Service Manual: Foreword

Foreword
The Operator's Manual
You and others can be killed or seriously injured

if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
SERVICE MANUAL Do not operate the machine without an Operator's

Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.

Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
LOADALL (ROUGH TERRAIN

VARIABLE REACH TRUCK) Contents
506-36, 507-42, 509-42, 512-56, 514-56
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air-
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
EN - 9823/1650 - ISSUE 1 - 06/2018
25 - Steering System
27 - Driveline
30 - Hydraulic System
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
Copyright 2018 © JCB SERVICE

78 - After Sales
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Notes:
9823/1650-1
Spine Cards
SERVICE MANUAL SERVICE MANUAL

Volume 1 Volume 2
506-36, 507-42, 506-36, 507-42,

509-42, 512-56, 514-56 509-42, 512-56, 514-56
EN 9823/1650 EN 9823/1650
SERVICE MANUAL SERVICE MANUAL

Volume 3 Volume 4
506-36, 507-42, 506-36, 507-42,

509-42, 512-56, 514-56 509-42, 512-56, 514-56
EN 9823/1650 EN 9823/1650
9823/1650-1
Notes:
9823/1650-1
01 - Machine
Contents Page No.
Acronyms Glossary .................................................................................................................................... 01-2
01-03 Safety
01-03-03 Safety - Yours and Others ............................................................................................... 01-3
01-03-06 Safety Warnings ............................................................................................................... 01-4
01-03-09 General Safety ................................................................................................................. 01-5
01-03-12 Maintenance Safety ......................................................................................................... 01-6
01-03-18 Operating Safety .............................................................................................................. 01-8
01-03-21 Worksite Safety .............................................................................................................. 01-11
01-03-24 Risk Assessment ............................................................................................................ 01-12
01-03-27 Maintenance Positions ................................................................................................... 01-13
01-06 About this Manual
01-06-03 Model and Serial Number .............................................................................................. 01-17
01-06-06 Using the Manual ........................................................................................................... 01-18
01-09 Description
01-09-00 General ........................................................................................................................... 01-21
01-09-03 Log Moving/Object Handling .......................................................................................... 01-23
01-09-06 Optional Equipment and Attachments ........................................................................... 01-24
01-09-12 Main Component Locations ........................................................................................... 01-25
01-33 Cleaning
01-33-00 General ........................................................................................................................... 01-27
9823/1650-1
2018-05-25
Acronyms Glossary
FOPS Falling Object Protective Structure

PIL Parts Identification List
ROPS Roll-Over Protective Structure
9823/1650-1
2018-05-25
01 - Machine
03 - Safety
03 - Safety
Contents Page No.
01-03-03 Safety - Yours and Others ............................................................................................... 01-3

01-03-06 Safety Warnings ............................................................................................................... 01-4
01-03-09 General Safety ................................................................................................................. 01-5
01-03-12 Maintenance Safety ......................................................................................................... 01-6
01-03-18 Operating Safety .............................................................................................................. 01-8
01-03-21 Worksite Safety .............................................................................................................. 01-11
01-03-24 Risk Assessment ............................................................................................................ 01-12
01-03-27 Maintenance Positions ................................................................................................... 01-13
01 - 1 9823/1650-1 01 - 1
Notes:
01 - 2 9823/1650-1 01 - 2
01 - Machine
03 - Safety
03 - Safety - Yours and Others
03 - Safety - Yours and Others
Introduction
All machinery can be hazardous. When a machine

is correctly operated and maintained, it is a safe
machine to work with. When it is carelessly operated
or poorly maintained it can become a danger to you
(the operator) and others.
In this manual and on the machine you will find

warning messages, you must read and understand
them. They inform you of potential hazards and how
to avoid them. If you do not fully understand the
warning messages, ask your employer or JCB dealer
to explain them.
Safety is not just a matter of responding to the

warnings. All the time you are working on or with the
machine you must be thinking of what hazards there
might be and how to avoid them.
Do not work with the machine until you are sure that
you can control it.
Do not start any work until you are sure that you and
those around you will be safe.
If you are not sure of anything, about the machine or

the work, ask someone who knows. Do not assume
anything.
Remember:
• Be careful
• Be alert
• Be safe.
01 - 3 9823/1650-1 01 - 3
01 - Machine
03 - Safety
06 - Safety Warnings
06 - Safety Warnings
Introduction
In this manual there are safety notices. Each notice

starts with a signal word. The signal word meanings
are given below.
The signal word 'DANGER' indicates a hazardous

situation which, if not avoided, will result in death or
serious injury.
The signal word 'WARNING' indicates a hazardous

situation which, if not avoided, could result in death
or serious injury.
The signal word 'CAUTION' indicates a hazardous

situation which, if not avoided, could result in minor
or moderate injury.
The signal word 'Notice' indicates a hazardous

situation which, if not avoided, could result in
machine damage.
The safety alert system symbol (shown) also helps

to identify important safety messages in this manual.
When you see this symbol your safety is involved,
carefully read the message that follows.
Figure 1. The safety alert system symbol
01 - 4 9823/1650-1 01 - 4
01 - Machine
03 - Safety
09 - General Safety
09 - General Safety Lifting Equipment

You can be injured if you use incorrect or faulty lifting
Introduction equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
Training equipment is in good condition and complies with all
To operate the machine safely you must know the local regulations.
machine and have the skill to use it. You must abide Raised Equipment
by all relevant laws, health and safety regulations
that apply to the country you are operating in. The Never walk or work under raised equipment unless
operator's manual instructs you on the machine, its it is supported by a mechanical device. Equipment
controls and its safe operation; it is not a training which is supported only by a hydraulic device can
manual. Ensure that you receive the correct training drop and injure you if the hydraulic system fails
before operating any machinery. Failing to do so will or if the control is operated (even with the engine
result in incorrect operation of the machine and you stopped).
will be putting yourself and others at risk. In some Make sure that no-one goes near the machine while
markets, and for work on certain jobsites, you may you install or remove the mechanical device.
be required to have been trained and assessed in
accordance with an operator competence scheme. Raised Machine
Make sure that you and your machine comply with Never position yourself or any part of your body
relevant local laws and jobsite requirements – it is under a raised machine which is not correctly
your responsibility. supported. If the machine moves unexpectedly you
Care and Alertness could become trapped and suffer serious injury or be
killed.
All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always Lightning
be alert for hazards. Lightning can kill you. Do not use the machine if there
Clothing is lightning in your area.
You can be injured if you do not wear the correct Machine Modifications
clothing. Loose clothing can get caught in the This machine is manufactured in compliance with
machinery. Keep cuffs fastened. Do not wear a prevailing legislative requirements. It must not be
necktie or scarf. Keep long hair restrained. Remove altered in any way which could affect or invalidate its
rings, watches and personal jewellery. compliance. For advice consult your JCB dealer.
Alcohol and Drugs
It is extremely dangerous to operate machinery when
under the influence of alcohol or drugs. Do not
consume alcoholic drinks or take drugs before or
while operating the machine or attachments. Be
aware of medicines which can cause drowsiness.
Feeling Unwell
Do not attempt to operate the machine if you are
feeling unwell. By doing so you could be a danger to
yourself and those you work with.
Mobile Phones
Switch off your mobile phone before entering an
area with a potentially explosive atmosphere. Sparks
in such an area could cause an explosion or fire
resulting in death or serious injury.
Switch off and do not use your mobile phone when
refuelling the machine.
01 - 5 9823/1650-1 01 - 5
01 - Machine
03 - Safety
12 - Maintenance Safety
12 - Maintenance Safety Hydraulic Pressure

Hydraulic fluid at system pressure can injure you.
Introduction Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose
Raised Machine service line has been vented before connecting or
Never position yourself or any part of your body removing hoses. Make sure the engine cannot be
under a raised machine which is not correctly started while the hoses are open.
supported. If the machine moves unexpectedly you 'O' rings, Seals and Gaskets
could become trapped and suffer serious injury or be
killed. Badly installed, damaged or rotted 'O' rings, seals
and gaskets can cause leakages and possible
Air Conditioning Maintenance accidents. Renew whenever disturbed unless
The air conditioning system is a closed loop system otherwise instructed. Do not use Triochloroethane or
and contains pressurised refrigerant. No part of the paint thinners near 'O' rings and seals.
system should be disconnected until the system Arc Welding
has been discharged by a refrigeration engineer
or a suitably trained person. You can be severely To prevent the possibility of damage to electronic
frostbitten or injured by escaping refrigerant. components, disconnect the battery and the
alternator before arc-welding on the machine or
Compressed Air attached implements.
Compressed air is dangerous. Wear personal If the machine is equipped with sensitive electrical
protective equipment. Never point a compressed air equipment, i.e. amplifier drivers, electronic control
jet at yourself or others. units (ECUs), monitor displays, etc., then disconnect
Springs them before welding. Failure to disconnect the
sensitive electrical equipment could result in
Always wear personal protective equipment when
irreparable damage to these components.
dismantling assemblies containing components
under pressure from springs. This will protect against Parts of the machine are made from cast iron, welds
eye injury from components accidentally flying out. on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable
Metal Splinters
or apply any weld to any part of the engine.
You can be injured by flying metal splinters when
Always connect the welder earth (ground) cable to
driving metal pins in or out. Use a soft faced hammer
the same component that is being welded to avoid
or copper drift to remove and install metal pins.
damage to pivot pins, bearings and bushes. Attach
Always wear personal protective equipment.
the welder earth (ground) cable a distance from the
Communications part being welded no more than 0.6 m.
Bad communications can cause accidents. If two Counterweights
or more people are working on the machine, make
Your machine may be installed with counterweights.
sure each is aware of what the others are doing.
They are extremely heavy. Do not attempt to remove
Before starting the engine make sure the others are
them.
clear of the danger areas. Examples of danger areas
are: the rotating blades and belt on the engine, the Accumulators
attachments and linkages, and anywhere beneath or The accumulators contain hydraulic fluid and gas at
behind the machine. People can be killed or injured high pressure. Prior to any work being carried out
if these precautions are not taken. on systems incorporating accumulators, the system
Repairs pressure must be discharged by a JCB dealer, as
the sudden release of the hydraulic fluid or gas may
If your machine does not function correctly in
cause serious injury or death.
any way, get it repaired straight away. Neglect of
necessary repairs could result in an accident or affect Hot Components
your health. Do not try to do repairs or any other Touching hot surfaces can burn skin. The engine and
type of maintenance work you do not understand. To machine components will be hot after the unit has
avoid injury and/or damage get the work done by a been running. Allow the engine and components to
specialist engineer. cool before servicing the unit.
Soft Ground
A machine can sink into soft ground. Never work
under a machine on soft ground.
01 - 6 9823/1650-1 01 - 6
01 - Machine
03 - Safety
12 - Maintenance Safety
Working Under the Machine

Make the machine safe before getting beneath it.
Make sure that any attachments on the machine are
correctly attached. Engage the park brake, remove
the ignition key, disconnect the battery. If the machine
has wheels use blocks to prevent unintentional
movement.
Lifting the Machine
Under no circumstances must the engine be run with
the transmission in gear and only one driving wheel
jacked clear of the ground, since the wheel on the
ground will move the machine.
Chemicals
Certain seals and gaskets (e.g. crankshaft oil
seal) on JCB machines contain fluoroelastomeric
materials such as Viton®, FluorelTM and
Technoflon®. Fluoroelastomeric materials subjected
to high temperatures can produce highly
corrosive hydrofluoric acid. This acid can severely
burn. New fluoroelastomeric components at
ambient temperature require no special safety
precautions. Used fluoroelastomeric components
whose temperatures have not exceeded 300 °C
( 571.6 °F) require no special safety precautions. If
evidence of decomposition (e.g. charring) is found,
refer to the next paragraph for safety instructions.
Do not touch component or surrounding area.
Used fluoroelastomeric components subjected to
temperatures greater than 300 °C ( 571.6 °F) (e.g.
engine fire) must be treated using the following
safety procedure. Make sure that heavy duty gloves
and special safety glasses are worn: Thoroughly
wash contaminated area with 10% calcium hydroxide
or other suitable alkali solution, if necessary use
wire wool to remove burnt remains. Thoroughly
wash contaminated area with detergent and water.
Contain all removed material, gloves etc. used in this
operation in sealed plastic bags and dispose of in
accordance with Local Authority Regulations. Do not
burn fluoroelastiometric materials.
Hydraulic Hoses
Never re-use hydraulic hose end crimps or use
reusable hose end crimps.
Personal Protective Equipment
Use the appropriate personal protective equipment
before performing maintenance on the machine,
otherwise you could be injured.
Working at Height
Use appropriate access equipment such as ladders
or a working platform if it is necessary to work at
height to perform maintenance tasks on the machine.
If you do not use suitable access equipment there is
a risk of falling, resulting in personal injury or death.
01 - 7 9823/1650-1 01 - 7
01 - Machine
03 - Safety
18 - Operating Safety
18 - Operating Safety exhaust extractor. If you begin to feel drowsy, stop

the machine at once and get into fresh air.
Introduction Worksites
Worksites can be hazardous. Examine the site
Training before working on it. You could be killed or injured
if the ground gives way under your machine or if
Make sure that you have had adequate training and piled material collapses onto it. Check for potholes
that you are confident in your ability to operate the and hidden debris, logs, ironwork etc. Any of these
machine safely before you use it. Practice using the could cause you to lose control of your machine.
machine and its attachments until you are completely Check for utilities such as electric cables (overhead
familiar with the controls and what they do. With and underground), gas and water pipes etc. Mark
a careful, well trained and experienced operator, the positions of the underground cables and pipes.
your machine is a safe and efficient machine. With Make sure that you have enough clearance beneath
an inexperienced or careless operator, it can be overhead cables and structures.
dangerous. Do not put your life, or the lives of others,
at risk by using the machine irresponsibly. Before you
start to work, tell your colleagues what you will be Communications
doing and where you will be working. On a busy site,
use a signalman. Before doing any job not covered Bad communications can cause accidents. Keep
in this manual, find out the correct procedure. Your people around you informed of what you will be
local JCB distributor will be glad to advise you. doing. If you will be working with other people,
make sure any hand signals that may be used are
understood by everybody. Worksites can be noisy, do
Fuel not rely on spoken commands.
Fuel is flammable, keep naked flames away from the
fuel system. Stop the engine immediately if a fuel Parking
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the An incorrectly parked machine can move without an
engine running. Completely wipe off any spilt fuel operator. Follow the instructions in the Operator's
which could cause a fire. There could be a fire and Manual to park the machine correctly.
injury if you do not follow these precautions.
Banks and Trenches
Machine Condition
Banked material and trenches can collapse. Do not
A defective machine can injure you or others. Do not work or drive too close to banks and trenches where
operate a machine which is defective or has missing there is danger of collapse.
parts. Make sure the maintenance procedures in this
manual are completed before using the machine. Safety Barriers
Machine Limits Unguarded machines in public places can be

dangerous. In public places, or where your visibility
Operating the machine beyond its design limits can is reduced, place barriers around the work area to
damage the machine, it can also be dangerous. keep people away.
Do not operate the machine outside its limits. Do
not try to upgrade the machine performance with Sparks
unapproved modifications or additional equipment.
Explosions and fire can be caused by sparks from
Engine/Steering Failure the exhaust or the electrical system. Do not use the
machine in closed areas where there is flammable
If the engine or steering fails, stop the machine as material, vapour or dust.
quickly as possible. Do not operate the machine until
the fault has been corrected. Hazardous Atmospheres
Exhaust Gases This machine is designed for use in normal out

door atmospheric conditions. It must not be used
Machine exhaust gases can harm and possibly kill in an enclosed area without adequate ventilation.
you or bystanders if they are inhaled. Do not operate Do not use the machine in a potentially explosive
the machine in closed spaces without making sure atmosphere, i.e. combustible vapours, gas or dust,
there is good ventilation. If possible, install an without first consulting your JCB dealer.
01 - 8 9823/1650-1 01 - 8
01 - Machine
03 - Safety
Regulations clearly. Modification of the machine's configuration

by the user (e.g. the fitting of large and non-
Obey all laws, worksite and local regulations which approved attachments) may result in a restriction of
affect you and your machine. the machine visibility.
Electrical Power Cables Hands and Feet

You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine. When
the machine or its attachments too close to electrical using the machine, keep your hands and feet clear
power cables. You are strongly advised to make of moving parts. Keep your hands and feet within the
sure that the safety arrangements on site comply operator compartment while the vehicle is in motion.
with the local laws and regulations concerning work
near electric power lines. Before you start using the Controls
machine, check with your electricity supplier if there
are any buried power cables on the site. There is You or others can be killed or seriously injured
a minimum clearance required for working beneath if you operate the control levers from outside the
overhead power cables. You must obtain details from machine. Operate the control levers only when you
your local electricity supplier. are correctly seated.
Working Platform Passengers

Using the machine as a working platform is Passengers in or on the machine can cause
hazardous. You can fall off and be killed or injured. accidents. Do not carry passengers.
Never use the machine as a working platform
unless with approved man-basket or man-crate (if Fires
applicable).
If your machine is equipped with a fire extinguisher,
Machine Safety make sure it is checked regularly. Keep it in the
correct machine location until you need to use it. Do
Stop work at once if a fault develops. Abnormal not use water to put out a machine fire, you could
sounds and smells can be signs of trouble. Examine spread an oil fire or get a shock from an electrical
and repair before resuming work. fire. Use carbon dioxide, dry chemical or foam
extinguishers. Contact your nearest fire department
Hot Components as quickly as possible.
Touching hot surfaces can burn skin. The engine and Roll Over Protection
machine components will be hot after the unit has
been running. Allow the engine and components to If the machine starts to roll over, you can be crushed
cool before servicing the unit. if you try to leave the cab. If the machine starts to roll
over, do not try and jump from the cab. Stay in the
Travelling at High Speeds cab, with your seat belt fastened.
Travelling at high speeds can cause accidents. Confined Areas

Always travel at a safe speed to suit working
conditions. Pay extra attention to proximity hazards when
operating in confined areas. Proximity hazards
Hillsides include buildings, traffic and bystanders.
Operating the machine on hillsides can be Safe Working Loads

dangerous if the correct precautions are not taken.
Ground conditions can be changed by rain, snow, ice Overloading the machine can damage it and make it
etc. Check the site carefully. When applicable, keep unstable. Study the specifications in the Operator's
all attachments low to the ground. Manual before using the machine.
Visibility Lightning
Accidents can be caused by working in poor visibility. If you are inside the machine during a lightning storm
Use your lights to improve visibility. Keep the road stay in the machine until the storm has passed. If
lights, windows, mirrors and cameras clean (when you are outside of the machine during a lightning
fitted). Do not operate the machine if you cannot see storm stay away from the machine until the storm
01 - 9 9823/1650-1 01 - 9
01 - Machine
03 - Safety
has passed. Do not attempt to mount or enter the

machine. If the machine is struck by lightning do
not use the machine until it has been checked for
damage and malfunction by trained personnel.
01 - 10 9823/1650-1 01 - 10
01 - Machine
03 - Safety
21 - Worksite Safety
21 - Worksite Safety An applicable worksite organisation is required in

order to minimise hazards that are caused by
restricted visibility. The worksite organisation is a
Introduction collection of rules and procedures that coordinates
the machines and people that work together in
WARNING You or others can be killed or seriously the same area. Examples of worksite organisation
injured if you do unfamiliar operations without first include:
practising them. Practise away from the worksite
on a clear area. Keep other people away. Do not • Restricted areas
perform new operations until you are sure you can • Controlled patterns of machine movement
do them safely. • A system of communication.
WARNING There could be dangerous materials
such as asbestos, poisonous chemicals or other You and/or your company could be legally liable for
harmful substances buried on the site. If you any damage you may cause to public utilities. It is
uncover any containers or you see any signs of your responsibility to make sure that you know the
toxic waste, stop the machine and advise the site locations of any public utility cables or pipes on the
manager immediately. worksite which could be damaged by your machine.
WARNING Before you start using the machine,
check with your local gas company if there are
any buried gas pipes on the site.
If there are buried gas pipes we recommend that
you ask the gas company for any specific advice
regarding the way you must work on the site.
Some modern gas pipes cannot be detected by
metal detectors, so it is essential that an accurate
map of buried gas pipes is obtained before any
excavation work commences.
Hand dig trial holes to obtain precise pipe
locations. Any cast iron pipes found must be
assumed to be gas pipes until contrary evidence
is obtained.
Older gas pipes can be damaged by heavy
vehicles driving over the ground above them.
Leaking gas is highly explosive.
If a gas leak is suspected, contact the local gas
company immediately and warn all personnel on
the site. Ban smoking, make sure that all naked
lights are extinguished and switch off any engines
which may be running.
You are strongly advised to make sure that the
safety arrangements on site comply with the local
laws and regulations concerning work near buried
gas pipes.
CAUTION Before you start using the machine,
check with your local public water supplier if there
are buried pipes and drains on the site. If there
are, obtain a map of their locations and follow the
advice given by the water supplier.
You are strongly advised to make sure that the
safety arrangements on site comply with the local
laws and regulations concerning work near buried
pipes and drains.
CAUTION If you cut through a fibre optic cable,
Do not look into the end of it, your eyes could be
permanently damaged.
01 - 11 9823/1650-1 01 - 11
01 - Machine
03 - Safety
24 - Risk Assessment
24 - Risk Assessment Loading/Unloading Area

• Is it level? Any slope of more than 2.5% (1 in
Introduction 40) must be carefully considered.
• Is more than one direction of approach to the
load possible? Approaching across the slope
It is the responsibility of the competent people that must be avoided, if possible.
plan the work and operate the machine to make a • Is the ground solid? Will it support the weight of
judgement about the safe use of the machine, they the machine when loaded?
must take into account the specific application and • How rough is the ground? Are there any
conditions of use at the time. sharp projections which could cause damage,
particularly to the tyres?
It is essential that a risk assessment of the work to be • Are there any obstacles or hazards in the area,
done is completed and that the operator obeys any for example, debris, excavations, manhole
safety precautions that the assessment identifies. covers, power lines?
• Is the space sufficient for safe manoeuvring?
If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be
a specific task, contact your JCB dealer who will be in or to enter the area while operations are in
pleased to advise you. progress?
The following considerations are intended as
suggestions of some of the factors to be taken into The Route to be Travelled
account when a risk assessment is made. Other • How solid is the ground, will it provide sufficient
factors may need to be considered. traction and braking? Soft ground will affect the
stability of the machine and this must be taken
A good risk assessment depends on the training and into account.
experience of the operator. Do not put your life or the • How steep are any slopes, up/down/across?
lives of others at risk. A cross slope is particularly hazardous, is it
possible to detour to avoid them?
Personnel
• Are all persons who will take part in the Weather
operation sufficiently trained, experienced and • How windy is it? High wind will adversely affect
competent? Are they fit and sufficiently rested? the stability of a loaded machine, particularly if
A sick or tired operator is a dangerous operator. the load is bulky.
• Is supervision needed? Is the supervisor • Is it raining or is rain likely? The ground that
sufficiently trained and experienced? was solid and smooth when dry will become
• As well as the machine operator, are any uneven and slippery when wet, and it will not
assistants or lookouts needed? give the same conditions for traction, steering
or braking.
The Machine
• Is it in good working order?
• Have any reported defects been corrected?
• Have the daily checks been carried out?
• Are the tyres still at the correct pressure and
in good condition and is there sufficient fuel to
complete the job (if applicable)?
The Load
• How heavy is it? Is it within the capabilities of
the machine?
• How bulky is it? The greater the surface area,
the more affected it will be by wind speeds.
• Is it an awkward shape? How is the weight
distributed? Uneven loads are more difficult to
handle.
• Is there a possibility of the load shifting while
being moved?
01 - 12 9823/1650-1 01 - 12
01 - Machine
03 - Safety
27 - Maintenance Positions
27 - Maintenance Positions Introduction

Introduction .................................................... 01-13 You can complete most of the maintenance
Health and Safety .......................................... 01-14 procedures with the lift arm lowered. Unless a
maintenance procedure instructs you differently, you
must lower the lift arm.
Lift Arm Lowered

1. Park the machine on level, solid ground.
2. Make the machine safe.
Refer to: PIL 01-03.
3. Release the hydraulic pressure.
4. Retract and lower the lift arm.
5. Put the attachment flat on the ground.
6. Stop the engine and remove the ignition key. If
the keyless ignition option is installed stop the
engine and wait
Duration: 15 s
7. Disconnect the battery to prevent accidental
operation of the engine.
8. If necessary, put blocks against the two ends of
the wheels before you get below the machine.
Figure 2.
A
A Lift arm lowered
Lift Arm Raised

1. Install the maintenance strut.
01 - 13 9823/1650-1 01 - 13
01 - Machine
03 - Safety
27 - Maintenance Positions
Health and Safety

WARNING Maintenance must be done only by
suitably qualified and competent persons.
Before doing any maintenance make sure the
machine is safe, it must be correctly parked on
solid, level ground.
To prevent anyone starting the engine, remove
the ignition key. Disconnect the battery (by means
of the battery isolator if installed) when you are
not using electrical power. If you do not take these
precautions you could be killed or injured.
WARNING Make the machine safe before getting
beneath it. Make sure that any attachments on
the machine are correctly attached. Engage the
park brake, remove the ignition key, disconnect
the battery.
01 - 14 9823/1650-1 01 - 14
01 - Machine
06 - About this Manual
Contents Page No.
01-06-03 Model and Serial Number .............................................................................................. 01-17

01-06-06 Using the Manual ........................................................................................................... 01-18
01 - 15 9823/1650-1 01 - 15
Notes:
01 - 16 9823/1650-1 01 - 16
01 - Machine
03 - Model and Serial Number
03 - Model and Serial Number
Introduction
This manual provides information for the following
model(s) in the JCB machine range:
Model From: To:
506-36 1402020
507-42 1402000
509-42 1402000
512-56 1402020
514-56 1402020
01 - 17 9823/1650-1 01 - 17
01 - Machine
06 - Using the Manual
06 - Using the Manual
Introduction
Information in this manual conforms to a standard List). These headings are assigned numerical
JCB service manual format. The format uses section identification references.
headings taken from a PIL (Parts Identification
Table 1.
Example Section Main Assembly / Head- Component / Sub-head-
ing ing
PIL reference 33 03 03
Heading Electrical System Battery Isolator Switch
Information within each PIL reference is included information is contained within another PIL reference
under a set of standard headings such as a cross reference is provided.
Introduction, Health and Safety, Technical Data and
Operation for example. Where additional relevant The main systems information is contained in the
manual as follows.
Table 2.
System PIL Reference Heading
Hydraulic System PIL 30-00-50 Schematic Circuit
Electrical System PIL 33-03-03 Battery - Isolator Switch
PIL 33-09-00 Power Distribution (including fuses
and relays)
PIL 33-00-50 Schematic Circuit
Electronic Diagnostic PIL 33-57-00 Electronic Diagnostic (including
Servicemaster)
Machine Variants • Use the applicable Servicemaster diagnostics

tools.
Where information is different depending on machine
variant, the applicable information sets are included Torque Tightening
within the same PIL reference. Headings are
included to identify which information is for which When you replace components, always tighten the
variant. Make sure you use the correct information. applicable fixings to the correct torque value. Use the
torque tightening values contained in the individual
Diagnostics procedures (Remove and Install, Disassemble and
Assemble etc.). If no torque values are specified, use
Information in this manual can help you diagnose the standard torque tightening values. For the torque
machine faults. setting to be effective, do the following before you
install the fixings. Refer to PIL 72-00-00.
Before attempting to diagnose possible faults check
the following. • Make sure that all the applicable component
assemblies are correct.
• Make sure that the operator understands the • Make sure that the applicable fixings are to the
machine controls, functions and use. Refer to correct specification. If necessary discard the
the applicable Operator Manual. original fixings and replace them with new ones.
• Check that the maintenance record complies The relevant procedures indicate when this is
with the applicable schedule for the operating necessary.
environment. • Make sure that the applicable fixings and
• Check that the fluids in use comply with the threaded holes are free from contamination.
standards specified. This includes dirt, debris, old sealants and
• Make sure that the machine electronic set-up compounds, fluids and lubricants.
is applicable. Use the applicable Servicemaster
vehicle set-up tool.
01 - 18 9823/1650-1 01 - 18
01 - Machine
09 - Description
09 - Description
Contents Page No.
01-09-00 General ........................................................................................................................... 01-21

01-09-03 Log Moving/Object Handling .......................................................................................... 01-23
01-09-06 Optional Equipment and Attachments ........................................................................... 01-24
01-09-12 Main Component Locations ........................................................................................... 01-25
01 - 19 9823/1650-1 01 - 19
Notes:
01 - 20 9823/1650-1 01 - 20
01 - Machine
09 - Description
00 - General
00 - General Introduction
Introduction .................................................... 01-21 The JCB Loadall is a self propelled, seated operator,
Operation ....................................................... 01-22 wheeled machine for operation on unimproved
natural terrain and disturbed terrain.
A main structural support is designed to carry an

extending boom with a carriage mounted on the front
to which forks or an approved attachment can be
fitted.
When used normally the machine lifts and places

loads by extending/retracting, raising/lowering the
boom.
01 - 21 9823/1650-1 01 - 21
01 - Machine
09 - Description
00 - General
Operation
The machine is intended to be used in normal

conditions for the applications described in this
manual. If the machine is used for other applications
or in dangerous environments, for example in
a flammable atmosphere or in areas with dust
containing asbestos, special safety regulations must
be obeyed and the machine must be equipped for
use in these environments.
01 - 22 9823/1650-1 01 - 22
01 - Machine
09 - Description
03 - Log Moving/Object Handling
03 - Log Moving/Object Handling
Introduction
Do not use the machine to move or handle logs

unless sufficient log protection is installed. You could
cause serious injury to yourself and damage to the
machine. For more information, contact your JCB
dealer.
01 - 23 9823/1650-1 01 - 23
01 - Machine
09 - Description
06 - Optional Equipment and Attachments
06 - Optional Equipment and

Attachments
Introduction
A wide range of optional attachments are available

to increase the versatility of your machine. Only the
JCB approved attachments are recommended for
use with your machine. Contact your JCB dealer for
the full list of approved attachments available.
01 - 24 9823/1650-1 01 - 24
01 - Machine
09 - Description
12 - Main Component Locations
12 - Main Component Locations
Component Identification
Figure 3.
A D
E F
C
B
A Lift arm B Carriage

C Battery D ROPS (Roll-Over Protective Structure)/FOPS
(Falling Object Protective Structure) cab
E Hydraulic tow hitch (Agricultural machines only) F Mechanical tow hitch
01 - 25 9823/1650-1 01 - 25
01 - Machine
33 - Cleaning
33 - Cleaning
Contents Page No.
01-33-00 General ........................................................................................................................... 01-27
01 - 26 9823/1650-1 01 - 26
01 - Machine
33 - Cleaning
00 - General
WARNING When using cleaning agents, solvents
Introduction .................................................... 01-27 or other chemicals, you must adhere to
Preparation .................................................... 01-28 the manufacturer's instructions and safety
precautions.
CAUTION To avoid burning, wear personal
protective equipment when handling hot
components. To protect your eyes, wear goggles
when using a brush to clean components.
Notice: Cleaning metal parts with incorrect
solvents can cause corrosion. Use only
recommended cleaning agents and solvents.
Notice: The efficiency of the rams will be affected
if they are not kept free of solidified dirt. Clean dirt
from around the rams regularly. When leaving or
parking the machine, close all rams if possible to
reduce the risk of weather corrosion.
Notice: Never use water or steam to clean inside
the operator station. The use of water or steam
could damage the machine electrics and render
the machine inoperable. Remove dirt using a
brush or damp cloth.
Clean the product with water and/or steam. Do not

let mud, debris etc. to collect on the product.
Before you do any service procedures that require

components to be removed:
• The cleaning must be done either in the area

of components to be removed, or in the case
of major work, or work on the fuel system, the
whole engine and the surrounding product must
be cleaned.
• When cleaning is complete, move the product
away from the wash area or alternatively,
remove the material washed from the product.
When you remove components, be aware of

exposure to dirt and debris. Cover any open ports
and remove the deposits before proceeding.
Detergents
Do not use a full strength detergent. Always
dilute the detergents as per the manufacturer's
recommendations, or damage to the paint finish can
occur.
Always obey the local regulations regarding the

disposal of debris created from cleaning the product.
Pressure Washing and Steam Cleaning

CAUTION When using a steam cleaner, wear
safety glasses or a face shield as well as
protective clothing. Steam can cause personal
injury.
01 - 27 9823/1650-1 01 - 27
01 - Machine
33 - Cleaning
00 - General
Notice: The engine and other components could Preparation

be damaged by high pressure washing systems.
Special precautions must be taken if the machine
is to be washed using a high pressure system. 1. Make the machine safe. Stop the machine and
let it cool for at least one hour. Do not try to clean
Make sure that the alternator, starter motor and any part of the machine while it is running.
any other electrical components are shielded
and not directly cleaned by the high pressure 2. Make sure that all of the electrical connectors are
cleaning system. Do not aim the water jet directly correctly coupled.
at bearings, oil seals or the engine air induction
system. 3. If the connectors are open, attach the correct
caps or seal with waterproof tape.
Use a low pressure water jet and brush to remove
dried mud or dirt.
Use a pressure washer to remove soft dirt and oil.
The product must always be greased (if appropriate)

after pressure washing or steam cleaning.
01 - 28 9823/1650-1 01 - 28
03 - Attachments, Couplings and Load Handling
Contents Page No.
03-00 Attachments
03-00-00 General ............................................................................................................................. 03-3
03-33 Fork
03-33-00 General ............................................................................................................................. 03-7
03-33-03 Carriage .......................................................................................................................... 03-10
03-82 Jib
03-82-00 General ........................................................................................................................... 03-13
03-82-06 Shackle ........................................................................................................................... 03-15
03-84 Hook
03-84-06 Snatch Block .................................................................................................................. 03-19
9823/1650-1
2017-08-14
Notes:
9823/1650-1
2017-08-14
00 - Attachments
00 - Attachments
Contents Page No.
03-00-00 General ............................................................................................................................. 03-3
03 - 1 9823/1650-1 03 - 1
Notes:
03 - 2 9823/1650-1 03 - 2
00 - Attachments
00 - General
Introduction ...................................................... 03-3 A wide range of optional attachments are available
Health and Safety ........................................... 03-4 to increase the versatility of your machine. Only JCB
approved attachments are recommended for use
with your machine. Consult your JCB Distributor for
the full list of approved attachments available.
Some attachments are supplied complete with

instructions on safety, installing and removing,
operation and maintenance. Read and fully
understand the information before fitting, using and
servicing the attachment. If there is anything you do
not understand, ask your JCB Distributor.
Before using any attachment, read Working With

The Machine in the Operator Manual and consider
how the attachment is going to affect operational
safety. With the attachment installed, there may
be changes in the machine's centre of gravity or
overall dimensions. This could have an effect on, for
example, machine stability, the gradients on which it
is safe to operate or the safe distance from power
lines.
Practice using attachments off the job before working

with them for the first time.
JCB attachments are designed and manufactured

specifically to suit the machine's hydraulic system,
mounting arrangements and safe load requirements.
Attachments which are not designed for use with
this machine may cause damage and create safety
hazards for which JCB cannot be held responsible.
In addition the machine's warranty and any other
legislative compliance may be affected by the use of
non JCB approved attachments.
If your machine needs the hydraulic system adapting

to facilitate the use of auxiliary attachments, you
must consult your distributor. Only suitably qualified
personnel must reroute hydraulic hoses.
All optional attachments will have limits on their

operation. i.e. lifting capacity, speeds, hydraulic flow
rates, etc. Always check in the literature supplied
with the attachment or in the Specification section of
this manual. Some specification limits may also be
displayed on the attachments Data/Rating Plate.
Important: Do not operate or work with attachments

until the machine hydraulic oil has reached its normal
working temperature.
03 - 3 9823/1650-1 03 - 3
00 - Attachments
00 - General
Health and Safety

Attachments
Use only the JCB approved attachments that are
specified for your machine. Operating with non-
specified attachments can overload the machine,
causing possible damage and machine instability
which could result in injury to yourself or others.
The use of non-approved attachments could
invalidate your warranty.
Attachments
If you have an attachment which is not covered in the
Operator's Manual do not install it, use it or remove
it until you have obtained, read and understood the
pertinent information. Install attachments only on the
machines for which they were designed.
WARNING! Load and unload on firm, level ground.
Always be alert for possible hazards. Take special
care when turning or reversing.
DANGER! Before lowering the attachments to the
ground, make sure that the machine and the area
around it are clear of other people. Anyone on or
close to the machine could fall and be crushed by the
attachments, or get caught in the linkages.
DANGER! Using the forks alone as a working
platform is hazardous; you can fall off and be killed
or injured. Never use the forks as a working platform.
03 - 4 9823/1650-1 03 - 4
33 - Fork
33 - Fork
Contents Page No.
03-33-00 General ............................................................................................................................. 03-7

03-33-03 Carriage .......................................................................................................................... 03-10
03 - 5 9823/1650-1 03 - 5
Notes:
03 - 6 9823/1650-1 03 - 6
33 - Fork
00 - General
Introduction ...................................................... 03-7 Forks can be installed on many different types of
Health and Safety ........................................... 03-8 agricultural or construction machines. Forks can be
Adjust .............................................................. 03-8 directly mounted on to a lift arm or carriage or
mounted to a lift arm via a quickhitch assembly.
There are a vast amount and size of forks used for
numerous applications.
Forks can be used to lift, raise and carry heavy things

and stack them where required.
03 - 7 9823/1650-1 03 - 7
33 - Fork
00 - General
Health and Safety Adjust

DANGER Using the forks alone as a working WARNING Loads can fall off incorrectly spaced
platform is hazardous; you can fall off and be forks. Always space the forks correctly for the
killed or injured. Never use the forks as a working load. Make sure the forks are completely under
platform. the load before lifting.
WARNING Loads can fall off incorrectly spaced CAUTION To prevent unintentional detachment
forks. Always space the forks correctly for the of forks during travel or transportation, the forks
load. Make sure the forks are completely under must not overlap the lower removal notch or be
the load before lifting. secured in the central two positions on top of the
carriage.
WARNING If the fork/locking pin is not fully
engaged, the fork could become unintentionally CAUTION The forks are heavy. Make sure
disengeged. suitable lifting equipment is used to support and
transport them.
WARNING Do not try to correct the alignment
of the fork tips by bending the forks or adding WARNING If the fork/locking pin is not fully
shims. Never repair damaged forks by heating or engaged, the fork could become unintentionally
welding. Forks are made of special steel using disengeged.
special procedures. Always replace the damaged
forks.
Repositioning the Forks
WARNING Overloaded scaffolding can collapse.
Never load scaffolding beyond the regulation Industrial Carriage Fork Adjustment
capacity.
WARNING The forks project in front of the 1. Make the machine safe. Apply the park brake (if
machine. Make sure there is enough clearance installed).
for the forks when making turns.
2. Lower the forks as required to enable the use of
CAUTION A load lifted on one fork can slip off. suitable lifting equipment to move the forks.
Never lift a load with one fork.
3. Stop the engine. Remove the ignition key.
CAUTION Never unload the forks by stopping the
machine suddenly. Follow the procedures in the 4. Release the locking pins and slide the forks to the
Operator Manual for unloading. desired position using suitable lifting equipment.
CAUTION The forks are heavy. Make sure Your machine will have either 'twist and pull'
suitable lifting equipment is used to support and or 'pull' type fork locking pins. Forks must not
transport them. overlap the lower removal notch or be secured in
the central two positions on top of the carriage,
CAUTION Do not exceed the total rated load see shaded 'no fork' zone.
capacity of the forks being used. Forks can break
resulting in a loss of load and possible injury.
CAUTION Loads stacked on uneven ground can
topple. Never stack loads on uneven ground.
03 - 8 9823/1650-1 03 - 8
33 - Fork
00 - General
Figure 4.
A Locking pins
B Lower removal notch
C 'No fork' zone
5. Re-engage the locking pins. Make sure the pins
and forks are correctly located.
6. Remove the lifting equipment.
03 - 9 9823/1650-1 03 - 9
33 - Fork
03 - Carriage
03 - Carriage
Remove and Install
3, 4 and 5 Stage Booms

Remove
2. Position the lift arm so that the fork carriage can
be safely supported when it is disconnected from
the lift arm assembly.
3. Discharge the hydraulic pressure.
4. Support the fork carriage.
5. Remove the tilt ram pivot pin lock nut and bolt.
6. Remove the pivot pin 1. Make sure that the tilt
ram piston rod is not damaged.
7. Remove the lock nut and bolt from the pivot pin
trunnion.
8. Remove the pivot pin 2 from its location.
9. Remove the fork carriage.
Figure 5.
D
C A E
A
A Fork carriage
B Ram pivot pin lock nut and bolt
C Pivot pin 1
D Pivot pin trunnion lock nut and bolt
E Pivot pin 2
Install
1. The installation procedure is the opposite of the
removal procedure.
03 - 10 9823/1650-1 03 - 10
82 - Jib
82 - Jib
Contents Page No.
03-82-00 General ........................................................................................................................... 03-13

03-82-06 Shackle ........................................................................................................................... 03-15
03 - 11 9823/1650-1 03 - 11
Notes:
03 - 12 9823/1650-1 03 - 12
82 - Jib
00 - General
Introduction .................................................... 03-13
Health and Safety .......................................... 03-14
Safety
Read and understand all the warning messages.
Follow all the safety instructions given in this
Operator Manual. Do not install/operate an
attachment until you are sure that you can operate it.
Use the attachment only if it carries up to date test

certificates.
Operation
You must obey the following precautions when using
this attachment.
• Before you lift or manoeuvre a load with the

attachment, check the appropriate load chart in
the cab and understand the lift capacities.
• Make sure the machine is in a level position.
If necessary, reposition the machine using
chassis levelling control or stabilisers (if fitted).
• Use the lifting shackle which is suitable for the
job, in good condition and proof tested where
necessary.
• Always sling the load safely and in accordance
with any local regulations.
• Make sure that the hook safety catch is closed
correctly to prevent the sling(s) from slipping off
the hook.
• Always lift the load carefully, to avoid snatching
the sling(s).
• Keep yourself and other people clear of a
suspended load, especially from beneath the
load.
• Always remember that the effective length of
the boom is increased when an attachment is
installed. Before manoeuvring the machine with
an attachment make sure you have sufficient
clearance.
• You must be careful while carrying a suspended
load. Keep the load as low to the ground
as possible. If necessary, use guide ropes to
prevent the load from swinging.
• Always travel in 1st gear at walking speed when
carrying a suspended load. Wherever possible,
travel on firm, level ground. Avoid rough or
excessively uneven ground.
• Do not carry suspended loads on public roads.
• Always be aware of the affects of wind velocity
on the load being handled.
03 - 13 9823/1650-1 03 - 13
82 - Jib
00 - General
Health and Safety

WARNING This attachment has a maximum safe
working load. Do not exceed the safe working
load. Do not exceed the machine stability limits
shown on the load chart(s) in the cab.
WARNING Load and unload on firm, level ground.
Always be alert for possible hazards. Take special
care when turning or reversing.
WARNING The attachment is heavy. Take care
when lifting and handling it. Use suitable lifting
equipment. Make sure the lifting equipment is in
good condition. Make sure the lifting equipment
complies with all pertinent regulations. Wear
gloves and safety shoes.
WARNING Refer to the load chart in the cab for
permissible loading for each position of the jib
extension.
03 - 14 9823/1650-1 03 - 14
82 - Jib
06 - Shackle
06 - Shackle
Introduction
This a Q-fit attachment. It gives your machine greater Figure 7.

reach and height. This attachment is supplied with
test certificates for its fabrication, its hook and its D
shackle. The safe working load is stamped on a plate
mounted on the attachment.
Figure 6.
A F
G
A Roof truss jib
B Hook B
Installing/Removing
A
The attachment is heavy. Take care when lifting
and handling it. Use suitable lifting equipment. Make
sure the lifting equipment is in good condition. Make C
sure the lifting equipment complies with all relevant
regulations. Wear gloves and safety shoes. A Skid
B Lynch pin
The installation will be easier if the attachment is C Pin
rested on wooden blocks. D Jib- fully extended
E Jib- extended position 1
Store the attachment carefully to prevent damage F Jib- extended position 2
and corrosion. G Jib- fully retracted
Extending the Jib 1. Remove the load and lower the jib to the ground.
2. Make sure the skid is supporting the weight of
The jib may be extended to one of four positions:
the jib.
3. Remove the lynch pin, then pin.
4. Move the jib extension to the required position;
fully extended or fully retracted.
5. Insert the pin and secure with lynch pin.
Changing the Jib Angle

The angle of the jib may be set in one of two
positions.
03 - 15 9823/1650-1 03 - 15
82 - Jib
06 - Shackle
• Placing position • Travel position
Figure 8.
A B
D F
C E
C
A Placing position B Travel position

C Lynch pin D Stops
E Bar F Stops
When in the travel position, do not extend the boom

and do not raise the boom more than 45 °
To change the jib position:
1. Remove the load and lower the jib to the ground.

2. Make sure the skid is supporting the weight of
the jib.
3. Remove the lynch pin, then pin.
4. Use the tilt control in the cab to rotate the carriage
until the holes align in the required position.
Stops will prevent excessive movement of the jib.
5. Insert the bar and secure with lynch pin.
03 - 16 9823/1650-1 03 - 16
84 - Hook
84 - Hook
Contents Page No.
03-84-06 Snatch Block .................................................................................................................. 03-19
03 - 17 9823/1650-1 03 - 17
Notes:
03 - 18 9823/1650-1 03 - 18
84 - Hook
06 - Snatch Block
06 - Snatch Block Introduction

Introduction .................................................... 03-19 The fork mounted hook allows the machine to carry
Remove and Install ....................................... 03-20 slung loads with safety. It incorporates a swivel hook
with a spring loaded safety catch. This attachment is
supplied with test certificates for its fabrication and
its hook. Its safe working load is stamped on a plate
mounted on the attachment.
03 - 19 9823/1650-1 03 - 19
84 - Hook
06 - Snatch Block
Remove and Install 3.4. Make sure that both mounting brackets are
installed securely.
Figure 9.
C A
A Mounting sockets
B Lynch pin
C Locking bar
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Lower the attachment so that it just clears the
ground.
3. Apply the park brake and stop the engine.
4. Remove the attachment.
4.1. Remove the lynch pin and locking bar.
4.2. Carefully slide the attachment off the forks.
4.3. Install the locking bar and secure with lynch
pin.
4.4. Store the attachment carefully to prevent
damage and corrosion.
Install
1. Space the forks, equally on either side of the
machine centreline, so that the mounting sockets
can be slid onto them.
2. Tighten the fork clamping screws to prevent
movement.
3. Install the attachment.
3.1. Remove the lynch pin and locking bar.
3.2. Slide attachment over the forks so that the
rear of the attachment butts against the
heels of the forks.
3.3. Install the locking bar and secure with lynch
pin.
03 - 20 9823/1650-1 03 - 20
Contents Page No.
06-00 Body and Framework

06-00-00 General ............................................................................................................................. 06-3
06-03 Chassis
06-03-00 General ............................................................................................................................. 06-7
06-06 Moveable Panel and Cover
06-06-00 General ........................................................................................................................... 06-11
06-06-03 Battery Compartment ..................................................................................................... 06-12
06-06-06 Engine Compartment ..................................................................................................... 06-13
06-12 Lift Arm
06-12-00 General ........................................................................................................................... 06-19
06-12-66 Chain .............................................................................................................................. 06-28
06-30 Pivot Pins
06-30-00 General ........................................................................................................................... 06-31
06-42 Stabiliser
06-42-00 General ........................................................................................................................... 06-35
06-54 Fender
06-54-00 General ........................................................................................................................... 06-41
06-63 Identification Label
06-63-00 General ........................................................................................................................... 06-45
06-63-06 Engine ............................................................................................................................ 06-46
06-63-15 Operator Protective Structure ........................................................................................ 06-48
06-66 Tools
06-66-00 General ........................................................................................................................... 06-51
06-69 Maintenance Strut
06-69-00 General ........................................................................................................................... 06-53
06-69-03 Lift Arm ........................................................................................................................... 06-54
06-75 Fire Extinguisher
06-75-00 General ........................................................................................................................... 06-59
06-89 Window Guard
06-89-00 General ........................................................................................................................... 06-61
9823/1650-1
2018-06-05
Acronyms Glossary

OECD Organization for Economic
Cooperation and Development
9823/1650-1
2018-06-05
Contents Page No.
06-00-00 General ............................................................................................................................. 06-3
06 - 1 9823/1650-1 06 - 1
Notes:
06 - 2 9823/1650-1 06 - 2
00 - General
00 - General Clean
Clean ............................................................... 06-3 Keep all intakes and grilles clear from snow, ice and
Check (Condition) ............................................ 06-4 debris.
Debris can collect under the boom. Remove all

debris from under the boom.
Thoroughly dry the piston rams and protect them with

clean transmission or hydraulic oil if necessary.
06 - 3 9823/1650-1 06 - 3
00 - General
Check (Condition)
1. Make sure that all of the guards and protective
devices are in position, secured by their locking
devices and free from damage.
2. Inspect all of the steelwork for damage. Include
the following:
2.1. Examine all of the lifting point welds.
2.2. Examine all of the pivot point welds.
2.3. Examine the condition of all the pivot pins.
2.4. Check that the pivot pins are correctly
in position and secured by their locking
devices.
3. Check the steps and handrails are undamaged
and correctly attached.
4. Check for broken, cracked or crazed window
glass and mirrors. Replace the damaged items.
4.1. The right hand side cab glass is installed
for the operators protection. If the cab glass
becomes damaged, the machine should not
be operated until it has been replaced.
5. Check that the lamp lenses are undamaged.
6. Check that all of the attachment teeth are
undamaged and correctly attached.
7. Check that all of the safety and instructional
labels are undamaged and in position. Install new
labels where necessary.
8. Note any damaged paintwork for future repair.
9. Inspect the machine for broken or loose
fasteners.
06 - 4 9823/1650-1 06 - 4
03 - Chassis
03 - Chassis
Contents Page No.
06-03-00 General ............................................................................................................................. 06-7
06 - 5 9823/1650-1 06 - 5
Notes:
06 - 6 9823/1650-1 06 - 6
03 - Chassis
00 - General
Introduction ...................................................... 06-7 The chassis is the underpart of the vehicle or
Health and Safety ........................................... 06-8 machine, consisting of the frame on which the body
or cab is mounted.
06 - 7 9823/1650-1 06 - 7
03 - Chassis
00 - General
Health and Safety

CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
06 - 8 9823/1650-1 06 - 8
06 - Moveable Panel and Cover
Contents Page No.
06-06-00 General ........................................................................................................................... 06-11

06-06-03 Battery Compartment ..................................................................................................... 06-12
06-06-06 Engine Compartment ..................................................................................................... 06-13
06 - 9 9823/1650-1 06 - 9
Notes:
06 - 10 9823/1650-1 06 - 10
00 - General
00 - General
Introduction
When moved to their maintenance position, the

access panels give you access to parts or areas of
the machine that are not required during machine
operation.
Before you operate the machine, make sure that all

of the access panels are correctly in their closed or
installed positions.
06 - 11 9823/1650-1 06 - 11
03 - Battery Compartment
03 - Battery Compartment
Remove and Install
Notice: Do not stand on the battery cover. 2. Hold the battery cover, then remove the bolts.
3. Lower the cover.
Open
Figure 10.
A B
A Bolts B Battery cover
Close
1. Close the battery compartment cover.
2. Hold the battery cover closed, then install the
bolts.
3. Tighten the bolts to the correct torque value.
06 - 12 9823/1650-1 06 - 12
06 - Engine Compartment
06 - Engine Compartment Open and Close

Open and Close ............................................ 06-13
Remove and Install ....................................... 06-14
Open
WARNING The engine has exposed rotating
parts. Switch off the engine before working in the
engine compartment. Do not use the machine
with the engine cover open.
Access to the engine compartment is provided by

opening the engine cover.
Before you stop the engine, you must let the engine
run at low idle for 4 min. The delay lets the coolant
temperature to stabilise before you open the engine
cover.

2. Unlock and release the latch. Allow the cover to
raise on its gas strut. Keep hold of the cover while
it rises.
Figure 11.
A B
A Engine cover
B Latch
Close
1. Push the cover down.
2. Make sure that the cover is correctly latched.
3. Make sure to lock the engine cover.
06 - 13 9823/1650-1 06 - 13
Remove and Install
CAUTION The exhaust pipe becomes extremely 4. Support the cover using suitable overhead lifting
hot when the engine is running and will remain so equipment.
for some time after the engine is stopped. If you
touch the hot pipe you could be severely burned. 5. Remove the gas strut mount securing nut and
remove the strut from the support bracket.
A typical engine cover removal and installation 6. Remove the hinge bolts.
procedure is given below. Your machine may differ
from that shown. 7. Take the top engine cover away from the
machine with the lifting equipment.
Remove 8. Remove the exhaust outlet pipe. Refer to fuel
1. Make the machine safe. Refer to (PIL 01-03). system- Exhaust. Refer to (PIL 18-24).
2. Follow the general safety precautions. Refer to 9. Support the engine pod base.
(PIL 01-03). 10. Remove the bolts and washers and lower the
3. Open the engine compartment cover. Refer to engine pod complete along with the guards to the
(PIL 06-06) ground.
06 - 14 9823/1650-1 06 - 14
Figure 12.
A
D
C
G
F
A Engine pod cover B Hinge bolts

C Support bracket D Strut mount securing nut
E Engine pod base F Bolts
G Washers
06 - 15 9823/1650-1 06 - 15
Install
removal procedure. Additionally do the following
steps.
1.1. Tighten the bolts to the specified torque
value.
1.2. Tighten the strut mount securing nut to the
specified torque value.
Table 3. Torque Values

Item Description Nm
B Hinge bolts 18
D Strut mount securing nut 18
06 - 16 9823/1650-1 06 - 16
12 - Lift Arm
12 - Lift Arm
Contents Page No.
06-12-00 General ........................................................................................................................... 06-19

06-12-66 Chain .............................................................................................................................. 06-28
06 - 17 9823/1650-1 06 - 17
Notes:
06 - 18 9823/1650-1 06 - 18
12 - Lift Arm
00 - General
Introduction .................................................... 06-19
Hydraulic Ram and Chain Operated Lift
Arms
Operation ....................................................... 06-22
Calibrate ........................................................ 06-27 Twin lift rams operate the lift arm raise and lower
function. A single displacement ram is hydraulically
connected to the tilt ram and operates a parallel lift
feature.
The telescopic lift arm function is actuated by a single

hydraulic extension ram which extends or retracts
the 1st intermediate lift arm section. As the ram
moves the intermediate lift arm section a system of
chains extend or retract the inner lift arm section.
On 4 stage lift arm machines shown in this service

manual, there is an extra intermediate lift arm
section, also operated by chains. All the lift arm
sections extend/retract at the same time.
Clearance between the lift arm sections is

maintained by sets of wear pads and shims.
Refer to body and framework, lift arm, general,

component identification. Refer to: PIL 06-12-00.
All intermediate and inner lift arm sections slide

against adjustable / replaceable wear pads installed
in the lift arm sections. Refer to: PIL 06-12-00. Refer
to: PIL 06-12-24.
Table 4.
Machine Lift Arm
506-36 3 Section, 3 stage
Refer to body and framework, lift arm, general,

component identification. Refer to: PIL 06-12-00.
All lift arm sections are identified in a similar way

irrespective of the number of sections or method of
operation. Not all types of lift arm are installed on
the machines shown in this service manual. Refer to
Figure 13.
06 - 19 9823/1650-1 06 - 19
12 - Lift Arm
00 - General
Figure 13. Common Lift Arm Configurations

E
A
E
A B
A B C
A B D
C
A Outer lift arm section
B Intermediate lift arm section (identified as
intermediate section 1 on H and J)
C Intermediate lift arm section 2
D Intermediate lift arm section 3
E Inner lift arm section
F 2 Stage, 2 section lift arm
G 3 Stage, 3 section lift arm
H 4 Stage, 4 section lift arm
J 5 Stage, 5 section lift arm
06 - 20 9823/1650-1 06 - 20
12 - Lift Arm
00 - General
Health and Safety

Lifting Equipment
equipment. You must identify the weight of the item to
equipment is in good condition and complies with all
local regulations.
DANGER! Before removing the boom from the
machine, make sure that the counterweight is
adequately supported as in certain ground conditions
the machine could tip backwards. Never travel or
transport the machine with the boom removed.
CAUTION! Make sure you know the weight of the
load before trying to lift it. Raise the load only a
few centimetres at first, to check that the machine is
stable. Lower the load straight away if the machine
begins to feel unstable. Do not exceed the loading
limits shown on the Load Charts.
CAUTION! This component is heavy. It must only be
removed or handled using a suitable lifting method
and device.
WARNING! The limits shown on the load charts are
for a stationary, level machine. Do not raise or extend
the lift arm while the machine is moving. Retract the
lift arm fully and lower it as far as possible before you
travel with a load.
WARNING! Under no circumstances should
personnel be lifted into the air without using an
approved and properly secured platform. Failure to
follow this warning could result in death or serious
injury.
WARNING! Do not work under raised lift arms
unless they are adequately supported by stands and/
or slings.
WARNING! You could be killed or injured if the
boom drops while you are working under it. Install the
boom maintenance strut as instructed before doing
any maintenance work with the boom raised. Keep
people away from the machine while you install or
remove the boom maintenance strut.
WARNING! Make sure the machine cannot tip
over when this component (or components) is (are)
removed during this operation.
06 - 21 9823/1650-1 06 - 21
12 - Lift Arm
00 - General
Operation
For: 4 Stage (4 Section) ............ Page 06-22 Lift arm extend 4 stage (4 section) lift arm
For: 3 Stage (3 Section) ............ Page 06-26
When the controls are moved to extend the lift arm,
hydraulic ram extends. The piston rod pushes the
(For: 4 Stage (4 Section)) 1st intermediate lift arm section out from the outer lift
arm.
Telescopic Operation Introduction
At the same time the chain roller 1 attached to lift
Refer to Lift Arm- Introduction (PIL 06-12-00). arm section, causes extension chain 2 to pull the 2nd
intermediate lift arm section out from lift arm the 1st
intermediate lift arm.
Figure 14.
G
F
H
E
D C B A
At the same time the chain roller 2 attached to

the 2nd intermediate lift arm section, causes the
Table 5. extension chain 1 to pull the inner lift arm out from
Item Description the 2nd intermediate lift arm.
A Outer lift arm
Lift arm retract 4 stage (4 section) lift arm
B 1st intermediate lift arm
C 2nd intermediate lift When the controls are moved to retract the lift arm,
arm
(1)
the hydraulic ram retracts. The piston rod pulls the
D Inner lift arm 1st intermediate lift arm section inside the inner lift
arm 1.
E Extension chain 1
F Extension chain 2 At the same time the chain roller 3 attached to the 1st
G Chain roller 1 intermediate lift arm section, causes the retraction
H Chain roller 2 chain 1 to pull the 2nd intermediate lift arm section
inside the 1st intermediate lift arm section.
J Piston rod
K Hydraulic ram
(1) 4 section lift arm only
06 - 22 9823/1650-1 06 - 22
12 - Lift Arm
00 - General
Figure 15.
D C B A
P M
N L
J
K
retraction chain 2 to pull the inner lift arm section

inside the 2nd intermediate lift arm section.
Table 6.
Item Description Hydraulic hoses and pipes 3 stage (3
A Outer lift arm section) lift arm
B 1st intermediate lift arm
When the lift arm extends and retracts, the hydraulic
C 2nd intermediate lift hoses and pipes connected to the tilt and auxiliary
arm
(1)
services extend and retract at the same time.
D Inner lift arm
J Piston rod Extend
K Hydraulic ram
When the lift arm extends the extend ram pulls the
L Chain roller 3 intermediate lift arm out from inside the outer lift arm.
M Retraction chain 1 At the same time the chain system extends the inner
N Chain roller 4 lift arm.
P Retraction chain 2
The hydraulic hoses are clamped to the outer lift arm
(1) 4 section lift arm only and inner lift arm sections and are pulled out with the
lift arm sections.
At the same time the chain roller 4 attached to
the 2nd intermediate lift arm section, causes the
Figure 16.
C B A
A Outer lift arm B Intermediate lift arm

C Inner lift arm K Hydraulic ram
Q Guide roller
06 - 23 9823/1650-1 06 - 23
12 - Lift Arm
00 - General
A guide roller is fixed to the intermediate lift arm. The The hydraulic hoses are clamped to the outer lift arm
guide roller controls the hoses as they transfer from and inner lift arm sections and are pulled out with the
inside the outer lift arm to inside the inner lift arm lift arm sections.
section.
Retract
When the lift arm retracts the extend ram pulls the
intermediate lift arm inside the outer lift arm. At the
same time the chain system retracts the inner lift arm.
Figure 17.
C B A
A Outer lift arm B Intermediate lift arm

C Inner lift arm K Hydraulic ram
Q Guide roller
A guide roller is fixed to the intermediate lift arm Extend

section. The guide roller controls the hoses as they
transfer from inside the inner lift arm section to the When the lift arm extends, the extend ram pulls the
outer lift arm. 1st intermediate lift arm out from the outer lift arm.
At the same time the chain system extends the 2nd
Hydraulic hoses and pipes 4 stage (4 intermediate lift arm and the inner lift arm.
section) lift arm The hydraulic hoses are pulled out with the lift arm
sections by the inner lift arm pipe assembly, which
When the lift arm extends and retracts, the hydraulic
is fixed to the rear of the 2nd intermediate lift arm.
hoses and pipes connected to the tilt and auxiliary
A guide bracket at the front of the pipe assembly
services extend and retract at the same time.
moves inside the inner lift arm as it extends. The
guide bracket is installed with nylon wear pads.
Figure 18.
D C B A
R
A Outer lift arm B 1st intermediate lift arm

C 2nd intermediate lift arm D Inner lift arm
K Hydraulic ram Q Guide roller
06 - 24 9823/1650-1 06 - 24
12 - Lift Arm
00 - General
R Inner lift arm pipe assembly
A guide roller is fixed to the 1st intermediate lift arm arm. At the same time the chain system retracts the
section. The guide roller controls the hoses as they 2nd intermediate lift arm section and the inner lift
transfer from inside the outer lift arm to inside the 1st arm.
intermediate lift arm section.
The hydraulic hoses are pulled in with the lift arm
Retract sections by the inner lift arm pipe assembly, which
is fixed to the rear of the 2nd intermediate lift arm
When the lift arm retracts, the extend ram pulls the section. The guide bracket at the front of the pipe
1st intermediate lift arm section inside the outer lift assembly moves inside the inner lift arm as it retracts.
The guide bracket is installed with nylon wear pads.
Figure 19.
R D C B A
A Outer lift arm B 1st intermediate lift arm

C 2nd intermediate lift arm D Inner lift arm
K Hydraulic ram Q Guide roller
R Inner lift arm pipe assembly
A guide roller is fixed to the 1st intermediate lift arm transfer from inside of the 1st intermediate lift arm
section. The guide roller controls the hoses as they section to inside the outer lift arm.
06 - 25 9823/1650-1 06 - 25
12 - Lift Arm
00 - General
(For: 3 Stage (3 Section))
Figure 20. Telescopic Operation- 3 Stage (3 Section) Lift Arm

A B C D E J
F K G H
A Outer section B Intermediate section

C Inner section D Outer extension ram
E Inner extension ram F Hose guide roller
G Wear pad H Tilt ram
J Example hose routing- auxiliary service K Wear pad- inner extension ram
The telescopic boom consists of three sections, an To ensure the reliable operation of the telescopic
inner, intermediate and outer section. function it is critical that the hoses are routed and
fitted correctly.
When the boom is extended or retracted the inner
and outer sections move simultaneously. This is To ensure the correct clearances and smooth
achieved by hydraulically interconnecting the inner movement between the boom sections, special wear
and outer extension rams. For an explanation of the pads together with shims are fitted. Wear pads are
hydraulic operation refer to (PIL 30-00). fitted at the top, bottom and sides at both ends of
the boom sections. The inner extension ram is also
From the diagrams we can see that the hydraulic fitted with a wear pad since the inner boom moves in
hoses connected to the tilt ram, auxiliary service relation to the ram cylinder.
and inner extension ram (telescopic services) are
arranged to follow the movement of the inner and
intermediate boom sections. As the boom extends
the hose runs at the bottom of the inner boom are
drawn around the guide roller and along the top of
the inner extension ram.
If the inner and intermediate booms move out of

phase the telescopic service hoses will be damaged.
Should a hose of the incorrect length be fitted
damage can also occur.
06 - 26 9823/1650-1 06 - 26
12 - Lift Arm
00 - General
Calibrate 8. Make sure that the difference in shim thickness of

shim 1 and shim 2 does not exceed the specified
value.
When the boom is assembled, do a check of
Length/Dimension/Distance: 3.2 mm
the carriage alignment to make sure that the
measurement is accurate. 9. Make sure that the maximum wear pad clearance
does not exceed the specified value.
Length/Dimension/Distance: 3 mm
2. Make sure that the tyre pressures are correct.
Figure 23.
3. Make sure that the machine is parked on flat level
ground.
B
4. Check the inclinometer to make sure that the
chassis is level.
Figure 21.
A
A Inclinometer
5. Measure the left and right side carriage height
from the ground to the top of the carriage and C F
D E
note the dimensions.
B Maximum wear pad clearance
Figure 22. C Lower wear pad 1
D Lower wear pad 2
E Shim 1
F Shim 2
X Y
X Left side dimension

Y Right side dimension
6. If there is a difference between left and right side
dimension, the front lower wear pads 1 and wear
pads 2 can be shimmed.
7. Add or remove the shim 1 and shim 2 as
necessary to align the carriage. Refer to adjust
(PIL 06-12-30).
06 - 27 9823/1650-1 06 - 27
12 - Lift Arm
66 - Chain
66 - Chain
Clean
CAUTION You must climb on the machine to
install or remove the central access panels. Take
care, especially if the machine is wet. Remove
mud and oil before you climb on the machine. Do
not put your body weight on the central access
panels.
CAUTION Make sure the steps, handrails, and
your footwear soles are clean and dry before
climbing onto the machine. Always face the
machine when climbing on and off it.
1. Make the machine safe with the boom raised.

Refer to: PIL 01-03-27.
2. Debris can collect under the boom. Remove all
combustible material.
3. Do not aim the jet wash directly at the boom
chains.
Figure 24.
06 - 28 9823/1650-1 06 - 28
30 - Pivot Pins
30 - Pivot Pins
Contents Page No.
06-30-00 General ........................................................................................................................... 06-31
06 - 29 9823/1650-1 06 - 29
Notes:
06 - 30 9823/1650-1 06 - 30
30 - Pivot Pins
00 - General
Introduction .................................................... 06-31 Pivot pins are a short shaft or pin that supports
Lubricate ........................................................ 06-32 something that turns. Pivot pins are installed in
Remove and Install ....................................... 06-32 numerous positions on the machine. There is usually
a greasing point associated with the pivot pin.
Make sure that the pivot points are greased at
regular intervals. Refer to the Machine Maintenance
Schedules. Refer to: PIL 78-24.
Slide Hammer Kit

The slide hammer kit is used to remove pivot pins that
must be extracted, i.e. cannot be 'knocked through'.
The purpose of this description is to explain how the
kit and the various components are used to remove
the pivot pins.
The adaptors that form part of the kit have a screwed

thread at each end. One of the threads will always
be M20 size, this is to accommodate the end stops.
The other end of the adaptor will have varying thread
sizes to suit the different size of threads in the pivot
pins.
06 - 31 9823/1650-1 06 - 31
30 - Pivot Pins
00 - General
Lubricate Remove and Install

Special Tools
Extension Ram Pivot Pin Description Part No. Qty.
Slide Hammer Kit 993/68100 1
Use another pivot pin to support the ram while
greasing the other pivot pin. Make a note that the illustration shows a typical pivot
pin. The actual pivot pin installed on the machine may
1. Make the machine safe. Refer to (PIL 01-03). look different.
2. Follow the general health and safety procedures. 1. Prepare the pivot pin for removal, remove the
Refer to (PIL 01-03). locking device e.g. pivot pin retaining bolt.
3. Remove the inner extension ram pivot pin and 2. Prepare the slide hammer kit.
apply waxoyl. Refer to (PIL 06-30).
Special Tool: Slide Hammer Kit (Qty.: 1)
4. Install the inner extension ram pivot pin.
2.1. Install the slide hammer onto the slide bar.
5. Remove the tilt ram pivot pin and coat with
waxoyl. Refer to (PIL 06-30). 2.2. Determine the thread size of the pivot pin
and then install the appropriate adaptor.
6. Install the tilt ram pivot pin. Use the spanner flats to securely install the
adaptor.
Figure 25.
2.3. Install an end stop onto the other end of the
adaptor (M20 thread size), make sure that
the adaptor threads are fully engaged.
2.4. Install the slide bar into the end stop. Make
sure that the threads are fully engaged.
2.5. Finally install the other end stop at the end
of the slide bar. The slide hammer kit is now
ready to use.
A B 3. To extract the pivot pin, slide the hammer along
the bar until it contacts the end stop. Repeat this
step until the pivot pin is released.
4. To remove the slide hammer kit, reverse steps 2
to 3.
A Inner extension ram pivot pin

B Tilt ram pivot pin
06 - 32 9823/1650-1 06 - 32
30 - Pivot Pins
00 - General
Figure 26. Typical Machine
A Adaptor
B End stop
C End stop
D Spanner flats
E Slide bar
F Slide hammer
06 - 33 9823/1650-1 06 - 33
42 - Stabiliser
42 - Stabiliser
Contents Page No.
06-42-00 General ........................................................................................................................... 06-35
06 - 34 9823/1650-1 06 - 34
42 - Stabiliser
00 - General
Introduction .................................................... 06-35 The stabilisers are a safety device to stop the
Health and Safety .......................................... 06-36 machine tipping over when the lift arm is extended.
There are two stabiliser legs. The stabiliser legs
can be deployed by controls in the cab, to give
the machine added stability when the machine is
stationary.
06 - 35 9823/1650-1 06 - 35
42 - Stabiliser
00 - General
Health and Safety

WARNING The stability of the machine can
be reduced when you use the lift arm without
stabilisers. Before using the lift arm make sure the
stabilisers are set on stable ground.
WARNING You must be sitting in the operators
seat when operating the machines lift arm,
stabiliser or drive controls.
WARNING Bystanders could be crushed and
obstacles could be damaged if they are beneath
the stabilisers while they are being lowered.
Before lowering the stabilisers, make sure any
bystanders are clear of the machine. Also make
sure that there are no obstacles beneath the
stabilisers.
Notice: Before you extend the boom make sure
that the stabiliser legs are deployed to the ground
and the weight of the machine is supported.
06 - 36 9823/1650-1 06 - 36
42 - Stabiliser
00 - General
Remove and Install
6. Remove the bolts.

(For: 512-56 [T4i], 514-56 [T4i]) 7. Move the plate to get access to the electrical
Make sure you use the correct lifting equipment. The connector.
stabiliser assembly weighs approximately 700 kg 8. Disconnect the connector.
Remove 9. Label the hydraulic hoses and disconnect the

hoses from the inside of bulkhead connectors.
1. Lower the stabilisers but keep them clear of the
ground. 10. Pull the hoses and electrical harness back
through the opening of the chassis.
2. Make the machine safe with the lift arm raised.
Refer to (PIL 01-03). 11. Remove the frame to axle fasteners. Keep the
washers.
3. Install the maintenance strut. Refer to (PIL
06-69). 12. Use the lifting equipment to pull the assembly
forward and disengage the pivot from the nose
4. Put supports under the chassis on both sides of fabrication.
the machine.
13. Remove the spacer assemblies.
5. Support the stabiliser frame with suitable lifting
equipment.
06 - 37 9823/1650-1 06 - 37
42 - Stabiliser
00 - General
Figure 27.
J C
K E
C
E
B
H
A B
G
F
E
G A D
Table 7. Item Description

Item Description J Electrical connector
A Stabiliser frame K Washers
B Bolts
C Bulkhead connectors Install
D Opening of the chassis 1. The installation procedure is the opposite of the
E Axle fasteners removal procedure. Additionally do the following
F Pivot steps.
G Spacer assemblies 1.1. Check the condition of the pivot bush. If
H Plate necessary replace the bush with a new one.
06 - 38 9823/1650-1 06 - 38
42 - Stabiliser
00 - General
Figure 28.
L Pivot bush
1.2. Check the condition of the pivot pin. If

necessary replace the pin with a new one.
1.3. Correctly install the spacer assemblies.
1.4. Washers are hardened. You must use the
correct washers.
1.5. Tighten the fasteners of the specified length
to the correct torque value.
1.6. Grease the stabiliser frame pivot. Refer to
(PIL 01-03-27).
1.7. Check the operation of the stabilisers.
1.8. Check the hydraulic fluid level. Refer to (PIL
30-00).
06 - 39 9823/1650-1 06 - 39
54 - Fender
54 - Fender
Contents Page No.
06-54-00 General ........................................................................................................................... 06-41
06 - 40 9823/1650-1 06 - 40
54 - Fender
00 - General
00 - General
Remove and Install
Top Guard Assembly 2.1. If the washers on top of the fender are
metal, discard them and obtain the correct
Remove new nylon shoulder washers.
1. Make the machine safe. Refer to (PIL 01-03). 3. Remove the lower saddle clamp.
2. Remove the nuts, bolts and washers. 4. Lift off the fender cover.
5. Inspect the fender for cracks, particularly around
the mounting holes.
Figure 29.
A
E B
A Bolts B Fender cover

C Lower saddle clamp D Nuts
E Washers
5.1. Also check all other fenders on the machine Figure 30.
for cracks.
5.2. If cracks are found, discard the fender and
install a new one.
Install
L
steps.
1.1. Make sure you install the correct nylon
shoulder washers. Do not reuse metal
washers (if they were installed originally).
L Nylon shoulder washer
06 - 41 9823/1650-1 06 - 41
54 - Fender
00 - General
1.2. Drill out the fender mounting holes to the 2. Remove the road wheel if greater access is
specified diameter and de-burr the hole if necessary. Refer to (PIL 27-29).
required.
3. Remove the top guard assembly.
1.3. Make sure the shoulder washers are 4. Remove the mounting arm bolts, nuts and
located correctly in the fender hole. washers.
1.4. Tighten the nuts to the specified torque 5. Remove the arm assembly.
value.
6. Remove the support bracket nuts.
Torque: 14 N·m
7. Remove the bracket from the trunnion studs.
Complete Fender Assembly
Remove
Figure 31.
P
N
M
R
S
M Mounting arm nuts N Mounting arm washers

P Arm assembly Q Mounting arm bolts
R Bracket S Support bracket fastenings
Install Table 8. Torque table

1. The installation procedure is the opposite of the Item Value
removal procedure. Additionally do the following M 28 N·m
step. S
(1)
139 –154 N·m
1.1. Tighten the bracket nuts to the correct S
(2)
28 N·m
torque value. (1) 550-80 machines.
(2) Other machines.
06 - 42 9823/1650-1 06 - 42
63 - Identification Label
Contents Page No.
06-63-00 General ........................................................................................................................... 06-45

06-63-06 Engine ............................................................................................................................ 06-46
06-63-15 Operator Protective Structure ........................................................................................ 06-48
06 - 43 9823/1650-1 06 - 43
Notes:
06 - 44 9823/1650-1 06 - 44
00 - General
00 - General
Introduction
The machine has identification plates that contain

important information relating to the specific machine
details, for example VIN or PIN number and engine
serial number. These serial numbers can help you
identify exactly what equipment has been installed
on the machine.
06 - 45 9823/1650-1 06 - 45
06 - Engine
06 - Engine
The engine data labels are attached to the cylinder

block as shown.
Figure 32.
B
A C
A Engine data label - rocker cover B Engine identification number

C Stamp
The data label includes the engine identification

number.
Table 9. Example of the engine identification number

SH 320/40001 U 00001 04
Digit 1-2 3-10 11 12-16 17-18
Table 10.
Digit 1-2 Engine Type
DA 4.8 L naturally aspirated mechanical fuel injection (Tier 2)
DB 4.8 L turbocharged mechanical fuel injection (Tier 2)
DC 4.8 L turbocharged and aftercooled mechanical fuel injection (Tier 2)
DE 4.8 L turbocharged and aftercooled electronic common rail fuel injection (Tier 2)
DD 4.8 L turbocharged mechanical fuel injection (Tier 3)
DF 4.8 L turbocharged and aftercooled mechanical fuel injection (Tier 3)
DK 4.8 L turbocharged and aftercooled electronic common rail fuel injection (Tier 3)
DH 4.8 L turbocharged and aftercooled electronic common rail fuel injection (Tier 4i)
DJ 4.8 L turbocharged and aftercooled electronic common rail fuel injection (Tier
4F)
FL 3 L turbocharged and aftercooled electronic common rail fuel injection (Tier 4F
SEF > 55 kW)
SA 4.4 L naturally aspirated mechanical fuel injection (Tier 2)
SB 4.4 L turbocharged mechanical fuel injection (Tier 2)
SC 4.4 L turbocharged and aftercooled mechanical fuel injection (Tier 2)
SD 4.4 L turbocharged mechanical fuel injection (Tier 3)
06 - 46 9823/1650-1 06 - 46
06 - Engine
Digit 1-2 Engine Type

SE 4.4 L turbocharged and aftercooled electronic common rail fuel injection (Tier 3)
SF 4.4 L turbocharged and aftercooled mechanical fuel injection (Tier 3)
SH 4.4 L turbocharged and aftercooled electronic common rail fuel injection (Tier 4i)
SJ 4.4 L turbocharged and aftercooled electronic common rail fuel injection (Tier
4F)
SL 4.4 L turbocharged and aftercooled electronic common rail fuel injection (Tier 4F
55kw)
Table 11. Explanation of the engine identification number

Digit Explanation
3-10 Engine part number
11 Country of manufacture. U = United Kingdom
12-16 Engine serial number
17-18 Year of manufacture
The country of manufacturer, engine serial number

and year of manufacture of the engine are also
stamped on the crankcase. Refer to Figure 32.
06 - 47 9823/1650-1 06 - 47
15 - Operator Protective Structure
15 - Operator Protective Structure certification. If damage has occurred then an

authorised JCB dealer should be consulted.
Component Identification A machine with a ROPS (Roll-Over Protective

WARNING You could be killed or seriously injured Structure) can be identified by referring to the
if you operate a machine with a damaged or cab identification plate. Work place (work site, job
missing ROPS/FOPS/FOGS. If the ROPS/FOPS/ site) risk assessment should facilitate the machine
FOGS has been in an accident, do not use the selection and the need for an machine with a ROPS.
machine until the structure has been renewed.
Modifications and repairs that are not approved Figure 33.
by the manufacturer may be dangerous and will
invalidate the ROPS/FOPS/FOGS certification.
WARNING Machines with a ROPS, FOPS,FOGS
or TOPS are equipped with a seat belt. The
ROPS, FOPS,FOGS or TOPS is designed to give
you protection in an accident. If you do not wear
the seat belt you could be thrown off the machine
Data plate - ROPS/FOPS standards
and crushed. You must wear a seat belt when
using the machine. Fasten the seat belt before Figure 34.
starting the engine.
FOPS Data Plate

WARNING Do not use the machine if the falling
objects protection level provided by the structure
is not sufficient for the application. Falling objects
can cause serious injury. Data plate - ROPS/FOPS and OECD
(Organization for Economic Cooperation and
If the machine is used in any application where there Development) standards
is a risk of falling objects then a FOPS (Falling Object
Protective Structure) must be installed. For further Protection Offered by the Cab
information, contact your JCB dealer.
Definition of Category 1
The FOPS has a data plate attached. The data
plate indicates what level of protection the structure The Cab meets the requirements defined in EN
provides. 15695-1. This means that the air delivery and
filtration system does not provide a specified level
There are two levels of FOPS: of protection against hazardous substances but only
from external atmospheric conditions (e.g. rain, wind,
• Level I Impact Protection - impact strength snow etc.).
for protection from small falling objects
(e.g. bricks, small concrete blocks, hand
Definition of Category 2
tools) encountered in operations such as
highway maintenance, landscaping and other The Cab meets the requirements defined in EN
construction site services. 15695-1. This means that the air delivery and
• Level II Impact Protection - impact strength for filtration system provides protection against dust and
protection from heavy falling objects (e.g. trees, the minimum differential pressure. The necessary
rocks) for machines involved in site clearing, filtered fresh air flow rate can be obtained using A/
overhead demolition or forestry. C system and by adjusting the maximum fan speed
provided that doors, windows and hatches are closed
ROPS Data Plate and the recirculation device is deactivated.
WARNING Your machine may be installed with a
Roll-Over Protective Structure (ROPS) indicating Comfort and Safety Inside the Cab
that the purchaser specified the machine for use
in applications where there is risk of roll-over. The cab category 1 does not guarantee full protection
ROPS is a device to protect the operator in the against dust, aerosols and vapours.
event of roll-over. Any damage or modification
The cab category 2 cab offers protection against
to the structure may invalidate the ROPS
dust but only partially for aerosols and vapours:
for application of plant protection products (e.g.
06 - 48 9823/1650-1 06 - 48
pesticides, fungicides, herbicides), refer to the

instructions provided by the supplier of the chemical
agent as well as instructions provided by the
sprayer's manufacturer.
Personal protective equipment (PPE) must be used

inside the cab when specified by those directions.
The air delivery system cannot offer a full protection,

but a partial protection can be achieved by following
some basic rules:
• Keep doors windows and hatches closed during

the spraying operation.
• Keep the cab interior clean.
• Do not enter the cab with contaminated shoes
and/or clothing.
• Keep all used personal protective equipment
outside the cab.
• Bring the wire harness of the remote spray
control box into the tractor cab.
• Remove the outside air delivery cab filter after
the spraying operation and store it in a dry
dust free room. Reserve it for the next spraying
operation; replace with a service part filter.
• Active carbon filters must be properly stored
in a sealed plastic bag to preserve their
functionality.
• Use only genuine JCB filters and ensure that
the filter is correctly installed.
• Check the condition of the sealing material and
have it repaired when required.
06 - 49 9823/1650-1 06 - 49
66 - Tools
66 - Tools
Contents Page No.
06-66-00 General ........................................................................................................................... 06-51
06 - 50 9823/1650-1 06 - 50
66 - Tools
00 - General
00 - General
Introduction
All tools must be kept in the toolbox (if installed) when

not in use.
06 - 51 9823/1650-1 06 - 51
69 - Maintenance Strut
Contents Page No.
06-69-00 General ........................................................................................................................... 06-53

06-69-03 Lift Arm ........................................................................................................................... 06-54
06 - 52 9823/1650-1 06 - 52
00 - General
00 - General
Introduction
Before you start any service procedures on the

machine, make sure that the relevant maintenance
strut is installed in its correct position and secure.
06 - 53 9823/1650-1 06 - 53
03 - Lift Arm
03 - Lift Arm
Remove and Install
CAUTION You will have to climb onto the Figure 35.

machine to install or remove the strut. Take care, A
especially if the machine is wet. Remove mud and
oil before climbing onto the machine. Do not use
the exhaust as a handhold. It can burn you.
WARNING You could be killed or injured if the lift
arm drops while you are working under it. Install
the lift arm maintenance strut as instructed before
doing any maintenance work with the lift arm
raised. Keep people away from the machine while
you install or remove the lift arm maintenance
strut. A Lift arm raised
WARNING Make sure that you use the correct
JCB maintenance strut for the machine. Make Installing the Maintenance Strut
sure that the safety strut is only used with the
correct JCB retaining bolt or securing device.
Never substitute this bolt or securing device, 2. Follow all general health and safety procedures.
always use the correct JCB part. Refer to (PIL 01-03).
Make sure that the strut and bolt/securing device
is installed correctly. Never use a strut intended 3. Fully retract the lift arm.
for another machine. If in doubt, consult your JCB 4. Raise the lift arm just far enough to install the
dealer. strut.
If you raise the lift arm to get access for maintenance, 5. Stop the engine and remove the ignition key.
you must install the maintenance strut on the lift arm.
6. Use the steps for access to the strut. Undo the
Before you install the maintenance strut remove any
hand bolt and remove the strut from its stowage
load on the forks and empty shovels or attachments.
position. Some machines have two steps on the
chassis and no steps on the axle.
7. Lower the strut so that the cut-out locates with
the pipe on the lift ram. Place the strut around the
lift cylinder piston rod. Secure the strut in position
with hand bolt.
8. Lower the lift arm carefully onto the strut. Stop as
soon as the weight of the lift arm is on the strut.
06 - 54 9823/1650-1 06 - 54
03 - Lift Arm
Figure 36.
C
C
D
E
A
A X
A Steps B Bolt
C Strut D Lift cylinder piston rod
E Cut-out X Stowage position
Removing the Maintenance Strut

2. Follow all general health and safety procedures.
Refer to (PIL 01-03).
3. Raise the lift arm just enough to allow the strut
to be removed.
4. Stop the engine and remove the ignition key.
5. Use the steps for access and support the strut.
Undo the hand bolt and lift the strut clear of the
steel pipe on the lift ram. Some machines have
two steps on the chassis and no step on the axle.
6. Secure the strut with hand bolt in its stowage
position.
06 - 55 9823/1650-1 06 - 55
03 - Lift Arm
Figure 37.
C
B
A
A
A Steps
B Bolt
C Strut
X Stowage position
06 - 56 9823/1650-1 06 - 56
75 - Fire Extinguisher
Contents Page No.
06-75-00 General ........................................................................................................................... 06-59
06 - 57 9823/1650-1 06 - 57
Notes:
06 - 58 9823/1650-1 06 - 58
00 - General
00 - General
Check (Condition)
In addition to the operator check the extinguisher

must be serviced every 12 months by a suitably
qualified person.
1. Examine the fire extinguisher for damage and

leaks.
2. Make sure the fire extinguisher is correctly
attached.
3. Make sure that the gauge indicates that the
extinguisher is charged i.e. the needle is in the
green segment
3.1. If the needle is in or very near the red
segment at either end of the gauge, the
extinguisher must be serviced or replaced.
4. Make sure the safety pin is correctly installed.
Figure 38.
A Gauge
B Safety Pin
06 - 59 9823/1650-1 06 - 59
89 - Window Guard
89 - Window Guard
Contents Page No.
06-89-00 General ........................................................................................................................... 06-61
06 - 60 9823/1650-1 06 - 60
89 - Window Guard
00 - General
00 - General Figure 39. Front screen guard
Remove and Install A E
Screen Guard B
Remove C
D
2. Follow all general health and safety procedures. A
3. Support the guard.
4. Remove the upper nuts, bolts and washers.
5. Remove the lower nuts and washers.
6. Remove the guard from the machine.
Installation
removal procedure.
F
G
H F
A Screen guard
B Washer
C Bolts
D Nut
E Mounting lug
F Washer
G Washer
H Nut
06 - 61 9823/1650-1 06 - 61
Notes:
06 - 62 9823/1650-1 06 - 62
Contents Page No.
09-00 Operator Station

09-00-00 General ............................................................................................................................. 09-3
09-00-06 Operator Protective Structure .......................................................................................... 09-4
09-09 Window
09-09-00 General ............................................................................................................................. 09-7
09-12 Operator Seat
09-12-00 General ........................................................................................................................... 09-15
09-12-03 Seat Base ...................................................................................................................... 09-17
09-15 Seat Belt
09-15-00 General ........................................................................................................................... 09-19
09-18 Door
09-18-03 Lock ................................................................................................................................ 09-23
09-18-12 Handle ............................................................................................................................ 09-24
09-27 Controls
09-27-36 Accelerator Pedal ........................................................................................................... 09-27
09-27-57 Park Brake ..................................................................................................................... 09-29
09-30 Trim Panel
09-30-03 Roof Trim ....................................................................................................................... 09-31
09-33 Safety Label/Chart
09-33-00 General ........................................................................................................................... 09-33
09-36 Steering Wheel
09-36-00 General ........................................................................................................................... 09-37
09-48 Floor mat
09-48-03 Front Floor mat .............................................................................................................. 09-39
9823/1650-1
2018-06-07
Acronyms Glossary
ECU Electronic Control Unit

9823/1650-1
2018-06-07
Contents Page No.
09-00-00 General ............................................................................................................................. 09-3

09-00-06 Operator Protective Structure .......................................................................................... 09-4
09 - 1 9823/1650-1 09 - 1
Notes:
09 - 2 9823/1650-1 09 - 2
00 - General
00 - General
Health and Safety

Raised Equipment
Never walk or work under raised equipment unless
it is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails
or if the control is operated (even with the engine
stopped).
Make sure that no-one goes near the machine while
you install or remove the mechanical device.
Lifting Equipment
equipment. You must identify the weight of the item to
equipment is in good condition and complies with all
local regulations.
09 - 3 9823/1650-1 09 - 3
Check (Condition)
by the manufacturer may be dangerous and will

(For: 506-36 [T4i], 507-42 [T4i], 512-56 invalidate the ROPS/FOPS/FOGS certification.
[T4i], 514-56 [T4i])
1. Check condition of the structure for damage.
WARNING You could be killed or seriously injured
if you operate a machine with a damaged or 2. Make sure that all the ROPS (Roll-Over
missing ROPS/FOPS/FOGS. If the ROPS/FOPS/ Protective Structure)/FOPS (Falling Object
FOGS has been in an accident, do not use the Protective Structure) mounting bolts are in place
machine until the structure has been renewed. and are undamaged.
Modifications and repairs that are not approved
3. Make sure that the ROPS/FOPS mounting bolts
are tightened to the correct torque value.
Figure 40.
A
A Bolts

Item Nm
A 205
09 - 4 9823/1650-1 09 - 4
09 - Window
09 - Window
Contents Page No.
09-09-00 General ............................................................................................................................. 09-7
09 - 5 9823/1650-1 09 - 5
Notes:
09 - 6 9823/1650-1 09 - 6
09 - Window
00 - General
Introduction ...................................................... 09-7 The service procedures, explain how to correctly
Health and Safety ........................................... 09-8 remove and install panes of glass that are directly
Preparation ...................................................... 09-8 bonded to the cab frame apertures. When you carry
Remove and Install ....................................... 09-10 out any service procedure, you must always refer to
the relevant safety precautions, Health and Safety.
1. Always wear safety glasses during removal and

replacement.
2. Use protective gloves - heavy duty leather
gauntlet type gloves when cutting out the broken
glass, non-slip type gloves when handling/
moving panes of glass, surgical type gloves
when you use the polyurethane adhesives.
3. Wear protective overalls.
4. Do not smoke - the activators and primers used
in the procedures are highly flammable.
5. Do not attempt to handle or move panes of glass
unless you are using glass lifters.
Several special tools are required to successfully

complete the removal and replacement procedures.
Reference is made to the tools in the procedures.
The majority of these tools can be obtained locally
and the remainder from JCB Service.
The work must only be carried out in a dry, frost free

environment. A protective canopy may be required
or the machine/frame must be moved to a sheltered
area.
In damp or wet conditions, hinged doors and window

frames can be removed from the machine and taken
to a more suitable (dry) environment.
Glass should not be replaced at temperatures below

5 °C ( 41.0 °F).
09 - 7 9823/1650-1 09 - 7
09 - Window
00 - General
Health and Safety Preparation

CAUTION Laminated glass must be handled Special Tools
with extra care to prevent breakage. Wherever Description Part No. Qty.
possible, store and handle it in a vertical attitude. Glass Lifter 892/00842 2
When placing or lifting the glass in a horizontal
attitude it must be supported over its whole area, Folding Stand 892/00843 1
not just at the edges. Cartridge Gun 892/00845 1
WARNING Always wear safety glasses when Rubber Spacer Blocks 926/15500 4
removing or installing screen glass. Never use a Mobile Oven (12V) 992/12300 1
power operated knife when removing the sealant Static Oven (240V) 992/12400 1
around a toughened glass screen. The action
of the knife could cause particles of glass to Consumables
be thrown with sufficient force to cause serious Description Part No. Size
injury, even when safety glasses are being worn. Black Primer/Activator 4104/2304 0.1 L
Use only hand operated tools when working with
toughened glass. Polyurethane Adhesive 4103/2110 0.31 L
Surface Cleaning Fluid 4103/1204 1L
Operator Station Aperture

1. If damp or wet, dry the aperture area using a hot
air gun (sourced locally).
2. Use surface cleaning fluid to thoroughly clean
and prime the trimmed sealant. Use a lint free
cloth to apply the cleaner, allow to dry.
Duration: 5 min
Consumable: Surface Cleaning Fluid
Note: Do not use any other type of cleaning fluids,

otherwise they may be absorbed into the old sealant
and ultimately prevent the new glass from bonding.
New Glass
1. Make sure that the new glass correctly fits the
frame aperture.
1.1. Put two spacer blocks on to the bottom part
of the frame aperture.
Special Tool: Rubber Spacer Blocks (Qty.:
2)
1.2. Install the new glass on the spacer blocks
- Always use glass lifters. Check that there
is an equal sized gap all round the edge
of the glass. Note: The spacer blocks are
rectangular in section to give two common
gap widths. If necessary they can be
trimmed to a smaller size to give an equal
sized gap around the glass. Important: The
glass edges must not touch the frame,
otherwise movement of the frame will chip
and eventually break the newly installed
glass.
Special Tool: Glass Lifter (Qty.: 2)
09 - 8 9823/1650-1 09 - 8
09 - Window
00 - General
Figure 41. Figure 43.
4. Clean the glass.

4.1. Use surface cleaner to thoroughly clean
and prime the black ceramic ink band
printed on the glass (see Note). Use a lint
A Frame aperture free cloth to apply the cleaner, allow to
B Spacer blocks dry. Important: Do not touch the glass after
C Glass lifters cleaning with the surface cleaner.
2. After checking for size, remove the new glass Duration: 5 min
and place it on a purpose made glass stand. Consumable: Surface Cleaning Fluid
Small panes of glass will need locating on a
600 x 700 mm x 15 to 19 mm thick plywood 4.2. If the glass does not have a black ceramic
board, sourced locally to fit the glass stand. It is ink band, paint a band on the glass using
recommended that an access hole is cut in the Black Primer. Make sure that the band
board to accommodate the glass lifter, making it measures the correct width and that the
easier and safer to handle small panes of glass. edge is a neat straight line.
The board should be covered with felt or carpet Dimension: 25 mm
to give an anti-scratch surface. Resting the glass Consumable: Black Primer/Activator
on four spacer blocks will ensure clearance of
the cartridge nozzle tip during application of the Figure 44.
polyurethane sealant.
Special Tool: Rubber Spacer Blocks (Qty.: 4)
Special Tool: Folding Stand (Qty.: 1)
Figure 42.
5. Install the Ultra Fast Adhesive cartridge into a

suitable applicator gun:
Special Tool: Static Oven (240V) (Qty.: 1)
Special Tool: Mobile Oven (12V) (Qty.: 1)
Special Tool: Cartridge Gun (Qty.: 1)
Consumable: Polyurethane Adhesive
5.1. Remove the aluminium disc cover from
3. Make sure the glass is positioned on the stand the base of the cartridge and discard the
the correct way up (i.e. with the black ceramic dessicant capsule.
ink band upwards) ready for application of primer
etc. 5.2. Make sure that the rolled edge of the
cartridge is not damaged - if necessary, the
edges should be pressed flat, otherwise it
09 - 9 9823/1650-1 09 - 9
09 - Window
00 - General
will be difficult to remove the cartridge from Remove and Install

the applicator gun.
Special Tools
5.3. Pierce the front nozzle end of the cartridge
to its maximum diameter. Description Part No. Qty.
Glass Lifter 892/00842 2
5.4. Install the pre-cut nozzle.
Glass Extractor 892/00846 1
5.5. Install the cartridge in the applicator gun. (Handles Only)
Note: Cold material will be very difficult to Nylon Spatula 892/00847 1
extrude. The cartridges must be pre-heated
Wire Starter 892/00848 1
in a special oven for 1 hour to a temperature
of 80°C (176°F). Pre-heating the cartridges Braided Cutting Wire 892/00849 1
makes the adhesive more workable and Rubber Spacer Blocks 926/15500 2
also brings the curing time down to 30 Cut-Out Knife 992/12800 1
minutes. 'L' Blades 992/12801 1
Figure 45.
Consumables
Description Part No. Size
Black Polyurethane 4102/2310 0.31 L
Sealant
A Black Primer/Activator 4104/2304 0.1 L
Glass Replacement Kit 993/55701 -
Hand Cleaner 4104/1310 -
B JCB Glass Cleaner 4006/3175 0.75 L
Surface Cleaning Fluid 4103/1204 1L
A 12.5 mm
B 9 mm
Removal
6. Apply the pre-heated adhesive to the glass (do
not start in a corner). Keep the nozzle guide 1. Position the machine on level ground and apply
against the edge of the glass and make sure the park brake. Stop the engine. Put protective
that the adhesive forms a continuous pyramid' covers over the cab seat and control pedestals.
shape. Note: Once the pre-heated adhesive has
2. If a laminated pane breaks it will stay in one piece
been applied to the glass, install the glass in the
even though the glass is cracked. A toughened
aperture as soon as possible. If you wait too long
pane will shatter and fall apart. The method of
then the sealant will form a skin, this will prevent
removal of the glass depends upon which type
the glass from bonding.
it is.
Duration: 10 min
2.1. Laminated glass - leave installed until the
Figure 46. old sealant has been cut away, after which
it will be possible to lift the broken screen
away from its frame housing in one piece.
2.2. Toughened glass - remove as much of the
shattered glass as possible prior to cutting
out the old sealant.
3. Cut out the old sealant, leaving approximately 1
to 2 mm on the cab frame. There are several tools
and techniques for doing this:
3.1. Pneumatic Knife - This provides one of the
A Nozzle guide easiest methods of removing the sealant
7. After applying the adhesive, leave a small around laminated glass. The tool, powered
amount of sealant protruding from the nozzle. by compressed air, should be sourced
This will prevent any adhesive left in the cartridge locally. Press the handle to start the knife
from curing. blade oscillating. Important: This tool must
not be used on toughened glass. Insert the
knife blade into the sealant. Slowly move
the knife along the sealant with the blade
positioned as close to the glass as possible.
09 - 10 9823/1650-1 09 - 10
09 - Window
00 - General
Do not allow the knife blade to overheat or Figure 48.

the sealant will melt.
Figure 47.
3.2. Braided Cutting Wire and Handles - This

method uses a 3-core wire, a wire starter
tube and two handles. Insert the steel tube
into the old sealant on the inside of the
glass. Insert the braided cutting wire down
the centre of the steel tube. If necessary,
from the outside, cut out local sealant at the
point of the tube to gain access to the wire.
Using suitable pliers, pull the cutting wire
through the sealant to the outer side of the A Wire starter
glass. Secure the end of the braided cutting B Braided cutting wire
wire (found on the outer side of the glass) in C Glass extractor (handles)
the special handle. Slowly remove the steel D Glass extractor (handles)
tube. Secure the second end of the braided 3.3. Cut-out Knife - The cut-out knife can be
cutting wire in the special handle. Move the used as a left handed or right handed tool.
cutting wire backwards and forwards in a Insert the knife blade into the sealant. Make
sawing motion and at the same time gently sure that the blade of the knife is against the
push or pull the wire to cut through the old glass. Use the 'pull-handle' to pull the knife
sealant. along and cut out the old sealant.
Special Tool: Wire Starter (Qty.: 1) Special Tool: 'L' Blades (Qty.: 1)
Special Tool: Glass Extractor (Handles Special Tool: Cut-Out Knife (Qty.: 1)
Only) (Qty.: 1)
Special Tool: Braided Cutting Wire (Qty.: 1) Figure 49.
A Glass
3.4. Craft Knife - The blades are replaceable.
Insert the knife blade into the sealant. Pull
the knife along and cut out the old sealant.
09 - 11 9823/1650-1 09 - 11
09 - Window
00 - General
Figure 50. glass. Make sure the two spacer blocks are in
position. Refer to Preparation - New Glass
2. Install the glass in the frame aperture:
2.1. Always use the glass lifting tools when
moving the glass. Use a lifting strap to hold
large panes of glass in position.
Special Tool: Glass Lifter (Qty.: 2)
Figure 52. Typical Machine
A Blades
3.5. Glass Replacement Kit - This kit is
designed for removal of one pane of glass.
The kit comprises: Cartridge Polyurethane
Adhesive (310ml), Primer/Activator (10ml),
Surface Cleaner Wipe, Abrasive Pad,
Applicator Nozzle, Wool Dauber, Cutting
Wire, Rubber Blocks.
Consumable: Glass Replacement Kit
4. Laminated glass - lift out the broken pane using
glass lifters. Toughened glass - remove the cut off 2.2. Sit the bottom edge of the glass on the
sealant and all remaining particles of shattered spacer blocks.
glass. Special Tool: Rubber Spacer Blocks (Qty.:
2)
5. If necessary, trim off the remaining old sealant
to leave approximately 1 to 2 mm on the upright Figure 53.
face of the cab frame aperture.
Figure 51.
A 1.5 mm
6. Apply a coat of Black Primer to the paintwork if:
Consumable: Black Primer/Activator
6.1. Paintwork was damaged or scratched
during the glass/sealant removal
procedures. 2.3. Make sure that the glass is correctly
positioned, then gently press around the
6.2. The old sealant was inadvertently cut back edges of the glass and ensure full adhesive
to the cab frame during the glass/sealant contact is achieved. Do not press too hard
removal procedures. or too much adhesive will squeeze out.
Installing new Glass 3. Make the inside seal smooth:
1. If the internal trim strip is damaged, renew it (cut 3.1. Wearing surgical gloves, dip your finger in
to length as required) before installing the new a soapy water solution.
09 - 12 9823/1650-1 09 - 12
09 - Window
00 - General
3.2. Use your finger to make the inside seal

smooth.
4. All exposed edges must be sealed using Black
Polyurethane Sealant. Important: Use extreme
caution when wiping the inside of the new glass
- pushing too hard on the inside of the glass will
affect the integrity of the bonded seal.
Special Tool: Nylon Spatula (Qty.: 1)
Consumable: Black Polyurethane Sealant
5. Clean the glass after installation:
5.1. Small amounts of sealant can be cleaned
from the glass using the surface cleaner.
5.2. Large amounts of excess sealant should be
left to cure and then cut off with a sharp
knife. Note: On completion of the glass
replacement procedures, the sealant curing
time is 30 minutes. This means that the
machine can be driven and used after 30
minutes, but it must not be used during the
curing period of 30 minutes.
5.3. Clean the glass using a purpose made
glass cleaner.
Consumable: Hand Cleaner
Consumable: JCB Glass Cleaner
6. On completion of the glass installation
procedures tidy the work area:
6.1. Remove all broken glass from the cab area.
6.2. Remove the protective covers from the cab
seat and control pedestals.
6.3. Renew all safety and instructional labels so
that the new installation conforms with the
original cab installation.
09 - 13 9823/1650-1 09 - 13
12 - Operator Seat
12 - Operator Seat
Contents Page No.
09-12-00 General ........................................................................................................................... 09-15

09-12-03 Seat Base ...................................................................................................................... 09-17
09 - 14 9823/1650-1 09 - 14
12 - Operator Seat
00 - General
00 - General Check (Condition)

Check (Condition) .......................................... 09-15 1. Check that the seat adjustments operate
Remove and Install ....................................... 09-16 correctly.
2. Check the seat is undamaged.
3. Check the seat mounting bolts are undamaged,
correctly installed and tight.
4. Make sure the seat is clear from unwanted
materials and hazards at all times.
09 - 15 9823/1650-1 09 - 15
12 - Operator Seat
00 - General
Remove and Install

method and device.
Remove
2. Disconnect the electrical connections to the seat.
3. Remove the bolts that attach the seat to the seat
base.
Figure 54.
A
A Bolt (x4)
4. Attach suitable lifting equipment to the seat.
5. Use the lifting equipment to remove the seat from
the machine.
Install
step.
1.1. Tighten the bolts to the correct torque value.
Refer to: PIL 72.
09 - 16 9823/1650-1 09 - 16
12 - Operator Seat
03 - Seat Base
03 - Seat Base
Remove and Install
Remove
1. Make the machine.
2. Remove the seat.
3. Fully move the seat slide adjustment backward,
then remove the front fixing bolts from the slide
rails.
4. Fully move the seat slide adjustment forward and
remove the rear fixing bolts from the slide rails.
5. Remove the slide adjustment assembly.
Install
removal procedure.
09 - 17 9823/1650-1 09 - 17
15 - Seat Belt
15 - Seat Belt
Contents Page No.
09-15-00 General ........................................................................................................................... 09-19
09 - 18 9823/1650-1 09 - 18
15 - Seat Belt
00 - General
WARNING When a seat belt is installed on your
Introduction .................................................... 09-19 machine replace it with a new one if it is damaged,
Check (Condition) .......................................... 09-20 if the fabric is worn, or if the machine has been in
an accident.
The seat belt is to protect the operator if the machine

rolls over or is involved in an accident.
Some machines have a seat belt sensor installed

as part of the Green Beacon safety kit. The sensor
informs the Green Beacon ECU (Electronic Control
Unit) that the seat belt is correctly connected.
The Green Beacon ECU operates an external green

flashing beacon which informs observers that the
operator has correctly connected the seat belt.
09 - 19 9823/1650-1 09 - 19
15 - Seat Belt
00 - General
Check (Condition)
WARNING When a seat belt is installed on your
machine replace it with a new one if it is damaged,
if the fabric is worn, or if the machine has been in
an accident.
WARNING If the seat belt does not 'lock' when
you check if the seat belt is operating correctly, do
not drive the machine. Get the seat belt repaired
or replaced immediately.
1. Make sure the seat belt can be adjusted.

2. Examine the seat belt for signs of fraying and
stretching.
3. Check that the stitching is not loose or damaged.
4. Check that the belt mounting bolts are
undamaged, correctly installed and tight.
5. Check that the buckle assembly is undamaged
and operates correctly.
09 - 20 9823/1650-1 09 - 20
18 - Door
18 - Door
Contents Page No.
09-18-03 Lock ................................................................................................................................ 09-23

09-18-12 Handle ............................................................................................................................ 09-24
09 - 21 9823/1650-1 09 - 21
Notes:
09 - 22 9823/1650-1 09 - 22
18 - Door
03 - Lock
03 - Lock
Remove and Install
09 - 23 9823/1650-1 09 - 23
18 - Door
12 - Handle
12 - Handle Figure 55.
Remove and Install A

B
Remove
The inner and outer handle are combined in one unit.

C D
2. Support the outer handle.
F
3. Remove the screws from the inside of the door
and lift away the cover plate. E
4. Disconnect the latch assembly from the handle

lever.
5. Slightly tilt the handle unit to unhook the unit from
the door assembly. Retain the gasket and trim
plate.
E E
A Gasket
B Trim plate
C Latch assembly
D Handle- exterior
E Retaining screws
F Cover plate
Install
removal procedure.
09 - 24 9823/1650-1 09 - 24
27 - Controls
27 - Controls
Contents Page No.
09-27-36 Accelerator Pedal ........................................................................................................... 09-27

09-27-57 Park Brake ..................................................................................................................... 09-29
09 - 25 9823/1650-1 09 - 25
Notes:
09 - 26 9823/1650-1 09 - 26
27 - Controls
36 - Accelerator Pedal
Remove and Install
Consumables
JCB Threadlocker 4101/0250 0.01 L
and Sealer (Medium 4101/0251 0.05 L
Strength)
Figure 56.
B B
E A
A Pedal assembly B Pedal bolts

C Spacer D Clip retaining nuts
E Electrical harness connectors F Access hole
Remove 5. Remove the clip retaining nuts to release the

clips and connectors from the cab floor.
6. Remove the pedal bolts.
7. Make sure to retain the spacer plate.
2. Make sure that the engine cannot be started.
8. Slowly remove the pedal assembly from inside
3. Remove the floor mat from the cab. the cab making sure to pull the connectors
Refer to: PIL 09-48. through the access hole in the cab floor.
4. Working below the cab, disconnect the electrical

connectors from the chassis harness.
09 - 27 9823/1650-1 09 - 27
27 - Controls
Install
step.
2. Apply JCB Threadlocker and Sealer to the
threads of the pedal bolts.
Consumable: JCB Threadlocker and Sealer
(Medium Strength)
09 - 28 9823/1650-1 09 - 28
27 - Controls
57 - Park Brake
57 - Park Brake Installation

Remove and Install removal procedure. Additionally do the following
step.
Removal 1.1. To align the switch correctly, engage the

switch location dowel with the hole in the
1. Make the machine safe. mounting bracket.
2. Put blocks under the wheels. Release the park
brake.
3. Remove the rubber gaiter.
4. Disconnect the electrical connector from the
switch connector.
5. Hold the switch and remove screw.
6. Remove the switch.
Figure 57.
A Rubber gaiter
B Switch
C Electrical connector
D Switch connector
E Screw
F Switch location dowel
G Hole in mounting bracket
09 - 29 9823/1650-1 09 - 29
30 - Trim Panel
30 - Trim Panel
Contents Page No.
09-30-03 Roof Trim ....................................................................................................................... 09-31
09 - 30 9823/1650-1 09 - 30
30 - Trim Panel
03 - Roof Trim
03 - Roof Trim
Remove and Install

Notice: Take care during the removal and
replacement of the roof liner. Make sure your
hands and clothes are clean. The roof liner is
easily damaged.
Remove
2. With the aid of one more person hold the roof
liner and remove the screws.
3. Lower the liner to get access to the electrical
connectors at the interior lights and audio
speakers (if installed).
4. Disconnect the electrical connectors from the
interior lights and audio speakers.
5. Remove the roof liner.
6. Put the roof liner into a clean plastic bag and keep
it in a safe place. The roof liner is damaged easily.
Figure 58.
A A A A
C
C
D D
B
A A A
A Screws
B Roof liner
C Interior lights
D Audio speakers
Install
1. The installation procedure is the opposite of
step.
1.1. If seals are attached to the panel, make
sure they are in good condition. If damaged,
replace the seals.
09 - 31 9823/1650-1 09 - 31
33 - Safety Label/Chart
Contents Page No.
09-33-00 General ........................................................................................................................... 09-33
09 - 32 9823/1650-1 09 - 32
00 - General
Introduction .................................................... 09-33 The safety labels are strategically placed around the
Health and Safety .......................................... 09-34 product to remind you of possible hazards.
If you need eye-glasses for reading, make sure you

wear them when reading the safety labels. Do not
over-stretch or put yourself in dangerous positions to
read the safety labels. If you do not understand the
hazard shown on the safety label, then refer to Safety
Label Identification.
Keep all of the safety labels clean and readable.

Replace a lost or damaged safety label. Make
sure the replacement parts include the safety labels
where necessary. Each safety label has a part
number printed on it, use this number to order a new
safety label from your JCB dealer.
09 - 33 9823/1650-1 09 - 33
00 - General
Health and Safety

WARNING Safety labels on the machine warn
you of particular hazards. You can be injured if
you do not obey the safety instructions shown.
09 - 34 9823/1650-1 09 - 34
36 - Steering Wheel
36 - Steering Wheel
Contents Page No.
09-36-00 General ........................................................................................................................... 09-37
09 - 35 9823/1650-1 09 - 35
Notes:
09 - 36 9823/1650-1 09 - 36
36 - Steering Wheel
00 - General
00 - General 1.1. If the key becomes damaged during the

removal procedure, replace with a new key.
Remove and Install 1.2. Make sure that the steering wheel aligns
with the marks you made during removal.
1.3. If removed, install the foam collar. Attach
Remove the adhesive lined side to the column trim
panel before you install the steering wheel.
Refer to: PIL 01-03. Figure 60.
2. Mark the position of the steering wheel on the

splined shaft.
3. Take out the steering wheel centre cap from the
wheel.
G
4. Remove the steering wheel securing nut.
5. Remove the washer.
6. Remove the steering wheel away from the
splined shaft.
7. Make sure to retain the key.
8. Remove the foam collar (if installed).
Figure 59.
A
B
H
C
G Column trim panel
H Foam collar
D
A Steering wheel center cap

B Steering wheel securing nut
C Washer
D Key
E Steering wheel
F Shaft
Install
steps.
09 - 37 9823/1650-1 09 - 37
48 - Floor mat
48 - Floor mat
Contents Page No.
09-48-03 Front Floor mat .............................................................................................................. 09-39
09 - 38 9823/1650-1 09 - 38
48 - Floor mat
03 - Front Floor mat
03 - Front Floor mat
Remove and Install
Remove
2. Remove the nuts and remove the pedal pads
from the machine.
3. Remove the bolts and the retaining plate.
4. Remove the screws and the kick strips.
5. Remove the trim retainers from the front section
of the mat.
6. Remove the mat from the machine.
Figure 61.
A
D E
C F
G D
A Pedal pads
B Nuts
C Kick strips
D Screws
E Bolts
F Retaining plate
G Trim retainers
Install
removal procedure.
09 - 39 9823/1650-1 09 - 39
Notes:
09 - 40 9823/1650-1 09 - 40
12 - Heating, Ventilating and
Air-Conditioning (HVAC)
Contents Page No.
12-00 Heating, Ventilating and Air-Conditioning (HVAC)

12-00-00 General ............................................................................................................................. 12-3
12-03 HVAC Unit
12-03-00 General ........................................................................................................................... 12-21
12-03-03 Evaporator ...................................................................................................................... 12-23
12-03-06 Pressure Switch ............................................................................................................. 12-24
12-03-09 Expansion Valve ............................................................................................................. 12-27
12-03-12 Blower Motor .................................................................................................................. 12-28
12-03-15 Thermostat ..................................................................................................................... 12-29
12-03-18 Heater Coil ..................................................................................................................... 12-31
12-04 Heater Unit
12-04-00 General ........................................................................................................................... 12-33
12-09 Compressor
12-09-00 General ........................................................................................................................... 12-37
12-12 Receiver Drier
12-12-00 General ........................................................................................................................... 12-41
12-15 Condenser
12-15-00 General ........................................................................................................................... 12-45
12-18 Filter
12-18-00 General ........................................................................................................................... 12-53
12-18-06 Fresh Air ........................................................................................................................ 12-54
12-21 Heater Valve
12-21-00 General ........................................................................................................................... 12-57
12-96 Pipe
12-96-00 General ........................................................................................................................... 12-61
9823/1650-1
2018-02-23
Acronyms Glossary
FEAD Front End Accessory Drive

HVAC Heating Ventilation Air Conditioning
PAG Polyalkyline Glycol
RPM Revolutions Per Minute
TXV Thermal Expansion Valve
9823/1650-1
2018-02-23
12 - Heating, Ventilating and Air-Conditioning (HVAC)
Contents Page No.
12-00-00 General ............................................................................................................................. 12-3
12 - 1 9823/1650-1 12 - 1
Notes:
12 - 2 9823/1650-1 12 - 2
00 - General
Introduction ...................................................... 12-3 To maintain optimum operator comfort in warm
Health and Safety ........................................... 12-4 climates or during seasons of high ambient
Technical Data ................................................. 12-5 temperature, the air conditioning system delivers
Component Identification ................................. 12-6 cool, dehumidified air into the cab. Cooling is
provided by passing the warm ambient air, together
Operation ......................................................... 12-9 with recirculated air, over an evaporator matrix in the
Fault-Finding .................................................. 12-12 air conditioning unit.
Discharge and Pressurise ............................. 12-15
Check (Operation) ......................................... 12-18 The air conditioning system is a closed circuit
through which the refrigerant is circulated, its state
Check (Pressure) .......................................... 12-18 changing from gas to liquid and back to gas again,
Adjust ............................................................ 12-19 as it is forced through the system. The major
components of the system are the:
• Compressor
• Condenser matrix
• Receiver drier
• Expansion valve
• Evaporator matrix
12 - 3 9823/1650-1 12 - 3
00 - General
Health and Safety • DO NOT steam clean refrigerant system

components.
• When charging or discharging the refrigerant
Air Conditioning Maintenance
system, no smoking or naked flames should
The air conditioning system is a closed loop system be allowed in the immediate vicinity. The
and contains pressurised refrigerant. No part of the refrigerant does not give off a poisonous odour,
system should be disconnected until the system however, when it comes into contact with a
has been discharged by a refrigeration engineer naked flame, a poisonous gas is produced.
or a suitably trained person. You can be severely • When handling refrigerant, rubber gloves and
frostbitten or injured by escaping refrigerant. goggles should be worn. Operators should
Air Conditioning Refrigerant ensure no refrigerant comes into contact with
the skin. Particular care should be taken when
Do not operate the air conditioning system when connecting or disconnecting charging hoses or
there is no refrigerant in the system, otherwise the pressure switches. When these components
compressor will be damaged. are connected to the system, a short release of
Welding refrigerant occurs. This results in a high velocity,
very cold gas being emitted from the connection
Do not carry out welding operations close to the air point.
conditioning refrigerant circuit. A poisonous gas is • Use caution when working near exposed
produced when refrigerant comes into contact with evaporator fins. Painful cuts can be inflicted by
naked flames. Do not smoke or allow naked flames the edges of the fins. Also, damage to the fins
close to the refrigerant circuit. will reduce the efficiency of the system.
CAUTION! Polyalkylene Glycol (PAG) type oil is an • Make sure pressure cylinders are not over filled,
irritant. It can cause skin irritation. Breathing PAG particularly when recovering refrigerant.
vapour can cause irritation of the eyes, nose and • Disconnect battery before doing any work.
lungs. Prolonged inhalation can cause drowsiness.
WARNING! Polyalkylene Glycol (PAG) type oil
vapour is extremely flammable. Do not smoke or eat
near PAG contaminated material. Exercise caution
when working around hot and moving engine parts.
CAUTION! When working on the HVAC System
gloves, eye protection and protective clothing must
be worn. Refrigerant may be released which can be
harmful to your skin or eyes.
Safety Procedures
The air conditioning system includes a pressurised
closed circuit containing a non-CFC, environmentally
friendly refrigerant, Type R-134a. Any service
procedure which breaks into the closed circuit
and therefore requires discharging of the system,
must only be carried out by service personnel with
specialist knowledge of air conditioning systems. The
following guidelines should be adhered to by all
personnel servicing the air conditioning system:
• It is critical that the correct refrigerant (R-134a)

is used and that charging is done only by
qualified personnel. It is illegal to discharge
the refrigerant into the atmosphere but as
a precaution in case of accidental leakage,
discharging and charging of the vehicle
refrigerant system must be conducted in a well-
ventilated area.
• Containers of refrigerant should be stored in a
cool environment away from direct sunlight.
• DO NOT perform welding operations close to
refrigerant hoses (maintain a distance of at least
0.5m from hoses).
12 - 4 9823/1650-1 12 - 4
00 - General
Technical Data
Table 13. Binary pressure switch settings

Item Specification
Low pressure 2 bar ( 29.0 psi)
High pressure 26 bar ( 376.8 psi)
Table 14. Thermostatic switch settings

Item Specification
Cut out 0.2 –1.4 °C ( 32.4 –34.5
°F)
Cut in 3.4 –4.8 °C ( 38.1 –40.6
°F)
Table 15. Refrigerant

Item Specification
Type R134a gas
Charge amount (maxi- 1 kg
mum)
(1)
Charge amount (maxi- 1.7 kg

mum)
(2)
(1) Systems with cooling pack mounted condenser.

(2) Systems with roof mounted condenser.
Table 16. Oil

Item Specification
Type PAG (Polyalkyline Gly-
col) oil
Charge amount
(3)
-
Complete system 0.0426 L
Condenser remove and 0.0284 L
install
Evaporator remove and 0.0568 L
install
Hoses remove and in- 0.0085 L
stall
Receiver drier remove 0.0142 L
and install
Compressor remove and None- pre charged
install
(3) The quantity of oil replaced should be the same
as that taken out during `Recovery' procedure.
12 - 5 9823/1650-1 12 - 5
00 - General
Heater Only
Figure 62.
E
D
D
D
C D
B
Item Description
D Cab heater vents
Table 17.
E Heater Control panel
(1)
Item Description
A Heater and ventilation (1) A typical heater control panel is shown. Refer to
unit (HV) the applicable Operator Manual for machine specific
controls.
B Heater valve
12 - 6 9823/1650-1 12 - 6
00 - General
Machines with Air Conditioning
Figure 63.
E
F
H F
A
B
C
D
Item Description
G Condenser (cooling
Table 18.
pack mounted)
Item Description H Condenser (roof mount-
A TXV (Thermal Expan- ed) (Available as an op-
sion Valve) tion on some machines).
B Evaporator matrix (1) Typical heater control panel shown. Refer to
C Compressor the correct operator manual for machine specific
D FEAD (Front End Acces- controls.
sory Drive)
Table 19. Component Locations
E Heater/air conditioning
control panel
(1)
HVAC System Location (All Ma-
F Heater/air conditioning chines)
vents HVAC (Heating Venti- Fixed to cab (RHS)
lation Air Conditioning)
unit
TXV Part of HVAC unit
12 - 7 9823/1650-1 12 - 7
00 - General
HVAC System Location (All Ma-

chines)
Evaporator matrix Part of HVAC unit
Compressor Fixed to engine (RHS)
Binary switch Fixed to pipe next to
compressor
Receiver drier Fixed to chassis inside
engine compartment
Condenser - cooling Part of machine cooling
pack mount pack inside engine com-
partment
Condenser - roof mount Fixed to a frame fixed at
the rear of the cab roof.
Includes electric cooling
fans
12 - 8 9823/1650-1 12 - 8
00 - General
Operation
Fresh air is supplied to the cab interior through the fan. In the condenser, the refrigerant changes state
cab air vents. The heater and ventilation unit (HV) to a high pressure, high temperature liquid but with
uses a blower fan to increase the air speed. The a lower heat content.
air can also be heated by the heat exchange matrix
housed within the HV unit. The refrigerant passes through the receiver drier,
which contains a desiccant to remove moisture from
On machines with air conditioning, the unit also the system. The receiver drier serves as a tank for
houses the air conditioning evaporator matrix to refrigerant and also includes a filter to remove foreign
become a combined HVAC (Heating Ventilation Air particles from the system.
Conditioning) unit. Refer to (PIL 12-03).
Figure 64.
The machine operator can control the air
temperature and speed from within the cab on the F
E
heater control panel. For operation of the heater
controls refer to the applicable Operator Manual.
The operator uses the fan speed switch to select

the blower fan speed. The temperature control knob
is connected to a cable which operates the heater
valve. B
The heater valve regulates the flow of hot engine

coolant through the HV unit. The hot engine coolant
flows through the heat exchange matrix and the fan
blows air over the fins of the matrix, warming the air.
The air conditioning system is a closed circuit A C

D
through which the refrigerant is circulated, its state
changing from gas to liquid and back to gas again, A Compressor
as it is forced through the system. B Condenser matrix
C Receiver drier
The major components of the system are as follows. D Binary pressure switch
E TXV
• Compressor F Evaporator matrix
• Condenser matrix
• Receiver drier The receiver drier can only hold a limited amount of
• Binary pressure switch moisture, additional moisture can lead to icing and
• TXV (Thermal Expansion Valve) ultimately blockage of the thermostatic expansion
• Evaporator matrix valve. If the air conditioning system has been left
open or has been leaking for a prolonged period of
Operate the air conditioning as described in the time, the desiccant will become saturated and the
operator manual. receiver drier will need to be replaced with new one.
Air conditioning system power is generated from The high temperature, high pressure refrigerant
the engine, through an electromagnetic clutch to is forced by compressor action into the TXV,
the compressor. Switches, connected in series, are which meters the amount of refrigerant entering
included in the clutch supply line, all must be closed the evaporator. In the TXV the refrigerant
for the clutch and therefore the air conditioning instantaneously expands to become a low pressure,
system to operate. low temperature liquid.
The compressor draws in low pressure refrigerant The refrigerant is drawn through the evaporator
gas from the suction line (evaporator to matrix by the suction of the compressor. The
compressor) and increases refrigerant pressure temperature of refrigerant is now considerably below
through compression. This process also increases that of the air being drawn across the evaporator
the refrigerant temperature. matrix by the blowers. Heat is transferred from the
ambient and re circulated air to the refrigerant,
High pressure refrigerant is forced from the causing the low pressure liquid to vaporise and
compressor to the condenser. Ambient air is drawn become a low pressure gas. Moisture in the air
across the condenser by the engine- driven cooling
12 - 9 9823/1650-1 12 - 9
00 - General
condenses on the evaporator matrix and is drained The low temperature, low pressure, high heat
away through condensate. content refrigerant gas, is now drawn by suction back
to the compressor, where the cycle is completed.
Cool de-humidified air is emitted through air vents
into the cab.
Figure 65.
X F Y
C E A
A Compressor B Condenser matrix

C Receiver drier D Binary pressure switch
E TXV F Evaporator matrix
X Refrigerant is in liquid state Y Refrigerant is in gas state
System control 2. The high and low level binary pressure switch
located in the pipework near to the compressor.
The system is a manual control type and is set to on This switch is not adjustable.
or off by switch. There is no automatic control of the
cab air temperature. 3. The freeze protection thermostat switch located
inside the HVAC unit. This switch is not
Refrigerated air will be heated by the heater matrix If adjustable.
the heater control is not set to ‘cold’.
When the air conditioning switch is set to on
You can control the system by activating and the refrigeration system is active. The system
deactivating the compressor electromagnetic clutch. operates within fixed temperature and pressure limits
When current is fed to the field coil of the compressor controlled by the freeze protection thermostat switch
clutch, a magnetic field develops between the field and the binary pressure switch. The system does not
coil and the armature which pulls the field coil, respond to changes in the cab air temperature.
complete with clutch assembly, onto the compressor
rotor. Since the clutch assembly is turned constantly If the compressor runs continuously condensate
by the crankshaft pulley drive belt, the compressor on the evaporator matrix will freeze and the
armature turns, starting the refrigeration cycle. system will not be effective. The freeze protection
thermostat switch has its sensor probe installed
Current is fed to the field coil through a series of in the evaporator matrix. When the temperature
switches. of the probe is near 0 °C ( 32.0 °F) the
thermostat switch contacts open. The compressor
1. The manual air conditioning on/off switch in the clutch disengages, closing down the refrigeration
control console. cycle. As the temperature of the probe increases the
12 - 10 9823/1650-1 12 - 10
00 - General
thermostat switch contacts close. The compressor

clutch engages and refrigeration re-starts.
Figure 66.
D Binary pressure switch G Manual air conditioning on/off switch

H Freeze protection thermostat switch
If the refrigerant pressure exceeds the upper

pressure limit or falls below the lower limit,
the contacts of the binary switch open and the
compressor clutch disengages, closing down the
refrigeration cycle.
12 - 11 9823/1650-1 12 - 11
00 - General
Fault-Finding
Fault
Poor performance (For system diagnosis using test gauges, refer to Check Table 20. Page 12-12
Operation, PIL 12-03)
Warm air or slightly cool air emitted from unit Table 21. Page 12-12
Compressor clutch continually cuts out Table 22. Page 12-12
Poor performance- Compressor function tests Table 23. Page 12-13
Compressor not achieving 24 bar pressure Table 24. Page 12-13
No air conditioning Table 25. Page 12-13
Table 20. Poor performance (For system diagnosis using test gauges, refer to Check Operation, PIL
12-03)
Cause Remedy
Condenser matrix air flow restricted Remove debries from matrix using compressed air
HVAC (Heating Ventilation Air Conditioning) Unit air Refer to (PIL 12-18)
intake filter blocked
Compressor drive belt too slack Refer to (PIL 15-18)
Low system pressure Discharge and recharge the system
Table 21. Warm air or slightly cool air emitted from unit
Cause Remedy
Expansion valve stuck open or closed Renew expansion valve. Refer to (PIL 12-03)
Table 22. Compressor clutch continually cuts out

Cause Remedy
Condenser matrix blockage Remove debris from matrix or
Overcharging of refrigerant system Discharge and recharge the system. Refer to (PIL
12-00)
Blocked expansion valve or condenser Clear blocked component. Refer to (PIL 12-03)
Compressor fault Do compressor function tests. Refer to (PIL 12-03)
12 - 12 9823/1650-1 12 - 12
00 - General
Table 23. Poor performance- Compressor function tests

Cause Remedy
(1) Is the compressor rotation smooth? With the YES = Check (2), NO = Renew compressor
engine having been turned off for 5 minutes, turn
the compressor shaft by turning the armature plate
by hand. Check for smooth rotation. Grinding or
hanging during shaft rotation is caused by a broken
component within the compressor.
(2) Is the field coil receiving greater than 7.5 V? YES = Check (3), NO = Rectify electrical problem
This test should be conducted with the electrical
system on and clutch engaged. Unplug the electrical
connector and measure on the machine side.
(Reversing polarity will short diode resulting in blown
fuses).
(3) Is the field coil resistance between 3 and 4 ohms? YES = Check (4), NO = Renew compressor
Coil resistance out of this range will not engage
or will cause fused circuits to open. Unplug the
electrical connector, measure on compressor side.
(4) Is compressor capable of producing 24 bar or YES = Compressor is functioning correctly, No =
more? To check this do the pressure tests. Refer Follow the pressure fault finding table (Compressor
to (PIL 12-03). Excessive high pressure can be not achieving 24 bar pressure).
artificially produced by preventing air flow across
the condenser. Preventing air flow through the
condenser minimises heat removal from the system
resulting in high pressure.
Table 24. Compressor not achieving 24 bar pressure

Cause Remedy
Low refrigerant charge - possible leakage, suction TEST = Discharge and recharge the system,
and discharge pressure are low. ACTION = Repair leak & check system pressures
(Compressors with dirt/oil build up at hose
connections are most likely to have damaged 'O'
rings. Check for leaks and replace 'O' rings.
System high pressure side blockage - flow to the TEST = Check suction pressure is 0.35 bar or less,
compressor is stopped or limited. ACTION = Compressor is functioning correctly,
remove the system blockage.
Compressor failure - internal compressor damage. TEST = Suction pressure high, discharge pressure
low, do compressor function tests (See table 4),
Action = Renew compressor
Test performed below 10 ºC - Low ambient TEST = Move machine to area where temperature is
temperature limits pressure. higher, ACTION = Check system pressures
Table 25. No air conditioning

Cause Remedy
(1) Are the controls set correctly, i.e. air conditioning YES = Check (2), NO = Reset controls and retest
selected, heater control set to coldest position and
blower switched on?
(2) Is the air conditioning (evaporator) blower YES = Check (30), NO = Reset controls and retest
working?
(3) Is the compressor running (visual check of pulley/ YES = Check (10), NO = check (5)
clutch)?80 % or betetr
(4) Is the air conditioning fuse(s) blown? For details YES = Renew fuses and retest, NO = Check (9)
of the electrical circuit and connections, Refer to (PIL
33-00-50)
(5) Is there a 12V supply to the binary pressure YES = Check (6), NO = Check (7)
switch harness?
12 - 13 9823/1650-1 12 - 13
00 - General
Cause Remedy
(6) Does the compressor clutch engage with binary YES = Replace binary pressure switch assembly, NO
pressure switch assembly bypassed? = Check (8)
(7) Does the clutch engage with freeze thermostat YES = Renew freeze thermostat switch and retest,
switch bypassed? NO = Check all electrical connections.
(8) Is there a 12V supply at the compressor? YES = Renew the compressor clutch and re-test, NO
= Renew the compressor relay and re-test.
(9) Are blower switch and wiring OK? YES = Renew blower unit complete, NO = Renew
switch or wiring.
(10) Is the system correctly charged with refrigerant YES = Check (11), NO = Charge check required by
OK? refrigeration engineer or suitably trained person.
(11) Is condenser air flow blocked? YES = Clean condenser and radiator, NO = Check
(12).
(12) Is evaporator air flow blocked? YES = Clean/Replace HVAC Unit Air Intake filter.
Refer to (PIL 12-03), NO = If necessary replace the
evaporator. Call in refrigeration engineer or suitably
trained person.
12 - 14 9823/1650-1 12 - 14
00 - General
Discharge and Pressurise 10. Close the valves and remove all equipment.
Figure 67.
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the
system should be disconnected until the system
has been discharged by a refrigeration engineer
or a suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
Refer to the Health and Safety section. Refer to: PIL

12.
Refrigerant Recovery
The recovery process clears the system refrigerant,
prior to servicing or for refrigerant renewal.
Do not re-use refrigerant unless you are aware of its

purity.
The JCB recommended Javac unit only recovers

refrigerant as a gas. Other units can recover
refrigerant as a liquid and/or gas. Always check the
manufacturer's instructions before use.

A Low pressure hose (blue)
2. Make sure that the engine is OFF and the engine B High pressure hose (red)
is cool. C Hose (yellow)
D Filter
3. Remove the ignition key. E Javac unit
F Empty receiver bottle
4. Connect the manifold to the system with the blue
hose connected to the system low pressure port.
Do not connect the red hose. Make sure that both Evacuate
valves are closed.
This procedure follows on from the Recovery
5. Connect the yellow hose to the Javac unit filter. process and is necessary to make sure that the
system is correctly refilled with refrigerant. To avoid
6. Connect the filter to the Javac unit. leakage in the vacuum system itself, Do not use
extensions to the yellow hose (use standard 2 metre
7. Connect the Javac unit to an empty receiver length).
bottle. Weigh the bottle before and after filling to
assess the system capacity. Note: Do not fill the 1. Recover all refrigerant from the system, refer to
receiver bottle to more than 80% by weight. refrigerant recovery.
8. Switch on Javac unit and open the low pressure 2. Close all valves and connect the manifold.
manifold valve. Note: If the high pressure Connect the blue hose to the system low
warning light on the Javac unit comes on, throttle pressure port and the red hose to the high
back the manifold low pressure valve to provide pressure port.
a restriction.
3. Connect the yellow hose to the vacuum pump.
9. The Javac unit will automatically switch off when Note: If the Electronic vacuum gauge is used
a pressure balance exists between the system connected as shown. Refer to Electronic Vacuum
and the receiver bottle. Switch off Javac unit at Gauge for further information.
main switch, but leave the system connected.
Switch on after the specified time and the Javac 4. Open the manifold valves.
unit will restart if residual pressure remains.
5. Switch on the vacuum pump until 740mm (29
Duration: 10 min in) mercury vacuum reads on both gauges.
12 - 15 9823/1650-1 12 - 15
00 - General
Note: achievable vacuum will vary with altitude. 6. Switch on the vacuum pump and open the high
Maximum gauge reading will be 25mm (1 in) less pressure side valve.
for every 305 metres (1000 feet) above sea level.
7. Unscrew the oil injector cap and add the specified
6. Maintain suction for approximately the specified quantity of refrigerant oil.
time. Note: If the vacuum falls rapidly the system
is leaking. Check all connections and reseal. If 8. When 740mm (29 in) mercury shows on the
the point of leakage is not obvious, recharge the vacuum gauge, open the oil injector valve to
system and test again. allow the oil into the system.
Duration: 30 min 9. If more oil is needed repeat the above procedure.
The quantity of oil should be the same as that
7. Close the valves and remove all equipment. taken out during the Recovery procedure. Note:
Figure 68. Use only PAG oil in R-134a systems.
Figure 69.

B High pressure hose (red)
C Hose (yellow) F
D Vacuum pump
E Electronic vacuum gauge
B High pressure hose (red)
Re-lubricate C Hose (yellow)
D Vacuum pump
Re-lubrication is essential after recovering the
E Oil injector
system refrigerant, vacuuming and component
F Low pressure point
flushing. The system should be evacuated to a
vacuum of 740mm (29 in) of mercury before re-
lubricating. Charge
1. Make sure that the engine is OFF and the engine This procedure is the industry recommended
is cool. practice for refilling air conditioning systems with
refrigerant. Evacuate the system beforehand to
2. Remove the ignition key. 740mm (29 in) of mercury.
3. Close all valves and connect the manifold as 1. Close all valves and connect the manifold
shown, with the blue hose connected to the oil as shown. Connect the blue hose to system
injector and the red hose to the system high low pressure and the red hose to system
pressure port. high pressure. Connect the yellow hose to the
refrigerant cylinder.
4. Connect the yellow hose to the vacuum pump.
2. Invert the single valve cylinder on the scales and
5. Connect the other end of the oil injector to the zero the scale reading. Note: Some refrigerant
system low pressure point. cylinders have separate valves for gas and liquid.
12 - 16 9823/1650-1 12 - 16
00 - General
Be sure to connect to the liquid port when Figure 71.

following the above procedure. Note: Refrigerant
can be used either in gas or liquid form. If
recharging with gas follow the manufacturers
instructions and recharge only via the low
pressure port. Do not use liquid refrigerant at the
low pressure port.
3. Slowly open the high pressure valve and allow
the vacuum to draw-in refrigerant to the specified
weight for the system. Refer to Technical
Data. Add refrigerant until the scales indicate
the specified weight for the system or the
weight obtained when the system refrigerant
was previously recovered. Note: To speed up
the process a thermostatically controlled thermal
blanket can be used around the replenishing
cylinder.
4. Close all valves and remove the equipment.
Figure 70.
A396790
Table 26.
Gauge Reading Description
ATM/BAT Normal atmospheric
pressure reading. Bat-
tery condition.
15"/510mbar 381mm (15 in)Hg. Par-
tial vacuum- Vacuum
system is operating.
29"/980mbar 736mm (29 in)Hg. No
vacuum drawn- Possible
system leakage.
8000 8.0mm (0.31 in)Hg. Par-
tial vacuum - If the read-
ing does not progress
the system may have a
slow leak.
1000 1.0mm (0.039 in)Hg.
A Low pressure hose (blue) Deeper vacuum.
B High pressure hose (red) 600 0.6mm (0.023 in)Hg.
C Hose (yellow) Deep vacuum.
D Refrigerant cylinder 400 0.4mm (0.015 in)Hg.
E Scales Deep vacuum.
F Thermal blanket
200 0.2mm (0.0078 in)Hg.
Deep vacuum.
Electronic Vacuum Gauge
25 0.025mm (0.00098
The CPS VG100 vacuum gauge is an electronic type in)Hg. Pump Test. Max-
using LED's to indicate various states of vacuum. It imum sustainable vacu-
is used in place of or to supplement the gauge on the um.
vacuum pump. Before connecting into the system,
switch on to check that the first LED lights to show
that the battery is in good condition.
Note: The indicator lights show pressure in inches of

mercury (Hg) and vacuum in microns (0.001mm Hg).
12 - 17 9823/1650-1 12 - 17
00 - General
Check (Operation) Check (Pressure)

The air conditioning system needs to be checked
regularly to make sure it operates efficiently and The air conditioning system is a closed loop system
safely. and contains pressurised refrigerant. No part of the
Before you do any service operation, carry out a has been discharged by a refrigeration engineer
basic service check as described below. or a suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
1. Start the engine and operate at fast idle speed of
1000 RPM (Revolutions Per Minute). WARNING! Leak testing of Air Conditioning systems
should only be carried out in well ventilated areas.
2. Switch on the air conditioning and set to
maximum cooling. The refrigerant is heavier than air and will leak
downwards from the defective component. Check in
3. The cab temperature should be above the a well ventilated area.
specified value.
Hose or pipe connections are likely leakage points of
Temperature: 20 °C ( 68.0 °F)
any refrigerant circuit.
4. At low ambient temperatures it may be necessary
to operate the heating system to prevent the air It is essential that an electronic leak detector is used
conditioning system switching off. to locate leaks accurately. However, if a leak detector
is not available, an approximate source can be found
5. Operate the engine at operating temperature for by applying soap solution to the suspect area.
five to ten minutes.
To test for leaks in the high pressure side of
6. Close the cab door and windows and allow the the system i.e. from the compressor output to the
internal temperature to stabilize. expansion valve, run the air conditioning for a few
minutes then switch off the engine and test for
7. Measure the temperature at the evaporator leakage using an electronic leak detector or soapy
outlets. The temperature should change as the water.
compressor clutch cycles in and out.
To test for leakage in the low pressure side of the
8. The outlet temperature with the clutch engaged, system, switch off the air conditioning and leave for
should be significantly below the ambient a new minutes before you do the test.
temperature (4°C to 10°C) which can raise upto
the specified value when the clutch disengages.
Tightening leaking hoses
Temperature: 6 –8 °C ( 42.8 –46.4 °F)
The refrigerant hoses have crimped ferrule end
9. Stop the engine when the tests are complete. fittings. The hose connectors have an O-ring seal
which compresses when the connection is tight and
Off-Season Operation create an air tight seal.
During the off-season, the air conditioning system Hoses are used to connect the inlets and outlets
should be operated for at least five minutes every of the compressor, condenser, receiver drier and
month to circulate the oil in the system to lubricate expansion valve (the evaporator coil is connected to
the fittings and seals. the expansion valve within the air conditioning unit
using rigid pipes).
When you operate the system, make sure of the
followings. If leakage is detected from a hose connector, either
by means of an electronic leak detector or soapy
• Engine idle speed is more than 1000 RPM. water, tighten the connector up and repeat the
• Ambient temperature is more than the specified leakage test. If leakage is still evident, it will be
value. 0 °C ( 32.0 °F) necessary to discharge the system and renew the
• Cab temperature is more than the specified connector O-ring seal.
value. 20 °C ( 68.0 °F)
• The engine is at normal operating temperature.
12 - 18 9823/1650-1 12 - 18
00 - General
Adjust
For compressor drive belt adjustment, please see

(PIL 15-18).
12 - 19 9823/1650-1 12 - 19
03 - HVAC Unit
03 - HVAC Unit
Contents Page No.
12-03-00 General ........................................................................................................................... 12-21

12-03-03 Evaporator ...................................................................................................................... 12-23
12-03-06 Pressure Switch ............................................................................................................. 12-24
12-03-09 Expansion Valve ............................................................................................................. 12-27
12-03-12 Blower Motor .................................................................................................................. 12-28
12-03-15 Thermostat ..................................................................................................................... 12-29
12-03-18 Heater Coil ..................................................................................................................... 12-31
12 - 20 9823/1650-1 12 - 20
03 - HVAC Unit
00 - General
00 - General 9.2. Remove the chassis side cover from the

machine.
Remove and Install Refer to: PIL 06-06-13.

10. Remove the bolt 1 and bolt 2 which secure the
Air Conditioning Maintenance HVAC unit to the machine.
The air conditioning system is a closed loop system
11. Carefully remove the unit sufficiently to access
and contains pressurised refrigerant. No part of the
the electrical harness connector at the rear.
has been discharged by a refrigeration engineer 12. The electrical harness connector is located
or a suitably trained person. You can be severely behind the unit and cannot be disconnected until
frostbitten or injured by escaping refrigerant. the unit is pulled away from the machine.
The heating and ventilation unit (HV) contains a 13. Disconnect the electrical connector.
blower unit and heat exchanger matrix. It is located
under the right front side of the cab. 14. Remove the assembly from the machine.
The HVAC (Heating Ventilation Air Conditioning) unit Figure 72.

is the same as the HV unit but also contains an
evaporator matrix and thermostat.
F
Put labels on all the hoses before removal for easy G
installation.
Remove
Get access to the TXV (Thermal Expansion Valve)
by lowering the unit without disconnecting the hoses.
In this case it is not necessary to discharge the
refrigerant.

2. Install the safety strut. E
3. To remove the HVAC unit it is necessary to A C B D
discharge the refrigerant from the system. A Heater valve
B Heater matrix
Refer to: PIL 12.
C TXV (If installed)
4. Drain the cooling system. D Bolt 1
E Bolt 2
Refer to: PIL 21. F Clip
G Cable
5. If installed, remove the cab side cover to get
access to the HVAC unit.
Install
6. Disconnect the heater hoses from the heater
valve and from the heater matrix. 1. The installation procedure is the opposite of the
7. Disconnect the HVAC hoses from the TXV (if steps.
installed).
1.1. Make sure that the TXV is installed correctly
8. Remove the clip and disconnect the cable from with the diaphragm, located below the
the heater valve. valve.
9. For 526-56 machines only:
9.1. Remove the cab frame from the machine.
12 - 21 9823/1650-1 12 - 21
03 - HVAC Unit
00 - General
Figure 73.
C TXV
J Diaphragm
1.2. Charge the HVAC system and check for
leaks.
Refer to: PIL 12.
1.3. Fill the cooling system and check for leaks.
Refer to: PIL 21.
12 - 22 9823/1650-1 12 - 22
03 - HVAC Unit
03 - Evaporator
03 - Evaporator
Introduction
The evaporator works in the opposite way as the

condenser, here the liquid refrigerant is converted
to gas, absorbing the heat from the air in the
compartment.
The evaporator is located inside the HVAC (Heating

Ventilation Air Conditioning) unit.
12 - 23 9823/1650-1 12 - 23
03 - HVAC Unit
06 - Pressure Switch
06 - Pressure Switch Introduction

Introduction .................................................... 12-24 The binary pressure switch assembly has a low and
Check (Operation) ......................................... 12-25 high pressure switch designed to operate at specified
Remove and Install ....................................... 12-26 pressure values.
When the refrigerant pressure is within the specified

limits, the pressure switches will be closed and if the
thermostat and on/of switches are closed, current
will be supplied to the field coil of the clutch. Due
to the electromagnetic action the field coil clutch will
be pulled towards the compressor's clutch and the
refrigeration cycle will start.
12 - 24 9823/1650-1 12 - 24
03 - HVAC Unit
Check (Operation) Figure 74.
Binary Switch
The binary pressure switch is located in the
HVAC (Heating Ventilation Air Conditioning) system
pipework. Refer to: PIL 12-03.
Before testing the binary pressure switch, check the

refrigerant charge level. If the refrigerant charge level
is satisfactory, test the switch as described below:

2. Switch off the engine and remove the harness
connectors from the pressure switch.
3. Connect a link wire between the two harness B
connectors (effectively bypassing the pressure
switch). A
4. Switch on the engine and HVAC system. If the

system operates, one of the switches inside the
binary pressure switch assembly is faulty.
5. Install a new pressure switch assembly. If the
clutch still fails to operate, check the harness
electrical wiring for damage and open or short
circuits. A Binary pressure switch
B Harness connectors
12 - 25 9823/1650-1 12 - 25
03 - HVAC Unit
Remove and Install 4.1. If leaks are found, tighten the pressure
switch further until the leaking stops.
Remove
2. Discharge the HVAC (Heating Ventilation Air
Conditioning) system.
Refer to: PIL 12.
3. Remove the harness connectors.
4. Remove the screws and then remove the
pressure switch assembly.
Figure 75.
B
A
A Pressure switch
B Harness connectors
Install
1. Screw the pressure switch into the threaded port
and tighten sufficiently to form a gas tight seal.
2. Connect the harness connectors.
3. Charge the HVAC system.
Refer to: PIL 12.
4. Operate the HVAC system and check around the
pressure switch for leaks.
12 - 26 9823/1650-1 12 - 26
03 - HVAC Unit
09 - Expansion Valve
09 - Expansion Valve
Introduction
The purpose of the expansion valve is to remove

pressure from the liquid refrigerant and to allow the
refrigerant to change from liquid to vapour in the
evaporator. The expansion valve is located in the
HVAC unit.
12 - 27 9823/1650-1 12 - 27
03 - HVAC Unit
12 - Blower Motor
12 - Blower Motor
Fault-Finding
Fault
Blower operates on fan speed 3 only Table 27. Page 12-28
Blower does not operate Table 28. Page 12-28
Table 27. Blower operates on fan speed 3 only

Cause Remedy
Blower resistor defective. Install new resistor
Blower motor defective. Remove and install new blower motor unit.
Table 28. Blower does not operate

Cause Remedy
Fuse defective. Install new fuse and test again.
12 - 28 9823/1650-1 12 - 28
03 - HVAC Unit
15 - Thermostat
15 - Thermostat
Remove and Install
Remove 4. Remove the fixing bolts (x2) and then remove the
electrical connectors.
5. Carefully remove the thermostat and the
Refer to: PIL 01-03. thermostat sensor. Note the routing of the sensor
2. Install the safety strut. probe. Do not make sharp bends in the sensor
probe.
3. Remove the screws (x12) and take out the HVAC
(Heating Ventilation Air Conditioning) unit cover.
Figure 76.
H G
A
C E
D D
A Screws (x12) B HVAC unit cover

C Electrical connectors D Fixing bolt (x2)
E Sensor F Thermostat
G Protective sleeve H New sensor
12 - 29 9823/1650-1 12 - 29
03 - HVAC Unit
15 - Thermostat
Install
steps.
1.1. If a new thermostat is to be installed,
carefully remove the protective sleeve from
the new sensor. Do not make sharp bends
in the sensor probe.
1.2. Make sure that the HVAC cover sealing
gasket locates correctly.
12 - 30 9823/1650-1 12 - 30
03 - HVAC Unit
18 - Heater Coil
18 - Heater Coil
Introduction
The heater coil is a tube and fin construction, with the

inlet and outlet on one end of the coil. Hoses connect
the coil to the engine.
The heat energy for heating cab air comes from the
hot engine coolant. The heater systems are designed
to transfer heat energy from the engine coolant to the
air in the cab.
12 - 31 9823/1650-1 12 - 31
04 - Heater Unit
04 - Heater Unit
Contents Page No.
12-04-00 General ........................................................................................................................... 12-33
12 - 32 9823/1650-1 12 - 32
04 - Heater Unit
00 - General
00 - General Operation
Operation ....................................................... 12-33 For the heater unit operation, refer to HVAC (Heating
Fault-Finding .................................................. 12-34 Ventilation Air Conditioning)- general, refer to (PIL
12-00).
12 - 33 9823/1650-1 12 - 33
04 - Heater Unit
00 - General
Fault-Finding
Fault
Blower operates on fan speed(3) only Table 29. Page 12-34
Blower does not operate Table 30. Page 12-34
Table 29. Blower operates on fan speed(3) only

Cause Remedy
Blower resistor failed Replace the resistor.
Blower motor failed Replace the complete blower motor unit.
Table 30. Blower does not operate

Cause Remedy
Fuse blown Replace the fuse and re-check.
12 - 34 9823/1650-1 12 - 34
09 - Compressor
09 - Compressor
Contents Page No.
12-09-00 General ........................................................................................................................... 12-37
12 - 35 9823/1650-1 12 - 35
Notes:
12 - 36 9823/1650-1 12 - 36
09 - Compressor
00 - General
Introduction .................................................... 12-37 The compressor is located at the front of the engine,
Remove and Install ....................................... 12-38 it is the heart of the air conditioning system since
it produces the refrigerant flow. The compressor is
driven by the engine drive belt.
12 - 37 9823/1650-1 12 - 37
09 - Compressor
00 - General
Remove and Install
Remove 5.1. Put a label on the hoses to help installation.

5.2. Plug all the open ports and hoses to prevent
contamination.
6. Remove the high pressure hose to the
2. Discharge the air conditioning system refrigerant. compressor.
Refer to: PIL 12. 6.1. Put a label on the hoses to help installation.
3. Remove the FEAD (Front End Accessory Drive) 6.2. Plug all the open ports and hoses to prevent
belt. contamination.
7. Support the compressor and remove the
4. Disconnect the electrical harness connector from mount bolts that attach the compressor to the
the compressor and binary pressure switch. crankcase.
5. Remove the low pressure hose to the 8. Lift the compressor and remove from the
compressor. machine.
Figure 77.
E G
A B F
C D
J H
K B
A FEAD belt B Compressor

C Harness connector- binary pressure switch D Bolt
E Harness connector- compressor F High pressure hose
G Mount bolts H Low pressure hose
J Bolt K Cable ties
12 - 38 9823/1650-1 12 - 38
09 - Compressor
00 - General
Install
steps.
2. Replace the FEAD belt.
3. Recharge the air conditioning system refrigerant.
Refer to: PIL 12.
4. Check the air conditioning system for leaks and
correct operation.
12 - 39 9823/1650-1 12 - 39
12 - Receiver Drier
12 - Receiver Drier
Contents Page No.
12-12-00 General ........................................................................................................................... 12-41
12 - 40 9823/1650-1 12 - 40
12 - Receiver Drier
00 - General
Introduction .................................................... 12-41 The receiver drier is a device that removes
Check (Condition) .......................................... 12-42 moisture from the refrigerant as well as filtering any
contaminants or particulates from it. It also acts as a
tank to store excess coolant. Refer to: PIL 12-00-00.
12 - 41 9823/1650-1 12 - 41
12 - Receiver Drier
00 - General
Check (Condition) Figure 79.
1. Make the machine safe with the lift arm lowered.

2. Clean the sight glass on the top housing of the
receiver drier.
3. Check the sight glass.
3.1. Make sure that the sight glass is clear.
4. Check the pipe connections to the receiver drier
for signs of cracks or wear. 3. Clouded - Dessicant breakdown in the receiver
drier. Refer to Figure 80.
5. Make sure that the pipes are correctly clamped.
Figure 80.
5.1. If necessary, replace the pipes and clamps.
6. Do not remove the pipes from the charged HVAC
(Heating Ventilation Air Conditioning) system.
Sight glass indications

An approximate indication of the condition of the
refrigerant is seen through the receiver drier sight
glass.
1. Clear - No fault show unless the system cannot

supply cool air. The indication then is that the
system is completely discharged of refrigerant.
Refer to Figure 78.
Figure 78.
2. Foam or bubbles - Refrigerant is low and needs

of charging. Some slight bubbling is to be
expected when R134a refrigerant is used. Refer
to Figure 79.
12 - 42 9823/1650-1 12 - 42
15 - Condenser
15 - Condenser
Contents Page No.
12-15-00 General ........................................................................................................................... 12-45
12 - 43 9823/1650-1 12 - 43
Notes:
12 - 44 9823/1650-1 12 - 44
15 - Condenser
00 - General
Introduction .................................................... 12-45 A condenser is a component used to condense
Clean ............................................................. 12-46 a substance from its gaseous to its liquid state,
Check (Condition) .......................................... 12-46 typically by cooling it. In so doing the latent heat is
Remove and Install ....................................... 12-47 given up by the substance, and will transfer to the
condenser coolant.
12 - 45 9823/1650-1 12 - 45
15 - Condenser
00 - General
Clean Check (Condition)
When you are cleaning take extra care not to damage 1. Inspect the condenser coil for a build of dirt. If
the condenser fins or tubes. Damaged fins must necessary, clean the condenser coil.
be straightened out to make sure of a good airflow Refer to: PIL 12-15-00.
through the coil.
2. Inspect the condenser fins or tubes for damage.
1. Make the machine safe. Straighten out the damaged fins and make sure
Refer to: PIL 01-03. of a good airflow through the coil.
2. Raise the grille at the rear of the machine. The working environment of the machine can build
up airborne particles on the condenser coil over a
3. Use compressed air or low pressure water to period of time. This restricts the airflow around the
back flow through the coil fins. Make sure that the condenser coil and reduces the heat dissipation from
fins are not damaged. the refrigerant to the air. This results in poor air
conditioning performance.
4. Start the HVAC (Heating Ventilation Air
Conditioning) system and check the cooling The heavy build up on the condenser coil leads to
performance. over pressurisation of the system. This can cause
the high pressure cut-out switch to operate and
switch off the system. The internal blockage of the
condenser coil can also operate the high pressure
cut-out switch.
12 - 46 9823/1650-1 12 - 46
15 - Condenser
00 - General
Remove and Install
CAUTION When working on the HVAC System 6. Remove the work light securing screws and
gloves, eye protection and protective clothing remove the lights and brackets from the machine.
must be worn. Refrigerant may be released which Make sure the work lights and harness are clear
can be harmful to your skin or eyes. of the condenser.
7. Remove the bolt securing the pipe clamp,
Roof Mounted Condenser remove the clamp.
The condenser matrix is mounted on the cab roof. 8. Disconnect the condenser harness connector.
Use the assistance of a refrigeration engineer or 9. Put a label on the pipes to help installation.
suitably trained person to remove the condenser
10. Disconnect the HVAC pipes at the pipe stubs on
matrix since the refrigerant needs to be drained from
the condenser.
the system.
11. Plug all the open ports and pipes to prevent
Remove contamination.
1. Make the machine safe. 12. To prevent damage to the condenser when you
Refer to: PIL 01-03. remove or install the pipes, hold the hexagon
flats on the pipe stubs with a spanner when you
2. Disconnect the battery. loosen or tighten the pipe nuts.
Refer to: PIL 33-03. 13. When you remove the components or hoses,
retain any lubricant within the component/pipe
3. Make sure that the HVAC (Heating Ventilation Air
and fill the system with the same amount of clean
Conditioning) system is fully discharged.
lubricant (PAG Oil).
Refer to: PIL 12.
14. Using lifting equipment support the weight of the
4. Support the protective cover and remove the condenser unit.
nuts. Lower the cover from the matrix.
15. Remove the nuts and carefully lift the condenser
5. Remove the cable ties to release the work light matrix from the machine.
harness if installed.
12 - 47 9823/1650-1 12 - 47
15 - Condenser
00 - General
Figure 81.
A F
D D
F
B
F
E
C
G J
K
L
L
M
M
L
M
P
L
A Condenser matrix B Protective cover

C Cover fasteners D Air conditioning pipes
E Cable ties F Condenser support bolts
G Work light harness H Pipe clamp bolt
J Pipe clamp K Condenser electrical connector
L Condenser support nuts M Bracket securing screws
N Condenser unit P Support bracket
12 - 48 9823/1650-1 12 - 48
15 - Condenser
00 - General
Install Remove
1. The installation procedure is the opposite of the 1. Make the machine safe.
steps.
2. Open the engine compartment cover.
1.1. Recharge the HVAC system after
installation. Refer to: PIL 06-06.
Refer to: PIL 12. 3. Disconnect and remove the battery.
1.2. Operate the HVAC system and check for Refer to: PIL 33-00.
leaks.
4. Make sure that the HVAC system is fully
1.3. In the cab, set the HVAC system to discharged.
maximum cooling and check that cooled air
comes through the vents. Refer to: PIL 12.
5. Put a label on the hoses to help installation.
Cooling Pack Mounted Condenser
6. Disconnect the HVAC hoses at the pipe stubs on
The condenser matrix is mounted onto the cooling the side of the condenser.
pack in the engine compartment. If the condenser is
removed only to gain access to the cooling pack, this 7. Plug all the open ports and hoses to prevent
can be done without disconnecting the HVAC hoses contamination.
and with the system fully charged. Put the condenser
carefully on to one side with the hoses still connected 8. To prevent damage to the condenser when you
after you remove the nuts. Take care not to kink the remove or install the hoses, hold the hexagon
hoses. Do not allow the condenser to hang on the flats on the pipe stubs with a spanner when you
hoses unsupported. loosen or tighten the hose nuts.
Use the assistance of a refrigeration engineer or 9. When you remove the components or hoses,
suitably trained person to remove the condenser retain any lubricant within the component/hose
matrix since the refrigerant needs to be drained from and fill the system with the same amount of clean
the system. lubricant (PAG Oil).
10. Remove the nuts and carefully lift the condenser
matrix from the machine.
12 - 49 9823/1650-1 12 - 49
15 - Condenser
00 - General
Figure 82.
A C
B
C
A Condenser matrix B Pipe stub

C Nuts
12 - 50 9823/1650-1 12 - 50
15 - Condenser
00 - General
Install
steps.
1.1. Recharge the HVAC system after
installation.
Refer to: PIL 12.
1.2. Operate the HVAC system and check for
leaks.
1.3. In the cab, set the HVAC system to
maximum cooling and check that cooled air
comes through the vents.
12 - 51 9823/1650-1 12 - 51
18 - Filter
18 - Filter
Contents Page No.
12-18-00 General ........................................................................................................................... 12-53

12-18-06 Fresh Air ........................................................................................................................ 12-54
12 - 52 9823/1650-1 12 - 52
18 - Filter
00 - General
00 - General
Introduction
CAUTION The filter may be filled with dust. Wear
goggles and a face mask when removing the filter.
The air conditioning filter assemblies are designed to

filter all the contamination that is generated through
use to the required level of cleanliness.
The filters must be serviced to the requirements

of the machine maintenance schedules. To ensure
optimum performance and reliability it is important
that the machine's air conditioning system is serviced
periodically in accordance with the manufacturers
requirements.
Important: In dusty conditions the filter will require

cleaning/changing more often than detailed in the
maintenance schedule.
12 - 53 9823/1650-1 12 - 53
18 - Filter
06 - Fresh Air
06 - Fresh Air 1.1. Carefully install the new filter into the
housing.
Remove and Install 1.2. Make sure that the tab locates behind the
edge of the panel before you install the
CAUTION The filter may be filled with dust. Wear screw.
goggles and a face mask when removing the filter.
In dusty conditions the filter will require cleaning/

changing more often than detailed in the service
schedule.
Remove
2. Install the safety strut.
3. Remove the screw and the cover to access the
filter.
4. Remove the filter.
Figure 83.
C
E
A Screw
B Cover
C Filter
D Tab
E Panel
Install
Do not try to clean the filter. If the filter gets clogged,
install a new one.

steps.
12 - 54 9823/1650-1 12 - 54
21 - Heater Valve
21 - Heater Valve
Contents Page No.
12-21-00 General ........................................................................................................................... 12-57
12 - 55 9823/1650-1 12 - 55
Notes:
12 - 56 9823/1650-1 12 - 56
21 - Heater Valve
00 - General
00 - General
Remove and Install
The cab heater valve is part of the heater assembly 5. Align the marks on the control cable outer and
installed on the external part of the cab. the valve body.
6. Remove the clip 1.
Remove
7. Be careful, when you remove the hoses from the
valve, some amount of engine coolant will leak.
8. Loosen the clip 2 and remove the hoses from the
2. Remove the ignition key. valve.
3. If the engine is hot let it cool for one hour. 9. Disconnect the control cable from the valve lever.
4. Secure the heater hoses with clamps.
Figure 84.
A
C
D
E
G
H
B
B
F
A Cab heater valve B Heater hoses

C Control cable outer D Valve body
E Clip 1 F Clip 2
G Control cable H Valve lever.
12 - 57 9823/1650-1 12 - 57
21 - Heater Valve
00 - General
Install
steps.
1.1. Align the marks on the control cable outer
and valve body and then install a new clip 1.
1.2. Check the level of the engine coolant.
After installation
1. Start the engine and operate the cab heater at
the maximum temperature.
2. Operate the engine for the specified time.
Duration: 5 min
3. Stop the engine and check for any coolant leaks.
12 - 58 9823/1650-1 12 - 58
96 - Pipe
96 - Pipe
Contents Page No.
12-96-00 General ........................................................................................................................... 12-61
12 - 59 9823/1650-1 12 - 59
Notes:
12 - 60 9823/1650-1 12 - 60
96 - Pipe
00 - General
Introduction .................................................... 12-61 The refrigeration pipes are responsible for carrying
Check (Condition) .......................................... 12-62 the refrigerant ( liquid and gas) around the closed
loop air conditioning system. There are usually 4
pipes that connect the system components:
• Suction Line-Evaporator to Compressor, the

low pressure refrigerant gas line.
• Discharge Line-Compressor to Condensor, the
high pressure, hot gas line coming out of the
compressor.
• Condenser drain line-Condensor to Receiver
drier
• Liquid line-Receiver drier to Evaporator
12 - 61 9823/1650-1 12 - 61
96 - Pipe
00 - General
Check (Condition)
2. Check all the visible pipes and connectors.
3. Look for areas where the hoses flex or are
fastened, clamped, connected, bent or go
through panels. All these areas are potential
wear and damage points.
4. Do not remove the pipes from the charged HVAC
(Heating Ventilation Air Conditioning) system.
5. Tighten the pipes and adaptors to the correct
torque value.
12 - 62 9823/1650-1 12 - 62
15 - Engine
Contents Page No.
15-00 Engine
15-00-00 General ............................................................................................................................. 15-3
15-03 Crankcase
15-03-00 General ........................................................................................................................... 15-41
15-06 Cylinder Head
15-06-00 General ........................................................................................................................... 15-45
15-09 Bedplate
15-09-00 General ........................................................................................................................... 15-53
15-12 Crankshaft
15-12-00 General ........................................................................................................................... 15-61
15-12-03 Main Bearing .................................................................................................................. 15-70
15-12-06 Front Oil Seal ................................................................................................................. 15-72
15-12-09 Rear Oil Seal ................................................................................................................. 15-75
15-12-12 Pulley .............................................................................................................................. 15-79
15-15 Camshaft
15-15-00 General ........................................................................................................................... 15-81
15-18 Engine Belt
15-18-00 General ........................................................................................................................... 15-89
15-18-03 Drive Belt ....................................................................................................................... 15-92
15-18-21 Tensioner ........................................................................................................................ 15-96
15-21 Oil Filter
15-21-00 General ........................................................................................................................... 15-99
15-24 Air Filter
15-24-00 General ......................................................................................................................... 15-107
15-24-09 Dust Valve .................................................................................................................... 15-110
15-27 Crankcase Ventilation Filter
15-27-00 General ......................................................................................................................... 15-113
15-30 Valve
15-30-00 General ......................................................................................................................... 15-117
15-30-12 Valve Spring ................................................................................................................. 15-126
15-30-24 Stem Seal .................................................................................................................... 15-127
15-33 Connecting Rod
15-33-00 General ......................................................................................................................... 15-129
15-33-06 Big-End Bearing ........................................................................................................... 15-133
15-36 Piston
15-36-00 General ......................................................................................................................... 15-139
15-36-03 Piston Ring ................................................................................................................... 15-151
15-39 Manifold
15-39-00 General ......................................................................................................................... 15-153
15-42 Rocker and Fittings
15-42-00 General ......................................................................................................................... 15-155
15-42-06 Rocker Cover ............................................................................................................... 15-164
9823/1650-1
2018-06-08
15-42-09 Push Rod ..................................................................................................................... 15-166
15-42-21 Tappet ........................................................................................................................... 15-168
15-42-24 Tappet Cover ................................................................................................................ 15-170
15-45 Oil Sump
15-45-00 General ......................................................................................................................... 15-173
15-48 Grid Heater
15-48-00 General ......................................................................................................................... 15-179
15-51 Timing Gear
15-51-00 General ......................................................................................................................... 15-183
15-51-03 Crankshaft Gear ........................................................................................................... 15-186
15-51-06 Camshaft Gear ............................................................................................................. 15-189
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-190
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-193
15-51-22 Rear Case .................................................................................................................... 15-196
15-54 Flywheel
15-54-00 General ......................................................................................................................... 15-201
15-54-03 Housing ........................................................................................................................ 15-205
15-54-09 Gear Ring ..................................................................................................................... 15-209
15-54-12 Drive Plate .................................................................................................................... 15-210
15-60 Oil Pump
15-60-00 General ......................................................................................................................... 15-213
15-63 Mount
15-63-00 General ......................................................................................................................... 15-221
15-69 Oil Cooler
15-69-00 General ......................................................................................................................... 15-225
15-72 Alternator
15-72-00 General ......................................................................................................................... 15-231
15-72-03 Pulley ............................................................................................................................ 15-237
15-72-06 Voltage Regulator ......................................................................................................... 15-238
15-75 Starter Motor
15-75-00 General ......................................................................................................................... 15-241
15-75-03 Solenoid ....................................................................................................................... 15-249
15-75-06 Brush Gear ................................................................................................................... 15-250
15-80 Glow Plug
15-80-00 General ......................................................................................................................... 15-253
15-84 Sensor
15-84-00 General ......................................................................................................................... 15-257
15-84-03 Crankshaft Position ...................................................................................................... 15-268
15-84-06 Camshaft Position ........................................................................................................ 15-272
15-84-09 Knock ........................................................................................................................... 15-276
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-279
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-282
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-285
15-84-18 Temperature and Mass Air Flow (TMAF) ..................................................................... 15-288
15-84-24 Fuel Temperature ......................................................................................................... 15-291
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-294
15-84-29 Foot Throttle Control .................................................................................................... 15-297
15-84-33 Coolant Temperature .................................................................................................... 15-301
15-84-42 Engine Oil Temperature ............................................................................................... 15-304
15-84-43 Engine Oil Level ........................................................................................................... 15-307
15-84-48 Intercooler Outlet Temperature .................................................................................... 15-310
9823/1650-1
2018-06-08
15-86 Solenoid
15-86-00 General ......................................................................................................................... 15-315
15-86-09 Cold Start Advance ...................................................................................................... 15-316
15-87 Switch
15-87-00 General ......................................................................................................................... 15-321
15-87-03 Engine Oil Pressure ..................................................................................................... 15-322
15-87-09 Cold Start ..................................................................................................................... 15-325
15-90 Air Intake
15-90-00 General ......................................................................................................................... 15-331
9823/1650-1
2018-06-08
Acronyms Glossary
CAN Controller Area Network

CCV Crankcase Ventilation
DC Direct Current
DEF Diesel Exhaust Fluid
DTC Diagnostic Trouble Code
DTI Dial Test Indicator
ECM Engine Control Module
EGR Exhaust Gas Recirculation
ESOS Engine Shut-Off Solenoid
HPV High Pressure Valve
IMV Inlet Metering Valve
LMS Loadall Monitoring System
MAF Mass Air Flow
PTO Power Take-Off
SCR Selective Catalytic Reduction
TDC Top Dead Centre
TMAF Temperature and Mass Air Flow
TMAP Temperature Manifold Air Pressure
VGT Variable Geometry Turbocharger
9823/1650-1
2018-06-08
15 - Engine
00 - Engine
00 - Engine
Contents Page No.
15-00-00 General ............................................................................................................................. 15-3
15 - 1 9823/1650-1 15 - 1
Notes:
15 - 2 9823/1650-1 15 - 2
15 - Engine
00 - Engine
00 - General
Introduction ...................................................... 15-3 This section contains information about the complete
Health and Safety ........................................... 15-7 engine assembly. For specific engine technical
Technical Data ................................................. 15-8 information refer to the technical data section.
Component Identification ............................... 15-10
Make sure that the correct engine service tools,
Operation ....................................................... 15-14 consumables and torque figures are used when you
Diagram ......................................................... 15-18 perform service procedures.
Fault-Finding .................................................. 15-19
Drain and Fill ................................................. 15-29 Renewal of oil seals, gaskets, etc., and any
component showing obvious signs of wear or
Clean ............................................................. 15-29 damage is expected as a matter of course.
Check (Condition) .......................................... 15-30
Check (Leaks) ............................................... 15-31 It is expected that components will be cleaned and
Check (Pressure) .......................................... 15-31 lubricated where appropriate, and that any opened
hose or pipe connections will be blanked to prevent
Remove and Install ....................................... 15-33 excessive loss of hydraulic fluid, engine oil and
Store and Recommission .............................. 15-37 ingress of dirt.
Basic Description
The JCB ecoMax engine is a 4 cylinder diesel engine
in which the fuel is ignited by compression ignition.
The engine operates on a four stroke cycle.
The engine is started by an electric starter motor. The

starter motor turns the engine via a pinion and teeth
on the engine flywheel. Refer to: PIL 15-75.
When the engine runs the crankshaft drives the

camshaft via gears. The camshaft opens and closes
the inlet and exhaust valves and via push rods in time
with the four stroke cycle. The engine has 16 valves,
2 inlet and 2 exhaust valves for each cylinder.
The crankshaft also drives a high pressure fuel pump

via gears. The pump is part of the electronically
controlled common rail fuel injection system. Refer
to: PIL 18-00.
Air is drawn into the engine, via the inlet manifold

and exhaust gases exit via the exhaust manifold.
The engine uses a VGT (Variable Geometry
Turbocharger) which pressurises the air at the inlet
manifold. Refer to PIL 18-36.
A mechanical lubrication oil pump is driven by

the crankshaft via gears. The pump pressurises
and circulates oil for engine lubrication and cooling
purposes.
A drive belt driven by the crankshaft, drives a

coolant circulation pump, alternator, radiator cooling
fan and other ancillaries such as an air conditioning
compressor.
15 - 3 9823/1650-1 15 - 3
15 - Engine
00 - Engine
00 - General
Figure 85.
8
5
3
1
10
1 Flywheel 2 Crankshaft
3 Camshaft 4 Inlet valves (x8)
5 Exhaust valves (x8) 6 Push rods (x8)
7 High pressure fuel pump drive gear 8 Turbocharger
9 Lubrication oil pump 10 Front end drive belt
15 - 4 9823/1650-1 15 - 4
15 - Engine
00 - Engine
00 - General
Internal
The following identifies the main internal components
of a typical engine assembly. Some variants may
differ in detail.
Figure 86.
1 Rocker assembly 2 Valve bridge piece (x8)

3 Valve spring (x16) 4 Inlet valve (x8)
5 Exhaust valve (x8) 6 Piston assembly (x4)
6a Piston ring - top compression (x4) 6b Piston ring - 2nd compression (x4)
6c Piston ring - oil control (x4) 6d Gudgeon pin (x4)
7 Connecting rod assembly (x4) 8 Crankshaft
9 Main bearing - crankshaft (x5) 10 Big end bearing - crankshaft / connecting rod
(x4)
11 Front crankshaft oil seal 12 Flywheel
13 High duty PTO (Power Take-Off) idler gear (if
installed)
15 - 5 9823/1650-1 15 - 5
15 - Engine
00 - Engine
00 - General
Figure 87.
11
10 5
1a
6 7 4 3
1 Flywheel 1A Flywheel - crankshaft fixing bolts (x8)

2 Fuel injector (atomiser) (x4) 3 Flywheel hub
4 Crankshaft drive gear 5 High duty PTO idler gear (if installed)
6 Camshaft drive gear 7 Lubrication oil pump
8 High pressure fuel pump drive gear 9 Camshaft
10 Tappet (x8) 11 Push rod (x8)
15 - 6 9823/1650-1 15 - 6
15 - Engine
00 - Engine
00 - General
Health and Safety accordance with local regulations. Use authorised

waste disposal sites.
Hot Components
Touching hot surfaces can burn skin. The engine and
been running. Allow the engine and components to
cool before servicing the unit.
Turning the Engine
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
Notice: The engine and other components could
Special precautions must be taken if the machine is
to be washed using a high pressure system. Make
sure that the alternator, starter motor and any other
electrical components are shielded and not directly
cleaned by the high pressure cleaning system. Do
not aim the water jet directly at bearings, oil seals or
the engine air induction system.
WARNING! To bleed the injectors you must turn the
engine. When the engine is turning, there are parts
rotating in the engine compartment. Before starting
this job make sure that you have no loose clothing
(cuffs, ties etc) which could get caught in rotating
parts. When the engine is turning, keep clear of
rotating parts.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
Notice: Do not exceed the maximum level of engine
oil in the sump. If the maximum is exceeded, the
excess must be drained to the correct level. An
excess of engine oil could cause the engine speed
to increase rapidly without control.
WARNING! The engine has exposed rotating parts.
Switch off the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
WARNING! Hot oil and engine components can
burn you. Make sure the engine is cool before doing
this job. Used engine crankcase lubricants contain
harmful contaminants. In laboratory tests it was
shown that used engine oils can cause skin cancer.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
WARNING! Do not open the high pressure fuel
system with the engine running. Engine operation
causes high fuel pressure. High pressure fuel spray
can cause serious injury or death.
CAUTION! It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
lubricants. Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
15 - 7 9823/1650-1 15 - 7
15 - Engine
00 - Engine
00 - General
Technical Data
Table 31.
Description SL Engine SH Engine DH Engine DM Engine
Engine Variants Turbocharged with Turbocharged with Turbocharged with Turbocharged with
intercooler Intercooler Intercooler Intercooler
Emission compli- US-EPA Tier 4 Final, US-EPA Tier 4i, EU US-EPA Tier 4i, EU MAR-1 (Brazil)
ance EU Stage IV Stage IIIB Stage IIIB
Rated speed 2200 RPM (Revolu- 2200 RPM 2200 RPM ( 108 2200 RPM ( 108
tions Per Minute) kW), 2050 RPM ( kW), 2050 RPM (
129 kW) 129 kW)
Weight (Dry) (Dry weight-No cool- (Dry weight-No cool- (Dry weight-No cool- (Dry weight-No cool-
ing fan drive) 496 ing fan drive) 496 ing fan drive) 496 ing fan drive) 496
kg kg kg kg
Number of cylinders 4 4 4 4
Nominal bore size 103 mm 103 mm 106 mm 106 mm
Stroke 132 mm 132 mm 135 mm 135 mm
Cylinder arrange- In line In line In line In line
ment
Combustion Cycle 4-stroke 4-stroke 4-stroke 4-stroke
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Displacement 4.399 L 4.399 L 4.765 L 4.765 L
Compression ratio 16.7: 1 16.7: 1 16.7: 1 16.7: 1
Engine Compres- Compression vari- Compression vari- Compression vari- Compression vari-
sion ance between each ance between each ance between each ance between each
cylinder should be cylinder should be cylinder should be cylinder should be
no greater than 3.5 no greater than 3.5 no greater than 3.5 no greater than 3.5
bar ( 50.7 psi) bar ( 50.7 psi) bar ( 50.7 psi) bar ( 50.7 psi)
Direction of rotation Clockwise Clockwise Clockwise Clockwise
(viewed from front
{crankshaft pulley}
end)
Valves 4 per cylinder 4 per cylinder 4 per cylinder 4 per cylinder
Valve clearances
measured at the
tappet end of the
rockers (measured
cold)
- Inlet 0.15 –0.21 mm 0.15 –0.21 mm 0.15 –0.21 mm 0.15 –0.21 mm
- Exhaust 0.43 –0.49 mm 0.43 –0.49 mm 0.43 –0.49 mm 0.43 –0.49 mm
Lubricating oil pres- 1.6 –6.5 bar ( 23.2 – 1.6 –6.5 bar ( 23.2 – 1.6 –6.5 bar ( 23.2 – 1.6 –6.5 bar ( 23.2 –
sure (Dependent on 94.2 psi) 94.2 psi) 94.2 psi) 94.2 psi)
engine temperature
and speed)
Filter type Screw-on canister Screw-on canister Screw-on canister Screw-on canister
(with drain facility) (with drain facility) (with drain facility) (with drain facility)
(2) (2) (2) (2)
Pressure to open - 1.6 bar ( 23.2 psi) 1.6 bar ( 23.2 psi) 1.6 bar ( 23.2 psi)
by-pass valve
Oil pressure relief 6 bar ( 87.0 psi) 6 bar ( 87.0 psi) 6 bar ( 87.0 psi) 6 bar ( 87.0 psi)
valve setting
Oil pressure switch 0.6 bar ( 8.7 psi) 0.6 bar ( 8.7 psi) 0.6 bar ( 8.7 psi) 0.6 bar ( 8.7 psi)
setting falling falling falling falling
Oil pump
(1)
Integral unit with re- Integral unit with re- Integral unit with re- Integral unit with re-
lief valve lief valve lief valve lief valve
15 - 8 9823/1650-1 15 - 8
15 - Engine
00 - Engine
00 - General
Description SL Engine SH Engine DH Engine DM Engine

Combustion system Common rail direct Common rail direct Common rail direct Common rail direct
Injection Injection Injection Injection
High pressure fuel High pressure with High pressure with High pressure with High pressure with
pump electronically con- electronically con- electronically con- electronically con-
trolled fuel metering trolled fuel metering trolled fuel metering trolled fuel metering
(1) The oil pump is a non-serviceable part
(2) Some variants have ports for connection of a remote filter assembly.
15 - 9 9823/1650-1 15 - 9
15 - Engine
00 - Engine
00 - General
External
The following identifies the main components of a
typical engine assembly visible from the exterior.
Some variants may differ in detail.
Figure 88. Left hand Side
2 23 9
1
8
15
10
4
20
14 17
5
13
16
19
12
11
21
7
18
22 6
1 Rocker cover 2 Fuel injectors and high pressure fuel pipes

3 Lubrication oil filler cap 4 Timing gear case
5 Flywheel housing 6 Bedplate
7 Lubrication oil sump 8 EGR (Exhaust Gas Recirculation) cooler
9 Air inlet manifold 10 High pressure fuel pump
11 Fuel filter 12 Lubrication oil filler cap
13 Lubrication oil filter 14 Lubrication oil cooler housing
15 - 10 9823/1650-1 15 - 10
15 - Engine
00 - Engine
00 - General
15 Lubrication oil dipstick 16 Low duty PTO (Power Take-Off) (blanking

cover if no device is installed)
17 Low pressure fuel pipe (to tank) 18 Oil drain plug (sump)
19 Oil filter housing drain plug 20 IMV (Inlet Metering Valve)
21 ECM (Engine Control Module) 22 Crankcase ventilation filter assembly
23 Inlet manifold induction heater
Figure 89. Right Hand Side

6
11 14
8
2
16
3
10
9
4
12 15 13
1 EGR valve heatshield 2 Timing gear case
3 Flywheel housing 4 Bedplate
5 Lubrication oil sump 6 VGT (Variable Geometry Turbocharger)
15 - 11 9823/1650-1 15 - 11
15 - Engine
00 - Engine
00 - General
7 Exhaust manifold 8 Alternator

9 Coolant pump housing (crankcase) 10 Coolant inlet/radiator hose connector
11 Heavy duty PTO (blanking cover if no device 12 Starter motor assembly
is installed)
13 Turbocharger oil drain pipe 14 Turbocharger oil feed pipe
15 Oil drain plug (sump) 16 Cab heater connections
Figure 90. Front End

12
11
2
10
9
7
6 5
1 Rocker cover 2 Cylinder head

3 Crankcase 4 Bedplate
5 Lubrication oil sump 6 Crankshaft pulley
7 FEAD tensioner 8 Coolant pump and drive pulley assembly
9 Alternator and drive pulley assembly 10 Coolant thermostat housing/radiator hose
connector
11 VGT 12 Coolant temperature sensor
15 - 12 9823/1650-1 15 - 12
15 - Engine
00 - Engine
00 - General
Figure 91. Rear End
1 Rocker cover 2 Cylinder head

3 Flywheel 4 High pressure fuel pump drive gear cover
5 Flywheel housing 6 Engine electrical harness
7 VGT linkage 8 VGT actuator
9 Turbocharger 10 EGR valve
11 EGR co-axial cooler 12 EGR plate cooler
13 EGR water cooler pipe 14 Low pressure return pipe to tank
15 - 13 9823/1650-1 15 - 13
15 - Engine
00 - Engine
00 - General
Operation
It is important to note that number 1 cylinder is firing

The Four Stroke Cycle - 4 Cylinder and about to start its power stroke. Rotating the
Engine crankshaft a further full rotation would position the
pistons as described but the engine would be at a
This section describes the cycle sequence, for the 4 different stage in its four stroke cycle, with number 1
cylinder engine. cylinder about to start its Induction stroke.
With the crankshaft positioned as shown, the pistons The stages in the four stroke cycle for each cylinder
in numbers 1 and 4 cylinders are at top dead centre are as follows:
and pistons in numbers 2 and 3 cylinders are at
bottom dead centre.
Table 32. The Four Stroke Cycle

Stage num- Piston operation Valve operation
ber
1 The piston is at the top of its Compression Inlet and exhaust valves closed
stroke and is about to start its Power stroke.
2 The piston is at the bottom of its Power stroke Inlet valves closed, exhaust valves about to
and is about to start its Exhaust stroke. open
3 The piston is at the bottom of its Induction Exhaust valves closed, inlet valves about to
stroke and is about to start its Compression close
stroke.
4 The piston is at the top of its Exhaust stroke Valve Operation Exhaust valves about to
and is about to start its Induction stroke. close, inlet valves about to open
Firing Order From the stages described, it can be seen that

number 1 cylinder will be next to fire. Number 3
A cylinder is said to be firing, when the fuel / air cylinder is starting its compression stroke and is next
mixture ignites and the piston is about to start its in the cycle, followed by cylinders 4 and 2.
power stroke.
The firing order is therefore; 1, 3, 4, 2.
15 - 14 9823/1650-1 15 - 14
15 - Engine
00 - Engine
00 - General
Figure 92.
CYL1 CYL2 CYL3 CYL4
1 2
C B C B C B C B
G H J K
4
3
745620
745620
G H J K
C B
B C
A A A A
C B
B C
CYL1 Cylinder number 1 CYL2 Cylinder number 2

CYL3 Cylinder number 3 CYL4 Cylinder number 4
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation F Front of engine
1 Exhaust valves 2 Inlet valves
3 Crankshaft 4 Crankshaft gear
5 Camshaft drive gear
15 - 15 9823/1650-1 15 - 15
15 - Engine
00 - Engine
00 - General
Four Stroke Cycle revolution of the crankshaft, thus, in one cycle of a

four stroke engine, the crankshaft revolves twice.
Induction
Figure 93.
As the piston travels down the cylinder, it draws
filtered air through inlet valves into the cylinder.
Compression
When the piston reaches the bottom of its stroke the 3

inlet valves close. The piston then starts to rise up the 2
cylinder compressing the air trapped in the cylinder.
This causes the temperature and pressure of the air
to rise. Fuel is injected into the cylinder when the
piston is near to TDC (Top Dead Centre).
Power
C
The piston continues to rise after the start of fuel B
injection causing a further increase in pressure and
temperature.
The temperature rises to a point at which the fuel/air 1 4

mixture ignites. A cylinder is said to be firing, when
the fuel/air mixture ignites.
This combustion causes a very rapid rise in

both temperature and pressure. The high pressure 746030
generated propels the piston downward turning the 1 Induction stroke
crankshaft and producing work. 2 Compression stroke
3 Power stroke
Exhaust 4 Exhaust stroke
A Camshaft
Once the piston has reached the bottom of its travel, B Camshaft lobe - Inlet valve operation
the exhaust valves open and momentum stored C Camshaft lobe - Exhaust valve operation
in the flywheel forces the piston up the cylinder BDC Bottom dead centre
expelling the exhaust gases. TDC TDC
In a running engine these four phases are
continuously repeated. Each stroke is half a
15 - 16 9823/1650-1 15 - 16
15 - Engine
00 - Engine
00 - General
Figure 94.
717620
1 2 3 4
B C
A A A A
C B B C B
C
1 Induction stroke 2 Compression stroke

3 Power stroke 4 Exhaust stroke
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation
15 - 17 9823/1650-1 15 - 17
15 - Engine
00 - Engine
00 - General
Diagram
Electrical Operation and Schematics signal will be sent between the Transmission ECU
(Electronic Control Unit) and Engine ECU via the
The schematic diagram shows a typical system. CAN (Controller Area Network)bus to tell the Engine
For machine specific schematics, refer to electrical ECU that the transmission is in Neutral.
system- general, refer to (PIL 33-00).
The engine ECU provides power to the engine
The schematic is shown with the ignition switch compartment fusebox to energise the start relay, the
set to position III and the transmission set to N. A fuel pump relay, the starter motor and the fuel pump.
Figure 95.
Charge
D+
W
A
ECU
F
M
D
+VE -VE
3
4
5 H
1 6
2 7 M
E 8
9 K
10
J
C ECU
+VE G -VE
A Alternator B Battery
C Ignition switch D Starter motor
E Primary fuse F RHC/LMS (Loadall Monitoring System) display
G Engine compartment fusebox H Start signal relay
J Fuel pump relay K Fuel pump
L Engine ECU
15 - 18 9823/1650-1 15 - 18
15 - Engine
00 - Engine
00 - General
Fault-Finding
Fault
Engine - Will Not Start or Difficult to Start (No Exhaust Smoke) Table 33. Page 15-19
Engine - Will Not Start or Difficult to Start (Exhaust Smoke) Table 34. Page 15-20
Engine - Will Not Crank or Cranks Slowly Table 35. Page 15-21
Engine - Starts Then Stops Table 36. Page 15-21
Engine - Poor Running Table 37. Page 15-22
Engine - Poor Running at Idle Table 38. Page 15-22
Engine - Noise Excessive Table 39. Page 15-23
Engine - Compression Knocks Table 40. Page 15-24
Engine - Reduced Power Output Table 41. Page 15-24
Engine - Will Not Reach Maximum RPM Table 42. Page 15-25
Engine - RPM Surges Table 43. Page 15-25
Engine - Vibration Excessive Table 44. Page 15-26
Engine - Exhaust Smoke Excessive (Black Smoke) Table 45. Page 15-26
Engine - Exhaust Smoke Excessive (White/Blue Smoke) Table 46. Page 15-27
Engine - Will Not Shut Off Table 47. Page 15-27
Lubricating Oil - Consumption Excessive Table 48. Page 15-27
Lubricating Oil - Contaminated Table 49. Page 15-28
Lubricating Oil - Pressure Low Table 50. Page 15-28
Lubricating Oil - Pressure High Table 51. Page 15-28
Table 33. Engine - Will Not Start or Difficult to Start (No Exhaust Smoke)
Cause Remedy
No fuel in supply tank. Check the level in the fuel tank, use sight gauge or
dipstick. Replenish as required.
Ignition switch or starter electrical system failure. Check the operation of the ignition switch. Check the
correct electrical wires for open or short circuits.
Improper starting procedure. Verify proper starting procedure.
Fuel Filter blocked with water or other contamination. Drain fuel/water separator or replace fuel filter.
Defective fuel lift pump (fuel supply inadequate). Check that the lift pump operates and delivers fuel
to the high pressure fuel pump. Check the correct
electrical wires for open or short circuits. Check
fuses.
Fuel is aerated. Check the fuel system for loose connections and
possible air ingress points. Rectify and bleed the fuel
system.
Fuel inlet restriction. Maximum inlet restriction to fuel lift pump must not
exceed 100mm Hg.
Air intake or exhaust system blocked. Visually check the air intake and exhaust system for
blockage or obstruction. Remove as required. Check
the air filter elements for signs of blocking. Replace
as required.
Fuel drain return line blocked, not connected Verify that the fuel return line is not obstructed and
properly. connected to the top of the fuel tank.
One or more fuel injectors worn or malfunctioning. Check the electronic fault codes. Check the electrical
connections at the injectors.
15 - 19 9823/1650-1 15 - 19
15 - Engine
00 - Engine
00 - General
Cause Remedy
ECM (Engine Control Module) or electrical sensor Check the electronic fault codes. Check the electrical
fault. connections at the ECM and sensors.
Worn or malfunctioning high pressure fuel pump. Check the electronic fault codes. Do all the
necessary fault finding checks before removal of the
high pressure fuel pump.
Injectors Contaminated. Check the injectors. Use the Servicemaster test
procedure in Servicemaster Tools Actuator Test. Test
and replace as required.
Table 34. Engine - Will Not Start or Difficult to Start (Exhaust Smoke)
Cause Remedy
Starting procedure incorrect. Verify proper starting procedure.
Air intake system blocked or restricted. Visually check the air intake for blockage or
obstruction, remove as required. Check the air filter
elements for signs of blocking, replace as required.
system.
Fuel lift pump not operating correctly (fuel supply Check that the lift pump operates and delivers fuel
inadequate). to the high pressure fuel pump. Check the correct
fuses.
Fuel is contaminated or incorrect grade diesel fuel Stop the engine. Replace the fuel filters. Operate
used. the engine with a temporary supply of the correct
grade of clean fuel. Monitor the engine performance.
Dirty fuel will cause damage to the high pressure fuel
pump and injectors.
Fuel filter(s) blocked, fuel supply restricted. Check/replace the fuel filter(s). Check fuel lines for
restriction.
Fuel drain return line blocked, not connected Verify that the fuel return line is not obstructed and
Check fuel inlet restriction. Maximum inlet restriction to fuel transfer pump must
not exceed the specified amount:
Pressure: 0.133 bar ( 1.9 psi)
Inlet and exhaust valve clearances set incorrectly. Set the valve clearances to the recommended
clearances.
Engine compression low in one or more cylinders. Check the engine compression.
Cranking speed too slow. See Also: Table 35. Engine - Will Not Crank or
Cranks Slowly
ECM or electrical sensor fault. Check the electronic fault codes. Check the electrical
connections at the ECM and sensors.
15 - 20 9823/1650-1 15 - 20
15 - Engine
00 - Engine
00 - General
Table 35. Engine - Will Not Crank or Cranks Slowly

Cause Remedy
Starting electrical circuit connections loose or Clean and tighten connections.
corroded.
Battery charge low. Check battery voltage, charge the battery or
replace as required. Make sure that the alternator is
functioning correctly and charging the battery.
No electrical connection to starter solenoid. Check voltage to solenoid.
Crankshaft rotation restricted. Use special tool 892/01147 (crankshaft turning tool)
to manually turn the engine and check for any severe
rotational resistance.
Solenoid or starter motor fault. Replace starter motor.
Starter motor operating but not cranking. Remove the starter motor and check for broken teeth
on the ring gear or broken starter motor spring.
Table 36. Engine - Starts Then Stops

Cause Remedy
Engine starting under load. Check for added loading from malfunctioning
accessories or driven units, brakes dragging and
other changes in vehicle loading. Disengage the
hydraulic controls.
blockage or obstruction - remove as required. Check
the air filter elements for signs of blocking - replace
as required.
system.
Fuel lift pump not operating correctly (fuel supply Check that the lift pump is operating and delivering
inadequate). fuel to the injection pump.
Fuel is waxing due to extremely cold weather. Verify by inspecting the fuel filter. Clean the system
and use acclimatised fuel.
pump and injectors.
restriction.
Fuel drain return line blocked, not connected Verify that the fuel return lines are not obstructed and
ECM or Electrical sensor fault. Check the electronic fault codes. Check the electrical
connections at theECM and sensors.
15 - 21 9823/1650-1 15 - 21
15 - Engine
00 - Engine
00 - General
Table 37. Engine - Poor Running

Cause Remedy
Condition only occurs at idle. For possible poor running at idle faults.
See Also: Table 38. Engine - Poor Running at Idle
Engine is cold, coolant temperature sensor fault. Check the electrical connection at the coolant sensor.
Check the correct electrical wires for open or short
circuits.
Fuel injection lines leaking. Replace defective high pressure fuel lines. Do not
repair defective fuel lines. If there is a fuel leak
remove and discard the necessary components and
install new ones.
system
Fuel lift pump not operating correctly (fuel supply Check that the lift pump operates and delivers fuel
inadequate). to the high pressure fuel pump. Check the correct
fuses.
restriction.
pump and injectors.
Engine is cold - Thermostat fault. Drain Coolant, Remove and replace Thermostat.
Low Power (particularly at high speed) Exhaust back pressure high, Catalyst problem,
Check Servicemaster Diagnostics.
clearances.
Camshaft damaged. Inspect camshaft.
Tappets damaged. Inspect tappets.
Table 38. Engine - Poor Running at Idle

Cause Remedy
Coolant temperature sensor fault. Check the electrical connection at the coolant sensor.
circuits.
Engine mounts over-tightened, damaged or loose. Check/replace engine mounts.
install new ones.
system.
inadequate). fuel to the injection pump.
15 - 22 9823/1650-1 15 - 22
15 - Engine
00 - Engine
00 - General
Cause Remedy
restriction.
pump and injectors.
clearances.
Table 39. Engine - Noise Excessive

Cause Remedy
Drive belt squeal, insufficient tension or abnormally Check the tensioner and inspect the drive belt for
high loading. loading. deterioration, Make sure water pump,
tensioner pulley, fan, alternator turn freely. Check
for paint/oil or other material on pulleys. Check the
tension of accessory drive belts.
Coolant temperature sensor fault. Check the electrical connection at the coolant sensor.
circuits.
Air intake or exhaust leaks. See Also: Table 45. Engine - Exhaust Smoke
Excessive (Black Smoke)
pump and injectors.
clearances.
Turbocharger noise. Check turbocharger impeller and turbine wheel for
housing contact.
Inlet and exhaust valve springs broken. Check and install new valve springs.
Worn crank/connecting rod bearings (knocking under Check/replace rod and main bearings.
load).
Excessive camshaft bearing wear. Check bearings (engine overhaul required).
Worn or damaged pistons and/or piston rings. Check piston assemblies (engine overhaul required).
Gear train noise. Visually inspect and measure gear backlash.
Replace gears as required.
Loss of Pilot injection on one or more cylinders. Use service master to disable pilot injections to
identify audibly if they are still present.
15 - 23 9823/1650-1 15 - 23
15 - Engine
00 - Engine
00 - General
Table 40. Engine - Compression Knocks

Cause Remedy
system.
pump and injectors.
Inlet and exhaust valve springs broken. Check and install new valve springs.
Coolant operating temperature incorrect. Check and if necessary replace engine thermostat.
Table 41. Engine - Reduced Power Output

Cause Remedy
Oil level incorrect. Check oil level.
Engine overload. Check for added loading from malfunctioning
hydraulic controls.
Throttle position sensor (TPS) system defective. Check the throttle assembly. Check the electronic
fault codes.
pump and injectors.
Turbocharger boost control pipe leaking or damaged, Check boost control pressure. Inspect and tighten
or wastegate diaphragm ruptured. fittings, repair pipes, replace wastegate assembly.
install new ones.
restriction.
system.
inadequate). fuel to the injection pump. Check fuses.
as required.
Exhaust leak at the manifold or turbocharger. Check/repair leaks in the manifold or turbocharger
gaskets. Look for a cracked manifold.
Extra injector sealing washer installed under injector. Remove extra injector sealing washer.
15 - 24 9823/1650-1 15 - 24
15 - Engine
00 - Engine
00 - General
Cause Remedy
clearances.
high pressure fuel pump
Engine in reduced torque or limp home mode. Check the electronic fault codes.
Excessive exhaust back pressure Inspect Catalyst. Check Exhaust pressure readings
using Servicemaster.
Low DEF (Diesel Exhaust Fluid) Level. Fill the DEF Tank with clean DEF
Table 42. Engine - Will Not Reach Maximum RPM

Cause Remedy
Tachometer faulty. Verify engine speed with hand tachometer. Repair as
required.
Engine overloaded. Verify high idle speed without load. Investigate
operation to be sure correct gear is being used.
Pedal/ Hand Throttle position sensor (TPS) system Check the throttle assembly. Check the electronic
defective. fault codes.
system.
inadequate). fuel to the injection pump. Check fuses.
pump and injectors.
restriction.
Turbocharger wastegate actuator diaphragm Repair or replace turbocharger.
ruptured.
Table 43. Engine - RPM Surges

Cause Remedy
Fuel level low. Check the level in the fuel tank, use sight gauge or
Pedal/ Hand Throttle position sensor (TPS) system Check the throttle assembly. Check the electronic
defective. fault codes.
install new ones.
Fuel tank cap vent/breather blocked. Inspect and rectify as required. Replace cap if
necessary.
15 - 25 9823/1650-1 15 - 25
15 - Engine
00 - Engine
00 - General
Cause Remedy
system.
Table 44. Engine - Vibration Excessive

Cause Remedy
Engine not running smoothly/misfiring. See Also: Table 38. Engine - Poor Running at Idle
Fan damaged or accessories faulty. Check/replace the vibrating component. Refer to the
machine's service manual for correct installation and
torque figures.
Fan hub faulty. Inspect/replace the fan hub. Refer to the machine's
service manual for correct installation and torque
figures.
Engine mounts over-tightened, damaged or loose. Check/replace engine mounts.
clearances.
Alternator bearing worn or damaged. Check/replace the alternator.
Flywheel housing misaligned. Check/repair flywheel alignment.
Drive line components worn or unbalanced. Check and inspect drive line components such as
propshafts. Refer to the machine's service manual for
correct installation and torque figures.
Table 45. Engine - Exhaust Smoke Excessive (Black Smoke)

Cause Remedy
Engine being lugged down. Check for added loading from malfunctioning
hydraulic controls.
as required.
Air leak between the turbocharger and the intake Check/repair leaks in the air crossover tube, hoses,
manifold. or manifold cover. Visually inspect MAF (Mass Air
Flow) sensor tube
Intercooler faulty. Check for blocked cooler matrix.
Exhaust leak at the manifold or turbocharger Check/repair leaks in the manifold or turbocharger
gaskets. Look for a cracked manifold.
Turbocharger wastegate faulty. Repair or replace turbocharger.
15 - 26 9823/1650-1 15 - 26
15 - Engine
00 - Engine
00 - General
Cause Remedy
Turbocharger malfunction. Replace turbocharger.
connections at the ECM and sensors
Smokes under load at all speeds, but mainly low to
mid speed range.
Table 46. Engine - Exhaust Smoke Excessive (White/Blue Smoke)

Cause Remedy
Improper starting procedure. Verify proper starting procedure.
pump and injectors.
Diesel or hydraulic oil in sump. Check oil consistency. If oil contamination is
suspected check equipment such as PTO (Power
Take-Off) pump for hydraulic oil leaks past the seal
into the engine. Drain, flush and fill with clean oil.
Coolant temperature too low (over-cooling) - light Check the thermostat and replace if necessary.
blue or white high speed/light load.
One or more engine injectors worn or malfunctioning. Check the electronic fault codes. Check the electrical
- white/ blue smoke at operating temperature. connections at the injectors.
Coolant leaking into combustion chamber. Check the EGR (Exhaust Gas Recirculation) Cooler
for leaks. Replace Cylinder head gasket if necessary.
Leaking valve stem seals - evident after long idle Replace valve seals.
period and then acceleration.
Piston rings not sealing - evident with persistent blue Check the engine compression.
smoke at all speeds/load.
Table 47. Engine - Will Not Shut Off

Cause Remedy
Stop switch or stop switch electrical system failure. Check the operation of the stop switch. Check the
correct electrical wires for open or short circuits.
Table 48. Lubricating Oil - Consumption Excessive

Cause Remedy
Oil leaks. Inspect the engine for visible signs of leaks. Pay
particular attentions to seals, gaskets oil cooler and
external connections.
Oil level over-full. Check oil level.
Incorrect lubricating oil (specification of viscosity). Make sure the correct lubricating oil is being used.
Tier 4 Final Engines require a special oil grade. Refer Check for reduced viscosity from dilution with fuel.
to (PIL 75-03). Fuel dilution in lubricating oil can originate from a
defective high pressure fuel pump driveshaft seal.
Review/reduce the lubricating oil change intervals.
Crankcase ventilation (CCV) system blocked. Check the breather tube area for signs of lubricating
oil loss. Check and if necessary replace the CCV
filter.
Lubricating oil cooler leak. Check for lubricating oil in the coolant.
Turbocharger leaking lubricating oil to the air intake Inspect the air crossover tube for evidence of
or exhaust. lubricating oil transfer.
15 - 27 9823/1650-1 15 - 27
15 - Engine
00 - Engine
00 - General
Cause Remedy
Valve guide seals are leaking. Replace valve guide stem seals as required.
Piston rings not sealing - lubricating oil being Check the engine compression
consumed by the engine (blue smoke from exhaust).
Worn cylinder bores - lubricating oil being consumed Check the engine compression.
by the engine (blue smoke from exhaust).
Glazed cylinder bores. De-glaze bores as required.
Table 49. Lubricating Oil - Contaminated

Cause Remedy
Coolant in the lubricating oil, internal engine Check oil cooler O-rings. If necessary change the oil
component leaks. cooler.
Lubricating oil sludge excessive. Change oil and filter. Review oil and filter change
period. If operating in arduous applications, change
more frequently. Make sure the correct lubricating oil
is being used.
Fuel in the lubricating oil, engine operating too cold. Review the operation for excessive idling resulting in
the engine running below normal temperature.
Table 50. Lubricating Oil - Pressure Low

Cause Remedy
Check for reduced viscosity from dilution with fuel.
Fuel dilution in lubricating oil can originate from a
defective high pressure fuel pump driveshaft seal.
Review oil and filter change period. If operating in
arduous applications, change more frequently.
Pressure switch or gauge fault. Verify the pressure switch is functioning correctly.
Lubricating oil filter blocked. Change lubricating oil filter. Review oil and filter
change period. If operating in arduous applications,
change more frequently.
Lubricating oil filter drain down valve not installed. Change lubricating oil filter.
Suction pump pressure relief valve stuck open. Check/replace seal.
Oil pump pressure relief valve stuck open. Replace oil pump assembly.
Lubricating oil pump worn. Replace oil pump assembly.
Table 51. Lubricating Oil - Pressure High

Cause Remedy
Pressure switch or gauge fault. Verify the pressure switch is functioning correctly.
Engine running too cold. Check and if necessary replace the engine
thermostat.
Oil pump pressure relief valve stuck closed. Replace oil pump assembly.
15 - 28 9823/1650-1 15 - 28
15 - Engine
00 - Engine
00 - General
Drain and Fill Clean

Refer to: PIL 15-21-00. Notice: Clean the engine before you start engine
maintenance. Obey the correct procedures.
Contamination of the fuel system will cause
damage and possible failure of the engine.
Notice: The engine and other components could
Special precautions must be taken if the machine
is to be washed using a high pressure system.
Make sure that the alternator, starter motor and
any other electrical components are shielded
and not directly cleaned by the high pressure
cleaning system. Do not aim the water jet directly
at bearings, oil seals or the engine air induction
system.
Before carrying out any service procedures that

require components to be removed, the engine must
be properly cleaned.
Cleaning must be carried out either in the area of

components to be removed or, in the case of major
work, or work on the fuel system, the whole engine
and surrounding machine must be cleaned.
Stop the engine and allow it to cool for at least one

hour. DO NOT attempt to clean any part of the engine
while it is running.
1. Make sure that the electrical system is isolated.

2. Make sure that all electrical connectors are
correctly coupled. If connectors are open fit the
correct caps or seal with water proof tape.
3. Cover the alternator with a plastic bag to prevent
water ingress.
4. Seal the engine air intake, exhaust and breather
system.
5. Make sure that the oil filler caps and dipstick are
correctly installed.
6. Use a low pressure water jet and soft bristle
brush to soak off caked mud or dirt.
7. Apply an approved cleaning and degreasing
agent with a brush. Obey the manufacturers
instructions.
8. Use a pressure washer to remove the soft dirt
and oil. Important: DO NOT aim the water jet
directly at oil seals or electrical connectors and
electronic components such as ECU (Electronic
Control Unit)'s, alternator or fuel injectors. DO
NOT place the jet nozzle closer than the specified
distance to any part of the engine or exhaust
system.
15 - 29 9823/1650-1 15 - 29
15 - Engine
00 - Engine
00 - General
9. When the pressure washing is complete move Check (Condition)

the machine away from the wash area, or
alternatively, clean away the material washed
from the machine. Start the engine and check for:
10. Before working on specific areas of the engine • Excessive smoke

use a compressed air jet to dry off any moisture. • Excessive vibration
When the area is dry use a soft clean brush to • Excessive noise
remove any sand or grit particles that remain. • Overheating
• Performance
11. When removing components be aware of any • Unusual smells.
dirt or debris that may be exposed. Cover any
open ports and clean away the deposits before
proceeding.
Additional cleaning must be carried out prior to

working on the high pressure fuel system. Refer to:
PIL 18-00-00.
15 - 30 9823/1650-1 15 - 30
15 - Engine
00 - Engine
00 - General
Check (Leaks) Check (Pressure)

Special Tools
Before you start the machine, do a check for oil leaks: Description Part No. Qty.
Pressure Gauge (0-40 892/00278 1
Bar)
2. Get access to the engine compartment (if Digital Hydraulic 998/11051 1
applicable) Pressure Test Kit
3. Check the engine and the area below for oil This test is used to diagnose suspected poor
leaks. compression in one or more of the engine cylinders.
Use ServiceMaster to control the test.
4. Close the engine cover (if applicable).
5. If necessary, contact your JCB dealer. Engine Compression Test
1. Connect the Servicemaster tool to the machine.
2. Access the engine compression test and follow
the on screen commands.
3. There is a 5 second delay before the test starts.
4. The test disables the injectors and requests the
tester to crank the engine.
5. Crank the engine for at least 5 seconds, but no
longer than 10 seconds.
6. The engine ECU measures the variation in
engine cranking speed to determine if one
or more cylinders have lower than expected
compression values.
7. Turn off the ignition after the test.
Note: The engine cranking speed must be greater

than 200 rpm for the test to identify suspect cylinders,
ensure the battery condition is suitable to achieve
this test.
Engine Oil Pressure

Use the following procedures to measure the engine
oil pressure. Refer to Oil Sump (PIL 15-45) for a
full explanation of the lubricating oil circuit. Several
factors can influence the engine oil pressure, the
following conditions are assumed:
• The correct engine oil has been used. Refer to

Consumable Products (PIL 75-00).
• The engine oil level is correct. Refer to Oil Filter,
Check Level (PIL 15-21).
1. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
2. Get access to the engine.
3. Disconnect the electrical connector to the oil
pressure switch, remove the switch from the oil
cooler housing.
15 - 31 9823/1650-1 15 - 31
15 - Engine
00 - Engine
00 - General
4. Install a suitable adaptor into the vacant pressure 5. Start the engine and allow a few seconds to
switch port (M10 x 1.5mm thread) and a pressure gain oil pressure, increase the engine revs to
test gauge. Make sure that the gauge has a the rated speed. Record the pressure gauge
sealing washer as shown. reading, refer to Technical Data (PIL 15-00), for
the recommended circuit pressure.
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
Special Tool: Digital Hydraulic Pressure Test Kit 6. Remove the pressure gauge and install the
(Qty.: 1) pressure switch.
Figure 96.
High Lubrication Oil Pressure
High oil pressure will be evident when starting in cold
conditions. Typically the pressure will be 1 to 2 bar
and higher in cold operation, the pressure should
drop when the engine reaches normal operating
temperature.
If the pressure remains high when operating

temperature is achieved, check the oil level, if this is
correct, suspect the oil pump relief valve is at fault.
Low Lubrication Oil Pressure

A Several factors can be the cause of low lubricating
oil pressure:
• Low oil level - typically evident as a loss of

pressure when operating on uneven ground or
on a gradient.
• Blocked oil filter - a blocked filter will show as a
gradual loss of pressure.
• Blocked suction strainer (pick-up pipe) -
typically evident as low pressure on start up,
if the blockage frees itself in the sump, the
pressure will pick up to normal.
• Coolant in the oil - coolant in the lubricating oil
will show as a milky discolouration of the oil and
an increase in oil level. Check for damaged core
A plugs, lubricating oil cooler, cylinder head and/
or gasket.
• Fuel in the oil - fuel in the oil will result in thin'
black lubricating oil, the oil will also have a
diesel fuel smell. Check the fuel injection pump
(FIP) shaft seal refer to (PIL 18-18), piston ring
wear, lift pump diaphragm damage or injector
leakage if fuel is evident in the oil.
B • Damaged oil pump - oil pressure will be high at
low oil temperature but fall when oil becomes
hotter.
A Oil pressure switch

B Sealing washer
15 - 32 9823/1650-1 15 - 32
15 - Engine
00 - Engine
00 - General
Remove and Install
Special Tools recommended lifting equipment is shown. Use a

Description Part No. Qty. spreader bar when lifting the engine. Never attempt
Lifting Bracket Front 320/09062 1 to manually lift heavy components on your own.
Always use lifting equipment, or obtain the help of
Lifting Bracket Rear 320/09063 1 an assistant. Inspect the lifting brackets for signs
Engine Lifting Spreader 892/01382 1 of damage. The brackets must be correctly torqued
Bar to the crankcase. Make sure the lifting equipment
does not damage any of the engine dressing and the
Lifting Equipment rocker cover.
equipment. You must identify the weight of the item to Component Identification
enough and suitable for the job. Make sure that lifting The following component identification is for a typical
equipment is in good condition and complies with all engine installation. There will be some component
local regulations. differences depending on the machine variant.
Before attempting to remove the engine ensure that
The lifting equipment used must be an approved all the necessary components have either been
type and capable of lifting the engine safely. The removed, or safely disconnected from the engine.
Figure 97.
14 25 22 15
6
7
8
10 23
17
16
18
21
24
12 19
11
20
6 Engine mounting bolts 7 Lifting bracket- front

8 Lifting bracket fixing bolts 10 Fuel line connector- return to tank line
11 Fuel line connector at fuel filter- feed line from 12 Electrical connector- engine ECU machine
fuel pump side connector (grey)
15 - 33 9823/1650-1 15 - 33
15 - Engine
00 - Engine
00 - General
14 Electrical connections- alternator 15 Hose connection- cab heater

16 Electrical sensor- engine oil level 17 Electrical connections- starter motor
18 Lifting bracket- rear 19 Lifting bracket fixing bolts
20 Fixing bolts- gearbox to engine 21 Electrical connector- engine harness
22 Top hose 23 Bottom hose
24 Air inlet hose 25 Exhaust pipe
15 - 34 9823/1650-1 15 - 34
15 - Engine
00 - Engine
00 - General
Before Removal 16. Disconnect and plug the hoses at the hydraulic
pump.
the engine has been running, let it cool before 17. Disconnect the wiring to the hydraulic pump.
18. Remove the gearbox to engine retaining bolts,
2. Position the machine on firm level ground. Make pull the transmission and converter clear of
the machine safe, refer to (PIL 01-03). the engine, make sure that the converter stays
mounted on the gearbox shaft.
19. Attach slings to the engine lifting eyes.
Remove Special Tool: Lifting Bracket Front (Qty.: 1)
Special Tool: Lifting Bracket Rear (Qty.: 1)
1. Disconnect and remove the battery. Refer to (PIL Special Tool: Engine Lifting Spreader Bar (Qty.:
33-03). 1)
2. Drain the engine oil. Refer to (PIL 15-21). 20. Take the weight of the engine on the hoist and
remove the engine mounting bolts.
3. Drain the engine coolant, remove the cooling
pack. Refer to (PIL 21-03). 21. Withdraw the engine in a level attitude until the
hydraulic pump is clear of the chassis. Raise the
4. Discharge the hydraulic pressure. Refer to (PIL engine to lift it clear of the machine.
30-00).
22. Lower the engine into a suitable stand that is
5. Drain the hydraulic tank. Disconnect and plug capable of supporting the weight of the engine.
the hydraulic suction and delivery lines at the
transmission pump and gear pump. Label the
hoses to ensure correct reassembly. Refer to
(PIL 30-00).
6. Disconnect and plug the hydraulic cooler hoses.
Label the hoses to ensure correct reassembly.
7. Disconnect the exhaust system.
8. Label the cab heater hoses at the engine block
connectors. Release the hose clips and remove
the hoses.
9. Disconnect the wiring connections from the
starter motor. Refer to (PIL 15-75).
alternator. Refer to (PIL 15-72).
engine sensors and actuators. Refer to (PIL
15-84).
12. Disconnect the fuel supply line at the fuel lift
pump and the spill line at the fuel injection pump.
Cap all hoses and ports to prevent ingress of dirt.
13. Disconnect the electrical harness at the engine
harness.
14. Uncouple the electrical harness at the
ECM (Engine Control Module) machine side
connector. Important: Do not touch the connector
pins on the ECM or harness connectors. Cover
the connectors to prevent contamination.
15. Ensure that all relevant harnesses and hoses are
unclipped from the engine and tied out of the way.
15 - 35 9823/1650-1 15 - 35
15 - Engine
00 - Engine
00 - General
Figure 98. 3. Fill the cooling system with the correct mix of
coolant fluid. Refer to (PIL 21-00).
4. Fill and Check the hydraulic fluid level. Refer to
B (PIL 30-00).
5. Fill and Check the engine oil level. Make sure the
correct oil is used. Refer to (PIL 75-03).
6. On completion, check the hydraulic and cooling
system for leakage and levels.
7. Check the function of the drive and loader
services.

C Item Nm
A 47
A Lifting bracket mounting bolts

B Lifting equipment
C Spreader bar
Install
1. Replacement is a reversal of the removal
procedure. Note the following:
2. Important: It is vitally important that the torque
converter is installed at the gearbox and engine
flywheel correctly. Failure to locate the converter
correctly will result in damage to the gearbox oil
pump on engine start up.
15 - 36 9823/1650-1 15 - 36
15 - Engine
00 - Engine
00 - General
Store and Recommission
If an engine is to be placed into storage, all external

Engines should be stored in the original shipping signs of surface coating damage or corrosion should
packaging. Damaged or disturbed packaging should be cleaned and re-coated. Electrical connectors and
be made weatherproof immediately. components should be coated with a protective
spray.
If an engine is shipped with oil, it should be stored in
the correct (upright) position. Capping Engine Openings
If an engine is shipped dry of oil, after 6 months it
All openings on the engine must be suitably capped
should be filled with oil to the correct level and re-
to prevent ingress of water and contamination by
inhibited, refer to hot test description.
foreign particles.
All floor stock engines should be stored under cover
Some engine configurations may differ in detail to the
in dry conditions and not subjected to extreme
illustrations shown. Make sure you identify and cap
variations in temperature or humidity.
all openings.
Figure 99. Typical engine
13
5
3
4
6
14
17
16
12
11
10 2
15
15 - 37 9823/1650-1 15 - 37
15 - Engine
00 - Engine
00 - General
1 Top hose cap 2 Bottom hose cap

3 Turbocharger intake cap 4 Turbocharger compressor outlet cap
5 Turbocharger exhaust outlet cap 6 Inlet manifold cap
7 Dipstick plug 8 ECM (Engine Control Module) machine
harness connector cap
9 Fuel spill back line cap 10 Low duty PTO (Power Take-Off) (if installed)
cap
11 Heavy duty PTO (if installed) cap 12 Cab heater feed and return spigots
13 Coolant circuit de-gas spigot 14 CCV canister outlet on the closed loop
breathing circuit (55kW)
15 Low pressure fuel filter inlet spigot (engines 16 SCR (Selective Catalytic Reduction) coolant
with fuel filter attached) feed spigot (if installed)
17 Fuel pump low pressure inlet spigot (engines
with no fuel filter attached)
12 Month Revalidation Procedure Notice: Do not operate the starter motor for more
than 20 s at one time. Let the starter motor cool for
1. Pre-inspection: at least 2 min.
1.1. Inspect packaging for signs of damage. Table 53. Oil Pressure Switch Set Points
1.2. Inspect the caps for signs of damage. Oil pressure switch > 0.6 bar ( 8.7 psi)
closed
1.3. Inspect openings for signs of water or dirt
ingress. Oil pressure switch open < 0.6 bar ( 8.7 psi)
1.4. Inspect the engine for signs of external OEM Commissioning Check on Engine
corrosion. Installation After More Than 12 Months
1.5. Inspect the engine for signs of fluid leaks.
1. Flush the coolant system with proprietary
2. From storage: flushing solution.
2.1. Remove the air intake caps. 2. Refill the coolant system with 50/50 mix of long
life antifreeze mixture.
2.2. Make sure the engine oil level is correct.
2.3. Using a suitable power supply at the correct 3. Hot test engine according to the hot test profile.
voltage, crank the engine over. Refer to Table 54.
2.4. During cranking, check that the oil pressure 4. Drain engine oil and replace engine oil filter.
switch opens using a multimeter. The switch
is closed when there is no or low oil 5. Refill with the correct oil and inhibit the cooling
pressure and opens when oil pressure system using the correct product.
reaches a set point. After three separate 20 6. Record details of work as required.
second cranking periods, If the oil pressure
switch does not open (indicating no, or
low oil pressure), contact your JCB engine
Hot Test Description
dealer. WARNING When using cleaning agents, solvents
or other chemicals, you must adhere to
2.5. Recap all engine openings.
the manufacturer's instructions and safety
2.6. Coat any exposed bare metal with a precautions.
suitable product.
2.7. Electrical connectors and components All engines despatched from JCB will have been
should be coated with a protective spray if subjected to a hot test (checking items such as oil
exposed. pressure, engines speeds, torque values etc.) and
therefore the interior surfaces will have been coated
2.8. Cover in weatherproof packaging. with engine oil.
2.9. Place in storage, under cover on level
ground or shelving. All coolant galleries are coated with CRODAFLUID
PA75 corrosion inhibitor.
2.10. Record details of work as required.
2.11. Do not expose to extremes of temperature Stored engines will require re-inhibiting every 12
or humidity. months, this will include hot testing the engine using
a dynamometer. The hot test profile is:
15 - 38 9823/1650-1 15 - 38
15 - Engine
00 - Engine
00 - General
Table 54. Hot Test Profile

Stage Mode Speed Torque Time
(rpm) (Nm) (secs)
1 Speed/ 830 0 50
Torque
2 Speed/ 1300 50 60
Torque
3 Speed/ 2500 0 60
Torque
4 Speed/ 1300 0 25
Torque
5 Speed/ 800 0 35
Torque
15 - 39 9823/1650-1 15 - 39
15 - Engine
03 - Crankcase
03 - Crankcase
Contents Page No.
15-03-00 General ........................................................................................................................... 15-41
15 - 40 9823/1650-1 15 - 40
15 - Engine
03 - Crankcase
00 - General
Introduction .................................................... 15-41 The crankcase is the housing for the crankshaft.
Technical Data ............................................... 15-42 The enclosure forms the largest cavity in the engine
and is located below the cylinders. It is integral with
the cylinder bank and forms an engine block. It has
an opening in the bottom to which an oil sump is
attached with a gasket and bolted joint.
The crankcase protects the crankshaft and

connecting rods from foreign objects it also keeps
the engine oil contained and allows the oil to be
pressurised and also provide the rigid structure with
which to join the engine to the transmission.
Figure 100.
A
A Crankcase
B Crankshaft
15 - 41 9823/1650-1 15 - 41
15 - Engine
03 - Crankcase
00 - General
Technical Data
Table 55. Crankcase and Bedplate Data

4.4 L 4.8 L
Cylinder bore
(1)
103 –103.02 mm 106 –106.02 mm
Main bearing bolts torque
(2)
First stage 50 N·m 50 N·m

Second stage 115 N·m 115 N·m
Final stage Turn a further 180 ° Turn a further 180 °
Surface finish for cylinder head Rz < 15 m, Rmax < 20 Rz < 15 m, Rmax < 20
joint
(3)
Diameter of first oversize bore 103.5 –103.52 mm 106.5 –106.52 mm

Diameter of second oversize bore 104 –104.02 mm
Main bearing bore (without bear-
ings)
Numbers 1 to 4 92 –92.02 mm 92 –92.02 mm
Number 5 105 –105.02 mm 105 –105.02 mm
Main bearing bore (with bearings)
Numbers 1 to 4 88.047 –88.09 mm 88.047 –88.09 mm
Number 5 100.047 –100.09 mm 100.047 –100.09 mm
Camshaft bore
Numbers 1 to 4 60.04 –60.07 mm 60.04 –60.07 mm
Number 5 (bush) 60.29 –60.32 mm 60.29 –60.32 mm
Permissible wave profile wt < 10 m (2.5 distance) wt < 10 m (2.5 distance)
(1) Nominal diameter to be measured 63mm below the cylinder head face.
(2) Torque information MUST be used in conjunction with the recommended procedures contained in this
manual. Failure to use the appropriate and correct removal, replacement, dismantle and assembly procedures
may result in an engine failure in service. Refer also to the procedures for the correct bolt tightening sequence.
(3) The crankcase to cylinder head surface may be skimmed and restored using the oversize gaskets (0.25mm
and 0.5mm).
15 - 42 9823/1650-1 15 - 42
15 - Engine
06 - Cylinder Head
06 - Cylinder Head
Contents Page No.
15-06-00 General ........................................................................................................................... 15-45
15 - 43 9823/1650-1 15 - 43
Notes:
15 - 44 9823/1650-1 15 - 44
15 - Engine
06 - Cylinder Head
00 - General
Introduction .................................................... 15-45 The cylinder head is located above the cylinders
Technical Data ............................................... 15-46 on top of the crankcase. It closes in the top of the
Component Identification ............................... 15-47 cylinder, forming the combustion chamber. This joint
Remove and Install ....................................... 15-48 is sealed by a cylinder head gasket.
The cylinder head also provides the space for the

passages that feed air and fuel to the cylinder and
allow the exhaust to escape. The cylinder head is
also used to mount the valves and fuel injectors.
15 - 45 9823/1650-1 15 - 45
15 - Engine
06 - Cylinder Head
00 - General
Technical Data
Table 56. Cylinder Head Data

Cylinder head distortion (maximum permissible)
(1)
- End to end 0.05 mm

- Side to side 0.03 mm
Valve recess depth
- Inlet 0.85 mm
- Exhaust 0.85 mm
Valve seat angle
- Inlet 120 (inclusive)
- Exhaust 90 (inclusive)
Cylinder head bolts tourque
(2)
- First stage 40
- Second stage 75
- Third stage Repeat 75
- Fourth stage Torque angle + 90
- Final stage Torque angle + 180
Surface finish for cylinder head joint Rz < 15 Rmax < 20
Permissible wave profile wt < 10 m 2.5 distance
(1) The block to cylinder head surface may be skimmed and restored using the oversize gaskets (0.25mm
and 0.5mm).
(2) Torque information MUST be used in conjunction with the recommended procedures contained in this
manual. Failure to use the appropriate and correct remove, install, disassemble and assemble procedure may
result in an engine failure in service. Refer also to the procedures for the correct bolt tightening sequence.
15 - 46 9823/1650-1 15 - 46
15 - Engine
06 - Cylinder Head
00 - General
Figure 101.
C
A Cylinder head
B Cylinder head gasket
C Cylinder head bolts
15 - 47 9823/1650-1 15 - 47
15 - Engine
06 - Cylinder Head
00 - General
Remove and Install
Special Tools 2. Make sure that the engine is safe to work on. If
Description Part No. Qty. the engine has been running, let it cool before
Torque Wrench 993/70111 1 you start the service work.
(10-100Nm) 3. Get access to the engine.
Consumables 4. Remove the thermostat, refer to (PIL 21-12).
Cleaner/Degreaser 4104/1557 0.4 L 5. Remove the fuel pipes, refer to (PIL 18-96).
- General purpose 6. Remove the rocker cover, refer to (PIL 15-42).
solvent based parts
cleaner 7. Remove the fuel injectors, refer to (PIL 18-18).
Before Removal 8. Remove the rocker assembly, refer to (PIL

15-42).
1. This procedure requires service parts. Make sure
9. Remove the exhaust manifold, refer to (PIL
you have obtained the correct parts before you
18-24).
start, refer to Parts Catalogue.
10. Remove the inlet manifold, refer to (PIL 18-24).
15 - 48 9823/1650-1 15 - 48
15 - Engine
06 - Cylinder Head
00 - General
Figure 102.
21
22
20
19
18 14 10 6 2 3 7 11
15
16
17 13 9 5 1 4 8 12
0° +90° +180°
1-18 Cylinder head fixing bolts (x18) 19 Cylinder head

20 Crankcase 21 Location dowels (x2)
22 Cylinder head gasket
15 - 49 9823/1650-1 15 - 49
15 - Engine
06 - Cylinder Head
00 - General
Remove Special Tool: Torque Wrench (10-100Nm)

(Qty.: 1)
1. Progressively remove the cylinder head bolts in
4.2. Then, further tighten the bolts, starting with
reverse order, starting at bolt 18. Note that the
the middle pair and working outwards (in
bolts MUST NOT be re-used. Discard the bolts.
sequence 1- 18) to the 2nd stage pre-
2. Carefully lift the cylinder head from the torque.
crankcase. If necessary use a soft face hammer. 4.3. Then, re-tighten the bolts, starting with
DO NOT use a lever to separate the cylinder the middle pair and working outwards (in
head from the crankcase. Discard the head sequence 1-18) to the 3rd stage pre-torque.
gasket.
4.4. Use the angle gauge to angle tighten the
3. Using a suitable cleaning agent, carefully remove bolts, starting with the middle pair and
all traces of the head gasket material from the working outwards (in sequence 1-18) to the
cylinder head and crankcase mating faces. 4th stage pre-torque. As a visual check,
Consumable: Cleaner/Degreaser - General matchmark the bolts to the cylinder head
purpose solvent based parts cleaner before you start. When the bolts have
been angle tightened, the matchmarks will
4. Check the cylinder head and crankcase mating appear as shown at Y.
faces for signs of damage and distortion, refer to 4.5. Finally, angle tighten the bolts, starting with
Technical Data (PIL 15-06). the middle pair and working outwards (in
sequence 1- 18) for the final stage torque.
Before Assembly
Table 57.
1. Obtain the correct new cylinder head bolts. Note
that the original bolts MUST NOT be re-used. Description Torque Value
Cylinder head to
2. Obtain the correct replacement head gasket. crankcase bolts 1-18
Note the number of identification holes as shown - first stage torque 40 N·m
at X.
- second stage torque 75 N·m
3. Make sure that all items are clean and free from - third stage torque 75 N·m
damage and corrosion. - fourth stage torque 90 °
- final stage torque 180 °
Assemble
The cylinder head bolts are tightened using a torque
and angle method, refer to Fasteners and Fixings,
General, Introduction (PIL 72-00).
1. Replacement is the reversal of the removal

procedure.
2. Make sure that the location dowels are correctly
installed into the crankcase. Use a dowel punch
to install the dowels as required.
3. Position a new head gasket on to the crankcase
mating face. Make sure that the gasket is
installed the correct way around and correctly
located over the dowels.
4. Lower the cylinder head on to the crankcase.
Make sure that the cylinder head is correctly
located on the dowels. Install new cylinder head
bolts. Tighten the bolts in five stages, use the
torque and angle method, refer to Fasteners and
Fixings, General, Introduction (PIL 72-00).
4.1. Tighten the bolts, starting with the middle
pair and working outwards (in sequence
1-18) to the 1st stage pre-torque.
15 - 50 9823/1650-1 15 - 50
15 - Engine
09 - Bedplate
09 - Bedplate
Contents Page No.
15-09-00 General ........................................................................................................................... 15-53
15 - 51 9823/1650-1 15 - 51
Notes:
15 - 52 9823/1650-1 15 - 52
15 - Engine
09 - Bedplate
00 - General
Introduction .................................................... 15-53 The bedplate acts as the main strength component
Remove and Install ....................................... 15-54 of the engine. it maintains the correct alignment and
supports the weight of the internal components.
Figure 103.
1
1 Bedplate
2 Crankcase
15 - 53 9823/1650-1 15 - 53
15 - Engine
09 - Bedplate
00 - General
Remove and Install
Special Tools 10. Remove the rocker assembly including the push
Description Part No. Qty. rods, refer to (PIL 15-42).
Template for Sealant 892/12356 1 11. It is not necessary to remove the cylinder head
Bedplate to Crankcase assembly to remove the crankshaft. If however
(4 Cyl) the cylinder head needs to be removed for other
Torque Wrench 993/70111 1 reasons (for piston and connecting rod removal
(10-100Nm) for example) remove it now, refer to (PIL 15-06).
Consumables 12. Remove the fuel injection pump, refer to (PIL
Description Part No. Size 18-18).
Cleaner/Degreaser 4104/1557 0.4 L 13. Remove the starter motor, refer to (PIL 15-75).
- General purpose
solvent based parts 14. Remove the high duty PTO (Power Take-Off)
cleaner device (if installed).
CAUTION This component is heavy. It must only 15. Position the engine upside down in a suitable jig
be removed or handled using a suitable lifting or fixture, supported at the front of the cylinder
method and device. block.
16. Remove the flywheel, refer to (PIL 15-54).
Before Removal
17. Remove the flywheel housing, refer to (PIL
1. This procedure requires service parts. Make 15-54).
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue. 18. Remove the fuel injection pump drive gear, refer
to (PIL 15-51).
the engine has been running, let it cool before 19. Remove the oil pump, refer to (PIL 15-60).
20. Remove the high duty PTO idler drive gear (if
3. Remove the engine, refer to (PIL 15-00). installed), refer to (PIL 15-51).
4. Remove the drive belt, refer to (PIL 15-18). 21. Remove the crankshaft drive gear, refer to (PIL
15-51).
5. Remove the crankshaft pulley, refer to (PIL
15-12). 22. Remove the camshaft, refer to (PIL 15-15).
6. Remove the oil sump, refer to (PIL 15-45). 23. Remove the rear timing case, refer to (PIL
15-51).
7. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96). 24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
8. Remove the rocker cover, refer to (PIL 15-42). caps, refer to (PIL 15-12).
9. Remove the fuel injectors, refer to (PIL 18-18).
15 - 54 9823/1650-1 15 - 54
15 - Engine
09 - Bedplate
00 - General
Figure 104.
4 1 5
11
8 9
7 10
3 P3 2 6
X
12 18
18
18
18
18
13
18
1-10 Main bearing bolts (x10) 11 Bedplate peripheral bolts (x16)

12 Bedplate 13 Crankcase
18 Upper bearing shell (x5) P3 O-ring (if installed)
T1 Lifting bolts (obtain locally)
15 - 55 9823/1650-1 15 - 55
15 - Engine
09 - Bedplate
00 - General
Remove suitable lifting equipment (if the bedplate is lifted

manually, two people will be required). DO NOT
1. Remove the bedplate peripheral bolts. use a lever to separate the bedplate.
2. Progressively remove the main bearing bolts in 4. Remove and discard the O-ring.
reverse order starting at bolt 10. The bolts MUST
NOT be re-used. Discard the bolts. 5. Carefully remove the upper bearing shells from
the bedplate, remove the bedplate.
3. Install the four temporary lifting bolts. Carefully
separate the bedplate from the crankcase. Use
Figure 105.
Y P2 Y A (T5) T4
T4
P2
P3
B (T5)
Y Y P2 T6
18
18 18
X
18
T6 18
4 1 5 T6
11
8 9
W
18
12
T6
7 10
3 2 6
13
1-10 Main bearing bolts 11 Bedplate peripheral bolts (x16)

12 Bedplate 13 Crankcase
18 Lower bearing shells (x5) A Left side template
B Right side template T3 Angle Gauge (obtain locally)
15 - 56 9823/1650-1 15 - 56
15 - Engine
09 - Bedplate
00 - General
T4 Guide pins (x2 obtain locally) T5 Sealant template

T6 Lifting bolts (x4 obtain locally) V Sealant template portion for removal
W Bearing tab X Rear main bearing
Y Bearing location tab P2 Anaerobic sealant
P3 O-ring
15 - 57 9823/1650-1 15 - 57
15 - Engine
09 - Bedplate
00 - General
Before Installation as a guide apply beads of sealant P2 around the

crankcase/bedplate mating face as shown to the
1. Clean off all traces of the old sealant compound dimension specified.
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
9. Remove the four fixing bolts at positions Y.
clean the main bearing saddles in the bedplate
Remove the templates A and B, make sure
and crankcase. Take care not to block the oil
you do not smudge the sealant. Discard the
ways or the piston cooling jets.
templates.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner 10. Add beads of sealant P2 around the four bolt
holes at positions Y, so as to join the sealant
Important: Anaerobic sealant will not start to cure beads as shown at X.
whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are 11. Make sure that the location guide pins T4 are in
put together) it will immediately start to harden. Make position in the crankcase. Assemble the bedplate
sure that all the necessary tools, bolts etc. are readily to the crankcase use the alignment guide pins.
available prior to assembling the components. The 12. Note: The bedplate is heavy. Two people will
parts must be installed and tightened to the correct be required to lift and rotate the bedplate safely
torque value within 5 minutes (with a maximum on to the crankcase. Install new main bearing
permissible time of 15 minutes). bolts 1-10. Tighten the bolts to the correct torque
value in pairs, starting in the centre and working
Important: BEFORE installing the bedplate: DO NOT
outwards (in sequence 1-10) to the 1st stage pre-
rotate the crankshaft. Make sure that the upper main
torque.
bearing shells are flush with the bottom face of the
crankcase. Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
Install 13. Install the bedplate peripheral bolts. Tighten the
1. The installation procedure is the opposite of the bolts to the correct torque value.
14. After installation and tightening the bedplate
steps.
peripheral bolts, further tighten the main bearing
2. Make sure that all items are clean and free from bolts in pairs, starting in the centre and working
damage and corrosion. outwards (in sequence 1-10) to the 2nd stage
pre-torque.
3. Install the two guide pins T4 to the crankcase
bedplate fixing holes as shown. 15. Finally, angle tighten the main bearing bolts in
pairs, starting in the centre and working outwards
4. Install the four lifting bolts T6 to the bedplate as (in sequence 1-10) for the final stage torque. Use
shown. the torque and angle method, refer to Fasteners
and Fixings, General, Introduction (PIL 72-00).
5. Install a new O-ring at the bedplate.
Important: If the parts have not been tightened to the
6. Use a suitable degreasing agent to clean both correct torque value within the maximum 15 minute
sides of the lower bearing shells. Assemble the time period, then the parts must be separated,
lower bearing shells into the bedplate. Lubricate thoroughly cleaned and fresh sealant applied.
the lower bearing shells with clean engine oil.
Note: Make sure that the location tab W engages
in the slot as shown.
After Installation
Consumable: Cleaner/Degreaser - General 1. Check that the crankshaft can be freely rotated
purpose solvent based parts cleaner by hand. Remove the bedplate lifting bolts T6.
7. Note: The sealant template T5 is used on 2. Carry out the procedures listed, Before removal
the crankcase, NOT the bedplate. The sealant in reverse order.
template T5 comprises of two pieces, A and B.
Modify the template A by removing portion V.
Table 58. Torque Table
Special Tool: Template for Sealant Bedplate to
Crankcase (4 Cyl) (Qty.: 1) Item Torque Value
1-10 (1st Stage) 50 N·m
8. Locate the holes in the templates A and B using 1-10 (2nd Stage) 115 N·m
four fixing bolts at positions Y. Use the templates
15 - 58 9823/1650-1 15 - 58
15 - Engine
09 - Bedplate
00 - General
Item Torque Value

1-10 (Final Stage) 180 °
11 24 N·m
15 - 59 9823/1650-1 15 - 59
15 - Engine
12 - Crankshaft
12 - Crankshaft
Contents Page No.
15-12-00 General ........................................................................................................................... 15-61

15-12-03 Main Bearing .................................................................................................................. 15-70
15-12-06 Front Oil Seal ................................................................................................................. 15-72
15-12-09 Rear Oil Seal ................................................................................................................. 15-75
15-12-12 Pulley .............................................................................................................................. 15-79
15 - 60 9823/1650-1 15 - 60
15 - Engine
12 - Crankshaft
00 - General
Introduction .................................................... 15-61 The crankshaft is housed inside the crankcase. It is
Technical Data ............................................... 15-62 connected to the piston via a connecting rod, they
Component Identification ............................... 15-63 form a simple mechanism that converts reciprocating
Operation ....................................................... 15-64 motion into rotating motion. Refer to: PIL 15-00-00.
Check (Condition) .......................................... 15-65
15 - 61 9823/1650-1 15 - 61
15 - Engine
12 - Crankshaft
00 - General
Technical Data
Table 59.
Main bearing journal diameter (x4)
- min 87.98 mm
- max 88 mm
Main rear bearing journal diameter (x1)
- min 99.98 mm
- max 100 mm
Connecting rod bearing journal diameter
- min 72.98 mm
- max 73 mm
Maximum wear and ovality on journals
(1)
Crankshaft induction hardness 55 HRc min on surface

Thrust washer width
- min 2.44 mm
- max 2.5 mm
Crankshaft end float
- min 0.05 mm
- max 0.28 mm
(1) No visible damage/wear or marks
15 - 62 9823/1650-1 15 - 62
15 - Engine
12 - Crankshaft
00 - General
Figure 106.
A
A Crankcase
B Crankshaft
15 - 63 9823/1650-1 15 - 63
15 - Engine
12 - Crankshaft
00 - General
Operation
diameter of the upper main bearing shell allows oil

Lubrication transfer to cross drillings in the crankshaft to feed
each of the big end bearings. Crankshaft gear is
Oil is fed from the main gallery via five drillings, one 'splash' lubricated. Front and rear crankshaft oil seals
to each of the main bearings. A groove around the prevent oil leakage from, and dirt ingress to, the
engine.
Figure 107.
1 Main gallery 2 Drillings (x5)

3 Main bearings 4 Big end bearings
5 Cross drillings 6 Crankshaft gear
7 Crankshaft oil seal 8 Crankshaft oil seal
15 - 64 9823/1650-1 15 - 64
15 - Engine
12 - Crankshaft
00 - General
1. Check the main bearing surfaces for damage and

excessive wear.
Figure 108.
C
D
A
C J-jets
D Fixing screws
A Main bearing shells

2. Measure the crankshaft diameters to confirm
they are within service limits, refer to Technical
Data (PIL 15-12).
Figure 109.
B Crankshaft
3. Check that the oil-way cross drillings in the
crankshaft are clear and free from debris.
Blocked or restricted oil-ways will cause oil
starvation at the big end bearings.
4. Check that the piston cooling J-jets are clear. If
the J-jets cannot be cleared remove the fixing
screws. Remove theJ-jets and discard them.
5. Install new J-jets.
15 - 65 9823/1650-1 15 - 65
15 - Engine
12 - Crankshaft
00 - General
Remove and Install
Consumables reasons (for piston and connecting rod removal

Description Part No. Size for example) remove it now, refer to (PIL 15-06).
Cleaner/Degreaser 4104/1557 0.4 L 12. Remove the fuel injection pump, refer to (PIL
- General purpose 18-18).
solvent based parts
cleaner 13. Remove the starter motor, refer to (PIL 15-75).
CAUTION This component is heavy. It must only 14. Remove the high duty PTO device (if installed).
method and device. 15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
Before Removal
16. Remove the flywheel, refer to (PIL 15-54).
1. This procedure requires service parts. Make
sure you have obtained the correct service parts 17. Remove the flywheel housing, refer to (PIL
before you start, refer to Parts Catalogue. 15-54).
2. Make sure that the engine is safe to work on. If 18. Remove the fuel injection pump drive gear, refer
the engine has been running, let it cool before to (PIL 15-51).
19. Remove the oil pump, refer to (PIL 15-60).
3. Remove the engine, refer to (PIL 15-00).
20. Remove the high duty PTO idler drive gear (if
4. Remove the drive belt, refer to (PIL 15-18). installed), refer to (PIL 15-51).
5. Remove the crankshaft pulley, refer to (PIL 21. Remove the crankshaft drive gear, refer to (PIL
15-12). 15-51).
6. Remove the oil sump, refer to (PIL 15-45). 22. Remove the camshaft, refer to (PIL 15-15).
7. Disconnect and remove the fuel pipes from the 23. Remove the rear timing case, refer to (PIL
injectors, refer to (PIL 18-96). 15-51).
8. Remove the rocker cover, refer to (PIL 15-42). 24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
9. Remove the fuel injectors, refer to (PIL 18-18). caps, refer to (PIL 15-12).
10. Remove the rocker assembly including the push 25. Remove the bedplate, refer to (PIL 15-09).
rods, refer to (PIL 15-42).
Remove
11. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however 1. Remove the thrust washers between the
the cylinder head needs to be removed for other crankshaft and crankcase rear main bearing.
15 - 66 9823/1650-1 15 - 66
15 - Engine
12 - Crankshaft
00 - General
Figure 111.
A
A
A Thrust Washers B Crankshaft

C Rear main bearing
2. Put labels on the thrust washers to make sure Before Installation

that they are installed in the correct positions
during assembly. 1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
3. Use suitable lifting equipment to carefully lift the
crankshaft from the crankcase (if the crankshaft 2. Use a suitable degreasing agent to carefully
is lifted manually, two people will be required). clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
4. Carefully lift out the bearing shells. ways or the piston cooling jets.
Figure 112. Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
D
Important: Cleanliness is of the utmost importance.
Blocked oil-ways or oil jets will cause engine failure.
Before you install the crankshaft make sure that ALL
oil-ways and jets are clear and free from debris.
Install
steps.
2. Make sure that all items are clean and free from
3. If removed or a new crankcase is being installed
D Main bearing shells then install cooling J jets as follows:
5. It is recommended that the bearing shells are

replaced. If however they are to be used again,
put label on the shells to make sure that they
are installed in their original positions during
assembly.
6. Inspect the crankshaft and main bearings etc.
for damage and excessive wear. Refer to Check
Condition (PIL 15-12).
15 - 67 9823/1650-1 15 - 67
15 - Engine
12 - Crankshaft
00 - General

G
D
E
F
D Main bearing shells

G Bearing location tab
E J jets (x4)
F Fixing screws 4.1. Use a suitable degreasing agent to make
sure that the surface of the upper bearing
3.1. Insert the cooling jets into the crankcase. shells are clean.
3.2. Note: There are different types of cooling Consumable: Cleaner/Degreaser - General
jets installed depending on the engine purpose solvent based parts cleaner
application. The jets are colour coded. 4.2. Assemble the bearing shells into the
3.3. Be sure to install the correct jets. Refer to crankcase bearing saddles. Make sure that
the relevant parts catalogue for the correct the location tab engages into the slot as
cooling jet identification. shown.
3.4. Tighten the retaining screws to the correct 4.3. Important: Make sure that the oil-way holes
torque value. in the bearing saddles align with the holes
in the bearing shell. If the holes are even
4. Install the upper bearing shells as follows: partially misaligned the piston cooling oil jet
will be restricted, causing the engine to fail.
4.4. Lubricate the upper bearing shells with
clean engine oil.
5. Use suitable lifting equipment (if the crankshaft
is lifted manually, two people will be required), to
carefully lower the crankshaft into the crankcase.
DO NOT rotate the crankshaft, the bearing shells
can become dislodged, refer to step 4.
6. Install the thrust washers as follows:
15 - 68 9823/1650-1 15 - 68
15 - Engine
12 - Crankshaft
00 - General
Figure 115.
B H
A
A
A Thrust washers B Crankshaft

C Rear main bearing H Oil slot - thrust washers
6.1. Slide the thrust washers between the

crankshaft and the crankcase rear main
bearing.
6.2. Make sure that they are installed in the
correct positions, with the two slots facing
outwards from the bearing saddle.
6.3. If necessary, push the crankshaft forward
and then backwards to obtain clearance to
install the thrust washers.
6.4. DO NOT rotate the crankshaft, the bearing
shells can become dislodged, refer to step
4.
7. Check that the crankshaft end float is within
service limits, refer to Technical Data (PIL 15-12).

Item Nm
F 24
15 - 69 9823/1650-1 15 - 69
15 - Engine
12 - Crankshaft
03 - Main Bearing
03 - Main Bearing Introduction

Introduction .................................................... 15-70 In a piston engine, the main bearings are the
Check (Condition) .......................................... 15-71 bearings on which the crankshaft rotates.
The bearings hold the crankshaft in place and
prevent the forces created by the piston and
transmitted to the crankshaft by the connecting rods
from dislodging the crankshaft, instead forcing the
crank to convert the reciprocating movement into
rotation.
Figure 116.
A Main bearing
B Crankshaft
15 - 70 9823/1650-1 15 - 70
15 - Engine
12 - Crankshaft
03 - Main Bearing
Check (Condition) Remove and Install

1. Check the bearing shell surfaces for signs of
damage and excessive wear.
2. Measure the crank pin diameters to confirm they
are within service limits.
3. Renew any parts that are worn or not within the
specified tolerances.
15 - 71 9823/1650-1 15 - 71
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
06 - Front Oil Seal
Remove and Install
Special Tools Figure 117.

Description Part No. Qty.
Crankshaft Front Oil 892/01157 1 C
Seal Installation Tool
B
Before Removal
before you start, refer to Parts Catalogue.
3. Get access to the engine. A
4. Remove the drive belt, refer to (PIL 15-18).

5. Remove the crankshaft pulley, refer to (PIL
15-12-12).
A Crankshaft oil seal
Remove B Crankcase
C Crankshaft hub
1. Use a suitable lever behind the lip of the
seal, carefully prise out the oil seal from the
counterbore in the crankcase. Take care not Install
to scratch or damage the counterbore or the 1. Make sure that the counterbore and the
crankshaft hub. Damaged or dirty sealing faces crankshaft hub are clean and free from damage
will cause the oil seal to fail. and corrosion. Use a suitable degreasing agent
to clean all traces of oil and grease from the
counterbore. Important: The oil seal has a special
coating and MUST be installed dry without
lubricant.
2. Dismantle the seal installation tool. Bolt the
centre body to the crankshaft hub, using the
bolts. Refer to Figure 118.
Special Tool: Crankshaft Front Oil Seal
Installation Tool (Qty.: 1)
3. Install the oil seal on to the centre body. Make
sure that the seal is installed the correct way
around. Assemble the outer sleeve on to the
centre body and install the screw. Refer to Figure
118.
15 - 72 9823/1650-1 15 - 72
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
Figure 118.
F D A
G G
E
A Crankshaft oil seal B Crankcase

C Crankshaft hub D Seal installation tool
E Fixing bolts (x3) F Centre body
G Outer sleeve H Screw
4. Turn the screw to push the seal squarely into Figure 119.
the counterbore until the outer sleeve comes
up against the front edge of the counterbore. B
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore A
within the specified tolerance. Refer to Figure
119. G
Dimension: -0.5 -0/+0.5 mm
C
A Crankshaft oil seal
B Crankcase
C Crankshaft hub
F Centre body
G Outer sleeve
5. Remove the seal installation tool.
15 - 73 9823/1650-1 15 - 73
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
After Installation
1. Install the crankshaft pulley, refer to (PIL
15-12-12).
2. Install the drive belt, refer to (PIL 15-18).
15 - 74 9823/1650-1 15 - 74
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
09 - Rear Oil Seal
Remove and Install
Special Tools Figure 121. 15mm Hub

Crankshaft Rear Oil 892/01156 1
Seal Installation Tool A
Crankshaft Rear Oil 892/01158 1
Seal Alignment Tool
B
Note: The flywheel hub and crankshaft rear oil seal
need to be replaced as a pair.
Before Removal
you start the service work. C E
3. Get access to the engine. A Crankshaft rear oil seal

B Flywheel housing
4. Remove the flywheel, refer to (PIL 15-54). C Flywheel hub
E Fixing bolt
Remove
Install (24mm Hub)
1. Use a suitable lever behind the lip of the seal
to carefully prise out the rear oil seal from the 1. Make sure that the counterbore and the flywheel
counterbore in the flywheel housing. Take care hub are clean and free from damage and
not to scratch or damage the counterbore or the corrosion.
flywheel hub. Damaged or dirty sealing faces will
cause the oil seal to fail.
Figure 120. 24mm Hub
C B
A Crankshaft rear oil seal
B Flywheel housing
C Flywheel hub
15 - 75 9823/1650-1 15 - 75
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
Figure 122.
B
D
A
C
A Crankshaft rear oil seal B Flywheel housing

C Flywheel hub D Oil seal alignment tool
2. To prevent the seal lip rolling over and becoming Special Tool: Crankshaft Rear Oil Seal Alignment
damaged, make sure that you use the oil seal Tool (Qty.: 1)
alignment tool to initially install the oil seal on to
the flywheel hub. Locate the alignment tool over 3. Apply lubricant P80 around the seal outer rubber
the end of the hub, then carefully push the oil seal diameter.
over the alignment tool and on to the crankshaft
diameter. Make sure that the oil seal is installed 4. Dismantle the oil seal installation tool. Bolt the
the correct way around. centre body to the flywheel hub, using the two
flywheel bolts. Assemble the outer sleeve on to
Special Tool: Crankshaft Rear Oil Seal the centre body and install the screw.
Installation Tool (Qty.: 1)
Figure 123.
F
B
E
A C H
H
G
G F

C Outer sleeve E Oil seal installation tool
F Flywheel bolts G Centre body
H Flywheel hub J Screw
5. Turn the screw to push the seal squarely into 6. Remove the oil seal installation tool.
the counterbore until the outer sleeve comes
up against the front edge of the counterbore. Install (15mm Hub)
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore 1. Make sure that the counterbore and the hub are
within the tolerance specified. clean and free from damage.
15 - 76 9823/1650-1 15 - 76
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
Figure 124.
B
D
A
C

C Flywheel hub D Oil seal alignment tool
2. Install the new hub on to the crankshaft gear and Special Tool: Crankshaft Rear Oil Seal
install the old hub on the outside of the new hub Installation Tool (Qty.: 1)
to create a double thickness flywheel hub, install Special Tool: Crankshaft Rear Oil Seal Alignment
the fixing bolt as shown at A. Do not touch the Tool (Qty.: 1)
PTFE seal lips of the crankshaft oil seal.
4. Apply the lubricant P80 around the seal outer
3. Make sure that you use the oil seal alignment tool rubber diameter.
to initially install the oil seal on to the flywheel
hub to prevent damage to the seal lip. Locate the 5. Dismantle the oil seal installation tool. Use the
alignment tool over the end of the hub, carefully two flywheel bolts to attach the centre body on to
push the oil seal over the alignment tool as far the flywheel hub. Assemble the outer sleeve on
on to the crankshaft hub as possible. Make sure to the centre body include the extension ring and
that the seal is installed the correct way around. install the screw.
Figure 125.
B F
G
A C1 K C2
H
L
K
J

C1 New hub C2 Old hub
F Flywheel bolts G Oil seal installation tool
H Extension ring J Centre body
K Outer sleeve L Screw
6. Turn the screw to push the seal into position in

the counterbore so that the screw will not turn.
15 - 77 9823/1650-1 15 - 77
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
7. Remove the oil seal installation tool, remove the

old hub and install the fixing bolt. Repeat steps 5
and 6 to fully install the rear oil seal.
8. Remove the oil seal installation tool.
After Installation
1. Install the flywheel, refer to (PIL 15-54).

Item Nm
E 47
15 - 78 9823/1650-1 15 - 78
15 - Engine
12 - Crankshaft
12 - Pulley
12 - Pulley Install
steps.
Special Tools
Description Part No. Qty. 2. Make sure that all items are clean and free from
Torque Wrench 993/70111 1 damage and corrosion.
(10-100Nm)
3. Renew the fixing bolts. Tighten the new bolts in
three stages to the correct torque value.
Before Removal
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1. This procedure requires service parts. Make 1)
before you start, refer to Parts Catalogue. 4. The bolts are tightened using a torque and
angle method. Refer to Fasteners and Fixings,
2. Make sure that the engine is safe to work on. If General, Introduction (PIL 72-00).
you start the service work. Figure 127.

4. Remove the drive belt. Refer to (PIL 15-18).
Remove
1. Remove the fixing bolts and withdraw the pulley C
from the crankshaft.
Figure 126.
C Angle gauge (obtain locally)
After Replacement
1. Install the drive belt. Refer to (PIL 15-18).
A
Table 62.
Item Torque Value Torque Angle
(Nm) (Degrees)
2 (1st stage) 30 N·m
2 (2nd stage) 75 N·m
2 (Final stage) 180 °
A
B
A Crankshaft pulley
B Fixing bolts (x3)
2. The bolts must not be reused. Discard the bolts.
15 - 79 9823/1650-1 15 - 79
15 - Engine
15 - Camshaft
15 - Camshaft
Contents Page No.
15-15-00 General ........................................................................................................................... 15-81
15 - 80 9823/1650-1 15 - 80
15 - Engine
15 - Camshaft
00 - General
Introduction .................................................... 15-81 When the engine runs the crankshaft drives the
Technical Data ............................................... 15-82 camshaft via gears. The camshaft opens and closes
Component Identification ............................... 15-83 the inlet and exhaust valves via push rods in time with
Operation ....................................................... 15-84 the four stroke cycle. Refer to: PIL 15-00-00.
Check (Condition) .......................................... 15-85 The relationship between the rotation of the camshaft
Remove and Install ....................................... 15-85 and the rotation of the crankshaft is of critical
importance. Since the valves control the flow of the
air/fuel mixture intake and exhaust gases, they must
be opened and closed at the appropriate time during
the stroke of the piston. For this reason, the camshaft
is connected to the crankshaft directly, via a gear
mechanism.
15 - 81 9823/1650-1 15 - 81
15 - Engine
15 - Camshaft
00 - General
Technical Data
Table 63. Camshaft Data

Camshaft journal diame-
ter
- 4 off 59.99 –59.97 mm
- 1 off 60.25 –60.22 mm
Camshaft lobe wear lim-
its
Inlet lift 7.161 –7.271 mm
Exhaust lift 7.2 –7.31 mm
Camshaft bore diameter
- 4 off 60.07 –60.04 mm
- 1 off 60.32 –60.29 mm
Camshaft gear
(1)
104 teeth
(1) The camshaft gear is not available as a separate
item. The gear must be heated on to the camshaft
in the correct timed position. Specialist fixtures are
used during the production process to achieve the
correct timing.
15 - 82 9823/1650-1 15 - 82
15 - Engine
15 - Camshaft
00 - General
Figure 128.
6c
6b
6a
7
9
10
15
3
5
16
1
4
2
3a
745700
1 Camshaft drive gear 2 Crankshaft gear

3 Camshaft 3a Camshaft lobes
4 Tappets 5 Push rods
15 Inlet valves 16 Exhaust valves
15 - 83 9823/1650-1 15 - 83
15 - Engine
15 - Camshaft
00 - General
Operation
during the cycle it follows that the camshaft is driven

As the crankshaft rotates the camshaft also rotates, at half crankshaft (engine) speed.
driven by a gear on the crankshaft. The inlet and
exhaust valves are opened by lobes on the camshaft Lubrication
in time with the cycle.
Oil is fed from the main gallery via a drilling to the
The diagrams show the position of the camshaft at camshaft bearing. A groove around the diameter of
each part of the four stroke cycle, refer to Engine- the bearing and connecting the cross drilling ensures
General, Operation. Refer to: PIL 15-00-00. that oil is always fed to the centre drilling. Oil is then
transferred to the remaining camshaft bearings by
It can be seen that for a complete cycle the camshaft
further cross drillings in the shaft. The cam lobes and
revolves once. Since the crankshaft revolves twice
tappets are 'splash' lubricated.
Figure 129.
1 Main gallery 2 Camshaft bearing

3 Groove 4 Centre drilling
15 - 84 9823/1650-1 15 - 84
15 - Engine
15 - Camshaft
00 - General

1. Inspect the camshaft gear teeth for signs of
damage or excessive wear.
Before Removal
1. Drain the oil from the engine.
2. Inspect the cam lobes for signs of excessive
wear, scoring or pitting. 2. Disconnect and remove the fuel pipes from the
injectors. Refer to (PIL 18-96).
3. Inspect the cam bearing surfaces for signs
of excessive wear, or scoring. Check that the 3. Remove the rocker cover. Refer to (PIL 15-42).
dimensions are within service limits.
4. Remove the fuel injection pump. Refer to (PIL
4. Inspect the cam bearing surfaces inside the 18-18).
crankcase for signs of excessive wear, or
scoring. Check that the dimensions are within 5. Remove the rocker assembly and push rods.
service limits. Refer to (PIL 15-42).
5. Inspect the bearing surfaces of the tappets for 6. Remove the starter motor. Refer to (PIL 15-75).
signs of excessive wear or damage. Check that
the dimensions are within service limits. 7. Remove the oil sump. Refer to (PIL 15-45).
6. Inspect the tappet bores inside the crankcase for 8. Remove the flywheel. Refer to (PIL 15-54).
the dimensions are within service limits. 9. Remove the flywheel housing. Refer to (PIL
15-54).
7. If any of the camshaft bearings or lobes are worn
or damaged then the relative oil feed galleries 10. Rotate the crankshaft until the camshaft timing
in the crankcase and camshaft may be blocked. pin can be inserted through the gear and into the
Make sure all oil ways are clear and free from aligning hole in the rear gear case.
debris. Figure 130.
A Timing pin- camshaft

11. Remove the taper blanking plug and insert
crankshaft locking pin. The camshaft and
crankshaft locking pins must be in position to lock
the crankshaft and camshaft before removing the
camshaft assembly.
15 - 85 9823/1650-1 15 - 85
15 - Engine
15 - Camshaft
00 - General
Figure 131. 3. Access the tappets through the apertures in

the crankcase bedplate next to the crankshaft.
Lift out the tappets from the crankcase using a
suitable magnetic probe. Label the tappets to
ensure replacement in their original positions.
B
Figure 133.
C
B Timing pin- crankshaft E
C Blanking plug
E
12. Remove the fuel injection pump drive gear. Refer
to (PIL 15-51).
Remove
The engine must be inverted. Do not attempt to
remove the camshaft and its drive gears with the
engine upright. The tappets and push rods will
fall into the engine and further dismantling will be
required to retrieve them.
1. Remove the camshaft timing pin.

2. Carefully withdraw the camshaft and gear
assembly from the crankcase. Make sure that
you fully support the camshaft to prevent the
lobes contacting the bearing surfaces in the
crankcase. The bearing surfaces can easily be
damaged by the sharp hard edges on the cam
lobes.
Figure 132. E Tappet
F Magnetic probe
Inspection
1. Refer to Camshaft- Check Condition (PIL 15-15).
Install
1. Lubricate the tappets and tappet bores inside the
A crankcase with clean engine oil.
2. Insert the tappets in their original positions in the
crankcase using a suitable magnetic probe.
3. Lubricate the camshaft bearing journals inside
the crankcase with clean engine oil.
4. Carefully insert the camshaft assembly into the
crankcase as shown. Support the camshaft
preventing the lobes contacting the bearing
D surfaces in the crankcase. Before meshing the
camshaft gear with the crankshaft gear, rotate
the camshaft until the timing hole in the gear
A Timing pin - camshaft aligns with the dowel hole in the gear casing.
D Camshaft and drive gear Insert the timing pin T1 to lock the camshaft in
this position.
15 - 86 9823/1650-1 15 - 86
15 - Engine
15 - Camshaft
00 - General
After Installation
1. Note that the fuel injection pump drive gear
fixing nut is torque tightened as part of the fuel
injection pump replacement procedure. Refer to
(PIL 18-18).
2. Do the procedures in Before Removal in reverse
order.
15 - 87 9823/1650-1 15 - 87
15 - Engine
18 - Engine Belt
18 - Engine Belt
Contents Page No.
15-18-00 General ........................................................................................................................... 15-89

15-18-03 Drive Belt ....................................................................................................................... 15-92
15-18-21 Tensioner ........................................................................................................................ 15-96
15 - 88 9823/1650-1 15 - 88
15 - Engine
18 - Engine Belt
00 - General
Introduction .................................................... 15-89 A crankshaft pulley is used to drive a FEAD
Health and Safety .......................................... 15-90 (Front End Accessory Drive) belt. The belt drives
Component Identification ............................... 15-90 the coolant pump. Depending on the machine
application, the belt is configured to drive engine
mounted accessories, such as the alternator, cooling
fan and air conditioning compressor.
Some applications have a second pulley on the

crankshaft which drives a dedicated fan belt. The belt
drives an engine mounted cooling fan.
15 - 89 9823/1650-1 15 - 89
15 - Engine
18 - Engine Belt
00 - General
Health and Safety Component Identification

Turning the Engine Figure 134. A - With air condition-
Do not try to turn the engine by pulling the fan or fan ing compressor, no cooling fan
belt. This could cause injury or premature component
failure. A
4
Switch off the engine before working in the engine 5
engine cover open.
3
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts. 7
Figure 135. B - Without air condi-

tioning compressor, no cooling fan
B
4
3 4
1 Crankshaft drive pulley

2 Coolant pump drive pulley
3 Alternator drive pulley
4 Idler pulley
5 Tensioner pulley
7 Air conditioning compressor drive pulley
15 - 90 9823/1650-1 15 - 90
15 - Engine
18 - Engine Belt
00 - General
Figure 136. C - With air conditioning com-

pressor, cooling fan pulley installed
C
6
4
5
3
7
Figure 137. D - Without air conditioning

compressor, cooling fan pulley installed
D
6
3
4
1 Crankshaft drive pulley

2 Coolant pump drive pulley
3 Alternator drive pulley
4 Idler pulley
5 Tensioner pulley
6 Cooling fan drive pulley
7 Air conditioning compressor drive pulley
15 - 91 9823/1650-1 15 - 91
15 - Engine
18 - Engine Belt
03 - Drive Belt
03 - Drive Belt Introduction

Introduction .................................................... 15-92 The crankshaft pulley is used to drive the coolant
Health and Safety .......................................... 15-93 pump via a FEAD (Front End Accessory Drive) belt.
Check (Condition) .......................................... 15-93 In addition to the coolant pump the drive belt can
Adjust ............................................................ 15-94 also be configured to drive the engine mounted
accessories.
The belt is maintained at a constant tension by a
spring loaded tensioner. To achieve the necessary
belt/pulley contact area the belt is routed around
idler wheels as required. The configuration varies
depending on the accessories installed.
15 - 92 9823/1650-1 15 - 92
15 - Engine
18 - Engine Belt
03 - Drive Belt
Health and Safety Check (Condition)

Notice: A drive belt that is loose can cause
damage to itself and/or other engine parts. At the recommended service interval, visually inspect
the drive belt for damage.

2. Stop the engine and let it cool down.
3. Renew the drive belt if it has cracks or if it is
frayed or has pieces of material missing.
Figure 138.
B
A
C
A Crack in belt
B Missing piece of belt
C Frayed belt
15 - 93 9823/1650-1 15 - 93
15 - Engine
18 - Engine Belt
03 - Drive Belt
Adjust Remove and Install
Adjustment is not possible with this drive belt. A Remove

spring loaded tensioning unit ensures that the FEAD
(Front End Accessory Drive) belt is kept at the correct 1. Make the machine safe. Refer to (PIL 01-03).
tension.
3. Use a socket of the specified size to locate
on to the hexagon spigot nut, carefully rotate
the tensioner against the spring force in the
direction shown. Do not use excessive force or
the tensioner will be damaged.
Dimension: 16 mm
4. Keep holding the tensioner against the spring
force and lift the belt off the drive tensioner pulley.
5. Slowly release the spring force by rotating the
tensioner unit in the opposite direction.
15 - 94 9823/1650-1 15 - 94
15 - Engine
18 - Engine Belt
03 - Drive Belt
Figure 139.
A Spring loaded tensioner

B Drive belt
C Example of frayed drive belt (refer to Check
Condition)
D Spigot nut
Install
step.
2. Before you install the new belt, check that the
tensioner roller and the fan pulley rotate smoothly
and that there is no play in the bearings.
15 - 95 9823/1650-1 15 - 95
15 - Engine
18 - Engine Belt
21 - Tensioner
21 - Tensioner Install
steps.
Before Removal 2. Tighten the bolts to the correct torque value.
1. Make the machine safe. Refer to (PIL 01-03). 3. Install the drive belt, refer to (PIL 15-18).
2. Make sure that the engine is safe to work on. If 4. Make sure that the drive belt is under tension
the engine has been running, let it cool before and the locking pin is removed before starting the
you start the service work. engine. Refer to Drive Belt - Adjust (PIL 15-18).
3. Get access to the engine. Table 64. Torque Values

4. Remove the drive belt, refer to (PIL 15-18). Item Nm
2 24
Figure 140.
3 2 1
2
X
T3
1 Drive belt tensioner pulley
2 Fixing bolts (x3)
3 Drive belt
T3 Locking pin
X Spigot nut
Remove
The drive belt tensioner is a non-serviceable item.
If the drive belt tensioner or the idler wheel is faulty
or damaged it must be renewed as a complete
assembly.
1. To remove the tensioner assembly, remove the

bolts and lift the tensioner pulley from the cylinder
block.
15 - 96 9823/1650-1 15 - 96
15 - Engine
21 - Oil Filter
21 - Oil Filter
Contents Page No.
15-21-00 General ........................................................................................................................... 15-99
15 - 97 9823/1650-1 15 - 97
Notes:
15 - 98 9823/1650-1 15 - 98
15 - Engine
21 - Oil Filter
00 - General
Introduction .................................................... 15-99 The oil filter is a spin on type which screws on and
Health and Safety ........................................ 15-100 off the oil filter head.
Component Identification ............................. 15-101
Operation ..................................................... 15-103
Check (Level) .............................................. 15-103
Remove and Install ..................................... 15-104
15 - 99 9823/1650-1 15 - 99
15 - Engine
21 - Oil Filter
00 - General
Health and Safety

Oil
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves
to prevent skin contact. Wash skin contaminated with
oil thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
accordance with local regulations. Use authorised
CAUTION! Oil will gush from the hole when the drain
plug is removed. Keep to one side when you remove
the plug.
CAUTION! The oil filter canister will contain some oil
which could spill out when you remove the canister.
15 - 100 9823/1650-1 15 - 100

15 - Engine
21 - Oil Filter
00 - General
Figure 141.
1
13
A
16
5 6
14
4
19
15
18 8
10
10
3 9 9
11
13
B
16 11 1
14
19
15
18
12 17
3 3 8
1 Oil cooler and filter housing 2 Oil filler cap (not shown)
3 Oil filter head 4 Oil gallery - from pump to cooler
5 Oil cooler matrix 6 Sealing gasket - housing to crankcase
7 Coolant gallery 8 Oil filter drain down plug
9 Oil gallery - from cooler to filter head 10 Oil gallery - from filter head to main oil gallery
15 - 101 9823/1650-1 15 - 101

15 - Engine
21 - Oil Filter
00 - General
11 Oil filler port 12 Oil pressure switch

13 Oil filter 14 Filter element
15 Anti-drain seal 16 Spring
17 Oil Temperature Sensor 18 O-ring
19 Anti-drain pipe A Oil filter state - engine running
B Oil filter state - engine stopped
15 - 102 9823/1650-1 15 - 102

15 - Engine
21 - Oil Filter
00 - General
Operation Check (Level)
At Engine Running Engine oil and oil filter replacement must be

completed in accordance with the service schedules.
The oil pump delivers oil at pressure to the oil filter Failure to replace the oil and filter at the
via a port. The anti-drain seal is forced off its seat and recommended interval could cause serious engine
oil flows through a large area paper element. Filtered failure.
oil enters the inner part filter before leaving the filter
head via a port. 1. Make the machine safe, refer to (PIL 01-03).
At Engine Stopped
3. Check that the oil level is between the two marks
With the engine stopped oil pressure in the galleries on the dipstick.
and filter decays. The anti-drain seal falls on
its seat and oil is prevented from draining from 4. If necessary, add recommended oil through one
the filter assembly. The anti-drain pipe prevents of the filler points.
approximately half the filters oil capacity from
Figure 142.
draining. These features help protect the engine from
oil starvation on start up. B
A Dipstick
B Oil filler point
15 - 103 9823/1650-1 15 - 103

15 - Engine
21 - Oil Filter
00 - General
Remove and Install
Special Tools 9. If the engine has a dead crank feature, carry out
Description Part No. Qty. the following procedure.
Oil Filter Removal Tool 892/00292 1 9.1. Turn the ignition key to the on position.
Data Link Adaptor 892/01174 1
(DLA) Kit 9.2. Turn the ignition key to the off position.
9.3. Repeat steps 9.1 and 9.2 5 times.
Drain the oil when the engine is warm as
contaminants held in suspension will then be drained 9.4. Wait for the ECU (Electronic Control Unit) to
with the oil. shutdown.
Duration: 30 s
CAUTION! Oil will gush from the hole when the drain
plug is removed. Keep to one side when you remove 9.5. Turn the ignition key to the start position.
the plug. The engine will crank for an extended time
period before starting.
1. Place a container of suitable size beneath the
Duration: 10 s
drain plug.
10. If the engine does not have a dead crank feature,
2. Remove the oil sump drain plug and 'O' ring. Let
carry out the following procedure.
the oil drain out, then clean and install the drain
plug with a new 'O' ring. Tighten the plug to the 10.1. Connect a laptop to the engine with a data
correct torque value. link adaptor and open Servicemaster.
3. Loosen and remove the filter housing drain plug. Special Tool: Data Link Adaptor (DLA) Kit
Let the oil fully drain. Install the plug. Tighten the (Qty.: 1)
plug to the correct torque value. 10.2. Perform the IMV (Inlet Metering Valve)
4. Unscrew the filter canister, use special tool if Override test.
necessary. 10.3. The IMV Override test will allow the engine
Special Tool: Oil Filter Removal Tool (Qty.: 1) to be cranked for a set time period without
starting allowing sufficient time to prime
5. Clean the seal face of the filter head. the oil pressure.
6. Smear the seal on the new filter canister with Duration: 10 s

clean engine oil. 11. Operate the engine at idle, make sure that the
7. Screw in the new filter canister (hand tight only). oil pressure low warning light is extinguished
immediately after the engine starts. If it does not
8. Through one of the filler points, fill the engine with extinguish, stop the engine and investigate the
the recommended oil to the MAX mark on the cause.
dipstick. Wipe off any spilt oil, install the filler cap
and make sure it is secure. 12. Check for oil leakage. When the oil has cooled,
check the oil level again, and if necessary top up
with clean engine oil.
15 - 104 9823/1650-1 15 - 104

15 - Engine
21 - Oil Filter
00 - General
Figure 143.
B
A Dipstick B Oil filler points

C Oil sump drain plug D 'O' ring
E Filter housing drain plug F Filter canister
G Filter head H Seal

Item Description Nm
C Oil sump drain plug 40
E Filter housing drain plug 40
15 - 105 9823/1650-1 15 - 105

15 - Engine
24 - Air Filter
24 - Air Filter
Contents Page No.
15-24-00 General ......................................................................................................................... 15-107

15-24-09 Dust Valve .................................................................................................................... 15-110
15 - 106 9823/1650-1 15 - 106

15 - Engine
24 - Air Filter
00 - General
Introduction .................................................. 15-107 Engine performance and durability will be severely
Health and Safety ........................................ 15-108 affected if the quality of the air intake is poor.
Check (Condition) ........................................ 15-108
Remove and Install ..................................... 15-109 A dirty and blocked air cleaner element will reduce
the amount of air entering the combustion chamber
which can cause engine mis-firing, black smoke and
low output power.
A dirty and blocked air filter can also lead to abrasion

of the cylinder bores and valves (referred to as
dusting). This will cause excessive oil consumption,
black smoke, low output power and a reduced engine
life.
In hostile environments, change the air filter

elements more frequently.
In some applications, an air filter pre-cleaner can be

installed.
15 - 107 9823/1650-1 15 - 107

15 - Engine
24 - Air Filter
00 - General

Notice: Do not run the engine when the element
has been removed. The air filter element (s) should be changed at
the recommended service interval, refer to the
Notice: The outer element must be renewed Maintenance Schedules. Refer to: PIL 78-24.
immediately if the warning light on the instrument
panel illuminates. Check all the hose connections for loose installations
and damaged hose clamps, look specifically for splits
or cracks in the hoses. Pay particular attention to the
connections on the air intake to turbo compressor
and on the crossover tube.
Renew any damaged components.
In addition, most air filter housings will be installed

with a vacuum switch. The switch will detect if there
is a restriction on the air intake, and activate warning
indicators such as an audible alarm and/or a visual
indicator.
15 - 108 9823/1650-1 15 - 108

15 - Engine
24 - Air Filter
00 - General
Remove and Install Figure 144.
B
Do not attempt to wash or clean the elements, they
must only be renewed.
A new inner element must be installed at least

every other time the outer element is changed. As
a reminder, mark the inner element with marker pen
each time the outer element is changed.
F
Remove E
D
3. Depress the clips and lift off the cover.
4. Remove the outer element. Take care not to tap
or knock the element.
5. If the inner element is to be changed, lift up pulls
and remove the inner element.
G
C
B Clips
C Cover
D Outer element
E Inner element
F Housing
G Air holes
Install
steps.
2. Clean inside the housing, and cover, make sure
that the air holes are clear.
3. Install the cover and fasten the latch. Make sure
that dust valve is at the bottom.
15 - 109 9823/1650-1 15 - 109

15 - Engine
24 - Air Filter
09 - Dust Valve
09 - Dust Valve
Check (Condition)
• Check the dust valve for rips/tears.
• Check there are no obstructions.
• Check that the dust valve is free of dirt and dust.
• Check that the dust valve securely attached to
the air filter housing.
15 - 110 9823/1650-1 15 - 110

15 - Engine
27 - Crankcase Ventilation Filter
Contents Page No.
15-27-00 General ......................................................................................................................... 15-113
15 - 111 9823/1650-1 15 - 111

Notes:
15 - 112 9823/1650-1 15 - 112

15 - Engine
00 - General
Introduction .................................................. 15-113 Depending on the specification, the engine may be
Component Identification ............................. 15-114 installed with open loop, filtered open loop or a closed
Operation ..................................................... 15-115 loop CCV (Crankcase Ventilation) system.
15 - 113 9823/1650-1 15 - 113

15 - Engine
00 - General
Figure 145. Filtered open loop crankcase ventilation (CCV) system

C
H
D
G
A
A Crankcase vapour B Pressure relief valve

C Transfer hose D Filter element - second stage
E Filter element - first stage F Filtered vapour vent to atmosphere
G Oil droplets - return to sump H Crankcase ventilation filter assembly
15 - 114 9823/1650-1 15 - 114

15 - Engine
00 - General
Operation Remove and Install
Filtered open loop crankcase ventilation The filter element must be changed at the
recommended maintenance interval. Refer to (PIL
(CCV) system 78-24).
Crankcase emissions are created during the 1. Make the machine safe. Refer to (PIL 01-03).
combustion process. These emissions include
unburned fuel and 'blow by gases' which contain 2. Get access to the engine. Refer to (PIL 06-06).
hydrocarbon and engine oil contaminates. A large
proportion of these emissions are prevented from 3. Rotate the filter cover anti-clockwise and
entering the atmosphere by the CCV (Crankcase remove.
Ventilation) filter assembly.
4. Lift out the filter element and discard it.
A series of ports in the crankcase, cylinder head
and rocker cover allow pressure to vent from 5. Clean the inside of the filter housing. Remove all
the crankcase. The vapour from the crankcase oil and sludge contamination.
flows from the rocker cover to the filter assembly. 6. Make sure that the oil drain in the bottom of the
Combined two stage filter elements remove around filter housing is not blocked with sludge.
90 % of contaminates as the vapour passes from the
inside to the outside of the filter elements. Trapped oil 7. Install a new filter element. Make sure that the
is allowed to drain back to the sump via a non return correct type of filter element is installed.
valve. The filtered vapour vents to the atmosphere.
8. Align the arrows on both parts to install the filter
If the pressure inside the filter assembly rises due cover.
to a blocked filter non return valve in the oil drain
line prevents vapour being forced back into the Figure 146.
crankcase.
A
The ventilation circuit incorporates a pressure relief
valve. If the filter element becomes blocked the valve
opens bypassing the filter and preventing a build up
of pressure in the crankcase. Although this prevents
serious engine damage it must be remembered
that the filtration system does not function when B
bypassed. The filter element must be replaced at the
intervals specified to ensure a bypass condition is
avoided.
A Filter cover
B Filter element
C Filter housing
15 - 115 9823/1650-1 15 - 115

15 - Engine
30 - Valve
30 - Valve
Contents Page No.
15-30-00 General ......................................................................................................................... 15-117

15-30-12 Valve Spring ................................................................................................................. 15-126
15-30-24 Stem Seal .................................................................................................................... 15-127
15 - 116 9823/1650-1 15 - 116

15 - Engine
30 - Valve
00 - General
Introduction .................................................. 15-117 The valve train system opens and closes the
Technical Data ............................................. 15-118 valves with correct timing in relation to the piston
Component Identification ............................. 15-119 movements.
Operation ..................................................... 15-121
Each push rod has one end in a valve tappet and the
Adjust .......................................................... 15-121 other end under a rocker arm, or as applicable. The
Remove and Install ..................................... 15-124 adjusting screw has a ball shaped end that locates in
the push rod. The adjusting screw is used for setting
the valve clearance.
The valves extend through the cylinder head. There

are no sleeves or valve guides in the cylinder head.
The valves are made from a special metal to provide
a long service life. Damaged or worn valves cannot
be lapped or reground and must be replaced with
new ones. Each valve stem has an oil seal.
The Valve seat inserts are pressed into the cylinder

head. The seat inserts are also made from a special
metal to provide for a long service life. Damaged or
worn seat inserts can be removed and replaced with
new ones.
15 - 117 9823/1650-1 15 - 117

15 - Engine
30 - Valve
00 - General
Technical Data
Table 66. Inlet and Exhaust Valve Data

Max lift Inlet 9.64 mm @ 101 ° AT-
DC
Max lift Exhaust 9.84 mm @ 115 ° BTDC
Inlet opens (top of ramp) 6 ° BTDC
Inlet closes 28 ° ATDC
Exhaust opens 41 ° BTDC
Exhaust closes 6 ° ATDC
Valve stem diameter
- Inlet 6.928 –6.943 mm
- Exhaust 6.918 –6.933 mm
Valve spring free length 51.1 mm
Valve guide bore diame-
ter
- min 6.958 mm
- max 6.973 mm
Valve face angle
- Inlet 60.5 °
- Exhaust 45.17 °
Valve length 131.9 –132.4 mm
Valve sealing Stem seal with sealing
washer
Valve head depth (below
cylinder head surface)
- Inlet 0.89 –1.39 mm
- Exhaust 0.95 –1.45 mm
Valve rim thickness 2.98 –3.38 mm
Valve Clearances (en-
gine cold)
- Inlet 0.15 –0.21 mm
(1)
- Exhaust 0.43 –0.49 mm

(1)
(1) The values refer to the tappet adjuster end of the

valve rockers.
15 - 118 9823/1650-1 15 - 118

15 - Engine
30 - Valve
00 - General
Figure 147.
6c
6b
6a
7
9
10
15
3
5
16
1
4
2
3a
745700
1 Camshaft drive gear 2 Crankshaft gear

3 Camshaft 3a Lobes
4 Tappets (x8) 5 Push rods (x8)
6a Rockers - inlet (x4) 6b Rockers - exhaust (x4)
6c Adjusting screws (x8) 6d Swivel tip - rockers
7 Rocker shaft 8 Wave washers (x8)
9 Bridge pieces (x8) 10 Valve springs (x16)
11 Retainer (x16) 12 Collets (x32)
13 Oil seal - valve stems (x16) 14 Valve seat inserts (x16)
15 - 119 9823/1650-1 15 - 119

15 - Engine
30 - Valve
00 - General
15 Inlet valves (x8) 16 Exhaust valves (x8)

17 Valve stem
Cross Sectional View
Figure 148.
17
6c 11 12
8 10
6a 6b 13
6d
745930
14
6a Rockers - inlet (x4) 6b Rockers - exhaust (x4)

6c Adjusting screws (x8) 6d Swivel tip - rockers
8 Wave washers (x8) 9 Bridge pieces (x8)
10 Valve springs (x16) 11 Retainer (x16)
12 Collets (x32) 13 Oil seal - valve stems (x16)
14 Valve seat inserts (x16) 17 Valve stem
15 - 120 9823/1650-1 15 - 120

15 - Engine
30 - Valve
00 - General
Operation Adjust
Special Tools
The camshaft drive gear is driven by the crankshaft Description Part No. Qty.
gear at half the speed of the crankshaft. Camshaft Crankshaft Turning Tool 892/01147 1
lobes, two for each cylinder, (operating exhaust and (95.25mm PCD)- JCB
inlet valves) actuate the valve tappets. 4 Cylinder Ecomax and
Dieselmax
When the camshaft rotates the cam lobes act on the
tappets. The push rods act on the rockers which pivot Valve Clearance 892/01380 1
on the camshaft, depressing two valves at the same Service Kit
time via the bridge piece.
Engine Position
The screw is self locking in the rocker by means of
a tapered thread. Wave washers act like springs to The engine needs to be set to two different positions
keep the rockers in their correct positions along the to measure and adjust all of the valves. The graphics
camshaft and prevent them contacting one another. show which valves are applicable at which engine
The rockers incorporate a swivel tip to ensure position.
alignment with the bridge piece. This prevents
excessive wear. 1. Make sure that the engine is safe to work on. If
Each valve has a compression spring. The function you start the service work.
of the spring is to close the valve and at the same
time return the rocker arm and push rod to ensure 2. Get access to the engine.
that the tappets follow the camshaft lobes. The spring
is located on the valve stem by a retainer and split 3. Remove the tappet covers. Refer to (PIL 15-42).
collets.
4. Put the indicator pins into the holes inside the
tappet adjusters for cylinder number 4. Make
sure that the pins do not fall into the engine.
5. Use the crankshaft turning tool to turn the engine
crankshaft clockwise. Stop turning the crankshaft
when one indicator pin starts to move up after the
other pin has moved down. This is the position
where the exhaust valve is almost closed and the
inlet valve is just starting to open.
Special Tool: Crankshaft Turning Tool (95.25mm
PCD)- JCB 4 Cylinder Ecomax and Dieselmax
(Qty.: 1)
Special Tool: Valve Clearance Service Kit (Qty.:
1)
6. Put a mark on the crankshaft pulley at the 12
o'clock position.
15 - 121 9823/1650-1 15 - 121

15 - Engine
30 - Valve
00 - General
Figure 149. Figure 151. 360 Degree Position

A
360
T7
2B 4B
1A 2A
1A Exhaust valve-Cylinder 1
2A Exhaust valve-Cylinder 2
2B Inlet valve-Cylinder 2
T8 T8 Valve Clearances
The procedure describes how to measure and,
if necessary, adjust one valve clearance. The
procedure for all the valves is the same. Do the
A 12 o'clock position procedure for the correct valves at each of the two
T7 Crankshaft turning tool engine positions. Remember you must remove the
T8 Indicator pins (obtain locally) valve clearance service tools before you turn the
engine crankshaft.
7. Turn the engine crankshaft 90 degrees
clockwise. Important: The engine must be cold before you
8. Measure and, if necessary, adjust the clearances measure or adjust the valve clearances.
for the correct valves.
1. Install the adaptor plate in the correct position on
Figure 150. 90 Degree Position the rocker cover using the screws A.
2. Make sure that the crankshaft is in the correct
position.
3. Put the adaptor sleeve on the correct valve
tappet adjuster screw.
90 4. Push the lock bar into the correct valve tappet
adjuster screw.
1B 3B 5. Tighten the lock bar by turning it with your hand.
3A 4A
6. Assemble the DTI support and DTI.
3A Exhaust valve-Cylinder 3 7. Push and then pull the lock bar in the direction of
3B Inlet valve-Cylinder 3 the arrows X and Y. Do this until you are sure that
4A Exhaust valve-Cylinder 4 the lock bar is correctly installed and oil is moved
away from the cam follower and push rod.
9. Remove the valve clearance service tools. Turn
the engine crankshaft 360 degrees clockwise. 8. Important: Apply a side force on the lock bar
Use the mark on the crankshaft pulley as a at the same time as pushing and pulling. This
reference. prevents the rocker moving along the rocker
shaft and giving a false reading on the DTI. Apply
10. Measure and, if necessary, adjust the clearances a force to the left on the exhaust valve tappets
for the correct valves. and to the right on the inlet valve tappets.
15 - 122 9823/1650-1 15 - 122

15 - Engine
30 - Valve
00 - General
T1
C
T5
X A
T4 Y B
A
T3
T2
T6
A Screws B Tappet adjusters
T1 Dial Test Indicator (DTI)(obtain locally) C Rockers
T2 Adaptor plate (part of valve clearance service T6 Spanner open ended (obtain locally)
kit)
T3 Adaptor sleeve (part of valve clearance service
kit)
T4 Lock bar (part of valve clearance service kit)
T5 DTI Support (obtain locally)
9. Pull the lock bar in the direction of arrow Y and
turn the DTI to zero.
10. Push the lock bar in the direction of arrow X and
record the DTI indication.
11. Compare the valve clearance measurement with
the correct clearances. If an adjustment is
necessary:
11.1. Turn the tappet adjuster using an open
ended spanner on the adaptor sleeve.
Turn the sleeve clockwise to reduce
the clearance and counterclockwise to
increase the clearance.
11.2. Important: The tappet adjusters are set in
position by thread friction with the rockers.
Make sure that the torque to turn the
tappet adjusters is more than the minimum
necessary. If any of the adjusters show a
lower torque value then the adjuster and
its related rocker must be replaced.
15 - 123 9823/1650-1 15 - 123

15 - Engine
30 - Valve
00 - General
Remove and Install Figure 154. Valve Stand
Special Tools
Valve Stem Seal 892/01152 1
Installation Tool
(444/448/672 Engine)
EXHAUST
EXHAUST
EXHAUST
INLET
INLET
INLET
Before Removal
1. This procedure requires service parts. Make CYL. 1 CYL. 2 CYL. 3

2. Make sure that the engine is safe to work on. If Remove
you start the service work. 1. Use a spring compressor tool to compress each
valve spring and remove the collets. Make sure
3. Get access to the engine. that the springs are compressed squarely.
4. Remove the thermostat, refer to (PIL 21-12). Figure 155.
5. Remove all of the fuel injector pipes, refer to (PIL
18-96). B
6. Remove the rocker cover, refer to (PIL 15-42).

7. Remove the fuel injectors, refer to (PIL 18-18).
8. Remove the rocker assembly, refer to (PIL
15-42).
9. Remove the exhaust manifold, refer to (PIL A
18-24).
10. Remove the inlet manifold, refer to (PIL 18-24).
11. Remove the cylinder head assembly from the
cylinder block, refer to (PIL 15-06). A Spring compressor tool
12. Measure the valve recession with a suitable DTI B Collets
(Dial Test Indicator). Clean the carbon deposits 2. Remove the spring compressor tool and lift off
from a small area of the valve heads for location the retainer and valve spring.
of the DTI probe. If the valve recession is outside
the serviceable limits, it is advisable to obtain Figure 156.
a new or reconditioned cylinder head assembly,
refer to Technical Data (PIL 15-06). C
13. To aid removal and replacement, use a wooden

valve stand to retain the valves after removal. D
Add labels to make sure that the valves are
correctly replaced.
C Retainer
D Valve spring
3. Turn the cylinder head on its side and withdraw
the inlet valves and exhaust valves as shown.
15 - 124 9823/1650-1 15 - 124

15 - Engine
30 - Valve
00 - General
Figure 157. If there is evidence of wear or damage to the valves,

guides or seats, it is advisable to obtain a new or
reconditioned cylinder head assembly.
G
Before Installation
1. Position the cylinder head upside down in a
E
suitable jig or fixture.
F
3. Install the injectors into the cylinder head to
do a trial check of the nozzle protrusion. Note
the relative positions for the injectors, and then
remove the injectors for installation at a later
stage.
E Cylinder head Installation

F Inlet valves
G Exhaust valves 1. The installation procedure is the opposite of the
4. When removing, note the respective position of steps.
each valve. Use a suitable valve stand to keep
the valves together and identify them with their 2. Install the new valve stem seals as shown. Use
respective cylinder. Note: The exhaust valves the installation tool to avoid damaging the seals.
have smaller diameter heads. Pre-assemble the seal into the tool. Locate the
tool over the valve guide and gently press the
5. Remove the valve stem seals. Discard the seals. seal into place. Lubricate the seal with P80 fluid.
Figure 158. Special Tool: Valve Stem Seal Installation Tool
(444/448/672 Engine) (Qty.: 1)
3. With the cylinder head on its side, insert the
J H inlet valves and exhaust valves as shown. Make
sure that the valves are installed in the correct
positions. Lubricate the valve stems with clean
engine oil before assembly. Carefully push the
end of the valve stem through the stem seals.
4. Install the valve springs on to the valve
stems, together with a retainer. Use the spring
compressor tool to compress each valve spring
and insert the collets. Make sure that the collets
are correctly seated in the valve stem grooves,
before you remove the spring compressor tool.
H Valve stem seals After Installation

J Punch tool
1. Tap the valve stems in turn using a rubber mallet
top fully seat the valves.
Inspection
1. Carefully clean the carbon deposits from the
valves, take care not to damage the valve seats.
2. Check that the valves and valve seats are not
cracked, burnt or damaged.
3. Check the valve stems and valve guides for wear,
refer to Technical Data (PIL 15-30).
15 - 125 9823/1650-1 15 - 125

15 - Engine
30 - Valve
12 - Valve Spring
12 - Valve Spring
Remove and Install

15 - 126 9823/1650-1 15 - 126

15 - Engine
30 - Valve
24 - Stem Seal
24 - Stem Seal
Remove and Install

15 - 127 9823/1650-1 15 - 127

15 - Engine
33 - Connecting Rod
33 - Connecting Rod
Contents Page No.
15-33-00 General ......................................................................................................................... 15-129

15-33-06 Big-End Bearing ........................................................................................................... 15-133
15 - 128 9823/1650-1 15 - 128

15 - Engine
33 - Connecting Rod
00 - General
Introduction .................................................. 15-129 The connecting rod connects the piston to the
Technical Data ............................................. 15-130 crankshaft. They form a simple mechanism that
Component Identification ............................. 15-130 converts reciprocating motion into rotating motion.
Check (Condition) ........................................ 15-131
Connecting rods are usually made of high strength
Remove and Install ..................................... 15-131 steel. They are not rigidly fixed at either end, so that
Disassemble and Assemble ........................ 15-132 the angle between the connecting rod and the piston
can change as the rod moves up and down and
rotates around the crankshaft.
The small end of the connecting rod attaches to the

piston pin which is a press fit into the connecting rod.
The big end of the connecting rod connects to the

bearing journal on the crank throw, they run on
replaceable bearing shells that are accessible via the
connecting rod bolts which hold the bearing cap on
to the big end.
There is a pinhole bored through the bearing and

the big end of the connecting rod so that pressurised
lubricating engine oil squirts out on to the thrust
side of the cylinder wall to lubricate the travel of the
pistons and piston rings.
15 - 129 9823/1650-1 15 - 129

15 - Engine
33 - Connecting Rod
00 - General
Technical Data Component Identification
Table 67. Connecting Rods Data Refer to Piston- Component Identification.Refer to:
PIL 15-36-00.
Connecting rod type
(1)
Split fracture
Connecting rod bore di- 77 –77.01 mm
ameter
Connecting rod side
clearance
min 0.05 mm
max 0.4 mm
Big end bearings
Width 32.5 –33 mm
Thickness (at centre) 1.99 –1.981 mm
Small end bearings
Inside diameter 40.034 –40.02 mm
(1) Split fracture type connecting rods MUST NOT be
dot punched or etched in anyway during disassembly
- refer to relevant service procedures.
15 - 130 9823/1650-1 15 - 130

15 - Engine
33 - Connecting Rod
00 - General

1. Check the connecting rods for signs of bending. The removal and installation procedure for one
In the event of sufficient liquid entering the piston and connecting rod assembly is exactly the
engine, a hydraulic lock can occur. This may same. Refer to Piston - Remove and Install.Refer to:
result in bending of one or more of the connecting PIL 15-36-00.
rods. Bending of a connecting rod(s) can occur
even when the engine is cranked by the starter
motor. Bending of the connecting rod may be
very slight and can be checked prior to a full
engine strip down. For the checking procedure
refer to Calibration (PIL 15-36-00)
2. Check the connecting rod for signs of damage
and excessive wear.
The connecting rod small end bearing bush is not

renewable. If the small end bearing bush is damaged
or worn the connecting rod must be renewed as a
complete assembly.
15 - 131 9823/1650-1 15 - 131

15 - Engine
33 - Connecting Rod
00 - General
Disassemble and Assemble

15 - 132 9823/1650-1 15 - 132

15 - Engine
33 - Connecting Rod
06 - Big-End Bearing
06 - Big-End Bearing Introduction

Introduction .................................................. 15-133 In a piston engine, the big-end bearings are the
Check (Condition) ........................................ 15-134 bearings at the big-end of the connecting rod.
15 - 133 9823/1650-1 15 - 133

15 - Engine
33 - Connecting Rod

Special Tools
1. Check the bearing shell surfaces for signs of Description Part No. Qty.
Torque Wrench 993/70111 1
Refer to: PIL 15-33-00. (10-100Nm)
2. Measure the crank pin diameters to confirm they
are within service limits. Before Removal
Refer to: PIL 15-12-00. This procedure requires service parts. Make sure
you have obtained the correct service parts before
3. Renew any parts that are worn or not within the you start. Refer to Parts Catalogue.
specified tolerances.
3. Remove the engine from the machine.
injectors.
5. Remove the rocker cover.
6. Remove the fuel injectors.
8. Remove the oil sump.
9. Position the engine upside down in a suitable jig
or fixture, supported at the front of the crankcase.
The connecting rod and the big-end bearing cap

have been fracture split and must be kept together
as a set. Care must be taken to avoid contamination
and or damage to the fracture split surfaces.
Remove
1. It is recommended that the big-end bearing caps
are removed in pairs, cylinders 1 and 4 and
cylinders 2 and 3. Rotate the crankshaft so that
the big-end bearing caps on cylinders 2 and 3 are
positioned as shown.
2. Remove the bolts and lift off the big-end bearing
caps from the connecting rods. The bolts must
not be re-used, discard the bolts.
15 - 134 9823/1650-1 15 - 134

15 - Engine
33 - Connecting Rod
Z
X 3
1 2
1 Big-end bearing caps

2 Big-end bearing cap bolts
X Cast notch 6
2.1. Make sure that the tool is kept in inline 2

with the bolt to avoid damaging the screw 1 Big-end bearing cap
thread. 2 Bolts
3 Connecting rod
3. Lift out the bearing shells from the bearing caps. 4 Piston
Carefully rotate the crank to disengage from the 5 Piston rings
connecting rods and get access to the upper 6 Big end bearing shells
bearing shells. Lift out the upper bearing shells. Z Fracture split surfaces
It is recommended that the bearing shells are
renewed. If they are to be reused, label the 4. Carefully rotate the crankshaft to position the big-
bearing shells to make sure that they are installed end bearing caps of cylinders 1 and 4. Make
in their original positions on assembly. sure that the crank does not foul the connecting
rods of cylinders 2 and 3. Remove the bearing
caps and bearing shells as described in previous
steps.
5. Inspect the big-end bearings for signs of damage
and excessive wear.
Install
steps.
3. Install the upper bearing shell to the connecting
rod. Lubricate the bearing shell with clean engine
oil.
4. Install the lower bearing shell to the big-end
bearing cap. Lubricate the bearing shell with
15 - 135 9823/1650-1 15 - 135

15 - Engine
33 - Connecting Rod
clean engine oil. Install the big-end bearing cap

to the connecting rod. Make sure that the cast
notch on the bearing cap faces to the front of the
engine. Use compressed air to clean the fracture
surfaces before assembly.
5. Install new big end bearing cap bolts. Tighten the
new bolts in three stages to the correct torque
value.
1)
5.1. Make sure that the tool is kept in inline
with the bolt to avoid damaging the screw
thread.
5.2. The bolts are tightened using a torque and
angle method.
Figure 161.
0° +90°
Figure 162.
T3
T3 Angle gauge (obtain locally)
After Installation
1. The after installation procedure is the opposite of
the before removal procedure.

Item Torque Value Angle (de-
(Nm) grees)
2 (1st Stage) 35
2 (2nd Stage) 65
2 (Final Stage) 90
15 - 136 9823/1650-1 15 - 136

15 - Engine
36 - Piston
36 - Piston
Contents Page No.
15-36-00 General ......................................................................................................................... 15-139

15-36-03 Piston Ring ................................................................................................................... 15-151
15 - 137 9823/1650-1 15 - 137

Notes:
15 - 138 9823/1650-1 15 - 138

15 - Engine
36 - Piston
00 - General
Introduction .................................................. 15-139 The piston is acted upon by the pressure of the
Technical Data ............................................. 15-140 expanding combustion gases in the combustion
Component Identification ............................. 15-141 chamber space at the top of the cylinder. This force
Operation ..................................................... 15-142 then acts downwards through the connecting rod and
on to the crankshaft.
Check (Condition) ........................................ 15-143
Calibrate ...................................................... 15-143 The pistons are cast from aluminium alloys for
Remove and Install ..................................... 15-145 increased strength and improved fatigue life.
Disassemble and Assemble ........................ 15-148
The connecting rod is attached to the piston by a
swivelling piston pin. This pin is mounted within the
piston, The pin itself is of hardened steel and is fixed
in the piston, but free to move in the connecting rod.
The pins are prevented from moving sideways and
the ends of the pin digging into the cylinder wall by
circlips.
15 - 139 9823/1650-1 15 - 139

15 - Engine
36 - Piston
00 - General
Technical Data
Table 69.
Engine 444 448
Gudgeon pin bore diameter
- min. 40.01 mm 42.008 mm
- max. 40.015 mm 42.013 mm
Piston ring clearance
- Top ring Full keystone ring Full keystone ring
- Middle ring 0.125 –0.08 mm 0.125 –0.08 mm
- Bottom (oil) ring 0.09 –0.05 mm 0.09 –0.05 mm
Piston ring gap
- Top ring 0.3 –0.4 mm 0.3 –0.4 mm
- Middle ring 0.55 –0.8 mm 0.55 –0.8 mm
Piston height above crankcase 0.00025 –0.36825 mm
(1)
0.00025 –0.36825 mm
(1)
(cold)
Piston groove width
- Top ring 3.114 –3.134 mm 3.114 –3.134 mm
- Middle ring 2.575 –2.595 mm 2.575 –2.595 mm
Piston skirt 102.853 –102.871 mm 105.851 –105.869 mm
Piston pin 39.994 –40 mm 41.994 –42 mm
(1) Nominal measurement is 0.03325 mm
15 - 140 9823/1650-1 15 - 140

15 - Engine
36 - Piston
00 - General
Figure 163.
C
D
E
A F
F
A Piston
B Connecting rod
C Oil control ring
D Piston ring - compression No.1
E Piston ring - compression No.2
F Retaining circlips
G Piston pin
15 - 141 9823/1650-1 15 - 141

15 - Engine
36 - Piston
00 - General
Operation
top of the pistons. Oil spray also enters the small end
The groove around the diameter of the upper main bearing bushes via a feed hole on the top of each
bearing shells allows oil transfer to an oil jet located connecting rod.
in the crankcase bearing saddle. Jets are installed at
the main bearing positions. Note: On turbocharged engines additional J-jets are
installed. Oilways connect the J-shaped jets fixed to
The jets spray oil directly to the under side of the the crankcase at the underside of each cylinder bore.
pistons effectively transferring heat away from the
Figure 164.
1 1
6
2
5
1 Groove 2 Oil jet

3 Pistons 4 Bearing bushes
5 Crankshaft 6 J shaped jets
15 - 142 9823/1650-1 15 - 142

15 - Engine
36 - Piston
00 - General
Check (Condition) Calibrate

1. Check the piston for signs of damage and
excessive wear. Measure the piston skirt
Piston Height Measurement Above
diameter, piston pin bore and the clearance in Cylinder Block- DTI Method
the piston ring grooves to confirm they are within
service limits. In the event of sufficient liquid entering the engine, a
hydraulic lock can occur. This may result in bending
Refer to: PIL 15-36-00. of one or more of the connecting rods. Bending of the
connecting rod(s) can occur even when the engine is
2. Check the piston pin for signs of damage and cranked by the starter motor.
excessive wear. Measure the pin diameter to
confirm it is within service limits. Refer to Piston. Bending of the connecting rod may be very slight and
Refer to: PIL 15-36-00. can be checked by carrying out this procedure prior
to a full strip down:
The connecting rod small end bearing bush is not
renewable. If the small end bearing bush is damaged 1. With the cylinder head removed, make sure the
or worn the connecting rod must be renewed as a surface of the engine block and piston are clean.
complete assembly.
2. Zero a DTI (Dial Test Indicator) on the top face
of the cylinder block adjacent to the area on the
piston to be measured. The aim of the procedure
is to use the DTI to take a measurement across 2
locations on the piston that are on the axis of the
gudgeon pin. This will be towards the front and
rear of the engine.
3. Rotate the engine and bring the piston up until
it is 3mm below the engine block face. Carefully
reposition the zeroed DTI above the area of the
piston to be measured.
4. Rotate the engine to bring the piston up to
exactly TDC (Top Dead Centre) and record the
measurement at position 1.
5. Repeat steps 2 to 4 for position 2.
6. Calculate the average of the 2 readings to give
a figure of the piston height above the cylinder
block.
7. Compare the reading obtained to the technical
data.
7.1. If the reading obtained is lower than zero,
the connecting rod may be bent.
7.2. If the reading obtained is equal to the range
stated in technical data, the connecting rod
is not bent.
8. Repeat steps 2 to 7 to check all connecting rods/
pistons.
9. If any connecting rods are bent, strip the engine
and check for further damage.
10. If the engine is serviceable, any connecting rod
that is bent must be replaced.
15 - 143 9823/1650-1 15 - 143

15 - Engine
36 - Piston
00 - General
Figure 165. DTI Measurement 5. Calculate the average of the 2 readings to give
D a figure of the piston height above the cylinder
block.
C
5.1. If the reading obtained is lower than zero,
the connecting rod may be bent.
5.2. If the reading obtained is equal to the range
stated in technical data, the connecting rod
is not bent.
B Refer to: PIL 15-36-00.
6. Repeat steps 1 to 5.2 to check all connecting
rods/pistons.
Figure 166. Straight Edge Measurement
G
F
E
A Gudgeon pin axis

B Line of measurement above gudgeon pin axis K
C Piston measurement point 1
D Piston measurement point 2
L
Piston Height Measurement Above
Cylinder Block- Straight Edge Method
If a DTI is not available, a calibrated straight E Straight edge
edge may be used to take a measurement. The F Measurement position 1
measurement will be less accurate. G Measurement position 2
H Cylinder block- top face
1. With the cylinder head removed, make sure the J Gudgeon pin axis
surface of the engine block and piston are clean. K Piston
L Connecting rod
2. Rotate the engine until the piston to be measured
is at TDC.
3. Position the straight edge on top of the piston
along the axis of the gudgeon pin.
4. Use feeler gauges to measure the gap between
the cylinder block face and underside of the
straight edge on both sides, position 1 and
position 2.
15 - 144 9823/1650-1 15 - 144

15 - Engine
36 - Piston
00 - General
Remove and Install

Before Removal 4. Disconnect and remove the fuel pipes from the
The following procedure is for one piston and injectors. Refer to (PIL 18-96).
connecting rod assembly. Note that each assembly 5. Remove the rocker cover. Refer to (PIL 15-42).
must be replaced in the same cylinder bore. Label
each piston and connecting rod assembly to make 6. Remove the fuel injectors. Refer to (PIL 18-18).
sure it is installed in the correct position on assembly.
7. Remove the cylinder head assembly. Refer to
1. This procedure requires service parts. Make sure (PIL 15-06).
that you have obtained the correct service parts
before you start. Refer to Parts Catalogue. 8. Remove the oil sump. Refer to (PIL 15-45).
2. Make sure that the engine is safe to work on. If 9. Remove the big end bearing caps. Refer to (PIL
the engine has been running, let it cool before 15-33-06).
15 - 145 9823/1650-1 15 - 145

15 - Engine
36 - Piston
00 - General
Figure 167.
X
1
1 Piston 2 Piston ring

3 Connecting rod X Longest side of connecting rod
15 - 146 9823/1650-1 15 - 146

15 - Engine
36 - Piston
00 - General
Remove
The piston and connecting rod assemblies are
removed through the top of the crankcase.
1. Use a suitable scraper and wire wool to clean off

the carbon deposits from around the top of the
cylinder bore. Take care not to scratch or damage
the cylinder bore.
2. Use a hammer and a short length of wood to
tap the piston from the connecting rod side. Take
care not to scratch or damage the cylinder bore
or the connecting rod bearing surface.
Install
steps.
3. If the upper big end bearing shell has been
removed replace it. Refer to (PIL 15-33-06).
4. Lubricate the cylinder bore with clean engine oil.
5. Use a suitable compressor tool to compress the
piston rings.
6. Insert the piston and connecting rod assembly
into the cylinder bore, make sure that the longest
side of the connecting rod is on the exhaust side
of the crankcase. Take care not to damage the
cooling jets when you guide the connecting rod
down the cylinder bore and over the crank pin
diameter.
After Installation
1. Install the big end bearing caps. Refer to (PIL
15-33-06).
2. Carry out the procedures listed under Before
removal in reverse order.
15 - 147 9823/1650-1 15 - 147

15 - Engine
36 - Piston
00 - General
Carefully remove the piston rings from the piston.

Dismantle To avoid damage or distortion to the rings, use a
suitable piston ring expander tool. Note that the
1. Clamp the connecting rod in a vice. Take care not oil control ring is installed with a spiral wire. Pull
to damage the connecting rod. the wire apart and remove it.
2. It is recommended that the piston rings are 3. Remove the circlips and push out the piston pin.
renewed. If they are to be reused, label the
rings to ensure they are installed in the correct 4. Use a suitable cleaning agent, clean the carbon
positions and the correct way up on assembly. deposits from the piston.
15 - 148 9823/1650-1 15 - 148

15 - Engine
36 - Piston
00 - General
Figure 168.
A TOP
2 X
B 3
TOP
C
4a
TOP
1
4
6
7
0°
12
12
0°
120°
1 Piston 2 Piston ring - compression No.1

3 Piston ring - compression No.2 4 Piston ring - oil control ring
4a Spiral wire - oil control ring 5 Connecting rod
6 Piston pin 7 Retaining circlip (x2)
X Connecting rod - longest side Y Cast boss - piston
Inspect
1. Inspect the pistons for signs of wear or damage.
Refer to Check (Condition) (PIL 15-36-00).
15 - 149 9823/1650-1 15 - 149

15 - Engine
36 - Piston
00 - General
Assemble
1. The assembly procedure is the opposite of
the disassemble procedure. Additionally do the
following steps.
3. Lubricate the piston pin with clean engine oil.
Assemble the connecting rod to the piston and
insert the piston pin. Make sure that the long side
of the connecting rod is on the same side as the
internal cast boss in the piston.
4. Install new circlips. Make sure that they are
installed correctly in the groove in the piston.
5. Lubricate the piston with clean engine oil. Install
the piston rings to the piston in sequence as
follows:
5.1. Install the spiral wire for the oil control ring
in the bottom groove and locate the locking
wire inside both ends of the spiral as shown.
Using a piston ring expander tool to install
the oil control ring in the bottom groove and
locate the locking wire inside both ends of
the spiral as shown. Ensure that the ring
gap is positioned 180° to the locking wire.
Note: The correct ring orientation can also
be determined from the profile shape of the
ring as shown at C.
5.2. Install the No.2 compression ring into
the middle groove. Note that new rings
have a reference number etched on one
face. Make sure that this face is installed
uppermost in the piston groove. Note:
The correct ring orientation can also be
determined from the profile shape of the
ring as shown at B.
5.3. Install the No.1 compression ring into the
top groove. Note that new rings have a
reference number etched on one face.
Make sure that this face is installed
uppermost in the piston groove. Note:
The correct ring orientation can also be
determined from the profile shape of the
ring as shown at A.
6. Rotate the piston rings so that the ring gaps are
120° apart as shown.
15 - 150 9823/1650-1 15 - 150

15 - Engine
36 - Piston
03 - Piston Ring
03 - Piston Ring
Introduction
Gas sealing inside the piston is achieved by the use

of piston rings. The rings are loosely installed into
grooves in the piston. The rings are split at a point in
the rim, to allow them to press against the cylinder
with a light spring pressure.
Two types of ring are used:
- Upper rings have solid faces and provide gas

sealing
- Lower rings have narrow edges and have a U-

shaped profile, to act as oil scrapers.
15 - 151 9823/1650-1 15 - 151

15 - Engine
39 - Manifold
39 - Manifold
Contents Page No.
15-39-00 General ......................................................................................................................... 15-153
15 - 152 9823/1650-1 15 - 152

15 - Engine
39 - Manifold
00 - General
00 - General
Introduction
15 - 153 9823/1650-1 15 - 153

15 - Engine
42 - Rocker and Fittings
Contents Page No.
15-42-00 General ......................................................................................................................... 15-155

15-42-06 Rocker Cover ............................................................................................................... 15-164
15-42-09 Push Rod ..................................................................................................................... 15-166
15-42-21 Tappet ........................................................................................................................... 15-168
15-42-24 Tappet Cover ................................................................................................................ 15-170
15 - 154 9823/1650-1 15 - 154

15 - Engine
00 - General
Introduction .................................................. 15-155 The rocker assembly is an indirect valve actuating
Technical Data ............................................. 15-156 system consisting of rocker arms and a shaft.
Operation ..................................................... 15-158 The rocker arm is an oscillating lever that conveys
radial movement from the cam lobe into linear
Check (Condition) ........................................ 15-159 movement at the poppet valve to open it. One end is
Remove and Install ..................................... 15-160 raised and lowered by a rotating lobe of the camshaft
Disassemble and Assemble ........................ 15-162 via a tappet and push rod while the other end acts
on the bridge piece which is connected to the valve
stem.
15 - 155 9823/1650-1 15 - 155

15 - Engine
00 - General
Technical Data
Table 70. Rocker Levers, Rocker Shafts and Tappets Data

Valve clearances measured at the valve end of the
rockers (measured cold):
- Inlet 0.19 –0.27 mm
- Exhaust 0.56 –0.64 mm
Valve clearances measured at the tappet end of the
rockers (measured cold):
- Inlet 0.15 –0.21 mm
- Exhaust 0.43 –0.49 mm
Rocker lever bore diameter
- min 26.058 mm
- max 26.092 mm
Rocker shaft diameter
- min 26.003 mm
- max 26.021 mm
Tappets stem diameter
- min 19.975 mm
- max 19.985 mm
Tappet bore diameter
- min 20 mm
- max 20.021 mm
Tappet height (maximum) 55.25 mm
15 - 156 9823/1650-1 15 - 156

15 - Engine
00 - General
Figure 169.
2
4
6
2 1
4
3
5
7
2
4
2
4
2
4
2
4
2
4
743830
1 Rocker shaft assembly 2 Rocker shaft fixing bolts (x7)

3 Rocker shaft - oil feed pedestal fixing bolt (x1) 4 Pedestals (x7)
5 Oil feed pedestal (x1) 6 Bridge pieces (x8)
7 Push rods (x8)
15 - 157 9823/1650-1 15 - 157

15 - Engine
00 - General
Operation
rocker arm is permitted to return due to the camshafts

When the camshaft lobe raises the outside of the rotation, the inside rises to allow the valve spring to
rocker arm, the inside presses down on the valve close the valve.
stem to open the valve. When the outside of the
Figure 170.
1 Oil feed from main gallery 2 Small transfer gallery

3 Shaft pedestal 4 Rocker shaft fixing bolt hole
5 Centre rocker shaft drilling 6 Cross drillings
7 Rocker pivot bushes 8 Cross drilling
9 Groove
Lubrication in each rocker transfers oil to the top of the rocker

where it flows by gravity along a groove to the rocker
Oil is fed from the main gallery via a drilling which tip.
passes up through the crankcase and the cylinder
head to a small transfer gallery under the rocker
shaft pedestal. The oversize rocker shaft fixing bolt
hole allows oil to pass into a drilling in the centre of
the rocker shaft. Further cross drillings transfer oil
to each of the rocker pivot bushes. A cross drilling
15 - 158 9823/1650-1 15 - 158

15 - Engine
00 - General
Check (Condition)
1. Check the rocker shaft and rocker bushings for
signs of damage and excessive wear. Measure
the rocker shaft diameter and rocker bearing
bushes to confirm they are within service limits.
Refer to Technical Data. Note: The rocker
bearing bushes are not renewable. If a rocker
bearing bush is damaged or worn the rocker
must be renewed as a complete assembly.
2. Make sure that all oil-ways and cross drillings in
the rocker shaft, rocker arms and pedestals are
clear and free from debris. Use an air line to blow
through cross drillings.
15 - 159 9823/1650-1 15 - 159

15 - Engine
00 - General
Remove and Install

Before Removal 3. Disconnect and remove the fuel pipes from the
1. Make sure that the engine is safe to work on. If fuel injectors, refer to Fuel pipes (PIL 18-96).
Figure 171.
2
4
6
2 1
4
3
5
7
2
4
2
4
2
4
2
4
2
4
743830
1 Rocker shaft assembly 2 Rocker shaft fixing bolts (x7)

3 Rocker shaft - oil feed pedestal fixing bolt (x1) 4 Pedestals (x7)
5 Oil feed pedestal (x1) 6 Bridge pieces (x8)
7 Push rods (x8)
15 - 160 9823/1650-1 15 - 160

15 - Engine
00 - General
Remove
1. Remove the rocker shaft fixing bolts. DO NOT
withdraw the bolts. Lift the rocker shaft assembly
from the cylinder head complete with pedestals
still attached. Important: Keep all pedestals and
fixing bolts in their original positions.
2. Lift off the bridge pieces from the pairs of inlet
and exhaust valves.
3. Withdraw the push rods from the cylinder block.
Before Installation
damage and corrosion. Refer to Check Condition
(PIL 15-42).
2. Make sure that all oil-ways and cross drillings in
the cylinder head, rocker shaft and pedestals are
through the cross drillings.
Install
steps.
2. Use a suitable degreasing agent to clean the top
of the cylinder head.
3. Install the bridge pieces on to the pairs of inlet
and exhaust valves in the cylinder head.
4. Insert the push rods into the cylinder block. Make
sure that they engage with the camshaft tappets.
5. Install the rocker shaft assembly into the cylinder
head. Make sure that the pedestals are located in
their original positions. Note the position of the oil
feed pedestal and the longer bolt. Make sure that
the push rods engage with the tappet adjusters
and that the rockers are located over the bridge
pieces.
After Installation
1. Measure and adjust the valve clearances, refer
to (PIL 15-30).

Item Nm
2 24
3 24
15 - 161 9823/1650-1 15 - 161

15 - Engine
00 - General
2. Remove the rocker assembly. Refer to (PIL

Before Disassembly 15-42).
1. Remove the rocker cover. Refer to (PIL 15-42).
Figure 172.
2
2
3
1
2
2
4
4
4
5
4
5
6
7
4
1 Rocker shaft 2 Rocker shaft fixing bolts (x7)

3 Rocker shaft - Oil feed pedestal fixing bolt (x1) 4 Pedestals (x7)
5 Oil feed pedestal (x1) 6 Rockers - inlet (x4)
7 Rockers - exhaust (x4) 8 Wave washers (x8)
15 - 162 9823/1650-1 15 - 162

15 - Engine
00 - General
Disassemble
1. Lift out the rocker shaft fixing bolts, then slide
the pedestals, rockers and wave washers off the
rocker shaft as shown. Label the pedestals and
rockers to make sure that they are installed in the
correct positions on assembly.
2. Check the rocker shaft and rocker bushings for
signs of damage and excessive wear. Refer to
Check (Condition) (PIL 15-42).
Assemble
the disassemble procedure. Additionally do the
following steps.
2. Lubricate the rocker shaft and rocker bearing
bushes with clean engine oil.
3. Make sure that the rockers and pedestals are
installed in their original positions along the
rocker shaft. Note the position of the oil feed
pedestal.
4. Insert the rocker shaft fixing bolts to hold the
rockers and pedestals loosely in position before
fitting the assembly into the cylinder head. Note
the position of the longer bolt.
After Assembly
1. Install the rocker assembly. Refer to (PIL 15-42).
2. Install the rocker cover. Refer to (PIL 15-42).
15 - 163 9823/1650-1 15 - 163

15 - Engine
06 - Rocker Cover
06 - Rocker Cover
Remove and Install
2. Clean the engine. Refer to Engine - Clean (PIL

Before Removal 15-00).

Figure 173.
D
A Rocker cover B Bolts

C Gasket D Injector seals
15 - 164 9823/1650-1 15 - 164

15 - Engine
06 - Rocker Cover
Remove
2. Remove the high pressure fuel pipes. Refer to
Fuel Pipes (PIL 18-96).
3. Remove the fuel bleed off fuel pipes. Refer to
4. Disconnect the electrical connectors at the fuel
injectors. Refer to Fuel Injection (PIL 18-18).
5. Disconnect the electrical connector at the coolant
temperature sensor. Refer to Engine Sensors
(PIL 15-84).
6. Move the electrical harness away from the rocker
cover.
7. Remove the bolts and lift the rocker cover from
the cylinder head.
8. Discard the gasket.
9. The rocker cover injector seals must be replaced.
Refer to Injector seals (PIL 18-18).
Install
steps.
2. Remove all oil and sludge contamination from
inside the rocker chamber.
3. Renew the injector seals. Refer to Injector seals
(PIL 18-18).
4. Renew the rocker cover gasket.
5. Prevent damage to the seals. Put sleeves/covers
on the four injectors. Apply a rubber lubricant to
the seals and then install the rocker cover.
7. Remove the sleeves/covers.
After Installation
1. The high pressure fuel pipes must be replaced
with new parts. Refer to Fuel Pipes (PIL 18-96).
2. Start the engine and check for oil and fuel leaks.

Item Nm
B 24
15 - 165 9823/1650-1 15 - 165

15 - Engine
09 - Push Rod
09 - Push Rod Introduction

Introduction .................................................. 15-166 Push rods are used in a reciprocating engine to open
Remove and Install ..................................... 15-167 and close the valves. They are moved by the cams
on the camshaft. One end is pushed up by the cam
and the other end makes contact with the rocker
arms which rotates and pushes the valve open.
15 - 166 9823/1650-1 15 - 166

15 - Engine
09 - Push Rod
Remove and Install

15 - 167 9823/1650-1 15 - 167

15 - Engine
21 - Tappet
21 - Tappet Figure 175.
Remove and Install

B
Before Removal
injectors. Refer to (PIL 18-96). C
B Timing pin - crankshaft
3. Remove the rocker cover. Refer to (PIL 15-42). C Blanking plug
4. Remove the fuel injection pump. Refer to (PIL 12. Remove the fuel injection pump drive gear. Refer
18-18). to (PIL 15-51).
5. Remove the rocker assembly and push rods.
Refer to (PIL 15-42). Removal
6. Remove the starter motor. Refer to (PIL 15-75). The engine must be inverted. DO NOT attempt
to remove the camshaft and its drive gears with
7. Remove the oil sump. Refer to (PIL 15-45). the engine upright. The tappets and push rods will
8. Remove the flywheel. Refer to (PIL 15-54). fall into the engine and further dismantling will be
required to retrieve them.
9. Remove the flywheel housing. Refer to (PIL
15-54). 1. Remove the camshaft timing pin.
10. Rotate the crankshaft until the camshaft timing 2. Carefully withdraw the camshaft and gear
pin can be inserted through the gear and into the assembly from the crankcase. Make sure you
aligning hole in the rear gear case. fully support the camshaft to prevent the lobes
contacting the bearing surfaces in the crankcase.
Figure 174. The bearing surfaces can easily be damaged by
the sharp hard edges on the cam lobes.
Figure 176.
A Timing pin - camshaft

11. Remove the taper blanking plug and insert
the crankshaft locking pin. The camshaft and
crankshaft locking pins must be in position to lock
the crankshaft and camshaft before removing the
camshaft assembly.
D
A Timing pin - camshaft

D Camshaft and drive gear
15 - 168 9823/1650-1 15 - 168

15 - Engine
21 - Tappet
3. Access the tappets through the apertures in Installation

the crankcase bedplate next to the crankshaft.
Lift out the tappets from the crankcase using a 1. Lubricate the tappets and tappet bores inside the
suitable magnetic probe. Label the tappets to crankcase with clean engine oil.
ensure replacement in their original positions.
2. Insert the tappets in their original positions in the
Figure 177. crankcase using a suitable magnetic probe.
3. Lubricate the camshaft bearing journals inside
F the crankcase with clean engine oil.
4. Carefully insert the camshaft assembly into the
crankcase as shown. Support the camshaft
E preventing the lobes contacting the bearing
surfaces in the crankcase. Before meshing the
E camshaft gear with the crankshaft gear, rotate
the camshaft until the timing hole in the gear
aligns with the dowel hole in the gear casing.
Insert the timing pin to lock the camshaft in this
position.
After Installation
1. Note that the fuel injection pump drive gear
fixing nut is torque tightened as part of the fuel
injection pump replacement procedure. Refer to
(PIL 18-18).
2. Do the procedures in Before Removal in reverse
order.
E Tappet (8 off)
F Magnetic probe
Inspection
1. Inspect the camshaft gear teeth for signs of
damage or excessive wear.
2. Inspect the cam lobes for signs of excessive
wear, scoring or pitting.
3. Inspect the cam bearing surfaces for signs
of excessive wear, or scoring. Check that the
dimensions are within service limits.
4. Inspect the cam bearing surfaces inside the
crankcase for signs of excessive wear, or
scoring. Check that the dimensions are within
service limits.
5. Inspect the bearing surfaces of the tappets for
the dimensions are within service limits.
6. Inspect the tappet bores inside the crankcase for
the dimensions are within service limits.
7. If any of the camshaft bearings or lobes are worn
or damaged then the relative oil feed galleries
in the crankcase and camshaft may be blocked.
Make sure all oil ways are clear and free from
debris.
15 - 169 9823/1650-1 15 - 169

15 - Engine
24 - Tappet Cover
24 - Tappet Cover Install

steps.
It is not necessary to remove the tappet covers 2. Inspect the tappet cover seals for signs of
unless a new rocker cover is to be installed. It is damage. Replace any damaged seals.
necessary to remove the tappet covers to measure
and adjust the valve clearances. Refer to Valve- 3. Install the tappet covers. Tighten the screws to
Adjust, Valve Clearances (PIL 15-30). the correct torque value.
Remove Table 73. Torque Values

Item Nm
the engine has been running, let it cool before A 9
3. Clean the tappet covers and the adjacent areas
of the rocker cover. Refer to Engine - Clean.
Important: Make sure that the screws do not fall
into the engine.
4. Remove the tappet cover screws.
5. Keep the screws away from the engine.
6. Use a screwdriver in the slot to remove the tappet
covers. Make sure that dirt or debris does not fall
into the engine.
Figure 178.
B B D B B
B A
E C
A Screws
B Tappet covers
C Slot
D Rocker cover
E Tappet cover seals
15 - 170 9823/1650-1 15 - 170

15 - Engine
45 - Oil Sump
45 - Oil Sump
Contents Page No.
15-45-00 General ......................................................................................................................... 15-173
15 - 171 9823/1650-1 15 - 171

Notes:
15 - 172 9823/1650-1 15 - 172

15 - Engine
45 - Oil Sump
00 - General
Introduction .................................................. 15-173 The lubrication system distributes oil around the
Component Identification ............................. 15-174 engine by a system of galleries and drillings in the
Remove and Install ..................................... 15-175 crankcase and cylinder head. The oil lubricates and
seals the moving parts of the engine, reducing friction
and wear. In addition the oil plays an important role in
cooling the engine by carrying heat from the engine
to the cooler. A piston cooling jet sprays oil onto the
underside of the pistons to keep them cool, refer to
(PIL 15-36).
Oil is drawn from the oil sump by the integral oil pump
via the suction strainer. The strainer prevents any
large particles of debris passing through, which may
damage the pump.
The oil passes from the outlet side of the pump

through a relief valve which limits the maximum oil
pressure by venting oil back to the inlet side of the
pump, refer to (PIL 15-36).
From the pump the oil passes through the oil cooler
and filter, refer to (PIL 15-69 and PIL 15-21).
After cooling and filtering, the oil passes into the

main oil gallery. An oil pressure switch senses the
oil pressure. From the main gallery oil is delivered,
via drillings, to the crankshaft main bearings, rocker
assembly, camshaft and timing gears. Note that
drillings are through the crankcase and cylinder
head.
When the high pressure oil has passed through the

bearings it reverts to sump pressure and splash
lubricates the internal components such as rocker
tips, cam lobes and timing gear teeth. Gravity
drains the oil via drains into the cylinder head and
crankcase, back into the oil sump. A drain slot allows
the oil to drain from the timing case back to the oil
sump.
15 - 173 9823/1650-1 15 - 173

15 - Engine
45 - Oil Sump
00 - General
Figure 179.
1 Oil sump 2 Suction strainer

3 Oil pump 4 Oil cooler
5 Filter 6 Camshaft - high pressure oil feed
7 Crankshaft main bearings - high pressure oil 8 Rocker assembly - high pressure oil feed
feed
9 PTO (Power Take-Off) idler gear bearing/ 10 External high pressure oil feed connection
timing case - high pressure oil feed (crankcase) - Turbocharger (if installed)
11 Main high pressure oil feed gallery 12 Oil pressure switch
(crankcase)
Green- Oil at sump pressure Red- Oil at high pressure
Pink- Oil at lower pressure but higher than
sump pressure
15 - 174 9823/1650-1 15 - 174

15 - Engine
45 - Oil Sump
00 - General
Remove and Install
Special Tools 2. Drain the engine oil.

Template for Sealant 892/01149 1 Removal
Oil Sump - Pressed
1. Remove the fixing bolts and remove the oil sump
Oil Sump Location 892/01150 2
from the engine. The oil sump may be difficult to
Dowel
remove due to adhesion of sealing compound.
Template for Sealant 892/12354 1 If necessary, carefully lever the mating flanges
Oil Sump (Cast) apart. Do not use excessive force, the oil sump
could be damaged. Be sure to retrieve the oil pick
Consumables up seal.
Clear Silicone Sealant 4102/0901 0.31 L 2. Use a gasket removal compound, carefully
remove all traces of sealing compound from the
oil sump and engine mating faces. Do not allow
Before Removal the sealing compound to enter the engine.
1. Make sure that the engine is safe to work on. 3. Use a suitable degreasing agent to thoroughly
If the engine has been running, make sure the clean the oil sump.
engine has cooled sufficiently before you start.
Figure 180.
1 Oil sump 1a Integral suction tube

1b Integral baffle plates 2 Oil sump fixing bolts (x20)
3 Oil pick up seal
15 - 175 9823/1650-1 15 - 175

15 - Engine
45 - Oil Sump
00 - General
Installation Figure 182.
1. Lightly smear the new oil pick up seal with oil and X
install into the bedplate as shown.
Figure 181.
3 Oil pick up seal

2. Install the two guide pins at the oil sump screw
holes in the engine.
Special Tool: Oil Sump Location Dowel (Qty.: 2)
S Hole
3. Use the fixing bolts to locate the template to T Hole
the oil sump mating face. Make sure that the T2 Guide pins
template is the correct way round (note that holes X 4mm Bead of sealant
are on different centres).
8. Position the oil sump with the suction tube outlet
Special Tool: Template for Sealant Oil Sump aligned with the oil pump inlet port on the engine.
(Cast) (Qty.: 1) Take care not to damage the oil pick up seal when
Special Tool: Template for Sealant Oil Sump - you install the oil sump. Damage to the seal could
Pressed (Qty.: 1) cause a drop in oil pressure and subsequently
damage to the engine.
4. Apply a bead of sealing compound around the
oil sump flange using the inside edge of the 9. Locate the oil sump on the guide pins on the
template as a guide as shown. Note the beads engine. Avoid smudging the sealant beads. DO
around holes. NOT remove the guide pins until sufficient bolts
Length/Dimension/Distance: 4 mm have been installed to secure the oil sump.
Consumable: Clear Silicone Sealant 10. Install the bolts and tighten the bolts to the correct
5. Carefully remove the template without smudging torque value. Note that the bolts are not installed
the sealant beads. at 6 positions.
6. Apply a bead of sealant so as to join the sealant Figure 183.

beads around holes with the bead around the oil
sump flange.
7. After applying the sealing compound, the oil
sump must be installed and the bolts torque
tightened within
Duration: 5 min
2 Bolts
Y No bolts to be installed at this position (x6)
15 - 176 9823/1650-1 15 - 176

15 - Engine
45 - Oil Sump
00 - General
After Replacing
1. Allow the sealant to cure for
Duration: 20 min
2. Refill the engine with the recommended engine
oil. Refer to (PIL 75-00).
3. Start the engine and check for oil leaks.

Item Nm
2 24
15 - 177 9823/1650-1 15 - 177

15 - Engine
48 - Grid Heater
48 - Grid Heater
Contents Page No.
15-48-00 General ......................................................................................................................... 15-179
15 - 178 9823/1650-1 15 - 178

15 - Engine
48 - Grid Heater
00 - General
00 - General Operation
Operation ..................................................... 15-179 The system aids engine starting by heating the air
Diagram ....................................................... 15-181 in the induction manifold through an electrical grid
heater. Operation of the system is fully automatic and
is controlled by the engine ECU (Electronic Control
Unit).
The power to the grid heater is supplied by a primary

fuse through the link harness to relay. The relay when
energised supplies power to the heater through the
power lead.
The relay is located at the side of the coolant

expansion tank.
The relay is energised by a feed from the engine

compartment fusebox, with the engine ECU proving
an earth for the relay.
The heating sequence is as follows:
1. Ignition key set to the on position.

2. Warning light illuminated (grid heater on)- engine
not ready to start.
Figure 184.
B
A
G
C D
E
F
A Coolant expansion tank B Warning light- grid heater on
15 - 179 9823/1650-1 15 - 179

15 - Engine
48 - Grid Heater
00 - General
C Relay D Primary fuse

E Induction manifold F Grid heater
G Heater H Harness
3. After a preset pre-heat time the warning light will

off- engine ready to start.
3.1. The pre-heat stage can not be repeated
unless the ignition key is first set to the off
position.
4. Turn the ignition key to engage the starter motor
and start the engine- grid heater on.
5. Engine started and starter motor disengaged-
grid heater off.
5.1. If the engine stalls and is restarted without
turning the ignition key to off, the grid heater
will come on while the starter motor is
engaged.
The 'pre-heat' stage can not be repeated unless the

ignition key is first set to the off position.
If the engine stalls and is restarted without turning the

ignition key to off position, the grid heater will come
on while the starter motor is engaged.
15 - 180 9823/1650-1 15 - 180

15 - Engine
48 - Grid Heater
00 - General
Diagram
Figure 185.
FUSE
A C
D
FUSE
F
G
A Primary fuse link B Engine compartment fuse

C Cold start relay D Grid heater element
E Engine ECU (Electronic Control Unit) F +VE
G -VE
15 - 181 9823/1650-1 15 - 181

15 - Engine
51 - Timing Gear
51 - Timing Gear
Contents Page No.
15-51-00 General ......................................................................................................................... 15-183

15-51-03 Crankshaft Gear ........................................................................................................... 15-186
15-51-06 Camshaft Gear ............................................................................................................. 15-189
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-190
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-193
15-51-22 Rear Case .................................................................................................................... 15-196
15 - 182 9823/1650-1 15 - 182

15 - Engine
51 - Timing Gear
00 - General
Introduction .................................................. 15-183 The timing gears are located inside a case at the
Component Identification ............................. 15-184 flywheel end of the engine.
Operation ..................................................... 15-185
Check (Condition) ........................................ 15-185 The engine must be timed so that the camshaft
operates the valves at the correct times relative to
the crankshaft position.
Valve timing is achieved by ensuring that the

camshaft drive gear is meshed to the crankshaft gear
at their correct angular positions, refer to Engine-
General, Operation, The Four Stroke Cycle (PIL
15-00) for more information about valve timing.
15 - 183 9823/1650-1 15 - 183

15 - Engine
51 - Timing Gear
00 - General
Figure 186.
B E
A Crankshaft gear B Camshaft gear

C High pressure fuel pump gear D Oil pump gear
E Heavy duty PTO device gear (if installed) F Heavy duty PTO device gear (if installed)
G Low duty PTO device gear (if installed)
15 - 184 9823/1650-1 15 - 184

15 - Engine
51 - Timing Gear
00 - General
Operation Check (Condition)
All the gears are driven via the crankshaft gear as 1. Inspect the gears for wear or damage. If one or
follows. more of the gears are worn or damaged, replace
them.
• Camshaft gear-The camshaft is driven at half
crankshaft speed.
• High pressure fuel pump gear-The high
pressure fuel pump is driven via the camshaft
gear installed to the camshaft.
• Oil pump gear-The lubrication oil pump is driven
directly by the crankshaft gear.
• Power Take-Off (PTO)-driven by the crankshaft
gear via idler gear.
• Low Duty Power Take-Off (PTO) Gear (if
installed)-driven by the camshaft gear.
15 - 185 9823/1650-1 15 - 185

15 - Engine
51 - Timing Gear
03 - Crankshaft Gear
Remove and Install
Special Tools 2. Remove the flywheel. Refer to (PIL 15-54).

Crankshaft / 892/01148 2 15-54).
Camshaft Timing Pin
(444/448/672 Engine) 4. Rotate the crankshaft until the camshaft locking
pin can be inserted through the gear and into the
Note: The illustrations show the engine inverted. If aligning hole in the rear gear case. Note: The
the drive gear components are being removed prior camshaft and crankshaft locking pins must be
to crankshaft or camshaft removal the engine must in position to lock the crankshaft and camshaft
be inverted. If the gear components only are being before removing the crankshaft gear.
removed (for inspection/renewal) then the engine
need not be inverted. Special Tool: Crankshaft / Camshaft Timing Pin
(444/448/672 Engine) (Qty.: 2)
Before Removal 5. Remove the taper blanking plug and insert the
crankshaft locking pin.
1. Remove the starter motor. Refer to (PIL 15-75).
15 - 186 9823/1650-1 15 - 186

15 - Engine
51 - Timing Gear
Figure 187.
7 T1
T2
6
1 Drive gear and flywheel hub fixing bolt 2 Flywheel hub

3 Crankshaft gear 4 Location dowel
5 Camshaft drive gear 6 Blanking plug - crankcase
7 Crankshaft - gear location spigot T1 Timing pin - camshaft
T2 Timing pin - crankshaft
Remove 2. Remove the crankshaft gear from the crankshaft.

Make sure you retrieve the location dowel.
1. Remove the flywheel hub fixing bolt and remove
the flywheel hub.
15 - 187 9823/1650-1 15 - 187

15 - Engine
51 - Timing Gear
Inspect
1. Carefully inspect the outer diameter of the
flywheel hub for signs of wear or damage. Wear
or damage will cause the crankshaft rear oil seal
to fail. If in doubt renew the hub.
Install
1. Apply some clean engine oil to the location spigot
on the end of the crankshaft.
2. Make sure that the dowel is located in the
crankshaft gear and locate the gear and dowel
on to the crankshaft spigot.
3. Install the flywheel hub to the gear, locate on the
dowel. Fix the hub with fixing bolt. Tighten the bolt
to the correct torque value.

Item Nm
1 47
6 11
15 - 188 9823/1650-1 15 - 188

15 - Engine
51 - Timing Gear
06 - Camshaft Gear
06 - Camshaft Gear
Remove and Install
The camshaft drive gear is an interference fit on

the end of the camshaft and cannot be removed
individually. If the gear is damaged or worn the
complete camshaft and gear assembly must be
replaced. Refer to Camshaft- Remove and Install
(PIL 15-15).
15 - 189 9823/1650-1 15 - 189

15 - Engine
51 - Timing Gear
09 - Fuel Injection Pump Gear
Remove and Install
2. Loosely install the high pressure fuel pump and

Note: The illustrations show the engine inverted. If fixing nut, retain the gear.
the drive gear components are being removed prior
to crankshaft or camshaft removal the engine must 3. Remove the starter motor. Refer to (PIL 15-75).
be inverted. If the gear components only are being
removed (for inspection/renewal) then the engine 4. Remove the flywheel. Refer to (PIL 15-54).
need not be inverted. 5. Remove the flywheel housing. Refer to (PIL
15-54).
Before Removal
1. Remove the high pressure fuel injection pump.
15 - 190 9823/1650-1 15 - 190

15 - Engine
51 - Timing Gear
Figure 188.
1 Drive gear - high pressure fuel pump 2 Fixing nut - drive gear - high pressure fuel pump
Remove Install
1. Remove the fixing nut and lift out the gear. 1. Use the fixing nut to loosely install the high
pressure fuel pump and the drive gear. DO NOT
2. If the rear timing case is to be removed, remove lock the gear to the taper on the fuel pump drive
the high pressure fuel pump. shaft.
2. Follow the procedures listed under Before
Removal in reverse order. Note that the gear
fixing nut is torque tightened as part of the
15 - 191 9823/1650-1 15 - 191

15 - Engine
51 - Timing Gear
high pressure fuel pump replacement procedure.

15 - 192 9823/1650-1 15 - 192

15 - Engine
51 - Timing Gear
15 - Heavy Duty PTO Gear
Remove and Install
Before Removal
The illustrations show the engine inverted. If the
drive gear components are being removed prior to 1. This procedure requires service parts. Make
crankshaft or camshaft removal the engine must sure you have obtained the correct service parts
be inverted. If the gear components only are being before you start, refer to Parts Catalogue.
removed (for inspection / renewal) then the engine
need not be inverted. 2. Remove the starter motor. Refer to (PIL 15-75).
3. Remove the flywheel. Refer to (PIL 15-54).
15-54-03).
15 - 193 9823/1650-1 15 - 193

15 - Engine
51 - Timing Gear
Figure 189.
1 Z
6
5 W
4 W
X
2
Y
3
1
2
1 High duty PTO idler gear 2 Idler gear hub

3 Idler gear hub retaining screws (x3) 4 Flywheel hub
5 Flywheel hub fixing bolt 6 Idler gear bearing bush
X Crankshaft gear Y Idler gear hub location dowel
Z Oil feed drilling
Remove 3. If required, remove the idler gear hub retaining

screws and lift out the hub.
1. Remove the flywheel hub fixing bolt and remove
the flywheel hub. DO NOT remove the crankshaft Inspect
gear.
1. Check the idler gear teeth and idler gear bearing
2. Lift the High duty PTO (Power Take-Off) idler bush for signs of damage or excessive wear.
gear from the hub.
15 - 194 9823/1650-1 15 - 194

15 - Engine
51 - Timing Gear
2. Measure the bearing bush inside diameter

to confirm it is within service limits, refer to
Technical Data.
Install
steps.
3. Make sure the oil way in the idler gear hub is
through the oil feed drilling.
4. When you install the idler gear hub, make sure
the Idler gear hub location dowel locates into the
hole in the crankcase.
5. Lubricate the idler gear bearing bush with clean
engine oil.
6. Install the flywheel hub to the crankshaft gear,
locate on the dowel. Tighten the bolt to the
correct torque value.
After Installation
1. Install the flywheel housing. Refer to (PIL
15-54-03)
2. Install the flywheel to the crankshaft hub. Refer
to (PIL 15-54)
3. Install the starter motor. Refer to (PIL 15-75).

Item Nm
3 65
5 47
15 - 195 9823/1650-1 15 - 195

15 - Engine
51 - Timing Gear
22 - Rear Case
22 - Rear Case
Remove and Install
Special Tools 6. Remove the high duty PTO (Power Take-Off)

Description Part No. Qty. device (if installed).
Template for Sealant 892/01176 1 7. Remove the low duty PTO device (if installed).
Flywheel Housing to
Gear Case (4 Cyl and 6 8. Remove the flywheel. Refer to (PIL 15-54).
Cyl Elec)
Before Removal 15-54).
1. Drain the oil from the engine. Refer to (PIL 10. Remove the fuel injection pump drive gear. Refer
15-21). to (PIL 15-51).
2. Disconnect and remove the fuel pipes from the 11. Remove the oil pump. Refer to (PIL 15-60).
injectors. Refer to (PIL 18-96). 12. Remove the high duty PTO idler drive gear (if
3. Remove the fuel injection pump. Refer to (PIL installed). Refer to (PIL 15-51).
18-18). 13. Remove the crankshaft drive gear. Refer to (PIL
4. Remove the fuel lift pump. Refer to (PIL 18-21). 15-51).
5. Remove the starter motor. Refer to (PIL 15-75). 14. Remove the camshaft. Refer to (PIL 15-15).
15 - 196 9823/1650-1 15 - 196

15 - Engine
51 - Timing Gear
22 - Rear Case
Figure 190.
2
T1
3
T1
1
Y B (T2) C (T2) X X
P1 5 A (T2)
X
P1 1
Y
Y
P1 Y
X X
Z V
1 Timing gear case - rear 2 Timing case fixing bolts (x19)

3 Crankcase/bedplate assembly 4 Dowel
5 Dowel - with flats P1 Anaerobic sealant
T1 Alignment pins (Locally manufacture) T2 Sealant template (comprises: Main template
- A, Long gallery template - B, Short gallery
template - C
15 - 197 9823/1650-1 15 - 197

15 - Engine
51 - Timing Gear
22 - Rear Case
Remove pins T1 to install the final two bolts). Tighten the

bolts to the correct torque value.
1. Remove the timing case fixing bolts and then
separate the timing case from the crankcase/ Important: If the parts have not been torque tightened
bedplate assembly. Do not use a lever to within the maximum 15 minute time period, then the
separate the timing case from the crankcase/ parts must be separated, thoroughly cleaned and
bedplate assembly. fresh sealant applied
Important: Anaerobic sealant will not start to cure After Installation

whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are 1. Replace all the components listed under Before
put together) it will immediately start to harden. Make removal in reverse order.
sure that all the necessary tools, bolts etc. are readily
available prior to assembling the components. The Table 77. Torque Values
parts must be installed and torque tightened within
Item Nm
5 minutes (with a maximum permissible time of 15
minutes). 2 37
Install
1. Carefully remove all traces of the old sealing
compound from the timing case and crankcase/
bedplate assembly mating faces. Make sure
that the mating faces are clean and free from
damage. Clean the inside of the timing case
using a suitable degreaser.
2. Install two alignment pins T1 to the crankcase/
bedplate assembly.
3. Make sure that dowels are correctly located in the
crankcase. Note: Dowel 5 has flats which must
be positioned relative to dowel 4, as shown at
W. This ensures correct alignment of the timing
cover.
4. The sealant template T2 comprises three pieces.
Locate parts B and C using the holes in the
templates and fixing bolts at positions Y as
shown.
Special Tool: Template for Sealant Flywheel
Housing to Gear Case (4 Cyl and 6 Cyl Elec)
(Qty.: 1)
5. Use the templates B and C as a guide apply a
continuous 1.5 mm (0.060 in.) bead of sealant
P1 to the case. Remove the bolts from positions
Y. Remove the templates make sure you do not
smudge the sealant. Discard the templates.
6. Locate part A of the template T2 using the holes
in the template and bolts at positions X as shown.
7. Use the template A as a guide apply a continuous
1.5 mm (0.060 in.) bead of sealant P1 to the case.
Do not follow the template at V, instead apply a
continuous bead Z (inboard of the fixing hole).
Remove the bolts from positions X. Remove the
template make sure you do not smudge the
sealant. Discard the template.
8. Locate the timing case on the alignment pins T1
and install the timing case fixing bolts (remove
15 - 198 9823/1650-1 15 - 198

15 - Engine
54 - Flywheel
54 - Flywheel
Contents Page No.
15-54-00 General ......................................................................................................................... 15-201

15-54-03 Housing ........................................................................................................................ 15-205
15-54-09 Gear Ring ..................................................................................................................... 15-209
15-54-12 Drive Plate .................................................................................................................... 15-210
15 - 199 9823/1650-1 15 - 199

Notes:
15 - 200 9823/1650-1 15 - 200

15 - Engine
54 - Flywheel
00 - General
Introduction .................................................. 15-201 Flywheels are used to provide continuous energy in
Component Identification ............................. 15-202 systems, where the energy source is not continuous.
Remove and Install ..................................... 15-203 In such cases, the flywheel stores energy when
torque is applied by the energy source, and it
releases stored energy when the energy source is
not applying torque to it.
In a reciprocating engine, a flywheel is used to

maintain constant angular velocity of the crankshaft.
The flywheel, which is mounted on the crankshaft,

stores energy when torque is exerted on it by a firing
piston, and it releases energy to its mechanical loads
when no piston is exerting torque on it.
15 - 201 9823/1650-1 15 - 201

15 - Engine
54 - Flywheel
00 - General
Figure 191.
1 Flywheel
2 Flywheel gear ring
15 - 202 9823/1650-1 15 - 202

15 - Engine
54 - Flywheel
00 - General
Remove and Install

Before Removal the engine has been running, let it cool before
sure you have obtained the correct service parts 3. Get access to the engine.
before you start. The flywheel is installed with a
crankshaft position sensor target disc. DO NOT Removal
remove the target disc. If the disc is defective the
flywheel must be replaced. 1. Remove the bolts and withdraw the flywheel from
the crankshaft hub. The bolts MUST NOT be
reused. Discard the bolts.
Figure 192.
3 1 2
1
T3
1 Flywheel 2 Flywheel fixing bolts (x8)

3 Flywheel location dowel Y Angle tightening mark
15 - 203 9823/1650-1 15 - 203

15 - Engine
54 - Flywheel
00 - General
Installation
steps.
3. Align the flywheel location dowel.
4. Renew the fixing bolts. Tighten the new bolts to
the correct torque value in three stages.
Tighten the bolts in sequence in diagonally opposing

pairs. As a visual check, mark the bolts to the
flywheel before you start. When the bolts have been
angle tightened the marks will appear as at 120 °.

Item Torque Value Angle (de-
(Nm) grees)
2 (Ist Stage) 40
2 (2nd Stage) 120
2 (Final Stage) +120
15 - 204 9823/1650-1 15 - 204

15 - Engine
54 - Flywheel
03 - Housing
03 - Housing
Remove and Install
Special Tools 2. Remove the starter motor.

Description Part No. Qty. Refer to: PIL 15-75-00.
Template for Sealant 892/12349 1
Flywheel Housing to 3. Remove the flywheel.
Gear Case (4 Cyl Elec ) Refer to: PIL 15-54-00.
Before Removal Removal

The flywheel housing is integral with the drive gears 1. Remove the flywheel housing fixing bolts and
front case. When the housing is removed the drive then separate the flywheel housing from the gear
gears will be exposed. DO NOT attempt to remove case.
the camshaft and the drive gears. Removing the
camshaft with the engine in the upright position will 2. If required, undo the bolts and remove the access
cause the tappets to dislodge, requiring the engine cover.
block to be dismantled.
3. Remove and discard the crankshaft rear oil seal.
1. This procedure requires service parts. Make Take care not to damage the seal bore in the
sure you have obtained the correct service parts housing.
before you start.
15 - 205 9823/1650-1 15 - 205

15 - Engine
54 - Flywheel
03 - Housing
Figure 193.
4 Z
3
Y Y
2
6
2 X
T4 Y
1 Flywheel housing 2 Dowel - 12 mm

3 Dowel - 10 mm 4 Flywheel housing fixing bolts (x6) M10
5 Flywheel housing fixing bolts (x12) M8 6 Access cover
7 Access cover fixing bolts (x2) X Flywheel housing mating face
Y Fixing point Z Alternative fixing holes
T3 Alignment pins T4 Sealant template
Before Installation 2. Use a suitable degreasing agent to clean the

inside of the flywheel housing.
1. Carefully remove all traces of the old sealant
compound from the flywheel housing mating 3. Carefully inspect all gears, bearings and shafts
faces. for signs of excessive wear or damage. If wear
or damage is evident, the components must be
renewed.
15 - 206 9823/1650-1 15 - 206

15 - Engine
54 - Flywheel
03 - Housing
Installation Figure 194.
Anaerobic sealant will not start to cure whilst it

is open to the atmosphere, however when air is
excluded (for instance when the two parts are put
together) it will immediately start to harden. Make
sure that all the necessary tools, bolts etc. are readily
available prior to assembling the components. The
parts must be installed and torque tightened within 5
min with a maximum permissible time of 15 min

steps.
W
3. Make sure that the dowels are installed to the
mating face of the flywheel housing.
4. Install the sealant template T4 on the housing.
Locate the holes in the template, use the dowel
and three fixing bolts in the fixing points. W Sealant path
Special Tool: Template for Sealant Flywheel 8. Locate the flywheel housing on the alignment
Housing to Gear Case (4 Cyl Elec ) (Qty.: 1) pins T3 on the crankcase and install the fixing
bolts. Progressively tighten the bolts to the
5. Use the template T4 as a guide, apply a correct torque value.
continuous bead of sealant around the flywheel
housing mating face 8.1. Remove the alignment pins to install the last
two M10 fixing bolts.
8.2. The parts must be separated, thoroughly
5.1. Some engines feature a flywheel housing cleaned and fresh sealant applied if the
with a different fixing hole pattern. Use the parts have not been torque tightened within
template to apply the sealant but apply the maximum time period.
sealant manually in the position shown at Z.
Duration: 15 min
6. Remove the three fixing bolts at positions.
Remove the template T4, make sure not to 9. Install the access cover and use the bolts to
smudge the sealant. Discard the template. secure. Tighten the bolts to the correct torque
value.
7. Apply sealant manually to complete the sealant
path around the hole at position W. After Installation
1. Install a new crankshaft rear oil seal.
2. Install the flywheel.
3. Install the starter motor.
4. Allow the sealant to cure for the specified
duration before starting the engine. The
curing times vary depending on the ambient
temperature. Refer to Table 79.
15 - 207 9823/1650-1 15 - 207

15 - Engine
54 - Flywheel
03 - Housing
Table 79. Sealant Curing Times

Ambient temperature Curing time
40 °C ( 103.9 °F) 20 min
22 °C ( 71.6 °F) 1h
5 °C ( 41.0 °F) 24 h

Item Nm
4 47
5 24
7 24
15 - 208 9823/1650-1 15 - 208

15 - Engine
54 - Flywheel
09 - Gear Ring
09 - Gear Ring of the gear teeth as shown. Drive a chisel into the
adjacent tooth to spread the gear ring apart. Take
care not to damage the flywheel or the position
Remove and Install sensor target disc.
CAUTION Wear eye protection when you drive
the gear ring off the flywheel. Installation
If the flywheel gear teeth are damaged or excessively damage and corrosion.
worn, the gear ring can be replaced with a new one.
2. Heat up the new gear ring, preferably in an
Before Removal oven to make sure that the heat is applied
evenly around the circumference, to the specified
This procedure requires service parts. Make sure temperature.
you have obtained the correct service parts before Temperature: 280 °C ( 535.6 °F)
you start. Refer to the Parts Catalogue.
3. When the gear ring is sufficiently heated, install
1. Remove the flywheel from the crankshaft hub. the gear ring into position over the flywheel. Make
sure that the gear ring is installed the correct way
Figure 195. around.
X
4. Allow the gear ring to cool and shrink into
position.
After Installation
1. Install the flywheel to the crankshaft hub.
2
1
1 Flywheel
2 Gear ring
x Position of hole
Removal
1. Note that the gear teeth have a lead-in chamfer
on one side to assist the starter motor pinion to
engage. Note which way around the gear ring is
installed to make sure that the new gear ring is
installed the same way on assembly.
2. Place the flywheel flat on a firm surface. Drill a
hole through the gear ring below the root of one
15 - 209 9823/1650-1 15 - 209

15 - Engine
54 - Flywheel
12 - Drive Plate
12 - Drive Plate Introduction

Introduction .................................................. 15-210 This is a gear type coupling comprising a drive plate
Remove and Install ..................................... 15-211 bolted to the engine flywheel and a coupling clamped
to the input shaft of the wheel drive pump. Both are
contained within the engine bell housing and rear
support frame to which the wheel drive pump is fixed.
Figure 196.
B
A Drive plate
B Coupling (PIL 2731)
15 - 210 9823/1650-1 15 - 210

15 - Engine
54 - Flywheel
12 - Drive Plate
Remove and Install Table 81. Torque Values

Item Nm
Consumables
Description Part No. Size C 23
Strength)
Remove
1. Make the machine safe with the lift arm and cab
raised. Refer to (PIL 01-03).
2. Remove the Wheel drive pump and coupling,
refer to (PIL 27-31).
3. Remove the bolts, remove the drive plate from
the flywheel.
Install
removal procedure. additionally do the following
steps.
2. Make sure that the drive plate is installed with
the flat face against the flywheel and the boss is
facing outwards.
3. Coat the threads of the bolts with JCB
Threadlocker and Sealer and tighten to the
(Medium Strength)
Figure 197.
A Drive plate
C Bolts
E Boss
15 - 211 9823/1650-1 15 - 211

15 - Engine
60 - Oil Pump
60 - Oil Pump
Contents Page No.
15-60-00 General ......................................................................................................................... 15-213
15 - 212 9823/1650-1 15 - 212

15 - Engine
60 - Oil Pump
00 - General
Introduction .................................................. 15-213 The oil pump is a rotor type pump located inside the
Component Identification ............................. 15-214 timing gear case. The pump is driven by gears via
Check (Condition) ........................................ 15-216 the crankshaft.
The pump consists of two rotors, one running inside
the other. The outer rotor has one more lobe than the
inner rotor and turns on a different axis.
When rotated the gap between the inner and outer

rotor lobes increases, drawing oil in through the
inlet port. After a half rotation the gap reaches a
maximum, the inlet port is closed and the outlet port
opens.
Further rotation causes the gap between the lobes to

diminish, forcing the oil out through the outlet port.
A pressure relief valve assembly is integral with the

pump body. As oil pressure increases it acts on a
spool to overcome the pressure of the spring. As the
spool moves it uncovers a port allowing pressurised
oil directly back to the inlet port. In practice the
spool is continually opening and closing to maintain
the correct oil pressure value. The valve is not
adjustable.
15 - 213 9823/1650-1 15 - 213

15 - Engine
60 - Oil Pump
00 - General
Figure 198.
5
1
1 3 2 4
1 5
8 8a
7 7a
9 4
6
1 Oil pump 2 Outer rotor

3 Inner rotor 4 Inlet port
5 Outlet port 6 Relief valve assembly
7 Relief valve spring 7a Relief valve port (return to inlet port 4)
8 Relief valve spool 8a Relief valve pressure port (connected to port 5)
9 Oil pump connecting ports (engine bed plate)
15 - 214 9823/1650-1 15 - 214

15 - Engine
60 - Oil Pump
00 - General
Figure 199.
10
10 CCV Anti drain back valve
15 - 215 9823/1650-1 15 - 215

15 - Engine
60 - Oil Pump
00 - General
Check (Condition)
1. Check the oil pump internal parts for signs of
2. Check that the engine oil pressure is within the
specified tolerance.
15 - 216 9823/1650-1 15 - 216

15 - Engine
60 - Oil Pump
00 - General
Remove and Install
Special Tools Before Removal

Torque Wrench 993/70111 1 1. Make sure that the engine is safe to work on. If
(10-100Nm) the engine has been running, let it cool before
The illustrations show the engine inverted. If the 2. Drain the oil from the engine, refer to (PIL 15-21).
oil pump is being removed prior to crankshaft or
camshaft removal, the engine must be inverted. If 3. Remove the starter motor, refer to (PIL 15-75).
the oil pump only is being removed (for inspection or
renewal) then the engine need not be inverted. 4. Remove the flywheel, refer to (PIL 15-54).
This procedure requires service parts. Make sure 5. Remove the flywheel housing, refer to (PIL
you have obtained the correct service parts before 15-54).
you start, refer to Parts Catalogue.
Figure 200.
4 3 X
1 Oil pump 2 Oil pump fixing bolts (x4)

3 Flywheel hub 4 Flywheel hub fixing bolt
X Crankshaft gear Y Oil pump location dowel
15 - 217 9823/1650-1 15 - 217

15 - Engine
60 - Oil Pump
00 - General
Remove
1. Remove the flywheel hub fixing bolt.
2. Remove the flywheel hub. DO NOT remove the
crankshaft gear.
3. Remove the oil pump fixing bolts and lift the oil
pump away from the timing gear case.
The oil pump is a non-serviceable item. If the oil

pump is damaged or worn it must be renewed as a
complete assembly.
Install
steps.
2. Make sure that all parts are clean and free from
3. Lubricate the pump rotor with clean engine oil.
4. Make sure that the oil pump location dowel
locates into the hole in the gear timing case.
5. Install the flywheel hub into the crankshaft gear,
locating on the dowel. Tighten the bolts to the
1)
After Replacement
1. Install the flywheel housing, refer to (PIL 15-54).
2. Install the flywheel to the crankshaft hub, refer to
(PIL 15-54).
3. Install the starter motor, refer to (PIL 15-75).
4. Fill the engine with engine oil, refer to (PIL
15-21).

Item Nm
2 24
4 47
15 - 218 9823/1650-1 15 - 218

15 - Engine
63 - Mount
63 - Mount
Contents Page No.
15-63-00 General ......................................................................................................................... 15-221
15 - 219 9823/1650-1 15 - 219

Notes:
15 - 220 9823/1650-1 15 - 220

15 - Engine
63 - Mount
00 - General
Introduction .................................................. 15-221 Engine mounts support the engine and in some
Remove and Install ..................................... 15-222 cases the transmission, they dampen noise and
vibration. The mounts isolate the engine and
transmission from the chassis so that vibrations and
noise are not transmitted to the rest of the machine.
Most engine mounts consist of metal attachment

plates and large rubber insulator blocks. The rubber
portions of the mount are flexible and provide the
cushioning that dampens the engine vibrations.
The metal bracket part of the mount provides the
mechanical support and attachment points for the
engine mounts.
15 - 221 9823/1650-1 15 - 221

15 - Engine
63 - Mount
00 - General
Remove and Install
Remove
3. Remove the engine compartment cover.
4. Remove the engine.
5. Remove the engine mounts.
Install
removal procedure.
15 - 222 9823/1650-1 15 - 222

15 - Engine
69 - Oil Cooler
69 - Oil Cooler
Contents Page No.
15-69-00 General ......................................................................................................................... 15-225
15 - 223 9823/1650-1 15 - 223

Notes:
15 - 224 9823/1650-1 15 - 224

15 - Engine
69 - Oil Cooler
00 - General
Introduction .................................................. 15-225
Oil Cooler Assembly
Operation ..................................................... 15-226 The oil cooler and filter are incorporated in a housing
Check (Condition) ........................................ 15-227 that is bolted to the side of the crankcase. The
Remove and Install ..................................... 15-227 housing allows transfer of lubricating oil from the
crankcase to the oil cooler and filter head.
Some installations have a remote oil filter head. The
oil cooler housing incorporates feed and return ports
for hose connections to the filter head. A remote
oil filter head is used when access to the engine is
restricted.
Oil Cooler Matrix

The oil cooler matrix is a non-serviceable part and
must not be removed from the housing. The housing/
cooler assembly is leak tested during manufacture to
minimise the risk of cross contamination of coolant
and lubricating oil.
15 - 225 9823/1650-1 15 - 225

15 - Engine
69 - Oil Cooler
00 - General
Component Identification Operation

Figure 201. The oil cooler housing allows transfer of lubricating
oil from the crankcase to the oil cooler and filter head.
The coolant also transfers to the housing and passes
1 over the oil cooler matrix causing heat to exchange
from the oil to the coolant.
The cooled and filtered oil then passes back into the
main oil gallery into the crankcase.
An engine oil filler point is also included via cap and

port which aligns with a port in the crankcase.
1 Oil cooler housing

Figure 202.
1 3
2 4
8 5
7 6
1
1 Oil cooler housing

2 Oil cooler matrix
3 Sealing gasket (housing to crankcase)
4 Coolant gallery
5 Oil gallery (from cooler to filter head)
6 Oil fill port
7 Oil gallery (from filter head to main oil gallery)
8 Oil gallery (from pump to cooler)
15 - 226 9823/1650-1 15 - 226

15 - Engine
69 - Oil Cooler
00 - General

1. Inspect the sealing faces on the oil cooler matrix,
oil cooler housing and the crankcase. Make sure
Before Removal
that the faces are clean and free from scale or 1. Make sure that the engine is safe to work on. If
damage. the engine has been running, let it cool before
2. Inspect the sealing gasket and o-rings for signs
of damage. If in doubt, renew the gasket or O- 2. Drain the coolant, refer to (PIL 21-00).
rings.
3. Remove the oil filter, refer to (PIL 15-21).
Figure 203.
A B
C D
E
A Oil cooler housing (integral oil filter head)
B Oil cooler housing fixing bolts (x10)
C Oil filter head
D Oil cooler housing (remote oil filter head)
E Remote oil filter head hose ports
Remove
2. If applicable, disconnect the electrical connectors
at the oil pressure switch and the oil temperature
sensor.
3. If applicable, label and disconnect the electrical
connectors at the ECM (Engine Control Module).
Do not touch the electrical pins on the ECM.
Cap the connectors on the harnesses and the
15 - 227 9823/1650-1 15 - 227

15 - Engine
69 - Oil Cooler
00 - General
ECM to prevent ingress of oil and coolant. Tie the Table 83. Torque Values
harnesses away from the oil cooler housing.
Item Description Nm
4. If applicable disconnect the remote oil filter head B Bolts 24
hoses from the ports on the oil cooler.
5. Remove the bolts and lift the oil cooler housing
away from the crankcase. DO NOT attempt to
remove the oil cooler matrix from the oil cooler
housing.
If there is cross contamination of coolant and

lubricating oil, the oil cooler matrix may be faulty. If a
faulty matrix is suspected renew the matrix and the
seals.
Figure 204.
A
B C
A Oil cooler housing

B Oil cooler matrix
C Sealing gasket
Install
steps.
2. Make sure that sealing gasket is undamaged and
correctly located in its groove. A faulty gasket will
cause cross contamination of the lubricating oil
and coolant. If in doubt install a new gasket.
After Installation
1. If applicable, install the oil filter, refer to (PIL
15-21).
2. Refill the cooling system with the recommended
coolant mixture, refer to (PIL 21-00).
3. If applicable, make sure that the harness
connectors are connected to the correct
connectors on the ECM.
4. Start the engine and check for oil and coolant
leaks.
15 - 228 9823/1650-1 15 - 228

15 - Engine
69 - Oil Cooler
00 - General
Disassemble and Assemble Assemble

1. Locate the new O-rings. Install the oil cooler
Dismantling of the oil cooler and oil filter head matrix. Tighten the bolts to the correct torque
assembly is not necessary unless the oil cooler value.
matrix or the seals are faulty.
2. Install the sealing gasket to the oil cooler
Disassemble housing.
1. Remove the four fixing bolts and lift off the oil Table 84. Torque Values
cooler matrix. Item Nm
2. Remove and discard the two sealing O-rings. A 23
3. Remove the sealing gasket.

Figure 205.
D
C
A
B C
A
A
A
A Fixing bolts
B Oil cooler matrix
C O-rings
D Sealing gasket
E Oil cooler housing
Inspect
1. Refer to Oil Cooler - Check Condition.
15 - 229 9823/1650-1 15 - 229

15 - Engine
72 - Alternator
72 - Alternator
Contents Page No.
15-72-00 General ......................................................................................................................... 15-231

15-72-03 Pulley ............................................................................................................................ 15-237
15-72-06 Voltage Regulator ......................................................................................................... 15-238
15 - 230 9823/1650-1 15 - 230

15 - Engine
72 - Alternator
00 - General
Introduction .................................................. 15-231 The alternator is a three phase generator having a
Health and Safety ........................................ 15-232 rotating field winding and static power windings.
Technical Data ............................................. 15-232
Component Identification ............................. 15-233 When the ignition switch is turned on, the current
from the battery flows by way of the No Charge
Check (Condition) ........................................ 15-233 warning light to the field winding. This creates
Remove and Install ..................................... 15-235 a magnetic field which supplements the residual
Disassemble and Assemble ........................ 15-236 magnetism in the rotor poles. As the engine is
started, the FEAD (Front End Accessory Drive)
belt drives the rotor and the alternating current is
generated in the power windings as they are cut by
the rotating magnetic field. Output is controlled by a
solid state regulator which varies the field current in
accordance with electrical demand.
15 - 231 9823/1650-1 15 - 231

15 - Engine
72 - Alternator
00 - General
Health and Safety Technical Data

• Ensure that the battery negative terminal is Technical data may differ between machine variants
connected to the earthing cable. and installations. For full data relating to the
• Never make or break connections to the battery alternator refer to the applicable parts information.
or alternator, or any part of the charging circuit
whilst the engine is running. Disregarding this
instruction will result in damage to the regulator
or rectifying diodes.
• Main output cables are 'live' even when the
engine is not running. Take care not to earth
connectors in the moulded plug if it is removed
from the alternator.
• During arc welding on the machine, protect the
alternator by removing the moulded plug (or if
separate output cables installed, remove the
cables).
• If slave starting is necessary, connect the
second battery in parallel without disconnecting
the vehicle battery from the charging circuit.
The slave battery may then be safely removed
after a start has been obtained. Take care to
connect batteries positive to positive, negative
to negative.
15 - 232 9823/1650-1 15 - 232

15 - Engine
72 - Alternator
00 - General
Component Identification Check (Condition)

Figure 206.
Charging Circuit Test
1. Make sure that all the battery and alternator
D connections are in place, secure and making
good metal - to - metal contact, especially the
earth connections to chassis and engine.
2. Adjust the alternator drive belt tension if
necessary and make sure that the battery is well
charged.
3. Turn the ignition switch to the ON position. Oil
pressure and ''No Charge'' warning lights should
glow. If any light fails, re-check the connections.
4. Start the engine; all warning lights should
extinguish rapidly. If the ''No Charge'' warning
light remains ON, re-check the alternator drive
belt tension and that the battery is charged. If
the oil pressure warning remains on stop the
engine Immediately and investigate the engine
A Alternator lubrication system.
B Regulator and brush assembly
C Drive pulley Check 1
D Tie bolts
With the ignition switch ON, check that the heater
motor and screen wiper will operate.
If they operate normally, check the warning light bulb

for a blown filament.
Simultaneous failure of all items indicates a fault at

the ignition switch. Check for cable disconnection
before condemning the switch itself.
If the 'No Charge' warning bulb is in good order,

withdraw the triple plug from the back of the
alternator. Make a temporary connection between
the small terminal in the plug and earth as shown
below. If the 'No Charge' warning bulb still fails to
light, check the cable for continuity. If the bulb now
lights, check the alternator for a defective regulator.
Figure 207.
Check 2
The following checks should be made using an
analogue (moving pointer) type Multimeter.
15 - 233 9823/1650-1 15 - 233

15 - Engine
72 - Alternator
00 - General
1. Stop the engine and turn the ignition switch to 4. Alternatively, operate the starter for a few
OFF. moments with the ESOS (Engine Shut-Off
Solenoid) fuse removed.
2. Withdraw the alternator plug and connect the
Multimeter between the large terminals and 5. Install an open type shunt between the battery
earth. With the Multimeter set to measure, positive lead and the battery positive terminal.
Voltage: 12 V Current: 100 A
Figure 208. 6. Connect a Multimeter positive lead to machine
side of the shunt and negative lead to battery side
of the shunt.
7. Connect the leads to the Multimeter and set the
Multimeter to the relevant range as follows.
8. AVO 2002
8.1. Red lead to volts (middle) socket on
Multimeter.
8.2. Black lead to negative on Multimeter.
2.1. The Multimeter should show battery 8.3. Right side slider to DC (Direct Current)
voltage. voltage.
2.2. If the reading is zero, check the cables 8.4. Left side slider,Refer to Figure 209.
for continuity, particularly at the starter
9. AVO 2003
terminals.
9.1. Red lead to amps socket (A) on the
3. If the voltage is correct, check the alternator.
Multimeter.
Alternator Charging Test 9.2. Black lead to negative on Multimeter.
Figure 209. 9.3. Right side slider to DC voltage

9.4. Left side slider to 200 Shunt
10. FLUKE 85
10.1. Red lead to volts socket (V ) on Multimeter.
10.2. Black lead to COM socket on Multimeter.
10.3. Set dial to mV.
11. Start the engine and run at maximum speed
(see Technical Data). Multimeter should show
maximum alternator output in Amps (see
Technical Data). The Multimeter reading should
be taken as soon as possible after starting the
engine, as the charging current will fall rapidly.
12. A zero reading indicates failure of the alternator
and may be caused by one of the following
1. Make sure that all battery and alternator conditions. These are listed in the order of
connections are in place, secure and making probability.
good metal to metal contact, especially the earth
connections to chassis and engine. 12.1. Defective suppression capacitor.
2. Make sure that the alternator drive belt tension is 12.2. Dirty slip rings or worn brushes.
correctly adjusted. 12.3. Defective regulator.
3. If the battery is in a fully charged condition, before 12.4. Defective rectifier.
commencing the test switch on the working lights
for 12.5. Open or short circuited field (rotor)
windings.
Duration: 3 min
15 - 234 9823/1650-1 15 - 234

15 - Engine
72 - Alternator
00 - General
12.6. Open or short circuited power (stator) Remove and Install

windings.
13. To check for a fault, disconnect the capacitor and Figure 210. Alternator location
repeat the charging test. Renew the capacitor if
necessary.
14. To check for faults with the slip rings, bushes or
regulator, remove the regulator and brush box
assembly. Check the condition of the brushes
and, if necessary, clean the slip rings using extra-
fine glass paper. The regulator may only be
renewed.
15. Faults with the rectifier, rotor and stator may be
checked only by removing and dismantling the
alternator for further testing. Remove
1. Disconnect the negative (-) lead followed by the
positive (+) lead from the battery terminals.
2. Remove the alternator (accessory) drive belt.
3. Disconnect the electrical leads from the
alternator terminals. Label the leads to make
sure that they are installed in the correct positions
on assembly.
4. Undo the alternator securing bolts and lift the
alternator away from the cylinder block mounting.
Figure 211.
A
A Alternator
B Securing bolts
Inspect
1. Check the brushes for wear. Renew the brushes
if the length is less than
15 - 235 9823/1650-1 15 - 235

15 - Engine
72 - Alternator
00 - General
Install Disassemble and Assemble

removal procedure. Additionally do the following Voltage Regulator and Brushes
steps.
1. The voltage regulator and brush set is a
2. It is not necessary to adjust the position of the combined assembly. Refer to (PIL 15-72-06).
alternator in order to tension the drive belt, as
the accessory drive belt arrangement is self-
tensioning. Drive Pulley
3. Tighten the alternator securing bolts to the 1. Refer to (PIL 15-72-03).
4. Make sure you reconnect the electrical leads to
the alternator in the correct positions and tighten
to the correct torque.
Table 85. Alternator securing bolt torque

Item Torque Value
A 47 N·m
B 47 N·m
Figure 212.
Table 86. Alternator electrical connection torque

Item Torque Value
B+ 9 –13 N·m
L 2.7 –3.8 N·m
W 2.7 –3.8 N·m
15 - 236 9823/1650-1 15 - 236

15 - Engine
72 - Alternator
03 - Pulley
03 - Pulley
Remove and Install
This part is non-serviceable. If it fails, replace the

complete alternator. Refer to: PIL 15-72-00.
15 - 237 9823/1650-1 15 - 237

15 - Engine
72 - Alternator
06 - Voltage Regulator
06 - Voltage Regulator
Remove and Install
The voltage regulator is an integral part of the

alternator, it is designed to automatically maintain a
constant voltage level.
This part is non-serviceable. If it fails, replace the

complete alternator. Refer to: PIL 15-72-00.
15 - 238 9823/1650-1 15 - 238

15 - Engine
75 - Starter Motor
75 - Starter Motor
Contents Page No.
15-75-00 General ......................................................................................................................... 15-241

15-75-03 Solenoid ....................................................................................................................... 15-249
15-75-06 Brush Gear ................................................................................................................... 15-250
15 - 239 9823/1650-1 15 - 239

Notes:
15 - 240 9823/1650-1 15 - 240

15 - Engine
75 - Starter Motor
00 - General
Introduction .................................................. 15-241 The electric starter motor is either a permanent-
Health and Safety ........................................ 15-242 magnet or a series-parallel wound direct current
Technical Data ............................................. 15-242 electric motor with a starter solenoid mounted on to
Component Identification ............................. 15-243 it. When the current from the battery is applied to the
solenoid, through the key-operated ignition switch,
Check (Condition) ........................................ 15-243 the solenoid engages a lever that pushes out the
Remove and Install ..................................... 15-245 drive pinion on the starter driveshaft and meshes the
Disassemble and Assemble ........................ 15-247 pinion with the starter ring gear on the flywheel of the
engine.
The solenoid also closes high current contacts for the

starter motor, which begins to turn. Once the engine
starts, the key-operated ignition switch is opened,
a spring in the solenoid assembly pulls the pinion
gear away from the ring gear, and the starter motor
stops. The starter motor pinion is clutched to the drive
shaft through an overrunning clutch which permits
the pinion to transmit drive in only one direction. Drive
is then transmitted through the pinion to the flywheel
ring gear, but if the pinion remains engaged (as for
example because the operator fails to release the
key as soon as the engine starts, or if there is a short
and the solenoid remains engaged), the pinion will
spin independently of the drive shaft, this prevents
the engine driving the starter.
The starter motor is only designed for intermittent

use, the electrical components are designed only to
operate for a time period of 20 s before overheating.
15 - 241 9823/1650-1 15 - 241

15 - Engine
75 - Starter Motor
00 - General

WARNING Make the machine safe before
working on it. Park the machine on level ground Refer to Electrical System- General, Technical Data
and lower the loader arm. Stop the engine and (PIL 33-00).
remove the ignition key. Make sure the park brake
is engaged. Disconnect the battery to prevent the
engine being started. Block all four wheels.
Notice: Before carrying out arc welding on the
machine, disconnect the battery and alternator to
protect the circuits and components. The battery
must still be disconnected even if a battery
isolator is installed.
Notice: Do not isolate the machine electrics
when the engine is running, this may cause
damage to the machine electrics.
15 - 242 9823/1650-1 15 - 242

15 - Engine
75 - Starter Motor
00 - General

Figure 213. Before carrying out the multimeter tests, check
the battery condition and make sure that all the
1 applicable electrical connections are clean and tight.
Make sure that the starter motor fixing bolts are
tightened to the correct torque.
To prevent the engine starting during the tests make

sure that the applicable engine stop fuse is removed.
2 Check the readings in the following sequence using

a multimeter. Unless otherwise stated, the readings
must be taken with the ignition switch held in the
start position (HS) and the controls set to enable the
starter motor. The readings are shown for both 12
V and 24 V systems. The highest values are for
machines with 24 V systems. Identify the applicable
3 system before carrying out the tests.
1 Solenoid Do not operate the starter motor for more than 20 s

2 Brush gear at one time. Let the starter motor cool for at least 2
3 Tie bolts min between starts.
1. Connect the multimeter across the battery

terminals.
Figure 214.
1.1. Reading in start position approximately

Voltage: 10 V
Voltage: 20 V
1.2. Minimum permissible reading in start
position
Voltage: 9.5 V
Voltage: 18 V
1.3. A low reading probably indicates a fault in
the starter motor.
2. Connect the multimeter between the starter main
terminal and the commutator end bracket. In the
start position, the reading should not be below
the reading obtained in 1 by any more than
Voltage: 0.5 V
Voltage: 1 V
15 - 243 9823/1650-1 15 - 243

15 - Engine
75 - Starter Motor
00 - General
A Starter main terminal A Starter main terminal

B Commutator end bracket (Starter earth B Starter earth connection
connection) C Solenoid terminal
2.1. Minimum permissible reading in start D Start relay feed
position E Start relay switched output
H Battery positive and solenoid connection
Voltage: 9 V
Voltage: 17 V 4.1. If the reading is less than specified, connect
the multimeter between the start relay feed
2.2. If the reading is within this limit, continue to
and earth.
3. If the reading is outside the limit, proceed
to 4. 4.2. A faulty start relay or a fault in the feed to
the relay solenoid is indicated if the voltage
3. Connect the multimeter between the solenoid increases to
terminal and a good earth. Minimum permissible
reading in start position Voltage: 8 V
Voltage: 16 V
Voltage: 8 V
Voltage: 16 V 4.3. Check also the solenoid earth connection.
The fault must be in either the starter switch
Figure 216. or in the wiring between the solenoid, starter
switch, and the start relay, if the reading
between terminal and earth is less than
Voltage: 8 V
Voltage: 16 V
5. Connect the multimeter between battery
negative and starter earth connection. The
reading in the start position should be practically
zero, maximum permissible reading
Voltage: 0.25 V
Figure 218.
C Solenoid terminal
4. If the reading is less than specified, connect
the multimeter between the start relay switched
output and earth. A fault is indicated with the
wiring from the start relay to the solenoid if the
reading increases to
Voltage: 8 V
Voltage: 16 V
B Starter earth connection
15 - 244 9823/1650-1 15 - 244

15 - Engine
75 - Starter Motor
00 - General
5.1. If the reading is above the maximum Remove and Install

permissible voltage, a high resistance in the
earth lead or connections is indicated.
Figure 221.
6. Connect the voltmeter between battery positive
and the starter main terminal. With the starter A
switch off, the voltmeter should indicate battery E
voltage, but it should fall to practically zero when
the switch is turned to the on position, maximum
permissible reading B
Voltage: 0.25 V
Figure 219.
D
C
A Electrical lead (Terminal 30)
B Security cover
C Starter motor
D Bolt (x3)
E Electrical lead (Terminal 50)
A Starter main terminal Remove

7. If the reading is above the maximum permissible 1. Make the machine safe.
voltage, a high resistance is present in the
insulated lead or in the solenoid. Connect the Refer to: PIL 01-03.
multimeter between the battery positive and 2. Make sure the engine is safe to work on. If the
solenoid connection. If the multimeter now reads engine has been running, make sure that the
zero with the switch closed, the fault is in the engine has cooled sufficiently before you start
solenoid. work.
Figure 220. 3. Disconnect the battery negative lead followed by
the positive lead from the battery terminals.
4. Remove the security nut and bolt, remove the
security cover (if installed).
5. Disconnect the electrical leads from the starter
motor terminals. Label the leads to make sure
they are installed in the correct positions on
assembly.
6. Undo the bolts (x3) and withdraw the starter
motor from the flywheel housing.
H Battery positive and solenoid connection Inspection

8. Finally install the engine stop fuse. 1. Check the drive pinion splines for damage and
excessive wear.
2. Check the brushes for wear. Renew the brushes
if the length is less than
15 - 245 9823/1650-1 15 - 245

15 - Engine
75 - Starter Motor
00 - General
Install
steps.
2. Make sure that the flywheel housing and starter
motor mating faces are clean.
4. Make sure you reconnect the electrical leads to
the starter motor in the correct positions.
5. Install the security cover (if installed).

Item Nm
A 15 ± 3
D 47 ± 4
E 3.6 ± .6
15 - 246 9823/1650-1 15 - 246

15 - Engine
75 - Starter Motor
00 - General
These parts are non-serviceable if any part fails, sure the wave washer is installed inside the
replace the complete starter motor. For cleaning cover.
and checking purposes only, dismantle the motor as
1.6. Carefully install the commutator end cover,
follows:
then tighten the tie bolts.
Brush Gear Starter Solenoid
1. Check the brush gear as follows:
1. Check the starter solenoid as follows:
1.1. Remove the tie bolts and carefully separate
1.1. Disconnect the starter motor cable from the
the commutator end cover.
solenoid connector post.
1.2. Remove the screws. Remove the brush
1.2. Remove the screws and carefully withdraw
holder and brushes.
the solenoid assembly.
1.3. Check the brushes for wear. Install or
1.3. Make sure that the sealing ring is
renew the brush set as required. Renew the
undamaged and correctly installed.
brushes if they are less than
Length/Dimension/Distance: 8 mm 1.4. Before you install the solenoid make sure
you engage the pinion lever arm through
1.4. Clean the commutator. the hole in the solenoid actuator rod, then
tighten the screws.
1.5. Before installing the commutator end
cover, make sure that the sealing ring is 1.5. Reconnect the starter motor cable to the
undamaged and correctly installed. Make solenoid connector post.
15 - 247 9823/1650-1 15 - 247

15 - Engine
75 - Starter Motor
00 - General
Figure 222.
A
F C A
B
D P
E N
P G
H
K
M
743740-C1 J
L
A Starter solenoid B Screws - starter solenoid (3 off)

C Sealing ring - solenoid D Solenoid actuator rod
E Pinion lever arm F Tie bolts (2 off)
G Commutator end cover H Screws - commutator end cover (2 off)
J Brush set K Commutator
L Sealing ring - commutator end cover M Wave washer
N Cable connector post P Pinion gear
15 - 248 9823/1650-1 15 - 248

15 - Engine
75 - Starter Motor
03 - Solenoid
03 - Solenoid
Remove and Install
The solenoid is an integral part of the starter motor,

it is designed to relay a large electric current to the
starter motor, which in turn sets the engine in motion.
The solenoid also engages the starter pinion with the
ring gear of the engine.
This part is a non-serviceable part if it fails, replace

the complete starter motor.
15 - 249 9823/1650-1 15 - 249

15 - Engine
75 - Starter Motor
06 - Brush Gear
06 - Brush Gear
Remove and Install
The starter motor brushes are an integral part of the

starter motor.
This part is a non-serviceable part if it fails, replace

the complete starter motor.
15 - 250 9823/1650-1 15 - 250

15 - Engine
80 - Glow Plug
80 - Glow Plug
Contents Page No.
15-80-00 General ......................................................................................................................... 15-253
15 - 251 9823/1650-1 15 - 251

Notes:
15 - 252 9823/1650-1 15 - 252

15 - Engine
80 - Glow Plug
00 - General
Introduction .................................................. 15-253 A glow plug is a heating device used to help
Operation ..................................................... 15-254 start diesel engines. In cold weather, diesel engines
Remove and Install ..................................... 15-254 can be difficult to start because the mass of the
crankcase and cylinder head absorb the heat of
compression, preventing ignition due to the higher
surface to volume ratio.
The glow plug is a pencil shaped piece of metal with

a heating element at the tip. The heating element,
when electrified, heats due to its electrical resistance.
15 - 253 9823/1650-1 15 - 253

15 - Engine
80 - Glow Plug
00 - General
Operation Remove and Install
The glow plugs are controlled by the ECM (Engine The glow plugs for cylinders 1, 3 and 4 can be
Control Module). The ECM takes signals from engine removed without the need to remove any other
sensors such as the engine coolant temperature components. The glow plug for cylinder 2 requires
sensor to determine whether the glow plugs are the removal of the turbocharger to gain access. Refer
required and for how long. The glow plugs will be to: PIL 18-35-00.
activated when the ambient temperature is below 0
°C ( 32.0 °F). The glow plugs will be deactivated by Remove
the ECM after a predetermined time period.
3. Disconnect the electrical connector.
Figure 223.
B
A
A Electrical connector
B Glow plug
4. Remove the glow plug from the cylinder head.
Install
step.
2. Tighten the glow plug to the correct torque value.

Item Nm
B 15 ± 2
15 - 254 9823/1650-1 15 - 254

15 - Engine
84 - Sensor
84 - Sensor
Contents Page No.
15-84-00 General ......................................................................................................................... 15-257

15-84-03 Crankshaft Position ...................................................................................................... 15-268
15-84-06 Camshaft Position ........................................................................................................ 15-272
15-84-09 Knock ........................................................................................................................... 15-276
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-279
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-282
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-285
15-84-18 Temperature and Mass Air Flow (TMAF) ..................................................................... 15-288
15-84-24 Fuel Temperature ......................................................................................................... 15-291
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-294
15-84-29 Foot Throttle Control .................................................................................................... 15-297
15-84-33 Coolant Temperature .................................................................................................... 15-301
15-84-42 Engine Oil Temperature ............................................................................................... 15-304
15-84-43 Engine Oil Level ........................................................................................................... 15-307
15-84-48 Intercooler Outlet Temperature .................................................................................... 15-310
15 - 255 9823/1650-1 15 - 255

Notes:
15 - 256 9823/1650-1 15 - 256

15 - Engine
84 - Sensor
00 - General
Introduction .................................................. 15-257 The engine sensors continually send signals to the
Technical Data ............................................. 15-258 ECM (Engine Control Module) to help the ECM to
Component Identification ............................. 15-260 control the smooth running of the engine and related
Fault-Finding ................................................ 15-262 components.
Check (Operation) ....................................... 15-267 The ECM processes signals from the sensors
continually and its response will be based on an
evaluation of the combination of sensor signals.
After removal from the engine, protect the sensors

from knocks, dust and water ingress and any high
temperature sources.
The sensors are not serviceable, therefore they must

be replaced in the event of damage.
15 - 257 9823/1650-1 15 - 257

15 - Engine
84 - Sensor
00 - General
Technical Data Inlet Manifold Air Pressure and Temperature

Sensor (TMAP)
Atmospheric Output voltage +/- V
pressure bar V
Table 89.
( psi)
Crankshaft Position Sensor 0.98 -0.025/ 1.84 0.05
Type Hall effect. +0.025 ( 14.2
-0.4/+0.4 )
Table 90. Table 93.

Camshaft Position Sensor Knock Sensor
Type Hall effect. Type Piezo crystal.
Fixing screw tightening 24 N·m
torque
Table 91.
Fixing screw thread di- M8
Coolant Temperature Sensor ameter
Type Temperature dependant resis-
tance. Table 94.
Tightening 22 N·m max
Throttle Position Sensor (TPS)
(1)
torque
Thread diame- M12 x 1.5. Type Two channel ratio metric
ter voltage output sensor.
Temperature v Resistance Table Supply voltage 5V
Temperature Resistance Ω +/- % Rotational range 75 °
°C ( °F) Output range Linear output voltage
25 ( 77.0 ) 2,062 5.7 over the rotational
range.
50 ( 121.9 ) 833 4.3
(1) The throttle position sensor is not supplied as part
100 ( 211.9 ) 187 2
of the engine assembly. The technical data given is
110 ( 229.8 ) 144 2.4 compatible with the specification required.
Table 95.
Table 92.
Rail Pressure Sensor
Inlet Manifold Air Pressure and Temperature
Sensor (TMAP) Type The rail pressure sensor
is integral with the com-
Fixing screw 22 N·m max mon rail.
tightening
torque
Table 96.
Fixing screw M6
thread diameter High Pressure Rail Fuel Valve
Supply voltage 5 V Type The HPV (High Pressure
Temperature Sensor Valve) is integral with
the common rail.
Type Temperature dependant resistor.
Temperature v Resistance Table Table 97.
Temperature Resistance Ω +/- %
Fuel Temperature Sensor
°C ( °F)
Type The fuel temperature
5 ( 41.0 ) 4,707 4.66
sensor is integral with
10 ( 50.0 ) 3,791 4.55 the high pressure fuel
15 ( 59.0 ) 3,075 4.44 pump.
20 ( 68.0 ) 2,510 4.33
25 ( 77.0 ) 2,062 4.22 Table 98.
30 ( 86.0 ) 1,715 4.12 Oil Pressure Switch
Pressure Sensor Set pressure 0.6 bar ( 8.7 psi) falling.
Type Piezo-resistive Switch mode Normally open.
Atmospheric Pressure v Voltage Max pressure 27.5 bar ( 398.5 psi)
15 - 258 9823/1650-1 15 - 258

15 - Engine
84 - Sensor
00 - General
Oil Pressure Switch

Max working pressure 13.8 bar ( 200.0 psi)
Tightening torque 23 N·m max.
Thread diameter M12 x 1.5.
15 - 259 9823/1650-1 15 - 259

15 - Engine
84 - Sensor
00 - General
Engine Sensors and Actuators
Figure 224.
B
P
F
G
H
J
K
A Coolant temperature sensor (PIL 15-84) B Turbocharger actuator (not installed on 55Kw
engines) (PIL 18-36)
D TMAP (Temperature Manifold Air Pressure) (PIL E Fuel temperature sensor (PIL 15-84)
15-84)
F Fuel inlet metering valve (PIL 18-18) G Camshaft position sensor (PIL 15-84)
H Crankshaft position sensor (PIL 15-84) J Oil temperature sensor (PIL 15-84)
K Oil pressure switch (PIL 15-84) P Inter cooler outlet temperature sensor (PIL
15-84)
15 - 260 9823/1650-1 15 - 260

15 - Engine
84 - Sensor
00 - General
Figure 225.
M
C
C Exhaust manifold pressure sensor (PIL 15-84) L Fuel pressure relief valve (HPV) (PIL 15-84)
M EGR (Exhaust Gas Recirculation) actuator (PIL N Exhaust manifold temperature sensor (PIL
18-27) 15-84)
O Oil level switch (optional) (PIL 15-84)
15 - 261 9823/1650-1 15 - 261

15 - Engine
84 - Sensor
00 - General
Fault-Finding
Fault
General Sensor Fault Table 99. Page 15-262
Water in Fuel Sensor Fault Table 100. Page 15-262
Knock Sensors Table 101. Page 15-263
TMAP (Temperature Manifold Air Pressure) Sensor Fault (Boost Pressure) Table 102. Page 15-264
Crankshaft Position Sensor Table 103. Page 15-264
Camshaft Position Sensor Table 104. Page 15-265
TMAF (Temperature and Mass Air Flow) Sensor Table 105. Page 15-266
Table 99. General Sensor Fault

Cause Remedy
Sensor supply voltage fault Disconnect the sensor, check sensor voltage supply
at the harness connector (see relevant sensor help
file for pin numbers or refer to engine electrical
schematic). If voltage supply is faulty, disconnect all
other sensors in turn until voltage supply returns.
If sensor supply voltage is OK, proceed to 'Sensor
connection faulty'.
Sensor connection faulty Check the condition of sensor to harness connection,
make sure the seals are in place, check for signs
of corrosion or contamination. Repair/replace as
necessary.
If no fault is found, proceed to 'Sensor failure'.
Sensor failure Check the sensor resistance (see relevant help file
page). If sensor is out of specification replace.
If no faults is found, proceed to ECM (Engine Control
Module) connection fault'.
ECM connection fault Disconnect the harness from engine ECM and
inspect. Check seals are in place, check for signs of
corrosion or contamination.
If ECM pins are damaged, replace ECM and re-flash
appropriate calibration (see Re-flashing an ECM.
If harness is damaged, repair or replace as
necessary.
If no fault is found proceed to 'Wiring fault'.
Wiring fault Check the harness continuity. Check the machine
and engine earth contacts. Repair/ replace as
necessary.
If no fault is found, raise Techweb Helpdesk call.
Table 100. Water in Fuel Sensor Fault

Cause Remedy
Sensor supply voltage fault Check the presence of electrical supply on water
sensor.
connection faulty'.
necessary.
15 - 262 9823/1650-1 15 - 262

15 - Engine
84 - Sensor
00 - General
Cause Remedy
If no faults is found, proceed to ECM connection
fault'.
necessary.
Wiring fault Check the harness continuity and machine and
engine earth contacts. Repair/ replace as necessary.
Table 101. Knock Sensors

Cause Remedy
Sensor connection fault Check the following sensors and make sure they
work correctly. – Knock sensors – Water temperature
sensor – Air temperature sensor – Fuel temperature
sensor – Barometric pressure sensor (built inside the
ECM).
Check the knock sensors connection and screw
torque (Check particularly the ground shield
connection). Repair as necessary and re-enter all
injector calibration codes (read then write) in correct
position to reset learned parameters.
If no fault is found proceed to 'Knock sensors ground
fault'.
Knock sensors ground fault Check the grounding of knock sensors, repair as
necessary.
If no fault is found proceed to ECM connection fault'.
ECM connection fault Disconnect ECM and inspect. Check seals are in
place, check for signs of corrosion or contamination.
necessary.
Wiring fault Check the harness continuity and electrical
installation, repair/replace as necessary.
If no fault is found proceed to 'Injector calibration
codes fault'.
Injector calibration codes fault Check the injector calibration codes recorded in
ECM, if found fault re-enter all injector calibration
codes (read then write) in correct position to reset
learned parameters.
If the injector calibration codes are OK, test the
vehicle on road and check the DTC (Diagnostic
Trouble Code) again with the diagnostic tool. If the
problem is still present, replace the knock sensors.
15 - 263 9823/1650-1 15 - 263

15 - Engine
84 - Sensor
00 - General
Table 102. TMAP (Temperature Manifold Air Pressure) Sensor Fault (Boost Pressure)
Cause Remedy
Sensor supply voltage or calibration fault Disconnect the sensor, check sensor voltage supply
schematic). If voltage supply is faulty, disconnect
all other sensor in turn until voltage supply returns.
Replace the faulty sensor. If no sensor is faulty
replace the ECM.
If sensor supply voltage is OK, proceed to 'Air inlet
circuit fault'.
Air inlet circuit fault Check the consistency of barometric pressure
reading. Verify the conformity of air inlet circuit:– VGT
(Variable Geometry Turbocharger) / Turbo – Leakage
before VGT / Turbo – Air filter – Valve position using
ServiceMaster – Vane state.
Check all the hose connections for air leaks, repair
as necessary.
necessary.
fault'.
If ECM pins are damaged, replaceECM and re-flash
appropriate calibration (see Re-flashing an ECM
necessary.
If no fault found, raise Techweb Helpdesk call.
Table 103. Crankshaft Position Sensor

Cause Remedy
schematic). If voltage supply is faulty, replace the
sensor.
connection faulty'.
make sure the seals are in place, check for signs of
corrosion or contamination. Repair as necessary.
If no fault is found, proceed to ECM connection fault'.
15 - 264 9823/1650-1 15 - 264

15 - Engine
84 - Sensor
00 - General
Cause Remedy
necessary.
If no fault is found proceed to 'Sensor signals faulty'.
Sensor signals faulty Check the sensor signals. If scope available, display
Cam and crank signals on the scope. Change the
sensor as necessary.
If no fault is found, proceed to 'Sensor target wheel
fault'.
Sensor target wheel fault Check the crankshaft position sensor target wheel if
damaged, replace with a new crankshaft.
If no fault is found raise Techweb Helpdesk call.
Table 104. Camshaft Position Sensor

Cause Remedy
schematic). If voltage supply is faulty, replace the
sensor.
connection faulty'.
make sure the seals are in place, check for signs of
corrosion or contamination. Repair as necessary.
If no fault is found, proceed to Step 4.
necessary.
If no fault is found proceed to 'Sensor signals faulty'.
Sensor signals faulty Check the sensor signals. If scope available, display
Cam and crank signals on the scope. Change the
sensor as necessary.
If no fault is found, proceed to 'Sensor target wheel
fault'.
Sensor target wheel fault Check the Cam target wheel if damaged, replace
with new camshaft.
15 - 265 9823/1650-1 15 - 265

15 - Engine
84 - Sensor
00 - General
Table 105. TMAF (Temperature and Mass Air Flow) Sensor

Cause Remedy
Sensor supply voltage or calibration fault Disconnect the sensor, check sensor voltage supply
schematic). If voltage supply is faulty, disconnect
all other sensor in turn until voltage supply returns.
Replace the faulty sensor. If no sensor is faulty
replace the ECM
If sensor supply voltage is OK, proceed to 'Air inlet
fault'.
Air inlet fault Check all the hose connections for air leaks, repair
as necessary.
If no fault is found proceed to 'Sensor connection
faulty'.
necessary.
Sensor failure If sensor is out of specification replace.
If no faults is found, proceed to Step 5.
necessary.
If no fault is found proceed to Step 6.
If no fault found, raise Techweb Helpdesk call.
15 - 266 9823/1650-1 15 - 266

15 - Engine
84 - Sensor
00 - General
Check (Operation)
1. Check the applicable fuse.
2. Check the display for related fault codes.
3. Using Servicemaster perform the required
diagnostic tests.
4. Check the sensor condition, make sure the
sensor or housing is not damaged, broken,
contaminated or subjected to excess heat. If
necessary replace sensor and make sure the
damage can not reoccur.
5. Check the condition of sensor to harness
connection, make sure the seals are in place,
check for signs of corrosion or contamination.
Repair/replace as necessary.
6. Check the sensor location and make sure it is
mounted correctly. Where applicable check the
sensor is tightened to the correct torque. Refer to
the applicable sensor procedure for details.
7. Check the sensor is of the correct type and
specification. If incorrect replace with correct
sensor. Refer to the applicable sensor procedure
for details.
8. Disconnect the sensor, check sensor voltage
supply at the harness connector (Refer
to the applicable sensor Technical Data
and Component Identification procedures.
Alternatively refer to engine electrical
schematic). If the voltage supply is faulty,
disconnect all other sensors in turn until voltage
supply returns. Trace the supply fault and rectify.
9. Check the sensor characteristics. Refer to the
applicable sensor Technical Data. If sensor is out
of specification replace.
10. Disconnect the harness from the engine ECM
(Engine Control Module) and inspect. Check
seals are in place, check for signs of corrosion or
contamination.
11. Check the harness continuity. Check the
machine and engine earth contacts. Repair /
replace as necessary.
15 - 267 9823/1650-1 15 - 267

15 - Engine
84 - Sensor
03 - Crankshaft Position
03 - Crankshaft Position Introduction

Introduction .................................................. 15-268 The crankshaft position sensor is a device used
Operation ..................................................... 15-269 to monitor the position or rotational speed of the
Check (Operation) ....................................... 15-270 crankshaft. This information is used by the ECM
Remove and Install ..................................... 15-270 (Engine Control Module) to control the ignition
system timing and other engine parameters.
15 - 268 9823/1650-1 15 - 268

15 - Engine
84 - Sensor
Operation
processed by the ECM (Engine Control Module) to

A signal is generated by the crankshaft mounted determine the timing of fuel injection.
target wheel and crankshaft position sensor. It is
Figure 226.
TDC 2 3
5
4
C1 C2
D1 D2 6
1 ECM 2 Camshaft position sensor

3 Camshaft target wheel 4 Crankshaft position sensor
5 Crankshaft mounted target wheel 6 Fuel injector
A Camshaft sensor signal B Crankshaft position sensor signal
C1-C2 Current pulse-injector solenoid coil D1-D2 Fuel Injection
TDC TDC (Top Dead Centre)
15 - 269 9823/1650-1 15 - 269

15 - Engine
84 - Sensor
Check (Operation) Remove and Install

1. Carefully inspect the sensor. If it is found to be
defective, replace the sensor.
Before Removal
2. Inspect the sealing O-ring. If it is defective,
replace the sensor. The O-ring is integral to the
sensor and cannot be replaced.
2. Clean the sensor and the adjacent area of the
flywheel housing.
Figure 227.
A
D
C
A Crankshaft position sensor

B Electrical connector
C Bolt
D Guard
15 - 270 9823/1650-1 15 - 270

15 - Engine
84 - Sensor
Remove
2. Remove the guard.
3. Disconnect the electrical connector at the sensor.
4. Remove the bolt.
5. Remove the sensor from underneath the timing
gear casing.
The crankshaft position sensor is a non-serviceable

item. If the sensor is defective it must be replaced.
Install
steps.
2. Tighten the bolt to the correct torque value.

Item Nm
C 8
15 - 271 9823/1650-1 15 - 271

15 - Engine
84 - Sensor
06 - Camshaft Position
06 - Camshaft Position Introduction

Introduction .................................................. 15-272 The camshaft position sensor is a device that detects
Operation ..................................................... 15-273 the passing of a gap on a camshaft target wheel. It
Check (Operation) ....................................... 15-274 sends a signal to the ECM (Engine Control Module)
Remove and Install ..................................... 15-274 which stroke number piston is on so that the ECM
knows which cylinder to inject the fuel into.
15 - 272 9823/1650-1 15 - 272

15 - Engine
84 - Sensor
Operation
process the signal to determine the engine phase

A signal is generated by the camshaft mounted target (which cylinder is firing).
wheel and camshaft position sensor. This information
is used by the ECM (Engine Control Module) to The ECM will select the correct cylinder for fuel
injection.
Figure 228.
TDC 2 3
5
4
C1 C2
D1 D2 6

3 Camshaft target wheel 4 Crankshaft position sensor
5 Crankshaft mounted target wheel 6 Fuel injector
A Camshaft sensor signal B Crankshaft position sensor signal
C1-C2 Current pulse - injector solenoid coil D1-D2 Fuel Injection
TDC TDC (Top Dead Centre)
15 - 273 9823/1650-1 15 - 273

15 - Engine
84 - Sensor

1. Carefully inspect the sensor. If it is found to be
defective, replace the sensor.
Before Removal
crankcase.
Figure 229.
A
B
A Camshaft position sensor

C Bolt
D O-ring seal
Remove
3. Remove the bolt.
4. Remove the sensor from the crankcase together
with the O-ring.
The camshaft position sensor is a non-serviceable

item. If the sensor is defective it must be replaced.
15 - 274 9823/1650-1 15 - 274

15 - Engine
84 - Sensor
Install
steps.
2. Make sure that the sealing O-ring is correctly
installed.
3. Apply a small amount of grease to the O-ring.
4. Carefully push the sensor into the location bore
in the crankcase. Do not use excessive force.

Item Nm
C 8
15 - 275 9823/1650-1 15 - 275

15 - Engine
84 - Sensor
09 - Knock
09 - Knock Introduction
Introduction .................................................. 15-276 There are two knock sensors fixed to the side of the
Operation ..................................................... 15-277 crankcase with a centre mounted bolt. One sensor is
Check (Operation) ....................................... 15-277 situated between cylinders 1 and 2, and the second
Remove and Install ..................................... 15-278 is situated between cylinders 3 and 4.
A knock sensor is a device that measures engine

noise and transmits a signal to the ECM (Engine
Control Module) when there is detonation. It allows
the engine to run with the ignition timing as far
advanced as possible.
The ECM will continue to advance the timing until

the knock sensor detects pinging. At that point the
ECM retards the ignition timing just enough for the
pinging to stop. The knock sensor ensures that you
are getting as much power and fuel economy as
possible from your engine.
Figure 230. Knock sensor locations
A
B
A Knock sensor - cylinders 1 and 2

B Knock sensor - cylinders 3 and 4
15 - 276 9823/1650-1 15 - 276

15 - Engine
84 - Sensor
09 - Knock
Operation Check (Operation)
The knock sensors detect pre-ignition (knock) by 1. For the full inspection and testing procedure,
means of sensing engine vibration. The vibration refer to the help files in ServiceMaster.
signal is sent to the engine ECM (Engine Control
Module)where the ECM will adjust the fuel timing to
give optimum performance, economy and driveability
and prevent engine damage. The voltage signal is
proportional to engine vibration/acceleration.
15 - 277 9823/1650-1 15 - 277

15 - Engine
84 - Sensor
09 - Knock
Remove and Install 3. Tighten the bolt to the correct torque value.
Torque: 22 –26 N·m
The following procedure is for one knock sensor. The
procedure for both sensors is identical.
Before Removal
Remove
2. Disconnect the electrical connector at the knock
sensor.
3. Remove the bolt and remove the knock sensor
from the crankcase.
The knock sensor is a non-serviceable item. If the

sensor is defective it must be replaced.
Figure 231.
B C
A Knock sensor
C Bolt
Install
steps.
2. Make sure that the sensor mates fully with the
adjacent face on the crankcase.
15 - 278 9823/1650-1 15 - 278

15 - Engine
84 - Sensor
14 - Exhaust Manifold Temperature
14 - Exhaust Manifold Temperature Introduction

Introduction .................................................. 15-279 The exhaust manifold temperature sensor is screwed
Operation ..................................................... 15-280 directly into the top of the exhaust manifold between
Check (Operation) ....................................... 15-280 cylinder 3 and 4 exhaust outlet ports.
Figure 232. Exhaust manifold
temperature sensor location
15 - 279 9823/1650-1 15 - 279

15 - Engine
84 - Sensor
The exhaust manifold temperature sensor measures For the full inspection and testing procedure, refer to
the exhaust gas temperature from the engine, before the help files in ServiceMaster.
it reaches the turbocharger. The analogue voltage
signal is 1 –4.5 V.
15 - 280 9823/1650-1 15 - 280

15 - Engine
84 - Sensor
Remove and Install

Special Tools
Deep Socket 892/12351 1
Before Removal
Figure 233.
A
N
A Exhaust manifold temperature sensor
Remove
2. Disconnect the electrical connector at the
exhaust manifold temperature sensor.
3. Use the special tool to remove the sensor from
the exhaust manifold.
Special Tool: Deep Socket (Qty.: 1)
4. Discard the sealing washer.
The exhaust manifold temperature sensor is a non-

serviceable item. If the sensor is faulty or damaged
it must be renewed.
Install
steps.
2. Renew the sealing washer.
3. Tighten the exhaust manifold temperature
sensor to the correct torque value.

Item Nm
N 45
15 - 281 9823/1650-1 15 - 281

15 - Engine
84 - Sensor
16 - Exhaust Manifold Pressure
16 - Exhaust Manifold Pressure Introduction

Introduction .................................................. 15-282 The exhaust manifold pressure sensor also known
Operation ..................................................... 15-283 as the manifold absolute pressure sensor is a device
Check (Operation) ....................................... 15-283 that is used to calibrate the fuel delivery on an ECM
Remove and Install ..................................... 15-284 (Engine Control Module) Controlled engine.
The sensor is mounted in the rear section of the

rocker cover.
Figure 234.
C Exhaust manifold pressure sensor
15 - 282 9823/1650-1 15 - 282

15 - Engine
84 - Sensor
The exhaust manifold pressure sensor measures For the full inspection and testing procedure, refer to
the exhaust pressure from the engine. To attain an the help files in ServiceMaster.
accurate and stable reading, the take-off point is
piped from the exhaust manifold between cylinders
3 and 4. This is fed to a sample chamber where the
sensor is screwed directly into the pressure path. The
analogue voltage signal is 0.5 –4.5 V.
15 - 283 9823/1650-1 15 - 283

15 - Engine
84 - Sensor
Remove and Install 3. Use the special tool to tighten the exhaust
manifold pressure sensor to the correct torque
Special Tools value.
Item Nm
Before Removal 1 22.5

Figure 235.
P1
1 Exhaust manifold pressure sensor

2 Electrical connector
P1 Sealing washer
Remove
2. Disconnect the electrical connector at the
exhaust manifold pressure sensor.
the exhaust manifold.
4. Discard the sealing washer.
The exhaust manifold pressure sensor is a non-

it must be renewed.
Install
steps.
15 - 284 9823/1650-1 15 - 284

15 - Engine
84 - Sensor
17 - Temperature and Manifold Air Pressure (TMAP)
17 - Temperature and Manifold Air Introduction

Pressure (TMAP)
The TMAP (Temperature Manifold Air Pressure)
Introduction .................................................. 15-285 sensor is mounted in a port on top of the inlet
Operation ..................................................... 15-286 manifold. It measures the inlet manifold boost air
Check (Operation) ....................................... 15-286 pressure and temperature. The sensor incorporates
a piezo-resistive element and resistor.
Figure 236.
D TMAPsensor
15 - 285 9823/1650-1 15 - 285

15 - Engine
84 - Sensor
The TMAP (Temperature Manifold Air Pressure) 1. Remove oil and sludge contamination from the
sensor measures the inlet manifold boost air sensor.
pressure and temperature. The sensor produces an
analogue signal voltage proportional to air pressure. 2. Carefully inspect the sensor. If it is defective,
replace it.
15 - 286 9823/1650-1 15 - 286

15 - Engine
84 - Sensor
Remove and Install 3. Carefully push the sensor into its location bore in
the inlet manifold. Do not use excessive force.
Before Removal
1. Make sure that the engine is safe to work on. If Table 110. Torque Values
the engine has been running, let it cool before Item Nm
you start the service work. C 3.3
inlet manifold.
Figure 237.
A
C B
D
A TMAP (Temperature Manifold Air Pressure)
C Bolt
D O-ring seal
Remove
3. Remove the bolt.
4. Remove the sensor from the inlet manifold
together with O-ring.
The TMAP sensor is a non-serviceable item. If the

sensor is defective, it must be replaced.
Install
steps.
2. Make sure that the sealing O-ring is correctly
installed.
15 - 287 9823/1650-1 15 - 287

15 - Engine
84 - Sensor
18 - Temperature and Mass Air Flow (TMAF)
18 - Temperature and Mass Air Introduction

Flow (TMAF)
The TMAF (Temperature and Mass Air Flow) sensor
Introduction .................................................. 15-288 measures the amount of air coming in to the engine
Operation ..................................................... 15-289 and the air temperature. It is mounted between the
Check (Operation) ....................................... 15-289 air filter and turbo charger.
Remove and Install ..................................... 15-290 Figure 238.
15 - 288 9823/1650-1 15 - 288

15 - Engine
84 - Sensor
The TMAF (Temperature and Mass Air Flow) sensor Faults relating to the TMAF (Temperature and Mass
produces a digital signal measuring air flow, and an Air Flow) will normally be reported by the fault codes.
analogue signal measuring inlet air temperature.
1. Remove contamination from the sensor. Do not
touch the air flow sensor area or temperature
sensor area.
2. Carefully inspect the sensor. If it is defective,
replace it.
replace it.
Figure 239.
1 Air flow sensor area

2 Temperature sensor area
15 - 289 9823/1650-1 15 - 289

15 - Engine
84 - Sensor
Remove and Install Install

Do not install a TMAF sensor which has been
Before Removal dropped or damaged. Replace it with a new one.
1. Make sure that the engine is safe to work on. If 1. The installation procedure is the opposite of the
the engine has been running, let it cool before removal procedure. Additionally do the following
you start the service work. step.
2. Get access to the TMAF (Temperature and Mass 2. Tighten the screws to the correct torque value.
Air Flow) sensor
3. Clean the area around the sensor to prevent
Item Nm
contamination entering the engine.
2 5
Remove
Figure 240.
1 2
3
2 Screws (x2)
3 TMAF sensor
1. Disconnect the electrical connector. Do not touch
the connector pins.
2. Remove the screws (x2) which secure the TMAF
sensor to the air intake hose.
3. Remove the TMAF sensor together with the O-
ring from the air intake hose. Do not touch the air
flow sensor area or temperature sensor area.
Figure 241.
1 Air flow temperature sensor area

2 Temperature sensor area
15 - 290 9823/1650-1 15 - 290

15 - Engine
84 - Sensor
24 - Fuel Temperature
24 - Fuel Temperature Introduction

Introduction .................................................. 15-291 The fuel temperature sensor is an integral part of
Operation ..................................................... 15-292 the fuel injection high pressure pump, refer to (PIL
Check (Operation) ....................................... 15-292 18-18).
Figure 242.
E Fuel temperature sensor
15 - 291 9823/1650-1 15 - 291

15 - Engine
84 - Sensor
The fuel temperature sensor detects the fuel For the full inspection and testing procedure, refer to
temperature as it enters the high pressure fuel the help files in ServiceMaster.
injection pump.
15 - 292 9823/1650-1 15 - 292

15 - Engine
84 - Sensor
Remove and Install
This part is a non-serviceable component, if it is

defective, replace the fuel injection high pressure
pump. Refer to: PIL 18-18-15.
15 - 293 9823/1650-1 15 - 293

15 - Engine
84 - Sensor
27 - Fuel Rail Pressure
27 - Fuel Rail Pressure Introduction

Introduction .................................................. 15-294 The fuel rail pressure sensor measures the fuel
Operation ..................................................... 15-295 pressure in the common rail.
Check (Operation) ....................................... 15-295
A Fuel rail pressure sensor
15 - 294 9823/1650-1 15 - 294

15 - Engine
84 - Sensor
The fuel rail pressure sensor measures the fuel For the full inspection and testing procedure, refer to
pressure in the fuel rail. This allows the ECM (Engine the help files in ServiceMaster.
Control Module) to control the IMV (Inlet Metering
Valve) to deliver the correct amount of fuel to the high
pressure fuel pump. This keeps the fuel pressure in
the fuel rail constant at all engine RPM (Revolutions
Per Minute).
15 - 295 9823/1650-1 15 - 295

15 - Engine
84 - Sensor
Remove and Install
This part is a non-serviceable component, if it

is defective, replace the complete common rail
assembly. Refer to: PIL 18-18-12.
15 - 296 9823/1650-1 15 - 296

15 - Engine
84 - Sensor
29 - Foot Throttle Control
29 - Foot Throttle Control Technical Data

Technical Data ............................................. 15-297
Operation ..................................................... 15-298
Throttle Position Sensor
Remove and Install ..................................... 15-299 Figure 244. Throttle Pedal Movement
A
B
Table 112.
Pedal Position Voltage Output
A Signal 1 = 0 Signal 2 = 5
B Signal 1 = 2 Signal 2 = 3
C Signal 1 = 5 Signal 2 = 0
15 - 297 9823/1650-1 15 - 297

15 - Engine
84 - Sensor
Operation
The throttle pedal sensor (TPS) converts the

movement from the pedal into an electrical signal
for interpretation by the Engine ECU (Electronic
Control Unit), variflow pump ECU hi(if installed) or
the hydraulic control ECU.
The the movement of the throttle pedal is transmitted

from the footplate to the roller and the swing arm
on the throttle position sensor (TPS) unit. A variable
resistor within the TPS unit changes the voltage
output in relation to the position of the pedal.
Two signals are output from the unit, a track 1 signal

and a track 2 signal. One signal varies the voltage by
the angle below the foot pedal pad. The other signal
varies the voltage by the angle above the foot pedal
pad. Both signals will always add up to 5 V. Refer to
engine- sensor, refer to (PIL 15-84).
Figure 245.
B
A
C
D
A Throttle position sensor unit

B Throttle pedal
C Swing arm
D Roller
15 - 298 9823/1650-1 15 - 298

15 - Engine
84 - Sensor
Remove and Install
Consumables 4. Remove the floor mat from the cab.

JCB Threadlocker 4101/0250 0.01 L chassis harness, from below the cab.
Strength) 6. Remove the socket head bolts.
Remove 7. Make sure you keep the spacer plate (if

installed).
1. Park the machine and make it safe. Refer to (PIL
01-03). 8. Remove the nut to release the clip and the
connector from the floor.
2. Follow the general safety precautions. Refer to
(PIL 01-03). 9. Slowly remove the pedal assembly from inside
the cab.
3. Make sure that the engine cannot be started.
10. Pull the connector through the hole in the floor.
Figure 246.
D
B B
E
A
F
A Pedal assembly B Socket head bolts

C Spacer plate D Nut
E Connector F Hole in the floor
15 - 299 9823/1650-1 15 - 299

15 - Engine
84 - Sensor
Install
1. The installation is the opposite of the removal
procedure.
2. When you install do the following steps also:
2.1. Apply sealant to the thread of the bolts.
(Medium Strength)
15 - 300 9823/1650-1 15 - 300

15 - Engine
84 - Sensor
33 - Coolant Temperature
33 - Coolant Temperature Introduction

Introduction .................................................. 15-301 The coolant temperature sensor is located on the
Operation ..................................................... 15-302 cylinder head at the drive belt end.
Check (Operation) ....................................... 15-302
A
A Coolant temperature sensor
15 - 301 9823/1650-1 15 - 301

15 - Engine
84 - Sensor
The coolant temperature sensor detects the 1. For the full inspection and testing procedure,
temperature of the coolant in the cylinder head. refer to the help files in ServiceMaster.
The signal from the sensor is used to drive the

coolant temperature status display in the cab.
On engines with electronically controlled fuel

injection the ECM (Engine Control Module)
processes the signal to determine the engine
operating temperature. The ECM adjusts the
injection timing and the amount of fuel injected, this
can facilitate cold starting.
15 - 302 9823/1650-1 15 - 302

15 - Engine
84 - Sensor

Item Nm
1 16
Before Removal
2. Drain the coolant, refer to (PIL 21-00).
Figure 248.
1
P1
1 Coolant temperature sensor

P1 Sealing washer
Remove
3. Remove the sensor from the cylinder head.
4. Discard the sealing washer. Cap the open port
with a blanking cap to prevent loss of fluid and
ingress of dirt.
The coolant temperature sensor unit is a non-

serviceable item. If the switch is faulty or damaged it
must be renewed.
Install
steps.
3. Tighten the coolant temperature sensor to the
4. Refill the cooling system with the recommended
coolant mixture, refer to Technical Data (PIL
21-00).
5. Start the engine and check for coolant leaks.
15 - 303 9823/1650-1 15 - 303

15 - Engine
84 - Sensor
42 - Engine Oil Temperature
42 - Engine Oil Temperature Introduction

Introduction .................................................. 15-304 The engine oil temperature sensor is mounted in a
Operation ..................................................... 15-305 port on the oil cooler housing adjacent to the engine
Check (Operation) ....................................... 15-305 oil dipstick.
Figure 249. Engine oil tem-
perature sensor location
A Engine oil temperature sensor
15 - 304 9823/1650-1 15 - 304

15 - Engine
84 - Sensor
The oil temperature sensor informs the ECM (Engine 1. For the full inspection and testing procedure,
Control Module) of the engine oil temperature. The refer to the help files in ServiceMaster.
ECM processes the signal to determine the oil
temperature. The ECM adjusts the fuel delivery.
15 - 305 9823/1650-1 15 - 305

15 - Engine
84 - Sensor

Item Nm
Special Tools
Description Part No. Qty. 1 21
Before Removal
Figure 250.
B
A Sealing washer
B Engine oil temperature sensor
Remove
2. Disconnect the electrical connector at the engine
oil temperature sensor.
the oil cooler housing.
4. Discard the sealing washer. Cap the open port
with a blanking cap to prevent loss of fluid and
ingress of dirt.
The engine oil temperature sensor is a non-

it must be renewed.
Install
steps.
3. Use the special tool to tighten the engine oil
temperature sensor to the correct torque value.
15 - 306 9823/1650-1 15 - 306

15 - Engine
84 - Sensor
43 - Engine Oil Level
43 - Engine Oil Level Introduction

Introduction .................................................. 15-307 The engine oil level sensor is used to warn the
Operation ..................................................... 15-308 operator that the engine oil level is low and damage
Check (Operation) ....................................... 15-308 may be caused if it is not topped up immediately. It is
Remove and Install ..................................... 15-309 mounted on the engine oil sump.
15 - 307 9823/1650-1 15 - 307

15 - Engine
84 - Sensor
The engine oil level sensor is a normally closed 1. For the full inspection and testing procedure refer
switch. When the oil level drops below a certain point to the help files in ServiceMaster.
the switch will open and the low oil warning light will
be illuminated.
15 - 308 9823/1650-1 15 - 308

15 - Engine
84 - Sensor
Remove and Install
Before Removal 2. Make sure that the engine is safe to work on.
If the engine has been running, make sure the
1. Make the machine safe. engine has cooled sufficiently before you start.
Figure 251.
A
C
B
D
E
A Engine oil level sensor B Oil level sensor float

C Bolts (x2) D Clip
E Oil Sump
Remove
2. Drain the engine oil.
4. Remove the oil sump.
5. Remove the bolts (x2) securing the oil level
sensor float to the oil sump.
6. Remove the clip.
7. Remove the oil level sensor.
The engine oil level sensor is a non-serviceable item.

If the sensor is faulty or damaged it must be replaced.
Install
steps.

Item Nm
C 10 ± 1
15 - 309 9823/1650-1 15 - 309

15 - Engine
84 - Sensor
48 - Intercooler Outlet Temperature
48 - Intercooler Outlet Temperature Introduction

Introduction .................................................. 15-310 The intercooler outlet sensor is located in the air
Operation ..................................................... 15-311 intake on the inlet manifold.
Check (Operation) ....................................... 15-311
P Intercooler outlet sensor
15 - 310 9823/1650-1 15 - 310

15 - Engine
84 - Sensor
The intercooler outlet sensor measures the 1. For the full inspection and testing procedure,
temperature of the air coming from the intercooler refer to the help files in ServiceMaster.
into the inlet manifold. The sensor sends an
analogue voltage signal to the ECM (Engine Control
Module).
15 - 311 9823/1650-1 15 - 311

15 - Engine
84 - Sensor
Remove and Install
Before Removal
Figure 253.
A Intercooler outlet temperature sensor
Remove
3. Remove the sensor from the air intake.
4. Cap the open port with a blanking cap to prevent
dirt ingress.
Install
step.
2. Tighten the sensor to the correct torque value.

Item Nm
A 8.5
15 - 312 9823/1650-1 15 - 312

15 - Engine
86 - Solenoid
86 - Solenoid
Contents Page No.
15-86-00 General ......................................................................................................................... 15-315

15-86-09 Cold Start Advance ...................................................................................................... 15-316
15 - 313 9823/1650-1 15 - 313

Notes:
15 - 314 9823/1650-1 15 - 314

15 - Engine
86 - Solenoid
00 - General
00 - General
Introduction
A solenoid refers to a variety of transducer devices

that convert energy into linear motion. The term also
refers to a solenoid valve, which is an integrated
device containing an electromechanical solenoid
which actuates a hydraulic valve, or a solenoid
switch.
15 - 315 9823/1650-1 15 - 315

15 - Engine
86 - Solenoid
09 - Cold Start Advance
09 - Cold Start Advance Introduction

Introduction .................................................. 15-316 The cold start advance solenoid consists of an
Check (Condition) ........................................ 15-317 electrical solenoid and a valve which allows extra
Remove and Install ..................................... 15-318 fuel to spray into the inlet manifold at specific
temperatures for starting purposes. The fuel is
supplied to this valve by the electric fuel pump.
Under cold starting conditions, the solenoid is

energised that opens the fuel valve allowing jets of
fuel to spray into the inlet manifold and mix with the
incoming air, thus richening the air/fuel mixture to
help in cold starting conditions.
15 - 316 9823/1650-1 15 - 316

15 - Engine
86 - Solenoid
Check (Condition)
1. If a faulty solenoid is suspected, perform tests to
confirm its serviceability.
15 - 317 9823/1650-1 15 - 317

15 - Engine
86 - Solenoid
Remove and Install
Before Removal 2. Get access to the engine.

Figure 254.
2
1 Cold start advance solenoid 2 Fuel injection pump

3 O-ring - cold start advance solenoid
Removal Install
1. Disconnect the electrical connector at the cold 1. Replacement is the reversal of the removal
start advance solenoid. procedure.
2. Remove the solenoid cartridge from the fuel 2. Install a new O-ring seal.
injection pump body.
3. Discard the O-ring seal. Cap all open ports to
prevent ingress of dirt and debris. 4. Start the engine and check for fuel leaks.
The cold start advance solenoid is a non-serviceable Table 117. Torque Values
item. If the solenoid is faulty or damaged it must be Item Nm
renewed. It is essential that the correct solenoid is
1 15
installed.
15 - 318 9823/1650-1 15 - 318

15 - Engine
87 - Switch
87 - Switch
Contents Page No.
15-87-00 General ......................................................................................................................... 15-321

15-87-03 Engine Oil Pressure ..................................................................................................... 15-322
15-87-09 Cold Start ..................................................................................................................... 15-325
15 - 319 9823/1650-1 15 - 319

Notes:
15 - 320 9823/1650-1 15 - 320

15 - Engine
87 - Switch
00 - General
00 - General
Introduction
The engine electrical switches send signals to the

ECM (Engine Control Module) to help the ECM
to control the smooth running of the engine and
related components. The ECM processes signals
from the switches and its response will be based
on an evaluation of the combination of the switches
signals.
After removal from the engine, protect the switches

from knocks, dampness and any high temperature
sources. The switches are not serviceable, therefore
they must be replaced in the event of damage.
15 - 321 9823/1650-1 15 - 321

15 - Engine
87 - Switch
03 - Engine Oil Pressure
03 - Engine Oil Pressure Introduction

Introduction .................................................. 15-322 The oil pressure switch is mounted in a port on the
Operation ..................................................... 15-323 oil cooler housing.
Check (Operation) ....................................... 15-323
A
A Engine oil pressure switch
15 - 322 9823/1650-1 15 - 322

15 - Engine
87 - Switch
The oil pressure switch contacts open when the 1. For the full inspection and testing procedure,
engine oil pressure is below 0.6bar. refer to the help files in ServiceMaster.
15 - 323 9823/1650-1 15 - 323

15 - Engine
87 - Switch
Remove and Install
Before Removal
Remove
engine oil pressure switch.
4. Discard the sealing washer. Plug all the open
ports and hoses to prevent contamination.
The engine oil pressure switch is a non-serviceable

item. If the switch is faulty or damaged it must be
renewed.
Install
steps.
2. Replace the sealing washer.
3. Tighten the engine oil pressure switch to the
Torque: 16 N·m
15 - 324 9823/1650-1 15 - 324

15 - Engine
87 - Switch
09 - Cold Start
09 - Cold Start Introduction

Introduction .................................................. 15-325 The cold start switch will send a signal to turn on the
Check (Condition) ........................................ 15-326 cold start advance solenoid at specific temperatures
Remove and Install ..................................... 15-327 to help in cold starting conditions.
15 - 325 9823/1650-1 15 - 325

15 - Engine
87 - Switch
09 - Cold Start
Check (Condition)
1. If a faulty switch is suspected, use a suitable
multimeter to check that the correct supply
voltage is present at the switch electrical
connector.
2. Carry out tests on the machine electrical circuits
to check for possible wiring faults. The fault may
be caused by failure of other components within
the electrical system.
15 - 326 9823/1650-1 15 - 326

15 - Engine
87 - Switch
09 - Cold Start
Remove and Install
The engine cold start switch is a non-serviceable Before Removal

item. If the engine cold start switch is faulty or
damaged it must be renewed. 1. Make sure that the engine is safe to work on. If
2. Drain the coolant. Refer to (PIL 21-00).
Figure 256.
2
1 Engine cold start switch 2 Crankcase

3 Sealing washer - switch
15 - 327 9823/1650-1 15 - 327

15 - Engine
87 - Switch
09 - Cold Start
Removal
1. Disconnect the electrical connector at the engine
cold start switch.
2. Remove the engine cold start switch from the
crankcase.
3. Discard the O-ring. Cap the open ports to prevent
ingress of dirt.
Install
steps.
2. Install a new sealing washer.
3. Tighten the engine cold start switch to the correct
torque value.
After Installation
1. Fill the cooling system with the recommended
coolant mixture. Refer to (PIL 21-00).

Item Nm
1 16
15 - 328 9823/1650-1 15 - 328

15 - Engine
90 - Air Intake
90 - Air Intake
Contents Page No.
15-90-00 General ......................................................................................................................... 15-331
15 - 329 9823/1650-1 15 - 329

Notes:
15 - 330 9823/1650-1 15 - 330

15 - Engine
90 - Air Intake
00 - General
00 - General
Check (Condition)
15 - 331 9823/1650-1 15 - 331

Notes:
15 - 332 9823/1650-1 15 - 332

Contents Page No.
18-00 Fuel and Exhaust System

18-00-00 General ............................................................................................................................. 18-3
18-03 Tank
18-03-00 General ........................................................................................................................... 18-17
18-09 Filter
18-09-00 General ........................................................................................................................... 18-21
18-09-03 Filter Element ................................................................................................................. 18-26
18-09-09 Pre-Filter Element .......................................................................................................... 18-28
18-12 Water Separator
18-12-00 General ........................................................................................................................... 18-31
18-12-04 Water in Fuel Sensor ..................................................................................................... 18-34
18-18 Injection
18-18-00 General ........................................................................................................................... 18-37
18-18-03 Injector ............................................................................................................................ 18-52
18-18-07 Injector Seal ................................................................................................................... 18-57
18-18-12 Rail ................................................................................................................................. 18-59
18-18-15 Pump .............................................................................................................................. 18-61
18-18-27 High Pressure Rail Valve ............................................................................................... 18-68
18-21 Fuel Pump
18-21-00 General ........................................................................................................................... 18-73
18-24 Exhaust
18-24-00 General ........................................................................................................................... 18-79
18-24-03 Inlet Manifold .................................................................................................................. 18-81
18-24-04 Outlet Manifold ............................................................................................................... 18-85
18-27 Exhaust Gas Recirculation (EGR)
18-27-00 General ........................................................................................................................... 18-91
18-27-03 Actuator .......................................................................................................................... 18-98
18-35 Turbocharger
18-35-00 General ......................................................................................................................... 18-101
18-36 Variable Geometry Turbocharger (VGT)
18-36-00 General ......................................................................................................................... 18-109
18-36-03 Actuator ........................................................................................................................ 18-116
18-96 Fuel Pipe
18-96-00 General ......................................................................................................................... 18-119
18-96-03 High Pressure Pipe ...................................................................................................... 18-121
18-96-06 Low Pressure Pipe ....................................................................................................... 18-124
9823/1650-1
2018-01-31
Acronyms Glossary

HPV High Pressure Valve
IMV Inlet Metering Valve
NOx Nitrogen Oxide
PWM Pulse Width Modulation
WIF Water in Fuel
9823/1650-1
2018-01-31
Contents Page No.
18-00-00 General ............................................................................................................................. 18-3
18 - 1 9823/1650-1 18 - 1
Notes:
18 - 2 9823/1650-1 18 - 2
00 - General
Introduction ...................................................... 18-3 USE THE CORRECT FUEL. The potential for
Health and Safety ........................................... 18-4 engine damage due to the use of incorrect or
Technical Data ................................................. 18-4 contaminated fuel is much greater with common
Component Identification ................................. 18-5 rail injection technology than with mechanical
injection systems. For information about fuel types
Operation ......................................................... 18-6 and cleanliness requirements, refer to Consumable
Fault-Finding .................................................... 18-9 Products Refer to: PIL 75-00-00. Technical Data,
Discharge and Pressurise ............................. 18-11 Fuel, Acceptable and Unacceptable Fuels and
Clean ............................................................. 18-11 Cleanliness Requirements.
Check (Pressure) .......................................... 18-13 For information about the fuel injection system. Refer
Bleed ............................................................. 18-15 to: PIL 18-18.
Common Rail Fuel Injection

The common rail fuel injection system enables
the following advantages when compared with
mechanical direct injection systems:
• Reduced engine noise.

• Reduced polluting emissions.
• Increased engine performance, higher torque at
lower engine speeds in particular.
Unlike mechanical direct injection systems, common

rail systems employ electrically operated computer
controlled fuel injectors. The high pressure fuel
injection pump no longer controls the point of
injection but continually supplies pressurised fuel to
a common fuel rail.
The injectors are connected to the common rail and

inject fuel when supplied with electrical signals from
the ECM (Engine Control Module).
Several electrical sensors supply the ECM with

engine operating parameters such as engine speed,
engine phase (firing order), engine temperature,
inlet manifold air pressure and temperature, throttle
position etc. Software in the ECM memory is used
to interpret the data from the sensors and the fuel
injection characteristics are adjusted accordingly.
Prevention of fuel system contamination is even

more important than with mechanical direct injection
systems. To combat fuel contamination, a water
separator and pre-filter is installed in addition to the
main filter.
18 - 3 9823/1650-1 18 - 3
00 - General

Fuel Table 119. Fuel System Data
High pressure pump Delphi DFP 4.2
fuel system. Stop the engine immediately if a fuel
type
working on the fuel system. Do not refuel with the Direction of rotation from Anti-clockwise
engine running. Completely wipe off any spilt fuel drive end
which could cause a fire. There could be a fire and Fuel lift pump type Electrically operated
injury if you do not follow these precautions. Fuel filter micron rating
Fluid Under Pressure Pre-filter 5 micron
Fine jets of fluid at high pressure can penetrate the Main filter 2 micron
skin. Keep face and hands well clear of fluid under Fuel filter restriction - 0.65 bar ( 9.4 psi)
pressure and wear personal protective equipment. maximum pressure drop
Hold a piece of cardboard close to suspected Fuel return restriction - 0.22 bar ( 3.2 psi)
leaks and then examine the cardboard for signs of maximum
fluid. If fluid penetrates your skin, get medical help Injector information Electronically controlled
immediately. solenoid actuated in-
WARNING! Do not open the high pressure fuel jectors. Each injector is
system with the engine running. Engine operation marked with a unique
causes high fuel pressure. High pressure fuel spray calibration code.
can cause serious injury or death.
Notice: Do not allow dirt to enter the fuel system.
Before disconnecting any part of the fuel system,
thoroughly clean around the connection. When a
component has been disconnected, for example
a fuel pipe, always install protective caps and
plugs to prevent dirt ingress. Failure to follow these
instructions will lead to dirt entering the fuel system.
Dirt in the fuel system will seriously damage the fuel
injection equipment and could be expensive to repair.
Notice: The high pressure fuel system is extremely
susceptible to damage if it is contaminated. Always
clean the engine using the correct procedures before
carrying out maintenance. Contamination of the fuel
system can cause catastrophic failure of the engine.
Notice: Running the engine with air in the
system could damage the fuel injection pump. After
maintenance, the system must be bled to remove
any air.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
accordance with local regulations. Use authorised
18 - 4 9823/1650-1 18 - 4
00 - General
Figure 257.
3
2
15
A
6 6 6 6
14
13
1 16
1 ECM (Engine Control Module)(refer to PIL 2 High pressure fuel injection pump (refer to PIL
33-45) 18-18)
3 Common fuel rail (refer to PIL 18-18) 6 Fuel injectors (refer to PIL 18-18)
13 Fuel filter (2 micron) (refer to PIL 18-09) 14 Fuel pre-filter and water separator (5 micron)
(refer to PIL 18-12)
15 Electric feed pump (refer to PIL 18-21) A Electrical sensors (refer to PIL 15-84)
B Fuel tank (refer to PIL 18-03)
18 - 5 9823/1650-1 18 - 5
00 - General
Operation
Some fuel flows through the pump at all times to

The fuel system is central to the performance and provide internal lubrication and cooling. This fuel
efficiency of the engine, distributing an accurate bleeds back to tank via the bleed-off fuel lines.
amount of fuel to each cylinder at exactly the right
time. Pressurised fuel from the high pressure pump
passes into the common fuel rail. The high pressure
Fuel is drawn from the fuel tank by the electric pump is capable of pressurising the fuel in the rail
lift pump integral via the 5 micron pre-filter/water up to 2000 bar. The ECM controlled IMV is used to
separator. (The fuel lift pump is integral with the pre- control the amount, and therefore pressure of the fuel
filter/water separator assembly.) in the common rail.
Fuel is pressurised at low pressure by the electric In some operating conditions the inlet metering valve
lift pump and passes through an engine mounted 2 is not able to reduce the rail pressure quickly enough
micron fuel filter on its way to the inlet on the high (if the operator goes from full throttle to no throttle
pressure pump. suddenly for example). In these circumstances the
rail pressure is dumped to the bleed off line using the
Important: Use of the correct fuel grade, together ECM controlled electric HPV (High Pressure Valve).
with effective filtration and decontamination of the
fuel is essential. The high pressure pump, injectors High pressure fuel pipes connect the injectors to
and engine can be damaged beyond repair by the common fuel rail. The injectors are electrically
contaminated fuel or use of incorrect fuel. controlled and incorporate a small solenoid valve.
The high pressure fuel injection pump is a rotary type Injection timing is determined by the ECM. Electrical
and is gear driven by the engine. The pump consists data from several sensors is continually monitored
of two sections, the transfer pump and high pressure and processed by the ECM to determine when, how
pump. Fuel is first pressurised to about 6 bar by the much and to which cylinder fuel must be injected.
transfer pump. A constant pressure is maintained
regardless of engine speed by the regulating valve. The injectors inject fuel in response to a supply
of electrical current from the ECM. So precise is
Fuel is transferred to the high pressure pump via the control that several injections of fuel occur
the IMV (Inlet Metering Valve). The metering valve during each firing stroke for maximum efficiency and
controls the amount of fuel transferred depending on minimum emissions. During fuel injection some fuel
the engine operating parameters (throttle position, bleeds off the injectors and back to tank via bleed off
coolant temperature etc.). The metering valve is lines.
controlled by the ECM (Engine Control Module).
18 - 6 9823/1650-1 18 - 6
00 - General
Figure 258.
2b
2e 2
2c 2d
3b
3
5 4
15
6 6 6 6
14
16
13
1 ECM 2 Fuel high pressure pump

2b IMV 2c Fuel high pressure pump (transfer section)
18 - 7 9823/1650-1 18 - 7
00 - General
2d Fuel high pressure pump (high pressure 2e Pressure regulating valve (transfer section)
section)
3 Common fuel rail 3b HPV
4 High pressure fuel lines 5 Bleed off fuel lines
6 Fuel injectors 13 Fuel filter
14 Pre-filter/water separator 15 Electric fuel lift pump
16 Fuel tank
Table 120. Colour code key

Colour Component
Green Tank pressure
Blue Transfer pressure
Red Injection rail pressure
Yellow Electrical connections
-ECM - injectors
Light Green Pump internal pressure,
injector bleed-off
18 - 8 9823/1650-1 18 - 8
00 - General
Fault-Finding
Fault
Fuel Consumption Excessive Table 121. Page 18-9
Fuel/Oil- Leaking from Exhaust Manifold Table 122. Page 18-9
General Fuel System Faults Table 123. Page 18-10
Exhaust Gas Recirculation Table 124. Page 18-10
Table 121. Fuel Consumption Excessive

Cause Remedy
Additional load on engine. Check/repair accessories and vehicle components.
Refer to the equipment manufacturer's procedures.
Operator technique. Review operation for correct gear shifts, deceleration
and idling.
Fuel leaks. Check for external leaks at the fuel tank, fuel lines,
filters and lift pump WARNING: Do not repair
defective fuel lines. If there is a fuel leak remove and
discard the necessary components and install new
ones.
Air intake or exhaust leaks.
ECM (Engine Control Module)or electrical sensor Check the electronic fault codes. Check the electrical
fault. connections at the ECM and sensors.
One or more engine injectors worn or malfunctioning. Check the electronic fault codes. Check the electrical
clearances.
Table 122. Fuel/Oil- Leaking from Exhaust Manifold

Cause Remedy
Operating for extended periods under light or no load Review operation for correct gear shifts, deceleration
conditions. and idling.
Air intake or exhaust leaks.
Turbocharger lubricating oil drain line obstructed. Check/clean line.
Exhaust leak at the Manifold or Turbocharger. Check/repair leaks in the manifold or turbocharger
gaskets. Check for a cracked manifold.
Valve guide seals are leaking. Replace valve guide stem seals as required.
One or more engine injector worn or malfunctioning. Check the electronic fault codes. Check the electrical
18 - 9 9823/1650-1 18 - 9
00 - General
Table 123. General Fuel System Faults

Cause Remedy
Fuel supply fault Check the low pressure circuit connections are
secure.
Check the fuel pressure in low circuit/tank level.
Check the fuel type (EN590 Specification).
Check for the external diesel fuel leaks.
Check the filter is not blocked
Check the fuel lift pump operation (Refer to
ServiceMaster help files).
Replace/repair as necessary.
If no faults are found, proceed to "Engine does not
start," or "Engine starts," depending on symptoms
Engine does not start Complete the ‘Static Injector Leak Test’.
If the injector back leak is above the limit, replace
injector(s) as necessary.
If the injector back leak is OK check the rail pressure
is above 300 bar, if not, replace the high pressure
pump.
If the rail pressure is OK and back leak is within
limits, raise Techweb Helpdesk Call.
Engine starts Complete the ‘Dynamic IMV (Inlet Metering Valve)
Test’.
If the IMV is faulty replace the high pressure pump.
If the IMV is OK complete the ‘Dynamic Injector Back
leak Test’
If the back leak is above the limit, replace the
injector(s).
If the back leak is OK complete the ‘Dynamic HPV
(High Pressure Valve) test’
If the pump capacity is below the limit, replace the
high pressure pump.
If the pump capacity is OK, raise Techweb Helpdesk
Call.
Table 124. Exhaust Gas Recirculation

Cause Remedy
Air inlet circuit fault Check the air inlet circuit: – Valve position using
ServiceMaster – Check the EGR (Exhaust Gas
Recirculation) linkage – Vane state
If no fault is found proceed to 'EGR valve connection
fault'.
EGR valve connection fault Check the EGR valve connection. Check that the
supply voltage is correct. Repair as necessary.
Check that the EGR valve position can reach MIN
(0%) to MAX position (100%). Use ServiceMaster to
launch the learning procedure of the EGR position.
18 - 10 9823/1650-1 18 - 10
00 - General
Discharge and Pressurise Clean

Notice: Running the engine with air in the
system could damage the fuel injection pump. Cleanliness Requirements
After maintenance, the system must be bled to
remove any air. Important: Additional cleaning must be carried out
prior to working on the high pressure fuel system.
Obey all fuel system health and safety information. It is extremely important the high pressure fuel
Refer to (PIL 18-00). components and the adjacent parts of the engine
are meticulously cleaned before any components are
The entry of air into the fuel system can cause removed. Refer to: Effects of Contamination.
problems such as difficult engine starting and
unstable engine running. Air can enter the system if Before starting work on the high pressure fuel
the following occurs: system, make sure that the working environment
is suitable. Refer to: Maintenance Environment,
• A fuel system component has been Common Rail Fuel Injection.
disconnected. For example, a fuel filter renewal.
• A leak in the low pressure side of the fuel 1. Obey all fuel system health and safety
system during engine operation, or the low information.
pressure pipes have been disconnected. Refer Refer to: PIL 18-00-00.
to Fuel System - General (PIL 18-00) for a more
detailed description of the fuel circuit. 2. Clean the machine, prior to completing any
• The fuel tank is allowed to drain fully during maintenance work.
normal operation.
3. Clean the engine.
The engine installation features an electrically Refer to: PIL 15-00-00.
operated fuel lift pump. The system is designed to
bleed automatically when the lift pump is operated. 4. Remove the hoses, electrical harnesses and
Make sure that as much air is removed from the fuel ancillaries to improve access and expose any
as possible before you start the engine. Bleed the remaining trapped dirt close to the relevant high
system as follows: pressure components.
Important: DO NOT attempt to bleed the high 5. Wash away any remaining dirt or debris and then
pressure fuel system by loosening the high pressure dry the area using a compressed air jet. When
pipe connections even when the engine is not the area is dry use a soft clean brush to remove
running. To bleed the fuel system follow the correct sand or grit particles that remain.
procedure.
Effects of Contamination
1. Turn on the machine ignition switch to start the
fuel lift pump. DO NOT start the engine. Allow the Whist the requirement for a good level of cleanliness
pump to run for 30 seconds. is well known and common practice, the introduction
of high pressure common rail fuel injection
2. Turn off the machine ignition switch to stop the
necessitates working to new levels of cleanliness.
fuel lift pump. Wait 10 seconds and then turn the
ignition switch to start the pump. DO NOT start Once inside the system, fuel circuit contaminants
the engine. Allow the pump to run for 30 seconds. greatly affect the performance and life of the fuel
3. Repeat step 2 twice more before you start the injection equipment. For example, contaminants in
engine. the fuel pump will develop internal wear to cause
internal leakage and hence lower discharges. Use
4. Start the engine and make sure it runs smoothly. of poor quality fuels and poor maintenance could
also lead to contaminants entering the fuel injectors.
There is a possibility of catastrophic equipment
failure if debris should prevent the injectors from fully
closing. The main contaminants can be classified as
follows:
• Solid Particles - sand, fibres, metallic particles,

welding scale, sealing materials and wear
particles etc.
• Liquid - usually water and incompatible oils and
greases.
18 - 11 9823/1650-1 18 - 11
00 - General
• Gases - Air, sulphur dioxide etc. which can Maintenance Environment, Common
create corrosive compounds if dissolved in the Rail Fuel Injection
fluid.
Depending on circumstances engine maintenance
These contaminants can appear during may be required in various working environments.
manufacture, assembly, operation and maintenance. Obviously procedures are best carried out in a
dedicated workshop equipped with a suitable clean
The main filter is rated at 2 micron = 0.002 mm
room, but in practice this is not always possible.
(0.0007874 in). The pre-filter is rated at 5 micron.
Listed are a few typical comparisons of micron size: Maintenance procedures requiring removal or
replacement of fuel system components, particularly
Figure 259.
high pressure components, require special
precautions to make the working environment
suitable, reducing the risk of contamination to an
absolute minimum.
Use the following guidelines to make sure you reduce

the chances of fuel system contamination when
C working in different environments:
B
Worksite - Open to weather
This repair site is not an acceptable location. Only
A
in extreme circumstances should a machine be
repaired on an open site. Use the guidelines below:
A 8 Microns • Clean the engine, Refer to: PIL 15-00-00. If
B 70 Microns the machine is on hard standing, clean away the
C 100 Microns material washed from the engine.
• Red Blood Cell = 8 microns (0.008 mm, • Place suitable clean boards on the ground
0.000315 in). around the machine.
• Human Hair = 70 microns (0.07 mm, 0.00275 • Erect clean plastic sheeting to shelter the
in). engine from wind and rain.
• Grain of Salt = 100 microns (0.1 mm, 0.00394 • Wear a new disposable environmental type suit
in). when working on the fuel system. If the suit
• The smallest particle visible to the naked eye is becomes contaminated with mud, move away
40 microns (0.00157in) approximately. from the engine and change into a new suit.
• Use clean latex gloves (non-powdered).
The main filter and pre-filter must be changed in • Before you start work make sure that all the
accordance with the applicable service schedule required replacement parts and tools are on
and procedures. The water in fuel sensor must be site. Make sure that the replacement parts are
maintained to ensure correct operation at all times. still sealed inside their packaging.
• Cap all exposed ports and orifices immediately.
The potential for engine damage due to fuel Do not leave them open.
contamination is much greater when using common • High pressure fuel pipes MUST BE REPLACED
rail injection technology than with mechanical if any pipe joint is loosened or disconnected. DO
injection systems. This is because common rail NOT re-use the original pipe.
requires components with smaller manufacturing
tolerances, especially the fuel injectors. In addition, Worksite - Closed to weather from above
common rail operates at much higher fuel pressures,
over five times that of mechanical systems. This repair site is the least acceptable condition,
if possible move the machine to a more suitable
Similar pressures are used by commercial water environment. Use the guidelines below:
jet cutting machines to cut metal. Fortunately clean
diesel fuel has lubricating qualities that prevents • Clean the engine, Refer to: PIL 15-00-00.
erosion of components but it is obvious that Clean the floor of all material washed from the
contaminated fuel will cause serious damage at such engine.
high pressures. • Place suitable clean boards on the ground
around the machine.
18 - 12 9823/1650-1 18 - 12
00 - General
• Erect clean plastic sheeting to shelter the Check (Pressure)

engine from the wind and the possibility of
debris such as dirt and dust falling from above.
• Wear a new disposable environmental type suit When it is necessary to check the fuel rail pressure
when working on the fuel system. If it becomes function on a faulty vehicle, it is often difficult to
contaminated with mud, move away from the decide which component of the system has failed.
engine and change into a new suit. It is essential to keep in mind the principles of the
• Use clean latex gloves (non-powdered). function of the Common Rail Fuel system:
• Before you start work make sure that all the
required replacement parts and tools are on Table 125.
site. Make sure that the replacement parts are Principle Function
still sealed inside their packaging.
• Cap all exposed ports and orifices immediately. Pressure production The pump compresses
Do not leave them open. the fuel at high pressure
• High pressure fuel pipes MUST BE REPLACED Pressure regulation The pressure thus pro-
if any pipe joint is loosened or disconnected. DO duced is accumulated in
NOT re-use the original pipe. a rail and measured and
regulated (the rail pres-
Vehicle Maintenance Workshop sure sensor, the ECU
(Electronic Control Unit)
Unless the workshop has a dedicated `sealable and the IMV (Inlet Me-
clean room' work bay, precautions must still be taken. tering Valve) function in
a closed loop, excess
• Clean the engine, Refer to: PIL 15-00-00. pressure is drained to
Clean the engine in the dedicated area and tank by the HPV (High
then move it to the workshop. Pressure Valve)
• Clean the floor area around the machine. Pressure consumption This pressure is finally
• Erect clean plastic sheeting to shelter the consumed by the injec-
engine from any wind and the possibility of tors (injection into the
debris such as dirt and dust falling from above. engine cylinders and in-
• Ensure that workshop doors to the outside are jector management)
kept closed. A gust of wind through an open
door will easily blow sand particles into the air. This means that a pressure fault may come from
• Make sure your work wear is clean, non-flocking the producer, the regulator or the consumers. Simply
and lint free. If in doubt wear a new disposable studying the physical parameters of the rail pressure
environmental type suit. does not allow the disassociation of the producer and
the consumer.
• Use clean latex gloves (non-powdered).
• Before you start work make sure that all the Symptoms
required replacement parts and tools are on • The engine won’t start or is difficult to start.
site. Make sure that the replacement parts are • The engine stalls while running.
still sealed inside their packaging • Lack of power and dashboard warning lamps
• Cap all exposed ports and orifices immediately. light: the recovery mode may lead to engine
Do not leave them open. stop.
• High pressure fuel pipes MUST BE REPLACED
if any pipe joint is loosened or disconnected. DO Hydraulic System Status Analysis
NOT re-use the original pipe.
Hydraulic flow balance is established as follows:
Injected flow + Back leaks flow (Flow consumed)

= Capacity of the HP pump to supply the flow
requested for a given diesel fuel temperature
Hydraulic flow balance is upset if:

• The Injector back leak flow increases sharply,
exceeding the pump capacity.
• This can happen when particles disturb the
internal injector sealing, increasing the back
leak flow from one/several injectors or HPV
18 - 13 9823/1650-1 18 - 13
00 - General
Examples: • Excessive negative pressure at the pump inlet

(<- 300m Bar, fuel filter blocked).
• Heavy contamination of the fuel wear and tear
• Mechanical wear in the pump.
on the pump leads to the production of metallic
• Excessive pump inlet temperature.
particles that will seriously disturb the injector
function. Figure 261. Reduction in HP Pump Capacity
• Mechanical wear in the injector.
• HPV stuck open.
100 100
The capacity of the pump to supply the required
pressure is reduced due to internal pump wear,
pressure is reduced due to internal pump wear or a
fuel feed problem.
Figure 260. Increased Back Leak Flow
C
F
C
100 100
E D
0 0
B A
A Production
B Consumption
C Reduction in HP pump capacity
D Pressure deficit
E Pump capacity
E F Injected flow
G Back Leak flow
0 0
B A
A Production
B Consumption
C Increased back leak flow
D Pressure deficit
E Pump capacity
F Injected flow
Example
• Presence of air in the low pressure circuit.
18 - 14 9823/1650-1 18 - 14
00 - General
Bleed
WARNING Do not open the high pressure fuel bleed automatically when the lift pump is operated.
system with the engine running. Engine operation Make sure that as much air is removed from the fuel
causes high fuel pressure. High pressure fuel as possible before the engine is started.
spray can cause serious injury or death.
Do not try to bleed the high pressure fuel system by
WARNING Bleeding of the high pressure fuel loosening high pressure pipe connections even when
system by opening the high pressure lines is not the engine is stopped. To bleed the fuel system follow
required. High fuel pressure can persist for a the steps below.
period of time when the engine has stopped. High
pressure fuel spray can cause serious injury or 1. Turn on the ignition key to start the fuel lift pump.
death.
2. Do not start the engine. Allow the pump to run for
The engine installation contains an electrically the specified time.
operated fuel lift pump. The system is designed to Duration: 30 s
Figure 262.
A Fuel lift pump (The installation position and pump

may differ on your machine)
3. Turn off the ignition key to stop the fuel lift pump. 5. Start the engine and make sure it runs smoothly.
3.1. Wait for the specified time and turn the
ignition key to start the pump.
3.2. Do not start the engine. Allow the pump to
run for the specified time.
Duration: 30 s
4. Do the step 3 for two more times before you start
the engine.
18 - 15 9823/1650-1 18 - 15
03 - Tank
03 - Tank
Contents Page No.
18-03-00 General ........................................................................................................................... 18-17
18 - 16 9823/1650-1 18 - 16
03 - Tank
00 - General
Introduction .................................................... 18-17 The fuel tank is a safe container for storing flammable
Clean ............................................................. 18-18 fluids, from here the fuel is pumped into the engine.
There can be condensation in a partially filled fuel

tank. Therefore, you must fill the fuel tank after you
operate the engine.
Drain the water and sediment from any fuel storage

tank at the recommended service intervals.
18 - 17 9823/1650-1 18 - 17
03 - Tank
00 - General
Clean
The diesel tank must be drained if there is a chance

the fuel is contaminated or it has been filled with the
incorrect fuel.

2. Drain the diesel tank.
3. Drain the fuel from the low pressure fuel pipes.
4. Replace the fuel filters.
5. Refill the tank to the specified level with clean
diesel.
Percentage: 25 %
6. Start the engine and leave it to run for the
specified time period.
Duration: 10 min
7. Stop the engine.
8. Drain the water separator and the main fuel filter.
9. If there was any water or other liquid in the water
separator, repeat 6 to 8.
18 - 18 9823/1650-1 18 - 18
09 - Filter
09 - Filter
Contents Page No.
18-09-00 General ........................................................................................................................... 18-21

18-09-03 Filter Element ................................................................................................................. 18-26
18-09-09 Pre-Filter Element .......................................................................................................... 18-28
18 - 19 9823/1650-1 18 - 19
Notes:
18 - 20 9823/1650-1 18 - 20
09 - Filter
00 - General
Introduction .................................................... 18-21 The fuel filter consists of a paper element folded in
Component Identification ............................... 18-22 such a way as to give a very large surface area. It is
Operation ....................................................... 18-23 most important that the fuel filter is changed regularly
Drain and Fill ................................................. 18-23 in accordance with the machine maintenance
schedule. Use only the correct specification filters.
18 - 21 9823/1650-1 18 - 21
09 - Filter
00 - General
Figure 263.
1e 1
1f
1d
2a
2b 1a
2c 1b 1c
1 Fuel pre-filter/ water separator 1a Water bowl

1b Drain screw 1c Water level probe
1d Fuel filter element 1e Electric lift pump
1f Air bleed to tank 2 Fuel filter
2a Paper element 2b Sediment bowl
2c Drain screw
18 - 22 9823/1650-1 18 - 22
09 - Filter
00 - General
Operation Drain and Fill
Fuel is pumped into the filter and passes through 1. Make the machine safe. Refer to (PIL 01-03).
the paper element where any dirt particles or water
droplets are retained. An integral sediment bowl at 2. Drain off any water in the filter element by turning
the bottom of the filter enables water to be drained the drain tap. Any fuel and water mix drained
off by means of a drain screw. must be disposed of in accordance with local
regulations. Do not reuse the drained fuel.
Refer to fuel and exhaust system, filter, component
3. Drain off any water in the water separator bowl.
identification, (PIL 18-09).
Any fuel and water mix drained must be disposed
of in accordance with local regulations. Do not
reuse the drained fuel.
18 - 23 9823/1650-1 18 - 23
09 - Filter
00 - General
Remove and Install Remove - Disposable Type

Description Part No. Qty. E
Spanner - HP Fuel 334/G5933 1 C
Filter
Fuel Filter Removal 892/01383 1
Tool (4 cyl)
D
Before Removal
2. Get access to the filter.
A
2.1. On some machines the filter is located on
the engine. Other machines have remotely
located filters. There may be more than
one filter. Refer to the relevant service point
information for details.
2.2. There are different types of filters. Refer to B
the correct procedure. A Filter
B Drain tap
3. Thoroughly clean the outside of the filter housing C Low pressure fuel line
and around the filter head. D Screw
E Low pressure fuel line
4. Loosen the drain tap and allow the water / fuel to
drain into a suitable container. 1. Remove the low pressure fuel lines.
5. On machines with a fuel shut-off valve, set the 1.1. Put a label on the hoses to help installation.
valve to isolate the fuel supply.
Figure 264. contamination.
A
2. Release the filter strap retaining screw and lift the
filter upward.
Install - Disposable Type

1. Make sure that the filter is in the correct position
B to enable connection of the fuel lines.
2. Install the filter strap.
2.1. Tighten the filter strap to the correct torque
value.
A Fuel filter element
B Drain tap Torque: 24 N·m
3. Install the low pressure fuel lines.
3.1. Make sure they are installed at the correct
ports.
4. Open the fuel shut-off valve (if applicable).
5. Bleed the fuel system. Refer to Fuel System-
General, Discharge and Pressurise.
18 - 24 9823/1650-1 18 - 24
09 - Filter
00 - General
Remove - Element Type

Figure 266.
C
A Filter head
B Filter element
C Drain tap
1. Use the applicable service tool to unscrew the
filter element from the filter head (anticlockwise).
Special Tool: Fuel Filter Removal Tool (4 cyl)
(Qty.: 1)
Special Tool: Spanner - HP Fuel Filter (Qty.: 1)
Install - Element Type

1. Lubricate the element seals with clean fuel and
install a new filter element.
1.1. Make sure that the filter flange touches the
filter head.
1.2. Use the applicable service tool to tighten to
the correct torque value.
Torque: 35 N·m
Special Tool: Fuel Filter Removal Tool (4
cyl) (Qty.: 1)
Special Tool: Spanner - HP Fuel Filter (Qty.:
1)
18 - 25 9823/1650-1 18 - 25
09 - Filter
03 - Filter Element
03 - Filter Element Remove - Disposable Type

Figure 268.
Remove and Install E
Special Tools C
Spanner - HP Fuel 334/G5933 1
Filter
Fuel Filter Removal 892/01383 1 D
Tool (4 cyl)
Before Removal
you start the service work. A
2. Get access to the filter.
2.1. On some machines the filter is located on
the engine. Other machines have remotely
located filters. There may be more than
one filter. Refer to the relevant service point B
information for details. A Filter
B Drain tap
2.2. There are different types of filters. Refer to
C Low pressure fuel line
the correct procedure.
D Screw
3. Thoroughly clean the outside of the filter housing E Low pressure fuel line
and around the filter head.
1. Remove the low pressure fuel lines.
4. Loosen the drain tap and allow the water / fuel to
1.1. Put a label on the hoses to help installation.
drain into a suitable container.
5. On machines with a fuel shut-off valve, set the contamination.
valve to isolate the fuel supply.
2. Release the filter strap retaining screw and lift the
Figure 267. filter upward.
A
Install - Disposable Type
1. Make sure that the filter is in the correct position
to enable connection of the fuel lines.
2. Install the filter strap.
B
2.1. Tighten the filter strap to the correct torque
value.
Torque: 24 N·m
A Fuel filter element 3. Install the low pressure fuel lines.

B Drain tap
3.1. Make sure they are installed at the correct
ports.
18 - 26 9823/1650-1 18 - 26
09 - Filter
03 - Filter Element
Remove - Element Type

Figure 269.
C
A Filter head
B Filter element
C Drain tap
1. Use the applicable service tool to unscrew the
filter element from the filter head (anticlockwise).
Special Tool: Fuel Filter Removal Tool (4 cyl)
(Qty.: 1)
Special Tool: Spanner - HP Fuel Filter (Qty.: 1)
Install - Element Type

1. Lubricate the element seals with clean fuel and
install a new filter element.
1.1. Make sure that the filter flange touches the
filter head.
1.2. Use the applicable service tool to tighten to
Torque: 35 N·m
Special Tool: Fuel Filter Removal Tool (4
cyl) (Qty.: 1)
Special Tool: Spanner - HP Fuel Filter (Qty.:
1)
18 - 27 9823/1650-1 18 - 27
09 - Filter
09 - Pre-Filter Element
09 - Pre-Filter Element Introduction

Introduction .................................................... 18-28 The fuel pre-filter with water separator is installed on
Remove and Install ....................................... 18-29 to the fuel lift pump. The fuel lift pump is a sealed
integral electrical unit.
18 - 28 9823/1650-1 18 - 28
09 - Filter
09 - Pre-Filter Element

Remove removal procedure. Additionally do the following
steps.
2. Install a new filter element and secure in position
2. Get access to the filter. with the locking ring.
3. On machines with a fuel shut off valve, set the 3. Make sure that the water in fuel electrical
valve to isolate the fuel supply. connector is correctly installed.
4. Drain the water separator bowl. 4. On machines with a fuel shut-off valve, set the
valve to connect the fuel supply.
5. Disconnect the water in fuel sensor.
6. Release the locking ring and remove water
separator bowl. Any fuel and water mix drained
must be disposed of in accordance with local
regulations. Do not reuse the drained fuel.
7. Release the locking ring and remove the filter
element, discard the element.
Figure 270.
E
A Filter Element
B Filter element locking ring
C Water separator bowl locking ring
D Water separator bowl
E Water in fuel electrical connector
18 - 29 9823/1650-1 18 - 29
12 - Water Separator
Contents Page No.
18-12-00 General ........................................................................................................................... 18-31

18-12-04 Water in Fuel Sensor ..................................................................................................... 18-34
18 - 30 9823/1650-1 18 - 30
00 - General
Introduction .................................................... 18-31 The water separator with fuel pre-filter and the fuel
Drain and Fill ................................................. 18-32 lift pump is a sealed integral electrical unit. The
Clean ............................................................. 18-32 assembly is a non-serviceable component. If any
Remove and Install ....................................... 18-33 part is defective, replace the complete pump, filter
and separator assembly.
Figure 271.
A Fuel lift pump

B Fuel pre- filter
C Water separator
The pre-filter/water separator is designed to separate

water and dirt from the fuel using a special chemically
treated paper filter element. A bowl installed in the
bottom of the trap collects the water removed from
the fuel.
The bowl is installed with an electric probe which

senses when the water is above a preset level.
The probe enables a suitable alarm/indicator device.
Water can be drained off by means of the drain screw
installed in the base of the bowl. It is essential that
the water trap is drained regularly. Water must be
drained immediately if the probe signals an alarm.
Refer to fuel and exhaust system, filter, component

identification, (PIL 18-09).
18 - 31 9823/1650-1 18 - 31
00 - General
Drain and Fill Clean

1. Obey all fuel system health and safety
information.
Draining the Water Separator
Refer to: PIL 18-00-00. 1. Make the machine safe.
2. Make the machine safe. 2. Get access to the filter.

Refer to: PIL 01-03. 3. If there is water but no sediment, open the tap
to drain the water. If there is any sediment in
3. Drain off any water in the filter element by turning the bowl replace the fuel filter element. Do not
the tap. disconnect the electrical connector (if installed).
4. Drain off any water in the water separator bowl 4. Tighten the drain tap when all the water is
by turning the tap. Do not disconnect the water drained.
in fuel electrical connector (if installed).
Figure 273.
5. If there is sediment in the bowl after draining,
support the bowl and release the locking ring.
6. Wash the bowl in clean fuel.
7. Install the bowl, secure in position with the
locking ring.
8. Make sure that the water in fuel electrical
connector is correctly installed.
Figure 272. Typical Engine
A
B
B
A Tap
B Bowl
A Fuel filter
B Drain tap
18 - 32 9823/1650-1 18 - 32
00 - General
Remove and Install
Refer to Fuel and Exhaust system - Filter - Pre-Filter

Element. Refer to: PIL 18-09.
18 - 33 9823/1650-1 18 - 33
04 - Water in Fuel Sensor
04 - Water in Fuel Sensor Introduction

Introduction .................................................... 18-34 The water in fuel sensor is installed in the fuel
Remove and Install ....................................... 18-35 filter water bowl. A warning light will illuminate in
the instrument panel to indicate that water has
accumulated in the fuel filter water bowl and must be
drained.
18 - 34 9823/1650-1 18 - 34
04 - Water in Fuel Sensor
Remove and Install
Remove
2. Remove the ignition key.
3. Get access to the fuel filter.
4. Disconnect the electrical connections.
5. Remove the sensor fixing screw.
6. Remove the sensor.
Figure 274.
A 1
1 Fixing screw
2 Electrical connections
A Water in fuel sensor
Install
removal procedure.
18 - 35 9823/1650-1 18 - 35
18 - Injection
18 - Injection
Contents Page No.
18-18-00 General ........................................................................................................................... 18-37

18-18-03 Injector ............................................................................................................................ 18-52
18-18-07 Injector Seal ................................................................................................................... 18-57
18-18-12 Rail ................................................................................................................................. 18-59
18-18-15 Pump .............................................................................................................................. 18-61
18-18-27 High Pressure Rail Valve ............................................................................................... 18-68
18 - 36 9823/1650-1 18 - 36
18 - Injection
00 - General
Introduction .................................................... 18-37 Fuel at rail pressure is continuously supplied to the
Component Identification ............................... 18-38 injectors via high pressure fuel pipes.
Operation ....................................................... 18-39
Fault-Finding .................................................. 18-42 The high pressure fuel injector fuel pipes consist
of thick walled, seamless steel tubing. The ends of
Check (Operation) ......................................... 18-49 the tubes are formed with conical nipples for sealing
Calibrate ........................................................ 18-51 in the sealing cones on the common rail and on
the injector at port. It is essential that the tubes
are maintained and installed correctly for safe and
effective engine operation.
Important: If the high pressure fuel pipes are

removed for any reason they must be renewed.
Installing the original fuel pipes will cause fuel leaks
at the pipe connections.
Fuel injection takes place when the solenoid coil is

energised by the ECM (Engine Control Module).
Combustion
The engine employs a direct injection system. Fuel
is injected directly into the cylinder, the mixing taking
place in the combustion chamber which is recessed
into the crown of the piston.
The process of mixing starts during the induction

stroke and continues throughout the compression
stroke. The inlet porting and combustion chamber
are carefully designed to ensure that when the fuel
is injected it is mixed thoroughly with the air.
The multi-point injector and high injection pressure

ensure a good distribution of fuel throughout the air
which aids mixing. The mixing process continues
until combustion is complete.
To further enhance efficient combustion, the ECM

initiates several separate injections of fuel during the
compression stroke. The timing of the fuel injections
is also varied by the ECM depending on engine
operating parameters.
18 - 37 9823/1650-1 18 - 37
18 - Injection
00 - General
Figure 275.
3
2
15
A
6 6 6 6
14
13
1 16
1 ECM (Engine Control Module)(refer to PIL 2 High pressure fuel injection pump (refer to PIL
33-45) 18-18)
3 Common fuel rail (refer to PIL 18-18) 6 Fuel injectors (refer to PIL 18-18)
13 Fuel filter (2 micron) (refer to PIL 18-09) 14 Fuel pre-filter and water separator (5 micron)
(refer to PIL 18-12)
15 Electric feed pump (refer to PIL 18-21) A Electrical sensors (refer to PIL 15-84)
B Fuel tank (refer to PIL 18-03)
18 - 38 9823/1650-1 18 - 38
18 - Injection
00 - General
Operation
Fuel Injection Cycle
Figure 276.
TDC 2 3
5
4
C1 C2
D1 D2 6
1 ECM (Engine Control Module) 2 Camshaft position sensor

3 Camshaft target disc 4 Crankshaft position sensor
5 Crankshaft mounted target disc 6 Fuel injector
A Camshaft sensor signal - Signal is B Crank position sensor signal - Signal is
generated by camshaft target disc 3 and generated by crankshaft mounted target
sensor 2. Processed by the ECM 1 to disc 5 and sensor 4. Processed by the
determine which cylinder to inject. ECM 1 to determine timing of injection.
C1-C2 Current pulse - injector solenoid coil - D1-D2 Fuel Injection - Start and duration of
Sent to the injector (6) solenoid coil by actual injection. It can be seen that
the ECM 1 to initiate injection. Time of there is a time shift between the current
pulse calculated by the ECM to control pulse and actual injection. This is
the amount of fuel injected. Pulse C1 due to electrical resistance and the
controls pilot injection. Pulse C2 controls individual characteristics on the fuel
the main injection. injector assembly 6. D1 indicates the
pilot injection and D2 the main injection.
Total fuel injected for one cycle = D1 +
D2.
TDC Top dead centre - Shows when piston
is at top dead centre in relation to the
injection sequence.
18 - 39 9823/1650-1 18 - 39
18 - Injection
00 - General
Injection Cycle to bleed from the control chamber and ultimately

back to the fuel tank via the bleed off lines.
It is important to remember that the injector solenoid
coil does not directly lift the injector needle. Instead Although the control chamber is still connected to the
it operates a tiny valve which causes a fuel pressure rail pressure different sized metering orifices K and
imbalance inside the injector. In this way the needle L cause the pressure in the chamber to fall below
is lifted hydraulically. The method of operation is as the rail pressure. The metering orifice ensures full rail
follows: pressure is maintained in the chamber around the
needle.
State 1 - No fuel injection
When the pressure imbalance in the chambers is
The solenoid coil is not energised. Fuel at rail sufficient to overcome spring the needle lifts and
pressure fills the small chamber around the needle. injection begins.
Fuel at rail pressure also fills the control chamber.
Since the surface area of the needle inside the Figure 278.
control chamber is greater than the area inside
chamber the needle is held on its seat by hydraulic
(fuel) pressure. Spring holds the needle on its seat
when the engine is stopped (when the rail pressure
is low or zero).
Figure 277. F
E
L R
K
F
J
M
J
Q
B
B Needle
E Spool valve
Q F Solenoid coil
J Spring
B K Metering orifice
L Metering orifice
M Metering orifice
B Needle Q Small chamber
F Solenoid coil R Control chamber
J Spring
Q Small chamber State 3 - Fuel injection
R Control chamber
When the flow of fuel to the injection nozzle is
State 2 - Fuel injection start established the metering orifice causes a pressure
drop in the small chamber. Since the needle is now
At the commencement of fuel injection the solenoid lifted its surface area subjected to the pressure in the
coil is energised by the ECM.The solenoid coil lifts small chamber is increased. The force is sufficient to
spool valve off its seat. Fuel at rail pressure is allowed keep the needle lifted.
18 - 40 9823/1650-1 18 - 40
18 - Injection
00 - General
H
G
M M
Q Q
B B
B Needle B Needle
M Metering orifice E Spool valve
Q Small chamber F Solenoid coil
G Spring
State 4 - Fuel injection stop H Calibration dowel
J Spring
To stop fuel injection the ECM de-energises the M Metering orifice
solenoid coil. The spool valve is pushed on to its seat Q Small chamber
by the force of the spring. Fuel no longer bleeds from R Control chamber
the control chamber.
A calibration dowel, selected during manufacture, is

used to finely set the force from the spring.
Fuel pressure inside the control chamber reaches

the rail pressure. Since the needle is lifted its
surface area under pressure from the fuel in the
small chamber is increased. Force from the fuel in
the control chamber is now insufficient to push the
needle on to its seat.
The only way to push the needle on to its seat is

to reduce the fuel pressure in the small chamber.
This is achieved by the metering orifice. As fuel flows
through the metering orifice a pressure drop in the
small chamber is produced. The needle is forced on
to its seat by pressure in the control chamber. Fuel
injection stops.
18 - 41 9823/1650-1 18 - 41
18 - Injection
00 - General
Fault-Finding
Fault
Injector Calibration Table 126. Page 18-42
Injector Trim Codes Table 127. Page 18-42
Open Circuit Injector Table 128. Page 18-43
Injection Bank Table 129. Page 18-43
Short Circuit Injector Table 130. Page 18-44
Engine Low on Power Table 131. Page 18-44
Injector Calibration Table 132. Page 18-45
Open Circuit Injector Table 133. Page 18-45
High Pressure Injection Diagnostics Table 134. Page 18-46
Fuel Rail Pressure Calibration Table 135. Page 18-46
IMV Table 136. Page 18-47
HPV Table 137. Page 18-47
Table 126. Injector Calibration

Cause Remedy
Old/incorrect software version Check if the software is up to date or new software
that will solve this problem is available. Upgrade as
necessary. Re-flash the injector calibration codes,
respecting power down and up delay and taking care
of injector position; erase all the faults.
If no fault is found proceed to 'Injector cylinder
position and value fault'
Injector cylinder position and value fault Check that ‘individual injector corrections’ are
correctly entered in ECM (Engine Control Module).
Check the cylinder position and value.
If no faults is found, proceed to 'Injector program
fault'.
Injector program fault Re-flash the injector calibration codes, respecting
power down and up delay and taking care of injector
position; erase all the faults.
Electrical connection faulty Check the knock sensor connection and screw
torque, repair as necessary. Note: Check the ground
shield connection of knock sensor.
If no knock sensor is installed, raise Techweb
Helpdesk call.
Table 127. Injector Trim Codes

Cause Remedy
Sensor connection fault Check the following sensors and make sure they
work correctly. – Knock sensors – Water temperature
sensor – Air temperature sensor – Fuel temperature
sensor – Barometric pressure sensor (built inside the
ECM.
Check the knock sensors connection and screwing
torque (Check particularly the ground shield
connection). Repair as necessary and re-enter all
injector calibration codes (read then write) in correct
position to reset learned parameters.
If no fault is found proceed to 'Knock sensors ground
fault'.
Knock sensors ground fault Check the grounding of knock sensors, repair as
necessary.
If no fault is found proceed to ECM connection fault'.
18 - 42 9823/1650-1 18 - 42
18 - Injection
00 - General
Cause Remedy
ECM connection fault Disconnect the harness from ECM and inspect.
Check seals are in place, check for signs of corrosion
or contamination.
If ECMpins are damaged, replace ECM and re-flash
necessary.
insulation, repair/replace as necessary.
If no fault is found proceed to 'Injector calibration
codes faulty'.
Injector calibration codes faulty Check the injector calibration codes recorded inECM,
if found fault re-enter all injector calibration codes
(read then write) in correct position to reset learned
parameters.
If the injector calibration codes are OK, test the
vehicle on road and check the Defect Trouble Code
(DTC) again with the diagnostic tool. If the problem is
still present change the knock sensor.
Table 128. Open Circuit Injector

Cause Remedy
Fuel injector fault Perform the injector buzz test, if the injector is faulty
it will not produce a buzzing sound. In such instances
raise Techweb Helpdesk call.
If no fault is found proceed to 'Injector connection
fault'.
Injector connection fault Check the resistance of injector – For solenoid, it
should be less than 1 ohm.
If the resistance is incorrect, change the injector and
calibrate it.
If no fault is found proceed to 'Electrical/ECM
connection fault'.
ElectricalECM connection fault Disconnect the harness from engine ECM and
necessary.
Table 129. Injection Bank

Cause Remedy
Injector connection fault Check the injector connections corresponding to
faulty bank, repair as necessary.
If no fault is found proceed to 'Injector faulty'.
Injector faulty Check all the injectors individually. Replace the
injector and re-calibrate the ECM with the trim file of
the new injector.
If no fault is found proceed to
'Electrical/ECMconnection fault'.
18 - 43 9823/1650-1 18 - 43
18 - Injection
00 - General
Cause Remedy
Electrical/ECM connection fault Disconnect the harness from engineECM and
If ECM pins are damaged, replaceECM and re-flash
appropriate calibration (see Re-flashing anECM).
necessary.
Table 130. Short Circuit Injector

Cause Remedy
it not will produce a buzzing sound. In such instances
fault'.
Injector connection fault Disconnect the injector (one by one) to see if the fault
disappeared. Repair/ replace as necessary.
Disconnect the engine harness inter connect plug
it to see if the fault disappears. Repair/replace as
necessary.
connection fault'.
ElectricalECM connection fault Disconnect the harness from engine ECM and
IfECM pins are damaged, replaceECM and re-flash
appropriate calibration (see Re-flashing an ECM).
Table 131. Engine Low on Power

Cause Remedy
Injector fault - electrical If an electrical injector fault is present raise Techweb
Helpdesk call.
fault'.
Injector connection fault Check the Individual Injector Corrections and injector
connections. If the problem with C3I or injector
connection is evident,replace/repair as necessary.
If no fault is found proceed to 'Fuel rail pressure'.
Fuel rail pressure Check the fuel rail pressure.
If no fault is found proceed to 'Engine Cylinder
compression fault'.
Engine Cylinder compression fault Run the compression test (automatic or manual),
if any of the engine cylinder pressure is not in the
limits, repair/replace as necessary.
If no fault is found proceed to 'Blocked inlet tubes'.
18 - 44 9823/1650-1 18 - 44
18 - Injection
00 - General
Cause Remedy
Blocked inlet tubes Check the fuel lines for any blockage and
contamination. Clean the fuel lines as necessary.
If no fault is found proceed to 'Injector faulty'.
Injector faulty Swap the injectors with another. Re-write the trim
codes. Replace/repair as necessary and re-flash the
injector calibration codes.
Table 132. Injector Calibration

Cause Remedy
Injector calibration fault Re-write the injector calibration codes allowing the
power down and up delay and taking care of injector
position, erase the faults.
If no fault is found proceed to 'Power relay operation
fault'.
Power relay operation fault Check the power relay operation, repair the relay or
wiring as necessary.
If no fault is found proceed to 'ECM connection fault'.
Check the harness continuity and electrical
necessary.
Table 133. Open Circuit Injector

Cause Remedy
it will not produce a buzzing sound. In such instances
fault'.
Injector connection fault Check the resistance of injector. – For solenoid, it
should be less than 1 Ohm.
If the resistance is incorrect, change the injector and
calibrate it.
connection fault'.
ElectricalECM connection fault Disconnect the harness from engineECM and
IfECM pins are damaged, replace ECM and re-flash
appropriate calibration (see Re-flashing anECM).
necessary.
18 - 45 9823/1650-1 18 - 45
18 - Injection
00 - General
Table 134. High Pressure Injection Diagnostics

Cause Remedy
Pressure diagnostics fault Check the fault of type IMV (Inlet Metering Valve)
or HPV (High Pressure Valve) (if applicable) or rail
pressure sensor, repair the corresponding fault.
If no fault is found proceed to 'High pressure system
fault'.
High pressure system fault Read the Diagnostic Trouble Code (DTC).
Connect the battery booster.
If the DTC links to high pressure control: – Check
the fuel feed circuit is in good condition – Check the
diesel fuel is present in the system – Check there is
no air bubbles or emulsion in the pipes – Check there
is enough fuel pressure in the inlet pump – Check
there are no high pressure circuit leaks – Check the
quality and type of the diesel fuel.
If the low pressure circuit is faulty, repair the low
pressure circuit.
If no faults are found, proceed to 'Engine does not
start' or 'Engine starts' depending on symptoms,
replace the corresponding injectors.
Engine does not start Perform the ‘Dynamic IMV Test’.
If the IMV is faulty replace the IMV.
If the IMV is OK complete the ‘Dynamic Injector Back
leak Test’
If the back leak is above the limit, replace the
corresponding injector(s).
If the back leak is OK complete the ‘Pump Pressure
Build Capacity Test’
If the pump capacity is below the limit, replace the
high pressure pump.
If the pump capacity is OK, raise Techweb Helpdesk
Call.
Table 135. Fuel Rail Pressure Calibration

Cause Remedy
repair/replace as necessary.
If no fault is found, proceed to 'ECM connection fault'.
necessary.
If no fault is found proceed to 'Sensor failure'.
page). If sensor is out of specification replace, the
sensor.
fault'.
18 - 46 9823/1650-1 18 - 46
18 - Injection
00 - General
Cause Remedy
ECM connection fault Disconnect the harness from engine ECU (Electronic
Control Unit) and inspect. Check seals are in place,
check for signs of corrosion or contamination.
necessary.
If no fault is found proceed to 'Rail pressure sensor
and rail fault'.
Rail pressure sensor and rail fault Replace the rail pressure sensor and rail.
If the problem still not solved, raise Techweb
Helpdesk call.
Table 136. IMV

Cause Remedy
IMV (Inlet Metering Valve) connection fault Check the connection to IMV
If the IMV connection is faulty, replace the high
Pressure fuel injection pump.
If no fault is found proceed to 'ECM connection fault'.
ECMconnection fault Disconnect the harness from engine ECM and
If ECM pins are damaged, replace ECMand re-flash
necessary.
If no fault is found proceed to 'Electrical resistance
fault'.
Electrical resistance fault Measure the IMV electrical resistance around 5.3
ohms at 20 degrees C.
replace the high Pressure fuel injection pump if the
resistance fault occurs.
If no fault is found proceed to IMV buzz fault'.
IMV buzz fault Perform the IMV buzz test. If the IMV is not buzzing
replace the high Pressure fuel injection pump.
If the IMV buzzes, raise Techweb Helpdesk call.
Table 137. HPV

Cause Remedy
HPV (High Pressure Fuel Valve) connection fault Check the connection of HPV
If the HPV connection is faulty, repair or replace as
necessary.
If no fault is found proceed to ECMconnection fault'.
ECM connection fault Disconnect the harness from engineECM and
IfECM pins are damaged, replace ECM and re-flash
necessary.
18 - 47 9823/1650-1 18 - 47
18 - Injection
00 - General
Cause Remedy
If no fault is found proceed to 'Electrical resistance
fault'.
Electrical resistance fault Measure the HPVelectrical resistance, it should be
around 2.2 ohms at 25 degrees C.
If the electrical resistance is OK, replace the rail and
HPV.
If no fault is found proceed to 'HPV buzzing fault'.
HPV buzzing fault Perform the HPV buzz test. If theHPV is not buzzing
replace the rail and HPV.
If the HPV buzzes, raise Techweb Helpdesk call.
18 - 48 9823/1650-1 18 - 48
18 - Injection
00 - General
Check (Operation) Figure 281. Injector leak off test kit
Special Tools
Servicemaster 721/10855 1
Electronic Test Cable
Servicemaster 892/01033 1*
Electronic Test Kit 892/01174
Data Link Adaptor
(DLA) Kit
Injector Leak-off Test 892/12350 1
Kit ((Electronic Engine))
Injector Cap Kit 892/12359 1
*Unless otherwise stated, you can use any of the
tools shown.
To test the fuel injection system, there are two test

options available. Actuator tests, which supply a
voltage signal to the actuators and diagnostic tests Fuel System Diagnostic Test (Cranking only)
which require the engine to be cranked or started.
This test can be found in the fuel system diagnostic
Static Actuator Tests test (cranking) tab in the EcoMax engine test section
on the engine diagnostic tool within Servicemaster.
The IMV (Inlet Metering Valve), HPV (High Pressure This test closes the injectors, opens the IMV and
Valve) and the injectors can each be tested using the controls the rail pressure using the HPV.
engine diagnostic tool within Servicemaster.
1. Connect the fuel leak off test kit, ensure all open
The IMV test can be found under the fuel system tab fuel pipes are capped.
in EcoMax actuators section. The test sends a signal
to theIMV, normally the IMV can be heard operating Special Tool: Injector Leak-off Test Kit
and the test results will be displayed. ((Electronic Engine)) (Qty.: 1)
Special Tool: Injector Cap Kit (Qty.: 1)
The HPV test can be found under the fuel system
2. Use Servicemaster to control the tests and follow
tab in EcoMax actuators section. The test sends a
the on screen instructions in Servicemaster.
signal to the HPV, normally the HPV can be heard
operating. Special Tool: Servicemaster Electronic Test Kit /
Data Link Adaptor (DLA) Kit (Qty.: 1)
The injector test can be found under the injector test Special Tool: Servicemaster Electronic Test
tab in EcoMax actuators section. The test sends a Cable (Qty.: 1)
signal to each individual injector, normally the injector
can be heard operating. 3. Measure the quantity of diesel fuel obtained in
the leak off kit.
Diagnostic Tests 4. Replace the injectors whose back leak exceeds
the value given in the Servicemaster reference
To diagnose fuel system faults the return flow from table.
the fuel system must be measured using the fuel
Injector leak off test kit. Refer to Injector-Check 5. Replace the fuel rail if the HPV return volume
Operation (PIL 18-18). exceeds the value given in the Servicemaster
help file. Note: The HPV is a non-serviceable
There are two sets of dynamic tests, one for when part.
the engine does not start (Cranking only) and one for
when the engine does start (Engine running). 6. After each replacement confirm the results by re-
testing.
7. If the leak off volumes are within limits and the
maximum rail pressure during the test is below
500 bar this indicates the high pressure pump
capacity may be low.
18 - 49 9823/1650-1 18 - 49
18 - Injection
00 - General
Fuel System Diagnostic Tests (Engine 1. Warm the engine to over 60°C (depending on
Running) the application) and the fuel temperature to over
20°C to be able to start the cycle.
These tests can be found in the fuel system
diagnostic test (engine running) tab in the ecomax 2. Connect the HPV leak off bottle, make sure all
engine test section on the engine diagnostic tool open fuel pipes are capped.
within Servicemaster. 3. Use Servicemaster to control the tests and follow
IMV Dynamic test
4. Measure the quantity of diesel fuel obtained in
1. Warm the engine to over 60°C (depending on
the HPV leak off bottle.
the application) and the fuel temperature to over
20°C to be able to start the cycle. 5. Replace the fuel rail if the HPV return volume
exceeds the value given in the Servicemaster
part.
3. Check status. If test OK, it should report
6. After each replacement confirm the results by re-
Diagnosis finished and no problem detected.
testing.
If the test indicates it is not OK (status
report Diagnosis finished and problem detected).
Replace the High pressure pump. Note: The IMV
is a non-serviceable part.
High Pressure IMV Diagnostic test
This test is designed to check the fuel system by

controlling the rail pressure using the IMV only.
Excessive HPV. Leak off indicates a leaking HPV,
excessive leak off from the injectors indicates a faulty
injector.
1. Warm the engine to over 60°C (depending on

the application) and the fuel temperature to over
20°C to be able to start the cycle.
2. Connect the fuel leak off test kit, make sure all
open fuel pipes are capped.
4. Measure the quantity of diesel fuel obtained in
the leak off kit.
5. Replace the injectors whose back leak exceeds
the value given in the Servicemaster reference
table.
6. Replace the fuel rail if the HPV. return volume
exceeds the value given in the Servicemaster
part. Make sure you replace the high pressure
fuel pipes at the same time.
7. After each replacement confirm the results by re-
testing.
High Pressure FIE HPV Test
This test is designed to check the fuel pump capacity

by opening the IMV fully and controlling the rail
pressure using the HPV. Leak off flow from the HPV
indicates the high pressure pump capacity.
18 - 50 9823/1650-1 18 - 50
18 - Injection
00 - General
Calibrate
recorded in code form and attached to the injector

Since the injector operating components are by body.
necessity very small, even the most advanced
manufacturing techniques do not ensure consistent The codes for each injector installed to the engine are
injection cycle characteristics between injectors. programmed into the ECM (Engine Control Module).
The operating software in the ECM uses the data
For example, small variations in the metering orifice to adjust the control of the injector solenoid coil
sizes will alter the time durations for the start and accordingly. The injector is therefore effectively re-
stop of fuel injection. The small dimensions involved calibrated by the ECM.
mean that only a tiny variation will alter the orifice
area by a relatively large percentage. It follows that if injectors are removed they must
always be installed in their original positions. If
For this reason it is necessary to individually test and new injectors are installed the ECM must be
record the operating characteristics of each injector reprogrammed with the new injector codes.
assembly at the factory. The results of the test are
Figure 282.
18 - 51 9823/1650-1 18 - 51
18 - Injection
03 - Injector
03 - Injector Introduction
Introduction .................................................... 18-52 The fuel Injectors are electronically controlled and
Component Identification ............................... 18-53 incorporate a small solenoid valve. The injectors are
Check (Operation) ......................................... 18-53 supplied with pressurised fuel by the high pressure
Remove and Install ....................................... 18-54 fuel injection pump and when energised, the injector
atomizes the fuel into a fine mist so that it can burn
easily by the vehicle’s engine.
The fuel injectors are mounted in the inlet manifold

so that fuel is sprayed directly at the inlet valves. A
fuel supply rail connects all of the fuel injectors to the
fuel supply.
The injector tips are located inside the combustion

chambers, so effective cooling is essential. A special
thin walled sleeve is screwed into the cylinder head
which allows a coolant jacket close to the injector.
The coolant jacket is sealed at the bottom by sealant
on the sleeve thread and at the top by O-ring.
Figure 283.
52 5 1 4
1 Injector
2 Sleeve
3 Cylinder head
4 Coolant jacket
5 Sleeve thread
6 O-ring
18 - 52 9823/1650-1 18 - 52
18 - Injection
03 - Injector
Component Identification Check (Operation)

Special Tools
Figure 284. Description Part No. Qty.
Injector Leak-off Test 892/12350 1
N Kit ((Electronic Engine))
H
Injector Cap Kit 892/12359 1
G
The injectors can be tested using Servicemaster
D F diagnostics and by means of a leak off test. To test
M for a defective injector first use Servicemaster to
diagnose the problems with the high pressure fuel
E injection equipment, specifically when the engine
does not start.
C
Leak Off Test
J
The leak off test kit must be installed on the engine
and the ServiceMaster must be used to test the
engine.
1. Operate the engine until it reaches its normal

operating temperature.
2. Stop the engine. Remove the bleed off pipe at
B each injector. Refer to (PIL 18-96). Cap the open
connectors on the pipes with the caps in the
A injector leak off test kit.
Special Tool: Injector Leak-off Test Kit
((Electronic Engine)) (Qty.: 1)
Special Tool: Injector Cap Kit (Qty.: 1)
3. Connect the test pipes to the leak off ports on the
L four injectors.
4. Position the four plastic bottles as upright as
possible. Keep the test equipment clear of
A Multi-point injector nozzle components that get hot when the engine is
B Needle operated.
C Spacer
5. Connect a test pipe to the leak off ports on the
D Nut
High Pressure valve outlet. Cap the open pipe.
E Valve
F Solenoid coil 6. Make sure it is safe to start the engine.
G Valve spring
H Calibration dowel 7. Use ServiceMaster to control the tests. Refer to
J Injector spring Fuel Injection - Check Operation (PIL 18-18).
L Electrical connector
M Return port (bleed off) 7.1. Fuel System Diagnostic Test (Cranking
N High pressure port and filter element Only).
7.2. Fuel System Diagnostic Tests (Engine
Running).
8. Examine the fuel levels in the test bottles. If the
difference between any of the levels is more than
10 ml. this indicates that there are one or more
defective injectors.
9. Remove the test equipment and replace the
bleed off pipes. Refer to (PIL 18-96).
18 - 53 9823/1650-1 18 - 53
18 - Injection
03 - Injector
Figure 285. Remove and Install

B
The following procedure is for one injector, the
A procedures are identical for all injectors.
Note: The original injector calibration codes are

located on a label on the rocker cover.
A
Before Removal
A
A 4. Remove the fuel bleed off fuel pipes. Refer to

6. Record which injector is for which cylinder. The
injectors must be installed in the same positions.
Note: If a fuel injector is defective, it must be

replaced.
Remove
1. Remove the injector clamp retaining bolt and lift
the clamp away.
A Injectors (x4)
B HP valve
18 - 54 9823/1650-1 18 - 54
18 - Injection
03 - Injector
4 X 1 5
2
1 Injector
2 Injector clamp
3 Retaining bolt
4 Injector sleeve
X Injector bleed-off port 6
2. Remove and discard the sealing washer. Label
the injector to make sure it is installed in its
original cylinder. Put a clean protective cap over
the nozzle of the injector. 7
3. Remove and discard the O-ring.
5 Protective cap
6 Protective cap
7 Sealing washer
Install
Important: The fuel injectors are not interchangeable
between cylinders or other engines. Make sure you
install the injectors in the same positions. If a new
or different injector is installed, the engine electronic
control unit (ECU) must be re-programmed. Refer to
(PIL 33-45), Engine Electronic Control Unit, Vehicle
Set Up Data.
When new or different injectors are installed, record

the calibration code. Record which cylinder the
injector is installed into. Refer to (PIL 33-45), Engine
Electronic Control Unit, Vehicle Set Up Data.
18 - 55 9823/1650-1 18 - 55
18 - Injection
03 - Injector
Figure 288. Table 138. Torque Values

Item Nm
A 3 28
4 39
D
C
A Correction factor (20 characters)

B Manufacturers reference
C JCB part number
D Injector serial number
steps.
2. Clean off any sludge or oil from the inner bore
of the injector sleeve. Make sure you do not
damage the surface of the bore. Any damage
or surface contamination will cause the injector
sealing O-ring to fail.
3. Install a new O-ring.
4. Install a new sealing washer.
5. Make sure that the injector is installed in the
correct orientation, with the bleed-off port facing
the right hand side (exhaust manifold) of the
engine. Make sure the injector is pushed fully into
the cylinder head.
6. Tighten the injector clamp bolt to the correct
torque value.
After Installation
1. Replace the rocker cover, refer to (PIL 15-42).
2. Renew the high pressure fuel pipes, Refer to Fuel
Pipes (PIL 18-96).
3. Replace the low pressure fuel pipes, Refer to
4. Start the engine and check for fuel leaks.
18 - 56 9823/1650-1 18 - 56
18 - Injection
07 - Injector Seal
07 - Injector Seal
Remove and Install
Special Tools Before Removal

Injector Seal 892/12346 1 1. Make sure that the engine is safe to work on. If
Installation Tool the engine has been running, let it cool before
(Electronic Engine) you start the service work.
Injector Sleeve 892/12348 1 2. Clean the engine. Refer to Engine- Clean (PIL
Installation/Removal 15-00).
Tool
Figure 289.
D
A Rocker cover B Bolts

C Gasket D Injector seals
18 - 57 9823/1650-1 18 - 57
18 - Injection
07 - Injector Seal
Remove Figure 291.
1. Get access to the engine. E

Fuel Pipes (PIL 18-96). F
3. Remove the rocker cover from the cylinder head.

4. Put wooden supports under the rocker cover and
tap out the injector seals using the special tool.
Discard the seals. G
Special Tool: Injector Seal Installation Tool E Injector seal installation tool
(Electronic Engine) (Qty.: 1) F Injector seals
G Wooden supports
Figure 290.
4. Renew the rocker cover gasket.
F E
5. Prevent damage to the seals. Put sleeves/covers
on the injectors. Apply a rubber lubricant to the
seals.
Special Tool: Injector Sleeve Installation/
Removal Tool (Qty.: 1)
6. Install the rocker cover. Refer to (PIL 15-42).
G
After Installation
E Injector seal installation tool
F Injector seals 1. The high pressure fuel pipes must be replaced
G Wooden supports with new parts. Refer to Fuel Pipes (PIL 18-96).
Install 2. Start the engine and check for oil and fuel leaks.

steps.
2. Remove all oil and sludge contamination from
inside the valve chamber.
3. Renew the injector seals. Put supports under the
rocker cover and tap in the new seals using the
special tool.
Special Tool: Injector Seal Installation Tool
(Electronic Engine) (Qty.: 1)
18 - 58 9823/1650-1 18 - 58
18 - Injection
12 - Rail
12 - Rail Introduction
Introduction .................................................... 18-59 The fuel rail also known as a common rail, is a
Remove and Install ....................................... 18-60 pipe resembling a rail that is used to deliver fuel
to individual fuel injectors on internal combustion
engines. It is designed to have an outlet for each
injector, an inlet for a fuel supply and an outlet for a
fuel bleed off.
The fuel rail also incorporates an attached fuel

pressure sensor and a fuel valve. DO NOT
remove the high pressure fuel valve or the fuel
pressure sensor from the rail. If these components
are defective replace the complete common rail
assembly.
Figure 292.
A B
F
E
D
A Fuel pressure sensor

B Outlet
C Bleed off
D High pressure fuel valve
E Inlet
F Rail assembly
18 - 59 9823/1650-1 18 - 59
18 - Injection
12 - Rail

A B
Before Removal
C
1. Obey all fuel system health and safety
information. Refer to (PIL 18-00).
E F
2. Make sure that the engine is safe to work on. The
engine must cool and pressure in the fuel system
must decay before you start work. If the engine E
has been running, wait at least one hour before D
you start work.
A Fuel pressure sensor
3. Clean the engine. Refer to Engine-Clean (PIL B High pressure fuel pipe
15-00). C Fuel bleed off pipe
4. Remove the high pressure fuel pipes. Refer to D High pressure fuel valve
Fuel Pipes (high pressure) - Remove and Install E Bolts
(PIL 18-96). F Rail assembly
5. Remove the fuel bleed off pipe at the rail. Refer to Table 139. Torque Values
Fuel Pipes (low pressure) - Remove and Install Item Nm
(PIL 18-96). C 24
Remove
1. Disconnect the electrical connector at the high
pressure fuel valve.
2. Disconnect the electrical connector at the fuel
pressure sensor.
3. Remove the bolts and lift off the common rail
assembly.
Seal the common rail assembly inside a clean plastic

bag until it is ready for use. If the assembly is
defective discard it and get a new one.
Install
steps.
When renewing the rail assembly make sure to

replace all of the high pressure fuel pipes. Refer to
(PIL 18-96).
18 - 60 9823/1650-1 18 - 60
18 - Injection
15 - Pump
15 - Pump Introduction
Introduction .................................................... 18-61 The high pressure fuel injection pump is a rotary
Component Identification ............................... 18-62 type device that pumps fuel into the cylinders of
Operation ....................................................... 18-62 the engine. The pump is driven indirectly from the
Remove and Install ....................................... 18-64 crankshaft by gears.
18 - 61 9823/1650-1 18 - 61
18 - Injection
15 - Pump

Figure 294. The high pressure fuel injection pump is driven via a
7 8 2 10 gear on the engine and rotates at half engine speed.
The pump comprises of two sections, the transfer
pump and the high pressure pump.
1
9 Although the pump does not control fuel injection
timing, it is still timed in relation to engine phasing.
12 3 By timing the pump pressure pulses, the load on the
engine timing gears is reduced together with reduced
mechanical noise.
Transfer Pump Operation

The integral transfer pump is a vane type. An engine
driven rotor houses four vanes in slots. The rotor
13 rotates inside an eccentric liner. The vanes are
6 held in contact with the liner by springs. Fuel is
5 drawn into the pump chamber at port X, pressurised
by the decreasing volume inside the chamber and
expelled at port Y. Fuel pressure generated by the
4 2 11 transfer pump is limited to a specified pressure by an
1 Fuel injection pump integral pressure regulating valve. This pressure is
2 Pump fixing nuts (x3) maintained regardless of engine speed. 6 bar ( 87.0
3 Injection pump gear cover psi)
4 Inlet metering valve electrical connector
5 Fuel temperature sensor electrical connector Figure 295.
6 Fuel pipe connector (inlet)
7 Fuel bleed-off connector
8 Fuel bleed-off connector, injector bleed off
9 Drive shaft nut E
10 Drive gear A
11 Injection pump O-ring oil seal
12 High pressure fuel outlet port B
13 Gear cover O-ring oil seal
D
X Y
A Rotor
B Vanes (x4)
C Eccentric liner
D Springs
E Regulating valve
X Port X
Y Port Y
High Pressure Pump Operation

Fuel passes to the high pressure pump via the IMV
(Inlet Metering Valve). The ECM (Engine Control
18 - 62 9823/1650-1 18 - 62
18 - Injection
15 - Pump
Module) controlled IMV determines the amount of Fuel pressure in the chamber rises and forces the
fuel transferred to the high pressure pump. The inlet valve on to its seat. As the plunger is pushed
plunger actuator block is located on the engine driven further up its chamber the fuel pressure exceeds that
eccentric shaft. When the shaft rotates the actuator of the rail pressure and the delivery valve is forced off
block operates the two plungers. As one plunger is its seat. Fuel is forced into the rail at high pressure.
pushed up its chamber the other is pushed down by
its spring. Figure 297.
State 1 - Charging E
Note: The description is for one plunger. The
opposite plunger operates in an identical way. The
inlet and delivery ports from each plunger are
connected by internal galleries. D
When the eccentric shaft is in the position shown
force from spring moves the plunger down its C
chamber. Pressure in the chamber falls below the
rail pressure and the delivery valve closes. Transfer
pressure is now sufficient to force inlet valve off its
seat and allow the fuel to fill the chamber.
Figure 296.
E B
D
A Eccentric shaft
C B Actuator block
C Plunger
D Inlet valve
E Delivery valve
F
A Eccentric shaft
B Actuator block
C Plunger
D Inlet valve
E Delivery valve
F Spring
State 2 - Pumping
Note: The description is for one plunger. The
opposite plunger operates in an identical way. The
inlet and delivery ports from each plunger are
connected by internal galleries.
When the eccentric shaft is in the position shown the

actuator block moves the plunger up its chamber.
18 - 63 9823/1650-1 18 - 63
18 - Injection
15 - Pump

7 8 2 10
Special Tools
1
Crankshaft Turning Tool 892/01147 1
(95.25mm PCD)- JCB 9
4 Cylinder Ecomax and 3
Dieselmax 12
Crankshaft / 892/01148 1
Camshaft Timing Pin
(444/448/672 Engine)
Tamper proof Cover 892/01154 1
Removal Tool
Pump Gear Removal 892/01155 1
Tool 13
C-Shaped Ring 892/01179 1 6
Spanner 5
(10-100Nm) 4 2 11
Important: The following procedures include removal 1 Fuel injection pump
and replacement of fuel system components. Before 2 Pump fixing nuts (x3)
starting the procedures the engine assembly must be 3 Injection pump gear cover
cleaned. Clean the engine. Refer to Engine- Clean 4 IMV (Inlet Metering Valve) electrical connector
(PIL 15-00). 5 Fuel temperature sensor electrical connector
Important: Service procedures on the high pressure 7 Fuel bleed-off connector
fuel pump can only be carried out by specialist 8 Fuel bleed-off connector, injector bleed off
personnel with the relevant training and equipment. 9 Drive shaft nut
10 Drive gear
11 Injection pump O-ring oil seal
Before Removal 12 High pressure fuel outlet port
1. Make sure that the engine is safe to work on. If 13 Gear cover O-ring oil seal
you start the service work. Remove
2. Get access to the engine. 1. Release the fuel pipe couplings at the inlet
connection 6 and bleed-off connections 7 and 8
3. Remove the high pressure fuel pipe at port 12, on the pump. Cap all open ports and pipes.
refer to Fuel Pipes- Remove and Install. Cap all
open ports and pipes, refer to (PIL 18-96). 2. Uncouple the electrical connectors at the IMV
and the fuel temperature sensor.
4. To improve access to the pump, remove the fuel
filter, refer to (PIL 18-09). 3. Remove the bedplate plug.
Important: When removing components dirt and

debris may become exposed or dislodged. Stop the
removal procedures and clean away the exposed
deposits. Refer to Engine- Clean (PIL 15-00).
18 - 64 9823/1650-1 18 - 64
18 - Injection
15 - Pump
11
3
B
A
1
F G
1 Bedplate plug H
A Crankshaft / Camshaft timing pin
C Crankshaft turning tool
4. Use the crankshaft turning tool to turn the E
crankshaft until the timing pin engages in the
crankshaft timing hole.
Special Tool: Crankshaft Turning Tool (95.25mm
PCD)- JCB 4 Cylinder Ecomax and Dieselmax 3 Gear cover
(Qty.: 1) 11 Drive shaft nut
Special Tool: Crankshaft / Camshaft Timing Pin B Gear removal tool
(444/448/672 Engine) (Qty.: 1) E Pump gear removal tool, comprises:
F Pump gear removal tool (Reaction cap)
5. Use the gear removal tool and a suitable ratchet G Pump gear removal tool (Body)
drive to remove the fuel injection pump gear H Pump gear removal tool (Bolt)
cover.
Special Tool: Pump Gear Removal Tool (Qty.: 1) 7. Remove the nuts. Use the special C shaped
ring spanner to remove the nut closest to the
6. Remove the drive shaft nut. crankcase. Make sure you remove all nuts (X3).
8. Install the reaction cap over the pump shaft.
Screw the body to the housing. Use a suitable
ratchet drive and socket to screw the bolt in until
you feel a slight resistance.
Special Tool: C-Shaped Ring Spanner (Qty.: 1)
Special Tool: Pump Gear Removal Tool (Qty.: 1)
18 - 65 9823/1650-1 18 - 65
18 - Injection
15 - Pump

2 10
2 10
9
F
G
2 12
2 Fixing nuts
9 Gear pump nut
2 Fixing nuts
10 Drive gear
10 Injection pump drive gear
12 Drive shaft
F Pump gear removal tool (Reaction cap)
G Pump gear removal tool (Body) 2. Make sure that the oil seal is correctly located on
H Pump gear removal tool (Bolt) the pump mounting face.
9. The injection pump drive gear is located on a Figure 303.
taper on the pump drive shaft. To remove the
pump the taper lock must be broken. Support
the fuel pump. Tap the end of the bolt H with a
soft faced hammer. When the taper breaks there
will be an audible sound. Note: The pump drive 16
gear connects to the injection pump drive shaft by
means of taper lock alone, there is no mechanical
locking key.
10. Remove the service tools. Withdraw the pump
from the flywheel housing.
Install
1. Make sure that the taper surfaces on the injection 16 Oil seal
pump drive shaft and gear are clean and free 3. Locate the pump on to the mounting studs.
from oil and damage. Locate the drive gear over the pump drive shaft.
4. Install the fixing nuts and tighten to the correct
torque value.
5. Install the gear pump nut and tighten to the
correct torque value. Note: If a washer is supplied
with a replacement pump, Do not install the
washer. Secure the gear with the gear pump nut
only.
6. Use the tamperproof cover removal tool to install
the gear cover. Make sure its sealing O-ring is
correctly installed. Tighten the gear cover to the
1)
Special Tool: Tamper proof Cover Removal Tool
(Qty.: 1)
18 - 66 9823/1650-1 18 - 66
18 - Injection
15 - Pump
7 8
12
3
B
6
3 Gear cover 5
B Tamperproof cover removal tool
4
After Installation 4 IMV electrical connector
1. Remove the crankshaft turning tool. 5 Fuel temperature sensor electrical connector
2. Remove the crankshaft timing pin and install the 7 Fuel pump bleed-off connection
bedplate plug. 8 Fuel pump bleed-off connection
12 High pressure fuel outlet port
3. Reconnect the fuel pipe couplings at the inlet
connection, reconnect the bleed-off connections Table 140. Torque Values
on the pump.
Item Nm
4. Install a new high pressure fuel pipe, remove 2 24
the protective caps from the ports, refer to Fuel 3 70
Pipes- Remove and Install, refer to (PIL 18-96). 9 65
5. Connect the electrical connectors at the IMV and
the fuel temperature sensor.
6. Replace the fuel filter, refer to (PIL 18-09).
18 - 67 9823/1650-1 18 - 67
18 - Injection
27 - High Pressure Rail Valve
27 - High Pressure Rail Valve Introduction

Introduction .................................................... 18-68 The HPV (High Pressure Valve) is an integral part
Operation ....................................................... 18-69 of the common fuel rail assembly, If the valve
Check (Operation) ......................................... 18-69 is defective replace the complete common rail
Remove and Install ....................................... 18-70 assembly. (Refer to PIL 18-18).
Figure 306. High pressure valve location
Figure 307.
A HPV
B Solenoid coil
18 - 68 9823/1650-1 18 - 68
18 - Injection
In certain operating conditions, the HPV (High For the full inspection and testing procedure, refer to
Pressure Valve) controls the fuel pressure inside the the help files in ServiceMaster.
common rail.
When the valve opens, fuel is bled from the rail back
to the fuel tank, reducing the fuel pressure inside the
fuel rail. The valve is actuated by a solenoid coil and
features proportional control. The fuel flow through
the valve is proportional to the current supplied to
the coil. The current value is controlled by the ECM
(Engine Control Module) using PWM (Pulse Width
Modulation).
During normal engine operation, the fuel pressure is

controlled solely by the IMV (Inlet Metering Valve),
In some operating circumstances, the IMV is unable

to alter the fuel pressure in the common rail quickly
enough. At these times, the ECM activates the HPV.
Typically the valve is used in the following conditions:
• Extreme transients, for example if the operator

goes from full throttle to no throttle quickly.
• When the fuel is cold.
In the event of an IMV failure, the ECM compensates

by altering the control of the HPV to ensure the
engine performance is sufficient to limp home.
18 - 69 9823/1650-1 18 - 69
18 - Injection
Remove and Install
This part is a non-serviceable component, if it

is defective, replace the complete common rail
assembly. Refer to: PIL 18-18-12.
18 - 70 9823/1650-1 18 - 70
21 - Fuel Pump
21 - Fuel Pump
Contents Page No.
18-21-00 General ........................................................................................................................... 18-73
18 - 71 9823/1650-1 18 - 71
Notes:
18 - 72 9823/1650-1 18 - 72
21 - Fuel Pump
00 - General
Introduction .................................................... 18-73 The fuel lift pump is a sealed electrical unit integral
Technical Data ............................................... 18-75 with the fuel pre-filter and water separator.
Operation ....................................................... 18-76
Check (Operation) ......................................... 18-76 The fuel lift pump is a non-serviceable component.
If any part is defective, replace the complete pump,
Remove and Install ....................................... 18-77 filter and separator assembly.
Figure 308.
A Fuel lift pump

B Fuel pre- filter
C Water separator
Some lift pump installations are modified to operate

from a 24 V supply by means of an in-line voltage
reducer.
18 - 73 9823/1650-1 18 - 73
21 - Fuel Pump
00 - General
Figure 309.
A
A Lift pump motor

B Voltage reducer
C In-line electrical connector
D Harness electrical connector
18 - 74 9823/1650-1 18 - 74
21 - Fuel Pump
00 - General
Technical Data
Table 141.
Component Value
Operating pressure 0.8 bar ( 11.6 psi)
Expected minimum free 2.5 L/min
flow delivery
Table 142. Expected electrical values

Machine Minimum Maximum Minimum Maximum Minimum Maximum
Voltage V Voltage V Voltage V Resistance Resistance Current Draw Current Draw
Ohms Ohms A A
12 8 16 0.8 1.5 4 8
24 20 30 4.9 5.7 4 5.5
18 - 75 9823/1650-1 18 - 75
21 - Fuel Pump
00 - General
The pump draws fuel from the tank, through the water If the fuel lift pump is suspect, measure the delivery
separator, pumping it through the fuel filter and into flow rate.
the fuel injection pump. The pump has a built in
protection against running dry and will shut down Flow Test
after 2 min if no fuel is present.
2. Disconnect the fuel hose from the outlet of the
pump/ filter assembly.
3. Connect a length of fuel hose from the pump
outlet to a suitable fuel container.
Volume: 5 L
4. Activate the fuel pump. Do not attempt to start
the engine.
5. Run the pump. The fuel flow must be equal to or
greater than the value shown.
Duration: 1 min
Flowrate: 2.5 L/min
Machines with Electronic Control Fuel

Injection
When the ignition is set to ON the ECM (Engine
Control Module) energises the fuel lift pump. If the
engine is not started the pump is de-energised after
a period of 24 s. A fuel pump flow test can be carried
out during this period of time. Minimum expected fuel
flow. 1 L in 24 s.
Alternatively use the JCB engine diagnostic tool

within Servicemaster to energise the fuel pump (fuel
lift pump test). After a 5 s delay the pump runs for
a period of 24 s.
18 - 76 9823/1650-1 18 - 76
21 - Fuel Pump
00 - General
Remove and Install
4. Disconnect the WIF (Water in Fuel) sensor

Remove harness connector.
Refer to Figure 310. 5. Make sure to mark label on the fuel pipes to aid
in the installation.
The fuel lift pump is installed on the loader tower. 6. Disconnect the fuel pipes at the fuel lift pump by
This procedure is also similar for the machines with means of the quick release connectors.
lift pumps installed on the side of the fuel tank.
7. Disconnect the drain hose at drain tube.
8. Support the fuel lift pump and remove the bolts.
2. Disconnect the battery.
9. Remove the fuel lift pump together with its pre-
3. Disconnect the fuel lift pump harness connector. filter/separator from the machine.
Figure 310.
D
C
A B E
H
F
A WIF sensor harness connector B Fuel pipe

C Fuel lift pump harness connector D Fuel lift pump
E Fuel pipe F Bolt
G Drain tube H Pre-filter/Separator
J Fuel pipe
Install
removal procedure.
Table 143. Colour code

Fuel pipe Colour
E Blue
J Red
18 - 77 9823/1650-1 18 - 77
24 - Exhaust
24 - Exhaust
Contents Page No.
18-24-00 General ........................................................................................................................... 18-79

18-24-03 Inlet Manifold .................................................................................................................. 18-81
18-24-04 Outlet Manifold ............................................................................................................... 18-85
18 - 78 9823/1650-1 18 - 78
24 - Exhaust
00 - General
Introduction .................................................... 18-79 The exhaust system is used to guide exhaust gases
Health and Safety .......................................... 18-80 away from the controlled combustion inside the
Check (Condition) .......................................... 18-80 engine by means of an exhaust pipe. Depending
on the machine design, the exhaust gas may flow
through the following components:
• Cylinder head and exhaust manifold.

• Turbocharger to increase the engine power (if
installed).
• A catalytic converter or EGR (Exhaust Gas
Recirculation) system to reduce air pollution (if
installed).
• SCR (Selective Catalytic Reduction) (if
installed). In SCR system exhaust gases
pass through the DEF (Diesel Exhaust Fluid)
injection chamber to lower the NOx (Nitrogen
Oxide) concentration in the exhaust gases.
• A silencer or muffler to reduce noise (if
installed).
The exhaust pipe carries the toxic and noxious gases

away from the users of the machine. Note machines
or generators that work indoors can quickly fill an
enclosed space with carbon monoxide or other
poisonous exhaust gases if they are not properly
vented to the outdoors.
18 - 79 9823/1650-1 18 - 79
24 - Exhaust
00 - General

Exhaust Gases Excessive smoke from the exhaust stack combined
Machine exhaust gases can harm and possibly kill with a complaint of low power could be as a result of:
you or bystanders if they are inhaled. Do not operate
the machine in closed spaces without making sure • Dirt or dust (unfiltered air) ingested directly into
there is good ventilation. If possible, install an the engine, resulting in damage to the cylinder
exhaust extractor. If you begin to feel drowsy, stop bores, there will also be a possible increase in
the machine at once and get into fresh air. oil consumption.
• Air leaks from the air hose connections.
Sparks • Exhaust manifold leaks.
Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
machine in closed areas where there is flammable
material, vapour or dust.
Hazardous Atmospheres
This machine is designed for use in normal out
door atmospheric conditions. It must not be used
in an enclosed area without adequate ventilation.
Do not use the machine in a potentially explosive
atmosphere, i.e. combustible vapours, gas or dust,
without first consulting your JCB dealer.
Hot Components
Touching hot surfaces can burn skin. The engine and
been running. Allow the engine and components to
cool before servicing the unit.
Switch off the engine before working in the engine
engine cover open.
18 - 80 9823/1650-1 18 - 80
24 - Exhaust
03 - Inlet Manifold
03 - Inlet Manifold Introduction

Introduction .................................................... 18-81 The inlet manifold (or intake manifold) supplies
Component Identification ............................... 18-82 combustion air to the cylinders in compression
Check (Condition) .......................................... 18-82 ignition engines or the air/fuel mixture for spark
Remove and Install ....................................... 18-83 ignition engines (except most direct injection spark
ignition engines). Even distribution of the air or
air/fuel is important to optimize the efficiency and
performance of the engine.
The manifold is required to be air tight under pressure

and vacuum conditions and can be required to
provide mounting points for sensors, grid heaters,
throttle bodies and other components depending on
the engine type and specification.
18 - 81 9823/1650-1 18 - 81
24 - Exhaust
03 - Inlet Manifold

Figure 311. 1. Check the manifold mating faces for signs of
damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.
1
1 Inlet Manifold
18 - 82 9823/1650-1 18 - 82
24 - Exhaust
03 - Inlet Manifold
Remove and Install

4. Remove the fuel rail assembly. Refer to (PIL
18-18).
Figure 312.
6
12 11 10
8
13
9
3
4
5
1 Inlet manifold 2 Manifold gasket

3 Flanged hexagon bolt (x8) 4 Fuel rail mount
5 Screw (x4) 6 EGR (Exhaust Gas Recirculation) mixer tube
7 EGR Plug 8 Inlet manifold adaptor / throttle valve (not
shown)
9 Throttle O-ring 10 Flanged hexagon bolt (x4)
11 Inlet manifold bracket 12 Bolt M6 x 16mm (x1)
13 Bolt M8 x 25mm (x1)
Remove 4. Cap the inlet ports with blanking caps to prevent

ingress of dirt.
1. Disconnect the TMAP (Temperature Manifold Air
Pressure) sensor electrical connector. 5. Inspect the manifold, refer to Check Condition
(PIL 18-24).
2. Disconnect the air inlet hose.
3. Remove the bolts 3 and lift the inlet manifold from
the cylinder head. Discard the gasket.
18 - 83 9823/1650-1 18 - 83
24 - Exhaust
03 - Inlet Manifold
Install
steps.
2. Renew the manifold gasket.
3. Loosely assemble the manifold, together with the
new inlet gasket to the cylinder head, use the two
bolts (one at each end).
4. With the manifold and gasket in position, install
the remaining six bolts.

Item Nm
3 43
18 - 84 9823/1650-1 18 - 84
24 - Exhaust
04 - Outlet Manifold
04 - Outlet Manifold Introduction

Introduction .................................................... 18-85 The exhaust outlet manifold collects the exhaust
Component Identification ............................... 18-86 gases from the multiple cylinders and delivers it to
Check (Condition) .......................................... 18-86 the turbocharger or the exhaust pipe.
18 - 85 9823/1650-1 18 - 85
24 - Exhaust

Figure 313. 1. Check the manifold mating faces for signs of
A B damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.
4. Visually inspect for leaks at the exhaust manifold.
Make sure all gaskets are in good condition,
replace as required.
A Exhaust manifold
B Manifold gasket and heat shield
18 - 86 9823/1650-1 18 - 86
24 - Exhaust
Remove and Install

4. Disconnect the oil pipes to the turbocharger, refer
to (PIL 18-36).
Figure 314.
1 Exhaust manifold 2 Fixing bolts M10 x 57mm (x8)

3 Manifold gasket
Remove 2. Renew the manifold gasket.
1. Remove the upper four bolts. 3. Install the lower four bolts, together with the new
exhaust gasket to the cylinder head (screw in the
2. Loosen the lower four bolts and lift the exhaust bolts approximately to a length of 8 mm).
manifold from the cylinder head. Remove the
bolts and discard the gasket. 4. Rest the manifold in position on the row of
lower bolts by locating the slots, then install the
3. Cap the exhaust ports to prevent ingress of dirt. remaining four upper bolts.
4. Inspect the manifold, refer to Check Condition 5. Tighten the bolts to the correct torque value.
(PIL 18-24). Refer to Torque and Angle Tightening procedure
(PIL 72-00 ).
Install
After Installation
removal procedure. Additionally do the following 1. Reconnect the oil pipes to the turbocharger (if
steps. installed).
18 - 87 9823/1650-1 18 - 87
24 - Exhaust
2. Install the exhaust pipe and the silencer box.

3. Start the engine and check for exhaust leaks.

Item Torque Value Torque Angle
(Nm) (Degrees)
2 (First Stage) 25
2 (Final Stage) +90
18 - 88 9823/1650-1 18 - 88
27 - Exhaust Gas Recirculation (EGR)
Contents Page No.
18-27-00 General ........................................................................................................................... 18-91

18-27-03 Actuator .......................................................................................................................... 18-98
18 - 89 9823/1650-1 18 - 89
Notes:
18 - 90 9823/1650-1 18 - 90
00 - General
Introduction .................................................... 18-91 The EGR (Exhaust Gas Recirculation) system is
Component Identification ............................... 18-92 a technique that re-circulates a portion of the
Operation ....................................................... 18-93 exhaust gases back into the combustion chamber.
Check (Condition) .......................................... 18-94 The system cools and controls the quantity of re-
circulated exhaust gas.
The EGR valve is controlled by the CAN (Controller
Area Network)bus system (PIL 33-45), the valve
opens and closes to allow the exhaust gases to
flow back into the intake system via the EGR cooler.
This has the effect of lowering the combustion
temperature and reducing the formation of NOx
(Nitrogen Oxide).
In order to ensure full power is always available when

it is needed, the EGR valve will close when full power
is needed or when the engine is cold and inherently
inefficient this means that the engine is running as
lean and efficiently as possible at all times.
The EGR valve system comprises an actuator with

a feedback position sensor, linkage and a valve
mechanism. The valve actuator, which is controlled
by the CANbus system, position sensor and linkage,
drives the valve to the demanded position.
18 - 91 9823/1650-1 18 - 91
00 - General
Figure 315.
B
C
D
A E
F
G
A VGT (Variable Geometry Turbocharger) actuator B VGT

C EGR (Exhaust Gas Recirculation) valve D EGR actuator
E EGR intermediate cooler F Main plate cooler
G Mixer tube
Table 146. Colour Code Key

Colour System
Blue Coolant Flow 1
Red Recirculated Gas Flow
Green Air Flow
Yellow Coolant flow 2
18 - 92 9823/1650-1 18 - 92
00 - General
Operation Figure 318.
1. Exhaust gases enter the exhaust manifold.

Figure 316.
4. Exhaust gases enter the mixer tube.

Figure 319.
2. The exhaust gases travel through the
intermediate EGR (Exhaust Gas Recirculation)
cooler.
Figure 317.
5. The exhaust gases are mixed with new air and

re-enter the engine.
Figure 320.
3. The exhaust gases enter the main cooler which
reduces the heat.
18 - 93 9823/1650-1 18 - 93
00 - General
Check (Condition)
1. Check that the EGR (Exhaust Gas Recirculation)
for excessive carbon build up. Visually inspect for
leaks at the EGR. Make sure all gaskets are in
good condition, replace as required.
18 - 94 9823/1650-1 18 - 94
00 - General
Remove and Install

Before Removal
Figure 321.
C
B D
E
A
F
G

C EGR (Exhaust Gas Recirculation) actuator D EGR valve
E EGR Intermediate Cooler F Main Plate Cooler
G Mixer Tube
18 - 95 9823/1650-1 18 - 95
00 - General
Remove 8. Remove the bolts (x4) that retain the heat shield
to the EGR control module.
1. Remove the EGR cooler hose (Left side viewed
from the rear of the engine). 9. Remove the bolt from the cooler pipe.
2. Remove the EGR cooler bracket assembly bolts 10. Remove the cooler connections (banjo fittings
(x2). (x4) and copper washers) from the EGR control
module and electrical harness connector.
3. Carefully remove the main EGR cooler.
11. Remove the small bolts (x3) that fix the control
4. Remove the EGR cooler hose (Right side viewed module to the EGR valve.
from the rear of the engine).
12. Remove the bolts (x2) that fix the EGR bracket
5. Remove the nuts (x4) fixing the EGR tube in tube to the W-clip that clamp the cooler pipes together
cooler pipe assembly to the EGR valve. (captive nuts).
6. Remove the EGR actuator control rod pivot pin 13. Remove the EGR valve body from the mounting
fixing clips and the EGR control rod. studs fixed to the manifold with a steel gasket
both sides.
7. Remove the bolt fixing the EGR tube in tube
cooler to the rear of the cylinder head.
Figure 322.
19
22
41
42 41
45
5 41 35
25 20
17 41
10
29
38
32
19 41
3 20
22 15
7
37
4 13
20 20 6
42
12
27 8 40
1
26 39
20 42
42 14
43
23 16
9 21
34
2 28
23
24 31
1 Main EGR cooler 2 Intermediate EGR cooler

3 EGR valve 5 Pipe (Coolant return to header)
6 Pipe (Under actuator to coolant return) 7 Pipe (EGR actuator feed)
18 - 96 9823/1650-1 18 - 96
00 - General
8 Pipe (EGR cooler out) 9 Pipe (rear of head feed)

10 Pipe (Turbo actuator feed) 11 Pipe (Turbo actuator return)
12 Hose (EGR cooler in) 13 Hose (EGR cooler out)
14 Hose (EGR in, intermediate cooler) 15 Hose (EGR cooler out, intermediate cooler)
16 Hose (EGR actuator feed) 17 Hose (EGR cooler return)
18 Hose (Turbo actuator feed) 19 Hose (Turbo actuator feed/return)
20 Spring-band clamp form B (24mm Diameter) 21 Spring-band clamp form B (20mm Diameter)
22 Spring-band clamp (14mm Diameter) 23 Laminar seal ring (Large)
24 Laminar seal ring (Small) 25 O-ring (I.D.17.0mm x 3.5mm)
26 Gasket (EGR to Manifold) 27 Outlet lobe seal
28 Copper washer (M16) 29 Copper washer (M12)
30 Copper washer (M10) 31 Banjo bolt (M16)
32 Banjo bolt (M12) 33 Banjo bolt (M10 long)
34 EGR Cooler strap 35 EGR Valve heat-shield
36 W-Clip for 8mm O.D. pipe 37 Coolant pipe clamp
38 Pipe clamp strap 39 Locknut (M8 Special)
40 Stud (M8 x 80mm) 41 Bolt flange hexagon head (M6 x 16mm)
42 Bolt flange hexagon head (M8 x 16mm) 43 Screw hexagon head (M8 x 30mm)
Install 3. The EGR actuator is a CAN (Controller Area

Network) driven device and can only be
1. The installation procedure is the opposite of the evaluated with the use of Servicemaster. Refer
removal procedure. Additionally do the following to EGR Actuator (PIL 18-27).
steps.
4. All conditions of the EGR are reported by the fault
2. Renew all O-rings, sealing washers and gaskets. codes. Test the turbocharger boost pressure,
refer to Check Operation (PIL 18-36).
3. Tighten the fixings to the correct torque value.
Note: Tighten the EGR cross over tube bolts in Table 147. Torque Values
the correct order, 1 to 4 as shown in 2 stages.
Item Nm
Figure 323. 31 50
32 27
2
33 16
39 24
40 24
4
41 10.5
42 24
43 24
44 24
3
1
After Installation
1. Complete the actuator learn procedure, Refer to
Servicemaster, JCB Engine > Diagnostic Tool >
Ecomax Actuators > Actuator Learn > EGR Valve
Position Learn.
2. Start the engine and check for exhaust leaks and
coolant leaks.
18 - 97 9823/1650-1 18 - 97
03 - Actuator
03 - Actuator Introduction
Introduction .................................................... 18-98 The EGR (Exhaust Gas Recirculation) actuator is a
Remove and Install ....................................... 18-99 smart electronic CAN driven device and can only be
evaluated with the use of Servicemaster.
The device does a self check on the operating range

to check the adaption window every time the ignition
is switched off and on. The unit is extremely sensitive
and constantly monitors the conditions it is operating
under. If it detects over voltage, under voltage, high
or low current, movement, temperature etc, if it is
working outside of it's desired limits in any way at all,
it will shut down until the fault is rectified.
18 - 98 9823/1650-1 18 - 98
03 - Actuator
Remove and Install
The EGR (Exhaust Gas Recirculation) electronic

actuator is not a serviceable component, if it fails
replace the EGR valve assembly.
18 - 99 9823/1650-1 18 - 99
35 - Turbocharger
35 - Turbocharger
Contents Page No.
18-35-00 General ......................................................................................................................... 18-101
18 - 100 9823/1650-1 18 - 100

35 - Turbocharger
00 - General
Introduction .................................................. 18-101 The turbocharger (turbo) is a turbine driven forced
Component Identification ............................. 18-102 induction device that makes an engine more efficient
Check (Condition) ........................................ 18-103 and helps to produce more power for its size.
Check (Operation) ....................................... 18-104
Engine exhaust gasses drive a turbine, which in turn
Remove and Install ..................................... 18-105 drives a compressor via a common shaft. The shaft
bearings are lubricated by a feed from the engine
lubrication system.
A turbocharged engine is more powerful and efficient

than a naturally aspirated engine because the turbine
forces more air, and proportionately more fuel, into
the combustion chamber than atmospheric pressure
alone.
Some variants incorporate a wastegate assembly. A

flap type valve is housed in the turbocharger body.
The valve is actuated by a diaphragm type actuator
via an actuator rod. When the pressure generated
by the turbocharger compressor reaches a pre-set
value the actuator opens the valve, some exhaust
gas is diverted back to the exhaust manifold and
the turbocharger turbine speed reduces. In this way
the pre-set maximum boost pressure from the turbo
charger is not exceeded, regardless of engine speed.
18 - 101 9823/1650-1 18 - 101

35 - Turbocharger
00 - General
Figure 324.
7.5
7 7.4 7.3,4 1 9
12
7.2
8
11
7.3,13
3
6
8.8 5
1 Turbocharger 2 Exhaust manifold

3 Oil feed pipe (turbo bearing) 4 Banjo bolts M12
5 Oil drain pipe (turbo bearing) 6 Fixing bolts (x2)
7 Pipe adaptor (oil drain connection) 8 Retaining nuts (x4)
11 Pipe clip 12 Bolt - pipe adaptor ( oil drain connection)
13 Banjo bolts M16
18 - 102 9823/1650-1 18 - 102

35 - Turbocharger
00 - General
1. Visually inspect for leaks at the turbocharger.

Make sure that all gaskets are in good condition,
replace as required.
2. Check the turbine and compressor blades inside
the turbocharger rotate freely and smoothly by
hand. If the blades are stiff to turn, or damaged
the turbocharger must be replaced.
3. Make sure that the oil feed pipe and oil drain pipe
are clear and free from debris and sludge.
4. Check the turbine shaft running clearance.
4.1. Place the stylus of a DTI (Dial Test Indicator)
against the shaft.
4.2. Move the shaft sideways. 5.2. Move the shaft axially.
Figure 325. 5.3. Make sure that the shaft end float is within
the specified limits.
4.3. Make sure that the turbine shaft running

clearance is within the specified limits.
5. Check the shaft end float.
5.1. Place the stylus of the DTI against the end
of the shaft.
18 - 103 9823/1650-1 18 - 103

35 - Turbocharger
00 - General
Check (Operation)
To maximise the duration of the turbocharger follow

the rules described below.
Start-up
Start the engine and keep it at idle speed for about a
minute. The oil operating pressure is reached within
a few seconds, but it is useful to allow the moving
parts to warm up in good lubrication conditions.
Immediately increasing the engine speed after start
up will result in the turbocharger running at high rpm
with less than optimal lubrication. This may lead to
premature failure of the turbocharger.
After maintenance
When carrying out maintenance on the engine
or turbocharger, pre-lubricate the oil inlet of the
turbocharger by adding clean lubricant until it is
completely full. After pre-lubrication, let the engine
run via the starter motor without firing (engine /
fuel pump stop out) to allow the oil to circulate
through the complete system under pressure. Upon
engine start-up, make it run at idle speed for a few
minutes, allowing the oil and bearings system to work
satisfactorily.
Low temperature air or engine inactivity

If the engine has been inactive for a certain period
of time or the air temperature is very low, start
the engine and then let it run at idle speed. This
enables the oil to go into the lubrication system
before applying high loads and speeds to the engine
and turbocharger.
Engine shutdown
Before switching the engine off after intense activity,
you must allow the turbocharger to cool down, let the
engine run at idle speed for at least 2 minutes to allow
the turbocharger to cool.
Engine at idle speed

Avoid running the engine at idle speed for long
periods (above 20-30 minutes). Idle operation leads
to low pressure values in the turbocharger, which
may cause oil leaks from the seals at the ends of
the turbo bearing shaft. Even if this does not cause
damage, it can cause blue smoke from the exhaust
when the engine speed and load are increased.
18 - 104 9823/1650-1 18 - 104

35 - Turbocharger
00 - General
Remove and Install
Figure 327.
7.5
7 7.4 7.3,4 1 9
12
7.2
8
11
7.3,13
3
6
8.8 5
1 Turbocharger 2 Exhaust manifold

3 Oil feed pipe (turbo bearing) 4 Banjo bolts M12
5 Oil drain pipe (turbo bearing) 6 Fixing bolts (x2)
7 Pipe adaptor (oil drain connection) 8 Retaining nuts (x4)
11 Pipe clip 12 Bolt - pipe adaptor ( oil drain connection)
13 Banjo bolts M16
Before Removal 4. Get access to the engine.
1. This procedure requires service parts. Make sure 5. Drain the cooling system.
start, refer to Parts Catalogue. Remove
2. Make sure that the engine is safe to work on. 1. Disconnect the air induction hose at the inlet
If the engine has been running, make sure the manifold and turbocharger. Remove the hose.
engine has cooled sufficiently before you start.
2. Remove the pipe clip. Undo fixing bolts and
3. Remove the ignition key. remove the oil drain pipe. Note that the pipe pulls
18 - 105 9823/1650-1 18 - 105

35 - Turbocharger
00 - General
off the pipe adaptor, leaving the adaptor in place.

Cap the open ports to prevent ingress of dirt.
Discard the O-ring and the gasket.
3. Undo the banjo bolts at each end of the oil
feed pipe, remove the pipe. Cap the open ports
to prevent ingress of dirt. Discard the sealing
washers.
4. Remove the exhaust manifold from the cylinder
head complete with the turbocharger still
installed, refer to Exhaust Manifold-Removal
and Replacement. Discard the exhaust manifold
gasket.
5. With the exhaust manifold removed from the
engine, undo the nuts and separate the
turbocharger from the manifold. Discard the
gasket.
6. If the turbocharger is to be replaced remove the
bolts and pipe adaptor. Discard the gasket.
Install
steps.
2. Check the condition of the turbocharger (PIL
18-35)
3. Prime the top of the turbo with 200ml of fresh
clean engine oil. It is Important: not to run the new
turbo dry.
4. Renew all `O' rings, sealing washers and
gaskets.
5. Note that the exhaust manifold gasket also
functions as a heat shield. Be sure to position the
gasket the correct way round.
6. Tighten the nuts, bolts and banjo bolts to the

Item Nm
4 21
6 24
8 24
13 36
18 - 106 9823/1650-1 18 - 106

36 - Variable Geometry Turbocharger (VGT)
Contents Page No.
18-36-00 General ......................................................................................................................... 18-109

18-36-03 Actuator ........................................................................................................................ 18-116
18 - 107 9823/1650-1 18 - 107

Notes:
18 - 108 9823/1650-1 18 - 108

00 - General
Introduction .................................................. 18-109 The VGT (Variable Geometry Turbocharger) is
Component Identification ............................. 18-111 the next generation in turbocharger technology.
Operation ..................................................... 18-112 The turbocharger uses variable vanes to control
Check (Condition) ........................................ 18-113 exhaust flow and to introduce EGR (Exhaust Gas
Recirculation) to reduce emission in diesel engines.
Check (Operation) ....................................... 18-113 The turbocharger is bolted to the outlet port of the
Remove and Install ..................................... 18-114 exhaust manifold.
The turbo uses heat and energy from the waste

exhaust gases to drive a turbine which in turn drives
the compressor to pull new air at high pressure
into the cylinders. The extra volume of air allows
more fuel to be injected increasing the engine power
output.
This has the effect of lowering the combustion

temperature and reduces formation of NOx gases.
The air is compressed to a minimum pressure of

1 bar (14.5 lb/in2) depending upon engine speed
and load. The turbocharger spins at up to 100,000
rpm and reaches temperatures approaching 700 ºC
(1292 ºF); it is essential, therefore, that a good supply
of oil reaches it at all times. The oil not only lubricates
the turbocharger but also carries away excess heat.
External oil feed pipe connected to a port on the
crankcase supplies oil to the turbocharger bearing.
Oil returns to the engine oil sump via an external
drain pipe. Integral oil seals prevent oil escaping to
the compressor and turbine ends of the turbocharger.
18 - 109 9823/1650-1 18 - 109

00 - General
Figure 328.
B
A VGT
B VGT actuator
18 - 110 9823/1650-1 18 - 110

00 - General
Figure 329.
B
C
D
A E
F
G

C EGR (Exhaust Gas Recirculation) valve D EGR actuator
E EGR intermediate cooler F Main plate cooler
G Mixer tube
18 - 111 9823/1650-1 18 - 111

00 - General
1. Exhaust gases move through the scroll volume

spread across a slot and over the louvres turning
the turbine and out of the outlet.
Figure 330.
4. The angle of the airflow can be adjusted as it

strikes the adjustable louvres to change the turbo
performance.
Figure 333.
2. The louvre ring sits inside the turbine housing

with the turbine spinning in the centre.
Figure 331.
3. The outer ring is adjusted by the actuator.
18 - 112 9823/1650-1 18 - 112

00 - General
Check (Condition) Check (Operation)
Visually inspect for leaks at the turbocharger. Make To maximise the duration of the turbocharger follow
sure all gaskets are in good condition, replace as the rules described below.
required.
Start-up
Start the engine and keep it at idle speed for about a
minute. The oil operating pressure is reached within
a few seconds, but it is useful to allow the moving
parts to warm up in good lubrication conditions.
Immediately increasing the engine speed after start
up will result in the turbocharger running at high rpm
with less than optimal lubrication. This may lead to
premature failure of the turbocharger.
After maintenance
When carrying out maintenance on the engine
or turbocharger, pre-lubricate the oil inlet of the
turbocharger by adding clean lubricant until it is
completely full. After pre-lubrication, let the engine
run via the starter motor without firing (engine /
fuel pump stop out) to allow the oil to circulate
through the complete system under pressure. Upon
engine start-up, make it run at idle speed for a few
minutes, allowing the oil and bearings system to work
satisfactorily.
Low temperature air or engine inactivity

If the engine has been inactive for a certain period
of time or the air temperature is very low, start
the engine and then let it run at idle speed. This
enables the oil to go into the lubrication system
before applying high loads and speeds to the engine
and turbocharger.
Engine shutdown
Before switching the engine off after intense activity,
you must allow the turbocharger to cool down, let the
engine run at idle speed for at least 2 minutes to allow
the turbocharger to cool.
Engine at idle speed

Avoid running the engine at idle speed for long
periods (above 20-30 minutes). Idle operation leads
to low pressure values in the turbocharger, which
may cause oil leaks from the seals at the ends of
the turbo bearing shaft. Even if this does not cause
damage, it can cause blue smoke from the exhaust
when the engine speed and load are increased.
18 - 113 9823/1650-1 18 - 113

00 - General
Remove and Install
Before Removal 3. Remove the ignition key.
1. This procedure requires service parts. Make sure 4. Get access to the engine.
start, refer to Parts Catalogue. 5. Drain the cooling system. Refer to (PIL 21-00).
2. Make sure that the engine is safe to work on. If 6. Remove the EGR (Exhaust Gas Recirculation)
the engine has been running, let it cool before valve. Refer to (PIL 18-27).
Figure 334.
10
7
6
2
8
9 9
3
4
14
17
16 19 11
20
15 12
18
13
1 Turbocharger 2 Gasket
3 Studs M8 4 Lock nut
18 - 114 9823/1650-1 18 - 114

00 - General
5 Studs M10 6 Pipe adaptor (oil drain connection)

7 Gasket drain pipe 8 O-Ring
9 Bolt M6 10 Clip
11 Oil drain pipe 12 Gasket drain pipe
13 Bolts M8 14 Oil feed pipe
15 Pipe clip 16 Banjo bolts M12
17 Copper Washer 18 W Clip
19 Banjo bolts M16 20 Copper Washer M16
Remove 2. Test the VGT (Variable Geometry Turbocharger)

boost pressure.
1. Disconnect the air induction hose at the inlet
manifold and turbocharger. Remove the hose. Table 149. Torque Values
2. Undo the bolts and remove the oil drain pipe. Item Nm
Note that the pipe pulls off the pipe adaptor, 4 24
leaving the adaptor in place. Cap the open ports 9 10
to prevent ingress of dirt. Discard the O-ring and 13 24
the gasket.
16 36
3. Remove the pipe clips. Undo the banjo bolts at 19 21
each end of the oil feed pipe, remove the pipe.
Cap the open ports to prevent ingress of dirt.
Discard the sealing washers.
4. Remove the exhaust manifold from the cylinder
head complete with the turbocharger still
installed, refer to Exhaust Manifold- Removal
and Replacement. Discard the exhaust manifold
gasket.
5. With the exhaust manifold removed from the
engine, undo the nuts and separate the
turbocharger from the manifold. Discard the
gasket
6. If the turbocharger is to be replaced remove the
bolts and pipe adaptor. Discard gasket.
Install
steps.
2. Check the condition of the turbocharger. Refer to
(PIL 18-35).
3. Prime the top of the turbo with 200ml of fresh
clean engine oil. It is Important: not to run the new
turbo dry.
4. Renew all O-rings, sealing washers and gaskets.
5. Note that the exhaust manifold gasket also
functions as a heat-shield.
6. Tighten the nuts, bolts and banjo bolts to the
After Installation
1. Start the engine and check for exhaust leaks.
18 - 115 9823/1650-1 18 - 115

03 - Actuator
03 - Actuator Install
steps.
Special Tools
Description Part No. Qty. 2. Perform the VGT (Variable Geometry
Data Link Adaptor 892/01174 1 Turbocharger) position learn routine using
(DLA) Kit Servicemaster. Refer to the engine Helpfiles.
Special Tool: Data Link Adaptor (DLA) Kit (Qty.:
Before Removal 1)
1. Make the machine safe. Refer to (PIL 01-03). Table 150. Torque Values
2. Make sure that the engine is safe to work on. If Item Nm
the engine has been running, let it cool before B 10
you start the service work. C 13
Remove
Figure 335.
D A
A Actuator
B Actuator linkage
C Nuts (x4)
D Electrical connector
2. Disconnect the actuator linkage from the
actuator.
3. Disconnect the coolant hoses. Plug all the open
ports and hoses to prevent contamination. Make
sure that any spills or residual coolant is cleaned
up immediately.
4. Remove the nuts (x4) and remove the actuator
from the turbocharger housing.
18 - 116 9823/1650-1 18 - 116

96 - Fuel Pipe
96 - Fuel Pipe
Contents Page No.
18-96-00 General ......................................................................................................................... 18-119

18-96-03 High Pressure Pipe ...................................................................................................... 18-121
18-96-06 Low Pressure Pipe ....................................................................................................... 18-124
18 - 117 9823/1650-1 18 - 117

Notes:
18 - 118 9823/1650-1 18 - 118

96 - Fuel Pipe
00 - General
Introduction .................................................. 18-119 Fuel at rail pressure is continuously supplied to
Health and Safety ........................................ 18-120 the injectors via high pressure fuel pipes. The high
Component Identification ............................. 18-120 pressure fuel injector pipes consist of thick walled,
seamless steel tubing. The ends of the tubes are
formed with conical nipples for sealing in the sealing
cones on the common rail and on the injector at port.
It is essential that the pipes are maintained and

installed correctly for safe and effective engine
operation.
The high pressure fuel pipes connect the injectors to

the common rail. The injectors inject fuel in response
to a supply of electrical current from the ECM (Engine
Control Module). During fuel injection some fuel
bleeds off the injectors and back to tank via the low
pressure bleed off pipes.
Important: If the high pressure fuel pipes are

removed for any reason they must be renewed.
Installing the original fuel pipes will cause fuel leaks
at the pipe connections.
18 - 119 9823/1650-1 18 - 119

96 - Fuel Pipe
00 - General

WARNING Do not open the high pressure fuel
system with the engine running. Engine operation Figure 336.
causes high fuel pressure. High pressure fuel A
spray can cause serious injury or death. A A A
Notice: Do not allow dirt to enter the fuel system.
Before disconnecting any part of the fuel system, B
thoroughly clean around the connection. When a
component has been disconnected, for example
a fuel pipe, always install protective caps and H
plugs to prevent dirt ingress. Failure to follow
these instructions will lead to dirt entering the
fuel system. Dirt in the fuel system will seriously C
damage the fuel injection equipment and could be
expensive to repair. G
E
D
A Pipe assembly high pressure - fuel rail to

injector (x4)
B Injector
C Pipe assembly high pressure - injection pump to
fuel rail
D Pipe low pressure - return to tank
E Injection pump
F Pipe assembly low pressure - Fuel injectors to
tank
G Pipe assembly low pressure - fuel rail to tank
H Fuel rail
18 - 120 9823/1650-1 18 - 120

96 - Fuel Pipe
03 - High Pressure Pipe
03 - High Pressure Pipe 5.3. Remove any dirt or debris that is exposed.
Refer to Engine, Clean (PIL 15-00-00).
Remove and Install 6. Always use a spanner at the top of the fuel pipe
nut (this will prevent damage to the nut).
Special Tools
Description Part No. Qty. Figure 338.
Socket 17MM Offset - 331/27987 1
(HP Fuel pipes)
(10-100Nm)
Important. Before disconnecting or removing fuel

pipes proceed as follows.
1. Make sure that you have the correct new parts.

1.1. The high pressure fuel pipes MUST BE
REPLACED with new ones.
1.2. The new fuel pipes must remain sealed
inside their bags before use. If a bag is open
DO NOT USE the fuel pipe, get a new one.
2. Obey all fuel system health and safety Injector Fuel Pipes
information. Refer to (PIL 18-00).
Remove
3. Make sure that the engine is safe to work on.
The procedure describes how to remove one fuel
3.1. The engine must cool and pressure in the pipe.
fuel system must decay before you start
work. Figure 339.
3.2. If the engine has been running, wait at least B
one hour before you start work.
A
4. Clean the engine. Refer to Engine, Clean (PIL C
15-00-00).
5. Remove the protective cover as follows.
E
Figure 337.
B
A Fuel pipe
A B Nut 1
C Fuel injector
D Fuel rail
E Nut 2
C
1. Remove the fuel pipes one at a time as follows.
A Screw
B Plastic segment 1.1. Loosen the nut 2 at the fuel rail. Do not
C Protective cover remove the nut at this step.
1.2. Use the 17mm deep socket special tool at
5.1. Push out the plastic segments. the top of nut. This will prevent damage to
5.2. Remove the screws and lift off the cover. the nut.
18 - 121 9823/1650-1 18 - 121

96 - Fuel Pipe
Special Tool: Socket 17MM Offset - (HP Injection Pump to Rail Fuel Pipe
Fuel pipes) (Qty.: 1)
Special Tool: Torque Wrench (10-100Nm) Remove
(Qty.: 1)
Figure 340.
1.3. Push the fuel pipe against the injector cone
and at the same time remove the nut 1. A
B
1.4. Push the fuel pipe against the fuel rail cone
and at the same time remove the nut 2.
1.5. Make sure that there is no dirt or debris on
the fuel pipe or the connectors.
1.6. Remove the fuel pipe.
1.7. Seal all the open ports, use the correct parts
from the service kit.
2. Repeat step 1 to remove the other fuel pipes.
3. Discard the old fuel pipes.
Install
Important: The high pressure fuel pipes must be E
replaced with new ones. The new fuel pipes must
remain sealed inside their bags before use. If a bag
is open do not use the fuel pipe, get a new one. Do
not open the bag until you are ready to assemble the D
fuel pipe.
1. Make sure that the bleed-off adaptors are C

assembled on the injectors before you install the A Nut 1
high pressure pipes. B Fuel rail
C Injection pump
2. Assemble the fuel pipes one at a time. The D Nut 2
procedure describes how to assemble one fuel E Fuel pipe
pipe.
1. Remove the fuel pipe as follows.
2.1. Put the correct end of the fuel pipe against
the correct injector cone. 1.1. Loosen the nut 2. Do not remove the nut at
this step.
2.2. Tighten the nut 1 with your hand.
1.2. Use the 17mm deep socket special tool at
2.3. Put the other end of the fuel pipe against the
the top of nut. This will prevent damage to
correct fuel rail cone.
the nut.
2.4. Tighten the nut 2 with your hand. Special Tool: Socket 17MM Offset - (HP
2.5. Nuts must be tightened in the correct Fuel pipes) (Qty.: 1)
sequence. Tighten nut 1 and then nut 2. Special Tool: Torque Wrench (10-100Nm)
(Qty.: 1)
2.6. Use the special tool at the top of nut 1 and
tighten it to the correct torque value. 1.3. Push the fuel pipe against the injector cone
and at the same time remove the nut 1.
Torque: 27 N·m
Special Tool: Socket 17MM Offset - (HP 1.4. Push the fuel pipe against the rail cone and
Fuel pipes) (Qty.: 1) at the same time remove the nut 2.
2.7. Put the spanner at the top of nut 2 and 1.5. Make sure that there is no dirt or debris on
tighten it to the correct torque value. the fuel pipe or the connectors.
Torque: 27 N·m 1.6. Remove the fuel pipe.
1.7. Seal all the open ports, use the correct parts
from the service kit.
2. Discard the old fuel pipe.
18 - 122 9823/1650-1 18 - 122

96 - Fuel Pipe
Install
Important: The high pressure fuel pipes must be

replaced with new ones. The new fuel pipes must
remain sealed inside their bags before use. If a bag
is open do not use the fuel pipe, get a new one. Do
not open the bag until you are ready to assemble the
fuel pipe.
1. To assemble the fuel pipe.

1.1. Put the correct end of the fuel pipe against
the correct pump cone at the injection
pump.
1.3. Put the other end of the fuel pipe against the
correct fuel rail cone.
1.5. Nuts must be tightened in the correct
sequence. Tighten nut 2 and then nut 1.
1.6. Use the special tool at the top of nut 2 and
tighten it to the correct torque value.
Torque: 27 N·m
Special Tool: Socket 17MM Offset - (HP
Fuel pipes) (Qty.: 1)
1.7. Put the spanner at the top of nut 1 and
tighten it to the correct torque value.
Torque: 27 N·m
After Installation
1. Ensure that all pipes are correctly installed
and located in retaining clips as applicable. If
retaining clips are missing or damaged they must
be replaced or renewed
18 - 123 9823/1650-1 18 - 123

96 - Fuel Pipe
06 - Low Pressure Pipe
06 - Low Pressure Pipe Figure 341.

B
Remove and Install
A
Before Removal A
Obey all fuel system health and safety information.
Refer to Fuel System, Health and Safety (PIL 18-00). C
Low Pressure Fuel Pipes

Remove
The low pressure fuel pipes have a nylon fitting
attached to the pipe that replaces the nut and olive.
The fittings are part of the pipe and not a separate
item.
1. To release the fuel pipe, first press and hold the

release buttons (one each side of the coupler).
Push the coupler towards the connector spigot
and then withdraw.
2. Cap all open ports to prevent ingress of dirt and
debris.
Assemble
1. To install the fuel pipe, press and hold the release
buttons. Push the coupler over the connector A Release Buttons
spigot and release the button. The connector will B Coupler
be heard to click when it is fully home and locked C Spigot
in place.
After Assembly
2. To check that the connection has been fully
made, attempt to pull the connector from the 1. Make sure that all the fuel pipes are correctly
connector spigot without releasing the lock installed and located in the retaining clips as
mechanism. (A gentle pull is all that is required, applicable. If retaining clips are missing or
if the connection is not correct the connector will damaged, they must be replaced or renewed.
release very easily.)
Injector Bleed-off Pipes

Before Removal
Obey all fuel system health and safety information.
1. Make sure that the engine is safe to work on. The

engine must cool and pressure in the fuel system
must decay before you start work. If the engine
has been running, wait at least one hour before
you start work.
2. Clean the engine. Refer to Engine, Clean (PIL
15-00).
3. Remove the protective cover as follows.
18 - 124 9823/1650-1 18 - 124

96 - Fuel Pipe
06 - Low Pressure Pipe
3.1. Push out the plastic segments. Figure 343.

3.2. Remove the screws and lift off the cover.
Figure 342.
D
C
B
A B
C
A Screw A Location tabs
B Plastic segment B Bleed pipe connector
C Protective cover C Bleed pipe clip
D High pressure fuel pipe
3.3. Remove any dirt or debris that is exposed.
Refer to Engine, Clean (PIL 15-00). After Assembly
4. To remove the bleed pipe clips, remove the high 1. Make sure that all pipes are correctly installed
pressure fuel pipes first. Refer to (PIL 18-96-03). and located in retaining clips as applicable. If the
retaining clips are missing or damaged they must
5. DO NOT try to repair fuel pipes or connectors. be replaced or renewed.
Defective fuel pipe assemblies must be replaced.
Remove
3. Install the protective cover. Refer to Figure 342.
The following details the removal and replacement
of one bleed-off connector. The procedure for the
remaining connectors is identical.
1. Gently spring the location tabs apart and pull out

the bleed pipe connector. DO NOT use excessive
force on the tabs.
2. Remove and discard the O-ring.
3. If it is necessary to remove the bleed off pipe
assembly, remove the nylon fitting at the high
pressure pump.
4. Cap all open ports to prevent ingress of dirt and
debris.
Install
1. Install a new O-ring.
2. Push in the bleed pipe connector until the
location tabs snap over the connector.
3. If applicable, replace the high pressure fuel pipes
with new ones. DO NOT use a high pressure fuel
pipe that was removed. Refer to (PIL 18-96-03)
18 - 125 9823/1650-1 18 - 125

Notes:
18 - 126 9823/1650-1 18 - 126

21 - Cooling System
Contents Page No.
21-00 Cooling System

21-00-00 General ............................................................................................................................. 21-3
21-03 Cooling Pack
21-03-00 General ........................................................................................................................... 21-13
21-03-03 Radiator .......................................................................................................................... 21-19
21-03-09 Transmission Oil Cooler ................................................................................................. 21-20
21-05 Fan Motor
21-05-00 General ........................................................................................................................... 21-25
21-06 Expansion Tank
21-06-00 General ........................................................................................................................... 21-37
21-09 Pump
21-09-00 General ........................................................................................................................... 21-43
21-12 Thermostat
21-12-00 General ........................................................................................................................... 21-49
21-21 Inlet
21-21-00 General ........................................................................................................................... 21-55
21-93 Hose
21-93-00 General ........................................................................................................................... 21-59
9823/1650-1
2018-01-15
Acronyms Glossary
CAC Charge Air Cooler

9823/1650-1
2018-01-15
21 - Cooling System
00 - Cooling System
00 - Cooling System
Contents Page No.
21-00-00 General ............................................................................................................................. 21-3
21 - 1 9823/1650-1 21 - 1
Notes:
21 - 2 9823/1650-1 21 - 2
21 - Cooling System
00 - Cooling System
00 - General
Introduction ...................................................... 21-3 During the working cycle of the engine a great deal
Health and Safety ........................................... 21-4 of heat is generated. It is important that the engine is
Technical Data ................................................. 21-4 kept at its normal operating temperature to achieve
Component Identification ................................. 21-5 maximum efficiency. It is the function of the cooling
system to allow the engine to reach this temperature
Operation ......................................................... 21-7 quickly and then maintain it.
Fault-Finding .................................................... 21-8
Drain and Fill ................................................. 21-10
Check (Condition) .......................................... 21-10
Check (Leaks) ............................................... 21-11
Check (Level) ................................................ 21-11
21 - 3 9823/1650-1 21 - 3
21 - Cooling System
00 - Cooling System
00 - General

CAUTION The cooling system is pressurised
when the coolant is hot. When you remove the Table 151.
cap, hot coolant can spray out and burn you. Radiator cap pressure 1 bar ( 14.5 psi)
Make sure that the engine is cool before you work setting
on the cooling system.
Thermostat Wax element with by-
CAUTION Antifreeze can be harmful. Obey the pass blanking
manufacturer's instructions when handling full Thermostat operating
strength or diluted antifreeze. temperature:
- Nominal temperature 96 °C ( 204.7 °F)
- Start to open tempera-94 –98 °C ( 201.1 –
ture 208.3 °F)
- Full open temperature 110 °C ( 229.8 °F)
- Travel (fully open) 9 mm
Fan drive type FEAD (Front End Acces-
sory Drive) belt
Fan belt (FEAD) adjust- Automatic belt tensioner
ment
Fan belt (FEAD) type Multigroove belt
Coolant Temperature Refer to PIL 15-84
Switch/Sender range
Coolant pump (non-ser- Bolt on, belt driven unit
viceable part)
21 - 4 9823/1650-1 21 - 4
21 - Cooling System
00 - Cooling System
00 - General
Figure 344.
11
14
10
8
9
7
16 7
17
15
12
13 7
6
4 5
1 Coolant pump 2 Drive belt

3 Pump cavity (crankcase) 4 Pump outlet gallery (crankcase)
5 Oil cooler cavity (crankcase) 6 Coolant gallery (crankcase)
7 Cylinder cooling jackets (crankcase) 8 Link galleries (crankcase to cylinder head)
9 Thermostat housing (cylinder head) 10 Thermostat (cylinder head)
11 Top hose connection port (cylinder head) 12 By-pass gallery (cylinder head and crankcase)
13 Bottom hose connection port (crankcase) 14 Port for coolant temperature sensor and
switch unit
15 Cab heater coolant supply 16 Cab heater coolant return
21 - 5 9823/1650-1 21 - 5
21 - Cooling System
00 - Cooling System
00 - General
17 Port for coolant supply to SCR (Selective

Catalytic Reduction) dosing system and DEF
(Diesel Exhaust Fluid) tank (if applicable)
21 - 6 9823/1650-1 21 - 6
21 - Cooling System
00 - Cooling System
00 - General
Operation
The coolant pump is driven via a pulley and front end

accessory drive belt, the pump draws coolant from
the pump cavity.
The coolant is pumped through the outlet gallery

to the oil cooler cavity in the left-hand side of the
crankcase. As the coolant flows past the oil cooler
matrix, heat is exchanged from the oil to the coolant.
This enables the oil to function as a coolant as well
as a lubricant. Refer to Oil Cooler (PIL 15-69) and Oil
Filter (PIL 15-21).
The coolant leaves the oil cooler cavity and passes

into the main crankcase gallery. The gallery is
connected to the cylinder water jackets. Coolant
flows around and up the jackets and then passes into
the cylinder head via the link galleries. The coolant
circulates around the cylinder head where it conducts
heat away from the combustion chambers and also
the fuel injector tips, refer to (PIL 18-18). The coolant
then passes to the thermostat housing.
When the engine is below normal operating

temperature the thermostat is closed, preventing
coolant flowing to the machine radiator via the top
hose connection port. Instead coolant is directed
through the by-pass gallery back to the pump
cavity and is again drawn into the pump. Refer to
Thermostat (PIL 21-12).
When the engine is at operating temperature the

thermostat opens, closing the by-pass gallery to the
pump and opening the top hose connection port to
the machine radiator. The coolant passes through
the radiator matrix and is cooled. The coolant flows
back to the engine via the bottom hose connection
port and is again drawn into the pump. Refer to
Thermostat (PIL 21-12).
A coolant temperature gauge and warning light

sender unit is installed at port 14. Refer to Engine
Sensors (PIL 15-84).
A cab heater hose can be installed at port 15. This

enables coolant to circulate through a heater matrix
when the thermostat is open or closed, ensuring fast
heater warm up.
21 - 7 9823/1650-1 21 - 7
21 - Cooling System
00 - Cooling System
00 - General
Fault-Finding
Fault
Coolant - Loss. Table 152. Page 21-8
Coolant - Over Temperature. Table 153. Page 21-8
Coolant - Under Temperature. Table 154. Page 21-9
Coolant - Contaminated. Table 155. Page 21-9
Table 152. Coolant - Loss.

Cause Remedy
Incorrect coolant level. Check the level.
Coolant leaking from engine radiator or cab heater. Visually inspect the radiator heater, hoses and
connection to locate the leak. If oil is present in the
coolant, check for a transmission or engine oil cooler
leak.
External engine coolant leak. Visually inspect the engine and components for
seal, gasket hose connection leaks. Make sure all
hose clips are in good condition and torqued to the
recommended figure. Make sure all spring band
clamps are in good condition and apply sufficient
pressure to the hoses.
Overheating or compression gases leaking, resulting See Also: Table 153. Coolant - Over Temperature.
in loss through the radiator overflow.
If installed, transmission cooler leak. Check/replace the transmission cooler. Check for
coolant in the inlet manifold and in the oil.
Lubricating oil cooler leak. Check/replace the oil cooler. Check for coolant in the
oil.
EGR (Exhaust Gas Recirculation) cooler leak (if Check/replace the EGR cooler. Check for signs of
applicable). coolant leaking into combustion chamber.
Cylinder head gasket leak. Check/replace the head gasket.
Cylinder head cracked or porous. Check/replace the cylinder head.
Crankcase coolant passages leaking. Check/replace the crankcase.
Table 153. Coolant - Over Temperature.

Cause Remedy
Incorrect coolant level (low). Check the level.
See Also: Table 152. Coolant - Loss.
External radiator matrix blocked with dirt or chaff. Clean exterior or radiator matrix.
Air flow to the radiator inadequate or restricted. Check/repair fan shroud, anti-recirculation sealing,
shutters, fan sensors, fan speeds as required.
Coolant pump or fan drive belts loose. Check/correct belt tension.
Radiator hose collapsed, restricted or leaking. Check/replace hose.
Oil level overfilled. Check oil level.
Cooling system pressure cap incorrect or faulty. Replace cap with the correct rating for the system.
Over concentration of anti-freeze. Remove part of the coolant from cooling system and
replace with water.
Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the
gauge and temperature sensor are accurate.
Thermostat faulty, incorrect or missing. Check/replace the thermostat.
Air or combustion gases in the cooling system. Make sure the fill rate is not exceeded and the
correct vented thermostat is installed. If aeration
continued, check for a compression leak through the
head gasket.
21 - 8 9823/1650-1 21 - 8
21 - Cooling System
00 - Cooling System
00 - General
Cause Remedy
Coolant pump faulty. Check/replace the coolant pump.
Vent line from engine and/or radiator blocked or Check routing and operation or vent line.
incorrectly routed (sudden overheating).
Leak between the top tank and the auxiliary tank Check for coolant leakage between radiator auxiliary
(sudden overheating). tank and radiator top tank.
Cooling passages in radiator, cylinder head, head Flush the system and fill with clean coolant.
gasket or crankcase blocked.
ECM (Engine Control Module) or electrical sensor Check the electronic fault codes. Check the electrical
fault (if applicable). connections at the ECM and sensors.
One or more engine injector worn or malfunctioning. Check the electronic fault codes. Check the electrical
Table 154. Coolant - Under Temperature.

Cause Remedy
Air flow across the radiator excessive. Check/repair fan shroud, anti-recirculation sealing,
shutters, fan sensors, fan speeds as required.
Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the
gauge and temperature sensor are accurate.
Thermostat faulty, (open - not sealing). Check/replace the thermostat.
Coolant not flowing by temperature sensor. Check/clean coolant passages. A total coolant loss
may result in the gauge showing low temperature
initially. In which case, check the level.
Table 155. Coolant - Contaminated.

Cause Remedy
Coolant rusty, operation without correct mixture of Drain and flush the cooling system. Fill with correct
antifreeze and water. mixture of antifreeze and water. Review the coolant
change interval.
Engine oil cooler, or cooler housing allowing cross Remove the oil cooler assembly and check relevant
contamination of coolant with engine oil. sealing elements for damage.
Transmission lubricating oil cooler leaking (if Check/replace lubricating oil cooler. Refer to
applicable). equipment manufacturer's procedures.
Lubricating oil leaks from lubricating oil cooler, head See Also: Table 152. Coolant - Loss.
gasket, head and crankcase.
21 - 9 9823/1650-1 21 - 9
21 - Cooling System
00 - Cooling System
00 - General
Drain and Fill Check (Condition)

Consumables
Description Part No. Size 1. Visually inspect the engine and related cooling
components for:
Antifreeze HP/ 4006/1101 5L
Coolant ASTM D6210 4006/1120 20 L 1.1. Leaks.
Concentrate 4006/1103 200 L 1.2. Cracked, burnt or perished hoses.
The graphic shows a typical engine cooling system, 1.3. Hose clips are in good condition and
the system you are working on may look slightly torqued to the correct value.
different.

4. Carefully loosen the cap just enough to let any
pressure escape. Remove the cap when all
pressure is released.
5. Disconnect the bottom radiator hose and allow
the coolant to drain into a suitable container.
6. Flush the system by pouring clean water into the
filler port.
7. Connect the bottom radiator hose.
8. Fill the expansion tank, using the necessary anti-
freeze solution, to the level indicated.
Consumable: Antifreeze HP/Coolant ASTM
D6210 Concentrate
9. Run the engine for a while to raise the coolant
to working temperature and pressure. Stop the
engine and check for leaks. Check the level in
the expansion tank and top up if necessary.
Figure 345.
A
B
A Cap
B Bottom radiator hose
C Expansion tank
21 - 10 9823/1650-1 21 - 10
21 - Cooling System
00 - Cooling System
00 - General
Check (Leaks) Check (Level)
Before you start the machine, inspect the system for 1. Make the machine safe.
leaks. Refer to: PIL 01-03.
1. Make the machine safe. Refer to (PIL 01-03). 2. Get access to the coolant expansion tank.
2. Get access to the cooling pack. 3. Check the level of coolant in the coolant
expansion tank. If necessary remove the filler
3. Check the cooling system for leaks. cap and top up to the level indicated.
4. If necessary, contact your JCB dealer. 4. Install the filler cap and make sure it is tight.
5. Run the engine for a while to raise the coolant to
working temperature and pressure.
6. Stop the engine and check for leaks.
21 - 11 9823/1650-1 21 - 11
21 - Cooling System
03 - Cooling Pack
03 - Cooling Pack
Contents Page No.
21-03-00 General ........................................................................................................................... 21-13

21-03-03 Radiator .......................................................................................................................... 21-19
21-03-09 Transmission Oil Cooler ................................................................................................. 21-20
21 - 12 9823/1650-1 21 - 12
21 - Cooling System
03 - Cooling Pack
00 - General
Introduction .................................................... 21-13 The cooling pack contains the following major
Clean ............................................................. 21-14 components:
Check (Condition) .......................................... 21-14
Remove and Install ....................................... 21-15 • Radiator.
• Cooling fan.
Disassemble and Assemble .......................... 21-18 • CAC (Charge Air Cooler).
• Condenser for air-conditioning (if installed).
• Oil cooler (if installed).
21 - 13 9823/1650-1 21 - 13
21 - Cooling System
03 - Cooling Pack
00 - General
If the radiator tubes/fins get clogged the radiator will 1. Make the machine safe. Refer to (PIL 01-03).
be less efficient.
2. Let the engine cool.
3. Get access to the cooling pack. Refer to (PIL
2. Open the engine cover. Refer to (PIL 06-06-06). 21-03)
3. Remove the undershield. Refer to (PIL 4. Check the hoses, radiator and fan for:
06-06-30).
4.1. Condition.
4. Use a soft bristle brush to remove all unwanted 4.2. Damage.
material from the rear of the radiator.
4.3. Security.
5. Release the fastener and pull the condenser
away from the radiator. 5. If necessary, Replace the system hoses/radiator.
6. Use the soft bristle brush to remove all unwanted

material from both sides of condenser and
the front of the radiator. Then push back the
condenser and lock in position with the fastener.
7. Make sure that the loosened material is removed
out of the engine compartment.
21 - 14 9823/1650-1 21 - 14
21 - Cooling System
03 - Cooling Pack
00 - General
Remove and Install
10. Disconnect the transmission cooler hoses from

Although it is possible to remove individual the chassis.
components it is quicker and easier to remove
the complete sub assembly, particularly if access 11. Plug all the open ports and hoses to prevent
is necessary for engine overhaul or removal and contamination.
replacement for example.
12. Disconnect the hydraulic hoses from the chassis.
Disassembly 13. Plug all the open ports and hoses to prevent
contamination.
14. On 527-56 machines, the fan motor hydraulic
2. Make sure that the engine and hydraulic system hoses are connected to the bulkhead plate.
are cool before you start the removal procedure.
Figure 346.
3. Remove the engine cover and side console
assembly. Refer to (PIL 06-06).
4. Put a label on the fuel lines, hoses and electrical
connectors to help installation.
5. Disconnect the fuel lines and electrical connector
from the fuel separator or remove the fuel
separator bolts, the fuel line clips and tie the
assembly safely out of the way.
6. Disconnect the radiator bottom hose and drain
the coolant.
S T
7. Disconnect the radiator top hose.
8. Disconnect the fan motor electrical connections S Bulkhead plate
(if installed). T Fan motor hydraulic hoses
9. For 81 kW, 93 kW and 108 kW Machines. 15. Disconnect the intercooler inlet and outlet hoses.
9.1. Disconnect the electrical connectors from 16. Support the cooling pack assembly, remove the
the fan motor direction control valve (if fusebox bolts and the fixing bolts.
installed), control solenoid and the speed
sensor. 17. Carefully lift and move the assembly away from
the machine.
21 - 15 9823/1650-1 21 - 15
21 - Cooling System
03 - Cooling Pack
00 - General
Figure 347.
A
A
E
A
E
D
F
B
E
L F
C
G H K
Q
P J
Table 156.
Item Description
A Fusebox support bolts
B Fuel separator and pump
C Air to air intercooler matrix
(1)
D Hydraulic oil cooler matrix (if installed)

(1)
E Fixing points
21 - 16 9823/1650-1 21 - 16
21 - Cooling System
03 - Cooling Pack
00 - General
Item Description
F Hydraulic hoses- Fan Motor/Oil Cooler
G Solenoid valve- reversible fan (if installed)
H Fan speed sensor
J Proportional fan speed control solenoid
K Engine coolant radiator matrix
(1)
L Radiator top hose connection

M Intercooler inlet hose connection
N Fixed Speed Cooling fan and hydraulic motor assem-
bly (55KW engines)
P Variable Speed Cooling fan and hydraulic motor as-
sembly (81, 93 and 108 KW engines)
Q Intercooler outlet hose connection
R Radiator bottom hose connection
(1) The engine coolant radiator, transmission oil cooler and air to air inter cooler matrix are all integral part. If
any part of the assembly has failed the complete unit must be replaced.
Install 1.1. Tighten the clamps to the correct torque

value.
steps.
Figure 348.
U
U
U Clamp
1.2. Fill the engine cooling system with the Table 157. Torque Values
correct type of coolant. Refer to (PIL 21-00).
Item Description Nm
1.3. Operate the engine and check the fan motor U Clamp 5.5
speed.
30-00-00).
1.5. Check the transmission oil level and top up
as necessary.
21 - 17 9823/1650-1 21 - 17
21 - Cooling System
03 - Cooling Pack
00 - General
With the cooling pack removed from the machine

disassemble the components as necessary.
• Remove the transmission oil cooler. Refer to

(PIL 21-03-09).
• Remove the cooling fan motor. Refer to (PIL
21-05).
• Remove the hydraulic oil cooler. Refer to (PIL
21-03-12).
• Remove the fuel cooler. Refer to (PIL 18-39-00).
• Remove the air conditioning condenser. Refer
to (PIL 12-15-00).
21 - 18 9823/1650-1 21 - 18
21 - Cooling System
03 - Cooling Pack
03 - Radiator
03 - Radiator
Introduction
The radiator is a device in the cooling system that

removes heat from the coolant passing through it,
allowing the coolant to remove heat from the engine.
21 - 19 9823/1650-1 21 - 19
21 - Cooling System
03 - Cooling Pack
09 - Transmission Oil Cooler
09 - Transmission Oil Cooler Check (Condition)

Check (Condition) .......................................... 21-20 The liquid to liquid cooler is a possible source of
Remove and Install ....................................... 21-21 water contamination. It should be tested for possible
failure as follows:
1. Drain any remaining oil/water from the cooler.

2. Install a blanking plug to the outlet of the cooler.
3. Connect an air supply to the transmission oil inlet.
4. The air test pressure must not exceed the
specified value.
Pressure: 6 bar ( 87.0 psi)
5. Submerge the cooler in a tank of water and apply
air pressure to test for leakage. If bubbles are
visible there is a breakdown between the water
and hydraulic circuits.
6. Replace the cooler. Refer to cooling system-
cooling pack.
7. If the cooler is not damaged, clean and make it
dry before you assemble it to the machine.
21 - 20 9823/1650-1 21 - 20
21 - Cooling System
03 - Cooling Pack
Remove and Install
4. Drain the engine coolant. Refer to (PIL 21-00).

Remove 5. Disconnect the electrical oil temperature sensor.
6. Carefully disconnect the oil feed and return
2. Follow the general health and safety procedures. hoses. The oil may be hot.
7. Remove the water hose clips and the retaining
3. Remove the engine cover base for easy access clips. Take out the cooler.
to the transmission oil cooler. Refer to (PIL
06-06).
Figure 349.
A
C D C C C
A Electrical oil temperature sensor B Oil feed and return hoses

C Retaining clips D Cooler
21 - 21 9823/1650-1 21 - 21
21 - Cooling System
03 - Cooling Pack
Install
steps.
1.1. Check the transmission oil level. Refer to
(PIL 27-00).
1.2. Fill the cooling system. Refer to (PIL 21-00).
1.3. Operate the machine, stop the engine and
check for water/oil leaks at the cooler hose
connections.
1.4. Check the transmission oil level. Refer to
(PIL 27-00).
1.5. Check the coolant level.
If a faulty oil cooler has been replaced with a new

one, the transmission may be contaminated with
water. Carry out the flushing procedure. Refer to (PIL
27-06).
After 50- 100 operating hours, drain the transmission

oil and check for signs of water contamination. There
should be no contamination. Refill the transmission
with fresh oil.
21 - 22 9823/1650-1 21 - 22
21 - Cooling System
05 - Fan Motor
05 - Fan Motor
Contents Page No.
21-05-00 General ........................................................................................................................... 21-25
21 - 23 9823/1650-1 21 - 23
Notes:
21 - 24 9823/1650-1 21 - 24
21 - Cooling System
05 - Fan Motor
00 - General
Introduction .................................................... 21-25 The product is equipped with a hydraulically driven
Operation ....................................................... 21-26 fan motor to provide air flow though the cooling pack.
Disassemble and Assemble .......................... 21-35 Some products may have either a fixed speed fan or
a variable speed hydraulic fan.
On some products, the fan may be reversible to

assist with the removal of debris from the cooling
pack.
21 - 25 9823/1650-1 21 - 25
21 - Cooling System
05 - Fan Motor
00 - General
Operation
Schematic diagram
Fixed speed
Figure 350.
The schematic diagram shows an general overview D F
of the system. Your machine may have a triple pump
installed but the system will be similar. C
The cooling fan motor is hydraulically driven. The E

motor turns the cooling fan and air is drawn through
the radiators in the machine cooling pack.
Hydraulic oil from the pump supplies the fan motor

and pilot pressure supply valve.
The pressure relief valve prevents component

damage.
A Main pump
B Hydraulic tank
C Pump pressure supply
D Fan motor case drain line
E Fan motor pressure relief valve
F Fan motor
21 - 26 9823/1650-1 21 - 26
21 - Cooling System
05 - Fan Motor
00 - General
Table 158. Colour key-Oil flow and pressure to inform the right hand instrument ECU of the
ambient air temperature.
Full pressure
The ECU varies the speed of the fan motor according
Exhaust to the temperature signals, the fan will be at a higher
speed in high temperatures and a lower speed in low
temperatures.
Neutral
The ECU generates the correct PWM (Pulse Width
Modulation) signal for operation of the fan speed
proportional solenoid.
Variable speed
The proportional solenoid operates as a pressure
The engine cooling pack is cooled by a hydraulically reducing valve. The supply to the fan motor is at a
powered cooling fan motor. pressure in relation to the ambient temperature.
The fan speed is controlled by the right hand The fan speed sensor sends a signal to the ECU to
instrument ECU (Electronic Control Unit). record current fan speed.
The engine air temperature sensor sends a signal A reversible fan option is provided where an operator
over the machine CAN (Controller Area Network)bus switch energises the fan direction solenoid to reverse
the direction of the fan.
21 - 27 9823/1650-1 21 - 27
21 - Cooling System
05 - Fan Motor
00 - General
Schematic diagram
Figure 351.
G H
B
C
A Hydraulic tank B Hydraulic variflow pump assembly

C Hydraulic gear pump (Fan supply) D Oil cooler
E Fan speed proportional solenoid F Fan direction solenoid (if installed)
G Fan motor housing H Fan motor
21 - 28 9823/1650-1 21 - 28
21 - Cooling System
05 - Fan Motor
00 - General
Table 159. Colour key-Oil flow and pressure

Full pressure
Exhaust
Neutral
21 - 29 9823/1650-1 21 - 29
21 - Cooling System
05 - Fan Motor
00 - General
Remove and Install
If the performance is below that specified, the

Fixed Speed Fan (If Installed) motor should be renewed. Renewal of individual
components such as gears, bearings and housings
Your machine may be installed with a fixed or will not result in a permanent cure. If the motor
variable speed fan. Removal and installation of both performance is satisfactory, but there is external
types of fan are shown. leakage, it should be dismantled for re-sealing
purposes only.
Before you remove the fan motor, check its
performance.
21 - 30 9823/1650-1 21 - 30
21 - Cooling System
05 - Fan Motor
00 - General
Figure 352.
A Fan retaining nut B Motor retaining bolts

C Fan bracket securing bolts D Feed and return hoses
E Case drain hose
Remove 4. Mark the hydraulic feed and return hoses to help

identification when you install.
1. Make the machine safe. Refer to (PIL 01-06)
5. Disconnect and plug the feed and return hoses.
2. Install the safety strut. Refer to (PIL 06-69).
6. Disconnect and plug the case drain hose.
3. Discharge the hydraulic pressure. Refer to (PIL
30-00). 7. Remove the fan guard.
21 - 31 9823/1650-1 21 - 31
21 - Cooling System
05 - Fan Motor
00 - General
8. Undo the fan bracket securing bolts (x4) and lift 2. Follow the general health and safety procedures.
the fan and motor assembly from the machine. Refer to (PIL 01-03).
9. Prevent the fan from turning, release the tab 3. Install the safety strut. Refer to (PIL 06-69).
washer and then undo the fan retaining nut.
10. Withdraw the fan from the motor shaft. Retain the 30-00).
drive key (not shown).
5. Mark the electrical connectors to help in
11. Undo the motor retaining bolts and remove the identification when you install.
motor.
6. Disconnect the harness from the solenoid
Install electrical connector.
1. The installation procedure is the opposite of the 7. Disconnect the harness from the speed sensor
removal procedure. Additionally do the following electrical connector.
steps. 8. If installed, disconnect the harness from the
1.1. Tighten all the fastening nuts and bolts to direction solenoid.
the correct torque value. 9. Mark the hydraulic hoses to help in identification
1.2. Make sure all hoses are attached to the when you install.
correct ports. The case drain hose (if
installed) must be fed in to a tank line 10. Disconnect and plug the feed hose and return
otherwise damage to the motor will occur. hose.
1.3. Check and adjust the hydraulic fluid level. 11. If installed, disconnect and plug the case drain
hose.
Table 160. Torque Settings 12. Support the motor and the fan.
Item Value 13. Remove the bolts.
A 36 N·m
14. Remove the fan bracket, the fan and then the
B 28 N·m
motor from the machine.
C 47 N·m
15. Stop the fan from turning.
Variable Speed Fan (If Installed) 16. Remove the tab washer and then remove the nut.
Before you remove the fan motor, check its 17. Remove the fan from the motor shaft. Keep the
performance. drive key.
If the performance is below that specified, the motor 18. Remove the motor/ control pack retaining nuts.
should be renewed.
19. Remove the motor from the bracket.
Remove
21 - 32 9823/1650-1 21 - 32
21 - Cooling System
05 - Fan Motor
00 - General
Figure 353.
A
A
J H
E
B G
K
A D F
A
A Bolts B Case drain hose

C Feed hose D Return hose
E Motor retaining nuts F Solenoid electrical connector
G Speed sensor electrical connector H Bracket
J Direction solenoid K Fan nut
21 - 33 9823/1650-1 21 - 33
21 - Cooling System
05 - Fan Motor
00 - General
Install 1.2. The case drain hose (if installed) must be

fed into a tank line otherwise the motor can
1. The installation procedure is the opposite of the be damaged.
steps. 1.3. Replace the tab washer located on the fan
nut.
1.1. Make sure all hoses are attached to the 1.4. Check the hydraulic fluid level. Refer to (PIL
correct ports. 30-00).
Table 161. Torque settings

Item Value
B 27 N·m
C 48 N·m
D 48 N·m
K 36 N·m
21 - 34 9823/1650-1 21 - 34
21 - Cooling System
05 - Fan Motor
00 - General
Do not attempt to dismantle the motor. If it is

defective, it must be renewed.
21 - 35 9823/1650-1 21 - 35
21 - Cooling System
06 - Expansion Tank
06 - Expansion Tank
Contents Page No.
21-06-00 General ........................................................................................................................... 21-37
21 - 36 9823/1650-1 21 - 36
21 - Cooling System
06 - Expansion Tank
00 - General
Introduction .................................................... 21-37 The expansion tank retains coolant that has been
Remove and Install ....................................... 21-38 forced out of the machines radiator under pressure.
As the machine runs, the temperature of the coolant

circulating around the system increases, this causes
an increase of pressure in the cooling system. When
the pressure builds to a high enough point, the
radiator cap allows that pressure to escape into the
coolant tank through a rubber overflow tube that
is connected from the neck of the radiator to the
expansion tank.
Most of the coolant that is forced into the expansion

tank returns to the radiator naturally when the engine
is cold.
21 - 37 9823/1650-1 21 - 37
21 - Cooling System
06 - Expansion Tank
00 - General
Remove and Install
Consumables 5. Open the engine compartment cover. Refer to

Description Part No. Size (PIL 06-06).
JCB Threadlocker 4101/0250 0.01 L 6. Drain the engine coolant. Refer to (PIL 21-00).
Strength) 7. Remove the bolts.
Remove 8. Remove the expansion tank cover.
1. Make the machine safe. Refer to (PIL 01-03). 9. Disconnect the coolant level sensor electrical
connector (if installed).
2. Follow the general health and safety procedures.
Refer to (PIL 01-03). 10. Loosen the hose clips and disconnect the hoses
from the expansion tank.
3. Switch off the engine before working in the
engine compartment. Remove the ignition key or 11. Support the expansion tank.
isolate battery to prevent the engine from being 12. Remove the expansion tank from the bracket.
started. Refer to (PIL 33-03).
4. If the engine is hot, let it cool for one hour.
21 - 38 9823/1650-1 21 - 38
21 - Cooling System
06 - Expansion Tank
00 - General
Figure 354.
D A
E F E E
A Hose clips B Hoses

C Tank cover D Expansion tank
E Bolts F Bracket
21 - 39 9823/1650-1 21 - 39
21 - Cooling System
06 - Expansion Tank
00 - General
Install
steps.
1.1. Apply sealant to the bolts.
(Medium Strength)
1.2. Tighten the bolts to the specified torque
value.
1.3. Fill the engine cooling system with the
correct type of coolant. Refer to (PIL 21-00).
1.4. When the installation procedure is
complete, start the engine and check for
coolant leaks.

Item Description Nm
E Bolts 5
21 - 40 9823/1650-1 21 - 40
21 - Cooling System
09 - Pump
09 - Pump
Contents Page No.
21-09-00 General ........................................................................................................................... 21-43
21 - 41 9823/1650-1 21 - 41
Notes:
21 - 42 9823/1650-1 21 - 42
21 - Cooling System
09 - Pump
00 - General
Introduction .................................................... 21-43 The coolant pump is a centrifugal type located in the
Component Identification ............................... 21-44 front of the crankcase, driven by the engine drive belt.
Operation ....................................................... 21-44
Remove and Install ....................................... 21-45 The impeller rotates to circulate the coolant through
the cooling system. The pump shaft bearing and seal
are not renewable.
21 - 43 9823/1650-1 21 - 43
21 - Cooling System
09 - Pump
00 - General

Figure 355. The coolant pump is driven via a pulley and front end
1 accessory drive belt, the pump draws coolant from
2 the pump cavity. The coolant is pumped through the
outlet gallery to the oil cooler cavity in the left side
of the crankcase. As the coolant flows past the oil
cooler matrix, heat is exchanged from the oil to the
coolant. This enables the oil to function as a coolant
as well as a lubricant.
For cooling system operation.
1 Coolant pump
2 Drive pulley
3 Impeller
21 - 44 9823/1650-1 21 - 44
21 - Cooling System
09 - Pump
00 - General
Before Removal
1. Make sure that the machine is safe. If the engine
has been running, let it cool before you start the
service work. Refer to (PIL 01-03).
3. Drain the coolant.
4. Remove the coolant pump drive belt.
Remove
2
1. Remove the fixing screws. 1
2. Remove the coolant pump assembly.
3. Remove and discard the sealing O-ring.
1 Coolant pump assembly

2 Fixing screws
The pump is a non-serviceable item. If the pump is

faulty or damaged it must be renewed.
Install
steps.
2. Make sure that the mating face on the crankcase
is clean and free from damage.
3. Install a new sealing O-ring.
4. Tighten the screws to the correct torque value.
21 - 45 9823/1650-1 21 - 45
21 - Cooling System
09 - Pump
00 - General
Figure 357.
P1
P1 Sealing O-ring
After Installation
1. Install the coolant pump drive belt.
2. Refill the engine with the recommended coolant
mixture.

Item Nm
2 24
21 - 46 9823/1650-1 21 - 46
21 - Cooling System
12 - Thermostat
12 - Thermostat
Contents Page No.
21-12-00 General ........................................................................................................................... 21-49
21 - 47 9823/1650-1 21 - 47
Notes:
21 - 48 9823/1650-1 21 - 48
21 - Cooling System
12 - Thermostat
00 - General
Introduction .................................................... 21-49 The thermostat is located between the engine and
Component Identification ............................... 21-50 the radiator. The function of the thermostat is to block
Operation ....................................................... 21-50 the flow of coolant to the radiator until the engine has
Check (Condition) .......................................... 21-51 warmed up to a sufficient temperature.
Check (Operation) ......................................... 21-52 When the engine is cold, no coolant flows through
Remove and Install ....................................... 21-52 the engine. Once the engine reaches its operating
temperature, generally about 95 °C ( 203 °F), the
thermostat opens. By letting the engine warm up as
quickly as possible, the thermostat reduces engine
wear, deposits and emissions.
21 - 49 9823/1650-1 21 - 49
21 - Cooling System
12 - Thermostat
00 - General

Figure 358. The thermostat is a wax element type and is
configured for by-pass blanking. The thermostat
functions as follows:
State A - Closed (Engine Cold)

When the engine is cold the wax pellet has
contracted into its housing. This allows the spring to
act against the thermostat body and move the valve
A plate up against its seat, closing the outlet port to the
radiator. Since the bottom valve plate is connected
to the top valve plate it also moves up, opening the
bypass port. The coolant flows from the thermostat
housing inlet port into the bypass gallery.
Figure 359.
7 3
8 11
6
10
5
A Thermostat
4
1 Thermostat
2 Spring
3 Top valve plate
4 Bottom valve plate
5 Wax pellet
6 Diaphragm
7 Actuating rod
8 Outlet port to the radiator top hose
9 Inlet port thermostat housing
10 Outlet port bypass gallery
11 1 mm diameter orifice
State B - Open (Engine Hot)

When the engine is hot, the wax pellet melts,
as it does so it expands and pushes against
the diaphragm. The diaphragm reacts against
the actuating rod and both the top and bottom
valve plates move down into the thermostat body,
compressing spring. The outlet port to the radiator
is now open and the bypass port is closed. A 1
21 - 50 9823/1650-1 21 - 50
21 - Cooling System
12 - Thermostat
00 - General
mm diameter orifice allows trapped air to be expelled Check (Condition)

from the system.
Figure 360. 1. If the thermostat is suspected of being faulty,

7 3 perform a thermostat test, refer to Thermostat
- Check Operation to confirm its serviceability.
Note that the thermostat is a non-serviceable
8 11 item. If the thermostat is faulty or damaged it
must be renewed.
2. Inspect the seal for damage or splits. If necessary
renew the seal. Make sure that the seal is
correctly located.
9
6
10
5
4
1 Thermostat
2 Spring
3 Top valve plate
4 Bottom valve plate
5 Wax pellet
6 Diaphragm
7 Actuating rod
8 Outlet port to the radiator top hose
9 Inlet port thermostat housing
10 Outlet port bypass gallery
11 1 mm diameter orifice
21 - 51 9823/1650-1 21 - 51
21 - Cooling System
12 - Thermostat
00 - General
A period of 3 –5 min before the thermostat valve Before Removal

starts to operate is normal because of the time
required to heat soak the thermostat. 1. Make sure that the engine is safe to work on. If
1. Make sure that the engine is safe to work on. If you start the service work.
you start the service work. 2. Get access to the engine.
2. Remove the thermostat housing and the 3. Drain the coolant. Refer to (PIL 21-03-03).
thermostat. Refer to (PIL 21-12).
Figure 362.
3. Suspend the thermostat in a suitable container
of coolant. Use an external heat source to
gradually increase the temperature of the
coolant. Note: When working with boiling water,
all the necessary safety precautions must be
taken. Refer to Figure 361.
1
Figure 361.
4. Use a thermometer to measure the temperature

of the coolant.
5. When the coolant reaches the operating range of
the thermostat the valve should start to open, the
movement of the valve plate should be evident.
1 Radiator hose
6. Record the start to open temperature, the fully 2 Fixing bolts
open temperature and the amount of valve lift
travel when fully open. Compare this with the Remove
data in Technical Data (PIL 21-00).
1. Disconnect the radiator hose at the thermostat
housing.
2. Remove the fixing bolts and lift off the housing.
3. Lift out the thermostat.
21 - 52 9823/1650-1 21 - 52
21 - Cooling System
12 - Thermostat
00 - General
Figure 363.
3 4
3 Thermostat
4 Seal
4. If the thermostat is suspected of being faulty,
perform tests to confirm its serviceability.
Note The thermostat is a non-serviceable item. If the

thermostat is faulty or damaged it must be renewed.
Install
steps.
2. Inspect the seal for damage or splits. If necessary
renew the seal. Locate the seal correctly as
shown.
3. Make sure you install the thermostat the right way
up.
5. Reconnect the radiator hose at the housing.
After Installation
1. Fill the cooling system with the recommended
coolant mixture.
Refer to (PIL 21-03-03).

Item Nm
2 24
21 - 53 9823/1650-1 21 - 53
21 - Cooling System
21 - Inlet
21 - Inlet
Contents Page No.
21-21-00 General ........................................................................................................................... 21-55
21 - 54 9823/1650-1 21 - 54
21 - Cooling System
21 - Inlet
00 - General
00 - General Figure 364.
Remove and Install

1
Before Removal
the engine has been running, let it cool before 1
1
3. Drain the cooling system. 2
The housing may be orientated differently to that

shown in the illustration, depending on the engine
installation.
Remove
1. Disconnect the radiator hose at the inlet housing.
2. Undo the bolts and lift off the housing.
X 6.8
1 Inlet housing
2 Fixing bolts
6 Sealing Ring
X Locating tab - sealing ring
Install
steps.
2. Make sure that the sealing ring is undamaged.
If necessary install a new seal. Make sure that
the seal is correctly located in its groove on the
housing. Note the locating tab.
4. Reconnect the radiator hose at the housing.
After Installation
1. Refill the engine with the recommended coolant
mixture.
21 - 55 9823/1650-1 21 - 55
21 - Cooling System
21 - Inlet
00 - General

Item Nm
2 24
21 - 56 9823/1650-1 21 - 56
21 - Cooling System
93 - Hose
93 - Hose
Contents Page No.
21-93-00 General ........................................................................................................................... 21-59
21 - 57 9823/1650-1 21 - 57
Notes:
21 - 58 9823/1650-1 21 - 58
21 - Cooling System
93 - Hose
00 - General
Introduction .................................................... 21-59 The engine cooling hoses are essential parts of
Health and Safety .......................................... 21-60 the cooling system. They carry the liquid coolant
Check (Condition) .......................................... 21-60 between the engine and the radiator/cooling pack.
21 - 59 9823/1650-1 21 - 59
21 - Cooling System
93 - Hose
00 - General

CAUTION The cooling system is pressurised
when the coolant is hot. When you remove the 1. Visually inspect the engine and related cooling
cap, hot coolant can spray out and burn you. components for:
Make sure that the engine is cool before you work
on the cooling system. 1.1. Leaks.
1.2. Cracked, burnt or perished hoses.
1.3. Hose clips are in good condition and
tightened to the correct torque value.
21 - 60 9823/1650-1 21 - 60
24 - Brake System
Contents Page No.
24-00 Brake System

24-00-00 General ............................................................................................................................. 24-3
24-03 Service Brake
24-03-00 General ........................................................................................................................... 24-11
24-03-01 Master Cylinder .............................................................................................................. 24-19
24-03-39 Piston ............................................................................................................................. 24-20
24-03-45 Vacuum Servo Unit ........................................................................................................ 24-22
24-03-46 Vacuum Pump ................................................................................................................ 24-23
24-03-50 Light Switch .................................................................................................................... 24-24
24-03-57 Pressure Sensor ............................................................................................................ 24-28
24-18 Park Brake
24-18-00 General ........................................................................................................................... 24-31
24-18-03 Switch ............................................................................................................................. 24-43
24-18-06 Cable .............................................................................................................................. 24-44
24-18-15 Pad ................................................................................................................................. 24-54
24-18-18 Caliper ............................................................................................................................ 24-55
24-18-21 Disc ................................................................................................................................ 24-62
24-18-48 Actuator .......................................................................................................................... 24-72
9823/1650-1
2018-05-24
Acronyms Glossary
2WD Two Wheel Drive

4WD Four Wheel Drive
9823/1650-1
2018-05-24
24 - Brake System
00 - Brake System
00 - Brake System
Contents Page No.
24-00-00 General ............................................................................................................................. 24-3
24 - 1 9823/1650-1 24 - 1
Notes:
24 - 2 9823/1650-1 24 - 2
24 - Brake System
00 - Brake System
00 - General
00 - General Health and Safety

Health and Safety ........................................... 24-3 Brake Fluid
Fault-Finding .................................................... 24-5 Use of incorrect brake fluid will cause serious
Discharge and Pressurise ............................... 24-8 damage to the seals of the braking system. This will
result in brake failure.
Accumulators
The accumulators contain hydraulic fluid and gas at
high pressure. Prior to any work being carried out
on systems incorporating accumulators, the system
pressure must be discharged by a JCB dealer, as
the sudden release of the hydraulic fluid or gas may
cause serious injury or death.
Service Brake Bleeding
Before bleeding the service brake system, park on
level ground and set the park brake to on. Put blocks
on both sides of the wheels on one axle to prevent
the machine rolling. Stop the engine and disconnect
the battery so that the engine cannot be started. If
you do not take these precautions the machine could
run over you.
Park Brake Maintenance
Before working on the park brake, park on level
ground and put blocks on both sides of all wheels
to prevent the machine rolling. Stop the engine and
disconnect the battery so that the engine cannot be
started. If you do not take these precautions the
machine could run over you.
Make the machine safe before getting beneath it.
movement.
Brake Dust
Brake pads generate dust, which if inhaled may
endanger health. Wash off the caliper assemblies
before commencing work. Clean hands thoroughly
after completing the work.
Brake Dust
Brake shoes generate dust, which if inhaled
may endanger health. Make sure that dust is
removed correctly, particularly before installing
new components. Clean hands thoroughly after
completing the work.
Springs
Always wear personal protective equipment when
dismantling assemblies containing components
under pressure from springs. This will protect against
eye injury from components accidentally flying out.
Notice: Using incorrect fluid could damage the
system. See Fluids, Capacities and Lubricants for
24 - 3 9823/1650-1 24 - 3
24 - Brake System
00 - Brake System
00 - General
the correct fluid. The fluid can harm your skin. Wear
rubber gloves. Cover cuts or grazes.
WARNING! Before working on the brake system,
make sure that the machine is on solid level ground.
Put blocks on all wheels to prevent the machine
rolling.
WARNING! Do not use the machine with any part of
its brake system disconnected or inoperative. When
the test has been completed, make sure all brake
system components are installed and the system is
operating correctly.
WARNING! Before testing the park brake make sure
the area around the machine is clear of people.
WARNING! If the machine starts to move during the
park brake test, immediately apply the foot brake and
reduce the engine speed.
WARNING! If the machine starts to move during the
service brake test, immediately reduce the engine
speed and apply the park brake.
WARNING! Do not use a machine with a faulty park
brake.
WARNING! Non approved modifications to drive
ratios, machine weight or wheel and tyre sizes may
adversely affect the performance of the park brake.
WARNING! Oil on the brake disc will reduce brake
effectiveness. Keep oil away from the brake disc.
Remove any oil from the disc with a suitable solvent.
Read and understand the solvent manufacturer's
safety instructions. If the pads are oily, install with the
new pads.
WARNING! Faulty brakes can kill. If you have to top
up the brake oil reservoir frequently, get the brake
system checked by your JCB Dealer. Do not use the
machine until the fault has been put right.
WARNING! The park brake must not be used to
slow the machine from travelling speed, except in an
emergency, otherwise the efficiency of the brake will
be reduced. Whenever the park brake has been used
in an emergency the brake friction components must
be renewed and the other components inspected.
Notice: Over adjustment or failure to disengage the
park brake properly will cause excessive wear of the
park brake mechanism.
24 - 4 9823/1650-1 24 - 4
24 - Brake System
00 - Brake System
00 - General
Fault-Finding
Fault
One or more brakes do not apply. (Brake travel not excessive, brakes not Table 166. Page 24-5
pulling to one side)
Pedal travel excessive (but not touching floor) Table 167. Page 24-5
Pedal hard to operate Table 168. Page 24-5
Pedal touches floor under constant pressure- no fluid loss Table 169. Page 24-6
Pedal touches floor under constant pressure and fluid loss Table 170. Page 24-6
Poor braking (not pulling to one side) Table 171. Page 24-6
Brakes not releasing Table 172. Page 24-6
Poor braking when hot Table 173. Page 24-7
Excessive brake noise in operation (Due to the metal to metal contact of oil Table 174. Page 24-7
immersed brakes, limited noise can be heard which is consistent and normal
with this type of design).
Fluid loss when machine standing (for example- overnight). (Conform that Table 175. Page 24-7
the fault is as indicated by checking that the brake pedal does not touch the
floor when it is operated under constant pressure).
Table 166. One or more brakes do not apply. (Brake travel not excessive, brakes not pulling to one side)
Cause Remedy
Master cylinder fault. Check master cylinder to identify fault area, service
as necessary. Refer to (PIL 24-03-01).
Friction/counter plate distortion. Replace friction/counter plates- both sides of relevant
axle.
Table 167. Pedal travel excessive (but not touching floor)

Cause Remedy
Air in hydraulic system. Check fluid reservoir level. Check for fluid/air leaks,
correct as necessary. Refer to (PIL 24-03).
Bleed the brake system. Refer to (PIL 24-00-00).
Leak in hydraulic system. Check for fluid loss at master cylinder and brake
piston, all pipes and fittings for loose connections.
correct as necessary. Refer to (PIL 24-03-39).
Check fluid reservoir level. Check for fluid/air leaks,
axle.
Table 168. Pedal hard to operate

Cause Remedy
Tightness at pedal pivot. Check the pedal pivot. Free-off/lubricate.
Fluid contamination/seal damage. Flush system and renew all hydraulic seals. Bleed
the brake system. Refer to (PIL 24-00-00).
Misaligned push rod/pedal. Check and correct as necessary.
Kinked or crushed brake pipes. Check/replace brake pipework.
Vacuum failure due to low vacuum at source. Check/service engine mounted exhauster unit as
(Machines fitted with servo assisted brakes only). necessary.
Blocked/leaking vacuum pipe. (Machines fitted with Check/renew vacuum pipe. Refer to (PIL 24-03-96).
servo assisted brakes only).
Servo defect. (Machines fitted with servo assisted Replace the servo unit.
brakes only).
24 - 5 9823/1650-1 24 - 5
24 - Brake System
00 - Brake System
00 - General
Table 169. Pedal touches floor under constant pressure- no fluid loss
Cause Remedy
axle.
Air in hydraulic system. Check fluid reservoir level. Check for fluid/air leaks,
Table 170. Pedal touches floor under constant pressure and fluid loss
Cause Remedy
External fluid leaks. Check fluid reservoir level. Check for fluid/air leaks,
correct as necessary. Refer to (PIL 24-03)
Internal fluid leaks. Bleed the brake system. Refer to (PIL 24-00-00).
Table 171. Poor braking (not pulling to one side)

Cause Remedy
Friction plates worn beyond limits or distorted. Replace friction/counter plates- both sides of relevant
axle.
Annular piston fault. See table 'Brakes not releasing', item 'Annular brake
piston(s) binding in axle'.
Incorrect/low axle oil. Fill the axle with correct type of oil.
Vacuum failure Check vacuum source/pipes, service as necessary.
Table 172. Brakes not releasing

Cause Remedy
Brake pedal spring fault. Install a new spring.
Master cylinder fault (plunger stuck in bore). Check master cylinder to identify fault area, service
Blocked hole in master cylinder reservoir cap Install a new reservoir cap.
Brake pedal free travel incorrect. Adjust pedal free travel.
Fluid contamination/seal damage. Flush system and replace hydraulic seals. Refill with
clean fluid.
Annular brake piston(s) binding in axle. Check that correct brake fluid has been used
(incorrect fluid could swell the annular brake piston
seals).
Check if annular brake piston seals are in good
condition.
Check that annular brake piston rotates freely in its
housing with no seals installed.
Check that the annular brake piston seal retracts the
piston approximately to the specified value.
Length: 0.5 mm
Kinked or crushed brake pipes. Check and replace pipes as necessary.
Friction/counter plates not free on splines and/or Check friction/counter plates for free movement,
dowels. replace if necessary- both sides of relevant axle.
24 - 6 9823/1650-1 24 - 6
24 - Brake System
00 - Brake System
00 - General
Table 173. Poor braking when hot

Cause Remedy
Moisture in system vaporising when axle is hot. Strip axle and clean annular piston to remove
moisture.
Remove master cylinder and check for corrosion,
service as necessary.
Flush system and replace hydraulic seals. Refill with
clean fluid.
Table 174. Excessive brake noise in operation (Due to the metal to metal contact of oil immersed brakes,
limited noise can be heard which is consistent and normal with this type of design).
Cause Remedy
Deterioration of axle oil or wrong type of axle oil Change axle oil. Refer to check level (PIL 20-00)
Axle oil loss. Refill axle with correct oil and check for leaks. Refer
to (PIL 20-00).
Friction plates worn beyond limits. Renew friction/counter plates on both sides of
relevant axle.
Friction/counter plates in poor condition. Check for distortion or surface pitting and/or
roughness of the plates. (Annular grooving of counter
plates is acceptable).
Table 175. Fluid loss when machine standing (for example- overnight). (Conform that the fault is as
indicated by checking that the brake pedal does not touch the floor when it is operated under constant
pressure).
Cause Remedy
Severe damage or slight cut/nick in the brake piston Test the brake piston seals for leakage. If necessary,
seal. strip axle and renew seal(s).
External leakage through brake pipe connections etc. Check for and repair leaking connections.
24 - 7 9823/1650-1 24 - 7
24 - Brake System
00 - Brake System
00 - General
Discharge and Pressurise
This operation must be done before any attempt

is made to disconnect the hydraulic connections
including the brake pressure switch.

2. If necessary install the lift arm maintenance strut.
3. Stop the engine.
4. Turn on the ignition, but do not start the engine.
5. Press the brake pedal several times until no
resistance is felt.
5.1. This may take several pumps, depending
on the length of time since the engine was
last run.
6. Turn the starter switch to the off position and
remove the key.
24 - 8 9823/1650-1 24 - 8
24 - Brake System
03 - Service Brake
03 - Service Brake
Contents Page No.
24-03-00 General ........................................................................................................................... 24-11

24-03-01 Master Cylinder .............................................................................................................. 24-19
24-03-39 Piston ............................................................................................................................. 24-20
24-03-45 Vacuum Servo Unit ........................................................................................................ 24-22
24-03-46 Vacuum Pump ................................................................................................................ 24-23
24-03-50 Light Switch .................................................................................................................... 24-24
24-03-57 Pressure Sensor ............................................................................................................ 24-28
24 - 9 9823/1650-1 24 - 9
Notes:
24 - 10 9823/1650-1 24 - 10
24 - Brake System
03 - Service Brake
00 - General
Introduction .................................................... 24-11 The service brake is used to stop the machine when
Component Identification ............................... 24-12 it is in motion.
Diagram ......................................................... 24-14
Bleed ............................................................. 24-17 The service brake is a hydraulic system. The
machine operator applies pressure to the brake
pedal in the cab.
The pedal is connected to the master cylinder which

supplies hydraulic pressure to the applicable brake
units to apply the brakes.
The brake packs are located in the axle- some

machines have front and rear brakes whilst some
machines only have front axle brakes.
24 - 11 9823/1650-1 24 - 11
24 - Brake System
03 - Service Brake
00 - General
For: 506-36 [T4i] ....................... Page 24-12 The brake hydraulic fluid tank is situated outside the
For: 507-42 [T4i], 509-42 [T4i], 512-56 [T4i], cab, below the front windscreen.
514-56 [T4i] ............................... Page 24-13
An electrical switch is fitted to the pedal assembly for
operation of the rear facing brake lights.
(For: 506-36 [T4i])
Auto 4-wheel braking
Single axle service brakes system
To achieve 4-wheel braking, engage the 4WD (Four
The front axle integral brake packs are multi-disc Wheel Drive). In this way all 4 wheels are effectively
plates that are immersed in oil. The brake packs braked via the machine transmission.
are actuated hydraulically by a single foot pedal and
master cylinder. When 2WD (Two Wheel Drive) is selected, operating
the brake pedal will automatically select 4-wheel
On machines with servo assisted brakes, the drive. This gives increased braking effect. The
assistance is provided by means of an engine driven transmission will switch back to 2- wheel drive when
vacuum pump and remotely mounted servo unit the brake pedal is released.
which is located on the front of the cab.
Figure 365.
G
E
B
A
C
C A
A Front axle integral brake pack B Foot pedal

C Master cylinder D Exhauster (vacuum) pump (the location of
the pump will differ depending on the engine
installed)
E Servo unit F Brake fluid tank
24 - 12 9823/1650-1 24 - 12
24 - Brake System
03 - Service Brake
00 - General
G Brake light electrical switch
hydraulically by a single foot pedal and master

(For: 507-42 [T4i], 509-42 [T4i], 512-56 cylinder. An exhauster (vacuum) unit is fitted on the
[T4i], 514-56 [T4i]) engine to power the servo unit.
The brake hydraulic fluid tank is situated outside the

Twin axle service brakes system cab, below the front windscreen.
The service brakes act on the front and rear axle The location of servo unit varies between machine
half shafts of the machine. The multi-disc brakes are models. Refer to component location table.
immersed in oil. The brake packs and are operated
Table 176. Component Location Table

Braking system 508-66, 510-44, 510-55
Servo unit Located under the RH rear of the chassis
Figure 366.
A
B
LI O C
IL NO
YL
UA
RDYH
ES
TH
GI L
B CJ
C
E
A Servo unit (the location of servo unit varies B Vacuum unit

between machine models, refer to the
component location table).
C Brake fluid tank D Master cylinder
E Pedal
24 - 13 9823/1650-1 24 - 13
24 - Brake System
03 - Service Brake
00 - General
Diagram
For: 506-36 [T4i] ....................... Page 24-14

For: 507-42 [T4i], 509-42 [T4i], 512-56 [T4i],
514-56 [T4i] ............................... Page 24-16
(For: 506-36 [T4i])
Single axle service brakes system

Hose and pipework- Machines with trailer brakes
Figure 367.
B
D
E
C
A Servo exhauster unit B Master cylinder

C Servo unit D Front axle
E T-piece F Check valve
G Trailer brake valve
24 - 14 9823/1650-1 24 - 14
24 - Brake System
03 - Service Brake
00 - General
Hose and pipework- Machines without trailer brakes
Figure 368.
D
C
A Servo exhauster unit B Master cylinder

C Servo unit D Front axle
24 - 15 9823/1650-1 24 - 15
24 - Brake System
03 - Service Brake
00 - General
(For: 507-42 [T4i], 509-42 [T4i], 512-56 [T4i], 514-56 [T4i])
Twin axle service brakes system

Hydraulic operation and schematics
Figure 369.
A Fluid tank B Master cylinder

C Master cylinder (servo unit) D Servo unit
E Front brake packs F Rear brake packs
24 - 16 9823/1650-1 24 - 16
24 - Brake System
03 - Service Brake
00 - General
Bleed Figure 371. Servo unit
For: 506-36 [T4i] ....................... Page 24-17

For: 507-42 [T4i], 509-42 [T4i], 512-56 [T4i],
514-56 [T4i] ............................... Page 24-17
(For: 506-36 [T4i])
Single axle service brake system

WARNING Use of incorrect fluid will cause
serious damage to the seals which could in turn
cause brake failure.

2. Follow all the care and safety procedures. Refer
B
to (PIL 01-03).
3. Fill the tank with correct fluid. Refer to operators
manual.
4. Make sure that the fluid level does not fall under
the Minimum mark when you do the bleeding
procedure.
5. Bleed the brake system in the applicable
sequence as follows:
5.1. Machines without servo brakes- Bleed at
the point on the front axle.
B Bleed point on servo unit
Figure 370. Front axle
6. Attach a tube to the applicable bleed screw.
7. Make sure that the free end of the tube is put fully
into the fluid in a suitable container.
8. Open the bleed screw and apply one rapid full
stroke of the brake pedal followed by three rapid
A short strokes from the halfway pedal position.
After the third short stroke, allow the pedal to
return quickly to its stop.
9. Continue to bleed the air normally until all the air
is removed. Push the pedal fully and close the
bleed screw.
A Bleed point on front axle 10. Top up the tank to the full mark.
5.2. Machines with servo brakes- Bleed at the

point on the servo unit and the point on the (For: 507-42 [T4i], 509-42 [T4i], 512-56
front axle. [T4i], 514-56 [T4i])
Twin axle service brake system

WARNING Use of incorrect fluid will cause
serious damage to the seals which could in turn
cause brake failure.
24 - 17 9823/1650-1 24 - 17
24 - Brake System
03 - Service Brake
00 - General
2. Follow all the health and safety precautions. 9. Continue to bleed the air normally until all the air
Refer to (PIL 01-03). is removed. Push the pedal fully and close the
bleed screw.
3. Fill the tank with correct fluid. Refer to (PIL
75-00). 10. Top up the tank to the full mark.
4. Make sure that the fluid level does not fall under
the "minimum" mark when you do the bleeding
procedure.
5. Bleed the brake system as follows:
5.1. Bleed at the point on the servo unit, the
point on the front axle and the point on the
rear axle (first left side, then right side).
Figure 372. Servo unit
B Bleed point on servo unit

Figure 373. Axle bleed screw
A Bleed point on front axle

6. Attach a tube to the applicable bleed screw.
7. Make sure that the free end of the tube is put fully
into the fluid in a suitable container.
8. Open the bleed screw and apply one rapid full
stroke of the brake pedal followed by three rapid
short strokes from the halfway pedal position.
After the third short stroke, allow the pedal to
return quickly to its stop.
24 - 18 9823/1650-1 24 - 18
24 - Brake System
03 - Service Brake
01 - Master Cylinder
01 - Master Cylinder
The master cylinder is not serviceable and must be

renewed if faulty.
24 - 19 9823/1650-1 24 - 19
24 - Brake System
03 - Service Brake
39 - Piston
39 - Piston Introduction
Introduction .................................................... 24-20
Technical Data ............................................... 24-21
Brake Piston Seal Leakage
Disassemble and Assemble .......................... 24-21 The most common reason for internal piston seal
leakage is a build-up of axle contamination. It is
caused as a result of excessive brake wear caused
by extended service periods.
Two types of internal leakage can occur within the

axle or hub:
• Low Pressure Leaks- Seal damage, or scoring

to seal component surfaces, caused by a build-
up of metal particles.
• High Pressure Leaks- Mechanical leakage past
a badly damaged or perished seal.
Do the low pressure leak test first. Low pressure

leaks are difficult to find using a high pressure test.
The seals and other components can distort and form
a seal under pressure.
Do the low pressure or high pressure leak test

without disassembling the axle. Refer to brakes-
service brake, refer to (PIL 24-03).
Make sure that you do the leak test only when the
axle is cold.
24 - 20 9823/1650-1 24 - 20
24 - Brake System
03 - Service Brake
39 - Piston
Technical Data Disassemble and Assemble
Refer to brakes- general, refer to (PIL 24-00). Refer to driveline- front axle, refer to (PIL 27-20).
24 - 21 9823/1650-1 24 - 21
24 - Brake System
03 - Service Brake
45 - Vacuum Servo Unit
45 - Vacuum Servo Unit
Check (Leaks)
24 - 22 9823/1650-1 24 - 22
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
46 - Vacuum Pump
Introduction
The service brake system requires vacuum

assistance to operate.
On machines with standard hydraulic service brakes

the vacuum assistance is provided by a vacuum
pump mounted on the engine.
24 - 23 9823/1650-1 24 - 23
24 - Brake System
03 - Service Brake
50 - Light Switch
50 - Light Switch Diagram

Diagram ......................................................... 24-24 The foot brake pedal switch is connected to the panel
Adjust ............................................................ 24-25 harness.
Figure 374.
3 2 1 3 2 1
24 - 24 9823/1650-1 24 - 24
24 - Brake System
03 - Service Brake
50 - Light Switch
Adjust Brake Light Switch- (Reed Type)

Figure 376.
Brake Light Switch- Proximity Type
Figure 375.
D
E F
F
C
B
D Brake light switch
E Metal vane
F Switch faces
1. This type of switch is not adjustable.
2. If a switch failure is suspected, check all
associated wing and connectors for damage.
3. Make sure the vane moves between the switch
faces when the brake pedal is pressed.
4. If the switch does not work, it must be renewed.

Item Nm
A Proximity sensor C 20
B Brake lever
C Locknut
1. Set the ignition switch to the on position, do not
start the engine.
2. Adjust the proximity sensor to the correct
clearance between the sensor face and the edge
of the brake lever.
Length/Dimension/Distance: 2 –3 mm
3. Tighten the locknut to the correct torque.
4. Press the brake pedal and check that the sensor
operates (brake light illuminates) when the brake
pedal has travelled the correct distance. Check
that the sensor remains on throughout the rest of
the travel.
5. Check that the brake lights illuminate when the
brake pedal is pressed.
24 - 25 9823/1650-1 24 - 25
24 - Brake System
03 - Service Brake
50 - Light Switch
Remove and Install
Remove 4. Disconnect the electrical connector from the

panel harness.
5. Hold the switch and remove the screw.
Refer to (PIL 01-03). 6. Remove the switch from the bracket.
3. Press the brake pedal.
Figure 377.
A Electrical connector B Bracket

C Screw D Switch
24 - 26 9823/1650-1 24 - 26
24 - Brake System
03 - Service Brake
50 - Light Switch
Install
removal procedure.
24 - 27 9823/1650-1 24 - 27
24 - Brake System
03 - Service Brake
57 - Pressure Sensor
57 - Pressure Sensor
Check (Operation)
Special Tools
Servicemaster 892/01033 1*
Electronic Test Kit 892/01174
Data Link Adaptor
(DLA) Kit
*Unless otherwise stated, you can use any of the
tools shown.
Test Procedures
1. Use the applicable Servicemaster diagnostics
tool to identify faults. Ensure that the applicable
control interface operates correctly. Rectify as
required. Refer to (PIL 33-57).
Special Tool: Servicemaster Electronic Test Kit /
Data Link Adaptor (DLA) Kit (Qty.: 1)
2. Test the applicable wires and connectors for
continuity, shorts to battery and shorts to earth.
Rectify as required.
24 - 28 9823/1650-1 24 - 28
24 - Brake System
18 - Park Brake
18 - Park Brake
Contents Page No.
24-18-00 General ........................................................................................................................... 24-31

24-18-03 Switch ............................................................................................................................. 24-43
24-18-06 Cable .............................................................................................................................. 24-44
24-18-15 Pad ................................................................................................................................. 24-54
24-18-18 Caliper ............................................................................................................................ 24-55
24-18-21 Disc ................................................................................................................................ 24-62
24-18-48 Actuator .......................................................................................................................... 24-72
24 - 29 9823/1650-1 24 - 29
Notes:
24 - 30 9823/1650-1 24 - 30
24 - Brake System
18 - Park Brake
00 - General
Introduction .................................................... 24-31 The park brake also called the hand brake is a
Technical Data ............................................... 24-32 latching brake usually used to keep the vehicle
Operation ....................................................... 24-32 stationary. It is also used to prevent a vehicle from
Check (Condition) .......................................... 24-33 rolling when the operator needs both feet to operate
the clutch and throttle pedals.
Check (Operation) ......................................... 24-34
Adjust ............................................................ 24-35 The park brake usually consists of a cable directly
Disassemble and Assemble .......................... 24-38 connected to the brake mechanism on one end, and
to a hand-operated lever, on the floor at the side of
the driver.
24 - 31 9823/1650-1 24 - 31
24 - Brake System
18 - Park Brake
00 - General
Technical Data Operation

For: PS764, PS766 ................... Page 24-32 For: PS750 MK4 ....................... Page 24-32
For: PS750 MK4 ....................... Page 24-32 For: PS764, PS766 ................... Page 24-32
(For: PS764, PS766) (For: PS750 MK4)

Table 178. Park Brake Multi- The park brake is Independent of the service brakes.
pack Brakes (If Installed) It operates on the drive to the front axle by means of
a disc mounted on the gearbox output shaft.
Description Acceptable Tolerances
(mm) When the operator moves the park brake lever to the
Friction pack assembly 37.1 to 39.6 vertical position, the cable pulls the caliper reaction
thickness lever and pressure is applied to the caliper mounted
brake pads to hold the brake disc.
(For: PS750 MK4) Figure 378.

B
Table 179. Park Brake
Description Acceptable Tolerances
Disc minimum thickness 8.9 mm
Pad minimum thickness 1 mm C
D
A Gearbox output shaft

B Brake pads
C Caliper reaction lever
D Brake disc
The lever has a simple system for adjustment of the

cable when necessary.
An electrical switch senses if the park brake lever

is set to the brake on or brake off position. The
switch controls operator warnings and transmission
interlocks.
(For: PS764, PS766)
Internal park brake

The park brake is Independent of the service brakes.
It operates on the drive to the front axle via an oil
immersed, multi-plate brake pack housed inside the
gearbox. The brake assembly is mounted on the
gearbox layshaft.
When the operator moves the park brake lever to the

vertical position, the cable causes the brake plates
to be pressed together.
24 - 32 9823/1650-1 24 - 32
24 - Brake System
18 - Park Brake
00 - General
The lever has a simple system for adjustment of the Check (Condition)
cable when necessary.
For: PS764, PS766 ................... Page 24-33
Figure 379.
For: PS750 MK4 ....................... Page 24-34
(For: PS764, PS766)

A Before inspecting the brake components carefully
remove all traces of sealing compound from
component mating faces. Use a suitable degreaser,
clean the brake components including the brake
housing in the gearbox rear case.
Multi-Plate Pack
1. Carefully inspect the friction plates and counter
plates. If any of the plates show signs of damage
or distortion, renew the complete plate pack.
A Multi-plate brake pack Figure 380.
An electrical switch senses if the park brake lever

is set to the brake on or brake off position. The
1
switch controls operator warnings and transmission
interlocks.
1 Thrust plate
2 Counter plates
3 Friction plates
2. Assemble the friction and counter plates
(including the thrust plate) on a suitable datum
table. Measure the overall thickness of the
assembled friction pack. The thickness X must
be between the recommended tolerances, refer
to Technical Data.
Figure 381.
X Friction pack assembly thickness

2.1. If the friction pack is outside these limits,
the complete friction pack assembly must
be renewed.
24 - 33 9823/1650-1 24 - 33
24 - Brake System
18 - Park Brake
00 - General
Note: The friction pack may be outside the maximum Check (Operation)
thickness value if the plates are distorted, typically
after the brake has performed an emergency stop.
(For: PS764, PS766)
(For: PS750 MK4) WARNING! Before testing the park brake make
sure the area around the machine is clear of
WARNING Oil on the brake disc will reduce
people.
brake effectiveness. Keep oil away from the
brake disc. Remove any oil from the disc with 1. Park the machine and make it safe.
a suitable solvent. Read and understand the
solvent manufacturer's safety instructions. If the 2. Follow the care and safety procedures. Refer to
pads are oily, install with the new pads. (PIL 01-03).
1. Follow the brake pad removal instructions. refer 3. Apply the park brake fully.
to (PIL 24-03).
4. Start the engine and raise the attachments to the
2. Make sure that the minimum thickness of the appropriate travelling position.
friction material on either pad is 1mm (0.04 in),
5. Select the fourth gear.
but it is recommended to install new pads as it
may not be possible to adjust pads worn to this 6. Push down hard on foot brake pedal.
limit.
7. Select forward drive on the left hand column
3. Check the condition of the disc surface. Install a switch.
new disc if the surface is badly warped, pitted or
worn. WARNING! If the machine starts to move during
the park brake test, immediately apply the foot
4. Make sure the actuator is adjusted correctly. brake and reduce the engine speed.
8. Test the park brake as follows:

8.1. Move the park brake lever slowly forward
until the warning light is just extinguished.
8.2. Slowly release the foot brake pedal.
8.3. If the machine has not moved, use the
accelerator pedal to gradually increase the
engine speed to 1500 RPM (Revolutions
Per Minute) The machine should not move.
8.4. Do not do this test for more than the
specified time.
Duration: 20 s
8.5. Reduce the engine speed to idle and select
neutral on the left hand column switch.
8.6. Return the park brake lever to the fully on
position from its partially applied position.
8.7. Lower the attachments and stop the engine.
8.8. If the machine moved during this test, adjust
the park brake and repeat the test. Refer to
brakes- park brake, refer to (PIL 24-18).
WARNING! Do not use a machine with a faulty park
brake.
WARNING! Non approved modifications to drive
ratios, machine weight or wheel and tyre sizes may
adversely affect the performance of the park brake.
24 - 34 9823/1650-1 24 - 34
24 - Brake System
18 - Park Brake
00 - General
If you have any queries concerning this test Adjust

procedure or park brake adjustment, consult your
local JCB distributor. For: PS750 MK4 ....................... Page 24-35
For: PS764, PS766 ................... Page 24-36
Figure 382.
D D (For: PS750 MK4)

WARNING The park brake must not be used to
slow the machine from travelling speed, except
in an emergency, otherwise the efficiency of the
12
P
9 3
brake will be reduced. Whenever the park brake

10 15
RPM x 100
20
5
0 25
has been used in an emergency the brake pack

B
must be renewed.
working on it. Park the machine on level ground
535 530
and lower the loader arm. Stop the engine and
C engine being started. Block all four wheels.
Notice: Over adjustment or failure to disengage
the park brake properly will cause excessive wear
of the park brake mechanism.
Before you try to adjust the park brake after an

A emergency stop, remove and install new brake
friction components. Install other new components if
necessary.
A Park brake lever
B Left hand column switch The park brake must be engaged fully when the
C Foot brake pedal lever is vertical. The park brake indicator light should
D Warning light illuminate when the brake is engaged with the
forward and reverse lever away from neutral (starter
switch at IGN).
Do the park brake adjustment as follows:
1. Disengage the park brake (lever horizontal).

2. Pull and turn the handle grip clockwise, half a
turn.
3. Test the park brake. Refer to brakes- park brake,
4. If the brake fails the test, repeat steps 1, 2 and 3.
5. If no more adjustment is possible and the pin is
at the end of its travel, then adjust the cable at
the calliper. Refer to brakes- service brake, refer
to (PIL 24-18).
24 - 35 9823/1650-1 24 - 35
24 - Brake System
18 - Park Brake
00 - General
Figure 383. should illuminate when the brake is engaged with the
forward and reverse lever away from neutral (starter
A switch at IGN).

2. Follow the health and safety procedures. Refer
to (PIL 01-03).
3. Disengage the parking bake (lever horizontal).
4. Turn the hand grip half a turn clockwise.
B Figure 384.
A Handle grip
B Pin
D
(For: PS764, PS766)

Consumables
C
JCB Multi-Gasket 4102/1212 0.05 L
WARNING Before working on the brake system, B

make sure that the machine is on solid level
ground. Put blocks on all wheels to prevent the
machine rolling. A
Notice: Over adjustment or failure to disengage
the park brake properly will cause excessive wear
of the park brake mechanism.
WARNING Do not use a machine with a faulty A Screws
park brake. B Bolts 1
C Housing cut out
WARNING The park brake must not be used to D Cover plate
slow the machine from travelling speed, except
in an emergency, otherwise the efficiency of the Figure 385.
brake will be reduced. Whenever the park brake
has been used in an emergency the brake pack
must be renewed.
During normal operation little or no adjustment of

the brake cable at the lever is required. In the
event of poor brake performance it is likely that E
components have failed or, after extended service,
friction material is worn away. Remove, inspect and F
renew components if necessary.
E Hand grip
Adjustment at the park brake lever should only F Pin
be required after renewal of the cable, brake 5. Test the park brake. Refer to (PIL 24-18).
components or extended service.
6. If the brake fails the test, do 3 and 4 again. If there
Lever Adjustment is no more adjustment and if the pin is at the end
of its travel, remove, inspect and renew the park
The parking brake should be fully engaged when brake components as necessary.
the lever is vertical. The parking brake indicator light
24 - 36 9823/1650-1 24 - 36
24 - Brake System
18 - Park Brake
00 - General
7. After adjusting the park brake lever, do Figure 387.

the following steps to confirm correct brake
operation. Incorrect adjustment can result
damage to the brake components and excessive
overheating of the brake assembly.
7.1. Remove the 5 screws and 2 bolts 1. Using a
flat blade screwdriver located in the housing
cut out, lever off the cover plate.
7.2. Use the cover plate as a wear indicator.
Use a bolt 2 to install the plate at right
angles to the housing as shown. Pull the
plate down when tightening the bolt to take
up the clearance in the bolt hole.
Figure 386.
8.4. When the brake is released free play

between the plates should be easily
detectable. If the plates are not free, do not
operate the machine. Disassemble, inspect
and renew the park brake components as
required.
8.5. If the brake pack is serviceable, clean off
all traces of old sealant from the cover
plate and brake housing. Make sure that no
D sealant enters the gearbox. Apply a bead of
H
multi-gasket to the brake housing.
D Cover plate
Consumable: JCB Multi-Gasket
G Clevis pin
H Bolt 2 8.6. Install the cover plate.
7.3. Fully apply the park brake (lever vertical). If 8.7. Tighten the bolts to the specified torque
the brake is within service limits, the clevis value.
pin hexagon must not be visible above the
cover plate. Renew the friction pack if any Table 180. Torque Values
of the clevis pin hexagon is visible. Item Description Nm
8. If the friction pack components are distorted A Screws 16
(typically after performing an emergency stop) B Bolts 1 56
the clevis pin may not be visible in the check
described. If the park brake performance is
poor it may be due to distorted components.
Disassemble and inspect the park brake
assembly as follows.
8.1. Disengage the park brake (lever horizontal).
8.2. Make sure that the brake is fully released.
8.3. Remove the cover plate and feel the edge
of the brake pack plates.
24 - 37 9823/1650-1 24 - 37
24 - Brake System
18 - Park Brake
00 - General
(For: PS764, PS766)

Consumables
24 - 38 9823/1650-1 24 - 38
24 - Brake System
18 - Park Brake
00 - General
Disassemble
Figure 388.
D
E
X
A
A Bolt (x2) B Screw (x5)

C Cover plate D Cover
E Needle roller thrust bearing. F Reaction pins
G Thrust plate H Friction plate
J Counter plate X Location1 and Location 2 for bolt removal
24 - 39 9823/1650-1 24 - 39
24 - Brake System
18 - Park Brake
00 - General
1. Position the output yoke as shown. Refer to 5.3. Friction plates.

Figure 389.
5.4. Counter plates.
Figure 389.
6. If the brake assembly is being removed before
you disassemble the gearbox, then remove the
reaction pins. Refer to Figure 388.
7. If the brake actuator is to be disassembled, or the
cable is to replaced, then remove the park brake
cable as follows: Refer to Figure 390.
Figure 390.
M
K
K Output yoke
2. Remove the cover plate as follows: Refer to
Figure 388.
2.1. Remove only two bolts from location1 and
location 2.
2.2. Remove the screws.
2.3. Before the cover plate is removed, place a
container below to collect the gearbox oil.
2.4. Remove the cover plate with a flat bladed
screwdriver.
3. Remove the remaining bolts (x4) and carefully N
remove the cover, keeping it parallel to the
mating face of the gearbox. Refer to Figure 388.
4. Be aware that the needle roller thrust bearing and
the reaction pins may come away with the cover. L Brake cable
Refer to Figure 388. M Circlip
N Clevis pin
5. Remove the following: Refer to Figure 388.
7.1. Remove the clevis pin.
5.1. Needle roller thrust bearing. 7.2. Remove the circlip and then remove the
5.2. Thrust plate cable from the cover.
24 - 40 9823/1650-1 24 - 40
24 - Brake System
18 - Park Brake
00 - General
Assemble
Figure 391.
G
D
E
A X
C
Z
A Bolt (x2) B Screw (x5)

E Needle roller thrust bearing. F Reaction pins
J Counter plate X Location 1 and Location 2 for bolt installation
Y Sealant location on gearbox case Z Sealant location on cover
24 - 41 9823/1650-1 24 - 41
24 - Brake System
18 - Park Brake
00 - General
1. Inspect the brake pack. 5. Apply a bead of sealant to the mating face on the
gearbox case. Refer to Figure 391.
2. Assemble the reaction pins and then install the
friction pack in the gearbox case. Refer to Figure Consumable: JCB Multi-Gasket
391. 6. Attach the cover with the bolts (x4). Refer to
2.1. Note that a counter plate is installed first Figure 391.
followed by a friction plate and so on. 6.1. Note that 2 bolts at location 1 and location
2.2. Install the thrust plate last. 2 are not installed at this stage.
3. If removed during disassembly install the park 7. Tighten the bolts to the correct torque value.
brake cable as follows: Refer to Figure 392. Refer to Figure 391.
Figure 392. 8. Apply a bead of sealant to the mating face on the

cover. Refer to Figure 391.
L R Consumable: JCB Multi-Gasket
M 9. Attach the cover plate with screws (x5) and the

bolts (x2). Refer to Figure 391.
10. Tighten the screws and bolts to the correct torque
value. Refer to Figure 391.
It is essential that the park brake cable is adjusted

Q correctly when the gearbox is installed into the
machine. Incorrect adjustment of the cable can
result in damage to the brake components and
excessive overheating of the brake assembly. See
the applicable machine Service Manual for the cable
adjustment procedure.

Item Nm
A 56
B 16
N N 9
L Brake cable
M Circlip
N Clevis pin
P Brake actuator
Q O-ring
R Collar
3.1. Put the cable into the housing and connect
the fork end to the brake actuator with clevis
pin.
3.2. Never replace the clevis pin with a normal
bolt or screw.
3.3. Make sure that the O-ring is not damaged
and correctly installed on the collar.
3.4. Locate the collar inside the brake housing
and secure with the circlip.
4. Make sure that the needle roller thrust bearing is
correctly installed on the actuator assembly.
24 - 42 9823/1650-1 24 - 42
24 - Brake System
18 - Park Brake
03 - Switch
03 - Switch Install
Remove and Install removal procedure.
2. When installing do the following steps also:
Remove
2.1. To align the switch correctly, engage the
1. Park the machine and make it safe. Follow all switch location dowel with the hole in the
safety precautions. Please see (PIL 01-03). mounting bracket.
2. Put chocks on both sides of the wheels to prevent

the machine rolling. Release the park brake.
3. Remove the rubber gaiter.
switch connector.
5. Hold the switch and remove the screw.
Figure 393.
B G D
F
C
A Rubber gaiter
B Switch
D Switch connector
E Screw
F Dowel
G Mounting bracket
24 - 43 9823/1650-1 24 - 43
24 - Brake System
18 - Park Brake
06 - Cable
06 - Cable Adjust
Adjust ............................................................ 24-44 For: PS750 Mk4, PS750 MK4
................................................... Page 24-44
For: PS764, PS766 ................... Page 24-45
(For: PS750 Mk4, PS750 MK4)

If the adjustment of the park brake lever is not
sufficient, then adjust the cable at the calliper.
If it is not possible to adjust at the lever or at the

calliper, then change the brake pads.
Make sure that you install a new cable if the cable is

worn or damaged.
1. Park the machine and make it safe.

2. Follow the care and safety procedures. Refer to
(PIL 01-03).
4. Turn the hand grip anti-clockwise to centre the
pin in its slot.
5. Release the two locknuts and adjust the cable
length as required.
6. If you install a new cable, make sure to put the
threaded section of the cable with approximately
four threads visible below the bottom adjusting
nut.
7. Make sure there is enough freedom of movement
of the operating lever to ensure a positive brake
application. The lever must return to the rest
position when the park brake is released.
8. Make sure that the clearance between the brake
pad and the brake disc is within the specified
range.
Length/Dimension/Distance: 0.5 –0.75 mm
9. Test the park brake. Refer to brakes- park brake,
Make final adjustments at the park brake lever if

the brake fails the test. Refer to operator station-
controls, refer to (PIL 09-27).
24 - 44 9823/1650-1 24 - 44
24 - Brake System
18 - Park Brake
06 - Cable
Figure 394.
C
A Hand grip
B Pin
C Locknuts
Figure 395.
D
D Operating lever
friction material is worn away. Dismantle, inspect and

(For: PS764, PS766) install components as required.
During normal operation little or no adjustment of The park brake should be fully engaged when
the brake cable at the lever is required. In the the lever is vertical. The park brake indicator light
event of poor brake performance it is likely that should illuminate when the brake is engaged with the
components have failed or, after extended service, forward and reverse lever away from neutral (starter
switch at IGN).
24 - 45 9823/1650-1 24 - 45
24 - Brake System
18 - Park Brake
06 - Cable
1. Before attempting to adjust the park brake 4. Turn the hand grip clockwise, half a turn.
after an emergency stop remove and inspect
the brake friction components. Install new 5. Test the park brake. If the brake fails the test
components if necessary. repeat steps 3 and 4. Refer to (PIL 24-18). If there
is no more adjustment and the pin is at the end
2. Make the machine safe. Refer to (PIL 01-03). of its travel, dismantle, inspect and renew park
brake components as required.
3. Disengage the park bake (lever horizontal)
Figure 396.
A Screws (x5) B Bolts (x2)

C Housing cut out D Cover plate
Figure 397. 6. After adjusting the park brake lever makes sure
you carry out the following steps to make sure
that the park brake operates correctly. Incorrect
adjustment can result damage to the brake
components and excessive overheating of the
brake assembly.
E Hand grip
F Pin
24 - 46 9823/1650-1 24 - 46
24 - Brake System
18 - Park Brake
06 - Cable
Figure 398.
H J
G Clevis pin hexagon H Bolt

J Cover plate
6.1. Remove (x5) screws and (x2) bolts. Using a Figure 399.
flat blade screwdriver located in the housing
cut out, lever off the cover plate.
6.2. Use the cover plate as a wear indicator.
Use a bolt to fit the plate at right angles
to the housing as shown. Pull the plate
down when tightening the bolt to take up the
clearance in the bolt hole.
6.3. Fully apply the park brake (lever vertical). If
the brake is within service limits the clevis
pin hexagon must not be visible above the
cover plate. Renew the friction pack if any
of the clevis pin hexagon is visible.
6.4. If the friction pack components are distorted
(typically after performing an emergency
stop) the clevis pin may not be visible
in the check described. If the park brake
performance is poor it may be due
to distorted components. Dismantle and
inspect the park brake assembly.
8. If the plates are not free make sure that you do
not operate the machine, dismantle, inspect and
Make sure that the brake is fully released.
renew park brake components as required.
Remove the cover plate and feel the edge of the
brake pack plates. When the brake is released 9. If the brake pack is serviceable, clean off all
free play between the plates should be easily traces of old sealant from the cover plate and
detectable. brake housing. Make sure that no sealant enters
24 - 47 9823/1650-1 24 - 47
24 - Brake System
18 - Park Brake
06 - Cable
the gearbox. Apply a bead of JCB Multigasket to

the brake housing.
10. Install the cover plate. Tighten the bolts to the
correct torque.

Item Nm
A 16
B 56
24 - 48 9823/1650-1 24 - 48
24 - Brake System
18 - Park Brake
06 - Cable
Remove and Install
For: PS750 Mk4, PS750 MK4 Remove

................................................... Page 24-49
For: PS764, PS766 ................... Page 24-51 1. Make the machine safe. Obey all care and safety
procedures Refer to (PIL 01-03).
(For: PS750 Mk4, PS750 MK4) 2. Release the park brake lever (lever horizontal).
Consumables
Strength)
Figure 400.
A
A Clevis pin B Actuating lever

C Locknut 1 D Bracket
3. Remove the clevis pin from the park brake 9. Remove the lever fixing bolts.
caliper.
10. Remove the lever assembly together with the
4. Make sure you note which of the three holes on cable.
the actuating lever is used.
11. Measure and record the dimension between the
5. Remove the clip or loosen the locknut 1 as sleeve and the locknut.
applicable.
12. Remove both the buffer bracket fixing bolts.
6. Disconnect the cable from the bracket ad note
the cable routing located underside the cab. 13. Remove the cable nipple from the clevis and then
remove the cable sideways from the lever.
7. Remove the gaiter fixings and pull up the gaiter.
14. Disengage the cable nipple from the clevis.
8. Disconnect the park brake switch electrical
connector. 15. Remove the buffer assembly from the cable.
24 - 49 9823/1650-1 24 - 49
24 - Brake System
18 - Park Brake
06 - Cable
Figure 401.
K
K
N L
M
P
Install
Table 183. Installation is opposite of the removal procedure and
Item Description additionally do the steps below.
E Park brake lever (hori-
1. Make sure you correctly route the cable.
zontal)
F Electrical connector 2. Make sure that the locknut is screwed fully down.
G Lever fixing bolts
3. Adjust the sleeve to allow cable location to the
H Clevis lever assembly.
J Buffer assembly
K Bracket fixing bolts 4. Apply threadlocker to the buffer bracket fixing
bolts.
L Sleeve
M Locknut 2 Consumable: JCB Threadlocker and Sealer
(Medium Strength)
N Dimension between the
sleeve and locknut 2 5. Make sure that the buffer bracket assembly is
P Cable located correctly.
24 - 50 9823/1650-1 24 - 50
24 - Brake System
18 - Park Brake
06 - Cable
7. Adjust the sleeve and the locknut 2 until you get Figure 402.
the dimension measured between the sleeve and G
the locknut at the time of removal. A
8. If a new cable is installed make sure that the F

dimension between the sleeve and the locknut
will be of the specified value.
Dimension: 15 mm Y
9. Tighten the locknut 2.

D
10. Make sure that the cable clevis is is connected at
the correct hole in the caliper actuating lever.
11. Make sure that the actuating lever is not being B
pulled by the cable when the park brake lever is
in the off (horizontal) position.
12. If necessary adjust sleeve until the actuating
lever is allowed to return fully to its off position.
C E
13. Adjust the cable. Refer to (PIL 24-18-06).
A Cable
Table 184. Torque Values B Bolts (x2)
C Screws (x5)
Item Description Nm D Cover plate
K Bracket fixing bolts 3 E Clevis screw
F Circlip
G Cable assembly
(For: PS764, PS766) Y O-ring
Consumables 3. Clean off all dirt from the gearbox brake housing.
Description Part No. Size Make sure there is no dirt or debris trapped in the
JCB Multi-Gasket 4102/1212 0.05 L housing at the cable entry.
JCB Threadlocker 4101/0250 0.01 L 4. Remove the screws and the bolts securing the
and Sealer (Medium 4101/0251 0.05 L cover plate. Remove the cover plate.
Strength)
5. Remove the clevis screw and the circlip. Remove
Park Brake Maintenance the cable assembly from the housing.
Before working on the park brake, park on level 6. Working at the park brake lever, remove the
ground and put blocks on both sides of all wheels gaiter fixings and pull up the gaiter (not shown).
to prevent the machine rolling. Stop the engine and
disconnect the battery so that the engine cannot be 7. Disconnect the park brake switch electrical
started. If you do not take these precautions the connector.
machine could run over you.
8. Remove the lever fixing bolts and then remove
Internal park brake cable the lever assembly together with the cable.
9. Measure and record the dimension between the
Remove sleeve and the locknut.
1. Make the machine safe. Obey all care and safety 10. Remove the two buffer bracket fixing bolts.
procedures. Refer to (PIL 01-03).
11. Remove the cable sideways from the lever,
2. Release the park brake lever (lever horizontal). disengaging the cable nipple from the clevis
screw.
12. Remove the buffer assembly from the cable.
24 - 51 9823/1650-1 24 - 51
24 - Brake System
18 - Park Brake
06 - Cable
Figure 403.
H
J
N
S P
X Q
H Brake lever (Lever horizontal) J Electrical connector

K Lever fixing bolts L Clevis
M Buffer assembly N Buffer bracket fixing bolts
P Sleeve Q Locknut
R Cable X Dimension between the sleeve and the locknut
Install 5. Make sure that the buffer bracket assembly is

located correctly.
Installation is the opposite of the removal procedure.
During the installation procedure do these below 6. Tighten the buffer bracket fixing bolts to the
steps also. correct torque value.
1. Make sure you correctly route the cable. 7. Adjust the sleeve and the locknut until you get
the dimension measured between the sleeve and
2. Make sure that the locknut is screwed fully down. the locknut at the time of removal.
3. Adjust the sleeve to allow cable location to the 8. Tighten the locknut.
lever assembly.
9. Make sure that the O-ring is not damaged and
4. Apply JCB threadlocker to the buffer bracket install it properly.
fixing bolts.
10. After you connect both ends of the cable set the
Consumable: JCB Threadlocker and Sealer park brake lever to the off (horizontal) position.
(Medium Strength)
24 - 52 9823/1650-1 24 - 52
24 - Brake System
18 - Park Brake
06 - Cable
11. Feel the edge of the brake pack plates. When the Table 185. Torque Values
brake is released free play between the plates
Item Nm
should be easily detectable.
B 56
Figure 404. C 16
E 9
N 3
12. If necessary adjust sleeve until the plates are

free.
13. Clean off all traces of old sealant from the cover
plate and brake housing. Make sure that no
sealant enters the gearbox.
14. Apply a bead of JCB Multigasket to the brake
housing.
Figure 405.
T JCB Multigasket
15. Install the cover plate and secure it with the bolts.
24 - 53 9823/1650-1 24 - 53
24 - Brake System
18 - Park Brake
15 - Pad
15 - Pad
Check (Condition)

WARNING Oil on the brake disc will reduce
brake effectiveness. Keep oil away from the
brake disc. Remove any oil from the disc with
a suitable solvent. Read and understand the
solvent manufacturer's safety instructions. If the
pads are oily, install with the new pads.
1. Follow the brake pad removal instructions. refer

to (PIL 24-03).
2. Make sure that the minimum thickness of the
friction material on either pad is 1mm (0.04 in),
but it is recommended to install new pads as it
may not be possible to adjust pads worn to this
limit.
3. Check the condition of the disc surface. Install a
new disc if the surface is badly warped, pitted or
worn.
4. Install a new park brake cable if it is worn or
damaged.
24 - 54 9823/1650-1 24 - 54
24 - Brake System
18 - Park Brake
18 - Caliper
18 - Caliper Component Identification

Check (Condition) .......................................... 24-56
Disassemble and Assemble .......................... 24-59
Figure 406.
R
M
M
L
N
F S
E
C
M
D G
Q B A
H P
K J
Table 186. Item Description

Q Bearing ring
Item Description
R Housing
A Carrier side pad
S Shaft seal
B Lever side pad
C Screw
D Washer1
E Washer2
F Lever
G Spring
H Rotor
J Ball spacer
K Ball bearings
L Mounting bushes
M Dust seals
N O-rings
P Rotor Seal
24 - 55 9823/1650-1 24 - 55
24 - Brake System
18 - Park Brake
18 - Caliper
Check (Condition)

Refer to Component Identification, (PIL 24-18-18).
1. Clean and dry all parts.

2. Check that all the parts are free from excessive
wear, damage or corrosion. Light scores or stains
should be removed. Renew corroded or deeply
scored parts.
3. Check rotor for damage or distortion.
4. Install new if necessary. Make sure to change
both the brake pads if the park brake has been
used in an emergency.
5. Check the ball pockets in housing for signs of
scoring, pitting, damage or corrosion.
6. Install new housing if damaged. Check that the
spring is not broken or distorted.
7. Check the condition of the disc surface.
8. Install new disc if badly warped, pitted or worn.
Refer to brakes- park brake, refer to (PIL 24-18).
24 - 56 9823/1650-1 24 - 56
24 - Brake System
18 - Park Brake
18 - Caliper
Remove and Install
2. Release the park brake lever (horizontal).

(For: PS750 Mk4, PS750 MK4) 3. Remove the pin and disconnect the clevis joint,
Safety Critical Installation note which of the three holes on the lever is used.
This is a safety critical installation. Do not attempt 4. Remove the clip and disconnect the cable from
to do this procedure unless you are skilled and the bracket.
competent to do so.
Installation and mounting of the park brake caliper 5. Support the caliper and remove the two mounting
requires tightening of the mounting bolts to a specific bolts and hardened washers.
torque figure. Do not attempt to do this job unless you 6. Lift the caliper clear of the brake disc.
have the correct tools available.
7. Do not remove transmission mounting bracket,
Remove unless it is necessary to be replaced.
Figure 407.
A B C D
E
B
A Clip B Mounting bolts

C Clevis joint D Pin
E Operating lever F Transmission mounting bracket
24 - 57 9823/1650-1 24 - 57
24 - Brake System
18 - Park Brake
18 - Caliper
Install
Installation is the opposite of the removal procedure
but additionally do the below steps.
1. Locate the caliper on the brake disc.

2. Install new mounting bolts with hardened
washers.
3. Tighten the mounting bolts to the correct torque
value.
4. Attach the cable to the mounting bracket and
secure in place with the clip.
5. Install the clevis joint and the pin into the relevant
hole in the operating lever.
6. Make sure there is enough space for the
movement of the operating lever, to make sure
that positive brake application, and that the lever
returns to the rest position when the park brake
is released.
7. Adjust the park brake cable. Do not remove the
he clevis to adjust the cable.

Item Description Nm
B Mounting bolts 255
24 - 58 9823/1650-1 24 - 58
24 - Brake System
18 - Park Brake
18 - Caliper
7. Push out the rotor the remove the ball spacer and
(For: PS750 Mk4, PS750 MK4) the ball bearings.
Safety Critical Installation 8. Make sure you keep the ball bearings properly in
a container.
This is a safety critical installation. Do not attempt
to do this procedure unless you are skilled and 9. Push out the mounting bushes and then remove
competent to do so. the dust seals.
Installation and mounting of the park brake caliper
requires tightening of the mounting bolts to a specific 10. Remove the O-rings.
torque figure. Do not attempt to do this job unless you 11. Remove the rotor seal and then the bearing ring.
have the correct tools available.
12. Note that the rotor seal may be located on the
Disassembly rotor shaft or may have been left in the calliper
housing.
1. Remove the caliper and the brake pads. Refer to
remove and install (PIL 24-18-18). 13. It is not necessary to replace the shaft seal
unless it is excessively worn or damaged.
2. Hold the lever against the tension of the spring.
13.1. If removal is necessary, use a suitable
3. Remove the screw and both the washer 1, spacer block and a bench press to push
washer 2. the seal out from inside the housing.
4. Note the position of the lever with respect to the 13.2. Clean out any remains of the seal after
splines of the rotor shaft. removal.
5. Mark the end of the shaft and lever to assist in Before assembly make sure all parts are clean
assembly. and serviceable. Refer to park brake caliper-check
condition (PIL 24-18-18).
6. Remove the lever and the spring.
24 - 59 9823/1650-1 24 - 59
24 - Brake System
18 - Park Brake
18 - Caliper
Figure 408.
R
M
M
L
N
F S
E
C
M
D G
Q B A
H P
K J
1. If removed, Install a new shaft seal. Use a

Table 188. suitable spacer block and bench press to push
the seal into the housing.
Item Description
A Carrier side pad 2. Apply silicon grease on the shaft, the outer
B Lever side pad diameter and ball pockets of rotor and the ball
pockets of housing.
C Screw
D Washer 1 3. Install the three ball bearings into the pockets in
E Washer 2 the housing. Install the ball spacer.
F Lever 4. Apply silicon grease on the bearing ring and
G Spring install the ring to the inner diameter on rotor seal.
H Rotor
5. Assemble the rotor seal to the rotor.
J Ball spacer
K Ball bearings 6. Move the rotor through the casting and seat the
L Mounting bushes ball pockets against the bearings.
M Dust seals 7. Position the spring over the shaft of rotor.
N O-rings
8. Put the large diameter end of the spring into hole
P Rotor Seal
in the face of the housing. Refer to Figure 409.
Q Bearing ring
R Housing
S Shaft seal
Assembly
Before assembly make sure all parts are clean and
serviceable.
24 - 60 9823/1650-1 24 - 60
24 - Brake System
18 - Park Brake
18 - Caliper
Figure 409.
T U
T Spring hole
U Lever outside edge
9. Locate the small diameter end of spring around
the outside edge of lever. Refer to Figure 409.
10. Install the lever and align the lever to the mark
made at the time of disassembly.
11. Hold the lever against the tension of the spring
and install the washer 1 and washer 2.
12. Install the screw and tighten the screw to the
13. Install the brake pads.
14. Apply silicon grease to the dust seals and the
bushes.
15. Install the dust seals to the housing and put
mounting bushes.
16. Make sure that the dust seals locate in their
location grooves on the bushes and housing.
17. Lubricate and install new O-rings. Wipe off any
excess grease.
18. Before you install the caliper, make sure that the
lever rotates smoothly and that the lever side
pad returns to the off position when the lever is
released.
19. Install the brake caliper.
20. Install and adjust the park brake cable.
Table 189. Torque table

Item Torque value
Screw 13 –16 N·m
24 - 61 9823/1650-1 24 - 61
24 - Brake System
18 - Park Brake
21 - Disc
21 - Disc Introduction
Introduction .................................................... 24-62 A disc brake is a wheel brake that slows the rotation
Check (Condition) .......................................... 24-63 of the wheel by the friction caused by pushing brake
Remove and Install ....................................... 24-64 pads against a brake disc with a set of calipers.
24 - 62 9823/1650-1 24 - 62
24 - Brake System
18 - Park Brake
21 - Disc
Check (Condition)

1. Inspect the thickness of the park brake disc.
Renew the disc if it is below the minimum
thickness. Refer to (PIL 24-18-00).
2. Inspect the condition of the disc. If the disc is
deeply pitted or scored, replace it with a new one.
24 - 63 9823/1650-1 24 - 63
24 - Brake System
18 - Park Brake
21 - Disc
Remove and Install
7. Do not use a steel hammer, damage can occur

(For: PS750 MK4) to the output shaft bearing.
Special Tools 8. If necessary remove the oil seal. Do not damage

Description Part No. Qty. the seal housing.
Flange Spanner 992/04800 1
Install
Remove 1. Make sure that the oil seal interface on the brake
disc is clean and free from wear or damage.
1. If installed remove the park brake caliper.
2. If necessary install a new oil seal. Lubricate the
2. Bend back the stake nut locking ring.
lips of the seal.
3. Clean the brake disc and the gearbox around the
3. Install the brake disc onto the output shaft.
brake disc. Make sure no contamination enters
the gearbox when the brake disc is removed. 4. Install the washer.
4. Hold the brake disc with the service tool and 5. Hold the brake disc with the service tool.
remove the output shaft stake nut. Discard the
stake nut. 6. Install a new stake nut.
Special Tool: Flange Spanner (Qty.: 1) 7. Progressively tighten the nut to the correct torque
5. Remove the washer. value.
6. Lift off the brake disc. If necessary use a soft 8. Stake the nut to the shaft with a square ended
faced mallet to remove the brake disc. staking tool.
24 - 64 9823/1650-1 24 - 64
24 - Brake System
18 - Park Brake
21 - Disc
Figure 410.
E
D
C
B
A Brake disc B Stake nut

C Washer D Output shaft
E Oil seal F Bearings
G Oil seal interface H Stake nut locking ring

Item Nm
B 300
24 - 65 9823/1650-1 24 - 65
24 - Brake System
18 - Park Brake
21 - Disc
A separate disassembly procedure is given for each

(For: PS764, PS766) sub-assembly.
The internal park brake consists of a wet multi plate

friction pack and a mechanical actuator assembly.
24 - 66 9823/1650-1 24 - 66
24 - Brake System
18 - Park Brake
21 - Disc
Disassemble the multi-plate brake pack
Figure 411.
D
E
X
A
A Bolt B Screw (x5)

E Needle roller thrust bearing F Reaction pins
J Counter plate X Location 1 and Location 2 for bolt removal
24 - 67 9823/1650-1 24 - 67
24 - Brake System
18 - Park Brake
21 - Disc
1. From inside the cab, disengage the park brake 4. From underneath the machine, remove the two
(lever horizontal). Rotate the park brake lever to bolts and five screws that attach the cover plate.
fully slacken the cable.
5. Before the cover plate is removed, place a
2. Remove the rear propshaft. container below to collect the gearbox oil.
3. Position the output yoke. Refer to Figure 412. 6. Use a flat bladed screwdriver at the cover cutout
to remove the cover plate.
Figure 412.
7. Remove the remaining four bolts and carefully
remove the cover but make sure you keep it
square to the mating face on the gearbox. The
park brake cable is still attached at this stage.
8. If the cover does not come free then one or more
reaction pins will have remained in the cover.
9. Use a pair of long nosed pliers to push the pins
back into the gearbox case. Make sure that the
surface of the pin is not damaged.
10. Remove the needle roller thrust bearing, thrust
plate, friction plates and the counter plates.
11. If the brake actuator is to be disassembled, or the
K cable to be replaced then do the following steps.
K Output yoke (Shown in position required)
11.1. Remove the park brake cable.
Figure 413.
L Brake cable M Circlip

N Clevis screw pin
11.2. Remove the clevis screw pin. 11.3. Remove the cable from the housing.
24 - 68 9823/1650-1 24 - 68
24 - Brake System
18 - Park Brake
21 - Disc
Disassemble the brake actuator Inspection

Refer to park brake actuator (PIL 24-18-48). Refer to (PIL 24-18-00).
For inspection refer to park brake, check(condition) Assemble the brake actuator
(PIL 24-18-00).
Refer to park brake actuator (PIL 24-18-48).
Assemble the multi-plate brake pack
Figure 414.
G
D
E
A X
C
Z
24 - 69 9823/1650-1 24 - 69
24 - Brake System
18 - Park Brake
21 - Disc
A Bolts B Screws (x5)

E Needle roller thrust bearing F Reaction pins
J Counter plate X Location 1 and Location 2 for bolt installation
Y Sealant location on gearbox case Z Sealant location on cover
1. From underneath the machine, assemble the 2.1. Feed the cable into the housing and
reaction pins followed by the friction pack into the connect the fork end to the brake actuator
gearbox case. with the screw. Tighten to the correct torque.
1.1. Note that a counter plate is installed first, 2.2. The screw is a special clevis pin. Make sure
then a friction plate and so on. Install the that only the special screw clevis pin used.
thrust plate at last. Make sure that a normal bolt or screw is not
used.
2. If the park brake cable is removed then install the
park brake cable.
Figure 415.
L R
L Brake cable M Circlip

N Clevis screw pin P Brake actuator
Q O-ring R Collar
2.3. Make sure that the O-ring is not damaged 4. Before you install the cover, apply bead of JCB
and correctly installed on the collar. Locate Multigasket sealant to the mating face on the
the collar inside the brake housing and keep gearbox case.
with circlip.
5. Install the cover and four bolts. Tighten the bolts
3. Make sure that the needle roller thrust bearing is to the correct torque value.
correctly located on the brake actuator assembly,
if necessary apply grease to keep the bearing. 5.1. Do not install the two cover plate bolts at
this stage.
24 - 70 9823/1650-1 24 - 70
24 - Brake System
18 - Park Brake
21 - Disc
5.2. Carefully feed the park brake cable up into

the cab, through the opening in the cab
floor.
6. From inside the cab, connect the park brake
cable to the park brake lever and adjust the lever.
7. From under the machine, view the brake friction
pack through the housing aperture. Check the
operation. Play in the paltes will be easily felt
when the brake is off
8. Before you install the cover plate, apply a bead
of JCB Multigasket sealant to the mating face on
the cover.
8.1. Install all the five screws and remaining two
bolts.
8.2. Tighten the screws and bolts to the correct
toque value.
9. If any brake components have been replaced it
must be assumed that the gearbox oil will be
contaminated. Change the gearbox oil and filter.
Refer to clean, (PIL 27-06-00).
A small quantity of gearbox oil will be transferred from

the sump to fill the brake cavity when the engine is
started. Check the gearbox oil level and top up if
necessary. Refer to the operators manual.

Item Nm
A 56
B 16
N 9
24 - 71 9823/1650-1 24 - 71
24 - Brake System
18 - Park Brake
48 - Actuator
48 - Actuator Check (Condition)

Check (Condition) .......................................... 24-72
(For: PS764, PS766)
1. Before you check the brake components use
a suitable degreaser to clean the brake
components.
2. Check the ball bearings and their tapered
locating slots for signs of excessive wear or
damage.
3. Check the needle roller thrust bearing and the
corresponding bearing surfaces for signs of
excessive wear or damage.
3.1. Make a note that some discolouration of
the needle rollers is acceptable providing
the surface of the rollers is otherwise
undamaged.
Figure 416.
4
1 Tapered locating slots
2 Ball bearings
3 Tapered locating slots
4 Needle roller thrust bearing
4. Check condition of the park brake cable as
follows.
4.1. Make sure that the cable is smooth and free
in operation.
24 - 72 9823/1650-1 24 - 72
24 - Brake System
18 - Park Brake
48 - Actuator
4.2. Make sure that the cable cover is not cut or

split. They cut cable cover may allow water
ingress into the transmission.
4.3. Make sure that there is no corrosion or
debris passed through the O-ring seal.
4.4. Replace the cable if it is damaged or hard
to operate.
4.5. Tighten the screw to the correct torque
value.
Figure 417.
C
D
A Park brake cable

B Collar
C Circlip
D O-ring
E Screw
F Brake actuator

Item Nm
E 9
24 - 73 9823/1650-1 24 - 73
24 - Brake System
18 - Park Brake
48 - Actuator
2. Remove the washer 1 and washer 2.

(For: PS764, PS766) 3. Remove the spring 1 and spring 2.
Disassembly 4. Remove the brake actuator plate then the ball
bearings.
1. Carefully remove the screw.
1.1. Be careful the screw is under tension from
spring 1 and spring 2.
Figure 418.
Item Description
Table 193. E Washer 2
Item Description F Actuator plate
A Screw G Ball bearings (x5)
B Spring 1 H Brake actuator cover
C Spring 2
D Washer 1
24 - 74 9823/1650-1 24 - 74
24 - Brake System
18 - Park Brake
48 - Actuator
Assembly
1. Locate the ball bearings in their slots in the cover.
2. Install the actuator plate then the springs.
3. Install the washers.
4. Compress the springs and install the screw.
4.1. Tighten the screw to the correct torque
value.

Item Description Nm
A Screw 16
24 - 75 9823/1650-1 24 - 75
Notes:
24 - 76 9823/1650-1 24 - 76
Contents Page No.
25-00 Steering System

25-00-00 General ............................................................................................................................. 25-3
25-01 Pump
25-01-00 General ........................................................................................................................... 25-17
25-03 Priority Valve
25-03-00 General ........................................................................................................................... 25-19
25-06 Steer Unit/Valve
25-06-00 General ........................................................................................................................... 25-25
25-09 Mode Valve
25-09-03 Manual Mode Valve ....................................................................................................... 25-27
25-12 Column
25-12-00 General ........................................................................................................................... 25-35
25-15 Proximity Switch
25-15-00 General ........................................................................................................................... 25-39
25-18 Front Track Rod
25-18-00 General ........................................................................................................................... 25-45
25-33 Link Arm
25-33-00 General ........................................................................................................................... 25-55
9823/1650-1
2017-03-09
Acronyms Glossary
2WS Two Wheel Steer

4WS Four Wheel Steer
LS Load Sense
9823/1650-1
2017-03-09
Contents Page No.
25-00-00 General ............................................................................................................................. 25-3
25 - 1 9823/1650-1 25 - 1
Notes:
25 - 2 9823/1650-1 25 - 2
00 - General
Introduction ...................................................... 25-3
Health and Safety ........................................... 25-4
Manual Steer Mode System
Technical Data ................................................. 25-4 In a manual steer system, there are three steering
Operation ......................................................... 25-5 modes available:
Fault-Finding .................................................... 25-7
1. 2WS (Two Wheel Steer) (front axle only)- only
Check (Leaks) ............................................... 25-10 the front wheels are steered.
Check (Pressure) .......................................... 25-11
Adjust ............................................................ 25-12 2. 4WS (Four Wheel Steer) both axles are steered,
giving a smaller turning circle
Bleed ............................................................. 25-13
3. Crab steer- allows the machine to be driven
diagonally
25 - 3 9823/1650-1 25 - 3
00 - General

Engine/Steering Failure Table 195. Hydraulic steer unit
If the engine or steering fails, stop the machine as
Item Description
quickly as possible. Do not operate the machine until
the fault has been corrected. Model TBA
Volumetric displacement 95cc/rev (2:1 ratio)
gerotor 1:
Make the machine safe before getting beneath it. Volumetric displacement -
Make sure that any attachments on the machine are gerotor 2:
Relief valve operat- 195 –200 bar ( 2,826.1 –
ing pressure (at 1500 2,898.5 psi)
RPM (Revolutions Per
movement.
Minute))
Fluid Under Pressure Shock valve operating 255 bar ( 3,695.6 psi)
Fine jets of fluid at high pressure can penetrate the pressure- if installed
skin. Keep face and hands well clear of fluid under
pressure and wear personal protective equipment.
Hold a piece of cardboard close to suspected
leaks and then examine the cardboard for signs of
fluid. If fluid penetrates your skin, get medical help
immediately.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
service line has been vented before connecting or
removing hoses. Make sure the engine cannot be
started while the hoses are open.
WARNING! When getting access for maintenance
work, make sure no-one is in a position to be caught
and/or crushed by the wheels when the steering
wheel is turned.
25 - 4 9823/1650-1 25 - 4
00 - General
Operation
from the steer unit to the priority valve. The priority

(For: 506-36 [T4i], 507-42 [T4i], 509-42 valve then directs oil from the hydraulic pump to the
[T4i], 512-56 [T4i]) steer unit, which in turn directs the flow to the steer
rams on the axles.
The main components of the steering system are the
When the steering lock is achieved, the pressure
priority valve (PIL 25-03) , the load sensing steer
signal in the load sense line ceases. The priority
unit (PIL 25-06), the steer mode control valve (PIL
valve then directs the oil from the hydraulic pump
25-09) (if installed) and the double acting steer rams
into the main hydraulic system for operation of the
or power track rods as applicable (PIL 25-18 and or
hydraulic services.
19).
The maximum steering system pressure is set by a
When the you turn the steering wheel, a pressure
relief valve housed inside the steer unit.
signal (demand) is generated in the load sense line
Figure 419. Machine with Power Track Rods
A,B
D
E
C
25 - 5 9823/1650-1 25 - 5
00 - General
Figure 420. Machine with Steer Rams
F
D
A, B
F
C
Table 196.
Item Description
A Hydraulic pump
B Priority valve
C Steer unit
D Control valve
E Power track rods
F Steer rams
25 - 6 9823/1650-1 25 - 6
00 - General
Fault-Finding
Fault
Steering wheel difficult to turn Table 197. Page 25-7
Steering wheel turns on its own. Table 198. Page 25-7
Machine will not turn when the steering wheel turned. Table 199. Page 25-7
Steering 'drifts' out of phase during operation. Table 200. Page 25-8
Steering fails to respond to selected mode (solenoid operated mode valve Table 201. Page 25-8
only).
Table 197. Steering wheel difficult to turn

Cause Remedy
Tyres not inflated to correct pressure. Inflate tyres to correct pressure.
Insufficient hydraulic fluid. Check for leaks and top up the hydraulic tank as
Leaks in the relevant hoses or component Check hoses and connections for leaks. Refer to (PIL
connections. 30-00 ).
Air in the hydraulic system. Bleed system- bleed the load sense line. Refer to
(PIL 30-00).
Low pump flow. Check pump flow, if required service or replace
pump. Refer to (PIL 30-00).
Steer relief valve set incorrectly. Check pressure setting of steer unit relief valve,
adjust as required. Refer to (PIL 25-00).
Worn or damaged parts in the steer control valve. Remove and inspect. Refer to (PIL 25-00).
Priority valve not operating correctly. Check if the priority valve is sticking (contamination)
rectify as required. Check the load sense line from
the steer unit to the priority valve for signs of leaking
or poor connection. Refer to (PIL 25-00).
Steer mode valve not operating correctly (if fitted). Check if spools sticking, rectify as required. Refer
to the Steer Mode Valve topic. Check if solenoids
operating, replace solenoids as required. Refer to
(PIL 25-00).
Mechanical failure. Check for damaged axle components, such as rams,
track rods, linkages, etc. Refer to (PIL 27-00).
Table 198. Steering wheel turns on its own.

Cause Remedy
Dirt in the steer control unit (causing sleeves to stick Clean and inspect unit. Refer to (PIL 25-06).
open).
Steer control valve centring springs damaged, Check steer unit. Refer to (PIL 25-06).
broken or missing.
Steer control valve- position of rotor to shaft slot Correct as required. Refer to (PIL 25-06).
incorrect.
Table 199. Machine will not turn when the steering wheel turned.
Cause Remedy
Insufficient hydraulic fluid. Check for leaks and top up the hydraulic tank as
required. Refer to (PIL 30-00)
Leaks in the relevant hoses or component Check hoses and connections for leaks. Refer to (PIL
connections. 30-00).
Air in the hydraulic system. Bleed system- bleed the load sense line. Refer to
(PIL 25-00).
Low pump flow. Check pump flow, if required service or replace
pump. Refer to (PIL 30-00).
25 - 7 9823/1650-1 25 - 7
00 - General
Cause Remedy
Steer relief valve set incorrectly. Check pressure setting of steer unit relief valve,
adjust as required. Refer to (PIL 25-00).
Worn or damaged parts in the steer control valve. Remove and inspect. Refer to (PIL 25-00).
Priority valve not operating correctly. – Check if the priority valve is sticking
(contamination) rectify as required. Check the load
sense line from the steer unit to the priority valve for
signs of leaking or poor connection. Refer to (PIL
25-00).
Steer mode valve not operating correctly (if fitted). Check if spools sticking, rectify as required. Check if
solenoids operating, replace solenoids as required.
Refer to (PIL 25-00)
Mechanical failure. Check for damaged axle components, such as rams,
track rods, linkages, etc. Refer to (PIL 27-00)
Steer column splined shaft not fully engaged in steer Check shaft engagement. Refer to (PIL 25-12)
valve.
Power track rod/Steer Ram failure. Check power track rod/Steer Ram for signs of
damage, leaks etc. Refer to (PIL 30-15).
Table 200. Steering 'drifts' out of phase during operation.

Cause Remedy
(1) Does steering go out of phase in less than four YES = go to (2), NO = Ensure system is rephased
hours of continuous use? after four hours of continuous use (see Operator's
Handbook).
(2) Does steering go out of phase by a small amount YES = go to 3, NO = go to 4.
and drift no further when changing steer modes?
(3) Ensure operator changes steer mode at low YES = done, NO = Ensure power track-rod piston
engine speed and observes 5 second delay between is centralised and wheel tracking is correct. Adjust
modes (see Operator's Handbook), is it OK now? alignment of steer proximity switches to optimise
accuracy.
(4) Bleed steering system to remove air. Is it OK YES = done, NO = go to 5.
now?
(5) Possible leakage through anti-cavitation valve (if YES = done, NO = go to 6.
fitted). Replace Steer Unit. Refer to (PIL 25-06).
(6) Check both front and rear power track rods YES = done, NO = go to 7.
for internal leakage. Check the seal installation is
correct, check the seal damage, scoring or bore
ovality. Re-seal or renew faulty unit(s). Refer to (PIL
30-15). Is it OK now?
(7) Strip steer mode valve and inspect spool for YES = done, NO = go to 8.
scoring or damage. Renew valve if required. Refer to
(PIL 25-06). Is it OK now?
(8) Check for contamination in the hydraulic system. YES = Filter the hydraulic system. Refer to (PIL
30-00), NO = It is likely that one of the preceding
tests was not conclusive. Go to (1).
Table 201. Steering fails to respond to selected mode (solenoid operated mode valve only).
Cause Remedy
Electrical failure. (The steer mode ECU will generate Check relevant electrical connectors, if problem still
a blink code for some fault conditions). Refer to (PIL persists, do a wiring continuity check on relevant
57-90). circuits.
Selector switch faulty. Check selector switch, replace as required.
Proximity switches not operating correctly. Check operation of proximity switches, adjust or
replace switches as required. Refer to (PIL 25-15).
Steer mode relay not operating correctly. Renew relay. Refer to (PIL 33-09).
25 - 8 9823/1650-1 25 - 8
00 - General
Cause Remedy
Steer mode valve not operating correctly. – Check if spools sticking, rectify as required. Refer
to (PIL 25-06). Check if solenoids operating in
accordance with the mode selected. Refer to (PIL
25-06).
Leaks in the relevant hoses or component Check hoses and connections for leaks.
connections.
ECU failure. The ECU is normally a reliable component and
failure is unlikely. Before renewing the ECU make
sure that all relevant electrical connections and
components are functioning correctly. (Make sure
you do not connect a test meter directly to the pins
on the ECU).
25 - 9 9823/1650-1 25 - 9
00 - General
Check (Leaks) 4. Select the machine in 2WS mode and then close
the ball valves. Measure the length of one side of
the track rod and record the value.
Internal hydraulic leakage check 5. Drive the machine, in a circle, in one direction,
several times. Stop the machine and again
If hydraulic leaks at the steer mode valve or power
measure the track rod length. Compare the
track rods, the steering system will go progressively
measurements.
out of phase, the more the steering is operated the
further the front and rear wheels will drift out of phase. 5.1. If the track rod has moved then it can
be assumed that there is internal leakage
Some drifting out of phase is normal over time and across the piston seals in the power track
the system must be routinely re-phased. Refer to rod. This may be due to defective or
(PIL 25-00). incorrectly installed seals, or a defective
cylinder bore. Disassemble and inspect the
If the system goes out of phase over short periods
power track rod.
of time it is probable that there is hydraulic leakage.
External leakage is obvious and may occur at 5.2. If the track rod has not moved it can be
track rod seals, relevant hoses, pipes and adaptors. assumed there is internal leakage at the
Internal leakage can occur across power track rod steer mode valve.
piston seals or within the steer mode valve.
To check the internal leakage follow the below steps.
• 4WS (Four Wheel Steer) mode faults: Both

front and rear track rods and the steer mode
valve must be checked individually for possible
leakage.
• 2WS (Two Wheel Steer) mode faults: It is
possible to identify fault, if internal leakage is
at the rear power track rod, or steer mode
valve without first removing and dismantling
components. Follow the steps below.
2. Disconnect the hydraulic hoses from the rear
power track rod and Install isolating ball valves
at each port on the track rod and then reconnect
the hoses.
3. Open the ball valves. Start the engine and bleed
the system. Refer to (PIL 25-00).
Figure 421.
B C
B
A Hydraulic hoses
B Isolating ball valve
C Track rod
25 - 10 9823/1650-1 25 - 10
00 - General
Check (Pressure) 6. Set the steering to neutral (do not turn

the steering wheel), and start the engine.
Special Tools Gradually increase the engine speed to 1000
Description Part No. Qty. RPM (Revolutions Per Minute) and check the
Pressure Gauge (0-400 892/00279 1 maximum pressure gauge reading, it should be
Bar) within the specified limit.
Pressure Gauge (0-70 892/00346 1 Pressure: 5.9 –8.7 bar ( 85.5 –126.1 psi)
Bar)
6.1. If the pressure is more than the specified
The steer circuit pressure is integrated with operation limit then clean the priority valve. Refer to
of the hydraulic pump and the main hydraulic system (PIL 25-03).
pressures. Refer to (PIL 30-00-00) 6.2. If after cleaning the valve the pressure is
more than the specified limit then check
Gear pump machines the steering pump section flow rate and
pressure.
Hydraulic pressure tests 6.3. If the hydraulic pump flow and pressure
tests are satisfactory, then the priority valve
Standby pressure must be replaced with a new one. Refer to
1. Make the machine safe. Refer to (PIL 01-03). (PIL 25-03).
2. Turn the steering wheel to the left and to the right Steering pressure
several times to discharge the system pressure.
3. Disconnect hose 1 and install a pressure test
2. Turn the steering wheel to the left and to the right
gauge into the valve port.
several times to discharge the system pressure.
3. Connect a pressure gauge to the test point
4. Put the open end of hose 1 into a clean container located on the priority valve.
in order to collect any oil drainage.
Special Tool: Pressure Gauge (0-400 Bar) (Qty.:
Figure 422. 1)
G H Figure 423.
E K J F F
D K
F Priority valve
D Hose 2 K Test point
E LS (Load Sense) port adaptor
F Priority valve 4. Run the engine at 1500 RPM and turn the
G Hose 1 steering wheel to full lock.
H Hose 3
5. Hold the wheel on full lock and check the gauge
J Socket head screws
reading. This should be equal to the relief valve
K Test point
operating pressure. Refer to (PIL 25-00).
5. Disconnect hose 2 from load sensing port
6. If necessary, remove the plug on the hydraulic
adaptor and put a plug on the hose opening. Do
steer unit and adjust the pressure setting.
not cap the LS port adaptor.
25 - 11 9823/1650-1 25 - 11
00 - General
7. Use an Allen key to adjust the valve screw until Adjust

the correct pressure is shown on the gauge.
8. You can get access to the pressure adjusting To change the steer mode:
screw through a cut-out at the base of the
steering column after you remove the panels. 1. Stop the machine. Select the neutral position on
the forward/reverse lever.
Figure 424.
2. Turn the steering wheel until all the wheels are
pointing in the straight ahead position.
3. Use the steer mode selector lever to select the
steer mode required.
L Figure 425.
A
M
L Pressure adjusting screw B

M Plug
9. It may be necessary to remove the hydraulic C
steer unit if access is restricted.
D
10. Install the plug.
A Steer mode selector lever

B 4-wheel steer
C 2-wheel steer
D Crab steer
To align the wheels:
1. Stop the machine. Select the neutral position on

the forward/reverse lever.
2. Use the steer mode selector lever to select 4-
wheel steer.
3. Turn the steering wheel until the rear wheels are
4. Use the steer mode selector lever to select 2-
wheel steer.
5. Turn the steering wheel until the front wheels are
6. All wheels are now pointing straight ahead, select
the steer mode required and continue in the
normal manner.
25 - 12 9823/1650-1 25 - 12
00 - General
Bleed Machines with manual steer mode valve

(optional)
Machines with auto steer mode valve Whenever any hydraulic steering component is
disconnected or removed the system must be bled
Whenever any hydraulic steering component is as follows:
disconnected or removed the system must be bled
as follows: This procedure must be carried out in the correct
order that is laid down. You must not change the
With the engine running, the following procedure order of selections and operations.
must be carried out in the correct order that is laid
down. You must not change the order of selections 1. Start the engine.
and operations.
2. Select 2WS.
1. Select 2WS (Two Wheel Steer).
2.1. Turn the steering wheel to left, until front
1.1. Turn the steering wheel to left, until both the wheels are fully locked to the left.
front wheels are fully locked to the left. 2.2. Turn the steering wheel to right, until front
1.2. Turn the steering wheel to right, until both wheels are fully locked to the right.
the front wheels are fully locked to the right. 2.3. Turn the steering wheel to left until front
2. Select 4WS (Four Wheel Steer). wheels are in the straight ahead position.
2.1. Turn the steering wheel to left, until the front 3. Select 4WS.
wheels are fully locked to the left. 3.1. Turn the steering wheel to left, until front
3. Select 2WS. wheels are fully locked to the left.
3.2. Turn the steering wheel to right until front
3.1. Turn the steering wheel to full right lock. wheels are in the straight ahead position.
3.2. Turn the steering wheel to full left lock.
4. Select 2WS.
3.3. Turn the steering wheel to full right lock.
4. Select 4WS.
4.1. Turn the steering wheel to left, until the front 4.3. Turn the steering wheel to full right lock.
wheels are fully locked to the left.
4.4. Turn the steering wheel to left until front
5. Select 2WS. wheels are in the straight ahead position.
5.1. Turn the steering wheel to full right lock. 5. Select 4WS.
5.2. Turn the steering wheel to full left lock. 5.1. Turn the steering wheel to left, until the front
5.3. Turn the steering wheel to full right lock. wheels are fully locked to the left.
6. Select 4WS. 5.2. Turn the steering wheel to right until front
wheels are in the straight ahead position.
6.1. Turn the steering wheel to left, until front
wheels are fully locked to the left. 6. Select 2WS.
7. Select 2WS. 6.1. Turn the steering wheel to full right lock.
6.4. Turn the steering wheel to left until front
7.3. Turn the steering wheel to full right lock. wheels are in the straight ahead position.
8. Select 4WS. 7. Select 4WS.
8.1. Turn the steering wheel to left, until the front 7.1. Turn the steering wheel to left, until front
and rear wheels are fully locked. wheels are fully locked to the left.
9. Stop the engine and fill up the hydraulic tank as 7.2. Turn the steering wheel to right until front
necessary. wheels are in the straight ahead position
25 - 13 9823/1650-1 25 - 13
00 - General
8. Select 2WS.
8.4. Turn steering wheel to left until front wheels
are in the straight ahead position.
9. Select 4WS.
9.1. Turn the steering wheel to left, until the front
and rear wheels are fully locked.
10. Stop the engine and fill up the hydraulic tank as
necessary.
25 - 14 9823/1650-1 25 - 14
01 - Pump
01 - Pump
Contents Page No.
25-01-00 General ........................................................................................................................... 25-17
25 - 15 9823/1650-1 25 - 15
Notes:
25 - 16 9823/1650-1 25 - 16
01 - Pump
00 - General
00 - General
Introduction
Refer to gear pump, (PIL 30-11-00).
25 - 17 9823/1650-1 25 - 17
03 - Priority Valve
03 - Priority Valve
Contents Page No.
25-03-00 General ........................................................................................................................... 25-19
25 - 18 9823/1650-1 25 - 18
03 - Priority Valve
00 - General
00 - General Component Identification

Operation ....................................................... 25-21
Gear pump machines
Clean ............................................................. 25-23 The priority valve is mounted on the side of the gear
pump.
Figure 426.
LS P EF
EF
LS
EF Return line
P Pressure port
LS Load sense
Variable flow machines

The priority valve is an integral part of the control
valve block priority inlet section. Refer to (PIL 30-00).
Electro servo (Agri Xtra) machines

Figure 427.
A Control valve block priority inlet section
Electro servo (Agri excluding Extra)

machines
The priority valve is an integral part of the control
valve block priority inlet section. Refer to (PIL 30-00).
25 - 19 9823/1650-1 25 - 19
03 - Priority Valve
00 - General
Figure 428.
A Control valve block priority inlet section
25 - 20 9823/1650-1 25 - 20
03 - Priority Valve
00 - General
Operation
Neutral
The priority valve supplies hydraulic oil to the
steering circuit when it is necessary.
Figure 429. Gear pump type valve shown
LS P EF
LS
A
B
P EF
orifice 2, onto the end of the priority valve spool. This

creates a large pressure difference across the spool,
Table 202. causing it to move up against the force of the spring.
Item Description This allows the full pump flow to be directed through
port (EF) back to the tank or join with the main flow
A Pump outlet
to the control valve.
B Orifice 1
C Priority valve spool Turning
D Orifice 2
E Steering unit When the steering wheel is turned, a pressure signal
is generated in the load sense line from the steering
P Pressure line
unit.
LS Load sense line
EF Port Pressure is then applied to the spring end of
the priority valve spool. This reduces the pressure
When the steering is not being operated, flow to the difference across the spool, causing it to move down
steering circuit is dead ended by the closed centre under spring force. This allows some of the pump
steering unit, and no pressure signal (demand) is outlet flow to be directed through the pressure port
generated in the load sense line. Pressure from the to the steering unit, which in turn directs the flow to
pump outlet is directed through the orifice 1 and the corresponding steer rams to turn the wheels.
25 - 21 9823/1650-1 25 - 21
03 - Priority Valve
00 - General
Figure 430. Gear pump type valve shown
LS P EF
LS
A
B
P EF
Table 203.
Item Description
A Pump outlet
B Orifice 1
C Priority valve spool
D Orifice 2
E Steering unit
P Pressure line
LS Load sense line
EF Port
The excess flow goes through the port (EF) back to

the tank or joins with the main flow to the control.
When the steering reaches the required position,

the pressure signal in the load sense line from
the steering unit ceases and restore the pressure
difference across the spool. The spool moves back
up and allow the pump full flow to be directed through
port (EF) back to the tank or joins with the main flow
to the control valve.
The maximum steering system pressure is set by a

relief valve located inside the steering unit.
25 - 22 9823/1650-1 25 - 22
03 - Priority Valve
00 - General
Clean 10. Reconnect the hose to the LS port, and bleed the
LS line as described below.
The priority valve spool and spring may be removed 10.1. Start the engine.
for cleaning with the pump in the machine. 10.2. Loosen the connection on the valve, then
turn and hold the steering wheel fully in
1. Make the machine safe. Refer to (PIL 01-03). either direction.
2. Follow the general health and safety procedure. 10.3. When bubble free oil seeps from the joint,
Refer to (PIL 01-03). tighten the connection.
3. Discharge the hydraulic pressure. Refer to (PIL Table 204.
30-00).
Item Description
4. Turn the steering wheel to the left and to the right B 100 –105 N·m
several times to discharge system pressure.
C 75 –81 N·m
5. Disconnect the hose from the LS (Load Sense)
port. Blank off the hose to prevent loss of fluid.
6. Remove the adaptor and extract the priority valve
spring.
6.1. Remove the blanking plug and extract the
priority valve spool. Make sure that the bore
of the valve is not damaged.
7. Clean these components paying particular
attention to the orifices at each end of the spool.
Dry off and lubricate with clean hydraulic fluid.
Figure 431.
B D C
A Hose
B Adaptor
C Blanking plug
D Priority valve
8. Install the priority valve spool and make sure that
the spring seat end of the spool faces towards
the LS port.
9. Install the blanking plug and tighten it to the
25 - 23 9823/1650-1 25 - 23
06 - Steer Unit/Valve
Contents Page No.
25-06-00 General ........................................................................................................................... 25-25
25 - 24 9823/1650-1 25 - 24
00 - General
00 - General
Introduction
The steer unit valve controls the amount of hydraulic

fluid flow in the steering system.
25 - 25 9823/1650-1 25 - 25
09 - Mode Valve
09 - Mode Valve
Contents Page No.
25-09-03 Manual Mode Valve ....................................................................................................... 25-27
25 - 26 9823/1650-1 25 - 26
09 - Mode Valve
03 - Manual Mode Valve
03 - Manual Mode Valve Remove and Install

Remove
30-00).
5. Turn the steering wheel to the left and to the right
several times to discharge the system pressure
fully.
6. Make sure that the steering wheel is in the
straight ahead position.
8. Disconnect the hydraulic hoses from the steer
mode valve.
9. Plug all the open ports and hoses to prevent
contamination.
10. Remove the nuts and bolts that secure the steer
mode valve to the chassis.
11. Remove the steer mode selector control handle
located inside the cab.
12. Before you remove the steer mode valve
assembly from the machine, observe the routing
of the operating cable.
13. Remove the nuts securing the steer mode
selector unit to the cab.
14. The steer mode selector unit, operating cable
and valve can now be removed from the machine
as a complete assembly.
15. Make sure to collect the two washers to the rear
of the valve block which may fall out when screws
are removed.
16. Retain the spacer plate.
25 - 27 9823/1650-1 25 - 27
09 - Mode Valve
Figure 432.
A C
A B
A
A Hoses B Bolts
C Steer mode valve
25 - 28 9823/1650-1 25 - 28
09 - Mode Valve
Figure 433.
D Steer mode selector control handle
25 - 29 9823/1650-1 25 - 29
09 - Mode Valve
Figure 434.
E E
E Nuts F Steer mode selector unit
Figure 435.
G A B
H C
A Spacer plates B Bolts

C Steer mode valve G Chassis side plate
H Washer
25 - 30 9823/1650-1 25 - 30
09 - Mode Valve
Install
steps.
1.1. Make sure that the hoses are installed in the
correct position.
1.2. Bleed the steering system. Refer to (PIL
25-00).
1.3. Install the two washers between the valve
block, spacer and the chassis side plate.
1.4. Check the hydraulic oil level and top up as
25 - 31 9823/1650-1 25 - 31
09 - Mode Valve
Consumables travel away from the valve) until they disengage

Description Part No. Size the operating cable thread.
JCB Threadlocker 4101/0250 0.01 L 4. Remove the locknut 2 and disconnect the
and Sealer (Medium 4101/0251 0.05 L operating cable from valve adaptor.
Strength)
5. Remove the screws 2 from the end cap 2.
Disassemble
6. Remove the locknut 3. Rotate the locknut 3 and
1. Remove the steer mode valve assembly from the the end cap 2 counterclockwise (so that the parts
machine. Refer to (PIL 25-09). travel away from the valve) until they disengage
the operating cable thread.
2. Remove the screws 1 from the end cap 1.
7. Disengage the operating cable from the steer
3. Remove the locknut 1. Rotate the locknut 1 and mode selector.
the end cap 1 counterclockwise (so that the parts
Figure 436.
H K
E
A
C D
A Screws 1 B End cap 1

C Locknut 1 D Locknut2
E Operating cable F Adaptor
G Screws 2 H End cap 2
J Locknut 3 K Steer mode selector
25 - 32 9823/1650-1 25 - 32
09 - Mode Valve
Assemble
the disassembly procedure. Additionally do the
following steps.
Figure 437.
F
D
10 mm
D Locknut 2 F Adaptor
1.1. Before you connect the operating cable to

the valve, set the locknut 2 as shown in the
figure. Refer to Figure 437. In this position,
the locknut can be used as a guide as to
how far to wind the operating cable into the
valve adaptor.
2. Apply the specified sealant to the screws 1 and
the screws 2.
(Medium Strength)
25 - 33 9823/1650-1 25 - 33
12 - Column
12 - Column
Contents Page No.
25-12-00 General ........................................................................................................................... 25-35
25 - 34 9823/1650-1 25 - 34
12 - Column
00 - General
00 - General Figure 438.

X Y
Remove and Install
There are two types of steering column. Type X is

tilt adjustable and type Y is tilt and height adjustable.
The removal and installation procedures are the
same for both types.
Remove
3. Remove the steering wheel and steering column
surround. Refer to (PIL 09-36).
4. Remove the column switches. Refer to (PIL
33-27). H H
5. The electrical connector 1 and electrical
connector 2 are the same. Record the position of D E
the connectors.
6. Disconnect the electrical connector 1 and the
electrical connector 2.
7. Align the marks on the steering shaft and the C
steering column.
8. Remove the clips and the pins.
9. Hold the steering column assembly and remove
the lever lock (if installed).
10. Lift the column assembly away from the cab. A B
A Electrical connector 1
B Electrical connector 2
C Lever lock
D Steering shaft
E Steering column
F Clips
G Pins
H Steering shaft splines
25 - 35 9823/1650-1 25 - 35
12 - Column
00 - General
Install
steps.
1.1. Align the marks on the steering shaft and
the steering column put during removal.
1.2. Engage the steering shaft splines with the
steer valve internal spline.
1.3. Put the electrical connector 1 and the
electrical connector 2 in the correct
positions.
25 - 36 9823/1650-1 25 - 36
15 - Proximity Switch
Contents Page No.
25-15-00 General ........................................................................................................................... 25-39
25 - 37 9823/1650-1 25 - 37
Notes:
25 - 38 9823/1650-1 25 - 38
00 - General
Introduction .................................................... 25-39 These are installed on machines with auto steer
Adjust ............................................................ 25-40 mode system or manual (indicated) mode system.
25 - 39 9823/1650-1 25 - 39
00 - General
Adjust Figure 440.
A
If the proximity switch is defective, replace it. Refer
to steering system- proximity switch, refer to (PIL
25-15).
For electrical operation and testing, refer to electrical

system- electronic diagnostic, refer to (PIL 33-57).
B
The proximity switch setting procedure is the same
for both the front and rear axles. Y
1. Align the wheels in the straight ahead position.

D
2. Check the alignment as shown in the figure. Set
the steering so that the dimension X is of the
specified value. D C
Figure 439.
A Target disc
B Proximity switch
X C Bracket
D Bolts
Y Distance between the sensor tip and the end of
the target disc
5. If the dimension is not correct, adjust the switch
as follows:
5.1. Loosen the bolts.
5.2. Move the bracket up or down to make
dimension Y correct.
5.3. Tighten the bolts.
5.4. Repeat the step 4 again.
X Wheel alignment dimension

3. Remove the proximity switch cover.
4. Measure the dimension Y between the sensor tip
and the edge of the target disc and make sure
that it is to the specified value.
25 - 40 9823/1650-1 25 - 40
00 - General
Remove and Install
Working Under the Machine Remove

Make the machine safe before getting beneath it. 1. Make the machine safe. Follow all the general
Make sure that any attachments on the machine are safety procedures. Refer to (PIL 01-03).
the ignition key, disconnect the battery. If the machine 2. Disconnect the harness electrical connector from
has wheels use blocks to prevent unintentional the switch electrical connector.
movement.
3. Remove the proximity switch cover.
The following procedure applies to each of the steer
4. Remove the bolt and nut that secure the
proximity switches on the front and rear axles.
proximity switch to the support bracket.
5. Remove the proximity switch from the support
bracket.
Figure 441.
C B
A Proximity switch B Nut

C Support bracket D Proximity switch electrical connector
25 - 41 9823/1650-1 25 - 41
00 - General
Install
During the installation procedure do this below step
also.
1. Make sure to set the proximity switch air gap.
25 - 42 9823/1650-1 25 - 42
18 - Front Track Rod
Contents Page No.
25-18-00 General ........................................................................................................................... 25-45
25 - 43 9823/1650-1 25 - 43
Notes:
25 - 44 9823/1650-1 25 - 44
00 - General

Check (Condition) .......................................... 25-45
Check Energiser Seals
Disassemble and Assemble .......................... 25-50 If there is difficulty in steering the machine and
routine fault finding indicates power track rod
leakage, it is possible that the rectangular section
piston head seal on the power track rod piston head
is installed incorrectly i.e. twisted.
Check the front and rear power track rods as follows:
1. Disassemble the ram. Refer to Steering System-

Track Rod. Refer to (PIL 25-18).
2. Remove the piston seal and check to see if
the energiser seal has been installed twisted or
rolled.
3. Inspect the cylinder bore and piston rod for
scoring, nicks and burrs.
Figure 442.
A
B
A Piston seal
B Energiser seal
4. Assemble the ram with new seals. Make sure that
the energiser seal is not twisted or rolled. Check
the white installation marks.
Figure 443.
B
B Energiser seal
5. To prevent damage to the seals, clamp the
cylinder in a vertical position and lower the piston
rod assembly into the cylinder during installation.
25 - 45 9823/1650-1 25 - 45
00 - General
6. Install new wiper seals (not shown).

7. Install the power track rod assembly again.
8. Check the tracking. Refer to Driveline - Front
Wheel. Refer to (PIL 27-29).
9. Check for correct operation and steer phasing.
10. Check the hydraulic oil level and top up as
Figure 444.
25 - 46 9823/1650-1 25 - 46
00 - General
Remove and Install
10.5. Remove the adaptor 2.

Remove 10.6. Plug all the open ports and hoses to
prevent contamination.
11. At this point, if the power track rod is to be
2. Follow the general health and safety procedures dismantled, loosen the track rod link arms while
for the hydraulic system. Refer to (PIL 30-00). the track rod is still securely clamped. Refer to
3. Discharge the hydraulic pressure. Refer to (PIL steering system, Arm. Refer to (PIL 25-33).
30-00). 12. Remove the screw and the pin at each end
4. Turn the steering wheel to the left and to the right of the axle and separate the link arms from
several times to discharge the system pressure. their mounting points. Discard the two web seals
Make sure that the steering wheel is in the seated in the eye of each link arm.
straight ahead position. 13. Make alignment marks on the cylinder flange,
5. Before you start work, clean the area around the the end cover of the power track rod and on the
axle and the power track rod. housing flange of the axle.
6. Raise the front or the rear wheels from the 14. Remove the mounting screws 2 (x4).
ground with suitable lifting equipment. 15. If you work on the front axle, do the following
7. Block the chassis. steps:
8. Remove the front left or the rear right wheel as 15.1. Use suitable jacks to support both ends
applicable. of the axle and then remove the mounting
nuts from both ends. Leave the bolts in
9. If you work on the front axle, do the following position.
steps: 15.2. Lower the jack at the left end so that there
9.1. Put a label on the hoses to help installation. is sufficient room for removal of the power
track rod.
9.2. Disconnect hose 1 and hose 2 and then
remove the adaptor 1. 15.3. Use a soft-faced hammer to gently tap the
closed end of the track rod cylinder to the
9.3. Plug all the open ports and hoses to prevent left and out of its mounting.
contamination.
16. If you work on the rear axle, do the following
10. If you work on the rear axle, do the following steps:
steps:
16.1. Use a suitable jack to raise the left end of
10.1. Put a label on the hoses to help the axle so as to swivel the right end down
installation. to make room for removal of the power
10.2. Disconnect the pipe assembly from the track rod.
power track rod at the end point 1 and the 16.2. Use a soft-faced hammer to gently tap the
end point 2. closed end of the track rod cylinder to the
10.3. Remove the mounting screw 1. right and out of its mounting.
10.4. Remove the pipe assembly.
25 - 47 9823/1650-1 25 - 47
00 - General
Figure 445.
B
A
P
L
K N
F
E
H
D
M
A Hose 1 B Hose 2
C Adaptor 1 D Pipe assembly
E End point 1 F End point 2
G Mounting screw 1 H Adaptor 2
J Screw K Pin
L Link arm M Mounting screw 2
N Nuts P Bolt
25 - 48 9823/1650-1 25 - 48
00 - General
Install
steps.
1.1. Apply grease and install the two new web
seals in each link arm eye. Make sure that
they are installed correctly and fully seated.
1.2. Apply grease to the machined external
shoulders of the power track rod. Install by
tapping with a soft-faced hammer on the
mounting flange.
1.3. Take care to align the marks made during
removal.
1.4. Check the steer proximity switch setting.
1.5. Before you drive the machine, bleed the
steering system. Refer to (PIL 25-00).

Item Description Nm
G Mounting screw 56
H Adaptor 2 56
J Screw 56
M Mounting screw 166
N Mounting nut 600
P Bolts 600
25 - 49 9823/1650-1 25 - 49
00 - General
Consumables 3. Remove the end cap and then pull the piston rod
Description Part No. Size assembly from the cylinder.
Cleaner/Degreaser 4104/1557 0.4 L 4. Do not allow the piston rod to come into contact
- General purpose with the cylinder bore. The cylinder bore may be
solvent based parts damaged by careless dismantling.
cleaner
JCB Multi-Gasket 4102/1212 0.05 L 5. Position the piston rod assembly on the bench in
place of the ram cylinder.
Use the alphabetical sequence shown on the
illustration as a guide to disassembly. Refer to Figure 6. Remove and discard the wear rings and the seal/
446. energising ring.
7. The piston head cannot be removed from the
Disassemble rod, if there is damage to the rod or piston head,
replace the complete assembly.
1. Fix the ram assembly on a locally manufactured
strip/ rebuild bench. 8. Carefully inspect the bore of the cylinder and the
piston rod outer diameter for scoring, nicks and
2. Remove the steering link arm 1 and the steering burrs. If damaged, install a new component.
link arm 2. Refer to steering system- track rod,
25 - 50 9823/1650-1 25 - 50
00 - General
Figure 446.
AA
K C
E
G
J H L
A
D
F J
CC
B
BB
K
A Screw B End cap

C Cylinder D Piston head
E Wear ring 1 F Wear ring 2
G Seal H Energising seal
J Piston rod seals K Wiper rings
L Cover seal AA Steering link arm 1
BB Steering ring arm 2 CC Piston sleeve
25 - 51 9823/1650-1 25 - 51
00 - General

F G E
H
E Wear ring 1
F Wear ring 2
G Seal
Figure 448. H Energising seal
8. Apply grease to the piston seal and to the
surfaces of the piston rod.
9. Install the piston rod assembly.
10. Clamp the cylinder vertically.
11. Lower the piston rod assembly from the top.
Make sure its orientation is correct so that the
piston sleeve is nearest to the closed end of the
cylinder. Refer to Figure 448.
12. Make sure that the piston rod does not touch the
cylinder bore.
13. Engage the new piston head wear rings and
Assemble seals carefully into the cylinder.
1. Make sure all threads are free of grease, 14. If the piston head wear rings or the seals
hydraulic oil and sealant with the degreaser. are damaged during this stage, they must be
replaced.
purpose solvent based parts cleaner 15. When operating in conditions which are
consistently below freezing, it is recommended
2. Allow the degreaser to dry for 15 minutes and that the track rod is operated slowly to its full
then apply the sealant. extent in both directions before you start normal
Consumable: JCB Multi-Gasket working.
3. Make sure that the lubricants used during 16. Check the energiser seals. Refer to Front Track
assembly do not come into contact with the JCB Rod - Check Condition (PIL 25-18).
multi-gasket.
4. Install the piston rod seals and the wiper rings
correctly into the closed end of cylinder and into
the cover along with the cover seal.
5. Make sure that the energiser ring is not twisted.
6. If the installation is not correct, it may lead to
leakage of the hydraulic fluid between the two
sides of the power track rod and will cause
steering problems.
7. Make sure that three white marks are visible on
the outside diameter arrowed before install the
seal.Refer to Figure 449.
25 - 52 9823/1650-1 25 - 52
33 - Link Arm
33 - Link Arm
Contents Page No.
25-33-00 General ........................................................................................................................... 25-55
25 - 53 9823/1650-1 25 - 53
Notes:
25 - 54 9823/1650-1 25 - 54
33 - Link Arm
00 - General
00 - General
Remove and Install
Consumables Figure 450.

Strength)
Remove
If you have to dismantle the power track rod or
replace the link arms, do the following steps:
Remove
1. Fix the assembly on a locally made strip/rebuild 2. Use two suitable open ended spanners at point1
bench. Refer to Figure 450. and point2 and turn against each other until one
ball joint unscrews as shown. Refer to Figure
451.
3. For this explanation, assume the ball joint at
point1 is now loose, do as follows:
25 - 55 9823/1650-1 25 - 55
33 - Link Arm
00 - General
Figure 451.
A
B
A Point1 B Point2
25 - 56 9823/1650-1 25 - 56
33 - Link Arm
00 - General
C Point3 D Point4
3.1. Unscrew the ball joint until you can fit an Install
open ended spanner on the rod at point3.
Turn the ball joint towards the spanner to If the you have to dismantle the power track rod
secure it and to prevent damage to the rod. ram, carry out the procedure before you remove and
install the link arms. Refer to (PIL 30-15).
3.2. The piston rod operates at full length. Any
damage to the surface will cause fluid leaks. 1. The installation procedure is the opposite of the
Make sure you do not damage it or attempt removal procedure.
to grip the rod diameter with pipe grips etc.
3.3. Hold the spanner at point3 and remove the 2. When you install, also do the following steps:
ball joint at point4 by moving it against the 2.1. Install the target disc (where applicable).
spanner at point3.
2.2. Apply threadlocker and sealer on the first
4. Remove the target disc where applicable. three threads of the inner ball joint where it
screws into the end of the track rod.
5. If you replace the inner or outer ball joints, make
sure you install a replacement link arm assembly. Consumable: JCB Threadlocker and Sealer
(Medium Strength)
Figure 452.
2.3. If the link arms have been renewed, make
sure you check the wheel alignment.
2.4. Bring the wheels to straight ahead position.
J 2.5. Measure the distance1 and distance2

between the outer edges of the wheel hub
as shown.
2.6. Make sure that the difference between
the distance1 and the distance2 is of the
specified value for correct alignment.
E F G H 2.7. To adjust the wheel alignment, remove
the lock nuts. Turn the threaded adjusters
equally to get the correct alignment. Tighten
E Lock nut the lock nuts.
F Threaded adjuster 2.8. Check the target disc and proximity switch
G Spanner flat on ball joint setting (where applicable). Refer to steering
H Spanner flat on the rod system- track rod, refer to (PIL 25-18).
J Target disc
25 - 57 9823/1650-1 25 - 57
33 - Link Arm
00 - General
Figure 453.
X Distance1 Y Distance2

Item Description Nm
G Ball joint 250
G Rod 250
E Lock nut 250
F Adjuster 250
25 - 58 9823/1650-1 25 - 58
27 - Driveline
Contents Page No.
27-00 Driveline
27-00-00 General ............................................................................................................................. 27-3
27-06 Semi-Automatic Gearbox
27-06-00 General ............................................................................................................................. 27-7
27-06-06 Clutch - Reverse ............................................................................................................ 27-85
27-06-07 Clutch - 2WD/4WD ......................................................................................................... 27-89
27-06-08 Clutch - Layshaft .......................................................................................................... 27-118
27-06-09 Clutch - Main Shaft ...................................................................................................... 27-138
27-06-10 Clutch - 6 Speed .......................................................................................................... 27-152
27-06-11 Clutch - Forward (Input) ............................................................................................... 27-160
27-06-15 Solenoid Control Valve ................................................................................................. 27-175
27-06-18 Pressure Relief Valve ................................................................................................... 27-180
27-06-21 Pressure Maintenance Valve (PMV) ............................................................................ 27-181
27-06-24 Oil Pump ...................................................................................................................... 27-183
27-06-27 Speed Sensor .............................................................................................................. 27-185
27-06-30 Oil Pressure Sensor ..................................................................................................... 27-196
27-06-33 Oil Temperature Sensor ............................................................................................... 27-200
27-06-39 Filter ............................................................................................................................. 27-209
27-06-40 Suction Strainer ............................................................................................................ 27-211
27-06-45 Piston Ring Seal .......................................................................................................... 27-213
27-06-47 Oil Seal ........................................................................................................................ 27-215
27-06-52 Driveshaft ..................................................................................................................... 27-217
27-06-54 Main Shaft .................................................................................................................... 27-220
27-06-56 Layshaft ........................................................................................................................ 27-223
27-06-57 Input Shaft .................................................................................................................... 27-224
27-06-58 Output Shaft ................................................................................................................. 27-225
27-06-81 Mount ........................................................................................................................... 27-235
27-06-85 Oil Feed Pipe ............................................................................................................... 27-236
27-06-86 Oil Transfer Pipe .......................................................................................................... 27-237
27-06-90 Front Case ................................................................................................................... 27-238
27-06-91 Rear Case .................................................................................................................... 27-248
27-06-95 Coupling Yoke 4WD ..................................................................................................... 27-250
27-12 Transfer Gearbox
27-12-00 General ......................................................................................................................... 27-255
27-14 Torque Converter
27-14-00 General ......................................................................................................................... 27-281
27-14-06 Control Valve ................................................................................................................ 27-289
27-14-09 Relief Valve .................................................................................................................. 27-291
27-22 Drivehead
27-22-00 General ......................................................................................................................... 27-295
27-22-06 Crownwheel .................................................................................................................. 27-315
9823/1650-1
2018-05-24
27-22-09 Pinion Gear .................................................................................................................. 27-317
27-24 Differential
27-24-00 General ......................................................................................................................... 27-321
27-27 Hub
27-27-00 General ......................................................................................................................... 27-333
27-27-66 Wheel Stud ................................................................................................................... 27-347
27-29 Wheel
27-29-00 General ......................................................................................................................... 27-349
27-33 Tyre
27-33-00 General ......................................................................................................................... 27-353
27-47 Propshaft
27-47-00 General ......................................................................................................................... 27-357
27-51 Driveshaft
27-51-00 General ......................................................................................................................... 27-363
27-51-15 Shaft Hub Side ............................................................................................................. 27-367
9823/1650-1
2018-05-24
Acronyms Glossary
2WD Two Wheel Drive

LSD Limited Slip Differential
LSP Load Sense Pump
LSRV Load Sense Relief Valve
MRV Main Relief Valve
PMV Pressure Maintenance Valve
PTFE Polytetrafluoroethylene
PTO Power Take-Off
RAS Rear Axle Stabilization
9823/1650-1
2018-05-24
Notes:
9823/1650-1
2018-05-24
27 - Driveline
00 - Driveline
00 - Driveline
Contents Page No.
27-00-00 General ............................................................................................................................. 27-3
27 - 1 9823/1650-1 27 - 1
Notes:
27 - 2 9823/1650-1 27 - 2
27 - Driveline
00 - Driveline
00 - General

Health and Safety ........................................... 27-3 Working Under the Machine
Technical Data ................................................. 27-4 Make the machine safe before getting beneath it.
Operation ......................................................... 27-5 Make sure that any attachments on the machine are
movement.
WARNING! A raised and badly supported machine
can fall on you. Position the machine on a firm, level
surface before raising one end. Ensure the other
end is securely chocked. Do not rely solely on the
machine hydraulics or jacks to support the machine
when working under it. Disconnect the battery, to
prevent the machine being started while you are
beneath it.
WARNING! Before disconnecting any propshaft,
make sure you block both sides of all wheels to
prevent machine movement. The park brake will
become ineffective or may only operate on 2 wheels
(depending on machine specification).
WARNING! If a 4 wheel drive machine is to be
raised and the engine/transmission run, make sure
all four wheels are raised off the ground. Make sure
the machine is correctly supported by the correct
axle stands. If only one pair of wheels is raised, the
machine could move and fall off the stands.
WARNING! Under no circumstances must the
engine be run with the transmission in gear and only
one driving wheel jacked clear of the ground, since
the wheel on the ground will move the machine.
27 - 3 9823/1650-1 27 - 3
27 - Driveline
00 - Driveline
00 - General
Technical Data
Table 207.
Component 506-36 507-42, 509-42, 510-42, 510-56,
512-56, 514-56, 516-42
Transmission PS750 PS750
Front Axle SD 70 Pivot Mount, 3 Piece SD 80 Pivot Mount, 3 Piece
Rear Axle SD 55 Pivot mount 1 piece SD 80 Pivot mount 3 piece
Front drive head 80 Series 3 piece 80 Series 3 piece
Front differential Maxtrac Maxtrac
Rear drive head SD 55 Series 1 piece SD 80 Series 3 piece
Rear differential Maxtrac Maxtrac
Front hub 55 Series 80 Series
Front swivels and drive shafts 55 Series 55 Series
Front axle brakes 70 Series integral brakes 70 Series integral brakes centre
mounted
Rear swivels and drive shafts 55 Series 1 piece 55 Series
Rear axle brakes . 70 Series integral brakes centre
mounted
27 - 4 9823/1650-1 27 - 4
27 - Driveline
00 - Driveline
00 - General
Operation
The transversely mounted engine drives a The bevel gearbox and the gearbox share the same
permanently engaged 90 ° bevel gearbox. A torque lubricating oil. The transmission has dedicated oil
converter is mounted on the output end of the bevel filtering and cooling systems.
gearbox. The output from the torque converter drives
an electro hydraulically controlled gearbox. Drive Drive is taken from the bevel gearbox to the main
from the gearbox is transmitted to the steer drive hydraulic pump via a short splined tube.
front axle and to the steer drive rear axle via the
propshafts. The engine has a vibration damper bolted to the
flywheel.
Figure 454.
A Engine B Bevel gearbox

C Output end of the bevel gearbox D Electro hydraulically controlled gearbox
E Steer drive front axle F Steer drive rear axle
G Propshafts J Hydraulic pump
K Flywheel
27 - 5 9823/1650-1 27 - 5
27 - Driveline
06 - Semi-Automatic Gearbox
Contents Page No.
27-06-00 General ............................................................................................................................. 27-7

27-06-06 Clutch - Reverse ............................................................................................................ 27-85
27-06-07 Clutch - 2WD/4WD ......................................................................................................... 27-89
27-06-08 Clutch - Layshaft .......................................................................................................... 27-118
27-06-09 Clutch - Main Shaft ...................................................................................................... 27-138
27-06-10 Clutch - 6 Speed .......................................................................................................... 27-152
27-06-11 Clutch - Forward (Input) ............................................................................................... 27-160
27-06-15 Solenoid Control Valve ................................................................................................. 27-175
27-06-18 Pressure Relief Valve ................................................................................................... 27-180
27-06-21 Pressure Maintenance Valve (PMV) ............................................................................ 27-181
27-06-24 Oil Pump ...................................................................................................................... 27-183
27-06-27 Speed Sensor .............................................................................................................. 27-185
27-06-30 Oil Pressure Sensor ..................................................................................................... 27-196
27-06-33 Oil Temperature Sensor ............................................................................................... 27-200
27-06-39 Filter ............................................................................................................................. 27-209
27-06-40 Suction Strainer ............................................................................................................ 27-211
27-06-45 Piston Ring Seal .......................................................................................................... 27-213
27-06-47 Oil Seal ........................................................................................................................ 27-215
27-06-52 Driveshaft ..................................................................................................................... 27-217
27-06-54 Main Shaft .................................................................................................................... 27-220
27-06-56 Layshaft ........................................................................................................................ 27-223
27-06-57 Input Shaft .................................................................................................................... 27-224
27-06-58 Output Shaft ................................................................................................................. 27-225
27-06-81 Mount ........................................................................................................................... 27-235
27-06-85 Oil Feed Pipe ............................................................................................................... 27-236
27-06-86 Oil Transfer Pipe .......................................................................................................... 27-237
27-06-90 Front Case ................................................................................................................... 27-238
27-06-91 Rear Case .................................................................................................................... 27-248
27-06-95 Coupling Yoke 4WD ..................................................................................................... 27-250
27 - 6 9823/1650-1 27 - 6
27 - Driveline
00 - General
Introduction ...................................................... 27-7 Semi-automatic gearboxes are a hybrid form of
Technical Data ................................................. 27-8 transmission where an integrated control system
Component Identification ............................... 27-16 handles manipulation of the clutch automatically,
Operation ....................................................... 27-29 but the driver can still take manual control of gear
selection.
Fault-Finding .................................................. 27-56
Drain and Fill ................................................. 27-63 Many of these transmissions allow the driver to fully
Clean ............................................................. 27-64 delegate gear shifting choice to the control system,
Check (Condition) .......................................... 27-64 which then effectively acts as if it is an automatic
transmission. An automatic transmission uses a
Check (Level) ................................................ 27-65 torque converter instead of a straight friction clutch
Check (Pressure) .......................................... 27-66 to manage the connection between the transmission
Remove and Install ....................................... 27-79 gearing and the engine.
A typical JCB semi-automatic transmission is called
Powershift, it has an (A) on the gearshift to signify
Automatic. In this mode the machine will gear change
automatically according to road speed. The following
types exist:
• PS700
• PS750
• PS764
• PS766
Not all types of transmission are available on all

types of machine. Check the operators manual
or transmission identification label for the type of
transmission installed on your machine.
27 - 7 9823/1650-1 27 - 7
27 - Driveline
00 - General
Technical Data
For: PS750 MK4 ......................... Page 27-8

For: PS764 ................................ Page 27-10
For: PS766 ................................ Page 27-13
(For: PS750 MK4)

Table 208. PS 750 4- Speed 2/4 Wheel Drive
Designation PS 750 MkIV Powershift - ECU Control
Description Full electro-hydraulic transmission unit with input, reverse, layshaft and main-
shaft drive clutch packs giving 4 forward and 4 reverse speeds. ECU (Electron-
ic Control Unit) controlled gear selection. Permanent 4 wheel drive or selectable
2/4 wheel drive variants.
Weight (dry) 2/4 wheel drive 215 kg
Permanent 4 wheel drive TBA
Clutch solenoid current draw 1.36 A maximum (at 20 °C ( 68.0 °F))
Gearbox 'Limp Modes' (Powershift Mode Possible Reason

Electronic Control) Only 1st, 2nd and 3rd If the ECU does not de-
gears available. tect any input from the
When applicable, the gearbox ECU provides speed sensor it will pre-
restricted or modified gearbox operation if faults are vent selection of any
detected by the ECU. Typical 'limp mode' forms of gear above 3rd.
operation are shown here. Fault codes may also be
Limp Mode 4 (Repeating Error reading transmis-
displayed on the instrument panel. For fault codes
beeps until ECU power sion speed
refer to (PIL 33-57-90).
is reset)
On power up, the ECU will normally sound 3 beeps. Machine holds a gear If the ECU detects and
These beeps can be masked by other audible error with the speed
warnings on start up. sensor while operating,
it prevents autoshifting.
Table 209. Gearbox 'Limp
Modes' (Powershift Electronic Control). Stall Speed Combinations
Mode Possible Reason
The tests carried out at the factory record the correct
Limp Mode 1 (2 beeps Internal 'setup data'
engine r.p.m. (stall speed) when under maximum
at power up). ECU fault.
load from the transmission and hydraulic systems.
Machine autoshifts at If on power up the ECU
different road speeds detects an internal fault The figures relate to tests conducted at an ambient
than normal. with its 'set up' data, it temperature of 25 °C ( 77.0 °F) and barometric
will revert to use of a de- pressure of 1 bar ( 14.5 psi)at sea level. The changes
fault set of values. in ambient temperature, pressure and humidity and
Limp Mode 2 (1 beep at Error with ECU applica- fuel grade will affect engine power and hence the stall
power up). tion software. figures.
Machine remains in neu- If on power up, the ECU For example, at 10,000 ft the power reduction of a
tral at all times. detects an internal fault naturally aspirated engine could be 29% and for a
with its 'core operating turbo engine 8%.
software' it will prevent
operation of the gear- The figures apply to `bedded-in' engines, i.e. engines
box. that have done a minimum of 250 working hours.
Limp Mode 3 (Machine Error reading transmis- Therefore they should not be used for pre-delivery
will not autoshift). sion speed. inspection (PDI) checks.
All figures are recorded with the transmission oil at

60 °C ( 139.9 °F) and the hydraulic oil at 55 °C ( 130.9
°F). Figures achieved should be within +/- 100 RPM
27 - 8 9823/1650-1 27 - 8
27 - Driveline
00 - General
(Revolutions Per Minute) from the figures given in the

table.
Table 210. Stall Speed Combinations

Engine Build Code SL SH
Engine Power 55kW 4 Speed PS750 (4 Speed 81kW 4 Speed PS750/PS764
SS700)
(1)
Model 531-70 5AA, 535-95 5AB, 541-70 531-70 5A(T)A, 535-95 5AB(TD),
5AD, 533-105 5AH, 540-140 536-60 5A(T)C, 541-70 5A(T)D,
5AL, 535-125 5AN, 535-140 5AP, 540-170 5AF, 550-140 5AG,
536-70 5AR, 526-56 5AS 533-105 5AH, 540-140 5AL,
550-1705AM, 535-125 5AN,
535-140 5AP, 536-70 5AR(TE),
526-56 5AS
Hydraulic System:
Gearpump
Variflow
Engine Stall Speeds RPM
Torque Converter Only
Hydraulics (MRV (Main Relief
Valve)) Only
Combined Converter + MRV
(2)
Combined Converter + LSRV

(Load Sense Relief Valve)
LSP (Load Sense Pump) Variflow
LSP Electro Servo
(1) 526-56 Machines only
(2) Combined stall tests on machines fitted with a hydraulic gearpump are performed with the crowd service
operated until the relief valve is lifted.
Gearbox Specifications
Table 211. Oil Pressures
Pressure
Converter pressure (in neutral)
Converter In at 50 °C ( 121.9 °F) 1000 RPM 1.5 –4 bar ( 21.7 –58.0 psi)
2000 RPM 5 –7 bar ( 72.5 –101.4 psi)
Converter Out at 50 °C ( 121.9 °F) 1000 RPM TBA
2000 RPM TBA
Converter inlet relief pressure 6.5 bar ( 94.2 psi)
(max.)
Lubrication pressure (in neutral)
Oil at 50 °C ( 121.9 °F) 1000 RPM 0.14 –0.28 bar ( 2.0 –4.1 psi)
2000 RPM 0.28 –0.55 bar ( 4.1 –8.0 psi)
Main Line Pressure (in neutral)
Oil at 50 °C ( 121.9 °F) 1000 RPM 11 –13 bar ( 159.4 –188.4 psi)
2000 RPM 12 –14.5 bar ( 173.9 –210.1 psi)
Clutch pressure All clutch pressures should be the same as mainline pressure to within
0.7 bar ( 10.1 psi).
27 - 9 9823/1650-1 27 - 9
27 - Driveline
00 - General
Flow Rates (in Flow Rate

neutral)
Table 212. Oil Flow Rates
Pump oil flow at 1000 RPM 11 –15
Flow Rates (in Flow Rate 50 °C ( 121.9
neutral) °F)
Cooler oil 1000 RPM 8 –13 2000 RPM 22.5 –29.5
flow at 50 °C
( 121.9 °F) For new gearboxes (i.e. under 100 hours service),
2000 RPM 19 –25 or gearboxes that have been fully serviced, the
pressures will be slightly higher than those shown
(approximately 0.7 –1 bar ( 10.1 –14.5 psi)).
(For: PS764)
Table 213. PS 764 4- Speed 2/4 Wheel Drive
Designation PS 764 Powershift
Description Full electro-hydraulic transmission unit with input, reverse, layshaft and main-
shaft drive clutch packs giving 4 forward and 4 reverse speeds. ECU controlled
gear selection.
Weight (dry) Permanent 4 wheel drive 242 kg
Clutch ratio solenoid types 3 way, 2 position, normally closed, with integral pro-
portional solenoid.
Clutch ratio solenoid current draw 0.85 A for clutch pressure of 12 bar ( 173.9 psi)
Clutch ratio solenoid coil resistance 7.25 Ω (at 20 °C ( 68.0 °F))
Clutch 4WD (Four Wheel Drive) solenoid type 3 way, 2 position, normally closed, with integral on/off
solenoid and suppression diode.
Clutch 4WD solenoid current draw 1.68 A at 12 V at 20 °C ( 68.0 °F)
Torque converter diameter 310 mm
Torque converter identification W300
Torque multiplication at stall 2.02:1

Modes' (Powershift Electronic Control).
Table 214. Gear ratios
Gear (Forward) Ratio Limp Mode 1 (2 beeps Internal 'setup data'
1st 6.17:1 at power up). ECU fault.
2nd 3.32:1 Machine autoshifts at If on power up the ECU
3rd 1.86:1 different road speeds detects an internal fault
4th 1.00:1 than normal. with its 'set up' data, it
will revert to use of a de-
fault set of values.
Gearbox 'Limp Modes' (Powershift
Electronic Control) Limp Mode 2 (1 beep at Error with ECU applica-
power up). tion software.
When applicable, the gearbox ECU provides Machine remains in neu- If on power up, the ECU
restricted or modified gearbox operation if faults are tral at all times. detects an internal fault
detected by the ECU. Typical 'limp mode' forms of with its 'core operating
operation are shown here. Fault codes may also be software' it will prevent
displayed on the instrument panel. For fault codes operation of the gear-
refer to (PIL 33-57-90). box.
Limp Mode 3 (Machine Error reading transmis-
On power up, the ECU will normally sound 3 beeps. will not autoshift). sion speed.
These beeps can be masked by other audible
warnings on start up.
27 - 10 9823/1650-1 27 - 10
27 - Driveline
00 - General
Mode Possible Reason The figures relate to tests conducted at an ambient

Only 1st, 2nd and 3rd If the ECU does not de- temperature of 25 °C ( 77.0 °F) and barometric
gears available. tect any input from the pressure of 1 bar ( 14.5 psi)at sea level. The changes
speed sensor it will pre- in ambient temperature, pressure and humidity and
vent selection of any fuel grade will affect engine power and hence the stall
gear above 3rd. figures.
Limp Mode 4 (Repeating Error reading transmis- For example, at 10,000 ft the power reduction of a
beeps until ECU power sion speed naturally aspirated engine could be 29% and for a
is reset) turbo engine 8%.
Machine holds a gear If the ECU detects and
error with the speed The figures apply to `bedded-in' engines, i.e. engines
sensor while operating, that have done a minimum of 250 working hours.
it prevents autoshifting. Therefore they should not be used for pre-delivery
inspection (PDI) checks.
Stall Speed Combinations All figures are recorded with the transmission oil at
The tests carried out at the factory record the correct °F). Figures achieved should be within +/- 100 RPM
engine r.p.m. (stall speed) when under maximum from the figures given in the table.

Engine Build Code SH
Engine Power 81kW 4 Speed PS750/PS764
Model 531-70 5A(T)A, 535-95 5AB(TD), 536-60 5A(T)C,
541-70 5A(T)D, 540-170 5AF, 550-140 5AG, 533-105
5AH, 540-140 5AL, 550-1705AM, 535-125 5AN,
535-140 5AP, 536-70 5AR(TE), 526-56 5AS
Hydraulic System:
Gearpump
Variflow
Engine Stall Speeds RPM
Torque Converter Only
Hydraulics (MRV) Only
Combined Converter + MRV
(1)
Combined Converter + LSRV

LSP Variflow
LSP Electro Servo
(1) Combined stall tests on machines fitted with a hydraulic gearpump are performed with the crowd service
operated until the relief valve is lifted.
27 - 11 9823/1650-1 27 - 11
27 - Driveline
00 - General
Engine Build SH DH
Code
Variflow
Engine Build SH DH
Code Engine Stall Speeds RPM
Engine Power 93kW 4 Speed 108kW 4 Speed Torque Convert-
PS764 PS764 er Only
Model 531-70 5A(T)A, 531-70 5A(T)A, Hydraulics
535-95 535-95 (MRV) Only
5AB(TD), 5AB(TD), Combined Con-
verter + MRV
(1)
536-60 5A(T)C, 536-60
541-70 5A(T)D, 5A(T)C, 541-70 Combined Con-
540-170 5AF, 5A(T)D, 536-70 verter + LSRV
550-140 5AG, 5AR(TE), LSP Variflow
540-140 5AL, 550-80
550-1705AM, 5AW(UW) LSP Electro
536-70 Servo
5AR(TE), (1) Combined stall tests on machines fitted with a
550-80 hydraulic gearpump are performed with the crowd
5AW(UW) service operated until the relief valve is lifted.
Hydraulic System:
Gearpump
Pressure
Converter pressure in neutral
Converter In at 50 °C ( 121.9 °F) 1000 RPM 1.4 –2.2 bar ( 20.3 –31.9 psi)
2000 RPM 5.8 –6.9 bar ( 84.1 –100.0 psi)
Converter In at 100 °C ( 211.9 °F) 1000 RPM 0.5 –1.3 bar ( 7.2 –18.8 psi)
2000 RPM 2.5 –3.5 bar ( 36.2 –50.7 psi)
Converter Out at 50 °C ( 121.9 °F) 1000 RPM 0.6 –1.6 bar ( 8.7 –23.2 psi)
2000 RPM 2.8 –3.8 bar ( 40.6 –55.1 psi)
Converter Out at 100 °C ( 211.9 1000 RPM 0.2 –1 bar ( 2.9 –14.5 psi)
°F)
2000 RPM 1 –1.9 bar ( 14.5 –27.5 psi)
Converter inlet relief pressure 7.1 bar ( 102.9 psi)
(max.)
2000 RPM 1.1 –2.1 bar ( 15.9 –30.4 psi)
2000 RPM 0.4 –1.4 bar ( 5.8 –20.3 psi)
Oil at 50 °C ( 121.9 °F) 1000 RPM 11 –13 bar ( 159.4 –188.4 psi)
2000 RPM 13 –15.2 bar ( 188.4 –220.3 psi)
2000 RPM 11.4 –14.5 bar ( 165.2 –210.1 psi)
Clutch pressure All clutch pressures should be the same as mainline pressure to within
0.7 bar ( 10.1 psi) and 4WD clutch pressure to be within 1.4 bar ( 20.3
psi)
27 - 12 9823/1650-1 27 - 12
27 - Driveline
00 - General

neutral)
Pump oil flow at 1000 RPM 11.5 –15.6 L/
Flow Rates (in Flow Rate 100 °C ( 211.9 min
neutral) °F)
Cooler oil 1000 RPM 8.5 –11 L/min 2000 RPM 24 –33 L/min
flow at 50 °C
( 121.9 °F) For new gearboxes (i.e. under 100 hours service),
2000 RPM 17 –25.1 L/min or gearboxes that have been fully serviced, the
Cooler oil flow 1000 RPM 6.2 –9.5 L/min pressures will be slightly higher than those shown
at 100 °C (approximately 0.7 –1 bar ( 10.1 –14.5 psi)).
( 211.9 °F)
2000 RPM 15 –19.5 L/min
(For: PS766)
Table 220. PS 766 6- Speed 4 Wheel Drive
Designation PS 766 Powershift
Description Full electro-hydraulic transmission unit with input, reverse, layshaft, mainshaft,
6 speed and 4 wheel drive clutch packs giving 6 forward and 4 reverse speeds.
Electronically controlled gear selection. Integral wet multi-plate park brake.
Weight (dry) Permanent 4 wheel drive 285 kg
Clutch solenoid types 3 way, 2 position, normally closed, integral suppres-
sion diode
Coil resistance 7.5 Ω maximum (at 20 °C ( 68.0 °F))
Torque converter diameter 310 mm
Torque converter identification W300 Lock up torque converter (LUC)
Torque multiplication at stall 2.52:1

Modes' (Powershift Electronic Control).
Table 221. Gear ratios
Gear (Forward) Ratio Limp Mode 1 (2 beeps Internal 'setup data'
1st 8.17:1 at power up). ECU fault.
2nd 4.90:1 Machine autoshifts at If on power up the ECU
3rd 3.62:1 different road speeds detects an internal fault
4th 2.25:1 than normal. with its 'set up' data, it
will revert to use of a de-
5th 1.35:1
fault set of values.
6th 1.00:1
Limp Mode 2 (1 beep at Error with ECU applica-
power up). tion software.
Gearbox 'Limp Modes' (Powershift
Machine remains in neu- If on power up, the ECU
Electronic Control) tral at all times. detects an internal fault
with its 'core operating
When applicable, the gearbox ECU provides software' it will prevent
restricted or modified gearbox operation if faults are operation of the gear-
detected by the ECU. Typical 'limp mode' forms of box.
operation are shown here. Fault codes may also be
displayed on the instrument panel. For fault codes Limp Mode 3 (Machine Error reading transmis-
refer to (PIL 33-57-90). will not autoshift). sion speed.
Only 1st, 2nd and 3rd If the ECU does not de-
On power up, the ECU will normally sound 3 beeps. gears available. tect any input from the
These beeps can be masked by other audible speed sensor it will pre-
warnings on start up. vent selection of any
gear above 3rd.
27 - 13 9823/1650-1 27 - 13
27 - Driveline
00 - General
Mode Possible Reason Table 223. Stall Speed Combinations

Limp Mode 4 (Repeating Error reading transmis- Engine Build SH DH
beeps until ECU power sion speed Code
is reset) Engine Power 93kW 6 Speed 108kW 6 Speed
Machine holds a gear If the ECU detects and PS766 PS766
error with the speed Model 531-70 5A(T)A, 531-70 5A(T)A,
sensor while operating, 535-95 535-95
it prevents autoshifting. 5AB(TD), 5AB(TD),
536-60 536-60
Stall Speed Combinations 5A(T)C, 541-70 5A(T)C, 541-70
5A(T)D, 536-70 5A(T)D, 536-70
The tests carried out at the factory record the correct 5AR(TE) 5AR(TE)
engine r.p.m. (stall speed) when under maximum Hydraulic System:
Gearpump
The figures relate to tests conducted at an ambient Variflow
temperature of 25 °C ( 77.0 °F) and barometric Engine Stall Speeds RPM
pressure of 1 bar ( 14.5 psi)at sea level. The changes
in ambient temperature, pressure and humidity and Torque Convert-
fuel grade will affect engine power and hence the stall er Only
figures. Hydraulics
(MRV) Only
For example, at 10,000 ft the power reduction of a Combined Con-
naturally aspirated engine could be 29% and for a verter + MRV
(1)
turbo engine 8%.

Combined Con-
The figures apply to `bedded-in' engines, i.e. engines verter + LSRV
that have done a minimum of 250 working hours. LSP Variflow
Therefore they should not be used for pre-delivery LSP Electro
inspection (PDI) checks. Servo
(1) Combined stall tests on machines fitted with a
All figures are recorded with the transmission oil at
hydraulic gearpump are performed with the crowd
service operated until the relief valve is lifted.
°F). Figures achieved should be within +/- 100 RPM
from the figures given in the table.
Pressure
Converter pressure (in neutral)
Converter In at 50 °C ( 121.9 °F) 1000 RPM 2 –4.95 bar ( 29.0 –71.7 psi)
2000 RPM 4 –6.8 bar ( 58.0 –98.6 psi)
Converter Out at 50 °C ( 121.9 °F) 1000 RPM 0.6 –2.25 bar ( 8.7 –32.6 psi)
2000 RPM 1.25 –2.5 bar ( 18.1 –36.2 psi)
Lock up torque converter inlet relief valve pressure (Maximum) 8.5 bar ( 123.2 psi)
Oil at 50 °C ( 121.9 °F) 1000 RPM 0.25 –1 bar ( 3.6 –14.5 psi)
2000 RPM 0.5 –1 bar ( 7.2 –14.5 psi)
2000 RPM 12.4 –17 bar ( 179.7 –246.4 psi)
27 - 14 9823/1650-1 27 - 14
27 - Driveline
00 - General

neutral)
Cooler oil 1000 RPM 14 L/min
flow at 50 °C
( 121.9 °F)
2000 RPM 17 L/min
Pump oil flow at 1000 RPM 16 L/min
50 °C ( 121.9
°F)
2000 RPM 34 L/min
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 bar ( 10.1 –14.5 psi)).
27 - 15 9823/1650-1 27 - 15
27 - Driveline
00 - General
For: PS750 MK4 ....................... Page 27-16 Figure 455.

For: PS764, PS766 ................... Page 27-22
(For: PS750 MK4)
Unit Identification
The gearbox serial number is stamped on the
unit identification plate as shown. When you make
an order for parts replacement, always quote the
details on the unit identification plate. In the case of
gear replacements, always check the part number
stamped on the gear, and the number of teeth.
A Identification plate
27 - 16 9823/1650-1 27 - 16
27 - Driveline
00 - General
Main Component Identification
Figure 456. External components
27 - 17 9823/1650-1 27 - 17
27 - Driveline
00 - General
Item Description
13 Oil pump
Table 226.
14 Park brake caliper
Item Description bracket
1 Front case with integral 15 Park brake disc and dri-
torque converter hous- ve shaft coupling
ing
16 Suction strainer
2 Rear case
17 Speed sensor 1
3 Torque converter relief
18 Road speed sensor (if
valve
installed)
4 Pressure maintenance
19 Oil transfer pipe
valve
20 Oil filler / dipstick port
5 Oil pressure switch
21 Oil filter
6 Oil outlet port- to oil
cooler 22 2/4 wheel drive solenoid
control valve (if installed)
7 Oil inlet port- from oil
cooler 23 Input (forward) clutch
solenoid control valves
8 Clutch shaft inspection
port- reverse clutch 24 Main shaft / layshaft
clutch solenoid control
valves
port- main shaft clutch
25 Reverse clutch solenoid
control valves
port- layshaft clutch
26 Oil drain plug
11 Input shaft
12 Yoke- drive shaft cou-
pling
27 - 18 9823/1650-1 27 - 18
27 - Driveline
00 - General
Figure 457. Internal component
19 2
1 18
11 10 4
17 3
12
13
4
7 4
6
12
4
9
6 5
16 15
7
10.5
4
14
8
Item Description
5 Yoke - drive shaft cou-
Table 227.
pling
Item Description 6 Oil seal
1 Rear case 7 Locking nut (stake nut)
2 Front case 8 Oil feed pipe
3 Gearbox oil pump 9 Park brake disc
4 Shim
27 - 19 9823/1650-1 27 - 19
27 - Driveline
00 - General
Item Description Item Description

10 Park brake caliper 18 Input shaft clutch as-
bracket sembly
11 Park brake caliper 19 Reverse shaft clutch as-
12 Output shaft support sembly
bearings (1) Permanent 4 wheel drive variants have a one-
13 Spacer piece shaft in place of the 2/4 wheel drive clutch
14 2/4 wheel drive clutch
(1) assembly.
15 Layshaft clutch assem- The internal component drawing is not a true
bly sectional view. It is drawn to show the main
16 Main shaft clutch as- components as clearly as possible
sembly
17 Output shaft
27 - 20 9823/1650-1 27 - 20
27 - Driveline
00 - General
Figure 458. Test Point
1 4
Test point Description

4 Forward high ratio clutch
Table 228.
pressure
Test point Description 5 Forward low ratio clutch
1 Mainline pressure pressure
2 Main shaft clutch pres- 6 Reverse high ratio clutch
sure pressure
3 Converter inlet and con- 7 Reverse low ratio clutch
verter relief valve pres- pressure
sure
27 - 21 9823/1650-1 27 - 21
27 - Driveline
00 - General
Test point Description Clutch Control Solenoids

8 Layshaft clutch pressure
Figure 459.
9 2/4 wheel drive clutch
pressure
3022
3021
3033
3041
3029
3040
Table 229.
Gear Clutches engaged Solenoids energised Refer to
Figure 459.
1st gear forward Forward Low 3022
Layshaft 3029
2nd gear forward Forward high 3021
Layshaft 3029
3rd gear forward Forward low 3022
Mainshaft 3033
4th gear forward Forward high 3021
Mainshaft 3033
1st gear reverse Reverse Low 3041
Layshaft 3029
2nd gear reverse Reverse high 3040
Layshaft 3029
3rd gear reverse Reverse low 3041
Mainshaft 3033
4th gear reverse Reverse high 3040
Mainshaft 3033
an order for parts replacement, always quote the

(For: PS764, PS766) details on the unit identification plate. In the case of
gear replacements, always check the part number
Unit Identification
The gearbox serial number is stamped on the
unit identification plate as shown. When you make
27 - 22 9823/1650-1 27 - 22
27 - Driveline
00 - General
Figure 460.
27 - 23 9823/1650-1 27 - 23
27 - Driveline
00 - General
Main component identification
Figure 461.
H N
A
S J
B
C
D
R
Q
T
U
K L E
C
P
M V
Item Description
M Hose connection (to oil
Table 230.
cooler)
Item Description N Hose connection (from
A Torque converter oil cooler)
B Forward and input clutch P 6 speed assembly (if in-
C Reverse clutch stalled)
D Main shaft assembly Q Oil filter
E Layshaft assembly R Driveshaft (typically dri-
F 2 and 4 Wheel drive ves a hydraulic pump)
clutch S Gear drive to reverse
G Torque converter relief clutch
valve T Solenoid control valves
H Oil pressure mainte- U Transmission oil pres-
nance valve sure switch
J Transmission oil pump V Speed sensor
K Park brake actuator
L Park brake friction pack
27 - 24 9823/1650-1 27 - 24
27 - Driveline
00 - General
Sectional Drawing
Figure 462.
1 2
23
22 3
21 4
17
18
20
12
16
14
15
13
11 5
10
9 19
7 6
8
27 - 25 9823/1650-1 27 - 25
27 - Driveline
00 - General
Item Description
13 Bearing end float control
Table 231.
spacer
Item Description 14 Oil seal
1 Rear case 15 Transfer gear and shaft
2 Front case 16 Yoke - drive shaft cou-
3 Torque converter hous- pling
ing 17 Auxiliary device mount-
4 Gearbox oil pump ing interface
5 Yoke - drive shaft cou- 18 Auxiliary device drive
pling shaft
6 Oil seal 19 Layshaft and layshaft
7 4WD (Four Wheel Drive) clutch assembly
case 20 Main shaft and clutch
8 4WD clutch assembly assembly
9 Integral park brake as- 21 Input shaft and forward
sembly cover (if in- clutch assembly
stalled) 22 Reverse shaft and clutch
10 Park brake friction plate assembly
pack (if installed) 23 6 speed shaft and clutch
11 Park brake actuator (if assembly (if installed)
installed)
12 Transfer gear shaft sup- The drawing is not a true sectional view. It is drawn
port bearings to show the main components as clearly as possible.
Clutch Control Solenoids

PS764
Figure 463. PS764
A B C D
G F E
27 - 26 9823/1650-1 27 - 26
27 - Driveline
00 - General
Table 232.
Gear Clutches engaged Solenoids engaged Refer to Fig-
ure 463.
1st gear forward Forward low A
Layshaft E
2nd gear forward Forward high B
Layshaft E
3rd gear forward Forward low A
Mainshaft F
4th gear forward Forward high B
Mainshaft F
1st gear reverse Reverse low C
Layshaft E
2nd gear reverse Reverse high D
Layshaft E
3rd gear reverse Reverse low C
Mainshaft F
4th gear reverse Reverse High D
Mainshaft F
PS766
Figure 464. PS766
A B C D
G F E
Table 233.
ure 464.
1st gear forward 6 speed E
Layshaft F
2nd gear forward Forward low A
27 - 27 9823/1650-1 27 - 27
27 - Driveline
00 - General

ure 464.
Layshaft F
3rd gear forward Forward high B
Layshaft F
4th gear forward 6 speed E
Mainshaft G
5th gear forward Forward low A
Mainshaft G
6th gear forward Forward high B
Mainshaft G
1st gear reverse Reverse low C
Layshaft F
2nd gear reverse Reverse high D
Layshaft F
3rd gear reverse Reverse low C
Mainshaft G
4th gear reverse Reverse High D
Mainshaft G
27 - 28 9823/1650-1 27 - 28
27 - Driveline
00 - General
Operation
For: PS764 ................................ Page 27-29 A gearbox mounted ground speed sensor detects
For: PS750 MK4 ....................... Page 27-37 the ground speed of the machine. Signals from the
sensor are connected to the transmission ECU via
For: PS766 ................................ Page 27-45
the machine control ECU and the CANbus. The ECU
responds by preventing ratio selection if the machine
(For: PS764) ground speed is not within pre-set values.
The gearbox system is controlled electronically. When the ratio up (plus) button is pressed the
Inputs from control devices are connected to various transmission ECU selects the next (higher) gear
ECU (Electronic Control Unit)s. The ECU’s energise ratio. When the ratio down (minus) button is pressed
the applicable electrical devices depending on the the transmission ECU selects the next (lower) gear
machine status. The ECU’s are connected to the ratio.
machine CAN (Controller Area Network)bus which
enables integrated control of all the main machine Park brake on
systems.
When the park brake is on, an electrical switch sends
For details of the ECUs installed on the machine refer a signal to the transmission ECU which sets the
to (PIL 33-45). transmission to neutral even if forward or reverse is
selected. A warning sound will be audible.
Start up
Transmission dump
Electrical interlocks prevent the engine being started,
unless the transmission is set to neutral. The A transmission dump switch on the hydraulic control
interlock is controlled by the ECU. lever sends a signal to the transmission ECU which
de-selects the transmission drive when the switch is
Direction Control operated.
A column switch controls the direction control, Foot Brake Control

forward, neutral or reverse. The switch is connected
to inputs on the ECU which in turn energise the When the foot brake operates a pressure transducer
applicable gearbox control solenoids. mounted in the hydraulic brake line detects the
change in brake system pressure. Input from
Joystick Direction Control the transducer is connected to the transmission
ECU. The transmission ECU selects neutral even
Drive direction can also be controlled with the joystick if Forward or Reverse is selected. The feature
direction control switch. Inputs from the switch are enables an increase in machine braking efficiency.
connected to the transmission ECU via the joystick An operator switch in the cab can be set to enable or
powerbase ECU and the CANbus. There is a logic disable the feature.
control for drive direction selection. Selection of
Forward or Reverse with the column switch disables
the joystick direction control switch. Both the joystick 2/4 Wheel drive select
and column switch must first be set to Neutral before
A cab mounted switch controls 2 or 4 wheel
the joystick switch is enabled.
drive selection. The switch provides an input to
the transmission ECU which in turn energises
Manual gear select the applicable gearbox control solenoid. The
transmission automatically selects 4 wheel drive
A rotating barrel switch controls selection of the gear when the service brakes are applied.
ratios (1,2,3 or 4). The switch is connected to inputs
on the ECU which energise the applicable gear box
control solenoids. Transmission Oil Pressure and
Temperature
Joystick Gear Selection
Oil pressure and temperature sensors are connected
Gear ratio selection can be controlled with the to the machine instrumentation which displays the
joystick ratio up (plus) and down (minus) buttons. pressure and temperature status. Warning displays
Inputs from the buttons are connected to the and fault codes are activated if the oil pressure or
transmission ECU via the machine control ECU and temperature is not within pre-set values.
the CANbus.
27 - 29 9823/1650-1 27 - 29
27 - Driveline
00 - General
Limp Modes Figure 466. 2nd gear forward (4 wheel drive)
When necessary the transmission ECU will provide

alternative gear selection should faults occur. This
enables the machine to be moved (`limped') under its
own power. For limp mode details refer to Technical
Data (PIL 27-06).
U
Fault codes may also be displayed on the instrument
panel. For fault codes refer to (PIL 33-57-90).
Drive paths
Forward
Z
Figure 465. 1st gear forward (4 wheel drive) S
T Table 235.
Clutches engaged Solenoids energised
Forward high ratio (U) 3021 (Us)
Layshaft (Z) 3029 (Zs)
2/4 wheel drive (spring -
applied) (S)
Z Figure 467. 3rd gear forward (4 wheel drive)
Table 234.
Clutches engaged Solenoids energised T
Forward low ratio (T) 3022 (Ts) Y
applied) (S)
Table 236.
Forward low ratio (T) 3022 (Ts)
Mainshaft (Y) 3033 (Ys)
applied) (S)
27 - 30 9823/1650-1 27 - 30
27 - Driveline
00 - General
Figure 468. 4th gear forward (4 wheel drive) Figure 470. 2nd gear reverse
S S
Table 237. Table 239.

Clutches engaged Solenoids energised Clutches engaged Solenoids energised
Forward high ratio (U) 3021 (Us) Reverse high ratio (V) 3040 (Vs)
Mainshaft (Y) 3033 (Ys) Layshaft (Z) 3029 (Zs)
2/4 wheel drive (spring - 2/4 wheel drive (spring -
applied) (S) applied) (S)
Reverse
Figure 471. 3rd gear reverse
Figure 469. 1st gear reverse
W
W
S
S
Table 240.
Table 238.
Clutches engaged Solenoids energised Reverse low ratio (W) 3041 (Ws)
Reverse low ratio (W) 3041 (Ws) Mainshaft (Y) 3033 (Ys)
Layshaft (Z) 3029 (Zs) 2/4 wheel drive (spring -
2/4 wheel drive (spring - applied) (S)
applied) (S)
27 - 31 9823/1650-1 27 - 31
27 - Driveline
00 - General
Figure 472. 4th gear reverse torque is transferred from the converter assembly to
the clutch/gear assemblies through the input shaft on
the forward clutch assembly.
V
The forward clutch assembly contains two
hydraulically operated clutches: one clutch gives a
forward low ratio drive and the other gives a forward
high ratio drive. The clutches are controlled by a
three position solenoid valve. When the applicable
solenoid is energised, pressurised oil is directed to
Y
either the forward low (solenoid 3022) or forward high
(solenoid 3021) clutch.
The reverse clutch assembly is also similar to the

forward clutch assembly. It contains two hydraulically
operated clutches: one clutch gives a reverse low
S ratio drive and the other gives a reverse high ratio
drive. The reverse clutches are controlled by a
either the reverse low (solenoid 3041) or reverse high
Table 241.
Clutches engaged Solenoids energised Both the mainshaft and the layshaft assemblies have
Reverse high ratio (V) 3040 (Vs) a single clutch each. Both clutches are controlled
by a three position solenoid valve. When energised,
Mainshaft (Y) 3033 (Ys) solenoid 3029 directs pressurised oil to the layshaft
2/4 wheel drive (spring - clutch and solenoid 3033 directs pressurised oil the
applied) (S) mainshaft clutch.
Hydraulic operation and schematics When a gear is selected through the control switch in
the cab, two clutches are always engaged. When you
The engine directly drives the oil pump through the select different pairs of clutches different gear ratios
torque converter. are engaged. The hydraulic control ECU electrically
controls the solenoids. All the clutches work on the
Oil from the pump is fed through an internal passage same principle.
via the filter to the PMV (Pressure Maintenance
Valve), which maintains pressure to the solenoid The 2/4 wheel drive unit also has a single clutch.
valves for clutch selection. Excess oil from the In normal operation the clutch is spring loaded and
maintenance valve flows back through the case to therefore engaged to give 4 wheel drive. When
the torque converter. A relief valve controls pressure 2 wheel drive is selected, solenoid valve 3002 is
in the converter and dumps oil from the converter line energised and directs pressurised oil to the 2/4 wheel
back to the sump. drive clutch.
Oil from the torque converter flows out of the gearbox In the schematic, the gearbox is shown with 2nd
to the external oil cooler and again comes back to gear forward engaged. 2nd gear forward requires
the converter. Oil then flows through internal oil ways the forward low clutch T and layshaft clutch Z to
providing lubrication for clutches and bearings before be engaged. When the gear selection switch is
it goes back to the gearbox sump. moved to 2nd gear forward, the electrical control
system energises solenoid valves 3022 and 3029.
The torque converter is a fluid coupling bolted to Pressurised oil is diverted to the back of pistons
a drive plate which in turn is bolted to the engine in both clutches to engage the drive. At the same
driven bevel gearbox. As the engine starts to rotate, time all other solenoids are de-energised, diverting
the converter gives smooth power take off and oil from the back of the other clutch pistons to the
gradually increases the torque transmitted. This gearbox sump. The 4 wheel drive clutch 3002 is also
energised to give 2 wheel drive.
27 - 32 9823/1650-1 27 - 32
27 - Driveline
00 - General
Figure 473.
H G
2 1 K X
2 3 3
3004 C
5 1 W V Q A
3021 J
3022 T U
1
3002
B
3041
Y
M
3040 z
L 6
3033
D
E S
3029
N F
P
Table 242.
Item Description
A Torque converter
B Forward clutch assembly
C Reverse clutch assembly
D Mainshaft assembly
E Layshaft assembly
F 2/4 wheel drive unit
G Torque converter relief valve
H Pressure maintenance valve
J Pump
L Park brake pack
M Hose connection - to oil cooler
N Hose connection - from oil cooler
P 6-Speed clutch assembly (if installed)
S Gear drive to reverse unit clutch assembly
Q Oil filter
T Forward low ratio clutch
U Forward high ratio clutch
V Reverse high ratio clutch
W Reverse low ratio clutch
X 6 speed clutch (PS766 only)
Y Mainshaft clutch
Z Layshaft clutch
1 Solenoid port 1
27 - 33 9823/1650-1 27 - 33
27 - Driveline
00 - General
Item Description
2 Solenoid port 2
3 Solenoid port 3
5 Solenoid valve control block
6 External oil cooler
Forward and Reverse Clutch Operation is then transmitted from the input shaft to the gear
1. Clutch for gear 2 is disengaged and no drive is
The forward and reverser clutch assembly transfers transmitted to gear 2 plate carrier. The gear is also
drive from the input shaft to either gear 1 or gear 2 free to rotate on the input shaft assembly.
depending on which of the two clutches is engaged,
giving forward or reverse drive. Actuation of the hydraulic pistons and is controlled
via three position solenoid control valve.
When neither clutch is engaged, neutral is selected.
When neutral is selected both solenoids are
The clutches are of the wet, multi plate type. deactivated and the flow of pressurised oil to the
clutches is blocked. The gear springs 1 and 2 move
The clutch housings and input shaft are a one piece the pistons away from the clutch plates and oil from
assembly. The assembly is permanently driven by both pistons is vented to the sump.
the engine via the torque converter.
When either forward or reverse is selected, the
Clutch counter plates are also permanently driven solenoid control valve diverts pressurised oil via
via meshing teeth inside the clutch housings. Clutch cross drillings inside the input shaft to the appropriate
friction plates are meshed with the gear plate clutch piston in the unit. Pressure from the other
carriers. clutch is vented to the sump via the solenoid valve
spool. Oil is prevented from leaking by seals on the
In the diagram, clutch for gear 1 is engaged. pistons and ring seals on the input shaft.
The counter plates and friction plates are pressed

together by a hydraulically actuated piston. Drive
27 - 34 9823/1650-1 27 - 34
27 - Driveline
00 - General
Figure 474.
B C D E F
A G1 G2
H H H
K J
N
M
R
Q
A Input shaft assembly B Gear 1 clutch

C Gear 1 piston D Piston external seal
E Gear 2 piston F Gear 2 clutch
G1 Gear 1 G2 Gear 2
H Input shaft ring seals J Gear 2 spring
K Gear 1 spring L Piston internal seal
M Clutch friction plates N Clutch counter plates
P Solenoid - gear 1 Q Solenoid - gear 2
R Solenoid control valve
27 - 35 9823/1650-1 27 - 35
27 - Driveline
00 - General
Mainshaft and Layshaft Clutch Operation The clutch is engaged and disengaged by
introducing or dumping pressurised oil behind the
The mainshaft and layshaft units incorporate one piston via a solenoid valve. The solenoid valve is
clutch and not two, as in the forward and reverse operated by a switch in the cab.
units. The operation of the single clutches is the
same as for one clutch in the forward or reverse units. When the switch is in the 4WD position, the solenoid
valve is de-energised. With the solenoid 1 de-
2 and 4 Wheel Drive Clutch Operation energised, the valve spool moves under the force of
the spring. The oil supply to the piston is blocked. At
the same time oil vents from the back of the piston to
4 Wheel Drive Operation the sump via ports 1 and 2.
This clutch is of the Spring-ON (4WD (Four Wheel Because there is no pressure behind the piston, the
Drive))/Pressure-OFF (2WD (Two Wheel Drive)) clutch friction/counter plates of the clutch pack are
type. forced together by the disc springs, thus driving the
output yoke.
Figure 475.
B C
A1
3 2
1
A2
A Solenoid control valve A1 Solenoid 1

A2 Solenoid 2 B Clutch pack
C Piston D Springs
E Output yoke
27 - 36 9823/1650-1 27 - 36
27 - Driveline
00 - General
2 Wheel Drive Operation and then the pressure plate against the force of the
springs, thus releasing the spring force on the clutch
When the switch is in the 2WD position, the solenoid friction/counter plates of the clutch pack.
valve is energised. The energised solenoid 1 causes
the valve spool to move and form a connection Because there is no spring force, the friction/counter
between ports 3 and 2. plates of the clutch pack now freely rotate on the
output shaft, thus disengaging drive to the front axle.
Pressurised oil is directed to the piston via ports
3 and 2. The piston moves the actuating sleeve
Figure 476.
B C
A1
A
3 2
1
A2

C Piston D Springs
E Output yoke F Actuating sleeve
G Pressure plate
Drive direction and gear ratio are selected by means

(For: PS750 MK4) of electrical control switches (typically a steering
column mounted lever and swivel switch). Inputs
from control devices are connected to various ECUs.
Operation Overview The ECUs energise the applicable electrical devices
depending on the machine status. The ECUs are
The Powershift gearbox is an electro-hydraulic
connected to the machine CANbus which enables
transmission unit. Input from the engine is by
integrated control of all the main machine systems.
means of a torque converter. Gear shifting and
direction selection are controlled by engaging and For ECU details refer to (PIL 33-45).
disengaging multi-disc clutch packs.
Electric solenoid valves divert pressurised oil Start up

(provided by the gearbox oil pump) to the selected
clutch packs. Electrical interlocks prevent the engine being started,
unless the transmission is set to neutral.
27 - 37 9823/1650-1 27 - 37
27 - Driveline
00 - General
Drive Direction Control Transmission dump

A column switch controls the drive direction, forward, The input from the transmission `dump' switch on the
neutral or reverse. Inputs from the switch are joystick is connected to the transmission ECU. When
connected to the transmission ECU via the CANbus the switch is pressed the ECU selects Neutral even
which in turn energise the applicable gearbox control if Forward or Reverse is selected.
solenoids.
2/4 Wheel drive select
Joystick Direction Controls
A cab mounted switch controls 2 or 4 wheel drive
Drive direction can also be controlled with the joystick selection. Inputs from the switch are connected to
F / N / R (Forward / Neutral / Reverse) direction the machine control ECU which in turn energises
control switch. Inputs from the switch are connected the applicable gearbox control solenoid. The
to the transmission ECU via the joystick powerbase transmission automatically selects 4 wheel drive
ECU and the CANbus. There is a logic control for when the service brakes are applied.
drive direction selection. Selection of Forward or
Reverse with the column switch disables the joystick Transmission Oil Pressure and
direction control switch. Both the joystick and column
switch must first be set to Neutral before the joystick Temperature
direction control switch is enabled.
Oil pressure and temperature sensors are connected
to the machine instrumentation which displays the
Manual Gear Controls pressure and temperature status. Warning displays
and fault codes are activated if the oil pressure or
A rotating barrel switch controls selection of the temperature is not within pre-set values.
gear ratios (1,2,3 or 4). Inputs from the switch are
connected to the transmission ECU via the CANbus
which in turn energise the applicable gearbox control Drive paths
solenoids.
Forward
Joystick Gear Controls Figure 477. 1st gear forward
Gear ratio selection can be controlled with the
joystick ratio up (plus) and down (minus) buttons. A
Inputs from the buttons are connected to the
transmission ECU via the machine control ECU and
the CANbus.
A gearbox mounted ground speed sensor detects

the ground speed of the machine. Signals from the E
sensor are connected to the transmission ECU via
responds by preventing ratio selection if the machine
ground speed is not within pre-set values.
When the ratio up (plus) button is pressed the

transmission ECU selects the next (higher) gear
ratio. When the ratio down (minus) button is pressed
the transmission ECU selects the next (lower) gear Table 243.
ratio
Park brake on Forward low ratio (A) 3022
Layshaft (E) 3029
When the park brake is ON the park brake switch
state changes. Inputs from the switch are connected
to the transmission ECU via the machine control
ECU and the CANbus. The ECU selects Neutral
even if Forward or Reverse is selected. An audible
warning sounds.
27 - 38 9823/1650-1 27 - 38
27 - Driveline
00 - General
Figure 478. 2nd gear forward Table 246.

B Forward high ratio (B) 3021
Mainshaft (F) 3033
Reverse
E Figure 481. 1st gear reverse
E
Table 244.
Forward high ratio (B) 3021
Layshaft (E) 3029
Figure 479. 3rd gear forward C
A
Table 247.
F
Reverse low ratio (C) 3041
Layshaft (E) 3029
Figure 482. 2nd gear reverse
Table 245.
Clutches engaged Solenoids energised E
Forward low ratio (A) 3022
Mainshaft (F) 3033
Figure 480. 4th gear forward

D
B
F Table 248.
Reverse high ratio (D) 3040
Layshaft (E) 3029
27 - 39 9823/1650-1 27 - 39
27 - Driveline
00 - General
Figure 483. 3rd gear reverse to the solenoid valves for clutch selection. Excess oil
from the maintenance valve flows back through the
case to the torque converter. A relief valve controls
pressure in the converter and dumps oil from the
converter line back to the sump.
F
Oil from the torque converter flows out of the gearbox
to the external oil cooler (if installed) and again
comes back to the converter. Oil then flows through
internal oil ways providing lubrication for clutches
and bearings before it goes back to the gearbox
sump.
The torque converter is a fluid coupling bolted to

a drive plate which in turn is bolted to the engine
C drive. As the engine starts to rotate, the converter
gives smooth power take off and gradually increases
the torque transmitted. This torque is transferred
Table 249. from the converter assembly to the clutch/gear
assemblies through the input shaft on the forward
Clutches engaged Solenoids energised clutch assembly.
Reverse low ratio (C) 3041
Mainshaft (F) 3033 The forward clutch assembly contains two
Figure 484. 4th gear reverse high ratio drive. The clutches are controlled by a
F
The reverse clutch assembly is also similar to the
ratio drive and the other gives a reverse high ratio
either the reverse low (solenoid 3041) or reverse high
D Both the mainshaft and the layshaft assemblies have
a single clutch each. Both clutches are controlled
Table 250. solenoid 3029 directs pressurised oil to the layshaft
Clutches engaged Solenoids energised clutch and solenoid 3033 directs pressurised oil the
mainshaft clutch.
Reverse high ratio (D) 3040
Mainshaft (F) 3033 When a gear is selected through the control switch
in the cab, two clutches are always engaged. When
Hydraulic operation and schematics you select different pairs of clutches different gear
ratios are engaged. ECUs control the solenoids. All
The engine directly drives the oil pump through the the clutches work on the same principle.
torque converter.
Oil from the pump is fed through an internal passage

via the filter to the PMV, which maintains pressure
27 - 40 9823/1650-1 27 - 40
27 - Driveline
00 - General
Figure 485.
K
U J Q
L
D C
V N
R
W P
B A
M
X
H
Y S1
F
S2 G S
Z 4
3
2
E
1
Table 251.
Item Description
A Forward low ratio clutch
B Forward high ratio clutch
C Reverse low ratio clutch
D Reverse high ratio clutch
E Layshaft assembly
F Mainshaft assembly
G Layshaft clutch
H Mainshaft clutch
J Pressure maintenance valve
K Relief valve
L Oil filter
M Forward clutch assembly
N Reverse clutch assembly
P Pump
Q Oil flows to the external oil cooler from the torque
converter
R External oil cooler
S Torque converter
T Oil flows back to the torque converter from the exter-
nal oil cooler
U Solenoid 3040
V Solenoid 3041
W Solenoid 3021
27 - 41 9823/1650-1 27 - 41
27 - Driveline
00 - General
Item Description
X Solenoid 3022
Y Solenoid 3029
Z Solenoid 3033
Forward and Reverse Clutch Operation The counter plates and friction plates are pressed
The forward and reverser clutch assembly transfers is then transmitted from the input shaft to the gear
drive from the input shaft to either gear 1 or gear 2 1. Clutch for gear 2 is disengaged and no drive is
depending on which of the two clutches is engaged, transmitted to gear 2 plate carrier. The gear is also
giving forward or reverse drive. free to rotate on the input shaft assembly.
When neither clutch is engaged, neutral is selected. Actuation of the hydraulic pistons and is controlled
via three position solenoid control valve. When
The clutches are of the wet, multi plate type. neutral is selected both solenoids are deactivated
and the flow of pressurised oil to the clutches is
The clutch housings and input shaft are a one piece blocked. The gear springs 1 and 2 move the pistons
assembly. The assembly is permanently driven by away from the clutch plates and oil from both pistons
the engine via the torque converter. is vented to the sump.
Clutch counter plates are also permanently driven When either forward or reverse is selected, the
via meshing teeth inside the clutch housings. Clutch solenoid control valve diverts pressurised oil via
friction plates are meshed with the gear plate cross drillings inside the input shaft to the appropriate
carriers. clutch piston in the unit. Pressure from the other
clutch is vented to the sump via the solenoid valve
In the diagram, clutch for gear 1 is engaged. spool. Oil is prevented from leaking by seals on the
pistons and ring seals on the input shaft.
27 - 42 9823/1650-1 27 - 42
27 - Driveline
00 - General
Figure 486.
B C D E F
A G1 G2
H H H
K J
N
M
R
Q

G1 Gear 1 G2 Gear 2
27 - 43 9823/1650-1 27 - 43
27 - Driveline
00 - General
Mainshaft and Layshaft Clutch Operation piston via a solenoid valve. The solenoid valve is
operated by a switch in the cab.
The mainshaft and layshaft units incorporate one
clutch and not two, as in the forward and reverse When the switch is in the 4WD position, the solenoid
units. The operation of the single clutches is the valve is de-energised. With the solenoid 1 de-
same as for one clutch in the forward or reverse units. energised, the valve spool moves under the force of
2 and 4 Wheel Drive Clutch Operation the same time oil vents from the back of the piston to
the sump via ports 1 and 2.
4 Wheel Drive Operation Because there is no pressure behind the piston, the
clutch friction/counter plates of the clutch pack are
This clutch is of the Spring-ON (4WD)/Pressure-OFF forced together by the disc springs, thus driving the
(2WD) type. output yoke.
The clutch is engaged and disengaged by
Figure 487.
D B E
A A1
3 2
1
A2 C

C Piston D Springs
E Output yoke
27 - 44 9823/1650-1 27 - 44
27 - Driveline
00 - General
Figure 488.
D G B F E
A A1
3 2
1
A2

C Piston D Springs
G Pressure plate
Direction Control
(For: PS766)
A column switch controls the direction control,
The gearbox system is controlled electronically. forward, neutral or reverse. The switch is connected
Inputs from control devices are connected to various to inputs on the ECU which in turn energise the
ECUs. The ECU’s energise the applicable electrical applicable gearbox control solenoids.
devices depending on the machine status. The
ECU’s are connected to the machine CANbus which Joystick Direction Control
enables integrated control of all the main machine
systems. Drive direction can also be controlled with the joystick
direction control switch. Inputs from the switch are
For details of the ECUs installed on the machine refer connected to the transmission ECU via the joystick
to (PIL 33-45). powerbase ECU and the CANbus. There is a logic
control for drive direction selection. Selection of
Start up Forward or Reverse with the column switch disables
the joystick direction control switch. Both the joystick
Electrical interlocks prevent the engine being started, and column switch must first be set to Neutral before
unless the transmission is set to neutral. The the joystick switch is enabled.
interlock is controlled by the ECU.
27 - 45 9823/1650-1 27 - 45
27 - Driveline
00 - General
Manual gear select transmission to neutral even if forward or reverse is

selected. A warning sound will be audible.
When the machine is “Manual” transmission mode
(Transmission mode switch set to “Off”) the gears Transmission dump
can be selected manually. A rotating barrel switch
controls selection of the gear ratios (1,2,3 or 4). The A transmission dump switch on the hydraulic control
switch is connected to inputs on the ECU which lever de-selects the transmission drive when the
energise the applicable gear box control solenoids. switch is operated.
Joystick Gear Selection 2/4 Wheel drive select

Gear ratio selection can be controlled with the A cab mounted switch controls 2 or 4 wheel
joystick ratio up (plus) and down (minus) buttons. drive selection. The switch provides an input to
Inputs from the buttons are connected to the the transmission ECU which in turn energises
transmission ECU via the machine control ECU and the applicable gearbox control solenoid. The
the CANbus. transmission automatically selects 4 wheel drive
when the service brakes are applied.
A gearbox mounted ground speed sensor detects
the ground speed of the machine. Signals from the
sensor are connected to the transmission ECU via Foot Brake Control
responds by preventing ratio selection if the machine When the foot brake operates a pressure transducer
ground speed is not within pre-set values. mounted in the hydraulic brake line detects the
change in brake system pressure. Input from
When the ratio up (plus) button is pressed the the transducer is connected to the transmission
transmission ECU selects the next (higher) gear ECU. The transmission ECU selects neutral even
ratio. When the ratio down (minus) button is pressed if Forward or Reverse is selected. The feature
the transmission ECU selects the next (lower) gear enables an increase in machine braking efficiency.
ratio. An operator switch in the cab can be set to enable or
disable the feature.
Automatic gear select
Transmission Oil Pressure and
An operator switch in the cab can be set to enable Temperature
‘Auto mode’. The gearbox will automatically up shift
and down shift. The transmission ECU programme Oil pressure and temperature sensors are connected
selects the most economical gear for a given road to the machine instrumentation which displays the
speed and engine load. To enable up shifts the pressure and temperature status. Warning displays
accelerator pedal must be pressed, this prevents up and fault codes are activated if the oil pressure or
shifting when coasting down hill for example, thus temperature is not within pre-set values.
ensuring maximum machine control.
Lock up torque converter option
Kickdown operation
The lock up torque converter operates automatically
The column switch incorporates a kickdown switch between preset parameters when F5 or F6 gears are
which enables the operator to down shift to the selected. When field mode is selected the lock up
next lowest gear, depending on which `mode' is torque converter can be disabled.
selected. The transmission ECU checks to see if the
machine road speed is suitable before down shifting Limp Modes
the gearbox. If the road speed is too high a single
double beep is sounded. When necessary the transmission ECU will provide
alternative gear selection should faults occur. This
Pressing the kick down switch a second time causes enables the machine to be moved (`limped') under its
the transmission ECU to select the previous gear. An own power. For limp mode details refer to Technical
indicator light will illuminate until the operator selects Data (PIL 27-06).
another gear position using the column switch.
Fault codes may also be displayed on the instrument
Park brake on panel. For fault codes refer to (PIL 33-57-90).
When the park brake is on, an electrical switch sends

a signal to the transmission ECU which sets the
27 - 46 9823/1650-1 27 - 46
27 - Driveline
00 - General
Drive paths Table 253.

Forward Forward low ratio (T) 3022 (Ts)
Figure 489. 1st gear forward (4 wheel drive) Layshaft (Z) 3029 (Zs)
X applied) (S)
Figure 491. 3rd gear forward (4 wheel drive)
U
Z
S
Table 252.
6 speed (X) 3004 (Xs)
2/4 wheel drive (spring - Table 254.
applied) (S) Clutches engaged Solenoids energised
Figure 490. 2nd gear forward (4 wheel drive) Layshaft (Z) 3029 (Zs)
applied) (S)
27 - 47 9823/1650-1 27 - 47
27 - Driveline
00 - General
Figure 492. 4th gear forward (4 wheel drive) Table 256.

X
Forward low ratio (T) 3022 (Ts)
applied) (S)
Figure 494. 6th gear forward (4 wheel drive)
Z
U
S
Y
Table 255.
6 speed (X) 3004 (Xs)
S
applied) (S)
Figure 493. 5th gear forward (4 wheel drive) Table 257.

applied) (S)
27 - 48 9823/1650-1 27 - 48
27 - Driveline
00 - General
Reverse Table 259.
Figure 495. 1st gear reverse Clutches engaged Solenoids energised

Reverse high ratio (V) 3040 (Vs)
applied) (S)
W
Figure 497. 3rd gear reverse
S
Y
Table 258.
Clutches engaged Solenoids energised S
Reverse low ratio (W) 3041 (Ws)
applied) (S)
Table 260.
Figure 496. 2nd gear reverse Clutches engaged Solenoids energised

Reverse low ratio (W) 3041 (Ws)
applied) (S)
27 - 49 9823/1650-1 27 - 49
27 - Driveline
00 - General
Figure 498. 4th gear reverse torque is transferred from the converter assembly to
the clutch/gear assemblies through the input shaft on
the forward clutch assembly.
The forward clutch assembly contains two

V high ratio drive. The clutches are controlled by a
Y The reverse clutch assembly is also similar to the

ratio drive and the other gives a reverse high ratio
S either the reverse low (solenoid 3041) or reverse high
Both the mainshaft and the layshaft assemblies have

a single clutch each. Both clutches are controlled
Table 261. solenoid 3029 directs pressurised oil to the layshaft
Clutches engaged Solenoids energised clutch and solenoid 3033 directs pressurised oil the
Reverse high ratio (V) 3040 (Vs) mainshaft clutch.
Mainshaft (Y) 3033 (Ys) On 6-speed gearboxes, the 6-speed clutch X is
2/4 wheel drive (spring - controlled via solenoid valve 3004.
applied) (S)
When a gear is selected through the control switch
Hydraulic operation and schematics in the cab, two clutches are always engaged.
When you select different pairs of clutches different
The engine directly drives the oil pump through the gear ratios are engaged. Relays electrically control
torque converter. the solenoids. All the clutches work on the same
principle.
Oil from the pump is fed through an internal passage
via the filter to the PMV, which maintains pressure The 2/4 wheel drive unit also has a single clutch.
to the solenoid valves for clutch selection. Excess oil In normal operation the clutch is spring loaded and
from the maintenance valve flows back through the therefore engaged to give 4 wheel drive. When
case to the torque converter. A relief valve controls 2 wheel drive is selected, solenoid valve 3002 is
pressure in the converter and dumps oil from the energised and directs pressurised oil to the 2/4 wheel
converter line back to the sump. drive clutch.
Oil from the torque converter flows out of the gearbox In the schematic, the gearbox is shown with 2nd
to the external oil cooler and again comes back to gear forward engaged. 2nd gear forward requires
the converter. Oil then flows through internal oil ways the forward low clutch T and layshaft clutch Z to
providing lubrication for clutches and bearings before be engaged. When the gear selection switch is
it goes back to the gearbox sump. moved to 2nd gear forward, the electrical control
system energises solenoid valves 3022 and 3029.
The torque converter is a fluid coupling bolted to Pressurised oil is diverted to the back of pistons
a drive plate which in turn is bolted to the engine in both clutches to engage the drive. At the same
driven bevel gearbox. As the engine starts to rotate, time all other solenoids are de-energised, diverting
the converter gives smooth power take off and oil from the back of the other clutch pistons to the
gradually increases the torque transmitted. This gearbox sump. 4 wheel drive clutch 3002 is also
energised to give 2 wheel drive.
27 - 50 9823/1650-1 27 - 50
27 - Driveline
00 - General
Figure 499.
H G
2 1 K X
2 3 3
3004 C
5 1 W V Q A
3021 J
3022 T U
1
3002
B
3041
Y
M
3040 z
L 6
3033
D
E S
3029
N F
P
Table 262.
Item Description
A Torque converter
B Forward clutch assembly
C Reverse clutch assembly
D Mainshaft assembly
E Layshaft assembly
F 2/4 wheel drive unit
G Torque converter relief valve
H Pressure maintenance valve
J Pump
L Park brake pack
M Hose connection - to oil cooler
N Hose connection - from oil cooler
P 6-Speed clutch assembly (if installed)
S Gear drive to reverse unit clutch assembly
Q Oil filter
T Forward low ratio clutch
U Forward high ratio clutch
V Reverse high ratio clutch
W Reverse low ratio clutch
X 6 speed clutch (PS766 only)
Y Mainshaft clutch
Z Layshaft clutch
1 Solenoid port 1
27 - 51 9823/1650-1 27 - 51
27 - Driveline
00 - General
Item Description
2 Solenoid port 2
3 Solenoid port 3
5 Solenoid valve control block
6 External oil cooler
Forward and Reverse Clutch Operation is then transmitted from the input shaft to the gear
1. Clutch for gear 2 is disengaged and no drive is
The forward and reverser clutch assembly transfers transmitted to gear 2 plate carrier. The gear is also
drive from the input shaft to either gear 1 or gear 2 free to rotate on the input shaft assembly.
depending on which of the two clutches is engaged,
giving forward or reverse drive. Actuation of the hydraulic pistons and is controlled
via three position solenoid control valve.
When neither clutch is engaged, neutral is selected.
When neutral is selected both solenoids are
The clutches are of the wet, multi plate type. deactivated and the flow of pressurised oil to the
clutches is blocked. The gear springs 1 and 2 move
The clutch housings and input shaft are a one piece the pistons away from the clutch plates and oil from
assembly. The assembly is permanently driven by both pistons is vented to the sump.
the engine via the torque converter.
When either forward or reverse is selected, the
Clutch counter plates are also permanently driven solenoid control valve diverts pressurised oil via
via meshing teeth inside the clutch housings. Clutch cross drillings inside the input shaft to the appropriate
friction plates are meshed with the gear plate clutch piston in the unit. Pressure from the other
carriers. clutch is vented to the sump via the solenoid valve
spool. Oil is prevented from leaking by seals on the
In the diagram, clutch for gear 1 is engaged. pistons and ring seals on the input shaft.
The counter plates and friction plates are pressed

27 - 52 9823/1650-1 27 - 52
27 - Driveline
00 - General
Figure 500.
B C D E F
A G1 G2
H H H
K J
N
M
R
Q

G1 Gear 1 G2 Gear 2
27 - 53 9823/1650-1 27 - 53
27 - Driveline
00 - General
Mainshaft and Layshaft Clutch Operation piston via a solenoid valve. The solenoid valve is
operated by a switch in the cab.
The mainshaft and layshaft units incorporate one
clutch and not two, as in the forward and reverse When the switch is in the 4WD position, the solenoid
units. The operation of the single clutches is the valve is de-energised. With the solenoid 1 de-
same as for one clutch in the forward or reverse units. energised, the valve spool moves under the force of
2 and 4 Wheel Drive Clutch Operation the same time oil vents from the back of the piston to
the sump via ports 1 and 2.
4 Wheel Drive Operation Because there is no pressure behind the piston, the
clutch friction/counter plates of the clutch pack are
This clutch is of the Spring-ON (4WD)/Pressure-OFF forced together by the disc springs, thus driving the
(2WD) type. output yoke.
The clutch is engaged and disengaged by
Figure 501.
B C
A1
3 2
1
A2

C Piston D Springs
E Output yoke
27 - 54 9823/1650-1 27 - 54
27 - Driveline
00 - General
Figure 502.
B C
A1
A
3 2
1
A2

C Piston D Springs
G Pressure plate
27 - 55 9823/1650-1 27 - 55
27 - Driveline
00 - General
Fault-Finding
Fault
Machine drives but lacks power in all gears. Gearbox oil may also be Table 263. Page 27-56
overheating.
Machine does not drive in any gear. Table 264. Page 27-57
Some gears fail to engage or lack power. Table 265. Page 27-58
Gearbox oil overheating. Table 266. Page 27-58
Noisy operation. Table 267. Page 27-59
Cannot engage 4WD (Four Wheel Drive) (Spring ON clutch). Table 268. Page 27-59
Cannot engage 2WD (Spring ON clutch). Table 269. Page 27-59
Gearbox oil contaminated with water. Table 270. Page 27-60
Consequential Faults (Gearbox faults caused typically by water Table 271. Page 27-60
contamination and other factors related to the gearbox oil.)- Pressurisation
of gearbox casing. Dipstick blows out and oil escapes from dipstick tube.
contamination and other factors related to the gearbox oil.)- Clutch failure
due to friction lining separation.
contamination and other factors related to the gearbox oil.)- Badly worn or
noisy bearings.
Machine does not achieve maximum speed when travelling on the highway Table 274. Page 27-61
(Lock-up torque converter variants only).
Gear shifts fail to function normally- Sychroshuttle gearboxes only. Table 275. Page 27-61
Gear shifts fail to function normally or shifts occur at the incorrect road Table 276. Page 27-61
speed.
The gear fails to autoshift (Note that on 6 speed gearboxes, 4th, 5th and Table 277. Page 27-61
6th gears utilise clutches used for 1st, 2nd and 3rd gears. If 4th, 5th or 6th
gears fail to engage, check that the lower 3 gears function correctly before
investigating a possible Shiftmaster fault, refer to `Fault Table- Some gears
fail to engage or lack power').
Table 263. Machine drives but lacks power in all gears. Gearbox oil may also be overheating.
Cause Remedy
Gearbox oil level low. Check for leaks and top up oil level as required.
Gearbox oil contaminated or wrong grade. Investigate the reason for the contamination and
rectify as required. Drain the oil and flush the
gearbox. Refer to driveline- semi automatic gearbox,
Suction strainer restricted or blocked. Remove the suction strainer and clean or install new
as applicable. Refer to driveline- semi-automatic
gearbox, refer to (PIL 27-06).
Pressure maintenance valve defective. Carry out oil pressure and flow tests. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Remove the pressure maintenance valve and inspect
for signs of damage or excessive wear. Clean or
install new as applicable.
Torque converter relief valve defective. Carry out oil pressure and flow tests. Refer to
27-06).
Remove the torque converter relief valve and inspect
for signs of damage or excessive wear. Clean or
install new as applicable.
27 - 56 9823/1650-1 27 - 56
27 - Driveline
00 - General
Cause Remedy
Oil cooler lines restricted or blocked. Internal Carry out oil pressure and flow tests. Refer to
blockage within the oil cooler matrix due to driveline- semi-automatic gearbox, refer to (PIL
contamination. 27-06).
Clear the restriction. Inspect the hose routing
and install new the hoses or oil cooler matrix as
applicable.
Faulty torque converter. Carry out torque converter stall tests to confirm stall
speeds are within specification. Refer to driveline-
Torque converter, refer to (PIL 27-14).
Remove the gearbox and install new the torque
converter. Note that the torque converter assembly is
a non serviceable item.
Failure of oil pump assembly. Carry out the oil pressure and flow tests. Refer to
27-06).
Remove the gearbox and inspect the oil pump for
signs of damage or excessive wear. Install new oil
pump as applicable.
Gearbox internal leakage fault. Carry out oil pressure and flow tests. Refer to
27-06).
Remove and disassemble the gearbox. Inspect all
components for signs of damage or excessive wear.
In particular, check the seals and install new as
applicable.
Table 264. Machine does not drive in any gear.

Cause Remedy
Park brake switch or transmission dump switch Check the function of the park brake switch and
defective. transmission dump switch.
Inspect the condition of the associated electrical
wiring, plugs and connectors for damage and check
that the relevant fuses are intact.
Gear selector column switch defective. Check the function of the gear selector column
switch.
Clutch solenoid wiring defective Inspect the condition of the associated electrical
Low mainline oil pressure. Carry out oil pressure and flow tests. Refer to
27-06).
Failure of oil pump assembly. Carry out oil pressure and flow tests. Refer to
27-06).
Remove the gearbox and inspect oil pump for signs
of damage or excessive wear. Install new oil pump as
applicable.
27 - 57 9823/1650-1 27 - 57
27 - Driveline
00 - General
Table 265. Some gears fail to engage or lack power.

Cause Remedy
Gear selector column switch defective. Check the function of the gear selector column
switch.
The relevant solenoid valve is not being energised. Inspect the condition of the associated electrical
Solenoid coil faulty. Check the solenoid for open or short circuits.
Measure the solenoid coil resistance. If required,
install new solenoid coil.
Clutch operating oil pressure low. Carry out oil pressure and flow tests. Refer to
27-06).
Failure of clutch assembly. Check for clutch internal leakage. Carry out oil
pressure and flow tests. Refer to driveline- semi-
automatic gearbox, refer to (PIL 27-06).
Check for clutch slippage. Carry out torque
converter stall tests to confirm stall speeds are within
specification. Refer to driveline- Torque converter,
Remove and disassemble the gearbox. Inspect
relevant clutch components for signs of damage or
excessive wear. Install new as applicable.
Table 266. Gearbox oil overheating.

Cause Remedy
Oil cooler heat exchanger matrix clogged with dirt Clean the oil cooler matrix. Refer to operators
particles or chaff. (Air blast coolers only. Some manual.
machines have liquid to liquid type coolers.)
gearbox. Refer to driveline- semi-automatic gearbox,
Suction strainer restricted or blocked. Remove the suction strainer and clean or renew
Oil cooler hoses kinked or trapped. Clear the restriction. Inspect the hose routing and
reroute or renew the hoses as applicable.
Machine being operated incorrectly i.e. Incorrect gear Educate the operator.
ratio.
Torque converter relief valve defective. Carry out oil pressure and flow tests. Refer to
27-06).
Failure of oil pump assembly. Carry out oil pressure and flow tests. Refer to
27-06).
Remove the gearbox and inspect oil pump for signs
of damage or excessive wear. Install new the pump
as applicable.
27 - 58 9823/1650-1 27 - 58
27 - Driveline
00 - General
Table 267. Noisy operation.

Cause Remedy
gearbox. Refer to driveline- semi-automatic gearbox,
Suction strainer restricted or blocked. Remove the suction strainer and clean or install new
Low lubrication oil pressure. Carry out oil pressure and flow tests. Refer to
27-06).
Gearbox components damaged or excessively worn. Remove and disassemble the gearbox. Inspect all
the components for signs of damage or excessive
wear. In particular, check shaft seals and bearings.
Install new as applicable.
Table 268. Cannot engage 4WD (Four Wheel Drive) (Spring ON clutch).
Cause Remedy
4 wheel drive solenoid valve spool is sticking in Remove and inspect the solenoid valve cartridge.
the 2WD (Two Wheel Drive) drive position due to Clean the valve or renew as applicable.
contamination.
Solenoid coil permanently energised. Check the function of the 4WD selector switch.
Failure of clutch assembly Remove the 4WD clutch assembly. Inspect the clutch
Renew as applicable.
Table 269. Cannot engage 2WD (Spring ON clutch).

Cause Remedy
4WD selector switch defective. Check the condition of the 4WD selector switch.
4WD solenoid valve is not being energised. Inspect the condition of the associated electrical
Solenoid coil faulty. Check the solenoid for open or short circuits.
install a new solenoid coil.
4WD solenoid valve spool is sticking in the 4WD Remove and inspect the solenoid valve cartridge.
position due to contamination. Clean the valve or install new as applicable.
Clutch operating oil pressure low. Carry out oil pressure and flow tests. Refer to
27-06).
Failure of clutch assembly. Check for clutch internal leakage. Carry out oil
pressure and flow tests. Refer to driveline- semi-
Remove the 4WD clutch assembly. Inspect the clutch
Install new as applicable.
27 - 59 9823/1650-1 27 - 59
27 - Driveline
00 - General
Table 270. Gearbox oil contaminated with water.

Cause Remedy
Water ingress during filling or topping-up. Drain the oil and flush the gearbox. Refer to
27-06).
Missing or incorrect dipstick. Damaged filler tube. Install new parts as required. Drain the oil and flush
the gearbox.
Machine operated in deep water. Drain the oil and flush the gearbox. Refer to
27-06).
Gearbox oil cooler faulty, gearbox oil contaminated Remove and test the oil cooler. Refer to cooling
with engine coolant. (Liquid to liquid oil coolers only.) system- cooling pack, refer to (PIL 21-03-09).
Gearbox casings damaged. Inspect the gearbox casing. Renew missing or
damaged parts. Drain the oil and flush the gearbox.
Refer to driveline- semi-automatic gearbox, refer to
(PIL 27-06).
Gearbox oil circuit pipework or hoses damaged. Inspect the pipework and hoses. Renew missing or
damaged parts. Drain the oil and flush the gearbox.
Refer to driveline- semi-automatic gearbox, refer to
(PIL 27-06).
Table 271. Consequential Faults (Gearbox faults caused typically by water contamination and other
factors related to the gearbox oil.)- Pressurisation of gearbox casing. Dipstick blows out and oil escapes
from dipstick tube.
Cause Remedy
Water in the oil combined with heat from torque Replace or renew the dipstick.
converter causes steam. Drain the oil and flush the gearbox. Refer to
27-06).
factors related to the gearbox oil.)- Clutch failure due to friction lining separation.
Cause Remedy
Water ingress. Remove and dismantle gearbox. Inspect relevant
clutch components for signs of damage or excessive
wear. Install new as applicable.
Overheating transmission oil. Drain the oil and flush the gearbox. Refer to
27-06).
factors related to the gearbox oil.)- Badly worn or noisy bearings.
Cause Remedy
Water ingress. Remove and dismantle the gearbox. Inspect all
Install new components as applicable.
Insufficient lubrication. Drain the oil and flush the gearbox. Refer to
27-06).
Carry out oil pressure and flow tests. Refer to
27-06).
27 - 60 9823/1650-1 27 - 60
27 - Driveline
00 - General
Table 274. Machine does not achieve maximum speed when travelling on the highway (Lock-up torque
converter variants only).
Cause Remedy
Operator error. Educate the operator. Ensure operator fully
understands the characteristics of the lock up
function.
Lock up torque converter solenoid not being Inspect the condition of the associated electrical
energised. wiring, plugs and connectors for damage and check
Lock up torque converter solenoid coil faulty. Check the solenoid for open or short circuits.
renew the solenoid coil.
Engine or transmission speed sensor faulty. Use the applicable JCB Diagnostics software to
check the ECU (Electronic Control Unit) inputs
and outputs. Refer to electrical system- electronic
diagnostic, refer to (PIL 33-57).
wiring, plugs and connectors or damage and check
that the relevant fuses are intact. If required, install a
new speed sensor.
Faulty lock up torque converter. Remove the gearbox and renew the lock up torque
converter. Note that the torque converter assembly is
a non serviceable item.
Table 275. Gear shifts fail to function normally- Sychroshuttle gearboxes only.
Cause Remedy
Cable shift mechanism faulty Adjust or replace gear shift cables as necessary.
Table 276. Gear shifts fail to function normally or shifts occur at the incorrect road speed.
Cause Remedy
Gear selector column switch faulty Check the function of the gear selector column
switch. Also Inspect the condition of the associated
electrical wiring, plugs and connectors for damage
and make sure that the relevant fuses are intact.
Table 277. The gear fails to autoshift (Note that on 6 speed gearboxes, 4th, 5th and 6th gears utilise
clutches used for 1st, 2nd and 3rd gears. If 4th, 5th or 6th gears fail to engage, check that the lower 3
gears function correctly before investigating a possible Shiftmaster fault, refer to `Fault Table- Some
gears fail to engage or lack power').
Cause Remedy
Transmission speed sensor faulty. Check the function of the speed sensor.
If required, install a new speed sensor.
27 - 61 9823/1650-1 27 - 61
27 - Driveline
00 - General
Cause Remedy
Gearbox ECU defective. (In response to certain Use the ECU Diagnostics software to check the
faults the ECU will enter a `Limp Mode'. For a ECU inputs and outputs. Refer to electrical system-
detailed description of the Limp Modes, refer electronic diagnostic, refer to (PIL 33-57).
to `Service Procedures - Powershift Gearbox, Inspect the condition of the associated electrical
Electronic Control Unit'.) wiring, plugs and connectors for damage and check
Install new ECU. (The ECU is inherently reliable.
It is protected internally from electrical damage.
It is housed in a rugged case for protection from
mechanical damage and ingress of dirt and moisture.
Faults with associated systems are more likely to be
caused by wiring or other input and output device
failure. Before renewing the ECU make sure beyond
reasonable doubt that it is faulty.)
27 - 62 9823/1650-1 27 - 62
27 - Driveline
00 - General
Drain and Fill 13. Continue this procedure for the specified
duration, if possible during machine operation.
Duration: 30 min
Transmission Oil and Filter
14. Allow the machine to cool then drain the
Refer to driveline, semi-automatic gearbox, Filter, transmission oil through the suction strainer
(PIL 27-06-39). aperture. Refer to (PIL 27-06-40).
15. Test the oil for contamination. If the oil is still
Transmission Oil Suction Strainer contaminated, repeat the flushing procedure
Refer to driveline, semi-automatic gearbox, Suction from step 3
Strainer, (PIL 27-06-40). 16. If the oil is clean:
Flushing the Transmission Oil 16.1. Replace the suction strainer. Refer to (PIL
27-06-40).
1. If the transmission oil has been contaminated
with water or incorrect oil types, the transmission 16.2. Install a new oil filter. Refer to (PIL
must be flushed to effectively remove the 27-06-39).
contaminated oil. 16.3. Fill the transmission with the correct grade
of fresh oil. Refer to (PIL 75-00)
2. Park the machine and make it safe.
16.4. Check the oil level and top up as required.
3. Drain the oil from the gearbox. Refer to (PIL Refer to (PIL 27-06-00).
27-06-40).
4. Remove the suction strainer. Refer to (PIL
27-06-40).
5. Clean the suction strainer and install. Refer to
(PIL 27-06-40).
6. Replace the oil filter. Note that the filter may be
remotely mounted on some installations. Refer to
(PIL 27-06-39).
7. Fill the transmission with the correct grade of
fresh oil. Refer to (PIL 75-00).
8. Check the oil level and top up as required. Refer
to (PIL 27-06-00).
9. Start the engine and run the machine until the
normal operating temperature is as specified.
Temperature: 50 –100 °C ( 121.9 –211.9 °F)
10. Stall the torque converter for the specified
duration. Refer to (PIL 27-14).
Duration: 5 s
10.1. Do not stall the torque converter for
longer than the maximum duration or the
transmission oil will overheat.
Duration: 10 s
11. Continue running the engine under normal
conditions for the specified duration.
Duration: 5 min
12. Repeat step 10.
27 - 63 9823/1650-1 27 - 63
27 - Driveline
00 - General

Consumables Consumables
Description Part No. Size Description Part No. Size
Cleaner/Degreaser 4104/1557 0.4 L JCB Threadlocker 4101/0250 0.01 L
- General purpose and Sealer (Medium 4101/0251 0.05 L
solvent based parts Strength)
cleaner
Before assembling the gearbox, make sure that a
1. Carefully remove all traces of the gasket thorough inspection of all components is carried out.
or gasket compound from the following Remember that although a failed component may
components: be easy to identify, the cause of that failure may be
less easy to trace. It is also possible that a failed
1.1. Front and rear case mating faces component may have caused damage to other areas
1.2. Front case and torque converter housing of the gearbox.
mating faces
1. Cleaning: Refer to Semi-Automatic Gearbox -
1.3. Solenoid control valve manifold and case Clean, refer to (PIL 27-06).
mating faces
2. General Inspection:
1.4. 4WD case mating faces (if applicable)
1.5. Layshaft cover and rear case mating faces. 2.1. Carefully inspect all gears, bearings and
shafts for signs of excessive wear or
2. Clean the inside of the cases using a suitable damage. If wear or damage is evident, the
degreasing agent. components must be renewed.
Consumable: Cleaner/Degreaser - General 2.2. Make sure that all oil way cross drillings are
purpose solvent based parts cleaner clear and free from debris. Blocked oil ways
are a common cause of bearing failure. If
necessary use an air line to blow through
the oil ways.
3. Clutch Units:
3.1. If a clutch failure is suspected see the
relevant clutch dismantling and assembly
procedure, refer to (PIL 27-06).
4. Gearbox Oil Pump-Renew:
4.1. If tests have shown the pump performance
to be unacceptable, the pump must be
renewed as a complete unit.
4.2. Make sure that the pump mating face on the
gearbox front cover is clean and free from
surface damage.
5. Gearbox Oil Pump-Replace: If the existing pump
is to be re-installed proceed as follows:
5.1. Undo the security screw and separate
the pump body. Carefully inspect the gear
teeth, white metal bearing and gear/body
mating faces for signs of wear and damage,
(If either is evident, the pump must be
renewed).
5.2. Carefully remove and discard the oil seal.
Take care not to damage the seal housing.
5.3. Install a new seal. Install the seal the correct
way around. Push the seal flush with the
front of the housing.
27 - 64 9823/1650-1 27 - 64
27 - Driveline
00 - General
5.4. Re-assemble the pump. Check (Level)

Figure 503.
2. Start the engine and operate at low idle for the
specified time. This allows the oil to fill the filter,
pump, torque converter, oil cooler and hoses.
Duration: 4 min
3. Stop the engine.
4. Remove the ignition key.
5. Gain access to the dipstick. Refer to (PIL 06-06).
A
B 6. Before you complete a check of the oil level, you
must wait as shown on the instructional label.
The instructional label shows the waiting time in
seconds.
7. Make sure that the area around the dipstick and
tube are clean and free of debris before removing
B the dipstick.
8. Check the gearbox oil level on the dipstick. The
C oil level must be between the end of the dipstick
and maximum mark on the dipstick.
A Security screw
B Oil seal 9. Clean the dipstick with a clean lint free cloth.
C Housing Make sure that no debris remain on the dipstick
or enters the transmission via the dipstick tube.
6. Cases:
10. If necessary add clean new oil through the
6.1. If the gearbox cases are to be renewed, be dipstick tube.
sure to install blanking plugs and adaptors
as required. Inspect the original cases Water Contamination
and identify the blanking plug and adaptor
positions. Transfer the plugs and adaptors Carefully inspect the gearbox oil for signs of water
to the new cases. Apply JCB Threadlocker contamination. Contaminated oil will contain water
and Sealer to the threads. Note that new droplets or be visibly emulsified.
plugs may be supplied with a sealant patch,
in which case sealant need not be applied. Water droplets may be visible on the dipstick or
Consumable: JCB Threadlocker and Sealer inside the filler tube. For oil analysis purposes, the
(Medium Strength) maximum permissible water content of the oil is
0.10%. If the gearbox oil has been contaminated
with water, faults or damage to the gearbox may
be apparent as a result. Before trying to remedy,
thoroughly investigate and rectify the cause of the
water contamination.
27 - 65 9823/1650-1 27 - 65
27 - Driveline
00 - General
Check (Pressure)
Special Tools Before you start any of the transmission pressure/

Description Part No. Qty. flow test, make sure that the oil level is correct and
Flowmeter 892/00229 1 at normal operating temperature (not less than 50
°C ( 121.9 °F)).
Pressure Gauge (0-40 892/00278 1
Bar) Do the these test procedures:
To help with fault identification, record the test results • Pump flow test
on a check list. The check list will help the engineer to • Mainline pressure test
identify the cause of a gearbox fault and if needed it • Converter in pressure
can be sent to JCB Technical Service by email. Refer • Converter relief (safety) valve pressure
to Figure 510. • Converter out pressure and oil cooler flow rate
• Lubrication pressure
Make sure you follow all safety procedures before • Clutches- Isolating a suspect clutch
working on the machine. Refer to (PIL 01-03). • Clutches- Individual clutch leakage test
27 - 66 9823/1650-1 27 - 66
27 - Driveline
00 - General
Figure 504. Test points
A D
H
Item Description
F Reverse high ratio clutch
Table 278. Test points
pressure
Item Description G Reverse low ratio clutch
A Mainline pressure pressure
B Mainshaft clutch pres- H Layshaft clutch pressure
sure J 2/4 wheel drive clutch
C Converter inlet and con- pressure
(1)
verter relief valve pres-

sure (1) Machines with selectable 2/4 wheel drive option.
D Forward high ratio clutch
pressure
E Forward low ratio clutch
pressure
27 - 67 9823/1650-1 27 - 67
27 - Driveline
00 - General
Mainline pressure 2.1. A low reading can be caused by either

a faulty pressure maintenance valve or a
1. Stop the engine, connect a pressure gauge of the worn pump. Refer to Figure 505.
specified limit to the mainline pressure test point.
2.2. A high or low reading may indicate a
Refer to Figure 505.
faulty pressure maintenance valve. Refer to
Pressure: 0 –20 bar ( 0.0 –289.9 psi) Figure 505.
2. Start engine and run at 1000 RPM (Revolutions 3. Do the 2 again with engine running at 2000 RPM
Per Minute). With the transmission in neutral the note the gauge readings. Refer to Figure 505.
pressure gauge will show the main line pressure.
Refer to Figure 505. 4. Stop engine and remove the test gauge. Refer to
Figure 505.
27 - 68 9823/1650-1 27 - 68
27 - Driveline
00 - General
Figure 505. Pump flow test
A
L
X Y Z
P
Q
N
27 - 69 9823/1650-1 27 - 69
27 - Driveline
00 - General
Special Tool: Flowmeter (Qty.: 1)
Table 279. 4. Start engine and run at 1000 RPM. With the
transmission in neutral the flowmeter will show
Item Description
the pump flow. Refer to Figure 505.
A Mainline pressure test
point 4.1. A low reading indicates a worn pump or
K Transmission oil filter blocked suction strainer. Refer to Figure
L Flowmeter 505.
M Male adapter 5. Again do step 4 and note gauge readings with
N Female adapter engine running at 2000 RPM. Refer to Figure
P Banjo bolt 505.
Q Fitting adapter 6. Stop engine and remove test adapters. Remove
R Pressure test adapter the gearbox adapter and install the filter. Refer to
Figure 505.
Pump flow (machines with direct mount
oil filter) Converter in pressure
1. Stop the engine. Clean the area around the Note that the converter in pressure is affected by
transmission oil filter. Refer to Figure 505. the transmission oil temperature, cooler circuit back
pressure and torque converter relief valve operation.
2. Remove the filter and the adapter installed to the Before carrying out tests check the operation of the
gearbox. Refer to Figure 505. relief valve.
3. Install one of the three alternative pump flow 1. Stop the engine, connect a pressure gauge of the
test adapters in place of the oil filter. The choice specified limit to the converter inlet and converter
of adapter is best determined by the ease of relief valve pressure test point. Refer to Figure
installation and/or accessibility. Refer to Figure 506.
505.
Pressure: 0 –20 bar ( 0.0 –289.9 psi)
3.1. Note that adapter type 'z' is installed as Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
standard on machines with a remote oil
filter. Refer to Figure 505. 2. Start engine and run at 1000 RPM. With the
transmission in neutral the pressure gauge will
3.2. Type 'x': Install the female adapter in the show the converter in pressure. Refer to Figure
gearbox case. Install the male adapter in 506.
the female adapter. Install the pressure test
adapter over the female and male adapter. 2.1. A low reading could indicate a worn pump,
Install the oil filter to clamp the pressure test a worn pump would also be evident during
adapter in place.Refer to Figure 505. a pump flow test. Refer to Figure 506.
3.3. Type 'y': With the component parts 2.2. A high pressure together with low flow could
assembled, install and secure with banjo be caused by a blocked oil cooler. Refer to
bolt screwed into the gearbox and tightened Figure 506.
to the correct torque value. Refer to Figure 2.3. Low pressure could be caused by a faulty
505. pump or internal leakage. Refer to Figure
3.4. Type 'z': With the component parts 506.
assembled, install and secure with fitting
adapter screwed into the gearbox, and 3. Stop the engine and remove the pressure test
tightened to the correct torque value. Refer gauge. Refer to Figure 506.
to Figure 505.
3.5. Connect the flowmeter to the flow and
return adapters (shown with arrows). Refer
to Figure 505.
27 - 70 9823/1650-1 27 - 70
27 - Driveline
00 - General
Figure 506. Converter in, converter relief valve pressure tests

S
C Converter inlet and converter relief valve S Load valve

pressure test point
27 - 71 9823/1650-1 27 - 71
27 - Driveline
00 - General
Converter relief (safety valve) pressure does not indicate a fault. If necessary reset the
load valve and perform the test again, carefully
The purpose of the torque converter relief valve is watch the pressure gauge. Refer to Figure 506.
to protect the torque converter from excessive oil
pressure. Excessive oil pressure can be generated 6. If the converter relief valve opens at a pressure
when the transmission oil temperature is below 50 higher than specified then the valve is faulty.
°C ( 121.9 °F) and/or the engine is run at over 2000 Refer to Figure 506.
RPM. 7. A low opening pressure indicates a leaking pump
to casing seal or a faulty converter relief valve.
In this event the relief valve opens and returns
oil directly to the transmission sump, bypassing
the torque converter, cooler and clutch lubrication 8. Stop engine, remove test gauges and the load
circuits, protecting against damage due to excessive valve. Refer to Figure 506.
pressure.
9. Install hoses to their original position. Refer to
For this reason it is essential that the transmission Figure 506.
oil should be more than 50 °C ( 121.9 °F) and the
engine should run between idle and 1000 RPM when Bypassing the converter relief valve
you test the relief valve.
During some powershift pressure and oil flow tests
1. Connect a pressure gauge of the specified limit
it is advisable to temporarily bypass the converter
to the converter inlet and converter relief valve
relief valve. If the relief valve opens at the time of the
pressure test point. Refer to Figure 506.
following tests it will cause false results.
Pressure: 0 –20 bar ( 0.0 –289.9 psi)
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) • Converter out pressure/Oil cooler flow rate
• Converter in pressure
2. Install a load valve into the converter out line. • Lubrication pressure
Make sure the load valve is fully open before • Torque converter stall test
starting the test. Refer to Figure 506.
Before you bypass the torque converter relief valve
3. Do not allow the pressure to exceed more than make sure that the mainline pressure is correct and
the specified value, or else it can damage the that the transmission oil filter is fitted.
converter seals. Refer to Figure 506.
Pressure: 8.3 bar ( 120.3 psi) To temporarily bypass the relief valve (prevent the
valve from opening) proceed as follows:
4. Start the engine and run at 1000 RPM. With the
transmission in neutral, slowly screw down the 1. Stop the engine and remove the relief valve.
load valve and monitor the gauge reading which Refer to Figure 507.
should increase to the converter relief (safety)
valve pressure setting. Refer to Figure 506. 2. Carefully remove the spring. Refer to Figure 507.
5. The gauge pressure will fall, once the valve has 3. Obtain a suitable plug, drill and tap the centre
opened. This is normal relief valve operation and then install a locking bolt. Refer to Figure 507.
27 - 72 9823/1650-1 27 - 72
27 - Driveline
00 - General
Figure 507. Bypass the converter relief valve
U
T
T Spring U Locking bolt

V Spool
4. Install the plug assembly to the relief valve 2. Do not run the engine at more than 2000 RPM
housing and tighten the bolt to hold the spool on for more than the specified time. Refer to Figure
its seat. Refer to Figure 507. 507.
5. Do not damage the spool and its seat. Refer to Duration: 1 min
Figure 507.
When the check is complete make sure to remove
The torque converter can be damaged when the the plug assembly and install the spring and cover/
converter relief valve is bypassed. To prevent the plug.
torque converter from damage follow the below
steps. Converter out pressure and oil cooler
flow rate
1. Before you start the engine make sure that
the transmission oil temperature is above the Note that the converter out pressure and oil cooler
specified value. Refer to Figure 507. flow rate are affected by the torque converter relief
Temperature: 50 °C ( 121.9 °F) valve operation. Before you carry out the test check
the operation of the relief valve.
27 - 73 9823/1650-1 27 - 73
27 - Driveline
00 - General
1. Stop the engine. Connect a pressure gauge cooler flow rate. Make sure that the readings are
of the specified limit and flowmeter into the correct. Refer to Figure 508.
converter out line. Refer to Figure 508.
4.1. A high pressure together with low flow could
Pressure: 0 –20 bar ( 0.0 –289.9 psi) be caused by a blocked oil cooler. Low
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) pressure could be caused by a faulty pump
Special Tool: Flowmeter (Qty.: 1) or internal leakage. Refer to Figure 508.
2. The flowmeter may cause back pressure, so 5. Do the steps 3 and 4 with engine running at 2000
bypass the torque converter relief valve or else RPM and note gauge readings. Refer to Figure
it may open and cause false readings. Refer to 508.
Figure 508.
6. Stop the engine. Remove test gauges and install
3. Run the engine at 1000 RPM with transmission hoses to original position. Refer to Figure 508.
in neutral. Refer to Figure 508.
7. Make sure you remove the torque converter
4. The pressure gauge indicates the converter out relief valve by-pass assembly and install the
pressure and the flowmeter indicates the oil relief valve (ball, spring and cover/plug). Refer to
Figure 508.
Figure 508. Converter out, Lubrication pressure tests
W
L
AA
L Flowmeter W Pressure gauge

AA Pressure gauge connected to the return line
from the oil cooler
27 - 74 9823/1650-1 27 - 74
27 - Driveline
00 - General
Lubrication pressure park brake on. Therefore, so that we can

complete the test, move the park brake lever
Note that the lubrication pressure is affected by fractionally forward until the warning light is just
the torque converter relief valve operation and back extinguished; hold the lever in this position for the
pressure in the oil cooler circuit. Before you carry out duration of the test.
the test check the operation of the relief valve.
4. Do not move the lever too far forward, otherwise
1. Stop the engine, connect a suitable pressure the park brake will not be fully operational.
gauge into the return line from the oil cooler to Alternatively, disconnect the switch at the park
the transmission. Refer to Figure 508. brake.
2. Start the engine and run at 1000 rev/min. 5. Start engine and run at 1000 RPM, engage1st
With the transmission in neutral the pressure gear forward. Record the pressure reading.
gauge will indicate the lubrication pressure which Repeat the test for all gears in forward drive and
should be correct. Refer to Figure 508. record the pressure readings. Refer to Refer to
Table 280.
3. Do step 2 and note gauge readings with engine
running at 2000 RPM. If the pressure is high the 5.1. Readings should not vary between clutches
oil cooler may be blocked. Refer to Figure 508. by more than the specified value.
4. Stop the engine and remove the pressure gauge.
5.2. In the table of examples shown, we can
Isolate a suspect clutch see that pressure is low when 2nd and 4th
gear forward is selected, indicating clutch
1. Stop the engine. Connect a pressure gauge of leakage. Refer to Table 280.
the specified to the mainline pressure test point. 5.3. From the table we can see that the forward
Refer to Figure 509. high clutch is used for selection of both 2nd
Pressure: 0 –20 bar ( 0.0 –289.9 psi) and 4th gear forward.
5.4. We know from the table that the mainshaft
2. Make sure that both sides of all four wheels are and layshaft clutches are working normally
chocked. Apply the foot brake and park brake. (1st and 3rd gear selection show normal
operating pressure). So we can assume
3. When fully engaged, the park brake electrically that the forward high clutch is leaking.
disconnects the transmission drive, this prevents
the machine from being driven with the 6. If necessary, do the above test again using
reverse clutch ratios.
Table 280.
Gear select Ratio clutch Mainshaft or layshaft Value (Examples Only)
clutch
1st Forward low Layshaft 9.65 bar ( 139.9 psi)
2nd Forward high Layshaft 8.62 bar ( 124.9 psi)
3rd Forward low Mainshaft 9.65 bar ( 139.9 psi)
4th Forward high Mainshaft 8.62 bar ( 124.9 psi)
27 - 75 9823/1650-1 27 - 75
27 - Driveline
00 - General
Figure 509.
A D
AB
A Mainline pressure (test point) D Forward high ratio clutch pressure (test point)
AB Layshaft clutch solenoid (3029)
Before you carry out individual clutch leakage tests, 4. Make sure that both sides of all four wheels are
we can confirm that the forward high clutch is leaking: chocked. Apply the foot brake and park brake.
Individual clutch leakage test 5. When fully engaged, the park brake electrically
In the following procedures the forward high clutch disconnects the transmission drive, this prevents
is tested, therefore in step 2 a pressure gauge is the machine from being driven with the
connected to the forward high clutch test point. park brake on. Therefore, so that we can
complete the test, move the park brake lever
When you test the other suspect clutches, connect fractionally forward until the warning light is just
a gauge to the relevant suspect clutch test point. extinguished; hold the lever in this position for the
Because the forward high clutch is suspect, a gear duration of the test. Refer to Figure 509.
must be selected that will use the forward high clutch, 6. Do not move the lever too far forward, otherwise
in this instance 2nd gear forward. the park brake will not be fully operational.
Alternatively, disconnect the switch at the park
1. Stop the engine. Connect a pressure gauge of
brake. Refer to Figure 509.
the specified to the mainline pressure test point.
Refer to Figure 509. 7. Start engine and run at 1000 RPM, select 2nd
Pressure: 0 –20 bar ( 0.0 –289.9 psi) gear forward. Note the pressure readings on both
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) gauges, which should not vary more than the
specified value. If the difference on the gauges is
2. Connect a pressure gauge of the specified vale greater than the specified value do the following.
to the forward high ratio clutch test point. Refer Refer to Figure 509.
to Figure 509.
Pressure: 0 –20 bar ( 0.0 –289.9 psi)
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) 7.1. Stop the engine and interchange the
gauges. Refer to Figure 509.
3. Remove the electrical connector from the
layshaft clutch solenoid. This will ensure that only 7.2. Start the engine and run at 1000 RPM,
the forward high clutch is energised when 2nd select 2nd gear forward. If the difference on
gear forward is selected. Refer to Figure 509. the gauges is still greater than the specified
27 - 76 9823/1650-1 27 - 76
27 - Driveline
00 - General
value then disassemble the forward high 7.3. If after interchanging the gauges, the
clutch. Refer to Figure 509. readings are different than the value
mentioned in step 7 then calibrate the
gauges and again do the check. Refer to
Figure 509.
27 - 77 9823/1650-1 27 - 77
27 - Driveline
00 - General
Figure 510. Transmission Technical Data Checklist
27 - 78 9823/1650-1 27 - 78
27 - Driveline
00 - General
Remove and Install
Remove 7. Carefully remove the gearbox from the torque

converter, keep the assemblies square to each
1. Because of the configuration of the engine and other.
transmission mounting system, the powershift
gearbox should be removed from the machine Figure 511.
together with the engine, bevel gearbox, torque
converter and hydraulic pump as a full assembly.
Refer to Engine- General. Refer to (PIL 15-00).
2. Support the engine and transmission assembly
on a suitable frame. Remove the engine lifting
beam.
3. Make sure that the engine is safely supported
when the transmission components are
removed.
5. Disconnect the following external oil hoses and
pipes, typically as follows.
5.1. Oil cooler hose 1 and hose 2.
5.2. Bevel gearbox drain pipe.
5.3. Remote oil filter pipes (if installed). x
6. Support the gearbox with suitable lifting gear and

remove the bolts that connect the gearbox to the X Hole
torque converter housing.
27 - 79 9823/1650-1 27 - 79
27 - Driveline
00 - General
Figure 512.
E C F
B D
A Frame B Cooler hose 1

C Cooler hose 2 D Drain pipe
E Oil filter pipes F Bolts
27 - 80 9823/1650-1 27 - 80
27 - Driveline
00 - General
Install
steps.
1.1. Before you install the powershift gearbox,
make sure that the pressure test points are
installed at the clutch pressure test points.
Refer to driveline- semi-automatic gearbox.
1.2. Make sure you align the gearbox square to
the torque converter housing.
1.3. Insert the torque converter drive shaft in to
the opening of the pump, make sure that
the drive shaft engages correctly with the
pump. Take care not to damage the oil seal.
1.4. Do not use the housing bolts or any other
device to pull the assemblies together.
1.5. Make sure you install any cable tie locators
retained by the bolts.
27 - 81 9823/1650-1 27 - 81
27 - Driveline
00 - General
For: PS750 MK4 ....................... Page 27-82 the correct machine service documentation. The
For: PS764, PS766 ................... Page 27-83 table lists all the service procedures for the gearbox.
For some procedures it is necessary to do other
procedures first, these are shown in the table.
(For: PS750 MK4)
Before following some of the procedures, remove
the gearbox from its machine installation. Refer to
Table 281. Service Procedures List

Serial No. Procedure Name Do these procedures first
1 Oil Filter - Removal and Replace- -
ment. Refer to (PIL 27-06-39).
2 Suction Strainer - Removal and -
Replacement. Refer to (PIL
27-06-40).
3 4 Wheel Drive Yoke and Oil Seal - -
Removal and Replacement. Refer
to (PIL 27-06-95).
4 Brake Disc - Removal and Re- -
placement Refer to (24-18-21).
5 Solenoid Control Valves - Re- -
moval and Replacement. Refer to
(27-06).
6 Torque Converter Relief Valve - -
Removal and Replacement. Refer
to (27-14).
7 Pressure Maintenance Valve - Re- -
(27-06-21).
8 Speed Sensors - Removal and Re- -
placement.
9 Oil Pressure Switch - Removal and -
Replacement. Refer to (27-06-30).
10 Oil Pump - Removal, Inspec- -
tion and Replacement. Refer to
(27-06-24).
11 Clutches - Removal. Refer to 1, 2, 3, 5, 8, 9, 10
(1)
(27-06).
12 Clutches - Replacement. Refer to -
(27-06).
13 Output Shaft and Bearing - Re- 11
(27-06-58).
14 Input Clutch, Forward and Revers- 11
er Clutch - Disassemble. Refer to
(27-06).
15 Input Clutch, Forward and Revers- -
er Clutch - Assemble. Refer to
(27-06).
16 Layshaft Clutch - Disassemble. 11
Refer to (27-06-08).
17 Layshaft Clutch - Assemble. Refer -
to (27-06-08).
27 - 82 9823/1650-1 27 - 82
27 - Driveline
00 - General
Serial No. Procedure Name Do these procedures first

18 Main shaft Clutch - Disassemble. 11
Refer to (27-06-54).
19 Main shaft Clutch - Assemble. Re- -
fer to (27-06-54).
20 2 and 4 Wheel Drive Clutch (4WD 11
Pressure ON) - Disassemble. Re-
fer to (27-06-07).
21 2 and 4 Wheel Drive Clutch (4WD -
Pressure ON) - Assemble. Refer to
(27-06-07).
21 2 and 4 Wheel Drive Clutch S1 11
(4WD Spring ON) - Disassemble.
Refer to (27-06-07).
23 2 and 4 Wheel Drive Clutch S1 -
(4WD Spring ON) - Assemble. Re-
fer to (27-06-07).
24 2 And 4 Wheel Drive Clutch (4WD 11
Spring ON) - Pressure Testing. Re-
fer to (27-06-07).
25 PTFE Piston Ring Seals. Refer to 11
(27-06-45).
(1) The components depicted in the procedures 5, 8, and 9 are to be removed to prevent component damage
during the disassembly of the gearbox.
Figure 513.
(For: PS764, PS766)
Special Tools
Gearbox Assembly 892/01082 1
Cradle
Note: The Disassembly and Assembly procedures

given below illustrate and describe the 6x4 gearbox.
Procedures for the 4x4 version of the gearbox
are identical in most respects. Where there are
differences, procedures are identified under the
heading 4x4 Gearbox.
With the gearbox removed from the machine, place

suitable wooden blocks to securely support the
assembly. If the gearbox is installed with an integral B
A
park brake the brake assembly must be removed
before you disassemble the gearbox. Refer to (PIL A Layshaft cover
27-06). B Bolt 1
Gearboxes compatible with a lock up torque 1.1. Remove the bolts.

converter are installed with a control valve and 1.2. Remove the cover.
interconnecting pipe. These components must be
removed before dismantling the gearbox. 1.3. Note: Unless the cases are to be replaced,
or the gearbox oil has been contaminated it
is not necessary to remove the cover.
Disassemble
2. Separate the front and rear case and remove the
1. If installed, remove the layshaft cover. Refer to
clutch shafts.
Figure 513.
3. Do not attempt to disassemble the gearbox
further until it is safely positioned in a suitable
work cradle.
27 - 83 9823/1650-1 27 - 83
27 - Driveline
00 - General
4. Separate the front case and remove the clutch

shaft assemblies. Refer to (PIL 27-06).
5. Remove the transfer gear.
Install
1. Use suitable lifting equipment and put the rear
case of the gearbox in a work cradle.
Special Tool: Gearbox Assembly Cradle (Qty.: 1)
1.1. Clamp the gearbox at the three clamping
points on the rear case.
2. Do not attempt to assemble the gearbox further
until it is safely positioned in a suitable work
cradle.
3. Install the transfer gear.
4. Install the clutch shaft assemblies and the front
case. Refer to (PIL 27-06)
5. If applicable, install the layshaft cover as follows:
Figure 514.
B
A
A Layshaft cover
B Bolt 1
5.1. Make sure that the case mating faces are
clean and not damaged.
5.2. Apply a thin bead of sealant to the rear case
and install the layshaft cover.
5.3. Install the bolts 1.
5.4. Tighten the bolts 1 to the correct torque
value.

Item Description Nm
B Bolt 56
27 - 84 9823/1650-1 27 - 84
27 - Driveline
06 - Clutch - Reverse
06 - Clutch - Reverse Introduction

Introduction .................................................... 27-85 A clutch is a mechanical device that engages and
Check (Condition) .......................................... 27-86 disengages drive, from driving shaft to driven shaft.
Check (Pressure) .......................................... 27-86
Remove and Install ....................................... 27-87 Each gear on the gearbox has an associated clutch
which is operated using the applicable solenoid.
When the solenoid is engaged fluid is applied to the
clutch to move it into position. When in position the
clutch connects the selected gear with the driven
shaft.
A combination of clutches is often used within the

gearbox to allow different gears to be engaged.
27 - 85 9823/1650-1 27 - 85
27 - Driveline
Check (Condition) Check (Pressure)

Special Tools
Carry out a visual inspection of the friction and Description Part No. Qty.
counter plates: Hand Pump Pressure 892/00223 1
Test
Counter plates Pressure Test Adaptor 993/59300 1
1. Light scoring or polishing is permissible, plates
that are not flat, worn or heavily marked or scored 1. Assemble the 2 and 4 wheel drive clutch. Refer to
must be replaced with a new set. the relevant Clutch- Disassemble and Assemble
procedure (PIL 27-06).
Friction plates 2. Check the clutch pack end float and adjust
as required. Refer to the relevant Clutch -
1. The cross hatching should be clearly visible, Disassemble and Assemble procedure (PIL
plates that are not flat, have friction material 27-06).
damage or scoring must be replaced with a new
set. 3. Use the service tool (993/59300), insert the
adaptor into the oil gallery in the end of the 2
2. DO NOT mix old and new plates, if a plate is and 4 wheel drive clutch shaft as shown. Hold the
damaged or worn install a complete new set. adaptor in position with clamp.
3. Needle roller bearings should slide into position Special Tool: Pressure Test Adaptor (Qty.: 1)
freely, do not bend or distort the cage to install. If
the cage has been distorted install new bearings. 4. Use the hand pump (892/00223) to pressurise
the clutch assembly until the gear can be turned
4. Take care when handling disc springs to avoid by hand. Note the pressure gauge reading. Do
marking or damage, which could result in stress not exceed the given value.
cracking. If in doubt install a new disc spring.
Special Tool: Hand Pump Pressure Test (Qty.: 1)
5. If the pressure gauge reading is between
the given values, then the clutch is operating
correctly and can be installed in the gearbox.
Pressure: 8.6 –9.3 bar ( 124.6 –134.8 psi)
6. If the pressure gauge reading is above the
given value, then check the clutch for assembly
defects, especially the clutch pack end float (the
shim may not be to the correct thickness). Re-
test after checking and rectify assembly defects.
27 - 86 9823/1650-1 27 - 86
27 - Driveline
The layshaft clutch, 2WD (Two Wheel Drive) / 4WD

(Four Wheel Drive) clutch, reverse clutch, main shaft
clutch and forward / input clutch are all part of the
main shaft assembly.
Refer to the main shaft remove and install procedure.

A Adaptor (Part of 993/59300)

B Clamp (Part of 993/59300)
27 - 87 9823/1650-1 27 - 87
27 - Driveline

For: PS750 MK4 ....................... Page 27-88
For: PS764, PS766 ................... Page 27-88
(For: PS750 MK4)

Refer to Clutch-Input, Disassembly and Assembly
(PIL 27-06-11).
(For: PS764, PS766)

Refer to Clutch-Input, Disassembly and Assembly
(PIL 27-06-11).
27 - 88 9823/1650-1 27 - 88
27 - Driveline
07 - Clutch - 2WD/4WD
07 - Clutch - 2WD/4WD Introduction

Introduction .................................................... 27-89 A clutch is a mechanical device that engages and
Component Identification ............................... 27-90 disengages drive, from driving shaft to driven shaft.
Check (Condition) .......................................... 27-96
Check (Pressure) .......................................... 27-96 Each gear on the gearbox has an associated clutch
Disassemble and Assemble ........................ 27-101 When the solenoid is engaged fluid is applied to the
shaft.

27 - 89 9823/1650-1 27 - 89
27 - Driveline
For: PS750 MK4, PS764, PS766

................................................... Page 27-90
For: PS750 MK4, PS764, PS766
................................................... Page 27-91
For: PS764, PS766 ................... Page 27-93
(For: PS750 MK4, PS764, PS766)
Figure 516. Pressure ON

G
F
E
F
D
C
M
L
K
J
H U
S
Q
P
N
A
A Bearing 1 B Piston ring seal

C Bearing 2 D Thrust washer 1
E 4WD (Four Wheel Drive)gear and splined hub F Needle roller bearing
G Thrust washer 2 H Circlip 1
J Shim K Pressure end plate
L Friction plate M Counter plate
N Circlip 2 P Spring retaining plate
Q Piston spring R Oil baffle
S Piston T O-ring 1 (Piston)
27 - 90 9823/1650-1 27 - 90
27 - Driveline
U O-ring 2 (Shaft)
(For: PS750 MK4, PS764, PS766)
Figure 517. S1 Spring ON
E F
L
F
D
C G N
M
U
H2
K
J
S
T
H1
Y
R
W
V

C Bearing 2 D Thrust washer
E 4WD gear F Needle roller bearing
G Circlip 1 H1 Disc spring 1
H2 Disc spring 1 J Pressure end plate
K Shim L Friction and counter plates
M Circlip 2 N Support washer
P Clutch drum Q Actuating sleeve
R Disc spring 2 S Piston
T Spring steel ring U O-ring 1
V O-ring 2 W Piston housing
X Shaft Y Spacer
27 - 91 9823/1650-1 27 - 91
27 - Driveline
Figure 518. S2 Spring ON

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16
1 Piston ring seal 2 Bearing 1

3 Thrust washer 1 4 4WD gear
5 Needle roller bearing 1 6 Needle roller bearing 2
7 Thrust washer 2 8 Circlip
9A Disc spring 1 9B Disc spring 1
10 Pressure end plate 11 Shim(s)
12 Friction plates and counter plates 13 Bearing 2
14 Thrust washer 3 15 Piston housing
16 O-ring 1 17 O-ring 2
18 Piston 19 Spring steel ring
20 Disc spring 2 21 Actuating sleeve
22 Clutch drum 23 Shaft
27 - 92 9823/1650-1 27 - 92
27 - Driveline
(For: PS764, PS766)
Figure 519. S1 - 4WD Spring ON
U
M
L
F
E
C
B
A
Q
G
S
H
P
T
N W
V
J1
J2
A Piston ring seal B Taper roller bearing 1

C Thrust washer 1 D Gear and splined hub
E Needle roller bearings F Thick thrust washer
G Taper roller bearing 2 H Locknut
J1 Disc spring J2 Disc spring
K Friction and counter plates retaining circlip L Shims
M Pressure end plate N Friction plates
P Counter plates Q Pressure end plate
27 - 93 9823/1650-1 27 - 93
27 - Driveline
R Piston S O-ring 1
T O-ring 2 U O-ring 3
V Capscrew W Reaction pin

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

27 - 94 9823/1650-1 27 - 94
27 - Driveline

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

9 Disc spring 1 10 Pressure end plate
11 Shim(s) 12 Friction plates and counter plates
13 Bearing 2 14 Thrust washer 3
15 Piston housing 16 O-ring 1
17 O-ring 2 18 Piston
19 Spring steel ring 20 Disc spring 2
21 Actuating sleeve 22 Clutch drum
23 Shaft
27 - 95 9823/1650-1 27 - 95
27 - Driveline
Check (Condition) Check (Pressure)
Do a visual check of the friction and counter plates (For: PS750 MK4, PS764, PS766, Spring
and gears:
ON)
Counter plates Special Tools
1. Light scoring or polishing is permissible, plates Hand Pump Pressure 892/00223 1
that are not flat, worn or heavily marked or scored Test
must be replaced with a new one.
Pressure Test Adaptor 993/59300 1
Friction plates 1. Assemble the 2 and 4 wheel drive clutch. Refer to
1. The lubrication slots should be clearly visible, the relevant Clutch- Disassemble and Assemble
plates that are not flat, have friction material procedure (PIL 27-06).
damage or scoring must be replaced with a new 2. Check the clutch pack end float and adjust
one. as required. Refer to the relevant Clutch -
2. Do not change individual plates, if a plate is Disassemble and Assemble procedure (PIL
damaged or worn install a complete new set. 27-06).
3. Needle roller bearings should slide into position 3. Use the service tool (993/59300), insert the
freely, do not bend or distort the cage to install. If adaptor into the oil gallery in the end of the 2
the cage has been distorted install new bearings. and 4 wheel drive clutch shaft as shown. Hold the
adaptor in position with clamp.
The piston consists of a small check valve. Visually Special Tool: Pressure Test Adaptor (Qty.: 1)
check the piston to make sure that the ball is in
place and that the seat is free from contamination. 4. Use the hand pump (892/00223) to pressurise
If necessary clean the valve by blowing through with the clutch assembly until the gear can be turned
an air line. Do not use a wire rod (or screwdriver) as by hand. Note the pressure gauge reading. Do
it can damage the valve seat. not exceed the given value.
Gears Special Tool: Hand Pump Pressure Test (Qty.: 1)
1. Check the gear teeth for wear, cracking or 5. If the pressure gauge reading is between
damage. the given values, then the clutch is operating
correctly and can be installed in the gearbox.
Pressure: 8.6 –9.3 bar ( 124.6 –134.8 psi)
6. If the pressure gauge reading is above the
given value, then check the clutch for assembly
defects, especially the clutch pack end float (the
shim may not be to the correct thickness). Re-
test after checking and rectify assembly defects.
27 - 96 9823/1650-1 27 - 96
27 - Driveline

For: PS764, PS766 ................... Page 27-97
For: PS750 MK4 ..................... Page 27-100
(For: PS764, PS766)

Special Tools
Drive Coupling 892/00812 1
Spanner
Remove
1. Remove the 4WD clutch assembly as follows:
Figure 523.
B
D C
A Adaptor (Part of 993/59300) H

B Clamp (Part of 993/59300) E
A Output yoke
B Bolt 1 (If applicable)
C Thick washer (If Bolt 1 is installed)
D Nut
E Bolt 2
F Cover
G O-ring (If installed)
H Oil seal
J 4WD clutch and shaft assembly
1.1. Hold the output yoke with the tool.
27 - 97 9823/1650-1 27 - 97
27 - Driveline
Special Tool: Drive Coupling Spanner (Qty.: 1.1. Make sure that the inner bearing outer cup
1) is correctly installed in the front case.
1.2. Either remove the nut or the bolt1 along 1.2. Put the clutch and shaft assembly in the
with the thick washer. The nut or bolt is very housing.
tight and the help of a assistant would be
1.3. Make sure that the front and 4WD case
required.
mating faces are clean and not damaged.
1.3. Remove the yoke
1.4. If applicable install the O-ring to the front
1.4. Remove the bolts 2 (x8) and lift off the cover. case. The O-ring deforms to get positioned
in the recess.
1.5. Make sure to remove the bearing outer cup
from inside the cover. 1.5. For gearbox variants installed with an O-
ring apply a bead of Loctite 509 of the
1.6. If installed, remove the o-ring.
specified thickness to the front case at the
1.7. Remove the output shaft oil seal. Take care locations shown. Refer to Figure 525.
not to damage the seal housing. Dimension: 3 mm
1.8. Lift the 4WD clutch and shaft assembly from
the housing. Figure 525.
1.9. Remove the inner bearing outer cup from

the case. P G
2. Remove the torque converter relief valve as
P
follows: Refer to Figure 524.
Figure 524.
K
L
M P
N
G O-ring
P Loctite 509
1.6. For gearbox variants not installed with O-
ring apply a bead of Loctite 509 of the
specified thickness on the front case at the
locations shown. Refer to Figure 526.
Dimension: 3 mm
K Plug
L Sealing washer
M Spring
N Poppet
2.1. Remove the plug.
2.2. Remove the sealing washer and the spring.
2.3. Remove the poppet.
Install
1. Install the 4WD clutch assembly as follows: Refer
to Figure 527.
27 - 98 9823/1650-1 27 - 98
27 - Driveline

B
P
D C
P
A
H
P E
G
P
P Loctite509
J
1.7. Note that the bead is applied near the inner
or outer edge of the flange as applicable at
positions shown.
1.8. Make sure that the outer bearing outer cup
is correctly installed inside the cover.
1.9. Install the cover with the bolts 2 (x8).
1.10. Tighten the bolts 2 to the correct value.
A Output yoke
B Bolt 1 (If applicable)
C Thick washer (If Bolt 3 is installed)
D Nut
E Bolt 2
F Cover
G O-ring 3 (If installed)
H Oil seal
J 4WD clutch and shaft assembly
2. Measure the 4WD clutch shaft end float. as
follows:
2.1. The end float will be within limits provided
the components are installed correctly.
Rotate the shaft by hand, it should rotate
smoothly.
2.2. Install a bolt to the threaded hole in the end
of the shaft.
2.3. Pull up the bolt a to detect excessive end
float.
2.4. The end float must be within the range
specified.
Dimension: 0.01 –0.16 mm
3. Continue the installation of the 4WD clutch
assembly as follows:
27 - 99 9823/1650-1 27 - 99
27 - Driveline
3.1. Install a new oil seal. Make sure that the (For: PS750 MK4)
seal is positioned correctly in the housing.
3.2. Install the output yoke. The layshaft clutch, 2WD (Two Wheel Drive) / 4WD
(Four Wheel Drive) clutch, reverse clutch, mainshaft
3.3. As applicable install either the thick washer clutch and forward / input clutch are all part of the
and bolt 1 or the stake nut. mainshaft assembly.
3.4. Hold the yoke with the tool.
Refer to the mainshaft remove and install procedure.
Special Tool: Drive Coupling Spanner (Qty.: Refer to (PIL 27-06-54).
1)
3.5. Tighten the bolt or nut to the correct torque
value.
3.6. If the stake nut is installed, then stake the
nut with a square ended staking tool.
4. Install the torque converter relief valve as follows:
Figure 528.
K
L
M
N
K Plug
L Sealing washer
M Spring
N Poppet
4.1. Install the poppet and the spring.
4.2. Use a new sealing washer and install the
plug.
4.3. Tighten the plug to the correct torque value.

Item Description Nm
B Bolt 1 400
D Nut 300
E Bolt 2 56
K Plug 56
27 - 100 9823/1650-1 27 - 100

27 - Driveline
For: PS750 MK4, PS764, PS766, Pressure

ON ........................................... Page 27-101
For: PS750 MK4, S1, Spring ON
................................................. Page 27-105
For: PS750 MK4, S2, Spring ON
................................................. Page 27-108
For: PS764, PS766 ................. Page 27-111
(For: PS750 MK4, PS764, PS766, Pressure ON)

Special Tools
Hand Pump Pressure 892/00223 1
Test
27 - 101 9823/1650-1 27 - 101

27 - Driveline
Disassemble
Figure 529.
G
F
E
F
D
C
M
L
K
J
H U
S
Q
P
N
A

C Bearing 2 D Thrust washer 1
E 4WD gear and splined hub F Needle roller bearing
G Thrust washer 2 H Circlip 1
J Shim K Pressure end plate
L Friction plate M Counter plate
N Circlip 2 P Spring retaining plate
Q Piston spring R Oil baffle
S Piston T O-ring 1 (Piston)
U O-ring 2 (Shaft)
1. Remove the bearing 1, only if it is required to be or damage on shaft grooves. If necessary

replaced. remove burrs with a fine grade abrasion
paper and oil.
2. Carefully remove the piston ring seal.
2.1. Note: If the piston ring seal is damaged
or excessively worn then check for burrs
27 - 102 9823/1650-1 27 - 102

27 - Driveline
3. With a puller or press, remove the 4WD gear and Figure 531.
splined hub, together with its bearing 2, needle
roller bearing and thrust washer 1.
4. Remove the thrust washer 2.
4.1. Note the thrust washer 1 and thrust washer
2 are not interchangeable.
5. Remove the circlip 1 that retains the friction and
counter plates.
6. Remove the pressure end plate and shim (If
applicable).
7. Remove the friction plates and the counter
plates.
7.1. Keep them together in sets, do not mix the 12. Remove the piston.
plates with those from other clutches.
13. Remove and discard the piston O-ring 1.
8. Put the clutch assembly in a suitable press.
14. Remove and discard the shaft O-ring 2.
8.1. With a cut away tube compress the piston
spring and remove the circlip 2.
Assemble
Figure 530.
1. Install the new O-ring 1 onto the piston.
2. Install the new O-ring 2 onto the shaft.
3. Lubricate the piston with oil and press fully into
the bore of the clutch housing.
4. Install the oil baffle and piston spring. Make sure
that the spring is positioned properly in the piston.
5. Install the spring retaining plate.
6. Compress the spring with a cut away tube and
install the circlip 2.
7. Install one counter plate followed by one friction
plate.
9. Lift off the spring retaining plate. 7.1. Continue to install alternate counter and
friction plates, finishing with a friction plate.
10. Remove the spring and oil baffle.
8. Install the pressure end plate. Make sure the
11. Turn the assembly over and knock the clutch chamfered face of the pressure end plate faces
shaft on a piece of aluminium (or wood) to loosen the clutch pack.
the piston.
9. Make sure that the teeth are not aligned with the
11.1. If the piston does not loosen, then hand lubrication slots in the housing.
pump air down the shaft oil inlet hole.
10. Do not install the shim at this stage.
Special Tool: Hand Pump Pressure Test
(Qty.: 1) 11. Install the friction and counter plate retaining
circlip 1.
12. With a DTI (Dial Test Indicator) measure the end
float of the pressure end plate. The value should
be within the specified range.
27 - 103 9823/1650-1 27 - 103

27 - Driveline
Figure 532. end plate, with either a shim or an extra counter

plate between the retaining circlip 1 and the
pressure end plate.
14. Use an air line to check the operation of the
clutch.
15. Install the thrust washer 2.
16. Carefully align the teeth of the clutch plates with
a thin rod (or screwdriver) and install the 4WD
gear and splined hub, needle roller bearings and
thrust washer 1.
17. Apply gearbox oil on the clutch end bearing 2 and
press the bearing onto the shaft to seat on the
13. If it is necessary to adjust the end float to bring it thrust washer 1.
within tolerance, there is a choice of installing a
6.0mm (0.23in) or 6.5mm (0.25in) thick pressure 18. Install the new piston ring seals.
27 - 104 9823/1650-1 27 - 104

27 - Driveline
(For: PS750 MK4, S1, Spring ON)
Disassemble
Figure 533.
E F
L
F
D
C G N
M
U
H2
K
J
S
T
H1
Y
R
W
V

C Bearing 2 D Thrust washer
E 4WD gear F Needle roller bearing
G Circlip 1 H1 Disc spring 1
H2 Disc spring 1 J Pressure end plate
K Shim L Friction and counter plates
M Circlip 2 N Support washer
P Clutch drum Q Actuating sleeve
R Disc spring 2 S Piston
T Spring steel ring U O-ring 1
V O-ring 2 W Piston housing
X Shaft Y Spacer
1. Remove the bearing 1 from the shaft only if it is 2. Carefully remove the piston ring seal.
to be replaced.
27 - 105 9823/1650-1 27 - 105

27 - Driveline
2.1. Note: If the piston ring seal is damaged 8. Install the clutch drum in the housing.
or excessively worn then check for burrs
or damage on shaft grooves. If necessary 9. Install the support washer and drum retaining
remove burrs with a fine grade abrasion circlip 2.
paper and oil.
10. Build up the clutch pack. Install one friction plate
3. With a suitable puller, remove the 4WD gear followed by one counter plate.
together with its bearing 2, thrust washer, and the
needle roller bearings (x2). 10.1. Continue to install alternate counter and
friction plates, finish with the pressure
CAUTION! The spring (or springs) apply plate.
considerable force. Make sure you take care to 11. Use the 4WD gear to align the clutch plate
avoid damage or injury. splines. Make sure that all the plates are
engaged with the gear shaft splines.
4. Use a suitable press and compress the disc
springs to remove the circlip 1. 12. Rotate the 4WD gear back and forth to create
maximum backlash then remove the gear taking
4.1. There is considerable force applied by the
care not to disturb the pack.
springs.
Weight/Force: 26,700 N 13. Put the first two disc springs 1 with their convex
sides uppermost, onto the clutch pack. (There
5. Remove the disc springs 1 (x4), pressure end are four disc springs 1, which are identical). Put
plate and the shims. the other two disc springs 1, with their convex
sides down, onto the first two.
6. Remove the clutch pack friction plates and
counter plates. Figure 534.
6.1. Keep them together in sets, do not mix the
7. Remove the clutch drum retaining circlip 2 and
support washer.
8. Remove the clutch drum and the actuating
sleeve.
9. Remove the disc spring 2.
10. Remove the piston and its spring steel ring.
11. Remove and discard the piston O-ring 1 and O-
ring 2.
CAUTION! The spring (or springs) apply
12. If necessary, remove the piston housing. The
considerable force. Make sure you take care to
piston housing is a press fit on the shaft.
avoid damage or injury.
Assemble 14. Use a suitable press to compress the disc spring
and install the circlip 1.
1. Lubricate the shaft.
15. Use levers to remove free play.
2. Install the piston housing by pressing the shaft
squarely into the housing (make sure the housing
is securely supported).
3. Install the O-ring 1 and O-ring 2 onto the piston.
the bore of the housing.
5. Install the spring steel ring. Make sure that the
seal seats properly in its groove.
6. Put the disc spring 2 into the housing.
7. Put the actuating sleeve onto the disc spring.
27 - 106 9823/1650-1 27 - 106

27 - Driveline
Figure 535. 16.3. The shim can be a combination of a

single counter plate, shim (thinner than the
counter plate) or both counter plate and
shim.
16.4. Make sure that the clutch pack splines are
still aligned.
17. Install the two needle roller bearings into 4WD
gear.
18. Install the 4WD gear onto the shaft.
19. Install the thrust washer.
press the bearing onto the shaft to seat on the
16. Measure the gap between the pressure end plate thrust washer.
and the actuating sleeve.
21. Install the new piston ring seal.
16.1. The gap should be within the range
specified. 22. If required, install the new bearing 1 onto the
shaft.
Length/Dimension/Distance: 0.75 –1.5
mm 23. Before pushing the outer cup of bearing 1 into the
housing cover make sure you install the spacer.
16.2. If necessary, install a new shim to get the
correct gap. 24. Do an operational test of the clutch assembly.
27 - 107 9823/1650-1 27 - 107

27 - Driveline
(For: PS750 MK4, S2, Spring ON)
Disassemble
Figure 536.
8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

9 Disc spring 1 (x4) 10 Pressure end plate
27 - 108 9823/1650-1 27 - 108

27 - Driveline

23 Shaft
1. Carefully remove the piston ring seal from the Figure 537.
shaft. AA
1.1. If the piston ring seal is damaged or
excessively worn then check for burrs or
damage on the shaft grooves. If necessary
remove burrs with a fine grade abrasion
paper and oil.
2. Use a suitable puller to remove the 4WD gear
with its related bearing 1, thrust washer 1, needle
roller bearing 1, and needle roller bearing 2. AB
AA Rounded profile
CAUTION! The spring (or springs) apply AB Flat profile
considerable force. Make sure you take care to
avoid damage or injury. 1.2. Install the needle roller bearings on the
4WD gear with the flat end profiles facing
3. Use a suitable press to compress the disc spring out (nearest the ends of the shaft).
1 and remove the circlip.
1.3. Use a suitable press to press the needle
3.1. There is considerable clamping force acting roller bearings into the 4WD gear.
on the springs.
2. Install the O-rings 1 and O-rings 2 onto the
Weight/Force: 26,700 N piston.
4. Remove the disc spring 1 (x4), pressure end 3. Lubricate the piston with oil and press fully into
plate and shim(s). the bore of the piston housing.
5. Remove the clutch pack friction plates and 4. Install the spring steel ring onto the piston. Make
counter plates. sure that the seal seats firmly in its groove.
5.1. Keep them together in sets, do not mix the Figure 538.
6. Remove the thrust washer 2.
7. Use a suitable press on the output end of the
shaft and push the clutch drum with its related
bearing 2, thrust washer 3, piston housing, and
actuating sleeve.
8. Remove the disc springs 2.
18 19
9. Remove the piston and its spring steel ring.
18 Piston
10. Remove and discard the piston O-ring 1 and O- 19 Spring steel ring
ring 2.
5. Use a suitable press to assemble the shaft to the
Assemble piston housing and clutch drum as follows:
1. Install the needle roller bearing 1 and needle 5.1. Place the thrust washer 3 on the press.
roller bearing 2 to the 4WD gear in the correct Arrange the press so that the shaft can
orientation. pass through the thrust washer a sufficient
distance during assembly.
1.1. One end of the bearing has a rounded 5.2. Put the piston housing and piston assembly
profile and the other end has a flat profile. centrally on the thrust washer.
5.3. Put the disc spring 2 in position.
27 - 109 9823/1650-1 27 - 109

27 - Driveline
Figure 539. 5.7. The shaft will approximately drop to

the specified distance when the splines
engage.
Distance: 3 mm
5.8. Important: Make sure that the shaft and
clutch drum splines align and engage
correctly. If the splines are not aligned
the force from the press will damage the
components.
5.9. Put a suitable bushing at the top of the shaft
18 Piston and use the press to push the shaft fully
20 Disc spring 2 onto the piston housing and clutch drum.
Make sure that there are no splines visible.
5.4. Put the actuating sleeve over the clutch
drum and then put the clutch drum in the 6. Install the thrust washer 2. Make sure that the
piston housing. thrust washer 2 is positioned over the collar on
the shaft correctly.
Figure 540.
Figure 542.
AD
7 Thrust washer 2
23 Shaft
15 Piston housing AD Collar
20 Disc spring 2
21 Actuating sleeve 7. Build the clutch pack. Install one friction plate
22 Clutch drum followed by one counter plate.
5.5. Put the shaft on the clutch drum and piston 7.1. Continue to install alternate counter and
housing. friction plates.
Figure 541. 7.2. Install the friction plates so that the cross
hatching pattern aligns with each adjacent
plate.
Figure 543.
AC
22 Clutch drum
23 Shaft
AC Splines
5.6. Hold the clutch drum and carefully rotate the AE
shaft until the splines engage. 24 Cross hatching pattern
27 - 110 9823/1650-1 27 - 110

27 - Driveline
7.3. Install the shim or shims as applicable after 14. Measure the gap between the pressure end plate
you install the final counter plate. and actuating sleeve.
8. Install the pressure plate with its chamfer side 14.1. The gap should be within the specified
facing down. range.
9. Use the 4WD gear to align the clutch plate Distance: 0.75 –1.5 mm
splines. 14.2. If necessary install a new shim to achieve
the correct gap.
9.1. Make sure that all the plates are engaged
with the gear shaft splines. 14.3. The shim can be a combination of a
single counter plate, shim (thinner than the
9.2. Rotate the 4WD gear back and forth to counter plate) or both counter plate and
create maximum backlash then remove the shim.
gear taking care not to disturb the pack.
15. Make sure that the clutch pack splines are still
10. Place the first two disc springs 1 with their convex aligned and install the 4WD gear.
sides uppermost, onto the clutch pack. (There
are four disc springs 1, which are identical). 16. Install the thrust washer 1.
11. Place the other two disc springs 1, with their 17. Apply oil on the bearing 1 and press the bearing
convex sides down, onto the first two. onto the shaft to seat on the thrust washer 1.
Figure 544. 18. Install the thrust washer 2.
19. Apply oil on the bearing 2 and press the bearing
onto the shaft to seat on the thrust washer 2.
20. Install the new piston ring seal.
21. Do an operational test of the clutch assembly.
(For: PS764, PS766)

Special Tools
Test
CAUTION! The spring (or springs) apply Pressure Test Adaptor 993/59300 1
considerable force. Make sure you take care to Adaptor Spanner 998/10738 1
Consumables
12. Use a suitable press to compress the disc springs Description Part No. Size
1 and install the retaining circlip.
13. Use levers to remove the free play. and Sealer (Medium 4101/0251 0.05 L
Strength)
Figure 545.
This range of gearboxes can be installed with one of
three clutch types, all are 4WD (Four Wheel Drive)
Spring ON.
Disassembly
1. Carefully remove the piston ring seal from the
shaft.
1.1. If the piston ring seal is damaged or
excessively worn then check for burrs or
damage on the shaft grooves. If necessary
remove burrs with a fine grade abrasion
paper and oil.
27 - 111 9823/1650-1 27 - 111

27 - Driveline
2. Use a suitable puller or press to remove the 4WD 11.1. Match mark the piston and the clutch
gear and splined hub together with its taper roller housing, to make sure that the piston is
bearing 1, needle roller bearing and the thrust assembled in the same orientation when
washer 1. they are assembled again.
2.1. Remove the thick thrust washer. Figure 546.
2.2. Note, the thick thrust washer and thrust
washer1 are not interchangeable.
3. Use a suitable puller or press to remove the taper
roller bearing 2.
4. Use an adaptor spanner and a 1/2" square drive
socket to remove the locknut.
Special Tool: Adaptor Spanner (Qty.: 1)
5. Use the 4WD output yoke secured in a vice as
a holding fixture, to support the clutch assembly
and prevent it from rotation when torque is
applied.
6. Lift off the disc springs.
11.2. If the piston does not loosen, then hand
7. Turn the assembly over and remove the friction pump air down the shaft oil inlet hole.
and counter plates retaining circlip. Special Tool: Hand Pump Pressure Test
8. Remove the pressure end plate 1 and shims, if (Qty.: 1)
installed. 12. Remove the piston.
9. Remove the friction plates and the counter 13. Remove and discard the O-ring 1 and O-ring 2
plates. from the piston.
9.1. Keep them together in sets, do not mix the 14. Remove and discard the O-ring 3 from the shaft.
15. If it is necessary to replace, remove the
10. Remove the pressure end plate 2. capscrews and the reaction pins.
11. Turn the assembly over and knock the clutch
shaft on a piece of aluminium (or wood) to loosen
the piston.
27 - 112 9823/1650-1 27 - 112

27 - Driveline
U
M
L
F
E
C
B
A
Q
G
S
H
P
T
N W
V
J1
J2
A Piston ring seal B Taper roller bearing 1

C Thrust washer 1 D Gear and splined hub
E Needle roller bearings F Thick thrust washer
G Taper roller bearing 2 H Locknut
J1 Disc spring J2 Disc spring
K Friction and counter plates retaining circlip L Shims
M Pressure end plate N Friction plates
P Counter plates Q Pressure end plate
R Piston S O-ring 1
T O-ring 2 U O-ring 3
27 - 113 9823/1650-1 27 - 113

27 - Driveline
V Capscrew W Reaction pin

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

27 - 114 9823/1650-1 27 - 114

27 - Driveline

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

9 Disc spring 1 10 Pressure end plate
23 Shaft
27 - 115 9823/1650-1 27 - 115

27 - Driveline
Assembly retaining circlip and the pressure end plate

2.
1. Assemble the reaction pins.
Figure 550.
1.1. If removed then install the reaction pins to
the piston. do the steps below to make sure
that the pins are correctly aligned.
1.2. Put the piston into the bore of the clutch
housing. Do not install any O-rings at this
stage.
1.3. Install each reaction pin in turn from the
opposite end of the housing and secure to
the piston with a capscrew.
1.4. Apply JCB Threadlocker and Sealer to the
threads of the capscrews before you install
them.
Consumable: JCB Threadlocker and Sealer 7. Install the thick thrust washer.
(Medium Strength)
8. Carefully use a thin rod (or screwdriver) to align
1.5. When all four reaction pins are installed, the teeth of the clutch plates.
tighten the capscrews to the specified
torque value. 8.1. Install the 4WD gear, splined hub and the
needle roller bearings.
1.6. Match mark the piston and the clutch 9. Install the thrust washer1.
housing to make sure that the piston is 9.1. Apply gearbox oil to the taper roller bearing
assembled in the same orientation. 2 and press the bearing onto the shaft to
1.7. Temporarily remove the piston from the seat on the thrust washer 1.
clutch housing and assemble the clutch
pack. 10. Turn the assembly over and install a new O-ring
3 to the shaft.
2. Install the pressure end plate 2.
10.1. Install a new O-ring 1 and O-ring 2 to the
3. Install one counter plate followed by one friction piston.
plate. 10.2. Lubricate the piston with gearbox oil and
3.1. Continue to install alternate counter and press fully into the bore of the clutch
friction plates, finishing with a friction plate. housing (note the match marks made at
the time of disassembly).
4. Install the pressure end plate 1 but do not install
the shim at this stage. 11. Install the first two disc springs with their concave
sides uppermost (there are four disc springs,
4.1. Make sure that the chamfered face of the which are identical).
pressure end plate faces the clutch pack.
11.1. Place the other two disc springs with their
4.2. Make sure the teeth are not aligned with the concave sides down, on top of the first two
lubrication slots in the housing. as shown.
5. Install the friction and counter plates retaining 12. Use an adaptor spanner and a 1/2" square drive
circlip. socket to install the locknut and tighten the nut to
6. Use a DTI to measure the end float of the
pressure end plate. It should be within the Special Tool: Adaptor Spanner (Qty.: 1)
specified limit.
12.1. Note that the locknut is assembled dry
Dimension: 4 –5 mm with no thread lockers or sealant on the
threads.
6.1. If it is necessary to adjust the end float to
bring it within the specified limit mentioned 13. Use the 4WD output yoke secured in a vice as
in step6, Install a 6.0mm (0.23in) or 6.5mm a holding fixture, to support the clutch assembly
(0.25in) pressure end plate1 together with a and prevent it from rotation when torque is
shim or an extra counter plate, between the applied.
27 - 116 9823/1650-1 27 - 116

27 - Driveline
14. Use the pressure test adaptor and clamp

assembly to check the operation of the clutch
assembly.
Special Tool: Pressure Test Adaptor (Qty.: 1)
14.1. Make sure that the clutch fully disengages
at the specified working pressure.
Pressure: 13 bar ( 188.4 psi)
15. Apply gearbox oil to the taper roller bearing 2 and
press the bearing onto the shaft.
16. Install the piston ring seal.

Item Description Nm
H Locknut 300
27 - 117 9823/1650-1 27 - 117

27 - Driveline
08 - Clutch - Layshaft
08 - Clutch - Layshaft Introduction

Introduction .................................................. 27-118 A clutch is a mechanical device that engages and
Component Identification ............................. 27-119 disengages drive, from driving shaft to driven shaft.
Check (Condition) ........................................ 27-124
Calibrate ...................................................... 27-125 Each gear on the gearbox has an associated clutch
shaft.

27 - 118 9823/1650-1 27 - 118

27 - Driveline
For: PS750 MK4 ..................... Page 27-120

For: PS764, PS766 ................. Page 27-122
27 - 119 9823/1650-1 27 - 119

27 - Driveline
(For: PS750 MK4)
Figure 551.
AA
D AB X
C
AC
P
Z L
J
R
Q B
N
K
H A
G
F
U S
W
V
T
A Piston ring seals B Taper roller bearing 1

C 4 wheel drive transfer gear D Taper roller bearing 2
E Piston housing F Spring retaining plate
27 - 120 9823/1650-1 27 - 120

27 - Driveline
G Spring H Oil baffle

J O-ring 1 K O-ring 2
L Circlip 1 M Gear and splined hub
N Thrust washer 1 P Thrust bearing 1
Q Thin thrust washer 1 R Needle roller bearings
S Thin thrust washer 2 T Thrust bearing 2
U Circlip 2 V Outer pressure end plate
W Shim (if installed) X Friction plates
Y Counter plates Z Inner pressure end plate
AA Piston AB O-ring 3 (Piston)
AC Thrust washer 2
27 - 121 9823/1650-1 27 - 121

27 - Driveline
(For: PS764, PS766)
Figure 552.
L
J2
J1
F
K
H S
C
A
G
D
B
M
R
U
T
X Y Z
V W
Item Description
Table 285.
C Circlip 1
Item Description D 4 wheel drive transfer
A Piston ring seals gear
B Taper roller bearing 1
27 - 122 9823/1650-1 27 - 122

27 - Driveline
Item Description
E Gear and splined hub
F Thin thrust washers 1
G Thrust bearing 1
H Needle roller bearings
J1 Thin thrust washer 2
J2 Thin thrust washer 3
K Thrust bearing 2
L Thick thrust washer
M Taper roller bearing 2
N Friction and counter
plates retaining circlip
P Pressure end plate
Q Shim
R Friction plates
S Counter plates
T Circlip 2
U Spring retaining plate
V Spring
W Oil baffle
X Piston
Y O-ring 1
Z O-ring 2
27 - 123 9823/1650-1 27 - 123

27 - Driveline
Check (Condition)
Do a visual check of the friction and counter plates:
Counter plates
1. Light scoring or polishing is permissible, plates
that are not flat, worn or heavily marked or scored
Friction plates
1. The cross hatching should be clearly visible,
plates that are not flat, have friction material
one.
2. Do not change individual plates, if a plate is
damaged or worn install a complete new set.
3. Needle roller bearings should slide into position
the cage has been distorted install new bearings.
The piston consists of a small check valve. Visually

place and that the seat is free from contamination.
If necessary clean the valve by blowing through with
an air line. Do not use a wire rod (or screwdriver) as
it can damage the valve seat.
27 - 124 9823/1650-1 27 - 124

27 - Driveline
Calibrate
.............................................. Page 27- Later clutch assemblies feature an additional thin

For: PS764, PS766 ................. Page 27-125 thrust washer. If any of the components listed below
are to be replaced, the end float of gear must be
measured and reset as required:
End float measurement
• Shaft assembly
1. Use a DTI (Dial Test Indicator) to measure the • Gear and plate carrier assembly
end float of the pressure end plate. • Thin thrust washers1
2. The end float should be within the specified limit. • Thin thrust washer2 and thin thrust washer3
• 4 wheel drive (WD) transfer gear or spacer as
Dimension: 1.9 –2.5 mm applicable
Figure 553. Measure the end float as follows:
1. Temporarily install thick thrust washer, thin

thrust washer3, thrust bearing2 and thin thrust
washer2.
2. Install the needle roller bearing.
A
3. Temporarily install the gear and plate carrier
assembly.
4. Install the thin thrust washer1 and thrust bearing1
followed by the remaining thrust washer1.
5. Temporarily install the 4WD transfer gear 4 onto
the layshaft spline. Make sure that the gear is
installed in the correct orientation.
5.1. 2 wheel drive machines have a spacer
installed instead of a gear.
6. Install the circlip1.
A DTI 7. Make sure that the 4 wheel drive gear (or spacer)
is fully seated against circlip1.
3. If the end float is more than the specified value
then install a 6.0mm (0.23in) or 6.5mm (0.25in) 8. Measure the end float of gear.
thick pressure end plate, with either a shim or an
extra counter plate between the retaining circlip 9. The end float should be within the specified
and the pressure end plate. range.
clutch. 10. If the end float is to be adjusted select a suitable
thrust washer from the spacer kit and again
assemble the components given in steps 1 to 6.
(For: PS764, PS766) Special Tool: Thrust Washer Kit (Qty.: 1)
Special Tools
11. Measure the end float again and assemble the
clutch assembly.
Thrust Washer Kit 823/10420 1
12. Make sure you install the correct thick thrust
End Float Setting - Plate Carrier and Gear washer on final assembly.
Note: The following procedure is only applicable to

clutch assemblies fitted with thin thrust washer3.
27 - 125 9823/1650-1 27 - 125

27 - Driveline
Figure 554.
L
J2
J1
F
K
H S
C
A
G
D
B
M
R
U
T
X Y Z
V W
A Piston ring seals B Taper roller bearing1

C Circlip1 D 4 wheel drive transfer gear
E Gear and splined hub F Thin thrust washers1
G Thrust bearing1 H Needle roller bearings
J1 Thin thrust washer2 J2 Thin thrust washer3
K Thrust bearing2 L Thick thrust washer
M Taper roller bearing2 N Friction and counter plates retaining circlip
P Pressure end plate Q Shim
27 - 126 9823/1650-1 27 - 126

27 - Driveline
R Friction plates S Counter plates

T Circlip2 U Spring retaining plate
V Spring W Oil baffle
X Piston Y O-ring1
Z O-ring2
27 - 127 9823/1650-1 27 - 127

27 - Driveline
Remove and Install
The layshaft clutch, 2WD (Two Wheel Drive) / 4WD

(Four Wheel Drive) clutch, reverse clutch, mainshaft
clutch and forward / input clutch are all part of the
mainshaft assembly.

27 - 128 9823/1650-1 27 - 128

27 - Driveline
For: PS750 MK4 ..................... Page 27-130

For: PS764, PS766 ................. Page 27-133
27 - 129 9823/1650-1 27 - 129

27 - Driveline
(For: PS750 MK4)
Disassemble
Figure 555.
AA
D AB X
C
AC
P
Z L
J
R
Q B
N
K
H A
G
F
U S
W
V
T
27 - 130 9823/1650-1 27 - 130

27 - Driveline
C 4 wheel drive transfer gear D Taper roller bearing 2

E Piston housing F Spring retaining plate
G Spring H Oil baffle
J O-ring 1 K O-ring 2
L Circlip 1 M Gear and splined hub
N Thrust washer 1 P Thrust bearing 1
Q Thin thrust washer 1 R Needle roller bearings
S Thin thrust washer 2 T Thrust bearing 2
U Circlip 2 V Outer pressure end plate
W Shim (if installed) X Friction plates
Y Counter plates Z Inner pressure end plate
AA Piston AB O-ring 3 (Piston)
AC Thrust washer 2
1. Carefully remove the piston ring seals. 11. Remove the thin thrust washer 2 and thrust
bearing 2.
1.1. If the piston ring seals are excessively worn
then check for burrs or damage on the shaft 12. Remove the circlip 2 that retains the friction
grooves. If necessary remove burrs with a plates and counter plates.
fine grade abrasion paper and oil.
13. Remove the outer pressure end plate and shim
2. Remove the taper roller bearing 1 with a suitable (if installed).
puller and press.
14. Remove the friction plates and the counter
2.1. This bearing would not normally be plates.
removed unless it was damaged. It is
permissible to use a standard bearing 14.1. Keep them together in sets, do not mix the
puller, although damage to the bearing cage plates with those from other clutches.
may be incurred which will require a new
bearing. 15. Remove the inner pressure end plate.
3. From the opposite side of the shaft, use a 16. Remove the piston.
suitable puller to remove the 4WD transfer gear 17. Remove and discard the O-ring 3 from the piston.
(if applicable) and the taper roller bearing 2.
3.1. The gear and bearing 1 are under pressure Assemble
from the spring, make sure you proceed
with caution. 1. Install the O-ring 3 onto the piston.
3.2. Make sure to remove the thrust washer 2. 2. Lubricate the piston with oil and press fully into
3.3. Make a record of the orientation of the gear
for ease during assembly. 3. Install the inner pressure end plate. Make sure
3.4. The 2 wheel drive machines have a spacer that the teeth are not aligned with the lubrication
installed instead of a gear. slots in the housing.
4. Lift off the piston housing complete with clutch 3.1. Note: The inner pressure end plate is 4 mm
pack. (0.157 in) thick and should not be confused
with the outer pressure end plate which is
5. Lift off the spring retaining plate. either 6 mm (0.23 in) or 6.5 mm (0.25 in)
thick.
6. Remove the spring and the oil baffle.
4. Install one friction plate followed by one counter
7. Remove and discard the O-ring 1 and O-ring 2 plate.
from the shaft.
4.1. Continue to install alternate friction and
8. Remove the circlip 1. counter plates, finishing with a friction plate.
9. Remove the gear and the splined hub together 5. Install the outer pressure plate.
with the thrust washer 1, thrust bearing 1, and
thin thrust washer 1. 5.1. Make sure that the flatter of the two faces is
installed outermost. It will face against the
10. Remove the two needle roller bearing retaining circlip 2 when this is installed.
assemblies.
27 - 131 9823/1650-1 27 - 131

27 - Driveline
5.2. Make sure that the teeth are not aligned with 17.1. Note: Always check that the oil baffle plate
the lubrication slots in the housing. and spring retaining plate are in the correct
order.
18. Carefully align the teeth of the clutch plates using
7. Install the friction and counter plates retaining a thin rod (or screwdriver).
circlip 2.
18.1. Wedge the plates together by inserting two
8. With a DTI (Dial Test Indicator) measure the end blunt tools (small rounded screwdrivers)
float of the pressure end plate. The value should through the bottom holes in the side of the
be within the specified range. clutch housing.
Figure 557.
Figure 556.
A A
A DTI
A Screwdrivers
9. If it is necessary to adjust the end float to bring
it within tolerance, there is a choice to install a 18.2. Position the clutch assembly onto the shaft
6.0mm (0.23in) or 6.5mm (0.25in) thick pressure and splined hub.
end plate, with either a shim or an extra counter
plate between the retaining circlip 2 and pressure 19. Position the 4 wheel drive transfer gear onto the
end plate. shaft spline.
10. Install the thrust bearing 2 and thin thrust washer 19.1. Make sure that the gear is installed in the
2. correct position.
19.2. The 2 wheel drive machines have a spacer
11. Install the two needle roller bearings. installed instead of a gear.
12. Install the gear and splined hub. 20. Install the thrust washer 2 over the shaft.
13. Install the thin thrust washer 1, thrust bearing 1, 21. Apply gearbox oil onto the taper roller bearing
and thrust washer 1. 2 and install the bearing and the 4 wheel drive
14. Install the circlip 1. transfer gear into position with a bench press.
15. Install the spring and spring retainer. 21.1. When the taper roller bearing and the 4
wheel drive transfer gear have been fully
16. Install the new o-ring 1 and o-ring 2 onto the installed on the shaft, remove the two blunt
shaft. tools (small rounded screwdrivers) used to
wedge the clutch plates.
17. Install the oil baffle.
21.2. Rotate the gear to make sure that the
clutch has been correctly installed.
27 - 132 9823/1650-1 27 - 132

27 - Driveline
21.3. Use an air line to check the operation of puller, although it can damage the bearing
the clutch. cage which will require a new bearing.
22. Apply gearbox oil onto the taper roller bearing 1 8. Remove the friction and counter plates retaining
and install the bearing onto the shaft. circlip.
23. Install the new piston ring seals. 9. Remove the pressure end plate and shim, if
installed.
(For: PS764, PS766) 10. Remove the friction plates and the counter
plates.
Special Tools
Description Part No. Qty. 10.1. Keep them together in sets, do not mix the
Hand Pump Pressure 892/00223 1 plates with those from other clutches.
Test 11. Put the clutch assembly in a suitable press.
The illustration shows a main shaft assembly for a 6 11.1. With a cut away tube compress the piston
speed gearbox. The main shaft assembly for 4 speed spring and then remove the circlip 2.
gearboxes has some small differences. Procedures
are applicable for both 4 and 6 speed variants. Figure 558.
Disassembly
1. Carefully remove the piston ring seals.
then check for burrs or damage on the shaft
grooves. If necessary remove burrs with a
2. Remove the taper roller bearing 1 with a suitable
puller and press.
3. Remove the circlip 1 and remove the 4 wheel
drive(4WD) transfer gear.
3.1. Make a note in which orientation the gear is
installed for assembly. 12. Lift off the spring retaining plate.
3.2. The 2 wheel drive (2WD) machines have a 13. Remove the spring and oil baffle.
spacer installed instead of a gear.
4. Remove the gear and the splined hub together shaft on a piece of aluminium (or wood) to loosen
with the thin thrust washer1 and thrust bearing1. the piston.
5. Remove the two needle roller bearing 14.1. If the piston does not loosen, then hand
assemblies. pump air down the shaft oil inlet hole.
5.1. 4-speed transmissions have only one Special Tool: Hand Pump Pressure Test
needle roller bearing installed. (Qty.: 1)
6. Remove the thin thrust washer 2, thrust bearing

2, thin thrust washer 3 (if installed) and thick
thrust washer 1.
7. Use a puller to remove the taper roller bearing 2.
7.1. It must be discarded and replaced.
7.2. This bearing would not normally be
removed unless it was damaged.
7.3. If a collet tool is not available, then it
is permissible to use a standard bearing
27 - 133 9823/1650-1 27 - 133

27 - Driveline
Figure 559. 15. Remove the piston.

16. Remove and discard the piston O-ring 1.
17. Remove and discard the shaft O-ring 2.
27 - 134 9823/1650-1 27 - 134

27 - Driveline
Figure 560.
L
J2
J1
F
K
H S
C
A
G
D
B
M
R
U
T
X Y Z
V W
Item Description
D 4 wheel drive transfer
Table 286.
gear
Item Description E Gear and splined hub
A Piston ring seals F Thin thrust washers 1
B Taper roller bearing 1 G Thrust bearing 1
C Circlip 1
27 - 135 9823/1650-1 27 - 135

27 - Driveline
Item Description 7.1. Continue to install alternate counter and

H Needle roller bearings friction plates, finishing with a friction plate.
J1 Thin thrust washer 2 8. Install the pressure end plate. Make sure that the
J2 Thin thrust washer 3 chamfered face of the pressure end plate faces
K Thrust bearing 2 the clutch pack.
L Thick thrust washer 9. Make sure that the teeth are not aligned with the
M Taper roller bearing 2 lubrication slots in the housing.
N Friction and counter
plates retaining circlip 10. A spring disc is not installed in this clutch pack.
P Pressure end plate 11. Do not install the shim at this stage.
Q Shim
12. Install the friction and counter plate retaining
R Friction plates
circlip.
S Counter plates
T Circlip 2 13. Use a DTI to measure the end float of the
U Spring retaining plate pressure end plate. The value should be within
the specified range.
V Spring
W Oil baffle Dimension: 1.9 –2.5 mm
X Piston Figure 562.
Y O-ring 1
Z O-ring 2
Assembly
2. Install the new O-ring 2 onto the shaft.
4. Install the oil baffle and piston spring. Make
sure that the spring is positioned correctly in the
piston. 14. If it is necessary to adjust the end float to
bring it within tolerance, there is a choice of
5. Install the spring retaining plate. installing a 6.0mm (0.23in) or 6.5mm (0.25in)
thick pressure end plate, with either a shim or an
6. Compress the spring with a cut away tube and extra counter plate between the retaining circlip
install the circlip 2. and the pressure end plate.
Figure 561. 15. Use an airline to check the operation of the
clutch.
16. Install the thick thrust washer 1, thin thrust
washer 3, thrust bearing 2 and the thin thrust
washer 2.
17. Install the two needle roller bearing assemblies.
17.1. 4-speed transmissions have only one
needle roller bearing installed.
18. Carefully align the teeth of the clutch plates using
a thin rod (or screwdriver) and install the gear and
splined hub.
19. Install the thin thrust washer 1 and thrust bearing
1.
plate.
27 - 136 9823/1650-1 27 - 136

27 - Driveline
20. Install the 4 wheel drive transfer gear onto

the layshaft spline. Make sure that the gear is
installed in the correct orientation.
20.1. 2 wheel drive machines have a spacer
installed instead of a gear.
20.2. Install the circlip 1.
21. Apply gearbox oil on the taper roller bearing
1 and taper roller bearing 2 then push both
bearings onto the shaft.
22. Install new piston ring seals.
27 - 137 9823/1650-1 27 - 137

27 - Driveline
09 - Clutch - Main Shaft
09 - Clutch - Main Shaft Introduction

Check (Condition) ........................................ 27-144
Remove and Install ..................................... 27-144 Each gear on the gearbox has an associated clutch
shaft.

27 - 138 9823/1650-1 27 - 138

27 - Driveline
For: PS750 MK4 ..................... Page 27-140

For: PS764, PS766 ................. Page 27-142
27 - 139 9823/1650-1 27 - 139

27 - Driveline
(For: PS750 MK4)
Figure 563.
M
N
P J
K
L
Q
G
B
A
27 - 140 9823/1650-1 27 - 140

27 - Driveline
Item Description
H Counter plates
Table 287.
J Circlip 2
Item Description
K Spring retaining plate
A Piston ring seals
L Spring
B Taper roller bearing 1
M Oil baffle
C Taper roller bearing 2
N Piston
D Circlip 1
P O-ring 1 (Piston)
E Pressure plate
Q O-ring 2 (Shaft)
F Shim (if installed)
G Friction plates
27 - 141 9823/1650-1 27 - 141

27 - Driveline
(For: PS764, PS766)
Figure 564.
D
C
L
B M1
N
S
P
A Q
V R
T
M2
J
E
F
G
H

C Gear 1 D Gear 2
E Taper roller bearing 2 F Circlip 1
G Pressure end plate H Shim
J Friction plate K Counter plate
L Circlip 2 M1 Spring retaining plate (6 speed gearbox)
M2 Spring retaining plate (4 speed gearbox) N Spring
27 - 142 9823/1650-1 27 - 142

27 - Driveline
P Oil baffle Q Piston

R Piston O-ring S Shaft O-ring
T Circlip 3 U Clutch housing
V O-ring 1
27 - 143 9823/1650-1 27 - 143

27 - Driveline
Do a visual check of the friction and counter plates: The layshaft clutch, 2WD / 4WD clutch, reverse
clutch, mainshaft clutch and forward / input clutch are
Counter plates all part of the mainshaft assembly.
1. Light scoring or polishing is permissible, plates Refer to the mainshaft remove and install procedure.
that are not flat, worn or heavily marked or scored Refer to (PIL 27-06-54).
Friction plates
one.

27 - 144 9823/1650-1 27 - 144

27 - Driveline
For: PS750 MK4 ..................... Page 27-145

For: PS764, PS766 ................. Page 27-148
(For: PS750 MK4)

Special Tools
Test
27 - 145 9823/1650-1 27 - 145

27 - Driveline
Disassemble
Figure 565.
M
N
P J
K
L
Q
G
B
A

C Taper roller bearing 2 D Circlip 1
E Pressure plate F Shim (if installed)
G Friction plates H Counter plates
J Circlip 2 K Spring retaining plate
L Spring M Oil baffle
27 - 146 9823/1650-1 27 - 146

27 - Driveline
N Piston P O-ring 1 (Piston)

Q O-ring 2 (Shaft)
1. Carefully remove the piston ring seals. 10.1. Note: If the piston does not loosen, then
hand pump air down the shaft oil inlet hole.
1.1. Note: If the piston ring seals are excessively
worn then check for burrs or damage on the Special Tool: Hand Pump Pressure Test
shaft grooves. If necessary remove burrs (Qty.: 1)
with a fine grade abrasion paper and oil. Figure 567.
2. Remove the taper roller bearing 1 with a suitable
puller and press.
2.1. Note: This bearing would not normally
be removed unless it was damaged. It
is permissible to use a standard bearing
puller, although damage to the bearing cage
may be incurred which will require a new
bearing.
3. Remove the taper roller bearing 2 from the
opposite of the shaft.
4. Remove the retaining circlip 1 of the friction and
counter plates.
5. Remove the pressure end plate and shim if
installed. 11. Remove the piston.
6. Remove the friction plates and counter plates. 12. Remove and discard the piston O-ring 1.
6.1. Keep them together in sets, do not mix the 13. Remove and discard the shaft O-ring 2.
Assemble
spring and then remove the circlip 2. 2. Install the new O-ring 2 onto the shaft.
Figure 566. 3. Lubricate the piston with oil and press fully into
that the spring is positioned properly in the piston.
plate.
7.1. Continue to install alternate counter and
8. Install the pressure end plate. Make sure that the
chamfered face of the pressure end plate faces
8. Lift off the spring retaining plate. the clutch pack.
9. Remove the spring and oil baffle. 9. Make sure the teeth are not aligned with the
10. Turn the assembly over and knock the clutch lubrication slots in the housing.
shaft on a piece of aluminium (or wood) to loosen 10. Do not install the shim at this stage.
the piston.
27 - 147 9823/1650-1 27 - 147

27 - Driveline
11. Install the friction and counter plate retaining 6.0mm (0.23in) or 6.5mm (0.25in) thick pressure
circlip 1. end plate, with either a shim or an extra counter
12. With a DTI (Dial Test Indicator) measure the end pressure end plate.
float of the pressure end plate. The value should
be within the specified range. 14. Use an airline to check the operation of the
Length/Dimension/Distance: 1.9 –2.5 mm clutch.
Figure 568. 15. Apply gearbox oil to the taper roller bearings 1
and 2.
16. Install the bearings onto the shaft.
(For: PS764, PS766)

Special Tools
Test
The illustration shows a main shaft assembly for a 6

speed gearbox. The main shaft assembly for 4 speed
gearboxes has some small differences. Procedures
13. If it is necessary to adjust the end float to bring it are applicable for both 4 and 6 speed variants.
27 - 148 9823/1650-1 27 - 148

27 - Driveline
Disassemble
Figure 569.
D
C
L
B M1
N
S
P
A Q
V R
T
M2
J
E
F
G
H

C Gear 1 D Gear 2
E Taper roller bearing 2 F Circlip 1
G Pressure end plate H Shim
J Friction plate K Counter plate
L Circlip 2 M1 Spring retaining plate (6 speed gearbox)
M2 Spring retaining plate (4 speed gearbox) N Spring
27 - 149 9823/1650-1 27 - 149

27 - Driveline
P Oil baffle Q Piston

R Piston O-ring S Shaft O-ring
T Circlip 3 U Clutch housing
V O-ring 1
1. Carefully remove the piston ring seals. 11. Turn the assembly over and knock the clutch
shaft on a piece of aluminium (or wood) to loosen
1.1. If the piston ring seals are excessively worn the piston.
then check for burrs or damage on shaft
grooves. If necessary remove burrs with a 11.1. If the piston does not loosen, then hand
fine grade abrasion paper and oil. pump air down the shaft oil inlet hole.
2. Use a puller or press to remove the taper roller Special Tool: Hand Pump Pressure Test
bearing 1. (Qty.: 1)
3. Remove gear 1 and gear 2. Before removal make Figure 571.

a record of the orientation of the gears.
4. From the opposite end of the shaft remove the
taper roller bearing 2 with a suitable puller.
5. Remove the circlip 1 that retains the friction and
counter plates.
6. Remove the pressure end plate and the shims (If
applicable).
7. Remove the friction plates and counter plates.
7.1. Keep them together in sets, do not mix the

considerable force. Make sure you take care to 12. Remove the piston.
13. Remove and discard the piston O-ring.
14. Remove and discard the shaft O-ring.
15. Remove the circlip 3 and the remove the clutch
spring and remove the circlip 2.
housing from the shaft.
Figure 570.
16. Remove and discard the O-ring 1.
Assemble
1. Install the new O-ring 1.
2. Press the clutch housing onto the shaft spline
and install the circlip 3.
3. Install the new piston and shaft O-rings.
that the spring seats in the piston correctly.
6. Install the spring retaining plate. The 4 speed
9. Remove the spring retaining plate. The 4 speed transmissions have a different shaped spring
transmissions have a different shaped spring retaining plate installed.
retaining plate installed.
10. Remove the spring and oil baffle. install the circlip 2.
27 - 150 9823/1650-1 27 - 150

27 - Driveline

plate.
9. Install the pressure end plate. Make sure that the
the clutch pack.
lubrication slots in the housing.
circlip 1.
13. Use a DTI to measure the end float of the
pressure end plate. The value should be within
Figure 572.
14. If it is necessary to adjust the end float to bring it

6.0mm (0.23in) or 6.5mm (0.25in) thick pressure
end plate, with either a shim or an extra counter
pressure end plate.
clutch.
16. Apply gearbox oil onto the taper roller bearing 2
and press the bearing onto the shaft.
17. At the opposite end of the shaft press gear 1 and
gear 2 onto the shaft spline.
18. Make sure that the gears are installed in their
correct orientation.
19. Apply gearbox oil onto the taper roller bearing 1
and press the bearing onto the shaft.
27 - 151 9823/1650-1 27 - 151

27 - Driveline
10 - Clutch - 6 Speed
10 - Clutch - 6 Speed Introduction

Check (Condition) ........................................ 27-155
Disassemble and Assemble ........................ 27-156 Each gear on the gearbox has an associated clutch

shaft.

27 - 152 9823/1650-1 27 - 152

27 - Driveline
Figure 573.
AA
C N
Q
P
B
A
R
S
U
V
A
D
F
G
H
L
J
M
E
K
A Piston ring seal B Taper roller bearing

C Gear 1 D Clutch end bearing
E Splined hub F Thick thrust washer 1
G Thrust bearing 1 H Thin thrust washer 1
J Needle roller bearing K Thin thrust washer 2
27 - 153 9823/1650-1 27 - 153

27 - Driveline
L Thrust bearing 2 M Thick thrust washer 2

N Circlip 1 P Pressure end plate
Q Shim R Friction plates
S Counter plates T Disc spring
U Circlip 2 V Spring retaining plate
W Spring X Oil baffle
Y Piston Z Piston O-ring
AA Shaft O-ring
27 - 154 9823/1650-1 27 - 154

27 - Driveline
Check (Condition)
Do a visual check of the friction and counter plates:
Counter Plates
1. Counter plates- light scoring or polishing is
permissible, plates that are not flat, worn or
heavily marked or scored must be replaced with
a new one.
Friction Plates
one.

27 - 155 9823/1650-1 27 - 155

27 - Driveline
Disassembly 11. Remove the friction plates and the counter

plates. Keep them together in a set.
1. Carefully remove the piston ring seals from each
end of the shaft. 12. Do not mix the plates with those from other
clutches assemblies.
2. If the piston ring seals are excessively worn
then check for burrs or damage on the shaft 13. Remove the disc spring.
grooves. If necessary remove burrs with a fine
grade abrasion paper and oil. 14. Put the clutch assembly in a suitable press to
compress the piston spring, then remove the
3. Use a collet tool to push and remove the taper circlip 2.
roller bearing.
15. Lift off the spring retaining plate.
4. Remove the gear and make a note of, in which
orientation the gear is installed. 16. Remove the spring and the oil baffle.
5. Use a puller to remove the clutch end bearing 17. Turn the assembly over and hit the clutch shaft
from the opposite end. gently on a piece of aluminium (or wooden) block
to loosen the piston.
6. Remove the gear and the splined hub together
with the thick thrust washer 1, thin thrust washer 18. If the piston does not loosen when you hit the
1 and the thrust bearing 1. clutch shaft then hand pump air down the shaft
oil inlet hole.
7. Remove the needle roller bearing.
19. Remove the piston.
8. Remove the thin thrust washer 2, thrust bearing
2 and the thick thrust washer 2. 20. Remove the piston O-ring and the shaft O-ring.
9. Remove the friction and the counter plate Before you assemble the clutch assembly check
retaining circlip 1. the condition of the clutch assembly. Refer to
Semi- Automatic Gearbox, Clutch- 6 Speed, Check
10. If installed, remove the pressure end plate and Condition (PIL 27-06-10).
shims.
27 - 156 9823/1650-1 27 - 156

27 - Driveline
Figure 574.
AA
C N
Q
P
B
A
R
S
U
V
A
D
F
G
H
L
J
M
E
K
A Piston ring seal B Tapper roller bearing

C Gear 1 D Clutch end bearing
E Splined hub F Thick thrust washer 1
G Thrust bearing 1 H Thin thrust washer 1
J Needle roller bearing K Thin thrust washer 2
L Thrust bearing 2 M Thick thrust washer 2
N Circlip 1 P Pressure end plate
Q Shim R Friction plates
27 - 157 9823/1650-1 27 - 157

27 - Driveline
S Counter plates T Disc spring

U Circlip 2 V Spring retaining plate
W Spring X Oil baffle
Y Piston Z Piston O-ring
AA Shaft O-ring
27 - 158 9823/1650-1 27 - 158

27 - Driveline
Assembly 16. Use an air line to check the operation of the

clutch.
1. Install both the piston O-ring and the shaft O-ring.
17. Install the thick thrust washer 2, thrust bearing 2,
2. Lubricate the piston with hydraulic oil and push and the thin thrust washer 2.
fully into the bore of the clutch housing.
18. Install the needle roller bearing.
3. Install the oil baffle and the piston spring. Make
sure that the spring seats in the piston. 19. Carefully use a thin rod (or screwdriver) to align
the teeth of the clutch plates.
20. Install the gear and splined hub.
5. Compress the spring and install the circlip 2.
21. Install the thin thrust washer 1, thrust bearing 1
6. If applicable, install the disc spring assembly. and the thick thrust washer 1.
7. Make sure that the disc spring is installed with 22. Smear the clutch end bearing with gearbox oil
the teeth facing towards the clutch pack. and push the bearing onto the shaft.
8. Make sure that the teeth are not aligned with the 23. At the opposite end, push the gear onto the shaft
lubrication slots in the housing. spline. Make sure that the gear is installed in the
correct orientation.
9. Install the counter plates and friction plates
alternately, starting with a counter plate and finish 24. Smear the tapper roller bearing with gearbox oil
with a friction plate. and push the bearing onto the shaft.
10. Install the pressure end plate. Do not install the 25. Install new piston ring seals at each end of the
shims at this stage. shaft.
11. Make sure that the chamfered face is installed, Refer to: PIL 27-06-45.
facing the clutch pack.
13. Install the clutch friction and counter plate
retaining circlip 1.
14. Use a DTI (Dial Test Indicator) to measure the
end float of the pressure end plate and it should
be within the specified limit.
Figure 575.
15. If it is necessary to adjust the end float to bring

it within specified limit mentioned in step 14,
Install a 6.0mm (0.23in) or 6.5mm (0.25in) thick
pressure end plate together with a shim or an
extra counter plate, between the retaining circlip
and the pressure end plate.
27 - 159 9823/1650-1 27 - 159

27 - Driveline
11 - Clutch - Forward (Input)
11 - Clutch - Forward (Input) Introduction

Clean ........................................................... 27-165
Check (Condition) ........................................ 27-165 Each gear on the gearbox has an associated clutch
shaft.

27 - 160 9823/1650-1 27 - 160

27 - Driveline
For: PS750 MK4 ..................... Page 27-161

For: PS764, PS766 ................. Page 27-163
(For: PS750 MK4)
Figure 576.
L
J X Y
W
C E
A
P
H
K
A
G F V
D U
T R
S
B
R
N
S
Y T
U H
V J
W P
Q
M
X
L
M
N
Q
Z
AB
AA
AC
G
AD
AE
27 - 161 9823/1650-1 27 - 161

27 - Driveline
Table 288.
Item Description
A Piston ring seal 1
B Clutch end bearing
C Gear
D Needle roller thrust bearing 1
E Thrust washer 1
F Gear and splined hub 1
G Needle roller bearing 2
H Thrust washer 2
J Needle roller bearing thrust washer
K Thrust washer 3
L Friction/counter plates retaining circlip
M Shim
N Pressure end plate
P Friction plates
Q Counter plates
R Disc spring assembly
S Circlip 1
T Spring retaining plate
U Spring
V Oil baffle
W Piston
X O-ring 1
Y O-ring 2
Z Piston seal rings 2
AA Bearing 1
AB Thrust washer 4
AC Needle roller bearing 3
AD Thrust washer 5
AE Gear and splined hub 2
27 - 162 9823/1650-1 27 - 162

27 - Driveline
(For: PS764, PS766)
Figure 577.
L
J X Y
W
C E
A
P
H
A K
G F V
D U
T R
S
A B
R
N
S
Y T
U
V H
J
Q P
W
M
L
M
N
Q Z
AB
AA
AC
AF
AD
AE
Item Description
Table 289. C Gear
Item Description D Thrust bearing 1
A Piston ring seal 1 (For- E Thin thrust washer 1
ward and reverse clutch F Gear and splined hub 1
only) G Needle roller bearing 1
B Clutch end bearing 1
27 - 163 9823/1650-1 27 - 163

27 - Driveline
Item Description
H Thick thrust washer 1
J Thrust bearing 2
K Thin thrust washer 2
L Friction and counter
plate retaining circlip
M Shim
P Friction plates
Q Counter plates
R Disc spring assembly
S Circlip 2
T Spring retaining plate
U Spring
V Oil baffle
W Piston
X Piston O-ring
Y Shaft O-ring
Z Piston ring seal 2
AA Clutch end bearing 2
AB Thick thrust washer 2
AC Thrust bearing 3
AD Thin thrust washer 3
AF Needle roller bearing 2
27 - 164 9823/1650-1 27 - 164

27 - Driveline

Consumables
Description Part No. Size Carry out a visual inspection of the friction and
Surface Cleaning Fluid 4103/1204 1L counter plates:
1. Carefully remove all traces of gasket or gasket Counter plates

compound from the front and rear case mating
faces. 1. Light scoring or polishing is permissible, plates
that are not flat, worn or heavily marked or scored
1.1. Use a gasket removal product such as must be replaced with a new set.
Loctite Chisel when you remove the gasket
compound. Friction plates
1.2. Make sure that the mating faces are not 1. The cross hatching should be clearly visible,
damaged. plates that are not flat, have friction material
1.3. Clean the mating faces with a fine damage or scoring must be replaced with a new
carborundum paper. set.
1.4. Use a solvent cleaner and a clean cloth to 2. DO NOT mix old and new plates, if a plate is
finally remove all traces of oil or debris. damaged or worn install a complete new set.
Consumable: Surface Cleaning Fluid 3. Needle roller bearings should slide into position
2. Use a suitable degreasing agent to clean the freely, do not bend or distort the cage to install. If
inside of the case. the cage has been distorted install new bearings.
4. Take care when handling disc springs to avoid
marking or damage, which could result in stress
cracking. If in doubt install a new disc spring.
27 - 165 9823/1650-1 27 - 165

27 - Driveline
Remove and Install
The layshaft clutch, 2WD / 4WD clutch, reverse

clutch, mainshaft clutch and forward / input clutch are
all part of the mainshaft assembly.

27 - 166 9823/1650-1 27 - 166

27 - Driveline
For: PS750 MK4 ..................... Page 27-167

For: PS764, PS766 ................. Page 27-171
(For: PS750 MK4)

Special Tools Description Part No. Qty.
Description Part No. Qty. Spring Compressor 892/00916 1
Hand Pump Pressure 892/00223 1 Tool
Test
27 - 167 9823/1650-1 27 - 167

27 - Driveline
Disassemble
Figure 578.
H
X
K Y
W
L
E
P
J
B F
G
V
A D U
T
S
C
R
S
N
R
Y T
U
V
H
W P J
Q
M
X
L
M
N
Z
Q
AA
AC
AF
AE
AB
AD
A Piston ring seals 1 B Clutch end bearing 1

C Gear D Thrust bearing 1
E Thin thrust washer 1 F Gear and splined hub 1
G Needle roller bearing 1 H Thrust bearing 2
27 - 168 9823/1650-1 27 - 168

27 - Driveline
J Thick thrust washer 1 K Thin thrust washer 2

L Circlip 1 M Pressure end plate
N Shim (If installed) P Friction plates
Q Counter plates R Disc spring
S Circlip 2 T Spring retaining plate
U Spring V Oil baffle
W Piston X O-ring 1 (Piston)
Y O-ring 2 (Shaft) Z Piston ring seals 2
AA Clutch end bearing 2 AB Thrust bearing 3
AC Thick thrust washer 2 AD Thin thrust washer 3
AE Gear and splined hub 2 AF Needle roller bearing 2
1. Carefully remove the piston ring seals1. Figure 579.

grooves. If necessary remove burrs with a
2. Remove the clutch end bearing 1 and gear with
a suitable puller and press.
3. Remove the thrust bearing 1 and thin thrust
washer 1.
4. Remove the gear and splined hub 1 assembly
with the needle roller bearing 1.
5. Remove the thrust bearing 2, thick thrust washer
1 and thin thrust washer 2.
10.2. If a press is not available use the spring
6. Remove the retaining circlip 1 of the friction and compressor tool A (892/00916) to remove
counter plates. the circlip 2.
7. Remove the pressure end plate and shim (if Special Tool: Spring Compressor Tool
installed). (Qty.: 1)
8. Remove the friction plates and counter plates. 11. Lift off the spring retaining plate.
8.1. Keep them together in sets, do not mix the 12. Remove the spring and oil baffle.
9. Remove the disc spring assembly shaft on a piece of aluminium (or wood) to loosen
the piston.
considerable force. Make sure you take care to 13.1. If the piston does not loosen, then hand
avoid damage or injury. pump air down the shaft oil inlet hole.
10. Put the clutch assembly in a suitable press. (Qty.: 1)
spring and then remove the circlip 2.
27 - 169 9823/1650-1 27 - 169

27 - Driveline
Figure 580. 8. Install one counter plate followed by one friction

plate.
9. Install the pressure end plate. Make sure the
the clutch pack.
circlip 1.
14. Remove the piston. 13. Use a DTI (Dial Test Indicator) to measure the
end float of the pressure end plate. The value
15. Remove and discard the piston O-ring 1. should be within the specified range.
16. Remove and discard the shaft O-ring 2. Length/Dimension/Distance: 1.9 –2.5 mm
17. To disassemble the opposite clutch, carefully Figure 581.

remove the piston ring seals 2.
18. Remove the bearing 2 with a suitable puller.
21. Do the steps 5 to 16 to disassemble the clutch
assembly.
Assemble
14. If it is necessary to adjust the end float to bring it
1. Install the new O-ring 1 onto the piston. within tolerance, there is a choice of installing a
6.0mm (0.23in) or 6.5mm (0.25in) thick pressure
2. Install the new O-ring 2 onto the shaft. end plate, with either a shim or an extra counter
3. Lubricate the piston with oil and press fully into plate between the retaining circlip 1 and the
the bore of the clutch housing. pressure end plate.
4. Install the oil baffle and piston spring. Make sure 15. Use an airline to check the operation of the
that the spring is positioned properly in the piston. clutch.
5. Install the spring retaining plate. 16. Install the thick washer 1, thin washer 2, and the
thrust bearing 2.
CAUTION! The spring (or springs) apply 17. Carefully align the teeth of the clutch plates using
considerable force. Make sure you take care to a thin rod (or screwdriver) and install the gear and
avoid damage or injury. splined hub 1.
6. Compress the spring with a cut away tube and 18. Install the needle roller bearing 1.
19. Install the thrust bearing 1 and thin thrust washer
7. Install the disc spring assembly. 1.
7.1. Make sure that the disc spring is installed 20. Apply gearbox oil on the clutch end bearing 1 and
with the teeth towards the clutch pack. install the gear and bearing 1 onto the shaft.
7.2. Make sure that the teeth are not aligned with
the lubrication slots in the housing. 21. Install the new piston ring seals 1.
27 - 170 9823/1650-1 27 - 170

27 - Driveline
22. To assemble the opposite clutch do the steps 1 8.1. Keep them together in sets, do not mix the
to 19. plates with those from other clutches.
23. Carefully align the teeth of the clutch plates using 9. If installed, remove the disc spring assembly.
a thin rod (or screwdriver) and install the gear and
splined hub 2. 10. Put the clutch assembly in a suitable press.
24. Install the needle roller bearing 2. 10.1. With a cut away tube compress the piston
spring and then remove the circlip 2.
25. Install the thrust bearing 3, thick washer 2, and
thin washer 3. Figure 582.

install the gear and bearing 2 onto the shaft.
27. Install the new piston ring seals 2.
(For: PS764, PS766)

Special Tools
Test
This procedure is the same for the input and reverse

clutch assemblies. If there are any differences it will
be identified in the procedure. 11. Lift off the spring retaining plate.
Disassembly 12. Remove the spring and the oil baffle.
The illustrations show a reverse clutch assembly for 13. Turn the assembly over and knock the clutch
a 6 speed gearbox. 4 speed gearbox clutches have shaft on a piece of aluminium (or wood) to loosen
fewer friction and counter plates. Procedures are the piston.
applicable for both 4 and 6 speed variants.
13.1. If the piston does not loosen, then hand
1. Carefully remove the piston ring seals 1. pump air down the shaft oil inlet hole.
1.1. If the piston ring seals are excessively worn (Qty.: 1)
grooves. If necessary remove burrs with a Figure 583.
1.2. The input shaft does not have piston ring
seals installed at this end of the shaft.
2. Use a suitable puller and press to remove the
clutch end bearing 1 and the gear.
3. Remove the thrust bearing 1 and thin thrust
washer 1.
6. Remove the friction and counter plates retaining
circlip. 14. Remove the piston.
7. If installed, remove the pressure end plate and 15. Remove and discard the piston O-ring 1.
shim. 16. Remove and discard the shaft O-ring 2.
8. Remove the friction plates and counter plates.
27 - 171 9823/1650-1 27 - 171

27 - Driveline
17. To disassemble the opposite clutch, carefully 19. Remove the thrust bearing 3, thick thrust washer
remove the piston ring seals 2. 2 and thin thrust washer 3.
17.1. The input shaft has four piston ring seals 20. Remove the gear and splined hub 2 assembly
installed at this end of the shaft. with the needle roller bearing 2.
18. Loosen the clutch end bearing 2 and use a 21. Do the steps 5 to 16 to disassemble the opposite
suitable puller to remove it. side clutch assembly.
Figure 584.
L
J X Y
W
C E
A
P
H
A K
G F V
D U
T R
S
A B
R
N
S
Y T
U
V H
J
Q P
W
M
L
M
N
Q Z
AB
AA
AC
AF
AD
AE
27 - 172 9823/1650-1 27 - 172

27 - Driveline
7.1. Make sure that the disc spring is installed

Table 290. with the teeth towards the clutch pack.
Item Description 7.2. Make sure that the teeth are not aligned with
A Piston ring seal1 (For- the lubrication slots in the housing.
ward and reverse clutch
only) 7.3. In PS760 variant no disc spring is installed.
B Clutch end bearing 1 8. Install one counter plate followed by one friction
C Gear plate.
D Thrust bearing 1 8.1. Continue to install alternate counter and
E Thin thrust washer 1 friction plates, finishing with a friction plate.
F Gear and splined hub 1
G Needle roller bearing 1 9. Install the pressure end plate. Make sure the
H Thick thrust washer 1 the clutch pack.
J Thrust bearing 2
K Thin thrust washer 2 10. Make sure that the teeth are not aligned with the
L Friction and counter
plate retaining circlip 11. Do not install the shim at this stage.
M Shim
circlip.
P Friction plates
Q Counter plates 13. Use a DTI to measure the end float of the
R Disc spring assembly pressure end plate. For PS760 variant the value
should be within the specified range.
S Circlip 1
T Spring retaining plate Dimension: 1.9 –2.5 mm
U Spring Figure 585.
V Oil baffle
W Piston
X Piston O-ring
Y Shaft O-ring
Z Piston ring seal 2
AA Clutch end bearing 2
AB Thick thrust washer 2
AC Thrust bearing 3
AD Thin thrust washer 3
AF Needle roller bearing 2
14. If it is necessary to adjust the end float to
Assembly bring it within tolerance, then you can choose
either 6.0mm (0.23in) or 6.5mm (0.25in) thick
1. Install the new piston O-ring onto the piston. pressure end plate, with either a shim or an extra
counter plate between the retaining circlip and
2. Install the new shaft O-ring onto the shaft. the pressure end plate.
3. Lubricate the piston with oil and push fully into 15. Use an airline to check the operation of the
the bore of the clutch housing. clutch.
4. Install the oil baffle and the piston spring. Make 16. Install the thick thrust washer 1, thin thrust
sure that the spring is positioned properly in the washer 2, and the thrust bearing 2.
piston.
17. Use a thin rod (or screwdriver) to carefully align
5. Install the spring retaining plate. the teeth of the clutch plates and install the gear
6. Compress the spring with a cut away tube and and splined hub 1.
secure with circlip 2. 18. Install the needle roller bearing 1.
7. Install the disc spring assembly.
27 - 173 9823/1650-1 27 - 173

27 - Driveline
19. Install the thrust bearing 1 and thin thrust washer

1.
20. Apply gearbox oil on the clutch end bearing then
push the gear and the clutch end bearing 1 onto
the shaft.
21. Install the piston ring seals 1.
21.1. The input shaft does not have piston ring
seals installed at this end of the shaft.
22. To assemble the opposite side clutch do the
steps 1 to 15 again.
23. Use a thin rod (or screwdriver) to carefully align
the teeth of the clutch plates and install the gear
and splined hub 2.
24. Install the needle roller bearing 2.
25. Install the thrust bearing 3, thick thrust washer 2,
and thin thrust washer 3.
26. Apply gearbox oil on the clutch end bearing then
push the gear and the clutch end bearing 2 onto
the shaft.
27. Install the piston ring seals 2.
27.1. The input shaft has four piston ring seals
installed at this end of the shaft.
27 - 174 9823/1650-1 27 - 174

27 - Driveline
15 - Solenoid Control Valve
15 - Solenoid Control Valve Introduction

Introduction .................................................. 27-175 The solenoid control valves provides the switching
Check (Condition) ........................................ 27-176 for forward drive and reverse drive to select the
Remove and Install ..................................... 27-176 direction of travel.
On some transmission systems the solenoid control

valves are also used for gear selection and 2WD
(Two Wheel Drive) / 4WD (Four Wheel Drive)
selection.
27 - 175 9823/1650-1 27 - 175

27 - Driveline

For: PS750 MK4 ..................... Page 27-176
If damage to any component or distortion of the
For: PS764, PS766 ................. Page 27-178
spool is evident the complete valve assembly must
be renewed. Great care should be taken when
dismantling and assembling the valve to avoid the (For: PS750 MK4)
following:
Consumables
• Contamination Description Part No. Size
• Damage to spools JCB Transmission Fluid 4000/2601 5L
• Damage to seal grooves EP SAE 30 4000/2605 20 L
4000/2603 200 L
Any of the above may result in possible problems
with the operation of the valve.
There are two types of solenoid installed.
Solenoid valve - nut retained - this has a nut securing

the solenoid coil to the stem.
Solenoid valve - bolt retained - the solenoid is

enclosed in a metal casing and the casing is bolted
to the transmission housing.
Solenoid Valve - Nut retained

The procedure for the solenoid control valves is
the same. The following procedure is for one valve.
The gearbox shown has three solenoid valves, other
gearbox variants may contain a different quantity of
valves.
Remove
1. Put a label on the harness connector to help
installation.
2. Disconnect the electrical harness connector (if
installed) at the solenoid coil 1 and coil 2.
3. Record the position of the solenoid coil electrical
connectors on the valve stem.
4. Clean the area around the solenoid valves. Do
not allow particles of grit to fall into the gearbox..
5. Remove the nut, coil 1, spacer and coil 2. Make
sure that you record the orientation of the spacer
for correct installation.
6. Clean the area around the valve stem and the
gearbox case to prevent contamination of the
gearbox. Plug all the open ports and hoses to
prevent contamination.
7. Remove the valve stem from the gearbox case.
27 - 176 9823/1650-1 27 - 176

27 - Driveline
Figure 586. gauze is defective, replace the valve with a new

one.
4. Inspect the O-ring seals for damage. Refer to
Check Condition (PIL 27-06-15).
5. Put some clean gearbox oil on the O-ring seals.
Consumable: JCB Transmission Fluid EP SAE
30
6. Use an extended socket to tighten the valve stem
to the correct torque value. Refer to Table 291.
7. Install the solenoid coils and spacer in the correct
orientation.
8. Put the solenoid coil electrical connectors in the
correct position on the valve stem.
9. Tighten the nut to the correct torque value. Refer
to Table 291.
10. Connect the electrical harness connectors at the
solenoid coils in the correct positions.
Solenoid Valve - Bolt retained

Remove
1. Put a label on the harness connector to help
installation.
2. Disconnect the electrical harness connector.
3. Clean the area around the solenoid valve. Do not
allow particles of grit to fall into the gearbox.
4. Remove the bolts and valve from the gearbox
housing. Make sure that you record the
orientation of the solenoid for correct installation.
A Valve 1 4.1. Take care not to grip the unit by its electrical
B Valve 2 connector block. The connector block is not
C Valve 3 designed as a leverage point.
D Solenoid coil 1 4.2. Slowly rotate and at the same time pull
E Solenoid coil 2 the valve to remove it from the gearbox
F Nut housing.
G Spacer
H O-ring 5. Plug all the open ports and hoses to prevent
J Valve stem contamination.
Install
steps.
2. Inspect the gauze filters (if installed) on the valve
stem for contamination and damage.
3. Do not touch the gauze. Remove contamination
by rinsing the valve stem in clean gearbox oil.
If this fails to remove the contamination or the
27 - 177 9823/1650-1 27 - 177

27 - Driveline
Figure 587. Table 291. Torque Values

Item Nm
L F 6
J 27
K L 6
M
(For: PS764, PS766)
Remove
1. Put tags on the electrical harness connectors.
L
2. Disconnect the connectors from the solenoids.
3. Clean the area around the solenoid valve block.
Do not allow particles of dirt to fall into the
gearbox.
4. Remove the socket head cap screws along with
the washers and lift off the valve block assembly.
5. Do not use a screwdriver to lift the valve block,
the sealing faces will get damaged.
5.1. If it is difficult to remove the valve block,
lightly tap the manifold block with a soft
faced hammer.
N 6. If any of the individual solenoid valve cartridges
are to be removed, take care not to grip the unit
N by its electrical connector block. The connector
block is not designed as a leverage point.
N
7. Remove and discard the valve block sealing
K Electrical harness connector gasket.
L Retaining bolts
M Valve 7.1. The gasket may disintegrate on removal,
N O-ring seals make sure that all traces are removed and
discarded.
Install
steps.
2. Replace the O-ring seals.
3. Put some clean gearbox oil on the O-ring seals.
Consumable: JCB Transmission Fluid EP SAE
30
4. Install the solenoid in the correct orientation.
Refer to Table 291.
27 - 178 9823/1650-1 27 - 178

27 - Driveline
Figure 588. 6. If any of the individual solenoid valve cartridges

are to be replaced, take care not to grip the unit
by its electrical connector block. The connector
block is not designed as a leverage point.
B 7. Install the electrical harness connectors to the
solenoid valve cartridge connector block.
A Table 292. Torque Values
Item Nm
A 35
D
C
A Capscrews
B Solenoid valve block
C Valve cartridge
D Valve cartridge connector block
Install
1. Install two guide studs at the valve interface on
the front case.
2. Install a new valve block sealing gasket. Care is
needed as the gasket is thin.
Figure 589.
A
177
/10
813
E Gasket
3. Put the valve block in position against the front
case.
4. Install the socket head capscrews and the
washers.
5. Progressively tighten the screws to the correct
torque value.
27 - 179 9823/1650-1 27 - 179

27 - Driveline
18 - Pressure Relief Valve
18 - Pressure Relief Valve
Introduction
The pressure relief valve is a type of valve used to

control or limit the pressure which can build up due
to a fault in the system.
The pressure is relieved by allowing the pressurised

fluid to flow from an auxiliary passage out of the
system. The relief valve is designed to open at
a predetermined set pressure to protect pressure
vessels from being subjected to pressures that
exceed their design limits.
27 - 180 9823/1650-1 27 - 180

27 - Driveline
21 - Pressure Maintenance Valve (PMV)
21 - Pressure Maintenance Valve

(PMV)
Remove and Install
2. Do not allow particles of grit to fall into the

(For: PS750 MK4) gearbox.
3. Remove the plug then the sealing washer, the
Remove spring and the valve spool.
1. Clean the area around the valve and the gearbox
case.
Figure 590.
B
C
D
A Plug B Sealing washer

C Spring D Valve spool
27 - 181 9823/1650-1 27 - 181

27 - Driveline
21 - Pressure Maintenance Valve (PMV)
Install
At the time of installation do the following step.
1. Tighten the plug to the correct torque value.

Item Description Nm
A Plug 56
27 - 182 9823/1650-1 27 - 182

27 - Driveline
24 - Oil Pump
24 - Oil Pump Check (Condition)

Check (Condition) ........................................ 27-183
(For: PS750 MK4, PS764, PS766)
Check (Condition)
A pump which is damaged or worn can cause
damage to the gearbox.
1. Remove the screws and then remove the pump

body.
2. Carefully check for any signs of wear or damage
on the gear teeth, white metal bearing and gear
mating faces. If any signs of wear or damage is
visible then you must replace the pump with a
new one.
3. Carefully remove and discard the oil seal.
Figure 591.
A
B
C
A Screw
B Oil seal
C Pump housing
4. Make sure that the seal housing is not damaged.
5. Install a new seal.
6. Install the seal the correct way around. Push the
seal flush with the front of the housing.
7. Assemble the pump again.
8. Make sure that the pump and the mating face on
the gearbox front cover is clean and free from
surface damage.
27 - 183 9823/1650-1 27 - 183

27 - Driveline
24 - Oil Pump
Remove and Install Consumable: JCB Threadlocker and Sealer

(Medium Strength)
5. Install the bolts together with the new sealing
(For: PS750 MK4, PS764, PS766) washers.
Consumables
Description Part No. Size 6. Progressively tighten the bolts to the correct
torque value.
and Sealer (Medium 4101/0251 0.05 L 7. Put some clean, new, oil into the pump at the
Strength) location shown.

Item Nm
1. Clean the area around the pump. Do not allow
A 28
any dirt or contamination to fall into the gearbox.
2. Remove the fixing bolts and lift the pump
assembly off the input shaft.
3. Remove the sealing washers and the pump
sealing ring.
4. Discard the washers and sealing ring.
Figure 592.
B A
F
D
E
A Bolt
B Oil pump
C Sealing washer
D Input shaft
E Sealing ring
F Oil filling location
Install
1. If the existing pump is to be installed then inspect
the pump for damage.
2. Install a new sealing ring.
3. Install the pump over the input shaft. Make sure
that the bolt holes are aligned.
4. Apply sealant to the threads of the bolts.
27 - 184 9823/1650-1 27 - 184

27 - Driveline
27 - Speed Sensor
27 - Speed Sensor Introduction

Introduction .................................................. 27-185 The sensor sends a varying frequency signal to
Component Identification ............................. 27-186 the Transmission ECU to determine the current
Operation ..................................................... 27-189 rotational speed of the input shaft or torque
Diagram ....................................................... 27-190 converter. The ECU uses the input shaft speed to
determine the slippage across the torque converter
Remove and Install ..................................... 27-192 and potentially to determine the rate of slippage
across the clutches. This information is vital to
regulate the application of the torque converter lock-
up clutch smoothly and effectively.
27 - 185 9823/1650-1 27 - 185

27 - Driveline
27 - Speed Sensor
For: PS750 MK4 ..................... Page 27-186 (For: PS750 MK4)

For: PS764, PS766 ................. Page 27-187
Figure 593. Location
A
A Ground speed sensor
Wires and Connectors
Figure 594. Ground Speed Sensor
6 1
5 2
4 3
1 Signal A - power (red) 2 Signal A - earth (black)

3 Signal A - output (white) 4 Signal B - power (orange)
5 Signal B- earth (brown) 6 Signal B - output (yellow)
27 - 186 9823/1650-1 27 - 186

27 - Driveline
27 - Speed Sensor
(For: PS764, PS766)
A Ground speed sensor B Input speed sensor
Figure 596. Ground Speed Sensor
6 1
5 2
4 3
1 Signal A - power (red) 2 Signal A - earth (black)

3 Signal A - output (white) 4 Signal B - power (orange)
5 Signal B- earth (brown) 6 Signal B - output (yellow)
27 - 187 9823/1650-1 27 - 187

27 - Driveline
27 - Speed Sensor
Figure 597. Input Speed Sensor
B A
A Earth B Power
C Signal output
27 - 188 9823/1650-1 27 - 188

27 - Driveline
27 - Speed Sensor
Operation
(For: PS750 MK4, PS764, PS766)

Machines with PS766 and PS750 transmission have
a Ground Speed Sensor and an Input Speed Sensor.
Machines with PS750 transmission only use the

Ground Speed Sensor.
Ground Speed Sensor Operation

The ground speed sensor is a magnetic induction
type. The sensor detects the passing of gear teeth as
the gear rotates inside the gearbox. The installation
ensures the correct air gap between the gear teeth.
When the gear rotation speed changes the frequency

of the output signal from the sensor changes.
The ground speed sensor installation senses the

rotation of the gearbox output gear.
The speed sensor incorporates two sensor elements

and a dual output signal to enable diagnosis if there
is a disagreement between the two sensor outputs.
Input Speed Sensor Operation

The input speed sensor is a magnetic induction type.
The sensor detects the passing of gear teeth as
the gear rotates inside the gearbox. The installation
ensures the correct air gap between the gear teeth.
When the gear rotation speed changes the frequency

of the output signal from the sensor changes.
The input speed sensor senses the rotation of the

gearbox input shaft via the reverse clutch driven
gear.
27 - 189 9823/1650-1 27 - 189

27 - Driveline
27 - Speed Sensor
Diagram
For: PS750 MK4 ..................... Page 27-190 3 Signal A - output (white)

For: PS764, PS766 ................. Page 27-191 4 Signal B - power (orange)
5 Signal B- earth (brown)
6 Signal B - output (yellow)
(For: PS750 MK4)
Figure 598. Ground Speed
Sensor Internal Schematic
1
5
R R 3
A 6
B 2
4
A Sensor element
B Diagnostic element
R Resistor
1 Signal A - power (red)
2 Signal A - earth (black)
Figure 599. Speed Sensor Connections
ECU J1
ECU J2
6
3 1
5 4 F
ECU J5
2
B +
A Hydraulic control ECU (Electronic Control Unit) B Ground speed sensor

F Fuse
27 - 190 9823/1650-1 27 - 190

27 - Driveline
27 - Speed Sensor
(For: PS764, PS766) 4 Signal B - power (orange)

5 Signal B- earth (brown)
Figure 600. Ground Speed 6 Signal B - output (yellow)
1 Figure 601. Input Speed
5
B
R
R R R
3 C
A 1
6
R
R
B 2
4 2
A
A Sensor element
B Diagnostic element
R Resistor
1 Signal A - power (red) A Earth
2 Signal A - earth (black) B Power
3 Signal A - output (white) C Signal output
R Resistor
1 Sensor element
2 Diagnostic element
Figure 602. Speed Sensor Connections
ECU
A
A
B
C
D
ECU J2
6
3 1
5 4 F
ECU J5
2
C +
B
A Transmission ECU B Hydraulic control ECU

C Ground speed sensor D Input speed sensor
F Fuse
27 - 191 9823/1650-1 27 - 191

27 - Driveline
27 - Speed Sensor
Remove and Install
For: PS750 Mk4, PS750 MK4 3. Do not allow particles of grit to fall into the
................................................. Page 27-192 gearbox.
For: PS764, PS766 ................. Page 27-193
4. Remove the screw 1.
(For: PS750 Mk4, PS750 MK4) 5. Remove the speed sensor 1 from the housing.
Speed sensors are installed depending on the Install

machine application. The gearbox has provision for
two speed sensors. 1. Installation is the opposite of the removal
procedure. At the time of installation do the
Speed sensor 1 following steps.
2. If the O-ring 1 is damaged replace it with a new
Remove one.
1. If connected, disconnect the speed sensor 3. Install the screw 1.
electrical connector.
4. Tighten the screw 1 to the correct torque value.
2. Clean the area around the speed sensor.
Figure 603.
B
A
G B
27 - 192 9823/1650-1 27 - 192

27 - Driveline
27 - Speed Sensor
5. Install the screw 2.
Table 295. 6. Tighten the screw 2 to the correct torque value.

Item Description Table 296. Torque Values
A Speed sensor 1
Item Description Nm
B Speed sensor 2
C Screw 1 28
C Screw 1
E Screw 2 12
D O-ring 1
E Screw 2
F O-ring 2 (For: PS764, PS766)
G Shims or spacers
Speed sensors are installed depending on the
Speed sensor 2 machine application. The gearbox has provision for
two speed sensors.
Remove
Speed sensor 1
1. If connected, disconnect the speed sensor
electrical connector. Remove
2. Clean the area around the speed sensor. 1. If connected, disconnect the speed sensor
gearbox. 2. Clean the area around the speed sensor.
4. Remove the screw 2. 3. Do not allow particles of grit to fall into the
gearbox.
5. Remove the speed sensor 2 from the housing.
4. Remove the screw 1.
6. If installed remove the shims or the spacers with
the sensor 2. 5. Remove the speed sensor 1 from the housing.
Install Install
1. Installation is the opposite of the removal 1. Installation is the opposite of the removal
procedure. At the time of installation do the procedure. At the time of installation do the
following steps. following steps.
2. If the O-ring 2 is damaged replace it with a new 2. If the O-ring 1 is damaged replace it with a new
one. one.
3. If the spacers or the shims were removed replace 3. Install the screw 1.
them correctly.
4. The speed sensor may be damaged or fail to
operate correctly if it is not at the correct distance
inside the housing.
27 - 193 9823/1650-1 27 - 193

27 - Driveline
27 - Speed Sensor
Figure 604.
B
A
G B

Table 297. gearbox.
Item Description 4. Remove the screw 2.
A Speed sensor 1 (Input
Speed) 5. Remove the speed sensor 2 from the housing.
B Speed sensor 2 (Ground
6. If installed remove the shims or the spacers with
Speed)
the sensor 2.
C Screw 1
D O-ring 1 Install
E Screw 2
1. Installation is the opposite of the removal
F O-ring 2
G Shims or spacers following steps.
Speed sensor 2 2. If the O-ring 2 is damaged replace it with a new

one.
Remove 3. If the spacers or the shims were removed replace
them correctly.
1. If connected, disconnect the speed sensor
2. Clean the area around the speed sensor.
27 - 194 9823/1650-1 27 - 194

27 - Driveline
27 - Speed Sensor
4. The speed sensor may be damaged or fail to

operate correctly if it is not at the correct distance
inside the housing.
5. Install the screw 2.

Item Description Nm
C Screw 1 28
E Screw 2 12
27 - 195 9823/1650-1 27 - 195

27 - Driveline
30 - Oil Pressure Sensor
30 - Oil Pressure Sensor Introduction

Introduction .................................................. 27-196 The transmission pressure sensor is a form of switch
Component Identification ............................. 27-197 that closes an electrical contact when a certain
Remove and Install ..................................... 27-198 set pressure has been reached on its input. The
switch may be designed to make contact either on a
pressure rise or on a pressure fall.
27 - 196 9823/1650-1 27 - 196

27 - Driveline
Component Identification (For: PS764, PS766)

For: PS750 MK4 ..................... Page 27-197 Figure 607. Location
For: PS764, PS766 ................. Page 27-197
A
(For: PS750 MK4)

A Transmission Oil Pressure Switch

Figure 606. Wires and Connectors
A B
2 1
A Instrument panel
B Transmission Oil Pressure Switch

A B
2 1
A Instrument panel
B Transmission Oil Pressure Switch
27 - 197 9823/1650-1 27 - 197

27 - Driveline

For: PS750 MK4 ..................... Page 27-198 1. Installation is the opposite of the removal
For: PS764, PS766 ................. Page 27-199
following steps.
(For: PS750 MK4) 2. The oil pressure switch is non serviceable. If it is

faulty or damaged, it must be replaced with new
Remove one.
1. Clean off all debris, dirt and grit from around the
pressure switch. 4. Tighten the pressure switch to the correct torque
value.
2. There must be no signs of debris, dirt or grit
inside the gearbox. Table 299. Torque Values
3. Remove the pressure switch and discard the Item Description Nm
sealing washer. A Pressure switch 16
4. Put caps on all the open ports of the gearbox.
Figure 609.
A Pressure switch
B Sealing washer
27 - 198 9823/1650-1 27 - 198

27 - Driveline
(For: PS764, PS766) 4. Disconnect the harness electrical connector from

the switch.
Remove 5. Remove the switch and discard the sealing
washer.
Figure 610.
A
Install
B
steps.
2. The switch is non serviceable. If it is faulty or
damaged, it must be replaced with new one.
4. Tighten the switch to the correct torque value.
Refer to Table 300.

Item Nm
A 10

B Seal
C Transmission Oil Pressure harness electrical
connector
switch.
inside the gearbox.
27 - 199 9823/1650-1 27 - 199

27 - Driveline
33 - Oil Temperature Sensor
33 - Oil Temperature Sensor Introduction

Introduction .................................................. 27-200 The transmission oil temperature sensor sends
Technical Data ............................................. 27-201 an analog signal to the instrument panel ECU
Component Identification ............................. 27-204 (Electronic Control Unit) to warn if the transmission
Remove and Install ..................................... 27-207 oil temperature is outside of specified limits.
The resistance of the sensor will change according

to the temperature of the oil - therefore the signal
to the ECU will change. The ECU will calculate the
resistance and the temperature that is sensed by the
sensor. For resistance and temperature values refer
to Technical Data (PIL 27-06-33).
If outside of the specified limits the instrument panel

ECU will broadcast a message on the machine
CAN (Controller Area Network)bus to other machine
ECUs and fault codes and displays will be triggered
to prevent damage to the transmission.
27 - 200 9823/1650-1 27 - 200

27 - Driveline
Technical Data
For: PS750 MK4 ..................... Page 27-201

For: PS764, PS766 ................. Page 27-201
(For: PS750 MK4)

Table 301. Sensor Resistance Values
Temperature °C ( °F) Sensor Resistance Ω
-40 89,665
-30 47,304
-20 26,017
-10 14,862
0 8,790
10 5,365
20 3,372
30 2,176
40 1,439
50 973
60 672
70 473
80 339
90 247
100 183
110 137
120 104
130 80
140 63
150 49
(For: PS764, PS766)
540-170 and 540-140 Machines

-40 89,665
-30 47,304
-20 26,017
-10 14,862
0 8,790
10 5,365
20 3,372
30 2,176
40 1,439
50 973
60 672
70 473
80 339
90 247
27 - 201 9823/1650-1 27 - 201

27 - Driveline

100 183
110 137
120 104
130 80
140 63
150 49
Other Machines

-40 332,094
-35 239,900
-30 175,200
-25 129,287
-20 96,358
-15 72,500
-10 55,046
-5 42,157
0 32,554
5 25,339
10 19,872
15 15,698
20 12,488
25 10,000
30 8,059
35 6,535
40 5,330
45 4,372
50 3,605
55 2,989
60 2,490
65 2,084
70 1,753
75 1,481
80 1,256
85 1,070
90 915.4
95 786
100 677.3
105 585.7
110 508.3
115 442.6
120 386.6
125 338.7
130 297.7
135 262.4
140 231.9
27 - 202 9823/1650-1 27 - 202

27 - Driveline

145 205.5
150 182.6
27 - 203 9823/1650-1 27 - 203

27 - Driveline
For: PS750 MK4 ..................... Page 27-204

For: PS764, PS766 ................. Page 27-206
(For: PS750 MK4)
B A
A Transmission Oil Temperature Sender B Transmission Oil Cooler
27 - 204 9823/1650-1 27 - 204

27 - Driveline
2 1
1 2
Figure 613.
ECU
A Transmission ECU (Electronic Control Unit)

B Transmission Oil Temperature Sender
27 - 205 9823/1650-1 27 - 205

27 - Driveline
(For: PS764, PS766)

A Transmission Temperature Sender

1 2
ECU
2
1
1 Transmission ECU
2 Temperature Sender
27 - 206 9823/1650-1 27 - 206

27 - Driveline
Remove and Install
For: PS750 MK4 ..................... Page 27-207

For: PS764, PS766 ................. Page 27-208
(For: PS750 MK4)
Remove
Figure 616.
C B
A Temperature Sender harness electrical B Temperature Sender

connector
C Transmission Oil Cooler
1. Make the machine safe. Refer to (PIL 01-03). 2. The sender is non serviceable. If it is faulty or
2. Access to the transmission oil cooler is made
easier if the engine cover base is removed. Refer 3. Replace the sealing washer.
to (PIL 06-06-06).
4. Tighten the sender to the correct torque value.
3. Clean off all debris, dirt and grit from around the Refer to Table 304.
sender.
4. Disconnect the harness electrical connector from
the sender. Item Nm
B 27
5. When removing the sender there may be some
transmission oil spillage.
6. Remove the sender from the oil cooler.
7. Put caps on all the open ports of the cooler.
Install
steps.
27 - 207 9823/1650-1 27 - 207

27 - Driveline
(For: PS764, PS766) 4. Disconnect the harness electrical connector from

the switch.
Remove 5. Remove the switch and discard the sealing
washer.
Figure 617.
A
Install
B
steps.
2. The switch is non serviceable. If it is faulty or
4. Tighten the switch to the correct torque value.
C Refer to Table 305.

Item Nm
A 16
A Temperature Switch
B Seal
C Temperature Switch harness electrical
connector
switch.
inside the gearbox.
27 - 208 9823/1650-1 27 - 208

27 - Driveline
39 - Filter
39 - Filter Introduction
Introduction .................................................. 27-209 The transmission filter is designed to filter all the
Remove and Install ..................................... 27-210 contamination that is generated through use to
the required level of cleanliness. The filter must
be serviced to the requirements of the machine
maintenance schedules.
27 - 209 9823/1650-1 27 - 209

27 - Driveline
39 - Filter
Remove and Install Consumable: JCB Transmission Fluid EP SAE

30
Special Tools
Description Part No. Qty. 2. Screw the filter on until it just contacts the filter
head.
Oil Filter Removal Tool 892/00292 1
3. Turn the filter at least another 3/4 of a turn.
Consumables
JCB Transmission Fluid 4000/2601 5L
EP SAE 30 4000/2605 20 L
4000/2603 200 L
For draining the gearbox, refer to Gearbox, Drain and

Fill (PIL 27-06).
Remove
1. Clean the area around the filter. Do not allow
particles of grit to fall into the gearbox.
2. If required, use a strap wrench to loosen the oil
filter.
Special Tool: Oil Filter Removal Tool (Qty.: 1)
3. Remove and discard the filter.
Figure 618.
A Gearbox filter
B Seal
Assemble
1. Smear the seal with transmission oil.
27 - 210 9823/1650-1 27 - 210

27 - Driveline
40 - Suction Strainer
40 - Suction Strainer Introduction

Introduction .................................................. 27-211 The suction strainer is a component used for trapping
Remove and Install ..................................... 27-212 large and coarse particles entering the transmission
system.
27 - 211 9823/1650-1 27 - 211

27 - Driveline

Item Nm
Consumables
Description Part No. Size B 12
Strength)
Remove
1. Clean the area around the strainer. Do not allow
2. Place a container, of suitable size beneath the
suction strainer. Remove the bolts. Remove the
strainer and the gasket. Allow the oil to drain into
the container. Be aware that the oil may be hot.
Refer to Gearbox, Drain and Fill (PIL 27-06).
3. Clean the strainer with a suitable solvent. Follow
the solvent manufacturer's instructions on safety.
Figure 619.
A Strainer
B Bolts
D Gasket
Install
1. Install the strainer and a new gasket.
2. Apply JCB Threadlocker and Sealer to the
threads of the bolts. Tighten the bolts to the
(Medium Strength)
27 - 212 9823/1650-1 27 - 212

27 - Driveline
45 - Piston Ring Seal
45 - Piston Ring Seal Introduction

Introduction .................................................. 27-213 A piston ring is a split ring that fits into a groove on
Remove and Install ..................................... 27-214 the outer diameter of a piston
27 - 213 9823/1650-1 27 - 213

27 - Driveline
45 - Piston Ring Seal
Remove and Install
Remove
1. Refer to the relevant Clutch - Disassemble and
Assemble procedure (PIL 27-06).
Install
1. Wind the PTFE (Polytetrafluoroethylene) piston
ring seal around your finger as shown, so that the
seal forms a coil.
Figure 620.
2. Lubricate the seal and then install the seal to the

shaft. Make sure that the seal sits below or flush
with the outer diameter of the shaft. If necessary,
use finger pressure as shown to make the seal
flush with the shaft.
Figure 621.
3. If the seal is not set below or flush with the outer

diameter of the shaft, then the seal will cut when
the shaft is installed to its mating component.
27 - 214 9823/1650-1 27 - 214

27 - Driveline
47 - Oil Seal
47 - Oil Seal Introduction

Introduction .................................................. 27-215 Oil seals close spaces between components in
Remove and Install ..................................... 27-216 mechanical systems, they are designed to:
• Prevent lubricant escape

• Prevent harmful contaminants from entering a
system
• Prevent corrosive moisture from entering a
system
• Prevent mixture of two different mediums e.g.
lubricating oil and water.
27 - 215 9823/1650-1 27 - 215

27 - Driveline
47 - Oil Seal

1. Make sure that the oil seal interface on the yoke
Remove is clean and free from wear or damage.
1. Bend back the stake nut locking ring. 2. Install a new oil seal. Locate the seal in the
position shown, the seal does not locate to the
2. Remove the yoke and the washer, refer to back of the housing.
Gearbox, Yoke- Remove and Install (27-06-95).
3. Lubricate the lips of the oil seal.
3. Remove the oil seal. Do not damage the seal
housing. 4. Install the yoke, refer to Gearbox, Yoke- Remove
and Install (27-06-95).
Figure 622.
5. Install a NEW stake nut. Tighten to the correct
torque value.
6. Stake the nut to the shaft using a square ended
staking tool, as shown.

Item Nm
B 400
A Yoke
B Stake nut
C Oil seal
D Oil seal interface
E Washer
F Locking ring
27 - 216 9823/1650-1 27 - 216

27 - Driveline
52 - Driveshaft
52 - Driveshaft Introduction
Introduction .................................................. 27-217 The driveshaft is a mechanical component for
Remove and Install ..................................... 27-218 transmitting torque and rotation, it is used to connect
other components of the driveline that cannot be
connected directly because of the distance or the
need to allow for relative movement between them.
27 - 217 9823/1650-1 27 - 217

27 - Driveline
52 - Driveshaft
Remove and Install
1.2. Draw the pump away from the gearbox,

(For: PS764, PS766) disengage the drive shaft.
1.3. Lift the pump clear.
Remove
2. Remove the circlip and the bearing.
1. If the main hydraulic pump has not already been
removed proceed as follows: 3. Remove the driveshaft.
1.1. Support the pump, and remove the bolts. 4. Remove the sealing ring from the shaft.
Figure 623.
A
A
B E
F
C
A Bolts B Pump
C Circlip D Ball bearing
E Driveshaft F Sealing ring
27 - 218 9823/1650-1 27 - 218

27 - Driveline
52 - Driveshaft
Install
1. Install a new sealing ring to the shaft.
2. Apply clean oil to the sealing ring and install the
shaft inside the gearbox.
3. Apply clean oil to the ball bearing.
4. Install the bearing followed by the circlip.
5. Install the pump as follows:
5.1. Engage the pump with the driveshaft.
5.2. Support the pump and install the bolts.
27 - 219 9823/1650-1 27 - 219

27 - Driveline
54 - Main Shaft
54 - Main Shaft Introduction

Introduction .................................................. 27-220 The main shaft receives its power from the engine
Check (Condition) ........................................ 27-221 and transmits the power to other components in the
Remove and Install ..................................... 27-221 gearbox.
Refer to Driveline, Semi-Automatic Gearbox, Output

Shaft, Introduction (PIL 27-06-58).
27 - 220 9823/1650-1 27 - 220

27 - Driveline
54 - Main Shaft

1. Carefully inspect all gears, bearings and shafts
for signs of excessive wear or damage. If wear
(For: PS750 MK4)
or damage is evident, the components must be
renewed. Remove
2. Make sure that all oil way cross drillings are clear 1. Carefully lift out the clutch/shaft assemblies in the
and free from debris. Blocked oil ways are a following order.
common cause of bearing failure. If necessary
use an air line to blow through the oil ways. 1.1. Layshaft clutch assembly.
1.2. 2/4 wheel drive clutch or the permanent
4WD (Four Wheel Drive) shaft, as
applicable.
Figure 624.
P
K
M
N
L
K Layshaft clutch assembly

L 2/4 wheel drive clutch
M Reverse clutch assembly
N Main shaft clutch assembly
P Input clutch assembly
Q Bearing outer cups 1
R Shims
1.3. Reverse clutch assembly.
1.4. Main shaft clutch assembly.
1.5. Input clutch assembly.
2. Remove the bearing outer cups 1 and shims from
the rear case. Record the position of the cups
and shims to make sure the correct assembly.
27 - 221 9823/1650-1 27 - 221

27 - Driveline
54 - Main Shaft
Clutch Disassemble and Assemble 2.3. With the help of an assistant slightly raise
Procedures and tilt the input clutch and main shaft
clutch, install the reverse clutch.
For detailed disassemble and assemble procedures 2.4. Install the 2/4 wheel drive clutch or
refer to the following procedures: permanent 4WD shaft, as applicable.
• Reverse clutch - refer to (PIL 27-06-06) 2.5. Install the layshaft clutch.
• 2WD (Two Wheel Drive) / 4WD clutch - refer to
(PIL 27-06-07) 3. Install the correct bearing outer cups 2 to the
• Layshaft clutch - refer to (PIL 27-06-08) clutch shaft bearings.
• Mainshaft clutch - refer to (PIL 27-06-09) 4. Install the main shaft bearing outer cup to the
• Forward / input clutch - refer to (PIL 27-06-11) centre of the output shaft.
Install
1. Install the shims and the bearing outer cups 1 at
their correct locations in the rear case.
2. Install the clutch assemblies as follows.
2.1. Lubricate the clutch shaft bearings.
2.2. Install the input clutch and at the same time
install the main shaft clutch into the front
case.
Figure 625.
P
V
K
V
M V
V
N
L
K Layshaft clutch assembly

L 2/4 wheel drive clutch
M Reverse clutch assembly
N Main shaft clutch assembly
P Input clutch assembly
Q Bearing outer cups 1
R Shims
V Bearing outer cups 2
W Main shaft bearing outer cup
27 - 222 9823/1650-1 27 - 222

27 - Driveline
56 - Layshaft
56 - Layshaft
Introduction
The layshaft is an intermediate shaft within a gearbox

that carries gears, but does not transfer the primary
drive of the gearbox either in or out of the gearbox.
27 - 223 9823/1650-1 27 - 223

27 - Driveline
57 - Input Shaft
57 - Input Shaft
Introduction
Refer to Driveline, Semi-Automatic Gearbox, Output

Shaft, Introduction (PIL 27-06-58).
27 - 224 9823/1650-1 27 - 224

27 - Driveline
58 - Output Shaft
58 - Output Shaft Introduction

Introduction .................................................. 27-225 In the gearbox, the input and output shafts lie along
Calibrate ...................................................... 27-226 the same line, and are sometimes combined into a
Remove and Install ..................................... 27-227 single shaft within the gearbox. This single shaft is
called the main shaft.
The input and output ends of this combined shaft

rotate independently, at different speeds, which is
possible because one piece slides into a hollow bore
in the other piece, where it is supported by a bearing.
Sometimes the term main shaft refers to just the input
shaft or just the output shaft, rather than the entire
assembly.
In many gearboxes the input and output components

of the main shaft can be locked together to create a
1:1 gear ratio, causing the power flow to bypass the
layshaft. The main shaft then behaves like a single,
solid shaft: a situation referred to as direct drive.
27 - 225 9823/1650-1 27 - 225

27 - Driveline
58 - Output Shaft
Calibrate
(For: PS750 MK4, PS764, PS766)

Refer to the individual Remove and Install tasks of
the Output Shaft for the calibration procedure.
27 - 226 9823/1650-1 27 - 226

27 - Driveline
58 - Output Shaft
Remove and Install
For: PS750 MK4 ..................... Page 27-227 Figure 626.

For: PS764, PS766 ................. Page 27-231
B
A
(For: PS750 MK4)
Special Tools
Setting Tool Kit 892/00918 1
Spacer Kit 921/52600 1
Flange Spanner 992/04800 1 D
End Float Setting Tool 993/70100 1 H E
Kit
(10-100Nm) J
Remove K
Before removing the output shaft and its bearings
remove all the clutch assemblies.
1. Remove the output shaft as follows: Refer to

Figure 626.
1.1. Hold the brake disc (or output yoke) with the
service tool.
1.2. Remove the output shaft nut.
Special Tool: Flange Spanner (Qty.: 1)
1.3. Support the output shaft from inside the
case and remove the brake disc (or output
yoke). F
1.4. Remove the output shaft.
1.5. Remove and discard the oil seal. G
C
1.6. Remove the outer taper roller bearing.
1.7. Remove the spacer and keep for assembly.
1.8. Use a suitable puller to remove the output
shaft inner bearing.
A Brake disc
1.9. If required, the park brake bracket can B Output shaft nut
be removed at this stage. Before removal, C Output shaft
mark the position of the bracket with respect D Oil seal
to the case. E Outer taper roller bearing
1.10. Note: Due to different ratio options, some F Spacer
gearboxes may have a larger diameter G Inner taper roller bearing
output gear. When you remove the output H Bolt 1
shaft the gear may touch the gearbox J Park brake bracket
housing, preventing removal. Refer to K Rear case
Section- Output Shaft Removal- Larger
Diameter Gears within this procedure. Install
1. If removed, the park brake bracket must be
installed at this stage as follows: Refer to Figure
627.
27 - 227 9823/1650-1 27 - 227

27 - Driveline
58 - Output Shaft
H E
M
J
L K
H Bolt1
J Park brake bracket
K Rear case
L 82 mm
M 75 mm
1.1. Put the bracket in position marked during
disassembly.
F
1.2. Attach the park brake bracket with the bolts
1.
1.3. Tighten the bolts to the correct torque value. C
1.4. Drill a hole of the specified diameter at the G
location shown to enable the installation of
the service tool for checking the end float.
Dimension: 12.5 mm
C Output shaft
Special Tool: End Float Setting Tool Kit
D Oil seal
(Qty.: 1)
E Outer taper roller bearing
2. Pre-assemble the output shaft as follows: Refer F Service spacer
to Figure 628. G Inner taper roller bearing
K Rear case
2.1. Apply oil on the inner bearing and cup and
install on the output shaft.
2.2. Install the bearing cups into the case.
2.3. Install the service spacer onto the output
shaft and install the output shaft into the
case.
Special Tool: Spacer Kit (Qty.: 1)
2.4. Apply oil on the outer bearing and cup and
install onto the output shaft.
2.5. Do not install the oil seal at this stage.
3. Measure the output shaft assembly end float.
3.1. Install the service tool sleeve (which
temporarily replaced the disc brake) and
secure it with the service nut. Refer to
Figure 629.
Special Tool: Setting Tool Kit (Qty.: 1)
27 - 228 9823/1650-1 27 - 228

27 - Driveline
58 - Output Shaft
3.2. Tighten the service tool nut to the correct Figure 630.
torque value.
Torque: 50 N·m S
3.3. Install the service tool support pillar so that
the fork end engages in the service tool nut.
3.4. Tighten the bolt 2.
Figure 629.
Q T
S DTI
P T Torque wrench
3.7. Select the right size spacer based on the
N example given in the table. Refer to Table
308.
3.8. Note: If the measurement obtained is
outside the spacer kit range, then check the
assembly of the bearings.
3.9. Disassemble the service tools and install
the correct size spacer. Assemble the
transfer gear output shaft.
3.10. Install the service tool sleeve and secure
it with the service nut.
3.11. Tighten the service tool nut to the correct
torque value.
N Service tool sleeve
P Service tool nut Torque: 50 N·m
Q Support pillar 3.12. Make sure that there is no end float and
R Bolt2 the rolling torque is less than the specified
3.5. Install the DTI (Dial Test Indicator). Refer to value.
Figure 630. Torque: 1.5 N·m
3.6. Set the torque wrench to the specified value 3.13. If the rolling torque exceeds the specified
and measure the end float while you rotate value then check that the output shaft is
the output shaft. installed correctly.
Torque: 35 N·m 3.14. If the rolling torque is too high, install the
Special Tool: Torque Wrench (10-100Nm) next largest spacer.
(Qty.: 1)
3.15. If the rolling torque is too low, install the
next smallest spacer.
3.16. Remove the service tool nut and the
service tool sleeve.
4. Output shaft final assembly. Refer to Figure 631.
27 - 229 9823/1650-1 27 - 229

27 - Driveline
58 - Output Shaft
Figure 631. 4.4. Install the brake disc (or output yoke) with
reference to the alignment marks made
A B during disassembly.
4.5. Note: Do not excessively hammer the disc
during assembly or damage to the shaft
bearings could occur. If necessary, press
D fit the parts. Fully support the shaft during
assembly.
4.6. Install the new retaining nut and washer.
4.7. Progressively tighten the nut to the correct
torque value.
4.8. The combined seal and bearing rolling
torque should not exceed the specified
value when fully torque tightened, provided
the correct size spacer has been selected.
A Brake Disc Torque: 2 N·m
B Output shaft nut
F Oil seal 4.9. If the rolling torque is too high, install the
next largest spacer.
4.1. Lubricate the seal lips of a new oil seal.
4.10. If the rolling torque is too low, install the
4.2. Install the new oil seal. next smallest spacer.
4.3. Make sure that the seal is pushed square to 4.11. Stake the nut into the slot in the shaft with
the housing. a square ended staking tool.
Table 308. Spacer Selection Example

Service spacer 13.7
Subtract end float 0.41
Total 13.29
Subtract bearing tolerance and pre-load 0.12
Result 13.17
Use next smallest spacer i.e. 13.15

Item Nm
B 300
H 166
Output Shaft Removal - Larger Diameter bearing inner cup and taper rollers will be forced
Gears partially up the output shaft, it will not be possible
to remove them at this stage.
In the event that the output gear fouls against the
2. Pull the output shaft up and position suitable
gearbox housing at position 1 when attempting to
spacers between the taper rollers and bearing
remove the output shaft, proceed as follows:
outer cup as shown.
Note: The following procedure will be required 3. Push the output shaft down again, the inner cup
when dismantling the gearbox, and also after initial and taper rollers will be forced further up the shaft
assembly, since the output shaft will need to be allowing them to be removed.
removed when setting the end float.
4. If the inner cup and taper rollers are still engaged
To enable the output shaft removal past the case at on the output shaft repeat steps 2 and 3 using
position 1, the bearing inner cup and taper rollers thicker spacers.
must first be removed from the output shaft.
5. With the bearing inner cup and taper rollers
1. Push the output shaft down until the gear removed, the output shaft and gear can be
contacts the housing at position 1, take care not lowered and tilted to one side, allowing the gear
to damage the housing or gear. Although the to clear the housing and the shaft to be removed.
27 - 230 9823/1650-1 27 - 230

27 - Driveline
58 - Output Shaft
Figure 632. Remove

1. Remove the pressure maintenance valve as
follows:
C C 1.1. Remove the plug.
1
1.2. Remove the spring and valve spool from the
2 rear case.
2. If required, remove the speed sensor as follows:
2.1. Remove the bolt 1.
2.2. Remove the sensor and its O-ring from the
3 rear case.
3. Hold the output yoke with the service tool.
Special Tool: Drive Coupling Spanner (Qty.: 1)
A
4. Remove the bolt 2 and the thick washer.
4.1. The bolt is very tight, the help of an assistant
will be required.
B
1 Output shaft 5. Remove the yoke.
2 Taper rollers
3 Bearing outer cup 6. Remove and discard the oil seal. Make sure that
A Gear you do not damage the seal housing.
B Position 1
7. Support the transfer gear shaft assembly and
C Spacers
remove the gear from inside the rear case.
Note: If the output shaft is being removed after initial 8. The gear assembly will come down along with
assembly, typically to set the end float, take extreme the following components:
care to avoid damage to the bearing outer cup and
inner cup and taper rollers. Use only soft spacers 8.1. Inner taper roller bearing.
such as aluminium, Do not use hardened steel items
such as screwdrivers. 8.2. Inner taper bearing outer cup.
8.3. Solid spacer.
If the bearing is damaged a new bearing MUST be
installed. The tolerance difference between the new 9. Remove the outer taper rolling bearing and the
bearings is expected to be less than the difference outer bearing outer cup.
between the solid spacer sizes so changing a
bearing should not affect the end float. 9.1. Note: If the inner and outer taper roller
bearings are to be used again, keep the
bearings together with their respective outer
(For: PS764, PS766) cups in their original relationships.
Special Tools 9.2. Put tags on the bearings to make sure that
assembly of them in their original positions.
Drive Coupling 892/00812 1 9.3. If any of the two bearings is worn or
Spanner damaged, both the bearings must be
Transfer Gear 892/01083 1 replaced and a new solid spacer be
Assembly Tool selected and installed.
Bearing Assembly Tool 892/01084 1 10. Remove the layshaft bearing outer cup from the
rear case.
Before Removal
1. Remove the front case and the clutch shafts.
27 - 231 9823/1650-1 27 - 231

27 - Driveline
58 - Output Shaft

F
G H
R
P
E
Q
D
R Layshaft bearing outer cup
C
M
B
N
A
L
K
A Plug
B Spring
C Spool
D Bolt 1
E Speed sensor
F Bolt 2
G Thick washer
H Yoke
J Oil seal
K Transfer gear shaft assembly
L Inner taper roller bearing
M Inner bearing outer cup
N Solid spacer
P Outer taper roller bearing
Q Outer bearing outer cup
27 - 232 9823/1650-1 27 - 232

27 - Driveline
58 - Output Shaft
Install 3. Measure the transfer gear output shaft assembly

end float as follows: Refer to Figure 636.
1. Install the layshaft outer bearing cup into the rear
case. Figure 636.
2. Assemble the transfer gear output shaft as

follows:
2.1. Install the outer bearing outer cup into the Z
case. U
2.2. Apply oil onto the inner taper bearing. V
2.3. Push the inner bearing onto the transfer
gear/shaft. W
X
2.4. Install a service spacer of the specified
dimension. T
Dimension: 13.7 mm
2.5. Install the inner bearing outer cup into the
case.
Y
2.6. Put the transfer gear assembly in position
against the case from inside. Z
2.7. Use the service tool to hold the transfer gear V
in position. Refer to Figure 635.
Special Tool: Transfer Gear Assembly Tool
(Qty.: 1) X
Figure 635.
S
K
T Service tool sleeve

U Service tool 1
V Service tool 2
W Bolt 3
X Support bracket
Y DTI
Z Torque wrench
3.1. Install the service tool sleeve over the
H Transfer gear transfer output shaft and secure with the
S Transfer gear retaining tool service tool 1.
3.2. Tighten the service tool 1 to the correct
2.8. If the gear is not held in position torque value.
the bearings may get damaged during
assembly. Torque: 50 N·m
2.9. Apply oil onto the outer bearing. 3.3. Temporarily loosen the service tool sleeve.
2.10. Use the service tool to push the outer 3.4. Install the support bracket to the gearbox
bearing into the rear case. case.
Special Tool: Bearing Assembly Tool (Qty.: 3.5. Install the service tool 2 so that the fork end
1) engages in the groove of the service tool 1.
2.11. Do not install the oil seal at this stage. 3.6. Tighten the bolt 3 to secure the service tool
2 to the support bracket.
27 - 233 9823/1650-1 27 - 233

27 - Driveline
58 - Output Shaft
3.7. Install a DTI to measure the end float of the 3.19. Remove the service tool 1 and the service
output shaft. tool sleeve.
3.8. Set the torque wrench to the specified 4. Transfer gear output shaft final assembly.
torque value and measure the end float
while you rotate the output shaft. 4.1. Use special tool to install a new oil seal.
Make sure the seal is pushed square to the
3.9. Select the right size spacer based on the
housing.
example given in the table. Refer to Table
310. 4.2. Install the yoke, the thick washer and the
bolt 2.
3.10. Note: If the measurement obtained is
outside the spacer kit range, then check 4.3. Hold the yoke with the tool.
the assembly of the bearings.
Special Tool: Drive Coupling Spanner (Qty.:
3.11. Disassemble the service tools and install 1)
the correct size spacer. Assemble the
4.4. Tighten the bolt to the correct torque value.
transfer gear output shaft.
4.5. The combined seal and bearing rolling
3.12. Install the service tool sleeve over the
torque should not exceed the specified
output shaft and secure with the service
value when fully torque tightened provided,
tool 1.
the correct size spacer has been selected.
3.13. Tighten the service tool 1 to the correct Torque: 2 N·m
torque value.
Torque: 50 N·m 5. If removed, install the speed sensor as follows:
3.14. Make sure that there is no end float and 5.1. Install the O-ring on the sensor. Make sure
the rolling torque is less than the specified that it is correctly installed.
value.
5.2. Attach the sensor with the bolt 1.
Torque: 1.5 N·m
5.3. Tighten the bolt 1 to the correct torque
3.15. If the rolling torque exceed the specified value.
value then check that the output shaft is
installed correctly. 6. Install the pressure maintenance valve as
follows:
3.16. If the rolling torque is too high, install the
next largest spacer. 6.1. Apply oil to the spool and install to the case.
3.17. If the rolling torque is too low, install the 6.2. Install the spring.
next smallest spacer.
6.3. Use a new sealing washer and install the
3.18. Use the service tool to hold the transfer plug.
gear in position. Refer to Figure 635.
6.4. Tighten the plug to the correct torque value.

Service spacer 13.7
Subtract end float obtained at step 3.7 0.41
Total 13.29
Subtract bearing tolerance and pre-load 0.12
Result 13.17
Use next smallest spacer i.e. 13.15
After Installation
1. Instal the clutch shafts and the front case.

Item Nm
A 56
D 28
F 300
27 - 234 9823/1650-1 27 - 234

27 - Driveline
81 - Mount
81 - Mount
Check (Condition)
2. Get access to the mounting(s).
3. Make sure that the entire mounting(s) system is
in good condition.
3.1. Inspect brackets and casings for cracks,
damage and security.
3.2. Inspect rubber mountings (if installed) for
wear and tears and too much movement.
3.3. Make sure that all fastenings are there and
they are tightened to the correct torque.
Refer to (PIL 72).
4. Install new components if any are defective.
Refer to the correct section in the service manual
as necessary.
27 - 235 9823/1650-1 27 - 235

27 - Driveline
85 - Oil Feed Pipe
85 - Oil Feed Pipe
Remove and Install
Remove
1. Remove the adaptor bolts 1.
2. Remove all the sealing washers 1 (x4).
3. Remove the external oil feed pipe.
Figure 637.
C
B
B External oil feed pipe

C Adaptor bolts 1 (x2)
D Sealing washers 1 (x4)
Install
1. Install the external oil feed pipe with the adaptor
bolts 1 and the sealing washers 1.
2. Tighten the bolts 1 to the correct torque value.

Item Description Nm
C Adaptor bolts 1 26.5
27 - 236 9823/1650-1 27 - 236

27 - Driveline
86 - Oil Transfer Pipe
86 - Oil Transfer Pipe
Remove and Install
The oil transfer pipe is located on the rear case, if

the pipe is damaged or the gearbox is contaminated
then the pipe must be removed for cleaning or
replacement.
Remove
1. Remove the adaptor bolts 2.
2. Remove all the sealing washers 2.
3. Remove the oil transfer pipe.
Figure 638.
S
T
U
U
S Adaptor bolts 2 (x2)

T Oil transfer pipe
U Sealing washers 2 (x4)
Install
1. Install the oil transfer pipe with the adaptor bolts
2 and sealing washers 2.
2. Tighten the bolts 2 to the correct torque value.

Item Description Nm
S Adaptor bolts 2 26.5
27 - 237 9823/1650-1 27 - 237

27 - Driveline
90 - Front Case
90 - Front Case Clean

Consumables
Clean ........................................................... 27-238
Check (Condition) ........................................ 27-239
Cleaner/Degreaser 4104/1557 0.4 L
Remove and Install ..................................... 27-239 - General purpose
solvent based parts
cleaner
1. Carefully remove all traces of gasket or gasket

compound from the front and rear case mating
faces. When removing gasket compound use a
gasket removal product such as Loctite Chisel.
Take care not to damage the mating faces. Clean
the faces with a fine carborundum paper. Use
a solvent cleaner and a clean cloth to finally
remove all traces of oil or debris
2. Clean the inside of the cases using a suitable
degreasing agent.
27 - 238 9823/1650-1 27 - 238

27 - Driveline
90 - Front Case

Consumables For: PS750 MK4 ..................... Page 27-239
Description Part No. Size For: PS764, PS766 ................. Page 27-242
Strength)
(For: PS750 MK4)
Consumables
1. If the gearbox cases are to be renewed, be Description Part No. Size
sure to install blanking plugs and adaptors as JCB Multi-Gasket 4102/1212 0.05 L
required. Inspect the original cases and identify
the blanking plug and adaptor positions. Transfer
the plugs and adaptors to the new cases. Apply Before removal
JCB Threadlocker and Sealer to the threads
before installation. Before splitting the front and rear case do the
following procedures.
(Medium Strength) • Remove the oil filter. Refer to (PIL 27-06-39).
• Remove the suction strainer. Refer to (PIL
27-06-40)
• Remove the solenoid control valves. Refer to
(PIL 27-06).
• Remove the 4WD (Four Wheel Drive) yoke and
seal. Refer to (PIL 27-06-95).
• Remove the speed sensors. Refer to (PIL
27-06-27).
• Remove the torque converter relief valve. Refer
to (PIL 27-14-09).
Cleanliness is of the utmost importance when you

service the gearbox. All precautions to prevent any
ingress of dirt, grit etc. must be taken.
• Remove deposits of dirt, grit and oil from the

outer cases and components.
• Prevent dirt, grit and debris falling into the
gearbox.
• Put caps on all open ports, hoses, pipes and
orifices.
Use lifting equipment to locate the gearbox in a

work cradle as shown. Do not try to disassemble the
gearbox further unless it is safely located in a work
cradle.
27 - 239 9823/1650-1 27 - 239

27 - Driveline
90 - Front Case
Figure 639. 2. Use lifting equipment to carefully lift off the rear
case.
3. Remove the shaft bearing outer cups. The cups
will be left on the bearings, or inside the front
case.
Figure 641.
H
H
H H
A H
A Cradle
Remove the external oil feed pipe. Refer to (PIL

27-06-85).
J
Remove
J
Front and rear case
1. Remove all the case fixing screws. H Bearing outer cups
J O-ring seals
Figure 640.
4. Keep the cups with their associated bearings.
5. Remove and discard the O-ring seals from the
front case.
F After removal
Remove the oil transfer pipe. Refer to (PIL 27-06-86).
Remove the clutch assemblies - refer to the following

procedures:
E • Mainshaft - (including layshaft clutch assembly,

2WD (Two Wheel Drive) / 4WD clutch
assembly, reverse clutch assembly, mainshaft
F clutch assembly and forward/input clutch
assembly) - refer to (PIL 27-06-54).
For detailed clutch disassemble and assemble

procedures refer to the following procedures:
• Reverse clutch - refer to (PIL 27-06-06)

• 2WD / 4WD clutch - refer to (PIL 27-06-07)
G • Layshaft clutch - refer to (PIL 27-06-08)
• Mainshaft clutch - refer to (PIL 27-06-09)
E Case fixing screws (x22) • Forward / input clutch - refer to (PIL 27-06-11)
F Rear case
G Front case
27 - 240 9823/1650-1 27 - 240

27 - Driveline
90 - Front Case
Before installation Figure 643.

• If you remove the output shaft and bearing then
install them. Refer to (PIL 27-06-58).
• Make sure the clutch assemblies are correctly
J
assembled and are free from defects. Refer to
(PIL 27-06). J
• Replace the clutch shaft piston ring seals with
new ones. Make sure that the piston ring seals X
are correctly installed in the shaft grooves.
Use lifting equipment to locate the gearbox in a work

cradle as shown. Do not try to assemble the gearbox
further unless it is safely located in a work cradle.
Figure 642.
J O-ring seals
X Friction counter plates
Y JCB Multigasket
2. Apply a continuous bead of JCB Multigasket to
the front case mating face.
A 3. Use two small rods or screwdrivers to align all the
friction counter plates in the main shaft clutch.
4. Use suitable lifting equipment to carefully lower
A Cradle the rear case and to align the output gear splines
with the main shaft clutch friction plates.
Clean and check the condition of all components
before you install them.
Install the oil transfer pipe. Refer to (PIL 27-06-86).
Install the clutch shaft assemblies. Refer to (PIL

27-06).
Install the front and rear case

1. Install new O-ring seals in the front case.
27 - 241 9823/1650-1 27 - 241

27 - Driveline
90 - Front Case
Figure 644. The Disassembly and Assembly procedures given

illustrate and describe the 6x4 gearbox. Procedures
for the 4x4 version of the gearbox are identical
in most respects. Where there are differences,
procedures are identified under the heading 4x4
Gearbox.
F
With the gearbox removed from the machine, place
assembly. If the gearbox is installed with an integral
park brake the brake assembly must be removed
before you disassemble the gearbox. Refer to (PIL
27-06).
E
Gearboxes compatible with a lock-up torque
converter are installed with a control valve and
F interconnecting pipe. These components must be
removed before dismantling the gearbox.
Disassemble
1. Remove the main hydraulic pump and driveshaft.
2. Remove the solenoid control valve. Refer to (PIL
G 27-06-15).
E Case fixing screws (x22) 3. Use suitable lifting equipment to put the gearbox
F Rear case in a work cradle. Refer to Figure 645.
G Front case Special Tool: Gearbox Assembly Cradle (Qty.: 1)
5. If necessary rotate the output shaft a small 3.1. Clamp the gearbox at the three clamping
amount to align the splines. points on the rear case.
6. Apply sealant to the threads of the case fixing Figure 645.
bolts and install them.
After installation
Install the external oil feed pipe.

Item Description Nm A
E Case fixing screws 56
A Clamping points (x3)
(For: PS764, PS766) 4. Do not attempt to disassemble the gearbox

further until it is safely positioned in a suitable
Special Tools work cradle.
5. Remove the torque converter housing as follows:
Gearbox Assembly 892/01082 1 Refer to Figure 646.
Cradle
Consumables
Strength)
27 - 242 9823/1650-1 27 - 242

27 - Driveline
90 - Front Case
C F
D
F Front case
G Bolt 2
E
8.2. With suitable lifting equipment carefully lift
B Bolt1 the front case.
C Torque converter housing
8.3. Make sure you remove all the shaft bearing
D O-ring 1 (x5)
outer cups.
E O-ring 2 (x3): Only for lock-up torque converter
variants 8.4. The cups may be left on the bearings, or
inside the front case. Keep the cups with
5.1. Remove the bolts 1. their relative bearings.
5.2. Lift off the housing. 8.5. Remove and discard the sealing O-rings
5.3. Remove and retain the O-rings 1 (x5). from the front case.
5.4. For lock-up torque converter variants: 8.6. Remove the oil transfer pipes from the front
Remove and retain the O-rings 2 (x3). case only when they are damaged or the oil
is contaminated. Refer to Figure 648.
6. Remove the gearbox oil pump. Refer to (PIL
27-06-24).
7. Remove the 4WD clutch assembly. Refer to (PIL
27-06-07).
8. Separate the front and rear cases as follows:
8.1. Remove the bolts 2 that attach the cases.
27 - 243 9823/1650-1 27 - 243

27 - Driveline
90 - Front Case
Figure 648. 9.3. Forward/Input clutch shaft.

9.4. Layshaft clutch.
H 9.5. Main shaft clutch.
10. Remove the bearing outer cups from the rear
case and centre of the transfer gear. Refer to
Figure 650.
Figure 650.
R
Q S
T
H Transfer pipes (x3)

9. Carefully remove the clutch shaft assemblies in
the sequence given below: Refer to Figure 649.
Figure 649.
L M K Q Bearing cups
N R Rear case
S Transfer gear
P T Layshaft bearing cup
11. The layshaft bearing cup cannot be removed until
the transfer gear output shaft has been removed.
12. Keep the bearings cups together with their
relative bearings.
Install
1. Make sure that the sealing rings (x4) on the
clutch pack shafts are in good condition and
lubricated with oil.
2. Install the bearing outer cups at their correct
positions in the rear case and centre of the
J transfer gear.
J O-rings 3 3. Install the clutch shaft assemblies in the
K 6 Speed clutch (not installed on 4x4 gearbox) sequence given below: Refer to Figure 651.
L Reverse clutch unit
M Forward/Input clutch shaft
N Layshaft clutch
P Main shaft clutch
9.1. 6 Speed clutch (not installed on 4x4
gearbox).
9.2. Reverse clutch unit.
27 - 244 9823/1650-1 27 - 244

27 - Driveline
90 - Front Case
Figure 651. 5.1. Make sure that the O-rings are correctly
installed to the rear case. Refer to Figure
L M K 651.
N 5.2. Apply a thin bead of sealant to the rear case
mating face as shown in the figure. Refer to
P
Figure 653.
Figure 653.
J O-rings 3 V
K 6 Speed clutch (not installed on 4x4 gearbox) V Sealant
L Reverse clutch unit
M Forward/Input clutch shaft 5.3. Make sure that the shaft bearing outer cups
N Layshaft clutch are correctly installed in the front case.
P Main shaft clutch 5.4. Carefully lower the front case over the
3.1. Main shaft clutch. clutch shafts until it mates with the rear
case. Do not use excessive force when you
3.2. Layshaft clutch. Take care not to damage install the case.
the rear bearing on the transfer gear teeth
when you install the layshaft clutch. 5.5. Install the bolts 2 that attach the cases
together. Refer to Figure 654.
3.3. Forward/Input clutch shaft.
Figure 654.
3.4. Reverse clutch unit.
3.5. 6 Speed clutch (not installed on 4x4 F
gearbox).
4. Before you install the rear case make sure that
the sealing rings (x4) on the clutch pack shafts
are in good condition and lubricated with oil.
Figure 652.
U
G
F Front case
G Bolt 2
U Sealing rings (x4)
5.6. Tighten the bolts to the correct torque value.
5. Assemble the front and rear cases as follows:
27 - 245 9823/1650-1 27 - 245

27 - Driveline
90 - Front Case
6. Measure the end float of the clutch shafts except 7.2. The end float of the shaft should be within
the input shaft as follows: Refer to Figure 655. the specified range.
6.1. For 4x4 gearbox: Remove the plug 1. Length/Dimension/Distance: 0.02 –0.16
mm
6.2. For 6x4 gearbox: Remove plug 1 and plug
2. 8. Provided components are assembled correctly
the end float will be within the limits given. Check
6.3. Install a bolt to the threaded hole in the end that the shafts can be rotated by hand (turn the
of the shaft. input shaft and output yoke). The shafts should
6.4. Pull the bolt to detect excessive end float. rotate smoothly. The end floats can be checked
Remove the bolt. to confirm correct assembly.
6.5. The end float of the shafts should be within 9. Install the 4WD clutch assembly.
10. Install the gearbox oil pump.
Length/Dimension/Distance: 0.02 –0.16
mm 11. Install the torque converter housing as follows:
6.6. Apply sealant to the plug 1 and plug 2 (for Refer to Figure 656.
6x4 gearbox only).
11.1. Make sure that the front case and torque
Consumable: JCB Threadlocker and Sealer converter housing mating faces are clean,
(Medium Strength) dry and not damaged.
6.7. Tighten the applicable plugs to the correct 11.2. Install the O-rings 1 (x5) to the front case.
torque value.
11.3. For gearboxes installed with lock up
Figure 655. torque converter: Install the O-rings 2 (x3)
to the front case.
L W X K
M N Figure 656.
E
P
D Y
D O-ring 1 (x5)
E O-ring 2 (x3): Only for Lock up torque converter
variants
W Loctite 509
K 6 Speed clutch (not installed on 4x4 gearbox)
L Reverse clutch unit 11.4. Apply a bead of Loctite 509 of the specified
M Forward/Input clutch shaft thickness to the front case.
N Layshaft clutch Dimension: 3 mm
P Main shaft clutch
W Plug 1 11.5. According to the gearbox configuration
X Plug 2 Install the 13 or 14 bolts 2. Refer to Figure
657. or Refer to Figure 658.
7. Measure the end float of the input shaft as
follows: Refer to Figure 655.
7.1. Pull the input shaft to detect excessive end
float.
27 - 246 9823/1650-1 27 - 246

27 - Driveline
90 - Front Case
Figure 657. 13 Bolts Configuration

C
B Bolt 1 (x13)
Figure 658. 14 Bolts Configuration
C
B Bolt 1 (x14)
11.6. Tighten the bolts to the correct torque
value.
12. Install the solenoid control valve.
13. Install the main hydraulic pump and driveshaft.

Item Description Nm
B Bolt 1 56
G Bolt 2 56
W-X Plug 102
27 - 247 9823/1650-1 27 - 247

27 - Driveline
91 - Rear Case
91 - Rear Case Clean

Clean ........................................................... 27-248 Refer to Front Case - Clean (PIL 27-06-90).
Check (Condition) ........................................ 27-249
27 - 248 9823/1650-1 27 - 248

27 - Driveline
91 - Rear Case
Refer to Front Case - Check Condition (PIL (For: PS750 MK4)

27-06-90).
The front and rear case are separated at the same
time. Refer to the removal procedure of the front
case. Refer to (PIL 27-05-90).
27 - 249 9823/1650-1 27 - 249

27 - Driveline
95 - Coupling Yoke 4WD
95 - Coupling Yoke 4WD Introduction

Introduction .................................................. 27-250 The drive yoke is an important component of a
Remove and Install ..................................... 27-251 driveshaft assembly. The drive yoke assembly allows
a driveshaft or PTO (Power Take-Off) to flex or slip
with their given application. The drive yoke is also
essential for allowing u-joints to rotate properly with
the driveshaft.
27 - 250 9823/1650-1 27 - 250

27 - Driveline
Special Tools
Spanner
Remove
1. Bend back the stake nut locking ring.
2. Clean the area around the yoke. Do not allow
3. Use service tool 892/00812 to hold the yoke and
at the same time undo the nut. The nut is very
tight, the help of an assistant will be required.
Discard the nut.
Special Tool: Drive Coupling Spanner (Qty.: 1)
4. Remove the yoke and the washer.
5. If necessary remove the oil seal. Do not damage
the seal housing.
A Yoke
B Stake nut
C Oil seal
D Oil seal interface
E Washer
F Locking ring
Install
1. Make sure that the oil seal interface on the yoke
is clean and free from wear or damage.
2. If necessary install a new oil seal. Locate the seal
in the position shown, the seal does not locate to
the back of the housing.
3. Lubricate the lips of the oil seal.
4. Install the yoke.
5. Install the stepped washer the correct way
around with the plan face facing the stake nut as
shown.
27 - 251 9823/1650-1 27 - 251

27 - Driveline
6. Install a NEW stake nut. Tighten to the correct

torque value.
7. Stake the nut to the shaft using a square ended
staking tool, as shown.

Item Nm
B 400
27 - 252 9823/1650-1 27 - 252

27 - Driveline
12 - Transfer Gearbox
Contents Page No.
27-12-00 General ......................................................................................................................... 27-255
27 - 253 9823/1650-1 27 - 253

Notes:
27 - 254 9823/1650-1 27 - 254

27 - Driveline
00 - General
Introduction .................................................. 27-255 The transfer gearbox is a system of gears used in
Component Identification ............................. 27-256 4WD (Four Wheel Drive) vehicles, which transfers
Clean ........................................................... 27-259 torque from the transmission to the front and rear
Check (Condition) ........................................ 27-259 driveshafts or propshafts. Putting a transfer gearbox
in neutral disconnects the transmission from the
Calibrate ...................................................... 27-260 wheels.
Disassemble and Assemble ........................ 27-269 Transfer gearboxes typically have two gear ranges,
High and Low.
• High Range is used for typical road use.

• Low Range is used for off-road conditions.
27 - 255 9823/1650-1 27 - 255

27 - Driveline
00 - General
order for parts replacement, always give the details

Unit Identification mentioned on the unit identification plate. In the case
of gear replacements, always check the part number
The gearbox serial number is stamped on the unit stamped on the gear, and the number of teeth.
identification plate as shown. When you make an
27 - 256 9823/1650-1 27 - 256

27 - Driveline
00 - General
Figure 660. Component Identification (For: Bevel Gearbox)
AF
T
U
AD
Z
X
AA
AC
V
AB
AE
Y
W
S
Q L
R
E
C
D
K
H
N
F J
B M
G
27 - 257 9823/1650-1 27 - 257

27 - Driveline
00 - General
Table 317.
Item Description
A Gearbox case
B Bolt 1
C Pinion gear case
D Extraction holes
E Shim set 1
F Nut 1
G Spacer 1
H O-ring 1
J Pinion gear
K Bearing 1
L Bearing 2
M Spacer 2
N Triple lip seal 1
P O-ring 2
Q Mounting bushes
R Housing bosses
S Bolt 2
T Bevel gear case
U Extraction holes
V Shim set 2
W Nut 2
X Washer
Y Drive flange
Z O-ring 3
AA Bevel gear
AB Bearing 3
AC Bearing 4
AD Spacer 3
AE Triple lip seal 2
AF O- ring 4
27 - 258 9823/1650-1 27 - 258

27 - Driveline
00 - General

Consumables Consumables
Description Part No. Size Description Part No. Size
Cleaner/Degreaser 4104/1557 0.4 L JCB Threadlocker 4101/0250 0.01 L
- General purpose and Sealer (Medium 4101/0251 0.05 L
solvent based parts Strength)
cleaner
Surface Cleaning Fluid 4103/1204 1L Inspection
1. Carefully remove all traces of the gasket Before you assemble the gearbox, do a full
or gasket compound from the dropbox case inspection of all the components. It may be easy to
mating faces. Note: When removing the gasket find out a component failure but the cause behind
compound use a gasket removal product such the failure may not be as easy to find out. It is also
as Loctite Chisel. Take care not to damage the possible that a failed component may have caused
mating faces. damage to other areas of the gearbox.
2. Clean the faces with a fine carborundum paper. 1. General inspection.
Use a solvent cleaner and a clean cloth to finally
remove all traces of oil or debris. 1.1. Carefully inspect all the gears, bearings and
shafts for any signs of excessive wear or
damage. If you find any damage during the
3. Clean the inside of the dropbox case using a inspection, components must be replaced.
suitable degreasing agent. 1.2. Make sure that all oil way cross drillings
Consumable: Cleaner/Degreaser - General are clear and free from contamination and
purpose solvent based parts cleaner foreign particles. Blocked oil ways are
a common cause of bearing failure. If
necessary use an air line to blow through
the oil ways.
2. Case inspection
2.1. If the gearbox case is to be replaced, then
make sure that all the necessary blanking
plugs and the adaptors are installed.
2.2. Check the original case and locate all the
locations of the blanking plugs and adaptors
on the case.
2.3. Move the plugs and adaptors to the new
cases. Apply sealant to the threads.
(Medium Strength)
2.4. New plugs may be supplied with a sealant
patch, in which case sealant is not
necessary.
27 - 259 9823/1650-1 27 - 259

27 - Driveline
00 - General
Calibrate
Figure 661.
AF
T
U
AD
Z
X
AA
AC
V
AB
AE
Y
W
S
Q L
R
E
C
D
K
H
N
F J
B M
G
A Gearbox housing B Bolt 1
27 - 260 9823/1650-1 27 - 260

27 - Driveline
00 - General
C Pinion gear housing D Extraction holes

E Shim set 1 F Nut1
G Spacer 1 H O-ring 1
J Pinion gear K Bearing 1
L Bearing 2 M Spacer 2
N Triple lip seal 1 P O-ring 2
Q Mounting bushes R Housing bosses
S Bolt 2 T Bevel gear housing
U Extraction holes V Shim set 2
W Nut 2 X Washer
Y Drive flange Z O-ring 3
AA Bevel gear AB Bearing 3
AC Bearing 4 AD Spacer 3
AE Triple lip seal 2 AF O-ring 4
End Float Measurement 6. If the pinion gear housing becomes difficult to

turn by hand, then stop tightening the vice and
The end float measurement procedure given below install the next largest spacer.
is applicable for both the pinion drive gear and the
bevel gear. 7. The rolling torque can be measured as a rolling
force. Use a spring balance and a cord wrapped
1. Install the bearings into the pinion gear housing. around the pinion gear housing.
1.1. Note: The taper roller bearings1 and 2 must Figure 663.
be preloaded 0.01 to 0.06 mm to give a
rolling torque of 0.5 to 1.5 Nm. The correct
pre-load is achieved by selecting a spacer
of the correct thickness.
2. Select the largest spacer and assemble with the
bearings in a vice. Use a suitable socket as a
clamping spacer.
Figure 662.
AQ M,AD
AR
AR 75 mm
8. Pull the spring balance until the pinion gear
housing stops to rotate and then record the
reading.
Weight/Force: 6.9 –19.6 N
9. If the rolling force is too low, assemble again
using the next smallest size spacer.
M Spacer 2
AD Spacer 3 10. When the correct spacer has been selected,
AQ Socket remove the assembly from the vice and measure
the dimension shown.
3. Tighten the vice and measure the end float on the
housing. To select the correct size spacer Refer
to Table 318. for the calculation.
4. Select the nearest size spacer and assemble
again in a vice.
5. Carefully tighten the vice and make sure that the
pinion gear housing is free to rotate.
27 - 261 9823/1650-1 27 - 261

27 - Driveline
00 - General
Figure 664. Table 318. Spacer size calculation

Largest spacer 8
End float (example) 0.42
7.58
Pre-load required 0.04
Spacer required 7.54
Backlash Adjustment
Figure 665.
1. Carefully install the gear assemblies into their (use the bolt and lock nut as a reference point).
correct positions with the shim sets. Refer to Figure 665.
1.1. Note: Do not install the O-rings 2 and 4 at 5. Take measurements at four positions and
this stage. Make sure that the shims are calculate the average. The average should be
correctly aligned with the non-symmetrical between the specified values.
bolt holes. Length/Dimension/Distance: 0.13 –0.2 mm
2. Turn the gear shafts slightly to make sure that the 6. Adjust the shim sets equally from each drive gear
gears mesh with each other. to calculate the correct backlash.
3. Attach each drive gear in position with three
bolts. Gear Meshing Check
4. Hold the pinion drive gear stationary and do a 1. Apply engineers marking compound on the teeth
backlash check at the bevel gear drive flange of the gears.
27 - 262 9823/1650-1 27 - 262

27 - Driveline
00 - General
2. With the gearbox under load, rotate the gears in Figure 667.
both directions.
2.1. Note: It is recommended that the gearbox is
secured to the engine to provide a load.
3. When the pinion is too deeply (Refer to Figure
666. ) in mesh with the bevel gear do the
following:
Figure 666.
J
AA
J
AA
4.1. Decrease the shim thickness between the

pinion drive assembly and the main case.
4.2. Increase the shim thickness between the
bevel gear assembly and the main case
equally to maintain backlash.
5. When the correct gear meshing is achieved,
calculate the backlash check.
3.1. Increase the shim thickness between the Shim Selection Methods
pinion drive assembly and the main case.
3.2. Decrease the shim thickness between the Three methods of shim selection are used which
bevel gear assembly and the main case depends on the parts replaced during assembly:
equally to maintain backlash.
• Method A: Assembly using all the original
4. When the pinion is too far (Refer to Figure 667. ) components.
out of mesh with the bevel gear do the following: • Method B: Assembly using complete new gear/
bearing assemblies or gearbox case.
• Method C: Comparing relevant sizes of old and
replacement components and then adjusting
the shim pack accordingly. This method must
be used when you replace the taper roller
bearings. It can also be of use if some deviation
markings are illegible.
Method A
1. As the original gears and bearings are being
installed use the shims that were removed during
disassembly in their original positions.
2. Set the backlash.
27 - 263 9823/1650-1 27 - 263

27 - Driveline
00 - General
Method B
Figure 668.
AH AL
V
E
AK
AG
AN AP
AJ AM
E Shim set 1 V Shim set 2

AG Pinion assembly deviation AH Pinion gear deviation
AJ Pinion housing deviation AK Bevel assembly deviation
AL Bevel gear deviation AM Bevel housing deviation
AN When installing replacement pinion drive gear AP When installing replacement bevel drive gear
assemblies, the sum of AG and AH is marked assemblies, the sum of AK and AL is marked
at AN. at AP.
When you assemble the new gear/bearing Table 319. Pinion Drive Gear Assembly
assemblies it is possible to arrive at a nominal shim
Item Description Devia-
stack thicknesses by calculation.
tion/Thick-
Due to component tolerancing some deviation is ness
built up from base dimensions. These deviations AG Pinion assembly deviation 0
are marked on the relevant components during AH Pinion gear deviation +18
manufacture. Typical locations of deviation markings AN
(1)
=18
are shown. Refer to Figure 668.
AJ Pinion housing deviation +19
If some of the markings are not visible then it will Total =37
not be possible to calculate shim thicknesses. In this Constant +40
event start by installing 0.5 mm nominal shims to Shim stack thickness 0.77
each gear assembly, then set the backlash.
(1) When installing replacement pinion drive gear
Calculate the shim stack thickness. Refer to Table assemblies, the sum of AG and AH is marked at AN.
319. and Refer to Table 320.. When you note down Table 320. Bevel Gear Assembly
the pinion gear housing and bevel gear housing
deviations a positive value becomes a negative value Item Description Devia-
and a negative value becomes a positive value, e.g. tion/Thick-
-19 becomes +19 in the pinion gear calculation. Refer ness
to Table 319. AK Pinion assembly deviation 17
AL Pinion gear deviation +60
AP
(1)
=77
27 - 264 9823/1650-1 27 - 264

27 - Driveline
00 - General
Item Description Devia- Figure 669.

tion/Thick-
ness
AM Pinion housing deviation +27
Total =104
Constant +20
Shim stack thickness 1.24
(1) When installing replacement pinion drive gear
assemblies, the sum of AK and AL is marked at AP.
Select shims to make up the nearest thickness for

each gear assembly.
Important: In all cases use the calculations as a

starting point. Verify with the backlash and gear tooth
mark checks.
X
Method C
1. When the taper roller bearings are replaced: 1.3. Subtract the value derived in step 1.2 from
the relevant shim stack.
1.1. Measure and record the thickness of the
existing shim stack. Length/Dimension/Distance: 0.33 mm
1.2. Compare the old and new dimension
measured during assembly. Refer to Table
321.
Table 321.
Old = 40.65
New = 40.32
Result = 0.33
1. When the pinion and bevel gears are replaced: 1.3. Subtract the value derived in step 1.2 from
1.2. Compare the old and new gear deviations.

Refer to Table 322.
Table 322.
AH Old (Pinion gear) = 30
AH New (Pinion gear) = 40
Result = + 0.1
1. When the gearbox case is replaced: 1.4. Subtract the value derived in step 1.2 from
1.2. Compare the old and new housing Figure 670.

deviations. Refer to Table 323.
1.3. When you record the housing deviation 0
a positive figure becomes a negative
figure and a negative value becomes a
positive value, e.g. -19 becomes +19 in a -8 + 19
calculation. Refer to Table 323. - 27
27 - 265 9823/1650-1 27 - 265

27 - Driveline
00 - General
Table 323.
AJ Old (Pinion gear) = 30
AJ New (Pinion gear) = 40
Result The deviation has altered from +19
to -8, a total of -27 units. Refer to
Figure 670.
If the case deviation markings are not visible it will Figure 671.
not be possible to calculate shim stack adjustment.
In this event start by installing 0.5 mm nominal shims
to each gear assembly, then set the backlash.
1. Replacement of the gear assemblies when the

deviation markings are not visible:
existing shim stack.
1.2. Remove the gear and measure the new
dimension.
1.3. Compare the old and new dimension (old

dimension measured during dismantling,
see gear disassembly procedure).
1.4. Compare the old and new gear deviations.
1.5. Subtract the value derived in step 1.4 from
Table 324.
Old = 40.65
New = 40.32
Result = - 0.33
Table 325.
AH Old (Pinion gear) = 30
AH New (Pinion gear) = 40
Difference = + 0.1
Add difference from Refer to Table = - 0.33
324.
Result = - 0.23
27 - 266 9823/1650-1 27 - 266

27 - Driveline
00 - General
Remove and Install
Remove 3. Remove the torque converter. Refer to driveline-

torque converter, refer to (PIL 27-14).
1. Because of the configuration of the engine
and the transmission mounting system, we 4. Remove the hydraulic pump. Refer to hydraulic
recommend to remove the engine and the system- gear pump, refer to (PIL 30-11).
transmission as a full assembly.
5. Support the bevel gearbox with suitable lifting
2. Remove the gearbox. Refer to driveline- semi- equipment and remove the flywheel housing
automatic gearbox, refer to (PIL 27-06). bolts on the engine.
6. Take out the gearbox from the engine.
Figure 672.
A Flywheel housing bolts
27 - 267 9823/1650-1 27 - 267

27 - Driveline
00 - General
Install
removal procedure.

Item Nm
A 70
27 - 268 9823/1650-1 27 - 268

27 - Driveline
00 - General
Special Tools Special Tool: Reaction Block Fixture (Qty.:

Description Part No. Qty. 1)
Heavy Duty Socket 892/00912 1 1.5. With a heavy duty socket of the specified
46mm A/F value, remove the stake nut 1.
Heavy Duty Socket 892/00914 1 Dimension: 55 mm
55mm A/F Special Tool: Heavy Duty Socket 55mm A/
Reaction Block Fixture 892/00915 1 F (Qty.: 1)
Consumables 1.6. Remove the spacer 1.

Description Part No. Size 1.7. Remove the O-ring 1 and then remove the
Special HP Grease 4003/2020 0.5 kg pinion gear. Make sure you also remove the
4003/2017 0.4 kg bearing 1 and spacer 2.
4003/2006 12.5 kg 1.8. Remove the triple-lip seal 1 and the O-ring
4003/2005 50 kg 2.
1.9. Important: If the bearings or the gear
Machines (Before 2011) assembly is to be replaced, measure and
record the dimension as shown below.
Earlier (before 2011) and later (after 2011) Make sure you use suitable measuring
procedures are shown. Make sure you refer to the equipment with an accuracy of the specified
correct procedures for your machine. value.
Dimension: 0.01 mm
Disassemble
Figure 673.
Remove the gearbox from the machine, place
assembly.
Cleanliness is of the utmost importance when you

service the gearbox. All precautions to prevent any
ingress of dirt, grit etc. must be taken. Wash the
exterior of the gearbox assembly, refer to Transfer
Gearbox-Clean (PIL 27-12).
Make sure you note the orientation of the mounting

bushes if their replacement is required. Use a
suitable tube to press the outer steel ring of the
bushes during removal/installation of the mounting
bushes. Make sure the new bushes are installed in
their correct orientation and are positioned properly
in the housing bosses.
X
Disassemble the gear assembly as follows (For
Machines before 2011).
1.10. Remove the bearing cups from the pinion
1. Remove the pinion drive gear assembly. gear housing.
1.11. Put a suitable drift through the two holes
1.1. Remove the bolts 1 that attach the in the pinion gear and then remove the
pinion drive gear assembly to the gearbox bearing2 from the gear.
housing.
1.2. If necessary, use a jacking bolt in the tapped 2. Remove the bevel gear assembly.
extraction holes on the pinion gear housing. 2.1. Remove the bolts 2 that attach the bevel
1.3. Remove the shim set 1 and put a label as gear assembly to the gearbox housing.
'for use with the pinion gear assembly.' 2.2. If necessary, use a jacking bolt in the tapped
1.4. Use a reaction block to hold the gear extraction holes on the bevel gear housing.
assembly in a vice.
27 - 269 9823/1650-1 27 - 269

27 - Driveline
00 - General
2.3. Remove the shim set 2 and put a label as Figure 674.
'for use with the bevel gear assembly.'
2.4. Use a reaction block to hold the gear
assembly in a vice.
Special Tool: Reaction Block Fixture (Qty.:
1)
2.5. With a heavy duty socket of the specified
value, remove the stake nut 2.
Dimension: 46 mm
Special Tool: Heavy Duty Socket 46mm A/
F (Qty.: 1)
2.6. Remove the washer, drive flange 1, and the
O-ring 3.
2.7. Remove the bevel gear. Make sure you also
remove the bearing 3 and spacer 3.
X
2.8. Remove the triple-lip seal 2 and the O-ring
4.
2.10. Remove the bearing cups from the bevel
2.9. Important: If the bearings or the gear gear housing.
assembly is to be replaced, measure and
record the dimension as shown below. 2.11. Put a suitable drift through the two holes
Make sure you use suitable measuring in the pinion gear and then remove the
equipment with an accuracy of the specified bearing 4 from the gear.
value.
Dimension: 0.01 mm
27 - 270 9823/1650-1 27 - 270

27 - Driveline
00 - General
Figure 675. Gearbox (Before 2011)

AF
T
U
AD
Z
X
AA
AC
V
AB
AE
Y
W
S
Q L
R
E
C
D
K
H
N
F J
B M
G
A Gearbox housing B Bolt 1

C Pinion gear housing D Extraction holes
E Shim set 1 F Nut 1
G Spacer 1 H O-ring 1
27 - 271 9823/1650-1 27 - 271

27 - Driveline
00 - General
J Pinion gear K Bearing 1

L Bearing 2 M Spacer 2
N Triple lip seal 1 P O-ring 2
Q Mounting bushes R Housing bosses
S Bolt 2 T Bevel gear housing
U Extraction holes V Shim set 2
W Nut 2 X Washer
Y Drive flange 1 Z O-ring 3
AA Bevel gear AB Bearing 3
AC Bearing 4 AD Spacer 3
AE Triple lip seal 2 AF O-ring 4
27 - 272 9823/1650-1 27 - 272

27 - Driveline
00 - General
Assemble Figure 676.
The bevel gear and the pinion drive gear are a

matched pair and must be replaced as a set if
one of the two gears is damaged or excessively
worn. It is recommended that complete built-up gear/
bearing assemblies are installed in the event of gear
replacement.
Important: When you assemble the gearbox with

replacement or original components, the rolling
torques, backlash, shim stacks and gear meshing 2.15. Use the reaction block to hold the
must be checked and adjusted as required. assembly in the vice.
1. Make sure all bearings are lubricated before Special Tool: Reaction Block Fixture (Qty.:
installation. Rotate the bearings while you set 1)
them. Make sure the oil ways in the bearing
2.16. Install the nut 1.
carriers and gearbox housing are clean and
clear. This is particularly important if bearings 2.17. Tighten the nut to the correct torque value
have failed. Make sure you install new o-rings with a socket of the specified dimension.
and stake nuts. Dimension: 55 mm
2. Assemble the pinion drive gear (for machines 2.18. Do not stake the nut 1 at this stage.
before 2011):
2.19. Measure the bearing rolling torque. Make
2.1. Check the pinion drive gear assembly end sure the rolling torque is between the
float. specified value.
2.2. Press the inner bearing 2 onto the pinion Torque: 0.5 –2.5 N·m
gear. 2.20. Excessive rolling torque indicates an
2.3. Install the spacer 2 selected in step 2.1. incorrectly installed seal.
2.4. Install the pinion gear and the bearing 2 into 2.21. Stake the nut 1 with a square ended
the pinion gear housing. staking tool.
2.5. Install the inner bearing 1 onto the pinion Figure 677.
gear.
2.6. Use the reaction block to hold the pinion
gear assembly in a vice.
2.7. Install the spacer 1 and nut 1.
2.8. Tighten the nut to the correct torque value
with a socket of the specified dimension.
Dimension: 55 mm
2.9. Do not stake the nut 1 at this stage.
2.10. Measure the bearing rolling torque. Make F
sure the rolling torque is between the
specified value. 2.22. For figure, Refer to Figure 675.
Torque: 0.5 –1.5 N·m 3. Assemble the bevel gear assembly (for
2.11. Remove the nut 1 and the spacer 1. machines before 2011).
2.12. Install the new O-ring 1. 3.1. Check the bevel gear assembly end float.
2.13. Install a new triple lip seal 1 with a 3.2. Press the inner bearing 4 onto the bevel
suitable mandrel. Make sure that the seal gear.
is installed correctly in its housing.
3.3. Install the spacer 3 selected in step 3.1.
2.14. Carefully install the spacer 1 inside the
triple lip seal 1. Make sure that the outer 3.4. Install the pinion gear and the bearing 4 into
lip of the seal is against the housing. the bevel gear housing.
27 - 273 9823/1650-1 27 - 273

27 - Driveline
00 - General
3.5. Install the inner bearing 3 onto the bevel 3.18. Do not stake the nut 2 at this stage.
gear.
3.19. Measure the rolling torque. Make sure
3.6. Use the reaction block to hold the bevel the rolling torque is between the specified
gear assembly in a vice. value.
Special Tool: Reaction Block Fixture (Qty.: Torque: 0.5 –2.5 N·m
1)
3.20. Excessive rolling torque indicates an
3.7. Install the drive flange 1, washer, and the incorrectly installed seal.
nut 2.
3.21. For figure, Refer to Figure 675.
3.8. Tighten the nut 2 to the correct torque value
with a socket of the specified dimension. Table 327. Torques (Before 2011)
Dimension: 46 mm Item Torque
3.9. Do not stake the nut 2 at this stage. B 85
F 300
3.10. Measure the bearing rolling torque. Make
sure the rolling torque is between the S 85
specified value. W 300
Torque: 0.5 –1.5 N·m
Machines (After 2011)
3.11. Remove the nut 2, washer, and the drive
flange 1. Disassemble
3.12. Install the new O-ring 3.
Disassemble the gear assembly as follows (for
3.13. Install a new triple lip seal 2 with a machines after 2011).
suitable mandrel. Make sure that the seal
is installed correctly in its housing. 1. Remove the bolted bevel gear assembly.
3.14. Carefully install the drive flange 1 inside 1.1. Remove the screws that attach the adaptor
the triple lip seal 2. Make sure that the to the drive flange.
outer lip of the seal is against the housing.
1.2. Remove the adaptor.
Figure 678.
assembly in a vice.
1)
1.4. Remove the set screw.
1.5. Remove the drive flange.
1.6. Remove the pinion gear.
1.7. Remove the triple lip seal and the O-ring 2.
3.15. Use the reaction block to hold the 1.8. Remove the O-ring 1.
assembly in the vice.
1.9. Remove the bearing and spacer.
1) 1.10. Put a suitable drift through the two holes
in the pinion gear and then remove the
3.16. Install the washer and the nut 2. bearing 8 from the gear.
3.17. Tighten the nut 2 to the correct torque
value with a socket of the specified
dimension.
Dimension: 46 mm
27 - 274 9823/1650-1 27 - 274

27 - Driveline
00 - General
Figure 679. Bevel Gear Assembly (Bolt)

8
2
9
20
16 17 5 4 2 3 1
1 Bevel gear 2 Bearing

3 Spacer 4 Carrier- bearing
5 Triple lip seal 8 O-ring 1
9 O-ring 2 16 Drive flange
17 Setscrew 20 Adaptor
1. Remove the bevel gear assembly (nut). Refer to

Figure 680.
assembly in a vice.
1)
1.2. Remove the stake nut.
1.3. Remove the pinion gear from the bearing
carrier.
1.4. Remove the triple lip seal 3 and the O-ring
5.
1.5. Remove the O-ring 6.
1.6. Remove the bearing 6 and spacer 5.
1.7. Put a suitable drift through the two holes
in the pinion gear and then remove the
bearing 6 from the gear.
27 - 275 9823/1650-1 27 - 275

27 - Driveline
00 - General
Figure 680. Bevel Gear Assembly (Nut) AM Spacer 4

AN Stake nut 3
AP O-ring 6
AQ O-ring 5
Make sure you do not discard any component at this

stage.
Inspect the gearbox assembly. Refer to (PIL 27-12).
AN
AM
AQ
AL
AK
AP
AJ
AH
AG
AG Pinion gear 2
AH Bearing 6
AJ Spacer 5
AK Bearing 5
AL Triple lip seal 3
27 - 276 9823/1650-1 27 - 276

27 - Driveline
00 - General
Figure 681. Gearbox (After 2011)
4
8
3 2 5 16
17 20
11 2
5 9
6
7
1
8 2
2 3
459-10234-2
1 Bevel gear 2 Bearing- taper roller

3 Kit- bearing spacer 4 Carrier- bearing
5 Seal- triple lip 6 Spacer- seal ring
7 Nut- stake M36 (55 mm head) 8 O-ring seal
9 O-ring seal 11 Bevel gear
16 Flange- drive 17 Setscrew
20 Adaptor
Assemble sure the bearings are rotated whilst being

set.
1. Assemble the bevel gear assembly (bolt). (For
Consumable: Special HP Grease
machines after 2011)
1.2. Make sure the lubrication route and seal
1.1. Make sure the bearing rollers are packed vents in the bearing hub are not blocked
with the correct grease before setting. Make by excess grease. Do not overpack the
bearings.
27 - 277 9823/1650-1 27 - 277

27 - Driveline
00 - General
1.3. Pack the cavity between the seal lips with 1.17. Excessive rolling torque indicates an
the correct grease before assembly. incorrectly installed seal. Renew the seal
if it is damaged.
1.4. Select a bearing spacer to achieve the
specified preload. 1.18. Install the adaptor. Tighten the fastenings
to the correct torque. Refer to (PIL 72).
1.5. Press the bearings into the bearing carrier 2. Assemble bevel pinion drive gear (nut). (For
Make sure you install the spacer. Refer to machines after 2011). Refer to Figure 680.
Figure 681. and Refer to Figure 680.
2.1. Make sure the bearing rollers are packed
1.6. Install the triple lip seal. with the correct grease before setting. Make
sure the bearings are rotated whilst being
1.7. Install the pinion gear the bevel gear
set.
bearing housing.
1.8. Carefully install the drive flange 2 inside the
triple lip seal 4. Make sure that the outer lip 2.2. Make sure the lubrication route and seal
of the seal is against the housing. vents in the bearing hub are not blocked
by excess grease. Do not overpack the
Figure 682. bearings.
2.3. Pack the cavity between the seal lips with
the correct grease before assembly.
2.4. Select a bearing spacer to achieve the
specified preload.
2.5. Press the bearings into the bearing carrier.
Make sure you install the spacer. Refer to
Figure 681. and Refer to Figure 680.
1.9. Use the reaction block to hold the bevel 2.6. Install the triple lip seal.
2.7. Install the pinion gear in the bevel gear
bearing housing.
1)
2.8. Install the O-ring 5.
1.10. Take up the free play on the setscrew.
2.9. Carefully install the spacer 4 inside the triple
1.11. Check the seal drag is within specified
lip seal 3. Make sure that the outer lip of the
limits.
seal is against the housing.
Torque: 0.4 –0.75 N·m
Figure 683.
1.12. If the seal drag is within limits, tighten the
setscrew to the specified torque value.
Torque: 395 N·m
the rolling torque is between the specified
value.
1.14. Use the reaction block to hold the bevel
2.10. Install the O-ring 6.
1.15. Install the set screw and tighten it to the
specified torque value. 2.11. Use the reaction block to hold the bevel
Torque: 395 N·m
1.16. Measure the rolling torque. Make sure 1)
value. 2.12. Take up the free play on the stake nut. Do
not stake the nut.
27 - 278 9823/1650-1 27 - 278

27 - Driveline
00 - General
2.13. Check the seal drag is within specified 6. Set the backlash. Refer to driveline, transfer
limits. gearbox, calibrate (PIL 27-12-00).
Torque: 0.4 –0.75 N·m 7. Examine the gear meshing. Refer to driveline,
2.14. If the seal drag is within limits, tighten the transfer gearbox, calibrate (PIL 27-12-00).
stake nut to the specified torque value.
Torque: 395 N·m
value.
2.16. Excessive rolling torque indicates an
incorrectly installed seal. Renew the seal
if it is damaged.
2.17. If the rolling torque is correct, stake the nut.
The nut is to be split axially using a square
ended tool.
Figure 684.
3. Install the bevel gear assemblies into the

gearbox case. Tighten the bolts to the correct
torque value.
4. Measure the correct thickness required for the
bevel gear assembly shim sets 1 and 2.
5. Important: Correct gear meshing and backlash
settings are essential for the reliable operation of
the gearbox. The settings are obtained by means
of variable shim stacks. Three methods of shim
selection are used which depends on the parts
replaced during assembly:
5.1. Method A: Assembly using all the original
components.
5.2. Method B: Assembly using complete
new gear/bearing assemblies or gearbox
casing.
5.3. Method C: Shim pack thickness can be
calculated by comparing relevant sizes of
old and replacement components and then
adjusting the shim pack accordingly. This
method must be used when you replace the
taper roller bearings. It can also be of use if
some deviation markings are not visible.
27 - 279 9823/1650-1 27 - 279

27 - Driveline
14 - Torque Converter
Contents Page No.
27-14-00 General ......................................................................................................................... 27-281

27-14-06 Control Valve ................................................................................................................ 27-289
27-14-09 Relief Valve .................................................................................................................. 27-291
27 - 280 9823/1650-1 27 - 280

27 - Driveline
00 - General
Introduction .................................................. 27-281 The torque converter is a type of fluid coupling that
Component Identification ............................. 27-282 is used to transfer rotating power from the engine to
Operation ..................................................... 27-282 a rotating driven load.
Check (Operation) ....................................... 27-283
The torque converter normally takes the place of
Remove and Install ..................................... 27-287 a mechanical clutch in a vehicle with an automatic
transmission, allowing the load to be separated from
the power source.
It is usually located between the engine flywheel and

the transmission.
The key characteristic of a torque converter is its

ability to multiply torque when there is a substantial
difference between input and output rotational
speed, thus providing the equivalent of a reduction
gear. Some torque converters are equipped with a
temporary locking mechanism which rigidly locks the
engine to the transmission when their speeds are
nearly equal, to avoid slippage and a resulting loss
of efficiency.
27 - 281 9823/1650-1 27 - 281

27 - Driveline
00 - General

Figure 685. The torque converter is similar to a fluid coupling,
which utilises the centrifugal force exerted in the
transmission oil to transmit power from the engine to
D the gearbox. It multiplies the torque from the engine
and functions as a combined clutch and infinitely
variable reduction gearbox.
The torque converter is enclosed in a casing and

consists of three basic parts, the impeller, reaction
member and turbine.
A
The impeller is driven by the engine.
B The reaction member does not rotate. Its hub
engages with a splined tube on the gearbox oil pump
and is held stationary.
The turbine is engaged with the splined end of the

G C gearbox input shaft.
The impeller driven by the engine, forms one set

of shaped blades, it can be likened to a centrifugal
pump imparting energy to the transmission oil. This
F E energy is transferred to another set of shaped
blades, which form the turbine. The turbine is
connected to the gearbox and converts the energy
back to a mechanical torque.
H
When the impeller is rotating faster than the turbine,
the fixed reaction member causes some of the
energy in the oil to be transferred back to the impeller.
This has the effect of multiplying the torque available.
When the impeller (input) is running much faster

than the turbine (output) there is a substantial
circulation of transmission oil around the blades. The
oil circulation is maximum when the turbine (output)
is stalled, and is almost zero when the impeller and
turbine speeds are equal i.e. the ratio is near 1:1.
If the turbine (output) is stalled whilst the impeller
(input) is revolving, all the power is dissipated as
A Impeller heat.
B Turbine
C Reaction member Because of the absence of a direct mechanical
D Drive plate (engine driven bevel gearbox) connection between the engine and the gearbox,
E Drive to gearbox input shaft the flexibility of the torque converter drive greatly
F Spline location for reaction member reduces wear on the transmission, absorbing shocks
G Direct drive from the engine to the gearbox oil and torsional vibration from the engine. The engine
pump cannot be stalled due to overload, as the fluid
H Direction of oil flow coupling slips.
For illustration refer to Component Identification (PIL

27-14-00).
27 - 282 9823/1650-1 27 - 282

27 - Driveline
00 - General
Check (Operation)
CAUTION Do not stall the converter for longer torque converter. This is the point at which, due to
than 10 seconds or the transmission fluid will torque applied by the engine the torque converter
overheat. Make sure the transmission oil level stops transmitting drive to the gearbox.
is correct before and after carrying out the test.
Make sure you check the oil level at normal The engine speed at which stalling occurs is
operating temperature. compared to speeds recorded for a machine in
normal condition.
Notice: Before starting the stall test, make sure
that the mainline and clutch pressures are correct. Stall tests can be used to diagnose faults with the
If the pressures are not correct, the clutches transmission.
could slip, resulting in premature wear of the
transmission friction plates. Also make sure the
machine neutral circuit and steer circuit pressures Technical Data Check List
are correct.
Record the test results in a check list for easy fault
identification. This section includes a blank check list
Stall Test to copy and use as required. Refer to Figure 686.
The purpose of the stall test is to check the The check list will help the engineer to identify the
performance of the transmission by stalling the cause of a gearbox fault, and if required, can be sent
to the JCB Technical Service Team via e-mail.
27 - 283 9823/1650-1 27 - 283

27 - Driveline
00 - General
Figure 686.
27 - 284 9823/1650-1 27 - 284

27 - Driveline
00 - General
Procedure 4. When fully engaged, the park brake electrically

disconnects the transmission drive. This
The purpose of the stall test is to check the prevents the machine from being driven with
performance of the transmission by `stalling' the the park brake on. Therefore, so that we can
torque converter. This is the point at which, due to complete the test, move the park brake lever
torque applied by the engine, the torque converter fractionally forward until the warning light is just
stops transmitting drive to the gearbox. The engine extinguished.
speed at which `stalling' occurs is compared to
speeds recorded for a machine in normal condition. 5. Hold the lever in this position for the duration of
Abnormal stall speed results can be used to identify the test.
possible faults as follows: 6. Do not move the lever too far forward, otherwise
the park brake will not be fully operational.
1. Poor engine performance
7. Do not disconnect the switch at the park brake.
2. Faulty torque converter
8. Select the 1st speed forward drive and open
3. Faulty gearbox hydraulic clutches
throttle fully. Record the engine speed from the
4. Faulty torque converter relief valve tachometer.
5. Transmission hydraulic leaks 9. Repeat the test in reverse drive.
6. Faulty hydraulic system relief valves 10. Repeat the test with the machine in each
configuration as described in the stall data tables.
For normal stall speed values refer to driveline- semi- Refer to driveline- semi-automatic gearbox, refer
automatic gearbox, refer to (PIL 27-06). to (PIL 27-06).
Do not stall the converter for longer than 10 seconds 11. For the machines with powershift gearboxes,
or the transmission fluid will overheat. Make sure repeat the test in 2nd and 3rd gears in both
that the oil level is correct and at normal operating forward and reverse drive.
temperature.
12. All recorded readings should be as specified.
If the machine is installed with a variflow hydraulic Refer to driveline- semi-automatic gearbox, (PIL
pump, make sure that the hydraulic oil temperature 27-06).
is above 50 °C ( 121.9 °F). Also make sure that
the valve block LSRV (Load Sense Relief Valve) Interpreting the Test Results
pressure and the variflow pump Delta P pressure are
set correctly. If all the engine speeds are below the stated figures
either the engine is losing power and should be
Before completing the following test, remove the serviced/ overhauled or the torque converter reaction
transmission dipstick. If there is any sign of member clutch is slipping. To check the engine,
smoke emitting from the dipstick tube stop the select neutral, open throttle fully and operate a
test immediately and dismantle the transmission for hydraulic service to 'blow off' the main relief valve.
servicing. Engine speed should fall to slightly below the
maximum governed speed. Refer to (PIL 15-00). If
1. Check all engine fluid levels. Run the engine at engine speed is correct the torque converter reaction
maximum speed and check the no load speed. member clutch is slipping.
Refer to Engine, General, General, Technical
Data, (PIL 15-00-00). If all the engine speeds are higher than the stated
figures in all gears the torque converter safety relief
2. Make sure that the engine and transmission are valve may be faulty. Alternatively there may be
at normal working temperature (the transmission internal oil leakage.
oil must be above the specified temperature).
Run engine at maximum speed and check the If the engine speeds are higher than the stated
engine speed is correct (High Idle/ maximum figures in some gears, check the transmission for
governed speed). Refer to engine- general, refer clutch slippage or internal leakage.
to (PIL 15-00).
The example given below shows how the results can
be used to isolate a suspect clutch.
3. Apply the park brake and foot brake firmly.
If necessary, set the machine against a fixed
obstruction.
27 - 285 9823/1650-1 27 - 285

27 - Driveline
00 - General
Table 328.
Stall Test Results- 4 Speed Powershift
Gear Clutches engaged
Forward RPM (Revolutions Reverse RPM
Per Minute)
1st T, Z 1990 W, Z 1980
2nd U, Z 2060 V, Z 1975
3rd T, Y 1985 W, Y 1990
In the example shown, the engine speed is

abnormally high when 2nd gear forward drive is
selected, indicating a slipping clutch, possibly U or
Z. We can now use the results to determine which
clutch is at fault.
As per the details from the table, there is no problem

with clutch Z since it is engaged in other gears,
the stall speeds for those gears are normal. This
indicates that the clutch U is slipping.
Clutches may slip for several reasons. Hydraulic

leakage is possible and this can be confirmed by
carrying out a pressure test. Refer to driveline- semi-
27 - 286 9823/1650-1 27 - 286

27 - Driveline
00 - General
Remove and Install 3.3. Make a note that it is important to protect

the converter drive tube against damage or
Special Tools contamination at all times.
4. Install the drive plate retaining bolt 1 (x4).
Torque Converter 892/01110 1
Alignment Tool 5. Tighten the drive plate retaining bolt to the correct
torque value.
Remove
6. Remove the alignment tool.
1. Due to the configuration of the engine and
7. Install the remaining bolt 1 (x2).
transmission mounting system, we recommend
to remove the engine and the transmission as a 8. Keep the torque converter and drive plate
full assembly. assembly on the flywheel.
2. The torque converter is part of the gearbox 9. Install the bolt 1 (x3) on the drive plate and the
assembly. Remove the gearbox with torque flywheel.
converter.
10. Check the converter run-out as shown.
Install
11. Make sure that the converter run-out is within the
1. Make sure that the flywheel face, drive plate and specified limits.
hardware are clean and free from burrs or other Dimension: 0.38 mm
surface imperfections.
12. If the run-out exceeds the specified limit, do the
2. Keep the drive plate on the torque converter. following.
3. Place the specified torque converter alignment 12.1. Remove the converter.
tool over the torque converter spigot.
12.2. Check the spigot for burrs.
Special Tool: Torque Converter Alignment Tool
(Qty.: 1) 12.3. Remove the drive plate.
3.1. Make a note that the alignment tool is used 12.4. Rotate the specified drive plate to the
one way around for the 12” and the other specified angle on the torque converter.
way round for W300 torque converters. Angle: 180 °
3.2. Make sure that the tool locates in two of the 12.5. Do the steps 3 to 12 again.
torque converter bolt holes as shown. Refer
to Figure 687. Figure 688.
G
Figure 687.
E
D
B A
E
F
A Drive plate
E Bolt 1
F DTI (Dial Test Indicator)
G Bolt 2
B Drive plate retaining bolts 13. Remove the torque converter and drive plate
C Alignment tool assembly from the flywheel.
D Torque converter assembly
14. Install the torque converter with its drive plate
assembly onto the transmission input shaft.
27 - 287 9823/1650-1 27 - 287

27 - Driveline
00 - General
15. Make sure that the converter pump drive shaft

engages with the recesses in the pump.
16. Take care not to damage the oil seal.
17. Rotate the engine flywheel so that one bolt hole
is in a six O' clock position.
18. Rotate the torque converter and drive plate
assembly so that one bolt hole is in a six O' clock
position.
19. Install the transmission/torque converter
assembly to the engine.
19.1. It is very important to install the torque
converter at the gearbox and engine
flywheel correctly.
19.2. Failure to locate the converter correctly will
result in damage to the gearbox oil pump
on engine start up.
20. Remove the access plate from the bottom of the
engine flywheel case.
21. Install the flanged bolt 2 in the six 'O' clock
position through the access hole.
22. Tighten the flanged bolt 2 by hand.
23. Rotate the flywheel until the next bolt 2 hole is
accessible.
24. Install and hand tighten the next bolt 2.
25. Do the steps 21 to 24 for all the bolts 2.
26. Tighten the bolt 2 to the specified torque value.
27. Install the access plate.

Item Nm
B 84
G 44
27 - 288 9823/1650-1 27 - 288

27 - Driveline
06 - Control Valve
06 - Control Valve Figure 689.

E
Remove and Install
C
Gearboxes compatible with a lock-up torque
converter are installed with a control valve and an
interconnecting pipe. Before you disassemble the
gearbox the pipe and valve must be removed.
C
Remove D
1. Remove the pipe nuts and lift off the pipe.
2. Remove the capscrews and remove the solenoid
control valve.
3. Make sure to remove the O-rings (x3) from the
bottom of the valve. D D
C A
B
A Nuts
B Pipe
C Control valve
D Capscrews (x3)
E O-rings (x3)
Install
1. Make sure that the valve sealing interface is not
damaged.
2. Install new O-rings to the valve.
3. Carefully put the valve in position against the
gearbox.
3.1. Make sure that the O-rings are not loose in
their seat.
4. Attach the valve with the capscrews.
5. Tighten the capscrews to the correct torque
value.
27 - 289 9823/1650-1 27 - 289

27 - Driveline
06 - Control Valve
6. Install the pipe and tighten the nuts to the correct

torque value.

Item Nm
A 56
D 9
27 - 290 9823/1650-1 27 - 290

27 - Driveline
09 - Relief Valve
09 - Relief Valve
Remove and Install

(For: PS750 MK4) gearbox.
3. Remove the plug, sealing washer, spring and the
Remove poppet.
1. Clean the area around the valve and the gearbox
case.
Figure 690.
B
C
A Plug B Sealing washer

C Spring D Poppet
27 - 291 9823/1650-1 27 - 291

27 - Driveline
09 - Relief Valve
Install
At the time of installation do the following step.
1. Tighten the plug to the correct torque value.

Item Description Nm
A Plug 56
27 - 292 9823/1650-1 27 - 292

27 - Driveline
22 - Drivehead
22 - Drivehead
Contents Page No.
27-22-00 General ......................................................................................................................... 27-295

27-22-06 Crownwheel .................................................................................................................. 27-315
27-22-09 Pinion Gear .................................................................................................................. 27-317
27 - 293 9823/1650-1 27 - 293

Notes:
27 - 294 9823/1650-1 27 - 294

27 - Driveline
22 - Drivehead
00 - General
Introduction .................................................. 27-295 The axle drivehead transmits drive from the input
Component Identification ............................. 27-296 coupling yoke to the driveshafts through the
Disassemble and Assemble ........................ 27-302 differential unit.
27 - 295 9823/1650-1 27 - 295

27 - Driveline
22 - Drivehead
00 - General
For: 55 Series (3 Piece Axle) ... Page 27-296 Figure 691.

For: 55 Series (1 Piece Axle) ... Page 27-298
(For: 55 Series (3 Piece Axle))
Unit Identification
The axle serial number is stamped on the unit
identification plate. When ordering replacement A
parts, always quote the details on the unit
identification plate. In the case of gear replacements,
always check the part number stamped on the gear,
and the number of teeth. A Identification plate
27 - 296 9823/1650-1 27 - 296

27 - Driveline
22 - Drivehead
00 - General
Location Drawing (448/00063)
Figure 692.
1 15 11 10 16
14
13
12
2
3
5 4
6
7
8
Item Description
Table 332. 10 Bolt Verbus-ripp
Item Description 11 Crownwheel and pinion
assembly
1 Drive case
12 Bearing (taper roller)
13 Side nut
3 Shim
14 Brake piston
4 Spacer
15 Differential assembly
16 Brake piston housing
6 Pinion seal
7 Coupling yoke
8 Stake nut
27 - 297 9823/1650-1 27 - 297

27 - Driveline
22 - Drivehead
00 - General
(For: 55 Series (1 Piece Axle)) Figure 694.
Unit Identification
identification plate as shown. When you make an
mentioned on the unit identification plate. In the case
Figure 693.
27 - 298 9823/1650-1 27 - 298

27 - Driveline
22 - Drivehead
00 - General
Figure 695.
4 5
2 3 6 7 8
Item Description
5 Bevel gears
Table 333.
6 Side nut locking pin
Item Description
7 Differential housing
1 Coupling yoke
8 Crownwheel
2 Driveshaft
3 Side nut
4 Pinion
27 - 299 9823/1650-1 27 - 299

27 - Driveline
22 - Drivehead
00 - General
Location Drawing (448/00040)
Figure 696.
15 10
14
12
13
1
2
11
3
4
5
Item Description
Table 334. 4 Spacer
Item Description 5 Bearing (taper roller)
1 Drivehead carrier 6 Pinion seal
2 Bearing (taper roller) 7 Coupling yoke
3 Shim 8 Stake nut
27 - 300 9823/1650-1 27 - 300

27 - Driveline
22 - Drivehead
00 - General
Item Description
10 Bolt-Verbus Ripp
11 Crown wheel and pinion
assembly
13 Side nut
14 Side nut locking pin
15 Differential assembly
27 - 301 9823/1650-1 27 - 301

27 - Driveline
22 - Drivehead
00 - General
For: 55 Series (3 Piece Axle) ... Page 27-302 2. Mark the brake piston housing and the drivehead
For: 55 Series (1 Piece Axle) ... Page 27-309 for their correct assembly with respect to each
other. Refer to Figure 697.
(For: 55 Series (3 Piece Axle)) 3. Remove the brake piston housing. Refer to
Figure 697.
Special Tools
Description Part No. Qty. 4. Remove the differential side nut locking pin to
Drive Coupling 892/00812 1 allow for readjustment on assembly. Refer to
Spanner Figure 698.
Setting Tool Kit 892/00918 1
Figure 698.
Torque Wrench 993/70111 1 C
(10-100Nm)
Support Bracket 997/11000 1
Disassembly
When the drivehead is installed on the machine it
cannot be disassembled. It is recommended that you
remove the complete axle.
The crownwheel and pinion are matched and should

be replaced as a pair, if either of them are damaged
or excessively worn.
The two differential case halves are also matched as C Side nut locking pin
are the differential side gears and planet gears, do
not use unmatched halves or gears. 5. Remove the other brake piston housing if it is
damaged, but its locking pin must be removed
1. Place the drivehead with the crownwheel at the to allow the side load adjustment on assembly.
top and then remove the capscrews. Refer to Refer to Figure 698.
Figure 697.
6. Lift off the crownwheel/ differential assembly.
Figure 697. Refer to Figure 699.
B A
A Capscrew
B Brake piston housing
27 - 302 9823/1650-1 27 - 302

27 - Driveline
22 - Drivehead
00 - General
H
D
J
G
F
E Pinion
F Pinion seal
D Crownwheel/ differential assembly G Outer bearing cone
H Inner bearing cup
7. If it is necessary to remove the brake piston J Shim
housings then mark the crownwheel end of the
drivehead case to make sure that they are 11. If necessary, drive out the pinion inner bearing
correctly assembled at the time of assembly. cup and shims. Refer to Figure 700.
12. Discard the shims. Refer to Figure 700.
8. Use the spanner to lock the drive yoke and then
remove the stake nut and the yoke. Refer to 13. Do the step 11 to remove the outer bearing cup.
Figure 700. Refer to Figure 700.
Special Tool: Drive Coupling Spanner (Qty.: 1) 14. There are no shims for the outer bearing cup.
9. Use a soft faced hammer to hit the pinion end
shaft until the pinion is free from its front bearing 15. Remove the pinion spacer. Refer to Figure 701.
and then remove the pinion. Refer to Figure 700.
Figure 701.
10. Remove the pinion seal and the outer bearing
cone. Refer to Figure 700.
K L
K Inner bearing cone

L Pinion spacer
16. Remove the inner bearing cone. Refer to Figure
701.
27 - 303 9823/1650-1 27 - 303

27 - Driveline
22 - Drivehead
00 - General
17. Disassembly of the differential unit. Refer to 6. Put the top half of the differential housing on
Figure 702. to the differential and make sure that you have
aligned it correctly. Refer to Figure 703.
17.1. Remove the bolts.
Figure 703.
17.2. Lift off the top half housing.
Figure 702.
M
R
N
R
N S
S P
Q
P
Q
M Bolt
N Top half housing
M Bolt P Spherical washer 1
N Top half housing Q Spherical washer 2
P Spherical washer 1 R Differential bearing cone
Q Spherical washer 2 S Differential gear
R Differential bearing cone
7. Apply Loctite 242 to the threads of the bolts and
S Differential gear
then install them. Refer to Figure 703.
17.3. Remove the differential gears, the
8. Tighten the bolt to the correct torque value. Refer
spherical washer 1 and spherical washer
to Figure 703.
2.
17.4. Remove the differential bearing cones. 9. Check the gears for free rotation. Refer to Figure
703.
Assembly 10. Install the new inner bearing cone on to the
pinion. Refer to Figure 704.
1. If necessary, install a new crownwheel to the
differential case half.
2. Install the crownwheel retaining bolt.
3. Tighten the bolt to the specified torque value.
Torque: 94 N·m
4. Assemble the differential gear and the spherical
washer 1 and spherical washer 2 into the bottom
half of the differential housing. Refer to Figure
703.
5. Install the differential bearing cones. Refer to
Figure 703.
27 - 304 9823/1650-1 27 - 304

27 - Driveline
22 - Drivehead
00 - General
H
K L
J
G
F
K Inner bearing cone
L Pinion spacer
11. Install the largest available solid spacer
E Pinion
(14.20mm) from the solid spacer setting kit. Refer
F Pinion seal
to Figure 704.
G Outer bearing cone
Special Tool: Spacer Kit (Qty.: 1) H Inner bearing cup
J Shim
12. Find the correct thickness for the shims. Refer to
Front Drivehead, Pinion Gear- Calibrate. Refer to 17. Before you put the pinion into the bore, make
Figure 704. sure that it is matched with the crownwheel.
Refer to: PIL 27-22-09. Refer to Figure 705.
13. Install the shims behind the pinion inner bearing 18. The code numbers etched on the pinion end
cup. Refer to Figure 705. face and the crownwheel perimeter should be the
same. Refer to Figure 705.
14. Use a puller tool to make sure that the inner
bearing cup is installed in square. Do not use a 19. Install the pinion outer bearing cone. Refer to
hammer. Refer to Figure 705. Figure 705.
15. Install the outer bearing cup. Refer to Figure 705. 20. Do not install the oil seal at this stage. Refer to
Figure 705.
16. Put the pinion into its bore. Refer to Figure 705.
21. Install the special tool sleeve and the special
pinion shaft adapter. Refer to Figure 706.
22. Tighten the adaptor to the correct torque value.
23. Make sure that the pinion is free to rotate and
there is end float. Refer to Figure 706.
24. End float will prevent the bearing from damage.
27 - 305 9823/1650-1 27 - 305

27 - Driveline
22 - Drivehead
00 - General
T Z
Y
U
1
T Pinion shaft adaptor X Support pillar
U Special tool sleeve Y DTI
V Special bracket Z Torque wrench
W Bolt (M10x30)
33. Set the torque wrench to the specified value and
25. If the pinion is not free to rotate or there is no end measure the end float while you rotate the shaft.
float at this stage check the bearing is installed Refer to Figure 707.
correctly. Refer to Figure 706. Torque: 35 N·m
26. Make sure that the correct size spacer is Special Tool: Torque Wrench (10-100Nm) (Qty.:
installed. Refer to Figure 706. 1)
27. Use two bolts (M10x30) to install the special 34. Correct size solid spacer selection. Refer to
bracket to the drivehead housing. Refer to Figure Figure 707. Refer to Table 335.
706. 34.1. To select the correct size spacer, subtract
Special Tool: Support Bracket (Qty.: 1) the end float obtained at step 33 from the
solid spacer size (14.20 mm).
28. Install the special tool support pillar to the bracket
so that the fork end engages in adaptor. Refer to 34.2. Also subtract 0.04 mm to allow for
Figure 706. theoretical bearing tolerance and pre load.
34.3. The result is the size of spacer to be
29. Make sure that the fork is centrally located on the
installed from the solid spacer kit.
adaptor. Refer to Figure 706.
34.4. If there is no spacer of this size, fit the next
30. If necessary, align the bracket again. Refer to nearest size spacer from the spacer kit.
Figure 706.
31. Install a DTI (Dial Test Indicator). Refer to Figure
707. 35. Remove the sleeve and the temporary spacer.
32. Make sure that the DTI is installed on the
drivehead not on the bracket. Refer to Figure 36. When you remove the temporary spacer make
707. sure that the outer bearing is not damaged. Refer
to Figure 706.
37. Install the correct size spacer from the spacer kit.
27 - 306 9823/1650-1 27 - 306

27 - Driveline
22 - Drivehead
00 - General
38. Install the sleeve. Refer to Figure 706. 49. Gradually tighten the stake nut to the minimum
specified torque value, occasionally rotate the
39. Tighten the adaptor to the specified value, to coupling yoke. Refer to Figure 708.
protect against bearing damage while spacer
selection is verified and make sure that the pinion Torque: 250 N·m
is free to rotate. Refer to Figure 706. 50. If the correct size spacer is selected, the rolling
Torque: 50 N·m torque should be within the specified torque
value including the seal drag. Refer to Figure
40. Check there is no end float and pinion is free to 708.
turn smoothly by hand. Refer to Figure 706.
41. Remove the adaptor and install the stake nut.
Refer to Figure 706. 51. When the torque value is correct, use a square-
ended staking tool to stake the nut to the pinion
42. Check that rolling torque is less than 2.0 Nm. If shaft. Refer to Figure 708.
the rolling torque exceeds 2.0 Nm, check that the
shaft is assembled correctly. Refer to Figure 706. 52. The stake nut tightening torque value can be
increased to a maximum of 300 Nm if the pinion
43. If the pinion is not free to rotate then check the rolling torque does not exceed the maximum of
correct size spacer is installed or not. Refer to 3.4 Nm. Refer to Figure 708.
Figure 706.
Figure 709.
44. If rolling torque measured at step 42 is too high
then install the next larger size spacer. If the
rolling torque is too low then install the next
smallest size spacer. Refer to Figure 706.
45. If a correct spacer is not available from the range,
check that drivehead is assembled correctly.
46. Remove the stake nut and the sleeve. Refer to
Figure 706.
47. Lubricate the seal lips and then install the new oil
seal. Refer to Figure 708.
Figure 708.
AA
AB 53. If the brake piston housing is removed then install
AC one at the opposite end to the crownwheel. Refer
to Figure 711.
54. Apply Loctite 574 to the drivehead mating face,
then install the brake piston housing. Refer to
Figure 711.
55. Make sure that the mark made between the
drivehead and the brake piston housing at the
time of disassembly is aligned. Refer to Figure
AA Oil seal 711.
AB Coupling yoke
AC Stake nut 56. Install the crownwheel/ differential assembly into
the drivehead. Refer to Figure 710.
48. Install the coupling yoke and the new stake nut.
27 - 307 9823/1650-1 27 - 307

27 - Driveline
22 - Drivehead
00 - General
Figure 710. 60. Adjust the differential side nuts to give a bearing
pre-load of the specified value.
Torque: 1.13 –2.26 N·m
D
61. Measure the pre-load by taking another rolling
torque reading and subtracting the torque figure
measured at step 50. The difference is the
bearing pre-load.
62. Measure the crownwheel backlash, it should be
within the specified limit.
63. Adjust the differential side nuts by equal amounts
when you change the backlash.
64. When the backlash and pre-load are both
correct, install the side nut locking pins. Refer to
Figure 711.
65. Check the tooth marks to make sure that
the crownwheel and pinion are set correctly.
D Crownwheel/ differential assembly Refer to Front Drivehead, Crownwheel- Check
(Operation).
57. Install the other side brake piston housing onto Refer to: PIL 27-22-06.
the drivehead. Refer to Figure 711.
Figure 712.
Figure 711.
AD
B A

Value
(1)
Temporary spacer size 14.20

A Capscrew Subtract end float 0.25
B Brake piston housing Total 13.95
C Side nut locking pin
AD Differential side nut Subtract tolerance and 0.04
pre-load
58. Install the capscrews. Refer to Figure 711. Result 13.91
Use next smallest spac- 13.90
59. Tighten the capscrews to the correct torque
er
value. Refer to Figure 711.
(1) All the values are in millimetre (mm).
27 - 308 9823/1650-1 27 - 308

27 - Driveline
22 - Drivehead
00 - General
Table 336. Torque Values 6. Pull out the tension pin 1 and tension pin 2, and
remove the castellated nut 1 and castellated nut
Item Description Nm
2.
M Bolt 46
T Pinion shaft adaptor 50 7. Remove the bearing outer race 1 and bearing
AC Stake nut 250 outer race 2 from the drivehead carrier bores.
A Capscrew 56 8. Drive off the taper roller bearing cone 1 from the
crownwheel differential case half.
(For: 55 Series (1 Piece Axle)) 9. Remove the differential assembly from the
carrier.
Special Tools
Description Part No. Qty. 10. Mark the position of the drive yoke on the splined
shaft.
Spanner 11. Use the special tool to prevent the drive yoke
Setting Tool Kit 892/00918 1 from rotating and remove the pinion nut.
Spacer Kit 921/52600 1 Special Tool: Drive Coupling Spanner (Qty.: 1)
Torque Wrench 993/70111 1 12. Remove the drive yoke.
(10-100Nm) 13. Remove the pinion shaft from the drivehead
Support Bracket 997/11000 1 carrier.
Consumables 14. Prise the pinion oil seal out of the bore.
15. Remove the pinion tail bearing.
JCB Threadlocker 4101/0250 0.01 L 16. If necessary, remove the bearing outer race 3.
Strength) 17. If necessary, remove the bearing cup from
the opposite side of the drivehead carrier and
remove the pinion shims.
Disassembly
18. Remove the spacer and the taper roller bearing
The drivehead consists of the drivehead carrier cone 3 from the pinion.
and pinion assembly, and the differential unit. A
separate disassembly procedure is given for each Disassemble the differential unit (If
sub assembly. necessary)
Disassemble the Drivehead Carrier 1. For LSD (Limited Slip Differential) Refer to Front
Differential, Disassemble and Assemble.
1. Drain the oil from the axle centre case.
2. Remove the differential assembly retaining bolt
2. Completely remove both hub assemblies with the and separate the case half 1 and case half 2.
driveshafts.
3. Remove the side gears and the thrust washer 1
3. Mark the installation position of the drivehead (2 off each).
carrier with respect to the axle case.
4. Remove the bevel gears and thrust washer 2 (4
4. Remove the drivehead carrier retaining bolt and off each) from the trunnion pins.
then remove the drivehead carrier from the axle
case. 5. Remove the taper roller bearing cone 2 from the
differential case half.
5. Clean the drivehead carrier and axle case mating
faces. 6. Remove the Verbus-ripp bolts.
7. Remove the crownwheel from the differential
case half.
27 - 309 9823/1650-1 27 - 309

27 - Driveline
22 - Drivehead
00 - General
Figure 713.
D K L
T
M
Q
G E C
P
R W N
S
F
H J
V
A
B
AG
U
AD
AE
Z
AF
AC
AB
AA
X Y
27 - 310 9823/1650-1 27 - 310

27 - Driveline
22 - Drivehead
00 - General
housing halves are also matched. Do not use

unmatched halves.
Table 337.
Item Description Assemble the differential unit (if necessary)
A Drivehead carrier retain- 1. For LSD Refer to Front Differential, Disassemble
ing bolt and Assemble.
B Drivehead carrier
C Tension pin 1 2. Assemble the trunnion pin, bevel gear 1 and the
bevel gear 2 then the thrust washer 1 and thrust
D Tension pin 2 washer 2 into differential half case 2.
E Castellated nut 1
F Castellated nut 2 3. Put the differential half case 1 onto the half case
2. Make sure you align them properly.
G Bearing outer race 1
H Bearing outer race 2 4. Apply sealant to the differential assembly
J Taper roller bearing retaining bolt and then install it.
cone 1 Consumable: JCB Threadlocker and Sealer
K Differential assembly (Medium Strength)
L Differential assembly re-
taining bolt 5. Tighten the bolt to the correct torque value.
M Case half 1 6. Check the gears for free rotation.
N Case half 2
7. Use new Verbus-ripp bolts to install the
P Side gear
crownwheel.
Q Thrust washer 1
R Bevel gear 8. Tighten the bolt to the correct torque value. Refer
S Thrust washer 2 to table1.
T Taper roller bearing Assemble the drivehead carrier
cone 2
U Verbus-ripp bolt 1. Measure the correct thickness for the seam.
V Crownwheel Refer to Front Drivehead, Pinion Gear- Calibrate.
W Trunnion pin Refer to: PIL 27-22-09.
X Pinion nut
2. Install the shim behind the new bearing cup.
Y Drive yoke
Z Pinion shaft 3. Install the new pinion head bearing cone onto the
AA Pinion oil seal pinion.
AB Pinion tail bearing 4. Install the pinion and bearings into the drivehead
AC Bearing outer race 3 case.
AD Bearing cup
5. Install the largest available solid spacer (14.20
AE Drive pinion shim mm).
AF Spacer
AG Taper roller bearing
cone 3 6. Apply a coat of oil and then install the pinion tail
bearing.
Assembly 7. Do not install the oil seal at this stage.
The procedure below refers to the following aspects 8. Install the special tool sleeve and the special
of the drivehead assembly, which are covered pinion shaft adaptor from the setting kit.
separately in detail.
• Pinion depth setting
• Crownwheel and pinion meshing 9. Tighten the adaptor to the correct torque value.
10. Make sure that the pinion is free to rotate and
Both the crownwheel and pinion and the bevel gear
there is end float, this will prevent any damage
1 and bevel gear 2 are matched and should be
to the bearing. If the pinion is not free to rotate
replaced as a set, if any of their components are
or there is no end float at this stage check the
damaged or excessively worn. The two differential
27 - 311 9823/1650-1 27 - 311

27 - Driveline
22 - Drivehead
00 - General
bearing is installed properly. Also check that the Figure 715.

correct size spacer is installed.
11. Use two (M10x30) nuts and bolts to install the
special bracket on the drivehead housing.
Special Tool: Support Bracket (Qty.: 1) AN
Figure 714.
AM
AL
AJ
AK
AH
AM DTI
AN Torque wrench
16. Set the torque wrench to the specified value and
measure the end float while you rotate the shaft.
Torque: 35 N·m
1)
AH Special tool sleeve
AJ Adaptor 17. To select the right size spacer do the following
AK Special bracket steps. Refer to Table 340.
AL Support pillar 17.1. Subtract the end float obtained in step
12. Install the special support pillar on the bracket so 16 from the solid spacer thickness value
that the fork end engages with the adaptor. (14.20 mm).
17.2. Subtract 0.04mm to allow for theoretical
13. Make sure that the fork is centrally located on the bearing tolerance and pre-load.
adaptor.
17.3. The result is the size of spacer to be
14. If necessary, align the bracket again. installed from the solid spacer setting kit.
15. Install a DTI. Make sure that the DTI is mounted Special Tool: Spacer Kit (Qty.: 1)
on the drivehead and not on the bracket. 17.4. If there is no spacer of this size, then install
the next nearest size spacer.
18. Remove the sleeve and the temporary spacer.
19. Install the correct size spacer from the solid
spacer setting kit.
20. Make sure that you do not damage the outer
bearing.
21. Again install the sleeve and then install the
adaptor.
27 - 312 9823/1650-1 27 - 312

27 - Driveline
22 - Drivehead
00 - General
22. Tighten the adaptor to the correct torque value, 41. Measure the backlash between the crownwheel
to protect against bearing damage while spacer and the pinion and it should be within the
selection is verified making sure the pinion is free specified limit.
to rotate. Length/Dimension/Distance: 0.17 –0.28 mm
23. Check there is no end float and the pinion is free 42. When altering the backlash adjust both the
to turn smoothly by hand. castellated nut in equal amounts.
24. Remove the adaptor and then install the nut. 43. When the backlash and pre-load are both
25. Make sure that the rolling torque is less than 2.0 correct, install the tension pin 1 and tension pin 2.
Nm, if the rolling torque exceeds 2.0 Nm, then 44. Check the tooth marks to verify that the
check that the shaft is assembled correctly or not. crownwheel and the pinion are set correctly.
26. If the pinion is not free to rotate, check the correct 45. Apply JCB Multigasket to the mating faces of the
size spacer has been installed. drivehead carrier and the axle case.
27. If the rolling torque measured at step 25 is Consumable: JCB Multi-Gasket
too high, install the next larger size spacer. If
the rolling torque is too low, install the next 46. Install the drivehead carrier to the axle case with
smallest size spacer. If a correct spacer is not the crownwheel towards the short driveshaft.
available from the range, check that drivehead is
assembled correctly. 47. Install the drivehead carrier retaining bolts.
28. Remove the adaptor and the sleeve. 48. Tighten the bolt to the correct torque value.
29. Lubricate the seal lips and then install the new 49. Reassemble both driveshafts and hub
oil seals. assemblies.
30. Install the coupling yoke and the new stake nut.
Table 338. Torque Settings (55 Series)
31. Gradually tighten the stake nut up to the specified Item Description Nm
torque value, while occasionally rotating the
coupling yoke. A Drivehead carri- 98
er retaining bolt
Torque: 250 N·m U Verbus-ripp bolt 94
32. If the correct size spacer is selected then the
pinion rolling torque should with in the specified
limit. Table 339. Torque Settings (70 and 80 Series)
Torque: 2.3 –3.4 N·m Item Description Nm

A Drive head car- 166
33. The nut tightening torque value can be increased rier retaining
to a maximum of 300 Nm but the pinion rolling bolt
torque does not exceed the maximum of 3.4 Nm. U 'Verbus Ripp' 200
bolt
34. Finally stake the nut into the slot.
35. Install the differential assembly onto the
drivehead carrier. Table 340. Spacer Selection Example
Value
(1)
36. Push the taper roller bearing onto the spigot of

the differential half case2. Temporary spacer size 14.20
Subtract end float 0.25
37. Install the bearing outer race 1 and bearing outer Total 13.95
race 2.
Subtract tolerance and 0.04
38. Install the castellated nut 1 and castellated nut 2 preload
to the drivehead carrier. Result 13.91
39. Do not install the tension pin 1 and tension pin 2 Use next smallest spac- 13.90
at this stage. er
(1) All the values are in millimetre (mm).
40. Adjust the castellated nut to give an increase in
input pinion rolling torque of between 1.36 and
2.5 Nm more than that specified in Step25.
27 - 313 9823/1650-1 27 - 313

27 - Driveline
22 - Drivehead
00 - General

Item Description Nm
L Differential assembly 46
retaining bolt
AJ Adaptor 50
27 - 314 9823/1650-1 27 - 314

27 - Driveline
22 - Drivehead
06 - Crownwheel
06 - Crownwheel Introduction
Introduction .................................................. 27-315 A crown wheel is a rotating gear wheel with teeth set
Check (Operation) ....................................... 27-316 at right angles to its plane, it is usually matched with a
pinion gear that meshes with the crown wheel. They
are mainly used in vehicles to maintain a forward
movement.
27 - 315 9823/1650-1 27 - 315

27 - Driveline
22 - Drivehead
06 - Crownwheel
Check (Operation) Figure 718.
Crownwheel and Pinion Meshing

Meshing of the gears should be checked by marking
three of the pinion teeth with engineers marking
compound and rotating the pinion. The marking will
then be transferred to the crown wheel teeth.
1. Correct tooth marking.

Figure 716.
2. Pinion too deeply in mesh. Move the crown wheel

towards the pinion to correct the backlash.
Figure 717.
3. Pinion too far out of mesh. Move the crown wheel

away from the pinion to correct the backlash.
27 - 316 9823/1650-1 27 - 316

27 - Driveline
22 - Drivehead
09 - Pinion Gear
09 - Pinion Gear Introduction

Introduction .................................................. 27-317 A pinion gear is a small gear that meshes with a
Calibrate ...................................................... 27-318 larger crownwheel. They are mainly used in vehicles
to maintain a forward movement.
27 - 317 9823/1650-1 27 - 317

27 - Driveline
22 - Drivehead
09 - Pinion Gear
Calibrate and record the height. The bearing cups and

rollers are matched sets. Always keep the
Special Tools bearing assemblies together. Make sure that you
Description Part No. Qty. measure only the inner bearing.
Shim Kit 921/M0229 1 Figure 721.
Pinion Depth Setting

E
Determine the pinion depth setting shim size as
follows:
E Inner bearing height
1. Note the deviation figure etched on the pinion
and the deviation figure on the drivehead Shim Size Calculation Example
housing. Both figures are in units of 0.01 mm.
Note: The pinion depth may be etched on the Table 342. Calculation 1.
gear face or on the rear of a gear tooth. Actual Drivehead Case Size
Special Tool: Shim Kit (Qty.: 1) Item Typical Fig- Description
ures
Figure 719.
A 187.6 mm Nominal drive-
D head case size,
fixed at the fac-
tory
B -0.14 mm Drivehead
case deviation,
marked on the
case
Sum of A and B 187.46 mm Actual drive-
head case size
Table 343. Calculation 2. -

Actual Pinion and Bearing Size
Item Typical Fig- Description
ures
D Pinion depth C 150.0 mm Nominal pinion
length, fixed at
Figure 720. the factory
D 0.10 mm Pinion devia-
tion, marked on
the pinion
E 36.6 mm Bearing size, in-
ner pinion bear-
ing
Sum of C, D 186.70 mm Actual pinion
and E and bearing
size
Table 344. Calculation 3. Shim

Size = Calculation 1 - Calculation 2
Typical Figures Description
187.46 - 186.70 = Select the nearest shim
0.76mm size from the shim kit.
B Deviation figure
2. Assemble the pinion inner bearing and its
cup on a flat surface. Lightly oil and rotate
the bearing before measurement. Make sure
that the bearing cup is square and measure
27 - 318 9823/1650-1 27 - 318

27 - Driveline
24 - Differential
24 - Differential
Contents Page No.
27-24-00 General ......................................................................................................................... 27-321
27 - 319 9823/1650-1 27 - 319

Notes:
27 - 320 9823/1650-1 27 - 320

27 - Driveline
24 - Differential
00 - General
Introduction .................................................. 27-321 A differential is a particular type of simple planetary
Component Identification ............................. 27-323 gear train.
Check (Condition) ........................................ 27-325
Disassemble and Assemble ........................ 27-326 The differential couples the drive shaft to half-shafts
that connect to the rear driving wheels. The purpose
of the differential is to allow a speed differential
between the inner and outer wheel while being driven
by the input shaft. In its most common form, the
differential consists of a pinion and ring and planetary
bevel gears to connect the output shafts.
The axle can have the following type of differentials.
1. Open Differential.
2. LSD (Limited Slip Differential).
Open Differential
A standard differential, or what is referred to as an
open carrier. A conventional open differential always
supplies close to equal (because of limited internal
friction) torque to each side. The differential gearing
allows the outer drive wheel to rotate faster than the
inner drive wheel during a turn. This is necessary
when the vehicle turns, making the wheel that is
travelling around the outside of the turning curve roll
farther and faster than the other.
In a standard [open type] differential, the rotational

velocity of the input shaft is the average of the
rotational velocity of the output shafts under normal
traction conditions. Therefore, increasing the speed
of one output shaft will decrease the speed of the
other output shaft.
The problem is an open differential always tries to

balance the torque. It means that if the spider gears
are pushing on both drive gears and one of them
offers lots of resistance and the other side offers no
resistance then it will try to find a balance where both
sides are receiving almost no torque at all. All the
rotational energy is guided to the side with the least
resistance. In the end, that side spins very fast and
the pressure on each drive gear is the same. Almost
no torque is needed to spin one wheel, and since
the open differential always sends the same amount
of torque to both output shafts, almost no torque is
going to the other side as well.
Limited Slip Differential (LSD)

In the most basic sense, a LSD equalizes the
difference in either speed between output shafts or
applied torque between output shafts to maintain
traction in adverse or performance conditions. The
benefits of installing an LSD are:
1. Enhanced traction in snow, gravel, and sand.
27 - 321 9823/1650-1 27 - 321

27 - Driveline
24 - Differential
00 - General
2. More predictable handling at the limits of grip.
This type behaves as an open differential unless one

wheel begins to spin and exceeds that threshold.
The LSD will remain open unless enough torque is
applied to cause one wheel to lose traction and spin,
at which point it will engage.
An LSD can use clutches when engaged, or may

also be a solid mechanical connection like a locker
or spool. It is called limited slip because it does just
that; it limits the amount that one wheel can slip.
27 - 322 9823/1650-1 27 - 322

27 - Driveline
24 - Differential
00 - General
For: 55 Series (3 Piece Axle), Limited Slip

Differential (LSD) ..................... Page 27-323
For: Max-Trac .......................... Page 27-324
(For: 55 Series (3 Piece Axle), Limited Slip Differential (LSD))
Figure 722. Limited Slip Differential (LSD)
E
F
H
J
K
N P
A M
G K
C J
H
G
A Verbus-ripp bolts B Crownwheel

C Bolts D Differential assembly case
E Differential assembly case F Shims
G Shims H Counter plates
J Friction plates K Pressure plates
L Side gears M Trunnion pins
N Bevel gears P Thrust washers
27 - 323 9823/1650-1 27 - 323

27 - Driveline
24 - Differential
00 - General
(For: Max-Trac)
Figure 723. JCB Maxtrac Differential
E C
B
D
A Capscrews
B Side gears
C Thrust washers
D Bevel gears
E Spherical washers
F Differential bearing cones
27 - 324 9823/1650-1 27 - 324

27 - Driveline
24 - Differential
00 - General
Check (Condition)
(For: Limited Slip Differential (LSD))

1. For JCB axles only: measure and note the
thickness of the friction plates, the result must not
be less than the specified dimension.
Dimension: 1.25 mm
2. Check the condition of the friction material, which
should be even over both surfaces. If in doubt,
discard the set (friction and counter plates).
27 - 325 9823/1650-1 27 - 325

27 - Driveline
24 - Differential
00 - General
For: 55-Series, 80-Series, Front, Limited Slip 2. Remove the crownwheel.

Differential (LSD) ..................... Page 27-326
For: Front, Max-Trac, Rear ...... Page 27-329 3. Put marks on the two halves of the differential
housing before disassembly to make sure of
correct assembly.
(For: 55-Series, 80-Series, Front, Limited
Slip Differential (LSD)) 4. Remove the capscrews.
The numerical sequence shown on the illustration is 5. Disengage the two halves of the differential and
intended as a guide for disassembly. remove the following components:
5.1. Trunnion pins.
The number of friction and counter plates shown in
the illustration is typical only. The actual number of 5.2. Side gears.
plates is determined by the axle variant. 5.3. Bevel gears.
Important: The crownwheel and pinion are matched 5.4. Spherical washers.
and should be renewed as a pair if either one is
damaged or excessively worn. The two halves of 5.5. Pressure plates.
the differential housing are also matched as are the 5.6. Counter plates.
differential side gears and bevel gears, do not use
unmatched halves or gears. 5.7. Friction plates.
5.8. Shims.
Disassemble
6. Make a note of the relative positions of the
1. Use a heavy duty socket to remove the verbus- friction plates, counter plates and spacers before
ripp bolts. Discard the bolts. disassembly, they must be installed in the same
positions.
Figure 724. Limited Slip Differential (LSD)
E
F
H
J
K
N P
A M
G K
C J
H
G
27 - 326 9823/1650-1 27 - 326

27 - Driveline
24 - Differential
00 - General
A Verbus-ripp bolts B Crownwheel

C Bolts D Differential assembly case
E Differential assembly case F Shims
G Shims H Counter plates
J Friction plates K Pressure plates
L Side gears M Trunnion pins
N Bevel gears P Thrust washers
27 - 327 9823/1650-1 27 - 327

27 - Driveline
24 - Differential
00 - General
Assembly 1.6. Thrust washers.
1. Install the following components into the 2. Do not install the shims at this stage.
crownwheel half of the differential assembly:
3. Align the two halves of the differential assembly
1.1. Trunnion pins. with the bolts. Make sure that the marks made
during disassembly are aligned.
1.2. Side gears with pressure plates.
4. Use a DTI (Dial Test Indicator) (or feeler gauges),
1.3. Counter plates.
with two screwdrivers or suitable levers, gently
1.4. Friction plates. apply pressure to prise the side gear away from
the trunnion pins.
1.5. Bevel gears.
Figure 725.
5. Measure and record the end float of the side assembled differential as this is only an
gear. initial setting figure which allows for bedding
in.
6. Turn the differential assembly over and repeat
steps 4 and 5 for the second side gear. 8.2. Select the minimum number of shims to
give the correct thickness.
7. Disassemble the differential assembly.
9. Do the steps 4 to 6 again.
8. Add shims to give an end float between the
specified range. 10. If the end float is correct, tighten bolts to the
11. Install the crownwheel with new verbus-ripp
8.1. Shimming must be carried out whenever bolts.
the differential is dismantled, however, the
end float 0.1 and 0.2 mm (0.004 and 12. Tighten the verbus-ripp bolts to the correct torque
0.008 in) can be exceeded on previously value.
27 - 328 9823/1650-1 27 - 328

27 - Driveline
24 - Differential
00 - General

Item Nm
1
(1)
94
1
(2)
200
3 56
(1) The torque value is applicable for the 55 Series drivehead.
(2) The torque value is applicable for the 80 Series drivehead.
Figure 726.
(For: Front, Max-Trac, Rear)
Consumables
A
Strength)
F
The crownwheel and pinion are matched and should
be replaced as a pair if either one is damaged or
excessively worn.
The two halves of the differential housing are also

matched as are the differential side gears and bevel E C
gears. Do not use unmatched halves or gears.
B
If it is necessary to install a new crownwheel to the
D
differential unit, then install it and torque tighten the
crownwheel retaining bolts to the specified torque
value. 94 N·m
Disassembly
1. Before you disassemble match-mark the two
halves of the differential housing for the correct
assembly. A Capscrews
B Side gears
2. Remove the capscrews. C Thrust washers
D Bevel gears
3. Disengage the two halves of the differential E Spherical washers
housing. F Differential bearing cones
4. Remove the side gears, thrust washers, bevel
gears and spherical washers. Assembly
5. Remove the differential bearing cones. 1. Assemble the side gears, thrust washers,
bevel gears and spherical washers into the
crownwheel half of the differential housing.
2. Position the top half housing onto the differential.
2.1. Make sure that they are aligned with
the match mark made at the time of
disassembly.
2.2. Apply sealant to the threads of capscrews
and install them.
(Medium Strength)
2.3. Tighten the capscrews to the correct torque
value.
27 - 329 9823/1650-1 27 - 329

27 - Driveline
24 - Differential
00 - General
3. Check the gears for free rotation.

4. Install the differential bearing cones.

Item Description Nm
A Capscrews 46
27 - 330 9823/1650-1 27 - 330

27 - Driveline
27 - Hub
27 - Hub
Contents Page No.
27-27-00 General ......................................................................................................................... 27-333

27-27-66 Wheel Stud ................................................................................................................... 27-347
27 - 331 9823/1650-1 27 - 331

Notes:
27 - 332 9823/1650-1 27 - 332

27 - Driveline
27 - Hub
00 - General
Introduction .................................................. 27-333 The hub is the part of the axle where the wheel
Component Identification ............................. 27-334 is mounted and where the axle shaft (if installed)
Drain and Fill ............................................... 27-336 passes through.
Calibrate ...................................................... 27-339
Some hubs are not driven and rotate due to motion
Disassemble and Assemble ........................ 27-340 of the machine and some driven hubs may also have
reduction gearing installed.
The hub may also be designed to allow steering of

the wheels and/or incorporate brakes.
27 - 333 9823/1650-1 27 - 333

27 - Driveline
27 - Hub
00 - General

Unit Identification
Figure 729.
identification plate as shown. When you make an G H
mentioned on the unit identification plate. In the case
A
Figure 727.
J
A
K
D
E L
Figure 728.
F M
Table 347.
Item no Description
A Annulus ring
B Planet gear assembly
(x3)
C Thrust pad
D Sun gear
E Planet gear carrier
A Identification plate F Wheel stud (x5)
G Bearing carrier
H Hub swivel
J Driveshaft
K Oil seal
L Wheel bearing (inner)
M Wheel bearing (outer)
27 - 334 9823/1650-1 27 - 334

27 - Driveline
27 - Hub
00 - General
Sectional Drawing
Figure 730.
13 10 7 11 5 3 4 57 1
12
14
8 18
16
15
17
20
19
23
26 9 22 24 25
Item no Description
Table 348. 17 Thrust pad
Item no Description 18 Driveshaft
1 Swivel hub 19 Sun gear
3 Bearing (taper roller) 20 Circlip (external)
4 Oil seal 22 O-ring
5 Bearing carrier 23 Drain plug
7 Annulus carrier 24 Bearing
8 Dowels 25 Oil seal
9 Bolt Verbus-ripp 26 Spacer (55 Series hub
only)
10 Annulus ring
57 Cover plate
11 Circlip (internal)
12 Planet gear
13 Planetary hub carrier
14 Bearing
15 Circlip (L-shaped)
16 Circlip (external)
27 - 335 9823/1650-1 27 - 335

27 - Driveline
27 - Hub
00 - General
Drain and Fill
4. Apply the park brake.

Check the hub oil level of one wheel at a time.
Complete the steps below to check the hub oil. 5. Set the transmission to the neutral position.
1. Make the machine safe. Refer to (PIL 01-03). 6. Lower the attachments to the ground.
2. Set the machine level with the wheels above the 7. Stop the engine and remove the ignition key.
ground.
8. Clean the area around the hub plug.
2.1. Use suitable lifting equipment to lift the
9. Remove the hub plug.
machine axles to the same level.
10. Check the oil level of the hub.
3. Set the hub oil level mark to the horizontal
position. 10.1. The hub oil level must be level with the
bottom surface of the plug hole.
3.1. Turn the wheel manually to get the hub oil
level mark to the horizontal position. 10.2. If necessary, add the correct axle oil. Refer
to (PIL 75).
3.2. The specified tolerance is permitted above
or below the oil level mark horizontal 11. Clean the plug before you install it.
position.
Length/Dimension/Distance: 5 mm 12. Install the hub plug and tighten to the correct
torque.
Figure 731.
12.1. To Make sure you use the correct torque
A tightening information, identify the correct
axle for your machine. Refer to Figure 732.
B and Refer to Figure 733.
12.2. Make sure you identify the correct plug
for your machine. Then use the related
torque information. Refer to Figure 734.
and Refer to Figure 735.
D C
A Wheel
B Hub
C Plug
D Level mark
E Tolerance 5 mm
27 - 336 9823/1650-1 27 - 336

27 - Driveline
27 - Hub
00 - General
Figure 732. JCB Axles With Inboard Brakes (If installed)
A
B
A Axle drain plug 1 location
Table 349. JCB Axles With Inboard Brakes

Type of Differential Plug In- Hub Plug Installed Hub Plug Torque (Nm)
stalled on Your Machine
Axle drain plug 1 with hexagonal Taper plug (3/4 in NPSF) 50
head and bonded washer
Axle drain plug 1 with tapered plug Taper plug (3/4 in BSP) 80
Figure 733. JCB Axles With Braked Hubs (If installed)

D
D Drain plug E Axle drain plug 2 location
Table 350. Axles With Braked Hubs

Type of Differential Plug In- Hub Plug Installed Hub Plug Torque (Nm)
stalled on Your Machine
Axle drain plug 2 with hexagonal Plug (M22) 37.5
head and bonded washer
Axle drain plug 2 with tapered plug Taper plug (3/4 in BSP) 80
Figure 734. Hexagonal Head Plug and

Bonded Washer (Prior to January 2011)
27 - 337 9823/1650-1 27 - 337

27 - Driveline
27 - Hub
00 - General
Figure 735. Taper Plug (If in-

stalled) (January 2011 Onwards)
27 - 338 9823/1650-1 27 - 338

27 - Driveline
27 - Hub
00 - General
Calibrate
Refer to the relevant Disassemble and Assemble

procedure (PIL 27-27).
27 - 339 9823/1650-1 27 - 339

27 - Driveline
27 - Hub
00 - General

Description Part No. Qty. F
Heavy Duty Socket 892/00333 1
19mm A/F x 3/4 in D
Drive G
Wheel Hub Service Kit 892/01092 1 B
Reaction Plate M14 998/M1374 4
Studs
Reaction Plate 998/M1375 1
Disassemble
WARNING A raised and badly supported
machine can fall on you. Position the machine
on a firm, level surface before raising one end.
Ensure the other end is securely chocked. Do
not rely solely on the machine hydraulics or jacks B Planet gear carrier
to support the machine when working under it. D Planet gear
Disconnect the battery, to prevent the machine G Driveshaft thrust pad
being started while you are beneath it. F External circlip 1
5.1. Remove the external circlip 1.
The illustrations in this procedure show the axle
removed from the machine but the hubs can be 5.2. Remove the planet gear.
disassembled without removing the axle. Refer to 5.3. The driveshaft thrust pad is drilled and
Figure 742. tapped for removal purposes. Use a
suitable M6 screw to extract the thrust pad
1. Drain the oil from the hub. from inside the planet gear carrier.
2. Remove the screws. 6. Remove the external circlip 2.
3. Remove the planet gear carrier from the bearing 7. Remove the sun gear from the driveshaft.
carrier.
8. To remove the verbus-ripp bolts it is necessary
4. Remove and discard the O-ring. to remove the spacer (if installed). Rotate the
spacer with a suitable drift to align the holes in
5. Remove the planet gears only if they are the spacer with the space between the bolts.
damaged. Note: Planet gears can only be
replaced as an assembly which contains the 9. Use two dowels and two heel bars to remove the
gear, bearing, and two L-shaped circlips. Refer spacer as shown. Refer to Figure 737.
to Figure 736. and Refer to Figure 741.
27 - 340 9823/1650-1 27 - 340

27 - Driveline
27 - Hub
00 - General
Figure 737. 11.2. Install the four M14 studs and nuts on
the annulus carrier. Some annulus carriers
J have two tapped holes for use with jacking
K screws. Use two high grade M14 bolts
as jacking screws to remove the annulus
carrier.
Special Tool: Reaction Plate (Qty.: 1)
Special Tool: Reaction Plate M14 Studs
(Qty.: 4)
11.3. Engage the reaction plate.
AF 11.4. Adjust the studs to maintain a clearance
between the reaction plate and the
H driveshaft.
11.5. Install a three leg puller. Engage the puller
legs through the holes in the annulus
carrier.
H External circlip 2 11.6. Use the puller to remove the annulus

J Spacer carrier along with the annulus ring from the
K Verbus-ripp bolt axle stub shaft.
AF Sun gear 11.7. Make sure that the dowels remain either
in the annulus carrier or in the stub shaft.
10. Remove the verbus-ripp bolts with a heavy duty Note: It is normal for fretting to occur on
socket. the mating surfaces between the axle stub
Special Tool: Heavy Duty Socket 19mm A/F x 3/4 shaft and annulus carrier. Do not attempt
in Drive (Qty.: 1) to repair it.
10.1. Note: the verbus-ripp bolts are very tight 12. Remove the internal circlip to separate the
and care must be taken not to distort the annulus ring from the annulus carrier.
bolt heads. Use an extension bar as short
as possible. Discard the verbus-ripp bolts 13. Remove the outer wheel bearing and the bearing
after removal. carrier as follows:
11. Remove the annulus carrier along with the 13.1. Attach the legs of the bearing puller
annulus ring as follows: Refer to Figure 738. onto two diametrically opposite wheel
studs and put the reaction tube over the
Figure 738. driveshaft. Refer to Figure 739.
Special Tool: Wheel Hub Service Kit (Qty.:
1)
AG 13.2. The reaction tube must be used otherwise
damage to the driveshaft and driveshaft
bearings will occur.
AJ
13.3. On five wheel stud axles, the modified
wheel studs from the Wheel Hub Service
Kit must be used. Bolt to two diametrically
opposite holes provided on the bearing
carrier.
13.4. Slowly turn the screw until the bearing
AH carrier and the outer wheel bearing are
released from the axle stub shaft.
AG M14 studs and nuts 13.5. If the wheel hub starts to rotate use a
AH Reaction plate suitable bar to prevent further rotation.
AJ 3 Leg puller
13.6. If the screw becomes hard to turn, tap the
11.1. Put marks on the stub shaft and annulus back of the bearing carrier with a soft faced
carrier to identify their relative angular mallet to help release the bearing.
position during installation.
27 - 341 9823/1650-1 27 - 341

27 - Driveline
27 - Hub
00 - General
Figure 739. 15. Remove the inner wheel bearing as follows:

W Y
Figure 741.
X
Q
Q Bearing carrier W
W Reaction tube
X Screw
Y Bar
W Reaction tube
14. Remove and discard the outer part of the X Screw
combination oil seal by cutting the outer seal with
a sharp chisel. Take care not to damage the seal 15.1. Clamp the plates around the inner wheel
seat on the axle stub shaft. Refer to Figure 740. bearing.
Figure 740. 15.2. Attach the puller rods and put the reaction
tube over the driveshaft.
15.3. The reaction tube must be used otherwise
damage to the driveshaft and driveshaft
bearings will occur.
Z
15.4. Slowly turn the screw until the inner wheel
bearing is released from the axle stub
shaft.
15.5. Remove and discard the inner part of the
combination oil seal.
16. If installed do not remove the dirt shield.
T Combination oil seal

Z Chisel
27 - 342 9823/1650-1 27 - 342

27 - Driveline
27 - Hub
00 - General
Figure 742.
F
D
V
E P
V
C N
L
B
J K
AF
G T
R U
S
A
A Screw B Planet gear carrier

C O-ring D Planer gear
E Bearing F External circlip 1
G Driveshaft thrust pad H External circlip 2
J Spacer K Verbus-ripp bolt
L Annulus carrier M Annulus ring
N Internal circlip P Dowel
Q Bearing carrier R Outer wheel bearing
S Inner wheel bearing T Combination oil seal
U Dirt shield (If installed) V L-shaped circlip
AF Sun gear
27 - 343 9823/1650-1 27 - 343

27 - Driveline
27 - Hub
00 - General
Assemble Figure 745.
1. Install the outer wheel bearing cup into the AA

bearing carrier.
2. Install the inner wheel bearing cup and cone into
the bearing carrier.
3. Use the seal dolly 892/00891 from the Wheel
Hub Service Kit to install a new combination oil
seal. The seal dolly has two sides 'A' and 'B' B
marked for identification. Do not lubricate the
seal before installation. Refer to Figure 743.
Figure 743. Q
AA
A
Q Bearing carrier
AA Seal dolly
5. Install the seal on the dolly.
B
6. Use a soft-faced mallet to drive the seal squarely
AA Seal dolly into the bearing carrier until the dolly flange is up
against the carrier. Refer to Figure 746.
4. Make sure you use the correct side of the seal
dolly as follows: Figure 746.
4.1. For axles with a steel dirt shield use side 'A'
of the seal dolly. Refer to Figure 744.
Figure 744. AA
AA U
A
Q Bearing carrier
AA Seal dolly
7. Attach the bearing press extension shaft onto the
Q
end of the axle stub with four verbus-ripp bolts.
Figure 747.
Q Bearing carrier
U Dirt shield
AA Seal dolly
4.2. For axles without a steel dirt shield use side
'B' of the seal dolly. Refer to Figure 745.
K Verbus-ripp bolts
27 - 344 9823/1650-1 27 - 344

27 - Driveline
27 - Hub
00 - General
8. Lightly apply oil on the inner wheel bearing cone. 22. Install the new verbus-ripp bolts.
9. Position the bearing carrier (complete with inner 23. Do not tighten the verbus-ripp bolts at this stage.
bearing) onto the axle stub over the extension
shaft. 24. Measure the seal drag rolling force:
10. Assemble the bearing press as shown. Refer to Figure 749.

Figure 748.
Figure 748.
BB
R AC BA
AD
AB BA Cord
BB Spring balance
R Outer wheel bearing 24.1. Install the planet gear carrier.

AB Handle 24.2. Do not install the sun gear.
AC Thrust washers (x2)
AD Reaction tube 24.3. Wrap a cord around the planet gear carrier
flange and attach a spring balance to it as
11. Slide the reaction tube over the extension shaft shown. Refer to Figure 749.
(the wide opening towards the bearing).
24.4. Pull the spring balance so that the hub
12. Make sure that the bearing and bearing carrier rotates, do this several times to let the seal
are properly positioned against the axle stub. bed in and record the reading.
24.5. Remove the planet gear carrier.
13. Attach the handle and make sure that the
thrust bearing is installed between the two thrust 25. Tighten the verbus-ripp bolts to the correct torque
washers. value.
14. Slowly turn the handle to press the inner wheel 26. Measure the rolling force:
bearing correctly into position, then remove the
handle and reaction tube. 26.1. Install the planet gear carrier.
15. Install the outer wheel bearing cone into the 26.2. Do not install the sun gear.
bearing carrier. 26.3. Wrap a cord around the planet gear carrier
flange and attach a spring balance to it as
16. Assemble the reaction tube and handle onto the
shown.
extension shaft.
26.4. Pull the spring balance so that the hub
17. Slowly turn the handle to press the outer bearing rotates and record the reading.
correctly into position until the free play is
removed. 26.5. To calculate the rolling force, subtract
the seal drag force (24.4) from the value
18. Remove the handle and reaction tube. obtained in the step 26.4.
19. Assemble the annulus ring onto the annulus 26.6. The rolling force should be within the
carrier and then install the internal clip. specified range.
20. Make sure that the dowels are correctly installed.
26.7. If the values are outside the limits specified
21. Attach the annulus assembly to the axle stub then check if the seal is installed correctly,
shaft in the same angular position based on the
marks made during installation.
27 - 345 9823/1650-1 27 - 345

27 - Driveline
27 - Hub
00 - General
and/or replace the wheel bearings if 30.1. Note: The sun gear must be installed with
necessary. the 1.5mm x 45° chamfer inboard.
26.8. Remove the planet gear carrier. 31. Install a new O-ring, and then install the planet
gear carrier onto the bearing carrier. Make sure
27. Press the driveshaft thrust pad (chamfered side
that the two tapped holes are in line with those
faces downwards) into the recess in the planet
on the bearing carrier.
gear carrier.
32. Do not strike the centre of the planet gear
28. Install the new planet gears in the position of any
carrier during installation as this may dislodge the
that were removed during disassembly. Refer to
driveshaft thrust pad.
Figure 749.
33. Apply sealant to the threads of the screws. Refer
28.1. Important: Make sure that you install the
to Figure 752.
planet gears in the correct orientation.
Install the large radius end of the bearing Figure 752.
over the pin first. Refer to Figure 750.
Q
Figure 750.
AE
A
A Screw
AE Large radius end 34. Install the screw to attach the planet gear carrier.
28.2. Secure the planet gears with external 35. Tighten the screws to the correct torque value.
circlip 1.
36. Fill the hub with the correct grade oil.
Figure 751.
F Table 351. Torque Values
Item Nm
D
G A 56
B K 320
B Planet gear carrier

D Planet gear
G Driveshaft thrust pad
F External circlip 1
29. Install the spacer (If installed).
30. Install the sun gear onto the driveshaft and
secure with the external circlip 2.
27 - 346 9823/1650-1 27 - 346

27 - Driveline
27 - Hub
66 - Wheel Stud
66 - Wheel Stud Figure 754.

B
Remove and Install
This remove and install procedure is the same for all

wheel studs.
WARNING! If, for whatever reason, a wheel stud

is renewed, all the studs for that wheel must be
changed as a set, since the remaining studs may A
have been damaged.
Remove
C
A Wheel stud
2. Follow the general health and safety procedures. B Wheel stud hole
Refer to (PIL 01-03). C Hub carrier
3. Remove the wheel from the hub. Refer to (PIL 2. Use a nut and washer to pull the stud into the hub
27-29). carrier.
4. Push out the wheel stud. 3. Check the stud and make sure that it is installed
correctly.
Figure 753.
A 4. If the stud is loose replace the whole hub carrier
assembly.
A
A Wheel stud
5. Remove and discard all the wheel studs.
Check the condition of the wheel stud holes in the

hub carrier. If the holes are defective do not use the
hub carrier. Replace the hub carrier with a new one.
Install
1. Install the stud into the hub carrier hole.
27 - 347 9823/1650-1 27 - 347

27 - Driveline
29 - Wheel
29 - Wheel
Contents Page No.
27-29-00 General ......................................................................................................................... 27-349
27 - 348 9823/1650-1 27 - 348

27 - Driveline
29 - Wheel
00 - General
Introduction .................................................. 27-349 On new machines, and whenever a wheel has been
Health and Safety ........................................ 27-350 removed, check the wheel nut torques every two
Remove and Install ..................................... 27-350 hours until they stay correct. Every day, before
starting work, check that the wheel nuts are tight.
Tighten the wheel nuts (in a diagonal sequence) to
the correct torque value, refer to Technical Data.
27 - 349 9823/1650-1 27 - 349

27 - Driveline
29 - Wheel
00 - General
Health and Safety Remove and Install

WARNING If, for whatever reason, a wheel stud WARNING Whenever a wheel has been
is renewed, all the studs for that wheel must be changed, check the nut torques every two hours.
changed as a set, since the remaining studs may When the nuts stay tight for 8 h, the interval for
have been damaged. checking can revert to the period stated in the
servicing schedule.
WARNING Wheels and tyres are heavy. Take
care when lifting or moving them. Store with care DANGER Run flat inserts may be installed in the
to ensure that they cannot fall and cause injury. rear wheels. These must remain installed to the
Use suitable lifting equipment if necessary. rear wheels to ensure machine stability is not
compromised in the event of a deflated tyre.
WARNING An exploding tyre can kill. Inflated
tyres can explode if over-heated or over-inflated. Make sure that all tyres are inflated to the correct
Follow the instructions given when inflating the pressure and have run flat inserts as required.
tyres. Do not cut or weld the rims. Use a tyre/ Where run flat inserts have been specified for use,
wheel specialist for all repair work. ensure that replacement wheels also have run flat
WARNING Deflate the tyre you wish to change inserts to ensure the machine stability.
before removing the wheel from the machine.
Air pressure in the tyres can cause the tyre and
rim sections to explode causing serious injury or Remove (One Wheel)
death. Never loosen the nuts that hold the inner
and outer wheel halves together when there is air
pressure in the tyre. Always wear safety glasses. 2. Follow the general health and safety procedures.
WARNING Wheels installed with semi-solid tyres Refer to (PIL 01-03).
are heavy. Removing and installing them requires
special equipment and training. Have the work 3. Put chocks 1 under the rear wheels.
carried out by your JCB dealer or a tyre specialist. 4. Loosen the five wheel nuts by half a turn.
WARNING Do not install pneumatic tyres on a
wheel made for a solid tyre. Do not install a solid 5. Put a jack under the axle arm. Use the correct
tyre on a wheel made for a pneumatic tyre. If jack.
you are unsure of the correct specification for
6. Use the jack to lift the machine until the front
your machine, contact your local JCB dealer or a
wheel is off the ground.
trained specialist.
DANGER Run flat inserts may be installed in the 7. Put chocks 2 under the axle arm.
rear wheels. These must remain installed to the
rear wheels to ensure machine stability is not 8. Hold the wheel and remove the wheel nuts.
compromised in the event of a deflated tyre. 9. Remove the wheel.
Make sure that all tyres are inflated to the correct
pressure and have run flat inserts as required.
Where run flat inserts have been specified for use,
ensure that replacement wheels also have run flat
inserts to ensure the machine stability.
27 - 350 9823/1650-1 27 - 350

27 - Driveline
29 - Wheel
00 - General
Figure 755.
E
C
D
B
A Chocks 1
B Wheel nuts
C Jack
D Front wheel
E Chocks 2
Install
steps.
1.1. Make sure that the mating surfaces of the
wheel and axle hub are clean.
1.2. Tighten the wheel nuts to the correct torque
value.

Item Torque value
B 680 N·m
27 - 351 9823/1650-1 27 - 351

27 - Driveline
33 - Tyre
33 - Tyre
Contents Page No.
27-33-00 General ......................................................................................................................... 27-353
27 - 352 9823/1650-1 27 - 352

27 - Driveline
33 - Tyre
00 - General
Introduction .................................................. 27-353 Tyres provide a flexible cushion that absorb shocks,
Health and Safety ........................................ 27-354 while keeping the wheel in close contact with the
Check (Condition) ........................................ 27-354 ground.
Tyre materials are usually synthetic rubber, natural

rubber, fabric and wire, along with other compound
chemicals. They consist of a tread and a body.
The tread provides traction while the body ensures
support.
Make sure that the tyres are kept in good condition.
27 - 353 9823/1650-1 27 - 353

27 - Driveline
33 - Tyre
00 - General

DANGER Make sure that all tyres are inflated
to the correct pressure. Refer to the machine Always drive with consideration for the condition
operator manual. of the tyres. Incorrect tyre pressures will affect the
stability of the machine. Check the tyres daily for
WARNING An exploding tyre can kill. Inflated the correct tyre pressure and signs of damage. For
tyres can explode if over-heated or over-inflated. example:
Follow the instructions given when inflating the
tyres. Do not cut or weld the rims. Use a tyre/ • Signs of distortion (bulges).
wheel specialist for all repair work. • Cuts or wear.
WARNING Wheels and tyres are heavy. Take • Embedded objects (nails, etc.).
care when lifting or moving them. Store with care
to ensure that they cannot fall and cause injury. Install the valve caps firmly to prevent dirt from
Use suitable lifting equipment if necessary. entering the valve. Inspect for leaks when you check
the tyre pressures.
WARNING Do not use the machine with
damaged, incorrectly installed, incorrectly inflated Inspect the tyre valve for leaks, when you check the
or excessively worn tyres. Recognise the speed tyre pressures.
limitation of the tyres installed and do not operate
at more than their recommended maximum
speed.
Tyre Inflation
WARNING Running tyres outside recommended Always try to maintain the tyre pressure to the
guidelines may result in failure of the tyres which recommended settings. Using a machine with under-
at high speeds may endanger life. inflated tyres means:
WARNING Deflate the tyre you wish to change
• Decreasing the machines stability.
before removing the wheel from the machine.
• Higher tyre temperatures.
Air pressure in the tyres can cause the tyre and
• Excessive strain of the tyre fabric.
rim sections to explode causing serious injury or
• Causes bulging of the sidewalls.
death. Never loosen the nuts that hold the inner
• Shortens the tyres life.
and outer wheel halves together when there is air
pressure in the tyre. Always wear safety glasses. Using the machine with over-inflated tyres is
WARNING Do not install pneumatic tyres on a dangerous:
wheel made for a solid tyre. Do not install a solid
tyre on a wheel made for a pneumatic tyre. If • It causes excessive tensile loads in the fabric:
you are unsure of the correct specification for this makes a tyre more susceptible to cuts and
your machine, contact your local JCB dealer or a punctures.
trained specialist.
Do not cut or weld on the rim of an inflated tyre.
WARNING When ordering tyres, you must
specify not only the tyre size but also the speed After checking or amending the tyre pressure always
designation. The correct tyres for the machine are replace and secure the valve cap.
shown in the Operator's Manual. On no account
should you use tyres of other designations Always deflate the tyre before removing foreign
without first gaining approval from the machine obstacles from the tread.
manufacturer.
WARNING Remove the valve core to make sure Procedure
the tyre is fully deflated. If the tyre is not fully
deflated, unseen damage to the wheel and / or These instructions are for adding air to a tyre which is
tyre could cause the assembly to explode. already inflated. If the tyre has lost all its air pressure,
call in a qualified tyre mechanic. The tyre mechanic
should use a tyre inflation cage and the correct
equipment to do the job.
1. Prepare the wheel. Before you add air to the tyre,

make sure it is correctly installed on the machine
or installed in a tyre inflation cage.
27 - 354 9823/1650-1 27 - 354

27 - Driveline
33 - Tyre
00 - General
Figure 756.
2. Prepare the equipment.

2.1. Use only an air supply system which
includes a pressure regulator. Set the
regulator no higher than 1.38 bar (20 psi)
above the recommended tyre pressure.
2.2. Use an air hose fitted with a self-locking air
chuck and remote shut-off valve.
3. Add the air.
3.1. Make sure that the air hose is correctly
connected to the tyre valve. Clear other
people from the area. Stand behind the
tread of the tyre while adding the air.
3.2. Inflate the tyre to the recommended
pressure. Do not over-inflate.
27 - 355 9823/1650-1 27 - 355

27 - Driveline
47 - Propshaft
47 - Propshaft
Contents Page No.
27-47-00 General ......................................................................................................................... 27-357
27 - 356 9823/1650-1 27 - 356

27 - Driveline
47 - Propshaft
00 - General

Check (Condition) ........................................ 27-357 1. Make the machine safe. Refer to (PIL 01-03).
Lubricate ...................................................... 27-358
2. Check the propshaft tube for damage or cracks.
3. Check the centre bearing (if installed) for
security, cracks or damage.
4. Check the universal joints for security, cracks
or damage. Make sure that there is no play in
the joint and that grease points are present (if
installed).
5. Check the sliding joints for security, cracks or
damage. Make sure that there is no play in
the joint and that grease points are present (if
installed).
6. Check any sensor or sensor ring for security,
cracks or damage (if installed).
7. Make sure the correct fasteners are installed and
tightened to the correct torque.
8. Renew any defective component as needed.
27 - 357 9823/1650-1 27 - 357

27 - Driveline
47 - Propshaft
00 - General
Lubricate
2. Make sure you have the correct grease.
3. Use a grease gun to lubricate the universal joint
grease points until fresh grease appears past the
seals of all four bearings in each joint.
3.1. If grease does not appear, push the
propshaft away from the bearing that
grease does not appear from and grease
again.
3.2. If grease still does not appear, remove and
examine the bearing. Renew if necessary.
4. Remove any excess grease.
27 - 358 9823/1650-1 27 - 358

27 - Driveline
47 - Propshaft
00 - General
Remove and Install
Consumables Figure 757.

Strength)
Special MPL-EP 4003/1501 0.4 kg
Grease 4003/1506 12.5 kg
4003/1510 50 kg
WARNING Before disconnecting any propshaft,

make sure you block both sides of all wheels B
to prevent machine movement. The park brake
will become ineffective or may only operate on 2
wheels (depending on machine specification). C
Remove
1. Make the machine safe with the lift arm
raised. Refer to (PIL 01-03). Install the lift arm
maintenance strut, refer to (PIL 06-69). A
2. Remove the central access panels. refer to (PIL A Bolts 1
06-06). B Bolts 2
C Strap
3. Put marks on both propshaft companion flanges
and the sliding joints before removal to help 4.2. Remove the nuts and the bolts 1 to
during the replacement procedure. disconnect the propshaft coupling from the
transmission.
4. Machines without RAS (Rear Axle Stabilization):
4.3. Remove the bolts 2 and straps to
4.1. Support the propshaft. disconnect the propshaft form the axles.
5. Machines with RAS:
5.1. Support the auxiliary speed sensor plate.
5.2. Support the propshaft.
5.3. Remove the bolts 1 to disconnect the
propshaft coupling from the transmission.
5.4. Remove the auxiliary speed sensor plates
from behind the park brake disc.
5.5. Remove the bolts 2 and straps to
disconnect the propshaft coupling from the
axle.
Consumable: Special MPL-EP Grease
27 - 359 9823/1650-1 27 - 359

27 - Driveline
47 - Propshaft
00 - General
Figure 758.
F D E
A
A Bolts 1 D Park brake disc

E Propshaft F Auxiliary speed sensor plate
Install 3. Straps must always be replaced with new ones.
Installation is the opposite of the removal procedure. 4. The propshaft must have both ends exactly on
At the time of installation follow the steps below. the same plane as shown below. Refer to Refer
to Figure 759.
1. Lubricate the sliding joints with the specified
4.1. The yokes must not be at right angles or
grease only, then align the shafts against
at an intermediate angle. Refer to Refer to
identification marks previously made or, in
Figure 759.
the case of a shaft being replaced use the
manufacturer's alignment markings.
Consumable: Special MPL-EP Grease
2. Apply sealant to the threads of all the flange
bolts.
(Medium Strength)
27 - 360 9823/1650-1 27 - 360

27 - Driveline
47 - Propshaft
00 - General
Figure 759.
X Same plane (correct)

Y Right angle (not correct)
Z Intermediate angle (not correct)
5. Tighten the bolts 1 and bolts 2 to the correct
torque value.

Item Description Nm
A Bolts 1 137
B Bolts 2 70
27 - 361 9823/1650-1 27 - 361

27 - Driveline
51 - Driveshaft
51 - Driveshaft
Contents Page No.
27-51-00 General ......................................................................................................................... 27-363

27-51-15 Shaft Hub Side ............................................................................................................. 27-367
27 - 362 9823/1650-1 27 - 362

27 - Driveline
51 - Driveshaft
00 - General
Introduction .................................................. 27-363 The driveshaft is a mechanical component for
Component Identification ............................. 27-364 transmitting torque and rotation, usually used to
Check (Condition) ........................................ 27-366 connect other components of the driveline that
Lubricate ...................................................... 27-366 cannot be connected directly because of distance
or the need to allow for relative movement between
them.
27 - 363 9823/1650-1 27 - 363

27 - Driveline
51 - Driveshaft
00 - General
Figure 760.
1 2 3 4
Item Description
4 Axle arm
Table 354.
5 Driveshaft
Item Description
1 Hub swivel
7 Trunnion (lower)
2 Trunnion (upper)
27 - 364 9823/1650-1 27 - 364

27 - Driveline
51 - Driveshaft
00 - General
Sectional Drawing
Figure 761.
1 2 3 4 5 6 7 8
5 9
Table 355.
Item Description
1 Bearing (needle roller)
2 Circlip (internal)
3 Oil seal
4 Spacer
5 Grease nipple
6 Seal
7 Trunnion
9 Retaining bolt
27 - 365 9823/1650-1 27 - 365

27 - Driveline
51 - Driveshaft
00 - General
Check (Condition) Lubricate

1. Make the machine safe. Refer to (PIL01-03). 1. Make the machine safe. Refer to (PIL 01-03).
2. Check the joint for damage, cracks or play. 2. Make sure you have the correct grease. Refer to
(PIL 75-00).
3. Renew any defective component as needed.
3. Use a grease gun to lubricate the universal joint
grease points until fresh grease appears past the
seals of all four bearings in each joint.
3.1. If grease does not appear, push the
driveshaft away from the bearing that
grease does not appear from and grease
again.
3.2. If grease still does not appear, remove and
examine the bearing. Renew if necessary.
4. Remove any excess grease.
27 - 366 9823/1650-1 27 - 366

27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side
15 - Shaft Hub Side Remove and Install

(For: 55-Series)
Consumables
Strength)
Calibrate
Previous axles had a shim installed under the top
trunnion. The shim controls the bearing pre-load.
When you assemble, select the correct thickness

shim and check the bearing pre-load as follows:
1. Locate the hub swivel and install the bottom

trunnion.
2. Apply JCB Threadlocker to the bottom trunnion
bolts.
(Medium Strength)
3. Tighten the bolts to the specified torque value.
Torque: 98 N·m
4. Install the top trunnion and finger tighten the top
trunnion bolts.
5. Attach a spring balance to the track rod swivel
and note the reading. Refer to Figure 762.
Figure 762. Measuring the swivel turning force
6. Tighten the top trunnion bolts to stop end float

but not the bearing pre-load, so that there is no
increase in the spring balance reading.
27 - 367 9823/1650-1 27 - 367

27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side
7. Measure the gap at the top trunnion and subtract

1 mm (0.040 in) to give the shim thickness
(bearing pre-load). Refer to Figure 763.
Figure 763. Measuring the top trunnion gap
8. Remove the top trunnion and install the correct

shim.
9. Install the top trunnion.
10. Apply JCB Threadlocker to the top trunnion bolts.
(Medium Strength)
11. Tighten the bolts to the specified torque value.
Torque: 98 N·m
12. Check that the spring balance reading which
should be 4.5 kgf (10lbf) more than the reading
mentioned in the step 5.
Table 356. Example of

shim thickness calculation
Gap 1.55 mm
Subtract 1 mm
Shim Thickness 0.55 mm
27 - 368 9823/1650-1 27 - 368

27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side
Special Tools 3. Mark the position of the top and bottom trunnions.
Description Part No. Qty. Remove the bolts and remove the trunnions.
Impulse Extractor 892/00224 1 4. Remove the hub swivel.
Bearing Removal Tool 892/00225 1
Adaptor 993/59500 1 5. To easily remove the trunnions, pump grease
through the grease nipple.
Consumables Consumable: Special HP Grease
JCB Threadlocker 4101/0250 0.01 L 6. If it is necessary to replace, remove the top and
and Sealer (Medium bottom trunnion oil seals and bearings.
4101/0251 0.05 L
Strength) 7. Use an adaptor with a slide hammer tool to
Special HP Grease 4003/2020 0.5 kg remove the driveshaft oil seal1 and the needle
4003/2017 0.4 kg roller bearing from the hub swivel.
4003/2006 12.5 kg Special Tool: Impulse Extractor (Qty.: 1)
4003/2005 50 kg Special Tool: Adaptor (Qty.: 1)
8. Remove the driveshaft from the axle.
Disassembly
9. Prise out the driveshaft oil seal 2 from the axle
The hub assembly must be removed before you ram.
attempt to remove the hub swivel and driveshaft.
Refer to the applicable axle hub removal procedure. 10. Use a tool (892/00225) to remove the drive shaft
inner bearing.
1. Disconnect the track rod and steering cylinder
Special Tool: Bearing Removal Tool (Qty.: 1)
from the axle steer knuckles.
11. If there has been a component failure, remove
2. The top and bottom trunnions are the same.
all traces of debris from the axle and clean the
magnetic drain plug.
27 - 369 9823/1650-1 27 - 369

27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side
Figure 764.
20 Trunnions 21 Trunnion bolts

23 Hub swivel 24 Trunnions seals
25 Bearing 26 Driveshaft
27 Drive shaft seal 28 Needle roller bearing
30 Driveshaft inner oil seal 31 Circlip
32 Driveshaft inner bearing
27 - 370 9823/1650-1 27 - 370

27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side
Assembly 19. Connect the track rod and steering cylinder to the
axle steer knuckles.
1. Tap the driveshaft inner bearing into the position
in the axle case. Table 357. Torque Values
2. Install a new driveshaft oil seal 2. Apply grease Item Description Nm

between the lips of the seal. 21 Trunnion bolts 98
3. Tap the driveshaft needle roller bearing into the
position in the hub swivel driveshaft bore.
4. Install new driveshaft oil seal 1. Apply grease
between the lips of the seal.
5. Instal the spacer.
6. Install the driveshaft. Carefully locate the end into
the splines of the differential gears.
7. Push the new trunnion oil seals into the position
followed by the bearings.
8. Apply grease on the bearing and the oil seal
before you install them to the axle.
9. In the following step, take care not to damage the
trunnion oil seals when you tighten the trunnion
bolts.
10. Previous axles have a shim installed under the
top trunnion. Where a shim is installed follow the
calibration procedure.
11. Locate the hub swivel and install the top and
bottom trunnions.
12. Apply JCB Threadlocker to threads of trunnion
bolts.
(Medium Strength)
13. First finger tighten all of the bolts then
sequentially tighten them to bring the two
trunnions together.
15. Make sure that the swivel rotates smoothly on its
trunnions.
16. Stiff movement may result if seals have become
displaced and damaged during assembly.
17. Make sure that the grease nipple is clear and not
damaged, replace as necessary.
18. Tighten the nipple to the specified torque value.
Torque: 56 N·m
27 - 371 9823/1650-1 27 - 371

Notes:
27 - 372 9823/1650-1 27 - 372

Contents Page No.
30-00 General
30-00-00 General ............................................................................................................................. 30-3
30-00-49 Schematic Symbols ........................................................................................................ 30-14
30-00-50 Schematic Circuit ........................................................................................................... 30-18
30-03 Tank
30-03-00 General ........................................................................................................................... 30-39
30-03-12 Suction Strainer .............................................................................................................. 30-40
30-04 Filter
30-04-00 General ........................................................................................................................... 30-43
30-11 Gear Pump
30-11-00 General ........................................................................................................................... 30-45
30-15 Cylinder / Ram
30-15-00 General ........................................................................................................................... 30-55
30-15-34 Steering .......................................................................................................................... 30-62
30-15-99 Seal Kit ........................................................................................................................... 30-65
30-18 Accumulator
30-18-00 General ........................................................................................................................... 30-69
30-53 Servo System Control Valve Block
30-53-00 General ........................................................................................................................... 30-75
30-53-03 Main Relief Valve (MRV) ................................................................................................ 30-85
30-53-06 Auxiliary Relief Valve (ARV) ........................................................................................... 30-87
30-53-27 Pressure Compensator Valve ........................................................................................ 30-89
30-53-36 Load Hold Check Valve ................................................................................................. 30-92
30-53-80 Spool .............................................................................................................................. 30-93
30-54 Parallel Circuit Control Valve Block
30-54-00 General ........................................................................................................................... 30-97
30-54-06 Auxiliary Relief Valve (ARV) ......................................................................................... 30-114
30-54-39 Load Hold Check Valve ............................................................................................... 30-117
30-60 Directional Control Valve
30-60-00 General ......................................................................................................................... 30-119
30-60-12 Electro Proportional Control ......................................................................................... 30-121
30-60-15 Joystick ......................................................................................................................... 30-126
30-60-27 Auxiliary Circuit ............................................................................................................ 30-138
30-60-90 Flow Regulator ............................................................................................................. 30-139
30-63 Hose Burst Check Valve
30-63-00 General ......................................................................................................................... 30-141
30-93 Hose
30-93-00 General ......................................................................................................................... 30-145
30-93-03 Lift Arm ......................................................................................................................... 30-149
30-96 Pipe
30-96-03 Lift Arm ......................................................................................................................... 30-151
30-97 Connectors
9823/1650-1
2018-06-07
30-97-03 Quick Release Coupling .............................................................................................. 30-153
30-97-09 Adaptor ......................................................................................................................... 30-155
30-97-24 Push Lock Fitting ......................................................................................................... 30-157
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-158
9823/1650-1
2018-06-07
Acronyms Glossary
ARV Auxiliary Relief Valve

HBCV Hose Burst Check Valve
LHCV Load Hold Check Valve
LLMC Longitudinal Load Moment Control
LSRV Load Sense Relief Valve
MRV Main Relief Valve
QRC Quick Release Coupling
SRS Smooth Ride System
9823/1650-1
2018-06-07
Notes:
9823/1650-1
2018-06-07
00 - General
00 - General
Contents Page No.
30-00-00 General ............................................................................................................................. 30-3

30-00-49 Schematic Symbols ........................................................................................................ 30-14
30-00-50 Schematic Circuit ........................................................................................................... 30-18
30 - 1 9823/1650-1 30 - 1
Notes:
30 - 2 9823/1650-1 30 - 2
00 - General
00 - General

Health and Safety ........................................... 30-3 Hydraulic Pressure
Technical Data ................................................. 30-4 Hydraulic fluid at system pressure can injure you.
Component Identification ................................. 30-6 Before connecting or removing any hydraulic hose,
Operation (Hydraulic) ...................................... 30-8 residual hydraulic pressure trapped in the service
Fault-Finding .................................................... 30-9 service line has been vented before connecting or
Discharge and Pressurise ............................. 30-11 removing hoses. Make sure the machine cannot be
Clean ............................................................. 30-12 started while the hoses are open.
Check (Level) ................................................ 30-13 WARNING! Fine jets of fluid at high pressure can
penetrate the skin. Keep face and hands well clear of
pressurised fluid and wear protective glasses. If fluid
penetrates your skin, get medical help immediately.
WARNING! Take care when disconnecting hydraulic
hoses and fittings as the oil will be hot.
WARNING! Damaged hoses can cause fatal
accidents. Examine the hoses regularly. Do not use
the machine if a hose or hose fixture is damaged.
Notice: Do not allow dirt to enter the system. Before
disconnecting any part of the system, thoroughly
clean around the connection. When a component
has been disconnected, always install protective
caps and plugs to prevent dirt ingress. Failure to
follow these instructions will lead to dirt entering the
system. Dirt in the system will seriously damage
the systems components and could be expensive to
repair.
CAUTION! The temperature of the hydraulic oil will
be high soon after stopping the machine. Wait until it
cools before beginning maintenance.
30 - 3 9823/1650-1 30 - 3
00 - General
00 - General
Technical Data Table 359. Relief Valve Pressures-

Load Sense Relief Valve
For: 506-36 [T4i], 507-42 [T4i], 509-42 [T4i], 2C-Load sense relief 260 bar ( 3,768.1 psi)
512-56 [T4i], 514-56 [T4i], LSP Electro
valve
(1)
Servo System .............................. Page 30-4
For: 506-36 [T4i], 507-42 [T4i], 509-42 [T4i], (1) Before testing the Load Sense Relief Valve
512-56 [T4i], 514-56 [T4i], Parallel System pressure, allow the hydraulic system to warm up to
..................................................... Page 30-5 ensure an accurate reading. 50 °C ( 121.9 °F)
Table 360. Relief Valve Pressures-

(For: 506-36 [T4i], 507-42 [T4i], 509-42 Auxiliary Relief Valves (ARV's)
[T4i], 512-56 [T4i], 514-56 [T4i], LSP
2L-Boom extend ram 200 bar ( 2,898.5 psi)
(2)
Electro Servo System) head side
2J-Carriage tilt ram head 240 bar ( 3,478.2 psi)
Flow share control valve block side
For full details of the flow share valve block refer to 2H-Carriage tilt ram rod 275 bar ( 3,985.5 psi)
(PIL 30-53). side
(2) Machines from serial number 1402062 will be set
Figure 765. to 215 bar ( 3,115.9 psi)
Table 361. Pilot Pressure Range

All machines 10 –30 bar ( 144.9 –
434.8 psi)
Hydraulic Pump (110 L/Min)

Table 362.
L Type Gear pump
Mounting Gearbox
Direction of rotation Counter clockwise
Maximum speed 3000 RPM
Minimum speed 500 RPM
Weight 33.3 kg
Table 363. Theoretical Displacement

Description Value
Main services pump 29 cc/rev
2C Load sense relief valve (mounting flange end)
2H Carriage tilt ram rod side Steering pump 19 cc/rev
2J Carriage tilt ram head side
2L Boom extend ram head side Cooling fan pump 16 cc/rev
Table 364. Flow

Table 358. Flow share Control Valve Block Description Value
Type 3 spool, load sense- pressure Main services pump 57.4 L/min
compensated, double acting (mounting flange end)
(1)
spools Steering pump 37.6 L/min

Spool 1 Carriage tilt ser- Pilot operated Cooling fan pump 31.7 L/min
vice
Spool 2 Boom extend Pilot operated (1) Flow at 2200 RPM and system pressure (90%
and retract ser- min. displacement).
vice
Table 365. Maximum Pressure
Spool 3 Lift and lower Pilot operated
service Description Value
Port EF 265 bar ( 3,840.6 psi)
Port P 200 bar ( 2,898.5 psi)
30 - 4 9823/1650-1 30 - 4
00 - General
00 - General
Table 367. Relief Valve Pressures

(For: 506-36 [T4i], 507-42 [T4i], 509-42 LSRV (Mounted within 260 ( 3,768.1 )
[T4i], 512-56 [T4i], 514-56 [T4i], Parallel flowshare valve block)
System) ARV C 140 ( 2,029.0 )
ARV D 140 ( 2,029.0 )
2 Section Valves
Figure 766. 2 Section Parallel Valve
Hydraulic Pump (110 L/Min)
Control Block (2 Spool, Parallel
Table 368.
Service, Double Acting Spools)
C Type Gear pump
Mounting Gearbox
Direction of rotation Counter clockwise
Maximum speed 3000 RPM
P B B Minimum speed 500 RPM
1 2 Weight 33.3 kg
T A A Table 369. Theoretical Displacement
Description Value
Main services pump 29 cc/rev
D (mounting flange end)
1 Spool 1- Auxiliary service (manually operated) Steering pump 19 cc/rev
2 Spool 2- Sway service (manually operated) Cooling fan pump 16 cc/rev
Table 366. Relief Valve Pressures Table 370. Flow

LSRV (Load Sense Re- 260 ( 3,768.1 ) Description Value
lief Valve) (Mounted Main services pump 57.4 L/min
within flowshare valve
(mounting flange end)
(1)
block)
Steering pump 37.6 L/min
ARV (Auxiliary Relief 140 ( 2,029.0 )
Valve) C Cooling fan pump 31.7 L/min
ARV D 140 ( 2,029.0 ) (1) Flow at 2200 RPM and system pressure (90%
min. displacement).
5 Section Valves
Table 371. Maximum Pressure
Figure 767. 5 Section Parallel Valve
Description Value
Control Block (5 Section, 4 Spool, Par-
allel Service, Double Acting Spools) Port EF 265 bar ( 3,840.6 psi)
C Port P 200 bar ( 2,898.5 psi)
P B B B B
1 5 2 3 4
T A A A A
D
1 Spool 1, Auxiliary service, (manually operated)
2 Spool 2, Sway service manually operated
3 Spool 3, Stabiliser, manually operated
4 Spool 4, Stabiliser, manually operated
5 Section 5, Isolation valve (spools 2, 3 and 4)
Electrical solenoid operation
30 - 5 9823/1650-1 30 - 5
00 - General
00 - General
Figure 768.
B
F
G
H
E
D
C1 C3 C2 A
L P
M Q
N R
Item Description
Table 372. Components C Pump assembly Three section gear
Item Description pump C1, C2, C3
A Control valve block Flowshare valve with C1 Pump1
servo spools C2 Pump 2
B Control valve block Parallel valve with C3 Pump 3
manual spools
30 - 6 9823/1650-1 30 - 6
00 - General
00 - General
Item Description
D Pilot pressure supply Supplies oil at pilot
valve pressure to the servo
control valves
E Hydraulic oil filter Positioned in the ser-
vo pilot valve feed
line
F Servo control valve Two axis control
lever
G Servo control valve Single axis control
lever
H Fan motor Driven by pump sec-
tion C2
J Hydraulic oil filter Positioned in the re-
turn line to tank
K Hydraulic tank
Table 373. Hydraulic Connections Colour Code

Item Description
L Oil from pump section C1
M Oil at pilot pressure
N Oil suction line from the tank to the pump
sections
P Return to tank
Q Oil from pump section C3
R Oil from pump section C2
30 - 7 9823/1650-1 30 - 7
00 - General
00 - General
Operation (Hydraulic) and leakage and can lead to major problems. The
main contaminants can be classified as follows:
The hydraulic system is a power transmission system 1. Solid Particles - Sand, fibres, metallic particles,
that uses the force of flowing liquids to transmit power welding scale, sealing materials and wear
to specific components in a machine. particles etc.
To help you trace specific hydraulic problems to a 2. Liquid - Usually water and incompatible oils and
faulty unit (valve, actuator, ram etc.), refer to Fault greases.
finding. Refer to: PIL 30-00-00.
3. Gases - Air, sulphur dioxide etc. which can create
Once you have traced the faulty unit, refer to corrosive compounds if dissolved in the fluid.
the relevant section for removal, disassembly and
checking instructions. These contaminants can appear during
manufacture, assembly and operation.
To help identify circuits, valves, rams etc. mentioned
in the fault finding procedures. Refer to the hydraulic
schematic diagrams. Refer to: PIL 30-00-50.
• Before you begin fault finding, read the Health

and Safety Information. Refer to: PIL 30-00-00.
• Make simple checks before you remove or
disassemble a major component.
• Make sure that the hydraulic fluid is at the
correct working temperature 50 °C ( 121.9 °F).
• Whatever the fault, check the condition of the
hydraulic fluid. Drain and replace if necessary.
Refer to Hydraulic fluid quality in this procedure
and Hydraulic System - Clean. Refer to: PIL
30-00-00.
• Make sure you remove ALL contamination and
if possible identify its origin. It may be part of a
component from elsewhere in the circuit.
Hydraulic Fluid Quality

This machine uses a large volume of fluid in the
hydraulic system for power transmission, equipment
lubrication, rust prevention and sealing. According
to a survey conducted by a pump manufacturer,
seventy per cent of the causes of problems in
hydraulic equipment were attributable to inadequate
maintenance of the quality of the hydraulic fluid.
Therefore, it is obvious that control of the quality of
the hydraulic fluid helps prevent hydraulic equipment
problems and greatly improves safety and reliability.
Furthermore from an economic angle it extends the
life of the hydraulic fluid if quality is maintained.
Hydraulic Contamination
Once inside the system, hydraulic circuit
contaminants greatly affect the performance and life
of hydraulic equipment. For example, contaminants
in a hydraulic pump develop internal wear to cause
internal leakage and hence lower discharges. Wear
particles generated will circulate with the hydraulic
fluid to cause further deterioration in the performance
of this and other equipment. Contaminants also
enter principal sliding sections of the equipment
causing temporary malfunction, scuffing, sticking
30 - 8 9823/1650-1 30 - 8
00 - General
00 - General
Fault-Finding
Fault
One service fails, or is slow to operate. Table 374. Page 30-9
The engine tends to stall when hydraulics are under load. Table 375. Page 30-9
Forks creep down Table 376. Page 30-10
Parallel lift faulty Table 377. Page 30-10
Ram creep Table 378. Page 30-10
Table 374. One service fails, or is slow to operate.

Cause Remedy
LLMC (Longitudinal Load Moment Control) Active. Ensure operator fully understand the characteristics
of the LLMC system.
Boom and stabiliser interlocks engaged. Educate the operator. Make sure operator fully
(Construction machines) understands the characteristics of the interlock
system.
Related service pipework or hoses leaking, Check the pipework and hoses. Replace as
damaged, trapped or kinked. necessary.
ARV (Auxiliary Relief Valve) out of adjustment or Check and adjust as necessary.
defective.
Related ram leaking. Carry out ram leakage checks. Renew seals as
necessary.
Related service spool not operating correctly. Manual Spools: Check that the control lever
and related linkage is operating the spool to full
displacement, rectify as necessary.
Servo Operated Spools: Check the condition of
the related harness wiring and the connectors for
damage. Check the solenoid coil for open or short
circuits. Measure the solenoid coil resistance. Renew
the solenoid coil
Servo Operated Spools: Check the condition of
the related harness wiring and the connectors
for damage. Renew the electronic control lever
assembly.
Pressure compensator piston sticking due to Disassemble and inspect the related pressure
contamination. compensator piston.
Service spool or related load hold check valves Disassemble and inspect the related service spool or
damaged or sticking due to contamination. load hold check valves.
Electronic fault Use Servicemaster to find the problem. Refer to
servicemaster, refer to (PIL 33-57).
Counterbalance valve not working correctly. Check operation of the related counterbalance valve.
Counterbalance pressure sensor (lift ram) not Check operation of the lift ram pressure sensor.
working correctly
Table 375. The engine tends to stall when hydraulics are under load.
Cause Remedy
MRV (Main Relief Valve) or LSRV (Load Sense Check and adjust as necessary.
Relief Valve)not adjustable or defective.
Poor engine performance. Check engine performance.
Check engine high and low idle speeds.
Check MRV/LSRV setting and adjust as necessary.
Check ARV setting and adjust as necessary.
Machines with Variflow Pump: Variflow pump fault.
30 - 9 9823/1650-1 30 - 9
00 - General
00 - General
Table 376. Forks creep down

Cause Remedy
Circuit routed incorrectly. Check if any work has been Check the circuit. Re-route the hoses if necessary.
done on the machine recently.
Tilt ram HBCV (Hose Burst Check Valve) leaking, Check for leakage in the tilt ram circuit.
tilt ram seals leaking, control valve spool leaking or
valve block section leaking internally.
Table 377. Parallel lift faulty

Cause Remedy
Displacement/lift link valve broken or leaking. Examine the valve. Check for damages on the ball.
Fit blank to isolate valve from circuit.
Fit latest type valve.
Check pipes, tilt spool, HBCV for missing ball.
Tilt section ARVs set incorrectly, causing oil to leak Check tilt ARV setting. Adjust if necessary.
from tilt/compensating ram circuit.
Tilt section ARVs could be sticking open due to Clean or install new as necessary.
contamination.
Leaking seals in tilt ram or compensation ram. Check tilt/compensation rams for leakage (use hand
pump if available). Install new seals as necessary.
working correctly.
Table 378. Ram creep

Cause Remedy
Associated ram or pipe lines from ram leaking. Check and rectify as necessary.
Check valve. Check operation and rectify as necessary.
working correctly
30 - 10 9823/1650-1 30 - 10
00 - General
00 - General
Discharge and Pressurise Figure 769. Vent switch (If installed)
(For: 506-36 [T4i], 512-56 [T4i], 514-56

[T4i])
WARNING Depending on your machines
specification, other hydraulic systems will require
additional venting. These may include (but not
limited to) SRS, refer to (PIL 30-18-00) and power
brakes, refer to (PIL 24-03-00).
CAUTION Do not run the machine with the
hydraulic tank filler cap removed.
CAUTION Allow the hydraulic fluid temperature to
cool before removing the hydraulic tank filler cap.
Open the cap slowly to prevent oil being forced
out of the filler neck.
1. Make the machine safe with the lift arm lowered.

2. Operate the controls to remove the hydraulic
pressure from the service hose lines.
2.1. For manually operated services, operate
the controls several times of the service to
be disconnected.
2.2. For 550-80 machines without hydraulic 1 Position 1- Off
venting switch - make sure the battery 2 Position 2- Vent position, hold switch down
is connected and the battery isolator is for on position (battery connected, isolator on,
set to on. Turn the ignition key to the on ignition switch set to on, engine off)
position and operate the lift arm raise and 3. Make sure that the pressure is vented correctly.
lower controls several times. On 550-80 Electrical and pilot services have a limited
machines the lift arm lower and retract amount of accumulated pressure available for
service are still operative when the engine venting.
is not running until the hydraulic pressure
is fully released. Make sure that the lift arm 4. Depending on your machines specification, other
is lowered or supported fully on the safety systems will require additional venting. These
strut. may include (but not limited to) SRS (Smooth
2.3. For electrical and servo operated services, Ride System), refer to (PIL 30-18-00) and power
make sure the battery is connected and brakes, refer to (PIL 24-03-00).
the battery isolator is set to on. Turn the 5. Clean the top of the tank around the filler cap.
ignition key to the on position and operate
the controls several times of the service to 6. Slowly remove filler cap to allow the system to
be disconnected. vent fully and to prevent the oil from being forced
2.4. For machines installed with a vent switch, out of the filler neck.
make sure the battery is connected and 6.1. Some filler caps have a side mounted barrel
the battery isolator is set to on. Turn the lock, operated by the ignition key. Your
ignition key to the on position and push and machine may differ from the one shown.
hold the vent switch while you operate the
controls of the service to be vented. Make 7. Make sure that the seal is in good condition and
sure you operate the controls several times installed correctly in the cap. Replace the seal if
while the vent switch is set to on. While the necessary.
vent switch is on, a buzzer will sound and
the venting symbol will be displayed on the
dash.
30 - 11 9823/1650-1 30 - 11
00 - General
00 - General
Figure 770. Hydraulic tank filler cap - Clean

machines without external sight gauge
Special Tools
A Description Part No. Qty.
Hydraulic Flushing Rig 892/01255 1
Cleaning Operation
The purpose of cleaning oil is to remove
contaminants of all types and sludge by filtering
hydraulic fluid through a cleaning unit. Follow the
instructions in the Hydraulic flushing rig instruction
manual.
A Filler cap Procedure
Figure 771. Hydraulic tank filler cap - 1. Connect the Hydraulic flushing rig in place of the
machines with external sight gauge hydraulic filter.
Special Tool: Hydraulic Flushing Rig (Qty.: 1)
A 2. Run the system for sufficient time to pump all the

hydraulic fluid through the unit.
3. Disconnect the cleaning unit and reconnect the
filter.
4. Top up the system with clean hydraulic fluid as
required.
Figure 772.
A Filler cap
A Hydraulic flushing rig
Contaminant Standards
Dirt that damages your system is in many cases
too small to be seen with the eye. The particle
size is measured in microns (1 micron = 0.001 mm
(0.0000394 in).
Listed below are a few typical comparisons:
30 - 12 9823/1650-1 30 - 12
00 - General
00 - General
• Red Blood Cell = 8 microns (0.008 mm, Check (Level)

0.000315 in)
• Human Hair = 70 microns (0.07 mm, 0.00275
in) 1. Make the machine safe.
• Grain of Salt = 100 microns (0.1 mm, 0.00394 Refer to: PIL 01-03.
in)
2. Machines may be installed with a sight tube or a
The smallest particle visible to the naked eye is dipstick for hydraulic fluid level display.
40 microns (0.00157) approximately. Standards will
often be quoted to ISO (International Standards Machines with a Sight Tube
Organisation) for which literature can be obtained.
1. Look at the hydraulic fluid in the sight tube. If
the hydraulic fluid is cloudy, water or air is in the
system. Water or air in the system can damage
the hydraulic pump. Refer to Hydraulic System
Clean and Fault Finding.
2. The level of hydraulic fluid should be between the
two marks on the sight tube.
3. If necessary, add the recommended hydraulic
fluid:
3.1. Discharge the pressure from the hydraulic
tank. Refer to (PIL 30-00).
3.2. Get safe access to the hydraulic filler port.
3.3. Use a suitable container to add the
hydraulic fluid through the filler port.
3.4. Check the level of hydraulic fluid.
Machines with a Dipstick

1. Open the rear cover if installed. Refer to (PIL
06-06-14).
2. Discharge the pressure from the hydraulic tank.
3. Get access to the hydraulic dipstick / breather.
Remove the dipstick from the hydraulic tank.
4. If the hydraulic fluid is cloudy, water or air is in the
system. Water or air in the system can damage
the hydraulic pump. Refer to Hydraulic System
Clean and Fault Finding.
5. Check the hydraulic oil level. The level of
hydraulic fluid should be between the two marks
on the dipstick
6. If necessary, add the recommended hydraulic
fluid:
6.1. Get safe access to the hydraulic filler port.
6.2. Use a suitable container to add the
hydraulic fluid through the filler port.
6.3. Check the level of hydraulic fluid.
30 - 13 9823/1650-1 30 - 13
00 - General
49 - Schematic Symbols
49 - Schematic Symbols Introduction

Introduction .................................................... 30-14 Complex hydraulic components and circuits can
Diagram ......................................................... 30-15 be described to the engineer by using graphical
symbols. The tables illustrate and give a brief
description for some of the more common symbols
used.
There are many symbols in use and it would

be impossible to 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.
Once familiar with the symbols, the engineer can use

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.
30 - 14 9823/1650-1 30 - 14
00 - General
Diagram Table 382. Directional control valves

Symbol Description
Used to enclose sever-
Table 379. General al valves indicating they
are supplied as one unit
Symbol Description
Spring
Flow restriction affected 3-Position, 4-port spring
by viscosity centered pilot operated
valve
Direction of flow 3-position, 6-port spring
centered manually oper-
Indication of rotation ated valve
3-Position, 4-port spring
Indication of direction centered solenoid & pilot
and paths of flow pressure operated valve
3-Position, 4-port spring
Variable control centered detent hand
operated valve
Non-return valve
Table 380. Cylinder Rams

Non-return valve with
Symbol Description back pressure spring
Single acting Pilot operated non-re-
turn valve
Double acting
One way restrictor

Double ended
High pressure selector

Double acting with
(shuttle valve)
damping at rod area end
Throttling orifice - nor-

mally closed
Table 381. Pumps and Motors
Symbol Description
Variable capacity pump Throttling orifice - nor-
two directions of flow mally open
Fixed capacity motor

one direction of flow Relief valve
Fixed capacity motor

two directions of flow
Variable restrictor
Variable capacity motor
one direction of flow
Variable capacity motor

two directions of flow
30 - 15 9823/1650-1 30 - 15
00 - General
Table 383. Energy Symbol Description

Transmissions and Conditioning Filter or strainer
Symbol Description
Working line, return or
feed Water trap
Pilot control
Drain lines
Flexible pipe Cooler - with no indica-
tion of coolant flow
Line junction Cooler - indicating direc-

tion of coolant flow
Heater
Crossing lines
Table 384. Control Mechanisms
Symbol Description
Rotating shaft - one di-
rection
Rotating shaft - two di-
rections
Detent
Air bleed Locking device
Line plugged, also pres-

sure test point Over centre device
Line plugged with take-
off line Simple linkage
QRC (Quick Release
Coupling) - connected General control
QRC - disconnected
Push button operated
Tank - return line above
fluid level Lever operated
Tank - return line below

Pedal operated
fluid level
Stem operated
Header tank
Spring operated
Pressure sealed tank Roller operated
Accumulator Roller trip operated (one

directional)
Solenoid one winding
Solenoid two windings
30 - 16 9823/1650-1 30 - 16
00 - General
Symbol Description
Electric motor operated
M
Internal pressure pilot

operated
External pressure pilot

operated
Pressure operated
spring release
Pilot operated by sole-
noid pilot valve
Pilot operated by a so-
lenoid or separate pilot
valve
Pressure gauge
Pressure switch
30 - 17 9823/1650-1 30 - 17
00 - General
50 - Schematic Circuit
50 - Schematic Circuit Introduction

Introduction .................................................... 30-18 A schematic wiring diagram is a simplified pictorial
Diagram ......................................................... 30-19 representation of the machines hydraulic circuit. It
shows the components of the circuit as simplified
hydraulic symbols, and the connections between
the different components. The schematic diagram
is used to troubleshoot problems and to make
sure that all the connections have been made and
that everything is present. Detailed schematics for
individual systems are given in the relevant PIL
section.
30 - 18 9823/1650-1 30 - 18
00 - General
Diagram
(For: 506-36 [T4i], 512-56 [T4i], 514-56 [T4i])

Figure 773. 332/C5224-12 - 506-36....................................................................................... Page 30-21
Figure 774. 332/D0698-13 - 507-42, 509-42, 510-42, 516-42............................................... Page 30-25
Figure 775. 332/D0983-14 - 510-56....................................................................................... Page 30-29
Figure 776. 333/F7277-6 - 512-56, 514-56............................................................................ Page 30-33
30 - 19 9823/1650-1 30 - 19
Notes:
30 - 20 9823/1650-1 30 - 20
00 - General
Page 30-22 Figure 773. 332/C5224-12 - 506-36 Page 30-23
F
D
E
G H
J N
K
L
M P
30 - 21 9823/1650-1 30 - 21
00 - General
Page Page
30-22 30-23
Figure 773. (Part 1 of 2)
Page 30-23
G H
J N
K
L
M P
30 - 22 9823/1650-1 30 - 22
00 - General
Page Page
30-22 30-23
C
Page 30-22
F
D
30 - 23 9823/1650-1 30 - 23
00 - General
Item Description
6 Pilot pressure supply
Table 385. 332/C5224-12 - 506-36
valve
Item Description 10 Lift cylinder
A Tilt section 12 Tilt cylinder
B Extend section 13 Displacement cylinder
C Lift section 14 Extend cylinder
D Auxiliary section 16 Steer cylinder
E Sway section 20 Return line filter
F Auxiliary quick release 21 Suction strainer
connectors
30 Counterbalance car-
G Two axis hand control tridge
lever
H Single axis hand control tridge
lever
34 Counterbalance valve
J Lower service port con-
35 Adaptor
nector
37 Hydraulic filler / breather
K Extend service port con-
cap
nector
40 Cooling fan motor - 19cc
L Retract service port con-
nector 41 Cooling fan motor - 15cc
M Lift service port connec- 50 Accumulator
tor 51 Mini filter
N Dump service port con- 55 Steer control unit
nector 56 Manual steer mode
P Crowd service port con- valve
nector 60 Parallel control valve
1 Pump assembly 61 Sway cylinder
2 Servo control lever- twin 62 Pilot piston
axis 63 Check valve - low leak
3 Servo control lever- sin- 64 Restrictor
gle axis
65 Regeneration valve
5 Flowshare control valve
30 - 24 9823/1650-1 30 - 24
00 - General
Page 30-26 Figure 774. 332/D0698-13 -

507-42, 509-42, 510-42, 516-42 Page 30-27
D F
G H
J N
K
L
M P
30 - 25 9823/1650-1 30 - 25
00 - General
Page Page
30-26 30-27
Page 30-27
G H
J N
K
L
M P
30 - 26 9823/1650-1 30 - 26
00 - General
Page Page
30-26 30-27
C
Page 30-26
D F
30 - 27 9823/1650-1 30 - 27
00 - General
Item Description
12 Tilt cylinder
Table 386. 332/D0698-13 -
507-42, 509-42, 510-42, 516-42 13 Displacement cylinder
14 Extend cylinder
Item Description
16 Steer cylinder
A Tilt section
20 Return line filter
B Extend section
21 Suction strainer
C Lift section
D Auxiliary section
tridge
E Sway section
F Auxiliary quick release tridge
connectors
G Two axis hand control
35 Adaptor
lever
H Single axis hand control
cap
lever
40 Cooling fan motor - 19cc
J Lower service port con-
nector 41 Cooling fan motor - 15cc
K Extend service port con- 50 Accumulator
nector 51 Mini filter
L Retract service port con- 55 Steer control unit
nector 56 Manual steer mode
M Lift service port connec- valve
tor 60 Parallel control valve
N Dump service port con- 61 Sway cylinder
nector 62 Pilot piston
P Crowd service port con- 63 Check valve - low leak
nector
64 Restrictor
1 Pump assembly
65 Regeneration valve
2 Servo control lever- twin
axis 70 RAS (Rear Axle Stabi-
lization) cylinder - left
3 Servo control lever- sin-
gle axis 71 RAS cylinder - right
4 Dual pilot control valve 72 Inline check valve
5 Flowshare control valve 75 Proportional poppet
valve
valve 76 Thermal relief valve
10 Lift cylinder - 507-42 77 Check valve
11 Lift cylinder - 509-42,
510-42
30 - 28 9823/1650-1 30 - 28
00 - General
Page 30-30 Figure 775. 332/D0983-14 - 510-56 Page 30-31
D
F
G
K L
N
S
P H J
Q T
R
30 - 29 9823/1650-1 30 - 29
00 - General
Page Page
30-30 30-31
Page 30-31
K L
N
S
P
Q T
R
30 - 30 9823/1650-1 30 - 30
00 - General
Page Page
30-30 30-31
C
Page 30-30
D
F
H J
30 - 31 9823/1650-1 30 - 31
00 - General
Item Description
13 Displacement cylinder
Table 387. 332/D0983-14 - 510-56
14 Extend cylinder
Item Description
16 Steer cylinder
A Tilt section
B Extend section
21 Suction strainer
C Lift section
D Left stabiliser section tridge
E Right stabiliser section 31 Counterbalance car-
F Sway section tridge
G Unloader section 34 Counterbalance valve
H Auxiliary section 35 Adaptor
J Auxiliary quick release 37 Hydraulic filler / breather
connectors cap
K Two axis hand control 40 Cooling fan motor - 15cc
lever 50 Accumulator
L Single axis hand control 51 Mini filter
lever
55 Steer control unit
N Lower service port con-
56 Manual steer mode
nector
valve
P Extend service port con-
60 Parallel control valve
nector
61 Sway cylinder
Q Retract service port con-
nector 62 Pilot piston
R Lift service port connec- 63 Check valve - low leak
tor 64 Restrictor
S Dump service port con- 65 Regeneration valve
nector 70 RAS cylinder - left
T Crowd service port con- 71 RAS cylinder - right
nector 72 Inline check valve
1 Pump assembly 75 Proportional poppet
2 Servo control lever- twin valve
axis 76 Thermal relief valve
3 Servo control lever- sin- 77 Check valve
gle axis
80 Stabiliser cylinder - left
81 Stabiliser cylinder - right
valve 82 Stabiliser lock-out valve
10 Lift cylinder 83 Pressure transducer
12 Tilt cylinder
30 - 32 9823/1650-1 30 - 32
00 - General
Page 30-34 Figure 776. 333/F7277-6 - 512-56, 514-56 Page 30-35
30 - 33 9823/1650-1 30 - 33
00 - General
Page Page
30-34 30-35
Page 30-35
30 - 34 9823/1650-1 30 - 34
00 - General
Page Page
30-34 30-35

Page 30-34
30 - 35 9823/1650-1 30 - 35
00 - General
Item Description
Table 388. 333/F7277-6 - 512-56, 514-56 50 Accumulator
Item Description 51 Mini filter
A Tilt section 55 Steer control unit
B Extend section 56 Manual steer mode
C Lift section valve
D Left stabiliser section 58 Bi-directional check
valve
E Right stabiliser section
60 Parallel control valve
F Sway section
61 Sway cylinder
G Unloader section
62 Pilot piston
H Auxiliary section
63 Check valve - low leak
J Auxiliary quick release
connectors 64 Restrictor
K Two axis hand control 65 Regeneration valve
lever 70 RAS cylinder - left
L Single axis hand control 71 RAS cylinder - right
lever 72 Inline check valve
N Lower service port con- 75 Proportional poppet
nector valve
P Extend service port con- 76 Thermal relief valve
nector 77 Check valve
Q Retract service port con- 80 Stabiliser cylinder - left
nector
81 Stabiliser cylinder - right
R Lift service port connec-
82 Stabiliser lock-out valve
tor
83 Pressure transducer
S Dump service port con-
nector
T Crowd service port con-
nector
1 Pump assembly
2 Servo control lever- twin
axis
3 Servo control lever- sin-
gle axis
valve
10 Lift cylinder
12 Tilt cylinder
13 Displacement cylinder
14 Extend cylinder
16 Steer cylinder
21 Suction strainer
tridge
tridge
35 Adaptor
cap
40 Cooling fan motor
30 - 36 9823/1650-1 30 - 36
03 - Tank
03 - Tank
Contents Page No.
30-03-00 General ........................................................................................................................... 30-39

30-03-12 Suction Strainer .............................................................................................................. 30-40
30 - 37 9823/1650-1 30 - 37
Notes:
30 - 38 9823/1650-1 30 - 38
03 - Tank
00 - General
00 - General
Introduction
The hydraulic tank holds excess hydraulic oil to

accommodate volume changes due to the following.
• Cylinder ram extension and contraction.

• Temperature driven expansion and contraction.
• Hydraulic oil leaks.
The tank is also designed to aid in the separation

of air from the fluid and it also acts as a heat
accumulator to cover losses in the system when peak
power is used.
The tank also houses filters or strainers that help to

separate dirt and other particulates from the oil.
The cleanliness of this component is critical. Refer

to: PIL 30-00-00.
30 - 39 9823/1650-1 30 - 39
03 - Tank
Introduction
The suction strainer is a component used for trapping

large and coarse particles, preventing them entering
the hydraulic system. The strainer is usually located
inside the hydraulic tank, at the hydraulic pump
suction port.
30 - 40 9823/1650-1 30 - 40
04 - Filter
04 - Filter
Contents Page No.
30-04-00 General ........................................................................................................................... 30-43
30 - 41 9823/1650-1 30 - 41
Notes:
30 - 42 9823/1650-1 30 - 42
04 - Filter
00 - General
00 - General
Introduction
Hydraulic filters are an important part of the

machines hydraulic system. Metal particles are
continually produced by mechanical components
and need to be removed along with other
contaminants.
The hydraulic filter assemblies are designed to filter

all the contamination that is generated through use
to the required level of cleanliness.
Filters are positioned in many different locations.

Refer to the relevant hydraulic filter for the location
and removal procedure.
The filters must be serviced to the requirements

of the machine maintenance schedules. To ensure
optimum performance and reliability it is important
that the machine's hydraulic system is serviced
periodically in accordance with the manufacturers
requirements.
30 - 43 9823/1650-1 30 - 43
11 - Gear Pump
11 - Gear Pump
Contents Page No.
30-11-00 General ........................................................................................................................... 30-45
30 - 44 9823/1650-1 30 - 44
11 - Gear Pump
00 - General
00 - General Component Identification

Component Identification ............................... 30-45 Figure 777. Typical Double Pump
Operation ....................................................... 30-46
Diagram ......................................................... 30-47 A
Check (Pressure) .......................................... 30-48
D
C
Figure 778. Typical Triple Pump
A
D
B
C
A Main services section
B Steering section (if fitted)
C Cooling fan section
D Steering priority valve
30 - 45 9823/1650-1 30 - 45
11 - Gear Pump
00 - General
Operation
The pump is a gear type and driven by the engine. the gears come into mesh the oil is forced through the
The separate sections of the gear pump assembly outlet port, or through an internal port into the integral
supply hydraulic oil to the main hydraulic circuits, to priority valve depending on the type of pump.
the steering circuit and to the hydraulic cooling fan
circuit. Some oil is allowed to circulate behind the bushes to
hold them in balance against the gears and minimise
The separate sections of the gear pump operate oil leakage.
individually as described below.
Lubrication is provided by the hydraulic oil,which is
The working principle of a gear pump depends on the directed around the unit via oil ways, by the motion
meshing of two spur gears. Oil is picked up on the of the meshing gears.
suction side of the pump by the gears and carried
round between the gear teeth and the pump body. As For the priority valve operation, refer to (PIL 25-03).
Figure 779.
A Spur gear 1 B Spur gear 2

C Bushes 1 D Bushes 2
Table 389. Colour coding

Color Coding Description
Green Pump oil inlet (suction
side)
Amber Pump oil outlet (at pump
pressure)
30 - 46 9823/1650-1 30 - 46
11 - Gear Pump
00 - General
Diagram
A typical triple pump layout is shown. For double

pump schematics and machine specific details refer
to the hydraulic systems and schematics (PIL 30-00).
Figure 780.
LS P EF F G
C A
B
Item Description
Table 390. Main components EF Control valve block sec-
Item Description ondary feed
A Main pump section LS Steering load sense port
B Steering pump section
C Fan and pilot pump sec-
tion
D Priority steer valve
E Hydraulic tank
Table 391. Port details

Item Description
F Fan and pilot valve feed
G Test point
P Pump main output
30 - 47 9823/1650-1 30 - 47
11 - Gear Pump
00 - General
Check (Pressure) Figure 782.
Special Tools
Flowmeter 892/00229 1 D
Load Valve 892/00270 1
Digital Hydraulic 998/11051 1
Pressure Test Kit
Double pump
The gear pump assembly has isolated sections that
supply hydraulic oil to the main services circuits, to
circuit. To find if the pump, steer circuit or services
circuit has a problem, measure the output flow at
system pressure from each pump outlet port.

2. Make sure that you follow the hydraulic health D Hose 1
and safety information. Refer to (PIL 30-00).
5. Connect the flow meter, digital pressure test kit
3. Discharge the hydraulic pressure. Refer to (PIL and a load valve into the discharge line from the
30-00). cooling fan pump as follows:
Figure 781. 5.1. Disconnect the hose 2 from the pump.

B 5.2. Install the flowmeter and the load valve
between the hose 2 and the pump 2.
Figure 783.
C A
A Flowmeter
B Pressure gauge
C Load valve
4. Connect the flowmeter, digital pressure test kit E
and a load valve into the discharge line from the
main service pump as follows:
Special Tool: Load Valve (Qty.: 1)
Special Tool: Flowmeter (Qty.: 1)
Special Tool: Digital Hydraulic Pressure Test Kit
(Qty.: 1) E Hose 2
4.1. Disconnect the hose 1 from the pump. 6. Make sure that the load valve and the flowmeter
4.2. Install the flow meter and the load valve is installed in the correct way with the direction
between the hose 1 and the pump 1. arrow pointing away from the pump.
7. Make sure the load valve is in the open position,
(the adjusting knob screwed fully out), before
starting the following pressure test. Failure to do
so could damage the pump.
30 - 48 9823/1650-1 30 - 48
11 - Gear Pump
00 - General
8. Start the engine and put the hydraulic system up 4.1. Install the flow meter and load valve in the
to working temperature. discharge line1 at an applicable place in the
hose and pipework. Make sure that there
are no other hydraulic connections between
9. Put the steering and control valve block spools to the pump and the load valve.
the neutral position. 4.2. Disconnect the valve from the steer priority
valve port.
10. Set the engine speed to 2200 RPM (Revolutions
Per Minute). 4.3. Install cap in the open hose.
11. Carefully adjust the load valve to make the gauge 4.4. Connect a slave hose to the hydraulic tank.
reading to the specified value. 4.5. Slowly remove the hydraulic tank filler cap
Pressure: 240 bar ( 3,478.2 psi) and place the end of the slave hose inside
the filler tube.
12. Check the flow reading.
Figure 785.
13. If the flow reading is low, you will not get the
required pressure. Refer to (PIL 30-00).
14. Switch off the engine and allow to cool after the H
test.
15. Disconnect the test equipment and connect the
hydraulic hoses again. G
Triple pump F
The gear pump assembly has isolated sections that

supply hydraulic oil to the main services circuits, to
circuit. To find if the pump, steer circuit or services
circuit has a problem, measure the output flow at
system pressure from each pump outlet port.

2. Make sure that you follow the hydraulic health
3. Discharge the hydraulic pressure. Refer to (PIL F Discharge line 1
30-00). G Priority valve port
H Slave hose
Figure 784.
5. Connect the flowmeter, digital pressure test kit
B
and a load valve into the discharge line 2 from
the steering pump as follows:
5.1. Install the flowmeter and load valve in the
discharge line 2 at an applicable place in the
the pump and the load valve.
C A
A Flow meter
B Pressure gauge
C Load valve
the main service pump as follows:
30 - 49 9823/1650-1 30 - 49
11 - Gear Pump
00 - General
Figure 786. 10. Put the steering and control valve block spools to
the neutral position.
11. Set the engine speed to 2200 RPM.
12. Carefully adjust the load valve to make the gauge
reading to the specified value.
Pressure: 240 bar ( 3,478.2 psi)
J
13. Check the flow reading.
14. If the flow reading is low, you will not get the
required pressure. Refer to (PIL 30-00).
15. Test the priority valve. Refer to (PIL 25-03).
Figure 788.
J Discharge line 2
the cooling fan pump as follows:
6.1. Install the flowmeter and load valve in the
discharge line 3 at an applicable place in the
the pump and the load valve.
Figure 787.
16. Switch off the engine and allow to cool after the
test.
17. Disconnect the test equipment and connect the
hydraulic hoses again.
K Discharge line 3
7. Make sure that the load valve and the flowmeter
are installed in the correct way with the direction
arrow pointing away from the pump.
8. Make sure the load valve is in the open position,
(the adjusting knob screwed fully out), before
starting the following pressure test. Failure to do
so could damage the pump.
9. Start the engine and bring the hydraulic system
up to working temperature.
30 - 50 9823/1650-1 30 - 50
11 - Gear Pump
00 - General
Remove and Install 5. Plug all the open ports and hoses to prevent
contamination.
be removed or handled using a suitable lifting 6. Disconnect the feed hoses.
method and device.
contamination.
Before Removal
8. For triple pump, remove the socket head screws.
1. Make the machine safe. Refer to PIL (01-03).
8.1. Disconnect the outlet pipe from the pump
2. Make sure that you follow the hydraulic health body.
Figure 790. Typical triple pump
3. Before you remove and disassemble the pump, A
check the flow and pressure. If either of these
are low and cannot be corrected at the relief
valve, replace the appropriate pump section
completely.
D
4. If you replace the pump component such as
gears, bearings and the housing will not effect a
permanent cure.
5. If the pump output is satisfactory but there is
external leakage, the pump should be removed B C
and disassembled for re-sealing only.
6. Before you remove or disassemble the pump,
make sure the exterior of the pump and working
area is thoroughly cleaned and free of possible A Flange bolts (x4)
sources of contamination. B Socket head screws
C Outlet pipe
Remove D Mounting bolts
1. Discharge the hydraulic pressure. Refer to (PIL 8.2. Plug all the open ports and hoses to prevent
30-00). contamination.
2. Drain the hydraulic fluid from the hydraulic tank 9. Use a sling to secure the pump body.
into a suitable clean container. 10. With the pump suitably supported, remove the
3. Put a label on the hoses to help installation. mounting bolts.
4. Remove the flange bolts and then disconnect the 11. Carefully remove the pump from the gearbox.
suction hose flange from the pump body. 12. Keep the drive coupling.
Figure 789. Typical double pump
Install
A
steps.
1.1. Before assembly, make sure the pump
flange and gearbox mating faces are clean
and free from oil and grease.
1.2. Install new O-ring seals.
1.3. Install the drive coupling and then engage
the pump drive into the coupling.
D
1.4. Support the pump and secure the pump to
the gearbox with the mounting bolts.
A Flange bolts (x4)
D Mounting bolts
30 - 51 9823/1650-1 30 - 51
11 - Gear Pump
00 - General
1.5. Tighten the mounting bolts to the correct Disassemble and Assemble
torque value.
1.6. Make sure that the mounting bolts are 10.9 Do not try to disassemble this component. If this
grade M12 Tuf-Lok. component is defective a new one must be installed.
1.7. Make sure that correct bolts are installed.
1.8. Make sure that the hoses are correctly
installed, and phased in the same position
as removal to prevent chafing.
1.9. Check the hydraulic oil level and top up as
1.10. After you install a new or serviced pump
and before you start the engine, screw out
the MRV (Main Relief Valve) four full turns.
1.11. Adjust the MRV.
1.12. Check the fan motor speed. Refer to (PIL
21-03).
1.13. Check the hydraulic pressure. Refer to
Technical Data (PIL 30-00).

Item Description Nm
A Flange bolts 46
B Socket head screws 46
D Mounting bolts 96
30 - 52 9823/1650-1 30 - 52
15 - Cylinder / Ram
15 - Cylinder / Ram
Contents Page No.
30-15-00 General ........................................................................................................................... 30-55

30-15-34 Steering .......................................................................................................................... 30-62
30-15-99 Seal Kit ........................................................................................................................... 30-65
30 - 53 9823/1650-1 30 - 53
Notes:
30 - 54 9823/1650-1 30 - 54
15 - Cylinder / Ram
00 - General
Introduction .................................................... 30-55 A hydraulic cylinder ram is a mechanical actuator
Health and Safety .......................................... 30-56 that is used to give a single directional force
Operation ....................................................... 30-58 through a single action stroke. It is used in many
Check (Condition) .......................................... 30-61 applications, the cylinder gets the power from
pressurised hydraulic oil. The hydraulic cylinder
consists of a cylinder barrel, in which a piston
connected to a piston rod moves back and forth.
The barrel is closed on one end by the cylinder

cap and the other end by the cylinder head where
the piston rod comes out of the cylinder. The piston
has sliding rings and seals. The piston divides the
inside of the cylinder into two chambers, the bottom
chamber (cap end) and the piston rod side chamber
(rod end / head end).
30 - 55 9823/1650-1 30 - 55
15 - Cylinder / Ram
00 - General
Health and Safety Caution During Use

1. Use only under designated conditions.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. 1.1. If hydraulic oil other than the designated oil
Before connecting or removing any hydraulic hose, is used, the seals quickly degenerate and
residual hydraulic pressure trapped in the service become damaged. If the relief valve is set at
hose line must be vented. Make sure the hose a value higher than specified, it may cause
service line has been vented before connecting or ram damage and is dangerous.
removing hoses. Make sure the engine cannot be 1.2. In high temperature environments (approx.
started while the hoses are open. 90°C and above) or low temperature
Lifting Equipment environments (below -20°C), seals quickly
become damaged. Special seal materials
You can be injured if you use incorrect or faulty lifting are necessary so check to see if the ram
equipment. You must identify the weight of the item to that you are using is suitable or not.
enough and suitable for the job. Make sure that lifting 1.3. The number one cause of ram oil leakage is
equipment is in good condition and complies with all rod damage. Be careful not to damage the
local regulations. rod.
WARNING! A raised and badly supported machine 2. Warm up sufficiently before beginning work.
can fall on you. Position the machine on a firm, level
surface before raising one end. Ensure the other 2.1. In cold conditions the rod seals may
end is securely chocked. Do not rely solely on the be frozen, so if the ram is operated at
machine hydraulics or jacks to support the machine maximum pressure and maximum speed,
when working under it. Disconnect the battery, to the seals will be damaged.
prevent the machine being started while you are
2.2. There is a large amount of air in a new
beneath it.
ram or one which has been left for a long
time, so the ram will not operate smoothly.
Precautions for Installation Also, if pressure is applied suddenly without
bleeding the air, high temperatures will be
1. Precautions when installing the ram on the
generated due to adiabatic compression
machine.
and the seals may burn.
1.1. When installing and removing from the 2.3. Before beginning work, always move the
machine, suspend the ram safely. ram at full stroke with no load and expel air
1.2. Suspending the ram by the piping is not only from the cylinder.
dangerous, but can also cause damage to
3. When stopping or storing, do it at a safe and fixed
the cylinder.
position.
1.3. Secure the piston rod with a band. It is very
dangerous if the rod extends unexpectedly. 3.1. The installed ram cannot maintain the same
Also, the rod can be damaged and become position for a long period of time, because
unusable. the oil inside the ram may leak and the
hydraulic oil volume decreases as it cools.
2. Welding after installing the ram may result in Stop or store the machine in a safe and
damage. fixed position.
2.1. If electric welding is done even at a point Maintenance, Inspection Points

away from the ram, there may be sparking
inside the ram and it will become necessary 1. Carry out daily maintenance and inspection.
to replace the ram with a new one.
1.1. The key point for correct long-term
3. When painting the machine, mask the ram. If ram function is daily maintenance and
paint adheres to the rod surface or to the wiper inspection. Carry out maintenance and
ring and the ram is operated, the wiper ring will inspection so that the ram functions fully at
not function properly and foreign matter and paint all times. Always remove any mud, water,
can easily enter the ram. This will cause damage dust or oil film adhering to the rod and
to the seals, drastically shortening the life of the keep it in normal condition. However, when
ram. cleaning the wiper ring and seals, do not get
them wet with water but wipe clean with a
4. Install the ram only when it is clean.
rag. To prevent rust forming during storage,
the amount of exposed ram piston rod
30 - 56 9823/1650-1 30 - 56
15 - Cylinder / Ram
00 - General
should be kept to a minimum. If leaving for

more than one week, apply a light coating
of suitable grease or petroleum jelly to the
exposed part of the ram piston rod.
2. Use genuine JCB parts when replacing parts.
2.1. If parts other than genuine JCB parts
are used, the desired results may not be
obtained. Use only genuine JCB parts.
3. Caution during dismantling and reassembly.
3.1. Dismantling the ram while it is still installed
on the machine can be dangerous as
unexpected movements of the machine can
occur. Remove the ram from the machine
and then dismantle.
3.2. If reassembled with dirty hands, foreign
matter can enter the ram causing a shorter
life span and also the other hydraulic
equipment may be damaged. Reassemble
in a clean state.
3.3. Follow the instructions in the diagrams
regarding torque tightening for screwed
parts. If the torque is too high or too low, it
can cause damage.
30 - 57 9823/1650-1 30 - 57
15 - Cylinder / Ram
00 - General
Operation
Ram- Cylinder end

(For: 507-42 [T4i])
A restrictor probe installed to the end of the cylinder,
aligns with a groove in the piston rod.
Ram end damping
As the ram closes to full retract, the probe engages
When you operate the lift and extension rams, it can with the groove in the piston rod, the damping effect
cause a shake when the ram is at full travel. This is caused as the orifice plate seats on the face of
could cause load instability and operator discomfort. the piston rod counterbore. The holes in the probe
control the speed of the ram by restricting the flow of
oil at a gradual rate until the ram is fully closed.
Figure 791. Ram retracting (Cylinder end of ram)

A
C D E F G H
A Feed port C Cylinder end

D Orifice plate E Piston rod counterbore
F Piston rod G Restrictor probe
H Piston rod hole
To extend the ram, oil goes into the feed port and the oil pushes on the ram decreasing the pressure
through the centre of the probe to the hole in the necessary to extend the ram (pressure spike).
piston rod. This flow pushes the orifice plate away
from the counterbore increasing the area on which The flow rate, pressure, load and viscosity of the oil
have an effect on the damping rate.
30 - 58 9823/1650-1 30 - 58
15 - Cylinder / Ram
00 - General
Figure 792. Ram extending (Cylinder end of ram)

A
C D E F G H
A Feed port C Cylinder end

D Orifice plate E Piston rod counterbore
F Piston rod G Restrictor probe
H Piston rod hole
30 - 59 9823/1650-1 30 - 59
15 - Cylinder / Ram
00 - General
Ram- Rod end flows through the four holes in the end cap through
the cylinder port. The O- ring compresses on the anti
The damping effect is caused by a tapered collar on extrusion ring which closes the four oil galleries on
the piston rod which engages with the end cap to the front of the end cap. The damping effect is caused
decrease the flow of oil. by the tapered collar gradually decreasing the area
between the piston rod and the end cap restricting
As the ram opens to full extend the tapered collar the flow of oil.
on the piston rod engages with the end cap, the oil
Figure 793.
N J
J
Q K M
L
J End cap K Piston rod

L Oil feed port M Tapered collar
N Flats of the tapered collar P End cap front
Q Oil hole in the end cap
To retract the ram, oil flows through the feed port, this
pushes the anti extrusion ring and compresses the
O-ring and allow oil to flow through the four galleries
which pushes on the piston head. Also the oil flows
through the four holes in the end cap through the flats
of the tapered collar. The function of the flats and
oil pathways is to decrease the pressure necessary
to retract the ram from full open centres (pressure
spike).
Figure 794.
R S
R O-ring
S Extrusion ring
30 - 60 9823/1650-1 30 - 60
15 - Cylinder / Ram
00 - General
Check (Condition)
Check the primary components for scoring, damage,

wear, distortion, uneven surface (i.e. polished or
pitted areas) and scratches. Replace all damaged
parts.
Check the components for burrs. Give special

attention to the traversing diameters, locking pin
holes and mounting chamfers. If minor burrs are
seen, remove them by polishing with a fine grade
abrasive paper.
Check pivot bushes for signs of wear or damage.

Replace if necessary.
If a cylinder is damaged it must be replaced. New

piston seals will fail after only a short period of time
if the cylinder is worn or damaged.
30 - 61 9823/1650-1 30 - 61
15 - Cylinder / Ram
34 - Steering
34 - Steering Remove and Install

Remove and Install ....................................... 30-62 Working Under the Machine
Disassemble and Assemble .......................... 30-64 Make the machine safe before getting beneath it.
movement.
Remove
Before you remove the steer rams clean the area
around the axle and steer rams.
The following procedure applies to each of the

steering rams on the front and rear axles:

4. Disconnect all the three hoses.
5. Plug all the open ram ports and hoses to prevent
contamination.
6. Remove the screws and the pins from each end
of the ram.
7. Lift the ram from the axles.
Figure 795.
B
C
A
A Hoses B Screws
C Pins
30 - 62 9823/1650-1 30 - 62
15 - Cylinder / Ram
34 - Steering
Install
steps.
1.1. Tighten the screws to the correct torque
value.
1.2. Before you drive the machine, bleed the
steering system. Refer to (PIL 25-00).

Item Description Nm
B Screws 56
30 - 63 9823/1650-1 30 - 63
15 - Cylinder / Ram
34 - Steering
Refer to Hydraulic system, cylinder ram, general (PIL

30-15-00).
30 - 64 9823/1650-1 30 - 64
15 - Cylinder / Ram
99 - Seal Kit
99 - Seal Kit Figure 796.
Remove and Install

Special Tools
Ram Protection Sleeve 892/00167 1
(90mm rod diameter)
Ram Seal Installation 892/00334 1 A Ram seal installation tool
Tool B Pins
Ram Protection Sleeve 892/01016 1 1.2. Open the seal installation tool and insert
(25mm rod diameter) the new rod seal. Install the seal behind the
Ram Protection Sleeve 892/01017 1 two front pins but in front of the rear pin as
(30mm rod diameter) shown.
Ram Protection Sleeve 892/01018 1 Figure 797.
(40mm rod diameter)
(50mm rod diameter)
- Slew (50mm rod
diameter)
(60mm rod diameter)
- Slew (60mm rod
diameter)
A Rod seal
(65mm rod diameter) 1.3. Later ram end caps and piston heads
Ram Protection Sleeve 892/01024 1 have metric threads. The seals are also
(70mm rod diameter) different, make sure that the correct seals
Ram Protection Sleeve 892/01025 1 are installed. On metric threaded rams,
(75mm rod diameter) make sure that the seals are installed the
correct way around, as shown.
(80mm rod diameter) Figure 798.
Ram Seal Assembly 892/01027 1
Tool
Remove
1. Remove and discard the old seals.
Install
1. Install new rod seals:
A Inner seal
1.1. Use the ram seal installation tool to install B Outer seal
rod seals, the size (diameter) and position
of pins is determined by the diameter and 1.4. Close the tool. The seal must form a
radial width of the rod seal being installed. reniform (kidney shape).
The pins are screwed into threaded holes
in the tool body, the spacing of the holes is
designed to suit small or large diameter rod
seals.
Special Tool: Ram Seal Installation Tool
(Qty.: 1)
30 - 65 9823/1650-1 30 - 65
15 - Cylinder / Ram
99 - Seal Kit
Figure 799. Special Tool: Ram Protection Sleeve - Slew

(60mm rod diameter) (Qty.: 1)
Special Tool: Ram Protection Sleeve
1.5. Before you install the rod seals, check that (80mm rod diameter) (Qty.: 1)
the seal grooves are free of contamination Special Tool: Ram Protection Sleeve
and sharp edges. (90mm rod diameter) (Qty.: 1)
1.6. Locate the seal in the end cap groove. Figure 801.
When the seal is in position, open the tool
to release the seal. Make sure the seal is
correctly installed in its grooved and remove
the tool.
Figure 800.
A Protection Sleeve (various sizes)

2. Install new head piston seals.
2.1. Use the Piston seal assembly tool to lever
the inner seal into the piston head seal
groove. Do not let the seal twist. There are
identification marks on the outer diameter
1.7. Install the rod wiper seal into the seal of the seal, make sure that the marks are
groove. Make sure that the seal is correctly visible and the seal is free to rotate, if not
installed as shown. Note: Some rod wipers, remove the seal and retry.
i.e. power track rod, may use a metal
encased seal which is pressed into the Special Tool: Ram Seal Assembly Tool
housing. Care must be taken to make sure (Qty.: 1)
that the seal is square before it is pressed Figure 802.
in.
1.8. A special sleeve must be used to protect
the rod seals from damage, when installing
the end cap on to the piston rod. There are
various sizes of sleeve, make sure you use
the correct size sleeve and also make sure
that the hexagon on the end cap is towards
the eye end of the rod.
Special Tool: Ram Protection Sleeve - Slew A Piston seal assembly tool
(50mm rod diameter) (Qty.: 1) B Inner seal
Special Tool: Ram Protection Sleeve C Outer seal
30 - 66 9823/1650-1 30 - 66
15 - Cylinder / Ram
99 - Seal Kit
2.2. Use the same procedure to install the outer

seal as stated for the inner seal. Check that
the external grooves are visible.
2.3. Make sure that the O-ring is installed into
the internal seal groove on the piston head.
Screw the piston head on to the thread of
the piston rod and tighten to the correct
torque value.
2.4. Install the piston head retaining dowel.
2.5. Install wear rings, rotate the wear rings so
that the piston retention dowel is covered by
the wear ring, not as shown at C.
Figure 803.
A Outer wear ring

B Inner wear ring
C Incorrect installation
3. Install the piston rod and head assembly into the
cylinder.
3.1. Insert the piston/rod assembly into the
cylinder ram. Align the rod and head
assembly until parallel with the cylinder ram
then push the assembly into the cylinder.
3.2. Install the end cap and assemble the ram
assembly.
30 - 67 9823/1650-1 30 - 67
18 - Accumulator
18 - Accumulator
Contents Page No.
30-18-00 General ........................................................................................................................... 30-69
30 - 68 9823/1650-1 30 - 68
18 - Accumulator
00 - General
Introduction .................................................... 30-69 A hydraulic accumulator is a pressure storage
Health and Safety .......................................... 30-70 reservoir used to store hydraulic fluid, the non-
Component Identification ............................... 30-70 compressible hydraulic fluid is held under pressure
Discharge and Pressurise ............................. 30-71 by a compressed nitrogen gas. It is designed to
increase or relieve pressure in the hydraulic system.
Accumulators enable a hydraulic system to cope with

extremes of demand using a less powerful pump, to
respond more quickly to a temporary demand, and
to smooth out pulsations.
It is not possible to disassemble the accumulators.

The extent of permissible servicing is limited to
checking the nitrogen gas pre-charge pressure. If an
accumulator is suspected as being faulty it must be
renewed as a complete assembly.
Make sure you have read and understood the Health

and Safety implications. Refer to: PIL 30-18-00.
There are three different types of accumulator

installed on JCB machines:
• Diaphragm (sealed for life) - Non

Rechargeable.
• Diaphragm (with gas valve) - Rechargeable.
• Piston Bladder - Rechargeable.
Although some accumulators are identical in

appearance, the accumulators are charged to
different pressures. When renewing an accumulator
make sure you know the correct charge pressure,
refer to the applicable Technical Data.
Upon installation of a new accumulator the correct

label stating the charge pressure must be attached.
The original label which states a zero charge must
be removed.
30 - 69 9823/1650-1 30 - 69
18 - Accumulator
00 - General

DANGER Use only nitrogen gas to charge
accumulators. The use of any other gas can Figure 804.
cause the accumulators to explode. Remember
that although nitrogen is not poisonous you can
be killed by suffocation if it displaces the air in your
workplace. Do not allow excessive quantities of
nitrogen to be discharged into the atmosphere.
CAUTION To reduce pressure use the
recommended charging tool or the charge valve
could be damaged which may result in rapid C
discharge of the accumulator.
WARNING You must vent all the hydraulic
pressure from the accumulators before A
disconnecting them from the hydraulic system.
Replacement accumulators will only be supplied in B

an uncharged, non pressurised condition to meet
Health and Safety, and Air freight hazardous goods
requirements.
A Diaphragm (sealed for life)-Non Rechargeable

B Diaphragm (with gas valve)-Rechargeable
C Piston Bladder-Rechargeable
30 - 70 9823/1650-1 30 - 70
18 - Accumulator
00 - General
Discharge and Pressurise Figure 805.
Special Tools
Accumulator Charging 892/01042 1 B
Kit (Diaphragm)
Accumulator Charging 892/01043 1 A
J
Adaptor
WARNING You must vent all the hydraulic

pressure from the accumulators before
C
disconnecting them from the hydraulic system.
DANGER Use only nitrogen gas to charge F
accumulators. The use of any other gas can H G
cause the accumulators to explode. Remember
that although nitrogen is not poisonous you can
be killed by suffocation if it displaces the air in your D
workplace. Do not allow excessive quantities of
nitrogen to be discharged into the atmosphere.
E
Before removing accumulators make sure hydraulic
pressure is released.
Even when the hydraulic pressure is released the A Adaptor

accumulator still contains pressurised nitrogen gas. B Filler plug
Do not attempt to discharge the gas pressure. C Gas bottle valve
D Pressure regulator
Do not transport accumulators charged with E Charging hose
pressurised gas by air freight. F Discharge plug
G Charging unit
Charging H Charging unit knob
J Pressure gauge
Important: The following charging procedure is only 1. Hold the accumulator vertical and remove the
applicable to accumulators supplied in a discharged plastic cap from the top of the accumulator.
state.
2. Note: Some accumulators are supplied with a
Operating charge pressures: Accumulators are measured quantity of oil inside the gas chamber.
charged to different operating pressures depending Take care to prevent oil loss.
on the application. Refer to: PIL 30-18. for the
correct charge pressure. 3. With a suitable allen key, slowly remove the filler
plug.
Charge the replacement accumulator with nitrogen
as follows: 3.1. Remove the sealing washer and plug.
3.2. Lightly oil the sealing washer.
3.3. Install the new plug.
3.4. Loosen the plug by 1/8 of a turn.
4. Connect the accumulator adaptor to the
accumulator.
Special Tool: Accumulator Charging Adaptor
(Qty.: 1)
5. Connect the charging unit to the accumulator
adaptor.
Special Tool: Accumulator Charging Kit
(Diaphragm) (Qty.: 1)
30 - 71 9823/1650-1 30 - 71
18 - Accumulator
00 - General
6. Connect the charging hose to the pressure Figure 806.

regulator on the nitrogen gas bottle with the
correct adaptor.
7. Set the pressure regulator on the gas bottle to
the minimum pressure.
8. Turn the charging tool knob to open the filler plug
by three turns.
9. Open the discharge valve on the charging unit.
10. Carefully open the nitrogen gas bottle valve and
A
make sure that the nitrogen gas flows freely
through the discharge valve.
C
11. Close the gas bottle valve and the discharge
valve. B
12. Carefully open the gas bottle valve.

13. Slowly increase the pressure using the gas bottle
pressure regulator and watching the gauge on
the charging unit, allow nitrogen to flow until
the pressure reading reaches the specified value A Label position
above the operating charge pressure. B Discharged state label
Pressure: 4 bar ( 58.0 psi) C Pressurised warning label
14. Important: Do not exceed the maximum working 25. Install the accumulator and make sure the
pressure of the accumulator. The maximum pressurised warning label is clearly visible.
working pressure is marked on the accumulator
body.
15. Close the gas bottle valve.
16. Wait for the specified duration to dissipate the
heat generated during charging.
Duration: 10 min
17. Carefully open and close the discharge valve to
reduce the pressure in the accumulator to the
specified operating charge pressure.
18. Turn the charging tool knob to close the filler plug
and tighten to the correct torque value.
Torque: 20 N·m
19. Open the discharge valve to release the pressure
from the charging hose.
20. Disconnect the charging unit and adaptor from
the accumulator.
21. Pour oil around the filler plug to make sure that
it is gas tight.
22. Replace the plastic cap.
23. Remove the discharged state label.
24. Attach the pressurised warning label on the
accumulator at the position shown.
30 - 72 9823/1650-1 30 - 72
53 - Servo System Control Valve Block
Contents Page No.
30-53-00 General ........................................................................................................................... 30-75

30-53-03 Main Relief Valve (MRV) ................................................................................................ 30-85
30-53-06 Auxiliary Relief Valve (ARV) ........................................................................................... 30-87
30-53-27 Pressure Compensator Valve ........................................................................................ 30-89
30-53-36 Load Hold Check Valve ................................................................................................. 30-92
30-53-80 Spool .............................................................................................................................. 30-93
30 - 73 9823/1650-1 30 - 73
Notes:
30 - 74 9823/1650-1 30 - 74
00 - General
Introduction .................................................... 30-75 There are two types of control valve used on each
Diagram ......................................................... 30-76 machine.
Fault-Finding .................................................. 30-78
Remove and Install ....................................... 30-79 The Parallel control valve controls the auxiliary, sway
and stabiliser services. For details of the parallel
Disassemble and Assemble .......................... 30-81 control valve Refer to: PIL 30-54.
The Servo System control valve is a Flow Share type

and controls the lift arm extend/retract, raise/lower
and tilt services.
30 - 75 9823/1650-1 30 - 75
00 - General
Diagram
Figure 807.
1A Flushing valve 1B Flushing valve spring

1C LSRV (Load Sense Relief Valve) 1D LHCV (Load Hold Check Valve)
1E Tilt spool 1F Pressure compensator valve
1G Tilt head side ARV (Auxiliary Relief Valve) 1H Tilt rod side ARV
30 - 76 9823/1650-1 30 - 76
00 - General
1J Extend spool 1L Extend head side ARV

1M Lift spool
30 - 77 9823/1650-1 30 - 77
00 - General
Fault-Finding
Refer to the Hydraulic System Fault Finding
procedure. Refer to (PIL 30-00).
30 - 78 9823/1650-1 30 - 78
00 - General
Remove and Install
CAUTION This component is heavy. It must only Refer to: PIL 06-69.
method and device. 3. Discharge the hydraulic pressure.
The valve assembly should be handled correctly as
it can be permanently damaged. The valve block 4. Put labels on the hoses to help installation.
should be lifted by holding the ends of the valve body. 5. Disconnect the hoses and pipes from the valve
assembly.
Remove
1. Make the machine safe with the lift arm raised. contamination.
Refer to: PIL 01-03. 7. With the valve block suitably supported, remove
2. Install the safety strut. the mounting bolts. Carefully lift the valve block
and move away from the machine.
Figure 808.
C
B A
B
B
B
D
A
A Valve block mounting bolts B Pilot control hoses

C Valve block D Mounting bracket
30 - 79 9823/1650-1 30 - 79
00 - General
Install 1.3. Operate the machines hydraulic system.

Check for correct operation and leaks.
1.4. Fill the hydraulic system with the
recommended hydraulic fluid as necessary.
steps.
1.1. Tighten the hoses/adaptors to the correct
torque value. Refer to Table 394. 1.5. After installation, check the LSRV (Load
Sense Relief Valve) and ARV (Auxiliary
1.2. For hose connectors with no specified Relief Valve) pressures.
torque setting - use the JCB Standard
torque setting. Refer to: PIL 30-00-00.
Figure 809.
2
3

Item Hose to adaptor or adaptor to adaptor
1 24 –27 N·m
2 115 –126 N·m
3 84 –92 N·m
4 84 –92 N·m
5 122 N·m
30 - 80 9823/1650-1 30 - 80
00 - General
Consumables Take care when you disassemble and assemble the

Description Part No. Size valve. Make sure you do not damage to seals and
JCB Hydraulic Fluid OP 4002/2001 5L seal grooves. Damage or contamination can cause
46 problems with valve operation.
4002/2005 20 L
4002/2003 200 L Disassemble
JCB Threadlocker and 4101/0550 0.01 L
Sealer (High Strength) 4101/0552 0.2 L 1. Remove the valve block from the machine.
The valve block is a 'sectional' type, which is
made up of a number of separate sections. Make 2. Remove the tie rod nuts (x3).
sure you note the location of all components when
you disassemble. Although some components may 3. Carefully remove the end plate.
appear to be identical, they are not interchangeable,
for example service spools are two different types. 4. Disconnect and remove the remaining service
Make sure that components are assembled in their sections and the inlet section.
original positions. 5. If the inlet section is to be replaced, remove and
keep the tie rods.
30 - 81 9823/1650-1 30 - 81
00 - General
Figure 810.
G
F
C
H
C
K
L
M
N
A
A Flushing valve B Pressure compensator valves

C LHCV (Load Hold Check Valve) D Tie rod nuts
E Tie rods F End plate
G Pilot operated service spool H Service sections
J ARV (Auxiliary Relief Valve) K Blanking plug
L LSRV (Load Sense Relief Valve) M Flow regulator valve
30 - 82 9823/1650-1 30 - 82
00 - General
N Inlet / outlet section
30 - 83 9823/1650-1 30 - 83
00 - General
Assembly
following steps.
1.1. Clean the valve components in an
applicable solvent. Make sure that the
mating faces of the valve sections are fully
clean before assembly.
1.2. Replace the O-rings located between the
valve sections. Install the O-rings correctly.
1.3. Check the LHCV O-rings and replace if
necessary.
1.4. Apply lubricant on all the parts before
assembly. Make sure that all the parts move
freely.
Consumable: JCB Hydraulic Fluid OP 46
1.5. Apply sealant to the tie rods and nuts before
you assemble them.
(High Strength)
1.6. Screw the tie rods into the inlet section until
they are tight.
1.7. Unscrew the tie rods for one turn.
1.8. Once the valve block is fully assembled
these rods may be adjusted to allow
sufficient thread for the tie rod nuts to
tighten.
1.9. Tighten the tie rod nuts to the correct torque
value.

Item Nm
D 35
30 - 84 9823/1650-1 30 - 84
03 - Main Relief Valve (MRV)
03 - Main Relief Valve (MRV) Introduction

Introduction .................................................... 30-85 Refer to (PIL 30-51-03).
30 - 85 9823/1650-1 30 - 85
03 - Main Relief Valve (MRV)
Remove and Install 1.1. Replace all the O-rings and thrust rings.
1.2. Lubricate the parts with JCB hydraulic fluid
The LSRV (Load Sense Relief Valve) is not before assembling.
serviceable. Replace the complete valve if it is 1.3. Tighten the valve to the specified torque
defective. value. Refer to Table 396.
Do not remove or damage the tamper proof cap as 1.4. Adjust the pressure setting as required.
this may invalidate a warranty claim. 1.5. Install tamper proof cap.

Item Nm
D 45
3. Remove the valve assembly from the valve
block.
4. Remove the O-rings and thrust ring.
4.1. When you remove the O-rings and seals,
use a rounded tool that will not cause any
damage to the seal grooves.
4.2. Discard all the O-rings.
4.3. Do not use worn or damaged items.
Figure 811.
A
B
A O-ring
B Thrust ring
C O-ring
D Valve assembly
E Tamper proof cap
Install
steps.
30 - 86 9823/1650-1 30 - 86
06 - Auxiliary Relief Valve (ARV)
06 - Auxiliary Relief Valve (ARV) Introduction

Introduction .................................................... 30-87 Refer to (PIL 30-51-06).
30 - 87 9823/1650-1 30 - 87
Consumables
A
JCB Hydraulic Fluid OP 4002/2001 5L
46 4002/2005 20 L
4002/2003 200 L
The ARV (Auxiliary Relief Valve)'s are not B

serviceable. The complete valve must be replaced if C
it is not operational.
D
Do not remove or damage the tamper proof cap as
this may void the warranty claim.
Remove
block. E
2. Remove the O-rings then remove the thrust ring.

3. Use a rounded tool to remove the O-rings, that
will not cause any damage to the seal grooves. F
4. Discard all O-rings and back-up rings. Do not use

worn or damaged items. A Load hold check valve assembly
B O-ring
5. If necessary, remove the load hold check valve C Thrust ring
assembly. D O-ring
E Valve assembly
Refer to: PIL 30-53-36. F Tamper proof cap
Install
steps.
1.1. Make sure the tamper proof cap supplied
with the valve, is installed.
1.2. Replace all O-rings and back-up rings.
1.3. Before you assemble the parts, apply
lubricants on them.
1.4. If necessary, adjust the ARV pressure
setting.

Item Nm
E 70
30 - 88 9823/1650-1 30 - 88
27 - Pressure Compensator Valve
27 - Pressure Compensator Valve Operation

Operation ....................................................... 30-89
Pressure Compensation (Flowshare)
Each service spool incorporates a pressure
compensator valve. When services are operated
simultaneously the system ensures consistent
operating speed for all services, even when the limit
of the hydraulic pump performance is approached.
The oil from the main hydraulic pump arrives at

the inlet gallery. When the relevant service spool
is selected, the spool moves against the force of
the centring spring. This allows the oil flow to move
the required service. When the service spool is de-
selected, the centring spring returns the spool to the
neutral position.
When one or more services are selected, the

pressure compensator valve detects the service
generating the highest pressure and allows the pump
to deliver oil at sufficient pressure to move the load.
The load hold check valve prevents the load falling
back if the load pressure is greater than the pump
pressure.
The closed centre design ensures consistent service

operation regardless of load.
For information about service spool and pressure

compensator valve operation, refer to hydraulic
system- lift arm control valve block, refer to (PIL
30-51).
30 - 89 9823/1650-1 30 - 89
Figure 813.
B A
F B
E C D F
A Service spool B Centering spring

C Pressure compensator valve D Load hold check valve
E Inlet gallery F Drain port
30 - 90 9823/1650-1 30 - 90

A
Consumables
Cleaner/Degreaser 4104/1557 0.4 L
- General purpose
solvent based parts
cleaner B
JCB Threadlocker and 4101/0550 0.01 L
Sealer (High Strength) 4101/0552 0.2 L
This procedure can be carried out with the valve

block removed or in position.
Remove
1. Make the machine safe with the lift arm raised. C
Refer to: PIL 06-69-03. A Compensator plug
B Compensator piston
3. Discharge the hydraulic pressure. C Centre tie rod hole
Inspection
4. Remove the hydraulic filler cap.
Examine the valve components for scratches, pitting,
5. Put a label on the hoses connected to the valve
corrosion or damage. Replace if necessary.
slice to help installation.
6. Disconnect the hoses. Install
7. Plug all the open ports and hoses to prevent Although the pressure compensator valves look
contamination. identical, they are not interchangeable.
8. To gain access to the pressure compensator 1. The installation procedure is the opposite of the
valves, remove the middle tie rod from the hole removal procedure. Additionally do the following
(leaving the valve block sections held together steps.
with the remaining two tie rods). In order to
remove the middle tie rod, it may be necessary to 1.1. Clean the valve components in an
undo the valve block securing nuts, and pull the applicable solvent.
valve block away from the chassis.
9. Use an 8mm Allen key to remove the purpose solvent based parts cleaner
compensator plug. 1.2. Replace all the O-rings and back-up rings.
10. Remove the compensator piston from the bore 1.3. Lubricate the parts with JCB Hydraulic Fluid
with a magnet. before assembling.
1.4. Apply JCB Threadlocker and Sealer to the
threads of the tie rod, and tie rod nut before
fitting.
(High Strength)

Item Nm
A 60
30 - 91 9823/1650-1 30 - 91
36 - Load Hold Check Valve
36 - Load Hold Check Valve Install

Disassemble and Assemble removal procedure. Additionally do the following
steps.
Consumables
Description Part No. Size 1.1. Clean the valve components in an
Cleaner/Degreaser 4104/1557 0.4 L applicable solvent.
- General purpose Consumable: Cleaner/Degreaser - General
solvent based parts purpose solvent based parts cleaner
cleaner
1.2. Replace all the O-rings and back-up rings.
Remove 1.3. Lubricate the parts with JCB Hydraulic Fluid
before assembling.
Refer to: PIL 01-03. Table 399. Torque Values
Item Nm
A 30
4. Remove the hydraulic filler cap.
5. Remove the control valve from the machine.
6. Disassemble the control valve sections to get
access to the LHCV (Load Hold Check Valve).
7. Use an Allen key to remove the LHCV plug.
8. Remove spring and poppet.
Figure 815.
A
B
C
A LHCV plug
B Spring
C Poppet valve
Inspection
Examine the valve components for scratches, pitting,
corrosion or damage. Replace if necessary.
Ensure good condition of seating faces on poppets

and on the mating faces in the valve block.
30 - 92 9823/1650-1 30 - 92
80 - Spool
80 - Spool
Consumables Refer to: PIL 30-00-00.

4. Disconnect any hoses or pipes which may
Cleaner/Degreaser 4104/1557 0.4 L interfere with the removal of the spool.
- General purpose
solvent based parts 4.1. Put a label on the hoses to help installation.
cleaner
JCB Hydraulic Fluid HP 4002/0801 5L
contamination.
46 4002/0805 20 L
4002/0803 200 L 5. Disconnect the pilot hoses connected to the end
caps at each end of the spool.
It is possible to remove a spool without removing the
valve block from the machine. 5.1. Put a label on the hoses to help installation.
Before commencing work, ensure that the exterior contamination.
of the valve block and the working area are
thoroughly cleaned and free of possible sources of 6. Remove the screws and carefully lift off the end
contamination. cap.
6.1. Retrieve the spring and spring retainer, then
Disassemble withdraw the spool from the valve body.
1. Make the machine safe. 7. When you remove the O-rings and seals, use a
Refer to: PIL 01-03. rounded tool that will not cause damage to the
seal grooves.
8. Discard all the O-rings and back-up rings. Do not
use worn or damaged items.
30 - 93 9823/1650-1 30 - 93
80 - Spool
Figure 816.
A
G
A Assembly orientation markings B End cap screws

C Pilot end cap D O-ring
E Spring F Spring retainer
G Spool
30 - 94 9823/1650-1 30 - 94
80 - Spool
Assemble
Before you assemble, check the valve components
for scratches, pitting, corrosion or other type of
damage. Replace if required.

following steps.
2. Clean the valve components in an applicable
solvent.
3. Lubricate the parts with hydraulic fluid before
assembling. Make sure that all the parts move
freely.
Consumable: JCB Hydraulic Fluid HP 46
4. Replace all O-rings.
5. Make sure that the spools are in the correct
position before installing into the valve block
body.
6. The spool may have assembly orientation
markings, which must be positioned downwards.
7. Tighten the end cap screws to the correct torque
value.

Item Nm
B 10
30 - 95 9823/1650-1 30 - 95
54 - Parallel Circuit Control Valve Block
Contents Page No.
30-54-00 General ........................................................................................................................... 30-97

30-54-06 Auxiliary Relief Valve (ARV) ......................................................................................... 30-114
30-54-39 Load Hold Check Valve ............................................................................................... 30-117
30 - 96 9823/1650-1 30 - 96
00 - General
Introduction .................................................... 30-97
Parallel valve block- 2 section
Diagram ....................................................... 30-102 The 2 section control valve operates the auxiliary and
Fault-Finding ................................................ 30-105 sway hydraulic services.
The valve spools are operated by mechanical
Disassemble and Assemble ........................ 30-111 linkages attached to control levers.
For diagram, refer to the lift arm control valve block-

2 section, Diagram (PIL 30-51-00).
Parallel valve block- 5 section

The 5 section control valve operates the auxiliary,
sway and stabiliser hydraulic services.
The valve spools are operated by mechanical

linkages attached to control levers.
Section 3 of the valve block isolates sway spool

sections, stabiliser service spool 1 and stabiliser
service spool 2 from oil at pump pressure when its
unloader valve solenoid coil is energised.
Electrical switches, spool neutral switch 1, spool

neutral switch 2 and spool neutral switch 3 close
when the applicable spool is not in the neutral
position. The switches are part of the rear axle
stability system.
For diagram, refer to the lift arm control valve block-

5 section, Diagram (PIL 30-51-00).
30 - 97 9823/1650-1 30 - 97
00 - General
Figure 817.
B
C
H E F
A Hydraulic tank B Parallel control valve

C Filter D Servo valve
E Fan supply pump F Main hydraulic supply pump
G Fan return pipework H Flowshare control valve
J Steer circuit return
30 - 98 9823/1650-1 30 - 98
00 - General
Figure 818.
R S
L K
N M
Item Description -
P Control lever Control lever
Table 401.
(Single axis)
Item Description - Q Control valve Parallel valve
K Main hydraulic Gear pump block with manual
supply section spools
L Priority valve Steering R 2 Section paral- -
M Steering section Gear pump lel control valve
N Fan section Gear pump block
30 - 99 9823/1650-1 30 - 99
00 - General
Item Description - Figure 819. Parallel valve block- 2 section

S 5 Section paral- -
lel control valve
block
T Flowshare The system is LS
valve inlet/outlet connected to
section the load sense
components in
the inlet/outlet
section of the
flowshare valve. 2
U Hydraulic oil fil- Positioned in
ter the return line
to tank
V Hydraulic tank - 1A
1B 1
P T
1 Auxiliary service spool
1A ARV (Auxiliary Relief Valve) 1
1B ARV 2
LS Load sense port
P Pressure port- Oil from pump
T Tank port
30 - 100 9823/1650-1 30 - 100

00 - General
Figure 820. Parallel valve block- 5 section
1 Auxiliary service spool 1A ARV 1

1B ARV 2 2 Sway service spool
2A Spool neutral switch 1 3 Unloader valve (stabiliser isolation)
3A Unloader valve solenoid coil 4 Stabiliser service spool 1
4A Spool neutral switch 2 5 Stabiliser service spool 2
5A Spool neutral switch 3 LS Load sense port
P Pressure port- Oil from pump T Tank port
30 - 101 9823/1650-1 30 - 101

00 - General
Diagram
1 Auxiliary service spool 1A ARV (Auxiliary Relief Valve) 1

1B ARV 2 1C Load sense check valve 1
1D Load hold check valve 1 2 Sway service spool
2C Load sense check valve 2 2D Load hold check valve 2
P Pressure Port- Oil from pump T Tank port
LS Load sense port
30 - 102 9823/1650-1 30 - 102

00 - General
1 Auxiliary service spool 1A ARV 1

1B ARV 2 1C Load sense check valve 1
1D Load hold check valve 1 2 Sway service spool
2A Spool neutral switch 1 2B Load sense check valve 2
2C Load hold check valve 2 3 Unloader valve (Stabiliser isolation)
3A Unloader valve solenoid coil 4 Stabiliser service spool 1
4C Load hold check valve 3 5 Stabiliser service spool 2
30 - 103 9823/1650-1 30 - 103

00 - General

5C Load hold check valve 4 P Pressure Port- Oil from pump
T Tank port LS Load sense port
30 - 104 9823/1650-1 30 - 104

00 - General
Fault-Finding
Fault
Lack of power at all hydraulic functions Table 402. Page 30-105
All mechanically operated hydraulic services slow to operate Table 403. Page 30-105
All solenoid/servo operated hydraulic services slow to operate Table 404. Page 30-105
Is the machine experiencing boom extend or retract problems? Table 405. Page 30-105
Bleed air from the hydraulic cylinders - is it OK now? Table 406. Page 30-105
Table 402. Lack of power at all hydraulic functions

Cause Remedy
Insufficient hydraulic fluid. Check for leaks and top up as necessary.
Hydraulic leaks in system. Check hoses, If necessary replace with new one.
Engine performance. Check engine performance.
MRV (Main Relief Valve) setting not correct. Check and adjust as necessary.
Low pump flow. Check pump flow.
Check for external leaks, replace seals.
Priority valve sticking. Refer to (PIL 25-03).
Replace pump.
Table 403. All mechanically operated hydraulic services slow to operate

Cause Remedy
Neutral circuit or low pressure lines leaking, Check pipe lines and if necessary replace.
damaged, trapped or kinked.
MRV setting not correct. Check and adjust as necessary.
Low pump flow. Check pump flow.
Check for external leaks, replace seals.
Priority valve sticking. Refer to (PIL 25-03).
Replace pump.
Table 404. All solenoid/servo operated hydraulic services slow to operate

Cause Remedy
Refer to Table 2 -
Low pilot pressure Check that the pressure maintenance valve is not
sticking open.
Check the pressure reducing valve.
Solenoid power supply not present. Check fuse 2.
Table 405. Is the machine experiencing boom extend or retract problems?

Cause Remedy
YES = Go to Table 5, NO = done
Table 406. Bleed air from the hydraulic cylinders - is it OK now?

Cause Remedy
YES = Done, NO = Go to Table 6
30 - 105 9823/1650-1 30 - 105

00 - General
Remove and Install
Figure 823.
Parallel control valve- 2 section A A
method and device.
B
Remove
C
1. Make the machine safe. Refer to (PIL 01-03). B
2. Follow the hydraulic safety procedures. Refer to
(PIL 30-00). A

30-00).
5. Remove the central access panel and access the A Mounting screws
valve. Refer to (PIL 06-06). B Control rod linkages (shown not connected)
C Valve block switch
6. Put a label on each hose to help installation.
Install
7. Disconnect the hoses.
8. Plug all the open ports and hoses to prevent removal procedure. Additionally do the following
contamination. steps.
9. Disconnect the control rod linkages from the
valve spools.
10. If installed, disconnect the electrical connector at
the valve block switch.
11. Support the valve block, remove the mounting
screws.
12. Carefully lift and remove the valve block from the
machine.
30 - 106 9823/1650-1 30 - 106

00 - General
Figure 824. not vertical, loosen the locknuts at each end

of the control rod. Turn the control rod to
F increase or decrease the length of the rod
E as required. Tighten the locknuts.
D
1.3. To make adjustment for machines with
cranked control rods, disconnect the clevis
and turn it as required. Make sure that the
control rod is phased correctly before you
tighten the locknut.
1.4. Tighten the hose connector 1, the hose
connector 2 and the hose connector 3 to
B the specified torque value. For the hose
connectors with no specified torque setting,
refer to JCB standard torque settings. Refer
to (PIL 72-00).
1.5. Operate the hydraulic system. Check for
correct operation and make sure that there
are no leaks.
30-00).
B
Item Nm
G 25
H 88
J 61
B Control rod linkages
D Control rod
E Locknut Parallel control valve- 5 section
F Clevis CAUTION This component is heavy. It must only
Figure 825. be removed or handled using a suitable lifting
method and device.
G
Remove
2. Follow the hydraulic safety procedures. Refer to
(PIL 30-00).
30-00).
5. Remove the central access panel and access the
valve. Refer to (PIL 06-06).
6. Put labels on each hose to help installation.
H
J
G Connector 1
H Connector 2 8. Plug all the open ports and hoses to prevent
J Connector 3 contamination.
1.1. After installation, check the operation of the 9. Remove the stabiliser control lever knobs and
mechanical control linkages. gaiters from inside the cab.
1.2. Make sure that the control levers in the cab 10. Remove the clevis pin and disconnect the control
are vertical when in neutral. If the lever is rod linkages from the valve spool rod.
30 - 107 9823/1650-1 30 - 107

00 - General
11. Put labels on the connectors to help installation. not vertical, loosen the locknuts at the end
of the control rod. Turn the control rod to
12. Disconnect the electrical connectors connected increase or decrease the length of the rod
to the valve block switches and the isolation as required. Tighten the locknuts.
solenoid.
1.3. To adjust some machines with cranked
13. Support the valve block, remove the mounting control rods, disconnect the clevis and turn
screws. it as required. Make sure that the control rod
is phased correctly before you tighten the
14. Carefully lift and remove the valve block from the locknut.
machine.
1.4. Tighten the hose connector 1, the hose
Install connector 2 and the hose connector 3 to
the specified torque value. For the hose
1. The installation procedure is the opposite of the connectors with no specified torque setting,
removal procedure. Additionally do the following refer to JCB standard torque settings. Refer
steps. to (PIL 72-00).
1.1. After installation, check the operation of the 1.5. Operate the hydraulic system. Check for
mechanical control linkages. correct operation and make sure that there
are no leaks.
1.2. Make sure that the control levers in the cab
are vertical when in neutral. If the lever is 1.6. Check the hydraulic fluid level. Refer to (PIL
30-00).
30 - 108 9823/1650-1 30 - 108

00 - General
Figure 826.
K K
P L
T
L
B L
C
K
E
F
G H
A Hose connector 1 B Hose connector 2

C Hose connector 3 D Spool rod
E Clevis pin F Rod linkages
30 - 109 9823/1650-1 30 - 109

00 - General
G Locknut H Control rod

J Gaiters K Mounting screw
L Electrical connectors

Item Nm
A 25
B 61
C 88
30 - 110 9823/1650-1 30 - 110

00 - General
For: 506-36 [T4i], 507-42 [T4i], 509-42 Figure 827.

[T4i], Parallel Control Valve 2 Section
................................................. Page 30-111
For: 512-56 [T4i], 514-56 [T4i], Parallel
Control Valve 5 Section ........... Page 30-112 B C C C G
(For: 506-36 [T4i], 507-42 [T4i], 509-42

[T4i], Parallel Control Valve 2 Section)
Consumables
46 4002/2005 20 L
4002/2003 200 L
and Sealer (Medium A D E F
4101/0251 0.05 L
Strength) A Tie rods
B Inlet section
2 Section Valve Block C Section O-rings
D Auxiliary section
The valve block is made up of a number of separate E Sway section
sections. The illustration is intended as a guide to F Outlet section
identify the components. G Tie rod nuts
Note the location of all the components when Assemble
you disassemble. Although some components may
appear to be identical they are not interchangeable. 1. The assembly procedure is the opposite of
Make sure that you assemble the components in the disassembly procedure. Additionally do the
their original positions. following steps.
Take great care when you disassemble and 1.1. Clean the valve components in an
assemble the valve. Avoid the following: appropriate solvent. Make sure that the
mating faces of the valve sections are
• Contamination. thoroughly clean before assembly.
• Damage to the spools.
1.2. Install new O-rings located between the
• Damage to the seal grooves.
valve sections. Make sure the O-ring seals
Any of the above may result in possible problems are not trapped or damaged.
with the operation of the valve. 1.3. Lubricate the parts with hydraulic fluid
before you assemble them. Make sure that
Disassemble all the parts move freely.
1. Remove the valve block from the machine. Consumable: JCB Hydraulic Fluid OP 46
1.4. If the tie rods were removed, apply sealant
2. Remove the three tie rod nuts.
to the threads before you install it again.
3. Carefully separate and remove the outlet section Torque tighten to the specified value.
followed by the sway section and the auxiliary Consumable: JCB Threadlocker and Sealer
section. If the inlet section is to be replaced, (Medium Strength)
remove and keep the tie rods safe.
Item Description Nm
G Tie rod nuts 43
30 - 111 9823/1650-1 30 - 111

00 - General
(For: 512-56 [T4i], 514-56 [T4i], Parallel Make sure that you assemble the components in
Control Valve 5 Section) their original positions.
Consumables Take great care when you disassemble and

Description Part No. Size assemble the valve. Avoid the following:
• Contamination.
46 4002/2005 20 L • Damage to the spools.
4002/2003 200 L • Damage to the seal grooves.
and Sealer (Medium Any of the above may result in possible problems
4101/0251 0.05 L
Strength) with the operation of the valve.
Disassemble
5 Section Valve Block
1. Remove the valve block from the machine.
The valve block is made up of a number of separate
sections. The illustration is intended as a guide to 2. Remove the tie rod nuts (x3).
identify the components.
3. Carefully separate and remove the outlet section
Note the location of all the components when followed by the auxiliary section, the isolation
you disassemble. Although some components may section, the sway section, the stabiliser section
appear to be identical they are not interchangeable. 1 and the stabiliser section 2. If the inlet section
is to be replaced, remove and keep the tie rods
safe.
Figure 828.
B C C C C C C K
A D E F G H J
A Tie rods B Inlet section

C Section O-rings D Auxiliary section
E Isolation section F Sway section
G Stabiliser section 1 H Stabiliser section 2
J Outlet section K Tie rod nuts
30 - 112 9823/1650-1 30 - 112

00 - General
Assemble
following steps.
1.1. Clean the valve components in an
appropriate solvent. Make sure that the
mating faces of the valve sections are
thoroughly clean before assembly.
1.2. Install new O-rings located between the
valve sections. Make sure the O-ring seals
are not trapped or damaged.
1.3. Lubricate the parts with hydraulic fluid
before you assemble them. Make sure that
all the parts move freely.
1.4. If the tie rods were removed, apply sealant
to the threads before you install it again.
Tighten to the specified torque value.
(Medium Strength)

Item Description Nm
K Tie rod nuts 43
30 - 113 9823/1650-1 30 - 113

06 - Auxiliary Relief Valve (ARV) Introduction

Introduction .................................................. 30-114 The auxiliary relief valves are not serviceable. The
Operation ..................................................... 30-115 complete valve must be replaced if it is defective.
Do not remove or damage the tamper proof cap as
this may invalidate a warranty claim.
30 - 114 9823/1650-1 30 - 114

Operation Figure 830. Poppet opens
The ARV (Auxiliary Relief Valve) are located in the

control valve to limit potentially damaging pressures
within specified services due to external loadings.
ARV may also be used to limit the maximum pressure

in a specified service to less than the LSRV (Load
Sense Relief Valve) setting.
Valve at rest EX
A service is selected but pressure in the service

gallery has not reached the setting of the ARV which
is held closed by its spring. S
S Service gallery
Figure 829. Valve at rest
EX Exhaust gallery
Anti-cavitation mode
When a service is operated in such a way that low
pressure, or cavitation, exists in the service line, the
relatively high pressure oil in the exhaust gallery acts
on the lower poppet and flows into the service gallery
to make up the deficiency.
Figure 831. Anti-cavitation mode

EX
S Service gallery
EX Exhaust gallery
Poppet opens
The setting of the ARV is exceeded by the service EX
pressure which causes the poppet to rise against
spring force allowing the pressure to be released into
the exhaust gallery. S
S Service gallery
EX Exhaust gallery
30 - 115 9823/1650-1 30 - 115

The ARV (Auxiliary Relief Valve) is not serviceable.

Replace the valve if it is defective.
Remove
1. Make the machine safe. Refer to (PIL 01-03)
30-00). A

block.
4. Remove the O-rings.
4.1. When you remove the O-rings and seals,
use a rounded tool that will not cause any
damage to the seal grooves.
4.2. Discard all the O-rings.
4.3. Do not use worn or damaged items.
A Valve assembly
Install
steps.
1.1. Replace all the O-rings.
1.2. Lubricate the parts with JCB hydraulic fluid
before assembling.
1.3. Tighten the valve assembly to the specified
torque value.
1.4. Adjust the pressure setting as required.

Item Description Nm
A Valve assembly 20
30 - 116 9823/1650-1 30 - 116

39 - Load Hold Check Valve
39 - Load Hold Check Valve Figure 833.
B
Remove and Install
Consumables
and Sealer (Medium 4101/0251 0.05 L C
Strength)
Remove
working on it. Park the machine on level ground A
and lower the loader arm. Stop the engine and
engine being started. Block all four wheels.
1. Remove the valve block securing nuts and pull

the valve blocks away from the chassis.
A Middle tie rod hole
2. Remove the middle tie rod from the hole to get B Compensator plug
access to the pressure compensator valves. The C Compensator valve
valve block sections are held together with the
remaining two tie rods. Install
3. Remove the compensator plug with an Allen key The installation procedure is the opposite of the
of specified value. removal procedure.
1. When installing do the following steps also:
4. Remove the compensator valve from the bore
with a magnet. 1.1. Clean the valve components with the
correct solvent.
5. Check the valve components for scratches,
pitting, corrosion or any other kind of damage. 1.2. Lubricate the parts with JCB hydraulic fluid
Replace if necessary. before you assemble them. Make sure that
all the parts move freely.
1.3. Install new O-rings and back-up rings.
1.4. Apply the specified sealant to the threads
of the tie rod and the tie rod nut before
installation.
(Medium Strength)

Item Description Nm
B Compensator plug 60
30 - 117 9823/1650-1 30 - 117

60 - Directional Control Valve
Contents Page No.
30-60-00 General ......................................................................................................................... 30-119

30-60-12 Electro Proportional Control ......................................................................................... 30-121
30-60-15 Joystick ......................................................................................................................... 30-126
30-60-27 Auxiliary Circuit ............................................................................................................ 30-138
30-60-90 Flow Regulator ............................................................................................................. 30-139
30 - 118 9823/1650-1 30 - 118

00 - General
00 - General
Introduction
Flow Control Valves Figure 837.
Control valves are usually represented by one or

more square boxes.
The number of boxes indicates the number of

possible valve operating positions, (3 boxes, 3
positions etc).
Figure 834.
1 Position 1 (P1 - P2, P3 - P4)

3 Position 3 (P1 - P4, P2 - P3)
In circuit diagrams the pipework is usually shown It must be noted that not all spools are of the
connected to the box which represents the same type. Their operating designs can be seen
unoperated condition. (Hydraulic circuit diagrams are by following the path the flow arrows take in their
usually shown in the unoperated condition). respective operating squares.
Figure 835. 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 movement.
'F' spools are often shown as four position spools

A valve described as a 3-position, 4-port control with the three normal positions for neutral and
valve. Port describes the openings to and from the service control; and the forth position, which has a
valve by which the hydraulic fluid enters or leaves. In detent, connects both sides of the ram together to
an unoperated condition all ports are blocked. allow the service to 'float'.
2 Position 2 (all 4 ports blocked)

'N' spools are sometimes used to control hydraulic
If the valve spool was moved to Position 1, motors, and it can be seen from the flow arrows, that
movement of the spool would connect Port P1 to Port in neutral position both service ports are connected
P2, and Port P3 to Port P4. to the exhaust oil port
If the valve spool was moved to Position 3, Figure 839.

movement of the spool would connect Port P1 to Port
P4, and Port P3 to Port P2.
30 - 119 9823/1650-1 30 - 119

00 - General
Figure 840. Simple Schematic Circuit Example
A
B
C G
D E
A Hydraulic tank B Strainer

C Fixed displacement pump D Relief valve
E Spool F One way valve
G Double acting hydraulic ram
Some of the symbols described on the preceding

pages have been arranged into a simple schematic
circuit.
The hydraulic tank is a pressurised tank with an

internally mounted strainer on the suction line to the
fixed displacement pump. System pressure is limited
to the setting of relief valve.
The valve spool is an open-centre spool that is in

neutral 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. Notice that
the fluid must first open one way valve before flowing
to the ram.
30 - 120 9823/1650-1 30 - 120

12 - Electro Proportional Control
12 - Electro Proportional Control Component Identification

Operation ..................................................... 30-122
Diagram ....................................................... 30-123
Figure 841.
A
A
P
SB
SA
A Outlet port A B Outlet port B

P Inlet port SA Solenoid A
SB Solenoid B T Tank return
30 - 121 9823/1650-1 30 - 121

Operation
In addition to the pilot pressure control valve there is

a valve to allow control of the crowd / dump functions
via a joystick roller.
The joystick roller supplies electrical signals to

the RAS (Rear Axle Stabilization) ECU (Electronic
Control Unit). The ECU then energises the applicable
solenoid for crowd or dump.
The crowd / dump solenoids are located in the electro

servo valve block.
When energised these supply pressure to the

corresponding side of the spool in the hydraulic
control valve block to move the tilt ram in the required
direction.
Both solenoids can be de-energised by the use of the

hydraulic isolation switch stopping the supply to both
solenoids.
For details of the joystick roller operation and output

30 - 122 9823/1650-1 30 - 122

Diagram
Figure 842. Electrical Schematic
CONNECTOR J1
1 1
ECU
9 C036 P135
6 7
8 10
CONNECTOR J2
P016 1 9
ECU
C037 P136
C036 Crowd Solenoid C037 Dump solenoid

P016 Hydraulic isolation switch P135 RAS (Rear Axle Stabilization) ECU
(Electronic Control Unit) connector J1
P136 RAS ECU connector J2
Figure 843. Hydraulic Schematic

P F
C
T
D
E
B A
A Port A outlet (cylinder rod side) B Port B outlet (cylinder head side)
C Electro servo valve block D Control valve block
E Crowd / dump spool F Crowd / dump cylinder
P Pilot valve inlet T Tank return
30 - 123 9823/1650-1 30 - 123

Remove and Install
5. Disconnect the electrical harness connectors at

Remove the solenoid electrical connectors.
1. Make the machine safe. 6. Put a label on the hoses to help installation.
Refer to: PIL 01-03. 7. Disconnect the hoses.
2. Install the safety strut. 8. Plug all the open ports and hoses to prevent
Refer to: PIL 06-69-03. contamination.
3. Discharge the hydraulic pressure. 9. Support the valve block. Loosen and remove the
2 bolts and lift out the valve.
4. Put a label on the electrical harness connectors
to help installation.
Figure 844.
C
C
A Valve block bracket B Electro servo valve block

C Bolts D Solenoid electrical connectors
30 - 124 9823/1650-1 30 - 124

Install
steps.
1.1. Make sure that the hoses are connected
back to the correct ports.
1.2. Check the hydraulic fluid level and top up
as required.
1.3. After installation, check the pilot pressure.
30 - 125 9823/1650-1 30 - 125

15 - Joystick
15 - Joystick Introduction
Introduction .................................................. 30-126 To control the hydraulic services there are multiple
Operation ..................................................... 30-127 control levers or joysticks located in the operator
Operation (Electrical) ................................... 30-129 station.
Fault-Finding ................................................ 30-131
• Two joysticks control the stabiliser and sway
Remove and Install ..................................... 30-132 services - if installed.
Disassemble and Assemble ........................ 30-137 • One joystick controls the carriage tilt service
• One joystick controls the lift arm and auxiliary
services.
The stabiliser controls are mechanical levers

connected directly to the control valve block.
The auxiliary control is via an electrical roller switch

on the joystick.
The lift arm raise and extend controls are provided by

a servo joystick. The joystick is a valve which directs
servo pilot oil to the pilot control valve and then to
the applicable valve block service spool when the
joystick is moved.
The carriage tilt service is controlled via a single axis

servo valve.
30 - 126 9823/1650-1 30 - 126

15 - Joystick
There are two types of servo control valves installed

AA
on the machine.
• Single axis control valve, this controls tilt and

A
crowd operation of the lift arm. AB
Figure 845.
A B
C
A Twin axis control
B Single axis control
• Twin axis control valve, this controls the D
extension and retraction operation as well as F
the lift and lower operation of the lift arm.
Twin axis control valve

The servo control valve operate as direct acting
pressure regulating valves, which consist of the
control lever and four proportional pilot control valve
P T
capsules. Each pilot valve capsule consists of a
spool with a control spring, a plunger and a plunger A Twin axis control
return spring. C Spool
D Plunger return spring
In neutral, the control lever is kept central by the E Plunger
force of the plunger return springs. In this position the F Drillings
joystick service ports are connected to the tank port P Pressure port
via the drillings in the spools. T Tank port
When the control lever is operated, the relevant

plunger pushes on the return spring and the spool Table 413. Colour code to oil flow and pressure
control spring. The spool control spring in turn moves Item Description
the spool down which connects the selected service
port to the pressure port. AA Servo
AB Exhaust
The spool regulates the incoming hydraulic servo

pressure to balance the pressure in the service
port with the force of the control spring. The spool
interacts with the control spring in such a way that the
joystick will produce a pilot pressure in the selected
service port which is proportional to the position of
the control lever.
30 - 127 9823/1650-1 30 - 127

15 - Joystick
Single axis control valve

The single axis control valve works in the same
way as the twin axis valve. The valve only has two
proportional pilot control valve capsules instead of
four proportional pilot control valves.
30 - 128 9823/1650-1 30 - 128

15 - Joystick
Operation (Electrical)
• Signal 1 = 4.3 V
The joystick roller switch outputs 2 variable signals. • Signal 2 = 0.2 V
When the roller is in the up position: These signals are sent to the RAS (Rear Axle
Stabilization) ECU (Electronic Control Unit) which
• Signal 1 = 0.2 V according to the input values can calculate the
• Signal 2 = 4.3 V position of the roller and send a signal to the
applicable crowd or dump solenoid on the pilot
When the roller is in the centre (Neutral) position: control valve to operate the selected service.
• Signal 1 = 2.5 V A push switch operates the transmission dump when
• Signal 2 = 2.5 V required.
When the roller is in the down position:
30 - 129 9823/1650-1 30 - 129

15 - Joystick
Figure 847. Joystick Roller Electrical Operation

A
B
4.3V
0.7V
C
0.2V X1
A B C
4.3V
0.7V
0.2V X2
A B C
CONNECTOR J1
19
31
14
28
ECU
P135
1
3
X1 2
6
X2
5 4
F
16
C012
1 6 P004
2 5
3 4 4
C015
A Roller in up position B Roller in central (neutral) position

C Roller in down position F Fuse
P135 RAS ECU C015 Transmission dump solenoid
C012 Joystick electrical connector X1 Roller output 1
X2 Roller output 2
30 - 130 9823/1650-1 30 - 130

15 - Joystick
Fault-Finding
For related fault finding information refer to (PIL
30-00).
Machines with an electronic instruments system will
log some system faults as a fault code. These fault
codes can be accessed with the correct diagnostics
software tool, using a laptop computer connected to
the machine CAN system. Refer to (PIL 33-57).
30 - 131 9823/1650-1 30 - 131

15 - Joystick
Remove and Install

There are two types of control lever installed on the
machine. 2. Install the safety strut.
The Stabiliser services use manual control levers.
The Lift Arm services use a two axis servo control
lever. Refer to: PIL 30-00-00.
The Carriage Tilt service uses a single axis servo 4. Remove the stabiliser control lever knobs and the
control lever. surround from inside the cab.
5. Remove the securing clip.
Manual Control Lever - Stabiliser Service
6. Pull the control lever off the connecting rod.
Remove
7. Repeat the step 5 and the step 6 again for the
1. Make the machine safe with the lift arm raised. other control lever.
30 - 132 9823/1650-1 30 - 132

15 - Joystick
Figure 848.
C
D
A Control lever knobs B Securing clip

C Bush D Control lever
E Lever surround F Trim clip
30 - 133 9823/1650-1 30 - 133

15 - Joystick
Install Refer to: PIL 01-03.
1. The installation procedure is the opposite of the 2. Discharge the hydraulic pressure.
removal procedure. Additionally do the following Refer to: PIL 30-00-00.
steps.
3. Single axis control lever.
1.1. Check the lever bush and replace if worn.
1.2. Operate the hydraulic system. Check for 3.1. Put a label on the hoses to help installation.
correct operation and leaks. 3.2. Disconnect all the hydraulic hoses.
Servo Control Lever - Lift Arm Services contamination.
Remove 3.4. Remove the nuts and bolts and remove the
lever from the machine.
4. Two axis control lever.
30 - 134 9823/1650-1 30 - 134

15 - Joystick
Figure 849.
A Bolt B Washer
C Nut D Single axis control lever
E Two axis control lever
4.1. Lift the gaiter then remove the nuts and 4.4. Disconnect all the hydraulic hoses.
bolts.
4.2. Lift the control lever sufficiently to gain contamination.
access to the hydraulic hoses.
4.6. Disconnect the electrical connector.
4.3. Put a label on the hoses to help installation.
30 - 135 9823/1650-1 30 - 135

15 - Joystick
4.7. Remove the nuts and bolts and remove the

lever from the machine.
Install
steps.
2. Make sure that all the hoses are connected to the
correct ports.
3. Carry out one of the following as required.
3.1. Tighten all the hydraulic connections to the
4. Connect the electrical connection for the two axis
control lever.
5. Check the hydraulic fluid level and top up as
30 - 136 9823/1650-1 30 - 136

15 - Joystick
Do not attempt to dismantle the joystick. If the joystick

is defective, a new unit must be installed.
Externally facing seals, port adaptors, gaiters and

joystick handles may be replaced if the correct parts
are available and the correct cleanliness procedures
are followed.
30 - 137 9823/1650-1 30 - 137

27 - Auxiliary Circuit
27 - Auxiliary Circuit
Discharge and Pressurise
Refer to discharge and pressurise, (PIL 30-00).
30 - 138 9823/1650-1 30 - 138

90 - Flow Regulator
90 - Flow Regulator
Introduction
30 - 139 9823/1650-1 30 - 139

63 - Hose Burst Check Valve
Contents Page No.
30-63-00 General ......................................................................................................................... 30-141
30 - 140 9823/1650-1 30 - 140

00 - General
Introduction .................................................. 30-141 The HBCV (Hose Burst Check Valve) prevents the
Check (Operation) ....................................... 30-142 uncontrolled movement of the cylinder ram pistons.
The HBCV will lock if the hydraulic pressure is
unsatisfactory or if a hose bursts.
30 - 141 9823/1650-1 30 - 141

00 - General
Check (Operation) 5.2. If the lift arm moves after the engine stops,
then the lift arm HBCV is faulty. Do not use
DANGER Before lowering the attachments to the the machine until you correct the fault.
ground, make sure that the machine and the area
around it are clear of other people. Anyone on or Carriage tilt cylinder
close to the machine could fall and be crushed by
the attachments, or get caught in the linkages. 1. Pick up a load on the forks.
WARNING Maintenance must be done only by 2. Tilt the carriage fully back.
suitably qualified and competent persons.
Before doing any maintenance make sure the 3. Make sure to engage the park brake and put the
machine is safe, it must be correctly parked on transmission to neutral.
solid, level ground. 4. Raise the lift arm and put it in a position that, the
To prevent anyone starting the engine, remove carriage can be tilted forward fully.
of the battery isolator if installed) when you are 5. Run the engine at mid speed and operate the
not using electrical power. If you do not take these control lever to tilt the carriage forward. While the
precautions you could be killed or injured. carriage is moving, switch off the engine.
5.1. The carriage movement must slow as the
Check each movement in turn. engine slows. The carriage movement must
stop when the engine stops.
Lift arm lift cylinders 5.2. If the carriage moves after the engine stops,
1. Start the engine. then the HBCV is faulty. Do not use the
machine until you correct the fault.
2. Make sure to engage the park brake and put the
transmission to neutral. Stabiliser cylinder (if installed)
3. Raise the lift arm to the specified angle. 1. Start the engine.
Angle: 45 ° 2. Make sure to engage the park brake and put the
4. Run the engine at mid speed and operate the transmission to neutral.
control lever to lower the lift arm. While the lift 3. Lower the stabilisers.
arm is moving, switch off the engine.
4. Make sure that the stabiliser legs are in the down
4.1. The lift arm movement must slow as the position and supports the machine weight. Make
engine slows. The lift arm movement must sure that the front wheels are lifted from the
stop when the engine stops. ground.
4.2. If the lift arm moves after the engine stops,
then both the lift arm HBCV (Hose Burst 5. Stop the machine.
Check Valve) are faulty. Do not use the
6. Operate the stabiliser controls.
machine until you correct the fault.
7. Make sure that the front wheels of the machine
Lift arm extension cylinder do not lower to the ground.
1. Start the engine. 7.1. If the machine moves when the stabiliser
controls are operated after the engine is
2. Make sure to engage the park brake and put the stopped, the HBCV are faulty. Do not use
transmission to neutral. the machine until you correct the fault.
3. Raise the lift arm fully.
4. Extend the lift arm fully.
5. Run the engine at mid speed and operate the
control lever to retract the lift arm. While the lift
arm is retracting, switch off the engine.
5.1. The lift arm movement must slow as the
engine slows. The lift arm movement must
stop when the engine stops.
30 - 142 9823/1650-1 30 - 142

00 - General
Figure 850.
X Gap between the wheel and the ground
Sway cylinder (if installed)

1. Start the engine.
2. Make sure to engage the park brake and put the
transmission to neutral.
3. Sway the machine body approximately halfway
to the left and release the sway control.
4. Stop the engine.
5. Operate the sway control to the left. Check that
the machine does not sway.
6. Do steps 1 to 5 again for right sway.
7. If the body moves when the sway control is
moved with the engine stopped, the hose burst
protection valves are faulty.
8. Do not use the machine until you correct the fault.
30 - 143 9823/1650-1 30 - 143

93 - Hose
93 - Hose
Contents Page No.
30-93-00 General ......................................................................................................................... 30-145

30-93-03 Lift Arm ......................................................................................................................... 30-149
30 - 144 9823/1650-1 30 - 144

93 - Hose
00 - General
Introduction .................................................. 30-145 Hydraulic hoses are used to connect different
Disconnect and Connect ............................. 30-146 components in the hydraulic circuit. The hoses
Check (Condition) ........................................ 30-148 are graded by pressure, temperature, and fluid
compatibility. Hoses are built up with rubber and steel
layers. A rubber interior is surrounded by multiple
layers of woven wire and rubber. The exterior is
designed for abrasion resistance. The bend radius
of a hydraulic hose is carefully designed into the
machine, since hose failures can be deadly, and
violating the hose's minimum bend radius will cause
failure. Hydraulic hoses generally have steel fittings
swaged on the ends.
30 - 145 9823/1650-1 30 - 145

93 - Hose
00 - General
Disconnect and Connect 3. Push the coupling into the port as far as possible.
For: 506-36 [T4i], 512-56 [T4i], 514-56 [T4i] 3.1. The coupling will click when it is fully
................................................. Page 30-146 engaged.
Otherwise ................................ Page 30-146 4. Pull the hose to verify that the coupling is fully
engaged.
(For: 506-36 [T4i], 512-56 [T4i], 514-56 4.1. If the connection is not good the coupling
[T4i]) will release very easily.
Special Tools
Description Part No. Qty. (Otherwise)
Quick Connect Hose 825/10053 1
Release Tool Some attachments are hydraulically powered. The
following procedures show how to connect and
WARNING Hydraulic fluid at system pressure disconnect the hydraulic hoses safely.
can injure you. Before connecting or removing
any hydraulic hose, residual hydraulic pressure Connecting the Hydraulic Hoses
trapped in the service hose line must be vented.
Make sure the hose service line has been vented 1. Make the machine safe.
before connecting or removing hoses. Do not start Refer to: PIL 01-03.
the engine with loose or open hose connections.
2. Discharge the hydraulic system pressure.
Disconnect Refer to: PIL 30-00-00.
1. Make the machine safe. 3. Check the hoses and adaptors for damage.
Refer to: PIL 01-03. 4. Connect the hoses:
2. Push the hose. Refer to Figure 851. 4.1. Make sure that the hose is not twisted.
Pressure applied to a twisted hose can
3. Insert the specified tool. cause the hose to fail or the connections to
Special Tool: Quick Connect Hose Release Tool loosen.
(Qty.: 1) Figure 852.
4. Push on the hose, and at the same time use the
tool as a lever to release the coupling.
Figure 851.
A
4.2. Make sure that the hose does not touch

hot parts. High ambient temperatures can
cause the hose to fail.
B
4.3. Make sure that the hose does not touch
A Hose parts which can rub or cause abrasion.
B Quick connect hose release tool
4.4. Use the hose clamps (where possible) to
support long hose runs and keep the hoses
Connect away from moving parts, etc.
1. Make sure that the hose coupling is clean and
the O-rings are not damaged.
1.1. Apply some clean hydraulic fluid to the O-
rings.
2. Align the coupling to the hydraulic port.
30 - 146 9823/1650-1 30 - 146

93 - Hose
00 - General
Figure 853. 6.4. Check for indications of leakage at the hose

connections. Correct, as necessary.
4.5. To allow for length changes when the hose

is pressurised, do not clamp at the bend.
The curve absorbs the change.
Figure 854.
5. Check for leaks:

5.1. Start the machine.
5.2. Operate the related controls to increase the
pressure in the hydraulic system.
5.3. Stop the machine then remove the key.
5.4. Check for indications of leakage at the hose
connections. Correct, as necessary.
Disconnecting the Hydraulic Hoses

2. Discharge the hydraulic system pressure.
4. Check the hoses and adaptors for damage.
5. If necessary, install the blanking caps.
6. Check for leaks:
6.1. Start the machine.
6.2. Operate the related controls to increase the
pressure in the hydraulic system.
6.3. Stop the machine then remove the key.
30 - 147 9823/1650-1 30 - 147

93 - Hose
00 - General
Check (Condition)
Hydraulic Hoses
WARNING Damaged hoses can cause fatal
accidents. Examine the hoses regularly. Do not
use the machine if a hose or hose fixture is
damaged.
WARNING Fine jets of fluid at high pressure can
penetrate the skin. Keep face and hands well
clear of fluid under pressure and wear personal
protective equipment. Hold a piece of cardboard
close to suspected leaks and then examine the
cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
Examine the hoses for:
• Damaged hose ends

• Worn outer covers
• Ballooned outer covers
• Kinked or crushed hoses
• Exposed armouring in the outer covers
• Displaced hose end fittings.
• Worn cover sheathing or hose burst protection
covering
Replace a damaged hose before you use the

machine again.
The replacement hoses must be of the same size,

standard and pressure rating. If necessary, for more
information contact your JCB dealer.
30 - 148 9823/1650-1 30 - 148

93 - Hose
03 - Lift Arm
03 - Lift Arm
Technical Data
Refer to hydraulic system, hose, lift arm, component

identification (PIL 30-93-03).
30 - 149 9823/1650-1 30 - 149

96 - Pipe
96 - Pipe
Contents Page No.
30-96-03 Lift Arm ......................................................................................................................... 30-151
30 - 150 9823/1650-1 30 - 150

96 - Pipe
03 - Lift Arm
03 - Lift Arm
Refer to component identification, (PIL 30-93-03).
30 - 151 9823/1650-1 30 - 151

97 - Connectors
97 - Connectors
Contents Page No.
30-97-03 Quick Release Coupling .............................................................................................. 30-153

30-97-09 Adaptor ......................................................................................................................... 30-155
30-97-24 Push Lock Fitting ......................................................................................................... 30-157
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-158
30 - 152 9823/1650-1 30 - 152

97 - Connectors
03 - Quick Release Coupling
03 - Quick Release Coupling Introduction

Introduction .................................................. 30-153 The flat face quick release couplings allow the
Disconnect and Connect ............................. 30-154 operator to remove and install attachments swiftly
and efficiently. Generally, your machine pipework will
have female couplings installed, and the optional
attachment hoses will have male couplings installed.
The quick release couplings will be trouble free and

relatively easy to connect and disconnect, if they are
kept clean and used correctly. The recommendations
listed below must always apply when using flat face
quick release couplings.
Read the correct connecting and releasing

procedures before you install or remove any optional
attachment connected with quick release couplings.
Figure 855.
A B
A Female coupling
B Male coupling
Essential Do's
• Before connecting or removing any hydraulic
hose, the residual hydraulic pressure trapped
in the service hose line must be vented. Make
sure the hose service line has been vented
before connecting or removing the hoses.
• Always wipe the two mating faces clean before
connecting.
• Use caps and plugs when the couplings are
disconnected.
• Always align the external locking ball (if used)
with the notch in the locking sleeve and then pull
the locking sleeve back fully to disconnect.
• If a coupling sticks, first check that pressure
has been released. Make sure the locking ball
and notch in the locking sleeve are aligned,
pull back the sleeve and twist the couplings
apart. Sticking is normally caused by dirt in the
coupling or physical damage due to abuse.
• Connect and disconnect the new couplings
two or three times to work the PTFE seals.
Sometimes a new coupling will stick if the seal
has not been worked.
• When connecting the couplings, only apply the
spanner or grips to the hexagon and nowhere
else.
• Avoid damage to the coupling faces. Burrs
and scratches cause damage to the seals and
cause leaks. They can also impede connection
and disconnection of the couplings.
30 - 153 9823/1650-1 30 - 153

97 - Connectors
03 - Quick Release Coupling
• Periodically lubricate the internal locking balls Disconnect and Connect

on the female half of the coupling with silicone
grease.
Some attachments are hydraulically powered. The
Essential Don'ts following procedures show how to connect and
disconnect the hydraulic hoses safely.
• Never try to reconnect using a damaged half
coupling as this will destroy the seals in the
mating half and necessitate replacement of Connect
both halves. 1. Make the machine safe.
• Do not leave the coupling where it may be run
over by a machine or otherwise crushed, this Refer to: PIL 01-03.
will distort the sleeve and prevent connection
and disconnection. 2. Discharge the hydraulic pressure.
• Never try to turn the sleeve when the coupling is Refer to: PIL 30-00-00.
disconnected as this will cause the locking ball
to jam under the locking sleeve and damage the 3. Wipe the two faces of the male and female
coupling. couplings and make sure they are clean.
• Never try to strip the coupling down, there are
no user serviceable parts. If the coupling is 4. Make sure that the ball in the female coupling is
damaged it must be replaced with a new one. located in one of its slots.
• Never hit the centre poppet of the coupling to 5. Connect the male coupling into the female
try and release the locked in pressure. This can coupling.
cause irreparable damage to the coupling and
serious injury. 6. Where applicable, rotate the sleeve half a turn
• When connecting the couplings, never clamp and make sure that the locking ball does not align
on the sleeve of the female or nose of the male, with the slot.
this will cause distortion and/or damage.
• Never subject the couplings to external forces, Disconnect
especially side load. This can decrease the life
of the coupling or cause failure. 1. Make the machine safe.
• Never allow the torsional forces transmitted
from the hoses to unscrew/screw together the Refer to: PIL 01-03.
couplings.
• Never use a coupling as a plug.
• Do not connect and disconnect with pressure in Refer to: PIL 30-00-00.
the line unless the coupling type is specifically
designed to do so. 3. Where applicable, align the slot with the ball.
4. Pull back the sleeve to release the coupling.
Figure 856.
C D E
C Ball
D Slot
E Sleeve
30 - 154 9823/1650-1 30 - 154

97 - Connectors
09 - Adaptor
09 - Adaptor Introduction
Introduction .................................................. 30-155 On a typical machine, some hydraulic components
Remove and Install ..................................... 30-156 may utilise Positional Type Hydraulic Adaptors.
When you install a Positional Type Hydraulic
Adaptor, it is important to adopt the Remove and
Install procedure. Refer to: PIL 30-97-09.
If this procedure is not followed correctly, damage to

the O-ring seal can occur which can result in oil leaks.
Figure 857.
A O-ring seal
B Locknut
C Washer
30 - 155 9823/1650-1 30 - 155

97 - Connectors
09 - Adaptor
1. Make sure that the locknut is screwed back on to

the body of the adaptor as far as possible.
2. Check that the O-ring backing washer is a tight
fit on the adaptor. Note that the washer should
not move freely, if the washer is slack do not use
the adaptor.
3. Check that the O-ring seal is installed and
that it is free from damage or nicks. Before
you install the adaptor, smear the O-ring with
clean hydraulic fluid. The dimensions and shore
hardness of the O-ring seal is critical. Should it
become necessary to replace the O-ring seal,
make sure you use JCB Genuine Parts.
Figure 858.
Z Adaptor thread
6. Tighten the locknut to the correct torque value.
A O-ring seal
B Locknut
C Backing washer
4. Screw the adaptor into the port of the hydraulic
component as far as possible, so that all the
threads engage and the O-ring seal is correctly
seated against the sealing face.
5. Set the angular position of the adaptor as
required, then secure by tightening the locknut.
When installed correctly no more than one thread
should be visible at Z as shown.
30 - 156 9823/1650-1 30 - 156

97 - Connectors
24 - Push Lock Fitting
24 - Push Lock Fitting
Remove and Install
The fitting is installed and removed without the need

for tools, it is removable and reusable.
1. To release the tube push the collet and release

the tube. All tubes have an assembly mark to
assist installation.
Figure 860.
D A
C B
A Tube
B Collet
C O-ring
D Steel support tube
30 - 157 9823/1650-1 30 - 157

97 - Connectors
27 - Rapid Assembly Hose Fitting
27 - Rapid Assembly Hose Fitting
Remove and Install
The hose has a toolless installation. The hose is not

removable. The complete hose and fitting assembly
must be replaced.
1. To install the hose, push the tube into the fitting

body.
Figure 861.
A B C
E D
A Snap ring
B O-ring and back-up ring
C Tube
D Fitting body
E Hose
30 - 158 9823/1650-1 30 - 158

Contents Page No.
33-00 Electrical System

33-00-00 General ............................................................................................................................. 33-3
33-00-50 Schematic Circuit ............................................................................................................. 33-8
33-00-90 Earth Point ................................................................................................................... 33-164
33-03 Battery
33-03-00 General ......................................................................................................................... 33-167
33-03-03 Isolator Switch .............................................................................................................. 33-177
33-06 Battery Cable
33-06-00 General ......................................................................................................................... 33-179
33-09 Power Distribution
33-09-00 General ......................................................................................................................... 33-183
33-09-03 Fuse ............................................................................................................................. 33-185
33-09-06 Relay ............................................................................................................................ 33-186
33-12 Harness
33-12-00 General ......................................................................................................................... 33-189
33-12-04 Chassis ......................................................................................................................... 33-202
33-12-06 Lift Arm ......................................................................................................................... 33-217
33-12-09 Engine .......................................................................................................................... 33-223
33-12-12 Operator Station ........................................................................................................... 33-241
33-12-15 Front Console ............................................................................................................... 33-247
33-12-19 Engine Compartment Cover ........................................................................................ 33-340
33-12-30 Gearbox ........................................................................................................................ 33-352
33-12-48 LiveLink ........................................................................................................................ 33-356
33-12-53 Stabiliser ....................................................................................................................... 33-360
33-12-56 Extreme Cold Climate Heater ...................................................................................... 33-379
33-12-64 Rear Axle Stabilization (RAS) ...................................................................................... 33-388
33-15 Alarm
33-15-03 Reverse Warning .......................................................................................................... 33-399
33-21 Immobiliser
33-21-00 General ......................................................................................................................... 33-401
33-24 Instruments
33-24-03 Instrument Panel .......................................................................................................... 33-407
33-24-10 Hourmeter .................................................................................................................... 33-411
33-27 Interior Switch
33-27-03 Multi-Purpose ............................................................................................................... 33-413
33-40 Bulb
33-40-00 General ......................................................................................................................... 33-417
33-45 Control Module
33-45-00 General ......................................................................................................................... 33-421
33-45-06 Engine .......................................................................................................................... 33-425
33-45-09 Gearbox ........................................................................................................................ 33-427
9823/1650-1
2018-06-08
33-48 Entertainment
33-48-03 Radio ............................................................................................................................ 33-443
33-51 Beacon
33-51-00 General ......................................................................................................................... 33-447
33-51-03 Socket .......................................................................................................................... 33-448
33-54 Window Washer/Wipe
33-54-00 General ......................................................................................................................... 33-451
33-57 Electronic Diagnostic
33-57-00 General ......................................................................................................................... 33-453
33-57-03 Servicemaster .............................................................................................................. 33-455
33-57-90 Fault Codes .................................................................................................................. 33-471
33-66 Load Motion Control System
33-66-00 General ......................................................................................................................... 33-475
33-84 Sensor
33-84-09 Speed Sensor .............................................................................................................. 33-479
33-84-15 Transmission Oil Temperature ..................................................................................... 33-480
9823/1650-1
2018-06-08
Acronyms Glossary
2WD Two Wheel Drive

DLA Data Link Adaptor
DTC Diagnostic Trouble Code
HP High Pressure
ISO International Organization for
Standardization
LCD Liquid Crystal Display
LED Light Emitting Diode
LLMC Longitudinal Load Moment Control
LLMI Longitudinal Load Moment Indicator
LMS Loadall Monitoring System
MIL Malfunction Indicator Lamp
NOx Nitrogen Oxide
TMAF Temperature and Mass Air Flow
9823/1650-1
2018-06-08
Notes:
9823/1650-1
2018-06-08
Contents Page No.
33-00-00 General ............................................................................................................................. 33-3

33-00-50 Schematic Circuit ............................................................................................................. 33-8
33-00-90 Earth Point ................................................................................................................... 33-164
33 - 1 9823/1650-1 33 - 1
Notes:
33 - 2 9823/1650-1 33 - 2
00 - General
Introduction ...................................................... 33-3 It is important that the electrical system on the
Health and Safety ........................................... 33-4 machine is in a sound state of repair.
Technical Data ................................................. 33-4
Fault-Finding .................................................... 33-5 Make sure that all the health and safety warnings
in this section are followed. The machine must be
Check (Condition) ............................................ 33-7 safe with the battery isolated before you attempt to
disconnect any electrical connections or work in the
engine compartment.
33 - 3 9823/1650-1 33 - 3
00 - General

Arc Welding Table 414.
To prevent the possibility of damage to electronic
Description Data
components, disconnect the battery and the
alternator before arc-welding on the machine or Battery
attached implements. Rating 1000 CCA (Cold Crank-
ing Amps)
If the machine is equipped with sensitive electrical
equipment, i.e. amplifier drivers, electronic control Voltage 12 V
units (ECUs), monitor displays, etc., then disconnect Capacity 120 Ah
them before welding. Failure to disconnect the Alternator
sensitive electrical equipment could result in Voltage 12 V
Current rating 95 A
Parts of the machine are made from cast iron, welds Starter motor
on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable Voltage 12 V
or apply any weld to any part of the engine. Power rating 4.2 kW
Always connect the welder earth (ground) cable to
the same component that is being welded to avoid
the welder earth (ground) cable a distance from the
part being welded no more than 0.6 m.
Notice: Do not disconnect the battery while the
engine is running, otherwise the electrical circuits
may be damaged.
CAUTION! Understand the electrical circuit
before connecting or disconnecting an electrical
component. A wrong connection can cause injury
and/or damage.
33 - 4 9823/1650-1 33 - 4
00 - General
Fault-Finding
Fault
Battery Fault Table 415. Page 33-5
General Relay Fault Table 416. Page 33-5
Electrical Network - CAN (Controller Area Network) Bus system Table 417. Page 33-6
ECM Faults Table 418. Page 33-6
Table 415. Battery Fault

Cause Remedy
Battery Voltage Switch on the ignition key and check the battery
voltage with a multimeter. If the terminal voltage of
the battery is below 9 Volt or above 16 Volt, charge
or replace the battery.
Battery Connection Fault Disconnect the electrical connection from the battery.
Check for signs of corrosion or contamination in the
battery terminals, clean the terminals. Repair as
necessary.
If no fault is found proceed to ECM (Engine Control
Module) Connection Faulty.
ECM Connection Faulty Disconnect the harness from ECM and inspect.
Check seals are in place, check for signs of corrosion
or contamination.
necessary.
Check the resistance between the vehicle chassis
ground and ECM ground, if the resistance is high
repair the ECM ground.
If no fault is found proceed to 'Battery Charge Circuit
Fault'.
Battery Charge Circuit Fault Check the battery charge circuit, if the circuit is found
faulty repair as necessary.
If no fault is found raise a Techweb Helpdesk call.
Table 416. General Relay Fault

Cause Remedy
Relay Supply Voltage Fault Perform the relay test routine.
If relay supply voltage is found fault, proceed to
'Relay Connection Faulty'.
If relay supply voltage is OK, raise Techweb
Helpdesk Call.
Relay Connection Faulty Check the condition of relay to harness connection,
necessary.
If no fault is found, proceed to ECM connection fault.
33 - 5 9823/1650-1 33 - 5
00 - General
Cause Remedy
ECM Connection Fault Disconnect the harness from engine ECM and
necessary.
Check the continuity and electrical insulation, repair
or replace as necessary.
If a relay fault is found, raise Techweb Helpdesk Call.
Table 417. Electrical Network - CAN (Controller Area Network) Bus system
Cause Remedy
necessary.
If no fault is found proceed to Wiring Fault.
Wiring Fault Check the harness continuity and electrical
insulation, repair or replace as necessary.
If no fault is found, proceed to 'Network and CAN
Resistors Faulty'.
Network and CAN Resistors Faulty Check the network and CAN resistors, repair as
necessary.
If no fault is found proceed to raise Techweb
Helpdesk call.
Table 418. ECM Faults

Cause Remedy
ECM Overheat Identify the root cause and repair as necessary: – Air
intake problem – Engine too hot – Cooling fan failure
– Extreme hot soak.
If no fault is found proceed to ECM temperature fault.
ECM Temperature Fault Check the ECM temperature is consistent with
physical ECM temperature, if found faulty raise
Techweb Helpdesk call.
ECM General Fault Visually check the ECM pins and connections on the
wiring harness. If ECM pins are damaged, replace
ECM and re-flash appropriate calibration (see Re-
flashing an ECM).
If no fault is found proceed to ECM connection fault.
Check the conformity of ground connection of vehicle
chassis. If harness is damaged, repair or replace as
necessary.
necessary.
33 - 6 9823/1650-1 33 - 6
00 - General
Check (Condition)
Examine the electrical circuits regularly for:
• Damaged connectors.
• Loose connections.
• Chafing on the wiring harnesses.
• Corrosion.
• Missing insulation.
• Incorrect routing of the wiring harnesses.
Do not use the machine if one or more of these faults

are found. You must make sure that the electrical
circuit is repaired immediately.
33 - 7 9823/1650-1 33 - 7
50 - Schematic Circuit Introduction

Introduction ...................................................... 33-8 A schematic wiring diagram is a simplified pictorial
Diagram ......................................................... 33-11 representation of the machines electrical circuit. It
shows the components of the circuit as simplified
electrical symbols, and the power and signal
connections between the devices. The wiring
diagram is used to troubleshoot problems and to
make sure that all the connections have been made
and that everything is present.
Use the schematics together with the correct

electrical harness drawings to reference the
connector pin details.
This section may contain more than one set of

electrical schematics for different machine variants.
Understanding Electrical Schematics

Use the applicable schematic set to trace wires
and connections between electrical devices. In most
cases it will be necessary to trace wires across more
than one schematic sheet.
The example identifies the information contained on

the diagrams. It also shows how to follow wires from
one diagram sheet to another.
The harness inter-connector codes and device

harness connector codes are the same as used on
the applicable harness drawings.
Splices are not normally accessible. Splices are

inside the harness sheath and not visible on the
outside. Wires are welded together at a splice, there
are no individual connector components.
33 - 8 9823/1650-1 33 - 8
Figure 862.
/7.B4 TO
0.50 mm² 1009A -S012
TO SWITCH:MAIN WIPER C116 #1996
C 7
-SW5
A 701/E0089
7219/0013 SWITCH: MAIN WIPER
FROM SPLICE:BACKLIGHTING S012 #1996
-C116 8 7
0.50 mm² 1009A 8/10 7/10
/3.D1 FROM
0.50 mm² 8100J B

-S011 1 D
F F 2/10 2
L H 3 3/10
4 4/10
-IC08_M -IC08_M
0.75 mm² 8006 21/21 21/21 0.75 mm² 8006 5/10 5
/9.B5 TO
#1783 6 6/10
TO MOTOR:WIPER-UPPER C058
D GD
K J
E
7236/0002
MOTOR:WIPER UPPER 9
-C058
6/6 6/6 RED 5/6 5/6 1.00 mm² 8006 5/20 5/20 0.75 mm² 8006 FROM
/7.B4
BLACK #1783 FROM SWITCH:MAIN WIPERS C116
2/6 2/6 GREEN
YELLOW
-B8 3/6 3/6
1/6 1/6 BROWN
WHITE 4/6 4/6
A Wire size (area) and number B Device harness connector code

C Device description D Connector pin number (wire location / total)
E Device internal schematic F Harness inter-connector codes
G Harness inter-connector symbol H Splice code and symbol
J Destination reference number K Destination (harness connector code)
L Destination (diagram sheet and grid)
To help locate a wire destination from other diagram Due to space limitations, the grid is sometimes
sheets use the grid reference. This identifies the omitted.
applicable location zone on the sheet in a similar way
to a map reference.
33 - 9 9823/1650-1 33 - 9
Figure 863. Grid reference example (D4)
1 2 3 4 5 6 7 8
F GROUND
RC012:6 /15.C5 FROM 1.00 mm² 601SP
F
GROUND 1.00 mm² 601AV
RC011:1 /13.A4 FROM
GROUND 1.00 mm² 601AX CAN SHLD

RC007:2 /13.B4 FROM
P006:5 /3.D2 FROM 0.75 mm² 601HB
GROUND 2.00 mm² 601AR 6.00 mm² 601RC1 CAN SHLD

RC009:1 /12.F6 FROM
P006:10 /3.D2 FROM 0.75 mm² 601EK

-SRC5
CAN SHLD 0.75 mm² 601HK
P007:10 /3.C2 FROM
GROUND 1.50 mm² 600WP CAN SHLD

RC18:2 /12.C6 FROM
P007:5 /3.C2 FROM 0.75 mm² 601HL
GROUND 2.00 mm² 601AW CAN SHLD

RC004:1 /12.E6 FROM
P008:10 /3.A2 FROM 0.75 mm² 601X
GROUND 2.00 mm² 601FK CAN SHLD

RC003:2 /14.F7 FROM
P008:5 /3.B2 FROM 0.75 mm² 601JJ
GROUND 2.00 mm² 601DG CAN SHLD -SP3

RC005:2 /13.C7 P101:10 1.00 mm² 601TS 3.00 mm² 601JC
E /8.D4
FROM
FROM
GROUND 2.00 mm² 601KG 6.00 mm² 601RC2 10.00 mm² 601RC CAN SHLD
E
RC008:2 /13.C7 FROM
P014:1 /13.F1 0.75 mm² 601LH

-RC06
FROM
-SRC6 -SRC7 M10
CAN SHLD 0.75 mm² 601SH

P014:5 /13.E1 FROM
HYD ECU SENSOR GND 0.75 mm² 699CE CAN SHLD

SP43 /30.E6 FROM
P058:4 /15.E2 FROM 1.00 mm² 601RD
HYD ECU SENSOR GND 1.00 mm² 699SK CAN SHLD CAN SHLD
SP44 /25.C5 FROM
P013:5 /8.C1 FROM 1.00 mm² 601LL P072:17 /9.C5 FROM 1.00 mm² 601DE
HYD ECU SENSOR GND 1.00 mm² 699CH CAN SHLD CAN SHLD
P095:3 /26.D1 FROM
P016:5 /11.E6 FROM 0.75 mm² 601SY P112:2 /14.C4 FROM 1.00 mm² 601HT
HYD ECU SENSOR GND 1.00 mm² 699SJ CAN SHLD CAN SHLD -SP11
P095:6 /26.D1 FROM
P016:10 /11.E6 FROM 0.75 mm² 601JB P020:7 /11.D3 FROM 0.75 mm² 601AD 3.00 mm² 601JE
HYD ECU SENSOR GND 0.75 mm² 699CB CAN SHLD CAN SHLD
P091:2 /29.E5 FROM
P010:5 /4.E2 FROM 0.75 mm² 601NS P063:7 /9.F7 FROM 1.00 mm² 601HP
HYD ECU SENSOR GND 0.75 mm² 699CC -SP42 1.50 mm² 699CA HYD ECU SENSOR GND CAN SHLD CAN SHLD
P092:2 /29.E5 FROM FROM
/22.B7 SC9 / P039:F7 P011:5 /10.F6 FROM 0.75 mm² 601BL P073:A /17.D1 FROM 1.00 mm² 601C
D
HYD ECU SENSOR GND 0.75 mm² 699CD CAN SHLD
P087:2 /21.B7 P036:7 /25.D2 1.00 mm² 601DZ
D
FROM
FROM
HYD ECU SENSOR GND 1.00 mm² 699CG

SP2 /27.E4 FROM
HYD ECU SENSOR GND 0.75 mm² 699CF

P111:2 /29.B6 FROM
CAN SHLD 1.00 mm² 601FV

P067:10 /14.D4 FROM
CAN SHLD 1.00 mm² 601KP -SP29 3.00 mm² 601JH -SP62 10.00 mm² 600 -P030 M10
P015:10 /14.D5 FROM
CAN SHLD 1.00 mm² 601V

P013:10 /10.B1 FROM
CAN SHLD 1.00 mm² 601AC

P015:5 /14.D3 FROM
CAN SHLD 2.00 mm² 601TR

P070:16 /21.C6 FROM
CAN SHLD
C CAN SHLD 1.50 mm² 606TR
P052:1 /14.E7 FROM 1.00 mm² 601DD
P070:15 /21.C6 FROM
C
CAN SHLD 1.00 mm² 601AC CAN SHLD 1.00 mm² 610ACF
CAN SHLD P017:7 /14.C5 FROM
P013:5 /14.E2 FROM
P055:1 /12.B6 FROM 2.00 mm² 600P 10.00 mm² 600

-SP61 -P035 M10 CAN SHLD
P062:7 /27.E4 FROM 1.00 mm² 601KK
CAN SHLD 2.00 mm² 601BU
P130:3 /13.D7 FROM
CAN SHLD 0.50 mm² 601P

CAN SHLD P40:10 /9.A3 FROM
P130:4 /13.D7 FROM 2.00 mm² 601AL

CAN SHLD 1.00 mm² Y
CAN SHLD P066:11 /8.B7 FROM
2.00 mm² SCR

SPMC12 /17.C3 FROM
CAN SHLD 0.75 mm² 601BF

CAN SHLD P024:7 /10.C1 FROM
2.00 mm² SCR

SVMC15 /17.D5 FROM
CAN SHLD 1.00 mm² 601DC -SP6 2.00 mm² 601JD

CAN SHLD P023:7 /10.F2 FROM
1.00 mm² 600H

P034:2 /7.C2 FROM
CAN SHLD 1.00 mm² 601AC

P026:7 /13.F3 FROM
CAN SHLD 1.00 mm² 601AY CAN SHLD 1.00 mm² 601BB
P028:7 /13.B2 FROM
P017:7 /25.E3 FROM
B P029:7 /13.E3
CAN SHLD 1.00 mm² 601KA P021:7 /12.F3
CAN SHLD 1.00 mm² 601BH
B
FROM FROM
CAN SHLD 1.00 mm² 601AL CAN SHLD 1.00 mm² 601DX 2.00 mm² 601JF
P061:7 /16.F2 FROM
P022:7 /12.E3 FROM
-SP28
CAN SHLD 1.00 mm² 601BL CAN SHLD 1.00 mm² 601KC
P052:7 /14.B5 FROM
P065:2 /15.B5 FROM
CAN SHLD 1.00 mm² 601N

P027:7 /21.B4 FROM
CAN SHLD 0.75 mm² 601AK

P042-A /28.E2 FROM
CAN SHLD 1.00 mm² 601EN

P018:7 /30.F2 FROM
A
A
1 2 3 4 5 6 7 8
33 - 10 9823/1650-1 33 - 10
Diagram
For: 506-36 [T4i], 507-42 [T4i], 509-42 [T4i],

JCB Tier 4i /T4F <55kW Engine 4 Cyl
................................................... Page 33-11
For: 512-56 [T4i], 514-56 [T4i], JCB Tier 4i /
T4F <55kW Engine 4 Cyl .......... Page 33-91
(For: 506-36 [T4i], 507-42 [T4i], 509-42 [T4i], JCB Tier 4i /T4F <55kW Engine 4 Cyl)
Figure 864. .............................................................................................................................Page 33-13
Figure 865. .............................................................................................................................Page 33-17
Figure 866. .............................................................................................................................Page 33-21
Figure 867. .............................................................................................................................Page 33-25
Figure 868. .............................................................................................................................Page 33-29
Figure 869. .............................................................................................................................Page 33-33
Figure 870. .............................................................................................................................Page 33-37
Figure 871. .............................................................................................................................Page 33-41
Figure 872. .............................................................................................................................Page 33-45
Figure 873. .............................................................................................................................Page 33-49
Figure 874. .............................................................................................................................Page 33-53
Figure 875. .............................................................................................................................Page 33-57
Figure 876. .............................................................................................................................Page 33-61
Figure 877. .............................................................................................................................Page 33-65
Figure 878. .............................................................................................................................Page 33-69
Figure 879. .............................................................................................................................Page 33-73
Figure 880. .............................................................................................................................Page 33-77
Figure 881. .............................................................................................................................Page 33-81
Fusebox A P001 Ignition
33 - 11 9823/1650-1 33 - 11
Notes:
33 - 12 9823/1650-1 33 - 12
Page 33-14 Figure 864. Page 33-15
160-E8028-1_SHEET1
33 - 13 9823/1650-1 33 - 13
Page Page
33-14 33-15
Page 33-15
33 - 14 9823/1650-1 33 - 14
Page Page
33-14 33-15

Page 33-14
160-E8028-1_SHEET1
33 - 15 9823/1650-1 33 - 15
Fusebox B P002
33 - 16 9823/1650-1 33 - 16
160-E8028-1_SHEET2
33 - 17 9823/1650-1 33 - 17
Page Page
33-18 33-19
Page 33-19
33 - 18 9823/1650-1 33 - 18
Page Page
33-18 33-19

Page 33-18
160-E8028-1_SHEET2
33 - 19 9823/1650-1 33 - 19
Fusebox C P003
33 - 20 9823/1650-1 33 - 20
160-E8028-1_SHEET3
33 - 21 9823/1650-1 33 - 21
Page Page
33-22 33-23
Page 33-23
33 - 22 9823/1650-1 33 - 22
Page Page
33-22 33-23

Page 33-22
160-E8028-1_SHEET3
33 - 23 9823/1650-1 33 - 23
Fusebox D P004
33 - 24 9823/1650-1 33 - 24
160-E8028-1_SHEET4
33 - 25 9823/1650-1 33 - 25
Page Page
33-26 33-27
Page 33-27
33 - 26 9823/1650-1 33 - 26
Page Page
33-26 33-27

Page 33-26
160-E8028-1_SHEET4
33 - 27 9823/1650-1 33 - 27
Speed Sensors, Immobiliser and Transmission Control
33 - 28 9823/1650-1 33 - 28
160-E8028-1_SHEET5
33 - 29 9823/1650-1 33 - 29
Page Page
33-30 33-31
Page 33-31
33 - 30 9823/1650-1 33 - 30
Page Page
33-30 33-31

Page 33-30
160-E8028-1_SHEET5
33 - 31 9823/1650-1 33 - 31
Right Hand Cluster Connectors, P055 and P056
33 - 32 9823/1650-1 33 - 32
160-E8028-1_SHEET6
33 - 33 9823/1650-1 33 - 33
Page Page
33-34 33-35
Page 33-35
33 - 34 9823/1650-1 33 - 34
Page Page
33-34 33-35

Page 33-34
160-E8028-1_SHEET6
33 - 35 9823/1650-1 33 - 35
Instruments - Warning Lamps
33 - 36 9823/1650-1 33 - 36
160-E8028-1_SHEET 7
33 - 37 9823/1650-1 33 - 37
Page Page
33-38 33-39
Page 33-39
33 - 38 9823/1650-1 33 - 38
Page Page
33-38 33-39

Page 33-38
160-E8028-1_SHEET 7
33 - 39 9823/1650-1 33 - 39
Road Lamps, Reverse Alarm, Trailer Electrics
33 - 40 9823/1650-1 33 - 40
160-E8028-1_SHEET 8
33 - 41 9823/1650-1 33 - 41
Page Page
33-42 33-43
Page 33-43
33 - 42 9823/1650-1 33 - 42
Page Page
33-42 33-43

Page 33-42
160-E8028-1_SHEET 8
33 - 43 9823/1650-1 33 - 43
Wipers and Motors
33 - 44 9823/1650-1 33 - 44
160-E8028-1_SHEET 9
33 - 45 9823/1650-1 33 - 45
Page Page
33-46 33-47
Page 33-47
33 - 46 9823/1650-1 33 - 46
Page Page
33-46 33-47

Page 33-46
160-E8028-1_SHEET 9
33 - 47 9823/1650-1 33 - 47
Work Lamps, Rotating Beacon, Heated Seat and Interior Lamp
33 - 48 9823/1650-1 33 - 48
160-E8028-1_SHEET 10
33 - 49 9823/1650-1 33 - 49
Page Page
33-50 33-51
Page 33-51
33 - 50 9823/1650-1 33 - 50
Page Page
33-50 33-51

Page 33-50
160-E8028-1_SHEET 10
33 - 51 9823/1650-1 33 - 51
Air Conditioning
33 - 52 9823/1650-1 33 - 52
160-E8028-1_SHEET 11
33 - 53 9823/1650-1 33 - 53
Page Page
33-54 33-55
Page 33-55
33 - 54 9823/1650-1 33 - 54
Page Page
33-54 33-55
160-E8028-1_SHEET 11
Page 33-54
33 - 55 9823/1650-1 33 - 55
In Cab Entertainment
33 - 56 9823/1650-1 33 - 56
160-E8028-1_SHEET 12
33 - 57 9823/1650-1 33 - 57
Page Page
33-58 33-59
Page 33-59
33 - 58 9823/1650-1 33 - 58
Page Page
33-58 33-59

Page 33-58
160-E8028-1_SHEET 12
33 - 59 9823/1650-1 33 - 59
RAS Controller
33 - 60 9823/1650-1 33 - 60
160-E8028-1_SHEET 13
33 - 61 9823/1650-1 33 - 61
Page Page
33-62 33-63
Page 33-63
33 - 62 9823/1650-1 33 - 62
Page Page
33-62 33-63

Page 33-62
160-E8028-1_SHEET 13
33 - 63 9823/1650-1 33 - 63
RAS Interface
33 - 64 9823/1650-1 33 - 64
160-E8028-1_SHEET 14
33 - 65 9823/1650-1 33 - 65
Page Page
33-66 33-67
Page 33-67
33 - 66 9823/1650-1 33 - 66
Page Page
33-66 33-67

Page 33-66
160-E8028-1_SHEET 14
33 - 67 9823/1650-1 33 - 67
RAS Chassis / Panel
33 - 68 9823/1650-1 33 - 68
160-E8028-1_SHEET 15
33 - 69 9823/1650-1 33 - 69
Page Page
33-70 33-71
Page 33-71
33 - 70 9823/1650-1 33 - 70
Page Page
33-70 33-71

Page 33-70
160-E8028-1_SHEET 15
33 - 71 9823/1650-1 33 - 71
CAN Architecture
33 - 72 9823/1650-1 33 - 72
160-E8028-1_SHEET 16
33 - 73 9823/1650-1 33 - 73
Page Page
33-74 33-75
Page 33-75
33 - 74 9823/1650-1 33 - 74
Page Page
33-74 33-75

Page 33-74
160-E8028-1_SHEET 16
33 - 75 9823/1650-1 33 - 75
T4i Engine (Starter and Fuel Pump)
33 - 76 9823/1650-1 33 - 76
160-E8028-1_SHEET 17
33 - 77 9823/1650-1 33 - 77
Page Page
33-78 33-79
Page 33-79
33 - 78 9823/1650-1 33 - 78
Page Page
33-78 33-79

Page 33-78
160-E8028-1_SHEET 17
33 - 79 9823/1650-1 33 - 79
T4i Engine (Sensors)
33 - 80 9823/1650-1 33 - 80
160-E8028-1_SHEET 18
33 - 81 9823/1650-1 33 - 81
Page Page
33-82 33-83
Page 33-83
33 - 82 9823/1650-1 33 - 82
Page Page
33-82 33-83

Page 33-82
160-E8028-1_SHEET 18
33 - 83 9823/1650-1 33 - 83
Table 419. ‘A’ Rear Cab Harness

Item Description
AA Cab/Panel harness connector
AB Heated seat
AC Air suspension seat
AD Rear wiper
AE Worklight LH
AF Earth
AG Beacon
AH Worklight RH
AJ Roof wiper
AK1 Interior light (+ve)
AK2 Interior light (-ve)
AL Park brake switch
Table 420. ‘B’ Twin Primary Fuse Link

Item Description
B001 TBA
B002 TBA
B003 TBA
Table 421. ‘C’ Chassis Harness

Item Description
C001 R/H headlight
C002 L/H headlight
C003 Accelerator
C004 Engine supply
C005 Starter motor
C006 Stabiliser isolation valve
C007 Chassis harness to panel harness connector
C008 Chassis earth
C010 Fuel level sender
C011 Transmission speed sensor
C013 Rear lights
C014 Transmission connector
C015 Transmission dump
C016 Horn
C017 Reverse alarm
C017 Hydraulic isolation
C032 Engine pod harness connector
C033 Starter motor solenoid
Table 422. ‘C’ Grid Heater relay to Heater Power Lead

Item Description
C001 TBA
C002 TBA
33 - 84 9823/1650-1 33 - 84
Table 423. ‘CE’ Engine Harness

Item Description
CE001A Accelerometer 1
CE001B Accelerometer 2
CE002 TMAP (Temperature Manifold Air Pressure)
CE005 Crank speed sensor ELTEK
CE006 Coolant temp sensor
CE007 Cam position sensor
CE008 EGR (Exhaust Gas Recirculation) actuator
CE010 EcoMax CAN (Controller Area Network) terminator
CE011 Exhaust manifold pressure sensor
CE015 Intake throttle valve
CE016 Intercooler out temperature sensor
CE019 Oil pressure switch
CE020 Oil temperature sensor
CE021 Exhaust temperature sensor
CE026 Comp in pressure sensor
CE030 Rail pressure sensor
CE032 Fuel temperature sensor
CE033 VGT (Variable Geometry Turbocharger) actuator
CE035 HP (High Pressure) fuel pressure regulator
CE037 Machine interface connector
CE040 Injector number 1
CE044 Fuel Inlet metering valve
CE045 Engine ECU (Electronic Control Unit) connector
CE091 Shield cut end 2
CE092 Shield cut end 3
CE093 Shield cut end
Table 424. ‘CS’ Grid Heater Fuse Link Lead

CS1 TBA
CS5 TBA
Table 425. ‘E’ Engine Pod Harness

Item Description
E001 Fuse/relay box
E002 Agglomerator
E003 Fuel pump
E004 Engine ECU connector
E005 Engine harness connector
E006 Air filter vacuum switch
E007 Lambda sensor
E008 TMAF (Temperature and Mass Air Flow)
E009 Chassis harness connector
E010 Powertrain CAN bus resistor
E011 Transmission oil temp
E012 Reversing fan solenoid
33 - 85 9823/1650-1 33 - 85
Item Description
E013 Proportional fan solenoid
E014 Fan speed sensor
E020 Grid heater
E023 EcoMax CAN bus resistor
E024-1 Air con binary switch 1
E024-2 Air con binary switch 2
E025 Air con compressor
Table 426. ‘L’ Rear Worklights Harness

Item Description
L001 Worklight
L002 Panel harness connector
Table 427. ‘L’ Air Filter Link Harness

Item Description
L001 Air filter
L002 Engine harness
Table 428. ‘P’ Panel Harness

Item Description
P001 Secondary fuse box A
P002 Secondary fuse box B
P003 Secondary fuse box C
P004 Secondary fuse box D
P005 Neutral start relay
P006 Ignition relay 1
P006 Forward drive relay
P008 Flasher relay
P009 Reverse drive relay
P011 Front working lamps relay
P011 Rear working lamps relay
P012 Transmission dump relay
P012 Parkbrake warning lamp relay
P013 Drive relay
P013 Driveshaft relay
P014 Reverse high/low relay
P014 Forward high/low relay
P017 Brakelights relay
P017 Roadlamps relay
P018 Engine running relay
P018 Parkbrake relay
P019 Parkbrake 2 wheel drive relay
P019 Stabiliser isolation relay
P020 Chassis harness connector
P023 Air conditioning switch +ve
P024 Air conditioning switch -ve
33 - 86 9823/1650-1 33 - 86
Item Description
P025 Hazard switch
P026 Roof wiper switch
P027 Rear wiper switch
P028 Fog lamp switch
P029 Roadlights switch
P030 Worklamps switch
P032 Beacon switch
P034 Stabiliser isolation switch
P036 Indicator diode
P037 Heater connector
P038 Heater switch
P039 Earth
P040 Earth
P041 L/H column switch
P042 Diode gate
P043 Info button
P046 Diagnostic connector
P052 Centre cluster warning lights
P055 RHC connector J1
P056 RHC connector J2
P057 Rear cab harness connector
P058 R/H column switch
P059 Ignition switch
P061 Primary fuse
P062 Primary fuse
P063 Diode gate
P064 Primary fuse blue
P065 Primary fuse grey
P066 Footbrake
P067 Face level fan +ve
P068 Face level fan -ve
P069 Washer pump
P071 Spare
P076 Front wiper motor
P077 Auxiliary socket
P078 Auxiliary socket illumination
P082 Radio
P088 Worklamps
P091 Terminating resistor
P092 Engine supply
P093 Immobiliser
P094 Immobiliser link
P097 Hydraulic isolation switch
P098 Hour meter +ve
P099 Hour meter -ve
P100 Hour meter signal
P101 RAS (Rear Axle Stabilization) interface 1
P102 RAS interface 2
33 - 87 9823/1650-1 33 - 87
Item Description
P103 RAS link 1
P104 RAS link 2
P105 RAS LH/RH relay
P106 Ground speed
Table 429. ‘PA’ RAS Panel Harness

Item Description
PA001 Panel connector
PA002 RAS interface 1
PA003 RAS interface 2
PA004 Ground speed R/H feedback
PA005 Parkbrake
PA006 RAS controller J1
PA007 RAS controller J2
PA008 CAN
PA009 CAN terminator
Table 430. ‘RA’ RAS Chassis Harness

Item Description
RA001 Panel connector
RA002 Left RAS cylinder
RA003 Right RAS cylinder
RA004 Sway switch
RA005 Left stabiliser switch
RA006 Right stabiliser switch
RA007 Inloader valve
RA008 Ground
RA009 Left stabiliser link
RA010 Right stabiliser link
Table 431. ‘RL’ Stabiliser / Headlights

Item Description
RL001 Right stabiliser transducer
RL002 Left stabiliser transducer
RL003 Right headlight
RL004 Left headlight
RL005 Chassis harness connector
Table 432. ‘RL’ Rear Lights Harness

Item Description
RL001 Chassis connector
RL002 Left rear lamp
RL003 Right rear lamp
Table 433. ‘ST’ Starter Motor Harness

Item Description
ST01 Chassis harness connector
ST03 Charge lead
ST04 D+ terminal
33 - 88 9823/1650-1 33 - 88
Item Description
ST05 Charge lead
ST06 W terminal
Table 434. `S' Splices

Item Description
SA Refer to Figure 872.
SA Refer to Figure 873.
SB Refer to Figure 873.
SC Refer to Figure 872.
SC Refer to Figure 874.
SC01 Refer to Figure 871.
SP1 Refer to Figure 864.
33 - 89 9823/1650-1 33 - 89
Item Description
SRA1 Refer to Figure 877.
SRL1 Refer to Figure 871.
ST2 Refer to Figure 868.
Table 435. ‘T’ Transmission Harness

Item Description
T001 Chassis harness connector
T003 Transmission oil pressure
T004 Reverse low solenoid
T005 Reverse high solenoid
T006 Mainshaft solenoid
T007 Layshaft solenoid
T008 Forward low solenoid
T009 Forward high solenoid
T010 4 Wheel drive solenoid
33 - 90 9823/1650-1 33 - 90
(For: 512-56 [T4i], 514-56 [T4i], JCB Tier 4i /T4F <55kW Engine 4 Cyl)
Figure 882. SP3, SP9, SP19, SP41, SP35 (Sheet 1 of 19)................................................... Page 33-93
Figure 883. SP14, SP18, SP20, SP58, SP59, SP60, SC11, SB (Sheet 2 of 19)................... Page 33-97
Figure 884. SP6, SP10, SP23, SP32, SA (Sheet 3 of 19)................................................... Page 33-101
Figure 885. SP24 (Sheet 4 of 19)........................................................................................ Page 33-105
Figure 886. SP25, SP26, SP27, SP28, SP29, SP30, SP33, SP34, SP63, SP64, SC06, SC14, ST1,
P039, C008 (Sheet 5 of 19)................................................................................................. Page 33-109
Figure 887. Right hand cluster connectors, P055, P056 (Sheet 6 of 19)............................. Page 33-113
Figure 888. SP5, SP7, SP8, SP13, SP39, SP61, SP62 (Sheet 7 of 19)..............................Page 33-117
Figure 889. SC01, SC04, SC05, SC08, SC09, SC10, SRL1, SRL2, SRL3, SRL4 and Front SRL1,
SRL2, SRL5 (Sheet 8 of 19)................................................................................................ Page 33-121
Figure 890. SA, SC, SP16, SP17, SP37, SP38, SP40 (Sheet 9 of 19)............................... Page 33-125
Figure 891. SP21, SP22, SB (Sheet 10 of 19).................................................................... Page 33-129
Figure 892. SC02, SC (Sheet 11 of 19)............................................................................... Page 33-133
Figure 893. In Cab Entertainment (Sheet 12 of 19)............................................................. Page 33-137
Figure 894. SP65, SP66, SP68 (Sheet 13 of 19)................................................................ Page 33-141
Figure 895. SRL3, SRL4. SP67, SP72, SP73, SC12 (Sheet 14 of 19)................................ Page 33-145
Figure 896. RAS Chassis/Panel (Sheet 15 of 19)................................................................Page 33-149
Figure 897. CAN Architecture (Sheet 16 of 19)................................................................... Page 33-153
Figure 898. Engine Circuit including Start Circuit (Sheet 17 of 19)......................................Page 33-157
Figure 899. Engine Circuit - Sensors (Sheet 18 of 19)........................................................ Page 33-161
Sheet 19 is not included as it only contains an index
to the other sheets.
33 - 91 9823/1650-1 33 - 91
Notes:
33 - 92 9823/1650-1 33 - 92
Page 33-94 Figure 882. SP3, SP9, SP19,

SP41, SP35 (Sheet 1 of 19) Page 33-95
160/E8085-1
33 - 93 9823/1650-1 33 - 93
Page Page
33-94 33-95
Page 33-95
33 - 94 9823/1650-1 33 - 94
Page Page
33-94 33-95

Page 33-94
160/E8085-1
33 - 95 9823/1650-1 33 - 95
33 - 96 9823/1650-1 33 - 96
Page 33-98 Figure 883. SP14, SP18, SP20, SP58,

SP59, SP60, SC11, SB (Sheet 2 of 19) Page 33-99
160/E8085-1
33 - 97 9823/1650-1 33 - 97
Page Page
33-98 33-99
Page 33-99
33 - 98 9823/1650-1 33 - 98
Page Page
33-98 33-99

Page 33-98
160/E8085-1
33 - 99 9823/1650-1 33 - 99
33 - 100 9823/1650-1 33 - 100

Page 33-102 Figure 884. SP6, SP10, SP23,

SP32, SA (Sheet 3 of 19) Page 33-103
160/E8085-1
33 - 101 9823/1650-1 33 - 101

Page Page
33-102 33-103
Page 33-103
33 - 102 9823/1650-1 33 - 102

Page Page
33-102 33-103

Page 33-102
160/E8085-1
33 - 103 9823/1650-1 33 - 103

33 - 104 9823/1650-1 33 - 104

Page 33-106 Figure 885. SP24 (Sheet 4 of 19) Page 33-107
160/E8085-1
33 - 105 9823/1650-1 33 - 105

Page Page
33-106 33-107
Page 33-107
33 - 106 9823/1650-1 33 - 106

Page Page
33-106 33-107

Page 33-106
160/E8085-1
33 - 107 9823/1650-1 33 - 107

33 - 108 9823/1650-1 33 - 108

Figure 886. SP25, SP26, SP27, SP28, SP29,
Page 33-110 SP30, SP33, SP34, SP63, SP64, SC06,

SC14, ST1, P039, C008 (Sheet 5 of 19) Page 33-111
160/E8085-1
33 - 109 9823/1650-1 33 - 109

Page Page
33-110 33-111
Page 33-111
33 - 110 9823/1650-1 33 - 110

Page Page
33-110 33-111

Page 33-110
160/E8085-1
33 - 111 9823/1650-1 33 - 111

33 - 112 9823/1650-1 33 - 112

Page 33-114 Figure 887. Right hand cluster

connectors, P055, P056 (Sheet 6 of 19) Page 33-115
160/E8085-1
33 - 113 9823/1650-1 33 - 113

Page Page
33-114 33-115
Page 33-115
33 - 114 9823/1650-1 33 - 114

Page Page
33-114 33-115

Page 33-114
160/E8085-1
33 - 115 9823/1650-1 33 - 115

33 - 116 9823/1650-1 33 - 116

Page 33-118 Figure 888. SP5, SP7, SP8, SP13,

SP39, SP61, SP62 (Sheet 7 of 19) Page 33-119
160/E8085-1
33 - 117 9823/1650-1 33 - 117

Page Page
33-118 33-119
Page 33-119
33 - 118 9823/1650-1 33 - 118

Page Page
33-118 33-119

Page 33-118
160/E8085-1
33 - 119 9823/1650-1 33 - 119

33 - 120 9823/1650-1 33 - 120

Figure 889. SC01, SC04, SC05, SC08,
Page 33-122 SC09, SC10, SRL1, SRL2, SRL3, SRL4 and

Front SRL1, SRL2, SRL5 (Sheet 8 of 19) Page 33-123
160/E8085-1
33 - 121 9823/1650-1 33 - 121

Page Page
33-122 33-123
Page 33-123
33 - 122 9823/1650-1 33 - 122

Page Page
33-122 33-123

Page 33-122
160/E8085-1
33 - 123 9823/1650-1 33 - 123

33 - 124 9823/1650-1 33 - 124

Page 33-126 Figure 890. SA, SC, SP16, SP17,

SP37, SP38, SP40 (Sheet 9 of 19) Page 33-127
160/E8085-1
33 - 125 9823/1650-1 33 - 125

Page Page
33-126 33-127
Page 33-127
33 - 126 9823/1650-1 33 - 126

Page Page
33-126 33-127

Page 33-126
160/E8085-1
33 - 127 9823/1650-1 33 - 127

33 - 128 9823/1650-1 33 - 128

Page 33-130 Figure 891. SP21, SP22, SB (Sheet 10 of 19) Page 33-131
160/E8085-1
33 - 129 9823/1650-1 33 - 129

Page Page
33-130 33-131
Page 33-131
33 - 130 9823/1650-1 33 - 130

Page Page
33-130 33-131

Page 33-130
160/E8085-1
33 - 131 9823/1650-1 33 - 131

33 - 132 9823/1650-1 33 - 132

Page 33-134 Figure 892. SC02, SC (Sheet 11 of 19) Page 33-135
160/E8085-1
33 - 133 9823/1650-1 33 - 133

Page Page
33-134 33-135
Page 33-135
33 - 134 9823/1650-1 33 - 134

Page Page
33-134 33-135

Page 33-134
160/E8085-1
33 - 135 9823/1650-1 33 - 135

33 - 136 9823/1650-1 33 - 136

Page 33-138 Figure 893. In Cab

Entertainment (Sheet 12 of 19) Page 33-139
160/E8085-1
33 - 137 9823/1650-1 33 - 137

Page Page
33-138 33-139
Page 33-139
33 - 138 9823/1650-1 33 - 138

Page Page
33-138 33-139

Page 33-138
160/E8085-1
33 - 139 9823/1650-1 33 - 139

33 - 140 9823/1650-1 33 - 140

Page 33-142 Figure 894. SP65, SP66, SP68 (Sheet 13 of 19) Page 33-143
160/E8085-1
33 - 141 9823/1650-1 33 - 141

Page Page
33-142 33-143
Page 33-143
33 - 142 9823/1650-1 33 - 142

Page Page
33-142 33-143

Page 33-142
160/E8085-1
33 - 143 9823/1650-1 33 - 143

33 - 144 9823/1650-1 33 - 144

Page 33-146 Figure 895. SRL3, SRL4. SP67,

SP72, SP73, SC12 (Sheet 14 of 19) Page 33-147
160/E8085-1
33 - 145 9823/1650-1 33 - 145

Page Page
33-146 33-147
Page 33-147
33 - 146 9823/1650-1 33 - 146

Page Page
33-146 33-147

Page 33-146
160/E8085-1
33 - 147 9823/1650-1 33 - 147

33 - 148 9823/1650-1 33 - 148

Page 33-150 Figure 896. RAS Chassis/Panel (Sheet 15 of 19) Page 33-151
160/E8085-1
33 - 149 9823/1650-1 33 - 149

Page Page
33-150 33-151
Page 33-151
33 - 150 9823/1650-1 33 - 150

Page Page
33-150 33-151

Page 33-150
160/E8085-1
33 - 151 9823/1650-1 33 - 151

33 - 152 9823/1650-1 33 - 152

Page 33-154 Figure 897. CAN Architecture (Sheet 16 of 19) Page 33-155
160/E8085-1
33 - 153 9823/1650-1 33 - 153

Page Page
33-154 33-155
Page 33-155
33 - 154 9823/1650-1 33 - 154

Page Page
33-154 33-155

Page 33-154
160/E8085-1
33 - 155 9823/1650-1 33 - 155

33 - 156 9823/1650-1 33 - 156

Page 33-158 Figure 898. Engine Circuit including

Start Circuit (Sheet 17 of 19) Page 33-159
160/E8085-1
33 - 157 9823/1650-1 33 - 157

Page Page
33-158 33-159
Page 33-159
33 - 158 9823/1650-1 33 - 158

Page Page
33-158 33-159

Page 33-158
160/E8085-1
33 - 159 9823/1650-1 33 - 159

33 - 160 9823/1650-1 33 - 160

Page 33-162 Figure 899. Engine Circuit

- Sensors (Sheet 18 of 19) Page 33-163
160/E8085-1
33 - 161 9823/1650-1 33 - 161

Page Page
33-162 33-163
Page 33-163
33 - 162 9823/1650-1 33 - 162

Page Page
33-162 33-163

Page 33-162
160/E8085-1
33 - 163 9823/1650-1 33 - 163

90 - Earth Point
90 - Earth Point
Introduction
The ground or earth refers to the reference point in an

electrical circuit from which voltages are measured,
a common return path for electrical current, or a
direct physical connection to earth. Electrical circuits
may be connected to ground or earth to prevent
user contact with dangerous voltage if the electrical
insulation fails.
Earth points can be useful when tracing electrical

faults typically when several electrical devices are
malfunctioning.
33 - 164 9823/1650-1 33 - 164

03 - Battery
03 - Battery
Contents Page No.
33-03-00 General ......................................................................................................................... 33-167

33-03-03 Isolator Switch .............................................................................................................. 33-177
33 - 165 9823/1650-1 33 - 165

Notes:
33 - 166 9823/1650-1 33 - 166

03 - Battery
00 - General
Introduction .................................................. 33-167 Batteries used in normal temperate climate
Health and Safety ........................................ 33-168 applications should not need topping up. However,
Technical Data ............................................. 33-169 in certain conditions (such as prolonged operation
Fault-Finding ................................................ 33-170 in high ambient temperatures or if the alternator
overcharges) the electrolyte level should be checked
Disconnect and Connect ............................. 33-171 frequently and topped up as necessary.
Clean ........................................................... 33-174
Check (Condition) ........................................ 33-174 The electrolyte level should be checked in
Charge ......................................................... 33-175 accordance with the routine maintenance schedule.
Shorter maintenance intervals are required if the
Remove and Install ..................................... 33-176 machine is operating at high ambient temperatures
or continuously for long periods.
Later Machines may have the new type batteries

installed which include a sight glass to check the
condition of the battery. New batteries should be
used as replacements if replacing the battery on
earlier machines.
Figure 900.
A Maintenance free battery
Maintenance
To make sure that the battery provides optimum
performance the following steps should be observed:
• Make sure that the electrical connections are

clean and tight. Smear petroleum jelly on
connectors to prevent corrosion.
• When applicable - never allow the electrolyte
level to fall below the recommended level of 6
mm above the plates. Use only distilled water
for topping up.
• Keep the battery at least three quarters
charged, otherwise the plates may become
sulphated (hardened) - this condition makes
recharging the battery very difficult.
Extra precautions must be taken when bench

charging maintenance free batteries, they are more
prone to damage by overcharging than the standard
type of battery:
• Never boost charge a maintenance free battery

(if installed).
33 - 167 9823/1650-1 33 - 167

03 - Battery
00 - General
• Never charge a battery at a voltage in excess Health and Safety

of 15.8 V.
• Never continue to charge a battery after it DANGER Batteries give off an explosive gas.
begins to gas. Do not smoke when handling or working on the
battery. Keep the battery away from sparks and
Quiescent Current Drain flames.
Battery electrolyte contains sulphuric acid. It can
If the machine has no permanently live circuits there burn you if it touches your skin or eyes. Wear
should be zero quiescent current drain, when the goggles. Handle the battery carefully to prevent
key-switch is off and all the lights are switched off. spillage. Keep metallic items (watches, rings, zips
etc) away from the battery terminals. Such items
It should be noted that some permanently live circuits could short the terminals and burn you.
will place a quiescent drain on the battery. Typically
the quiescent drain will be in the range of 10–20 Set all switches to off before disconnecting and
mA. If the quiescent drain measures 40 mA or more, connecting the battery. When disconnecting the
there is a problem with the wiring insulation or the battery, take off the earth (-) lead first.
accessories, if the fault is not rectified it will continue Re-charge the battery away from the machine,
to drain the battery. in a well ventilated area. Switch the charging
circuit off before connecting or disconnecting the
battery. When you have installed the battery in the
machine, wait 5 min before connecting it up.
When reconnecting, attach the positive (+) lead
first.
WARNING Keep metal watch straps and any
metal fasteners on your clothes, clear of the
positive (+) battery terminal. Such items can short
between the terminal and nearby metal work. If it
happens you can get burned.
WARNING Battery electrolyte is toxic and
corrosive. Do not breathe the gases given off
by the battery. Keep the electrolyte away from
your clothes, skin, mouth and eyes. Wear safety
glasses.
WARNING Do not top the battery up with acid.
The electrolyte could boil out and burn you.
CAUTION Understand the electrical circuit
before connecting or disconnecting an electrical
component. A wrong connection can cause injury
and/or damage.
Notice: Do not disconnect the battery while the
engine is running, otherwise the electrical circuits
may be damaged.
CAUTION The machine is negatively earthed.
Always connect the negative pole of the battery
to earth.
When connecting the battery, connect the earth
(-) lead last.
When disconnecting the battery, disconnect the
earth (-) lead first.
DANGER If you try to charge a frozen battery, or
jump start and run the engine, the battery could
explode. Do not use a battery if its electrolyte
is frozen. To prevent the battery electrolyte from
freezing, keep the battery at full charge.
CAUTION Damaged or spent batteries and any
residue from fires or spillage must be put in a
33 - 168 9823/1650-1 33 - 168

03 - Battery
00 - General
suitable closed receptacle and must be disposed Technical Data

of in accordance with local environmental waste
regulations.
Table 436.
Notice: Before carrying out arc welding on the
machine, disconnect the battery and alternator to Voltage Cold Cranking Battery Type
protect the circuits and components. The battery Amps (CCA)
must still be disconnected even if a battery 12V 1000 1131XMF Main-
isolator is installed. tenance free
33 - 169 9823/1650-1 33 - 169

03 - Battery
00 - General
Fault-Finding
The most obvious sign of a battery problem is a
machine not being able to start. However, because
the battery is part of a larger electrical system
connected to other parts of the machine, a flat battery
may indicate another problem.
If something else is going wrong in the electrical
system, for example, a weak alternator, corrosion or
loose connections, cold weather starting, electrical
equipment being left on without the engine running,
interrogate the cause of the problem.
The best way to test the condition of the battery is
with an electronic battery tester. Refer to Battery-
Check Condition.
When the machine is not in use, make sure that the
electrical system is not causing a drain on the battery.
On machines with electronically controlled engines
check the operation of the power hold relay. Refer to
PIL 33-09-06.
33 - 170 9823/1650-1 33 - 170

03 - Battery
00 - General
Disconnect and Connect
Notice: Before you install a pair of batteries to Figure 901. Parallel and
a machine, make sure you know the machines Series Connection (Example)
voltage. Some machines require two batteries but
have a 12 V electrical system. This means the
batteries need to be connected in parallel.
For 24 V machines, the batteries must be
_ _
connected in series. Incorrect voltage may result
in serious damage to the electrical system. + +
A
C
C
The illustrations show typical battery connections.
The actual battery connections installed on your
machine may look different. _ + _ +
Make sure you connect the batteries correctly for
your machine.
Disconnect 12 V 24 V
1. Make the machine safe. D B D B
Refer to: PIL 01-03-27. Figure 902. Twin Battery 12V Ma-
chines- Parallel Connection (Example)
2. Get access to the battery or batteries (depending
on the specification of your machine). The actual B
installation on your machine may vary from those
shown below.
3. If the machine has a battery isolator, move the
switch to the OFF position, then remove the key. C
4. Disconnect the battery negative lead first.
5. Disconnect the battery positive lead and store
away from the batteries.
A
A D
6. Disconnect and remove the battery link lead or
leads.
A Battery
B Positive lead
C Battery link lead
D Negative lead
33 - 171 9823/1650-1 33 - 171

03 - Battery
00 - General
Figure 903. 24 Volt Machines- Series Connection (Example)

C
_ _ + +
A Battery B Positive lead

C Battery link lead D Negative lead
33 - 172 9823/1650-1 33 - 172

03 - Battery
00 - General
Connect
1. Check the battery as follows:
1.1. If any terminals are dirty, clean them.
1.2. If the terminal is corroded and has white
powder, wash the terminal with hot water.
Make sure the water does not enter the
battery cells.
1.3. If considerable corrosion is found, then
clean with a wire brush or abrasive
paper. Make sure you use eye and hand
protection. Refer to Figure 904.
Figure 904.
1.4. After cleaning, apply a thin coat of

petroleum jelly to the terminals.
2. Connect the leads.
2.1. For single battery machines, connect the
positive lead then the negative lead.
2.2. For twin battery machines, first connect the
link lead or leads, then the positive terminal,
and finally the negative terminal.
3. If the machine has a battery isolator, move the
switch to the ON position.
4. Close and lock the access panels.
33 - 173 9823/1650-1 33 - 173

03 - Battery
00 - General

WARNING Keep metal watch straps and any
metal fasteners on your clothes, clear of the Battery Test
positive (+) battery terminal. Such items can short
between the terminal and nearby metal work. If it This test is to determine the electrical condition of
happens you can get burned. the battery and to give an indication of the remaining
useful life.
Before you test the battery, make sure that the
2. Get access to the battery. battery is at least 75% charged (Specific Gravity of
1.23 to 1.25 for ambient temperature up to 27°C).
3. If the terminal posts are corroded and covered
with white powder wash them with hot water. Make sure that the battery is completely
If there is considerable corrosion, clean the disconnected from the vehicle.
terminal posts with a wire brush or abrasive
paper. Refer to Figure 905. Figure 906.
Figure 905.
4. Apply a thin layer of petroleum jelly to the

terminal posts.
A Battery voltage switch
B Check load switch
Connect up the battery tester as follows:
1. Set the Check Load switch to OFF.

2. Set the battery voltage switch to 12V.
3. Connect the red flying lead to the battery positive
(+) terminal and the black flying lead to the
battery negative (-) terminal.
4. Set the Check/Load switch to CHECK to read the
battery no-load voltage which should be at least
12.4 volts.
5. Set the Check/Load switch to LOAD and hold
down for 5-10 seconds until the meter reading
stabilises. The reading should be at least 9 volts.
6. If the tests are unsatisfactory, refer to the fault
diagnosis table.
33 - 174 9823/1650-1 33 - 174

03 - Battery
00 - General
Table 437. Fault Diagnosis Charge

Battery Tester Read- Remedy
ings
CHECK: 0 -12.6 Volts: Renew battery Precautions Before Charging
LOAD: less than 6 Volts
Follow all the precautions described below, to
CHECK: 6 -12.4 Volts: Recharge and re-test. If prevent damage to the alternator and battery.
LOAD: less than 9 Volts tests are still unsatisfac-
and falls steadily but re- tory renew battery 1. Make the machine safe.
mains in yellow zone
CHECK: less than 10 Indicates battery has
Volts: LOAD: less than 3 been over-discharged 2. Make sure that the battery negative terminal is
Volts and unlikely to recover. connected to the earth cable.
Renew battery
CHECK: more than 11 Charge battery which 3. Do not connect or disconnect the battery
Volts: LOAD: 6 - 10 Volts will probably recover or alternator connections, or any part of the
steady charging circuit while the engine is in operation.
If you disregard this instruction, the regulator or
Specific Gravity Test rectifying diodes will be damaged.
4. Main output cables are always in an active state
The specific gravity of the electrolyte gives an idea of current flow even when the engine is not in
of the state of charge of the battery. Readings operation. If the alternator connector is removed,
should be taken using a hydrometer, when the do not earth the moulded plug.
electrolyte temperature is 15°C (60°F). If the battery
has recently been on charge, wait approximately one 5. When you do arc welding on the machine,
hour (or slightly discharge the battery) to dissipate remove the moulded plug (or if the separate
the surface charge before testing. output cables are installed, remove the cables)
to protect the alternator.
Readings should be as tabulated and should not vary
between cells by more than 0.04. A greater variation 6. If it is necessary to jump start the battery, do the
indicates an internal fault on that particular cell. following steps.
If the electrolyte temperature is other than 15°C 6.1. Connect a secondary battery in parallel
(60°F) a 'correction factor' must be applied to the without disconnecting the vehicle battery
reading obtained. Add 0.07 per 10°C (18°F) if the from the charging circuit.
temperature is higher than 15°C (60°F) and subtract 6.2. Connect the batteries using suitable jump
the same if the temperature is lower. leads. Connect the positive lead to the
positive terminals of both batteries. Connect
Table 438. Specific Gravity at 15°C (60°F))
the negative lead to the negative terminals
Ambient Fully Half Dis- Fully Dis- of both batteries.
Temper- Charged charged charged
ature de- 6.3. After the jump start, safely disconnect the
grees C jump leads and remove the secondary
(degrees battery.
F)
Below 27 1.270-1.290 1.190-1.210 1.110-1.130
( 80 )
Above 27 1.240-1.260 1.170-1.190 1.090-1.110
( 80 )
33 - 175 9823/1650-1 33 - 175

03 - Battery
00 - General
Remove and Install
CAUTION This component is heavy. It must only 4. Disconnect the battery. Refer to (PIL 33-03).
method and device. 5. Make sure that all battery connection wires are
clear of battery top cover.
Remove 6. Remove the wing nuts and disconnect the battery

clamp.
7. Lift the clamp clear of the battery.
2. Follow the hydraulic care and safety procedures.
Refer to (PIL 33-00). 8. Remove the battery from the compartment and
make sure that you do not use the access cover
3. Get access to the battery. Refer to (PIL to support the weight of the battery.
06-06-03).
Figure 907.
A
B
A Battery B Wing nuts

C Battery clamp
Install
removal procedure.
33 - 176 9823/1650-1 33 - 176

03 - Battery
03 - Isolator Switch
03 - Isolator Switch
Introduction
The battery isolator switch is used to disconnect the

battery from the machine electrics. The switch must
be turned to the OFF position if any maintenance
work is to be performed on the machine.
Some machine systems perform shut down cycles

after the engine stops. Wait until shut down cycles
are complete before setting the battery isolator
switch to the OFF position. For more information
refer to Disconnect and Connect. Refer to: PIL
33-03-00.
33 - 177 9823/1650-1 33 - 177

06 - Battery Cable
06 - Battery Cable
Contents Page No.
33-06-00 General ......................................................................................................................... 33-179
33 - 178 9823/1650-1 33 - 178

06 - Battery Cable
00 - General
Introduction .................................................. 33-179 The cables connect the battery positive and negative
Check (Condition) ........................................ 33-180 terminals to the machine electrical system.
33 - 179 9823/1650-1 33 - 179

06 - Battery Cable
00 - General
Check (Condition)
2. Make sure that all battery terminals and
connections are secure and tight.
3. Make sure that all earth connections are secure
and tight.
4. Check that the battery terminals or cables are not
corroded. Refer to clean, (PIL 33-03-00).
4.1. Remove any corrosion.
4.2. Apply petroleum jelly to battery
connections.
5. Check the cables are not damaged or chaffed.
6. Repair or replace as needed.
33 - 180 9823/1650-1 33 - 180

09 - Power Distribution
Contents Page No.
33-09-00 General ......................................................................................................................... 33-183

33-09-03 Fuse ............................................................................................................................. 33-185
33-09-06 Relay ............................................................................................................................ 33-186
33 - 181 9823/1650-1 33 - 181

Notes:
33 - 182 9823/1650-1 33 - 182

00 - General
Introduction .................................................. 33-183 The electrical circuits are protected by fuses. If a
Health and Safety ........................................ 33-184 fuse blows, find out why and rectify the fault before
installing a new one.
A full up to date list of fuses and relays and their

locations can be found in the relevant operator
manual, maintenance section.
33 - 183 9823/1650-1 33 - 183

00 - General
Health and Safety

Notice: Always replace fuses with ones of correct
ampere rating to avoid electrical system damage.
Notice: When installing auxiliary electrical
components always ensure that the additional
load rating is suitable for that particular circuit. It
is unacceptable to simply increase the fuse rating
as this can cause overloading and consequential
failure of wiring, along with failure of integral
circuit components, which the fuse is protecting.
33 - 184 9823/1650-1 33 - 184

03 - Fuse
03 - Fuse
Figure 908. Fuse Box Termi-
nal Pin Number Identification
A B
1 2 1 2
3 4 3 4
5 6 5 6
7 8 7 8
9 10 9 10
11 12 11 12
13 14 13 14
15 16 15 16
17 18 17 18
19 20 19 20
C D
1 2 1 2
3 4 3 4
5 6 5 6
7 8 7 8
9 10 9 10
11 12 11 12
13 14 13 14
15 16 15 16
17 18 17 18
19 20 19 20
E
1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
17 18
19 20
33 - 185 9823/1650-1 33 - 185

06 - Relay
06 - Relay
The relay mounting bases are connected to the Each relay base can hold 2 relays. Pins 1-5 being
Panel Harness. used for relay position B and pins 6-10 being used
for relay position A. Therefore each relay could have
Specific location and connector number will change. alternative pin numbers due to its position in relay
base.
Figure 909. Relay Base Pin Number Identification
A B
6
5 4 3
7
2
8 9 10
1
8 10 4
1
2
7
6
3
9 5
A B
A Relay A B Relay B
33 - 186 9823/1650-1 33 - 186

12 - Harness
12 - Harness
Contents Page No.
33-12-00 General ......................................................................................................................... 33-189

33-12-04 Chassis ......................................................................................................................... 33-202
33-12-06 Lift Arm ......................................................................................................................... 33-217
33-12-09 Engine .......................................................................................................................... 33-223
33-12-12 Operator Station ........................................................................................................... 33-241
33-12-15 Front Console ............................................................................................................... 33-247
33-12-19 Engine Compartment Cover ........................................................................................ 33-340
33-12-30 Gearbox ........................................................................................................................ 33-352
33-12-48 LiveLink ........................................................................................................................ 33-356
33-12-53 Stabiliser ....................................................................................................................... 33-360
33-12-56 Extreme Cold Climate Heater ...................................................................................... 33-379
33-12-64 Rear Axle Stabilization (RAS) ...................................................................................... 33-388
33 - 187 9823/1650-1 33 - 187

Notes:
33 - 188 9823/1650-1 33 - 188

12 - Harness
00 - General
Introduction .................................................. 33-189
Health and Safety ........................................ 33-190
Harness Drawings
Component Identification ............................. 33-191 Drawings are reproduced from production electrical
Repair .......................................................... 33-196 harness drawings. Each harness drawing includes
Check (Condition) ........................................ 33-198 tables showing wire connections and destinations
for all the connectors on the harness. To identify
the correct harness drawing for a particular machine
refer to the relevant Harness Interconnection page
for the machine serial number range.
33 - 189 9823/1650-1 33 - 189

12 - Harness
00 - General
Health and Safety

Notice: When installing auxiliary electrical
components always ensure that the additional
load rating is suitable for that particular circuit. It
is unacceptable to simply increase the fuse rating
as this can cause overloading and consequential
failure of wiring, along with failure of integral
circuit components, which the fuse is protecting.
Harness Repair (Butane Heater)

WARNING In addition to the warnings
incorporated into this procedure, extreme care
should be taken when handling the gas heating
tool to ensure that the flame does not damage or
set fire to any items in the vicinity of the repair,
i.e. other wires, floor panels, floor mats, sound
proofing, paintwork, etc. This tool should not be
used in any restricted location prohibiting the use
of "Naked Flames" or where risk of explosive gas
or similar safety parameters apply. No other heat
source should be used to attempt a sealed joint.
CAUTION When the heater is in use, the reflector
and the air coming out are extremely hot. Keep
away to avoid accidental burns. Do not touch the
reflector until it has had time to cool down after
switching off. If flame reappears at the reflector
when the heater is in use, the catalytic element is
damaged or used up. Stop work immediately and
replace the heater.
33 - 190 9823/1650-1 33 - 190

12 - Harness
00 - General
Wire and Harness Number Identification

This section details the allocation of wire numbers
and the identification of wires in the wiring harness.
Figure 910.
The illustration shows a typical connector and wires. it's length. The number stamped on the wire identifies
Each wire has an individual identification number the following:
permanently marked on it, at regular intervals along
Table 439. Wire and Harness Number Identification

Identification Number Description
# The # indicates the start of the identification num-
ber. It is always printed to the left of the identification
number.
B If applicable- The colour of the flying lead that the
harness wire should mate with. For instance, if wire
819 from harness 719/37100 mated with a flying lead
coloured black (colour code B) then the number print-
ed on the wire would be B-819 9/371.
819 The wire's unique identification number. The wire
functions and numbers allocated to them are consis-
tent through out the JCB range of products. Refer to
Wire Numbers and Functions.
9/371 If applicable- The part number of the harness that the
wire originates from. If the harness part number is
719/37100, the number printed on the harness wires
will be 9/371 (71 and 00 are common numbers and
therefore deleted).
Wire Numbers and Functions Table 441. Wires 200-399 (These

numbers are reserved for battery feeds)
Table 440. Wires 000-199 (These Wire Number Description
numbers are reserved for ignition feeds,
heater start circuits and start circuits) Wires 200 - 299 Unfused battery feeds
Wires 300 - 399 Fused battery feeds
Wire Number Description
Wires 000 - 099 Unfused ignition feeds
Wires 100 - 199 Fused ignition feeds
33 - 191 9823/1650-1 33 - 191

12 - Harness
00 - General
Table 442. Wires 400-599 Figure 912.

Wires 400-599 These numbers are re-
served for instruments,
i.e. alternators to tachos,
temperature switches
to warning lights, etc.
and signal wires used in
electronic systems
Table 443. Wires 600-799

Wires 600-799 These numbers are
used for earth wires.
When the number is
printed on to a wire it General Points
is prefixed by the Earth
1. Wires continue to have the same number even
symbol. This symbol is
after passing through a connector block to
printed onto the wire, it
another harness.
may however be omitted
from harness drawings 2. If all the numbers in a category have been
allocated, then the category is re-used with an
additional prefix '1', i.e. 1832.
Figure 911.
Electrical Connectors- RAS System
The RAS (Rear Axle Stabilization) system is not
600 installed on all Loadall machines.
The table shows the harness connectors that

connect to the electrical devices. The connectors
are shown looking at the mating face when
disconnected. Remember that the drawings show
Table 444. Wires 800-999 the harness connectors and not the device
Wire Number Description connectors.
Wires 800-999 These numbers are re- Use the table and the relevant electrical schematic
served for switched sup- to identify the pins in the harness connectors.
plies to electrical loads, Continuity checks on the harness wires can be
i.e. to lights, etc. carried out using a multimeter. Do not touch the ECU
(Electronic Control Unit) connector pins. Do not use
a multimeter on ECU connector pins.
Table 445. Wires In Splices
Various The main input wire is
allocated with a wire
number and a suitable
description, i.e. Wire 640
earth splice to earth.
The additional wires in
the splice are allocated
the same wire number
and a postfix, i.e. 640A,
640B, etc.
33 - 192 9823/1650-1 33 - 192

12 - Harness
00 - General
Table 446. Electrical Connectors- RAS System

Device Description Location Harness Con-
nector
1042A Stabiliser isolation switch Located on the instrument panel. Re-
move the switch to get access to the
connector.
1058 Sway spool switch Located on the parallel valve block

sway valve spool.
1062A Right stabiliser pressure trans- Located on the stabiliser cylinder

ducer body.
1062B Left stabiliser pressure trans- Located on the stabiliser cylinder

ducer body.
1063 Left stabiliser switch Located on the parallel valve block

left stabiliser valve spool.
1064 Right stabiliser switch Located on the parallel valve block

right stabiliser valve spool.
1065 Lift arm proximity switch- 60 ° Inside face of the right side chassis
(stabiliser isolation) near the lift arm pivot.
1066 Lift arm proximity switch- 60 ° Inside face of the left side chassis
near the lift arm pivot.
1067 Lift arm extend proximity TBA

switch
2000 Relays Refer to electrical system- fuse and

relay, refer to (PIL 33-09).
3054 Sway / stabiliser isolation Located on the parallel valve block.
valve solenoid
3055 Lift pilot pressure supply isola- Located on the pilot pressure supply
tion valve solenoid valve.
4013 LMS (Loadall Monitoring Sys- The ECU connectors are located be- 10 1
tem) display connector J2 hind the LMS display unit. Be sure to
identify the correct connector. Con- 20 11
nector J2 is coloured black.

4018A ECU connector1 (black) The ECU is installed below the oper-
ators seat. The panel harness con-
nector connects directly to the ECU. 12
23
1
13
35 24
4018B ECU connector2 (white) The ECU is installed below the oper-
ators seat. The panel harness con-
nector connects directly to the ECU. 12
23
1
13
35 24
33 - 193 9823/1650-1 33 - 193

12 - Harness
00 - General
Device Description Location Harness Con-

nector
8000 Harness interconnections Refer to electrical system- harness,
9000 Fuses Refer to electrical system- fuse and
relay, refer to (PIL 33-09).
Electrical Connectors- Gearbox Harness Use the table and the relevant electrical schematic
to identify the pins in the harness connectors.
The table shows the harness connectors that Continuity checks on the harness wires can be
connect to the electrical devices. The connectors carried out using a multimeter. Do not touch ECU
are shown looking at the mating face when connector pins. Do not use a multimeter on ECU
disconnected. The drawings show the harness connector pins.
connectors, not the device connectors.
Table 447. Gearbox Harness Electrical Connectors

Device Description Location Harness connector
1013 Column Switch L/H A cable and connector
connects to the panel har-
ness at the steering col-
umn below the steering
wheel. Refer to driveline-
semi-automatic gearbox,
1068 Transmission Dump The switch is installed
Switch to the hydraulic control
lever. A cable and con-
necter connects to the
chassis harness below
the hydraulic control
lever. Refer to driveline-
1057 Park Brake Switch The switch is installed to
the park brake lever. A
cable and connector con-
nects to the rear cab har-
ness at the park brake
lever. Refer to driveline-
2000 Relays Refer to electrical system-
fuse and relay, refer to
(PIL 33-09).
3021 Forward high solenoid Located on the gearbox.
3022 Forward low solenoid Refer to driveline- se-
mi-automatic gearbox, re-
3029 Layshaft solenoid
fer to (PIL 27-06).
3033 Mainshaft solenoid
3040 Reverse high solenoid Located on the gearbox.
3041 Reverse low solenoid Refer to driveline- se-
mi-automatic gearbox, re-
fer to (PIL 27-06).
7014 Diode Gate- Gearbox Connects to the panel
harness below the left
side instrument console.
33 - 194 9823/1650-1 33 - 194

12 - Harness
00 - General
Device Description Location Harness connector

8000 Harness interconnections Refer to electrical sys-
tem- harness, refer to
(PIL 33-12).
9000 Fuseboxes Refer to electrical system-
fuse and relay, refer to
(PIL 33-09).
-000 Earth Points Refer to electrical sys-
tem- harness, refer to
(PIL 33-12).
33 - 195 9823/1650-1 33 - 195

12 - Harness
00 - General
Repair 2. Using the correct sized splice, attach the new

section of wire required or auxiliary flying
Special Tools lead to the existing harness and secure using
Description Part No. Qty. the crimp tool. Note that each of the splices
Wiring Crimp Tool 892/00349 1 detailed is colour-coded to make size and range
readily visible. They are secured using the
Butane Heater 892/00350 1 corresponding size and matching colour-coded
jaws of the crimp tool to ensure joint security.
Consumables This tool also incorporates a ratchet closing
Description Part No. Size mechanism which will not release until the splice
Wiring Splice 892/00351 - is fully closed to the correct compression size.
(0.5-1.5mm Red,
Consumable: Wiring Splice (0.5-1.5mm Red,
contains 50 off)
contains 50 off)
Wiring Splice 892/00352 - Consumable: Wiring Splice (1.5-2.5mm Blue,
(1.5-2.5mm Blue, contains 50 off)
contains 50 off) Consumable: Wiring Splice (3-6mm Yellow,
Wiring Splice (3-6mm 892/00353 - contains 50 off)
Yellow, contains 50 off)
3. With the Butane heater assembly, seal the
Instances occur where it is necessary to incorporate connection.
auxiliary electrical components into existing electrical Special Tool: Butane Heater (Qty.: 1)
circuits and although unlikely with present wiring
harnesses, repair or replace specific individual wires 3.1. Remove the cap from the end of the
within a harness. This will also apply to other disposable gas cartridge.
machines in addition to those of manufacture.
Figure 914.
To make sure that either the inclusion of an auxiliary
electrical component or a repair within a harness is
completed to an acceptable standard it is strongly A
recommended that the following tools, equipment
and procedures are always used. Note that JCB
harnesses have an Ingress Protection rating of 67
(I.P.67). B
The sheath covering of the recommended splice is A Cap

heat shrunk onto the original wire insulation. This B Gas cartridge
results in a seal and corresponding joint to IP 67
specifications. 3.2. Before assembling the gas cartridge to the
reflector element, turn the red ring to the left,
Procedure (in the direction of the minus sign marked
on the ring).
1. Cut the wire and remove the protective insulation
for a suitable distance dependent upon the size Figure 915.
of wire and splice to be used.
Special Tool: Wiring Crimp Tool (Qty.: 1)
Figure 913.
A
C Reflector element
D Red ring
3.3. Position the tube hanging down from inside
the reflector assembly into the hole at the
top of the gas cartridge. Then press the gas
A Distance for splice (check size)
33 - 196 9823/1650-1 33 - 196

12 - Harness
00 - General
cartridge up into the reflector assembly as Figure 918.

far as possible until the two elements are
clasped firmly together. An audible click will
be heard.
Figure 916.
D Red ring
3.6. Hold the heater vertically and, using a
match or cigarette lighter, light the gas as
shown. Hold the heater vertically for 1 to 2
minutes until the catalytic reaction occurs.
This is indicated when the blue flame fades
3.4. Turn the small ring so that the air holes are and the ceramic element glows red. Then
completely closed. turn the small ring until the air holes at
are completely open. The tool is ready
Figure 917. for use. Note: The fact that the sound of
liquid cannot be heard when the cartridge is
shaken does not mean it is empty. No sound
will be heard even when the cartridge is full.
Figure 919.
E Small ring
F Air holes
3.5. Turn the red ring to the right (in the direction
of the plus sign) in order to turn on the E Small ring
gas. Important: Before turning the heater F Air holes
on, make sure that the cartridge is not hotter
than the reflector element. This may occur 3.7. The heater can be used in two modes:
if the cartridge is held in the hand for a long
time. The temperature difference between 3.8. Side wings down, reflector head completely
the cartridge and the reflector element may open. In this mode the infra-red heat waves
cause long yellow flames to appear on are dominant (recommended for the light
ignition. coloured plastic splices).
33 - 197 9823/1650-1 33 - 197

12 - Harness
00 - General
Figure 920. Check (Condition)
This section describes how to use electrical

measuring devices that are used in electrical fault
finding.
Use of Multimeters
In order to obtain the maximum benefit from the
fault finding information contained in the Electrical
Section, it is important that the technician fully
understands the approach to fault finding and the
use of the recommended test equipment, in this case
a FLUKE 85 or AVO 2003 digital multimeter, or a
moving pointer analogue multimeter. The approach
is based on a fault finding check list. In tracing
G Side wings the fault from the symptoms displayed you will be
directed to make measurements using a multimeter.
3.9. Side wings up, reflector head opening These instructions are intended to cover the use of
reduced. In this mode the heating is done the recommended meters.
only by the hot gas (use for dark coloured
plastic splices). 1. Make sure that the test leads are plugged into
the correct sockets. The black test lead should
Figure 921.
be plugged into the black socket (sometimes, this
socket is also marked by a -, or E or marked as
COMMON or COM). The red test lead should be
plugged into the red socket marked with +, V or
Ω.
2. When you make a measurement, make sure that
the test probes have a good clean contact with
bare metal, free from grease, dirt, and corrosion
as these can cause a false reading.
3. When you measure a voltage, make sure that
the correct range is selected, that it is set to the
selector value equal to or greater than that you
are about to measure. e.g. If asked to measure
12 Volts, set the selector to the 12V range. If
D Red ring there is no 12V range, set the selector to the next
G Side wings range higher, 20V for instance. If the meter is set
to a range that is too low, it may be damaged.
e.g. setting to the 2V range to measure 12V.
Measuring DC Voltage
1. Select the correct range on the multimeter.
1.1. On the digital multimeter, turn the switch to
position B.
33 - 198 9823/1650-1 33 - 198

12 - Harness
00 - General
Figure 922. Fluke 85 Multimeter Figure 923. AVO 2003 Multimeter
1.2. On the AV0 meter, move the right slider

switch to position A, and the left hand slider 1.3. On an analogue meter, turn the dial to the
switch to the appropriate range. appropriate DC Volts range.
Figure 924. Typical Analogue Multimeter
2. Connect the black probe to the nearest available

suitable earth point, usually this will be the starter
motor earth, the battery negative, or the chassis.
Connect the red probe to the wire or contact from
which you are measuring the voltage.
33 - 199 9823/1650-1 33 - 199

12 - Harness
00 - General
Measuring Resistance Measuring Frequency

1. Make sure that there is no power to the part of The AVO meter and the analogue meter are not
the circuit you are about to measure. capable of measuring frequency, therefore a digital
multimeter must be used.
2. Connect one probe at one end of the component
or wire to be checked and the other probe at the 1. Insert the black plug into the COM socket on
other end. It does not matter which way round the the meter and attach the probe to the nearest
two probes are placed. suitable earth point on the chassis, for example,
the battery negative terminal.
3. Select the correct range on the multimeter.
2. Insert the red probe into socket J.
3.1. On the digital multimeter. Turn the switch to
position C and check that the W sign at the 3. Turn the selector switch to position A and
right hand side of the display window is on. depress G repeatedly until F is highlighted on the
If the F sign is on instead, press the blue top row of the display.
button G to change the reading to Ω. Touch
the meter lead probes together and press 4. Press button H once.
the REL3 key on the meter to eliminate the
lead resistance from the meter reading. 5. Touch or connect the red probe to the frequency
source to be measured. Press and hold the
3.2. On the AV0 meter, move the right hand button if an average reading is required.
slider switch to position B, and the left hand
slider switch to the appropriate Ohms (Ω) Testing a Diode or a Diode Wire
range.
3.3. On an analogue meter, move the dial to the A diode wire is a diode with male connector installed
appropriate Ohms (Ω) range. on one end and a female connector installed on the
other end. The diode is sealed in heatshrink sleeving.
Measuring Continuity To test a Diode or a Diode Wire.
1. Make sure that there is no power to the part of 1. On the digital multimeter:
the circuit you are checking for continuity.
1.1. Turn the switch to position D.
2. Connect one probe to one end of the component 1.2. Press the HOLD button and check that the
or wire to be checked and the other probe to the H sign appears at the top right hand side of
other end. It does not matter which way round the the display window.
two probes are placed.
1.3. Connect the black probe to the end of the
3. Select the correct range on the multimeter. diode with a band or to the male connector
of the diode wire. Connect the red probe
3.1. On the digital multimeter, turn the switch to the other end of the diode or diode wire.
to position C and check that the beeper If the beeper does not sound the diode or
symbol appears at the left hand side of diode wire is faulty.
the display window. If the F sign is on
instead, press the button labelled F. If there 1.4. Connect the red probe to the end of the
is continuity in the circuit, the beeper will diode marked with a band, or to the male
sound. If there is no continuity (open circuit), connector of the diode wire, the black probe
the beeper will not sound. should be connected to the other end of the
diode or diode wire. If the beeper sounds or
3.2. On the AV0 meter, move the right hand the meter does not read O.L., the diode or
slider switch to position B, and the left diode wire is faulty.
hand slider switch to position C. If there is
continuity (i.e. very low resistance) between 1.5. Press the HOLD button and check that the
two points the buzzer will sound. H sign disappears from the right hand side
of the display window.
3.3. On an analogue meter, turn the dial to
the lowest Ohms (Ω) range. If there is 2. On the AV0 meter:
continuity (i.e. very low resistance) between
two points the needle will move across fully 2.1. Move the right hand slider to position A, and
(or almost fully) to the right hand side of the the left hand slider switch to position C.
scale. 2.2. Connect the black probe to the end of the
diode marked with a band, or to the male
connector of the diode wire, the red probe
should be connected to the other end of the
33 - 200 9823/1650-1 33 - 200

12 - Harness
00 - General
diode or diode wire. If the Avo meter does

not buzz the diode is faulty.
2.3. Connect the red probe to the end of the
diode marked with a band, or to the male
connector of the diode wire, the black probe
diode or diode wire. If the Avo meter does
not read 1 the diode is faulty.
3. On an analogue meter:
3.1. Select the Ohms 1000s (1k) range, connect
the black probe to the end of the diode
marked with a band, or to the male
connector of the diode wire, the red probe
diode or diode wire. The meter should read
20-400 kΩ, if it reads more than this the
diode is faulty.
3.2. Select the Ohms 100s range, connect the
red probe to the end of the diode marked
with a band, or to the male connector of
the diode wire, the black probe should
be connected to the other end of the
diode or diode wire. The meter should read
300-400Ω, if it reads less than this the diode
is faulty.
33 - 201 9823/1650-1 33 - 201

12 - Harness
04 - Chassis
04 - Chassis
Diagram
For: 506-36 [T4i], 507-42 [T4i], 509-42 [T4i]

................................................. Page 33-202
For: 512-56 [T4i], 514-56 [T4i]
................................................. Page 33-207
(For: 506-36 [T4i], 507-42 [T4i], 509-42 [T4i])

Figure 925. 721/C9295-4 Sheet 1........................................................................................ Page 33-203
33 - 202 9823/1650-1 33 - 202

12 - Harness
04 - Chassis
Page 33-204 Figure 925. 721/C9295-4 Sheet 1 Page 33-205
33 - 203 9823/1650-1 33 - 203

12 - Harness
04 - Chassis
Page Page
33-204 33-205
Page 33-205
33 - 204 9823/1650-1 33 - 204

12 - Harness
04 - Chassis
Page Page
33-204 33-205

Page 33-204
33 - 205 9823/1650-1 33 - 205

12 - Harness
04 - Chassis
Figure 926. 721-C9295-4 Sheet 2
Item Description
C011 Transmission speed
Table 448.
sensor
Item Description C013 Rear lights
C001 Right side head light C014 Transmission connector
C002 Left side head light C015 Transmission dump
C003 Accelerator C016 Horn
C004 Engine supply C017 Reverse alarm
C005 Starter motor C018 Hydraulic isolation
C006 Stabiliser isolation valve C032 Engine pod connector
C007 Panel connector C033 Starter motor solenoid
C008 Chassis ground
C010 Fuel level sender
33 - 206 9823/1650-1 33 - 206

12 - Harness
04 - Chassis
(For: 512-56 [T4i], 514-56 [T4i])

Figure 927. Chassis Harness 721/C9296-4 sheet 1............................................................ Page 33-209
Figure 928. Chassis Harness 721/C9296-4 sheet 3............................................................ Page 33-213
Chassis Harness
33 - 207 9823/1650-1 33 - 207

Notes:
33 - 208 9823/1650-1 33 - 208

12 - Harness
04 - Chassis
Page 33-210 Figure 927. Chassis Harness

721/C9296-4 sheet 1 Page 33-211
33 - 209 9823/1650-1 33 - 209

12 - Harness
04 - Chassis
Page Page
33-210 33-211
Page 33-211
33 - 210 9823/1650-1 33 - 210

12 - Harness
04 - Chassis
Page Page
33-210 33-211

Page 33-210
33 - 211 9823/1650-1 33 - 211

12 - Harness
04 - Chassis
33 - 212 9823/1650-1 33 - 212

12 - Harness
04 - Chassis
Page 33-214 Figure 928. Chassis Harness

721/C9296-4 sheet 3 Page 33-215
33 - 213 9823/1650-1 33 - 213

12 - Harness
04 - Chassis
Page Page
33-214 33-215
Page 33-215
33 - 214 9823/1650-1 33 - 214

12 - Harness
04 - Chassis
Page Page
33-214 33-215

Page 33-214
33 - 215 9823/1650-1 33 - 215

12 - Harness
04 - Chassis
C002 Front chassis connector C003 Accelerator

C004 Engine supply C005 Starter motor connector
C007 Panel connector C008 Chassis ground
C009 45 ° Proximity switch C010 Fuel level sender
C011 Transmission speed sensor C013 Rear lights
C014 Transmission connector C015 Transmission dump
C016 Horn C017 Reverse alarm
C018 Hydraulic isolation C019 60 ° Proximity switch
C020 Right RAS (Rear Axle Stabilization) ram C021 Left RAS ram
C023 Lift arm extend proximity switch C024 Lift isolation solenoid
C025 Sway switch C026 Right stabiliser switch
C027 Left stabiliser switch C029 Stabiliser isolation valve
C032 Engine pod connector C033 Starter motor solenoid
33 - 216 9823/1650-1 33 - 216

12 - Harness
06 - Lift Arm
06 - Lift Arm
Diagram
(For: 512-56 [T4i], 514-56 [T4i])

Figure 929. Lift Arm Harness 332/D7010- Issue 1 (sheet 1 of 1)........................................ Page 33-219
33 - 217 9823/1650-1 33 - 217

Notes:
33 - 218 9823/1650-1 33 - 218

12 - Harness
06 - Lift Arm
Page 33-220 Figure 929. Lift Arm Harness

332/D7010- Issue 1 (sheet 1 of 1) Page 33-221
33 - 219 9823/1650-1 33 - 219

12 - Harness
06 - Lift Arm
Page Page
33-220 33-221
Page 33-221
33 - 220 9823/1650-1 33 - 220

12 - Harness
06 - Lift Arm
Page Page
33-220 33-221

Page 33-220
33 - 221 9823/1650-1 33 - 221

12 - Harness
06 - Lift Arm
B001 Proximity switch B002 Chassis harness connector
33 - 222 9823/1650-1 33 - 222

12 - Harness
09 - Engine
09 - Engine
Diagram
For: SH Engine ....................... Page 33-223

For: SH Engine ....................... Page 33-236
(For: SH Engine)
Figure 930. Engine Harness - 320/09653-1 (Sheet 1 of 2).................................................. Page 33-225
Figure 931. Engine Harness - 320/09653-1 (Sheet 2 of 2).................................................. Page 33-229
Figure 932. Hitch Switch Harness - 721/C9280-2 (Sheet 1 of 1)......................................... Page 33-233
33 - 223 9823/1650-1 33 - 223

Notes:
33 - 224 9823/1650-1 33 - 224

12 - Harness
09 - Engine
Page 33-226 Figure 930. Engine Harness

- 320/09653-1 (Sheet 1 of 2) Page 33-227
33 - 225 9823/1650-1 33 - 225

12 - Harness
09 - Engine
Page Page
33-226 33-227
Page 33-227
33 - 226 9823/1650-1 33 - 226

12 - Harness
09 - Engine
Page Page
33-226 33-227

Page 33-226
33 - 227 9823/1650-1 33 - 227

12 - Harness
09 - Engine
33 - 228 9823/1650-1 33 - 228

12 - Harness
09 - Engine
Page 33-230 Figure 931. Engine Harness

- 320/09653-1 (Sheet 2 of 2) Page 33-231
33 - 229 9823/1650-1 33 - 229

12 - Harness
09 - Engine
Page Page
33-230 33-231
Page 33-231
33 - 230 9823/1650-1 33 - 230

12 - Harness
09 - Engine
Page Page
33-230 33-231

Page 33-230
33 - 231 9823/1650-1 33 - 231

12 - Harness
09 - Engine
33 - 232 9823/1650-1 33 - 232

12 - Harness
09 - Engine
Page 33-234 Figure 932. Hitch Switch Harness

- 721/C9280-2 (Sheet 1 of 1) Page 33-235
33 - 233 9823/1650-1 33 - 233

12 - Harness
09 - Engine
Page Page
33-234 33-235
Page 33-235
33 - 234 9823/1650-1 33 - 234

12 - Harness
09 - Engine
Page Page
33-234 33-235

Page 33-234
33 - 235 9823/1650-1 33 - 235

12 - Harness
09 - Engine
(For: SH Engine)
Figure 933. Starter Motor Harness 721/C7691- Issue 3 (sheet 1 of 1)................................ Page 33-237
Starter Motor Harness
33 - 236 9823/1650-1 33 - 236

12 - Harness
09 - Engine
Page 33-238 Figure 933. Starter Motor Harness

721/C7691- Issue 3 (sheet 1 of 1) Page 33-239
B,· A4k
Cp
33 - 237 9823/1650-1 33 - 237

12 - Harness
09 - Engine
Page Page
33-238 33-239
B,· A4k
Cp
Page 33-239
33 - 238 9823/1650-1 33 - 238

12 - Harness
09 - Engine
Page Page
33-238 33-239

Page 33-238
33 - 239 9823/1650-1 33 - 239

12 - Harness
09 - Engine
ST01 Chassis connector ST03 Charge lead

ST04 D Terminal ST05 Charge lead
ST06 W Terminal
33 - 240 9823/1650-1 33 - 240

12 - Harness
Diagram
Figure 934. Rear Cab Harness 721/12005-2....................................................................... Page 33-243
Rear Cab Harness
33 - 241 9823/1650-1 33 - 241

Notes:
33 - 242 9823/1650-1 33 - 242

12 - Harness
Page 33-244 Figure 934. Rear Cab Harness 721/12005-2 Page 33-245
33 - 243 9823/1650-1 33 - 243

12 - Harness
Page Page
33-244 33-245
Page 33-245
33 - 244 9823/1650-1 33 - 244

12 - Harness
Page Page
33-244 33-245

Page 33-244
33 - 245 9823/1650-1 33 - 245

12 - Harness
AA Cab / panel harness connector AB Heated seat

AC Air suspension seat AD Rear wiper
AE Left hand work light AF Earth
AG Beacon AH Right hand work light
AJ Roof wiper AK1 Interior light (+ve)
AK2 Interior light (-ve) AL Park brake switch
33 - 246 9823/1650-1 33 - 246

12 - Harness
15 - Front Console
15 - Front Console
Diagram
For: 506-36 [T4i], 507-42 [T4i], 509-42 [T4i]

................................................. Page 33-247
For: 512-56 [T4i], 514-56 [T4i]
................................................. Page 33-314
(For: 506-36 [T4i], 507-42 [T4i], 509-42 [T4i])
Figure 935. Panel Harness T4i 721/C9292-4 Sheet 1......................................................... Page 33-249
Figure 938. Panel Harness- Harness Interconnections T4i 721/C92902-4 Sheet 4............. Page 33-261
Figure 939. Panel Harness- Harness Interconnections T4i 721/C9292-4 Sheet 5............... Page 33-265
Figure 940. Panel Harness- Harness Interconnections T4i 721/C9292-4 Sheet 6............... Page 33-269
Figure 941. Panel Harness T4F 721/G5990-1 Sheet 1........................................................Page 33-275
Figure 944. Panel Harness- Harness Interconnections T4F 721/G5990-1 Sheet 4............. Page 33-287
Figure 950. Panel Harness- Harness Interconnections T4F 721/G5990-1 Sheet 10........... Page 33-311
721/C9292-4 Panel Harness T4i (For Item Description
Machines up to 4th June 2017) P014 Forward high/low relay
Table 449. Key to Connectors P017 Brake lights relay
P017 Road lights relay
Item Description
P018 Engine running relay
P001 Secondary fusebox A
P018 Park brake relay
P002 Secondary fusebox B
P019 Park brake / 2WD (Two
P003 Secondary fusebox C Wheel Drive) relay
P004 Secondary fusebox D P019 Stabiliser isolation relay
P005 Neutral start relay P020 Chassis harness con-
P006 Forward drive relay nector
P006 Ignition relay 1 P023 Air conditioning switch
P008 Flasher relay +ve
P009 Ignition relay 2 P024 Air conditioning switch -
P009 Reverse drive relay ve
P010 Ignition relay 3 P025 Hazard switch
P010 Ignition relay 4 P026 Roof wiper switch
P011 Front work lights relay P027 Rear wiper switch
P011 Rear work lights relay P028 Fog light switch
P012 Transmission dump re- P029 Road lights switch
lay P030 Work lights switch
P012 Park brake warning light P032 Beacon switch
relay P034 Stabiliser isolation
P013 Drive relay switch
P013 Drive shaft relay P036 Indicator diode
P014 Reverse high/low relay P037 Heater connector
33 - 247 9823/1650-1 33 - 247

12 - Harness
15 - Front Console

P038 Heater switch P069 Washer pump
P039 Earth P071 Spare
P040 Earth P076 Front wiper motor
P041 Left hand column switch P077 Auxiliary socket
P042 Diode gate P078 Auxiliary socket illumina-
P043 Information button tion
P046 Diagnostic connector P082 Radio
P052 Centre cluster warning P088 Work lights
lights P091 Terminating resistor
P055 Right hand cluster con- P092 Engine supply
nector J1 P093 Immobiliser
P056 Right hand cluster con- P094 Immobiliser link
nector J2 P097 Hydraulic isolation
P057 Rear cab harness con- switch
nector P098 Hour meter +ve
P058 Right hand column P099 Hour meter -ve
switch
P101 RAS (Rear Axle Stabi-
P060 Ignition switch lization) interface 1
P061 Primary fuse C&D P102 RAS interface 2
P062 Primary fuse A&B P103 RAS link 1
P063 Diode gate P104 RAS link 2
P064 Primary fuse blue G&H P105 RAS left hand / right
P065 Primary fuse grey E&F hand relay
P066 Foot brake P106 Ground speed
P067 Face fan
33 - 248 9823/1650-1 33 - 248

12 - Harness
15 - Front Console
Page 33-250 Figure 935. Panel Harness

T4i 721/C9292-4 Sheet 1 Page 33-251
33 - 249 9823/1650-1 33 - 249

12 - Harness
15 - Front Console
Page Page
33-250 33-251
Page 33-251
33 - 250 9823/1650-1 33 - 250

12 - Harness
15 - Front Console
Page Page
33-250 33-251

Page 33-250
33 - 251 9823/1650-1 33 - 251

12 - Harness
15 - Front Console
33 - 252 9823/1650-1 33 - 252

12 - Harness
15 - Front Console

T4i 721/C9292-4 Sheet 2 Page 33-255
33 - 253 9823/1650-1 33 - 253

12 - Harness
15 - Front Console
Page Page
33-254 33-255
Page 33-255
33 - 254 9823/1650-1 33 - 254

12 - Harness
15 - Front Console
Page Page
33-254 33-255

Page 33-254
33 - 255 9823/1650-1 33 - 255

12 - Harness
15 - Front Console
33 - 256 9823/1650-1 33 - 256

12 - Harness
15 - Front Console

T4i 721/C9292-4 Sheet 3 Page 33-259
33 - 257 9823/1650-1 33 - 257

12 - Harness
15 - Front Console
Page Page
33-258 33-259
Page 33-259
33 - 258 9823/1650-1 33 - 258

12 - Harness
15 - Front Console
Page Page
33-258 33-259

Page 33-258
33 - 259 9823/1650-1 33 - 259

12 - Harness
15 - Front Console
33 - 260 9823/1650-1 33 - 260

12 - Harness
15 - Front Console
Page 33-262 Figure 938. Panel Harness- Harness

Interconnections T4i 721/C92902-4 Sheet 4 Page 33-263
33 - 261 9823/1650-1 33 - 261

12 - Harness
15 - Front Console
Page Page
33-262 33-263
Page 33-263
33 - 262 9823/1650-1 33 - 262

12 - Harness
15 - Front Console
Page Page
33-262 33-263

Page 33-262
33 - 263 9823/1650-1 33 - 263

12 - Harness
15 - Front Console
33 - 264 9823/1650-1 33 - 264

12 - Harness
15 - Front Console

33 - 265 9823/1650-1 33 - 265

12 - Harness
15 - Front Console
Page Page
33-266 33-267
Page 33-267
33 - 266 9823/1650-1 33 - 266

12 - Harness
15 - Front Console
Page Page
33-266 33-267

Page 33-266
33 - 267 9823/1650-1 33 - 267

12 - Harness
15 - Front Console
33 - 268 9823/1650-1 33 - 268

12 - Harness
15 - Front Console

33 - 269 9823/1650-1 33 - 269

12 - Harness
15 - Front Console
Page Page
33-270 33-271
Page 33-271
33 - 270 9823/1650-1 33 - 270

12 - Harness
15 - Front Console
Page Page
33-270 33-271

Page 33-270
33 - 271 9823/1650-1 33 - 271

12 - Harness
15 - Front Console
721/G5990-1 Panel Harness T4F (For Item Description

machines from 5th June 2017) P043 Ignition switch
Table 450. Key to Connectors P045 Fuse link box grey A/B
P046 Fuse link box blue C/D
Item Description
P047 Fuse link box grey 2 E/F
P001 Fusebox A
P048 Fuse link box blue 2 G/H
P002 Fusebox B
P049 Rear cab connector
P003 Fusebox C
P050 Foot brake switch
P004 Fusebox D
P051 Face fan
P005 Fusebox E
P053 Washer pump
P006 Ignition relay 1/2
P055 Front wiper motor
P056 Mobile phone
P057 Mobile phone illumina-
P009 Heater hose relay
tion
P010 Neutral start / Reverse
P058 Radio
alarm
P058A P058 blank
P011 Brake and repeater
lights P059 Lift arm work lights
diode
P012 Front and rear work
lights P061 Reverse fan switch
P013 Purge hold inhibit and P063 Info button
road P064A Diode
P014 Engine running and P064B Diode
livelink P065 Auxiliary connector
P015 Air condition and lift arm P065A P065 blank
work lights P066 Immobiliser
P016 Hydraulic ISO (Interna- P067 Horn relay and freeze
tional Organization for valve
Standardization)
P068 Livelink 3
P018 Joystick isolation switch
P071 Instrument cluster J1
P020 Hazard switch
P072 Instrument cluster J2
P021 Roof wiper switch
P073 Diagnostic connector
P022 Rear wash wipe switch
P074 CAN (Controller Area
P023 Fog light switch Network) term connector
P024 Head lights switch P087 100R trailer sense RES
P026 Work lights switch P093 Engine supply
P028 Beacon switch P098 Hour meter +ve
P029 Lift arm work lights P099 Hour meter -ve
switch
P030 Ground
P101 NOx (Nitrogen Oxide)
P031 Turn signal diode sensor and right side
P032 Turn signal diode WL
P033 Heater connector P102 Hose heater 2 (white)
P034 Heater control P103 1st gear 820R
P035 Ground P104 2nd gear 1K2
P036 Stabiliser isolation P105 3rd gear 1K8
switch P106 4th gear 3K3
P037 Left column switch P107 1 and 2 gear pull down
P038 Right column switch 332R
P039 Panel to chassis con- P108 3 and 4 gear pull down
nection 332R
P040 Center cluster
33 - 272 9823/1650-1 33 - 272

12 - Harness
15 - Front Console

P112 Heater 100R P136 RAS J2
P113 Livelink perm ground P137 Daily checks
P126 Italian head lights P138 Right side work lights
P127 Italian head lights (DEL) switch
P128 Front work lights diode P139 Right side work lights
diode
P129 Rear work lights diode
P140 Diode
P130 Work lights
P141 3rd / 4th gear diode
P131 5K36 resistor connector
P142 4th gear diode
P132 5K36 resistor
P143 Camera interface
P133 Speed sensor pull up
P199 Tank harness connector
P134 Park brake
P135 RAS J1
33 - 273 9823/1650-1 33 - 273

Notes:
33 - 274 9823/1650-1 33 - 274

12 - Harness
15 - Front Console

T4F 721/G5990-1 Sheet 1 Page 33-277
-P093
ENGINE SUPPLY
-P199 1 2
TANK HARNESS CONNECTOR -P066
IMMOBILISER
1 2 3 4 5 6
2 1 GREY KEY A 12 11 10 9 8 7
12 11 10 9 8 7 KEY B
-P051 1 2 3 4 5 6
540 mm
350 mm
25 mm
400 mm
20
10
8
18
12
16
14
4
6
2
-P001
A FUSE BOX A
-SCREEN 3
-P039
PANEL TO CHASSIS CONN
mm
15
11
13
17
19
1
3
5
7
9
25
20
10
8
18
12
16
14
4
6
2
-P002
B 22
0m
-VMC13:TW1#1
mm
FUSE BOX B
50
10
11
12
7
9
G
m
6
240 mm
15
11
13
17
19
m
1
50
3
5
7
9
mm
m
220
10
11
12
7
9
F
mm
6
0
20
10
8
18
12
16
14
4
6
2
-P003
C
85
40 mm 30 mm 40 mm 70 mm 70 mm 25 mm 20 mm 25 mm
10
11
12
FUSE BOX C
9
-SP19 -SP33 -SP21 -SP9 -SP73
6
35 mm
15
11
13
17
19
190 mm
1
3
5
7
9
-SVMC16
35 mm
10
11
12
7
9
D
70 mm
6
mm
30 mm
D
20
10
8
18
12
16
14
4
6
2
-P004
35 mm
190
10
11
12
7
9
C
FUSE BOX D
-SP37
6
mm
35 mm
-P108
-SVMC17
60
m
15
11
13
17
19
3&4 GEAR PULL DOWN 332R

1
3
5
7
9
0m
-SVMC18
10
11
12
7
9
B
m
-VMC11:TW1#0
100 mm
50
6
25
0m
1,2
24
-VMC13:TW1#0
-SP65
mm
0m
WITH ANTI SCOOP FEATURE

E mm
20
TAPE TO HARNESS AS
10
8
18
12
16
14
4
6
2
-P005
20
10
11
12
7
9
DESCRIBED IN STD00141
40
-VMC11:TW1#1
A
m
-VMC12:TW1
150
6
30 mm
FUSE BOX E -P107 -VMC08:TW1#0
mm
15
11
13
17
19
1
m
3
5
7
9
1,2
50 mm m 280 mm
40
mm
TAPE TO HARNESS AS
DESCRIBED IN STD00141 -SP15 -SP32
500
mm
40 mm
-P106
50
310 mm
4TH GEAR 3K3
-SP34
1,2
50
TAPE TO HARNESS AS
mm 817/17282 -SP22
50 mm
190 mm
250 mm
-P105
3RD GEAR 1K8 817/17282
-SVMC13
-SVMC14
TAPE TO HARNESS AS
1,2
50 mm -SP26
DESCRIBED IN STD00141 4 3 2 1
-SVMC15
-P142 50 mm 817/17273
90 mm
50 mm
8 7 6 5
4TH GEAR DIODE
7219/0005
817/17318
40 mm
817/17273
TAPE TO HARNESS AS
DESCRIBED IN STD00141 -P055
110 mm
m 40 mm
150 mm
3 2 1
FRONT WIPER MOTOR
-P141
m
50
4
-SP35
7 6 5
3RD/4TH GEAR DIODE 11 10 9 8

-VMC10:TW1#0
14 13 12
-SP77 2 1
TAPE TO HARNESS AS
150 mm
3
40 mm
400 mm
-P038
COLUMN SWITCH R/H -P053
WASHER PUMP
-SP78
817/17263
40 mm 750 mm -P033
50 mm -P113 M10
-VMC10:TW1#1 -SCREEN 5
817/17263
HEATER CONNECTOR
LIVE LINK PERM GROUND
-SP24
200 mm
817/17306
50 mm
-P104
40 mm
2ND GEAR 1K2 3 1
50 m
2
TAPE TO HARNESS AS
1,2
m -P065A
6 5 4
P065 BLANK
A/B
200 mm
450 mm
-P103 -P045
m AGREYB
50 m
1ST GEAR 820R 1 2
2 1
50 mm
GREY
FUSE LINK BOX GREY A/B
7219/0005
1,2
TAPE TO HARNESS AS
10 mm
-P065
817/17296
AUXILLIARY CONNECTOR
C/D 200 mm 3 2 1
-P046
7 6 5 4
ABLUEB
11 10 9 8
11
1
7219/0005
FUSE LINK BOX BLUE C/D 14 13 12
GREY 'B'
3 2 1
-P049
250 mm
6 5 4
REAR CAB CONNECTOR

7
E/F 10
20
11 10 9 8
14 13 12 -SP16
-P047 -P137
AGREYB DAILY CHECKS
FUSE LINK BOX GREY 2 E/F
-P037
COLUMN SWITCH L/H
G/H 250 mm
-P048
ABLUEB
A
FUSE LINK BOX BLUE 2 G/H
SEE SHEET 2
33 - 275 9823/1650-1 33 - 275

12 - Harness
15 - Front Console
Page Page
33-276 33-277

TANK HARNESS CONNECTOR
2 1
-P051
540 mm
20
10
18
8
12
16
14
4
6
2
-P001
A FUSE BOX A
15
13
17
11
19
1
3
5
7
9
20
10
18
8
12
16
14
4
6
2
-P002
B 22
0m
mm
FUSE BOX B
50
m
15
13
17
11
19
mm
1
50
3
5
7
9
220
m m
20
10
18
8
12
16
14
4
6
2
-P003
C FUSE BOX C
40 mm -SP19 30 mm -SP33 40 mm 70 mm -SP21 70 mm
15
13
17
11
19
190 mm
1
3
5
7
9
D mm
20
10
18
8
12
16
14
4
6
2
-P004
190
FUSE BOX D
-SP37
mm
-P108
60
m
15
13
17
11

19
1
3
5
7
9
0m
1,2
50
24
-SP65
mm
E mm
20
TAPE TO HARNESS AS
10
18
8
12
16
14
4
6
2
-P005 DESCRIBED IN STD00141
40
150
FUSE BOX E -P107
mm
15
13
17
11
19
1
m
3
5
7
9
50 mm m
1,2
40
m
TAPE TO HARNESS AS
m
500
-P106
m m
4TH GEAR 3K3
-SP34 50
1,2
50
TAPE TO HARNESS AS
mm 817/17282
50 mm
-P105
3RD GEAR 1K8 190 mm 817/17282
TAPE TO HARNESS AS
1,2
50 mm
DESCRIBED IN STD00141 4 3 2 1
-P142 50 mm 817/17273
50 mm
8 7 6 5
4TH GEAR DIODE
7219/0005
Page 33-277
817/17273
TAPE TO HARNESS AS
DESCRIBED IN STD00141 -P055
m 40 mm FRONT WIPER MOTOR
3 2 1
-P141
m
50
7 6 5 4
3RD/4TH GEAR DIODE 11 10 9 8
14 13 12
-SP77
TAPE TO HARNESS AS
40 mm -P038
COLUMN SWITCH R/H
-SP78
40 mm
50 mm -P113 M10
LIVE LINK PERM GROUND

-SP24
817/17306
-P104
40 mm
2ND GEAR 1K2
50 m
TAPE TO HARNESS AS
1,2
m -P065A
P065 BLANK
A/B
-P103 -P045
m AGREYB
50 m
1ST GEAR 820R 1 2
2 1
1,2
50 mm FUSE LINK BOX GREY A/B
TAPE TO HARNESS AS
-P065
817/17296
AUXILLIARY CONNECTOR
C/D
-P046
ABLUEB
7219/0005
FUSE LINK BOX BLUE C/D
3 2 1
7 6 5 4
E/F
11 10 9 8
14 13 12
-P047 AGREYB
-P037
COLUMN SWITCH L/H
G/H
-P048
ABLUEB
33 - 276 9823/1650-1 33 - 276

12 - Harness
15 - Front Console
Page Page
33-276 33-277
Figure 941. (Part 2 of 2) -P093

ENGINE SUPPLY
-P199 1 2
TANK HARNESS CONNECTOR -P066
IMMOBILISER
1 2 3 4 5 6
12 11 9 8 7
GREY KEY A 10
12 11 10 9 8 7 KEY B
1 2 3 4 5 6
350 mm
25 mm
400 mm
-P039
-SCREEN 3 PANEL TO CHASSIS CONN
mm
25
-VMC13:TW1#1
50
10
11
12
7
9
G
240 mm
6
m
m
m
0m
10
11
12
7
9
F
6
85
70 mm 25 mm 20 mm 25 mm
10
11
12
7
9
-SP21 -SP9 -SP73
6
35 mm
-SVMC16
35 mm
10
11
12
7
9
D
70 mm
6
30 mm
35 mm
10
11
12
7
9
C
6
35 mm
-SVMC17
-SVMC18
10
11
12
7
9
B
m
-VMC11:TW1#0
100 mm
6
25
0m
-VMC13:TW1#0
0m
WITH ANTI SCOOP FEATURE

20
10
11
12
7
9
-VMC11:TW1#1
A
m
-VMC12:TW1
6
30 mm
-VMC08:TW1#0
280 mm
-SP15 -SP32
40 mm
310 mm
-SP22
250 mm
-SVMC13
-SVMC14
-SP26 -SVMC15
90 mm
817/17318
Page 33-276
40 mm
110 mm
150 mm
-SP35 -VMC10:TW1#0
2 1
150 mm
3
400 mm
-P053
WASHER PUMP
817/17263
750 mm -P033
-VMC10:TW1#1 -SCREEN 5 HEATER CONNECTOR
817/17263
200 mm
50 mm
3 2 1
6 5 4
200 mm
450 mm
AGREYB
GREY
FUSE LINK BOX GREY A/B

7219/0005
10 mm
200 mm 7
3
6
2
5
1
ABLUEB
11 10 9 8
11
1
FUSE LINK BOX BLUE C/D 14 13 12

GREY 'B'
-P049
250 mm REAR CAB CONNECTOR
10
20
-SP16
-P137
AGREYB DAILY CHECKS
250 mm
ABLUEB
A
SEE SHEET 2
33 - 277 9823/1650-1 33 - 277

12 - Harness
15 - Front Console
33 - 278 9823/1650-1 33 - 278

12 - Harness
15 - Front Console

T4F 721/G5990-1 Sheet 2 Page 33-281
-P101 -P102 -P009 -P014 -P016 -P008 -P007 -P006
8 8 8 8 8 8 8 8
9 7 6 9 7 6 9 7 6 9 7 6 9 7 6 9 7 6 9 7 6 9 7 6
10 10 10 10 10 10 10 10
5 5 5 5 5 5 5 5
1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 -SVMC04
3 3 3 3 3 3 3 3
-SVMC05
-SVMC06 30 mm -SP79 30 mm SEE SHEET 1
A
50 mm
50 mm
50 mm
50 mm
50 mm
50 mm
50 mm
-P068
LIVELINK 3
40 mm -SP30
80 mm 30 mm 30 mm 30 mm 30 mm 30 mm 30 mm
-P064A
DIODE
25 mm
TAPE TO HARNESS AS
-P133
m
50 m
50 mm
SPEED SENSOR PULL UP
-P035 -P030
1
1 2 -P132 GROUND GROUND

2 1
10 mm
5K36 RESISTOR
M10
40 mm
50 m
TAPE TO HARNESS AS
mm
10
M
-P064B
-P131 m
40 m
2
100
50
5K36 RESISTOR CONNECTOR DIODE
mm
-SP17 TAPE TO HARNESS AS
-SP39 -SP71
40 m
-SP62 -P140
m
m
-VMC03:TW1#1
50 m
DIODE
-VMC04:TW1#1
30 mm
130 mm
50 m
-SP61
50 mm
30 mm
100 mm
m -SP63
5m
m
-P073
21
m
50 m
25 mm
DIAGNOSTIC CONNECTOR
25 mm
25 mm
25 mm
25 mm
25 mm
30 mm
30 mm
E D
C
B
25 mm 200 mm -SP20 40 mm -SP29 -SP46 50 mm -SP3 50 mm 50 mm 50 mm -SP75 -SP76 -SP23 150 mm 2 1 -P130
F
A
G
H J WORKLIGHTS
-SCREEN 1 -SVMC01 -SVMC02 -SVMC03 30 mm 50 mm 75 mm 30 mm 30 mm 30 mm 30 mm 40 mm 4 3
50 mm
-VMC02:TW1#1 -VMC01:TW1#0 -VMC03:TW1#0
-VMC02:TW1#0
50 mm
30 mm
200 mm
ID Label
1100 mm 2 1 1 2
-P058A P058 TO BE TAPED
30 mm
P058 BLANK
3 4 BACK USING
-SP14
-SP74 280 mm 4 3
TEARABLE TAPE
-VMC01:TW1#1
-P058
-VMC06:TW1#0
817/17314 RADIO
50 mm
-VMC08:TW1#1
-VMC09:TW1#0
30 mm
25 mm
-SP70 40 mm -SVMC10 -SVMC11

817/17324
-P074A
CAN TERMINATOR RESISTOR
230 mm -SP28 120 mm 50 mm
7
4
8
1
-SVMC12 5 2
30 mm 30 mm 30 mm
6
9
3
10
-P021
3 2 1
35
120 OHM 500 mm 0m ROOF WIPER SWITCH
200 mm
-P074 A B
CAN TERM
-SP10 -P050
FOOT BRAKE SWITCH -SP69
CAN TERM CONNECTOR 250
C
-P044
mm
B
75 mm
6 5
10 mm
BOOT IGNITION SWITCH

100 mm
7 400/G4318
ADAPTOR -P134 9 7 8
10
8 1
TAPE TO HARNESS AS PARK BRAKE 4
40 mm
m 320 mm 15
5 2
40 m CAP 6 3
-P128 3 2 1
0 75 -P061
mm
9 10
mm -P043
50 mm
-P067 -P013 -P012 -P010 -P015 -P011 334/F2685 3
IGNITION SWITCH REVERSE FAN SWITCH
40 m TAPE TO HARNESS AS
SEE SHEET 3
4
m DESCRIBED IN STD00141
1 2
100 mm
8 8 8 8 8 8
7 6 7 6 7 6 7 6 7 6 7 6
30 mm
9
10
9
10
9
10
9
10
9
10
9
10
-P129
5 5 5 5 5 5
1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 -P057
817/17297
3 3 3 3 3 3
MOBILE PHONE ILLUMINATION -SP5 7 8
100 mm 50 mm
100 mm
4 1
-SP2 5 2
6 3
50 mm
50 mm
50 mm
50 mm
50 mm
50 mm
9 10
-P022
30 mm
TAPE TO HARNESS AS
DESCRIBED IN STD00141 REAR WASH WIPE SWITCH
40 mm -P059
40 mm
-SP72
80 mm 30 mm 30 mm 30 mm 30 mm 60 mm 40 m
TAPE TO HARNESS AS
817/17263
m -P139 50 mm 817/17283
817/17263
50 mm 7
4
8
1
5 2
-SP68 BLACK
6 3 817/17283
1 9 10 -P018
3 2 1
50 mm 2 JOYSTICK ISOLATION SWITCH
6 5 4
-P056
40 m
40 mm
-P034
m HEATER CONTROL
mm
-SCREEN 4
80
817/17319
7 8
50 mm 4 1
5 2
60 m 6 3
m -VMC09:TW1#1
9 10
-P036
STAB ISOLATION SWITCH
40 mm
mm
30
817/17301
50 mm 7
4
8
1
5 2
6 3
9 10
-P029
24
24
1
BOOM WORKLIGHTS SWITCH

NATURAL
NATURAL
BLACK
BLACK
12
12
35
35
817/17259
-P135 -P136
90 mm
7 8
4 1
RAS J1 RAS J2
5 2
6 3 817/17259
9 10 -P138
RH SIDE WORKLIGHTS SWITCH
33 - 279 9823/1650-1 33 - 279

12 - Harness
15 - Front Console
Page Page
33-280 33-281
Figure 942. (Part 1 of 2) -P101 -P102 -P009 -P014 -P016 -P008 -P007 -P006
8 8 8 8 8 8 8 8
9 7 6 9 7 6 9 7 6 9 7 6 9 7 6 9 7 6 9 7 6 9 7 6
10 10 10 10 10 10 10 10
5 5 5 5 5 5 5 5
1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 -SVMC04
3 3 3 3 3 3 3 3
-SVMC05
-SVMC06 30 mm -SP79 30 mm
50 mm
50 mm
50 mm
50 mm
50 mm
50 mm
50 mm
-P068
LIVELINK 3
40 mm -SP30
80 mm 30 mm 30 mm 30 mm 30 mm 30 mm 30 mm
25 mm
-P133
m
50 m
50 mm
SPEED SENSOR PULL UP
-P035
1
1 2 -P132 GROUND
2 1 5K36 RESISTOR
M1
50 m
mm
0
10
m
M
-P131
100
50
5K36 RESISTOR CONNECTOR
mm
-SP39 -SP71
m
-VMC03:TW1#1
50 m
-VMC04:TW1#1
30 mm
50 m
-SP61
50 mm
100 mm
m -SP63
5m
m
-P073
21
m
50 m
25 mm
DIAGNOSTIC CONNECTOR
25 mm
25 mm
25 mm
25 mm
25 mm
30 mm
30 mm
E D
C
B
25 mm 200 mm -SP20 40 mm -SP29 -SP46 50 mm
F
A
H J
G
-SCREEN 1 -SVMC01 -SVMC02 -SVMC03 30 mm 50 mm 75 mm 30 mm 30 mm

-VMC02:TW1#1 -VMC01:TW1#0 -VMC03:TW1#0
-VMC02:TW1#0
50 mm
30 mm
200 mm
ID Label
30 mm
-VMC01:TW1#1
-SP14
817/17314
-VMC09:TW1#0
25 mm
-P074A -SP70 40 mm -SVMC10
CAN TERMINATOR RESISTOR
30 mm 30 mm
3 2 1
120 OHM 500 mm

-P074 A B
CAN TERM
-SP10 -P050
Page 33-281
FOOT BRAKE SWITCH -SP69
CAN TERM CONNECTOR
C
B
10 mm
BOOT
ADAPTOR 100 mm -P134
TAPE TO HARNESS AS
PARK BRAKE
320 mm
40 mm -P128
-P067 -P013 -P012 -P010 -P015 -P011
40 m TAPE TO HARNESS AS
SEE SHEET 3
8 8 8 8 8 8
m DESCRIBED IN STD00141
7 6 7 6 7 6 7 6 7 6 7 6
30 mm
9
10
9
10
9
10
9
10
9
10
9
10
-P129
5 5 5 5 5 5
1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4
3 3 3 3 3 3
-SP2
100 mm
50 mm
50 mm
50 mm
50 mm
50 mm
30 mm
TAPE TO HARNESS AS
40 mm -P059
-SP72
80 mm 30 mm 30 mm 30 mm 30 mm 60 mm 40 m
TAPE TO HARNESS AS
m -P139 50 mm
-SP68
50 mm
40 m
m
mm
-SCREEN 4
80
60 m
m -VMC09:TW1#1
mm
30
24
24
1
1
NATURAL
NATURAL
BLACK
BLACK
12
12
35
35
-P135 -P136
RAS J1 RAS J2
33 - 280 9823/1650-1 33 - 280

12 - Harness
15 - Front Console
Page Page
33-280 33-281
SEE SHEET 1
A
-P068
LIVELINK 3
-P064A
DIODE
TAPE TO HARNESS AS
-P030
GROUND
10 mm
M1
40 mm
TAPE TO HARNESS AS
m
0
10
M
-P064B
m
m
40 m
100
50
DIODE
mm
-SP17 TAPE TO HARNESS AS
40 m
-SP62 -P140
m
m
50 m
DIODE
130 mm
50 m
30 mm
-SP63
m
m
50 m
50 mm -SP3 50 mm 50 mm 50 mm -SP75 -SP76 -SP23 150 mm 2 1 -P130

WORKLIGHTS
30 mm 30 mm 30 mm 40 mm 4 3
50 mm
1100 mm 2 1 1 2
-P058A P058 TO BE TAPED
P058 BLANK
3 4 BACK USING
-SP74 280 mm 4 3
TEARABLE TAPE
-P058
-VMC06:TW1#0
RADIO
50 mm
-VMC08:TW1#1
-VMC09:TW1#0
30 mm 817/17324
-SVMC10 -SVMC11
230 mm -SP28 120 mm 50 mm
7
4
8
1
-SVMC12 5 2
30 mm 30 mm 30 mm
6
9
3
10
-P021
35
0m ROOF WIPER SWITCH
m
200 mm
Page 33-280
250
-P044
mm
75 mm
6 5
7 IGNITION SWITCH 400/G4318
-P134 9 7 8
10
8 1
PARK BRAKE 4
40 mm
320 mm CAP 15
5
6
2
3
3 2 1
0m 75 9 10 -P061
mm -P043
50 mm
334/F2685 m 3
4
IGNITION SWITCH REVERSE FAN SWITCH
1 2
100 mm
-P057
817/17297
MOBILE PHONE ILLUMINATION -SP5 7 8
50 mm
100 mm
4 1
5 2
6 3
50 mm
9 10
-P022
REAR WASH WIPE SWITCH
40 mm
817/17263
817/17283
817/17263
50 mm 7
4
8
1
5 2
BLACK
6 3 817/17283
1 9 10 -P018
3 2 1
2 JOYSTICK ISOLATION SWITCH
6 5 4
-P056
40 mm
0m -P034
m HEATER CONTROL
mm
80
817/17319
7 8
50 mm 4 1
5 2
6 3
9 10
-VMC09:TW1#1
-P036
STAB ISOLATION SWITCH
40 mm
mm
30
817/17301
50 mm 7
4
8
1
5 2
6 3
9 10
-P029
24
1

NATURAL
NATURAL
12
35
817/17259
-P136
90 mm
7 8
4 1
RAS J2
5 2
6 3 817/17259
9 10 -P138
RH SIDE WORKLIGHTS SWITCH
33 - 281 9823/1650-1 33 - 281

12 - Harness
15 - Front Console
33 - 282 9823/1650-1 33 - 282

12 - Harness
15 - Front Console

T4F 721/G5990-1 Sheet 3 Page 33-285
SEE SHEET 2
B
-P071 -P072
INSTRUMENT CLUSTER J1 INSTRUMENT CLUSTER J2
20
10
20
10
5 mm
GREY 'B'
-P063
INFO BUTTON
BLACK 'A'
10
-SP27
3
2
8
6
9
7
4
5
30 mm
11
11
1
1
-SP7 INFO
30 mm
-P126 -P127
ITALIAN HEAD LIGHTS ITALIAN HEAD LIGHTS (DEL)
-P028 -P026 -P023 -SP8
GREY
BEACON SWITCH WORK LIGHTS SWITCH FOG LIGHT SWITCH
1 2
2 1
817/17260 817/17258 817/17256
817/17260
817/17256
25 mm
150 mm
817/17258
50 mm
-VMC07:TW1#1
10 9 10 9 10 9
3 6 3 6 3 6
100 mm
2 5 2 5 2 5
1 4 1 4 1 4
8 7 8 7 8 7
75 mm
-SP50
-P024
40 mm
100 mm
100 mm
100 mm
HEAD LIGHTS SWITCH
50 mm
817/17257
100 mm
100 mm
80 mm
30 mm
30 mm
30 mm
30 mm
817/17257
50 mm
2
10 9 130 mm 30 mm 30 mm 40 mm -SP1 -SP12 -SP6 -SP13 100 mm 250 mm 100 mm
3 6
2 5
40 mm 40 mm 40 mm
1 4
50 mm 50 mm -SP40 -SP11 -SVMC07 -SVMC08 -SVMC09 50 mm
80 mm
8 7
1
60
mm
-VMC04:TW1#0 -VMC07:TW1#0
50 mm
-VMC06:TW1#1
mm -P112
50
100 mm
50 mm
HEATER 100R
30 100 -P143
m m m mm TAPE TO HARNESS AS CAMERA INTERFACE
30 m
30 mm
-P020
30 mm -P032 20 mm
1 2
-SP31 TURN SIGNAL DIODE 1 6

TAPE TO HARNESS AS
-P087 2 5
30 m
100R TRAILER SENSE RES 3 4
9
m
10
-P031
NO END CAP
3 6
2 5 TURN SIGNAL DIODE "CAMERA"
BLACK TEXT WHITE BACKGND
1 4
8 7
817/17277 NOTE:- RESIS TORS SHOULD BE

TAPED TO THE HARNESS
817/17277
100 mm
-P098 -P099 -P100

HOUR METER +VE HOUR METER -VE HOUR METER SIGNAL
+ - S
150 mm -SP49 50 mm
11 12 13 14 15 16 17 18 19 20
-P040
1 2 3 4 5 6 7 8 9 10 CENTER CLUSTER
33 - 283 9823/1650-1 33 - 283

12 - Harness
15 - Front Console
Page Page
33-284 33-285
Figure 943. (Part 1 of 2) SEE SHEET 2
5 mm
INFO BUTTON
-SP27
8
7
30 mm
-SP7
30 mm
-P126 -P127
ITALIAN HEAD LIGHTS ITALIAN HEAD LIGHTS (DEL)
-P028 -P026 -P023 -SP8
BEACON SWITCH WORK LIGHTS SWITCH FOG LIGHT SWITCH
1 2
2 1
817/17260 817/17258 817/17256
817/17256
817/17260
150 mm
817/17258
10 9 10 9 10 9
3 6 3 6 3 6
100 mm
2 5 2 5 2 5
1 4 1 4 1 4
8 7 8 7 8 7
-P024
40 mm
100 mm
100 mm
100 mm
HEAD LIGHTS SWITCH

817/17257
817/17257
Page 33-285
10 9 130 mm 30 mm 30 mm 40 mm -SP1 -SP12 -SP6 -SP13 100 mm 250 mm
3 6
2 5
40 mm 40 mm 40 mm
1 4
50 mm 50 mm -SP40
80 mm
8 7
100 mm
50 mm
100
mm mm
30
30
30 mm
30 mm
mm
-P020
-SP31
9 30 m
m
10
3 6
2 5
1 4
8 7
817/17277
817/17277
100 mm
-P098 -P099 -P100

HOUR METER +VE HOUR METER -VE HOUR METER SIGNAL
+ - S
150 mm -SP49
33 - 284 9823/1650-1 33 - 284

12 - Harness
15 - Front Console
Page Page
33-284 33-285
-P071 -P072
INSTRUMENT CLUSTER J1 INSTRUMENT CLUSTER J2
20
10
20
10
GREY 'B'
-P063
INFO BUTTON
BLACK 'A'
10
1
3
2
8
6
9
7
4
5
11
11
1
1
INFO
GREY
25 mm
150 mm
50 mm
-VMC07:TW1#1
75 mm
50 mm -SP50
100 mm
100 mm
80 mm
30 mm
30 mm
30 mm
30 mm
50 mm
Page 33-284
2
250 mm 100 mm
-SP40 -SP11 -SVMC07 -SVMC08 -SVMC09 50 mm

1
60
mm
-VMC04:TW1#0 -VMC07:TW1#0
50 mm
-VMC06:TW1#1
mm -P112
50
HEATER 100R
100 -P143
mm TAPE TO HARNESS AS
CAMERA INTERFACE
30 mm -P032 20 mm
1 2
TURN SIGNAL DIODE 1 6

TAPE TO HARNESS AS
-P087 2 5
30 m
100R TRAILER SENSE RES 3 4
m -P031
NO END CAP
TURN SIGNAL DIODE "CAMERA"

BLACK TEXT WHITE BACKGND
NOTE:- RESIS TORS SHOULD BE

TAPED TO THE HARNESS
150 mm -SP49 50 mm
11 12 13 14 15 16 17 18 19 20
-P040
1 2 3 4 5 6 7 8 9 10 CENTER CLUSTER
33 - 285 9823/1650-1 33 - 285

12 - Harness
15 - Front Console
33 - 286 9823/1650-1 33 - 286

12 - Harness
15 - Front Console

Interconnections T4F 721/G5990-1 Sheet 4 Page 33-289
-P001 FUSE BOX A -P004 FUSE BOX D -P008 IGNITION RELAY 5 / 6 -P013 PURGE HOLD INHIBIT&ROAD
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
1 001A 4.00 mm² YE -P044:5 -HRNS_CAB BUS BAR WITH 5 1 1 201E 4.00 mm² YE -SP15:S -HRNS_CAB 1 463 1.00 mm² YE -P039:E10 -HRNS_CAB
2 100 1.00 mm² YE -SP20:S -HRNS_CAB 2 203 2.00 mm² YE -SP68:S -HRNS_CAB 2 017E 4.00 mm² YE -P003:5 -HRNS_CAB 2
3 005A 4.00 mm² YE -P043:3 -HRNS_CAB BUS BAR WITH 5 3 3 100F 0.75 mm² YE -SP20:S -HRNS_CAB 3 100ISO 1.00 mm² YE -SP20:S -HRNS_CAB
4 004 4.00 mm² YE -P010:1 -HRNS_CAB 4 301R 1.00 mm² YE -P098:1 -HRNS_CAB 4 4 463A 1.00 mm² YE -P039:E11 -HRNS_CAB
BUS BAR WITH 7 5 5 201G 4.00 mm² YE -SP30:S -HRNS_CAB 5 601JJ 0.75 mm² YE -SP3:S -HRNS_CAB 5 600ISO 1.00 mm² YE -SP63:S -HRNS_CAB
6 121 1.00 mm² YE -P065:1 -HRNS_CAB 6 300NX 1.50 mm² YE -P101:1 -HRNS_CAB 6 202G 4.00 mm² YE -SP30:S -HRNS_CAB 6 306 2.00 mm² YE -P003:18 -HRNS_CAB
6 121CKR 1.00 mm² YE -P143:1 -HRNS_CAB BUS BAR WITH 5 7 7 011G 4.00 mm² YE -P004:15 -HRNS_CAB 7 828 2.00 mm² YE -P024:5 -HRNS_CAB
7 015B 4.00 mm² YE -P006:2 -HRNS_CAB 8 300 1.00 mm² YE -P020:5 -HRNS_CAB 8 100A 0.75 mm² YE -SP20:S -HRNS_CAB 8 100C 0.75 mm² YE -SP20:S -HRNS_CAB
8 109E 1.00 mm² YE -P018:1 -HRNS_CAB BUS BAR WITH 5 9 9 9
BUS BAR WITH 7 9 10 301E 1.00 mm² YE -SP40:S -HRNS_CAB 10 601X 0.75 mm² YE -SP3:S -HRNS_CAB 10 601RL 1.00 mm² YE -SP29:S -HRNS_CAB
10 1100 1.00 mm² YE -P199:9 -HRNS_CAB BUS BAR WITH 15 11
10 1100A 1.00 mm² YE -P101:3 -HRNS_CAB 12 311 1.50 mm² YE -P015:6 -HRNS_CAB 7241/0003 10 Way twin micro relay base 7241/0003 10 Way twin micro relay base
BUS BAR WITH 7 11 BUS BAR WITH 15 13 Additional Components Additional Components
12 107B 1.00 mm² YE -P039:D1 -HRNS_CAB 14 110LL 1.00 mm² YE -P014:6 -HRNS_CAB
BUS BAR WITH 15 13 15 011G 4.00 mm² YE -P008:7 -HRNS_CAB
-P014 ENG RUNNING&LIVE LINK
14 102 2.00 mm² YE -P033:3 -HRNS_CAB 16 500AA 2.00 mm² YE -SP73:S -HRNS_CAB -P009 HEATER HOSE RELAY
ID Tag Size Colour Destination Cable Cavity Seal
15 010B 4.00 mm² YE -P006:7 -HRNS_CAB BUS BAR WITH 15 17 ID Tag Size Colour Destination Cable Cavity Seal
1 601LH 0.75 mm² YE -SP3:S -HRNS_CAB
16 108A 1.00 mm² YE -P050:3 -HRNS_CAB 18 106SS 1.00 mm² YE -P039:D2 -HRNS_CAB 1 300HH 2.00 mm² YE -P005:18 -HRNS_CAB
16 108 1.00 mm² YE -P011:1 -HRNS_CAB 18 106 1.00 mm² YE -P071:2 -HRNS_CAB 2 8214A 2.00 mm² YE -P199:8 -HRNS_CAB
3 407F 1.00 mm² YE -SP14:S -HRNS_CAB
BUS BAR WITH 15 17 BUS BAR WITH 15 19 3 8215A 1.00 mm² YE -SP39:S -HRNS_CAB
4
18 20 Y2 1.00 mm² YE -P066:8 -HRNS_CAB 4
5 601SH 0.75 mm² YE -SP3:S -HRNS_CAB
BUS BAR WITH 15 19 20 155 1.00 mm² YE -P135:11 -HRNS_CAB 5 8216 1.00 mm² YE -P199:7 -HRNS_CAB
6 110LL 1.00 mm² YE -P004:14 -HRNS_CAB
20 104 1.00 mm² YE -P038:14 -HRNS_CAB 6 8225 1.50 mm² YE -P199:10 -HRNS_CAB
7241/0001 10 Way Sec Fusebox Housing 7 110LLA 1.00 mm² YE -P068:M2 -HRNS_CAB
7 6301A 1.50 mm² YE -SP46:S -HRNS_CAB
7241/0001 10 Way Sec Fusebox Housing Additional Components 8 100LL 1.00 mm² YE -SP20:S -HRNS_CAB
8 8215B 1.00 mm² YE -SP39:S -HRNS_CAB
Additional Components 9
7241/0002 9
10 601LL 1.00 mm² YE -SP3:S -HRNS_CAB
7241/0002 10 8217 1.00 mm² YE -P199:4 -HRNS_CAB
7241/0003 10 Way twin micro relay base
FUSE BOX B FUSE BOX E 7241/0003 10 Way twin micro relay base
-P002 -P005 Additional Components
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal Additional Components
BUS BAR WITH 3 1 1 833 2.00 mm² YE -P038:9 -HRNS_CAB
2 2 834 1.50 mm² YE -P039:D10 -HRNS_CAB -P010 NEUTRAL START / REV ALARM
-P015 AIR CON & BOOM WORKLIGHTS
3 013C 4.00 mm² YE -P007:2 -HRNS_CAB 3 836 2.00 mm² YE -P038:13 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
4 133 2.00 mm² YE -SP16:S -HRNS_CAB 4 838 2.00 mm² YE -SP19:S -HRNS_CAB 1 004 4.00 mm² YE -P001:4 -HRNS_CAB
1 997 2.00 mm² YE -P002:8 -HRNS_CAB
BUS BAR WITH 3 5 5 942D 2.00 mm² YE -SP22:S -HRNS_CAB 2 842 4.00 mm² YE -P093:2 -HRNS_CAB
2 883 2.00 mm² YE -SP10:S -HRNS_CAB
6 110 1.50 mm² YE -SP33:S -HRNS_CAB 6 829E 1.50 mm² YE -SP7:S -HRNS_CAB 3 100NS 1.00 mm² YE -P136:6 -HRNS_CAB
3 884AC 1.00 mm² YE -P071:3 -HRNS_CAB
7 012C 4.00 mm² YE -P007:7 -HRNS_CAB 7 942E 2.00 mm² YE -SP22:S -HRNS_CAB 4
4
8 997 2.00 mm² YE -P015:1 -HRNS_CAB 8 830 0.75 mm² YE -P039:E2 -HRNS_CAB 5 601NS 1.00 mm² YE -SP29:S -HRNS_CAB
5 601AC 1.00 mm² YE -SP29:S -HRNS_CAB
BUS BAR WITH 7 9 9 832B 1.00 mm² YE -SP21:S -HRNS_CAB 6 109RA 1.50 mm² YE -P003:2 -HRNS_CAB
6 311 1.50 mm² YE -P004:12 -HRNS_CAB
10 119 1.50 mm² YE -P056:2 -HRNS_CAB 10 905 1.00 mm² YE -P023:2 -HRNS_CAB 7 807A 1.50 mm² YE -P039:C7 -HRNS_CAB
BUS BAR WITH 15 11 11 601LG 1.00 mm² YE -P113:1 -HRNS_CAB 7 807RCB 1.00 mm² YE -P143:3 -HRNS_CAB
8 891C 1.00 mm² YE -SP2:S -HRNS_CAB
12 300RDM 1.00 mm² YE -P137:1 -HRNS_CAB 12 601L 1.00 mm² YE -SP79:S -HRNS_CAB 8 807 1.00 mm² YE -P135:27 -HRNS_CAB
9
BUS BAR WITH 15 13 13 014 4.00 mm² YE -P044:6 -HRNS_CAB 9
10 610B 0.75 mm² YE -P059:1 -HRNS_CAB
14 308 2.00 mm² YE -P012:1 -HRNS_CAB 14 151B 2.00 mm² YE -P051:1 -HRNS_CAB 10 601RA 1.00 mm² YE -SP29:S -HRNS_CAB
15 200D 4.00 mm² YE -P046:B -HRNS_CAB 14 151 2.00 mm² YE -P049:7 -HRNS_CAB 7241/0003 10 Way twin micro relay base
16 310 1.00 mm² YE -P028:2 -HRNS_CAB BUS BAR WITH 17 15 7241/0003 10 Way twin micro relay base
Additional Components
BUS BAR WITH 15 17 16 3100A 2.00 mm² YE -P199:1 -HRNS_CAB Additional Components
18 301 1.00 mm² YE -SP27:S -HRNS_CAB 17 202E 4.00 mm² YE -SP15:S -HRNS_CAB
-P011 BRAKE & REPEATER LIGHTS -P016 HYDRAULIC ISO
BUS BAR WITH 15 19 18 300HH 2.00 mm² YE -P009:1 -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
1 108 1.00 mm² YE -P001:16 -HRNS_CAB 1 600BK 1.00 mm² YE -SP71:S -HRNS_CAB
20
7241/0001 10 Way Sec Fusebox Housing 2 2
Additional Components 7241/0001 10 Way Sec Fusebox Housing 3 815 1.00 mm² YE -P050:1 -HRNS_CAB 3 559 1.00 mm² YE -P135:25 -HRNS_CAB
Additional Components 4 816 1.00 mm² YE -P039:A7 -HRNS_CAB 4 600BJ 1.00 mm² YE -P039:A5 -HRNS_CAB
7241/0002
5 616B 0.75 mm² YE -SP29:S -HRNS_CAB 5 600BL 1.00 mm² YE -SP71:S -HRNS_CAB
7241/0002
6 6 600BM 1.50 mm² YE -SP71:S -HRNS_CAB
-P003 FUSE BOX C -P006 IGNITION RELAY 1 /2
7 7
8 804D 2.00 mm² YE -SP49:S -HRNS_CAB 8 560 1.00 mm² YE -P135:26 -HRNS_CAB
BUS BAR WITH 5 1 1 200B 4.00 mm² YE -SP35:S -HRNS_CAB
9 9 603D 1.50 mm² YE -P039:C2 -HRNS_CAB
2 109RA 1.50 mm² YE -P010:6 -HRNS_CAB 2 015B 4.00 mm² YE -P001:7 -HRNS_CAB
10 601SY 0.75 mm² YE -SP3:S -HRNS_CAB 10 600BP 1.00 mm² YE -SP71:S -HRNS_CAB
BUS BAR WITH 5 3 3 100J 0.75 mm² YE -SP20:S -HRNS_CAB
4 100RDM 1.00 mm² YE -P137:8 -HRNS_CAB 4 7241/0003 10 Way twin micro relay base 7241/0003 10 Way twin micro relay base
5 017E 4.00 mm² YE -P008:2 -HRNS_CAB 5 601HB 0.75 mm² YE -SP3:S -HRNS_CAB Additional Components Additional Components
6 100WBL 1.00 mm² YE -P039:G3 -HRNS_CAB 6 203B 4.00 mm² YE -SP35:S -HRNS_CAB
7241/0004;1 # Bottom Mount Bracket for Relay Housings
BUS BAR WITH 5 7 7 010B 4.00 mm² YE -P001:15 -HRNS_CAB
8 181 1.00 mm² YE -P058:1 -HRNS_CAB 8 100B 0.75 mm² YE -SP20:S -HRNS_CAB -P012 FRONT & REAR WORKLIGHTS -P018 JOYSTICK ISOLATION SWITCH
BUS BAR WITH 5 9 9 ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
10 109CS 1.00 mm² YE -SP65:S -HRNS_CAB 10 601EK 0.75 mm² YE -SP3:S -HRNS_CAB 1 308 2.00 mm² YE -P002:14 -HRNS_CAB 1 109E 1.00 mm² YE -P001:8 -HRNS_CAB
BUS BAR WITH 15 11 2 831 2.00 mm² YE -SP23:S -HRNS_CAB 2 1900 1.00 mm² YE -P039:F10 -HRNS_CAB
12 299LL 1.00 mm² YE -P068:M4 -HRNS_CAB 7241/0003 10 Way twin micro relay base 3 891B 1.00 mm² YE -SP2:S -HRNS_CAB 3
BUS BAR WITH 15 13 Additional Components 4 4
14 309 2.00 mm² YE -P012:6 -HRNS_CAB 7241/0004;1 # Bottom Mount Bracket for Relay Housings 5 609A 0.75 mm² YE -P128:1 -HRNS_CAB 5
15 200F 4.00 mm² YE -P047:A -HRNS_CAB 6 309 2.00 mm² YE -P003:14 -HRNS_CAB 6
16 307 2.00 mm² YE -P024:2 -HRNS_CAB 7 945 2.00 mm² YE -P049:6 -HRNS_CAB 7 601EN 1.00 mm² YE -SP28:S -HRNS_CAB
-P007 IGNITION RELAY 3 / 4
BUS BAR WITH 15 17 8 100QB 1.00 mm² YE -P126:2 -HRNS_CAB 8 829Y 1.00 mm² YE -SP7:S -HRNS_CAB
18 306 2.00 mm² YE -P013:6 -HRNS_CAB 8 891A 1.00 mm² YE -SP2:S -HRNS_CAB 9
BUS BAR WITH 15 19 9 10
2 013C 4.00 mm² YE -P002:3 -HRNS_CAB
20 304 2.00 mm² YE -SP37:S -HRNS_CAB 10 609B 0.75 mm² YE -P129:1 -HRNS_CAB
3 100H 0.75 mm² YE -SP20:S -HRNS_CAB 7219/0013 10 Way 6.3 Fastin Switch Hsg
7241/0001 10 Way Sec Fusebox Housing 4 7241/0003 10 Way twin micro relay base Additional Components
Additional Components 5 601HL 0.75 mm² YE -SP3:S -HRNS_CAB Additional Components
7241/0002
7 012C 4.00 mm² YE -P002:7 -HRNS_CAB
8 100G 0.75 mm² YE -SP20:S -HRNS_CAB
9
10 601HK 0.75 mm² YE -SP3:S -HRNS_CAB

33 - 287 9823/1650-1 33 - 287

12 - Harness
15 - Front Console
Page Page
33-288 33-289
Figure 944.
-P001(Part 1 ofFUSE
2) BOX A -P004 FUSE BOX D
1 001A 4.00 mm² YE -P044:5 -HRNS_CAB BUS BAR WITH 5 1
2 100 1.00 mm² YE -SP20:S -HRNS_CAB 2 203 2.00 mm² YE -SP68:S -HRNS_CAB
3 005A 4.00 mm² YE -P043:3 -HRNS_CAB BUS BAR WITH 5 3
4 004 4.00 mm² YE -P010:1 -HRNS_CAB 4 301R 1.00 mm² YE -P098:1 -HRNS_CAB
BUS BAR WITH 7 5 5 201G 4.00 mm² YE -SP30:S -HRNS_CAB
6 121 1.00 mm² YE -P065:1 -HRNS_CAB 6 300NX 1.50 mm² YE -P101:1 -HRNS_CAB
6 121CKR 1.00 mm² YE -P143:1 -HRNS_CAB BUS BAR WITH 5 7
7 015B 4.00 mm² YE -P006:2 -HRNS_CAB 8 300 1.00 mm² YE -P020:5 -HRNS_CAB
8 109E 1.00 mm² YE -P018:1 -HRNS_CAB BUS BAR WITH 5 9
BUS BAR WITH 7 9 10 301E 1.00 mm² YE -SP40:S -HRNS_CAB
10 1100A 1.00 mm² YE -P101:3 -HRNS_CAB 12 311 1.50 mm² YE -P015:6 -HRNS_CAB
BUS BAR WITH 7 11 BUS BAR WITH 15 13
12 107B 1.00 mm² YE -P039:D1 -HRNS_CAB 14 110LL 1.00 mm² YE -P014:6 -HRNS_CAB
BUS BAR WITH 15 13 15 011G 4.00 mm² YE -P008:7 -HRNS_CAB
14 102 2.00 mm² YE -P033:3 -HRNS_CAB 16 500AA 2.00 mm² YE -SP73:S -HRNS_CAB
15 010B 4.00 mm² YE -P006:7 -HRNS_CAB BUS BAR WITH 15 17
16 108A 1.00 mm² YE -P050:3 -HRNS_CAB 18 106SS 1.00 mm² YE -P039:D2 -HRNS_CAB
BUS BAR WITH 15 17 BUS BAR WITH 15 19
18 20 Y2 1.00 mm² YE -P066:8 -HRNS_CAB
20 104 1.00 mm² YE -P038:14 -HRNS_CAB
7241/0001 10 Way Sec Fusebox Housing
7241/0001 10 Way Sec Fusebox Housing Additional Components
Additional Components 7241/0002
7241/0002
-P002 FUSE BOX B -P005 FUSE BOX E

2 2 834 1.50 mm² YE -P039:D10 -HRNS_CAB
3 013C 4.00 mm² YE -P007:2 -HRNS_CAB 3 836 2.00 mm² YE -P038:13 -HRNS_CAB
4 133 2.00 mm² YE -SP16:S -HRNS_CAB 4 838 2.00 mm² YE -SP19:S -HRNS_CAB
BUS BAR WITH 3 5 5 942D 2.00 mm² YE -SP22:S -HRNS_CAB
7 012C 4.00 mm² YE -P007:7 -HRNS_CAB 7 942E 2.00 mm² YE -SP22:S -HRNS_CAB
8 997 2.00 mm² YE -P015:1 -HRNS_CAB 8 830 0.75 mm² YE -P039:E2 -HRNS_CAB
BUS BAR WITH 15 11 11 601LG 1.00 mm² YE -P113:1 -HRNS_CAB
12 300RDM 1.00 mm² YE -P137:1 -HRNS_CAB 12 601L 1.00 mm² YE -SP79:S -HRNS_CAB
14 308 2.00 mm² YE -P012:1 -HRNS_CAB 14 151B 2.00 mm² YE -P051:1 -HRNS_CAB
Page 33-289
15 200D 4.00 mm² YE -P046:B -HRNS_CAB 14 151 2.00 mm² YE -P049:7 -HRNS_CAB
BUS BAR WITH 15 17 16 3100A 2.00 mm² YE -P199:1 -HRNS_CAB
BUS BAR WITH 15 19 18 300HH 2.00 mm² YE -P009:1 -HRNS_CAB
20
7241/0001 10 Way Sec Fusebox Housing
Additional Components 7241/0001 10 Way Sec Fusebox Housing
7241/0002 Additional Components
7241/0002
-P003 FUSE BOX C -P006 IGNITION RELAY 1 /2
2 109RA 1.50 mm² YE -P010:6 -HRNS_CAB 2 015B 4.00 mm² YE -P001:7 -HRNS_CAB
BUS BAR WITH 5 3 3 100J 0.75 mm² YE -SP20:S -HRNS_CAB
4 100RDM 1.00 mm² YE -P137:8 -HRNS_CAB 4
5 017E 4.00 mm² YE -P008:2 -HRNS_CAB 5 601HB 0.75 mm² YE -SP3:S -HRNS_CAB
6 100WBL 1.00 mm² YE -P039:G3 -HRNS_CAB 6 203B 4.00 mm² YE -SP35:S -HRNS_CAB
BUS BAR WITH 5 7 7 010B 4.00 mm² YE -P001:15 -HRNS_CAB
8 181 1.00 mm² YE -P058:1 -HRNS_CAB 8 100B 0.75 mm² YE -SP20:S -HRNS_CAB
BUS BAR WITH 5 9 9
10 109CS 1.00 mm² YE -SP65:S -HRNS_CAB 10 601EK 0.75 mm² YE -SP3:S -HRNS_CAB
BUS BAR WITH 15 11
12 299LL 1.00 mm² YE -P068:M4 -HRNS_CAB 7241/0003 10 Way twin micro relay base
BUS BAR WITH 15 13 Additional Components
14 309 2.00 mm² YE -P012:6 -HRNS_CAB 7241/0004;1 # Bottom Mount Bracket for Relay Housings
15 200F 4.00 mm² YE -P047:A -HRNS_CAB
16 307 2.00 mm² YE -P024:2 -HRNS_CAB
-P007 IGNITION RELAY 3 / 4
BUS BAR WITH 15 17
18 306 2.00 mm² YE -P013:6 -HRNS_CAB
BUS BAR WITH 15 19
2 013C 4.00 mm² YE -P002:3 -HRNS_CAB
20 304 2.00 mm² YE -SP37:S -HRNS_CAB
3 100H 0.75 mm² YE -SP20:S -HRNS_CAB
7241/0001 10 Way Sec Fusebox Housing 4
Additional Components 5 601HL 0.75 mm² YE -SP3:S -HRNS_CAB
7241/0002
7 012C 4.00 mm² YE -P002:7 -HRNS_CAB
8 100G 0.75 mm² YE -SP20:S -HRNS_CAB
9
10 601HK 0.75 mm² YE -SP3:S -HRNS_CAB

33 - 288 9823/1650-1 33 - 288

12 - Harness
15 - Front Console
Page Page
33-288 33-289
Figure 944. (Part

-P008 2 of 2) IGNITION RELAY 5 / 6 -P013 PURGE HOLD INHIBIT&ROAD
Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
1 201E 4.00 mm² YE -SP15:S -HRNS_CAB 1 463 1.00 mm² YE -P039:E10 -HRNS_CAB
-HRNS_CAB 2 017E 4.00 mm² YE -P003:5 -HRNS_CAB 2
3 100F 0.75 mm² YE -SP20:S -HRNS_CAB 3 100ISO 1.00 mm² YE -SP20:S -HRNS_CAB
-HRNS_CAB 4 4 463A 1.00 mm² YE -P039:E11 -HRNS_CAB
-HRNS_CAB 5 601JJ 0.75 mm² YE -SP3:S -HRNS_CAB 5 600ISO 1.00 mm² YE -SP63:S -HRNS_CAB
-HRNS_CAB 6 202G 4.00 mm² YE -SP30:S -HRNS_CAB 6 306 2.00 mm² YE -P003:18 -HRNS_CAB
7 011G 4.00 mm² YE -P004:15 -HRNS_CAB 7 828 2.00 mm² YE -P024:5 -HRNS_CAB
-HRNS_CAB 8 100A 0.75 mm² YE -SP20:S -HRNS_CAB 8 100C 0.75 mm² YE -SP20:S -HRNS_CAB
9 9
-HRNS_CAB 10 601X 0.75 mm² YE -SP3:S -HRNS_CAB 10 601RL 1.00 mm² YE -SP29:S -HRNS_CAB
-HRNS_CAB 7241/0003 10 Way twin micro relay base 7241/0003 10 Way twin micro relay base
Additional Components Additional Components
-HRNS_CAB
-HRNS_CAB
-P014 ENG RUNNING&LIVE LINK
-HRNS_CAB -P009 HEATER HOSE RELAY
-HRNS_CAB 1 300HH 2.00 mm² YE -P005:18 -HRNS_CAB
-HRNS_CAB 2 8214A 2.00 mm² YE -P199:8 -HRNS_CAB
4
-HRNS_CAB 4
5 601SH 0.75 mm² YE -SP3:S -HRNS_CAB
-HRNS_CAB 5 8216 1.00 mm² YE -P199:7 -HRNS_CAB
6 110LL 1.00 mm² YE -P004:14 -HRNS_CAB
6 8225 1.50 mm² YE -P199:10 -HRNS_CAB
7 110LLA 1.00 mm² YE -P068:M2 -HRNS_CAB
9
9
10 8217 1.00 mm² YE -P199:4 -HRNS_CAB
Cable Cavity Seal Additional Components
-HRNS_CAB
-HRNS_CAB -P010 NEUTRAL START / REV ALARM
-P015 AIR CON & BOOM WORKLIGHTS
-HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
1 997 2.00 mm² YE -P002:8 -HRNS_CAB
-HRNS_CAB 3 100NS 1.00 mm² YE -P136:6 -HRNS_CAB
3 884AC 1.00 mm² YE -P071:3 -HRNS_CAB
-HRNS_CAB 4
4
-HRNS_CAB 5 601NS 1.00 mm² YE -SP29:S -HRNS_CAB
5 601AC 1.00 mm² YE -SP29:S -HRNS_CAB
-HRNS_CAB 6 109RA 1.50 mm² YE -P003:2 -HRNS_CAB
6 311 1.50 mm² YE -P004:12 -HRNS_CAB
-HRNS_CAB 7 807A 1.50 mm² YE -P039:C7 -HRNS_CAB
-HRNS_CAB 7 807RCB 1.00 mm² YE -P143:3 -HRNS_CAB
9
-HRNS_CAB 9
10 610B 0.75 mm² YE -P059:1 -HRNS_CAB
-HRNS_CAB 10 601RA 1.00 mm² YE -SP29:S -HRNS_CAB
Page 33-288
-HRNS_CAB 7241/0003 10 Way twin micro relay base

-HRNS_CAB Additional Components
-HRNS_CAB
-P011 BRAKE & REPEATER LIGHTS -P016 HYDRAULIC ISO
-HRNS_CAB
1 108 1.00 mm² YE -P001:16 -HRNS_CAB 1 600BK 1.00 mm² YE -SP71:S -HRNS_CAB
2 2
4 816 1.00 mm² YE -P039:A7 -HRNS_CAB 4 600BJ 1.00 mm² YE -P039:A5 -HRNS_CAB
5 616B 0.75 mm² YE -SP29:S -HRNS_CAB 5 600BL 1.00 mm² YE -SP71:S -HRNS_CAB
6 6 600BM 1.50 mm² YE -SP71:S -HRNS_CAB
7 7
Cable Cavity Seal
8 804D 2.00 mm² YE -SP49:S -HRNS_CAB 8 560 1.00 mm² YE -P135:26 -HRNS_CAB
-HRNS_CAB
9 9 603D 1.50 mm² YE -P039:C2 -HRNS_CAB
-HRNS_CAB
10 601SY 0.75 mm² YE -SP3:S -HRNS_CAB 10 600BP 1.00 mm² YE -SP71:S -HRNS_CAB
-HRNS_CAB
7241/0003 10 Way twin micro relay base 7241/0003 10 Way twin micro relay base
-HRNS_CAB Additional Components Additional Components
-HRNS_CAB
7241/0004;1 # Bottom Mount Bracket for Relay Housings
-HRNS_CAB
-HRNS_CAB -P012 FRONT & REAR WORKLIGHTS -P018 JOYSTICK ISOLATION SWITCH
-HRNS_CAB 1 308 2.00 mm² YE -P002:14 -HRNS_CAB 1 109E 1.00 mm² YE -P001:8 -HRNS_CAB
2 831 2.00 mm² YE -SP23:S -HRNS_CAB 2 1900 1.00 mm² YE -P039:F10 -HRNS_CAB
3 891B 1.00 mm² YE -SP2:S -HRNS_CAB 3
4 4
5 609A 0.75 mm² YE -P128:1 -HRNS_CAB 5
6 309 2.00 mm² YE -P003:14 -HRNS_CAB 6
7 945 2.00 mm² YE -P049:6 -HRNS_CAB 7 601EN 1.00 mm² YE -SP28:S -HRNS_CAB
8 100QB 1.00 mm² YE -P126:2 -HRNS_CAB 8 829Y 1.00 mm² YE -SP7:S -HRNS_CAB
Cable Cavity Seal
8 891A 1.00 mm² YE -SP2:S -HRNS_CAB 9
-HRNS_CAB
9 10
-HRNS_CAB
10 609B 0.75 mm² YE -P129:1 -HRNS_CAB
-HRNS_CAB 7219/0013 10 Way 6.3 Fastin Switch Hsg
7241/0003 10 Way twin micro relay base Additional Components
-HRNS_CAB Additional Components
-HRNS_CAB
-HRNS_CAB
-HRNS_CAB
-HRNS_CAB
33 - 289 9823/1650-1 33 - 289

12 - Harness
15 - Front Console
33 - 290 9823/1650-1 33 - 290

12 - Harness
15 - Front Console

-P020 HAZARD SWITCH -P039 PANEL TO CHASSIS CONN -P028 BEACON SWITCH -P035 GROUND
1 A1 530 1.00 mm² YE -P135:31 -HRNS_CAB 1 1 600AA 10.00 mm² YE -SP61:S -HRNS_CAB
2 804A 2.00 mm² YE -SP49:S -HRNS_CAB A2 531 1.00 mm² YE -P135:19 -HRNS_CAB 2 310 1.00 mm² YE -P002:16 -HRNS_CAB
3 804E 1.00 mm² YE -P020:8 -HRNS_CAB A3 456 1.00 mm² YE -P135:28 -HRNS_CAB 3 844A 1.00 mm² YE -P049:8 -HRNS_CAB 7207/1510 Ring Terminal M10 6.0-10.0
4 A4 947A 1.50 mm² YE -SP75:S -HRNS_CAB 4 Additional Components
5 300 1.00 mm² YE -P004:8 -HRNS_CAB A5 600BJ 1.00 mm² YE -P016:4 -HRNS_CAB 5 7000/3212 ; 45
6 509A 0.75 mm² YE -P071:13 -HRNS_CAB A6 910 1.00 mm² YE -P136:5 -HRNS_CAB 6
7 601AD 0.75 mm² YE -SP11:S -HRNS_CAB A7 816 1.00 mm² YE -P011:4 -HRNS_CAB 7 601AY 1.00 mm² YE -SP6:S -HRNS_CAB
-P036 STAB ISOLATION SWITCH
8 804E 1.00 mm² YE -P020:3 -HRNS_CAB A8 1850 1.00 mm² YE -P136:15 -HRNS_CAB 8 829U 1.00 mm² YE -SP7:S -HRNS_CAB
9 A9 1851 1.00 mm² YE -P136:14 -HRNS_CAB 9
1 908A 1.00 mm² YE -P136:21 -HRNS_CAB
10 A10 1840 1.00 mm² YE -P071:12 -HRNS_CAB 10
2 500N 1.00 mm² YE -SP73:S -HRNS_CAB
A11 838B 2.00 mm² YE -SP19:S -HRNS_CAB
7219/0013 10 Way 6.3 Fastin Switch Hsg 7219/0013 10 Way 6.3 Fastin Switch Hsg 3
A12 884A 2.00 mm² YE -P067:7 -HRNS_CAB
Additional Components Additional Components 4
B1 858 1.00 mm² YE -P136:7 -HRNS_CAB
5
B2 857 1.00 mm² YE -P136:8 -HRNS_CAB
-P021 ROOF WIPER SWITCH -P029 BOOM WORKLIGHTS SWITCH 6
B3 1852 1.00 mm² YE -P136:31 -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal 7 601DZ 1.00 mm² YE -SP11:S -HRNS_CAB
B4 1853 1.00 mm² YE -P136:19 -HRNS_CAB
1 854 2.00 mm² YE -P049:2 -HRNS_CAB 1 8 829AX 1.00 mm² YE -SP7:S -HRNS_CAB
B5 407 1.00 mm² YE -SP14:S -HRNS_CAB
2 849 2.00 mm² YE -P049:3 -HRNS_CAB 2 610D 0.75 mm² YE -SP1:S -HRNS_CAB 9
B6 408 1.00 mm² YE -P072:11 -HRNS_CAB
3 133E 2.00 mm² YE -SP16:S -HRNS_CAB 3 610AC 0.75 mm² YE -SP74:S -HRNS_CAB 10
B7 402 1.00 mm² YE -P072:1 -HRNS_CAB
4 4
B8 512 1.00 mm² YE -P136:26 -HRNS_CAB 7219/0013 10 Way 6.3 Fastin Switch Hsg
5 5
B9 100TT 1.00 mm² YE -P072:12 -HRNS_CAB Additional Components
6 901 2.00 mm² YE -SP17:S -HRNS_CAB 6
B10 405 0.50 mm² YE -P040:17 -HRNS_CAB
7 601BH 1.00 mm² YE -SP28:S -HRNS_CAB 7 601KA 1.00 mm² YE -SP6:S -HRNS_CAB
B11 513 1.00 mm² YE -P136:3 -HRNS_CAB
8 829M 1.00 mm² YE -SP7:S -HRNS_CAB 8 829AJ 1.00 mm² YE -SP7:S -HRNS_CAB
B12 859 1.00 mm² YE -P135:24 -HRNS_CAB -P037 COLUMN SWITCH L/H
9 9
C1 412 1.00 mm² YE -P072:7 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
10 10
C2 603D 1.50 mm² YE -P016:9 -HRNS_CAB 1 7210/0001
7219/0013 10 Way 6.3 Fastin Switch Hsg C3 699C 1.00 mm² YE -SP70:S -HRNS_CAB 7219/0013 10 Way 6.3 Fastin Switch Hsg 2 7210/0001
Additional Components C4 811 1.00 mm² YE -P136:11 -HRNS_CAB Additional Components 3 7210/0001
C5 860 1.00 mm² YE -P136:10 -HRNS_CAB 4 416F 1.00 mm² YE -P135:10 -HRNS_CAB
C6 812 1.00 mm² YE -P135:13 -HRNS_CAB -P030 GROUND 5 873 1.00 mm² YE -SP78:S -HRNS_CAB
-P022 REAR WASH WIPE SWITCH
C7 807A 1.50 mm² YE -P010:7 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal 6 416N 1.00 mm² YE -P135:21 -HRNS_CAB
C8 7210/0205 1 600 10.00 mm² YE -SP62:S -HRNS_CAB 7 109CS1 1.00 mm² YE -SP65:S -HRNS_CAB
1 926 2.00 mm² YE -P049:4 -HRNS_CAB
C9 620 1.50 mm² YE -P136:1 -HRNS_CAB 8 814RLY 1.00 mm² YE -P067:3 -HRNS_CAB
2 925 2.00 mm² YE -P049:5 -HRNS_CAB 7207/1510 Ring Terminal M10 6.0-10.0
C10 CAN 12 SCR 0.50 mm² ?01? -SVMC18:S -VMC12 9 872 1.00 mm² YE -P104:1 -HRNS_CAB
3 133C 2.00 mm² YE -SP16:S -HRNS_CAB Additional Components
C11 CAN 12 H 0.50 mm² YE -SVMC16:S -VMC12 10 416R 1.00 mm² YE -P135:9 -HRNS_CAB
4
C12 CAN 12 L 0.50 mm² GN -SVMC17:S -VMC12 7000/3212 ; 45 11 304B 2.00 mm² YE -SP37:S -HRNS_CAB
5
D1 107B 1.00 mm² YE -P001:12 -HRNS_CAB -P031 TURN SIGNAL DIODE 12 871 1.00 mm² YE -P103:1 -HRNS_CAB
D2 106SS 1.00 mm² YE -P004:18 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal 13 874 1.00 mm² YE -SP77:S -HRNS_CAB
7 601DX 1.00 mm² YE -SP28:S -HRNS_CAB
D3 806C 2.00 mm² YE -SP9:S -HRNS_CAB 1 805B 2.00 mm² YE -SP8:S -HRNS_CAB 14 109CS2 1.00 mm² YE -SP65:S -HRNS_CAB
8 829AF 1.00 mm² YE -SP7:S -HRNS_CAB
D4 805D 2.00 mm² YE -SP8:S -HRNS_CAB 2 804 2.00 mm² YE -SP49:S -HRNS_CAB
9 7219/0005 14 Way HW090 Socket Housing
D5 7210/0205
10 7514/0006 BUTT DIODE ASSY 6A 1000V Additional Components
D6 1854 1.00 mm² YE -P136:32 -HRNS_CAB
D7 1855 1.00 mm² YE -P136:20 -HRNS_CAB Additional Components 7219/0007
7219/0013 10 Way 6.3 Fastin Switch Hsg
D8 410 1.00 mm² YE -P136:18 -HRNS_CAB 7000/3212 ; 65
D9 481 1.00 mm² YE -P136:30 -HRNS_CAB 332/C5617
332/C5617 -P038 COLUMN SWITCH R/H
D10 834 1.50 mm² YE -P005:2 -HRNS_CAB
-P023 FOG LIGHT SWITCH 7000/3212 ; 50 ID Tag Size Colour Destination Cable Cavity Seal
D11 829A 1.00 mm² YE -SP7:S -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal 1 110E 1.50 mm² YE -SP33:S -HRNS_CAB
D12 856 1.00 mm² YE -P136:27 -HRNS_CAB
1 -P032 TURN SIGNAL DIODE 2 982 1.50 mm² YE -P055:3 -HRNS_CAB
E1 521 1.00 mm² YE -P136:2 -HRNS_CAB
2 905 1.00 mm² YE -P005:10 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal 3 983 1.50 mm² YE -P055:4 -HRNS_CAB
E2 830 0.75 mm² YE -P005:8 -HRNS_CAB
3 941 1.00 mm² YE -SP31:S -HRNS_CAB 1 806B 2.00 mm² YE -SP9:S -HRNS_CAB 4 304A 2.00 mm² YE -SP37:S -HRNS_CAB
E3 510 1.00 mm² YE -P136:29 -HRNS_CAB
4 2 804C 2.00 mm² YE -SP49:S -HRNS_CAB 5 7210/0001
E4 581 1.00 mm² YE -P135:22 -HRNS_CAB
5 6 839 1.50 mm² YE -SP32:S -HRNS_CAB
E5 941B 1.00 mm² YE -SP31:S -HRNS_CAB 7514/0006 BUTT DIODE ASSY 6A 1000V
6 7 840 1.50 mm² YE -P055:2 -HRNS_CAB
E6 514 1.00 mm² YE -P136:23 -HRNS_CAB Additional Components
7 601DC 1.00 mm² YE -SP6:S -HRNS_CAB 8 832A 2.00 mm² YE -SP21:S -HRNS_CAB
E7 614 1.00 mm² YE -P135:35 -HRNS_CAB
8 829AE 1.00 mm² YE -SP7:S -HRNS_CAB 7000/3212 ; 65 9 833 2.00 mm² YE -P005:1 -HRNS_CAB
E8 509 1.00 mm² YE -P136:25 -HRNS_CAB 332/C5617
9 10 800R 0.75 mm² YE -P072:4 -HRNS_CAB
E9 814 2.00 mm² YE -P067:2 -HRNS_CAB 332/C5617
10 11 800L 0.75 mm² YE -P071:17 -HRNS_CAB
E10 463 1.00 mm² YE -P013:1 -HRNS_CAB 7000/3212 ; 50 12 841 1.50 mm² YE -P055:5 -HRNS_CAB
7219/0013 10 Way 6.3 Fastin Switch Hsg E11 463A 1.00 mm² YE -P013:4 -HRNS_CAB
13 836 2.00 mm² YE -P005:3 -HRNS_CAB
Additional Components E12 630 1.50 mm² YE -P136:24 -HRNS_CAB -P033 HEATER CONNECTOR
14 104 1.00 mm² YE -P001:20 -HRNS_CAB
F1 515 1.00 mm² YE -P136:12 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
F2 615 1.00 mm² YE -P135:12 -HRNS_CAB 1 600T 2.00 mm² YE -SP63:S -HRNS_CAB 7219/0005 14 Way HW090 Socket Housing
-P024 HEAD LIGHTS SWITCH
F3 480A 1.00 mm² YE -P136:33 -HRNS_CAB 2 801 1.00 mm² YE -SP50:S -HRNS_CAB Additional Components
F4 500A 1.00 mm² YE -SP73:S -HRNS_CAB 3 102 2.00 mm² YE -P001:14 -HRNS_CAB
1 7219/0007
F5 593 1.00 mm² YE -P072:8 -HRNS_CAB 4 883A 2.00 mm² YE -SP10:S -HRNS_CAB
2 307 2.00 mm² YE -P003:16 -HRNS_CAB
F6 592 1.00 mm² YE -P072:19 -HRNS_CAB 5 884 2.00 mm² YE -P067:8 -HRNS_CAB
F7 506 1.00 mm² YE -P135:8 -HRNS_CAB 6
F8 7210/0205
5 828 2.00 mm² YE -P013:7 -HRNS_CAB 7236/0007 6 Way .250 Female Housing
F9 480 1.00 mm² YE -SP72:S -HRNS_CAB
6 832 2.00 mm² YE -SP21:S -HRNS_CAB Additional Components
F10 1900 1.00 mm² YE -P018:2 -HRNS_CAB
7 601BF 0.75 mm² YE -SP6:S -HRNS_CAB
F11 507 1.00 mm² YE -P136:13 -HRNS_CAB
8 100D 0.75 mm² YE -SP20:S -HRNS_CAB -P034 HEATER CONTROL
F12 1870 1.00 mm² YE -P136:4 -HRNS_CAB
9 ID Tag Size Colour Destination Cable Cavity Seal
G1 419E 1.00 mm² YE -P137:5 -HRNS_CAB
10 1 7210/0205
G2 420CL 1.00 mm² YE -P137:6 -HRNS_CAB
2 828HC 1.00 mm² YE -SP7:S -HRNS_CAB
7219/0013 10 Way 6.3 Fastin Switch Hsg G3 100WBL 1.00 mm² YE -P003:6 -HRNS_CAB
3 887A 1.00 mm² YE -P072:5 -HRNS_CAB
Additional Components G4 421WBL 1.00 mm² YE -P137:7 -HRNS_CAB
G5 948A 1.50 mm² YE -SP76:S -HRNS_CAB
5 610 1.00 mm² YE -P071:15 -HRNS_CAB
-P026 WORK LIGHTS SWITCH G6 502 1.00 mm² YE -P135:1 -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal G7 503 1.00 mm² YE -P136:9 -HRNS_CAB
1 G8 7210/0205 7216/0043 6 WAY MX150 SOCKET HOUSING
2 609RH1 0.75 mm² YE -SP1:S -HRNS_CAB G9 7210/0205 Additional Components
3 609AC 0.75 mm² YE -SP12:S -HRNS_CAB G10 7210/0205
4 G11 7210/0205
5 609RH 0.75 mm² YE -SP1:S -HRNS_CAB G12 7210/0205
6 609BC 0.50 mm² YE -SP13:S -HRNS_CAB
7 601AE 1.00 mm² YE -SP6:S -HRNS_CAB 7219/0282 84 Way SRC2 Male hsg anti scoop
8 829J 1.00 mm² YE -SP7:S -HRNS_CAB Additional Components
9
10

33 - 291 9823/1650-1 33 - 291

12 - Harness
15 - Front Console
Page Page
33-292 33-293
Figure 945. (Part

-P020 1SWITCH
HAZARD of 2) -P039 PANEL TO CHASSIS CONN -P028
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal ID Tag
1 A1 530 1.00 mm² YE -P135:31 -HRNS_CAB 1
2 804A 2.00 mm² YE -SP49:S -HRNS_CAB A2 531 1.00 mm² YE -P135:19 -HRNS_CAB 2 310
3 804E 1.00 mm² YE -P020:8 -HRNS_CAB A3 456 1.00 mm² YE -P135:28 -HRNS_CAB 3 844A
4 A4 947A 1.50 mm² YE -SP75:S -HRNS_CAB 4
5 300 1.00 mm² YE -P004:8 -HRNS_CAB A5 600BJ 1.00 mm² YE -P016:4 -HRNS_CAB 5
6 509A 0.75 mm² YE -P071:13 -HRNS_CAB A6 910 1.00 mm² YE -P136:5 -HRNS_CAB 6
7 601AD 0.75 mm² YE -SP11:S -HRNS_CAB A7 816 1.00 mm² YE -P011:4 -HRNS_CAB 7 601AY
8 804E 1.00 mm² YE -P020:3 -HRNS_CAB A8 1850 1.00 mm² YE -P136:15 -HRNS_CAB 8 829U
9 A9 1851 1.00 mm² YE -P136:14 -HRNS_CAB 9
10 A10 1840 1.00 mm² YE -P071:12 -HRNS_CAB 10
A11 838B 2.00 mm² YE -SP19:S -HRNS_CAB
7219/0013 10 Way 6.3 Fastin Switch Hsg A12 884A 2.00 mm² YE -P067:7 -HRNS_CAB 7219/0013
Additional Components B1 858 1.00 mm² YE -P136:7 -HRNS_CAB Additional Components
B2 857 1.00 mm² YE -P136:8 -HRNS_CAB
-P021 ROOF WIPER SWITCH -P029
B3 1852 1.00 mm² YE -P136:31 -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal ID Tag
B4 1853 1.00 mm² YE -P136:19 -HRNS_CAB
1 854 2.00 mm² YE -P049:2 -HRNS_CAB 1
B5 407 1.00 mm² YE -SP14:S -HRNS_CAB
2 849 2.00 mm² YE -P049:3 -HRNS_CAB 2 610D
B6 408 1.00 mm² YE -P072:11 -HRNS_CAB
3 133E 2.00 mm² YE -SP16:S -HRNS_CAB 3 610AC
B7 402 1.00 mm² YE -P072:1 -HRNS_CAB
4 4
B8 512 1.00 mm² YE -P136:26 -HRNS_CAB
5 5
B9 100TT 1.00 mm² YE -P072:12 -HRNS_CAB
6 901 2.00 mm² YE -SP17:S -HRNS_CAB 6
B10 405 0.50 mm² YE -P040:17 -HRNS_CAB
7 601BH 1.00 mm² YE -SP28:S -HRNS_CAB 7 601KA
B11 513 1.00 mm² YE -P136:3 -HRNS_CAB
8 829M 1.00 mm² YE -SP7:S -HRNS_CAB 8 829AJ
B12 859 1.00 mm² YE -P135:24 -HRNS_CAB
9 9
C1 412 1.00 mm² YE -P072:7 -HRNS_CAB
10 10
C2 603D 1.50 mm² YE -P016:9 -HRNS_CAB
7219/0013 10 Way 6.3 Fastin Switch Hsg C3 699C 1.00 mm² YE -SP70:S -HRNS_CAB 7219/0013
Additional Components C4 811 1.00 mm² YE -P136:11 -HRNS_CAB Additional Components
C5 860 1.00 mm² YE -P136:10 -HRNS_CAB
REAR WASH WIPE SWITCH

C6 812 1.00 mm² YE -P135:13 -HRNS_CAB -P030
-P022 C7 807A 1.50 mm² YE -P010:7 -HRNS_CAB ID Tag
C8 7210/0205 1 600
1 926 2.00 mm² YE -P049:4 -HRNS_CAB
C9 620 1.50 mm² YE -P136:1 -HRNS_CAB
2 925 2.00 mm² YE -P049:5 -HRNS_CAB 7207/1510
C10 CAN 12 SCR 0.50 mm² ?01? -SVMC18:S -VMC12
3 133C 2.00 mm² YE -SP16:S -HRNS_CAB Additional Components
C11 CAN 12 H 0.50 mm² YE -SVMC16:S -VMC12
4
C12 CAN 12 L 0.50 mm² GN -SVMC17:S -VMC12 7000/3212 ; 45
5
D1 107B 1.00 mm² YE -P001:12 -HRNS_CAB -P031
D2 106SS 1.00 mm² YE -P004:18 -HRNS_CAB ID Tag
7 601DX 1.00 mm² YE -SP28:S -HRNS_CAB
D3 806C 2.00 mm² YE -SP9:S -HRNS_CAB 1 805B
8 829AF 1.00 mm² YE -SP7:S -HRNS_CAB
D4 805D 2.00 mm² YE -SP8:S -HRNS_CAB 2 804
9
D5 7210/0205
10 7514/0006
D6 1854 1.00 mm² YE -P136:32 -HRNS_CAB
D7 1855 1.00 mm² YE -P136:20 -HRNS_CAB Additional Components
D8 410 1.00 mm² YE -P136:18 -HRNS_CAB 7000/3212 ; 65
Page 33-293
D9 481 1.00 mm² YE -P136:30 -HRNS_CAB 332/C5617
D10 834 1.50 mm² YE -P005:2 -HRNS_CAB 332/C5617
-P023 FOG LIGHT SWITCH 7000/3212 ; 50
D11 829A 1.00 mm² YE -SP7:S -HRNS_CAB
D12 856 1.00 mm² YE -P136:27 -HRNS_CAB
1
E1 521 1.00 mm² YE -P136:2 -HRNS_CAB
-P032
2 905 1.00 mm² YE -P005:10 -HRNS_CAB ID Tag
E2 830 0.75 mm² YE -P005:8 -HRNS_CAB
3 941 1.00 mm² YE -SP31:S -HRNS_CAB 1 806B
E3 510 1.00 mm² YE -P136:29 -HRNS_CAB
4 2 804C
E4 581 1.00 mm² YE -P135:22 -HRNS_CAB
5
E5 941B 1.00 mm² YE -SP31:S -HRNS_CAB 7514/0006
6
E6 514 1.00 mm² YE -P136:23 -HRNS_CAB Additional Components
7 601DC 1.00 mm² YE -SP6:S -HRNS_CAB
E7 614 1.00 mm² YE -P135:35 -HRNS_CAB
8 829AE 1.00 mm² YE -SP7:S -HRNS_CAB 7000/3212 ; 65
E8 509 1.00 mm² YE -P136:25 -HRNS_CAB 332/C5617
9
E9 814 2.00 mm² YE -P067:2 -HRNS_CAB 332/C5617
10
E10 463 1.00 mm² YE -P013:1 -HRNS_CAB 7000/3212 ; 50
7219/0013 10 Way 6.3 Fastin Switch Hsg E11 463A 1.00 mm² YE -P013:4 -HRNS_CAB
Additional Components E12 630 1.50 mm² YE -P136:24 -HRNS_CAB -P033
F1 515 1.00 mm² YE -P136:12 -HRNS_CAB ID Tag
F2 615 1.00 mm² YE -P135:12 -HRNS_CAB 1 600T
-P024 HEAD LIGHTS SWITCH
F3 480A 1.00 mm² YE -P136:33 -HRNS_CAB 2 801
F4 500A 1.00 mm² YE -SP73:S -HRNS_CAB 3 102
1
F5 593 1.00 mm² YE -P072:8 -HRNS_CAB 4 883A
2 307 2.00 mm² YE -P003:16 -HRNS_CAB
F6 592 1.00 mm² YE -P072:19 -HRNS_CAB 5 884
F7 506 1.00 mm² YE -P135:8 -HRNS_CAB 6
F8 7210/0205
5 828 2.00 mm² YE -P013:7 -HRNS_CAB 7236/0007
F9 480 1.00 mm² YE -SP72:S -HRNS_CAB
F10 1900 1.00 mm² YE -P018:2 -HRNS_CAB
7 601BF 0.75 mm² YE -SP6:S -HRNS_CAB
F11 507 1.00 mm² YE -P136:13 -HRNS_CAB
8 100D 0.75 mm² YE -SP20:S -HRNS_CAB
F12 1870 1.00 mm² YE -P136:4 -HRNS_CAB
-P034
9 ID Tag
G1 419E 1.00 mm² YE -P137:5 -HRNS_CAB
10 1
G2 420CL 1.00 mm² YE -P137:6 -HRNS_CAB
2 828HC
7219/0013 10 Way 6.3 Fastin Switch Hsg G3 100WBL 1.00 mm² YE -P003:6 -HRNS_CAB
3 887A
Additional Components G4 421WBL 1.00 mm² YE -P137:7 -HRNS_CAB
4 997A
G5 948A 1.50 mm² YE -SP76:S -HRNS_CAB
5 610
-P026 WORK LIGHTS SWITCH G6 502 1.00 mm² YE -P135:1 -HRNS_CAB
6 997B
ID Tag Size Colour Destination Cable Cavity Seal G7 503 1.00 mm² YE -P136:9 -HRNS_CAB
1 G8 7210/0205 7216/0043
2 609RH1 0.75 mm² YE -SP1:S -HRNS_CAB G9 7210/0205 Additional Components
3 609AC 0.75 mm² YE -SP12:S -HRNS_CAB G10 7210/0205
4 G11 7210/0205
5 609RH 0.75 mm² YE -SP1:S -HRNS_CAB G12 7210/0205
6 609BC 0.50 mm² YE -SP13:S -HRNS_CAB
7 601AE 1.00 mm² YE -SP6:S -HRNS_CAB 7219/0282 84 Way SRC2 Male hsg anti scoop
8 829J 1.00 mm² YE -SP7:S -HRNS_CAB Additional Components
9
10

33 - 292 9823/1650-1 33 - 292

12 - Harness
15 - Front Console
Page Page
33-292 33-293
Figure 945. (Part 2BEACON

-P028 of 2) SWITCH -P035 GROUND
Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
1 1 600AA 10.00 mm² YE -SP61:S -HRNS_CAB
2 310 1.00 mm² YE -P002:16 -HRNS_CAB
3 844A 1.00 mm² YE -P049:8 -HRNS_CAB 7207/1510 Ring Terminal M10 6.0-10.0
4 Additional Components
5 7000/3212 ; 45
6
7 601AY 1.00 mm² YE -SP6:S -HRNS_CAB
-P036 STAB ISOLATION SWITCH
8 829U 1.00 mm² YE -SP7:S -HRNS_CAB
9
1 908A 1.00 mm² YE -P136:21 -HRNS_CAB
10
2 500N 1.00 mm² YE -SP73:S -HRNS_CAB
7219/0013 10 Way 6.3 Fastin Switch Hsg 3
5
-P029 BOOM WORKLIGHTS SWITCH 6
ID Tag Size Colour Destination Cable Cavity Seal 7 601DZ 1.00 mm² YE -SP11:S -HRNS_CAB
1 8 829AX 1.00 mm² YE -SP7:S -HRNS_CAB
2 610D 0.75 mm² YE -SP1:S -HRNS_CAB 9
3 610AC 0.75 mm² YE -SP74:S -HRNS_CAB 10
4
5 7219/0013 10 Way 6.3 Fastin Switch Hsg
7 601KA 1.00 mm² YE -SP6:S -HRNS_CAB
8 829AJ 1.00 mm² YE -SP7:S -HRNS_CAB
-P037 COLUMN SWITCH L/H
9
10
1 7210/0001
7219/0013 10 Way 6.3 Fastin Switch Hsg 2 7210/0001
Additional Components 3 7210/0001
4 416F 1.00 mm² YE -P135:10 -HRNS_CAB
-P030 GROUND 5 873 1.00 mm² YE -SP78:S -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal 6 416N 1.00 mm² YE -P135:21 -HRNS_CAB
7210/0205 1 600 10.00 mm² YE -SP62:S -HRNS_CAB 7 109CS1 1.00 mm² YE -SP65:S -HRNS_CAB
8 814RLY 1.00 mm² YE -P067:3 -HRNS_CAB
7207/1510 Ring Terminal M10 6.0-10.0 9 872 1.00 mm² YE -P104:1 -HRNS_CAB
Additional Components 10 416R 1.00 mm² YE -P135:9 -HRNS_CAB
7000/3212 ; 45 11 304B 2.00 mm² YE -SP37:S -HRNS_CAB
-P031 TURN SIGNAL DIODE 12 871 1.00 mm² YE -P103:1 -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal 13 874 1.00 mm² YE -SP77:S -HRNS_CAB
1 805B 2.00 mm² YE -SP8:S -HRNS_CAB 14 109CS2 1.00 mm² YE -SP65:S -HRNS_CAB
7210/0205 7219/0005 14 Way HW090 Socket Housing
7514/0006 BUTT DIODE ASSY 6A 1000V Additional Components
7000/3212 ; 65
Page 33-292
332/C5617
332/C5617 -P038 COLUMN SWITCH R/H
7000/3212 ; 50 ID Tag Size Colour Destination Cable Cavity Seal
1 110E 1.50 mm² YE -SP33:S -HRNS_CAB
-P032 TURN SIGNAL DIODE 2 982 1.50 mm² YE -P055:3 -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal 3 983 1.50 mm² YE -P055:4 -HRNS_CAB
1 806B 2.00 mm² YE -SP9:S -HRNS_CAB 4 304A 2.00 mm² YE -SP37:S -HRNS_CAB
2 804C 2.00 mm² YE -SP49:S -HRNS_CAB 5 7210/0001
7514/0006 BUTT DIODE ASSY 6A 1000V 7 840 1.50 mm² YE -P055:2 -HRNS_CAB
Additional Components 8 832A 2.00 mm² YE -SP21:S -HRNS_CAB
7000/3212 ; 65 9 833 2.00 mm² YE -P005:1 -HRNS_CAB
332/C5617 10 800R 0.75 mm² YE -P072:4 -HRNS_CAB
332/C5617 11 800L 0.75 mm² YE -P071:17 -HRNS_CAB
7000/3212 ; 50 12 841 1.50 mm² YE -P055:5 -HRNS_CAB
13 836 2.00 mm² YE -P005:3 -HRNS_CAB
-P033 HEATER CONNECTOR
14 104 1.00 mm² YE -P001:20 -HRNS_CAB
1 600T 2.00 mm² YE -SP63:S -HRNS_CAB 7219/0005 14 Way HW090 Socket Housing
3 102 2.00 mm² YE -P001:14 -HRNS_CAB
7219/0007
5 884 2.00 mm² YE -P067:8 -HRNS_CAB
6
7210/0205
7236/0007 6 Way .250 Female Housing
-P034 HEATER CONTROL

1 7210/0205
2 828HC 1.00 mm² YE -SP7:S -HRNS_CAB
3 887A 1.00 mm² YE -P072:5 -HRNS_CAB
5 610 1.00 mm² YE -P071:15 -HRNS_CAB
7210/0205 7216/0043 6 WAY MX150 SOCKET HOUSING

7210/0205
7210/0205
7210/0205
33 - 293 9823/1650-1 33 - 293

12 - Harness
15 - Front Console
33 - 294 9823/1650-1 33 - 294

12 - Harness
15 - Front Console

-P040 CENTER CLUSTER -P050 FOOT BRAKE SWITCH -P063 INFO BUTTON -P067 HORN RELAY & FREEZE VALVE
1 829WL 0.50 mm² YE -SP7:S -HRNS_CAB 1 815 1.00 mm² YE -P011:3 -HRNS_CAB 1 1 304C 1.00 mm² YE -SP37:S -HRNS_CAB
2 838A 0.50 mm² YE -SP19:S -HRNS_CAB 2 7210/0052 2 100K 0.75 mm² YE -SP20:S -HRNS_CAB 2 814 2.00 mm² YE -P039:E9 -HRNS_CAB
3 804B 0.50 mm² YE -SP49:S -HRNS_CAB 3 108A 1.00 mm² YE -P001:16 -HRNS_CAB 3 2910 0.75 mm² YE -P072:3 -HRNS_CAB 3 814RLY 1.00 mm² YE -P037:8 -HRNS_CAB
4 4 4
5 7213/0034 3 Way DTM06 Socket Housing 5 5 699HR 1.00 mm² YE -SP28:S -HRNS_CAB
6 609BB 0.50 mm² YE -SP13:S -HRNS_CAB Additional Components 6 6 883B 2.00 mm² YE -SP10:S -HRNS_CAB
7 609AB 0.50 mm² YE -SP12:S -HRNS_CAB 7213/0035 7 601HP 1.00 mm² YE -SP11:S -HRNS_CAB 7 884A 2.00 mm² YE -P039:A12 -HRNS_CAB
8 610AB 0.50 mm² YE -SP74:S -HRNS_CAB 8 829AH 1.00 mm² YE -SP7:S -HRNS_CAB 8 884 2.00 mm² YE -P033:5 -HRNS_CAB
9 -P051 FACE FAN 9 9
10 601P 0.50 mm² YE -SP6:S -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal 10 10 601FV 1.00 mm² YE -SP29:S -HRNS_CAB
11 941A 0.50 mm² YE -SP31:S -HRNS_CAB 1 151B 2.00 mm² YE -P005:14 -HRNS_CAB
12 2 601DD 2.00 mm² YE -SP63:S -HRNS_CAB 7219/0013 10 Way 6.3 Fastin Switch Hsg 7241/0003 10 Way twin micro relay base
13 Additional Components Additional Components
14 7212/0052 2 Way DT06 Socket Housing
Additional Components DIODE LIVELINK 3
15 -P064A -P068
16 7212/0031;1 # 2 Way DT06 Wedge ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
17 405 0.50 mm² YE -P039:B10 -HRNS_CAB 332/E0988;1 # Deutsch DT04 2 Way Blanking Cap 1 831J 2.00 mm² YE -SP23:S -HRNS_CAB A1 7210/0239
18 2 942A 2.00 mm² YE -SP22:S -HRNS_CAB A2 7210/0239
19 -P053 WASHER PUMP A3 7210/0239
20 106C 0.50 mm² YE -SP20:S -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal 7514/0006 BUTT DIODE ASSY 6A 1000V A4 7210/0239
1 901A 2.00 mm² YE -SP17:S -HRNS_CAB Additional Components B1 7210/0239
7239/0032 20 Way Micro Fit Fem Hsg 2 839A 1.50 mm² YE -SP32:S -HRNS_CAB 7000/3212 ; 65 B2 7210/0239
Additional Components 3 601JG 2.00 mm² YE -SP63:S -HRNS_CAB 332/C5617 B3 7210/0239
332/C5617 B4 7210/0239
IGNITION SWITCH 7213/0005 3 Way HW090 Socket Housing 7000/3212 ; 50
-P043 C1 7210/0239
ID Tag Size Colour Destination Cable Cavity Seal Additional Components C2 7210/0239
7213/0007 -P064B DIODE
1 200A 4.00 mm² YE -P045:B -HRNS_CAB C3 7210/0239
2 C4 7210/0239
3 005A 4.00 mm² YE -P001:3 -HRNS_CAB -P055 FRONT WIPER MOTOR D1 7210/0239
4 ID Tag Size Colour Destination Cable Cavity Seal D2 7210/0239
1 600P 2.00 mm² YE -SP61:S -HRNS_CAB 7514/0006 BUTT DIODE ASSY 6A 1000V D3 7210/0239
7234/0003 4 WAY IGN SWT FEM HSG 2 840 1.50 mm² YE -P038:7 -HRNS_CAB D4 CAN5 H 0.75 mm² YE -SVMC04:S -HRNS_CAB
Additional Components 3 982 1.50 mm² YE -P038:2 -HRNS_CAB E1 7210/0239
7000/3212 ; 65
4 983 1.50 mm² YE -P038:3 -HRNS_CAB 332/C5617 E2 7210/0239
-P044 IGNITION SWITCH 5 841 1.50 mm² YE -P038:12 -HRNS_CAB 332/C5617 E3 7210/0239
ID Tag Size Colour Destination Cable Cavity Seal 6 110D 1.50 mm² YE -SP33:S -HRNS_CAB 7000/3212 ; 50 E4 CAN5 L 0.75 mm² YE -SVMC05:S -HRNS_CAB
5 001A 4.00 mm² YE -P001:1 -HRNS_CAB 7 839B 1.50 mm² YE -SP32:S -HRNS_CAB F1 7210/0239
6 014 4.00 mm² YE -P005:13 -HRNS_CAB 8 7210/0001 -P065 AUXILLIARY CONNECTOR F2 7210/0239
7 ID Tag Size Colour Destination Cable Cavity Seal F3 7210/0239
8 7218/0001 8 Way HW090 Socket Housing 1 121 1.00 mm² YE -P001:6 -HRNS_CAB F4 7210/0239
9 Additional Components 2 601KC 1.00 mm² YE -SP28:S -HRNS_CAB G1 7210/0239
10 7218/0003 G2 7210/0239
7212/0001 2 Way HW090 Socket Housing G3 7210/0239
7236/0003 6 WAY IGN SWT FEM HSG MOBILE PHONE Additional Components
-P056 G4 7210/0239
Additional Components ID Tag Size Colour Destination Cable Cavity Seal 7212/0003 H1 7210/0239
1 601AS 1.50 mm² YE -SP61:S -HRNS_CAB H2 7210/0239
-P045 FUSE LINK BOX GREY A/B 2 119 1.50 mm² YE -P002:10 -HRNS_CAB -P065A P065 BLANK H3 7210/0239
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal H4 7210/0239
A 202B 4.00 mm² YE -SP35:S -HRNS_CAB 7232/0028 2 Way Pos Lock Housing T Type 1 7210/0001 J1 LINK1 0.75 mm² YE -P068:K1 -HRNS_CAB
B 200A 4.00 mm² YE -P043:1 -HRNS_CAB Additional Components 2 7210/0001 J2 7210/0239
J3 7210/0239
7232/0009 2 Way Fem Hsg Pri Fuse Grey 7212/0002 2 Way HW090 Pin Housing J4 7210/0239
Additional Components -P057 MOBILE PHONE ILLUMINATION Additional Components K1 LINK1 0.75 mm² YE -P068:J1 -HRNS_CAB
7212/0004;1 # 2 Way HW090 Pin Retainer K2 7210/0239
1 829AK 1.00 mm² YE -SP7:S -HRNS_CAB
-P046 FUSE LINK BOX BLUE C/D K3 7210/0239
ID Tag Size Colour Destination Cable Cavity Seal 7201/0403 1 Way Pos Lock Housing Straight -P058A P058 BLANK K4 7210/0239
A 200C 4.00 mm² YE -SP26:S -HRNS_CAB Additional Components ID Tag Size Colour Destination Cable Cavity Seal L1 7210/0240
B 200D 4.00 mm² YE -P002:15 -HRNS_CAB 1 7210/0001 L2 600LL 1.00 mm² YE -SP63:S -HRNS_CAB
2 7210/0001 L3 601LA 1.00 mm² YE -SP79:S -HRNS_CAB
7232/0008 2 Way Fem Hsg Pri Fuse Blue -P058 RADIO
3 7210/0001 L4 7210/0240
Additional Components ID Tag Size Colour Destination Cable Cavity Seal
4 7210/0001 M1 7210/0240
1 181 1.00 mm² YE -P003:8 -HRNS_CAB
M2 110LLA 1.00 mm² YE -P014:7 -HRNS_CAB
-P047 FUSE LINK BOX GREY 2 E/F 2 301F 1.00 mm² YE -SP27:S -HRNS_CAB 7214/0002 4 Way HW090 Pin Housing M3 601LB 1.00 mm² YE -SP79:S -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal 3 829AM 1.00 mm² YE -SP7:S -HRNS_CAB Additional Components M4 299LL 1.00 mm² YE -P003:12 -HRNS_CAB
A 200F 4.00 mm² YE -P003:15 -HRNS_CAB 4 601RD 1.00 mm² YE -SP3:S -HRNS_CAB
7214/0004;1 # 4 Way DT04 Wedge
B 200E 4.00 mm² YE -SP15:S -HRNS_CAB 7219/0285 48W CMC Mat sealed fem hsg right
7214/0001 4 Way HW090 Socket Housing IMMOBILISER
-P066 Additional Components
7232/0009 2 Way Fem Hsg Pri Fuse Grey Additional Components ID Tag Size Colour Destination Cable Cavity Seal
7243/0453;1 # Cover for 48 and 28 CMC fem conn
Additional Components 7214/0003 1 7210/0052
2 7210/0052
-P048 FUSE LINK BOX BLUE 2 G/H -P059 BOOM WORKLIGHTS DIODE
3 7210/0052
4 7210/0052
A 200G 4.00 mm² YE -SP30:S -HRNS_CAB 1 610B 0.75 mm² YE -P015:10 -HRNS_CAB
5 7210/0052
B 319 4.00 mm² YE -P093:1 -HRNS_CAB 2 610A 0.75 mm² YE -SP74:S -HRNS_CAB
6 7210/0052
7232/0008 2 Way Fem Hsg Pri Fuse Blue 7514/0006 BUTT DIODE ASSY 6A 1000V 7 Y1 1.00 mm² YE -SP27:S -HRNS_CAB
Additional Components Additional Components 8 Y2 1.00 mm² YE -P004:20 -HRNS_CAB
9 CAN 13 H 0.50 mm² YE -SVMC16:S -VMC13
7000/3212 ; 65
-P049 REAR CAB CONNECTOR 332/C5617 10 CAN 13 L 0.50 mm² GN -SVMC17:S -VMC13
ID Tag Size Colour Destination Cable Cavity Seal 332/C5617 11 Y3 1.00 mm² YE -SP6:S -HRNS_CAB
1 133B 2.00 mm² YE -SP16:S -HRNS_CAB 7000/3212 ; 50 12 7210/0052
2 854 2.00 mm² YE -P021:1 -HRNS_CAB
REVERSE FAN SWITCH 7219/0019 12 Way DTM06 Socket Housing Key B
3 849 2.00 mm² YE -P021:2 -HRNS_CAB -P061
4 926 2.00 mm² YE -P022:1 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal Additional Components
5 925 2.00 mm² YE -P022:2 -HRNS_CAB 1 7219/0024
6 945 2.00 mm² YE -P012:7 -HRNS_CAB 2 100P 1.00 mm² YE -SP20:S -HRNS_CAB
7 151 2.00 mm² YE -P005:14 -HRNS_CAB 3 1840D 1.00 mm² YE -P071:18 -HRNS_CAB
8 844A 1.00 mm² YE -P028:3 -HRNS_CAB 4
9 301J 1.00 mm² YE -SP27:S -HRNS_CAB 5 100PA 1.00 mm² YE -SP20:S -HRNS_CAB
10 500S 1.00 mm² YE -SP73:S -HRNS_CAB 6 1840C 1.00 mm² YE -P072:6 -HRNS_CAB
11 847SS 1.00 mm² YE -P136:16 -HRNS_CAB 7 601AL 1.00 mm² YE -SP11:S -HRNS_CAB
13 7210/0001 9
14 7210/0001 10
7219/0005 14 Way HW090 Socket Housing 7219/0013 10 Way 6.3 Fastin Switch Hsg
7219/0007
V1.1 30/06/2016
33 - 295 9823/1650-1 33 - 295

12 - Harness
15 - Front Console
Page Page
33-296 33-297
Figure 946. (Part

-P040 CENTER 1 of 2)
CLUSTER -P050 FOOT BRAKE SWITCH -P063 INFO BUTTON
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size
1 829WL 0.50 mm² YE -SP7:S -HRNS_CAB 1 815 1.00 mm² YE -P011:3 -HRNS_CAB 1
2 838A 0.50 mm² YE -SP19:S -HRNS_CAB 2 7210/0052 2 100K 0.75 mm²
3 804B 0.50 mm² YE -SP49:S -HRNS_CAB 3 108A 1.00 mm² YE -P001:16 -HRNS_CAB 3 2910 0.75 mm²
4 4
5 7213/0034 3 Way DTM06 Socket Housing 5
6 609BB 0.50 mm² YE -SP13:S -HRNS_CAB Additional Components 6
7 609AB 0.50 mm² YE -SP12:S -HRNS_CAB 7213/0035 7 601HP 1.00 mm²
8 610AB 0.50 mm² YE -SP74:S -HRNS_CAB 8 829AH 1.00 mm²
9 -P051 FACE FAN 9
10 601P 0.50 mm² YE -SP6:S -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal 10
11 941A 0.50 mm² YE -SP31:S -HRNS_CAB 1 151B 2.00 mm² YE -P005:14 -HRNS_CAB
12 2 601DD 2.00 mm² YE -SP63:S -HRNS_CAB 7219/0013 10 Way 6.3 Fastin Switch Hsg
14 7212/0052 2 Way DT06 Socket Housing
Additional Components DIODE
15 -P064A
16 7212/0031;1 # 2 Way DT06 Wedge ID Tag Size
17 405 0.50 mm² YE -P039:B10 -HRNS_CAB 332/E0988;1 # Deutsch DT04 2 Way Blanking Cap 1 831J 2.00 mm²
18 2 942A 2.00 mm²
19 -P053 WASHER PUMP
20 106C 0.50 mm² YE -SP20:S -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal 7514/0006 BUTT DIODE ASSY 6A 1000V
1 901A 2.00 mm² YE -SP17:S -HRNS_CAB Additional Components
7239/0032 20 Way Micro Fit Fem Hsg 2 839A 1.50 mm² YE -SP32:S -HRNS_CAB 7000/3212 ; 65
Additional Components 3 601JG 2.00 mm² YE -SP63:S -HRNS_CAB 332/C5617
332/C5617
IGNITION SWITCH 7213/0005 3 Way HW090 Socket Housing 7000/3212 ; 50
-P043
ID Tag Size Colour Destination Cable Cavity Seal Additional Components
7213/0007 -P064B DIODE
1 200A 4.00 mm² YE -P045:B -HRNS_CAB
ID Tag Size
2
1 947B 1.50 mm²
3 005A 4.00 mm² YE -P001:3 -HRNS_CAB -P055 FRONT WIPER MOTOR
2 942C 1.50 mm²
4 ID Tag Size Colour Destination Cable Cavity Seal
1 600P 2.00 mm² YE -SP61:S -HRNS_CAB 7514/0006 BUTT DIODE ASSY 6A 1000V
7234/0003 4 WAY IGN SWT FEM HSG 2 840 1.50 mm² YE -P038:7 -HRNS_CAB Additional Components
Additional Components 3 982 1.50 mm² YE -P038:2 -HRNS_CAB
7000/3212 ; 65
4 983 1.50 mm² YE -P038:3 -HRNS_CAB 332/C5617
-P044 IGNITION SWITCH 5 841 1.50 mm² YE -P038:12 -HRNS_CAB 332/C5617
ID Tag Size Colour Destination Cable Cavity Seal 6 110D 1.50 mm² YE -SP33:S -HRNS_CAB 7000/3212 ; 50
5 001A 4.00 mm² YE -P001:1 -HRNS_CAB 7 839B 1.50 mm² YE -SP32:S -HRNS_CAB
6 014 4.00 mm² YE -P005:13 -HRNS_CAB 8 7210/0001 -P065 AUXILLIARY CON
7 ID Tag Size
8 7218/0001 8 Way HW090 Socket Housing 1 121 1.00 mm²
9 Additional Components 2 601KC 1.00 mm²
10 7218/0003
7212/0001 2 Way HW090 Socket Housing
7236/0003 6 WAY IGN SWT FEM HSG MOBILE PHONE Additional Components
-P056
Additional Components ID Tag Size Colour Destination Cable Cavity Seal 7212/0003
1 601AS 1.50 mm² YE -SP61:S -HRNS_CAB
Page 33-297
-P045 FUSE LINK BOX GREY A/B 2 119 1.50 mm² YE -P002:10 -HRNS_CAB -P065A P065 BLANK
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size
A 202B 4.00 mm² YE -SP35:S -HRNS_CAB 7232/0028 2 Way Pos Lock Housing T Type 1
B 200A 4.00 mm² YE -P043:1 -HRNS_CAB Additional Components 2
7232/0009 2 Way Fem Hsg Pri Fuse Grey 7212/0002 2 Way HW090 Pin Housing
Additional Components -P057 MOBILE PHONE ILLUMINATION Additional Components
7212/0004;1 # 2 Way HW090 Pin Retainer
1 829AK 1.00 mm² YE -SP7:S -HRNS_CAB
-P046 FUSE LINK BOX BLUE C/D
ID Tag Size Colour Destination Cable Cavity Seal 7201/0403 1 Way Pos Lock Housing Straight -P058A P058 BLANK
A 200C 4.00 mm² YE -SP26:S -HRNS_CAB Additional Components ID Tag Size
B 200D 4.00 mm² YE -P002:15 -HRNS_CAB 1
2
7232/0008 2 Way Fem Hsg Pri Fuse Blue -P058 RADIO
3
4
1 181 1.00 mm² YE -P003:8 -HRNS_CAB
-P047 FUSE LINK BOX GREY 2 E/F 2 301F 1.00 mm² YE -SP27:S -HRNS_CAB 7214/0002 4 Way HW090 Pin Housing
ID Tag Size Colour Destination Cable Cavity Seal 3 829AM 1.00 mm² YE -SP7:S -HRNS_CAB Additional Components
A 200F 4.00 mm² YE -P003:15 -HRNS_CAB 4 601RD 1.00 mm² YE -SP3:S -HRNS_CAB
7214/0004;1 # 4 Way DT04 Wedge
B 200E 4.00 mm² YE -SP15:S -HRNS_CAB
7214/0001 4 Way HW090 Socket Housing IMMOBILISER
-P066
7232/0009 2 Way Fem Hsg Pri Fuse Grey Additional Components ID Tag Size
Additional Components 7214/0003 1
2
-P048 FUSE LINK BOX BLUE 2 G/H -P059 BOOM WORKLIGHTS DIODE
3
4
A 200G 4.00 mm² YE -SP30:S -HRNS_CAB 1 610B 0.75 mm² YE -P015:10 -HRNS_CAB
5
B 319 4.00 mm² YE -P093:1 -HRNS_CAB 2 610A 0.75 mm² YE -SP74:S -HRNS_CAB
6
7232/0008 2 Way Fem Hsg Pri Fuse Blue 7514/0006 BUTT DIODE ASSY 6A 1000V 7 Y1 1.00 mm²
Additional Components Additional Components 8 Y2 1.00 mm²
9 CAN 13 H 0.50 mm²
7000/3212 ; 65
-P049 REAR CAB CONNECTOR 332/C5617 10 CAN 13 L 0.50 mm²
ID Tag Size Colour Destination Cable Cavity Seal 332/C5617 11 Y3 1.00 mm²
1 133B 2.00 mm² YE -SP16:S -HRNS_CAB 7000/3212 ; 50 12
2 854 2.00 mm² YE -P021:1 -HRNS_CAB
REVERSE FAN SWITCH 7219/0019 12 Way DTM06 Socket Housing K
3 849 2.00 mm² YE -P021:2 -HRNS_CAB -P061
4 926 2.00 mm² YE -P022:1 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal Additional Components
5 925 2.00 mm² YE -P022:2 -HRNS_CAB 1 7219/0024
6 945 2.00 mm² YE -P012:7 -HRNS_CAB 2 100P 1.00 mm² YE -SP20:S -HRNS_CAB
7 151 2.00 mm² YE -P005:14 -HRNS_CAB 3 1840D 1.00 mm² YE -P071:18 -HRNS_CAB
8 844A 1.00 mm² YE -P028:3 -HRNS_CAB 4
9 301J 1.00 mm² YE -SP27:S -HRNS_CAB 5 100PA 1.00 mm² YE -SP20:S -HRNS_CAB
10 500S 1.00 mm² YE -SP73:S -HRNS_CAB 6 1840C 1.00 mm² YE -P072:6 -HRNS_CAB
13 7210/0001 9
14 7210/0001 10
7219/0005 14 Way HW090 Socket Housing 7219/0013 10 Way 6.3 Fastin Switch Hsg
7219/0007
V1.1 30/06/2016
33 - 296 9823/1650-1 33 - 296

12 - Harness
15 - Front Console
Page Page
33-296 33-297
Figure 946. (Part INFO

-P063 2 ofBUTTON
2) -P067 HORN RELAY & FREEZE VALVE
1 1 304C 1.00 mm² YE -SP37:S -HRNS_CAB
7210/0052 2 100K 0.75 mm² YE -SP20:S -HRNS_CAB 2 814 2.00 mm² YE -P039:E9 -HRNS_CAB
3 2910 0.75 mm² YE -P072:3 -HRNS_CAB 3 814RLY 1.00 mm² YE -P037:8 -HRNS_CAB
4 4
5 5 699HR 1.00 mm² YE -SP28:S -HRNS_CAB
6 6 883B 2.00 mm² YE -SP10:S -HRNS_CAB
7 601HP 1.00 mm² YE -SP11:S -HRNS_CAB 7 884A 2.00 mm² YE -P039:A12 -HRNS_CAB
8 829AH 1.00 mm² YE -SP7:S -HRNS_CAB 8 884 2.00 mm² YE -P033:5 -HRNS_CAB
9 9
Cavity Seal 10 10 601FV 1.00 mm² YE -SP29:S -HRNS_CAB
7219/0013 10 Way 6.3 Fastin Switch Hsg 7241/0003 10 Way twin micro relay base
-P064A DIODE -P068 LIVELINK 3

1 831J 2.00 mm² YE -SP23:S -HRNS_CAB A1 7210/0239
2 942A 2.00 mm² YE -SP22:S -HRNS_CAB A2 7210/0239
A3 7210/0239
Cavity Seal 7514/0006 BUTT DIODE ASSY 6A 1000V A4 7210/0239
Additional Components B1 7210/0239
7000/3212 ; 65 B2 7210/0239
332/C5617 B3 7210/0239
332/C5617 B4 7210/0239
7000/3212 ; 50 C1 7210/0239
C2 7210/0239
-P064B DIODE
C3 7210/0239
C4 7210/0239
D1 7210/0239
Cavity Seal D2 7210/0239
7514/0006 BUTT DIODE ASSY 6A 1000V D3 7210/0239
Additional Components D4 CAN5 H 0.75 mm² YE -SVMC04:S -HRNS_CAB
E1 7210/0239
7000/3212 ; 65
332/C5617 E2 7210/0239
332/C5617 E3 7210/0239
7000/3212 ; 50 E4 CAN5 L 0.75 mm² YE -SVMC05:S -HRNS_CAB
F1 7210/0239
7210/0001 -P065 AUXILLIARY CONNECTOR F2 7210/0239
ID Tag Size Colour Destination Cable Cavity Seal F3 7210/0239
1 121 1.00 mm² YE -P001:6 -HRNS_CAB F4 7210/0239
2 601KC 1.00 mm² YE -SP28:S -HRNS_CAB G1 7210/0239
G2 7210/0239
7212/0001 2 Way HW090 Socket Housing G3 7210/0239
Additional Components G4 7210/0239
Cavity Seal 7212/0003 H1 7210/0239
H2 7210/0239
Page 33-296
-P065A P065 BLANK H3 7210/0239

ID Tag Size Colour Destination Cable Cavity Seal H4 7210/0239
1 7210/0001 J1 LINK1 0.75 mm² YE -P068:K1 -HRNS_CAB
2 7210/0001 J2 7210/0239
J3 7210/0239
7212/0002 2 Way HW090 Pin Housing J4 7210/0239
Additional Components K1 LINK1 0.75 mm² YE -P068:J1 -HRNS_CAB
Cavity Seal
7212/0004;1 # 2 Way HW090 Pin Retainer K2 7210/0239
K3 7210/0239
-P058A P058 BLANK K4 7210/0239
ID Tag Size Colour Destination Cable Cavity Seal L1 7210/0240
1 7210/0001 L2 600LL 1.00 mm² YE -SP63:S -HRNS_CAB
2 7210/0001 L3 601LA 1.00 mm² YE -SP79:S -HRNS_CAB
3 7210/0001 L4 7210/0240
Cavity Seal
4 7210/0001 M1 7210/0240
M2 110LLA 1.00 mm² YE -P014:7 -HRNS_CAB
7214/0002 4 Way HW090 Pin Housing M3 601LB 1.00 mm² YE -SP79:S -HRNS_CAB
Additional Components M4 299LL 1.00 mm² YE -P003:12 -HRNS_CAB
7214/0004;1 # 4 Way DT04 Wedge
7219/0285 48W CMC Mat sealed fem hsg right
-P066 IMMOBILISER Additional Components
7243/0453;1 # Cover for 48 and 28 CMC fem conn
1 7210/0052
2 7210/0052
3 7210/0052
Cavity Seal
4 7210/0052
5 7210/0052
6 7210/0052
7 Y1 1.00 mm² YE -SP27:S -HRNS_CAB
8 Y2 1.00 mm² YE -P004:20 -HRNS_CAB
10 CAN 13 L 0.50 mm² GN -SVMC17:S -VMC13
11 Y3 1.00 mm² YE -SP6:S -HRNS_CAB
12 7210/0052
7219/0019 12 Way DTM06 Socket Housing Key B

Cavity Seal Additional Components
7219/0024
33 - 297 9823/1650-1 33 - 297

12 - Harness
15 - Front Console
33 - 298 9823/1650-1 33 - 298

12 - Harness
15 - Front Console

-P071 INSTRUMENT CLUSTER J1 -P098 HOUR METER +VE -P108 3&4 GEAR PULL DOWN 332R -P132 5K36 RESISTOR
1 829AB 1.00 mm² YE -SP7:S -HRNS_CAB 1 301R 1.00 mm² YE -P004:4 -HRNS_CAB 1 415C 1.00 mm² YE -SP34:S -HRNS_CAB 1 480C 1.00 mm² YE -P131:1 -HRNS_CAB
2 106 1.00 mm² YE -P004:18 -HRNS_CAB 2 688E 0.75 mm² YE -SP70:S -HRNS_CAB 2 480D 1.00 mm² YE -P131:2 -HRNS_CAB
3 884AC 1.00 mm² YE -P015:3 -HRNS_CAB 7201/0403 1 Way Pos Lock Housing Straight
4 877 1.00 mm² YE -P087:1 -HRNS_CAB Additional Components 334/G3718 GA resistor 332R butt joint 333/D0616 Resistor 5K360R Metal Film 0.25W 0.1%
5 7210/0205 Additional Components Additional Components
6 7210/0205 -P099 HOUR METER -VE 332/C5617
-P112 HEATER 100R 332/C5617
7 CAN 7 L 0.50 mm² GN -SVMC08:S -VMC07 ID Tag Size Colour Destination Cable Cavity Seal
ID Tag Size Colour Destination Cable Cavity Seal 7000/3212 ; 85
8 CAN 7 H 0.50 mm² YE -SVMC07:S -VMC07 1 601GY 1.00 mm² YE -SP6:S -HRNS_CAB
9 CAN 7 SCR 0.50 mm² ?01? -SVMC09:S -VMC07
7201/0403 1 Way Pos Lock Housing Straight 2 601HT 1.00 mm² YE -SP11:S -HRNS_CAB
10 301EA 1.00 mm² YE -SP40:S -HRNS_CAB -P133 SPEED SENSOR PULL UP
11 407B 1.00 mm² YE -SP14:S -HRNS_CAB Additional Components ID Tag Size Colour Destination Cable Cavity Seal
333/R2410 RESISTOR 100R WIRE WOUND
12 1840 1.00 mm² YE -P039:A10 -HRNS_CAB Additional Components 1 500M 1.00 mm² YE -SP73:S -HRNS_CAB
13 509A 0.75 mm² YE -P020:6 -HRNS_CAB -P100 HOUR METER SIGNAL 7000/3212;80 # Adhesive Lined Heatshrink
14 7210/0205 ID Tag Size Colour Destination Cable Cavity Seal
15 610 1.00 mm² YE -P034:5 -HRNS_CAB 1 407C 1.00 mm² YE -SP14:S -HRNS_CAB 7212/0001 2 Way HW090 Socket Housing
-P113 LIVE LINK PERM GROUND Additional Components
16 7210/0205
7201/0403 1 Way Pos Lock Housing Straight ID Tag Size Colour Destination Cable Cavity Seal
17 800L 0.75 mm² YE -P038:11 -HRNS_CAB 7212/0003
Additional Components 1 601LG 1.00 mm² YE -P005:11 -HRNS_CAB
18 1840D 1.00 mm² YE -P061:3 -HRNS_CAB
19 7210/0205 7207/1513 Ring Terminal M10 0.5-1.0 -P134 PARK BRAKE
20 301EB 1.00 mm² YE -SP40:S -HRNS_CAB -P101 NOx SENSOR & RH SIDE WL Additional Components ID Tag Size Colour Destination Cable Cavity Seal
ID Tag Size Colour Destination Cable Cavity Seal 1 815B 1.00 mm² YE -P135:32 -HRNS_CAB
7000/3212 ; 45
332/E3213 20 Way MX150 Skt hsg Grey Key B 1 300NX 1.50 mm² YE -P004:6 -HRNS_CAB 2 815A 1.00 mm² YE -P135:20 -HRNS_CAB
Additional Components 2 8223 1.50 mm² YE -P199:2 -HRNS_CAB 3 699A 1.00 mm² YE -SP70:S -HRNS_CAB
3 1100A 1.00 mm² YE -P001:10 -HRNS_CAB -P126 ITALIAN HEAD LIGHTS
INSTRUMENT CLUSTER J2 7213/0034 3 Way DTM06 Socket Housing
-P072 4 ID Tag Size Colour Destination Cable Cavity Seal
ID Tag Size Colour Destination Cable Cavity Seal 5 6302X 1.00 mm² YE -SP46:S -HRNS_CAB 1 100QA 0.75 mm² YE -SP20:S -HRNS_CAB Additional Components
1 402 1.00 mm² YE -P039:B7 -HRNS_CAB 6 312 1.50 mm² YE -P002:20 -HRNS_CAB 2 100QB 1.00 mm² YE -P012:8 -HRNS_CAB 7213/0035;1 # 3 Way DTM06 Wedge
2 7210/0205 7 948 1.50 mm² YE -SP76:S -HRNS_CAB 334/F2685;1 # Dust cap to fit DTM06-3S
3 2910 0.75 mm² YE -P063:3 -HRNS_CAB 8 891D 1.00 mm² YE -SP2:S -HRNS_CAB 7212/0001 2 Way HW090 Socket Housing
4 800R 0.75 mm² YE -P038:10 -HRNS_CAB 9 Additional Components
7212/0003 -P137 DAILY CHECKS
5 887A 1.00 mm² YE -P034:3 -HRNS_CAB 10 610CB 0.75 mm² YE -P139:1 -HRNS_CAB
6 1840C 1.00 mm² YE -P061:6 -HRNS_CAB
7241/0003 10 Way twin micro relay base 1 300RDM 1.00 mm² YE -P002:12 -HRNS_CAB
7 412 1.00 mm² YE -P039:C1 -HRNS_CAB
Additional Components -P127 ITALIAN HEAD LIGHTS (DEL) 2 600RDM 1.00 mm² YE -SP3:S -HRNS_CAB
8 593 1.00 mm² YE -P039:F5 -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal 3 CAN 10 L 0.50 mm² GN -SVMC14:S -VMC10
1 LINK 0.75 mm² YE -P127:2 -HRNS_CAB 4 CAN 10 H 0.50 mm² YE -SVMC13:S -VMC10
10 805F 2.00 mm² YE -SP8:S -HRNS_CAB -P102 HOSE HEATER 2 (WHITE)
2 LINK 0.75 mm² YE -P127:1 -HRNS_CAB 5 419E 1.00 mm² YE -P039:G1 -HRNS_CAB
11 408 1.00 mm² YE -P039:B6 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
6 420CL 1.00 mm² YE -P039:G2 -HRNS_CAB
12 100TT 1.00 mm² YE -P039:B9 -HRNS_CAB 1 8226 1.50 mm² YE -P199:11 -HRNS_CAB 7212/0002 2 Way HW090 Pin Housing 7 421WBL 1.00 mm² YE -P039:G4 -HRNS_CAB
13 7210/0205 2 6301B 1.50 mm² YE -SP46:S -HRNS_CAB Additional Components 8 100RDM 1.00 mm² YE -P003:4 -HRNS_CAB
14 7210/0205 3 8215C 1.00 mm² YE -SP39:S -HRNS_CAB
7212/0004 9 7210/0205
15 7210/0205 4
10 7210/0205
16 7210/0205 5 8219 1.00 mm² YE -P199:5 -HRNS_CAB
-P128 FRONT WORK LIGHTS DIODE 11 7210/0205
17 601DE 1.00 mm² YE -SP11:S -HRNS_CAB 6 8227 1.50 mm² YE -P199:12 -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal 12 7210/0205
18 997C 1.00 mm² YE -SP5:S -HRNS_CAB 7 6031C 1.50 mm² YE -SP46:S -HRNS_CAB
1 609A 0.75 mm² YE -P012:5 -HRNS_CAB 13 7210/0205
19 592 1.00 mm² YE -P039:F6 -HRNS_CAB 8 8215D 1.00 mm² YE -SP39:S -HRNS_CAB
2 609AA 0.75 mm² YE -SP12:S -HRNS_CAB 14 7210/0205
15 7210/0205
10 8222 1.00 mm² YE -P199:6 -HRNS_CAB 7514/0006 BUTT DIODE ASSY 6A 1000V
332/C8190 20 Way MX150 Skt Hsg Black Key A 16 7210/0205
Additional Components 7241/0003 10 Way twin micro relay base
7000/3212 ; 65 18 7210/0205
332/C5617 19 7210/0205
-P073 DIAGNOSTIC CONNECTOR 332/C5617 20 7210/0205
ID Tag Size Colour Destination Cable Cavity Seal -P103 1ST GEAR 820R 7000/3212 ; 50
A 601C 1.00 mm² YE -SP11:S -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal 332/E3213 20 Way MX150 Skt hsg Grey Key B
B 301M 1.00 mm² YE -SP27:S -HRNS_CAB 1 871 1.00 mm² YE -P037:12 -HRNS_CAB Additional Components
-P129 REAR WORK LIGHTS DIODE
C CAN 2 H 0.50 mm² YE -SVMC01:S -VMC02 2 414A 1.00 mm² YE -SP24:S -HRNS_CAB
D CAN 2 L 0.50 mm² GN -SVMC02:S -VMC02
334/G3724 GA resistor 820R butt joint 1 609B 0.75 mm² YE -P012:10 -HRNS_CAB
E 7210/0030
Additional Components 2 609BA 0.75 mm² YE -SP13:S -HRNS_CAB
F 7210/0030 -P138 RH SIDE WORKLIGHTS SWITCH
G 7210/0030 7514/0006 BUTT DIODE ASSY 6A 1000V ID Tag Size Colour Destination Cable Cavity Seal
H 7210/0030 -P104 2ND GEAR 1K2 Additional Components 1
J 7210/0030 ID Tag Size Colour Destination Cable Cavity Seal 2 610C 0.75 mm² YE -SP1:S -HRNS_CAB
7000/3212 ; 65
1 872 1.00 mm² YE -P037:9 -HRNS_CAB 332/C5617 3 610CA 0.75 mm² YE -P139:2 -HRNS_CAB
7219/0098 9 Way Male J1939 Housing Jam Nut Type 2 414B 1.00 mm² YE -SP24:S -HRNS_CAB 4
332/C5617
7000/3212 ; 50
7210/0116 334/G3723 GA resistor 1K2 butt joint 6
7210/0117 Additional Components WORKLIGHTS
-P130 7 601KD 1.00 mm² YE -SP6:S -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal 8 829AN 1.00 mm² YE -SP7:S -HRNS_CAB
-P074 CAN TERM CONNECTOR -P105 3RD GEAR 1K8 1 831B 2.00 mm² YE -SP23:S -HRNS_CAB 9
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal 2 831K 2.00 mm² YE -SP23:S -HRNS_CAB 10
A CAN 1 H 0.50 mm² YE -SVMC01:S -VMC01 1 873B 1.00 mm² YE -SP78:S -HRNS_CAB 3 601BU 2.00 mm² YE -SP61:S -HRNS_CAB
B CAN 1 L 0.50 mm² GN -SVMC02:S -VMC01 2 415A 1.00 mm² YE -SP34:S -HRNS_CAB 4 601AM 2.00 mm² YE -SP61:S -HRNS_CAB 7219/0013 10 Way 6.3 Fastin Switch Hsg
C CAN 1 SCR 0.50 mm² ?01? -SVMC03:S -VMC01 Additional Components
334/G1168 GA resistor 1K8 Butt joint 7214/0001 4 Way HW090 Socket Housing
7213/0041 3 Way DT06 Socket Housing With Boot Adaptor Additional Components Additional Components
7213/0043;1 # 3 Way DT06 Wedge CAN J1939 -P106 4TH GEAR 3K3
-P131 5K36 RESISTOR CONNECTOR
-P087 100R TRAILER SENSE RES 1 415BA 1.00 mm² YE -P142:2 -HRNS_CAB
1 480C 1.00 mm² YE -P132:1 -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal 2 415B 1.00 mm² YE -SP34:S -HRNS_CAB
2 480D 1.00 mm² YE -P132:2 -HRNS_CAB
1 877 1.00 mm² YE -P071:4 -HRNS_CAB
2 601TS 1.00 mm² YE -SP11:S -HRNS_CAB 334/G3721 GA resistor 3K3 butt joint
7212/0002 2 Way HW090 Pin Housing
7212/0004
Additional Components 1&2 GEAR PULL DOWN 332R
-P107
7000/3212;80 # Adhesive Lined Heatshrink ID Tag Size Colour Destination Cable Cavity Seal
-P093 ENGINE SUPPLY 2 688A 0.75 mm² YE -SP70:S -HRNS_CAB
1 319 4.00 mm² YE -P048:B -HRNS_CAB 334/G3718 GA resistor 332R butt joint
2 842 4.00 mm² YE -P010:2 -HRNS_CAB Additional Components
7212/0063 2 Way DTP04 Pin Housing

7212/0061
33 - 299 9823/1650-1 33 - 299

12 - Harness
15 - Front Console
Page Page
33-300 33-301
Figure 947. (Part

-P071 1 of CLUSTER
INSTRUMENT 2) J1 -P098 HOUR METER +VE -P108
1 829AB 1.00 mm² YE -SP7:S -HRNS_CAB 1 301R 1.00 mm² YE -P004:4 -HRNS_CAB 1 415C
2 106 1.00 mm² YE -P004:18 -HRNS_CAB 2 688E
3 884AC 1.00 mm² YE -P015:3 -HRNS_CAB 7201/0403 1 Way Pos Lock Housing Straight
4 877 1.00 mm² YE -P087:1 -HRNS_CAB Additional Components 334/G3718 GA resistor 332R butt j
5 7210/0205 Additional Components
6 7210/0205 -P099 HOUR METER -VE
7 CAN 7 L 0.50 mm² GN -SVMC08:S -VMC07 ID Tag Size Colour Destination Cable Cavity Seal
-P112
ID Tag
8 CAN 7 H 0.50 mm² YE -SVMC07:S -VMC07 1 601GY 1.00 mm² YE -SP6:S -HRNS_CAB
1 801B
9 CAN 7 SCR 0.50 mm² ?01? -SVMC09:S -VMC07
7201/0403 1 Way Pos Lock Housing Straight 2 601HT
10 301EA 1.00 mm² YE -SP40:S -HRNS_CAB
11 407B 1.00 mm² YE -SP14:S -HRNS_CAB Additional Components
333/R2410 RESISTOR 100R WIR
12 1840 1.00 mm² YE -P039:A10 -HRNS_CAB Additional Components
13 509A 0.75 mm² YE -P020:6 -HRNS_CAB -P100 HOUR METER SIGNAL 7000/3212;80 # Adhesive Lined He
14 7210/0205 ID Tag Size Colour Destination Cable Cavity Seal
15 610 1.00 mm² YE -P034:5 -HRNS_CAB 1 407C 1.00 mm² YE -SP14:S -HRNS_CAB
16 7210/0205
-P113
7201/0403 1 Way Pos Lock Housing Straight ID Tag
17 800L 0.75 mm² YE -P038:11 -HRNS_CAB
Additional Components 1 601LG
18 1840D 1.00 mm² YE -P061:3 -HRNS_CAB
19 7210/0205 7207/1513 Ring Terminal M10 0.5
20 301EB 1.00 mm² YE -SP40:S -HRNS_CAB -P101 NOx SENSOR & RH SIDE WL Additional Components
7000/3212 ; 45
332/E3213 20 Way MX150 Skt hsg Grey Key B 1 300NX 1.50 mm² YE -P004:6 -HRNS_CAB
Additional Components 2 8223 1.50 mm² YE -P199:2 -HRNS_CAB
3 1100A 1.00 mm² YE -P001:10 -HRNS_CAB -P126
-P072 INSTRUMENT CLUSTER J2 4 ID Tag
ID Tag Size Colour Destination Cable Cavity Seal 5 6302X 1.00 mm² YE -SP46:S -HRNS_CAB 1 100QA
1 402 1.00 mm² YE -P039:B7 -HRNS_CAB 6 312 1.50 mm² YE -P002:20 -HRNS_CAB 2 100QB
2 7210/0205 7 948 1.50 mm² YE -SP76:S -HRNS_CAB
3 2910 0.75 mm² YE -P063:3 -HRNS_CAB 8 891D 1.00 mm² YE -SP2:S -HRNS_CAB 7212/0001 2 Way HW090 Socket
4 800R 0.75 mm² YE -P038:10 -HRNS_CAB 9 Additional Components
5 887A 1.00 mm² YE -P034:3 -HRNS_CAB 10 610CB 0.75 mm² YE -P139:1 -HRNS_CAB 7212/0003
6 1840C 1.00 mm² YE -P061:6 -HRNS_CAB
7 412 1.00 mm² YE -P039:C1 -HRNS_CAB 7241/0003 10 Way twin micro relay base
8 593 1.00 mm² YE -P039:F5 -HRNS_CAB Additional Components -P127
ID Tag
1 LINK
10 805F 2.00 mm² YE -SP8:S -HRNS_CAB -P102 HOSE HEATER 2 (WHITE)
2 LINK
11 408 1.00 mm² YE -P039:B6 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
12 100TT 1.00 mm² YE -P039:B9 -HRNS_CAB 1 8226 1.50 mm² YE -P199:11 -HRNS_CAB 7212/0002 2 Way HW090 Pin Hou
13 7210/0205 2 6301B 1.50 mm² YE -SP46:S -HRNS_CAB Additional Components
14 7210/0205 3 8215C 1.00 mm² YE -SP39:S -HRNS_CAB
7212/0004
15 7210/0205 4
16 7210/0205 5 8219 1.00 mm² YE -P199:5 -HRNS_CAB
17 601DE 1.00 mm² YE -SP11:S -HRNS_CAB 6 8227 1.50 mm² YE -P199:12 -HRNS_CAB
-P128
ID Tag
18 997C 1.00 mm² YE -SP5:S -HRNS_CAB 7 6031C 1.50 mm² YE -SP46:S -HRNS_CAB
1 609A
19 592 1.00 mm² YE -P039:F6 -HRNS_CAB 8 8215D 1.00 mm² YE -SP39:S -HRNS_CAB
Page 33-301
2 609AA
10 8222 1.00 mm² YE -P199:6 -HRNS_CAB 7514/0006 BUTT DIODE ASSY 6A
332/C8190 20 Way MX150 Skt Hsg Black Key A
Additional Components 7241/0003 10 Way twin micro relay base
7000/3212 ; 65
332/C5617
-P073 DIAGNOSTIC CONNECTOR 332/C5617
ID Tag Size Colour Destination Cable Cavity Seal -P103 1ST GEAR 820R 7000/3212 ; 50
A 601C 1.00 mm² YE -SP11:S -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
B 301M 1.00 mm² YE -SP27:S -HRNS_CAB 1 871 1.00 mm² YE -P037:12 -HRNS_CAB
C CAN 2 H 0.50 mm² YE -SVMC01:S -VMC02 2 414A 1.00 mm² YE -SP24:S -HRNS_CAB
-P129
ID Tag
D CAN 2 L 0.50 mm² GN -SVMC02:S -VMC02
334/G3724 GA resistor 820R butt joint 1 609B
E 7210/0030
Additional Components 2 609BA
F 7210/0030
G 7210/0030 7514/0006 BUTT DIODE ASSY 6A
H 7210/0030 -P104 2ND GEAR 1K2 Additional Components
J 7210/0030 ID Tag Size Colour Destination Cable Cavity Seal
7000/3212 ; 65
1 872 1.00 mm² YE -P037:9 -HRNS_CAB 332/C5617
7219/0098 9 Way Male J1939 Housing Jam Nut Type 2 414B 1.00 mm² YE -SP24:S -HRNS_CAB 332/C5617
7000/3212 ; 50
7210/0116 334/G3723 GA resistor 1K2 butt joint
-P130
ID Tag
-P074 CAN TERM CONNECTOR -P105 3RD GEAR 1K8 1 831B
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal 2 831K
A CAN 1 H 0.50 mm² YE -SVMC01:S -VMC01 1 873B 1.00 mm² YE -SP78:S -HRNS_CAB 3 601BU
B CAN 1 L 0.50 mm² GN -SVMC02:S -VMC01 2 415A 1.00 mm² YE -SP34:S -HRNS_CAB 4 601AM
C CAN 1 SCR 0.50 mm² ?01? -SVMC03:S -VMC01
334/G1168 GA resistor 1K8 Butt joint 7214/0001 4 Way HW090 Socket
7213/0041 3 Way DT06 Socket Housing With Boot Adaptor Additional Components Additional Components
7213/0043;1 # 3 Way DT06 Wedge CAN J1939 -P106 4TH GEAR 3K3
-P131
ID Tag
-P087 100R TRAILER SENSE RES 1 415BA 1.00 mm² YE -P142:2 -HRNS_CAB
1 480C
ID Tag Size Colour Destination Cable Cavity Seal 2 415B 1.00 mm² YE -SP34:S -HRNS_CAB
2 480D
1 877 1.00 mm² YE -P071:4 -HRNS_CAB
2 601TS 1.00 mm² YE -SP11:S -HRNS_CAB 334/G3721 GA resistor 3K3 butt joint
7212/0002 2 Way HW090 Pin Hou
7212/0004
Additional Components 1&2 GEAR PULL DOWN 332R
-P107
7000/3212;80 # Adhesive Lined Heatshrink ID Tag Size Colour Destination Cable Cavity Seal
-P093 ENGINE SUPPLY 2 688A 0.75 mm² YE -SP70:S -HRNS_CAB
1 319 4.00 mm² YE -P048:B -HRNS_CAB 334/G3718 GA resistor 332R butt joint
2 842 4.00 mm² YE -P010:2 -HRNS_CAB Additional Components
7212/0063 2 Way DTP04 Pin Housing

7212/0061
33 - 300 9823/1650-1 33 - 300

12 - Harness
15 - Front Console
Page Page
33-300 33-301
Figure-P108
947. (Part 23&4
ofGEAR
2) PULL DOWN 332R -P132 5K36 RESISTOR
1 415C 1.00 mm² YE -SP34:S -HRNS_CAB 1 480C 1.00 mm² YE -P131:1 -HRNS_CAB
2 688E 0.75 mm² YE -SP70:S -HRNS_CAB 2 480D 1.00 mm² YE -P131:2 -HRNS_CAB
334/G3718 GA resistor 332R butt joint 333/D0616 Resistor 5K360R Metal Film 0.25W 0.1%
332/C5617
-P112 HEATER 100R 332/C5617
Cavity Seal
2 601HT 1.00 mm² YE -SP11:S -HRNS_CAB
-P133 SPEED SENSOR PULL UP
333/R2410 RESISTOR 100R WIRE WOUND ID Tag Size Colour Destination Cable Cavity Seal
Additional Components 1 500M 1.00 mm² YE -SP73:S -HRNS_CAB
7000/3212;80 # Adhesive Lined Heatshrink
Cavity Seal
-P113 LIVE LINK PERM GROUND Additional Components
7212/0003
1 601LG 1.00 mm² YE -P005:11 -HRNS_CAB
7207/1513 Ring Terminal M10 0.5-1.0 -P134 PARK BRAKE

Cavity Seal 1 815B 1.00 mm² YE -P135:32 -HRNS_CAB
7000/3212 ; 45
2 815A 1.00 mm² YE -P135:20 -HRNS_CAB
-P126 ITALIAN HEAD LIGHTS
ID Tag Size Colour Destination Cable Cavity Seal 7213/0034 3 Way DTM06 Socket Housing
1 100QA 0.75 mm² YE -SP20:S -HRNS_CAB Additional Components
2 100QB 1.00 mm² YE -P012:8 -HRNS_CAB 7213/0035;1 # 3 Way DTM06 Wedge
334/F2685;1 # Dust cap to fit DTM06-3S
7212/0003 -P137 DAILY CHECKS
1 300RDM 1.00 mm² YE -P002:12 -HRNS_CAB
-P127 ITALIAN HEAD LIGHTS (DEL) 2 600RDM 1.00 mm² YE -SP3:S -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal 3 CAN 10 L 0.50 mm² GN -SVMC14:S -VMC10
1 LINK 0.75 mm² YE -P127:2 -HRNS_CAB 4 CAN 10 H 0.50 mm² YE -SVMC13:S -VMC10
2 LINK 0.75 mm² YE -P127:1 -HRNS_CAB 5 419E 1.00 mm² YE -P039:G1 -HRNS_CAB
Cavity Seal
6 420CL 1.00 mm² YE -P039:G2 -HRNS_CAB
7212/0002 2 Way HW090 Pin Housing 7 421WBL 1.00 mm² YE -P039:G4 -HRNS_CAB
Additional Components 8 100RDM 1.00 mm² YE -P003:4 -HRNS_CAB
7212/0004 9 7210/0205
10 7210/0205
-P128 FRONT WORK LIGHTS DIODE 11 7210/0205
ID Tag Size Colour Destination Cable Cavity Seal 12 7210/0205
1 609A 0.75 mm² YE -P012:5 -HRNS_CAB 13 7210/0205
Page 33-300
2 609AA 0.75 mm² YE -SP12:S -HRNS_CAB 14 7210/0205

15 7210/0205
7514/0006 BUTT DIODE ASSY 6A 1000V 16 7210/0205
7000/3212 ; 65 18 7210/0205
332/C5617 19 7210/0205
332/C5617 20 7210/0205
7000/3212 ; 50
Cavity Seal 332/E3213 20 Way MX150 Skt hsg Grey Key B
REAR WORK LIGHTS DIODE Additional Components
-P129
1 609B 0.75 mm² YE -P012:10 -HRNS_CAB
2 609BA 0.75 mm² YE -SP13:S -HRNS_CAB
-P138 RH SIDE WORKLIGHTS SWITCH
7514/0006 BUTT DIODE ASSY 6A 1000V ID Tag Size Colour Destination Cable Cavity Seal
Cavity Seal 2 610C 0.75 mm² YE -SP1:S -HRNS_CAB
7000/3212 ; 65
332/C5617 3 610CA 0.75 mm² YE -P139:2 -HRNS_CAB
332/C5617 4
7000/3212 ; 50 5
6
-P130 WORKLIGHTS 7 601KD 1.00 mm² YE -SP6:S -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal 8 829AN 1.00 mm² YE -SP7:S -HRNS_CAB
1 831B 2.00 mm² YE -SP23:S -HRNS_CAB 9
Cavity Seal 2 831K 2.00 mm² YE -SP23:S -HRNS_CAB 10
3 601BU 2.00 mm² YE -SP61:S -HRNS_CAB
4 601AM 2.00 mm² YE -SP61:S -HRNS_CAB 7219/0013 10 Way 6.3 Fastin Switch Hsg
7214/0003
-P131 5K36 RESISTOR CONNECTOR

Cavity Seal
1 480C 1.00 mm² YE -P132:1 -HRNS_CAB
2 480D 1.00 mm² YE -P132:2 -HRNS_CAB
7212/0002 2 Way HW090 Pin Housing

7212/0004
Cavity Seal
33 - 301 9823/1650-1 33 - 301

12 - Harness
15 - Front Console
33 - 302 9823/1650-1 33 - 302

12 - Harness
15 - Front Console

-P135 RAS J1
-P139 RH SIDE WORKLIGHTS DIODE -SP1 WORKLIGHTS SWITCH -SP7 ILLUMINATION
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
1 502 1.00 mm² YE -P039:G6 -HRNS_CAB
1 610CB 0.75 mm² YE -P101:10 -HRNS_CAB S 609RH1 0.75 mm² YE -P026:2 -HRNS_CAB S 829AE 1.00 mm² YE -P023:8 -HRNS_CAB
2 610CA 0.75 mm² YE -P138:3 -HRNS_CAB S 609LH 0.75 mm² YE -P014:2 -HRNS_CAB S 829E 1.50 mm² YE -P005:6 -HRNS_CAB
S 609RH 0.75 mm² YE -P026:5 -HRNS_CAB S 829J 1.00 mm² YE -P026:8 -HRNS_CAB
4 203G 1.00 mm² YE -SP68:S -HRNS_CAB 7514/0006 BUTT DIODE ASSY 6A 1000V S 610D 0.75 mm² YE -P029:2 -HRNS_CAB S 829AH 1.00 mm² YE -P063:8 -HRNS_CAB
5 203H 1.00 mm² YE -SP68:S -HRNS_CAB Additional Components S 610C 0.75 mm² YE -P138:2 -HRNS_CAB S 829AL 1.00 mm² YE -P061:8 -HRNS_CAB
6 203J 1.00 mm² YE -SP68:S -HRNS_CAB
7000/3212 ; 65 S 829AM 1.00 mm² YE -P058:3 -HRNS_CAB
7 414 1.00 mm² YE -SP24:S -HRNS_CAB 332/C5617 7000/3104 In Line Ultrasonic Splice S 829AK 1.00 mm² YE -P057:1 -HRNS_CAB
8 506 1.00 mm² YE -P039:F7 -HRNS_CAB 332/C5617 Additional Components S 829WL 0.50 mm² YE -P040:1 -HRNS_CAB
9 416R 1.00 mm² YE -P037:10 -HRNS_CAB 7000/3212 ; 50 7000/3212 ; 45 S 829A 1.00 mm² YE -P039:D11 -HRNS_CAB
10 416F 1.00 mm² YE -P037:4 -HRNS_CAB
S 829AX 1.00 mm² YE -P036:8 -HRNS_CAB
11 155 1.00 mm² YE -P004:20 -HRNS_CAB -SP2 WORKLIGHT RELAYS
S 828HC 1.00 mm² YE -P034:2 -HRNS_CAB
12 615 1.00 mm² YE -P039:F2 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
-P140 DIODE S 829U 1.00 mm² YE -P028:8 -HRNS_CAB
13 812 1.00 mm² YE -P039:C6 -HRNS_CAB S 891B 1.00 mm² YE -P012:3 -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal S 829AF 1.00 mm² YE -P022:8 -HRNS_CAB
14 699 1.00 mm² YE -SP70:S -HRNS_CAB S 891 1.00 mm² YE -P024:4 -HRNS_CAB
1 948B 1.50 mm² YE -SP76:S -HRNS_CAB S 829M 1.00 mm² YE -P021:8 -HRNS_CAB
15 615A 1.00 mm² YE -SP69:S -HRNS_CAB S 891D 1.00 mm² YE -P101:8 -HRNS_CAB
2 942F 1.50 mm² YE -SP22:S -HRNS_CAB S 829Y 1.00 mm² YE -P018:8 -HRNS_CAB
16 615B 1.00 mm² YE -SP69:S -HRNS_CAB S 891C 1.00 mm² YE -P015:8 -HRNS_CAB
S 829AJ 1.00 mm² YE -P029:8 -HRNS_CAB
17 615C 1.00 mm² YE -SP69:S -HRNS_CAB 7514/0006 BUTT DIODE ASSY 6A 1000V S 891A 1.00 mm² YE -P012:8 -HRNS_CAB
S 829AN 1.00 mm² YE -P138:8 -HRNS_CAB
7000/3104 In Line Ultrasonic Splice S 829AB 1.00 mm² YE -P071:1 -HRNS_CAB
19 531 1.00 mm² YE -P039:A2 -HRNS_CAB
7000/3212 ; 65
20 815A 1.00 mm² YE -P134:2 -HRNS_CAB Additional Components
332/C5617 7000/3104 In Line Ultrasonic Splice
21 416N 1.00 mm² YE -P037:6 -HRNS_CAB 7000/3212 ; 45
332/C5617 Additional Components
22 581 1.00 mm² YE -P039:E4 -HRNS_CAB 7000/3212 ; 50
-SP3 GROUND 7000/3212 ; 45
23 332/U1483
24 859 1.00 mm² YE -P039:B12 -HRNS_CAB -P141 3RD/4TH GEAR DIODE -SP8
S 601RD 1.00 mm² YE -P058:4 -HRNS_CAB
25 559 1.00 mm² YE -P016:3 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
S 601LL 1.00 mm² YE -P014:10 -HRNS_CAB
26 560 1.00 mm² YE -P016:8 -HRNS_CAB 1 874A 1.00 mm² YE -SP77:S -HRNS_CAB S 805F 2.00 mm² YE -P072:10 -HRNS_CAB
S 601SH 0.75 mm² YE -P014:5 -HRNS_CAB
27 807 1.00 mm² YE -P010:8 -HRNS_CAB 2 873A 1.00 mm² YE -SP78:S -HRNS_CAB S 805D 2.00 mm² YE -P039:D4 -HRNS_CAB
S 601LH 0.75 mm² YE -P014:1 -HRNS_CAB
28 456 1.00 mm² YE -P039:A3 -HRNS_CAB S 805B 2.00 mm² YE -P031:1 -HRNS_CAB
7514/0006 BUTT DIODE ASSY 6A 1000V S 601SY 0.75 mm² YE -P011:10 -HRNS_CAB
29 332/U1483
Additional Components S 601X 0.75 mm² YE -P008:10 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice
30 480AA 1.00 mm² YE -SP72:S -HRNS_CAB
S 601JJ 0.75 mm² YE -P008:5 -HRNS_CAB Additional Components
31 530 1.00 mm² YE -P039:A1 -HRNS_CAB 7000/3212 ; 65
332/C5617 S 601HK 0.75 mm² YE -P007:10 -HRNS_CAB
32 815B 1.00 mm² YE -P134:1 -HRNS_CAB 7000/3212 ; 45
332/C5617 S 601HL 0.75 mm² YE -P007:5 -HRNS_CAB
34 CAN 9 H 0.50 mm² YE -SVMC10:S -VMC09 7000/3212 ; 50 S 601EK 0.75 mm² YE -P006:10 -HRNS_CAB -SP9
S 601HB 0.75 mm² YE -P006:5 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
35 614 1.00 mm² YE -P039:E7 -HRNS_CAB
S 601JC 3.00 mm² YE -SP63:S -HRNS_CAB S 806A 2.00 mm² YE -P072:20 -HRNS_CAB
-P142 4TH GEAR DIODE
332/F8042 35 WAY AMPSEAL FEM HSG BLACK S CAN GND 2.00 mm² YE -SVMC18:S -HRNS_CAB S 806C 2.00 mm² YE -P039:D3 -HRNS_CAB
Additional Components S 600RDM 1.00 mm² YE -P137:2 -HRNS_CAB S 806B 2.00 mm² YE -P032:1 -HRNS_CAB
2 415BA 1.00 mm² YE -P106:1 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
7514/0006 BUTT DIODE ASSY 6A 1000V
7000/3212 ; 45 7000/3212 ; 45
-P136 RAS J2 7000/3212 ; 65 -SP5 HEATER SPEED -SP10
ID Tag Size Colour Destination Cable Cavity Seal 332/C5617 ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
1 620 1.50 mm² YE -P039:C9 -HRNS_CAB 332/C5617 S 997C 1.00 mm² YE -P072:18 -HRNS_CAB S 883 2.00 mm² YE -P015:2 -HRNS_CAB
2 521 1.00 mm² YE -P039:E1 -HRNS_CAB 7000/3212 ; 50 S 997B 1.00 mm² YE -P034:6 -HRNS_CAB S 883A 2.00 mm² YE -P033:4 -HRNS_CAB
3 513 1.00 mm² YE -P039:B11 -HRNS_CAB
S 997A 1.00 mm² YE -P034:4 -HRNS_CAB S 883B 2.00 mm² YE -P067:6 -HRNS_CAB
4 1870 1.00 mm² YE -P039:F12 -HRNS_CAB
5 910 1.00 mm² YE -P039:A6 -HRNS_CAB -P143 CAMERA INTERFACE 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
6 100NS 1.00 mm² YE -P010:3 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal Additional Components Additional Components
7 858 1.00 mm² YE -P039:B1 -HRNS_CAB 1 121CKR 1.00 mm² YE -P001:6 -HRNS_CAB
7000/3212 ; 45 7000/3212 ; 45
8 857 1.00 mm² YE -P039:B2 -HRNS_CAB 2 601CK 1.00 mm² YE -SP11:S -HRNS_CAB
9 503 1.00 mm² YE -P039:G7 -HRNS_CAB 3 807RCB 1.00 mm² YE -P010:7 -HRNS_CAB -SP6 GROUND -SP11
10 860 1.00 mm² YE -P039:C5 -HRNS_CAB 4 7210/0030 ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
11 811 1.00 mm² YE -P039:C4 -HRNS_CAB 5 7210/0030 S Y3 1.00 mm² YE -P066:11 -HRNS_CAB S 601C 1.00 mm² YE -P073:A -HRNS_CAB
12 515 1.00 mm² YE -P039:F1 -HRNS_CAB 6 7210/0030 S 601DC 1.00 mm² YE -P023:7 -HRNS_CAB S 601HT 1.00 mm² YE -P112:2 -HRNS_CAB
13 507 1.00 mm² YE -P039:F11 -HRNS_CAB S 601AE 1.00 mm² YE -P026:7 -HRNS_CAB S 601TS 1.00 mm² YE -P087:2 -HRNS_CAB
14 1851 1.00 mm² YE -P039:A9 -HRNS_CAB 7216/0041 6 WAY DT06 SOC HSG NO END CAP S 601GY 1.00 mm² YE -P099:1 -HRNS_CAB S 601DE 1.00 mm² YE -P072:17 -HRNS_CAB
15 1850 1.00 mm² YE -P039:A8 -HRNS_CAB Additional Components S 601P 0.50 mm² YE -P040:10 -HRNS_CAB S 601HP 1.00 mm² YE -P063:7 -HRNS_CAB
16 847SS 1.00 mm² YE -P049:11 -HRNS_CAB 7216/0016;1 # 6 Way DT06 Wedge S 601AY 1.00 mm² YE -P028:7 -HRNS_CAB S 601AL 1.00 mm² YE -P061:7 -HRNS_CAB
17 332/U1483 S 601BF 0.75 mm² YE -P024:7 -HRNS_CAB S 601DZ 1.00 mm² YE -P036:7 -HRNS_CAB
18 410 1.00 mm² YE -P039:D8 -HRNS_CAB -P199 TANK HARNESS CONNECTOR S 601KA 1.00 mm² YE -P029:7 -HRNS_CAB S 601AD 0.75 mm² YE -P020:7 -HRNS_CAB
19 1853 1.00 mm² YE -P039:B4 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal S 601KD 1.00 mm² YE -P138:7 -HRNS_CAB S 601JE 3.00 mm² YE -SP63:S -HRNS_CAB
20 1855 1.00 mm² YE -P039:D7 -HRNS_CAB 1 3100A 2.00 mm² YE -P005:16 -HRNS_CAB S 601JD 2.00 mm² YE -SP63:S -HRNS_CAB S 601CK 1.00 mm² YE -P143:2 -HRNS_CAB
22 615D 1.00 mm² YE -SP69:S -HRNS_CAB 3 8215 1.00 mm² YE -SP39:S -HRNS_CAB 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
23 514 1.00 mm² YE -P039:E6 -HRNS_CAB 4 8217 1.00 mm² YE -P009:10 -HRNS_CAB Additional Components Additional Components
24 630 1.50 mm² YE -P039:E12 -HRNS_CAB 5 8219 1.00 mm² YE -P102:5 -HRNS_CAB 7000/3212 ; 45 7000/3212 ; 45
25 509 1.00 mm² YE -P039:E8 -HRNS_CAB 6 8222 1.00 mm² YE -P102:10 -HRNS_CAB
-SP12 FRONT WORKLIGHTS
26 512 1.00 mm² YE -P039:B8 -HRNS_CAB 7 8216 1.00 mm² YE -P009:5 -HRNS_CAB
27 856 1.00 mm² YE -P039:D12 -HRNS_CAB 8 8214A 2.00 mm² YE -P009:2 -HRNS_CAB
S 609AC 0.75 mm² YE -P026:3 -HRNS_CAB
28 846SS 1.00 mm² YE -P049:12 -HRNS_CAB 9 1100 1.00 mm² YE -P001:10 -HRNS_CAB
S 609AB 0.50 mm² YE -P040:7 -HRNS_CAB
S 609AA 0.75 mm² YE -P128:2 -HRNS_CAB
30 481 1.00 mm² YE -P039:D9 -HRNS_CAB 11 8226 1.50 mm² YE -P102:1 -HRNS_CAB
31 1852 1.00 mm² YE -P039:B3 -HRNS_CAB 12 8227 1.50 mm² YE -P102:6 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice
32 1854 1.00 mm² YE -P039:D6 -HRNS_CAB Additional Components
33 480A 1.00 mm² YE -P039:F3 -HRNS_CAB 7219/0067 12 Way DT04 Pin Housing Grey KEY A
7000/3212 ; 45
34 332/U1483 Additional Components
35 332/U1483 7219/0010
332/F8043 35 WAY AMPSEAL FEM HSG NATURAL

33 - 303 9823/1650-1 33 - 303

12 - Harness
15 - Front Console
Page Page
33-304 33-305
Figure
-P135 948. (Part
RAS J11 of 2)
-P139 RH SIDE WORKLIGHTS DIODE -SP1
ID Tag Size Colour Destination Cable Cavity Seal ID
1 502 1.00 mm² YE -P039:G6 -HRNS_CAB
1 610CB 0.75 mm² YE -P101:10 -HRNS_CAB S
2 610CA 0.75 mm² YE -P138:3 -HRNS_CAB S
S
4 203G 1.00 mm² YE -SP68:S -HRNS_CAB 7514/0006 BUTT DIODE ASSY 6A 1000V S
5 203H 1.00 mm² YE -SP68:S -HRNS_CAB Additional Components S
6 203J 1.00 mm² YE -SP68:S -HRNS_CAB
7000/3212 ; 65
7 414 1.00 mm² YE -SP24:S -HRNS_CAB 332/C5617 7000/3104
8 506 1.00 mm² YE -P039:F7 -HRNS_CAB 332/C5617 Additional Components
9 416R 1.00 mm² YE -P037:10 -HRNS_CAB 7000/3212 ; 50 7000/3212 ; 45
10 416F 1.00 mm² YE -P037:4 -HRNS_CAB
11 155 1.00 mm² YE -P004:20 -HRNS_CAB -SP2
12 615 1.00 mm² YE -P039:F2 -HRNS_CAB ID
-P140 DIODE
13 812 1.00 mm² YE -P039:C6 -HRNS_CAB S
14 699 1.00 mm² YE -SP70:S -HRNS_CAB S
15 615A 1.00 mm² YE -SP69:S -HRNS_CAB S
16 615B 1.00 mm² YE -SP69:S -HRNS_CAB S
17 615C 1.00 mm² YE -SP69:S -HRNS_CAB 7514/0006 BUTT DIODE ASSY 6A 1000V S
19 531 1.00 mm² YE -P039:A2 -HRNS_CAB 7000/3104
7000/3212 ; 65
20 815A 1.00 mm² YE -P134:2 -HRNS_CAB Additional Components
332/C5617
21 416N 1.00 mm² YE -P037:6 -HRNS_CAB 7000/3212 ; 45
332/C5617
22 581 1.00 mm² YE -P039:E4 -HRNS_CAB 7000/3212 ; 50
23 332/U1483
-SP3
ID
24 859 1.00 mm² YE -P039:B12 -HRNS_CAB -P141 3RD/4TH GEAR DIODE
S
25 559 1.00 mm² YE -P016:3 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
S
26 560 1.00 mm² YE -P016:8 -HRNS_CAB 1 874A 1.00 mm² YE -SP77:S -HRNS_CAB
S
27 807 1.00 mm² YE -P010:8 -HRNS_CAB 2 873A 1.00 mm² YE -SP78:S -HRNS_CAB
S
28 456 1.00 mm² YE -P039:A3 -HRNS_CAB
7514/0006 BUTT DIODE ASSY 6A 1000V S
29 332/U1483
Additional Components S
30 480AA 1.00 mm² YE -SP72:S -HRNS_CAB
S
31 530 1.00 mm² YE -P039:A1 -HRNS_CAB 7000/3212 ; 65
332/C5617 S
32 815B 1.00 mm² YE -P134:1 -HRNS_CAB
332/C5617 S
7000/3212 ; 50 S
S
35 614 1.00 mm² YE -P039:E7 -HRNS_CAB
S
-P142 4TH GEAR DIODE
332/F8042 35 WAY AMPSEAL FEM HSG BLACK S
Additional Components S
2 415BA 1.00 mm² YE -P106:1 -HRNS_CAB 7000/3104
7514/0006 BUTT DIODE ASSY 6A 1000V
7000/3212 ; 45
RAS J2
Page 33-305
-P136 7000/3212 ; 65
-SP5
332/C5617 ID
1 620 1.50 mm² YE -P039:C9 -HRNS_CAB 332/C5617 S
2 521 1.00 mm² YE -P039:E1 -HRNS_CAB 7000/3212 ; 50 S
3 513 1.00 mm² YE -P039:B11 -HRNS_CAB
S
4 1870 1.00 mm² YE -P039:F12 -HRNS_CAB
5 910 1.00 mm² YE -P039:A6 -HRNS_CAB -P143 CAMERA INTERFACE 7000/3104
6 100NS 1.00 mm² YE -P010:3 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal Additional Components
7 858 1.00 mm² YE -P039:B1 -HRNS_CAB 1 121CKR 1.00 mm² YE -P001:6 -HRNS_CAB
7000/3212 ; 45
8 857 1.00 mm² YE -P039:B2 -HRNS_CAB 2 601CK 1.00 mm² YE -SP11:S -HRNS_CAB
9 503 1.00 mm² YE -P039:G7 -HRNS_CAB 3 807RCB 1.00 mm² YE -P010:7 -HRNS_CAB -SP6
10 860 1.00 mm² YE -P039:C5 -HRNS_CAB 4 7210/0030 ID
11 811 1.00 mm² YE -P039:C4 -HRNS_CAB 5 7210/0030 S
12 515 1.00 mm² YE -P039:F1 -HRNS_CAB 6 7210/0030 S
13 507 1.00 mm² YE -P039:F11 -HRNS_CAB S
14 1851 1.00 mm² YE -P039:A9 -HRNS_CAB 7216/0041 6 WAY DT06 SOC HSG NO END CAP S
15 1850 1.00 mm² YE -P039:A8 -HRNS_CAB Additional Components S
16 847SS 1.00 mm² YE -P049:11 -HRNS_CAB 7216/0016;1 # 6 Way DT06 Wedge S
17 332/U1483 S
18 410 1.00 mm² YE -P039:D8 -HRNS_CAB -P199 TANK HARNESS CONNECTOR S
19 1853 1.00 mm² YE -P039:B4 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal S
20 1855 1.00 mm² YE -P039:D7 -HRNS_CAB 1 3100A 2.00 mm² YE -P005:16 -HRNS_CAB S
22 615D 1.00 mm² YE -SP69:S -HRNS_CAB 3 8215 1.00 mm² YE -SP39:S -HRNS_CAB 7000/3104
23 514 1.00 mm² YE -P039:E6 -HRNS_CAB 4 8217 1.00 mm² YE -P009:10 -HRNS_CAB Additional Components
24 630 1.50 mm² YE -P039:E12 -HRNS_CAB 5 8219 1.00 mm² YE -P102:5 -HRNS_CAB 7000/3212 ; 45
27 856 1.00 mm² YE -P039:D12 -HRNS_CAB 8 8214A 2.00 mm² YE -P009:2 -HRNS_CAB
28 846SS 1.00 mm² YE -P049:12 -HRNS_CAB 9 1100 1.00 mm² YE -P001:10 -HRNS_CAB
30 481 1.00 mm² YE -P039:D9 -HRNS_CAB 11 8226 1.50 mm² YE -P102:1 -HRNS_CAB
32 1854 1.00 mm² YE -P039:D6 -HRNS_CAB
33 480A 1.00 mm² YE -P039:F3 -HRNS_CAB 7219/0067 12 Way DT04 Pin Housing Grey KEY A
34 332/U1483 Additional Components
35 332/U1483 7219/0010
332/F8043 35 WAY AMPSEAL FEM HSG NATURAL

33 - 304 9823/1650-1 33 - 304

12 - Harness
15 - Front Console
Page Page
33-304 33-305
Figure-SP1
948. (Part 2 of 2)
WORKLIGHTS SWITCH -SP7 ILLUMINATION
S 609RH1 0.75 mm² YE -P026:2 -HRNS_CAB S 829AE 1.00 mm² YE -P023:8 -HRNS_CAB
S 609LH 0.75 mm² YE -P014:2 -HRNS_CAB S 829E 1.50 mm² YE -P005:6 -HRNS_CAB
S 609RH 0.75 mm² YE -P026:5 -HRNS_CAB S 829J 1.00 mm² YE -P026:8 -HRNS_CAB
S 610D 0.75 mm² YE -P029:2 -HRNS_CAB S 829AH 1.00 mm² YE -P063:8 -HRNS_CAB
S 610C 0.75 mm² YE -P138:2 -HRNS_CAB S 829AL 1.00 mm² YE -P061:8 -HRNS_CAB
S 829AM 1.00 mm² YE -P058:3 -HRNS_CAB
7000/3104 In Line Ultrasonic Splice S 829AK 1.00 mm² YE -P057:1 -HRNS_CAB
Additional Components S 829WL 0.50 mm² YE -P040:1 -HRNS_CAB
7000/3212 ; 45 S 829A 1.00 mm² YE -P039:D11 -HRNS_CAB
S 829AX 1.00 mm² YE -P036:8 -HRNS_CAB
-SP2 WORKLIGHT RELAYS
S 828HC 1.00 mm² YE -P034:2 -HRNS_CAB
S 829U 1.00 mm² YE -P028:8 -HRNS_CAB
S 891B 1.00 mm² YE -P012:3 -HRNS_CAB
Cavity Seal S 829AF 1.00 mm² YE -P022:8 -HRNS_CAB
S 891 1.00 mm² YE -P024:4 -HRNS_CAB
S 829M 1.00 mm² YE -P021:8 -HRNS_CAB
S 891D 1.00 mm² YE -P101:8 -HRNS_CAB
S 829Y 1.00 mm² YE -P018:8 -HRNS_CAB
S 891C 1.00 mm² YE -P015:8 -HRNS_CAB
S 829AJ 1.00 mm² YE -P029:8 -HRNS_CAB
S 891A 1.00 mm² YE -P012:8 -HRNS_CAB
S 829AN 1.00 mm² YE -P138:8 -HRNS_CAB
7000/3104 In Line Ultrasonic Splice S 829AB 1.00 mm² YE -P071:1 -HRNS_CAB
7000/3104 In Line Ultrasonic Splice
7000/3212 ; 45
-SP3 GROUND 7000/3212 ; 45
S 601RD 1.00 mm² YE -P058:4 -HRNS_CAB
-SP8
Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
S 805F 2.00 mm² YE -P072:10 -HRNS_CAB
S 601SH 0.75 mm² YE -P014:5 -HRNS_CAB
S 805D 2.00 mm² YE -P039:D4 -HRNS_CAB
S 601LH 0.75 mm² YE -P014:1 -HRNS_CAB
S 805B 2.00 mm² YE -P031:1 -HRNS_CAB
S 601SY 0.75 mm² YE -P011:10 -HRNS_CAB
S 601X 0.75 mm² YE -P008:10 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice
S 601JJ 0.75 mm² YE -P008:5 -HRNS_CAB Additional Components
S 601HK 0.75 mm² YE -P007:10 -HRNS_CAB
7000/3212 ; 45
S 601HL 0.75 mm² YE -P007:5 -HRNS_CAB
S 601EK 0.75 mm² YE -P006:10 -HRNS_CAB -SP9
S 601HB 0.75 mm² YE -P006:5 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
S 601JC 3.00 mm² YE -SP63:S -HRNS_CAB S 806A 2.00 mm² YE -P072:20 -HRNS_CAB
S CAN GND 2.00 mm² YE -SVMC18:S -HRNS_CAB S 806C 2.00 mm² YE -P039:D3 -HRNS_CAB
Cavity Seal
S 600RDM 1.00 mm² YE -P137:2 -HRNS_CAB S 806B 2.00 mm² YE -P032:1 -HRNS_CAB
7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice

7000/3212 ; 45 7000/3212 ; 45
Page 33-304
-SP5 HEATER SPEED -SP10

S 997C 1.00 mm² YE -P072:18 -HRNS_CAB S 883 2.00 mm² YE -P015:2 -HRNS_CAB
S 997B 1.00 mm² YE -P034:6 -HRNS_CAB S 883A 2.00 mm² YE -P033:4 -HRNS_CAB
S 997A 1.00 mm² YE -P034:4 -HRNS_CAB S 883B 2.00 mm² YE -P067:6 -HRNS_CAB

Cavity Seal Additional Components Additional Components
7000/3212 ; 45 7000/3212 ; 45
-SP6 GROUND -SP11

7210/0030 ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
7210/0030 S Y3 1.00 mm² YE -P066:11 -HRNS_CAB S 601C 1.00 mm² YE -P073:A -HRNS_CAB
7210/0030 S 601DC 1.00 mm² YE -P023:7 -HRNS_CAB S 601HT 1.00 mm² YE -P112:2 -HRNS_CAB
S 601AE 1.00 mm² YE -P026:7 -HRNS_CAB S 601TS 1.00 mm² YE -P087:2 -HRNS_CAB
S 601GY 1.00 mm² YE -P099:1 -HRNS_CAB S 601DE 1.00 mm² YE -P072:17 -HRNS_CAB
S 601P 0.50 mm² YE -P040:10 -HRNS_CAB S 601HP 1.00 mm² YE -P063:7 -HRNS_CAB
S 601AY 1.00 mm² YE -P028:7 -HRNS_CAB S 601AL 1.00 mm² YE -P061:7 -HRNS_CAB
S 601BF 0.75 mm² YE -P024:7 -HRNS_CAB S 601DZ 1.00 mm² YE -P036:7 -HRNS_CAB
S 601KA 1.00 mm² YE -P029:7 -HRNS_CAB S 601AD 0.75 mm² YE -P020:7 -HRNS_CAB
Cavity Seal S 601KD 1.00 mm² YE -P138:7 -HRNS_CAB S 601JE 3.00 mm² YE -SP63:S -HRNS_CAB
S 601JD 2.00 mm² YE -SP63:S -HRNS_CAB S 601CK 1.00 mm² YE -P143:2 -HRNS_CAB

7000/3212 ; 45 7000/3212 ; 45
-SP12 FRONT WORKLIGHTS

S 609AB 0.50 mm² YE -P040:7 -HRNS_CAB
S 609AA 0.75 mm² YE -P128:2 -HRNS_CAB

7000/3212 ; 45
33 - 305 9823/1650-1 33 - 305

12 - Harness
15 - Front Console
33 - 306 9823/1650-1 33 - 306

12 - Harness
15 - Front Console

-SP13 REAR WORKLIGHTS -SP22 -SP31 FOG LIGHTS -SP46 AFTER TREATMENT GND
S 609BB 0.50 mm² YE -P040:6 -HRNS_CAB S 942D 2.00 mm² YE -P005:5 -HRNS_CAB S 941A 0.50 mm² YE -P040:11 -HRNS_CAB S 6031C 1.50 mm² YE -P102:7 -HRNS_CAB
S 609BC 0.50 mm² YE -P026:6 -HRNS_CAB S 942E 2.00 mm² YE -P005:7 -HRNS_CAB S 941B 1.00 mm² YE -P039:E5 -HRNS_CAB S 6301B 1.50 mm² YE -P102:2 -HRNS_CAB
S 609BA 0.75 mm² YE -P129:2 -HRNS_CAB S 942A 2.00 mm² YE -P064A:2 -HRNS_CAB S 941 1.00 mm² YE -P023:3 -HRNS_CAB S 6302X 1.00 mm² YE -P101:5 -HRNS_CAB
S 942B 2.00 mm² YE -P024:3 -HRNS_CAB S 6301A 1.50 mm² YE -P009:7 -HRNS_CAB
7000/3104 In Line Ultrasonic Splice S 942C 1.50 mm² YE -P064B:2 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice S 6001 4.00 mm² YE -SP61:S -HRNS_CAB
Additional Components S 942F 1.50 mm² YE -P140:2 -HRNS_CAB Additional Components
7000/3212 ; 45 7000/3212 ; 45 7000/3104 In Line Ultrasonic Splice
7000/3104 In Line Ultrasonic Splice Additional Components
-SP14 Additional Components 7000/3212 ; 45
-SP32
7000/3212 ; 45 ID Tag Size Colour Destination Cable Cavity Seal
S 407C 1.00 mm² YE -P100:1 -HRNS_CAB
S 839B 1.50 mm² YE -P055:7 -HRNS_CAB -SP49
S 407 1.00 mm² YE -P039:B5 -HRNS_CAB -SP23 S 839A 1.50 mm² YE -P053:2 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
S 407F 1.00 mm² YE -P014:3 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
S 839 1.50 mm² YE -P038:6 -HRNS_CAB S 804B 0.50 mm² YE -P040:3 -HRNS_CAB
S 407B 1.00 mm² YE -P071:11 -HRNS_CAB S 831 2.00 mm² YE -P012:2 -HRNS_CAB
S 804C 2.00 mm² YE -P032:2 -HRNS_CAB
S 831K 2.00 mm² YE -P130:2 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice
7000/3104 In Line Ultrasonic Splice S 804 2.00 mm² YE -P031:2 -HRNS_CAB
S 831B 2.00 mm² YE -P130:1 -HRNS_CAB Additional Components
Additional Components S 804A 2.00 mm² YE -P020:2 -HRNS_CAB
S 831J 2.00 mm² YE -P064A:1 -HRNS_CAB
7000/3212 ; 45 S 804D 2.00 mm² YE -P011:8 -HRNS_CAB
7000/3212 ; 45
PRIMARY FUSE F Additional Components -SP33
-SP15 ID Tag Size Colour Destination Cable Cavity Seal Additional Components
S 110 1.50 mm² YE -P002:6 -HRNS_CAB 7000/3212 ; 45
S 200E 4.00 mm² YE -P047:B -HRNS_CAB
-SP24 S 110E 1.50 mm² YE -P038:1 -HRNS_CAB -SP50 HEATER RESISTOR
S 201E 4.00 mm² YE -P008:1 -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal S 110D 1.50 mm² YE -P055:6 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
S 202E 4.00 mm² YE -P005:17 -HRNS_CAB
S 414C 1.00 mm² YE -P107:1 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice S 801A 1.00 mm² YE -P072:9 -HRNS_CAB
S 414B 1.00 mm² YE -P104:2 -HRNS_CAB Additional Components S 801 1.00 mm² YE -P033:2 -HRNS_CAB
S 414A 1.00 mm² YE -P103:2 -HRNS_CAB 7000/3212 ; 45
7000/3212 ; 45
-SP16 -SP34
ID Tag Size Colour Destination Cable Cavity Seal Additional Components ID Tag Size Colour Destination Cable Cavity Seal 7000/3212 ; 45
S 133 2.00 mm² YE -P002:4 -HRNS_CAB 7000/3212 ; 45 S 415 1.00 mm² YE -P135:18 -HRNS_CAB
S 133B 2.00 mm² YE -P049:1 -HRNS_CAB S 415C 1.00 mm² YE -P108:1 -HRNS_CAB -SP61 GROUND
S 133C 2.00 mm² YE -P022:3 -HRNS_CAB -SP26 PRIMARY FUSE C S 415B 1.00 mm² YE -P106:2 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
S 133E 2.00 mm² YE -P021:3 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal S 415A 1.00 mm² YE -P105:2 -HRNS_CAB S 601AM 2.00 mm² YE -P130:4 -HRNS_CAB
S 200C 4.00 mm² YE -P046:A -HRNS_CAB S 601BU 2.00 mm² YE -P130:3 -HRNS_CAB
7000/3104 In Line Ultrasonic Splice S 202C 4.00 mm² YE -P007:6 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice S 600P 2.00 mm² YE -P055:1 -HRNS_CAB
Additional Components S 201C 4.00 mm² YE -P007:1 -HRNS_CAB Additional Components S 600AA 10.00 mm² YE -P035:1 -HRNS_CAB
7000/3212 ; 45 7000/3212 ; 45 S 600BS 3.00 mm² YE -SP71:S -HRNS_CAB
7000/3104 In Line Ultrasonic Splice S 6001 4.00 mm² YE -SP46:S -HRNS_CAB
Additional Components PRIMARY FUSE A
-SP17 -SP35 S 601AS 1.50 mm² YE -P056:1 -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal 7000/3212 ; 45 ID Tag Size Colour Destination Cable Cavity Seal
S 901A 2.00 mm² YE -P053:1 -HRNS_CAB S 202B 4.00 mm² YE -P045:A -HRNS_CAB 7000/3104 In Line Ultrasonic Splice
S 901B 2.00 mm² YE -P022:6 -HRNS_CAB -SP27 S 203B 4.00 mm² YE -P006:6 -HRNS_CAB
S 901 2.00 mm² YE -P021:6 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal S 200B 4.00 mm² YE -P006:1 -HRNS_CAB 7000/3212 ; 45
S Y1 1.00 mm² YE -P066:7 -HRNS_CAB
7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice -SP62 GROUND
S 301 1.00 mm² YE -P002:18 -HRNS_CAB
Additional Components Additional Components ID Tag Size Colour Destination Cable Cavity Seal
S 301M 1.00 mm² YE -P073:B -HRNS_CAB
S 601JH 3.00 mm² YE -SP29:S -HRNS_CAB
7000/3212 ; 45 S 301F 1.00 mm² YE -P058:2 -HRNS_CAB 7000/3212 ; 45
S 600 10.00 mm² YE -P030:1 -HRNS_CAB
S 301J 1.00 mm² YE -P049:9 -HRNS_CAB
S 615AA 4.00 mm² YE -SP69:S -HRNS_CAB
-SP19 -SP37 COLUMN SWITCH
7000/3104 In Line Ultrasonic Splice S 600K 8.00 mm² YE -SP63:S -HRNS_CAB
S 838 2.00 mm² YE -P005:4 -HRNS_CAB Additional Components S 304 2.00 mm² YE -P003:20 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice
S 838A 0.50 mm² YE -P040:2 -HRNS_CAB 7000/3212 ; 45 S 304A 2.00 mm² YE -P038:4 -HRNS_CAB Additional Components
S 838B 2.00 mm² YE -P039:A11 -HRNS_CAB S 304B 2.00 mm² YE -P037:11 -HRNS_CAB
7000/3212 ; 45
-SP28 S 304C 1.00 mm² YE -P067:1 -HRNS_CAB
7000/3104 In Line Ultrasonic Splice GROUND
ID Tag Size Colour Destination Cable Cavity Seal -SP63
Additional Components S 601DX 1.00 mm² YE -P022:7 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice ID Tag Size Colour Destination Cable Cavity Seal
7000/3212 ; 45 S 601BH 1.00 mm² YE -P021:7 -HRNS_CAB Additional Components S 601JF 2.00 mm² YE -SP28:S -HRNS_CAB
S 601EN 1.00 mm² YE -P018:7 -HRNS_CAB 7000/3212 ; 45 S 601JE 3.00 mm² YE -SP11:S -HRNS_CAB
-SP20 S 601JF 2.00 mm² YE -SP63:S -HRNS_CAB S 601JC 3.00 mm² YE -SP3:S -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal S 601KC 1.00 mm² YE -P065:2 -HRNS_CAB -SP39 HEATED HOSE RELAY S 601JD 2.00 mm² YE -SP6:S -HRNS_CAB
S 100PA 1.00 mm² YE -P061:5 -HRNS_CAB S 699HR 1.00 mm² YE -P067:5 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal S 600K 8.00 mm² YE -SP62:S -HRNS_CAB
S 100ISO 1.00 mm² YE -P013:3 -HRNS_CAB S 8215 1.00 mm² YE -P199:3 -HRNS_CAB S 601JG 2.00 mm² YE -P053:3 -HRNS_CAB
S 100 1.00 mm² YE -P001:2 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice S 8215D 1.00 mm² YE -P102:8 -HRNS_CAB S 600T 2.00 mm² YE -P033:1 -HRNS_CAB
S 100C 0.75 mm² YE -P013:8 -HRNS_CAB Additional Components S 8215C 1.00 mm² YE -P102:3 -HRNS_CAB S 600ISO 1.00 mm² YE -P013:5 -HRNS_CAB
S 100K 0.75 mm² YE -P063:2 -HRNS_CAB 7000/3212 ; 45 S 8215B 1.00 mm² YE -P009:8 -HRNS_CAB S 601DD 2.00 mm² YE -P051:2 -HRNS_CAB
S 100P 1.00 mm² YE -P061:2 -HRNS_CAB S 8215A 1.00 mm² YE -P009:3 -HRNS_CAB S 600LL 1.00 mm² YE -P068:L2 -HRNS_CAB
S 106C 0.50 mm² YE -P040:20 -HRNS_CAB
-SP29
ID Tag Size Colour Destination Cable Cavity Seal 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
S 100D 0.75 mm² YE -P024:8 -HRNS_CAB
S 601RL 1.00 mm² YE -P013:10 -HRNS_CAB Additional Components Additional Components
S 100A 0.75 mm² YE -P008:8 -HRNS_CAB 7000/3212 ; 45 7000/3212 ; 45
S 601FV 1.00 mm² YE -P067:10 -HRNS_CAB
S 100F 0.75 mm² YE -P008:3 -HRNS_CAB
S 601AC 1.00 mm² YE -P015:5 -HRNS_CAB -SP65 SUPPLY FNR/GEAR SELECT
S 100G 0.75 mm² YE -P007:8 -HRNS_CAB -SP40 INSTRUMENT +VE
S 616B 0.75 mm² YE -P011:5 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
S 100H 0.75 mm² YE -P007:3 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
S 601RA 1.00 mm² YE -P010:10 -HRNS_CAB S 109CS 1.00 mm² YE -P003:10 -HRNS_CAB
S 100B 0.75 mm² YE -P006:8 -HRNS_CAB S 301E 1.00 mm² YE -P004:10 -HRNS_CAB
S 601NS 1.00 mm² YE -P010:5 -HRNS_CAB S 109CS2 1.00 mm² YE -P037:14 -HRNS_CAB
S 100J 0.75 mm² YE -P006:3 -HRNS_CAB S 301EA 1.00 mm² YE -P071:10 -HRNS_CAB
S 109CS1 1.00 mm² YE -P037:7 -HRNS_CAB
S 100QA 0.75 mm² YE -P126:1 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice S 301EB 1.00 mm² YE -P071:20 -HRNS_CAB
Additional Components 7000/3104 In Line Ultrasonic Splice
7000/3212 ; 45 Additional Components
7000/3212 ; 45
7000/3212 ; 45 7000/3212 ; 45
-SP30 PRIMARY FUSE G
-SP21 ID Tag Size Colour Destination Cable Cavity Seal
ID Tag Size Colour Destination Cable Cavity Seal S 200G 4.00 mm² YE -P048:A -HRNS_CAB
S 832B 1.00 mm² YE -P005:9 -HRNS_CAB S 202G 4.00 mm² YE -P008:6 -HRNS_CAB
S 832A 2.00 mm² YE -P038:8 -HRNS_CAB S 201G 4.00 mm² YE -P004:5 -HRNS_CAB
S 832 2.00 mm² YE -P024:6 -HRNS_CAB
Additional Components 7000/3212 ; 45
7000/3212 ; 45
33 - 307 9823/1650-1 33 - 307

12 - Harness
15 - Front Console
Page Page
33-308 33-309
Figure 949. (Part

-SP13 1 of 2)
REAR WORKLIGHTS -SP22 -SP31
S 609BB 0.50 mm² YE -P040:6 -HRNS_CAB S 942D 2.00 mm² YE -P005:5 -HRNS_CAB S 941A
S 609BC 0.50 mm² YE -P026:6 -HRNS_CAB S 942E 2.00 mm² YE -P005:7 -HRNS_CAB S 941B
S 609BA 0.75 mm² YE -P129:2 -HRNS_CAB S 942A 2.00 mm² YE -P064A:2 -HRNS_CAB S 941
S 942B 2.00 mm² YE -P024:3 -HRNS_CAB
7000/3104 In Line Ultrasonic Splice S 942C 1.50 mm² YE -P064B:2 -HRNS_CAB 7000/3104
Additional Components S 942F 1.50 mm² YE -P140:2 -HRNS_CAB Additional Components
7000/3212 ; 45 7000/3212 ; 45
-SP14 Additional Components
-SP32
7000/3212 ; 45 ID Tag
S 407C 1.00 mm² YE -P100:1 -HRNS_CAB
S 839B
S 407 1.00 mm² YE -P039:B5 -HRNS_CAB -SP23 S 839A
S 407F 1.00 mm² YE -P014:3 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
S 839
S 407B 1.00 mm² YE -P071:11 -HRNS_CAB S 831 2.00 mm² YE -P012:2 -HRNS_CAB
S 831K 2.00 mm² YE -P130:2 -HRNS_CAB 7000/3104
7000/3104 In Line Ultrasonic Splice S 831B 2.00 mm² YE -P130:1 -HRNS_CAB Additional Components
Additional Components S 831J 2.00 mm² YE -P064A:1 -HRNS_CAB
7000/3212 ; 45
7000/3212 ; 45
PRIMARY FUSE F Additional Components -SP33
-SP15 ID Tag
S 110
S 200E 4.00 mm² YE -P047:B -HRNS_CAB
S 201E 4.00 mm² YE -P008:1 -HRNS_CAB
-SP24 S 110E
ID Tag Size Colour Destination Cable Cavity Seal S 110D
S 202E 4.00 mm² YE -P005:17 -HRNS_CAB
S 414 1.00 mm² YE -P135:7 -HRNS_CAB
S 414C 1.00 mm² YE -P107:1 -HRNS_CAB 7000/3104
S 414A 1.00 mm² YE -P103:2 -HRNS_CAB 7000/3212 ; 45
7000/3212 ; 45
-SP16 -SP34
ID Tag Size Colour Destination Cable Cavity Seal Additional Components ID Tag
S 133 2.00 mm² YE -P002:4 -HRNS_CAB 7000/3212 ; 45 S 415
S 133B 2.00 mm² YE -P049:1 -HRNS_CAB S 415C
S 133C 2.00 mm² YE -P022:3 -HRNS_CAB -SP26 PRIMARY FUSE C S 415B
S 133E 2.00 mm² YE -P021:3 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal S 415A
S 200C 4.00 mm² YE -P046:A -HRNS_CAB
7000/3104 In Line Ultrasonic Splice S 202C 4.00 mm² YE -P007:6 -HRNS_CAB 7000/3104
Additional Components S 201C 4.00 mm² YE -P007:1 -HRNS_CAB Additional Components
7000/3212 ; 45 7000/3212 ; 45
-SP17 -SP35
ID Tag Size Colour Destination Cable Cavity Seal 7000/3212 ; 45 ID Tag
S 901A 2.00 mm² YE -P053:1 -HRNS_CAB S 202B
S 901B 2.00 mm² YE -P022:6 -HRNS_CAB -SP27 S 203B
Page 33-309
S 901 2.00 mm² YE -P021:6 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal S 200B
S Y1 1.00 mm² YE -P066:7 -HRNS_CAB
7000/3104 In Line Ultrasonic Splice S 301 1.00 mm² YE -P002:18 -HRNS_CAB 7000/3104
Additional Components S 301M 1.00 mm² YE -P073:B -HRNS_CAB Additional Components
7000/3212 ; 45 S 301F 1.00 mm² YE -P058:2 -HRNS_CAB 7000/3212 ; 45
S 301J 1.00 mm² YE -P049:9 -HRNS_CAB
-SP19 -SP37
ID Tag Size Colour Destination Cable Cavity Seal 7000/3104 In Line Ultrasonic Splice ID Tag
S 838 2.00 mm² YE -P005:4 -HRNS_CAB Additional Components S 304
S 838A 0.50 mm² YE -P040:2 -HRNS_CAB 7000/3212 ; 45 S 304A
S 838B 2.00 mm² YE -P039:A11 -HRNS_CAB S 304B
-SP28 S 304C
7000/3104 In Line Ultrasonic Splice ID Tag Size Colour Destination Cable Cavity Seal
Additional Components S 601DX 1.00 mm² YE -P022:7 -HRNS_CAB 7000/3104
7000/3212 ; 45 S 601BH 1.00 mm² YE -P021:7 -HRNS_CAB Additional Components
S 601EN 1.00 mm² YE -P018:7 -HRNS_CAB 7000/3212 ; 45
-SP20 S 601JF 2.00 mm² YE -SP63:S -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal S 601KC 1.00 mm² YE -P065:2 -HRNS_CAB -SP39
S 100PA 1.00 mm² YE -P061:5 -HRNS_CAB S 699HR 1.00 mm² YE -P067:5 -HRNS_CAB ID Tag
S 100ISO 1.00 mm² YE -P013:3 -HRNS_CAB S 8215
S 100 1.00 mm² YE -P001:2 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice S 8215D
S 100C 0.75 mm² YE -P013:8 -HRNS_CAB Additional Components S 8215C
S 100K 0.75 mm² YE -P063:2 -HRNS_CAB 7000/3212 ; 45 S 8215B
S 100P 1.00 mm² YE -P061:2 -HRNS_CAB S 8215A
S 106C 0.50 mm² YE -P040:20 -HRNS_CAB
-SP29
ID Tag Size Colour Destination Cable Cavity Seal 7000/3104
S 100D 0.75 mm² YE -P024:8 -HRNS_CAB
S 601RL 1.00 mm² YE -P013:10 -HRNS_CAB Additional Components
S 100A 0.75 mm² YE -P008:8 -HRNS_CAB 7000/3212 ; 45
S 601FV 1.00 mm² YE -P067:10 -HRNS_CAB
S 100F 0.75 mm² YE -P008:3 -HRNS_CAB
S 100G 0.75 mm² YE -P007:8 -HRNS_CAB
S 616B 0.75 mm² YE -P011:5 -HRNS_CAB
-SP40
S 100H 0.75 mm² YE -P007:3 -HRNS_CAB ID Tag
S 601RA 1.00 mm² YE -P010:10 -HRNS_CAB
S 100B 0.75 mm² YE -P006:8 -HRNS_CAB S 301E
S 601NS 1.00 mm² YE -P010:5 -HRNS_CAB
S 100J 0.75 mm² YE -P006:3 -HRNS_CAB S 301EA
S 100QA 0.75 mm² YE -P126:1 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice S 301EB
7000/3104 In Line Ultrasonic Splice 7000/3104
7000/3212 ; 45
7000/3212 ; 45 7000/3212 ; 45
-SP30 PRIMARY FUSE G
-SP21 ID Tag Size Colour Destination Cable Cavity Seal
ID Tag Size Colour Destination Cable Cavity Seal S 200G 4.00 mm² YE -P048:A -HRNS_CAB
S 832B 1.00 mm² YE -P005:9 -HRNS_CAB S 202G 4.00 mm² YE -P008:6 -HRNS_CAB
S 832A 2.00 mm² YE -P038:8 -HRNS_CAB S 201G 4.00 mm² YE -P004:5 -HRNS_CAB
S 832 2.00 mm² YE -P024:6 -HRNS_CAB
7000/3212 ; 45
33 - 308 9823/1650-1 33 - 308

12 - Harness
15 - Front Console
Page Page
33-308 33-309
Figure 949. (Part 2FOG

-SP31 of 2)
LIGHTS -SP46 AFTER TREATMENT GND
S 941A 0.50 mm² YE -P040:11 -HRNS_CAB S 6031C 1.50 mm² YE -P102:7 -HRNS_CAB
S 941B 1.00 mm² YE -P039:E5 -HRNS_CAB S 6301B 1.50 mm² YE -P102:2 -HRNS_CAB
S 941 1.00 mm² YE -P023:3 -HRNS_CAB S 6302X 1.00 mm² YE -P101:5 -HRNS_CAB
S 6301A 1.50 mm² YE -P009:7 -HRNS_CAB
7000/3104 In Line Ultrasonic Splice S 6001 4.00 mm² YE -SP61:S -HRNS_CAB
7000/3212 ; 45 7000/3104 In Line Ultrasonic Splice
-SP32 7000/3212 ; 45
S 839B 1.50 mm² YE -P055:7 -HRNS_CAB -SP49
S 839A 1.50 mm² YE -P053:2 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
Cavity Seal
S 804C 2.00 mm² YE -P032:2 -HRNS_CAB
7000/3104 In Line Ultrasonic Splice S 804 2.00 mm² YE -P031:2 -HRNS_CAB
Additional Components S 804A 2.00 mm² YE -P020:2 -HRNS_CAB
7000/3212 ; 45 S 804D 2.00 mm² YE -P011:8 -HRNS_CAB

-SP33
S 110 1.50 mm² YE -P002:6 -HRNS_CAB 7000/3212 ; 45
S 110E 1.50 mm² YE -P038:1 -HRNS_CAB -SP50 HEATER RESISTOR
Cavity Seal S 110D 1.50 mm² YE -P055:6 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
S 801B 1.00 mm² YE -P112:1 -HRNS_CAB
7000/3104 In Line Ultrasonic Splice S 801A 1.00 mm² YE -P072:9 -HRNS_CAB
Additional Components S 801 1.00 mm² YE -P033:2 -HRNS_CAB
7000/3212 ; 45
-SP34
S 415 1.00 mm² YE -P135:18 -HRNS_CAB
S 415C 1.00 mm² YE -P108:1 -HRNS_CAB -SP61 GROUND
S 415B 1.00 mm² YE -P106:2 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal
Cavity Seal S 415A 1.00 mm² YE -P105:2 -HRNS_CAB S 601AM 2.00 mm² YE -P130:4 -HRNS_CAB
S 601BU 2.00 mm² YE -P130:3 -HRNS_CAB
7000/3104 In Line Ultrasonic Splice S 600P 2.00 mm² YE -P055:1 -HRNS_CAB
Additional Components S 600AA 10.00 mm² YE -P035:1 -HRNS_CAB
7000/3212 ; 45 S 600BS 3.00 mm² YE -SP71:S -HRNS_CAB
S 6001 4.00 mm² YE -SP46:S -HRNS_CAB
-SP35 PRIMARY FUSE A S 601AS 1.50 mm² YE -P056:1 -HRNS_CAB
S 202B 4.00 mm² YE -P045:A -HRNS_CAB 7000/3104 In Line Ultrasonic Splice
Page 33-308
Cavity Seal S 200B 4.00 mm² YE -P006:1 -HRNS_CAB 7000/3212 ; 45
7000/3104 In Line Ultrasonic Splice -SP62 GROUND

7000/3212 ; 45
S 600 10.00 mm² YE -P030:1 -HRNS_CAB
S 615AA 4.00 mm² YE -SP69:S -HRNS_CAB
-SP37 COLUMN SWITCH
S 600K 8.00 mm² YE -SP63:S -HRNS_CAB
S 304 2.00 mm² YE -P003:20 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice
S 304A 2.00 mm² YE -P038:4 -HRNS_CAB Additional Components
S 304B 2.00 mm² YE -P037:11 -HRNS_CAB
7000/3212 ; 45
S 304C 1.00 mm² YE -P067:1 -HRNS_CAB
Cavity Seal -SP63 GROUND
7000/3104 In Line Ultrasonic Splice ID Tag Size Colour Destination Cable Cavity Seal
Additional Components S 601JF 2.00 mm² YE -SP28:S -HRNS_CAB
7000/3212 ; 45 S 601JE 3.00 mm² YE -SP11:S -HRNS_CAB
S 601JC 3.00 mm² YE -SP3:S -HRNS_CAB
-SP39 HEATED HOSE RELAY S 601JD 2.00 mm² YE -SP6:S -HRNS_CAB
ID Tag Size Colour Destination Cable Cavity Seal S 600K 8.00 mm² YE -SP62:S -HRNS_CAB
S 8215 1.00 mm² YE -P199:3 -HRNS_CAB S 601JG 2.00 mm² YE -P053:3 -HRNS_CAB
S 8215D 1.00 mm² YE -P102:8 -HRNS_CAB S 600T 2.00 mm² YE -P033:1 -HRNS_CAB
S 8215C 1.00 mm² YE -P102:3 -HRNS_CAB S 600ISO 1.00 mm² YE -P013:5 -HRNS_CAB
S 8215B 1.00 mm² YE -P009:8 -HRNS_CAB S 601DD 2.00 mm² YE -P051:2 -HRNS_CAB
S 8215A 1.00 mm² YE -P009:3 -HRNS_CAB S 600LL 1.00 mm² YE -P068:L2 -HRNS_CAB
Cavity Seal 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
7000/3212 ; 45 7000/3212 ; 45
-SP65 SUPPLY FNR/GEAR SELECT

-SP40 INSTRUMENT +VE
S 109CS 1.00 mm² YE -P003:10 -HRNS_CAB
S 301E 1.00 mm² YE -P004:10 -HRNS_CAB
S 301EA 1.00 mm² YE -P071:10 -HRNS_CAB
S 301EB 1.00 mm² YE -P071:20 -HRNS_CAB
7000/3212 ; 45
7000/3212 ; 45
Cavity Seal
33 - 309 9823/1650-1 33 - 309

12 - Harness
15 - Front Console
33 - 310 9823/1650-1 33 - 310

12 - Harness
15 - Front Console

-SP68 RAS ECU VBAT
-SP77 4TH GEAR SPLICE -SVMC07 CAN H 3 -SVMC13 CAN H 5
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
S 203 2.00 mm² YE -P004:2 -HRNS_CAB
S 874 1.00 mm² YE -P037:13 -HRNS_CAB S CAN 4 H 0.50 mm² YE -SVMC04:S -VMC04 S CAN 8 H 0.50 mm² YE -SVMC10:S -VMC08
S 203J 1.00 mm² YE -P135:6 -HRNS_CAB
S 874A 1.00 mm² YE -P141:1 -HRNS_CAB S CAN 6 H 0.50 mm² YE -SVMC10:S -VMC06 S CAN 11 H 0.50 mm² YE -SVMC16:S -VMC11
S 203H 1.00 mm² YE -P135:5 -HRNS_CAB
S 874B 1.00 mm² YE -P142:1 -HRNS_CAB S CAN 7 H 0.50 mm² YE -P071:8 -VMC07 S CAN 10 H 0.50 mm² YE -P137:4 -VMC10
S 203G 1.00 mm² YE -P135:4 -HRNS_CAB
S 203E 1.00 mm² YE -P135:3 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
S 203A 1.00 mm² YE -P135:2 -HRNS_CAB Additional Components Additional Components Additional Components
7000/3212;45 # Adhesive Lined Heatshrink 7000/3212 ; 45 7000/3212 ; 45
-SP78 3RD GEAR SPLICE -SVMC08 CAN L 3
7000/3212 ; 45 -SVMC14 CAN L 5
-SP69 RAS ECU GROUND S 873 1.00 mm² YE -P037:5 -HRNS_CAB S CAN 4 L 0.50 mm² GN -SVMC05:S -VMC04
S CAN 8 L 0.50 mm² GN -SVMC11:S -VMC08
ID Tag Size Colour Destination Cable Cavity Seal S 873A 1.00 mm² YE -P141:2 -HRNS_CAB S CAN 6 L 0.50 mm² GN -SVMC11:S -VMC06
S 615D 1.00 mm² YE -P136:22 -HRNS_CAB S 873B 1.00 mm² YE -P105:1 -HRNS_CAB S CAN 7 L 0.50 mm² GN -P071:7 -VMC07
S CAN 10 L 0.50 mm² GN -P137:3 -VMC10
S 615C 1.00 mm² YE -P135:17 -HRNS_CAB
S 615B 1.00 mm² YE -P135:16 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
S 615A 1.00 mm² YE -P135:15 -HRNS_CAB Additional Components Additional Components
S 615AA 4.00 mm² YE -SP62:S -HRNS_CAB 7000/3212;45 # Adhesive Lined Heatshrink 7000/3212 ; 45
7000/3212 ; 45
7000/3104 In Line Ultrasonic Splice LL3 CAN SHIELD 3 CAN SHIELD 5
-SP79 -SVMC09 -SVMC15
Additional Components ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
7000/3212 ; 45 S 601LB 1.00 mm² YE -P068:M3 -HRNS_CAB S CAN 4 SCR 0.50 mm² ?01? -SVMC06:S -VMC04 S CAN 10 SCR 0.50 mm² ?01? -SCREEN 5:S -VMC10
S 601LA 1.00 mm² YE -P068:L3 -HRNS_CAB S CAN 6 SCR 0.50 mm² ?01? -SVMC12:S -VMC06 S CAN 8 SCR 0.50 mm² ?01? -SVMC12:S -VMC08
-SP70 SENSOR GND
S 601L 1.00 mm² YE -P005:12 -HRNS_CAB S CAN 7 SCR 0.50 mm² ?01? -P071:9 -VMC07 S CAN 11 SCR 0.50 mm² ?01? -SVMC18:S -VMC11
S 699 1.00 mm² YE -P135:14 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
S 699A 1.00 mm² YE -P134:3 -HRNS_CAB Additional Components Additional Components Additional Components
S 688E 0.75 mm² YE -P108:2 -HRNS_CAB
7000/3212;45 # Adhesive Lined Heatshrink 7000/3212 ; 45 7000/3212 ; 45
S 688A 0.75 mm² YE -P107:2 -HRNS_CAB
S 699C 1.00 mm² YE -P039:C3 -HRNS_CAB
-SVMC10 CAN H 4 -SVMC16 CAN H 6
7000/3104 In Line Ultrasonic Splice ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
Additional Components S CAN 9 H 0.50 mm² YE -P135:34 -VMC09 S CAN 12 H 0.50 mm² YE -P039:C11 -VMC12
S CAN 6 H 0.50 mm² YE -SVMC07:S -VMC06 S CAN 13 H 0.50 mm² YE -P066:9 -VMC13
7000/3212 ; 45
S CAN 8 H 0.50 mm² YE -SVMC13:S -VMC08 S CAN 11 H 0.50 mm² YE -SVMC13:S -VMC11
-SP71 ISOLATION GROUND RELAY 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
ID Tag Size Colour Destination Cable Cavity Seal Additional Components Additional Components
S 600BP 1.00 mm² YE -P016:10 -HRNS_CAB
-SVMC01 CAN H 1 7000/3212 ; 45 7000/3212 ; 45
S 600BM 1.50 mm² YE -P016:6 -HRNS_CAB
S 600BL 1.00 mm² YE -P016:5 -HRNS_CAB -SVMC11 CAN L 4 -SVMC17 CAN L 6
S CAN 2 H 0.50 mm² YE -P073:C -VMC02
S 600BK 1.00 mm² YE -P016:1 -HRNS_CAB ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
S CAN 1 H 0.50 mm² YE -P074:A -VMC01
S 600BS 3.00 mm² YE -SP61:S -HRNS_CAB S CAN 9 L 0.50 mm² GN -P135:33 -VMC09 S CAN 12 L 0.50 mm² GN -P039:C12 -VMC12
S CAN 3 H 0.50 mm² YE -SVMC04:S -VMC03
S CAN 6 L 0.50 mm² GN -SVMC08:S -VMC06 S CAN 13 L 0.50 mm² GN -P066:10 -VMC13
7000/3104 In Line Ultrasonic Splice S CAN 8 L 0.50 mm² GN -SVMC14:S -VMC08 S CAN 11 L 0.50 mm² GN -SVMC14:S -VMC11
7000/3212 ; 45 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
7000/3212 ; 45
-SP72 SPEED SENSOR PULL-UP -SVMC02 CAN L 1 7000/3212 ; 45 7000/3212 ; 45
S 480AA 1.00 mm² YE -P135:30 -HRNS_CAB S CAN 2 L 0.50 mm² GN -P073:D -VMC02 -SVMC12 CAN SHIELD 4 -SVMC18 CAN SHIELD 6
S 480B 1.00 mm² YE -P133:2 -HRNS_CAB S CAN 1 L 0.50 mm² GN -P074:B -VMC01 ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
S 480 1.00 mm² YE -P039:F9 -HRNS_CAB S CAN 3 L 0.50 mm² GN -SVMC05:S -VMC03 S CAN 9 SCR 0.50 mm² ?01? -SCREEN 4:S -VMC09 S CAN 12 SCR 0.50 mm² ?01? -P039:C10 -VMC12
S CAN 6 SCR 0.50 mm² ?01? -SVMC09:S -VMC06 S CAN 13 SCR 0.50 mm² ?01? -SCREEN 3:S -VMC13
7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice S CAN 8 SCR 0.50 mm² ?01? -SVMC15:S -VMC08 S CAN 11 SCR 0.50 mm² ?01? -SVMC15:S -VMC11
Additional Components Additional Components S CAN GND 2.00 mm² YE -SP3:S -HRNS_CAB
SWITCH SUPPLY CAN SHIELD 1 7000/3212 ; 45 Additional Components
-SP73 -SVMC03
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal 7000/3212 ; 45
S 500M 1.00 mm² YE -P133:1 -HRNS_CAB S CAN 2 SCR 0.50 mm² ?01? -SCREEN 1:S -VMC02
S 500S 1.00 mm² YE -P049:10 -HRNS_CAB S CAN 1 SCR 0.50 mm² ?01? -P074:C -VMC01
S 500A 1.00 mm² YE -P039:F4 -HRNS_CAB S CAN 3 SCR 0.50 mm² ?01? -SVMC06:S -VMC03
S 500N 1.00 mm² YE -P036:2 -HRNS_CAB
S 500AA 2.00 mm² YE -P004:16 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice
7000/3104 In Line Ultrasonic Splice 7000/3212 ; 45
7000/3212 ; 45 -SVMC04 CAN H 2
ID Tag Size Colour Destination Cable Cavity Seal -SCREEN 1 SCREEN 1 -SCREEN 4 SCREEN 4
-SP74 BOOM WORKLIGHTS SWITCH
S CAN 3 H 0.50 mm² YE -SVMC01:S -VMC03 ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
S CAN 4 H 0.50 mm² YE -SVMC07:S -VMC04 S CAN 2 SCR 0.50 mm² ?01? -SVMC03:S -VMC02 S CAN 9 SCR 0.50 mm² ?01? -SVMC12:S -VMC09
S CAN5 H 0.75 mm² YE -P068:D4 -HRNS_CAB
S 610A 0.75 mm² YE -P059:2 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
S 610AB 0.50 mm² YE -P040:8 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice Additional Components Additional Components
Additional Components 7000/3212 ; 45 7000/3212 ; 45
7000/3212 ; 45
Additional Components SCREEN 3 SCREEN 5
-SCREEN 3 -SCREEN 5
7000/3212 ; 45 ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
-SVMC05 CAN L 2
S CAN 13 SCR 0.50 mm² ?01? -SVMC18:S -VMC13 S CAN 10 SCR 0.50 mm² ?01? -SVMC15:S -VMC10
-SP75 BOOM WORKLIGHT
S CAN 3 L 0.50 mm² GN -SVMC02:S -VMC03 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
S CAN 4 L 0.50 mm² GN -SVMC08:S -VMC04 Additional Components Additional Components
S 947 1.50 mm² YE -P015:7 -HRNS_CAB
S CAN5 L 0.75 mm² YE -P068:E4 -HRNS_CAB
S 947B 1.50 mm² YE -P064B:1 -HRNS_CAB 7000/3212 ; 45 7000/3212 ; 45
S 947A 1.50 mm² YE -P039:A4 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice
7000/3212 ; 45
7000/3212 ; 45
-SVMC06 CAN SHIELD 2
-SP76 RH SIDE WORKLIGHT ID Tag Size Colour Destination Cable Cavity Seal
ID Tag Size Colour Destination Cable Cavity Seal S CAN 3 SCR 0.50 mm² ?01? -SVMC03:S -VMC03
S 948 1.50 mm² YE -P101:7 -HRNS_CAB S CAN 4 SCR 0.50 mm² ?01? -SVMC09:S -VMC04
S 948B 1.50 mm² YE -P140:1 -HRNS_CAB
S 948A 1.50 mm² YE -P039:G5 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice
7000/3212 ; 45
V1.1 30/06/2016
33 - 311 9823/1650-1 33 - 311

12 - Harness
15 - Front Console
Page Page
33-312 33-313
Figure 950. (Part

-SP68 RAS ECU1VBAT
of 2) 4TH GEAR SPLICE
-SP77 -SVMC07
S 203 2.00 mm² YE -P004:2 -HRNS_CAB
S 874 1.00 mm² YE -P037:13 -HRNS_CAB S CAN 4 H 0.50 mm²
S 203J 1.00 mm² YE -P135:6 -HRNS_CAB
S 874A 1.00 mm² YE -P141:1 -HRNS_CAB S CAN 6 H 0.50 mm²
S 203H 1.00 mm² YE -P135:5 -HRNS_CAB
S 874B 1.00 mm² YE -P142:1 -HRNS_CAB S CAN 7 H 0.50 mm²
S 203G 1.00 mm² YE -P135:4 -HRNS_CAB
S 203E 1.00 mm² YE -P135:3 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
7000/3212;45 # Adhesive Lined Heatshrink 7000/3212 ; 45
7000/3212 ; 45 -SP78 3RD GEAR SPLICE -SVMC08
-SP69 RAS ECU GROUND S 873 1.00 mm² YE -P037:5 -HRNS_CAB S CAN 4 L 0.50 mm²
ID Tag Size Colour Destination Cable Cavity Seal S 873A 1.00 mm² YE -P141:2 -HRNS_CAB S CAN 6 L 0.50 mm²
S 615D 1.00 mm² YE -P136:22 -HRNS_CAB S 873B 1.00 mm² YE -P105:1 -HRNS_CAB S CAN 7 L 0.50 mm²
S 615C 1.00 mm² YE -P135:17 -HRNS_CAB
S 615B 1.00 mm² YE -P135:16 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
S 615AA 4.00 mm² YE -SP62:S -HRNS_CAB 7000/3212;45 # Adhesive Lined Heatshrink 7000/3212 ; 45
7000/3104 In Line Ultrasonic Splice LL3

-SP79 -SVMC09
Additional Components ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size
7000/3212 ; 45 S 601LB 1.00 mm² YE -P068:M3 -HRNS_CAB S CAN 4 SCR 0.50 mm²
S 601LA 1.00 mm² YE -P068:L3 -HRNS_CAB S CAN 6 SCR 0.50 mm²
-SP70 SENSOR GND
S 601L 1.00 mm² YE -P005:12 -HRNS_CAB S CAN 7 SCR 0.50 mm²
S 699 1.00 mm² YE -P135:14 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
S 688E 0.75 mm² YE -P108:2 -HRNS_CAB
7000/3212;45 # Adhesive Lined Heatshrink 7000/3212 ; 45
S 688A 0.75 mm² YE -P107:2 -HRNS_CAB
S 699C 1.00 mm² YE -P039:C3 -HRNS_CAB
-SVMC10
7000/3104 In Line Ultrasonic Splice ID Tag Size
Additional Components S CAN 9 H 0.50 mm²
S CAN 6 H 0.50 mm²
7000/3212 ; 45
S CAN 8 H 0.50 mm²
-SP71 ISOLATION GROUND RELAY 7000/3104 In Line Ultrasonic Splice

S 600BP 1.00 mm² YE -P016:10 -HRNS_CAB
-SVMC01 CAN H 1 7000/3212 ; 45
S 600BM 1.50 mm² YE -P016:6 -HRNS_CAB
S 600BL 1.00 mm² YE -P016:5 -HRNS_CAB
S CAN 2 H 0.50 mm² YE -P073:C -VMC02
-SVMC11
S 600BK 1.00 mm² YE -P016:1 -HRNS_CAB ID Tag Size
S CAN 1 H 0.50 mm² YE -P074:A -VMC01
S 600BS 3.00 mm² YE -SP61:S -HRNS_CAB S CAN 9 L 0.50 mm²
S CAN 3 H 0.50 mm² YE -SVMC04:S -VMC03
S CAN 6 L 0.50 mm²
7000/3104 In Line Ultrasonic Splice S CAN 8 L 0.50 mm²
7000/3212 ; 45 7000/3104 In Line Ultrasonic Splice
7000/3212 ; 45
Page 33-313
-SP72 SPEED SENSOR PULL-UP -SVMC02 CAN L 1 7000/3212 ; 45
S 480AA 1.00 mm² YE -P135:30 -HRNS_CAB S CAN 2 L 0.50 mm² GN -P073:D -VMC02 -SVMC12
S 480B 1.00 mm² YE -P133:2 -HRNS_CAB S CAN 1 L 0.50 mm² GN -P074:B -VMC01 ID Tag Size
S 480 1.00 mm² YE -P039:F9 -HRNS_CAB S CAN 3 L 0.50 mm² GN -SVMC05:S -VMC03 S CAN 9 SCR 0.50 mm²
S CAN 6 SCR 0.50 mm²
7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice S CAN 8 SCR 0.50 mm²
-SP73 SWITCH SUPPLY -SVMC03 CAN SHIELD 1 7000/3212 ; 45
S 500M 1.00 mm² YE -P133:1 -HRNS_CAB S CAN 2 SCR 0.50 mm² ?01? -SCREEN 1:S -VMC02
S 500S 1.00 mm² YE -P049:10 -HRNS_CAB S CAN 1 SCR 0.50 mm² ?01? -P074:C -VMC01
S 500A 1.00 mm² YE -P039:F4 -HRNS_CAB S CAN 3 SCR 0.50 mm² ?01? -SVMC06:S -VMC03
S 500N 1.00 mm² YE -P036:2 -HRNS_CAB
S 500AA 2.00 mm² YE -P004:16 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice
7000/3212 ; 45 -SVMC04 CAN H 2
ID Tag Size Colour Destination Cable Cavity Seal -SCREEN 1
-SP74 S CAN 3 H 0.50 mm² YE -SVMC01:S -VMC03 ID Tag
S CAN 4 H 0.50 mm² YE -SVMC07:S -VMC04 S CAN 2 SCR
S CAN5 H 0.75 mm² YE -P068:D4 -HRNS_CAB
S 610A 0.75 mm² YE -P059:2 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice
S 610AB 0.50 mm² YE -P040:8 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice Additional Components
7000/3212 ; 45
-SCREEN 3
7000/3212 ; 45 ID Tag
-SVMC05 CAN L 2
S CAN 13 SCR
-SP75 BOOM WORKLIGHT
S CAN 3 L 0.50 mm² GN -SVMC02:S -VMC03 7000/3104 In Line Ultrasonic Splice
S CAN 4 L 0.50 mm² GN -SVMC08:S -VMC04 Additional Components
S 947 1.50 mm² YE -P015:7 -HRNS_CAB
S CAN5 L 0.75 mm² YE -P068:E4 -HRNS_CAB
S 947B 1.50 mm² YE -P064B:1 -HRNS_CAB 7000/3212 ; 45
S 947A 1.50 mm² YE -P039:A4 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice
7000/3212 ; 45
7000/3212 ; 45
-SVMC06 CAN SHIELD 2
-SP76 RH SIDE WORKLIGHT ID Tag Size Colour Destination Cable Cavity Seal
ID Tag Size Colour Destination Cable Cavity Seal S CAN 3 SCR 0.50 mm² ?01? -SVMC03:S -VMC03
S 948 1.50 mm² YE -P101:7 -HRNS_CAB S CAN 4 SCR 0.50 mm² ?01? -SVMC09:S -VMC04
S 948B 1.50 mm² YE -P140:1 -HRNS_CAB
S 948A 1.50 mm² YE -P039:G5 -HRNS_CAB 7000/3104 In Line Ultrasonic Splice
7000/3212 ; 45
V1.1 30/06/2016
33 - 312 9823/1650-1 33 - 312

12 - Harness
15 - Front Console
Page Page
33-312 33-313
Figure 950. (PartCAN

2 of
H3
2) CAN H 5
-SVMC07 -SVMC13
S CAN 7 H 0.50 mm² YE -P071:8 -VMC07 S CAN 10 H 0.50 mm² YE -P137:4 -VMC10

7000/3212 ; 45 7000/3212 ; 45
-SVMC08 CAN L 3
-SVMC14 CAN L 5
Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
S CAN 7 L 0.50 mm² GN -P071:7 -VMC07
S CAN 10 L 0.50 mm² GN -P137:3 -VMC10
7000/3212 ; 45
7000/3212 ; 45
-SVMC09 CAN SHIELD 3 -SVMC15 CAN SHIELD 5

S CAN 7 SCR 0.50 mm² ?01? -P071:9 -VMC07 S CAN 11 SCR 0.50 mm² ?01? -SVMC18:S -VMC11

7000/3212 ; 45 7000/3212 ; 45
-SVMC10 CAN H 4 -SVMC16 CAN H 6

S CAN 9 H 0.50 mm² YE -P135:34 -VMC09 S CAN 12 H 0.50 mm² YE -P039:C11 -VMC12
S CAN 6 H 0.50 mm² YE -SVMC07:S -VMC06 S CAN 13 H 0.50 mm² YE -P066:9 -VMC13

7000/3212 ; 45 7000/3212 ; 45
Cavity Seal
-SVMC11 CAN L 4 -SVMC17 CAN L 6
S CAN 9 L 0.50 mm² GN -P135:33 -VMC09 S CAN 12 L 0.50 mm² GN -P039:C12 -VMC12
S CAN 6 L 0.50 mm² GN -SVMC08:S -VMC06 S CAN 13 L 0.50 mm² GN -P066:10 -VMC13
S CAN 8 L 0.50 mm² GN -SVMC14:S -VMC08 S CAN 11 L 0.50 mm² GN -SVMC14:S -VMC11

Page 33-312
7000/3212 ; 45 7000/3212 ; 45
Cavity Seal
-SVMC12 CAN SHIELD 4 -SVMC18 CAN SHIELD 6
S CAN 9 SCR 0.50 mm² ?01? -SCREEN 4:S -VMC09 S CAN 12 SCR 0.50 mm² ?01? -P039:C10 -VMC12
S CAN GND 2.00 mm² YE -SP3:S -HRNS_CAB
7000/3212 ; 45 Additional Components
Cavity Seal 7000/3212 ; 45
Cavity Seal -SCREEN 1 SCREEN 1 -SCREEN 4 SCREEN 4


7000/3212 ; 45 7000/3212 ; 45
-SCREEN 3 SCREEN 3 -SCREEN 5 SCREEN 5

Cavity Seal
7000/3212 ; 45 7000/3212 ; 45
Cavity Seal
33 - 313 9823/1650-1 33 - 313

12 - Harness
15 - Front Console
(For: 512-56 [T4i], 514-56 [T4i])

Figure 951. Panel Harness Connections 721/D9067- Issue 3 (sheet 1 of 6)....................... Page 33-317
Panel Harness P034 Stabilizer isolation
switch
P036 Indicator diode
Table 451.
P037 Heater connector
P001 Secondary fusebox A P038 Heater switch
P002 Secondary fusebox B P039 Earth
P003 Secondary fusebox C P040 Earth
P004 Secondary fusebox D P041 Left hand column switch
P005 Neutral start relay P042 Diode gate
P006 Forward drive relay P043 Information button
P006 Ignition relay 1 P046 Diagnostic connector
P008 Ignition relay 1 P052 Centre cluster warning
P009 Flasher relay lights
P009 Ignition relay 2 P055 Right hand cluster con-
P010 Reverse drive relay nector J1
P010 Ignition relay 3 P056 Right hand cluster con-
P011 Ignition relay 4 nector J2
P011 Front work lights relay P057 Rear cab harness con-
nector
P012 Rear work lights relay
P058 Right hand column
P012 Transmission dump re- switch
lay
P013 Park brake warning light
relay P060 Ignition switch
P013 Drive relay P061 Primary fuse C & D
P014 Driveshaft relay P062 Primary fuse A & B
P014 Reverse high/low relay P063 Diode gate
P017 Brake lights relay P064 Primary fuse blue G & H
P017 Road lights relay P065 Primary fuse grey E & F
P017 Engine running relay P066 Foot brake
P018 Park brake relay P067 Face level fan (+ve)
P019 Park brake relay P068 Face level fan (-ve)
P020 Chassis harness con- P069 Washer pump
nector P071 Spare
P023 Air conditioning switch P076 Front wiper motor
(+ve) P077 Auxiliary socket
P024 Air conditioning switch (- P078 Auxiliary socket illumina-
ve) tion
P025 Hazard switch P082 Radio
P026 Roof wiper switch P088 Work lights
P027 Rear wiper switch P091 Terminating resistor
P028 Fog light switch P092 Engine supply
P029 Road lights switch P093 Immobiliser
P030 Work lights switch P094 Immobiliser link
P032 Beacon switch
33 - 314 9823/1650-1 33 - 314

12 - Harness
15 - Front Console
P097 Hydraulic isolation P105 Left hand and right hand

switch RAS return relay
P098 Hour meter (+ve) P106 RAS ECU (Electronic
P099 Hour meter (-ve) Control Unit) J1
P100 Hour meter signal P107 RAS ECU J2
P101 Lift arm raise return, P109 Park brake
sway/stab isolation re-
turn relay
33 - 315 9823/1650-1 33 - 315

Notes:
33 - 316 9823/1650-1 33 - 316

12 - Harness
15 - Front Console
Page 33-318 Figure 951. Panel Harness Connections

33 - 317 9823/1650-1 33 - 317

12 - Harness
15 - Front Console
Page Page
33-318 33-319
Page 33-319
33 - 318 9823/1650-1 33 - 318

12 - Harness
15 - Front Console
Page Page
33-318 33-319

Page 33-318
33 - 319 9823/1650-1 33 - 319

12 - Harness
15 - Front Console
33 - 320 9823/1650-1 33 - 320

12 - Harness
15 - Front Console

33 - 321 9823/1650-1 33 - 321

12 - Harness
15 - Front Console
Page Page
33-322 33-323
Page 33-323
33 - 322 9823/1650-1 33 - 322

12 - Harness
15 - Front Console
Page Page
33-322 33-323

Page 33-322
33 - 323 9823/1650-1 33 - 323

12 - Harness
15 - Front Console
33 - 324 9823/1650-1 33 - 324

12 - Harness
15 - Front Console

33 - 325 9823/1650-1 33 - 325

12 - Harness
15 - Front Console
Page Page
33-326 33-327
Page 33-327
33 - 326 9823/1650-1 33 - 326

12 - Harness
15 - Front Console
Page Page
33-326 33-327

Page 33-326
33 - 327 9823/1650-1 33 - 327

12 - Harness
15 - Front Console
33 - 328 9823/1650-1 33 - 328

12 - Harness
15 - Front Console

33 - 329 9823/1650-1 33 - 329

12 - Harness
15 - Front Console
Page Page
33-330 33-331
Page 33-331
33 - 330 9823/1650-1 33 - 330

12 - Harness
15 - Front Console
Page Page
33-330 33-331

Page 33-330
33 - 331 9823/1650-1 33 - 331

12 - Harness
15 - Front Console
33 - 332 9823/1650-1 33 - 332

12 - Harness
15 - Front Console

33 - 333 9823/1650-1 33 - 333

12 - Harness
15 - Front Console
Page Page
33-334 33-335
Page 33-335
33 - 334 9823/1650-1 33 - 334

12 - Harness
15 - Front Console
Page Page
33-334 33-335

Page 33-334
33 - 335 9823/1650-1 33 - 335

12 - Harness
15 - Front Console
33 - 336 9823/1650-1 33 - 336

12 - Harness
15 - Front Console

33 - 337 9823/1650-1 33 - 337

12 - Harness
15 - Front Console
Page Page
33-338 33-339
Page 33-339
33 - 338 9823/1650-1 33 - 338

12 - Harness
15 - Front Console
Page Page
33-338 33-339

Page 33-338
33 - 339 9823/1650-1 33 - 339

12 - Harness
19 - Engine Compartment Cover
Diagram
Figure 957. Engine Pod Harness - 721/C5852-6 (Sheet 1 of 3).......................................... Page 33-341
33 - 340 9823/1650-1 33 - 340

12 - Harness
Page 33-342 Figure 957. Engine Pod Harness

- 721/C5852-6 (Sheet 1 of 3) Page 33-343
33 - 341 9823/1650-1 33 - 341

12 - Harness
Page Page
33-342 33-343
Page 33-343
33 - 342 9823/1650-1 33 - 342

12 - Harness
Page Page
33-342 33-343

Page 33-342
33 - 343 9823/1650-1 33 - 343

12 - Harness
33 - 344 9823/1650-1 33 - 344

12 - Harness

- 721/C5852-6 (Sheet 2 of 3) Page 33-347
33 - 345 9823/1650-1 33 - 345

12 - Harness
Page Page
33-346 33-347
Page 33-347
33 - 346 9823/1650-1 33 - 346

12 - Harness
Page Page
33-346 33-347

Page 33-346
33 - 347 9823/1650-1 33 - 347

12 - Harness
33 - 348 9823/1650-1 33 - 348

12 - Harness

- 721/C5852-6 (Sheet 3 of 3) Page 33-351
33 - 349 9823/1650-1 33 - 349

12 - Harness
Page Page
33-350 33-351
Page 33-351
33 - 350 9823/1650-1 33 - 350

12 - Harness
Page Page
33-350 33-351

Page 33-350
33 - 351 9823/1650-1 33 - 351

12 - Harness
30 - Gearbox
30 - Gearbox
Diagram
(For: 506-36 [T4i], 507-42 [T4i], 509-42 [T4i], 512-56 [T4i], 514-56 [T4i], PS750 Mk4)
Figure 960. Transmission Harness - 721/C7537-3 (Sheet 1 of 1)........................................Page 33-353
33 - 352 9823/1650-1 33 - 352

12 - Harness
30 - Gearbox
Page 33-354 Figure 960. Transmission Harness

- 721/C7537-3 (Sheet 1 of 1) Page 33-355
33 - 353 9823/1650-1 33 - 353

12 - Harness
30 - Gearbox
Page Page
33-354 33-355
Page 33-355
33 - 354 9823/1650-1 33 - 354

12 - Harness
30 - Gearbox
Page Page
33-354 33-355

Page 33-354
33 - 355 9823/1650-1 33 - 355

12 - Harness
48 - LiveLink
48 - LiveLink
Diagram
Figure 961. LiveLink Harness - 721/C0140-1 (Sheet 1 of 1)............................................... Page 33-357
33 - 356 9823/1650-1 33 - 356

12 - Harness
48 - LiveLink
Page 33-358 Figure 961. LiveLink Harness

- 721/C0140-1 (Sheet 1 of 1) Page 33-359
33 - 357 9823/1650-1 33 - 357

12 - Harness
48 - LiveLink
Page Page
33-358 33-359
Page 33-359
33 - 358 9823/1650-1 33 - 358

12 - Harness
48 - LiveLink
Page Page
33-358 33-359

Page 33-358
33 - 359 9823/1650-1 33 - 359

12 - Harness
53 - Stabiliser
53 - Stabiliser
Diagram
For: 506-36 [T4i], 507-42 [T4i], 509-42 [T4i]

................................................. Page 33-360
For: 512-56 [T4i], 514-56 [T4i]
................................................. Page 33-365
(For: 506-36 [T4i], 507-42 [T4i], 509-42 [T4i])

Figure 962. Stabiliser / Headlights Harness 721/12107-1.................................................... Page 33-361
Stabiliser / Headlights Harness
33 - 360 9823/1650-1 33 - 360

12 - Harness
53 - Stabiliser
Page 33-362 Figure 962. Stabiliser /

Headlights Harness 721/12107-1 Page 33-363
33 - 361 9823/1650-1 33 - 361

12 - Harness
53 - Stabiliser
Page Page
33-362 33-363
Page 33-363
33 - 362 9823/1650-1 33 - 362

12 - Harness
53 - Stabiliser
Page Page
33-362 33-363

Page 33-362
33 - 363 9823/1650-1 33 - 363

12 - Harness
53 - Stabiliser
RL001 Right stabiliser transducer

RL002 Left stabiliser transducer
RL003 Right headlight
RL004 Left headlight
RL005 Chassis connector
33 - 364 9823/1650-1 33 - 364

12 - Harness
53 - Stabiliser
(For: 512-56 [T4i], 514-56 [T4i])

Figure 963. Stabiliser Harness 332/D7008-1....................................................................... Page 33-367
Figure 964. Stabiliser / headlights harness 332/D7007-1.....................................................Page 33-371
Figure 965. Stabiliser link harness 332/D7009-1................................................................. Page 33-375
Stabiliser Harness
33 - 365 9823/1650-1 33 - 365

Notes:
33 - 366 9823/1650-1 33 - 366

12 - Harness
53 - Stabiliser
Page 33-368 Figure 963. Stabiliser Harness 332/D7008-1 Page 33-369
33 - 367 9823/1650-1 33 - 367

12 - Harness
53 - Stabiliser
Page Page
33-368 33-369
Page 33-369
33 - 368 9823/1650-1 33 - 368

12 - Harness
53 - Stabiliser
Page Page
33-368 33-369

Page 33-368
33 - 369 9823/1650-1 33 - 369

12 - Harness
53 - Stabiliser
RL001 Right stabiliser transducer RL002 Left stabiliser transducer

33 - 370 9823/1650-1 33 - 370

12 - Harness
53 - Stabiliser
Page 33-372 Figure 964. Stabiliser /

headlights harness 332/D7007-1 Page 33-373
33 - 371 9823/1650-1 33 - 371

12 - Harness
53 - Stabiliser
Page Page
33-372 33-373
Page 33-373
33 - 372 9823/1650-1 33 - 372

12 - Harness
53 - Stabiliser
Page Page
33-372 33-373

Page 33-372
33 - 373 9823/1650-1 33 - 373

12 - Harness
53 - Stabiliser
RL001 Right stabiliser transducer RL002 Left stabiliser transducer

RL003 Right headlight RL004 Left headlight
33 - 374 9823/1650-1 33 - 374

12 - Harness
53 - Stabiliser
Page 33-376 Figure 965. Stabiliser link harness 332/D7009-1 Page 33-377
33 - 375 9823/1650-1 33 - 375

12 - Harness
53 - Stabiliser
Page Page
33-376 33-377
Page 33-377
33 - 376 9823/1650-1 33 - 376

12 - Harness
53 - Stabiliser
Page Page
33-376 33-377

Page 33-376
33 - 377 9823/1650-1 33 - 377

12 - Harness
53 - Stabiliser
S001 Pressure switch

S002 Stabiliser harness connector
33 - 378 9823/1650-1 33 - 378

12 - Harness
56 - Extreme Cold Climate Heater
Diagram
Figure 966. Grid Heater Fuse Link Lead - 718/E0209-3 (Sheet 1 of 1)............................... Page 33-381
Figure 967. Grid Heater Relay to Heater Power lead - 718/E0210-3 (Sheet 1 of 1)............ Page 33-385
33 - 379 9823/1650-1 33 - 379

Notes:
33 - 380 9823/1650-1 33 - 380

12 - Harness
Page 33-382 Figure 966. Grid Heater Fuse Link

Lead - 718/E0209-3 (Sheet 1 of 1) Page 33-383
33 - 381 9823/1650-1 33 - 381

12 - Harness
Page Page
33-382 33-383
Page 33-383
33 - 382 9823/1650-1 33 - 382

12 - Harness
Page Page
33-382 33-383

Page 33-382
33 - 383 9823/1650-1 33 - 383

12 - Harness
33 - 384 9823/1650-1 33 - 384

12 - Harness
Page 33-386 Figure 967. Grid Heater Relay to Heater

Power lead - 718/E0210-3 (Sheet 1 of 1) Page 33-387
33 - 385 9823/1650-1 33 - 385

12 - Harness
Page Page
33-386 33-387
Page 33-387
33 - 386 9823/1650-1 33 - 386

12 - Harness
Page Page
33-386 33-387

Page 33-386
33 - 387 9823/1650-1 33 - 387

12 - Harness
64 - Rear Axle Stabilization (RAS)
Diagram
(For: 507-42 [T4i], 509-42 [T4i], 512-56 [T4i], 514-56 [T4i])

Figure 968. RAS Panel Harness 332/D8490- Issue 1 (sheet 1 of 2)................................... Page 33-389
Figure 970. RAS Chassis Harness 332/D8489- Issue 1 (sheet 1 of 1)................................ Page 33-393
RAS Harness
33 - 388 9823/1650-1 33 - 388

12 - Harness
Page 33-390 Figure 968. RAS Panel Harness

33 - 389 9823/1650-1 33 - 389

12 - Harness
Page Page
33-390 33-391
Page 33-391
33 - 390 9823/1650-1 33 - 390

12 - Harness
Page Page
33-390 33-391

Page 33-390
33 - 391 9823/1650-1 33 - 391

12 - Harness
PA001 Panel connector PA002 RAS (Rear Axle Stabilization) interface 1

PA003 RAS interface 2 PA004 Ground speed right hand feedback
PA005 Park brake PA006 RAS Controller J1
PA007 RAS Controller J2 PA008 CAN (Controller Area Network)
PA009 CAN terminator
Figure 969. RAS Panel Harness 332/D8490- Issue 1 (sheet 2 of 2)
33 - 392 9823/1650-1 33 - 392

12 - Harness
Page 33-394 Figure 970. RAS Chassis Harness

33 - 393 9823/1650-1 33 - 393

12 - Harness
Page Page
33-394 33-395
Page 33-395
33 - 394 9823/1650-1 33 - 394

12 - Harness
Page Page
33-394 33-395

Page 33-394
33 - 395 9823/1650-1 33 - 395

12 - Harness
RA001 Panel connector RA002 Left RAS cylinder

RA003 Right RAS cylinder RA004 Sway switch
RA005 Left stabiliser switch RA006 Right stabiliser switch
RA007 Inloader valve RA008 Ground
RA009 Left stabiliser link RA010 Right stabiliser link
33 - 396 9823/1650-1 33 - 396

15 - Alarm
15 - Alarm
Contents Page No.
33-15-03 Reverse Warning .......................................................................................................... 33-399
33 - 397 9823/1650-1 33 - 397

Notes:
33 - 398 9823/1650-1 33 - 398

15 - Alarm
03 - Reverse Warning
03 - Reverse Warning
Introduction
The reverse alarm will sound when the machine is

moving in the reverse direction. The alarm will sound
anytime the drive control is moved into the reverse
position. In this position the drive control sends a
signal to the main ECU (Electronic Control Unit) to
sound the alarm.
33 - 399 9823/1650-1 33 - 399

21 - Immobiliser
21 - Immobiliser
Contents Page No.
33-21-00 General ......................................................................................................................... 33-401
33 - 400 9823/1650-1 33 - 400

21 - Immobiliser
00 - General
00 - General Preparation
Special Tools
Preparation .................................................. 33-401
Check (Operation) ....................................... 33-404
(DLA) Kit
The immobiliser set-up tool is provided to setup or

amend the immobiliser settings. Situations which
may require the immobiliser settings to be changed
may be:
• Transfer of machine ownership.

• Replacement of immobiliser system
components.
• Loss of keys/codes to deactivate the
immobiliser.
The tool is used to perform the following actions:
• Obtain an unlock ‘Response Code’ for security

authorisation to re-configure the immobiliser.
(The ‘Response Code’ is only available via JCB
Tech Web.)
• Configure a new immobiliser. (Change from
‘Factory Mode’ to key system or keypad system
mode as applicable).
• Configure new immobiliser keys. (Key systems
only).
• Configure new immobiliser codes. (Keypad
systems only).
• Delete existing keys/codes.
Installing Immobiliser Set-Up

The set-up tool is fully integrated within JCB
Servicemaster. To use the set-up tool you must install
JCB Servicemaster onto a suitable laptop computer.
For full instructions on how to install

JCB Servicemaster software please refer to
the documentation which accompanies JCB
Servicemaster.
Starting Immobiliser Set-Up

1. Connect the Servicemaster diagnostic tool.
1)
2. Turn on the machine ignition.
3. Start JCB Servicemaster on the laptop computer
and select the correct machine range.
4. Start the diagnostics tool running by clicking on
the Immobiliser Set-up icon.
33 - 401 9823/1650-1 33 - 401

21 - Immobiliser
00 - General
Figure 971. • System diagram.

• Active Fault Codes.
This tool is used to show the following:
• Status of the immobiliser internal switches.

• Status of devices connected to the immobiliser
ECU. (includes key antenna and keypad
devices).
Using The Immobiliser Set up Tool • View active fault codes.
To use the immobiliser set up tool click on the “Help
Menu” and select “Help”. The Help file will display
Installing Immobiliser Diagnostics
and details the procedures to unlock and use the tool. The diagnostics tool is fully integrated within JCB
Refer to Figure 972. Servicemaster. To use the set-up tool you must install
JCB Servicemaster onto a suitable laptop computer.
Figure 972.
For full instructions on how to install
JCB Servicemaster software please refer to
the documentation which accompanies JCB
Servicemaster.
Connecting Immobiliser Diagnostics

To use the diagnostics tool the DLA and your
laptop computer must be connected to the machine
diagnostics connector.
Starting Immobiliser Diagnostics

1. Connect the Servicemaster diagnostic tool.
2. Turn ON the machine ignition.
3. Start JCB Servicemaster on the laptop computer
and select the correct machine range.
4. Start the diagnostics tool running by clicking on
the Immobiliser Diagnostics icon.
Figure 973.
Immobiliser Diagnostic Tool Using the Immobiliser Diagnostics Tool

The immobiliser diagnostics tool has the following
To use the immobiliser diagnostics tool click on the
status windows:
‘Help Menu’ and select ‘Help’. The Help file will
display and details the procedures for use of the tool.
33 - 402 9823/1650-1 33 - 402

21 - Immobiliser
00 - General
Figure 974.
33 - 403 9823/1650-1 33 - 403

21 - Immobiliser
00 - General
Check (Operation)
Special Tools
(DLA) Kit
1. Use the applicable Servicemaster diagnostics

tool to identify the faults.
1)
2. Make sure that the applicable control interface
operates correctly. Rectify as required.
4. Do not use a multimeter at the pins on the ECU
(Electronic Control Unit). Only use the meter at
the pins on the harness connectors.
5. Without the use of sophisticated electronic test
equipment it is not possible to test the ECU. If the
ECU is returned under warranty it will be tested
at the factory to confirm possible faults.
33 - 404 9823/1650-1 33 - 404

24 - Instruments
24 - Instruments
Contents Page No.

33-24-10 Hourmeter .................................................................................................................... 33-411
33 - 405 9823/1650-1 33 - 405

Notes:
33 - 406 9823/1650-1 33 - 406

24 - Instruments
03 - Instrument Panel
03 - Instrument Panel Introduction

Introduction .................................................. 33-407 The instrument panel communicates information to
Fault-Finding ................................................ 33-408 the operator about the systems on the machine and
Remove and Install ..................................... 33-408 warns of any abnormal conditions that may occur.
The instrument panel houses all the gauges and
warning lights on the machine i.e. fuel gauge, coolant
warning, engine oil pressure warning light. For more
detailed information refer to the operator manual.
33 - 407 9823/1650-1 33 - 407

24 - Instruments
Fault-Finding
For the full list of fault codes, refer to (PIL 33-57). Remove and Install
Centre Warning Light Panel

Remove
3. Remove the screws (x2) that hold the centre
display panel in place.
4. Disconnect all connections and remove the
panel.
Figure 975. Centre Warning Light Panel
A A
00: 00: 05
A Retaining screws (x2)
Install
removal procedure.
Heater Control Panel

Remove
3. Remove the screws (x2) that hold the heater
control panel in place, disconnect all connections
and remove the panel.
33 - 408 9823/1650-1 33 - 408

24 - Instruments
Depending on the specification of your machine, you Install

will have one of two types of heater control panel.
Refer to Figure 976. and Refer to Figure 977. 1. The installation procedure is the opposite of the
Install step.
1. The installation procedure is the opposite of the 1.1. Make sure that the switch housing is aligned
removal procedure. correctly with the panel to make sure that
the switch is in the correct position for all the
Figure 976. Heater Control Panel (S1) switch settings.
Figure 978. Left Side Switch Panel
A A
A
A
A Retaining screws (x2) B

Figure 977. Heater Control Panel (S2)
B Left side switch panel
Figure 979. Left Side Switch Panel
C
Left Side Switch Panel

Remove D

E
3. Remove the screws (x2) that hold the left
side switch panel in place and disconnect all
connections. Remove the panel.
4. To remove the rotary switch:
4.1. Remove the knob from the front of the F
panel.
4.2. Mark the position of the switch housing in C Knob
relation to the trim panel. D Panel
E Switch
4.3. Unscrew the locknut and remove the switch F Locknut
from the panel.
33 - 409 9823/1650-1 33 - 409

24 - Instruments
Right Side Instrument Panel

Notice: Make sure you do not touch
the electrical connector pins on electronic
instruments. Make sure you put protective caps
on harness connectors and the connectors on the
instruments.
Remove
3. Remove the radio (if installed).
4. Remove the screws (x3) that hold the main
switch and instrument panel in place. Disconnect
all connections and remove the panel.
Install
removal procedure.
Figure 980. Right Side Instrument Panel
D
D
D
C Electronic instruments
D Retaining screws (x3)
E Radio (if installed)
33 - 410 9823/1650-1 33 - 410

24 - Instruments
10 - Hourmeter
10 - Hourmeter
Introduction
The hourmeter is a device that records the operating

time of an engine, machine, or mechanism, it is used
to monitor and log the service life of the engine. The
hours of operation are determined from the number
of revolutions of the engine.
33 - 411 9823/1650-1 33 - 411

27 - Interior Switch
Contents Page No.
33-27-03 Multi-Purpose ............................................................................................................... 33-413
33 - 412 9823/1650-1 33 - 412

03 - Multi-Purpose
03 - Multi-Purpose Figure 981.
Remove and Install
Remove
Refer to (PIL 01-03). A A
B
3. Remove the steering wheel. Refer to (PIL 09-36).
4. Remove the screws (x2) on the top of the
steering column upper surround.
5. Remove the button head screws (x2). 00:00:05
6. Remove the steering column lower surround.

7. Remove the button head screws (x2).
C
8. Remove the steering column upper surround.
9. Remove the steering column switch retaining
plate screw.
10. Remove the retaining plate (if installed).
A Steering upper column surround
11. Remove the switch covers. B Button head screw 1
C Button head screw 2
12. Disconnect the harness connectors.
Figure 982.
13. Remove the retaining screw from the switch
collar. D
14. Pull the column switches away from the column.

E F
F
H
H G
J
J
K
D Retaining plate screw

E Switch retaining plate
F Switch cover
G Switch collar
H Column switch
J Harness connector
K Retaining screw
33 - 413 9823/1650-1 33 - 413

03 - Multi-Purpose
Install
steps.
1.1. Make sure that the transmission lever
securing bolt has 2 washers installed as
shown. Refer to Figure 983.
Figure 983.
L Transmission lever securing bolt
33 - 414 9823/1650-1 33 - 414

40 - Bulb
40 - Bulb
Contents Page No.
33-40-00 General ......................................................................................................................... 33-417
33 - 415 9823/1650-1 33 - 415

Notes:
33 - 416 9823/1650-1 33 - 416

40 - Bulb
00 - General
Introduction .................................................. 33-417 Make sure the bulbs are replaced with the same type
Technical Data ............................................. 33-418 and rating as the damaged bulb.
33 - 417 9823/1650-1 33 - 417

40 - Bulb
00 - General
Technical Data Remove and Install
Table 452. Remove

Application Rating Type
1. Before replacing any bulb, make the machine
Work lights 55 W H3 safe with the lift arm lowered. Refer to (PIL
Headlights 55 W H3 01-03).
Dip beam 55 W H7
2. Stop the engine and isolate the battery. Refer to
Side lights 4W T4W
(PIL 33-03-03).
Direction indica- 21 W
tor lights 3. If necessary, wait for the light to cool down.
Brake lights 21 W
4. Wear protective gloves.
Interior light 10 W
Warning lights 1.2 W 5. Gain access to the defective bulb.
Beacon (if fit- 55 W
6. Remove the defective bulb
ted)
Install
1. Replace the bulb with one of the correct type
and specification. Refer to technical data, (PIL
33-40-00).
2. Where applicable, make sure you follow the bulb
manufacturers installation instructions. Make
sure you do not touch halogen bulbs by the glass.
Use gloves if necessary.
3. Make sure that the bulb is correctly aligned as it
is installed. Some bulb caps have projections to
make sure they are fitted in the correct orientation
and/or application.
4. If necessary, make sure that the light lens is clean
and the electrical contacts are free of corrosion.
5. Make sure that any seals are in serviceable
condition and are installed correctly.
6. Install any items removed when removing the
bulb.
7. Connect the battery. Refer to (PIL 33-03-03).
8. Make sure that the light works. (It is good practice
to check that the other lights are working too).
9. If appropriate, check the alignment of any light
unit that has had a bulb replacement.
33 - 418 9823/1650-1 33 - 418

45 - Control Module
45 - Control Module
Contents Page No.
33-45-00 General ......................................................................................................................... 33-421

33-45-06 Engine .......................................................................................................................... 33-425
33-45-09 Gearbox ........................................................................................................................ 33-427
33 - 419 9823/1650-1 33 - 419

Notes:
33 - 420 9823/1650-1 33 - 420

45 - Control Module
00 - General
Introduction .................................................. 33-421 Modern machines use ECU (Electronic Control Unit)
Health and Safety ........................................ 33-422 to control machine systems such as hydraulics,
Operation ..................................................... 33-422 transmission and engine. In much the same way as
office computers can be ‘networked’ to communicate
with each other the machine ECU’s can be
‘networked’. Some advantages of networking are:
• Improved more intelligent control systems

• More comprehensive and reliable in-cab
instrumentation
• Service software tools can be used for fault
finding and machine control set up
The ECM (Engine Control Module) can communicate

with other machine ECU using a CANbus network
system.
CANbus Communications System

CAN (Controller Area Network) is an electronic
communications system that connects all the
machine ECU to one pair of data wires, this is called
the CANbus. Coded data is sent to and from the
ECU on the CANbus. By connecting Servicemaster
diagnostic software to the CANbus, data is seen and
decoded for use by a service engineer.
CANbus System Schematic

A typical CANbus system architecture is shown for
illustration purposes only below: Refer to Figure 984.
Figure 984. Typical CANbus architecture
ECU ECU ECU ECU ECU
F B C E G
Hi
Lo
Hi H
ECU Lo
A D
The CAN architecture may differ on your machine.

33 - 421 9823/1650-1 33 - 421

45 - Control Module
00 - General
Health and Safety Operation

Arc Welding The machines use an ECU (Electronic Control
To prevent the possibility of damage to electronic Unit) to control machine operations. The ECU uses
components, disconnect the battery and the analogue and digital signals from machine sensors,
alternator before arc-welding on the machine or switches etc. and uses this data to supply a feed or
attached implements. a ground connection for other machine devices. The
If the machine is equipped with sensitive electrical machines can have one or more ECU’s depending
equipment, i.e. amplifier drivers, electronic control on the model variant. For information on each ECU,
units (ECUs), monitor displays, etc., then disconnect refer to the correct topic in the subsequent pages.
them before welding. Failure to disconnect the
The machine ECU's can be connected to JCB
sensitive electrical equipment could result in
servicemaster diagnostic software to check ECU
version and operation. Refer to electrical system-
Parts of the machine are made from cast iron, welds electronic diagnostic. Refer to: PIL 33-57.
on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable ECU Inputs
or apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to There are two main types of input, digital and
the same component that is being welded to avoid analogue.
the welder earth (ground) cable a distance from the Digital inputs (On-Off switch type inputs)
part being welded no more than 0.6 m.
Digital type inputs are on-off type inputs (i.e.
Notice: Do not disconnect the battery while the switches). The digital inputs can be low side inputs or
engine is running, otherwise the electrical circuits high side inputs. The low side inputs are inputs that
may be damaged. provide a ground to the ECU. The high side inputs
are the inputs that provide a positive feed to the ECU.
Low side input
The low side input is the most frequently used input

on an electrical system. The low side input can be in
the form of rocker switches or pressure switches.
Figure 985.
C
12 v
B
A ECU
B Input
C Switch (rocker, pressure etc.)
High side input
The high side input is used on circuits that require a

positive feed when the ignition is switched off, e.g.
sidelights or hazard lights.
33 - 422 9823/1650-1 33 - 422

45 - Control Module
00 - General

A A
C
C
12 v 12 v
B B
A ECU A ECU
B Input B Output
C Switch (lights etc.) C Solenoid or relay coil
Analogue inputs (Sensor type switch inputs) High side output
Analogue inputs are sensor type inputs that provide In the high side output circuit, the solenoid or relay
a varying type input to the ECU. This input could be which is being driven already has a ground available.
a voltage, resistance or frequency type input. The ECU provides the positive side of the circuit.
A A C
E
B
5v 12 v
C B
D A ECU
B Output
C Solenoid or relay coil
A ECU
B Sensor ref voltage Modulated outputs
C Sensor ref 0 voltage
D Thumbwheel input (potentiometer type input) In the modulated output circuit, the ECU provides
E Thumbwheel position switch a PWM (Pulse Width Modulation) signal to a
proportional valve. As the ECU varies the duty cycle
ECU Outputs of the signal, the proportional valve will be selected
depending on the change in duty cycle.
There are three main types of outputs. Low side
output, High side output and Modulated output. Figure 990.
Low side output A C
In the low side output circuit, the solenoid or relay

which is being driven already has a positive feed B
available. The ECU then provides ground to the
circuit.
A ECU
B Output
C Proportional solenoid
33 - 423 9823/1650-1 33 - 423

45 - Control Module
Check (Operation)
Special Tools
(DLA) Kit
1. Use the Servicemaster diagnostics tool to

identify faults.
1)
2. Make sure that the applicable control interface
operates correctly. Rectify as required.
4. Do not use a multimeter at the pins on the ECU
(Electronic Control Unit). Only use the meter at
the pins on the harness connectors.
5. Without the use of sophisticated electronic test
equipment, it is not possible to test the ECU. If the
ECU is returned under warranty it will be tested
at the factory to confirm possible faults.
33 - 424 9823/1650-1 33 - 424

45 - Control Module
06 - Engine
06 - Engine Introduction
Introduction .................................................. 33-425 Central to the engine control system is the ECM
Operation ..................................................... 33-426 (Engine Control Module). The prime function of the
ECM is to initiate fuel injection. The engine cannot
run without the ECM.
Signals from electrical sensors are continually

monitored and processed by the ECM to determine
when, how much and to which cylinder fuel must be
injected.
The ECM controls fuel injection by energising

electrical actuators in the fuel injectors, high pressure
fuel pump and the common fuel rail.
Note: Other devices are connected to the ECM to

control other engine related systems, refer to (PIL
15-84).
Figure 991.
TDC 2 3
5
4
C1 C2
D1 D2 6

3 Camshaft target disc 4 Crankshaft position sensor
5 Crankshaft mounted target disc 6 Fuel injector
33 - 425 9823/1650-1 33 - 425

45 - Control Module
06 - Engine
Operation Other operating parameters may initiate automatic

engine shut down by the ECM. For example low
engine oil pressure or sensor faults.
The ECM (Engine Control Module) achieves
effective fuel injection by controlling two main Engine Fault Diagnostics
systems:
Since the ECM continually scans for expected inputs
Pressure Control from all connected devices it is capable of detecting
related electrical faults. These faults are datalogged
Fuel pressure in the common rail is varied according in the ECM memory. By connecting diagnostics
to engine operating parameters. software any faults recorded can be displayed in
code form. This assists service personnel when
For example when the engine speed and load is tracing faults with the fuel injection system.
high, fuel can be injected at very high pressure to
achieve optimum combustion. When engine speed In addition to fault datalogging, the ECM will respond
and load is low, fuel pressure must be reduced. In to some faults by shutting the engine down, thus
these conditions injecting fuel at too high a pressure preventing serious engine damage.
would result in poor combustion.
The ECM also has the facility to drive cab mounted
Engine cold starts require special conditions. The warning devices such as coolant temperature and oil
ECM increases fuel pressure to facilitate cold starting pressure displays.
and cold running.
The ECM actuates the inlet metering valve and high

pressure rail fuel valve to control fuel pressure.
Injection Control
Injection control requires the ECM calculation of the
following:
• Engine phase - to determine which cylinder is

firing.
• Injection timing - to determine when injection
takes place in relation to crankshaft position.
• Fuel flow - to determine how much fuel and
therefore, the duration of injection. The ECM
uses data from the various engine sensors
to calculate the injection timing and fuel flow
requirements using a `data map' stored in its
memory. Refer to the Fuel Injection Cycle
Idle Speed Control

The ECM incorporates an engine idle speed control
module. When the operator closes the throttle the
ECM initiates the idle control. The minimum fuel is
calculated to maintain the programmed idle speed.
Engine Shut Down

The ECM initiates engine shut down in response to
inputs from an operator controlled stop ignition key
switch.
Engine shut down is achieved by ceasing fuel

injection. When an engine stop input is received by
the ECM no current is sent to the injector solenoid
coils.
33 - 426 9823/1650-1 33 - 426

45 - Control Module
09 - Gearbox
09 - Gearbox Introduction
Introduction .................................................. 33-427 The transmission ECU (Electronic Control Unit)
Component Identification ............................. 33-428 installed on the machine is dependent on the
Remove and Install ..................................... 33-439 gearbox variant.
Machines with PS750 transmission use an 0711 ECU

with 2 connectors both with 18 pins.
Machines with PS764 or PS766 transmission use an

IFM ECU with 1 connector with 55 pins.
Figure 992. PS750 0711 ECU
Figure 993. PS764 PS766 IFM ECU
33 - 427 9823/1650-1 33 - 427

45 - Control Module
09 - Gearbox
For: PS750 MK4 ..................... Page 33-428

For: PS764, PS766 ................. Page 33-435
(For: PS750 MK4)
Transmission ECU 0711

Location
Figure 994.
33 - 428 9823/1650-1 33 - 428

45 - Control Module
09 - Gearbox
1 Transmission ECU (Electronic Control Unit) 2 Transmission ECU 0711 (Other Machines)
0711 (526-56 Machines)
33 - 429 9823/1650-1 33 - 429

45 - Control Module
09 - Gearbox
Power and Earth Connections
Figure 995.
J1
J2
A
1
15
A
12
ECU 16
A Fuse B Transmission 0711 ECU
33 - 430 9823/1650-1 33 - 430

45 - Control Module
09 - Gearbox
Figure 996.
1 2
6 5 4 3 2 1
12 11 10 9 8 7
18 17 16 15 14 13
1 Connector J1 (key C) 2 Connector J2 (key B)

3 Connector identification letter
33 - 431 9823/1650-1 33 - 431

45 - Control Module
09 - Gearbox
ECU Pin Outs

540-170, 550-170 machines
Table 453. Connector J1
Connector Pin Number Connected to Type
1 Transmission oil temperature sen- Low side output
sor (Machines with PS760 trans-
mission only)
2 Neutral start relay - pin 5 Low side output
3 Left column multi function switch / Digital input
gear selection diodes
4 Steer mode ECU Digital input
5 Transmission Forward High sole- High side output
noid - power
6 Transmission Forward Low sole- High side output
noid - power
7 Steer mode relay 2 High side output
8 Transmission oil temperature sen- Resistive input
sor
9 Operator present seat switch Frequency input
10 Steer mode switch - pin 6 Frequency input
11 Left column multi function switch - Digital input
direction selection
12 Steer mode switch - pin 3 Digital input
13 6th gear solenoid (PS766 gear- Low side output
box) / Mainshaft and Layshaft sole-
noid earth (PS750 gearbox)
14 Steer mode relay 2 High side output
15 Transmission Layshaft solenoid High side output
power
16 Transmission Mainshaft solenoid High side output
power
17 Transmission Reverse low sole- High side output
noid power
18 Transmission Reverse high sole- High side output
noid power

1 Battery Wake up input
2 Not used
3 Not used
4 CAN (Controller Area Network)bus CAN - low
5 CANbus CAN - shield
6 Sensor voltage 5 V reference voltage
7 Not used
8 Not used
9 Not used
10 CANbus CAN - high
11 Sensor earth Sensor earth
12 Power Feed from battery
13 Not used 3.3 V reference voltage
33 - 432 9823/1650-1 33 - 432

45 - Control Module
09 - Gearbox

14 Park brake relay Voltage input
15 Earth Earth
16 Earth Low side driver supply input
17 Power High side driver supply input
18 Power High side driver supply input
Machines with Gearpump Hydraulic Pump

1 Transmission oil temperature sen- Low side output
sor (Machines with PS760 trans-
mission only) / Forward drive sole-
noid earth (526-56)
3 Left column multi function switch / Digital input
gear selection diodes
4 Transmission oil temperature Digital input
sensor (machines with PS750 or
SS700 transmission)
5 Transmission Forward High sole- High side output
noid - power
6 Transmission Forward Low sole- High side output
noid - power
7 Brake lights relay - pin 5 High side output
8 Foot brake dump switch (550-80 Resistive input
machines)
9 Foot brake pressure switch Frequency input
11 Left column multi function switch - Digital input
direction selection
12 Operator present seat switch Digital input
13 6th gear solenoid (PS766 gear- Low side output
box) / Mainshaft and Layshaft sole-
noid earth (PS750 gearbox)
14 Reverse alarm / lights relay High side output
15 Transmission Layshaft solenoid High side output
power
16 Transmission Mainshaft solenoid High side output
power
17 Transmission Reverse low sole- High side output
noid power
18 Transmission Reverse high sole- High side output
noid power

2 Not used
3 Not used
4 CANbus CAN - low
5 CANbus CAN - shield
33 - 433 9823/1650-1 33 - 433

45 - Control Module
09 - Gearbox

7 Not used
8 Not used
9 Not used
14 Transmission dump Voltage input
15 Earth Earth
17 0711 Transmission ECU Drive High side driver supply input
Shutdown Relay pin 9
Machines with Variable Hydraulic Pump

1 Variflow Pump Control Solenoid Low side output
Earth
3 Manual / auto switch - pin 2 Digital input
4 Transmission oil temperature sen- Digital input
sor
5 Not used High side output
6 Variflow Pump Control Solenoid High side output
Power
7 Brake lights relay - pin 5 High side output
8 Foot brake dump switch (550-80 Resistive input
machines)
9 Foot brake pressure switch Frequency input
11 Brake charge pressure transducer Digital input
(550-80 machines)
12 Operator present seat switch Digital input
13 Not used Low side output
14 Reverse alarm / lights relay High side output

2 Not used
3 Not used
4 CANbus CAN - low
5 Not used CAN - shield
33 - 434 9823/1650-1 33 - 434

45 - Control Module
09 - Gearbox

7 Not used
8 Not used
9 Not used
14 Not used Voltage input
15 Earth Earth
Figure 997.
(For: PS764, PS766)
Location
The IFM Transmission ECU is located below the
drivers seat.
1 IFM Transmission ECU
Power and Earth Connections
Figure 998.
1
A 20
19
32 42
B
10 ECU
A Secondary fuse B Primary fuse

C IFM ECU
33 - 435 9823/1650-1 33 - 435

45 - Control Module
09 - Gearbox

The IFM transmission ECU is connected to the panel
harness.
Figure 999.
38 55
20
37
1 19
ECU Pin Outs
Table 459.
2 Not Used
3 Not Used
4 Not Used
5 Not Used
6 Transmission forward high sole- High side output
noid - power
7 Transmission reverse low solenoid High side output
- power
8 Transmission layshaft solenoid - High side output
power
9 Transmission 6th gear solenoid - High side output
power
11 Transmission 4WD (Four Wheel High side output
Drive) solenoid - pin 1
12 Transmission mainshaft solenoid - High side output
power
13 Transmission reverse high sole- High side output
noid - power
14 Transmission forward low solenoid High side output
- power
33 - 436 9823/1650-1 33 - 436

45 - Control Module
09 - Gearbox

15 Torque converter lock up solenoid - High side output
power
16 Not used
17 Transmission 4WD solenoid - pin 2 High side output
18 Not used
19 Ignition feed Ignition feed
20 Earth Earth
21 Left column multi function switch - Input
3rd gear manual selection
Neutral direction selection
direction selection switch power
pin 3 - not used
25 Not used
26 Not used
27 Not used
28 Not used
29 CANbus CAN - low
30 Not used
31 Not used
32 Ignition feed Ignition feed
33 Not used
34 Transmission speed sensor - sig- Input
nal output B
35 Not used
36 Transmission speed sensor - sig- Input
nal output A
37 Not used
38 Not used
39 Not used
40 Not used
forward direction selection
42 Earth Earth
43 Not used
44 Not used
45 Not used
46 Not used
48 Not used
49 Not used
50 Not used
52 Not used
53 Not used
33 - 437 9823/1650-1 33 - 437

45 - Control Module
09 - Gearbox

54 Transmission oil temperature sen- Input
sor 1 - power
55 Transmission oil temperature sen- Input
sor 2 - power
33 - 438 9823/1650-1 33 - 438

45 - Control Module
09 - Gearbox
Remove and Install
For: PS764, PS766 ................. Page 33-439

For: PS750 MK4 ..................... Page 33-439
(For: PS764, PS766)
Removal
Figure 1000.
2
2 3
1 Drivers seat platform 2 Bolts (X4)

3 ECU (Electronic Control Unit)
1. Make the machine safe. Refer to (PIL 01-03). the correct Servicemaster set-up tool. Refer
to (PIL 33-57).
(For: PS750 MK4)
3. Isolate the battery. Refer to (PIL 33-03).
4. Remove the applicable trim panels / instrument Remove
panels to get access to the ECU.
5. Disconnect the electrical connectors from the
ECU. Make sure you do not touch the connector 2. Follow the general health and safety procedures.
pins on the ECU. Refer to (PIL 01-03).
6. Support the ECU and remove the four mounting 3. Isolate the battery. Refer to (PIL 33-03).
bolts which secure the ECU to the underside of 4. Remove the applicable trim panels / instrument
the drivers seat platform. panels to get access to the ECU.
7. Remove the ECU from the machine. 5. Disconnect the electrical connectors from the
ECU. Make sure you do not touch the connector
Install pins on the ECU.
1. The installation procedure is the opposite of the 6. Support the ECU and remove the mounting
removal procedure. Additionally do the following screws.
step.
7. Remove the ECU from the machine.
1.1. Before you operate the machine, make sure
that the ECU is configured correctly. Use
33 - 439 9823/1650-1 33 - 439

45 - Control Module
09 - Gearbox
Figure 1001. 526-56 Machines
1
2
A Mounting screws
B ECU
Figure 1002. Other Machines
1
A Mounting screws
B ECU
Install
step.
2. Before you operate the machine, make sure that
the ECU is configured correctly. Use the correct
Servicemaster set-up tool. Refer to (PIL 33-57).
33 - 440 9823/1650-1 33 - 440

48 - Entertainment
48 - Entertainment
Contents Page No.
33-48-03 Radio ............................................................................................................................ 33-443
33 - 441 9823/1650-1 33 - 441

Notes:
33 - 442 9823/1650-1 33 - 442

48 - Entertainment
03 - Radio
03 - Radio Introduction
Introduction .................................................. 33-443 The manufacturer is not responsible for any
Diagram ....................................................... 33-444 radio or TV interference caused by unauthorized
modifications to this equipment. Such modifications
could void the User's authority to operate the
equipment.This device complies with Part 15 of the
FCC rules. Operation is subject to the following two
conditions:
1. This device may not cause harmful interference.

2. This device must accept any interference
received, including interference that may cause
undesired operation.
33 - 443 9823/1650-1 33 - 443

48 - Entertainment
03 - Radio
Diagram
The wiring diagram depicts all the wiring connections connection with switched power, such as IGN or
required for the correct operation of the unit. ACC.
Do not connect the red wire to a constant power

connection. It should be connected to a vehicle
Figure 1003.
6 4 5
2
3
17
16 8
9 7
15
14
13 12 11 10
1 Antenna connector (black wire) 2 PCB

3 Headphone output (1/4 inch) 4 Washer
5 Nut 6 Rubber cap
7 Vehicle panel or headphone mounting bracket 8 Heatshrink tubing
9 Fuse 3A 10 Accessory (red)
11 Ground (black) 12 Right speaker -ve (grey/black)
13 Right speaker +ve (grey) 14 Left speaker -ve (white/black)
15 Left speaker +ve (white) 16 Black wire
17 9 - Pin Connector (male)
33 - 444 9823/1650-1 33 - 444

51 - Beacon
51 - Beacon
Contents Page No.
33-51-00 General ......................................................................................................................... 33-447

33-51-03 Socket .......................................................................................................................... 33-448
33 - 445 9823/1650-1 33 - 445

Notes:
33 - 446 9823/1650-1 33 - 446

51 - Beacon
00 - General
00 - General
Introduction
Beacons are rotating or flashing lights affixed to

the top of a machine to attract the attention of
surrounding vehicles and pedestrians.
33 - 447 9823/1650-1 33 - 447

51 - Beacon
03 - Socket
03 - Socket Introduction
Introduction .................................................. 33-448 The machine has two separate beacon sockets
Component Identification ............................. 33-449 installed depending on variant.
• Socket A - is for the Green Beacon (if installed)

• Socket B - is for the standard beacon
The beacon is operated from a rocker switch in the

operator compartment.
Figure 1004.
A Green Beacon socket (if installed) B Standard beacon socket
33 - 448 9823/1650-1 33 - 448

51 - Beacon
03 - Socket
Figure 1005. Harness connector -
Beacon socket - RC07 / AG (stan-
dard beacon), C22-RC (Green Beacon)
1 Earth
2 Standard beacon : + 24 V from beacon switch
2 Green beacon : + 24 V from beacon ECU
(Electronic Control Unit)
33 - 449 9823/1650-1 33 - 449

54 - Window Washer/Wipe
Contents Page No.
33-54-00 General ......................................................................................................................... 33-451
33 - 450 9823/1650-1 33 - 450

00 - General
00 - General
Introduction
The wash/wipe system is used to remove rain and

debris from the front or rear window. The main
components of the system are:
• Wiper Arm.
• Wiper Blade.
• Nozzle (jet).
• Wiper Motor Mechanism.
• Tank (reservoir).
• Washer Pump.
• Wash/Wipe Switch.
• Multifunction Switch (intermittent speed
settings).
The wiper assembly consists of an arm, pivoting at

one end with a long rubber blade attached to the
other. The blade is swung back and forth over the
glass, pushing water from its surface. The speed is
normally adjustable, with several continuous speeds
and often one or more intermittent settings. Some
machines may use two wiper arms.
The wipers operate together with the washer system.

The washer pump supplies a mixture of water,
alcohol, and detergent (washer fluid) from a tank to
the windows through a hose. The fluid is dispensed
through small nozzles mounted below the screen. It
is essential the correct washer fluid is used as an
incorrect fluid could freeze in colder climates and
damage the pump. Although antifreeze is chemically
similar to windscreen wiper fluid, it should not be
used because it can damage the paintwork.
33 - 451 9823/1650-1 33 - 451

57 - Electronic Diagnostic
Contents Page No.
33-57-00 General ......................................................................................................................... 33-453

33-57-03 Servicemaster .............................................................................................................. 33-455
33-57-90 Fault Codes .................................................................................................................. 33-471
33 - 452 9823/1650-1 33 - 452

00 - General
Introduction .................................................. 33-453 JCB machines use the latest developments in
Health and Safety ........................................ 33-454 electronic management of machine systems. This
means that machine systems such as service
hydraulics, engine, transmission and steering are
controlled using ECU (Electronic Control Unit)'s.
The ECU's process inputs from electrical sensors
and then send signals to electrical actuators on the
applicable devices. The ECU's are also connected
to the machine CAN (Controller Area Network) bus
electronic communication system.
Fault Finding
Faults with ECU controlled systems can be difficult
or impossible to trace using traditional methods. In
addition to the primary function of machine control
the ECU's are also able to detect possible faults
with sensors and actuators. The faults are logged
using a code system. Use Servicemaster to see and
understand these codes. In addition Servicemaster
has direct links to relevant on screen help information
about relevant devices. This information is designed
to help you identify, test, and if applicable, remove
and replace devices.
Poor Maintenance
System faults that are present, or have happened in
the past can be seen. This is not only useful when
fault finding but can also identify poor standards of
maintenance - for example a log showing a history
of water in fuel detected. Use Servicemaster to see
and understand these logs.
Machine Set-up Data

Machine parameters such as tyre sizes, gear shift
points and engine injector calibration codes are all
stored and used by the relevant control ECU's.
During the life of the machine it will be necessary
to change some of these parameters. Without the
correct data the machine will not operate correctly.
Re-Programming ECU's
The ECU's use pre-loaded data to compute
responses to inputs from sensors. If an ECU is
replaced the correct data files must be programmed
(`flashed') into the ECU memory. New data files may
also be issued by JCB Service to improve machine
operation. This will also require the ECU to be re-
programmed.
Summary
With the latest Servicemaster software loaded on
your laptop and you can:
33 - 453 9823/1650-1 33 - 453

00 - General
• Fault find. Health and Safety

• Check maintenance standards, to see if the
machine has been abused. WARNING Make sure you read and follow any
• View and change machine set-up data. on screen instructions. Failure to follow the
• Flash ECU's with the correct data files instructions could result in death or injury.
33 - 454 9823/1650-1 33 - 454

03 - Servicemaster
03 - Servicemaster
Introduction
JCB Servicemaster is an application to allow Figure 1006. Typical Front Screen

engineers to diagnose and setup the various
electronic control units within the JCB product range.
The tools comprise of a front end generic user
interface that allows the user to select the machine
which they wish to work on as well as a number of
various tools which allow:
• Programming electronic control units

• Diagnosing electronic issues
• Setup of various options
• Checking the service history of the machine
JCB Servicemaster is updated on a monthly basis by

incorporating Web Update. This is a program which
works alongside Servicemaster to let the user know
and allow them to download an update as and when
it becomes available.
JCB Servicemaster software is for use with Microsoft

Windows and a laptop personal computer. The
laptop computer is connected to the machine Once the user has clicked on the applicable machine
diagnostic socket using special cables and an type they will be able to select the tool they require
adaptor. from a list of the tools available for that machine
range. Below are screen-shots showing the different
Use Servicemaster software to: machine tool sets.
• Display data from a machine ECU (Electronic Servicemaster Tools

Control Unit)
• Change data stored in a ECU Servicemaster tool sets are different for each
machine range. When you have navigated to the
Servicemaster software communicates with the correct machine type via the front end, you will be
machine ECM (Engine Control Module) using the greeted with the relevant tools for that particular
CAN (Controller Area Network) bus, refer to Control machine. These tools are accessed by a single click
Modules (PIL 33-45). on the icon of the tool you require. There are 6 main
tools within Servicemaster, these are:
Structure
Figure 1007. Machine/Engine Set-up tool
Servicemaster software is supplied via DVD and
updated via the internet. A selector window is used
to choose the correct software tool set for each
machine range. Each tool is specific to the chosen
machine range. The tool icons are shortcuts to the
tool software files. Detailed information about how
to use the tools is given in the applicable machine
documentation. View and change engine and machine specification
data stored in the engine ECU. Settings include:
Servicemaster Front Screen
• Parameter settings
The start-up page of Servicemaster is known as the • Option/Attachment control
front screen. This interface allows the user to easily • Alternative Language Support
and quickly navigate to the machine they are working • Model/Serial Number Identification
on to ensure that they have the applicable tools for
that machine.
33 - 455 9823/1650-1 33 - 455

03 - Servicemaster
Figure 1008. Diagnostics tool need to be installed. These tools are denoted by the
following symbol:
Figure 1013.
View engine operating parameters in real time.

Perform engine electrical actuator tests. View, save
or clear ECM fault code log.
To install these applications you need to take the
Figure 1009. Flash Programmer tool following steps:
1. On the front end, click the other tab.

2. Click on general.
3. Click onto "extra applications".
4. Choose the relevant tool which you require to be
installed and run the installer.
View ECM software file version. Upload and
Reprogramme software updates to the ECM Once the installer has been run, the icon should have
memory. Upload revisions to software. changed within the machine tool page. e.g. the above
icon has now become:
Figure 1010. Data Logger tool
Figure 1014.
Running Data Collection, Operating Data, Statistics, Diagnostics Tool - User Guide
Device Error Log Recording.
Introduction
Figure 1011. Service History
The diagnostics software tool is part of the
JCB Servicemaster software suite. The diagnostics
software is designed to be an easy to use fault finding
tool.
Connecting the Diagnostics

To use Diagnostics your laptop computer must be
Engine Hour records, Service Dealership Codes. connected to the machine CAN bus.
Figure 1012. Help
Starting the Diagnostics
1. Connect the Servicemaster tool to the machine.
Refer to Disconnect and Connect.
Comprehensive information about engine related 2. Turn ON the machine ignition and additionally
sensors, actuators and ECM fault codes. start the engine if required (taking normal
precautions).
Additional Service Tool
3. Start JCB Servicemaster on the laptop computer.
As well as the tools stated above there are also third
party tools for some of the machine ranges which will
33 - 456 9823/1650-1 33 - 456

03 - Servicemaster
Figure 1015. opens. Check the button to match to the current

device. Click Apply.
Figure 1016.
Diagnostics Overview
4. Make sure that the correct DLA (Data Link There are several key elements to the diagnostics
Adaptor) is selected in the chooser. Click on tool. These can be seen labelled below. Each
Utilities, DLA Setup. The DLA chooser window element is explained in detail in later sections.
Figure 1017.
5 10 6 7 8
1
2
3
9
11
4 12
1 Menu bar 2 Start and stop buttons

3 Engine selection buttons 4 Main window
5 Engine connector page 6 Machine connector page
7 Actuator test page 8 Fault codes page
9 Page list 10 LED (Light Emitting Diode) status key
11 Status bar 12 CAN communication status LEDs
33 - 457 9823/1650-1 33 - 457

03 - Servicemaster
Navigating within Diagnostics Menu Bar-Options Menu
Navigation is designed to be via a mouse. On Laptop Figure 1019.

PCs this may take the form of a small joystick
or touch sensitive pad and some buttons, usually
located near to the keyboard.
As with most Windows based programs, it is possible

to navigate the diagnostics software using the
keyboard by pressing certain combinations of keys.
Note: This can be particularly useful for certain

Laptop computers where the mouse/joystick can be
oversensitive. Try out the following, it may come in
useful one day.
There are two main methods of navigation described • Start Diagnostics to commence
below: communications with the ECM.
• Stop Diagnostics to cease communications.
• Pressing the ALT key will cause the File option • Controller Status Click on the buttons to toggle
on the Menu Bar to be highlighted. You can then ON or OFF the diagnostics connection with the
use the arrow keys to navigate the menus. machine CAN system.
• Notice that all the menu items on the Menu
Bar have a letter that is underlined (e.g. the Figure 1020.
'F' in File). Holding down the ALT key and
pressing the required letter key will activate that
option (i.e. either open the menu or execute
a function). For example, if you wish to open
the Preferences Dialogue this can be done by
pressing ALT + O (to open the Options menu)
then ALT + P (to execute the Preferences
option).
Menu Bar-File Menu
The File Menu contains an Exit option to close down

the program.
• Preferences option opens up the Preference
Figure 1018. Dialogue.
• From the Preferences Dialogue there is support
for multiple languages. Use the drop-down
menu and scroll bar to chose the required
language. Languages available are:
• English (United Kingdom)
• French (France)
• German (Germany)
On exiting the program communications with both
• Spanish (International Sort)
ECU and DLA are shut down.
Note: The language option only effects text within the
Main Window (e.g. Page List, LED Status Key, etc).
Language support is not available for the text within
the page displays.
Once your preferences have been selected either:
Click on the OK button to apply them or click on the

Cancel button to leave them unchanged.
33 - 458 9823/1650-1 33 - 458

03 - Servicemaster
Menu Bar-Help Menu function keys, F2, F3 etc. can also be used to select
pages as required.
Figure 1021.
Status bar
There are 2 items of interest displayed on the

Status Bar, which is located along the bottom of the
Diagnostics main window.
Figure 1024.
• About: Opens a window showing the part

number and the version number of the installed
copy of the Diagnostics software Connected ECU: The type of ECU connected to the
• Help: Opens a help file about the software. Diagnostics tool is indicated on the far left side of the
• Engine Help: Opens a help file containing Status bar.
information about the engine sensor and
actuator devices for engine control. CAN communications: Two small LEDs indicate data
being transmitted (red) and received (green) over the
Start and Stop Buttons CAN communications link.
These offer the same function as the Start These LEDs can be seen to be flashing rapidly
Diagnostics and Stop Diagnostics options within as data is transported. This can be another useful
the Options Menu. To start the Diagnostics tool aid to determining the state of any established
communicating with the gearbox ECU simply click communications.
on the Start Button (large green LED) at the top of
the Main Window. Similarly, click on the Stop Button Connection Status: Indicates if the diagnostics
(large red LED) to cease communications. software is connected, connecting or not connected
to the ECM.
Figure 1022.
Information Window: Displays information about data
on the diagnostics pages when the mouse is rolled
over the fields.
LED Status Key
Displays a key for the colour status of the LEDs

shown on the diagnostics pages. The LEDs change
colour dependant on the electrical signal.
Page List
Figure 1025.
In the top left corner of the main window is displayed
a list of pages which can be displayed.
Figure 1023.
Table 460.
LED Colour Electrical signal status
Clicking in the box next to the required page will Red Off
make that page appear in the main window display
Green On/Active
area. (A tick will also appear in the box to show it
is being displayed.) At any time the user may swap Blue Open Circuit
between displayed pages simply by clicking in the Yellow Short Circuit
check box of the required page in the page list. The Grey No Data
33 - 459 9823/1650-1 33 - 459

03 - Servicemaster
Fault Codes Page
Figure 1026.
This page allows the engineer to access fault codes The Engine Setup tool can be used to view and
logged by the ECM. The ECM logs a fault code if change data stored the ECM. If the machine or
sensor or actuator signals are not valid. These codes engine specification is changed due to operational or
are useful when fault finding. maintenance requirements the relevant data must be
changed in the ECM.
• Active Fault Codes: Displays fault codes for
active faults in real time. To link to information Connecting Engine Setup
about the fault code click on the code. Note:
Start the engine to see all the active fault codes. To use Vehicle Setup your laptop computer must be
Note: To check if a fault code is no longer connected to the machine CANbus.
active set engine ignition system to OFF and
then restart the engine. The Servicemaster log Starting Engine Setup
display will not delete codes that are no longer
active until the engine ignition system is set to 1. Turn ON the machine ignition and additionally
OFF. start the engine if required (taking normal
• Previously Active Fault Codes: Displays fault precautions).
codes for faults that have occurred but are not 2. Start JCB Servicemaster on the laptop computer.
necessarily active. To link to information about
the fault code click on the code.
• Save Faults: Click the button to save the fault
code lists as a file to a computer location.
• Link to Fault Code List: Click to link to a
complete list of possible fault codes.
• Erase Fault Codes: Click the button to erase
logged fault codes from the ECM memory.
Engine Setup Data Tool-User Guide
Introduction
The Engine Setup software tool is part of the JCB

Servicemaster software suite.
33 - 460 9823/1650-1 33 - 460

03 - Servicemaster
4. Select Engine Tools from the drop down list

and then start the vehicle setup tool running by
clicking on the Engine Setup icon.
Figure 1029.
3. Make sure that the correct DLA is selected in
the chooser. Click on Utilities, DLA Setup. The
DLA Chooser window opens. Check the button
to match to the Current Device. Click Apply.
5. The Engine Setup tool will then open. There are

four groups of data to available shown by the
tabs:
• General
• Wheels
• Options
• Injector Calibration
33 - 461 9823/1650-1 33 - 461

03 - Servicemaster
General
Figure 1030.
33 - 462 9823/1650-1 33 - 462

03 - Servicemaster
Wheels
Figure 1031.
33 - 463 9823/1650-1 33 - 463

03 - Servicemaster
Options
Figure 1032.
33 - 464 9823/1650-1 33 - 464

03 - Servicemaster
Injector Calibration
Figure 1033.
Each injector is individually tested at the factory can be used to access the data file name currently
to record its operational characteristics. This loaded in the ECM memory and is necessary upload
information is written as a calibration code. The code a new data file to the ECM.
for each injector is loaded into the ECM. The ECM
uses this data to adjust control of the injector solenoid Connecting Flash Loader
and ensure correct injection.
To use Flashloader your laptop computer must be
The currently stored codes for each injector are connected to the machine CANbus.
displayed in the fields. If an injector or the ECM is
replaced the codes must be transferred or altered. Starting Flashloader
Flashloader Tool-User Guide 1. Turn ON the machine ignition but DO NOT start
the engine.
The Flashloader software tool is part of the JCB
Servicemaster software suite. If the ECM Engine 2. Start JCB Servicemaster on the laptop computer.
Control Module is replaced and the data file in its
flash memory is not applicable it will be necessary to
flash the ECM Engine Control Module memory with
the correct data file. The Flashloader software tool
33 - 465 9823/1650-1 33 - 465

03 - Servicemaster
Figure 1034. 3. Click on the Browse button and select the correct
data file. Click Open.
Figure 1037.
3. Make sure that the correct DLA is selected in

the chooser. Click on Utilities, DLA Setup. The
DLA Chooser window opens. Check the button
to match to the Current Device. Click Apply.
4. Select the required machine range. 4. Click on the Start button. A confirmation window
will appear. Click on the Yes to start the
Figure 1035.
reprogramming of the ECM. The progress bar is
displayed.
5. When the programming is complete switch
the machine ignition to the OFF position.
Important: Re-flashing the ECM changes the
base programme. Re-flashing the ECM does
not configure the machine settings such as fuel
injector calibration codes, and other machine
specific options.
Figure 1038.
5. The Flashloader tool will then open.

Figure 1036.
Using Flashloader
Important: Do not turn off the ignition or isolate the

system by accidentally engaging the operators seat
isolation switch when using the flashloader. This
will interrupt the flash signal to the ECM and will
irreparably damage the ECM.
1. Make sure that the machine ignition switch is set 6. Before starting the engine make sure that the
to ON but do not start the engine. machine setup data is correct. You must check
that all other relevant machine settings are
2. Click on the ECM icon. correctly configured. Use the setup software tool.
33 - 466 9823/1650-1 33 - 466

03 - Servicemaster
Re-Flashing Guide Figure 1040.
Load the Ecomax Engine Setup Tool for the correct

application. Make sure that the following is correct for
the application.
• Make
• Machine Type
• Power Rating
Figure 1039.
5. The Additional Info Tab should have the correct

Make, Model and Power Rating.
Figure 1041.
1. If the Make or Machine Type is incorrect please

change and then press Write.
2. If the Power Rating is incorrect please order a
replacement ECM of the correct power rating.
3. Close the Tool.
4. Load the JCB Flashloader.
6. Press the button highlighted to select the flash

file.
7. Navigate to the Machine SW folder. (C:
\JCB_Servicemaster_2\Machine SW).
33 - 467 9823/1650-1 33 - 467

03 - Servicemaster
8. Navigate to the relevant application folder.

9. Navigate to the ECM folder.
14. Before pressing start please ensure that:
10. Select and Open the relevant file that matches
the Make, Model and Power Rating. 14.1. All electrical connections between the
laptop and machine are secure.
11. If the file selected does not match the Make,
Model and Power Rating which is currently 14.2. The laptop battery is sufficient.
stored in the ECM it will cause an error. 14.3. You are familiar with any safety cut out
feature on the machine (seat switch) and
Figure 1043. do not invoke it during the flash.
15. Pressing Yes will flash the ECM.
Figure 1045.
12. Please make another selection or close the 16. Pressing No will abort the download.
Flashloader tool and use the Engine Setup tool 17. Ecomax Engine only - If the Engine Immobiliser
to correct the Make or Model. is active you can not flash the ECM. You will get
13. If no error occurs and the file information below this warning.
the file path populates you are ready to flash the Figure 1046.
engine.
18. Please refer to the immobiliser guide to disable

the immobiliser before proceeding.
19. Flashing process will then start and progress bar
will update.
33 - 468 9823/1650-1 33 - 468

03 - Servicemaster
23. If Cold Start Kit required, Set to “Function and

Diagnostics” and then press Write.
Figure 1050.
20. ECM Download will complete.

21. Load the Ecomax Engine Setup Tool for the
correct application. Note: Ecomax Only Software
Identification will contain the name of the flash
file you just downloaded to the ECM.
Figure 1048.
24. Ensure Injector Calibration is complete and

correct.
Figure 1051.
22. Both Ecomax and Dieselmax Press Restore

Default Press Yes.
33 - 469 9823/1650-1 33 - 469

03 - Servicemaster
25. Ecomax Press Write Injector Codes.

26. DieselMax Press Write.
33 - 470 9823/1650-1 33 - 470

90 - Fault Codes
90 - Fault Codes displayed. The engineer also has a facility to erase

the fault code log.
Introduction Failure Type Byte (FTB) Numbers
Should faults occur related to an ECU (Electronic Table 461.

Control Unit) or devices connected to it, the
electronic system will generate the applicable fault Number Failure Type Byte (FTB) De-
codes. A complete list of fault codes is stored within scription
the applicable Servicemaster tools set. 0 No sub-type information.
2 General signal failure.
Fault Code Structure 4 System internal failure.
5 System programming failure.
The structure of fault codes, otherwise known
as DTC (Diagnostic Trouble Code)'s has been 7 Mechanical failure.
standardised to a 7 digit code for all on and off- 9 Component failure.
highway machine and vehicle applications. The 11 Short Circuit To Ground (SC2G).
standard (referred to as J2012) requires all fault 12 Short Circuit To Battery
codes to conform to the following structure. (SC2VBAT).
• 1st character - defines the system on the 13 Open Circuit (OC).
vehicle (e.g. P = Powertrain, C= Chassis, U = 16 Circuit voltage below threshold.
Network). 17 Circuit voltage above threshold.
• 2nd and 3rd characters - defines the sub- 18 Circuit current below threshold.
system (e.g. transmission, CAN (Controller
Area Network) network, brakes etc). 19 Circuit current above threshold.
• 4th and 5th characters - specifies the particular 1A Circuit resistance above thresh-
component, circuit or fault (e.g. starter relay). old.
• 6th and 7th characters - referred to as the 1B Circuit resistance below thresh-
'Failure Type Byte' (FTB) which indicates the old.
particular failure (e.g. 11 = short circuit to 1C Circuit voltage out of range.
ground). See FTB Numbers below for a full list.
1F Circuit intermittent.
Some specific fault codes are defined by 23 Signal stuck low.
international standard, while other codes may be 24 Signal stuck high.
defined by individual vehicle manufacturers. 26 Signal rate of change below
threshold.
Fault Code Display Systems 27 Signal rate of change above
threshold.
Depending on the machine specification fault codes
recorded by the engine ECU can be accessed and 29 Signal invalid.
displayed in several ways: 2F Signal erratic.
31 No Signal (lost/missing).
CAN Enabled Display 36 Signal frequency too low.
37 Signal frequency too high.
The machine may be equipped with a CAN enabled
display. Such a display will be capable of displaying 38 Signal frequency incorrect.
all recorded codes, for example P0047. All logged 45 Program memory failure.
codes will be displayed. The operator may also 46 Calibration / Parameter memory
have a facility to erase the fault code log. See failure.
the applicable machine documentation for further 47 Watchdog / micro-controller / mi-
information. croprocessor failure.
CAN BUS Connected Computer 4B Over temperature.
62 Signal compare failure.
Fault codes logged can be accessed via a 64 Signal plausibility failure.
suitable laptop computer running the applicable 71 Actuator stuck.
diagnostics software, JCB 444 Engine Diagnostics
for example. The computer must be connected to the 72 Actuator stuck open.
machine CAN BUS socket using a DLA (Data Link 73 Actuator stuck closed.
Adaptor). Once connected all recorded codes can be 85 Signal above allowable range.
33 - 471 9823/1650-1 33 - 471

90 - Fault Codes
Number Failure Type Byte (FTB) De- Fault Codes, Introduction, Malfunction Indicator Light
scription (MIL). Refer to: PIL 33-57-90.
86 CAN signal invalid.
92 Performance or incorrect opera- Fault Code log
tion.
The fault code log can be read on the instrument
98 Component or system over tem- panel LCD (Liquid Crystal Display). Alternatively use
perature. the JCB Servicemaster diagnostics tool.
Malfunction Indicator Light (MIL) Read the fault code log on the instrument panel LCD
via the service menu. Use JCB Servicemaster and
Figure 1052. a laptop computer connected to machine CANbus to
see the codes.
Amber/Red light. The MIL (Malfunction Indicator

Lamp) light comes on to show that a system error
has been detected. Refer to Figure 1052.
- Red light. The light comes ON (and a continuous

audible alarm sounds) to indicate faults that may
result in serious damage to the machine or make the
machine dangerous to operate. This is known as a
‘STOP NOW’ fault.
- Amber light. The light comes ON (and an audible

alarm sounds for one second) to indicate faults that
may result in reduced machine performance but are
not dangerous. They are unlikely to damage the
machine. This is known as a ‘SERVICE’ fault.
When the MIL light comes ON another applicable

system warning may display. These lights can show
a blink code. Refer to: PIL 33-57-90.
Blink Codes
Some machine systems are equipped with a
dedicated indicator light. If there is a system fault the
light can display fault codes as a series of blinks.
For example code E127 can be displayed as a series

of blinks as follows:
Table 462.
1 Blink
2 Second delay
2 Blink Blink
2 Second delay
7 Blink Blink Blink Blink Blink Blink Blink
The light will be ON for approximately 1 s and OFF

for approximately 0.5 s. There is an OFF time of
approximately 2 s between error code digits.
When a blink code is displayed the MIL light can

also come ON. Refer to Electronic Diagnostic,
33 - 472 9823/1650-1 33 - 472

66 - Load Motion Control System
Contents Page No.
33-66-00 General ......................................................................................................................... 33-475
33 - 473 9823/1650-1 33 - 473

Notes:
33 - 474 9823/1650-1 33 - 474

00 - General
Introduction .................................................. 33-475 The LLMI (Longitudinal Load Moment Indicator) and
Disassemble and Assemble ........................ 33-476 LLMC (Longitudinal Load Moment Control) systems
are both described in (PIL 33-66-00) for ease of
explanation. Your machine may be installed with
either or no system.
33 - 475 9823/1650-1 33 - 475

00 - General
Disassemble and Assemble 2.1. During assembly renew the seal 1, seal 2
and the seal 3.
3. Make sure that all components are tightened to
Disassemble the correct torque.
1. Remove the LLMC (Longitudinal Load Moment
Control) valve block. Refer to electrical system- Table 463. Torque Values
load motion control system, refer to (PIL 33-66). Item Nm
1A 27
2. Before you remove the solenoid assemblies or
coils, put a label on them for correct installation. 1B 27
1C 27
3. Loosen and remove the securing nut on the coil 4 4.1
on the valve you wish to remove.
5 4.1
4. Remove the solenoid. 6 4.1
5. Loosen and remove the cartridge.
6. Remove and discard the seal.
7. Repeat steps for the removal of the other valves.
3 to 6
Figure 1053.
2B 3B
5 6
3A
1B
1 3
4 1A 2 2A
1 Solenoid valve assembly 1
1A Cartridge 1
2A Cartridge 2
3A Cartridge 3
1B Seal 1
2B Seal 2
3B Seal 3
4 Securing nut
5 Securing nut
6 Securing nut
Assemble
Although the solenoid assemblies look very similar,
they have different flow characteristics.

removal procedure.
2. When you install, do the following step also:
33 - 476 9823/1650-1 33 - 476

84 - Sensor
84 - Sensor
Contents Page No.
33-84-09 Speed Sensor .............................................................................................................. 33-479

33-84-15 Transmission Oil Temperature ..................................................................................... 33-480
33 - 477 9823/1650-1 33 - 477

Notes:
33 - 478 9823/1650-1 33 - 478

84 - Sensor
09 - Speed Sensor
09 - Speed Sensor
Introduction
For details of the speed sensors - refer to (PIL

27-06-27).
33 - 479 9823/1650-1 33 - 479

84 - Sensor
15 - Transmission Oil Temperature
15 - Transmission Oil Temperature
Introduction
For details of the transmission oil temperature sensor

33 - 480 9823/1650-1 33 - 480

Contents Page No.
72-00 Fasteners and Fixings

72-00-00 General ............................................................................................................................. 72-3
72-03 Screws
72-03-00 General ............................................................................................................................. 72-7
72-06 Bolts
72-06-00 General ........................................................................................................................... 72-11
72-18 Bearings
72-18-00 General ........................................................................................................................... 72-15
72-21 Clips
72-21-03 Worm Drive .................................................................................................................... 72-17
72-36 Threaded Insert
72-36-00 General ........................................................................................................................... 72-23
9823/1650-1
2018-04-09
Notes:
9823/1650-1
2018-04-09
Contents Page No.
72-00-00 General ............................................................................................................................. 72-3
72 - 1 9823/1650-1 72 - 1
Notes:
72 - 2 9823/1650-1 72 - 2
00 - General
00 - General Fastener Type Colour Part Number

Suffix
Zinc Nickel - Black, chalky N (e.g.
Introduction black texture 1315/3712N)
Zinc flake - Black, slight B (e.g.
JCB Fasteners (Before September 2017) black gloss 1315/3712B)
Some external fasteners on JCB machines are Torque and Angle Tightening
manufactured using an improved type of corrosion
resistant finish. This type of finish is called Dacromet Insufficient pre-load of a bolted joint can cause
and replaces the original Zinc and Yellow Plating major problems, such as cylinder head warp, leaking
used on earlier machines. The two types of fasteners gasket joints etc. There are several methods of
can be readily identified by colour and part number achieving an accurate pre-load of a bolted joint, the
suffix. Refer to Table 1. Fastener Types. two main methods used on the JCB engine are:
Table 464. • Torque Control Tightening - Using a torque
Fastener Type Colour Part Number meter to control the torque is the most
Suffix popular means of controlling pre-load, and
in the majority of instances this method is
Zinc and Yellow Golden Finish Z (e.g. adequate. It should be noted that with this
1315/3712Z) process, the majority of the torque is used
Dacromet Mottled Silver D (e.g. to overcome friction, therefore slight variations
Finish 1315/3712D) in the frictional conditions can lead to large
changes in the bolt pre-load.
Note: As the Dacromet fasteners have a lower torque • Angle Control Tightening - Where a more
setting than the Zinc and Yellow fasteners, the torque precise pre-load is required, the torque and
figures used must be relevant to the type of fastener. angle tightening method is used. The bolt
is tightened to a predetermined torque (this
A Dacromet bolt should not be used in conjunction may be done in stages), and then as a
with a Zinc or Yellow plated nut, as this could final sequence, the bolt is tightened to a
change the torque characteristics of the torque predetermined angle - this method of tightening
setting further. For the same reason, a Dacromet nut the bolts results in a smaller variation in the
should not be used with a Zinc or Yellow plated bolt. final pre-load. It is critical that the predetermined
tightening angle is accurately achieved, failure
All bolts used on JCB machines are high tensile and to tighten accurately to the specified angle could
must not be replaced by bolts of a lesser tensile result in the bolt pre-load being incorrect - this
specification. will lead to eventual failures. It is good practice
to replace all bolts that have been tightened
Dacromet bolts, due to their high corrosion using the torque + angle procedure.
resistance are used in areas where rust could
occur. Dacromet bolts are only used for external
Tightening Method
applications. They are not used in applications
such as gearbox or engine joint seams or internal The following example explains the recommended
applications. torque and angle procedure. A torque angle gauge
should be used for accuracy, but as a visual check,
JCB Fasteners (After September 2017) the bolts can be match marked as described below.
1. Tighten the bolt to the specified torque (specified

Table 465. torque values will be detailed in the relevant PIL
Fastener Type Colour Part Number sections).
Suffix
2. Mark a line across the centre of the bolt, and a
Zinc flake-silver White alu- D (e.g. second line on the part to be clamped - the two
minium (sil- 1315/3712D) lines should be aligned. Refer to Figure 1054.
ver-grey), Dull
Zinc and heavy Silver (Bright iri- V (e.g.
trivalent passi- descent) 1315/3712V)
vated with seal
Zinc Nickel - sil- Dark, dull silver Not assigned
ver/grey grey
72 - 3 9823/1650-1 72 - 3
00 - General
Figure 1054.
0°
3. Mark a third line at the specified torque angle - in

this instance the additional torque angle is 90°.
This line must be marked the specified angle in
a clockwise direction (to further tighten the bolt).
Figure 1055.
+90°
4. In some instances, angle torque tightening can

be specified in two stages, for instance in this
example, the first angle quoted is 90° and then a
second angle of 180°. The additional 180° angle
is from the LAST tightened position. Refer to
Figure 1056.
Figure 1056.
+180°
+90°
5. Tighten the bolt so that the line on the bolt

aligns with the angle(s) marked on the item to
be clamped - remember, to ensure complete
accuracy an angle gauge should be used.
72 - 4 9823/1650-1 72 - 4
03 - Screws
03 - Screws
Contents Page No.
72-03-00 General ............................................................................................................................. 72-7
72 - 5 9823/1650-1 72 - 5
Notes:
72 - 6 9823/1650-1 72 - 6
03 - Screws
00 - General
Introduction ...................................................... 72-7 Use the torque setting tables (Technical Data) only
Technical Data ................................................. 72-8 where no torque setting is specified in the text. Note:
Dacromet fasteners are lubricated as part of the
plating process, do not lubricate. Torque settings are
given for the following conditions:
Table 466. Up to September 2017

Type Condition 1 Condition 2
no coating Unlubricated fas- Zinc flake silver
teners (Dacromet) fas-
teners.
2 (obso- Zinc fasteners Lubricated zinc
lete from and yellow plated
September fasteners.
2017).
3, 4 (obso- Yellow plated fas- Where there is
lete from teners a natural lubri-
September cation. For ex-
2017). ample, cast iron
components.
Table 467. From September 2017

no coating Unlubricated fas- Dacromet) fas-
teners teners.
1 Zinc flake - silver Zinc flake silver
(Dacromet) fas-
teners.
5 Zinc and heavy
trivalent with seal
7 Zinc nickel - silver
8 Zinc nickel - black
9 Zinc flake - black
72 - 7 9823/1650-1 72 - 7
03 - Screws
00 - General
Technical Data
Table 468. Torque Settings - Internal

Hexagon Headed Capscrews (Zinc)
Bolt Size
mm N·m
3 2
4 6
5 11
6 19
8 46
10 91
12 159
16 395
18 550
20 770
24 1,332
72 - 8 9823/1650-1 72 - 8
06 - Bolts
06 - Bolts
Contents Page No.
72-06-00 General ........................................................................................................................... 72-11
72 - 9 9823/1650-1 72 - 9
Notes:
72 - 10 9823/1650-1 72 - 10
06 - Bolts
00 - General
Introduction .................................................... 72-11 Use the torque setting tables (Technical Data) only
Technical Data ............................................... 72-12 where no torque setting is specified in the text. Note:
Dacromet fasteners are lubricated as part of the
plating process, do not lubricate. Torque settings are
given for the following conditions:
Table 469. Up to September 2017

no coating Unlubricated fas- Zinc flake silver
teners (Dacromet) fas-
teners.
2 (obso- Zinc fasteners Lubricated zinc
lete from and yellow plated
September fasteners.
2017).
3, 4 (obso- Yellow plated fas- Where there is
lete from teners a natural lubri-
September cation. For ex-
2017). ample, cast iron
components.
Table 470. From September 2017

no coating Unlubricated fas- Dacromet) fas-
teners teners.
1 Zinc flake - silver Zinc flake silver
(Dacromet) fas-
teners.
5 Zinc and heavy
trivalent with seal
7 Zinc nickel - silver
8 Zinc nickel - black
9 Zinc flake - black
Verbus-Ripp Bolts
Torque settings for these bolts are determined by the
application. Refer to the relevant procedure for the
required settings.
Figure 1057.
72 - 11 9823/1650-1 72 - 11
06 - Bolts
00 - General
Technical Data Table 473. Torque Settings -

Coarse Metric Grade 8.8 Fasteners
Bolt Tread Hexa- Condi- Condi-
From JCB standard STD00019 issue 15.
Size Pitch gon (A/ tion 1 tion 2
1. This information does not apply to:- F)
mm mm mm N·m N·m
1.1. Hydraulic fittings (i.e. BSP, SAE O-ring 4 0.7 7 2.9 2.6
boss, UNF, four bolt split flange and JIC).
5 0.8 8 5.8 5.2
1.2. Locking type fasteners (those with a nylon 6 1 10 9.9 9
insert, or with distorted thread nuts such as
8 1.25 13 24 22
Cleveloc).
10 1.5 17 47 43
2. For information on fastener conditions, refer to 12 1.75 19 83 74
fasteners and fixings, bolts, general, introduction. 14 2 22 132 119
16 2 24 205 184
Table 471. Torque Settings - UNF S Fasteners 20 2.5 30 400 360
Bolt Treads Hexa- Condi- Condi- 24 3 36 690 621
Size per Inch gon (A/ tion 1 tion 2 30 3.5 46 1,372 1,235
F) 36 4 55 2,399 2,159
in in in N·m N·m
(1/4 in) 28 7/16 11.2 10 Table 474. Torque Settings - Coarse
(5/16 in) 24 1/2 22.3 20 Metric Grade 10.9 Fasteners
(3/8 in) 24 9/16 40 36 Bolt Thread Hexa- Condi- Condi-
(7/16 in) 20 5/8 64 57 Size Pitch gon (A/ tion 1 tion 2
F)
(1/2 in) 20 3/4 98 88
mm mm mm N·m N·m
(9/16 in) 18 13/16 140 126
4 0.7 7 4 3.6
(5/8 in) 18 15/16 196 177
5 0.8 8 8.1 7.3
(3/4 in) 16 1 1/8 343 309
6 1 10 13.9 12.5
(7/8 in) 14 1 15/16 547 492
8 1.25 13 34 30
(1 in) 12 1 1/2 814 732
10 1.5 17 67 60
(1 1/8 in) 12 1 7/8 1,181 1,063
12 1.75 19 116 104
(1 1/4 in) 12 2 1/4 1,646 1,481
14 2 22 185 167
16 2 24 288 259
Table 472. Torque Settings - UNF X Fasteners 20 2.5 30 562 506
Bolt Treads Hexa- Condi- Condi- 24 3 36 971 874
Size per Inch gon (A/ tion 1 tion 2 30 3.5 46 1,930 1,737
F)
36 4 55 3,374 3,036
in in in N·m N·m
(1/4 in) 28 7/16 17.6 15.9 Table 475. Torque Settings - Coarse
(5/16 in) 24 1/2 35.2 31.6 Metric Grade 12.9 Fasteners
(3/8 in) 24 9/16 64 57 Bolt Thread Hexa- Condi- Condi-
(7/16 in) 20 5/8 101 91 Size Pitch gon (A/ tion 1 tion 2
(1/2 in) 20 3/4 155 139 F)
(9/16 in) 18 13/16 221 199 mm mm mm N·m N·m
(5/8 in) 18 15/16 310 279 4 0.7 7 4.8 4.4
(3/4 in) 16 1 1/8 542 488 5 0.8 8 9.8 8.8
(7/8 in) 14 1 15/16 864 777 6 1 10 16.6 15
(1 in) 12 1 1/2 1,285 1,156 8 1.25 13 40 36
(1 1/8 in) 12 1 7/8 1,865 1,679 10 1.5 17 80 72
(1 1/4 in) 12 2 1/4 2,598 2,339 12 1.75 19 139 125
14 2 22 223 200
16 2 24 345 311
72 - 12 9823/1650-1 72 - 12
06 - Bolts
00 - General
Bolt Thread Hexa- Condi- Condi-

Size Pitch gon (A/ tion 1 tion 2
F)
mm mm mm N·m N·m
20 2.5 30 674 607
24 3 36 1,165 1,048
30 3.5 46 2,316 2,084
36 4 55 4,049 3,644
Table 476. Torque Settings - Rivet Nuts / Bolts

Bolt Size
mm N·m
3 1.2
4 3
5 6
6 10
8 24
10 48
12 82
72 - 13 9823/1650-1 72 - 13
18 - Bearings
18 - Bearings
Contents Page No.
72-18-00 General ........................................................................................................................... 72-15
72 - 14 9823/1650-1 72 - 14
18 - Bearings
00 - General
00 - General
Check (Condition)
1. Carefully inspect all rollers, cages and cups
for wear, chipping, or nicks to determine the
condition of the bearings for further use.
2. Do not replace a bearing cone or cup individually.
Replace the mating cup and the cone at the same
time.
3. After inspection, lubricate the bearings with a
suitable clean oil.
4. Wrap the bearings in clean lint free cloth or paper
to protect them until you install the bearings
again.
72 - 15 9823/1650-1 72 - 15
21 - Clips
21 - Clips
Contents Page No.
72-21-03 Worm Drive .................................................................................................................... 72-17
72 - 16 9823/1650-1 72 - 16
21 - Clips
03 - Worm Drive
03 - Worm Drive Introduction

Introduction .................................................... 72-17
Technical Data ............................................... 72-18
Plain Worm Drive Clips
Component Identification ............................... 72-21 There are three types of plain worm drive clips.
• Standard worm drive clip

• Heavy duty worm drive clip
• Spring assisted worm drive clip
Spring assisted worm drive clip contains a spring

insert on the inside of the band to provide
compensation against hose compression set.
Use the torque setting tables (Technical Data) only

where no torque setting is specified in the text.
Constant Torque Worm Drive Clips

Your machine may be installed with constant torque
worm drive clips.
Use the torque setting tables (Technical Data) only

where no torque setting is specified in the text.
72 - 17 9823/1650-1 72 - 17
21 - Clips
03 - Worm Drive
Technical Data
Dimensions
Figure 1058. Plain Worm Drive Clips
C
J
H
Table 477.
A B C D H J K
Clamping Band thick- Housing Band width Hex size Bolt and Bolt and
range ness width across flats housing housing
length overall
height
Standard worm drive clips and spring assisted worm drive clips
8 –16 mm 0.7 mm 13 mm 9 mm 7 mm 21 mm 11 mm
12 –22 mm 21 mm
16 –27 mm up 0.8 mm 14.6 mm 12 mm 30 mm 12.5 mm
to 60 –80 mm
70 –90 mm up 36 mm
to 160 –180
mm
72 - 18 9823/1650-1 72 - 18
21 - Clips
03 - Worm Drive
A B C D H J K
Clamping Band thick- Housing Band width Hex size Bolt and Bolt and
range ness width across flats housing housing
length overall
height
Heavy duty worm drive clips
172 –206 mm 0.7 mm 23.1 mm 16 mm 7 mm 37 mm 13 mm
Figure 1059. Constant Torque Worm Drive Clips
Table 478.
A B
Clamping range Band Width
14 –27 mm 14.2 mm
25 –45 mm 15.7 mm
32 –54 mm 15.7 mm
45 –67 mm 15.7 mm
54 –79 mm 15.7 mm
70 –92 mm 15.7 mm
83 –105 mm 15.7 mm
95 –118 mm 15.7 mm
Torque Values Clamping Part number Torque values

range
Table 479. Standard Worm Drive Clip 20 –32 mm 2201/0006 5 -0/+0.5 N·m
25 –40 mm 2201/0007 5 -0/+0.5 N·m
Clamping Part number Torque values
range 35 –50 mm 2201/0008 5 -0/+0.5 N·m
8 –16 mm 2201/0001 2 -0/+0.5 N·m 40 –60 mm 2201/0010 5 -0/+0.5 N·m
12 –22 mm 2201/0003 3 -0/+0.5 N·m 50 –70 mm 2201/0012 5 -0/+0.5 N·m
16 –27 mm 2201/0005 5 -0/+0.5 N·m 60 –80 mm 2201/0013 5 -0/+0.5 N·m
72 - 19 9823/1650-1 72 - 19
21 - Clips
03 - Worm Drive

range
70 –90 mm 2201/0014 5 -0/+0.5 N·m
80 –100 mm 2201/0015 5 -0/+0.5 N·m
90 –110 mm 2201/0016 5 -0/+0.5 N·m
100 –120 mm 2201/0021 5 -0/+0.5 N·m
120 –140 mm 2201/0017 5 -0/+0.5 N·m
130 –150 mm 2201/0018 5 -0/+0.5 N·m
150 –170 mm 2201/0019 5 -0/+0.5 N·m
160 –180 mm 2201/0020 5 -0/+0.5 N·m
Table 480. Heavy Duty Worm Drive Clip

range
172 –194 mm 2201/0022 10 -0/+0.5 N·m
184 –206 mm 2201/0023 10 -0/+0.5 N·m
Table 481. Spring Assisted Worm Drive Clip

range
16 –27 mm 2206/1627 5 -0/+0.5 N·m
20 –32 mm 2206/2032 5 -0/+0.5 N·m
25 –40 mm 2206/2540 5 -0/+0.5 N·m
30 –45 mm 2206/3045 5 -0/+0.5 N·m
35 –50 mm 2206/3550 5 -0/+0.5 N·m
40 –60 mm 2206/4060 5 -0/+0.5 N·m
50 –70 mm 2206/5070 5 -0/+0.5 N·m
60 –80 mm 2206/6080 5 -0/+0.5 N·m
70 –90 mm 2206/7090 5 -0/+0.5 N·m
Table 482. Constant Torque Worm Drive Clips

range
14 –27 mm 334/J4514 5 N·m
25 –45 mm 334/J9549 10 N·m
32 –54 mm 333/K2259 OR 10 N·m
400/P2870
45 –67 mm 821/10236 10 N·m
54 –79 mm 821/10191 10 N·m
70 –92 mm 821/10192 10 N·m
83 –105 mm 332/K3479 10 N·m
95 –118 mm 332/S8033 10 N·m
72 - 20 9823/1650-1 72 - 20
21 - Clips
03 - Worm Drive
Component Identification Figure 1062. Spring Assisted Worm Drive Clip

A B
Figure 1060. Standard Worm Drive Clip
C
A B
C
D
F
E
A Screw support flange

B Asymmetric housing
C Asymmetric extension
A Screw support flange D Short housing saddle
B Asymmetric housing E Stamped inside
C Asymmetric extension F Spring insert
D Short housing saddle G Identification of material/clamping range
E Stamped inside
Figure 1063. Constant Torque Worm Drive Clips
F Identification of material/clamping range
A B
Figure 1061. Heavy Duty Worm Drive Clip
F
D C
A
E
C
B
A Housing
B Screw
C Belleville spring
D Saddle
E Liner
F Band
A Extended bridge
B Band width ( 16 mm)
C Identification of clamping range
72 - 21 9823/1650-1 72 - 21
36 - Threaded Insert
Contents Page No.
72-36-00 General ........................................................................................................................... 72-23
72 - 22 9823/1650-1 72 - 22
00 - General
Introduction .................................................... 72-23 A threaded insert also known as a rivet nut is a
Technical Data ............................................... 72-24 one piece fastener installed blind from one side of
Remove and Install ....................................... 72-24 the machine body/framework. The threaded insert is
compressed so that a section of its shank forms an
upset against the machine body/framework, leaving
a durable thread.
Figure 1064.
A Threaded insert
B Durable thread
Threaded inserts are installed to various parts of

the machine body and framework. They are used in
a number of applications, for instance, hose clamp
and hydraulic valve retention etc. Various sized
threaded inserts are available, refer to technical data
to determine the correct size of threaded insert to be
used for particular applications.
If for any reason a new threaded insert is required,

the correct installation procedure must be followed.
72 - 23 9823/1650-1 72 - 23
00 - General
Technical Data Remove and Install

Consumables
Table 483. Specifications Description Part No. Size
Thread Outside Materi- Total Drill Threaded Insert (M10 x 826/01104 -
Diame- Diame- al Thick- Rivet Hole Di- 23mm)
ter ter ness Length ameter Threaded Insert (M10 x 826/01105A -
mm mm mm mm mm 26mm)
(inch) (inch) (inch) (inch) Threaded Insert (M6 x 826/01099 -
M5 7 0.25 –3 14 7.1 16mm)
M5 7 3 –5.5 17 7.1 Threaded Insert (M6 x 826/01101 -
M6 9 0.5 –3 16 9.1 19mm)
M6 9 3 –5.5 19 9.1 Threaded Insert (M8 x 826/01102 -
18mm)
M8 11 0.5 –3 18 11.1
Threaded Insert (M8 x 826/01103 -
M8 11 3 –5.5 21 11.1
21mm)
M10 13 1 –3.5 23 13.1
M10 13 3.5 –6 26 13.1 The threaded insert installation tool is available from
Bolhoff Fastenings Ltd. www.bolhoff.com.
Install
1. Drill a hole in the machine body/framework where
the threaded insert is to be installed, refer to
technical data for the correct size.
2. De-burr the hole edges.
3. Screw the threaded insert on to the mandrel of
the installation tool. The bottom of the mandrel
should be in line with the bottom of the threaded
insert.
Consumable: Threaded Insert (M6 x 16mm)
Figure 1065.
A Threaded insert
4. Wind the body of the installation tool down the
threaded mandrel until it touches the head of the
threaded insert.
72 - 24 9823/1650-1 72 - 24
00 - General
Figure 1066.
B Head of threaded insert

5. Insert the threaded insert (assembled to the tool)
into the hole drilled in step 1.
6. Hold handle and at the same time draw the
mandrel into the installation tool by turning nut.
The threaded insert will contract in length and
form an upset (smooth bulge) seating itself
against the body/ framework. Note: The thread
of the threaded insert must not be stripped, take
care when upsetting the threaded insert.
Figure 1067.
C Handle
D Nut
E Body/Framework
7. Remove the installation tool.
72 - 25 9823/1650-1 72 - 25
Notes:
72 - 26 9823/1650-1 72 - 26
Contents Page No.
75-00 Consumable Products

75-00-00 General ............................................................................................................................. 75-3
75-03 Oil
75-03-00 General ............................................................................................................................. 75-9
75-03-03 Engine ............................................................................................................................ 75-10
75-06 Grease
75-06-00 General ........................................................................................................................... 75-13
75-09 Fluids
75-09-00 General ........................................................................................................................... 75-17
75-09-03 Antifreeze ....................................................................................................................... 75-18
75-10 Locking Fluids
75-10-00 General ........................................................................................................................... 75-21
75-14 Solvents and Primers
75-14-00 General ........................................................................................................................... 75-25
75-15 Adhesive
75-15-00 General ........................................................................................................................... 75-29
75-16 Sealant
75-16-00 General ........................................................................................................................... 75-35
75-18 Fuel
75-18-00 General ........................................................................................................................... 75-43
9823/1650-1
2018-06-07
Acronyms Glossary
PTFE Polytetrafluoroethylene
9823/1650-1
2018-06-07
Contents Page No.
75-00-00 General ............................................................................................................................. 75-3
75 - 1 9823/1650-1 75 - 1
Notes:
75 - 2 9823/1650-1 75 - 2
00 - General
Introduction ...................................................... 75-3 JCB recommend that you use the JCB lubricants
Health and Safety ........................................... 75-4 shown as they have been verified by JCB for use
Technical Data ................................................. 75-6 on JCB machines. However, you could use other
lubricants that are equivalent to the JCB standards
and quality or offer the same machine component
protection.
Before you start work, make sure that:
• All safety precautions are observed in

accordance with the information contained
within the relevant support documentation.
• The consumables are used in accordance with
the manufacturer's recommendations.
• The consumables shown are available in the
correct quantity.
Consumables other than those listed may be

required. It is expected that general consumables will
be available in any well equipped workshop or be
available locally.
75 - 3 9823/1650-1 75 - 3
00 - General
Health and Safety
Oil Waste Disposal

Oil is toxic. If you swallow any oil, do not induce CAUTION It is illegal to pollute drains, sewers
vomiting, seek medical advice. Used engine oil or the ground. Clean up all spilt fluids and/or
contains harmful contaminants which can cause skin lubricants.
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves Used fluids and/or lubricants, filters and
to prevent skin contact. Wash skin contaminated with contaminated materials must be disposed of in
oil thoroughly in warm soapy water. Do not use petrol, accordance with local regulations. Use authorised
diesel fuel or paraffin to clean your skin. waste disposal sites.
Fluid Under Pressure CAUTION Damaged or spent batteries and any
residue from fires or spillage must be put in a
Fine jets of fluid at high pressure can penetrate the suitable closed receptacle and must be disposed
skin. Keep face and hands well clear of fluid under of in accordance with local environmental waste
pressure and wear personal protective equipment. regulations.
Hold a piece of cardboard close to suspected
leaks and then examine the cardboard for signs of
fluid. If fluid penetrates your skin, get medical help All waste products must be disposed of in
immediately. accordance with all the relevant regulations.
Fuel The collection and disposal of used oil must be in
Fuel is flammable, keep naked flames away from the accordance with any local regulations. Never pour
fuel system. Stop the engine immediately if a fuel used engine oil into sewers, drains or on the ground.
working on the fuel system. Do not refuel with the Handling
engine running. Completely wipe off any spilt fuel
CAUTION The temperature of the hydraulic oil
which could cause a fire. There could be a fire and
will be high soon after stopping the machine. Wait
until it cools before beginning maintenance.
Hygiene
New Oil
JCB lubricants are not a health risk when used
correctly for their intended purposes. There are no special precautions needed for the
handling or use of new oil, beside the normal care
However, excessive or prolonged skin contact can and hygiene practices.
remove the natural fats from your skin, causing
dryness and irritation. Used Oil
Low viscosity oils are more likely to do this, so take Used engine crankcase lubricants contain harmful
special care when handling used oils, which might be contaminants.
diluted with fuel contamination.
Here are precautions to protect your health when
Whenever you are handling oil products you must handling used engine oil:
maintain good standards of care and personal and
plant hygiene. For details of these precautions we • Avoid prolonged, excessive or repeated skin
advise you to read the relevant publications issued contact with used oil
by your local health authority, plus the following. • Apply a barrier cream to the skin before
handling used oil. Note the following when
Storage removing engine oil from skin:
• Wash your skin thoroughly with soap and
Always keep lubricants out of the reach of children. water
• Using a nail brush will help
Never store lubricants in open or unlabelled • Use special hand cleansers to help clean
containers. dirty hands
• Never use petrol, diesel fuel, or paraffin for
washing
• Avoid skin contact with oil soaked clothing
• Don't keep oily rags in pockets
• Wash dirty clothing before re-use
75 - 4 9823/1650-1 75 - 4
00 - General
• Throw away oil-soaked shoes Battery

Warning Symbols
The following warning symbols may be found on the
battery.
Figure 1068.
A B C D E F
A Keep away from children B Shield eyes

C No smoking, no naked flames, no sparks D Explosive gas
E Battery acid F Note operating instructions
First Aid - Oil Swallowing
Eyes Do not induce vomiting. Drink large quantities of

water or milk. Then drink milk of magnesia, beaten
In the case of eye contact, flush with water for 15 egg or vegetable oil. Get medical help.
min. If irritation persists, get medical attention.
Skin
Swallowing
Flush with water, remove affected clothing. Cover
If oil is swallowed do not induce vomiting. Get burns with a sterile dressing then get medical help.
medical advice.
Skin
In the case of excessive skin contact, wash with soap
and water.
Spillage
Absorb with sand or a locally approved brand of
absorbent granules. Scrape up and remove to a
chemical disposal area.
Fires
WARNING Do not use water to put out an oil fire.
This will only spread it because oil floats on water.
Extinguish oil and lubricant fires with carbon
dioxide, dry chemical or foam.
First Aid - Electrolyte

Eyes
In the case of eye contact, flush with water for 15
min. always get medical attention.
75 - 5 9823/1650-1 75 - 5
00 - General
Technical Data
and quality or offer the same machine component

JCB recommend that you use the JCB lubricants protection.
shown as they have been verified by JCB for use
on JCB machines. However, you could use other No warranty liability will be accepted for engine
lubricants that are equivalent to the JCB standards failures where unacceptable fuel grades (or their
equivalent) have been used at any stage.
Table 484.
Item Capacity Fluid/Lubricant JCB Part Num- Container
ber Size
(1)
Diesel Fuel Tank 132 L Diesel Oil

Engine (Oil)
(2)
Min 12.5 L - JCB Engine Oil EP 15W40 -10 – 4001/2605 20 L
Max 15 L 50 °C ( 14.0 –121.9 °F)
JCB Cold Climate Engine Oil EP 4001/2705
5W40 -20 –50 °C ( -4.0 –121.9
°F)
Engine (Coolant)
(3)
20 L JCB Antifreeze HP/Coolant + Wa- 4006/1120 20 L
ter
Gearbox 19 L JCB Transmission Fluid EP 10W, 4000/2505 20 L
-32 –40 °C ( -25.6 –103.9 °F)
(4)
Front axle housing 18 L JCB Gear oil HP plus 4000/2205

(5)
20 L
Front Hubs 2L JCB Gear oil HP plus 4000/2205
(5)
20 L
Rear axle housing 13 L JCB Gear oil HP plus 4000/2205
(5)
20 L
Rear Hubs 2L JCB Gear oil HP plus 4000/2205
(5)
20 L
Brake system JCB Hydraulic fluid HP 15
(6)
4002/0503 5L
Hydraulic tank
(7)
128 L JCB Multi-grade Hydraulic Fluid 4002/2020 20 L
46
Grease Points JCB Special HP Grease
(8)
4003/2017 0.4 kg
JCB Special MPL-EP Grease 4003/1501 0.4 kg
Wear pad runways JCB Waxoyl 4004/0502 5L
Boom hoses JCB Special Slide Lubricant 4003/1115 0.4 kg
Boom chains JCB Chain Lubricant 4004/0237A 0.3 L
(1) For information about the different container sizes that are available (and their part numbers), contact your
JCB Dealer.
(2) Do not use ordinary engine oil.
(3) It is recommended that the cooling system be filled at a maximum rate of 6L (1.6gal) per minute. If the fill
rate is any higher than this then there is a possibility of air becoming trapped in the system.
(4) Friction modified oils must not be used (eg Dexron ATF type).
(5) Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
(6) Do not use ordinary brake fluid.
(7) This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used.
Fill with all cylinders closed. Watch level sight glass when filling.
(8) JCB Special HP Grease is the recommended specification grease. If JCB Special MPL-EP Grease is used,
all 50 h greasing operations must be carried out at 10 h intervals; all 500 h greasing operations must be
carried out at 50 h intervals.
75 - 6 9823/1650-1 75 - 6
03 - Oil
03 - Oil
Contents Page No.
75-03-00 General ............................................................................................................................. 75-9

75-03-03 Engine ............................................................................................................................ 75-10
75 - 7 9823/1650-1 75 - 7
Notes:
75 - 8 9823/1650-1 75 - 8
03 - Oil
00 - General
00 - General
Introduction
New Oil
There are no special precautions needed for the
handling or use of new oil, besides the normal
health and safety practices mentioned in the relevant
section of this service manual.
Used Oil
Used engine crankcase lubricants contain harmful
contaminants. Here are precautions to protect your
health when handling used engine oil:
1. Avoid prolonged, excessive or repeated skin

contact with used oil.
2. Apply a barrier cream to the skin before handling
used oil.
3. Note the following when removing engine oil from
skin:
3.1. Wash your skin thoroughly with soap and
water.
3.2. Using a nail brush will help.
3.3. Use special hand cleansers to help clean
dirty hands.
3.4. Never use petrol, diesel fuel, or paraffin for
washing.
4. Avoid skin contact with oil soaked clothing.
5. Don't keep oily rags in pockets.
6. Wash dirty clothing before re-use.
7. Throw away oil-soaked shoes.
First Aid
EYES - In the case of eye contact, flush with water for
15 minutes. If irritation persists, get medical attention.
SWALLOWING - If oil is swallowed do not induce

vomiting. Get medical advice.
SKIN - In the case of excessive skin contact, wash

with soap and water.
SPILLAGE - Absorb on sand or a locally approved

brand of absorbent granules. Scrape up and remove
to a chemical disposal area.
FIRES - Extinguish with carbon dioxide, dry chemical

or foam. Firefighters should use self-contained
breathing apparatus.
75 - 9 9823/1650-1 75 - 9
03 - Oil
03 - Engine
03 - Engine
Introduction
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).
A minimum API CJ4 grade oil must be used. Superior

grade oils may be more appropriate for heavy duty
applications (such as sustained high loads and
operation at elevated temperatures).
The choice of lubricant viscosity should be made

based on the lowest ambient temperature at which
the machine will be started and the maximum
ambient temperature at which it will operate.
The technical data section provides guidance as to

the temperature range that can be accommodated
by standard oil viscosities and can be used to select
an appropriate grade.
Important: When selecting the oil viscosity grade

make sure the oil conforms with or exceeds the
recommended specification.
75 - 10 9823/1650-1 75 - 10
06 - Grease
06 - Grease
Contents Page No.
75-06-00 General ........................................................................................................................... 75-13
75 - 11 9823/1650-1 75 - 11
Notes:
75 - 12 9823/1650-1 75 - 12
06 - Grease
00 - General
00 - General 5. JCB Autogrease

Consumable: JCB Autogrease
Introduction 6. JCB EP Hammer Grease
Special Tools Consumable: EP Hammer Grease
7. JCB Special Hammer Grease
Grease Gun 892/00913 1
Attachment Consumable: Special Hammer Grease
Grease Gun 992/11300 1
8. JCB Special Slew Pinion Grease
Consumables Consumable: Special Slew Pinion Grease
EP Hammer Grease 4003/2107 0.4 kg Greasing Procedure
4003/2106 12.5 kg
Extreme Performance 4003/1327 0.4 kg
Moly Grease Refer to: PIL 01-03.
4003/1326 12.5 kg
JCB Autogrease 4003/2305 0.5 kg 2. If necessary, install any maintenance or
Special HP Grease 4003/2020 0.5 kg articulation struts.
4003/2017 0.4 kg 3. Make a note of the following:
4003/2006 12.5 kg
4003/2005 50 kg 3.1. The machine must always be greased after
pressure washing or steam cleaning.
Special Hammer 4003/1119 0.4 kg
Grease 3.2. Greasing must be done with a grease gun.
Special MPL-EP 4003/1501 0.4 kg Normally, two strokes of the gun should be
Grease sufficient.
4003/1506 12.5 kg
4003/1510 50 kg Special Tool: Grease Gun (Qty.: 1)
Special Tool: Grease Gun Attachment (Qty.:
Special Slew Pinion 4003/1619 0.4 kg
1)
Grease
Special Slide Grease 4003/1115 0.4 kg 3.3. Stop greasing when fresh grease appears
at the joint.
There are various greasing points on the machine. 3.4. Use only the recommended type of grease.
You must grease the machine regularly to keep
it working efficiently. Regular greasing will also 3.5. Do not mix different types of grease, keep
lengthen the machine's working life. You must grease them separate.
the machine as stated in the maintenance schedule.
Refer to: PIL 78-24. 4. Count off the grease points as you grease each
one.
JCB grease is manufactured to provide significant 5. Install the dust caps after greasing (if installed).
load protection for your machine. It is recommended
to use only JCB grease on your machine because
they are specifically designed for the particular JCB Special HP Grease
application. The list of JCB greases comprises:
JCB Special HP grease is a premium quality,
1. JCB Special HP Grease extreme pressure grease. It is recommended
for use in arduous operating conditions, such
Consumable: Special HP Grease as high temperatures, excessive loading and
extensive exposure to water. The sophisticated
2. JCB Special MPL-EP Grease
additive package combines with excellent adhesive
Consumable: Special MPL-EP Grease properties to give high performance protection to
your machine.
3. JCB Extreme Performance Moly Grease
Consumable: Extreme Performance Moly Table 485. JCB Special HP Grease Properties
Grease Description Data
4. JCB Special Slide Grease Colour Blue
Soap type Lithium complex
Consumable: Special Slide Grease
75 - 13 9823/1650-1 75 - 13
06 - Grease
00 - General
Description Data Table 488. JCB Special Slide Grease Properties

Drop point 245 °C ( 472.7 °F) Description Data
Working temperature -20 –150 °C ( -4.0 – Colour Dark grey
range 301.8 °F) Soap type Lithium
Drop point 180 °C ( 355.7 °F)
JCB Special MPL-EP Grease Working temperature -20 –120 °C ( -4.0 –
range 247.8 °F)
JCB Special MPL-EP grease is a true multipurpose
grease. It is recommended for a wide range of
lubricating applications, such as pivot pins and wheel JCB Autogrease
bearings, where excellent anti wear and anti rust
performance is required. Its EP additive makes it JCB Autogrease is for use with the automatic
particularly suitable for the shock load and vibrating greasing system. It is a mineral oil based paste.
conditions found on machines. It contains an aluminium complex soap and solid
lubricants. It is suitable for use under water or in
Table 486. JCB Special high ambient temperatures. The specially designed
MPL-EP Grease Properties cartridges screw into the automatic greasing system
installed on the machine.
Description Data
Colour Brown The clear cartridge allows the operator to easily
Soap type Lithium monitor the grease usage from inside of the operator
Drop point 180 °C ( 355.7 °F) station.
Working temperature -20 –130 °C ( -4.0 – Table 489. JCB Autogrease
range 265.8 °F)
Description Data
JCB Extreme Performance Moly Grease Colour Black
Soap type Aluminium complex, sol-
JCB Extreme Performance Moly grease is an id lubricants
advanced performance, multipurpose grease. It is Drop point 260 °C ( 499.6 °F)
recommended for heavily loaded bearing surfaces Working temperature -20 –110 °C ( -4.0 –
and in particular where limited or oscillating range 229.8 °F)
motion causes fretting. The addition of molybdenum
disulphide provides extra protection against scoring
and wear. This grease is ideal for automotive, JCB EP Hammer Grease
industrial, agricultural and earthmoving equipment.
JCB EP Hammer grease is a unique formulation
Table 487. JCB Extreme aluminium complex grease for use where extremes
Performance Moly Grease Properties of pressure and temperature are likely to be
encountered. It is suitable for the hammer
Description Data applications where resistance to water washing and
Colour Grey Black migration may be critical.
Soap type Lithium
Drop point 185 °C ( 364.7 °F) Table 490. JCB EP Hammer Grease
Working temperature -20 –120 °C ( -4.0 – Description Data
range 247.8 °F) Colour Black
Soap type Aluminium complex
JCB Special Slide Grease Drop point 250 °C ( 481.6 °F)
Working temperature -20 –160 °C ( -4.0 –
JCB Special Slide grease is formulated to provide range 319.8 °F)
excellent protection under heavy load and extreme
pressure, where water and dirt are prevalent. It
maintains a film of lubrication on slow moving slides. JCB Special Hammer Grease
It has an excellent resistance to squeeze out and
superb corrosion resistance. JCB Special Hammer grease provides a highly
effective lubricant on slow moving slides and an
excellent corrosion resistant property. It combines
the self healing action of oils and the resistance to
drip of viscous compounds.
75 - 14 9823/1650-1 75 - 14
06 - Grease
00 - General
Table 491. JCB Special Hammer Grease

Description Data
Colour Dark grey
Soap type Lithium
Drop point 185 °C ( 364.7 °F)
Working temperature -15 –120 °C ( 5.0 –247.8
range °F)
JCB Special Slew Pinion Grease

JCB Special Slew Pinion grease is a soft, black and
tenacious grease. It is designed specifically for the
lubrication of large and heavy duty open gears. It has
an excellent corrosion protection and load carrying
properties throughout a large temperature range.
Table 492. JCB Special Slew Pinion Grease

Description Data
Colour Black
Soap type Organically modified
clay
Working temperature -40 –100 °C ( -39.9 –
range 211.9 °F)
75 - 15 9823/1650-1 75 - 15
09 - Fluids
09 - Fluids
Contents Page No.
75-09-00 General ........................................................................................................................... 75-17

75-09-03 Antifreeze ....................................................................................................................... 75-18
75 - 16 9823/1650-1 75 - 16
09 - Fluids
00 - General
00 - General
Introduction
It is most important that you read and understand this

information and the publications referred to. Make
sure all your colleagues who are concerned with
lubricants read it too.
Hygiene
JCB lubricants are not a health risk when used
properly for their intended purposes.
However, excessive or prolonged skin contact can

remove the natural fats from your skin, causing
dryness and irritation.
Low viscosity oils are more likely to do this, so take

special care when handling used oils, which might be
diluted with fuel contamination.
Whenever you are handling oil products you should

maintain good standards of care and personal and
plant hygiene. For details of these precautions we
advise you to read the relevant publications issued
by your local health authority, plus the following.
Storage
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled
containers.
Waste Disposal
All waste products should be disposed of in
accordance with all the relevant regulations.
The collection and disposal of used oil should be in

accordance with any local regulations. Never pour
used engine oil into sewers, drains or on the ground.
75 - 17 9823/1650-1 75 - 17
09 - Fluids
03 - Antifreeze
03 - Antifreeze Introduction
Introduction .................................................... 75-18
Coolant Mixtures
Technical Data ............................................... 75-19 Check the strength of the coolant mixture at least
once a year, preferably at the start of the cold period.
Do not use solutions of more than 60% or damage to
the engine may occur. Replace the coolant mixture
according to the intervals shown in the machine's
maintenance schedule.
You must dilute full strength antifreeze with clean

water before use. Use clean water of no more
than a moderate hardness (pH value 8.5). If this
cannot be obtained, use de-ionized water. For further
information advice on water hardness, contact your
local water authority.
The correct concentration of antifreeze protects the

engine against frost damage in winter and provides
year round protection against corrosion. Always
renew the antifreeze every two years.
The protection provided by High Performance

Antifreeze and Inhibitor is shown below. If any
other antifreeze is used, refer to the manufacturer's
instructions and make sure that a corrosion inhibitor
is included.
Table 493.
Solution Maintains cir- Protects
culation down against dam-
to: age down to:
50% Concen- -33 °C ( -27.4 -40 °C ( -39.9
tration (Stan- °F) °F)
dard)
60% Concen- -42 °C ( -43.5 -56 °C ( -68.7
tration (Stan- °F) °F)
dard)
Important: Do not exceed a 60% concentration, as

the freezing protection provided reduces beyond this
point.
If you use any other brand of antifreeze:
• Make sure that the antifreeze complies with

International Specification ASTM D6210.
• Always read and understand the
manufacturer's instructions.
• Make sure that a corrosion inhibitor is included.
Serious damage to the cooling system can
occur if corrosion inhibitors are not used.
• Make sure that the antifreeze is ethylene
glycol based and does not use Organic Acid
Technology (OAT).
75 - 18 9823/1650-1 75 - 18
09 - Fluids
03 - Antifreeze

CAUTION The cooling system is pressurised CAUTION Antifreeze can be harmful. Obey the
when the coolant is hot. When you remove the manufacturer's instructions when handling full
cap, hot coolant can spray out and burn you. strength or diluted antifreeze.
Make sure that the engine is cool before you work
on the cooling system. Check the strength of the coolant mixture at least
CAUTION Antifreeze can be harmful. Obey the once a year, preferably at the start of the cold period.
manufacturer's instructions when handling full
strength or diluted antifreeze. Replace the coolant mixture according to the
intervals shown in the machine's Service Schedule.
You must dilute full strength antifreeze with clean

water before use. Use clean water of no more
than a moderate hardness (pH value 8.5). If this
cannot be obtained, use de-ionized water. For further
information advice on water hardness, contact your
local water authority.
The correct concentration of antifreeze protects the

engine against frost damage in winter and provides
year round protection against corrosion.
The protection provided by JCB High Performance

Antifreeze and Inhibitor is shown below.
Table 494.
Concentration Level of protection
50 % (Standard) Protects against dam-
age down to -40 °C
( -40 °F)
60 % (Extreme Condi- Protects against dam-
tions Only) age down to -56 °C
( -69 °F)
Do not exceed a 60% concentration, as the freezing

protection provided reduces beyond this point.
If you use any other brand of antifreeze:
• Make sure that the antifreeze complies with

International Specification ASTM D6210.
• Always read and understand the
manufacturer's instructions.
• Make sure that a corrosion inhibitor is included.
Serious damage to the cooling system can
occur if corrosion inhibitors are not used.
• Make sure that the antifreeze is ethylene
glycol based and does not use Organic Acid
Technology (OAT).
75 - 19 9823/1650-1 75 - 19
10 - Locking Fluids
10 - Locking Fluids
Contents Page No.
75-10-00 General ........................................................................................................................... 75-21
75 - 20 9823/1650-1 75 - 20
10 - Locking Fluids
00 - General
Introduction .................................................... 75-21 All locking fluids should be used at all times in line
Technical Data ............................................... 75-22 with the manufacturer’s recommendations.
Locking fluids are used for the locking of threaded

fasteners and for the retention of ball & roller
bearings and similar cylindrical items on to shafts and
into housings. These fluids consist of an anaerobic
resin in a liquid form which hardens when confined
between closely fitting metal to metal and many
metal to non-metal surfaces.
The fluids available possess a wide span of

break-loose strengths, viscosities and gap filling
properties and are marketed for a variety of locking
and retaining purposes requiring different strength
grades. Some of the sealants in use in JCB are
also of anaerobic resin type and only differ from
the locking fluids in respect of viscosity and other
technical details.
Strength grades
Various strength grades of fluid are available,
the highest strength type for permanent locking
where disassembly is unlikely, medium strength
for permanent locking but allowing disassembly
with ordinary tools and low strength for locking
of components where frequent adjustment or easy
dismantling is required.
It is recommended that trials be carried out before

scheduling locking fluids for any new type of
application that has not been already proved as
satisfactory in production or when use at elevated
temperatures is intended.
Additional technical information is normally available

from the product manufacturers.
Approved locking fluids

The table shown in Technical Data shows the
approved locking fluids available to use on JCB
machines. The table also provides basic details to
help with selection of locking fluids. More up to
date information can be found on the manufacturer’s
website.
75 - 21 9823/1650-1 75 - 21
10 - Locking Fluids
00 - General
Technical Data
Table 495. Locking Fluids Approved Product Information

Subsec- Commer- Product Colour Shelf Strength Comments
tion cial name Number life
High Loctite 4101/0100 Green 365 80 –120 bar For the retention of threads up to M20 di-
strength 270
(1)
fluores- d ( 1,159.4 – ameter where disassembly is unlikely and
cent 1,739.1 psi) for locking bearings etc. onto shafts and in-
R.A.S. Red breakaway to housing. Has a maximum gap fill of 0.05
threadlock strength mm.
for studs
(1)
High Loctite 4101/1400 Green, 365 More than Maximum gap fill of 0.25 mm. Maximum
strength 638 UV fluo- d 250 bar strength at room temperature.
rescent ( 3,623.2
psi) com-
pressive
shear
strength
High Per- 4101/0500 Red, flu- 365 100 – Fast curing ( 10 –15 min) thread locking up
strength mabond ores- d 150 bar to M20, especially for use on oily surfaces,
A115
(1)
cent ( 1,449.3 – plated and clean parts.
Loctite 2,173.9 psi)
262 prevailing
strength
High Loctite 4101/0600 Green, 365 More than Designed for holding gears and sprockets
strength 648(1) fluores- d 250 bar onto gearbox shafts and rotors on electric
Per- cent ( 3,623.2 motor shafts.
mabond psi) com-
A118 pressive
shear
strength
High Loctite 4101/1700 Green 365 260 – Designed for permanent locking and seal-
strength 2701 d 500 bar ing of threaded fasteners. Particularly suit-
( 3,768.1 – ed for use on inactive substrates and/or
7,246.3 psi) where maximum resistance to hot oil is re-
breakaway quired.
torque
Medium Loctite 4101/1100 Blue 365 140 – Suitable for all nuts, bolts, screws up to
to high 243 d 340 bar M36.
( 2,029.0 –
4,927.5 psi)
breakaway
torque
Medium Per- 4101/0900 Blue 365 80 –120 bar Maximum gap fill of 0.25 mm. Handling
strength mabond d ( 1,159.4 – strength in 10 –15 min.
A119
(1)
1,739.1 psi)
static shear
strength
Medium Loctite 4101/1200 Green, 365 150 – Product has a slow cure rate, used on parts
strength 640 fluores- d 330 bar unlikely to be disassembled.
cent ( 2,173.9 –
4,782.6 psi)
static shear
strength
75 - 22 9823/1650-1 75 - 22
10 - Locking Fluids
00 - General
Subsec- Commer- Product Colour Shelf Strength Comments

tion cial name Number life
Medium Loctite 4101/0200 Blue, 365 80 –120 bar Suitable for all nuts, bolts and screws up to
strength 242
(1)
fluores- d ( 1,159.4 – M36 and hydraulic fittings up to 25mm in di-
Per- cent 1,739.1 psi) ameter. Permabond A113 and A1042 are
mabond static shear the preferred choices. The difference be-
A1042 strength tween A113 and A1042 is timing for han-
dling and working strength. A113 handling
Per- time 10 –25 min, working strength 1 h.
mabond A1042 handling time 5 –10 min, working
A113 strength 30 min.
Low Loctite 4101/0300 Purple, 365 15 –40 bar For screwed fasteners up to M20 that re-
strength 222 fluores- d ( 217.4 – quire easy disassembly or frequent ad-
cent 579.7 psi) justment. Maximum gap fill of 0.05 mm.
Achieves handling strength in 10 –30 min.
Low Per- 4101/1500 Blue 365 120 bar Allows dismantling of parts for mainte-
strength mabond d ( 1,739.1 nance. Suitable for sealing small hydraulic
A1098 psi) shear and pneumatic fittings. Handling strength in
strength 5 –10 min.
Low Loctite 4101/1600 Off- 365 17 bar For the locking and sealing of metal ta-
strength 567 white d ( 246.4 psi) pered threads and fittings. High lubricat-
breakaway ing properties prevent galling on stainless
torque steel, aluminium and all other metal pipe
threads and fittings.
Very low Loctite 4101/0400 Brown/ 365 7 –18 bar Can be disassembled with hand tools. 10
strength 932(1) red d ( 101.4 –30 min cure time for handling strength.
Per- –260.9 Used on large diameter screw threads big-
mabond psi) aver- ger than 50mm.
A011 age shear
strength
(1) This is a non preferred product.
75 - 23 9823/1650-1 75 - 23
14 - Solvents and Primers
Contents Page No.
75-14-00 General ........................................................................................................................... 75-25
75 - 24 9823/1650-1 75 - 24
00 - General
Introduction .................................................... 75-25 This section contains information on primers,
Technical Data ............................................... 75-26 solvents, cleaning solutions etc. that are in use at
JCB.
All primers and solvents should be used at all times

in line with the manufacturer’s recommendations.
Approved primers and solvents

The table shown in Technical Data shows the
approved primers and solvents available to use on
JCB machines. The table also provides basic details
to help with the selection of primers and solvents.
More up to date information can be found on the
manufacturer’s website.
75 - 25 9823/1650-1 75 - 25
00 - General
Technical Data
Table 496. Primers and Solvents Approved Product Information

Subsec- Commer- Product Colour Shelf Drying Comments
tion cial name Number life Time
Activa- Loctite 332/U7901 Colour- 365 Less than 5 Used to make low energy surfaces suit-
tor/Primer 770 less d s able for bonding with cyanocrylate adhe-
sives. It is recommended for polyethylene,
polypropylene, PTFE and thermoplastic
rubber materials. Can be used with Loctite
406 (332/U7899).
Activator Loctite 4104/1700 Clear 730 Apply and HIGHLY FLAMMABLE. Organic accelera-
7455 amber d leave to dry tor, non CFC solvent based surface activa-
for 30 s be- tor. Designed to promote the speed of cure
fore apply- of cyanoacrylic adhesives.
ing adhe-
sive
Activator Loctite 4104/0200 Colour- 365 1 –3 min Used with anaerobic products it increases
7471 less d cure speed. Recommended for inert sur-
Per- faces and large bond gaps.
mabond
A905
Water Loctite 4104/0500 - - - A water proofing solution for protecting
proofing water joints made using cyanoacrylate adhesive.
proofing Apply to Loctite 495 (4103/0900).
Solvent Loctite 4104/1500 Colour- 365 1 min at 20 HIGHLY FLAMMABLE, cleaner and de-
7063 less d °C ( 68.0 greaser. Removes grease, oil and dirt from
°F) electrical parts, tools and precision equip-
ment.
Cleaning Loctite 4101/2200 Colour- 365 No wipe Cleaning treatment to remove most greas-
fluid 7070 less d 5 –10 min, es, oils, lubrication fluids and metal cuttings
post wipe 1
–2 min
Cleaning Simple 332/E9240 Colour- 365 - An all purpose cleaner and degreaser used
fluid green ex- less d diluted in water for direct, spray and dip
treme tank procedures.
Applica- A4GBCJCB4104/3300 Blue 730 - Vinyl labels application fluid for use with the
tion fluid d insignia/livery labels.
Gasket Loctite 4104/3200 Colour- 730 Allow 10 – This is a product to aid the removal of
cleaner 7200 less d 15 min for cured chemical gaskets. Apply for time
gasket, 30 specified and remove gasket with soft
min for sil- scraper.
icone gas-
ket.
Hand Loctite 4104/3100 Light 540 - Is a heavy duty hand cleaner, specially for-
cleaner 7855 grey d mulated for the most difficult to remove
soils like polyurethane, paints, primers, ad-
hesives etc. The product is free from sil-
icone and harsh solvents. Can be used
without water.
Hand Sika hand 4104/1300 Off - - A non-abrasive hand cleaner for use when
cleaner cleaner white using direct glazing materials.
75 - 26 9823/1650-1 75 - 26
00 - General
Subsec- Commer- Product Colour Shelf Drying Comments

tion cial name Number life Time
Direct Sika acti- 4104/2100 Clear 365 10 min mini- HIGHLY FLAMMABLE. A cleaning and acti-
glazing vator d mum drying vating agent specifically formulated for the
time treatment of bonded faces in direct glaz-
ing applications prior to applying the direct
glazing adhesive.
Direct Sika re- 4104/1900 Trans- - - A cleaning agent for removing contami-
glazing mover parent nates on painted surfaces and glass.
208 (use
4104/3600)
Direct Sika 4104/1200 Clear - - A cleaning agent for removing contami-
glazing cleaner nates on painted surfaces and glass.
205 (use
4104/3600)
Direct Sika 4104/2300 Black 270Application Used to prime painted surfaces and plas-
glazing primer d temperature tic substrates prior to bonding with Sikaflex
209 (use 10 –35 °C products.
4104/3500) ( 50.0 –95.0
°F)
Direct Sika akti- 4104/2400 Clear 365 10 min at Used to clean and give improved adhe-
glazing vator d more than sion on glass, ceramic-coated glass, the cut
15 °C ( 59.0 face of old polyurethane adhesive beads,
°F) or 30 polyurethane coated windows glass and
min at less paints.
than 15 °C
( 59.0 °F)
Active Tero- 4104/3400 Colour- 270 Minimum Applied with a clean cloth to the surface,
wipe for stat 8560 less d 30 s and the adhesive may then be applied after the
surface AC-25 maximum 1 drying time. Applied to glass or ceramic
h coating but only in the bonding area.
Direct Terostat 4102/3500 Black 0.1 L Approx. 2 Used to promote adhesion in direct glazing
glazing 8519 P bot- min to glass and glass ceramics.
tle =
365
d.
0.01
L
and
0.035
L
bot-
tle =
540
d
Cleaner Teroson 4104/3600 Clear 730 Depend- Used for degreasing and cleaning of sub-
FL clean- d ing on con- strates prior to application of adhesives and
er ditions be- sealants.
tween 2 –
10 min.
75 - 27 9823/1650-1 75 - 27
15 - Adhesive
15 - Adhesive
Contents Page No.
75-15-00 General ........................................................................................................................... 75-29
75 - 28 9823/1650-1 75 - 28
15 - Adhesive
00 - General
Introduction .................................................... 75-29 All adhesives should be used at all times in line with
Technical Data ............................................... 75-30 the manufacturer’s recommendations.
Adhesives are used for the bonding of a number

of engineering materials used in production at JCB.
Many types are available on the market but in the
interests of variety reduction and economy only a
limited selection is purchased for regular use.
Types of adhesive
Various types of adhesive are covered by JCB
Standards:
1. General purpose adhesives for bonding

laminated plastics, wood, rubber etc. to
themselves and to each other.
2. The more expensive cyanoacrylate adhesives
for use where high strength, resistance to many
chemicals and fast cure times are required.
3. Adhesives specially developed for bonding of
foam rubber to painted metal surfaces.
Additional health and safety for

cyanoacrylates
These adhesives require very careful handling on
account of their exceptional properties. They bond
together strongly and rapidly to most surfaces
including body tissue, the curing process being
initiated by surface moisture. For further information
on cyanoacrylates refer to the Manufacturer’s
recommendations.
Approved adhesives
The tables shown in Technical Data are the approved
adhesives available to use on JCB machines. The
tables also provide basic details to help with the
selection of adhesives. More up to date information
can be found on the manufacturer’s website.
75 - 29 9823/1650-1 75 - 29
15 - Adhesive
00 - General
Technical Data
Table 497. Adhesives Approved Product Information

Subsec- Commer- Product Colour Shelf Technical Comments
tion cial name Number life data
High Per- 4103/3100 Mixed 730 d 3 –5 min Two part adhesive mixed in equal parts. A
strength mabond grey for han- toughened adhesive system which bonds
5002 dling metals, plastics, wood, glass, ceramics and
strength composites; even plated or coated surfaces
can be securely fastened.
High Loctite 4103/1000 Green 365 d 16 –30 bar This product is a single component anaero-
strength 601 fluores- ( 231.9 – bic adhesive. Used to bond cylindrical fitting
cent 434.8 psi) parts, particularly where low viscosity is re-
static shear quired. Maximum gap fill is 0.15 mm.
strength
Cyano- Loctite 4103/3500 Colour- - 18 –26 bar Suitable for most materials including plastic
acrylate 424 less to ( 260.9 and rubber. Takes 30 s to cure to working
straw –376.8 strength.
psi) shear
strength
Cyano- Loctite 4103/2300 Colour- 180 d 18 –26 bar Designed for general purpose use. For use
acrylate 401 less ( 260.9 – on acidic and porous surfaces, reaching
376.8 psi) handling strength in seconds. Materials in-
tensile clude plated metals, composite materials,
strength wood, cork, foam, leather and paper.
Cyano- Loctite 332/U7899 Colour- 180 d 18 –26 bar Designed for bonding of plastics and elas-
acrylate 406 less ( 260.9 – tomeric materials where very fast fixturing
376.8 psi) is required. Can be used with Loctite 770
lap shear as a primer (332/U7901)
strength
Cyano- Loctite 4103/2400 Black 120 d 22 bar 0.2 mm, gap fill. A rubber toughened ethyl
acrylate 410 ( 318.8 psi) cyanoacrylate adhesive with enhanced re-
lap shear sistance to peel and shock. Bonds rubber,
strength metals and plastics for use in difficult condi-
tions.
Cyano- Loctite 4103/3800 Black - 22 –30 bar A rubber toughened adhesive with in-
acrylate 480 ( 318.8 – creased flexibility and peel strength along
434.8 psi) with enhanced resistance to shock.
lap shear
strength
Cyano- Loctite 4103/0900 Colour- 270 d 12 h maxi- High speed bonding, suitable for rubber to
acrylate 495 less mum cure itself and other materials reaching handling
Per- time strength in a matter of seconds. Joint must
mabond be waterproofed with Loctite water proofing
C2 (4104/0500).
Low Dunlop 4103/1100 Clear 90 d - Sprayable adhesive, non-structural appli-
strength 1727 to light cations. For the bonding of flexible foam
British vita straw to themselves, wood, painted metal, chip-
company board, fibreglass, hessian, felt etc.
VB 165
Acrylic 3M 4941P 4103/3900 Dark 730 d Peel adhe- High bond acrylic double sided foam tape.
foam grey sion 350 Its allows more complete bond contact area
strip ad- N/ 100 mm when bonding rigid or irregular materials
hesive due to its conformability. Its core adhesive
composition makes the product well suited
to many paints and primers.
75 - 30 9823/1650-1 75 - 30
15 - Adhesive
00 - General

General Araldite 4103/1400 Clear / 730 d 560 bar Two part, equal parts by weight. Wear pad
purpose XD 580 cream ( 8,115.9 fixing to castings and telescopic compo-
gap fill- psi) flexural nents, alignments of fixings pads without
ing ma- strength expensive machining. This product is a
terial general purpose gap-filling material. Cure
time 2 h at 25 °C ( 77.0 °F).
Methacry- Loctite 4103/3600 Cream - - This is a sag resistant, two component,
late Speed- to light equal parts, methacrylate adhesive system
bonder yellow formulated to bond automotive grade cold
H3151 rolled steel without the use of an external
primer. Suitable for bonding a wide variety
of plastic and metal substrates. Provides
a long open time ( 40 –60 min) for correct
aligning of parts.
Methacry- Plexus 4103/3700 Off- 365 d 186 – Two part methacrylate adhesive for struc-
late MA420 white or 206 bar tural bonding of thermoplastic, metal and
blue ( 2,695.6 composite assemblies. Combined at 10:1
–2,985.5 ratio. It has a working time of 4 –6 min.
psi)
Structur- Scotch- 332/S7420 Black 180 d - Two part acrylic based adhesive (10:1 ra-
al plastic weld tio by vol.) that can bond many low surface
structural energy plastics, including many grades of
plastic ad- polypropylene, polyethylene and TPO’s
hesive without special surface preparation.
Non-pre- Evo-Stick 4103/0800 None- 365 d HIGHLY A thin even film of adhesive should be ap-
ferred 528 pre- FLAMMA- plied to both surfaces being bonded and al-
adhesive ferred BLE lowed to become touch dry. This is a con-
tact adhesive and coated surfaces can-
not therefore be slid into position since the
bond forms on contact. It is often conve-
nient to align the parts along an edge and
then bring the two areas into contact.
Direct Sika 4103/2100 Black - - A one component polyurethane pre-poly-
glazing 250PC mer based adhesive. A mastic adhesive
Sikat- which reacts with atmospheric moisture to
ack Ultra- form a rubber like solid.
fast (use
4103/4000
or
4102/4900)
Direct Sika 4103/2200 Black - - For bonding glass to cab frames. A mas-
glazing 255FC tic adhesive which reacts with atmospheric
(use moisture to form a rubber like solid. When
4102/5000) using this product ensure both surfaces
are clean and dry. Use Sika cleaner 205
(4104/1200).
Direct Sikaflex 4103/3200 Black - - A high performance, elastic, gap, filling one
glazing 552 (use part structural adhesive cures on exposure
4102/5000) to atmospheric moisture to form a durable
elastomer. Contains no isocyanate.
75 - 31 9823/1650-1 75 - 31
15 - Adhesive
00 - General

Industri- Loctite 333/Y7062 Light - 307 bar Single component, heat activated formu-
al grade Hysol Grey ( 4,449.3 lation develops tough, strong, structur-
epoxy E-214 HP Paste psi) tensile al bonds which provide excellent peel re-
adhesive strength sistance and impact strength. When fully
cured, the product offers superior thermal
shock resistance, excellent mechanical and
electrical resistance properties and with-
stands exposure to a wide variety of sol-
vents and chemicals. Bonds to a wide vari-
ety of materials, including metals, glass, ce-
ramics and plastics. Cure at 120 °C ( 247.8
°F) or above until completely firm. Heat up
to 150 °C ( 301.8 °F) for 2 h, to maximize
properties.
Anaero- Scotch- 333/L9575 Green 365 d - Single component anaerobic adhesives de-
bic ad- weld signed to secure cylindrical metal assem-
hesive RT-20 blies such as bearings on shafts, bush-
(Dimethacry- ings, sleeves, housings, and keyways. Help
late) prevent loosening, corrosion and leakage
caused by shock and vibration. Full cure
time 24 h. Temperature range = - 54 °C
( 129.1 °F) to 450 °C ( 841.4 °F). Not rec-
ommended for use on most plastics due to
potential cracking of plastic parts.
Direct Terostat 4102/4900 Black 540 - Cure rate: approx. 3 –4 mm/ 24 h. Glazing
glazing 8597 CT d in time: maximum 20 min (period of time be-
orig- tween beginning of material application until
inal inserting of the pane).
pack-
aging
Direct Teroson 4102/5000 Black, 365 - Skin formation time: approx. 10 min. Cure
glazing 939CT / off- d in rate: approx. 3 mm/ 24 h.
Terostat white, orig-
MS939 grey, inal
black pack-
aging
Direct Terostat 4103/4000 Black 180 d 80 bar One component, pumpable adhe-
glazing 8900 HV ( 1,159.4 sive/sealant based on polyurethane, which
psi) tensile cures by reaction with moisture to an elas-
strength tic rubber. The skin formation and curing
time are dependent on humidity, tempera-
ture and depth of joint. High temperature
and high moisture reduces curing time.
Sag resistant, temperature range of - 40 °C
( 103.9 °F) to 90 °C ( 193.9 °F).
Direct Tero- 4103/4100 Black 270 d 85 bar Single component, moisture curing, ad-
glazing stat 8594 ( 1,231.9 hesive/sealant for repair. Product with
HMLC psi) tensile high shear modulus and low conductivity.
strength Suitable for all applications that require very
high electrical insulation of the adhesive
used for the bonding of windows. Sag resis-
tant.
75 - 32 9823/1650-1 75 - 32
15 - Adhesive
00 - General

Direct Terostat 4103/4200 Black 365 80 bar One component, pumpable adhe-
glazing 8900 LV d in ( 1,159.4 sive/sealant based on polyurethane, which
car- psi) tensile cures by reaction with moisture to an elas-
tridges.strength tic rubber. The skin formation and curing
180 time are dependent on humidity, tempera-
d in ture and depth of joint. High temperature
sausage and high moisture reduces curing time.
pack. Sag resistant, temperature range of - 40 °C
180 ( 103.9 °F) to 90 °C ( 193.9 °F) short expo-
d in sure (up to 1 h) of 130 °C ( 265.8 °F).
hob-
bocks
and
drums
Direct Sika 295 4103/4300 Black, 365 d - Direct glazing adhesive for plastic glazing
glazing UV white panels. One component polyurethane ad-
hesive of paste like consistency. 60 min
tack free time, 1 d cure time ( 4 mm at 23
°C ( 73.4 °F)). Good UV, fresh water and
seawater resistance. Do not apply below
temperatures of 10 °C ( 50.0 °F) or above
35 °C ( 95.0 °F).
75 - 33 9823/1650-1 75 - 33
16 - Sealant
16 - Sealant
Contents Page No.
75-16-00 General ........................................................................................................................... 75-35
75 - 34 9823/1650-1 75 - 34
16 - Sealant
00 - General
Introduction .................................................... 75-35 All sealants should be used at all times in line
Technical Data ............................................... 75-36 with the manufacturer’s recommendations. Sealants
are used mainly for the sealing of screwed joints,
sealing flanges and flat surfaces and where gap
filling properties are required.
Types of Sealant
Various types of sealant are specified in JCB
Standards:
1. Those for the sealing of screwed joints.

2. Sealants for joining flanges and flat surfaces.
(Flange size and likelihood of dismantling
require consideration when selecting this type of
sealant).
3. Sealants for use where gap filling properties are
required. (The gap dimensions, joint movement
if any, type of materials being joined and
aesthetic appearance require consideration
when selecting this type of sealant).
Approved Sealants
The table shown in Technical Data are the approved
sealants available to use on JCB machines. The
table also provides basic details to help with selection
of sealants. More up to date information can be found
on the manufacturer’s website.
75 - 35 9823/1650-1 75 - 35
16 - Sealant
00 - General
Technical Data
Table 498. Sealants Approved Product Information

Subsec- Com- Product Colour Shelf Technical Comments
tion mercial Number life data
name
High Loctite 4102/0500 Green 730 d 250 bar Non drip formulation, used on larger fittings,
strength 275(1) ( 3,623.2 coarse threads.
Per- psi) torque
mabond strength
A140 (on M8)
High Forge- 4102/3100 Yellow 270 d 25 bar Can be painted over with some 2 pack
strength way ( 362.3 psi) paint. Maximum width of joint = 35 mm,
240FC
(1)
breaking minimum width = 2 mm, minimum depth =
strength 2 mm. Recommended depth of joint = width
of joint.
Medium Loctite 4102/3500 Green - More than Used for locating pins in radiator assem-
to high 620 241 bar blies, sleeves into pump housings and
strength ( 3,492.7 bearings in auto transmissions. Not suitable
psi) shear for plastics. Diametrical clearance: up to
strength 0.2 mm
Medium Loc- 4102/2000 Red, flu- 365 d 90 bar Typically used as form-in-place gasket on
strength tite 518 ores- ( 1,304.3 rigid flanged connections.
Gasket cent psi) tensile
Elimina- strength
tor
Medium Loctite 4102/4100 Red gel, - 80 bar It is manufactured to minimise air bubbles
strength 5182 fluores- ( 1,159.4 in the package. Used to seal gaskets, hous-
cent psi) shear ings, cases and covers. It can also be used
strength to repair and replace cut gaskets (up to
0.08 mm in thickness).
Medium Loctite 4102/2500 Clear 365 d 6 mm gap Formulated to withstand weathering and
strength 595 filling extreme temperature cycling. Used for pot-
ting, coating and sealing. Can be applied
horizontal, vertical and overhead.
Medium Loctite 4102/1900 Yellow 365 d 170 bar A fast curing thread sealant used on coarse
strength 577(1) ( 2,463.8 threads and pipe fittings up to 75 mm
Per- psi) break- thread size. Clearance for gap filling 0.8
mabond away mm.
A1044 torque
Medium Loctite 4102/2700 Blue 365 d 140 – Taper thread sealant, non-fluorescing to
strength 2431 340 bar see oil leaks. Suitable for all taper fittings
( 2,029.0 up to M36.
–4,927.5
psi) break-
away
torque
Low Clayton 4102/2200 White 12 h Maximum Seals pipes and plugs against leakage of
strength Dewan- opaque full seal pres- air, fuels, lubricants and coolants. Hardens
dre air cure sure 29 to a tough seal resistant to shock and vibra-
brake bar ( 420.3 tion. Easily dismantled.
sealant psi)
SC1252
Low Red 4102/0800 - - Resistant Non-hardening paste jointing for joints reg-
strength Her- to oil ularly opened for servicing.
metite
75 - 36 9823/1650-1 75 - 36
16 - Sealant
00 - General

name
Low Loctite 4102/1100 White 730 d 40 –100 Used where slow cure is required to permit
strength 572 opaque bar ( 579.7 component alignment. PTFE (Polytetrafluo-
–1,449.3 roethylene) filler.
psi) break-
away
torque
Gas- Loc- 4102/3200 Blue to 0.2 72 h full Easy disassembly, used as form-in-place
keting tite 509 green mm strength on gasket.
medium Gasket gap steel
strength Elimi- filling
nator
Flange
Sealant
Gas- Loctite 4102/1200 Red 730 d 2 h working Does not creep or relax after curing, no bolt
keting 574
(1)
strength re-tightening is required. Oil resistant. Ideal
medium Per- for formed in-situ gaskets.
strength mabond
A136
Sealant Loctite 4102/2600 Black 365 d Resists Used to dress new or worn gaskets. Dries
for gas- FAG 2 / pressures slowly, sets to pliable film for easy disman-
kets Loctite up to tling.
5922 345 bar
( 5,000.0
psi)
Rubber Dow 4102/0900 Clear or 270 d 16.7 bar A synthetic rubber joint sealant suitable for
jointing corning translu- ( 242.0 joints between non-porous surfaces such
com- 781 cent psi) tensile as glass and metal, metal and metal where
pound Loc- strength relatively large gap filling properties are re-
tite su- quired. Suitable for vertical and overhead
perflex applications under normal atmospheric con-
clear ditions. Joint movement approx.+/-12.5%.
RTV3 Cure time to 6 mm depth in 24 h.
EVO-
stick
stan-
dard in-
dustri-
al clear
silicone
sealant
Dun-
lop high
modulus
silicone
sealant
DP2205
Epoxy Loc- 4102/2400 Slightly - - 0.05 L container requires special bi-mixer
resin tite fast coloured / (gun) so it is mixed as dispensed, 0.024 L
epoxy trans- is mixed by hand.
sealant parent
75 - 37 9823/1650-1 75 - 37
16 - Sealant
00 - General

name
Room Loctite 4102/3400 Metal- - Dry to Designed for flange sealing, good resis-
tempera- 5910, lic black touch in 40 tance to oils and allows high joint move-
ture vul- Flange paste min ment.
canising sealant,
RTV Sil-
icon
Room Loctite 4102/4200 Black 730 d 18 bar Used for gaskets. Excellent resistance to
tempera- 5970 ( 260.9 engine oils. Typical applications include
ture vul- psi) tensile stamped sheet metal covers (timing covers
canising strength and oil sumps) where good oil resistance
and the ability to withstand high joint-move-
ment are required.
Room Loc- 4102/2900 Black 270 d 16 bar Thixotropic allowing easy application, hori-
tempera- tite su- ( 231.9 zontal, vertical and overhead. Seals against
ture vul- perflex psi) tensile water and many solvents.
canising black strength
silicone
Room Loctite 4102/3700 Grey 730 d 14 bar Designed specifically for on line, low pres-
tempera- 5901 ( 202.9 sure tests carried out before product be-
ture vul- psi) shear gins to cure. Product exhibits excellent re-
canising strength sistance to automotive engine oils. Primari-
ly for flange sealing, it withstands high joint-
movement requirements.
Room Loctite 4102/3900 Black 730 d 20 bar Generally used for sealing applications, but
tempera- 5368 paste ( 289.9 also for bonding and for high temperature
ture vul- psi) tensile protection.
canising strength
Room Loctite 4102/4000 Clear 730 d 20 bar Designed specifically for use as a bond-
tempera- 5366 paste ( 289.9 ing agent to ensure perfect sealing, as
ture vul- psi) shear well as bonding and protection. Examples
canising strength are sealing side windows in trains, seal-
ing heat sources (heat exchangers and wa-
ter heaters) and for protection/insulation of
electrical boxes.
Room Hylomar 332/D5695 Black 540 d 40 bar A special purpose adhesive and sealant
tempera- 607 paste ( 579.7 that can be used for a variety of applica-
ture vul- psi) tensile tions. It has good resistance to oils and
canising strength aqueous anti-freeze agents, and is particu-
larly suitable for high strength applications
in odour sensitive environments.
Joining Loctite 4102/3800 Black 730 d 14 bar JCB Service ONLY. Introduced for joining
oil pan to 5900 paste ( 202.9 the oil pan to the bedplate face during ser-
bedplate psi) shear vice. High resistance to engine oils. The
strength joint should be clamped to spread the ad-
hesive and allowed to cure for 7 d before
heavy service duty.
Anti-cor- To mil- 4102/4300 Yellow - Type 1 Used to coat surfaces of dissimilar metals
rosive itary Class C prior to assembly to prevent corrosion. Zinc
spec chromate containing substance ideal for ap-
TT- plication to joints between aluminium and
P-1757B steel to prevent corrosion and seizure. FOR
1CY USE ON MILITARY VEHICLES ONLY.
75 - 38 9823/1650-1 75 - 38
16 - Sealant
00 - General

name
Gas- Bondloc 4102/4500 Clear/ - Full cure B555 is an anaerobic gasket sealant. It
keting B555 Opaque time 24 seals close fitting joints between rigid metal
medium h. 50 bar faces and flanges. Tensile strength to ISO
strength ( 724.6 6922.
psi) tensile
strength
Seam Terolan 4102/4600 Light 90 d - Serves as a seam sealant between sheet
sealant 3412 grey metal butt and overlap joints (interior
AA-25 seems) on vehicle bodies. Can be cured at
temperatures of minimum 140 °C ( 283.8
°F) (effective metal temperature) for 15
min. The material is applied to electro-dip
coated steel sheets.
Direct Sikaflex 4102/2800 Yellow - - Direct glazing one component polyurethane
glazing 221 based adhesive and sealant compound.
(use Tack free time of 50 min.
4102/4800)
Direct Sikaflex 4102/2300 Black - - A one component polyurethane pre-poly-
glazing 252 mer based sealant. For sealing glass to
(use frames. A mastic sealant which reacts with
4102/4700)
(1)
atmospheric moisture to form a rubber like
solid.
Direct Teroson 4102/4700 - 365 - The substrates must be clean, dry, oil and
glazing PU92 d in grease free. Skin formation time: approx.
CT orig- 20 min Cure rate: approx. 4 mm/ 24 h
inal
pack-
aging
Direct 930 4102/4800 Yellow 365 - The substrates must be clean, dry, oil and
glazing JCB d in grease free. It can be necessary to rough-
Branded orig- en the surface or to use a primer/adhe-
yellow inal sion promoter to provide optimum adhe-
CT pack- sion. When manufacturing of plastics, ex-
aging ternal release agents are often used; these
agents must be absolutely removed prior.
Skin formation time : approx. 20 min Cure
rate : approx. 4 mm/ 24 h
Direct Terostat 4102/4900 Black - - Isocyanate free solution. Designed for use
glazing 8597 without primer or activator. When you use
CT this sealant on operator station, it should be
used with Teroson PU 8519P black primer
(and Teroson 450 clear adhesion promoter
when specified specially). Cross compatible
with all OEM / OES / AAM DGX sealants,
including MS and PU chemistry (any re-
maining bead must be fully cured before
application).
75 - 39 9823/1650-1 75 - 39
16 - Sealant
00 - General

name
Silicone Si- 4102/5100 Black - - High modulus permanently flexible 100 %
sealant - ka/Ever- silicone. Temperature resistant up to 300
Heat rebuild °C ( 571.6 °F). Ideal for sealing industrial
sistant Heat and high performance gaskets, oven doors
Mate etc.
Gas- Loctite 4102/6100 Opaque - - Introduced for Heavy products India (swing
ket and 510 pink motor/ gearbox face).
sealing
(1) This is a non preferred product.
75 - 40 9823/1650-1 75 - 40
18 - Fuel
18 - Fuel
Contents Page No.
75-18-00 General ........................................................................................................................... 75-43
75 - 41 9823/1650-1 75 - 41
Notes:
75 - 42 9823/1650-1 75 - 42
18 - Fuel
00 - General
Introduction .................................................... 75-43 Refer to SCR (Selective Catalytic Reduction)
Health and Safety .......................................... 75-44 Introduction and Technical Data (PIL 18-30).
75 - 43 9823/1650-1 75 - 43
18 - Fuel
00 - General
Health and Safety

Fuel
fuel system. Stop the engine immediately if a fuel
working on the fuel system. Do not refuel with the
engine running. Completely wipe off any spilt fuel
which could cause a fire. There could be a fire and
WARNING! Do not use petrol in this machine. Do
not mix petrol with the diesel fuel. In storage tanks
the petrol will form flammable vapours.
75 - 44 9823/1650-1 75 - 44
78 - After Sales
Contents Page No.
78-24 Maintenance Schedules

78-24-00 General ............................................................................................................................. 78-3
78-24-03 Maintenance Intervals ...................................................................................................... 78-5
78-24-06 Pre-start Cold Checks, Service Points and Fluid Levels .................................................. 78-6
78-24-09 Functional Tests and Final Inspection .............................................................................. 78-9
78-81 Clothing and Personal Protective Equipment (PPE)
78-81-00 General ........................................................................................................................... 78-13
78-93 Special Tools
78-93-00 General ........................................................................................................................... 78-15
78-93-03 Parts List ........................................................................................................................ 78-16
78-94 Non JCB Tools
78-94-00 General ........................................................................................................................... 78-55
78-96 Units of Measurement
78-96-00 General ........................................................................................................................... 78-57
9823/1650-1
2018-06-07
Acronyms Glossary

9823/1650-1
2018-06-07
78 - After Sales
24 - Maintenance Schedules
Contents Page No.
78-24-00 General ............................................................................................................................. 78-3

78-24-03 Maintenance Intervals ...................................................................................................... 78-5
78-24-06 Pre-start Cold Checks, Service Points and Fluid Levels .................................................. 78-6
78-24-09 Functional Tests and Final Inspection .............................................................................. 78-9
78 - 1 9823/1650-1 78 - 1
Notes:
78 - 2 9823/1650-1 78 - 2
78 - After Sales
00 - General
WARNING Maintenance must be done only by
Introduction ...................................................... 78-3 suitably qualified and competent persons.
Operation ......................................................... 78-4
Before doing any maintenance make sure the
machine is safe, it must be correctly parked on
solid, level ground.
To prevent anyone starting the engine, remove
of the battery isolator if installed) when you are
not using electrical power. If you do not take these
precautions you could be killed or injured.
A badly maintained machine is a danger to

the operator and the people working around the
operator. Make sure that the regular maintenance
and lubrication tasks listed in the service schedules
are done to keep the machine in a safe and efficient
working condition.
To ensure the correct functioning of the engine

and emissions control system all operation and
maintenance must be conducted in accordance
with the instructions in this manual. Incorrect
operation, maintenance or repair of the engine
and emissions control system may lead to reduced
product life, loss of performance or malfunctions.
It is the machine owner's responsibility to ensure
maintenance is conducted properly in accordance
with the requirements in this manual.
Apart from the daily tasks, the schedules are based

on the machine running hours. Keep a regular
check on the hourmeter readings to correctly gauge
the service intervals. When there is no hourmeter
installed, use the calendar equivalents to determine
the service intervals.
Do not use a machine which is due for a service.

Make sure any defects found during the regular
maintenance checks are corrected immediately.
More frequent checks of engine components than

the engine manufacturer recommends do not
invalidate emissions warranty.
78 - 3 9823/1650-1 78 - 3
78 - After Sales
00 - General
Operation
The schedules show the service tasks which must be

done and their intervals.
The services must be done at either the hourly

interval or the calendar equivalent, whichever occurs
first.
The intervals given in the schedules must not

be exceeded. If the machine is operated under
severe conditions (high temperature, dust, water,
etc.) shorten the intervals.
Table 499.
Service task can be completed by a
competent operator. Details of how to
complete the service task are given in
the Operator's Manual.
We recommend that a Service Engi-
neer completes the service task. De-
tails of how to complete the service
task are given in the Service Manual.
78 - 4 9823/1650-1 78 - 4
78 - After Sales
03 - Maintenance Intervals
03 - Maintenance Intervals
Introduction
Table 500.
Interval ( h) Calendar Equivalent
10 Daily
50 Weekly
250 Three months
500 Six months
1000 Yearly
2000 Two years
6000 Six years
8000 Eight years
78 - 5 9823/1650-1 78 - 5
78 - After Sales
06 - Pre-start Cold Checks, Service Points and Fluid Levels
06 - Pre-start Cold Checks, Service

Points and Fluid Levels
Technical Data
Table 501.
10 h 50 h 100 500 1,000 h 1,500 h 2,000 h 8,000 h
h h
ENGINE
Oil level Check
Coolant Quality/ level Check
Coolant or Oil Leaks Check
Water Seperator Check
Fuel Filter (Machine Replace
mounted)
Oil and Filter
(2, 3)
Replace
All Hoses - Condition Check
Radiator
(4)
Clean
FEAD (Front End Ac- Check
cessory Drive) Belt Con-
dition
Fuel Filter (engine Replace
mounted)
Air Cleaner Outer Ele- Replace
ment
(4)
Crankcase Ventilation Replace

Filter
Air Cleaner Inner Ele- Replace
ment
Valve Clearances
(5)
Check and Adjust
Oil Filler and Dipstick O- Replace
rings
Cooling system Drain and Fill
FEAD Belt Replace
Injectors
(5)
Replace
Injector(s) Leak-Off Replace
Rail
(5)
High Pressure Fuel Replace

Lines
(5)
TRANSMISSION, AXLES AND STEERING

Transmission Mount Se- Check
curity
Transmission Oil Level Check
Transmission Oil
(6)
Replace
Transmission Oil Filter Replace
Axle Mount Security Check
78 - 6 9823/1650-1 78 - 6
78 - After Sales
10 h 50 h 100 500 1,000 h 1,500 h 2,000 h 8,000 h

h h
Axle(s) Oil Level Check
Axle(s) Oil Replace
Hub Oil Level (Without Check
Oil Immersed Brakes)
Hub Oil (Without Oil Im- Replace
mersed Brakes)
(7)
Hub Oil (With Oil Im- Replace

mersed Brakes)
(7)
Axle Breather(s) Check

Steering Stops (if fitted) Security
Wheel Nut Security Check
Tire Pressures/Condi- Check
tion
Wheel Alignment Check
Transmission Strainer Clean
Drive Shafts and Univer- Security and Lu-
sal Joints
(8)
bricate
Axle Pivots and Link- Lubricate
ages
(8)
HYDRAULICS
Oil Level Check
Oil
(5)
Sample, Replace
Oil Filter Replace
Suction Strainer Clean
Pilot Filter (if fitted) Replace
BRAKES
Brake System Fluid Lev- Check
el
Brake System Fluid Replace
ELECTRICS
Battery Electrolyte Level Check
(if applicable)
Battery Terminals for Check
Condition and Tightness
BODYWORK AND CAB
Lift/Displacement/Tilt/ Lubricate
Steer Cylinder Pivot
Pins
Extension Cylinder Pis- Lubricate
ton Rod Pivot Pin
All Other Pivot Pins Lubricate
Fire Extinguisher (if fit- Check
ted)
Wing Mirrors Condition Check
and Security
78 - 7 9823/1650-1 78 - 7
78 - After Sales
10 h 50 h 100 500 1,000 h 1,500 h 2,000 h 8,000 h

h h
ROPS (Roll-Over Pro- Check
tective Structure)/FOPS
(Falling Object Protec-
tive Structure) Structure
Doors and Hinges Lubricate
Control Lever Linkages Lubricate
Windshield Washer Flu- Check
id Level
Cab Heater Fresh Air Replace
Filter (if fitted)
Boom Wear Pad Run- Waxoyl
ways
Inner Boom Hoses Lubricate
Boom Wear Pad Clear- Check/Adjust
ance
(9)
Boom Wear Pad Con- Check/Adjust

dition and Security (Re-
place if required)
(9)
ATTACHMENTS
Carriage Lock Pins Lubricate
REGISTRATION/CERTIFICATION
SWL Stickers (UK) and Renew as Re-
Flip Chart quired
(1) First 100 h Service only, to be completed by your JCB Distributor.
(2) If operating under arduous conditions, do an engine oil flush (use the normal recommended engine oil)
every 250 h. Change the engine oil and filter every 250 h.
(3) When the engine is operated with 20 % biodiesel change the engine oil and filter every 250 h. Refer to
Fuel System for more information.
(4) More frequently if operating in dusty working environments.
(5) Jobs which should only be done by a specialist.
(6) After a major transmission repair, the new oil should be run to operating temperature and changed again to
remove any contamination which entered during the repair. Change the oil after a further 100 h if the oil was
heavily contaminated because of, or from the failure (e.g. water contamination).
(7) After a hub repair, the new oil should be run to operating temperature and changed again to remove any
contamination which entered during the repair. Change the oil after a further 100 h to remove any bedding-in
wear. This is particularly important if new brake plates have been installed.
(8) The axles and propshafts are factory greased with a high performance grease, if during service a standard
grease is used, then the interval must be reduced to every 50 h, contact your JCB Distributor for advice.
(9) If operating under arduous conditions, check the boom wear pads every 250 h.
78 - 8 9823/1650-1 78 - 8
78 - After Sales
09 - Functional Tests and Final Inspection
09 - Functional Tests and Final

Inspection
Technical Data
Table 502.
Component Task 10 h 50 h 100 500 1,000 2,000 6,000
h
(1)
h h h
ENGINE
Idle speed
(2)
Check
Torque converter stall speed
(2)
Check
Max. no load speed
(2)
Check
Exhaust system security
(2)
Check
Air inlet system security Check
TRANSMISSION, AXLES AND STEERING
Steering - Operation/Phasing Check
2WD/4WD Selection (if in- Check
stalled)
Transmission Operation Check
Forward/Reverse/Gear - Check
Selection/ Operation
Torque Converter Main Line Check
Pressure
(2)
Neutral Start Operation Check

Clutch Disconnect/Dump But- Check
ton
HYDRAULICS
MRV Pressure at Max RPM
(2)
Check and adjust
Operation of All Services Check
Hose Burst Protection Valves Check
(if installed)
ARV Pressure at idle
(2)
Check and adjust
Steer Circuit MRV Pressure
(2)
Check and adjust
Fan Motor Speed (If in- Check
stalled)
(2)
Attachment Operation/Remote Check

Servo (if installed)
Piston Rods Chrome Check
Parallel Lift/Lower Check
Stabiliser Leg Cut-out (if in- Check
stalled)
(2)
Chassis Levelling (Sway) Cut- Check

out (if installed)
Boom raise Cut-out (if in- Check
stalled)
BRAKES
78 - 9 9823/1650-1 78 - 9
78 - After Sales
09 - Functional Tests and Final Inspection
Component Task 10 h 50 h 100 500 1,000 2,000 6,000

h
(1)
h h h
Foot Brake - Operation Check
Park Brake Check and adjust
ELECTRICS
Alternator - Output
(2)
Check
All Electrical Equipment Oper- Check
ation, (warning lights, beacon,
alarms, horn, wipers etc.)
Stabiliser Indicators (if in- Check
stalled)
BODYWORK AND CAB
Inclinometer (if installed)
(2)
Check
Glazing for Correct Fit/Leaks Check
Seat/Seat Belts Check
Air Conditioning (if installed) Check
Forks
(2)
Fit and Check security
Generally for damage, leaks Check
and wear
BOOM CHAIN SERVICING
Boom Chains Oil
Boom Chains - Tension
(4)
Check (tension and phasing)
Boom Chains - Wear and De- Check
fects
(2, 3)
Boom Roller - Wear Check

Boom Roller Pivot Pin (with Grease
grease point installed)
RAS SYSTEM
Operation
(2)
Check
ELECTRONIC DATA LOG
Fault code log
(2)
Check
Service log
(2)
Record
LIFTING EQUIPMENT
Fit for Purpose Test
(4)
Check
(1) First 100 Hours Service only, to be completed by your JCB Distributor.
(2) Jobs which should only be done by a specialist.
(3) If operating under arduous conditions, complete this operation every 250 hours.
(4) This may be required every six months or at least annually in some countries to meet and comply with
legislation and for insurance purposes.
78 - 10 9823/1650-1 78 - 10
78 - After Sales
81 - Clothing and Personal Protective Equipment (PPE)
Contents Page No.
78-81-00 General ........................................................................................................................... 78-13
78 - 11 9823/1650-1 78 - 11
Notes:
78 - 12 9823/1650-1 78 - 12
78 - After Sales
00 - General
00 - General
Introduction
Do not wear loose clothing or jewellery that can get

caught on controls or moving parts. Wear protective
clothing and personal safety equipment issued or
called for by the job conditions, local regulations or
as specified by your employer.
78 - 13 9823/1650-1 78 - 13
78 - After Sales
93 - Special Tools
93 - Special Tools
Contents Page No.
78-93-00 General ........................................................................................................................... 78-15

78-93-03 Parts List ........................................................................................................................ 78-16
78 - 14 9823/1650-1 78 - 14
78 - After Sales
93 - Special Tools
00 - General
00 - General
Introduction
The tools shown are the special tools required for

completing the procedures described in this manual.
These tools are available from JCB Service or in
some instances can be manufactured locally.
The tools are divided into three categories:
• Special Tool = Only available from JCB.

• Recommended Tool = Available from JCB but
other tool manufacturers/suppliers may offer a
tool with the same characteristics.
• General Tool = A tool which is widely available.
Tools other than those listed will be required. It is

expected that such general tools will be available in
any well equipped workshop or be available locally
from any good tool supplier.
Before you start work, make sure that all safety

precautions are observed in accordance with the
information contained within the relevant support
documentation.
78 - 15 9823/1650-1 78 - 15
78 - After Sales
93 - Special Tools
03 - Parts List
03 - Parts List Introduction

Introduction .................................................... 78-16
Tool Category Part No. Description Qty. Comments

Special Tool 993/68100 Slide Hammer Kit 1

Recommended Tool 892/00842 Glass Lifter 2
Recommended Tool 892/00843 Folding Stand 1
Recommended Tool 892/00845 Cartridge Gun 1
Recommended Tool 892/00846 Glass Extractor 1
(Handles Only)
Recommended Tool 892/00847 Nylon Spatula 1
Recommended Tool 892/00848 Wire Starter 1
Recommended Tool 892/00849 Braided Cutting Wire 1
Recommended Tool 926/15500 Rubber Spacer Blocks 4
General Tool 992/12300 Mobile Oven (12V) 1
General Tool 992/12400 Static Oven (240V) 1
Recommended Tool 992/12800 Cut-Out Knife 1
Recommended Tool 992/12801 'L' Blades 1
15 - Engine

Special Tool 320/09062 Lifting Bracket Front 1
Special Tool 320/09063 Lifting Bracket Rear 1
Special Tool 892/00278 Pressure Gauge (0-40 1
Bar)
Special Tool 892/00292 Oil Filter Removal Tool 1
Special Tool 892/01147 Crankshaft Turning Tool 1
(95.25mm PCD)- JCB
4 Cylinder Ecomax and
Dieselmax
Special Tool 892/01148 Crankshaft / 2
Camshaft Timing Pin
(444/448/672 Engine)
Special Tool 892/01149 Template for Sealant Oil 1
Sump - Pressed
Special Tool 892/01150 Oil Sump Location 2
Dowel
Special Tool 892/01152 Valve Stem Seal 1
Installation Tool
(444/448/672 Engine)
Special Tool 892/01156 Crankshaft Rear Oil 1
78 - 16 9823/1650-1 78 - 16
78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool 892/01157 Crankshaft Front Oil 1
Special Tool 892/01158 Crankshaft Rear Oil 1
Seal Alignment Tool
Special Tool 892/01174 Data Link Adaptor 1
(DLA) Kit
Special Tool 892/01176 Template for Sealant 1
Flywheel Housing to
Gear Case (4 Cyl and 6
Cyl Elec)
Special Tool 892/01380 Valve Clearance 1
Service Kit
Special Tool 892/01382 Engine Lifting Spreader 1
Bar
Flywheel Housing to
Gear Case (4 Cyl Elec )
Recommended Tool 892/12351 Deep Socket 1
Special Tool 892/12354 Template for Sealant Oil 1
Sump (Cast)
Bedplate to Crankcase
(4 Cyl)
General Tool 993/70111 Torque Wrench 1
(10-100Nm)
Special Tool 998/11051 Digital Hydraulic 1
Pressure Test Kit

Recommended Tool 331/27987 Socket 17MM Offset - 1
(HP Fuel pipes)
Special Tool 334/G5933 Spanner - HP Fuel 1
Filter
Special Tool 721/10855 Servicemaster 1
Electronic Test Cable
Special Tool 892/01033 Servicemaster 1 Unless otherwise stated, you
892/01174 Electronic Test Kit can use any of the tools shown.
Data Link Adaptor
(DLA) Kit
Special Tool 892/01147 Crankshaft Turning Tool 1
(95.25mm PCD)- JCB
4 Cylinder Ecomax and
Dieselmax
Special Tool 892/01148 Crankshaft / 1
Camshaft Timing Pin
(444/448/672 Engine)
Special Tool 892/01154 Tamper proof Cover 1
Removal Tool
Special Tool 892/01155 Pump Gear Removal 1
Tool
(DLA) Kit
78 - 17 9823/1650-1 78 - 17
78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool 892/01179 C-Shaped Ring 1
Spanner
Special Tool 892/01383 Fuel Filter Removal 1
Tool (4 cyl)
Special Tool 892/12346 Injector Seal Installation 1
Tool (Electronic Engine)
Special Tool 892/12348 Injector Sleeve 1
Installation/Removal
Tool
Special Tool 892/12350 Injector Leak-off Test 1
Kit ((Electronic Engine))
Special Tool 892/12359 Injector Cap Kit 1
(10-100Nm)
24 - Brake System

Special Tool 892/01033 Servicemaster 1 Unless otherwise stated, you
892/01174 Electronic Test Kit can use any of the tools shown.
Data Link Adaptor
(DLA) Kit
Special Tool 992/04800 Flange Spanner 1

Bar)
Bar)
27 - Driveline

Special Tool 823/10420 Thrust Washer Kit 1
Special Tool 892/00223 Hand Pump Pressure 1
Test
Special Tool 892/00224 Impulse Extractor 1
Special Tool 892/00225 Bearing Removal Tool 1
Special Tool 892/00229 Flowmeter 1
Bar)
Special Tool 892/00292 Oil Filter Removal Tool 1
General Tool 892/00333 Heavy Duty Socket 1
19mm A/F x 3/4 in
Drive
Special Tool 892/00812 Drive Coupling Spanner 1
46mm A/F
78 - 18 9823/1650-1 78 - 18
78 - After Sales
93 - Special Tools
03 - Parts List

55mm A/F
Special Tool 892/00915 Reaction Block Fixture 1
Special Tool 892/00916 Spring Compressor 1
Tool
Special Tool 892/00918 Setting Tool Kit 1
Special Tool 892/01082 Gearbox Assembly 1
Cradle
Special Tool 892/01083 Transfer Gear 1
Assembly Tool
Special Tool 892/01084 Bearing Assembly Tool 1
Special Tool 892/01092 Wheel Hub Service Kit 1
Special Tool 892/01110 Torque Converter 1
Alignment Tool
Special Tool 921/52600 Spacer Kit 1
Special Tool 921/53300 Spacer Kit 1
Special Tool 921/M0229 Shim Kit 1
Special Tool 992/04800 Flange Spanner 1
Special Tool 993/59300 Pressure Test Adaptor 1
Special Tool 993/59500 Adaptor 1
Special Tool 993/70100 End Float Setting Tool 1
Kit
(10-100Nm)
Special Tool 997/11000 Support Bracket 1
Special Tool 998/10738 Adaptor Spanner 1
Special Tool 998/M1374 Reaction Plate M14 4
Studs
Special Tool 998/M1375 Reaction Plate 1

Special Tool 825/10053 Quick Connect Hose 1
Release Tool
Special Tool 892/00167 Ram Protection Sleeve 1
(90mm rod diameter)
Special Tool 892/00229 Flowmeter 1
Special Tool 892/00270 Load Valve 1
Special Tool 892/00334 Ram Seal Installation 1
Tool
(25mm rod diameter)
(30mm rod diameter)
(40mm rod diameter)
(50mm rod diameter)
- Slew (50mm rod
diameter)
78 - 19 9823/1650-1 78 - 19
78 - After Sales
93 - Special Tools
03 - Parts List

(60mm rod diameter)
- Slew (60mm rod
diameter)
(65mm rod diameter)
(70mm rod diameter)
(75mm rod diameter)
(80mm rod diameter)
Special Tool 892/01027 Ram Seal Assembly 1
Tool
Special Tool 892/01042 Accumulator Charging 1
Kit (Diaphragm)
Special Tool 892/01043 Accumulator Charging 1
Adaptor
Special Tool 892/01255 Hydraulic Flushing Rig 1
Special Tool 998/11051 Digital Hydraulic 1
Pressure Test Kit

General Tool 892/00349 Wiring Crimp Tool 1
General Tool 892/00350 Butane Heater 1
(DLA) Kit

Recommended Tool 892/00913 Grease Gun 1
Attachment
General Tool 992/11300 Grease Gun 1
78 - 20 9823/1650-1 78 - 20
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 320/09062 - Lifting Bracket Front
Special Tool - 320/09063 - Lifting Bracket Rear
Recommended Tool - 331/27987 - Socket 17MM Offset - (HP Fuel pipes)

Use to remove and replace high pressure fuel pipes.
Use with 993/70111 torque wrench.
78 - 21 9823/1650-1 78 - 21
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 334/G5933 - Spanner - HP Fuel Filter
Special Tool - 721/10855 - Servicemaster Electronic Test Cable
C D
B E
A
J F
H G
Special Tool - 823/10420 - Thrust Washer Kit

After using a spacer, obtain a replacement to keep the
set complete.
Item Part No. Description Qty.

1 823/10421 Shim 4.3mm thick 1
2 823/10422 Shim 4.4mm thick 1
3 823/10423 Shim 4.5mm thick 1
4 823/10424 Shim 4.6mm thick 1
5 823/10425 Shim 4.7mm thick 1
5 823/10426 Shim 4.8mm thick 1
Special Tool - 825/10053 - Quick Connect Hose Release Tool

Special tool to release pilot hose quick-connect
couplings.
78 - 22 9823/1650-1 78 - 22
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/00167 - Ram Protection Sleeve (90mm rod diameter)
Special Tool - 892/00223 - Hand Pump Pressure Test
Special Tool - 892/00224 - Impulse Extractor
Special Tool - 892/00225 - Bearing Removal Tool
Special Tool - 892/00229 - Flowmeter
78 - 23 9823/1650-1 78 - 23
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/00270 - Load Valve
Special Tool - 892/00278 - Pressure Gauge (0-40 Bar)
Special Tool - 892/00292 - Oil Filter Removal Tool

Use to install or remove spin-on filter canister.
78 - 24 9823/1650-1 78 - 24
78 - After Sales
93 - Special Tools
03 - Parts List
General Tool - 892/00333 - Heavy Duty Socket 19mm A/F x 3/4 in Drive
Special Tool - 892/00334 - Ram Seal Installation Tool
General Tool - 892/00349 - Wiring Crimp Tool
78 - 25 9823/1650-1 78 - 25
78 - After Sales
93 - Special Tools
03 - Parts List
General Tool - 892/00350 - Butane Heater
Special Tool - 892/00812 - Drive Coupling Spanner

PTO coupling spanner for yoke type couplings.
Recommended Tool - 892/00842 - Glass Lifter

Essential for glass installation, 2 required to handle
large panes of glass. Ensure suction cups are protected
from damage during storage.
Recommended Tool - 892/00843 - Folding Stand

Essential for preparing new glass prior to installation.
78 - 26 9823/1650-1 78 - 26
78 - After Sales
93 - Special Tools
03 - Parts List
Recommended Tool - 892/00845 - Cartridge Gun

Hand operated. Essential for the application of
sealants, polyurethane materials etc.
Recommended Tool - 892/00846 - Glass Extractor (Handles Only)

Used with braided cutting wire to cut out broken glass.
Refer to special tool 892/00849 (Braided Cutting Wire)
Recommended Tool - 892/00847 - Nylon Spatula

General tool used for smoothing sealants - also used
to re-install glass in rubber glazing because metal tools
will chip the glass edge.
Recommended Tool - 892/00848 - Wire Starter

Used to access braided cutting wire through original
polyurethane seal.
Refer to special tool 892/00849 (Braided Cutting Wire)
Recommended Tool - 892/00849 - Braided Cutting Wire

Consumable heavy duty cut-out wire used with the
glass extraction tool. Length: Approximately 25m.
Refer to special tool 892/00846 (Glass Extractor

(Handles Only))
78 - 27 9823/1650-1 78 - 27
78 - After Sales
93 - Special Tools
03 - Parts List
General Tool - 892/00912 - Heavy Duty Socket 46mm A/F

Used to remove 46mm Stake nut.
Recommended Tool - 892/00913 - Grease Gun Attachment
General Tool - 892/00914 - Heavy Duty Socket 55mm A/F

Used to remove 55mm Stake nut.
78 - 28 9823/1650-1 78 - 28
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/00915 - Reaction Block Fixture
Special Tool - 892/00916 - Spring Compressor Tool
78 - 29 9823/1650-1 78 - 29
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/00918 - Setting Tool Kit

1a 892/01164 Adaptor (PS760 - 1
1 1a 2004)
1b 892/01165 Sleeve (PS760 - 1
2004)
1c 892/01163 Support Bracket 1
(PS760 - 2004)
1b 1d 998/11350 Adaptor 1
1e 998/11351 Sleeve (40 series 1
drivehead - front
1c axles)
1e 998/11352 Sleeve (40 series 1
drivehead - rear
axles)
1d 1e
78 - 30 9823/1650-1 78 - 30
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01020 - Ram Protection Sleeve - Slew (50mm rod diameter)
Special Tool - 892/01022 - Ram Protection Sleeve - Slew (60mm rod diameter)
78 - 31 9823/1650-1 78 - 31
78 - After Sales
93 - Special Tools
03 - Parts List
78 - 32 9823/1650-1 78 - 32
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01027 - Ram Seal Assembly Tool
7m m
11o
20m m 10m m
5m m
mm
R3
110m m
175m m
3o
R
1.
4m
m
Special Tool - 892/01033 - Servicemaster Electronic Test Kit

No longer available to order.
Replaced by special tool 892/01174 (Data Link Adaptor
(DLA) Kit)
Special Tool - 892/01042 - Accumulator Charging Kit (Diaphragm)
Special Tool - 892/01043 - Accumulator Charging Adaptor
78 - 33 9823/1650-1 78 - 33
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01082 - Gearbox Assembly Cradle

620.0
325.0 171.6
151.9 103.4 20.0
111.6
R 5.0
TYP
168.0
10.0
160.0
49
51.8 73.2 REF
107.3
0
1.
2
2
R1
48
R1 2 5
. 0
600.0
140.1
6 0 .7
9
216.6
1 5 3 .2
263.6
325.6 REF
R1 3 7 .0
9
TYP 9 PLACES
0
09.
R1
R6
2
20.0
.0
25.0
== 2.9 30
TYP 9 PLACES 53.2
95.0
142.3 118.7
Support legs will also be required. These must be

locally manufactured so that the gearbox can be
supported as shown at A.
Special Tool - 892/01083 - Transfer Gear Assembly Tool
78 - 34 9823/1650-1 78 - 34
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01084 - Bearing Assembly Tool
Special Tool - 892/01092 - Wheel Hub Service Kit

A 5
1
6
8, 9
7
2 10
3
4
B
13,23 15
19,20
14
C 16
18
17
8
21
A Bearing Puller 1
B Bearing Press 1
C Seal Dolly - 1
comprises:
1 998/M5626 Puller Beam 1
2 998/1067 Clamp Plates 1
3 1315/3731Z Bolt M16 x 220mm 2
4 1370/0601Z Nut M16 2
5 998/10614 Reaction Tube 1
6 998/10624 Modified Wheel 2
Stud
7 1370/0701Z Puller Leg 2
78 - 35 9823/1650-1 78 - 35
78 - After Sales
93 - Special Tools
03 - Parts List

8 1370/0701 Nut M20 4
9 1420/0012Z Washer M20 4
10 998/10610 Rod 2
11 1370/0401Z Nut M12 2
12 1420/0009Z Washer M12 2
13 998/10608 Bearing Centre 1
Puller
14 1315/3414Z Bolt M10 1
15 1370/0301Z Nut M10 1
16 Reaction Tube 1
(same part as item
5)
17 998/10616 Handle Nut 1
18 1315/3833Z Bolt M20 2
19 445/12303 Washer 2
20 917/02800 Bearing 1
21 892/00891 Seal Dolly 1
22 998/10609 Bearing Installation 1
Tube
23 998/M5629 Bearing Centre 1
Puller (87 Series)
Special Tool - 892/01110 - Torque Converter Alignment Tool
Special Tool - 892/01147 - Crankshaft Turning Tool (95.25mm PCD)- JCB 4 Cylinder Ecomax
and Dieselmax
Use to manually turn the crankshaft, for instance when
setting top dead centre (TDC). 4 x mounting holes to
suit crankshaft pulley.
78 - 36 9823/1650-1 78 - 36
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01148 - Crankshaft / Camshaft Timing Pin (444/448/672 Engine)

1. Use to correctly align the crankshaft at top dead
centre (TDC). 2. Use to align the camshaft in the correct
timed position when removing/fitting the fuel injection
pump.
Special Tool - 892/01149 - Template for Sealant Oil Sump - Pressed

Use to ensure correct sealant application, correct
positioning of the sealant is critical to prevent leaks.
Special Tool - 892/01150 - Oil Sump Location Dowel

Use to correctly align the sump, prevent sump
movement during fitting, correct positioning of the sump
is critical to ensure a good joint and prevent leaks.
Special Tool - 892/01152 - Valve Stem Seal Installation Tool (444/448/672 Engine)
Use to ensure positive engagement of the valve stem
seals.
Special Tool - 892/01154 - Tamper proof Cover Removal Tool

Use to gain access to the mechanical fuel injection
pump gear retaining locknut. The tool is used to remove
the tamperproof cover.
78 - 37 9823/1650-1 78 - 37
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01155 - Pump Gear Removal Tool

Use to remove the gear from the fuel injection pump
shaft.
Special Tool - 892/01156 - Crankshaft Rear Oil Seal Installation Tool

Use to correctly install the crankshaft rear oil seal.
Special Tool - 892/01157 - Crankshaft Front Oil Seal Installation Tool

Use to correctly install the crankshaft front oil seal.
Special Tool - 892/01158 - Crankshaft Rear Oil Seal Alignment Tool

Use to position the crankshaft rear oil seal before using
installation tool 892/01156. This tool must be used to
position the seal, otherwise the lip of the seal may
be inverted during the installation process - leading to
potential oil leak.
78 - 38 9823/1650-1 78 - 38
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01174 - Data Link Adaptor (DLA) Kit

1 1 Interconnecting 1
cable, DLA to
machine ECU
diagnostics socket.
2 2 Interconnecting 1
cable, DLA to
machine ECU
C D
B E
A
J F
H G
diagnostics socket.
3 3 Kit carrying case. 1
4 Interconnecting 1
cable, DLA to laptop
PC.
5 Data Link Adaptor 1
(DLA), enables data
5 exchange between
the machine ECU
(Electronic Control
4 Unit) and a laptop
PC loaded with
the applicable
diagnostics
software.
6 Interconnecting 1
6 cable, DLA to laptop
PC.
Special Tool - 892/01176 - Template for Sealant Flywheel Housing to Gear Case (4 Cyl and 6
Cyl Elec)
78 - 39 9823/1650-1 78 - 39
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01179 - C-Shaped Ring Spanner

Use to access the inner mounting nut of the fuel
injection pump.
Special Tool - 892/01255 - Hydraulic Flushing Rig
78 - 40 9823/1650-1 78 - 40
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01380 - Valve Clearance Service Kit

Use to measure and adjust valve clearances without
removal of the rocker cover.
Special Tool - 892/01382 - Engine Lifting Spreader Bar
78 - 41 9823/1650-1 78 - 41
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01383 - Fuel Filter Removal Tool (4 cyl)
Special Tool - 892/12346 - Injector Seal Installation Tool (Electronic Engine)

Use to correctly set and install the rocker cover injector
seals.
Special Tool - 892/12348 - Injector Sleeve Installation/Removal Tool

Use to install and remove the injector sleeves. The
sleeves are pre-fitted on cylinder head assemblies.
78 - 42 9823/1650-1 78 - 42
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/12349 - Template for Sealant Flywheel Housing to Gear Case (4 Cyl Elec )
Special Tool - 892/12350 - Injector Leak-off Test Kit ((Electronic Engine))

Use to confirm a defective injector. You need 2 of these
kits for electronic 6 cylinder engines.
Recommended Tool - 892/12351 - Deep Socket
78 - 43 9823/1650-1 78 - 43
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/12354 - Template for Sealant Oil Sump (Cast)

Special Tool - 892/12356 - Template for Sealant Bedplate to Crankcase (4 Cyl)

78 - 44 9823/1650-1 78 - 44
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/12359 - Injector Cap Kit
Special Tool - 921/52600 - Spacer Kit

set complete.
78 - 45 9823/1650-1 78 - 45
78 - After Sales
93 - Special Tools
03 - Parts List

1 921/52628 Spacer 12.60mm 1
thick
2 921/52629 Spacer 12.65mm 1
thick
3 921/52630 Spacer 12.7mm 1
thick
4 921/52601 Spacer 12.75mm 1
thick
5 921/52602 Spacer 12.80mm 1
thick
6 921/52603 Spacer 12.85mm 1
thick
7 921/52604 Spacer 12.9mm 1
thick
8 921/52605 Spacer 12.95mm 1
thick
9 921/52606 Spacer 13.00mm 1
thick
10 921/52607 Spacer 13.05mm 1
thick
11 921/52608 Spacer 13.10mm 1
thick
12 921/52609 Spacer 13.15mm 1
thick
13 921/52610 Spacer 13.20mm 1
thick
14 921/52611 Spacer 13.25mm 1
thick
15 921/52612 Spacer 13.30mm 1
thick
16 921/52613 Spacer 13.35mm 1
thick
17 921/52614 Spacer 13.40mm 1
thick
18 921/52615 Spacer 13.45mm 1
thick
19 921/52616 Spacer 13.50mm 1
thick
20 921/52617 Spacer 13.55mm 1
thick
21 921/52618 Spacer 13.60mm 1
thick
22 921/52619 Spacer 13.65mm 1
thick
23 921/52620 Spacer 13.70mm 1
thick
24 921/52621 Spacer 13.75mm 1
thick
25 921/52622 Spacer 13.80mm 1
thick
78 - 46 9823/1650-1 78 - 46
78 - After Sales
93 - Special Tools
03 - Parts List

26 921/52623 Spacer 13.85mm 1
thick
27 921/52624 Spacer 13.90mm 1
thick
28 921/52625 Spacer 13.95mm 1
thick
29 921/52626 Spacer 14.00mm 1
thick
30 921/52627 Spacer 14.20mm 1
thick
Special Tool - 921/53300 - Spacer Kit

set complete.

1 921/53322 Spacer 13.55mm 1
thick
2 921/53323 Spacer 13.575mm 1
thick
3 921/53324 Spacer 13.6mm 1
thick
4 921/53325 Spacer 13.625mm 1
thick
5 921/53301 Spacer 13.65mm 1
thick
6 921/53302 Spacer 13.675mm 1
thick
7 921/53303 Spacer 13.7mm 1
thick
8 921/53304 Spacer 13.725mm 1
thick
9 921/53305 Spacer 13.75mm 1
thick
10 921/53306 Spacer 13.775mm 1
thick
11 921/53307 Spacer 13.80mm 1
thick
12 921/53308 Spacer 13.825mm 1
thick
13 921/53309 Spacer 13.850mm 1
thick
14 921/53310 Spacer 13.875mm 1
thick
15 921/53311 Spacer 13.90mm 1
thick
16 921/53312 Spacer 13.925mm 1
thick
17 921/53313 Spacer 13.950mm 1
thick
18 921/53314 Spacer 13.975mm 1
thick
19 921/53315 Spacer 14.00mm 1
thick
78 - 47 9823/1650-1 78 - 47
78 - After Sales
93 - Special Tools
03 - Parts List

20 921/53316 Spacer 14.025mm 1
thick
21 921/53317 Spacer 14.050mm 1
thick
22 921/53318 Spacer 14.075mm 1
thick
23 921/53319 Spacer 14.10mm 1
thick
24 921/53320 Spacer 14.125mm 1
thick
25 921/53321 Spacer 14.150mm 1
thick
Special Tool - 921/M0229 - Shim Kit

After using a shim, obtain a replacement to keep the set
complete.

1 921/M0230 Shim 0.15mm thick 1
2 921/M0231 Shim 0.2mm thick 1
3 921/M0232 Shim 0.25mm thick 1
Recommended Tool - 926/15500 - Rubber Spacer Blocks

Used to provide the correct set clearance between
glass edge and cab frame. Unit quantity: 500 off.
Special Tool - 992/04800 - Flange Spanner
78 - 48 9823/1650-1 78 - 48
78 - After Sales
93 - Special Tools
03 - Parts List
General Tool - 992/11300 - Grease Gun
General Tool - 992/12300 - Mobile Oven (12V)

Required to pre-heat adhesive prior to use. It is fitted
with a male plug (703/23201) which fits into a female
socket (715/04300). Cartridge capacity: 1.
General Tool - 992/12400 - Static Oven (240V)

Required to pre-heat adhesive prior to use. No plug
supplied. Cartridge capacity: 2.
Recommended Tool - 992/12800 - Cut-Out Knife

Used to remove broken glass.
Refer to special tool 992/12801 ('L' Blades)
Recommended Tool - 992/12801 - 'L' Blades

Refer to special tool 992/12800 (Cut-Out Knife)
25 mm (1 in.) cut. Replacement blades for cut-out knife.

Unit quantity = 5 off.
78 - 49 9823/1650-1 78 - 49
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 993/59300 - Pressure Test Adaptor
Special Tool - 993/59500 - Adaptor
Special Tool - 993/68100 - Slide Hammer Kit

1 993/68101 Slide hammer 1
2 993/68102 End Stops 3
3 993/68103 Adaptor (M20 x 5/8" 1
UNF)
4 993/68104 Adaptor (M20 x 1" 1
UNF)
5 993/68105 Adaptor (M20 x 1
M20)
6 993/68106 Adaptor (M20 x 1
M24)
7 993/68107 Bar (M20 x M20 X 1
800mm)
8 993/68108 Adaptor (M20 x 7/8" 1
UNF)
9 993/68109 Adaptor (M20 x 1
M12)
10 993/68110 Adaptor (M20 x 5/8" 1
UNF - Shoulder)
11 993/68111 Adaptor (M20 x 1/2" 1
UNF)
78 - 50 9823/1650-1 78 - 50
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 993/70100 - End Float Setting Tool Kit
1
7
4 11
3
12 6
5
10
8 6
13
9
2 993/70101 Base Plate 1
3 993/70160 Setting Yoke 1
4 993/70130 Main Shaft Adaptor 1
5 993/70104 Main Shaft Pillar 1
6 993/70106 Lay Shaft Reverse 1
Pillar
7 993/70120 Lay Shaft Adaptor 1
8 993/70140 Reverser Shaft 1
Adaptor
9 1391/3305 Capscrew M8 x 1
20mm
10 826/01417 Setscrew M10 x 1
30mm
11 Torque Wrench 1
12 993/70112 Input Shaft Pillar 1
13 993/70150 Input Shaft Adaptor 1
78 - 51 9823/1650-1 78 - 51
78 - After Sales
93 - Special Tools
03 - Parts List
General Tool - 993/70111 - Torque Wrench (10-100Nm)
Special Tool - 997/11000 - Support Bracket
Special Tool - 998/10738 - Adaptor Spanner
Special Tool - 998/11051 - Digital Hydraulic Pressure Test Kit

1 998/11052 Hand Held 1
4-Channel
ServiceMaster Unit
2 998/11053 SensoWin Software 1
Kit and PC Cable
3 998/11054 Equipment Case 1
4 998/11055 0-600 Bar Pressure 2
Transducer
5 998/11056 0-100 Bar 2
PressureTransducer
78 - 52 9823/1650-1 78 - 52
78 - After Sales
93 - Special Tools
03 - Parts List

6 998/11057 RPM Tachometer 1
(includes fixed
cable, 2 metres)
7 998/11058 5 Metre Connecting 1
Cable
8 998/11059 M16 Metric 4
Adaptors for Test
Points
9 998/11060 400mm Test Hose 2
90° HSP to M16
10 998/11061 400mm Test Hose 2
Straight HSP to M16
Special Tool - 998/M1374 - Reaction Plate M14 Studs
Special Tool - 998/M1375 - Reaction Plate
78 - 53 9823/1650-1 78 - 53
78 - After Sales
94 - Non JCB Tools
94 - Non JCB Tools
Contents Page No.
78-94-00 General ........................................................................................................................... 78-55
78 - 54 9823/1650-1 78 - 54
78 - After Sales
94 - Non JCB Tools
00 - General
00 - General
Introduction
The tools shown are the special tools required

for completing some procedures described in this
manual.
These tools are not available from JCB Service but

may be manufactured locally (if the information is
available) or purchased complete from suppliers.
Tools other than those listed will be required. It is

expected that such general tools will be available in
any well equipped workshop or be available locally
from any good tool supplier.
Before you start work, make sure that:
1. All safety precautions are observed in

accordance with the information contained within
the relevant support documentation.
2. Make sure that any locally manufactured tool is
suitable for the task required of it.
78 - 55 9823/1650-1 78 - 55
78 - After Sales
96 - Units of Measurement
Contents Page No.
78-96-00 General ........................................................................................................................... 78-57
78 - 56 9823/1650-1 78 - 56
78 - After Sales
00 - General
00 - General Table 508. Flow

Measurement Convert to Multiply by
Technical Data (unit)
Litre/Minute (L/ UK Gal- 0.220
m) lon/Minute
The standard units of measurement used by JCB are US Gal- 0.264
listed below together with the formula for conversion lon/Minute
for countries using non metric standards.
Table 509. Area
Standard Units Measurement Convert to Multiply by
(unit)
Table 503. Force Square Millime- Square Inch 0.0015
Measurement Convert to Multiply by tre (mm²) (in²)
(unit) Square Metre Square Foot 10.764
Newton (N) Kilogram force 0.102 (m²) (ft²)
(kgf) Square Yard 1.196
Pound force 0.225 (yd²)
(lbf)
Table 510. Torque
Table 504. Length Measurement Convert to Multiply by
(unit)
(unit) Newton metre Pound force 0.7376
(Nm) foot (lb f ft)
Millimetre (mm) Inch (in) 0.0394
Metre (m) Feet (ft) 3.281 Table 511. Pressure
Yard (yd) 1.094 Measurement Convert to Multiply by
Kilometre (km) Mile (mile) 0.621 (unit)
Bar Pound force/ 14.5
Table 505. Mass inch² (psi)
Measurement Convert to Multiply by Table 512. Fuel Consumption
(unit)
Gram (g) Ounce (oz) 0.035
(unit)
Kilogram (kg) Pound (lb) 2.205
Kilometre/Litre Miles/Gallon 2.825
Tonne Ton 0.984 (km/l) (mpg)
Miles/ US Gal- 2.352
Table 506. Speed lon
Measurement Convert to Multiply by Table 513. Temperature
(unit)
Kilometre/Hour mile/hour (mph) 0.621 Measurement Convert to Formula
(km/h) (unit)
Metre/Second feet/second (ft/ 3.281 Degrees Cel- Degrees Multiply by 9,
(m/s) s) sius (°C) Fahrenheit (°F) Divide by 5,
Add 32
Table 507. Volume Table 514. Power
Measurement Convert to Multiply by Measurement Convert to Multiply by
(unit) (unit)
Cubic Centime- Cubic Inch (in³) 0.061 KiloWatt (kW) Horsepower 1.341
tre (cm³) (hp)
Cubic Metre Cubic Foot (ft³) 35.315
(m³) Table 515. Time
Cubic Yard (yd³) 1.308
Millilitre (ml) Fluid ounce (fl 0.035 Measurement (unit)
oz) Second (s)
Litre (l) UK Gallon 0.220 Minute (min)
US Gallon 0.264 Hour (h)
78 - 57 9823/1650-1 78 - 57
78 - After Sales
00 - General
Table 516. Current

Measurement (unit)
Ampere (A)
Table 517. Voltage

Measurement (unit)
Volt (V)
Table 518. Noise Levels

Measurement (unit)
Sound pressure level (LpA)
Sound power level (LwA)
78 - 58 9823/1650-1 78 - 58

Service Manual: Foreword

Uploaded by

Copyright:

Available Formats

Service Manual: Foreword

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service Manual: Foreword

Uploaded by

Copyright:

Available Formats

Foreword

The Operator's Manual

You and others can be killed or seriously injured

SERVICE MANUAL Do not operate the machine without an Operator's

Treat the Operator's Manual as part of the machine.

LOADALL (ROUGH TERRAIN

Copyright 2018 © JCB SERVICE

SERVICE MANUAL SERVICE MANUAL

506-36, 507-42, 506-36, 507-42,

SERVICE MANUAL SERVICE MANUAL

506-36, 507-42, 506-36, 507-42,

Acronyms Glossary .................................................................................................................................... 01-2

FOPS Falling Object Protective Structure

Contents Page No.

01-03-03 Safety - Yours and Others ............................................................................................... 01-3

03 - Safety - Yours and Others

All machinery can be hazardous. When a machine

In this manual and on the machine you will find

Safety is not just a matter of responding to the

If you are not sure of anything, about the machine or

In this manual there are safety notices. Each notice

The signal word 'DANGER' indicates a hazardous

The signal word 'WARNING' indicates a hazardous

The signal word 'CAUTION' indicates a hazardous

The signal word 'Notice' indicates a hazardous

The safety alert system symbol (shown) also helps

Figure 1. The safety alert system symbol

09 - General Safety Lifting Equipment

12 - Maintenance Safety Hydraulic Pressure

Working Under the Machine

18 - Operating Safety exhaust extractor. If you begin to feel drowsy, stop

Machine Limits Unguarded machines in public places can be

Exhaust Gases This machine is designed for use in normal out

Regulations clearly. Modification of the machine's configuration

Electrical Power Cables Hands and Feet

Working Platform Passengers

Travelling at high speeds can cause accidents. Confined Areas

Operating the machine on hillsides can be Safe Working Loads

has passed. Do not attempt to mount or enter the

21 - Worksite Safety An applicable worksite organisation is required in

24 - Risk Assessment Loading/Unloading Area

27 - Maintenance Positions Introduction

Lift Arm Lowered

A Lift arm lowered

Lift Arm Raised

Health and Safety

06 - About this Manual

Contents Page No.

01-06-03 Model and Serial Number .............................................................................................. 01-17

03 - Model and Serial Number

06 - Using the Manual

Machine Variants • Use the applicable Servicemaster diagnostics

Contents Page No.

01-09-00 General ........................................................................................................................... 01-21

A main structural support is designed to carry an

When used normally the machine lifts and places

The machine is intended to be used in normal

03 - Log Moving/Object Handling

Do not use the machine to move or handle logs