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Introduction
General Information
Backhoe Loaders
Loadalls
Service
Data RTFL
Book Excavators
1992 on
Wheeled Loaders
SEPTEMBER 2003
Fastrac
Robot
Skidsteer Range
1CX
Teletruk
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; ©
ROCESTER, STAFFORDSHIRE, ST14 5LS,
ENGLAND
Articulated Dump Trucks
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Publication No. 9804/1103

INDEX
Introduction
1992 Data Book
The JCB Service Data Book is compiled in sections as listed on the main title page at the front of the book. The section names
on the title page register with the tabs of the section divider cards to promote rapid reference to the relevant machine ranges.
The General Section is applicable to all machine ranges, covering such subjects as conversion tables, torque settings etc.
The various machine range sections contain information on current or recent machines as detailed in their respective contents
pages. Information on earlier machines is contained in the previous Data Book, publication no. 9804/1102.
The page numbering in each section is not continuous. This is to allow for additional pages to be inserted as they are issued.
A basic explanation of the page number system is given below to enable correct location of pages.
Page number example: 20 - 05 - 02/1
A B C
Machine Range Subject classification Number to suit

e.g. Backhoe Loader, Data, Fault Finding, etc detail variation
Loadall etc. within subject
When locating pages, refer to the page number in the sequence A, followed by B, followed by C.
The service data book is not intended as a substitute for service manuals which should be consulted for all further details.
9804/1103 70 - XX - XX/X Issue 1

CONTENTS
INDEX
General
Contents
Metric Units 1-1

Conversion Factors 1-2
Conversion Tables
- Capacity 1-3
- Length 1-4
- Pressure 1-5
- Temperature 1-6
Hydraulic Formulae 1-7
Torque Settings 2-1
Antifreeze Protection 3-1
Hydraulic Circuit Symbols 4-1
9804/1103 General Section Contents Issue 1

CONTENTS
CONTENTS 1-1
General
Metrication - S.I.Units
The following list gives the units and symbols to be found in technical publications.
Quantity Name of Unit Unit Symbol
Angle second "

minute '
degree 0
Area square millimetre mm2
Capacity litre l
Electric — Current Ampere A

— Resistance ohm
— Tension Volt V
Flow litre per minute l/m
Force Newton N
Length millimetre mm
metre m
kilometre km
Mass kilogram kg
Moment of force Newton metre Nm
Pressure bar bar
Speed kilometre per hour km/h
Temperature degree Celsius °C
Time second s
minute min
hour h
day d
Volume cubic millimetre mm3

cubic centimetre cm3
cubic metre m3
9804/1103 1-1 Issue 1

CONTENTS
CONTENTS 1-2
General
Conversion Factors
Imperial to S.l. Units
To convert imperial units to Sl multiply by the conversion factor.
To convert Sl units to imperial divide by the conversion factor.
Quantity Imperial Metric Conversion Factor
Area in2 mm2 645.2

ft2 m2 0.0929
yd2 m2 0.8361
Capacity pints—UK I 0.5683

pints—US I 0.4731
gallon—UK I 4.5461
gallon—US l 3.785
Flow gal/min—UK l/min 4.5461

gal/min—US I/min 3.785
Force Ibf N 4.45
Length in mm 25.4
mile km 1.6093
Mass Ib kg 0.4536
Moment of force Ibf in Nm 0.112 985

Ibf ft Nm 1.3558
Ibf ft kgf m 0.1383
Pressure Ibf/in2 bar 0.068 95

Ibf/in2 kgf/cm2 0.070 31
Speed ft/s m/s 0.3048

mile/h km/h 1.6093
Volume in3 cm3 16.387

yd3 m3 0.7646
9804/1103 1-2 Issue 1

CONTENTS
CONTENTS 1-3
General
Conversion Tables - Capacity
UK gallons to US gallons and litres
Select the known capacity from the centre column and read off the required conversion.
US gallon UK gallon Litres UK gallon
1.201 1 0.833 4.546 1 0.219

2.402 2 1.665 9.092 2 0.440
3.603 3 2.498 13.638 3 0.659
4.804 4 3.331 18.184 4 0.879
6.005 5 4.163 22.730 5 1.099
7.206 6 4.996 27.276 6 1.319
8.407 7 5.829 31.822 7 1.539
9.608 8 6.661 36.368 8 1.759
10.809 9 7.494 40.914 9 1.979
12.010 10 8.327 45.461 10 2.199
18.014 15 12.490 68.191 15 3.299
24.019 20 16.653 90.922 20 4.399
30.024 25 20.815 113.652 25 5.499
36.029 30 24.980 136.383 30 6.599
42.033 35 29.143 159.113 35 7.699
48.038 40 33.307 181.844 40 8.799
54.043 45 37.470 204.574 45 9.898
60.047 50 41.634 227.305 50 10.998
66.052 55 45.797 250.035 55 12.098
72.057 60 49.960 272.766 60 13.198
78.062 65 54.124 295.496 65 14.298
84.067 70 58.287 318.227 70 15.398
90.071 75 62.450 340.957 75 16.498
96.076 80 66.614 363.688 80 17.598
102.081 85 70.777 386.418 85 18.697
108.086 90 74.940 409.149 90 19.797
114.090 95 79.104 431.879 95 20.897
120.095 100 83.267 454.610 100 21.997
9804/1103 1-3 Issue 1

CONTENTS
CONTENTS 1-4
General
Conversion Tables - Length
Fractions of an inch to decimals of an inch and millimetres.
Inch Millimetre
1/64 0.015 625 0.396 875

1/32 0.031 250 0.793 750
1/16 0.062 500 1.587 500
1/8 0.125 000 3.175 000
3/16 0.187 500 4.762 500
1/4 0.250 000 6.350 000
5/16 0.312 500 7.937 500
3/8 0.375 000 9.525 000
7/16 0.437 500 11.112 500
1/2 0.500 000 12.700 000
9/16 0.562 500 14.287 500
5/8 0.625 000 15.875 000
11/16 0.687 500 17.462 500
3/4 0.750 000 19.050 000
13/16 0.812 500 20.637 500
7/8 0.875 000 22.225 000
15/16 0.937 500 23.812 500
1 1.000 000 25.400 000
Inches to millimetres and feet to metres
Select the known length from the centre column and read off the required conversion.
Inch Millimetres Feet Metres
0.039 1 25.4 3.281 1 0.3048

0.078 2 50.8 6.562 2 0.6096
0.118 3 76.2 9.843 3 0.9144
0.157 4 101.6 13.124 4 1.2192
0.197 5 127.0 16.405 5 1.5240
0.236 6 152.4 19.686 6 1.8288
0.275 7 177.8 22.967 7 2.1336
0.315 8 203.2 26.248 8 2.4384
0.354 9 228.6 29.529 9 2.7432
0.394 10 254.0 32.810 10 3.0480
0.590 15 381.0 49.215 15 4.5720
0.787 20 508.0 65.620 20 6.0960
0.984 25 635.0 82.025 25 7.6200
1.181 30 762.0 98.430 30 9.1440
1.378 35 889.0 114.835 35 10.668
1.574 40 1016.0 131.240 40 12.192
1.772 45 1143.0 147.645 45 13.716
1.968 50 1270.0 164.050 50 15.240
2.165 55 1397.0 180.455 55 16.764
2.362 60 1524.0 196.860 60 18.288
2.559 65 1651.0 213.265 65 19.812
2.756 70 1778.0 229.670 70 21.336
2.953 75 1905.0 246.075 75 22.860
3.149 80 2032.0 262.480 80 24.384
3.346 85 2159.0 278.885 85 25.908
3.543 90 2286.0 295.290 90 27.432
3.740 95 2413.0 311.695 95 28.956
3.937 100 2540.0 328.100 100 30.480
9804/1103 1-4 Issue 1

CONTENTS
CONTENTS 1-5
General
Conversion Tables - Pressure
Ibf/in2 to kgf/cm2 and Bar
Select the known pressure from the centre column and read off the required conversion.
Ibf/in2 kgf/cm2 Ibf/in2 Bar
142.233 10 0.703 145.038 10 0.690

284.466 20 1.406 290.076 20 1.379
426.699 30 2.109 435.114 30 2.069
568.932 40 2.812 580.152 40 2.758
711.165 50 3.516 725.190 50 3.448
853.398 60 4.219 870.228 60 4.137
995.631 70 4.922 1015.266 70 4.827
1137.864 80 5.625 1160.304 80 5.516
1280.097 90 6.328 1305.342 90 6.206
1422.330 100 7.031 1450.380 100 6.895
2844.660 200 14.062 2900.760 200 13.790
4266.990 300 21.093 4351.140 300 20.685
5689.320 400 28.124 5801.520 400 27.580
7111.650 500 35.155 7251.900 500 34.475
8533.980 600 42.186 8702.280 600 41.370
9956.310 700 49.217 10152.660 700 48.265
11378.640 800 56.248 11603.040 800 55.160
12800.970 900 63.279 13053.420 900 62.055
14223.300 1000 70.310 14503.800 1000 68.950
28446.600 2000 140.620 29007.600 2000 137.900
42669.900 3000 210.930 43511.400 3000 206.850
9804/1103 1-5 Issue 1

CONTENTS
CONTENTS 1-6
General
Conversion Tables - Temperature
Select the known temperature from the centre column and read off:
To the right for equivalent in deg F

To the left for equivalent in deg C.
Deg C Deg F Deg C Deg F
- 31.7 - 25 - 13.0 87.8 190 374

- 28.9 - 20 - 4.0 90.6 195 383
- 26.1 - 15 5.0 93.3 200 392
- 23.3 - 10 14.0 96.1 205 401
- 20.6 -5 23.0 98.9 210 410
- 17.8 0 32.0 101.7 215 419
- 15.0 5 41.0 104.4 220 428
- 12.2 10 50.0 107.2 225 437
- 9.4 15 59.0 110.0 230 446
- 6.7 20 68.0 112.8 235 455
- 3.9 25 77.0 115.6 240 464
- 1.1 30 85.0 118.3 245 473
1.7 35 95.0 121.1 250 482
4.4 40 104.0 123.9 255 491
7.2 45 113.0 126.7 260 500
10.0 50 122.0 129.4 265 509
12.8 55 131.0 132.2 270 518
15.6 60 140.0 135.0 275 527
18.3 65 149.0 137.8 280 536
21.1 70 158.0 140.6 285 545
23.9 75 167.0 143.3 290 554
26.7 80 176.0 146.1 295 563
29.4 85 185.0 148.9 300 572
32.2 90 194.0
35.0 95 203.0
37.8 100 212.0
40.6 105 221.0
43.3 110 230.0
46.1 115 239.0
48.9 120 248.0
51.7 125 257.0
54.4 130 266.0
57.2 135 275.0
60.0 140 284.0
62.8 145 293.0
65.6 150 302.0
68.3 155 311.0
71.1 160 320.0
73.9 165 329.0
76.7 170 338.0
79.4 175 347.0
82.2 180 356.0
85.0 185 365.0
9804/1103 1-6 Issue 1

CONTENTS
CONTENTS 1-7
General
Hydraulic Formulae
Pump flow (litres/min) = Displacement (cm3/rev) x Speed (rev/min)

1000
Pump flow (UK gal/min) = Displacement (in3/rev) x Speed (rev/min)

277.4
Power output of Hydraulic Pump (kw) = Flow (litres/min) x Pressure (bar)

600
Power output of Hydraulic Pump (hp) = Flow (UK gal/min) x Pressure (Ibf/in2)
1430
Power output of Hydraulic Motor (kw) = Torque (Nm) x Speed (rev/min)

9550
Power output of Hydraulic Motor (hp) = Torque (Ibf ft) x Speed (rev/min)
5250
Cylinder Thrust (kgf) = pressure (bar) x piston area (mm2)

98
Cylinder Thrust (Ibf) = pressure (Ibf/in2) x piston area (in2)
9804/1103 1-7 Issue 1

CONTENTS
General
Torque Settings (for all machines except JS Range)
Use only where no torque setting is specified in the text. Values are for dry threads and may be within three percent of the
figures stated. For lubricated threads the values should be REDUCED by one third.
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
UNF Grade 'S' Bolts
Bolt Size Hexagon (A/F) Torque Settings

in. (mm.) in. Nm kgf m lbf ft
1/4 (6.3) 7/16 14 1.4 10

5/16 (7.9) 1/2 28 2.8 20
3/8 (9.5) 9/16 49 5.0 36
7/16 (11.1) 5/8 78 8.0 58
1/2 (12.7) 3/4 117 12.0 87
9/16 (14.3) 13/16 170 17.3 125
5/8 (15.9) 15/16 238 24.3 175
3/4 (19.0) 1.1/8 407 41.5 300
7/8 (22.2) 1.5/16 650 66.3 480
1 (25.4) 1.1/2 970 99.0 715
1.1/4 (31.7) 1.7/8 1940 198.0 1430
1.1/2 (38.1) 2.1/4 3390 345.0 2500
Metric Grade 8.8 Bolts
Bolt Size Hexagon Torque Settings

No. (mm.) mm. Nm kgf m lbf ft
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
Metric Socket-head Capscrews
Torque Settings
Bolt Size No. (mm) Nm kgfm lbf ft
M5 (5) 11 1.1 8
M6 (6) 19 2.0 12
M8 (8) 46 4.8 34
M10 (10) 91 9.5 67
M12 (12) 159 16 120
M16 (16) 395 40 290
M20 (20) 770 79 570
M24 (24) 1332 135 980
9804/1103 2-1 Issue 1

CONTENTS
General
Torque Settings - continued (for all machines except JS Range)
RIVET NUT BOLTS/SCREWS
Bolt Size Torque Settings (for steel rivet nuts)

(mm) Nm kgf m lbf ft
M3 (3) 1.2 0.12 0.9

M4 (4) 3.0 0.3 2.0
M5 (5) 6.0 0.6 4.5
M6 (6) 10 1.0 7.5
M8 (8) 24 2.5 18.0
M10 (10) 48 4.9 35.5
M12 (12) 82 8.4 60.5
HOSE & PIPEWORK CONNECTIONS USING 'O' RING FACE SEALS (ORFS)
Note: Adapters A always have a UNF thread for the ORFS hose connection B but the thread A on the opposite end of the
adapter may be either UNF or metric. Measure the thread diameter carefully before choosing the relevant torque setting table.
'O' Ring Boss Adapters (Item A above)
Nominal Diameter Nominal Diameter

of UNF Thread Torque Settings of Metric ThreadTorque Settings
(inches) Nm kgf m lbf ft (mm) Nm kgf m lbf ft
7/16 20 2.1 15 8 10 1.1 7

9/16 35 3.6 26 10 20 2.1 15
3/4 81 8.3 60 12 35 3.6 26
7/8 108 11.1 80 14 45 4.7 33
11/16 183 18.7 135 16 55 5.8 41
15/16 298 30.5 220 18 70 7.1 52
15/8 380 38.8 280 20 80 8.2 59
17/8 488 50 360 22 100 10 74
27 170 17 125
33 310 32 229
42 330 34 243
48 420 43 310
60 500 51 369
ORFS Hydraulic Hose Connections (Item B above)
Nominal Thread Torque Settings

Diameter (inches) Nm kgf m lbf ft
9/16 24 2.5 18
11/16 33 3.3 24
13/16 44 4.8 35
1 58 6.0 43
13/16 84 8.6 62
1 7/16 115 11.8 85
111/16 189 19.4 140
2 244 24.9 180
9804/1103 2-2 Issue 1

CONTENTS
General
Antifreeze Protection
The protection provided by JCB Universal Anti-freeze is shown below. If any other anti-freeze is used, refer to the
manufacturers' instructions and ensure that a corrosion inhibitor is included.
DO NOT use solutions of more than 60% or less than 50% or damage to the cooling system will occur.
Solution Maintains circulation Protects against

down to damage down to
deg C deg F deg C deg F
55% -36 -33 -41 -42
The strength of the anti-freeze solution must be checked at least once a year, preferably at the beginning of the cold period.
It is an advantage to leave the anti-freeze in all the year round as it gives continued protection against corrosion. Always renew
the anti-freeze every two years.
A 50% anti-freeze mixture must be used even if frost protection is not needed. This gives protection against corrosion and raises
the coolant's boiling point.
! WARNING
Antifreeze can be harmful. Obey the manufacturer's instructions when handling neat or diluted antifreeze.
7-3-4-4
9804/1103 3-1 Issue 1

CONTENTS
General
Introduction to Hydraulic Schematic Symbols
Complex hydraulic components and circuits can be described Pumps & Motors
to the engineer by using graphical symbols. The following
pages illustrate and give a brief description for some of the
more common symbols used.
Fixed capacity pump
There are many symbols in use and it would be impossible to one direction of flow
include them all here. However it should be noted that most
are only variations or refinements on the basic principles
explained here. If more detailed information is required you
are recommended to obtain a copy of BS2917 or IS01219.
Fixed capacity pump
Once familiar with the symbols, the engineer can use two directions of flow
hydraulic circuit diagrams as an aid to fault finding. It will be
possible to see the complete hydraulic circuit and decipher
the relationship between hydraulic components.
Variable capacity pump
General (Basic & Functional Symbols) one direction of flow
Spring
Variable capacity pump

Flow restriction two directions of flow
affected by viscosity
Direction of flow
Fixed capacity motor
one direction of flow
Indication of rotation
Indication of direction Fixed capacity motor

and paths of flow two directions of flow
Variable control
Variable capacity motor

one direction of flow
Rams
Single acting Variable capacity motor

two directions of flow
Double acting
Double ended
Double acting with

damping at rod area end
9804/1103 4-1 Issue 1

CONTENTS
General
Introduction to Hydraulic Schematic Symbols (continued)
Control Valves
Used to enclose several One way restrictor

valves indicating that they
are supplied as one unit
3-Position, 4-Port High pressure selector

spring centred pilot (shuttle valve)
operated valve
3-Position, 6-Port
spring centred hand Throttling orifice -
operated valve normally closed
3-Position, 4-Port
spring centred solenoid &
pilot pressure operated valve
Throttling orifice -
normally open
3-Position, 4-Port
spring centred detent
hand operated valve
Relief valve
Non - return valve
Non - return valve with

back pressure spring
Variable restrictor
Pilot operated
non - return valve
9804/1103 4-2 Issue 1

CONTENTS
General
Energy Transmissions and Conditioning
Working line, return or feed

Reservoir - return line
above fluid level
Pilot control
Reservoir - return line

Drain lines below fluid level
Flexible pipe Header tank
Pressure sealed tank

Line junction
Accumulator
Crossing lines
Filter or strainer
Air bleed Water trap
Line plugged, also

pressure test point
Cooler - with no
indication of coolant flow
Line plugged with

take off line
Cooler - indicating
direction of coolant flow
Quick release
couplings - connected Heater
Quick release
couplings - disconnected
9804/1103 4-3 Issue 1

CONTENTS
General
Control Mechanisms
Rotating shaft-one direction Solenoid one winding
Rotating shaft-two directions

Solenoid two winding
Detent
M Electric motor operated
Locking device
Internal pressure
pilot operated
Over centre device
External pressure
pilot operated
Simple linkage
Pressure operated
spring release
General control
Pilot operated by solenoid

pilot valve
Push button operated
Pilot operated by a solenoid

or separate pilot valve
Lever operated
Pressure gauge
Pedal operated
Stem operated Pressure switch
Spring operated
Roller operated
Roller trip operated

(one directional)
9804/1103 4-4 Issue 1

CONTENTS
General
Control Valves
FIG 1
Control valves are usually represented by one or more
square boxes.
Position 1 Position 2 Position 3
Fig. 1 shows a control valve represented by three boxes. The
number of boxes indicates the number of possible valve
operating positions, (4 boxes - 4 positions etc).
Fig. 2 - In circuit diagrams the pipework is usually shown

connected to the box which represents the unoperated
condition. (Hydraulic circuit diagrams are usually shown in
the unoperated condition). FIG 2
Fig. 3 shows a valve described as a 3- position, 4-port control

valve. Port describes the openings to and from the valve by
which the hydraulic fluid enters or leaves. In the fig shown,
Position 2 indicates that in an unoperated condition all 4 ports
are blocked.
If the valve spool was moved to Position 1, movement of the

spool would connect Port 1 to Port 2, and Port 3 to Port 4.
If the valve spool was moved to Position 3, movement of the Port 1 Port 3
spool would connect Port 1 to Port 4, and Port 3 to Port 2.
FIG 3
It must be noted that not all spools are of the same type.
Their operating designs can be seen by following the path the
flow arrows take in their respective operating squares.
Three typical JCB style spools are known as 'D' spools, 'F'
spools and 'N' spools.
The 'D' spools generally control rams because when in the

neutral position the outlet ports are blocked, preventing ram Port 2 Port 4
movement. Fig 3 shows a 'D' type spool.
Fig 4 - 'F' spools are often shown as four position spools with
the three normal positions for neutral and service control; and
the forth position, which has a detent, connects both sides of
the ram together to allow the service to 'float'. FIG 4
Fig 5 - 'N' spools are sometimes used to control hydraulic

motors, and it can be seen from the flow arrows, that in
neutral position both service ports are connected to the
exhaust oil port
FIG 5
9804/1103 4-5 Issue 1

CONTENTS
General
Example of Schematic Circuit
Some of the symbols described on the preceding pages have Example Circuit Key
been arranged into a simple schematic circuit shown below.
A Hydraulic Tank
Hydraulic tank A is a pressurised tank with an internally B Strainer
mounted strainer B on the suction line to the fixed C Fixed Displacement Pump
displacement pump C. System pressure is limited to the D Relief Valve
setting of relief valve D. E Spool
F One Way Valve
Valve spool E is an open-centre spool that is in neutral G Double Acting Hydraulic Ram
position; flow from the pump passes through the spool and
returns to the hydraulic tank.
If the lever operated spool is moved away from neutral

position hydraulic fluid is directed to either head side or rod
side of hydraulic ram G. Notice that the fluid must first open
one way valve F before flowing to the ram.
A
B
C G
D
E
F
9804/1103 4-6 Issue 1

CONTENTS
Backhoe Loaders Contents i
2CX, 2DX, 210S, 212S and Variants

Contents
Page No.
* General Information
-Lubricants and Capacities
- 2CX from m/c no 655000 to 656500 10 - 00 - 01/1
- 210S from m/c no 655000 to 656500 10 - 00 - 01/2
- 2CX, 2CXL, 210S, 210SL from m/c no. 657001 10 - 00 - 01/3
- 2DX from m/c no. 659249 10 - 00 - 01/4
- 2CX from m/c no. 659598 10 - 00 - 01/5
- 2CX, 2DX from m/c no. 659599 (N. America to m/c no 659599) 10 - 00 - 01/6
- 210S, 212S from m/c no. 762080 10 - 00 - 01/7
* -Statics Dimensions and Weight

- 2CX, 210S from m/c no 655000 to 656500 10 - 00 - 02/1
- 2CX, 210S from m/c no. 657001 10 - 00 - 02/2
- 2CX, 210S with Extending Dipper from m/c no. 657001 10 - 00 - 02/3
- 2CX, 210SL from m/c no. 657001 10 - 00 - 02/4
- 2CX Airmaster from m/c no. 657001 10 - 00 - 02/5
- 2CX Farm Master from m/c no. 657001 10 - 00 - 02/6
- 2CXU, 210SU from m/c no. 657001 10 - 00 - 02/7
- 2DX, 212SU from m/c no. 659249 10 - 00 - 03/1
- 2DX, 212S with Extending Dipper from m/c no. 659249 10 - 00 - 03/2
* Data - Electrical
- 2CX, 210S from m/c no. 655000 to 656500 10 - 05 - 01/1
- 2CX, 2CXL, 210S, 210SL from m/c no. 657001 10 - 05 - 01/2
- 2DX from m/c no. 659249 10 - 05 - 01/3
- 2CX, 2DX, 210S and Variants from m/c no. 657001 10 - 05 - 01/4
- 2CX from m/c no. 655030 to 656999 10 - 05 - 01/5
- 2DX from m/c no. 657001 10 - 05 - 01/6
- 2CX from m/c no. 659600 to 761891 10 - 05 - 01/6
- 2CX, 2DX, 210S, 212S from m/c no. 760841 10 - 05 - 01/7
- 212SU (N. Am) from m/c no. 657001 10 - 05 - 01/8
* Data - Hydraulics
-Machine Hydraulics
- 2CX, 210S from m/c no. 655000 to 656500 10 - 05 - 02/1
- 2CX, 2CXL, 210S, 210SL from m/c no. 657001 to 658960 10 - 05 - 02/2
- 2CX, 2DX from m/c no. 658961 10 - 05 - 02/3
-Steer Hydraulics
- 2CX, 210S from m/c no. 655000 to 656500 10 - 05 - 03/1
- 2CX, 2CXL, 210S, 210SL from m/c no. 657001 to 658960 10 - 05 - 03/1
- 2CX, 2CXL, 2DX, 210S, 210SL from m/c 658961 10 - 05 - 03/1
* Data - Transmission
- Front and Rear Axles
- 2CX, 210S from m/c no. 655000 to 656500 10 - 05 - 04/1
- 2CX, 210S from m/c no. 657001 10 - 05 - 04/1
- 2CXAM, 2CXL, 210FM, 210SL, 2DX from m/c no. 657001 10 - 05 - 04/1
- Syncro Shuttle
- 2CX, 210S from m/c no. 655000 to 656500 10 - 05 - 05/1
- 2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL from m/c no. 657001 10 - 05 - 05/2,3
- 2CXAM from m/c no. 657001 10 - 05 - 05/4
- Tyre Sizes and Pressures
- 2CX, 210S from m/c no. 655000 to 656500 10 - 05 - 06/1
- 2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL from m/c no. 657001 10 - 05 - 06/2
Data - Brakes
- 2CX, 210S from m/c no. 655000 to 656500 10 - 05 - 07/1
* Data Engine
- 2CX, 210S from m/c no. 655000 to 656500 10 - 05 - 08/1
- 2DX Range from m/c no. 659249 (including 212S to m/c no. 762079) 10 - 05 - 08/2
9804/1103 Backhoe Loader Contents - 1 Issue 6*

CONTENTS
Backhoe Loaders Contents ii

Contents (continued)
Page No.
Data - Pneumatics
- 2CXAM from m/c no. 657001 10 - 05 - 09/1
Fault Finding
- Syncro Shuttle - Mechanical
- 2CX, 2DX, 210S, 212S from m/c no. 655000 10 - 10 - 01/1,2,3
- Syncro Shuttle - Hydraulics
- 2CX, 210S from m/c no. 655000 10 - 10 - 01/4,5
- Parking Brake
- Pneumatics
- 2CXAM from m/c no. 657001 10 - 10 - 03/1
- Air Conditioning
- 2CX, 2DX, 210S, 212S 10 - 10 - 04/1,2
Circuit Diagrams - Electrical

- 2CX, 210S from m/c no. 655000 to 656500 10 - 15 - 01/1,2
- 2CX, 2CXL, 2CXFM, 210S, 210SL from m/c no. 657001 10 - 15 - 01/3,4
- 2DX from m/c no. 659249 to760840 10 - 15 - 01/5,6,7,8
- 2CX from m/c no. 659599 to 760840 10 - 15 - 01/5,6,7,8,
- 2CXAM to m/c no. 658332 10 - 15 - 01/9,10
- 2CXAM from m/c no. 658333 to 659598 10 - 15 - 01/11,12
- 2CXAM from m/c no. 659599 10 - 15 - 01/13
- 2CX, 2DX, 210S, 212S from m/c no. 760841 10 - 15 - 01/14,15,16,17
- 2CXU, 212SU (N,America only) from m/c no. 657001 10 - 15 - 01/18,19,20,21
* - 2CX, 2DX, 212SU from m/c no. 489724 10 - 15 - 01/22 to 27
- Electrical Circuit Options and Variations
- Electrical Pick-up Hitch 10 - 15 - 02/1
* - 2CX, 2DX, 212SU - Worklights Circuit, German/Italian Builds 10 - 15 - 02/2
* - 2CX, 2DX, 212SU - Heater Circuit, Heater/Air Conditioning Circuit 10 - 15 - 02/3
* - Later Machines - Compressor Circuit, Radio Circuit 10 - 15 - 02/4
* - Later Machines - Hammer Circuit, Hand Held Hydraulic Tools Circuit, Hydraclamp Circuit 10 - 15 - 02/5
Circuit Diagrams - Hydraulics

- 2CX, 210S from m/c no. 655000 to 656500 10 - 20 - 01/1,2
- 2CX, 210S from m/c no. 657001 to 658960 10 - 20 - 01/3,4
- 2CX, 2CXL, 210S, 210SL - Auxiliary Hand Held Tools 10 - 20 - 01/5
- 2CX, 2DX from m/c no. 658961 10 - 20 - 02/1,2
- 2CXL, 210SL, 2CXFM from m/c no. 657001 10 - 20 - 02/3
- 2CX, 212SU (N.America only) from m/c no. 657001 10 - 20 - 02/4,5
- Steering
- 2CX, 210S from m/c no. 655000 to 656500 10 - 20 - 03/1
- 2CX, 2CXL, 210S, 210SL from m/c no. 10 - 20 - 03/2
- Pneumatics
- 2CXAM from m/c no. 657001 10 - 20 - 03/3

CONTENTS
Backhoe Loaders Contents iii
3CX, 4CX (200 Series)

General Information
Fluids, Lubricants and Capacities 15 - 00 - 01/1-8
* - 3CX, 4CX & variants from m/c no. 930000 15 - 00 - 01/9 - 10
Static Dimensions - from m/c no. 400001

- 3CX (214) 4x4 (Sideshift) 15 - 00 - 02/1
- 3CX (214) 4x4 (Centremount) 15 - 00 - 02/2
- 4C (215) 4x4 15 - 00 - 02/3
- 4CN (216) 4x4 15 - 00 - 02/4
- 3CX (214) 4x4 Sitemaster (Sideshift) 15 - 00 - 02/5
- 3CX (214) 4x4 Sitemaster (Centremount) 15 - 00 - 02/6
- Hammermaster 4x4 15 - 00 - 02/7
- 217 15 - 00 - 02/8
- 4CX (214S) 4x4x4 (Sideshift) 15 - 00 - 02/9
- 4CX (214S) 4x4x4 (Centremount) 15 - 00 - 02/10
- 4C (215S) 4x4x4 15 - 00 - 02/11
- 4CN 4x4x4 15 - 00 - 02/12
- 4CX (214S) 4x4x4 Sitemaster (Sideshift) 15 - 00 - 02/13
- 4CX (214S) 4x4x4 Sitemaster (Centremount) 15 - 00 - 02/14
- 217S 15 - 00 - 02/15
- 3CX Super 4x4x4 (from m/c. no. 430001) 15 - 00 - 02/16
- 4CX Super 4x4x4 (from m/c. no. 430001) 15 - 00 - 02/17
- 3CXE (214E) 15 - 00 - 02/18
Static Dimensions - from m/c no. 460001
- 3CX Sideshift 15 - 00 - 03/1
- 4CX Sideshift 15 - 00 - 03/1
- 3CX Super 15 - 00 - 03/3
- 3CX Centremount 15 - 00 - 03/4
- 4CX Centremount 15 - 00 - 03/5
- 4C, 4CN 15 - 00 - 03/6
Data
-Electrical (3CX, 4CX - 200 Series)
- General (from m/c no. 400001) 15 - 05 - 01/1
- Circuit Protection (from m/c no. 400001 to 430000) 15 - 05 - 01/2
- Circuit Protection (from m/c. no. 430001) 15 - 05 - 01/3
- Relay Identification - Syncro Shuttle m/c's (from m/c. no. 400001 to 430000) 15 - 05 - 01/4
- Relay Identification - Powershift m/c's (from m/c. no. 400001 to 430000) 15 - 05 - 01/5
- Relay Identification - All Machine Models (from m/c. no. 430001) 15 - 05 - 01/6
-Electrical (2DX, 212 Servo Machines and Variants (except 2CX) from m/c no. 400001
- General 15 - 05 - 01/10
- Fuses 15 - 05 - 01/11
- Bulbs 15 - 05 - 01/11
- Relay Identification 15 - 05 - 01/12,13
- Pin Identification
- Logic Box 15 - 05 - 01/14
- RH Joystick 15 - 05 - 01/15
- LH Joystick 15 - 05 - 01/15
- Harness Identification 15 - 05 - 01/16,17
-Electrical (3CX, 4CX and Variants from m/c no. 460001)
- General 15 - 05 - 01/19
- Fuse Identification 15 - 05 - 01/20,20A,23,24,25
- Link Box Fuses 15 - 05 - 01/21
- Bulbs 15 - 15 - 01/21
- Relay Identification 15 - 05 - 01/22,23,24,25,26
- Harness Identification 15 - 05 - 01/27,28,29
-Hydraulic (3CX, 4CX Standard Machines)
- Machine Hydraulics (from m/c no. 400001) 15 - 05 - 02/1,2,3,4,5
- Steer Hydraulics (AWS) (from m/c no. 400001) 15 - 05 - 02/6
- Steer Hydraulics (2WS) (from m/c no. 400001) 15 - 05 - 02/6
-Hydraulic (3CXE (214E) Machines)
- Machine Hydraulics 15 - 05 - 02/7
-Hydraulic 2DX, 212 Servo Machines and Variants (except 2CX) from m/c no. 400001)
- Machine Hydraulics 15 - 05 - 02/8,9,10
-Hydraulic Pumps (3CX, 4CX and Variants from m/c no. 460001) 15 - 05 - 02/11,11A,12
-Loader Valve (3CX, 4CX and Variants from m/c no. 460001) 15 - 05 - 02/13,14,15,16
-Backhoe Valve (3CX, 4CX and Variants from m/c no. 460001) 15 - 05 - 02/17,18

CONTENTS
Backhoe Loaders Contents iv
Data (continued) Page No.
-Transmission
- Front Axle (2DX, 212 and Variants (except 2CX ) from m/c no. 400001) 15 - 05 - 03/1
- Rear Axle (3CX, 4CX and Variants from m/c no. 460001) 15 - 05 - 04/1
- Tyre Sizes and Pressures (3CX, 4CX from m/c no. 400001) 15 - 05 - 05/1
- Tyre Sizes and Pressures (3CX, 4CX and Variants from m/c no. 460001) 15 - 05 - 05/2,3
- Syncro Shuttle (3CX, 4CX from m/c no. 400001) 15 - 05 - 06/1,2
- Powershift (3CX, 4CX from m/c no. 400001) 15 - 05 - 07/1,2
- Syncro Shuttle (3CX, 4CX and Variants from m/c no. 460001) 15 - 05 - 07/2A,2B
- Stall Figures - 3CX, 4CX AWS Machines from m/c no. 400001 15 - 05 - 07/3
- Stall Figures - 3CX, 4CX 2WS Machines from m/c no. 400001 15 - 05 - 07/4
- Stall Figures (3CX, 4CX and Variants from m/c no. 460001) 15 - 05 - 07/5,6,7,8,9
-Brakes
- Standard Machines (All Models (except 2CX) from m/c no. 400001) 15 - 05 - 08/1
- Servo Machines (All Models (except 2CX) from m/c no 400001) 15 - 05 - 08/1
- 3CX, 4CX and Variants from m/c no. 460001 15 - 05 - 08/2
-Engine
- All Models (except 2CX) from m/c no. 400001 15 - 05 - 09/1
- 3CX, 4CX and Variants from m/c no. 460001 15 - 05 - 09/2
Fault Finding
-Electrical (3CX, 4CX and Variants from m/c no. 460001) 15 - 10 - 01/1,2
-Hydraulic (Standard Machines) (All Models (except 2CX) from m/c no. 400001)
- Introduction 15 - 10 - 02/1
- Diagnosis 15 - 10 - 02/1,2,3,4
-Hydraulic (Servo Machines) (All Models (except 2CX) from m/c no. 400001) 15 - 10 - 03/1
-Variable Flow Hydraulics (All Models (except 2CX) from m/c no. 460001) 15 - 10 - 03/2,3
-Syncro Shuttle (All Models (except 2CX) from m/c no. 400001)
- Gearbox 15 - 10 - 06/1,2,3
- 2/4 Wheel Drive Clutch - 'Spring-on to 4WD' (3CX, 4CX from m/c. no. 400077 to 415011) 15 - 10 - 06/4
- 2/4 Wheel Drive Clutch - 'Pressure-on to 4WD' (3CX, 4CX from m/c. no. 415012) 15 - 10 - 06/5,6
- 2/4 Wheel Drive Clutch (3CX, 4CX and Variants from m/c no. 460001) 15 - 10 - 6/7,8
-Powershift Gearbox (All Models (except 2CX) from m/c no. 400001
- Introduction and Index 15 - 10 - 07/1
- Diagnosis 15 - 10 - 07/2,3
- Powershift Transmission (3CX, 4CX and Variants from m/c no. 460001)
- Introduction and Index 15 - 10 - 07/4
- Diagnosis 15 - 10 - 07/5,6,7,8
-Brakes All Models (except 2CX) from m/c no. 400001) 15 - 10 - 08/1,2,3,4
-Steering (3CX, 4CX and Variarts from m/c no. 460001) 15 - 10 - 09/1,2,3

-Machines from 400001 to 430000
- Basic Machines (3CX 2WS with Syncro Shuttle) 15 - 15 - 01/1,2
- Steer Circuit (AWS Machines Only) 15 - 15 - 01/3
- Powershift Transmission 15 - 15 - 01/4
- 2/4 Wheel Drive (to m/c. no. 409434) 15 - 15 - 01/5
- Transmission Dump (to m/c. no. 413772) 15 - 15 - 01/5
- Instrument Lights Test Button (to m/c. no. 404502) 15 - 15 - 01/6
- Hydraulic Speed Control (to m/c. no. 406613) 15 - 15 - 01/6
-Machines from 430001
- Basic Machines (3CX 2WS with Syncro Shuttle) 15 - 15 - 01/7,8,9,10
- Powershift & Steer Circuit (AWS Machines Only) 15 - 15 - 01/11,12
- Powershift Transmission (2WS Machines Only)
and Steer Circuit for 3CX 4x4x4x Machines 15 - 15 - 01/13,14
- 3CX, 4CX and Variants from m/c no. 460001
- Basic Machines (3CX 2WS with Syncro Shuttle) 15 - 15 - 01/15,16,17,18
- Powershift Transmission (PS700) and Steer Circuit-AWS 15 - 15 - 01/19,20
- Powershift Transmission (PS700) - 2WS 15 - 15 - 01/21,22
- Steer Circuit - 3CX 4x4x4 Machines only 15 - 15 - 01/21,22
- 3CXE (214 Series 3) only 15 - 15 - 01/23,24,25
9804/1103 Backhoe Loader Contents - 4 Issue 1

CONTENTS
Backhoe Loaders Contents v

Circuit Diagrams - Electrical (continued)

- 3CX, 4CX, and Variants from m/c no.460001 (cont’d)
- 214e Series 4 only 15 - 15 - 01/26,27,28
- Autoshift Transmission - 2WS only 15 - 15 - 01/29,30
- Autoshift Transmission - AWS only 15 - 15 - 01/31,32
- Powershift Transmission (PS750) and Steer Circuit - AWS 15 - 15 - 01/33,34
- Powershift Transmission (PS750) - 2WS 15 - 15 - 01/35,36
- Steer Circuit - 3CX 4x4x4 only 15 - 15 - 01/35,36
- Auxiliary Options 15 - 15 - 01/37,38,39
- Servo Machines 15 - 15 - 02/5,6
* - 3CX, 4CX and Variants from m/c no. 495455
* - Basic Machine 15 - 15 - 03/1/,2,3,4
* - Transmission and Steering 15 - 15 - 03/5,6
* - Options 15 - 15 - 03/7,8,9,10
* - Autoshift Transmission 15 - 15 - 03/11,12
* - Servo Command Pilot Circuit 15 - 15 - 03/13,14
Circuit Diagrams - Hydraulic
-Standard Machine
- 3CX, 4CX Basic Machine from m/c no. 402174 15 - 20 - 02/1,2
- Circuit Variations from m/c no. 400001 15 - 20 - 02/3,4
- Steer Hydraulics (AWS from m/c no 400001) 15 - 20 - 02/5
- Steer Hydraulics (2WS from m/c no. 400001) 15 - 20 - 02/6
-Servo Machines (All Models except 2CX)

- from machine no. 400001 to 420485 15 - 20 - 03/1,2
- from machine no. 420486 15 - 20 - 03/3,4
3CX, 4CX, 214, 215, 217 & ‘S’ Series Machines from m/c no. 460001 15 - 20 - 04/1,2
3CX, (214E Series 3) Machines only 15 - 20 - 04/3
214e (Series 4) only (from m/c no. 460001) 15 - 20 - 04/4
* 214Se (Series 4) Only 15 - 20 - 04/4A
3CX ‘S’ Series Options (from m/c no. 460001) 15 - 20 - 04/5,6
4CX Gear Pump Option (from m/c no. 460001) 15 - 20 - 04/5
Variable Flow Hydraulics (from m/c no. 460001)
- 7-Spool with High Flow Options 15 - 20 - 04/7,8
- 6-Spool with High/Low Flow Options 15 - 20 - 04/9,10
- 4CXE, 4CX Super-Hand Held Tools Option 15 - 20 - 04/11
* - Brakes (All Models (except 2CX) from m/c no. 400001)

- Standard Machines 15 - 25 - 01/1
- Servo Machines 15 - 25 - 02/1
9804/1103 Backhoe Loaders Contents - 5 Issue 2*

CONTENTS
CONTENTS
Backhoe Loaders 10 - 00 - 01/1
2CX From m/c no. 655000 to 656500
Lubricants & Capacities
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently
run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without load).
Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100
hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30
Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine.
After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below.
ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL

Litres (UK Gal) SPECIFICATION
Fuel Tank 64 (14) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 7.2 (1.6) JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B,

-10 °C to 50 °C (14 °F to 122 °F) API CD/SE, MIL-L-2104D
JCB Super Universal Agricultural SAE10W/30, MIL-L-2105,

-15 °C to 30 °C (5 °F to 86 °F) API CD/SE, MIL-L-2104C
MIL-L-46152
JCB Torque Converter Fluid SAE10W, MIL-L-46152,

Engine (Coolant) 12.5 (2.75) JCB Universal Antifreeze/water ASTM D3306-74

(See Coolant Mixtures)
Syncro Shuttle 19 (4.2) JCB Special Transmission Fluid ESP-M2C 33G
Front Axle
Housing 4 (0.88) JCB HD90 Gear Oil API-GL-5
Hubs (x2) 1 (0.22) JCB HD90 Gear Oil MIL-L-2105
Rear Axle
Housing 4 (0.88) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 1 (0.22) JCB Special Gear Oil
Brake System JCB Light Hydraulic Fluid †† ISO VG15
Hydraulic System 70 (15.4) JCB High Performance Hydraulic Oil ISO VG46
(including tank) (Above 38 °C, 100 °F) †
JCB Special Hydraulic Fluid ISO VG32

(Below 38 °C, 100 °F)
Grease Points --- JCB MPL Grease Lithium based, No. 2

consistency.
† Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level
indicator on hydraulic tank.
†† DO NOT USE ORDINARY BRAKE FLUID.
9804/1103 10 - 00 - 01/1 Issue 1

CONTENTS
CONTENTS
210S From m/c no. 655000 to 656500
Lubricants & Capacities (210S)
run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without load).
Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine.
After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below.

US Gal (litres) SPECIFICATION
Fuel Tank 16.81 (64) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 1.92 (7.2) JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B,

14° F to 122° F (-10° C to 50° C) API CD/SE, MIL-L-2104D

5° F to 86° F (-15° C to 30° C) API CD/SE, MIL-L-2104C
MIL-L-46152

0° F to 32° F (-18° C to 0° C) API CD/SE, MIL-L-2104D

Syncro Shuttle 5.04 (19.0) JCB Special Transmission Fluid ESP-M2C 33G
Front Axle
Housing 1.05 (4.0) JCB HD90 Gear Oil API-GL-5
Hubs (x2) 0.26 (1.0) JCB HD90 Gear Oil MIL-L-2105
Rear Axle
Housing 1.05 (4.0) JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 0.26 (1.0) JCB Special Gear Oil
Brake System JCB Light Hydraulic Fluid †† ISO VG15
Hydraulic System 18.49 (70.0) JCB High Performance Hydraulic Oil ISO VG46
(including tank) (Above 100° F, 38° C) †

(Below 100° F, 38° C)

consistency.
† Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level
†† DO NOT USE ORDINARY BRAKE FLUID.
9804/1103 10 - 00 - 01/2 Issue 1

CONTENTS
CONTENTS
2CX, 2CXL, 210S, 210SL From m/c no. 657001

Lubricants and Capacities
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-
in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without load). Engines
of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours
operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30
Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the
machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below.

Litres UK Gal USA Gal SPECIFICATION
Fuel Tank 83.2 18.3 22.0 Diesel Oil ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 10.7 2.4 2.9 JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B,
-10 °C to 50 °C (14 °F to 122 °F) API CE/SF, MIL-L-2104D

MIL-L-46152

Engine (Coolant) 11 2.4 2.9 JCB Universal Antifreeze/water ASTM D3306-74

Syncro Shuttle 17.5 3.8 4.6 JCB Special Transmission Fluid ESP-M2C 33G
Axles (2CX, 210S)

Housing 4 0.88 1.1 JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x4) 1 0.22 0.26 JCB Special Gear Oil
Axles (2CXL, 2CX Farm Master, 210SL)

Housing 8.8 1.94 2.33 JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x4) 1.8 0.4 0.48 JCB Special Gear Oil
Hydraulic System † 77 17 20.4 JCB High Performance Hydraulic Oil ISO VG46
(including tank) (Above 38 °C, 100 °F)

(Below 38 °C, 100 °F)

consistency.
--- JCB HP Grease (High Performance) Lithium based, No. 2

consistency.
† Note:The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level
9804/1103 10 - 00 - 01/3 Issue 2

CONTENTS
CONTENTS
2DX From m/c no. 659249

in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without load). Engines

Fuel Tank 83.2 18.3 22 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
MIL-L-46152
Engine (Coolant) 12.0 2.6 3.2 JCB Universal Antifreeze/water ASTM D3306-74
Axles (SD55)
Hydraulic System* 82 18.04 21.7 JCB High Performance Hydraulic Oil ISO VG46
(Below 38 °C, 100 °F)

consistency.
consistency.
* Note:The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level
9804/1103 10 - 00 - 01/4 Issue 2

CONTENTS
CONTENTS
2CX From m/c no. 659598

in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without load).
machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended
below.

Fuel Tank 83.2 18.3 22.0 Diesel Oil ASTM D975-66T Nos. 1D, 2D
-10 °C to 50 °C (14 °F to 122 °F) API CE/SF, MIL-L-2104D

MIL-L-46152

Engine (Coolant) 11 2.4 2.9 JCB Universal Antifreeze/water ASTM D3306-74

Axles (2CX, 210S)

Housing 4 0.88 1.1 JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x4) 1 0.22 0.26 JCB Special Gear Oil
Axles (2CXL, 2CX Farm Master, 210SL)

Hydraulic System † 77 17 20.4 JCB High Performance Hydraulic Oil ISO VG46

(Below 38 °C, 100 °F)

consistency.

consistency.
9804/1103 10 - 00 - 01/5 7110-3/1-1.5 Issue 1

CONTENTS
CONTENTS
2CX, 2DX From m/c no. 659599

North American Machines to m/c no. 762079
below.

Fuel Tank 83.2 18.3 22 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
MIL-L-46152
Engine (Coolant) 12.0 2.6 3.2 JCB Universal Antifreeze/water ASTM D3306-74
Axles
Housing (SD55) 8.8 1.94 2.3 JCB Special Gear Oil API-GL4
Housing (SD40) 4.0 0.88 1.0 JCB Special Gear Oil API-GL4
Hubs (x4 - SD55) 1.8 0.4 0.5 JCB Special Gear Oil API-GL4
Hubs (x4 - SD40) 1.0 0.22 0.25 JCB Special Gear Oil API-GL4
Hydraulic System† 82 18.04 21.7 JCB High Performance Hydraulic Oil ISO VG46
(Below 38 °C, 100 °F)

consistency.
consistency.
9804/1103 15 - 00 - 01/6 7110 - 3/1-2.3 Issue 1

CONTENTS
CONTENTS
210S, 212S From m/c no. 762080

below.

USA Gal Litres SPECIFICATION
Fuel Tank 22 83.2 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 2.9 11.1 JCB 15W/40 Engine Oil CF-4/SG, SAE15W/40
-10 °C to 50 °C (14 °F to 122 °F)
JCB Engine Oil 10W CF-4/SG, SAE10W

-20 °C to 10 °C (-4 °F to 50 °F)
Engine (Coolant) 3.2 12.0 JCB Universal Antifreeze/water ASTM D3306-74
Syncro Shuttle 4.6 17.5 JCB Special Transmission Fluid ESP-M2C 33G
Axles
Housing (SD55) 2.3 8.8 JCB Special Gear Oil API-GL4
Hubs (x4 - SD55) 0.5 1.8 JCB Special Gear Oil API-GL4
Hydraulic System† 21.7 82 JCB High Performance Hydraulic Oil ISO VG46
(Below 38 °C, 100 °F)
Grease Points --- JCB Moly EP#2 Grease Lithium based, No. 2
9804/1103 15 - 00 - 01/7 3270 - 3/1-3.1 Issue 1

CONTENTS
CONTENTS
214e (N. America) From m/c no. 460001

Fluids, Lubricants and Capacities (cont’d)
➄ !WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl.
Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the
affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not
breathe the fumes. Apply in a well-ventilated area.
GEN-1-3
➅ Note: AWS axles with limited slip differential must use JCB Special Gear Oil.
9804/1103 15 - 00 - 01/8 3270 - 3/1-5.1 Issue 1

CONTENTS
CONTENTS
2CX, 210S From m/c no. 655000 to 656500

Static Dimensions
S136710
9804/1103 10 - 00 - 02/1 Issue 1

CONTENTS
2CX, 210S From m/c no. 657001

Static Dimensions and Weight
Item Description Dimensions

A Overall length 4.88m (16ft 0in)
B Overall height 2.67m (8ft 9in)
C Height to top of cab 2.63m (8ft 6in)
D Wheelbase 1.92m (6ft 3in)
E Minimum ground clearance 0.35m (1ft 2in)
F Slew ground clearance 0.46m (1ft 6in)
G Width 1.85m (6ft 1in)
Machine weight - Fully operational with
6-in-1 shovel, 450mm (18in.) excavator bucket,
full fuel tank and 80kg operator. 5230kg (11532lb)
Note: Dimensions based on standard tyres fitted (12.5 x 18, 10 PR traction). For Backhoe and Loader dimensions contact
your JCB Distributor.
B C
F E
D
G
A
A182671
9804/1103 10 - 00 - 02/2 3060/179 Issue 2*

CONTENTS
CONTENTS
2CX, 210S with Extending Dipper From m/c no. 657001

2CX (with Extending Dipper)

full fuel tank and 80kg operator. 5310kg (11708lb)
B
C
F E
D
G
A208661
9804/1103 10 - 00 - 02/3 3060/180 Issue 2*

CONTENTS
CONTENTS
2CXL, 210SL From m/c no. 657001

* Static Dimensions and Weight

C Wheelbase 1.92m (6ft 3in)
D Width 1.85m (6ft 1in)

Quickhitch and 6-in-1 shovel, full fuel tank
and 80kg operator. 5574kg (12290lb)
Note: Dimensions based on standard tyres fitted (12.5 x 18, 10 PR traction). For Loader dimensions contact your JCB
Distributor.
D C
A
A198341
9804/1103 10 - 00 - 02/4 3060/181 Issue 2*

CONTENTS
CONTENTS
* 2CX Airmaster From m/c no. 657001
Static Dimensions
1.92m
(6ft 3in)
4.90m
(16ft 1in)
2.49m
(8ft 2in)
1.80m
1.37m
(5ft 11in)
(4ft 6in)
9804/1103 10 - 00 - 02/5 3060/179 Issue 2*

CONTENTS
CONTENTS
2CX Farm Master From m/c no. 657001


C Wheelbase 1.92m (6ft 3in)
D Width 1.95m (6ft 5in)

Quickhitch and standard shovel, full fuel tank
and 80kg operator. 5670kg (12502lb)
Note: Dimensions based on standard tyres fitted (405/70 R 20, XM27). For Loader dimensions contact your JCB Distributor.
C
D
A
A220291
9804/1103 10 - 00 - 02/6 3060/182 Issue 1

CONTENTS
CONTENTS
2CXU, 210SU From m/c no. 657001


A Overall length 4.47 m (14 ft 8 in)
C Height to top of cab 2.68 m (8 ft 7 in)
D Wheelbase 1.92 m (6 ft 3 in)
E Minimum ground clearance 0.33 m (1 ft 1 in)
G Width 1.95 m (6 ft 5 in)
Machine weight - Base unit 4907 Kg (10814 lbs)
With cab 5088 Kg (11214 lbs)
The machine weight includes, standard shovel, three point hitch, full fuel tank and 80 kg (176 lbs) operator.
The 2CXU machine must have either an implement or counterweight attached to the three point hitch before the machine is
used to its full loader capabilities.
Maximum rated operating load with a 0.07 m3 (2.50 ft3) general purpose shovel - with counterweight 2150 Kg (4740 lbs)
without counterweight 1400 Kg (3087 lbs)
Lift capacity, bottom hitch links at ball end H when fully lowered 3000 Kg (3 tonne)
Maximum load on each axle 5500 Kg (5.5 tonne)
When an implement is attached, the weight on the front axle should be greater than or equal to 0.2 the gross weight of the
machine. However do no exceed the maximum load of the rear axle.
D
G
A A182672
9804/1103 10 - 00 - 02/7 3060/183 Issue 1

CONTENTS
CONTENTS
2DX, 212S From m/c no. 659249


B Width over tyres 1.95m (6ft 5in)
C Overall height 3.41m (11ft 2in)
D Standard shovel width 2.10m (6ft 10in)
Operating weight with 1.37m shovel 6500kg (14326lbs)
D A B
A227680
9804/1103 10 - 00 - 03/1 3270 - F/1-3.1 Issue 1

CONTENTS
CONTENTS
2DX, 212S with Extending Dipper From m/c no. 659249


B Width over tyres 1.95m (6ft 5in)
C Overall height 3.39m (11ft 3in)
D Standard shovel width 2.10m (6ft 10in)
and full fuel tank. 6840 kg (15082 lbs)
Note: Dimensions based on standard tyres fitted (12.5x20 industrial traction). For Backhoe and Loader dimensions contact
D A B
A279700
9804/1103 10 - 00 - 03/2 3060/178 Issue 1

CONTENTS
CONTENTS
2CX, 210S From m/c no. 655000 to 656500

Data - Electrical
System 12 Volt, negative earth
Battery
Cranking Performance at -18 °C (0 °F) 410 Amps to 1.4 V.P.C.
Reserve Capacity (minutes) for 25 amp load 180
Alternator A127, 55 Amp max. output
Starter Motor S12-85 (2M113)
Light Bulbs
Side/Tail 5 W (front & rear)
Stop 21 W (rear)
Direction Indicators 21 W (front & rear)
Head 55 W dip, 60 W main
Number Plate 2x5W
Interior 10 W
Work 55 W (front & rear)
Instrument 1.2 W
Beacon 70 W Halogen
Inspection Lamp (where fitted) 55 W (floodlight pattern)
Circuit Protection
Circuits Rating (Amps) Fuse No.
Brake Lights 5 A1
Instruments 5 A2
Left hand side/tail lights; number plate lights 5 A3
Right hand side/tail lights; panel lights 5 A4
Spare - A5
Hazard warning lights 10 A6
Interior (cab) light; radio (if fitted); beacon 10 A7
Spare (Option: Stabiliser relay) - (10) A8
Horn (front); headlight flash; front wiper and wash 10 A9
Rear wiper and wash 5 B1
Horn (rear) 5 B2
Headlight - dipped beam 10 B3
Headlight - main beam; warning lights 10 B4
Front working lights 10 B5
Direction indicators 5 B6
Dump relay; forward/reverse relay; reverse alarm 5 B7
Heater 10 B8
Buzzer; hand dump 5 B9
Rear working lights 10 C1
Spare (Option: Rear window heater) - (20) C2
Spare (Option: Engine/Transmission oil pressure warning lights) - ( 5) C3
Spare (Option:Engine coolant/Transmission oil temperature
warning lights) - (5) C4
Spare - C5 to C8
Spare (Option: Breaker) - (5) C9
S136670
9804/1103 10 - 05 - 01/1 Issue 1

CONTENTS
CONTENTS
Backhoe Loaders
Data - Electrical
Battery
Fuses Bulbs Rating (Watts)

Headlights - main 45 W
The electrical circuits are protected by fuses. The fuses are Headlights - dip 37.5 W
located in a fuse box on the switch console. If a fuse Indicators 21 W (front & rear)
ruptures, find out why and rectify the fault before fitting a new Instruments 1.2 W
one. Work lights 55 W Halogen (front & rear)
Number plate light 2x5W
Fuse Circuit Fuse Rating Side/tail lights 5W (front & rear)
No. (Amps) Interior lights 10 W
A1 Brake lights 5 Stop lights 21 W (rear)
A2 Instruments 10 Beacon 70 W Halogen
A3 LH side/tail lights; number plate lights 5 Inspection lamp (where fitted) 55 W (floodlight pattern)
A4 RH side/tail lights 5 Rear fog 21 W
Warning lights 3W
A5 Thermostart 15
A6 Hazard warning lights 10
Relay Identification
A7 Interior (cab) light; beacon 20
A8 Stabiliser leg interlock 5 1 Parking brake
A9 Horn (front); windscreen wiper; 2 Road lights
headlight flash 15 3 Reverse
4 Forward
B1 Rear wiper and wash 10 5 Transmission dump
6 Flashers
B2 Horn (rear) 10
7 Neutral start
B3 Dipped beam; rear fog light 10 8 Stabiliser leg lock
B4 Main beam; warning lights 10 9 Parking brake solenoid
B5 Front work lights 10 10 Buzzer
B6 Direction indicators 10 11 Parking brake start
B7 Dump relay; forward/reverse solenoid; 5 12 4 Spool option
reverse alarm 13 4 Spool option
B8 Heater motor 15 14 Trailer flasher buzzer
B9 Buzzer; hand dump 5
C1 Rear work lights 10

C2 Engine shut off system 5
C3 Parking brake solenoid 5
C4 Radio; wiper park 15
C5 Road lights relay 15
C6 Attachments socket 15
C7 Blank
C8 2/4WS steering circuit (where fitted) 5
C9 Air conditioning unit (where fitted)/
High output heater (where fitted) 20
A201931
9804/1103 10 - 05 - 01/2 Issue 1

CONTENTS
CONTENTS
Backhoe Loaders
2DX From m/c no. 659249
Data - Electrics
Fuses Bulbs Rating (Watts)
The electrical circuits are protected by fuses. The fuses are Headlights - dip 37.5 W
located in the front console, underneath cover A. If a fuse Indicators 21 W (front & rear)
ruptures, find out why and rectify the fault before fitting a new Instruments 1.2 W
one. Work lights 55 W Halogen (front & rear)
Fuse Circuit Fuse Rating Side/tail lights 5W (front & rear)
No. (Amps) Interior lights 10 W
A1 Brake lights 5 Stop lights 21 W (rear)
A2 Instruments 5 Beacon 70 W Halogen
A3 LH side/tail lights/number plate light 5 Inspection lamp (where fitted) 55 W (floodlight pattern)
A4 RH side/tail lights/number plate light 5 Rear fog 21 W
A5 Rear wiper and wash 5 Warning lights 3W
A7 Interior (cab) light; beacon; face level fan 10 Relays
A8 Radio 5 R1 Transmission Dump
A9 Horn (front); windscreen wiper; R2 Neutral Start
headlight flash 10 R3 Parking Brake
B1 Attachments socket 15 R4 Buzzer
B2 Engine shut off system 5 R5 Parking Brake Light
B3 Dipped beam 10 R6 Indicators
B4 Main beam; warning lights 10 R7 Forward
B5 Front work lights 10 R8 ‘Ignition’ 1
B6 Direction indicators 5 R9 Reverse
B7 Parking brake solenoid 5 R10 ‘Ignition’ 2
B8 Heater motor 20 R11 Stabiliser Leg Lock;Compressor
B9 Horn (rear) 10 R12 Road Lights
C1 Rear work lights 10 R13 Hammer
C2 Where fitted - 2/4WS steering circuit; R14 Neutral Lock
compressor; Stabiliser leg interlock 5 R15 4 Spool Option (if fitted)
C3 Dump relay; forward/reverse solenoid; 10 R16 Quick Hitch (if fitted)
reverse alarm R17 4 Spool Option (if fitted)
C4 Rear fog light 5 R18 Quick Hitch Buzzer (if fitted)
C5 Thermostart 15 R19 Trailer Warning Buzzer (if fitted)
R20 Shutdown Relay (if fitted)
R1 R2 R7 R8 S227260
R3 R4 R9 R10
R5 R6 R11 R12
R13 R14
9 10 10
A
15
8 5 20 R15 R16
7 10 5
R17 R18
6 10 5
10
5 5 10 15 R19 R20
4 5 10 5
3 5 10 10
2 5 5 5
1 5 15 10
5
A230370
A B C
9804/1103 10 - 05 - 01/3 Issue 1

CONTENTS
CONTENTS
2CX, 2DX, 210S, 212S and Variants From m/c no. 657001
Data - Electrical

Battery
The electrical circuits are protected by fuses. The fuses are located in the front console, underneath cover A. If a fuse ruptures,
find out why and rectify the fault before fitting a new one.
The fuses are identified using column letters (A, B and C) and row numbers (1 to 9). Note that all the fuses are shown (including
optional equipment fuses). Your machine may not be equipped with all the fuses shown on these pages.
Bulbs Rating (Watts)

Headlights - dip 37.5 W
Indicators 21 W (front & rear)
Instruments 1.2 W
Work lights 55 W Halogen (front & rear)
Side/tail lights 5W (front & rear)
Interior lights 10 W
Stop lights 21 W (rear)
Beacon 70 W Halogen
Inspection lamp (where fitted) 55 W (floodlight pattern)
Rear fog 21 W
Warning lights 3W
9804/1103 10 - 05 - 01/4 3270 - C/1-1.5 Issue 1

CONTENTS
CONTENTS
2CX From m/c no. 655030 to 656999

Data - Electrics
Fuses Relay Identification
1 Parking brake
Fuse Circuit Fuse Rating
2 Road lights
No. (Amps)
3 Reverse
A1 Brake lights 5
4 Forward
A2 Instruments 10 5 Transmission dump
A3 LH side/tail lights; number plate lights 5 6 Flashers
A4 RH side/tail lights 5 7 Neutral start
A5 Thermostart 15 8 Stabiliser leg lock
A6 Hazard warning lights 10 9 Parking brake solenoid
A7 Interior (cab) light; beacon 20 10 Buzzer
11 Parking brake start
A8 Stabiliser leg interlock 5
12 4 Spool option
A9 Horn (front); windscreen wiper; 13 4 Spool option
headlight flash 15 14 Trailer flasher buzzer
B1 Rear wiper and wash 10

B2 Horn (rear) 10
B3 Dipped beam; rear fog light 10
B4 Main beam; warning lights 10
B5 Front work lights 10
B6 Direction indicators 10
B7 Dump relay; forward/reverse solenoid; 5
reverse alarm
B8 Heater motor 15
B9 Buzzer; hand dump 5

C2 Engine shut off system 5
C3 Parking brake solenoid 5
C4 Radio; wiper park 15
C5 Road lights relay 15
C6 Attachments socket 15
C7 Blank
C8 2/4WS steering circuit 5
C9 Air conditioning unit, high output heater 20
A201931
S181851
9804/1103 10 - 05 - 01/5 7110 - C/1-2.3 Issue 1

CONTENTS
CONTENTS
2DX from m/c no. 657001

2CX from m/c no. 659600 to 761891
Data-Electrics
Fuses Relays
Fuse Circuit Fuse Rating R1 Transmission Dump

No. (Amps) R2 Neutral Start
A1 Brake lights 5 R3 Parking Brake
A2 Instruments 5 R4 Buzzer
A3 LH side/tail lights/number plate light 5 R5 Parking Brake Light
A4 RH side/tail lights/number plate light 5 R6 Indicators
A5 Rear wiper and wash 5 R7 Forward
A6 Hazard warning lights 10 R8 ‘Ignition’ 1
A7 Interior (cab) light; beacon; face level fan 10 R9 Revers
A8 Radio 5 R10 ‘Ignition’ 2
A9 Horn (front); windscreen wiper; R11 Stabiliser Leg Lock;Compressor
headlight flash 10 R12 Road Lights
R13 Hammer
B1 Attachments socket 15 R14 Neutral Lock
B2 Engine shut off system 5 R15 4 Spool Option
B3 Dipped beam 10 R16 Quick Hitch
B4 Main beam; warning lights 10 R17 4 Spool Option
B5 Front work lights 10 R18 Quick Hitch Buzzer
B6 Direction indicators 5 R19 Trailer Warning Buzzer
B7 Parking brake solenoid 5 R20 Shutdown Relay
B8 Heater motor 20
B9 Horn (rear) 10

C2 2/4WS steering circuit;
compressor; stabiliser leg interlock 5
C3 Dump relay; forward/reverse solenoid; 10
reverse alarm
C4 Rear fog light 5
C5 Thermostart 15
A R1 R2 R7 R8
R3 R4 R9 R10
R5 R6 R11 R12
9 10 10
R13 R14
A
15
8 5 20 R15 R16
7 10 5
R17 R18
6 10 5
10
5 10 10 15 R19 R20
4 5 10 5
3 5 10 10
2 5 5 5
1 5 15 10
5
A B C
A230371 S227260
9804/1103 10 - 05 - 01/6 7110 - C/1-3.2 Issue 1

CONTENTS
CONTENTS
2CX, 2DX, 210S, 212S From m/c no. 760841

Data - Electrics
Fuses Relays
R1 Transmission Dump
No. (Amps)
R2 Neutral Start
A1 Brake lights 5
R3 Parking Brake
A2 Instruments 5
R4 Buzzer
A3 LH side/tail lights/number plate light 5
R5 Brake Light
A4 RH side/tail lights/number plate light 5
R6 Indicators
A5 Rear wiper and wash 5
R7 Forward
R8 ‘Ignition’ 1
A7 Interior (cab) light; beacon; face level fan 10
R9 Reverse
A8 Radio 5
R10 ‘Ignition’ 2
A9 Horn (front); windscreen wiper;
R11 Stabiliser Leg Lock;Compressor
headlight flash 10
R12 Road Lights
R13 Hammer
B1 Attachments socket 10
R14 Compressor Neutral Start
B2 Engine shut off system 5
R15 Engine Shut Off Solenoid
B3 Dipped beam 15
R16 Front Work Lights
B4 Main beam 15
R17 Front Auxiliary
R18 Front Auxiliary
R19 Air Conditioning
B7 Parking brake 5
R20 Rear Quickhitch
B8 Heater motor; air conditioning 15
R21 Front Quickhitch
B9 Horn (rear) 10
R22 Trailer Indicator Buzzer

C2 Where fitted - compressor; Stabiliser leg interlock 5
C3 Transmission Dump 7.5
C4 Rear fog light 5
C5 Thermostart 15
A R1 R2 R7 R8
R3 R4 R9 R10
R5 R6 R11 R12
A
9 R13 R14
8
7 R15 R16
6
R17 R18
5
4
R19 R20
3
2
R21 R22
1
A B C
A300850 S227260
9804/1103 10 - 05 - 01/7 Issue 1

CONTENTS
CONTENTS
212SU (N.Am) From m/c no. 657001

Data - Electrics
Fuses Relays
R1 Neutral Start
No. (Amps)
R2 ‘Ignition’ 1
A1 Brake lights 5
R3 Transmission Dump
A2 Instruments 5
R4 ‘Ignition’ 2
A3 LH side/tail lights/number plate light 5
R5 Front Work Lights
A4 RH side/tail lights/number plate light 5
R6 Parking Brake
A5 Rear wiper and wash 7.5
R7 Warning Buzzer
R8 Forward
A7 Beacon 15
R9 Indicators
A8 Radio 5
R10 Reverse
A9 Horn (front); windscreen wiper;
headlight flash 20
B1 Attachments socket 10
B2 Engine shut off system 5
B3 Dipped beam 15
B4 Main beam 15
B7 Parking brake 5
B8 Heater motor; air conditioning 15
B9 Blank 15

C2 Power Take off 5
C3 Transmission Dump 7.5
C4 Rear fog light 5
C5 Thermostart 15
R1 R2
9
8
R3 R4
7
A
6
R5 R6
5
4
3 R7 R8
2
1 R9 R10
A B C
A300870 S227260
9804/1103 10 - 05 - 01/8 7110 - C/1-5.1 Issue 1

CONTENTS
CONTENTS
2CX, 210S From m/c no. 655000 to 656500
Data - Machine Hydraulics
Pump
Type 550
Flow at 2250 rev/min and system pressure 56.25 litres/min 12.38 UK gal/min (14.87 US gal/min)
Relief Valve Operating Pressures bar kgf/cm2 lbf/in2
Main Relief Valve (M.R.V.) 220 225 3200
Auxiliary Relief Valves (A.R.V.)

Loader
Shovel Ram Head Side (pilot-operated) 207 211 3000
Shovel Ram Rod Side (pilot-operated) 207 211 3000
Auxiliary Ram Head Side (direct acting) 241 246 3500
Auxiliary Ram Rod Side (direct acting) 241 246 3500
Excavator
Slew Ram Head Side (pilot-operated) 241 246 3500
Slew Ram Rod Side (pilot-operated) 241 246 3500
Boom Ram Head Side (pilot-operated) 241 246 3500
Boom Ram Rod Side (direct acting) 262 267 3800
Dipper Ram Head Side (pilot-operated) 241 246 3500
Dipper Ram Rod Side (direct acting) 241 246 3500
Bucket Ram Head Side (direct acting) 241 246 3500
Return Line Filter bar kgf/cm2 lbf/in2
By-pass pressure 1.72 1.76 25
Ram Torque Settings Nm kgf m lbf ft
Piston Head
Lift Ram 405 41.5 300
Shovel Ram 405 41.5 300
Slew Ram 405 41.5 300
Boom Ram 405 41.5 300
Stabiliser Ram 405 41.5 300
Dipper Ram 405 41.5 300
Bucket Ram 405 41.5 300
Hydraclamp Ram 405 41.5 300
End Cap
Lift Ram 450 45.9 332
Shovel Ram 450 45.9 332
Slew Ram 450 45.9 332
Boom Ram 450 45.9 332
Stabiliser Ram 450 45.9 332
Dipper Ram 450 45.9 332
Bucket Ram 450 45.9 332
Hydraclamp Ram 450 45.9 332
9804/1103 10 - 05 - 02/1 Issue 1

CONTENTS
CONTENTS
2CX, 2CXL, 210S, 210SL From m/c no. 657001 to 658960

Hydraulic Pump (to machine serial number 657447)
Model/Reference Single-Priority/3939
Rotation Clockwise
Mounting Engine Timing Case (with adapter)
Flow at 2000 rev/min and system pressure litres/min UK gal/min US gal/min
58 12.76 15.32
Hydraulic Pump (from machine serial number 657448)
Model/Reference Single-Priority/4506
Rotation Clockwise
Mounting Engine Timing Case (direct - no adapter required)
58 12.76 15.32

Loader
Shovel Ram Rod Side (pilot-operated) 277.7 281 4000
Excavator
Slew Ram (pilot-operated) 241 246 3500
Boom Ram Head Side (pilot-operated) 241 246 3500
Boom Ram Rod Side (direct acting) 262 267 3800
Dipper Ram Head Side (pilot-operated) 241 246 3500
Dipper Ram Rod Side (direct acting) 241 246 3500
Bucket Ram Head Side (direct acting) 241 246 3500
Hammer 241 246 3500
Hydraulic Tool Circuit (HTC) 138 141 2000
Piston Head
Lift Rams 405 41.5 300
Shovel Rams 405 41.5 300
Slew Rams 405 41.5 300
Boom Ram 405 41.5 300
Stabiliser Rams 405 41.5 300
Dipper Ram 405 41.5 300
Bucket Ram 405 41.5 300
Clam Shovel Ram 405 41.5 300
End Cap
Lift Rams 678 69.2 500
Slew Rams 678 69.2 500
Boom Ram 678 69.2 500
Dipper Ram 678 69.2 500
Bucket Ram 678 69.2 500
9804/1103 10 - 05 - 02/2 Issue 2

CONTENTS
CONTENTS

Main Hydraulic Pump
Model/Reference Single/5910P
Rotation Clockwise
Mounting Engine Timing Case (with adapter)
58 12.76 15.32
Auxiliary Hydraulic Pump (2DX only)
Model/Reference Single/4240J
Rotation Anti-Clockwise
Mounting Auxiliary Take-Off
28 6.16 7.39
Relief Valve Operating Pressures (2DX)
Note: Relief valve settings for the 2CX range of machines remain as shown on page 10 - 05 - 02/2.
bar kgf/cm2 lbf/in2

Loader
Shovel Ram Rod Side (pilot-operated) 277.7 281 4000
Excavator
Slew Ram (Head Side) 262 267 3800
Slew Ram (Rod Side) 262 267 3800
Boom Ram Head Side 248 253 3600
Boom Ram Rod Side 316 267 4495
Dipper Ram Head Side 248 253 3600
Dipper Ram Rod Side 248 253 3600
Bucket Ram Head Side 248 253 3600
Hydraulic Tool Circuit (HTC) (When Fitted) 138 141 2000
Piston Head
Lift Rams 405 41.5 300
Slew Rams 405 41.5 300
Boom Ram 405 41.5 300
Dipper Ram 405 41.5 300
Bucket Ram 405 41.5 300
End Cap
Lift Rams 678 69.2 500
Slew Rams 678 69.2 500
Boom Ram 678 69.2 500
Dipper Ram 678 69.2 500
Bucket Ram 678 69.2 500
9804/1103 10 - 05 - 02/3 Issue 1

CONTENTS
CONTENTS
2CX, 210S From m/c no. 655000 to 656500

Data - Steer Hydraulics
System Type Full power hydrostatic
Pump (See Page 10 - 05 - 02/1)
Steering Unit Type OSPC 100LS
Priority Valve Type OLS 80
Operation Pressures bar kgf/cm2 lbf/in2

Relief Valve Operating Pressure (up to Machine No. 655603) 125 128 1800
Relief Valve Operating Pressure (from Machine No. 655604) 138 141 2000
Shock Valve Operating Pressure (up to Machine No. 655493) 250 255 3625
Shock Valve Operating Pressure (from Machine No. 655494) 192 197 2800
Steer Ram Torque Settings Nm kgf m lbf ft

Piston Head 405 41.5 300
End Cap 678 69.2 500
2CX, 2CXL, 210S, 210SL From m/c no. 657001 to 658960

Pump (See Page 10 - 05 - 02/2)
Steering Unit OSPCLS
Priority Valve Integral with pump

Relief Valve Operating Pressure 139 142 2000
Shock Valve Operating Pressure 193 197 2800
Anti-cavitation Valve - 2CX Farm Master m/c’s only 20 20.4 290
(optional on 2CXL, 210SL m/c’s)

End Cap 450 45.9 332
2CX, 2CXL, 2DX, 210S, 210SL From m/c no. 658961


Pump (See Page 10 - 05 - 02/3)
Steering Unit OSPCLS
Priority Valve Integral with brakes charge valve

Relief Valve Operating Pressure 139 142 2000
Shock Valve Operating Pressure 193 197 2800
Anti-cavitation Valve 20 20.4 290

End Cap 450 45.9 332
Brakes Charge/Steering/Priority Valve

Brake Circuit Operating Pressures
Cut-in 90 bar (1305 lbf/in2)
Cut-out 110 bar (1595 lbf/in2)
9804/1103 10 - 05 - 03/1 Issue 3

CONTENTS
CONTENTS
2CX, 210S From m/c no. 655000 to 656500

Data - Front & Rear Axles
Front Axle Rear Axle
Type SD40 SD40 (with brakes)
Weight (dry, less wheels; approx.) 245 kg (540 lb) 245 kg (540 lb)
Overall Gear Ratio 16.154:1 21.818:1 (TUV) 16.154:1 21.818:1 (TUV)
Crownwheel & Pinion Ratio 13:35 11:40 (TUV) 13:35 11:40 (TUV
Number of Steer Rams 1 1
Type of Mounting Pivot Pad
Type of Brakes — 3 Plate
2CX, 210S From m/c no. 657001

Type JCB spiral bevel input with epicyclic hub reduction

Designation SD40 (with brakes)
Type of Brakes Oil immersed multi-plate disc located in hubs
Installation
Front Centre pivot
Rear Rigid pad mount
Weight (dry, less wheels; approx.) 245 kg (540 lb)
Overall Gear Ratio 16.154:1
Crownwheel & Pinion Ratio 2.692:1
Number of Teeth
Crownwheel 35
Pinion 13
Hub reduction 6:1
Toe-in 0°
Castor angle 0°
Camber angle 1°
Kingpin inclination 0°
Number of steer rams 1
Input type Yoke coupling
2CXAM, 2CXL, 210FM, 210SL, 2DX From m/c no. 657001

Installation
Front Centre pivot
Rear Rigid pad mount
Weight (dry, with no steer rams and
without wheels) 330 kg (728 lb) approx
Crownwheel & Pinion Ratio 3:1
Number of Teeth
Crownwheel 33
Pinion 11
Hub reduction 5.4:1
Toe-in 0°
Castor angle 0°
Camber angle 1°
9804/1103 10 - 05 - 04/1 Issue 3

CONTENTS
CONTENTS
2CX 210S
2CX, From m/c no. 655000 to 656500
Data - Syncro Shuttle
Syncro Shuttle Combined torque converter, reverser, and gearbox unit with
integral parking brake.
Type SS600
Drive Output 4 wheel-drive, double yoke
Weight (dry) 150 kg (330 lb)
Torque Converter Dia. 280 mm (11 in)
Torque Multiplication at Stall 2.45:1
Gear Ratios 1st 5.55:1
2nd 3.44:1
3rd 1.83:1
4th 1.00:1
Minimum Engine Rev/Min at Converter Stall 2100 rev/min
Converter Pressures (in neutral) bar kgf/cm2 lbf/in2
Converter In at 50 deg.C 1000 rev/min 2.4 - 3.4 2.5 - 3.5 35 - 50

2000 rev/min 5.2 - 6.5 5.3 - 6.7 75 - 95
2000 rev/min 5.2 - 5.9 5.3 - 6.0 75 - 85
Converter Out at 50 deg.C 1000 rev/min 1.0 - 1.7 1.1 - 1.8 15 - 25

2000 rev/min 2.0 max 2.0 max 29 max
Converter Out at 100 deg.C 1000 rev/min 0.3 - 0.6 0.3 - 0.6 4.0 - 8.0
2000 rev/min 1.0 - 1.7 1.1 - 1.8 15 - 25
Converter Inlet Relief Valve Pressure (max.) 6.5 6.7 95
Lubrication Pressures (in neutral)
At 50 deg.C 1000 rev/min 0.2 - 0.3 0.2 - 0.4 3.0 - 5.0

2000 rev/min 0.4 - 0.7 0.4 - 0.7 6.0 - 10.0
At 100 deg.C 1000 rev/min 0.1 - 0.2 0.1 - 0.2 2.0 - 3.0
2000 rev/min 0.3 - 0.6 0.3 - 0.6 4.0 - 8.0
Main Line Pressure (in neutral)
At 50 deg. C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150

2000 rev/min 10.7 - 11.7 10.9 - 12.0 155 - 170
At 100 deg.C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
2000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
Clutch Pressure (forward and reverse)
At 50 deg. C 1000 rev/min 5.5 - 6.2 5.6 - 6.3 80 - 125

2000 rev/min 6.9 - 7.6 7.0 - 7.7 100 - 145
At 100 deg.C 1000 rev/min 5.5 - 6.2 5.6 - 6.3 80 - 125

2000 rev/min 6.2 - 6.9 6.3 - 7.0 90 - 140
Flow Rates (in neutral) litres/min US gal/min UK gal/min
Cooler at 50 deg.C 1000 rev/min 10.4 - 13.6 2.8 - 3.6 2.3 - 3.0
2000 rev/min 14.5 - 20.0 3.8 - 5.3 3.2 - 4.4
2000 rev/min 22.7 - 26.1 6.0 - 6.9 5.0 - 5.7
Pump at 50 deg.C 1000 rev/min 11.0 - 15.0 2.9 - 4.0 2.5 - 3.3
2000 rev/min 22.5 - 29.5 6.0 - 7.8 5.0 - 6.5
9804/1103 10 - 05 - 05/1 Issue 1

CONTENTS
CONTENTS
2CX, 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL From m/c no. 657001
Data - Synchro Shuttle
Syncro Shuttle Combined torque converter, reverser, and gearbox unit with
Type SS400
Drive Output 4 wheel-drive, double yoke
Gear Ratios 30 kph (18 mph) 20 kph (12 mph)
1st 4.27:1 6.31:1
2nd 2.50:1 3.70:1
3rd 1.18:1 1.75:1
4th 0.70:1 1.03:1
Torque Converters
Ratio 2.8:1 2.78:1 2.4:1

Colour Coded Dots 3 Brown 1 Pink & 1 Yellow 2 Orange & 1 Green
Designation SSL11 SSS11 WH11
Stall Figures
2CX Airmaster Farm 2CX - 20 kph 210SU 2DX

2CXL Master
Engine Stall Speed

1 Converter only
max r.p.m. 2127 2127 1790 2170 2127 N/A
min. r.p.m. 2027 2027 1700 2070 2027 N/A
2 Converter + MRV
max. r.p.m. 1825 1825 1490 1848 1825 N/A
min. r.p.m. 1725 1725 1400 1748 1725 N/A
Build Specification
Engine Size 65 bhp ● ● ● ●
74 bhp ● ●
Converter Type SSL11 (2.8:1) ● ● ● ●

SSS11 (2.78:1) ●
WH11 (2.4:1) ●
Pump Size 58 l/min (12.7 gal/min) ● ● ● ● ● ●

(15.3 USA gal/min)
Fan Ratio 1 to 1 ● ● ●
1 to 1.25 ● ● ●

2000 rev/min 5.2 - 6.5 5.3 - 6.7 75 - 95
2000 rev/min 5.2 - 5.9 5.3 - 6.0 75 - 85
Converter Out (measure at 50 deg.C and 2000 rev/min) 3.4 3.5 50 max
Converter Relief (Safety) Valve Pressure 6.5 6.7 95 max
9804/1103 10 - 05 - 05/2 Issue 2

CONTENTS
CONTENTS
Data - Synchro Shuttle (cont'd)
At 50 deg.C 1000 rev/min 0.2 - 0.3 0.2 - 0.4 3.0 - 5.0

2000 rev/min 0.4 - 0.7 0.4 - 0.7 6.0 - 10.0
At 100 deg.C 1000 rev/min 0.1 - 0.2 0.1 - 0.2 2.0 - 3.0
2000 rev/min 0.3 - 0.6 0.3 - 0.6 4.0 - 8.0
At 50 deg. C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150

2000 rev/min 10.7 - 11.7 10.9 - 12.0 155 - 170
At 100 deg.C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
2000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
Clutch Pressure (forward and reverse) †
At 50 deg. C 1000 rev/min 7.6 - 9.7 7.7 - 9.8 110 - 140

2000 rev/min 9 - 11 9.1 - 11.25 130 - 160
At 100 deg.C 1000 rev/min 7.6 - 9.7 7.7 - 9.8 110 - 140
2000 rev/min 7.6 - 9.7 7.7 - 9.8 110 - 140
† Note: The forward and reverse clutch pressures should always be the same as the mainline pressure less (a maximum of)
1.7bar (25lbf/in2; 1.8kgf/cm2). If the mainline pressure is in the lower part of the tolerance band, then the forward and reverse
clutch pressures should also be in the lower part of the tolerance band and vice versa.
Flow Rates (in neutral) litres/min UK gal/min US gal/min
2000 rev/min 14.5 - 20.0 3.2 - 4.4 3.8 - 5.3
2000 rev/min 22.7 - 26.1 5.0 - 5.7 6.0 - 6.9
2000 rev/min 22.5 - 29.5 5.0 - 6.5 6.0 - 7.8
9804/1103 10 - 05 - 05/3 Issue 1

CONTENTS
CONTENTS
2CXAM From m/c no. 657001

Data - Synchro Shuttle
Syncro Shuttle with PTO (Power Take Off)
Description Combined torque converter, reverser, and gearbox unit with
Type SS400
Drive Output 4 wheel-drive, double yoke with additional PTO for
compressor drive
PTO Solenoid operated, multi-plate friction drive in constant mesh
Weight (dry without converter) 190kg (418.95 lbs)
Gear Ratios 30 kph (18 mph)
1st 4.27:1
2nd 2.50:1
3rd 1.18:1
4th 0.70:1
Torque Converter
Ratio 2.83:1
Colour Coded Dots 2 Yellow, 1 Orange
Engine Rev/Min at Converter Stall 2027 - 2127
Engine Rev/Min at Converter Stall + MRV Operating 1725 - 1825

2000 rev/min 5.2 - 6.5 5.3 - 6.7 75 - 95
2000 rev/min 5.2 - 5.9 5.3 - 6.0 75 - 85
Converter Out (measure at 50 deg.C and 2000 rev/min) 3.4 3.5 50 max
Converter Relief (Safety) Valve Pressure 6.5 6.7 95 max

At 50 deg.C 1000 rev/min 0.2 - 0.3 0.2 - 0.4 3.0 - 5.0
2000 rev/min 0.4 - 0.7 0.4 - 0.7 6.0 - 10.0
At 100 deg.C 1000 rev/min 0.1 - 0.2 0.1 - 0.2 2.0 - 3.0
2000 rev/min 0.3 - 0.6 0.3 - 0.6 4.0 - 8.0

At 50 deg. C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
2000 rev/min 10.7 - 11.7 10.9 - 12.0 155 - 170
At 100 deg.C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
2000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
Clutch Pressure (forward and reverse) †

At 50 deg. C 1000 rev/min 7.6 - 9.7 7.7 - 9.8 110 - 140
2000 rev/min 9 - 11 9.1 - 11.25 130 - 160
At 100 deg.C 1000 rev/min 7.6 - 9.7 7.7 - 9.8 110 - 140
2000 rev/min 7.6 - 9.7 7.7 - 9.8 110 - 140
Flow Rates (in neutral) litres/min UK gal/min US gal/min

2000 rev/min 14.5 - 20.0 3.2 - 4.4 3.8 - 5.3
2000 rev/min 22.7 - 26.1 5.0 - 5.7 6.0 - 6.9
2000 rev/min 22.5 - 29.5 5.0 - 6.5 6.0 - 7.8
† Note: The forward and reverse clutch pressures should always be the same as the mainline pressure less (a maximum of)
1.7bar (25lbf/in2; 1.8kgf/cm2). If the mainline pressure is in the lower part of the tolerance band, then the forward and reverse
clutch pressures should also be in the lower part of the tolerance band and vice versa.
9804/1103 10 - 05 - 05/4 Issue 1

CONTENTS
CONTENTS
2CX, 210S From m/c no. 655000 to 656500
Data - Tyre Sizes & Pressures
Cross Ply
Front
Type Size Ply Pressure (Normal Duty) † Pressure (Heavy Duty) ††

bar lbf/in2 bar lbf/in2
Industrial 10.5 - 18 10 3.3 48 3.75 54 Not 210S

Traction
Industrial 12.5 - 18 10 2.3 34 3.4 49

Traction
Rear
Type Size Ply Pressure (Normal Duty) † Pressure (Heavy Duty) †††
Industrial 10.5 - 18 10 2.3 34 2.75 40 Not 210S

Traction
Industrial 12.5 - 18 10 1.8 26 2.5 36

Traction
† These tyre pressures are recommended for road travel and normal working conditions.
†† These tyre pressures are recommended when handling heavy or palletised loads.
††† These tyre pressures are recommended when using a rock breaker or patch planer.
Radial Ply
Front
Type Size Pressure
bar lbf/in2
XM27 335/80R18 1.8 26
Rear
Type Size Pressure
bar lbf/in2
XM27 335/80R18 1.8 26
9804/1103 10 - 05 - 06/1 Issue 1

CONTENTS
CONTENTS
Data - Tyre Sizes & Pressures
Note: Wheel fixing on SD40 axle was changed from 8 stud to 4 stud at machine serial number 657150. Wheel fixing on SD40
Limited Slip Differential axle was changed from 8 stud to 4 stud at machine serial number 657159. The first machine fitted with
SD55 axles (5 stud fixing) was serial number 657628.
FRONT
Type Size Ply Pressure (Normal Duty) † Pressure (Heavy Duty) ††

Firestone Super Traction Lug 12.5 x 18 10 1.5 22 2.1 30
Goodyear Sure Grip Lug 12.5/80 x 18 10 2.5 36 3.5 51
Continental AS Farmer 12.5 x 18 10 1.75 26 2.55 37
Michelin X M27 335/80 R18 - 1.8 26 2.7 39
Dunlop SP PG7 385/55 R18 - 2.5 36 3.8 55
Goodyear SG Implement 12.5/80 x 18 10 2.5 36 3.5 51
Michelin X M27 405/70 R 20 - 1.4 20 2.4 34
REAR
Type Size Ply Pressure (Normal Duty) † Pressure (Heavy Duty) †††
Firestone Super Traction Lug 12.5 x 18 10 1.7 25 1.9 28
Traction S.G. Goodyear 12.5/80 x 18 10 2.25 33 2.5 36
Continental AS Farmer 12.5 x 18 10 1.75 26 2.0 29
Michelin X M27 335/80 R18 - 1.8 26 2.2 32
Dunlop SP PG7 385/55 R18 - 2.25 33 3.0 44
Goodyear SG Implement 12.5/80 x 18 10 2.25 33 2.5 36
Michelin X M27 405/70 R 20 - 1.4 20 1.8 26
† These tyre pressures are recommended for road travel and normal working conditions.
†† These tyre pressures are recommended when handling heavy or palletised loads.
††† These tyre pressures are recommended when using a rock breaker or patch planer.
Note: If the tyres fitted to your machine are not listed, then contact your JCB Distributor for advice, DO NOT guess tyre
pressures.
9804/1103 10 - 05 - 06/2 Issue 2

CONTENTS
CONTENTS
2CX, 210S From m/c no. 655000 to 656500

Data - Brakes
Service Brakes
Type JCB Oil-Immersed Multi-Plate Disc

Actuation Hydraulic
Location Rear axle hubs
Friction Plates (3 per brake pack, i.e. 6 per axle)
Outside Diameter 166 mm (6.54 in)
Inside Diameter 120 mm (4.72 in)
Nominal Facing Area per Plate 20660 mm2 (32 in2)
Hydraulic Piston Diameter 128.5 mm (5.06 in) inside diameter, 150.1 mm (5.91 in) outside diameter
Master Cylinder
Type Lucas Girling CV

Piston Diameter (each) 25.4 mm (1 in)
Piston Area (each) 507 mm2 (0.79 in2)
Parking Brake
Type Manually Adjusted Caliper, cable operated, mounted on transmission output

Disc Diameter 279.4 mm (11 in)
Data - Brakes
Service Brakes
Type JCB oil-immersed multi-plate disc high pressure brakes with hydraulic
accumulators for emergency application.
Actuation Hydraulic ON, spring OFF.
Location Front and rear axle hubs.
Friction Plates 2 per brake pack, i.e., 8 per machine.
Counter Plates 3 per brake pack, i.e., 12 per machine.
Accumulator Pressure 25 bar (363 lbf/in2).
Brake Circuit Operating Pressure
Cut-in 90 bar (1305 lbf/in2).
Cut-out 110 bar (1595 lbf/in2).
Parking Brake
Type Oil-immersed multi-plate disc.

Actuation Spring ON, hydraulic OFF.
Location Within the gearbox.
Friction Plates
30 k.p.h. Gearbox 9 off
Counter Plates
9804/1103 10 - 05 - 07/1 Issue 3

CONTENTS
CONTENTS
2CX, 210S From m/c no. 655000 to 656500
Data Engine
Type Perkins D3.152 naturally aspirated
Number of cylinders 3
Bore and Stroke 91.44 mm (3.60 in) x 127.0 mm (5.00 in)
Swept Volume 2500 cm3 (152.7 in3)
Compression Ratio 18.5:1
Compression Pressure 17-31 bar (250-450 lbf/in2)
[maximum variation between cylinders; 3.5 bar (50
lbf/in2)]
Injection Sequence 1,2,3
Valve Clearance - Cold 0.30 mm (0.012 in)
Oil Pressure (Hot) at maximum speed 2.1-4.1 bar (30-60 lbf/in2)
Fuel System
Injection Pump Type C.A.V., D.P.A., mechanically governed
Injection Pump Setting Code Perkins/ISO 36960TW/2/2470
Maximum Governed Speed 2250 rev/min
Maximum No-load Speed 2470 rev/min
Idling Speed 750 rev/min
Injection Timing Static 20° BTDC (equivalent to 0.192 in displacement)
Engine Angle 27° (checked at TDC compression)

Fuel Pump Angle 37°
Injectors - Working Pressure 170 atm
- Setting Pressure 185 atm
Cooling System
Coolant Pressure 0.48 bar (7 lbf/in2)
Coolant Temperature (normal) 80-85 deg C
Temperature Warning Light operates at 98 deg C
9804/1103 15 - 05 - 08/1 7110 - C/1-.5 Issue 4*

CONTENTS
Backhoe Loaders 10 - 05 - 08/1A
2CX, 210S From m/c no. 657001

Data Engine
2CX Range
Including 210S, 212SU to m/c no. 762079
Type Perkins 1004-4LR2 naturally aspirated
Build Number AA50429 (65BHP)
Bore and Stroke 100 mm (3.937 in) x 127.0 mm (5.00 in)
Swept Volume 3990 cm 3 (243.5 in 3 )
Compression Pressure 20-34 bar (240-493 lbf/in 2 )
[maximum variation between cylinders - 3.5 bar (50
lbf/in 2 )]
Injection Sequence 1, 3, 4, 2
Valve Clearance - Hot or Cold
- inlet 0.20 mm (0.008 in)

- exhaust 0.45 mm (0.018 in)
Maximum Speed (no load) 2160 rev/min
Governed Speed 2000 rev/min
Fuel System
Injection Pump Setting Code 2643C621/HM46L/850/7/2160
Injection Timing 16° ± 2° BTDC
Injection Setting Pressure 250 atm
Lift Pump Type AC Diaphragm
Induction System
Air Cleaner Typ 2 stage, dry element
Max. Restriction (at which warning
light operates) 635 mm (25 in) H 2 0
Lubrication System
Oil Pump Type Eccentric rotor
Oil Pressure (hot) at maximum speed 2.0 bar (30 lbf/in 2 ) (minimum)
Cooling System
Coolant Pressure 0.48 bar (7 lbf/in 2 )
Coolant Temperature (normal) 80-85 °C (176 - 185 °F)
Temperature Warning Light operates at 98 °C (209 °F)
* Note: For further details of the engine refer to Engine Service Manual 9806/0100
9804/1103 10 - 05 - 08/1A 7110 - C/1-.5 Issue 1*

CONTENTS
2DX Range From m/c no. 659249

(including 212S to m/c no. 762079)
Data Engine
Type Perkins 1000 Series, naturally aspirated
Build Number AA50525 (75HP)
Bore and Stroke 100 mm (3.937 in) x 127.0 mm (5.00 in)
Swept Volume 4 litres (243 in 3 )
Compression Pressure 28 bar (400 lbf/in 2 )
[maximum variation between cylinders - 3.5 bar
(50 lbf/in 2 )]
Injection Sequence 1, 3, 4, 2
Valve Clearance - Hot or Cold
- inlet 0.20 mm (0.008 in)
- exhaust 0.45 mm (0.018 in)
Maximum Speed (no load) 2320 - 2420 rev/min
Governed Speed 2200 rev/min
Fuel System

Injection Pump Setting Code DM55L/1000/1/2420
Injection Timing 16.5° BTDC
Injection Setting Pressure 220 atm
Lift Pump Type AC Diaphragm
Induction System
Air Cleaner Type 2 stage, dry element

Max. Restriction (at which warning
light operates) 559mm (22 in) H 2 0
Lubrication System

Oil Pressure (hot) at maximum speed 2.0 bar (30 lbf/in 2 ) (minimum)
Cooling System
Coolant Pressure 0.48 bar (7 lbf/in 2 )

Coolant Temperature (normal) 80-85 °C (176 - 185 °F)
Temperature Warning Light operates at 98 °C (209 °F)
Note: For further details of the engine refer to Engine Service Manual 9806/0100
9804/1103 15 - 05 - 08/2 7110 - C/1-1.5 Issue 2*

CONTENTS
CONTENTS

Data - Pneumatics
Performance
Maximum working pressure 6.9 bar (100 Ibf/in2)
Rated F.A.D. at full output to ISO 1217 73.2 Itr/sec (4.4 m3/min, 155 ft3/min)
Maximum air delivery temperature at full output

- at compressor unit discharge 120°C (248°F)
- at delivery manifold 110°C (230°F)
Maximum permissible ambient temperature

(continuous full load) 50°C (122°F)
Compressor
Air delivery Two 3/4” BSP Cocks
Air filter dry paper element
Load control method speed control and inlet throttling
Oil filter single bowl, spin-on cartridge type
Method of lubrication pressure feed to bearings and rotors
Oil cooler air blast
Oil reclamation combined kinetic/filtration
Oil system capacity (approx.) 19.5 litre (41/4 imp. gal)
9804/1103 10 - 05 - 09/1 Issue 1

CONTENTS
CONTENTS
2CX, 2DX, 210S, 212S From m/c no. 655000

Fault Finding - Syncro Shuttle - Mechanical
Before carrying out the checks listed the machine should, if possible, be operated to determine the fault area(s), and bring the
systems to their normal working temperatures. Ensure that the correct quantity and grade of oil is used and that there are no
obvious leaks.
A If the transmission is noisy, start at check 1.
B If the transmission is overheating, start at check 4.
C If the transmission will not pull, start at check 12.
D If there is no drive in one or both directions, start at check 17.
E If the transmission is jumping out of gear, start at check 29.
F If the transmission is sticking in gear, start at check 39.
G If ratios are 'crash changing', start at check 41.
CHECK ACTION
1 Is there noise when selecting direction? YES: Check 3

NO: Check 2
2 Is there noise when running with direction selector YES: Check 9

in neutral and ratio selector in a gear? NO: Check 19
3 Is there air in the hydraulic system? YES: Continue running to expel air.
NO: Check 4
4 Is the fluid level correct? YES: Check 5

NO: Check level only when machine is cold
and top-up as required.
5 Are the oil passages restricted? YES: Clear the restriction.

NO: Check 6
6 Is the suction strainer restricted? YES: Remove and clean strainer.

NO: Check 7
7 Is pump pressure as specified? YES: Check 9

NO: Check clutch pressure maintenance
valve is free to operate.
8 When flow testing pump, is output low? YES: Renew pump.

NO: Check converter sprag clutch for wear or
slip.
9 Does the noise continue when direction selector YES: Check 10

is in forward or reverse? NO: Check 11
10 Is transmission misaligned? YES: Renew mountings and check

position.
NO: Check 'converter out' pressure and
flow.
11 Are the pump bushes worn? YES: Renew

NO: Check converter for wear or cooler for
restriction to
flow.
12 Is the transmission not pulling in one direction only? YES: Check 16

NO: Check 13
13 Is the transmission not pulling in both YES: Stall test machine, Check 14.
Forward and Reverse? NO: Check 16
9804/1103 10 - 10 - 01/1 3270 - F/1-3.1 Issue 3*

CONTENTS
2CX, 2DX, 210S, 212S From m/c no. 655000

CHECK ACTION
14 Is 'converter in' pressure as specified? YES: Check 15

NO: Inspect converter relief valve for
damage. Check the relief valve pressure
setting.
15 Is pump being driven by converter? YES: Check pump pressure.

NO: Renew damaged parts.
16 Are clutch sealing rings damaged? YES: Tap pressure gauge into clutch feed
lines to monitor pressure.
NO: Check clutch plates for damage.

17 Is there drive in one direction only? YES: Check 19
NO: Check 18
18 Is the start switch in the run position and supplying YES: Check 19
current to the neutral start relay? NO: Rectify.
19 Is the fault only when the transmission is hot? YES: Dismantle solenoid and check
components.
NO: Check microswitches, relay and wiring
loom.
20 Is the noise a growl, hum or grinding? YES: Check gears for damage or wear.
NO: Check 21
21 Is the noise a hiss, thump or bumping? YES: Check bearings for damage or wear.
NO: Check 22
22 Is the noise a squeal? YES: Check free running gears for seizure.
NO: Check 23
23 Is the noise present when in neutral or when in gear? NEUTRAL: Check 24

IN GEAR: Check 27
24 Is the countershaft or its bearings worn or damaged? YES: Renew damaged parts.
NO: Check 25
25 Is there excessive backlash in the gears? YES: Adjust by checking shaft end float.
NO: Check 26
26 Is the mainshaft pilot bearing worn? YES: Renew.

NO: Check gear teeth for scuffing.
27 Is the mainshaft rear bearing worn? YES: Renew.

NO: Check 28
28 Are the sliding gear teeth worn or damaged? YES: Renew gears.
NO: Check 29
29 Are the selector forks loose? YES: Tighten screws.

NO: Check 30
30 Are the selector fork pads or grooves in gears worn? YES: Renew worn parts.
NO: Check 31
31 Are the dog gear teeth worn? YES: Renew.

NO: Check 32
32 Are the selector rod detent springs broken? YES: Renew.

NO: Check 33
9804/1103 10 - 10 - 01/2 3270 - F/1-2.2 Issue 3*

CONTENTS
2CX, 2DX, 210S, 212S From m/c no. 655000

CHECK ACTION
33 Are the selector rods worn or damaged? YES: Renew.

NO: Check 34
34 Are the selector fork pads out of position? YES: Reposition or renew (check interlock).
NO: Check 35
35 Is there excessive end float in gears or shafts? YES: Adjust.

NO: Check thrust washers and mating faces.
36 Is the synchroniser bronze worn? YES: Renew synchro pack.

NO: Check 37
37 Are steel chips embedded in the bronze? YES: Continue using, chips will either embed
below bronze or be rejected.
NO: Check 38
38 Are the synchroniser components damaged? YES: Renew.

NO: Check free running gears for seizure or
damage.
39 Are the sliding gears tight on the splines? YES: Free or renew.
NO: Check 40
40 Are chips wedged between splines of shaft YES: Remove chips.

or gear? NO: Ensure that clutch is disengaged when
dump pedal is pressed.
41 Are steel chips embedded in the bronze? YES: Continue using, chips will either
embed below bronze or be rejected.
NO: Check 42
42 Are the synchroniser spring pins damaged? YES: Renew synchro.

NO: Check 43
43 Is the synchroniser bronze worn? YES: Renew synchro.

NO: Check blocker pins.
9804/1103 10 - 10 - 01/3 3270 - F/1-2.2 Issue 3*

CONTENTS
CONTENTS
2CX, 210S From m/c no. 655000

Fault Finding - Syncro Shuttle - Hydraulic
Before commencing with the fault finding procedure make sure that the correct type of transmission fluid has been used.
LACK OF POWER
Possible Cause Remedy
1 Poor engine condition. 1 Check and if necessary repair engine.
2 Low oil level. 2 Top up system.
3 Worn pump. 3 Check flow and if necessary repair or renew pump.
4 Torque converter damage. 4 Check and if necessary repair or renew torque converter.
5 Low mainline pressure. 5 See fault 'Low Mainline Pressure'.
6 Clutches slipping. 6 See fault 'Low Clutch Pressure'.
7 Internal leakage. 7 a) Check internal cored galleries and casting for porosity.
b) Check condition of seals.
8 High stall speeds. 8 See fault 'High Stall Speeds'.
9 Low stall speeds. 9 See fault 'Low Stall Speeds'.
10 Overheating. 10 See fault 'Overheating'.
LOW MAINLINE PRESSURE (in neutral)

2 Blocked suction strainer. 2 Clean suction strainer.
3 Pressure maintaining valve sticking/leaking. 3 Free off or renew valve.
4 Oil aerated (foaming). 4 a) Internal leakage (cored galleries) - inspect/repair
transmission.
b) Dirty suction strainer - clean strainer.
c) High oil level - drain to proper level.
d) Incorrect grade of oil - drain then refill with correct oil.
5 Oil leak through parking brake on/off circuit. 5 a) Check external pipework for parking brake circuit.
b) Check parking brake (pressure) circuit - refer to
parking brake fault finding procedure on page 10-10-01/9.
c) Disconnect parking brake and re-check.
HIGH STALL SPEEDS (Forward & Reverse Clutches)

1 Damaged converter blades. 1 Check and if necessary renew converter.
2 Clutches slipping. 2 See fault 'Low Clutch Pressure'.
LOW STALL SPEEDS (Forward & Reverse Clutches)

2 Torque converter reaction member clutch slipping. 2 Check and if necessary renew torque converter.
LOW CONVERTER OUT PRESSURE

1 Low mainline pressure. 1 See fault heading 'Low Mainline Pressure'.
2 Converter internal leakage. 2 Check and if necessary renew converter.
3 Converter relief valve faulty. 3 Check and if necessary repair relief valve.
4 Restriction in converter feed. 4 See item 10 in fault 'Overheating'
LOW PUMP FLOW

3 Worn pump. 3 Repair or renew pump.
9804/1103 10 - 10 - 01/4 Issue 2

CONTENTS
CONTENTS
2CX, 210S From m/c no. 655000

Fault Finding - Syncro Shuttle - Hydraulic (cont’d)
HIGH CONVERTER OUT PRESSURE
1 Oil cooler/lines blocked. 1 Clean cooler, free blockage.
2 Converter in pressure incorrect 2 Check converter in pressure correct
LOW LUBRICATION PRESSURE

2 Oil cooler/lines blocked. 2 Clean cooler, free blockage.
3 Ruptured lubrication line. 3 Repair line.
5 Converter relief valve faulty. 5 Check and if necessary repair or renew relief valve.
6 Leak at pump to case joint (indicated by low cooler flow) 6 Check and if necessary repair or replace as necessary.
7 Restriction in converter feed 7 See item10 in fault 'Overheating'
LOW CLUTCH PRESSURE AND/OR CLUTCH SLIPPING

3 Blocked restrictor orifice in F/R solenoid valve block. 3 Remove F/R solenoid and clear restriction in solenoid
(Both F/R clutches will indicate low pressure). valve block.
4 Clutch seals worn. 4 Confirm with a clutch leak test, if required renew clutch
seals
5 Clutch piston rings worn. 5 Confirm with a clutch leak test, renew piston rings.
6 Mechanical failure. 6 Strip and rebuild clutch, renew parts as required.
LOW COOLER FLOW

2 Leak at pump to case joint . 2 Check and if necessary repair or replace as necessary.
5 Restriction in converter feed. 5 See item 10 in fault 'Overheating'.
OVERHEATING
2 High oil level. 2 Drain oil to correct level.
3 Trapped or kinked hoses in cooler system. 3 Renew or repair hoses.
4 Low converter out pressure and flow rate. 4 Repair or renew the converter relief valve.
5 Oil cooler blocked. 5 Clean cooler.
6 Operating in wrong gear range. 6 Select correct gears to suit working conditions.
7 Water system overheating. 7 Rectify water system problems, eg radiator, cooler lines,
low water level etc.
8 Oil aerated (foaming). 8 See fault 'Low Mainline Pressure', item 4.
9 Clutch piston(s) sticking on return stroke. 9 Check and repair clutch piston(s) and seal(s).
10 Cored galleries on front housing pump mounting 10 Replace front housing (or rectify existing housing).
face wrong depth (indicated by excessively low
pressure and flow on converter out cooling line).
11 Leakage across pump mounting face and front case. 11 Check for damaged surface on both components and
loose pump mounting bolts.
9804/1103 10 - 10 - 01/5 Issue 2

CONTENTS
CONTENTS
2CX 2CXL, 2CXAM, 2CXFM, 2DX, 210S, 210SL
2CX, From m/c no. 657001
Fault Finding - Parking Brake
PARKING BRAKE INOPERATIVE BUT TRANSMISSION FUNCTIONS IN FORWARD AND REVERSE
Check Action
1 Is distance spacer fitted to centre bolt? YES: Check 2.

NO: Fit spacer.
2 Is the parking brake solenoid spool sticking? YES: Free off or renew valve.
NO: Check 3.
3 Put the starter switch in 'IGN' position. Disengage the YES: Dismantle parking brake and check condition.
parking brake, is there a voltage reading at the parking NO: Check 4.
brake feed wire?
4 Put the starter switch in 'IGN' position. Is there a voltage YES: Renew parking brake relay.
reading at the parking brake solenoid feed wire? NO: Check switch and wiring.
PARKING BRAKE PERMANENTLY ENGAGED
Check Action
1 Is the parking brake solenoid spool sticking? YES: Free off or renew valve.
NO: Check 2.
2 Put the starter switch in 'IGN' position. Disengage the YES: Check 4.
parking brake, is there a voltage reading at the parking NO: Check 3.
brake feed wire?
3 Put the starter switch in 'IGN' position. Is there a voltage YES: Check 4.
reading at the parking brake solenoid feed wire? NO: Check switch and wiring.
4 Has the parking brake been dismantled recently? YES: Dismantle and check for correct build.
NO: Check 5.
5 Is the transmission main line pressure correct? YES: Check 6.

NO: See Transmission Fault Finding.
6 Is the main line pressure correct with the parking brake YES: Dismantle parking brake and check condition.
circuit isolated? NO: See Transmission Fault Finding.
9804/1103 10 - 10 - 02/1 Issue 2

CONTENTS
CONTENTS
Fault Finding - Pneumatics
FAULT POSSIBLE CAUSE REMEDY
Compressor fails to build up to a Choked air intake filter a Change air intake filter element
working pressure
b Suction unloader valve stuck on seat b Inspect and release valve through
unloader air intake
c Faulty blow down valve c Overhaul or change blow down valve
d Faulty gauge d Overhaul or change gauge
Compressor fails to off-load a Suction unloader valve stuck open a Inspect and release valve through
(safety valve blowing) unloader air intake
b Suction unloader/compressor joint leak b Tighten or renew joint
c Punctured diaphragm on pressure c Inspect and renew
regulator or unloader piston
d Safety valve faulty d Inspect and rectify
e Air/oil separator faulty e Clean or change element
Plant not operating at correct a Speed control faulty a Reset speed control
minimum or maximum speed
b Engine fault b Refer to engine Service Manual
Excessive compressor oil a Receiver scavenge oil restrictor a Clean oil restrictor
consumption choked
b Air/oil separator faulty b Clean or change element
c Incorrect grade of oil c Drain and refill with correct grade of oil
Shut down due to high air a Machine not standing level or sited a Level machine or resite for maximum air
delivery temperature badly flow
b Air receiver level low b Top up air receiver oil
c Incorrect grade of compressor oil c Drain and refill with correct grade of oil
d Air/oil separator choked d Clean or change element
e External surface of oil cooler clogged e Clean external surface of oil cooler
f Clogging of compressor oil circulating f Drain, flush and refill oil circulating
system system
g Faulty temperature switch or circuit g Check circuit and/or change faulty
switch(es)
Compressor drive will not a Parking brake not applied, a Engage parking brake, put transmission
engage transmission not in neutral in neutral
b Power take-off solenoid fuse (A8) b Change fuse
blown
c Power take-off solenoid faulty c Check circuit and change solenoid if
necessary
9804/1103 10 - 10 - 03/1 Issue 1

CONTENTS
CONTENTS
2CX, 2DX, 210S, 212S

Fault Finding - Air Conditioning
Harness Wires
Use the harness illustration below to complete continuity checks on the air conditioning harness wires.The harness connects to
the mainframe harness via connector A, located behind the side console panel.
ITEM DESCRIPTION
A Air Conditioning Power (from fuse C9) B

B Controls
C Pressure Switch
D Pressure Switch
E
F
Compressor
Splice
A
F
WIRE DESCRIPTION
20 Controls to Power
21 Controls to Compressor
685 Power to Splice
686
687
Controls to Pressure Switch
Pressure Switch to Splice
E
688 Pressure Switch to Pressure Switch
689 Controls to Splice
D C
A201500
9804/1103 10 - 10 - 04/1 7110 - B/3-2.1 Issue 1

CONTENTS
CONTENTS
2CX, 2DX, 210S, 212S From m/c no. 657001

Fault Finding - Air Conditioning (cont’d)
No Air Conditioning
CHECK ACTION
1 Are the controls set correctly, i.e. air conditioning YES: Check 2
selected, thermostat switch set to coldest position NO: Reset controls and retest.
and blower switched on?
2 Is the air conditioning (evaporator) blower working? YES: Check 3.

NO: Check 4.
3 Is the compressor running (visual check of pulley/clutch)? YES: Check11.

NO: Check 7.
4 Is the air conditioning fuse (B8) blown? YES: Renew fuse and retest.
NO: Check 5.
5 Is there a 12V supply to the pressure switch harness? YES: Check 6.

(See Pressure Switch Testing) NO: Check 9.
6 Does the compressor clutch engage with both YES: Check 7.

pressure switches bypassed? NO: Renew the compressor clutch and retest.
(See Pressure Switch Testing)
7 Does the compressor clutch engage with YES: Renew high pressure switch and retest.
HP switch bypassed? NO: Check 8.
8 Does the compressor clutch engage with YES: Renew low pressure switch and retest.
LP switch bypassed? NO: Charge check required by refrigeration engineer.
9 Does the clutch engage with thermostat switch YES: Renew thermostat switch and retest.
bypassed? NO: Check all electrical connections.
10 Are blower switch and wiring OK? YES: Renew blower motor.
NO: Renew switch or wiring.
11 Is sight glass indication OK? YES: Check 12.

NO: Charge check required by refrigeration engineer.
12 Is condensor air flow blocked? YES: Clean condensor and radiator.

NO: Check 13.
13 Is evaporator air flow blocked? YES: Clean filter and, if necessary the evaporator.
NO: Call in refrigeration engineer.
9804/1103 10 - 10 - 04/2 7110 - B/3-3.1 Issue 1

CONTENTS
CONTENTS
2CX, 210S From m/c no. 655000 to 656500
Main Components & Switches Fuses
1 Battery A1 - A9
2 Starter Switch B1 - B9 See page 10 - 05 - 01/1 for fuse details
3 Thermostart C1 - C9
4 Neutral Start Relay
5 Starter Solenoid Lights
6 Starter Motor 70 Parking Brake
7 Loader Dump Switch 71 Engine Oil Temperature Warning (Option)
8 Gear Lever Dump Switch 72 Engine Coolant Temperature Warning (Option)
9 Dump Relay 73 Transmission Oil Temperature Warning
10 Parking Brake Relay 74 Engine Oil Pressure Warning
11 Forward/Reverse Switch 75 Transmission Oil Pressure Warning
12 Forward Relay 76 Blocked Air Filter Warning
13 Reverse Relay 77 No Charge Warning
14 Forward Solenoid 78 Hazard Warning
15 Reverse Solenoid 79 Hazard Warning Switch Repeater
16 Reverse Alarm (Option) 80 Direction Indicator Switch
17 Parking Brake Switch 81 Right Hand Indicator
18 Water Temperature Gauge 82 Right Hand Indicator
19 Fuel Gauge 83 Left Hand Indicator
20 Water Temperature Gauge Sender 84 Left Hand Indicator
21 Fuel Gauge Sender 85 Beacon
22 Diodes 86 Interior
23 Buzzer 87 Brake
24 Transmission Oil Temperature Switch 88 Brake
25 Engine Oil Pressure Switch 89 Main Beam
26 Transmission Oil Pressure Switch 90 Main Beam
27 Air Filter Switch 91 Main Beam Warning
28 Warning Lights Test Switch 92 Dip Beam
29 Diodes 93 Dip Beam
30 Speedo/Tachometer 94 Front Work
31 Alternator 95 Front Work
32 Rear Wash/Wipe Switch 96 Front Work Warning
33 Rear Washer 97 Left Hand Tail
34 Rear Wiper 98 Left Hand Side
35 Hazard Switch 99 Water Temperature Gauge
36 Flash Unit 100 Fuel Gauge
37 Diode 101 Speedo/Tachometer Gauge
38 Direction Indicator Switch 102 Number Plate
39 Heater Switch 103 Number Plate
40 Resistor 104 Right Hand Tail
41 Heater 105 Right Hand Side
42 Beacon 106 Dipper
43 Interior Light Switch 107 Rear Work
44 Radio (Option) 108 Rear Work
45 Front Wash/Wipe Switch 109 Rear Work Warning
46 Front Washer
47 Front Wiper Cable Colour Code
48 Horn B Black
49 Horn Push G Green
50 Rear Horn (Option) K Pink
51 Rear Horn Push (Option) LG Light Green
52 Brake Lights Switch N Brown
53 Headlight Flash Switch O Orange
54 Dip Switch P Purple
55 Road Light Switch R Red
56 Road Light Relay S Slate
57 Front Work Lights Switch U Blue
58 Rear Work Lights Switch W White
59 Stabiliser Leg/Neutral Start Interlock Relay Y Yellow
60 Stabiliser Leg/Neutral Start Interlock Solenoid
9804/1103 10 - 15 - 01/1 Issue 2

CONTENTS
CONTENTS Backhoe Loaders Backhoe Loaders 10 - 15 - 01/2
2CX, 210S From m/c no. 655000 to 656500
153201
9804/1103 10 - 15 - 01/2 10 - 15 - 01/2 Issue 2

CONTENTS
CONTENTS
CONTENTS
Backhoe Loaders Backhoe Loaders 10 - 15 - 01/3
2CX, 2CXL, 2CXFM, 210S, 210SL From m/c no. 657001
22
17 202 201 204
200
817 3 251 9 10 6 256 7
C7 C2 C6
203
4
10
205
258
226
807
8
C1 C5 C4
4
A9 A7 B8 B6 A6 B1
803
804
415
882 A1 B2 A2 A8 B7 B9 C3
17 16
880
219
224
806
97
254
211
830
838
223
217
883
21
2
18
16
225
79 71 57 45 7
81 23 805
233 826
99
232
812
11
861
229
230
827
412
414
855
865
257 6
100
841
884
856
B3 B4 101
237
236
410
238
825
248
98
209
80 41 19 18 15 8
810
243
221
239 32 681
245
244
227
70 67 66 63 62 48 42 413
56
1/2
249
249
228 9
46 40 37 36 35 34 33
234
833
212
49 +
808
800
863
862
218
207
1
859
857
255
247 -
82 250 A5
411
78 50
96 68 65
231
102
400
242
246
253
39 38
842
A4 A3 B5 64 61 55 47 3
241
409
814
836
213
850
849
14 10 5
235
216
44 43 401
408
404
252
844/845
214
820
866
222
851
853
811
802
801
60 25 24
416
848
847
846
215
819
822
821
818
886
839
837
832
831
835
834
816
815
853
860
407
406
402
405
403
20 12 11
93 91 89 87 86 84 75 74 72 59 53 51
809
95 77 31 30 29 28 27 26 4
94 92 90 88 85 83 76 73 69 58 54 52
13
607
646/647
605
684
619
680
651
624
660
658
638
649
661
659
637
637
637
639
648
623
652
633
639
638
637
638
648
649
614
604
642
669
654
656
653
643
639
649
637
633
627
644
657
637
640
664
603
618
637
637
602
636
622
631
620
682
621
630
631
668
655
639
648
638
612
617
A183041 A183040-1
9804/1103 10 - 15 - 01/3 10 - 15 - 01/3 Issue 2

CONTENTS
CONTENTS
2CX, 2CXL, 2CXFM, 210S, 210SL From m/c no. 657001

Main Components, Lights and Switches
1 Battery 61 Front Windscreen Wiper Motor

2 Starter Switch 62 Front Windscreen Wiper Switch
3 Thermostart 63 Front Windscreen Washer Pump Switch
4 Starter Motor 64 Front Windscreen Washer Pump
5 Starter Solenoid 65 Front Horn
6 Neutral Start Relay 66 Front Horn Button
7 Parking Brake Switch 67 Rear Horn Button (optional)
8 Parking Brake Interlock Relay 68 Rear Horn (optional)
9 Forward/Reverse Switch 69 Rear Brake Lights
10 Forward Relay 70 Rear Brake Light Switch
11 Forward Solenoid 71 Headlamp Flasher Switch
12 Reverse Solenoid 72 Right Hand Main Beam Lamp
13 Reverse Alarm (optional) 73 Left Hand Main Beam Lamp
14 Reverse Relay 74 Main Beam Warning Light
15 Parking Brake Warning Relay 75 Right Hand Dipped Beam Light
16 Gear Lever Dump Switch 76 Left Hand Dipped Beam Light
17 Loader Lever Dump Switch 77 Rear Fog Light (optional)
18 Dump Relay 78 Rear Fog Light Switch (optional)
19 Parking Brake Relay 79 Headlight Dip Switch
20 Parking Brake Solenoid 80 Road Lights Relay
21 Stabiliser Leg/Neutral Start Interlock Relay 81 Road Lights Switch
22 Stabiliser Leg/Neutral Start Interlock Solenoid (optional) 82 Front Working Lights Switch
23 Instrument Console 83 Front Working Lights
24 Water Temperature Sender 84 Front Working Lights Warning Light
25 Fuel Gauge 85 Left Hand Tail Light
26 Engine Coolant Temperature Switch 86 Left Hand Side Light
27 Transmission Oil Temperature Switch 87 Water Temperature Gauge Light
28 Engine Oil Low Pressure Warning Light Switch 88 Fuel Gauge Light
29 Transmission Oil Low Pressure Warning Light Switch 89 Speedo/Tachometer Light
30 Air Filter Blocked Switch 90 Number Plate Lights
31 Warning Lights Test Button (if fitted) 91 Right Hand Tail Light
32 Instrument Console Light 92 Right Hand Side Light
33 Engine Coolant Temperature Warning Light 93 Rear Working Lights
34 Transmission Oil Temperature Warning Light 94 Rear Working Lights Warning Light
35 Engine Oil Low Pressure Warning Light 95 Low Brake Pressure Warning Light
36 Transmission Oil Low Pressure Warning Light 96 Engine Shut Off System
37 Air Filter Blocked Warning Light 97 Radio Carrier
38 Speedo/Tachometer 98 Rear Work Light Switch
39 Alternator 99 Attachments Power Socket
40 Alternator No Charge Light 100 Low Brake Pressure Warning Switch
41 Buzzer 101 Diodes
42 Rear Windscreen Wash/Wipe Switch 102 Diodes
43 Rear Windscreen Wiper Motor
44 Rear Windscreen Wiper Wash Motor
Fuses
45 Hazard Warning Light Switch
A1 - A9
46 Flasher Unit
47 Hazard Warning Light B1 - B9 - See Technical Data pages for fuse details
48 Diode C1 - C9
49 Direction Indicator Switch
50 Direction Indicator Light
51 Right Hand Indicator Light - Front
52 Right Hand Indicator Light - Rear
53 Left Hand Indicator Light - Front
54 Left Hand Indicator Light - Rear
55 Heater Motor
56 Heater Resistor
57 Heater Switch
58 Beacon
59 Cab Interior Light
60 Cab Interior Light Switch
9804/1103 10 - 15 - 01/4 Issue 2

CONTENTS
CONTENTS
2DX from m/c no. 659249 to 760840

2CX from m/c no. 659599 to 760840
Circuit Diagram - Electrical
15 111 114 117 26 27 81

10 82
3 64 116 118 80
6 77
5
2 63 7 71 76
8 112 75
9 17 115 119 74
20
110 113
29
4 177
11 12
78 79
174 175
171 ➁ 179 21
19 28
13
69 73 121 123 125 127 129 131 133
176 14
66 16
120 122 124 126 128 130 132
1
25
170 18 22 23 24
62
65
A1
67
178 68
173
72
70
C5 C3 B7 C2 B1 B6 A6
61
172
CONTENTS
9804/1103 10 - 15 - 01/5 3270 - C/18-1.3 Issue 2*
CONTENTS
CONTENTS
2DX from m/c no. 659249 to 760840

2CX from m/c no. 659599 to 760840
Main Components Switches
1 Battery 61 Starter Switch
2 Thermostart 62 Forward/Reverse Switch
3 Starter Motor 63 Gear Lever Dump Switch
4 Starter Solenoid 64 Loader Lever Dump Switch
5 Forward Solenoid 65 Parking Brake Switch
6 Reverse Solenoid 66 Compressor Switch ➀
7 Reverse Alarm 67 Front Proximity Switch ➀
8 Parking Brake Solenoid 68 Rear Proximity Switch ➀
9 PTO Solenoid ➀ 69 Steer Mode Selector Switch ➀
10 Compressor Temperature Sender ➀ 70 Brake Lights Switch ➀
11 Compressor Temperature Gauge ➀ 71 Hammer Switch
12 Compressor Hourmeter ➀ 72 Hazard Warning Light Switch
13 Stabiliser Leg Solenoids ➀ 73 Direction Indicator Switch
14 Steer Mode Solenoids ➀ 74 Engine Coolant Temperature Switch
15 Steer Mode Unit ➀ 75 Transmission Oil Temperature Switch
16 Junction Box 76 Engine Oil Low Pressure Warning Light Switch
17 Hammer Solenoid ➀ 77 Transmission Oil Low Pressure Warning Light Switch
18 Flasher Unit 78 Air Filter Blocked Switch
19 Diode 79 Low Brake Pressure Warning Switch
20 Trailer Indicator Warning Buzzer ➀ 80 Compressor Air Filter Switch ➀
21 Side Instrument Console 81 Air Receiver Temperature Switch ➀
22 Tachometer 82 Air/Oil Delivery Temperature Switch ➀
23 Water Temperature Gauge 83 Rear Horn Button
24 Fuel Gauge 84 Rear Windscreen Wash/Wipe Switch
25 Hourmeter 85 Front Windscreen Wash/Wipe Switch
26 Water Temperature Sender 86 Front Horn Button
27 Fuel Sender 87 Road Lights Switch
2 Buzzer 88 Headlamp Flasher Switch
29 Shut Down System (Compressor) ➀ 89 Headlight Dip Switch
30 Engine Shut Off System 90 Front Working Lights Switch
31 Front Instrument Console 91 Rear Work Light Switch
32 Alternator 92 Beacon Switch
33 Rear Horn ➀ 93 Cab Interior Light Switch
34 Rear Windscreen Washer Pump 94 Heater Switch ➀
35 Rear Windscreen Wiper Motor 95 Air Conditioning Switch ➀
36 Front Windscreen Washer Pump 96 Freeze Valve ➀
37 Front Windscreen Wiper Motor 97 Low Pressure Switch ➀
38 Front Horn 98 High Pressure Switch ➀
39 Dipper Socket 99 Heater Switch
40 Face Level Fan ➀ 100 Rear Fog Light Switch ➀
41 Beacon Motor
42 Tracker ➀
4 Radio ➀
44 RH Speaker ➀
4 LH Speaker ➀
4 Heater Resistor ➀
47 Heater Motor ➀
48 Air Conditioning Motor ➀
4 Heater Resistor
50 Heater Motor
9804/1103 15 - 15 - 01/6 Issue 2*

CONTENTS
2DX from m/c no. 659249 to 760840

2CX from m/c no. 659599 to 760840
Lights Relays
110 Left Hand Brake Light 170 Neutral Start Relay
111 Left Hand Trailer Brake Light ➀ 171 Neutral Lock Relay
112 Right Hand Trailer Brake Light ➀ 172 ‘Ignition’ Relay 1
113 Right Hand Brake Light 173 Transmission Dump Relay
114 Left Hand Trailer Indicator Light ➀ 174 Forward Relay
115 Left Hand Indicator Light - Front 175 Reverse Relay
116 Left Hand Indicator Light - Rear 176 Parking Brake Light Relay
117 Right Hand Trailer Indicator Light ➀ 177 Parking Brake Relay
178 Compressor Neutral or Stabiliser Leg Lock Relay
179 Hammer Relay ➀
119 Right Hand Indicator Light - Rear
120 Alternator No Charge Light 180 Shutdown Relay ➀
121 Parking Brake Warning Light 181 ‘Ignition’ Relay 2
122 Engine Coolant Temperature Warning Light 182 Road Lights Relay
123 Transmission Oil Temperature Warning Light 183 Air Conditioning Relay ➀
124 Engine Oil Low Pressure Warning Light
125 Transmission Oil Low Pressure Warning Light
126 Air Filter Blocked Warning Light Fuses
127 Low Brake Pressure Warning Light A1 - A9
128 2 Wheel Steer Selected Warning Light B1 - B9 - See Technical Data pages for fuse details
129 4 Wheel Steer Selected Warning Light C1 - C9
130 Hazard Warning Light
131 Main Beam Warning Light Note ➀ : Indicates non standard equipment
132 Side Instrument Console Light
133 Direction Indicator Light Note ➁ : Link wire to be fitted to neutral lock relay on non
134 Front Instrument Console Warning Lights Airmaster machines.
135 Side Lights Warning Light
136 Rear Working Lights Warning Light Note ➂ : On standard build when no optional shutdown
137 Front Working Lights Warning Light system is fitted, a link wire is fitted on wire 105.
138 Rear Fog Light Warning Light ➀
139 Left Hand Main Beam Light
140 Right Hand Main Beam Light
141 Left Hand Dipped Beam Light
142 Right Hand Dipped Beam Light
143 Left Hand Trailer Light ➀
144 Left Hand Number Plate Light
145 Left Hand Tail Light
146 Left Hand Side Light
147 Right Hand Trailer Light ➀
148 Right Hand Number Plate Light
149 Right Hand Tail Light
150 Right Hand Side Light
151 Front Working Lights
152 Rear Working Lights
153 Rear Fog Light ➀
9804/1103 10 - 15 - 01/7 7110 - C/1-1.5 Issue 2*

CONTENTS
CONTENTS
2DX from m/c no. 659249 to 760840

2CX from m/c no. 659599 to 760840
142 144 148 43 98

30
139 141 143 147 39 45
180 ➂ 140 93 48
153 145 149 151 152
36 38 146 41
150 40 47 50
34
97
37
33 35
32 44
B3 42 183
B4
100
88 89 A3 A4
31 96
46 49
85
128 135 130 137 83 84 86 92
134 133 131 136 138 C4
90
87 91 95
94
99
B5 C1
B2 A2 B9 A5 A9
A7 A8
B8
181
182
9804/1103 10 - 15 - 01/8 3270 - C/18-1.3 Issue 2*

CONTENTS
Backhoe Loaders
2CX AM To m/c no. 658332
Electrical Schematic Circuit
Component Key

2 Parkbrake Switch
3 Parkbrake Interlock Relay
4 Parkbrake Warning Relay
5 Parkbrake Relay
6 Compressor Switch
7 Temperature Sender
8 Parkbrake Solenoid
9 Temperature Gauge
10 Hourmeter
11 Power Take Off (PTO) Solenoid
12 Neutral Start Interlock
13 Parkbrake Interlock
14 Air Receiver Temperature Switch
15 Air Filter Blocked Switch
16 Air/Oil Delivery Temperature Switch
17 Engine Shut Off Solenoid (ESOS) Relay
18 Engine Shut Off Solenoid (ESOS)
> From Starter Switch (IGN ON)
9804/1103 10 - 15 - 01/9 Issue 1

CONTENTS
Backhoe Loaders
2CX AM to m/c no. 658332
Electrical Schematic Circuit (continued)
C3 2
7 9
A8 6
10
11
12
13
14
15
16
17
C2
18 A212850
9804/1103 10 - 15 - 01/10 Issue 1

CONTENTS
Backhoe Loaders
2CX AM From m/c no. 658333 to 659598
2
3
5 8
7
9
10
11
12
13
6 14
15
16
17
18
A252070
9804/1103 10 - 15 - 01/11 Issue 1

CONTENTS
Backhoe Loaders
2CX AM From m/c no. 658333 to 659598
Electrical Schematic Circuit (continued)
Component Key

2 Parkbrake Switch
3 Parkbrake Interlock Relay
4 Parkbrake Warning Relay
5 Parkbrake Relay
6 Compressor Switch
7 Temperature Sender
8 Parkbrake Solenoid
9 Temperature Gauge
10 Hourmeter
11 Power Take Off (PTO) Solenoid
12 Neutral Start Interlock
13 Parkbrake Interlock
14 Air Receiver Temperature Switch
16 Air/Oil Delivery Temperature Switch
17 Engine Shut Off Solenoid (ESOS) Relay
18 Engine Shut Off Solenoid (ESOS)
> From Starter Switch (IGN ON)
9804/1103 10 - 15 - 01/12 Issue 1

CONTENTS
Backhoe Loaders
2CX AM from m/c no. 659599
With the introduction of the revised cab (2CX machines
from serial number 659599), the compressor electrical
circuit is shown as an option on the main 2DX machine
electrical circuit. Refer to Service Manual, publication
number 9803/7110.
9804/1103 10 - 15 - 01/13 Issue 1

CONTENTS
CONTENTS
2CX, 2DX, 210S, 212S From m/c no. 760841

26 27 79 81
10 111 112 114 117 82
79
78 29
116 118 75 77
3 5 6 7 154 14
2 63 71 74 76
8 17 115 119
9
64 20
110 113
4
11 12
174 175 177 185
171 179
184 28
2
13 19 25
73 22
176 16 121 123 125 127 130 132
69
120 122 124 126 128129 131 133
66
1 23 24
170 18
62 21
173
65 178
72
67 68
70
61
172
9804/1103 10 - 15 - 01/14 7110 - C/7-8.1 Issue 1

CONTENTS
CONTENTS
2CX, 2DX, 210S, 212S From m/c no. 760841

Note: Circuits shown with dashed lines indicate non- Switches

standard equipment. For instance, compressor components 61 Starter Switch
are only fitted on the JCB Airmaster machine. 62 Forward/Reverse Switch
63 Gear Lever Dump Switch
Main Components 64 Loader Lever Dump Switch
1 Battery 65 Parking Brake Switch
2 Thermostart
66 Compressor Switch ➀
3 Starter Motor
67 Front Proximity Switch ➀
4 Starter Solenoid
5 Forward Solenoid 68 Rear Proximity Switch ➀
6 Reverse Solenoid 69 Steer Mode Selector Switch ➀
7 Reverse Alarm 70 Brake Lights Switch ➀
8 Parking Brake Solenoid 71 Hammer Switch
9 PTO Solenoid ➀ 72 Hazard Warning Light Switch
10 Compressor Temperature Sender ➀ 73 Direction Indicator Switch
11 Compressor Temperature Gauge ➀ 74 Engine Coolant Temperature Switch
12 Compressor Hourmeter ➀ 75 Transmission Oil Temperature Switch
13 Stabiliser Leg Solenoids ➀ 76 Engine Oil Low Pressure Warning Light Switch
14 Steer Mode Solenoids ➀
77 Transmission Oil Low Pressure Warning Light Switch
15 Steer Mode Unit ➀
16 Junction Box
17 Hammer Solenoid ➀ 79 Low Brake Pressure Warning Switch
18 Flasher Unit 80 Compressor Air Filter Switch ➀
19 Diode 81 Air Receiver Temperature Switch ➀
20 Trailer Indicator Warning Buzzer ➀ 82 Air/Oil Delivery Temperature Switch ➀
21 Side Instrument Console 83 Rear Horn Button
22 Tachometer 84 Rear Windscreen Wash/Wipe Switch
23 Water Temperature Gauge 85 Front Windscreen Wash/Wipe Switch
24 Fuel Gauge 86 Front Horn Button
25 Hourmeter 87 Road Lights Switch
26 Water Temperature Sender
88 Headlamp Flasher Switch
27 Fuel Sender
89 Headlight Dip Switch
28 Buzzer
29 Shut Down System (Compressor) ➀ 90 Front Working Lights Switch
30 Engine Shut Off System 91 Rear Work Light Switch
31 Front Instrument Console 92 Beacon Switch
32 Alternator 93 Cab Interior Light Switch
33 Rear Horn ➀ 94 Heater Switch ➀
34 Rear Windscreen Washer Pump 95 Air Conditioning Switch ➀
35 Rear Windscreen Wiper Motor 96 Freeze Valve ➀
36 Front Windscreen Washer Pump 97 Low Pressure Switch ➀
37 Front Windscreen Wiper Motor 98 High Pressure Switch ➀
38 Front Horn
99 Heater Switch
39 Dipper Socket
100 Rear Fog Light Switch ➀
40 Face Level Fan ➀
41 Beacon Motor
42 Tracker ➀
43 Radio ➀
44 RH Speaker ➀
45 LH Speaker ➀
46 Heater Resistor ➀
47 Heater Motor ➀
48 Air Conditioning Motor ➀
49 Heater Resistor
50 Heater Motor
9804/1103 10 - 15 - 01/15 7110 - C/7-9.1 Issue 1

CONTENTS
CONTENTS
2CX, 2DX, 210S, 212S From m/c no. 760841

Lights Relays
111 Left Hand Trailer Brake Light ➀ 171 Neutral Lock Relay ➁
112 Right Hand Trailer Brake Light ➀ 172 ‘Ignition’ Relay 1
113 Right Hand Brake Light 173 Transmission Dump Relay
114 Left Hand Trailer Indicator Light ➀ 174 Forward Relay
115 Left Hand Indicator Light - Front 175 Reverse Relay
116 Left Hand Indicator Light - Rear 176 Parking Brake Light Relay
117 Right Hand Trailer Indicator Light ➀ 177 Parking Brake Relay
118 Right Hand Indicator Light - Front 178 Compressor Neutral or Stabiliser Leg Lock Relay
119 Right Hand Indicator Light - Rear 179 Hammer Relay ➀
120 Alternator No Charge Light 180 Shutdown Relay ➀ ➂
121 Parking Brake Warning Light 181 ‘Ignition’ Relay 2
122 Engine Coolant Temperature Warning Light 182 Road Lights Relay
123 Transmission Oil Temperature Warning Light 183 Air Conditioning Relay ➀
124 Engine Oil Low Pressure Warning Light 184 2 Wheel steer Relay
125 Transmission Oil Low Pressure Warning Light 185 4 Wheel Steer relay
126 Air Filter Blocked Warning Light
127 Low Brake Pressure Warning Light Fuses
128 2 Wheel Steer Selected Warning Light A1 - A9
129 4 Wheel Steer Selected Warning Light B1 - B9 - See Technical Data pages for fuse details
130 Hazard Warning Light C1 - C9
131 Main Beam Warning Light
132 Side Instrument Console Light Wire Number Identification
133 Direction Indicator Light See Wire Number Identification on Page 8 -10 for wire and
134 Front Instrument Console Warning Lights harness number details.
135 Side Lights Warning Light
136 Rear Working Lights Warning Light Note ➀: Indicates non standard equipment
137 Front Working Lights Warning Light
138 Rear Fog Light Warning Light ➀ Note ➁: Link wire to be fitted to neutral lock relay on non
139 Left Hand Main Beam Light Airmaster machines.
141 Left Hand Dipped Beam Light Note ➂ : On standard build when no optional shutdown
142 Right Hand Dipped Beam Light system is fitted, a link wire is fitted on wire 105.
154 Reverse light
9804/1103 10 - 15 - 01/16 7110 - C/7-10.1 Issue 1

CONTENTS
CONTENTS
2CX, 2DX, 210, 212 From m/c no. 760841

9804/1103 10 - 15 - 01/17 7110 - C/7-11.1 Issue 1

CONTENTS 10 - 15 - 01/18
CONTENTS
Backhoe Loaders
2CXU, 212SU (N. America only) From m/c no. 657001
600
119
7 9 75
117 78
2 3 114 32
5 6 8 118 79 74 76 77
116 26 27
30 115
4 64 63
16
174 175
19
73
18 22 23 24
176
121 127 122 124 125 130
1 28
133 120 123 126 131
62
25
65
31
173 72
66
176
61
172
001
830Y
837C
200
160AH
9804/1103 10 - 15 - 01/18 7110 - C/7-12.2 Issue 1

CONTENTS
CONTENTS
2CXU, 210SU (N. America) From m/c no. 657001

1 Battery 61 Starter Switch
3 Starter Motor 63 Gear Lever Dump Switch
4 Starter Solenoid 64 Loader Lever Dump Switch
5 Forward Solenoid 65 Parking Brake Switch
6 Reverse Solenoid 66 Power Take Off Switch
7 Reverse Alarm 70 Brake Lights Switch ➀
8 Parking Brake Solenoid 72 Hazard Warning Light Switch
9 Power Take Off Solenoid 73 Direction Indicator Switch
16 Junction Box 74 Engine Coolant Temperature Switch
18 Flasher Unit 75 Transmission Oil Temperature Switch
19 Diode 76 Engine Oil Low Pressure Warning Light Switch
22 Tachometer 77 Transmission Oil Low Pressure Warning Light Switch
23 Water Temperature Gauge 78 Air Filter Blocked Switch
24 Fuel Gauge 79 Low Brake Pressure Warning Switch
25 Hourmeter 84 Rear Windscreen Wash/Wipe Switch
26 Water Temperature Sender 85 Front Windscreen Wash/Wipe Switch
27 Fuel Sender 86 Front Horn Button
28 Buzzer 87 Road Lights Switch
30 Engine Shut Off System 88 Headlamp Flasher Switch
31 Front Instrument Console 89 Headlight Dip Switch
32 Alternator 90 Front Working Lights Switch
34 Rear Windscreen Washer Pump 91 Rear Work Light Switch
35 Rear Windscreen Wiper Motor 92 Beacon Switch
36 Front Windscreen Washer Pump 93 Cab Interior Light Switch
37 Front Windscreen Wiper Motor 99 Heater Switch
38 Front Horn 100 Rear Fog Light Switch ➀
41 Beacon Motor
43 Radio ➀
44 RH Speaker ➀
45 LH Speaker ➀
49 Heater Resistor
50 Heater Motor
9804/1103 10 - 15 - 01/19 7110 - C/7-13.2 Issue 1

CONTENTS

Lights Relays
111 Left Hand Trailer Brake Light ➀ 172 ‘Ignition’ Relay 1
112 Right Hand Trailer Brake Light ➀ 173 Transmission Dump Relay
113 Right Hand Brake Light 174 Forward Relay
114 Left Hand Trailer Indicator Light ➀ 175 Reverse Relay
115 Left Hand Indicator Light - Front 176 Parking Brake Light Relay
116 Left Hand Indicator Light - Rear 178 Working Lights Relay
117 Right Hand Trailer Indicator Light ➀ 181 ‘Ignition’ Relay 2
119 Right Hand Indicator Light - Rear Fuses
120 Alternator No Charge Light A1 - A9
121 Parking Brake Warning Light B1 - B9 - See Technical Data pages for fuse details
122 Engine Coolant Temperature Warning Light C1 - C9
123 Transmission Oil Temperature Warning Light
124 Engine Oil Low Pressure Warning Light Note ➀: Indicates non standard equipment
125 Transmission Oil Low Pressure Warning Light
126 Air Filter Blocked Warning Light
127 Low Brake Pressure Warning Light
128 Reverse Lights
131 Main Beam Warning Light
133 Not Fitted In This Application
139 Left Hand Main Beam Light
141 Left Hand Dipped Beam Light
142 Right Hand Dipped Beam Light
9804/1103 10 - 15 - 01/20 7110 - C/7-14.2 Issue 1

CONTENTS
CONTENTS

600
143 145 147 149

45
111 151 153
34 139 141
112 35 140 142 43
110 36 38
50 152
144 146 148 150 41
113
49
93 44
100
89
88
70 90
85
178
86
84 91 92
87
99
181
001
830Y
837C
200
160AH
9804/1103 10 - 15 - 01/21 7110 - C/7-15.2 Issue 1

1
010 003 THERMOSTART
FUSE P4
FUSE P1
FUSE P2
FUSE P3
FUSE C7
9804/1103
BATTERY
CONTENTS
IGNITION
SWITCH BATTERY
6
3
NEUTRAL START RELAY STARTER MOTOR
1
5
200B
004
8
2
200C 842 STARTER SOLENOID
2
6
4
9 8 7 3 4 5 6
NEUTRAL START RELAY
IGNITION RELAY 1
810
FORWARD RELAY
9
FUSE C9
FOR / REV
3
2CX, 2DX and Variants
8
SWITCH
6
809
2
FUSE A5 F FORWARD RELAY
2
N
002 107 812
10
FORWARD SOLENOID
4
200
8
5
IGNITION R
8
REVERSE RELAY
7
10
RELAY 1
808
4
6
811
1
912
REVERSE SOLENOID
2
PARKBRAKE REVERSE RELAY
12 13
REVERSE ALARM
3
5
RELAY
11
15
14
8
TRANS DUMP
10
RELAY
001
011
7
6
200G/200L
200E/200R
200D/200M
401
9
934 DUMP SWITCH (GEAR)
16
17
DUMP SWITCH (LOADER)

1
5
934
7
18
10 - 15 - 01/22
6
967
2
PARKBRAKE
122 936
8
FUSE A4
9
10
Backhoe Loaders
19
953
COMPRESSOR COMPRESSOR
121
CONNECTOR CONNECTOR
FUSE A6
952 COMPRESSOR SOLIENOID

20
BRAKE LIGHTS
SWITCH LH BRAKE LIGHT
21
126 933 816 RH BRAKE LIGHT

22
FUSE B6 FUSE A8
23
105 E.S.O.S.
FUSE A2 REAR WASH/
WIPE SWITCH
5
M
863
24 25
REAR WASHER PUMP

6
27
1
M
862 REAR WIPER

26
FUSE B5
2
103 864
8
7
829
BATTERY FEED
28
829 HEATER/AIR CON HEATER/AIR CON

CONNECTOR CONNECTOR
102
FUSE C8
29
INTERIOR LIGHT
303
30
FACE LEVEL FAN

FUSE
C5
M
110 839 FRONT WASHER PUMP
31
M
FRONT WIPER
32
33
FRONT
W/W SWITCH
840
841
34
303
110 814 FRONT HORN

FUSE B2 FRONT HORN SWITCH
35
JUNCTION BOX
JUNCTION BOX
101
36
FUSE A1
HAZARD SWITCH
803
HAZARD SWITCH 805 805

37
LH FRONT INDICATOR
INDICATOR
SWITCH LH REAR INDICATOR
41
8
38
10
828
42
806
39
FLASHER
RELAY
RH FRONT INDICATOR
18
2
804 806 RH REAR INDICATOR

40
17
104 49a
1
31
FUSE A3
4
802
2
6
49
FLASHER UNIT
300 C2
3
FUSE C4
43
401
U 409 WATER TEMP SENDER

44
+ WATER TEMP GAUGE

45
U 408 FUEL SENDER

46
+ FUEL GAUGE
47
TACHOMETER
TACHOMETER
48
HOURMETER
49
9 9 9 9 9 9
7110 - C/7-16.1
ILLUMINATION
011
007
829
830
106
828
401
110
804
806
805
407
412
50
From m/c no. 489724
10 - 15 - 01/22
Issue 1
110
011
007
829
830
804
806
106
828
401
805
407
412
9804/1103
CONTENTS
200G/200L
200E/200R
200D/200M
11
51
MASTER
INSTRUMENTS
WARNING
FRONT CONSOLE
LIGHTS
12
2 W STEER
TURN SIGNAL
5
4
52
SIDE LIGHRS
2CX, 2DX and Variants
3
53
MAIN BEAM
2
54
HAZARD WARNING
6
55
REAR W/L
8
56
FRONT W/L
7
57
REAR FOG
Circuit Diagram - Electrical (cont’d)
9
58
16
ALTERNATOR
7
3
HAND BRAKE
458 BRAKE PRESS SWITCH
18
WATER TEMP
406 WATER TEMP SWITCH
12
TRANS OIL TEMP
BATTERY FEED
404
9
TRANS OIL TEMP SWITCH
10 - 15 - 01/23
ENGINE OIL PRES
SIDE CONSOLE
403 ENGINE OIL PRESS SWITCH
INSTRUMENTS
11
TRANS OIL PRES
405 TRANS OIL PRESS SWITCH
10
60 61 62 63 64 65
59
AIR FILTER
402 AIR FILTER VAC. SWITCH
17
66
Backhoe Loaders
411
407
106
FUSE
B1
67
BUZZER
68
W
ALTERNATOR
RADIO SOCKET
69
304
FUSE
C6
8
7
71
70
3
871 REAR HORN

2
118
1
FUSE
B3
REAR HORN SWITCH
114
73
POWER SOCKET
72
5
FUSE
8
B4
24
6
IGNITION RELAY 2
F/W/L SWITCH
IGNITION
RELAY 2
5
76
6
LINK REQUIRED 855

FRONT WORKING LIGHTS
4
FOR UK BUILD 116

75
6
2
3
011
2
855
8
7
310
74
FUSE
B9
4
6
4
6
011 861
2
1
8
78
117
2
309 REAR WORKING LIGHTS

3
FUSE 861
B7
7
77
79
8
BEACON SWITCH
R/W/L SWITCH
8
7
BEACON
80
FUSE
81
M
B10
3
894
2
314
1
8
7
FOG LIGHT
82
83
H/LIGHT
FUSE C1
3
FLASH 835
2
862
1
84
FOG LT SWITCH
LIGHTS RELAY
ROAD LIGHTS
RELAY
834 RH DIP BEAM
88
85
5
FUSE C2
2
5
833 834 834

6
127 LH DIP BEAM

312 832
4
FUSE B8 836 837

2
837
89 90
FUSE C10 LH MAIN BEAM

3
311
87
DIP/MAIN
FUSE BEAM SWITCH 837 RH MAIN BEAM
C3
91
86
ROAD 828 829 LH TAIL LIGHT

92
LIGHTS
SWITCH FUSE A9
829 LH SIDE LIGHT
93
830
FUSE A10
DIPPER SOCKET
7110 - C/7-18.1
RH TAIL LIGHT
94
830
95
RH SIDE LIGHT
From m/c no. 489724
10 - 15 - 01/23
Issue 1
CONTENTS
2CX, 2DX and Variants From m/c no. 489724

Circuit Diagrams - Electrical (Cont’d)
Main Components
1 Thermostart 61 Parking brake warning lamp

2 Battery 62 Engine coolant temperature warning lamp
3 Starter motor 63 Transmission oil temperature warning lamp
4 Starter relay 64 Engine oil low pressure warning lamp
5 Neutral start relay 65 Transmission oil low pressure warning lamp
6 Ignition switch 66 Air filter blocked warning lamp
7 Ignition relay 1 67 Buzzer
8 Forward/Reverse switch 68 Alternator
9 Forward relay 69 Radio socket
10 Forward solenoid 70 Rear horn switch
11 Reverse relay 71 Rear horn
12 Reverse solenoid 72 Auxiliary power connector
13 Reverse alarm 73 Ignition relay 2
14 Transmission dump relay 74 Front worklights switch
15 Parking brake relay 75 Front worklights
16 Gear lever dump switch 76 Front worklights relay
17 Loader lever dump switch 77 Rear worklights switch
18 Parking brake switch 78 Rear worklights
19 Compressor connector 79 Rear worklights relay
20 Compressor solenoid 80 Beacon
21 LH brake light 81 Beacon switch
22 RH brake light 82 Fog light
23 Brake lights switch 83 Fog light switch
24 Engine shut off solenoid (E.S.O.S.) 84 Headlight flash switch
25 Rear washer pump 85 Road lights relay
26 Rear wiper motor 86 Road lights switch
27 Rear wash/wipe switch 87 Dip/main beam switch
28 Heater/air con. connector 88 RH dipped beam
29 Interior light switch 89 LH dipped beam
30 Face level fan 90 LH main beam
31 Front washer pump 91 RH main beam
32 Front wiper motor 92 LH tail light
33 Front wash/wipe switch 93 LH side light
34 Front horn 94 RH tail light
35 Front horn switch 95 RH side light
36 Junction box
37 LH front indicator
38 LH rear indicator
39 RH front indicator
40 RH rear indicator
41 Indicator switch
42 Hazard switch
43 Flasher relay
44 Water temperature sender
45 Water temperature gauge
46 Fuel level sender
47 Fuel gauge
48 Tachometer
49 Hourmeter
50 Panel illumination
51 Front instrument console
52 Turn signals lamp
53 Side lights lamp
54 Main beam lamp
55 Hazard warning lamp
56 Rear work lights lamp
57 Front work lights lamp
58 Rear fog lights lamp
59 Side instrument console
60 Alternator ‘no charge’ lamp
9804/1103 10 - 15 - 01/24 7110 - C/7-17.1 Issue 1

1
212SU
9804/1103
1
010 003 THERMOSTART
CONTENTS
FUSE P4
FUSE P1
FUSE P2
FUSE P3
FUSE C7
2
BATTERY
IGNITION
SWITCH BATTERY
5
4
6
3
1
5
200B
004
8
2
200C 842 STARTER SOLENOID
2
6
4
9 8 7 3 4 5 6
NEUTRAL START RELAY
IGNITION RELAY 1
892
967
FORWARD RELAY
9
FUSE C9 FOR / REV
SWITCH
3
5
6
809
8
2
F FORWARD RELAY
FUSE A5
2
N
002 107 812
10
FORWARD SOLENOID
4
200
8
5
R
7
8
IGNITION REVERSE RELAY
10
RELAY 1
808
4
6
811
1
REVERSE SOLENOID
12
912
2
11
REVERSE RELAY
13
PARKBRAKE
REVERSE ALARM
3
5
810
RELAY
14
15
TRANS DUMP
8
10
RELAY
001
011
200G
7
200E/200R
200D/200M
9
411 824
16
DUMP SWITCH (GEAR)

934 DUMP SWITCH (LOADER)
17
10 - 15 - 01/25
936
1
5
18
122
FUSE A4 936
6
2
815 PARKBRAKE
Backhoe Loaders
10
PARKBRAKE
SWITCH
4
19
5
6
1
2
3
PTO SWITCH 891

21
20
8
JUNCTION BOX
22
101
FUSE A1 BRAKE LIGHTS
24
LH BRAKE LIGHT
SWITCH FUSE A8
126 933 816 RH BRAKE LIGHT
25
FUSE B6
23
105 E.S.O.S.
FUSE A2
27
M
863
26 28
REAR WASHER PUMP

6
REAR WASH/
1
M
WIPE SWITCH 862 REAR WIPER

29
FUSE B5
3
103 864
BATTERY FEED
8
7
829
30
829 AIR CON

CONNECTOR
31
HEATER SWITCH
1
2
33
32
102
HEATER RESISTOR HEATER FAN MOTOR
4
FUSE C8
5
M
800 HEATER
6
800B
7
8
34
INTERIOR LIGHT
303
35
FACE LEVEL FAN

FUSE
C5 FRONT W/W SWITCH
M
110 839 FRONT WASHER PUMP
36
M
FRONT WIPER
37
38
840
841
303
110 814 FRONT HORN

39
40
FUSE B2 FRONT HORN SWITCH
HAZARD SWITCH
803
HAZARD SWITCH 805 805

44
LH FRONT INDICATOR
INDICATOR
SWITCH LH REAR INDICATOR
42
10
45
828
41
806
5
46
RH FRONT INDICATOR
18
2
804 806
47
RH REAR INDICATOR
17
104 49a
1
31
FUSE A3 802
4
6
49
FLASHER UNIT
300 C2
3
FUSE C4
FLASHER
43
RELAY
7110 - C/7-19.1
411
110
011
007
829
804
806
828
411
805
From m/c no. 489724
10 - 15 - 01/25
Issue 1
212SU
110
011
007
829
804
806
828
411
805
9804/1103
CONTENTS
200G
200E/200R
CONTENTS
200D/200M
48
+ WATER TEMP GAUGE
49
-
U 408 FUEL SENDER
50
+ FUEL GAUGE
51
-
CONTENTS
TACHOMETER
TACHOMETER
HOURMETER
9 9 9 9 9 9
52 53
ILLUMINATION
411
407
412
TURN SIGNAL
5
4
HAZARD WARNING
3
1
MAIN BEAM
2
MASTER WARNING
55 56 57 58
LIGHTS
BATTERY FEED
10 - 15 - 01/26
54
10
ALTERNATOR
12
11
HAND BRAKE
458 BRAKE PRESS SWITCH
13
Backhoe Loaders
WATER TEMP
9
TRANS OIL TEMP
404
8
ENGINE OIL PRES
INSTRUMENTS
403 ENGINE OIL PRESS SWITCH
17
FRONT CONSOLE
TRANS OIL PRES
405 TRANS OIL PRESS SWITCH
14
AIR FILTER
402 AIR FILTER VAC. SWITCH
6
59 60 61 62 63 64 65
411
407
106
FUSE
B1
BUZZER
67
66
W
ALTERNATOR
8
RADIO SOCKET
68
7
304
FUSE
C6
8
24
6
IGNITION RELAY 2
F/W/L SWITCH
IGNITION
69
5
RELAY 2
6
011
2
72
855
8
116 FRONT WORKING LIGHTS

2
310
3
FUSE 855
B9
70
7
71
4
6
4
6
011
75
861
2
1
117
2
309 REAR WORKING LIGHTS

3
FUSE 861
73
B7
7
74
8
BEACON SWITCH
R/W/L SWITCH
8
7
76
BEACON
77
FUSE M
B10
3
894
2
314
1
8
7
FOG LIGHT
78
79
FUSE C1
3
835
H/LIGHT
2
862
1
FLASH
FOG LT SWITCH
80
LIGHTS RELAY
ROAD LIGHTS
RELAY RH DIP BEAM
84
81
FUSE C2
5
833 834
2
LH DIP BEAM
85
FUSE B8 832
6
127
312 836 837
4
LH MAIN BEAM
86
FUSE C10
2
DIP/MAIN
3
311 BEAM SWITCH RH MAIN BEAM

87
83
FUSE
C3
7
82
ROAD
LIGHTS
SWITCH 828 829 LH TAIL LIGHT
88
FUSE A9
829 LH SIDE LIGHT
89
830
7110 - C/7-21.1
FUSE A10
DIPPER SOCKET
90
RH TAIL LIGHT
91
830
92
RH SIDE LIGHT
From m/c no. 489724
10 - 15 - 01/26
Issue 1
CONTENTS
CONTENTS
212SU From m/c no. 489724

Circuit Diagrams - Electrical (cont’d)
Main Components
1 Thermostart 61 Engine coolant temperature warning lamp

2 Battery 62 Transmission oil temperature warning lamp
3 Starter motor 63 Engine oil low pressure warning lamp
4 Starter relay 64 Transmission oil low pressure warning lamp
5 Neutral start relay 65 Air filter blocked warning lamp
6 Ignition switch 66 Buzzer
7 Ignition relay 1 67 Alternator
8 Forward/reverse switch 68 Radio socket
9 Forward relay 69 Ignition relay 2
10 Forward solenoid 70 Front worklights relay
11 Reverse relay 71 Front worklights switch
12 Reverse solenoid 72 Front worklights
13 Reverse alarm 73 Rear worklights relay
14 Transmission dump relay 74 Rear worklights switch
15 Parking brake relay 75 Rear worklights
16 Gear lever dump switch 76 Beacon switch
17 Loader lever dump switch 77 Beacon
18 Parking brake solenoid 78 Fog light switch
19 Parking brake switch 79 Fog light
20 Power take-off switch 80 Headlight flash switch
21 P.T.O. solenoid 81 Road lights relay
22 Junction box 82 Road lights switch
23 Brake light switch 83 Dip/main beam switch
24 LH brake light 84 RH dip beam
25 RH brake light 85 LH dip beam
26 Engine shut off solenoid (E.S.O.S.) 86 LH main beam
27 Rear wash/wipe switch 87 RH main beam
28 Rear washer pump 88 LH tail light
29 Rear wiper motor 89 LH side light
30 Air conditioning connector 90 Dipper socket
31 Heater switch 91 RH tail light
32 Heater resistor 92 RH side light
33 Heater fan motor
34 Interior light
35 Face level fan
36 Front washer pump
37 Front wiper motor
38 Front wash/wipe switch
39 Front horn switch
40 Front horn
41 Hazard switch
42 Indicator switch
43 Flasher relay
44 LH front indicator
45 LH rear indicator
46 RH front indicator
47 RH rear indicator
50 Fuel level sender
51 Fuel gauge
52 Tachometer
53 Hourmeter
54 Front instrument console
55 Turn signals lamp
56 Hazard warning lamp
57 Main beam lamp
58 Master warning lamps
59 Alternator ‘no charge’ lamp
60 Parking brake warning lamp
9804/1103 10 - 15 - 01/27 7110 - C/7-20.1 Issue 1

CONTENTS
CONTENTS
Electrical Circuit Options and Variations

Electrical Pick-up Hitch
1 Battery
2 Starter Switch
46 Flasher Unit
48 Diode
+
-
50 Direction Indicator Light
1
52 Right Hand Indicator Light - Rear C6
53 Left Hand Indicator Light - Front
101AL
54 Left Hand Indicator Light - Rear 2
203
10
69 Rear Brake Lights
70 Rear Brake Light Switch
103 Trailer Brake Lights B6 A6 A1
101AM
922
104 Trailer Indicator Warning Buzzer
105 Right Hand Trailer Indicator Light
223
217
106 Left Hand Trailer Indicator Light
211
107 Diverter Switch † 107
108 Diverter Solenoid Valve † 45
† The auxiliary hydraulic control lever operates either the 70

auxiliary loader service (e.g. 6-in-1 clamshovel) or the trailer
hitch ram. Diverter switch 107 must be in the ON position to 946
237
236
238
operate the hitch ram.
239
243
600GC
48
46
49 255
50
455
410
253
108
47
850
849
815
816
851
853
805K
806L
600GD
816J
853
104 69
53 51
106
600GE
105
649
648
54 52
639
649
633
103
648
638
637
9804/1103 10 - 15 - 02/1 7110 - C/7-7.1 Issue 1

CONTENTS
2CX, 2DX, 212SU From m/c no. 489724

Electrical Circuit Options and Variants
Worklights Circuit - German/Italian Builds
Main Components
1 Front worklights relay 11 Right hand dip beam

2 Front worklights switch 12 Left hand dip beam
3 Front worklights 13 Left hand main beam
4 Rear worklights relay 14 Right hand main beam
5 Rear worklights switch 15 Left hand rear light
6 Rear worklights 16 Left hand side light
7 Headlights flash switch 17 Dipper socket
8 Road lights relay 18 Right hand tail light
9 Road lights switch 19 Right hand side light
10 Dip/main beam switch
FRONT WORKING
DIPPER SOCKET
REAR WORKING
RH MAIN BEAM
LH MAIN BEAM
LIGHTS RELAY
RH SIDE LIGHT
LH SIDE LIGHT
RH TAIL LIGHT
LH TAIL LIGHT
RH DIP BEAM
LIGHTS
LH DIP BEAM
LIGHTS
12 14
11 13 16 19
17
834
837
829
830
3 6
834
837
15 18
834
837
FUSE C10
FUSE C2
861
855
861
855
833
836
829
830
TO INST PANEL
TO FOG LT SW
FUSE A10
FUSE A9
6 3 7 TO INST PANEL
F/W/L SWITCH
2 4 6 1 3 7
BEAM SWITCH
R/W/L SWITCH
DIP/MAIN
5 2
116
5 2 8
5 10
117
832
828
4 2 5 4 2 5
1 4 4 6 3 7
SWITCH
6 8 6 8
LIGHTS
ROAD
011
011
TO HAZARD SW 5 2 9
TO INST PANEL
SW ILUMINATION
TO INST PANEL
311
FLASH
H/LIGHT
127
309
310
ON GERMAN/ITALIAN
LINK NOT REQUIRED
ROAD LIGHTS
5 2 4
BUILDS
7
FUSE
RELAY
FUSE
B7
B9
3 1
011 IGN FEED

8
312
110 FEED
FUSE B8
FUSE C3
FUSE P4
FUSE P1
A363450
9804/1103 10 - 15 - 02/2 7110 - C/7-22.1 Issue 1

CONTENTS
2CX, 2DX, 212SU From m/c no. 489724

Electrical Circuit Options and Variants
Heater Circuit Heater/Air Conditioning Circuit
Main Components Main Components
1 Heater switch 1 Heater switch

2 Heater resistor 2 Air conditioning switch
3 Heater fan motor 3 Heater resistor
4 Heater fan motor
5 Freeze valve switch
6 Air conditioning relay
7 Low pressure switch
8 High pressure switch
9 Compressor clutch
AIR CON.
HEATER
HEATER
8
HIGH PRESS
SWITCH
HEATER FAN MOTOR
965
3 M 9
7 M
LOW PRESS
4
SWITCH
M
961
964
2 1 3
6
HEATER RESISTOR
2 4 5
800B
963
800B
FREEZE
AIR CON
VALVE
RELAY
RESISTOR
3 5
HEATER
800
962
7 3 1
1 3 4 6 7
SWITCH
AIR CON
HEATER SWITCH
1 8 2
2
800B
800A
800
2 5
8
800E
B4 B3 A4 C1
B5
B1
SWITCH
HEATER
1
102
829
600
102
829
600
FUSE C8
FUSE C8
A363460 A363470
9804/1103 10 - 15 - 02/3 7110 - C/7-23.1 Issue 1

CONTENTS
2CX, 2DX, 212SU Later Machines

Electrical Circuit Options & Variations
Compressor Circuit - 2CX, 2DX Radio Circuit
Main Components Main Components
1 Stop/Start button 1 Radio unit

2 Start button 2 Loudspeaker
3 Compressor start relay 3 Loudspeaker
4 Compressor shut-down relay
5 Compressor interlock relay
6 Compressor hourmeter
7 Compressor temperature sender
8 Compressor temperature gauge
9 Air filter blocked switch
10 Air receiver temperature cut-out switch
11 Air delivery temperature cut-out switch
12 Compressor solenoid (already fitted)
COMPRESSOR
COMPRESSOR
COMPRESSOR
COMPRESSOR
TEMP SENDER
AIR FILTER SW
AIR RECIEVER
HOURMETER
TEMP SW
TEMP SW
AIR DELIVERY
TEMP GAUGE
SOLENOID
RADIO
12
7
602
2
511
4
3
6
2
1
8
U
-
952
860
9 10 11
952
10 7 9
COMPRESSOR
1
INTERLOCK
RELAY
5
8 6
955
459
459
459
859
951
4 2 5
COMPRESSOR
SHUTDOWN
RELAY
4
2
601
1 3
3
5 2 4
COMPRESSOR
3
RELAY
START
3 1
959
BUTTON
157
START
1
953
600
600
304
STOP/START
SWITCH
121
PARKBRAKE
LIGHTS RELAY
FUSE A6
FUSE C6
A363490
A363480
9804/1103 10 - 15 - 02/4 7110 - C/7-24.1 Issue 1

CONTENTS
2CX, 2DX, 212SU Later Machines

Electrical Circuit Options & Variations
Hammer Circuit Hand Held Hydraulic Tools Circuit Hydraclamp Circuit
Main Components Main Components Main Components
1 Hammer relay 1 Selector switch 1 Selector switch

2 Hammer solenoid 2 Actuating solenoid 2 Actuating solenoid
3 Hammer ON/OFF switch
TOOLS SOLENOID
HAND HELD
HYDROCLAMP
SOLENOID
HAMMER
SOLENOID
2
2
801
3
801
966
1 3 7
899
1 3 7
1
1 2 8
2 8
HAMMER
RELAY
1
FEED SKT
AUXILIARY
FEED SKT
101
829
600
AUXILIARY
101
829
600
101
600
FUSE A1
FUSE A1
FUSE A1
A364130 A364140 A364150
9804/1103 10 - 15 - 02/5 711 0 - C/7-25.1 Issue 1

CONTENTS
CONTENTS
2CX, 210S From m/c no. 655000 to 656500
Component Key
T Tank 23 Shovel Ram L.H.

S Suction Line 24 Lift Ram R.H.
P Pump 25 Lift Ram L.H.
1A 30 Hydraclamp
Neutral Circuit Lines 31 Hydraclamp
1B 32 Stabiliser Ram
2 Priority Valve 33 Stabiliser Ram
X To Steering Circuit 34 Slew Ram
3 Loader Valve Block 35 Slew Ram
3A Loader Shovel Ram Spool 36 Boom Ram
3B Loader Lift Ram Spool 37 Dipper Ram
3C Auxiliary Ram Spool 38 Bucket Ram
3D Main Relief Valve 39 Breaker Ram
3E Shovel Ram Head Side A.R.V. 50 Bi-Restrictor
3F Shovel Ram Rod Side A.R.V. 51 Bi-Restrictor
3G 52 Bi-Restrictor
3H Load Hold Check Valves 53 Bi-Restrictor
3J
3K Auxiliary Ram Head Side A.R.V. Note: Excavator services shown here are to the JCB 'X'
3L Auxiliary Ram Rod Side A.R.V. control pattern.
4 Excavator Valve Block
4A Slew Spool
4B Boom Spool
4C Stabiliser Spool
4D Stabiliser Spool
4E Dipper Spool
4F Bucket Spool
4G Hydraclamp Valve
4H Slew A.R.V.
4J Slew A.R.V.
4K Boom Ram Head Side A.R.V.
4L Boom Ram Rod Side A.R.V.
4M Dipper Ram Rod Side A.R.V.
4N Dipper Ram Head Side A.R.V.
4P Bucket Ram Head Side A.R.V.
4R
4S
4T
4U Load Hold Check Valves
4V
4W
4X Bucket Ram Rod Side A.R.V.
4Y Breaker Spool
4Z Breaker Ram Head Side A.R.V.
4AA Auxiliary Ram A.R.V. (Not used with Rock Breaker)
4AB Load Hold Check Valve
4AD Blanking Plug
5 Suction Strainer
6 Filter
6A Filter By-pass Valve
7 Cooler
8 Pressure Test Connector (prior to Machine No.
655604
8A Pressure Test Connector (from Machine No.
655604
20 Auxiliary Ram R.H.
21 Auxiliary Ram L.H.
22 Shovel Ram R.H.
9804/1103 10 - 20 - 01/1 Issue 3

CONTENTS
CONTENTS
2CX, 210S From m/c no. 655000 to 656500
S9808/9047-1
9804/1103 10 - 20 - 01/2 10 - 20 - 01/2 Issue 3

CONTENTS
CONTENTS
2CX, 210S From m/c no. 657001 to 658960

Circuit Diagram - Hydraulic
20
26
11 27
21
1 4
4W
5 4A 4H
10
19 28
22
R L
19
9B 3
2 4W
4B 4J
4L
7
3A 19
24 3E 3F 4W
8
3J 4C 4K
6 LS
9
6A 9A 4W 30 31
P T 4D
3B
29
3J 4E 4W
4N
13 3C 19
15 17 25 4W
4F 4M
3G 3H 4R
3J
3D
16 18 4W
14
23 4P 27
8 4S 4T
14
8 12
12 32
4V
4U 1
4G
33
12
A210610
9804/1103 10 - 20 - 01/3 7110 - E/2-2.6 Issue 4*

CONTENTS
CONTENTS
2CX, 210S From m/c no. 657001 to 658960

Component Key Rams
1 Tank 22 Shovel Ram R.H.

2 Pump and Priority Valve 23 Shovel Ram L.H.
3 Loader Valve block (2 or 3 Spool) 24 Lift Ram R.H.
3A Loader Shovel Ram Spool 25 Lift Ram L.H.
3B Loader Lift Ram Spool with Float 26 Hydraclamps
3C Auxiliary /Quick Hitch Ram Spool 27 Stabiliser Rams
3D Main Relief Valve 28 Slew Rams
3E Shovel Ram Head Side A.R.V. 29 Boom Ram
3F Shovel Ram Rod Side A.R.V. 30 Dipper Ram
3G Auxiliary /Quick Hitch Ram Head Side A.R.V. 31 Bucket Ram
3H Auxiliary /Quick Hitch Ram Rod Side A.R.V. 32 Rockbreaker
3J Load Hold Check Valves 33 Extending Dipper
4 Excavator Valve Block (6 or 7 Spool)
4A Slew Spool
4B Boom Spool Note 1: Excavator services shown here are to the JCB 'X'
4C Stabiliser Spool control pattern. For ISO '+' control pattern, components 4B,
4D Stabiliser Spool 4L and 4K swap positions with items 4E, 4M and 4N
4E Dipper Spool respectively.
4F Bucket Spool
4G Hydraclamp Valve Note 2: Blanking plug 4V is used when only the hammer
4H Slew A.R.V. circuit is installed (the hammer return line goes straight back
4J Slew A.R.V. to the hydraulic tank).
4R Bucket Ram Rod Side A.R.V.
4S Auxiliary /Breaker Spool
4T Auxiliary/ Breaker Ram Head Side A.R.V.
4U Auxiliary Ram A.R.V. (Not used with Rockbreaker)
4V Blanking Plug (see note 2)
4W Load Hold Check Valves
5 Suction Strainer
6 Filter
7 Cooler
8 Pressure Test Connectors
9 Steer Valve
9A Steer Relief Valve
9B Steer Shock Valves
10 Steering Alignment Valve
11 Auxiliary Attachment Quick Release Couplings
12 Rockbreaker Quick Release Couplings
13 Brakes Charge Valve
14 Accumulators
15 Brake Valve
16 Pressure Warning Switch
17 Front Brakes
18 Rear Brakes
19 Bi-restrictor
20 Hydraulic Quickhitch
21 Quickhitch Locking Tap
9804/1103 10 - 20 - 01/4 Issue 2

CONTENTS
CONTENTS
2CX, 2CXL, 210S, 210SL

Circuit Diagrams - Auxiliary Hand Held Tools
Component Key
1 Hydraulic Tank
2 Pump
3 Loader Valve Block
4 Filter
6 B.H.T.M.A. Class 'C' Quick Release Couplings
7 Auxiliary Tool Switch
8 Priority Flow Divider
9 Hi-flow Return Line
1
5
9
2
6
A173420
A173420
9804/1103 10 - 20 - 01/5 Issue 1

CONTENTS
CONTENTS

Component Key Rams
1 Tank 22 Shovel Ram R.H.

2 Main Pump 23 Shovel Ram L.H.
2A Auxiliary Pump 24 Lift Ram R.H.
3 Loader Valve block (2 or 3 Spool) 25 Lift Ram L.H.
3A Loader Shovel Ram Spool 26 Hydraclamps
3B Loader Lift Ram Spool with Float 27 Stabiliser Rams
3C Auxiliary /Quick Hitch Ram Spool 28 Slew Rams
3D Main Relief Valve 29 Boom Ram
3E Shovel Ram Head Side A.R.V. 30 Dipper Ram
3F Shovel Ram Rod Side A.R.V. 31 Bucket Ram
3G Auxiliary /Quick Hitch Ram Head Side A.R.V. 32 Rockbreaker
3H Auxiliary /Quick Hitch Ram Rod Side A.R.V. 33 Breaker Valve
3J Load Hold Check Valves 33A Solenoid
4 Excavator Valve Block (6 or 7 Spool) 33B Check Valve
4A Slew Spool * 34 Check Valve
4B Boom Spool * 35 Front Steer Ram
4C Stabiliser Spool * 36 Rear Steer Ram
4D Stabiliser Spool
4E Dipper Spool Note: Excavator services shown here are to the JCB 'X'
4F Bucket Spool control pattern. For ISO '+' control pattern, components 4B,
4G Hydraclamp Valve 4L and 4K swap positions with items 4E, 4M and 4N
4H Slew A.R.V. respectively.
4J Slew A.R.V.
4W Load Hold Check Valves
5 Suction Strainer
6 Filter
7 Cooler
9 Steer Valve
12 Rockbreaker Quick Release Couplings
13 Brakes Charge/Priority Valve
14 Accumulators
15 Brake Valve
17 Front Brakes
18 Rear Brakes
19 Bi-restrictor
9804/1103 10 - 20 - 02/1 3270 - F/1-3.1 Issue 4*

CONTENTS
CONTENTS
2CX, 2DX, 210S, 212S From m/c no. 658961

26
27
10
R L
1 9B 4
8
5 20 4W
2A 4A 4H
36 35
19 28
22 21
11
19
3
LS 4W
9 4B 4J
4L
7
2 9A 3A 19
P T
8
24 3E 3F 4W
G1 S 13 3J 4C 4K
6
6A 4W 30 31
4D
3B
G2 16 29
3J 4E 4W
4N
EF P T LS A1 A2
3C 19
25 4W
15 4F 4M
3G 3H
8
17 3J
3D
14
23 4P 27
14
18
4G
8 34
33A
33
33B
12 32
CONTENTS
9804/1103 10 - 20 - 02/2 7110 - E/2-2.6 Issue 4*
CONTENTS
CONTENTS
2CXL, 210SL, 2CXFM From m/c no. 657001

Circuit Diagrams - Basic Machine
Component Key 8 Pressure Test Connectors
9 Steer Valve
1 Tank 9A Steer Relief Valve
2 Pump and Priority Valve 9B Steer Shock Valves
3 Loader Valve block (2 or 3 Spool) 10 Steering Alignment Valve
3A Loader Shovel Ram Spool 11 Auxiliary Attachment Quick Release Couplings
3B Loader Lift Ram Spool with Float 13 Brakes Charge Valve
3C Auxiliary /Quick Hitch Ram Spool 14 Accumulators
3D Main Relief Valve 15 Brake Valve
3E Shovel Ram Head Side A.R.V. 16 Pressure Warning Switch
3F Shovel Ram Rod Side A.R.V. 17 Front Brakes
3G Auxiliary /Quick Hitch Ram Head Side A.R.V. 18 Rear Brakes
3H Auxiliary /Quick Hitch Ram Rod Side A.R.V. 20 Hydraulic Quickhitch
3J Load Hold Check Valves 21 Quickhitch Locking Tap
5 Suction Strainer 22 Shovel Ram R.H.
6 Filter 23 Shovel Ram L.H.
6A Filter By-pass Valve 24 Lift Ram R.H.
7 Cooler 25 Lift Ram L.H.
40 Anti-cavitation Valve
40
V C
20
P 21
5
10
11
1
22
R L
9B 3
2
7
3A
24 3E 3F
8
3J
6 LS
9
6A 9A
P T
3B
3J
13 3C
15 17 25
3G 3H
3J
3D
16 18
14
23
8
14
8
A221000
A221000
9804/1103 10 - 20 - 02/3 Issue 3

CONTENTS
CONTENTS
2CX, 212SU 9N. America only) From m/c no. 657001

4
29
4A
4E
4G
28 4B
4G
27
4F 4C
40 4G
V C 26
4D
P
10 4G
31 32
5 30
1
22
L R
9B 3
2
7
3A
24 3E 3F
8
3J
6 LS
9
6A 9A
P T
3B
3J
13 3C
15 17 25
3G 3H
3J
3D
16 18
14
23
8
14
8
11
20 21
9804/1103 10 - 20 - 02/4 7110 - E/2-6.2 Issue 1

CONTENTS
CONTENTS
CONTENTS
2CX, 212SU (N. America only) From m/c no. 657001

Component Key
1 Tank
2 Pump and Priority Valve
3 Loader Valve block (2 or 3 Spool)
3A Loader Shovel Ram Spool
3B Loader Lift Ram Spool with Float
3C Auxiliary /Quick Hitch Ram Spool
3D Main Relief Valve
3E Shovel Ram Head Side A.R.V.
3F Shovel Ram Rod Side A.R.V.
3G Auxiliary /Quick Hitch Ram Head Side A.R.V.
3H Auxiliary /Quick Hitch Ram Rod Side A.R.V.
3J Load Hold Check Valves
4 3 Point Hitch Valve Block
4A Lift/Lower/Float Spool
4B Pitch Spool
4C Tilt Spool
4D Auxiliary Spool
4E Lift ARV
4F Tilt ARV
4G Load Hold Check Valves
5 Suction Strainer
6 Filter
7 Cooler
9 Steer Valve
13 Brakes Charge Valve
14 Accumulators
15 Brake Valve
17 Front Brakes
18 Rear Brakes
22 Shovel Ram R.H.
23 Shovel Ram L.H.
24 Lift Ram R.H.
25 Lift Ram L.H.
26 Auxiliary Cylinder
27 Tilt Cylinder
28 Pitch Cylinder
29 Lift Cylinder
30 2/4 Wheel Steer Selector Valve
31 Front Steer Cylinder
32 Rear Steer Cylinder
40 Anti-cavitation Valve
9804/1103 10 - 20 - 02/5 7110 - E/2-7.2 Issue 1

CONTENTS
CONTENTS
CONTENTS
2CX, 210S From m/c no. 655000 to 656500

Circuit Diagrams - Steering
Component Key
T Tank
S Suction Line
P Pump
2 Priority Valve
5 Suction Strainer
6 Filter
7 Cooler
8 Pressure Test Connector (prior to Machine No. 655604)
8A Pressure Test Connector (from Machine No. 655604)
40 Front Steer Ram
41 Rear Steer Ram
42 Counterbalance Valve
43 Steering Control Valve
43A Shock Valve
43B Relief Valve
43C Non-return Valve
Note: Components T, S, P, 2, 5, 6, 6A, 7 and 8 are common to

both the hydraulic circuit and the steering circuit.
S9808/9002-2
9804/1103 10 - 20 - 03/1 Issue 1

CONTENTS
CONTENTS

Circuit Diagrams - Steering
Component Key
P Pump and Priority Valve

S Suction Line
T Tank
X To Loader Valve Block
5 Suction Strainer
8 Pressure Test Connector
40 Front Steer Ram
41 Rear Steer Ram
42 Steer Alignment Tap
43 Steering Control Valve
43A Shock Valve
43B Relief Valve
43C Non-return Valve
58 Steer Load Sense Line
Note: Components P, S, T, 5 and 8 are common to both the

hydraulic circuit and the steering circuit.
9804/1103 10 - 20 - 03/2 Issue 1

CONTENTS
CONTENTS

Circuit Diagram - Pneumatics
Component Key
1 Air Reciever
2 Hose
3 Oil Cooler
4 Hose
5 Oil Filter
6 Hose
7 Compressor
8 Hose
6 2
5 4 3
A213330
9804/1103 10 - 20 - 03/3 3270 - F/1-3.1 Issue 2*

CONTENTS
CONTENTS
3CX, 4CX, (200 Series) From m/c no. 400001

General Information - Fluids, Lubricants and Capacities
Litres UK Gal SPECIFICATION
Fuel Tank 100 22 Diesel Oil ASTM D975-66T Nos. 1D, 2D
Engine (Oil) ➀ JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B,

2 Wheel Steer Machines -10 °C to 50 °C (14 °F to 122 °F) API CD/SE, MIL-L-2104D
- Build AA 9.7 2.1
- Build AA (Hot Climate) 11.0 2.4 JCB Super Universal Agricultural SAE10W/30, MIL-L-2105,
- Build AB 10.0 2.2 -15 °C to 30 °C (5 °F to 86 °F) MIL-L-46152, API CD/SE,
MIL-L-2104C
4 Wheel Steer Machines
- Build AB 10.0 2.2 JCB Torque Converter Fluid SAE10W, MIL-L-46152,
-18 °C to 0 °C (0 °F to 32 °F) MIL-L-2104D, API CD/SE
Engine (Coolant) 20.0 4.4 JCB Universal Antifreeze/water ASTM D3306-74
Syncro Shuttle (2WD) ➁ 15.75 3.5 JCB Special Transmission Fluid ESP-M2C 33G
Syncro Shuttle (4WD) ➁ 16.25 3.6
(machines up to serial number 431230)
(machines from serial number 431230)
Powershift ➁ 14.75 3.25 JCB Special Transmission Fluid ESP-M2C 33G
Front Axle (4WD)

Housing (2WS) 13 2.86 JCB HD90 Gear Oil API-GL-5
Housing (AWS) ➅ 18 3.96 MIL-L-2105C
Hubs (x2) 2.0 0.44
Rear Axle (AWS)

Housing 18 3.96 JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x2) 2.0 0.44
Rear Axle (2WS) 23 5.0 JCB Special Gear Oil ESEN-M2C 86A/B
Slew Gearbox 4.3 0.9 JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Brake System
- Standard 1.2 0.26 JCB Light Hydraulic Fluid ISO VG15
- Servo 1.4 0.31 ! CAUTION: DO NOT USE ORDINARY BRAKE FLUID
Hydraulic System ➂ 135 29.7 JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
JCB Hydraulic Fluid HP32 ISO VG32

(Below 38 °C, 100 °F)
Air Conditioning System 1544 g 3.4 lb Refrigerant R134a .
Boom Lock 1.0 0.22 JCB Light Hydraulic Fluid ISO VG15
.............continued
9804/1103 15 - 00 - 01/1 Issue 3
CONTENTS
CONTENTS

General Information - Fluids, Lubricants and Capacities (cont’d)

Grease Points --- JCB MPL Grease or Lithium based, No. 2

JCB HP Grease ➃ consistency.
Extending Dipper --- Waxoyl ➄
Electrical --- As a corrosion and moisture inhibitor all exposed connections should be
connections coated liberally with petroleum jelly.
➀ Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is
gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up
without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be
drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the
lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or
reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is
replaced by the lubricant recommended. The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on
the dipstick when filling the system. Figures quoted within ±0.5 litre (0.11 U.K. gal).
➁ Note: The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system.
Figures quoted within ±1.0 litre (0.22 U.K. gal).
➂ Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level
➃ Note: JCB HP Grease is a high specification grease, in certain applications this grease must be used, for instance
transmission bearings during an overhaul.
➄ ! WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl.
affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe
the fumes. Apply in a well-ventilated area.
GEN-1-3
9804/1103 15 - 00 - 01/2 Issue 1

CONTENTS
CONTENTS
3CX, 4CX and Variants From m/c no. 460001


†Fuel Tank (with toolbox) 110 24.2 Diesel Oil ASTM D975-66T Nos. 1D, 2D
†Fuel Tank (without toolbox) 150 33 Diesel Oil ASTM D975-66T Nos. 1D, 2D
Fuel Tank (All later m/c’s) 130 28.6 Diesel Oil ASTM D975-66T Nos. 1D, 2D
†Initial build machines only, all machines built after Feb. 1997 have a 130 litre (28.6 gal.) capacity tank.
Engine (Oil) ➀ JCB 15W/40 Multigrade SAE15W/40

* 2 Wheel Steer Machines -10 °C to 50 °C (14 °F to 122 °F) API CF4/SG
- Build AA 9.7 2.1
- Build AA (Hot Climate) 11.0 2.4 JCB Super Universal Agricultural SAE10W/30
- Build AB 10 2.2 -15 °C to 30 °C (5 °F to 86 °F) API CE/SF
4 Wheel Steer Machines JCB Torque Converter Fluid SAE10W

- Build AB 10.0 2.2 -18 °C to 0 °C (0 °F to 32 °F) API CD/SF

- Build AR 11.0 2.4 JCB Super Multigrade 15W/40 SAE15W/40
- Build AK 10 2.2 -10°C to +50°C (14°F to 122°F) CF-4/SG
4 Wheel Steer Machines JCB Super Multigrade 10W/30 SAE10W/30

- Build AK 10.0 2.2 -15°C to +40°C (5°F to 104°F) CF-4/SG
Engine (Coolant) 23.0 5.1 JCB Four Seasons Antifreeze ASTM D3306, BS6580
& Summer Coolant/Water
(see Coolant Mixtures)
Syncro Shuttle (4WD) ➁ 15.4 3.4 Friction modified oils MUST NOT be used (eg. Dexron ATF type)

15.4 3.4 Friction modified oils MUST NOT be used (eg. Dexron ATF type).
Front Axle (4WD) JCB HD90 Gear Oil (without LSD) API-GL-5
Housing (2WS) 13 2.86 JCB Special Gear Oil Plus (with LSD) API-GL-4
Housing (4WS) ➅ 18 3.96 Must be suitable for use with limited slip differentials (LSD).
Hubs (x2) 2.0 0.44
Rear Axle (4WS) JCB Special Gear Oil Plus API-GL-4

Housing 18 3.96 Must be suitable for use with oil immersed brakes and limited
Hubs (x2) 2.0 0.44 slip differentials (LSD).
Rear Axle (2WS) 23 5.0
Brake System
- Standard 1.2 0.26 JCB Light Hydraulic Fluid ISO VG15
(Above 38 °C, 100 °F)

(Below 38 °C, 100 °F)
9804/1103 15 - 00 - 01/3 3270 - 3/1-2.2 Issue 1

CONTENTS
CONTENTS

Fluids, Lubricants and Capacities (Cont’d)

Grease Points --- JCB HP Grease Lithium complex NLGI No.2

consistency
including extreme pressure additives
or JCB Special MPL-EP Grease ➃ Lithium based NLGI No.2 consistency
Power Sideshift Chains --- JCB Chain Lubricant
drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in
the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or
replaced by the lubricant recommended. The figure quoted is TOTAL system capacity. Use the MIN and MAX marks
onthe dipstick when filling the system. Figures quoted within ±0.5 litre (0.11 U.K. gal).
➁ Note: The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system.
➂ Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch
level indicator on hydraulic tank.
GEN-1-3
9804/1103 15 - 00 - 01/4 3270 - 3/1-3.2 Issue 1

CONTENTS
214, 214E, 215, 215E, 217 (N. America) From m/c no. 460001
Fluids, Lubricants and Capacities

US Gal Liters SPECIFICATION
†Fuel Tank (with toolbox) 29 110 Diesel Oil ASTM D975-66T Nos. 1D, 2D
†Fuel Tank (without toolbox) 39.6 150 Diesel Oil ASTM D975-66T Nos. 1D, 2D
Fuel Tank (All later m/c’s) 34.3 130 Diesel Oil ASTM D975-66T Nos. 1D, 2D
Engine (Oil) ➀
- Build AA 2.6 9.7 JCB 10W or JCB 15W/40 † API CF4/SG,
- Build AA (Hot Climate) 2.9 11.0 Below 32 °F (0°C) † MIL-L-2104F
- Build AB 2.7 10
JCB 30W or JCB 15W/40 † Note: spec given for 15W/40
4 Wheel Steer Machines Above 32 °F (0°C)
- Build AB 2.7 10.0

- Build AR 13.2 2.4 JCB 15W/40 Engine Oil SAE15W/40
4 Wheel Steer Machines JCB 10W Engine Oil SAE10W

- Build AK 12.0 2.2 -20°C to +10°C (-4°F to 50°F) CF-4/SG
Engine (Coolant) 6.07 23 Anti-freeze/Water ASTM D3306-74
Front Axle (4WD)

Housing (2WS) 3.4 13 JCB GL-5 80W/90 API-GL-5
Housing (4WS) ➅ 4.8 18 JCB GL-5 85W/140
Hubs (x2) 0.5 2.0
Rear Axle (4WS)

Housing 4.8 18 JCB Special Gear Oil Plus API-GL-4
Hubs (x2) 0.5 2.0
Rear Axle (2WS) 6.1 23 JCB Special Gear Oil Plus API-GL-4
Brake System
- Standard 0.32 1.2 Light Hydraulic Fluid ISO VG15
Hydraulic System ➂ 34.3 130 JCB Hydraulic Fluid ISO VG46

Grease Points --- JCB Moly EP # 2 Grease Lithium based, No. 2
†Initial build machines only, all machines built after Feb. 1997 have a 34.3 gal. (130 liter) capacity tank.
Continued.......
9804/1103 15 - 00 - 01/5 3270 - 3/1-4.1 Issue 1

CONTENTS
CONTENTS
214, 214E, 215, 215E, 217 (N. America) From m/c no. 460001
Fluids, Lubricants and Capacities (Cont’d)
➁ Note: The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the
system.
➂ Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch
GEN-1-3
9804/1103 15 - 00 - 01/6 3270 - 3/1-2.2 Issue 1

CONTENTS

NORTH AMERICAN MACHINES - 214e & 214Se

US Gal Liters SPECIFICATION
Fuel Tank 34.3 130 Diesel Oil ASTM D975-66T Nos. 1D, 2D
Engine (Oil) !
- Build AR 2.6 9.7 JCB 15W/40 CF 4/SG, SAE 15W/40
-10°C to + 50°C (14°F to 122°F)
JCB 10W CF 4/SG, SAE 10W
-20°C to + 10°C (-4°F to 50°F)
Engine (Coolant) 6.07 23 Anti-freeze/Water ASTM D3306-74
Syncro Shuttle (2WD) " 3.8 14.4 JCB Special Transmission Fluid ESP-M2C 33G
Syncro Shuttle (4WD) " 4.0 15.4
Front Axle
Housing (2WS) 3.4 13 JCB GL-5 80W/90 API-GL-5
Hubs (x2) 0.5 2.0
Rear Axle 6.1 23 JCB Special Gear Oil Plus API-GL-4
Brake System
- Standard 0.32 1.2 Light Hydraulic Fluid ISO VG15
Hydraulic System # 34.3 130 JCB Hydraulic Fluid ISO VG46
Grease Points --- JCB Moly EP # 2 Grease Lithium based, No. 2
Extending Dipper --- Waxoyl $
! Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
" Note: The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the
system.
# Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch
*% Note: JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing must
be carried out more frequently.
Continued.......
9804/1103 15 - 00 - 01/7 3270 - 3/1-6.2 Issue 2*
CONTENTS
CONTENTS

Fluids, Lubricants and Capacities (cont’d)
GEN-1-3
9804/1103 15 - 00 - 01/8 3270 - 3/1-5.1 Issue 1

CONTENTS Backhoe Loaders 15 - 00 - 01/9
* 3CX, 4CX and Variants From m/c no. 930000
General Information - Service Capacities and Lubricants

Fuel Tank 150 33 Diesel Oil ASTM D975-66T Nos. 1D, 2D
Engine (Oil) ➀
- Build AR 11.0 2.4 JCB Super Multigrade 15W/40 SAE15W/40
- Build AK 10 2.2 -10°C to +50°C (14°F to 122°F) CF-4/SG
4 Wheel Steer Machines JCB Super Universal Agricultural SAE10W/30

Engine (Coolant) 23.0 5.1 JCB Four Seasons Antifreeze ASTM D3306, BS6580
& Summer Coolant/Water
(see Coolant Mixtures)
Syncro Shuttle (2WD) ➁ 14.4 3.2 JCB Extreme Performance SAE10W

(Below 40°C, 104°F)
Syncro Shuttle (4WD) ➁ 15.5 3.4 JCB Extreme Performance SAE10W
(Below 40°C, 104°F)
Powershift 6 speed ➁ 16 3.5 JCB Extreme Performance SAE10W

(Below 40°C, 104°F)
Powershift 4 speed ➁ 15.5 3.4 JCB Extreme Performance SAE10W
(Below 40°C, 104°F)
Front Axle (4WD) JCB HD90 Gear Oil (without LSD) API-GL-5
Housing (2WS) 13 2.86 JCB Special Gear Oil Plus (with LSD) API-GL-4
Housing (4WS) ➅ 18 3.96 Must be suitable for use with limited slip differentials (LSD).
Hubs (x2) 2.0 0.44
Rear Axle (4WS) JCB Special Gear Oil Plus API-GL-4

Housing 18 3.96 Must be suitable for use with oil immersed brakes and limited
Hubs (x2) 2.0 0.44 slip differentials (LSD).
Rear Axle (2WS) 23 5.0
Brake System 1.4 0.3 JCB Light Hydraulic Fluid ISO VG15
! CAUTION: DO NOT USE ORDINARY BRAKE FLUID
(Above 38 °C, 100 °F)

(Below 38 °C, 100 °F)
9804/1103 15 - 00 - 01/9 3280 - 3/28-1.1 Issue 1*

CONTENTS Backhoe Loader 15 - 00 - 01/10

General Information - Service Capacities and Lubricants

Grease Points --- JCB HP Grease Lithium based NLGI No.2 consistency
or JCB Special MPL-EP Grease ➃ Lithium based NLGI No.2 consistency
Power Sideshift Chains --- JCB Chain Lubricant
replaced by the lubricant recommended. The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on
the dipstick when filling the system. Figures quoted within +0.5 litre (0.11 UK gal).
➁ Note: The figure quoted us TOTAL system capacity. Use the MIN and MAX amrks on the dipstick when filling the
system. Figures quoted within +1.0 litre (0.22 UK gal)
➂ Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level
➃ Note: JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing must
be carried out more frequently
GEN-1-3
➅ Note: 4WS alxes with liited slup differential must use JCB Special Gear Oil Plus
Coolant Mixtures
! WARNING
Antifreeze can be harmful. Obey the manufacturer’s instructions when handling neat or diluted antifreeze.
7-3-4-4
The protection provided by JCB Four Seasons Antifreeze and Summer Coolant is shown below. If any other antifreeze is used
refer to the manufacturer’s instructions and ensure that a corrosion inhibitor is included. DO NOT use solutions of more than
60% or less than 50% or damage to the cooling system will occur.
55% Solution - Maintains circulation down to -36°C (-33°F), protects agains damage down to -41°C (-42°F)
The strength of the antifreeze solution must be checked at least once a year, preferably at the beginning of the cold period. It
is an advantage to leave the antifreeze in all year round as it gives continued protection against corrosion. Always renew the
antifreeze every two years. A 50% antifreeze mixture must be used even if frost protection is not needed. This gives
protection against corrosion and raises the coolant’s boiling point.
It should be noted that serious damage to the cooling system can occur if corrosion inhibitors are not used.
9804/1103 15 - 00 - 01/10 3270 - 3/28-2.2 Issue 1*

CONTENTS
CONTENTS
3CX (214) 4X4 SIDESHIFT From m/c no. 400001

General Information - Static Dimensions
A Overall length 6.00m(19ft 8in)
B Overall height 3.54m(11ft 7in)
C Height to top of cab 2.84m(9ft 4in)
D Wheelbase
- 2WD 2.11m(6ft 11in)
- 4WD 2.17m(7ft 1in)
E Minimum ground clearance 0.36m(1ft 2in)
F Slew ground clearance 0.5m(1ft 8in)
G Width 2.35m(7ft 8in)
J Centreline of rear axle/centreline of kingpost 1.32m(4ft 4in)
H Cabless build, Maximum fixed height 2.06m(6ft 9in)
C
H
F E
J D
A
G
A163130
B
A163130
9804/1103 15 - 00 - 02/1 Issue 1

CONTENTS
CONTENTS
3CX (214) 4X4 CENTREMOUNT From m/c no. 400001

D Wheelbase
- 2WD 2.21m(7ft 3in)
- 4WD 2.27m(7ft 5in)
C
H
F E
J D
A
G
B
A163140
9804/1103 15 - 00 - 02/2 Issue 1

CONTENTS
CONTENTS
4C (215) 4X4 From m/c no. 400001

- with Extra-Dig 3.96m(13ft 1in)
D Wheelbase
- 2WD 2.21m(7ft 3in)
- 4WD 2.27m(7ft 5in)
C
H
F E
J D
A
G
B
A163140
9804/1103 15 - 00 - 02/3 Issue 1

CONTENTS
CONTENTS
4CN (216) 4X4 From m/c no. 400001

D Wheelbase
- 2WD 2.21m(7ft 3in)
- 4WD 2.27m(7ft 5in)
C
H
F E
J D
A
G
B
A163150
9804/1103 15 - 00 - 02/4 Issue 1

CONTENTS
CONTENTS
3CX (214) 4X4 SITEMASTER (SIDESHIFT) From m/c no. 400001

D Wheelbase
- 2WD 2.11m(6ft 11in)
- 4WD 2.17m(7ft 1in)
C
H
F E
G J D
A163160
9804/1103 15 - 00 - 02/5 Issue 1

CONTENTS
CONTENTS
3CX (214) 4X4 SITEMASTER (CENTREMOUNT) From m/c no. 400001

D Wheelbase
- 2WD 2.21m(7ft 3in)
- 4WD 2.27m(7ft 5in)
C
H
F E
J D
A
G
A166290
9804/1103 15 - 00 - 02/6 Issue 1

CONTENTS
CONTENTS
HAMMERMASTER 4X4 From m/c no. 400001

D Wheelbase
- 2WD 2.11m(6ft 11in)
- 4WD 2.17m(7ft 1in)
C
H
F E
J D
A
G
A163130
B
A163130
9804/1103 15 - 00 - 02/7 Issue 1

CONTENTS
CONTENTS
217 From m/c no. 400001

D Wheelbase
- 2WD 2.26m(7ft 5in)
- 4WD
J Centreline of rear axle/centreline of kingpost Not available at print
H Cabless build, Maximum fixed height Not available at print
C
H
F E
J D
A
G
B
A163140
9804/1103 15 - 00 - 02/8 Issue 1

CONTENTS
CONTENTS
4CX (214S) 4x4x4 (SIDESHIFT) From m/c no. 400001

H Cabless build, Maximum fixed height 2.01m (6ft 7in)
J Centreline of rear axle/centreline of kingpost 1.32m (4ft 4in)
C
H
F E
J D
A
G
B
A162830
9804/1103 15 - 00 - 02/9 Issue 1

CONTENTS
CONTENTS
4CX (214S) 4x4x4 (CENTREMOUNT) From m/c no. 400001

C
H
F E
D
A
G
A170890
9804/1103 15 - 00 - 02/10 Issue 1

CONTENTS
CONTENTS
4C (215S) 4x4x4 From m/c no. 400001

B Overall height 3.89m (12 ft 9in)
- with Extra-Dig 3.96 (13ft 1in)
C
H
F E
D
A
G
A170890
9804/1103 15 - 00 - 02/11 Issue 1

CONTENTS
CONTENTS
4CN 4x4x4 From m/c no. 400001

B Overall height 3.89m (12 ft 9in)
F E
D
A
G
B
A171020
9804/1103 15 - 00 - 02/12 Issue 1

CONTENTS
CONTENTS
4CX (214S) 4x4x4 SITEMASTER (SIDESHIFT) From m/c no. 400001

C
H
F E
G J D
A162850
9804/1103 15 - 00 - 02/13 Issue 1

CONTENTS
CONTENTS
4CX (214S) 4x4x4 SITEMASTER (CENTREMOUNT) From m/c no. 400001

C
H
F E
J D
A
G
A170771
9804/1103 15 - 00 - 02/14 Issue 1

CONTENTS
CONTENTS
217S From m/c no. 400001

D Wheelbase 2.32m(7ft 8in)
E Minimum ground clearance Not available at print
J Centreline of rear axle/centreline of kingpost Not available at print
H Cabless build, Maximum fixed height Not available at print
C
H
F E
J D
A
G
B
A165850
9804/1103 15 - 00 - 02/15 Issue 1

CONTENTS
CONTENTS
3CX Super 4x4x4 From m/c no. 400001

Machine weight - 4WD with 610mm (24in)

excavator bucket, General Purpose shovel
and full fuel 7650kg (16865lb)
* Note: Dimensions based on standard tyres fitted (16.9/14 x 24 -12PR).
B
C
H
F E
J D
A
A229150
9804/1103 15 - 00 - 02/16 Issue 2*

CONTENTS
CONTENTS
4CX Super 4x4x4 From m/c no. 400001

A Overall length 6.07m (19ft 11in
B Overall height 3.93 m ( 12ft 10in)

excavator bucket, 6-in-1 shovel, bucket
mounted forks and full fuel 8460kg (18654lb)
* Note: Dimensions based on standard tyres fitted (16.9/14 x 24 -12PR).
C
H
F E
G J D
A162850
9804/1103 15 - 00 - 02/17 Issue 2*

CONTENTS
CONTENTS
3CXE (214E) From m/c no. 400001

B Overall height 3.43 m ( 11ft 3in)
D Wheelbase
- 2WD 2.21m (7ft 3in)
- 4WD 2.26m (7ft 5in)

excavator bucket, 0.95m3 loader bucket 6641kg (14870lbs)
Note: Dimensions based on following tyres fitted -rear: 18.4 x 26 industrial; front: 10.5/80 x 18PR.
F E
D
A
G
A257120
9804/1103 15 - 00 - 02/18 Issue 1

CONTENTS
3CX Sideshift From m/c no. 460001

B
C
F E
G
G D
3CX 3CX Sitemaster 3CX Sitemaster Plus 3CX Powermaster

A Overall length 5.62 5.62 5.62 5.62
B Overall height
- standard backhoe fitted 3.52 - - -
- extending dipper fitted 3.60 3.60 3.60 3.60
C Height to top of cab 2.87 2.87 2.87 2.87
D Wheelbase 2.17 2.17 2.17 2.17
E Ground clearance - stabiliser 0.37 0.37 0.37 0.37
F Ground clearance - kingpost 0.52 0.52 0.52 0.52
G Width 2.23 2.23 2.23 2.23
Dimensions in metres and are based on standard tyres fitted. For Backhoe and Loader dimensions contact your JCB
Distributor.
9804/1103 15 - 00 - 03/1 5380/205 Issue 1

CONTENTS
4CX Sideshift From m/c no. 460001

B
C
F E
G
G D
4CX 4CX Sitemaster 4CX Super 4CX Super Sitemaster

A Overall length 5.91 5.91 5.91 5.91
B Overall height
- standard backhoe fitted 3.59 - - -
- extending dipper fitted 3.67 3.67 3.92 3.96
C Height to top of cab 2.84 2.84 2.84 2.84
D Wheelbase 2.22 2.22 2.22 2.22
E Ground clearance - stabiliser 0.34 0.34 0.34 0.34
F Ground clearance - kingpost 0.50 0.50 0.50 0.50
G Width 2.33 2.33 2.33 2.33
Distributor.
9804/1103 15 - 00 - 03/2 5380/206 Issue 1

CONTENTS
3CX Super From m/c no. 460001

B
C
F E
G
G D
A270000
3CX Super 3CX Super Sitemaster

A Overall length 5.91 5.91
B Overall height 3.49 3.57
C Height to top of cab 2.82 2.82
D Wheelbase 2.22 2.22
E Ground clearance - stabiliser 0.33 0.33
F Ground clearance - kingpost 0.48 0.48
G Width 2.23 2.23
Distributor.
9804/1103 15 - 00 - 03/3 5380/207 Issue 1

CONTENTS
3CX Centremount From m/c no. 460001

B
C
F E
G
G D
3CX 3CX Sitemaster 3CXE

A Overall length 7.19 7.19 7.19
B Overall height
- standard backhoe fitted 3.43 - 3.43
- extending dipper fitted 3.53 3.53 -
C Height to top of cab 2.84 2.84 2.84
D Wheelbase
- 2WD 2.21 2.21 2.21
- 4WD 2.28 2.26 2.26
E Ground clearance - mainframe 0.33 0.33 0.33
F Ground clearance - front axle 0.28 0.28 0.28
G Width 2.23 2.23 2.23
Distributor.
9804/1103 15 - 00 - 03/4 5380/208 Issue 1

CONTENTS
4CX Centremount From m/c no. 460001

B
C
F E
D
A
G
Sitemaster machine shown.

A260730
4CX 4CX Sitemaster

A Overall length 7.37 7.37
B Overall height
- standard backhoe fitted 3.43 -
- extending dipper fitted 3.53 3.53
C Height to top of cab 2.84 2.84
D Wheelbase 2.31 2.31
E Ground clearance - mainframe 0.34 0.34
F Ground clearance - front axle 0.45 0.45
G Width 2.33 2.33
Distributor.
9804/1103 15 - 00 - 03/5 5380/209 Issue 1

CONTENTS
4C, 4CN From m/c no. 460001

B
C
F E
D G
A
G
A260770
4C 4X4 4C 4X4X4 4CN 4X4X4

A Overall length 7.49 7.47 TBA
B Overall height
- standard backhoe fitted 3.89 3.89 3.89
- extending dipper fitted 3.91 3.91 3.91
C Height to top of cab 2.84 2.84 2.84
D Wheelbase 2.31 2.31 2.31
E Ground clearance - mainframe 0.34 0.34 0.34
F Ground clearance - front axle 0.28 0.45 0.45
G Width 2.33 2.33 2.35
Distributor.
9804/1103 15 - 00 - 03/6 5380/210 Issue 1

CONTENTS
CONTENTS

Data - Electrical
System Type 12 Volt, negative earth
Battery (Heavy Duty)
- Cold crank amps for 1 minute to
1.4 volts per cell at -18 deg C (0 deg F) 550
- Reserve capacity (minutes) for 25 amp load 220
Battery (Temperate)
Alternator
2WS Lucas - 65 Amp maximum output
4WS Magnetti Marelli - 72 Amp maximum output
4WS (air conditioning or ServoPlus builds) Magneti Marelli - 85 Amp maximum output
Starter Motor Lucas
Light Bulbs
Head lights - main/dip 45/37.5W
Work lights 55W Halogen (front & rear)
Front side lights 5W
Tail/stop lights 5/21W
Fog light 21W
Direction turn indicators 21W (front & rear)
Instruments 1.2W
Warning lights 3W
† Number plate light 2 x 5W
Interior light 10W
† Beacon 70W Halogen
† Note: These items are not apllicable to U.S.A.
9804/1103 15 - 05 - 01/1 Issue 2

CONTENTS
CONTENTS
3CX, 4CX, (200 Series) From m/c no. 400001 to 430000

Data - Electrical
?@
Circuit Protection ?W&@@@@@@@@@@@@@@@@@@0M?

?7@@@@@@@@@@@@@@@@(M
J@@@@@@@@@@@@@@@@0Y?
?W&@@@@@@@@@@@@@@(M?
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J@@@@@@@@@@@@@@0Y?
7@@@@@@@@@@@@(M?
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?J@@@@@@@@@@5?
?7@@@@@@@@@@H?
J@@@@@@@@@@5
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@@@@@@@@@5
@@@@@@@@@H
@@@@@@@@@?
@@@@@@@@@?
@@@@@@@@@?
@@@@@@@@@?
@@@@@@@@@?
@@@@@@@@@?
O2@@@0M?
W2@@@0M?
?O&@@0M?
O2@@@@@@@@@@@@@6?2@@@@6KO2@@6?2@@@6K?O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6Kf?O@K
@@@@@@@@@@
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?J@@@@@@@@@@
O&@@@@@@@@@@
?O2@@@@@@@@@@@@@@@@@@@@@@@@@@@
O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@
O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@
?O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@5
?O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@?
?O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@1
?O2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@
?W2@@@@@@@@@@@@@@@@@@@@@e@@@@@@@@@@@@@@@@@@@@@@@@@@
W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@
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?W&@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@
W&@@@@@@@@@@@@@@@@@@@@@@@@0M
O2@@@@@@@6K?
O2@@@@@@@@@@@@@@@@6K
O2@@@@@@@@@@@@@@@@@@@@@@@@@@@6K?
O2@@@@@@@@0MhfI4@@@@@@@@@@@6K?
O2@@@@@0M?
O2@@@@0M I4@@@@@@@@@6K?
I4@@@@@@@@@6K?
I'@@@@@@@6X?
?V4@@@@@@@)X
?I4@@@@@@)K?
?@6X
?@@)?2@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@6?2@6K?e?O26K?
?@@@@@@@
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O2@@6K
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fuse melts, find out why and rectify the fault before fitting a
new one. The fuses are identified using column letters (A, B
and C) and row numbers (1 to 9).
! CAUTION
Fuses
Always replace fuses with ones of correct ampere rating
to avoid electrical system damage.
8-3-3-5
COLUMN 'A' Fuse

Rating
1 Reverse alarm, brake lights, 2/4WD solenoid
†††. 10 Amp
2 Gauges, stabiliser lock relay. 5 Amp
3 Left hand sidelights, dipper light. 5 Amp
4 Gauge illumination, right hand sidelights. 5 Amp
5 Rear wiper. 5 Amp
6 Hazard warning lights. 10 Amp S143211
7 Beacon, Interior light. 10 Amp

† Note: Machines prior to serial number 400077 have the
8 Radio. 5 Amp fog light circuit protected by fuse B3, not C4 as
9 Horn, headlight flash, front wiper/washer. 10 Amp indicated.
COLUMN 'B' †† Note: Steering solenoids and proximity switches are

fitted to AWS machines only.
1 Junction box, remote unload solenoid (HSC). 10 Amp
2 Fuel pump solenoid (engine stop). 5 Amp ††† Note: Machines up to serial number 403024 have the
brake lights protected by fuse A1.
3 Dip beam†. 10 Amp
4 Main beam. 10 Amp Machines from serial number 403025 to 404851 have
the brake lights protected by fuse C3.
5 Front work lights. 10 Amp
6 Direction turn indicators. 5 Amp Machines from serial number 404852 have the brake
lights, and 2/4WD solenoid protected by fuse A1 (as
7 Dump relay. 5 Amp indicated in the fuse identification chart).
8 Heater. 15 Amp
9 Hand dump, buzzer. 5 Amp
COLUMN 'C'
1 Rear work lights. 10 Amp
2 Steering solenoids, proximity switches ††. 5 Amp
3 2/4 WD switch & relay, forward relay and
solenoid, reverse relay and solenoid.
Powershift only - forward high/low relay &

solenoid, reverse high/low relay & solenoid,
drive (mainshaft/layshaft) relay & solenoid,
neutral relay. 10 Amp
4 Fog light †. 10 Amp
5 When applicable - heated seat, clock & cigar
lighter. 15 Amp
9804/1103 15 - 05 - 01/2 Issue 2

CONTENTS
CONTENTS

Data - Electrical
Circuit Protection
The relays and fuses are located in the side console
underneath cover A.
! CAUTION
Fuses
8-3-3-5
Fuse Identification
* If a fuse melts, find out why and rectify the fault before fitting
a new one. The fuses are identified using column letters (A,
B and C) and row numbers (1 to 9). Note that all the fuses
are shown (including optional equipment fuses). Your
machine may not be equipped with all the fuses shown on
this page.
COLUMN 'A' Fuse Rating COLUMN 'C'

1 Brake lights. 5 Amp 1 Rear work lights. 10 Amp
2 Warning lights, buzzer, gauges. 5 Amp 2 Steer mode, hydraulic speed control (HSC) 5 Amp
3 Left hand sidelights. 5 Amp 3 Gearbox control, reverse alarm. 10 Amp
4 Right hand sidelights. 5 Amp 4 Fog light. 5 Amp
5 Rear wiper/washer. 5 Amp 5 Heated seat, clock & cigar lighter 15 Amp
6 Hazard warning lights. 10 Amp 6 Forward and reverse controls, reverse alarm 3 Amp
7 Beacon, Interior light. 10 Amp
*
8 Radio. 5 Amp * Note: Fuse C6 is only fitted on machines from serial number:
9 Horn, headlight flash, front wiper/washer. 15 Amp 3CX (214) - 438636; 4CX (214S) - 437866. Prior to this, the
*
gear controls were protected by fuse C3.
COLUMN 'B'
1 Junction box 10 Amp
2 Fuel pump solenoid (engine stop). 5 Amp
3 Dip beam. 10 Amp
4 Main beam. 10 Amp
5 Front work lights. 10 Amp
6 Indicators. 5 Amp
7 4WD (automatic brake). 5 Amp
8 Heater. 30 Amp
9 Rear horn. 10 Amp
S247030
9804/1103 15 - 05 - 01/3 Issue 3*

CONTENTS
CONTENTS

Data - Electrical
Relay Identification - Syncro Shuttle M/c's
Relays are used in electrical circuits for a variety of reasons. However, the more usual application is to protect components like
switches etc. from being overloaded. A relatively small current (from the switch) energises the relay coil, this coil causes
internal contacts to open (or close) and therefore controls a (larger) current in another circuit. Although relays look similar,
internally they can be different, for example, they can be single contact or double contact; normally closed or normally open.
Make sure you fit the correct type of relay, otherwise the machine electrical circuits will not function properly.
All the relays on your machine (except items T & U) are housed in the front console as shown. Items T & U are secured to the
parking brake mounting bracket, as shown in the inset.
Relay Description Description

(to serial no. 409434) (from 409435 to 430000)
B Neutral Start Neutral Start
C Stabiliser Leg Lock (if fitted) Stabiliser Leg Lock (if fitted)
D Reverse Alarm (if fitted) Reverse Alarm (if fitted)
E Buzzer Buzzer
F Road Lights Road Lights
G Parking Brake Parking Brake
H Forward Drive Brake Lights
J Reverse Drive 2WD Select
K Flasher Flasher
L Transmission Dump Transmission Dump
R 2/4WD Brake Forward Drive
S 2WD Select Reverse Drive
T Hydraulic Speed Control † Hydraulic Speed Control †
U Hydraulic Speed Control † Hydraulic Speed Control †
V - Parkbrake Dump ††
Note † : From machine serial number 406613 the hydraulic speed control circuit is operated with a single relay, not two relays
as shown.
Note ††: The parkbrake dump relay is only applicable on machines from serial number 413772.
DC
E B
F G
H J
K L
U R
S V
9804/1103 15 - 05 - 01/4 Issue 2

CONTENTS
CONTENTS

Relay Identification - Powershift M/c's
Relay Description Description
(to serial no. 409434) (from 409435 to 430000)
A Ignition Ignition
B Neutral Start Neutral Start
C Stabiliser Leg Lock (if fitted) Stabiliser Leg Lock (if fitted)
D Reverse Alarm (if fitted) Reverse Alarm (if fitted)
E Buzzer Buzzer
F Road Lights Road Lights
G Parking Brake Parking Brake
H Forward Drive Forward High/Low Ratio
J Reverse Drive Reverse High/Low Ratio
K Flasher Flasher
L Transmission Dump Transmission Dump
M Forward High/Low Ratio Forward Drive
N Reverse High/Low Ratio Reverse Drive
P Drive (Layshaft/Mainshaft) Drive (Layshaft/Mainshaft)
Q Neutral (Powershift) Neutral (Powershift)
R 2/4WD Brake Brake Lights
S 2WD Select 2WD Select
T Hydraulic Speed Control † Hydraulic Speed Control †
U Hydraulic Speed Control † Hydraulic Speed Control †
V - Parkbrake Dump ††
Note †: From machine serial number 406613 the hydraulic speed control circuit is operated with a single relay, not two relays
as shown.
Note ††: The parkbrake dump relay is only applicable on machines from serial number 413772.
E A
D C
B
F G
R S
K L
H M
U P
Q
J V
N S215400
9804/1103 15 - 05 - 01/5 Issue 1

CONTENTS
CONTENTS

Data - Electrical
Relay Identification - All Machine Models * Note 1: On 3CXE (214E) machines the lights relay (item 15)
will be fitted at position 7 (in place of the hydraulic speed
control relay). Items 13 to 24 will not be fitted.
* The relays and fuses are located in the side console
underneath cover A. Note that all the relays are shown
(including optional equipment relays). Your machine may not * Note 2: Earlier Powershift machines had the neutral relay
be equipped with all the relays shown on this page. (item 24) located in position 5.
Relay Identification * Note 3: On 3CX 4x4x4 machines, the neutral relay (item 24)
is moved to a single relay base located on the left hand side
1 Ignition
of the fuse base. Positions 23 and 24 then house 2 wheel
2 Neutral Start steer and 4 wheel steer select relays respectively (see inset
3 Indicators X).
4 Ignition
* 5 5-Speed
6 Transmission Dump
* 7 Hydraulic Speed Control (HSC) - see Note 1
8 Forward Drive
9 Buzzer
10 Parking Brake
11 Reverse Drive
12 Reverse Horn
13 Auxiliary Attachment (Jaw)
14 Heater
15 Lights - see Note 1
16 Worklights (Italian Requirement Only)
17 Hammer Circuit
18 All Wheel Braking
19 Forward High/Low Ratio ➀
20 2 Wheel Drive ➁
21 Reverse High/Low Ratio ➀
22 Drive (Layshaft/Mainshaft) ➀
* 23 -
* 24 Neutral ➀ - see Notes 2 & 3 A
➀ Powershift Machines Only

S247030
➁ All Wheel Steer Machines Only
S247490
X
23 24
1 4 7 10 13 16 19 21
2 5 8 11 14 17 20 22
3 6 9 12 15 18 23 24
S247020
9804/1103 15 - 05 - 01/6 Issue 2*

CONTENTS
CONTENTS
ALL MODELS (EXCEPT 2CX) From m/c no. 400001

Data - Electrical (Servo Machines)
General
System Type 12V, negative earth
Alternator 85amp maximum output
Logic Control Box supply input 12V d.c.

range 11V - 15V
current consumption (no load) 25mA (max)
electromagnetic compatibility
- test procedure to ISO WD11452
* - test frequency 1MHz to 1GHz
field strength
- 25V/m, control box should function to functional specification
- 50V/m, control box should exhibit no hazardous effects or permanent damage to the
system
signal inputs
- joystick X and Y axis, range 3V to 9V full axis travel†
- joystick Z axis, LH wiper range, 6V to 3V†
- joystick Z axis, RH wiper range 6V to 9V†
signal outputs
- hydraulic control valves, neutral position, 6V ± 0.6V†
* Note: Logic control boxes from February 1994 are designed to isolate the excavator and
loader control relays when the joysticks are in the neutral position. This neutral position
switch will activate almost immediately the joystick is left in neutral.
- control limits, loader valve, 4.2V to 7.8V normal operation†

- control limits, loader valve, 9V with float enabled†
- control limits, backhoe valve, 3V to 9V†
See relevant pages for logic box description of operation.
Joysticks operating range 11V to 15V

axis output (refer to signal inputs - logic box)
† These are nominal values proportional to the supply input voltage, i.e. 25 to 75% of the
battery voltage
See relevant pages for joystick (and axis) descriptions of operation.
9804/1103 15 - 05 - 01/10 Issue 2*

CONTENTS
CONTENTS

Fuses Bulbs
The electrical circuits are protected by fuses. The fuses are Bulbs Bulb Rating
located in a fuse box to the right of the steering pedestal. If a Headlights - main/dip 45/37.5 W
fuse melts, find out why and rectify the fault before fitting a
Work lights 55 W Halogen (front & rear)
new one. The fuses are identified using column letters (A, B
and C) and row numbers (1 to 9). Front Side lights 5W
Tail/stop lights 5/21 W
Fog light 21 W
! CAUTION
Indicators 21 W (front & rear)
Fuses
Always replace fuses with ones of correct ampere rating Instruments 1.2 W
to avoid electrical system damage. Warning lights 3W
8-3-3-5
COLUMN 'A' Fuse Rating Interior light 10 W
A1 4WD/Brakes, Stop Lights 10 Amp Beacon 70 W Halogen
A2 Instruments, Reverse Alarm† 5 Amp
A3 Left Hand Sidelights 5 Amp
A4 Right Hand Sidelights 5 Amp
A5 Rear Wiper, Rear Wash† 5 Amp
A6 Hazard Warning Lights 10 Amp
A7 Beacon, Interior Light 10 Amp
A8 Radio† 5 Amp
A9 Horn, Front Wash/Wiper 10 Amp
COLUMN 'B'
B1 Hydraulic Options 10 Amp
B2 Fuel Pump solenoid (Engine Stop) 5 Amp
B3 Dipped Beam 10 Amp
B4 Main Beam 10 Amp
B5 Front Work Lights 10 Amp
B6 Indicators 5 Amp
B7 Dump Relay Feed 10 Amp
B8 Heater 15 Amp
B9 Hand Dump, Buzzer 5 Amp
COLUMN 'C'
C1 Rear Work Lights. 10 Amp
C2 Steering solenoids, proximity switches. 5 Amp
C3 Gearbox Control, 2 Wheel Drive 10 Amp
C4 Fog light† 5 Amp
C5 Heated seat, clock & cigar lighter† 15 Amp
C6 Servo Controls 20 Amp
Note: Items marked with a '†' are available as optional

extras.
S190050
9804/1103 15 - 05 - 01/11 Issue 1

CONTENTS
CONTENTS

4 3 2 1
5 6
7 8
9 10
16 15 14 13 12 11
22
21
23 20
25 24
S193280
17 18 19
9804/1103 15 - 05 - 01/12 Issue 1
CONTENTS
CONTENTS

Relays 1 to 16 are housed in the front console, at the side of the steering pedestal. Relays 17 to 25 are housed behind the
side console panel.
The relays are identified as follows:
Relay Description
1 Ignition
2 Neutral Start
3 Reverse Alarm
4 Buzzer
5 Road Lights
6 Parking Brake
7 2/4WD Brake
8 2WD Select
9 Flasher
10 Transmission Dump
11 Neutral (Powershift)
12 Drive (Layshaft/Mainshaft)
13 Reverse Drive
14 Forward Drive
15 Reverse High/Low Ratio
16 Forward High/Low Ratio
17 Hydraulic Speed Control
18 Steering
19 Loader
20 Backhoe
21 Hammer
22 Hydraclamp
23 Horn
24 Horn Change Over
25 Jaw (aux)
9804/1103 15 - 05 - 01/13 Issue 1

CONTENTS
CONTENTS

Logic Box - Pin Identification

Connector A PIN DESTINATION * WIRE Connector C PIN DESTINATION * WIRE
* A Boom Signal 418 A LH Joystick (+ve Out ) 423
B Bucket Signal 417 B LH Joystick (-ve Out) 424
C Slew Signal 416 C LH Joystick (Common) 428
D Steering Signal 451 D RH Joystick (+ve Out) 430
E 12V Switch Supply 421 E RH Joystick (-ve Out) 431
F Steering On/Off 444 F RH Joystick (Common) 435
G 12V Input (Direct) 112H G LH Joystick (Z Axis Left Signal) 429
H Reverse Gear Switch 888 H LH Joystick (Z Axis Right Signal) 427
J Forward Gear Switch 887 J LH Joystick (X Axis Signal ) 425
K Forward Gear Relay 809 K LH Joystick (Y Axis Signal) 426
L - - L - -
M Reverse Gear Relay 808 M - -
N - - N RH Joystick (Y Axis Signal) 433
P Shovel Signal 415 P - -
R Clam Signal 414 R - -
* S Dipper Signal 419 S - -
* T RH Mode Switch (LH Joystick) 446 T RH Joystick (Z Axis Right Signal) 434
* U LH Mode Switch (LH Joystick) 445 U RH Joystick (X Axis Signal ) 432
V Loader Signal 413 V RH Joystick (Z Axis Left Signal) 436
Connector B PIN DESTINATION * WIRE

A +ve Input (via reset) 882H
B Loader Valve Relay 440
C 12V Common Earth 605N
D Backhoe Valve Relay 450
E - -
F - -
G Seat Forward Switch 895A
H Seat Rearward Switch 896
J Safety Solenoid 422
K Reset Required Indicator 439
L Float Available Indicator 437
M RTD Available Indicator 438
N Shovel Position Switch (Arms) 844
P RTD Enable Switch 443
R - -
S Fault Reset Switch 882G
T Float Enable Switch - Input 1 441
U Float Enable Switch - Input 2 442
V Joystick Isolator Switch 449
A244360
A A A
M B M B M B
L U N C L U N C L U N C
K T V P D K T V P D K T V P D
J S R E J S R E J S R E
H H H
G F G F G F
Harness Harness Harness

Connector 'A' Connector 'B' Connector 'C'
9804/1103 15 - 05 - 01/14 Issue 2*

CONTENTS
CONTENTS

RH Joystick - Pin Identification

PIN DESTINATION WIRE
A - -
B - -
C Logic Box (+ve Out) 430
D - -
E Logic Box (Z Axis Right Signal) 434
F Logic Box (X Axis Signal ) 432
G Seat Harness Splice (Aux Switch) 110F
H Auxiliary Relay 898
J Logic Box (Y Axis Signal) 433
K Logic Box (Z Axis Left Signal) 436
L - -
M Logic Box (-ve Out) 431
N Seat Harness Splice (Transmission
Dump Switch) 107J
P Transmission Dump Relay 838B
R Cab Harness Splice (HSC Switch) 101T
S HSC Relay 889
T Logic Box (Common) 435
U - -
V - -
A
B M
C N L
P U
D V K
R T
E S J
F
G H
A244100
Harness
Connector
LH Joystick - Pin Identification

PIN DESTINATION WIRE
A Hydraclamp Relay 885
B Seat Harness Splice (Hydraclamp Switch) 112K
C Logic Box (Supply Input) 423
D - -
E Logic Box (Z Axis Right Signal) 427
F Logic Box (X Axis Signal ) 425
G Horn Relay 890
H Seat Harness Splice (Horn Switch) 110G
J Logic Box (Y Axis Signal) 426
K Logic Box (Z Axis Left Signal) 429
L - -
M Logic Box (-ve Out) 424
N Logic Box (LH Mode Switch) 445
P Seat Harness Splice (LH Mode Switch) 421E
R Seat Harness Splice (RH Mode Switch) 421F
S Logic Box (RH Mode Switch) 446
T Logic Box (Common) 428
U - -
V - -
9804/1103 15 - 05 - 01/15 Issue 2

CONTENTS
CONTENTS

H
G L
K
6
8 5
7
F
3 D
C
E
B A
1
S193310
9804/1103 15 - 05 - 01/16 Issue 2

CONTENTS
CONTENTS

Harness Identification
Key
1 Mainframe Harness
A Mainframe to Panel Connector 1

B Mainframe to Panel Connector 2
C Mainframe to Cab Connector
D Backhoe Valve Block Solenoid Connectors
E Loader Valve Block Solenoid Connectors
2 Cab Harness
C Cab to Mainframe Connector

F Cab to Panel Connector
G Cab to Logic Box Connectors
H Cab to Seat Connectors
J Cab to Roof Harness (2 off)
3 Panel Harness
A Panel to Mainframe Connector 1

B Panel to Mainframe Connector 2
F Panel to Cab Connector
4 Seat Harness
H Seat to Cab Connectors

K Left Hand Joystick Connectors
L Right Hand Joystick Connectors
5 Cab Roof Harness
J Roof to Cab Harness (2 off)
6 Seat Proximity Switch Harness
7 Rear Lights Extension Harness
Note: The routing of the rear light extension harnesses will vary depending on whether the machine is a sideshift or
centremount type. The centremount routing is shown in dotted line form, the sideshift routing shown in solid line form.
8 Logic Box
9804/1103 15 - 05 - 01/17 Issue 1

CONTENTS
CONTENTS

Data - Electrical
General
System Type 12 Volt, negative earth
Battery (Heavy Duty)
Battery (Temperate)
Electronic Control Unit
Shift points Hz
2nd to 3rd 3rd to 4th 4th to 3rd 3rd to 2nd 2nd to 1st
449/05401 693 1467 1304 570 326
Note: The part number and ECU settings can be verified and checked on the Psion Workabout.
Alternator
2WS 65 Amp nominal output
4WS 72 Amp nominal output
4WS (air conditioning or ServoPlus builds) 85 Amp nominal output
9804/1103 15 - 05 - 01/19 3270 - C/1-1.3 Issue 1

CONTENTS

Data - Electrical
Fuse Identification
! CAUTION
8-3-3-5

underneath cover A.
If a fuse melts, find out why and rectify the fault before fitting
a new one. The fuses are identified using column letters (A, B
and C) and row numbers (1 to 9). Note that all the fuses are
shown (including optional equipment fuses). Your machine
may not be equipped with all the fuses shown on this page.
ALL MODELS (Except 3CXE, 214E)

COLUMN 'A' Fuse Rating
1 Hydraulic Auxiliary, Smooth Ride System 10 Amp
2 Fuel pump solenoid (engine stop) 5 Amp
3 Indicators 7.5 Amp
4 Steer mode, proximity switches 7.5 Amp
5 Gearbox Control, Transmission 10 Amp
6 Powered rear window 20 Amp
7 Brake lights 5 Amp
8 4WD (automatic brake) 3 Amp
9 Left hand sidelights 3 Amp
10 Right hand sidelights 3 Amp
COLUMN 'B' Fuse Rating

1 Instruments, buzzer 5 Amp 10 9 8 7 6 5 4 3 2 1
2 Front Horn, front wiper/washer 15 Amp
4W
3 Rear horn 7.5 Amp A
4 Heated seat, cigar lighter, face level fan 15 Amp 3A 3A 3A 5A 20A 10A 7.5A 7.5A 5A 10A
5 Rear wiper/washer 5 Amp R

6 Brake switch 10 Amp B
7 Rear work lights 25 Amp 25A 20A 25A 10A 5A 15A 7.5A 15A 5A
8 Headlights 20 Amp
9 Front work lights 25 Amp 0
C
10 Spare -
15A 15A 3A 30A 20A 5A 10A 15A 7.5A 3A A276790
COLUMN 'C' Fuse Rating

1 Fog light 3 Amp
2 Main lights 7.5 Amp
3 Hazard lights 15 Amp
4 Beacon, interior light 10 Amp
5 Radio 5 Amp
6 Thermostart 20 Amp
7 Heater 30 Amp A
8 Ignition relay coils 3 Amp
9 Main Beam 15 Amp
10 Dip Beam 15 Amp
S252511
9804/1103 15 - 05 - 01/20 3270 - 3/1-2.3 Issue 2*

CONTENTS

Data - Electrical
Fuse Identification Relay Identification
The relays and fuses are located in the side console 1 Ignition
underneath cover A. 2 Neutral Start
3 Indicators
COLUMN 'A' Fuse Rating 4 Ignition
1 Hydraulic Auxiliary, Smooth Ride System 10 Amp 5 Front Work Lights
2 Fuel pump solenoid (engine stop) 5 Amp 6 Transmission Dump
3 Indicators 7.5 Amp 7 Rear Work Lights
4 Steer mode, proximity switches 7.5 Amp 8 Forward Drive
5 Gearbox Control, Transmission 10 Amp 9 Buzzer
6 Powered rear window 20 Amp 10 Parking Brake
7 Brake lights 5 Amp 11 Reverse Drive
8 4WD (automatic brake) 3 Amp 12 Reverse Horn
9 Left hand sidelights 3 Amp
10 Right hand sidelights 3 Amp
COLUMN 'B' Fuse Rating

1 Instruments, buzzer 5 Amp
2 Front horn, front wiper/washer 15 Amp
3 Rear horn 7.5 Amp
4 Heated seat, cigar lighter, face level fan 15 Amp
5 Rear wiper/washer 5 Amp
6 Brake switch 10 Amp
7 Rear work lights 25 Amp
8 Headlights 20 Amp
9 Front work lights 12 Amp
10 Spare -

1 Fog light 3 Amp
2 Main lights 7.5 Amp
3 Hazard lights 15 Amp
4 Beacon, interior light 10 Amp
10 9 8 7 6 5 4 3 2 1
4W
A
3A 3A 3A 5A 20A 10A 7.5A 7.5A 5A 10A
R A
B
25A 20A 25A 10A 5A 15A 7.5A 15A 5A
0
C A333470
15A 15A 3A 30A 20A 5A 10A 15A 7.5A 3A
A276790
0 1 0 4 7 0
P
0 2 5 8 !
F R
3 6 9 @
R
A265070
9804/1103 15 - 05 - 01/20A 3270 - 3/1-4.3 Issue 1

CONTENTS

Data - Electrical
Link Box Fuses Bulbs

Head lights - main/dip † 45/37.5W
To further protect the machine wiring harnesses and
electrical circuits, a fuse link box is fitted to the battery, as Front Lights †† 55W Halogen
shown at B. Remember to check the main circuit fuses as Work lights 55 Halogen (front & rear)
well as the link box fuses shown on this page.
Front side lights † 5W
1 Hazard warning lights, Beacon, Lights 30 Amp Tail/stop lights 5/21W
Fog light † 21W
2 Wash/Wipe, Transmission, Indicators 50 Amp
Direction turn indicators 21W (front & rear)
3 Work lights, Fog Lights, Brake lights 50 Amp Instruments 1.2W

Warning lights 3W
4 Ignition, Heater, Thermostart 50 Amp Number plate light † 1 x 5W
Interior light 10W
Beacon † 70W Halogen
Note: These items are not applicable to North America

Note: These items are applicable to North America only
B
S254320
1 2
3 4 A254310
9804/1103 15 - 05 - 01/21 3270 - C/1-3.1 Issue 1

CONTENTS
CONTENTS

Data - Electrical
The relays and fuses are located in the side console 3CXE, 214E only
underneath cover A. Note that all the relays are shown B Ignition
(including optional equipment relays). Your machine may not C Neutral Start
be equipped with all the relays shown on this page. D Indicators
E Ignition
All Models (Except 3CXE, 214E) F Front Work Lights
1 Ignition G Transmission Dump
2 Neutral Start H Rear Work Lights
3 Indicators J Forward Drive
4 Ignition K Buzzer
5 Heater L Parking Brake
6 Transmission Dump M Reverse Drive
N Reverse Horn
7 Hydraulic Speed Control (HSC)
8 Forward Drive
9 Buzzer
10Parking Brake 0 0
11Reverse Drive P
12Reverse Horn B E H L
13Front Work Lights
14
15
Worklights (Italian, German requirement only)
Lights
0
F R
C F J M
16Rear Work Lights
17Intermittent Wash/Wipe R
18All Wheel Braking (standard machines) D G K N
18Reverse alarm (autoshift machines)
19Forward High/Low Ratio ! A265070
202 Wheel Drive "

21Neutral
22Reverse High/Low Ratio !
23Drive (Layshaft/Mainshaft) !
24Auto Hydraulic Speed Control (HSC)
254 Wheel Steer #
262 Wheel Steer #
27Hammer Circuit
28Steer Relay 1 #
29Steer Relay 2 #
30Auxiliary Attachment (Jaw) A
! Powershift Machines Only
"$ All Wheel Steer Machines Only
# 3CX 4x4x4 Machines Only - not applicable to N.Am.
S252511
25 26 27 1 4 7 10 19 22
13 16
0 0
P F R
28 29 30 8 11 14 17
2 5 20 23
0
F R D
9 12 15 18 21 24
3 6
R 4W N AUTO
R
A260440
9804/1103 15 - 05 - 01/22 3270 - C/1-3.3 Issue 2*

CONTENTS
CONTENTS

Data - Electrical
Fuse Identification - Servo Command Relay Identification - Servo Command
R1 Ignition
underneath cover A.
R2 Front seat
R3 Front mode changeover
Fuse Rating
R4 Rear seat
5 Right hand pilot valve 5 Amp
R5 Rear mode changeover
6 Left hand pilot valve 5 Amp
R6 Right hand joystick proportional switch supply
7 Return to dig 1 amp
R7 Right hand amplifier supply
8 Main feed 10 Amp
R8 Front auxiliary supply
9 Servo isolation switch 3 Amp
R9 Hammer interlink
10 Change over solenoids 15 Amp
R10 Stabiliser isolate
R11 Left hand amplifier supply
R12 Sweeper/Clam changeover
R13 Pilot valves changeover
R14 Auxiliary/Clam 2 changeover
R15 Auxiliary/Clam 1 changeover
R16 Stabiliser/Clam 2 changeover
R17 Stabiliser/Clam 1 changeover
R18 Stabiliser/Auxiliary 1 changeover
R19 Stabiliser/Auxiliary 2 changeover
R20 Stabiliser lower changeover
R21 Stabiliser raise changeover
R22 Stabiliser lower/mode changeover
R23 Stabiliser raise/mode changeover
R24 Dump interlink (autoshift only)
R25 Spare
R11 R10 R8 R9
R13 R12 R6 R7
A R15 R14 R4 R5
R17 R16 R2 R3
R1
BUZZER
10
2
3
4
5
6
7
8
9
1
R18 R20 R22 R24
R19 R21 R23 R25

A334090
9804/1103 15 - 05 - 01/23 3270 - C/1-5.2 Issue 1

CONTENTS

Data Electrical
Fuse Identification - 214Se Relay Identification 214Se
COLUMN 'A' Fuse Rating A 4 Wheel brake
1 Hydraulic auxiliary 5 Amp B Lights
2 Fuel pump solenoid (engine stop) 5 Amp C Turn signals
3 Turn signals 7.5 Amp D Reverse drive
4 Spare E Forward drive
5 Gearbox control, Transmission 10 Amp F Front work lights
6 Spare G Parking brake
7 4WD (automatic brake) 3 Amp H Transmission dump
8 Brake lights 5 Amp J Rear work lights
9 Right hand sidelights 3 Amp K Neutral start
10 Left hand sidelights 3 Amp L Ignition 1
M Buzzer
COLUMN 'B' Fuse Rating N Ignition 2
1 Instruments, buzzer 5 Amp
2 Front horn, front wiper/washer 15 Amp
3 Spare
4 Auxiliary power socket 20 Amp
5 Rear wiper/washer 15 Amp
6 Brake switch 10 Amp
7 Rear work lights 25 Amp
8 Headlights 20 Amp
9 Front work lights 25 Amp
10 Beacon 10 Amp

1 Spare
2 Dip beam 15 Amp
3 Lights 7.5 Amp
4 Hazard 15 Amp
5 Face level fan 10 Amp
6 Radio 1 Amp
7 Thermostart 20 Amp
8 Heater 30 Amp
9 Ignition relay coils 3 Amp
10 Main beam 15 Amp
A B C
4W 4W
D E F
10 9 8 7 6 5 4 3 2 1
4W
A
A G H J
3A
3A 3A 5A
5A 3A 10A
10A 7.5A
7.5A 5A 5A
5A 5A
B
B
K L
10A 25A 20A
10A 25A 15A 20A
20A 25A 10A 15A 15 5A
15A 5A
1 1
M N
C
15A 3A 30A 20A 1A 10A 15A
15A 3A 7.5A 15A
15A 7.5A 15A 2 2
345740 345741
817/16774
9804/1103 15 - 05 - 01/24 3270 - C/1-6.2 Issue 1
CONTENTS

Data - Electrical
Fuse Identification A Heater
Fuse Rating B Direction indicator
1 Dip beam 15 Amp C Ignition
2 Fog light 3 Amp D Ignition
3 Main beam 15 Amp E Neutral start
4 Ignition relay coils 3 Amp F Buzzer
5 Heater 30 Amp G Intermittent wash/wipe switch
6 Thermostart 20 Amp H Rear working lights
7 Radio 5 Amp J Front working lights
8 Beacon, Interior light 10 Amp K Rear horn
9 Hazard light 15 Amp L 2/4 wheel braking
10 Lights 7.5 Amp M Engine run
11 Front working lights 25 Amp N Auxiliary (jaw bucket)
12 Headlights 20 Amp P Reverse alarm
13 Rear working lights 25 Amp Q Hydraulic speed control
14 Return to dig enable 5 Amp R Hammer
15 Brake switch 10 Amp S Main lights
16 Rear wiper/wash 10 Amp T 2 wheel drive
17 Heated seat, Cigar lighter, Face level fan 15 Amp U Parking brake
18 Rear horn 7.5 Amp
19 Front horn, Front washer/wiper 15 Amp
20 Instruments, Buzzer 5 Amp
21 Right hand side lights 5 Amp
22 Left hand side lights 5 Amp
23 4 wheel drive (automatic brakes) 3 Amp
24 Brake lights 5 Amp
25 Spare
26 Gearbox control, Transmission 10 Amp
27 Steer mode proximity switch 7.5 Amp
28 Direction indicators 7.5 amp
29 Fuel pump solenoid (engine stop) 5 amp
30 Hydraulic auxiliary 10 Amp
P N M L K J H
Q R S T U
G F E D C B A
A356072
A357830
A356071 21 22 23 24 25 26 27 28 29 30
4WD
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
9804/1103 15 - 05 - 01/25 3270 - C/1-7.2 Issue 1

CONTENTS
CONTENTS

Data - Electrical
Relay Identification - Autoshift Only Relay Identification - Powershift
Transmission From Serial No. 495455
underneath cover A. 1 Spare
2 Reverse drive
1 Ignition 3 Reverse (High/Low ratio)
2 Neutral Start 4 Forward (High/Low ratio)
3 Indicators 5 Transmission dump
4 Ignition 6 Forward drive
5 Heater 7 Driveshaft interlock
6 Parking Brake 8 Drive (Layshaft/Mainshaft)
7 Hydraulic Speed Control
8 Auxiliary Attachment (Jaw)
9 Buzzer
10 Auto Hydraulic Speed Control
11 Hammer
12 Reverse Horn
14 Working Lights (Italian, German requirement only)
15 Lights
17 Intermittent Wash/Wipe
18 Reverse Alarm
1 2 3 4
5 6 7 8
A359330
Relay Identification - Syncro Shuttle

Transmission From Serial No. 495455
1 Transmission dump
2 Forward drive
3 Spare
A 4 Reverse drive
A333470
1 4 7 0 £ ^
2 5 8 ! $ &
1 2
3 6 9 @ % * 3 4
A334100 A357840
9804/1103 15 - 05 - 01/26 3270 - C/1-8.2 Issue 1

CONTENTS

Data Electrical
3 4
1
7 5
ITEM DESCRIPTION
Note: The illustration shows a typical machine.
1 Mainframe Harness
2 Panel Harness
3 Cab Harness
4 Cab Roof Harness
5 Solenoid Harness
6 Rear Light Harnesses
7 Engine Shut Off Harness
9804/1103 15 - 05 - 01/27 3270 - C/40-1.2 Issue 1

CONTENTS

Data - Electrical
Item Description
1 Seat
3 Auxiliary Valve Block
5 Manifold Block
9804/1103 15 - 05 - 01/28 3270 - C/40-2.1 Issue 1

CONTENTS

Data Electrical
Item Description
1 Chassis Harness
2 Cab Panel Harness
3 Cab Roof Harness
4 Powershift Transmission Harness (not shown)
5 Rear Cab (Sideshift) Harness
6 Rear Lights (Sideshift) Harness
7 Auxiliary Harness
8 Head Lights Harness (not shown)
9 Powershift Relay Harness
10 Steer Mode Harness
11 Air Conditioning Harness (not shown)
12 Power Tool Extension Harness
13 Servo Auxiliary Chassis Harness
14 3CX Link Connector (not shown)
16 Strap Earth
9804/1103 15 - 05 - 01/29 3270 - C/40-3.1 Issue 1

CONTENTS
CONTENTS
3CX, 4CX From m/c no. 400001

Data - Hydraulic (Standard Machines)
Machine Hydraulics
Hydraulic Pumps ('Hamworthy' type) - UK and Rest of World, except North America
Hydraulic Pump - Option 1

Model/Reference Double pump/190906
Rotation Clockwise (AWS), Anti-clockwise (2WS)
Mounting:
AWS M/c's Engine Timing Case
2WS M/c's Chassis (driveshaft driven)
Machines/Models applicable to: See - Hydraulic Pump Applicability Chart
Flow at 2200 rev/min and system pressure: litres/min UK gal/min
Pump section 1 (mounting flange end) 82.2 18.0
Pump section 2 58.4 12.8
Maximum working pressure See - Relief Valve Operating Pressures

Mounting:

Mounting:

Mounting:
Hydraulic Pump Applicability Chart
Pump Type 2-Wheel Steer Machines All Wheel Steer Machines

3CX S/Master H/Master 4CX 4C 4CN S/Master
190906
* 190706 √ √ √ √ √ √ √
190705 √ √ √
190606
Note: The applicability chart is intended as a guide only, make sure that you check the pump data plate (mounted on the
pump) to determine exactly which type of pump is fitted to your machine.
9804/1103 15 - 05 - 02/1 Issue 4*

CONTENTS
CONTENTS

Machine Hydraulics
Hydraulic Pumps ('Ultra' type) - UK and Rest of World, except North America

Model/Reference Double pump/4071 (2WS), 4075 (AWS)
Mounting:

Mounting:

Model/Reference Double pump/4070 (2WS)
Rotation Anti-clockwise
Mounting:

Rotation Anti-clockwise
Mounting:
Maximum working pressure see - Relief Valve Operating Pressures

3CX S/Master H/Master 4CX 4C 4CN S/Master
4071
4075
4072 √ √ √
* 4074 √ √ √ √
4070 √ √ √
4073
Note: The applicability chart is intended as a guide only, make sure that you check the pump data plate (mounted on the
pump) to determine exactly which type of pump is fitted to your machine.
9804/1103 15 - 05 - 02/2 Issue 4*

CONTENTS
CONTENTS
Data - Hydraulic (Standard Machines) (continued)
* Machine Hydraulics
Hydraulic Pumps ('Hamworthy' type) - NORTH AMERICA ONLY

Rotation Clockwise (AWS), Anit-clockwise (2WS)
Mounting:
Flow at 2200 rev/min and system pressure
Pump section 1 (mounting bracket end) 21.6 US gal/min
Pump section 2 15.4 US gal/min

Mounting:

Mounting:

Mounting:
214 215 216 217 S/Master 214S 215S 216S 217S S/Master
190906
190706
190705
190606
Note: The applicability chart is intended as a guide only, make sure that you check the pump data plate (mounted
on the pump) to determine exactly which type of pump is fitted to your machine.
9804/1103 15 - 05 - 02/3 Issue 2*

CONTENTS
CONTENTS
Data - Hydraulic (Standard Machines) (continued)
* Machine Hydraulics
Hydraulic Pumps ('Ultra' type) - NORTH AMERICA ONLY
Mounting:
Flow at 2200 rev/min and system pressure:
Pump section 1 (mounting flange end) 21.48 US gal/min
Mounting:
Mounting:
Mounting:
214 215 216 217 S/Master 214S 215S 216S 217S S/Master
4071
4075
4072
4074
4070
4073
Note: The applicability chart is intended as a guide only, make sure that you check the pump data plate (mounted on the pump) to
determine exactly which type of pump is fitted to your machine.
9804/1103 15 - 05 - 02/4 Issue 2*

CONTENTS
CONTENTS

Machine Hydraulics
Main Relief Valve (M.R.V.) @ 1500 RPM 228 - 240 233 - 245 3300 - 3500
Unloader Valve 207 - 220 211 - 225 3000 - 3200

† Loader
Shovel Ram Head Side 165 - 200 168 - 204 2400 - 2900
Shovel Ram Rod side 303 - 317 309 - 323 4400 - 4600
Backhoe
Boom Ram Head Side 241 - 255 246 - 260 3500 - 3700
Boom Ram Rod Side
* to m/c 435209 (Sideshift ), 434984 (C/mount) 303 - 317 309 - 323 4400 - 4600
* from m/c 435210 (Sideshift ), 434985 (C/mount) 338 - 352 344 - 358 4900 - 5100
Bucket Ram Head Side
Centremount (17' backhoe - 217 models only) 303 - 317 309 - 323 4400 - 4600
Centremount (14' backhoe) 241 - 255 246 - 260 3500 - 3700
Centremount (15' 6" backhoe up to M/C 413521) 241 - 255 246 - 260 3500 - 3700
Centremount (15' 6" backhoe from M/C 413522
except knuckle boom) 303 - 317 309 - 323 4400 - 4600
Sideshift 241 - 255 246 - 260 3500 - 3700
Bucket Ram Rod Side (Machines with Powerbreaker only) 241 - 255 246 - 260 3500 - 3700
Dipper Ram Head Side 241 - 255 246 - 260 3500 - 3700
Dipper Ram Rod Side 241 - 255 246 - 260 3500 - 3700
Slew Left and Right 255 - 269 260 - 274 3700 - 3900
Attachments bar kgf/cm2 lbf/in2
Extradig Ram Head Side 138 - 150 141 - 153 2000 - 2200
Extradig Ram Rod Side 207 - 220 211 - 225 3000 - 3200
Jaw Bucket Ram Head Side 138 - 145 141 - 148 2000 - 2100
Jaw Bucket Ram Rod Side 207 - 214 211 - 218 3000 - 3100
Knuckle Ram Head Side 138 - 145 141 - 148 2000 - 2100
Knuckle Ram Rod Side 207 - 214 211 - 218 3000 - 3100
Hammermaster 207 - 214 211 - 218 3000 - 3100
Roadbreaker 138 - 150 141 - 153 2000 - 2200
Sequence Valve 21 21 300
Hose Burst Protection Valves (optional) bar kgf/cm2 lbf/in2
Machine Serial Numbers - up to 402173
Boom Ram Rod Side 303 - 317 309 - 323 4400 - 4600
Loader Lift Rams Head Side 303 - 317 309 - 323 4400 - 4600
Machine Serial Numbers - from 402174

Boom Ram Rod Side 250 255 3625
Dipper Ram Rod Side 250 255 3625
Loader Lift Rams Head Side 250 255 3625
Stabiliser Check Valve Relief Valve (Centremount M/c's) 303 - 317 309 - 323 4400 - 4600
† When setting 'Hamworthy' Loader Valve A.R.V.'s using a hand pump, set 15 bar (220 lbf/in2) below nominal figure shown.
† When setting 'Husco' Loader Valve A.R.V.'s using a hand pump, set to the figure shown above.
Note: Later type loader valves are produced by a different manufacturer (Husco). When appropriate, the loader valve will be
identified using the manufacturer's name, (Hamworthy - earlier type, or Husco - later type). In some instances, there will be no
need to differentiate (e.g., descriptions of operation - the valves operate in the same manner).
9804/1103 15 - 05 - 02/5 Issue 3*

CONTENTS
CONTENTS

Steer Hydraulics (AWS Machines)
System Type Full Power Hydrostatic
Hydraulic Supply From Main Hydraulic Pump Via Priority Valve
Control Unit Type Load Sensing With Integral Relief Valve
Control Unit Relief Valve Operating Pressure
(at 1500 revs/min) 120 ± 3.5 bar 122 ± 3.5 kgf/cm2 1740 ± 50 lbf/in2
Control Unit Shock Valve Operating Pressure 175 - 190 bar 178 - 199 kgf/cm2 2538 - 2756
lbf/in2
Front Steer Ram(s) Dimensions

Bore 60 mm (2.362 in)
Rod Diameter 30 mm (1.181 in)
Stroke 210.6 mm (8.290 in)
End Cap Assembly A/F 55 mm (2.165 in)
Piston Head Assembly A/F 41 mm (1.614 in)
Rear Steer Ram(s) Dimensions

Bore 60 mm (2.362 in)
Stroke 210.6 mm (8.290 in)

Piston Head 405 41 300
End Cap 678 69 500
Steer Hydraulics (2WS Machines)

Control Unit Relief Valve Operating Pressure
(at 1500 revs/min) 120 ± 3.5 bar 122 ± 3.5 kgf/cm2 1740 ± 50 lbf/in2
Control Unit Shock Valve Operating Pressure 175 - 190 bar 178 - 199 kgf/cm2 2538 - 2756
lbf/in2
Steer Ram(s) Dimensions

2 Wheel Drive Machines
Location 1 Ram - Front Axle (Right Hand Side)
Bore 70 mm (2.756 in)
Stroke 290 mm (11.417 in)
4 Wheel Drive Machines

Location 1 Ram - Front Axle (Left Hand Side)
Bore 70 mm (2.756 in)

Piston Head 405 41 300
End Cap 678 69 500
9804/1103 15 - 05 - 02/6 Issue 3

CONTENTS
CONTENTS

Data - Hydraulic (3CXE (214E) Machines)
Machine Hydraulics
Hydraulic Pump
Model/Reference: Single pump/6197
Rotation: Anti-clockwise
Mounting: Chassis (driveshaft driven)
Machines/Models applicable to: 3CXE machines only
Flow at 2200 rev/min and system pressure: 99.0 litres/min; 21.9 UK gal/min; 26.3 US gal/min
Maximum working pressure 230 bar; 234.5 kg/cm2; 3335 lbf/in2

Loader
Shovel Ram
Head Side 172 - 176 175 - 179 2500 - 2550
Rod side 308 - 312 314 - 318 4475 - 4525
Backhoe
Boom Ram
Head Side 245 - 252 249 - 257 3550 - 3650
Rod Side 308 - 312 314 - 318 4475 - 4525
Bucket Ram
Head Side 245 - 252 249 - 257 3550 - 3650
Rod Side 245 - 252 249 - 257 3550 - 3650
Dipper Ram
Head Side 245 - 252 249 - 257 3550 - 3650
Rod Side 245 - 252 249 - 257 3550 - 3650
Slew Ram
Left and Right 258 - 266 263 - 271 3750 - 3850
Stabiliser Ram
Left and Right 303 - 317 309 - 323 4400 - 4600
Steering 120 - 125 122 - 127 1740 - 1813
Attachments
Hammermaster
170 173 2465 3
1
Loader Valve Identification (Fig 1)
1 - Loader Arm Spool 2
2 - Shovel Spool
2A - Rod Side
2B - Head Side
3 - Auxiliary Relief Valve
4 - Inlet Port 5
5 - Outlet Port 2A
6 - High Pressure Carry Over Port 6
2B 4
3
A248220
Fig 1
9804/1103 15 - 05 - 02/7 Issue 3

CONTENTS
CONTENTS

Data - Hydraulic (Servo Machines)
Machine Hydraulics
Hydraulic Pumps See Page E/1-2, in Service Manual 9803/3260
Loader Valve
Electric Supply Logic Box
Metering Characteristics Closed Centre Load Sensed
Section Designation
- Loader, Shovel, Clam PVG 32
Auxilary Relief Valve Pressures Bar kgf/cm2 lbf/in2
- Shovel Ram Head Side 165 - 179 168 - 183 2400 - 2600
- Shovel Ram Rod Side 303 - 317 309 - 323 4400 - 4600
Main Relief Valve Pressure - see Note 1
* - machines up to serial no. 419307 260 265 3770
* - machines from serial no. 419308 230 235 3335
Valve Block Identification Refer to Fig 1 (view shown as fitted on machine)
- Spool 1 Loader Arms Service
- Spool 2 Shovel Service
-A Head Side
-B Rod Side
-C Load Sense Line Connection Port
-D Pump
-E Tank
-F Pressure Test Point (plugged - use test point on backhoe valve)
- Spool 3 (Optional) Clam Service
-A Rod Side
-B Head Side
Output Descriptions Operation Port Neutral Full Deflection - see Note 2
- Loader Arm Lift A 6V 4.2V
Lower B 6V 7.8V
* Float - 6V 9V (with ‘Float Enable’ selected)
- Shovel Dump A 6V 3V
Crowd B 6V 9V
* Return-to Dig B 6V 9V (with ‘RTD Enable’ selected)
- Clam Open A 6V 3V
Close B 6V 9V
Note 1: On machines up to serial number 419307 both the

loader and the backhoe valves house main relief valves.
However, the main relief in the loader valve is factory set at D
E
260 bar and would therefore never reach 'cracking'
pressure. The MRV in the backhoe valve is set at 230 bar F C
and therefore controls the hydraulic system pressure.
A 1
On machines from serial number 419308 only the loader B
valve houses a main relief valve (a blanking plug is fitted in
the backhoe valve). The MRV in the loader valve is set at
A
230 bar and controls the hydraulic system pressure. B 2
Note 2: Figures assume 12V battery voltage - output is A

proportional to battery voltage. B 3
A193570
9804/1103 15 - 05 - 02/8 Issue 2*

CONTENTS
CONTENTS

Data - Hydraulic (Servo Machines) (continued)
Machine Hydraulics
Backhoe Valve
Electric Supply Logic Box
Metering Characteristics Open Centre Load Sensed
Section Designation
- Bucket, Slew, Steering PVG 32
- Boom, Dipper PVG 120
Auxilary Relief Valve Pressures Bar kgf/cm2 lbf/in2
* - Boom Ram Head Side 266 - 280 271 - 285 3850 - 4060
* - Boom Ram Rod Side 341 - 355 348 - 362 4945 - 5148
* - Bucket Ram Head Side 303 - 317 309 - 323 4400 - 4600
* - Bucket Ram Rod Side 241 - 255 246 - 260 3500 - 3700
- Dipper Ram Head Side 241 - 255 246 - 260 3500 - 3700
- Dipper Ram Rod Side 241 - 255 246 - 260 3500 - 3700
* - Slew Left and Right 241 - 255 246 - 260 3500 - 3700
Main Relief Valve Pressure - see Note 1
* - machines up to serial no. 419307 260 265 3770
* - machines from serial no. 419308 230 235 3335
Valve Block Identification Refer to FIG 2, (view shown as fitted on machine)
- Spool 1 Boom
* A Rod Side
* B Head Side
- Spool 2 Dipper
- Spool 3 Bucket
* A Head Side
* B Rod Side
- Spool 4 Slew
* A&B Slew Cylinders
- Spool 5 Steering
* A Port ‘P’ Steer Mode Valve, Port ‘L’ Orbitrol Unit
* B Front Steer Rams - LH rod side & RH head side, Port ‘R’ Orbitrol Unit
* - Port C Load Sense Line Connection Port
* - Port D Pump
* - Port E Tank
* - Item F Pressure Test Point
* - Item G Valve Sections Interface
* Note 1: On machines up to serial number 419307

both the loader and the backhoe valves house main 1 2
relief valves. However, the main relief in the loader 3 4 5
valve is factory set at 260 bar and would therefore G
never reach 'cracking' pressure. The MRV in the
backhoe valve is set at 230 bar and therefore
controls the hydraulic system pressure. C
B B
B B B
On machines from serial number 419308 only the D E A A A
loader valve houses a main relief valve (a blanking
plug is fitted in the backhoe valve). The MRV in the A A
loader valve is set at 230 bar and controls the
hydraulic system pressure.
F
FIG 2 A193580
9804/1103 15 - 05 - 02/9 Issue 2*

CONTENTS
CONTENTS

Data - Hydraulic (Servo Machines) (continued)
Machine Hydraulics
Backhoe Valve (continued)
Output Descriptions (ISO + Pattern) Operation Port Neutral Full Deflection
- Boom Lift A 6V 3V
Lower B 6V 9V
- Dipper Lift B 6V 9V
Lower A 6V 3V
- Bucket Dump B 6V 9V
Crowd A 6V 3V
- Slew Left B 6V 3V
Right A 6V 9V
Auxiliary Valve
Relief Valve Pressures Bar kgf/cm2 lbf/in2
- Main 227 231.5 3300
- Auxiliary
Head 138 - 145 141-148 2000-2100
Rod Side 207 - 214 211 - 218 3000 - 3100
Slew Motion Control Valve - see Note 1
- Slew Left and Right 235 238.5 3408
Unloader Valve
- Unloader 207 211 3000
Hose Burst Protection Valves

200 204 2900
High Pressure Filter
Filter 'Clogged' Indicator - see Note 2 'Pop-up Button' Differential Pressure Indicator Mounted on Top of Filter
Note 1: ServoPlus machines from serial number 420485 are not fitted with a slew motion control valve. Instead, new type
spools are fitted on the slew service of the excavator valve block; these spools are also able to fine control the slewing motion
of the backhoe. In addition to the spools, new relief valves are fitted on the slew services. Technical Bulletin 2/148 also refers.
Note 2: On later machines the ‘pop-up’ visual indicator is deleted from the specification of the hydraulic filter. Make sure that
the filters are changed at the recommended interval.
9804/1103 15 - 05 - 02/10 Issue 1

CONTENTS
CONTENTS
Data - Hydraulic
Hydraulic Pumps
Model/Reference Double pump/4070H

Rotation (viewed on end of driveshaft) Anti-clockwise
Mounting Chassis (driveshaft driven)
Theoretical displacement: cc/rev cu in/rev
Pump section 1 (mounting flange end) 33 2.01
Pump section 2 23 1.40
Flow at 2200 rev/min and system pressure (95% displacement): litres/min UK gal/min
Maximum continuous pressure (P1) 230 bar (3335 lbf/in 2 )
Maximum speed @ pressure P1 3000 rev/min
Minimum speed @ pressure P1 500 rev/min
Approximate Weight 20.7kg (45.6 lbs)
Model/Reference Double pump/8282B
Approximate Weight 23.8kg (52 lbs)
Model/Reference Double pump/7441N
Approximate Weight 22kg (48.5 lbs)
Model/Reference Double pump/4071F
S273090
9804/1103 15 - 05 - 02/11 3270 - E/1-10.2 Issue 2*

CONTENTS
CONTENTS

Data - Hydraulics (cont’d)
Hydraulic Pumps (continued)

Machine models applicable to 4CX, 4CX Super
Type Variable Displacement
Reference A10VO - 978753
Load Sense Pressure (in neutral position) Maximum permitted - 5 bar; 72.5 lbf/in2
Load sense pressure relief Valve (if fitted) 230 bar; 3335 lbf/in2
Stand-by Pressure 20 bar; 290 lbf/in2
Maximum Hydraulic Stall Pressure
460001 to 472554 without relief valve 232 bar; 3364 lbf/in2
460001 to 472554 with relief valve and all from 472555 270 bar; 3915 lbf/in2
Maximum Displacement 74cc/rev; 4.5 in3/rev
Flow at 2200 rev/min and 2500 lb/in2 pressure †
- minimumum acceptable flow rate (new or rebuilt pump) 75 -80 litres/min; 16.5 - 17.6 UK gal/min
- minimumum acceptable flow rate (used pump) 70 - 75 litres/min; 15.4 - 16.5 UK gal/min
Flow in the Load Sense Line at 2200 rev/min (no pressure) 1 - 5 litres/min; 0.22 - 1.1 UK gal/min
Weight TBAkg (TBA lbs)
† Note: It is not possible to test full pump flow at system pressure, figures quoted give a ‘snapshot’ indication of pump
performance.
S273090
9804/1103 15 - 05 - 02/11A 3270 - E/1-10.2 Issue 1

CONTENTS

Data Hydraulic (cont’d)
Hydraulic Pumps (continued)
Model/Reference Single pump/6197C
Theoretical displacement 51 cc/rev; 3.11 cu in/rev
Flow at 2200 rev/min and system pressure (95% displacement): 104.5 litres/min; 22.9 UK gal/min
Maximum continous pressure (P1) 330 bar (4785 lbf/in2)
Model/Reference Single pump/J101702

Theoretical displacement 51 cc/rev; 3.05 cu in/rev
Flow at 2200 rev/min and system pressure (95% displacement): 105 litres/min; 23.1 UK gal/min
Maximum continous pressure (P1) 265 bar (3842 lbf/in2)
Approximate Weight 13 kg (28.6 lbs)
Relief Valve Operating Pressures: bar kgf/cm2 lbf/in2

Extradig Ram Head Side 138 - 145 141 - 148 2000 - 2100
Extradig Ram Rod Side 207 - 214 211 - 218 3000 - 3100
Jaw Bucket Ram Head Side 138 - 145 141 - 148 2000 - 2100
Jaw Bucket Ram Rod Side 207 - 214 211 - 218 3000 - 3100
Knuckle Ram Head Side 138 - 145 141 - 148 2000 - 2100
Knuckle Ram Rod Side 207 - 214 211 - 218 3000 - 3100
Hammermaster 207 - 214 211 - 218 3000 - 3100
Power Sideshift (both) 207 - 214 211 - 218 3000 - 3100
Roadbreaker 138 - 150 141 - 153 2000 - 2200
Weight:
TBA kg (TBA lbs)
Stabiliser Check Valve Relief Valve (Centremount M/c's)

Check Valve 303 - 317 309 - 323 4400 - 4600
Weight:
TBA kg (TBA lbs)
Hydraulic Filter Element

By-pass pressure 3.0 - 3.5 3.0 - 3.6 43.5
9804/1103 15 - 05 - 02/12 3270 - E/1-2.2 Issue 2*

CONTENTS
CONTENTS
Data - Hydraulic (cont’d)
Loader Valve
Machine Models applicable to:
3CX, 4CX, 214, 215, 217, ‘S’ Series
Valve Block Identification:

ITEM DESCRIPTION ITEM DESCRIPTION
1 Arms lift service 8 Unloader solenoid
2 Shovel service 9 Auxiliary relief valve
3 Auxiliary (optional) 10 Tank port
4 Pump section 1 - inlet 11 High pressure carry-over (HPCO) port
5 Pump section 2 - inlet 12 Service ports
6 Pressure test port 13 Load hold check valve assemblies
7 Unloader Assembly 14 Data plate

Unloader Valve 203 - 207 207 - 211 2950 - 3000
Loader
Weight
25kg (55lbs)
1 2 3
7
9
8
@ @ @
6
5 $ £
0 !
@ @ @
4
A262160
9804/1103 15 - 05 - 02/13 3270 - E/1-3.2 Issue 2*

CONTENTS
Loader Valve
Machine Models Applicable to:
3CXE, 214E Series 3

ITEM DESCRIPTION
1 Arms lift service
2 Shovel service
3 Pump inlet
4 Tank port
5 Auxiliary relief valve
6 High pressure carry-over (HPCO) port
7 Service ports

Loader
Weight:
8kg (17.6lbs)
A262420
9804/1103 15 - 05 - 02/14 3270 - E/1-4.2 Issue 2*

CONTENTS
CONTENTS

Loader Valve
214e Series 4

ITEM DESCRIPTION
1 Auxiliary service
2 Arms lift service
3 Shovel service
4 Pump inlet
5 Tank port
7 High pressure carry-over (HPCO) port
8 Service ports

Main Relief Valve (M.R.V.) 228 - 235 233 - 239 3300 - 3400
Loader
Note: The pressure testing and adjustment MUST be carried out as detailed on pages E/13-1 to E/13-8.
Weight:
10 kg (22 lbs)
A313430
9804/1103 15 - 05 - 02/15 3270 - E/1-5.3 Issue 2*

CONTENTS
CONTENTS

Loader Valve
4CX, 4CX Super

1 Auxiliary (optional) service 8 Priority work port (to steer until)
2 Shovel service 9 Load sense carry over port (to backhoe valve)
3 Arms lift service 10 Service ports
4 Pump inlet 11 Auxiliary relief valve (rod side)
5 Tank port 12 Auxiliary relief valve (head side)
6 Load sense port (to pump) 13 Priority relief valve†
7 Priority load sense port (from steer unit)

Priority Relief Valve† 170 - 176 173 - 179 2450 - 2550
Auxiliary Relief Valves (A.R.V.) @ 0.5gal/min (1.9 litres/min)
† Note: Steer circuit pressure is controlled by a relief valve housed in the orbitrol unit (see section H). The priority relief valve
housed in the loader valve must be set at 2500 lb/in2, this will ensure it does not interfere with the operation of the relief valve
housed in the orbitrol unit.
Weight:
2 Spool - TBA kg (TBA lbs)
3 Spool - TBA kg (TBA lbs)
A273670
9804/1103 15 - 05 - 02/16 3270 - E/1-11.1 Issue 1

CONTENTS

Backhoe Valve
3CX, 3CXE, 4CX, 214, 214E, 215, ‘S’ Series

1 Bucket crowd 8 Tank port
2 Dipper † 9 High pressure carry-over (HPCO) port
3 Stabiliser 10 Service ports
4 Stabiliser 11 Load hold check valve assemblies
5 Boom † 12 Make-up check valve assembly
6 Slew

Boom Ram Head Side 241 - 255 246 - 260 3500 - 3700
Boom Ram Rod Side 338 - 352 344 - 358 4900 - 5100
Bucket Ram Head Side
Centremount (17' , 15’ 6” backhoe - except knuckle) 303 - 317 309 - 323 4400 - 4600
Centremount (14' backhoe, 15’ 6” backhoe with a knuckle fitted) 241 - 255 246 - 260 3500 - 3700
Sideshift 241 - 255 246 - 260 3500 - 3700
Bucket Ram Rod Side (Machines with Powerbreaker only) 241 - 255 246 - 260 3500 - 3700
Dipper Ram Head Side 241 - 255 246 - 260 3500 - 3700
Slew Left and Right 255 - 269 260 - 274 3700 - 3900
Weight:
44 kg (97 lbs) - Centremount
46 kg (101 lbs) - Sideshift
† System shown is for JCB plus pattern and JCB diagonal pattern. For ISO system, the boom and dipper spools change
position, i.e. boom is position 2 and dipper is position 5. The bottom ARV from spool 5 will also be swapped with the bottom
ARV from spool 2.
1 2 3 4 5 6
7 7 7
8
0 0 0 0 0 0
9
! ! ! ! ! !
@
0 0 0 0 0 0
FIG SHOWS A 7 7 7 7
CENTREMOUNT VALVE A262520
9804/1103 15 - 05 - 02/17 3270 - 3/1-2.2 Issue 1

CONTENTS
CONTENTS
2DX, 212 and Variants (except 2CX) From m/c no. 460001
Data Transmission
Front Axle
Note: It is essential that the correct ratio axle in relation to the gearbox ratio is fitted to the machine. Do not fit a new axle with
a
different ratio to the axle being replaced.
ALL WHEEL STEER MACHINES

Designation SD70
Installation Centre pivot
Weight
(dry, with no steer rams and without wheels) 385 kg (850 lbs) approximately
Crownwheel and Pinion Ratio 4.625:1
Number of Teeth
Crownwheel 37
Pinion 8
Hub Reduction 5.4:1
Input Type Yoke
Oscillation ± 5°
Toe - in 0°
Castor Angle 0°
Camber Angle 1°
King - pin inclination 0°
2 WHEEL STEER MACHINES (4 Wheel Drive)

Designation SD55
Weight
(dry, with no steer rams and without wheels) 330 kg (728 lbs) approximately
Hub Reduction 5.4:1
Input Type Yoke
Oscillation ± 5°
Toe - in 0°
Castor Angle 0°
Camber Angle 1°
Ratios OPTION 1 OPTION 2
Overall 16.2:1 19.2:1
Crownwheel and Pinion 3:1 3.556:1
Number of Teeth
Crownwheel 33 32
Pinion 11 9
2 WHEEL STEER MACHINES (2 Wheel Drive)
Type JCB centre oscillation, non-driven

Weight
(dry, with steer ram and without wheels) 239 kg (525 lbs)
Oscillation ± 5°
Toe - in 0°
Castor Angle 0°
Camber Angle 3 ° positive
9804/1103 15 - 05 - 03/1 3270 - F/1-2.2 Issue 2*

CONTENTS
CONTENTS
Rear Axle
Note: It is essential that the correct ratio axle in relationship to the gearbox ratio is fitted to the machine. Do not fit a new axle
with a different ratio to the axle being replaced.

Type 3 piece, JCB spiral bevel input with epicyclic hub reduction and inboard braking
Designation SD70
Installation Rigid pad mount
Number of steer rams 1 (Double rod)
Weight (dry, with no steer rams 410 kg (904 lbs) approx.
and without wheels)
Half (Axle) Shaft Braking/Type 5 friction plate, 6 counter plate (each half shaft)
Input Type Yoke
Oscillation ± 5°
Toe - in 0°
Castor Angle 0°
Camber Angle 1°
Hub Reduction 5.4:1
Ratios OPTION 1 OPTION 2 OPTION 3
Overall 15.78:1 18.16:1 13.7:1
Crownwheel and Pinion 2.923:1 3.363:1 2.538:1
Number of Teeth
Crownwheel 38 37 33
Pinion 13 11 13
* Note: From 1st April 1999 the hub is splined and not doweled. Machine serial number TBA.
2 WHEEL STEER MACHINES

Type 3 piece, JCB spiral bevel input with epicyclic hub reduction and inboard braking
Designation PD70
Installation Rigid pad mount
Weight (dry and without wheels) 386 kg (851 lbs) approx.
Half (Axle) Shaft Braking/Type 5 friction plate, 6 counter plate (each half shaft)
Input Type Yoke
Hub Reduction 5.4:1
Ratios OPTION 1 OPTION 2 OPTION 3
Overall 15.78:1 18.16:1 13.7:1
Crownwheel and Pinion 2.923:1 3.363:1 2.538:1
Number of Teeth
Crownwheel 38 37 33
Pinion 13 11 13
9804/1103 15 - 05 - 04/1 3270 - F/1-2.2 Issue 3*

CONTENTS
CONTENTS

Data - Transmission (continued)
Tyre Sizes and Pressures
TWO WHEEL STEER MACHINES
Type Size Ply Pressure
bar lbf/in2
Front - 2WD
Ribbed (Armstrong) 11L x 16 12 4.4 64
Ribbed (Goodyear) 11.0 x 16 12 4.2 60
Industrial 11L x 16 12 4.4 64
Industrial 10.5 x 18 10 3.8 55
Industrial 12.0 x 18 12 3.5 50
Front - 4WD
† Industrial 14 x 17.5 10 3.8 55
Traction 10.5 x 18 10 3.8 55
Industrial (Firestone) 12.0 x 18 12 3.5 50
Industrial (Olympic) 12.0 x 18 12 4.5 65
Radial 335/80 x R18 XM27 3.5 50
Industrial 12.5/80 x 18 10 4.25 61 * (see WARNING below)
† Radial 335/80 - R20 XM27 3.0 43.5
† Radial 12.5 - R20 XM27 3.0 43.5
Industrial 12.5/12.0 x 18 12 3.5 50
Rear - 2WD & 4WD

Industrial 16.9 x 24 10 2.2 32
Industrial 19.5L x 24 10 1.9 27.5
Industrial 19.5L x 24 12 2.3 33
Industrial 21L x 24 12 2.2 32
Traction (Goodyear) 18.4 x 26 12 2.5 36 * (see WARNING below)
Traction (Olympic) 18.4 x 26 12 2.0 29
Industrial 18.4 x 26 12 2.0 29
Traction 16.9 x 28 12 2.4 35
Industrial 16.9 x 28 12 2.2 32
Radial 16.9 - R28 XM27 3.1 45
Industrial 18.4 x 30 14 2.0 29

Front and Rear - 4WD
† Industrial 16.9 x 28 10 2.2 32 * (see WARNING below)
† Industrial 16.9 x 28 12 2.6 38
† Industrial 16.9 x 28 14 2.6 38
Industrial 16.9 x 24 12 2.6 38
† Radial 16.9 x R28 XM27 3.1 45
Radial 15.5 x 25 XTLA 2.5 36 * (see WARNING below)
Note: 12 ply tyres must be fitted on rear wheels when any backhoe attachment is used. For the correct pressure see the table
above. The front wheels from machine serial number 400001 are made from a stronger construction than front wheels fitted
prior to 400001. Wheels fitted to Backhoe Loaders prior to 400001 must not be used on the new Backhoe Loaders.
† Steering lock restriction stops must be fitted to 4 wheel drive machines that have this type of tyre fitted, consult your JCB
Distributor for advice.
WARNING: Tyres indicated above with an asterix (*) are not recommended or approved for use on 5-speed machines. DO
NOT use these tyres on 5-speed machines.
9804/1103 15 - 05 - 05/1 Issue 3

CONTENTS
CONTENTS

Front Wheels
Note: If the tyres fitted to your machine are not listed, then contact JCB for advice, DO NOT guess tyre pressures.
Front Wheels
AWS/4WD MACHINES
Item Size x Ply Type Make Remarks Pressure
bar lbf/in2
1 16.9x24x12 IND ARMSTRONG TUBELESS 2.6 38
2 16.9x24x12 IND GOODYEAR TUBELESS 2.6 38
3 15.5x25 XTLA MICHELIN TUBELESS 2.5 36
7 16.9x28 XM27 MICHELIN TUBELESS 2.7 39
8 16.9x28x14 IND NOKIA TUBE 2.6 38
10 16.9x28x12 TRAC OLYMPIC TUBELESS 2.6 38
11 16.9x28x12 IND OLYMPIC TUBE 2.6 38
13 16.9x28 IND GOODYEAR TUBELESS 2.5 36
2WS/2WD MACHINES
21 11.0x16x12 RIB ARMSTRONG TUBELESS 4.4 64
22 11.0x16x12 RIB GOODYEAR TUBELESS 4.2 61
23 11Lx16x12 IND ARMSTRONG TUBELESS 4.4 64
24 10.5x18x10 IND FIRESTONE TUBELESS 3.8 55
2WS/4WD MACHINES
31 14x17.5x10 IND ARMSTRONG TUBELESS 3.8 55
32 14x17.5x10 IND GOODYEAR TUBELESS 3.8 55
35 12.0x18x12 IND OLYMPIC TUBELESS 4.25 62
36 335 x18 XM27 MICHELIN TUBELESS 3.5 51
38 335 x20 XM27 MICHELIN TUBE 3.0 43.5
39 340 x18 IND GOODYEAR TUBELESS 3.2 46
Items 4, 5, 6, 7,8, 9, 10, 11, 13, 38 must have steering lock restriction stops fitted.
9804/1103 15 - 05 - 05/2 3270 - F/1-3.1 Issue 1

CONTENTS

Rear Wheels
Note: If the tyres fitted to your machine are not listed, then contact JCB for advice, DO NOT guess tyre pressures.
AWS MACHINES
Item Size x Ply Type Make Remarks Pressure
bar lbf/in2
3 15.5x25 XTLA MICHELIN TUBELESS 2.5 36
8 16.9x28x14 IND NOKIA TUBE 2.6 38
11 16.9x28x12 IND OLYMPIC TUBE 2.6 38
2WS MACHINES
21 16.9x24x10 IND ARMSTR0NG TUBELESS 2.2 32
22 16.9x24x12 IND GOOOYEAR TUBELESS 2.2 32
25 21L x24x12 IND GOODYEAR TUBELESS 2.2 32
26 18.4x26x12 TRAC GOODYEAR TUBELESS 2.5 36
30 16.9x28x12 TRAC FIRESTONE TUBE 2.2 32
33 18.4x30x14 IND GOODYEAR TUBE 2.0 29
Note: 12 ply tyres must be fitted on rear wheels when any backhoe attachment is used. For the correct pressure see the table
above.
Items 4, 5, 6, 7,8, 9, 10, 11, 13 must have steering lock restriction stops fitted.
9804/1103 15 - 05 - 05/3 3270 - F/1-4.1 Issue 1

CONTENTS
CONTENTS

Data - Transmission (cont’d)
Syncro Shuttle
Designation SS640 (4 wheel drive)
Number of Teeth Std Ratio Low Ratio
Transfer Gear 36 38
Layshaft 19 17
Input Gear (4WD)
- 2WS 24 26
- AWS 24 24
Output Gear (4WD)
- 2WS 34 32 or 33
- AWS 34 34
Gear Ratios Std Ratio Low Ratio
1st 5.56:1 6.56:1
2nd 3.45:1 4.06:1
3rd 1.83:1 1.90:1
4th 1.00:1 1.00:1
Torque Converter Dia. 279mm (11in.)
Torque Multiplication at Stall 2.20:1 or
2.40:1 or
2.80:1
Torque Converter Colour Code Identification 2.20:1 Ratio 2.40:1 Ratio 2.80:1 Ratio
Colour Coded Dots 2 purple 2 Orange 3 Brown
1 White 1 Green
Minimum Engine Rev/Min at Converter Stall See pages 15 - 05 - 07/3 and 07/4

2000 rev/min 5.2 - 6.5 5.3 - 6.7 75 - 95

2000 rev/min 5.2 - 5.9 5.3 - 6.0 75 - 85

2000 rev/min 1.0 - 1.7 1.1 - 1.8 15 - 25
Lubrication Pressures (in neutral) bar kgf/cm2 lbf/in2

At 50 deg.C 1000 rev/min 0.2 - 0.3 0.2 - 0.4 3.0 - 5.0
2000 rev/min 0.4 - 0.7 0.4 - 0.7 6.0 - 10.0
At 100 deg.C 1000 rev/min 0.1 - 0.2 0.1 - 0.2 2.0 - 3.0
2000 rev/min 0.3 - 0.6 0.3 - 0.6 4.0 - 8.0
.....cont'd
9804/1103 15 - 05 - 06/1 Issue 2

CONTENTS
CONTENTS

Syncro Shuttle (cont'd)
Main Line Pressure (in neutral) bar kgf/cm2 lbf/in2
At 50 deg. C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
2000 rev/min 10.7 - 11.7 10.9 - 12.0 155 - 170
At 100 deg.C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
2000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
Clutch Pressure (forward and reverse) bar kgf/cm2 lbf/in2

At 50 deg. C 1000 rev/min 8.3 - 9.0 8.4 - 9.1 120 - 130
2000 rev/min 9.0 - 10.0 9.1 - 10.2 130 - 145
At 100 deg.C 1000 rev/min 8.3 - 9.0 8.4 - 9.1 120 - 130
2000 rev/min 8.3 - 9.0 8.4 - 9.1 120 - 130
Clutch Pressure (to disconnect 4 wheel drive)
At 50 deg. C 1000 rev/min 8.6 - 9.3 8.8 - 9.5 125 - 135

2000 rev/min 8.6 - 9.3 8.8 - 9.5 125 - 135
Flow Rates (in neutral) L/min US gal/min UK gal/min

2000 rev/min 14.5 - 20.0 3.8 - 5.3 3.2 - 4.4
2000 rev/min 22.7 - 26.1 6.0 - 6.9 5.0 - 5.7
2000 rev/min 22.5 - 29.5 6.0 - 7.8
9804/1103 15 - 05 - 06/2 Issue 2

CONTENTS
CONTENTS

Powershift
Description Full electro-hydraulic transmission unit with input, reverse,
layshaft, mainshaft and 4 wheel drive clutch packs. Torque
converter and parking brake integral .
Designation PS740 (4 wheel drive)
Weight (dry) - 4-Speed Gearbox 236 kg (520 lb)
Weight (dry) - 5-Speed Gearbox 265 kg (585 lb)
Number of Teeth Std Ratio Low Ratio
Transfer Gear 45 46
Layshaft 18 16
Input Gear (4WD)
- 2WS 26 26 or 25
- AWS 24 24
Output Gear (4WD)
- 2WS 41 41
- AWS 44 44
1st 5.72:1 6.58:1
2nd 3.23:1 3.71:1
3rd 1.77:1 1.77:1
4th 1.00:1 1.00:1
5th (if fitted) 0.788:1 0.788:1
Torque Multiplication at Stall 2.20:1 or 2.40:1 or 2.80:1
Torque Converter Colour Code Identification 2.20:1 Ratio 2.40:1 Ratio 2.80:1 Ratio
Colour Coded Dots 2 Purple 2 Orange 3 Brown
1 White 1 Green
5-Speed Gearboxes Only - 1 Black 2 Black N/A

1 Orange 1 Green
Minimum Engine Rev/Min at Converter Stall See pages 15-05-07/3 & 15-05-07/4

2000 rev/min 4.8 - 6.2 4.9 - 6.3 70 - 90
2000 rev/min 2.3 - 2.7 2.3 - 2.7 33 - 39

At 50 deg.C 1000 rev/min 0.14 - 0.28 0.14 - 0.28 2.0 - 4.0
2000 rev/min 0.28 - 0.55 0.28 - 0.56 4.0 - 8.0
9804/1103 15 - 05 - 07/1 Issue 2

CONTENTS
CONTENTS

Powershift (cont'd)
Mainline Pressure (in neutral) bar kgf/cm2 lbf/in2
At 50 deg. C 1000 rev/min 9.0 - 10.0 9.1 - 10.2 130 - 145
2000 rev/min 9.7 - 11.0 9.8 - 11.3 140 - 160

2000 rev/min 14.5 - 20.0 3.8 - 5.3 3.2 - 4.4
2000 rev/min 22.5 - 29.5 6.0 - 7.8 5.0 - 6.5
The following clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2):
Input Clutch Pressure (high and low ratio)

Reverse Clutch Pressure (high and low ratio)
Layshaft Clutch Pressure
Mainshaft Clutch Pressure
2/4 Wheel Drive Clutch Pressure
9804/1103 15 - 05 - 07/2 Issue 2

CONTENTS
CONTENTS

Syncro Shuttle
Designation SS640 (4 wheel drive)
Weight (dry)
2WD 157 kg (346 lb)
4WD 176 kg (388 lb)
1st 5.56:1 6.56:1
2nd 3.45:1 4.06:1
3rd 1.83:1 1.90:1
4th 1.00:1 1.00:1
Torque Convertor
Torque Converter Dia. 310 mm (12.2 in.)
Torque Converter Identification 12.2 - D 12.2 - P
Torque Multiplication at Stall 2.82:1 2.54:1
Torque Convertor Colour Coded Dots 2 Purple 2 Orange
1 Yellow 1 Yellow

2000 rev/min 5.2 - 6.5 5.3 - 6.7 75 - 95
2000 rev/min 5.2 - 5.9 5.3 - 6.0 75 - 85
2000 rev/min 1.0 - 1.7 1.1 - 1.8 15 - 25

At 50 deg.C 1000 rev/min 0.2 - 0.3 0.2 - 0.4 3.0 - 5.0
2000 rev/min 0.4 - 0.7 0.4 - 0.7 6.0 - 10.0
At 100 deg.C 1000 rev/min 0.1 - 0.2 0.1 - 0.2 2.0 - 3.0
2000 rev/min 0.3 - 0.6 0.3 - 0.6 4.0 - 8.0
Main Line Pressure (in neutral) † bar kgf/cm2 lbf/in2

At 50 deg. C 1000 rev/min 9.7 - 12.8 9.8 - 13.0 140 - 185
2000 rev/min 11.4 - 14.1 11.6 - 14.4 165 - 205
At 100 deg.C 1000 rev/min 11.4 - 12.8 11.6 - 13.0 165 - 185
2000 rev/min 11.4 - 13.4 11.6 - 13.7 165 - 195
Clutch Pressures † All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2)

2000 rev/min 14.5 - 20.0 3.8 - 5.3 3.2 - 4.4
2000 rev/min 22.7 - 26.1 6.0 - 6.9 5.0 - 5.7
2000 rev/min 22.5 - 29.5 6.0 - 7.8 5.0 - 6.5
† Note: For gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be slightly
higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2 ).
9804/1103 15 - 05 - 07/2A 3270 - F/1-5.1 Issue 1

CONTENTS
Backhoe Loaders 15 - 05 - 07/2B

Powershift
Description Full electro-hydraulic transmission unit with input, reverse,
layshaft, mainshaft and 4 wheel drive clutch packs. Torque
converter and parking brake integral .
Designation PS740 (4 wheel drive) and PS750
Weight (dry)
2WD 220 kg (484 lb)
4WD 236 kg (519 lb)
1st 5.72:1 6.58:1
2nd 3.23:1 3.71:1
3rd 1.77:1 1.77:1
4th 1.00:1 1.00:1
Torque Convertor
Torque Converter Dia. 310 mm (12.2 in.)
Torque Converter Identification 12.2 - D 12.2 - P
Torque Multiplication at Stall 2.82:1 2.54:1
Torque Convertor Colour Coded Dots 2 Purple 2 Orange
1 Yellow 1 Yellow
2000 rev/min 4.8 - 6.2 4.9 - 6.3 70 - 90

2000 rev/min 2.3 - 2.7 2.3 - 2.7 33 - 39

At 50 deg.C 1000 rev/min 0.14 - 0.28 0.14 - 0.28 2.0 - 4.0
2000 rev/min 0.28 - 0.55 0.28 - 0.56 4.0 - 8.0
Main Line Pressure (in neutral) † bar kgf/cm2 lbf/in2

At 50 deg. C 1000 rev/min 9.7 - 12.8 9.8 - 13.0 140 - 185
2000 rev/min 11.4 - 14.1 11.6 - 14.4 165 - 205
At 100 deg.C 1000 rev/min 11.4 - 12.8 11.6 - 13.0 165 - 185
2000 rev/min 11.4 - 13.4 11.6 - 13.7 165 - 195
Clutch Pressures † All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2)

2000 rev/min 14.5 - 20.0 3.8 - 5.3 3.2 - 4.4
2000 rev/min 22.5 - 29.5 6.0 - 7.8 5.0 - 6.5
† Note: For new gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be
slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2 ).
9804/1103 15 - 05 - 07/2B 3270 - F/1-6.2 Issue 1

CONTENTS
CONTENTS

Stall Figures
The figures given below and on the following page apply to 'bedded-in' engines, i.e. engines that have done a minimum of 250
working hours, therefore they should not be used for PDI checks. They are intended to be used as guideline figures only and
should not be considered as servicing parameters.
4CX 4CX 4CX 4CX 217S

214S option option N.Am.
215S Nordic Malasia
N.Am. Iceland
ServoPlus
Engine Stall Speed

1 Converter only
max r.p.m. 2170 2130 2160 2120 2100
min. r.p.m. 2100 2065 2085 2055 2030
2 Converter + MRV
max. r.p.m. 1795 1770 1685 1660 1640
min. r.p.m. 1700 1670 1575 1550 1530
Build Specification
Engine Size N.A. (74 bhp)
T2 (90 bhp)
T3 (96 bhp) ● ● ● ● ●
Converter Type SSL 11 (2.8:1)

WH 11 (2.4:1) ● ● ● ● ●
W11 (2.2:1)
Pump Size 26 gal

(UK gals) 28 gal
30 gal ● ●
34 gal ● ● ●
Fan Ratio 1 to 1 ● ●
1 to 1.25 ● ●
1 to 1.36 ●
9804/1103 15 - 05 - 07/3 Issue 1

CONTENTS
9804/1103

3CX, 4CX, (200 Series)
CONTENTS
Stall Figures
TWO WHEEL STEER MACHINES
Note: All tests conducted with single pump option selected unless specified thus #, then tests to be conducted with double pump option selected.
3CX 3CX 214 3CXT 3CXT 3CXT+ 3CXT+ 3CXT 3CXT 214T 215 217
N.Am. option option N.Am. N.Am. N.Am.
Nordic South
Iceland Africa
Engine Stall Speed
Backhoe Loaders
1 Convertor Only max r.p.m. 1755 1735 2215# 1900 1875 1890 1870 1880 1860 2070 2065 1915
min r.p.m. 1695 1670 2145# 1830 1810 1820 1800 1810 1790 2000 1995 1840
2 Convertor + MRV max r.p.m. 1360 1340 1830# 1525 1510 1515 1495 1380 1365 1730 1675 1465
15 - 05 - 07/4
min r.p.m. 1260 1245 1730# 1420 1405 1410 1390 1220 1200 1630 1570 1345
Build Specification
Engine Size N.A. (74 bhp) ● ● ●

T2 (90 bhp) ● ● ● ● ● ● ● ●
T3 (96 bhp) ●
Convertor Type SSL 11 (2.8:1) ●

WH 11 (2.4:1) ● ●
W11 (2.2:1) ● ● ● ● ● ● ● ● ●
Pump Size 26 UK gal. ● ● ● ●

(U.K. gals) 28 UK gal. ● ●
30 UK gal.
From m/c no. 400001

● ● ●
34 UK gal. ● ● ●
Fan Ratio 1 to 1 ● ● ● ●
1 to 1.25 ● ● ● ● ● ● ●
1 to 1.36 ●
15 - 05 - 07/4
Issue 1
9804/1103 CONTENTS

3CX, 4CX and Variants
Pump/Transmission Stall Speed Combinations 2WS Machines, 12.2 Convertor, Gear Pump, 1000 Series Engine
CONTENTS
Note. On all double pump options the test is to be carried out with single pump option selected.
3CXE 3CX 3CXT 3CXT 3CXT 3CXT 3CXT 3CXT 214E 214 214T/215E 214T/215E 215/217 215/217
N. Am. N. Am. N. Am. N. Am. N. Am. N. Am.
Engine Speed @ Stall Combination

1.Convertor only.
Max.r.p.m. 1880 1905 2040 2015 2040 2015 2100 2070 2160 2200 2230 2220 2070 2060
Min.r.p.m. 1790 1800 1935 1910 1935 1910 2000 1980 2050 2095 2170 2160 1975 1960
2.Convertor + M.R.V.
Max.r.p.m. 1100 1465 1575 1550 1475 1445 1655 1635 1345 1650 1745 1720 1630 1620
Min.r.p.m. stall 1365 1430 1405 1310 1270 1560 1545 1140 1575 1620 1580 1540 1540
Build specification.
Backhoe Loaders
Engine size.
N.A. (75hp) (56kw) ● ● ● ●
T2 (91hp) (68kw) ● ● ● ● ● ●
15 - 05 - 07/5
T3 (96hp) (72kw) ● ● ● ●
Convertor type.
12.2D (2.82) ● ● ● ●
12.2P (2.54) ● ● ● ● ● ● ● ● ● ●
Pump size.
50cc ● ●
33/23cc ● ●
36/26cc ● ●
41/26cc ● ● ● ● ● ●
41/29cc ● ●
Fan Ratio.
1 to 0.85 ● ● ● ● ● ● ● ●
3270 - F/1-7.1
From m/c no. 460001

1 to 1.06 ● ● ● ● ●
1 to 1.16 ●
Air Conditioning
None (Europe) ● ● ● ● ●
15 - 05 - 07/5
None (R.O.W.) ● ● ● ● ● ● ● ● ●
Europe ● ● ●
Europe (Hot) ● ● ●
Isssue 1
R.O.W. ● ● ● ● ●
9804/1103 CONTENTS

Pump/Transmission Stall Speed Combinations - AWS Machines, 12.2 Convertor, Gear Pump, 1000 Series Engine
CONTENTS
3CXSuper 3CXSuper 4CX 4CX 4C/4CN 4C/4CN 4C/4CN 214S 214S 215S/217S 215S/217S
N. Am. N. Am. N. Am. N. Am.

1.Convertor only.
Max.r.p.m. 2040 2015 2100 2070 2095 2070 2060 2100 2075 2070 2060
Min.r.p.m. 1935 1910 2000 1980 2000 1975 1960 2000 1980 1975 1960
Max.r.p.m. 1575 1550 1655 1635 1650 1630 1620 1655 1635 1630 1620
Min.r.p.m. 1430 1405 1560 1545 1560 1540 1530 1560 1545 1540 1530
Backhoe Loaders
Engine size.
N.A. (75hp) (56kw)
T2 (91hp) (68kw) ● ●
● ● ● ● ● ● ● ● ●
15 - 05 - 07/6
T3 (96hp) (72kw)
Convertor type
12.2D (2.82)
12.2P (2.54) ● ● ● ● ● ● ● ● ● ● ●
Pump size.
50cc
33/23cc
36/26cc ● ●
41/26cc ● ● ● ●
41/29cc ● ● ● ● ●
Fan Ratio.
1 to 0.85 ● ● ● ●
3270 - F/1-8.1
From m/c no. 460001

1 to 1.06 ● ● ● ● ●
1 to 1.16 ● ●
Air Conditioning
None (Europe) ● ● ●
15 - 05 - 07/6
None (R.O.W.) ● ● ● ● ● ●
Europe ● ● ● ●
Europe (Hot) ●
Issue 1
R.O.W. ● ● ● ● ●
CONTENTS
9804/1103
Data Transmission (cont’d)

Pump/Transmission Stall Speed Combinations - AWS Machines, 12.2 Convertor, Variable Pump, 1000 Series Engine
CONTENTS
4CX 4CX 4CXSuper 4CXSuper 4CXSuper

1.Convertor only.
Max.r.p.m. 2155 2130 2155 2130 2155
Min.r.p.m. 2055 2035 2055 2035 2020
Engine size.
N.A. (75hp) (56kw)
T2 (91hp) (68kw)
T3 (96hp) (72kw) ● ● ● ● ●
Backhoe Loaders
Convertor type
12.2D (2.82)
12.2P (2.54) ● ● ● ● ●
15 - 05 - 07/7
Pump size.
74 Variable ● ● ● ● ●
Fan Ratio.
1 to 0.85 ● ●
1 to 1.06 ● ●
1 to 1.16 ●
Air Conditioning
None (Europe) ● ●
None (R.O.W.) ● ●
Europe ● ●
Europe (Hot) ● ●
R.O.W. ● ●
3270 - F/1-9.2
From m/c no. 460001

15 - 05 - 07/7
Issue 1
9804/1103 CONTENTS

Low Emission Engine Stall Speed Combinations - 2WS Machines
CONTENTS
3CX 3CXT 3CXT 3CXT 3CXT 3CX 3CX 214E 214e 214 214e.T 215E 215E 215
214T 214T 217
Std lift Std lift Hi. lift Hi. lift Contractor Contractor N. Am. N. Am. N. Am. N. Am. N. Am. N. Am. N. Am.

1.Convertor only.
Max.r.p.m. 1965 2080 2070 2080 2070 2135 2125 2170 2240 2220 2240 2240 2230 2120
Min.r.p.m. 1850 1975 1960 1980 1965 2030 2020 2075 2170 2110 2170 2165 2160 2015
Max.r.p.m. 1520 1735 1720 1675 1660 1770 1760 1415 1555 1770 1745 1890 1875 1760
Min.r.p.m. 1380 1615 1600 1545 1530 1660 1650 stall 1280 1625 1580 1760 1745 1645
Backhoe Loaders
Engine size.
N.A. (75hp) (56kw) ● ● ● ●
T1 (80hp (60kw) ●
● ● ● ● ● ●
15 - 05 - 07/8
T2 (91hp) (68kw)
T3 (100hp) (74kw) ● ● ●
Convertor type.
SSL11(2.83) ● ●
12.2D (2.82) ● ● ● ● ●
12.2P (2.54) ● ● ● ● ● ● ●
Pump size.
50cc ● ● ●
33/23cc ● ●
36/26cc ● ●
41/26cc ● ● ● ● ● ●
41/29cc ●
3270 - F/1-10.2
From m/c no. 460001

Fan Ratio.
1 to 0.85 ● ● ● ●
1 to 1.06 ● ● ● ● ●
1 to 1.16 ● ● ● ● ●
15 - 05 - 07/8
Air Conditioning ● ●
None ● ● ● ● ● ● ● ● ● ●
Europe ● ● ●
Issue 1
ROW ● ● ●
CONTENTS
9804/1103

Low Emission Engine Stall Speed Combinations - AWS Machines
CONTENTS
3CXS 3CXS 3CXS 3CXS 4CX 4CX 4CXS/4C 4CXS/4C 4CXS 4CXS 214S 215S/217S
Std lift Std lift Hi. lift Hi. lift 4CX 4CX N. Am. N. Am.

1.Convertor only.
Max.r.p.m. 2080 2070 2080 2070 2135 2125 2135 2120 2180 2170 2125 2120
Min.r.p.m. 1975 1965 1980 1965 2030 2020 2030 2015 2080 2065 2020 2015
Max.r.p.m. 1735 1720 1675 1660 1770 1760 1770 1760 1760 1760
Min.r.p.m. 1615 1600 1545 1530 1660 1650 1660 1645 1650 1645
Backhoe Loaders
Engine size.
N.A. (75hp) (56kw)
T2 (91hp) (68kw) ● ● ● ●
T3 (100hp) (74kw) ● ● ● ● ● ● ● ●
15 - 05 - 07/9
Convertor type
12.2D (2.82)
12.2P (2.54) ● ● ● ● ● ● ● ● ● ● ● ●
Pump size.
50cc
33/23cc
36/26cc ● ●
41/26cc ● ● ● ● ●
41/29cc ● ● ●
74 Variable ● ●
Fan Ratio.
3270 - F/1-11.1
From m/c no. 460001

1 to 0.85
1 to 1.06 ● ● ● ● ●
1 to 1.16 ● ● ● ● ● ● ●
Air Conditioning ● ●
15 - 05 - 07/9
None (Europe) ● ● ● ● ●
None ● ●
Europe ● ● ● ● ●
Issue 1
Europe (Hot)
R.O.W. ● ● ● ● ●
CONTENTS
CONTENTS

Data - Brakes
STANDARD MACHINES
Service Brake
Actuation Hydraulic - vacuum servo assisted for machines powered by model
AB turbocharged engine
Location Rear Axle Centre Casing (2 brake packs)
Friction Plates (5 per brake pack)

Nominal Facing Area per Plate 12616 mm2 (19.3 in2)
Hydraulic Piston Diameter 216 mm (8.5 in)
Master Cylinder (combined servo assistance)

Number of Cylinders 2
Type Frenos compensated master cylinder
Piston Diameter (each) 22.22 mm (0.875 in)
Exhauster
Type Frenos Iruna
Parking Brake
Type Manually Adjusted Caliper, cable operated, mounted on transmission
output
SERVO MACHINES
Service Brake
Type As 'Standard Machines'
Actuation As 'Standard Machines'
Location As 'Standard Machines'

Outside Diameter As 'Standard Machines'
Inside Diameter As 'Standard Machines'
Nominal Facing Area per Plate As 'Standard Machines'
Hydraulic Piston Diameter As 'Standard Machines'
Master Cylinder
Number of Cylinders 3 (two front and one rear)
Type
Front Frenos compensated master cylinder with integral servo unit
Rear Frenos master cylinder with remote mounted servo unit
Piston Diameter
Front (each) 22.22 mm (0.875 in)
Rear 28.575mm (1.125 in)
Brake Changeover Valve

Number of Changeover Valves 2
Purpose Isolate front brake system from rear brake system
Exhauster
Parking Brake
Disc Diameter As 'Standard Machines'
9804/1103 15 - 05 - 08/1 Issue 2

CONTENTS
CONTENTS

Data - Brakes
Service Brake
Actuation Hydraulic - vacuum servo assisted for machines powered by model AB

turbocharged engine
Location Rear Axle Centre Casing (2 brake packs)

Nominal Facing Area per Plate 18603 mm2 (28.8 in2)
Master Cylinder (combined servo assistance)

Type Compensated master cylinder
Piston Diameter (each) 22.22 mm (0.875 in)
Parking Brake
Type Manually Adjusted Caliper, cable operated, mounted on transmission output
Note: Because the service brakes are located in the rear axle, instructions for dismantling and assembly are shown in the
Transmission Section (Rear Axle Brakes).
9804/1103 15 - 05 - 08/2 3270 - G/1-1.2 Issue 1

CONTENTS
CONTENTS
Data - Engine
Type Perkins 1000 Series 4 cylinder Engines

AB - turbocharged, AA - Naturally Aspirated
Bore (nominal) 100mm (3.937 in)
Stroke 127mm (5.000 in)
Swept Volume 4 litres (243 in3)
Compression Ratio Turbocharged 16.0:1, Naturally Aspirated 16.5:1
Compression Pressure 28 bar (400 lbf/in2)
[maximum variation between cylinders 3.5 bar (50 lbf/in2)]
Injection Sequence 1,3,4,2
Valve Clearance - Cold - Inlet 0.20mm (0.008 in)
- Exhaust 0.45mm (0.018 in)
Oil Pressure (hot) at maximum speed - AA 2.1 bar (30 lbf/in2)
- AB 2.6 bar (40 lbf/in2)
Maximum Air Cleaner Restriction 559mm (22 in H2O)
Fuel System
Injection System Details
Engine Injection Pump Injectors
Model Type BHP Code Static Timing Code Working/Setting

Pressures
All Wheel Steer Machines

AB50364 Turbocharged 96 CM78L/1100/1/2420 15.5° BTDC JG 230 atm

AA50386 Naturally Aspirated 76 DM55L/1000/1/2420 16.5° BTDC HZ 220 atm
AB50388 Turbocharged 90 GM64L/1000/2/2420 23.0° BTDC JK 220 atm
AB50389 Turbocharged 96 CM78L/1100/1/2420 15.5° BTDC JG 230 atm
Idling Speed - All builds 750 rev/min

Maximum Governed Speed - All builds 2200 rev/min
Maximum No-load Speed (High Idle) - All builds 2320 - 2420 rev/min
Cooling System
Coolant Temperature (Normal) 80-85 °C (176-185 °F)
Temperature Warning Light operates at: 98 °C (208 °F)
Note: When removing the engine from the machine the following points must be noted:
i Engine removal is possible 'through the top'.
ii The front crankshaft pulley must be removed prior to engine removal.
iii Special lifting wires must be used to lift the engine see 'General Information', Section 1, in the Service Manual
(publication number 9803/3260).
iii The torque convertor can be left on the transmission (flexi plate removed from flywheel).
iv The alternator, starter motor and hydraulic pump can be left on the engine.
For further details see Engine Manual Publication No. 9806/0100
9804/1103 15 - 05 - 09/1 Issue 1

CONTENTS
CONTENTS

Data - Engine
Type 1000 Series 4 cylinder Engines
AB - Turbocharged
AA - Naturally Aspirated
AK - Turbocharged
AM - Turbocharged and Intercooled
AR - Naturally Aspirated
Engine Build List Number AA50608 - AR50656, AR50654, AR50678 - 56kw (75bhp), AK50745 60kw (80bhp)
AA50606 - 56kw (75bhp)
AB50607 - 67.5 kw (90.5bhp), AK50628 - 68.5 kw (92bhp)
AB50609 - 71.5kw (96bhp), AK50640 - 74.6 kw (100bhp) AM50647 85.5 kw (115bhp)
Bore
AA, AB, AK, AM 100mm (3.937 in)
AR 103mm (4.055 in)
Swept Volume AB, AA, AK, AM 4 litres (243 in3)
AR 4.23 litres (258 in3)
Compression Ratio AB 16.0:1
AA 16.5:1
AK, AM 17.25:1
AR 18.5:1
Oil Pressure (hot) at maximum speed - AA 2.1 bar (30 lbf/in2)
- AB, AK, AM 2.6 bar (40 lbf/in2)
- AR 2.0 bar (30 lbf/in2)
Injection System Details - Refer to appropriate Engine Service Manual.
Idling Speed - All builds 880 - 930 rev/min

Maximum Governed Speed - All builds 2200 rev/min
Maximum No-load Speed (High Idle) - All builds 2400 - 2440 rev/min
Cooling System
For further engine details see Engine Service Manual:

AA, AB - 9806/0100
AK, AM, AR - 9806/2140
9804/1103 15 - 05 - 09/2 3270 - K/1-1.2 Issue 1

CONTENTS
CONTENTS

Fault Finding - Electrical
Contents Introduction
Page No. The purpose of this section is to help you trace electrical
faults to a faulty unit. Once you have traced the faulty unit,
Introduction 15-10-01/1 refer to the appropriate dismantling, inspecting and test
No drive on power up 15-10-01/1 instructions given in the Service Manual.
No drive and continuous warning buzzer 15-10-01/1
No drive 15-10-01/1 To help identify circuits, refer to the electrical schematic
Missing gears 15-10-01/1 diagrams.
No 4th gear (4 speed machines only) 15-10-01/1
Downshift protection not operating 15-10-01/2 Refer to Section F, Fault Finding also as this section will deal
No dump 15-10-01/2 with the mechanical aspect.
No 4 wheel drive 15-10-01/2
Intermittent 4 wheel drive 15-10-01/2 1 Before you begin fault finding, read the Safety
Transmission will not downshift 15-10-01/2 information at the beginning of this manual.
Lower gear than switch selected engaged 15-10-01/2
Kickdown not operating 15-10-01/2 2 Make simple checks before say, stripping a major
Reverse will not select 15-10-01/2 component.
Psion unit will not operate 15-10-01/2
3 Make any relevant electrical checks before commencing
work.
Fault Probable Cause Action
No drive on power-up. Blown ECU fuse. Check ECU fuse A5
ECU mainframe connector loose. Check connector is mating correctly with ECU.
Gear twist switch not in neutral. Gear switch must be in neutral on power up
before a gear can be selected.
No drive and continuous Attempting to select drive with the

warning buzzer. handbrake engaged. Release handbrake.
No drive. Faulty gear switch. Check switches and wiring.
Handbrake sticking. Check handbrake assembly.
Faulty gearbox harness. Check gearbox harness and connector for

continuity.
Faulty dump input. Check dump switch and wiring.
Missing gears Faulty solenoid(s) Check solenoid(s) and wiring.
Fault gear switch Check switch and wiring
Low oil pressures Check clutch pack pressures, see Section F.

Check mainline pressure, see Section F.
Mechanical failure See Section F.
No 4th gear Faulty speed signal Check speed sensor and wiring.
(4 speed machine only) Check speed sensor installation.
..... continued
9804/1103 15 - 10 - 01/1 3270 - C/6-1.1 Issue 1

CONTENTS

Fault Finding - Electrical
Downshift protection not operating Faulty speed signal Check speed sensor and wiring.
Check speed sensor installation.
No dump selection Faulty dump input Check dump switch and wiring.
No 4 wheel drive (if fitted) Faulty 4 wheel drive input Check 4 wheel drive switch and wiring.
Faulty 4 wheel drive solenoid Check solenoid and wiring.
Intermittent 4 wheel drive Faulty 4 wheel drive input Check 4 wheel drive switch and wiring.
2/4 wheel drive brake switch

operating Check brake switch and wiring.
Transmission will not downshift Speed too fast for selected downshift Slow the machine.
Lower gear engaged than selected Kickdown engaged Check kickdown switch and wiring.
Kickdown not operating Speed too fast to engage lower gear Slow the machine.
Faulty kickdown input Check kickdown switch and wiring.
Reverse will not operate Speed too fast to reverse direction Slow machine.
Psion will not communicate Faulty connecting lead. Check lead connection.
No power to ECU Turn ignition ON.

Check fuse A5.
Check power supply to ECU.
9804/1103 15 - 10 - 01/2 3270 - C/6-2.1 Issue 1

CONTENTS
CONTENTS

Fault Finding - Hydraulic (Standard Machines)
Fault Finding Contents Introduction

Page No. The purpose of this section is to help you trace hydraulic
faults to a faulty unit (valve, actuator, ram etc). Once you
Introduction 15 - 10 - 02/1 have traced the faulty unit, refer to the appropriate
dismantling, inspecting and test instructions given in the
Lack of power in all hydraulic functions 15 - 10 - 02/1 Service Manual.
All hydraulic rams slow to operate 15 - 10 - 02/2 To help identify circuits, valves, rams etc mentioned in the
fault finding procedures, refer to the hydraulic schematic
One hydraulic service fails to operate or is diagrams.
slow to operate 15 - 10 - 02/2
1 Before you begin fault finding, read the Safety
The engine tends to stall when the information at the beginning of the Service Manual.
hydraulics are under load 15 - 10 - 02/2
2 Make simple checks before say, stripping a major
A spool is sticking 15 - 10 - 02/3 component.
Leaking Oil Seal (Control Valves) 15 - 10 - 02/3 3 Make sure that the hydraulic fluid is at correct working
temperature (50 °C, 122 °F).
Ram creep 15 - 10 - 02/3
4 What ever the fault, check the condition of the hydraulic
Hydraulic oil becomes too hot 15 - 10 - 02/4 fluid. Drain and replace if necessary.
Steering fails to operate or 5 Make any relevant electrical checks before moving on to
is stiff to operate 15 - 10 - 02/4 the hydraulics.
Steering fails to respond to 6 Be sure to remove ALL contamination and if possible

selected mode 15 - 10 - 02/4 identify its origin. It may be part of a component from
elsewhere in the circuit.
7 Replace any seals such as 'O' rings before re-

assembling hydraulic components.
1 Lack of power in all hydraulic functions. Insufficient hydraulic fluid. Check for leaks and top up as required.
Hydraulic leaks in system. Check hoses, replace as required.
Engine performance. Check engine performance, see

transmission section for stall speed
test procedures.
Main relief valve (MRV) Check and adjust as required.

setting incorrect.
Low pump flow. Check pump flow, if required service or

replace pump.
Hydraulic tank breather Clean or replace the breather
Tank filter by-pass valve Check condition of hydraulic filter
Unloader valve pressure Check pressure setting of the

setting too high unloader valve.
..... continued
9804/1103 15 - 10 - 02/1 Issue 2

CONTENTS
CONTENTS

Fault Finding - Hydraulic (Standard Machines) (continued)
5 A spool is sticking. Oil temperature abnormally high. Check for correct fluid, see Lubricants and
Capacities. Check oil cooler and grille for
blockage.
The hydraulic fluid is dirty. Clean the tank strainer. If strainer badly
clogged, drain and flush hydraulic system
Fill with clean hydraulic fluid.
The service pipe connection Check tightening torque.

is over tightened.
The valve housing was twisted Loosen retaining bolts and tighten to
during installation. correct torque figures.
Pressure too high. Check system pressure.
A control linkage is bent Disconnect the linkage. Repair the linkage

if possible, or fit a new one
A spool is bent Dismantle the control valve. Renew spool

as necessary.
A return spring is broken. Renew as necessary.
A return spring or cap is out of Remove the cap, check that the spring is
alignment. in the correct position. Refit cap and
torque tighten bolts
Temperature distribution within Warm the entire system up before

control valve not uniform. using service.
6 Leaking Oil Seal (Control Valves) Paint or dirt on the seal face. Remove the seal and clean.
The back pressure in the valve Check circuit pressures. Adjust if possible.
circuit is excessively high. Otherwise investigate thoroughly.
Spool damaged. Dismantle. Inspect all parts. Renovate or

renew as necessary.
The seal is not secured. Clean the seal and tighten the retaining
bolts to the correct torque.
The seal is cut or damaged. Fit a new seal.
7 Ram creep. Associated ram or pipe lines from Check and rectify as required.
ram leaking.
Check valve malfunctioning Test check valve, rectify as required.

(if fitted, e.g. stabiliser circuit)
Associated valve section spools Rectify, check for contamination.

leaking.
Associated ARV leaking Rectify, check for contamination.
..... continued
9804/1103 15 - 10 - 02/3 Issue 2

CONTENTS
CONTENTS

Fault Finding - Hydraulic (Standard Machines) (continued)
8 Hydraulic oil becomes too hot Oil cooler obstructed Remove debris from cooler fins
Restriction in neutral circuit Check hoses, replace as necessary

lines
Hydraulic filter clogged and Change hydraulic filter

by-pass valve not working
9 Steering fails to operate or Tyres not inflated to Inflate tyres to correct pressure
is stiff to operate correct pressure
Insufficient hydraulic fluid. Check for leaks and top up as required.
Low pump flow. Check pump flow, if

required service or replace pump.
Leaks in the relevant hoses or Check hoses and connections for leaks
component connections
Steer relief valve set Check pressure setting of steer unit relief
incorrectly valve, adjust as required.
Priority valve not operating Check if the priority valve is sticking,

correctly rectify as required.
Check the load sense line from the steer

unit to the priority valve for signs of leaking
or poor connection.
Steer mode valve not operating Check if spools sticking, rectify as required
correctly
Check if solenoids operating, replace
solenoids as required
Mechanical failure Check for damaged axle components,

such as rams, trackrods, linkages etc.
Check for damaged steer unit

components.
Steering column and associated

components not set correctly.
10 Steering fails to respond to Selector switch faulty Check selector switch, replace as required
selected mode
Proximity switches not operating Check setting of proximity switches, reset
correctly or replace switches as required.
Steer mode valve not operating Check if spools sticking, rectify as required
correctly
Check if solenoids operating, replace
solenoids as required.
Leaks in the relevant hoses or Check hoses and connections for leaks
component connections
Electrical failure Check relevant electrical connectors, if

problem still persists, do a wiring continuity
check on relevant circuits.
9804/1103 15 - 10 - 02/4 Issue 2

CONTENTS
CONTENTS

Fault Finding - Hydraulic (Servo Machines)
If there appears to be a fault with the machine, eliminate the obvious and easiest tasks first before doing any detailed fault
finding:
1 Check that the hydraulic oil level is correct.

2 Check that the joystick isolator switch has not been pressed.
3 Check that the system reset switch is not illuminated, (if so, press the switch to reset the system).
4 Check that the seat is in its detent position (forward or rearward), remember the system will not work unless the seat is
correctly positioned.
5 Check that the relevant fuses and relays are intact.
6 If a service is not operating (e.g. dipper), check the L.E.D. on the solenoid, if showing green then the problem is not
associated with the valve, if showing red, the problem will be valve related.
7 Check if any 'unofficial' electrical modifications have been made, for instance all relays should be diode protected, etc.
8 If the engine will not start, check that the gear select switch is not in the 'padlock' position (turned fully anti-clockwise).
9 Determine if the fault is electrical or hydraulic.
The following descriptions identify briefly some possible problems that may occur, and the associated remedial checks.
1 System Continually Resets 11 Aux. Solenoid (e.g. Jaw) Inoperative

Check seat alignment. Check proximity switch Check wiring to switch. Check relay and wiring. Check
adjustment. Check that stop switch is not depressed wiring to solenoid. Check fuse B1
2 Seat Rear and Seat Forward Functions Mixed Up. 12 Float Inoperative
Check that proximity switches are connected correctly Check wiring to switch. Check that hose burst check
valves are not fitted on the loader arm circuit
3 System Is Completely Dead
Check that fuse C6 has not blown 13 RTD Inoperative
Check shovel reset switch. Check wiring to switch
4 LH Joystick is Inoperative
Check feed from control box at wire 423. Remember 14 Loader Valve Block Inoperative
when seat is forwards that LH joystick is inoperative Check relay and wiring. Check wire 440 to control box
5 RH Joystick is Inoperative 15 Excavator Valve Block Inoperative

Check feed from control box at wire 430 Check relay and wiring. Check wire 450 to control box
6 RH Mode Switch Inoperative 16 Hydraulics Inoperative

Check feed from control box at wire 421. Check that wire Check backhoe 'fault' solenoid. Check safety solenoid.
446 is connected to control box Check unloader valve. Check joystick isolator switch not
pressed. Check if air has entered load sense line (purge
7 LH Mode Switch Inoperative as required)
Check that RH mode works correctly. Check that wire
445 is connected to control box 17 Joystick Steering Inoperative
Check wiring to switch. Check relay and wiring. Check
8 Horn Inoperative logic box output at wire 444
Check wiring to switch. Check relay and wiring. Check
that seat forward proximity switch is switching change 18 Hydraulic Services Inoperative
over relay Check output from logic box at relevant valve block
solenoid. Check relevant valve block. Check input to
9 Hydraclamp Inoperative logic box from joysticks
Check wiring to switch. Check wiring to relay. Check
wiring to solenoid
10 Machine Will Not Start

Not in neutral. Gear select switch in lock position (turned
fully anti-clockwise). Check that transmission dump
switch is not stuck. Check relay and wiring
9804/1103 15 - 10 - 03/1 Issue 1

CONTENTS
CONTENTS

Fault Finding - Variable Flow Hydraulics
Fault Finding Contents Introduction

Page No.
This section details the possible faults that may be found with
the loader and backhoe valve blocks. The faults listed only
Introduction 15 - 10 - 03/3 appertain to valve blocks fitted on variable flow hydraulic
machine systems (Rexroth valves).
High or low system pressure 15 - 10 - 03/3
Pump stays at high pressure 15 - 10 - 03/3 information at the beginning of this manual.
Pressure or flow obtained at one port only 15 - 10 - 03/3 2 Make simple checks before say, stripping a major
component.
No pressure or flow at either port 15 - 10 - 03/3
3 Make sure that the hydraulic fluid is at correct working
High work port leakage 15 - 10 - 03/3 temperature (50 °C, 122 °F).
Leaks between sections 15 - 10 - 03/4 4 What ever the fault, check the condition of the hydraulic
fluid. Drain and replace if necessary.
Sticking spool 15 - 10 - 03/4
5 Make any relevant electrical checks before moving on to
Detent will not hold 15 - 10 - 03/4 the hydraulics.
Electrical detent will not hold 15 - 10 - 03/4 6 Be sure to remove ALL contamination and if possible
identify its origin. It may be part of a component from
Poor performance, slow operating speed and/or elsewhere in the circuit.
low maximum stall speed 15 - 10 - 03/4
PROBLEM: High or Low system pressure.

POSSIBLE CAUSE: 1) Wrong pressure and/or flow regulator valve settings. 2) Loss of pilot signal due to shuttle
failure.
CORRECTIVE ACTION: 1) Readjust regulator valves. 2) Operate individual services to determine which shuttle is at fault,
(see page E/16-2).
PROBLEM: Pump stays at high pressure.

POSSIBLE CAUSE: 1) Sticking main spool. 2) Sticking compensator spool.
CORRECTIVE ACTION: 1) See ‘Sticking Spool’ guide. 2) Remove & clean compensator spool.
PROBLEM: Can only obtain pressure or flow at one port.

POSSIBLE CAUSE: 1) Dirt in primary shuttle or damaged o-ring.
CORRECTIVE ACTION: 1) Remove & clean shuttle, inspect o-ring and replace if required.
PROBLEM: No pressure or flow at either port.

POSSIBLE CAUSE: 1) Dirt in secondary shuttle.
CORRECTIVE ACTION: 1) Shift one spool at a time with blocked ports until faulty section found, remove shuttle and
clean, inspect o-ring and replace if required.
PROBLEM: High work port leakage.

POSSIBLE CAUSE: 1) Spool not centred. 2) Dirt in port relief valve.
CORRECTIVE ACTION: 1) Check centring springs. 2) Remove & clean relief valve.
....continued
9804/1103 15 - 10 - 03/2 3270 - E/4-10.2 Issue 1

CONTENTS

Fault Finding - Variable Flow Hydraulics (cont’d)
PROBLEM: Leaks between sections.

POSSIBLE CAUSE: 1) Missing or cut seals.
CORRECTIVE ACTION: 1) Disassemble valve stack and check for missing or cut o-rings.
PROBLEM: Sticking spool.

POSSIBLE CAUSE: 1) Linkage binding. 2) Damaged spool. 3) Uneven torque of tie-rod. 4) Incorrect number of shims
on tie-rods.
CORRECTIVE ACTION: 1) Check linkage. 2) Remove and inspect spool. 3) Loosen tie-rod bolts, check and re-torque. 4)
Disassemble and check that each tie-rod has one shim.
PROBLEM: Mechanical detent will not hold.

POSSIBLE CAUSE: 1) Broken detent shaft.
CORRECTIVE ACTION: 1) Remove detent & inspect.
PROBLEM: Electrical detent will not hold.

POSSIBLE CAUSE: 1) Current broken.
CORRECTIVE ACTION: 1) Check current going into detent.
PROBLEM: Poor performance, slow operating speed and/or low maximum stall speed.
POSSIBLE CAUSE: 1) Blocked flow regulator spool.
CORRECTIVE ACTION: 1) Flow check, remove and clean flow regulator valve, see page E/10-36.
9804/1103 15 - 10 - 03/3 3270 - E/4-11.1 Issue 1

CONTENTS
CONTENTS
Fault Finding - Syncro Shuttle Gearbox
systems to their normal working temperatures.
Ensure that the correct quantity and grade of oil is used and that there are no obvious leaks.

CHECK ACTION

NO: Check 2

in neutral and ratio selector in 1st? NO: Check 19
NO: Check 4

NO: Check level only when machine is cold and top-up as
required.

NO: Check 6

NO: Check 7

NO: Check clutch pressure maintenance valve is free to
operate.

NO: Check converter sprag clutch for wear or slip.

10 Is transmission misaligned? YES: Renew mountings and check position.

NO: Check 'converter out' pressure and flow.

NO: Check converter for wear or cooler for restriction to
flow.

NO: Check 13
13 Is the transmission not pulling in both YES: Stall test machine, Check 14.
Forward and Reverse? NO: Check 16
9804/1103 15 - 10 - 06/1 Issue 1

CONTENTS
CONTENTS
Fault Finding - Syncro Shuttle Gearbox (continued)
CHECK ACTION

NO: Inspect converter relief valve for damage. Check cooler
bypass valve pressure setting.

16 Are clutch sealing rings damaged? YES: Tap pressure gauge into clutch feed lines to monitor
pressure.

NO: Check 18
19 Is the fault only when the transmission is hot? YES: Dismantle solenoid and check components.
NO: Check microswitches, relay and wiring loom.
NO: Check 21
NO: Check 22
NO: Check 23
23 Is the noise present when in neutral or when in gear? NEUTRAL: Check 24

IN GEAR: Check 27
NO: Check 25
NO: Check 26


NO: Check 28
NO: Check 29

NO: Check 30
NO: Check 31
31 Are the dog gear teeth worn? YES: Renew.

NO: Check 32
32 Are the selector rod detent springs broken? YES: Renew.

NO: Check 33
9804/1103
15 - 10 - 06/2 Issue 1
CONTENTS
CONTENTS
Fault Finding - Syncro Shuttle Gearbox (continued)
CHECK ACTION

NO: Check 34
NO: Check 35


NO: Check 37
37 Are steel chips embedded in the bronze? YES: Continue using, chips will either embed below bronze
or be rejected.
NO: Check 38

NO: Check free running gears for seizure or damage.
NO: Check 40

or gear? NO: Ensure that clutch is disengaged when dump pedal is
pressed.
41 Are steel chips embedded in the bronze? YES: Continue using, chips will either embed below bronze
or be rejected.
NO: Check 42

NO: Check 43

9804/1103 15 - 10 - 06/3 Issue 1

CONTENTS
CONTENTS

Fault Finding - 2/4 Wheel Drive Clutch
‘Spring-On’ to 4WD Type Clutch

2WD Cannot be Engaged
In normal operation the 2/4 wheel drive clutch is spring loaded and therefore engaged to give 4 wheel drive. The clutch must
be pressurised to give 2 wheel drive. Before starting the more detailed fault finding procedures - eliminate the obvious:
1 Check that the transmission oil level is correct.

2 Check that the fuse for the 2/4WD circuit is intact.
3 Check that the 4-wheel drive external pipework is not damaged.
4 Check that all the electrical connections are clean and secure.
5 Check that the mainline pressure is correct (see 'Low Mainline Pressure').
6 Check that the pump flow rate is correct.
If the fault is not rectified after eliminating the obvious, check the following:
7 Low mainline pressure 7 Identify if the fault is related to the 2/4WD disconnect:
(Minimum pressure required to disengage 2/4WD clutch 7.1 Disconnect the external pipework to the 2/4WD
is 8.6 bar; 125 lb/in2). clutch. Cap and plug open orifices.
7.2 Check the mainline pressure - if the pressure is

correct, the fault must be within the 2/4WD (see step
8). If the reading is still low check the transmission
in the normal manner.
8 Low mainline pressure (due to 2/4WD clutch): 8 Rectify fault:
8.1 2/4WD solenoid spool sticking. 8.1 Strip, clean and re-assemble solenoid valve, renew
valve if required.
8.2 2/4WD solenoid permanently energised. 8.2 Check the 2/4WD relay and select switch, replace
as necessary.
8.3 2/4WD solenoid spool O-ring failed. 8.3 Renew O-ring.
8.4 Clutch shaft sealing rings leaking. 8.4 Renew clutch shaft sealing rings.
8.5 Excessive clutch shaft end float. 8.5 Rectify fault, renew parts as required, reset end float
(should not exceed 0.03 mm; 0.001 in)
8.6 Wrong type clutch piston fitted. 8.6 Fit correct type clutch piston (ie, without bleed hole).
8.7 Clutch piston O-ring failed. 8.7 Replace clutch piston O-ring.
9 Defective 2/4WD clutch: 9 Rectify fault:
9.1 Worn pressure plate 9.1 Inspect pressure plate, renew as required.
9.2 Worn actuating sleeve. 9.2 Measure length of actuating sleeve and renew as
required, sleeve length should be 60.70 mm; 2.390
inches
9.3 Incorrect clutch pack end float. 9.3 Measure clutch pack end float (should be 0.75 - 1.5
mm; 0.030 - 0.059 inches). Correct as required.
4WD Cannot be Engaged

No pressure is required to engage 4WD (spring loaded). Check that the front wheel drive train is intact (ie propshaft and axle).
Also check that the solenoid spool is not sticking (in the 2WD position). Finally check the 2/4 wheel drive switch and relays.
9804/1103 15 - 10 - 06/4 Issue 2

CONTENTS
CONTENTS

Fault Finding - 2/4 Wheel Drive Clutch
‘Pressure-On’ to 4WD Type Clutch

4WD CANNOT BE ENGAGED
In normal operation the 2/4 wheel drive clutch is spring loaded off and therefore disengaged to give 2 wheel drive. The clutch
must be pressurised to give 4 wheel drive. Before starting the more detailed fault finding procedures - eliminate the obvious:

2 Check that the fuse (C3) for the 2/4WD circuit is intact.
3 Check that the 4-wheel drive external pipework is not damaged and that the drive train is intact.
4 Check that all the electrical connections are clean and secure. Also check that the solenoid spool is not sticking (in the
2WD position).
7 Low mainline pressure 7 Identify if the fault is related to the 2/4WD

disconnect:
7.1 Disconnect the external pipework to the

2/4WD clutch. Cap and plug open orifices.
7.2 Check the mainline pressure - if the pressure

is correct, the fault must be within the 2/4WD
(see step 8). If the reading is still low check
the transmission in the normal manner.
8.1 2/4WD solenoid spool sticking. 8.1 Strip, clean and re-assemble solenoid valve,
renew valve if required.
8.4 Excessive clutch shaft end float. 8.4 Rectify fault, renew parts as required, reset
end float (should not exceed 0.03 mm; 0.001
in)
8.5 Wrong type clutch piston fitted. 8.5 Fit correct type clutch piston (ie, without bleed
hole).
9.1 Worn friction/counter plates 9.1 Inspect friction/counter plates, renew as

required.
9.2 Mechanical failure of 4WD unit 9.2 Strip and inspect 4WD unit. Check that the
electrical and hydraulic circuits are functioning
correctly.
9.3 Incorrect clutch pack end float. 9.3 Measure clutch pack end float (should be 1.0
to 2.3 mm). Correct as required.
9804/1103 15 - 10 - 06/5 Issue 1

CONTENTS
CONTENTS

Fault Finding - 2/4 Wheel Drive Clutch (cont’d)
‘Pressure-On’ to 4WD Type Clutch
2WD CANNOT BE ENGAGED (CONT’D)
No pressure is required to engage 2WD(spring loaded). Check that the solenoid spool is not sticking (in the 4WD position),
then see below.
10 Incorrect type of solenoid valve fitted. 10 Check solenoid.
Note: Powershift and Syncro Shuttle machines

have different types of solenoid - check parts list.
11 Non-return valve faulty (noticeable because 2WD 11 Check the non-return valve.
cannot be engaged).
Note: NOT fitted on Powershift machines.
12 2/4WD solenoid permanently energised. 12 Check the 2/4WD relay and select switch, replace
as necessary.
9804/1103 15 - 10 - 06/6 Issue 1

CONTENTS
CONTENTS

Fault Finding - Syncro Shuttle Transmission
2/4 Wheel Drive Clutch

2WD position).

disconnect:


in)
8.5 Wrong type clutch piston fitted. 8.5 Fit correct type clutch piston (ie, without bleed
hole).

required.
correctly.
9804/1103 15 - 10 - 06/7 3270 - F/61-4.1 Issue 1

CONTENTS

Fault Finding - Syncro Shuttle Transmission
2/4 Wheel Drive Clutch (cont'd)
then see below.

11 Non-return valve faulty (noticeable because 2WD 11 Check the non-return valve.
cannot be engaged).
Note: NOT fitted on Powershift machines.
as necessary.
9804/1103 15 - 10 - 06/8 3270 - F/61-5.1 Issue 1

CONTENTS
CONTENTS

Fault Finding - Powershift Gearbox
Introduction
The Powershift fault finding procedures concern themselves
with general problems normally associated with this type of
transmission system, and so the layout is a 'Possible Cause
and Remedy' type.
Full flow, pressure and stall testing procedures for the

Powershift transmission start on page F/91-1 in the service
manual (publication number 9803/3260).
Before commencing with the fault finding procedure make

sure that the correct type of transmission fluid has been used
(JCB Special Transmission Fluid).
Powershift Fault Finding - Index
Page No.
Lack of Power 15 - 10 - 07/2
Low Mainline Pressure 15 - 10 - 07/2
High Stall Speeds (On All Clutches) 15 - 10 - 07/2
Low Stall Speeds (On All Clutches) 15 - 10 - 07/2
Low Converter Out Pressure 15 - 10 - 07/2
Low Pump Flow 15 - 10 - 07/2
High Converter Out Pressure 15 - 10 - 07/3
Low Lubrication Pressure 15 - 10 - 07/3
* Low Clutch Pressure and/or Clutch Slipping 15 - 10 - 07/3
Overheating 15 - 10 - 07/3
9804/1103 15 - 10 - 07/1 Issue 2*

CONTENTS
CONTENTS

Fault Finding - Powershift Gearbox (continued)
LACK OF POWER

3 Worn pump. 3 Check and if necessary repair or renew pump.
6 Clutches slipping. 6 Check clutch pressures, check clutch piston rings.
7 Internal leakage. 7 Check internal cored galleries and the casting for porosity.
8 High stall speeds. 8 See fault 'High Stall Speeds (on ALL clutches)'.
9 Low stall speeds. 9 See fault 'Low Stall Speeds (on ALL clutches)'.
10 Overheating 10 See fault 'Overheating'.
LOW MAINLINE PRESSURE

transmission.
5 Oil leak thru' 2/4WD circuit. 5 a) Check external pipework for 2/4WD circuit.
b) Check 2/4WD (pressure) circuit - refer to 2/4 wheel
drive clutch fault finding procedure on pages 15-10-
06/4 or 15-10-06/5.
HIGH STALL SPEEDS (ON ALL CLUTCHES)

1 Damaged converter blades. 1 Check and if necessary repair or renew converter.
2 Clutches slipping. 2 Strip, inspect and fit new clutch friction/counter plates.
LOW STALL SPEEDS (ON ALL CLUTCHES)

2 Torque converter reaction member clutch slipping. 2 Check and if necessary repair torque converter.

* 4 Restriction in converter feed. 4 See item 10 in fault 'Overheating'.
LOW PUMP FLOW

1 Low oil level 1 Top up system.
3 Worn Pump. 3 Repair or renew pump

1 Oil cooler/lines blockage. 1 Clean cooler, free blockage.
* 2 Converter in pressure incorrect. 2 Check converter in pressure correct.
* 3 Converter relief valve faulty. 3 Check and if necessary repair relief valve.
9804/1103 15 - 10 - 07/2 Issue 2*

CONTENTS
CONTENTS

Fault Finding - Powershift Gearbox (continued)

1 Low mainline pressure 1 See fault 'Low Mainline Pressure'.
* 6 Leak at pump to case joint (indicated by low cooler flow) 6 Check and if necessary repair or replace as necessary.
* 7 Restriction in converter feed 7 See item 10 in fault 'Overheating'

*1 Low mainline pressure. 1 See fault heading 'Low Mainline Pressure'.
*2 Worn pump. 2 Check flow and if necessary repair or renew pump.
*3 Blocked restrictor orifice in solenoid valve block. 3 Remove solenoid(s) and clear restriction in solenoid
valve block.
*4 Clutch seals worn. 4 Confirm with a clutch leak test, if required renew clutch
seals.
* 6 Mechanical failure. 6 Strip and rebuild clutch, renew parts as required.
OVERHEATING

5 Oil cooler blockage. 5 Clean cooler.
6 Operating in wrong gear range usage. 6 Select correct gears to suit working conditions.
10 Cored galleries on front housing pump mounting
face wrong depth (indicated with an excessively low
pressure and flow on the converter out cooling line).
See illustration below. 10 Replace front housing (or rectify existing housing).
11 Leakage across pump mounting face and front case. 11 Check for damaged surface on both components and loose
pump mounting bolts.
S154080
9804/1103 15 - 10 - 07/3 Issue 2*

CONTENTS
CONTENTS

Fault Finding - Powershift Transmission
Introduction
The Powershift fault finding procedures concern themselves
with general problems normally associated with this type of
transmission system, and so the layout is a 'Possible Cause
and Remedy' type.
Full flow, pressure and stall testing procedures for the

Powershift transmission start on page F/111-1.
Before commencing with the fault finding procedure check

the condition of the transmission oil. The type and condition
of the oil is vital to the long term integrity of the gearbox.
Check for the following transmission oil faults:
Incorrect oil type (must be JCB Special Transmission Fluid).

Incorrect oil level (stop the engine before checking the
gearbox oil level).
Oil overheating.
Oil contaminated with water.
Many types of faults can be caused by the above. In

particular see the fault finding section on oil contaminated
with water.
Powershift Fault Finding - Index

Page No.
Lack of Power 15 - 10 - 07/5
Low Mainline Pressure 15 - 10 - 07/5
High Stall Speeds (On All Clutches) 15 - 10 - 07/5
Low Stall Speeds (On All Clutches) 15 - 10 - 07/5
Low Converter Out Pressure 15 - 10 - 07/5
Low Pump Flow 15 - 10 - 07/5
High Converter Out Pressure 15 - 10 - 07/5
Low Lubrication Pressure 15 - 10 - 07/6
Low Clutch Pressure and/or Clutch Slipping 15 - 10 - 07/6
Overheating 15 - 10 - 07/6
4WD Cannot Be Engaged 15 - 10 - 07/7
2WD Cannot Be Engaged 15 - 10 - 07/7
Transmission Oil Contaminated with Water 15 - 10 - 07/8
9804/1103 15 - 10 - 07/4 3270 - F/101-1.2 Issue 1

CONTENTS

Fault Finding - Powershift Transmision (cont’d)
LACK OF POWER
6 Clutches slipping. 6 Check clutch pressures, check clutch piston rings.
8 High stall speeds. 8 See fault 'High Stall Speeds (on ALL clutches)'.
9 Low stall speeds. 9 See fault 'Low Stall Speeds (on ALL clutches)'.
10 Overheating 10 See fault 'Overheating'.
11 Converter safety relief valve faulty. 11 Check and if necessary repair safety relief valve.
LOW MAINLINE PRESSURE

transmission.
5 Oil leak thru' 2/4WD circuit. 5 a) Check external pipework for 2/4WD circuit.
b) Check 2/4WD (pressure) circuit - refer to 2/4 wheel
drive clutch fault finding procedure on page 15 - 10 -
07/7
HIGH STALL SPEEDS (ON ALL CLUTCHES)

1 Damaged converter blades. 1 Check and if necessary repair or renew converter.
2 Clutches slipping. 2 Strip, inspect and fit new clutch friction/counter plates.
4 Converter safety relief valve faulty. 4 Check and if necessary repair safety relief valve.
LOW STALL SPEEDS (ON ALL CLUTCHES)

2 Torque converter reaction member clutch slipping. 2 Check and if necessary repair torque converter.

4 Restriction in converter feed. 4 See item 10 in fault 'Overheating'.
LOW PUMP FLOW

1 Low oil level 1 Top up system.
3 Worn Pump. 3 Repair or renew pump

2 Converter in pressure incorrect. 2 Check converter in pressure correct.
9804/1103 15 - 10 - 07/5 3270 - F/101-2.2 Issue 1

CONTENTS
CONTENTS

Fault Finding - Powershift Transmission (cont’d)

1 Low mainline pressure 1 See fault 'Low Mainline Pressure'.
6 Leak at pump to case joint (indicated by low cooler flow) 6 Check and if necessary repair or replace as necessary.
7 Restriction in converter feed 7 See item 10 in fault 'Overheating'

3 Blocked restrictor orifice in solenoid valve block. 3 Remove solenoid(s) and clear restriction in solenoid
valve block.
4 Clutch seals worn. 4 Confirm with a clutch leak test, if required renew clutch
seals.
6 Mechanical failure. 6 Strip and rebuild clutch, renew parts as required.
OVERHEATING
5 Oil cooler blockage. 5 Clean cooler.
6 Operating in wrong gear range usage. 6 Select correct gears to suit working conditions.
10 Cored galleries on front housing pump mounting 10 Replace front housing (or rectify existing housing).
face wrong depth (indicated by an excessively low pressure
and flow on the converter out cooling line).
11 Leakage across pump mounting face and front case. 11 Check for damaged surface on both components and loose
pump mounting bolts.
9804/1103 15 - 10 - 07/6 3270 - F/101-3.1 Issue 1

CONTENTS

2/4 Wheel Drive Clutch

2WD position).

disconnect:

in)
8.5 Leakage through piston ball valve, due 8.5 Replace piston or rectify as required.
to contamination or valve not seating correctly.

required.
correctly.
then see below.

as necessary.
12 Piston ball valve blocked. 12 Replace piston or rectify as required.
9804/1103 15 - 10 - 07/7 3270 - F/101-4.2 Issue 1

CONTENTS

Transmission Oil Contaminated with Water
Carefully inspect the transmission oil for signs of water contamination. Contaminated oil will contain water droplets or be visibly
emulsified. Water droplets may be visible on the dipstick or inside the filler tube. For oil analysis purposes, the maximum
permissible water content of the oil is 0.10%.
If the transmission oil has been contaminated with water, faults or damage to the gearbox may be apparent as a result. Before
remedying, thoroughly investigate and rectify the cause of the water contamination.

1 Water ingress during filling/topping up. Carry out flushing procedure.
Refill with JCB Special Transmission Fluid.
2 Missing/incorrect dipstick, damaged filler tube. Renew missing/incorrect/damaged components.

Carry out flushing procedure.
3 Machine operated in deep water. Carry out flushing procedure.

4 Oil cooler failure. Remove, inspect, test oil cooler. Renew if applicable.
5 Gearbox or bevel gearbox casings damaged. Inspect, renew damaged components.

6 Gearbox oil circuit pipes/hoses damaged. Inspect, renew damaged components.

Gearbox faults caused typically by water contamination and other factors related to the transmission oil:
Fault Possible Cause Remedy

1 Pressurisation of transmission Water in oil combined with heat Replace/renew dipstick.
casing - Dipstick blows out/oil from torque converter causes Carry out flushing procedure.
leaking from dipstick tube. steam. Refill with JCB Special Transmission Fluid.
Gearbox over filled with oil. Drain the oil level to the correct level,
see Routine Maintenance - Checking
Transmission Oil Level.
2 Clutch Failure - Friction Lining Water ingress. Renew friction plates.

Separation. Carry out flushing procedure.
3 Clutch Failure - Clutch Piston Water ingress causing nylon Carry out flushing procedure.
Seizing. components to swell and stick Refill with JCB Special Transmission Fluid.
when hot. Note: If after a period of service without
water contamination seizing still occurs,
renew piston.
Overheating transmission oil. See Fault Finding - Overheating.
4 Badly worn/noisy bearings. Water ingress. Fit new bearings.

Insufficient lubrication. Refill with JCB Special Transmission Fluid.
9804/1103 15 - 10 - 07/8 3270 - F/101-5.1 Issue 1

CONTENTS
CONTENTS

Fault Finding - Brakes
Note: The brakes generate a high temperature when operating, this means that the casing will be hot to touch, this condition
is normal.
Note: 4WS machines do not have dual pedal braking.
FAULT POSSIBLE CAUSE POSSIBLE CAUSE
A One or both brakes do not apply. 1 Check master fault 1 Check master cylinder in
(Brake travel not excessive,
brakes not pulling to one side) 2 Friction/counter plate distortion. 2 Check friction/counterplates.
1 Air in Hydrualic system. 1 Check fluid reservoir level. Check

B Pedal travel excessive (but not for fluid/air leaks,rectify as
touching floor). required.
2 Leak in hydraulic system. 2 Check for fluid loss at master

cylinder and brake piston, all pipes
and fittings for loose connections.
Rectify as required.
3 Friction/counter plate distortion. 3 Renew friction/counter plates -

BOTH sides.
C Applying one brake (pedals 1 Valve stem seal inside (non-active) 1 Renew master cylinder position.
unlocked) also partially engages master cylinder piston not sealing.
the other brake.
D Pedal hard to operate. 1 Tightness at pedal pivot. 1 Inspect pedal pivot.

Free-off/lubricate.
2 Fluid contamination seal damage. 2 Flush system and renew all

hydraulic seals.
3 Misaligned push rod/pedal. 3 Check and rectify as required.
4 Kinked or crushed brake pipes. 4 Check/renew brake pipwork.
Items 5 to 7 are for machines fitted with

servo assisted brakes only:
5 Vacum failure due to low vacim at 5 Inspect/service engine mounted

source. exhauster unit as required.
6 Blocked/leaking vacum pipe. 6 Check/renew vacum pipe.
7 Servo defect. 7 Renew servo unit.
E Pedals touch floor under constant 1 Master cylinder fault. 1 Check master cylinder in single
pressure - no fluid loss and coupled pedal modes to
identify fault area, service as
required.
2 Friction/counter plate distortion. 2 Renw friction/counter [plates -

BOTH sides.
3 Air in hydraulic system. 3 See item B. 1.
F Pedals touch floor under constant 1 External fluid leaks. 1 Visually Check brake circuit for
pressure - and fluid loss fluid loss, service as required.
2 I nternal fluid leaks. 2 See ‘Brake Piston Seal Leakage

Test’ on page 15-10-08/04.
9804/1103 15 - 10 - 08/1 3270 - F/101-1.2 Issue 2*

CONTENTS

Fault Finding - Brakes (cont’d)
FAULT POSSIBLE CAUSE POSSIBLE CAUSE
G Pulling to one side when pedals 1 Compensating feature not working. 1 Inspect master cylinder
locked together. compensating. Check if blockage
in bridging pipe. Service as
required.
2 Braking system inoperative on one 2 Unlatch pedals to test circuits

side. individually.
3 Friction plates worn beyond limits 3 Renew friction counter plates -

or distortion on one side. BOTH sides.
4 Badley adjusted push rods. 4 Adjust push rod (1mm minimum).
5 Servo operating rod out of 5 Adjust servo operating rod.

adjustment.
6 Annular piston fault (see item J6) 6 See item J6.
H Poor braking (not pulling to one 1 Friction plates worn beyond limits 1 Renew friction/counter plates -
side). or distorted on one side. BOTH sides.
2 Master cylinder fault. 2 Check master cylinder in single

and coupled pedal modes to
identify fault area, service as
required.
3 Annular piston fault (see item J6) 3 See itemJ6.
4 Incorrect/low axle oil. 4 Fill axle with correct type of oil.
5 Vacum failure (machines fitted with 5 Inspect vacum source/pipes,

servo assisted brakes only). service as required.
J One or both brakes not releasing. 1 Fit a new spring
1 Brake pedal spring fault.
2 Master cylinder fault (plunger stuck 2 Service as required.

in bore).
3 Blocked hole in master cylinder 3 Fit a new resvoir cap

resvoir cap.
4 Adjust pedal free travel.
4 Brake pedal free travel incorrect.
5 Flush system and renew hydraulic
5 Fluid contamination/seal damage. seals.
6 Annular brake piston(s) binding in 6.1 Check that the correct brake fluid
axle. has been used (incorrect fluid
could swell the annular brake
piston seals).
6.2 Check if annular brake piston seals

in good condition.
6.3 Check that the annular brake

piston rotates freely in its own
housing with no seals fitted.
6.4 Check that the annular brake

piston seal retracts the piston
approximately 0.5mm (0.020 in).
7 Kinked or crushed brake pipes. 7 Check and renew pipes as
required.
8 Friction/counter plates not free on 8 Check friction/counter plates for

splines and/or dowels. free movement, replace if required
- BOTH sides.
9804/1103 15 - 10 - 08/2 3270 - F/101-2.2 Issue 2*

CONTENTS
CONTENTS
Fault Finding - Brakes (continued)
FAULT POSSIBLE CAUSE ACTION
K Poor braking when hot. 1 Moisture in system vapourizing when 1 Strip axle and clean annular piston to
axle is hot. remove moisture. Remove master
cylinders and check for corrosion,
service as required. Flush hydraulic
brake system.
L Excessive brake noise in operation. 1 Deterioration of axle oil or wrong 1 Change axle oil.
type of axle oil.
Note: Due to the metal to metal contact
of oil immersed brakes, limited noise can 2 Axle oil loss. 2 Refill axle with correct oil and check
be heard which is consistent with this for leaks.
type of design - this is normal.
3 Friction plates worn beyond limits. 3 Renew friction/counter plates.
4 Friction/counter plates in poor 4 Check for distortion or surface pitting

condition. and/or roughness of friction/counter
plates (annular grooving of counter
plates is acceptable).
M Fluid loss when machine standing, 1 Slight cut or nick in the brake piston 1 Strip axle, replace seal.
for instance - overnight (see note). seal, see 'Brake Piston Seal Leakage
Test' page 15-10-08/4.
Note: Confirm fault is as indicated by
checking that the pedals DO NOT touch
floor under constant pressure.
9804/1103 15 - 10 - 08/3 Issue 1

CONTENTS
CONTENTS
Fault Finding - Brakes (continued)
Brake Piston Seal Leakage Test
The following procedure explains how to check if a brake 5 Repeat steps 1 to 4 for the opposite brake piston seal.
piston seal is severely damaged/perished or if the seal has a
small cut or nick. The test must only be done when the axle is 6 Reconnect all brake pipes and bleed the brake system
COLD. as recommended in the service manual (publication no.
9803/3260).
!WARNING
Before working on the brake system make sure the
machine is on level ground and chock all four wheels.
BRAK 1-4
!WARNING
Do not drive the machine with any part of its brake
system disconnected. When the following test has been
completed reconnect all brake pipes and bleed the brake
system using the recommended procedure.
BRAK 2-1
1 Remove and cap brake piston feed pipe A.

Use illustration 107710 and
2 Fill the brake piston housing with JCB Light Hydraulic amend to show clear tube fitted,
Fluid. also show level indicator mark on tube.
3 Check for severe piston seal damage:
3.1 Install a hand pump (see note 1) fitted with a 0 - 40

bar (0 - 600lbf/in2) pressure gauge to port B, as
shown at X.
Note 1: The hand pump MUST be filled with JCB Light

Hydraulic Fluid. DO NOT exceed 69bar (1000lbf/in2).
3.2 Use the hand pump to generate a pressure in the

brake piston housing.
3.3 If the pressure falls off rapidly, or if no pressure

reading can be obtained, the seal is severely
damaged and needs replacing with a new one.
4 Check for small cuts or nicks in the piston seal:
4.1 Install an adapter fitted with a piece of clear tube

(approximately 122mm [48in.] long) to the brake
piston port B, as shown at Y (see note 2).
Note 2: The tube must be kept vertical during the test, use
tape to attach the tube to the side of the machine.
4.2 Fill the tube until approximately three quarters full

with JCB Light Hydraulic Fluid
4.3 Using a suitable pen, mark the level line of the brake
fluid on the tube, as shown at C.
4.4 After approximately 1/2 hour, check if the level has

dropped below the original marked line, if it has then
check the brake piston seal for slight nicks, cuts or
generally for wear.
9804/1103 15 - 10 - 08/4 Issue 1

CONTENTS
CONTENTS

Fault Finding - Steering
Contents Introduction
Page No. The purpose of this section is to help you trace hydraulic
faults to a faulty unit (valve, actuator, ram etc). Once you
Introduction 15 - 10 - 09/1 have traced the faulty unit, refer to the appropriate
dismantling, inspecting and test instructions given
Steering wheel difficult to turn 15 - 10 - 09/1 elsewhere in the steering section.
Steering wheel turns on its own 15 - 10 - 09/2 To help identify circuits, valves, rams etc mentioned in the
fault finding procedures, refer to the hydraulic schematic
Machine will not turn when the diagrams (near the beginning of the Hydraulics Section).
steering wheel turned. 15 - 10 - 09/2
Steering fails to respond to information at the beginning of this manual.
selected mode (4WS Machines only) 15 - 10 - 09/3
2 Make simple checks before say, stripping a major
component.
3 Make sure that the hydraulic fluid is at correct working

temperature (50 °C, 122 °F).
4 What ever the fault, check the condition of the

hydraulic fluid. Drain and replace if necessary.
5 Make any relevant electrical checks before moving on

to the hydraulics.
6 Be sure to remove ALL contamination and if possible

identify its origin. It may be part of a component from
elsewhere in the circuit.

1 Steering wheel difficult to turn. Tyres not inflated to Inflate tyres to correct
correct pressure pressure
Insufficient hydraulic fluid. Check for leaks and top up as

required.
Leaks in the relevant hoses or Check hoses and

component connections connections for leaks
Air in the hydraulic system. Bleed system - bleed the load

sense line.
Low pump flow. Check pump flow, if required

service or replace pump.
Steer relief valve set Check pressure setting of

incorrectly steer unit relief valve,
adjustas required.
Worn or damaged parts in the steer Remove and inspect.

control valve.
....... continued
9804/1103 15 - 10 - 09/1 3270 - H/4-1.1 Issue 1*

CONTENTS

Fault Finding - Steering (cont’d)
1 Steering wheel difficult to turn. Priority valve not operating Check if the priority valve
(continued) correctly is sticking, rectify as
required.
Check the load sense line

from the steer unit to the
priority valve for signs of
leaking or poor connection.
Steer mode valve not operating Check if spools sticking,

correctly (4WS Machines only) rectify as required
Check if solenoids
operating, replace
solenoids as required
Mechanical failure Check for damaged axle

components, such as rams,
trackrods, linkages etc.
2 Steering wheel turns on its own. Dirt in the steer control unit Clean and inspect unit.
(causing sleeves to stick open)
Steer control valve centring springs Check unit.

damaged, broken or missing.
Steer control valve - position of See page H/16-4, step 9.

rotor to shaft slot incorrect. Correct as required.
3 Machine will not turn when the Insufficient hydraulic fluid. Check for leaks and top
steering wheel turned. up as required.

Air in the hydraulic system. Bleed system - bleed the

load sense line.
Low pump flow. Check pump flow, if

required service or replace
pump.
Steer relief valve set Check pressure setting of

incorrectly steer unit relief valve,
adjust as required.
Worn or damaged parts in the steer Remove and inspect.

control valve.
Priority valve not operating Check if the priority valve

correctly is sticking, rectify as
required.
Check the load sense line

from the steer unit to the
priority valve for signs of
leaking or poor connection.
9804/1103 15 - 10 - 09/2 3270 - H/4-2.1 Issue 1

CONTENTS
CONTENTS

Fault Finding - Steering (cont’d)
3 Machine will not turn when the
steering wheel turned (continued). Steer mode valve not operating Check if spools sticking,
correctly (4WS Machines only) rectify as required
Check if solenoids
operating, replace solenoids
as required
Mechanical failure Check for damaged axle

components, such as rams,
trackrods, linkages etc.
Steer column splined shaft not fully Check shaft engagement.

engaged in steer valve.
Power track rod failure Check power track rod for

signs of damge, leaks etc.
4 Steering fails to respond to Selector switch faulty Check selector switch,

selected mode (4WS Machines only) replace as required
Proximity switches not operating Check setting of proximity

correctly switches, reset or replace
switches as required.
Steer mode valve not operating Check if spools sticking,

correctly rectify as required
Check if solenoids
operating, replace
solenoids as required.

Electrical failure Check relevant electrical

connectors, if problem still
persists, do a wiring
continuity check on relevant
circuits.
9804/1103 15 - 10 - 09/3 3270 - H/4-3.1 Issue 1

CONTENTS
CONTENTS

Basic Machine Component List 56 Front Washer/Wiper Switch
57 Front Wiper Motor
The basic circuit shows a standard 3CX (214) machine fitted 58 Horn (Front)
with syncro shuttle transmission and 2 wheel steer. Refer to 59 Horn Push (Front)
pages 15-15-01/3 to 15-15-01/6 for circuit differences, e.g. 60 Head Light Flasher Switch
AWS circuit, Powershift circuit etc. Note that ONLY the 61 Head Light Main Beam Lamps
differences are shown. 62 Main Beam Warning
63 Dipped Head Light Lamps
1 Battery 64 Head Light Dip Switch
2 Starter Switch 65 Head and Side Lights Switch
3 Thermostart 67 Front Working Lights
4 Starter Solenoid 69 Front Working Lights Switch
5 Starter Motor 70 Lighting Relay
6 Neutral Start Relay 71 Rear Working Lights
7 Transmission Dump Relay 72 Rear Working Lights Switch
8 Forward Relay 75 Gauge Illumination (Tacho, Water, Fuel)
9 Transmission Foot Dump Switch 76 Reverse Alarm Relay
9A Transmission Hand Dump Switch 77 Reverse Alarm
10 Forward Solenoid 78 Side Light Left Hand
11 Park Brake Relay 79 Tail Light Left Hand
11A Park Brake Dump Relay 80 Socket (Dipper Light)
12 Reverse Relay 81 LH Number Plate Light (Cab)
13 Reverse Solenoid 82 Number Plate (Chassis)
14 Park Brake Switch 83 Side Light Right Hand
15 Coolant Temperature Gauge 84 Tail Light Right Hand
16 Coolant Temperature Sender 85 Hydraulic Speed Control Switch
17 Fuel Gauge 87 Hydraulic Speed Control Switch
18 Fuel Gauge Sender 88 Hydraulic Speed Control Relay
19 Diode Bank 89 Hydraulic Speed Control Solenoid
20 Engine Coolant Temperature Switch 90 Socket (Junction Box Feed)
21 Transmission Oil Temperature Switch 119 Rear Fog Light ➀
22 Engine Oil Pressure Switch 120 Rear Fog Light Switch ➀
23 Transmission Oil Pressure Switch 125 Rear Washer Motor
24 Air Filter Restriction Switch 126 Rear Washer Switch
26 Speedometer / Tachometer
27 Alternator ➀ Note: Machines prior to serial number 400077 have the
28 Alternator Warning fog light circuit protected by fuse B3, not C4 as
29 Warning Buzzer indicated.
30 Park Brake Indicator Light
31 Brake Light Switch ➁ ➁ Note: Machines up to serial number 403024 have the
32 Brake Lights ➁ brake lights protected by fuse A1.
34 2/4 Wheel Drive Solenoid ➂
35 2/4 Wheel Drive Relay ➂ Machines from serial number 403025 to 404851 have
36 2/4 Wheel Drive Brake Relay ➂ the brake lights protected by fuse C3.
37 2/4 Wheel Drive Select Switch ➂
Machines from serial number 404852 have the brake
38 Rear Wiper Motor
lights and 2/4WD solenoid protected by fuse A1 (as
39 Rear Wiper Switch
indicated in the fuse identification chart).
40 Fuel Pump Solenoid
41 Indicator Flasher Relay
➂ Applicable to 2WS machines only (from serial number
42 Hazard Warning Switch
409435). For 2WS machines prior to 409434 and all
43 Hazard Warning Lamp
4WS machines, refer to page C/15-5.
44 RH Direction Indicators
45 LH Direction Indicators
Fuses
47 Diode
A1 - A9
48 Heater Motor
B1 - B9
49 Heater Switch
C1 - C4
50 Beacon
51 Beacon Switch
Refer to page 15-05-01/2 for fuse details and ratings.
52 Interior Lamp
53 Interior Light Switch
54 Radio
55 Washer Motor
9804/1103 15 - 15 - 01/1 Issue 2

CONTENTS
CONTENTS
CONTENTS
3CX, 4CX (200 Series) From m/c no. 400001 to 430000
Basic Machine (2WS with Syncro Shuttle)
600G
600AD 600BN 600BG 600AZ 600G 604A
600H 600CB 600BL 600AJ 600AX
600AZ 600G 600BC 600BM 600H
600AC 600AP 600AK 600AZ 600AU 604
600BT 600DF
600Y 600BS
600CE 600C 600BU
34 600H 600BC
52 600DY
600BC 600DW
600T 600P
600BF
600V
10 13 16 600CF 32 600AS 600AV
89
600CK
600CD
600BD 600B 63 78 81 600AR 600AY 600BJ
75
600S 816D
816E
600 43 44 45 50
811
18 21 23 M 62 83 71
812
14 53
77 600AA
600AB
600BK 61 85
815
816
40 834A
67 861B
3 36
804
M 79 84 82
8 12 837A
834B
861A
M
20 22 24 853
894 837B
855A
867B
4 912 912A 807
35
303A 57 855B
M 46 55 603
809 808A
5 M
M
839
76 806 805 841 80 855
877A
38 119
003 15 17 125 47 834 B5 88
877 56 840 829 830
831
837
108 600BH
864
804A 600N
842 808 863 69
F N R 909
862
41
48
- 31 853B 103A 803 56 830D
852 26 27 800A 600EB B4 B3

1 912 108B
A3 835
+ 815
802
800B 58 836
A4 101A
815A 126 51 833

828 828A
6 7 11 11A
814
866 865
810C 810A 404 405 49
838 401
412 407
102A
60
107M 107N 406 403 402
004
200 42 303F
868A 120
868
200A 110A
39 110B 59 908 C4
103E 907
100A 28 108 104B 110C 64 87
9 9A 30 103 303
100
105 104A 300 70 861
106
37 102 110 832B 828B
101P
19
111A
104C
600BE 90
B7 29 B2
832
101
103C
A2 107
A1 A5 A6 B8 A7 A9
B9 000D
411
B6 000B 200H 72
002K 001D
107D
001C
001E
001F
200J
002H
000A 65 B1
000E
C3 002C 002D 002G
002L 002B 002A 000C 000F
302
111 001B
002J 200E 104C
103B
002F
C2
2
601
602
C1
200G 859 860
A8 54
200K 304 600R
A214640
A214640
9804/1103 15 - 15 - 01/2 15 - 15 - 01/2 Issue 2

CONTENTS
CONTENTS

Circuit Diagram Component List -
Steer Circuit (AWS Machines Only)
2 Starter Switch
110 Front Proximity Switch
111 Rear Proximity Switch
112 Steer Mode Select Switch
113 Steer Mode Printed Circuit Board
114 Crab/4 Wheel Steer Solenoid
115 4 Wheel Steer Solenoid 600L
116 Crab Steer Solenoid

117 2 Wheel steer Solenoid 113
822 823
821
112
826A 824A 825A
845 826B 824B 825B

819
820
115 116 117
600BW
109C 109D 109F

600BV
114
110 111
109E
109A 109B
2
002E 109
C2
002B
A2
A216990
9804/1103 15 - 15 - 01/3 Issue 2

CONTENTS
CONTENTS

Circuit Diagram Component List -
Powershift Transmission
1 Battery
2 Starter Switch
7 Transmission Dump Relay
9A Transmission Hand Dump Switch
11 Park Brake Relay >> Indicates feed to the 2WD circuit, only applicable on
14 Park Brake Switch machines up to serial number 409435.
29 Warning Buzzer
140 Drive Relay (Layshaft & Mainshaft)
141 Layshaft Solenoid
142 Mainshaft Solenoid
143 Forward High/Low Relay
144 Forward Low Solenoid
145 Forward High Solenoid
146 Neutral Relay
147 Reverse High/Low Relay 600BZ 600BX 600BT
148 Reverse Low Solenoid 600BY
600BS 600AF
149 Reverse High Solenoid 144 600AC

149
150 Powershift Column Switch 142 600CA
151 'Ignition' Relay 148 600BF

152 Forward Relay 145 600AH 600AD
600AG
141 600AE
812 811
153 Reverse Relay
848 X 810 849
851 14
600Y
600V 850
846
817
143 146 147 847 815
600BN
6 813
810A 11
810C
140 107F
152 107B 153 107E
401
883B
808A
30
884B 884C
809
A2
7
R F 2 4 3 1
N
838A 29
9A
- 150
111A 852
1
+ 600W
2
107
100 C3
001A
151
B9 B7
200C 002
200D
A216980
9804/1103 15 - 15 - 01/4 Issue 2

CONTENTS
CONTENTS

Circuit Diagram Component Lists -
2/4 Wheel Drive (all machines up to serial Transmission Dump Circuit (machines up to
number 409434) serial number 413772)
2 Starter Switch 2 Starter Switch
31 Brake Light Switch 6 Neutral Start Relay
32 Brake Lights 7 Transmission Dump Relay
34 2/4 Wheel Drive Solenoid 8 Forward Relay
35 2/4 Wheel Drive Relay 9 Transmission Foot Dump Switch
36 2/4 Wheel Drive Brake Relay 9A Transmission Hand Dump Switch
37 2/4 Wheel Drive Select Switch 10 Forward Solenoid
11 Park Brake Relay
12 Reverse Relay
13 Reverse Solenoid
14 Park Brake Switch
19 Diode Bank
29 Warning Buzzer
600CB
34
600AB
600BR 600AD 600BN A216960
600AC
32 600Y 600BS
600BT
600BF
600V
10 13
853
811
812
600AA 14
815
8 12
816
107B 107E
809 808A
35
853A
854 818
36
F N R
852
108B
877
815
37
6 7 11
810C 810A
838 401
107D
31
108
100A
9 9A 30
100
A1 106
111A
19
B7 107
A2 29
B9 000D
411
C3
000E
C3
2 A216950 2 111 001B
9804/1103 15 - 15 - 01/5 Issue 2

CONTENTS
CONTENTS

Circuit Diagram Component Lists -
Instrument Lights Test Button (machines up to Hydraulic Speed Control - 2 Relays (machines
serial number 404502) up to serial number 406613)
2 Starter Switch 2 Starter Switch
19 Diode Bank 85 Hydraulic Speed Control Switch
20 Engine Coolant Temperature Switch 86 Hydraulic Speed Control Warning
21 Transmission Oil Temperature Switch 87 Hydraulic Speed Control Switch
22 Engine Oil Pressure Switch 88 Hydraulic Speed Control Relay
23 Transmission Oil Pressure Switch 89 Hydraulic Speed Control Solenoid
24 Air Filter Restriction Switch
25 Warning Lights Test Button
29 Warning Buzzer
600BP
600C 600BU
600CF
21 23 25
600CK
85
20 22 24
89
867A
410 101A
86
88 867B
867
88
866A
101C
866
404 405
406 403 402
87
101A
A2 19
29
101
2
2 B9 B1
A216970 A216940
9804/1103 15 - 15 - 01/6 Issue 2

CONTENTS
CONTENTS
CONTENTS
3CX, 4CX (200 Series) From m/c no. 430001
19 20 73 74 75 76 77
143 145
60 61 7 8
3 5 140
6 9 141 10 11 12 13 14 15 142 144
1
68
63
113 114 116

4
16
54
118
117
72 24
21 22 23
69 147 149 151 153 155 156
146 148 150 152 154 155
65
110 115 17
62
67 18
112 66 70
71
64
111
A228951
(CAD 852/35036 - 1/4)
9804/1103 15 - 15 - 01/7 15 - 15 - 01/7 Issue 3

CONTENTS
CONTENTS

Basic Machine Component List
The basic circuit shows a standard 3CX (214) machine fitted
with syncro shuttle transmission and 2 wheel steer. Refer to
pages 15-15-01/11 to 15-15-01/14 for circuit differences, e.g.
AWS circuit, Powershift circuit etc. Note that ONLY the
differences are shown.

1 Battery 60 Transmission Dump Switch (Gear)
2 Starter Switch 61 Transmission Dump Switch (Loader)
4 Starter Solenoid 63 Park Brake Switch
5 Starter Motor 64 Brake Light Switch
6 Forward Solenoid 65 Brake/Drive Select Switch
7 Reverse Solenoid 66 Hydraclamp Switch
8 Reverse Alarm 67 Hydraulic Speed Control Switch
9 2/4 Wheel Drive Solenoid 68 Hydraulic Speed Control Switch
10 Fuel Pump Solenoid 69 Shovel Reset Switch
11 Hydraclamp Solenoid 70 Rear Horn
12 Hydraulic Speed Control Solenoid 71 Hazard Warning Switch
13 Socket (Junction Box Feed) 72 Direction Indicator Switch
14 Shovel Reset Solenoid 73 Engine Coolant Temperature Switch
15 Rear Horn 74 Transmission Oil Temperature Switch
16 Diode 75 Engine Oil Pressure Switch
17 Indicator Flasher Unit 76 Transmission Oil Pressure Switch
18 Side Instrument Console 77 Air Filter Restriction Switch
19 Coolant Temperature Sender 78 Face Level Fan Switch
20 Fuel Gauge Sender 79 Heated Seat Switch
21 Tachometer 80 Rear Washer/Wiper Switch
22 Coolant Temperature Gauge 81 Head Light Flasher Switch
23 Fuel Gauge 82 Front Washer/Wiper Switch
24 Hourmeter 83 Horn Push (Front)
25 Front Instrument Console 84 Rear Fog Light Switch
26 Alternator 85 Head and Side Lights Switch
27 Cigar Lighter 86 Head Light Dip Switch
28 Clock 87 Front Working Lights Switch
29 Face Level Fan 88 Rear Working Lights Switch
30 Heated Seat 89 Interior Light Switch
31 Rear Washer Motor 90 Interior Light Switch
32 Rear Wiper Motor 91 Beacon Switch
33 Washer Motor 92 Heater Switch
34 Front Wiper Motor 93 Air Conditioning Switch
35 Horn (Front) 94 Air Conditioning Pressure Switch
36 Socket (Dipper Light) 95 Air Conditioning Pressure Switch
37 Beacon
38 Tracker
Fuses
39 Radio
A1 - A9
40 Heater Motor B1 - B9
41 Heater Resistor C1 - C6
42 Air Conditioning Compressor
54 Warning Buzzer Note: Fuse C6 is only fitted on machines from serial number:
3CX (214) - 438636; 4CX (214S) - 437866.
Prior to this, the gear controls were protected by fuse C3.
Refer to page 15-05-01/3 for fuse details and ratings.
9804/1103 15 - 15 - 01/8 Issue 2

CONTENTS
CONTENTS

Basic Machine Component List (continued)
Relays
111 Ignition Relay ‘1’
113 Forward Relay
114 Reverse Relay
115 Park Brake Relay
116 4 Wheel Brake Relay
117 Hydraulic Speed Control Relay
118 Rear Horn Relay
120 Road Lights Relay
121 Italian Worklight Relay
122 Heater Relay
Lights
140 LH Brake Light
141 RH Brake Light
142 LH Front Indicator
143 LH Rear Indicator
144 RH Front Indicator
145 RH Rear Indicator
146 Alternator Warning Indicator Light
148 Water Temperature Indicator Light
149 Transmission Temperature Indicator Light
150 Engine Oil Pressure Indicator Light
151 Transmission Oil Pressure Indicator Light
152 Air Filter Blocked Indicator Light
153 Hazard Warning Indicator Light
154 Main Beam Warning Indicator Light
155 Gauge Illumination
156 Turn Signal Indicator Light
157 Master Warning Lights
158 Side Lights Indicator Light
159 Rear Work Lights Indicator Light
160 Front Work Lights Indicator Light
161 Rear Fog Light Indicator Light
162 Rear Fog Light
163 LH Main Beam Light
164 RH Main Beam Light
165 LH Dip Beam Light
166 RH Dip Beam Light
167 LH Number Plate Light
168 LH Tail Light
169 LH Side Light
170 RH Number Plate Light
171 RH Tail Light
172 RH Side Light
9804/1103 15 - 15 - 01/9 Issue 1

CONTENTS
CONTENTS
CONTENTS
162 164 165 167 169 170 172
163 166 89
168 171 173 174
33 35 37 42
39
27 29 31 36 41
26
34 90
28 30 32
40
84 95
25
86
82
94
158 153 160 78 79 87 88
157
156 154 159 161
80 91
83
93
121
92
81
119 120
85
A228960 A2289611
(CAD 852/35036 - 2/4)
9804/1103 15 - 15 - 01/10 15 - 15 - 01/10 Issue 2

CONTENTS
Powershift Transmission & Steer Circuit - AWS Machines Only

9804/1103

CONTENTS
8
43 45 48
9
3 5
61 63 44 46 47
102
1
16 16
Backhoe Loaders
4 123
126 16
16 101
15 - 15 - 01/11
116 53
115
125 127
16
113 114
124
16
110
16
16
16
49
100
175 176 177 178
16 50 51 52
112
62
96 64
97
From m/c no. 430001

98 99
FUSE C3
FUSE C6
15 - 15 - 01/11
111 119
A228972
A228972
Issue 2
CONTENTS
Powershift Transmission & Steer Circuit - AWS Machines Only

9804/1103

CONTENTS
Note: Except for the transmission and steer circuits
(shown above), the AWS electrical circuit is the
same as shown on Page15-15-01/7 to 15-15-01/10.
Main Components Relay

1 Battery 110 Neutral Start Relay
2 Starter Switch 111 Ignition Relay ‘1’
3 Thermostart 112 Transmission Dump Relay
4 Starter Solenoid 113 Forward Relay
5 Starter Motor 114 Reverse Relay
8 Reverse Alarm 115 Park Brake Relay
9 2/4 Wheel Drive Solenoid 116 4 Wheel Brake Relay
16 Diode 119 Ignition Relay ‘2’
43 Mainshaft Solenoid 123 Neutral Relay
Backhoe Loaders
44 Layshaft Solenoid 124 Auto 2 Wheel Drive Relay
45 Forward Low Solenoid 125 Drive Relay (Layshaft & Mainshaft)
46 Forward High Solenoid 126 Forward High/Low Relay
15 - 15 - 01/12
47 Reverse High Solenoid 127 Reverse High/Low Realy

48 Reverse Low Solenoid
50 4 Wheel Steer Solenoid
Lights
51 Crab Solenoid
175 4 Wheel Steer Indicator Light
From m/c no.

176 Crab Steer Indicator Light
53 Steer Mode Printed Circuit Board
178 Front Instrument Console Illumination
Switches
Note: Fuse C6 is only fitted on machines from serial
*
61 Transmission Dump Switch (Loader)

number:
62 Forward/Reverse Switch 3CX (214) - 438636; 4CX (214S) - 437866
63 Park Brake Switch Prior to this, the gear controls were protected by
64 Brake Light Switch fuse C3.
From m/c no. 430001

96 4 Wheel Drive Switch
97 Powershift Column Switch
101 4 WS/Crab Selector (part of PCB - item 53)
102 2 WS/4 WS Selector (part of PCB - item 53)
Issue 2*
CONTENTS
Powershift Transmission - 2WS Machines Only

9804/1103

CONTENTS
and Steer Circuit for 3CX 4x4x4 Machines
8 140 43 45 48
9
5
3
61 63 141 44 46 47
1
Backhoe Loaders
123
129 130
116 126
4
15 - 15 - 01/13
115
125 127
113 114
16
110 65
147 16
16
16
100
50
112
62
64 52 177 178
97
98 99
From m/c no. 430001

2 111
FUSE C6
119
A228981
15 - 15 - 01/13
FUSE C2
Issue 2
CONTENTS
Powershift Transmission - 2WS Machines Only - and Steer Circuit for 3CX 4x4x4 Machines
9804/1103

CONTENTS
Note: Except for the transmission circuit (shown
above), the 2WS electrical circuit is the same as
shown on Pages 15-15-01/7 to 15-15-01/10.

43 Mainshaft Solenoid 123 Neutral Relay
Backhoe Loaders
44 Layshaft Solenoid 125 Drive Relay (Layshaft & Mainshaft)
45 Forward Low Solenoid 126 Forward High/Low Relay
46 Forward High Solenoid 127 Reverse High/Low Relay
15 - 15 - 01/14
47 Reverse High Solenoid * 129 4 Wheel Steer Relay

48 Reverse Low Solenoid * 130 2 Wheel Steer Relay
* 50 4 Wheel Steer Solenoid
* 52 2 Wheel Steer Solenoid
Lights
140 LH Brake Light
141 RH Brake Light
Switches 147 Park Brake Indicator Light
61 Transmission Dump Switch (Loader) * 177 2 Wheel Steer Indicator Light
62 Forward/Reverse Switch * 178 Front Instrument Console Illumination
64 Brake Light Switch
Wire Number Identification
65 Brake/Drive Select Switch
Refer to pages C/42-1 on for full wire number
97 Powershift Column Switch identification and descriptions.
* 98 Front Proximity Switch
From m/c no. 430001

* 99 Rear Proximity Switch Note: Fuse C6 is only fitted on machines from serial
* 100 Steer Mode Select Switch number:
3CX (214) - 438636; 4CX (214S) - 437866
Prior to this, the gear controls were protected by
15 - 15 - 01/14
fuse C3.
Issue 2
CONTENTS
CONTENTS

Basic Machine
60 61 19 20 73 75 77
74 76 106
143 145
63 B B
3 5 140 13 14 15 142 144
9 10 57 11 12
1 8
112 B/N B/O

116 141 68
56
6 7
4
114 54
113
118 16
105 117 69
72
147 149 151 175
146 148 150 152 155
65 17
110 22 23 21 24
18
67
115
66 70
62
71
64
111
9804/1103 15 - 15 - 01/15 3270 - C/18-1.3 Issue1

CONTENTS
CONTENTS

Basic Machine
Component List 1
Refer to pages 15 - 15 - 01/15 and 15 - 15 - 01/18
The basic circuit shows a standard 3CX (214) machine fitted with syncro shuttle transmission and 2 wheel steer.Pages
15 - 15 - 01/19 to 15 - 15 - 01/31 show machine circuits that differ from the ‘basic’. Note that ONLY the differences are shown.

1 Battery 60 Transmission Dump Switch (Gear)
2 Starter Switch 61 Transmission Dump Switch (Loader)
4 Starter Solenoid 63 Park Brake Switch
5 Starter Motor 64 Brake Light Switch
6 Forward Solenoid 65 Brake/Drive Select Switch
7 Reverse Solenoid 66 Hydraclamp Switch
8 Reverse Alarm 67 Hydraulic Speed Control Switch
9 2/4 Wheel Drive Solenoid 68 Hydraulic Speed Control Switch
10 Fuel Pump Solenoid 69 Shovel Reset Switch
11 Hydraclamp Solenoid 70 Rear Horn
12 Hydraulic Speed Control Solenoid 71 Hazard Warning Switch
13 Socket (Junction Box Feed) 72 Direction Indicator Switch
14 Shovel Reset Solenoid 73 Engine Coolant Temperature Switch
15 Rear Horn 74 Transmission Oil Temperature Switch
16 Diode 75 Engine Oil Pressure Switch
17 Indicator Flasher Unit 76 Transmission Oil Pressure Switch
18 Side Instrument Console 77 Air Filter Restriction Switch
19 Coolant Temperature Sender 78 Face Level Fan Switch
20 Fuel Gauge Sender 79 Heated Seat Switch
21 Tachometer 80 Rear Washer/Wiper Switch
22 Coolant Temperature Gauge 81 Head Light Flasher Switch
23 Fuel Gauge 82 Front Washer/Wiper Switch
24 Hourmeter 83 Horn Push (Front)
25 Front Instrument Console 84 Rear Fog Light Switch
26 Alternator 85 Head and Side Lights Switch
27 Cigar Lighter 86 Head Light Dip Switch
28 Clock 87 Front Working Lights Switch
29 Face Level Fan 88 Rear Working Lights Switch
30 Heated Seat 89 Interior Light Switch
31 Rear Washer Motor 90 Interior Light Switch
32 Rear Wiper Motor 91 Beacon Switch
33 Washer Motor 92 Heater Switch
34 Front Wiper Motor 93 Air Conditioning Switch
35 Horn (Front) 94 Air Conditioning Pressure Switch
36 Socket (Dipper Light) 95 Air Conditioning Pressure Switch
37 Beacon 105 Electric Rear Window Switch
38 Tracker 106 Brake Fluid Low Level Warning Switch
39 Radio
40 Heater Motor Fuses
A1 - A10
41 Heater Resistor
B1 - B10
42 Air Conditioning Compressor
C1 - C10
54 Warning Buzzer
56 Electric Rear Window ECU Refer to page 15 - 05 - 01/20 for further fuse details and
57 Electric Rear Window Motor ratings.
..... continued
9804/1103 15 - 15 - 01/16 3270 - C/18-2.2 Issue 1

CONTENTS
CONTENTS

Basic Machine
Component List 2
Refer to pages 15 - 15 - 01/15 and 15 - 15 - 01/18 173 Front Working Lights
Relays 175 Brake Fluid Low Level Warning Light
111 Ignition Relay ‘1’ Cable Colour Code
112 Transmission Dump Relay B Black
113 Forward Relay N Brown
S Slate
114 Reverse Relay
G Green
115 Park Brake Relay O Orange
116 4 Wheel Brake Relay U Blue
117 Hydraulic Speed Control Relay K Pink
118 Rear Horn Relay P Purple
119 Ignition Relay ‘2’ W White
120 Road Lights Relay LG Light Green
121 Italian Worklight Relay R Red
122 Heater Relay Y Yellow
132 Front Working lights Relay
133 Rear Working lights Relay
Refer to page 15 - 05 - 01/22 for relay identification
Lights
140 LH Brake Light
141 RH Brake Light
154 Main Beam Warning Indicator Light
155 Gauge Illumination
156 Turn Signal Indicator Light
158 Side Lights Indicator Light
159 Rear Work Lights Indicator Light
160 Front Work Lights Indicator Light
161 Rear Fog Light Indicator Light
162 Rear Fog Light
163 LH Main Beam Light
164 RH Main Beam Light
165 LH Dip Beam Light
166 RH Dip Beam Light
167 LH Number Plate Light
168 LH Tail Light
169 LH Side Light
170 RH Number Plate Light
171 RH Tail Light
172 RH Side Light
9804/1103 15 - 15 - 01/17 3270 - C/18-3.3 Issue 1

CONTENTS
CONTENTS
CONTENTS

Basic Machine
162 164 165 167 169 170 172

35
34 173 174 89 42
163 166 168 171
33 37
27 29 31 39
36 41
30 32 90
95
26
40
84
25
78 79 86 94
86 87
80
157 158 154 160
156 153 159 161
83
82 88
85
121
91 93
132 133
92
81
120
119
9804/1103 15 - 15 - 01/18 15 - 15 - 01/18 3270 - C/18-4.3 Issue 1

CONTENTS
CONTENTS
CONTENTS

Powershift (PS700) Transmission and Steer Circuit - AWS Machines only
63
16 61
12
43 44 68
5
3
8 140
1 9 16 102
136 134
112 53
141
114 46 47 48
45 117
102
101
4 115 135 116
124
67
127
113 100
110 114
64 176 177 178

49 175
97
96
50 52
51
62
98 99
2 111
119
9804/1103 15 - 15 - 01/19 15 - 15 - 01/19 3270 - C/18-5.? Issue 1

CONTENTS
CONTENTS

Powershift Transmission (PS700) and Steer Circuit - AWS Machines only
Component List
Refer to page 15 - 15 - 01/19
Note: Except for the transmission and steer circuits (shown

opposite), the AWS electrical circuit is the same as shown on
Pages 15 - 15 - 01/15 to 15 - 15 - 01/18.
It should be noted that some of the options shown may not

be fitted on all machine models.

12 Hydraulic Speed Control Solenoid 117 Hydraulic Speed Control Relay
43 Mainshaft solenoid 123 Neutral Relay
45 Forward Low Solenoid 126 Forward High/Low Relay
46 Forward High Solenoid 127 Reverse High/Low Relay
47 Reverse High Solenoid 134 Auto Hydraulic Speed Control Relay
48 Reverse Low Solenoid 135 Driveshaft interlock Relay
49 Crab/4 Wheel Steer Solenoid 136 Driveshaft Relay
51 Crab Solenoid Lights
52 2 Wheel Steer Solenoid 140 LH Brake Light
53 Steer Mode Printed Circuit Board 141 RH Brake Light
Switches 177 2 Wheel Steer Indicator Light
61 Transmission Dump Switch (Loader) 178 Front Instrument Console Illumination
62 Forward/Reverse Switch
67 Hydraulic Speed Control Switch
9804/1103 15 - 15 - 01/20 3270 - C/18-6.3 Issue 1

CONTENTS
CONTENTS

Powershift Transmission(PS700) - 2WS Machines only
Steer Circuit 3CX 4X4X4 Machines
Component List
Refer to page 15 - 15 - 01/22

opposite), the 2WS and the 3CX 4x4x4 electrical circuit is the
same as shown on Page 15 - 15 - 01/15 to 15 - 15 - 01/18.


12 Hydraulic Speed Control Solenoid 116 4 Wheel Brake Relay
16 Diode 117 Hydraulic Speed Control Relay
44 Layshaft Solenoid 119 Ignition Relay ‘2’
45 Forward Low Solenoid 125 Driveshaft Relay
47 Reverse High Solenoid 127 Reverse High/Low Relay
48 Reverse Low Solenoid 129 4 Wheel Steer Relay
50 4 Wheel Steer Solenoid 130 2 Wheel Steer Relay
52 2 Wheel Steer Solenoid 131 Steer Relay
67 Hydraulic Speed Control Switch 134 Auto Hydraulic Speed Control Relay
68 Hydraulic Speed Control Switch 135 Steer Relay
136 Drive Relay (Layshaft & Mainshaft)
Switches
61 Transmission Dump Switch (Loader) Lights
62 Forward/Reverse Switch 140 LH Brake Light
63 Park Brake Switch 141 RH Brake Light
64 Brake Light Switch 147 Park Brake Indicator Light
65 Brake/Drive Select Switch 177 2 Wheel Steer Indicator Light
97 Powershift Column Switch 178 Front Instrument Console Illumination
9804/1103 15 - 15 - 01/21 3270 - C/18-7.3 Issue 1

CONTENTS
CONTENTS
CONTENTS

Powershift (PS700) - AWS Machines only
Steer Circuit 2CX 4X4X4 Machines
63
43 44 61 12
5 49
3
1 140 112 68
141 117 134

136
8
65 129 130
46 48
115 45
47
4 135 116
124 126
147 113 114 67

127
110
135
100 175
50
62 64
52 177 178
131
97 99 98
111
119
9804/1103 15 - 15 - 01/22 15 - 15 - 01/22 3270 - C/18-8.3 Issue 1

CONTENTS
CONTENTS
CONTENTS

3CXE (214E Series 3) only
TO PAGE
C/18 - 11
19 20 73 75 77
74 76
143 145
5 60 7
3 6 140 15 142 144
9 10
1 8
61
141
63
113 114
4
118
37 16 54
16 72 147 149 151

96 146 148 150 152 155
17
110 22 23 21 24
62 115
18
70
112
71
64
A274310
(CAD 852/30213)
2 111
9804/1103 15 - 15 - 01/23 15 - 15 - 01/23 3270 - C/18-9.? Issue 1

CONTENTS
CONTENTS

3CXE (214E Series 3) only
Component List
Main Components Relays
6 Forward Solenoid 115 Park Brake Relay
7 Reverse Solenoid 118 Rear Horn Relay
8 Reverse Alarm 119 Ignition Relay ‘2’
9 2/4 Wheel Drive Solenoid 132 Front Working lights Relay
10 Fuel Pump Solenoid 133 Rear Working lights Relay
15 Rear Horn
16 Diode Lights
17 Indicator Flasher Unit 140 LH Brake Light
18 Side Instrument Console 141 RH Brake Light
19 Coolant Temperature Sender 142 LH Front Indicator
20 Fuel Gauge Sender 143 LH Rear Indicator
21 Tachometer 144 RH Front Indicator
22 Coolant Temperature Gauge 145 RH Rear Indicator
23 Fuel Gauge 146 Alternator Warning Indicator Light
24 Hourmeter 147 Park Brake Indicator Light
25 Front Instrument Console 148 Water Temperature Indicator Light
26 Alternator 149 Transmission Temperature Indicator Light
35 Horn (Front) 150 Engine Oil Pressure Indicator Light
37 Strobe Light Socket 151 Transmission Oil Pressure Indicator Light
54 Warning Buzzer 152 Air Filter Blocked Indicator Light
Switches 155 Gauge Illumination
60 Transmission Dump Switch (Gear) 156 Turn Signal Indicator Light
61 Transmission Dump Switch (Loader) 159 Rear Work Lights Indicator Light
62 Forward/Reverse Switch 160 Front Work Lights Indicator Light
63 Park Brake Switch 173 Front Working Lights
64 Brake Light Switch 174 Rear Working Lights
70 Rear Horn
Fuses
A1 - A10
73 Engine Coolant Temperature Switch
B1 - B10
74 Transmission Oil Temperature Switch C1 - C10
75 Engine Oil Pressure Switch
76 Transmission Oil Pressure Switch Refer to page 15 - 05 - 01/2 for further fuse details and
77 Air Filter Restriction Switch ratings.
83 Horn Push (Front)
87 Front Working Lights Switch
88 Rear Working Lights Switch
9804/1103 15 - 15 - 01/24 3270 - C/18-10.2 Issue 1

CONTENTS
CONTENTS
CONTENTS

3CXE (214 E Series) only
FROM PAGE
C/18 - 9
173 174
35
26
25
87
156 153 159 160 83 88
132 133
119
A274320
(CAD 852/30213)
9804/1103 15 - 15 - 01/25 15 - 15 - 01/25 3270 - C/18-11.2 Issue 1

CONTENTS
CONTENTS
Backhoe Loader 15 - 15 - 01/26

214E Series 4 only
19 20
143 145
35
5 60 7 8 40
3 140 37 13 142 144
6 9 10 58
1 31 33
61
141
32 34
113
41 97
4
72
114 116
17
80 82
115 96
83 25
110 92 22 23 21
62
112
64
71
111
2
9804/1103 15 - 15 - 01/26 3270 - C/18-12.12 Issue1

CONTENTS
CONTENTS
3CX, 4CX and Variant From m/c no. 460001

214e Series 4 only
Component List
Main Components Relays
6 Forward Solenoid 115 Park Brake Relay
7 Reverse Solenoid 118 Rear Horn Relay
8 Reverse Alarm 119 Ignition Relay ‘2’
9 2/4 Wheel Drive Solenoid 132 Front Working lights Relay
10 Fuel Pump Solenoid 133 Rear Working lights Relay
15 Rear Horn
16 Diode Lights
17 Indicator Flasher Unit 140 LH Brake Light
18 Side Instrument Console 141 RH Brake Light
19 Coolant Temperature Sender 142 LH Front Indicator
20 Fuel Gauge Sender 143 LH Rear Indicator
21 Tachometer 144 RH Front Indicator
22 Coolant Temperature Gauge 145 RH Rear Indicator
23 Fuel Gauge 146 Alternator Warning Indicator Light
24 Hourmeter 147 Park Brake Indicator Light
25 Front Instrument Console 148 Water Temperature Indicator Light
26 Alternator 149 Transmission Temperature Indicator Light
35 Horn (Front) 150 Engine Oil Pressure Indicator Light
37 Strobe Light Socket 151 Transmission Oil Pressure Indicator Light
54 Warning Buzzer 152 Air Filter Blocked Indicator Light
Switches 155 Gauge Illumination
60 Transmission Dump Switch (Gear) 156 Turn Signal Indicator Light
61 Transmission Dump Switch (Loader) 159 Rear Work Lights Indicator Light
62 Forward/Reverse Switch 160 Front Work Lights Indicator Light
63 Park Brake Switch 173 Front Working Lights
64 Brake Light Switch 174 Rear Working Lights
70 Rear Horn
Fuses
A1 - A10
73 Engine Coolant Temperature Switch
B1 - B10
74 Transmission Oil Temperature Switch C1 - C10
76 Transmission Oil Pressure Switch Refer to page 15-15-01/2 for further fuse details and ratings.
77 Air Filter Restriction Switch
83 Horn Push (Front)
87 Front Working Lights Switch
88 Rear Working Lights Switch
9804/1103 15 - 15 - 01/27 3270 - C/18-13.2 Issue 1

CONTENTS
CONTENTS Backhoe Loader 15 - 15 - 01/28

214 E Series 4 only
74 76
59
73 75 77 173 174
39
60
26
29
54
87
78
88
24
147 149 151
146 148 150 152
28 18
132
133
119
9804/1103 15 - 15 - 01/28 3270 - C/18-14.2 Issue1

CONTENTS
CONTENTS

Autoshift Transmission - 2WS Machines Only
1
4 5
3
70
90 71
50
72
73 7
8
51
9
52
53 10
54
11
16 12
13
55 14
77
15
180D
17
74
18
56 75 19
57
76
9804/1103 15 - 15- 01/29 3270 - C/18-15.2 Issue 1

CONTENTS
CONTENTS

Autoshift Transmission - 2WS Machines Only
Component List
Refer to page 15-15-01/29
Except for the circuits shown opposite the 2WS Autoshift

electrical circuit is the same as shown on pages 15-15-01/15
to 15-15-01/18.
Main Components
1 Thermostart
2 Battery
3 Starter Switch
4 Starter Solenoid
5 Starter Motor
6 Reverse Alarm
7 Speed Sensor
8 Autoshift Electronic Control Unit (ECU)
14 Reverse High Solenoid
15 Autoshift Gear Selector
17 Warning Buzzer
18 Psion Tester Connection
19 Hydraulic Speed Control Solenoid
Switches
52 Transmission Dump Switch
53 Autoshift Kickdown Switch
54 Autoshift Throttle Switch
55 Brake Mode Selector
Relays
71 Parking Brake Relay
72 Ignition 1 Relay
73 Reverse Alarm Relay
74 Ignition 2 Relay
76 Auto Hydraulic Speed Control Relay
77 2 Wheel Brake Relay
Lights
90 Parking Brake Indicator
Fuses
A1 - A10
B1 - B10
C1 - C10
Refer to page 15 - 05 - 01/2 for further fuse details and

ratings.
9804/1103 15 - 15 - 01/30 3270 - C/18-16.2 Issue 1

CONTENTS
CONTENTS

Autoshift Transmission - AWS Machines Only
1
4 5
3
70
90 71
50
72
73 6
51
9
52
53 10
54
11
12
16
13
14
55 15
17
74
18
56 75 19
57
76
9804/1103 15 - 15 - 01/31 3270 - C/18-17.1 Issue 1

CONTENTS
CONTENTS

Autoshift Transmission - AWS Machines only
Component List
Refer to page 15 - 15 - 01/31
Except for the circuits shown opposite the AWS Autoshift

electrical circuit is the same as shown on pages 15 - 15 -
01/15 to 15 - 15 - 01/18
Main Components
1 Thermostart
2 Battery
3 Starter Switch
4 Starter Solenoid
5 Starter Motor
6 Reverse Alarm
7 Speed Sensor
8 Autoshift Electronic Control Unit (ECU)
15 4 Wheel Drive Solenoid
17 Warning Buzzer
18 Psion Tester Connection
19 Hydraulic Speed Control Solenoid
Switches
53 Autoshift Kickdown Switch
54 Autoshift Throttle Switch
Relays
72 Ignition 1 Relay
74 Ignition 2 Relay
Lights
90 Parking Brake Indicator
Fuses
A1 - A10
B1 - B10
C1 - C10
Refer to page 15 - 05 - 01/2 for further fuse details and

ratings.
9804/1103 15 - 15 - 01/32 3270 - C/18-18.1 Issue 1

CONTENTS
CONTENTS

Powershift Transmission (PS750) and Steer Circuit - AWS Machines only
Refer to pages 15-15-01/34

opposite), the AWS electrical circuit is the same as shown on
15-15-01/15 to 15-15-01/18


12 Hydraulic Speed Control Solenoid 117 Hydraulic Speed Control Relay
43 Mainshaft solenoid 124 Auto 2 Wheel Drive Relay
44 Layshaft Solenoid 126 Forward High/Low Relay
45 Forward Low Solenoid 127 Reverse High/Low Relay
46 Forward High Solenoid 134 Auto Hydraulic Speed Control Relay
47 Reverse High Solenoid 135 Driveshaft Interlock Relay
48 Reverse Low Solenoid 136 Driveshaft Relay
50 4 Wheel Steer Solenoid Lights
51 Crab Solenoid 140 LH Brake Light
52 2 Wheel Steer Solenoid 141 RH Brake Light
53 Steer Mode Printed Circuit Board 142 Parking Brake Indicator Light
Switches 177 2 Wheel Steer Indicator Light
61 Transmission Dump Switch (Loader) 178 Front Instrument Console Illumination
9804/1103 15 - 15 - 01/33 3270 - C/18-19.2 Issue 1

CONTENTS
CONTENTS Backhoe Loaders 15 - 15 - 01/34

Circuit Diagram (cont’d)
Powershift (PS750) Transmision and Steer Circuit - AWS Machines only
63
16 61 12
43 44 68
5
3
8 140
1 9
112 53
141
136 48
102
46 45 134
47 117
116
4 135
115 124 126 101
67
127
142 113 114 100
110 16
16
64 175 176 177 178
49
97
96
62 50 51 52
16
98 99
2
111 119
9804/1103 15 - 15 - 01/34 3270 - C/18-20.1 Issue1

CONTENTS
CONTENTS

Powershift (PS750) Transmission - 2WS Machines
Steer Circuit - 3CX 4X4X4 Machines only
63 12
3 16 43 44 49 61
5
1 140 112 68
125 141 117

8 45 132
65 46 48 131
47
134
4 115 135 116
63
124 126
113 114 127 67

147
110
130
16 100 50
178
16
62 52
64
16 177
129
97 99 98
2
111
119
9804/1103 15 - 15 - 01/35 3270 - C/18-21.? Issue1

CONTENTS

Powershift Transmission (PS750) - 2WS Machines
Steer Circuit - 3CX 4X4X4 Machines only
Component List
Refer to page 15-15-01/35

opposite), the 2WS and the 3CX 4x4x4 electrical circuit is the
same as shown on Pages 15-15-01/15 to 15-15-01/18.


12 Hydraulic Speed Control Solenoid 116 4 Wheel Brake Relay
16 Diode 117 Hydraulic Speed Control Relay
43 Mainshaft Solenoid 119 Ignition Relay ‘2’
45 Forward Low Solenoid 125 Driveshaft Relay
47 Reverse High Solenoid 127 Reverse High/Low Relay
48 Reverse Low Solenoid 129 4 Wheel Steer Relay
49 Drive/Brake Solenoid 130 2 Wheel Steer Relay
50 4 Wheel Steer Solenoid 131 2 Wheel Steer Solenoid Relay
52 2 Wheel Steer Solenoid 132 4 Wheel Steer Solenoid Relay
135 Driveshaft Interlock Relay
Switches
61 Transmission Dump Switch (Loader) Lights
62 Forward/Reverse Switch 140 LH Brake Light
63 Park Brake Switch 141 RH Brake Light
64 Brake Light Switch 147 Park Brake Indicator Light
65 Brake/Drive Select Switch 177 2 Wheel Steer Indicator Light
67 Hydraulic Speed Control Switch 178 4 Wheel steer Indicator Light
9804/1103 15 - 15 - 01/36 3270 - F/18-22.1 Issue 1

CONTENTS
CONTENTS

Auxiliary Options
Hand Held Tools Dedicated Quick Hitch

(Gear Pump) Pole Planter Smooth Ride System (SRS)
1 Hydraulic Enable Switch
1 Switch 2 Indicator Lamp 1 Selector Switch 1 Selector Switch/LED
2 Indicator Lamp 3 Warning Buzzer 2 Grab Solenoid 2 Accumulator Solenoids
3 Solenoid 4 Operator Switches 3 Rotation Solenoid
5 Relay
6 Solenoid
9804/1103 15 - 15 - 01/37 3270 - C/18-23.1 Issue 1

CONTENTS
CONTENTS

Auxiliary Options (cont’d)
Hammer Hand Held Tools (Variable Flow Pump)
1 Micro Switch 1 Switch

2 Relay 2 Indicator Lamp
3 Panel Switch 3 Solenoid (normally open)
4 Hammer Solenoid 4 Solenoid
9804/1103 15 - 15 - 01/38 3270 - C/18-24.1 Issue 1

CONTENTS

Auxiliary Options (cont’d)
Powershift (PS750) 2/4WD Powered On 2WD (Germany) Power Sideshift with Hammer Circuit
1 Brake Light Switch 1 Micro Switch

2 Brake Mode Switch 2 Hammer Relay
3 Auto 2WD Relay 3 Hammer Switch
4 4 Wheel Brake Relay 4 Hydraclamp Switch
5 4WD/4WB Relay 5 Hammer Solenoid
6 Hydraclamp Solenoid
7 Power Sideshift Solenoid
8 Buzzer
9804/1103 15 - 15 - 01/39 3270 - C/18-25.1 Issue 1
CONTENTS
CONTENTS

Circuit Diagrams - Electrical (Servo Machines)
446
446
9804/1103 15 - 15 - 02/5 Issue 2

CONTENTS
CONTENTS

Circuit Diagrams - Electrical (Servo Machines) (continued)
Servo Controls Component Key

29 Gear Select Switch
43 Safety Solenoid
44 Steer Relay
45 Steer Solenoid
46 Clam Solenoid
47 Shovel Solenoid
48 Loader Solenoid
49 Dipper Solenoid
50 Slew Solenoid
51 Bucket Solenoid
52 Boom Solenoid
53 Backhoe Relay
54 Loader Relay
55 Joystick Steer Enable Switch
56 Forward/Reverse Select Switch
57 Joystick Isolator Switch
58 Right Hand Joystick
59 Left Hand Joystick
60 Shovel Position Switch
61 Return to Dig (RTD) Enable Switch
62 Float Enable Switch
63 Fault Reset Switch
64 Seat Rear Switch
65 Seat Forward Switch
66 Hydraclamp Relay
68 Auxiliary Service Relay (e.g. Jaw Bucket)
69 Auxiliary Service Solenoid (e.g. Jaw Bucket)
70 Horn Relay
71 Horn Change Over Relay
72 Front Horn
73 Rear Horn
74 Logic Control Box
75 Backhoe Valve Solenoid
9804/1103 15 - 15 - 02/6 Issue 1

FUSE C5
1
010 003 THERMOSTART
9804/1103
2
BATTERY
BATTERY ISOLATOR
CONTENTS
BATTERY
CONTENTS
6
7
200
8
2
004
200 842 STARTER SOLENOID
Basic Machine
KEY SWITCH
4
PRIMARY
4
NEUTRAL START RELAY
FUSE 4
810
5
200 ALTERNATOR
8
FROM NEUTRAL
9
SELECT
001
IGNITION RELAY 1
FUSE C7
6
4
407
412
133 FUSE A5
11
002 107
2
13
200
8
WAXSTAT
PRIMARY TO GEARBOX
IGNITION
14
CONTROL FEED COLD START ADVANCE
FUSE 3 RELAY 1 10
105 E.S.O.S.
12
FUSE A2
6
4
133 IGNITION RELAY 2
8
200
15
IGNITION
RELAY 2
007
HAZARD SWITCH
15 - 15 - 03/1
19
803 LH REAR INDICATOR

HAZARD SWITCH B/N
20
LH FRONT INDICATOR
INDICATOR
SWITCH LH REAR INDICATOR ROOF-USA
21
002
8
10
805
18
22
LH FRONT INDICATOR ROOF-USA
830
3
16
806
Backhoe Loaders
B/O
5
23
RH FRONT INDICATOR
18
804 806
24
RH REAR INDICATOR
17
104 49a
1
31
FUSE A3 802
25
2
49
RH FRONT INDICATOR ROOF-USA
300 C2
3
26
RH REAR INDICATOR ROOF-USA

PRIMARY FUSE C2
FLASHER
17
FUSE 1 UNIT
FLASHER UNIT
200
27
106 + WATER TEMP GAUGE

29
FUSE B1 -
U 408
28
FUEL SENDER
+ FUEL GAUGE
30
CLOCK
DIRECT EARTH CLOCK
617
31
304 TACHOMETER TACHOMETER

32
FUSE C4
HOURMETER
4 4 0 3
33
HOURMETER
35
ALTERNATOR
HAND BRAKE
WATER TEMP
TRANS OIL TEMP 404 TRANS OIL TEMP SWITCH

34 SIDE CONSOLE
INSTRUMENTS
ENGINE OIL PRES 403 ENGINE OIL PRESS SWITCH
TRANS OIL PRES 405 TRANS OIL PRESS SWITCH

830
402
36 37 38 39 40 41
53 54 55 56 57
AIR FILTER AIR FILTER VAC. SW
ILLUMINATION
42
INSTRUMENT PANEL
BUZZER
43
411
45
MASTER
45
805
WARNING
806
45
LIGHTS
45
TURN SIGNAL
46
SIDE LIGHTS
WARNING CLUSTER
47
HAZARD WARNING
804
48
MAIN BEAM
44
49
LH
RH
SPEAKER
SPEAKER
REAR W/L
INSTRUMENTS
FRONT CONSOLE
50
FRONT W/L
51
601
602
860
59
60
REAR FOG
859
52
3270 - C/19_1.1
304A
RADIO
001
133
002
007
200
830
837
861
855
835
401
407
58
EARTH
From m/c no. 495455
15 - 15 - 03/1
Issue1
CONTENTS
CONTENTS

Basic Machine (cont’d)
The basic circuit shows a standard mahine. Pages 15 - 15 - 03/5 to 15 - 15 - 03/14 show machine circuits that differ from the
‘basic’. Note that ONLY the differences are shown.
Main Components
1 Thermostart 49 Main Beam Warning Indicator Light

2 Battery Isolator 50 Rear Working Light Indicator
3 Battery 51 Front Working Light Indicator
4 Starter Switch 52 Rear Fog Light Indicator
5 Neutral Start Relay 53 Engine Coolant Temperature Switch
6 Starter Solenoid 54 Transmission Oil Temperature Switch
7 Starter Motor 55 Engine Oil Pressure Switch
8 Alternator 56 Transmission Oil Pressure Switch
9 From Neutral Selector 57 Air Filter Restriction Switch
10 Cold Start Advance 58 Radio (if fitted)
11 Cold advance start 59 RH Speaker
12 Engine Shut Off Switch (ESOS) 60 LH Speaker
13 To Gearbox Control Feed
17 Indicator Flasher Unit
21 LH Rear Roof Indicator (N. Am)
22 LH Front Roof Indicator (N. Am)
25 RH Front Roof Indicator (N. Am)
26 RH Rear Roof Indicator (N. Am)
27 Coolant Temperature Sender
28 Fuel Gauge Sender
29 Coolant Temperature Gauge
30 Fuel Gauge
31 Clock
32 Tachometer
33 Hourmeter
34 Side Instrument Console
42 Panel Illumination
43 Warning Buzzer
44 Front Instrument Console
46 Turn Signal Indicator
47 Side Lights Indicator
48 Hazard Warning Indicator
9804/1103 15 - 15 - 03/2 3270 - C/19-2.1 Issue 1

001
133
007
200
830
829
837
861
855
835
407
9804/1103
CONTENTS
CONTENTS
114
CIGAR LIGHTER
61
FUSE B4 830
FACE LEVEL FAN

63
62
Basic Machine (cont’d)
HEATED SEAT SWITCH
HEATED SEAT
65
64
5
M
REAR 863
68
REAR WASHER PUMP
6
WASH/
WIPE
1
M
SWITCH 862 REAR WIPER
67
3
103 864
66
8
7
FUSE B5
839
M
FRONT WASHER PUMP
70
FRONT W/W SWITCH

FUSE B2
110 983
M
FRONT WIPER
72
69
982
15 - 15 - 03/3
110
73
841
984
ECU
71
840
INTERMITTENT
H/LIGHT
FLASH
FRONT HORN SWITCH

Backhoe Loaders
814 FRONT HORN
74
75
8
7
FOG LIGHT
829 FOG LIGHT SWITCH
76
REMOVED FOR TERRITORIES TERRITORIAL OPTION
78
ITALY, GERMAN ONLY ITALY, GERMAN ONLY
3
835
77
868
79
FUSE C1 LIGHTS RELAY
B/U B LH MAIN BEAM
83
ROAD LIGHTS
RELAY DIP FUSE C10
1133
4
SWITCH
836 837 B/U B
10
RH MAIN BEAM
80
5
832
6
82
833 834
127 B/Y B
7
LH DIP BEAM
84 85
6
2
FUSE C9
FUSE 2
3
FUSE B9 FUSE A9 B/Y B RH DIP BEAM

86
PRIMARY
829
7
830
ROAD
LIGHTS
311
SWITCH
828
FUSE A10
FUSE C1
81
LH TAIL LIGHT
87
B/G B LH SIDE LIGHT

88
DIPPER SOCKET
89
No PLATE LIGHT
90
RH TAIL LIGHT
91
B/P B RH SIDE LIGHT

92
LIGHT SWITCH
ENGINE RUNING
RELAY
3
93 5
407
2
1133
1853
96
F/W/L SWITCH
5
94
FRONT WORKING LIGHTS

6
855
4
116
98
2
3
310 855
8
4
7
FUSE B10
5
6
6
4
1
117
2
REAR WORKING LIGHTS

2
3
309
8
861
99
FUSE B8
97
95
8
861
R/W/L SWITCH
303 INTERIOR LIGHT
100
FUSE C3
BEACON SWITCH
8
7
101
3
M
894 BEACON
2
102
HEATER RELAY HEATER FAN MOTOR

1042
8
M
935 HEATER
102
105
HEATER RESISTOR
FUSE C7 800
6
4
HEATER SWITCH
3270 - C/19-4.1
106
HEATER RELAY
103
8
7
AIR-CON SWITCH 902 904 903

AIR-CONDITIONING
107
3
109
110
108
2
From m/c no. 495455
15 - 15 - 03/3
Issue1
AIR-CON COMPRESSOR
9
1
13
9804/1103
CONTENTS
401 401
START RELAY
TO NEUTRAL
10
8
810
CONTENTS
TO FUSE A5
6
815 815
9
3
810
934 934 815 P/BRAKE SWITCH
TRANS DUMP
RELAY
4
8
3
5
5 6
107 FORWARD RELAY DUMP SWITCH (GEARLEVER)
Transmission and Steering
1
2
4
812
10
FORWARD SOLENOID
809
3
5
852
7
F
N
107 FORWARD/REVERSE RELAY
R
REVERSE RELAY
FOR / REV
10
8
SWITCH
808
7
12
811 REVERSE SOLENOID
6
11
811 847
14
REVERSE ALARM
15 - 15 - 03/5
1
9
Backhoe Loaders
14
401
START RELAY
TO NEUTRAL
810
TO FUSE A5
2
815
3
810
934 815 P/BRAKE SWITCH
TRANS DUMP
RELAY
4
5
3
5
107
10
FORWARD RELAY
13
INTERLOCK 851
1
DRIVE RELAY MAINSHAFT SOLENOID
1
RELAY
2
4
4
1
1
15
809 850
3
5
LAYSHAFT SOLENOID
852
11
7
3
3
5
F
N
107 TRANSMISSION EARTH
12
R
REVERSE RELAY
883
FOR / REV
10
SWITCH
808
7
16
847 REVERSE ALARM

6
883
18
POWER SHIFT
GEAR SELECTOR REVERSE 849 REVERSE LOW SOLENOID
H/L RELAY
9
1
6
7
811 REVERSE HIGH SOLENOID

2
8
856
10
19
107 3
17
4
858
21
FORWARD 848 FORWARD LOW SOLENOID

H/L RELAY
9
6
7
812 FORWARD HIGH SOLENOID

8
10
22
20
FRONT PROX SW
1
PROXIMITY SWITCHES
6
002 109 819 821

CRAB RELAY
2
3
FUSE A4
5
820 CRAB/4WS
REAR PROX SW RELAY
7
822
2WS RELAY
8
STR MODE SW 823

4WS RELAY
CRAB/4WS SOLENOID
11
007 106 845

FUSE B1
4
12
P.C.B.
4WS SOLENOID
826
STEER MODE
13
4WS WRNG LGHT 824

9
2WS/4WS
14
3270 - C/19-5.1
CRAB SOLENOID 4WS/CRAB MODE SELECTOR

MODE SELECTOR
15
CRAB WRNG LGHT

STEER MODE P.C.B.
10
16
2WS SOLENOID
825
(SIDE CONSOLE)
17
2WS WRNG LIGHTS

18
From m/c no. 495455
15 - 15 - 03/5
Issue1
(FRONT CONSOLE)
CONTENTS
CONTENTS

Transmission And Steering
Manual Transmission Steer Mode - 4CX and 3CX Super (4x4x4)
1 To wire 401 on page C/19-1 1 Front Proximity Switch

2 Parking Brake Relay 2 Rear Proximity Switch
3 Parking Brake Switch 3 Steer Mode Selector Switch
4 Transmission Dump Relay 4 Steer Mode Printed Circuit Board
5 Dump Switch on Loader Lever 5 Crab/4WS Relay
6 Dump switch on Gear lever 6 Crab Relay
7 Forward/Reverse Selector Lever 7 2WS Relay
8 Forward Relay 8 4WS Relay
9 To Neutral Start Relay on page C/19-1 9 4WS/Crab Selector (part of 4)
10 Forward Solenoid 10 2WS/4WS Selector (part of 4)
11 Reverse Relay 11 Crab/4WS Solenoid
12 Reverse Solenoid 12 4WS Solenoid
13 To Fuse A5 on page C/19-1 13 4WS Indicator Light
14 Reverse Alarm 14 Crab Solenoid
15 Crab Indicator Light
16 2WS Solenoid
Powershift Transmission 17 2WS Indicator Light Side Console
1 To wire 401 on page C/19-1 18 2WS Indicator Light Front Console
3 Parking Brake Switch
5 Dump Switch on Loader Lever
6 Gear Selector Switch
7 Forward/Reverse Selector Lever
8 Forward Relay
9 To Neutral Start Relay on page C/19-1
10 Interlock Relay
11 Drive Relay
12 Reverse Relay
14 To Fuse A5 on page C/19-1
16 Reverse Alarm
17 Reverse High/Low Relay
9804/1103 15 - 15 - 03/6 3270 - C/19-6.1 Issue 1

1
858 818
TH
FROM 4 GEAR
2
SELECTOR
9804/1103
854
Options
CONTENTS
107
FUSE A5
8
CONTENTS
AUTO 2WD RELAY
10
4
5
AUTO 2WD RELAY 2WD/2WB
BRAKE LIGHTS 2WD/4WB
SWITCH
3
853 4WD/4WB SOLENOID
1
126 933 BR MODE SW
6
FUSE B6 922 4 WB RELAY
5
877
3
FUSE A8
7
4WB RELAY LH BRAKE LIGHT
8
816 RH BRAKE LIGHT
FUSE A7
2
ILLUNINATION
8
7
830
6
4
4WD SWITCH
FUSE A5 AUTO 2WD RELAY
3
10
922
2
5
107
6
853 4WD SOLENOID
15 - 15 - 03/7
AUTO 2WD RELAY
1
2
BRAKE LIGHTS 877 4WB RELAY
5
818
SWITCH FUSE A8
7
126 933 4WB RELAY LH BRAKE LIGHT

Backhoe Loaders
3
8
1
858 FUSE B6 816 RH BRAKE LIGHT
TH FUSE A7
FROM 4 GEAR
SELECTOR
5
JAW RELAY
1
3
5
875
2
873
7
874
1
JAW SOLENOID
4
7
8
ILLUMINATION
829
1
FUSE A1
2
101 872
2
5
6
6
AUX HYD SWITCH

6
7
898
8
870 HAMMER SOLENOID

899
8
10
HAMMER RELAY
101
1830
HYDRACLAMP SWITCH
7
8
4
2
3
9
920 HYDRACLAMP SOLENOID

4
5
1
FUSE A4 SPEED SENSOR

SPEED
109 SENSOR 974
2
FUSE C4
304
FUSE A5
107
SPEEDO
FUSE A10
830
3
3270 - C/19-8.1
From m/c no. 495455
15 - 15 - 03/7
Issue1
CONTENTS
CONTENTS

Options (cont’d)
2 Wheel Steer/Brake Mode Auxiliary and Hydraclamp Hydraulics
1 From 4th Gear Selector 1 Excavator Lever Push Button Selector Switch
2 Auto 2 Wheel Drive Relay 2 Auxiliary Selector Switch
3 4 Wheel Braking Relay 3 Floor Push Button Selector Switch
4 Brake mode Selector Switch 4 Hydraclamp Selector Switch
5 4 Wheel Drive/4 Wheel Brake Solenoid 5 Jaw Relay
6 Brake Light Switch 6 Hammer Relay
7 LH Brake Light 7 Jaw Solenoid
8 RH Brake Light 8 Hammer Solenoid
All Wheel Steer/Brake Mode
1 From 4th Gear Selector Speedometer Option
2 4 Wheel Drive Selector Switch 1 Speed Sensor
3 Brake Light Switch 2 Speedometer
4 Auto 2 Wheel Drive Relay 3 Illumination
5 4 Wheel Braking Relay
7 LH Brake Light
8 RH Brake Light
9804/1103 15 - 15 - 03/8 3270 - C/19-7.1 Issue 1

CONTENTS
3CX, 4CX and variants From m/c no. 495455

Options (cont’d)
Auxiliary
ROTATION SOLENOID
HAND HELD TOOLS
4WD/AWB SOLENOID
AUTO 2WD RELAY
GRAB SOLENOID
QUICK HITCH
4 WB RELAY
2WD/2WB
2WD/4WB
4WD/4WB
QUICK-HITCH
SOLENOID
7
932
ROADBREAKER
SOLENOID
3
QUICK-HITCH
RELAY
6
853
931
2
2 3
2 4 10
AUTO 2WD RELAY
7
1855
OPERATOR HOLD-IN SWITCHES

1 6 8
930
972
801
801
877
107
854
ROADBREAKER
BR MODE SW
4
SWITCH
1
3
3
FUSE A8
FUSE A5
2 1
929
858
114
FEED SWITCH
QUICK-HITCH
933
114
1
BRAKE LIGHTS
SWITCH
1
FUSE B4
101
FUSE B4
126
FUSE A1
A370070
Powershift 4WD
Auto 2WD In 4th
Powered on 2WD German Hand Held Tools Dedicated Quick Hitch Pole Planter
1 Brake Light Switch 1 Rockbreaker Switch 1 Hitch Enable Switch 1 Selector Switch
2 4 Wheel Brake Relay 2 Indicator Lamp 2 Indicator Lamp 2 Grab Solenoid
3 Brake Mode Selector 3 Rockbreaker Solenoid 3 Alarm 3 Rotation Solenoid
4 Auto 2WD Relay 4 Push Button
5 4WD/AWB Solenoid 5 Push Button
6 Quick Hitch Relay
7 Quick Hitch Solenoid
9804/1103 15 - 15 - 03/9 3270 - C/19-11.1 Issue 1

CONTENTS

Options (cont’d)
Auxiliary (cont’d)
H.S.C. SOLENOID
ACCUMULATOR
H.S.C. RELAY
LEVER 'HOLD'
SOLENOID
SOLENOIDS
867
3
6 10
4
H.S.C. RELAY
2
844
9 7 8
PROXIMITY SWITCH
1857
866
865
CROWD RAM
2
1 6
H.S.C. SWITCH
7 3 4
1801
1851
7 3 7 3
SHOVEL RESET
8 2 5
2
SWITCH
SWITCH
SRS
1 1
1856
829
8 2 8 2
H.S.C. BUTTON
3
830
829
FUSE A9
818
GEAR
SELECTOR
TH
FROM 4
132
132
101
FUSE A1
FUSE B7
Smooth Ride System Return To Dig

(SRS) (Shovel Reset) Hydraulic Speed Control
1 Selector Switch 1 Selector Switch 1 Supply from 4th Gear Selector
2 Accumulator Solenoids 2 Ram Proximity Switch 2 Selector Switch
3 Lever ‘hold in’ Solenoid 3 Control Lever Push Button
4 Relay
5 HSC Solenoid
9804/1103 15 - 15 - 03/10 3270 - C/19-12.1 Issue 1

CONTENTS

Autoshift Transmission
A378770
9804/1103 15 - 15 - 03/11 3270 - C/19-9.1 Issue 1

CONTENTS

Autoshift Transmission (cont’d)
1 From Ignition Relay 2, see item 15 page 15 - 15 - 03/1

2 From Ignition Relay 1, see item 14 page 15 - 15 - 03/1
3 From Parking Brake Relay, see item 36 page 15 - 15 - 03/1
4 To Neutral Start Relay, see item 5 page 15 - 15 - 03/1
8 Reverse Alarm
9 Speed Sensor
10 Forward/Reverse Selector Switch
11 Dump Switch
12 Kickdown Switch
13 Throttle Switch
15 Autoshift Electronic Controller
16 All Wheel Steer Machines Only
17 From Brake Switch, see item 3 page 15 - 15 - 03/7
18 4 Wheel Drive Selector Switch
19 2 Wheel Steer machines Only
20 Brake Mode Selector Switch
21 From Brake Switch, see item 3 page 15 - 15 -03/7
22 2 Wheel Braking Relay
23 Alarm
24 To Hydraulic Speed Control Switch, see item 2 page 15 - 15 - 03/10
32 Psion Diagnostic Connector
9804/1103 15 - 15 - 03/2 3270 - C/19-10.1 Issue 1

CONTENTS
CONTENTS

Servo Command Pilot Circuit
1
IGN
1808
SW
200V
1816
107
D3 D4
12V
101AB
+VE SERVO
FUSE 15A
FUSE 10A
FUSE 3A
FEED BUZZER FROM
TRANS DUMP
6 7
101
931
RELAY
37 844 D10 LH 17 4
1821 1851
R1 R7 5 AMPLIFIER
PUMP DUMP
1808
EXISTING FUSE 3A 3 2 1
1826
5 6 7
MODE
+VE FEED
STAB
2
AUTO DUMP
012 TO HORN
S2
R
131
929
RELAY
3 6
8 9
830 8
SWEEPER PROPORTIONAL
934
L2
12 SWITCH.
921
BLOWER
1825
1823
1846
1822
1840
1839
1827
7 2 8 2 5 LH STAB,
SERVO L3 SWITCH AUX.OPT.
QUICK HITCH SWITCHES

L1 S1 3 ENABLE 4 TO
AUTO
10 FLOAT AUX
1857
SWITCH
112
ECU
8
2 3 7 6 7 2 FEED 16
1804
S3
1809
18
1824
1805
RTD 1813
4k
934
0.5k 0.5k
930
FUSE 1A
875
1814 D6
1811
0V 1V 9V 10V
TO HSC
1806
TRANS DUMP
RELAY
11 RTD
REAR HORN
D1
AUX
FROM TACHO ILLUMINATION
1805 D7 14 16 D9
1824
13 15
D8
6 7
RH
19 4
D5
1812 1833 1850
D2
5 AMPLIFIER
1810 D11
FUSE 3A 3 2 1
R2 R3 R4 R5 1807
PROPORTIONAL
SWITCH.
1841
1843
1842
1807 CLAM, AUX,
HAMMER RH STAB.
SOLENOID FEED
870
20
1844 0.5k 4k 0.5k
R10 R18 R19 0V

870
R8 R9 R12 R13 R14 R15 R16 R17 1V 9V 10V
1838 1845
1834
1849 1832
1847
1807
947
1829 1848
R20 R21 R22 R23
FUSE 5A
FUSE 5A
1837
1836
AUX AUX AUX

AUX
1831
1802
1828
960
956
1803
CLAM CLAM
959
957
955
954
EXT
958
953
EXT L.STAB L.STAB R.STAB R.STAB OPTION

OPTION
DIP DIP
1 2 3 4 6 5
H T B R R H T H B R T H B R
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
ARMS/BOOM SHOVEL/BUCKET
CHANGEOVER VALVE LOADER VALVE AUX VALVE GROUND
CHANGEOVER VALVE EXCAVATOR VALVE LH LH/RH AUX VALVE
PILOT PILOT
PRESSURE PRESSURE
VALVE VALVE
9804/1103 15 - 15 - 03/13 3270 - C/19-14.1 Issue1

CONTENTS
CONTENTS

Servo Command Pilot Circuit (cont’d)
The circuit shown refers to the Servo option only, for the
remainder of the circuit see the appropriate additional
circuit.
Main Components
R20 Stabiliser Lower Changeover
1 Starter Switch
R21 Stabiliser Raise Changeover
2 Return To Dig Switch
R22 Stabiliser Lower Mode Changeover
3 Servo Enable Switch R23 Stabiliser Raise Mode Changeover
4 Sweeper Blower Switch
5 Shovel Limit Switch On the illustration:
6 Forward Seat Proximity Switch B = Bottom
7 Rearward Seat Proximity Switch T = Top
8 Mode Changeover Switch H = Head
9 Stabiliser Switch R = Rod
10 Float Electro Magnetic Latch Coil
11 Return To Dig Electro Magnetic Latch Coil
14 Auxiliary Switch
15 Rear Horn
16 Quick Hitch Switch
17 Left Hand Amplifier
18 Left Hand Proportional Rocker Switch
19 Right Hand Amplifier
20 Right Hand Proportional Rocker Switch
21/22 Manifold Arms/Boom Changeover Solenoid
23/24 Manifold Shovel/Bucket Changeover Solenoid
25/26 Loader Solenoid
27/28 Auxiliary Solenoid
29/30 Excavator Left Hand Stabiliser Solenoid
31/32 Excavator Right Hand Stabiliser Solenoid
33 Manifold Left Hand Pilot Pressure Valve
34 Manifold Left/Right Hand Pilot Pressure Valve
35/36 Auxiliary Option Solenoid
37 Alarm
Relays
R1 Ignition
R2 Front Seat
R3 Front Mode Changeover
R4 Rear Seat
R5 Rear Mode Changeover
R6 Spare
R7 Dump Interlink (autoshift only)
R8 Front Auxiliary Supply
R9 Hammer Interlink
R10 Stabiliser Isolator
R11 Spare
R12 Sweeper/Clam Changeover
R13 Pilot Valve Changeover
R14 Auxiliary/Clam 2 Changeover
R15 Auxiliary/Clam 1 Changeover
R16 Stabiliser/Clam 2 Changeover
R17 Stabiliser/Clam 1 Changeover
R18 Stabiliser/Auxiliary 1 Changeover
R19 Stabiliser/Auxiliary 2 Changeover
9804/1103 15 - 15 - 03/14 3270 - C/19-13.1 Issue 1

CONTENTS
CONTENTS

Circuit Diagrams - Hydraulic (Standard Machines)
Basic Machine (2WS & AWS Machines)

Component Key
P1 Pump, Main Section 34 Lift Ram L.H.

P2 Pump, Secondary Section 35 Clam Shovel Ram R.H.
P2A Pressure Test Point (auxiliary attachments) 36 Clam Shovel Ram L.H.51 Bucket Ram
S Suction Line 52 Boom Ram
T Tank 53 Stabiliser Ram
1A Neutral Circuit Line 54 Stabiliser Ram
1B Neutral Circuit Line 55 Dipper Ram
2A Neutral Circuit Line 56 Left Hand Slew Ram(Centremount Machines Only)
3 Loader Valve Block 57 Right Hand Slew Ram(Centremount Machines Only)
3A Pressure Test Point (M.R.V.) 58 One Way Restrictor
3B Main Relief Valve 59 Stabiliser Check Valve (Standard on Centremount,
3C Loader Lift Ram Spool Optional on Sideshift Machines)
3D Loader Shovel Ram Spool 61 Hose Burst Protection Valve (optional)
3E Clamshovel Spool 62 Hydraclamps (Sideshift Machines Only)
3F Shovel Ram Head Side A.R.V. 62A Hydra-clamp Exhaust Line
3G Shovel Ram Rod Side A.R.V. 64 Slew Cylinders (Sideshift Machines Only)
3H Load Hold Check Valve 65 One Way Restrictor (Centremount Machines Only)
3J Load Hold Check Valve 66 Hose Burst Protection Valve (optional)
3K Load Hold Check Valve
3L Unloader Valve Spool Note: Excavator services shown here are to the JCB control
3M Unloader Pilot Valve pattern. If ISO, Case or Ford control pattern is used, the
3N Unloader Check Valve excavator spools and relief valves will apply to different
3P Pressure Test Point (Unloader) services.
3Q Hydraulic Speed Control Solenoid
4 Excavator Valve Block Note: The policy of JCB is one of continuous improvement,
4A Slew Spool therefore as products develop, there may be variations to the
4B Boom Spool circuits. Page 15-20-02/3 titled 'Circuit Variations' will identify
4C Stabiliser Spool these differences.
4D Stabiliser Spool
4E Dipper Spool
4F Bucket Spool
4G Hydraclamp Valve
4H Slew A.R.V.
4J Slew A.R.V.
4K Boom Ram Rod Side A.R.V.
4L Boom Ram Head Side A.R.V.
4M Dipper Ram Head Side A.R.V.
4N Dipper Ram Rod Side A.R.V.
4R Load Hold Check Valve
4S Load Hold Check Valve
4T Load Hold Check Valve
4U Load Hold Check Valve
4V Load Hold Check Valve
4W Load Hold Check Valve
4X Make-up Check Valve
6 In-tank Filter
7 Priority Valve
7B Connection to Steer Circuit
13 Anti-cavitation Check Valve
25 Sequence Valve
26 Hydraulic Oil Cooler
31 Shovel Ram R.H.
32 Shovel Ram L.H.
33 Lift Ram R.H.
9804/1103 15 - 20 - 02/1 Issue 3

CONTENTS
CONTENTS
62A 54
62 4
35
4G
T
31 4X 61
33
6 C2
4R 4H 58
E
P
6A C2 4A
E 1B
T V2
P
4S 4J
3 59
S
66 T V2 4K
65 65
4B
3E
P2 P1 4T 52 55 51
4L
C
25 3K
3G 64
56
4C
V2 3D
V1 V
4U 61
3F
3J C2
E
4D
T V2 P
3C
4V
64
26 4M 57 T V2
P 3H
E
C2 1A
4E
66 3M
13 3Q 4W 4N
1A 3L 59
4P
2A
4F
3B 3N 3P
34 32
3A
36 EF
P
53
7B P2A
CF
9808/9555-2
PP 7
9808/9555-2
9804/1103 15 - 20 - 02/2 15 - 20 - 02/2 Issue 3

CONTENTS
CONTENTS

Circuit Variations
The hydraulic schematic diagram shown on page 15 - 20 - 02/2 shows the latest machine hydraulic circuit. The purpose of this
page is to identify 'older' circuit variations, where possible the machine serial numbers will be given to help identify the machine
range(s).
Hose Burst Protection Valves (to Serial Number 402173)
The illustration shows the HBPV when fitted to the

boom circuit. This valve is also fitted on the dipper
ram and the loader arms.
4
61
4S 4B
4K Component Key
C2
V2
V1 4S Load Hold Check Valve
C1 4K Boom Ram Rod Side A.R.V.
4L 52 4L Boom Ram Head Side A.R.V.
4B Boom Spool
52 Boom Ram
61 Hose burst Protection Valve (Optional)
A196780
'Hamworthy' Type Loader Valve
The illustration shows the 'Hamworthy' type

loader valve, the latest type loader valve
(Husco) has the pilot valve solenoid (used to
control the unloader spool) as an integral part
of the valve block, not a separate item as
1A
shown at 3Q.
3M 3
Component Key
3L
P1 Pump, main Section
P2 Pump, Secondary Section
T Tank
3N 1A Neutral Circuit Line
3P 3 Loader Valve Block
3Q 3L Unloader Valve Spool
T 3M Unloader Pilot Valve
3N Unloader Check Valve
3P Pressure Test Point (Unloader)
3Q Hydraulic Speed Control Solenoid
P2
P1
A197090
9804/1103 15 - 20 - 02/3 Issue 2

CONTENTS
CONTENTS

Circuit Variations (cont'd)

Hydraclamp Control Valve (to Serial Number 430000)
The illustration shows the manual type hydraclamp control valve. Machines from serial number 430001 have the hydraclamp
valve operated by a switch (and solenoid).
Component Key
T Tank
1B Neutral Circuit Line
1B T
4
4A Slew Spool
4G Hydraclamp Valve 62
4H Slew A.R.V.
4R Load Hold Check Valve 4G
4X Make-up Check Valve
4X
62 Hydraclamps (Sideshift Machines Only)
4R 4H
4A
A217690
9804/1103 15 - 20 - 02/4 Issue 3

CONTENTS
CONTENTS

Steer Hydraulics (All Wheel Steer Machines)

Component Key
P1 Pump, Main Section

P2A Pressure Test Point
S Suction Line
T Tank
6 In-tank Filter
7 Priority Valve
8 Steer Mode Valves Assembly
9 Front Steer Ram - Left Hand
10 Front Steer Ram - Right Hand
11 Rear Steer Ram - Right Hand
12 Rear Steer Ram - Left Hand
42 Steer Control Unit
43 Shock Valve
44 Steer Control Unit Relief Valve
Note: Hydraulic component port identification letters are shown in parenthesis, e.g. (LS). The same letters will be stamped on
the actual component.
T
6
43 (L) (R) 9 10
42 (T) (P)
(LS)
P2 P1
8
(P) 44 (T)
(CF)
(LS) (A) (B)
(P)
7
P2A
12 11
9808/9510-3
9804/1103 15 - 20 - 02/5 Issue 2

CONTENTS
CONTENTS

Steer Hydraulics (2-Wheel Steer Machines)

Component Key
P1 Pump, Main Section

P2A Pressure Test Point
S Suction Line
T Tank
6 In-tank Filter
7 Priority Valve
9 Front Steer Ram - Left Hand (4 wheel drive only)
10 Front Steer Ram - Right Hand (2 wheel drive only)
43 Shock Valve
44 Steer Control Unit Relief Valve
Note: Hydraulic component port identification letters are shown in parenthesis, e.g. (LS). The same letters will be stamped on
the actual component.
T
6
43 (L) (R)
10
S 9
42
(LS)
P2 P1
(P) 44 (T)
(CF)
(LS)
(P)
7
P2A
9808/9545-1
9804/1103 15 - 20 - 02/6 Issue 1

CONTENTS
CONTENTS


ORBITROL VALVE - FIG 1

Model 160 OSPC
- Volumetric Displacement 160 cc/rev
- Relief Valve Fitted
- Check Valve Fitted
- Shock Valve Fitted
- Relief Valve Operating Pressure (at 1500 revs/min) 120 ± 3 bar 122 ± 3.5 kgf/cm2 1740 ± 50 lbf/in2
- Shock Valve Operating Pressure 175 - 190bar 178 - 199 kgf/cm2 2538 - 2756 lbf/in2
PRIORITY VALVE - FIG 2

Stand by Pressure 7 bar 7.1 kgf/cm2 102 lbf/in2
LS
EF
LS
LS
FIG 1 FIG 2
9804/1103 15 - 20 - 02/7 3270 - H/1-1.1 Issue 1

CONTENTS
CONTENTS


ORBITROL VALVE - FIG 1

Model 200 OSPC
- Shock Valve Fitted
- Shock Valve Operating Pressure 175 - 190bar 178 - 199 kgf/cm2 2538 - 2756 lbf/in2
Model 250 OSPC
- Shock Valve Not Fitted
PRIORITY VALVE - FIG 2

Stand by Pressure 7 bar 7.1 kgf/cm2 102 lbf/in2
LS
EF
LS
LS
FIG 1 FIG 2
9804/1103 15 - 20 - 02/8 3270 - H/1-2.1 Issue 1

CONTENTS
CONTENTS
ALL MODELS (EXCEPT 2CX) From m/c no. 400001 to 420484

Circuit Diagrams - Hydraulic (Servo Machines)
Pumps, Valves, Filters & Tank
P1 Pump, Main Section 11 Safety Solenoid Valve

P2 Pump, Secondary Section 12 Auxiliary Valve (Stabilisers)
P1A Pressure Test Point (Loader & Backhoe MRV & ARV) 12A Extending Dipper/Knuckle Spool
P2A Pressure Test Point (Unloader Valve, Auxiliary 12B Relief Valve
Attachments & Steer Circuit) 12C Auxiliary Relief Valve (Head Side)
S Suction Line 12D Auxiliary Relief Valve (Rod Side)
T Tank 12E Stabiliser Spool
TA In-tank Filter 12F Stabiliser Spool
1 Hydraulic Oil Cooler 13 Check Valve (Fitted with Knuckle Option)
1A Twin Check Valve (Cooler & Make Up) 14 Stabiliser Check & Relief Valve
2 High Pressure Filters 15 Stabiliser Check & Relief Valve
3 Loader Valve Block 16 Slew Motion Control Valve
3A Pressure Relief Valve (& Filter) 17 One Way Restrictor
3B Pressure Adjustment Spool 18 Hose Burst Protection Valve (see page E/2-3, service
3C Pressure Reduction Valve (Pilot Pressure) manual 9803/3260, item 61 for details)
3D Pressure Relief Valve (Pilot Pressure)
3E Shovel Ram Head Side A.R.V.
3F Shovel Ram Rod Side A.R.V.
3G Anti-cavitation Valves Rams
3H Shuttle Valves
3J Load Hold Check Valves 30 Clam Shovel Ram L.H.
3K Loader Lift Ram Spool 31 Clam Shovel Ram R.H.
3L Loader Shovel Ram Spool 32 Lift Ram L.H.
3M Clamshovel Spool 33 Lift Ram R.H.
4 Backhoe Valve Block 34 Shovel Ram L.H.
4A Pressure Relief Valve 35 Shovel Ram R.H.
4B Pressure Adjustment Spool 36 Front Steer Ram LH
4C Pressure Compensator 37 Front Steer Ram RH
4D Shuttle Valves 38 Rear Steer Ram RH
4E Load Hold Check Valves (LHCV) 39 Rear Steer Ram LH
4G Pressure Compensator Valve (with integral LHCV) 40 Hydraclamps (Sideshift Machines Only)
4H Pressure Relief Valve (Pilot Pressure) 41 Boom Ram
4J Pressure Reducing Valve (Pilot Pressure) 42 Dipper Ram
4K Boom Spool 43 Bucket Ram
4L Boom Ram Head Side A.R.V. 44 Left Hand Slew Ram(Centremount Machines Only)
4M Boom Ram Rod Side A.R.V. 45 Right Hand Slew Ram(Centremount Machines Only)
4N Dipper Spool 46 Slew Cylinders (Sideshift Machines Only)
4P Dipper Ram Head Side A.R.V. 47 Stabiliser Ram
4Q Dipper Ram Rod Side A.R.V. 48 Stabiliser Ram
4R Bucket Spool 49 Extending Dipper Ram
4S Bucket Ram Head Side A.R.V. 50 Knuckle Boom Ram
4T Slew Spool
4W Steer Spool
4X Backhoe Valve Fault Solenoid
4Z Filter
5 Unloader Valve
5A Unloader Valve Spool
5B Unloader Pilot Valve
5C Unloader Check Valve
6 Hydraulic Speed Control Valve
7 Priority Valve
8A Shock Valves
8B Steer Unit Relief Valve
9 Steer Mode Valve
9A 2WS/AWS Solenoid Valve
9B Crab/AWS Solenoid Valve
10 Hydraclamp Valve
9804/1103 15 - 20 - 03/1 Issue 2

CONTENTS
CONTENTS
ALL MODELS (EXCEPT 2CX) From m/c no. 400001 to 420485
31
10
16
40
LS
33 15
4D
37
48
3 36 4W
35 4C
3H
39
3M 38
4D
17
9B
4T
9 4C 44
3H
9A
3F 3L
4D 46
3E 3J L 8 R
8A
4R
3H 45
4E 4S
3G
3K
3G LS 4H
3J 42
41 43
8B 4Z 4J
34 3C
P T
P
LS
EF P2A
32 3B P 4D 18
CF
3D 4N 4P 4Q 18
4G
3A T
47
LS 7 14
30
T
HPCO T
TA 4D
4K 4L 4M
4G
5 P
5C C 12F
4X
6 4A
S 5A 4B
P1A
P2 P1 5B 12E
T
4 MA P
12D 12C
1 2 11
12A 49
1A
13
12B
50
P 12
A193291
9804/1103 Issue 2
15 - 20 - 03/2 15 - 20 - 03/2
CONTENTS
CONTENTS
31
10
40
B
LS
33 A 15
4D
37
3 48
36 4X
35 4C
B
3H
B
39
A 4W
3M 38
4D
A 17
9B
4U 4V
9 4C 44
B 3H
3F 9A
B
A 3L
4T 46
4D A
3E 3J L 8 R
8A
3H 4R
B
4E 45
4S
A
3G
3K
3G LS 4H
3J 42
41 43
8B 4Z 4J
34 3C
P T
P
LS B
A
EF P2A
32 3B P 4D 18
CF
3D 4N 4P 4Q 18
4G
3A T
47
LS 7 14
30 B
T A
HPCO T
TA 4D
4K 4L 4M
4G
5 P
5C C 12F
4Y
6
S 5A 4B
P1A
P2 P1 5B 12E
T
4 MA P
12D 12C
1 2 11
12A 49
1A
13
12B
50
P 12
A245980
9804/1103 Issue 1
15 - 20 - 03/3 15 - 20 - 03/3
CONTENTS
CONTENTS

Pumps, Valves, Filters & Tank
P1 Pump, Main Section 8 Steer Control Unit

P2 Pump, Secondary Section 8A Shock Valves
P1A Pressure Test Point (Loader & Backhoe MRV & ARV) 8B Steer Unit Relief Valve
P2A Pressure Test Point (Unloader Valve, Auxiliary 9 Steer Mode Valve
Attachments & Steer Circuit) 9A 2WS/AWS Solenoid Valve
S Suction Line 9B Crab/AWS Solenoid Valve
T Tank 10 Hydraclamp Valve
TA In-tank Filter 11 Safety Solenoid Valve
1 Hydraulic Oil Cooler 12 Auxiliary Valve (Stabilisers)
1A Twin Check Valve (Cooler & Make Up) 12A Extending Dipper/Knuckle Spool
2 High Pressure Filters 12B Relief Valve
3 Loader Valve Block 12C Auxiliary Relief Valve (Head Side)
3A Pressure Relief Valve (& Filter) 12D Auxiliary Relief Valve (Rod Side)
3B Pressure Adjustment Spool 12E Stabiliser Spool
3C Pressure Reduction Valve (Pilot Pressure) 12F Stabiliser Spool
3D Pressure Relief Valve (Pilot Pressure) 13 Check Valve (Fitted with Knuckle Option)
3E Shovel Ram Head Side A.R.V. 14 Stabiliser Check & Relief Valve
3F Shovel Ram Rod Side A.R.V. 15 Stabiliser Check & Relief Valve
3G Anti-cavitation Valves 17 One Way Restrictor
3H Shuttle Valves 18 Hose Burst Protection Valve (see page E/2-3, service
3J Load Hold Check Valves manual 9803/3260, item 61 for details)
3K Loader Lift Ram Spool
3L Loader Shovel Ram Spool
3M Clamshovel Spool
4 Backhoe Valve Block Rams
4A Pressure Relief Valve 30 Clam Shovel Ram L.H.
4B Pressure Adjustment Spool 31 Clam Shovel Ram R.H.
4C Pressure Compensator 32 Lift Ram L.H.
4D Shuttle Valves 33 Lift Ram R.H.
4E Load Hold Check Valves (LHCV) 34 Shovel Ram L.H.
4G Pressure Compensator Valve (with integral LHCV) 35 Shovel Ram R.H.
4H Pressure Relief Valve (Pilot Pressure) 36 Front Steer Ram LH
4J Pressure Reducing Valve (Pilot Pressure) 37 Front Steer Ram RH
4K Boom Spool 38 Rear Steer Ram RH
4L Boom Ram Head Side A.R.V. 39 Rear Steer Ram LH
4M Boom Ram Rod Side A.R.V. 40 Hydraclamps (Sideshift Machines Only)
4N Dipper Spool 41 Boom Ram
4P Dipper Ram Rod Side A.R.V. 42 Dipper Ram
4Q Dipper Ram Head Side A.R.V. 43 Bucket Ram
4R Bucket Spool 44 Left Hand Slew Ram(Centremount Machines Only)
4S Bucket Ram Head Side A.R.V. 45 Right Hand Slew Ram(Centremount Machines Only)
4T Bucket Ram Rod Side A.R.V. 1 46 Slew Cylinders (Sideshift Machines Only)
4U Slew Spool 47 Stabiliser Ram
4V Slew A.R.V. 48 Stabiliser Ram
4W Slew A.R.V. 49 Extending Dipper Ram
4X Steer Spool 50 Knuckle Boom Ram
4Y Backhoe Valve Fault Solenoid
4Z Filter Note 1: The auxiliary relief valve on the bucket ram rod side
5 Unloader Valve service is only installed when a hammermaster is fitted.
5A Unloader Valve Spool
5B Unloader Pilot Valve
5C Unloader Check Valve
6 Hydraulic Speed Control Valve
7 Priority Valve
9804/1103 15 - 20 - 03/4 Issue 1

CONTENTS
CONTENTS
* 3CX, 4CX, 214, 215, 217 & ‘S’ Series Machines From m/c no. 460001
The policy of JCB is one of continuous improvement, 13 Anti-cavitation Check Valve
therefore as products develop, there may be variations to the 14 Check Valve (optional)
circuits. 15 Smooth Ride System Selector Valve Assembly
16 Smooth Ride System Accumulator
Component Key 26 Hydraulic Oil Cooler
C Tank Cap 31 Shovel Ram R.H.
JJ Connections (as applicable) 32 Shovel Ram L.H.
P1 Pump, Main Section 33 Lift Ram R.H.
P2 Pump, Secondary Section 34 Lift Ram L.H.
P2A Pressure Test Point (auxiliary & unloader) 35 Clam Shovel Ram R.H.
S Suction Line 36 Clam Shovel Ram L.H.
T Tank 38 2 Wheel Steer Power Track Rod
M Connections (as applicable) 39 AWS Rear Axle Power Track Rod
MM Quick Release Couplings 40 AWS Front Axle Power Track Rod
1A Neutral Circuit Line 41 AWS Valve Assembly
1B Neutral Circuit Line 42 Steer Control Valve
2A Neutral Circuit Line 43 Shock Valves
3 Loader Valve Block 44 Steer Control Valve Relief Valve
3A Pressure Test Point (M.R.V.) 51 Bucket Ram
3B Unloader Pilot Valve 52 Boom Ram
3C Loader Lift Ram Spool 53 Stabiliser Ram
3D Loader Shovel Ram Spool 54 Stabiliser Ram
3E Clamshovel Spool 55 Dipper Ram
3F Shovel Ram Head Side A.R.V. 56 Left Hand Slew Ram
3G Shovel Ram Rod Side A.R.V. 57 Right Hand Slew Ram
3J Load Hold Check Valve 59 Stabiliser Check Valve
3L Unloader Valve Spool 62 Hydraclamps (Sideshift Machines Only)
3M Main Relief Valve 65 Restrictor
3N Unloader Check Valve 66 Dipper Restrictor with By-Pass
3Q Hydraulic Speed Control Solenoid 67 Manual Isolation Valve
4 Excavator Valve Block 68 Manual Change Over Valve
Excavator services shown here are to the JCB control 69 Extending Dipper Ram
pattern. If ISO, Case or Ford control pattern is used, the 70 High Flow Options
excavator spools and relief valves will apply to different 71 Low Flow options
services.
4A Slew Spool
4B Boom Spool
4C Stabiliser Spool HIGH FLOW OPTIONS
4D Stabiliser Spool
4E Dipper Spool
4F Bucket Spool
4G Hydraclamp Valve (Sideshift Machines Only)
4H Slew A.R.V.
4J Slew A.R.V.
4K Boom Ram Rod Side A.R.V.
4L Boom Ram Head Side A.R.V.
4M Dipper Ram Head Side A.R.V.
4N Dipper Ram Rod Side A.R.V.
5 Auxiliary Valve Block (foot operated)
5A Auxiliary Spool
5B A.R.V.
5C A.R.V. LOW FLOW OPTIONS
6 In-tank Filter
6A Filter By-pass Valve JJ
6B Suction Strainer MM
7 Priority Valve Hammer

8 Filter
Fitted from machine s/no. 475518 or see bulletin 2/218. 69
M
MM
9 Filter
M
Fitted from machine s/no. (twin pump) 473385 and (single 68
67
pump) 473444 or see bulletin 2/218. 11
10 Diverter Valve (hammer only) EXTENDING MM
11 Sequence Valve (hammer only) DIPPER

12 Flow Regulator Valve
9804/1103 15 - 20 - 04/1 3270 - E/6-1.4 Issue 2*

CONTENTS
CONTENTS
3CX, 4CX, 214, 215, 217, “S” Series From m/c no. 460001
Circuit Diagrams - Hydraulic (cont’d)
C 35
1B
31
4
T 62 54
4G
6 33 4H
6B 4A
6A 40 4J
S 3
59 65
39 4B 4K
3E
4L 56
3F 38 52
3D 41 4C
P2 P1
3J 3G 55
3C 4D
43
34 66 57
3B 3J 3A 4M
P1 P2 15 42 4E
2A 4N
3M 59 51
26 3Q 44
T ACC 4F
JJ
3L JJ
4P T
16
3N 7 53
8 10
13
32 11
12 14
36 P2A
9
1A
5A 5B M
5C
CONTENTS
9804/1103 15 - 20 - 04/2 3270 - E/6-2.6 Issue 3*
CONTENTS
CONTENTS * Backhoe Loaders 15 - 20 - 04/3
3CXE (214E Series 3) From m/c no. 460001

Circuit Diagram - Hydraulic (cont’d)
Component Key
A Hydraulic Tank K Flow Regulator Valve BB Dipper Ram
B In Tank Filter L Pressure Test Point CC Bucket Ram
C Hydraulic Oil Cooler N Steer Valve DD Suction Strainer
D Single Stage Hydraulic Pump Q Priority Valve EE Stabilizer Check Valve
E One Way Restrictor S Excavator Valve Block FF Filter
F Shovel Rams W Stabiliser Rams Fitted from m/c no. 475518
G Quick Release Couplings Y One Way Restrictor or see bulletin 2/218
H Lift Rams Z Slew Rams GG Tank Cap
J Loader Valve Block AA Boom Ram
CONTENTS
9804/1103 15 - 20 - 04/3 3270 - E/7-1.2 Issue 3*
CONTENTS
CONTENTS * Backhoe Loaders 15 - 20 - 04/4
214e Series 4 only From m/c no. 460001

GG
P NEUTRAL CIRCUIT H.P.C.O.
S W
F
A
EE
SLEW
B DD
H
2WS FRONT
POWER TRACK ROD
SHOVEL
J4
BOOM
ENGINE F
Y Y
D
LOADER J3 Z
STABILISER
L R
BB CC
N
AA
AUX J2 STABILISER
Z
C
Y
P LS T DIPPER
MRV
J1 J LS
EF P
CF
Q BUCKET
PP
H EE
FF H.P.C.O.
E
W
F
HAMMERMASTER HAMMERMASTER HAMMERMASTER
260L 280 360
B
L
A
G G
NEUTRAL CIRCUIT / TANK RETURN K M
HAMMER RETURN
HAMMER FEED
Component Key
J2 Auxiliary Spool Q Priority Valve FF Filter
A Hydraulic Tank J3 Lift Spool S Excavator Valve Block Fitted from machine serial number
B In-tank Filter J4 Shovel Spool W Stabiliser Rams 475518 or see bulletin 2/218.
C Hydraulic Oil Cooler K Flow Regulator Valve (Option) Y One Way Restrictor GG Tank Cap
D Single Stage Hydraulic Pump L Pressure Test Point Z Slew Rams
E Twin Check Valve M Auxiliary Valve Block (Option) AA Boom Ram
F Shovel Rams Either option K or M can be fitted but not BB Dipper Ram
G Quick Release Couplings both. CC Bucket Ram
H Lift Rams N Steer Valve DD Suction Strainer
J Loader Valve Block P Auxiliary Rams EE Stabiliser Check Valve
J1 Main Relief Valve
CONTENTS
9804/1103 15 - 20 - 04/4 3270 - E/7-2.2 Issue 2*
CONTENTS
CONTENTS
214 Se Series 4 Only From m/c no. 460001

NEUTRAL CIRCUIT H.P.C.O.
GG
1
P
S W
F
A 2
S1 EE
SLEW
B DD
H
SHOVEL
J4 S2 BOOM
ENGINE
L R
Y Y
D 3
LOADER J3 S3 Z
STABILISER
BB CC HH
N
S4 AA
AUX J2 STABILISER
Z
C
Y
P LS T S5 DIPPER
MRV
J1 J LS
EF P
CF
L Q J4 BUCKET
PP
H EE
FF H.P.C.O.
E
W
F
HAMMERMASTER HAMMERMASTER HAMMERMASTER
260L 280 360
B
L
A
G G
NEUTRAL CIRCUIT / TANK RETURN K M
HAMMER RETURN
HAMMER FEED
Component Key
J2 Auxiliary Spool Q Priority Valve W Stabiliser Rams FF Last Chance Filter
A Hydraulic Tank J3 Lift Spool S Excavator Valve Block Y One Way Restrictor GG Tank Cap
B Return filter J4 Shovel Spool S1 Slew Spool Z Slew Rams HH Extending Dipper
C Hydraulic Oil Cooler K Flow Regulator Valve (Option) S2 Boom Spool AA Boom Ram 1 Front Power Track Rod
D Single Stage Hydraulic Pump L Pressure Test Point S3 Stabiliser Spool BB Dipper Ram 2 Rear Power Track Rod
E Twin Check Valve M Auxiliary Valve Block (Option) S4 Stabiliser Spool CC Bucket Ram 3 Steer Control Valve
F Shovel Rams Either option K or M can be fitted but not S5 Dipper Spool DD Suction Strainer 4 Steer Selector Valve
G Quick Release Couplings both. S6 Bucket Spool EE Stabiliser Check Valve
H Lift Rams N Steer Valve
J Loader Valve Block P Auxiliary Rams A356640
J1 Main Relief Valve
9804/1103 15 - 20 - 04/4A 3270 - E/6-9.1 Issue 1

CONTENTS

3CX ‘S’ Series & 4CX Gear Pump Options 3CX ‘S’ Series Options
This circuit shows the Extending Dipper and Power Sideshift, This circuit shows the Low Flow Hammer, Extending Dipper
for the main hydraulic circuit see pages 15-20-04/1 and 15- and Power Sideshift, for the main hydraulic circuit see
20-04/2. pages 15-20-04/1 and 15-20-04/2
Component Key Component Key

HPCO High Pressure Carry Over (From Excavator Valve HPCO High Pressure Carry Over (From Excavator Valve
Block 4) Block 4)
M Hydraulic Connections M Hydraulic Connections
MM Quick Release Couplings MM Quick Release Couplings
T Hydraulic Tank Return T Hydraulic Tank Return
10 Diverter valve 11 Sequence valve
11 Sequence valve 69 Extending Dipper Ram
69 Extending Dipper Ram 72 Change Over Valve
72 Change Over Valve 73 Power Sideshift Cylinder
73 Power Sideshift Cylinder 74 Relief Valve
74 Relief Valve 76 Isolation Valve
75 Manual Change Over Valve 77 Hammer
76 Isolation Valve
69 69
75
77
11 11
10
HPCO
76
HPCO 76
72 72
74 T 74
M T
M
M
73
73
9804/1103 15 - 20 - 04/5 3270 - E/6-3.1 Issue 1

CONTENTS
CONTENTS
3CX ‘S’ Series From m/c no. 460001

Options
This circuit shows the Low Flow Hammer and Extending
Dipper, for the main hydraulic circuit see pages 15 - 20 - 04/1
and 15 - 20 - 04/2
Component Key
HPCO High Pressure Carry Over (From Excavator Valve

Block 4)
M Hydraulic Connections
T Hydraulic Tank Return
11 Sequence valve
69 Extending Dipper Ram
76 Isolation Valve
77 Hammer
69
77
11
HPCO 76
M
M
9804/1103 15 - 20 - 04/6 3270 - E/6-4.1 Issue 1

CONTENTS
CONTENTS
4CXE, 4CX Super-Variable Flow Hydraulics From m/c no. 460001

(7 Spool with High Flow Options)
49
7 T LS 25 P
50 54
P
8 26
L R 18 49
3 17
P T 45
B
48 15
S 27 B
T B
5 6 A 53
P A 15A
46
4 LS 51
52
L 28
17 18
L1
47
16
29 B
36
P T A
16
43
T 28
17 18
37
P PRLS LS T
1 15
9 30 B
11
17
10 A
2 15
PR
20
17 18
21 44
19 17
22 31 B
18
12 38
A
B
17 18
A
17 32 B 39
19
18 A
13
15 17 18 40
B
A 15
33 B
24 15
T ACC A
23 17 16
19
18
14 17 18
41
22 P1 P2
B 16
34 B
21
A
20 LS A
16A
9804/1103 15 - 20 - 04/7 3270 - E/7-10.3 Issue1

CONTENTS
CONTENTS
4CXE, 4CX Super - Variable Flow Hydraulics From m/c no. 460001
(7 - Spool with High Flow Options)
Component Key
Small letters on the schematic indicate port markings. Refer

to Technical Data pages at the beginning of this section for
more information. Ports A and B are always identified as
service ports (feed and return from respective ram).
T Hydraulic Tank
1 By-pass Filter
2 Suction Line
P Pump Variable Flow 38 Stabiliser Ram
3 Stroking Piston 39 Stabiliser Ram
4 Control Piston 40 Dipper Ram
5 System Pressure Spool 41 Bucket Ram
6 Stand-by Pressure Spool 42 Accumulator
7 Hydraclamp Valve 43 Oil Cooler
8 Hydraclamps 44 Load Sense Relief Valve
9 Loader Valve Block 45 Steer Unit Assembly
10 Priority Inlet Section 46 Steer Valve
11 Relief Valve † 47 Relief Valve
12 Auxiliary Service Spool 48 Shock Valves
13 Shovel Service Spool 49 Quick release Couplings
14 Lift Service Spool 50 Isolation Valve
15 Auxiliary Relief Valves (anti-cavitation) 51 Extending Dipper Isolation Valve
15A ARV item 16 if Rockerbreaker Application 52 Foot Valve
16 Auxiliary Relief Valves (direct acting) 53 Extending Dipper Ram
16A ARV Only Fitted For Rockbreaker Application 54 Hammer
17 Secondary Shuttle Valve
18 Primary Shuttle Valve † Note: Steer circuit pressure is controlled by a relief valve
19 Load Hold Check Valve housed in the orbitrol unit (see section H). The priority relief
20 Auxiliary Rams valve housed in the loader valve must be set at 2500 lb/in2
21 Shovel Rams (173 bar, 176 kgf/cm2) this will ensure it does not interfere
22 Lift Rams with the operation of the relief valve housed in the orbitrol
23 Smooth Ride Selector Valve unit.
24 Smooth Ride Accumulator
25 Backhoe Loader Valve Block
26 Extradig Priority Valve
27 Extradig Service Spool
28 Compensator Valves
29 Slew Service Spool
30 Boom Service Spool
31 Stabiliser Service Spool
33 Dipper Service Spool
34 Bucket Service Spool
35 Extradig Ram
36 Slew Rams
37 Boom Ram
9804/1103 15 - 20 - 04/8 3270 - E/7-11.3 Issue 1

CONTENTS
(6 - Spool with High/Low Flow Options)
Component Key
Small letters on the schematic indicate port markings. Refer

to Technical Data pages at the beginning of this section for
more information. Ports A and B are always identified as
service ports (feed and return from respective ram).
T Hydraulic Tank
1 By-pass Filter
2 Suction Line
P Pump Variable Flow 38 Stabiliser Ram
3 Stroking Piston 39 Stabiliser Ram
4 Control Piston 40 Dipper Ram
5 System Pressure Spool 41 Bucket Ram
6 Stand-by Pressure Spool 42 Accumulator
7 Hydraclamp Valve 43 Oil Cooler
8 Hydraclamps 44 Load Sense Relief Valve
9 Loader Valve Block 45 Steer Unit Assembly
10 Priority Inlet Section 46 Steer Valve
11 Relief Valve † 47 Relief Valve
12 Auxiliary Service Spool 48 Shock Valves
13 Shovel Service Spool 49 Quick release Couplings
14 Lift Service Spool 50 Isolation Valve
15 Auxiliary Relief Valves (anti-cavitation) 54 Hammer
16 Auxiliary Relief Valves (direct acting) 55 Load Sense Isolation Valve
16A ARV Only Fitted For Rockbreaker Application
17 Secondary Shuttle Valve † Note: Steer circuit pressure is controlled by a relief valve
18 Primary Shuttle Valve housed in the orbitrol unit (see section H). The priority relief
19 Load Hold Check Valve valve housed in the loader valve must be set at 2500 lb/in2
20 Auxiliary Rams (173 bar, 176 kgf/cm2) this will ensure it does not interfere
21 Shovel Rams with the operation of the relief valve housed in the orbitrol
22 Lift Rams unit.
23 Smooth Ride Selector Valve
24 Smooth Ride Accumulator
25 Backhoe Loader Valve Block
28 Compensator Valves
29 Slew Service Spool
30 Boom Service Spool
33 Dipper Service Spool
34 Bucket Service Spool
36 Slew Rams
37 Boom Ram
9804/1103 15 - 20 - 04/9 3270 - E/7-12.1 Issue 1

CONTENTS
CONTENTS
(6 - Spool with High/Low Flow Options)
49
7 50
54
P
8
L R 49
3
P T 45 55
B
48
S
T B
5 6
P A
T LS P
46 25
4 LS
L X 28
17 18
L1
47
16
29 B
36
P T A
16
43
T 28
17 18
37
P PRLS LS T
1 15
9 30 B
11
17
10 A
2 15
PR
20
17 18
21 44
19 17
22 31 B
18
12 38
A
B
17 18
A
17 32 B 39
19
18 A
13
15 17 18 40
B
A 15
33 B
24 15
T ACC A
23 17 16
19
18
14 17 18
41
22 P1 P2
B 16
34 B
21
A
20 LS A
16A
9804/1103 15 - 20 - 04/10 3270 - E/7-13.1 Issue1

CONTENTS
Hand Held Tools Option
2
3
LS
4
9 25
LS LS
5
T
P
6
A322650
Component Key
P Pump Variable Flow

T Hydraulic Tank
X Main Circuit Connection
1 Pressure Flow Regulator
2 High Pressure Flow Spool
3 Relief Valve (2000 lb/in2 - 138 bar - 146 kgf/cm2)
4 Load Sense Solenoid
5 Hand Held Tool
6 Shuttle Valve
9804/1103 15 - 20 - 04/11 3270 - E/7-14.1 Issue 1

CONTENTS
CONTENTS

Circuit Diagrams - Brakes (Standard Machines)
1 Engine mounted exhauster unit

2 Brake system reservoir
3 Front RH servo unit and master cylinder
4 Front RH brake pedal
5 Front LH servo unit and master cylinder
6 Front LH brake pedal
7 Axle (RH) brake pack
8 Axle (LH) brake pack
1
4
3
6
5
8
A198310
9804/1103 15 - 25 - 01/1 Issue 1

CONTENTS
CONTENTS

Circuit Diagrams - Brakes (Servo Machine)
1 Engine mounted exhauster unit

2 Brake system reservoir
3 Front RH servo unit and master cylinder
4 Front RH brake pedal
5 Front LH servo unit and master cylinder
6 Front LH brake pedal
7 Brake changeover valve
8 Brake changeover valve
9 Axle (RH) brake pack
10 Axle (LH) brake pack
11 Rear master cylinder
12 Rear servo unit
1 7
12
4
3
2
11
6
5
10
A194220
9804/1103 15 - 25 - 02/1 Issue 1

INDEX
Loadalls Contents i
ALL MODELS
Contents
Page No.
General Information
- 525-58, 525-67, 527-58, 527-67, 530-95 20 - 00 - 01/1
- 530-110 20 - 00 - 01/2
- 530-10 (AK/AR Builds) 20 - 00 - 01/2A
- 530-120, 537-120, 537-130 20 - 00 - 01/3
- 505-19, 505-22 20 - 00 - 01/4
- 506-36 20 - 00 - 01/5
- 508-40 & 510-40 20 - 00 - 01/6
- 525-58 FS Plus, 530-67, 535-67 20 - 00 - 01/7
- 520-55 RS 20 - 00 - 01/8
- 520-55 AWS (AA/AB Builds) 20 - 00 - 01/9
- 520-55 AWS (AK/AR Builds) 20 - 00 - 01/9A
- 526-55, 526, 526S (AA/AB Builds) 20 - 00 - 01/10
- 526-55, 526, 526S (AK/AR Builds) 20 - 00 - 01/10A
- 520-50 (N. America) 20 - 00 - 01/11
- 528-70, 528S 20 - 00 - 01/12
- 506B, 506C, 506C (HL), 508C 20 - 00 - 01/13
- 520-50, 525-50 (AA Build) 20 - 00 - 01/14
- 520-50, 525-50, 525-52 (AK/AR Builds) 20 - 00 - 01/15
- 526 (N.America) 20 - 00 - 01/16
- 530, 535, 540 20 - 00 - 01/17
* - 530, 533, 535, 540 20 - 00 - 01/17A & 17B
- 532, 537, 550 20 - 00 - 01/18.
Static Dimensions & Weights

- 525-58, 525-67, 527-58,527-67 20 - 00 - 02/1
- 530-95 20 - 00 - 02/2
- 530-110 20 - 00 - 02/3, 3A
- 530-120, 537-130 20 - 00 - 02/4
- 505-19 & 505-22 20 - 00 - 02/5
- 506-36 20 - 00 - 02/6
- 508-40 20 - 00 - 02/7
- 510-40 20 - 00 - 02/8
- 520-55, 520S 20 - 00 - 02/9
- 526-55, 526, 526S 20 - 00 - 02/10
- 537-120 20 - 00 - 02/11
- 530-67, 535-67 20 - 00 - 02/12
- 520-50, 525-50, 525-52 20 - 00 - 02/13
- 530, 540 20 - 00 - 02/14
- 535 20 - 00 - 02/14A
- 530, 535, 540 Performance Dimensions 20 - 00 - 02/15
- 532, 537, 550 20 - 00 - 02/16, 17
- 506, 506 (HC), 508 (N. America) 20 - 00 - 02/18, 19
- 526 (N. America) 20 - 00 -02/20
- 528-70, 528S 20 - 00 - 02/21, 22
Data - Electrical
- From m/c no. 567362

General 20 - 05 - 01/1
Fuses 20 - 05 - 01/2
Relay Indentification 20 - 05 - 01/3
- 520-55, 520S, 520-55 RS (504B N. Am), 526-55, 526, 526S (526N.Am)
from m/c no. 277001
General & Fuses 20 - 05 - 01/6
Relay Indentification 20 - 05 - 01/6
Fuses 20 - 05 - 01/7
- 520-50, 525-50, 525-52 from m/c no. 754000
General 20 - 05 - 01/8
Relay Identification 20 - 05 - 01/8
Fuses 20 - 05 - 01/9
9804/1103 Loadall Contents - 1 Issue 6*

INDEX
Loadalls Contents ii
ALL MODELS
Page No.
Data - Electrical (cont’d)
520-55, 526-55, 526, 526S (526 N.Am) From m/c no. 279000 to 280299
Fuse Identification 20 - 05 - 01/12
526, 526S (526N. Am)

530, 535, 540 From m/c no 767001

Relay Identification 20 - 05 - 01/14 ,14A, 14B,15, 15A
* 532, 537, 540-170, 550, 5508 From m/c no. 767001

Relay Identification 20 - 05 - 01/17, 18, 18A, 18B,
Fuse Links 20 - 05 - 01/19
528-70 Syncro Shuttle Transmission From m/c no. 796000

Fuse and Relay Identification 20 - 05 - 01/20, 23
528S From m/c 796102

528-70, 528S From m/c no. 796000

Fuse Links 20-05-01/23
506B, 506C, 506C(HL), 508C

Data Hydraulics
- 525-58, 525-67, 527-58, 527-67, 535-67 From m/c no. 567362 20 - 05 - 02/1
- 530-95 From m/c no. 567362 20 - 05 - 02/2
- 530-110 From m/c no. 567362 20 - 05 - 02/3
- 530-120 From m/c no. 567362 20 - 05 - 02/4
- 505-19 & 505-22 From m/c no. 567362 20 - 05 - 02/5
- 506-36 From m/c no. 567362 20 - 05 - 02/6
- 508-40 From m/c no. 567362 20 - 05 - 02/7
- 510-40 From m/c no. 567362 20 - 05 - 02/8
- 520-55, 526-55, 520S, 526, 526S from m/c no. 567362 20 - 05 - 02/9
- 537-120 From m/c no. 567362 20 - 05 - 02/10
- 537-130 From m/c no. 567362 20 - 05 - 02/11
- 520-50, 525-50, 525-52 From m/c no. 754000 20 - 05 - 02/12
- 530 Agricultural 20 - 05 - 01/13
- 530 Construction 20 - 05 - 02/14
- 540 Agricultural From m/c no. 767001 20 - 05 - 02/14A
- 540 Construction From m/c no. 767001 20 - 05 - 02/14B
- 535 From m/c no. 767001 20 - 05 - 02/14C
- 532 from m/c no. 567362 20 - 05 - 02/15
- 537, 550 From m/c no. 767001 20 - 05 - 02/16
- 528-70, 528S From m/c no. 796000 20 - 05 - 02/17
- 506B, 506C 20 - 05 - 02/18
- 506C (HL), 508C 20 - 05 - 02/19
- 540-170, 5508 with Servo Controls from m/c no. 780925 20 - 05 - 02/20
Data Engine
- All models from m/c no. 567362 20 - 05 - 03/1
- 520-55, 526-55, 526, 526S From m/c no.277001 20 - 05 - 03/2
- 520-50, 525-50, 525-52 From m/c no. 754000 20 - 05 - 03/3
- 530, 535, 540 and 532, 537, 550 From m/c no. 767001 20 - 05 - 03/4

INDEX
Loadalls Contents iii
ALL MODELS
- 506B, 506C, 506C (HL), 508C 20 - 05 - 03/5
* Page No.
Axles
- 525-58, 67, 527-58, 67, 530-67, 95, 535-67, 505-19 & 22 From m/c no. 567362 20 - 05 - 04/1
- 530-120, 537-120, 130, 508-40 & 510-40 From m/c no. 567362 20 - 05 - 04/1
- 530-110 & 506-36 From m/c no. 567362 20 - 05 - 04/1
- 520-55 RS From m/c 277001 20 - 05 - 04/2
- 520-55 4 Wheel Steer to m/c no. 2768610 20 - 05 - 04/2
- 520-55 4 Wheeled Steer from m/c no. 2768611 20 - 05 - 04/2
- 526-55, 526, 526S to m/c no. 280999 20 - 05 - 04/2
- 526-55, 526, 526S to m/c no. 280299 20 - 05 - 04/3
- 520-50, 525-50 from m/c no. 754000, 20 - 05 - 04/3
- 526, 526S from m/c no. 280300 20 - 05 - 04/3
- 528-70 from m/c no. 796000 20 - 05 - 04/4
- 528S from m/c no. 796102 20 - 05 - 04/4
- 506B, 506C, 506C (HL),508C 20 - 05 - 04/5
Data-Tyres
- All models, except 530, 532, 535, 537, 540, 550 20 - 05 - 04A/1
- 530, 532, 535, 537, 550, 540 20 - 05 - 04A/4
Data Transmission
- Syncro Shuttle, All models from m/c no. 567362 20 - 05 - 05/1, 2
- 520-55 Syncro Shuttle from m/c no. 277001 20 - 05 - 05/2
- 520-50, 525-50, 525-52 from m/c no. 754000 20 - 05 - 05/2
- 520, 526 Powershift from m/c no. 277001 20 - 05 - 05/3
- 528 Powershift from m/c no. 796000 20 - 05 - 05/3
- 506, 508 Powershift 20 - 05 - 05/3
- 520, 526 Syncro Shuttle from m/c no. 277001 20 - 05 - 05/3A
- 528 Syncro Shuttle from m/c no. 796000 20 - 05 - 05/3A
- 506, 508 Syncro Shuttle 20 - 05 - 05/3A
- 530, 532, 535, 537, 540, 550 Powershift 20 - 05 - 05/4
- 532, 537, 550, Axles and Stall Speeds from m/c no. 767001 20 - 05 - 05/5
- 530, 535, 540 Axles and Stall Speeds from m/c no. 767001 20 - 05 - 05/6
Data-Brakes
- 525-58/67, 527-58/67, 530-67, 535-67, 505-19/22 From m/c no. 567362 20 - 05 - 07/1
- 530-95/110, 506-36 from m/c no. 567362 20 - 05 - 07/1
- 530-120, 537-120/130, 508-40, 510-40 from m/c no. 567362 20 - 05 - 07/2
- 520-55 RS from m/c no. 277001 to 279119 20 - 05 - 07/2
- 520-55 AWS from m/c no. 277001 to 279119 20 - 05 - 07/3
- 526-55, 526, 526S from m/c no. 277467 to 280299 20 - 05 - 07/3
- 520-55 AWS from m/c no. 279120 20 - 05 - 07/3
- 520-50, 525-50, 525-52 20 - 05 - 07/3
- 526-55, 526, 526S, 520-55 4WS, from m/c no. 2768611 20 - 05 - 07/4
- 532, 537 from m/c no. 2768611 20 - 05 - 07/4
- 528-70 from m/c no. 796000 20 - 05 - 07/5
- 528S from m/c no. 796102 20 - 05 - 07/5
- 530, 535, 540 from m/c no. 767001 20 - 05 - 07/6
- 532, 537, 550 fromm/c no. 767001 20 - 05 - 07/6
- 506B, 506C, 506C(HL), 508C 20 - 05 - 07/7

INDEX
Loadalls Contents iv
ALL MODELS
Contents (contunued)
Page No.
Data-Steering
- All models from m/c no. 567362 20 - 05 - 08/1
- 520-55, 526-55, 526, 526S from m/c no. 277001 20 - 05 - 08/1
* -All models from m/c no. 773135 20 - 05 - 08/1A
- 520-50, 525-50, 525-52 from m/c no. 754000 20 - 05 - 08/2
- 530, 532, 537 from m/c no 754000 20 - 05 - 08/2
- 528-70 from m/c no. 796000 20 - 05 - 08/3
- 528S from m/c no. 796102 20 - 05 - 08/3
- 530, 535, 540 from m/c no. 767001 20 - 05 - 08/4
- 532, 537, 550 from m/c no. 767001 20 - 05 - 08/4
- 506B, 506C, 506C (HL), 508C 20 - 05 - 08/5
Circuit Diagrams-Electrical
- All models from m/c no. 567362 20 - 15 - 01/1 to 3
- 520-55 (504B N. Am), 520-55 RS from m/c no. 277001 to 277535 20 - 15 - 01/4 to 6
- 520-55 from m/c no. 277536 20 - 15 - 01/7 to 9
- 526-55 to m/c no. 278965 20 - 15 - 01/7 to 9
- All models from 567362 (Powershift option) 20 - 15 - 01/10
- Safe Load Indicator Circuit from m/c no. 576404 20 - 15 - 01/11
- 520-55, 520S from m/c no. 278966 20 - 15 - 01/12 to 14
- 526-55, 526S (526 N.Am) from m/c no. 278966 to 280299 20 - 15 - 01/12 to 14
- 526-55, 526, 526S (526 N.Am)(Powershift ECU) from m/c no. 280300 to 280576 20 - 15 - 01/15 to 21
- 526-55, 526, 526S (526 N. Am) (Syncroshuttle) from m/c no. 280300 20 - 15 - 01/22 to 27
- 520-55 (Syncro Shuttle) from m/c no. 281847 20 - 15 - 01/22 to 27
- 526, 526S (526 N. Am) (Powershift) from m/c no. 280577 20 - 15 - 01/29 to 34
- 528-70 (Syncro Shuttle) from m/c no. 796000 20 - 15 - 01/37 to 40
- 528S (Powershift) from m/c no. 796102 20 - 15 - 01/41 to 46
- 528S (Syncro Shuttle) from m/c no. 796102 20 - 15 - 01/47 to 52
- 530 Without Neutral Start Relay from m/c no. 767001 to768836 20 - 15 - 02/1 to 4
- 530 With Nuetral Start Relay/ECU from m/c no. 768837 to 770053 20 - 15 - 02/5 to 8
- 530 With Relay Controlled Transmission (ECU not fitted) from m/c no. 770054 to 770958 20 - 15 - 02/9 to 12
- 530, 540 Sway Machines from m/c no. 770959 20 - 15 - 02/13 to 16
- 530, 540 Non-Sway Machines from m/c no. 770959 20 - 15 - 02/17 to 20
- 530, 540 With Manual Auxiliary Controls from m/c no. 775402 20 - 15 - 02/21 to 26
- 535 With Manual Auxiliary Controls from m/c no. 777362 20 - 15 - 02/21 to 26
- 530, 540 With Single Lever Controls from m/c no. 775402 20 - 15 - 02/27 to 32
- 535 With Single Lever Controls from m/c no. 777362 20 - 15 - 02/27 to 32
- 530, 535, 540 from m/c no. 7670001/530 FS Super, 540 FS Super, 530SXL, 540 SXL 20 - 15 - 02/33 to 38
- 532, 537 Without Neutral Start Relay from m/c no. 767001 to 768956 20 - 15 - 03/1 to 4
- 532, 537 With Neutral Start Relay/ECU from m/c no. 768957 to 770063 20 - 15 - 03/5 to 8
- 532, 537 With Relay Controlled Transmission (ECU not fitted) from m/c no. 770064 to 770958 20 - 15 - 03/9 to 12
- 532, 537, 550 from m/c no. 770959 20 - 15 - 03/13 to 16
- 532, 537, 550 With Manual Auxiliary Controls from m/c no. 775402 20 - 15 - 03/17 to 22
* - 540-170, 5508 with Servo Controls to m/c no. 1004130 20 - 15 - 03/17 to 24
* - 540-170, 5508 with Servo Controls from m/c no. 1004131 20 - 15 - 03/25 to 32
- 506B (Syncro Shuttle) to m/c no. 578676 20 - 15 - 04/1 to 3
- 506B (Syncro Shuttle) from m/c no. 578677 20 - 15 - 04/4 to 6
- 506C, 508C (Syncro Shuttle) to m/c no. 585396 20 - 15 - 04/7 & 8
- 506C, 508C (Syncro Shuttle) from m/c no. 585397 20 - 15 - 04/9 & 10
- 506C, 508C (Powershift with 6 Transmission Relays) to m/c no. 585396 20 - 15 - 04/11 & 12
- 506C, 508C (Powershift with 7 Transmission Relays) to m/c no. 585396 20 - 15 - 04/13 & 14
- 506C, 508C(Powershift) from m/c no. 585397 20 - 15 - 04/15 & 16
* - 533-105 Machines 20 - 15 - 05/1 to 6

INDEX
Loadalls Contents v
ALL MODELS
Page No.
- 525-58/67, 527-58/67, 530-95 from m/c no. 567362 to 574295 20 - 20 - 02/1, 2
- 527-58/67, 535-67 from m/c no. 574296 20 - 20 - 02/2A, 2B
- 530-120 from m/c no. 567362 20 - 20 - 02/3, 4
- 530-110 from m/c no. 567362 20 - 20 - 02/5, 6
- 505-19 & 505-22 from m/c no 567362 to 574295 20 - 20 - 02/7, 8
- 505-19 & 505-22 from m/c no. 574296 20 - 20 - 02/8A, 8B
- 506-36 from m/c no. 567362 20 - 20 - 02/9, 10
- 508-40 from m/c no. 567362 20 - 20 - 02/11,12
- 510-40 from m/c no. 567362 20 - 20 - 02/13, 14
- 520-55 RS, 520-55 4 Wheel Steer from m/c no. 277001 to 278610 20 - 20 - 02/15, 16
- 520-50 4 Wheel Steer from m/c no. 278611 20 - 20 - 02/17, 18
- 526-55, 526, 526S from m/c no 277001 to 280299 20 - 20 - 02/17, 18
- 537-120, 537-130 from m/c no. 572900 20 - 20 - 02/19, 20
- 520-50, 525-50, 525-52 from m/c no. 754000 20 - 20 - 02/21, 22
- 520-55 RS, 520-55 4WS from 278610 20 - 20 - 02/23, 24
- 520-55 4WS from m/c no. 278611 20 - 20 - 02/25, 26
- 526-55, 526, 526S to m/c no. 280299 20 - 20 - 02/25, 26
- 526, 526S with Dual Lever Control from m/c no. 280300 20 - 20 - 02/27, 28
- 526, 526S with Single Lever Control Option from m/c no.280300 20 - 20 - 02/29, 30
- 528-70 from m/c. 796000 20 - 20 - 02/31, 32
- 528S from m/c no. 796102 20 - 20 - 02/31, 32
- 528S with Single Lever Controls from m/c no. 796102 20 - 20 - 02/33, 34
- 530, 540 Agricultural from m/c no. 767001 20 - 20 - 02/35, 36
- 530 Construction from m/c no. 767001 to 770616 20 - 20 - 02/37, 38
- 530, 540 Construction with Single Lever Control from m/c no. 767001 to 770617 20 - 20 - 02/39, 40
- 530 Construction with Manual Auxiliary Controls from m/c no. 775402 20 - 20 - 02/41, 42
* - 530 Construction with Manual Auxiliary Controls from m/c no. TBA 20 - 20 - 02/41A, 42A
(fitted with 2-stage pump)
* - 530 Construction with Manual Auxiliary Controls from m/c no. 775402 20 - 20 - 02/41B, 42B
- 540 Construction with Manual Auxiliary Controls from m/c no 775402 20 - 20 - 02/43, 44
* - 540 Construction with Manual Auxiliary Controls from m/c no. 775402 20 - 20 - 02/43A, 44A
- 535-95 from m/c no. 777362 20 - 20 - 02/45, 46
* - 535-95 Machines (fitted with a 3-stage pump) from m/c no. 777362 20 - 20 - 02/45A, 46A
* - 535-95 Machines (fitted with a 2-stage pump) from m/c no. TBA 20 - 20 - 02/45B, 46B
- 532 to m/c no. 770638 20 - 20 - 02/47, 48
- 537, 550 to m/c no. 770613 20 - 20 - 02/47, 48
- 532 from m/c no 770639 to 775401 20 - 20 - 02/49, 50
- 537, 550 from m/c no. 770614 to 775401 20 - 20 - 02/49, 50
- 532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402 20 - 20 - 02/51, 52
- 506B 20 - 20 - 02/53, 54
- 506C 20 - 20 - 02/55, 56
- 506C (HL), 508C 20 - 20 - 02/57, 58
- 540-170 with Servo Controls from m/c no. 780925 20 - 20 - 02/59, 60
* - 533-105 Machines from serial no. 786756 20 - 20 - 02/61, 62

CONTENTS
Loadalls 20 - 00 - 01/1
* 525-58, 525-67, 527-58, 527-67, 530-95 From m/c no. 567362
run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
below.

Litres (Gal) SPECIFICATION
Engine (Oil) 10 (2.2) JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B,

-10 °C to 50 °C (14 °F to 122 °F) API CD/SE, MIL-L-2104
JCB Super Universal Agricultural SAE10W/30, MIL-L-2105, MIL-L-46152

JCB Torque Converter Fluid SAE10W, MIL-L-46152, MIL-L-2104D

-18 °C to 0 °C (0 °F to 32 °F) API CD/SE
Engine (Coolant) 17 (3.7) JCB Universal Antifreeze/water ASTM D3306-74

( See Coolant Mixtures)
Gearbox
* Powershift ††15.0 (3.3) ††JCB Special Transmission Fluid ESP-M2C 33G
Front Axle
Hubs (x2) 2.0 (0.4) JCB Special Gear Oil ESEN-M2C 86A/B
Rear Axle
Brake System JCB Light Hydraulic Fluid ISO VG15
DO NOT USE ORDINARY BRAKE FLUID
* Hydraulic System †152 (33.5) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
(Below 38 °C, 100 °F)
Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency
Wear Pad Runways JCB Waxoyl
Boom Hoses JCB Special Slide Lubricant
* † Note: : This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill
with all rams closed. Watch level sight glass when filling.
* †† Note: This is a system capacity. Use the 'MIN' and 'MAX' marks on the dipstick when refilling the system.
Coolant Mixtures % Antifreeze Starts to Freeze
55 9.35 litres (2.04 gal) -36° C (-33 °F)
9804/1103 20 - 00 - 01/1 Issue 3*

CONTENTS
Loadalls 20 - 00 - 01/2
530-110 From m/c no. 567362

in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines





Front Axle
Rear Axle
Hydraulic System †190 (41.8) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
JCB HP32 ISO 32
(Below 38 °C, 100 °F)
JCB Light Hydraulic Fluid ISO VG15
(For Iceland, Norway, Sweden
and Finland ONLY)
† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with
all rams closed. Watch level sight glass when filling.
55 10 litres (2.2 gal) -36° C (-33 °F)
9804/1103 20 - 00 - 01/2 Issue 2

CONTENTS
Loadalls 20 - 00 - 01/2A
530-110
AK and AR Engine Builds
Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first
100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB
10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to
the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended
below.

Engine (Oil) 10 (2.2) JCB High Performance Engine oil SAE15W/40

-10°C to 50°C (14°F to 122°F) API CF4/SG (ACEA E2:B2:A2)
JCB High Performance Engine oil SAE10W/30

-15 °C to 30 °C (5 °F to 86 °F) API CF4/SG (ACEA E2:B2:A2)
Engine (Coolant) 18 (3.9) JCB Four Seasons Antifreeze/water ASTM D3306-74

55% Concentration 10 (2.2) And Summer Coolant
Syncro Shuttle 18.25 (4.0) JCB High Performance JCB 4000/0900

Transmission Fluid Friction modified oils MUST NOT be
used (eg. Dexron ATF type).
Front Axle
Housing 18 (3.9) JCB High Performance JCB 4000/2200
Hubs (x2) 2.0 (0.4) Gear Oil Plus Must be suitable for use with oil
immersed brakes and limited slip
Rear Axle Differentials (LSD).
Housing 13 (2.8)
Hubs (x2) 2.0 (0.4)
Hydraulic Tank † 190 (41.8) JCB High Performance Hydraulic Fluid 46 ISO VG46
(Above 38 °C, 100 °F)
JCB High Performance Hydraulic Fluid 32 ISO VG32
(Below 38 °C, 100 °F)
Grease Points †† JCB HP Grease Lithium complex NLGI No. 2

consistency including extreme
pressure additives.
JCB Special MPL-EP Grease Lithium based NLGI No. 2
pressure additives.
† Note 1: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check
†† Note 2: If JCB MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals; all
500 hour greasing operations must be carried out at 50 HOUR intervals.
9804/1103 20 - 00 - 01/2A 2055/127 Issue 1

CONTENTS
Loadalls 20 - 00 - 01/3
* 530-120, 537-120 & 537-130 From m/c no. 567362
below.





Front Axle
Rear Axle
Hydraulic System †292 (64.3) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
JCB HP32 ISO 32
(Below 38 °C, 100 °F)
55 12.92 litres (2.84 gal) -36° C (-33 °F)
9804/1103 20 - 00 - 01/3 Issue 3*

CONTENTS
Loadalls 20 - 00 - 01/4
505-19, 505-22 From m/c no. 567362

below.

Gal (Liters) SPECIFICATION
Engine (Oil) 2.6 (10) JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B,



Engine (Coolant) 4.4 (17) JCB Universal Antifreeze/water ASTM D3306-74

Syncro Shuttle 5.7 (22) JCB Special Transmission Fluid ESP-M2C 33G
Front Axle
Housing 4.7 (18) JCB Special Gear Oil ESEN-M2C 86A/B
Rear Axle
Hydraulic System †28.8 (110) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
JCB HP32 ISO 32
(Below 38 °C, 100 °F)
55 2.45 gal (9.35 liters) -22 °F (-36° C)
9804/1103 20 - 00 - 01/4 Issue 2

CONTENTS
Loadalls 20 - 00 - 01/5
506-36 From m/c no. 567362

below.




Engine (Coolant) 4.7 (18) JCB Universal Antifreeze/water ASTM D3306-74

Front Axle
Rear Axle
(Above 38 °C, 100 °F)
JCB HP32 ISO 32
(Below 38 °C, 100 °F)
55 2.6 gal (10 liters) -22 °F (-36° C)
9804/1103 20 - 00 - 01/5 Issue 2

CONTENTS
Loadalls 20 - 00 - 01/6
508-40, 510-40 From m/c no. 567362

below.





Front Axle
Rear Axle
(Above 38 °C, 100 °F)
JCB HP32 ISO 32
(Below 38 °C, 100 °F)
55 3.4 gal (12.92 liters) -22 °F (-36° C)
9804/1103 20 - 00 - 01/6 Issue 2

CONTENTS
Loadalls 20 - 00 - 01/7
525-58 FS Plus, 530-67, 535-67 From m/c no. 567362

in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines





Gearbox
Powershift †15.0 (3.3) JCB Special Transmission Fluid ESP-M2C 33G
Front Axle
Rear Axle
Hydraulic Tank ††152 (34.5) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
(Below 38 °C, 100 °F)
†† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with
† Note: This is a system capacity. Use the 'MIN' and 'MAX' marks on the dipstick when refilling the system.
55 9.35 litres (2.04 gal) -36° C (-33 °F)
9804/1103 20 - 00 - 01/7 Issue 2

CONTENTS
Loadalls 20 - 00 - 01/8
520-55 RS From m/c no. 277001

hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB
below.
Litres UK Gal US Gal SPECIFICATION
* Fuel Tank
Up to serial No. 279000 120 26.4 31.7 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
From serial No. 279001 160 35.2 42.2
* Engine (Oil) 10 2.2 JCB High Performance Engine Oil SAE15W/40
JCB Super Universal SAE10W/30
Agricultural API CD/SF
-15 °C to 30 °C (5 °F to 86 °F)
JCB Torque Converter Fluid SAE10W
-18 °C to 0 °C (0 °F to 32 °F) API CD/SF
NORTH AMERICA
2.6 JCB 15W/40 Engine Oil SAE 15W/40
14°F to 122°F (-10°C to 50°C) API CF4/SG
JCB 10W Engine Oil SAE 10W
-4°F to 50° F (-20°C to 10°C) API CF4/SG
* Engine (Coolant) 20 4.4 JCB Four Seasons Antifreeze ASTM D3306-74
55% Antifreeze 11 2.4 And Summer Coolant
Starts to freeze -36 °C (-33 °F)
NORTH AMERICA
5.3 Permanent Antifreeze ASTM D3306-74
2.9 Starts to freeze -33 °F (-36 °C)
* Syncro Shuttle 17 3.7 4.5 JCB High Performance JCB: 4000/0900
Transmission Transmission Fluid Friction modified oils MUST NOT
be used (eg Dexron ATF type).
* Front Axle JCB High performance JCB: 4000/2200
Housing 9.7 2.1 2.5 Gear Oil Plus MUST be suitable for use with
Hubs (x2) 0.6 0.1 0.16 oil immersed brakes and limited
slip differentials (LSD).
* Rear Axle
Housing 5.0 1.1 1.3
Hubs (x2) 1.5 0.3 0.4
* Hydraulic Tank (1) JCB High Performance ISO VG46
Up to serial No. 279000 100 22.0 Hydraulic Fluid 46
From serial No. 279001 110 24.2 (Above 38 °C, 100 °F)
JCB High Performance ISO VG32
Hydraulic Fluid 32
(Below 38 °C, 100 °F)
Up to serial No. 279000 26.4 NORTH AMERICA (All Machines)
From serial No. 279001 29.0 JCB Hydraulic Fluid ISO VG46
* Grease Points (2) JCB HP Grease Lithium complex NLGI No. 2
constsituency including extreme
pressure additives.
pressure additives.
* Wear Pad Runways JCB Waxoyl
* Boom Hoses JCB Special Slide Lubricant
* Note 1: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used.
Fill with all rams closed. Watch level sight glass when filling.
* Note 2: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR
intervals. All 500 hour greasing operations must be carried out at 50 HOUR intervals.
9804/1103 20 - 00 - 01/8 3610 - 3/1-2.4 Issue 4*

CONTENTS
Loadalls 20 - 00 - 01/9
* 520-55 AWS * From m/c no. 277001
AA and AB Engine Builds
below.
* Fuel Tank
From serial No. 279001 160 35.2 42.2
* Engine (Oil) 10 2.2 JCB High Performance Engine Oil SAE15W/40
JCB Super Universal SAE10W/30
Agricultural API CD/SF
-15 °C to 30 °C (5 °F to 86 °F)
NORTH AMERICA
* Engine (Coolant) 20 4.4 JCB Four Seasons Antifreeze ASTM D3306-74
NORTH AMERICA
* Syncro Shuttle 17 3.7 4.5 JCB High Performance JCB: 4000/0900
* Front Axle JCB High performance JCB: 4000/2200
* Rear Axle
Housing 5.0 1.1 1.3
Hubs (x2) 1.5 0.3 0.4
* Hydraulic Tank (1) JCB High Performance ISO VG46
Hydraulic Fluid 32
(Below 38 °C, 100 °F)
* Grease Points (2) JCB HP Grease Lithium complex NLGI No. 2
pressure additives.
pressure additives.
* Boom Hoses JCB Special Slide Lubricant
* Note 1: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill
with all rams closed.
intervals; all 500 hour greasing operations must be carried out at 50 HOUR intervals. All 500 hour greasing
operations must be carried out at 50 HOUR intervals.
9804/1103 20 - 00 - 01/9 3610 - 3/1-3.4 Issue 5*
CONTENTS
Loadalls 20 - 00 - 01/9A
520-55 AWS From m/c no. 277001

below.
* ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL
Fuel Tank
160 35.2 42.2 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 10 2.2 JCB High Performance Engine Oil SAE15W/40

JCB High Performance Engine Oil SAE10W/30
-15 °C to 40 °C (5 °F to 104 °F)
API CF4/SG (ACEA E2:B2:A2)
NORTH AMERICA
Engine (Coolant) 20 4.4 JCB Four Seasons Antifreeze ASTM D3306-74
NORTH AMERICA
Syncro Shuttle 17 3.7 4.5 JCB High Performance JCB 4000/0900
Front Axle JCB High Performance JCB 4000/2200
Rear Axle
Housing 5.0 1.1 1.3
Hubs (x2) 1.5 0.3 0.4
Hydraulic Tank (1) 110 24.2 JCB High Performance ISO VG46
Hydraulic Fluid 46
(Above 38 °C, 100 °F)
Hydraulic Fluid 32
(Below 38 °C, 100 °F)
29.0 NORTH AMERICA (All Machines)
JCB Hydraulic Fluid ISO VG46
Grease Points (2) JCB HP Grease Lithium complex NLGI No. 2
pressure additives.
pressure additives.
Boom Hoses JCB Special Slide Lubrican
intervals; all 500 hour greasing operations must be carried out at 50 HOUR intervals. All 500 hour greasing
operations must be carried out at 50 HOUR intervals.
9804/1103 20 - 00 - 01/9A 3610 - 3/1-5.2 Issue 2*

CONTENTS
Loadalls 20 - 00 - 01/10
526-55, 526, 526S From m/c no. 277001

AA and AB Engine Builds
hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB
below.
Fuel Tank
From serial No. 279001 160 35.2 42.2
JCB Super Universal Agricultural SAE10W/30
-15 °C to 30 °C (5 °F to 86 °F)
API CD/SF
NORTH AMERICA
NORTH AMERICA ASTM D3306-74 Fr
5.3 Permanent Antifreeze us
Front Axle JCB High performance JCB 4000/2200
Housing 9 1.98 2.4 Gear Oil Plus MUST be suitable for use with
Hubs (x2) 2 0.44 0.5 oil immersed brakes and limited
Rear Axle
Housing 8.4 1.85 2.2
Hubs (x2) 2 0.44 0.5
From serial No. 280300 Do not use ordinary brake fluid
Hydraulic Tank (1) JCB High Performance ISO VG46
Hydraulic Fluid 32
(Below 38 °C, 100 °F)
pressure additives.
pressure additives.
9804/1103 20 - 00 - 01/10 3610 - 3/1-4.3 Issue 4*
CONTENTS
Loadalls 20 - 00 - 01/10A
526-55, 526, 526S From m/c no. 277001
AR and AK Engine Builds
below.
Fuel Tank

-15 °C to 40 °C (5 °F to 104 °F)
API CF4/SG (ACEA E2:B2:A2)
NORTH AMERICA
NORTH AMERICA
Rear Axle
Housing 8.4 1.85 2.2
Hubs (x2) 2.0 0.44 0.5
Hydraulic Tank (1) 110 24.2 JCB High Performance ISO VG46
Hydraulic Fluid 46
(Above 38 °C, 100 °F)
Hydraulic Fluid 32
(Below 38 °C, 100 °F)
29.0 NORTH AMERICA (All Machines)
JCB Hydraulic Fluid ISO VG46
pressure additives.
pressure additives.
9804/1103 20 - 00 - 01/10A 3610 - 3/1-6.2 Issue 2*

CONTENTS
Loadalls 20 - 00 - 01/11
* 520-50 (N. America) * From m/c no. 754000
Notice: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
below.

* US Gal (Liters) SPECIFICATION
* Fuel Tank 23.8 (90) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
* Engine (Oil) 2.6 (10) JCB 15W/40 Engine Oil SAE15W/40,

- 14 °F to 122 °F (10 °C to 50 °C) API CF4/SG
JCB 10W Engine Oil SAE10W/30,

- 5 °F to 86 °F(15 °C to 30 °C) API CF4/SG
* Engine (Coolant) 5.3 (20) JCB Universal Antifreeze/water ASTM D3306-74

55% Antifreeze 2.9 (11) Starts to freeze -33 °F (-36 °C)
* Gearbox 4.6 (17.5) JCB Special Transmission Fluid ESP-M2C 33G

Friction modified oils MUST NOT be
used (eg. Dexron ATF type).
* Axles
Housing 2.3 (8.8) JCB Special Gear Oil Plus API GL4
Hubs (x4) 0.47 (1.8) Must be suitable for use with oil
immersed brakes and limited slip
differentials (LSD).
* Hydraulic Tank †18.5 (70) JCB High Performance Hydraulic Oil ISO VG46
(Above 100 °F, 38 °C)
(Below 100 °F, 38 °C)
* Grease Points †† JCB HP Grease Lithium based, No. 2 consistency
* † Notice: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all
rams closed. Watch level sight glass when filling.
* †† Notice: If JCB MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All
9804/1103 20 - 00 - 01/11 8185/109 Issue 2*

CONTENTS
Loadalls 20 - 00 - 01/12
528-70, 528S From m/c no. 796000


Fuel Tank
Engine (Oil) 10 2.2 JCB Super 15W/40 Multigrade SAE15W/40

-10°C to 50°C (14°F to 122°F) API CF4/SG
JCB Super 10W/30 Multigrade SAE10W/30
-15°C to 40°C (5°F to 104°F) API CF4/SG

55% Antifreeze 11 2.4 & Summer Coolant
Transmission 17 3.7 4.5 JCB Special Transmission JCB 4000/0900

Syncro Shuttle & Fluid Friction modified oils MUST NOT
Powershift be used (eg Dexron ATF type).

Housing 9 1.98 2.4 Gear Oil Plus MUST be suitable for use with
Hubs (x2) 2 0.44 0.5 oil immersed brakes and limited
Rear Axle JCB Special Performance

Housing 8.4 1.85 2.2 Gear Oil Plus
Hubs (x2) 2 0.44 0.5
Hydraulic Tank † 110 24.2 JCB High Performance ISO VG46

Hydraulic Fluid 46
(Above 38 °C, 100 °F)
Hydraulic Fluid 32
(Below 38 °C, 100 °F)
Grease Points †† JCB HP Grease Lithium complex NLGI No. 2

pressure additives.
JCB Special MPL-EP Grease Lithium based NGLI No. 2
pressure additives.
† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill
and check with all rams closed.
†† Note: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR
intervals. All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals
9804/1103 20 - 00 - 01/12 8450/147 Issue 1

CONTENTS
Loadalls 20 - 00 - 01/13
506B, 506C, 506C (HL), 508C (N. America)

Notice: Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
below.

US Gal (Liters) SPECIFICATION
Engine (Oil) 2.6 (10) JCB 15W/40 Engine Oil SAE 15W/40

-4°F to 50°F (-20°C to 10°C) API CF4/SG
Engine (Coolant) 6.2 (23.5) Permanent Antifreeze ASTM D3306-74

Transmission ESP-M2C 33G

Syncro Shuttle 4.8 (18.25) JCB Special Transmission Fluid Friction modified oils must not be
Powershift 3.9 (15.0) used (eg. Dexron ATF type)
Front Axle
Housing 4.7 (18) JCB Special High performance API GL4
Hubs (x2) 0.5 (2.0) Gear Oil MUST be suitable for use with
oil immersed brakes and limited-slip
Rear Axle differentials (LSD)
Housing 3.4 (13)
Hubs (x2) 0.5 (2.0)
Brake System JCB Hydraulic Fluid ISO VG15
Hydraulic Tank
506C, 506C †32.0 (121) JCB High Performance Hydraulic Oil ISO VG46
506C, 508C †48.0 (181) (Above 100 °F, 38 °C)
Grease Points JCB Moly EP #2 Grease Lithium based, No. 2 consistency
Boom Chains JCB Chain Lubricant
†Notice: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and
check with all cylinders closed. Watch level sight glass when filling.
IF JCB MPL-EP or MPL-Moly grease is used all 50 hour greasing operations must be carried out at 10 HOUR intervals, All
55 3.4 gal (12.92 litres) -36° C (-33 °F)
9804/1103 20 - 00 - 01/13 3640U - 3/1-1.3 & 3/1-2.3 Issue 1

CONTENTS
Loadalls 20 - 00 - 01/14
520-50, 525-50
AA Engine Build
below.

Engine (Oil) 10 (2.2) JCB High Performance Engine Oil SAE15W/40


-15°C to 30°C (5°F to 86°F) API CD/SE

-18°C to 0°C (0°F to 32°F) API CD/SE
Coolant Capacity 20 (4.4) JCB Four Seasons Antifreeze ASTM D3306-74

55% Concentration 9.4 (2.0) And Summer Coolant
Gearbox 17.5 (3.8) JCB High Performance JCB 4000/0900

Transmission Fluid Friction modified oils MUST NOT
be used (eg. Dexron ATF type).
Axles
Housing (520-50) 4.0 (0.88) JCB High Performance JCB 4000/2200
Housing (525-50) 8.8 (1.94) Gear Oil Plus
Housing (525-52) 8.8 (1.94) Must be suitable for use with
Hubs (x4 - 520-50) 1.0 (0.22) oil immersed brakes and limited slip
Hubs (x4 - 525-50) 1.8 (0.4) differentials (LSD).
Hubs (x4 - 525-52) 1.8 (0.4)
Hydraulic Tank (†) 70 (15.4) JCB High Performance Hydraulic Fluid 46 ISO VG46
(Above 38°C, 100°F)
(Below 38°C, 100°F)
Grease Points (††) JCB HP Grease Lithium complex NLGI No. 2

pressure additives.
JCB Special MPL-EP Grease Lithium based NLGI No. 2 consistency
including extreme pressure
additives
†Note: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check
††Note: If JCB MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals; all 500
hour greasing operations must be carried out at 50 HOUR intervals.
9804/1103 20 - 00 - 01/14 8170/109 Issue 1

CONTENTS
Loadalls 20 - 00 - 01/15
520-50, 525-50, 525-52

below.

Engine (Oil) 10 (2.2) JCB High Performance Engine Oil SAE15W/40


Coolant Capacity 20 (4.4) JCB Four Seasons Antifreeze ASTM D3306-74

55% Concentration 9.4 (2.0) And Summer Coolant
Gearbox 17.5 (3.8) JCB High Performance JCB 4000/0900

Transmission Fluid Friction modified oils MUST NOT
be used (eg. Dexron ATF type).
Axles
Housing (520-50) 4.0 (0.88) JCB High Performance JCB 4000/2200
Housing (525-50) 8.8 (1.94) Gear Oil Plus
Housing (525-52) 8.8 (1.94) Must be suitable for use with
Hubs (x4 - 520-50) 1.0 (0.22) oil immersed brakes and limited slip
Hubs (x4 - 525-50) 1.8 (0.4) differentials (LSD).
Hubs (x4 - 525-52) 1.8 (0.4)
Hydraulic Tank (†) 70 (15.4) JCB High Performance Hydraulic Fluid 46 ISO VG46
(Above 38°C, 100°F)
(Below 38°C, 100°F)

pressure additives.
including extreme pressure
additives
9804/1103 20 - 00 - 01/15 8170/110 Issue 1

CONTENTS
Loadalls 20 - 00 - 01/16
526 (N. America)

Notice: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
below.

Engine Oil 12 (2.2) JCB 15W/40 Engine Oil SAE 15W/40


-4°F to 50°F (-20°C to 10°C) API CF4/SG
Engine (Coolant) 5.2 (20) Permanent Antifreeze ASTM D3306-74

Transmission
Syncro Shuttle 4.4 (17) JCB Special Transmission Fluid ESP-M2C 33G
Powershift 4.0 (15.5)
Front Axle
Housing 2.3 (9) JCB Special Gear Oil Plus API GL4
Hubs (x2) 0.5 (2) Must be suitable for oil immersed
brakes and Limited Slip Differentials
Rear Axle (LSD).
Housing 2.2 (8.4)
Hubs (x2) 0.5 (2)

From Serial No. 280300 Do Not Use Ordinary Brake Fluid
Hydraulic Tank †29.0 (110) JCB Hydraulic Fluid ISO VG46

(Above 100 °F (38 °C)
Grease Points ††JCB HP Grease Lithium based, No. 2 consistency
† Notice: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and
check with all cylinders closed.
†† Notice: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR
intervals; all 500 hour greasing operations must be carried out at 50 HOUR intervals.
9804/1103 20 - 00 - 01/16 8037/121 Issue 1

CONTENTS
Loadalls 20 - 00 - 01/17
530, 535, 540


Litres UK Gal US gal SPECIFICATION
Fuel Tank 125 27.5 30 Diesel Oil ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 10 (2.2) JCB Super Multigrade 15W/40 CF4/SG, SAE15W/40

-10 °C to +50 °C (14 °F to 122 °F)
JCB Super Multigrade 10W/30 CF4/SG, SAE10W/30
-15 °C to +40 °C (5 °F to 104 °F)
NORTH AMERICA
2.6 JCB 15W/40 Engine Oil CF4/SG, SAE15W/40
14 °F to 122 °F (-10 °C to +50 °C)
JCB Engine Oil 10W CF4/SG, SAE10W
-4 °F to +50 °F (-20 °C to +10 °C)
* Engine (Coolant) JCB Four Seasons Antifreeze ASTM D3306-74

Except AM Engine 23 5.0 6.0 and Summer Coolant
AM Engine only 23.5 5.2 6.2
NORTH AMERICA
Permanent Antifreeze ASTM D3306-74
Transmission 21 4.6 5.5 JCB Special Transmission Fluid ESP-M2C 33G

(See Note 1) 23 5.0 6.0
Axles
Housing 18 3.9 JCB High Performance Gear Oil API GL4
Hubs (x4) 2.0 0.4
NORTH AMERICA
Housing 4.6 JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x4) 0.48
Hydraulic Tank JCB High Performance ISO VG46

(See Note 2) Hydraulic Oil
(Above 38 °C, 100 °F)
530, 540 112 24.6 JCB Special Hydraulic Fluid ISO VG32
535 121 26.6 (Below 38 °C, 100 °F)
530, 540 29.5 NORTH AMERICA

535 32.0 JCB Hydraulic oil ISO VG46
Braking System 3 0.7 0.8 JCB Light Hydraulic Fluid ISO VG15
DO NOT USE ORDINARY
BRAKE FLUID
Grease Points JCB HP Grease Lithium based

(See Note 3)
NORTH AMERICA
JCB Moly EP 2 Grease Lithium based No. 2 constituency
Note 1: Wet fill capacity, eg. at fluid change 21 litres, dry fill capacity eg. after rebuild 23 litres.
Note 2: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check
Note 3: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals.
All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals.
9804/1103 20 - 00 - 01/17 3630 - 3/1-3.5 Issue 2*

CONTENTS
Loadalls 20 - 00 - 01/17A
530, 533, 535, 540 From m/c no. 767001

Type AA and AB Engines

Engine (Oil) 10 (2.2) JCB Super Multigrade 15W/40 SAE15W/40

-10 °C to +50 °C (14 °F to 122 °F) API CF4/SG
JCB Super Universal
Agricultural SAE10W/30,
-15 °C to +40 °C (5 °F to 104 °F) API CD/SE,
JCB Torque Converter Fluid SAE 10W,
NORTH AMERICA
2.6 JCB 15W/40 Multigrade SAE15W/40
14 °F to 122 °F (-10 °C to +50 °C) API CF4/SG
10W/30 Multigrade SAE10W/30
-4 °F to +50 °F (-20 °C to +10 °C) API CD/SE
JCB 10W SAE10W

and Summer Coolant
6.0 NORTH AMERICA

Transmission 21 4.6 5.5 JCB Extreme Performance JCB: 4000/2501

(See Note 1) 23 5.0 6.0 Transmission Oil
Axles
Hubs (x4) 2.0 0.4
NORTH AMERICA
Hubs (x4) 0.48

(Above 38 °C, 100 °F)
535, 533 121 26.6 (Below 38 °C, 100 °F)

535, 533 32.0 JCB Hydraulic oil ISO VG46
DO NOT USE ORDINARY
BRAKE FLUID

(See Note 3)
NORTH AMERICA
9804/1103 20 - 00 - 01/17A 3630 - 3/1-2.6 Issue 1*
CONTENTS
Loadalls 20 - 00 - 01/17B
530, 533, 535, 540 From m/c no. 767001

Type AR, AK and AB Engines

Engine (Oil) 10 (2.2) JCB Super Multigrade 15W/40 SAE15W/40

-10 °C to +50 °C (14 °F to 122 °F) API CF4/SG
JCB Super Universal
Agricultural SAE10W/30,
-15 °C to +40 °C (5 °F to 104 °F) API CD/SE,
JCB Torque Converter Fluid SAE 10W,
NORTH AMERICA
2.6 JCB 15W/40 Multigrade SAE15W/40
14 °F to 122 °F (-10 °C to +50 °C) API CF4/SG
10W/30 Multigrade SAE10W/30
-4 °F to +50 °F (-20 °C to +10 °C) API CD/SE
JCB 10W SAE10W

and Summer Coolant
6.0 NORTH AMERICA

Transmission 21 4.6 5.5 JCB Extreme Performance JCB: 4000/2501

(See Note 1) 23 5.0 6.0 Transmission Oil
Axles
Hubs (x4) 2.0 0.4
NORTH AMERICA
Hubs (x4) 0.48

(Above 38 °C, 100 °F)
535, 533 121 26.6 (Below 38 °C, 100 °F)

535, 533 32.0 JCB Hydraulic oil ISO VG46
DO NOT USE ORDINARY
BRAKE FLUID

(See Note 3)
NORTH AMERICA
9804/1103 20 - 00 - 01/17B 3630 - 3/1-3.6 Issue 1*
CONTENTS
Loadalls 20 - 00 - 01/18
532, 537, 550

below.

Fuel Tank 125 (27.5) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) JCB Super Multigrade 15W/40 SAE15W/40

Engine Type: 10 (2.2) -10 °C to 50 °C (14 °F to 122 °F) API CF4/SG
AA, AB, AR & AK JCB Super Multigrade 10W/30 SAE10W/30
Builds -15 °C to 40 °C (5 °F to 104 °F) API CF4/SG
Engine Type: JCB Super Universal Agricultural SAE10W/30

AA & AB Builds -15 °C to 30 °C (5 °F to 86 °F) API CD/SE
Only JCB Torque Converter Fluid SAE10W
Engine (Coolant) 23 (5.0) JCB Four Seasons Antifreeze ASTM D3306-74

And Summer Coolant
Gearbox JCB Special Transmission Fluid ESP-M2C 33G

Wet fill 21 (4.6) Friction modified oils MUST NOT be
Dry fill 23 (5.0) used (eg. Dexron ATF type).
Axles JCB High Performance Gear Oil API GL4

Housing 18 (3.9) Must be suitable for use with oil
Hubs (x4) 2.0 (0.4) immersed brakes and limited slip
differentials (LSD).

Hydraulic Tank (†) 131 (28.8) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)
(Below 38 °C, 100 °F)

pressure additives.
9804/1103 20 - 00 - 01/18 8130/120 Issue 1

CONTENTS
CONTENTS
Loadalls 20 - 00 - 02/1
* 525-58, 525-67, 527-58, 527-67 From m/c no. 567362
Static Dimensions and Weights
D K
B E
F
G
A122340
DESCRIPTION DIMENSION
525-58, 527-58 525-58FS, 527-58FS 525-67, 527-67 525-67FS, 527-67FS
A Overall height 2.59 m (8 ft 6 in) 2.57 m (8 ft 5 in) 2.59 m (8 ft 6 in) 2.57 m (8 ft 5 in)
B Overall width 2.34 m (7 ft 8 in) 2.35 m (7 ft 8 in) 2.34 m (7 ft 8 in) 2.35 m (7 ft 8 in)
C Inside width of cab

(between windows) 0.93 m (3 ft 0 in) 0.93 m (3 ft 0 in) 0.93 m (3 ft 0 in) 0.93 m (3 ft 0 in)
D Track 1.90 m (6 ft 3 in) 1.90 m (6 ft 3 in) 1.90 m (6 ft 3 in) 1.90 m (6 ft 3 in)
E Wheelbase 2.38 m (7 ft 10 in) 2.38 m (7 ft 10 in) 2.49 m (8 ft 2 in) 2.49 m (8 ft 2 in)
F Overall length to front tyres 3.87 m (12 ft 8 in) 3.87 m (12 ft 8 in) 4.05 m (13 ft 3 in) 4.05 m (13 ft 3 in)
G Overall length to front of

Q-Fit carriage 4.46 m (14 ft 7 in) 4.46 m (14 ft 7 in) 4.79 m (15 ft 8 in) 4.79 m (15 ft 8 in)
H Ground clearance 0.42 m (1 ft 5 in) 0.40 m (1 ft 4 in) 0.42 m (1 ft 5 in) 0.40 m (1 ft 4 in)
K Centre of gravity (unladen) 1.21 m (3 ft 11 in) 1.21 m (3 ft 11 in) 1.34 m (4 ft 3 in) 1.34 m (4 ft 3 in)
Weight (unladen) 6300 kg (13,860 lb) 6300 kg (13,860 lb) 6422 kg (14,128 lb) 6422 kg (14,128 lb)
9804/1103 20 - 00 - 02/1 Issue 3*

CONTENTS
Loadalls 20 - 00 - 02/2
530-95 From m/c no. 567362

K
J
D E
B F
G A198790
A Overall height 2.59 m (8 ft 6 in)
B Overall width 2.35 m (7 ft 8 in)

(between windows) 0.94 m (3 ft 1 in)
D Track 1.90 m (6 ft 3 in)
E Wheelbase 2.49 m (8 ft 2 in)
F Overall length to front tyres 4.78 m (15 ft 8 in)

Q-Fit carriage 5.60 m (18 ft 4 in)
H Ground clearance 0.4 m (1 ft 4 in)
J Boom overhang 0.54 m (1 ft 8 in)
Weight (unladen) 7960 kg (17,550 lbs) Approximately
9804/1103 20 - 00 - 02/2 Issue 1

CONTENTS
Loadalls 20 - 00 - 02/3
530-110 From m/c no. 567362

D K
B E
F
G
*A122430
* A Overall height 2.59 m (8 ft 6 in)
* B Overall width 2.35 m (7 ft 8 in)

(between windows) 0.94 m ( 3 ft 1 in)
* F Overall length to front tyres 4.78 m (15 ft 8 in)
* G Overall length to front of

* H Ground clearance 0.4 m ( 1 ft 4 in)
* K Centre of gravity (unladen,

stabilisers raised) 1.36 m (4 ft 6 in)
9804/1103 20 - 00 - 02/3 8190/151 Issue 2*

CONTENTS
Loadalls 20 - 00 - 02/3A
530-110 From m/c no. 567362
Performance Data
Forklift Performance †
Lift capacity to full height 3000 kg (6,614 lb)
Lift capacity at full reach 950 kg (2,095 lb)
Lift height 10.95 m (36 ft 1 in)
Reach at maximum lift height 1.55 m (5 ft 5 in)
Maximum forward reach 6.85 m (23 ft 0 in)
Placing height 10.3 m (33 ft 9 1/2 in)
† Based on 500 mm (20 in) Load Centre. See Load Charts.
Loader Performance (Standard GP Bucket)

Bucket rated capacity 1.0 m3 (35 cu ft)
Maximum dump height at 45 degrees TBA
Maximum dump height 10.65 m (35 ft 1 in)
Maximum loadover height 10.80 m (35 ft 5 in)
Placing height TBA
9804/1103 20 - 00 - 02/3A 8190/152 Issue 1

CONTENTS
Loadalls 20 - 00 - 02/4
530-120, 537-130 From m/c no. 567362

D E
B G
S140100

(between windows) 0.94 m ( 3 ft 1 in)

H Ground clearance 0.38 m ( 1 ft 3 in)
9804/1103 20 - 00 - 02/4 Issue 1

CONTENTS
Loadalls 20 - 00 - 02/5
505-19, 505-22 From m/c no. 567362

D K
B E
F
G
A122340
505-19 505-22
A Overall height 8 ft 6 in (2.59 m) 8 ft 6 in (2.59 m)

B Overall width 7 ft 6 in (2.29 m) 7 ft 6 in (2.29 m)

(between windows) 3 ft 2.5 in (0.92 m) 3 ft 2.5 in (0.92 m)
D Track 6 ft 3 in (1.90 m) 6 ft 3 in (1.90 m)
E Wheelbase 7 ft 10 in (2.38 m) 8 ft 2 in (2.49 m)
F Overall length to front tires 12 ft 8 in (3.86 m) 13 ft 3 in (4.04 m)

Q-Fit carriage 14 ft 7 in (4.45 m) 15 ft 8 in (4.77 m)
H Ground clearance 1 ft 4.5 in (0.42 m) 1 ft 41/2 in (0.42 m)
Weight (unladen) 13,960 lbs (6300 kg) 15,345 lbs (6960 kg)
Notice: Dimensions are based on a machine with 15.5-25 tires fitted.
9804/1103 20 - 00 - 02/5 Issue 1

CONTENTS
Loadalls 20 - 00 - 02/6
506-36 From m/c no. 567362

D
E
B
F
G
S157670
A Overall height 8 ft 6 in (2.59 m)
B Overall width 7 ft 6 in (2.29 m)

(between windows) 3 ft 21/2 in (0.92 m)
D Track 6 ft 3 in (1.90 m)
E Wheelbase 7 ft 10 in (2.38 m)
F Overall length to front tires 12 ft 8 in (3.86 m)

Q-Fit carriage 14 ft 7 in (4.45 m)
H Ground clearance 1 ft 41/2 in (0.42 m)
Weight (unladen) 20,616 lbs (9350 kg) Approximately
9804/1103 20 - 00 - 02/6 Issue 1

CONTENTS
Loadalls 20 - 00 - 02/7
508-40 From m/c no. 567362

D E
B G
S141370

(between windows) 3 ft 1 in (0.94 m)

Weight (unladen) 24,458 lbs (11,094 kg) Approximately
9804/1103 20 - 00 - 02/7 Issue 1

CONTENTS
Loadalls 20 - 00 - 02/8
510-40 From m/c no. 567362

D E
B G
S140100

(between windows) 3 ft 1 in (0.94 m)

H Ground clearance 1 ft 4 in (0.4 m)
Weight (unladen) 26,808 lbs (12,160 kg)
9804/1103 20 - 00 - 02/8 Issue 1

CONTENTS
Loadalls 20 - 00 - 02/9
520-55, 520S From m/c no. 567362

C
D E
B F
G A245130
B Overall width 7 ft 11/2 in (2.17 m)
C Inside width of cab 2 ft 11 in (0.88 m)
D Front track 6 ft 2 in (1.87 m)
F Overall length to front tyres 12 ft 4 in (3.76 m)
G Overall length to front of Q-Fit carriage 14 ft 6 in (4.42 m)
H Ground clearance 1 ft 1 in (0.32 m)
Weight (unladen) 10745 lb (4875 kg)

8020/191
Note: The above figures are based on a machine fitted with 12.5/80 X 18" tyres.
* Performance Dimensions †
Forklift Performance
Lift capacity to full height 4500 lb (2041 kg)
Lift capacity at full reach 2000 lb (907 kg )
Lift height 18 ft 0 in (5.50 m)
Maximum forward reach 10 ft 6 in (3.20 m)
Placing height 15 ft 61/2 in (4.74 m)

8020/193
* † Based on 24 in (610 mm) Load Centre. See Load Charts.
9804/1103 20 - 00 - 02/9 Issue 3*

CONTENTS
Loadalls 20 - 00 - 02/10
526-55, 526, 526S From m/c no. 277001

D E
B F
G
A195450
ø
DESCRIPTION DIMENSION DIMENSION DIMENSION
526-55 526 526S
A Overall height 7 ft 61/2 in (2.30 m) 7 ft 61/2 in (2.30 m) 7 ft 81/2 in (2.38 m)
B Overall width 7 ft 31/4 in (2.23 m) 7 ft 31/4 in (2.23 m) 7 ft 31/4 in (2.23 m)
C Inside width of cab 2 ft 11 in (0.88 m) 2 ft 11 in (0.88 m) 2 ft 11 in (0.88 m)
D Front track 6 ft 0 in (1.85 m) 5 ft 11 in (1.81 m) 5 ft 11 in (1.81 m)
E Wheelbase 7 ft 5 in (2.26 m) 7 ft 7 in (2.33 m) 7 ft 7 in (2.33 m)
F Overall length to front tyres 12 ft 51/2 in (3.80 m) 12 ft 91/2 in (3.90 m) 12 ft 91/2 in (3.90 m)
G Overall length to front of Q-Fit carriage 14 ft 6 in (4.42 m) 14 ft 10 in (4.52 m) 14 ft 10 in (4.52 m)
H Ground clearance 1 ft 2 in (0.36 m) 1 ft 51/2 in (0.45 m) 1 ft 51/2 in (0.45 m)
Weight (unladen) 12122 lb (5500 kg) 12171 lb (5520 kg) 12877 lb (5840 kg)
8020/192
* Performance Dimentional
Forklift Performance†
Lift capacity at full reach 2204 lb (1000 kg)
Placing height 15 ft 8 in (4.78 m)
†Based on 24 in (610 mm) Load Centre. See Load Charts. 8020/193
9804/1103 20 - 00 - 02/10 Issue 3*

CONTENTS
Loadalls 20 - 00 - 02/11
537-120 From m/c no. 567362

D E
B G
S141370


Q-Fit carriage 5.87 m (19 ft 3 in
K Centre of gravity
(unladen, stabilisers raised) 1.28 m (4 ft 2 in)
Weight (unladen) 11,100 kg (24,458 lbs) Approximately
9804/1103 20 - 00 - 02/11 Issue 1

CONTENTS
Loadalls 20 - 00 - 02/12
530-67, 535-67 From m/c no. 567362

H
K
D E
B F
G
A214860


K Centre of gravity (unladen) 1.44 m (4 ft 9 in)
Weight (unladen) 7170 kg (15,770 lb)
9804/1103 20 - 00 - 02/12 Issue 1

CONTENTS
Loadalls 20 - 00 - 02/13
* 520-50, 525-50, 525-52 From m/c no. 754000
* Static Dimensions and Weight
D K
B E
G
A234930
* DESCRIPTION DIMENSION DIMENSION DIMENSION

520-50 525-50 525-52
A Standard overall height 2120 mm (6ft 11in) 2190 mm (7ft 2in) 2250 mm (7ft 5in)
Low cab option 1985 mm (6ft 6in) 2055 mm (6ft 9in) 2115 mm (6ft 11in)
B Overall width 1800 mm (5ft 11in) 1820 mm (6ft 0in) 1880 mm (6ft 2in)

(between windows) 830 mm (2ft 7in) 830 mm (2ft 7in) 830 mm (2ft 7in)
D Track 1530 mm (5ft 0in) 1490 mm (4ft 11in) 1490 mm (4ft 11in)
E Wheelbase 2000 mm (6ft 7in) 2000 mm (6ft 7in) 2000 mm (6ft 7in)
F Overall length to front tyres 3080 mm (10ft 1 in) 3130 mm (10ft 3in) 3130 mm (10ft 3in)

carriage 3590 mm (11ft 9in) 3620 mm (11ft 11in) 3620 mm (11ft 11in)
H Ground clearance 300 mm (1ft 0in) 360 mm (1ft 2in) 420 mm (1ft 4in)
K Centre of gravity (unladen) 1020 mm (3ft 9in) 1020 mm (3ft 9in) 1020 mm (3ft 9in)
Weight (unladen) 4700 Kg (10,362lb) 5400 Kg (11,905lb) 5400 Kg (11,905lb)
* Note: Only 520-50 machines are available in N. America.
9804/1103 20 - 00 - 02/13 8170/151 Issue 2*

CONTENTS
Loadalls 20 - 00 - 02/13A
520-50, 525-50, 525-52 From m/c no. 754000

Performance Dimensions
Forklift Performance † (except N. America)
520-50 525-50 525-52
Lift capacity to full height 2000 Kg (4,410 lb) 2500 Kg (5,511 lb) 2500 Kg (5,511 lb)
Lift capacity at maximum reach 700 Kg (1,543 lb) 1000 Kg (2,205 lb) 1000 Kg (2,205 lb)
Maximum lift height 5000 mm (16ft 4in) 5000 mm (16ft 4in) 5200 mm (17ft 1in)
Reach at maximum lift height 500 mm (1ft 6in) 500 mm (1ft 6in) 500 mm (1ft 6in)
Maximum forward reach 2820 mm (9ft 2 in) 2820 mm (9ft 2in) 2820 mm (9ft 2in)
Reach with 1 tonne load 2255 mm (7ft 3in) 2820 mm (9ft 2in) 2820 mm (9ft 2in)
Placing height, 2 tonne load 4600 mm (15ft 0in) 4600 mm (15ft 0in) 4600 mm (15ft 0in)
8170/152
† Based on 500 mm (20 in) Load Centre.
Forklift Performance ††(N. America)

Lift capacity to full height 4,400 lb. (1998 kg)
Lift capacity at maximum reach 1,650 lb. (749 kg)
Maximum lift height 16 ft 4 in (5000 mm)
Reach at maximum lift height 1 ft 10 in (559 mm)
Maximum forward reach 9 ft 6 in (2896 mm)
Reach with 2,200 lb load 8 ft 5 in (2565 mm)
Placing height, 4,400 lb load 15 ft 0 in (4572 mm)
†† Based on 24 in (609 mm) Load Center. 8185/152
Loader Performance (Standard GP Bucket)

520-50 525-50 525-52
Bucket rated capacity 0.7 m3 (24 cu ft) 0.9 m3 (32 cu ft) 0.95 m3 (33 cu ft)
Maximum dump height at 45° bucket angle 4.07 m (13ft 3in) 4.11 m (13ft 6in) 4.17 m (13ft 8in)
8170/152
9804/1103 20 - 00 - 02/13A Issue 1

CONTENTS Loadalls 20 - 00 - 02/14
530, 540 * From m/c no. 767001

H
K
D E
B F
G
A264240
DESCRIPTION DIMENSION DIMENSION
530 540
A Overall height 2480 mm (8ft 1 in) 2490 mm (8ft 2in)
B Overall width 2230 mm (7ft 1 in) 2290 mm (7ft 6in)

(between windows) 940 mm (3ft 1in) 940 mm (3ft 1in)
D Track 1794 mm (5ft 10in) 1870 mm (6ft 2in)
E Wheelbase 2750 mm (9ft 0in) 2750 mm (9ft 0in)
F Overall length to front tyres 4380 mm (14ft 4in) 4380 mm (14ft 4in)

carriage 4940 mm (16ft 2in) 4990 mm (16ft 4in)
H Ground clearance 390 mm (1ft 2in) 400 mm (1ft 4in)
K Centre of gravity (unladen) 1420 mm (4ft 8in) -
Weight (unladen) 6475 kg (14,277 lb) 7400 kg (16,314 lb)
9804/1103 20 - 00 - 02/14 8130/151 Issue 2*

CONTENTS
Loadalls 20 - 00 - 02/14A
535 From m/c no. 767001

A1 A2
W
15 H1 H2 X H3
115 K
D L E P
B F
M G
M A345760
T
S R1/R2
R3
U1/U2
R4
DIMENSION DIMENSION
A1 2465 mm (8ft 1in) P 1030 mm (3ft 5in)

A2 2630 mm (8ft 8in) R1 4277 mm (14 ft) - 1067mm forks (T)
B 2290 mm (7ft 6in) R2 4392 mm (14ft 5in) - 1200mm forks (T)
C 960 mm (3ft 2in) R3 3176 mm (10ft 5in) (T)
D 1870 mm (6ft 2in) R4 559 mm (1ft 10in) (T)
E 2750 mm (9ft 0in) S 1226 mm (4ft)
F 4410 mm (14ft 6in) - without hitch T 103 mm (4 in)
4520 mm (14ft 10in) with hitch U1 3718 mm (12ft 3in) - 1067mm forks (T)
G 4980 mm (16ft 4in) U2 3833 mm (12 ft 7in) - 1200mm forks (T)
H1 410 mm (1ft 5in) V 6817 mm (22ft 5in) - 1067mm forks (T)
H2 380 mm (1ft 4in) W 30° with hitch
H3 411 mm (1ft 5in) 40° without hitch
K 1415 mm (4ft 8in) - Unladen X 16.3°
L 1200 mm (3ft 11in)
M 1067 mm (3ft 6in) Weight (unladen) 7910 kg (17,438 lb)
1200 mm (3ft 11in)
N 1830 mm (6ft) Entries marked (T) are theoretical not measured values.
Machine tested with 445/70 R24 XM47 tyres.
9804/1103 20 - 05 - 02/14A 8130/152 Issue 1

CONTENTS
Loadalls 20 - 00 - 02/15
530, 540 From m/c no. 767001

* Forklift Performance † 530 * 535 540
Maximum lift capacity 3000 kg (6,615 lb) 3500 kg (7,716 lb) 4000 kg (8,818 lb)
Lift capacity to full height 2500 kg (5,512 lb) 1750 kg (3,858 lb) 3000 kg (6,614 lb)
Lift capacity at maximum reach 1250 kg (2,756 lb) 600 kg (1,323 lb) 1500 kg (3,307 lb)
Maximum lift height 7000 mm (22ft 9in) 9500 mm (31 ft 2 in) 7000 mm (22ft 8in)
Reach at maximum lift height 480 mm (1ft 6in) 2430 mm (7 ft 11 in) 480 mm (1ft 7in)
Maximum forward reach 3700mm (12ft 2in) 6520 mm (12 ft 2 in) 3700 mm (12ft 2in)
Reach with 1 tonne load 3700mm (12ft 2in) 5290 mm (17 ft 4 in) 3700 mm (12ft 2in)
* † Based on 500 mm (20 in) Load Centre.
9804/1103 20 - 00 - 02/15 Issue 2*

CONTENTS
Loadalls 20 - 00 - 02/16
532, 537, 550 * From m/c no. 767001

H
D K
E
B
F
G
A264250
DESCRIPTION DIMENSION DIMENSION DIMENSION
532 537 550
A Overall height 2580 mm (8ft 5in) 2580 mm (8ft 5in) 2590 mm (8ft 6in)
B Overall width 2350 mm (7ft 8in) 2350 mm (7ft 8in) 2350 mm (7ft 8in)

(between windows) 940 mm (3ft 1in) 940 mm (3ft 1in) 940 mm (3ft 1in)
D Track 1900 mm (6ft 2in) 1900 mm (6ft 2in) 1900 mm (6ft 2in)
E Wheelbase 2750 mm (9ft 0in) 2900 mm (9ft 5in) 2900 mm (9ft 5in)
F Overall length to front tyres 4830 mm (15ft 10in) 5180 mm (17ft 0in) 5180 mm (17ft 0in)

carriage 5800mm (19ft 0in) 6190 mm (20ft 3in) 6230 mm (20ft 5in)
H Ground clearance 390 mm (1ft 2in) 390 mm (1ft 2in) 400 mm (1ft 4in)
K Centre of gravity (unladen) 1380 mm (4ft 6in) 1660 mm (5ft 5in) -
Weight (unladen) 9430 kg (20,793 lbs) 10,600 kg (23,373 lbs) 11,300 kg (24,912 lbs)
9804/1103 20 - 00 - 02/16 Issue 2*

CONTENTS
Loadalls 20 - 00 - 02/17
532, 537, 550 * From m/c no. 767001

Forklift Performance* 532 537 550
Maximum lift capacity 3200 kg (7,056 lb) 3700 kg (8158 lb) 4536 kg (10,00 0 lb)
Lift capacity to full height 3200 kg (7,056 lb) 3700 kg (8158 lb) 4536 kg (10,000 lb)
Lift capacity at maximum reach 1250 kg (2,756 lb) 1500 kg (3,307 lb) 1134 kg (2,500 lb )
Maximum lift height 12000 mm (39ft 4 in) 13500 mm (44ft 3in) 13500 mm (44ft 3in)
Reach at maximum lift height 1450 mm (4ft 9 in) 1680 mm (5ft 5in) 1680 mm (5ft 6in)
Maximum forward reach 8010 mm (26ft 3in) 9250 mm (30ft 3in) 9250 mm (30ft 4in)
Reach with 1 tonne load 8010 mm (26ft 3in) 9250 mm (30ft 3in) -
Placing height, 2 tonne load - - -
* Based on 500 mm (20 in) Load Centre.
9804/1103 20 - 00 - 02/17 Issue 2*

CONTENTS
Loadalls 20 - 00 - 02/18
506, 506 (HL), 508 (N. America)

D E
B G
A196390
506 506 (HL) 508
A Overall height 8 ft 8 in (2.67 m) 8 ft 8 in (2.67 m) 8 ft 8 in (2.67 m)
B Overall width 7 ft 8 in (2.13 m) 8 ft 1 in (2.46 m) 8 ft 1 in (2.46 m)

(between windows) 3 ft 0 in (0.93 m) 3 ft 0 in (0.93 m) 3 ft 0 in (0.93 m)
D Track 6 ft 3 in (1.92 m) 6 ft 7 in (2.01 m) 6 ft 7 in (2.01 m)
E Wheelbase 9 ft 1 in (2.78 m) 9 ft 10 in (3.00 m) 9 ft 10 in (3.00 m)

Q-Fit carriage 17 ft 6 in (5.34 m) 20 ft 1 in (6.12 m) 20 ft 1 in (6.12 m)
H Ground clearance 1 ft 3 in (0.38 m) 1 ft 4 in (0.41 m) 1 ft 4 in (0.41 m)
Weight (unladen) 21,040 lbs (9,540 kg) 22,150 lbs (10,069 kg) 25,225 lbs (11,440 kg)
9804/1103 20 - 00 - 02/18 8205/171 Issue 1

CONTENTS
Loadalls 20 - 00 - 02/19
506, 506 (HL), 508 (N. America)

Performance Data
506 506 (HL) 508
Lift capacity to full height 6,000 lb (3000 kg) 6,000 lb (3000 kg) 8,000 lb (3628 kg)
Lift capacity at full reach 2,000 lb (900 kg) 1,500 lb (681 kg) 1,800 lb (816 kg)
Lift height 36 ft 1 in (11.0 m) 42 ft 0 in (12.8 m) 42 ft 0 in (12.8 m)
Reach at maximum lift height 5 ft 5 in (1.65 m) 5 ft 11 in (1.80 m) 5 ft 11 in (1.80 m)
Maximum forward reach 23 ft 5 in (7.1 m) 27 ft 4 in (8.33 m) 27 ft 4 in (8.33 m)
Placing height 33 ft 10 in (10.31 m) - -
† Based on 24 in (610 mm) Load Center. See Load Charts.
9804/1103 20 - 00 - 02/19 8205/172 Issue 1

CONTENTS
Loadalls 20 - 00 - 02/20
526 (N. America)

H
D E
B F
G
A245130
A Overall height 7 ft 81/2 in (2.38 m)
B Overall width 7 ft 31/4 in (2.23 m)
C Inside width of cab 2 ft 11 in (0.88 m)
D Front track 5 ft 11 in (1.81 m)
F Overall length to front tires 12 ft 91/2 in (3.90 m)
G Overall length to front of Q-Fit carriage 14 ft 10 in (4.52 m)
Weight (unladen) 12877 lb (5840 kg)
Lift capacity at full reach 2204 lb (1000 kg)
Placing height 15 ft 8 in (4.78 m)
† Based on 24 in (610 mm) Load Center.
9804/1103 20 - 00 - 02/20 8037/191 and 192 Issue 1

CONTENTS
Loadalls 20 - 00 - 02/21
528-70, 528S
H
D E
B F
G
A314940
DESCRIPTION DIMENSION DIMENSION

528-70 528S
A Overall height 8 ft 11 in (2.46 m) 8 ft 11 in (2.46 m)
B Overall width 7 ft 6 in (2.29 m) 7ft 7 in (2.31 m)
C Inside width of cab 2 ft 11 in (0.88 m) 2 ft 11 in (0.88 m)
D Front track 6 ft 2 in (1.88 m) 6 ft 2 in (1.88 m)
E Wheelbase 8 ft 10 in (2.70 m) 8 ft 10 in (2.70 m)
F Overall length to front tyres 14 ft 7 in (4.45 m) 14 ft 7 in (4.45 m)
G Overall length to front of Q-Fit carriage 16 ft 11 in (5.15 m) 16 ft 11 in (5.15 m)
H Ground clearance 1 ft 7 in (0.48 m) 1 ft 7 in (0.48 m)
Weight (unladen) 13800 lb (6260 kg) 14575 lb (6610 kg)
Turn radius over tyres (4WS) 11 ft 9 in (3.58 m) TBA
9804/1103 20 - 00 - 02/21 8450/191 Issue 1

CONTENTS
Loadalls 20 - 00 - 02/22
528-70, 528S
Forklift Performance † 528-70 528S
Lift capacity to full height 5292 lb (2400 kg) 5071 lb (2300 kg)
Lift capacity at full reach 2756 lb (1250 kg) 2756 lb (1250 kg)
Lift height 22 ft 2 in (6.75 m) 22 ft 2 in (6.75 m)
Maximum forward reach 12 ft 3 in (3.73 m) 12 ft 3 in (3.73 m)
Placing height 20 ft 0 in (6.1 m) 20 ft 0 in (6.1 m)
Note: Lift capacity to full height is reduced to 5071 lb (2300 kg) for 528S machines fitted with 17.5LR24 tyres.
† Based on 20 in (500 mm) Load Centre.
9804/1103 20 - 00 - 02/22 8450/192 Issue 1

CONTENTS
Loadalls 20 - 05 - 01/1
ALL MODELS From m/c no. 567362

Data - Electrical
System Type 12 volts, negative earth
Battery
* Cold Crank amps for 1 minute to
* 1.4 VPC at -18°C (0°F) 410 to 585
* Reserve capacity (minutes) for 25 amp load 170 to 230
Alternator Lucas A127-65, 65 amp maximum output

Starter Motor Lucas M127/2.8
Light Bulbs
Headlights main/dip 45W/40W or 60/55W (halogen)

Working lamps 55W (Halogen)
Front side lamps 5W
* Stop/tail lamps/reverse (if fitted) 21W/5W/21W
Indicator lamps 21W
Number plate lamp 10W
Fog lamp 21W
Interior lamp 18W
Panel/warning lamps 1.2W
Beacon 55W (Halogen)
9804/1103 20 - 05 - 01/1 Issue 2*

CONTENTS
Loadalls 20 - 05 - 01/2

Data - Electrical
The electrical circuits are protected by fuses. The fuses are located in a fuse box near the steering pedestal. They are in three
rows, labelled A, B, and C. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one.
Row A Row B Row C
Fuse Circuit Rating Fuse Circuit Rating Fuse Circuit

Rating
1 Starter relay 1 1 Reversing lights, 1 L.H. Main beam 7.5

panel warning light 5
2 Safe load indicator 1 2 R.H. main beam, main
2 Forward/reverse switch, beam warning light 7.5
3 Brake lock (USA) 5 transmission dump
switch (if fitted), 3 Cooling fan solenoid
4 Heater 15 manual gearbox 7.5 (if fitted) 15
powershift gearbox 15
5 Seat/parking brake 4 Radio (if fitted) 1
warning (if fitted) 10 3 Interior lights,
roof wiper (if fitted) Note: The radio fuse may need to be
6 Horn 20 beacon (if fitted) 10 replaced by one of a higher rating as
or as above specified in radio fitting instructions.
7 Indicators 7.5 plus rear wiper 15
5 Servo control 10
8 Hazard warning lights 15 4 Brake lights 7.5
6 Headlamp flasher 15
9 Engine shut-off 5 Steer circuit (if fitted)
solenoid (ESOS) 5 (without IP67) 5
(with IP67) 7.5 *9 Reverse alarm (powershift) 5
6 Panel illumination,
L.H. sidelights 7.5
7 R.H. sidelights,
number plate light,
one working light, 10
or above but with
two working lights 15
8 L.H. dipped beam 7.5
9 R.H. dipped beam 7.5
Note: Machines not fitted with road lights should not have fuses fitted at positions A7, A8, B8, B9, C1 and C2.
S112251
9804/1103 20 - 05 - 01/2 Issue 3*

CONTENTS
Loadalls 20 - 05 - 01/3

Data - Electrical
Location
The relays are located in front of the steering wheel, to gain

access remove the panel.
Non servo machines Basic servo machines (525-58, 525- 67, 505-19 & 505-22)
A
A
F F
B E B
E
C J C
D D
G
S167142
S167140
A Steer mode PCB relay A Steer mode PCB relay

B Reverse alarm relay B Reverse alarm relay
C Buzzer relay C Buzzer relay
D Flasher relay D Flasher relay
E Sidelights relay E Sidelights relay
F Hand brake warning relay F Hand brake warning relay
G Servo controls relay
Servo/Remote machines
(530-110, 530-120)
E
H D B
J
FC
G S167142
A Steer mode PCB relay

B Reverse alarm relay
C Flasher relay
D Sidelights relay
E Hand brake warning relay
F Stop relay
G Servo remote controls relay
H Buzzer isolation relay
J Buzzer relay
9804/1103 20 - 05 - 01/3 Issue 1

CONTENTS
Loadalls 20 - 05 - 01/4

Data - Electrical
Machines with IP67 electrics Machines with transmission dump relay
(All except 530-120 up to serial No. 572168, 530-120 up to (All except 530-120 from serial No. 572169, 530-120 from
serial No. 572242) serial No. 572243)
K
L
L K
N H
M
E J J E
H D
F
D C
F G
C B
B
G
A
A
S172170 S215940
A Steer mode printed circuit board A Steer mode printed circuit board
B Reverse alarm relay B Reverse alarm relay
C Buzzer relay C Buzzer relay
D Forward relay D Forward relay
E Flasher relay E Flasher relay
F Sidelights relay F Sidelights relay
G Hand brake warning relay G Hand brake warning relay
H Ignition relay H Ignition relay
J Parking brake relay J 4 Wheel drive/brake relay
K Neutral start relay K Neutral start relay
L Reverse relay L Reverse relay
M Transmission dump relay
N Diode gate
9804/1103 20 - 05 - 01/4 Issue 2

CONTENTS
Loadalls 20 - 05 - 01/5

Data - Electrical
Machines with Powershift option
P
K
N H
M E
R
J F
D
C G
B Q S
S215930
A Steer mode printed circuit board

C Buzzer relay
D Forward relay
E Flasher relay
F Sidelights relay
G Hand brake warning relay
H Ignition relay
J 4 Wheel drive/brake relay
K Neutral start relay
N Diode gate
P Reverse high/low relay
Q Forward high/low relay
R Drvieshaft relay
S Neutral drive relay
9804/1103 20 - 05 - 01/5 Issue 2

CONTENTS
Loadalls 20 - 05 - 01/6
* 520-55, 520S, 520-55 RS (504B N. Am), 526-55, 526, 526S (526 N. Am) From m/c no.
277001
Data - Electrical
* Fuse Identification
The electrical circuits are protected by fuses. The fuses are located in a fuse box inside the door. They are in three rows,
labelled A, B and C. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one.
Note: The radio fuse may need to be replaced by one of a higher rating as specified in radio fitting instructions.
520-55, 526-55, 520-55RS (504B N.Am) From Machine Serial Number 277001 to 278965 (279014 504B)
Row A Row B Row C
Fuse Circuit Rating Fuse Circuit Rating Fuse Circuit Rating

1 Starter relay 1 1 Reversing lights, 1 L.H. Main beam 7.5
2 Safe load indicator 1 panel warning light 7.5 2 R.H. main beam, main
3 Diverter valve relay 5 2 Forward/reverse switch, beam warning light 7.5
4 Heater 15 transmission dump relay 5 3 Headlamp flash 15
5 Spare 3 Interior lights, 4 Radio (if fitted) 1
6 Horn, Front wiper, beacon (if fitted) 10 5 Face level fan 10
Washer pump 15 4 Brake lights 7.5 or air conditioning 15
7 Indicators 7.5 5 Spare
8 Hazard warning lights 10 6 Panel illumination,
9 Engine shut-off L.H. sidelights 7.5
solenoid (ESOS) 5 7 R.H. sidelights,
number plate light,
working light 15
8 L.H. dipped beam 7.5
9 R.H. dipped beam 7.5
526, 526S (526 N.Am) With Powershift Transmission From Machine Serial Number 278966 to 280576
526, 526S (526 N.Am) With Syncro Shuttle Transmission From Machine Serial Number 278966 to 280573
520-55, 520S From Machine Serial Number 278966 Onwards
Row A Row B Row C
1 Starter relay 1 1 Safe load indicator (SLI) 1 1 R.H. Side lights,

2 Engine shut off 2 Horn, Headlamp flasher 10 Working lights 15
solenoid (ESOS) 5 3 Heater/Air conditioning 2 L.H. Side lights 7.5
3 Spare fan (if fitted) 15 3 Dip beam 10
4 Forward/reverse switch 15 (10)+ 4 Face fan, Air conditioning 4 Main beam 10
5 Transmission ECU (if fitted) 7.5 compressor (if fitted) 15 5 Brake lights 10
6 Reverse alarm 10 5 Wipers, Washers 15 6 Hazard warning lights 15
7 Spare 6 Beacon, Interior light 7.5 7 Indicators 10
8 Spare 7 Radio 5 8 Spare
9 Diverter valve 10 8 Instrument panel 5 9 Spare
9 Spare
+ Machines with syncro shuttle transmission.
Fuse links
Circuit Rating
1 Horn, Hazard warning lights, Beacon, Interior light 40
2 Road lights, Working lights 40
3 Not used
4 ESOS, Forward/reverse switch, Brake lights 40
5 Diverter valve, SLI, Heater, Wipers, Radio, Instruments 80
2
4 1
5
3
S245110
S192451
9804/1103 20 - 05 - 01/6 3610-C/1-4.2 Issue 4*

CONTENTS
Loadalls 20 - 05 - 01/7
* 520-55, 520-55 RS (504B N. Am), 526-55, 526, 526S (526 N. Am) From m/c no. 277001
Data - Electrical
* Relay Identification
520-55, 526-55, 520-55RS (504B N.Am) From Machine Serial Number 277001 to 278965 (279014 504B)
1 Indicator relay 4 Side lights relay 7 Buzzer relay 10 Brake light relay
2 Forward relay 5 Parking brake relay 8 Reverse alarm relay 12/13 Starter relay
3 Reverse relay 6 Dump switch relay 9 Auxiliary solenoid relay 11/14 Neutral start relay
Note: Relays 13 and 14 can be fitted either way round, to identify them the Neutral Relay has an ‘I’ on it. On later machines
relay 13 is on the main board 12 and diode 15 is fitted in its place. Diode 15 links the handbrake warning light and transmission
dump to disconnect the drive when the handbrake is applied. Also, relay 14 is on the main board 12.
520-55, 520S, 526-55 From Machine Serial Number 278966 (279015 504B) onwards
1 Indicator relay 4 Side lights relay 7 Buzzer relay 10 Air conditioning relay
2 Forward relay 5 Parking brake relay 8 Spare 11 Neutral start relay
3 Reverse alarm relay 6 Dump switch relay 9 Spare 12 Starter relay
526, 526S (526 N.Am) From Machine Serial Number 280300 to 280576 (Powershift Transmission)
2 Spare 5 Spare 8 Spare 11 Neutral start relay
3 Reverse relay 6 Spare 9 Auxiliary solenoid relay 12 Starter relay
526, 526S (526 N.Am) From Machine Serial Number 280300 to 280573 (Syncro Shuttle Transmission)
3 Reverse alarm relay 6 Dump switch relay 9 Auxiliary solenoid relays 12 Starter relay
1 2 3
5 6
4
£ $
7 8 9
0 ! @
S192450
9804/1103 20 - 05 - 01/7 3610 - C/1-2.6 Issue 3*

CONTENTS
Loadalls 20 - 05 - 01/8
* 520-50, 525-50, 525-52 From m/c no. 754000
Data - Electrical
Battery 12 volts, negative earth
Cold Crank amps for 1 minute to
1.4 VPC at -18°C (0°F) 410 to 58
Reserve capacity (minutes) for 25 amp load 170 to 230

Starter Motor Lucas M127/2.8
Light Bulbs
Headlights main/dip 45W/40W or 60/55W (halogen)
Working lamps 55W (Halogen)
Front side lamps 5W
Stop/tail lamps/reverse 21W/5W/21W
Indicator lamps 21W
Number plate lamp 10W
Fog lamp 21W
Interior lamp 18W
Panel/warning lamps 1.2W
Beacon 55W (Halogen)
Relays are used in the electrical circuits for a variety of reasons. The most usual application is to protect components like
switches etc. from being overloaded. A relatively small current (from the switch) energises the relay coil, this causes internal
contacts to open or close which controls a larger current in another circuit.
Although relays look similar, internally they can be different, for example, they can be single or double contact; normally closed
or open. Make sure you fit the correct type of relay, otherwise the machine electrical circuits will not function correctly. The
relays are identified as follows:
1 Work light 5 Buzzer 9 Flasher

2 Parking brake light 6 Neutral start 10 Ignition 1
3 Park brake 7 Reverse 11 Ignition 2
4 Transmission dump 8 Forward 12 Lights
1 2 3 4
5 6 7 8
9 0 ! @
S239200
9804/1103 20 - 05 - 01/8 3620-C/1-1.1 Issue 2*

CONTENTS
Loadalls 20 - 05 - 01/9
* 520-50, 525-50, 525-52 From m/c no. 754000
Data - Electrical
Fuse Identification
Row A Row B Row C
Fuse Circuit Rating Fuse Circuit Rating Fuse Circuit

Rating
1 Brake lights 5 1 Junction box 1 Spare
2 Panel warning lights, (if fitted) 15 2 Safe load indicator 5
Warning buzzer, 2 Engine shut-off 3 Forward/reverse switch, 5
Instrument lights 5 solenoid (ESOS) 5 transmission dump relay 10
3 L.H. sidelights 3 L.H. dipped beam 4 Spare
L.H. number plate R.H. dipped beam 10 5 Thermostart 15
light, L.H. trailer 4 L.H. main beam 6 Spare
light (if fitted) 5 R.H. main beam 10 7 Spare
4 R.H. sidelights, 5 Working lights - Opt 15 8 Spare
R.H. number plate Working lights - Std 10 9 Spare
light, R.H. trailer 6 Indicators 5
light (if fitted) 5 7 Parking brake circuit 5
5 Roof wiper, rear 8 Heater 15
wash/wipe switch 5 9 Spare
6 Hazard warning lights 10
7 Face level fan (if
fitted), beacon switch 10
8 Radio (if fitted) 5
9 Front wash/wipe
switch, horn switch,
headlight flasher 10
Fuse links
Circuit Rating
1 Starter relay 60 1
2 Tracker, Radio, Hazard lights, Wipers 30 3
3 Lights relay 40 2
4 Starter switch 30 5
5 Not used 80 4
S245110
S239200
9804/1103 20 - 05 - 01/9 3620-C/1-2.2 Issue 2*

CONTENTS
Loadalls 20 - 05 - 01/10
* 520-55, 526-55, 526, 526S (526N.Am) * From m/c no. 279000 to 280299
Data - Electrical
Relays are used in the electrical circuits for a variety of reasons. The most usual application is to protect components like
switches etc. from being overloaded. A relatively small current (from the switch) energises the relay coil, this causes internal
contacts to open or close which controls a larger current in another circuit.
Although relays look similar, internally they can be different, for example, they can be single or double contact; normally closed
or open. Make sure you fit the correct type of relay, otherwise the machine electrical circuits will not function correctly. The
relays are identified as follows:
From Machine Serial Number 279000 to 280299 (Powershift Transmission)

2 Spare 5 Spare 8 Spare 11 Neutral start relay
3 Reverse relay 6 Spare 9 Auxiliary solenoid relay 12 Starter relay
From Machine Serial Number 279000 to 280299 (Syncro Shuttle Transmission)

3 Reverse alarm relay 6 Dump switch relay 9 Auxiliary solenoid relays 12 Starter relay
1 2 3
5 6
4
£ $
7 8 9
0 ! @
S192450
9804/1103 20 - 05 - 01/10 Issue 2*

CONTENTS
Loadalls 20 - 05 - 01/11
* 526, 526S (526 N.Am)
Relay Identification (cont’d)
* 526, 526S (526 N.Am) - Powershift Transmission * 526, 526S (526 N.Am) - Syncro Shuttle Transmission
* From M/c Serial No 280577 Onwards * From M/c Serial No 280574 Onwards
The relay configuration for machines with powershift The relay configuration for machines with syncro shuttle
transmission is shown at A. transmission is shown at B.
1 Buzzer relay 1 Buzzer relay

2 Neutral start relay 2 Neutral start relay
3 Starter relay 3 Starter relay
4 Side lights relay 4 Side lights relay
5 Parking brake relay 5 Parking brake relay
6 Auxiliary solenoid relay 6 Auxiliary solenoid relay
7 Air conditioning relay 7 Air conditioning relay
8 Reverse alarm/light relay 8 Spare
9 Dump switch relay 9 Dump switch relay
10 Reverse high/low relay 10 Hazard warning light relay
11 Forward high/low relay 11 Reverse relay
12 Drive shaft relay 12 Forward relay
13 Reverse relay
14 Forward relay
15 Drive relay
16 Hazard warning light relay
1 4 7
2 58 0
3 6 9 ! @
1 4 7 0 £
2 5 8 ! $ ^
3 6 9 @ %
A282130
9804/1103 20 - 05 - 01/11 * 3610-C/1-3.3 Issue 2*

CONTENTS
Loadalls 20 - 05 - 01/12
* 520-55, 526-55, 526, 526S (526 N.Am) From m/c no. 279000 to 280299
Fuse Identification
Row A Row B Row C

1 Starter relay 1 1 Safe load indicator (SLI) 1 1 R.H. Side lights,

2 Engine shut off 2 Horn, Headlamp flasher 10 Working lights 15
solenoid (ESOS) 5 3 Heater/Air conditioning 2 L.H. Side lights 7.5
3 Spare fan (if fitted) 15 3 Dip beam 10
4 Forward/reverse switch 15 (10)+ 4 Face fan, Air conditioning 4 Main beam 10
5 Transmission ECU (if fitted) 7.5 compressor (if fitted) 15 5 Brake lights 10
6 Reverse alarm 10 5 Wipers, Washers 15 6 Hazard warning lights 15
7 Spare 6 Beacon, Interior light 7.5 7 Indicators 10
8 Spare 7 Radio 5 8 Spare
9 Diverter valve 10 8 Instrument panel 5 9 Spare
9 Spare
+ Machines with syncro shuttle transmission.
Fuse links
Circuit Rating
1 Horn, Hazard warning lights, Beacon, Interior light 40
3 Not used
4 ESOS, Forward/reverse switch, Brake lights 40
5 Diverter valve, SLI, Heater, Wipers, Radio, Instruments 80
2
4 1
5
3
S245110
S192451
9804/1103 20 - 05 - 01/1 Issue 2*

CONTENTS
Loadalls 20 - 05 - 01/13
* 526, 526S (526 N.Am)
Data - Electrical
Fuse Identification
located in a fuse box, as shown. If a fuse blows, find out why
before fitting a new one.
Additional fuse links are fitted at the battery positive terminal.
Note: The radio fuse may have a higher rating, depending on

the type of radio fitted. Check radio fitting instructions.
* From M/c Serial No 280577 (Powershift), 280574 (Syncro

Shuttle).
Fuse Circuit Rating

1 Flasher Relay 7.5
2 Face fan, air conditioning compressor (if fitted) 10
3 Diverter valve 10
4 Heater/air conditioning fan (if fitted) 15
5 Wipers, Washers 15
6 Safe load indicator (SLI) 1
7 Instrument panel 5
8 Spare
9 Spare
10 Spare
11 Starter Relay 1
12 Engine shut off solenoid (ESOS) 5 1 11 21
13 Forward/reverse Switch 2 12 22
(Powershift transmission) 15 3 13 23
(Syncro Shuttle transmission) 10 4 14 24
14 Joystick control (if fitted) 7.5 5 15 25
15 Spare 6 16 26
16 Brake lights 10 7 17 27
17 Reverse alarm/light 5 8 18 28
18 Spare 9 19 29
19 Spare 10 20 30
20 Spare
A282120
21 Right hand side lights/work lights 15
22 Left hand side lights 5
23 Dip beam 10
24 Main beam 10
25 Spare
26 Spare
27 Head lamp flash or horn 15
28 Beacon, interior light 7.5
29 Radio 5
Fuse Links
2
Fuse Circuit Rating 4 1
1 Headlight flash, horn, beacon, interior light,
hazards, radio 40
2
3
Roadlights, worklights
Indicators, face fan, Air conditioning
40
5 3
compressor clutch (if fitted), hydraulic
hitch, changeover valve, heater/Air
conditioning fan, wash/wipers, safe load
indicator, instruments 40
4 Starter, ESOS, transmission, brake lights,
safe load indicator, reverse alarm/lights,
thermostart 40
5 Not used 80
9804/1103 20 - 05 - 01/1 * 3610-C/1-5.2 Issue 2*
CONTENTS
Loadalls 20 - 05 - 01/14
* 530, 535, 540 *From m/c no. 767001
* Data - Electrical
Relays are used in the electrical circuits for a variety of
reasons. The most usual application is to protect components
like switches etc. from being overloaded. A relatively small
current (from the switch) energises the relay coil, this causes
internal contacts to open or close which controls a larger
current in another circuit.
Although relays look similar, internally they can be different,

for example, they can be single or double contact; normally
closed or open. Make sure you fit the correct type of relay,
otherwise the machine electrical circuits will not function
correctly. The relays are identified as follows
530 only (from S/N 767001 to S/N 768836) 1 4 90

(Without Neutral Start)
1 Audible alarm
2 Reverse lights 2 56 !@ %^
3 Starter
4 Hazard warning lights
5 Side lights
6 Air conditioning 3 78 £$ &*
7 Sway isolation
8 Auxiliary change-over
9 Auxiliary A
10 Auxiliary B
11 -
12 -
13 Retract
14 Extend
15 -
16 2 Wheel drive brake
17 -
18 -
530 only (from S/N 768837 to S/N 770053)

(With Neutral Start)
1 Audible alarm
2 Neutral start
3 Starter
4 Hazard warning lights A335670
5 Side lights
6 Air conditioning
7 Sway isolation NOTE: ECU deletion cut-in numbers are transmission
8 Auxiliary change-over dependant.
9 Auxiliary A
10 Auxiliary B Transmission Part Number Serial Number of cut-in
11 -
12 - 449/06100 770055
13 Retract 449/06200 770065
14 Extend 449/06300 770053
15 Reverse 449/06400 770069
16 2 Wheel drive brake 449/06500 770063
17 - 449/06600 770093
18 -
9804/1103 20 - 05 - 01/14 3630 - C/1-2.4 Issue 2*

CONTENTS
Loadalls 20 - 05 - 01/14A
530, 535, 540 From m/c no. 767001

Data - Electrical
530, 540 Fitted with smooth Ride System (SRS)
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
8 Sidelights
9 Air conditioning
10 Forward relay
11 Reverse 1
12 Reverse 2
13 2 wheel drive brake
14 -
15 -
17 Sway isolation
18 Forward HI/LO
19 Reverse HI/LO
20 Drive
21 Driveshaft
22 Neutral
23 Dump
24 -
25 SRS relay
1 7 16 17
2 8 9 18 19
3 10 11 20 21
4 12 13 22 23
5 6 14 15 24 25
A335680
9804/1103 20 - 05 - 01/14A 3630 - 3/1-5.2 Issue 1

CONTENTS
Loadalls 20 - 05 - 01/14B
530, 535, 540 From m/c no. 767001

Data - Electrical
530 FS Super, 540 FS Super Machines with Five Speed Powershift Transmission
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
6 Sidelights
7 Air conditioning
9 Sway isolation
10 Reverse 2
11 Two wheel drive brake relay
12 Neutral relay
13 Dump relay Smooth Ride System
14 -
15 SRS relay
16 -
17 -
1 5
2 6 7 12 13
3 8 9 14 15
4 10 11 16 17
A372461
9804/1103 20 - 05 - 01/14B 3630 - 3/1-6.2 Issue 1

CONTENTS
Loadalls 20 - 05 - 01/15
530, 535, 540 From m/c no. 767001

* Relay Identification (continued)
* 530 only (from S/N 770054 to S/N 770958)
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
8 Sidelights
9 Air conditioning
10 Auxiliary change-over 2
12 Forward relay
13 Reverse 1
14 Reverse 2
16 Auxiliary A
17 Auxiliary B
18 -
19 -
20 Retract
21 Extend
22 Forward HI/LO
23 Reverse HI/LO
24 Drive
25 Driveshaft
1
1 7
7 ^
16 &
17
2
2 8
8 9
9 *
18 (
19
3
3 0
10 !
11 ) 21
20 21
4
4 @
12 £
13 22 23
22 23
5
5 6
6 $
14 %
15 24
24 25
A335680
9804/1103 20 - 05 - 01/15 3630 - C/1-3.4 Issue 3*

CONTENTS
Loadalls 20 - 05 - 01/15A
530, 535, 540 From m/c no. 767001

Relay Identification (continued)
530/540 (from S/N 770959 onwards)

535 (from S/N 777362 onwards)
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
8 Sidelights
9 Air conditioning
10 Forward relay
11 Reverse 1
12 Reverse 2
15 Sway isolation
16 Forward HI/LO
17 Reverse HI/LO
18 Drive
19 Driveshaft
2 7
3 8 9 14 15
4 10 11 16 17
5 6 12 13 18 19
360940
9804/1103 20 - 05 - 01/15A 3630 - C/1-4.4 Issue 1

CONTENTS
Loadalls 20 - 05 - 01/16
530, 535, 540 From m/c no. 767001

Fuse Identification
This illustration shows a typical fuse installation.


1 11 21 31
Note: The radio fuse may have a higher rating, depending on
2 12 22 32
the type of radio fitted. Check radio fitting instructions.
3 13 23 33
Circuit Rating 4 14 24 34
1 Boom isolator 7.5 5 15 25 35
2 Joystick controls 10 6 16 26 36
3 Safe Load Indicator (SLI)/Load Moment 7 17 27 37
Indicator (LMI) 5 8 18 28 38
4 Heater 15 9 19 29 39
5 Air conditioning, face fan 15 10 20 30 40
6 Wipers 15
7 Clock, radio, heater seat 5
8 Instrument panel 7.5 A348080
9 Direction Indicators 10
10 Auxiliary hydraulics 7.5
11 Starter relay 5
12 Engine shut-off solenoid (ESOS) 5
13 Steer mode selector 7.5
14 Powershift 15
15 2/4 Wheel drive selector 5
2/4 Wheel drive selector with trailer electrics (530) 10
16 Auxiliary socket 10
17 Brake lights 10
18 Rear work light 7.5 B A
19 Reverse lights, reverse alarm 7.5
20 BLANK
D
21
22
Right hand side lights
Left hand side lights
10
10
C
23 Dip beam lights 10 E
24 Main beam lights 10
25 Front working light 10 S245111
26 Rear fog light 5
27 BLANK Fuse Links S/N 767000 to 770053
28 Horn, Headlight flash 10
29 Warning beacon, Interior light, Radio 5 Circuit Rating
30 Hazard lights 15 A Horn, Hazard warning lights, Beacon,
Interior light 30
31 Smooth Ride System (if fitted) 5 B Road lights, Working lights 30
32 SPARE C Not used
33 SPARE D ESOS, Forward/reverse switch, Brake lights 40
34 Air suspension seat (if fitted) 15 E SLI, Heater, Wipers, Radio, Instruments 80
35 SPARE
36 BLANK Fuse Links S/N 770054 onwards
37 BLANK
38 BLANK Circuit Rating
39 BLANK A Horn, Hazard warning lights, Beacon,
40 BLANK Interior light 40
B Road lights, Working lights 40
C SLI, Heater, Wipers, Radio, Instruments 40
D ESOS, Forward/reverse switch, Brake lights 40
E Not used 80
9804/1103 20 - 05 - 01/16 3630 - C/1-5.1 Issue 3*

3630 - C/1-6.1
CONTENTS
Loadalls 20 - 05 - 01/17
* 532, 537, 550 *From m/c no. 767001
* Relay Identification
Relays are used in the electrical circuits for a variety of
reasons. The most usual application is to protect components
like switches etc. from being overloaded. A relatively small
current (from the switch) energises the relay coil, this causes
internal contacts to open or close which controls a larger
current in another circuit.
Although relays look similar, internally they can be different,

for example, they can be single or double contact; normally
closed or open. Make sure you fit the correct type of relay,
otherwise the machine electrical circuits will not function
correctly. The relays are identified as follows
532/537 (from S/N 767001 to S/N 768956)

(Without Neutral Start)
1 Audible alarm
2 Reverse lights and alarm
3 Starter
5 Side lights
6 Air conditioning
7 Sway isolation
8 Stabiliser isolation
9 Auxiliary A
10 Auxiliary B
11 -
12 -
13 -
14 -
15 -
16 2 Wheel drive brake
17 -
18 -
532/537 (from S/N 768957 to S/N 770063)

(With Neutral Start)
1 Audible alarm
2 Neutral start
3 Starter
5 Side lights
6 Air conditioning Note: ECU deletion cut-in numbers are transmission
7 Sway isolation dependant.
9 Auxiliary A Transmission Part Number Serial Number of cut-in
10 Auxiliary B
11 Reverse 449/06100 770055
12 - 449/06200 770065
13 - 449/06300 770053
14 - 449/06400 770069
15 - 449/06500 770063
16 2 Wheel drive brake 449/06600 770093
17 -
18 -
9804/1103 20 - 05 - 01/17 3660 - C/1-2.1 Issue 2*

CONTENTS
Loadalls 20 - 05 - 01/18
* 532, 537, 550, 5508 From m/c no. 767001

532/537 (from S/N 770064 to
S/N 770958)
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
8 Sidelights
9 Air conditioning
10 Sway isolation
11 Stabilizer isolation
12 Forward relay
13 Reverse 1
14 Reverse 2
16 Auxiliary A
17 Auxiliary B
18 Auxiliary change-over 2
19 -
20 Forward HI/LO
21 Reverse HI/LO
22 Drive
23 Driveshaft
24 -
25 -
1
1 7
7 ^
16 &
17
Note: ECU cut-in numbers are transmission dependent (see

2
2 8
8 9
9 *
18 (
19
page 20 - 05 - 01/17 for transmission details).
3
3 0
10 !
11 )
20 (
21
4
4 @
12 £
13 22 23
22 23
5
5 6
6 $ 15 24 25
14 % 25
A343330
9804/1103 20 - 05 - 01/18 3660 - C/1-3.2 Issue 3*

CONTENTS
Loadalls 20 - 05 - 01/18A
532, 537, 540-170, 550, 5508 From m/c no. 767001


532/537/550
(from S/N 770959 onwards)
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
8 Sidelights
9 Air conditioning
10 Sway isolation
12 Forward relay
1 13 Reverse 1
14 Reverse 2
2 7 16 Forward HI/LO
17 Drive
18 Reverse HI/LO
3 8 9 14 15 19 EMPTY
4 10 11 16 17
5 6 12 13 18 19
A361560
* 532/537/550
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
8 Sidelights
9 Air conditioning
10 Sway isolation
12 Forward
13 Reverse
1 7
14 Reverse alarm/light
15 2 wheel drive/brakelights
16 EMPTY
2 8 9
17 Pump dump
18 Forward HI/LO
19 Reverse HI/LO
3 10 11 16 17 20 Drive
21 Driveshaft
4 12 13 18 19
5 6 14 15 20 21
A361561
9804/1103 20 - 05 - 01/18A 3660 - C/1-4.3 Issue 2*

CONTENTS
Loadalls 20 - 05 - 01/18B
532, 537, 540-170, 550, 5508 From m/c no. 767001


532/537/550
1 Audible alarm
2 Neutral start
3 IGN Feed 1
4 IGN Feed 2
5 Dump
6 Parkbrake
8 Sidelights
9 Air conditioning
10 Sway isolation
12 Forward relay
13 Reverse 1
14 Reverse Alarm/light
15 2 wheel drive/brake lights
16 Forward HI/LO
17 Reverse HI/LO
18 Drive relay
19 Driveshaft relay
20 EMPTY
21 EMPTY
22 Inner boom extend interlock (if fitted)
23 Lift isolation
24 Stabiliser lift unloader
25 Inner boom extend
1 7 16 17 * 540-170/5508 Machines from S/N 1004131
1 Audible alarm
2 Neutral start
2 8 9 18 19 3 IGN Feed 1
4 IGN Feed 2
5 Dump
3 10 11 20 21 6 Parkbrake
8 Sidelights
9 Air conditioning
4 12 13 22 23 10 Sway isolation
12 Forward relay
13 Reverse 1
5 6 14 15 24 25 14 Reverse alarm/light
15 2 wheel drive/brake lights
16 Left stabiliser
17 Right stabiliser
A361140 18 Forward HI/LO
19 Reverse HI/LO
20 Drive relay
21 Driveshaft relay
22 Extension boost
23 Lift isolation
24 Stabiliser lift unloader
25 Inner boom extend
9804/1103 20 - 05 - 01/18B 3660 - C/1-5.4 Issue 2*

CONTENTS
Loadalls 20 - 05 - 01/19
* 532, 537, 540-170, 550, 5508 From m/c no. 767001
Fuse Identification

Note: The radio fuse may have a higher rating, depending on 1 11 21 31

the type of radio fitted. Check radio fitting instructions. 2 12 22 32
3 13 23 33
Circuit Rating 4 14 24 34
1 Boom isolator 7.5 5 15 25 35
2 BLANK 6 16 26 36
Auxiliary controls (up to 775402 only) 10
7 17 27 37
3 Load Moment Indicator (LMI) 5
8 18 28 38
4 Heater 15
5 Air conditioning, face fan 15 9 19 29 39
6 Wipers 15 10 20 30 40
7 Radio, clock & heated seat 5
8 Instrument panel 7.5
9 Direction Indicators 10
10 EMPTY
11 Starter relay & road light switch illumination 5

13 Steer mode selector 7.5
14 Powershift 15
15 2/4 Wheel drive selector, or
Brake lights (540-170/5508 only) 5
2/4 Wheel drive with trailer electrics (if fitted) 10
16 Auxiliary socket 10 B A
17 Brake lights 10
2-Wheel drive relay coil (540-170/5508 only) 10
18 Rear work light 7.5
D
19
20
Reverse lights & Reverse Alarm
EMPTY
7.5
C
E
21 Right hand side light 10
S245111
22 Left hand side light 10
23 Dip beam lights 10
24 Main beam lights 10
25 Front working light 10
26 Rear fog light 5 Fuse Links S/N 768700 to 770053
27 EMPTY
28 Horn, Headlight flash 10 Circuit Rating
29 Warning beacon, Interior light 5 A Horn, Hazard warning lights, Beacon,
30 Hazard lights 15 Interior light 30
B Road lights, Working lights 30
31 Hydraulics (540-170/5508 only) 15 C Not used
32 Boom work light (540-170/5508 only) 5 D ESOS, Forward/reverse switch, Brake lights 40
33 SPARE E SLI, Heater, Wipers, Radio, Instruments 80
34 Air Suspension Seat (if fitted) 15
35 SPARE Fuse Links S/N 770054 onwards
36 EMPTY
37 EMPTY Circuit Rating
38 EMPTY A Horn, Hazard warning lights, Beacon,
39 EMPTY Interior light 40
40 EMPTY B Road lights, Working lights 40
C SLI, Heater, Wipers, Radio, Instruments 40
D ESOS, Forward/reverse switch, Brake lights 40
E Not used 80
9804/1103 20 - 05 - 01/19 3660 - C/1-6.2 Issue 3*

3660 - C/1-7.1
*
CONTENTS
Loadalls 20 - 05 - 01/20
528-70 From m/c no. 796000

Syncro Shuttle Transmission
Fuse Identification Relay Identification

Circuit Rating A Buzzer
B Neutral start
1 Indicators 7.5 C Ignition
2 Face level fan 7.5 D Sidelights
3 Auxiliary 2 5 E Park brake
4 Heater 15 F Rear work light
5 Blank G Spare
6 Windscreen washer & wipers 15 H Front work light
7 Safe Load Indicator/Load Moment Indicator 1 J Transmission dump
8 Instrument panel 5 K Flasher
9 Blank L Forward
10 Thermo-start 20 M Reverse
11 Ignition relays & road lights switch illumination 1

13 Transmission 10
14 Brake lights 7.5
15 Blank
16 Blank
17 Reverse alarm & reverse lights 5
18 Main lights 15
19 Front worklight relay 15
20 Rear worklight relay 10
21 Right hand side lights & illumination 5

23 Dip beam 10
24 Main beam 10
25 Rear fog light 5
26 Side lights (all) 7.5
27 Headlight flash & horn 15
28 Warning beacon & interior light 7.5
29 Radio 5 A D G
B E H K
C F J L M
1 11 21
2 12 22
3 13 23
4 14 24
5 15 25
6 16 26
7 17 27
8 18 28
9 19 29
10 20 30
321000
9804/1103 20 - 05 - 01/20 3650 - C/1-2.2 Issue 1

CONTENTS
Loadalls 20 - 05 - 01/21
528S From m/c no. 796102

Fuse Identification
Circuit Rating
1 Indicators 7.5
2 Face level fan
Air conditioning compressor (if fitted) 10
3 Auxiliary 2
Hitch hydraulics (if fitted) 10
4 Heater 15
5 Windscreen washers & wipers 15
6 Safe Load Indicator/Load Moment Indicator 1
8 Spare
9 Spare
10 Spare
11 Ignition relays & road lights switch illumination 1

13 Transmission (Syncro Shuttle) 10 A D G
Transmission (Powershift) 15
14 Single lever control (if fitted) 7.5
15 Rear worklight 15 B E H K
16 Brake lights 10
17 Reverse alarm & reverse lights 5
18 Spare
C F J L M
19 Spare
20 Spare
21 Right hand side lights & illumination 15

23 Dip beam 10
1 11 21
24 Main beam 10
25 Rear fog light 5 2 12 22
26 Spare 3 13 23
27 Headlight flash & horn 15 4 14 24
28 Warning beacon & interior light 7.5 5 15 25
29 Radio 5
6 16 26
7 17 27
8 18 28
9 19 29
10 20 30
321000
9804/1103 20 - 05 - 01/21 3650 - C/1-3.2 Issue 1

CONTENTS
Loadalls 20 - 05 - 01/22
528S From m/c no. 796102

Power Shift Transmision Syncro Shuttle Transmission
The relay configuration for machines with Powershift The relay configuration for machines with Syncroshuttle
Transmission is shown at A. Transmission is shown at B.
1 Buzzer 1 Buzzer
2 Neutral star 2 Neutral start
3 Ignition 3 Ignition
4 Side lights 4 Side lights
5 Parking brake 5 Parking brake
6 Auxiliary 2 change over 6 Auxiliary 2 change over
7 Air conditioning 7 Air conditioning
8 Reverse alarm & light 8 Spare
9 Dump switch 9 Transmission dump
10 Reverse high/low 10 Flasher
11 Forward high/low 11 Forward
12 Drive 12 Reverse
13 Reverse
14 Forward
15 Driveshaft
16 Flasher
1 4 7
2 5 8 0
3 6 9 ! @
A
1 4 7 0 £
2 5 8 ! $ ^
3 6 9 @ %
A282130
9804/1103 20 - 15 - 01/22 3650 - C/1-4.1 Issue 1

CONTENTS
Loadalls 20 - 05 - 01/23
528-70, 528S From m/c no. 796000

Fuse Links
Circuit Rating
1 Horn, Hazard warning lights, Beacon,

Interior light, Radio, Headlight flash 40
3 Direction indicators, Face fan, SLI, Instruments,
Wipers, Air conditioning compressor 40 2
4 Starter, ESOS, Transmission, Brake lights, 4 1
Reverse Alarm and lights, Thermostart 40
5 Not Used 5
3
S245110
A308110
9804/1103 20 - 15 - 01/23 3650 - C/1-5.1 Issue 1

*
CONTENTS
Loadalls 20 - 05 - 01/24
506B, 506C, 506C(HL), 508C

Data - Electrical
All Machines with Syncro Shuttle Transmission
Location
The relays are located in front of the steering wheel, remove

the panel to gain access.
A H
A Steer mode PCB relay
B Forward relay
C Reverse relay B
D Transmission dump relay C
E Parkbrake warning G
F Neutral start relay
G
H
Buzzer
Ignition Relay (506C & 508C only - not shown)
D
F E
S167142
506C And 508C Machines with Powershift Transmission
A Steer mode printed circuit board

C Buzzer relay Early Machines Later Machines
D Forward relay
E Flasher relay
F Sidelights relay R Q P P R
G Hand brake warning relay
H
J
Ignition relay
4 Wheel drive/brake relay D B H Q X
K Neutral start relay
N Diode gate C M B M G
P Reverse high/low relay
Q
R
Forward high/low relay
Driveshaft relay
K G D C K
S Neutral drive relay 328820
THE FOLLOWING RELAYS ARE NOT LOCATED:

FLASHER
SIDELIGHTS
4 WHEEL DRIVE/BRAKE
NEUTRAL DRIVE
DIODE GATE
9804/1103 20 - 05 - 01/24 3640U - C/1-1.2 Issue 1

CONTENTS
Loadalls 20 - 05 - 01/25
506B, 506C, 506(HL), 508C

Data - Electrical
Fuse Identification

located in a fuse box near the steering pedestal. They are
in three rows labelled A, B and C. Each fuse position in
each row is numbered. If a fuse blows, find out why before
fitting a new one.
Additional fuse links are fitted at the battery positive

terminal.
ROW A
Circuit Rating
2 Transmission 7.5
3 Spare (Max. 10A)
4 Heater 7.5
5 Washers, wipers & horn 15
6 Face fan 10
8 Reverse alarm 5
9 Work lights 10
ROW B
Circuit Rating
1 Interior light, roof wiper, rear wiper & beacon 10
2 Ignition relay 1
3-9 Not used

S269270
ROW C
Circuit Rating
Not used
9804/1103 20 - 05 - 01/25 3640U - C/1-2.3 Issue 1

CONTENTS
Loadalls 20 - 05 - 02/1
525-58, 525-67, 527-67, 527-58, 530-67 & 535-67 From m/c no. 567362
Data - Hydraulics
Pump
Type Sundstrand SP/230/40, gear type
Flow at max. engine rev/min
— at zero pressure 88.0 litres/min 19.4 UK gal/min 23.2 US gal/min
— at system pressure 84.0 litres/min 18.5 UK gal/min 22.2 US gal/min
Supplementary Pump (Farm Special Plus & 530-67, 535-67)

Type Ultra IPR/009/CT/DT/BE/8451
Control Valves
Type Kontak, parallel service, double acting spools.
Services Operated
— Spool 1 Boom Raise & Lower
— Spool 2 Boom Extend & Retract
— Spool 3 Auxiliary (see note)
— Spool 4 Carriage Tilt

Main Relief Valve (MRV) 220 224 3200
Auxiliary Relief Valves (ARV)
— Attachments 138 140 2000
— Carriage Tilt, head side 138 140 2000
— Carriage Tilt, rod side 275 281 4000
— Hydraulic Tow Hitch lower (head side) 96 98 1400
— Hydraulic Tow Hitch raise (rod side) 172 176 2500
— Sway, head side 131 133 1900
— Sway, rod side 165 168 2400
Note: On later machines the sway ARVs are not fitted
Rams Bore Rod Dia. Stroke

mm in mm in mm in
Boom Lift - 525-58, 527-58 110 4.3 60 2.4 615 24.2
Boom Lift - 525-67, 527-58, 530-67, 535-67 110 4.3 60 2.4 807 31.8
Boom Extension - 525-58, 527-58 70 2.8 50 1.9 1700 66.9
Boom Extension - 525-67, 527-58, 530-67, 535-67 70 2.8 50 1.9 1968 77.5
Tilt Ram 110 4.3 50 1.9 620 24.4
Displacement 110 4.3 50 1.9 355 13.9
Tow Hitch 70 2.8 30 1.2 220 8.7
Sway Ram 110 4.3 50 1.9 196 7.7
Sway Ram (later machines) 110 4.3 50 1.9 178 7.0
Filter
Filter Type Partial flow ('spin on')
Filtration Size 25 microns (0.001 in)
Relief Valve Setting 0.17 bar
Suction Strainer 125 microns (0.005 in)
Fan Motor
Type Sundstrand TFU 200/8, gear type / Ultra 1MR 084C 8784
Max fan speed at Max engine rev/min 18 inch fan 20 inch fan
40° C ambient 46° C ambient 40° C ambient 46° C ambient
temp. zone temp. zone temp. zone temp. zone
NAT ASP engine 2100 2500
TURBO engine 2100 2100 2300 2600
Note: The function of spools 3, 5 & 6 (where fitted) will vary from machine to machine but may include the following: Hydraulic
Tow Hitch, Sway Control and Auxiliary Attachment Control.
9804/1103 20 - 05 - 02/1 Issue 3*

CONTENTS
Loadalls 20 - 05 - 02/2
530-95 From m/c no. 567362

Data - Hydraulics
Pump

Control Valves

Services Operated
— Spool 6 Sway

— Sway, rod side 165 168 2400

mm in mm in mm in
Boom Lift 110 4.3 60 2.3 1020 40.1
Boom Extension 100 3.9 60 2.3 3860 151.9
Tilt Ram 120 4.7 65 2.5 495 19.4
Displacement 120 4.7 65 2.5 495 19.4
Sway 110 4.3 60 1.9 196 7.7
* Sway Ram (later machines) 110 4.3 50 1.9 178 7.0
Filter

Fan Motor
* Type Sundstrand TFU 200/8, gear type / Ultra 1MR 084C 8784
Max fan speed at Max engine rev/min 40° C ambient 46° C ambient
temp. zone temp. zone
TURBO engine 1800 2100
Note: The function of spools 3, 5 (where fitted) will vary from machine to machine but may include the following: Hydraulic
Tow Hitch, and Auxiliary Attachment Control.
9804/1103 20 - 05 - 02/2 Issue 2*

CONTENTS
Loadalls 20 - 05 - 02/3
530-110 From m/c no. 567362

Data - Hydraulics
Pump

Control Valves

Services Operated
— Spool 3 Auxiliary
— Spool 5 Stabiliser

Rams Bore Rod Dia Stroke

mm in mm in mm in
Boom Lift 110 4.3 60 2.3 1020 40.1
Boom Outer Extension 110 4.3 60 2.3 2560 100.7
Boom Inner Extension 90 3.5 60 2.3 2690 105.9
Tilt Ram 120 4.7 65 2.5 495 19.4
Displacement 120 4.7 65 2.5 495 19.4
Stabiliser 100 3.9 60 2.3 380 15
Filter

Fan Motor
* Type Sundstrand TFU 200/8, gear type / Ultra 1MR 084C 8784
9804/1103 20 - 05 - 02/3 Issue 2*

CONTENTS
Loadalls 20 - 05 - 02/4
530-120 From m/c no. 567362

Data - Hydraulics
Pump
* Type Sundstrand SP/230/50 or Ultra 2PR050, gear type

Control Valves

Services Operated
— Spool 7 Sway

— Sway, rod side 165 168 2400
* Note: On later machines the sway ARVs are not fitted

mm in mm in mm in
Boom Lift 120 4.7 65 2.5 1040 40.9
Tilt Ram 130 5.1 50 1.9 695 27.3
Displacement 130 5.1 50 1.9 500 19.6
Stabiliser 110 4.3 60 2.3 527 20.7
Sway 110 4.3 50 1.9 196 7.7
Sway Ram (later machines) 110 4.3 50 1.9 178 7.0
On machines from serial number 567736

Tilt Ram 130 5.1 65 2.5 695 27.3
Displacement 130 5.1 65 2.5 500 19.6
Filter

Fan Motor
* Type Sundstrand TFU 200/8, gear type or Ultra 1MR 084C 8784
9804/1103 20 - 05 - 02/4 Issue 2*

CONTENTS
Loadalls 20 - 05 - 02/5
505-19, 505-22 From m/c no. 567362

Data - Hydraulics
Pump

Control Valves

Services Operated

— Hydraulic Tow Hitch lower (head side) 96 98 1400
— Hydraulic Tow Hitch raise (rod side) 172 176 2500
— Sway, rod side 165 168 2400

mm in mm in mm in
Boom Lift - 505-19 (19 ft) 110 4.3 60 2.4 615 24.2
Boom Lift - 505-22 (22 ft) 110 4.3 60 2.4 807 31.8
Boom Extension - 505-19 (19 ft) 70 2.8 50 1.9 1700 66.9
Boom Extension - 505-22 (22 ft) 70 2.8 50 1.9 1968 77.5
Tilt Ram 110 4.3 50 1.9 620 24.4
Displacement 110 4.3 50 1.9 355 13.9
Tow Hitch 70 2.8 30 1.2 220 8.7
Sway Ram 110 4.3 50 1.9 196 7.7
Filter

Fan Motor
Type Sundstrand TFU 200/8, gear type
Max fan speed at Max engine rev/min 18 inch fan 505-19 ONLY 20 inch fan
40° C ambient 46° C ambient 40° C ambient 46° C ambient
temp. zone temp. zone temp. zone temp. zone
TURBO engine 2100 2100 2300 2600
Note: The function of spools 3, 5 & 6 (where fitted) will vary from machine to machine but may include the following: Hydraulic
Tow Hitch, Sway Control and Auxiliary Attachment Control.
9804/1103 20 - 05 - 02/5 Issue 2*

CONTENTS
Loadalls 20 - 05 - 02/6
506-36 From m/c no. 567362

Data - Hydraulics
Pump

Control Valves

Services Operated


mm in mm in mm in
Boom Lift 110 4.3 60 2.3 1020 40.1
Tilt Ram 120 4.7 65 2.5 495 19.4
Displacement 120 4.7 65 2.5 495 19.4
Stabilizer 100 3.9 60 2.3 380 15
Filter

Fan Motor
9804/1103 20 - 05 - 02/6 Issue 1

CONTENTS
Loadalls 20 - 05 - 02/7
508-40 From m/c no. 567362

Data - Hydraulics
Pump

Control Valves

Services Operated
— Spool 7 Sway

— Sway, rod side 165 168 2400

mm in mm in mm in
Boom Lift 110 4.3 60 2.3 1050 41.3
Tilt Ram 130 5.1 50 1.9 695 27.3
Displacement 130 5.1 50 1.9 500 19.6
Sway 110 4.3 50 1.9 196 7.7

Tilt Ram 130 5.1 65 2.5 695 27.3
Displacement 130 5.1 65 2.5 500 19.6
Filter

Fan Motor
9804/1103 20 - 05 - 02/7 Issue 1

CONTENTS
Loadalls 20 - 05 - 02/8
510-40 From m/c no. 567362

Data - Hydraulics
TECHNICAL DATA (510-40 Only)
Pump
* Type Sundstrand SP/230/50, or Ultra 2PR050 gear type

Control Valves

Services Operated
— Spool 5 Stabilizer
— Spool 6 Stabilizer
— Spool 7 Sway

— Sway, rod side 165 168 2400

mm in mm in mm in
Boom Lift 120 4.7 65 2.5 1040 40.9
Tilt Ram 130 5.1 50 1.9 695 27.3
Displacement 130 5.1 50 1.9 500 19.6
Stabilizer 110 4.3 60 2.3 527 20.7
Sway 110 4.3 50 1.9 196 7.7

Tilt Ram 130 5.1 65 2.5 695 27.3
Displacement 130 5.1 65 2.5 500 19.6
Filter

Fan Motor
9804/1103 20 - 05 - 02/8 Issue 2*

CONTENTS
Loadalls 20 - 05 - 02/9
520-55, 526-55, 520S, 526, 526S From m/c no. 567362

Data - Hydraulics
Pump
Type Powermaster 2PR 036, gear type

Flow at 2200 engine rev/min
Control Valves

Services Operated Mode of Operation
All Machines 526, 526S Machines with
except as column right Single Lever Control Option
— Spool 1 Auxiliary Mechanical Pilot

— Spool 2 Boom Raise & Lower Mechanical Mechanical
— Spool 3 Carriage Tilt Mechanical Mechanical
— Spool 4 Boom Extend & Retract Mechanical Pilot
* Relief Valve Operating Pressures
bar kgf/cm2 lbf/in2

— Auxiliary, rod side 193 196 2798
— Auxiliary, head side 144 144 2080
— Carriage Tilt Crowd, head side 250 255 3625
— Carriage Tilt Dump, rod side 276 281 4002
Rams Bore Rod Dia. Stroke Open centre Closed centre

mm in mm in mm in mm in mm in
Boom Lift 100 3.9 60 2.3 1101 43.3 2542 100.0 1440 56.6
Boom Extension 70 2.7 50 1.9 1700 66.0 3685 145 1985 78.1
Tilt Ram (520-55) 120 4.7 70 2.7 333 13.1 1023 40.3 690 27.1
Tilt Ram (526-55, 526, 526S) 130 5.1 75 2.9 333 13.1 1023 40.3 690 27.1
Displacement 70 2.7 40 1.5 700 27.5 1645 64.75 945 37.2
Hitch (earlier type) 50 1.9 25 1.0 254 10.0 698 27.5 444 17.5
Hitch (later type) 50 1.9 25 1.0 305 12.0 - - 475 18.7
Hitch (526S with 24 inch (600mm) wheels) 50 1.9 25 1.0 340 13.4 - - 510 20.0
Filter

9804/1103 20 - 05 - 02/9 3610 - E/1-1.5 Issue 5*

CONTENTS
Loadalls 20 - 05 - 02/10
537-120 From m/c no. 567362

Data - Hydraulics
Pump
* Type Sundstrand SP/230/50 or Ultra 2PR050, gear type

Control Valves

Services Operated
— Spool 5 Sway


mm in mm in mm in
Boom Lift 120 4.7 65 2.5 1040 40.9
Tilt Ram 130 5.1 65 2.5 695 27.3
Displacement 130 5.1 65 2.5 500 19.6
Stabiliser 110 4.3 60 2.3 527 20.7
Sway Ram 110 4.3 50 1.9 178 7.0
Filter

Fan Motor
Type Ultra 1MR 084C 8784
9804/1103 20 - 05 - 02/10 Issue 2*

CONTENTS
Loadalls 20 - 05 - 02/11
537-130 From m/c no. 567362

Data - Hydraulics
* Pump
Type Sundstrand SP/230/50 or Ultra 2PR050, gear type

Control Valves

Services Operated
— Spool 7 Sway


mm in mm in mm in
Boom Lift 120 4.7 65 2.5 1040 40.9
Tilt Ram 130 5.1 65 2.5 695 27.3
Displacement 130 5.1 65 2.5 500 19.6
Stabiliser 110 4.3 60 2.3 527 20.7
Sway Ram 110 4.3 50 1.9 178 7.0
Filter

Fan Motor
Type Ultra 1MR 084C 8784
9804/1103 20 - 05 - 02/11 Issue 2*

CONTENTS
Loadalls 20 - 05 - 02/12
520-50, 525-50, 525-52 From m/c no. 754000

Data - Hydraulics
Pump
Type Powermaster 2PR 036, gear type

Control Valves

Services Operated

* — Auxiliary, rod side 185 188 2683
* — Auxiliary, head side 185 188 2683
— Carriage Tilt Crowd, head side 250 255 3625
— Carriage Tilt Dump, rod side 275 280 3987

Boom Lift 110 4.3 60 2.3 1020 40.1 2390 94.0 1370 53.9
Boom Extension 70 2.7 50 1.9 1700 66.0 2545 100.2
Tilt 120 4.7 70 2.75 334 13.1 651 25.6
Displacement 70 2.7 40 1.5 503 19.8 744 29.3
Hitch 50 1.9 25 0.9 254 9.8 698 27.5 444 17.5
Filter

Hydraulic Tank
Capacity 70 litres (15.4 gals)
9804/1103 20 - 05 - 02/12 3620-E/1-1.2 Issue 3*

CONTENTS
Loadalls 20 - 05 - 02/13
530 Agricultural
Data - Hydraulics
* Triple Pump
Type Main pump 2PR036 82.0 litres/min (18.0 UK gal/min)

Fan pump 2PR016 (Machines to S/N 771429) 35.0 litres/min (7.7 UK gal/min)
Fan pump 1PX160 (Machines from S/N 771430) 36.5 litres/min (8.0 UK gal/min)
Steer pump 2PR019 43.3 litres/min (9.5 UK gal/min)
Priority valve 2VP-EAF-JIJ2V1-00-00-56
* Control Valves
Type Parallel service, double acting spools.
Services Operated
— Spool 3 Boom Extend & Retract (electro/servo operated)
— Spool 4 Auxiliary (electro/servo operated)
Servo Pressure Range bar kgf/cm2 lbf/in2
Machines to S/N 771429; 10 - 20 10.2 - 20.4 145 - 290

Machines from S/N 771430; 10 - 30 10.2 - 30.6 145 - 435
* Relief Valve Operating Pressures bar kgf/cm2 lbf/in2

— Auxiliary, rod side 138 (220†) 140 (223†) 2000 (3190†)
— Carriage Tilt Dump, head side (A port) 138 140 2000
— Carriage Tilt Crowd, rod side (B port) 275 280 3987

Boom Lift 130 5.1 70 2.7 753 29.6 1894 74.5 1141 44.9
Boom Extension 70 2.7 50 1.9 2470 97.2 5225 205.7 2755 108.4
Tilt 110 4.3 50 1.9 474 18.6 1306 51.4 832 32.7
Displacement 120 4.7 60 2.3 294 11.5 946 37.2 652 25.6
Hitch 50 1.9 25 0.9 429 16.8 1028 40.4 599 23.5
Sway 110 4.3 50 1.9 136 5.4 629 24.8 493 19.4
Filter

Relief Valve Setting 1.05 bar (15 lbf/in2)
Hydraulic Tank
Capacity 112 litres (24.6 UK gals)
Fan Motor
Oil Flow 30.0 litres/min (6.6 UK gal/min) at 190 bar (2760 lbf/in2)
Max fan speed at Max engine rev/min 2200
† Machines with pick-up hitch. Since this ARV also controls the pressure to the boom auxiliary service, ensure that this
pressure will not cause damage to attachments used with the machine.
9804/1103 20 - 05 - 02/13 3630 - E/1-1.4 Issue 2*

CONTENTS
Loadalls 20 - 05 - 02/14
530 Construction
Data - Hydraulics
* Triple Pump
Type Main pump 2PR036 82.0 litres/min (18.0 UK

gal/min)
* Control Valves
Type Parallel service, 4 double acting spools.
Services Operated
— Spool 4 Auxiliary/Sway (electro/servo operated)
* Servo Pressure Range bar kgf/cm2 lbf/in2
Machines to S/N 771429; 10 - 20 10.2 - 20.4 145 - 290

Machines from S/N 771430; 10 - 30 10.2 - 30.6 145 - 435
* Relief Valve Operating Pressures bar kgf/cm2 lbf/in2

— Auxiliary, rod side 138(220†) 140(223†) 2000(3190†)
— Boom Extend head side (A port) 241 245 3500
— Boom Extend rod side (B port) 241 245 3500
* Rams Bore Rod Dia. Stroke Open centre Closed centre

Boom Lift 140 5.5 75 2.9 753 29.6 1894 74.5 1141 44.9
Boom Extension 70 2.7 50 1.9 2470 97.2 5225 205.7 2755 108.4
Tilt 110 4.3 50 1.9 474 18.6 1306 51.4 832 32.7
Displacement 120 4.7 60 2.3 294 11.5 946 37.2 652 25.6
Hitch 50 1.9 25 0.9 429 16.8 1028 40.4 599 23.5
Filter

Hydraulic Tank
Fan Motor
9804/1103 20 - 05 - 02/14 3630 - E/1-2.4 Issue 2*

CONTENTS
Loadalls 20 - 05 - 02/14A
540 Agricultural From m/c no. 767001

Data - Hydraulics
Triple Pump

gal/min)
Control Valves
Services Operated
— Spool 3 Boom Extend & Retract (electro/servo operated)
— Spool 4 Auxiliary (electro/servo operated)
Machines to S/N 771429; 10 - 20 10.2 - 20.4 145 - 290

Machines from S/N 771430; 10 - 30 10.2 - 30.6 145 - 435


Boom Lift 140 5.5 75 2.9 753 29.6 1894 74.5 1141 44.9
Boom Extension 70 2.7 50 1.9 2470 97.2 5225 205.7 2755 108.4
Tilt 110 4.3 50 1.9 474 18.6 1306 51.4 832 32.7
Displacement 120 4.7 60 2.3 294 11.5 946 37.2 652 25.6
Hitch 50 1.9 25 0.9 429 16.8 1028 40.4 599 23.5
Filter

Hydraulic Tank
Fan Motor
9804/1103 20 - 05 - 02/14A 3630 - E/1-3.4 Issue 1

CONTENTS
Loadalls 20 - 05 - 02/14B
540 Construction From m/c no. 767001

Data - Hydraulics
Triple Pump
Type Main pump 2PR036 82.0 litres/min (18.0

UK gal/min)
Control Valves
Services Operated
— Spool 4 Auxiliary/Sway (electro/servo operated)
Machines to S/N 771429; 10 - 20 10.2 - 20.4 145 - 290

Machines from S/N 771430; 10 - 30 10.2 - 30.6 145 - 435


Boom Lift 140 5.5 75 2.9 753 29.6 1894 74.5 1141 44.9
Boom Extension 70 2.7 50 1.9 2470 97.2 5225 205.7 2755 108.4
Tilt 110 4.3 50 1.9 474 18.6 1306 51.4 832 32.7
Displacement 120 4.7 60 2.3 294 11.5 946 37.2 652 25.6
Hitch 50 1.9 25 0.9 429 16.8 1028 40.4 599 23.5
Filter

Hydraulic Tank
Fan Motor
9804/1103 20 - 05 - 02/14B 3630 - E/1-4.4 Issue 1

CONTENTS
Loadalls 20 - 05 - 02/14C
535 From m/c no. 767001

Data - Hydraulics
535 Machines
Triple Pump

gal/min)
Fan pump 1PX160 36.5 litres/min (8.0 UK gal/min)
Control Valves
Services Operated

— Carriage Tilt Dump, rod side (A port) 250 255 3626
— Carriage Tilt Crowd, head side (B port) 275 280 3988
Note: Since the auxiliary ARV also controls the pressure to the boom auxiliary service, ensure that this pressure will not cause
damage to attachments used with the machine.

Boom Lift 120 4.7 70 2.7 1114 43.9 2571 101.3 1457 57.4
Boom Extension (inner) 80 3.1 50 2.0 2653 104.5 5688 224.1 3035 119.6
Boom Extension (outer) 100 4.0 60 2.4 2653 104.5 5700 224.6 3047 120.0
Tilt 130 4.3 75 1.9 336 13.2 1110 43.7 774 30.5
Displacement 70 2.7 40 1.5 750 29.5 1745 68.7 995 39.1
Hitch 50 2.0 25 1.0 530 21.0 1230 48.4 700 27.5
Filter

Hydraulic Tank
Fan Motor
9804/1103 20 - 05 - 02/4C 3630 - E/1-5.4 Issue 1

CONTENTS
Loadalls 20 - 05 - 02/15
532 From m/c no. 567362

Data - Hydraulics
Triple Pump
Type Main pump 2PR029 63.0 litres/min (13.8 UK gall/min)

Fan pump 2PR016 (to m/c no. 771428) 35.0 litres/min (7.7 UK gall/min)
Fan pump 1Px160 (from m/c no. 771429) 36.5 litres/min (8.0 UK gall/min)
Steer pump 2PR019 C1W3 B1B1-240 41.0 litres/min (9.0 UK gall/min)
Control Valves
Type Kontak, parallel service, 6 spools.
Services Operated
— Spool 4 Auxiliary/Sway (electro/servo operated from m/c no. 767001)
Unloader section
— Spool 5 Right Hand Stabiliser
— Spool 6 Left Hand Stabiliser

M/c nos. to 771428 10-20 10.2-20.4 145-290
M/c nos. from 771429 10-30 10.2-30.6 145-435

— Auxiliary, rod side 138 140 2000 Sway ram option A.R.V.
— Auxiliary, head side 138 140 2000 Sway ram option A.R.V.
— Carriage Tilt Crowd, head side (A port) 330 336 4785
— Carriage Tilt Dump, rod side (B port) 275 280 3987

Boom Lift 130 5.1 75 3.0 1344 44.6 3098 122 1754 69.0
Boom Extension Outer 120 4.7 65 2.5 3170 124.8 6734 265.1 3564 140.3
Boom Extension Inner 100 3.9 60 2.3 3225 127.0 6832 269.0 3607 142.0
Tilt 130 5.1 70 2.7 362 14.3 1115 44.0 753 30.0
Displacement 90 3.5 50 2.0 282 11.1 1047 41.2 765 30.3
Stabiliser 110 4.3 60 2.3 392 15.4 1135 44.7 743 29.3
Sway 110 4.3 50 2.0 150 5.9 675 26.5 525 20.6
Filter

Hydraulic Tank
Fan Motor
Oil Flow 30.0 litres/min (6.6 gall/min) at 190 bar (2760 lbf/in2)
* Max fan speed at Max engine rev/min 2200 (to machine S/N 785165)
1800 nominal (from machine S/N 785166)
9804/1103 20 - 05 - 02/15 3630 - E/1-1.2 Issue 3*

CONTENTS
Loadalls 20 - 05 - 02/16
537, 550 From m/c no. 767001

Data - Hydraulics
Triple Pump
Type Main pump 2PR029 63.0 litres/min (13.8 UK gall/min)

Fan pump 2PR016 (to m/c no. 771428) 35.0 litres/min (7.7 UK gall/min)
Fan pump 1PX160 (from m/c no. 771429) 36.5 litres/in (8.0 UK gall/min)
Steer pump 2PR019 C1W3 B1B1-240 43.3 litres/min (9.5 UK gall/min)
Control Valves
Type Kontak, parallel service, 6 spools.
Services Operated
— Spool 4 Auxiliary/Sway (electro servo operated from m/c no. 767001)
Unloader section
M/c nos. to 771428 10-20 10.2-20.4 145-290

M/c nos. from 771429 10-30 10.2-30.6 145-345

— Auxiliary, rod side 138 140 2000 Sway ram option A.R.V.
— Auxiliary, head side 138 140 2000 Sway ram option A.R.V.
— Carriage Tilt Crowd, head side (A port) 330 336 4785
— Carriage Tilt Dump, rod side (B port) 275 280 3987

Boom Lift 160 6.2 80 3.1 1344 52.9 3110 122.4 1766 69.5
Boom Extension Outer 130 5.1 70 2.7 3826 150.6 8046 316.7 4220 166.1
Boom Extension Inner 110 4.3 65 2.6 3794 149.0 7970 314.0 4176 164.0
Tilt 140 5.5 75 3.0 362 14.3 1115 44.0 753 30.0
Displacement 90 3.5 50 2.0 330 13.0 1070 42.1 740 29.1
Stabiliser 110 4.3 60 2.3 392 15.4 1135 44.7 743 29.3
Sway 110 4.3 50 2.0 150 5.9 675 26.5 525 20.6
Filter

Hydraulic Tank
Fan Motor
Oil Flow 30.0 litres/min (6.6 gall/min) at 190 bar (2760 lbf/in2)
* Max fan speed at Max engine rev/min 2200 (to machine S/N 785165)
1800 nominal (from machine S/N 785166)
9804/1103 20 - 05 - 02/16 3630 - E/1-2.2 Issue 3*

CONTENTS
Loadalls 20 - 05 - 02/17
528-70, 528S From m/c no. 796000

Data - Hydraulics
Pump
Type Gear type

Displacement 36 cc/rev
Flow at 2200 engine rev/min:

Control Valves
Type Parallel service, double acting spools.
Loading Pattern:
Services Operated Mode of Operation
528-70 528S
— Spool 1 Auxiliary Mechanical Servo operated
— Spool 2 Boom Raise & Lower Mechanical Mechanical
— Spool 3 Carriage Tilt Mechanical Mechanical
— Spool 4 Boom Extend & Retract Mechanical Servo operated
bar kgf/cm2 lbf/in2

Servo Pressure: 10 - 30 10.2 - 30.6 145 - 435
Note: Spools 3 and 4 are reversed on 528-70 machines fitted with a placing control pattern.
Relief Valve Operating Pressures
bar kgf/cm2 lbf/in2

— Auxiliary (Port A) 193 196 2798
— Auxiliary (Port B) 193 196 2798
— Carriage Tilt Crowd, head side (Port A) 250 254 3625
— Carriage Tilt Dump, rod side (Port B) 276 280 4000
Rams Weight Bore Rod Dia. Stroke Open centre Closed centre
kg mm in mm in mm in mm in mm in
Boom Lift 94 110 4.3 60 2.3 1163 45.7 2666 104.9 1503 59.1
Boom Extension 91 70 2.7 50 1.9 2300 90.5 4885 192.3 2585
101.7
Tilt Ram (528-70) 63 120 4.7 70 2.7 384 15.1 1126 44.3 742 29.2
Tilt Ram (528S) 71 130 5.1 75 2.9 334 13.1 1026 40.4 692 27.2
Displacement 30 70 2.7 40 1.5 750 29.5 1745 68.7 995 39.1
Filter
Return Filter Type Partial flow

Relief Valve Setting 3 bar
Suction Strainer Type 'spin on'

9804/1103 20 - 05 - 02/17 3650 - E/1-1.2 Issue 1

CONTENTS
Loadalls 20 - 05 - 02/18
506B, 506C
Data - Hydraulics
Pump 506B 506C
Type Gear type Gear Type

Displacement 40 cc/rev 41 cc/rev
— at zero pressure 88.0 litres/min (23.2 US gal/min) 90.2 litres (23.8 US gal/min)
— at system pressure 85.0 litres/min (22.5 US gal/min) 87.0 litres (23.0 US gal/min)
Control Valves
Type Parallel service, double acting spools, except for sway, which is a
motor spool. On 506B extension spool is a half motor spool to
m/c no. 572655.
Services Operated
— Spool 1 Boom Raise & Lower Boom Raise & Lower
— Spool 2 Auxiliary Service Auxiliary Service
— Spool 3 Tilt Forwards and Backwards Tilt Forwards and Backwards
— Spool 4 Boom Extend and Retract Boom Extend and Retract
— Spool 5 Sway Sway
Anti-cavitation check valves fitted to all services
Relief Valve Operating Pressures bar kgf/cm2 lbf/in2 bar kgf/cm2 lbf/in2
Main Relief Valve (M.R.V.) 238 241 3450 238 241 3450

— Attachments (Port A) 138 140 2000 138 140 2000
— Attachments (Port B) 138 140 2000 138 140 2000
— Carriage Tilt, rod side (Port A) 138 140 2000 138 140 2000
— Carriage Tilt, head side (Port B) 275 280 4000 275 280 4000
— Boom Extend, head side (Port A) 193 196 2800 230 233 3335
— Boom Retract, In-line ARV (If fitted) 207 210 3000 207 210 3000
From m/n serial no. 585208

— Boom extend (Port A) - - - 230 233 3335
— Boom retract (Port B) - - - 2193 196 2800
Rams Bore Rod Dia. Stroke Bore Rod Dia. Stroke

mm in mm in mm in mm in mm in mm in
Boom Lift 110 4.3 65 2.5 1020 40.1 110 4.3 70 2.7 102040.1
Boom Extension 110 4.3 70 2.7 2625 103.3 110 4.3 70 2.7 2625103.3
Tilt Ram 120 4.7 65 2.5 422 16.6 120 4.7 65 2.5 422 16.6
Displacement 120 4.7 65 2.5 335 13.2 120 4.7 65 2.5 335 13.2
Sway 110 4.3 50 1.9 178 7.0 110 4.3 50 1.9 178 7.0
Filter
Filter Type Partial flow ('spin on') Partial flow ('spin on')
Filtration Size 25 microns (0.001 in) 25 microns (0.001 in)
Relief Valve Setting 1.05 bar 1.05 bar
Suction Strainer 125 microns (0.005 in) 125 microns (0.005 in)
Fan Motor
Type Gear type (8.4 cc/rev) 18 in. fan Gear type (15 cc/rev) 20 in. fan
Ambient temperature zone 40°C to 46°C 40°C to 46°C
Max fan speed at Max engine rev/min 2400 rev/min 2400 rev/min
9804/1103 20 - 05 - 02/18 3640U - E/1-1.3 & E1/1-2.3 Issue 1

CONTENTS
Loadalls 20 - 05 - 02/19
506C (HL), 508C

Data - Hydraulics
Pump
Type Gear type

— at zero pressure 110.0 litres/min 29.0 US gal/min
— at system pressure 105.0 litres/min 27.6 US gal/min
Control Valves
Type Parallel service, double acting spools, except for sway which is a
motor spool.
Services Operated
— Spool 2 Auxiliary Service
— Spool 3 Tilt Forwards and Backwards
— Spool 4 Boom Extend and Retract
— Spool 5 Sway
Anti-cavitation check valves fitted to all services

— Auxiliary (Port A) 138 140 2000
— Auxiliary (Port B) 138 140 2000
— Carriage Tilt, rod side (Port A) 138 140 2000
— Carriage Tilt, head side (Port B) 241 246 3500
— Boom Extend (Port A) 193 196 2800
— Boom Retract, In-line ARV (If fitted) 207 210 3000
From machine serial number 585196:
— Boom Extend (Port A) 230 206 2944

— Boom Retract (Port B) 207 210 3000

mm in mm in mm in
Boom Lift 120 4.7 75 3.0 1020 40.1
Boom Extension 110 4.3 75 3.0 3,187 125.5
Tilt Ram 120 4.7 65 2.5 422 16.6
Displacement 120 4.7 65 2.5 335 13.2
Sway 110 4.3 50 1.9 178 7.0
Filter

Relief Valve Setting 2 bar
Fan Motor
Type Gear type (8.4 cc/rev) 20 in. fan

Ambient temperature zone 40°C to 46°C
Max fan speed at Max engine rev/min 2600 rev/min
9804/1103 20 - 05 - 02/19 3640U - E/1-3.3 Issue 1

CONTENTS
Loadalls 20 - 05 - 02/20
540-170, 5508 with Servo Controls From m/c no. 780925

Data - Hydraulics
Triple Pump
Type Main pump 2PR041 89 litres/min 19.6 UK gal/min)

Steer pump 2PR033 72 litres/min 15.8 UK gal/min)
Fan pump 1PX160 16 litres/min (3.5 UK gal/min)
Main Control Valve
Type Parallel service, 6 spools.
Servo Operation
Manual Operation
10 - 30 10.2 - 30.6 145 - 435

— Carriage Tilt Dump, rod side (A port) 276 280 4000
— Carriage Tilt Crowd, head side (B port) 330 336 4785
Remote Control Valve
Type Parallel service, 2 spools.
Servo Operation
— Spool 2 Boom Extend
10 - 30 10.2 - 30.6 145 - 435
Filter

Hydraulic Tank
Capacity 180 litres (40 UK gals) approx.
Fan Motor
Max fan speed at Max engine rev/min 2200 rev/min
9804/1103 20 - 05 - 02/20 3660 - E/51-1.2 Issue 1

3660 - E/51-2.2
CONTENTS
Loadalls 20 - 05 - 03/1

Data - Engine
Type Perkins 1000 Series 4 cylinder Engines
AA - naturally aspirated (76 HP)
AB - turbocharged (94.5 HP)
AB - turbocharged (102 HP)
Bore (nominal) 100mm (3.937 in)
Swept Volume 4 litres (243 in3)
Compression Ratio Naturally aspirated 16.5:1
Turbocharged 16.0:1
Oil Pressure (Hot) at maximum speed - AA 2.1 bar (30 lbf/in2)
- AB 2.6 bar (40 lbf/in2)
Fuel System AA Build (76 HP) AB (94.5 HP) Build AB (102 HP) Build
Injection Pump Type C.A.V. D.P.A. C.A.V. D.P.A. C.A.V. D.P.A.

Governing Mechanical Mechanical Mechanical
Pump Setting Code DM55L/1000/1/2420 CM78L/1100/1/2420 AM77L/800/1/2420
Static Timing 16.5° BTDC 15.5° BTDC 19.5° BTDC
Idling Speed
525-58 & 67, 530-95 & 110, 505-19 & 22, 506-36 850 rev/min 850 rev/min 850 rev/min
Idling Speed
530-120, 508-40 & 510-40 900 rev/min 900 rev/min 900 rev/min
Maximum Governed Speed 2200 rev/min 2200 rev/min 2200 rev/min
Maximum No-load Speed 2420 rev/min 2420 rev/min 2420 rev/min
Injector Codes HZ JG JF
Injector Setting Pressure 220 atm 230 atm 250 atm
Cooling System

Steer/Fan Pump - Fan section
Type Sundstrand, gear type

Flow at max. engine rev/min at zero pressure 25 litres/min 5.5 UK gal/min 6.6 US gal/min
Fan Motor See Page 2/1-1
For further engine details see Engine Manual Publication No. 9806/0100
9804/1103 20 - 05 - 03/1 Issue 1

CONTENTS
Loadalls 20 - 05 - 03/2
520-55, 526-55,526, 526S From m/c no. 277001

Data - Engine
Type JCB diesel engine, 4 cylinder, water cooled
* Build Codes: AA50640 - naturally aspirated (76 HP)
AB50594 - turbo charged (106HP)
AB50514 - turbo charged (106HP)
AR50662 - naturally aspirated, low emission (80HP)
AK50652 - turbo charged, low emission (100 HP)
Bore (nominal): AA, AB, AK Builds - 100 mm (3.937 in)
AR Builds - 103 mm (4.055 in)
Stroke: 127 mm (5.000 in)
* Swept Volume: AA, AB, AK builds - 4 litres (243 in3)
AR Builds - 4.23 litres (258 in3)
Compression Ratio: AA, AB Builds - 16.5 :1
AR Builds - 17.25 : 1
AK Builds 18.5 : 1
* Compression Pressure: 20 - 30 bar (290 - 435 lbf/in2)
Valve Clearance - Cold or Hot
- Inlet 0.20 mm (0.008 in)
- Exhaust 0.45 mm (0.018 in)
* Idling Speed AA, AB builds - 750 rev/min
AR, AK builds - 800 rev/min
Injection system details Refer to appropriate engine service manual.
Maximum No-load speed 2350 rev/min
Induction System

Maximum Air Cleaner Restriction 635 mm (25 in H2O)
*
Lubrication System

Oil Pressure (Hot) at maximum speed AA Builds - 2.1 bar (30 lbf/in2)
AB, AK Builds - 2.6 bar (40 lbf/in2)
AR Builds - 2.0 bar (29 lbf/in2)
Cooling System
* Coolant Pressure 1 bar (14.5 lbf/in2)

Coolant Pressure (Normal) 80 - 85 °C (176 - 185°F)
For further engine details see Engine Manual Publication No. 9806/0100 (AA and AB Builds), 9806/2140 (AR and AK Builds).
9804/1103 20 - 05 - 03/2 3610 - K/1-1.3 Issue 5*

CONTENTS
Loadalls 20 - 05 - 03/3
* 520-50, 525-50, 525-52 From m/c no. 754000
* Data - Engine
Type: JCB diesel engine, 4 cylinder, water cooled
Build Codes:
520-50, 525-50 AA 50550- naturally aspirated (76 HP)
AR 50690 - naturally aspirated, low emission (75 HP)
525-52 AK - turbocharged, low emission (100 HP)
Bore (nominal)
AA, AK builds 100mm (3.937 in)
AR builds 103mm (4.055 in)
Swept Volume
AA, AK builds 4 litres (243 in3)
Compression Ratio
AA builds 16.5:1
AR builds 17.25:1
AK builds 18.5:1
Compression Pressure 20-30 bar (300-450 lbf/in2)

- Inlet 0.20mm (0.008 in)
Maximum No-load Speed

AA builds 2200 rev/min
AR builds 2260 rev/min
AK builds 2420 rev/min
Injection System Details - Refer to appropriate service manual.
Induction System

Lubrication System

Oil Pressure (Hot) at maximum speed 2.1 bar (30 lbf/in2)
Cooling system

For further engine details see Engine Manual Publication No. 9806/0100 (AA builds), 9806/2140 (AR and AK builds).
9804/1103 20 - 05 - 03/3 3620 - K/1-1.3 Issue 2*

CONTENTS
Loadalls 20 - 05 - 03/4
530, 535, 540 From m/c no. 767001
532, 537, 550
Data - Engine
Type JCB diesel engine, 4 cylinder, water cooled
AA - 50590, naturally aspirated 76HP
AB - 50592, turbocharged 96HP
AB - 50645, turbocharged 106HP 85A Alternator
AB - 50591, turbocharged 106HP 65A Alternator
AR - 50659, naturally aspirated, 80HP
AK - 50667, turbocharged, 102HP 65A Alternator
AK - 50671, turbocharged, 102HP 85A Alternator
Bore (nominal):
AA, AB, AK Builds 100mm (3.937 in)
AR Builds 103 mm (4.055 in)
Swept Volume
AA, AB, AK Builds 4 litres (243 in3)
AR Builds 4.23 litres (258 in3)
Compression Ratio
AA, AB Builds 16.5 : 1
AR Builds 17.25 : 1
AK Builds 18.5 : 1

maximum variation between cylinders 3.5 bar (50 lbf/in2)
Idling Speed 750 rev/min (AA/AB)

800 rev/min (AR/AK)
Maximum No-load Speed

AA/AB Build 2420 rev/min
AR/AK Build 2350 rev/min
Injection System Details - refer to appropriate Engine Service Manual (see below)
Lubrication System
Oil Pump type Eccentric rotor
Oil Pressure (Hot) at maximum speed:
AA Builds 2.1 bar (30 lbf/in2)
AB, AK Builds 2.6 bar (40 lbf/in2)
AR Builds 2.0 bar (29 lbf/in2)
Cooling System
* Fan Speed 2200 rev/min (to machine S/N 785165)
1800 rev/min nominal (from machine S/N 785166)
Coolant Pressure 1 bar (14.5 lbf/in2)
For further engine details see Engine Service Manual, Publication No. 9806/0100 (AA and AB builds), 9806/2140 (AR and AK
builds).
9804/1103 20 - 05 - 03/4 3630 - K/1-1.5 & 3660 - K/1-1.2 Issue 2*

CONTENTS
Loadalls 20 - 05 - 03/5
506B, 506C, 506C (HL), 508C
Data - Engine
Type JCB Diesel Engine, 4 cylinder, water cooled
Engine Build Codes

506B: AA - naturally aspirated (76 HP)
AB - turbo charged (106 hp)
506C: AA - naturally aspirated (76 HP)

AB - turbo charged (96 hp)
AR - naturally aspirated (low emission) 80 hp
AK - turbo charged (low emission) 100 hp
506C(HL): AR - naturally aspirated (low emission) 80 hp
508C: AB - turbo charged (96 hp)

AK - turbo charged (low emission) 100 hp
Bore (nominal)
AA, AK builds 3.937 in (100mm)
AR builds 4.055 in (103mm)
Stroke 5.000 in (127mm)
Swept Volume
AA, AK builds 243 in3 (4 litres)
AR builds 258 in3 (4.23 litres)
Compression Ratio AA Builds AR Builds AK Builds

16.5:1 17.25:1 18.5:1
Compression Pressure 300-500 lbf/in2 (20 to 35 bar) typical

Variance between cylinders 3.5 bar (50 lbf/in2) maximum
- Inlet 0.008 in (0.20mm)
- Exhaust 0.018 in (0.45mm)
Idling Speed AA, AB Builds AR, AK Builds

750 rev/min (±2) 800 rev/min (±25)

High Idle Speed (AA, AB Builds) 2420 rev/min
High Idle Speed (AR, AK Builds) 2350 rev/min
Induction System
Lubrication System
Oil Pressure (Hot) at maximum speed AA Builds AB, AK Builds AR Builds

30 lbf/in2 (2.1 bar) 2.6 bar (40 lbf/in2) 2.0 bar (30 lbf/in2)
Cooling system
Coolant Temperature (Normal) 80-85°C (176-185°F)
Temperature Warning Light operates at 98°C (208°F)
Fan Speed (506) 2400 rev/min
Fan Speed (506HL, 508) 2600 rev/min
For further engine details see Engine Manual Publication No. 9806/0100 (AA builds), 9806/2140 (AR and AK builds).
9804/1103 20 - 05 - 03/5 3640U - K/1-1.3 Issue 1

CONTENTS
Loadalls 20 - 05 - 04/1
525-58/67, 527-58/67, 530-67/95 & 535-67, 505-19, 505-22 From m/c no. 567362
Data - Axles
FRONT AXLE
Type JCB Spiral bevel with epicyclic hub reduction
Weight (approximate) 490 kg (1100 lb)
Overall Gear Ratio 18.16:1 (Germany 13.7:1)
Crownwheel & Pinion Ratio 3.36:1 (Germany 2.54:1)
Hub Reduction 5.4:1
REAR AXLE
Crownwheel and Pinion Ratio 4.38:1 (Germany 3.44:1)
Hub Reduction 5.4:1
Oscillation ± 9°
Castor Angle 2°
Camber Angle 2° Positive
King-pin Inclination Zero
Toe-in Zero
530-120, 537-120/130, 508-40, 510-40

FRONT AXLE

Hub Reduction 5.4:1
REAR AXLE

Hub Reduction 5.4:1
Oscillation ± 10°
Castor Angle Zero
Camber Angle 1°
Toe-in Zero
530-110, 506-36
FRONT AXLE

Hub Reduction 5.4:1
REAR AXLE

Hub Reduction 5.4:1
Oscillation ± 10°
Castor Angle 0°
Camber Angle 1°
Toe-in Zero
9804/1103 20 - 05 - 04/1 Issue 3

CONTENTS
Loadalls 20 - 05 - 04/2
Data - Axles
* 520-55 RS Machines from m/c no. 277001
Front Axle
Type Rigid, 2 wet brake packs, standard or limited slip differential
Axle Reduction 10.667:1
Drop Box
Location Rear face of front axle, housing parking brake, 2/4 wheel disconnect (if fitted)
Reduction ratio 1.178:1
Rear Axle
Type Steer, non braked, standard or limited slip differential, hydraulic track rod
Steer angle 50° non adjustable
Toe in 0°
520-55 4 Wheel Steer Machines up to Serial No. 2768610

Front Axle
Type Steer, 2 wet brake packs, standard or limited slip differential, hydraulic track rod
Toe in 0°
Drop Box
Location Rear face of front axle, housing parking brake, 2/4 wheel disconnect (if fitted)
Rear Axle
Type Steer, 2 wet brake packs, standard or limited slip differential, hydraulic track rod
Toe in 0°
* 520-55 4 Wheel Steer Machines from Serial No. 2768611

* 526-55, 526, 526S Machines to Serial No. 280299
Front Axle & Rear Axle
Number of Teeth
Crownwheel 31
Pinion 16
Hub reduction 5.4:1
Toe-in 0°
Castor angle 0°
Camber angle 1°
Drop Box
Location Rear face of front axle, housing parking brake
9804/1103 20 - 05 - 04/2 3610 - F/1-1.5 Issue 5*

CONTENTS
Loadalls 20 - 05 - 04/3
* 520-50, 526-55, 526, 526S
Data - Axles
* All 526-55 Machines, 526 & 526S Machines to Serial No. 280299
Front Axle & Rear Axle
Weight
(with no steer rams and without wheels) 330 kg (728 lb) approx
Crownwheel & Pinion Ratio 3:1
Number of Teeth
Crownwheel 33
Pinion 11
Hub reduction 5.4:1
Toe-in 0°
Castor angle 0°
Camber angle 1°
3610 - F/1-2.4
* 520-50/525-50 From m/c no. 754000

* Front Axle and Rear Axle 520-50 525-50
Designation SD40 (with brakes) SD55 (with brakes)
Weight
* (with no steer rams and without wheels) 245 kg (540lb) approx 330kg (728lb) approx
* Overall Gear Ratio 16.154 1 France (21.82:1) 16.2 : 1
Crownwheel & Pinion Ratio 2.692 1 France (3.626:1) 3:1
Number of Teeth
* Crownwheel 35 33
* Pinion 13 11
* Hub reduction 6 :1 5.4 : 1
Toe-in 0° 0°
Castor angle 0° 0°
Camber angle 1° 1°
Kingpin inclination 0° 0° 3610 - F/1-1.3
* 526, 526S From m/c no. 280300
Front Axle
Type JCB SD70. Spiral bevel with epicyclic hub reduction

Brakes Oil immersed multi-plate disc located in centre section
Steering Powered track rod mounted on rear of axle
Weight (approximate)
Overall Gear Ratio Standard 15.78:1 Extra Low 18.16:1
Crownwheel and Pinion Ratio Standard 2.923:1 Colour Code: Orange
Extra Low 3.364:1 Colour Code: Blue
Hub Reduction 5.4:1
Rear Axle

Crownwheel and Pinion Ratio 4.375:1 Colour Code: Blue
Hub Reduction 5.4:1
3610 - F/1-2.4
9804/1103 20 - 05 - 04/3 Issue 5*

CONTENTS
Loadalls 20 - 05 - 04/4
* 528-70 from m/c no. 796000
* 528S from m/c no. 796102 Continued
* Data- Axles
Front Axle

Overall Gear Ratio 16.19:1 (including drop box)
Overall Gear Ratio (Germany) 12.39:1 (including drop box)
Crownwheel and Pinion Ratio 16/31 teeth
Hub Reduction 5.4:1
Drop Box
Drop Box Ratio 1.547:1

Drop Box Ratio (Germany) 1.184:1
Rear Axle

Overall Gear Ratio 12.34:1 (including dropbox)
Crownwheel and Pinion Ratio 16/31 teeth
Hub Reduction 5.4:1
Tyres and Pressures
528-70
Size Ply lbf/in2 Bar

1300-24 15 78 5.4
15.5/80-24 12 58.0 4.0
528S
Size Ply lbf/in2 Bar

17.5LR24 - 54.0 3.7
IMPORTANT: A different load chart is needed if the 17.5LR24 tyre is fitted as a replacement for the 15.5/80-24 tyre. Contact
your JCB Distributor for advice.
Note: If the tyres fitted to your machine are not listed, then contact your JCB Distributor for advice, DO NOT guess tyre
pressures.
9804/1103 20 - 05 - 04/4 3650 - F/1-1.2 Issue 4*

CONTENTS
Loadalls 20 - 05 - 04/5
506B, 506C, 506C (HL), 508C

Data - Axles
Front Axle
506B & 506C

Type JSB Spiral bevel with epicyclic hub reduction
Hub Reduction 5.4:1
506C (HL) & 508C

Hub Reduction 5.4:1
Rear Axle
506B & 506C
Hub Reduction 5.4:1
Oscillation ± 10°
Castor Angle 0°
Camber Angle 1°
Toe-in Zero
506C (HL) & 508C

Hub Reduction 5.4:1
Oscillation ± 10°
Castor Angle 0°
Camber Angle 1°
Toe-in Zero
9804/1103 20 - 05 - 04/5 3640U-F/1-3.3 Issue 2*

CONTENTS
Loadalls 20 - 05 - 04A/1
All Models except 530, 532, 535, 537, 540, 550

Data - Tyres
Note: The maximum pressure embossed on the tyre may differ from the pressure stated below. Inflate to pressures below,
these are agreed with the tyre manufacturer/s in accordance with the European Tyre and Rim Technical Organisation
(ETRTO) standards to satisfy machine stability performance. If the tyres fitted to your machine are not listed, contact your JCB
Distributor for advice, DO NOT guess tyre pressures.
525-58, 527-58 Front Rear

Size Ply Bar lbf/in2 Bar lbf/in2 Manufacturer/Type
17.5 - LR 24 3.0 43.5 3.0 43.5 Michelin/Traction
15.5/80 - 24 10 3.0 43.5 3.0 43.5 Sure Grip/Traction
15.5-25 12 2.45 35.5 2.45 35.5 Industrial Traction
525-67, 527-67 Front Rear

17.5 - LR 24 3.7 54 3.7 54 Michelin/Traction
15.5/80 - 24 10 4.0 58 4.0 58 Sure Grip/Traction
15.5-25 12 4.0 58 4.0 58 Industrial Traction
530-67 Front Rear

17.5 - LR 24 3.7 54 3.7 54 Michelin/Traction
535-67 Front Rear

530-95 Front Rear

17.5 - LR 24 12 4.0 58 4.0 58 Sure Grip/Traction
505-19 Front Rear

15.5-25 12 2.45 35.5 2.45 35.5 Firestone
505-22 Front Rear

15.5-25 12 3.9 57 3.9 57 Firestone
530-110 Front Rear

17.5 - LR 24 10 4.0 58 4.0 58 Sure Grip/Traction
15.5 R25 4.0 58 4.0 58 Michelin/Traction
506-36 Front Rear

15.5-25 12 4.0 58 4.0 58 Firestone
Note: All tyres are water/calcium choride ballasted.
530-120 Front Rear

9804/1103 20 - 05 - 04A/1 Issue 1

CONTENTS
Loadalls 20 - 05 - 04A/2

Data - Tyres
(ETRTO) standards to satisfy machine stability performance. If the tyres fitted to your machine are not listed, contact your JCB
537-120 Front Rear

Size Ply Bar lbf/in2 Bar lbf/in2 Type
537-130 Front Rear

508-40 Front Rear

510-40 Front Rear

520-55 Front Rear

Size Ply Bar lbf/in2 Bar lbf/in2 3610 - F/1-3.2
12.5 x 18 x 80 10 3.5 51 3.5 51

12.5 x 20 10 3.0 44 3.0 44
335 x 80 x R18 - 3.5 51 3.5 51
375 x 75 x R20 - 4.0 58 4.0 58
335 x 80 x R20 - 3.5 51 3.5 51
14.5 - 20 10 4.0 58 4.0 58
526-55 & 526 Front Rear 3610 - F/1-3.2
Size Ply Bar lbf/in2 Bar lbf/in2

405 x 70 x R20 - 4.0 58 4.0 58
375 x 75 x R20 - 4.0 58 4.0 58
16.0/20-70 10 2.9 42 2.9 42
3610 - F/1-3.2
526S (526 N.Am) Front Rear
15.5/80-24 10 3.0 44 3.0 44
17.5LR 24 - 3.0 44 3.0 44
520-50 Front Rear 3620 - F/1-1.3

10.5/80 x 80 10 3.0 44 3.0 44
10.5/18 MPT 10 4.0 58 4.0 58
15.0/55-17 10 3.5 51 3.5 51
3620 - F/1-1.3
9804/1103 20 - 05 - 04A/2 Issue 1

CONTENTS
Loadalls 20 - 05 - 04A/3

Data - Tyres
these are agreed with the tyre manufacturer/s in accordance with the European Tyre and Rim Technical Organisation (ETRTO)
standards to satisfy machine stability performance. If the tyres fitted to your machine are not listed, contact your JCB
525-50 Front Rear

12.5 x 18 10/12 4.0 58 4.0 58
335/80 R18 10 4.5 65 4.5 65 3620 - F/1-1.3
525-52 Front Rear

405/70R20 10 TBA TBA TBA TBA
16.0/70-20 14 TBA TBA TBA TBA 3620 - F/1-1.3
506B, 506C Front Rear

1300-24 14 5.4 78 5.4 78 3640U - F/1-4.3
506C (HL), 508C

1300-24 14 5.4 78 5.4 78 3640U - F/1-4.3
Note Tires are not water/calcium chloride ballasted on 506C High Lift (HL) machines.
528-70, 506C Front Rear
13.0-24 14 5.4 78 5.4 78

15.5/80-24 12 4.0 58 4.0 58 8450/192
528S Front Rear
17.5LR24 3.7 54 3.7 54

460/70R24 3.7 54 3.7 54
15.5/80-24 12 4.0 58 4.0 58
13.0-24 14 5.4 78 5.4 70 8450/192
9804/1103 20 - 05 - 04A/3 Issue 1

CONTENTS
Loadalls 20 - 05 - 04A/4

Data - Tyres
(ETRTO) standards to satisfy machine stability performance. If the tyres fitted to your machine are not listed, then contact your
JCB Distributor for advice, DO NOT guess tyre pressures.
530 Front Rear

17.5 LR 24 -- 3.7 53 3.7 53 Traction
15.5/80 x 24 10 4.0 58 4.0 58 Sure Grip/Traction
15.5 - 25 12 4.0 58 4.0 58 Industrial traction
12.00 R24 X MINE D2 -- 4.0 58 4.0 58
* 535, 540 Front Rear

15.5 - 25 12 4.0 58 4.0 58 Industrial traction
445/70 R24 XM47 -- 4.0 58 4.0 58 Traction
12.00 R24 X MINE D2 -- 4.0 58 4.0 58
* 532 Front Rear

Size Ply Bar lbf/in2 †Ballast Bar lbf/in2 †Ballast Type
litres/US gal litres/US gal
15.5/80 x 24 12/16 4.0 58 4.0 58 Sure Grip/Traction
16.5/85 x 24 14 4.0 58 4.0 58
15.5 R25 (L2/L3) 4.5 65 4.5 65
12.00 R24 (L5) 5.8 84 5.8 84
* 537 Front Rear

17.5 -25 12 4.0 58 4.0 58
15.5 R25 (L2/L30 4.5 65 4.5 65
* 550 Front Rear

Size Ply Bar lbf/in2 †Ballast Bar lbf/in2 †Ballast Type
litres/US gal litres/US gal
17.5-25 12 4.0 58 288.5 (76.25) 4.0 58 288.5 976.25) Industrial Traction
† North America only (if applicable)
9804/1103 20 - 05 - 04A/4 Issue 1

CONTENTS
Loadalls 20 - 05 - 05/1

Data - Transmission
TECHNICAL DATA
Syncro Shuttle Combined torque converter, reverser, and gearbox unit with integral
parking brake.

2nd 3.45:1
3rd 1.83:1
4th 1.00:1

2000 rev/min 0.7 - 6.2 0.7 - 6.3 10 - 90
2000 rev/min 5.2 - 5.9 5.3 - 6.0 75 - 85

2000 rev/min 0 - 2.1 0 - 2.1 0 - 30.5
2000 rev/min 1.0 - 1.7 1.1 - 1.8 15 - 25
At 50 deg.C 1000 rev/min 0.2 - 0.3 0.2 - 0.4 3.0 - 5.0

2000 rev/min 0.4 - 0.7 0.4 - 0.7 6.0 - 10.0
At 100 deg.C 1000 rev/min 0.1 - 0.2 0.1 - 0.2 2.0 - 3.0
2000 rev/min 0.3 - 0.6 0.3 - 0.6 4.0 - 8.0
At 50 deg. C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150

2000 rev/min 10.7 - 11.7 10.9 - 12.0 155 - 170
At 100 deg.C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
2000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
At 50 deg. C 1000 rev/min 5.5 - 6.2 5.6 - 6.3 80 - 90

2000 rev/min 7.6 - 9.6 7.7 - 9.8 110 - 140
At 100 deg.C 1000 rev/min 5.5 - 6.2 5.6 - 6.3 80 - 90

2000 rev/min 6.2 - 6.9 6.3 - 7.0 90 - 100
9804/1103 20 - 05 - 05/1 Issue 4*

CONTENTS
Loadalls 20 - 05 - 05/2

Data - Transmission
2000 rev/min 14.5 - 20.0 3.8 - 5.3 3.2 - 4.4
2000 rev/min 22.7 - 26.1 6.0 - 6.9 5.0 - 5.7
2000 rev/min 22.5 - 29.5 6.0 - 7.8 5.0 - 6.5
520-55 From m/c no. 277001

Data - Transmission
As “All Models’.above except for the following:


2nd 3.45:1
3rd 1.83:1
4th 1.00:1
Minimum Engine Rev/Min at Converter Stall Engine Type Rev/Min

AA50261 1800
* 520-5, 525-50, 525-52 From m/c no. 754000

Data - Transmission 3620 - F/1-2.3
As ‘All Models’ above except for the following:
bar kgf/cm2 lbf/in2

At 50°C 1000 rev/min 7.6 - 9.6 7.7 - 9.8 110 - 140
2000 rev/min 9.0 - 11.0 9.1 - 11.2 130 - 160
At 100 °C 1000 rev/min 7.6 - 9.6 7.7 - 9.8 110 - 140

2000 rev/min 7.6 - 9.6 7.7 - 9.8 110 - 140
9804/1103 20 - 05 - 05/2 Issue 3*

CONTENTS
Loadalls 20 - 05 - 05/3
* 520,526 from m/c no. 277001
528 from m/c no. 796000,
506, 508
Data - Transmission
Powershift Full electro-hydraulic transmission unit with input, reverse, layshaft, mainshaft
and 4 wheel drive clutch packs. Torque converter and parking brake integral .
Designation PS740 (4 wheel drive)
* Number of Teeth Std Ratio Low Ratio Extra Low Ratio

(506, 508)
Transfer Gear 45 46 47
Layshaft 18 16 15
Input Gear (4WD) - - 21
Output Gear (4WD) - - 44
* Gear Ratios Std Ratio Low Ratio Extra Low Ratio

(506, 508)
1st 5.72:1 6.58:1 7.17:1
2nd 3.23:1 3.71:1 4.04:1
3rd 1.77:1 1.77:1 1.77:1
4th 1.00:1 1.00:1 1.00:1
Torque Multiplication at Stall 2.20:1 or 2.40:1 or 2.80:1
* Torque Converter Colour Code Identification 2.20:1 Ratio 2.40:1 Ratio 2.80:1 Ratio
Colour Coded Dots 2 (506/508-1) 2 Orange 3 Brown
Purple 1 (506/508-2)
1 White Green

2000 rev/min 4.8 - 6.2 4.9 - 6.3 70 - 90

2000 rev/min 2.3 - 2.7 2.3 - 2.7 33 - 39

At 50 deg.C 1000 rev/min 0.14 - 0.28 0.14 - 0.28 2.0 - 4.0
2000 rev/min 0.28 - 0.55 0.28 - 0.56 4.0 - 8.0

At 50 deg. C 1000 rev/min 9.0 - 10.0 9.1 - 10.2 130 - 145
2000 rev/min 9.7 - 11.0 9.8 - 11.3 140 - 160

2000 rev/min 14.5 - 20.0 3.8 - 5.3 3.2 - 4.4
2000 rev/min 22.5 - 29.5 6.0 - 7.8 5.0 - 6.5
The following clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2):
Input Clutch Pressure (high and low ratio)

Reverse Clutch Pressure (high and low ratio)
Layshaft Clutch Pressure
Mainshaft Clutch Pressure
2/4 Wheel Drive Clutch Pressure
* Note 1: For brand new gearboxes (i.e. under 100 hours service) or gear boxes that have been fully serviced the pressures will
be slightly higher by approximately 0.7 - 1.0 bar (10 - 15 lbf/in2) than those shown.
* Note 2: Using 2nd and 3rd gears in forward and reverse drive will ensure that ALL clutches are energised during the stall test -
refer to 'Torque Converter Stall Test'.
9804/1103 20 - 05 - 05/3 3610 - F/1-5.1 3650 - F/1-3.1 3640U - F/1-2.2 Issue 3*

CONTENTS
Loadalls 20 - 05 - 05/3A
520, 526 from m/c no. 277001

528 from m/c no. 796000
506, 508
Data - Transmission
Syncro Shuttle
CAUTION: Before attempting to tow the machine read carefully the instructions, see Towing Procedure, this Section.
Syncro Shuttle
Combined torque converter, reverser, and gearbox unit


2nd 3.45:1
3rd 1.83:1
4th 1.00:1
Stall Speeds AA/AR Builds (Nat Asp) AK Build (Turbo) 506, 508 AA/AB Builds
*
Hydraulic only 2290 rev/min 2296 rev/min 1650-1750/1830-1930
Converter only 2000 rev/min 2156 rev/min
Hydraulics and Converter 1589 rev/min 1815 rev/min

2000 rev/min 0.7 - 6.2 0.7 - 6.3 10 - 90
2000 rev/min 5.2 - 5.9 5.3 - 6.0 75 - 85
2000 rev/min 0 - 2.1 0 - 2.1 0 - 30.5
2000 rev/min 1.0 - 1.7 1.1 - 1.8 15 - 25
At 50 deg.C 1000 rev/min 0.2 - 0.3 0.2 - 0.4 3.0 - 5.0

2000 rev/min 0.4 - 0.7 0.4 - 0.7 6.0 - 10.0
At 100 deg.C 1000 rev/min 0.1 - 0.2 0.1 - 0.2 2.0 - 3.0
2000 rev/min 0.3 - 0.6 0.3 - 0.6 4.0 - 8.0
At 50 deg. C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150

2000 rev/min 10.7 - 11.7 10.9 - 12.0 155 - 170
At 100 deg.C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
2000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
At 50 deg. C 1000 rev/min 5.5 - 6.2 5.6 - 6.3 80 - 90

2000 rev/min 7.6 - 9.6 7.7 - 9.8 110 - 140
At 100 deg.C 1000 rev/min 5.5 - 6.2 5.6 - 6.3 80 - 90

2000 rev/min 6.2 - 6.9 6.3 - 7.0 90 - 100
Cooler at 50 deg. C 1000 rev/min 10.4 - 13.6 2.8 - 3.6 2.3 - 3.0
2000 rev/min 14.5 - 20.0 3.8 - 5.3 3.2 - 4.4
At 100 deg.C 1000 rev/min 10.2 - 12.5 2.7 - 3.3 2.3 - 2.8
2000 rev/min 22.7 - 26.1 6.0 - 6.9 5.0 - 5.7
Pump at 50 deg. C 1000 rev/min 11.0 - 15.0 2.9 - 4.0 2.5 - 3.3
2000 rev/min 22.5 - 29.5 6.0 - 7.8 5.0 - 6.5
9804/1103 20 - 05 - 05/3A 36400 - F/1-1.2 3610 - F/1-4.2 Issue 1

3650 - F/1-2.2
CONTENTS
Loadalls 20 - 05 - 05/4
530, 532, 535, 537, 540, 550

Data - Transmission
Powershift
Description Full electro-hydraulic transmission 4 or 5 speed (3 Germany) unit with input,

layshaft, mainshaft, reverse, 5th gear (if applicable) and 4 wheel drive clutch
packs.
Designation PS700 or PS750
Weight (dry) 2WD 157 kg (346 lb)

4WD 176 kg (388 lb)
Extra Low Ratio Std Ratio

2/4 Wheel Drive Ratio 1.495 1.307
4 Wheel Drive Number of Teeth Input Gear 21 23

Output Gear 44 44
4 Speed 5 Speed
Torque Converter Dia. 279mm (11in) 310mm (12.2in)
Torque Converter 2.20:1 Ratio 2.24:1 Ratio
Colour Coded Dots 2 purple/1 White 2 Blue

2000 rev/min 4.8 - 6.2 4.9 - 6.3 70 - 90

2000 rev/min 2.3 - 2.7 2.3 - 2.7 33 - 39
Converter Relief (Safety) Valve Setting 6.5 6.7 95

At 50 deg.C 1000 rev/min 0.14 - 0.28 0.14 - 0.28 2.0 - 4.0
2000 rev/min 0.28 - 0.55 0.28 - 0.56 4.0 - 8.0

At 50 deg. C 1000 rev/min 9.0 - 10.0 9.1 - 10.2 130 - 145
2000 rev/min 9.7 - 11.0 9.8 - 11.3 140 - 160

2000 rev/min 14.5 - 20.0 3.8 - 5.3 3.2 - 4.4
2000 rev/min 22.5 - 29.5 6.0 - 7.8 5.0 - 6.5
All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2).
Note: For new gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be
slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2 ).
9804/1103 20 - 05 - 05/4 3630 - F/1-1.5 Issue 3*

CONTENTS
Loadalls 20 - 05 - 05/5
532, 537, 550 * From m/c no. 767001

Data - Transmission
Front Axle

Steering 2 steer rams mounted on rear of axle
15.78:1 Germany
2.923 Germany Colour Code: Orange
Hub Reduction 5.4:1
Rear Axle

Brakes Oil immersed multi-plate disc located in hubs
Steering 2 steer rams mounted on rear of axle
Crownwheel and Pinion Ratio 4.625:1 Colour Code: Pink 3660 - F/1-2.1
Hub Reduction 5.4:1
* Pump/Transmission Stall Speed Combinations - with 11 inch Converters
* The figures given below apply to ‘bedded-in’ engines. ie. engines that have done a minimum of 250 working hours, therefore
they should not be used for pre-delivery inspection (PDI) checks. They are intended to be used as guideline figures only and
should not be considered as servicing parameters.
JCB Diesel Engine Build Codes

AA/AB AK/AR
* Torque Converter Stall

106 hp Turbo (rpm) 1965 ±100 -
76 hp NA (rpm) 1640 ±100 -
102 hp Turbo (rpm) - 1950 ±100
80 hp NA (rpm) - 1740 ±100
* Combined Stall
106 hp Turbo (rpm) 1205 ±100 -
76 hp NA (rpm) 855 ±100 -
102 hp Turbo (rpm) - 1490 ±100
80 hp NA (rpm) - 960 ±100
Pump Size (l/min) 110 110
Converter Type (W11) 2.2:1 2.2:1
Note: Combined stall tests are performed with the crowd service operated until the relief valve lifts.
*
3660 - F/1-3.1
9804/1103 20 - 05 - 05/5 Issue 2*

CONTENTS
Loadalls 20 - 05 - 05/6
530, 532, 537, 540, 550 From m/c no. 767001

Data - Transmission
Front Axle

Overall Gear Ratio Standard 15.78:1 Extra Low 18.16:1
Crownwheel and Pinion Ratio Standard 2.923:1 Colour Code: Orange
Extra Low 3.364:1 Colour Code: Blue
Hub Reduction 5.4:1
Rear Axle

3630 - F/1-2.4
Hub Reduction 5.4:1
Pump/Transmission Stall Speed Combinations - 11 inch & 12.2 inch Converter

JCB Diesel Engines - Build Codes AM
JCB Diesel Engines - Build Codes AA and AB
Torque Converter Stall
120 hp Turbo intercooled (rpm) 1980
106 hp Turbo (rpm) 1960
Hydraulic Stall
76 hp NA (rpm) 1685
Combined Stall
Combined Stall
76 hp NA (rpm) 1185
Pump Size (l/min) 82
Converter Type (12.2in) 2.24:1
Converter Type (11in) 2.2:1
JCB Diesel Engines - Build Codes AK and AR

80 hp NA (rpm) TBA
Hydraulic Stall
80 hp NA (rpm) TBA
Combined Stall
80 hp NA (rpm) TBA
Converter Type (11in) 2.2:1
Note: Combined stall tests are performed with the crowd service operated until the relief valve is
3630 - F/1-3.4
9804/1103 20 - 05 - 05/6 Issue 2*

CONTENTS
Loadalls 20 - 05 - 07/1
525-58/67, 527-58/67, 530-67 & 535-67, 505-19/22 From m/c no. 567362
Data - Brakes
Service Brake
Type JCB Oil-Immersed Disc

Actuation Single Circuit Hydraulic, Direct Actuation
Location Front Axle (2 Brake Packs)

Nominal Facing Area 12616 mm2 (19.3 in2)
Master Cylinder
Type Frenos Iruna

Piston Diameter 35 mm (1.125 in)
Parking Brake
Type Manually Adjusted Caliper

530-95, 530-110, 506-36 From m/c no. 567362

Data - Brakes
Service Brake
Type JCB Oil-Immersed Discs

Actuation Tandem Circuit Hydraulic, Direct Actuation
Friction Plates ( front axle 5 per brake pack)

Master Cylinder
Type Frenos Iruna

Parking Brake

9804/1103 20 - 05 - 07/1 Issue 3

CONTENTS
Loadalls 20 - 05 - 07/2
530-120, 537-120/130, 508-40, 510-40 From m/c no. 567362

Data - Brakes
Rear Axle (2 Brake Packs)
Friction Plates ( front axle 5 per brake pack and rear axle 3 per brake pack)
Master Cylinder
Type Frenos Iruna Tandem Cylinder

Piston Diameter 38.1mm (1.50 in)
Servo Unit
Type Frenos Iruna

Piston Diameter 203.2mm (8 in)
Exhauster
Type Clayton Dewandre H175

Ratio 1.4 times engine speed driven off timing gear
Parking Brake

520-55 RS From m/c no. 277001 to 279119

Data - Brakes
Service Brakes
Type Single Circuit, Oil-Immersed Multi-Plate Disc Actuation

Actuation Hydraulic
Master Cylinder
Type Frenos compensated master cylinder
Bore 19.05 mm (0.75 in)
Parking Brake
Type Manually Adjusted Disc, cable operated

Location Top rear face of front axle drop box
3610-G/1-1.5
9804/1103 20 - 05 - 07/2 Issue 4*

CONTENTS
Loadalls 20 - 05 - 07/3
520-55 AWS * From m/c no. 277001 to 279119

Data - Brakes
Service Brakes
Type Single Circuit, Oil-Immersed Multi-Plate Disc Actuation

Actuation Hydraulic
Location Front Axle (2 Brake Packs), Rear Axle (2 Brake Packs)
Master Cylinder
Type Frenos
Bore 25.4 (1.0 in)
Parking Brake
Type Manually Adjusted Disc, cable operated 3610 - G/1-1.5

* 526-55, 526, 526S from m/c no. 277467 to 280299

* 520-50 AWS from m/c no. 279120
Data - Brakes
Service Brakes
Type JCB oil-immersed multi-plate disc high pressure brakes with

hydraulic accumulators for emergency application.
Parking Brake
Type Manually Adjusted Disc, cable operated 3610 - G/1-1.5

* 520-50, 525-50, 525-52 From m/c no. 754000

Data - Brakes
Type Single Circuit, Oil-Immersed Multi-Plate Disc

Actuation Hydraulic
* System Pressure 90 - 110 bar (1303 - 1595 lbf/in2)
3620 - G/1-1.2
9804/1103 20 - 05 - 07/3 Issue 3*

CONTENTS
Loadalls 20 - 05 - 07/4
526-55, 526, 526S & 520-55 4 Wheel Steer From m/c no. 2768611
Data - Brakes
Service Brakes
Type JCB oil-immersed multi-plate disc high pressure brakes with hydraulic
accumulators for emergency application.
Parking Brake

532, 537 From m/c no. 2768611

Data - Brakes
Service Brakes

Actuation Hydraulic- vacuum servo assisted
Location Front Axle Centre Mounted (2 Brake Packs), Rear Axle Hub Mounted (2 Brake Packs)
Master Cylinder
Type Frenos master cylinder with remote servo unit

Piston diameter 38.1 mm (1.5 in)
Servo Unit
Type Frenos vacuum assisted hydraulic valve

Vacuum cylinder diameter 201 mm (7.9 in)
Hydraulic cylinder diameter 21.6 mm (0.85 in)
9804/1103 20 - 05 - 07/4 Issue 2*

CONTENTS
Loadalls 20 - 05 - 07/5
528-70 From m/c no. 796000

528S From m/c no. 796102
Data-Brakes
Service Brakes
Type JCB oil-immersed multi-plate disc with inboard brakes

Actuation Hydraulic
Location Front axle centre mounted (2 brake packs)
Parking Brake

Location Transmission output shaft
General Description
The service brakes act on the front axle half shafts of all machines. The brakes are oil immersed, multi-disc types which are
operated hydraulically by a single pedal and master cylinder arrangement.
The brake cylinder reservoir is situated in front of the instrument panel in the cab.
The cable operated parking brake acts on a disc which is mounted on the gearbox output shaft to the front axle.
9804/1103 20 - 05 - 07/5 3650 - G/1-1.2 Issue 1

CONTENTS
Loadalls 20 - 05 - 07/6
530, 535, 540 From m/c no. 767001

Data - Brakes
* Service Brakes

Actuation 530 - Hydraulic
535, 540, 530FS Super, 540FS Super, 530 SXL, 540 SXL - Hydraulic, servo assisted
Location All Machines - Front Axle Centre Mounted (2 Brake Packs)
* Master Cylinder
Type 530 - master cylinder

535, 540, 530FS Super, 540FS Super, 530 SXL, 540 SXL - master cylinder with remote
sservo unit
Stroke 530 - 35 mm (1.38 in)
535, 540, 530FS Super, 540FS Super, 530 SXL, 540 SXL - 25 mm (1.0 in)
* Servo Unit
Type Vacuum assisted hydraulic valve

Vacuum cylinder diameter 535, 540 - 135.5 mm (5.33 in)
Hydraulic cylinder diameter 535, 540, 530FS Super, 540FS Super, 530 SXL, 540 SXL - 19 mm (0.75 in)
9804/1103 20 - 05 - 07/6 3630 - G/1-1.4 Issue 2*

CONTENTS
Loadalls 20 - 05 - 07/7
506B, 506C, 506C(HL), 508C

Data - Brakes
Service Brakes

Rear Axle (2 Brake Packs)
Master Cylinder
Parking Brake

9804/1103 20 - 05 - 07/7 3640U-G/1-1.3 Issue 1

CONTENTS
Loadalls 20 - 05 - 08/1

Data - Steering
System Type Full power hydrostatic with selectable 2/4/crab steer
Tandem Steer/Fan Pump - Steer Section
Type Sundstrand, gear type AFGP8L/12.5L-31207, double gear

type
Controlled Flow litres/min UK gal/min US gal/min

Steer, at 1000 engine rev/min and neutral pressure 18.2 4.0 4.8
Fan, at max. engine rev/min at zero pressure 25.0 5.5 6.6
Total Flow through tank return line at 2200
engine rev/min (pressure outlet blocked) 48 10.5 12.7
Note: The outer section of the pump (furthest from the timing case) drives the steering system. The inner section (nearest the
timing case) drives the engine cooling fan.
Single Priority Steer/Fan Pump (For 527-58, 527-67, 535-67 from machine serial No. 574296 only)
Type Ultra 1PX090, Gear type
Flow at max. engine rev/min at zero pressure litres/min UK gal/min US gal/min

steering at neutral flow out of EF port 34.3 7.5 9.0
Control Unit
(525-58, 67, 527-58, 67, 530-67, 535-67, 530-95, 110) Danfoss Orbitrol OSPV 160
(530-120) Danfoss Orbitrol OSPB 200
Relief Valve Pressure 138 bar 2000 lbf/in2
With priority steer/fan pump (527-58, 67, 535-67) Danfoss Orbitrol OSPC 160
Relief Valve Pressure 175 bar 2537.5 lbf/in2
Ram Dimensions (525-58, 67, 527-58, 67 and 530-67, 95, 110)

Bore 50 mm (1.97 in)
Rod Dia. 25 mm (0.98 in)
Ram Dimensions (530-120 & 537-120, 130)

Bore 60 mm (23.62 in)
Stroke 209.5 mm (8.25 in)
Note: 530-120 & 537-120, 130 machines from Serial Number 574481, the rams are supplied by an alternative source. The
rams must all be the same type, DO NOT mix rams on a machine. The seal kits are also different.
520-55, 526-55, 526, 526S From m/c no. 277001

Data - Steering
System Type Full power hydrostatic, powered track rod on rear axle
Pump (see Data - Hydraulics)
Control Unit Type OSPC 125LS
2 2
Relief Valve Operating Pressure 175 bar (178 kgf/cm ; 2500 lbf/in )
235 bar (239 kgf/cm ; 3407 lbf/in2)
2
Shock Relief Valve Operating Pressure
Powered Track Rod
Stroke for each side 130 mm (5.11 in)
3610-H/1-1.3
9804/1103 20 - 05 - 08/1 Issue 5*

CONTENTS
Loadalls 20 - 05 - 08/1A
* ALL MODELS From m/c no. 773135
Data - Steering
System Type Fully hydraulic load sensing with selectable 2-wheel, 4-wheel and
crab steer modes. Anti-cavitation valve on 540-170 and 5508
machines. On other machines, the anti-cavitation valve was
discontinued from Serial No. 773135
Double acting cylinders on all wheels
Pump Gear type (19cc/rev) with load sensing priority flow divider delivering
41 litres/min (9 UK Gal/min, 10.8 US Gal/min)
Steering Valve
Machines except 540-170, 5508

2 2
2 2
Shock Relief Valve Operating Pressure 235 bar (239 kgf/cm ; 3407 lbf/in )
540-170, 5508 Machines 95 cc/rev (2:1 ratio)

Relief Valve Operating Pressure 175 bar (178 kgf/cm2; 2500 lbf/in2)
2 2
Shock Relief Valve Operating Pressure 235 bar (239 kgf/cm ; 3407 lbf/in )
9804/1103 20 - 05 - 08/1A 3630 - H/1-2.3 Issue 1*

CONTENTS
Loadalls 20 - 05 - 08/2
* 520-50, 525 - 50, 525 - 52 From m/c no. 754000
Data - Steering
System Type Full power hydrostatic, powered track rod on rear axle
Shock Relief Valve Operating Pressure 235 bar (239 kgf/cm2; 3407 lbf/in2)
Powered Track Rod 3620-H/1-1.1
Stroke for each side 130 mm (5.11 in)
530, 532, 537 From m/c no. 754000
Data - Steering
System Type Full power hydrostatic with selectable 2, 4 and crab steer
530 Powered track rod on rear of axles
532, 537 Steer rams on rear of axles

Control Unit Type
530 OSPV 160 LS
532, 537 OSPB 200 LS
2 2
235 bar (239 kgf/cm ; 3407 lbf/in2)
2
9804/1103 20 - 05 - 08/2 Issue 3*

CONTENTS
Loadalls 20 - 05 - 08/3
528-70 from m/c no. 796000

528S from m/c no. 796102
Data-Steering
System Type Fully hydraulic load sensing with optional 2-wheel, 4-wheel and crab
steer modes. Powered trackrods on both axles.
Pump Gear type (36 cc/rev) with load sensing priority flow divider.
Shock Relief Valve Operating Pressure 235 bar (239 kgf/cm2; 3407 lbf/in2)
9804/1103 20 - 05 - 08/3 3650 - H/1-1.2 Issue 1

CONTENTS
Loadalls 20 - 05 - 08/4
530, 535, 540 From m/c no. 767001

532, 537, 550
Data - Steering
530, 535, 540
crab steer modes. Anti-cavitation valve on Machines to Serial No.
773053.
Powered track rod on both axles
Control Unit Type OSPV 160 LS
Relief Valve Pressure: 175 bar (178 kgf/cm2; 2500 lbf/in2)

Shock Relief Valve Pressure: 235 bar (239 kgf/cm2; 3407 lbf/in2)
3630 - H/1-1.3
532, 537, 540

crab steer modes. Anti-cavitation valve on Machines to Serial No.
773134.
Double acting cylinders on all wheels
Control Unit Type OSPB 200 LS

2 2
Relief Valve Pressure: 175 bar (178 kgf/cm ; 2500 lbf/in )
Shock Relief Valve Pressure: 235 bar (239 kgf/cm2; 3407 lbf/in2) 3660 - H/1-1.1
9804/1103 20 - 05 - 08/4 Issue 1

CONTENTS
Loadalls 20 - 05 - 08/5
506B, 506C, 506C(HL), 508C

Data - Steering
System Type Full power hydrostatic with selectable 2/4/crab steer
506B
Type Double gear type

Fan, at max. engine rev/min at neutral pressure 18.8 4.1 4.9
engine rev/min (pressure outlet blocked) 27.5 6.0 7.2
Control Unit
Type OSPB 160
Ram Dimensions
Stroke 205.4 mm (8 in)
506C
Note: Hydraulic pressure supply from priority valve in main hydraulic circuit.
Control Unit
Type OSPC 160

Relief Valve Pressure 175 bar (2500 lbf/in2)
Ram Dimensions
Stroke 205.4 mm (8 in)
506C (HL), 508C

Type Double gear type

Fan, at max. engine rev/min at neutral pressure 18.8 4.1 4.9
engine rev/min (pressure outlet blocked) 27.5 6.0 7.2
Control Unit
Type OSPB 200
Ram Dimensions
Stroke 209.5 mm (8.25 in)
9804/1103 20 - 05 - 08/5 3640U - H/1-1.2 & H/1-2.2 Issue 1

CONTENTS
Loadalls 20 - 15 - 01/1

48 48 A
600
46
24 37
47 49 51 53
17 27 26
5 11 44 45 59 60
202 204 205 208 54
N
G/Y
U 50 52
415 811 812 815
414A 403 405 408 409
414 55
413A 814 203 34
413 839 841 402 404 406
2 414B 21
412
413B 801 42 43
407 56
416 400 600 206
N G/Y U
805 806 807
10 210 212 214

32 57 58
804 842
36 40 41 209 211 213 215
803
808A 809
20 23
31 803A
16 802 401
3 103A
30
810
25 19
9 207
808 39
800
- 101 411 200
1
+ 003
6 105 106A
100
300 61
15 103 104
800
100 106
200 842
A1 A2 A4 A5 A6 A7 A8 A9 B1 B2 004
200
103
000 000
4
000R 000R
200 200
004
842
A215190
9804/1103 20 - 15 - 01/1 Issue 2

CONTENTS
Loadalls 20 - 15 - 01/2

48 48 48
600
66 69
216 229 234
220 219 78
73 225 226 227 231 232 233
235
217 67 221
78B
78C 78D
230
65 78E 78F
218 818 835 838
829P 834 837
63 78A
301
831
847 99
B9 C1
62
816 72 821 823 848 829 830 B8 C2
822 826 824 825 86
844
817
68 77 B6 B7
112
828
833 836
410
83
71B 79 222 223 224
820
76
88
75 819
93
855
106D 827
71 80 81 82 832
110
108 109
87
B3 B4 B5 C4
103
000
000R
200
A215200
9804/1103 20 - 15 - 01/2 Issue 2

CONTENTS
Loadalls 20 - 15 - 01/3

The large bold numbers are main component identification numbers. The small plain numbers are cable identification numbers.
When a cable identification number has a suffix number, for clarity, the suffix number is not shown. The complete electrical
circuit is shown on page 20-15-01/1 and continued on page 20-15-01/2.
WIRING DIAGRAM
(All 527, 535 machines; 525-58/67, 530-95/110 from Serial No. 572168; 530-120 from Serial No. 572242)
* For SLI system circuit for machines from serial No. 576404 and 537-120/130 see page 20-15-01/11
Note: Item A is Syncro Shuttle option. For Powershift option see page 10/10-14.
Main Components Lamps

1 Battery 54 Hourmeter 202 Trailer Indicator Warning
2 Starter Motor 55 Alternator 203 Hazard Warning
3 Starter Solenoid 56 Tachometer 204 L.H. Indicators
4 Starter Switch 57 Fuel Gauge 205 R.H. Indicators
5 Thermostart 58 Water Temperature Gauge 206 Indicator Warning
6 Starter Relay 59 Fuel Gauge Sender 207 Hazard Indicator Warning
9 Safe Load Indicator Readout Box 60 Water Temperature Gauge 208 Reversing Lights
10 Rear SLI Boss Sender 209 Parking Brake Warning
11 Front SLI Boss 61 Warning Buzzer 210 Air Filter Blocked Warning
15 Heater Switch 62 L. H. Stabiliser Switch 211 Engine Oil Pressure Warning
16 Heater Resistor 63 R. H. Stabiliser Switch 212 Transmission Oil Temperature
17 Heater Motor 65 Interior Light Switch Warning
19 Seat Relay Swedish 66 Roof Wiper Motor and Switch 213 Transmission Oil Pressure
20 Parking Brake Switch machines 67 Rear Wiper Motor and Switch Warning
21 Seat Switch only 68 Beacon Switch 214 Water Temperature Warning
23 Horn Push 69 Beacon 215 Alternator Warning
24 Horn 71 Brake Switch 216 Stabiliser Indicators
25 Wash/Wipe Switch 71B Brake Switch Relay 217 Interior Light
26 Front Wiper Motor 72 2/4 Wheel Drive Switch (not fitted 218 Beacon Warning
27 Washer Pump on permanent 4 wheel drive) 219 2 Wheel Drive Warning
30 Hazard Switch 73 2 Wheel Drive Solenoid 220 L.H. Brake Lights
31 Indicator Relay 75 Front Axle Proximity Switch 221 R.H. Brake Lights
32 Indicator Switch 76 Rear Axle Proximity Switch 222 4 Wheel Steer Warning
34 Fuel Shut-off Solenoid 77 Steering Mode Selector Switch 223 Crab Steer Warning
36 Reverse Alarm Relay 78 Steer Mode Printed Circuit Board 224 2 Wheel Steer Warning
37 Reverse Alarm 78A Relay 2 225 Instrument Panel Illumination
39 Forward/Reverse Selector Switch 78B Relay 1 226 L.H. Side Light
40 Neutral Start Relay 78C Relay 1 (latch) 227 R.H. Side Light
41 Parking Brake Warning Relay 78D Relay 2 (unlatch) 229 Number Plate Light
42 Reverse Relay 78E Relay 1 (unlatch) 230 Working Light Warning
43 Forward Relay 78F Relay 2 (latch) 231 Cab Working Light
44 Reverse Solenoid 79 4 Wheel/Crab Steer Solenoid 232 Headlamp Dip Beam
45 Forward Solenoid 80 4 Wheel Steer Solenoid 233 Headlamp Main Beam
46 Transmission Dump Switch 81 Crab Steer Solenoid 234 Headlamp Main Beam Warning
47 Parking Brake Switch 82 2 Wheel Steer Solenoid 235 Inclinometer Illumination
48 Trailer Socket 83 Side Lights Relay
49 Air Filter Switch 86 Working Light Switch Fuses
50 Engine Oil Pressure Switch 87 Road Light Switch Fuses are numbered as shown on
51 Transmission Oil Temperature 88 Headlamp Dip Switch the fuse box in the cab.
Switch 93 Headlamp Flasher
52 Transmission Oil Pressure Switch 99 Radio (Optional) Cable Colour Code
53 Water Temperature Switch 100 Transmission Dump Relay
101 Transmission Dump Switch G Green
N Brown
U Blue
Y Yellow
Note: For machines without road lights a link is fitted (as shown) in place of Working Light Switch 86 and switch 87 operates
the Working Lights.
9804/1103 20 - 15 - 01/3 Issue 4*

CONTENTS
Loadalls 20 - 15 - 01/4
* 520-55 (504B N. Am), 520-55 RS From m/c no. 277001 to 277535

48
600
37
11 12
47 49 51 53
17 27
5 44 45
102 104 105 108 54
24 50 52
26 59 60
850 851
10 811 812 403 405
55
103 805 806 34 815
402 404 406
2 412
801 814 42 43
407 56
21 106
415
414 807
400
413
110 112 114
32 57 58
23 841
36 40 842 41
853
109 111 113 115
839 840
19 808A 809 401
116 16 31 804
9 20 802 803
3 30 810
101 25 808 39
800
- 114
107 106
411 200
1 15
113
+ 003
6 105 13
300 61
135
104
813
102 107
46
100
103
200 842 106
A1 A2 A3 A4 A6 A7 A8 A9 B1 B2
200
004
000 000 000

4
001 001 001
200 200 200
004
842
102 102
829 829
103 103
A190160
9804/1103 20 - 15 - 01/4 3610 - C/41-2.1 Issue 3*

CONTENTS
Loadalls 20 - 15 - 01/5
The large bold numbers are main component identification numbers. The small plain numbers are cable identification
numbers. When a cable identification number has a suffix number, for clarity, the suffix number is not shown.
1 Battery 55 Alternator 102 Trailer Indicator

2 Starter Motor 56 Tachometer 103 Hazard Warning
3 Starter Solenoid 57 Temperature Gauge 104 L.H. Indicators
5 Thermostart 59 Temperature Sender 106 Indicator Warning
6 Starter Relay 60 Fuel Sender 107 Hazard Indicator Warning
9 Safe Load Indicator Readout Box 61 Warning Buzzer 108 Reversing Lights
10 Rear Axle Transducer 65 Interior Light Switch 109 Parking Brake Warning
11 Trailer Hitch Diverter Valve 66 Roof Wiper Motor and Switch 110 Air Filter Blocked Warning
12 Auxiliary Diverter Valve 67 Rear Wiper Motor and Switch 111 Engine Oil Pressure Warning
13 Transmission Dump Relay 68 Beacon Switch 112 Transmission Temperature Warning
15 Heater Switch 69 Beacon 113 Transmission Oil Pressure Warning
16 Heater Resistor 71 Brake Switch 114 Water Temperature Warning
17 Heater Motor 83 Side Lights Relay 115 Alternator Warning
19 Trailer Hitch Selector Switch 86 Working Light Switch 116 Hitch Warning
20 Auxiliary Selector Switch 87 Road Light Switch 117 Interior Light
21 Auxiliary Relay 88 Headlamp Dip Switch 118 Beacon Warning
23 Horn Push 93 Headlamp Flasher 119 Roof Wiper Warning
24 Horn 99 Radio (optional) 120 L.H. Brake Lights
25 Wash/Wipe Switch 100 Roof Wiper Switch 121 R.H. Brake Lights
26 Front Wiper Motor 101 Brake Light Relay 125 Instrument Panel Illumination
27 Washer Pump 126 L.H. Side Light
30 Hazard Switch 127 R.H. Side Light
31 Indicator Relay 128 Trailer
32 Indicator Switch 129 Number Plate
34 Fuel Shut-off Solenoid 130 Working Light Warning
36 Reverse Alarm Relay 131 Cab Working Lights
37 Reverse Alarm 132 Headlamp Dip Beam
39 Forward/Reverse Switch 133 Headlamp Main Beam
40 Neutral Start Relay 134 Headlamp Main Beam Warning
41 Parking Brake Warning Relay 135 Heater Switch Warning
42 Reverse Relay 136 Road Light Warning
43 Forward Relay 137 Inclinometer Light
44 Reverse Solenoid
45 Forward Solenoid
46 Transmission Dump Switches
48 Trailer Socket
49 Air Filter Switch
51 Transmission Temperature Switch
52 Transmission Oil Pressure Switch
53 Water Temperature Switch
54 Hourmeter
Fuses are numbered as shown on the fuse box in the cab.
9804/1103 20 - 15 - 01/5 3610 - C/41-1.5 Issue 3*

CONTENTS
Loadalls 20 - 15 - 01/6

48 48 48
600 600
69 120 121 129 134

117
67
65 137 125 126 127 131 132 133
128
66 835 838
844 834 837
816
831
301
849
86 99
829 830
100 68 101
119 130
B9 C1
118 855
B8 C2
71 B6 B7
112
828
833 836
83
88
108
93
827
87 832 110
136
B3 B4 B5 C3 C4
000
001
200
102
829
103
A190170
9804/1103 3610 - C/41-3.2 20 - 15 - 01/6 Issue 3*

CONTENTS
Loadalls 20 - 15 - 01/7
* 520-55 (from m/c no. 277536)

* 526-55 (to m/c no. 278965)
48
600
37
11 12
47 102 49 51 53
17 27
5 44 45
202 203 204 205 208 54
24 50 52
26 59 60
850 851
10 811 812 403 405
55
805 806 34
402 404 406 408
2 42 43 412
814 815
407 56 409
21 106
415A
414 807
400
413
210 212 214
23 32 107
57 58
841
36 40 842 41
853 209 211 213 215
839 840
19 809 401
801
216 16 31 804
9 20 802 803
3 30 810
101 25 808 39
800
- 114
207 106
411 200
1 15
+ 003 46
6 105
300 61
235
104
13
102
100
103
200 842 106
A1 A2 A3 A4 A6 A7 A8 A9 B1 B2
200
004
810
000 000 000

4
001 001 001
200 200 200
004
842
102 102
829 829
103 103
A215620
9804/1103 20 - 15 - 01/7 3610 - C/41-5.1 Issue 2*

CONTENTS
Loadalls 20 - 15 - 01/8
* 520-55 (from m/c no. 277536)
* 526-55 (to m/c no. 278965)

When a cable identification number has a suffix number, for clarity, the suffix number is not shown.
* 1 Battery 55 Alternator 202 Trailer Indicator

2 Starter Motor 56 Tachometer 203 Hazard Warning
5 Thermostart 59 Temperature Sender 206 Indicator Warning
6 Starter Relay 60 Fuel Sender 207 Hazard Indicator Warning
9 Safe Load Indicator Readout Box 61 Warning Buzzer 208 Reversing Lights
10 Rear Axle Transducer 65 Interior Light Switch 209 Parking Brake Warning (see note)
11 Trailer Hitch Diverter Valve Solenoid 66 Roof Wiper Motor and Switch 210 Air Filter Blocked Warning
12 Auxiliary Diverter Valve Solenoid 67 Rear Wiper Motor and Switch 211 Engine Oil Pressure Warning
13 Transmission Dump Relay 68 Beacon Switch 212 Transmission Temperature
Warning
15 Heater Switch 69 Beacon 213 Transmission Oil Pressure
Warning
16 Heater Resistor 71 Brake Switch 214 Water Temperature Warning
17 Heater Motor 83 Side Lights Relay 215 Alternator Warning
19 Trailer Hitch Selector Switch 86 Working Light Switch 216 Hitch Warning
20 Auxiliary Selector Switch 87 Road Light Switch 217 Interior Light
21 Auxiliary Relay 88 Headlamp Dip Switch 218 Beacon Warning
23 Horn Push 93 Headlamp Flasher 219 Roof Wiper Warning
24 Horn 99 Radio (optional) 220 L.H. Brake Lights
25 Wash/Wipe Switch 99A Machine 18 Pin Socket 221 R.H. Brake Lights
26 Front Wiper Motor 99B Radio 18 Pin Plug 225 Instrument Panel Illumination
27 Washer Pump 99C Aerial 226 L.H. Side Light
30 Hazard Switch 99D Speakers 227 R.H. Side Light
31 Indicator Relay 100 Roof Wiper Switch 228 Trailer
32 Indicator Switch 101 Brake Light Relay 229 Number Plate
34 Fuel Shut-off Solenoid 102 Hydraulic Low Pressure Switch 230 Working Light Warning
36 Reverse Alarm Relay (526-55 Only) 231 Cab Working Lights
37 Reverse Alarm 103 Front Proximity Switch (526-55 Only) 232 Headlamp Dip Beam
39 Forward/Reverse Switch 104 Rear Proximity Switch (526-55 Only) 233 Headlamp Main Beam
40 Neutral Start Relay 105 Face Level Fan (if fitted) 234 Headlamp Main Beam Warning
41 Parking Brake Warning Relay 235 Heater Switch Warning
42 Reverse Relay 236 Road Light Warning
43 Forward Relay 237 Inclinometer Light
44 Reverse Solenoid 238 Front Axle Alignment Indicator
45 Forward Solenoid 239 Rear Axle Alignment Indicator
46 Transmission Dump Switches
48 Trailer Socket
54 Hourmeter
Colour Code
B Black R Red
B/W Black/White S Slate
G Green W/K White/Pink
Note: On the 526-55 machines Warning lamp 209 also indicates Low Brake Pressure.
9804/1103 20 - 15 - 01/8 3610 - C/41-4.4 Issue 3*

CONTENTS
Loadalls 20 - 15 - 01/9
* 520-55 (from m/c no. 277536)

* 526-55 (to m/c no. 278965)
48 48 48
600 600
69 220 221 229 234

217 105
67
65 239 238 225 226 227 231 232 233
601AG
228
66 835 838
844 834 837 99D
816
- + - +
831
301
849
86
820 819 829 830
100 68 101
219 230
B S S S S W/K
B9 C1
218 855
B8 C2 18 17 14 13 8 7 3
99A
71 B6 B7
828 18 17 14 13 8 7 3
99B
833 836
83
B R
112 115
B/W
B
88 G S
99C
108
93
827
103 104
87 832 110
99
236
810
B3 B4 C3 C4 C5
810
000
001
200
102
829
103
A215630
9804/1103 3610- C/41-6.2 Issue 2*

20 - 15 - 01/9
CONTENTS
Loadalls 20 - 15 - 01/10

WIRING DIAGRAM (Powershift option)
Main Components Lamps

1 Neutral Drive Relay 13 Column Gear Selector 208 Reversing Lights
2 Forward Drive Relay 14 2 Wheel Drive Switch 220 L.H. Brake Light
3 Forward High/Low Relay 39 Forward/Reverse Selector Switch 221 R.H. Brake Light
4 Reverse High/Low Relay 40 Neutral Start Relay 219 2 Wheel Drive Warning
5 Driveshaft Relay 41 Parking Brake Warning Relay
6 Reverse Relay 46 Transmission Dump Relay
7 Layshaft Solenoid 47 Parking Brake Switch
8 Mainshaft Solenoid 71 Brake Switch
9 Reverse High Solenoid 71B Brake Switch Relay
10 Reverse Low Solenoid 73 2 Wheel Drive Solenoid
11 Forward High Solenoid 100 Transmission Dump Relay
8 10 12
7 9 11
221 37 208
858 860 859
46 47
220 73 219 857 811 812
5 4 3
807
815
C9
816 818
2
865 862
863
863
71B 862
6 1 41
40 871 852
39
810
107
852 401
71 14
100
2 3
1 4 107
B4 13 B1 B2
108
000
000R
200
004
A215210
842
9804/1103 20 - 15 - 01/10 Issue 1

CONTENTS
Loadalls 20 - 15 - 01/11
* WIRING DIAGRAM * WIRING DIAGRAM

(530-120 from serial No. 576404 & all 537-120/130) (All machines from serial No. 576404 except 530-120 &
537-120/130 machines)
Safe Load Indicator Circuit
Safe Load Indicator Circuit
9 Safe Load Indicator Readout Box
10 Transducer 9 Safe Load Indicator Readout Box
10 Rear SLI Boss
11 Front SLI Boss
600
600
11
9
N
G/Y
414A
414
413A
413
414B
413 413B
414
N G/Y
10
10
101
9
101
A2
A221890
A2
A215191
9804/1103 20 - 15 - 01/11 Issue 2*

CONTENTS
Loadalls 20 - 15 - 01/12
* 520-55, 520S (from m/c no. 278966)
* 526-55, 526S (526 N. Am) (from m/c no. 278966 to 280299)

1 Battery 44 Alternator * 100 Hitch/Aux. Warning Indicator

2 Battery Isolator 45 Warning Buzzer 101 Heater Indicator
3 Fuse Links 46 Tachometer 102 Trailer Direction Indicator
4 Starter Motor 47 Temperature Sender 103 Hazard Warning Indicator
6 Starter Switch 49 Fuel Sender 105 R.H. Indicators
7 Thermostart 50 Fuel Gauge 106 Direction Indicator
8 Starter Relay 51 Interior Light Switch * 107 Hazard Warning Indicator
9 Safe Load Indicator Readout Box 52 Roof Wiper Switch 108 Reversing Lights
10 Rear Axle Transducer 53 Roof Wiper Motor and Parking Switch 109 Accumulator Pressure Warning
11 Hitch/Auxiliary Selector Switch 54 Rear Wiper Motor and Switch (see note)
12 Hitch Diverter Valve Solenoid 55 Beacon Switch 110 Air Filter Blocked Warning
13 Auxiliary Circuit Selector Switch 56 Beacon 111 Engine Oil Pressure Warning
14 Auxiliary Diverter Valve Solenoid 57 Brake Switch 112 Transmission Temperature Warning
15 Heater Switch 58 Front Proximity Switch (526-55 Only) 113 Transmission Oil Pressure Warning
16 Heater Resistor 59 Rear Proximity Switch (526-55 Only) 114 Water Temperature Warning
17 Heater Motor 60 Horn Push 115 Alternator Warning
18 Wash/Wipe Switch 61 Horn 116 Interior Light
19 Washer Pump 62 Side Lights Relay 117 Roof Wiper Indicator
20 Front Wiper Motor 63 Working Light Switch 118 Beacon Indicator
21 Hazard Warning Switch 64 Road Light Switch 119 L.H. Brake Lights
22 Indicator Relay 65 Headlamp Dip Switch 120 R.H. Brake Lights
23 Trailer Socket 66 Headlamp Flasher 121 Front Axle Alignment Indicator
24 Indicator Switch 67 Radio (optional) 122 Rear Axle Alignment Indicator
25 Fuel Shut-off Solenoid * 68 N/A 123 Instrument Panel Illumination
26 Reverse Alarm * 69 N/A 124 L.H. Side Lights
27 Neutral Start Relay * 70 N\A 125 R.H. Side Lights
28 Forward/Reverse Switch * 71 N/A 126 Trailer Lights
29 Reverse Relay 72 Face Level Fan (optional) 127 Number Plate
30 Reverse Solenoid 73 Air Conditioning Compressor 128 Cab Working Lights
31 Transmission Dump Switches Clutch Relay (optional) 129 Working Light Indicator
32 Transmission Dump Relay 74 Air Conditioning Thermostat (optional) 130 Road Light Switch Indicator
33 Forward Relay 75 Air Conditioning Reciever Drier 131 Headlamp Dip Beam
34 Forward Solenoid Pressure Switch (optional) 132 Headlamp Main Beam
35 Parking Brake Switch 76 Air Conditioning Compressor 133 Headlamp Main Beam Warning
36 Parking Brake Warning Relay Clutch (optional)
* 37 Accumulator Pressure Switch (if fitted)
43 Hourmeter
Colour Code
B Black R Red
B/W Black/White S Slate
G Green W/K White/Pink
Note: On the 526-55 machines Warning lamp 109 also indicates Low Brake Pressure.
9804/1103 20 - 15 - 01/12 3610 - C/41-7.3 Issue 2*

CONTENTS
Loadalls 20 - 15 - 01/13
* 520-55, 520S (from m/c no. 278966)

* 526-55, 526S (526 N. Am) (from m/c no. 278966 to 280299)
23
601
600
12 14 17 19 26 108 35 37 38 40 42 43
102 103 30 34
104 105 25 39 41
4 7 20 44
850 851 839 400 805 806 105 807 811 812 815 200
402 403 404 405 406 407
27 29 33 36
10
2
414
106 A6
401
110 112 114
5 413
16 24
109 111 113 115
9 808 810 004 842 809 107
22
800 801 840 841 802 803 804
28
18 21
1 11 15 107 31
8 100 13 32
101
411
200 842 003 200 101 104 003 107
114 102
45
110
3
A1 B1 A9 B3 B5 C7 C6 A2 A4 B8
6
000R
001
810
200H
200G
829
100A
110
883
A248190
9804/1103 3610 - C/41-8.1 20 - 15 - 01/13 Issue 2*

CONTENTS
Loadalls 20 - 15 - 01/14
* 520-55, 520S (from m/c no. 278966)

* 526-55, 526S (526 N. Am) (from m/c no. 278966 to 280299)
23
600 600
116 127 133

61 123
54 119 120
412 48 50 56
51 124 125 126 128 131 132 72 76
814
46 53 829 830 831 834 834 838 838
75
67
409 408 301 849 854 844 816
52 55 129
63 74
117 118
47 49 60
C2 C1 C3 C4
112
121 122 828
57 833 836
62
108 819 820
66 73
58 59 65
827
832 115
103 829
106 810
130
B6 C5 B2 B7 B4
64
000R
102
810
200H
200G
829
100A
110
883
A248200
9804/1103 20 - 15 - 01/14 3610 - C/41-9.2 Issue 2*

CONTENTS
Loadalls 20 - 15 - 01/15
526-55, 526, 526 N.Am 526S From m/c no. 280300 to 280576
(fitted with Powershift ECU gearbox control)
Component Key
The complete electrical circuit is shown on pages 20-15-01/16

to 20-15-01/21. Fuses are numbered as shown on the fuse
box in the cab.
Component Key
Item Description
Page 20-15-01/16 53A L.H. Side Light - Front
1 Battery
2 Starter Motor 53B L.H. Indicator - Front
3 Starter Solenoid 54A L.H. Side Light - Rear
4 Fusible Links 1 54B L.H. Side Indicator - Rear
5 Thermostart 55A L.H. Dip Beam
6 Ignition Switch 55B L.H. Main Beam
7 Neutral Start Relay 56A R.H. Dip Beam
8 Fusible Link 2 56B R.H. Main Beam
9 Ignition Solenoid 56C R.H. Side Light - Front
10 Engine Shut Off Solenoid (ESOS) 56D R.H. Indicator - Front
11 Reverse Light 57 Column Switch
12 Reverse Alarm 57A Dip/Main Beam Switch
13 Reverse Light/Alarm Relay 57B Indicator Switch
14 Auxiliary Solenoid 57C Wiper Switch
15 Auxiliary Relay 57D Washer Switch
16 Hydraulic Hitch Solenoid 58 Washer Pump
Page 20-15-01/20
17 Hydraulic Hitch Switch 59 L.H. Brake Lights
18 Load Indicator Transducer 60 R.H. Brake Lights
19 Load Indicator 61 Brake Lights - Switch
Page 20-15-01/17
20 Heater Switch 62 Hazard Switch
21 Face Fan 63 Flasher Relay
23 Air Conditioning Compressor Clutch (if fitted) 64 Trailer Indicator - Cab Warning LIght
24 Air Conditioning Relay (if fitted) 65 Diode
25 Air Conditioning Switch (if fitted) 66A R.H. Indicator - Front
26 Heater Fan 66B R.H. Side Light
28 Receiver Drier Switch (if fitted) 67 Column Switch
29 Roof Wiper 67A Forward/Reverse Switch
30 Roof Wiper Switch 67B Transmission Switch
31 Front Wiper 67C Horn Switch
32 Rear Wiper 68 Horn
33 Interior Light 69 Park Brake Switch
34 Beacon Switch 70 Transmission ECU - Input Signal Connectors
35 Beacon 71 Transmission ECU - Output Signal
36 Radio Power Connectors
Page 20-15-01/18 Page 20-15-01/21
37 Buzzer 72 Transmission Oil Pressure Switch
38 Instrument Panel 73 Transmission ECU Test Point
39 Air Filter Switch 74 Speed Sensor
40 Engine Oil Pressure Switch 75 Mainshaft Solenoid
41 Transmission Oil Temperature Switch 76 Layshaft Solenoid
42 Water Temperature Switch 77 Forward High Solenoid
43 Alternator 78 Forward Low Solenoid
44 Fuel Sender 79 Reverse HI/LOW Relay
45 Water Temperature Sender 79 Reverse High Solenoid
46 Rear Axle Alignment Indicator Light 80 Reverse Low Solenoid
* 47 Front Axle Alignment Indicator Light 81A Work Light
48 Front Proximity Axle Switch 81B Work Light
49 Rear Proximity Axle Switch 84 Number Plate Light
50A Trailer Socket - L.H. Indicator Pin 85 Joy Stick Control (if fitted)
50B Trailer Socket - R.H. Indicator Pin 86 Diode Pack (if fitted)
50C Trailer Socket - Side Light Pin 87 Valve Block Solenoid (if fitted)
50D Trailer Socket - Brake Light Pin 88 Valve Block Solenoid (if fitted)
Page 20-15-01/19 89 Valve Block Solenoid (if fitted)
51 Side Lights Relay
52 Road Lights - Switch 90 Valve Block Solenoid (if fitted)
91 Joystick Isolation Switch (if fitted)
9804/1103 20 - 15 - 01/15 3610 - C/41-10.2 Issue 3*

CONTENTS
Loadalls 20 - 15 - 01/16
* 526-55, 526, 526S (526 N.Am) From m/c no. 280300 to 280576
1 -
+
3
5
6
7
4
8
FA1 9
10
FA2
FA3
FA4
FA5
13
11
FA6
FA7
12
FA8
15
14
FA9
16
17
18
19
FB1
FB2
A282270
9804/1103 20 - 15 - 01/16 3610 - C/41-11.1 Issue 2*

CONTENTS
Loadalls 20 - 15 - 01/17
* 526-55, 526, 526S (526 N.Am) From m/c no. 280300 to 280576
PHB3
20
21
PHB4
24
25
23
26
28
PHB5
30
29
31
32
33
PHB6
34
35
PHB6
36
A282280
9804/1103 20 - 15 - 01/17 3610 - C/41-12.1 Issue 2*

CONTENTS
Loadalls 20 - 15 - 01/18
* 526-55, 526, 526S (526 N.Am) From m/c no. 280300 to 280576
37
PHB8
38
39
40
41
42
43
44
45
46
47
48
49
A282290
9804/1103 20 - 15 - 01/18 3610 - C/41-13.1 Issue 2*

CONTENTS
Loadalls 20 - 15 - 01/19
* 526 55, 526, 526S (526 N.Am) From m/c no. 280300 to 280576
50A
50B
PHB9
PHC1
51
52
53A
PHC2
50C
53B
54A
54B
55A
PHC3
55B
56A
PHC4
56B
56C
56D
57
57A
57B
57C
57D
58
A282300
9804/1103 20 - 15 - 01/19 3610 - C/41-14.1 Issue 2*

CONTENTS
Loadalls 20 - 15 - 01/20
* 526-55, 526, 526S (526 N.Am) From m/c no. 280300 to 280576
50D
59
61
PHC5
60
PHC6
PHC7
62
63
PHC8
65
64
PHC9
66A
66B
67
67A
R
F
67B
67C
68
69
70
71
A282310
9804/1103 20 - 15 - 01/20 3610 - C1-15.1 Issue 2*

CONTENTS
Loadalls 20 - 15 - 01/21
* 526-55, 526, 526S (526N.Am) From m/c no. 280300 to 280576
72
73
74
75
76
77
78
79
80
81A
83
81B
84
86
85
87
88
89
A282320
90
91
9804/1103 20 - 15 - 01/21 3610 - C/41-16.1 Issue 2*

520-55, 526, 526S (from m/c no. 280300)
520-55 (From m/c no. 281847)
* (fitted with Syncro Shuttle Transmission)
Component Key
* Component Key
Sheet 1
Item Description
1 Battery isolator
2 Battery
3 Fuse links
4 Starter motor
5 Starter solenoid
6 Key switch
7 Thermostart
8 Neutral start relay
9 Fuse link
10 Ignition relay
11 Sender unit
11A Cold start advance unit (see Note 1)
12 Engine shut-off solenoid (ESOS)
13 Rear work light
14 Rear work light switch
15 Front work lights
16 Front worklights switch
17 Brake lights
18 Brake light switch
19 Trailer brake lights connector
20 Reverse alarm
21 Reverse light
22 Parkbrake switch
23 Parkbrake relay
24 Front axle alignment lamp
25 Front axle proximity switch
26 Rear axle alignment lamp
27 Rear axle proximity switch
28 Radio
29 Load Moment Indicator (LMI) transducer
30 Load Moment Indicator (LMI)
31 Instrument panel
32 Warning buzzer
34 Engine oil pressure switch
35 Transmission oil temperature switch
36 Transmission oil pressure switch
37 Water temperature switch
38 Fuel gauge sender
40 Alternator
Note 1: Cold start advance unit 11A is part of fuel injection

pump.
9804/1103 20 - 15 - 01/22 3610 - C/41-17.2 Issue 3*

Loadalls 20 - 15 - 01/23
526, 526S (from m/c no. 280300)
520-55 (From m/c no. 281847)
*
40
39
38
F10
F9
33 34 35 36 37
F8
F7
32
31
F6
29
30
28
F29
27
26
24
25
22
23
20 21
F17
19
18
F16
17
F20
16
F19
15
F18
13
14
F15
12 F12
11A
11
F11
10
9
CONTENTS
7
7
5
4
2
1
3
9804/1103 20 - 15 - 01/23 3610 - C/41-18.2 Issue 3*
Loadalls 20 - 15 - 01/24
526, 526S From m/c no. 280300
520-55 (From m/c no. 281847
79
F4
78
77
76
75
74
73
F2
71
72
F28
70
69
F1
67
68
66
F30
65
63
64
F5
62 61
F27
60
F26
F24
57 58
59
F25
55 56
F21
54
F23
53
52
51
50
49
48
47
44 46
F22
CONTENTS
45
43
42
41
9804/1103 20 - 15 - 01/24 3610 - C/41-19.2 Issue 3*
CONTENTS
Loadalls 20 - 15 - 01/25
526, 526S (From m/c no. 280300)

520-55 (From m/c no. 281847)
* Fuses are numbered as shown on the fuse box in the cab.
* Component Key
Sheet 2
Item Description
41 Rear indicator - right hand

42 Rear side light - right hand
43 Trailer light socket
44 Number plate light
45 Sidelights relay
46 Front side light - left hand
47 Front indicator - left hand
48 Rear side light - left hand
49 Rear indicators - left hand
50 Trailer side light connection - left hand
51 Road lights switch
52 Dip beam - left hand
53 Main beam - left hand
54 Dip beam - right hand
55 Main beam - right hand
56 Front side lights - right hand
57 Front indicators - right hand
58 Fog lamp
59 Fog light switch
60 Steering column switch - right hand
61 Trailer indicators
62 Wash pump
63 Roof wiper motor
64 Roof wiper switch
66 Rear wiper motor
67 Hazard warning lights switch
68 Flasher relay
69 Trailer indicator light
70 Interior light
71 Warning beacon
72 Warning beacon switch
73 Face level fan
74 Air conditioning compressor
76 Heater
77 Receiver dryer
78 Air conditioning switch
79 Heater switch
9804/1103 20 - 15 - 01/25 3610 - C/41-20.2 Issue 3*

CONTENTS
Loadalls 20 - 15 - 01/26
526, 526S (From m/c no. 280300)

520-55 (From m/c no. 281847)
* Fuses are numbered as shown on the fuse box in the cab.
* Component Key
Sheet 3
Item Description
80 Column switch - left hand

81 Horn
82 Forward solenoid
83 Forward relay
84 Reverse solenoid
85 Reverse relay
86 Second auxiliary solenoid
87 Second auxiliary relay
88 Transmission dump relay
89 Hitch solenoid
90 Hitch switch
91 Transmission dump switch (control lever)
92 Transmission dump switch (gear change lever)
Single lever control (SLC) option:
93 Extend solenoid
94 Auxiliary solenoid
95 Retract solenoid
96 Single lever control joystick
97 Diodes
98 Transmission dump switch (joystick)
100 Lever isolation switch & auxiliary solenoid
9804/1103 20 - 15 - 01/26 3610 - C/41-21.2 Issue 3*

CONTENTS
Loadalls 20 - 15 - 01/27
526, 526S (From m/c no. 280300)

520 - 55(From m/c no. 281847)
*
100
99 F14
98
95
94
96
97
93
SLC
92
91
90
89
88
87
F3
86
84
85
83
82
81
80
F13
9804/1103 20 - 15 - 01/27 3610 - C/41-21.2 Issue 3*

CONTENTS
Loadalls 20 - 15 - 01/29
526, 526S From m/c no. 280577

* (fitted
with Powershift Transmission)
* Component Key
Item Description
1 Battery isolator
2 Battery
3 Fuse links
4 Starter motor
5 Starter solenoid
6 Key switch
7 Thermostart
9 Ignition relay
10 Fuse link
11 Sender unit
13 Rear work light
17 Brake lights
20 Reverse alarm
21 Reverse light
22 Reverse 2 relay
23 Parkbrake switch
24 Parkbrake relay
29 Radio
32 Instrument panel
33 Warning buzzer
41 Alternator
Note 1: Cold start advance unit 11A is part of fuel injection

pump.
9804/1103 20 - 15 - 01/29 3610 - C/41-24.2 Issue 3*

CONTENTS
Loadalls 20 - 15 - 01/30
526, 526S From m/c no. 280577

* (fitted with Powershift Transmission)

*
41
39 40
F10
F9
34 35 36 37 38
F8
F7
33
32
31
30
29
F29
28
27
26
25
24
23
21
22
F17
20
19
18
F16
17
16
F20
F19
15
F18
13
F15
12
14
F12
11A
11
F11
10
8
7
6
5
4
1
9804/1103 20 - 15 - 01/30 3610 - C/41-23.2 Issue 3*

CONTENTS
Loadalls 20 - 15 - 01/31
526, 526S From m/c no. 280577

* Component Key
Sheet 2
Item Description

46 Sidelights relay
51 Trailer side light - left hand
59 Fog lamp
60 Foglight switch
61 Column switch - right hand
63 Wash pump
64 Roof wiper motor
67 Rear wiper motor
69 Flasher relay
71 Interior light
72 Warning beacon
74 Face level fan
77 Heater
78 Receiver dryer
80 Heater switch
9804/1103 20 - 15 - 01/31 3610 - C/41-25.2 Issue 3*

CONTENTS
Loadalls 20 - 15 - 01/32
526, 526S From m/c no. 280577


*
80
F4
79
78
77
75
76
74
F2
72
73
F28
71
70
F1
69
68
67
F30
66
65
64
F5
63
62
61
F27
F26
F24
59
60
F25
56 57 58
F21
55
F23
54
53
51
50
52
49
48
47
F22
45
46
44
43
42
9804/1103 20 - 15 - 01/32 3610 - C/41-26.2 Issue 3*

CONTENTS
Loadalls 20 - 15 - 01/33
526, 526S From m/c no. 280577


* Component Key
Sheet 3
Item Description

82 Horn
83 Reverse low solenoid
84 Reverse high solenoid
85 Reverse high/low relay
86 Diodes
87 Reverse relay
88 Forward solenoid
89 Forward high solenoid
90 Forward low solenoid
91 Forward high/low solenoid
92 Drive interlock
93 Driveshaft relay
94 Layshaft solenoid
95 Mainshaft solenoid
99 Hitch solenoid
100 Hitch switch
102 Extend solenoid

104 Retract solenoid
107 Diodes
109 Single lever control isolation switch and
auxiliary solenoid
9804/1103 20 - 15 - 01/33 3610 - C/41-28.2 Issue 3*

CONTENTS
Loadalls 20 - 15 - 01/34
526, 526S From m/c no. 280577

*
109
108
F14
106
104
103
105
107
102
SLC
101
100
99
98
97
96
F3
95
93
94
92
90
91
89
88
87
86
84
85
83
82
81
F13
9804/1103 20 - 15 - 01/34 3610 - C/41-27.2 Issue 3*

CONTENTS
Loadalls 20 - 15 - 01/35
* 526, 526S (526 N.Am) * From m/c no. 280577
(fitted with Powershift Gearbox)
14E
14F
72
73
74
75
76
77
78
22
79
79A
80
81
A282250
9804/1103 20 - 15 - 01/35 3610 - C/41-30.1 Issue 2*

CONTENTS
Loadalls 20 - 15 - 01/36
* 526, 526S (526 N, Am) * From m/c no. 280577
(fitted with Powershift Gearbox)
83 84 86 87
82 82A 85 85A
A282260
9804/1103 20 - 15 - 01/36 3610 - C/41-31.1 Issue 2*

CONTENTS
Loadalls 20 - 15 - 01/37
528-70 From m/c no. 796000

With Syncro Shuttle Transmission
Component Key 1
The complete electrical circuit is shown on pages 20-15-01/38 and 20-15-01/39. Fuses are numbered as shown on the fuse
box in the cab.
Item Description
1 Fuse links
2 Battery
3 Battery isolator
4 Starter motor solenoid
5 Starter motor
6 Ignition switch
7 Thermostart
8 Ignition relay
9 Safe Load Indicator (SLI)
10 Auxiliary change-over switch
10A Auxiliary solenoid
11 Face level fan
12 Heater switch
13 Heater motor
14 Hazard warning light switch
15 Indicator relay
16 Left hand indicators
17 Indicator switch
18 Indicator warning lamp
9804/1103 20 - 15 - 01/37 3650 - C/41-1.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 01/38
528-70 To m/c no. 796000

with Syncro Shuttle Transmission
11 13 16 19 20 22 23 27 29 31
10A 21
5 7
3
26 28 30
18
F17
9 25
15 17
4
14 24
2 12
8 10
1 32
F10
F11
F30
F12
F13
F7
F1
F3
F2
F4
9804/1103 20 - 15 - 01/38 3650- C/41-2.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 01/39
528-70 From m/c no. 796000

54 55 57 62 65 66 67 68 70 71 73 76
59
35 36 37 38 39 41 42 52
43 48 49
50 56
45
F23
F21
F24
F22
47
Water Gauge
Fuel Gauge
Handbrake
64
F25
Hourmeter
33
Tacho
46
72 75
63
51
44 58
53
61 69 74
60
34
40
F18
F14
F19
F20
F29
F28
F26
F27
F8
F6
9804/1103 20 - 15 - 01 /39 3650- C/41-3.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 01/40
528-70 From m/c no. 796000

Component Key 2
The complete electrical circuit is shown on pages 20-15-01/38 and 20-15-01/39. Fuses are numbered as shown on the fuse
box in the cab.
Item Description
33 Instrument panel
34 Buzzer
35 Air filter switch
36 Oil pressure switch
40 Alternator
42 Fuel sender
43 Washer pump
44 Wash/wipe switch
45 Front wiper
46 Roof wiper warning lamp
47 Roof wiper
48 Rear wiper
49 Radio
50 Interior light
51 Rotating beacon switch
52 Rotating beacon
54 Left hand brake light
55 Right hand brake light
56 Fog light switch
57 Fog light
58 Horn push
59 Horn
60 Main beam flash
61 Main lights relay
62 Dip beam
64 Dip beam switch
65 Main beam
66 Main bean warning lamp
67 Instrument panel illumination
68 Left hand side lights
69 Front worklight relay
70 Right hand side lights
72 Front work light switch and warning lamp
74 Rear work light relay
75 Rear work light switch and warning lamp
76 Rear worklight
9804/1103 20 - 15 - 01/40 3650 - C/41-4.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 01/41
528S From m/c no. 796102

With Powershift Transmission
Component Key 1
The complete electrical circuit is shown on pages 20-15-01/42, 20-15-01/43 and 20-15-01/46. Fuses are numbered as shown on
the fuse box in the cab.
Item Description
1 Battery isolator
2 Battery
3 Fuse links
4 Starter motor
5 Starter solenoid
6 Key switch
7 Thermostart
9 Ignition relay
10 Fuse link
11 Sender unit
13 Rear work light
17 Brake lights
20 Reverse alarm
21 Reverse light
22 Reverse 2 relay
23 Parkbrake switch
24 Parkbrake relay
29 Radio
32 Instrument panel
33 Warning buzzer
41 Alternator
Note 1: Cold start advance unit 11A is part of fuel injection pump.
9804/1103 20 - 15 - 01/41 3650 - C/41-5.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 01/42
528S From m/c no. 796102

with Powershift Transmission
11A 12 15 17
4 21 23 25 27 34 35 36 37 38 39 40
19
1 7 31
11 13 20
29
5 14 16 18 22 24 26
2 8 9 30
28 32 41
33
F11
3 10
F16
F19
F20
F8
F9
F12
F17
F10
F15
F18
F29
F7
9804/1103 20 - 15 - 01/42 3650 - C/41-6.1 Issue 1
20 - 15 - 01/43
CONTENTS
Loadalls
528S From m/c no. 796102
Circuit Diagrams-Electrical cont’d
78
42 47 49 53 55 64 66 67 74 75
44 59 62 63 70
51
69 77
43 45 48 50 54 56 57 58 72
71
46 60 61 65 68 73 76 79
52
80
F26
F27
F30
F28
F22
F23
F21
F25
F24
F5
F1
F2
F4
9804/1103 20 - 15 - 01/43 3650 - C/41-7.1 Issue 1
CONTENTS
Loadalls 20 - 15 - 01/44
528S From m/c no. 796102

Component Key 2
The complete electrical circuit is shown on pages 20-15-01/42, 20-15-01/43 and 20-15-01/46. Fuses are numbered as shown
on the fuse boxc in the cab.
Item Description

46 Sidelights relay
51 Trailer side light - left hand
59 Fog lamp
60 Foglight switch
61 Column switch - right hand
63 Wash pump
64 Roof wiper motor
67 Rear wiper motor
69 Flasher relay
71 Interior light
72 Warning beacon
74 Face level fan
77 Heater
78 Receiver dryer
80 Heater switch
9804/1103 20 - 15 - 01/44 3650 - C/41-8.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 01/45
528S From m/c no. 796102

Circuit Diagram- Electrical (cont’d)
Component Key 3
on the fuse boxc in the cab.
Item Description

82 Horn
85 Reverse high/low relay
86 Diodes
87 Reverse relay
88 Forward solenoid
91 Forward high/low solenoid
92 Drive interlock
93 Driveshaft relay
99 Hitch solenoid
100 Hitch switch
102 Extend solenoid

107 Diodes
109 Single lever control isolation switch and
auxiliary solenoid
9804/1103 20 - 15 - 01/45 3650 - C/41-9.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 01/46
528S From m/c no. 796102

with Powershift Transmission
SLC
83 89 94
96
82 84 90 99 102 103 104 108
95
101
109
81 86
88 91 97 98 100 105 106
85 87
92 93
107
F13
F14
F3
9804/1103 20 - 15 - 01/46 3650 - C/41-10.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 01/47
528S From m/c no. 796102

11A 15 17
12
4 13 19 20 21 22 24 26 33 34 35 36 37 38
1 7 29 39
11
28
5 10 14 25
18
2 23 30
40
8 16 27 31
32
F11
3 9
7
F19
F20
F10
F18
F8
F9
F16
F17
F29
F12
F15
F6
F7
9804/1103 3650 - C/41-11.1 Issue 1
20 - 15 - 01/47
CONTENTS
Loadalls 20 - 15 - 01/48
528S From m/c no. 796102

Component Key 1
on the fuse box in the cab.
Item Description
1 Battery isolator
2 Battery
3 Fuse links
4 Starter motor
5 Starter solenoid
6 Key switch
7 Thermostart
9 Fuse link
10 Ignition relay
11 Sender unit
13 Rear work light
17 Brake lights
20 Reverse alarm
21 Reverse light
22 Parkbrake switch
23 Parkbrake relay
28 Radio
31 Instrument panel
32 Warning buzzer
40 Alternator
Note 1: Cold start advance unit 11A is part of fuel injection pump.
9804/1103 20 - 15 - 01/48 3650 - C/41-12.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 01/49
528S From m/c no. 796102

Component Key 2
Item Description

45 Sidelights relay
50 Trailer side light connection - left hand
58 Fog lamp
59 Fog light switch
60 Steering column switch - right hand
62 Wash pump
63 Roof wiper motor
66 Rear wiper motor
68 Flasher relay
70 Interior light
71 Warning beacon
73 Face level fan
76 Heater
77 Receiver dryer
79 Heater switch
9804/1103 20 - 15 - 01/49 3650 - C/41-13.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 01/50
528S From m/c no. 796102

77
42 47 53 55 56
41 49 54 63 65 66 73
44 46 48 52 57 58 62 69 74
43 50 61
68 76
71
70
45 51 59 60 64 67 72 75 78 79
F27
F24
F30
F26
F21
F25
F23
F28
F22
F2
F5
F1
F4
9804/1103 20 - 15 - 01/50 3650 - C/41-14.1 Issue 1
CONTENTS
Loadalls 20 - 15 - 01/51
528S From m/c no. 796102

SLC
82 84 86 89 93 94 95 99
81
91
80 100
92
83 85 87 88 90 96 98
97
F13
F14
F3
9804/1103 20 - 15 - 01/51 3650 - C/41-15.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 01/52
528S From m/c no. 796102

Component Key 3
Item Description

81 Horn
82 Forward solenoid
83 Forward relay
84 Reverse solenoid
85 Reverse relay
89 Hitch solenoid
90 Hitch switch
92 Transmission dump switch (gear change lever)
93 Extend solenoid
95 Retract solenoid
97 Diodes
100 Lever isolation switch & auxiliary solenoid
9804/1103 20 - 15 - 01/52 3650 - C/41-16.1 Issue 1

530 From m/c no. 767001 to 768836

Without Neutral Start Relay
48
601
601
601
601
600
600
601
600
601
600
601
601
601
601
600
601
601
600
601
601
601
600
601
600
600
600
600
411
856
400
856
58
825
601
601
601
601
12 14 18 32 60
840
47
600
601
601
45
43
24 27 M
50
601
601
37 65
841
66
848
883
885
5 61
800
59
7 801
64
820
2 M 39 M 41
824
826
8 44 57
52
17
33 56
6 23 26
901
1 16 42
105
109
28 M 49
55
100
1 2 3
926
925
911
854
120
917
9 51
106
104
15 M 38
600
(SLC)
31 34
21
22 25
102
120
884
003
4
851
829
F1 F7 F8 F9 F11 F12
115
F5 F6
101
120
F2 F3 F4
004
3 000 000 F13

M 200 200
001
+++
414
914
19
29 30 46 54
601
853
413
36 35 40 1 2 3 4 5 6 7 8
11 53 62
886
20
819
1
Z
2
13 823 3
X
Y
10 907
4
W X Y Z
822 5
821 6 63
9804/1103 20 - 15 - 02/1 3630

3630 - C/26-1.5
- C/25-1.1 Issue 1
530 From m/c no. 767001 to 768836

Component Key 1
To check if a neutral start relay is fitted, try starting the engine with the transmission in gear.
The complete electrical circuit is shown on pages 20 - 15 - 02/1 and 20 - 15 - 02/4
Key
1 Battery 59 Four-wheel/crab steer solenoid

2 Battery isolator 60 Four wheel steer solenoid
3 Starter motor 61 Crab steer solenoid
4 Ignition switch 62 Steer Mode Control Unit
5 Starting aid W Four-wheel/crab steer relay
6 Auto relay X Two wheel steer relay
7 High Speed Control relay Y Crab steer relay
8 Pump dump switch Z Four wheel steer relay
9 Single lever control 63 Steer mode switch
10 Sway isolation relay X Two wheel steer select
11 Sway/Auxiliary change-over Y Crab steer select
12 Auxiliary change-over valve 1 Z Four wheel steer select
13 Sway isolation switch 64 Front sensor
14 Auxiliary A solenoid 65 Rear sensor
15 Auxiliary A/B switch 66 Instrument panel
16 Auxiliary B relay
17 Auxiliary A relay
18 Auxiliary B solenoid Steer Sensor Wiring:
19 Auxiliary change-over switch
20 Auxiliary change-over relay Terminal Wire Code Wire Colour Description
21 Auxiliary change-over valve 2 1 820 or 819 Black Signal
22 Boom extend switch 2 600 or 601 Blue Earth
23 Extend relay 3 810 or 109 Brown Feed
24 Extend solenoid
25 Boom retract switch
26 Retract relay
27 Retract solenoid
28 Transmission dump switch
30 SLI transducer
31 Heater/air conditioning fan
32 Heater/air conditioning unit
34 Face level fan
37 Binary Switch
38 Rear wiper switch
39 Rear wiper motor
41 Roof wash pump
42 Roof wiper
43 Front wiper
44 Radio/cassette
45 Heater seat
46 Digital clock
47 Warning buzzer
49 Hazard switch
50 Indicator relay
51 Hazard diode
52 Interior light
54 Rotating beacon
55 Primary fuse
56 Ignition relay
57 ESOS
58 Two wheel steer solenoid
9804/1103 20 - 15 - 02/02 3630 - C/25-2.4 Issue 1

530 From m/c no. 767001 to 768836

Component Key 2
The complete electrical circuit is shown on pages 20 - 15 - 02/1 and 20 - 15 - 002/4.

70 Transmission oil temp switch
72 Alternator
73 Fuel sender
75 Steering column switch
76 Horn
77 Reverse relay
78 Powershift control unit
79 Park brake
80 Four wheel brake relay
81 Foot brake
82 Two wheel drive switch
83 Brakelights
84 Brakelights
85 Trailer rear
86 Reverse alarm
87 Auxiliary power socket
88 Rear worklight switch
89 Rear worklight
90 Sidelight relay
91 Main light switch
92 Primary fuse
93 Right hand sidelights
94 Trailer rear
95 Left hand sidelights
96 Trailer rear
97 Left hand worklights
98 Front worklight switch
99 Right hand worklights
100 Right hand dip beam
101 Left hand dip beam
102 Right hand main beam
103 Left hand main beam
104 Rear foglight switch
105 Trailer rear
107 Screen wash pump
108 Right hand indicators
109 Trailer rear
111 Trailer rear
Note: Powershift control unit (78) only shows input

connections from the mainframe harness.
Refer to the ECU fault finding information in this section for

control unit output connections.
9804/1103 20 - 15 - 02/3 3630 - C/25-3.4 Issue 1

20 - 15 - 02/4
CONTENTS Loadalls
530 To m/c no. 767001 to 768836
600
601
304
81
832
600
601
600
601
71
841
69 76 833
72 77 840
84 97
827
68 70 G 105
91
80
450
83 89
808
79 94 101 109
99
898
873
871
75 85 86
9 15 16 1 13 87 92 100 108
10 7 96
831
106
200
74 2
4 5
88 90 98 104
3
17 18 12 6 82
78 95
103
118
119
108
123
73 93
102 107 111
304
110
304
806
805
838
301
840
841
110
832
F18
F30
F16
F14
838
836
F28
F24
F25
F26
F21 F22 F23
F29
874
F19
F17
F15
A313920
9804/1103 20 - 15 - 02/4 3630

3630
- C/25-4.5
- C/26-1.5 Issue 1
20 - 15 - 02/5
CONTENTS Loadalls
530 From m/c to 768837 to 770053
With Neutral Start Relay and ECU Controlled Transmission
49
601
601
601
600
600
601
600
600
601
600
601
601
601
601
601
601
600
601
601
601
600
600
601
600
600
600
600
411
856
17
400
856
59
825
601
601
601
601
19 33 61
840
48
14
600
601
601
46
44
25 28 M
51
601
601
38 66
841
67
848
883
6 62
800
60
8 801
65
820
2 M 40 M 42
824
826
925
9 45 58
53
16
34 57
7 24 27
901
1 18 43
105
109
29 M 50
926
56
100
1 2 3
901
911
854
120
917
10 52
39
106
104
15 M
600
(SLC)
32 35
22
003
23 26
102
5
120
884
851
810
004
F1
F11
F7
F8
F9
F12
301
F5
F6
115
F2
F3
F4
101
120
874
F13
3
M 200 200
+++
414
842
20
30 31 47 55
4 601
853
413
37 36 41 1 2 3 4 5 6 7 8
12 54 63
886
21
819
1
Z
2
13 823 3
X
Y
11 907
4
W X Y Z
822 5
821 6 64
A313890
9804/1103 20 - 15 - 02/5 3630 - C/26-1.5 Issue 1

530 From m/c no. 768837 to 770053

with Neutral Start Relay and ECU Controlled Transmission
Component Key 1
The complete electrical circuit is shown on pages 20-15-02/5 and 20-15-02/8
1 Battery 58 Engine Shut-Off Solenoid

2 Battery isolator 59 Two wheel steer solenoid
3 Starter motor 60 Four-wheel/crab steer solenoid
4 Neutral start 61 Four wheel steer solenoid
5 Ignition switch 62 Crab steer solenoid
6 Starting aid 63 Steer Mode Control Unit
7 Auto relay W Four-wheel/crab steer relay
8 High Speed Control relay X Two wheel steer relay
9 Pump dump switch Y Crab steer relay
10 Single lever control Z Four wheel steer relay
11 Sway isolation relay 64 Steer mode switch
12 Sway/Aux change-over X Two wheel steer select
13 Sway isolation switch Y Crab steer select
15 Auxiliary A/B switch 65 Front sensor
16 Auxiliary A relay 66 Rear sensor
17 Auxiliary A solenoid 67 Instrument panel
19 Auxiliary B solenoid
20 Auxiliary change-over switch Steer Sensor Wiring:
21 Auxiliary change-over relay
22 Auxiliary change-over valve 2 Terminal Wire Code Wire Colour Description
23 Boom extend switch 1 820 or 819 Black Signal
24 Extend relay 2 600 or 601 Blue Earth
25 Extend solenoid 3 810 or 109 Brown Feed
27 Retract relay
28 Retract solenoid
31 SLI Transducer
33 Air conditioning unit
35 Face level fan
38 Binary switch
40 Rear wiper motor
42 Roof wash pump
43 Roof wiper
44 Front wiper
45 Radio/cassette
46 Heated seat
47 Digital clock
48 Warning buzzer
50 Hazard switch
51 Indicator relay
52 Hazard diode
53 Interior light
55 Rotating beacon
56 Primary fuse
57 Ignition relay
9804/1103 20 - 15 - 02/6 3630 - C/26-2.4 Issue 1

530 From m/c no. 768837 to 770053

Component Key 2
The complete electrical circuit is shown on pages 20-15-02/5 and 20-15-02/8.

73 Alternator
74 Fuel sender
77 Horn
78 Reverse relay
80 Parkbrake
82 Four wheel drive brake switch
83 Foot brake
84 Brakelights
85 Brakelights
86 Trailer rear
87 Reverse alarm
90 Rear worklights
91 Sidelight relay
93 Primary fuse
94 Right hand Sidelights
95 Trailer rear
96 Left hand sidelights
97 Trailer rear
106 Trailer rear
108 Front wash/wipe motor
110 Trailer rear
112 Trailer rear
Note: Powershift control unit (79) only shows input connections from the mainframe harness.
Refer to the ECU fault finding information in this section for control unit output connections.
9804/1103 20 - 15 - 02/7 3630 - C/26-3.3 Issue 1

20 - 15 - 02/8
CONTENTS Loadalls
530 From m/c no 768837 to 770053
With Neutral Start Relay and ECU Controlled Transmission
803
600
601
304
83
832
600
601
600
601
72
841
70 73 77 833
78 99
840
85
827
69 71 G 106
92
300
82
450
84 90
808
80 95 102 110
100
898
873
871
76 86 87
9 15 16 1 13 88 93 101 109
10 7 97
831
107
200
75 2
4 5
89 91 98 105
3
17 18 12 6 81
79 96
104
118
119
108
123
72 94
103 108 112
304
124
111
803
100
401
806
805
838
301
840
841
110
829 832
810
F18
F30
F16
F14
F21
F22
F28
F23
F24
F25
F26
836
F29
874
F17
F19
F15
A313900
9804/1103 20 - 15 - 02/8 3630 - C/26-4.4 Issue 1

20 - 15 - 02/9
CONTENTS Loadalls
530 From m/c no. 770054 to 770958
with Relay Controlled Transmission, ECU not fitted
47
601
601
601
601
601
601
600
601
601
601
600
601
601
600
601
600
601
600
601
601
600
600
600
600
411
601
601
601
400
57
825
601
601
601
601
6 59
840
46
600
601
601
44
13 42
24 27 M
49
32
601
601
64
003
36 60
841
16 18 65
848
883
003
800
58
801
5 63
820
12 17 (PP) M 38 M 40
824
826
925
8 43 56
51
31 55
004
7 23 26
901
200
41
105
109
4 48
M
54
100
926
15 1 2 3
901
11
854
50
37
106
104
M
600
14
9 30 33
20
22 25
102
840
2 884 841
110
851
829
810
810
F11
F12
F8
F9
F7
F5
F6
115
101
F4
F2
F3
120
120
F1
874
F13
842
000 000
200 200
3 001
M
414
21
28 29 45 53
601
853
+++
413
10 35 34 39 1 2 3 4 5 6 7 8
301
52 61
886
19
917
819
1
Z
2
823 3
X
4
Y
W X Y Z
822 5
821 6 62
A313870
9804/1103 20 - 15 - 02/9 3630 - C/27-1.5 Issue 1

530 From m/c no. 770054 to 770958

Component Key 1
1 Battery 58 Four-wheel/crab steer solenoid

2 Battery isolator 59 Four wheel steer solenoid
3 Starter motor
4 Neutral start relay 60 Crab steer solenoid
5 Ignition switch 61 Steer Mode Control Unit
6 Starting aid W Four-wheel/crab steer relay
7 not used X Two wheel steer relay
8 High Speed Control relay Y Crab steer relay
9 Ppump dump switch Z Four wheel steer relay
10 not used 62 Steer mode switch
11 Sway/Auxiliary change-over X Two wheel steer select
12 Auxiliary A relay Y Crab steer select
13 Auxiliary A solenoid Z Four wheel steer select
14 Auxiliary A/B switch 63 Front sensor
15 Auxiliary B relay 64 Rear sensor
16 Auxiliary B solenoid 65 Instrument panel
17 Auxiliary change-over relay 2
18 Auxiliary change-over valve 1
19 Auxiliary change-over relay Steer Sensor Wiring:
21 Auxiliary change-over switch Terminal Wire Code Wire Colour Description
22 Boom extend switch 1 820 or 819 Black Signal
23 Extend relay 2 600 or 601 Blue Earth
24 Extend solenoid 3 810 or 109 Brown Feed
26 Retract relay
27 Retract solenoid
29 SLI transducer
33 Face level fan
36 Binary switch (air con)
38 Rear wiper motor
40 Roof wash pump
41 Roof wiper
42 Front wiper
43 Radio/cassette
44 Heated seat
45 Digital clock
46 Warning buzzer
48 Hazard switch
49 Indicator relay
50 Hazard diode
51 Interior light
53 Rotating beacon
54 Primary fuse
55 Ignition relay
56 Engine Shut-Off Solenoid
9804/1103 20 - 15 - 02/10 3630 - C/27-2.4 Issue 1

530 From m/c no. 770054 to 770958

Component Key 2
71 Alternator
72 Fuel sender
75 Horn
76 Reverse relay 2
77 Ignition relay 2
79 Pump dump relay
80 Reverse 1 relay
81 Forward relay
82 Drive relay
83 Parkbrake relay
84 Reverse HI/LOW relay
87 Forward HI/LOW relay
90 Driveshaft relay
93 Two/four wheel drive solenoid
95 Parkbrake switch
96 Footbrake switch
97 Four wheel drive brake relay
99 Brakelights
100 Brakelights
101 Trailer rear
102 Reverse alarm
105 Rear worklight
106 Sidelight relay
108 Primary fuse
109 Right hand sidelight
110 Trailer rear
111 Left hand sidelight
112 Trailer rear
113 Front work light switch
114 Left hand work lights
115 Right hand work lights
120 Rear fog light switch
121 Rear fog light
125 Trailer rear
127 Trailer rear
9804/1103 20 - 15 - 02/11 3630 - C/27-3.4 Issue 1

20 - 15 - 02/12
CONTENTS Loadalls
530 From m/c 770054 to 770958
803
601
601
601
601
600
600
601
601
600
601
600
809
300
600
601
601
600
856
807
73 85 96
89
70
67 68 114
827
72
808
107 121
100
601
811
600
80 94
450
859
863
69 76 97
808 81 84 86 110 117
88 99 105 115
600
108
871
112
200
91
812
82 87 116
852
601
600
104 113 120
601
600
874 93
71 861
92
78 108
857
127
G 90 111 119
601
600
98 106
79 103
119
75 890
872
109
118
125
126
83 601
815
124
304
124
807
118
401
806
805
838
301
840
841
110
F28
601
F30
95 101 102
107
F18
F16
F21
F22
F23
F24
F25
F29
F26
77
815
F17
F19
F15
827
123
3 SPEED
ONLY
809
839
122
74
107
A313880
9804/1103 20 - 15 - 02/12 3630 - C/27-4.4 Issue 1

20 - 15 - 02/13
CONTENTS Loadalls
530, 540 Sway Machines From m/c no. 770959
601
601
601
601
601
601
600
600
600
601
600
600
600
600
600
600
600
601
601
601
44
601
601
601
11 23
411
400
5 55
29 825
20
601
601
601
601
15 57
840
43
600
601
601
7 41
851
13 18 39
801
800
M
46
601
601
33 58 62
841
63
24
848
853
4 56
883
61
820
M 35 M
824
826
37
925
932
40 54
48
004
935
28
200
934
53
931
901
6
17 21 38
105
109
882 M 45
933
51 52
100
926
1 2 3
901
12 14 19 22
854
47
34
106
27 M
810
850
120
30
102
2 9
301
884 840
841
451
114
16 110
829 829
810 810
F11
F12
10
F7
F8
F9
1
F5
F6
F10
115
101
F3
F4
F1
F13
F2
842
874 874
000
3 200 200
001
M +++
414
26 25 42 50
601
413
301
+++
8 32 31 36 1 2 3 4 5 6 7 8
49 59
886
819
1
Z
2
823 3
X
4
Y
W X Y Z
822 5
821 6 60
A314050
9804/1103 20 - 15 - 02/13 3630 - C/28-1.5 Issue 1


Component Key 1
The complete electrical circuit is shown on pages 20-15-02/13 and 20-15-02/16
1 Battery
2 Battery isolator
3 Starter motor 59 Steer Mode Control Unit
4 Ignition switch W Four-wheel/crab steer relay
5 Starting aid X Two wheel steer relay
6 Neutral start relay Y Crab steer relay
7 not used Z Four wheel steer relay
8 HSC pump dump switch 60 Steer mode switch
9 Auxiliary change-over valve 2 X Two wheel steer select
10 Sway/Auxiliary change-over switch Y Crab steer select
12 Auxiliary A switch 61 Front sensor
13 Auxiliary A solenoid 62 Rear sensor
14 Auxiliary B switch 63 Instrument panel
16 Joystick isolation switch
17 Single lever control - extend Steer Sensor Wiring:
18 Extend solenoid
19 Single lever control - retract Terminal Wire Code Wire Colour Description
20 Retract solenoid 1 820 or 819 Black Signal
21 Auxiliary 2 A switch 2 600 or 601 Blue Earth
22 Auxiliary 2 B switch 3 810 or 109 Brown Feed
24 Auxiliary change-over relay
26 SLI transducer
30 Face level fan
33 Binary switch (air conditioning)
35 Rear wiper motor
37 Roof wash pump
38 Roof wiper
39 Front wiper
40 Radio/cassette
41 Heated seat
42 Digital clock
43 Warning buzzer
45 Hazard switch
46 Indicator relay
47 Hazard diode
48 Interior light
50 Rotating beacon
51 Primary fuse
52 Primary fuse
53 Ignition relay
56 Four-wheel/crab steer solenoid
57 Four wheel steer solenoid
58 Crab steer solenoid
9804/1103 20 - 15 - 02/14 3630 - C/28-2.3 Issue 1


circuit Diagram - Electrical (cont’d)
Component Key 2
Component Key
65 Air filter blocked switch 125 Left hand indicators

66 Engine oil pressure switch 126 Trailer rear
69 Alternator
70 Fuel sender
73 Horn
74 Reverse relay 2
75 Ignition relay 2
78 Reverse 1 relay
79 Forward relay
80 Drive relay
81 Parkbrake relay
88 Driveshaft relay
91 Two/Four wheel drive solenoid
93 Parkbrake
95 Footbrake
97 Brakelights
98 Brakelights
99 Trailer rear
100 Reverse alarm
103 Rear worklight
104 Sidelight relay
105 Primary fuse 3
107 Primary fuse 2
109 Trailer rear
111 Trailer rear
120 Trailer rear
124 Trailer rear
9804/1103 20 - 15 - 02/15 3630 - C/28-3.4 Issue 2*

20 - 15 - 02/16
CONTENTS Loadalls
601
601
601
601
600
600
601
601
600
601
600
809
601
601
601
601
807
600
601
600
601
601
601
601
600
600
300
71 83 95
807
601
601
600
87
66 68 113
827
70
808
106 120
118
65 98
601
811
600
78 92
863
450
859
67 74 94
808 79 82 85 109 116
86 97 103 114
600
871
111
200
816
601
89
812
80 84 115
600
102 112 119
601
600
874 91
101
852
69 861
90
76 107
110
857
126
G 88 118
601
600
96
200
104
77
119
73 890
872
858
117
124
125
81 601 108
815
105
123
304
124
100
118
108
401
806
805
838
301
840
841
110
829
F28
F30
601
93 99 100
809
107
F18
F31
F32
F33
F34
F35
F16
F21
F22
F23
F24
F25
807
F29
F26
75
815
F17
F19
F15
122
3 SPEED
ONLY
121
839
832
72
F14
107
A314060
9804/1103 20 - 15 - 02/16 3630 - C/28-4.4 Issue 1

530, 540 Non-Sway Machines From m/c no. 770959

601
601
601
601
601
601
600
600
600
601
600
600
600
600
600
601
601
600
601
601
44
601
601
601
20 23
411
400
5 55
28 825
17
601
601
601
601
12 57
840
43
600
601
601
41
851
7 10 39
801
800
M
46
601
601
15 33 58 62
841
63
19
848
932
931
853
4 56
883
61
820
M 35 M
824
826
37
925
932
40 54
48
004
27
934
200
53
931
901
6
14 18 38
105
109
882
M 45
933
51 52
100
926
1 2 3
901
9 11 16 21
854
(DR) 47
34
106
26 M
810
120
30
102
2 301
884 840
841
451
13 22 110
829 829
810 810
114
F11
F12
F7
F8
F9
1
F5
F6
F10
115
101
F3
F4
F1
F13
F2
842
874 874
000
3 200 200
001
M +++
414
25 24 42 50
601
413
8 32 301
+++ 31 36 1 2 3 4 5 6 7 8
49 59
886
819
1
Z
2
823
X
3
4
Y
W X Y Z
822 5
821 6 60
A314070
9804/1103 20 - 15 - 02/17 3630

3630 - C/26-1.5
- C/29-1.3 Issue 1
CONTENTS
Loadalls 20 - 15 - 02/18

Component Key 1
1 Battery
2 Battery isolator
3 Starter motor 59 Steer Mode Control Unit
4 Ignition switch W Four-wheel/crab steer relay
5 Starting aid X Two wheel steer relay
7 not used Z Four wheel steer relay
8 Pump dump switch 60 Steer mode switch
9 Auxiliary A switch X Two wheel steer select
10 Auxiliary A solenoid Y Crab steer select
11 Auxiliary B switch Z Four wheel steer select
12 Auxiliary B solenoid 61 Front sensor
13 Joystick isolation switch 62 Rear sensor
14 Boom extend switch 63 Instrument panel
15 Extend solenoid
17 Retract solenoid Steer Sensor Wiring:
18 Auxiliary 2 A switch
19 Auxiliary change-over relay Terminal Wire Code Wire Colour Description
20 Auxiliary change-over valve 2 1 820 or 819 Black Signal
21 Auxiliary 2 B switch 2 600 or 601 Blue Earth
22 Stabilizer isolation switch 3 810 or 109 Brown Feed
25 SLI transducer
29 N/A
30 Face level fan
35 Rear wiper motor
37 Roof wash pump
38 Roof wiper
39 Front wiper
40 Radio/cassette
41 Heated seat
42 Digital clock
43 Warning buzzer
45 Hazard switch
46 Indicator relay
47 Hazard diode
48 Interior light
50 Rotating beacon
51 Primary fuse
52 Primary fuse
53 Ignition relay
9804/1103 20 - 15 - 02/18 3630 - C/29-2.2 Issue 1

CONTENTS
Loadalls 20 - 15 - 02/19

circuit Diagram - Electrical (cont’d)
Component Key 2
The complete electrical circuit is shown on pages 20-15-02/17
to 20-15-02/20.
65 Air filter blocked switch 124 Trailer rear

66 Engine oil pressure switch 125 Left hand indicators
67 Transmission oil temp switch 126 Trailer rear
69 Alternator
70 Fuel sender
73 Horn
74 Reverse relay 2
75 Ignition relay 2
78 Reverse 1 relay
79 Forward relay
80 Drive relay
81 Parkbrake relay
88 Driveshaft relay
93 Parkbrake
95 Footbrake
97 Brakelights
98 Brakelights
99 Trailer rear
100 Reverse alarm
103 Rear worklight
104 Sidelight relay
105 Primary fuse 3
107 Primary fuse 2
109 Trailer rear
111 Trailer rear
120 Trailer rear
9804/1103 20 - 15 - 02/19 3630 - C/29-3.3 Issue 2*

CONTENTS 20 - 15 - 02/20
Loadalls
601
601
601
601
600
600
601
601
600
601
600
809
601
601
601
601
807
600
601
600
601
601
601
601
600
600
300
71 83 95
807
601
601
600
87
66 68 113
827
70
808
106 120
118
65 98
601
811
600
78 92
863
450
859
67 74 94
808 79 82 85 109 116
86 97 103 114
600
871
111
200
816
601
89
812
80 84 115
600
102 112 119
601
600
874 91
101
852
69 861
90
76 107
110
857
126
G 88 118
601
600
96
200
104
77
119
73 890
872
858
117
124
125
81 601 108
815
105
123
304
124
100
118
108
401
806
805
838
301
840
841
110
829
F28
F30
601
93 99 100
809
107
F18
F31
F32
F33
F34
F35
F16
F21
F22
F23
F24
F25
807
F29
F26
75
815
F17
F19
F15
122
3 SPEED
ONLY
121
839
832
72
F14
107
A314060
9804/1103 20 - 15 - 02/20 3630

3630
- C/29-4.3
- C/26-1.5 Issue 1
CONTENTS
Loadalls 20 - 15 - 02/21
530, 540 From m/c no. 775402

535 From m/c no. 777362
all with Manual Auxiliary Controls
Component Key 1
The complete electrical circuit is shown on pages 20-15-02/22, 20-15-02/23 and 20-15-02/26
Key
1 Battery
2 Battery isolator
3 Starter motor
4 Starter solenoid
5 Ignition switch
5A Fuse link 2
6 Starting aid
8 Ignition feed relay 1
10 E.S.O.S.
11 Rear work lamp switch
11A Rear work lamp
12 Front work lamps switch
12A Front work lamps
12B Auxiliary power connector
13 2/4WD brake relay
13A Brake lamps
14 Brake switch
15 2/4WD switch
16 2/4WD solenoid
17 Reverse relay
17A Reverse lamp
18 Reverse alarm
19 Park brake relay
19A Park brake switch
20 Heated seat
21 Radio/cassette
22 Digital clock
23 Transducer - Load Moment Indicator (LMI)
24 Instrument panel
25 Warning buzzer
31 Fuel gauge
33 Alternator
* Optional fan reversing circuit shown at inset X
131 Fan reverse switch

132 Fan reverse solenoid
133 Fan reverse horn
Note: All the items listed here are not necessarily fitted to all
machines in the range.
9804/1103 20 - 15 - 02/21 3630 - C/30-1.3 Issue 2*

CONTENTS
Loadalls 20 - 15 - 02/22
530, 540 From m/c no. 775402

535 From m/c no. 777362
All with Manual Auxiliary Controls
10 16
31 32
2 6 17A 19A
18 23
13A
26
27
28
29
30
11A 12A 12B
20 21 X
3
4 7 8 9 22
601JM
601JN
601JR
1
11 12 13 15 17 19 132
33 133
1840a
1840
24
25
14
5
131
171
5A
417050
160-02292-1
9804/1103 20 - 15 - 02/22 3630 - C/30-2.3 Issue 2*

20 - 15 - 02/23
CONTENTS
Loadalls
530, 540 From m/c no. 775402
535 From m/c no. 777362
54
35 36 38 39 41 43 44 57 60 62
45 65
46 47 48 49 53 55 61
58
40 42 56
37 50
34 51 52 59 64
63
34A
160-02292-2
9804/1103 20 - 15 - 02/23 3630 - C/30-3.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 02/24
530, 540 From m/c no. 775402

535 From m/c no. 777362
Component Key 2
The complete electrical circuit is shown on pages 20-15-02/22, 20-15-02/23 and 20-15-02/26.
34 Sidelight relay
34A Fuse link 2
35 RH side lights
36 LH side lights
38 RH/LH dip beam
39 RH/LH main beam
41 Rear fog lamp (optional)
42 Column switch - RH
43 LH indicators
44 RH indicators
47 Rear wiper motor
48 Roof/rear washer pump
49 Roof wiper motor
52 Hazard warning switch
53 Hazard warning relay
54 Trailer indicator warning light
55 Interior light/switch
56 Beacon switch
57 Beacon lamp
58 Face level fan
60 Air conditioning - compressor motor
61 Air conditioning - freeze switch
62 Air conditioning - receiver drier
64 Heater/heater fan switch
65 Heater
Note: All the items listed here are not necessarily fitted to all machines in the range.
9804/1103 20 - 15 - 02/24 3630 - C/30-4.1 Issue 1

CONTENTS
Loadalls 20 - 05 - 02/25
530, 540 From m/c no, 775402

535 From m/c no. 777362
66 Column switch - LH
67 Horn
68 Reverse Hi/Lo relay
69 Reverse Lo relay
70 Reverse Hi relay
71 Diode pack (see Note below)
72 Reverse relay
73 Forward relay
74 Forward Hi/Lo relay
75 Forward Hi solenoid
76 Forward Lo solenoid
77 Drive interlock relay
78 Drive shaft relay
82 2nd auxiliary relay
83 2nd auxiliary solenoid
84 Hitch/boom hydraulics solenoid
85 Hitch switch
86 Sway switch
87 Sway diverter solenoid
88 Sway valve
89 Sway valve
90 2nd auxiliary push button
91 Isolation switch
92 Transmission dump push button
93 Steer mode control unit
A Four wheel/crab steer relay
B Two wheel steer relay
C Crab steer relay
D Four wheel steer relay
94 Steer mode selector switch
X Two wheel steer
Y Crab Steer
Z Four wheel steer
95 2WS solenoid
96 4WS solenoid
97 AWS solenoid
99 Proximity switch - front axle
100 Proximity switch - rear axle
Note: Diode indicated (†) not fitted to 3-speed machines.
9804/1103 20 - 15 - 02/25 3630 - C/30-5.1 Issue 1

20 - 15 - 02/26
CONTENTS
Loadalls
530, 540 From m/c no. 775402
535 From m/c no. 777362
95
69 70 96
67 97
75 76 79 80 83 84 87 88 89
98
71
86
66 90
94
Z
92 X
91 Y 99
68 72 73 74 77 78 81 82 85
100
93
160-02292-3
9804/1103 20 - 15 - 02/26 3630 - C/30-6./1 Issue 1

CONTENTS
Loadalls 20 - 15 - 02/27
530, 540 From m/c no. 775402

535 From m/c no. 777362
All with Single Lever Controls (SLC)
10 18
36
37
31
32
33
34
35
13 27
16
2 6 20 23
11A 12A
24 25
3
21 X
4 7 8 9 26
1
601JM
601JN
601JR
11 12 15 17 19 22 30
132
133
28
1840a
1840
29
14
131
5A
171
417050
160-02291-1
9804/1103 20 - 15 - 02/27 3630 - C/31-1.2 Issue 2*

CONTENTS
Loadalls 20 - 15 - 02/28
530, 540 From m/c no. 775402

535 From m/c no. 777362
all with Single Lever Controls (SLC)
Component Key 1
Key
1 Battery
2 Battery isolator
3 Starter motor
4 Starter solenoid
5 Ignition switch
5A Fuse link 2
6 Starting aid
9 Ignition reed relay 2
10 E.S.O.S.
11A Rear work lamp
12 Front work lamp switch
13 Auxiliary power connector
14 Brake switch
16 Brake lamps
17 2/4WD switch
18 2/4WD solenoid
19 Reverse relay
20 Reverse lamp
21 Reverse alarm
22 Park brake relay
23 Park brake switch
24 Heated seat
25 Radio/cassette
26 Digital clock
27 Transducer - load moment indicator (LMI)
28 Instrument panel
29 Warning buzzer
30 Alternator
36 Fuel gauge

9804/1103 20 - 15 - 02/28 3630 - C/31-2.2 Issue 2*

CONTENTS
Loadalls 20 - 15 - 02/29
530, 540 From m/c no. 775402

535 From m/c no. 777362
Component Key 2
38 Sidelight relay
38A Fuse link 1
39 RH side lights
40 LH side lights
42 RH/LH dip beam
43 RH/LH main beam
47 LH indicators
48 RH indicators
51 Rear wiper motor
53 Rear/roof washer pump
54 Roof wiper motor
59 Beacon switch
60 Beacon lamp
61 Face level fan
68 Heater
9804/1103 20 - 15 - 02/29 3630 - C/31-3.1 Issue 1

20 - 15 - 02/30
CONTENTS Loadalls
530, 540 From m/c no. 775402
535 From m/c no. 777362
39 40 42 43 47 48 61
50 51 53 54 57 65
45 60
49 68
58 63 64
38 46 56 59 62 66 67
41 44
52 55
160-02291-2
9804/1103 20 - 15 - 02/30 3630 - C/31-4.1 Issue 1

530, 540 From m/c no. 775402

535 From m/c no. 777362
100
83 87 102
70 72 73 78 79 101
91 93 95 96
82 86 103
69
99
Z
X
Y 104
89
105
71 75 76 77 80 81 84 85 88 90 92 94 97
98
160-02291-3
9804/1103 20 - 15 - 02/31 3630 - C/31-5.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 02/32
530, 540 From m/c no. 775402

535 From m/c no. 777362
Component Key 3
70 Horn
71 Reverse Hi/Lo relay
72 Reverse Lo Solenoid
73 Reverse Hi solenoid
74 Diode pack (see Note below)
75 Reverse relay
76 Forward relay
88 Hitch switch
89 Joystick isolation switch/lamp
90 2nd auxiliary extend switch
91 2nd auxiliary extend solenoid
92 2nd auxiliary retract switch
93 2nd auxiliary retract solenoid
94 Auxiliary A/B switch
95 Auxiliary A solenoid
C Crab steer relay
X Two wheel steer
Y Crab steer
Z Four wheel steer
100 2WS solenoid
101 4WS solenoid
102 AWS solenoid
9804/1103 20 - 15 - 02/32 3630 - C/31-6.1 Issue 1

530, 535, 540 From m/c no. 767001

530FS Super, 540FS Super, 530 SXL, 540 SXL
Component Key 1
1 Battery
2 Battery isolator
3 Starter motor
4 Starter solenoid
5 Ignition switch
6 Fuse link 2
7 Starting aid
11 Wax Thermostat
12 E.S.O.S.
14 Rear work lamp
15 Front work lamps switch
16 Front work lamps
17 Auxiliary power connector
19 Brake lamps
20 Brake switch
21 2/4WD switch
22 2/4WD solenoid
23 Reverse relay
24 Reverse lamp
25 Reverse alarm
26 Heated seat
27 Radio/cassette
28 Digital clock
29 Tracker
30 Transducer - Load Moment Indicator (LMI)
31 Fuse link 1
32 Instrument panel
33 Warning buzzer
38 Fuel gauge
40 Alternator
41 Air suspension seat

9804/1103 20 - 15 - 02/33 3630 - C/32-1.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 02/34
530, 535, 540 From m/c no. 767001

601
601
601
601
601
601
601
601
601
601
601
601
600
601
601
601
601
601
601
600
601
601
600
600
601
601
600
601
601
30A
2 7 25 34 37 38 39 M
24
LEAD
14 16 19 3536 41
11 12 17 22 *
26 27 X
405A
004
200
200
904
831
866
816
818
807
413
414
804
824
826
825
838
401
402
403
404
406
407
412
408
409
M
3
8 9 10 13 15 28
-
450
1 1 2 3
601JM
601JN
601JR
+
4 18 21 23
29 30B 40
132
151
133
LEAD
32
842
003
810
000
100
000
105
123
829
906
119
816
118
124
808
112
301
101
805
806
106
411
829
1840a
1840
33
20
003
106
108
5
200
200
11
12
18
25
16
17
15
19
29
28
30
31
32
33
34
35
7
8
6 131
001 31
171
+++
000
001
100
417050
300
301
304
804
805
806
808
810
824
825
826
827
829
838
401
A374060 405A
160/13114-1
9804/1103 20 - 15 - 02/34 3630 - C/32 - 2.3 Issue 2*

530, 535, 540

Component Key 2
42 Sidelight relay
43 Fuse link 1
44 RH side lights
45 LH side lights
47 RH/LH dip beam
48 RH/LH main beam
52 LH indicators
53 RH indicators
56 Rear wiper motor
57 Roof/rear washer pump
58 Roof wiper motor
63 Trailer indicator warning light
65 Beacon switch
66 Beacon lamp
67 Face level fan
74 Heater
75 Sway switch
77 Sway valve
78 Sway valve
79 Sway isolator relay
80 Sway isolator proximity switch
9804/1103 20 - 15 - 02/35 3630 - C/32-4.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 02/36
530, 535, 540

601
600
601
600
601
601
600
600
600
600
601
601
600
601
600
601
600
600
601
600
601
601
601
601
601
601
601
600
601
601
600
600
600
600
600
63
67
50
M M M M M 58 62 400 M M 71
44 45 47 48 52 53 66 69 74
54 55 56 57 64 70 76 77 78
828
830
829
834
838
898
805
806
839
840
841
925
926
901
849
854
802
803
886
884
883
885
882
801
800
850
931
932
46
827
49
42 51 59 60 61 68 72 73 75
65
909
200
905
832
833
836
304
803
841
840
110
829
300
805
804
104
301
115
102
829
79
907
80
121
21
22
23
27
24
1
43
000 000
001 001
100
300
301 301
304 304
804
805
806
808 808
810 810
824 824
825 825
826 826
827
829 829
838 A374070
160/13114-2
401 401
405A 405A
9804/1103 20 - 15 - 02/36 3630 - C/32 - 3.1 Issue 1

530, 535, 540

Component Key 3
82 5th gear solenoid
83 Speed sensor
90 Speedometer
91 Speedometer illumination
92 Throttle switch
94 Electronic control unit
95 Diagnostic port
96 Horn
97 Parkbrake switch
100 Hitch switch
103 Diode pack
104 2nd auxiliary B push button
105 Extend push button
106 Extend solenoid
107 2nd auxiliary A push button
108 Retract push button
110 Auxiliary A push button
112 Auxiliary B push button
C Crab steer relay
X Two wheel steer
Y Crab Steer
Z Four wheel steer
117 2WS solenoid
118 4WS solenoid
119 AWS solenoid
9804/1103 20 - 15 - 02/37 3630 - C/32-5.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 02/38
530, 535, 540

601
600
600
600
600
600
600
600
600
601
601
600
600
601
601
600
600
600
600
600
600
601
117
82 83 91 96 101
97 118
81 92
808
809
874
814
120
601
119
84 85 86 87 88 89 90 99 106 109 111 113
872
480
894
1807
405
858
857
812
859
860
815
851
850
853
893
811
R N F
871
93 A
116
315
45
0
1 2 Z
103 823
3 4 X
819
822
B 121
600J
821
5 6 Y
873
933
929
934
930
932
931
820
C
107
4 3 2 1 1 2 3 4 5 6 7 102
5 8 104 105 107 108 110 112 114
6 9
7 10 122
8 11 98 100 D
94 12
13 115
114
451
120
856
109
15
10
12 16
2
17
13
18
15 18 29 28 27 26 25 24 23 20
000
14
001 001
301
470A
473
470
474
304
A374080
808 95 160/13114-3
810
824 824
825 825
826 826
829
401
405A
9804/1103 20 - 15 - 02/38 363s0 - C/32 - 6.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 03/1
532, 537 From m/c no. 767001 to 768956

without Neutral Start Relay
Component Key 1
The complete electrical circuit diagram is shown on pages 20-15-03/2 and 20-15-03/3.
1 Battery 55 Steer Mode Control Unit
2 Battery isolator W All wheel steer relay
3 Starter motor X Two wheel steer relay
4 Ignition switch Y Crab steer relay
5 Starting aid Z Four wheel steer relay
6 not used
7 Sway isolation relay
8 Sway/Aux change-over 56 Steer mode switch
9 Sway/Aux 1 solenoid X Two wheel steer select
10 Sway isolation switch Y Crab steer select
11 Auxiliary A relay Z Four wheel steer select
12 Auxiliary B relay 57 Front steer sensor
13 Aux A/B switch 58 Rear steer sensor
16 Stabilizer isolation valve
17 Stabilizer isolation relay
18 Stabilizer isolation switch
19 Stabilizer isolation proximity switch
21 Not applicable
23 SLI transducer
24 Heater/air conditioning switch
27 Face level fan
32 Rear wiper motor
34 Roof wash pump
35 Roof wiper
36 Front wiper
37 Radio/Cassette
38 Heated seat
39 Digital clock
40 Left hand stabilizer warning light
41 Right hand stabilizer warning light
42 Warning buzzer
43 Hazard switch
44 Indicator relay
45 Interior light
47 Rotating beacon
48 Primary fuse
49 Ignition relay
52 All wheel steer solenoid
9804/1103 20 - 15 - 03/1 3660 - C/21-1.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 03/2
532, 537 From m/c no. 767001 to 768956

856
5 9 14 16
38
600
601
601
23
25
D F 44 47
30 M
601
601
825
54 58
C B A 35 59
15 53
42 52
11 27 45 57 820
M 32 M
883
2 M 51
34
848
826
824
36 50
910
819
19
26 28 M 39
43 46 49
6
913
912
8
1
105
109
12 21 37 40 41
882
7
100
48
851
18 31 33
24 29
911
RT
907 20 22
10
17
13
003
F1 F2 F3 F4 F5 F6 F7 F8 F9
F11 F12
004
874 874
3 000
M 200 F13
+++
601
1 2 3 4 5 6 7 8
55
819
1
Z
2
823 3
X
4
Y
W X Y Z
822 5
821 6 57
A312010
9804/1103 20 - 15 - 03/2 3630

3660 - C/26-1.5
- C/21-2.1 Issue 1
20 - 15 - 03/3
CONTENTS
Loadalls
532, 537 From m/c no. 767001 to 768956
601
601
74
601
601
600
601
64
62 65 69 70
77 91
827
61 63 G 98
84
73
450
76 82 94
72 87 102
873 92
871
68 78 79
9 15 16 1 13 80 85 101
10 7 89 99
200
67 2
4 5 93
81 83 90 97
3
17 18 12 6 75
71 88 96
118
119
108
123
66 86
95 100 104
103
F18
F30
F14 F16
F28
F23
F24
F25
F26
F21 F22
F29
F19
F17
F15
A312020
9804/1103 20 - 15 - 03/3 3660

3630
- C/21-3.1
- C/26-1.5 Issue 1
CONTENTS
Loadalls 20 - 15 - 03/4
532, 537 From m/c no. 767001 to 768956

Component Key 2

65 Alternator
66 Fuel sender
69 Horn
70 Reverse relay
72 Parkbrake switch
74 Foot brake switch
76 Brakelights
77 Brakelights
78 Rear light harness
79 Reverse alarm
82 Rear worklight
83 Sidelight relay
85 Primary fuse
86 Right hand front sidelight
87 Right hand rear sidelight
88 Left hand front sidelight
89 Left hand rear sidelight
98 Rear foglight
100 Screen wash pump
101 Right hand front indicator
102 Right hand rear indicator
103 Left hand front indicator
104 Left hand rear indicator
Refer to the ECU fault finding information in this section for control unit output connections..
9804/1103 20 - 15 - 03/4 3660 - C/21-4.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 03/5
532, 537 From m/c no. 768957 to 770063

Component Key 1
1 Battery 57 Steer Mode Control Unit (SMCU)

2 Battery isolator W Four wheel/crab steer relay
5 Ignition switch Z Four wheel steer relay
6 Starting aid 58 Steer mode switch
7 not used X Two wheel steer select
8 Sway isolation relay Y Crab steer select
9 Sway/Aux change-over switch Z Four wheel steer select
10 Sway isolation switch 59 Front steer sensor
11 Sway/Aux 1 solenoid 60 Rear steer sensor
12 Auxiliary A relay 61 Instrument panel
14 Aux A/B switch
22 Not applicable
24 SLI transducer
28 Face level fan
31 Binary switch
33 Rear wiper motor
35 Roof wash pump
36 Roof wiper
37 Front wiper
38 Radio/Cassette
39 Heated seat
40 Digital clock
43 Warning buzzer
44 Hazard switch
45 Indicator relay
46 Hazard diode
47 Interior light
49 Rotating beacon
50 Primary fuse
51 Ignition relay
52 Engine Shut-Off Solenoid (ESOS)
54 Four wheel/crab steer solenoid
9804/1103 20 - 15 - 03/5 3660 - C/22-1.1 Issue 1

20 - 15 - 03/6
CONTENTS
Loadalls
532, 537 From m/c no. 768957 to 770063
601
600
600
601
601
601
600
601
601
600
411
601
600
601
600
601
601
600
600
601
601
601
601
856 856
6 53
11 16 825
15
601
601
601
601
55 826
840
43
600
601
601
39
7 37
856
M
17 27 45
601
601
848
20 31 56 60
841
61
601
883
800
54
5 801
10
908
59
820
M 33 M
824
826
35
925
38 52
12
47
19 42
004
26 51
901
884
200
4 36
410
13 M 44
50
105
109
100
926
9 41
882
1 2 3
912
901
854
911
46
21
32
106
8
907
M
22 25
(SLC)
28
(SLC)
14 18
102
2
(SLC)
120
810
F11
F12
F7
F8
F9
F5
F6
101
115
301
F1
F2
F3
F4
842
874 874
F13
000 000
3
200 200
M 001 001
414
+++
23 24 40 49
601
413
30 29 34 1 2 3 4 5 6 7 8
48 57
886
819
1
Z
2
823 3
X
4
Y
W X Y Z
822 5
821 6 58
A313830
9804/1103 20 - 15 - 03/6 3660 - C/22-2.1 Issue 1

20 - 15 - 03/7
CONTENTS
Loadalls
532, 537 From m/c no. 768957 to 770063
803
601
601
304 805
76
600
600
809
405
832 806
600
600
601
601
601
600
601
66
841
64 833
67 71 72 840
79 93
827
63 65 G 100
86
75
450
78 84
808
74 89 96 104
873 94
871
70 80 81
9 15 16 1 13 82 87 103
10 7 91 101
200
69 2
4 5 95
83 85 92 99
3
N
R
17 18 12 6 77
73 90 98
118
119
108
123
68 88
97 102 106
304
836
803
110
832
105
839
401
806
805
838
301
840
841
110
829
810
F18
F30
F16
F14
F21
F22
F23
F24
F25
F26
F28
F29
827
F17
F19
F15
A313840
9804/1103 20 - 15 - 03/7 3660 - C/22-3.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 03/8
532, 537 From m/c no. 768957 to 770063

Component Key 2

67 Alternator
68 Fuel sender
71 Horn
72 Reverse relay
74 Parkbrake switch
76 Footbrake switch
78 Brakelights
79 Brakelights
80 Reverse lights
81 Reverse alarm
84 Rear worklight
85 Sidelight relay
87 Fusible link 1
100 Rear foglight
105 Left hand front indicator
106 Left hand rear indicator
Refer to the ECU fault finding information in this section for control unit output connections.
9804/1103 20 - 15 - 03/8 3660 - C/22-4.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 03/9
532, 537 From m/c no. 770064 to 770958

Component Key 1

1 Battery 57 Steer mode control unit (SMCU)
2 Battery isolator W Four-wheel/crab steer relay
5 Ignition switch Z Four wheel steer relay
6 Starting aid 58 Steer mode switch
9 Sway/auxiliary change over Z Four wheel steer select
10 Sway isolation proximity switch 59 Front steer sensor
11 Auxiliary A relay 60 Rear steer sensor
15 Auxiliary A/B switch Steer Sensor Wiring:
16 Auxiliary change over relay 2
17 Sway/auxiliary solenoid Terminal Wire Code Wire Colour Description
18 Stabilizer isolation relay 1 820 or 819 Black Signal
19 Stabilizer isolation valve 2 600 or 601 Blue Earth
20 Stabilizer isolation switch 3 810 or 109 Brown Feed
22 Not applicable
23 Safe load indicator (SLI)
24 SLI transducer
25 Heater/air conditioning fan motor
28 Face level fan
31 Binary switch - air conditioning
33 Rear wiper motor
35 Roof wash pump
36 Roof wiper motor
38 Radio/cassette
39 Heated seat
40 Digital clock
43 Warning buzzer
44 Hazard warning light
45 Indicator relay
46 Hazard diode
47 Interior light
48 Beacon switch
49 Beacon
50 Primary fuse
51 Ignition relay
52 Engine shut-off system (ESOS)
53 Two-wheel steer solenoid
55 Four-wheel steer solenoid
9804/1103 20 - 15 - 03/9 3660 - C/23-1.1 Issue 1

20 - 15 - 03/10
CONTENTS
Loadalls
532, 537 From m/c no. 770064 to 770958
601
601
601
601
600
600
601
601
601
600
600
600
411
601
600
601
601
600
601
601
600
600
601
601
601
6 53
17 12 14 825
601
601
601
601
55
840
43
600
601
601
7 39
37
19 27 M
45
601
601
21 31 60
56
841
601
883
61
848
800
5 801 54
10
908
59
820
M 33 M
824
410
826
11 35
925
38 52
20 47
004
26 42
200
51
9
901
4
36
13
410
105
109
M 44
50
100
926
41
912
1 2 3
901
911
854
46
909
8 32
907
106
22 25 M
(SLC)
15 18 28
102
2 301
884 840
(SLC)
841
110
829 829
120
810 810
F7
F8
F9
F11
F12
1
F5
F6
115
101
F1
F2
F3
F4
842
874 874
000
F13
3 200
M 001
+++
414
+++ 23 24 40 49
601
413
301
16 30 29 34 1 2 3 4 5 6 7 8
48 57
886
819
1
Z
2
823 3
X
4
Y
W X Y Z
822 5
821 6 58
A313850
9804/1103 20 - 15 - 03/10 3660 - C/23-2.1 Issue 1

20 - 15 - 03/11
CONTENTS
Loadalls
532, 537 From m/c no. 770064 to 770958
601
601
601
601
600
600
601
601
600
601
600
809
601
601
601
601
807
69 81 94
85
66
63 64 109
827
68
808
103 117
118
96
601
811
600
76 90
863
450
859
65 72 93
808 77 80 82 106 113
84 95 101 111
600
871
108
200
87
812
78 83 112
601
600
100 110 116
852
601
600
874 89
67 861
88
74 104
107
857
123
G 86 115
601
600
92 102
75 99
119
71 890
872
105
114
121
122
79 601
815
120
304
124
100
118
108
401
806
805
838
301
840
841
110
829
F28
F30
601
91 97 98
F18
F31
F32
F33
F34
F35
F16
F21
F22
F23
F24
F25
807
F29
F26
73
815
F17
F19
F15
119
3 SPEED
ONLY
118
839
832
70
F14
107
A313860
9804/1103 20 - 15 - 03/11 3660 - C/23-3.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 03/12
532, 537 From m/c no. 770064 to 770958

Component Key 2
63 Air filter blocked switch 121 Right hand rear indicator

64 Engine oil pressure switch 122 Left hand front indicator
65 Transmission oil temperature switch 123 Left hand rear indicator
67 Alternator
68 Fuel sender
71 Horn
72 Reverse 2 relay
73 Ignition relay 2
76 Reverse 1 relay
77 Forward relay
78 Drive relay
79 Parkbrake relay
80 Rev HI/LO relay
81 Reverse high/low solenoid
83 Forward HI/LO relay
86 Driveshaft relay
89 Two/four wheel drive solenoid
91 Parkbrake switch
92 Two-wheel drive switch
93 Two-wheel drive brake relay
94 Footbrake switch
95 Brake lights
96 Brake lights
97 Reverse lights
98 Reverse alarm
101 Rear work light
102 Side light relay
104 Primary fuse
109 Left hand worklight
117 Rear foglight
9804/1103 20 - 15 - 03/12 3660 - C/23-4.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 03/13
532, 535, 537 From m/c no. 770959

Component Key 1

1 Battery 56 Steer mode control unit (SMCU)
2 Battery isolator W All wheel steer relay
4 Ignition switch Y Crab steer relay
5 Starting aid Z Four wheel steer relay
6 Neutral start relay 57 Steer mode switch
9 Sway/auxiliary change over switch Z Four wheel steer select
10 Sway/auxiliary change-over valve 58 Front steer sensor
11 Sway isolation proximity switch (Not N. American 532 or 59 Rear steer sensor
550) 60 Instrument panel
11A Link Harness (N. American 532 and 550 only)
12 Sway/auxiliary solenoid
15A Auxiliary A button
15B Auxiliary B button
21 Safe load indicator (SLI)
22 SLI transducer
23 Heater/air conditioning fan motor
26 Face level fan
29 Binary switch - air conditioning
31 Rear wiper motor
33 Roof wash pump
34 Roof wiper motor
36 Heated seat
37 Radio/cassette
38 Digital clock
41 Warning buzzer
42 Hazard warning light
43 Indicator relay
44 Hazard diode
45 Interior light
46 Beacon switch
47 Beacon
48 Primary fuse 1
49 Fusible link
50 Ignition relay
51 Engine shut-off system (ESOS)
52 Two-wheel steer solenoid
54 Four-wheel steer solenoid
9804/1103 20 - 15 - 03/13 3660 - C/24-1.1 Issue 1

20 - 15 - 03/14
CONTENTS
Loadalls
532, 535, 537 From m/c no. 770959
24
600
600
600
5 12 52
10 18 825
54
16 36
600
601
601
22
800
43 47
29 M
601
601
35 55 59
4 34 60
848
13 25 M 41 49
53
26 45
200
M 31 M 58
820
M
824
33
826
51
935
27 38
42 46 50
20
9
882
105
109
37 39
926
100
15A 15B
1 2 3
6
30 32
7 28 40 RT 48
2 8 23
21
44
17
14
451
842
907
11
1
11A
120
810
F7
F8
F9
F5
F6
F11
F12
F1
F2
F3
F4
000
F13
3
200 200
19
601
1 2 3 4 5 6 7 8
+++ 56
819
1
Z
2
823 3
X
4
Y
W X Y Z
822 5
821 6 57
A311990
9804/1103 20 - 15 - 03/14 3660 - C/24-2.1 Issue 1

20 - 15 - 03/15
CONTENTS
Loadalls
532, 535, 537 From m/c no. 770959
601
601
600
600
601
601
600
601
600
601
601
601
601
68 80 93
84
65
62 63 109
827
67
808
103 117
95
863
601
811
600
75 89
450
859
64 71 92
808 76 79 81 106 113
83 94 100 111
600
871 104 108
86
812
77 82 112
601
600
99 101 110 116
601
600
88
852
66 861
87
73 107
857
123
G 85 115
601
600
91
74 98
119
70 890
872
105
114
121
122
78 601
815
102
120
304
124
F28
601
F30
90 96 97
F31
F32
F33
F34
F35
F18
F16
F21
F22
F23
F24
F25
F29
F26
72
815
F19
F17
F15
119
3 SPEED
ONLY
118
839
69
F14
107
A312000
9804/1103 20 - 15 - 03/15 3660 - C/24-3.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 03/16
532, 535, 537 From m/c no. 770959

Component Key 2
Tthe complete electrical circuit diagram is shown on pages 20-15-03/14 and 20-15-03/15.
62 Air filter blocked switch 122 Left hand front indicator

63 Engine oil pressure switch 123 Left hand rear indicator
66 Alternator
67 Fuel sender
70 Horn
71 Reverse 2 relay
72 Ignition relay 2
75 Reverse 1 relay
76 Forward relay
77 Drive relay
78 Parkbrake relay
79 Rev HI/LO relay
80 Reverse high/low solenoid
82 Forward HI/LO relay
85 Driveshaft relay
86 Layshaft solenod
90 Parkbrake switch
91 Two-wheel drive switch
92 Two-wheel drive brake relay
93 Footbrake
94 Brake lights
95 Brake lights
96 Reverse lights
97 Reverse alarm
100 Rear work light
101 Side light relay
102 Fusible link 3
104 Fusible link 2
106 Righ hand rear sidelight
109 Left hand worklight
117 Rear foglight
9804/1103 20 - 15 - 03/16 3660 - C/24-4.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 03/17
532, 537, 550 with Manual Auxiliary Controls from m/c no. 775402
* 540-170,5508 with Servo Controls to m/c no. 1004130
Component Key 1
The complete electrical circuit is shown on pages 20 - 15 - 03/18, 20-15-03/19, 20 - 15 - 03/22 and
20 - 15 - 03/23.
Key
1 Battery
2 Battery isolator
3 Starter motor
4 Starter solenoid
5 Ignition switch
5A Fuse link 2
6 Starting aid
10 E.S.O.S.
11A Rear work lamp
13A Brake lamps
14 Brake switch
15 2/4WD switch
16 2/4WD solenoid
17 Reverse relay
17A Reverse lamp
18 Reverse alarm
19 Park brake relay
20 Heated seat
21 Radio/cassette
22 Digital clock
22A Fuse link 1
24 Instrument panel
25 Warning buzzer
26 Alternator
32 Fuel gauge
34 LH stabiliser lamp switch
35 RH stabiliser lamp switch
Note 1: All the items listed here are not necessarily fitted to all machines in the range.
Note 2: 540-17- machines only. See page 20 - 15 - 03/23 for additional circuits.
Note 3: Fuses 31 and 32 for 540-170 machines are shown on page 20 - 15 - 03/23.
9804/1103 20 - 15 - 03/17 3630 - C/25-1.4 Issue 3*

CONTENTS
Loadalls 20 - 15 - 03/18
540-170, 5508 with Servo Controls to m/c no. 1004130
See
23
1828
10 34 35 Sheet 4
11A 17A 18
2 6 19A 32 33
12A 13A
28
29
30
31
27
12B 16 35
20 21
3
34
7 8 9 11 12 13 15 22
1
4 17 19
410
410
26
24
25
14
See Note 2
5 540-170
(5508 N.Am) Only
22A
5A
160-02290-1
9804/1103 20 - 15 - 03/18 3660 - C/25-2.2 Issue 3*

CONTENTS
Loadalls 20 - 15 - 03/19
* 532,
537, 550 with Manual Auxiliary Controls from m/c no. 775402
*
37
38
40
41
45
46
43 47 48 49 50 51 55 59 61 63
66
56 58
62
36 39 44 54 57 60 64
42 52
53 65
36A
160-02290-2
9804/1103 20 - 15 - 03/19 3630- C/25-3.1

3660 - C/26-1.5 Issue 3*
CONTENTS
Loadalls 20 - 15 - 03/20
Component Key 2
The complete electrical circuit is shown on pages 20-15-03/18, 20-15-03/19, 20-15-03/22 and 20-15-03/23.
36 Sidelight relay
36A Fuse link 1
37 RH side lights
38 LH side lights
40 RH/LH dip beam
41 RH/LH main beam
45 LH indicator lamps
46 RH indicator lamps
49 Rear wiper motor
51 Roof wiper motor
57 Beacon switch
58 Beacon lamp
59 Face level fan
66 Heater
9804/1103 20 - 15 - 03/20 3660 - C/25-4.4 Issue 3*

CONTENTS
Loadalls 20 - 15 - 03/21
Component Key 3
The complete electrical circuit is shown on pages 20-15-03/18, 20-15-03/19, 20-15-03/22 and 20-15-03/23.
68 Horn
69 Reverse Hi-Lo relay
70 Reverse Lo solenoid
71A Diode pack (see Note below)
72 Reverse relay
73 Forward relay
82 Stabiliser isolation switch
83 Stabiliser isolation relay
84 Stabiliser isolation solenoid
86 Sway isolation switch
88 Sway switch
90 Sway solenoid
91 Sway solenoid
C Crab steer relay
X Two wheel steer
Y Crab steer
Z Four wheel steer
95 2WS solenoid
96 4WS solenoid
97 AWS solenoid
9804/1103 20 - 15 - 03/21 3660 - C/25-5.4 Issue 3*

CONTENTS
Loadalls 20 - 15 - 03/22
95
79 80 90 91
96
68 70 71 75 76 84 89 97
98
67 71A
88
A
94
Z
73 74 77 92 X
69 72 78 81 82 83 85 86 87 B Y 99
C
100
D
93
160-02290-3
9804/1103 20 - 15 - 03/22 3660

3630
- C/25-6.2
- C/26-1.5 Issue 3*
Issue 1 3660 - C/25-7.2 20 - 15 - 03/23 9804/1103
From
Sheet 1
1823
000
1828
F31
CONTENTS
170
101
170F
601HS EXT ISOL. SW.
601GM
102
601FL EXT. RELAY
170B
104
103
601HZ EXT INTERLOCK
1833A
1825C 1833 1833

1820 601FN EXT. DIVERTER SOL.
105
1825B
119
1821 601JB LIFT ISOL. RELAY

1825A 1825 601TH
170L LIFT UNLOADER SOL
106
107
108
170E
601HR LIFT ISOL. SW.
110
1824 601FY STABILISER LIFT RELAY

1820 601FZ STAB LIFT UNLOADER SOL
170C
109
111
170D
601FW STAB. LIFT ISOL. SW.
112
1829A 1829 601HW

FULL LOCK SOL.
1829B
116
113
114
1830C
170J 1830B 1830 601HX

CROWD LOCK SOL.
170H
1830A 601HV
DUMP LOCK SOL.
115
601GA
118
117
1822A
F32
171 1822 601GB
BOOM WORKLIGHT

To m/c no. 1004130 540-170, 5508 with Servo Controls
20 - 15 - 03/23 Loadalls
CONTENTS
Loadalls 20 - 15 - 03/24
540-170, 5508 with Servo Controls To m/c no. 1004130

Component Key 4
101 Extend isolation switch

102 Extension relay
103 Inner boom extension switch
104 Extension interlock
105 Extension diverter valve solenoid
106 Lift/unloader solenoid
107 Lift solenoid relay
108 Lift solenoid switch
109 Stabiliser lift unloader solenoid
110 Stabiliser lift relay
111 Stabiliser lift isolation solenoid
112 Full lock solenoid
113 Diode
114 Lock solenoid - tilt back
115 Lock solenoid - tilt forward
117 Boom worklight
118 Boom worklight switch
119 Diode
9804/1103 20 - 15 - 03/24 3660 - C/25-8.3 Issue 2*

CONTENTS
Loadalls 20 - 15 - 03/25
* 540-170,5508 with Servo Controls from m/c no. 1004130
Component Key 1
1 Battery
2 Battery isolator
3 Starter motor
4 Starter solenoid
5 Ignition switch
5A Fuse link 2
6 Starting aid
10 E.S.O.S.
11A Rear work lamp
13A Brake lamps
14 Brake switch
15 2/4WD switch
16 2/4WD solenoid
17 Reverse relay
17A Reverse lamp
18 Reverse alarm
19 Park brake relay
20 Heated seat
21 Radio/cassette
22 Digital clock
22A Fuse link 1
24 Instrument panel
25 Warning buzzer
26 Alternator
32 Fuel gauge
9804/1103 20 - 15 - 03/25 3630 - C/26-1.4 Issue 1*

CONTENTS
Loadalls 20 - 15 - 03/26
Component Key 1
36 Sidelight relay
36A Fuse link 1
37 RH side lights
38 LH side lights
40 RH/LH dip beam
41 RH/LH main beam
47 Fornt washer pump
49 Rear wiper motor
51 Roof wiper motor
57 Beacon switch
58 Beacon lamp
59 Face level fan
66 Heater
9804/1103 20 - 15 - 03/26 3630 - C/2641.4 Issue 1*

CONTENTS
Loadalls 20 - 15 - 03/27
Component Key 3
68 Horn
71A Diode pack
72 Reverse relay
73 Forward relay
74 Forward Hi-Lo relay
88 Sway switch
90 Sway solenoid
91 Sway solenoid
C Crab steer relay
X Two wheel steer
Y Crab steer
Z Four wheel steer
95 2WS solenoid
96 4WS solenoid
97 AWS solenoid
9804/1103 20 - 15 - 03/27 3630 - C/26-5.4 Issue 1*

CONTENTS
Loadalls 20 - 15 - 03/28
Component Key 4
101 Right hand stabiliser relay
102 Right hand stabiliser LED
103 Left hand stabiliser relay
104 Left hand stabiliser LED
105 Inner boom extension switch
106 Inner boom extension relay
111 Lift/unloader solenoid
112 Lift isolation switch
113 Lift isolation relay
114 Stabiliser left unloader solenoid
115 Stabiliser lift relay
116 Stabiliser lift isolation switch
117 Fork lock solenoid
118 Fork lock solenoid
120 Boom worklight
121 Boom worklight switch
9804/1103 20 - 15 - 03/28 3630 - C/26-8.4 Issue 1*

CONTENTS
Loadalls 20 - 15 - 03/29
* 540-170,5508 Machines from m/c no. 1004131

31
28
29
27
30
601
601
601
601
601
601
601
601
601
601
6 01
601
601
600
601
601
601
601
600
601
601
600
601
601
601
601
601
601
601
410
481
10 23A
11A 17A 19A
2 6 22A 32 33
12A 13A 18
12B 16
20 21
34 35
401
200
904
831
818
825
838
403
404
405
406
407
200
816
807
826
409
004
8 15
414
402
408
866
413
824
412
8 04
3 M
7 8 9 11 12 13 15 22
-
450
1 1 2 3
+
4 17 19
22B 23 26
106
106
000
100
842
000
856
003
810
105
123
816
401
112
829
906
119
118
808
301
124
101
24
411
829
106
805
806
25
14
003
106
108
200
200
12
18
25
16
17
15
19
29
28
30
33
34
35
11
8
22A
5A
001
+++
000
000
001
100
300
301
304
804
805
806
808
810
824
825
826
827
829
838
160-13328
856
9804/1103 20 - 15 - 03/29 3660 - C/26-2.4 Issue 1*

CONTENTS
Loadalls 20 - 15 - 03/30

47 55
37
38
40
41
45
46
43 48 49 50 51 59 61 63
66
56 58
62
36 39 44 54 57 60 64
42 52
53 65
36A
160-13328-2
9804/1103 20 - 15 - 03/30 3660 - C/26-3.4 Issue 1*

CONTENTS
Loadalls 20 - 15 - 03/31

95
79 80 90 91
96
68 70 71 75 76 84 89 97
98
67 71A
88
A
94
Z
69 72 73 74 77 78 81 82 83 85 86 87 92 X
B Y 99
100
D
93
160-13328-3
9804/1103 20 - 15 - 03/31 3660 - C/26-6.4 Issue 1*

CONTENTS
Loadalls 20 - 15 - 03/32

601HW
601FN
601JW
601HT
601HV
601FZ
601JA
601JS
601JY
601JY
601JX
601GB
108 110 111 114 117 118
120
1825
601FY
601JB
1830A
104
1820
109
1829
1825A
1833
601FW
601HR
1829B 1830C
1825B
1829A
1830B
1842
112 115
601GM
601HS
601FL
601GA
1822
1833A
1833
315
1824
1821
0
45
105
119*
103
1834A
1834 1834B
113 116
1850
170K
1822A
106
1828
170C
170L
102
101
1823
121
170H
170J
170D
170E
106
107
171
410
170B
170F
481
170
F31
F36
000
828
160-13328-4
9804/1103 20 - 15 - 03/32 3660 - C/26-7.4 Issue 1*

20 - 15 - 04/1
CONTENTS
Loadalls
506B To m/c no. 578676
Syncroshuttle
48 48
600
46
24 37
47 49 51 53
17 27 26
5 11 44 45 59 60
202 204 205 208 54
N
G/Y
U 50 52
415 811 812 815
414A 403 405 408 409
414 55
413A 814 203 34
413 839 841 402 404 406
2 414B 21
412
413B 801 42 43
407 56
416 400 600 206
N G/Y U
805 806 807
10 210 212 214

32 57 58
804 842
36 40 41 209 211 213 215
803
808A 809
20 23
31 803A
16 802 401
3 103A
30
810
25 19
9 207
808 39
800
- 101 411 200
1
+ 003
6 105 106A
100
300 61
15 103 104
800
100 106
200 842
A1 A2 A4 A5 A6 A7 A8 A9 B1 B2 004
200
103
000 000
4
000R 000R
200 200
004
842
9804/1103 20 - 15 - 04/1 3640U - C/10-1.2 Issue 1

CONTENTS
Loadalls 20 - 15 - 04/2
506B To m/c no. 578676

Syncroshuttle
Component Key
1 Battery 54 Hourmeter Lamps
2 Starter Motor 55 Alternator 202 Trailer Indicator Warning
3 Starter Solenoid 56 Tachometer 203 Hazard Warning
4 Starter Switch 57 Fuel Gauge 204 L.H. Indicators
5 Thermostart 58 Water Temperature Gauge 205 R.H. Indicators
6 Starter Relay 59 Fuel Gauge Sender 206 Indicator Warning
9 Safe Load Indicator Readout Box 60 Water Temperature Gauge 207 Hazard Indicator Warning
10 Rear SLI Boss Sender 208 Reversing Lights
11 Front SLI Boss 61 Warning Buzzer 209 Parking Brake Warning
15 Heater Switch 62 L. H. Stabiliser Switch 210 Air Filter Blocked Warning
16 Heater Resistor 63 R. H. Stabiliser Switch 211 Engine Oil Pressure Warning
17 Heater Motor 65 Interior Light Switch 212 Transmission Oil Temperature
19 Seat Relay Swedish 66 Roof Wiper Motor and Switch Warning
20 Parking Brake Switch machines 67 Rear Wiper Motor and Switch 213 Transmission Oil Pressure
21 Seat Switch only 68 Beacon Switch Warning
23 Horn Push 69 Beacon 214 Water Temperature Warning
24 Horn 71 Brake Switch 215 Alternator Warning
25 Wash/Wipe Switch 71B Brake Switch Relay 216 Stabiliser Indicators
26 Front Wiper Motor 72 2/4 Wheel Drive Switch (not fitted 217 Interior Light
27 Washer Pump on permanent 4 wheel drive) 218 Beacon Warning
30 Hazard Switch 73 2 Wheel Drive Solenoid 219 2 Wheel Drive Warning
31 Indicator Relay 75 Front Axle Proximity Switch 220 L.H. Brake Lights
32 Indicator Switch 76 Rear Axle Proximity Switch 221 R.H. Brake Lights
34 Fuel Shut-off Solenoid 77 Steering Mode Selector Switch 222 4 Wheel Steer Warning
36 Reverse Alarm Relay 78 Steer Mode Printed Circuit Board 223 Crab Steer Warning
37 Reverse Alarm 78A Relay 2 224 2 Wheel Steer Warning
39 Forward/Reverse Selector Switch 78B Relay 1 225 Instrument Panel Illumination
40 Neutral Start Relay 78C Relay 1 (latch) 226 L.H. Side Light
41 Parking Brake Warning Relay 78D Relay 2 (unlatch) 227 R.H. Side Light
42 Reverse Relay 78E Relay 1 (unlatch) 229 Number Plate Light
43 Forward Relay 78F Relay 2 (latch) 230 Working Light Warning
44 Reverse Solenoid 79 4 Wheel/Crab Steer Solenoid 231 Cab Working Light
45 Forward Solenoid 80 4 Wheel Steer Solenoid 232 Headlamp Dip Beam
46 Transmission Dump Switch 81 Crab Steer Solenoid 233 Headlamp Main Beam
47 Parking Brake Switch 82 2 Wheel Steer Solenoid 234 Headlamp Main Beam Warning
48 Trailer Socket 83 Side Lights Relay 235 Inclinometer Illumination
49 Air Filter Switch 86 Working Light Switch
50 Engine Oil Pressure Switch 87 Road Light Switch Fuses
51 Transmission Oil Temperature 88 Headlamp Dip Switch Fuses are numbered as shown on the
Switch 93 Headlamp Flasher fuse box in the cab.
52 Transmission Oil Pressure Switch 99 Radio (Optional)
53 Water Temperature Switch 100 Transmission Dump Relay Cable Colour Code
G Green
N Brown
U Blue
Y Yellow
Note: For machines without road lights a link is fitted (as shown) in place of Working Light Switch 86 and switch 87 operates the
Working Lights. On North American machines the Safe Load Indicator System is not normally fitted, items 9, 10 and 11.
9804/1103 20 - 15 - 04/2 3640U - C/10-2.2 Issue 1

CONTENTS
Loadalls 20 - 15 - 04/3
506B To m/c no. 578676

Syncroshuttle
48 48 48
600
66 69
216 229 234
220 219 78
73 225 226 227 231 232 233
235
217 67 221
78B
78C 78D
230
65 78E 78F
218 818 835 838
829P 834 837
63 78A
301
831
847 99
B9 C1
62
816 72 821 823 848 829 830 B8 C2
822 826 824 825 86
844
817
68 77 B6 B7
112
828
833 836
410
83
71B 79 222 223 224
820
76
88
75 819
93
855
106D 827
71 80 81 82 832
110
108 109
87
B3 B4 B5 C4
103
000
000R
200
9804/1103 20 - 15 - 04/3 3630 -- C/10-3.1

3640U C/26-1.5 Issue 1
20 - 15 - 04/4
CONTENTS
Loadalls
506B From m/c no. 578677
Syncroshuttle
19
14 16 25 28 29 32
6
10 12
2
5
9 11
3
26
15
31
7
30
1 20
27
18
13
17
21 22 23 24
A1 A2 A4 A5 A6
A3
4
A269320
9804/1103 20 - 15 - 04/4 3640U-

3630C/10-4.2
- C/26-1.5 Issue 1
CONTENTS
Loadalls 20 - 15 - 04/5
506B From m/c no. 578677

Syncroshuttle
Component Key
1 Battery 49 Roof Wiper Motor and Switch

2 Starter Motor 50 Rear Wiper Motor and Switch
3 Starter Solenoid 51 Beacon
4 Starter Switch 52 Beacon Switch
5 Thermostart
6 Fuel Shut-off Solenoid
7 Neutral Start Relay Lamps
8 Forward/Reverse Selector Switch 80 Parking Brake Warning
9 Reverse Relay 81 4 Wheel Steer Warning
10 Reverse Solenoid 82 Crab Steer Warning
11 Forward Relay 83 2 Wheel Steer Warning
12 Forward Solenoid 84 Air Filter Blocked Warning
13 Transmission Dump Relay 85 Engine Oil Pressure Warning
14 Transmission Dump Switch 86 Transmission Oil Temperature
15 Parking Brake Warning Relay Warning
16 Parking Brake Switch 87 Transmission Oil Pressure
17 Rear Axle Proximity Switch Warning
18 Front Axle Proximity Switch 88 Water Temperature Warning
19 Steer Mode Printed Circuit Board 89 Alternator Warning
19A Relay 2 90 Instrument Panel Illumination
19B Relay 1 91 Cab Working Light
19C Relay 1 (latch) 92 Working Light Warning
19D Relay 2 (unlatch) 93 Interior Light
19E Relay 1 (unlatch) 94 Beacon Warning
19F Relay 2 (latch) 95 Beacon
20 Steering Mode Selector Switch
21 4 Wheel/Crab Steer Solenoid Fuses
22 4 Wheel Steer Solenoid Fuses are numbered as shown on the fuse box in the cab.
23 Crab Steer Solenoid
25 Heater Motor
26 Heater Resistor
27 Heater Switch
28 Horn
30 Horn Push
31 Wash/Wipe Switch
32 Washer Pump
35 Transmission Oil Temperature
Switch
38 Warning Buzzer
39 Hourmeter
40 Alternator
41 Tachometer
42 Fuel Gauge
44 Water Temperature Gauge
Sender
46 Reverse Alarm
47 Working Light Switch
48 Interior Light Switch
9804/1103 20 - 15 - 04/5 3640U - C/10-5.2 Issue 1

CONTENTS
Loadalls 20 - 15 - 04/6
506B From m/c no. 578677

Syncroshuttle
33 35 37 43 45 46 93
95
91 51
34 36
48 49 50
39
40
42 44
41
80 81 82 83 84 85 86 87 88 89
52 94
90
47 92
38
A7 A8 A9 B1
9804/1103 20 - 15 - 04/6 3640U - C/10-6.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 04/7
506C, 508C To m/c no. 585396

Syncroshuttle
14 16 26 28 30
6 36 38 39
17 32
5 20 21 24 25 88
27 29 90
10 12
2 33 89 42 43
41
35 37
80 82 84 86 34
3 18
9 11
81 83 85
7 15
22 44
23 87
1 19
40
13 31
8
45
9804/1103 20 - 15 - 04/7 3640U - C/10-7.2 Issue 1

CONTENTS
Loadalls 20 - 15 - 04/8
506C, 508C To m/c no. 585396

Syncroshuttle
Component Key
The complete electrical circuit is shown on page 20-15-04/7.
1 Battery Lamps
2 Starter Motor 80 Parking Brake Warning
3 Starter Solenoid 81 Air Filter Blocked Warning
4 Starter Switch 82 Engine Oil Pressure Warning
5 Thermostart 83 Transmission Oil Temperature Warning
6 Fuel Shut-off Solenoid 84 Transmission Oil Pressure Warning
7 Neutral Start Relay 85 Water Temperature Warning
8 Forward/Reverse Selector Switch 86 Alternator Warning
9 Reverse Relay 87 Instrument Panel Illumination
10 Reverse Solenoid 88 Cab Working Light
11 Forward Relay 89 Interior Light and Switch
12 Forward Solenoid 90 Beacon
14 Transmission Dump Switch Fuses
15 Parking Brake Warning Relay Fuses are numbered as shown on the fuse box in the cab.
17 Heater Motor
18 Heater Resistor
19 Heater Switch
20 Horn
22 Horn Push
23 Wash/Wipe Switch
24 Washer Pump
25 Face Fan
28 Transmission Oil TemperatureSwitch
31 Warning Buzzer
32 Hourmeter
33 Alternator
34 Tachometer
35 Fuel Gauge
38 Water Temperature Gauge Sender
39 Reverse Alarm
41 Auxiliary Earth
42 Roof Wiper Motor and Switch
43 Rear Wiper Motor and Switch
44 Beacon Switch
45 Ignition relay
9804/1103 20 - 15 - 04/8 3640U - C/10-8.2 Issue 1

CONTENTS
Loadalls 20 - 15 - 04/9
506C, 508C From m/c no. 585397

Syncroshuttle
Component Key
1 Battery Lamps
7 Neutral Start Relay 85 Water Temperature Warning
8 Forward/Reverse Selector Switch 86 Alternator Warning
9 Reverse Relay 87 Instrument Panel Illumination
10 Reverse Solenoid 88 Cab Working Light
11 Forward Relay 89 Interior Light
12 Forward Solenoid 90 Beacon
14 Transmission Dump Switch Fuses
15 Parking Brake Warning Relay Fuses are numbered as shown on the fuse box in the cab.
17 Heater Motor
18 Heater Resistor
19 Heater Switch
20 Horn
22 Horn Push
23 Wash/Wipe Switch
24 Washer Pump
25 Face Fan
31 Warning Buzzer
32 Hourmeter
33 Alternator
34 Tachometer
35 Fuel Gauge
39 Reverse Alarm
41 Auxiliary Earth
44 Beacon Switch
45 Ignition relay
9804/1103 20 - 15 - 04/9 3640U - C/10-9.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 04/10
506C, 508C From m/c no. 585397

Syncroshuttle
14 16 26 28 30
6 17 36 38 39
32
20 21 24 25 27 29 88 89 90
10 42 43
12
2 33
5
41
35 37
9 11 18 80 82 84 86 34
44
81 83 85
3 7 15
22
87
1 19
23 40
13
31
8
45
9804/1103 20 - 15-04/10 3640U - C/10-10.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 04/11
506C, 508C To m/c no. 585396

Powershift with 6 Transmission Relays
33 35 37
6 8 10 12 31 43 45
22 27 39
24 34 36 46 88 89 90
32 50
20 21
2 17 28 40
5 9 11 23 48
49
13
42 44
18 25 80 82 84 86 41
14 81 83 85
3
51
29
30 87
7 19
1
26
47
15 16 38
9804/1103 20 - 15 - 04/11 3640U - C/10-11.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 04/12
506C, 508C To m/c no. 585396

Component Key
1 Battery Lamps
7 Transmission Dump Relay 85 Water Temperature Warning
8 Transmission Dump Switch 86 Alternator Warning
9 Parking Brake Warning Relay 87 Instrument Panel Illumination
10 Parking Brake Switch 88 Cab Working Light
11 Drive Shaft Relay 89 Interior Light and Switch
12 Layshaft Solenoid 90 Beacon
13 Forward Relay
14 Reverse Relay Fuses
15 Forward/Reverse Selector Switch Fuses are numbered as shown on the fuse box in the cab.
16 Ratio Selector Switch
24 Heater Motor
25 Heater Resistor
26 Heater Switch
27 Horn
29 Horn Push
30 Wash/Wipe Switch
31 Washer Pump
32 Face Fan
38 Warning Buzzer
39 Hourmeter
40 Alternator
41 Tachometer
42 Fuel Gauge
46 Reverse Alarm
48 Auxiliary Earth
51 Beacon Switch
9804/1103 20 - 15 - 04/12 3640U - C/10-12.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 04/13
506C, 508C To m/c no. 585396

Component Key
1 Battery Lamps
11 Drive Interlock Relay 89 Interior Light and Switch
12 Drive Shaft Relay 90 Beacon
14 Mainshaft Solenoid Fuses
15 Forward Relay Fuses are numbered as shown on the fuse box in the cab.
16 Reverse Relay
26 Heater Motor
27 Heater Resistor
28 Heater Switch
29 Horn
31 Horn Push
32 Wash/Wipe Switch
33 Washer Pump
34 Face Fan
40 Warning Buzzer
41 Hourmeter
42 Alternator
43 Tachometer
44 Fuel Gauge
48 Reverse Alarm
50 Auxiliary Earth
53 Beacon Switch
9804/1103 20 - 15 - 04/13 3640U - C/10-13.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 04/14
506C, 508C To m/c no. 585396

29 35 37 39 90
8 10 11 48
6 13 14 24
33 41 45 47
26 36 38 88 89
34 52
22 23
2 19 30
5 9 12 42
25 50
51
15
44 46
20 80 82 84 86 43
16 27
81 83 85
3
31 53
32
21 87
1 7
28 49
17 18 40
9804/1103 20 - 15 - 04/14 3640U - C/10-14.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 04/15
506C, 508C From m/c no. 585397

Powershift
10 29 35 37 39
11
6 8 13 14 33 45 47
24 41
26 30 36 38 48 88 89 90
34 52
22 23
2 19 42
5 9 12
25 50 51
15
44 46
20 27 80 82 84 86 43
16
81 83 85
3
31 53
21 87
1 7
32 49
28
40
17 18
9804/1103 20 - 15 - 04/15 3640U - C/10-15.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 04/16
506C, 508C From m/c no. 585397

Powershift
1 Battery Lamps
11 Drive Interlock Relay 89 Interior Light and Switch
12 Drive Shaft Relay 90 Beacon
14 Mainshaft Solenoid Fuses
15 Forward Relay Fuses are numbered as shown on the fuse box in the cab.
16 Reverse Relay
26 Heater Motor
27 Heater Resistor
28 Heater Switch
29 Horn
31 Horn Push
32 Wash/Wipe Switch
33 Washer Pump
34 Face Fan
40 Warning Buzzer
41 Hourmeter
42 Alternator
43 Tachometer
44 Fuel Gauge
48 Reverse Alarm
50 Auxiliary Earth
53 Beacon Switch
9804/1103 20 - 15 - 04/16 3640U - C/10-16.1 Issue 1

CONTENTS
Loadalls 20 - 15 - 05/1
* 533-105Machines
Key
1 Battery
2 Battery isolator
3 Starter motor
4 Starter solenoid
5 Ignition switch
5A Fuse link 2
6 Starting aid
10 E.S.O.S.
11 Rear work lamp swich
11A Rear work lamp
13A Brake lamps
14 Brake switch
15 2/4WD switch
16 2/4WD solenoid
17 Reverse relay
17A Reverse lamp
18 Reverse alarm
19 Park brake relay
20 Heated seat
21 Radio/cassette
22 Digital clock
22A Fuse link 1
24 Instrument panel
25 Warning buzzer
26 Alternator
32 Fuel gauge
Optional fan reversing circuit shown at X

Note: all the items listed here are not necessarily fitted to all machines in the range.
9804/1103 20 - 15 - 05/1 3630 - C/33-2.2 Issue 1*

CONTENTS
Loadalls 20 - 15 - 05/2
533-105 Machine
See
23
1828
10 34 35 Sheet 4
11A 17A 18
2 6
12A 13A
19A 32 33 X
28
29
30
31
27
12B 16 35
20 21
3
34
22
601JM
601JN
601JR
7 8 9 11 12 13 15
1
4 17 19 132
410
410
26 133
1840a
1840
24
25
14
See Note 2
5 540-170
(5508 N.Am) Only
131
22A
5A
171
417050
160-02290-1
9804/1103 20 - 15 - 05/2 3660 - C/33-1.2 Issue 1*

CONTENTS
Loadalls 20 - 15 - 05/3
* 533-105Machines
Key
36 Sidelight reelay
36A Fuse link 1
37 RH side lights
38 LH side lights
40 RH/LH dip beam
41 RH/LH main beam
43 Rear fog lamp
49 Rear wiper motor
51 Roof wiper motor
57 Beacon switch
58 Beacon lamp
59 Face level fan
66 Heater
9804/1103 20 - 15 - 05/3 3630 - C/33-3.2 Issue 1*

CONTENTS
Loadalls 20 - 15 - 05/4
533-105 Machine
37
38
40
41
45
46
43 47 48 49 50 51 55 59 61 63
66
56 58
62
36 39 44 54 57 60 64
42 52
53 65
36A
160-02290-2
9804/1103 20 - 15 - 05/4 3660 - C/33-4.1 Issue 1*

CONTENTS
Loadalls 20 - 15 - 05/5
* 533-105Machines
Key
68 Horn
71A Diode pack
72 Reverse relay
73 Forward relay
74 Forward Hi-Lo relay
82 Stabiliser isloation switch
88 Sway switch
90 Sway solenoid
91 Sway solenoid
C Crab steer relay
X Two wheel steer
Y Crab steer
Z Four wheel steer
95 2WS solenoid
96 4WS solenoid
97 AWS solenoid
9804/1103 20 - 15 - 05/5 3630 - C/33-6.1 Issue 1*

CONTENTS
Loadalls 20 - 15 - 05/6
533-105 Machine
95
79 80 90 91
96
68 70 71 75 76 84 89 97
98
67 71A
88
A
94
Z
73 74 77 92 X
69 72 78 81 82 83 85 86 87 B Y 99
C
100
D
93
160-02290-3
9804/1103 20 - 15 - 05/6 3660 - C/33-5.1 Issue 1*

CONTENTS
Loadalls 20 - 20 - 02/1
* 525-58/67, 527-58/67 530-95 From m/c no. 567362 to 574295

Circuit Diagram - Hydraulics
35
12
34A
13
34B 42
34
13A
12A
11
36 15B
15A 10 10
15
V C
P
43
10A 10A
33
P
29
14
C V
2P 2M 2K 2H 2Y
S2 2X
P2 P3 2
31
2A
P1 S1 2Q 2N 2L 2J
S3
30
F
P4
2G 2F 2E 2D 2C 2B
2X 1B
2W 2V 2U 2T 2S 2R
1A
F1
32 40
T
41 41
a
a b
41A b
2CC
A166543
A166543
2S
9804/1103 20 - 20 - 02/1 Issue 3*

CONTENTS
Loadalls 20 - 20 - 02/2
525-58/67, 527-58/67, 530-95 From m/c no. 567362 to 574295

Note 1: Includes machines up to 567217 with TI 5/033
Revised Hydraulic Circuit incorporated.
Component Key
F Filter 30 Steering flow control valve

P1 Main pump 31 Steering pressure relief valve
P2 Steering pump 32 Steering pressure test point
P3 Cooling fan pump 33 Steering unit
P4 Supplementary pump (Farm Special Plus Only) 34 Steering mode valve
S1 Main pump suction line 34A Steering mode valve
S2 Steering pump suction line 34B Steering mode valve
S3 Cooling fan pump suction line 35 Front axle steering rams
T Tank 36 Rear axle steering rams
1A Neutral circuit feed line 40 Cooling fan pressure test point
1B Neutral circuit return line 41 Cooling fan motor (inset is for later machines)
2 Valve block 41A Cooling fan motor relief valve
2A Main relief valve (M.R.V.) 42 Auxiliary attachment ram
2B Lift spool 43 Displacement ram isolation valve (530-95 Only)
2C Extension spool
2CC Extension spool (Half motor spool type, 530-95 Only) Note 2: The circuit illustrated includes most of the services
2D Auxiliary spool see note 2 likely to be found on these machines. The exact order of the
2E Tilt spool spools in the valve block may vary from machine to
2F Auxiliary spool machine.
2G Sway spool
2H Auxiliary relief valve (A.R.V) Note 3: On later machines ARV's 2P and 2Q are not fitted.
2J Auxiliary relief valve (A.R.V)
2K Auxiliary relief valve (A.R.V)
2L Auxiliary relief valve (A.R.V)
2M Auxiliary relief valve (A.R.V)
2N Auxiliary relief valve (A.R.V)
2P Auxiliary relief valve (A.R.V) see note 3
2Q Auxiliary relief valve (A.R.V) see note 3
2Y Auxiliary relief valve (A.R.V) (530-95 Only)
2R Load hold check valve (L.H.C.V)
2S Load hold check valve (L.H.C.V)
2T Load hold check valve (L.H.C.V)
2U Load hold check valve (L.H.C.V)
2V Load hold check valve (L.H.C.V)
2W Load hold check valve (L.H.C.V)
2X Pressure test point
10 Lift rams
10A Lift ram check valves
11 Displacement ram
12 Extension ram
12A Extension ram check valve
13 Tilt ram
13A Tilt ram check valve
14 Non-return valve (525-58 Only)
15 Sway ram (530-95)
15A Sway ram check valve Optional
15B Sway isolation valve
29 Steering Anti-cavitation valve
9804/1103 20 - 20 - 02/2 Issue 2

CONTENTS
Loadalls 20 - 20 - 02/2A
527-58/67, 535-67 From m/c no. 574296

35
12
T P
34A 34B
13
34D 42 13A
34C
B A
12A
36
11
15B
15A 10 10
15
L 33 R
33B 33B
10A 10A
41
29 P
C V
14
33A
2M 2K 2H
16A
2X
2
33C P1 16
2X 2A
P T 2N 2L 2J
LS P EF P2
2G 2F 2E 2D 2C 2B
1B
P2B
2W 2V 2U 2T 2S 2R
P4 1A
S1
P2A
F
S2
C
F1
A230120
9804/1103 20 - 20 - 02/2A Issue 1

CONTENTS
Loadalls 20 - 20 - 02/2B
527-58/67, 535-67 From m/c no. 574296

Component Key
C Tank cap 33 Steering unit

F Filter 33A Steer valve
F1 Filter by-pass 33B Shock valves (option)
P1 Main pump 33C Main relief valve
P2 Steering/Cooling fan pump 34A Steering mode valve
P4 Supplementary pump (if fitted) 34B Steering mode valve
S1 Main pump suction line 35 Front axle steering rams
S2 Steering/Cooling fan pump suction line 36 Rear axle steering rams
T Tank 41 Cooling fan motor
1A Neutral circuit feed line 42 Auxiliary attachment ram
1B Neutral circuit return line
2 Valve block Note: The circuit illustrated includes most of the services
2A Main relief valve (M.R.V.) likely to be found on these machines. The exact order of the
2B Lift spool spools in the valve block may vary from machine to
2C Extension spool machine.
2D Auxiliary 1 spool
2E Tilt spool
2F Auxiliary 2 spool
2G Sway spool
2H Auxiliary relief valve (A.R.V)
2X Pressure test points
10 Lift rams
11 Displacement ram
12 Extension ram
13 Tilt ram
14 Non-return valve (527-58)
15 Sway ram
15A Sway ram check valve
16 Oil cooler (535-67 turbo machines only)
16A Check valve (535-67 turbo machines only)
29 Steering anti-cavitation valve
9804/1103 20 - 20 - 02/2B Issue 1

CONTENTS
Loadalls 20 - 20 - 02/3
530-120 From m/c no. 567362

23A
35
18
19
13
21 23 17
20
T P
13A
34A 34B
34
34C 34D 25
16C
B A 24A
16A
11 16
16B 16D
10 10
V C
P
36 42
22 24
15B
L 33 R
15A
15
10A 10A
33B 33B
26
14
29
33A
C V
2X
33C
2P 2K 2H
P T P1
31
2 1B
30
P2 2A
32 2Q 2L 2J
1A
2G 2Y 2Z 2E 2D 2C 2B 2CC
40 2S
S1 2W 2V 2U 2T 2SS 2S 2R
P3 S3 S2
41
F
41A
C
A142773
9804/1103 20 - 20 - 02/3 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/4
530-120 From m/c no. 567362

Component Key
F Filter 21 Right stabiliser ram

P1 Main pump 22 Left stabiliser ram
P2 Steering pump 23 Right stabiliser ram check valve
P3 Cooling fan pump 23A Right stabiliser weight on switch
S1 Main pump suction line 24 Left stabiliser ram check valve
S2 Steering pump suction line 24A Left stabiliser weight on switch
S3 Cooling fan pump suction line 25 Right stabiliser ram isolation valve
T Tank 26 Left stabiliser ram isolation valve
1A Neutral circuit feed line 29 Steering Anti-cavitation valve
1B Neutral circuit return line 30 Steering flow control valve
2 Valve block 31 Steering pressure relief valve
2A Main relief valve (M.R.V.) 32 Steering pressure test point
2B Lift spool 33 Steering unit
2C Extension spool 34 Steering mode valve (Machines without IP67 electrics)
2D Auxiliary spool 34A Steering mode valve
2E Tilt spool 34B Steering mode valve
2G Sway spool 35 Front axle steering rams
2Y Stabiliser Spool 36 Rear axle steering rams
2Z Stabiliser Spool 40 Cooling fan pressure test point
2H Auxiliary relief valve (A.R.V) 41 Cooling fan motor
2J Auxiliary relief valve (A.R.V) 41A Cooling fan motor relief valve
2K Auxiliary relief valve (A.R.V) 42 Displacement ram isolation valve
2P Auxiliary relief valve (A.R.V) Note: The circuit illustrated includes most of the services
2Q Auxiliary relief valve (A.R.V) likely to be found on these machines. The exact order of the
2R Load hold check valve (L.H.C.V) spools in the valve block may vary from machine to
2S Load hold check valve (L.H.C.V) machine.
2U Load hold check valve (L.H.C.V) Note: 2CC is extension spool half motor type.
10 Lift rams
11 Displacement ram
13 Tilt ram
15 Sway ram (Optional on 530-110)
16 Regenerative valve
17 Inner extension ram check valve
18 Inner extension ram
19 Outer extension ram
20 Regenerative circuit bleed point
9804/1103 20 - 20 - 02/4 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/5
530-110 From m/c no. 567362

23A
35
18
19
13
21 23 17
20
T P
13A
34A 34B
34
34C 34D 25
16C
B A 24A
16A
11 16
16B 16D
10 10
V C
P
36 42
22 24
15B
L 33 R
15A
15
10A 10A
33B 33B
26
14
29
33A
C V
2X
33C
2P 2K 2H
P T P1
31
2 1B
30
P2 2A
32 F 2Q 2L 2J
1A
2G 2Y 2Z 2E 2D 2C 2B 2CC
40 2S
S1 2W 2V 2U 2T 2SS 2S 2R
P3 S3 S2
41
41A
C
A166551
9804/1103 20 - 20 - 02/5 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/6
530-110 From m/c no. 567362

Component Key
F Filter 21 Right stabiliser ram

P1 Main pump 22 Left stabiliser ram
P2 Steering pump 23 Right stabiliser ram check valve
P3 Cooling fan pump 23A Right stabiliser weight on switch
S1 Main pump suction line 24 Left stabiliser ram check valve
S2 Steering pump suction line 24A Left stabiliser weight on switch
S3 Cooling fan pump suction line 25 Right stabiliser ram isolation valve
T Tank 26 Left stabiliser ram isolation valve
1A Neutral circuit feed line 29 Steering Anti-cavitation valve
1B Neutral circuit return line 30 Steering flow control valve
2 Valve block 31 Steering pressure relief valve
2A Main relief valve (M.R.V.) 32 Steering pressure test point
2B Lift spool 33 Steering unit
2C Extension spool 34 Steering mode valve (Machines without IP67 electrics)
2D Auxiliary spool 34A Steering mode valve
2E Tilt spool 34B Steering mode valve
2G Sway spool 35 Front axle steering rams
2Y Stabiliser Spool 36 Rear axle steering rams
2Z Stabiliser Spool 40 Cooling fan pressure test point
2H Auxiliary relief valve (A.R.V) 41 Cooling fan motor
2J Auxiliary relief valve (A.R.V) 41A Cooling fan motor relief valve
2L Auxiliary relief valve (A.R.V) Note: The circuit illustrated includes most of the services
2P Auxiliary relief valve (A.R.V) likely to be found on these machines. The exact order of the
2Q Auxiliary relief valve (A.R.V) spools in the valve block may vary from machine to
2R Load hold check valve (L.H.C.V) machine.
2T Load hold check valve (L.H.C.V) Note: 2CC is extension spool half motor type.
10 Lift rams
11 Displacement ram
13 Tilt ram
15 Sway ram
9804/1103 20 - 20 - 02/6 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/7
505-19 & 505-22 From m/c no. 567362 to 574295

35
12
34A
13
34B 42
34
13A
12A
11
36 15B
15A 10 10
15
V C
P
43
10A 10A
33
P
29
14
C V
2P 2M 2K 2H 2Y
S2 2X
P2 P3 2
31
2A
P1 S1 2Q 2N 2L 2J
S3
30
F
P4
2G 2F 2E 2D 2C 2B
2X 1B
2W 2V 2U 2T 2S 2R
1A
F1
32 40
T
41 41
a
a b
41A b
2CC
A166543
A166543
2S
9804/1103 20 - 20 - 02/7 Issue 2

CONTENTS
Loadalls 20 - 20 - 02/8
505-19, 505-22 From m/c no. 567362 to 574295

Component Key
F Filter 30 Steering flow control valve

P1 Main pump 31 Steering pressure relief valve
P2 Steering pump 32 Steering pressure test point
P3 Cooling fan pump 33 Steering unit
S1 Main pump suction line 34 Steering mode valve (Machines without IP67 electrics)
S2 Steering pump suction line 34A Steering mode valve
S3 Cooling fan pump suction line 34B Steering mode valve
T Tank 35 Front axle steering rams
1A Neutral circuit feed line 36 Rear axle steering rams
1B Neutral circuit return line 40 Cooling fan pressure test point
2 Valve block 41 Cooling fan motor
2A Main relief valve (M.R.V.) 41A Cooling fan motor relief valve
2B Lift spool 42 Auxiliary attachment ram
2C Extension spool
2D Auxiliary spool Note: The circuit illustrated includes most of the services
2E Tilt spool likely to be found on these machines. The exact order of the
2F Auxiliary spool spools in the valve block may vary from machine to
2G Sway spool machine.
2J Auxiliary relief valve (A.R.V) The test point may be at the valve block or the hydraulic
2K Auxiliary relief valve (A.R.V) pump.
2P Auxiliary relief valve (A.R.V)
2Q Auxiliary relief valve (A.R.V)
10 Lift rams
11 Displacement ram
12 Extension ram
13 Tilt ram
15 Sway ram (Optional)
29 Steering anti-cavitation valve (if fitted)
9804/1103 20 - 20 - 02/8 Issue 2

CONTENTS
Loadalls 20 - 20 - 02/8A
505-19 & 505-22 From m/c no.574296

35
12
T P
34A 34B
13
34D 42 13A
34C
B A
12A
36
11
15B
15A 10 10
15
L 33 R
33B 33B
10A 10A
41
29 P
C V
14
33A
2M 2K 2H
16A
2X
2
33C P1 16
2X 2A
P T 2N 2L 2J
LS P EF P2
2G 2F 2E 2D 2C 2B
1B
P2B
2W 2V 2U 2T 2S 2R
P4 1A
S1
P2A
F
S2
C
F1
A230120
9804/1103 20 - 20 - 02/8A Issue 1

CONTENTS
Loadalls 20 - 20 - 02/8B
505-19 & 505-22 From m/c no. 574296

Component Key
C Tank cap 33 Steering unit

F Filter 33A Steering valve
F1 Filter by-pass 33B Shock valves (option)
P1 Main pump 33C Main relief valve
P2 Steering pump/Cooling fan pump 34A Steering mode valve
S1 Main pump suction line 34B Steering mode valve
S2 Steering/Cooling fan pump suction line 35 Front axle steering rams
T Tank 36 Rear axle steering rams
1A Neutral circuit feed line 41 Cooling fan motor
1B Neutral circuit return line 42 Auxiliary attachment ram
2 Valve block
2A Main relief valve (M.R.V.) Note: The circuit illustrated includes most of the services
2B Lift spool likely to be found on these machines. The exact order of the
2C Extension spool spools in the valve block may vary from machine to
2D Auxiliary 1 spool machine.
2E Tilt spool
2F Auxiliary 2 spool
2G Sway spool
2X Pressure test points
10 Lift rams
11 Displacement ram
12 Extension ram
13 Tilt ram
14 Non-return valve (505-19)
15 Sway ram
29 Steering anti-cavitation valve (if fitted)
9804/1103 20 - 20 - 02/8B Issue 1

CONTENTS
Loadalls 20 - 20 - 02/9
506-36 From m/c no.567362

23A
35
18
19
13
21 23 17
20
T P
13A
34A 34B
34
34C 34D 25
16C
B A 24A
16A
11 16
16B 16D
10 10
V C
P
36 42
22 24
15B
L 33 R
15A
15
10A 10A
33B 33B
26
14
29
33A
C V
2X
33C
2P 2K 2H
P T P1
31
2 1B
30
P2 2A
32 F 2Q 2L 2J
1A
2G 2Y 2Z 2E 2D 2C 2B 2CC
40 2S
S1 2W 2V 2U 2T 2SS 2S 2R
P3 S3 S2
41
41A
C
A166552
9804/1103 20 - 20 - 02/9 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/10
506-36 From m/c no. 567362

Component Key
F Filter 29 Steering Anti-cavitation valve

P1 Main pump 30 Steering flow control valve
P2 Steering pump 31 Steering pressure relief valve
P3 Cooling fan pump 32 Steering pressure test point
S1 Main pump suction line 33 Steering unit
S2 Steering pump suction line 34 Steering mode valve (Machines without IP67 electrics)
S3 Cooling fan pump suction line 34A Steering mode valve
T Tank 34B Steering mode valve
1A Neutral circuit feed line 35 Front axle steering rams
1B Neutral circuit return line 36 Rear axle steering rams
2 Valve block 40 Cooling fan pressure test point
2A Main relief valve (M.R.V.) 41 Cooling fan motor
2B Lift spool 41A Cooling fan motor relief valve
2C Extension spool 42 Displacement ram isolation valve
2D Auxiliary spool
2E Tilt spool
2Y Stabilizer spool Note: The circuit illustrated includes most of the services
2Z Stabilizer spool likely to be found on these machines. The exact order of the
2H Auxiliary relief valve (A.R.V) spools in the valve block may vary from machine to
2J Auxiliary relief valve (A.R.V) machine.
2L Auxiliary relief valve (A.R.V) Note: 2CC is extension spool half motor type.
10 Lift rams
11 Displacement ram
13 Tilt ram
14 Non-return valve
21 Right stabilizer ram
22 Left stabilizer ram
23 Right stabilizer ram check valve
23A Weight on switch
24 Left stabilizer ram check valve
25 Right stabilizer ram isolation valve
26 Left stabilizer ram isolation valve
9804/1103 20 - 20 - 02/10 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/11
508-40 From m/c no.567362

18
19
35 13
17
20
13A
34A 16C
15A
34 15 16A
34B 16B 16
16D
11 10 10
V C
P
36 42
10A 10A
33
29
14
2P 2M 2K 2H
31
30
P2 2X 2
32 2A
S2 2Q 2N 2L 2J
P3 P1
S1
40 2G 2F 2E 2D 2C 2B 1B 2CC
F
2S
2W 2V 2U 2T 2S 2R
S3 1A
41
41A
A142782
9804/1103 20 - 20 - 02/11 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/12
508-40 From m/c no. 567362

Component Key
F Filter 29 Steering anti-cavitation valve

2D Auxiliary spool
2E Tilt spool
2F Auxiliary spool
2G Sway spool
10 Lift rams
11 Displacement ram
13 Tilt ram
14 Non-return valve
15 Sway ram
Note: The circuit illustrated includes most of the services

likely to be found on these machines. The exact order of the
spools in the valve block may vary from machine to machine.
Note: 2CC is extension spool half motor type.
9804/1103 20 - 20 - 02/12 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/13
510-40 From m/c no.567362

23A
18
19
13
35
21 23 17
20
13A
34A
34B 34 24A 25
11 16
10 10
V C
36 P
42
22 24
15A
15
10A 10A
26
33
29 14
31
30
P2 2X
32
S2
2P 2K 2H
P3 P1
S1
40
F 2 1B
2A
S3 2L 2J
2Q
1A
2G 2Y 2Z 2E 2D 2C 2B
T
41 2W 2V 2U 2T 2S 2R
41A
A154531
9804/1103 20 - 20 - 02/13 Issue 2

CONTENTS
Loadalls 20 - 20 - 02/14
510-40 From m/c no. 567362

Component Key
F Filter 29 Steering anti-cavitation valve

2D Auxiliary spool
2E Tilt spool
2G Sway spool
2Y Stabilizer spool
2Z Stabilizer spool
11 Displacement ram
13 Tilt ram
14 Non-return valve
23 Right stabilizer ram check valve
24 Left stabilizer ram check valve
25 Right stabilizer ram isolation valve
26 Left stabilizer ram isolation valve
Note: The circuit illustrated includes most of the services

likely to be found on these machines. The exact order of the
spools in the valve block may vary from machine to machine.
9804/1103 20 - 20 - 02/14 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/15
* 520-55 RS and 520-55 4 Wheel Steer From m/c no. 277001 to 278610
Circuit Diagram-Hydraulics
5 7
7A
4 5B 8
5C 7B 8A
8B
5A
a b
3
a b 9
3B 3B
6
9A
9B
2
3A
2K 2B 2K 2C 2K 2D 2E 14
1A
3C
12 13
2H 2F
LS P EF P1 2A
2J 2G 15
P1C
P1B 1C
P1A
A B A B A B A B 16
17 18
C 1B
S1
10
F
11
9804/1103 20 - 20- 02/15 3610 - E/2-2.5 Issue 4*

CONTENTS
Loadalls 20 - 20 - 02/16
* 520-55 RS and 520-55 4 Wheel Steer From m/c no. 277001 to 278610
Circuit Diagram
Component Key
C Cap
F Filter
P1 Main pump assembly
P1A Pump
P1B Pressure test point
P1C Priority valve
S1 Main pump suction line
T Tank
1A Neutral circuit feed line
1C Steer circuit return line
2 Valve block
2A Main relief valve (M.R.V.)
2B Auxiliary spool
* 2C Lift spool (see Note)
2D Tilt spool
* 2E Extension spool (see Note)
2F Auxiliary relief valve (A.R.V)
2G Auxiliary relief valve (A.R.V)
2K Load hold check valves (L.H.C.V’s)
3 Steer unit assembly
3A Steer valve
3B Shock valves (option)
3C Main relief valve
4 RS machine rear axle steer track rod
5 AWS machine steer circuit
5A Front axle steer track rod
5B Rear axle steer track rod
5C Steer alignment valve
6 Auxiliary 1 circuit (standard all machines)
7 Q Fit Carriage pin locking (option)
7A Q Fit Carriage pin locking ram
7B Q Fit Carriage manual diverter valve
8 Auxiliary 2 circuit (option)
8A Diverter valve
8B Auxiliary 2 ram
9 Hydraulic hitch (option)
9A Diverter valve
9B Hitch ram
10 Lift ram check valve
11 Lift ram
12 Displacement ram
13 Tilt ram
14 Tilt ram check valve
15 Extension ram check valve
16 Extension ram
* 17 Port restrictor
Note: On early machines spools 2C and 2E are half motor type.
9804/1103 20 - 20 - 02/16 3610 - E/2-1.5 Issue 4*

CONTENTS
Loadalls 20 - 20 - 02/17
* 520-55 4 Wheel Steer From m/c 278611

* 526-55, 526, 526S From m/c no. 277001 to 280299
*
5A 19
5D 5D
7
5C A P B
7A
8
18B 18C
18A 18A
T
18
7B 8A
5B 17B 8B
5D 5D 17 17C
L 3 R
3B 3B 9
6
17A
9A
1A 9B
2
3A
2K 2B 2K 2C 2K 2D 2E 14
3C
12 13
2H 2F
LS P EF P1 2A
2J 2G 15
P1C
P1B 1C
P1A
A B A B A B A B 16
20
22 23
C
1B
S1
10
F
11
9804/1103 20 - 20 - 02/17 3610 - E/2-4.3 Issue 3*

CONTENTS
Loadalls 20 - 20 - 02/18
* 520-55 Wheel Steer From m/c no. 278611
* 526-55, 526, 526S From m/c no. 277001 to 280299
Component Key
C Cap
F Filter
P1A Pump
P1C Priority valve
T Tank
2 Valve block
2B Auxiliary spool
2C Lift spool
2D Tilt spool
2E Extension spool
2F Auxiliary relief valve (A.R.V)
2G Auxiliary relief valve (A.R.V)
2K Load hold check valves (L.H.C.V's)
3A Steer valve
5C Steer mode selector valve
5D Brake packs
8A Diverter valve
8B Auxiliary 2 ram
9A Diverter valve
9B Hitch ram
11 Lift ram
12 Displacement ram
13 Tilt ram
16 Extension ram
17 Brake circuit charge valve
17A Main spool
17B Relief valve
17C Compensating valve (not used)
18 Accumulator manifold
18A Accumulator spheres
18B Pressure/vent connector
18C Brake pressure switch
19 Brake valve
20 Liquid/liquid cooler (not fitted)
21 not fitted
9804/1103 20 - 20 - 02/16 3610 - E/2-3.4 Issue 3*

CONTENTS
Loadalls 20 - 20 - 02/19
537-120, 537-130 From m/c no. 572900

35
23A
T P
34A 34B
18
34C 34D 19
B A 13
21 23 17
20
13A
36
25 16C
16A
24A 16
16B 16D
11
L 33 R
10 10
V C
33B 33B
P
12
22 24
15B
15A
15
10A 10A
33A
26
29
C V
33C
P
P T
31
30
P2 2X
32
S2
2K 2L
P1
S1
P3 2 1B
40
2A
S3
41 F 2J 2M
C 1A
41A
2F 2H 2G 2E 2D 2C 2B
T
2U 2T 2S 2R 2Q 2P 2N
A229130
9804/1103 20 - 20 - 02/19 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/20
537-120, 537-130 From m/c no. 572900

Component Key
C Tank cap 21 Right stabiliser ram
F Filter 22 Left stabiliser ram
P1 Main pump 23 Right stabiliser ram check valve
P2 Steering pump 23A Right stabiliser weight on switch
P3 Cooling fan pump 24 Left stabiliser ram check valve
S1 Main pump suction line 24A Left stabiliser weight on switch
S2 Steering pump suction line 25 Right stabiliser ram isolation valve
S3 Cooling fan pump suction line 26 Left stabiliser ram isolation valve
T Tank 29 Steering Anti-cavitation valve
1A Neutral circuit feed line 30 Steering flow control valve
1B Neutral circuit return line 31 Steering pressure relief valve
2 Valve block 32 Steering pressure test point
2A Main relief valve (M.R.V.) 33 Steering unit
2B Lift spool 33A Steer valve
2C Extension spool 33B Shock valves (option)
2D Auxiliary spool 33C Main relief valve
2E Tilt spool see note 1 34A 2 Wheel steer solenoid
2F Sway spool 34B 4 Wheel and crab steer solenoid
2G Stabiliser Spool 34C 4 Wheel steer solenoid
2H Stabiliser Spool 34D Crab steer solenoid
2J Auxiliary relief valve (A.R.V.) 35 Front axle steering rams
2K Auxiliary relief valve (A.R.V.) 36 Rear axle steering rams
2L Auxiliary relief valve (A.R.V.) 40 Cooling fan pressure test point
2M Auxiliary relief valve (A.R.V.) 41 Cooling fan motor
2N Load hold check valves (L.H.C.V.) 41A Cooling fan motor relief valve
2P Load hold check valves (L.H.C.V.)
2Q Load hold check valves (L.H.C.V.) Note 1: The circuit illustrated includes most of the services
2R Load hold check valves (L.H.C.V.) likely to be found on these machines. The exact order of the
2S Load hold check valves (L.H.C.V.) spools in the valve block may vary from machine to
2T Load hold check valves (L.H.C.V.) machine.
2U Load hold check valves (L.H.C.V.)
10 Lift rams
11 Displacement ram
12 Displacement ram isolation valve
13 Tilt ram
15 Sway ram
15A Sway ram check valve (if fitted)
16A Hose burst check valve
16B Relief valve
16C Check valve
16D Non return valve
9804/1103 20 - 20 - 02/20 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/21
* 520-50, 525-50, 525-52 From m/c no. 754000

20 22
7
10
21
11 7A
14
C
13
T
24 F
S
12
S1
15 P1
24A
17
16 X
17A
1C 17D
EF F T
23 23 2 1B P
T 3 P
1A F LS
3C LS
17E 17C
2F 2H
2A 17B
2G 2J
3A
A2 A1
X
2E 2D 2C 2B 18 18
2K 2K 2K 2K 3B 3B 19
25 A B
5C
5A 5B
5D 5D
5D 5D
A234942
9804/1103 20 - 20 - 02/21 3620 - E/2-2.3 Issue 3*

CONTENTS
Loadalls 20 - 20 - 02/22
520-50, 525-50, 525-52 From m/c no. 754000
Component Key
Component Key
C Cap
F Filter
LS Load Sensing line
P1 Main pump
S Suction strainer
T Tank
X Pressure test point
2 Valve block
2B Auxiliary spool
2C Lift spool
2D Tilt spool
2E Extension spool
2F Auxiliary relief valve (A.R.V's)
2G Auxiliary relief valve (A.R.V's)
2H Auxiliary relief valve (A.R.V's)
2J Auxiliary relief valve (A.R.V's)
3A Steer valve
3C Relief valve
5A Front steer ram
5B Rear steer ram
5C Steering alignment valve
5D Brake packs
7 Q Fit Carriage pin locking
7A Q Fit Carriage manual diverter valve
11 Lift ram
12 Displacement ram
13 Tilt ram
16 Extension ram
17 Brake charge/priority valve
17A Priority valve
17B Distributor valve
17C Pilot valve
17D Relief valve
17E Brake pressure switch
18 Accumulator
19 Brake valve
20 Auxiliary 1 quick release couplings
21 Electrical diverter valve (if fitted)
22 Auxiliary 2 quick release couplings
23 One-way restrictor
* 24 Hydraulic Hitch (Option)
* 25 Electrical Diverter Valve
* 26 Trailer Brake Valve (Option)
9804/1103 20 - 20 - 02/22 3620 - E/2-1.2 Issue 3*

CONTENTS
Loadalls 20 - 20 - 02/23
520-55 RS and 520-55 4 Wheel Steer To m/c no. 278610

Component Key
C Cap
F Filter
P1A Pump
P1C Priority valve
T Tank
2 Valve block
2B Auxiliary spool
2C Lift spool, see note
2D Tilt spool
2E Extension spool, see note
3A Steer valve
4 RS machine rear axle steer track rod
5 AWS machine steer circuit
5C Steer alignment valve
8A Diverter valve
8B Auxiliary 2 ram
9A Diverter valve
9B Hitch ram
11 Lift ram
12 Displacement ram
13 Tilt ram
16 Extension ram
Note: On early machines spools 2C and 2E are half motor

type.
9804/1103 20 - 20 - 02/23 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/24
520-55 RS and 520-55 4 Wheel Steer To m/c no. 278610

Circuit Diagram - Hydraulics (contÕd)
5 7
7A
4 5B 8
5C 7B 8A
8B
5A
a b
3
a b
3B 3B 9
6
9A
9B
2
3A
2K 2B 2K 2C 2K 2D 2E 14
1A
3C
12 13
2H 2F
LS P EF P1 2A
2J 2G 15
P1C
P1B 1C
P1A
16
C 1B
S1
10
F
11
A183561
9804/1103 20 - 20 - 02/24 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/25
520-55 4 Wheel Steer from Serial No. 278611 & 526-55, 526, 526S to Serial No. 280299
Component Key
C Cap
F Filter
P1A Pump
P1C Priority valve
T Tank
2 Valve block
2B Auxiliary spool
2C Lift spool
2D Tilt spool
2E Extension spool
3A Steer valve
5D Brake packs
8A Diverter valve
8B Auxiliary 2 ram
9A Diverter valve
9B Hitch ram
11 Lift ram
12 Displacement ram
13 Tilt ram
16 Extension ram
17 Brake circuit charge valve
17A Main spool
17B Relief valve
17C Compensating valve (not used)
18 Accumulator manifold
18A Accumulator spheres
18B Pressure/vent connector
18C Brake pressure switch
19 Brake valve
20 Liquid/liquid cooler (if fitted)
21 Restrictor (526-55, 526 & 526S)
9804/1103 20 - 20 - 02/25 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/26
520-55 4 Wheel Steer from Serial No. 278611 & 526-55, 526, 526S to Serial No. 280299
Circuit Diagram - Hydraulics (contÕd)
5A 19
5D 5D
7
5C A P B
7A
8
18B 18C
18A 18A
T
18
7B 8A
5B 17B 8B
5D 5D 17 17C
L 3 R
3B 3B 9
6
17A
9A
1A 9B
2
3A
2K 2B 2K 2C 2K 2D 2E 14
3C
12 13
2H 2F
LS P EF P1 2A
2J 2G 15
P1C
P1B 1C
P1A
16
20
C
1B 21
S1
10
F
11
A210540
9804/1103 20 - 20 - 02/26 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/27
526, 526S Machines with Dual Lever Control From m/c no. 280300
Component Key
C Cap
F Filter
P1A Pump
P1C Priority valve
1A Return line to tank
1B Steer circuit return line
1C Trailer brake valve return line
2 Valve block
2A Main relief valve (MRV)
2B Auxiliary spool
2C Raise/lower spool
2D Tilt spool
2E Extend/retract spool
* 2F Auxiliary relief valve (ARV) head side (Port A)
* 2G Auxiliary relief valve (ARV) rod side (Port B)
* 2H Auxiliary relief valve (ARV) (Port B)
* 2J Auxiliary relief valve (ARV) (Port A)
2K Load hold check valves (LHCVs)
*3 Steer unit assembly (with shock valves)
3A Steer valve
3B Main relief valve
3C Shock valves (option)
*4 Steer unit assembly (without shock valves)
* 4A Steer valve
* 4B Main relief valve
*7 Twin auxiliary option with hydraulic pin locking option
7A Quickfit carriage locking pin ram
7B Quickfit carriage manual diverter valve
* 7C Solenoid diverter valve (boom mounted)
* 7D Tool carrier locking pin ram
*8 Twin auxiliary option
* 8A Solenoid diverter valve (boom mounted)
*9 Hydraulic pick-up hitch (option)
* 9A Solenoid diverter valve (chassis mounted)
* 9B Pick-up hitch cylinder
* 9C Restrictor
* 9D Quick release coupling
* 10 Counter balance valve
11 Lift ram
12 Displacement ram
13 Tilt ram
16 Extension ram
19 Trailer brake valve (option)
19A Pilot valve
* 19B Trailer brake valve
19C Trailer brake coupling
19D Brake circuit connection
20 Liquid/liquid cooler (if fitted)
21 Check valve
22 Port restrictor (3.5 mm)
23 Port restrictor (3.5 mm)
9804/1103 20 - 20 - 02/27 3610 - E/2-6.3 Issue 3*

CONTENTS
Loadalls 20 - 20 - 02/28
526, 526S Machines with Dual Lever Control To m/c no. 280300
Circuit Diagram - Hydraulics (cont’d)
5A 16
2 15
23
P B Extend
A
B 2E A Retract
5C T 12 13
14
2K 22
5B
B Crowd
a b a b 2D 2F 2G A Dump
3 L R 4 21 11
3C 10
2K
B Raise
2C A Lower
c
6
d
3A 4A 2K
B
3B 4B 7D
2B A 7A
2H 2J 7B
P Ls T P1 A
2K D AUX1
a f g a f g c
P2 B
C
d
2A AUX2
P Ef Ls
7C
19C P T
P1B P1C P1 8
A
D AUX2
c B
P1A P2 C
S d AUX1
8A
C S1
B R
19B AUX1 9D 9
P1
Y A
D 9B
F N c B
19A P2
C
19D d 9C
P
19 9A
9804/1103 3610 - E/2-5.3 20 - 20 - 02/28 Issue 3*

CONTENTS
Loadalls 20 - 20 - 02/29
526, 526S Machines with Single Lever Control Option From m/c no. 280300

The single lever control option provides servo operated
boom extend/retract and auxiliary functions. The spools, 2F
and 2G respectively, are solenoid operated from lever
mounted switches which select the required function. The
raise/lower spool 2D and tilt spool 2E are both mechanically
operated with spring loading to the neutral (central) position.
* Component Key
C Cap 14 Counterbalance valve
F Filter 15 Counterbalance valve
P1 Main pump assembly 16 Extension ram
P1A Pump 19 Trailer brake valve (option)
P1B Pressure test point 19A Pilot valve
P1C Priority valve 19B Brake valve
S1 Main pump suction line 19C Trailer brake coupling
1A Return line to tank 19D Brake circuit connection
1B Steer circuit return line 21 Check valve
1C Trailer brake valve return line 22 Port restrictor (3.5mm)
2 Valve block 23 Port restrictor (3.5mm)
2A Main relief valve (MRV) 24 Port restrictor (2.5mm)
2B Pressure reducing valve (20 bar)
2C Pressure maintaining valve (10 bar)
2D Auxiliary spool
2E Raise/lower spool
2F Tilt spool
2G Extend/retract spool
2H Auxiliary relief valve (ARV) rod side (Port B)
2J Auxiliary relief valve (ARV) head side (Port A)
2K Auxiliary relief valve (ARV) (Port A)
2L Auxiliary relief valve (ARV) (Port B)
2M Load hold check valves LHCVs
2N Accumulator
2P Filter
3 Steer unit assembly (with shock valves)
3A Steer valve
4 Steer unit assembly (without shock valves)
4A Steer valve
7 Twin auxiliary option with hydraulic pin locking option
7A Quickfit carriage locking pin ram
7B Quickfit carriage manual diverter valve
7C Solenoid diverter valve (boom mounted)
7D Tool carrier locking pin ram
8 Twin auxiliary option
8A Solenoid diverter valve (boom mounted)
9 Hydraulic pick-up hitch option
9A Solenoid diverter valve (chassis mounted)
9B Pickup hitch cylinder
9C Restrictor
9D Quick release coupling
10 Counterbalance valve
11 Lift ram
12 Displacement ram
13 Tilt ram
9804/1103 20 - 20 - 02/29 3610 - E/2-7.3 Issue 3*

CONTENTS
Loadalls 20 - 20 - 02/30
526, 526S Machines with Single Lever Control Option To m/c no. 280300
*
5A
16
15
24
P
B 5C A 2
A
2G
T B
12 13
14
5B 2M 22
a b A
a b 2F
2H 2J B
3 L 3C R 4 2M
21 10 11
A
2E
B
2M
c
3A 4A A 6
d
2D
B
2K 2L
2M
3B 4B
7D
7 7B 7A
2C
P Ls T
P1 A
e f g 2P D
e f g 2B 2A c B
P2
C
2N d
P1 P Ef Ls
P T 7C
19C
P1B 1B
P1C
P1 A 8
D
P1A c B
P2 C
S
1C
d
1A
8A
C S1
F
B R 19B 9D 9
P1
A
c D 9B
P B
P2
19A 9C C
19D d
N
19
9A
9804/1103 3610 - E/2-8.3 20 - 20 - 02/30 Issue 3*

CONTENTS
Loadalls 20 - 20 - 02/31
528-70 from m/c no. 796000

528S from m/c no. 796102
Component Key
C Pressure cap breather 11A Counterbalance valve

F Return line filter 12 Tilt cylinder
F1 Filter by-pass 12A Counterbalance valve
N1 Neutral circuit feed line 12B Port restrictor (3.5mm)
N2 Neutral circuit return line 13 Displacement cylinder
S Main pump suction line 14 Check valve
S1 Suction strainer 15 Extension cylinder
T Hydraulic tank 15A Counterbalance valve
1 Main pump assembly 15B Port restrictor (3.5mm)
1A Pump 16 Trailer brake valve (option)
1B Pressure test point 16A Trailer brake coupling
1C Load sensing valve 16B Hydraulic hitch return line
2 Valve block 17 Hydraulic cooler:
2A Main relief valve (MRV) Liquid/liquid - 528-70 with high flow Aux option
2B Auxiliary spool 18 Hydraulic cooler:
2C Raise/lower spool liquid/air blast - 528S
2D Tilt spool
2E Extend/retract spool Note: Spools 2D and 2E are reversed on machines fitted
2F Auxiliary relief valve (ARV) head side - Port A with a placing control pattern.
2G Auxiliary relief valve (ARV) rod side - Port B
2H Auxiliary relief valve (ARV) - Port B
2J Auxiliary relief valve (ARV) - Port A
2K Load Hold Check Valve (LHCVs)
3A Steer valve
3D Non-return valve
3E Steer circuit return line
4A Steer valve
4C Non-return valve
5C Steer mode selector valve (steer mode option only)
5D AWS setting lever
6 Single auxiliary connectors
7 High flow auxiliary option
8 Twin auxiliary option with hydraulic pin locking
option
8A Diverter valve - boom mounted
8B Quick-fit carriage manual isolation valve
8C Pin locking cylinder
9 Twin auxiliary option
10 Hydraulic pick up hitch option
10A Diverter valve - chassis mounted
10B Pickup hitch cylinder
10C Restrictor
11 Lift cylinder
9804/1103 20 - 20 - 02/31 3650 - E/2-1.2 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/32
528-70 From m/c no. 796000

528S From m/c no. 796102
5A
2
15
15A
15B
5B 5C
2E
5D 5B 13 12
2K 12A
12B
5A
2D 2F 2G
11
3 4 2K 14 11A
3C
2C
6
3A 4A 2K 7
3B 4B 8C 8
2B 2H 2J 8B
3D 4D
2K
1 2A
8A
16A
1B 3E 9
1C
17
1A N1
16B
9A
C S N2
10
T B R 16
Y 18 10D
10B
F F1 N
S1 10C
10A
P
9804/1103 3650 - E/2-2.2 20 - 20 - 02/32 Issue 1

20 - 20 - 02/33
CONTENTS
Loadalls
528S With Single Lever Controls (SLC) From m/c no. 796102
5A
2
15
15A
15B
5B 5C
2E
5D 5B 13 12
2K 12A
12B
5A
2D 2F 2G
11
3 4 2K 14 11A
3C
2C
6
3A 4A 2K 7
3B 4B 8C 8
2B 2H 2J 8B
3D 4D
2K
1 2A
8A
16A
1B 3E 9
1C
17
1A N1
16B
9A
C S N2
10
T B R 16
Y 18 10D
10B
F F1 N
S1 10C
10A
P
9804/1103 3650 - E/2-3.1 Issue 1

20 - 20 - 02/33
CONTENTS
Loadalls 20 - 20 - 02/34
528S With Single Lever Control (SLC) From m/c no. 796102
Component Key
C Pressure Cap breather
F Return line filter 11 Lift cylinder
F1 Filter by-pass 11A Counterbalance valve
N1 Neutral circuit feed line 12 Tilt cylinder
N1 Neutral circuit return line 12A Counterbalance valve
S Main pump suction line 12B Port restrictor (3.5mm)
S1 Suction strainer 13 Displacement cylinder
T Hydraulic tank 14 Check valve
1 Main pump assembly 15 Extension cylinder
1A Pump 15A Counterbalance valve
1B Pressure test point 15B Port restrictor (3.5mm)
1C Load sensing valve 16 Trailer brake valve (option)
2 Valve block 16A Trailer brake coupling
2A Main relief valve (MRV) 16B Hydraulic hitch return line
2B Pressure reduction valve 17 Not fitted
2C Accumulator 18 Hydraulic cooler:
2D Pressure maintaining valve liquid/air blast
2E Auxiliary spool
2F Raise/lower spool Note: Spools 2D and 2E are reversed on machines equipped
2G Tilt spool with a placing control pattern.
2H Extend/retract spool
2J Auxiliary relief valve (ARV) rod side - Port B
2K Auxiliary relief valve (ARV) head side - Port A
2L Auxiliary relief valve (ARV) - Port B
2M Auxiliary relief valve (ARV) - Port A
2N Load Hold Check-Valves (LHCVs)
3A Steer valve
3D Non-return valve
3E Steer circuit return line
4A Steer valve
4C Non-return valve
5C Steer mode selector valve (steer mode option only)
5D AWS setting lever
6 Single auxiliary connectors
7 High flow auxiliary option
8 Twin auxiliary option with hydraulic pin locking option
8B Quick-fit carriage manual isolation valve
8C Pin locking cylinder
9 twin auxiliary option
10 Hydraulic pick up hitch option
10A Diverter valve - chassis mounted
10B Pick up hitch cylinder
10C Restrictor
9804/1103 20 - 20 - 02/34 3650 - E/2-4.1 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/35
530, 540 Agricultural From m/c no. 767001

Component Key
B Pressure cap breather (if fitted) 16 Rear power track rod

F Filter 17 Steer mode valve
F1 Filter by-pass 17A 2 Wheel steer solenoid
F2 See Note 1 17B 4 Wheel and crab steer solenoid
N1 Neutral circuit feed line 17C 4 Wheel steer solenoid
N2 Neutral circuit return line 17D Crab steer solenoid
S Pump suction line 17E Steering anti-cavitation valve - See Note 6.
T Tank 18 Front power track rod
1 Pump assembly - see Note 2 19 Trailer brake valve assembly option
1A Main pump 19A Pilot valve
1B Fan pump 19B Brake valve
1C Steer pump 19C Trailer brake coupling
1D Priority valve 19D Brake circuit connection
1E Test points 20 Restricted non return valve
1F Test point (if fitted)
2 Valve block Note 1: Later machines have direct return to tank from the
2A Main relief valve (M.R.V.) Filter F.
2C Pressure maintaining valve (10 bar) Note 2: From machine S/N 771430 the positions of fan pump
2D Lift spool 1B and steer pump 1C of pump assembly 1 are reversed.
2E Tilt spool
2F Extension spool Note 3: Early machines have auxiliary relief valves which
2G Auxiliary spool incorporate check valves.
2H Auxiliary relief valve (A.R.V.)
2J Auxiliary relief valve (A.R.V.) Note 4: Ports B and C of items 13A, 14A and 15A were
2K Auxiliary relief valve (A.R.V.)- see Note 3 Ports A and D on machines prior to serial number 775468.
2L Auxiliary relief valve (A.R.V.)- see Note 3
2M Load hold check valves (L.H.C.V's) Note 5: Restrictor adaptor 13E fitted to improve hitch control
2N Accumulator on machines fitted with a pickup hitch option. See Technical
3 Steering unit Information Bulletin 5/195 (E191).
3A Steer valve
3B Shock valves (option) Note 6: Steering anti-cavitation valve 17E is by-passed via
3C Main relief valve connector Y, as shown on inset Z, on machines from S/N
4 Cooling fan motor 773054.
4A Cooling fan motor drain line (if fitted)
5 Cooler (if fitted)
8 Lift ram
8A Lift ram check valve
9 Displacement ram
10 Tilt ram
11 Extension ram
11B Auxiliary relief valve (A.R.V.) (540 only)
11C Auxiliary relief valve (A.R.V.) (540 only)
12 Auxiliary 1 boom quick release couplings
13 Auxiliary 1 with trailer hitch option
13A Diverter valve (chassis) - see Note 4
13B Trailer hitch ram
13C Auxiliary 1 boom quick release couplings
13D Trailer/Auxiliary quick release coupling
13E Restrictor adaptor - See Note 5.
14 Auxiliary 1 and 2 option
14A Diverter valve (boom) - see Note 4
14B Auxiliary 2 boom quick release couplings
15 Auxiliary 1 and 2 with carriage pin locking option
15A Diverter valve (boom) - see Note 4
15D Manual change over valve
15E Hydraulic pin locking ram
9804/1103 20 - 20-02/35 3630 - E/5-1.5 Issue 1

20 - 20 - 02/36
CONTENTS
Loadalls
530, 540 Agricultural From m/c no. 767001
Circuit Diagrams - Hydraulics (cont’d)
17 15
Z
17A 17C 15D
17E 15E
18 16
15B
17B 17D
15C
Y 15A
17E
B3 14
14B
3
14C
14A
5 19C 13 13E 13D

3 3B
13C
4 2 13B
T
13A
4A
3A 19D
A 12
2G
B
3C B2 19A 19B 2M
11A 11
2K 2L
B1 A
19 2F
B
2M
1F 11B 11C
A
1 2E
1E 2H B
2M
1B 2J 10
1D A 9
F 2D
1C 1A B
F1 2M
20 10A
B 2C
S N2 2B 2A
T 2N
N1 8
F2 8A
A293711
9804/1103 20 - 20 - 02/36 3620 - E/5-2.4 Issue 1

CONTENTS
20 - 20 - 02/37
Loadalls
530 Construction From m/c no. 767001 to 770616
14
P1 B
14B
A
C
A D
P2
B 14C
17
14A
T 17A 17C B
18 16
P A
17B 17D
13
17E
P1 B 13C
C V A
C
A D
P2
13G
B
13A
2K 2L 13D
13B
5
L R
3 3B
4
T
3A
A
12
LS 2G
3C B
2 2M 2L
P T 2K
A
2E 2J 10
2H B
9
2M 11
A 11A
1E
LS P EF 1 2F 10A
1E B
2M
1D 1B
A
F 1C 2D
1A B
F1 N1 2M
20
S 2C
N2
B 2N
2B 2A
T P 8A
8
A259692
9804/1103 3630 - E/5-3.3 Issue 1

20 - 20 - 02/37
CONTENTS
Loadalls 20 - 20 - 02/38
530 Construction From m/c no. 767001 to 770616

Component Key
B Pressure cap breather 20 Restricted non return valve

F Filter
F1 Filter by-pass Note 1: From machine S/N 771430 the positions of fan pump
N1 Neutral circuit feed line 1B and steer pump 1C of pump assembly 1 are reversed.
N2 Neutral circuit return line
S Pump suction line
T Tank
1 Pump assembly - see Note 1.
1A Main pump
1B Fan pump
1C Steer pump
1D Priority valve
1E Test points
2 Valve block
2D Lift spool
2E Tilt spool
2F Extension spool
2G Auxiliary spool (open centre, see 13G)
2J Auxiliary relief valve (A.R.V.)
2K Auxiliary relief valve (A.R.V.) (Sway ram option A.R.V)
2L Auxiliary relief valve (A.R.V.) (Sway ram option A.R.V)
2M Load hold check valves (L.H.C.V's)
2N Accumulator
3 Steering unit
3A Steer valve
4 Cooling fan motor
5 Cooler
8 Lift ram
9 Displacement ram
10 Tilt ram
11 Extension ram
13 Auxiliary 1 with sway option
13A Sway ram
13B Sway ram check valve
13D Diverter valve (chassis)
13G Sway/auxiliary spool (motor spool, see 2G)
14A Diverter valve (boom)
16 Rear power track rod
17 Steer mode valve
17A 2 Wheel steer solenoid
17B 4 Wheel and crab steer solenoid
17C 4 Wheel steer solenoid
17D Crab steer solenoid
17E Steering anti-cavitation valve
18 Front power track rod
9804/1103 20 - 20 - 02/38 3630 - E/5-4.3 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/39
530, 540 Construction From m/c no. 767001 to 770617

with Single Lever Controls
Component Key
B Pressure cap breather 16 Auxiliary 1 with trailer hitch option
F Filter 16A Diverter valve (chassis) - See Note 3.
F1 Filter by-pass 16B Trailer hitch ram
F2 See Note 1. 16C Auxiliary 1 boom quick release couplings
N1 Neutral circuit feed line 16D Trailer/Auxiliary quick release coupling
N2 Neutral circuit return line 16E Restrictor adaptor - See Note 4.
S Pump suction strainer 17 Steer mode valve
T Tank 17A 2 Wheel steer solenoid
1 Pump assembly - see Note 2. 17B 4 Wheel and crab steer solenoid
1A Main pump 17C 4 Wheel steer solenoid
1B Fan pump 17D Crab steer solenoid
1C Steer pump 17E Steering anti-cavitation valve - See Note 5.
1D Priority valve 18 Front power track rod
1E Test points 19 Trailer brake valve assembly option
2 Valve block 19A Pilot valve
2A Main relief valve (M.R.V.) 19B Brake valve
2B Pressure reducing valve (20 bar) 19C Trailer brake coupling
2C Pressure maintaining valve (10 bar) 19D Brake circuit connection
2D Lift spool 20 Restricted non return valve
2E Extension spool 21 Rear power track rod
2F Tilt spool
2G Auxiliary spool Note 1: Later machines have direct return to tank from the
2H Auxiliary relief valve (A.R.V.) filter F.
2K Auxiliary relief valve (A.R.V.) (Sway ram option A.R.V.) Note 2: From machine S/N 771430 the positions of fan pump
2L Auxiliary relief valve (A.R.V.) (Sway ram option A.R.V.) 1B and steer pump 1C of pump assembly 1 are reversed.
2M Load hold check valves (L.H.C.V's)
2N Accumulator Note 3: Ports B and C of items 14A, 15A and 16A were
3 Steering unit Ports A and D on machines prior to serial number 775468.
3A Steer valve
3B Shock valves (option) Note 4: Restrictor adaptor 16E fitted to improve hitch control
3C Main relief valve on machines fitted with a pickup hitch option. See Technical
4 Cooling fan motor Information Bulletin 5/195 (E191).
5 Cooler (if fitted)
8 Lift ram Note 5: Steering anti-cavitation valve 17E is by-passed, as
8A Lift ram check valve shown on inset Z, on machines from S/N 773054.
9 Displacement ram
10 Tilt ram
11 Extension ram
11B Auxiliary relief valve (A.R.V.) (540 only)
11C Auxiliary relief valve (A.R.V.) (540 only)
13 Auxiliary 1 with sway option (if fitted)
13A Sway ram (if fitted)
13B Sway ram check valve (if fitted)
13D Diverter valve (chassis)
13E Diverter valve
13G Sway/auxiliary spool
14A Diverter valve (boom) - See Note 3.
15 Auxiliary 1 and 2 with hydraulic pin lock option
15A Diverter valve - See Note 3.
15D Hydraulic pin lock ram
15E Manual change over valve
9804/1103 20 - 20 - 02/39 3630 - E/5-5.5 Issue 1

CONTENTS
20 - 20 - 02/40
Loadalls
530, 540 Construction From m/c no. 767001 to 770617
with Single Lever Control
16 16E 16D
16C
16B
16A
Z
17 15
17E
17A 17C 15E
15B
18 21 15D
15C
17B 17D Y
15A
17E
3 14 14C 14B
14A
13
5 13G
3
3B 2M
19C 2K 2L
4
13A
2 13B
3A
13D 13C 13E
19D 2G
3C 12 11
2M 2K 2L 11A
B2 19A 19B
2F
B1 2H 2J
2M
19
1 2E
1E
2M 11B 11C
1B 10
1D 9
F 2D
1C 1A
N1 2M
F1
20 10A
B N2 2C
2B 2A
T
2N
S
F2 8A 8
A293721
9804/1103 3620 - E/5-6.4 Issue 1

20 - 20 - 02/40
CONTENTS
20 - 20 - 02/41
Loadalls
with Single Lever Control
16
15
16A 16C
17 18
16B 16D 15B
15A
15C
14D
14F
14E
14 14B 14C
L 3 R
3B
A 14A
13
B
2
13B 13C
3A
4
A
LS
2G 13A
B
3C
2M 12 11
P T 11A
2K 2L
A
2F
B
2M
2H 2J
A
LS P EF 1 2E
B
1E
2M
1C 10
1D P
A 9
F 2D
1B 1A B
2280
rev/min
F1 2M
19 10A
B
2A
S N1
T 8A 8
N2
9804/1103 3630 - E/5-7.3 Issue 1

20 - 20 - 02/41
CONTENTS
Loadalls 20 - 20 - 02/42

with Manual Auxiliary Controls
Component Key
B Pressure cap breather Note 1: Pump flow goes direct to the fan motor on non-sway
F Return line filter machines.
F1 Filter by-pass
N1 Neutral circuit feed line Note 2: Electrically operated steer mode valve shown.
N2 Neutral circuit return line Manual version also available.
S Pump suction strainer
T Tank
1 Pump assembly
1A Main pump
1B Fan pump
1C Steer pump
1D Priority valve
1E Test points
2 Valve block
2D Lift spool
2E Extension spool
2F Tilt spool
2G Auxiliary spool
2H Auxiliary relief valve (ARV)
2J Auxiliary relief valve (ARV)
2K Auxiliary relief valve (ARV)
2L Auxiliary relief valve (ARV)
2M Auxiliary relief valve (ARV)
2N Auxiliary relief valve (ARV)
2P Load hold check valves (LHCVs)
3 Steering unit
3A Steer valve
4 Cooling fan motor8 Lift ram
8A Counter-balance valve
9 Displacement ram
10 Tilt ram
11 Extension ram
13 Second auxiliary option
14 Second auxiliary with hydraulic pin locking option
14D Manual change-over valve
14E Flow restrictor
14F Hydraulic pin locking cylinder
15 Sway option
16 Steer mode valve - See Note 1.
16A Two Wheel steer solenoid
16B Four Wheel and crab steer solenoid
16C Four Wheel steer solenoid
17 Front power track-rod
18 Rear power track-rod
19 Restricted non return valve
9804/1103 20 - 20 - 02/42 3630 - E/5-8.3 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/41A
530 Construction Machines with Manual

Auxiliary Controls - fitted with 2-stage pump
(From Serial No. TBA)
Description
The diagram shows all the machine circuits to clarify the way 10A Counter-balance valve
in which they relate to each other. 11 Extension ram
The two stage pump assembly comprises two sections each 12 Auxiliary 1 boom quick release couplings
of which supplies oil to parts of the circuit as follows: (standard build)
1A Steer/valve block/auxiliary options 13A Diverter valve (boom)
1B Fan motor 13B Auxiliary 1 boom quick release couplings
The main services pump 1A has a priority valve 1D which 14 Second auxiliary with hydraulic pin locking option
always gives priority demand to the steer valve 3A. When 14A Diverter valve (boom)
there is no demand from the steer valve, oil flows from the 14B Auxiliary 1 boom quick release couplings
EF port to the control valve to provide loading auxiliary 14C Auxiliary 2 boom quick release couplings
services. 14D Manual change-over valve
14E Flow restrictor
The schematic shows a number of options, check your 14F Hydraulic pin locking cylinder
machine to see which options apply. 15 Sway control valve option
15A One way restrictors
Component Key 15B Pilot operated check-valve
15C Sway hydraulic cylinder
B Pressure cap breather (if fitted) 16 Steer mode valve - See Note 2
F Return line filter 16A Two wheel steer solenoid
F1 Filter by-pass 16B Four wheel and crab steer solenoid
N1 Neutral circuit feed line 16C Four wheel steer solenoid
N2 Neutral circuit return line 16D Crab steer solenoid
S Pump suction strainer 17 Front power track rod
T Tank 18 Rear power track rod
1 Pump assembly 19 Restricted non return valve
1A Main pump 20 Lift circuit with optional Smooth Ride System (SRS)
1B Fan pump 20A Solenoid valve
1D Priority valve 20B Solenoid valve
1E Test points 20C Accumulators
2 Valve block 20D Pressure switch
2D Lift Spool
2E Extension spool Note 1: Pump flow goes directt to the fan motor on non-
2F Tilt spool sway machines
2G Auxiliary spool
2H Auxiliary relief valve (A.R.V.) Note 2: Electrically operated steer mode valve shown.
2J Auxiliary relief valve (A.R.V.) Manual version also available.
2K Auxiliary relief valve (A.R.V.)
2L Auxiliary relief valve (A.R.V.)
2M Load hold check valves (LHCVs)
3 Steer unit assembly (Early type shown on main circuit at
X, later type shown in inset Y)
3A Steer valve
4 Cooling fan motor (non-reversible)
4A Relief valve - 190 bar (to M78434)
Relief valve - 108 bar (from M78435)
5 Reversible cooling fan motor option
5A Relief valves
5B Fan change-over solenoid
8 Lift ram
9 Displacement ram
10 Tilt ram
9804/1103 20 - 20 - 02/41A 3630 - E/5-9.5 Issue 1*

CONTENTS
Loadalls 20 - 20 - 02/42A
530 Construction Machines with Manual Auxiliary Controls - fitted with 2-stage pump From Serial No. TBA
16 15
16A 16C
17 18
16B 16D 15B
15A
4A
15C
B A
14D
14F
T P 14E
3
14 14B 14C
L R
3C
A 14A
3A 13
2 B
13B 13C
LS
4 A
2G 13A
3B 3D B
T P 2M 12 11
11A
2K 2L
A
2F
B
1E
2M
LS P EF 1
2H 2J
A
2E
B
1D 1A 2M
1B 16 36 10
2280 RPM A 9
F 2D
B
F1 2M
19 10A
B
2A
8A
S N1
T 20 20D
N2 8
8A
20B
20A
4
160-02300-4
20C
9804/1103 20 - 20 - 02/42A 3660 - E/5-10.5 Issue 1*

CONTENTS
Loadalls 20 - 20 - 02/41B

(From Serial No. 775402)
Description
The diagram shows all the machine circuits to clarify the way 10A Counter-balance valve
in which they relate to each other. 11 Extension ram
The two stage pump assembly comprises two sections each 12 Auxiliary 1 boom quick release couplings
of which supplies oil to parts of the circuit as follows: (standard build)
1A Valve block/auxiliary options 13A Diverter valve (boom)
1B Fan motor 13B Auxiliary 1 boom quick release couplings
1C Steer valve 13C Auxiliary 2 boom quick release couplings
The steer pump 1C has a priority valve 1D which always 14A Diverter valve (boom)
gives priority demand to the steer valve 3A. When there is 14B Auxiliary 1 boom quick release couplings
no demand from the steer valve, oil returns back to the tank. 14C Auxiliary 2 boom quick release couplings
The schematic shows a number of options, check your 14E Flow restrictor
machine to see which options apply. 14F Hydraulic pin locking cylinder
15 Sway control valve option
Component Key 15A One way restrictors
15B Pilot operated check-valve
B Pressure cap breather (if fitted) 15C Sway hydraulic cylinder
F Return line filter 16 Steer mode valve - See Note 2
F1 Filter by-pass 16A Two wheel steer solenoid
N1 Neutral circuit feed line 16B Four wheel and crab steer solenoid
N2 Neutral circuit return line 16C Four wheel steer solenoid
S Pump suction strainer 16D Crab steer solenoid
T Tank 17 Front power track rod
1 Pump assembly 18 Rear power track rod
1A Main pump 19 Restricted non return valve
1B Fan pump 20 Lift circuit with optional Smooth Ride System (SRS)
1C Steer pump 20A Solenoid valve
1D Priority valve 20B Solenoid valve
1E Test points 20C Accumulators
2 Valve block 20D Pressure switch
2D Lift Spool
2E Extension spool Note 1: Pump flow goes directt to the fan motor on non-
2F Tilt spool sway machines
2G Auxiliary spool
2H Auxiliary relief valve (A.R.V.) Note 2: Electrically operated steer mode valve shown.
2J Auxiliary relief valve (A.R.V.) Manual version also available.
3A Steer valve
5A Relief valves
8 Lift ram
9 Displacement ram
10 Tilt ram
9804/1103 20 - 20 - 02/41B 3630 - E/5-8.5 Issue 1*

CONTENTS
Loadalls 20 - 20 - 02/42B
530 Construction Machines with Manual Auxiliary Controls - fitted with 3-stage pump From Serial No. 775402
16
15
16A 16C
17 18
16B 16D
15B
15A
4A
15C
B A
14D
14F
T P 14E
a Y b a X b 14 14B 14C
L 3 R L 3 R
3B
3C A 14A
13
B
2
3A 13B 13C
3A
4 A
LS
LS 2G 13A
B
3B 3D 3D 3C
2M 12 11
T P P T 11A
2K 2L
A
2F
B
c c
2M
d d 2H 2J
A
LS P EF 1 2E
B
1E
2M
1C 10
1D P
16 19 32 A 9
F 2D
1B 1A B
2280
rev/min
F1 2M
19 10A
B
2A
8A
S N1
T 20
N2 20D
8
8A
20B
20A
160-02300-2
4
20C
9804/1103 20 - 20 - 02/42B 3660 - E/5-7.5 Issue 1*

CONTENTS
Loadalls 20 - 20 - 02/43

Component Key
B Pressure cap breather Note 1: Electrically operated steer mode valve shown.
F Return line filter Manual version also available.
F1 Filter by-pass
N1 Neutral circuit feed line
S Pump suction strainer
T Tank
1 Pump assembly
1A Main pump
1B Fan pump
1C Steer pump
1D Priority valve
1E Test points
2 Valve block
2D Lift spool
2E Extension spool
2F Tilt spool
2G Auxiliary spool
3 Steering unit
3A Steer valve
4 Cooling fan motor
8 Lift ram
9 Displacement ram
10 Tilt ram
11 Extension ram
14E Flow restrictor
15 Sway option
16 Steer mode valve - See Note 1.
16A Two Wheel steer solenoid
16B Four Wheel and crab steer solenoid
16C Four Wheel steer solenoid
17 Front power track-rod
18 Rear power track-rod
9804/1103 20 - 20 - 02/43 3630 - E/5-9.3 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/44

16
16A 16C
14D
17 18
14E
14F
16B 16D
14B 14C
14
14A
13B 13C
13
L 3 R 13A
3B
3A 4
12
LS A
2G
B
3C
P T 2P 11A
11
2M 2N
A
2F
B
2P
2K 2L
A
1 2E
B
1E
2P
1C 10
1D 2H 2J
A 9
2D
1B 1A B
2280
F rev/min 2P
B
F1 19 10A
2A
N2
T S N1 8A
9804/1103 3630 - E/5-10.3 20 - 20 - 02/44 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/43A

Description
The diagram shows all the machine circuits to clarify the way 9 Displacement ram
in which they relate to each other. 10 Tilt ram
The two stage pump assembly comprises two sections each 11 Extension ram
of which supplies oil to parts of the circuit as follows: 11A Counter-balance valve
1A Valve block/auxiliary options 13 Second auxiliary option
1B Fan motor 13A Diverter valve (boom)
1C Steer valve 13B Auxiliary 1 boom quick release couplings
The steer pump 1C has a priority valve 1D which always 14 Second auxiliary with hydraulic pin locking option
gives priority demand to the steer valve 3A. When there is 14A Diverter valve (boom)
no demand from the steer valve, oil returns back to the tank. 14B Auxiliary 1 boom quick release couplings
The schematic shows a number of options, check your 14D Manual change-over valve
machine to see which options apply. 14E Flow restrictor
Component Key 15 Sway option
16 Steer mode valve - See Note 1
B Pressure cap breather 16A Two wheel steer solenoid
F Return line filter 16B Four wheel and crab steer solenoid
F1 Filter by-pass 16C Four wheel steer solenoid
N1 Neutral circuit feed line 16D Crab steer solenoid
N2 Neutral circuit return line 17 Front power track rod
S Pump suction strainer 18 Rear power track rod
T Tank 19 Restricted non return valve
1 Pump assembly 20 Lift circuit with optional Smooth Ride System (SRS)
1A Main pump 20A Solenoid valve
1B Fan pump 20B Solenoid valve
1C Steer pump 20C Accumulators
1D Priority valve 20D Pressure switch
1E Test points
2 Valve block
2A Main relief valve (MRV) Note 1: Electrically operated steer mode valve shown.
2D Lift Spool Manual version also available.
2E Extension spool
2F Tilt spool
2G Auxiliary spool
2M Auxiliary relief valve (A.R.V.)
2N Auxiliary relief valve (A.R.V.)
3A Steer valve
5A Relief valves
8 Lift ram
9804/1103 20 - 20 - 02/43A 3630 - E/5-12.4 Issue 1*

CONTENTS
Loadalls 20 - 20 - 02/44A
540 Construction Machines with Manual Auxiliary Controls From Serial No. 775402
17 13
T
17A 17C T
B
F
18 16 13G
A
P 13F
P 13C
17B 17D 19C 13B
SA
5 19D
SB
Y
13E
13A
150 BAR
19 13D 15C
19B
B A
5B 15B
15A
5A R P1
T P
P2
15D
a Y b a X b B
L 3 R L 3 R N 19A 20
3C 4 P 12 20C
3C P1 A 20D
c
B D 20B
P2
2 C
20E
d
3A
3A 4A
20A
A
LS
LS 21
2G 2K 2L B
3B 3D 3D 3B
T P P T 2M
c c
A
25
2F 2H 2J B
d d
2M 24 23 22
e e A
LS P EF 1 24A
2E B
1E
2M
1C
1D P
1A
A
1B 16 19 32
F 2D
2280 B
rev/min 28 26
F1 2M 27
B
2A
P T 29
T
N1
S
F2 N2
30
31
A343503
160/12719
9804/1103 20 - 20 - 02/44A 3660 - E/5-11.4 Issue 1*

20 - 20 - 02/45
CONTENTS
Loadalls
535-95 From m/c no. 777362
17 13
T
17A 17C T
B
F
18 16 13G
A
P 13F
P 13C
17B 17D 19C 13B
SA
19D
SB
Y
13E
13A
150 BAR
19 13D 15C
19B
15B
15A
R P1
P2
15D
B
L 3 R N 19A 20
P 12 20C 20D
P1 A
4 B 20B
c D
3C P2
2 C
20E
d
3A
20A
A
LS 2G 21
2K 2L B
3D 3B
P T 2M
A
25
2F 2H 2J B
2M 24 23 22
A Extend
LS P EF 1 24A
2E B Retract
1E
2M
1C
1D P
1A
A
1B 16 19 32
F 2D
2280 B
rev/min 28 26
F1 2M 27
Crowd
B
N2 N1 2A
Dump
P T 29
T
S
Dump
F2
Lift
30
31
A343501
9804/1103 3630 - E/5-11.2 Issue 1

20 - 20 - 02/45
CONTENTS
Loadalls 20 - 20 - 02/46
535-95 From m/c no. 777362

Component Key
B Pressure cap breather 20D Trailer/Auxiliary quick release coupling

F Return line filter 20E Restrictor adaptor - see Note 2
F1 Filter by-pass 21 High flow auxiliary (option)
F2 Direct return to tank 22 Inner extension ram
S Pump suction strainer 23 Extension ram check/counter balance valve
T Tank 24 Outer extension ram
N1 Neutral circuit feed line 24A Bleed point
N2 Neutral circuit return line 25 Regenerative valve
1 Pump assembly 26 Tilt ram
1A Main pump 27 Tilt check/counterbalance valve
1B Fan pump 28 Displacement ram
1C Steer pump 29 Displacement lift valve
1D Priority valve 30 Lift ram
1E Test point 31 Lift check/counterbalance valve
2 Valve block
2A Main relief valve (MRV) Note 1: The schematic shows sway and trailer brake options.
2D Lift spool Pump flow goes direct to fan motor if sway is not fitted.
2E Extend spool
2F Tilt spool Note 2: Restrictor adaptor 20E is fitted to improve hitch
2G Auxiliary spool control on machines fitted with pick-up hitch option. See
2H Auxiliary Relief Valve (ARV) Technical Information Bulletin 5/195 (E191).
2J Auxiliary Relief Valve (ARV)
2K Auxiliary Relief Valve (ARV)
2L Auxiliary Relief Valve (ARV)
3A Steering valve
3D Non return valve
4 Cooling fan motor
12 Auxiliary 1 boom quick release couplings (standard
build)
13 Sway control valve (option)
13A Sway ram
13B Pilot operated check valve
13C One-way restrictor
13D One-way restrictor
13E Relief valve
13F Diverter valve
13G Sway valve spool
15A Hydraulic pin lock ram
15B Restrictor
15C Manual changeover valve
15D Auxiliary 2 boom quick release couplings
16 Rear power track rod
17 Steer mode valve (option)
17A 2 wheel steer solenoid
17B 4 wheel and grab steer solenoid
17C 4 wheel steer solenoid
19 Trailer brake valve assembly (option)
19A Pilot valve
19B Brake valve
19C Trailer brake coupling
19D Brake circuit connection
20 Pick-up hitch (option)
20A Solenoid diverter valve (chassis mounted)
20B Pick-up hitch ram
9804/1103 20 - 20-02/46 3630 - E/5-12.2 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/45A
535-95 Machines - fitted with 3-stage pump

Description
The diagram shows all the machine circuits to clarify the way 13B Pilot operated check valve
in which they relate to each other. 13C One-way restrictor
The two stage pump assembly comprises two sections each 13E Relief valve
of which supplies oil to parts of the circuit as follows: 13F Diverter valve
1A Valve block/auxiliary options 15A Hydraulic pin lock ram
1B Fan motor 15B Restrictor
1C Steer valve 15C Manual changeover valve
The steer pump 1C has a priority valve 1D which always 16 Rear power track rod
gives priority demand to the steer valve 3A. When there is 17 Steer mode valve (option)
no demand from the steer valve, oil returns back to the tank. 17A 2 wheel steer solenoid
The schematic shows a number of options, check your 17C 4 wheel steer solenoid
machine to see which options apply. 17D Crab steer solenoid
Component Key 19 Trailer brake valve assembly (option)
19A Pilot valve
B Pressure cap breather 19B Brake valve
F Return line filter 19C Trailer brake coupling
F1 Filter by-pass 19D Brake circuit connection
F2 Direct return to tank 20 Pick-up hitch (option)
S Pump suction strainer 20A Solenoid diverter valve (chasis mounted)
T Tank 20B Pick-up hitch ram
N1 Neutral circuit feed line 20C Auxiliary 1 boom quick release couplings
N2 Neutral circuit return line 20D Trailer/Auxiliary quick release coupling
1 Pump assembly 20E Restrictor adaptor
1A Main services pump 21 High flow auxiliary (option)
1B Fan pump 22 Inner extension ram
1C Steer pump 23 Extension ram check/counter balance valve
1D Priority valve 24 Outer extension ram
1E Test points 24A Bleed point
2 Valve block 25 Regenerative valve
2A Main relief valve (MRV) 26 Tilt ram
2D Lift Spool 27 Tilt check/counterbalance valve
2E Extension spool 28 Displacement ram
2F Tilt spool 29 Displacement lift valve
2G Auxiliary spool 30 Lift ram
2H Auxiliary relief valve (A.R.V.) 31 Lift check/counterbalance valve
2L Auxiliary relief valve (A.R.V.) Note 1: The schematic shows sway and trailer brake
2M Auxiliary relief valve (A.R.V.) options. Pump flow goes direct to fan motor if sway is not
3 Steer unit assembly fitted.
3A Steer valve
3B Main relief valve Note 2: Restrictor adaptor 20E is fitted to improve hitch
3C Shock valves (option) control on machines fitted with pick-up hitch option. See
3D Non-return valve Technical Information Bulletin 5/195 (E191).
5A Relief valves (108 bar)
(standard build)
13A Sway ram
9804/1103 20 - 20 - 02/45A 3630 - E/5-13.2 Issue 1*

CONTENTS
Loadalls 20 - 20 - 02/46A
535-95 Machines - fitted with 3-stage pump From Serial No. 777362
17 13
T
17A 17C T
B
F
18 16 13G
A
P 13F
P 13C
17B 17D 19C 13B
SA
5 19D
SB
Y
13E
13A
150 BAR
19 13D 15C
19B
B A 5B 15B
15A
5A R P1
T P
P2
15D
B
L 3 R N 19A 20
4 P 12
P1 A
20C 20D
c
B D 20B
3C P2
2 C
20E
d
3A 4A
20A
A
LS 2G 21
2K 2L B
3D 3B
P T 2M
A
b d 25
2F 2H 2J B
b c 2M 24 22
d 23
X A Extend
c
1E Y LS P EF 1
2E
24A
B Retract
1E
LS P EF 1
2M
1C
1D P
1A
A
1B 16 19 32
1D P F 2D
2280 B
1B 16 36 rev/min e 28 26
1A F1 a 2M 27
2280
rev/min
a e B
N2 N1 2A
N1
P T 29
T
S
F2
30
31
A343502
A343502
9804/1103 20 - 20 - 02/46A 3660 - E/5-14.2 Issue 1*

CONTENTS
Loadalls 20 - 20 - 02/45B
535-95 Machines - fitted with 2-stage pump

(From Serial No. TBA)
Description
The diagram shows all the machine circuits to clarify the way 13B Pilot operated check valve
in which they relate to each other. 13C One-way restrictor
The two stage pump assembly comprises two sections each 13E Relief valve
of which supplies oil to parts of the circuit as follows: 13F Diverter valve
1A Valve block/auxiliary options 15A Hydraulic pin lock ram
1B Fan motor 15B Restrictor
1C Steer valve 15C Manual changeover valve
The steer pump 1C has a priority valve 1D which always 16 Rear power track rod
gives priority demand to the steer valve 3A. When there is 17 Steer mode valve (option)
no demand from the steer valve, oil returns back to the tank. 17A 2 wheel steer solenoid
The schematic shows a number of options, check your 17C 4 wheel steer solenoid
machine to see which options apply. 17D Crab steer solenoid
Component Key 19 Trailer brake valve assembly (option)
19A Pilot valve
B Pressure cap breather 19B Brake valve
F Return line filter 19C Trailer brake coupling
F1 Filter by-pass 19D Brake circuit connection
F2 Direct return to tank 20 Pick-up hitch (option)
S Pump suction strainer 20A Solenoid diverter valve (chasis mounted)
T Tank 20B Pick-up hitch ram
N1 Neutral circuit feed line 20C Auxiliary 1 boom quick release couplings
N2 Neutral circuit return line 20D Trailer/Auxiliary quick release coupling
1 Pump assembly 20E Restrictor adaptor
1A Main services pump 21 High flow auxiliary (option)
1B Fan pump 22 Inner extension ram
1D Priority valve 23 Extension ram check/counter balance valve
1E Test points 24 Outer extension ram
2 Valve block 24A Bleed point
2A Main relief valve (MRV) 25 Regenerative valve
2D Lift Spool 26 Tilt ram
2E Extend spool 27 Tilt check/counterbalance valve
2F Tilt spool 28 Displacement ram
2G Auxiliary spool 29 Displacement lift valve
2H Auxiliary relief valve (A.R.V.) 30 Lift ram
2J Auxiliary relief valve (A.R.V.) 31 Lift check/counterbalance valve
2M Auxiliary relief valve (A.R.V.) Note 1: The schematic shows sway and trailer brake
3 Steer unit assembly options. Pump flow goes direct to fan motor if sway is not
3A Steering valve fitted.
3C Shock valves (option) Note 2: Restrictor adaptor 20E is fitted to improve hitch
3D Non-return valve control on machines fitted with pick-up hitch option. See
4 Cooling fan motor (non-reversible) Technical Information Bulletin 5/195 (E191).
4A Relief valve - 108 bar
(standard build)
13A Sway ram
9804/1103 20 - 20 - 02/45B 3630 - E/5-16.1 Issue 1*

CONTENTS
Loadalls 20 - 20 - 02/46B
535-95 Machines - fitted with 2-stage pump From Serial No. TBA
17 13
T
17A 17C T
B
F
18 16 13G
A
P 13F
P 13C
17B 17D 19C 13B
SA
5 19D
SB
Y
13E
13A
150 BAR
19 13D 15C
19B
B A
5B 15B
15A
5A R P1
T P
P2
15D
a Y b a X b B
L 3 R L 3 R N 19A 20
3C 4 P 12 20C
3C P1 A 20D
c
B D 20B
P2
2 C
20E
d
3A
3A 4A
20A
A
LS
LS 21
2G 2K 2L B
3B 3D 3D 3B
T P P T 2M
c c
A
25
2F 2H 2J B
d d
2M 24 23 22
e e A
LS P EF 1 24A
2E B
1E
2M
1C
1D P
1A
A
1B 16 19 32
F 2D
2280 B
rev/min 28 26
F1 2M 27
B
2A
P T 29
T
N1
S
F2 N2
30
31
A343503
160/12719
9804/1103 20 - 20 - 02/46B 3660 - E/5-15.1 Issue 1*

20 - 20 - 02/47
CONTENTS
Loadalls
532 to m/c no. 770638
537, 550 to m/c no. 770613
T 6A 6D B
7
5
T
P A
6B 6C
6E A
22A 22
C V 2K
B
5 7 2Q
A 21A 21
2J
B
2 2Q
20A
C3
2H C1
9
3 L R
3B A 18
20
4 2G B C2 C4
18A
2Q 2M
2L 19
3A A 16A
2F
LS 2N B
16
2Q 2P 17
3C
P T A
2E
B
13E
2Q 15 13
13B
A
2D
1E B 14
LS P EF 1 13C
2Q
1E 13D
11A
1D 1B 13A
2C 12 11
1C 2R
1A
2B
2A
8A
N2 8
S F
F1 P
B
T A260812
N1
9804/1103 20 - 20 - 02/47 3660 - E/5-1.1 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/48
532 to m/c no. 770638

537, 550 to m/c no. 770613
B Pressure cap breather 18A Sway ram check valve

F Filter 19 Auxiliary 1 boom quick release couplings
F1 Filter by-pass 20 Diverter valve (chassis)
N1 Neutral circuit feed line 20A Diverter valve - see Note 2.
N2 Neutral circuit return line 21 Right hand stabiliser ram
S Pump suction line 21A Right hand stabiliser ram check valve
T Tank 22 Left hand stabiliser ram
1 Pump assembly - see Note 1. 22A Left hand stabiliser ram check valve
1A Main pump
1B Fan pump Note 1: From machine S/N 771429 the positions of fan pump
1C Steer pump 1B and steer pump 1C of pump assembly 1 are reversed.
1D Priority valve
Note 2: See FSI 5/151 (E164 N.Am) and 5/152 (E166 N.Am)
1E Test points
for details of diverter valve 20A.
2 Valve block
2D Lift spool
2E Extension spool
2F Tilt spool
2G Sway/Auxiliary spool (motor spool with sway only)
2H Unloader valve
2J Right hand stabiliser spool
2K Left hand stabiliser spool
2L Auxiliary relief valve (A.R.V) (Sway ram option A.R.V.)
2M Auxiliary relief valve (A.R.V) (Sway ram option A.R.V.)
2Q Load hold check valves (L.H.C.V's)
2R Accumulator (only fitted with auxiliary circuit)
3 Steering unit
3A Steer valve
4 Cooling fan motor
5 Front steer rams
6 Steer mode valve
6E Steering anti-cavitation valve
7 Rear steer rams
8 Lift ram
9 Cooler
11A Inner extension ram check valve
13B Relief Valve
13C Check valve
13D Non-return valve
13E Non-return valve
14 Regenerative circuit bleed valve
16 Tilt ram
17 Displacement rams
18 Sway ram
9804/1103 20 - 20 - 02/48 3660 - E/5-2.1 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/49
532 from m/c no. 770689 to 775401

537, 550 from m/c no. 770614 to 775401
B Pressure cap breather 18 Sway ram

F Filter 18A Pilot check valve (sway ram)
F1 Filter by-pass 18B Sway function in-line restrictor
N1 Neutral circuit feed line 19 Auxiliary 1 boom quick release couplings
N2 Neutral circuit return line 20 Diverter valve (chassis)
S Pump suction strainer 20A Diverter valve (chassis)
T Tank 21 Right hand stabiliser ram
1 Pump assembly -see Note 1. 21A Right hand stabiliser ram check valve
1A Main pump 22 Left hand stabiliser ram
1B Fan pump 22A Left hand stabiliser ram check valve
1C Steer pump
1D Priority valve Note 1: From machine S/N 771429 the positions of fan pump
1E Test points 1B and steer pump 1C of pump assembly 1 are reversed.
2 Valve block
2A Main relief valve (M.R.V.) Note 2: Revised extend spool fitted due to boom over-run on
2B Pressure reducing valve (20 bar) machines prior to S/N 772366.
Note 3: Steering anti-cavitation valve 6E is by-passed via
2D Lift spool
connector Y, as shown on inset Z, on machines from S/N
2E Extension spool
773135. The anti-cavitation valve is not fitted from machine
2F Tilt spool
S/N 773630.
2G Sway/Auxiliary spool
2H Unloader valve
2J Right hand stabiliser spool
2K Left hand stabiliser spool
2Q Load hold check valves (L.H.C.V's)
2R Accumulator (only fitted with auxiliary circuit)
2S Extension motor spool - see Note 2
3 Steering unit
3A Steer valve
4 Cooling fan motor
5 Front steer rams
6 Steer mode valve
6E Steering anti-cavitation valve - see Note 3.
7 Rear steer rams
8 Lift ram
9 Cooler
11A Inner extension ram check valve
13B Relief Valve
13C Check valve
13D Non-return valve
13E Non-return valve
14 Regenerative circuit bleed valve
16 Tilt ram
17 Displacement rams
9804/1103 20 - 20 - 02/49 3660 - E/5-3.1 Issue 1

CONTENTS
20 - 20 - 02/50
Loadalls
532 from m/c no. 770639 to 775401
537, 550 from m/c no. 770614 to 775401
6
6A 6D 7
5
T
2
6B 6C
22A
6E
2K
22
5 7
21A
2J
2Q
21
3 9 20 20A
3B
2H
4 18B
3A 2G 18A
18
2Q
2L 2M 19
3C
2F
2N
2Q 16
1E 17
1 2P
6E 1E
2E
1B
1D 2Q 15 13E 13
16A
Y 1A 13B
1C
2D 14
13C
3 2Q
N2 13D
11A
12 11
13A
B 2C
F F1 2R
2B 2A
T
S
8A 8
P
N1 A293731
9804/1103 3660 - E/5-4.1 Issue 1

20 - 20 - 02/50
CONTENTS
20 - 20 - 02/51
Loadalls
532, 537, 550 From m/c no. 775402
19
19A 19C
18B
19B 19D
20 21 2 18A
18C
A
2K 17A
B
2R
A 17
2J 17B
L 19 B
L
16A
2R
2H
4 16
16B
15
LS A
2G
P T B
1E 2R
2N 2P
A
2F 14
1E 13
1 B
1E 14A
2R
1C 2L 2M
A
1D 12 11
2E
1B B 11B
1A
2R
10A
A 11C
2D 10 9
N2 B 11D
9A
B 2R
11A
F F1
2A
8
S
T 8A
N1
9804/1103 3660 - E/5-5.1 Issue 1

20 - 20 - 02/51
CONTENTS
Loadalls 20 - 20 - 02/52
532, 537, & 550 Machines with Manual From Serial No. 775402
Auxiliary Controls
Description
The diagram shows all the machine circuits to clarify the way 4 Cooling fan motor (non-reversible)
in which they relate to each other. * 4A Reversible cooling fan motor option (from Serial No.
785165)
The pump assembly comprises three sections each of which 8 Lift ram
supplies oil to parts of the circuit as follows: 8A Counter balance valve
1A Valve block/auxiliary options 9A Counter balance valve
1B Fan motor 10 Outer extension ram
1C Steer valve 11 Regenerative valve
11A Hose burst check-valve (HBCV)
The pump is mounted on the rear face of the bevel box. 11B Relief valve
11C Check valve
The valve block is mounted under the cab on the inboard 11D Non-return valve
side 11E Non return valve
12 Restricted non-return valve
The steer pump 1C has a priority valve 1D which always 13 Displacement cylinders
gives priority demand to the steer valve 3A. When there is 14 Tilt ram
no demand from the steer valve, oil returns back to the tank. 14A Counter-balance valve
The schematic shows a number of options, check your 16 Right hand stabilizer hydraulic cylinder
machine to see which options apply. 16A Stabilizer lock-out valve
16B Pressure switch (option)
Component Key 17 Left hand stablizer hydraulic cylinder
17A Stabilizer lock-out valve
B Pressure cap breather 17B Pressure switch (option)
F Return line filter 18 Sway control valve option
F1 Filter by-pass 18A One-way restrictor
N1 Neutral circuit feed line 18B Pilot operated check-valve
N2 Neutral circuit return line 18C Sway hydraulic cylinder
S Pump suction strainer * 18D relief valve (150 bar)
T Tank 19 Steer mode valve - see Note 2
1 Pump assembly 19A Two wheel steer solenoid
1A Main pump 19B Four wheel and crab steer solenoid
1B Fan pump 19C Four wheel steer solenoid
1C Steer pump 19D Crab steer solenoid
1D Priority valve 20 Front steer cylinders
1E Test points 21 Rear steer cylinders
2 Valve block
2D Lift spool Note 1: Pump flows goes direct ro the fan motor on non-
2E Extension spool sway machines.
2F Tilt spool
2G Auxiliary spool Note 2: Electrically operated steer mode valve shown.
2H Unloader valve Manual version also available.
2J Right hand stabilizer
2K Left hand stabilizer
2P Auxiliary relief valve (ARV)
2R Load hold check-valves (LHCVs)
3 Steering unit
3A Steer valves
3B Shock valves
9804/1103 20 - 20 - 02/52 3630 - E/5-6.2 Issue 2*

CONTENTS
Loadalls 20 - 20 - 02/53
506B
Component Key
C Cap Note 1: Machines from serial number 572655 have a

F Filter combined load hold check and regenerative valve 18 with a
P1 Main pump closed centre spool 2F fitted as standard. Some machines
P2 Steering pump before 572655 may have valve 18 fitted. Check your
P3 Cooling fan pump machine.
S2 Steering pump suction line Note 2: An in-line ARV 43 is available for the boom retract
S3 Cooling fan pump suction line service. See Technical Bulletin E193.
T Tank
2 Valve block
2B Lift spool
2C Auxiliary spool
2E Tilt spool
2F Extension spool (See Note 1)
2G Sway spool
2P Auxiliary relief valve (A.R.V.)
2Q Auxiliary relief valve (A.R.V.)
2R Load hold check valve (L.H.C.V.)
2S Load hold check valve (L.H.C.V.)
2T Load hold check valve (L.H.C.V.)
2U Load hold check valve (L.H.C.V.)
2V Load hold check valve (L.H.C.V.)
10 Lift cylinders
10A Lift cylinder check valves
11 Displacement cylinder
12 Extension cylinder
13 Tilt cylinder
13A Tilt cylinder check valve
14 Non-return valve
15 Sway cylinder
15A Sway cylinder check valve
17 Hose burst protection valve
18 Combined load hold check and regenerative valve
30 Steering flow control valve
31 Steering pressure relief valve
32 Steering pressure test point
33 Steering unit
34A Steering mode valve
34B Steering mode valve
35 Front axle steering cylinders
36 Rear axle steering cylinders
41 Cooling fan motor
42 Auxiliary attachment cylinder
43 In-line ARV (See Note 2)
9804/1103 20 - 20 - 02/53 3640U - E/4-1.2 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/54
506B
12
12
16
C2 18 C1
42
35 16C
16D
16B 13
18B
17 13A
34A
18A 18C
C2
34B
P 11
V2 V1
T V2
36
15A
15
2F 10
L
33
P R
10A 10A
P
29 14
T
C V
2P 2Q
A B A B A B A B A B
S2 2
2X
31 P2 P3 S3 C
P1 2M 2N 2L
43 2A
30
S1
2G 2F 2E 2C 2B 1B
2V 2U 2T 2S 2R 1A
F
32
41
T
9804/1103 3640U - E/4-2.2 20 - 20 - 02/54 Issue 1

20 - 20 - 02/55
CONTENTS
Loadalls
506C
35
P
A B
34 16
13
12
13A
36
C2 18 C1
11
18B
L 33 R
18C
15A 18A
15
33A 10
V2 V1
33C 10A 10A

See Note
P T 29 14
C V
LS P EF
P1 2W 2P 2Q
A B A B A B A B A B
2
C
P1C
S1
P1B 2A
S3 2M 2N 2L
P1A 42
2G 2F 2E 2C 2B 1B
P3 2V 2U 2T 2S 2R
1A
F
41
9804/1103 3640U - E/4-3.2 Issue 1

20 - 20 - 02/55
CONTENTS
Loadalls 20 - 20 - 02/56
506C
Component Key
C Cap
F Filter
P1A Pump
P1C Priority valve
P3 Cooling fan pump
S3 Cooling fan pump suction line
T Tank
2 Valve block
2B Lift spool
2C Auxiliary spool
2E Tilt spool
2F Extension spool
2G Sway spool
2W Auxiliary relief valve (A.R.V.) (See Note 2)
10 Lift cylinders
13 Tilt cylinder
14 Non-return valve
15 Sway cylinder
18A Retract load hold check valve
18B Regenerative check valve
18C Extend load hold check valve
29 Steering anti-cavitation valve (See Note 1)
33 Steering unit
33A Steer valve
34 Steering mode selctor valve
Note 1: Anti-cavitation valve (item 29) is not fitted to

machines from serial number 585873.
Note 2: An in-line ARV 42 is available for the boom retract

service on machines prior to 585208. See Technical Bulletin
E193. Machines after 585208 have an ARV 2W fitted within
the valve block.
9804/1103 20 - 20-02/56 3640U - E/4-4.1 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/57
506C (HL), 508C

Component Key
C Cap Note 1: An in-line ARV 42 is available for the boom retract

F Filter service on machines between 579569 and 585196. See
P1 Main pump Technical Bulletin E193. Machines after 585196 have an
P2 Steering pump ARV 2W fitted within the valve block.
P3 Cooling fan pump
S1 Main pump suction line Note 2: Non-return valve 43 fitted to 506C (HL) machines
S2 Steering pump suction line only.
S3 Cooling fan pump suction line
T Tank
2 Valve block
2B Lift spool
2C Auxiliary spool
2E Tilt spool
2F Extension spool
2G Sway spool
2W Auxiliary relief valve (A.R.V.)
10 Lift cylinders
13 Tilt cylinder
15 Sway cylinder
18A Retract load hold check valve
18B Regenerative check valve
18C Extend load hold check valve
30 Steering flow control valve
31 Steering pressure relief valve
32 Steering pressure test point
33 Steering unit
33A Steer valve
34 Steering mode selctor valve
43 Non-return valve (See Note 2)
9804/1103 20 - 20 - 02/57 3640U - E/4-5.2 Issue 1

20 - 20 - 02/58
CONTENTS
Loadalls
506C (HL), 508C
35
P
A B
34
16
T 13
12
13A
36
11
C2 18 C1
L 33 R
18B
15A
15
18A 18C 10
33A
V2 V1
P T 10A 10A
P
29 43
C V
2W 2P 2Q
A B A B A B A B A B
S2
2
2X
C
31 P3
S3 P1
P2 2M 2N 2L 2A
42
30 S1
2G 2F 2E 2C 2B 1B
F 2V 2U 2T 2S 2R 1A
32
41
9804/1103 20 - 20 - 02/58 3640U - E/4-6.2 Issue 1

CONTENTS
Loadalls 20 - 20 - 02/59

T
12
F
13B 13A
SA
5 SA
T B
11 13
13B
P A
A 14A
11A
6 7 B
11Q
16 14
A
A T B
11B 14B
B
11Q 15A
11C
L R 15
26 15B
1 11L 11M A
8
26A 11D
4 B
26B 18
26D 11Q 17
26C
T
26E P1
2
P2 11R 17A
T Extm 19
P
3 Ext
LS P EF Extr
3 P 11N 11P A
1 Retm 20
11E
Ret B
3A P4 Retr 21
2 11Q
16 33 41
Lowm 23
P3 P2 P1 4 22A
Low A P2
C
D
Lowr 11F B 22
B P1 A
9 2 Liftm
1 11Q
2 Lift
Liftr
P
T1 V1
11G
B
T Crdm
Crd
C1
24
11Q
T 1
24B
T2
C2
Dumpm 11J
V2
24A
Dump 11K
11H
T
25
10 25A
A
10A B
10E
A
10B
B
10E
10C
9804/1103 20 - 20 - 02/59 3630- E/52-1.2

3660 - C/26-1.5 Issue 1
CONTENTS
Loadalls 20 - 20 - 02/60

Component Key
T Tank 22A Counterbalance valve
P Pump 23 Boom section diverter valve
P1 Main services pump 24 Outer telescopic extension cylinder
P2 Steer pump 24A Regeneration valve
P3 Sway/fan pump 24B Pressure switch (100 bar)
P4 Priority flow diverter 25 Lift cylinder
1 Pressure cap breather 25A Counterbalance valve
2 Return line filter 26 Servo diverter valve
3 Steering valve 26A Filter
4 Engine cooling fan motor 26B Check valve
5 Steer mode valve 26C Test point
6 Front steering cylinders 26D Accumulator
7 Rear steering cylinders 26E Control isolate valve
8 Two axis servo hand controller: 26F Lift isolate valve
Port 1 Lift 26G Crowd isolate valve
Port 2 Retract 26H Dump isolate valve
Port 3 Lower
Port 4 Extend
9 Single axis servo hand controller:
Port 1 Crowd
Port 2 Dump
10 Two spool valve block
10A Extension spool
10B Lift spool
10C MRV Port A (240 bar)
10E Load hold check valves (LHCV)
11 Six spool valve block
11A Left hand stabiliser spool
11B Right hand stabiliser spool
11C Unloader section
11D Tilt spool
11E Auxiliary spool
11F Extension spool
11G Lift spool
11H MRV (260 bar)
11J Pressure maintaining valve (10 bar)
11K Pressure reducing valve (20 bar)
11L Tilt ARV Port B (330 bar)
11M Tilt ARV Port A (276 bar)
11N Auxiliary ARV Port B ( 138 bar)
11P Auxiliary ARV Port A (138 bar)
11Q Load hold check valves (LHCV)
11R Tilt isolator section
12 Sway control valve
13 Sway cylinder
13A Pilot operated check valve
13B One way restrictor
14 Left hand stabiliser cylinder
14A Stabiliser lockout valve
14B Pressure switch (35 bar)
15 Right hand stabiliser cylinder
15A Stabiliser lockout valve
15B Pressure switch (35 bar)
16 Stabiliser isolation valve
17 Tilt cylinder
17A Counterbalance valve
18 Displacement cylinders
19 Restricted check-valve
20 Auxiliary connectors, inner boom section
21 Auxilliary high flow connectors, outer boom section
(if fitted)
22 Inner extension cylinder
9804/1103 20 - 20 - 02/60 3660 - C/52-2.2 Issue 1

3660 - E/52-3.2
CONTENTS
Loadalls 20 - 20 - 02/61
533-105 Machines
(from serial No. 786756)
Description
The diagram shows all the machine circuits to clarify the way 15A Hydraulic ram pin lock
in which they relate to each other. 15B Restrictor
15C Manual changeover valve
The pump assembly comprises two sections each of which 15D Auxiliary 2 boom quick release couplings
supplies oil to parts of the circuit as follows: 16 Rear power track rod
17 Steer mode valve
1A Valve block/auxiliary options 17A 2 wheel steer solenoid
1B Fan motor 17B 4 wheel and grab steer solenoid
17C 4 wheel steer solenoid
The pump has a priority valve 1D which always gives priority 17D Crab steer solenoid
demand to the steer valve 3A. When there is no demand 18 Front power track rod
from the steer valve oil flows from the EF port to the control 21 High flow auxiliary (option)
valve to provide loading services. 22 Inner extension ram
23 Extension ram check/counter balance valve
Component Key 24 Outer extension ram
24A Bleed point
B Pressure cap breather 25 Regenerative valve
F Return line filter 26 Tilt ram
F1 Filter by-pass 27 Tilt check/counterblance valve
F2 Direct return to tank 28 Displacement ram
S Pump suction strainer 29 Displacement lift valve
T Tank 30 Lift ram
N1 Neutral circuit feed line 31 Lift check/counterbalance valve
1 Pump assembly
1A Main pump
1B Fan pump
1D Priority valve
1E Test point
2 Valve block
2A Main relief valve
2D Lift spool
2E Extend spool
2F Tilt spool
2G Auxiliary spool
2M Load hold check-valves (LHCVs)
3A Steering valve
3C Shock valves
3D Non return valve
4A Relief valve (108 bar)
5B Fan reversing valve
10A Left stabilizer lock out valve
10B Pressure switch
11A Right stabilizer lock out valve
11B Pressure switch (optional)
12 Auxiliary 1 boom quick release couplings (standard
build)
9804/1103 20 - 20 - 02/61 3630 - E/5-17.1 Issue 1*

CONTENTS
Loadalls 20 - 20 - 02/62
533-105 Machines From Serial No. 786756

17 B
T
18 P A
2 10A
10
A
5 2Q B
10B
2M
11A
B A 5B A
2P B 11
5A T P
3 2M 11B
L R
4 15C 15B
3C 15A
2N 12 15D
3A
A
4A
2G
LS 2K 2L B
3D P 2M 21
3B T
1E
2H 2J A
LS P EF 1 2F B
25
2M 24 23 22
1A
A
1C
1B 16 36
2E B
2280 RPM
2M
B F 2D B
28 27 26
2M
F1
S
T 2A 29
F2 N1 P T
30 160-13379
N2 31
9804/1103 20 - 20 - 02/62 3660 - E/5-17.1 Issue 1*

CONTENTS
RTFL Contents 1
926, 930
Contents
Page No.
General Information
- Fluids, Lubricants and Capacities (926, 930) 95 - 00 - 01/1,2
- Fluids, Lubricants and Capacities
- (926, 930, 940 N.Am) 95 - 00 - 01/3,4
- Static Dimensions (926, 930) 95 - 00 - 02/1,2
- Static Dimensions (926, 930, 940 N.Am) 95 - 00 - 02/3,4
Data
- Electrical 95 - 05 - 01/1 to 5
- Hydraulic 95 - 05 - 02/1,2
- Transmission 95 - 05 - 03/1
- Brakes 95 - 05 - 04/1
- Steering 95 - 05 - 05/1,2
- Engine 95 - 05 - 06/1
Fault Finding
- Transmission 95 - 10 - 01/1 to 3
* Circuit Diagrams
- Electrical 95 - 15 - 01/1 to 8
- Hydraulic 95 - 20 - 01/1,2
9804/1103 RTFL Contents - 1 Issue 2*

CONTENTS
RTFL 95 - 00 - 01/1
926 from m/c 602000

930 from m/c 607700
Fluids, Lubricants & Capacities (Type AA Engine Builds)
Engines of new machines are filled at the factory with JCB 10W/30 Mutigrade oil. This oil should be drained after the first 100
hours of operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB
10W/30 Mutigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to
below.

Engine (Oil) 10.5 (2.3) JCB Super Multigrade 15W/40 SAE15W/40

-10 °C to 50 °C (14 °F to 122 °F) API CF4/SG
JCB Super Multigrade 10W/30 SAE10W/30


And Summer Coolant
Transmission (2WD) 17.3 (3.8) JCB Special Transmission Fluid ESP-M2C 33G
Transmission (4WD) 18.3(4)
Front Axle 29.5 (6.5) JCB High Performance Gear Oil ESEN-M2C 86A/B
Rear Axle (4WD)

Differential 15 (3.3) JCB HD90 Gear Oil API GL-5
Hubs (x2) 1.3 (0.3)

Hydraulic System †64 (14) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)

(Below 38 °C, 100 °F)
Grease Points JCB HP Grease Lithium based, No. 2 consistency

and Fork Pivot Pins
Mast Chains JCB Chain Lubricant
†Note: This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and
check with all rams closed. Watch level sight glass when filling.
9804/1103 95 - 00 - 01/1 7576 - 108 Issue 1

CONTENTS
RTFL 95 - 00 - 01/2
926 from m/c 602000

930 from m/c 607700
Fluids, Lubricants & Capacities (Type AR Engine Builds)
below.




And Summer Coolant
Transmission (4WD) 18.3(4)
Front Axle 29.5 (6.5) JCB High Performance Gear Oil ESEN-M2C 86A/B
Rear Axle (4WD)

Differential 15 (3.3) JCB HD90 Gear Oil API GL-5
Hubs (x2) 1.3 (0.3)

Hydraulic System †64 (14) JCB High Performance Hydraulic Oil ISO VG46
(Above 38 °C, 100 °F)

(Below 38 °C, 100 °F)

and Fork Pivot Pins
9804/1103 95 - 00 - 01/2 7576 - 109 Issue 1

CONTENTS
RTFL 95 - 00 - 01/3
926 (N. Am) from m/c 603110 to 605999 and from m/c 660300
940 (N. Am) from m/c 660001
Fluids, Lubricants & Capacities (Type AA Engine Builds)
below.


14 °F to 122 °F (-10 °C to 50 °C) API CF4/SG

5 °F to 86 °F (-15 °C to 30 °C) API CD/SF

0 °F to 32 °F (-18 °C to 0 °C) API CD/SF
Engine (Coolant) 4.5 (17) JCB For Seasons Antifreeze ASTM D3306-74
And Summer Coolant
Transmission (4WD) 5.5 (20.8)
Front Axle 7.8 (29.5) JCB Special Gear Oil Plus ESEN-M2C 86A/B
Rear Axle (4WD)

Differential 4.0 (15) JCB HD90 Gear Oil API GL-5
Hubs (x2) 0.4 (1.3)

(Above 38 °C, 100 °F)

(Below 38 °C, 100 °F)

and Fork Pivot Pins
Mast Sideshift Carrier JCB Waxoyl
9804/1103 95 - 00 - 01/3 7591 - 107 Issue 1

CONTENTS
RTFL 95 - 00 - 01/4
940 (N. Am) from m/c 66001
Fluids, Lubricants & Capacities (Type AR Engine Builds)
below.



Engine (Coolant) 4.5 (17) JCB Four Seasons Antifreeze ASTM D3306-74
And Summer Coolant
Transmission (4WD) 5.5 (20.8)
Front Axle 7.8 (29.5) JCB Special Gear Oil Plus ESEN-M2C 86A/B
Rear Axle (4WD)

Differential 4.0 (15) JCB HD90 Gear Oil API GL-5
Hubs (x2) 0.4 (1.3)

(Above 38 °C, 100 °F)

(Below 38 °C, 100 °F)

and Fork Pivot Pins
Mast Sideshift Carrier JCB Waxoyl
9804/1103 95 - 00 - 01/4 7591 - 108 Issue 1

CONTENTS
RTFL 95 - 00 - 02/1
926 from m/c 602000

930 from m/c 607700
Static Dimensions
K L
H
A
G
F D
E
C B
151800
9804/1103 95 - 00 - 02/1 7576 - 111 Issue 1

CONTENTS
RTFL 95 - 00 - 02/2
926 from m/c 602000

930 from m/c 607700
Static Dimensions (cont’d)

Note: Unless otherwise indicated the following data applies to both the 926 and 930 machines.
A Overall cab height 2.57 m (8 ft 5 in)

B Overall width (over tyres) 2.20 m (7 ft 3 in)
C Overall length to front carriage 3.60 m (11 ft 10 in)
(industrial or bar)
D Inside width of cab 1.16 m (3 ft 10 in)
E Front track 1.80 m (5 ft 11 in)
F Wheel base
(2 wheel drive) 2.07 m (6 ft 10 in)
G Ground clearance
H Mast Closed Height
3.6 m mast 2.95 m (9 ft 8 in)
4.5 m mast 2.41 m (7 ft 10 in)
5.5 m mast 2.95 m (9 ft 8 in)
6.55 m mast 3.32 m (10 ft 11 in)
J Mast Open Height
3.6 m mast 4.78 m (15 ft 8 in)
4.5 m mast 5.41 m (17 ft 9 in)
5.5 m mast 6.61 m (21 ft 8 in)
6.55 m mast 7.67 m (25 ft 2 in)
Free lift (4.5 m mast only) 1.46 m (4 ft 10 in)
K Mast Tilt Forwards 18°
L Mast Tilt Backwards 10°
Forklift Performance
Outside turning radius
Departure angle - 926 machine
(2 wheel drive) 46°
Departure angle - 930 machine
Obstruction angle
Lift capacity † †
Lift height † †
†See Rating Plate
Weight (With Cab and 5.5 m Mast)

926 Machine
2 Wheel drive 5880 kg (12966 lb)
930 Machine
Note: The above data is based on a standard fork size of 1067 mm x 100 mm x 50 mm (42 in x 4 in x 2 in)
9804/1103 95 - 00 - 02/2 7576 - 112 Issue 1

CONTENTS
RTFL 95 - 00 - 02/3
940 (N. Am) from m/c 660001
Static Dimensions
K M B
J
D
L
E
F
9804/1103 95 - 00 - 02/3 7576 - 110 Issue 1

CONTENTS
RTFL 95 - 00 - 02/4
940 (N. Am) from m/c 660001
Static Dimensions (cont’d)
926 930 940
A Height to top of cab 8 ft 5 in (2.565 m) 8 ft 5 in (2.565 m) 8 ft 5 in (2.565 m)

3
B Overall width (over tires) 7 ft 5 in (2.26 m) 7 ft 11 in (2.41 m) 7ft 5 /4 in (2.279 m)
C Inside width of cab 3 ft 7 in (1.1 m) 3 ft 7 in (1.1 m) 3 ft 7 in (1.1 m)
D Front track 6 ft 2 in (1.88 m) 6 ft 2 in (1.88 m) 6 ft 2 in (1.88 m)
E Wheel base
(2-Wheel drive) 6 ft 9 in (2.06 m) 6 ft 10 in (2.07 m) 7ft 1 in (2.159 m)
(4-Wheel drive) 7 ft 0 in (2.13 m) 7 ft 0 in (2.13 m) 7ft 21/2 in (2.197 m)
F Overall length to front tires 11 ft 1 in (3.3 m) 11 ft 1 in (3.3 m) 11 ft 1 in (3.3 m)
G Overall length to front of carriage 11 ft 11 in (3.6 m) 11 ft 11 in (3.6 m)
H Ground clearance
3
(2-Wheel drive) 0 ft 11 in (280 mm) 1 ft 3 /4 in (400 mm) 1ft 4 in (406 mm)
(4-Wheel drive) 0 ft 11 in (280 mm) 0 ft 11 in (280 mm) 1 ft 01/2 in (318 mm)
WEIGHT
(With Cab)
2- Wheel drive 15036 lb (6820 kg) 14,740 lb (6,700kg)
4- Wheel drive 15991 lb (7253 kg)
2- Wheel drive & 12 ft mast 12520 lb (5679 kg)

4- Wheel drive & 12 ft mast 12860 lb (5834 kg)
2- Wheel drive & 21 ft 6 in mast 13305 lb (6035 kg)
4- Wheel drive & 21 ft 6 in mast 13645 lb (5989 kg)
FORKLIFT PERFORMANCE
Outside turning radius, unbraked

(2-Wheel drive) 11 ft 10 in (3.6 m) 11 ft 10 in (3.6 m) 12 ft 5 in (3.789 m)
3 3
(4-Wheel drive) 14 ft 8 /4 in (4.49 m) 14 ft 8 /4 in (4.49 m) 14 ft 9 in (4.495 m)
Lift capacity † † †
Lift height † † †
Mast tilt
K Maximum tilt forward (jobsite) 20° 20° 20°
L Maximum tilt forward (transporting) 37° 37° 42°
M Maximum tilt back 10° 10° 9.5°
†See Rating Plate
9804/1103 95 - 00 - 02/4 7591 - 111 Issue 1

CONTENTS
RTFL 95 - 05 - 01/1
926, 930
Data - Electrical
System Type 12 volt, negative earth
Battery
Cranking Performance at - 18 °C (0 °F) 410 amps to 1.4 V.P.C.
Reserve capacity (minutes) for 25 amp load 180
Starter Motor Lucas M127
Light Bulbs
Headlights 60/55 W H4 Halogen

Side/tail lights 5 W SBC
Stop lights 21 W SBC
Reversing light 21 W SBC
Direction indicators 21 W SBC
Number plate light 10 W
Instruments 3W
Beacon 55 W Halogen
IP67 Electrics
Machines from serial No. 602902 (926) and 608656 (930) are fitted with IP67 electrics which features different loom
construction and method of attachment.
9804/1103 95 - 05 - 01/1 5100 - 10/1-1.2 Issue 1

CONTENTS
RTFL 95 - 05 - 01/2
926, 930 To m/c no. 602073 (926), 607717 (930)

Data - Electrical
Fuses
The electrical circuits are protected by fuses. The fuses are located in a fuse box near the instrument panel. They are in two
rows, labelled A and B. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one.
Circuit Protection
Fuse Circuits Fuse Rating

Number (Amps)
A1 Dip Beam - left hand 10
A2 Dip Beam - right hand 10
A3 Main Beam - left hand 10
A4 Main Beam - right hand 10

Main Beam Warning Light
A5 Roof Wiper 10
Rear Wiper
Beacon
A6 Hazard Warning Lights 10
B1 Back-up Alarm 10
Transmission Solenoids
Parking Brake Buzzer
Engine Shut Off Solenoid
B2 Sidelights - left hand 10
B3 Sidelights - right hand 10
B4 Heater 10
Direction Indicators
B5 Gauges 10
Parking Brake Light
Instrument Panel
Warning Lights
Brake Lights
B6 Horn 10
Washer
Front Wiper
Headlight Flasher
9804/1103 95 - 05 - 01/2 5100 - 10/1-2.2 Issue 1

CONTENTS
RTFL 95 - 05 - 01/3
926, 930 From m/c no. 602074 (926), 607718 (930) & machines with IP67 Electrics
Data - Electrical
Fuses
The electrical circuits are protected by fuses. The fuses are located in fuse boxes near the instrument panel. They are in three
rows, labelled A, B and C. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one.
Circuit Protection
Fuse Circuits Fuse Rating

Number (Amps)
A1 Dip Beam - left hand 10
A2 Dip Beam - right hand 10
A3 Main Beam - left hand 10
A4 Main Beam - right hand 10

Main Beam Warning Light
A5 Rear Wiper 10
Beacon
or as above plus Roof Wiper 15
A6 Hazard Warning Lights 10
B1 Forward/Reverse Solenoids 10
via Relays
B2 Sidelights - left hand 10
B3 Sidelights - right hand 10

Number Plate Light
B4 Heater 10
B5 Gauges 10
Parking Brake Light
Instrument Panel
Warning Lights
Brake Lights
B6 Horn 10
Front Wiper
Direction Indicators 126820
C1 Engine Shut-Off Solenoid 5
C2 Back-Up Alarm 5
Reversing Light Circuit
C3 Headlight Flasher 10
9804/1103 95 - 05 - 01/3 5100 - 10/1-3.3 Issue 1

CONTENTS
RTFL 95 - 05 - 01/3A
926, 930 From m/c no. TBA

Data - Electrical
Fuses
The electrical circuits are protected by fuses. The primary
fuses are located in the engine bay adjacent to the battery.
The individual circuit fuses are located in fuse boxes near
the instrument panel. They are in two rows labelled A and
B. Each fuse position in each row is numbered. If a fuse
blows, find out why before fitting a new one.
PRIMARY FUSES
PR1 Feeding circuit fuses B1 - B4 50A
PR2 Feeding circuit fuses A7 - A9, B5 - B7 60A
PR3 Feeding ignition switch, circuit fuses A1 - A6 70A
PR4 Feeding air conditioning 60A
CIRCUIT FUSES
Row A
A1 Transmission 7.5A
A2 Instrumentation 5A
A3 Brake Lights 7.5A
A4 ESOS/Cold Start Advance 10A
A5 Rear/Roof Wiper, Face Fan (Option) 10A(15A)
A6 Front Wipe/Wash 10A
A7 Beacon 7.5A
A8 Hazard Warning Lights 10A
A9 Horn, Headlamp Flash 15A
A10 Thermostart 20A
PR1 PR2
Row B 50A 60A

B1 Direction Indicators 7.5A
B2 Dip Beam 15A
70A 817/17132 60A
B3 Worklamp 10A
B4 Heater Fan 10A PR3 PR4
B5 Left Hand Sidelights 5A
A370770
B6 Right Hand Sidelights 5A
B7 Fog Light 5A
B8 Not used
B9 Not used
B10 Not used
9804/1103 95 - 05 - 01/3A 5100 - 10/1-6.1 Issue 1

CONTENTS
RTFL 95 - 05 - 01/4
926, 930
Data - Electrical
Relay Location
The relays are located as follows:
A Neutral start relay

B Flasher relay
C Reverse alarm relay
D Side lights relay
E Parking brake relay
F Forward relay
G Reverse relay
9804/1103 95 - 05 - 01/4 5100 - 10/1-4.1 Issue 1

CONTENTS
RTFL 95 - 05 - 01/5
926, 930 From m/c 664290

Data - Electrical
Fuses Relay Location
The electrical circuits are protected by fusews. The fuses are A Buzzer
located in fuse boxes near the instrument panel. They are in B Flashers
three rows, labelled A, B and C. Each fuse position in each C Parbrake lamp
row is numbered. If a fuse blows, find out why before fitting a D Ignition
new one. E Neutral start
F Transmission dump
ROW A G Foeward
H Reverse
Circuit Rating
1 Brake Light 7.5A

2 Rotation Beacon 7.5A
3 Laft hand sidelights 5A
4 Right hand sidelights 5A
5 Engine shut-off Solenoid (ESOS) 5A
6 Hazard Warning Lights 10A
ROW B
Circuit Rating
1 Heater Fan 15A
2 Warning Lights 5A
3 Dip beam 15A
4 Main beam 15A
5 Worklamp 7.5A
6 Direction Indicators 7.5A
ROW C
Circuit Rating
1 Front wash/wipe 7.5A
2 Horn/headlamp flash 15A
3 Transmission 10A
4 Thermostart 20A
5 Rear/roof wiper 10A
- with fan level fan 15A
6 Main lighting 25A
9804/1103 95 - 05 - 01/5 5100 - 10/1-5.1 Issue 1

CONTENTS
RTFL 95 - 05 - 02/1
926, 930
940 (N. Am. only)
Data Hydraulic
Pump
Type Sundstrand gear AFGP25L27689

Flow at MRV pressure 55 litres/min 12 UK gal/min 14 US gal/min
Control Valves
Type Kontak Unit 18 Sectional, two to four spools according to
build.
Spool 1 Double-acting, carriage lift.
Spool 2 Double-acting, mast tilt.
Spool 3 Double-acting, attachments as required.
Relief Valve Operating Pressures bar kgf/cm@ lbf/in@

Carriage Lift A.R.V. (UK and Rest of World)

- JCB 926, 3.6 m Mast 138 141 2000
- JCB 926, 4.5 m Free Lift Mast 207 211 3000
- JCB 926, 5.5 & 6.55 m Masts 193 197 2800
- JCB 930, 3.6 m Mast 152 155 2200
- JCB 930, 4.5 m Free Lift Mast 234 239 3400
- JCB 930, 5.5 & 6.55 m Masts 172 176 2500
Carriage Lift A.R.V. (North America Machines only)

- 926, 144 Standard 2-rail Mast 110 113 1600
- 926, 171 Duplex 2-rail Mast 131 134 1900
- 926, 258 3-rail Mast 134 137 1940
- 930, All Masts 128 130 1850
- JCB 930, Sideshift 11 ft 9 in Duplex Mast 145 148 2100
- JCB 930, Sideshift 14 ft 9 in Free Lift Mast 234 239 3400
- JCB 930, Sideshift 21 ft 6 in Mast 207 211 3000/3050
- JCB 930, 28 ft Mast 162 165 2350
- 940, All Masts 155 159 2250
Note: For North America machines with JCB masts, refer to UK and Rest of World A.R.V. settings.
Multi-hitch A.R.V.'s (top & bottom) 172 176 2500

Other Attachments 145 148 2100
Sideshift A.R.V. (North America only)
- Top Port 158 161 2300
- Bottom Port 124 126 1800
Deration Relief Valve
- JCB 926, 5.5 m Mast 179/183 183/186 2600/2650
- JCB 926, 6.55 m Mast 155/159 158/162 2250/2300
- JCB 926, 6.55 m Mast (narrow track) 145/148 148/151 2100/2150
- JCB 930, 5.5 m Mast 152/155 155/158 2200/2250
- JCB 930, 6.55 m Mast 134/138 137/141 1950/2000
- JCB 930, 6.55 m Mast (narrow track) 121/124 123/126 1750/1800
Tilt A.R.V. 69 70 1000

Note: All hydraulic pressure settings to be carried out at maximum engine revs and hydraulic oil hot at 40 °C.
Rams JCB 926 Bore Rod Dia Stroke

mm in mm in mm in
3.6 m Mast - Lift 60 2.3 50 1.9 1833 72.2
- Tilt 70 2.8 40 1.6 254 10.0
4.5 m Mast - Lift (outer) 60 2.3 50 1.9 1525 60.0
- Lift (centre) 82 3.2 80 3.1 725 28.5
- Tilt 70 2.8 40 1.6 254 10.0
5.5 m Mast - Lift 60 2.3 50 1.9 1833 72.2
- Tilt 70 2.8 40 1.6 254 10.0
6.55 m Mast - Lift 60 2.3 50 1.9 2172 85.5
- Tilt 70 2.8 40 1.6 254 10.0
9804/1103 95 - 05 - 02/1 5100 - 2/1-1.6 Issue 1

CONTENTS
RTFL 95 - 05 - 03/1
926, 930
940 (N. Am. only)
Data Transmission
Syncro Shuttle Combined torque converter, reverser and gearbox unit
with optional four wheel drive output.
Torque Converter Diameter. 279 mm (11 in)
Torque Multiplication at Stall 2.2 : 1
Minimum Engine Speed at Converter Stall 1650 - 1750 rev/min
Gear Ratios 1st 5.55 : 1

2nd 3.45 : 1
3rd 1.83 : 1
4th 1.00 : 1
Converter In at 50 deg C 1000 rev/min 2.4 - 3.4 2.5 - 3.5 35 - 50

2000 rev/min 5.9 - 7.9 6.0 - 8.1 85 - 115
Converter In at 100 deg C 1000 rev/min 1.3 - 2.0 1.4 - 2.1 20 - 30
2000 rev/min 5.2 - 5.9 5.3 - 6.0 75 - 85
Converter Out at 50 deg C 1000 rev/min 1.0 - 1.7 1.1 - 1.8 15 - 25

2000 rev/min 2.1 - 3.1 2.1 - 3.2 30 - 45
Converter Out at 100 deg C 1000 rev/min 0.3 - 0.6 0.3 - 0.6 4-8
2000 rev/min 1.0 - 1.7 1.1 - 1.8 15 - 25
Converter Inlet Protection Pressure (max.) 7.9 8.1 115
At 50 deg C 1000 rev/min 0.2 - 0.3 0.2 - 0.4 3-5

2000 rev/min 0.4 - 0.7 0.4 - 0.7 6 - 10
At 100 deg C 1000 rev/min 0.1 - 0.2 0.1 - 0.2 2-3

2000 rev/min 0.3 - 0.6 0.3 - 0.6 4-8
Main Line Pressure
At 50 deg C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150

2000 rev/min 10.7 - 11.7 10.9 - 12.0 155 - 170
At 100 deg C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
2000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
At 50 deg C 1000 rev/min 8.3 - 9.0 8.4 - 9.1 120 - 130

2000 rev/min 9.0 - 10.0 9.1 - 10.2 130 - 145
At 100 deg C 1000 rev/min 8.3 - 9.0 8.4 - 9.1 120 - 130
2000 rev/min 8.3 - 9.0 8.4 - 9.1 120 - 130
Flow Rates l/min UK gal/min US gal/min
Cooler at 50 deg C 1000 rev/min 11.4 - 13.6 2.5 - 3.0 3.0 - 3.6
2000 rev/min 20.5 - 22.7 4.5 - 5.0 5.4 - 6.0
Cooler at 100 deg C 1000 rev/min 10.2 - 12.5 2.25 - 2.75 2.7 - 3.3
2000 rev/min 22.7 - 26.1 5.0 - 5.75 6.0 - 6.9
Pump at 50 deg C 1000 rev/min 11.0 - 15.0 2.5 - 3.3 3.0 - 4.0
2000 rev/min 22.5 - 29.5 5.0 - 6.5 6.0 - 8.0
9804/1103 95 - 05 - 03/1 5100 - 6/1-1.2 Issue 1

CONTENTS
RTFL 95 - 05 - 03/2
926, 930
940 (N. Am. only)
Drive Axle - Front
Type Epicyclic
Overall Gear Ratio 18.16 : 1
24.975 : 1 German
Steering Axle - Rear (2WD)
Weight with Steer Rams (but without wheels) 278 kg (613 lb)
Toe-in Zero
Castor Angle 2°
King-pin Angle Zero
Oscillation + 6°
Steering Axle - Rear (4WD)
Weight with Steer Rams (but without wheels) 352 kg (776 lb)
Overall Gear Ratio (JCB Syncro Shuttle) 18.6 : 1
Crownwheel and Pinion Ratio 3.44 : 1
Oscillation ± 9°
Castor Angle 2°
Toe-in Zero
Tyre Pressures
Front bar lbf/in2
15.5/80 x 24 x 10 3.0 44
15.5 x 25 x 8 3.0 44
16.5/85 x 24 x 8 3.0 44
16.9 x 24 x 12 (926 only) 2.0 29
Rear - JCB 926
9.00 x 16 x 8 3.9 57
10.5 x 18 x 10 2.5 36
11L x 16 x 10 3.6 52
12.5/80 x 18 x 8 1.5 22
12.5 x 18 x 10 1.7 25
12.5/80 x 18 x 10 1.7 25
14 x 17.5 x 10 (N. Am 4WD only) 1.7 25
Rear - JCB 930
10.5 x 18 x 10 3.7 5.4

12.5/80 x 18 x 8 2.1 30
12.5 x 18 x 10 2.1 30
12.5/80 x 18 x 10 2.1 30
14 x 17.5 x 10 (N. Am 4WD only)
14.5/75 x 16.1 x 10 (N. Am 4WD only)
Wheel Nut Torques
Front Rear
lbf ft Nm lbf ft Nm
500 678 500 678
9804/1103 95 - 05 - 03/2 5100 - 7/1-1.3 Issue 1

CONTENTS
RTFL 95 - 05 - 04/1
926, 930
Data - Brakes
Service Brakes
Type JCB Oil-Immersed Multi-plate Disc

Actuation Hydraulic
Location Front Axle
Nominal Facing Area 13266 mm2 (20 in2)
Master Cylinder, Single Brake Pedal Machines
Piston diameter (each) 28.58 mm (1.125 in)

Piston Area (each) 641.4 mm (0.994 in2)
Pedal Ratio 5.1 : 1
Master Cylinder, Dual Brake Pedal Machines
Total Stroke 35 mm (1.4in)
Parking Brake

9804/1103 95 - 05 - 04/1 5100 - 8/1-1.5 Issue 1

CONTENTS
RTFL 95 - 05 - 05/1
926, 930 To m/c nos. 602749 (926), 608299 (930)

Data - Steering
Pump A12.5/29926, gear type
Controlled Flow litres/min UK gal/min
at 1300 engine rev/min and neutral pressure 27.5 6.0
engine rev/min (pressure outlet blocked) 45.5 10.0
Control Unit Danfoss Orbitrol OSPB 160
Ram Dimensions (2 Wheel Drive)
Bore 50.8 mm (2.0 in)
Rod Dia. 25.4 mm (1.0 in)
Bore 50.0 mm (1.97 in)
Rod Dia. 25.0 mm (0.98 in)
9804/1103 95 - 05 - 05/1 5100 - 9/1-1.2 Issue 1

CONTENTS
RTFL 95 - 05 - 05/2
926, 930 From m/c no. 602750 to 602797 (926), 608300 to 608418 (930)
Data - Steering
Control Unit Type 2 Wheel Drive OSPC 160
Priority Valve Type OLSB 80
2 Wheel Drive 250 bar (255 kgf/cm2; 3625 lbf/in2)
Ram Dimensions (2 and 4 Wheel Drive)
Bore 50.0 mm (1.97 in)
Rod Dia. 25.0 mm (0.98 in)
926, 930 From m/c no. 602798 (926), 608419 (930)

Data - Steering
Priority Valve Type OLSB 80
Bore 70.0 mm (2.75 in)
Rod Dia. 30.0 mm (1.18 in)
Bore 70.0 mm (2.75 in)
Rod Dia. 30.0 mm (1.18 in)
9804/1103 95 - 05 - 05/2 5100 - 9/1-2.2 Issue 1

CONTENTS
RTFL 95 - 05 - 06/1
926, 930
Data - Engine
Type Perkins 1000 Series 4 cylinder Engine

AA - 50430, naturally aspirated
AR - 50681, naturally aspirated (low emission)
AA Build (76 HP) AR Build (75 HP)

Bore (nominal) 100 mm (3.937 in) 103 mm (4.055 in)
Stroke 127 mm (5.000 in) 127 mm (5.000 in)
Swept Volume 4 litres (243 in3) 4.23 litres (258 in3)
Compression Ratio 16.5:1 18.5:1
Compression Pressure 20-30 bar (300-450 lbf/in2) 25-35 bar (375-525 lbf/in2)
Injection Sequence 1,3,4,2 1,3,4,2
Valve Clearance - Hot or Cold - Inlet 0.20 mm (0.008 in) 0.20 mm (0.008 in)
- Exhaust 0.45 mm (0.018 in) 0.45 mm (0.018 in)
Idling Speed 750 rev/min 750 rev/min
Max. Governed Speed 2000 rev/min 2200 rev/min
Max. No Load Speed 2420 rev/min 2350 rev/min
Fuel System
Injection Pump Type CAV DPA Lucas DP203

Governing Mechanical Mechanical
Injector Pump Setting Code DM55L/1000/1/2420 2644G002RG/2350
Injection Timing 16 deg BTDC 3 deg BTDC Dynamic
Injector Setting Pressure 220 atm 290 atm
Injector Codes HZ KW
For further engine details see Engine Manual Publication No. 9806/0100 for AA Engine builds
9806/2140 for AR Engine builds
9804/1103 95 - 05 - 06/1 5100 - 5/1-1.4 Issue 1

CONTENTS
RTFL 95 - 10 - 01/1
926, 930
Fault Finding - Transmission
systems to their normal working temperatures.
Ensure that the correct quantity and grade of oil is used and that there are no obvious leaks.
CHECK ACTION

NO: Check 2

in neutral and ratio selector in 1st? NO: Check 19
NO: Check 4

NO: Check level only when machine is cold and top
up as required.

NO: Check 6

NO: Check 7

NO: Check clutch pressure maintenance valve is
free to operate.

NO: Check converter sprag clutch for wear or slip.

10 Is transmission misaligned? YES: Renew mountings and check position.

NO: Check 'converter out' pressure and flow.

NO: Check converter for wear or cooler for
restriction to flow.

NO: Check 13
13 Is the transmission not pulling in both YES: Stall test machine, Check 14
. Forward and Reverse? NO: Check 16
9804/1103 95 - 10 - 01/1 5100 - 6/4-1.1 Issue 1

CONTENTS
RTFL 95 - 10 - 01/2
926, 930
Fault Finding - Transmission (cont’d)
CHECK ACTION

NO: Inspect converter relief valve for damage.

16 Are clutch sealing rings damaged? YES: Tap pressure gauge into clutch feed lines to
monitor pressure.

NO: Check 18
19 Is the fault only when the transmission is hot? YES: Dismantle solenoid and check components.
NO: Check microswitches, relay and wiring loom.
NO: Check 21
NO: Check 22
NO: Check 23
23 Is the noise present when in neutral or when in gear? NEUTRAL:Check 24

IN GEAR: Check 27
NO: Check 25
NO: Check 26


NO: Check 28
NO: Check 29

NO: Check 30
NO: Check 31
31 Are the dog gear teeth worn? YES: Renew

NO: Check 32
32 Are the selector rod detent springs broken? YES: Renew

. NO: Check 33
9804/1103 95 - 10 - 01/2 5100 - 6/4-2.1 Issue 1

CONTENTS
RTFL 95 - 10 - 01/3
926, 930
Fault Finding - Transmission (cont’d)
CHECK ACTION

NO: Check 34
NO: Check 35


NO: Check 37
37 Are steel chips embedded in the bronze? YES: Continue using, chips will either embed below
bronze or be rejected.
NO: Check 38

NO: Check free running gears for seizure or
damage.
NO: Check 40

or gear? NO: Ensure that clutch is disengaged when dump
pedal is pressed.
41 Are steel chips embedded in the bronze? YES: Continue using, chips will either embed below
bronze or be rejected.
NO: Check 42

NO: Check 43

9804/1103 95 - 10 - 01/3 5100 - 6/4-3.1 Issue 1

CONTENTS
RTFL 95 - 15 - 01/1
926 to m/c 602902

930 to m/c 608656
Machines without IP67 electrics
9804/1103 95 - 15 - 01/1 5100 - 10/7-1.2 Issue 1

CONTENTS
RTFL 95 - 15 - 01/2
926 to m/c 602902

930 to m/c 608656
Circuit Diagrams -Electrical (cont’d)
Machines without IP67 electrical
Main Components & Switches

58 Fuse A2
1 Battery 59 Fuse A1
2 Starter Solenoid 60 Fuse B3
3 Starter Motor 61 Fuse B2
4 Starter Switch 62 Road Lights Switch
5 Thermostart 63 Side Lights Relay
6 Fuse B4 64 Diode
7 Heater Switch 65 Diode
8 Resistor 66 Neutral Start Relay
9 Heater Motor 67 Battery Isolator (optional)
10 Fuse B6
11 Horn Push Lights
12 Horn
13 Wash/Wiper Switch 70 Direction Indicator Warning
14 Washer Pump 71 Hazard Warning
15 Front Wiper 72 L.H. Front Indicator
16 Hazard Warning Switch 73 L.H. Rear Indicator
17 Indicator Relay 74 R.H. Front Indicator
18 Direction Indicator Switch 75 R.H. Rear Indicator
19 Fuse A6 76 Rear Working
20 Fuse A5 77 R.H. Stop
21 Rear Wiper 78 L.H. Stop
22 Roof Wiper 79 Beacon
23 Beacon 80 Blocked Air Filter Warning
24 Engine Stop Solenoid 81 Engine Oil Pressure Warning
25 Fuse C1 82 Transmission Oil Temperature Warning
26 Fuse C2 83 Transmission Oil Pressure Warning
27 Back-up Alarm Relay 84 Engine Coolant Temperature Warning
28 Back-up Alarm 85 Alternator Warning
29 Fuse B1 86 Parking Brake Warning
30 Forward/Reverse Switch 87 Fuel Gauge/Hourmeter Illumination
31 Parking Brake Buzzer Relay 88 L.H. Side
32 Forward Relay 89 L.H. Tail
33 Reverse Relay 90 R.H. Side
34 Diode 91 R.H. Tail
35 Reverse Solenoid 92 Number Plate Light
36 Forward Solenoid 93 L.H. Dip Beam
37 Dump Switch 94 R.H. Dip Beam
38 Parking Brake Switch 95 L.H. Main Beam
39 Fuse B5 96 R.H. Main Beam
40 Brake Switch 97 Main Beam Warning
41 Fuel Gauge 98 Hazard Warning Switch Repeater
42 Fuel Gauge Sender 99 Front Working Light (fitted to later machines)
44 Oil Pressure Switch Cable Colour Code
45 Transmission Oil Temperature Switch
46 Transmission Oil Pressure Switch B Black
47 Water Temperature Switch G Green
48 Diode K Pink
49 Alternator LG Light Green
50 Hourmeter N Brown
50 Hourmeter O Orange
51 Diode Bank P Purple
52 Buzzer R Red
53 Fuse C3 S Slate
54 Headlight Flasher Switch U Blue
55 Dip Switch W White
56 Fuse A4 Y Yellow
57 Fuse A3 Note: On machines from No. 602750 (926) and 608300
(930) the fuse A5, 20 for the rear wiper 21 and roof wiper
9804/1103 95 - 15 - 01/2 5100 - 10/7-2.4 Issue 1

CONTENTS
RTFL 95 - 15 - 01/3
926 from m/c 602903 to 664289

930 from m/c 608657 to 664289
Circuit Diagrams - Electrical (contd)
Machines with IP67 electerics
9804/1103 95 - 15 - 01/3 5100 - 10/7-3.2 Issue 1

CONTENTS
RTFL 95 - 15 - 01/4
926 from m/c 602903 to 664289

930 from m/c 608657 to 66289
Main Components & Switches
1 Battery 61 Fuse B2
2 Starter Solenoid 62 Road Lights Switch
3 Starter Motor 63 Side Lights Relay
4 Starter Switch 64 Diode
5 Thermostart 65 Diode
6 Fuse B4 66 Neutral Start Relay
7 Heater Switch 67 Battery Isolator (optional)
8 Resistor
9 Heater Motor Lights
10 Fuse B6
11 Horn Push 70 Direction Indicator Warning
12 Horn 71 Hazard Warning
13 Wash/Wiper Switch 72 L.H. Front Indicator
14 Washer Pump 73 L.H. Rear Indicator
15 Front Wiper 74 R.H. Front Indicator
16 Hazard Warning Switch 75 R.H. Rear Indicator
17 Indicator Relay 76 Rear Working
18 Direction Indicator Switch 77 R.H. Stop
19 Fuse A6 78 L.H. Stop
20 Fuse A5 79 Beacon
21 Rear Wiper 80 Blocked Air Filter Warning
22 Roof Wiper 81 Engine Oil Pressure Warning
23 Beacon 82 Transmission Oil Temperature Warning
24 Engine Stop Solenoid 83 Transmission Oil Pressure Warning
25 Fuse C1 84 Engine Coolant Temperature Warning
26 Fuse C2 85 Alternator Warning
27 Back-up Alarm Relay 86 Parking Brake Warning
28 Back-up Alarm 87 Fuel Gauge/Hourmeter Illumination
29 Fuse B1 88 L.H. Side
30 Forward/Reverse Switch 89 L.H. Tail
31 Parking Brake Buzzer Relay 90 R.H. Side
32 Forward Relay 91 R.H. Tail
33 Reverse Relay 92 Number Plate Light
34 Diode 93 L.H. Dip Beam
35 Reverse Solenoid 94 R.H. Dip Beam
36 Forward Solenoid 95 L.H. Main Beam
37 Dump Switch 96 R.H. Main Beam
38 Parking Brake Switch 97 Main Beam Warning
39 Fuse B5 98 Hazard Warning Switch Repeater
40 Brake Switch 99 Front Working Light (fitted to later machines)
41 Fuel Gauge
42 Fuel Gauge Sender Cable Colour Code
44 Oil Pressure Switch B Black
45 Transmission Oil Temperature Switch G Green
46 Transmission Oil Pressure Switch K Pink
47 Water Temperature Switch LG Light Green
48 Diode N Brown
49 Alternator O Orange
50 Hourmeter P Purple
50 Hourmeter R Red
51 Diode Bank S Slate
52 Buzzer U Blue
53 Fuse C3 W White
54 Headlight Flasher Switch Y Yellow
55 Dip Switch
56 Fuse A4
57 Fuse A3
58 Fuse A2
59 Fuse A1
60 Fuse B3
9804/1103 95 - 15 - 01/4 5100 - 10/7-4.3 Issue 1

CONTENTS
RTFL 95 - 15 - 01/5
926, 930 From m/c 664290

9804/1103 95 - 15 - 01/5 5100 - 10/7-6.1 Issue 1

CONTENTS
RTFL 95 - 15 - 01/6
926, 930 From m/c 664290

*Component Key
1 Battery 46 Indicator switch

2 Thermostart 47 Indicator repeater
3 Starter Motor 48 Front indicator - left hand
4 Starter Solenoid 49 Rear indicator - left hand
5 Neutral start relay 50 Flasher unit
6 Starter Switch 51 Beacon
7 Dump pedal 52 Beacon switch
8 Forward/reverse switch 53 Rear wiper motor
9 Forward Relay 54 Roof wiper motor
10 Forward solenoid 55 Face fan motor - optional
11 Reverse relay 56 Front wash/wipe switch
12 Transmission dump relay 57 Washer pump
13 Reverse solenoid 58 Front wiper motor
14 Reverse alarm 59 Horn switch
15 Reverse lights - right hand side 60 Horn
16 Reverse lights - left hand side 61 Main beam indication lamp
17 Ignition relay 62 Main beam - right hand
18 Parking brake buzzer relay 63 Headlight flash
19 Parking brake switch 64 Main beam - left hand
20 Buzzer 65 Dip beam - right hand
21 Parkbrake warning lamp 66 Dip beam - left hand
22 Water temperature warning lamp 67 Side lights - left hand
23 Water temperature switch 68 Road light switch
24 Transmission oil temperature warning lamp 69 Main beam/dip beam switch
25 Transmission oil temperature switch 70 Rear light - left hand
26 Engine oil pressure warning lamp 71 Number plate light - left hand
27 Engine oil pressure switch 72 Side light - right hand
28 Transmission oil pressure warning lamp 73 Rear light - right hand
29 Transmission oil pressure switch 74 Number plate light - right hand
30 Alternator warning lamp 75 Worklight switch
31 Alternator diode 76 Worklight
32 Hourmeter
33 Alternator
34 Brake lights switch
35 Brake light - right hand
36 Brake light - left hand
37 Fuel gauge
38 Fuel sender
40 Heater Switch
41 Heater resistor
42 Heater Motor
43 Front indicator - right hand
9804/1103 95 - 15 - 01/6 5100 - 10/7-5.1 Issue 2*

1
9804/1103
CONTENTS
926, 930
2
123
THERMOSTART
70A
60A
60A
50A
PRI FUSE 3
PRI FUSE 2
PRI FUSE 1
PRI FUSE 4
M
4
STARTER MOTOR
PRE
OFF
IGN
START
3
HEAT
004 5
310A 1 5 001
1 842
30
310B 2 6 001A
305
810A
310L
310D
15/54
810C 4 2 600V
17
4
50a
8 003A 600AC
7
003 FUSE A10
19
9
809 2
FORWARD RELAY
F 4
100 100A 810C 1 812 600BS
5
N
875 5 FORWARD SOLENOID
FUSE A1 R 3
10
600AD
9
REVERSE RELAY
808 4 2
12
1 811B 811 600BT
3 838 875A 5 REVERSE SOLENOID
100B 5 3
13
1
811A 600CD
6
100C 4 2 815B REVERSE ALARM
14
811G 600H
REVERSE LIGHT RHS
15
811F 600G
11
REVERSE LIGHT LHS
815 600CV
HANDBRAKE
SHOWN WITH HANDBRAKE OFF
16
810A 4 2 600BF
1
401H 5
3 815A
815B
401E
17
27
411B
411
106E 106C 411B 411
FUSE A2
401E
RTFL
106AK 401H
95 - 15 - 01/7
434B
404A
415A
403A
406A
406
106AB 406B 406B 600CK
WATER TEMP SWITCH
001 - 6 WAY BUSBAR IN FUSEBOX

404
106AC 404B 404B 600C
403
106AD 403B 403B 600HH
ENGINE OIL PRESS SWITCH
415
19 21 23 25
106AF 415B 415B 600BU

TRANS OIL PRESS SWITCH
434 407
18 20 22 24 26 29
106AA 434A 434 407A 407A 600HS
4 4 0 3
HOURMETER
31
28
106D
407
ALTERNATOR
200
30
200A
108 816C 816G 600H

RH BRAKE LIGHT
FUSE A3
32
816F 600G
LH BRAKE LIGHT
35
36
33 34
408 600CE
S
106 V FUEL SENDER
+ 600JA
-
830A 600HT
105B
COLD START ADVANCE
37
38
105 105A 600

E.S.O.S.
FUSE A4
39
103 103F 600BD

M REAR WIPER
FUSE A5
103H 600JF
M ROOF WIPER
40 41
103N 600EG
M FACE FAN
(OPTIONAL)
42
110 839 600BG

M WASHER PUMP
FUSE A6
43
44
840 600AK
M FRONT WIPER
45
106N +8 -7 600DY
1
BEACON SWITCH
303G 2
46
3 894 600AP
FUSE A7 M BEACON
2
701/60000
600DX
HAZARD SWITCH
805E 600BC
49
47
LH FRONT INDICATOR
-10 805F 600G
48
200N
FUSE A8 1 2
300 LH REAR INDICATOR
50
2 802 49 600BL
104 3 31 FLASHER UNIT
49a
54
FUSE B1
803B
803A
806A
805 806B
5
17 803B 803A
18
53
310G - 3 WAY BUSBAR IN FUSEBOX

805B
106F +8
55
701/60005
51
805A
806F 600H
RH REAR INDICATOR
001A 4 2
52
806D 806E 600AZ
1 002 RH FRONT INDICATOR

310L 5 600W
3 IGNITION RELAY
56
57
314 314B 814 600B

FRONT HORN
FUSE A9 600DW
ROADLIGHTS SWITCH
829C
59
600AU
LH No PLATE LIGHT
829D 600G
60
FUSE B6 LH TAIL LIGHT

829A 829E 600BC
61
58
LH SIDE LIGHT
830G 600AX
62
106K 8+ -7
1 RH No PLATE LIGHT
63
830B 600H
310P 2 RH TAIL LIGHT
828 - 2 WAY
BUSBAR IN
FUSEBOX
828
FUSE B7
64
+3 830A 830D 600AZ

830R RH SIDE LIGHT
600AZ
65
834A
138 5
RH DIP BEAM
834A 834B 600BC
6 832 834B LH DIP BEAM
FUSE B2
66
2
67
701/60004 314A 837 837C 600EK

MAIN BEAM IND
837A 600AZ
RH MAIN BEAM
70
68
837B 600BC LH MAIN BEAM

69
106J +8 -7 600N
1
FOGLIGHT SWITCH
832A 2
72
3 835 835A 600H

FUSE B8 LHS FOGLIGHT
835B 600G
2 RHS FOGLIGHT
002 - 4 WAY BUSBAR IN FUSEBOX
701/60000
73
74
71
106L -7 600CJ
+8
1
WORKLIGHT SWITCH
116 2
75
3 855 600AR
FUSE B3 WORKLIGHT
2
701/60000
106R +10 -7 600EB

1 HEATER SWITCH
2
3 800 600BH
M
87
HEATER MOTOR
76
SPLIT IF AIR 4
5
77
78
102 CON FITTED.

6 800B
FUSE B4 30/925403
102 102F 2
701/60016
LINK
106AT +8 -7 600FB
1
1 AIR CON SWITCH
2
3 800E
81
1 800 600MY
2
M
HEATER MOTOR
2
701/60001
3
962 600JG
5100 - 10/7-7.2
79
CONDENSER RELAY
80
980 600MX
A370710
M
CONDENSER FAN
83
82
962A 963 961 X

M
COMPRESSOR CLUTCH
84
85
86
All m/c’s from May2001
95 - 15 - 01/7
Issue 1
CONTENTS
RTFL 95 - 15 - 01/8
926, 930 All m/c’s from May 2001

Component Key
1 Battery 41 Face fan (optional)

2 Thermostart 42 Front wash/wipe switch
3 Starter motor/solenoid 43 Washer pump
4 Neutral start relay 44 Front wiper motor
5 Starter switch 45 Beacon switch
6 Dump pedal 46 Beacon
7 Forward/reverse switch 47 Hazard warning lights switch
8 Forward relay 48 Flasher unit
9 Reverse relay 49 Left hand front indicator
10 Forward solenoid 50 Left hand rear indicator
11 Transmission dump relay 51 Right hand rear indicator
12 Reverse solenoid 52 Right hand front indicator
13 Reverse alarm 53 Indicator repeater lamp
14 Reverse lights - right hand side 54 Indicator switch
15 Reverse lights - left hand side 55 Ignition relay
16 Parking brake switch 56 Horn switch
17 Parking brake buzzer relay 57 Horn
18 Parkbrake warning lamp 58 Road lights switch
19 Water temperature switch 59 Left hand number plate lamp
20 Water temperature warning lamp 60 Left hand tail light
21 Transmission oil temperature switch 61 Left hand side light
22 Transmission oil temperature warning lamp 62 Right hand number plate
23 Engine oil pressure switch 63 Right hand tail light
24 Engine oil pressure warning lamp 64 Right hand side light
25 Transmission oil pressure switch 65 Right hand dip beam
26 Transmission oil pressure warning lamp 66 Left hand dip beam
27 Buzzer 67 Main beam indicator lamp
28 Hourmeter 68 Right hand main beam
29 Alternator warning lamp 69 Left hand main beam
30 Alternator 70 Main beam/dip beam switch/light flash
31 Alternator diode 71 Fog light switch
32 Brake lights switch 72 Left hand fog light
33 Brake light - right hand 73 Right hand fog light
34 Brake light - left hand 74 Work light switch
35 Fuel gauge 75 Work light
36 Fuel sender 76 Heater switch
37 Cold start advance 77 Heater resistor
38 Engine shut-off solenoid (ESOS) 78 Heater motor
39 Rear wiper motor 79 Air conditioning switch
40 Roof wiper motor 80 Resistor switch - air conditioning
81 Heater motor - air conditioning
82 Condenser relay - air conditioning
83 Condenser fan motor - air conditioning
84 Thermostat - air conditioning
85 Pressure switch - air conditioning
86 Compressor clutch - air conditioning
87 Link removed if air conditioning fitted
9804/1103 95 - 15 - 01/8 5100 - 10/7-8.1 Issue 1

CONTENTS
RTFL 95 - 20 - 01/1
926, 930
1B
11 2 12
2E 2E 2D 2C
2F 1A
2G 2A
2X
10
S
P1
13
F
14
15 16
A184641
9804/1103 95 - 20 - 01/21 5100 - 2/11 -1.2 Issue 1

CONTENTS
RTFL 95 - 20 - 01/2
926, 930
Component Key
F Filter
P Priority valve
P1 Pump
T Tank
S Combined steering unit and shock valve
2 Valve block
2C Lift spool
2D Tilt spool
2E Auxiliary spool
2F Load hold check valve (L.H.C.V)
2G Auxiliary relief valves (A.R.V's)
2X System pressure test point
10 Lift rams
11 Tilt rams
12 Steer ram
13 Flow regulator cartridge
14 Hose burst protection valve
15 Deration diverter valve
16 Deration valve
9804/1103 95 - 20 - 01/2 5100 - 2/11 -2.2 Issue 1

CONTENTS
Excavators Contents 1
* JS 70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180, 200, 200W, 210, 220, 240, 260, 300,
330, 450LC, 460
Contents
Page No.
General Information
- JS 70 to m/c no. 695500 45 - 00 - 01/1
- JS 110, 130 to m/c no. 757999, 150LC 45 - 00 - 01/2
- JS 200LC to m/c no. 705000, 240LC to m/c no. 780500, 300LC, 450LC 45 - 00 - 01/3
- JS 130W, 150W 45 - 00 - 01/4
- JS 70 from m/c no. 695501 45 - 00 - 01/4A
- JS130 from m/c no. 758000, JS160 from m/c no. 702000 45 - 00 - 01/5
- JS180 45 - 00 - 01/5A
- JS130W frm m/c no. 716500, JS145W from m/c no. 810000,
JS160W from m/c no. 718500 45 - 00 - 01/4B
* - JS200, 220 from m/c no. 705001, JS210 from m/c no. 705648,JS240 from m/c no.708001,
JS260 from m/c no. 708501 45 - 00 - 01/6
- JS200W from m/c no. 0802000 to 802999 45 - 00 - 01/6A & 45 - 00 - 01/6B
- JS330 from m/c no. 712501, JS450 from m/c no. 714501,
JS460 from m/c no. 714550 45 - 00 - 01/7
- JS200W from m/c no. 809000 45 - 00 - 01/6C & 45 - 00 - 01/6D
Static Dimensions
- JS 70 to m/c no. 695500 45 - 00 - 02/1
- JS 110 45 - 00 - 02/2
- JS 130 to m/c no. 757999 45 - 00 - 02/3
- JS 150LC 45 - 00 - 02/4
- JS 200LC 45 - 00 - 02/5
- JS 240LC 45 - 00 - 02/6
- JS 300LC 45 - 00 - 02/7
- JS 450LC 45 - 00 - 02/8
- JS 130W 45 - 00 - 02/9
- JS 150W 45 - 00 - 02/10
- JS 70 from m/c no. 695501 45 - 00 - 02/10A
- JS130 from m/c no. 758000 45 - 00 - 02/11
- JS160 from m/c no. 702000 45 - 00 - 02/12
- JS180 45 - 00 - 02/12A
- JS200, 220 from m/c no. 705001 45 - 00 - 02/13
- JS210 45 - 00 - 02/13A
- JS240, 260 from m/c no. 708501 45 - 00 - 02/14
- JS220LC Long reach (LR) from m/c no. 705001 45 - 00 - 02/15
- JS330 from m/c no. 712501 45 - 00 - 02/16
- JS450 from m/c no. 714501 45 - 00 - 02/16A
- JS130W from m/c no. 0716500 45 - 00 - 02/17
- JS160W from m/c no. 0718500 45 - 00 - 02/18
- JS200W from m/c no. 0802000 to 802999 45 - 00 - 02/19 -
- JS200W from m/c no. 809000 45 - 00 - 02/20
* - JS460 from m/c no. 714550 45 - 00 - 02/21
Shipping Weights
- JS 70 to m/c no. 695500 45 - 00 - 03/1
- JS 110, 130, 150LC 45 - 00 - 03/2
- JS 200LC to m/c no. 70500, 240LC to m/c no. 780500, 300LC, 450LC 45 - 00 - 03/3
- JS 70 from m/c no. 695501 45 - 00 - 03/3A
- JS130 from m/c no. 758000, JS160, 180 from m/c no. 702000 45 - 00 - 03/4
- JS200, 210, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 45 - 00 - 03/4
- JS330 from m/c no. 712501, JS450 from m/c no. 714501,
JS460 from m/c no. 714550 45 - 00 - 03/4
- JS130W from m/c no. 0716501, JS160W from 0718501 45 - 00 - 03/5
- JS200W from m/c no. 0802000 to 802999 45 - 00 - 03/6
9804/1103 Excavator Contents - 1 Issue 9*

CONTENTS
* JS 70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180, 200, 200W, 210, 220, 240, 260, 300,
330, 450LC, 460
Contents
Data Page No.

Electrical
- JS 70 to m/c no. 695500 45 - 05 - 01/1
- JS 110, 130, 150LC 45 - 05 - 01/2
- JS 200LC, 240LC, 300LC, 450LC 45 - 05 - 01/3
- JS 130W, 150W 45 - 05 - 01/4 & 45 - 05 - 01/5
- JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 45 - 05 - 01/6
- JS130W from m/c no. 0716501, JS160W from m/c no. 0718501 45 - 05 - 01/7
* - JS70 from m/c no. 695501 45 - 05 - 01/8
- JS 200W from m/c no. 809000 45 - 05 - 01/9 & 45 - 05 - 01/10
* - JS330 from m/c no. 712501, JS450 from m/c no. 714501 45 - 05 - 01/11
JS460 from m/c 714550
- The A.M.S. System 45 - 05 - 01/12,13
Data
Hydraulic
- JS 70 to m/c no. 695500 45 - 05 - 02/1
- JS 110 45 - 05 - 02/2
- JS 130 to m/c no. 757999 45 - 05 - 02/3
- JS 150 45 - 05 - 02/4
- JS 200LC to m/c no. 705000 45 - 05 - 02/5
- JS 240LC 45 - 05 - 02/6
- JS 300LC 45 - 05 - 02/7
- JS 450LC 45 - 05 - 02/8
- JS 130W from m/c no. 0716501, JS145W from m/c no. 810000 45 - 05 - 02/9 to 45 - 05 - 02/10D
- JS 70 from m/c no. 695501 45 - 05 - 02/11
- JS130 from m/c no. 758000 45 - 05 - 03/1 & 45 - 05 - 03/2
- JS160 from m/c no. 702000 45 - 05 - 03/3 & 45 - 05 - 03/4
- JS200, 220 from m/c no. 705001 45 - 05 - 03/5 & 45 - 05 - 03/6
- JS240, 260 from m/c no. 708501 45 - 05 - 03/7 & 45 - 05 - 03/8
* - JS 200W from m/c no. 809000 45 - 05 - 03/9 to 45 - 05 - 03/11
- JS330 from m/c no. 712501 45 - 05 - 03/12 & 45 - 05 - 03/13
Track Motor/Gearbox
* - JS130 from m/c no. 758000, JS160 from m/c no. 702000 45 - 05 - 04/1
- JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 45 - 05 - 04/2
- JS330 from m/c no. 712501, JS450 from m/c no. 714501 45 - 05 - 04/3 to 45 - 05 - 04/5
JS460 from m/c no 714550
Control Valve
- JS 200W from m/c no. 809000 45 - 05 - 05/1
Drive Gearbox
- JS 200W from m/c no. 809000 45 - 05 - 06/1
Front Axle
- JS 200W from m/c no. 809000 45 - 05 - 07/1
- JS130W from m/c no. 716500 (SD70 PT) 45 - 07 - 07/1A
- JS130W from m/c no. 716500, JS160W from m/c no. 718500 (SD80PT) 45 - 07 - 07/1B
Rear Axle
- JS 200W from m/c no. 809000 45 - 05 - 07/2
- JS130W from m/c no. 716500 (PD70) 45 - 07 - 07/2A
- JS130W from m/c no. 716500, JS160W from m/c no. 718500 (PD80) 45 - 07 - 07/2B
Engine
- JS 70 to m/c no. 695500 45 - 05 - 08/1
- JS 110, 130, 150LC 45 - 05 - 08/2
- JS 200LC, 240LC 45 - 05 - 08/3
- JS 300LC, 450LC 45 - 05 - 08/4
- JS 70 from m/c no. 695501 45 - 05 - 08/4A
- JS 130W from m/c no. 785001, JS160W from m/c no. 702001 45 - 05 - 08/5
9804/1103 Issue 7*
CONTENTS
* JS 70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180, 200, 200W, 210, 220, 240, 260,
300, 330, 450LC, 460
Contents
*
Engine (cont’d) Page No.
- JS 330 from m/c no. 712501, JS450 from m/c no. 714501 45 - 05 - 08/6
JS460 from m/c no.714550
- JS460 Tier 2 45 - 05 - 08/6A
- JS 130 from m/c no. 716501, JS160 from m/c no. 718501 45 - 05 - 08/7
- JS130W from m/c no. 716500, JS145 from m/c no. 810000 45 - 05 - 08/7A
- JS175W from m/c no. 875000 45 - 05 - 08/8
* JS160W from m/c no. 718500,
- JS 200W from m/c no. 809000 45 - 05 - 08/9
- JS200, 220 from m/c no. 705001, JS210 from m/c no. 705648,JS240 from m/c no.708001,
JS260 from m/c no. 708501 45 - 05 - 08/10
Track and Running Gear

- JS330 from m/c no. 712501, JS450 from m/c no. 714501 45 - 05 - 09/1 & 45 - 05 - 09/2
Fault Finding
Hydraulics
- JS 70 to m/c no. 695500 45 - 10 - 01/1 to 45 - 10 - 01/3
- JS 110, 130 45 - 10 - 01/4 to 45 - 10 - 01/8
- JS 150LC 45 - 10 - 01/9 to 45 - 10 - 01/13
- JS 200LC, 300LC 45 - 10 - 01/14 to 45 - 10 - 01/19
- JS 240LC 45 - 10 - 01/20
- JS 450LC 45 - 10 - 01/21 to 45 - 10 - 01/23
- JS70 from m/c no. 695501 45 - 10 - 01/24 & 45 - 10 - 01/25
- JS 200W from m/c no. 809000 45 - 10 - 01/26 to 45 - 10 - 01/31
Track Gearbox
- JS 110, 130, 150LC 45 - 10 - 02/1 & 45 - 10 - 02/2
- JS 200LC, 240LC, 300LC, 450LC 45 - 10 - 02/3 & 45 - 10 - 02/4
Swing Gearbox
- JS70, 110, 130, 150LC, 200LC, 240LC, 300LC, 450LC 45 - 10 - 03/1
- JS130W from m/c no. 716500, JS160W from m/c no. 718500 45 - 10 - 03/6
- JS 200W from m/c no. 809000 45 - 10 - 03/6
*
Pump/ Regulator
- JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501 45 - 10 - 06/1 to 45 - 10 - 06/2
- JS330 from m/c no. 712501, JS450 from m/c no. 714501 45 - 10 - 06/3 & 45 - 10 - 06/4
*
Remote Control Valve
- JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501,
JS 200W from m/c no. 809000 45 - 10 - 07/1
JS460 from m/c no. 714550
Control Valve
- JS70 from m/c no. 695501 45 - 10 - 07/2 & 45 - 10 - 07/3
Multiple Valve
- JS70 from m/c no. 695501 45 - 10 - 07/4
Rams
- JS70 from m/c no. 695501 45 - 10 - 08/1 to 45 - 10 - 08/5
- JS130W from m/c no. 716500, JS160W from m/c no. 718500 45 - 10 - 08/1 to 45 - 10 - 08/5
Track Motor/Gearbox
- JS70 from m/c no. 695501 45 - 10 - 09/1 to 45 - 10 - 09/3
CONTENTS
* JS 70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180, 200, 200W,210, 220, 240, 260, 300,
330, 450LC, 460
Contents
Fault Finding (cont’d) Page No.

Slew Motor
- JS70 from m/c no. 695501 45 - 10 - 03/4 & 45 - 10 - 03/5
* - JS130 from m/c no. 758000, JS160 from m/c no. 702000 45 - 10 - 11/1 to 45 - 10 - 11/2
- JS130W from m/c no. 716500, JS145W from m/c no. 810000
JS160W from m/c no. 718500, JS175W from m/c no. 875000 45 - 10 - 11/1 to 45 - 10 - 11/2
- JS200, 220 from m/c no. 705001, JS240, 260 from m/c no. 708501,
JS 200W from m/c no. 809000 45 - 10 - 11/1 to 45 - 10 - 11/2
Engine
- JS70 from m/c no. 695501 45 - 10 - 12/1
Monitor Display
- JS70 from m/c no. 695501 45 - 10 - 13/1
Operating Controls
- JS70 from m/c no. 695501 45 - 10 - 13/2
Hydraulic Pump
- JS70 from m/c no. 695501 45 - 10 - 13/2
Working Attachments
- JS70 from m/c no. 695501 45 - 10 - 13/2
Travelling
- JS70 from m/c no. 695501 45 - 10 - 13/3
Slewing
* - JS70 from m/c no. 695501 45 - 10 - 13/3
Hydraulic Rams
- JS70 from m/c no. 695501 45 - 10 - 13/3
Electrics
Circuit Diagrams
Electrical
- JS70 to m/c no. 695500 45 - 15 - 01/1 & 45 - 15 - 01/2
- JS70 from m/c no. 695501 45 - 15 - 01/2A & 45 - 15 - 01/2B
- JS110, 130 to m/c no. 757999 45 - 15 - 01/3 & 45 - 15 - 01/4
- JS150LC 45 - 15 - 01/5 & 45 - 15 - 01/6
- JS200LC to m/c no. 705000 45 - 15 - 01/7 & 45 - 15 - 01/8
- JS240LC to m/c no. 780500 45 - 15 - 01/9 & 45 - 15 - 01/10
- JS300LC 45 - 15 - 01/11 & 45 - 15 - 01/12
- JS450LC 45 - 15 - 01/13 & 45 - 15 - 01/14
- JS130W, 150W (Common with JS130, JS150 Tracked Excavators) 45 - 15 - 02/1 & 45 - 15 - 02/2
- JS130W, 150W (Additional to JS130, JS150 Tracked Excavators) 45 - 15 - 02/3 & 45 - 15 - 02/4
- JS130W, 150W (Relay Box P.C.B.) 45 - 15 - 02/5 & 45 - 15 - 02/6
- JS130W from m/c no. 716501, 160W from 718501 45 - 15 - 02/7 to 45 - 15 - 02/11
* - JS130 from m/c no. 758000, JS160 from m/c no. 702000 45 - 15 - 02/11A & 45 - 15 - 02/11B
- JS200W from m/c no. 809000 45 - 15 - 02/12 & 45 - 15 - 02/13
- JS200, 220 from m/c no.705001, JS240 from m/c no. 708501 45 - 15 - 02/13A & 45 - 15 - 02/13B
- JS330 from m/c no. 712501 45 - 15 - 02/14 & 45 - 15 - 02/15
- JS450 from m/c no. 714501 45 - 15 - 02/16 & 45 - 15 - 02/17
- JS330/JS460 (AMS) 45 - 15 - 02/18 & 45 - 15 - 02/19
- JS460 Tier2 45 - 15 - 02/20 & 45 - 15 - 02/21

CONTENTS
JS 70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180,, 200, 200W, 210, 220, 240, 260,
300, 330, 450LC, 460
Contents
Hydraulic
- JS70 (Standard Boom to m/c 695001) 45 - 20 - 01/1 & 45 - 20 - 01/2
- JS70 (Offset Boom to m/c 695001) 45 - 20 - 01/3 & 45 - 20 - 01/4
- JS70 (Standard Boom from m/c 695002 to m/c 695500) 45 - 20 - 01/5 & 45 - 20 - 01/6
- JS70 (Offset Boom from m/c 695002 to m/c 695500) 45 - 20 - 01/7 & 45 - 20 - 01/8
Circuit Diagrams Page No.
Hydraulic (cont’d)
- JS70 from m/c no. 695501 45 - 20 - 01/8A &45 - 20 - 01/8B
- JS110 (To m/c 697013) & 130 (To m/c 699036) 45 - 20 - 01/9 & 45 - 20 - 01/10
- JS110 (From m/c 697014) & 130 (From m/c 699037 to m/c no. 757999) 45 - 20 - 01/11 & 45 - 20 - 01/12
- JS150LC (To m/c 701044) 45 - 20 - 01/13 & 45 - 20 - 01/14
- JS150LC (From m/c 701045) 45 - 20 - 01/15 & 45 - 20 - 01/16
- JS200LC (To m/c 704074) 45 - 20 - 01/17 & 45 - 20 - 01/18
- JS200LC (From m/c 704075 to m/c no. 705000) 45 - 20 - 01/19 & 45 - 20 - 01/20
- JS240LC to m/c no. 780500 45 - 20 - 01/21 & 45 - 20 - 01/22
- JS300LC 45 - 20 - 01/23 & 45 - 20 - 01/24
- JS450LC 45 - 20 - 01/25 & 45 - 20 - 01/26
- JS130W from m/c no. 716501, JS145W from m/c no. 810000,
160W from m/c no. 718501, JS175W from m/c no. 875000 45 - 20 - 02/1 & 45 - 20 - 02/2
- JS160W from m/c no. 718501, JS175W from m/c no. 875000 - TAB Option 45 - 20 - 02/3
- JS130W from m/c no. 716501, 160W from m/c no. 718501 45 - 20 - 02/4
- JS130 from m/c no. 758000 45 - 20 - 02/4A & 45 - 20 - 02/4B
- JS160 from m/c no. 702000 45 - 20 - 02/4C & 45 - 20 - 02/4D
- JS175W from m/c no. 875000 45 - 20 - 02/4E & 45 - 20 - 02/4F
- JS200, 220 from m/c no. 705001 45 - 20 - 02/6A & 45 - 20 - 02/6B
- JS240, 260 from m/c no. 708001 45 - 20 - 02/6C & 45 - 20 - 02/6D
- JS330 from m/c no. 712501 45 - 20 - 02/7 & 45 - 20 - 02/8
- JS450 from m/c no. 714501 45 - 20 - 02/9 & 45 - 20 - 02/10
- JS460 from m/c no. 714550 45 - 20 - 02/11 & 45 - 20 - 02/12
- JS330/JS460 Tier2 45 - 20 - 02/13 & 45 - 20 - 02/14
- JS450/JS460 - Control Valve 45 - 20 - 02/15
- JS460 Tier2 - Control Valve 45 - 20 - 02/16
- JS460 Tier2 - Circuit Descriptions 45 - 20 - 02/17 to 45 - 20 - 02/42
9804/1103 Excavators Contents - 5 Issue 2*

CONTENTS
CONTENTS
Excavators 45 - 00 - 01/1
* JS 70 to m/c no. 695500
immediately; glazing of the cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in.
Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
* Item Lubricant Capacity
ENGINE To Class API CD 6 litres

(see separate chart below) (1.32 UK gal)
TRACK GEARBOX JCB HD90 Gear Oil 2 x 1.7 litres

(2 x 0.37 UK gal)
SWING GEARBOX JCB HD90 Gear Oil 6 litres

(1.3 UK gal)
*JCB HP Grease 0.9 litres
(0.18 UK gal)
TRACK ROLLERS AND

IDLER WHEEL Engine Oil -
HYDRAULIC SYSTEM JCB Hydraulic Fluid 46 92 litres

(20.26 UK gal)
SWING RING
- BEARINGS *JCB HP Grease -
- GEAR TEETH *JCB HP Grease 3.2 kg (7.14 lb)
ALL OTHER GREASE

POINTS *JCB HP Grease
COOLING SYSTEM 10.4 litres

(2..29 UK gal)
FUEL TANK 130 litres

(28.6 UK gal)
ENGINE LUBRICATION CHART
*
Use according to ambient temperature (°C)
-20 -10 0 10 20 30 40
JCB 15W/40 MULTIGRADE ENGINE OIL

API CD MIL L-2104C
JCB SUPER UNIVERSAL AGRICULTURAL (10W/30)

API CD/SF
9804/1103 45 - 00 - 01/1 Issue 4*

CONTENTS
CONTENTS
JS 110, 130, 150LC

immediately; glazing of the cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in.
Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
Item Lubricant Capacity
JS110 JS130 JS150LC
ENGINE To Class API CD 13.8 litres 13.8 litres 13.8 litres

(see separate chart below) (3 UK gal) (3 UK gal) (3 UK gal)
TRACK GEARBOX JCB HD90 Gear Oil 2 x 2.5 litres 2 x 2.5 litres 2 x 3 litres
(2 x 0.55 UK gal) (2x 0.55 UK gal) (2x0.55UK gal)
SWING GEARBOX JCB HD90 Gear Oil 1.7 litres 1.7 litres 6 litres
(0.37 UK gal) (0.37 UK gal) (1.32 UK gal)
*JCB HP Grease 0.47 litres 0.47 litres Not applicable
(0.1 UK gal) (0.1 UK gal)
TRACK ROLLERS AND

IDLER WHEEL Engine Oil - - -
HYDRAULIC SYSTEM JCB Hydraulic Fluid 46 157 litres 157 litres 170 litres
SWING RING
- BEARINGS *JCB HP Grease - - -
- GEAR TEETH *JCB HP Grease 10 kg (22 lb) 10 kg (22 lb) 13 kg (28.7 lb)
EXCAVATOR GREASE
POINTS *JCB HP Grease
COOLING SYSTEM 17.8 litres 17.8 litres 17.8 litres

FUEL TANK 240 litres 240 litres 240 litres

-20 -10 0 10 20 30 40

API CD MIL L-2104C

API CD/SF
9804/1103 45 - 00 - 01/2 Issue 2*

CONTENTS
CONTENTS
JS 200LC,240LC,300LC,450LC
in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
Item Lubricant Capacity
JS200LC JS240LC JS300LC JS450LC
ENGINE To Class API CD 22.6 litres 20 litres 33 litres 45 litres

(see separate chart) (5 UK gal) (4.4 UK gal) (7.26 UK gal) (9.9 UK gal)
TRACK GEARBOX JCB HD90 Gear Oil Serial Nos up to 2 x 3.3 litres 2 x 8.5 litres 2 x 7 litres
704597 (2 x 0.73 UK gal) 2 x 1.87 UK gal) (2 x 1.54 UK gal)
2 x 5.6 litres
(2 x 1.23 UK gal)
Serial Nos from
704598 on
2 x 3.5 litres
(2 x 0.77 UK gal)
SWING GEARBOX JCB HD90 Gear Oil 6 litres 11 litres 14.5 litres 18 litres
(1.3 UK gal) (2.4 UK gal) (3.9 UK gal) (4 UK gal)
JCB HP Grease 0.9 litres - - -
(0.18 UK gal) - - -
TRACK ROLLERS AND

IDLER WHEEL Engine Oil - - - -
HYDRAULIC SYSTEM JCB Hydraulic Fluid 46 233 litres 350 litres 320 litres 450 litres
(51.3 UK gal) (77 UK gal) (68.4 UK gal) (99 UK gal)
SWING RING
- BEARINGS JCB HP Grease - - - -
- GEAR TEETH JCB HP Grease 13 kg (28.6 lb) 22 kg (48.4 lb) 27 kg (59.4 lb) 31 kg (68.2 lb)
ALL OTHER GREASE

POINTS JCB HP Grease
COOLING SYSTEM 25.8 litres 25 litres 34 litres 50 litres

(5.7 UK gal) (5.5 UK gal) (7.5 Uk gal) (11 UK gal)
FUEL TANK 280 litres 280 litres 500 litres 500 litres
(61.6 UK gal) (61.6 UK gal) (110 UK gal) (110 UK gal)
-20 -10 0 10 20 30 40

API CD MIL L-2104C

API CD/SF
9804/1103 45 - 00 - 01/3 Issue 2*

CONTENTS
CONTENTS
JS 130W, 150W
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is
gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up
without load).
Capacity
Item Lubricant
JS130W JS150W
ENGINE To Class API CD 13.8 litres 13.8 litres

(see separate chart) (3 UK gal) (3 UK gal)
SWING GEARBOX JCB HD90 Gear Oil 1.7 litres 6 litres

(0.37 UK gal) (1.32 UK gal)
JCB HP Grease 0.47 litres Not
(0.1 UK gal) Applicable
HYDRAULIC SYSTEM JCB Hydraulic Fluid 46 157 litres 170 litres

(34.5 UK gal) (37.4 UK gal)
SWING RING
- BEARINGS JCB HP Grease - -
- GEAR TEETH JCB HP Grease 10 kg (22lb) 13 kg (28.7 lb)
PROPSHAFTS JCB HP Grease
ALL OTHER GREASE

POINTS JCB HP Grease
COOLING SYSTEM 17.8 litres 17.8 litres

FUEL TANK 240 litres 240 litres

(52.8 UK gal) (52.8 UK gal)
FRONT AXLE
- DIFFERENTIAL JCB Gear Oil LS 9 litres 9 litres
(2 UK gal) (2 UK gal)
- HUB (x 2) JCB Gear Oil LS 0.9 litres 1.5 litres
(0.2 UK gal) (0.33 UK gal)
REAR AXLE
- DIFFERENTIAL JCB Gear Oil LS 12 litres 12 litres
(2.64 UK gal) (2.64 UK gal)
- HUB (x 2) JCB Gear Oil LS 0.9 litres 1.5 litres
(0.2 UK gal) (0.33 UK gal)
DRIVE GEARBOX JCB 15W/40 Multigrade Oil 3.4 litres 3.4 litres
(0.8 gal) (0.8 gal)
-20 -10 0 10 20 30 40

API CD MIL L-2104C

API CD/SF
9804/1103 45 - 00 - 01/4 Issue 2

CONTENTS
CONTENTS
Excavators 45 - 00 - 01/4A
JS 70 from m/c no. 695501

Note: New engines DO NOT require a running-in period. The engine should be used in a normal work cycle immediately;
glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no
circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
Item Fluid/Lubricant International Specification Capacity
ENGINE See separate chart - 6.8 litres

(1.49 UK gal)
SLEW GEARBOX JCB HP Grease Lithium based, No. 2 0.2 kg

consistency (0.44 lb)
TRACK GEARBOXES JCB Gear Oil HD90 API-GL-5, MIL-L-2105C 2 x 1.7 litres
(0.37 UK gal)
TRACK ROLLERS AND

IDLER WHEEL Engine Oil (see separate chart) - -
HYDRAULIC SYSTEM JCB Special Hydraulic Vickers 35VQ25/V104C: 92 litres

Fluid HP46 Sundstrand, Denison and (20.26 UK gal)
FZG Approval Tests
SLEW RING
- BEARINGS JCB HP Grease Lithium based, No. 2 -
- GEAR TEETH JCB HP Grease consistency 3.2 kg (7.14 lb)
ALL OTHER GREASE Lithium based, No. 2

POINTS JCB HP Grease consistency
COOLING SYSTEM ASTM D3306-74 10.1 litres

(2.22 UK gal)
FUEL TANK ASTM D975-66T 140 litres

Nos 1D, 2D (30.8 UK gal)
Engine Lubrication Chart
*
-20 -10 0 10 20 30 40
JCB SUPER 15W/40 MULTIGRADE ENGINE OIL

API CF4/SG MIL L-2104F

API CE/SF MIL L-2104D
9804/1103 45 - 00 - 01/4A Issue 1

CONTENTS
CONTENTS
Excavators 45 - 00 - 01/4B
JS 130W from m/c no. 716500, JS160W from m/c no. 718500
International Capacity
Item Fluid/Lubricant Specification
JS130W JS160W
ENGINE See separate chart 12.1 litres 12.1 litres

SLEW GEARBOX JCB Gear Oil HD90 API-GL-5: MIL-L-2105C 5 litres 5 litres
(1.09 UK gal) (1.09 UK gal)
HYDRAULIC SYSTEM JCB Special Hydraulic Vickers 35VQ25/V104C: 124 litres 124 litres
Fluid HP46 Sundstrand, Denison and (27.3 UK gal) (27.3 UK gal)
FZG Approval Tests
SLEW RING
- BEARINGS JCB HP Grease Lithium complex (NLGI) inc. - -
- GEAR TEETH JCB HP Grease extreme pressure additives 17 kg (37.48 lb) 17 kg (37.48 lb)
PROPSHAFTS JCB HP Grease Lithium complex (NLGI) inc.

extreme pressure additives
ALL OTHER GREASE Lithium complex (NLGI) inc.

POINTS JCB HP Grease extreme pressure additives
COOLING SYSTEM See Coolant Mixtures ASTM D3306-74 16.4 litres 17.2 litres
(3.6 UK gal) (3.78 UK gal)
FUEL TANK See Fuel System, ASTM D975-66T 240 litres 240 litres
Types of Fuel Nos 1D, 2D (52.8 UK gal) (52.8 UK gal)
FRONT AXLE
- DIFFERENTIAL JCB Special Gear API GL4: M2C-41B/134D, 18 litres 18 litres
Oil Plus JD20C (3.9 Uk gal) (3.9 Uk gal)
- HUB (x 2) JCB Special Gear MGF M1135/M1141/ 1.5 litres 1.5 litres
Oil Plus M1143 (0.33 UK gal) (0.33 UK gal)
REAR AXLE
- DIFFERENTIAL JCB Special Gear API GL4: M2C-41B/134D 17.7 litres 17.7 litres
AND HUBS (x 2) Oil Plus JD20C, (3.9 UK gal) (3.9 UK gal)
MGF M1135/M1141/
M1143
DRIVE GEARBOX JCB Super 15W/40 API CF4/SG: MIL-L-2104F 3.8 litres 3.8 litres
Multigrade Engine Oil (0.83 UK gal) (0.83 UK gal)
Engine Lubrication Chart - All Machines

-30 -20 -10 0 10 20 30 40 50


9804/1103 45 - 00 - 01/4B 6980 - 127.1 Issue 1

CONTENTS
CONTENTS
JS 130 from m/c no. 758000, JS160 from m/c no. 702000
* Lubricants and Capacities
Capacity
International
Item Lubricant
Specification JS130 JS160
ENGINE (see separate chart) 12.1 litres 12.1 litres

(3.2 US gal) (3.2 US gal)
TRACK GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 2 x 3.0 litres 2 x 3.0 litres
(2 x 0.66 UK gal) (2 x 0.66 UK gal)
(2 x 0.79 US gal) (2 x 0.79 US gal)
SLEW GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 5 litres 5 litres
(1.09 UK gal) (1.09 UK gal)
(1.31 US gal) (1.31 US gal)
JCB Special HP Grease Lithium based No. 2 1 litre 1 litre
consistency (0.22 UK gal) (0.22 UK gal)
(0.26 US gal) (0.26 US gal)
TRACK ROLLERS JCB HD 90 Gear OIl API-GL-5, MIL-L-2105 - -

IDLER WHEEL
RECOIL SPRING JCB Special HP Grease Lithium based, No. 2 - -

CYLINDER consistency
HYDRAULIC SYSTEM JCB Hydraulic Fluid 46 ISO VG46 124 litres 124 litres
(27.3 UK gal) (27.3 UK gal)
(32.8 US gal) (32.8 US gal)
SLEW RING
- BEARING JCB Special HP Grease Lithium based No. 2
consistency - -
- GEAR TEETH JCB Special HP Grease Lithium based No. 2
consistency 11kg (24.25 lb) 17kg (37.48 lb)
ALL OTHER GREASE

POINTS JCB Special HP Grease Lithium based No. 2
consistency - -
COOLING SYSTEM see Coolant Mixtures - 16.4 litres 17.2 litres

(3.6 UK gal) (3.78 UK gal)
(4.3 US gal) (4.5 US gal)
FUEL TANK see Type of Fuel - 240 litres 240 litres

(52.8 UK gal) (52.8 UK gal)
(63.4 US gal) (63.4 US gal)
ENGINE LUBRICATION CHART - ALL COUNTRIES EXCEPT NORTH AMERICAN

-30 -20 -10 0 10 20 30
API CF4/SG

API CF4/SG
ENGINE LUBRICATION CHART - NORTH AMERICAN
Use according to ambient temperature (°F)

-22 -5 0 14 32 50 68 90

API CF4/SG
JCB 10W ENGINE OIL

API CF4/SG
9804/1103 45 - 00 - 01/5 6410 - 3/1-1.2 Issue 3*

CONTENTS
CONTENTS
* JS 180 from m/c no. 702132
* Lubricants & Capacities
Capacity
International
Item Lubricant
Specification JS180
ENGINE (see separate chart) 12.1 litres

(2.7 UK gal)
(3.2 US gal)
TRACK GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 2 x 3.5 litres
(2 x .77 UK gal)
(2 x .92 US gal)
SLEW GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 5 litres

(1.09 UK gal)
(1.31 US gal)
TRACK ROLLERS JCB HD 90 Gear OIl API-GL-5, MIL-L-2105 -

IDLER WHEEL
RECOIL SPRING JCB Special HP Grease Lithium complex (NLGI) inc. -

CYLINDER extreme pressure additives
HYDRAULIC SYSTEM JCB Hydraulic Fluid 46 ISO VG46 124 litres

(27.3 UK gal)
(32.8 US gal)
SLEW RING
- BEARING JCB Special HP Grease Lithium complex (NLGI) inc.
extreme pressure additives -
- GEAR TEETH JCB Special HP Grease Lithium complex (NLGI) inc.
extreme pressure additives 17kg (37.48 lb)
ALL OTHER GREASE

POINTS JCB Special HP Grease Lithium complex (NLGI) inc.
extreme pressure additives -
COOLING SYSTEM see Coolant Mixtures - 17.2 litres

(3.78 UK gal)
(4.54 US gal)
FUEL TANK see Type of Fuel - 240 litres

(52.8 UK gal)
(63.4 US gal)
Use according to ambient temperature (¡C)
9804/1103 45 - 00 - 01/5A 6950 - 88 Issue 2*

CONTENTS
CONTENTS
* JS 200, 220 and variants from m/c no. 705001, JS 240, 260 from m/c no. 708501
Capacity
Item Lubricant International Specification
ENGINE (see separate chart) 21.5 litres

(4.72 UK gal)
(5.67 US gal)
TRACK GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 2 x 3.5 litres
(2 x 0.77 UK gal)
(2 x 0.92 US gal)
SLEW GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 5 litres

(1.09 UK gal)
(1.31 US gal)
TRACK ROLLERS JCB HD90 Gear Oil API-GL-5, MIL-L-2105 -- --

AND IDLER WHEEL
RECOIL SPRING JCB Special HP Grease Lithium complex (NLGI) inc. --

CYLINDER extreme pressure additives
HYDRAULIC SYSTEM JCB Hydraulic 203 litres

Fluid 46 ISO VG46 (44.64 UK gal)
(53.6 US gal)
SLEW RING
- BEARING JCB Special HP Grease Lithium complex (NLGI) inc. --
JS 200, JS 220
- GEAR TEETH JCB Special HP Grease Lithium complex (NLGI) inc. 17 kg (37.48 lb)
extreme pressure additives JS 240, JS 260
20 kg (44.10 lb)
ALL OTHER GREASE

POINTS JCB Special HP Grease Lithium complex (NLGI) inc. --
COOLING SYSTEM 25.5 litres

(5.6 UK gal)
(6.7 US gal)
FUEL TANK 310 litres

(68.19 UK gal)
Use according to ambient temperature (¡C)
9804/1103 45 - 00 - 01/6 6950 - 89 Issue 3*

CONTENTS
JS 200W from m/c no. 0802000 to 802999

JS200W
ENGINE See separate chart 18.5 litres

(4.0 UK gal)
(4.9 US gal)
SLEW GEARBOX JCB Gear Oil HD90 API-GL-5: MIL-L-2105C 5 litres

(1.09 UK gal)
(1.31 US gal)
JCB HP Grease Lithium based, No. 2 1 litre
consistency (0.22 UK gal)
(0.26 US gal)

FZG Approval Tests (32.7 US gal)
SLEW RING
- BEARINGS JCB HP Grease Lithium based, No. 2 -
- GEAR TEETH JCB HP Grease consistency 17 kg (37.48 lb)
PROPSHAFTS JCB HP Grease Lithium based, No. 2

consistency
ALL OTHER GREASE Lithium based, No. 2

POINTS JCB HP Grease consistency
COOLING SYSTEM See Coolant Mixtures ASTM D3306-74 27 litres

(5.9 UK gal)
(7.1 US gal)
FUEL TANK See Fuel System, ASTM D975-66T 310 litres

Types of Fuel in (68.2 UK gal)
Operator Handbook Nos 1D, 2D (81.2 US gal)
FRONT AXLE
- DIFFERENTIAL JCB Gear Oil HD90 API GL-5: MIL-L-2105D 9.0 litres
(1.98 UK gal)
(2.37 US gal)
- HUB (x 2) 2.0 litres
(0.44 UK gal)
(0.52 US gal)
REAR AXLE
AND HUBS (x 2) (3.74 UK gal)
(4.49 US gal)
DRIVE GEARBOX JCB Super 15W/40 API CF4/SG: MIL-L-2104F 3.8 litres
Multigrade Engine Oil (0.836 UK gal)
(1.0 US gal)
9804/1103 45 - 00 - 01/6A Issue 1

CONTENTS
Excavators 45 - 00 - 01/6B
JS 200W from m/c no. 0802000 to 802999
Lubricants & Capacities (cont’d)
Engine Lubrication Chart
-30 20 -10 0 10 20 30 40 50


9804/1103 45 - 00 - 01/6B Issue 1

CONTENTS
CONTENTS
Excavators 45 - 00 - 01/6C
* JS 200W from m/c no. 809000

JS200W
ENGINE See separate chart 18.5 litres

(4.0 UK gal)
(4.9 US gal)
SLEW GEARBOX JCB Gear Oil HD90 API-GL-5: MIL-L-2105C 5 litres

(1.09 UK gal)
(1.31 US gal)

FZG Approval Tests (32.7 US gal)
SLEW RING
- BEARINGS JCB HP Grease Lithium complex (NLGI) inc. -
- GEAR TEETH JCB HP Grease extreme pressure additives 17 kg (37.48 lb)
PROPSHAFTS JCB HP Grease Lithium complex (NLGI) inc.

ALL OTHER GREASE Lithium complex (NLGI) inc.

POINTS JCB HP Grease extreme pressure additives
COOLING SYSTEM ASTM D3306-74 27 litres

(5.9 UK gal)
(7.1 US gal)
FUEL TANK See Fuel System, ASTM D975-66T 310 litres

Types of Fuel in (68.2 UK gal)
Operator Handbook Nos 1D, 2D (81.2 US gal)
FRONT AXLE
(1.98 UK gal)
(2.37 US gal)
- HUB (x 2) 2.0 litres
(0.44 UK gal)
(0.52 US gal)
REAR AXLE
AND HUBS (x 2) (3.74 UK gal)
(4.49 US gal)
DRIVE GEARBOX JCB Super 15W/40 API CF4/SG: MIL-L-2104F 3.8 litres
Multigrade Engine Oil (0.836 UK gal)
(1.0 US gal)
9804/1103 45 - 00 - 01/6C 6980 - 128 Issue 1

CONTENTS
Excavators 45 - 00 - 01/6D
JS 200W from m/c no. 809000

Lubricants and Capacities (cont’d)
-30 20 -10 0 10 20 30 40 50


9804/1103 45 - 00 - 01/6D 6320 - 3/1-2.1 Issue 1

CONTENTS
* JS330 from m/c no. 712501, JS 450 from m/c no. 714501,
JS 460 from m/c no. 714550
Capacity
Item Lubricant International Specification
JS330 JS450/JS460
ENGINE (see separate chart) 34 litres 34 litres

(7.5 Uk gal) (7.5 UK gal)
TRACK GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 2 x 8.5 litres 2 x 7.0 litres
(2 x 1.9 UK gal) (2 x 1.5 UK gal)
SLEW GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 14.5 litres 18 litres
(3.2 UK gal) (4 UK gal)
TRACK ROLLERS JCB HD90 Gear Oil API-GL-5, MIL-L-2105 - -

IDLER WHEEL
RECOIL SPRING JCB Special HP Grease Lithium based, No. 2 - -

CYLINDER consistency
HYDRAULIC SYSTEM JCB Hydraulic Fluid 46 ISO VG46 320 litres 450 litres
(70.5 UK gal) (99 UK gal)
SLEW RNG
- BEARING JCB Special HP Grease Lithium based, No. 2
consistency - -
- GEAR TEETH JCB Special HP Grease Lithium based, No. 2
consistency 17 kg (34. 48 lb) 17 kg (34. 48 lb)
ALL OTHER GREASE JCB Special HP Grease Lithium based, No. 2

POINTS consistency - -
COOLING SYSTEM see Coolant Mixtures - 38 litres 43 litres

FUEL TANK see Type of Fuel - 580 litres 650 litres

(128 UK gal) (143 UK gal)

-30 -20 -10 0 10 20 30 40


9804/1103 45 - 00 - 01/7 6420 - 3/1-1.2 Issue 3*

CONTENTS
CONTENTS
Excavators
*JS 70 to m/c no. 695500
Static Dimensions
A Track length on ground 2050 mm (6 ft 9 in)
B Undercarriage - overall length 2680 mm (8 ft 10 in)
C Tail height 760 mm (2 ft 6 in)
D Tailswing radius 1600 mm (5 ft 3 in)
E Tail length 1600 mm (5 ft 3 in)
F Superstructure width 2200 mm (7 ft 3 in)
G Height over cab 2550 mm (8 ft 4 in)
H Ground clearance 360 mm (1 ft 2 in)
J Track gauge 1700 mm (5 ft 8 in)
K Track width - 450 mm (18 in) shoes 2150 mm (7 ft 1 in)

- 600 mm (24 in) shoes 2300 mm (7 ft 7 in)
L Transport length - standard boom 5860 mm (19 ft 3 in)

- offset boom 5950 mm (19 ft 6 in)
M Transport height - standard boom 2540 mm (8 ft 4 in)

- offset boom 2740 mm (9 ft 0 in)
N Track height 620 mm (2 ft 0 in)
P Dozer blade width 2250 mm (7 ft 5 in)
R Dozer blade height 460 mm (1 ft 6 in)
S Dozer blade reach in front of tracks 480 mm (1 ft 7 in)
9804/1103 45 - 00 - 02/1 Issue 3*

CONTENTS
CONTENTS Excavators 45 - 00 - 02/2
JS 110
Static Dimensions
C Tail Height 920 mm (3 ft 0 in)

L Transport length - 1.96 m dipper 7320 mm (24 ft 0 in)

- 2.26 m dipper 7340 mm (24 ft 1 in)
- 2.91 m dipper* 7380 mm (24 ft 3 in)
M Transport height - 1.96 m dipper 2600 mm (8 ft 6 in)

- 2.26 m dipper 2660 mm (8 ft 9 in)
- 2.91 m dipper* 2630 mm (8 ft 8 in)
*Dipper ram in transport position (as shown).
9804/1103 45 - 00 - 02/2 Issue 1

CONTENTS
CONTENTS
JS 130
Static Dimensions


- 2.50 m dipper 7690 mm (25 ft 3 in)
- 2.91 m dipper* 7700 mm (25 ft 4 in)

- 2.50 m dipper 2650 mm (8 ft 8 in)
- 2.91 m dipper* 2540 mm (8 ft 4 in)
*Dipper ram in transport position (as shown).
9804/1103 45 - 00 - 02/3 Issue 1

CONTENTS
CONTENTS
JS 150LC
Static Dimensions
A Track length on ground

3100 mm (10 ft 2 in)
B Undercarriage - overall length
3900 mm (12 ft 10 in)
C Tail Height
1050 mm (3 ft 5 in)
D Tailswing radius
2350 mm (7 ft 9 in)
E Tail length
2235 mm (7 ft 4 in)
F Superstructure width
2500 mm (8 ft 3 in)
G Height over cab
2850 mm (9 ft 4 in)
H Ground clearance
460 mm (1 ft 6 in)
J Track gauge
1990 mm (6 ft 6 in)
K Track width - 500 mm (20 in) shoes
2690 mm (8 ft 10 in)
L Transport length - 2.70 m dipper
- 3.15 m dipper* 8320 mm (27 ft 4 in)
8380 mm (27 ft 6 in)
M Transport height - 2.70 m dipper
- 3.15 m dipper* 2850 mm (9ft 4 in)
2865 mm (9ft 5 in)
N Track height
870 mm (2 ft 10 in)
*Dipper ram in transport position.
9804/1103 45 - 00 - 02/4 Issue 1

CONTENTS
CONTENTS
JS 200LC
Static Dimensions

- 2.36 m dipper 9480 mm (31 ft 1 in)
- 2.94 m dipper 9380 mm (30 ft 9 in)
- 2.36 m dipper 3010 mm (9 ft 11 in)
- 2.94 m dipper 2850 mm (9 ft 4 in)
9804/1103 45 - 00 - 02/5 Issue 1

CONTENTS
CONTENTS
JS 240LC
Static Dimensions
G Height over cab 2987 mm (9 ft10 in)


- 2.41 m dipper 9960 mm (32 ft 8 in)
- 3.05 m dipper 9870 mm (32 ft 5 in)
- 3.51 m dipper 9920 mm (32 ft 7 in)

- 2.41 m dipper 3230 mm (10 ft 7 in)
- 3.05 m dipper 3040 mm (10 ft 0 in)
- 3.51 m dipper 3300 mm (10 ft 10 in)
9804/1103 45 - 00 - 02/6 Issue 1

CONTENTS
CONTENTS
JS 300LC
Static Dimensions


- 2.63 m dipper 10970 mm (36 ft 0 in)
- 3.23 m dipper 10870 mm (35 ft 8 in)
- 4.03 m dipper 10970 mm (36 ft 0 in)

- 2.63 m dipper 3540 mm (11 ft 7 in)
- 3.23 m dipper 3330 mm (10 ft 11 in)
- 4.03 m dipper 3820 mm (12 ft 6 in)
9804/1103 45 - 00 - 02/7 Issue 1

CONTENTS
CONTENTS Excavators 45 - 00 - 02/8
JS 450LC
Static Dimensions


- 3.36 m dipper 12060 mm (39 ft 7 in)
- 4.00 m dipper 12070 mm (39 ft 7 in)
- 4.76 m dipper 12160 mm (39 ft 11 in)

- 3.36 m dipper 3430 mm (11 ft 3 in)
- 4.00 m dipper 3460 mm (11 ft 4 in)
- 4.76 m dipper 4060 mm (13 ft 4 in)
9804/1103 45 - 00 - 02/8 Issue 1

CONTENTS
Excavators
JS 130W
Static Dimensions
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Publication No. 9804/1103

1992 Data Book

Page number example: 20 - 05 - 02/1

Machine Range Subject classification Number to suit

9804/1103 70 - XX - XX/X Issue 1

Metric Units 1-1

9804/1103 General Section Contents Issue 1

Quantity Name of Unit Unit Symbol

Angle second "

Area square millimetre mm2

Electric — Current Ampere A

Flow litre per minute l/m

Moment of force Newton metre Nm

Pressure bar bar

Speed kilometre per hour km/h

Temperature degree Celsius °C

Volume cubic millimetre mm3

9804/1103 1-1 Issue 1

Imperial to S.l. Units

To convert imperial units to Sl multiply by the conversion factor.

To convert Sl units to imperial divide by the conversion factor.

Quantity Imperial Metric Conversion Factor

Area in2 mm2 645.2

Capacity pints—UK I 0.5683

Flow gal/min—UK l/min 4.5461

Force Ibf N 4.45

Moment of force Ibf in Nm 0.112 985

Pressure Ibf/in2 bar 0.068 95

Speed ft/s m/s 0.3048

Volume in3 cm3 16.387

9804/1103 1-2 Issue 1

Conversion Tables - Capacity

UK gallons to US gallons and litres

US gallon UK gallon Litres UK gallon

1.201 1 0.833 4.546 1 0.219

9804/1103 1-3 Issue 1

Conversion Tables - Length

Fractions of an inch to decimals of an inch and millimetres.

1/64 0.015 625 0.396 875

Inches to millimetres and feet to metres

Inch Millimetres Feet Metres

0.039 1 25.4 3.281 1 0.3048

9804/1103 1-4 Issue 1

Conversion Tables - Pressure

Ibf/in2 to kgf/cm2 and Bar

Ibf/in2 kgf/cm2 Ibf/in2 Bar

142.233 10 0.703 145.038 10 0.690

9804/1103 1-5 Issue 1

Conversion Tables - Temperature

To the right for equivalent in deg F

Deg C Deg F Deg C Deg F

- 31.7 - 25 - 13.0 87.8 190 374

9804/1103 1-6 Issue 1

Pump flow (litres/min) = Displacement (cm3/rev) x Speed (rev/min)

Pump flow (UK gal/min) = Displacement (in3/rev) x Speed (rev/min)

Power output of Hydraulic Pump (kw) = Flow (litres/min) x Pressure (bar)

Power output of Hydraulic Motor (kw) = Torque (Nm) x Speed (rev/min)

Cylinder Thrust (kgf) = pressure (bar) x piston area (mm2)

Cylinder Thrust (Ibf) = pressure (Ibf/in2) x piston area (in2)

9804/1103 1-7 Issue 1

Torque Settings (for all machines except JS Range)

UNF Grade 'S' Bolts