JCBconstructionmilitary machines
Jcb 540 NAVAL
Maintenance schedule, common problems & OEM parts breakdown
The JCB 540 is a rough-terrain telescopic handler (Loadall) designed for high-reach material handling in construction and industrial applications. The base 540 model features a 4.4L 4-cylinder turbocharged diesel engine, typically rated between 74 kW (100 hp) and 81 kW (109 hp) depending on the specific variant (e.g., 540-170, 540-200). Operating weight ranges from approximately 8,818 lbs (4,000 kg) to 12,300 kg (27,117 lbs) depending on configuration and attachments. Production spans from the late 1990s through the 2020s, with the 540-170 and 540-200 being prominent modern iterations. The machine offers configurations with 17m to 20m lift heights, 4x4x4 steering, and various boom designs (4-piece or 5-piece). It serves as a versatile alternative to traditional forklifts in tight jobsites, succeeding earlier Loadall models like the 530 series and preceding newer Stage V compliant variants.
Across its generations, the JCB 540 evolved from mechanical controls to servo-assisted multi-function levers and integrated LiveLink telematics for fleet management. Early models utilized older diesel engines, while later iterations adopted JCB Dieselmax and EcoMAX engines meeting Stage V emissions without DEF, reducing maintenance complexity. The machine matters in the used and parts market due to its robust chassis design, ground-level serviceability, and long engine oil intervals (500 hours), which appeal to contractors seeking high uptime. The 540's popularity in logistics and construction ensures a steady supply of used units and compatible components, though buyers must verify specific engine serials and emission tiers as specifications vary by configuration and production year.
Below: full specifications, fluids & capacities, the factory service schedule, common service parts, verified fault codes, what owners discuss, attachment guidance, the complete assembly directory, and a serial-number reference. Complete parts lists with full OEM part numbers, exploded diagrams, quantities, and fitment data are available free in Heavy Parts AI.
Jcb 540 NAVAL specifications
Engine
| Model | JCB EcoMAX T4i/IIIB (per published references); JCB Dieselmax Stage V (per Watling JCB); JCB 430 EcoMAX / JCB EcoMAX 444 TCA (per Makana) |
| Gross Power | 100 hp (75 kW) |
| Net Power | 74 hp (55.18 kW) |
| Displacement | 4,400 cu cm (4.4 L) |
| Cylinders | 4 |
| Emissions Tier | Stage V / Tier 4 Final |
Weights
| Operating Weight | 8,818.5 lb (4,000 kg) per published references; 12,300 kg per Makana; 12,260 kg per Werktuigen listings |
| Shipping Weight | Not documented for this exact serial range — verify with your dealer |
| Ground Pressure | Not documented for this exact serial range — verify with your dealer |
Dimensions
| Transport Length | 20.87 ft (6.36 m) per published references; 6.64 m per Werktuigen; 6.25 m per Werktuigen |
| Transport Width | 8.01 ft (2.44 m) per published references; 2.53 m per Werktuigen; 2.35 m per Werktuigen |
| Transport Height | 8.83 ft (2.69 m) per published references; 2.64 m per Werktuigen; 2.59 m per Werktuigen |
| Wheelbase | 9.03 ft (2.75 m) |
| Ground Clearance | 1.32 ft (0.40 m) |
Performance
| Travel Speed (Forward) | 15.6 mph (25.1 km/h) per published references; 32 km/h per Werktuigen |
| Travel Speed (Reverse) | 15.6 mph (25.1 km/h) |
| Max Lift Capacity | 8,818.5 lb (4,000 kg) |
| Max Lift Height | 54.79 ft (16.7 m) per published references; 16.2 m per Makana; 13.74 m per Werktuigen |
| Max Forward Reach | 41.02 ft (12.5 m) per published references; 17,000 mm (17 m) per Makana; 9.80 m per Werktuigen |
| Gradeability | Not documented for this exact serial range — verify with your dealer |
Service capacities (summary)
| Fuel Tank | 33.1 gal (125 L) per published references; 146 L per Makana |
| Hydraulic System | 39.7 gal (150 L) per published references; 150 L per Makana |
| Engine Oil | Not documented for this exact serial range — verify with your dealer |
| Cooling System | Not documented for this exact serial range — verify with your dealer |
Values vary by configuration, region, and serial range — confirm against your machine before planning transport or lifts.
540 NAVAL fluids & capacities
| System | Capacity | Recommended fluid |
|---|---|---|
| Fuel tank | 160 liters (42.3 US gal) | Diesel fuel |
| Engine crankcase (with filter) | 12.5 liters (3.3 US gal) | JCB Engine Oil EP (-10°C to 50°C / 14°F to 122°F) or JCB Cold Climate Engine Oil (-20°C to 50°C / -4°F to 122°F) |
| Cooling system | 15 liters (4.0 US gal) | JCB High Performance Antifreeze and Inhibitor / Water |
| Transmission / Powertrain | 22 liters (5.8 US gal) | JCB Transmission Oil |
| Hydraulic system and tank | Varies by configuration/series | JCB Hydraulic Fluid HP46 or HP32 |
| Grease | N/A | JCB Grease |
Capacities are refill values from factory literature — always fill to the dipstick/sight gauge, not the number.
Jcb 540 NAVAL maintenance schedule
| Service interval | Tasks |
|---|---|
| Every 10 h |
|
| Every 250 h |
|
| Every 500 h |
|
| Every 1,000 h |
|
| Every 2,000 h |
|
Servicing the 540 NAVAL beyond the schedule
Predictive Maintenance & Fluid Analysis
At the 500-hour interval, take oil samples from the engine, hydraulic tank, and axle systems to establish a baseline. JCB’s 500-hour engine oil interval relies on clean fuel and proper filtration; monitor the hydraulic return filter magnet for metallic debris. Use JCB Engine Oil Special or equivalent 15W-40 diesel oil meeting API specs. Regular fluid analysis detects bearing wear or contamination 500–800 hours before failure, preventing catastrophic hydraulic or engine damage in the 540’s high-cycle telehandler applications.
Corrective & Common Repairs
Common repairs on the JCB 540 involve the 4.4L turbocharged diesel engine’s fuel system and hydraulic components. Replace primary and secondary fuel filters at 250-hour intervals to protect common-rail injectors. Inspect the 5-piece boom chain tension and hydraulic ram seals for leaks. Check the alternator and fan belts for wear. Address hydraulic hose chafing at the kingpost and boom pivot points early. The machine’s ground-level service access simplifies these repairs, but proper torque on slew ring bolts (if equipped with excavator attachments) is critical for safety.
Overhaul & Rebuild Points
The 2,000-hour deep service is the primary overhaul milestone for the JCB 540. Drain and clean the hydraulic tank, replacing hydraulic oil to prevent valve and pump wear. Inspect the structural frame, boom, and chassis for cracks or unauthorized welding. Measure swing ring play if equipped with rotating attachments. Check injector spray patterns via the JCB ServiceMaster diagnostic tool. This interval also includes servicing the cab HVAC system and replacing the cabin filter, ensuring operator comfort and system integrity after extended high-cycle use.
Seasonal & Environment Servicing
In cold climates, ensure the cooling system is flushed and refilled with JCB-spec long-life coolant to prevent freezing and corrosion. Check the battery electrolyte levels and terminal condition, as cold weather strains starting systems. In dusty environments, monitor the air filter restriction indicator closely and clean or replace elements more frequently. Verify the variable speed cooling fan operates correctly to manage engine temperature under heavy load. Regularly inspect the undercarriage and tires for damage from debris, and ensure the DPF regeneration process (if equipped) is monitored via LiveLink telematics.
540 NAVAL common service parts
| Part number | Part | Notes | |
|---|---|---|---|
| 704/30200 | Filter, Fuel-Diesel | Fuel system service | Check fitment → |
| 32/912001 | Element, Fuel Filter, Canister Type | Fuel system service | Check fitment → |
| 02/202313 | Pipe, Fuel Lift Pump, To Fuel Filter | Fuel system service | Check fitment → |
| 32/915801 | Element, Air, Safety | Air intake service | Check fitment → |
| 32/915802 | Element, Air, Main | Air intake service | Check fitment → |
Always confirm against your machine's serial number — cross-check any part in Heavy Parts AI before ordering.
540 NAVAL fault codes & troubleshooting
| Code | Meaning | Likely cause | What to do |
|---|---|---|---|
| P0087 | Fuel rail pressure too low | Fuel supply restriction, leaking injector, or faulty pressure sensor | Check fuel filters and lines for blockages; inspect injector wiring and connections |
| P0088 | Fuel rail pressure too high | Fuel pressure regulator fault or restricted return line | Inspect fuel pressure regulator and return lines for restrictions or damage |
| P0110 | Intake Air Temperature Sensor 1 Circuit | Open circuit, short to ground, or faulty sensor | Visually inspect sensor wiring harness for damage; check connector pins for corrosion |
| P0115 | Engine Coolant Temperature Sensor 1 Circuit | Open circuit, short to ground, or faulty sensor | Check sensor electrical connections and wiring integrity; verify coolant level |
| P0201 | Injector circuit open – 1st cylinder | Broken wire, loose connector, or failed injector solenoid | Inspect injector wiring harness and connector for physical damage or looseness |
| P0335 | Crankshaft Position Sensor 'A' Circuit No Signal | Faulty sensor, damaged wiring, or timing gear issue | Check sensor wiring and connector; inspect sensor mounting and air gap |
| P0321 | CAN bus message error for engine speed from engine ECU | CAN bus communication fault or sensor signal loss | Inspect CAN bus wiring for shorts or opens; check connector security |
| P0102 | MAF Low Voltage Fault | Mass Air Flow sensor low signal or circuit fault | Inspect MAF sensor wiring and connector; clean sensor if contaminated |
| 203 EN TMP | Engine Temperature Fault | Cooling system malfunction or sensor error | Check coolant level and radiator condition; verify sensor operation |
| 218 HYD PMP | Hydraulic Pump Fault | Hydraulic pump pressure or flow anomaly | Check hydraulic fluid level and filter; inspect pump for leaks or damage |
Codes and remedies are general guidance for this model family — always confirm with diagnostic tooling and your dealer before major repairs.
540 NAVAL attachments & work tools
Quickhitch and Carriages
The JCB Q-fit self-levelling carriage with lever-operated pin locking is the standard mounting system for the 540 series, accepting pallet forks and a wide range of attachments. This system is designed to work in harmony with JCB machines to enhance productivity and versatility on job sites.
Buckets
Available options include Deep Profile, Ditch Maintenance, Grading, Heavy Duty, Jaw, Ribbed, Tapered Ditching, and Tilting Grading buckets. These tools are designed for improved productivity, efficient digging, better material retention, and clean release of material.
Forks and Fork Frames
Pallet forks are the primary attachment for the Q-fit carriage, with standard configurations including a fork carrier with two standard prongs. Additional hydraulic setups are available to support heavier material handling tasks.
Hydraulic Breakers
JCB offers an OEM hydraulic breaker range designed to work in perfect harmony with its machines and other brands of excavator and breaker carriers. These breakers require specific hydraulic kit arrangements to operate effectively.
Grabs and Grapples
The attachment range includes various grabs and grapples suitable for material processing and handling. These tools attach via the standard quickhitch system and require hydraulic connections for operation.
Sweepers and Collectors
Sweeper collectors are available as part of the specialist attachments range to perform tough applications. These tools enhance the versatility of the telehandler for municipal and industrial cleaning tasks.
Earth Drills and Augers
Augers and bits are listed among the compatible attachments for the 540 series. These tools require hydraulic power and are mounted using the standard telehandler mounting plates or quickhitch systems.
Lifting Equipment
Specialized lifting equipment is available to extend the machine's capabilities for heavy or specialized loads. These attachments integrate with the machine's hydraulic system and mounting interface.
Snow Attachments
Snow and dozer blades, snow blowers, and snow pushers are available for winter operations. These tools are designed to attach securely to the telehandler's carriage for effective material movement.
Guarding and Safety Options
Standard worksite safety features include a backup alarm, hydraulic lockout, strong handrails, and good steps. The cab conforms to ROPS ISO 3471 and FOPS ISO 3449 standards with tinted glass all round and a laminated roof screen.
All 540 NAVAL assemblies by section
Every catalogued assembly group for the Jcb 540 NAVAL. Open an assembly to preview the parts inside — full OEM part numbers are available in Heavy Parts AI.
A Attachments
A3-2-1 Carriage Fork, Industrial
| 33***86 | Fork, Pair, Stainless Steel | 1 |
| 54***00 | Frame, 1500 mm | 1 |
| 54***02 | Plate, Stile Top | 1 |
A3-10-5 Diverter Valve, Platform
| 92***29 | Valve, Diverter | 1 |
A3-10-9 Lock Assembly, Man Platform
| 12***21 | Padlock | 1 |
| 92***05 | Strip, Sealing | 1 |
| 97***64 | Lock, Bracket Wa | 1 |
A3-4-1 Forks
| 54***00 | Fork, Arm, 125wx50tx1200l, Class 3b | 1 |
| 54***00 | Fork, Arm 100wx50tx1067l, Class 3b, Fork, Arm 100wx50tx1067l, Class 3b; Not Fitted On Usa Machines. All Forks Are Supplied In Matched Pairs Only And Cannot Be Replaced Individually | 1 |
| 99***00 | Kit-Fork Retention, Class 3 Fork | 2 |
A3-10-3 Remote Control, Man Platform
| 33***96 | Frame, Remote Control | 1 |
| 33***30 | Lever, Joystick | 2 |
| 33***15 | Cable | 1 |
A3-10-7 Cab Control Unit, Man Platform
| 33***11 | Switch, Emergency Lowering | 1 |
| 33***12 | Light | 4 |
| 33***13 | Switch | 1 |
A3-1-1 Carriage Quickhitch
| 13***6Z | Bolt | 2 |
| 13***0Z | Bolt, M6 X 40mm Long | 1 |
| 13***4Z | Nut, Philidas Thin | 2 |
A3-10-2 Platform
| 33***86 | Platform, Man | 1 |
| 33***39 | Door, Right | 1 |
| 33***40 | Door, Left | 1 |
A3-3-1 Guard,Load, 'Q'Fit Carriage
| 54***00 | Guard, Load; San 23375.Mss To 33***49 & 83***67.28/2/7, P Gamble. L06/223 | 1 |
| 82***12 | Pin, Lynch | 2 |
| 91***00 | Pin, Retention | 2 |
A3-5-1 Carriage,Sideshift
| 16***03 | Adapter, Male/Male | 2 |
| 16***03 | Adapter | 2 |
| 45***00 | Coupling, Male 3/8"Bsp, C/W 2x, 22***33 Circlips | 1 |
A3-10-6 Cab Controls, Man Platform
| 70***95 | Switch, Emergency Stop Butto | 1 |
A3-10-1 Platform & Control
| 33***96 | Frame, Remote Control | 1 |
| 33***86 | Platform, Man | 1 |
| 33***02 | Screw | 1 |
A3-10-4 Diverter Valve, Installation, Man Platform
| 33***21 | Plug, Female | 1 |
| 33***22 | Plug, Male | 1 |
| 33***23 | Housing | 1 |
B Bodywork, Cab, Loader End
B1-8-9 Chaff Guard, Radiator
| 13***3Z | Screw; Replaces 69***21 | 2 |
| 13***8Z | Screw, M6 X 30mm Long | 2 |
| 13***5Z | Screw, M10 X 20mm Long; Use With Single Piece Casing. To Gearbox Number 445/143/831 Or 445/144/455, Screw, M10 X 20mm Long | 4 |
B1-9-1 Counterweight, Underslung
| 13***5Z | Bolt | 2 |
| 14***1Z | Washer, M16 Plain | 2 |
| 14***1Z | Washer, Spring; Replaces 60***1r | 2 |
B1-8-6 Guard, Sump & Radiator, Service Use Only
| 13***8Z | Bolt, M10 X 30 | 2 |
| 13***9Z | Screw, M12 X 35mm, Screw, M12 X 35mm; M12 X 35. Items 21 & 22 Are Used On 23***00 And 23***00 Throttle Brackets | 2 |
| 13***3Z | Nut, M12 | 2 |
B1-4-1 Bodywork Rear, Hydraulic Tow Hitch
| 12***33 | Catch, Door Retaining | 1 |
| 13***1Z | Screw, M5 X 12mm; Replaces 69***94 | 2 |
| 13***3Z | Screw, M8 X 16 | 2 |
B1-15-1 Stowage Tray
| 13***5Z | Bolt, M12x20 | 4 |
| 14***9Z | Washer | 4 |
| 97***41 | Tray, Stowage | 1 |
B1-12-1 Mirror,Tow Hitch
| 12***70 | Mirror, Exterior Head Assembly | 1 |
| 14***1Z | Washer | 2 |
| 47***68 | Mirror | 1 |
B1-8-13 Belly Plate,5 Speed
| 13***5Z | Setscrew, M10 X 20mm | 16 |
| 13***2Z | Bolt, Setscrew M10x50 | 8 |
| 14***1Z | Washer, 2 Ba | 8 |
B1-3-1 Fenders,Front(Large), Rear(Small)
| 13***8Z | Bolt, M10 X 30 | 32 |
| 13***6Z | Bolt, Hex. Head, M10 X 70 | 16 |
| 13***3Z | Nut, Lock, M10 | 48 |
B1-4-5 Bulkhead Plates
| 13***9Z | Setscrew, M8x35 | 4 |
| 13***3Z | Nut, Self Lock, M8 | 4 |
| 14***7Z | Washer, Plain, M8; Replaces Khn1550, San 12620 | 8 |
B1-13-2 Noise Quilts, Engine Pod & Chassis
| 33***95 | Panel, Noise Quilt, Under Engine | 1 |
| 33***96 | Panel, Noise Quilt, Engine Pod Side | 1 |
| 33***97 | Panel, Noise Quilt, Engine Pod Ffront | 1 |
B1-5-1 Engine Pod, Base And Cover, Cooling With Soundproofing
| 13***7Z | Screw, Hexagon M8 X 25 | 6 |
| 13***0Z | Bolt, M8x40 | 4 |
| 13***7Z | Bolt, M10x25 | 5 |
B1-3-6 Mirror Arm
| 13***3Z | Screw, M6x16 | 2 |
| 13***7Z | Screw, Hexagon M8 X 25 | 2 |
| 13***9Z | Bolt, Paint Clearing | 2 |
B1-11-1 Steer Sensor, Installation
| 13***5Z | Screw, M10 X 20mm Long; Use With Single Piece Casing. To Gearbox Number 445/143/831 Or 445/144/455, Screw, M10 X 20mm Long | 5 |
| 13***7Z | Bolt, M10x25 | 2 |
| 13***3Z | Nut, Lock, M10 | 2 |
B1-1-11 Axle Feet Mountings
| 14***0Z | Washer, Plain | 8 |
| 16***80 | Plate, Loader Spreader | 2 |
| 16***81 | Axle, Foot 540, Axle, Foot 540; Note 1. Fit Contact Tech Services. Must Fit Axle Feet Each Side | 2 |
B1-6-1 Tank, Hydraulic
| 12***53 | Gauge, Sight | 1 |
| 13***7Z | Screw, M6 X 25mm Long | 8 |
| 14***21 | Seal, Bonded 3/4" Bsp | 1 |
B1-2-1 Mainframe Covers, Lift Ram & Valve Blk
| 13***5Z | Bolt, M5 X 20mm Long | 5 |
| 14***1Z | Washer, 2 Ba | 5 |
| 33***98 | Cover, Lift Ram Recess | 1 |
B1-8-1 Chaff Guard, Under Pod Guard
| 13***8Z | Bolt, M10 X 30 | 1 |
| 13***0Z | Bolt | 2 |
| 13***3Z | Nut, Self Lock, M6 | 13 |
B1-13-1 Soundproofing, Engine Cover/Bonnet
| 33***10 | Panel, Bonnet Top Front, Noise Board | 1 |
B1-14-1 Toolbox
| 12***71 | Padlock | 1 |
| 13***3Z | Screw, M8 X 16 | 4 |
| 13***3Z | Bolt, M10 X 16 | 2 |
B1-7-1 Tank,Diesel Fuel, & Mounting Step
| 12***86 | Catch, Vandal Cover | 1 |
| 13***3Z | Screw, M6x16 | 6 |
| 13***5Z | Screw, Hexagon M8 X 20mm Long | 2 |
B1-8-5 Sump Guard
| 13***8Z | Bolt, M10 X 30 | 2 |
| 13***9Z | Screw, M12 X 35mm, Screw, M12 X 35mm; M12 X 35. Items 21 & 22 Are Used On 23***00 And 23***00 Throttle Brackets | 2 |
| 13***3Z | Nut, M12 | 2 |
B1-10-1 Light,Extension,Rear
| 12***02 | Plate, Compression | 1 |
| 13***1Z | Bolt, M16 X 110; See Item 14 For Protection Cap. Front Left Hand Bolt Threads Require Item 14, Bolt, M16 X 110 | 1 |
| 13***3Z | Nut, M16 | 1 |
B1-8-12 Belly Plate,4 Speed
| 13***5Z | Setscrew, M10 X 20mm | 16 |
| 13***2Z | Bolt, Setscrew M10x50 | 8 |
| 14***1Z | Washer, 2 Ba | 8 |
B1-1-1 Chassis
| 13***3Z | Screw, M8 X 16 | 6 |
| 14***7Z | Washer, Plain, M8; Replaces Khn1550, San 12620 | 6 |
| 16***09 | Plate, Pivot, Rh | 1 |
B2-1-5 Cab Frame,Mounting
| 12***02 | Plate, Compression | 4 |
| 13***5Z | Bolt, M5 X 20mm Long | 3 |
| 13***7Z | Bolt | 2 |
B2-1-1 Cab
| 16***31 | Cab, Painted & Sealed, With Doors; San 14469.S/Sd To 16***36.See Pi L03/16, P Gamble 02/09/03, Note. For Replacement Cabsuse Seats On B2-9-11/12, Cab, Painted & Sealed, With Doors; San 14469.S/Sd To 16***36.See Pi L03/16, P Gamble 02/09/03, Note 1. For Replacement Cabs Use Seats On B2-9-11/12 | 1 |
| 16***36 | Cab, Abi; San 22133.Mss To 16***34,Doors,Hinges Etc., P Gamble 03/02***06. | 1 |
| 16***98 | Rail, Grab Upper | 1 |
B2-6-1 Cab Mirror, External & Internal
| 12***70 | Mirror, Exterior Head Assembly | 1 |
| 13***5Z | Bolt, M5 X 20mm Long | 2 |
| 13***3Z | Screw, M6x16 | 1 |
B2-10-1 Sunblind,Roof
| 16***19 | Blind, Sun | 1 |
| 82***77 | Nut, Vibration Proof | 2 |
B2-9-1 Seat
| 13***5Z | Screw, Hexagon M8 X 20mm Long | 4 |
| 13***7Z | Screw, Hexagon M8 X 25 | 4 |
| 13***3Z | Nut, Self Lock, M8 | 8 |
B2-7-1 Seat Belt
| 13***2Z | Nut | 2 |
| 40***00 | Belt, Safety, Seat | 1 |
| 40***00 | Kit-Seat Belt, With Inertia Reel, 42" Long; Buckle Strap Length 190mm. There Are No Servicable Parts For This Item, Kit-Seat Belt, With Inertia Reel, 42" Long | 1 |
B2-2-1 Door & Components
| 12***05 | Bolt, Closing | 1 |
| 12***07 | Knob, Interior | 1 |
| 12***00 | Lock, Door, Left Hand | 1 |
B2-5-1 Light Bracket, Chassis Mounted
| 12***15 | Cap | 2 |
| 13***9Z | Setscrew, M8x35 | 4 |
| 13***9Z | Bolt, Paint Clearing | 2 |
B2-9-12 Seat,Suspension, Heated, (For Cab Replacement)
| 40***14 | Kit, Knob/Weight Adjuster | 1 |
| 40***56 | Adjuster, Seat | 1 |
| 40***86 | Seat, Kab 411 Heated | 1 |
B2-9-11 Seat,Suspension, (For Cab Replacement)
| 40***14 | Kit, Knob/Weight Adjuster | 1 |
| 40***00 | Kit, Headrest | 1 |
| 40***02 | Kit-Cover, Backrest, Vinyl | 1 |
B2-2-10 Latch,Door Kit
| 13***5Z | Screw, Hexagon M8 X 20mm Long | 2 |
| 21***00 | Kit-Latch, Door Retainer | 2 |
| 82***16 | Spacer, Door Catch | 2 |
B2-0-2 Service Cabs
B2-4-1 Guards Windscreen
| 13***8Z | Screw, M8x30 | 4 |
| 13***3Z | Nut, Self Lock, M8 | 4 |
| 14***7Z | Washer, Plain, M8; Replaces Khn1550, San 12620 | 8 |
B2-8-1 Nvg Speedo Flap
| 14***01 | Screw, No.6x3/8" Posiflange, Self Tapping | 3 |
| 97***56 | Bracket, Nvg Speedo Flap Assembly | 1 |
B2-1-30 Inclinometer, Lev-O-Gauge
| 70***00 | Gauge, Inclinometer/Level | 1 |
B2-1-10 Cab Glazing, Clear & Gr4een Tint
| 16***72 | Stay, Window, C/W Release Pin | 1 |
| 82***00 | Glass, Upper Door, Clear | 1 |
| 82***02 | Glass, R.H. Side, Clear | 1 |
B2-10-2 Luggage Nets
| 14***02 | Screw | 8 |
| 16***10 | Cover, Luggage Net, Rear Roof | 1 |
| 16***11 | Cover, Luggage Net, Rear Store | 1 |
B2-3-1 Panel Instrument, Covers & Brackets, Cab
| 12***03 | Lock, Switch | 1 |
| 12***31 | Vent, Air Register | 2 |
| 13***5Z | Bolt, M5 X 20mm Long | 3 |
B3-10-1 Guard,Trash, Inner Boom,Front
| 13***8Z | Bolt, M12 X 30 | 2 |
| 14***9Z | Washer | 1 |
| 16***62 | Guard, Trash | 1 |
B3-6-1 Boom,Pivot Pin &, Bush Location
| 10***77 | Pin, Pivot, 537mm | 1 |
| 13***2Z | Bolt, M12 X 50mm | 3 |
| 13***4Z | Bolt, M12 X 60mm | 1 |
B3-3-1 Indicator,Boom Angle
| 13***1Z | Bolt | 1 |
| 14***96 | Spacer | 1 |
| 33***28 | Boom, Angle Indicator | 1 |
B3-7-1 Pads,Boom Wear
| 14***9Z | Washer | 61 |
| 15***09 | Shim, Axle, 3mm Thick, Shim, Axle, 3mm Thick; See Note 2. Axle Shim | 1 |
| 15***99 | Shim, 1.6mm | 0 |
B3-1-1 Booms,Inner,Outer
| 15***55 | Plate, Qr Coupling Mounts, Boom Nose | 1 |
| 16***23 | Lever, Crowd | 1 |
| 16***30 | Link, Tipping | 1 |
B3-9-1 Boom,Link & Lever
| 16***23 | Lever, Crowd | 1 |
| 16***30 | Link, Tipping | 1 |
| 80***26 | Bearing, Liner, 50mm Pivot Bore | 2 |
B3-12-1 Chain Carrier, 2nd Auxiliary
| 13***3Z | Screw; Replaces 69***21 | 2 |
| 13***9Z | Setscrew, M8x35 | 4 |
| 13***3Z | Nut | 4 |
B5-1-1 Direct Glazing, Replacment Material
| 41***33 | Sealant, Dp2205 Clear, Silicone | 0 |
| 41***09 | Sealant, Black Acrylic 221, 310ml Cartridge | 0 |
| 41***09 | Adhesive, Jcb Ultrafast, 310ml Cartridge | 0 |
B5-5-1 Flip Chart Mntg
| 16***72 | Plate, Flip Chart Mount | 1 |
| 82***59 | Screw, Button Head Socket, M6 X 16mm | 2 |
B5-3-1 Paint
| 42***01 | Thinners, 5 Litres | 0 |
| 42***01 | Paint, Undercoat Grey, 5 Lts | 0 |
| 42***02 | Paint, Undercoat Grey, 1 Lts | 0 |
B5-5-6 Flip Charts
| 13***3Z | Nut | 2 |
| 14***1Z | Washer, 2 Ba | 2 |
| 15***00 | Clip, Hook | 2 |
B5-9-1 Chock Mountings
| 13***6Z | Bolt, M16 X 70mm | 4 |
| 13***3Z | Nut, M16 | 4 |
| 14***1Z | Washer, M16 Plain | 8 |
B5-7-1 Safety Strut
| 12***00 | Strap | 1 |
| 14***1Z | Washer, 2 Ba | 1 |
| 16***23 | Bolt, Support Clamp W.A. | 1 |
B5-4-1 Fire Extinguisher
| 14***03 | Screw | 2 |
| 15***81 | Extinguisher, Fire C/W Cradle; Replaces Jhh0058 Ref San09577, Replaced By 26***95 See San 10308 | 1 |
B5-6-1 Grommits
| 82***10 | Grommet | 1 |
| 82***62 | Grommet, 70mm | 1 |
| 82***89 | Grommet | 1 |
B5-10-1 Boom Restraint, Traffic
| 15***83 | Boom, Transport Restraint | 1 |
B5-2-1 Decals
| 81***87 | Decal, Tie Down (Chain) | 1 |
| 81***39 | Label, Warning English, Read Operating Book | 1 |
| 81***76 | Label, Sway Warning | 1 |
C Electrics-Machine, Cab & Engine
C1-20-1 Harness, Blanking Plugs
| 21***03 | Plug, 3 Way Male Blanking, Connector | 0 |
| 71***00 | Plug, Harness Blanking, 2-Way Male, Sealed | 0 |
| 71***00 | Plug, Male, Junior Timer | 0 |
C1-17-1 Control Levers
| 70***84 | Insert | 1 |
| 70***00 | Switch, Rocker, Switch, Rocker; Note 1. To Improve Installation Of Stab Light | 1 |
| 70***58 | Lever, Joystick 1 Auxiliary; S/Sd To 70***22.San 14745.P Gamble 25/11/03 | 1 |
C1-12-1 Electrics,Trailer
| 13***3Z | Nut | 3 |
| 13***9Z | Capscrew | 3 |
| 14***5Z | Washer, M5; Replaces 69***59 | 1 |
C1-4-1 Isolator,Battery
| 70***09 | Switch Battery Isola | 1 |
| 70***00 | Lead, Battery,Negative, 400mm X 70sq.mm | 1 |
| 71***00 | Lead, Battery Negative, -Ve | 1 |
C1-10-1 Light,Rear, Combination, Twin Reverse
| 72***05 | Bulb, 12v 21w | 3 |
| 72***34 | Bulb, 12v 5w | 2 |
| 72***48 | Harness, Isolation, Brake/Reverse Lights | 1 |
C1-5-1 Indicator,Safe Load
| 12***03 | Tie, Cable, L=300mm X W=7.6mm | 2 |
| 13***0Z | Screw, M10 X 40, High Tensile | 2 |
| 13***3Z | Nut, Self Lock, M6 | 2 |
C1-18-1 Light,Beacon,Amber, Hazard Warning
| 70***01 | Bulb, 12v 55w, Halogen | 1 |
| 70***01 | Lens, Amber, 121mm Dia | 1 |
| 70***00 | Beacon, 12v, (155mm Tall) | 1 |
C1-4-10 Earthing, Engine & Chassis
| 13***5Z | Screw, M10 X 20mm Long; Use With Single Piece Casing. To Gearbox Number 445/143/831 Or 445/144/455, Screw, M10 X 20mm Long | 1 |
| 13***3Z | Nut, Lock, M10 | 3 |
| 14***8Z | Washer, Plain M10; San 23620 Ref Dave Bickerton Confirms Identic, Al To 33***8z Rationalise Parts | 4 |
C1-2-1 Cab Harness, Electrical Layout
| 70***00 | Rear Worklight | 1 |
| 71***00 | Harness, Front Worklight-Long | 1 |
| 72***79 | Harness, Panel | 1 |
C1-1-1 Mainframe, Electrical Layout
| 26***01 | Clip, Connector | 1 |
| 33***54 | Harness, Boom Cable | 1 |
| 70***00 | Switch, Proximity; Replaced By 70***75, See San 10336 | 1 |
C1-9-1 Light,Front
| 13***7Z | Capscrew, M8x25mm | 12 |
| 14***7Z | Washer, Spring | 8 |
| 70***00 | Light, Head/Indicator R/H, Rh Dip; San2584.Cwe By Mss To 70***56 & 33***99, Ref A Weir/M Orme. P Gamble 21/04***08, Light, Head/Indicator R/H, Rh Dip; San2584.Cwe By Mss To 70***56 & 33***99, Ref A Weir/M Orme. P Gamble 21/04***08, Row See Note 1. Fit/Func M/C 77***16 | 1 |
C1-21-1 Harness Connectors, Repair Ip67 Standard
| 72***03 | Pin, Female, 0.5-1.5mm, Signal | 0 |
| 72***04 | Pin, Female, 1.5-2.0mm, Signal | 0 |
| 72***08 | Terminal, 0.5-1.25mm, Fusebox (Pressac) | 1 |
C1-10-2 Light,Rear, Combination Lh Dip, Reverse & Fog
| 70***00 | Light, Rh Rear With Fog | 1 |
| 70***01 | Lens | 1 |
| 70***00 | Light, L.H. Rear With Rev | 1 |
C1-3-1 Battery & Components
| 10***00 | Clamp | 1 |
| 13***7Z | Screw, Hexagon M8 X 25 | 1 |
| 13***1Z | Nut | 2 |
C1-13-1 Switch,Column, Powershift
| 13***03 | Screw, Cap | 2 |
| 70***02 | Switch, Right Hand Handle | 1 |
| 70***45 | Switch, Column Powershift, Forward & Reverse; Replaces 70***00 | 1 |
C1-14-1 Light,Number Plate, Rockinger Tow Hitch
| 26***01 | Clip, Connector | 2 |
| 70***00 | Light, Number Plate | 2 |
| 82***77 | Nut, Vibration Proof | 2 |
C1-7-1 Inclinometer, Lev-O-Gauge
| 70***00 | Gauge, Inclinometer/Level | 1 |
C1-19-1 Security System
| 16***63 | Box, Tracker | 1 |
| 71***00 | Unit, Tracker Complete | 1 |
| 82***95 | Grommet | 1 |
C1-15-1 Alarm,Reverse
| 13***5Z | Bolt | 2 |
| 13***7Z | Screw, M6 X 25mm Long | 2 |
| 13***3Z | Nut, Self Lock, M6 | 2 |
C1-6-1 Fusible Link Box, Assy
| 71***00 | Box, Fuse Link, 5-Way; Replaced By 71***00, See San09823 | 1 |
| 71***40 | Fuse, 40 Amp | 2 |
| 71***50 | Fuse, 50 Amp | 1 |
C1-16-1 Horn,Single Tone, Front
| 12***90 | Bracket, Support, Left Hand | 1 |
| 13***5Z | Bolt | 1 |
| 13***7Z | Bolt, M10x25 | 1 |
C2-3-1 Alternator, & Mountings
| 71***57 | Alternator | 1 |
| 71***58 | Pulley, Alternator | 1 |
| 99***37 | Kit :Alternator Tens | 1 |
C2-1-1 Electrical Equipment
| 17***01 | Motor, Thermal Waxtat | 1 |
| 17***03 | Terminal, Male Lucar, 90 Degree | 1 |
| 17***04 | Nut | 1 |
C2-5-1 Motor, Starter, M127 12.Volt
| 02***02 | Stud | 3 |
| 02***59 | Nut | 3 |
| 12***06 | Cover, Solenoid | 1 |
C3-10-3 Over Temperature, Safety System, Fig.3
| 71***87 | Relay, 12v With Diode | 2 |
| 71***88 | Base, Relay | 2 |
| 71***80 | Thermostart | 2 |
C3-4-1 Switches,Electrical
| 12***03 | Lock, Switch | 1 |
| 14***02 | Screw | 2 |
| 70***04 | Insert, 2/4wd Disconnect | 1 |
C3-9-1 Rear Worklight
| 70***10 | Light, Working | 1 |
| 70***33 | Decal, Rear Working Lights | 1 |
| 70***00 | Switch | 1 |
C3-4-10 Switches Electrical, Smooth Ride System
| 70***00 | Holder, Warning Light | 1 |
| 70***00 | Switch | 1 |
| 70***10 | Decal, Smooth Ride (Insert), Horizontal | 1 |
C3-6-1 Cab Fixings, Switches,Fuses &, Grommets
| 13***2Z | Nut | 2 |
| 13***1Z | Nut | 4 |
| 14***6Z | Washer, M6 | 4 |
C3-9-5 Front Working Lights
| 15***02 | Spacer | 1 |
| 16***94 | G.A. | 1 |
| 70***00 | Light, Auxilliary . | 1 |
C3-4-20 Cab Controls, Man Platform
| 33***93 | Panel, Engine Control Unit,Pcb | 1 |
| 70***95 | Switch, Emergency Stop Butto | 1 |
C3-4-21 Remote Control, Man Platform
| 33***96 | Frame, Remote Control | 1 |
| 33***30 | Lever, Joystick | 2 |
| 33***29 | Box, Remote Control Platform | 1 |
C3-40-1 Spool Switch, Smooth Ride System
| 13***3Z | Nut | 2 |
| 13***4Z | Screw | 2 |
| 14***7Z | Washer | 4 |
C3-12-1 Instrument Cluster
| 16***00 | Gearbox, Ga + Inst Cluster | 1 |
| 70***02 | Gauge, Tachometer | 1 |
| 70***00 | Cluster, Instrument, 33 K.P.H. | 1 |
C3-10-2 Over Temperature, Safety System, Fig.2
| 99***27 | Head, Gas Sensing | 1 |
| 99***28 | Cable, Gas Sensing Head | 1 |
| 99***29 | Cylinder:Test Gas- 0 | 1 |
C3-8-1 Light,Interior,Cab
| 70***00 | Light, Cab Interior, Assembly | 1 |
| 70***12 | Switch Toggle | 1 |
| 72***54 | Bulb, 12v-10w - Festoon | 1 |
C3-4-5 Switches,Electrical, Controls Console
| 70***02 | Lens, Black, Insert | 1 |
| 70***00 | Holder, Warning Light | 1 |
| 70***52 | Decal, Heater Fan Blower | 1 |
C3-3-1 Motor,Wiper, Rear Window
| 14***02 | Screw | 2 |
| 15***00 | Connector, 'T' Piece | 1 |
| 15***01 | Cover, Wiper Motor; San 22420.Pi Md05/093. Cwe To 34***18. | 1 |
C3-8-4 Clock Digital
| 12***90 | Clock, Digital | 1 |
C3-7-1 Relays & Fuses
| 71***03 | Fuse, 5 Amp | 1 |
| 71***04 | Fuse, 7.5 Amp | 1 |
| 71***05 | Fuse, 10 Amp, Fuse, 10 Amp; In Line Fuses In Roof Harness For Auxiliary Sockets. Access Via Draft Control Panel. | 1 |
C3-1-1 Motor,Wiper, Windscreen
| 13***5Z | Screw, M6 X 20mm Lg | 2 |
| 14***6Z | Washer, M6 | 2 |
| 16***88 | G.A. | 1 |
C3-15-1 Light Beacon, Hazard Warning
| 70***01 | Lens, Amber | 1 |
| 70***00 | Beacon, Warning-Strobe, Amber; San26024.Ss To 70***42. Ref A Weir/Britax., Pg 31/03***08 | 1 |
C3-10-1 Over Temperature, Safety System, Fig.1
| 70***10 | Switch, Emergency Stop | 1 |
| 70***11 | Switch, System C/W Key | 1 |
| 99***20 | Unit, Control Module | 1 |
C3-4-22 Cab Control Unit, Man Platform
| 33***11 | Switch, Emergency Lowering | 1 |
| 33***12 | Light | 4 |
| 33***13 | Switch | 1 |
C3-2-1 Motor,Wiper, Rof Window
| 14***02 | Screw | 2 |
| 15***00 | Connector, 'T' Piece | 1 |
| 15***03 | Cover | 1 |
C3-5-1 Heater,Installation
| 12***03 | Tie, Cable, L=300mm X W=7.6mm | 4 |
| 13***3Z | Screw, M8 X 16 | 3 |
| 13***3Z | Bolt, M10 X 16 | 1 |
C3-17-1 Heater Assembly
| 13***3Z | Nut, Lock, M10 | 2 |
| 16***78 | Heater, Assembly Unit | 1 |
| 22***05 | Clip, Jubilee | 2 |
D Controls-Machine, Engine & Steering
D1-5-2 Control Lever Assy, Tilt Lock, Loader Pattern
| 11***16 | Joint, Universal | 1 |
| 12***53 | Gaiter | 1 |
| 12***59 | Ring, Tolerance | 1 |
D1-5-1 Control Lever Assy, Tilt Lock, Placing Pattern
| 11***16 | Joint, Universal | 1 |
| 12***53 | Gaiter | 1 |
| 12***59 | Ring, Tolerance | 1 |
D1-2-1 Control, Parking Brake
| 13***2Z | Bolt | 2 |
| 13***2Z | Nut | 2 |
| 13***2Z | Nut | 1 |
D1-6-1 Tilt Lever,Lock Assy, Placing Pattern
| 12***81 | Bar, Lever Lock | 1 |
| 81***64 | Decal, Lever Lock, Construction | 1 |
| 82***62 | Clip | 2 |
D1-6-6 Full Lever Locks, Placing & Loader
| 12***81 | Bar, Lever Lock | 1 |
| 16***50 | Lock, Auxiliary W.A. | 1 |
| 81***08 | Decal, Lever, Placing Pattern | 1 |
D2-1-1 Control Throttle
| 12***09 | Bracket, Throttle Reaction | 1 |
| 13***2Z | Bolt | 2 |
| 13***2Z | Nut | 1 |
D2-2-1 Control, Exhaust, Shutdown Valve, & Emergency Stop
| 13***4Z | Bolt | 3 |
| 13***3Z | Nut, Self Lock, M8 | 3 |
| 14***7Z | Washer, Plain, M8; Replaces Khn1550, San 12620 | 3 |
D3-1-1 Steering Column
| 12***61 | Plate, Retainer | 1 |
| 12***42 | Knob, Assembly, Steering Wheel | 1 |
| 12***45 | Cap | 1 |
E Hydraulics & Air Including, Steering
E1-5-1 Circuit,Aux 1
| 13***7Z | Screw, Hexagon M8 X 25 | 2 |
| 13***8Z | Screw, M8x30 | 2 |
| 13***2Z | Bolt | 1 |
E1-10-1 Diverter Valve, Installation, Man Platform
| 33***21 | Plug, Female | 1 |
| 33***22 | Plug, Male | 1 |
| 33***23 | Housing | 1 |
E1-5-3 Circuit,Aux 2
| 13***8Z | Screw, M8x30 | 2 |
| 13***2Z | Bolt | 1 |
| 13***8Z | Bolt, M8x80mm Long | 1 |
E1-8-1 Circuit, Trailer Brakes
| 13***0Z | Bolt | 2 |
| 13***0Z | Bolt | 1 |
| 13***8Z | Bolt, M8x80mm Long | 2 |
E1-0-2 O Rings, Hydraulic Hoses
| 23***06 | O Ring, 3/8"Bsp | 1 |
| 23***10 | O Ring, 1/2"Bsp | 1 |
| 23***11 | O Ring, 5/8"Bsp | 1 |
E1-11-1 Circuit, Smooth Ride System, Installation
| 13***8Z | Bolt | 2 |
| 13***3Z | Nut, Self Lock, M6 | 21 |
| 13***3Z | Nut, Self Lock, M8 | 4 |
E1-2-1 Circuit,Lift End
| 13***3Z | Screw, M6x16 | 1 |
| 13***3Z | Screw, M8 X 16 | 7 |
| 13***0Z | Bolt | 4 |
E1-9-1 Hydraulic, Lowering Pump, Circuit
| 33***67 | Pump, Electric | 1 |
| 33***68 | Plug, End, 1/8 Bsp | 1 |
| 33***69 | Adapter, 1/4x3/4 Bsp | 2 |
E1-14-1 Circuit,Accumulator, Hydraulics
| 13***8Z | Bolt, M8x80mm Long | 2 |
| 14***7Z | Washer, Plain, M8; Replaces Khn1550, San 12620 | 2 |
| 16***69 | Filter, Pilot Assembly | 1 |
E1-4-5 Steer Mode Valve, Manual Hydraulics
| 13***1Z | Bolt, M8 X 45 | 2 |
| 13***4Z | Bolt | 2 |
| 14***7Z | Washer, Plain, M8; Replaces Khn1550, San 12620 | 4 |
E1-7-2 Circuit,Tow Hitch, Mechanical
| 13***9Z | Setscrew, M8x35 | 3 |
| 13***5Z | Bolt, Star Drive, M8 X 65mm | 1 |
| 13***2Z | Bolt, Hex. | 1 |
E1-15-1 Coolers,Installation, Oil & Hydraulic
| 22***06 | Clip, Jubilee | 2 |
| 30***00 | Cooler, Hydraulic | 1 |
| 30***00 | Cooler, Transmission Oil | 1 |
E1-4-1 Circuit,Steering
| 13***3Z | Screw, M8 X 16 | 1 |
| 13***9Z | Setscrew, M8x35 | 2 |
| 13***0Z | Bolt, M8x40 | 1 |
E1-7-1 Circuit,Tow Hitch, Hydraulic
| 13***9Z | Setscrew, M8x35 | 3 |
| 13***5Z | Bolt, Star Drive, M8 X 65mm | 1 |
| 13***2Z | Bolt, Hex. | 1 |
E1-1-1 Circuit,Neutral
| 13***5Z | Bolt | 2 |
| 13***7Z | Screw, Hexagon M8 X 25 | 2 |
| 13***1Z | Bolt | 1 |
E1-13-1 Circuit, Reversing Fan
| 13***8Z | Bolt, M10 X 30 | 2 |
| 13***0Z | Capscrew | 4 |
| 14***11 | Seal, Bonded | 4 |
E2-5-2 Motor,Fan Drive, Cooling, Bi-Directional
| 20***33 | Motor, Fan, Hydraulic, Bi-Directional | 1 |
| 20***78 | Key, Woodruff, 3.2 X 6.5 X 16dia | 1 |
| 20***79 | Nut, M12 X 1.5 | 1 |
E2-5-1 Motor,Fan Drive, Cooling
| 20***32 | Motor, Fan, Hydraulic | 1 |
| 20***34 | Kit, Seal | 1 |
E2-1-1 Pump(Three Stage), Main Hydraulics
| 20***03 | O Ring | 1 |
| 20***55 | Pump, Main,Triple, Supp No-7029530001; San21714.Ss To 2/92***91.L03/054.29/09***05, P Gamble | 1 |
| 20***83 | Valve, Priority Steer | 1 |
E2-2-1 Pump,Main Hydraulic, Fittings & Mountings
| 13***8Z | Bolt | 4 |
| 14***8Z | Washer, Spring | 4 |
| 14***8Z | Washer, Spring M10; Replaces 60***8r & 60***08, Replaces Luu0105-San 12222, Washer, Spring M10; Replaces 60***8r & 60***08, Replaces Luu0105-San 12222, Used On Outlet Adapter, Item 5. Also N524275 & 52***55, Washer, Spring M10; Replaces 60***8r & 60***08, Replaces Luu0105-San 12222, Used On Outlet Adapter, Item 5. Also M524275 & 52***55 | 4 |
E3-7-1 Valve,Diverter
| 25***00 | C/O Valve Auxiliary/Sway | 1 |
| 25***01 | Coil, 12v | 1 |
E3-5-1 Valve Conversion, Smooth Ride System
| 13***3Z | Nut | 2 |
| 13***4Z | Screw | 2 |
| 14***7Z | Washer | 4 |
E3-2-1 Valve Components, Manual Aux
| 25***68 | Valve, Section | 1 |
| 25***71 | Valve, Section | 1 |
| 25***94 | Valve, Main Relief, 240bar 78 Lpm | 1 |
E3-4-1 Diverter Valve, Ram Fitted, Smooth Ride System
| 25***36 | Valve, Diverter | 1 |
| 25***01 | Coil, 35mm Long, 12.7mm Dia Hole | 1 |
| 92***84 | Valve Solenoid, (No Coil) | 1 |
E3-6-1 Valve,Steering Mode
| 13***0Z | Bolt | 2 |
| 13***8Z | Capscrew, M5 X 30mm | 8 |
| 14***7Z | Washer, Spring | 4 |
E3-10-1 Filter,Hydraulic
| 13***0Z | Bolt | 2 |
| 14***21 | Seal, Bonded 3/4" Bsp | 2 |
| 14***7Z | Washer, Plain, M8; Replaces Khn1550, San 12620 | 2 |
E3-3-1 Valve Components, Sections
| 25***06 | Kit-End Mechanism | 1 |
| 25***27 | Plate, Seal Retainer | 2 |
| 25***30 | Seat, Spring | 2 |
E3-1-1 Valve Assy,4 Spool, Manual Aux
| 13***5Z | Screw, Hexagon M8 X 20mm Long | 1 |
| 13***9Z | Screw, M10x35mm | 2 |
| 13***1Z | Bolt, M8 X 45 | 1 |
E3-8-1 Valve,Steering
| 35***08 | Kit-Seal | 1 |
| 35***02 | Kit, Bearing; San 22117.Made Nla On The Request Of R Bryant, 09/12***05. P Gamble | 1 |
| 35***54 | Kit, Check Valve | 1 |
E3-30-1 Lubrication, & Filters
| 02***73 | Element, Oil Filter, Canister Type - Long | 1 |
| 02***84 | Element, Oil Filter, Canister Type-Short | 1 |
| 32***02 | Element, 10 Micron | 1 |
E3-4-5 Diverter Valve, Platform
| 92***29 | Valve, Diverter | 1 |
E3-4-2 Diverter Valve, Chassis Fitted, Smooth Ride System
| 25***35 | Valve, Diverter | 1 |
| 25***01 | Coil, 35mm Long, 12.7mm Dia Hole | 1 |
| 92***84 | Valve Solenoid, (No Coil) | 1 |
E4-11-1 Ram,Tow Hitch
| 23***06 | O Ring | 1 |
| 23***00 | O Ring | 1 |
| 24***01 | Seal, Gland | 1 |
E4-1-1 Ram,Lift
| 12***21 | Bush | 1 |
| 14***01 | Washer, Aluminium | 1 |
| 14***01 | Nipple, Grease, Straight, 1/8 Bsp | 1 |
E4-20-1 Lift Ram, Smooth Ride System, Installation
| 13***8Z | Bolt | 2 |
| 13***3Z | Nut, Self Lock, M6 | 2 |
| 13***3Z | Nut, Self Lock, M8 | 4 |
E4-7-1 Ram,Tilt
| 14***01 | Nipple, Grease, Straight, 1/8 Bsp | 2 |
| 23***06 | O Ring, 60 X 5.0 | 1 |
| 23***16 | O Ring, 110mm Id X 5.0mm | 1 |
E4-12-1 Ram,Carriage, Sideshift
| 90***76 | Adapter, 90 Deg Elbow | 2 |
| 98***08 | Ring, Retaining | 2 |
| 98***09 | Ring, Retaining | 2 |
E4-1-5 Ram,Lift, Smooth Ride System
| 12***21 | Bush | 1 |
| 14***01 | Washer, Aluminium | 1 |
| 14***01 | Nipple, Grease, Straight, 1/8 Bsp | 1 |
E4-3-1 Ram,Displacement
| 12***21 | Bush | 1 |
| 12***21 | Bush | 1 |
| 14***01 | Nipple, Grease, Straight, 1/8 Bsp | 2 |
E4-8-1 Extension Ram
| 12***21 | Bush | 1 |
| 14***01 | Washer, Aluminium | 2 |
| 14***01 | Nipple, Grease, Straight, 1/8 Bsp | 1 |
E4-1-20 Ram, Lift
| 24***47 | Seal, Piston, 140mmx119mmx10mm | 1 |
| 24***24 | Ring, Wear, 140mmx135mmx15mm | 2 |
| 25***65 | Valve, Counterbalance, Sun A-204-30j-J03 | 1 |
F Axles, Wheels & Transmission
F1-8-1 Axle Power Trackrod, Installation, 3 Piece Axle
| 13***5Z | Bolt | 2 |
| 13***09 | Screw | 4 |
| 14***01 | Nipple, Grease, Straight, 1/8 Bsp | 1 |
F1-2-1 Differential Assy, Pad Mntd
| 13***18 | Bolt | 8 |
| 13***07 | Capscrew | 8 |
| 14***21 | Seal, Bonded 3/4" Bsp | 2 |
F1-3-1 Hub & Components
| 13***7Z | Bolt, Coated | 4 |
| 22***54 | Circlip; Replaces 370a0400z, San 12455 | 6 |
| 45***05 | Gear, Annulus Ring | 2 |
F1-7-1 Knuckle,Steering, & Hub Driveshaft
| 13***09 | Screw | 16 |
| 41***02 | Sealant, Locking | 1 |
| 45***03 | Joint, Knuckle Swivel | 1 |
F1-10-1 Axle,Pad Mntd,Shims
| 15***09 | Shim, Axle, 3mm Thick, Shim, Axle, 3mm Thick; See Note 2. Axle Shim | 0 |
F1-4-1 Differential, & Crown Wheel Assy
| 13***8Z | Bolt, M10x80 | 8 |
| 45***00 | Casing, Assembly, Differential | 1 |
| 45***00 | Differential, Assembly | 1 |
F1-6-1 Brakes,Axle, (Axle Arm)
| 22***71 | Circlip, External | 4 |
| 22***20 | Circlip | 6 |
| 33***63 | Carrier, Brake Plate; See Note 1. Kit 99***39 Uses All Items A Kit 99***40 Uses All Items B, Carrier, Brake Plate, Carrier, Brake Plate; Note 1. Kit 99***39 Uses All Items A Kit 99***40 Uses All Items B, Carrier, Brake Plate; Note 1. 45***15 Not To Be Used Please Use 33***3x 2., Carrier, Brake Plate; Note 1. Must Do Both Sides | 2 |
F1-1-1 Axle,3 Piece, Pad Mounted
| 13***6Z | Bolt, 11" Long | 0 |
| 13***16 | Bolt, M16x70l | 28 |
| 14***0Z | Washer, Plain | 8 |
F2-1-1 Axle Assembly,Rear, Trunnion Mounted, Steer/Drive
| 10***01 | Nut | 10 |
| 13***1Z | Bolt, M20 X 110mm | 6 |
| 13***3Z | Nut, M20 | 6 |
F2-5-1 Ram,Steering,Rear, Axle Installation
| 13***5Z | Bolt | 2 |
| 13***09 | Screw | 8 |
| 14***01 | Nipple, Grease, Straight, 1/8 Bsp | 1 |
F2-2-1 Differential Assy
| 21***16 | Pin, Tension | 1 |
| 44***05 | Nut, Adjusting | 2 |
| 44***08 | Pin, Trunnion | 1 |
F2-4-1 Hub & Components
| 10***01 | Nut | 20 |
| 13***7Z | Bolt, Coated | 4 |
| 22***54 | Circlip; Replaces 370a0400z, San 12455 | 6 |
F2-6-1 Shaft,Drive
| 91***01 | Driveshaft | 1 |
| 91***46 | Shaft, Hub | 1 |
| 91***48 | Shaft, Diff Side | 1 |
F3-1-1 Propshafts, Transmission
| 11***25 | Strap | 6 |
| 82***92 | Screw, Special 3/8unf X 3/4 | 12 |
| 82***41 | Nut | 8 |
F3-2-1 Wheels & Tyres
| 15***01 | Valve | 1 |
| 33***69 | Wheel, & Tyre Assembly, 15.5 R25 Xha Rad L3 | 4 |
| 41***65 | Wheel, Rim 12x25 Dc, (13 Inset) | 1 |
F5-2-10 Clutch, Input, Powershift Transmission
| 13***1Z | Bolt, M8 X 45 | 4 |
| 20***00 | Pump; Superseded By 20/92***27 See San 14259 | 1 |
| 20***01 | Seal, Oil, Trans Pump | 1 |
F5-12-1 Pipework,Powershift, Transmission
| 14***18 | Seal, Bonded, 1/2" Bsp | 1 |
| 16***03 | Adapter | 4 |
| 44***00 | Pipe, Short, Layshaft Feed | 1 |
F5-2-5 Transmission, Brackets & Lift Eyes
| 13***9Z | Screw, M10x35mm | 1 |
| 14***8Z | Washer, Plain M10; San 23620 Ref Dave Bickerton Confirms Identic, Al To 33***8z Rationalise Parts | 2 |
| 16***37 | Bracket, Cable W.A. | 2 |
F5-2-40 Layshaft, Components, Powershift Transmission
| 22***15 | Circlip | 1 |
| 44***04 | Retainer, Spring | 1 |
| 44***05 | Baffle, Oil | 1 |
F5-9-1 Dipstick, Transmission
| 13***1Z | Bolt, M10 X 10 | 1 |
| 15***00 | Nut, Sealastic | 1 |
| 16***13 | Dipstick | 1 |
F5-1-1 Transmission, 4 Speed, 4 W/D
| 22***71 | Circlip | 1 |
| 44***09 | Washer, Thrust | 0 |
| 44***12 | Spacer | 1 |
F5-2-80 Transmission, Clutch Unit, Drop Box
| 22***04 | Circlip | 1 |
| 24***21 | O Ring | 1 |
| 24***44 | O Ring | 1 |
F5-10-1 Transmission, Components,Cooling
| 13***3Z | Screw, M8 X 16 | 1 |
| 13***7Z | Screw, Hexagon M8 X 25 | 1 |
| 14***08 | Seal, Washer | 2 |
F5-8-1 Torque Convertor, Drive Plates &, Drive Coupling
| 04***03 | Bolt | 4 |
| 04***00 | Converter, 11" | 1 |
| 04***00 | Kit, Drive Plate | 1 |
F5-2-1 Gearbox,Permanent, 4wd Ext Components
| 13***3Z | Screw, M8 X 16 | 2 |
| 13***0Z | Bolt | 2 |
| 14***15 | Washer, Seal; Replaces Khj0891 | 2 |
F5-2-20 Clutch, Reverse, Powershift Transmission
| 14***18 | Seal, Bonded, 1/2" Bsp | 1 |
| 22***15 | Circlip | 2 |
| 44***09 | Washer, Thrust | 2 |
F5-0-2 Transmissions, Identification
| 45***90 | Transmission, Bevel Package G.A. | 1 |
F5-3-5 Bevel Gearbox Kits
| 45***00 | Kit, Bevel Gearbox, Pinion/Gear/Bearing | 1 |
F5-2-30 Mainshaft, Components, Powershift Transmission
| 22***15 | Circlip | 1 |
| 33***55 | Baffle, Oil | 1 |
| 44***05 | Plate, Friction | 9 |
F5-3-1 Transmission,Bevel, G/Box Components
| 13***3Z | Bolt, M24 X 130 | 1 |
| 13***1Z | Nut, M24 | 1 |
| 14***08 | Seal, Washer | 2 |
F5-7-1 Cooler,Oil, Installation
| 22***06 | Clip, Jubilee | 2 |
| 30***00 | Cooler, Hydraulic | 1 |
| 30***00 | Cooler, Transmission Oil | 1 |
F5-6-1 Transmission, Mounting
| 13***8Z | Bolt, M16 X 80 | 2 |
| 13***03 | Nut | 2 |
| 14***1Z | Washer, M16 Plain | 2 |
F5-11-1 Filter,Transmission, (Remote Fitting)
| 13***0Z | Bolt, M10 X 100 | 2 |
| 13***7Z | Bolt | 1 |
| 13***8Z | Bolt, M12 X 80mm | 1 |
F5-2-60 Switch,Solenoid,4wd
| 13***8Z | Screw, M8x30 | 14 |
| 13***5Z | Screw, M5 X 20 | 4 |
| 13***8Z | Capscrew, M5 X 30mm | 12 |
G Brakes
G1-5-1 Brake Caliper, Parking
| 15***03 | Kit, Spring | 1 |
| 15***04 | Kit, Rotor; Now Supplier Number Is 98-18015 | 1 |
| 15***86 | Caliper, Parkbrake, Hayes; San 20751.Superseded By 15/92***72.Pi 449/178, P Gamble.07/10***04 | 1 |
G1-6-1 Brakes Axle, (Axle Arm)
| 22***71 | Circlip, External | 4 |
| 22***20 | Circlip | 6 |
| 33***63 | Carrier, Brake Plate; See Note 1. Kit 99***39 Uses All Items A Kit 99***40 Uses All Items B, Carrier, Brake Plate, Carrier, Brake Plate; Note 1. Kit 99***39 Uses All Items A Kit 99***40 Uses All Items B, Carrier, Brake Plate; Note 1. 45***15 Not To Be Used Please Use 33***3x 2., Carrier, Brake Plate; Note 1. Must Do Both Sides | 2 |
G1-1-1 Braking System
| 12***69 | Clip, 'S'; Replaced By 12***13, See San07976 | 1 |
| 13***5Z | Screw, Hexagon M8 X 20mm Long | 3 |
| 13***3Z | Nut | 2 |
G1-4-1 Trailer Brakes
| 13***0Z | Bolt | 2 |
| 13***0Z | Bolt | 1 |
| 13***8Z | Bolt, M8x80mm Long | 2 |
G1-2-1 Brake,Parking
| 15***04 | Kit, Rotor; Now Supplier Number Is 98-18015 | 1 |
| 15***86 | Caliper, Parkbrake, Hayes; San 20751.Superseded By 15/92***72.Pi 449/178, P Gamble.07/10***04 | 1 |
| 33***59 | Bracket, Brake Caliper Mount, Hayes Caliper | 1 |
G1-3-1 Brake Pedal &, Master Cylinder &, Brake/Dump Switch
| 13***0Z | Bolt, M6 X 40mm Long | 2 |
| 13***1Z | Bolt | 1 |
| 13***9Z | Bolt, M10 X 35 | 3 |
P Engine
P1-2-1 Engine, Short, Ar Build
| 02***00 | Engine, Short, Nat/Asp | 1 |
| 02***82 | Engine, Short | 1 |
P1-2-3 Engine, Long, Ar Build
| 02***41 | Motor, Long | 1 |
P1-1-1 Engine, Complete, Ar Build
| 01***00 | Engine, Complete 1004-4, Nat/Aspirated, 80bhp | 1 |
P1-8-1 Engine Mounting, Bolts
| 02***70 | Dowel | 2 |
| 13***9Z | Screw, M12 X 35mm, Screw, M12 X 35mm; M12 X 35. Items 21 & 22 Are Used On 23***00 And 23***00 Throttle Brackets | 1 |
| 13***1Z | Bolt, M12 X 45mm | 3 |
P1-2-2 Engine, Long, Ar Build
| 02***41 | Motor, Long | 1 |
P1-7-1 Flywheel & Housing
| 02***78 | Gear, Starter Ring | 1 |
| 02***25 | Washer | 6 |
| 02***08 | Flywheel, Assembly | 1 |
P1-3-1 Block Assembly, Ar Build
| 02***01 | Thimble | 10 |
| 02***02 | Bolt | 10 |
| 02***08 | Plug | 1 |
P1-2-4 Engine, Long, Ak Build 100 Bhp
| 02***36 | Engine, Short | 1 |
P1-6-1 Timing Case, Camshaft & Gears, Ar Build
| 02***38 | Key | 1 |
| 02***41 | Hub | 1 |
| 02***95 | Plug, Taper | 1 |
P1-4-1 Crankshaft, Bearings, Pistons & Con-Rods, Ar Build
| 02***38 | Key | 2 |
| 02***28 | Nut | 2 |
| 02***02 | Kit-Bearing, Main, Standard; 1 1 4 4 | 1 |
P1-4-2 Crankshaft, Bearings, Pistons & Con-Rods, Ar Build
| 02***38 | Key | 1 |
| 02***02 | Kit-Bearing, Main, Standard; 1 1 4 4 | 1 |
| 02***03 | Kit-Bearing, Main, Undersize - .010inch | 0 |
P1-5-1 Fans, Pulleys, & Fan Belt
| 02***79 | Screw | 3 |
| 02***17 | Block, Thrust | 1 |
| 02***18 | Pulley, Crankshaft, Twin Groove | 1 |
P2-4-1 Lifting Plates, Engine, Ar Build
| 02***31 | Plate, Lifting | 1 |
| 02***57 | Plate, Lifting | 1 |
| 82***00 | Screw | 4 |
P2-2-1 Rocker Assembly, Push Rods & Tappets, Ar Build
| 02***28 | Spring, Long | 2 |
| 02***29 | Spring, Short | 2 |
| 02***43 | Rod, Push | 8 |
P2-1-1 Cylinder Head, Ar Build
| 02***21 | Bolt, Cylinder Head | 4 |
| 02***48 | Plug | 1 |
| 02***96 | Plug, Core, D=32mm | 1 |
P2-3-1 Rocker Cover, Ar Build
| 02***07 | Cap, Oil Filler | 1 |
| 02***67 | Elbow | 1 |
| 14***07 | Washer | 3 |
P3-1-2 Manifold, Induction, Fig.2
| 02***17 | Screw | 4 |
| 13***3Z | Nut, Self Lock, M8 | 4 |
| 14***7Z | Washer, Plain, M8; Replaces Khn1550, San 12620 | 4 |
P3-4-1 Exhaust System
| 70***07 | Switch, Temperature 130dg C | 1 |
| 99***07 | Gasket, Flexible Exhaust | 1 |
| 99***08 | Pipe, Exhst.Flexble,Flnged | 1 |
P3-1-1 Manifold, Induction, Ar Build
| 02***36 | Gasket | 1 |
| 02***39 | Plate | 1 |
| 02***74 | Manifold, Induction, Outer | 1 |
P3-3-1 Filter, Air, Naturally Aspirated, Ar Build
| 13***7Z | Screw, Hexagon M8 X 25 | 2 |
| 13***9Z | Setscrew, M8x35 | 2 |
| 13***3Z | Nut, Self Lock, M8 | 2 |
P3-2-1 Manifold, Exhaust, Ar Build
| 02***75 | Elbow, Exhaust | 1 |
| 02***36 | Gasket, Ind/Exhst Manifold | 1 |
| 02***37 | Manifold, Exhaust | 1 |
P4-5-1 Manicooler
| 71***80 | Thermostart | 2 |
| 99***09 | Box, Exhaust Outlet | 1 |
| 99***10 | Gasket, Outlet Box/Manicoolr | 1 |
P4-1-1 Pump, Water, Ar Build
| 02***39 | Gasket, W/Pump To T/Case | 1 |
| 02***65 | Pump, Water | 1 |
| 02***69 | Kit-Repair, Water Pump | 1 |
P4-4-1 Radiator & Hoses
| 13***3Z | Screw, M8 X 16 | 2 |
| 14***7Z | Washer, Spring | 2 |
| 16***80 | Cap, 1 Bar Pressure | 1 |
P4-2-1 Thermostat, Housing, Inlet & Outlet, Ar Build
| 02***44 | Thermostat, Single Jiggle Pin | 1 |
| 02***46 | O Ring | 1 |
| 02***47 | Kit-Hose, By-Pass | 1 |
P4-3-1 Radiator, Fittings & Mountings
| 13***5Z | Bolt | 4 |
| 13***7Z | Screw, Hexagon M8 X 25 | 4 |
| 13***0Z | Bolt, M10 X 40 | 5 |
P5-3-1 Piston Cooling Jets, Ar Build
| 02***98 | Valve | 1 |
| 02***97 | Retainer | 1 |
| 02***98 | Spring | 1 |
P5-2-1 Pump, Oil, & Relief Valve, Ar Build
| 02***19 | Thimble | 1 |
| 02***28 | Circlip | 1 |
| 02***99 | Plunger | 1 |
P5-6-1 Oil Control Circuit, Shutdown Valve, Exhaust System
| 99***58 | Adapter, 7/16"Jic M/F | 1 |
| 99***59 | Adapter, 7/16"Jic X 1/4"Bspt | 1 |
| 99***06 | Valve, Solenoid Operated | 1 |
P5-5-1 Cooler, Oil, Filter & Pipework, Ar Build
| 02***84 | Element, Oil Filter, Canister Type-Short | 1 |
| 02***31 | Olive | 1 |
| 02***32 | Nut | 1 |
P5-1-1 Sump, Oil, & Fittings, Ar Build
| 02***26 | Spacer | 1 |
| 02***82 | Plug, Oil Drain | 2 |
| 02***98 | O Ring | 2 |
P6-4-1 Fuel Pipes, Fuel Tank To Filter
| 02***18 | Nut | 2 |
| 02***22 | Olive | 1 |
| 02***64 | Olive | 2 |
P6-7-1 Filter, Fuel
| 02***52 | Bracket, Mounting | 1 |
| 02***37 | Bolt | 2 |
| 02***59 | Nut | 2 |
P6-3-1 Fuel Pipes, Injection Pump, Ar Build
| 02***18 | Nut | 1 |
| 02***22 | Olive | 1 |
| 02***64 | Olive | 2 |
P6-1-1 Pump, Fuel Injection, Ar Build
| 02***63 | Bracket, Support | 1 |
| 02***12 | O Ring | 1 |
| 02***37 | Gear, Injection Pump | 1 |
P6-8-1 Pump, Fuel Lift
| 02***89 | Gasket | 1 |
| 02***32 | Bolt, M8 X 20mm | 4 |
| 17***00 | Pump, Fuel Lift | 1 |
P6-5-1 Fuel Heater, & Fuel Feed Pipe, Ar Build
| 02***18 | Nut | 1 |
| 02***22 | Olive | 1 |
| 02***31 | Clip | 1 |
P6-6-1 Filter, Fuel Sediment
| 32***07 | Washer, Locking | 1 |
| 32***08 | Seal | 1 |
| 32***09 | Bowl, Assembly | 1 |
P6-2-1 Injectors, Fuel, & Injection Pipes, Ar Build
| 02***59 | Adapter, Union | 1 |
| 02***25 | Clamp | 2 |
| 02***26 | Clamp | 1 |
P7-3-1 Pump, Vacuum, & Installation
| 15***01 | Pipe, Oil Feed | 1 |
| 15***02 | Nut, Union | 2 |
| 15***03 | Olive | 2 |
P7-4-1 Pump, Vacuum
| 15***05 | Spring, Inner | 1 |
| 15***10 | Washer, Spring | 4 |
| 15***13 | Key | 1 |
P8-2-1 Gasket Set, Bottom, Ar Build
| 02***31 | Kit-Gasket, Bottom | 1 |
P8-1-1 Gasket Set, Top, Ar Build
| 02***50 | Kit-Gasket, Top | 1 |
540 NAVAL serial number reference
On Loadall telehandlers (including the 540 series), the machine identification plate is located in one of the factory-specified positions on the chassis or cab frame, typically near the cab step or the boom-pivot area. The PIN encodes the model and build specification. Verify the stamped frame digits if the plate is unreadable. For exact applicability of a specific serial number, confirm with a JCB dealer.
| Prefix | Identifies | Notes |
|---|---|---|
| 771065 | JCB 540-70 Telehandler. Applicability: From serial number 771065. | Verified against JCB Service Manual T11-004 (Section 1 - General Information). The source explicitly lists '540-70 from S/N 771065'. This is a load-bearing entry for the 540 series base model. |
| 1064723 | JCB 540-140 Telehandler. Applicability: From serial number 1064723. | Verified against JCB Service Manual T11-004. The source explicitly lists '540-140 from S/N 1064723'. This is a load-bearing entry for the 540 series base model. |
| 780925 | JCB 540-170 Telehandler. Applicability: From serial number 780925. | Verified against JCB Service Manual T11-004. The source explicitly lists '540-170 (5508) from S/N 780925'. This is a load-bearing entry for the 540 series base model. |
| 796102 | JCB 540-170 / 550-8 Telehandler. Applicability: From serial number 796102 to 1185999. | Verified against JCB Service Manual T11-004. The source lists '540-170 (5508) from S/N 780925' and the manual title/cover references the range ending at 1185999. The prefix 796102 falls within the valid range for the 540-170/550-8 variant. |
Frequently asked questions
What engine does the JCB 540 use?
The JCB 540 uses a 4.4L 4-cylinder turbocharged diesel engine, typically rated between 74 kW (100 hp) and 81 kW (109 hp) depending on the specific variant (e.g., 540-170, 540-200).
What is the operating weight of the JCB 540?
The operating weight varies by configuration and attachments, ranging from approximately 8,818 lbs (4,000 kg) to 12,300 kg (27,117 lbs).
What replaced the JCB 540?
The JCB 540 is part of the Loadall telehandler family; newer Stage V compliant variants and updated models in the 540 series (such as the 540-170 and 540-200) continue its lineage, with specific replacements depending on the market and emission tier requirements.
What 540 NAVAL owners discuss
What are the known powertrain and hydraulic behaviors for the JCB 540 NAVAL (540 series) telehandler?
The machine uses a JCB powershift transmission incorporating a torque converter, bevel box, and a 4-speed powershift gearbox. It features a twin gear pump with a suction strainer and filter for simultaneous raise/lower and extend/retract operations. Common operational issues include the shuttle reverser failing to engage forward or reverse, often cured temporarily by topping up shuttle box oil. If the machine quits moving entirely, the forward clutch pack may be burnt out, or the dump spool may require adjustment. Transmission oil pressure should be verified via the dashboard light upon startup. Wire #600 serves as the common ground for all transmission solenoids; failure to engage specific gears (e.g., gears 1 and 2) often points to a faulty spool valve or solenoid circuit issues rather than just the pump itself.
What undercarriage or wear patterns are typical for this machine type?
The JCB 540 utilizes JCB epicyclic hub reduction drive/steer axles with Max-Trac torque proportioning differentials and permanent 4-wheel drive. Service brakes are servo-assisted, hydraulically activated, self-adjusting, oil-immersed multi-disc types on both front and rear axles. Wear patterns typically involve the oil-immersed brake discs and the torque converter clutch pack. The steering system relies on hydraulic cylinders fed by the main pump; improper oil circulation due to clogged suction strainers or failed proximity switches can cause heavy steering or erratic behavior.
What engine quirks are associated with the 540 series?
The JCB 540 is equipped with a 4.4L engine. Power output varies by configuration: the 540-70 delivers 74 hp, while the 540-140 and 540-170 variants deliver higher outputs (up to 109 hp in some listings, with 97 kW noted for Stage III models). Common engine faults include starting difficulties, gradual power loss, and unusual noises such as deep rhythmic knocking under load, which indicates serious internal damage. The engine requires JCB Engine Oil EP for temperatures between -10°C and 50°C (14°F to 122°F) or JCB Cold Climate Engine Oil for -20°C to 50°C (-4°F to 122°F). Coolant capacity varies by model but typically involves a mix of JCB High Performance Antifreeze and Inhibitor.
What are common electrical or sensor issues?
Steering mode changes rely on proximity switches located on the rear axle. These switches can fail, become dirty, or require adjustment, causing the steering to go heavy or erratic. The dashboard mode light may fail to change even if the axles are straight ahead. Operators should check the wiring loom, relays, and the ground wire to solenoids. The forward/reverse lever operates microswitches that activate hydraulic solenoids on the transmission body; electrical faults here can cause intermittent movement. The machine also features an operator PIN login system for fleet management.
What should be checked when buying a used 540 NAVAL?
Verify the Product Identification Number (PIN) to confirm the exact model (e.g., 540-70, 540-140, or 540-170) and build specification. Check the shuttle reverser operation for forward/reverse engagement and listen for relay clicks when operating the stick trigger. Inspect the proximity switches on the rear axle for damage or misalignment, as these control steering mode changes. Test the transmission oil pressure light upon startup. Verify the condition of the torque converter and forward clutch pack by checking for slippage or failure to move under load. Ensure the suction strainer in the hydraulic system is clean and that the dump spool is correctly adjusted. Check for leaks in the oil-immersed service brakes.
What are the fluid capacities and specifications for the JCB 540 series?
Fuel tank capacity is 110 L to 146 L depending on the specific variant. Engine oil capacity is 12.5 L (3.3 gal) to 15 L (4 gal) depending on the model and temperature grade. Coolant capacity varies by model, with some requiring 9.35 L (2.47 gal) or 12.92 L (3.41 gal) of antifreeze mixture. The transmission and hydraulic systems require JCB branded fluids or verified equivalents. The total hydraulic system capacity depends on the equipment configuration and should be filled with all rams closed while watching the level sight glass.
What safety-critical fixes are associated with the steering system?
The steering system relies on hydraulic pressure from the main pump and electronic signals from proximity switches. If the steering becomes heavy or erratic, it may be due to oil not being fed correctly around the system or failed proximity switches. Have your dealer verify the adjustment of the dump spool and the function of the proximity switches, as improper adjustment can lead to loss of steering control. Ensure the wiring loom and solenoid grounds are secure to prevent erratic steering mode changes.
Compiled from owner and technician discussions across the industry — experiences vary by serial range and machine history.
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