safety Notices
Safety Check List
!MWARNING !MWARNING
Scaffolding Powershift Transmission
Overloaded scaffolding can collapse. Never load Do not change from a high gear to a low gear (for
scaffolding beyond the regulation capacity. instance, 4th to 1st) in one sudden movement when
5-1-4-6 the machine is moving. Otherwise the machine will
rapidly decelerate, you or others could be killed or
!MCAUTION seriously injured. When selecting lower gears, allow
the engine speed to drop before each gear change.
Overhead Clearance 2-1-1-9_1
A raised boom can strike overhead objects. Always
IL
check for overhead clearance before raising the boom.
5-1-5-1
!MCAUTION
Passengers
!MWARNING Passengers in or on the machine can cause accidents.
Do not carry passengers.
Boom/Travelling INT-2-2-2_1
Operating the boom while travelling can cause
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accidents. You will not have total control of the
machine. Never operate the boom while travelling.
5-1-5-2
!MDANGER
Forks/Working Platform
Using the forks alone as a working platform is
hazardous; you can fall off and be killed or injured.
Never use the forks as a working platform.
BR
5-1-5-3
!MWARNING
Forks/Turning
The forks extend beyond the end of the boom. Make
sure there is enough clearance for the forks when
making turns.
5-1-5-4
!MWARNING
Entering/Leaving
B
Entering or leaving the cab or canopy must only be

made where steps and handrails are provided. Always
face the machine when entering and leaving. Make
sure the step(s), handrails and your boot soles are
clean and dry. Do not jump from the machine. Do not
JC
use the machine controls as handholds, use the

handrails.
INT-2-1-7_1
2-1-10 2-01-06 Issue 01 2-1-10

Safety Notices
Safety Check List
Maintenance Safety !MWARNING

!MWARNING Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
Communications skin. Keep face and hands well clear of fluid under
Bad communications can cause accidents. If two or pressure and wear protective glasses and gloves.
more people are working on the machine, make sure Hold a piece of cardboard close to suspected leaks
each is aware of what the others are doing. Before and then inspect the cardboard for signs of fluid. If
starting the engine make sure the others are clear of fluid penetrates your skin, get medical help
the danger areas; examples of danger areas are: the immediately.
rotating blades and belt on the engine, the INT-3-1-10_3
IL
attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or injured if
these precautions are not taken.
!MWARNING
INT-3-1-5
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
!MWARNING Before connecting or removing any hydraulic hose,

residual hydraulic pressure trapped in the service
AZ
Repairs hose line must be vented. Make sure the hose service
If your machine does not function correctly in any way, line has been vented before connecting or removing
get it repaired straight away. Neglect of necessary hoses. Make sure the engine cannot be started while
repairs could result in an accident or affect your the hoses are open.
health. Do not try to do repairs or any other type of INT-3-1-11_2
maintenance work you do not understand. To avoid
injury and/or damage get the work done by a specialist
engineer.
!MWARNING
GEN-1-5_2
Fuel
Fuel is flammable; keep naked flames away from the
BR
!MWARNING fuel system. Stop the engine immediately if a fuel leak
is suspected. Do not smoke while refuelling or
Metal Splinters working on the fuel system. Do not refuel with the
You can be injured by flying metal splinters when engine running. Completely wipe off any spilt fuel
driving metal pins in or out. Use a soft faced hammer which could cause a fire. There could be a fire and
or copper pin to remove and fit metal pins. Always injury if you do not follow these precautions.
wear safety glasses. INT-3-2-2_3
INT-3-1-3_2
!MWARNING
!MWARNING Oil
Electrical Circuits Oil is toxic. If you swallow any oil, do not induce
Understand the electrical circuit before connecting or vomiting, seek medical advice. Used engine oil
B
disconnecting an electrical component. A wrong contains harmful contaminants which can cause skin
connection can cause injury and/or damage. cancer. Do not handle used engine oil more than
INT-3-1-4
necessary. Always use barrier cream or wear gloves to
prevent skin contact. Wash skin contaminated with oil
thoroughly in warm soapy water. Do not use petrol,
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diesel fuel or paraffin to clean your skin.

INT-3-2-3
2-1-11 2-01-06 Issue 01 2-1-11

Safety Notices
Safety Check List
!MCAUTION !MCAUTION
It is illegal to pollute drains, sewers or the ground. 'O' rings, Seals and Gaskets
Clean up all spilt fluids and/or lubricants. Badly fitted, damaged or rotted 'O' rings, seals and
gaskets can cause leakages and possible accidents.
Used fluids and/or lubricants, filters and contaminated Renew whenever disturbed unless otherwise
materials must be disposed of in accordance with instructed. Do not use Triochloroethane or paint
local regulations. Use authorised waste disposal sites. thinners near 'O' rings and seals.
INT-3-2-14 INT-3-2-12
!MWARNING !MWARNING
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Soft Ground Hydraulic Hoses
A machine can sink into soft ground. Never work Damaged hoses can cause fatal accidents. Inspect the
under a machine on soft ground. hoses regularly. Do not use the machine if a hose or
INT-3-2-4 hose fitting is damaged.
INT-3-3-2_4
!MWARNING
AZ
Always wear safety glasses when dismantling
!MCAUTION
assemblies containing components under pressure Waxoyl contains turpentine substitute which is
from springs. This will protect against eye injury from flammable. Keep flames away when applying Waxoyl.
components accidentally flying out. Waxoyl can take a few weeks to dry completely. Keep
GEN-6-2 flames away during the drying period.
!MCAUTION Do not weld near the affected area during the drying
period. Take the same precautions as for oil to keep
Rams Waxoyl off your skin. Do not breathe the fumes. Apply
BR
The efficiency of the rams will be affected if they are in a well-ventilated area.
not kept free of solidified dirt. Clean dirt from around 5-3-1-9
the rams regularly. When leaving or parking the
machine, close all rams if possible to reduce the risk
of weather corrosion.
!MWARNING
INT-3-2-10 Working Under the Machine
Make the machine safe before getting beneath it.
!MCAUTION Ensure that any fitments on the machine are secure;
engage the park brake, remove the starter key,
Cleaning disconnect the battery.
Cleaning metal parts with incorrect solvents can cause INT-3-3-8_2
corrosion. Use only recommended cleaning agents
and solvents.
B
INT-3-2-11
!MWARNING
When using cleaning agents, solvents or other
JC
chemicals, you must adhere to the manufacturer's

instructions and safety precautions.
GEN-1-9
2-1-12 2-01-06 Issue 01 2-1-12

Safety Notices
Safety Check List
!MWARNING !MWARNING
Certain seals and gaskets (e.g. crankshaft oil seal) on To avoid burning wear personal protective equipment
JCB machines contain fluoroelastomeric materials (PPE) when handling hot components. To protect your
such as Viton®, FluorelTM and Technoflon®. eyes, wear personal protective equipment (PPE) when
Fluoroelastomeric materials subjected to high using a brush to clean components.
temperatures can produce highly corrosive HYD-1-3_3
hydrofluoric acid. THIS ACID CAN SEVERELY BURN.
New fluoroelastomeric components at ambient

!MWARNING
temperature require no special safety precautions. Arc Welding
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To prevent the possibility of damage to electronic
Used fluoroelastomeric components whose components, disconnect the battery and the alternator
temperatures have not exceeded 300°C (572°F) require before arc-welding on the machine or attached
no special safety precautions. If evidence of implements.
decomposition (e.g. charring) is found, refer to the
next paragraph for safety instructions DO NOT TOUCH If the machine is equipped with sensitive electrical
COMPONENT OR SURROUNDING AREA. equipment, i.e. amplifier drivers, electronic control
AZ
units (E.C.U.s), monitor displays, etc., then disconnect
Used fluoroelastomeric components subjected to them before welding. Failure to disconnect the
temperatures greater than 300°C (572°F) (e.g. engine sensitive electrical equipment could result in
fire) must be treated using the following safety irreparable damage to these components.
procedure. Make sure that heavy duty gloves and
special safety glasses are worn: Parts of the machine are made from cast iron; welds
on cast iron can weaken the structure and break. Do
1 Thoroughly wash contaminated area with 10% not weld cast iron. Do not connect the welder cable or
calcium hydroxide or other suitable alkali apply any weld to any part of the engine.
solution, if necessary use wire wool to remove
BR
burnt remains. Always connect the welder earth (ground) cable to the
same component that is being welded, i.e. boom or
2 Thoroughly wash contaminated area with dipper, to avoid damage to pivot pins, bearings and
detergent and water. bushes. Attach the welder earth (ground) cable no
more than 0.6 metres (2 feet) from the part being
3 Contain all removed material, gloves etc. used in welded.
this operation in sealed plastic bags and dispose INT-3-1-15_2
of in accordance with Local Authority
Regulations.
!MWARNING
DO NOT BURN FLUOROELASTOMERIC MATERIALS. Counterweights
INT-3-3-5_4 Your machine may be fitted with counterweights. They
are extremely heavy. Do not attempt to remove them.
!MWARNING
B
INT-3-2-5
Protect your eyes when grinding metal. Wear safety

glasses or goggles. Remove or protect any
!MWARNING
combustible materials from the area which could be Compressed air is dangerous. Wear suitable eye
ignited by sparks.
JC
protection and gloves. Never point a compressed air

GEN-1-12 jet at yourself or others.
0147_1
2-1-13 2-01-06 Issue 01 2-1-13

Safety Notices
Safety Check List
!MWARNING !MWARNING
Accumulators Battery Gases
The accumulators contain hydraulic fluid and gas at Batteries give off explosive gases. Keep flames and
high pressure. Prior to any work being carried out on sparks away from the battery. Do not smoke close to
systems incorporating accumulators, the system the battery. Make sure there is good ventilation in
pressure must be exhausted by a JCB distributor, as closed areas where batteries are being used or
the sudden release of the hydraulic fluid or gas may charged. Do not check the battery charge by shorting
cause injury. the terminals with metal; use an approved battery
INT-3-1-17 tester.
INT-3-1-8_2
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!MWARNING
Petrol
!MDANGER
Do not use petrol in this machine. Do not mix petrol Electrolyte
with the diesel fuel; in storage tanks the petrol will rise Battery electrolyte is toxic and corrosive. Do not
to the top and form flammable vapours. breathe the gases given off by the battery. Keep the
electrolyte away from your clothes, skin, mouth and
AZ
INT-3-1-6
eyes. Wear personal protective equipment (PPE).
!MWARNING INT-3-2-1_4
The cooling system is pressurised when the coolant is

hot. When you remove the cap, hot coolant can spray
!MWARNING
out and burn you. Make sure that the engine is cool Battery Terminals
before you work on the cooling system. The machine is negatively earthed. Always connect
9-3-3-1_2 the negative pole of the battery to earth.
!MCAUTION When connecting the battery, connect the earth (-) lead
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last.
Do not disconnect the battery while the engine is
running, otherwise the electrical circuits may be When disconnecting the battery, disconnect the earth
damaged. (-) lead first.
INT-3-1-14 INT-3-1-9
!MWARNING !MWARNING
If you try to charge a frozen battery, or jump start and An exploding tyre can kill. Inflated tyres can explode if
run the engine, the battery could explode. Do not use over-heated or over-inflated. Follow the instructions
a battery if its electrolyte is frozen. To prevent the given when inflating the tyres. Do not cut or weld the
battery electrolyte from freezing, keep the battery at rims. Use a tyre/wheel specialist for all repair work.
full charge. 2-3-2-7_2
B
0125
!MWARNING
Jacking
A machine can roll off jacks and crush you unless the
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wheels have been blocked. Always block the wheels at

the opposite end of the machine that is to be jacked.
Do not work underneath a machine supported only by
jacks. Always support a jacked-up machine on axle
stands before working underneath it.
INT-3-2-8
2-1-14 2-01-06 Issue 01 2-1-14

Safety Notices
Safety Check List
!MWARNING
Under no circumstances must the engine be run with
the transmission in gear and only one driving wheel
jacked clear of the ground, since the wheel on the
ground will move the machine.
INT-3-1-16
!MCAUTION
You must apply the park brake before you operate the
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attachment.
13-3-1-17
!MCAUTION
Never use water or steam to clean inside the cab. The
use of water or steam could damage the on-board
AZ
computer and render the machine inoperable. Remove
dirt using a brush or damp cloth.
8-3-4-8
!MWARNING
Boom Maintenance Strut
A raised boom can drop suddenly and cause serious
injury. Before working under a raised boom, fit the
boom maintenance strut. See Boom Maintenance
BR
Strut, MAINTENANCE section.
5-1-5-7_2
B
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2-1-15 2-01-06 Issue 01 2-1-15

Safety Notices
Safety Decals
Safety Decals
Introduction
!MWARNING
Safety Labels
Safety labels on the machine warn you of particular
hazards. You can be injured if you do not obey the
safety instructions shown.
IL
INT-1-3-11
Safety labels are strategically placed around the machine

to remind you of possible hazards.
If you need eye-glasses for reading, make sure you wear
AZ
them when reading the safety labels. Do not over-stretch
or place yourself in dangerous positions to read the safety
labels. If you do not understand the hazard shown on the
safety label refer to the machine operator manual.
Keep all safety labels clean and readable. Replace lost or

damaged safety labels. Make sure replacement parts
include safety labels where necessary. Each safety label
has a part number printed on it, use this number to order a
new safety label from your JCB distributor.
BR
B
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2-1-16 2-01-06 Issue 01 2-1-16

General Procedures
Introduction
When work is done on the machine it is important that the correct care is taken. This will help to prevent personal injury
and reduce the risk of component failure.
As part of the procedures in this manual you will need to do some general procedures. Two examples of these general
procedures are; parking the machine and making it safe, and venting hydraulic pressure.
IL
These procedures are given here as an alternative to again and again in the manual. Where applicable you will see a
cross reference to this section so that you can refer to the detailed procedures.
K Parking the Machine and Making it Safe ( T 2-2-4)

K Boom Safety Strut (P1) ( T 2-2-6)(1)
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K Boom Safety Strut (P2) ( T 2-2-9)(1)
K Venting the Hydraulic Pressure ( T 2-2-12)
K Venting the Brake System Pressure ( T 2-2-14)
K Connecting/Disconnecting Hydraulic Hoses ( T 2-2-15)
K Introduction ( T 2-2-15)
K Connecting the Hoses ( T 2-2-15)
K Disconnecting the Hoses ( T 2-2-15)
K Quick Release Couplings ( T 2-2-16)
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K Hydraulic Contamination ( T 2-2-18)
K Hydraulic Fluid Quality ( T 2-2-18)
K Effects of Contamination ( T 2-2-18)
K Cleaning Operation ( T 2-2-18)
K Contaminant Standards ( T 2-2-19)
K Filters ( T 2-2-19)
K Battery Disconnection/Connection ( T 2-2-20)
K Disconnection ( T 2-2-20)
K Connection ( T 2-2-20)
B
K Removing and Replacing Components ( T 2-2-22)

K Battery Charging System Precautions ( T 2-2-21)
K Hydraulic Rams ( T 2-2-24)
K Installation ( T 2-2-24)
JC
K Caution During Use ( T 2-2-24)

K Maintenance, Inspection Points ( T 2-2-24)
K Gas Hydraulic Bladder Accumulators ( T 2-2-26)
(1) Specification variants. Make sure you refer to the correct specification.
2-2-1 2-02-06 Issue 01 2-2-1

General Procedures
Introduction
Table 1. Specification Variants - Boom Safety Strut

Specifications (1) Machine Model Application
531-70, 535-95, 536-60, 541-70, 533- 506-36, 507-42, 509-42, 510-56, 512-
105, 536-70, 533-105, 536-70, 550- 56, 514-56
80, 540-170, 550-170, 540-140, 550-
140, 535-125 HiViz, 535-140 HiViz,
526-56, 527-58, 540-200
K Boom Safety Strut (P1) ( T 2-2-6) z
K Boom Safety Strut (P2) ( T 2-2-9) z
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(1) The table lists specification variants and the applicable machine models. Use the table to make sure you refer to the
correct information.
AZ
BR
B
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2-2-2 2-02-06 Issue 01 2-2-2

General Procedures
Related Topics
Related Topics
Table 2. Related Topics in This Publication

The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to
complete your procedures. Where applicable the text in this section contains cross references to this page to help you find
the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer
to Section 1 - Applications.
Sections Topic Titles Sub Titles
1 General Information ALL
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2 Safety Notices ALL
3 Maintenance Access Panels
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BR
B
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2-2-3 2-02-06 Issue 01 2-2-3

General Procedures
Parking the Machine and Making it Safe
Introduction
!MWARNING
Maintenance must be done only by suitably qualified
and competent persons.
Before doing any maintenance make sure the machine
IL
is safe, it should be correctly parked on level ground.
To prevent anyone starting the engine, remove the

starter key. Disconnect the battery when you are not
using electrical power. If you do not take these
precautions you could be killed or injured.
AZ
8-3-1-1
!MWARNING
Make the machine safe before getting beneath it. Park
the machine on level ground and lower the
attachments. Stop the engine and remove the starter
key. Make sure the park brake is engaged. Disconnect T015850-1
the battery to prevent the engine being started. Block Fig 1.

all four wheels before getting under the machine.
BR
3-3-1-1
Make the machine safe before you start a maintenance C C

procedure.
Refer to all of the warnings and information in the Safety

Notices topic. K Related Topics ( T 2-2-3)
When lifting a machine make sure the jack is positioned on

the correct point. On a Loadall these are on the front and 320610-C1
rear axle casings C. Fig 2.
Note: Before jacking the rear axle make sure the axle has You can complete most of the maintenance procedures
wedges added between the axle and the chassis with the boom lowered (Position A). Unless a maintenance
B
oscillation stop to stop the axle from oscillating. procedure instructs you differently, you must lower the
boom. Refer to How to Make the Machine Safe (Boom
Ensure the jack is placed on a firm and level surface and Lowered).
that the jack is of a suitable capacity for the load. Only jack
one point at a time. If you lift the boom to get access for maintenance (Position
JC
B), you must install the maintenance strut on the boom.

Refer to How to Make the Machine Safe (Boom Lifted).
Important: Until the hydraulic pressure is fully released on

550-80 machines the boom lower and retract service are
still operative when the engine is not running. Make sure
2-2-4 2-02-06 Issue 01 2-2-4

General Procedures
that the boom is lowered or supported fully on the safety
strut.
1 Position the machine on firm level ground. If possible

choose an area that is clean and dry. When possible
park the machine in a covered area if procedures
include work on the hydraulic or fuel systems.
2 Lower attachments to the ground and if necessary,

remove them. Refer to the correct documents and
procedures.
IL
3 If necessary install the boom safety strut. K Boom
Safety Strut (P1) ( T 2-2-6)
4 Stop the engine and apply the park brake.
5 Vent the hydraulic pressure. K Venting the
AZ
Hydraulic Pressure ( T 2-2-12)
6 If necessary vent the brake system pressure (550-80

and 527-58 machines). K Venting the Brake
System Pressure ( T 2-2-14)
7 Remove the starter key.
8 Let the machine cool sufficiently before you do work

on, or near to, the engine or hydraulic system.
BR
1 If procedures include work on the electrical system
disconnect the battery. K Battery Disconnection/
Connection ( T 2-2-20)
!MWARNING
Communications
Bad communications can cause accidents. If two or
more people are working on the machine, make sure
each is aware of what the others are doing. Before
starting the engine make sure the others are clear of
the danger areas; examples of danger areas are: the
B
rotating blades and belt on the engine, the

attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or injured if
these precautions are not taken.
INT-3-1-5
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2-2-5 2-02-06 Issue 01 2-2-5

General Procedures
Boom Safety Strut (P1)
Note: If you lift the boom to get access for maintenance,

you must install the maintenance strut on the boom.
Note: The stowage position of the Boom Safety strut

varies according to machine model/variant. All possible
strut stowage positions A are shown in the following
figures:
IL
– K Fig 3. ( T 2-2-6)
– K Fig 4. ( T 2-2-6)
– K Fig 5. ( T 2-2-6)
– K Fig 6. ( T 2-2-6)
AZ
807540-1
Fig 4.
BR
T012120-2
Fig 5.
B
C093690
Fig 3. 527-58 Machines
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266520-B1
Fig 6.
2-2-6 2-02-06 Issue 01 2-2-6

General Procedures
Installing
!MWARNING
You could be killed or injured if the boom drops while
you are working under it. Fit the safety strut as
instructed before doing any maintenance work with
the boom raised.
Keep people away from the machine while you fit or

remove the strut.
IL
5-3-1-2_1
Before installing the safety strut remove any load on the

forks and make sure that buckets or attachments are
263560-B1
empty. Fig 7.
AZ
1 Fully retract the boom (unless it necessary to extend
it for maintenance). Lift the boom sufficiently to install
the strut.
2 Stop the engine. Make sure the park brake is

engaged and the transmission is in neutral. Remove
the starter key.
!MCAUTION
You will have to climb onto the machine to fit or
BR
remove the strut. Take care, especially if the machine
is wet. Remove mud and oil before climbing onto the
machine. Do not use the exhaust as a handhold. It can
burn you.
5-3-1-4_1
3 Remove the strut from its stowage position A.
4 Put the strut B around the lift ram piston rod. Use the
strap to attach it to the ram piston rod.
5 To prevent boom creeping down and causing injury

the boom must be lowered onto the strut.
B
Note: Lower the boom carefully, to prevent possible

damage to the strut. Stop as soon as the weight of the
boom is on the strut.
JC
6 Disconnect the battery to prevent accidental

operation of the engine.
7 If necessary, put chocks against the two sides of the

wheels before you get below the machine.
2-2-7 2-02-06 Issue 01 2-2-7

General Procedures
Removing
!MWARNING
you are working under it. Fit the safety strut as
instructed before doing any maintenance work with
the boom raised.

remove the strut.
IL
5-3-1-2_1
1 Lift the boom to remove the weight from the strut.
2 Stop the engine. Make sure the park brake is

engaged and the transmission is in neutral. Remove
AZ
the starter key.
!MCAUTION
burn you.
5-3-1-4_1
BR
3 Remove the strut.
4 Attach the strut to its stowage position.

B
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2-2-8 2-02-06 Issue 01 2-2-8

General Procedures
Note: If you lift the boom to get access for maintenance, 4 Lower the strut C so that the cut out E locates with the
you must install the maintenance strut on the boom. pipe on the lift ram.
Installing the Maintenance Strut Place the strut C around the lift cylinder piston rod D.
Secure the strut in position with hand bolt B.
!MWARNING 5 Lower the boom carefully onto the strut. Stop as soon
You could be killed or injured if the boom drops while as the weight of the boom is on the strut.
IL
you are working under it. Fit the boom maintenance
strut as instructed before doing any maintenance
work with the boom raised.

remove the boom maintenance strut.
AZ
5-3-1-2_2
1 Park the machine on level, solid ground with the

wheels in the straight ahead position.
If necessary, refer to Stopping and Parking the

Machine.
Remove loads from the forks and empty buckets or

attachments.
BR
2 Fully retract the boom.
Raise the boom just far enough to install the strut C.
Stop the engine and remove the starter key.
!MCAUTION
burn you.
B
5-3-1-4_1
3 Use the steps A for access to the strut. Undo the hand
bolt B and remove the strut from its stowage position
X.
JC
Note: Some machines have two steps on the chassis and

no step on the axle.
2-2-9 2-02-06 Issue 01 2-2-9

General Procedures
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AZ
BR
C084250
Fig 8.
B
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2-2-10 2-02-06 Issue 01 2-2-10

General Procedures
Removing the Maintenance Strut
!MWARNING
you are working under it. Fit the boom maintenance
strut as instructed before doing any maintenance
work with the boom raised.

remove the boom maintenance strut.
IL
5-3-1-2_2
1 Park the machine on level, solid ground with the

wheels in the straight ahead position.
If necessary, refer to Stopping and Parking the
AZ
Machine.
2 Raise the boom just enough to allow the strut to

removed.
3 Stop the engine and remove the starter key.
!MCAUTION
BR
burn you.
5-3-1-4_1
4 Use the steps A for access and support the strut C.

Undo the hand bolt B and lift the strut clear of the steel
pipe on the lift ram.
Note: Some machines have two steps on the chassis and

no step on the axle.
5 Secure the strut with hand bolt B in its stowage C084260

B
position X. Fig 9.
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2-2-11 2-02-06 Issue 01 2-2-11

General Procedures
Venting the Hydraulic Pressure
!MWARNING Note: Make sure that the pressure is vented correctly.

Electrical and pilot services have a limited amount of
Hydraulic Pressure accumulated pressure available for venting.
Before disconnecting or connecting hydraulic hoses 3 If necessary, open rear cover A to get access to the
or couplings, vent the pressure trapped in the hoses in filler cap B. Refer to Section 3 - Access Panels,
accordance with the instructions given in this Rear Cover (if fitted).
publication.
IL
HYD-1-5 4 Clean the top of the tank around the filler cap B.
Important: This procedure is only to be used before

disconnecting hydraulic hoses. Before removing other
!MCAUTION
hydraulic components refer to the correct Removal Allow the hydraulic fluid temperature to cool before
procedure. removing the hydraulic tank filler cap. Open the cap
slowly to prevent oil being forced out of the filler neck.
AZ
1 Make the machine safe with the boom lowered. Refer 5-3-4-8
to Prepare the Machine for Maintenance.
2 Operate the controls to remove the hydraulic

!MCAUTION
pressure from the service hose lines. The procedure Do not run the engine with the hydraulic tank filler cap
varies according to machine model/variant: removed.
5-3-4-1
a 550-80 machines - turn the starter key to the ON
position. 5 Slowly remove filler cap B to allow the system to vent
fully and prevent oil being forced out of the filler neck.
BR
Important: Until the hydraulic pressure is fully released
the boom lower and retract service are still operative when
the engine is not running. Make sure that the boom is
lowered or supported fully on the safety strut. K Parking
the Machine and Making it Safe ( T 2-2-4)
Operate the boom raise/lower hydraulic services

until the pressure is released.
b Manually operated hydraulic services - operate

the controls of the service to be disconnected.
c Electrical and servo operated hydraulic

B
services -turn the starter key to the ON position.

A710870-5
Operate the controls of the service to be Fig 10. Machines with External Sight Gauge
disconnected.
Important: To release the hydraulic pressure from the

JC
550-80 machines and electrical/servo operated services

the battery must be connected while you operate the
controls.
2-2-12 2-02-06 Issue 01 2-2-12

General Procedures
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732370-5
Fig 11. Machines without External Sight Gauge
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BR
B
JC
2-2-13 2-02-06 Issue 01 2-2-13

General Procedures
Venting the Brake System Pressure
Venting the Brake System Pressure
!MWARNING
Hydraulic Pressure
Before disconnecting or connecting hydraulic hoses
or couplings, vent the pressure trapped in the hoses in
accordance with the instructions given in this
publication.
IL
HYD-1-5
Important: Important, this operation MUST be carried out

before any attempt is made to disconnect hydraulic
connections, including the brake pressure switch.
1 Park the machine and make it safe. K Parking the
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Machine and Making it Safe ( T 2-2-4).
2 If necessary install the boom safety strut. K Boom

Safety Strut (P1) ( T 2-2-6). Stop the engine.
3 Turn the starter key switch to ON but do not start the

engine.
4 Press the brake pedal until there is no resistance felt.

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Note: This may take several pumps, depending on the
length of time since the engine was last run.
5 Turn the starter switch to the OFF position and

remove the key.
B
JC
2-2-14 2-02-06 Issue 01 2-2-14

General Procedures
Connecting/Disconnecting Hydraulic Hoses
Connecting/Disconnecting Hydraulic Hoses
Introduction Disconnecting the Hoses

The following paragraphs describe how to connect and 1 Disconnect the hoses.
disconnect hydraulic hoses safely.
a For Quick Release Couplings see the procedures
Make sure to park the machine and make it safe. Obey the in this section. K Quick Release
care and safety procedures. Couplings ( T 2-2-16)
IL
Vent the hydraulic and/or braking pressure as applicable. b For all other hose connections, plug both sides of
K Venting the Hydraulic Pressure ( T 2-2-12) the connection to prevent loss of fluid.
K Venting the Brake System Pressure ( T 2-2-14)
2 Check for leaks. See step 2, K Connecting the
Connecting the Hoses Hoses ( T 2-2-15)
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1 Connect the hoses.
a For Quick Release Couplings refer to the correct

data. K Quick Release Couplings ( T 2-2-16)
b For all other hose connections, use correct tools

and ensure that connections are not cross-
threaded. Support the weight of the hose until the
connection is made. Do not exceed the
recommended torque loading.
BR
!MWARNING
Fluid Under Pressure
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses and gloves.
Hold a piece of cardboard close to suspected leaks
and then inspect the cardboard for signs of fluid. If
fluid penetrates your skin, get medical help
immediately.
INT-3-1-10_3
2 Check for leaks as follows:

B
a Start the engine.
b Operate the controls to pressurise the required

hose.
JC
c Switch off the engine. Remove the starter key.

Check for signs of leakage at the hose
connections.
2-2-15 2-02-06 Issue 01 2-2-15

General Procedures
Quick Release Couplings

T4-001_2
Connecting and Disconnecting wedge underneath the sleeve and destroy the
coupling.
Flat face quick release couplings allow the operator to – Don't damage the faces of the couplings - this can
remove and install attachments swiftly and efficiently. prevent connection and disconnection, or damage
Generally, your machine pipework will be fitted with a seals and cause leakage.
female coupling A and a male coupling B. The optional – Don't try to dismantle the couplings - they are non
attachment hoses will also be fitted with a female coupling serviceable parts. If a coupling is damaged it should
A and a male coupling B. K Fig 12. ( T 2-2-17).
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be replaced with a new one.
!MWARNING
The quick release couplings should be trouble free and
relatively easy to connect and disconnect, provided they
are kept clean and used correctly. The recommendations Hydraulic fluid at pressure can injure you. Make the
listed below should always apply when using flat face machine safe before connecting or disconnecting
quick release couplings. quick release couplings; stop the engine and then
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operate the attachment control a few times to vent
Finally, please read the correct fitting and releasing residual hydraulic pressure in the attachment hoses.
procedures before installing or removing any optional
2-4-1-11
attachment fitted with quick release couplings.
Quick Release Couplings - Do's and Don'ts !MWARNING

The external surfaces of the couplings must be clean
– Do wipe the two faces of the coupling and make sure before connecting or disconnecting. Ingress of dirt
they are clean before connecting. will cause fluid leaks and difficulty in connecting or
– Do make sure the outside sleeve (female coupling) is disconnecting. You could be killed or seriously injured
BR
pulled back when disconnecting. by faulty Quick Release Couplings.
– Do connect and disconnect a new coupling two or 2-4-1-15
three times to 'work' the PTFE seals - sometimes a
new coupling will stick if the seals have not been Before connecting or removing any hydraulic hose,
'worked'. residual hydraulic pressure trapped in the service hose line
must be vented. Make sure the hose service line has been
– Do use a spanner on the hexagon flats of the coupling
vented before connecting or removing hoses.
when fitting adaptors.
– Do use a rubber or hide hammer to disconnect a
coupling if it sticks - sticking may occur if there is dirt
present in the coupling.
– Don't attempt to re-connect a damaged half coupling
- this will destroy the seals and necessitate replacing
B
both half couplings.

– Don't leave the coupling where it may be run over by
a machine or otherwise crushed - this will distort the
coupling sleeve and prevent correct connection and
disconnection.
JC
– Don't clamp on the smooth diameter of the coupling

when fitting adaptors - always use the hexagon.
– Don't try to turn the sleeve (female coupling) when the
coupling has been disconnected - the locking ball will
2-2-16 2-02-06 Issue 01 2-2-16

General Procedures
Connecting Quick Release Couplings
1 Remove any residual hydraulic pressure trapped in

the service line hose.
2 Wipe the two faces of the male and female couplings

and make sure they are clean.
3 Make sure that ball 12-C in the female coupling is

located in one of its slots.
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4 Fit the male coupling into the female coupling; To
ensure that the coupling is not accidentally released,
rotate sleeve 12-E half a turn and make sure that the
locking ball 12-C does not align with the slot 12-D.
Disconnecting Quick Release Couplings
AZ
1 Remove any residual hydraulic pressure trapped in
the service line hose.
2 Align the slot 12-D with ball 12-C.
3 Pull back sleeve 12-E to release the coupling.

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B
Fig 12.
JC
2-2-17 2-02-06 Issue 01 2-2-17

General Procedures
Hydraulic Contamination
TE-002_3
Hydraulic Fluid Quality Procedure
This machine uses a large volume of fluid in the hydraulic Connect the cleaning unit in place of the hydraulic filter.
system for power transmission, equipment lubrication, rust K Fig 13. ( T 2-2-18). Run the system for sufficient time to
prevention and sealing. According to a survey conducted pump all the hydraulic fluid through the unit. Disconnect
by a pump manufacturer, seventy per cent of the causes of the cleaning unit and reconnect the filter. Top up the
problems in hydraulic equipment were attributable to system with clean hydraulic fluid as required.
inadequate maintenance of the quality of the hydraulic
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fluid. Therefore, it is obvious that control of the quality of
the hydraulic fluid helps prevent hydraulic equipment
problems and greatly improves safety and reliability.
Furthermore from an economic angle it extends the life of
the hydraulic fluid if quality is maintained.
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Effects of Contamination
Once inside the system, hydraulic circuit contaminants
greatly effect the performance and life of hydraulic
equipment. For example, contaminants in a hydraulic
pump develop internal wear to cause internal leakage and
hence lower discharges. Wear particles generated will
circulate with the hydraulic fluid to cause further
deterioration in the performance of this and other
equipment. Contaminants also enter principal sliding
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sections of the equipment causing temporary malfunction,
scuffing, sticking and leakage and can lead to major
problems.The main contaminants can be classified as
follows:
S168050-1
1 Solid Particles - sand, fibres, metallic particles, Fig 13. Cleaning Unit
welding scale, sealing materials and wear particles
etc.
2 Liquid - usually water and incompatible oils and

greases.
3 Gases - Air, sulphur dioxide etc. which can create

corrosive compounds if dissolved in the fluid.
B
These contaminants can appear during manufacture,

assembly and operation.
Cleaning Operation
JC
The purpose of cleaning oil is to remove contaminants of

all types and sludge by filtering hydraulic fluid through a
cleaning unit. K Fig 13. ( T 2-2-18). General Bulletin 011
also refers.
2-2-18 2-02-06 Issue 01 2-2-18

General Procedures
Contaminant Standards
Dirt that damages your system is in many cases too small
to be seen with the eye. The particle size is measured in
microns.
1 micron = 0.001 mm (0.0000394 in).
Listed below are a few typical comparisons:
– Red Blood Cell = 8 microns (0.008 mm, 0.000315 in)
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– Human Hair = 70 microns (0.07 mm, 0.00275 in)
– Grain of Salt = 100 microns (0.1 mm, 0.00394 in)
Smallest particle visible to the naked eye is 40 microns

(0.00157) approximately.
AZ
Standards will often be quoted to ISO (International
Standards Organisation) for which literature can be
obtained.
Filters
The filter assembly fitted to all product ranges is designed
to filter all the contamination that is generated through use
to the required level of cleanliness. The filter must be
serviced to the requirements of the machine Service
BR
Schedules.
To ensure optimum performance and reliability it is

important that the machines hydraulic system is serviced
periodically in accordance with the manufacturers
requirements.
B
JC
2-2-19 2-02-06 Issue 01 2-2-19

General Procedures
Battery Disconnection/Connection
Battery Disconnection/Connection
!MWARNING
Keep metal watch straps and any metal fasteners on
your clothes, clear of the positive (+) battery terminal.
Such items can short between the terminal and nearby
metal work. If it happens you can get burned.
5-2-2-4
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Disconnection
1 Park the machine and make it safe. Obey the care
and safety procedures.
2 Get access to the battery. Refer to Section 3 -
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Access Panels. K Related Topics ( T 2-2-3)
3 Remove the leads. Disconnect the earth (-) terminal

first.
Connection
1 Check the battery.
a If the terminal is dirty, clean the post.

BR
797650
Fig 14.
b If the terminal post is corroded and generates

B
white powder wash the terminal with hot water. If

considerable corrosion is detected, clean with a
wire brush or abrasive paper.
c After cleaning, apply a thin coat of petroleum jelly

JC
to the terminal.
2 Re-connect the leads. Connect the earth (-) terminal

last.
3 Close and lock the access panels.
2-2-20 2-02-06 Issue 01 2-2-20

General Procedures
Battery Charging System Precautions
Battery Charging System Precautions
Obey the procedures below to prevent damage to the

alternator and battery.
1 Ensure that the battery negative terminal is

connected to the earthing cable.
2 Never make or break connections to the battery or

alternator, or any part of the charging circuit whilst the
IL
engine is running. Disregarding this instruction will
result in damage to the regulator or rectifying diodes.
3 Main output cables are 'live' even when the engine is

not running. Take care not to earth connectors in the
moulded plug if it is removed from the alternator.
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4 When arc welding on the machine, protect the
alternator by removing the moulded plug (or if
separate output cables fitted, remove the cables).
5 If slave starting is necessary, connect the second

battery in parallel without disconnecting the vehicle
battery from the charging circuit. The slave battery
may then be safely removed after a start has been
obtained. Take care to connect batteries positive to
positive, negative to negative.
BR
B
JC
2-2-21 2-02-06 Issue 01 2-2-21

General Procedures
Removing and Replacing Components
Introduction
T3-062_2
!MCAUTION
Clean the machine using water and or steam. Do not allow The engine or certain components could be damaged
mud, debris etc. to build upon the machine. by high pressure washing systems; special
precautions must be taken if the engine is to be
Before carrying out any service procedures that require washed using a high pressure system.
components to be removed:
Ensure that the alternator, starter motor and any other
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1 Cleaning must be carried out either in the area of electrical components are shielded and not directly
components to be removed or, in the case of major cleaned by the high pressure cleaning system.
work, or work on the fuel system, the whole engine ENG-3-3
and surrounding machine must be cleaned.
Important: Do not aim the water jet directly at bearings, oil
2 When cleaning is complete move the machine away seals or electrical and electronic components such as the
engine electronic control unit (ECU), alternator or fuel
AZ
from the wash area, or alternatively, clean away the
material washed from the machine. injectors.
Important: When removing components be aware of any Use a low pressure water jet and brush to soak off caked
dirt or debris that may be exposed. Cover any open ports mud or dirt.
and clean away the deposits before proceeding.
Use a pressure washer to remove soft dirt and oil.
Detergents
Note: The machine must always be greased after
Avoid using full strength detergent - always dilute pressure washing or steam cleaning.
detergents as per the manufacturer's recommendations,
BR
otherwise damage to the paint finish may occur. Original Components
Always adhere to local regulations regarding the disposal Always Install new oil seals, gaskets, etc.
of debris created from machine cleaning.
Components showing obvious signs of wear or damage
Pressure Washing and Steam Cleaning should be replaced with new ones.
!MWARNING Before re-installing original components do the following:
When using a steam cleaner, wear safety glasses or a – Clean components using the applicable cleaning
face shield as well as protective clothing. Steam can materials.
cause serious personal injury. – Inspect components for signs of excessive wear or
defects.
B
13-3-2-10_2
– Check the component specifications such as wear
limits where applicable.
New Components
JC
Ensure that the correct new components are installed. Do

not substitute components from another machine.
Components may look the same but may not be
interchangeable. Refer to the JCB parts systems.
2-2-22 2-02-06 Issue 01 2-2-22

General Procedures
Torques and Fixings

When replacing components always tighten the applicable
fixings to the correct torque. For the torque setting to be
effective do the following before installing the fixings:
– Ensure that all the applicable component assemblies

are correct.
– Ensure that the applicable fixings are to the correct
specification. If necessary discard the original fixings
and replace them with new ones. The relevant
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procedures indicate when this is necessary.
– Ensure that the applicable fixings and threaded holes
are free from contamination. This includes; dirt,
debris, old sealants and compounds, fluids and
lubricants.
AZ
This manual provides reference to the correct torque
settings as follows:
– Where no torque setting is given in the applicable

procedure, use the standard torque setting. To obtain
the correct standard torque setting refer to Section 1
- Torque Settings.
– Where torque settings are given in the applicable
procedure use the settings given. These settings may
be different to the standard torque settings in the case
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of special fixings for example.
B
JC
2-2-23 2-02-06 Issue 01 2-2-23

General Procedures
Hydraulic Rams
Hydraulic Rams
Installation c The number one cause of ram oil leakage is rod

damage. Be careful not to damage the rod.
1 Precautions when installing the ram on the machine.
2 Warm up sufficiently before beginning work.
a When installing and removing from the machine,
suspend the ram safely. a In cold conditions the rod seals may be frozen, so
if the ram is operated at maximum pressure and
b Suspending the ram by the piping is not only maximum speed, the seals will be damaged.
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dangerous, but can also cause damage to the
cylinder. b There is a large amount of air in a new ram or one
which has been left for a long time, so the ram will
c Secure the piston rod with a band. It is very not operate smoothly. Also, if pressure is applied
dangerous if the rod extends unexpectedly. Also, suddenly without bleeding the air, high
the rod can be damaged and become unusable. temperatures will be generated due to adiabatic
compression and the seals may burn.
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2 Welding after installing the ram may result in damage.
c Before beginning work, always move the ram at
a If electric welding is done even at a point away full stroke with no load and expel air from the
from the ram, there may be sparking inside the cylinder.
ram and it will become necessary to replace the
ram with a new one. 3 When stopping or storing, do it at a safe and fixed
position.
3 When painting the machine, mask the ram.
a The installed ram cannot maintain the same
a If paint adheres to the rod surface or to the wiper position for a long period of time, because the oil
BR
ring and the ram is operated, the wiper ring will not inside the ram may leak and the hydraulic oil
function properly and foreign matter and paint can volume decreases as it cools. Stop or store the
easily enter the ram. This will cause damage to machine in a safe and fixed position.
the seals, drastically shortening the life of the ram.
Maintenance, Inspection Points
4 Install the ram only when it is clean.
1 Carry out daily maintenance and inspection.
Caution During Use
a The key point for correct long-term ram function is
1 Use only under designated conditions. daily maintenance and inspection. Carry out
maintenance and inspection so that the ram
a If hydraulic oil other than the designated oil is functions fully at all times. Always remove any
used, the seals quickly degenerate and become mud, water, dust or oil film adhering to the rod and
B
damaged. If the relief valve is set at a value higher keep it in normal condition. However, when
than specified, it may cause ram damage and is cleaning the wiper ring and seals, do not get them
dangerous. wet with water but wipe clean with a rag. To
prevent rust forming during storage, the amount of
b In high temperature environments (approx. 90°C exposed ram piston rod should be kept to a
JC
and above) or low temperature environments minimum. If leaving for more than one week,
(below -20°C), seals quickly become damaged. apply a light coating of suitable grease or
Special seal materials are necessary so check to petroleum jelly to the exposed part of the ram
see if the ram that you are using is suitable or not. piston rod.
2 Use genuine JCB parts when replacing parts.
2-2-24 2-02-06 Issue 01 2-2-24

General Procedures
Hydraulic Rams
a If parts other than genuine JCB parts are used,
the desired results may not be obtained. Use only
genuine JCB parts.
3 Caution during dismantling and reassembly.
a Dismantling the ram while it is still installed on the

machine can be dangerous as unexpected
movements of the machine can occur. Remove
the ram from the machine and then dismantle.
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b If reassembled with dirty hands, foreign matter
can enter the ram causing a shorter life span and
also the other hydraulic equipment may be
damaged. Reassemble in a clean state.
c Follow the instructions in the diagrams regarding

torque tightening for screwed parts. If the torque is
AZ
too high or too low, it can cause damage.
BR
B
JC
2-2-25 2-02-06 Issue 01 2-2-25

General Procedures
Gas Hydraulic Bladder Accumulators
Some hydraulic/transmission and or braking circuits and

valve blocks are fitted with gas hydraulic bladder type
!MWARNING
accumulators. Use only nitrogen gas to charge accumulators. The
use of any other gas can cause the accumulators to
Before removing accumulators make sure hydraulic explode. Remember that although nitrogen is not
pressure is vented. K Venting the Hydraulic poisonous you can be killed by suffocation if it
Pressure ( T 2-2-12) K Venting the Brake System displaces the air in your workplace. Do not allow
Pressure ( T 2-2-14) excessive quantities of nitrogen to be discharged into
IL
the atmosphere.
Even when the hydraulic pressure is vented the B-3-1-6
accumulator still contains pressurised nitrogen gas. DO
NOT attempt to discharge the gas pressure.
DO NOT transport accumulators charged with pressurised

gas by air freight.
AZ
2
Replacement 1
8
Replacement accumulators are generally supplied in a
discharged state with no nitrogen gas. A label attached to
the accumulator indicates the gas charge state.
3
Charging 4
K Fig 15. ( T 2-2-26) 7
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5
6
Important: The following charging procedure is only
applicable to accumulators supplied in a discharged state.
To carry out the charging procedure the following is

required:
– Pressurised bottle of nitrogen gas with a suitable

pressure reducing valve (3).
– Correct gas bottle adaptor depending on territory. C110540-C2
Fig 15.
– Charging kit 892/00239. Refer to Section 1.
1 Hold the accumulator upright and remove the plastic
B
Operating charge pressures; accumulators are charged

cap from the top of the accumulator.
to different operating pressures depending on the
application. For the correct charge pressure refer to the
Note: Some accumulators are supplied with a measured
applicable system specifications.
quantity of oil inside the gas chamber. Take care to prevent
oil loss.
JC
Before fitting a replacement accumulator charge it with

nitrogen gas as follows:
2 Using a suitable allen key, slowly remove the filler
plug 2.
Lightly oil the sealing washer beneath. Replace the

washer and plug. Loosen the plug by 1/8 of a turn.
2-2-26 2-02-06 Issue 01 2-2-26

General Procedures
3 Connect the accumulator adaptor 1 (from kit 892/
00239) to the accumulator. Connect the charging unit
6 to the accumulator adaptor.
Connect the charging hose to the pressure regulator

3 using the correct adaptor.
Set the pressure regulator 3 to the minimum

pressure.
4 Via the charging tool knob 7, open the filler plug 2 by 9
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three turns.
5 Open the discharge valve 5 on the charging unit.

10
Carefully open the nitrogen gas bottle valve 4 and 11
confirm that the nitrogen gas flows freely.
AZ
Shut the gas bottle valve and the discharge valve 5.
6 Carefully open the gas bottle valve. Slowly increase

the pressure using the gas bottle pressure regulator
C110550-C1.eps
and watching the gauge 8 on the charging unit, allow
Fig 16.
nitrogen to flow until the pressure reading reaches 4
bar (72.5 psi) ABOVE the operating charge pressure.
12 K Fig 16. ( T 2-2-27) Remove the discharged state
label 10 and attach the pressurised warning label 11
Important: DO NOT exceed the maximum working
at position 9 on the accumulator.
pressure of the accumulator. The maximum working
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pressure is marked on the accumulator body.
Install the accumulator and make sure the
pressurised warning label is clearly visible.
Close the gas bottle valve.
7 Wait 10 minutes to dissipate the heat generated

during charging.
8 Reduce the pressure in the accumulator to the

specified operating charge pressure by carefully
opening and closing the discharge valve 5. Turn the
knob 7 to shut the filler plug 2 and tighten to a torque
of 20 Nm (15 lb ft).
B
9 Release the pressure from the charging hose by

opening the discharge valve 5.
Disconnect the charging unit and adaptor from the

accumulator.
JC
10 Check the gas-tightness of filler plug 2 by pouring

some oil around it.
11 Replace the plastic cap.
2-2-27 2-02-06 Issue 01 2-2-27

General Procedures
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B
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2-2-28 2-02-06 Issue 01 2-2-28

Service Procedures
Introduction
The manplatform control systems are safety critical

installations. Before carrying out service and maintenance
procedures make sure that you understand how the
relevant systems and components operate. Refer to the
Hydraulic and Electrical systems topic.
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K Electrics ( T 51), K Hydraulics ( T 159)
Make sure to obey the Safety Notices and General

Procedures in this manual. K Safety Notices ( T 1),
K General Procedures ( T 1)
AZ
Important: Auxiliary electrical equipment must not be
wired into the machine electrical system without first
contacting a JCB dealer for advice on the connection
location. Connection of auxiliary items into the electrical
system of the machine may impair system operation or
leave machine inoperable.
BR
B
JC
29 9813/1400-1 29
Service Procedures
RCU Engine Start Procedure
RCU Engine Start Procedure
When in remote mode and the RCU is left on with the

engine running, the RCU will switch itself off if it is not
operated within 10 minutes. Press the RCU ON Button B.
The machine should activate the audible alarm for 3 H B C radiomatic
LED 1 LED 2
beeps.
I
SPARE 1
SPARE 2
If there are not 3 beeps when the Safety Key is inserted
SPARE 3
into the RCU the check the following:
SPARE 4
0
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AUTO
FULL
– Make sure that the Safety Key is fully and correctly
screwed into the RCU.
– Make sure that the park brake is on.
– Make sure that the stabilisers are down and the
stabiliser warning lights are on to show the machine
AZ
weight is supported.
– Make sure that the machine is in neutral.
– Make sure that the RCU is docked correctly on the
work platform.
– Make sure that the Emergency Stop buttons in the
cab and on the platform are not depressed.
– If the yellow LED is illuminated on the platform, then
weight on the platform is too great and it has cut out.
– Check for any fault codes on the instrument panel
A B C D
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display.
Press the and hold the buttons A and C to start the engine. C116120-C1
Fig 17.
To stop the engine press switch D.
B
JC
30 9813/1400-1 30
Service Procedures
Fault Finding
Fault Finding
Introduction
The JCB personnel platform operating system has several
interlocks and safety systems. When fault finding make
sure you understand how to operate the system correctly.
Refer to the correct Operator Manual. K About this
Supplement ( T 1)
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The fault finding procedures are given in the form of tables.
The tables are designed to identify possible causes by
performing checks. The tables are designed to identify
causes through a process of elimination, starting with the
simplest, most easily rectified faults.
AZ
The JCB ECU receives inputs via a CAN bus system. The
dual CAN bus system used to convey the signals has a
self-diagnostic capability and will fail safe by isolating the
fault and stopping the engine. By use of the JCB
Servicemaster Manplatform Diagnostics tool the engineer
can quickly identify faults with specific electrical circuits or
devices. K Loadall Machine Diagnostics - User
Guide ( T 35)
Note: When fault finding DO NOT use a multi meter on

ECU connector pins. Only test the associated wires and
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connectors.
Tables
K Remote Control Faults ( T 32)
K Engine Faults ( T 32)
K Hydraulic Service Faults ( T 33)
B
JC
31 9813/1400-1 31
Service Procedures
Fault Finding
Tables
Table 3. Remote Control Faults
Possible Cause Action
Remote control unit (RCU) does not Safety Key not correctly installed in Select remote mode by transferring
operate or engine fails to start from RCU Safety Key to RCU
RCU Cab isolation button pressed Release isolation button
Stabilisers not lowered Lower stabilisers and make sure that
the Stabiliser Down indicator lights
illuminate.
IL
Park brake not set to ON Set park brake to ON
Column FNR lever not set to Neutral Set FNR lever to Neutral
Ignition set to OFF Set ignition to ON
RCU emergency stop button pressed Release stop button
Platform emergency stop button Release stop button
AZ
pressed
Incorrect RCU engine start procedure Follow the correct procedure. K RCU
Engine Start Procedure ( T 30)
RCU battery low Charge or replace battery as
applicable
Cab isolation switch fault Check switch function and associated
wires and connectors
Platform isolation switch fault Check switch function and associated
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wires and connectors
Stabilizer switch fault Check switch function and associated
wires and connectors.
Park brake switch fault Check switch function and associated
wires and connectors.
Overloaded Platform (Yellow Light Reduce weight on platform.
illuminated on RCU)
Receiver fault Check wires and connectors between
receiver and ECU.
RCU not correctly installed in platform The RCU and platform dock have a
dock magnetic switch which informs the
machine that the RCU is correctly
B
docked. The RCU will not operate if not

correctly docked.
Other electrical system fault Check for fault codes on the instrument
panel display.
JC
Table 4. Engine Faults

Engine stops and will not restart Starting procedure incorrect (starting Follow correct procedure. K RCU
from the RCU) Engine Start Procedure ( T 30)
32 9813/1400-1 32
Service Procedures
Fault Finding

panel display.
Receiver fault Check wires and connectors between
receiver and JCB ECU.
Engine stops periodically when Safety system operation If the RCU is not operated during a 10
machine is in remote operation minute period the engine automatically
stops for safety reasons (no fault)
Engine speed restricted Engine speed actuator faulty Adjust actuator.
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Table 5. Hydraulic Service Faults
One or more boom services start/ Control sensitivity setting incorrect Use JCB Servicemaster to set
stop too slowly hydraulic sensitivity correctly.
K Manplatform Calibration - User
Guide ( T 36)
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panel display.
One or more boom services start/ Control sensitivity setting incorrect Use JCB Servicemaster to set
stop too suddenly hydraulic sensitivity correctly.
K Manplatform Calibration - User
Guide ( T 36)
panel display.
Platform will not tilt. Tilt only operative when boom angle is Lower boom.
BR
below 10º
panel display.
Platform slew function operates too Needle valve setting incorrect Adjust needle valve to give correct ram
slowly or too fast operating speed.
panel display.
Platform slew function does not Platform Slew Locks engaged Disengage the platform slew locks
operate
B
JC
33 9813/1400-1 33
Service Procedures
Servicemaster Tools
Servicemaster Tools
Table 6.
Tool Icon Description User Guide
Loadall Machine Perform manplatform set up, K Loadall Machine
Diagnostics calibration and diagnostics Diagnostics - User
Guide ( T 35),
IL
Fig 18.
Manplatform Calibration Enables machine load control and K Manplatform Calibration -
motion cut out system for use with User Guide ( T 36)
manplatform control system
AZ
Manplatform LCS Enable Enables machine load control and K Manplatform Enable -
motion cut out system for use with Machines with LLMC or
manplatform control system MC ( T 49)
BR
B
JC
34 9813/1400-1 34
Service Procedures
Loadall Machine Diagnostics - User Guide
Loadall Machine Diagnostics - User Guide
For details of the Loadall Machine diagnostics and

Servicemaster Operation refer to the Loadall Service
Manual:
– 9813/0950 for machines with Tier 3 Engine.
IL
AZ
BR
B
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35 9813/1400-1 35
Service Procedures
Manplatform Calibration - User Guide
IL
Introduction AZCare and Safety
C032980
BR
The Manplatform Calibration software tool is part of the
JCB Servicemaster software suite.
!MWARNING
Be sure to read and follow any on screen instructions.
Note: This software also incorporates diagnostics for the Failure to follow correct procedure could result in
JCB platform. Refer to the correct part of the manual for death or injury.
diagnostics procedures. 2-4-5-5
Note: This software guide is universal and some functions Installing Manplatform Calibration
may not be available on particular machine variants.
The Manplatform Calibration tool is fully integrated within
This software is intended for use on IBM Compatible JCB Servicemaster. To use Manplatform diagnostics you
Personal Computers (PCs) running Windows 9x, must install JCB Servicemaster onto a suitable laptop
B
Windows2000 and WindowsXP operating systems but is computer. Refer to the Loadall Machine Service Manual.
not compatible with either earlier versions of Windows 3.x.
Ideally the computer should be a laptop type. – 9813/0950 for machines with Tier 3 Engine.
JC
36 9813/1400-1 36
Service Procedures
Starting the Manplatform Calibration

Software
1 Connect a laptop computer to the machine and start
Servicemaster.
For details of the Loadall Connection Procedures and

Manual:
9813/0950 for machines with Tier 3 Engine.
IL
2 Double click on the ‘Manplatform’ icon.
K Fig 19. ( T 37)
AZ
Fig 19.
Set the ignition to ON. Switch between ‘cabin’ and ‘remote’

operation modes as applicable.
BR
B
JC
37 9813/1400-1 37
Service Procedures
Introduction Note: See the machine Service Manual for Calibration of

the LMI (Load Moment Indicator). K About this
The Calibration Procedure is divided into sections. Supplement ( T 1)
The following table shows which sections of the Calibration If calibration is to include the Load Signal, before starting
Procedure must be completed after replacing certain the job, make sure the following items are available:
electronic components. Complete the relevant sections in
the order indicated. – A test weight sufficient to allow the stability limit of the
machine to be exceeded and the back wheels lifted
off the ground.
– A stop watch.
IL
Table 7. Calibration Procedure
Component Replaced
ECU Radio Main Stabilizer Rear Axle Engine
Transmitter Joystick Joystick(1) Transducers Speed
and Actuator
AZ
Section Number Receiver
1 K Manplatform Enable
- Machines with LLMC 9
or MC ( T 49)
K Machine Model
2
Setup ( T 39) 9 9 9 9 9 9
3 K Load Signal ( T 41)
9 9
K Travel Speeds (Part
4
9 9 9
BR
1) ( T 43)
K Travel Speeds (Part
5
2) ( T 44) 9
K Hydraulic Control
6
Sensitivity ( T 46) 9 9 9
(1) Excludes 4-stage boom machines.
B
JC
38 9813/1400-1 38
Service Procedures
Machine Model Setup
IL
AZ
BR
Fig 20.
1 Open Servicemaster. d 'Cabin Joystick'

B
2 Open the software. K Starting the Manplatform The windows should be displayed as shown.
Calibration Software ( T 37) K Fig 20. ( T 39).
3 Pull down the 'Windows' menu and select the 4 Make sure that Cab control is selected and start
following: engine.
JC
a 'Setup'
b 'Internal Monitor'
c 'Connector I/O'
39 9813/1400-1 39
Service Procedures
5 Press the F8 key. The internal monitor window should 6 Select the correct machine type from the 'Setup'
display the following. K Fig 21. ( T 40). window. K Fig 22. ( T 40).
Note: If the required tab 1 is not visible in the Setup

a 'Normal'
window use the arrow buttons 2 to scroll through them.
b 'ENGINE_STARTED K Fig 23. ( T 40)
7 The 'Done!' window will be displayed.

K Fig 23. ( T 40). Click 'OK'.
IL
Fig 23.
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Fig 21. 8 The 'Store Parameters?' window will be displayed.
K Fig 24. ( T 40). If you are not sure that the correct
machine type has been set correctly, click 'No' and
repeat the settings.
Important: Ensure that the parameters are correct before

selecting 'Yes'. The machine may be disabled if the wrong
parameters have been set.
BR
Fig 24.
When the parameters are correct, select 'Yes'.
9 The machine will then shut down to allow the ECU to

accept the parameters and the 'Status! - Parameters
stored' window will be displayed. K Fig 25. ( T 40).
Select 'OK'.
B
JC
C124730 Fig 25.

Fig 22.
40 9813/1400-1 40
Service Procedures
Load Signal
1 Make sure that Cab control is selected and start
engine.
2 In the 'Setup' window, select 'Load signal'.

K Fig 26. ( T 41).
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AZ
Fig 27.
4 Pick up the test load described previously.

K Introduction ( T 38).
5 When the instruction 'Extend to NO load on rear axle'

appears, extend the boom until rear wheels lift off the
BR
Fig 26. ground. K Fig 28. ( T 41).
3 In the 'Setup' window, select `Load Calibration'.

K Fig 27. ( T 41).
Fig 28.
6 When the 'Done! - Setup' window appears.

K Fig 29. ( T 41). Select 'OK'.
B
JC
Fig 29.
7 When the instruction 'Retract to parking position'

appears, remove the test load and fully retract the
boom. K Fig 30. ( T 42).
41 9813/1400-1 41
Service Procedures
Fig 33.
Fig 30. When the parameters are correct, select 'Yes'.
8 With only forks fitted to the carriage, raise the forks A 11 The machine will then shut down to allow the ECU to
IL
to 300 mm (12 in.) above the ground. accept the parameters and the 'Status! - Parameters
K Fig 31. ( T 42). Then click on OK.
Select 'OK'.
AZ
Fig 34.
Note: Sensor 1 and Sensor 2 load values should be

similar. A value of 14000 Kg shows a transducer fault or
Fig 31.
incorrect calibration. K Fig 27. ( T 41)
9 The 'Calibration Done' window will be displayed.
BR
K Fig 32. ( T 42). Select 'OK'.
Fig 32.
10 The 'Store Parameters?' window will be displayed.

K Fig 33. ( T 42). If you are not sure that the
B
parameters have been set correctly, select 'No' and


JC
42 9813/1400-1 42
Service Procedures
Travel Speeds (Part 1)

1 Make sure that Cab control is selected and start
engine.
2 Select 'Travel Speeds' in the `Setup' window, then

select 'Up/Down speed'. K Fig 35. ( T 43). Fig 37.
a Make sure that:
i The parking brake is applied.
IL
ii The stabilizer legs are down and the machine
is levelled to the instructions in the cab.
b Remove the key and install in the RCU to select

Remote Mode.
AZ
All hydraulic functions in the cab are now
disconnected.
c Make sure that the machine isolation button in the

cab has been released (twist to release).
d Set the RCU engine speed switch to Auto.
e Make sure that the joysticks are both centralised.

Fig 35.
BR
f Press the engine start button.
3 When the instruction 'Retract and lower the boom
fully' appears, fully retract the boom and lower as 5 Move switch on the RCU to the 'Full' position.
much as possible to a position that will still allow full
extension to be achieved. K Fig 36. ( T 43). Select 6 When engine speed is correct, Set the engine speed
'OK'. switch to Auto. Engine speed will reduce to idle.
Select 'OK'. K Fig 38. ( T 43).
B
Fig 36.
Fig 38.
4 When the instruction 'From transmitter, activate Auto
mode' appears, activate auto mode as follows.
K Fig 37. ( T 43).
JC
43 9813/1400-1 43
Service Procedures
Travel Speeds (Part 2) 7 Select Out/In Speed in the Setup window.

K Fig 42. ( T 44).
1 When the instruction 'Fully raise boom and measure
time taken' appears, select boom raise on RCU and
measure time taken (in seconds) from fully lowered to
fully raised. K Fig 39. ( T 44). select 'OK'.
Note: Boom will not raise to full elevation when in remote

mode.
IL
Fig 39.
AZ
2 When instruction 'Enter the travel time' appears, enter
time in seconds. K Fig 40. ( T 44). Select ÒK'.
Fig 42.
8 When the instruction 'Extend boom fully and measure

time taken' appears, select boom extend on RCU and
measure time taken (in seconds) from fully retracted
to fully extended. K Fig 43. ( T 44). select 'OK'.
BR
Fig 40.
3 When the instruction 'Lower boom fully and measure

time taken' appears, select boom lower on RCU and
measure time taken (in seconds) from fully raised to
fully lowered. K Fig 41. ( T 44). Select 'OK'.
Fig 43.
9 When instruction 'Enter the travel time appears, enter

time in seconds. K Fig 44. ( T 44). Select 'OK'.
B
Fig 41.
4 When instruction Ènter the travel time appears, enter

time in seconds. K Fig 40. ( T 44). Select 'OK'.
JC
5 Repeat steps 8 to 11 noting that the time taken will be Fig 44.
longer than before.
10 When the instruction 'Retract the boom fully and
6 Continue repeating steps 8 to 11 until 'Success' is measure time taken' appear, select boom retract on
displayed. RCU and measure time taken (in seconds) from fully
44 9813/1400-1 44
Service Procedures
extended to fully retracted. K Fig 45. ( T 45). Select
'OK'.
Fig 45.
IL
11 When instruction 'Enter the travel time appears, enter
time in seconds. K Fig 44. ( T 44). Select ÒK'.
12 Continue repeating steps 15 to 18 until 'Success' is

displayed.
AZ
parameters have been set correctly, select `No' and


BR
Fig 46.

Select 'OK'.
B
JC
Fig 47.
15 Place boom in travel position.
45 9813/1400-1 45
Service Procedures
Hydraulic Control Sensitivity and the stop time setting is shown on scale D.
K Fig 49. ( T 46)
This procedure controls the ramp up/down of the lift/lower
and extend/retract services. a Unlock the setting for the required time parameter.
Drag the circle (A for example) fully to the 3
Important: Make sure that the control sensitivity settings second time scale and then back to the zero time
do not make the machine unsafe. If the controls are too scale.
sensitive the boom will stop and start suddenly, causing
the machine to sway and personnel in the platform to be b Double click on the circle A on the boom raise
thrown off balance. If the controls are not sensitive enough diagram. K Fig 50. ( T 46). The two arrows B will
the boom will stop too slowly when the controls are set to appear. Click on the arrows to reduce or increase
IL
stop. The operator will be unable to position the boom the over-run time.
safely.
1 Pull down the `Windows' menu and select' Ramps'.

K Fig 48. ( T 46)
AZ C088580-C1
BR
Fig 49.
4 Repeat step 3 for boom lower, boom extend and

boom retract, using the relevant diagrams in the
`Ramps' window. K Fig 50. ( T 46)
B
Fig 48.
2 On the 'Ramps' window, select `Remote'.

K Fig 48. ( T 46).
JC
C088580
Fig 50.
3 Operate the boom raise service from the RCU and
note how the service responds when starting and 5 In the Setup window, click on 'Features' tab and then
stopping. If the service starts or stops too suddenly or on 'Store All Parameters'. K Fig 51. ( T 47).
too slowly adjust the time settings in the ‘Ramps’
window. The start time setting is shown on scale C
46 9813/1400-1 46
Service Procedures
select 'OK'.
IL
Fig 53.
8 Select Cab Control. In the 'Ramps' window, select

`Cabin'. K Fig 54. ( T 47).
AZ
BR
Fig 54.
Fig 51. 9 Repeat steps 3 to 7, but operate the services from the
joystick in the cab.
6 The Store Parameters window will be displayed.
K Fig 52. ( T 47). If you are not sure that the 10 In the `Setup' window, click on 'Features' tab and then
parameters have been set correctly, select `No' and on 'Store All Parameters'. K Fig 55. ( T 48).

B

JC
Fig 52.
47 9813/1400-1 47
Service Procedures
accept the parameters and the 'Status! - Parameters'
stored window will be displayed. K Fig 57. ( T 48).
Click OK.
IL
Fig 57.
AZ
BR
Fig 55.

parameters have been set correctly, click 'No' and

B

JC
Fig 56.
When the parameters are correct, click 'Yes'.
48 9813/1400-1 48
Service Procedures
Manplatform Enable - Machines with LLMC or MC
After replacement of the JCB ECU and before using the 4 Close the Manplatform LCS software.
Manplatform calibration or diagnostics software enable the
Manplatform MCO feature.
1 Connect a laptop computer to the machine and start

Servicemaster.
For details of the Loadall Connection Procedures and
IL
Manual:
9813/0950 for machines with Tier 3 Engine.
2 Double click on the ‘Manplatform LCS Enable’ icon.

K Fig 58. ( T 49)
3
Fig 58.
Click on ‘Enable’. Enter password ‘3921’.

K Fig 59. ( T 49) The message ‘Waiting to enable’ AZ
BR
and ‘Successful’ messages appear.
B
JC
C088560
Fig 59.
49 9813/1400-1 49
Service Procedures
IL
AZ
BR
B
JC
50 9813/1400-1 50
Electrics
Fuses and Relays
Access and Location
!MCAUTION
IL
Fuses
Always replace fuses with ones of correct ampere
rating to avoid electrical system damage.
8-3-3-5
The electrical circuits are protected by fuses A. The fuses

are located in a fuse box inside the door. They are in four
AZ
banks. Each fuse position in each bank is numbered. If a
fuse ruptures, find out why and rectify the fault before fitting
a new one.
To access the fuses, unscrew the two fasteners and

remove cover B.
BR
810830-1
Fig 60.
B
JC
51 9813/1400-1 51
Electrics
Fuses and Relays
Fuses Table 8.
Fuse Circuit Rating
No. (Amps)
1 11 1 Jib Interface 5
2 12 2 Auxiliary/Hitch Hydraulics 10
3 13 3 Immobiliser 10
4 Air Conditioning 30
4 14
5 Heater 30
5 15
6 Indicators 10
IL
6 16 7 Longitudinal Load Moment Indicator 3
7 17 (LLMI)
8 18 8 Instruments 7.5
9 19 9 Steer mode selector 10

10 Reversing alarm/lights 10
10 20
AZ
11 Rear/roof Wiper 20
21 31 12 Front wiper 15
22 32 13 Cold Start 25
14 Dipped Beam 15
23 33
15 Main beam 20
24 34
16 Roadlights 20
25 35
17 Sidelights 5
26 36
BR
18 12 Volt accessory socket 15
27 37 19 Spare
28 38 20 Reverse Fan 5
29 39 21 Ignition 3
30 40 22 Immobiliser 10
23 Transmission 5
41 24 Transmission Dump 20
42 25 Brake lights 10
43 26 Roadlights 10
44 27 Headlight flasher, horn 25

B
28 Beacon 7.5
45
29 Instruments 10
46
30 Hazard lights 20
47
31 Neutral start 30
48
JC
32 Foglights 3
49 33 Boom worklight 25
50 34 Roadlights 20
333-f2430-1-sheet1[F] 35 Front worklamps 25
Fig 61.
36 Rear worklamps 15
Note: All the fuses are shown (including optional 37 Spare
equipment fuses). Your machine may not be equipped with 38 Heated seat, face fan 20
all the fuses shown.
39 Radio 10
40 Aux 3
41 Hydraulics ECU 20
42 Man Platform ECU 20
52 9813/1400-1 52
Electrics
Fuses and Relays
Fuse Circuit Rating

No. (Amps)
43 Man Platform Ignition 1 10
44 Man Platform Start 20
45 Man Platform Ignition 20
46 Radio Receiver 10
47 Basket Payload Switch / Emergency 10
Stop
48 Joystick Control Base Unit 10
IL
49 Recovery Pump 10
50 Man Platform Alarm 10
AZ
BR
B
JC
53 9813/1400-1 53
Electrics
Fuses and Relays
Relays Table 9.
Relay Circuit
No.
A B C D E F A1 Ignition
A2 Parkbrake Warning Light
1 A3 Ignition
A4 Rear Worklights
2 A5 Rear Axle Lock
A6 Roadlights
IL
3 A7 2WD
A8 Air Conditioning
4 B1 Neutral Start
B2 Engine Running
5 B3 Ignition
AZ
B4 Front Worklights
6 B5 Rear Axle Lock
B6 Fuel Pump
B7 Transmission Dump
7
B8 Man Platform
C1 Boom Worklight
8
C2 Steer Mode
BR
333-E1846-1
C3 Neutral Start
Fig 62.
C4 Not Used
Note: All the relays are shown (including optional C5 Flasher Unit
equipment relays). Your machine may not be equipped
D1 Brake Lights
with all the relays shown.
D2 2WD Parkbrake
D3 Engine Running
D4 Not Used
D5 Flasher Unit
E1 Ignition
E2 Reverse Drive
B
E3 Drive
E4 Forward High/Low
F1 Forward Drive
F2 Ignition
JC
F3 Driveshaft
F4 Reverse High/Low
54 9813/1400-1 54
Schematic Circuits
55
Overview Use the applicable schematic set to trace wires and The example shows how to follow a typical set of wires
connections between electrical devices. In most from a power supply (+ ve) through to the path to earth
This section contains sets of electrical schematics for cases it will be necessary to trace wires across more (- ve).
different machine variants. than one schematic sheet.
JC
SHEET 14 SHEET 7
B
C126900
Fig 63. Example - Horn Energised
Item(1) Description State Pins(2) Wire No. Sheet Explanation
CP27 Fuse box B + ve supply 6 118 14 Power supply from 7.5 A fuse
9813/1400-1
CP18 Relay closed 1-2 7 completes circuit to horn
CP06 / MF01 Harness interconnection 30 871 7
BR
MF40A / RL15A Harness interconnection 16 7
MF33 Horn energised 1-2 7
SRL2 (3) 600EL 7
Splice
MF40A / RL15A Harness interconnection 8 600ET 7
SMF3 Splice 7
MF22 Earth - ve earth 600A 7 Connects to chassis earth point
(1) Item identification code is the same as the connector code shown on the applicable harness drawing.
(2) The pin number is the same as the pin number of the harness connector shown on the applicable harness drawing.
AZ
(3) Splices are not normally accessible. Splices are inside the harness sheath and not visible on the outside.
Schematic Circuits
55
Electrics
IL
Electrics
Schematic Circuits
Sheets Sheet 1 is an index to the other sheets and is not

reproduced here.
Some sheets are only applicable to some machine
variants. Use the table to identify the correct schematic
sheet.
Table 10.
Schematic
K Sheet 2 - Battery and Fuses ( T 57)
K Sheet 3 - Road Lights ( T 58)
IL
K Sheet 4 - Road Lights ( T 59)
K Sheet 5 - Heating and Air Conditioning ( T 60)
K Sheet 6 - Work Lamps ( T 61)
K Sheet 7 - Instruments ( T 62)
K Sheet 8 - Wipers ( T 63)
AZ
K Sheet 9 - Steering ( T 64)
K Sheet 10 - Hydraulics ( T 65)
K Sheet 11 - Transmission ( T 66)
K Sheet 12 - Accessories ( T 67)
K Sheet 13 - ECU ( T 68)
K Sheet 14 - Boom and Basket ( T 69)
K Sheet 15 - Valve Block Harness ( T 70)
BR
K Sheet 16 - Joysticks ( T 71)
B
JC
56 9813/1400-1 56
57
JC
B
9813/1400-1
BR
AZ
333-F7202_1-SHT2.eps
Fig 64. Sheet 2 - Battery and Fuses
K Component Keys ( T 72) K Sheets ( T 56)
Schematic Circuits
57
Electrics
IL
58
JC
B
9813/1400-1
BR
AZ
333-F7202_1-SHT3.eps
Fig 65. Sheet 3 - Road Lights
Schematic Circuits
58
Electrics
IL
59
JC
B
9813/1400-1
BR
AZ
333-F7202_1-SHT4.eps
Fig 66. Sheet 4 - Road Lights
Schematic Circuits
59
Electrics
IL
60
JC
B
9813/1400-1
BR
AZ
333-F7202_1-SHT5.eps
Fig 67. Sheet 5 - Heating and Air Conditioning
Schematic Circuits
60
Electrics
IL
61
JC
B
9813/1400-1
BR
333-F7202_1-SHT6.eps
Fig 68. Sheet 6 - Work Lamps
AZ
Schematic Circuits
61
Electrics
IL
62
JC
B
9813/1400-1
BR
333-F7202_1-SHT7.eps
Fig 69. Sheet 7 - Instruments
AZ
Schematic Circuits
62
Electrics
IL
63
JC
B
9813/1400-1
BR
AZ
333-F7202_1-SHT8.eps
Fig 70. Sheet 8 - Wipers
Schematic Circuits
63
Electrics
IL
64
JC
B
9813/1400-1
BR
AZ
333-F7202_1-SHT9.eps
Fig 71. Sheet 9 - Steering
Schematic Circuits
64
Electrics
IL
65
JC
B
9813/1400-1
BR
333-F7202_1-SHT10.eps
Fig 72. Sheet 10 - Hydraulics
AZ
Schematic Circuits
65
Electrics
IL
66
JC
B
9813/1400-1
BR
AZ
333-F7202_1-SHT11.eps
Fig 73. Sheet 11 - Transmission
Schematic Circuits
66
Electrics
IL
67
JC
B
9813/1400-1
BR
333-F7202_1-SHT12.eps
Fig 74. Sheet 12 - Accessories
AZ
Schematic Circuits
67
Electrics
IL
68
JC
B
9813/1400-1
BR
AZ
333-F7202_1-SHT13.eps
Fig 75. Sheet 13 - ECU
Schematic Circuits
68
Electrics
IL
69
JC
B
9813/1400-1
BR
333-F7202_1-SHT14.eps
Fig 76. Sheet 14 - Boom and Basket
AZ
Schematic Circuits
69
Electrics
IL
70
JC
B
9813/1400-1
BR
AZ
333-F7202_1-SHT15.eps
Fig 77. Sheet 15 - Valve Block Harness
Schematic Circuits
70
Electrics
IL
71
JC
B
9813/1400-1
BR
333-F7202_1-SHT16.eps
Fig 78. Sheet 16 - Joysticks
AZ
Schematic Circuits
71
Electrics
IL
Component Keys P022 RAS Ram Relay P047A Diode
72
P023 Drive Shaft Relay P047B Diode
Table 11. Panel Harness
Key P023 Drive Relay P047C Diode
P001 Secondary Fuse Box A P024 Reverse High/Low Relay P047D Diode
P002 Secondary Fuse Box B P024 Forward/High Low Relay P048 Reverse Diode
P003 Secondary Fuse Box C P025 Panel Harness to Chassis Harness P049 Forward Diode
JC
Connector 84 pin P049A LLMI
P004 Secondary Fuse Box D
P026 Sway Switch P049B LLMI CANbus
P005 Neutral Start Relay
P027 Air Con Switch +ve P050 Centre Cluster
P005 Ignition Relay 5
P028 Air Con Switch -ve P051 LMS Cluster Connector J1
P006 Engine Run Relay
P006
P008
Parkbrake Relay
Hazard Lights Relay
B P029
P030
P031
Hazard Lights Switch
Roof Wiper Switch
Rear Wiper Switch
P052
P053
P054
LMS Cluster Connector J2
Info Switch
Reverse Fan Switch
P009 Parkbrake Relay
P032 Fog Lamp Switch P055 Parkbrake Switch
P009 Steer Mode Relay
P033 Road Lights Switch P056 ECU Earth
P034 Worklamps Switch P057 Steer Changeover Switch
P035 2 Wheel Drive SWitch P058 Steer Mode ECU
P012 Front Working Lamps Relay
P036 Beacon Switch
9813/1400-1
P012 Rear Working Lamps Relay P059 Panel Harness to Rear Cab Harness
P037 Boom Worklamp Switch Connector
P013 Brakelights Relay
P038 Stabiliser Isolation Switch P060 R/H Column Switch
BR
P013 Boom Worklamp Relay
P039 Engine Crank Relay P061 Ignition Switch
P014 Throttle Relay
P039 Engine Shut Off Solenoid (ESOS) Relay P062 Ignition Switch
P014 Roadlights Relay
P040 Jib Connector P063 Primary Fuse Blue
P015 Transmission Dump Relay
P041 Fuse Box E P064 Primary Fuse Grey
P015 2 Wheel Drive Relay
P041A Diode P065B Diode
P017 Panel Harness to Chassis Harness
Connector 10 pin P041B Diode P065C Diode
P019 Man Platform Ign Relay P042 Heater Connector P065D Diode
P019 Roof Air Con Relay P043 Heater Switch P067 Alternator B+ Signal
AZ
P020 Forward Drive Relay P044 Earth P068 Primary Fuse
P020 Ignition Relay 1 P045 Earth P069 Primary Fuse
P021 Ignition Relay 2 P046 L/H Column Switch P070 Footbrake Switch
P021 Reverse Drive Relay P047 Primary Fuse Box C P071 Face Level Fan +ve
Schematic Circuits
72
Electrics
IL
P072 Face Level Fan -ve C004 Chassis Harness to Engine Harness C060 Towing Link
73
P073 Washer Pump Connector C062 Chassis Harness to Stabiliser Harness
P078 Heated Screen C005 R/H Headlamp Connector
P079 Front Wiper Motor Connector C006 Chassis Harness to Transmission Harness C063 Chassis Harness to Sway Harness
Connector Connector
P080 Auxiliary Socket
C007 Reverse Fan Solenoid C065 Trailer Tip Valve
P081 Auxiliary Socket Illumination
JC
C008 Safety Key C066 Left Stabiliser
P085 Radio Connector
C009 Number Plate Lamp C067 Chassis Harness to Panel Harness
P086 Battery Connector 12 pin (Throttle Wiring).
C010 Chassis Earth
P087 Battery C068 Joystick Connector 1
C011 Cold Start
P088 Diode C069 Joystick Connector 3
C012 Agglomerator (Water in fuel)
P091
P094
P096
Worklamps
Diagnostics Socket
Terminating Resistor
B C015 Lower Diode
C017 R/H Rear Lamp
C070 Radio Receiver
C071 Axle Transducer
C018 L/H Rear Lamp C072 Retract Diode

P100 Hitch Switch C074 Pump +ve
C020 Number Plate Lamp
P101 L/H Headlamp C075 Tilt Lock Switch
C021 Reverse Alarm
P102 Audible Alarm C076 Chassis Harness to Valve Block Harness
C023 Boom Angle Sensor
P110 Immobiliser Connector 6 pin
C024 Rear Steer Proximity Switch
9813/1400-1
P111 Immobiliser Link C077 Throttle Actuator
C026 Front Steer Proximity Switch
P112 Position Feedback C078 Chassis Harness to Valve Block Harness
C028 2 Wheel Steer Solenoid Connector 12 pin
P113 Cab Emergency Stop
BR
C029 All Wheel Steer Solenoid C079 Chassis Harness to Panel Harness
P114 RX Terminator
P115 Manplatform ECU Connector J1
C031 Crab Steer Solenoid C080 Chassis Harness to Panel Harness
P116 Manplatform ECU Connector J2 Connector 10 pin
C035 Fuel Level Sender
P117 Panel Harness to Chassis Harness C081 Joystick Connector 4
Connector 12 pin C036 Air Filter Vacuum Switch
C082 Joystick Connector 2
P118 Panel Harness to Chassis Harness C039 Chassis Earth
C083 Emergency Stop Switch
Connector 14 pin C048 Hydraulic Control ECU Connector J1
C084 Emergency Pump Switch
C049 Hydraulic Control ECU Connector J2
Table 12. Chassis Harness C085 Joystick Isolation Switch
AZ
C050 Controller Earth
Key
C086 Ground Speed Sensor
C051 CANbus Terminator
C001 Chassis Harness to Panel Harness
C087 Boom Emergency Stop/Basket Overload
Connector 84 pin C052 Chassis Angle Sensor
Platform Connector
C003 Right Stabiliser C058 Horn
C088 RCU Battery Charger
Schematic Circuits
73
Electrics
IL
C089 Constant Aux Switch SS2 Positive CE006 Coolant Temp Sensor
74
C090 RAL Ram CE007 Cam Position Sensor
Table 15. Sway Harness
C091 Isolation Solenoid CE008 EGR Actuator
Key
C092 Position Feedback CE010 Dieselmax CAN Terminator
AA TBA
C093 Receiver Signal CE011 Exhaust Manifold Pressure Sensor
AB TBA
C094 Receiver -ve CE015 Intake Throttle Valve
AC TBA
JC
C095 Receiver +ve CE016 Intercooler Out Temperature Sensor
AD TBA
CE019 Oil Pressure Switch
Table 13. Valve Block Harness
Table 16. Boom Harness CE020 Oil Temperature Sensor
Key
Key CE021 Exhaust Temperature Sensor
V001 Valve Block Harness to Chassis Harness
V002
V003
Connector 12 pin
Boom Lower Solenoid
Boom Raise Solenoid
B L001
L002
L003
Work Lamp Connector
Retract Proximity Switch
Cable Reel
CE026
CE030
CE032
Comp in Pressure Sensor
Rail Pressure Sensor
Fuel Temperature Sensor
V004 Boom Retract Solenoid BW03 Chassis Connector CE033 VGT Actuator
V005 Boom Extend Solenoid CE035 HP Fuel Pressure Regulator
Table 17. Fixed Basket Harness
V006 Carriage Dump Solenoid Key CE037 Machine Interface Connector
V007 Carriage Crowd Solenoid BA001 Cable Reel CE040 Injector number 1
9813/1400-1
V008 Aux B Solenoid BA002 Overload Switch CE041 Injector number 2
V009 Aux A Solenoid BA003 Stop Switch CE042 Injector number 3
CE043 Injector number 4
BR
L001 R/H Stabiliser Lower Solenoid
L002 R/H Stabiliser Raise Solenoid Table 18. Slew Basket Harness CE044 Fuel Inlet Metering Valve
Key CE045 Engine ECU Connector
L003 L/H Stabiliser Lower Solenoid
BA001 Cable Reel CE091 Shield Cut End 2
L004 L/H Stabiliser Raise Solenoid
BA002 Overload Switch CE092 Shield Cut End 3
L005 Valve Block Harness to Chassis Harness
Connector 6 pin BA003 Stop Switch CE093 Shield Cut End
Table 14. Stabiliser Harness Table 19. ‘CE’ Engine Harness Table 20. ‘E’ Engine Pod Harness
Key Key Key
AZ
SH001 Mainframe Connector CE001A Accellerometer 1 E001 Fuse/Relay Box
SH002 LH Stab Transducer CE001B Accellerometer 2 E002 Agglomerator
SH003 RH Stab Transducer CE002 TMAP E003 Fuel Pump
SS1 Ground CE005 Crank Speed Sensor ELTEK E004 Engine ECU Connector
Schematic Circuits
74
Electrics
IL
E005 Engine Harness Connector T020 TCLU Solenoid
75
E006 Air Filter Vacuum Switch T021 Temperature 2 (Non TCLU)
E007 Lambda Sensor
E008 TMAF
E009 Chassis Harness Connector
E010 Powertrain CANbus Resistor
JC
E011 Transmission Oil Temp
E012 Reversing Fan Solenoid
E013 Proportional Fan Solenoid
E014 Fan Speed Sensor
E020
E023
E024-1
Grid Heater
Dieselmax CANbus Resistor
Air Con Binary Switch 1
B
E024-2 Air Con Binary Switch 2
E025 Air Con Compressor
Table 21. ‘T’ Transmission Harness

Key
9813/1400-1
T001 Chassis Harness Connector
T002 Forward High Solenoid
BR
T003 Reverse High Solenoid
T004 4 Wheel Drive Solenoid
T005 Transmission Oil Pressure Switch
T006 Transmission Oil Temperature Switch
T007 Forward Low Solenoid
T008 Reverse Low Solenoid
T009 Layshaft Solenoid
T010 Mainshaft Solenoid
AZ
T011 6th Gear Solenoid
T014 HVCS Pump Control Valve
T015 Temperature Sender
T018 Temperature Sensor 2
Schematic Circuits
75
Electrics
IL
Electrics
Component Location
Component Location
Machine Components
IL
AZ
BR
B
JC
C117690.jpg
Fig 79.
76 9813/1400-1 76
Electrics
Component Location
K Fig 79. ( T 76)
Item Description
1 Hydraulic Control ECU
2 Control Lever
3 Stabiliser Control Levers
4 Safety Key Socket (Cab Mode)
5 Stabiliser Pressure Transducers
IL
6 RAL Valve
7 LLMI/LLMC Axle Transducer
8 Cab Emergency Isolation Switch
9 Manplatform Control ECU
10 Fusebox and Relays
AZ
11 Emergency Pump
12 Control Valve
13 Engine Speed Actuator
14 LLMI/LLMC Unit
15 Radio Receiver
BR
B
JC
77 9813/1400-1 77
Electrics
Component Location
Platform Components
IL
AZ
BR
B
C124770
Fig 80.
Item Description
JC
1 RCU Mounting Dock

2 Cable Reel
3 Platform Emergency Isolation Switch
4 Cable Reel to Boom Harness Connector
5 Cable Reel to Platform Harness
Connector
6 Platform Weight Limit Sensor
78 9813/1400-1 78
Electrics
Component Location
Remote Control Unit Components (2) This will be covered when RCU is correctly docked,
the Platform Emergency Isolation Switch replaces the
need for this
A B C E
LED 1 LED 2
H B C radiomatic
I
SPARE 1
SPARE 2
SPARE 3
IL
SPARE 4
0
AUTO
FULL
D F
AZ
BR
G J K M
H L
C116120-C2.eps
Fig 81.
Item Description
A Lift/Lower Joystick
B Red LED
C Amber LED
B
D Engine Speed Switch

E Extend/Retract Joystick and Slew Control
Joystick
F RCU Status LED
JC
G Engine Start Switch(1) (Also used to

operate tilt/crowd when held down in
conjunction with joystick E)
H RCU Emergency Stop switch(2)
J RCU Power Button
K Engine Start Switch(1)
L Safety Key Socket
M Engine Stop Switch
(1) Hold down these two switches to start engine.
79 9813/1400-1 79
Electrics
Manplatform ECU Power and Earth Connections
Manplatform ECU Power and Earth Connections
2 P115 - J1 14
3 15
FUSE
4 SP65 4 SP74 P056
5 16
P041 6 17
IL
ECU
22
AZ
P116 - J2
+VE -VE
C116390-C2
Fig 82.
Key Device K Fig 84. ( T 82)

P041 Fuse Box E
P056 ECU Earth
BR
B
JC
80 9813/1400-1 80
Electrics
Engine Start Operation - Cabin Mode
For the engine to start in the normal way (engine started

from the cab), cabin mode must be selected. This is
Selected by inserting the Safety Key into the Safety Key
socket A. The Safety Key socket transmits a signal to the
Manplatform ECU to inform it that Cabin Mode is selected.
This enables the engine to be started in the same way as

non Man Platform Machines. For details of the machine
IL
start circuits refer to the machine service manual.
A AZ
BR
C116430
Fig 83.
C001/ Chassis Harness to Panel Harness Connector
P025 84 pin
B
C008 Safety Key

P003 Fuse Box C
P041 Fuse Box E
JC
P061/ Ignition Switch

P062
P063 Primary Fuse (Blue)
81 9813/1400-1 81
Electrics
P115 - J1
1 FUSE 2 20
22
9004
IL
3
FUSE
A B 1 5
P063
ECU
P061/
P062
AZ
FUSE
1
P003
C001/
FUSE
SC34 1 2
P025 SP77
20 17
81
P041
C008
BR
P116 - J2
+VE -VE
C116390
Fig 84. Engine Start - Cabin Mode
B
JC
82 9813/1400-1 82
Electrics
Engine Start Operation - Remote Mode
Remote Mode Select The Remote Control Receiver transmits a CANbus signal
to the Hydraulic Control ECU. The Hydraulic Control ECU
The Safety Key must be inserted into the Safety Key checks that the signal is correct.
socket A on the Remote Control Unit to select Remote
Mode. When the Safety Key is present and the RCU is powered
up there should be 3 LED’s illuminated on the RCU and the
The Safety Key sends a signal from the RCU via the machine will emit 3 Beeps from the Audible Alarm to
Remote Control Receiver. confirm that remote mode is selected.
IL
The Manplatform ECU checks that there is a signal on pin
10 to make sure that the receiver is working correctly. If this
signal is not present the Manplatform ECU prevents the
engine starting. If the connection is lost when the engine is
running the engine will stop.
AZ
Key Device
A A C070 Radio Receiver
P041 Fuse Box E
P044 Earth Point
P102 Audible Alarm
BR
C116440
Fig 85.
C080
FUSE
12
P017 1
ECU
5
P041
CAN H 6 P115 - J1
10
CAN L 7
B
C070
ECU
34 33
RCU
C048 - J1
5
JC
1 P116- J2
ECU
2
SP34
P102
SP33 P044
C049 - J2
+VE -VE
C116390-C1
Fig 86. Remote Mode Select
83 9813/1400-1 83
Electrics
Starter Motor Operation Key Device K Fig 87. ( T 85)

C001/ Chassis Harness to Panel Harness
The Manplatform ECU and Hydraulic Control ECU check P025 Connector 84 pin
inputs to make sure that:
C004 Chassis Harness to Engine Harness
– The stabiliser legs are down Connector
– The parkbrake is on C048 Hydraulic Control ECU Connector J1
– The transmission is in neutral C049 Hydraulic Control ECU Connector J2
– The cab and platform emergency isolation switches C070 Radio Receiver
are not activated P003 Fuse Box C
IL
– The platform is not above the weight limit
P004 Fuse Box D
– The radio receiver is receiving a signal
P005 Neutral Start Relay
These circuits are shown on the pages that follow: P039 Engine Crank/Engine Shut Off Solenoid
(ESOS) Relay
K Stabiliser Legs Down ( T 86) P041 Fuse Box E
AZ
K Park Brake ON ( T 88) P044 Earth Point
P045 Earth Point
K Transmission In Neutral ( T 89) P061/P062 Ignition Switch
K Cab Emergency Isolation Switch ( T 90) P063 Primary Fuse (Blue)
P102 Audible Alarm
K Platform Emergency Isolation Switch ( T 91)
P110 Immobiliser
K Platform Weight Limit ( T 92) P115 Manplatform ECU Connector J1
BR
The Radio signal is shown on the page that follows:
S Starter Motor
K Remote Mode Select ( T 83)
When the ECU’s receive the correct inputs they will allow
the engine start to commence.
The Manplatform ECU P116 via the Immobiliser P110

energises the ESOS relay P039 to energise the ESOS
solenoid to allow fuel to the engine.
The Hydraulic Control ECU C049 supplies power to the

Neutral Start Relay P005.
B
The Neutral Start Relay energises and supplies power to

the Engine Crank Relay P039. The Engine Crank Relay
supplies power to the starter motor S and solenoid to start
the engine.
JC

A Alternator
B Battery
84 9813/1400-1 84
Electrics
SP33
P044
C080
FUSE 1
12
P017
5
P041
ECU
CAN H 6
10
CAN L 7 P115 - J1
34 33
IL
20
RCU
C048 - J1 C070 22
35
ECU
AZ
C001
P025
6
36
C049 - J2 ECU
1 FUSE 2
P004
9
BR
4
3
P116 - J2
FUSE
5 3
A B 1 5 2
1 4
P063
P005
P061/ P045
P062
FUSE SP64
1
SP75
P003
B
5 3
FUSE
2 B+
8 1 4
P041 P039 A
8 10
FUSE C004
7
JC
4 6
7
P003
1
M +VE -VE
ECU
S
B
P110
+VE
-VE
C116420-C2
Fig 87. Starter Motor Operation
85 9813/1400-1 85
Electrics
Stabiliser Legs Down Key Device K Fig 89. ( T 87)

The stabiliser legs must be down before the engine will
start in remote mode. P116 Manplatform ECU Connector J2
SH001/ Stabiliser Harness to Chassis Harness
A pressure switch A is located in each stabiliser leg. C062 Connector
SH002 L/H Stabiliser Pressure Transducer
If the hydraulic pressure in the stabiliser ram is more than
25 bar, this indicates that the stabiliser leg is supporting the SH003 R/H Stabiliser Pressure Transducer
weight of the machine. The switch contacts CLOSE to
connect a live feed to illuminate the light in the instruments
IL
display P052 and sends a signal to the Manplatform ECU
P116.
If the hydraulic pressure in the stabiliser ram is less than

20 bar, this indicates that the stabiliser leg is not supporting
the weight of the machine. The switch contacts OPEN to
extinguish the light in the instruments display P052 and no
AZ
signal is sent to the Manplatform ECU P116.
BR
A
C116540
B
Fig 88.
P025 Connector 84 pin
JC
C067/P117 Chassis Harness to Panel Harness

Connector 12 pin
P001 Fuse Box A
P051 LMS ECU Connector J1
86 9813/1400-1 86
Electrics
P051 - J1
ECU
IL
12
P052 - J2
P115 - J1
AZ
C001/ SH001/
ECU P025 C062
71 5 2
18
9 3 3
1
C067/ 4
P117
SP74
4 SS1 SH002
BR
12
C001/
P025 SC8 SS2 2
6 C001/
2
P025
3
72 6 1
30
4
P116 - J2
10 1
SH003
FUSE
16
SP9
P001
B
+VE
-VE
C116550
Fig 89. Stabiliser Pressure Switches
JC
87 9813/1400-1 87
Electrics
Park Brake ON Key Device

P045 Earth Point
The park brake must be ON before the engine will start in
remote mode. P055 Park brake switch
When the park brake is ON, Pin 29 of the Manplatform
ECU P116 finds a path to earth through the parkbrake P116 Manplatform ECU Connector J2
switch P055.
IL
SP64 P045
S6 1
3 P115 - J1
2
AZ
P055
ECU
34
29
P116 - J2
BR
C116420-C3
Fig 90. Park brake ON
B
JC
88 9813/1400-1 88
Electrics
Transmission In Neutral Key Device K Fig 91. ( T 89)

When the column switch P046 is set to N the Hydraulic
Control ECU C048/C049 and Manplatform ECU P115/ C049 Hydraulic Control ECU Connector J2
P116 receive a signal via splice SP66. This informs both P044 Earth Point
ECU’s that the transmission is in Neutral and Forward/
Reverse are not selected. P046 L/H Column Switch
P110 Immobiliser
IL
21 P115 - J1
AZ
ECU
ECU
P110
4
P116 - J2
BR
C048 - J1
SP66
ECU
C067
P046 P117 14
C049 - J2
11
C116420-C4
Fig 91.
B
JC
89 9813/1400-1 89
Electrics
Cab Emergency Isolation Switch When the switch P113 is in the out (OFF) position, there is
no input at the Manplatform Control ECU P116.
The emergency isolation switch A must be OFF before the
engine will start in remote mode. The switch is OFF with Key Device K Fig 93. ( T 90)
the knob in the out position.
P113 Emergency Isolation Switch
IL
AZ
BR
C116490.jpg
Fig 92.
P115 - J1
ECU
B
1 2
3
FUSE
JC
10 2 26
4
SP76 P116 - J2
P041 P113
C116420-C5
Fig 93. Cab Emergency Isolation Switch
90 9813/1400-1 90
Electrics
Platform Emergency Isolation Switch Key Device

BA003 Emergency Isolation Switch
The platform emergency isolation switch A must be OFF
before the engine will start in remote mode. The switch is C079/P118 Chassis Harness to Panel Harness
OFF with the knob in the out position. Connector 14 pin
C087/L004 Chassis Harness to Boom Harness
Connector
L003 Cable Reel Connector
A
IL
AZ
C124640
Fig 94.
P115 - J1
ECU
BR
L003 C087/ C079/
FUSE
14
1 2 L004 P118 16
P041 3 2 3 8
4 28
3 4 9 P116 - J2
BA003
C116420-C7
Fig 95.
B
JC
91 9813/1400-1 91
Electrics
Machine Operation - Remote Mode
Platform Weight Limit
IL
1 2
A
C
AZ
B
3
BR
B
C124710
Fig 96.
The platform weight limit system uses an weight limit

switch 2 attached to the platform suspension. When the
JC
roller arm 1 rotates to a position greater than 26º the

normally closed contacts of the switch open and the earth
returns to the ECU are prevented. The ECU responds by
putting the system into overload mode. The stop 3 can be
adjusted to ensure that the switch opens at the correct
weight. The platform weight limit switch should be closed
to enable engine start operation.
92 9813/1400-1 92
Electrics
Key Device K Fig 93. ( T 90) Key Device K Fig 93. ( T 90)
BA002 Weight Limit Switch L003 Cable Reel Connector
C079/P118 Chassis Harness to Panel Harness P115 Manplatform ECU Connector J1
Connector 14 pin P116 Manplatform ECU Connector J2
C087/L004 Chassis Harness to Boom Harness
Connector
IL
P115 - J1
ECU
L003 C087/ C079/
AZ
B L004 P118 35
A
5 11 11
L003 C087/ C079/
L004 P118 33
C
P116 - J2
6 12 12
BA002
BR
C116420-C8
Fig 97.
B
JC
93 9813/1400-1 93
Electrics
Engine Speed Actuator Operation The ECU operates the actuator B which moves the lever
on the injection pump to increase or decrease speed.
The Switch A on the remote control unit is used to control
the Engine Speed Actuator. The engine speed can be Table 22. Schematic Key
adjusted between idle and 1500 rev/min, or put into Auto Component Key: K Fig 100. ( T 95) and
Mode where the speed control will operate automatically. K Fig 101. ( T 96)
At the centre position, the engine will remain at idle speed. C001/ Chassis Harness to Panel Harness
P025 Connector (84 pin)
IL
LED 1 LED 2
H B C radiomatic
I P117 Connector (12 pin)
SPARE 1
SPARE 2
C070 Remote Control Receiver

SPARE 3
0
SPARE 4
C077 Throttle Actuator
AUTO
P004 Fusebox D
FULL
AZ
P014 Throttle Actuator Reverse Relay
P041 Fusebox E
A P044 Earth Point
C116410
Fig 98.
When switched to the right (Auto), the engine speed

remains at idle until a service (for example: boom travel) is
selected, it then increases to 1500 rev/min until the service
is stopped.
BR
When switched to the left (Full), the engine speed will
remain at 1500 rev/min.
B
B
C096550-C3
JC
Fig 99.
The remote control unit sends a signal to the machine

receiver to tell the Hydraulic Control ECU what engine
setting is required.
94 9813/1400-1 94
Electrics
FULL
CAN H 6
IDLE
CAN L 7
ECU
AUTO
C070
IL
C067 RCU
P041
18
P117
34 33 7
C048 - J1
AZ
14 SC39
24
SC35
26
29
1 3
30
SC29
25
BR
2
5 M 4
SC36
ECU C077
P044
SP33
C001
P025 C067
P117
56
3
C067 P014
C049 - J2 P117
B
P004 2
14
+VE -VE
C116420
JC
Fig 100. Engine Speed Setting in Idle Position
When the RCU switch is moved to the Idle position, the power to the retract side of the throttle actuator C077.
RCU transmits a radio signal to the receiver C070. This When the ECU receives power on pin 24 it turns pin 25 into
transmits a signal to the Hydraulic Control ECU C048 via an earth. The motor moves the throttle lever on the engine
the CANbus. The hydraulic control ECU C048/C049 sends to the minimum position.
power to the actuator reverse P014. The relay supplies
95 9813/1400-1 95
Electrics
FULL
CAN H 6
IDLE
CAN L 7
ECU
AUTO
C070
IL
C067 RCU
P041
18 P117
34 33 7
C048 - J1
AZ
14 SC39
24
SC35
26
29
1 3
30
SC29
25
BR
2
5 M 4
SC36
ECU C077
P044
SP33
C001
P025 C067
P117
56
3
C067 P014
C049 - J2 P117
B
P004 2
14
+VE -VE
C116420-C1
JC
Fig 101. Engine Speed Setting in Full Position
When the RCU switch is moved to the Full position, the the Extend side of the throttle actuator C077. When the
RCU transmits a radio signal to the receiver C070. This ECU receives power on pin 25 it turns pin 24 into an earth.
transmits a signal to the Hydraulic Control ECU C048 via The motor moves the throttle lever on the engine to the
the CANbus. The hydraulic control ECU C048/C049 turns maximum position. The ECU also activates the throttle
off the power to the relay P014. Power is then supplied to extend when a hydraulic service is requested.
96 9813/1400-1 96
Electrics
Stabilizer and Sway Isolation Key Device K Fig 102. ( T 98)

The stabilizers must be down before the engine will start in
remote mode. K Stabiliser Legs Down ( T 86) P116 Manplatform ECU Connector J2
The RCU transmits a signal to the Radio Receiver C070

when the Safety Key is inserted in the Safety Key (Remote
mode selected) and the RCU is switched on.
The Remote Control Receiver transmits a CANbus signal

to the Hydraulic Control ECU C048/C049 which operates
IL
in Remote Mode.
When the machine is operated in remote mode the

stabilizer and sway services are isolated. The Manplatform
ECU P115/P116 will not activate the power supply to the
Stabiliser Valve Block Solenoids L001, L002, L003, L004
or the Sway Solenoids AB or AD.
AZ
AB Sway Right Solenoid
AC Sway/Fan Solenoid
AD Sway Left Solenoid
C039 Earth Point
BR
C063/AA Chassis Harness to Sway Harness
Connector
C070 Radio Receiver
C076/L005 Chassis Harness to Valve Block Harness
connector 6 pin
C079/P118 Chassis Harness to Valve Block Harness
connector 14 pin
C080/ Chassis Harness to Valve Block Harness
P017 connector 10 pin
L001 Proportional control valve solenoid - R/H
B
Stabiliser Lower
Stabiliser Raise
L003 Proportional control valve solenoid - L/H
Stabiliser Lower
JC

Stabiliser Raise
P041 Fuse Box E
P044 Earth Point
97 9813/1400-1 97
Electrics
C080
FUSE
12
P017 1
5 CAN H
P041 6
P115 - J1
CAN L 7 10
ECU
34 33
C048 - J1
ECU
C070
IL
ECU
RCU
P116- J2
SP33 P044
C049 - J2
C079/ C076/
P118 L005
AZ
12
P115 - J1 C079/ C076/ 3 3 SL1

26 P118 L005
1 1
C079/ C076/
P118 L005
27
1 13 4
L004 L003
BR
L/H STABILISER L/H STABILISER
ECU RAISE SOLENOID LOWER SOLENOID
C080/ C076/
P017 L005
1
1 6
C079/ C076/ SL2
P118 L005
11
C079/ C076/ 14 5
P118 L005
10
L001
2 R/H STABILISER
2
LOWER SOLENOID
L002
C080/ C063/
R/H STABILISER
RAISE SOLENOID P017 AA
B
4 3
C080/ C063/
P017 AA AC
12
3 2
C080/ C063/
JC
P017 AA AB
23 C063/
2 1 S1 AA C039
P116 - J2
4
AD
-VE
+VE
C116570
Fig 102.
98 9813/1400-1 98
Electrics
Longitudinal Load Moment Indicator (LLMI) Operation
A transducer B measures the load exerted on the rear axle The LLMI unit is CAN enabled. The calculated longitudinal
and sends a signal to the LLMI unit A. The unit converts load moment is transmitted on the CAN BUS.
the signal into the longitudinal load moment value and
drives the display LED’s as required.
IL
B
AZ
BR
C116700
Fig 103. LLMI System Component Location
Transducer C071 is powered from the LLMI unit (P049-A/
K Fig 104. ( T 100)
B).
Key
C001/P025 Chassis to panel harness interconnect One output from the transducer C071 is processed by the
LLMI unit. The unit drives its warning LEDs and audible
C071 Transducer - rear axle mounted
warning depending on the value of the calculated
P001 Fuse Box A longitudinal load moment. The other output is used for the
P049-A LLMI unit - CAN enabled LLMC system. K Longitudinal Load Moment Control
(LLMC) Operation ( T 101)
B
P049-B LLMI unit - CAN bus connection

The LLMI unit is CAN enabled. The calculated longitudinal
The LLMI unit P049-A/B is self contained. It is connected load moment is transmitted on the CAN BUS via connector
to the machine battery via the ignition switch and a fuse. P049-B.
Power is connected to the unit when the ignition is set to
JC
ON (P001, pin 14).
The LLMI unit must be calibrated for correct operation of

the LLMI system.
99 9813/1400-1 99
Electrics
6001
FUSE 14 1 4
CAN -003
3 LLMI
9001 2 LLMC
ECU
B
CAN L
IL
A
CAN H
4023
AZ
8004 2
15
3
16
C071
REAR AXLE
IGN +VE TRANSDUCER -VE
C093910
Fig 104. Electrical Schematic - LLMI System

BR
B
JC
100 9813/1400-1 100

Electrics
Longitudinal Load Moment Control (LLMC) Operation
The LLMC system is controlled by the machine hydraulic System Pump Shut Off
control ECU G. The ECU gets inputs from the axle
transducer B, chassis and boom mounted electric The hydraulic control ECU monitors the machine status. If
inclinometers D, boom retracted proximity switch F and the status is not as expected (e.g. the boom angle rate of
transmission speed sensor E. change is not as expected for the load moment or control
inputs), it is assumed that there is a hydraulic system fault.
The ECU compares the machine status to pre-set values The ECU isolates the main hydraulic system by energising
stored in its memory. Outputs from the ECU control the cut out solenoid valve. Boom, auxiliary, sway and stabiliser
IL
proportional solenoids on the main control valve. hydraulic services do not operate. The steering and
cooling fan operate as normal.
AZ
B
A
BR
C
G
B
D
JC
F E
C116700-C1
Fig 105. LLMC System Component Location
101 9813/1400-1 101

Electrics
Inputs/Outputs Boom Retracted/Extended When in Cabin mode the

LLMC is not active when the boom is fully retracted. When
in remote mode the LLMC is active with the boom
K Fig 106. ( T 103) retracted.
Key
Proximity switch L002 changes state when the boom is
fully retracted. The hydraulic control ECU detects the
Connector 84 pin
switch state.
C023 Inclinometer - boom mounted
C071 Transducer - rear axle mounted Outputs
C039 Chassis Earth
IL
The hydraulic control ECU responds to the motion control
C048 Hydraulic control ECU - connector J1 input devices. Outputs from the ECU control the
C049 Hydraulic control ECU - connector J2 proportional solenoids on the main control valve. As the
machine gets closer to its stability limit the hydraulic
C052 Inclinometer - chassis mounted
services operate at proportionally reduced speed and
C086 Transmission speed sensor ultimately stop.
AZ
C091 Isolation Solenoid
Pump Shut Off The hydraulic control ECU monitors the
L002 Boom Retracted Proximity Switch machine status. If the status is not as expected (e.g. the
L004/C087 Boom Harness to Chassis Harness boom angle rate of change is not as expected for the load
Connector 12 pin moment or control inputs), it is assumed that there is a
P049-A LLMI unit - CAN enabled hydraulic system fault. The ECU isolates the main
hydraulic system by energising isolation solenoid valve
P049-B LLMI unit - CAN bus connection C091.
BR
Inputs
Longitudinal Load Moment The axle transducer C071

outputs 2 signals. One signal is used by the LLMI ECU.
K Longitudinal Load Moment Indicator (LLMI)
Operation ( T 99)
The second signal from the transducer C071 is to the

Hydraulic Control ECU. The output varies depending on
the load exerted on the rear axle.
Machine Stationary/Travelling The signal from

transmission speed sensor C086 is used by the hydraulic
B
control ECU to determine when the machine is travelling

and when the machine is stationary.
Boom Angle The outputs from chassis and boom angle

electric inclinometers C023 and C052 change as the boom
JC
and chassis angles change in the longitudinal plane. The

output signals are used by the hydraulic control ECU to
calculate the boom elevation angle in relation to the
chassis.
102 9813/1400-1 102

Electrics
SC13 C039
2 1
C048 - J1
C091
ISOLATION SOLENOID 13
P051 19
SC15 27
SC8 +12v
14
IL
ECU
7
P052
18
13 19
SC16 2 1 28
+5v
C001/ 4 21
AZ
P025 5 SC39
3 9
6
4
C086
SPEED SENSOR
ECU
2
5
1 SC33
4
3
BR
6
C023 33
INCLINOMETER
BOOM
1
4
3
6
2 18
5 30
C052
INCLINOMETER
CHASSIS
5 21
B
4 C049 - J2
1
6
C071
JC
REAR AXLE
TRANSDUCER
L004/
C087
1
L004/
3 2 SC28
C087
4
2 5 SC27
9
6
L002
C116710
Fig 106. Electrical Schematic - LLMC System
103 9813/1400-1 103

Electrics
Control Valve Operation
Extend/Retract and Auxiliary Services

For details of joystick operation refer to the pages that
follow:
K Joystick Operation ( T 109)
IL
Item Description
C048 Hydraulic control ECU - connector J1
connector 6 pin
C078/V001 Chassis Harness to Valve Block Harness
AZ
connector 12 pin
V004 Proportional control valve solenoid -
retract service
extend service
auxiliary B service
BR
auxiliary A service
The Hydraulic Control ECU C049/C049 receives a request

from the joystick to operate extend/retract or auxiliary
services.
The ECU responds by producing a PWM signal in

proportion to the thumbwheel position to the proportional
solenoid coils V004, V005, V008 and V009 for operation of
the service spools.
B
JC
104 9813/1400-1 104

Electrics
C078/
C048 - J1 V001
12
12 SV4
8032
35
SC38 6 SV2
ECU
IL
C078/
V001
5
4
9
5 SC31
AZ
C078/ V004 V005
V001 RETRACT SOLENOID EXTEND SOLENOID
7
11
10
C049 - J2
V009 V008
AUX A SOLENOID AUX B SOLENOID
HYDRAULIC CONTROL ECU
BR
IGN +VE
C116500
Fig 107. Electrical Schematic - Extend/Retract and Auxiliary Services
B
JC
105 9813/1400-1 105

Electrics
Lift/Lower, Stabiliser and Tilt Services

For details of joystick operation refer to the pages that
follow:
K Joystick Operation ( T 109)
Item Description K Fig 108. ( T 107)

IL
connector 6 pin
connector 12 pin
connector 14 pin
AZ
connector 10 pin
Stabiliser Lower
Stabiliser Raise
Stabiliser Lower
BR
Stabiliser Raise
V002 Proportional control valve solenoid - lower
service
V003 Proportional control valve solenoid - raise
service
dump service
crowd service
B
The Hydraulic Control ECU C049 receives a request from

the joystick to operate extend/retract or auxiliary services.
The Hydraulic Control ECU C049 responds by producing a

JC
PWM signal in proportion to the joystick position to the

proportional solenoid coils V002, V003, V006 and V007 for
operation of the service spools.
The Manplatform ECU P115/P116 receives a request from

the stabiliser levers to operate the stabiliser valve block
spools.
The Manplatform ECU P155/P116 responds by producing

a PWM signal in proportion to the lever position to the
proportional solenoid coils L001, L002, L003 and L004 for
106 9813/1400-1 106

Electrics
12 2
C078/ SC30
V001 C078/
23
V001
1
V003 V002
C078/ RAISE SOLENOID LOWER SOLENOID
24 SC37 V001 SV1
C078/ 3
IL
7 V001
ECU 8
V007 V006
AZ
CROWD SOLENOID DUMP SOLENOID
C078/
V001
1 SV3
C049 - J2
9 C079/ C076/
P118 L005
12
P115 - J1
C079/ C076/ 3 3 SL1
26 P118 L005
1 1
BR
C079/ C076/
P118 L005
27
13 4
L004 L003
ECU L/H STABILISER L/H STABILISER
C080/ C076/ RAISE SOLENOID LOWER SOLENOID
P017 L005
1
1 6
C079/ C076/ SL2
P118 L005
11
C079/ C076/ 14 5
P118 L005
10
L001
B
2 R/H STABILISER
2
P116 - J2 LOWER SOLENOID
L002
IGN +VE R/H STABILISER
RAISE SOLENOID
JC
C116500-C1
Fig 108. Electrical Schematic - Lift/Lower, Stabiliser and Tilt Services
107 9813/1400-1 107

Electrics
Hydraulic Emergency Isolation Switch

The hydraulic emergency isolation switch A must be OFF
before the hydraulic controls can be operated. The switch C048 - J1
is OFF with the knob in the out position.
ECU
1 2
15
IL
SC15
C049 - J2
C083
C116420-C5
Fig 110. Hydraulic Emergency Isolation Switch
Fig 109.
C116490
AZ
BR
When the switch C083 is in the out (OFF) position, there is
no input at the Hydraulic Control ECU C049 pin 15.
Key Device
C083 Hydraulic Emergency Isolation Switch
B
JC
108 9813/1400-1 108

Electrics
Joystick Operation
Joystick Operation
Joystick and Controller

All of the machine hydraulic services are actuated
electrically. CAN enabled electronic control units and
proportional solenoid valves are central to the system.
IL
AZ
BR
M
4 1
3 2
1 2 3 4 5 6
B
12 11 10 9 8 7
C094140-C1
Fig 111.
A Main control lever handle G Auxiliary II button
B CAN joystick controller ECU H Axis 3 - Thumbwheel
JC
C Electrical connector - Thumbwheels J Axis 4 - Thumbwheel

D Electrical connector - buttons K Axis 2 - Carriage tilt
E Electrical connector - CAN joystick controller ECU L Axis 1 - Lift/Lower
F Not Used M Electrical connector - CAN joystick controller ECU
109 9813/1400-1 109

Electrics
Joystick Operation
Movement of the control lever A causes an electrical signal Proportional Signal Generation
proportional to the lever movement. The controller ECU B
monitors these signals (inputs) and converts the voltage When the control lever A is operated, the plunger B
into a corresponding CAN message (output) which is pushes against the return spring C. A variable resistor
broadcast on the machine CAN bus. position sensor is allocated to each axis. Slider D moves
up or down when the lever is moved changing the electrical
voltage depending on lever position.
Note: The position sensors are integral with the joystick

controller ECU. If a sensor is defective the controller ECU
must be renewed.
IL
AZ
BR
B
Fig 112.
JC
110 9813/1400-1 110

Electrics
Joystick Operation
Operator Interface
Operator Interface Electrical Schematic Control/Indicator Function

Joystick isolation switch K System Enable and Rocker switch. Press switch to isolate/enable the joystick
Isolation ( T 113) operated services.
Joystick control lever K Joystick and Proportional control of all the hydraulic services by means
Controller ( T 109) of moving the lever and thumbwheel switches.
Hydraulic system stop button K System Enable and Latching button. Latch the button to isolate the pump flow
Isolation ( T 113) from the main control valve.
IL
Tilt isolation switch K System Enable and Rocker switch. Press switch to isolate/enable the tilt
Isolation ( T 113) service.
Boom/Auxiliary and Stabiliser K Extend/Retract and
Services Auxiliary Services
(Thumbwheel
Switches) ( T 114), K Lift/
AZ
Lower and Tilt
Services ( T 116)
BR
B
JC
111 9813/1400-1 111

Electrics
Joystick Operation
Hydraulic Control ECU Power and Earth Key Device K Fig 113. ( T 112)
Connections C049 Hydraulic Control ECU Connector J2
C050 Earth Point
Key Device K Fig 113. ( T 112) C067/P117 Chassis Harness to Panel Harness
C001/ Chassis Harness to Panel Harness connector 12 pin
P025 connector 84 pin P001 Fuse Box A
C048 Hydraulic Control ECU Connector J1 P041 Fuse Box E
IL
AZ
C048 - J1
C001/
P001
FUSE 18
P025 11
SP48 38 SC2
2 15
SC4 C050
3 16
4 17
5
6
BR
ECU
C067/
P041 P117
FUSE 2
22
2 SC14
B
C049- J2
IGN +VE
C116580
Fig 113. Electrical Schematic - Hydraulic Control ECU Power and Ground
JC
112 9813/1400-1 112

Electrics
Joystick Operation
System Enable and Isolation The system will not enable unless switch C083 is latched.
When switch C083 is not latched its input is sensed by
hydraulic control ECU via connector C049. The ECU
K Fig 114. ( T 113) energises the Isolation solenoid coil 3064.
Key
Tilt isolation switch C075 state is sensed by inputs at the
hydraulic control ECU connector via C048/049. The ECU
C049 Hydraulic control ECU - connector J2 isolates the joystick control by switching off the PWM
C075 Tilt isolation switch signals to the control valve tilt spool proportional solenoids.
C083 Hydraulic stop switch
Joystick isolation switch C085 state is sensed by inputs at
IL
C085 Joystick controls isolation switch the hydraulic control ECU via connector C049. The ECU
C091 Isolation solenoid isolates the joystick controls by switching off the PWM
signals to the control valve proportional solenoids.
SC3 C039
AZ
2 1
C048 - J1
C091
SHUT OFF SOLENOID 13
10
22
6
5
BR
2
1
C075
TILT ISOLATION SWITCH
27
1 2
ECU
C083
HYDRAULIC STOP SWITCH 15
B
31
20
JC
6
5
2
1
C085
JOYSTICK ISOLATION SWITCH
C049 - J2
C116590
Fig 114. Electrical Schematic - System Enable and Isolation
113 9813/1400-1 113

Electrics
Joystick Operation
Extend/Retract and Auxiliary Services

(Thumbwheel Switches)
K Fig 115. ( T 115)

Key
Connector
IL
C081 CAN joystick controller ECU
P041 Fuse Box E
AZ
ECU C081 provides thumbwheel switches with a 5V power
supply via joystick Connector C069.
The thumbwheels send a voltage between 0.7V and 4.3V

to the ECU C081. The voltage is determined by the
position of the thumbwheel switch. ECU C081 responds by
broadcasting thumbwheel position as a message on the
machine CAN bus.
The CAN message is read by the hydraulic control ECU

BR
CANbus interface on connector C048. The ECU responds
by producing a PWM signal in proportion to the
thumbwheel position to the proportional solenoid coils for
Note: For operation of the service solenoids refer to

Control Valve Operation. K Control Valve
Operation ( T 104)
B
JC
114 9813/1400-1 114

Electrics
Joystick Operation
SC4 C050
C048 - J1
34
CAN H
ECU
33
2 CAN L
12
CAN L
11
1 CAN H
IL
4
+5V
AZ
7
GND
5 ECU
6
C081
CAN JOYSTICK
CONTROLLER
SC19
BR
AUX THUMBWHEEL
EXTEND/RETRACT
THUMBWHEEL
C069
C001/
P025
P041 80 C049 - J2
B
FUSE 16
IGN + VE
JC
C116600
Fig 115. Electrical Schematic - Extend/Retract and Auxiliary Services (Thumbwheel Switches)
115 9813/1400-1 115

Electrics
Joystick Operation
Lift/Lower and Tilt Services ECU C081 responds to operation of the joystick by
broadcasting the joystick position as a message on the
machine CAN bus.
K Fig 115. ( T 115)
Key The CAN message is read by the hydraulic control ECU
CAN bus interface on connector C048. The ECU responds
by producing a PWM signal in proportion to the joystick
Connector
position to the proportional solenoid coils for operation of
C048 Hydraulic control ECU - connector J1 the service spools.
Note: For operation of the service solenoids refer to
IL
Control Valve Operation. K Control Valve
C081 CAN joystick controller ECU Operation ( T 104)
P041 Fuse Box E
AZ
SC4 C050
C048 - J1
34
CAN H
ECU
33
CAN L
12
CAN L
11
CAN H
C081 ECU
BR
CAN JOYSTICK
CONTROLLER
C001/
P025
C049- J2
P041 80
FUSE 16
IGN +ve
C116610
Fig 116.
B
JC
116 9813/1400-1 116

Electrics
Stabiliser Lever Operation
The Stabiliser Lever converts the movement from the lever lever changes according to the lever position on the
into an electrical signal for interpretation by the Hydraulic resistor.
Control ECU.
Two signals are output from the unit, signal 1 and signal 2.
The lever is supplied with a 5 volt supply from the ECU. The voltage changes when the lever is moved. Both
The lever moves along a resistor and the output from the signals will always add up to 5v, for example K Table 23.
Lever Output ( T 117)
IL
A B C
5V
AZ
Signal 2
2.5V
0V Signal 1
A B C
BR
C116630
Fig 117. Lever Movement
Table 23. Lever Output

Lever Position Voltage output
C003 Right Stabiliser Control Lever
K Fig 117. ( T 117)
C066 Left Stabiliser Control Lever
A Signal 1 = 5V Signal 2 = 0V
B
B (Neutral) Signal 1 = 2.5V Signal 2 = 2.5V Connector

C Signal 1 = 0V Signal 2 = 5V P115 Manplatform ECU Connector J1
P056 ECU Earth
JC
117 9813/1400-1 117

Electrics
C001/
P025 SP74 P056
78
C001/
P025
SC20 1 3 7
74 P115 - J1
2 4 18
SC17
73
C003
C001/
IL
P025 31
1 3
76
2 4 19
75
C066
C001/
P025 28
AZ
77
ECU
-VE
P116 - J2
C116390-C3
Fig 118. Stabiliser Lever Inputs/Outputs
BR
B
JC
118 9813/1400-1 118

Electrics
Rear Axle Lock (RAL) Operation
The RAL system uses a hydraulic ram B to prevent

movement of the rear axle when using the Man Platform.
The Manplatform ECU gets a signal from the Safety Key A. B

When the switch is present a feed is sent to the ECU and
the relay and the machine is in Cabin Mode.
When the Safety Key is not present the Cabin mode feed
IL
is switched off.
A solenoid C on the RAL ram opens and closes to allow or

prevent hydraulic flow into and out of the ram.
AZ
C
C116810
Fig 120.
K Fig 122. ( T 121) and K Fig 121. ( T 120)
BR
Key
A C001/P025 Chassis Harness to Panel Harness
Connector
C008 Safety Key
C090 RAL Solenoid
P022 RAL Relay
C116430
P041 Fuse Box E
Fig 119.
P044 Earth Point
B

JC
119 9813/1400-1 119

Electrics
C048 - J1
SC21 SC22 ECU

2 1
3
C090
27
IL
C049 - J2
5 3
2
SP77 1 4
P115 - J1
AZ
P022
8 10
7
6
ECU
SP34
17
P116 - J2
C001/
BR
FUSE
1 2
P025
20
81
P041
C008 P044
-VE
+VE
C116800-C1
Fig 121. Safety Key in Cabin Mode, RAL unlocked
When the Safety Key C008 is present in the cab the Safety
Key provides power to the splice SP 77. This energises the
B
RAL Relays P022. The relays supply power and operate

an earth path for the RAL ram solenoid C090. The RAL
ram solenoid opens. This allows hydraulic fluid to flow into
and out of the ram allowing the axle to oscillate.
JC
120 9813/1400-1 120

Electrics
C048 - J1
SC21 SC22 ECU

2 1
3
C090
27
IL
C049 - J2
5 3
2
SP77 1 4
P115 - J1
AZ
P022
8 10
7
6
ECU
SP34
17
P116 - J2
C001/
BR
FUSE
1 2
P025
20
81
P041
C008 P044
-VE
+VE
C116800
Fig 122. Safety Key removed from cab, RAL Locked
When the Safety Key C008 is not present in the cab there
is no power supplied to the splice SP 77. The RAL Relays
B
P022 are not energised. Therefore no power or earth path

is provided for the RAL ram solenoid C090. The RAL ram
solenoid closes. This prevents hydraulic fluid flowing in or
out of the RAL ram and the axle position is locked.
JC
121 9813/1400-1 121

Electrics
Emergency Pump Operation
Emergency Pump Operation
P115 - J1
ECU
8 7
C001/
IL
FUSE 1
20 SC34 2 P025 19
3
P041 83
4
5
6 31
C084 82 8 P116 - J2
AZ
-
+
M
C074
+
+VE
BR
C117610
Fig 123. Emergency Pump in operation
Key
Connector
C074 Pump +ve
C084 Emergency Pump Switch
P041 Fuse Box E
B
When the Emergency pump switch C083 is operated in the

cab a signal is sent to the Manplatform ECU P116.
The Manplatform ECU P116 sends power to the

Emergency pump positive terminal C074.
JC
122 9813/1400-1 122

Electrics
Emergency Boom Operation
Boom Lower
2 C067/
P117 P115 - J1
13
1
4
C015
IL
ECU
C078/
V001
C067/
6 P117
24
P116 - J2
SC32 6
AZ
SC30
C048 - J1
2
ECU
V002
C078/ LOWER SOLENOID
V001
24 SV1
BR
12 SC37 3
C049 - J2
+VE
C117610-C1
Fig 124.
solenoid earth is provided by the Hydraulic Control ECU
C049.
C015 Lower Diode
C048 Hydraulic control ECU - connector J1 When the emergency boom lower service is required the
Manplatform ECU sends a feed to the splice SC30 to
power the Boom Lower Proportional solenoid V002 to
C067/P117 Chassis Harness to Panel Harness lower the boom. The solenoid earth is provided by the
connector 12pin Manplatform ECU via diode C015.
B

connector 12 pin
JC
V002 Proportional control valve solenoid - lower

service
During normal boom operation the Hydraulic Control ECU

C049 supplies power to the Boom Lower Proportional
solenoid V002 when the service is requested. The
123 9813/1400-1 123

Electrics
Boom Retract
C067/
P117 24 P115 - J1
ECU
IL
1
C067/
C072 P117
24
SC32 6
P116 - J2
AZ
C048 - J1
C078/
V001
35
SC38 6
ECU
C078/
SC31 V001
5 SV2
BR
9 5
C049 - J2
V004
+VE RETRACT SOLENOID
C117610-C2
Fig 125.
solenoid earth is provided by the Hydraulic Control ECU
C048.
C049 Hydraulic control ECU - connector J2 When the emergency boom retract service is required the
Manplatform ECU sends a feed to the splice SC31 to
power the Boom Retract Proportional solenoid V004 to
connector 12pin
retract the boom. The solenoid earth is provided by the
C072 Retract Diode Manplatform ECU via diode C072.
B

connector 12 pin
JC

retract service
During normal boom operation the Hydraulic Control ECU

C049 supplies power to the Boom Retract Proportional
solenoid V004 when the service is requested. The
124 9813/1400-1 124

Electrics
Harness Drawings
Harness Drawings
Introduction
Drawings are reproduced from production electrical
harness drawings.
When the drawing is continued on a second or third sheet,

the connecting points between the sheets are identified by
corresponding letters on the drawings.
IL
Example: Connecting points between drawing sheets:
Sheet 1 point X See Sheet 3 point X

Sheet 2 point Y See Sheet 3 point Y
AZ
Each harness drawing includes tables showing wire
connections and destinations for all the connectors on the
harness. These tables are shown on the drawing sheets
following the actual harness drawing.
BR
B
JC
125 9813/1400-1 125

Panel Harness P022 RAS Ram Relay P047A Diode
126
P023 Drive Shaft Relay P047B Diode
Key to Connectors: K Fig 126. ( T 128) P023 Drive Relay P047C Diode
P001 Secondary Fuse Box A P024 Reverse High/Low Relay P047D Diode
P002 Secondary Fuse Box B P024 Forward/High Low Relay P048 Reverse Diode
P003 Secondary Fuse Box C P025 Panel Harness to Chassis Harness P049 Forward Diode
JC
P004 Secondary Fuse Box D Connector 84 pin P049A LLMI
P005 Neutral Start Relay P026 Sway Switch P049B LLMI CANbus
P005 Ignition Relay 5 P027 Air Con Switch +ve P050 Centre Cluster
P006 Engine Run Relay P028 Air Con Switch -ve P051 LMS Cluster Connector J1
P006
P008
P009
Parkbrake Relay
Hazard Lights Relay
Parkbrake Relay
B P029
P030
P031
Hazard Lights Switch
Roof Wiper Switch
Rear Wiper Switch
P052
P053
P054
LMS Cluster Connector J2
Info Switch
Reverse Fan Switch
P009 Steer Mode Relay P032 Fog Lamp Switch P055 Parkbrake Switch
P010 Ignition Relay 3 P033 Road Lights Switch P056 ECU Earth
P010 Ignition Relay 4 P034 Worklamps Switch P057 Steer Changeover Switch
P012 Front Working Lamps Relay P035 2 Wheel Drive SWitch P058 Steer Mode ECU
P012 Rear Working Lamps Relay P036 Beacon Switch
9813/1400-1
P059 Panel Harness to Rear Cab Harness
P013 Brakelights Relay P037 Boom Worklamp Switch Connector
P013 Boom Worklamp Relay P038 Stabiliser Isolation Switch P060 R/H Column Switch
BR
P014 Throttle Relay P039 Engine Crank Relay P061 Ignition Switch
P014 Roadlights Relay P039 Engine Shut Off Solenoid (ESOS) Relay P062 Ignition Switch
P015 Transmission Dump Relay P040 Jib Connector P063 Primary Fuse Blue
P015 2 Wheel Drive Relay P041 Fuse Box E P064 Primary Fuse Grey
P017 Panel Harness to Chassis Harness P041A Diode P065B Diode
Connector 10 pin P041B Diode P065C Diode
P019 Man Platform Ign Relay P042 Heater Connector P065D Diode
P019 Roof Air Con Relay P043 Heater Switch P067 Alternator B+ Signal
AZ
P020 Forward Drive Relay P044 Earth P068 Primary Fuse
P020 Ignition Relay 1 P045 Earth P069 Primary Fuse
P021 Ignition Relay 2 P046 L/H Column Switch P070 Footbrake Switch
P021 Reverse Drive Relay P047 Primary Fuse Box C P071 Face Level Fan +ve
Harness Drawings
126
Electrics
IL
P072 Face Level Fan -ve
127
P073 Washer Pump
P078 Heated Screen
P079 Front Wiper Motor Connector
P080 Auxiliary Socket
P081 Auxiliary Socket Illumination
JC
P085 Radio Connector
P086 Battery
P087 Battery
P088 Diode
P091
P094
P096
Worklamps
Diagnostics Socket
Terminating Resistor
B
P100 Hitch Switch
P101 L/H Headlamp
P102 Audible Alarm
P110 Immobiliser
9813/1400-1
P111 Immobiliser Link
P112 Position Feedback
P113 Cab Emergency Stop
BR
P114 RX Terminator
Connector 12 pin
Connector 14 pin
AZ
Harness Drawings
127
Electrics
IL
128
JC
B
9813/1400-1
BR
721-D1199-SHEET1_1
Fig 126. 721/D1199 Issue 1 Sheet 1
AZ
K Panel Harness ( T 126)
Harness Drawings
128
Electrics
IL
129
JC
B
9813/1400-1
BR
721-D1199-SHEET2_1
AZ
Harness Drawings
129
Electrics
IL
130
JC
B
9813/1400-1
BR
721-D1199-SHEET3_1
AZ
Harness Drawings
130
Electrics
IL
131
JC
B
9813/1400-1
BR
AZ
721-D1199-SHEET4_1
Harness Drawings
131
Electrics
IL
132
JC
B
9813/1400-1
BR
AZ
721-D1199-SHEET5_1
Harness Drawings
132
Electrics
IL
133
JC
B
9813/1400-1
BR
AZ
721-D1199-SHEET6_1
Harness Drawings
133
Electrics
IL
Chassis Harness C039 Chassis Earth C082 Joystick Connector 2
134
C048 Hydraulic Control ECU Connector J1 C083 Emergency Stop Switch
K Fig 132. ( T 135)
C049 Hydraulic Control ECU Connector J2 C084 Emergency Pump Switch
Key to Connectors: C050 Controller Earth C085 Joystick Isolation Switch
C001 Chassis Harness to Panel Harness C051 CANbus Terminator C086 Ground Speed Sensor
Connector 84 pin C052 Chassis Angle Sensor C087 Boom Emergency Stop/Basket Overload
JC
C003 Right Stabiliser C058 Horn Platform Connector
C004 Chassis Harness to Engine Harness C060 Towing Link C088 RCU Battery Charger
Connector C062 Chassis Harness to Stabiliser Harness C089 Constant Aux Switch
C005 R/H Headlamp Connector C090 RAL Ram
Connector
C007 Reverse Fan Solenoid
B
C006 Chassis Harness to Transmission Harness C063 Chassis Harness to Sway Harness
Connector
C065 Trailer Tip Valve
C091 Isolation Solenoid
C092 Position Feedback
C093 Receiver Signal
C008 Safety Key C066 Left Stabiliser C094 Receiver -ve
C009 Number Plate Lamp C067 Chassis Harness to Panel Harness C095 Receiver +ve
C010 Chassis Earth Connector 12 pin (Throttle Wiring).
C011 Cold Start C068 Joystick Connector 1
C012 Agglomerator (Water in fuel) C069 Joystick Connector 3
9813/1400-1
C015 Lower Diode C070 Radio Receiver
C017 R/H Rear Lamp C071 Axle Transducer

BR
C018 L/H Rear Lamp C072 Retract Diode
C020 Number Plate Lamp C074 Pump +ve
C021 Reverse Alarm C075 Tilt Lock Switch
C023 Boom Angle Sensor C076 Chassis Harness to Valve Block Harness
Connector 6 pin
C024 Rear Steer Proximity Switch
C077 Throttle Actuator
C026 Front Steer Proximity Switch
C078 Chassis Harness to Valve Block Harness
C029 All Wheel Steer Solenoid C079 Chassis Harness to Panel Harness
AZ
C031 Crab Steer Solenoid C080 Chassis Harness to Panel Harness
Connector 10 pin
C035 Fuel Level Sender
C036 Air Filter Vacuum Switch
Harness Drawings
134
Electrics
IL
135
JC
B
9813/1400-1
BR
AZ
721-D5579-2-Sheet 1
K Chassis Harness ( T 134)
Harness Drawings
135
Electrics
IL
136
JC
B
9813/1400-1
BR
AZ
721-D5579-2-Sheet 2
Harness Drawings
136
Electrics
IL
137
JC
B
9813/1400-1
BR
721-D5579-2-Sheet 3
AZ
Harness Drawings
137
Electrics
IL
Valve Block Harness
138
K Fig 135. ( T 139)
Key to Connectors:
V001 Valve Block Harness to Chassis Harness
Connector 12 pin
JC
V002 Boom Lower Solenoid
V003 Boom Raise Solenoid
V004 Boom Retract Solenoid
V005 Boom Extend Solenoid
V006
V007
V008
Carriage Dump Solenoid
Carriage Crowd Solenoid
Aux B Solenoid
B
V009 Aux A Solenoid
L001 R/H Stabiliser Lower Solenoid
L002 R/H Stabiliser Raise Solenoid
L003 L/H Stabiliser Lower Solenoid
9813/1400-1
L004 L/H Stabiliser Raise Solenoid
L005 Valve Block Harness to Chassis Harness
Connector 6 pin
BR
AZ
Harness Drawings
138
Electrics
IL
139
JC
B
9813/1400-1
BR
721-E1793_1-SHEET1.eps
Fig 135. 721/E1793 Issue 1
K Valve Block Harness ( T 138)

AZ
Harness Drawings
139
Electrics
IL
Stabiliser Harness SH001 Mainframe Connector SS1 Ground
140
SH002 LH Stab Transducer SS2 Positive
Key to Connectors: SH003 RH Stab Transducer
JC
B
9813/1400-1
BR
AZ
Fig 136. 721/G8007 Issue 2
Harness Drawings
140
Electrics
IL
Sway Harness AA TBA AD TBA
141
AB TBA
Key to Connectors: AC TBA
JC
B
9813/1400-1
BR
Fig 137. 721/G0809 Issue 1
AZ
Harness Drawings
141
Electrics
IL
Boom Harness L001 Work Lamp Connector BW03 Chassis Connector
142
L002 Retract Proximity Switch
Key to Connectors: L003 Cable Reel
JC
B
9813/1400-1
BR
721/D9454-1
AZ
Fig 138. 721/D9454 Issue 1
Harness Drawings
142
Electrics
IL
Fixed Basket Harness BA001 Cable Reel
143
BA002 Overload Switch
Key to Connectors: BA003 Stop Switch
JC
B
9813/1400-1
BR
AZ
721-D9453_2-SHEET1.eps
Fig 139. 721/D9453 Issue 2
Harness Drawings
143
Electrics
IL
Slew Basket Harness BA001 Cable Reel
144
BA002 Overload Switch
Key to Connectors: BA003 Stop Switch
JC
B
9813/1400-1
BR
AZ
721-E6898_2-SHEET1.eps
Fig 140. 721/E6898-2
Harness Drawings
144
Electrics
IL
Electrics
Removal and Replacement
Stabiliser Levers
Removal
IL
G
B C
A G
AZ
F
D B
A
BR
C
A H
E
B
C116630-C4.eps
Fig 141.
Note: The lever is a non serviceable part. If it is faulty it 5 Turn the trim plate C over to get access to the
must be renewed. stabiliser lever securing screws G.
JC
1 Park the machine and make it safe with the boom 6 Remove the securing screws G and remove the
lowered. Refer to General Procedures. K General levers B from the trim plate.
Procedures ( T 1)
Replacement
2 Remove the screws A and lift the trim plate C
sufficiently to get access to the electrical connectors Replacement is the opposite of the removal procedure.
to the rear of the switches D and E.
During the replacement procedure do this work also:
3 Put a label on the electrical connectors to aid
identification when replacing. – Make sure that the stabiliser levers are positioned as
shown at F (each lever position is different).
4 Disconnect the stabiliser lever electrical connectors
H.
145 9813/1400-1 145

Electrics
LMI Transducer 5 Cut the cable securing tie A.
Removal 6 Remove the transducer cover bracket screws B and

remove the bracket C.
!MWARNING 7 Remove bolts E and F and remove the transducer D.

A raised and badly supported machine can fall on you.
Position the machine on a firm, level surface before
raising one end. Ensure the other end is securely
chocked. Do not rely solely on the machine hydraulics
or jacks to support the machine when working under E
IL
it.
Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-1-1
AZ
1 Park the machine and make it safe with the boom
lowered. Refer to General Procedures. K General
Procedures ( T 1)
2 Raise the rear end of the machine, under the chassis,

until the rear wheels are clear of the ground.
C117670
Important: Do not lift the machine from under the axle. Fig 143.
3 Remove a road wheel, position and support the axle

to get access to the transducer.
BR
4 Disconnect the electrical harness connector G.
A
B
D
JC
C
B B
C116680 C124750
Fig 142. Fig 144.
146 9813/1400-1 146

Electrics
Replacement e If the output is still out of range replace the
transducer.
1 Remove any old sealant, rust, dirt or paint from the
mating faces on the transducer and axle. f If the output is still out of range the axle mounting
surfaces will need to be inspected. If the surfaces
2 Make sure the mounting faces are flat, level and free are not completely flat or have a poor surface
of burrs. finish this can affect the transducer output.
3 Using JCB Solvent remove any surface 11 Replace the transducer cover bracket C and screws
contamination from the mating faces of the D (if fitted).
transducer and axle. Make sure that the faces are
IL
clean, dry and free of grease. Make sure that the 12 Use a cable securing tie A to secure the harness to
threaded holes are clean and free from grease. the bracket C.
4 Allow the Solvent to dry (approximately 1 minute at 13 Calibrate the LMI system.
20ºC).
5 Apply JCB Locking Fluid High Strength to the
AZ
transducer mating face on the axle
6 Position the transducer D on the axle.
Note: Do not apply locking fluid to the bolts E.
7 Secure the transducer with bolts E.
8 Torque tighten the bolts E. K Table 24. Torque

Settings ( T 147)
BR
Table 24. Torque Settings
Item Nm kgf m lbf ft
E 67 6.83 49.4
9 Connect the electrical harness. Ensure the cable to

the transducer is secured clear of the axle oscillation
stops, and cannot be damaged by movement of the
trackrod.
10 Use a Test Box to check the transducer output is in

the range of 44.0 mA to 56.0 mA. If the output is
outside of this range do the following:
B
a Loosen bolts E and torque tighten again.

K Table 24. Torque Settings ( T 147)
b Check output - as in Step 10.

JC
c If output is still out of range, loosen bolts E and

torque tighten in the opposite order. K Table 24.
Torque Settings ( T 147)
d Check output - as in Step 10.
147 9813/1400-1 147

Electrics
Hydraulic Electronic Control Unit (ECU)
IL
AZA
A
BR
B
C
D
C117560
Fig 145.
B
Before renewing the ECU note the following: If replaced with a new unit make sure to configure the ECU
correctly using JCB Servicemaster.
The ECU is a non serviceable part. Any units returned
under warranty found to have been tampered with will Removal
invalidate any claim.
JC

Before renewing the ECU carry out all the relevant fault raised. Refer to General Procedures. K General
finding and diagnostics to make sure that the ECU is Procedures ( T 1)
defective. Units returned under warranty found not to be
faulty will invalidate any claim. 2 Working below the boom put a label on the ECU
harness connectors to aid identification when
replacing.
148 9813/1400-1 148

Electrics
3 Disconnect the ECU harness connectors from the
ECU.
4 Disconnect the harness connector from the Chassis

Angle Sensor (not shown).
5 Support the ECU D.
6 Remove the ECU bracket securing screws A and lift

the ECU D and bracket C from the machine.
IL
7 Support the ECU D and remove the nuts and bolts B
and remove the ECU D from the bracket C.
Replacement
Replacement is the opposite of the removal procedure.
AZ
BR
B
JC
149 9813/1400-1 149

Electrics
Manplatform Electronic Control Unit Before renewing the ECU carry out all the relevant fault
finding and diagnostics to make sure that the ECU is
(ECU)
defective. Units returned under warranty found not to be
faulty will invalidate any claim.
The ECU is a non serviceable part. Any units returned
under warranty found to have been tampered with will
If replaced with a new unit make sure to configure the ECU
invalidate any claim.
correctly using JCB Servicemaster.
Removal
IL
AZ
BR
C066660-C2
Fig 146.
1 Park the machine and make it safe with the boom Replacement
Procedures ( T 1) Replacement is the opposite of the removal procedure.
2 Support the ECU 4 and bracket 2. During the replacement procedure do this work also:
3 Remove the four bolts 1 which secure the ECU – Install a new cable tie through the slots 3 to secure the
B
bracket 2 to the underside of the drivers seat platform. harness to the bracket 2.
– To ensure correct installation, the ECU harness
4 Remove and discard the cable tie. connectors have different key slot positions.
5 Remove the four bolts 5 and nuts 6 which secure the

JC
ECU 4 to the mounting bracket 2.
6 Remove the ECU 4 from the bracket 2.
7 Disconnect the ECU harness connectors and position

them away from the ECU.
150 9813/1400-1 150

Electrics
Radio Receiver 1 Park the machine and make it safe with the boom
Removal Procedures ( T 1)
2 Support the cover plate B and remove the screws A.
A 3 Remove the cover plate B from the machine.
4 Disconnect the receiver electrical connector F from

the chassis harness.
IL
5 Remove any cable ties/cable clips E making a note of
their position to aid replacement.
6 Support the receiver D.
7 Remove the bolts C and remove the receiver from the

B machine.
AZ
Replacement

C117660
Fig 147. During the replacement procedure do this work also:
– Make sure to replace cable ties/cable clips E in the

correct positions.
BR
C
E
B
E
JC
F
C117640
Fig 148.
151 9813/1400-1 151

Electrics
Platform Weight Limit Switch
3 5
IL
2 4
AZ C124710-C2
BR
Fig 149.
Removal Replacement
1 Park the machine and make it safe with the boom Replacement is the opposite of the removal procedure.
Procedures ( T 1) During the replacement procedure do this work also:
2 Make sure that the Man Platform is lowered to the – The weight limit system will need to be calibrated and
ground and suitably supported. the adjuster stop 3 will need to be set correctly.
K Adjustment ( T 152)
3 Disconnect the platform harness from the switch
harness connector 1. Adjustment
B
4 Remove the bolts 2 and remove the switch from the 1 Adjust the stop 3 so that the switch contacts open
mounting 4. when there is between 420-440 Kg of weight on the
platform.
JC
2 When the adjustment is correct torque tighten the nut

5. K Table 25. Torque Settings ( T 152)

5 56 5.7 41
152 9813/1400-1 152

Electrics
Engine Speed Actuator
IL
1
AZ
BR
1 2 3
B
JC
4 5 4 6 7
C096550-C4
Fig 150.
Removal 2 Stop the engine and remove the starter key. Raise the
engine cover.
Procedures ( T 1)
153 9813/1400-1 153

Electrics
!MWARNING
The engine has exposed rotating parts. Switch OFF the
engine before working in the engine compartment. Do
not use the machine with the engine cover open.
5-2-6-5
3 Remove the bolt 2 and the nut 3.
4 Remove the control rod 6 from the actuator 5.
IL
5 Remove the bolts 1.
6 Support the actuator 5 and remove the bolts 4.
7 Remove the actuator 5 from the engine.
Replacement
AZ
– Torque tighten the bolts 4. K Table 26. Torque

Settings ( T 154)
– Check the adjustment. K Adjustment ( T 155)

BR
4 22-26 2.2-2.6 16.2-19.1
B
JC
154 9813/1400-1 154

Electrics
Adjustment
IL
AZ
BR
1 2 3 4
C096550-C5
Fig 151.
1 Park the machine on firm level ground and engage 6 Put the engine speed setting to the maximum
the parking brake, see Section 2 - General position.
Procedures.
7 Make sure that the injection pump lever 4 is at the
2 Raise the boom and fit the safety strut, see Section 2 maximum position.
- General Procedures.
8 If the stop 2 requires adjustment:
3 Stop the engine and remove the starter key. Raise the
engine cover. a Slacken the bolt 3.
B
!MWARNING b Move the stop 2.
The engine has exposed rotating parts. Switch OFF the c Tighten the bolt 3 and repeat steps 4 to 7.
engine before working in the engine compartment. Do
JC
not use the machine with the engine cover open.

5-2-6-5
4 Put the engine speed setting to the minimum position.
5 Make sure that the stop 2 is clear of the injection

pump lever 4 and that the engine is at idle speed.
155 9813/1400-1 155

Electrics
Cable Reel
1 2
IL
5
3
AZ
BR
B
C124780
Fig 152.
Removal Replacement
1 Park the machine and make it safe with the boom Replacement is the opposite of the removal procedure.
JC

Procedures ( T 1)
2 Make sure that the Man Platform is lowered to the

ground and suitably supported.
3 Disconnect the cable connectors 4 and 5 from the

boom harness and platform harness.
4 Support the cable reel assembly 1.
5 Remove the bolts 3 and remove the cable reel

assembly 1 from the mounting bracket 2.
156 9813/1400-1 156

Electrics
Cable Guide Pulley
IL
1
2
6
AZ
5 3
4
2
C124790
Fig 153.
BR
Removal – Make sure that the pulley rotates freely. If not -
replace.
Procedures ( T 1)

ground and suitably supported.
3 Remove the nut 6 and washer 5.
4 Support the pulley 4.

B
5 Pull out the pulley pin 3 and make sure to retain the
spacers 2.
6 Remove the pulley 4 from the bracket 1.

JC
Replacement
157 9813/1400-1 157

Electrics
Platform Emergency Isolation Switch
IL
5
1
AZ
BR
2
3
C127600.eps
Fig 154.
Removal 4 Pull the switch electrical connector 5 through the

B
grommet 3.
lowered. Refer to General Procedures. K General 5 Remove the nuts 2 and remove the switch 1.
Procedures ( T 1)
Replacement
JC

ground and suitably supported. Replacement is the opposite of the removal procedure.
3 Disconnect the platform harness connector 4 from the

switch harness connector 5.
158 9813/1400-1 158

Hydraulics
Specifications
This supplement refers to components that differ from the machine service manual. K About this
standard non manplatform machine specification. For Supplement ( T 1)
details of standard specification components refer to the
Control Valve
IL
Table 27.
Type: 6 Spool, load sense - pressure compensated, double acting spools K Fig 155. ( T 160)
C Outlet Section
Spool 1 L/H Stabiliser Integral proportional electro servo pilot operated
AZ
Spool 2 R/H Stabiliser Integral proportional electro servo pilot operated
Spool 3 Auxiliary Service Integral proportional electro servo pilot operated
Spool 4 Carriage Tilt Service Integral proportional electro servo pilot operated
Spool 5 Boom Extend & Retract Service Integral proportional electro servo pilot operated
Spool 6 Boom Raise & Lower Service Integral proportional electro servo pilot operated
G Inlet Section
Pressures: K Fig 155. ( T 160)

BR
bar kgf/cm2 lbf/in2
F - Load Sense Relief Valve (1) 260 265 3770
Auxiliary Relief Valves (ARV's) (2)
D and J - Auxiliary Service 220 224 3190

E and H - Carriage Tilt 276 281 4003
(1) Before testing the Load Sense Relief Valve pressure, allow the hydraulic system to warm up to 50 °C (122 °F) to ensure
an accurate reading.
(2) The ARV’s are not adjustable. If the pressure setting is incorrect the ARV must be replaced.
B
JC
159 9813/1400-1 159

Hydraulics
Specifications
IL
D
3 J
E
H
AZ
4
6
BR
F G
C116210-C1
Fig 155.
B
JC
160 9813/1400-1 160

Hydraulics
Specifications
Emergency Hydraulic Pump
Table 28.
Type: Electric Motor Driven Single gear pump
Motor Specification: 1500W, 12V Relay, 150A
Direction of Rotation: Anti-clockwise
Theoretical displacement: cc/rev cu in/rev
1.6 2.19
Speed: 1300 rpm
IL
Weight: 10.8 kg
AZ
BR
B
JC
161 9813/1400-1 161

Hydraulics
Component Location
Component Location
Machine Components
IL
AZ
1
BR
2 3
4
5
6
B
7
JC
C117680
Fig 156.
Item Description
Item Description 4 Control Valve
1 Control Lever 5 Emergency Pump
2 Hydraulic Control ECU 6 RAL Ram
3 Manplatform ECU 7 RAL Valve
162 9813/1400-1 162

Hydraulics
Component Location
Platform Slew Components
A
A
IL
AZ
B
B
D
BR
C
C
C116330
Fig 157. Platform Slew Components (if fitted)
B
Item Description
A Quick Release Couplings
B Sequence Valves
C Slew Rams
JC
D Pilot Operated Check Valves
163 9813/1400-1 163

Hydraulic Operation and Schematics
164
Hydraulic Schematic 3 Steering Unit 15 Stabiliser Hydraulic Cylinder LH
3A Steer valve 15A Lock-out valve
Table 29. Component Key:
K Fig 158. ( T 165) 3B Shock valves (option) - if fitted 15B Pressure switch
3C Main relief valve 16 RAL Valve
JC
B Pressure cap breather
F Filter 3D Non-return valve 16A RAL Ram
F1 Filter by-pass 4 Cooling Fan Motor 17 Steer Mode Valve
S Pump suction strainer 5 Reversible Cooling Fan Motor (option) - if 17A 2 Wheel steer solenoid
fitted 17B 4 Wheel and crab steer solenoid
T Tank
1
1A
Pump Assembly
Main pump
B 5A
5B
6
Relief valves
Fan change-over solenoid
Sway/Fan Selector Valve
17C
17D
Crab steer solenoid
4 Wheel steer solenoid
1B Fan pump 18 Front Power Track Rod

6A Sway Direction Valve 19 Sway Ram
1C Check Valve
6B Sway/Fan Circuit Selector Valve 19A Pilot Operated Check Valve
1D Priority valve
7 Slew Hydraulics (if fitted) 19B Restrictor
2 Valve Block
7A Slew Ram 20 Restricted Non Return Valve
2A Load Sense Relief Valve (LSRV)
9813/1400-1
7B Pilot Operated Check Valve 21 Rear Power Track Rod
2B By Pass Compensator
7C Sequence Valve
2C Pump Pressure test point
7D Check Valve (Trailer Brake)
BR
2D Lift spool
8 Lift Ram
2E Extension spool
8A Lift Ram Counterbalance Valve
2F Tilt spool
9 Displacement Ram
2G Auxiliary spool
10 Tilt Ram
2H LS Drain Valve
10A Tilt Ram Counterbalance Valve
2J R/H Stabiliser Spool
11 Extension Ram
2K L/H Stabiliser Spool
11A Extension Ram Counterbalance Valve
2L Auxiliary relief valve (ARV)
12 Auxiliary Boom Quick Release Couplings
AZ
2N Load Sense pressure test point
13 Emergency Pump
2P Accumulator
14 Stabiliser Hydraulic Cylinder RH
2R Magnom Filter
14A Lock-out valve
2S Mesh Filter
14B Pressure switch
164
Hydraulics
IL
19B 19A
165
19B
19 A
17C
17D 6 2C
21 6A 2 2P
18 2R 2S
17A 17B 6B
17 7A 7 7A
JC
15B 15
5
2K 7B 7B
15A
5B 7C
3B 5A 7C
3 14A
2J
3A
3D 3C
4
B 2G
2L
14B 14
12
7D 7D
10A
10
2L
2L 9
2F
10A
11A
2L 11
2E 11
F
11A
F1 11A
9813/1400-1
A
2D
8A 8
B
BR
1C 2B
1D 16
2A
T 13 16A
S 1 1B 1A
2C
2N
2H
AZ
333-e9361-2-sheet1.eps
Fig 158. 333/E9361 Issue 2
165
Hydraulics
IL
Hydraulics
Control Valve
Load Sensing
The hydraulic system incorporates a hydraulic load sense

circuit. When no services are operated, there is no
demand for flow from the hydraulic system, the oil from the
gearpump flows to the inlet section of the control valve and
directly back to tank.
When a service is operated, the system senses the
IL
demand and responds by increasing the pump operating
pressure to a value slightly above that required to move the
load. The load sense feature also incorporates the main
pressure relief function, which is controlled by the load
sense relief valve.
AZ
BR
B
JC
166 9813/1400-1 166

Hydraulics
Electronic Servo Proportional Control
IL
AZ
3
BR
CANBus
C106610-C1.eps
Fig 159. Electro Servo Control
The control lever 1 and attached thumbwheels operate the changes the analogue signals and broadcasts messages
boom and auxiliary hydraulic services using electrical on the machine CANbus.
B
signals.
The Stabiliser Control Levers 5 operate the stabiliser
This type of lever has two functions, Proportional hydraulic services.
thumbwheel control and electro servo lever control.
The control lever and thumbwheel switches and stabiliser
JC
The control lever moves in two axis and also includes two control levers control twelve electro proportional solenoid
thumbwheel switches. valves which operate the six service spools in the valve
block 4.
In the control lever assembly is the powerbase ECU 2. The
ECU receives analogue electrical inputs in relation to the The hydraulic control ECU 3 recognises the CAN
movement of the lever or thumbwheel switches. The ECU messages and generates the correct PWM signal for
167 9813/1400-1 167

Hydraulics
operation of the proportional solenoids in the control valve
block 4.
The proportional solenoid valves operate as pressure

reducing valves. These supply servo pilot oil to move the
auxiliary, boom service or stabiliser service spool. The
supply is at a pressure in relation to the amount the
operator moves the joystick or thumbwheel switch.
IL
AZ
BR
B
JC
168 9813/1400-1 168

Hydraulics
Electro Servo Control Valve
Component Identification
1 9 8 7
IL
AZ
2
2
2
2
BR
B
6
3
4 5
JC
C116240
Fig 160.
Item Description Item Description
1 Accumulator 8 Outlet Port
2 ARV 9 Accumulator Check Valve
3 LSRV
4 Tank Port
5 Inlet Port
6 Inlet Section
7 Sump Port
169 9813/1400-1 169

Hydraulics
Pressure Compensation (Flowshare)
IL
E D
T
AZ T E
BR
P F G
C094420
Fig 161. Servo Pilot Operated Spool
Each service spool incorporates a pressure compensator The closed centre design ensures consistent service
valve F. When services are operated simultaneously the operation regardless of load.
system ensures consistent operating speed for all
services, even when the limit of the hydraulic pump For a full description of service spool and pressure
performance is approached. compensator valve operation refer to the applicable
machine service manual. K About this
Oil from the main hydraulic pump arrives at the inlet gallery Supplement ( T 1)
P. When the relevant service spool D is selected, the spool
moves against the force of the centring spring E, allowing Note: Any pressure values stated are for illustration only,
B
the oil to flow to move the required service. When the please see relevant specifications or schematic layout for
service spool D is de-selected the centring spring returns correct pressures for the vehicle variant.
the spool to the neutral position.
When one or more services are selected the pressure

JC
compensator valve F detects the service generating the

highest pressure and allows the pump to deliver oil at
sufficient pressure to move the load. The load hold check
valve G prevents the load falling back if the load pressure
is greater than the pump pressure.
170 9813/1400-1 170

Hydraulics
Main Hydraulic Circuit

To make the description as clear as possible the diagram
shows only part of the full hydraulic system. For the full
hydraulic schematics refer to the schematics.
No Services Operated
K Fig 162. ( T 172)
Oil from the primary pump 1a flows to the steer priority
IL
valve 1c. When there is no demand from the steering
system the hydraulic oil flows to the inlet section of the
control valve 3. As there is no load sense pressure the by-
pass valve 3a opens and the main pump flow is dumped to
tank.
AZ
Oil from pump 1B flows to the hydraulic fan motor 4.
The return from the fan passes through the return filter 5.
BR
B
JC
171 9813/1400-1 171

Hydraulics
C117580
IL
AZ
BR
Fig 162.
3
B
1c
1a
1b
JC
4
172 9813/1400-1 172

Hydraulics
Service Operation
When a service is operated, the boom extend for example,

movement of the control lever sends a signal to the ECU.
The ECU energises the related proportional solenoid valve
3b which operates and causes pilot oil to move the spool
3c. Oil flows across the service spool to the pressure
compensator valve 3e. The valve opens and sends oil to
the load sense gallery and load hold check valve 3f.
During service operation the main system pressure
IL
continues to increase until the load hold check valve 3f
opens and the boom extend ram 6 operates.
Oil from the other side of the ram 6 flows across the service
spool and back to the tank in the normal way.
Multiple Service Operation
AZ
In the normal hydraulic system the services are connected
in parallel. When multiple services are operated at the
same time, the operating pressure of one service can have
an effect on the speed of another service. This does not
occur with this system.
The pressure compensator valves for each service adjust

in relation to the differing load pressures. For example,
when a pressure compensator valve 3e senses a higher
BR
load sense pressure from another service, it decreases the
flow to its own service. The decrease in flow makes sure
that all the services operate at a stable speed
independently of the main system pressure.
B
JC
173 9813/1400-1 173

Hydraulics
C117580-C1
6
IL
AZ
3d
3e
3c
3f
3b
BR
3a
Fig 163.
3
B
1c
1a
1b
JC
4
174 9813/1400-1 174

Hydraulics
Main System Pressure Relief
IL
A
AZ
P T
C117580-C2
Fig 164.
When a service ram is at the end of its stroke or there is a

resistance, the pressure in the load sense line increases.
When this pressure is above 260 bar, the load sense relief
valve (LSRV) A opens and load sense oil is sent to tank, to
stop an increase in pressure.
BR
The LSRV unit includes a drain regulator valve B. The
drain regulator valve allows the excess load sense
pressure to drain to tank when no spools are operated. The
valve will close the drain line when the service spools are
in operation.
Note: The load sense pressure relief valve is factory set

and sealed with a plastic tamper proof cap. No adjustment
is normally necessary.
B
JC
175 9813/1400-1 175

Hydraulics
Slew Hydraulic Circuit
A B
IL
C C
AZ
BR
G
D
D G
B
JC
C116260
Fig 165.
The slew circuit is fed by the machine auxiliary circuit via
Item Description
the Quick Release Couplings A and B.
A Male Quick Release Coupling
B Female Quick Release Coupling The Sequence Valves G are used to ensure that the slew
rams E and F operate in the correct sequence.
C Check Valves
D Pilot Operated Check Valves The Pilot Operated Check Valves D are used to ensure
E Slew Ram B that only hydraulic pressure will operate the rams E and F
and not external forces.
F Slew Ram A
G Sequence Valves
176 9813/1400-1 176

Hydraulics
Slew Locks
The platform has two slew locks A. These are used to lock
the platform in position and when transporting.
For Slew Lock operation refer to the machine operator

manual.
IL
A AZ
BR
C124670-C1.eps
Fig 166.
B
JC
177 9813/1400-1 177

Hydraulics
Emergency Pump
IL
8
8a
In case of emergency, (engine failure for example) an AZ

Fig 167.
C117580-C4
BR
independent electrically driven hydraulic pump 8 is
provided. The pump allows the platform to be safely
lowered to the ground from the platform or the cab.
The pump is connected to the fan return line. This line is

used as a pump feed line in emergency operation. The
pump provides a feed to the control valve 3 to allow limited
low pressure operation of the boom services.
The check valve 8a prevents main pump flow from entering

the emergency pump circuit.
B
JC
178 9813/1400-1 178

Hydraulics
Rear Axle Lock (RAL)

RAL not Active
7c
7d
IL
7b
7
7
AZ
7a 7a 7b
7a 7a
3
7c
BR
C117580-C3
Fig 168. Rear Axle Lock not active
B
The RAL system is supplied by the main feed to the control

valve 3. The maximum pressure is limited to 30 bar by the
pressure reducing valve 7c.
The RAL solenoid valve 7b is located in the RAL Valve

block 7. When the solenoid valve 7b is energised the ports
JC
B and A are connected. This allows to the ram 7d to move

when the axle oscillates.
179 9813/1400-1 179

Hydraulics
RAL Active
7c
7d
7b
7
7
IL
7a 7a
7a 7b 7a
3
AZ 7c
BR
C117580-C5
Fig 169. Rear Axle Lock active
The RAL solenoid valve 7b located in the RAL Valve block

7. When the solenoid valve 7b is not energised the ports B
and A are not connected. This prevents the ram 7d moving
therefore preventing axle oscillation.
B
High ambient temperatures cause the hydraulic oil to

expand increasing the pressure inside the ram. Relief
valves 7a protect the ram from excessive pressure.
JC
180 9813/1400-1 180

Hydraulics
Engine Switched Off
7c
7d
7b
7
7
IL
7a 7a
7a 7b 7a
3 7e 7e
AZ 7c
BR
C117580-C6
Fig 170.
When the engine is switched off there is no pump flow. Non

return valves 7e close due to spring pressure and the
pressure inside the ram circuit is maintained.
B
JC
181 9813/1400-1 181

Hydraulics
Hose and Pipework

Main Hydraulics and Sway
IL
B D
E
F
A G
C H
AZ
J K
M
N S
P
BR
C116250
Fig 171.
Item Description Item Description
A Hydraulic Tank Filler Pipe M From Steer Valve Port P
B Main Return Line N Sway Valve
C Hydraulic Tank P Fan Return Filter
B
D Steering Return Line R Control Valve

E Fan Return Line S Sway Ram
F LS Return Line
G Sway Return Line
JC
H Fan Drain Line

J To Steer Valve Port LSI
K Hydraulic Pump
L Two Way Poppet Valve
182 9813/1400-1 182

Lift End Hydraulics
183
A
JC
F
B D
9813/1400-1
G
BR
C
B
C124600
Fig 172.
AZ
Item Description Item Description Item Description
A Control Valve D Outer Extension Ram G Tilt Ram
B Displacement Ram E Inner Extension Ram
C Lift Ram F Quick Release Coupling
183
Hydraulics
IL
Hydraulics
Test Procedures
Test Procedures
Pressure Testing
Load Sense Relief Valve
!MWARNING
Fluid Under Pressure
IL
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2
AZ
The maximum pressure that can be achieved within the
main hydraulic system is set by the load sense relief valve
(LSRV) B at the control valve block inlet section. To check
the load sense relief valve setting carry out the procedure
described below: B
Make sure that the hydraulic fluid is at working
temperature, i.e. 50°C (122°F).
C116270-C1
Fig 174.
BR
raised. Refer to General Procedures. K General
Procedures ( T 1)
2 Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure

gauge to the main system pressure (pump) test point
A.
3 With the engine running at 1500 rpm, check the load

sense relief valve setting by operating the boom
retract service and hold the boom ram fully closed.
Note the maximum reading on the pressure gauge.
The pressure reading must be between 260-265 bar
when the LSRV opens.
B
4 If the pressure is incorrect adjust the LSRV.

K Adjustment ( T 185)
JC
C127860.eps
Fig 173.
184 9813/1400-1 184

Hydraulics
Test Procedures
Adjustment Table 30. Torque Settings
C 9.5 0.96 7
IL
AZ
B
C
C116270
Fig 175.
BR
Note: Remove the LSRV protective cap. Always replace
after testing/adjustment.
1 If the maximum pressure is incorrect, adjust the relief

valve as described below:
a Position the boom and fit the Safety Strut.
b Switch OFF the engine and vent residual

hydraulic pressure.
c Remove the plastic cap from the load sense relief

valve. Loosen the locknut C and turn the adjuster
B
screw B clockwise to increase pressure and

counter-clockwise to decrease the pressure.
When the pressure is correct, tighten the locknut
and check the pressure again. Adjust as required.
JC
d When the pressure setting is correct torque

tighten the locknut C. K Torque
Settings ( T 185)
185 9813/1400-1 185

Hydraulics
Test Procedures
Auxiliary Relief Valve Pressure (ARV) - ARV’s set
lower than the LSRV
1 Park the machine and make it safe. Vent the hydraulic

pressure, see Section 2 - General Procedures.
2 Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure

gauge to the test point A.
3 Start the engine and bring the hydraulic system upto

working temperature 50º C (122º F).
IL
4 Set the engine to idle rev/min. and operate the
relevant service to full travel. Hold while checking the
maximum gauge reading which should be as stated in
Specifications. K Specifications ( T 159)
A335530-C4
Important: The engine must not be run at maximum Fig 177. Test Point (Typical Triple Pump)
AZ
speed as a significant increase in pressure will be
recorded.
5 If the pressure is incorrect, replace the relevant

A.R.V. K Auxiliary Relief Valve
Replacement ( T 189).
BR
B
416111-C10
Fig 176. Test Point (Typical Double Pump)
JC
186 9813/1400-1 186

Hydraulics
Test Procedures
Testing ARV’s Set Higher than the LSRV
IL
AZ
BR
C089870
Fig 178.
Tilt Ram the hose. Fit a 0 - 400 bar (0 - 6000 lbf/in2)

pressure gauge to the test point C. Make sure that
1 Head side A.R.V. there will be clearance between the test point and
chassis when the boom is lowered.
!MWARNING c Start the engine and remove the safety strut.
Hydraulic Pressure Slowly lower the boom to the horizontal position.
Hydraulic fluid at system pressure can injure you. As the boom is lowered the pressure gauge will
Before connecting or removing any hydraulic hose, show the A.R.V. pressure, which should be as
residual hydraulic pressure trapped in the service stated.
hose line must be vented. Make sure the hose service
B
line has been vented before connecting or removing d If the pressure is incorrect, replace the A.R.V.
hoses. Make sure the engine cannot be started while K Auxiliary Relief Valve Replacement ( T 189).
the hoses are open.
INT-3-1-11_2
!MWARNING
JC
a Park the machine and make it safe. Fit the boom Take care when disconnecting hydraulic hoses and
safety strut. Vent the hydraulic pressure. Obey the fittings as the oil will be HOT.
care and safety procedures. Vent the hydraulic TRANS-1-2
e After completing the test, fit the boom safety strut.
b Disconnect hose A from pipe connector B. Fit a Vent the hydraulic pressure. Obey the care and
test point C to the pipe connector and reconnect
187 9813/1400-1 187

Hydraulics
Test Procedures
safety procedures, see Section 2 - General f Disconnect the pressure gauge, remove the test
Procedures. point and reconnect the tilt ram head side hose A
to pipe connector B.
IL
AZ
C089890
Fig 179.
2 Rod side A.R.V. d If the pressure is incorrect, replace the A.R.V.

K Auxiliary Relief Valve Replacement ( T 189).
!MWARNING
Hydraulic Pressure
!MWARNING
Hydraulic fluid at system pressure can injure you. Take care when disconnecting hydraulic hoses and
Before connecting or removing any hydraulic hose, fittings as the oil will be HOT.
BR
residual hydraulic pressure trapped in the service TRANS-1-2
line has been vented before connecting or removing e After completing the test, fit the boom safety strut.
hoses. Make sure the engine cannot be started while Vent the hydraulic pressure. Obey the care and
the hoses are open. safety procedures, see Section 2 - General
INT-3-1-11_2 Procedures.
a Park the machine and make it safe. Fit the boom f Disconnect the pressure gauge, remove the test
safety strut. Vent the hydraulic pressure. Obey the point and reconnect the tilt ram head side hose A
care and safety procedures. Vent the hydraulic to pipe connector B.
b Disconnect hose A from pipe connector B. Fit a

B
test point C to the pipe connector and reconnect

the hose. Fit a 0 - 400 bar (0 - 6000 lbf/in2)
pressure gauge to the test point C. Make sure that
there will be clearance between the test point and
chassis when the boom is lowered.
JC
c Start the engine and remove the safety strut.

Slowly lower the boom to the horizontal position
then slowly raise the boom to approximately 45°
angle. As the boom is raised the pressure gauge
will show the A.R.V. pressure, which should be as
stated.
188 9813/1400-1 188

Hydraulics
Test Procedures
Auxiliary Relief Valve Replacement
Important: The ARV’s are not adjustable. If the pressure

is incorrect the valve must be replaced. Each ARV has its
pressure setting stamped on the top face, make sure to
replace the ARV with one of the same pressure setting.
Note: The ARV shown is for illustration purposes - make

sure to select the correct ARV. Refer to Specifications.
K Specifications ( T 159)
IL
A A
AZ
A A
C116280
BR
Fig 180.

Procedures ( T 1)
2 Vent the hydraulic pressure. Refer to General

Procedures. K General Procedures ( T 1)
3 Remove the ARV A by unscrewing it from the valve

block.
4 Install a new ARV into the valve block and torque

tighten. K Torque Settings ( T 189)
B

A 44.7 4.5 33
JC
189 9813/1400-1 189

Hydraulics
Control Valve
IL
A B C
D
E
AZ
F
BR
D
C117700
Fig 181.
Removal
!MWARNING
!MWARNING Hydraulic Pressure
B

You could be killed or injured if the boom drops while Before connecting or removing any hydraulic hose,
you are working under it. Fit the boom maintenance residual hydraulic pressure trapped in the service
strut as instructed before doing any maintenance hose line must be vented. Make sure the hose service
work with the boom raised. line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
JC
Keep people away from the machine while you fit or the hoses are open.
remove the boom maintenance strut. INT-3-1-11_2
5-3-1-2_2
Procedures ( T 1)
190 9813/1400-1 190

Hydraulics
2 Vent the hydraulic pressure. Refer to General Table 32. Torque Settings
Procedures. K General Procedures ( T 1) Item Nm kgf m lbf ft
3 Working below the boom, put a label on all of the A/B 48 4.9 35.4
hydraulic hoses F before disconnecting to enable D 47 4.8 34.6
correct replacement.
4 Disconnect and plug all hydraulic hoses F.
5 Put a label on all of the electrical connectors E to 1

enable correct replacement.
IL
2 4
6 Disconnect all electrical connectors E to the valve
block. 5
3
7 Remove the accumulator A and check valve B from 6
the valve block C.
AZ
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1
8 With the valve block C suitably supported, remove the

mounting screws D. Carefully lift the valve block away
from the bracket and clear of the machine.
BR
C117700-C1.eps
Replacement Fig 182.
Replacement is the opposite of the removal procedure. Table 33. Special Torque Settings
1,2,3,4,5,6 60 -66 6.1 - 6.7 44.2 -48.6
– Torque tighten the accumulator A, check valve B and
mounting screws D. K Table 32. Torque Settings
( T 191)
– Torque tighten the hose to control valve adaptor
connectors - where applicable refer to the special
torque settings. K Fig 182. ( T 191) K Table 33.
Special Torque Settings ( T 191)
B
– Operate the machines hydraulic system. Check for

correct operation and leaks.
– Fill the hydraulic system with the recommended
hydraulic fluid as necessary.
JC
– After replacement, check MRV and ARV pressures.

K Test Procedures ( T 184)
191 9813/1400-1 191

Hydraulics
Sequence Valves (if fitted)
A A
A
A
IL
C
C
B
A
A
AZ
Fig 183.
C116330-C1
BR
The Sequence Valves are fitted to platforms with optional 9 Remove the valves C from the platform.
Slew operation.
Replacement
Removal
Procedures ( T 1)
2 Lower the platform to the ground.
3 Remove the platform from the machine carriage.

B

5 Put a label on the hydraulic hoses A to help

identification when replacing.
JC
6 Disconnect the hydraulic hoses A from the valves C.
7 Support the valves C.
8 Remove the nuts and bolts B.
192 9813/1400-1 192

Hydraulics
Pilot Operated Check Valves (if fitted)
A
C
A
IL
C
AZ
A
A A
C116330-C2
Fig 184.
BR
The Pilot Operated Check Valves are fitted to platforms 9 Remove the valves B from the platform.
with optional Slew operation.
Replacement
Removal
Procedures ( T 1)

B

5 Put a label on the hydraulic hoses A to help

identification when replacing.
JC
6 Disconnect the hydraulic hoses A from the valves B.
7 Support the valves B.
8 Remove the nuts and bolts C.
193 9813/1400-1 193

Hydraulics
Emergency Pump
Removal
D E
IL
E
AZ
B C
A B
BR
A F G F
C117710
Fig 185.
!MWARNING !MWARNING
B
You could be killed or injured if the boom drops while Hydraulic Pressure
you are working under it. Fit the boom maintenance Hydraulic fluid at system pressure can injure you.
strut as instructed before doing any maintenance Before connecting or removing any hydraulic hose,
work with the boom raised. residual hydraulic pressure trapped in the service
JC
Keep people away from the machine while you fit or line has been vented before connecting or removing
remove the boom maintenance strut. hoses. Make sure the engine cannot be started while
5-3-1-2_2 the hoses are open.
INT-3-1-11_2
194 9813/1400-1 194

Hydraulics
1 Park the machine and make it safe with the boom 5 Remove the nuts D and disconnect the power and
raised. Refer to General Procedures. K General earth cables E from the pump C.
Procedures ( T 1)
6 With the pump suitably supported, remove the
2 Vent the hydraulic pressure. Refer to General mounting screws F. Carefully lift the pump C and
Procedures. K General Procedures ( T 1) brackets G clear of the machine.
3 Put a label on the hydraulic hoses A before 7 To remove the pump C from the bracket G, slacken
disconnecting to enable correct replacement. the clips B.
4 Disconnect and plug the hydraulic hoses A.
IL
AZ
1
2
BR
C124700
Fig 186.
B
Replacement – Operate the machines hydraulic system. Check for

correct operation and leaks.
Replacement is the opposite of the removal procedure. – Fill the hydraulic system with the recommended
hydraulic fluid as necessary.
JC

– Make sure to route the power cable 2 and earth cable
1 correctly as shown. K Fig 186. ( T 195)
– Make sure that the cables will not chafe against
chassis and sideplates.
195 9813/1400-1 195

Hydraulics
Slew Rams
IL
2
AZ
BR
1
3 4
C116330-C3
Fig 187.
B
Removal 7 Support the ram 1 and remove the pivot pins 2 from
each end of the ram.
The procedure shown is for one ram, the procedure for the
other ram is the same. 8 Remove the ram from the platform.
Replacement
JC

Procedures ( T 1) Replacement is the opposite of the removal procedure.

5 Put a label on the hydraulic hoses and disconnect

them from the ram connectors 4.
6 Remove the securing bolts 3.
196 9813/1400-1 196

Hydraulics
Rear Axle Lock Ram !MWARNING

Obey the general care and safety procedures for rams This component is heavy. It must only be removed or
during the removal and replacement procedures. handled using a suitable lifting method and device.
BF-4-1_1
K Fig 188. ( T 198)
10 Remove the bolts F from the bracket B and remove
Important: The RAL ram controls the oscillation of the ram C and trunnions A as one assembly.
rear axle. Removal of the ram can make the machine
unstable. Support the left and right sides of the chassis 11 Remove the trunnions A from the ram C.
before removal of the RAL ram.
IL
Replacement
!MWARNING Replacement is the opposite of the removal procedure.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. During the replacement procedure do this work also:
Before connecting or removing any hydraulic hose,
– Grease the ram pivot pin and trunnions.
AZ
hose line must be vented. Make sure the hose service – Make sure to replace spacers L.
line has been vented before connecting or removing – Bleed and test the RAL system. Follow the correct
hoses. Make sure the engine cannot be started while procedures.
the hoses are open.
INT-3-1-11_2
Removal

BR
Procedures ( T 1)

3 Support the chassis on both sides of the machine.
4 Disconnect the electrical connector at the solenoid

valve D.
5 Put a label each hydraulic hose E to aid replacement.
6 Disconnect hydraulic hoses E. Cap the open hoses

B
and pipes.
7 Support the RAL ram C.
8 Remove nut G and bolt J and withdraw pivot pin H

JC
from the axle bracket K. Make sure to retain spacers

L.
9 Attach suitable lifting equipment to the cylinder end of

the ram. Support the ram.
197 9813/1400-1 197

Hydraulics
B
A
A
IL
C
E AZ
BR
E
D
C L
G
B
K
H
JC
C116820-C2.eps
Fig 188.
198 9813/1400-1 198

Hydraulics
Rear Axle Lock Valve Block Important: The RAL Valve controls the flow to the RAL
Ram. Support the left and right sides of the chassis before
removal of the RAL Valve.
Removal
A
!MWARNING
Hydraulic Pressure
B Before connecting or removing any hydraulic hose,
IL
line has been vented before connecting or removing
C hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
AZ
Procedures ( T 1)

3 Support the chassis on both sides of the machine.
4 Disconnect the electrical connector at the solenoid

BR
valve E.
5 Put a label on the hydraulic hoses D.

D
6 Disconnect the hydraulic hoses D from the RAL valve
C.
7 Support the RAL Valve C.
8 Remove the cap screws A and remove the valve C

D from the hydraulic connector flange B.
Replacement
E
B

C117570-C1.eps
Fig 189.
JC
– Replace the gasket between the RAL valve C and the

hydraulic connector flange B.
Obey the general care and safety procedures for rams
– Bleed and test the RAL system. Follow the correct
during the removal and replacement procedures.
procedures.
199 9813/1400-1 199

Hydraulics
Dismantle and Assemble
Valve Block Sections Assemble
The valve block is made up of a number of sections. The Assembly is the opposite of the dismantling procedure.
illustration is intended as a guide to identifying the
components. During the assembly procedure do this work also:
Important: Make sure that new valve section ‘O’ rings are 1 Clean the valve components in an applicable solvent.
available before dismantling the valve block. Make sure that the mating faces of the valve sections
IL
are fully clean before assembly.
Be sure to record the location of all components when
dismantling. Although some components look the same 2 Replace the ‘O’ rings located between the valve
they are not interchangeable. The service spools for sections. Install the ‘O’ rings correctly. Incorrectly
example are of two different types. Make sure that the installed ‘O’ rings will be damaged.
components are assembled in the correct position.
3 Lubricate the parts with JCB Hydraulic Fluid before
AZ
Take care when dismantling and assembling a valve to assembling. Make sure that all the parts move freely.
prevent damage to seals and seal grooves. Damage or
contamination can cause problems with valve operation. 4 If the tie rods were removed, apply JCB Threadlocker
and Sealer to the threads before installing.
Dismantle
5 Screw the tie rods into the valve block until they are
1 Remove the valve block from the machine. tight. Unscrew them 1 turn. Once the valve block is
fully assembled these rods may be adjusted to allow
2 Remove the three tie rod nuts A. sufficient thread for the tie rod nuts A to tighten.
BR
3 Slide each valve section off the tie rods. 6 Torque tighten the tie rod nuts. K Table 34. Torque
Settings ( T 200)
4 If the outlet section J is to be replaced, remove and
retain the tie rods. Table 34. Torque Settings
A 54 5.5 40
B
JC
200 9813/1400-1 200

Hydraulics
A A
IL
B
AZ
C
D
E
F
G
H
J
BR
C116300
Fig 190.
Component Key:
A Tie Rod Nuts
B Inlet Section
C L/H Stabiliser Section
D R/H Stabiliser Section
E Auxiliary section
F Tilt section
B
G Extend / Retract Section

H Lift / Lower Section
J Outlet Section
JC
201 9813/1400-1 201

Hydraulics
Proportional Solenoids 3 Replace all 'O' rings and back-up rings.
The solenoids are not serviceable parts. Replace the 4 Torque tighten the screws B. K Table 35. Torque
solenoid valve assembly if it is defective. Settings ( T 202)
Removal Table 35. Torque Settings

This procedure is the same for all of the solenoid valves. B 2.0 0.2 1.5
1 Disconnect the solenoid valve electrical connections.
IL
2 Using a 2.5 mm allen key, remove the screws B.
3 Lift the solenoid A out of the valve block.
Note: The solenoids A are difficult to remove as the seals

are a tight fit in the valve block. To aid removal turn the
AZ
solenoid and use a flat bladed screwdriver to lever the
solenoid from the valve block. Make sure not to damage
the valve block.
A B
BR
B
C094490
Fig 191.
B
Replacement

JC
1 Clean the valve components in an applicable solvent.

assembling.
202 9813/1400-1 202

Hydraulics
Load Sense Relief Valve Table 36. Torque Settings

The load sense relief valve is not serviceable. Replace the
A 65 6.6 48
complete valve if it is defective.
Removal
1 Remove the valve assembly A from the valve block.
IL
AZ
BR
A
C116310
Fig 192.
Replacement

B
1 Torque tighten the valve. K Table 36. Torque

Settings ( T 203)
2 Replace all 'O' rings and back-up rings.

JC

assembling.
4 Adjust the pressure setting as required. K Pressure

Testing ( T 184)
203 9813/1400-1 203

Hydraulics
Auxiliary Relief Valves (ARV’s)

Refer to Test Procedures for ARV removal and
replacement procedure. K Auxiliary Relief Valve
Replacement ( T 189)
IL
AZ
BR
B
JC
204 9813/1400-1 204

Hydraulics
Changing the Accumulator Check Valve

Mesh Filter
The control valve accumulator check valve contains a
mesh filter which is not serviceable. Install a new check
valve and filter.
Removal

IL
Procedures ( T 1)

3 Remove the accumulator D and valve assembly C
AZ
from the valve block outlet section A.
Discard the valve assembly C.
4 Remove and discard the filter B.
Replacement

BR

assembling.
2 Install a new filter B.
3 Install a new check valve assembly C.
4 Torque tighten the check valve and accumulator.

K Table 37. Torque Settings ( T 205)

B

C 65 6.6 48
D 48 4.9 35.4
C116320
Fig 193.
JC
205 9813/1400-1 205

Hydraulics
IL
AZ
BR
B
JC
206 9813/1400-1 206

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Service Manual

535-125 HiViz and 535-140 HiViz

Fuses and Relays ........................................................................................ 51

Engine Start Operation - Remote Mode ...................................................... 83

About this Supplement

For Platform operation details and safety information refer

Only those areas of the machine which are different from

– 9813/0950 for machines with Tier 3 Engine.

Unless specified otherwise, all references to 'Service

Read the standard Service Manual and this supplement

Note: When the system is operated in remote mode a

Before remote operation is enabled, there are safety

The stabiliser and sway systems are isolated when the

Component Location and Identification

Engine speed control z z

Engine stop (after safety time period) z (7)

Emergency stop (cab isolation button) z

Emergency boom operation z (8)

In this publication and on the machine, there are safety

2-1-1 2-01-06 Issue 01 2-1-1

The Operator Manual Safety Warnings

!MWARNING This safety alert system identifies

2-1-2 2-01-06 Issue 01 2-1-2

Safety Check List

Common Rail (SE/SH/DH/SL Engine)

In addition to the general safety notices and general good

Diesel Fuel Quality

Important: The potential for engine damage due to the

2-1-3 2-01-06 Issue 01 2-1-3

– Do not attempt to remove and replace the rail

2-1-4 2-01-06 Issue 01 2-1-4

!MWARNING equipment. You must identify the weight of the item to

!MWARNING the control is operated (even with the engine stopped).

2-1-5 2-01-06 Issue 01 2-1-5

2-1-6 2-01-06 Issue 01 2-1-6

Operating Safety !MWARNING

!MWARNING beneath overhead cables and structures.

spaces without making sure there is good ventilation. INT-2-2-4_2

Banked material and trenches can collapse. Do not

2-1-7 2-01-06 Issue 01 2-1-7

2-1-8 2-01-06 Issue 01 2-1-8

There is a minimum clearance required for working

Use only the JCB approved attachments that are

Never unload the forks by stopping the machine

Operate the control levers only when you are correctly

2-1-9 2-01-06 Issue 01 2-1-9

Entering or leaving the cab or canopy must only be

use the machine controls as handholds, use the

2-1-10 2-01-06 Issue 01 2-1-10

Maintenance Safety !MWARNING

!MWARNING Before connecting or removing any hydraulic hose,

diesel fuel or paraffin to clean your skin.

2-1-11 2-01-06 Issue 01 2-1-11

chemicals, you must adhere to the manufacturer's

2-1-12 2-01-06 Issue 01 2-1-12

New fluoroelastomeric components at ambient

Protect your eyes when grinding metal. Wear safety

protection and gloves. Never point a compressed air